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.

6
ISUZU engine model name AU-4LE1T
Injection nozzles Throttle type
Specified fuel Diesel fuel (ASTM D975 No.2-D)
*2 Starter (V-kW) 12 – 2.2
*2 Alternator (V-A) 12 – 50
Specified engine oil (API grade) Refer to 3.LUBRICANT, Engine Oil Selection.
*2 Lub. oil volume L(qts) 7.6 (8.0) – 10.3 (10.9)
Coolant volume (Engine only) L(qts) 2.8 (3.0)
*2 Engine dry weight kg(lb) 190 (419)
Overall length mm(in) 647.5 (25.5)
Overall width mm(in) 523.6 (20.6)
*2 Engine dimensions
Overall height mm(in) 720.8 (28.4)
Valve clearance (cold) mm(in) 0.4 (0.0157)
Nozzle injection pressure MPa(psi) 14.7 (2132)
*2 Injection timing B.T.D.C. 12°
Maker and type of turbocharger IHI, RHF-3
Specification for items marked with an asterisk (*2) will vary according to the type of equipment in which the
engine is installed.

7
(2) Model BV-4LE1T
ISUZU engine model name BV-4LE1T
Engine family *SZXL02.2VTB
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 35 (46.9) / 1800
*2 Fuel flow at max rated power (mm3/stroke) 49.7
Exhaust emission control system EM, IDI, TC
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.

8
ISUZU engine model name BV-4LE1T
Injection nozzles Throttle type
Specified fuel Diesel fuel (ASTM D975 No.2-D)
*2 Starter (V-kW) 12 – 2.0
*2 Alternator (V-A) 12 – 35
Specified engine oil (API grade) Refer to 3.LUBRICANT, Engine Oil Selection.
*2 Lub. oil volume L(qts) 7.6 (8.0) – 10.3 (10.9)
Coolant volume (Engine only) L(qts) 2.8 (3.0)
*2 Engine dry weight kg(lb) 180 (397)
Overall length mm(in) 753.7 (29.7)
Overall width mm(in) 486.2 (19.1)
*2 Engine dimensions
Overall height mm(in) 601.8 (23.7)
Valve clearance (cold) mm(in) 0.4 (0.0157)
Nozzle injection pressure MPa(psi) 14.7 (2132)
*2 Injection timing B.T.D.C. 10°
Maker and type of turbocharger IHI, RHF-3
Specification for items marked with an asterisk (*2) will vary according to the type of equipment in which the
engine is installed.

9
(3) Model AV-4LE1N
ISUZU engine model name AV-4LE1N
Engine family *SZXL02.2VNA
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 35.9 (48.1) / 2600
*2 Fuel flow at max rated power (mm3/stroke) 35.5
Exhaust emission control system EM, IDI
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.

10
ISUZU engine model name AV-4LE1N
Injection nozzles Throttle type
Specified fuel Diesel fuel (ASTM D975 No.2-D)
*2 Starter (V-kW) 12 – 2.0
*2 Alternator (V-A) 12 – 35
Specified engine oil (API grade) Refer to 3.LUBRICANT, Engine Oil Selection.
*2 Lub. oil volume L(qts) 5.9 (6.2) – 8.4 (8.8)
Coolant volume (Engine only) L(qts) 2.8 (3.0)
*2 Engine dry weight kg(lb) 170 (375)
Overall length mm(in) 695.7 (27.4)
Overall width mm(in) 486.2 (19.1)
*2 Engine dimensions
Overall height mm(in) 601.8 (23.7)
Valve clearance (cold) mm(in) 0.4 (0.0157)
Nozzle injection pressure MPa(psi) 14.7 (2132)
*2 Injection timing B.T.D.C. 13°
Specification for items marked with an asterisk (*2) will vary according to the type of equipment in which the
engine is installed.

11
(4) Model BV-4LE1N
ISUZU engine model name BV-4LE1N
Engine family *SZXL02.2VNC
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 26.3 (35.3) / 1800
*2 Fuel flow at max rated power (mm3/stroke) 36.5
Exhaust emission control system EM, IDI
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.

12
ISUZU engine model name BV-4LE1N
Injection nozzles Throttle type
Specified fuel Diesel fuel (ASTM D975 No.2-D)
*2 Starter (V-kW) 12 – 2.0
*2 Alternator (V-A) 12 – 20
Specified engine oil (API grade) Refer to 3.LUBRICANT, Engine Oil Selection.
*2 Lub. oil volume L(qts) 5.9 (6.2) – 8.4 (8.8)
Coolant volume (Engine only) L(qts) 2.8 (3.0)
*2 Engine dry weight kg(lb) 170 (375)
Overall length mm(in) 671 (26.4)
Overall width mm(in) 496 (19.5)
*2 Engine dimensions
Overall height mm(in) 595 (23.4)
Valve clearance (cold) mm(in) 0.4 (0.0157)
Nozzle injection pressure MPa(psi) 14.7 (2132)
*2 Injection timing B.T.D.C. 10°
Specification for items marked with an asterisk (*2) will vary according to the type of equipment in which the
engine is installed.

13
(5) Engine family index
Engine Engine family Engine code
Injection nozzle
opening pressure
MPa(psi)
Injection timing
B.T.D.C.
(Static)
4LE1T *SZXL02.2UTA ALL –– ––
4LE1T *SZXL02.2VTB ALL –– ––
4LE1N *SZXL02.2VNA ALL –– ––
4LE1N *SZXL02.2VNC ALL –– ––
* 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

14
EMISSION CONTROL LABEL: ENGINE LABEL (EPA, EC COMBIND TYPE)
Emission control label is attached at the center of injection pump cover located at the right side of cylinder body, or on the
cylinder head cover.
The location of emission control label attached on the engine may vary depending on the engine specification.
The following is the sample of a label required for engine emission control information, along with location.
4LE1T
ENGINE FAMILY
ENGINE CODE
MODEL
POWER CATEGORY
ADVERTISED POWER (SAE NET)
: XX.X kW / XXXX RPM
FUEL RATE : XX mm
/st.
3
VALVE LASH (COLD)
INL/EXH : XX / XX mm.
INITIAL INJECTION TIMING
CURB IDLE : XXX RPM
EMISSION CONTROL INFORMATION
ISUZU MOTORS LTD. MADE IN JAPAN
THIS ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR XX MY
NONROAD DIESEL ENGINES AND CALIFORNIA REGULATIONS FOR XX
MY OFF-ROAD DIESEL ENGINES.
EXHAUST EMISSION CONTROL SYSTEM
SEE SERVICE MANUAL FOR
MODEL SPECIFICATIONS.
ENGINE FAMILY : XXXXXXXXXX ENGINE TYPE : XXXXXXXXXX
THIS ENGINE IS CONFORMED 97/68/EC DIRECTIVE.
ENGINE I.D.NUMBER : XXXX-XXXX
TYPE APPROVAL NUMBER : XXXXXXXXXXXXXXXXXX
XXXXXX
: XX-XXXXX
: XXXXXXXXX-XX
: XXXXXXX.XXXX
: XX < kW < XX
XXXXXXXXXXXXXXXXXX
: XXXXXXXXXXXXXXXXXX
LOW SULFUR FUEL OR ULTRALOW
SULFUR FUEL ONLY
XXXXXXXXXX XXXXXXXXXX
: XXX BTDC
IMLE0097

15
4LE1NA
ENGINE FAMILY
ENGINE CODE
MODEL
POWER CATEGORY
ADVERTISED POWER (SAE NET)
: XX.X kW / XXXX RPM
FUEL RATE : XX mm
/st.
3
VALVE LASH (COLD)
INL/EXH : XX / XX mm.
INITIAL INJECTION TIMING
CURB IDLE : XXX RPM
EMISSION CONTROL INFORMATION
ISUZU MOTORS LTD. MADE IN JAPAN
THIS ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR XX MY
NONROAD DIESEL ENGINES AND CALIFORNIA REGULATIONS FOR XX
MY OFF-ROAD DIESEL ENGINES.
EXHAUST EMISSION CONTROL SYSTEM
SEE SERVICE MANUAL FOR
MODEL SPECIFICATIONS.
ENGINE FAMILY : XXXXXXXXXX ENGINE TYPE : XXXXXXXXXX
THIS ENGINE IS CONFORMED 97/68/EC DIRECTIVE.
ENGINE I.D.NUMBER : XXXX-XXXX
TYPE APPROVAL NUMBER : XXXXXXXXXXXXXXXXXX
XXXXXX
: XX-XXXXX
: XXXXXXXXX-XX
: XXXXXXX.XXXX
: XX < kW < XX
XXXXXXXXXXXXXXXXXX
: XXXXXXXXXXXXXXXXXX
LOW SULFUR FUEL OR ULTRALOW
SULFUR FUEL ONLY
XXXXXXXXXX XXXXXXXXXX
: XXX BTDC
IMLE0110