Isuzu AU-4LE1T User manual

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive
harm.

FOREWORD
The ISUZU industrial diesel engines are a product of ISUZU’s long years of
experience, advanced technology. ISUZU takes great pride in the superior
durability and operating economy of these engines.
In order to get the fullest use and benefit from your industrial engine, it is
important that you operate and maintain it correctly. This Manual is
designed to help you do this.
Please read this Manual carefully and follow its operating and maintenance
recommendations. This will ensure many years of trouble-free and
economical engine operation.
Should your engine require servicing, please contact your nearest ISUZU
engine outlet. He knows your engine best and is ready to meet your
satisfaction.
All information, illustrations, and specifications contained in this Manual are
based on the latest product information available at the time of publication.
ISUZU reserves the right to make changes in this Manual at any time without
prior notice.

WARNING AND CAUTION
SAFETY WARNINGS
WARNING: These mean there is something that could hurt you or other
people.
In the warning area, we tell you what the hazard is. Then we tell you what to do
to help avoid or reduce the hazard. Please read these warnings. If you don’t,
you or others could be hurt.
ENGINE OR EQUIPMENT DAMAGE WARNINGS
CAUTION: These mean there is something that could damage your engine
or equipment.
In the caution area, we tell you about something that can damage your engine or
equipment. Many times, this damage would not be covered by your warranty, and it could
be costly. But the caution will tell you what to do to help avoid the damage.
EMPHASIZED WARNINGS
NOTICE: These mean there is something that needs to be emphasized but
which does not concern the possibility of personal injury or mechanical
damage.

TABLE OF CONTENTS
1. ENGINE EXTERNAL VIEWS .............................................................. 1
1. MODEL 4LE1T ............................................................................. 1
2. MODEL 4LE1NA .......................................................................... 3
2. GENERAL INFORMATION ................................................................. 5
1. EPA AND CARB CERTIFIED ENGINE DATA AND
SPECIFICATIONS........................................................................ 5
2. EC EMISSION CONTROL LABLE: ENGINE LABEL
(ONLY EC TYPE) ......................................................................... 18
3. ENGINE IDENTIFICATION........................................................... 19
4. ISUZU ENGINE AFTER SERVICE............................................... 21
3. FUEL, LUBRICANT, AND COOLANT................................................. 22
1. FUEL ............................................................................................ 22
2. LUBRICANT................................................................................. 27
3. COOLANT.................................................................................... 30
4. ENGINE OPERATION ......................................................................... 31
1. CHECK BEFORE OPERATION ................................................... 32
2. ENGINE STARTING ..................................................................... 38
3. CHECK AND OPERATION AFTER THE ENGINE START-UP .... 42
4. CARE IN THE ENGINE OPERATION .......................................... 45
5. ENGINE STOPPING..................................................................... 51
6. OPERATION AND CARE FOR NEW ENGINE ............................ 52

7. ENGINE CARE FOR OVER-COOLING ....................................... 52
8. OPERATION AND CARE FOR TURBOCHARGED ENGINE ...... 53
9. STARTING THE ENGINE AFTER BEING LEFT UNUSED
FOR A LONG PERIOD OF TIME ................................................. 54
5. PERIODICAL INSPECTION AND MAINTENANCE ............................ 55
1. LUBRICATING SYSTEM.............................................................. 55
2. COOLING SYSTEM ..................................................................... 64
3. FUEL SYSTEM............................................................................. 70
4. AIR INTAKE SYSTEM.................................................................. 77
5. ENGINE ELECTRICAL ................................................................ 79
6. ENGINE ASSEMBLY AND OTHERS ........................................... 83
6. ENGINE CARE IN COLD SEASON .................................................... 89
1. FUEL ............................................................................................ 89
2. COOLANT.................................................................................... 90
3. ENGINE OIL................................................................................. 92
4. BATTERY ..................................................................................... 92
5. ENGINE STARTING ..................................................................... 93
7. ENGINE MAINTENANCE SCHEDULE ............................................... 94
8. SIMPLE ENGINE TROUBLESHOOTING ........................................... 102

1. ENGINE EXTERNAL VIEWS
1
1. MODEL 4LE1T
(1) LH
Air inlet
Generator
Turbocharger
Water drain plug
Starter
IMLE0085
Note:
Engine details may
vary depending on the
specifications.

2
(2) RH
PCV
Nozzle holder
Solenoid stopper
Oil filler cap
Oil drain plug
Oil cooler
From oil filter
To oil filter
Water pump
Thermostat housing
IMLE0086
Note:
Engine details may
vary depending on the
specifications.

3
2. MODEL 4LE1NA
(1) LH
Air inlet
Generator
Water drain plug
Starter
IMLE0087
Note:
Engine details may
vary depending on the
specifications.

4
(2) RH
Nozzle holder
Solenoid stopper
Oil filler cap
Oil drain plug
Fuel filter
Oil filter
Thermostat housing
Water pump
IMLE0088
Note:
Engine details may
vary depending on the
specifications.

2. GENERAL INFORMATION
5
1. EPA AND CARB CERTIFIED ENGINE DATA AND SPECIFICATIONS
Se rapporter à la fin de ce document pour les informations EPA en français.
(1) Model AU-4LE1T
ISUZU engine model name AU-4LE1T
Engine family *SZXL02.2UTA
Engine code 4LE1XXXXX-XX
Engine type Water-Cooled, four cycle, in-line overhead valve type
Combustion type Swirl chamber type
No. of cylinders – bore ×stroke mm(in) 4 – 85 ×96 (3.35 ×3.78)
Engine displacement L(cid) 2.179 (133)
Compression ratio 21.5 to 1
Firing order 1 – 3 – 4 – 2
*2 Rated power: SAE NET kW(hp)/min-1 40 (53.6) / 2200
*2 Fuel flow at max rated power (mm3/stroke) 46.3
Exhaust emission control system EM, IDI, TC, EGR
Injection pump Bosch, PFR type
Governor Variable speed, Mechanical type
* Mark ; Put a letter codes for model year on the top of the letters.
Y : 2000, 1 : 2001, 2 : 2002, 3 : 2003, 4 : 2004, 5 : 2005, 6 : 2006, 7 : 2007, 8 : 2008, 9 : 2009, Model Year
Engine code varies depending on each engine.