Isuzu 3LD2 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.
Doosan purchased 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)

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.
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CAUTION AND NOTICE
SAFETY WARNINGS
CAUTION: These mean there is something that could hurt you or other
people.
In the caution 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 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 help avoid the
damage.

TABLE OF CONTENTS
1. ENGINE EXTERNAL VIEWS ........................................................... 7
2. GENERAL INFORMATION .............................................................. 3
7. EPA CERTIFIED ENGINE DATA AND SPECIFICATIONS ........ 3
2. ENGINE /DENT/FICA T/ON ........................................................ 7
3. ISUZU ENGINE AFTER SERVICE ............................................. 8
3. FUEL, LUBRICANT, AND COOLANT ............................................. 9
1. FUEL ........................................................................................... 9
2. LUBRICANT ............................................................................... 15
3. COOLANT .................................................................................. 16
4. ENGINE OPERAT/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

8. STARTING THE ENGINE AFTER BEING LEFT UNUSED
FOR A LONG PERIOD OF TIME .*.........................,..............,*... 40
5. PERIODICAL INSPECTION AND 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
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ENGINE 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
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2. EXTERNAL 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.
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2I GENERAL INFORMATION
I. EPA CERTIFIED ENGINE DATA AND SPECIFICATIONS
Se rapporter a la fin de ce document pour les informations EPA en francais.
(1) Model 3LD2
ISUZU engine model name 3LD2
Engine family *SZXLOl. 5YNB
Engine code 3LD2XXXXX-XX
Engine type Water-Cooled, four cycle, in-line overhead valve type
1 Combustion type Direct injection
No. of cylinders - 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.2-D)
* Mark ;Put a letter codes for model year on the top of the letters.
Y : 2000, 1 : 2001, 2 : 2002, 3 : 2003 Model Year
Engine code varies depending on each engine. 3

3LD2
*2 Starter (V-kW) 12 - 1.2
*2 Alternator W-4 12 - 20
Specified engine oil (API grade) CC or CD
*2 Lubrication oil volume L (qtd 6.3 (6.7)
Coolant volume (Engine only) L (qts) 2.5 (2.6)
*2 Engine dry weight kg (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.
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EMISSION CONTROL LABEL: ENGINE LABEL (FOR EPA)
Emission control label is attached at the center of injection pump cover located at the right side of cylinder
body, or on the upper side of 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.
ISUZU
IMPORTANT ENGINE INFORMATION
ISUZU MOTORS LTD. MADE IN JAPAN
ENGINE FAMILY: XXXXXXX.XXXX
ENGINE CODE : XXXXXXXXXXXX
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: XXXXXXX.XXXX
ENGINE CODE : xxxxxxxxxxxx
MODEL : xxxx
ENGINE DISPLACEMENT : XXXXcm3
DATE OF ENGINE MANUFACTURE : XX / XX
ENGINE SPECIFICATION
REFER TO OWNER’S MANUAL FOR MAINTENANCE
SPECIFICATION AND ADJUSTMENT.
THIS ENGINE CONFORMS TO XXXX MODEL YEAR
u’.S. EPA NON-ROAD DIESEL ENGINES.
mBarcodebejlaz\ P. NO. XXXXXXXXXX
equal to or more than 19 kW (25 hp) I 5
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SUPPLEMENTAL: ENGINE LABEL (FOR EPA)
Emission control label is attached at a visible point on the equipment.
ISlJaJ
IMPORTANT ENGINE INFORMATION
ISUaJ
IMPORTANT ENGINE INFORMATION
ISUZU MOTORS LTD. MADE IN JAPAN ISUZU MOTORS LTD. MADE IN JAPAN
ENGINE FAMILY: XXXXXXXXXXX *ENGINE SPECIFICATION
ENGINE CODE: XXXXXXXXXXXX ADVERTISED MAX.POWER.
MODEL : XXXX
ENGINE DISPLACEMENT : XXXXcm3
EXHAUST EMISSION :xXx IN3
CONTROL SYSTEM : xx
DATE OF ENGINE
MANUFACTURE :xx/xx
THIS ENGINE IS CERTIFIED TO
OPERATE ON DIESEL FUEL.
THIS ENGINE CONFORMS TO XXXX
MODEL YEAR U. S. EPA NON-ROAD
DIESEL ENGINES AND CALIFORNIA
SMALL OFF-ROAD ENGINES
REGULATION.
SAE NET
(FAN 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 DISENGAGED)
XXkW/XXXX min--1
XXHP/XXXX RPM
FUEL RATE
DATE OF ENGINE XX mm3/st.
MANUFACTURE :xx/xx VALVE LASH (COLD)
THIS ENGINE IS CERTIFIED TO IN : X.X mm.
EXH : X.X mm.
OPERATE ON DIESEL FUEL.
THIS ENGINE CONFORMS TO XXXX INITIAL INJECTION
MODEL YEAR U. S. EPA NON-ROAD TIMING : XX” BTDC
DIESEL ENGINES REGULATION. CURB IDLE : XXXmid/RPM
(*MODEL SPECIFICATION
SEE SERVICE MANUAL)
P-NO. XXXXXXXXXX
less than 19 kW (25 hp) equal to or more than 19 kW (25 hp)
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2. ENGINE IDENTIFICATION
Fig. 3
3LD2XXX-00
BA/IH
ISUZUMOTORSLTD.
Isu=t.J MADEINJAPAN I
ID LABEL
(1) Position of Display
The engine serial number is stamped on the front upper right
side of the cylinder body, and the engine model is cast on the
rear lower right side of cylinder body just above the oil filter.
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 number with the
engine stopped.
To avoid being injury, don’t check it, while the engine is
still hot.
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3. ISUZU ENGINE AFTER SERVICE
(I) lsuzu Engine After Service
Please feel free to contact your ISUZU dealer for periodical
inspection and maintenance.
(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
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FUEL, LUBRICANT, AhID COOLANT
1.
(1)
Fuel Selection
The following specific advantages are required for the diesel
fuel.
‘1)
Must be free from minute dust particles.
2)
Must have adequate viscosity.
3) Must have high cetane value.
4) Must have 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 function will be
lowered.
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(2) Fuel Requirements
NOTICE: The fuel injection pump, injector or other parts of the fuel
system and engine can be damaged if you use any fuel or
fuel additive other than those specifically recommended
by Isuzu.
Such damage is not Isuzu’s responsibility, and is not
covered by the Warranty. To help avoid fuel system or
engine damage, please heed the following:
l Some service stations mix used engine 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 (other than as rec-
ommended under “Biocide” in this section). At the time
this manual was printed, no other fuel additive was
recommended. (See your authorized dealer to find out
if this has changed.)
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Your engine is designed to use either Number I-D or Number 2-D
diesel fuel. However, for better fuel economy, use Number 2-D diesel
fuel whenever possible. At temperatures less than -7OC, (20°F),
Number 2-D fuel may pose operating problems (see “Cold Weather
Operation” which follows). At colder temperatures, use Number I-D
fuel (if available) 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 though your tank is not fulls.
NOTICE: Do not use home heating oil or gasoline in your diesel
engine; either may cause engine damage.

(3)
1
2
(4)
Handling of the Fuel
The fuel containing dust particles or water will cause engine
failure.
Therefore, the following notice must be observed.
Take care to prevent the fuel from entry of dust particles or
water when filling the fuel tank.
When fueling is done from an oil drum directly, keep the drum
stationary over a long time so that clean fuel can be used after
the dust particles 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 service station receives
contaminated fuel from its supplier(s).
To protect your engine from contaminated fuel, there is a fuel
filter system on the engine which allows you to drain excess
water.
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CAUTION: The water/diesel fuel mixture is flammable, and could be
hot. To help avoid personal injury and/or property damage,
do not touch the fuel coming from the drain valve, and do
not expose the fuel to open flames or sparks.
Be sure you do not overfill the container. Heat (such as
from the engine) can cause the fuel to expand. If the
container is too full, fuel could be forced out of the
container. This could lead to a fire and the risk of personal
injury and/or vehicle or equipment damage.
(5) Biocides
In 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 sterilize the fuel system
(follow the biocide manufacturer’ s instructions). Biocides are
available from your dealer, service stations, parts stores and
other automotive places. See your authorized dealer for advice
on using biocides in your area and for recommendations on
which biocides you should use.
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(6) Smoke Suppressants
Because 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.
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