Isuzu 3LD2 Instruction Manual Download Page 95

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Summary of Contents for 3LD2

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Page 2: ...Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of trademarks service marks logos or other proprietary identifying marks belonging to Ingersoll Rand Company in this manual is historical or nominative in nature and is not meant to suggest a current affiliation between Ingersoll Rand Company and Doosan Company or the products of either Revised 10 12 ...

Page 3: ... 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 ...

Page 4: ...d Please read these cautions If you don t you or others could be hurt ENGINE OR EQUIPMENT DAMAGE WARNINGS NOTICE These mean there is something that could damage your engine or equipment In the notice 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 notice will tell you what to do to...

Page 5: ...ISUZU ENGINE AFTER SERVICE 8 3 FUEL LUBRICANT AND COOLANT 9 1 FUEL 9 2 LUBRICANT 15 3 COOLANT 16 4 ENGINE OPERA T ON 17 7 CHECK BEFORE OPERATION 79 2 ENGINE STARTING 25 3 CHECK AND OPERATION AFTER THE ENGINE START UP 29 4 CARE IN THE ENGINE OPERATION 32 5 ENGINE STOPPING 38 6 OPERATION AND CARE FOR NEW ENGINE 39 7 ENGINE CARE FOR OVER COOLING 39 ...

Page 6: ...ND MAINTENANCE 4 1 1 LUBRICATING SYSTEM 47 2 COOLING SYSTEM 45 3 FUEL SYSTEM 49 4 AIR INTAKE SYSTEM 53 5 ENGINE ELECTRICAL 55 6 ENGINE ASSEMBLY AND OTHERS 58 6 ENGINE CARE IN COLD SEASON 62 7 ENGINE ELECTRICAL WIRING DIAGRAMS 67 8 ENGINE MAINTENANCE SCHEDULE 68 9 SIMPLE ENGINE TROUBLESHOOTING 75 c I i ...

Page 7: ... EXTERNAL VIEWS 1 EXTERNAL VIEW LH Thermostat housing Cylinder head cover I Water Alter 1 Water drain plug w aust manihold Star ter motor Note Engine details may vary depending on the specifications Fig 1 1 r I i ...

Page 8: ...AL VIEW RH Nozule holder Oil filler cap Injection pum Oil filter Cooling fan Oil dipstick Oil drain plug Fig 2 Oil filler cap Crank pulley Note I Engine details may vary depending on the specifications 2 c t I ...

Page 9: ... bore x stroke mm 3 83 1 x 92 Engine displacement L cid 1 496 91 3 Impression ratio I 18 8 to 1 I Firing order Rated power SAE NET kW hp minl Fuel flow at rated power mm3 stroke l 3 2 27 7 37 2 3250 22 4 Exhaust emission control system Injection pump Governor Engine modification Bosch PFR type Mechanical variable speed type Injection nozzles Specified fuel Multi hole type Diesel fuel ASTM D975 No ...

Page 10: ...g lb 132 291 Overall length mm in 537 21 1 2 Engine dimensions Overall width mm in 475 18 7 Overall height mm in 590 23 2 Valve clearance cold mm in 0 20 0 0078 for exhaust and intake Nozzle injection pressure MPa psi 17 7 2560 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 4 r c I ...

Page 11: ...X MODEL xxxx ENGINE DISPLACEMENT XXXXcm3 DATE OF ENGINE MANUFACTURE XX XX ENGINE SPECIFICATION REFER TO OWNER S MANUAL FOR MAINTENANCE SPEtlFltATlON AND ADJUSTMENT THIS ENGINE CONFORMS TO XXXX MODEL YEAR U S EPA NON ROAD DIESEL ENGINES AND A P NO XXXX XXXXX CALIFORNIA SMALL OFF ROAD ENGINES less than 19 kW 25 hp lsuzu IMPORTANT ENGINE INFORMATION ISUZU MOTORS LTD MADE IN JAPAN ENGINE FAMILY XXXXXX...

Page 12: ...AN DISENGAGED XXkW XXXX min 1 XXHP XXXX RPM FUEL RATE XX mm t VALVE LASH COLD IN XXmm EXH XXmm INITIAL INJECTION TIMING XX BTDC CURB IDLE XXXmin l RPM MODEL SPECIFICATION SEE SERVICE MANUAL P NO XXXXXXXXXX ENGINE FAMILY XXXXXXXXXXX ENGINE SPECIFICATION ENGINE CODE XXXXXXXXXXXX ADVERTISED MAX POWER MODEL XXXX ENGINE DISPLACEMENT XXXXcm3 EXHAUST EMISSION xXx IN3 CONTROL SYSTEM xx SAE NET FAN DISENGA...

Page 13: ...lter Further engine model is described also on an ID label on the top of the cylinder head cover 2 Confirmation of Engine Serial Number It is advisable to check the engine serial number engine model name and type of machine together with the equipment manufacturer s name as it is required when you contact the distributor for repair service or parts ordering Conduct confirmation of engine serial nu...

Page 14: ...tenance 2 lsuzu Genuine Parts The ISUZU genuine parts are identical with those of used in the engine production and accordingly they are warranted by ISUZU MOTORS LIMITED The ISUZU genuine parts are supplied by the ISUZU distributors or the authorized parts suppliers Please designate ISUZU Genuine Parts when you need engine parts Fig 4 8 ...

Page 15: ...ve high fluidity at low temperature 5 Must have low sulfur content 6 Must have little residual carbon FUEL Diesel fuels Applicable Standard Recommendation JIS JAPANESE INDUSTRIAL STANDARD NO 2 DIN DEUTSCHE INDUSTRIE NORMEN DIN 51601 SAE SOCIETY OF AUTOMOTIVE ENGINEERS Based on SAE J 313C NO 2 D BS BRITISH STANDARD Based on BS 2869 1970 Class A l If fuel other than the specified one is used engine ...

Page 16: ...ine oil with diesel fuel Some manufacturers of large diesel engines a low this however for your diesel engine do not use diesel fuel which has been contaminated with engine oil Besides causing engine damage such fuel can also affect emission control Before using any diesel fuel check with the service station operator to see if the fuel has been mixed with engine oil l Do not use any fuel additive ...

Page 17: ...or use a winterized Number 2 D a blend of Number I D and Number 2 D This blended fuel is usually called Number 2 D also but can be used in colder temperatures than Number 2 D fuel which has not been winterized Check with the service station operator to be sure you get the properly blended fuel Note that diesel fuel may foam during a fill up This can cause the automatic pump nozzle to shut off even...

Page 18: ...or water is completely sedimented Always fully fill the fuel tank Drain the sedimented particles in the fuel tank frequently by opening the tank draining hole Water in Fuel During refueling it is possible for water and other contami nants to be pumped into your fuel tank along with the diesel fuel This can happen if a service station does not regularly inspect and clean its fuel tanks or if a serv...

Page 19: ... warm or humid weather fungus and or bacteria may form in diesel fuel if there is water in the fuel NOTICE Fungus or bacteria can cause fuel system damage by plugging the fuel lines fuel filters or injector They can also cause fuel system corrosion If fungus or bacteria has caused fuel system problems you should have your authorized dealer correct these problems Then use a diesel fuel biocide to s...

Page 20: ... of extensive testing of treated fuel versus untreated fuel the use of a smoke suppressant additive is not recommended because of the greater possibility of stuck rings and valve failure resulting from excessive ash deposits 14 r t ...

Page 21: ...l Viscosity Engine oil viscosity largely affect engine startability performance oil consumption speed of wearing and occurence of seizure etc Using lubricants whose viscosity selected according to the atmospheric temperature is important NOTICE I Using a mixture of different brand or quality oils will adversely affect the original oil quality therefore never mix up different brand or different typ...

Page 22: ...Y GRADE AMBIENT TEMPERATURE Single grade Ambient 25 C 20 C 15 C 4 C 15 C 25 C 30 C Temperature 13 F 4 F 5 F 32 F 59 F 77 F 96 F Multi grade Fig 5 3 COOLANT Use drinking water for coolant and replace it periodically 16 c I ...

Page 23: ...Protect against carbon monoxide entry into the cab The best way is to keep the engine exhaust system cab and cab ventilation system properly maintained We rec ommend that the exhaust system and cab be inspected by competent technician l Each time the vehicle has an oil change l Whenever a change is noticed in the sound of the exhaust system l Whenever the exhaust system underbody or cab is damaged...

Page 24: ...to a building any more than needed to move the vehicle or the equipment Keep the exhaust tailpipe area clear of snow and other material to help reduce the buildup of exhaust gases under the vehicle or the equipment This is particularly important when parked in blizzard conditions 18 ...

Page 25: ...level by the level marks on the dipstick The oil level must be between the Max level mark and the Min level mark as illustrated Take care not to add too much engine oil l Drain oil to the max oil level if oil level is above the max level mark l Add oil to the max oil level if oil level is below the min level mark Fig 7 CAUTION For Safety s sake conduct the inspection before start up with the engin...

Page 26: ... at the front of the cylinder head cover or through the oil filler on the right side of the timing gear case A certain period of time is required before the engine oil completely flows down from the oil filler to the crankcase Check the oil level ten or twenty minutes after oil replenishment NOTICE If the engine oil is splashed on the fan drive belt it causes belt slipage or slackness therefore ta...

Page 27: ...s correct When the belt tension is too high it will result in alternator failure Contrarily loose belt will cause belt slipage which may result in damaged belt and abnormal noise 2 Check the belts Replace them if any damage is found NOTICE Replace all belts as a set even when one is not usable Single belt of similar size must not be used as a substitute for a matched belt set Otherwise premature b...

Page 28: ... CAUTION When removing the radiator filler cap while the engine is still hot cover the cap with clothing then turn it slowly to gradually release the internal steam pressure This will prevent you from getting burnt with hot steam spouted out from the filler port 2 Use clean drinking water as coolant When an anti freeze solution is required keep to the specified mixing ratio 4 Radiator Cap Conditio...

Page 29: ...ection Even a short period of reverse connection will damage the electrical parts 6 Battery Electrolyte Level The amount of electrolyte in the batteries will be reduced after repeated discharge and recharge Check the electrolyte for the level in the batteries replenish with a commercially available electrolyte such as distilled water if necessary The battery electrolyte level checking procedure wi...

Page 30: ...mount of water at once Then go and see a doctor 3 As highly flammable hydrogen gas is rising from the batteries do not make a spark or use fire in any other way near the batteries 4 When handling such metallic articles as a tool near the batteries be sure not to contact terminal As the vehicle body is 0 it may cause a big danger 5 When disconnecting the terminals start with terminal When connectin...

Page 31: ... that all hydraulic control levers etc on the equipment are in the NEUTRAL position Set the engine stop knob in the START position Switch ON the battery switch if so equipped Insert the starter switch key into the switch key hole Turn the key clockwise to DRIVE position and make sure that the meters and warning lamps are actuated Fig 13 25 ...

Page 32: ...the irreducible minimum of pre heating 1 Turn the key to the DRIVE position and the glow plug built in the engine will grow red hot to pre heat the engine At this time the pre heating indicator lamp on the meterboard is actuated 2 When the pre heating indicator lamp goes out try starting the engine at once Relationship between water temperature and pre heating time For ref 20 C 68OF About 0 5 sec ...

Page 33: ...onds is required until the control resistance coil become red 2 Turn the starter switch key clockwise to START position as soon as the control resistance coil red heat CAUTION Don t touch the red hot contiol resistance coil or allow combustible materials such as paper cloth or leaves on it This could lead to a fire and the risk of personal injury and or equipment damage 27 c 8 i ...

Page 34: ...CE Continuous re engagement of the starter to the flywheel ring gear without giving them a break will result in the damaged starter pinion gear and flywheel ring gear 2 If despited repeated operations the engine does not start wait for a minute or more until the functions of the batteries and starter are recovered and then repeat pre heating and starting operations 3 When repeating starting operat...

Page 35: ...wing items in the engine warming up operation Engine oil pressure Although the engine oil pressure gauge readings vary depending on ambient temperature or a type of oil the gauge registers around 390 to 690 kPa 57 to 100 psi in the warming up In the oil pressure warning lamp type make sure that the lamp is off Charge condition The charge condition is normal when once the ammeter registers plus sid...

Page 36: ...our l Abnormal Imperfect combustion NOTICE Engine noise after start up might be noisy than that of warmed up engine and the exhaust smoke colour also being more blackish than the normal condition However it will be normalized after warming up engine Leakage in the systems Check the following items l Lube oil leakage Check both sides and bottom of the engine assembly for lube oil leaks paying parti...

Page 37: ...olant level could drop depending on the equipment because the mixed air is expelled in about 5 minutes after the engine started Stop the engine remove radiator cap and add coolant CAUTION Hot steam will rush out and you could get burnt if the radiator cap is removed when the engine is hot Cover the radiator cap with a thick cloth and loosen the cap slowly to reduce the pressure then remove the cap...

Page 38: ...ssure at start up time If in continuous engine operation the engine oil pressure warning lamp is off engine oil pressure is normal When the engine oil pressure gauge shows the following abnormal conditions stop the engine immediately and check the engine oil amount in the oil sump and oil leakage l The engine oil pressure gauge shows below 200 kPa 28 psi though the engine speed is raised l The oil...

Page 39: ... of personal injury and severe vehicle or equipment damage Take immediate action as outlined following If you see or hear escaping steam or have other reason to suspect there is a serious overheat condition stop and park the vehicle or equipment as soon as it is safe to do so and then turn off the engine immediately and get out of the vehicle or equipment The engine cooling system may overheat if ...

Page 40: ... the transmission in Neutral increase the engine speed to about one half full operating speed or 1200 RPM maximum Bring the idle speed back to normal after two or three minutes If the engine coolant temperature does not start to drop within a minute or two l Let the engine run at normal idle speed for two or three minutes If the engine coolant temperature does not start to drop turn off the engine...

Page 41: ...ab or open the engine access cover If the engine coolant is boiling wait until it stops before proceeding Look at the see through reserve tank The engine coolant level should be between the MAX and MIN marks on the reserve tank If necessary pour engine coolant into the reserve tank only never directly into the radiator Also do not check engine coolant level at the radiator Make sure the fan belts ...

Page 42: ...but there is still an indication on the instrument panel of an overheat condition l YOU MUST LET ENGINE COOL FIRST You may then add engine coolant directly to the radiator Once the Engine Coolant Temperature Gage no longer signals an overheat condition you can resume operating at a reduced speed Return to normal operating after about ten minutes if the gage pointer does not again show an overheat ...

Page 43: ... on the hourmeter 4 Liquid and Exhaust Smoke Leakage Be careful with lubricant fuel coolant and exhaust smoke leakage 5 Abnormal Engine Noise Pay attention to the noise from the engine or other related parts checking if the noise is normal 6 State of the Exhaust Smoke Be careful with exhaust smoke colour check if it is whitish or blackish 7 Electrical System Don t turn the key to OFF position duri...

Page 44: ... idle speed about three minutes In this operation check the engine noise and the engine oil pressure for abnormalities 3 To stop the engine turn the starter switch key to OFF position Switch off the battery if so equipped NOTICE Leaving the starter switch key in the DRIVE position for a long while after the engine has been stopped will discharge the batteries wastefully 38 ...

Page 45: ... 100 operation hours observing the following notice 1 Do the warming up operation continuously until the engine is warmed up In this operation do not race the engine 2 Also do not operate the engine with rapid acceleration rapid machine starting and continuous high speed operation 7 ENGINE CARE FOR OVER COOLING Engine over cooling cause premature wear and increased fuel consumption When the coolan...

Page 46: ...E When the vehicle or equipment is left unused for more than three months without running the engine warming up conduct a thorough inspection of the vehicle before starting the engine After starting the engine be sure to warm it up for more than ten minutes at 1000 rpm 40 ...

Page 47: ... Filter Element Change Engine oil change and oil filter element change must be made simultaneously according to the following change schedule Change interval Engine Oil Initial 50 and thereafter every 250 operating hours Oil Filter Element Initial 50 and therefore every 500 operating hours Engine oil draining CAUTION To help avoid the damage of being burned do not drain oil while the engine is sti...

Page 48: ...e to receive the drained oil so that the engine and equipment may not be stained with the drained oil Fig 15 Oil filter element removal Use a filter wrench to remove the cartridge type oil filter element Oil filter element installation 1 Apply lightly engine oil to the O ring 2 Turn in new cartridge until its sealed face comes in contact with the O ring 3 Use a filter wrench to further turn in the...

Page 49: ...or oil leakage Oil level recheck Stop the engine and keep it stationary about twenty minutes Use the dipstick to recheck the oil level Replenish with engine oil if necessary to the specified level NOTICE When the engine is started the oil level will slightly drop from the initial level as the oil fully comes into the entire oil circuit 3 Engine Oil Additives Engine oils contain a variety of additi...

Page 50: ... oil it is suggested that you contact your dealer or service station This also applies to diesel fuel which is contaminated with water See Diesel Fuel in Section 3 5 Used Engine Oil CAUTION Used engine oil contains harmful contaminants that have caused skin cancer in laboratory animals Avoid prolonged skin contact Clean skin and nails thoroughly using soap and water not mineral oil fuels or solven...

Page 51: ... the belts are replaced CAUTION To help avoid being injury check and adjust fan belt tension with engine stopped Belt tension Belt tension is normal when it is depressed 7 5 to 8 5 mm with the thumb at the midway between the fan pulley and alternator pulley about 100 N 22 lb depressing force Fan belt slackness 7 5 8 5 mm 0 30 to 0 33 in 45 c I ...

Page 52: ...y slightly after the alternator is fixed Therefore recheck the belt tension after tightening the bolts 4 After the adjustment operate the engine about five minutes at a low idle speed and recheck the belt tension Particularly pay attention to this matter when installing new belts Belt tension may vary due to the initial belt conforming 2 Fan Belt Change Use of fan belt with poor quality will resul...

Page 53: ...k at the radiator lower part to drain the coolant in the radiator CAUTION When removing the radiator filler cap while the engine is still hot covbr the cap with a rag then turn it slowly to release the internal steam pressure This will prevent a person from scalding with hot steam spouted out from the filler port 2 Drain away the coolant from the engine by loosening the water drain plug at the rea...

Page 54: ...sh with the coolant Cleaning outside of Radiator Mud or dried grass caught between radiator fins will block the air flow resulting in lower cooling efficiency Clean the radiator fins with steam or compressed water For the cleaning interval refer to the instruction manual prepared by the equipment manufacturer If the fins are stuffed however clean them at any time Further if the fins are deformed r...

Page 55: ...can cause low output or automatic air bleeding failure Perform inspection and maintenance periodically as fol 1 Removal of Water from the Fuel If water reaches the fuel filter element bottom procedure below to drain the water Procedure follow the 1 Turn the fuel filter lever just above close until it stops to cut off the fuel See Fig 20 2 Loosen the ring nut remove the cup together with the elemen...

Page 56: ...uel tank draining for the water sedimentor and the fuel filter element change is done be sure to conduct air bleeding Because of the automatic air bleeding system being employed turn the starter switch to the Drive position and activate the electromagnetic pump to bleed the air Air bleeding procedure 1 When the starter switch is set to the Drive ON position to activate the electromagnetic pump fue...

Page 57: ... ring nut remove the cup and take out the element 3 Clean the cup install a new element and install new packing on the ring nut 4 Tighten the cut to the body securely with the ring nut 5 After installation turn the fuel filter lever to the open position NOTICE 7 With the lever positioned just above the fuel remains off and therefore the engine cannot be started 2 During removal be careful not to s...

Page 58: ... the filter assembly clockwise carefully to prevent the fuel from spilling until the O ring is fitted against the sealing face of the filter cover Turn 2 3 turn further with the filter wrench 2 3 4 Governor Control Seals As the governor timing gear case is precisely adjusted most of the controls are sealed please do not break them When the adjustment is necessary contact with your machine supply s...

Page 59: ...sulting in increased oil consumption reduced output and shortened engine life Handling of air cleaner varies with the equipment model Perform periodic inspection and maintenance following the equipment manufacturer s instructions NOTICE 7 Shorten the cleaning or change interval when the equipment is used in dusty areas 2 Change the element if element damage is found during air cleaner cleaning 3 T...

Page 60: ... cleaner When the air cleaner element is clogged air intake resistance becomes greater and the dust indicator signal turns into red indicating the element change timing When the signal turns into red clean the air cleaner or replace the element Then press the dust indicator button to reset the indication ...

Page 61: ...atteries The battery charge condition is judged by the electrolyte gravity measurement Periodically measure the electrolyte gravity of the batteries For the internal check follow the equipment manufacturer s standard The relationship between the electrolyte specific gravity and the battery conditions are as follows Electrolyte Specific Gravity Battery Conditions Over 1 300 Over 100 Over charged 1 ...

Page 62: ...ure s20 St 0 0007 t 20 S20 gravity at 20 C St gravity measured t electrolyte temperature whe measured Battery terminal connections Periodically check the battery terminals for loose connection and corrosion For the check interval follow the machine manufacturer s standard Loose connection will cause hard engine starting or deficient battery charging If the terminals are excessively corroded discon...

Page 63: ...circuit connection take place the circuit will be in short circuit instantaneously resulting the alternator failure 2 Do not put water directly on the generator Entry of water into the generator leads an electrolyte corrosion causing a alternator failure Pay attention particularly when cleaning the engine 3 When the battery is charged with a external electric source be sure to disconnect the batte...

Page 64: ...e fuel spray conditions Injection nozzle pressure test interval Every 1500 operation hours When the injection starting pressure is too high or too low or the fuel spray pattern is improper an abnormal fuel combustion take place in the engine leading a lowered output and blackish exhaust smoke Further it causes a piston seizure or piston damage etc In such cases the injection nozzle test or the noz...

Page 65: ... in When the engine is cold Adjustment Procedure Turn the crankshaft clockwise so that the mark groove on the crank pulley is aligned with the TDC mark cast out on the timing gear case cover Remove the cylinder head cover and check to see if cylinder No 1 is at TDC in the compression stroke or at TDC in the exhaust stroke When the intake and exhaust valves are closed the cylinder is at TDC in the ...

Page 66: ...n the compression stroke l lolol I loI When No 1 cylinder is at TDC in the compression stroke I I I l lol I When No 3 cylinder is at I Inlet E Exhaust Fig 30 4 On completion of the valve clearance adjustment in 3 above make mark alignment as in 1 above by giving a turn to the crankshaft in normal direction Then measure and adjust the clearance of the other valves be careful not to tighten the adju...

Page 67: ...emperature 75 C 167 F Repair the engine and or replace some parts of engine if compression pressure is lower than 2 55 MPa 370 psi 5 Starter and Generator Servicing Do the starter and the generator servicing every 1000 operating hours on the following items l Starter commutator cleaning l Alternator slip ring cleaning l Carbon brushes and the brush contact check 6 Radiator Pressurization Valve Che...

Page 68: ... fuel for such engine operation Use ASTM 975 No 2 D fuel if you expect temperature above 7 C 20 F Use Number I D if you expect temperatures below 7 C 20 F If Number I D is not available a winterized blend of I D and 2 D is available in some areas during the winter months Check with the service station operator to be sure you get the properly blended fuel 62 ...

Page 69: ...for use in these ISUZU diesel engines Concentrations over 65 adversely affect freeze protection heat transfer rates and silicate stability which may cause water pump leakage Never exceed a 60 40 antifreeze water mix which provides protection to about 50 C 58 F CAUTION Under some conditions the ethylene glycol in the engine coolant is combustible To help avoid being burned when adding engine coolan...

Page 70: ... causing serious silica gelation problems 3 Usage and mixing ratio etc should be followed to the antifreeze manufacture s recommendations 3 ENGINE OIL Engine oil viscosity largely affects engine startability so the use of lubricant with selected viscosity according to the atmospheric temperature is important Refer to page 15 16 At low atmospheric temperature engine oil viscosity will increase to c...

Page 71: ...gravity of the insufficiently charged battery s electrolyte is low it will easily be frozen Pay attention to keep the batteries warm in the cold season To replenish the battery with distilled water do it immediately before the engine operation If the work is done after the engine has already been in an operation the distilled water replenished will not be mixed with the original electrolyte allowi...

Page 72: ...ne time cranking must be limited to within 10 seconds 5 In cranking operation when a phenomenon that the starter pinion and the flywheel ring gear engagement to repeated disengage and engage take place as ths is a sign of weakened battery power charge the batteries with an external electrical source 6 In an extreme cold temperature engine starting do the engine cranking a while with setting the th...

Page 73: ...ECTRICAL WIRING DIAGRAMS As the electrical wiring differs depending on the respective equipment merely standard wirings are shown in the diagrams _ Timer OOS III Therm0 sewer 0 0 S III 12V 1 0 iQV t 2 KW Fig 31 67 ...

Page 74: ...leakage check Draining water in fuel filter Fuel filter element 1 replacement Injection nozzle check I operation hours Daily 50 250 500 750 1000 1250 1500 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 I Remark See nON OF MAIMEM SCHEDULE This is a recommended maintenance The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion...

Page 75: ...ting Radiator filler cap fitting condition condition 14 14 Fan belt tension check Fan belt tension check l Replace if necessary l Replace if necessary 0 0 0 0 0 0 0 0 see see ExPLANATloNoF 15 15 Coolant temperature Coolant temperature registration registration 16 16 Coolant replacement Coolant replacement 17 17 Radiator external face Radiator external face l cleaning l cleaning 18 18 Cooling syste...

Page 76: ...22 charge condition Charge warning lamp 23 Electrolyte gravity check 24 Starter and alternator check and cleaning 25 Wiring and connection g check operation hours Daily Remark 50 250 500 750 1000 1250 1500 0 0 0 0 See WlANA llONOF WNTEM SCHEDULE 0 26 Preheating condition check 27 Air cleaner element replacement 0 70 ...

Page 77: ...NTENANCE WNTENANCE 0 0 SCHEDULE SCHEDULE 0 0 0 0 This is a recommended maintenance The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion engine useful life Isuzu however urges that recommended maintenance service is performed at the indicated intervals Note 1 The service intervals after 1000 operation hours should also...

Page 78: ... in warmed up condition Check and repair the lubrication oil system if it is abnormal Oil pressure warning Warning lamp is off while engine running If it stays on check and repair the lamp lubrication system Engine oil replacement Change oil every 250 hours Oil filter element replacement Change element every 500 hours Fuel leakage check Inspect the fuel lines for damage which could cause leakage R...

Page 79: ... of 6 months or 12 months respectively if coolant is plain water or long life coolant LLC 17 Radiator external face According to the equipment manufacturer s specification cleaning 18 Cooling system circuit cleaning Clean the cooling system circuit every 1000 hours 19 Radiator filling cap Check radiator pressure cap perodically for proper operation according to the function check equipment manufac...

Page 80: ...Change element according to the manufacturer s specifications 28 Engine starting condition and noise condition Check engine stability and noise 29 Exhaust smoke condition Check exhaust smoke color 30 Cylinder compression Check every 1000 hours pressure 31 Valve clearance check Incorrect valve clearance will result in increased engine noise and lower engine output Thereby adversely affecting engine...

Page 81: ...ections Starter or starter switch failure I Safety relay failure Engine stop solenoid return failure No fuel in the fuel tank No fuel injection T Clogged fuel filter element Air in the fuel system 1 Control rack is stuck at no fuel position Unproper preheating operation Glow plug malfunction Fuel is injected but F Incorrect injection timing engine does not ignite Low cylinder compression pressure ...

Page 82: ...nor interior malfunction Engine hunting in medium speed range Governor spring deteriorated E Air in the fuel system r Insufficient fuel supply Clogged fuel filter element Piping failure squeezed etc Malfunction in engine at high speed range Uneven fuel injection amount between plungers Deteriorated governor spring Incorrect valve clearance adjustment Deteriorated valve spring Engine speed does not...

Page 83: ... oil pump Faulty relief valve Insufficient coolant amount Fan belt slippage Thermostat malfunction Radiator filler cap malfunction Cooling system interior fouled Radiator clogging Engine over loaded Air cleaner element clogging insufficient ventilator Stopped coolant flow high concentration of antifreezer etc Oil leakage Large oil consumption Wrong selection of kind and viscosity 77 ...

Page 84: ... Insufficient fuel supply to Air mixing in injection pump the injection pump Fuel filter clogged Overflow valve malfunction Governor malfunction re e gine control Deteriorated governor spring Incorrect valve clearance Cylinder compression pressure leakage Poor cylinder com pression pressure I t zZZ Elignment lnsuff icient air intake amount _____c Air cleaner clogging Such as inferior ventilation c...

Page 85: ...n of cylinder liner and piston ring Oil coming down Faulty valve stem seal Oil leakage E t ng Improper installation of filter and piping r Fuel leakage ___c Damaged packing Improper installation or tightening Excessive fuel consumption Too much injection amount Injection pump misadjustment Excessive mechanical loads 79 ...

Page 86: ...down Water mixing in fuel Much white smoke Low compression pressure Injection timing failure Low coolant temperature Crack in battery body Low electrolyte level ___L_ Natural consumption r Loose or damaged belt Battery overdischarge Faulty generator 1 Charging failure Damaged wrrrng or contact failure Low speed driving Excessive electrical loads lnsuff icient battery capacity 80 ...

Page 87: ...ree du moteur L cid I 7 496 97 3 I I Rapport de compression I 78 8 to 7 I I Sequence d allumage I 7 3 2 I 1 Puisance nominale SAE NET kW cv mi n l I 27 7 37 2 3250 I I bt decombustible au couple max mm3 course 1 22 4 I I Systbme decommanded bmission d bchappementI Midification du moteur I I Pompe a injection I Type PFR Bosch I I Regulateur I Type mecanique vitesse variable I I Buses a injection I ...

Page 88: ...67 I Volume du liquide de refroidissement seulement moteur 25 C 6 I Poids a set du moteur kg lb 732 297 I 1 Longueur hors tout mm in I 537 27 7 I Dimensions du moteur Largeur hors tout mm in 475 78 7 Hauteur hors tout mm in 590 23 2 I Jeu de soupape a froid mm in I 0 20 0 0078 pour I echappement et I admission I 1 Pression d injection d injecteur MPa psi 1 77 7 2560 I Calage d injection B T D C 73...

Page 89: ...DN FAMILLE DEMOTEUR XXXXXXX XXXX CODEDEMOTEUR XXXXXXXXXXXX MODELE xxxx CYLINDREE XXXXcm3 DATEDE LAFABRICATION DU MOTEUR Xx XX SPECIFICATION DU MOTEUR SERAPPORTERAU MANUELDU PRDPRIETAIREPOUR LESSPECIFICATIONS CONCERNANT LENTRETIEN ET LESREGLAGES CEMOTEURESTENCONFORMITEAVECLESREGLEMENTS DESMOTEURSDlESELSANSCHARGEU S EPADEMODELE DANNEEXXXXETDESMOTEURS OFF ROAD DE PETITE DIMENSION DE LACALIFORNIE mpco...

Page 90: ...D ANNEE XXXX ET DES MOTEURS OFF ROAD DE PETITE SPECIFICATION DU DIMENSION DE LA CALIFORNIE MODELE VOIR LE MANUEL DE SERVICE pcodei e jjc Xl NO P XXXXXXXXXX Moins de 19 kW 25 cv ISUcllJ INFORMATION IMPORTANTE SUE LE MOTEUR ISUZU MOTORS LTD FABRIQUE AU JAPON FAMILLE DE MOTEUR XXXXXXXXXXX SPECIFICATION DU MOTEUF CODE DE MOTEUR XXXXXXXXXXXX PUISSANCE MAX AFFICHEE MODELE XXXX CYLINDREE XXXXcm3 SAE NET ...

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Page 93: ...ormation available at the time of publication The right is reserved to make changes at any time without notice INSTRUCTION MANUAL INDUSTRIAL 3LD2 IDE 6010 Issued by ISUZU MOTORS LIMITED POWERTRAIN SERVICE PARTS POWERTRAIN OPERATIONS 6 26 1 Minami oi Shinagawa ku Tokyo 140 8722 Japan TEL 03 5471 I 111 003 O 1K ...

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