Isuzu 4LE2 User manual

4 mm (0.08 mm)
No.IDE-6450A
Printed in Japan
OWNERS MANUALE
PICTORIAL INDEX
INDEX
MAIN DATA
HANDLING OF ENGINE
INFORMATION
IN CASE OF EMERGENCY
HANDLING IN
COLD SEASON
INSPECTION AND
MAINTENANCE
IMPORTANT INFORMATION
4LE2
TIER 4/STAGE 3B
OWNER’S MANUAL E
4LE2 TIER 4/STAGE 3B
BLACK DIC252
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4 mm (0.08 mm)BLACK
We recommend that you also read the separate instructions for the
equipment on your vehicle that was installed by your Isuzu Distributor.
Your Isuzu Distributor will be glad to answer any questions you may have
about the information in this manual.
•
•
Please read this manual carefully, especially the information in the
"IMPORTANT INFORMATION" section and the instructions and
information identified by the following symbol/letter combinations:
DANGER , WARNING , CAUTION , ADVICE and NOTE .
Among them, DANGER , WARNING and CAUTION are reminders
to be especially careful. Failure to follow or wrongly following the
associated instructions could result in personal injury or accidents. Please
read them thoroughly.
Due to differences in engine specifications, the illustration used for
description may not match your engine.
The contents of this manual are current at the date of issue, but may
differ slightly from your engine due to specification changes or other
modifications made thereafter.
•
•
•
Notes on Reading This Manual
Published: Apr., 2014
Printed: Apr., 2014
Second Edition
Issued by ISUZU MOTORS LIMITED
Service Group
Powertrain Business Dept.
6-26-1, Minami-oi, Shinagawa-ku, Tokyo, 140-8722, Japan
All rights reserved.
131404-12K-x
DIESEL ENGINE 4LE2
OWNER'S MANUAL
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Symbols Used in This Manual
DANGER
Failure to follow these instructions identified by this symbol could result in death
or serious injury to you and/or other people.
WARNING
Failure to follow these instructions identified by this symbol could result in death
or severe injury/engine fire.
CAUTION
Failure to follow these instructions identified by this symbol could result in
injuries or an accident.
ADVICE
Failure to follow these instructions identified by this symbol could result in
engine failure/damage.
NOTE
This symbol identifies information that you need to know.
This symbol also identifies information that would be useful for operating the
engine.
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0
●HOW TO USE THIS MANUAL 0-2
●HOW TO FIND A SPECIFIC TOPIC 0-3
●CHAPTER DESCRIPTION 0-5
●PICTORIAL INDEX 0-6
HOW TO USE THIS MANUAL AND
HOW TO FIND A SPECIFIC TOPIC
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0-2 HOW TO USE THIS MANUAL
2-2 IMPORTANT INFORMATION
Before Operating the Engine
Perform Daily (Pre-Operating) Inspections Before
Operation
Daily (Pre-Operating) Inspection
Refer to Page 5-4
Fuel, Lubricant and Coolant
Use the Specified Fuel
CAUTION
Using fuel other than extra-low-sulfur diesel fuel (with sulfur content of 15
ppm or lower) may have a harmful effect on the engine, possibly resulting
in a breakdown. If a wrong type of fuel is filled in, drain it completely. It is
dangerous to start the engine with the wrong type of fuel filled in because
doing so may cause a fire or engine damage.
Any failures caused by the use of fuels other than extra-low-sulfur diesel fuel
are excluded from the coverage of warranty.
Open the fuel cap slowly. If the cap is opened quickly, the fuel may spurt out.
•
•
•
Symbols
See the preceding page for the meanings of these symbols.
Reference page
ADVICE
WARNING
NOTE
CAUTION
DANGER
Note: This page is shown only as an example. It is not intended to give you information on your particular engine.
Refers you to a page (or
pages) of this manual that
concerns the present topic
and that you should also
read.
All values in this manual are indicated primarily according to the International System of Units (or in SI units) with the
conventional metric values and American units indicated in parentheses.
Chapter/section titlesChapter index tab
Use this for quick access to
your desired chapter.
These titles are useful for getting the gist of the
content at a glance.
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0-3
HOW TO FIND A SPECIFIC TOPIC
Use chapter/section titles as keys
Page 0-5
Search for the page describing the specific
topic by using the general table of contents
under CHAPTER DESCRIPTION, the
CHAPTER INDEX, and/or the TABLE
OF CONTENTS on the first page of each
chapter.
Use the pictorial indexes
Pages 0-6 to 0-7
PICTORIAL INDEX
If you don't know the name of the parts
or other device for which you need
information, locate the page describing it
by using the pictorial indexes.
Use device names as keys
Page 8-1
INDEX
If you know the name of the switch or other
device for which you need information,
locate the page describing it by using the
Index at the end of this manual.
If you have a problem with
your engine
Pages 6-2 to 6-7
IN CASE OF EMERGENCY
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0-4
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0-5
CHAPTER DESCRIPTION
INFORMATION··············································· 1
IMPORTANT INFORMATION ························ 2
Describes what you should know before you operate the engine safely and
smoothly.
HANDLING OF ENGINE································ 3
Explains how to start and stop the engine and describes various switches.
HANDLING IN COLD SEASON ···················· 4
Describes the points you should be aware of to operate the engine safely
and smoothly under various conditions and in different seasons.
INSPECTION AND MAINTENANCE ············· 5
Describes daily and periodic inspections and other engine or machine
care and maintenance information necessary to keep your engine in good
condition.
MAIN DATA····················································· 7
INDEX ····························································· 8
PICTORIAL INDEX····································· 0-6
IN CASE OF EMERGENCY··························· 6
Enumerates possible emergency situations and describes the actions you
should take to deal with any one of them.
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0-6 PICTORIAL INDEX
Exterior
12
3
4
5
6
No. Equipment Reference
Page
1 Turbocharger 3-9
2 Starter 5-31
3 Oil dipstick 5-7
No. Equipment Reference
Page
4 Water drain plug 5-19
5 Oil drain plug 5-10
6 Generator 5-31
Some equipment and part shapes may vary depending on engine model and
specification.
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0-7
PICTORIAL INDEX
No. Equipment Reference
Page
1EGRvalve ―
2Injector ―
3Commonrail ―
No. Equipment Reference
Page
4Crankpulley ―
5Supplypump ―
6 Supply pump strainer 5-25
123
4
5
6
Some equipment and part shapes may vary depending on engine model and
specification.
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0-8 PICTORIAL INDEX
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1
INFORMATION
●Isuzu Genuine Parts 1-2
●Warranty 1-2
●Engine Number/Emission Label/Special Vehicle Labels 1-3
●Exhaust Emission Regulation Related Parts 1-4
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1-2 INFORMATION
Isuzu Genuine Parts
"Isuzu genuine parts" are manufactured with the same specifications as those
of the parts that are installed at the time of engine assembly, and the quality and
performance of them are guaranteed by Isuzu. For parts and oils required for
maintenance and service, use "Isuzu genuine parts".
Isuzu shall not be responsible for any failure or accident that is caused by use of
parts other than "Isuzu genuine parts".
"Isuzu genuine parts" are packed in the box with the mark above and sold at Isuzu
Distributors.
Warranty
If a failure occurs, repair shall be provided for free to the extent described in the
separate "warranty certificate" (service handbook).
Please bring the "warranty certificate" (service handbook), and ask the nearest Isuzu
Distributor.
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1-3
INFORMATION
Engine Number/Emission Label/Special Vehicle Labels
• If any of these labels is smudged, damaged, or peeled, contact an Isuzu
Distributor.
• For the labels on the machine side, refer to the instruction manual from the
relevant manufacturer.
• Some examples of these labels are indicated below, but there are many
others not shown. The contents of these labels may vary depending on the
specifications.
Engine Number/ID (Identification) Labels
The engine number is required for engine registration/inspection. Provide your
Isuzu Distributor with names of the machine manufacturer, type, etc. in addition
to the engine number when you are having the machine repaired or are ordering
replacement parts, so that the Isuzu Distributor can provide service more effectively
and efficiently.
WARNING
When checking the engine number, make sure to stop the engine to prevent
your body from being caught in the rotating unit and confirm that the engine
has sufficiently cooled down. Otherwise, you could get burned.
•
Location of Engine Number
It is stamped on the front section of the right side
of the cylinder block.
ID Label
It is attached to the intake chamber.
Engine number Engine number
AF BC
XX-4LE2XXXX-00
AF BC
XX-4LE2XXXX-00
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1-4 INFORMATION
Emission Labels
It is attached to the intake chamber.
The emission labels on the engine indicate very
important instructions and information that you
should respect to ensure safe and proper use of
the engine. Be sure to read them before using the
engine.
The descriptions in the emission labels are only
about the engine unit.
Special Vehicle Label
It may be attached to the intake chamber
depending on the machine on which the engine is
installed.
The information such as type specification
number or engine model is described on the
special vehicle label.
Exhaust Emission Regulation Related Parts
This engine has been certified to meet Japanese and international exhaust emissions
regulations. Do not remove or modify installed parts that are related to the exhaust
gas purification system.
Engine model
Type specification number
Engine model
Type specification number
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2
IMPORTANT INFORMATION
●Before Operating the Engine 2-2
●Fuel, Lubricant and Coolant 2-2
●Operating the Engine 2-7
●Staying Safe 2-11
●Preventing Engine Failure 2-12
●When to Visit an Isuzu Distributor 2-13
As this chapter contains information and cautions that
should be observed in order for safe and problem-free engine
operation, be sure to read it before operating the engine.
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2-2 IMPORTANT INFORMATION
Before Operating the Engine
Perform Daily (Pre-Operating) Inspections Before
Operation
Daily (Pre-Operating) Inspection
→Refer to Page 5-4
Fuel, Lubricant and Coolant
Use the Specified Fuel
CAUTION
Using fuel other than extra-low-sulfur diesel fuel (with sulfur content of 15
ppm or lower) may have a harmful effect on the engine, possibly resulting
in a breakdown. If a wrong type of fuel is filled in, drain it completely. It is
dangerous to start the engine with the wrong type of fuel filled in because
doing so may cause a fire or engine damage.
Any failures caused by the use of fuels other than extra-low-sulfur diesel fuel
are excluded from the coverage of warranty.
Open the fuel cap slowly. If the cap is opened quickly, the fuel may spurt out.
•
•
•
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2-3
IMPORTANT INFORMATION
ADVICE
For fuel of diesel engine, the following characteristics are required.
Use a type of extra-low-sulfur diesel fuel designated for general diesel vehicles
which satisfies these requirements.
No fine dust is contained.
Appropriate degree of viscosity is provided.
High in cetane value.
Good low-temperature fluidity.
Low sulfur content.
Low carbon residue.
Be sure to use extra-low-sulfur diesel fuel. Adding of or mixing with inferior
fuel, water remover, other fuel additives, gasoline, heating oil, heavy oil or
alcoholic fuel for use may cause a sliding failure of the fuel lubricating portions
in the fuel filter and injector, and have harmful effects on each part of the
engine which may result in an engine failure.
Only use fuels listed below. Do not use other fuels as they may adversely
affect the engine.
•
-
-
-
-
-
-
•
•
DIESEL FUEL/APPLICABLE STANDARD (Sulfur content below 15ppm)
JIS (JAPANESE INDUSTRIAL STANDARD) Based on K2204 Diesel Fuel
Type 2 or Type 3 (SPL)
DIN (DEUTSCHE INDUSTRIE NORMEN) Based on EN590: 2009
ASTM (AMERICAN SOCIETY FOR TESTING and MATERIALS) Based on D975: 2009 NO.1-D S15 or NO.2-D
S15 (below 15 ppm)
CGSB (CANADA GENERAL STANDARDS BOARD) Based on CGSB-3.517
BS (BRITISH STANDARD) Based on EN590: 2009
NOTE
The specifications of diesel fuel vary depending on the season and the region.•
Cautions for Use in Cold Regions and
Seasons →Refer to Page 4-2
When Selecting Fuels (for United States and Canada Only)
Your engine is designed to use either Type "A" (1-D) or Type "B" (2-D) diesel fuel. For
better fuel economy, use Type "B" (2-D) diesel fuel whenever possible. However, at
temperatures below -7°C (20°F), Type "B" (2-D) fuel may pose operating problems.
Fuel →Refer to Page 4-3
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2-4 IMPORTANT INFORMATION
Refueling Using Fuels that Contain Biodiesel Fuel (Fatty Acid Methyl
Esters (FAME)) (for Europe Only)
• You can use standard type diesel fuels that meet EN590. A standard type diesel
fuel means the fuel that contains biodiesel fuel (FAME) which meets EN14214.
• Using diesel fuels that do not meet EN590, or using fuels that contain FAME
which does not meet EN14214 may, in the worst case, cause a serious engine
failure.
• Do not leave the diesel fuel that contains FAME unused in the engine for a long
period of time. FAME contents may block up the fuel system, causing a serious
engine failure.
• The engine is covered under the engine warranty given when the fuel that
meets EN590 is used. However, if the engine is left unused for a long period of
time, the characteristics of the fuel may change, causing a engine failure. The
engine warranty is not applicable in such cases.
ADVICE
Biodiesel meeting EN14214 (blended at the point of sale) used only in
mixtures of up to a maximum 5% by volume with mineral diesel fuel complying
with the EN590 diesel fuel standard are acceptable for use in this engine.
The final product B5 must also comply with EN590.
•
NOTE
When changing from 0% FAME diesel to a fuel that contains an amount of
FAME that meets EN590, there may be a negative impact on performance
during engine startup and general operation.
•
Refueling Using Fuels that Contain Biodiesel Fuel (for United States
and Canada Only)
It is acceptable to use diesel fuel containing up to 5% biodiesel (B5), but the final
blended fuel must meet the same specification, ASTM D975 (Grade Ultra Low Sulfur
Diesel), as other fuels used in your engine, and the biodiesel used for making this
fuel must meet the latest version of ASTM specification D6751. Biodiesel is produced
from vegetable oils or animal fat that have been esterified to reduce the possibility of
damage to your fuel system and engine. The use of un esterified bio-oils blended into
diesel fuel at any concentration is not approved by Isuzu and could damage your fuel
system and engine.
Biodiesel blends between B6 and B20 could cause damage to your engine and fuel
system if these fuels do not meet strict quality standards. ASTM D7467 has been
established to specify the properties of B6 to B20 biodiesel blends. However, field
quality surveys have shown that many commercially available B6 to B20 blends do
not meet this standard and in fact can be very damaging to your engine. If you plan to
use biodiesel grades between B6 and B20, please contact your Isuzu Distributor.
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