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

Excessive oil consumption
Wrong selection of kind of
r
Improper oil
quantity .
Oil coming up Wrong selection of cylinder liner
and piston ring.
Oil coming down Faulty valve stem seal.
Oil leakage p,“;::: tY::::ig.
E
Improper installation of filter and
piping.
Excessive fuel consumption
Fuel leakage c Damaged packing.
Improper installation or tightening.
Too much injection amount- Injection pump misadjustment.
I Excessive mechanical loads
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 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
SPECIFICATION AND ADJUSTMENT.
THIS ENGINE CONFORMS TO XXXX MODEL YEAR
U.S. EPA NON-ROAD DIESEL ENGINES.
mBarcodebej1ahere.I P. NO. XXXXXXXXXX
80

SUPPLEMENTAL: ENGINE LABEL (FOR EPA)
Emission control label is attached at a visible point on the equipment.
ISlJaJ
IMPORTANT ENGINE INFORMATION
ISUZU MOTORS LTD. MADE IN JAPAN
ENGINE FAMILY: XXXXXXXXXXX *ENGINE SPECIFICATION
ENGINE CODE: XXMXXXXXXXX ADVERTISED MAX.POWER.
MODEL : XXXX
ENGINE DISPLACEMENT : XXXXcm3 SAE NET
(FAN DISENGAGED)
EXHAUST EMISSION :XXX IN3 XXkW/XXXX min--l
CONTROL SYSTEM : xx XXHP/XXXX RPM
FUEL RATE
DATE OF ENGINE XX mm%t
MANUFACTURE :xx/xx VALVE IASH (COLD)
THIS ENGINE IS CERTIFIED TO IN : X.X mm.
EXH : X.X mm.
OPERATE ON DIESEL FUEL.
THIS ENGINE CONFORMS TO XXXX
MODEL YEAR U. S. EPA NON-ROAD
DIESEL ENGINES REGULATION.
INITIAL INJECTION
TIMING : XX” BTDC
CURB IDLE : XXXmin-l/RPM
(*MODEL SPECIFICATION
SEE SERVICE MANUAL)
P.NO. XXXXXXXXXX
1
Incorrect injection timing m ;:: ;:t::;ce
Incorrect injection pressure
Injection nozzle malfunction. L ~nZEt~~~~ray condition
r
incorrect injection pump
adjustment.
c
Insufficient fuel supply to
the injection pump
!
L
L Overflow valve malfunction
Lack engine output
Governor malfunction.
[ r;;tte;xZ;;gine control
Deteriorated governor spring
r Incorrect valve clearance
L
Cylinder compression pressure
leakage.
Poor cylinder com-
pression pressure.
Insufficient air intake
amount 1 Air cleaner clogging
Such as inferior ventilation.
6 79

Engine overheat.
A
Insufficient coolant amount.
Fan belt slippage.
Thermostat malfunction.
r
Cooling system defect Radiator filler cap malfunction.
Cooling system interior fouled.
I Radiator clogging.
r
Engine over-loaded.
F Air cleaner element clogging.
L Improper servicing - - Insufficient ventilator.
I Stopped coolant flow
(high concentration of antifreezer, etc.)
Lack of oil
Improper oil Wrong selection of kind and
viscosity.
Low oil pressure
7
High coolant temperature - Over heat
Clogged filter and strainer.
Worn bearings and oil pump.
Faulty relief valve.
2. EC EMISSION CONTROL LABEL: ENGINE LABEL
Emission control label is attached at the front of injection pump cover located at the right side of cylinder
body.
The following is the detail of a label required for engine emission control information, along with location.
’ 1 s uz u IMPORTANT ENGINE INFORMATION
ISUZU MOTORS LTD. MADE IN JAPAN
ENGINEFAMILYNAME XXXX
ENGINETYPE xxxx-x
ENGlNEI.D.NUMBER xxxx-xxxxxx
TYPEAPPROVALNUMBER
e9*97/68CA*00/000XX*3005*00
\
P. N 0. X-XXXXX-XXX-X
78 7

m
(I) Position of Display
Fig. 5
r
4LE2XXX-00 -
I
BA/IH
I
ISUZUMOTORSLTD.
)su=u MADE IN JAPAN
ID LABEL
3. ENGINE IDENTIFICATION
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.
CAUTION: Conduct confirmation of engine serial number with the
engine stopped.
To avoid being injury, don’t check it, while the engine is
still hot.
Unstable low idling
Crack in injection pipe.
Injection nozzle failure.
Engine stop solenoid return
- Too high low idling speed.
Unstable engine running - Engine hunting in medium speedrange.
Malfunction in engine at
high speed range.
Engine speed does not be
. I
rowerea.
L
failure.
Uneven compression pressure
between cylinders.
Incorrect control lever
r adjustment.
I Governor interior
malfunction.
- Governor spring deteriorated.
r
Air in the fuel system
r
Insufficient fuel supply. Clogged fuel filter
+ element
I Piping failure (squeezed, etc.)
Uneven fuel injection amount between
plungers.
- Deteriorated governor spring.
Incorrect valve clearance
adjustment.
- Deteriorated valve spring.
Engine control restriction or
- .
seizure.
77

9. SIMPLE ENGINE TROUBLESHOOTING
This item contents a simple troubleshooting. When a failure takes place on your ISUZU engine, diagnose the
cause referring this troubleshooting. Should the cause of failure cannot be detected or you are unable to
manage the failure consult to your machine supply source or nearest ISUZU engine service outlet.
r Battery discharged.
-I=
Imperfect cable connections.
r
Starter does not turn. Starter or starter switch failure.
I Safety relay failure. r Engine stop solenoid return failure.
t-
No fuel in the fuel tank.
Engine do= not start. -
- Starter turns but engine
does not ignite.
- No fuel injection. - Clogged fuel filter element. .
- Air in the fuel system.
L
Control rack is stuck at no fuel
position.
Unproper preheating operation.
Glow plug malfunction.
Fuel is injected but
engine does not ignite.
Incorrect injection timing.
Low cylinder compression
pressure. a
L
Engine stop solenoid incomplete e
Fig. 6
return.
I Engine jgnite but
stall immediately.
- Air in the fuel system.
Improper low idling speed
adjustment.
4. ISUZU ENGINE AFTER SERVICE
’
(1) 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.
76

3m FUEL, LUBRICANT, AND COOLANT
1.
(1)
1
2
3
FUEL
Fuel Selection
The following specific advantages are required for the diesel
fuel.
) Must be free from minute dust particles.
) Must have adequate viscosity.
) 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.
Diesel fuels
Applicable Standard Recommendation
JIS (JAPANESE INDUSTRIAL STANDARD)
DIN (DEUTSCHE INDUSTRIE NORMEN)
SAE (SOCIETY OF AUTOMOTIVE ENGINEERS)
Based on SAE-J-313C
BS (BRITISH STANDARD)
Based on BS/2869-1970
NO. 2
DIN 51601
NO. 2-D
Class A-l
23. Electrolyte gravity
check
24. Starter and alternator
check and cleaning
25. Wiring and connection
check
26. Preheating condition
check
27. Air cleaner element
replacement
28. Engine starting
condition and noise
condition
29. Exhaust smoke
condition
30. Cylinder compression
pressure
31. Valve clearance check
If fuel other than the specified one is used, engine function will be
lowered.
32. Positive crankcase
ventilation valve
cleaning
Check according to the equipment manufacturer’s specifications.
Check wear condition of brush and commutator.
Check according to the equipment specifications.
Check preheating condition of the system.
Change element according to the manufacturer’s specifications.
Check engine stability and noise.
Check exhaust smoke color.
Check every 1000 hours.
Incorrect valve clearance will result in increased engine noise and lower engine
output. Thereby adversely affecting engine performance.
Check and adjust every 1000 hours.
Perform the adjustment, cleaning, repair or replacement every 1500 hours.
IO
75

11. Coolant level and
fouling check
12.
13.
Coolant leakage check
Radiator filler cap
fitting condition
14.
15.
Fan belt tension check Check and adjust fan belt deflection. Look for cracks, fraying and wear.
Coolant temperature
registration
16.
Coolant replacement
17.
Radiator external face
cleaning
18.
Cooling system
circuit cleaning
19.
20.
21.
22.
Radiator filling cap Check radiator pressure cap perodically for proper operation according to the
function check
equipment manufacturer’s specifications.
Electrolyte level check
Replenish with distilled water if necessary.
Battery cleaning Clean the terminals.
Battery charge
condition
74
Check coolant level and add coolant if necessary.
Repair part for coolant leakage.
The radiator cap must be installed tightly.
Coolant temperature is normal at about 75 to 85°C (167 to 185°F). Check and
repair the cooling system if coolant temperature is abnormal.
Change coolant at intervals of 6 months or 12 months respectively if coolant is
plain water, or long life coolant (LLC).
According to the equipment manufacturer’s specification.
Clean the cooling system circuit every 1000 hours.
Ammeter registration goes to plus (+) side while engine running. In the lamp
type, the lamp is completely being off while engine running.
Check charging circuit if the lamp is not off.
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 allow
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.)
11

Your engine is designed to use either Number I-D or Number Z-D
diesel fuel. However, for better fuel economy, use Number 2-D diesel
fuel whenever possible. At temperatures less than -7OC, (2O”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.
EXPLANATION OF MAINTENANCE SCHEDULE
The following is a brief explanation of the services listed in the preceding Engine Maintenance schedule.
1. Oil level and oil fouling Check that the oil level is between the max. level mark and the min. level mark.
Drain oil to the max. level mark if oil level is above the max. level mark. Add oil
to the max. level mark if oil is below the min. level mark.
2. Oil leakage check Replace any damaged or malfunctioning parts which could cause leakage.
3. Oil pressure gauge . Engine oil pressure is normal at about 290 to 590 kPa (43 to 85 psi) in warmed-
registration up condition. Check and repair the lubrication oil system, if it is abnormal.
4. Oil pressure warning Warning lamp is off while engine running. If it stays on, check and repair the
lamp lubrication system.
NOTICE= Do not use home heating oil or gasoline in your diesel
engine; either may cause engine damage.
5. Engine oil replacement Change oil every 250 hours.
6. Oil filter element
replacement Change element every 500 hours.
7. Fuel leakage check Inspect the fuel lines for damage which could cause leakage. Replace any
damaged or malfunctioning parts.
8. Draining water in fuel Drain water in fuel filter if water reaches the fuel element.
filter
9. Fuel filter element
replacement Change element every 500 hours.
12
IO. Injection nozzle check Clean the injection nozzle tips every 1500 hours. (This is a recommended
maintenance) Check and adjust injection opening pressure and spray condition.
73

NO. Description of check
and maintenance
(operation hours)
Daily Remark
50 250 500 750
1000 1250 1500
29. Exhaust smoke condition 0 See “EXPLANATION OF
MAINTENANCE
3. Cylinder compression
. pressure (*) 0 SCHEDULE”
clearance check (*) I I I I I lo1 I I
32 Positive crankcase
. ventilation valve cleaning
I i I I I I I lo*1
* 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 1500 operation hours should also be made every 250 operation hours in accordance with this check
and maintenance schedule.
2. When the servicing on the asterisked (*) items are necessary, consult the equipment supplier.
(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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I
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 dama-qe.
(5) Biocides
In warm or humid weather, fungus and/or bacteria may form ir
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.
(operation hours)
NO. Description of check Daily Remark
and maintenance 50 250 500 750 1000 1250 1500
20. Electrolyte level check 0
21. Battery cleaning 0
Ammeter
Battery registration 0
22. charge
condition Charge
warning lamp 0 See “EXPLANATION
23. Electrolyte gravity check
24 Starter and alternator
. check and cleaning (*)
25 Wiring and connection
l check
OFMAINTENANCE
SCHEDULE”
0
26 ’ Preheating condition
check
27 Air cleaner element
’ replacement
0
14 71