Isuzu 3CH1-NGZG01, 3CJ1-NGZG01, 3CH1-SDZP01, 3CJ1-SDZP01 Introduction Manual
TNV_OperationManual_T4(under 19kW).book Page i Wednesday, June 17, 2015 11:23 AM
TNV Operation Manual
INTRODUCTION
To help you enjoy your Isuzu C series engine for
many years to come, please follow these
recommendations:
• Read and understand this Operation Manual
before you operate the machine to ensure that
you follow safe operating practices and
maintenance procedures.
• Keep this Operation Manual in a con venient plac e
for easy access.
• If this Operation Manual is lost or damaged, order
a new one from your Isuzu Distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should be
considered a permanent part of the engine and
remain with it.
• Constant efforts are made to improve the quality
and performance of Isuzu products, so some
details included in this Operation Manual may
differ slightly from your engine. If you have any
questions about these differences , please contact
your Isuzu Distributor.
• The specifications and components (instrument
panel, fuel tank, etc.) described in this manual
may differ from ones installed on your machine.
Please refer to the manual provided by the
manufacturer of these components.
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INTRODUCTION
RECORD OF OWNERSHIP
Take a few moments to record the information you need when you contact Isuzu for service, parts or
literature.
Engine model:________________________________________________________________________
Engine serial No.: _____________________________________________________________________
Date purchased: ______________________________________________________________________
Dealer: ______________________________________________________________________________
Dealer phone: ________________________________________________________________________
SYMBOL EXPLANATION
The following symbols are used throughout this manual to identify specific engine model information
This symbol indicates information pertaining to the following indirect injection engines:
• 3CH1-NGZG01
• 3CH1-SDZP01
• 3CJ1-NGZG01
• 3CJ1-SDZP01
All of the models conform to the engine emission regulations (EPA 2013 rules).
This symbol indicates information pertaining to the following direct injection engines:
•3CE1
This model conform to the engine emission regulations (EPA 2013 rules).
ii
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TABLE OF
CONTENTS
Introduction............................................................................................... i
Record of Ownership........................................................................... ii
Symbol Explanation............................................................................. ii
Table of Contents ................................................................................... iii
Isuzu Engine After Service .................................................................... 1
Isuzu Genuine Parts........................................................................... 2
Emission-Related Installation Instructions (REF) ............................... 2
Installation of Nonroad Engines into Equipment........................... 2
Allowable Air Intake Restriction and Exhaust Back Pressure....... 2
Allowable Air Intake Restriction.................................................... 2
Allowable Exhaust Back Pressure................................................ 2
Safety....................................................................................................... 3
Safety Statements .............................................................................. 3
Safety Precautions.............................................................................. 4
Before You Operate...................................................................... 4
During Operation and Maintenance.............................................. 4
Product Overview................................................................................. 13
Isuzu C series Engine Features and Applications............................ 13
Component Identification.................................................................. 14
Location of Labels............................................................................. 17
Function of Major Engine Components ............................................ 18
Function of Cooling System Components ........................................ 20
Electronic Control System ................................................................ 21
Main Electronic Control Components and Features......................... 24
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TABLE OF CONTENTS
Gauges and Indicators...................................................................... 26
Gauges........................................................................................ 26
Indicators..................................................................................... 27
Gauges and Indicators of Electronic Control System........................ 28
Gauges........................................................................................ 28
Indicators..................................................................................... 28
Controls............................................................................................. 29
Key Switch................................................................................... 29
Glow Plugs.................................................................................. 30
Governor Lever ........................................................................... 30
Engine Stop Solenoid (IDI Engines)............................................ 31
Speed Control of Electronically Controlled Engines.................... 31
Electronic Engine Speed Control ................................................ 32
Before You Operate .............................................................................. 35
Diesel Fuel ........................................................................................ 36
Diesel Fuel Specifications........................................................... 36
Filling the Fuel Tank.................................................................... 41
Priming the Fuel System............................................................. 42
Engine Oil.......................................................................................... 43
Engine Oil Specifications............................................................. 43
Engine Oil Viscosity..................................................................... 44
Checking Engine Oil.................................................................... 44
Adding Engine Oil........................................................................ 44
Engine Oil Capacity (Typical)...................................................... 45
Engine Coolant.................................................................................. 46
Engine Coolant Specifications..................................................... 47
Filling Radiator with Engine Coolant ........................................... 47
Daily Check of the Cooling System............................................. 48
Engine Coolant Capacity (Typical).............................................. 48
Daily Checks ..................................................................................... 49
Visual Checks.............................................................................. 49
Check Diesel Fuel, Engine Oil and Engine Coolant Levels......... 49
Check Engine Speed Control...................................................... 49
Check Operator’s Console.......................................................... 50
Check Indicators.......................................................................... 50
Engine Operation .................................................................................. 53
Starting Engine.................................................................................. 54
Cold Start Device .............................................................................. 56
High-altitude Injection Control Device............................................... 56
Checking the Engine During Operation............................................ 57
Adjust Engine Speed......................................................................... 59
Shutting Down the Engine................................................................. 60
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Periodic Maintenance........................................................................... 61
Precautions....................................................................................... 62
The Importance of Periodic Maintenance................................... 62
Performing Periodic Maintenance............................................... 62
The Importance of Daily Checks................................................. 62
Keep a Log of Engine Hours and Daily Checks.......................... 62
Isuzu Replacement Parts............................................................ 62
Tools Required ........................................................................... 62
Ask Your Isuzu Distributor For Help ........................................... 62
Required EPA/ARB Maintenance USA Only.............................. 62
EPA/ARB Installation Requirements USA Only.......................... 63
Tightening Fasteners.................................................................. 63
Standard Torque Chart..................................................................... 63
Periodic Maintenance Schedule....................................................... 64
Periodic Maintenance Chart ....................................................... 64
Periodic Maintenance Procedures.................................................... 66
After Initial 50 Hours of Operation .............................................. 66
Every 50 Hours of Operation ...................................................... 71
Every 250 Hours of Operation .................................................... 75
Every 500 Hours of Operation .................................................... 79
Every 1000 Hours of Operation .................................................. 83
Every 1500 Hours of Operation .................................................. 85
Every 2000 Hours of Operation .................................................. 86
Every 3000 Hours of Operation .................................................. 87
Troubleshooting ................................................................................... 89
Troubleshooting Chart...................................................................... 90
Troubleshooting of Electronic Control System.................................. 92
Fault Detection Capability........................................................... 92
Troubleshooting Information............................................................. 94
List of Possible Faults of Electronically Controlled Engines............. 95
Long-Term Storage .............................................................................. 99
Before You Place the Engine In Long-Term Storage ..................... 100
Returning the Engine to Service..................................................... 101
Specifications ..................................................................................... 103
Engine General Specifications........................................................ 104
Principal Engine Specifications....................................................... 105
TABLE OF CONTENTS
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TABLE OF CONTENTS
This Page Intentionally Left Blank
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TNV Operation Manual
ISUZU ENGINE
AFTER SERVICE
Please feel free to contact your Isuzu distributor for
periodical inspection and maintenance.
1
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ISUZU ENGINE AFTER SERVICE
ISUZU 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.
EMISSION-RELATED INSTALLATION INSTRUCTIONS (REF)
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment
violates Federal Law (40 CFR1068.105(B)), subject to fines or other penalties as described in the clean air
act.
Installation of Nonroad Engines into Equipment
To ensure engines operate under the certified configurations, Isuzu has established defined application
requirements when installing any certified engine into a piece of equipment. The instructions outlined below
are included in our certification process and any failure to comply will be considered tampering.
Isuzu certifies engines to operate under variable speed or constant speed conditions. Engines certified as
constant speed are prohibited from installation into variable speed applications. The emission control
information label will identify an engine certified as constant speed.
Allowable Air Intake Restriction and Exhaust Back Pressure
Resistance to intake airflow and exhaust gas flow is generated in the intake and exhaust systems.
Exceeding the limitations will affect the operation of an engine and its certified configuration. Refer to the
installation requirements and limitations of the Isuzu C series Application Manual for the engine being
equipped with these systems.
Allowable Air Intake Restriction
Engine model
All models 2.94 (300) 6.23 (635)
Initial upper limit Upper limit for air cleaner replacement
Allowable air intake restriction kPa (mmAq)
Allowable Exhaust Back Pressure
Engine model
3CH1, 3CJ1 9.81 (1000) 11.77 (1200)
3CE1 12.75 (1300) 15.30 (1560)
Initial upper limit Upper limit for exhaust system cleaning
Allowable exhaust back p ressure kPa (mmAq)
2
DANGER
WARNING
CAUTION
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TNV Operation Manual
SAFETY
SAFETY STATEMENTS
Isuzu is concerned for your safety and your
machine’s condition. Safety statements are one of
the primary ways to call your attention to the
potential hazards associated with Isuzu C series
engine operation. Follow the precautions listed
throughout the manual before operation, during
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine . Keep the
labels from becoming dirty or torn and replace them
if they are lost or damaged. Also, if you need to
replace a part that has a label attached to it, make
sure you order the new part and label at the same
time.
DANGER indicates a hazardous situation which,
if not avoided, will result in death or serious
injury.
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
This safety alert symbol appears with
most safety statements. It means
attention, become alert, your safety is
involved! Please read and abide by the
message that follows the safety alert
symbol.
NOTICE
NOTICE indicates a situation which can cause
damage to the machine, personal property and/or
the environment or cause the equipment to operate
improperly.
3
NOTICENOTICE
DANGER
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SAFETY
SAFETY PRECAUTIONS
Before You Operate
• Never permit any one to operate the
engine or driven machine without
proper training.
• Read and understand this Operation Manual
before you operate or service the machine to
ensure that you follow safe operating practices
and maintenance procedures.
• Machine safety signs and labels are additional
reminders for safe operating and maintenance
techniques.
• See your Isuzu Distributor for additional training.
During Operation and Maintenance
Scald Hazard!
• Never remove the radiator cap if
the engine is hot. Steam and hot
engine coolant will spurt out and
seriously burn you. Allow the
engine to cool down before you
attempt to remove the radiator
cap.
• Tighten the radiator cap securely after you
check the radiator. Stea m can spurt out during
engine operation if the cap is loose.
• Always check the level of the engine coolant
by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
DANGER
Explosion Hazard!
• Keep the area around the battery
well-ventilated. While the engine
is running or the battery is
charging, hydrogen gas is
produced which can be easily
ignited.
• Keep sparks, open flame and any other form
of ignition away while the engine is running or
battery is charging.
• Never short out the battery terminals,
including when checking the remaining
battery charge. This will result in a spark and
may cause an explosion or fire. Use a
hydrometer to check the remaining battery
charge.
• If the electrolyte is frozen, slowly warm the
battery before you recharge it.
• Failure to comply will result in death or
serious injury.
Sudden Movement Hazard!
• Never start the engine by
shorting out the starter terminal
and the battery terminal
(Jump-start). The machine may
move suddenly if the machine
safety circuit is released, but
the gear is still engaged.
• Failure to comply will result in death or
serious injury.
4
DANGER
(Continued)
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DANGER
Fire and Explosion Hazard!
• Diesel fuel is extremely
flammable and explosive under
certain conditions.
• When you remove any fuel system component
to perform maintenance (such as changing
the fuel filter) place an approved container
under the opening to catch the fuel.
• Never use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
remove any fuel system component.
• Only use the key switch to start the engine.
• Never jump-start the engine. Sparks caused
by shorting the battery to the starter terminals
may cause a fire or explosion.
• If the unit has an electric fuel pump, in the
case of DI engine, since air is automatically
bled, by keeping the key of the starter switch
in the ON position for 10 to 15 seconds, the
fuel system can be primed. If this is an IDI
engine, keep the key in the ON position
(within 15 seconds) until fuel without bubbles
comes out from the air bleeding bolt. Here, do
not turn the key to the START position.
• If the unit has a mechanical fuel pump, when
you prime the fuel system, operate the fuel
priming lever of the mechanical fuel pump
several times until the fuel filter cup is filled
with fuel. On top of that, operate the fuel feed
pump for several times until fuel without
bubbles comes out from the air bleeding bolt.
• Never use diesel fuel as a cleaning agent.
• Never remove the fuel cap with the engine
running.
• Only fill the fuel tank with diesel fuel. Filling
the fuel tank with gasoline may result in a fire
and will damage the engine.
• Never refuel with the engine running.
• Keep sparks, open flames or any other form of
ignition (match, cigarette, static electric
source) well away when refueling.
• Never overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated area, away
from any combustibles or sources of ignition.
• Be sure to place the diesel fuel container on
the ground when transferring the diesel fuel
from the pump to the container. Hold the hose
nozzle firmly against the side of the container
while filling it. This prevents static electricity
buildup which could cause sparks and ignite
fuel vapors.
• Never place diesel fuel or other flammable
material such as oil, hay or dried grass close
to the engine during engine operation or
shortly after shutdown.
• Before you operate the engine, check for fuel
leaks. Replace rubberized fuel hoses every
two years or every 2000 hours of engine
operation, whichever comes first, even if the
engine has been out of service. Rubberized
fuel lines tend to dry out and become brittle
after two years or 2000 hours of engine
operation, whichever comes first.
• When you prime the fuel system, operate the
fuel priming lever of the mechanical fuel pump
several times until the fuel filter cup is filled
with fuel.
• Failure to comply will result in death or
serious injury.
SAFETY
5
DANGER
WARNING
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SAFETY
Crush Hazard!
• When you need to transport an
engine for repair, have a helper
assist you to attach it to a hoist
and load it on a truck.
• Never stand under a hoisted engine. If the
hoist mechanism fails, the engine will fall on
you, causing death or serious injury.
• Failure to comply will result in death or
serious injury.
Sever Hazard!
• Keep hands and other body parts
away from moving/rotating parts
such as the cooling fan, flywheel
or PTO shaft.
• Wear tight-fitting clothing and keep your hair
short or tie it back while the engine is running.
• Remove all jewelry before you operate or
service the machine.
• Never start the engine in gear. Sudden
movement of the engine and/or machine
could cause death or serious personal injury.
• Never operate the engine without the guards
in place.
• Before you start the engine make sure that all
bystanders are clear of the area.
• Keep children and pets away while the engine
is operating.
• Check before starting the engine that any
tools or shop rags used during maintenance
have been removed from the area.
• Failure to comply could result in death or
serious injury.
• Never block windows, vents, or other means
of ventilation if the engine is operating in an
enclosed area. All internal combustion
engines create carbon monoxide gas during
operation. Accumulation of this gas within an
enclosure could cause illness or even death.
• Make sure that all connections are tightened
to specifications after repair is made to the
exhaust system.
• Failure to comply could result in death or
serious injury.
• Never operate the engine when you are feeling
ill.
• Failure to comply could result in death or
serious injury.
WARNING
Exhaust Hazard!
• Never operate the engine in an
enclosed area such as a garage,
tunnel, underground room,
manhole or ship’s hold without
proper ventilation.
WARNING
Alcohol and Drug Hazard!
• Never operate the engine while
you are under the influence of
alcohol or drugs.
6
WARNING
WARNING
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WARNING
Exposure Hazard!
• Wear personal protective
equipment such as gloves, work
shoes, eye and hearing
protection as required by the
task at hand.
• Never wear jewelry, unbuttoned cuffs, ties or
loose-fitting clothing when you are working
near moving/rotating parts such as the
cooling fan, flywheel or PTO shaft.
• Always tie back long hair when you are
working near moving/rotating parts such as a
cooling fan, flywheel, or PTO shaft.
• Never operate the engine while wearing a
headset to listen to music or radio because it
will be difficult to hear the alert signals.
• Failure to comply could result in death or
serious injury.
• Failure to comply could result in death or
serious injury.
WARNING
Burn Hazard!
• Wait until the engine cools before
you drain the engine coolant. Hot
engine coolant may splash and
burn you.
• Never check for a fuel leak with your hands.
• If you must drain the engine oil while it is still
hot, stay clear of the hot engine oil to avoid
being burned.
• Always wear eye protection.
• Keep your hands and other body parts away
from hot engine surfaces such as the muffler,
exhaust pipe, turbocharger (if equipped) and
engine block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the engine is
operating and could seriously burn you.
• Failure to comply could result in death or
serious injury.
Always use a piece of wood or cardboard.
Have your Isuzu Distributor repair the
damage.
• Failure to comply could result in death or
serious injury.
SAFETY
Burn Hazard!
• Batteries contain sulfuric acid.
Never allow battery fluid to come
in contact with clothing, skin or
eyes. Severe burns could result.
Always wear safety goggles and
protective clothing when
servicing the battery. If battery
fluid contacts the eyes and/or
skin, immediately flush the
affected area with a large amount
of clean water and obtain prompt
medical treatment.
High-Pressure Hazard!
• Avoid skin contact with the
high-pressure diesel fuel spray
caused by a fuel system leak
such as a broken fuel injection
line. High-pressure fuel can
penetrate your skin and result in
serious injury. If you are e xposed
to high-pressure fuel spray,
obtain prompt medical treatment.
7
WARNING
WARNING
WARNING
CAUTION
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SAFETY
Shock Hazard!
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.
• Check the electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors. Always keep the connectors and
terminals clean.
• Failure to comply could result in death or
serious injury.
• Failure to comply may result in minor or
moderate injury.
CAUTION
Coolant Hazard!
• Wear eye protection
and rubber gloves
when you handle
long life or extended
life engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water.
Entanglement Hazard!
• Stop the engine before you begin
to service it.
• Never leave the key in the key switch when
you are servicing the engine. Someone may
accidentally start the engine and not realize
you are servicing it. This could result in a
serious injury.
• If you must service the engine while it is
operating, remove all jewelry, tie back long
hair, and keep your hands, other body parts
and clothing away from moving/rotating parts.
• Failure to comply could result in death or
serious injury.
Sudden Movement Hazard!
• Engaging the transmission or PTO at an
elevated engine speed could result in
unexpected movement of the equipment.
• Failure to comply could result in death or
serious injury.
CAUTION
Flying Object Hazard!
• Always wear eye protection when
servicing the engine and when
using compressed air or
high-pressure water. Dust, flying
debris, compressed air,
pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or
moderate injury.
• When using a 120 V system only, push the
change-over switch to the right (120 V).
• The main switch should always be kept in the
ON position during operation.
• Before starting the engine, always turn the
switches on the working instruments (lighting
apparatus, motor, etc.) to their OFF position. If
the switches are not OFF, the sudden
application of load when the engine is started
could be very dangerous.
8
NOTICE
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NOTICE
• Only use diesel fuels recommended by Isuzu for
the best engine performance, to prevent engine
damage and to comply with EPA/ARB warranty
requirements.
• Only use clean diesel fuel.
Never attempt to adjust the low or high idle speed
limit screw. This may impair the safety and
performance of the machine and shorten its life. If
adjustment is ever required, contact your Isuzu
Distributor.
SAFETY
• Never remove the primary strainer (if equipped)
from the fuel tank filler port. If removed, dirt and
debris could get into the fuel system causing it to
clog.
• Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause internal
engine components to seize and/or shorten
engine life.
• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick and
the surrounding area before you remove the cap.
• Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
engine oil.
• Never overfill the engine with engine oil.
• Always keep the oil level between the upper and
lower lines on the oil cap/dipstick.
• Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
damage.
If any problem is noted during the visual check, the
necessary corrective action should be taken before
you operate the engine.
New engine break-in:
• On the initial engine start-up, allow the engine to
idle for approximately 15 minutes while y ou check
for proper engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for proper
operation of the indicators and/or gauges.
• During the first hour of operation, vary the engine
speed and the load on the engine. Short periods
of maximum engine speed and load are
desirable. Avoid prolonged operation at minimum
or maximum engine speeds and loads f or the next
four to five hours.
• During the break-in period, carefully observe the
engine oil pressure and engine temperature.
• During the break-in period, check the engine oil
and coolant levels frequently.
• Only use the engine coolant specified. Other
engine coolants may affect warranty coverage,
cause an internal buildup of rust and scale and/or
shorten engine life.
• Prevent dirt and debris from contaminating the
engine coolant. Carefully clean the radiator cap
and the surrounding area before you remove the
cap.
• Never mix different types of engine coolants. This
may adversely affect the properties of the engine
coolant.
If any indicator fails to illuminate when the key
switch is in the ON position, see your Isuzu
Distributor for service before operating the engine.
Never hold the key in the START position for longer
than 15 seconds or the starter motor will overheat.
9
NOTICE
TNV_OperationManual_T4(under 19kW).book Page 10 Wednesda y, June 17, 2015 11:23 AM
SAFETY
If the engine fails to start:
Wait until the engine comes to a complete stop
before you attempt to start it again. Engaging the
starter while the engine is still rotating will result in
damage to the starter and flywheel.
Never use an engine starting aid such as ether.
Engine damage will result.
Observe the following environmental operating
conditions to maintain engine performance and
avoid premature engine wear:
• Avoid operating in extremely dusty conditions.
• Avoid operating in the presence of chemical
gases or fumes.
• Avoid operating in a corrosive atmosphere such
as salt water spray.
NOTICE
Never engage the starter motor while the engine is
running. This may damage the starter motor pinion
and/or ring gear.
Make sure the engine is installed on a le v el surf ace.
If a continuously running engine is installed at an
angle greater than (30°) in any direction or if an
engine runs for short periods of time (less than
three minutes) at an angle greater than (35°) i n an y
direction, engine oil may enter the combustion
chamber causing excessive engine speed and
white exhaust smoke. This may cause serious
engine damage.
If any indicator illuminates during engine operation,
stop the engine immediately. Determine the cause
and repair the problem before you continue to
operate the engine.
The illustrations and descriptions of optional
equipment in this manual, such as the operator’s
console, are for a typical engine installation. Refer
to the documentation supplied by the optional
equipment manufacturer for specific operation and
maintenance instructions.
• Never install the engine in a floodplain unless
proper precautions are taken to avoid being
subject to a flood.
• Never expose the engine to the rain.
• The standard range of ambient temperatures for
the normal operation of Isuzu engines is from
-15 °C (+5 °F) to +45 °C (+113 °F).
• If the ambient temperature exceeds +45 °C
(+113 °F) the engine may overheat and cause
the engine oil to break down.
• If the ambient temperature is below -15 °C (+5 °F)
the engine will be hard to start and the engine oil
may not flow easily.
• Contact your Isuzu Distributor if the engine wi ll be
operated outside of this standard temperature
range.
• Contact your Isuzu Distributor if the engine wi ll be
operated at high altitude. High altitude reduces
engine power, de-stabilizes operation and
generates exhaust gas that exceeds the
specification amount in design.
10
NOTICE
TNV_OperationManual_T4(under 19kW).book Page 11 Wednesda y, June 17, 2015 11:23 AM
NOTICE
• When the engine is operated in dusty conditions,
clean the air cleaner element more frequently.
• Never operate the engine with the air cleaner
element(s) removed. This may allow foreign
material to enter the engine and damage it.
The maximum air intake restriction, in terms of
differential pressure measurement, must not
exceed 0.90 psi (6.23 kPa; 635 mmAq). Clean or
replace the air cleaner element if the air intake
restriction exceeds the above mentioned value.
Establish a periodic maintenance plan according to
the engine application and make sure you perform
the required periodic maintenance at intervals
indicated. Failure to follow these guidelines will
impair the engine’s safety and performance
characteristics, shorten the engine’s life and may
affect the warranty coverage on your engine.
Consult your Isuzu Distributor for assistance when
checking items marked with a
Make it a habit to perform daily checks. See Daily
Checks in the Before You Operate Section of this
manual.
SAFETY
●
.
For maximum engine life, Isuzu recommends that
when shutting the engine down, you allow the
engine to idle, without load, for five minutes. This
will allow the engine components that operate at
high temperatures, such as the turbocharger (if
equipped) and exhaust system, to cool slightly
before the engine itself is shut down.
• Never attempt to modify the engine’s design or
safety features such as defeating the engine
speed limit control or the diesel fuel injection
quantity control.
• Modifications may impair the engine’s safety and
performance characteristics and shorten the
engine’s life. Any alterations to this engine may
void its warranty. Be sure to use Isuzu genuine
replacement parts.
Protect the air cleaner, turbocharger (if equipped)
and electric components from damage when you
use steam or high-pressure water to clean the
engine.
Periodic maintenance prevents unexpected
downtime, reduces the number of accidents due to
poor machine performance and helps extend the
life of the engine.
The tightening torque in the Standard Torque Chart
in the Periodic Maintenance Section of this manual
should be applied only to the bolts with a “7” head.
(JIS strength classification: 7T)
• Apply 60 % torque to bolts that are
not listed.
• Apply 80 % torque when tightened to
aluminum alloy.
Never use high-pressure water or compressed air
at greater than 28 psi (193 kPa; 19686 mmAq) or a
wire brush to clean the radiator fins. Radiator fins
damage easily.
11
NOTICE
TNV_OperationManual_T4(under 19kW).book Page 12 Wednesda y, June 17, 2015 11:23 AM
SAFETY
• Always be environmentally
responsible.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
Precautions for handling desiccant
Disposal:
This material is disposable as non-flammable.
howev er , the bag is flammab le and if it is necessary ,
then tear the bag and discard the bag and the
contents separately.
It is desirable to bury the contents in the bag under
ground.
Dispose in accordance with the disposal standards
for industrial waste defined by local laws and
regulations.
Handling:
The contents of the bag do not leak out in the
normal use.
Take the following emergency measures, however,
if the contents leak out.
NOTICE
• If the contents get on the skin, rinse thoroughly
with running water.
• If the contents get in the eyes, rinse thoroughly
with water. Consult with doctors when any
abnormalities are found.
• If the contents get in the mouth, rinse thoroughly
with water. Drink water to dilute if the content is
swallowed, though a small amount is harmless.
Consult with doctors when any abnormalities are
found.
Characteristics of materials:
• Calcium Chloride (CaCl
• Grain Polysaccharide Approx. 28 %
• Grain Skins Approx. 9 %
• Ethylene Polymer (Bag) Approx. 5 %
Hazard information:
• Explosiveness None
• Inflammability Inflammable
• Combustibility None
• Oxidation None
) Approx. 57 %
2
12
TNV_OperationManual_T4(under 19kW).book Page 13 Wednesda y, June 17, 2015 11:23 AM
TNV Operation Manual
PRODUCT
OVERVIEW
ISUZU C SERIES ENGINE FEATURES AND APPLICATIONS
Isuzu C series engine is environmentally friendly
and is designed to:
• Lower the amount of exhaust gas emissions.
• Reduce engine noise and vibration.
• Be easy to start thanks to the specially designed
fuel injection pump and combustion system.
• Be economical to run because diesel fuel and
engine oil consumption are reduced.
• Be easy to operate due to the mi nimum amount o f
required maintenance and their compact design.
• Be durable and reliable due in part to the newly
designed fuel injection valve and fuel injection
pump.
Isuzu C series engine is designed to supply power
to a wide variety of driven machines including:
• Construction
• Agriculture
• Power generation
We are sure that you will agree these features
provide excellent value in an industrial diesel
engine.
These engines are designed to deliver power to
driven machines by means of a “direct coupled
drive” or “belt drive.” In direct coupled drive engine
applications, the engine’s flywheel housing or end
plate is coupled directly to the driven machine. In
belt drive engine applications, a belt drive is used to
power the driven machine. If you have applications
that require a belt drive and/or front power take-off
(PTO), please contact your Isuzu Distributor.
The engine is designed for a wide range of
applications. Options, such as fuel tank, control
panel, indicators, gauges and alarms, are available
to customize the application.
Since designing the application and installing the
engine require special knowledge and skill, always
consult your Isuzu Distributor for these services.
They will help you:
• Select optional equipment. Optional equipment
should be selected to match the work conditions
and environment.
• Maximize engine performance with a minimum
amount of downtime and safety related incidents
by carefully matching the characteristics of the
engine with the driven machine.
• Plan for safe fuel piping, e xhaust piping, elec trical
wiring, ventilation and accurate engine installation.
• Design your applications so they meet
requirements of the local authorities.
13
12 3
4
5
67891011
12
13
14
15
16
17
18
19
20 21
22
23
24
25
045080-00X00
TNV_OperationManual_T4(under 19kW).book Page 14 Wednesda y, June 17, 2015 11:23 AM
PRODUCT OVERVIEW
COMPONENT IDENTIFICATION
3CH1-NGZG01, 3CH1-SDZP01, 3CJ1-NGZG01
Figure 1 shows where major indirect injection engine components are located.
1 – Lifting eye (flywheel end)
2 – Engine coolant pump
3 – Lifting eye (engine cooling fan end)
4 – Engine cooling fan
5 – V-belt
6 – Crankshaft V-pulley
7 – Side filler port (eng in e oi l)
8 – Drain plug (engine oil)*
9 – Fuel inlet
10–Mechanical fu el pump
11– D ip st ick (engi ne oi l)
12– Fuel priming lever
13– Engi ne oil filter
* Engine oil drain plug location may vary based on oil pan options.
14
Figure 1
14– G over nor lever
15– Fuel injection pump
16– Intak e manifold
17– Ai r intake port (from air cleaner)
18– Fuel filter
19–Fuel return to fuel tank
20–Top filler port (engine oil)
21–Rocker arm cover
22– Flywheel
23–Star ter motor
24– Exhaust manifold
25– Alternator
044905-00X00
123 4 5 6
789101112131415
16 17 18
192021
TNV_OperationManual_T4(under 19kW).book Page 15 Wednesda y, June 17, 2015 11:23 AM
3CJ1-SDZP01
Figure 2 shows where major indirect injection engine components are located.
PRODUCT OVERVIEW
1 – Air intake port (from air cleaner)
2 – Lifting eye (flywheel end)
3 – Intake manifold
4 – Lifting eye (engine cooling fan end)
5 – Engine coolant pump
6 – Engine cooling fan
7–V-belt
8 – Crankshaft V-pulley
9 – Side filler port (engine oi l)
10– D ra in plu g (e ngine oil)*
11–Engine oil filt er
* Engine oil drain plug location may vary based on oil pan options.
12– Mec hanical fuel pump
13– Fuel injection pump
14–Dipstick (engine oil)
15– Governor lever
16– Top filler port (engine oil)
17 – Rocker arm cover
18– Exhaust manifold
19–Flywheel
20–Starter motor
21–Alternator
Figure 2
15
045002-00X00
231
456789101112
1
3
1
4
1
5
16 17 18
19202122
TNV_OperationManual_T4(under 19kW).book Page 16 Wednesda y, June 17, 2015 11:23 AM
PRODUCT OVERVIEW
3CE1
Figure 3 shows where major direct injection engine components are located.
1 – Lifting eye (flywheel end)
2 – Lifting eye (engine cooling fan end)
3 – Engine coolant pump
4 – Engine cooling fan
5 – Crankshaft V-pulley
6 – V-belt
7 – Side filler port (eng in e oi l)
8 – Engine oil cooler
9 – Fuel injection pump
10– Engi ne oil filter
11–Intake manifold
12– Dipstick (engine oil)
13– Fuel filter
14–Fuel return to fuel tank
15– Fuel inlet
16–Top filler port (engine oil)
17 – Rocker arm cover
18– EGR valve
19– Flywheel
20–Star ter motor
21– Exhaust manifold
22– Alternator
Figure 3
* Engine oil drain plug location may vary based on oil pan options.
16
1
K0000585A
045044-00X01
TNV_OperationManual_T4(under 19kW).book Page 17 Wednesda y, June 17, 2015 11:23 AM
LOCATION OF LABELS
Figure 4 shows the location of regulatory and safety labels on Isuzu C series indirect injection
model engine.
The typical location of the emission control
2
Figure 4
information label is shown (Figure 4, (1)).
Typical location of the engine nameplate is shown
(Figure 4, (2)).
PRODUCT OVERVIEW
Figure 5 shows the location of regulatory and safety labels on Isuzu C series direct injection
model engine.
12
Figure 5
■ Location of labels/nameplates on direct injection model engines
Model Engine nameplate EPA/ARB certification label
3CE1 On the top of the locker arm cover (cooling
fan end) Figure 5, (2)
On the top of the locker arm cover
(flywheel end) Figure 5, (1)
17
TNV_OperationManual_T4(under 19kW).book Page 18 Wednesda y, June 17, 2015 11:23 AM
PRODUCT OVERVIEW
FUNCTION OF MAJOR ENGINE COMPONENTS
Components Functions
Air cleaner The air cleaner prevents airbo rn e contaminants from entering the engine.
Since the air cleaner is application specific, it must be carefully selected by
an application engineer. It is not part of the basic engine package as shipped
from the Isuzu factory. Periodic replacement of the air cleaner filter element
is necessary. See the Periodic Maintena nce Schedule on page 64 for the
replacement frequency.
Starter motor The starter motor is powered by the battery. When you turn the key swit ch
in the operator’s console t o the START position, the starter motor engages
with the ring gear installed on the flywheel and starts the flywheel i n motion.
Alternator The alternator is driven by a V-belt which is po wer ed by the crankshaft
V-pulley. The alternator su ppl i es ele ct ric ity t o the engine systems and
charges the battery while the engine is running.
Dipstick (engine oil) The engine oil dipstick is used to deter m i ne t he am ount of engine oil in the
crankcase.
Side and top filler port (engine oil) You can fill the crankcase with engine oil from either the side or top filler
port depending upon which on e is mo st convenient.
Engine oil filter The engine oil filter removes conta m in ant s and sedi m ent from the engine
oil. Periodic replacemen t o f the en gi ne oil filter is necessary. See the
Periodic Maintenance Schedule on page 64 for the replacement frequency.
Engine oil cooler
(if equipped)
Fuel tank The fuel tank is a reservoir that holds diesel fuel. When fuel leaves the fuel
Water separator The water separator removes contaminants, sediment and water fro m
Electric fuel pump The electric fuel pump ma kes sure there is a constant supply of diesel fuel
The engine oil cooler helps to keep the engine oil cool. Engine coolant from
the cooling system is circulated by the coolant pump through an adapter at
the base of the engine to the oil co ol er and then t o th e cy linder block and
back to the coolant pump.
tank it goes to the water separator. Next, fuel is pumped to the fuel filter by
the electric or mechanical fuel pump. Next the fuel goes to the fuel injection
pump. Since fuel is used to keep the fuel injection pump cool and lubricated,
more fuel than necess ar y enters the injection pump. When the injectio n
pump pressure reaches a preset value, a relief valve allows excess fuel to
be returned back to the fue l tank . The f uel t ank is a required engine
component.
diesel fuel going to the fuel filter . Thi s is a re quired component of the fuel
system and is standard equipment with every engine. The separator is
installed between the fue l tank and the fu el pum p. Per iodically drain the
water from the water separator using the drain valve at the bottom of the
separator.
to the fuel injection pump. The electric fuel pump is electro-magnetic and
runs on 12 V DC. An electric fuel pump may be installed as an option or as
standard equipment. Standard equipment may vary based on engine model
and specification. If an electric fuel pump is installed, turn the key switch to
the ON position for 10 to 15 seconds to prime the fuel system.
18
TNV_OperationManual_T4(under 19kW).book Page 19 Wednesda y, June 17, 2015 11:23 AM
PRODUCT OVERVIEW
Components Functions
Mechanical fuel pump
Fuel priming lever
Fuel filter The fuel filter removes contaminant s and sediments from the diesel fuel.
The mechanical fuel pump is a diaphragm-type of pump and is installed on
the fuel injection pump body. The mechanical fuel pump is driven by a cam
on the camshaft of the fuel injection pump. An electric fuel pump is available
as an option. The mechanical fuel pump is not installed on the fuel injection
pump if the electric fuel pump opt i on i s i nstalled.
If the unit has a mechanical fu el pum p, a fuel priming lever on the
mechanical fuel pump primes the fuel system. The fuel system needs to be
primed before you start the engine for the first time, if you run out of fuel, or
if fuel system service is perf ormed. To prime the fuel system, operate the
fuel priming lever until the cup in the fuel filter is full of fuel.
Periodic replacement of the fu el filte r is nec essary. See the Periodic
Maintenance Schedule on page 64 for the replacement frequency. Please
note that the word “diesel” is implied thr oughout this manual when the
word “fuel” is used.
19
TNV_OperationManual_T4(under 19kW).book Page 20 Wednesda y, June 17, 2015 11:23 AM
PRODUCT OVERVIEW
FUNCTION OF COOLING SYSTEM COMPONENTS
Components Functions
Cooling system The C series engine is liqu id-c ool ed by means of a cooling system. The
cooling system cons ist s of a rad i at or , radi at or cap, engine cooling fan,
engine coolant pump , ther m ostat, and reserve tank. Note that all cooling
system components are required for pr oper engine operation. Since
some of the components ar e application specific, they must be
carefully selected by an application engineer. The application specific
items are not part of the basic engine package as shipped from the
Isuzu factory.
• Engine cooling fan The engine cooling fan is dri ven by a V-belt which is powered by the
cranksha ft V-pu lley . The purp ose of t he engin e cooli ng fan is t o circ ulate ai r
through the radiator.
• Engine coolant pump The engine coolant pump circulates the engine coolant through the cylinder
block and cylinder hea d an d returns the engine coolant to the radiator.
• Radiator The radiator acts as a heat exchanger. As the engine coolant circulates
through the cylinder block it absorbs heat. The heat in the engine coolant is
dissipated in the radiator. As the engine cooling fan circulates air through the
radiator, the heat is transferred to the air.
• Radiator cap The radia t or cap controls t he cooling syst em pressure. The cooling system
is pressurized to raise the boiling point of the engine coolant. As the engine
coolant temperatur e rises, the system pressure and the coolant vo lu m e
increases. When the pressure reaches a preset value, the release valve in
the radiator cap opens and the excess engine coolant flows into the reserve
tank. As the engine coolan t tem perature is reduced, the system pressure
and volume is reduced and the vacu um valve in the radiator cap opens
allowing engine coolant to flow from the reserve tank back into the radiator.
• Reserve tank The reserve tank contai ns the overflow of engine coolant from the radiator.
If you need to add engine coolant to the system, add it to the reserve tank,
not the radiator.
• Thermostat A thermostat is placed in the cooling system to prevent engine coolant from
circulating into the radiator until the engine coolant temperature reaches a
preset temperature. When the engine is cold, no engine coolant flows
through the radiator. Once the engine reaches its operating temperature the
thermostat opens and allows engine coolant to flow through the radiator. By
letting the engine warm up as qu ickl y as pos sibl e, th e t her m ostat reduces
engine wear, deposi t s and e m i ssions.
20
WARNING
WARNING
TNV_OperationManual_T4(under 19kW).book Page 21 Wednesda y, June 17, 2015 11:23 AM
ELECTRONIC CONTROL SYSTEM
3CE1
WARNING
• Never use the E-ECU for other purposes than
intended or in other ways than specified by
Isuzu. Doing so could result in the violation of
emission control regulations and will void the
product warranty.
• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.
WARNING
• Be sure to use the E-ECU in conjunction with
the engines whose models or serial numbers
are specified by Isuzu.
Other E-ECU/engine combinations than
specified will void the engine warranty.
• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.
• Replacing the fuel injection pump involves
rewriting the fuel injection data in the E-ECU.
Be sure to contact your Isuzu Distributor
before replacing the fuel injection pump.
Failure to rewrite the fuel injection data before
replacing the fuel injection pump will void the
engine warranty.
• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.
• Replacing the E-ECU involves migrating the
fuel injection data to the existing E-ECU to the
new unit. Be sure to contact your Isuzu
Distributor before replacing the E-ECU.
Failure to migrate the fuel injection data
before replacing the E-ECU will void the
engine warranty.
• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.
PRODUCT OVERVIEW
21
NOTICE
NOTICE
NOTICE
TNV_OperationManual_T4(under 19kW).book Page 22 Wednesda y, June 17, 2015 11:23 AM
PRODUCT OVERVIEW
Shut down the engine if the fault indicator comes
on.
Continuing running the engine with the fault
indicator being on may result in a serious
malfunction of or damage to the engine, and will
void the engine warranty.
• Do not plug or unplug the E-ECU f or a period of at
least 6 seconds after power to the unit has been
turned on or off.
• Do not touch connector pins of the E-ECU with
bare hands.
Doing so may result in corrosion of the connector
pins and/or damage to the internal circuits of the
E-ECU due to static electricity.
NOTICE
Do not energize the starter for a period of longer
than 15 seconds.
Take a pause of at least 30 seconds between
energization of the starter.
Otherwise the starter could suffer damage.
• High-pressure washing not recommended.
• Avoid using high-pressure washing for electronic
or electric devices installed in, on or around the
engine, including the E-ECU, relays and harness
couplers.
Otherwise such devices ma y suff er malfunction due
to water ingress into them.
• Do not force a measuring probe into the female
coupler.
Doing so may cause contact failure of the
connector pins, resulting in malfunction of the
E-ECU.
• Take care to prevent water from entering the
couplers when plugging or unplugging the
connector.
Water inside the couplers may cause corrosion,
resulting in malfunction of the E-ECU.
• Avoid plugging/unplugging the connector more
than approx. 10 times.
Frequent plugging/unplugging of the connector
may cause contact failure of the connector pins,
resulting in malfunction of the E-ECU.
• Do not use the E-ECU that has ev er suffered drop
impact.
NOTICE
Always check the battery for proper charge.
Otherwise the electronically controlled engines may
fail to start.
22
E-ECU
CSD
Engine speed
sensor
Rack position
sensor
Eco-governor
Fuel injection pump
Actuator
Intake Exhaust
EGR-Valve
Piston
Liner
Inj.Nozzle
Re-circulation
EGR
Starting aid
Coolant temperature
sensor
Starter
Operator's console
Stop switch
Key switch
OFF
Accelerator sensor
CAN
Engine
ON
START
TNV_OperationManual_T4(under 19kW).book Page 23 Wednesda y, June 17, 2015 11:23 AM
PRODUCT OVERVIEW
Model 3CE1 engine come with the Exhaust Gas
Recirculation (EGR) system to conform to the
engine emission regulations (EPA 2013 rules).
The EGR system and an electronic governor
(Eco-governor) constitute an electronic engine
control system.
The electronic engine control system regulates the
exhaust gas recirculation flow rate and the fuel
injection volume depending on the engine load and
speed signals from the engine controller (E-ECU),
so that the exhaust gas is kept clean according to
the emission control regulations. Figure 6
illustrates the electronic engine control system.
Features of the electronic engine control system
include:
• Engine speed control schemes
Droop control/Low-idling speed up/Auto
deceleration/High-idling speed down/Black smok e
suppression
• Starting aid
Auto preheating/After heating
• Engine failure detection
• CAN communication with the control system of
the driven machine
Consult the operation manual for the driven
machine for applicability of the features that
depends on the machine.
Figure 6
23
TNV_OperationManual_T4(under 19kW).book Page 24 Wednesda y, June 17, 2015 11:23 AM
PRODUCT OVERVIEW
MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES
3CE1
Component/feature Description
Engine controller (E-E CU ) Adjusts the rack position of the fuel injec tion pump depending
on the speed command signal from the accelerator sensor, thus
regulating the engine speed and power. The engine controller
also regulates the opening of the EGR valve depending on the
engine speed and power. It serves as the master station for the
following component s/ control features.
Electronic governor (Eco-governor) Consists of the engine speed sensor, rack actuator, etc., and is
directly connected to the fuel injection pump in order to regulate
the rack position of the fue l injection pump depending on the
signals communicat ed wit h the E-ECU.
Fuel injection pump (fo r Ec o- gov ernor) Is of single plunger type and equipped with a CSD solenoid
valve that allows the fue l injection timing to advance and the
injection quantity to incr ease, thereby improving the cold start
performance of the engine.
EGR valve Controls the exhaust gas r eci r culation flow rate depending on
the engine speed/load signals from the E-ECU. It is installed on
the top of the exhaust man ifold.
Accelerator sensor Unlike mechanical governors, the Eco-governor has no
governor lever. The accelerator sensor serves as the governor
lever to provide the speed command signal (voltage signal) to
the E-ECU for engine speed control. It is installed in the
operator cabin of the driven machine. Constant speed engines
for e.g. generator use do not require accelerator sensors
because the engine speed can be shifted via a switch on the
operator's console.
Optional CAN communication capa bil ity is available as an option.
Fault indicator Is installed on the operat or ’s console. If a fault occurs in the
E-ECU or Eco-governor, the fault indicator flashes alerting the
operator to a fault. The number of flashes and/or the flashing
pattern vary depending on the type or source of the fault,
Optional
Engine diagnosis tool Allows the operator to troubleshoo t the cause of a problem
Option for service
Engine coolant temper at ure sensor Allows the C SD and ERG to be controlled in engine cold-start
enabling quick-fix.
based on detailed information regarding the problem occurring
in the E-ECU or Eco-governor. This tool can also be used for
data maintenance tasks including programming and mapping.
See Troubleshooting Char t on page 90.
conditions.
24
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