Isuzu 4LE2 User manual

Revised (10-12)
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.

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 oth,er reproductive
Ih
arm.

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.
AII 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.

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.
All information, illustrations and specifications contained in this manual are
based on the latest product information available at the time of publication.
The right is reserved to make changes at any time without notice.
INSTRUCTION MANUAL (INDUSTRIAL)
4LE2
IDE-6030
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
910-01 K

TABLE OF CONTENTS
1. ENGINE EXTERNAL VIEWS .
.......................................................... 1
2. GENERAL INFORMATION .............................................................. 3
1. EPA CERTIFIED ENGINE DATA AND SPECIFICATIONS.. ...... 3
2. EC EMISSION CONTROL LABEL ............................................. 7
3. ENGINE /DENT/FICA T/ON ........................................................ 8
4. ISUZU ENGINE AFTER SERVICE ............................................. 9
3. FUEL, LUBRICANT, AND COOLANT ............................................. IO
1. FUEL ........................................................................................... IO
2. LUBRICANT ............................................................................... 16
3. COOLANT .................................................................................. 17
4. ENGINE OPERATION ...................................................................... 18
1. CHECK BEFORE OPERATION .................................................. 20
2. ENGINE STARTING .................................................................. 26
3. CHECK AND OPERATION AFTER THE ENGINE START-UP ... 30
4. CARE IN THE ENGINE OPERATION
........................................ 33
5. ENGINE STOPPING .................................................................. 39
6. OPERATION AND CARE FOR NEW ENGINE .......................... 40
7. ENGINE CARE FOR OVER-COOLING ...................................... 40

8. STARTING THE ENGINE AFTER BElNG LEFT UNUSED
FOR A LONG PERIOD OF TIME ..............*................................ 41
5. PERIODICAL INSPECTION AND MAINTENANCE. ........................ 42
7. LUBRICATING SYSTEM .....*....*...................................*.......*.... 42
2. COOLING SYSTEM ................................................................... 46
3. FUEL SYSTEM ........................................................................... 50
4. AIR INTAKE SYSTEM ............................................................... 54
5. ENGINE ELECTRICAL ............................................................... 56
6. ENGINE ASSEMBLY AND OTHERS ........................................ 59
6. ENGINE CARE IN COLD SEASON ................................................. 63
7. ENGINE ELECTRICAL W/RING DIAGRAMS .................................. 68
8. ENGINE MAINTENANCE SCHEDULE ............................................ 69
9. SIMPLE ENGINE TROUBLESHOOTING
....................................... 76
ADDITION : ETIQUETTE DU MOTEUR (POUR EPA)
L’etiquette de commande d’emission est fix6 sur un emplacement visible de Equipement.
ISlJaJ
INFORMATION IMPORTANTE SUE LE MOTEUR
ISUZU MOTORS LTD. FABRIQUE AU JAPON
FAMILLE DE MOTEUR: XXXXXXXXXXX *SPECIFICATION DU MOTEUR
CODE DE MOTEUR: XXXXXXXXXXXX PUISSANCE MAX. AFFICHEE
MODELE : XXXX
CYLINDREE : XXXXcm3 SAE NET
:XXX IN3 (VENTIlATEUR LIBERE)
SYSTEME DE COMMANDE D EMISSION XXkW/XXXX min--’
XXHP/XXXX TR-MN
D ECHAPPEMENT : xx TAUX DE COMBUSTIBLE
DATE DE LA FABRICATION XX mm3/st
DU MOTEUR :xx/xx JEU DE SOUPARE (A FROID)
IL EST CERTIFIE QUE CE MOTEUR ADMISSION : X.X mm.
ECHAPPEMENT : X.X mm.
.E
FUNCTIONNE AVEC COMBUSTIBL
DIESEL.
CE MOTEUR EST CONFORMITE AVEC
LES REGLEMENTS DES MOTEURS
DIESEL SANS CHARGE U.S.EPA DE
MODELE D ANNEE XXXX.
INJECTION INITIALE
CAlAGE : XX” BTDC
RALENTI EN COURBE :
XXXmin-l/TR-M N
*SPECIFICATION DU
MODELE VOIR LE MANUEL
I
DE SERVICE) I
1 -p - - ‘7 NO. P XXXXXXXXXX 1
Le code de bares eugre&c en cet endrot
85

ETIQUETTE DE COMMANDE D’EMISSION : ETIQUETTE DU MOTEUR (POUR EPA)
L’etiqutte de commande d’emission est fixee au centre du couvercle de la pompe d’injection situe sur la
droite du corps du cylindre, ou sur le couvercle de la culasse. L’emplacement de I’etiquette de commande
d’emission fixee au moteur peut varier selon les specifications du moteur.
voici-ci apres un echatillon requis pour les informations concernant la commande d’emission du moteur,
ensemble avec son emplacement.
lsuzu
INFORMATION IMPORTANTE SUE LE MOTEUR
ISUZU MOTORS LTD. FABRIQUE AU JAPON
FAMILLE DE MOTEUR : XXXXXXX.XXXX
CODE DE MOTEUR : xxxxxxxxxxxx
MODELE : xxxx
CYLINDREE : XXXXcm3
DATE DE LA FABRICATION DU MOTEUR : XX/XX
SPECIFICATION DU MOTEUR
SE RAPPORTER AU MANUEL DU PROPRIETAIRE POUR
LES SPECIFICATIONS CONCERNANT L ENTRETIEN ET
LES REGLAGES.
CE MOTEUR EST EN CONFORMITE AVEC LES REGLEMENTS
DES MOTEURS DIESEL SANS CHARGE U.S.EPA DE MODELE
D ANNEE XXXX.
mpcodedetre$c ‘en1 N 0. P XXXXXXXXXX
1. ENGINE .EXTERNA L VIEWS
1. MODEL 4LE2
[II LH
Thermostat housing
I Exh. silencer
Water pump
\I I
Starter motor
Alternate;
Water drain
Plug
Note:
Engine details may
vary depending on the
specifications.
1
Fig. 1
84

PI RH
Injection nozzle Injection pump
control lever
Fig. 2
Note:
Engine details may
vary depending on the
specifications.
4LE2
I
Combustible specific ---I--- ~ Combustible Diesel (ASTM D975 No.2-D) I
I
Demarreur W-kW 1 12 - 2,0 I
Alternateur W-4 12 - 35
Huile moteur specifiee (API grade) CC or CD
I
Volume d’huile de lubrication L (qts)
8J (83
I
Volume du liquide de refroidissement
(seulement moteur) L (qts)
Poids a set du moteur
kg (lb)
2,8 (3,0)
155 (342)
Longueur hors-tout mm (in)
Dimensions ’
du moteur Largeur hors-tout mm (in)
Hauteur hors-tout mm (in)
Jeu de soupape (a froid) mm (in)
Pression d/injection d’injecteur M Pa (psi)
687 (27,O)
472 (18,6)
592 (23,3)
0,4 (0,0157)
17,7 (2560)
1 Calage d’injection B.T.D.v II0
I
Fabricant et type de turbochargeur NA
2 83

2m GENERAL INFORMATION 2I GENERAL INFORMATION
1. CARACTERISTIQUES TECHNIQUES ET DONNEES DU MOTEUR
CARTIFIE EPA
(I) Mod&le 4LE2
Designation du modele du moteur ISUZU 4LE2
1. EPA CERTIFIED ENGINE DATA AND SPECIFICATIONS
Se rapporter a la fin de ce document pour les informations EPA en francais.
(1) Model 4LE2
I
ISUZU engine model name 4LE2 I
I
Famille de moteur --
*SZXLOZ.ZYNB I
1 Engine family I
*SZXL02.2YNB I
1 Code de moteur I 4LE2XXXXX-XX I 1 Engine code I 4LE2XXXXXXX I
Type de moteur Type de soupape en tete en ligne, quatre temps, a
refroidissement a eau
Type de combustion Injection directe
1 No. de cylindres - al&age x course mm (in) 85 x 96 (3,35 x 3,78)
I
Cylindree du moteur
Rapport de compression
L (cid)
2,179 (133)
18,8 to 1
r Sequence d’allumage I-
l-3-4-2
I
1 Puisance nominale: SAE NET kW(cv)/min-l 1 29,7 (39,9) / 2300 .I
bbii decombustibleaucouple max.(mm3/cor 29,5
-I
Systime de commande d’kmissiond’kchappement
Pompe 5 injection
Midification du moteur
Type PFR, Bosch
I---
Regulateur I--
Type mecanique, vitesse variable I
Buses & injection Type a orifices multiples
* Marque ; Placer un code de lettres pour I’annee du modele sur la partie superieure des Iettres.
Annee du modele Y : 2000, 1 : 2001, 2 : 2002,3 : 2003
82
Le code du moteur varie selon chaque moteur.
I
Engine type
dIpm Water-Cooled, four cycle, in-line overhead valve type 1
1 Combustion type
Direct Injection
No. of cylinders - bore x strokemm (in)
Engine displacement L (cid)
85 x 96 (3.35 x 3.78)
2.179 (133)
I Compression ratio I
18.8 to 1
I
( Firing order I
l-3-4-2
I
I Rated power: SAE NET kW(hp)/minl I 29.7 (39.9) / 2300
I
I Fuel flow at max rated power (mm3/stro ke) I 29.5
I
I Exhaust emission control system
Engine modification
I
Injection pump
I
Bosch, PFR type
I
Governor
Injection nozzles
Variable speed, Mechanical type
Multi-hole type
Specified fuel
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

Clogged air cleaner.
Nozzle damage.
4LE2
Starter (V-kW) 12 - 2.0
Alternator W-4 12 - 35
Specifile engine oil (API grade) CC or CD
Lub. oil volume
L (qts)
8.1 (8.3)
Coolant volume (Engine only) L (qts) 2.8 (3.0)
Engine dry weight
I
kg (lb) 155 (342)
I
Overall length mm (in) 687 (27.0)
- _
Engine
dimensions Overall width mm (in) 472 (18.6)
Overall height mm (in)
Valve clearance (cold) mm (in)
Nozzle injection pressure MPa (psi)
Injection timing B.T.D.C.
Maker and type of turbocharger
592 (23.3)
0.4 (0.0157)
17.7 (2560)
II”
NA
r
Much black smoke - Nozzle misadjustment.
- Injection timing failure.
t-
Injection amount misadjustment.
Improper exhaust I Improper fuel.
r Oil coming up or down.
t
Water mixing in fuel.
I Much white smoke Low compression pressure.
Injection timing failure.
I Low coolant temperature.
Crack in battery body.
r
Low electrolyte level Natural consumption.
r Loose or damaged belt.
Battery overdischarge F Faulty alternator.1 Charging failure Damaged wiring or contact failure.
L
I Low speed driving.
Excessive electrical loads - Insufficient battery capacity.
4 81