Isuzu 3CH1-NGZG01, 3CJ1-NGZG01, 3CH1-SDZP01, 3CJ1-SDZP01 Introduction Manual

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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).

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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

iii

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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.

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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)

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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.

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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.

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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

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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.

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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.

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.

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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.

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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.

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NOTICE

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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.

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NOTICE

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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.

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NOTICE

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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 %

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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.

Page 20

12 3

67891011

20 21

045080-00X00

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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.

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

Page 21

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

Page 22

045002-00X00

231

456789101112

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.

Page 23

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

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.

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)

Page 24

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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.

Page 25

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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.

Page 26

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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.

Page 27

WARNING

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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

Page 28

NOTICE

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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.

Page 29

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

Page 30

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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.

Page 31

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PRODUCT OVERVIEW

Component/feature Description

ON-glow at start Optional When the key switch is turned to the ON position, the glow plugs

are energized for up to 15 sec onds. The duration of energization depends on t he engine coolant temperature. The HEAT indicator is on during ener gization. When the i ndicator goes out, turn the key switch to the START position to start the engine.

Droop control Reduces the engine spee d by a certain percentage from no

load to full (rated) load in steady state operation. The same percentage droop i s maintained even when the load increases at any no-load speed.

Isochronous control Optional Offers a constant engine speed from no load to full load. The

engine speed does not decrease even when the load i ncreases at any no-load speed.

Low-idling speed up

Increases the low-idling speed to up to 1000 min depending on the engine coolant temperature. When the coolant temperature reaches a predetermined value, this feature returns the engine speed to the normal low idl e setting, thus reducing the warm-up time.

High-idling speed down Optional Decreases the high-idling spe ed depending on the engine

coolant temperature. When the coolant temperature falls to a predetermined value, this fe at ur e re tu rn s t he engine speed to the normal high idle settin g, th us m i ni m i zi ng t he e m issi on of white smoke at low temper at ures.

Auto deceleration Optional Brings the running engine in low idle mode automatically when

the accelerator pedal is not operated for a predetermined period of time. When the pedal is operated, i.e., the accelerator sensor is activated, the low idle mode is cancelled.

-1

(rpm)

Page 32

NOTICE

K0000023A

100

180

220

250

x100

RPM

VDO

PSI

bar

100

120

AUX

MC-704HP-G4

K0000024A

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PRODUCT OVERVIEW

GAUGES AND INDICATORS

The operator’s console provides you with the means to start and stop the unit and a series of gauges and indicators that inform you about the current status of the engine. This is a required engine component. Since the operator’s console is application specific, it must be carefully sel ected by an application engineer. It is not part of the basic engine package as shipped from the Isuzu factory.

Gauges

The following gauges are located on a typical operator’s console. Some operator’s consoles may not have the gauges described here or may have different gauges.

Figure 7

Figure 8

Tachometer - The tachometer display (Figure 7, (1)) or (Figure 8, (1)) shows the engine

speed in revolutions per minute (RPM). Engine coolant temperature - The engine coolant

temperature display (Figure 7, (2)) or (Figure 8, (2)) shows the temperature of the engine coolant.

Engine oil pressure - The engine oil pressure display (Figure 7, (3)) or (Figure 8, (3)) shows the pressure of the engine oil.

Hour meter - The hour meter display (Figure 7, (4)) or (Figure 8, (4)) shows the total

number of hours the engine has run. This is useful for planning the Periodic Maintenance Procedures

on page 66.

Page 33

100

180

220

250

x100

RPM

VDO

PSI

bar

100

120

AUX

MC-704HP-G4

K0000024B

K0000025B

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PRODUCT OVERVIEW

Indicators

The following indicators are located on a typical operator’s console.

Figure 9

HEAT indicator (Figure 9, (1)) - For the “ON-glow” type of the starter switch that does not have the HEAT position in the counterclockwise direction of the ON position, by turning the key to the ON position, the preheating function automatically activates, and the HEAT indicator (Figure 9, (1)) lights up. 4 seconds after the indicator turns off is when to start the operation. In the case of 3CE1 (DI), the indicator goes off after 15 seconds. Please

refer to HEAT on page 28 about the HEAT indicator of the electronic controlled engine.

HEAT indicator (Figure 10, (1)) - When cold starting the engine, in order to activate the glow plug, the starter key needs to be turned to the HEAT position (left side of OFF) (Figure 10, (5)). By turning the key to the HEAT position and keeping it at that position, the HEAT indicator (Figure 10, (1)) lights up, and after 4 seconds, it turns off. The time the indicator turns off is when to start the operation. In the case of 3CE1 (DI), the indicator goes off after 15 seconds.

Battery charge (Figure 9, (2)) or (Figure 10, (2)) When the key is turned to the ON position, the charge indicator lights up. When the engine is started, the alternator (or dynamo) generates power, and the battery starts charging. Then the indicator goes off. This indicator will also come on when there is a problem in the charging system. This indicator does not tell you the charging timing (when the battery is low). See Troubleshooting Chart on page 90.

Engine oil pressure (Figure 9, (3)) or (Figure 10, (3)) - This indicator will come on if the

engine oil pressure is below or exceeds normal limits. See Troubleshooting Chart on page 90.

Engine coolant temperature (Figure 9, (4)) or (Figure 10, (4)) - This indicator will come on if the

engine coolant temperature exceeds normal limits. See Troubleshooting Chart on page 90.

Figure 10

Auxiliary (Figure 9, (5)) - Used for special applications.

Page 34

NOTICE

Optional key switch: Turning it to ON energizes the glow plugs automatically.

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PRODUCT OVERVIEW

GAUGES AND INDICATORS OF ELECTRONIC CONTROL SYSTEM

3CE1

Gauges

The following gauges are located on a typical operator’s console of the electronically controlled engines. Some operator’s consoles may not have the gauges described here or may have different gauges.

Indicators

The following indicators are located on a typical operator’s console.

See the Gauges and Indicators section for description of indicators that are not described below.

Fault (F igur e 11, (1)) (optio nal) - T his indica tor will flash if a fault occurs in the E -ECU or Eco-governor . The number of flashes and/or the flashing pattern vary depending on the type or source of the fault. See Troubleshooting Chart on page 90.

Auxiliary (Figure 11, (2)) - Rese rved as an optional fault indicator.

HEAT (Figure 11, (3)) - This indicator will come on when the glow plugs are energized when cold starting the engine. For the electronic controlled engine, by turning the key switch to the ON position (Figure 11, (7)), the ECU detects the temperature of the engine coolant, and the HEAT indicator turns on for a preset period of time (Maximum 15 seconds), then the glow plug will be preheated. The time the lamp came off is when to start the operation. When an optional after heater is installed, it is energized for up to 80 sec. after the engine has started, during which, however, the indicator is not on.

Others (optional) - Other optional indicators including those for indicating the air cleaner is clogged or the water separator is filled with water can also be installed on the console. See the operation manual f or the driv en machine f or detai ls .

Machine events including alarms and faults are all stored in memory of the E-ECU and can be loaded into the service tool.

Figure 11

Figure 11 Typical Operator’s Console

Page 35

NOTICE

100

180

220

250

x100

RPM

VDO

PSI

bar

100

120

AUX

K0000011A

TNV_OperationManual_T4(under 19kW).book Page 29 Wednesda y, June 17, 2015 11:23 AM

PRODUCT OVERVIEW

CONTROLS

Key Switch

The key s witch for the operator’s console illustrated in Figure 12 has three positio ns - OFF, ON, START and HEAT.

MC-704HP-G4

Figure 12

NOTICE

OFF (key straight up and down) (Figure 12, (1)) and (Figure 13, (1)) - When y ou turn the key to this position the engine shuts down. Electric current to the gauges and indicators is shut off. You can insert and remove the key in this position.

ON (Figure 12, (2)) and (Figure 13, (2)) - This is the position the key will be in when the engine is running. When the engine is not running, use this position to energize the gauges, indicators, electric fuel pump and auxiliary devices.

Never hold the key in the START position for longer than 15 seconds or the starter motor will overheat.

START (Figure 12, (3)) and (Figure 13, (3)) - Turn the key to this position to start the engine. As soon as the engine starts, release the key and it will automatically return to the ON position. Some key switches may be equipped with a feature that prevents you from turning the key to the START position while the engine is running. When operating a key switch with this feature, you cannot turn the key to the START position without first returning the key to the OFF position.

The key swi tch for the operator’s console illustrated in Figure 13 has four positions - OFF, ON, START, and HEAT.

Page 36

NOTICE

K0000021A

K0000648A

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PRODUCT OVERVIEW

Glow Plugs

Glow plugs help make the engine easy to start at cold temperatures. During the engine starting sequence, the glow plugs are activated for approximately 4 seconds (15 seconds in case of 3CE1). After the pre-heat indicator goes out, the engine can be started.

These plugs are installed in the cylinder head swirl chambers for IDI engines or in the combustion chambers for DI engines.

Governor Lever

Figure 13

Never hold the k e y in the START position for longer than 15 seconds or the starter motor will overheat.

HEAT (Figure 13, (4)) - You must turn the key to the HEAT position to activate the glow plug. The indicator will flash for several seconds when you turn the key to HEAT. You can turn the key to START when the indicator goes out.

Figure 14

NOTICE

The governor lever (Figure 14, (1)) controls the engine speed. The lever is linked to the engine speed control device in the driven machine.

The high idle speed limit screw (Figure 14, (2)) restricts the maximum engine speed when the engine is operated without a load.

The low idle speed limit screw (Figure 14, (3)) sets engine speed while it is idling.

Page 37

045045-00X00

Rack actuator

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Engine Stop Solenoid (IDI Engines)

PRODUCT OVERVIEW

Figure 16

Figure 15

When the key is turned to the ON position, the engine stop solenoid (Figure 15, (1)) is energized and allows the fuel injection pump to deliver fuel to the engine, allowing the engine to be started. When the key is turned to the OFF position, the engine stop solenoid is de-energized and shuts off the fuel supply from the fuel injection pump to the engine, causing the engine to stop.

Speed Control of Electronically Controlled Engines

3CE1

The electronically controlled engines have no governor lever. For these engines, the position signal of the throttle lever or accelerator pedal of the driven machine is converted into an electric signal by the accelerator sensor Figure 16, which is then delivered to the rack actuator of the Eco-governor Figure 18 through the E-ECU Figure 17, allowing the engine speed to be controlled.

Figure 17

Figure 18

Page 38

Engine speed

Torque

30 %

100 %

110 %

120 %

100 %60 %

800 min

-1

TNV_OperationManual_T4(under 19kW).book Page 32 Wednesda y, June 17, 2015 11:23 AM

PRODUCT OVERVIEW

Electronic Engine Speed Control

3CE1

■ Start and stop of electronic controlled engines

The electronic controlled engines have no engine stop solenoid. The ECU controls the engine start/stop sequence.

■ Engine performance curves

Figure 20 shows typical engine speed curves that

outline the relationship between engine speed and load.

Droop control

The VM series engines for general use are designed so that the engine speed is reduced by a certain percentage from 30 % load to full rated load. See curves (1) in Figure 19 below. The same percentage droop is maintained at any no-load speed.

Isochronous control

The CL series consists of isochronous design engines, the speed of which is kept constant from no load to full rated load. See curves (2) in Figure 19 below.

Some VM series engines for general use may be custom-engineered and have the isochronous capability. Consult the operation manual for the driven machine for application details of such engines.

Figure 19

Figure 20

Figure 20 Typical operator’s console and switch arrangement

Low-idling speed up

This feature increases the low-idling speed to some extent depending on the engine coolant temperature. When the coolant temperature reaches a predetermined value, this f eature returns the engine speed to the normal low idle setting, thus reducing the warm-up time.

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Auto deceleration (optional)

This feature brings the running engine in low idle mode automatically when the accelerator pedal is not operated for a predetermined period of time. When the pedal is operated, i.e., the accelerator sensor is activated, the low idle mode is cancelled.

A certain ON/OFF combination of switches (1) - (4) on the operator’s console Figure 20 will implement this optional feature. For details, see the operation manual for the driven machine.

High-idling speed down (optional)

This feature decreases the high-idling speed depending on the engine coolant temperature. When the coolant temperature falls to a predetermined value, this feature returns the engine speed to the normal high idle setting, thus minimizing the emission of white smoke at low temperatures.

PRODUCT OVERVIEW

A certain ON/OFF combination of switches (1) - (4) on the operator’s console Figure 20 will implement this optional feature. For details, see the operation manual for the driven machine.

Others

Other optional features can be provided by selecting certain ON/OFF combinations of switches (1) - (4) on the operator’s console Figure 20 will implement this optional f eature. For details, see the operation manual for the driven machine.

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PRODUCT OVERVIEW

This Page Intentionally Left Blank

Page 41

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TNV Operation Manual

BEFORE YOU

OPERATE

This section of the Operation Manual describes the diesel fuel, engine oil, and engine coolant specifications and how to replenish them. It also describes the daily engine checkout.

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BEFORE YOU OPERATE

DIESEL FUEL

Diesel Fuel Specifications

Diesel fuel should comply with the following specifications. The table lists several worldwide specifications for diesel fuels.

Diesel fuel specifica tion Location

ASTM D975 No. 1D S 1 5 No. 2D S 1 5

EN590:96 European Union ISO 8217 DMX International BS 2869-A1 or A2 United Kingdom JIS K2204 Grade No. 2 Japan KSM-2610 Korea GB252 China

■ Additional technical fuel requirements

• When operating the engine in cold districts or

high altitudes, the fuel cetane number should be equal to 45 or higher.

• The sulfur content must not exceed 15 ppm by

volume. A higher sulfur content fuel may cause sulfuric acid corrosion in the cylinders of the engines. Especially in U.S.A. and Canada, Ultra Low Sulfur fuel must be used.

• Use the fuel that can be used where the

temperature is 12 °C (53.6 °F) lower than the expected lowest temperature to prevent the fuel from freezing.

USA

• PAH (Polycyclic Aromatic Hydrocarbons) content should be below 10 % by volume.

• Metal content of Mg, Si, and Al should be equal to or lower than 1 mass ppm. (Test analysis method JPI-5S-44-95)

• The diesel fuel should be free from Zn and Na.

• Lubricity: Wear mark of WS1.4 should be Max.

0.018 in. (460 µm) at HFRR test.

■ Precautions and concerns regarding the

use of diesel fuel

• Never use kerosene.

• Never mix kerosene or used engine oil with the diesel fuel.

• Never use residual fuels that cause diesel fuel filter clogging and carbon deposits on the nozzles.

• Never use fuels stored f or long time in a drum can or the like.

• Never keep fuel in containers with zinc plating on the inside.

• Never use fuels purchased from unauthorized dealer.

• Fuel additives are not recommended. Some fuel additives may cause poor engine performance. Consult your Isuzu representative for more information.

• Bio-diesel fuels. See Bio-diesel fuels on page 37.

• Water and sediment in the fuel s hould not e x ceed

0.05 % by volume.

• Ash content not to exceed 0.01 % by volume.

• Carbon residue content not to exceed 0.35 % by volume. Less than 0.1 % is preferred.

• Total aromatics content should not exceed 35 % by volume. Less than 30 % is preferred.

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BEFORE YOU OPERATE

■ Bio-diesel fuels

General description of biodiesel

1. Biodiesel is a renewable , o xygenated fuel made from agricultural and renewable resources such as soybeans or rapeseeds. Biodiesel is a fuel comprised of methyl or ethyl ester oxygenates of long chain fatty acids derived from the transesterification of vegetable oils, animal fats, and cooking oils. It contains no petroleum-based diesel fuel but can be blended at any level with petroleum-based diesel fuel. In case it is not blended with petroleum-based diesel fuel such biodiesel is referred to as “B100”, which means that it consists of 100 % (pure) biodiesel. However, most common biodiesel is blended with conventional (petroleum-based) diesel fuel. The percentage of the blend can be identified by its name. For example, “B7” consists of 7 % biodiesel and 93 % conventional diesel fuel. The unprocessed vegetable oil is not considered as diesel fuel.

2. Advantages of biodiesel:

• Biodiesel produces less visible smok e and a lower amount of particulate matter.

• Biodiesel is biodegradable and nontoxic.

• Biodiesel is safer than con ventional diesel fuel because of its higher flash point.

Following the increased interest in the reduction of emissions and the reduction of the use of petroleum distillate based fuels; many governments and regulating bodies encourage the use of biodiesel.

3. Disadvantages of biodiesel: Concentrations that are higher than 7 % of

biodiesel (higher than B7) can hav e an adverse affect on the engine’s perf ormance, its integrity and/or durability . The risk of problems occurring in the engine increases as the le v el of biodiesel blend increases. The f ollowing negative aff ects are exempl ary and typical for the usage of high concentrated biodiesel blends:

• Biodiesel can accelerate the oxidation of Aluminum, Brass, Bronz e, Copper and Zinc.

• Biodiesel damages, and finall y seeps through certain seals, gaskets, hoses, glues and plastics.

• Certain natural rubbers, nitride and butyl rubbers will become harder and more brittle as degradation proceeds when used with biodiesel.

• The deteriorated biodiesel creates deposits i n the engines.

• Due to its natural char acteristic, biodiesel will decrease the engine output by appro ximately 2 percent (in case of B20) comparing to conventional (petroleum-based) diesel fuel .

• The fuel consumption ratio will increase by approximately 3 percent (in case of B20) comparing to conventional d iesel fuel.

Approved engines

Isuzu C series engine can be operated with biodiesel with concentrations up to B20. In case of using biodiesel fuel up to B7 concentrations, no special preparations etc. have to be made and the original operating conditions and service intervals as stated in the operating manuals apply. In case of running below indicated engines with biodiesel concentrations from B8 to B20, the required operating conditions (see below Conditions for the operation with biodiesel (from B8 to B20) ) have to be observed.

Other than the following listed engines cannot be run with biodiesel:

• 3CE1, 3CH1 and 3CJ1 Tier 4

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BEFORE YOU OPERATE

Approved fuel

In case of using biodiesel (only concentrations up to B20) such fuel should comply with the below recommended standards. However, raw pressed vegetable oils are not considered to be biodiesel and are not acceptable for use as fuel in any concentration in Isuzu engines.

1. EN14214 (European standard) and/or ASTM D-6751 (American standard). In North America, biodiesel and biodiesel blends must be purchased from the BQ-9000 accredited producers and BQ-9000 certified distributors.

2. All applicable engines can be operated with biodiesel fuel up to B20 (20 % bio-fuel blend) as a maximum concentration. (For your information: In Japan, the legally allowed maximum concentration for on-road applications is B5.)

Conditions for the operation with biodiesel (from B8 to B20)

When operating your applicable Isuzu C series engine with biodiesel blends concentrated above B8, we seriously recommend observing the following operation, service and maintenance conditions:

1. The original service interval of the below stated services as indicated in the respective Isuzu engine standard operation manual, the application manual and the service manual should be halved (please refer to your own manuals for the each service interval):

• Replacement interval of engine oil filter , engine oil and the fuel filter.

• Cleaning interval of the water separator

• Drain interval of the fuel tank.

2. It is required to inspect, clean and adjust the fuel injector every 1000 operating hours.

3. Before using the bio-die sel fuel of B10 or higher, replace the following parts.

• Fuel hose (The hose must be replaced every 2 years or 2000 hours regardless of the bio fuel type.)

• O-ring of fuel filter

• O-ring of water separator

• When replacing a diaphragm type fuel f eed pump to an electronic type, replace to the feed pump and the pump cover i nstructed to the attached list.

• If the water separator is not attached, it needs to be attached.

Please refer to the attached list of exchange parts for details.

4. Please use only biodiesel fuel that is appropriate to the intended operation environment of the engines. This especially applies if the operating ambient temperature falls below 0 degree centigrade.

5. In particular, operation with biodiesel requires daily maintenance as follows:

• Please daily check the engine oil le vel. If the oil level rises abo ve the oil lev el of the pre vious day, the engine oil needs to be immediately replaced.

• Please daily check the water l ev el of the water separator. If the water le vel rises abo ve the “max” indicator, an immediate drain of the water separator is required.

6. Biodiesel blends up to B20 can only be used for a limited time of up to 3 months of the date of biodiesel manufacture. Therefore biodiesel needs to be used at latest within 2 months from the time of filling the tank or within 3 months from the time of production by the fuel supplier , whichever comes first.

7. Before a long-term storage without operating the engine, the biodiesel needs to be drained out completely and the engine has to be run for 30 minutes with conventional diesel fuel as indicated in your operation manual.

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■ KIT parts list for B10 through B 20

3CH1, 3CJ1 3CE1

5-8640-2407-0 5-8640-2408-0

No need

Need to change only O-ring.

P44: 5-8640-2246-0 --> A

Need to change only O-ring.

P44: 5-8640-2246-0 --> B

Fuel oil tank / - Fuel oil tank

Fuel feed pump

- Fuel oil filter

Fuel oil filter

- Fuel injection pump

Fuel injection pump

- Fuel oil filter

Cap, fuel injection no zzle

Fuel injection nozzle

-Fuel injection nozzle

Fuel injection nozzle

- Fuel injection pump

Fuel oil filter

Water separator

No. (1) (1)

Length 2000 2000

Part No. 5-8640-2241-0 5-8640-2241-0

Part name FO-T CMP FO-T CMP

Number 2 2

No. (3) (4)

Length 450 1000

Part No. 5-8640-2242-0 5-8640-2247-0

Part name FO-T CMP FO-T CMP

Number 1 1

No. (6) (5)

Length 270 220

Part No. 5-8640-2243-0 5-8640-2248-0

Part name FO-T CMP FO-T CMP

Number 1 1

No. (11) (7)

Length 450 300

Part No. 5-8640-2244-0 5-8640-2249-0

Part name FO-T CMP FO-T CMP

Number 1 1 Part No.

Part name

Number

No.

Length 115

Part No. 5-8640-1791-0

Part name FO-T CMP

Number 2

No. (16) (17)

Length 150 Formed pipe

Part No. 5-8640-2245-0 5-8640-2250-0

Part name FO-T CMP FO-T CMP

Number 1 1

BEFORE YOU OPERATE

5-8640-1423-0 5-8640-0112-0

CAP CLIP

1 1

(13)

No need

(Because of cartridge type)

Need to change only O-ring. G75 : 5-8640-2251-0 --> C P16 : 5-8640-1755-0 --> D P7 : 5-8640-2252-0 --> E G65 : 5-8640-2418-0 --> C (Need only for TAIYO-GIKEN)

Fuel feed pump

5-8640-2409-0

Electric feed pump: 5-8640-0024-0

Cover assy, feed pump: 5-8640-1927-0

Page 46

033051-00X

033050-00X

033042-00X

Part number

A 5-8640-2246-0 (P44) B 5-8640-2246-0 (P44) C 5-8640-2251-0 (G75) D 5-8640-1755-0 (P16) E 5-8640-2252-0 (P7)

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BEFORE YOU OPERATE

Page 47

NOTICE

K0000002A

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Filling the Fuel Tank

BEFORE YOU OPERATE

DANGER

Fire and Explosion Hazard!

• Diesel fuel is flammable and explosive under certain conditions.

• 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.

• Wipe up all spills immediately.

• 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.

• 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.

• Failure to comply will result in death or serious injury.

• 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 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.

Note that a typical fuel tank is shown. The fuel tank on your equipment may be different.

1. Clean the area around the fuel cap

(Figure 1, (1)).

2. Remove the fuel cap from the fuel tank

(Figure 1, (2)).

3. Observe the fuel level sight gauge

(Figure 1, (3)) and stop filling when gauge shows fuel tank is full. Never overfill the fuel tank.

4. Replace the fuel cap (Figure 1, (1)), hand

tighten. Over tightening the fuel cap will damage it.

Figure 1

Page 48

DANGER

K0000649A

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BEFORE YOU OPERATE

Priming the Fuel System

Fire and Explosion Hazard!

• Diesel fuel is flammable and explosive under certain conditions.

• If the unit has an electric fuel pump, when you prime the fuel system, turn the key switch to the ON position for 10 to 15 seconds to allow the electric fuel pump to prime the system.

• 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.

• Failure to comply will result in death or serious injury.

The fuel system needs to be primed under certain conditions:

T o prime the fuel system if an electric fuel pump is installed:

1. Turn the key to the ON position for 10 to 15 seconds. This will allow the electric fuel pump to prime the fuel system.

2. Never use the starter motor to crank the engine in order to prime the fuel system. This may cause the starter motor to overheat and damage the coils, pinion and/or ring gear.

To prime the fuel system if a mechanical fuel pump is installed:

1. Operate the fuel priming lever (Figure 2, (1)) several times until the fuel filter cup (Figure 2, (2)) is filled with fuel.

2. Never use the starter motor to crank the engine in order to prime the fuel system. This may cause the starter motor to overheat and damage the coils, pinion and/or ring gear.

• Before starting the engine for the first time

• After running out of fuel and fuel has been added to the fuel tank

• After fuel system maintenance such as changing the fuel filter and draining the water separator, or replacing a fuel system component.

Figure 2

Page 49

NOTICE

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ENGINE OIL

The fuel system needs to be primed under certain conditions:

• Before starting the engine for the first time

• After running out of fuel and fuel has been added to the fuel tank

• After fuel system maintenance such as changing the fuel filter and draining the water separator, or replacing a fuel system component.

To prime the fuel system:

1. Turn the key to the ON position for 10 to 15

seconds. This will allow the electric fuel pump to prime the fuel system.

2. Never use the starter motor to crank the engine

in order to prime the fuel system. This may cause the starter motor to overheat and damage the coils, pinion and/or ring gear.

• 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. Overfilling may result in white exhaust smoke, engine overspeed or internal damage.

BEFORE YOU OPERATE

Engine Oil Specifications

Use an engine oil that meets or exceeds the following guidelines and classifications:

■ Service categories

• API service categories CD, CF, CF-4, CI-4 (Use an API CF or higher quality oil for electronically controlled engines.)

• ACEA service categories E-3, E-4, and E-5

• JASO service category DH-1

■ Definitions

• API classification (American Petroleum Institute)

• ACEA classification (Association des Constructeurs Européens d’Automobilies)

• JASO (Japanese Automobile Standards Organization)

Page 50

-30°C -20°C -10°C 0 10°C 20°C 30°C

SAE 5W-30

SAE 15W-40

SAE 20

SAE 30

SAE 10W-30

K0000005A05

40°C

K0000587AX

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BEFORE YOU OPERATE

Note:

• Be sure the engine oil, engine oil storage containers, and engine oil filling equipment are free of sediments and water.

• Change the engine oil after the first 50 hours of operation and then at every 250 hours thereafter.

• Select the oil viscosity based on the ambient temperature where the engine is being operated. See the SAE Service Grade Viscosity Chart (Figure 3).

• Isuzu does not recommend the use of engine oil “additives.”

■ Additional technical engine oil

requirements:

The engine oil must be changed when the Total Base Number (TBN) has been reduced to 1.0 mgKOH/g. TBN (mgKOH/g) test method; JIS K-201-5.2-2 (HCI), ASTM D4739 (HCI).

Engine Oil Viscosity

Select the appropriate engine oil viscosity based on the ambient temperature and use the SAE service grade viscosity chart in Figure 3.

Checking Engine Oil

1. Make sure engine is level.

2. Remove dipstick (Figure 4, (1)) and wipe with clean cloth.

3. Fully reinsert dipstick.

4. Remove dipstick. The oil level should be

between upper (Figure 4, (2)) and lower (Figure 4, (3)) lines on the dipstick.

5. Fully reinsert dipstick.

Adding Engine Oil

1. Make sure engine is level.

2. Remove oil cap (Figure 4, (4)).

3. Add indicated amount of engine oil at the top or side engine oil filler port (Figure 4, (5)).

4. Wait three minutes and check oil level.

5. Add more oil if necessary.

6. Reinstall oil cap (Figure 4, (4)) and hand-tighten. Over-tightening may damage the cap.

Figure 3

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045046-00X01

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Engine Oil Capacity (Typical)

Note: These are the engine oil capacities

The following are the engine oil capacities for various Isuzu C series engine.

BEFORE YOU OPERATE

associated with a “Deep Standard” oil pan. Oil capacity will vary dependent upon which optional oil pan is used. Refer to the operation manual provided by the driven machine manufacturer for the actual engine oil capacity of your machine.

Engine oil capacity (typical)

Figure 4

CAUTION

To refuel the engine oil, refuel slowly after removing the dipstick and both caps. If you refuel rapidly, the oil intrusion to the intake occurs through the PCV valve of the valve cover. It will result in an oil hammer at engine start, which may cause damage to the engine.

Engine model

3CH1-NGZG01 3CH1-SDZP01

3CJ1-NGZG01 3,0/1,6 qt (2,8/1,5 ℓ) 3CJ1-SDZP01 3.1/1.7 qt (2.9/1.6 ℓ)

Engine oil capacity (typical)

Engine model

3CE1 7.1/4.1 qt (6.7/3.9 ℓ)

Dipstick

upper limit/lower limit

3.6/1.9 qt (3.4/1.8 ℓ)

Dipstick

upper limit/lower limit

Page 52

DANGER

WARNING

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BEFORE YOU OPERATE

ENGINE COOLANT

Scald Hazard!

• 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.

Burn Hazard!

• Wait until the engine cools before you drain the engine coolant. Hot engine coolant may splash and burn you.

• Failure to comply could result in death or serious 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.

• Failure to comply may result in minor or moderate injury.

NOTICE

• 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.

Page 53

FULL

LOW

K0000029A

045047-00X00

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BEFORE YOU OPERATE

Engine Coolant Specifications

Use a Long Life Coolant (LLC) or an Extended Life Coolant (ELC) that meets or exceeds the following guidelines and specifications.

• ASTM D6210, D4985 (US)

• JIS K-2234 (Japan)

• SAE J814C, J1941, J1034 or J2036 (International)

■ Alternative engine coolant

If an Extended or Long Life Coolant is not availab le, alternatively, you may use an ethylene glycol or propylene glycol based conventional coolant (green).

NOTICE

• Always use a mix of coolant and water . Ne v er use water only.

• Mix coolant and water per the mixing instructions on the coolant container.

• Water quality is important to coolant performance. Isuzu recommends that soft, distilled or demineralized water be used to mix with c oolants.

• Never mix extended or long life coolants and conventional (green) coolants.

Filling Radiator with Engine Coolant

Fill the radiator and reserve tank as follows. This procedure is for filling the radiator for the first time or refilling it after it is flushed. Note that a typical radiator is illustrated.

1. Check to be sure the radiator drain plug is installed and tightened or the drain valve (Figure 5, (1)) is closed. Also make sure the coolant drain plug (Figure 6, (1)) in the cylinder block is closed.

Figure 5

• Never mix different types and/or colors of extended life coolants.

• Replace the coolant every 1000 engine hours or once a year.

Figure 6

Page 54

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BEFORE YOU OPERATE

2. Remove the radiator cap (Figure 5, (2)) by turning it counterclockwise about 1/3 of a turn.

3. Pour the engine coolant slowly into the radiator until it is even with the lip of the engine coolant filler port. Make sure that air bubbles do not develop as you fill the radiator.

4. Reinstall the radiator cap (Figure 5, (2)). Align the tabs on the back side of the radiator cap with the notches on the engine coolant filler port. Press down and turn the cap clockwise about 1/3 of a turn.

5. Remove the cap of the reserve tank (Figure 5, (3)), and fill it to the LOW (COLD) mark (Figure 5, (4)) with engine coolant. Reinstall the cap.

6. Check the hose (Figure 5, (5)) that connects the reserve tank (Figure 5, (3)) to the radiator. Be sure it is securely connected and there are no cracks or damage. If the hose is damaged, engine coolant will leak out instead of going into the reserve tank.

7. Run the engine until it reaches operating temperature. Check the level of engine coolant in the reserve tank When the engine is running and the engine coolant is at normal temperature, the coolant level in the reserve tank should be at or neat the FULL (HOT) mark (Figure 5, (6)). If the coolant is not at the FULL (HOT) mark, add coolant to the reserve tank to bring the coolant level to the FULL (HOT) mark.

Daily Check of the Cooling System

1. Check the level of engine coolant in the reserve tank. When the engine is cold, the coolant level in the tank should be at or slightly above the LOW (COLD) mark (Figure 5, (4)) on the coolant reserve tank.

If the coolant lev el is at the FULL (HO T) mark (Figure 5, (6)) when the engine is c old, the coolant will expand when it becomes hot and possibly spray out of the overflo w hose.

2. Add additional engine coolant to the reserve tank if necessary.

3. Check the radiator hoses for cracks, abrasions, cuts or other damage. Replace as necessary.

Engine Coolant Capacity (Typical)

Note: Capacities listed are for the engine only

without a radiator. Refer to the operation manual provided by the driven machine manufacturer for actual engine coolant capacity on your machine.

The following are the engine coolant capacities for various Isuzu C series engine.

Engine coolant capacity (t ypical)

Engine model

3CH1-NGZG01 3CH1-SDZP01

3CJ1-NGZG01 1.0 qt (0.9 ℓ) 3CJ1-SDZP01 1.1 qt (1.0 ℓ)

Engine coolant capacity

1.0 qt (0.9 ℓ)

Engine coolant capacity (t ypical)

Engine model

3CE1 2.1 qt (2.0 ℓ)

Engine coolant capacity

Page 55

WARNING

NOTICE

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BEFORE YOU OPERATE

DAILY CHECKS

Before you begin any job, make sure the Isuzu C series engine is in good operating condition. Make sure you check the following items before you start your shift and have any repairs completed before you start work.

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 exposed to high-pressure fuel spray, obtain prompt medical treatment.

• Never check for a fuel leak with your hands. 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.

NOTICE

Make it a habit to perform daily checks. See Daily Checks in the Before You Operate Section of this manual.

Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor machine performance and helps extend the life of the engine.

Visual Checks

1. Check for engine oil leaks.

2. Check for fuel leaks.

3. Check for engine coolant leaks.

4. Check for damaged or missing parts.

5. Check for loose, missing or damaged fasteners.

6. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors.

7. Check hoses for cracks, abrasions, and damaged, loose or corroded clamps.

8. Check and clean radiator fins as necessary.

See Check and clean radiator fins on page 76.

9. Check the water separator for presence of water and contaminants. If you find any water or contaminants, drain the water separator. See Drain water separator on page 71. If you have to drain the water separator frequently , drain the fuel tank and check for the presence of water in your fuel supply. See Drain fuel tank on page 75.

If any problem is noted during the visual check, the necessary corrective action should be taken before you operate the engine.

Check Diesel Fuel, Engine Oil and Engine Coolant Levels

Follow the procedures in Diesel Fuel on page 36, Engine Oil on page 43 and Engine Coolant on page 46 to check these levels.

Check Engine Speed Control

Check the engine speed control for smooth operation, adjust and lubricate or clean as necessary. See Check and adjust the governor

lever and engine speed control (except electronically controlled engines) on page 77.

Page 56

AUX

K0000009AX01

K0000025AX

3CE1

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BEFORE YOU OPERATE

Check Operator’s Console

Before you operate the engine you should make sure that all of the indicators are functioning properly.

Check Indicators

Isuzu C series engine are available with various operator’s consoles. In the below Figures, three types of typical operator’ s console including the one for electronic controlled engines are shown as examples.

HEAT Figure 8 shows a typical indicator arrangement on

the operator’s console. With the specification of standard glow (preheat), as you turn the key switch to the HEAT position, the HEAT indicator is turned on for 4 seconds, showing that the glow plugs are energized. When the indicator goes off , turn the ke y switch to START position and start the engine. In the case of 3CE1 (DI), the indicator goes off after 15 seconds.

Figure 9

Figure 7

Figure 8

Figure 7 shows an indicator arrangement with the specification for ON-glow. As you turn the key switch to ON position, the HEAT indicator is turned on for 4 seconds. When the indicator goes off, turn the key switch to the START position and start the engine. In the case of 3CE1 (DI), the indicator goes off after 15 seconds.

Figure 9 shows an operator’s console of an electronic controlled engine. The electronic controlled engine has an ON-glow specification. Depending on the water temperature, the heat indicator will turn on for 15 seconds at the longest, and preheats the glow plugs. When the indicator goes off, turn the key switch to the START position and start the engine.

Page 57

TNV_OperationManual_T4(under 19kW).book Page 51 Wednesda y, June 17, 2015 11:23 AM

Battery charge (Figure 7, (2)) or (Figure 8, (2)) or (Figure 9, (4)) - Stays on until the engine is running

and the alternator is supplying charging current. This indicator does not indicate whether the battery is discharged.

Engine oil pressure (Figure 7, (3)) or (Figure 8, (3)) or (Figure 9, (5)) - Stays on until the

engine is running and the oil pressure is within normal limits.

Engine coolant temperature (Figure 7, (4)) or (Figure 8, (4)) or (Figure 9, (6)) - Stays on

momentarily. Comes back on if engine overheats. Auxiliary (Figure 7, (5)) or (Figure9, (2)) - Stays

on momentarily. Used for special applications. Here is a summary of how these indicators

function. The table shows what happens when you turn the key in a certain direction (e.g., OFF to ON).

BEFORE YOU OPERATE

Fault indicator (Figure 9, (1)) (optional) -

Illuminates for approx. 2 sec. when the key sw itch is turned to ON, and stays off while the engine is running. If a fault occurs in the Eco-governor system or during energization of the E-ECU, this indicator will flash in a certain pattern to indicate what fault has occurred. See the troubleshooting section for details.

Page 58

TNV_OperationManual_T4(under 19kW).book Page 52 Wednesda y, June 17, 2015 11:23 AM

BEFORE YOU OPERATE

Indicator OFF to HEAT OFF to ON ON to OFF

IDI (3CH1, 3CJ1) turns off after indicating for 4 seconds. DI (3CE1 ) turns off after indicating for 15 seconds.

ON-glow

HEAT

type

Figure 7, (1) Figure 8, (1) Figure 9, (3)

HEAT position available on key switch

Battery ch arge

Figure 7, (2) Figure 8, (2) Figure 9, (4)

Engine oil pressure

Figure 7, (3) Figure 8, (3) Figure 9, (5)

Engine coolant temperature

Figure 7, (4) Figure 8, (4) Figure 9, (6)

Auxiliary

Figure 7, (5) Figure 9, (2)

Fault (optional)

Figure 9, (1)

3CE1

Glow NA

IDI (3CH1, 3CJ1) turns off

Glow

after indicating for 4 seconds. DI (3CE1) turns off after indicating for 15 seconds.

NA ON

NA Lights for 2 sec. only.

Note that, for electronic control type engines (3CE1), the indicators are controlled from 1 to 15 seconds depending on the temperature of co oling water.

OFF

OFF OFF

OFF (Stays on until alternator is supplying charging current. Remains on if there is a problem in the charging system. This indicator does not indicate whether the battery is discharged.)

OFF (Stays on until oil pressure reaches normal operating pressure. Remains on, or comes back on, if there is a pr obl e m in t he lubrication system.)

OFF (Stays on momentarily. Comes back on if there is a problem in the cooling system.)

OFF

OFF (Flashes or intermittently lights if a fault occurs in the E-ECU or Eco-governor.)

Page 59

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TNV Operation Manual

ENGINE OPERATION

This section of the Operation Manual describes the procedures for starting the engine, checking engine performance during operation, and shutting the engine down.

Page 60

NOTICE

c o

K0000655A

K0000012B

AUX

K0000009BX

TNV_OperationManual_T4(under 19kW).book Page 54 Wednesda y, June 17, 2015 11:23 AM

ENGINE OPERATION

STARTING ENGINE

Use the following procedure to start the engine. Note that two typical operator’ s consoles are shown for illustrative purposes only.

1. Make sure you follow the procedures stated in the Daily Checks on page 49.

2. Before first starting electronically controlled engines 3CE1: The E-ECU of the electronically controlled engines shown above needs to be initialized at initial power up. When the fault indicator comes on at initial power up, the E-ECU has finished initialization. Then always turn the key switch to the OFF position once before starting the engine. (The E-ECU has usually been initialized before the driven machine is delivered). From the second power up, make sure the fault indicator is on for 2 sec. when turning the key switch to the ON position.

3. Make sure the water separator fuel valve

(Figure 1, (1)) is in the ON position (Figure 1, (2)).

4. Set the transmission (if equipped) in the NEUTRAL position.

5. Disengage the PTO (if equipped).

6. Set the engine speed control to the mid-position.

Figure 2

Never use an engine starting aid such as ether. Engine damage will result.

7. Insert the key int o the key switch (Figure 2, (1)) or (Figure 3, (1)).

Figure 1

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NOTICE

K0000025C

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10. If the engine fails to start:

Figure 3

8. Turn the key to the ON position (Figure 2, (2)) or the HEAT position (Figure 3, (2)). The pre-heat indicator (Figure 2, (3)) flashes for several seconds and then goes out. After the pre-heat indicator goes out you can start the engine.

Note: The glow plugs are used to assist

starting in cold weather conditions. If you are operating your engine in normal or warm weather conditions, you may bypass the Pre-Heat/Heat functions and go directly to Start.

ENGINE OPERATION

1- 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.

Note: Some key s witc hes are equipped with an

interlock that will not allow you to re-engage the starter without first turning the key to the OFF position.

2- Wait at least 30 seconds before you attempt

to start the engine again. This procedure will allow the battery voltage to recover and prevent damage to the starter motor due to the low battery voltage.

Never hold the key in the ST AR T position for longer than 15 seconds or the starter motor will overheat.

9. Turn the key clockwise to the START position (Figure 2, (4)) or (Figure 3, (4)). Release the key as soon as the engine starts. It will return to the ON position (Figure 2, (2)) or (Figure 3, (5)).

Note: The starter of electronically controlled

engines 3CE1 will start with a delay of approx. 0.5 sec. after the key switch has been turned to the ON position. This is because the E-ECU self-diagnostics has run and is not a failure.

Page 62

WARNING

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ENGINE OPERATION

HIGH-ALTITUDE INJECTION CONTROL DEVICE

COLD START DEVICE

3CH1, 3CJ1

This series has a high-altitude injection control

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.

The cold start device on direct injection models improves engine starting at lower temperatures.

• If the engine cooling system temperature is below 5 °C (41 °F), the cold start device automatically advances the fuel injection timing and slightly increases the fuel injection volume.

• The engine idle speed will be slightly elevated for approximately the first 5 minutes of operation.

• When the cold start device is activated, you may notice a slight increase in the amount of exhaust smoke. This is normal.

• Never engage the transmission or PTO while the cold start device is activated or unexpected movement of the machine may result.

device installed. It suppresses black smoke when operating at high altitudes and at the same time aims to control particulate matter.

The device consists of an output control solenoid that is attached to the fuel injection pump and a solenoid driver (with an atmospheric pressure sensor) that is assembled on the implement side. The output control solenoid actuates at engine start. (It does not actuate during engine operation.) At engine start, the starter operates and the engine starts running. 4 seconds after the starter turns off, the solenoid driver measures the atmospheric pressure and determines whether to actuate the solenoid. (The solenoid is energized during normal operation, but it is turned off during the start of the control device.) If at this time the atmospheric pressure sensor determines that the altitude is 2624 ft (800 m) or more, the control device operates. It reduces the fuel injection amount and thus controls the occurrence of black smoke. Because of this reduction in the injection amount, the output decreases. At 5500 ft (1676 m), the decrease in output (i.e. torque) is 20 % of the maximum at low altitudes. Therefore, only apply medium to low load when operating at high altitudes.

NOTICE

The injection control device does not actuate during engine operation. (Switch operation is not performed.) Therefore, when the control device is not yet operating and the machine is moved to a high altitude during operation, or when the control device is already operating and the machine is moved to a low altitude, turn the key switch to OFF (engine stop). This resets the control device. After re-starting the engine, the necessity for injection control is again determined.

Page 63

WARNING

NOTICE

Control solenoid

045348-00X00

TNV_OperationManual_T4(under 19kW).book Page 57 Wednesda y, June 17, 2015 11:23 AM

CHECKING THE ENGINE DURING OPERATION

Figure 4

• Never check for a fuel leak with your hands. 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.

ENGINE OPERATION

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 exposed to high-pressure fuel spray, obtain prompt medical treatment.

Make sure the engine is installed on a lev el surf ace. If a continuously running engine is installed at an angle greater than (IDI = 25°, DI = 30°) in any direction or if an engine runs for short periods of time (less than three minutes) at an angle greater than (IDI = 30°, DI = 35°) in any direction, engine oil may enter the combustion chamber causing excessive engine speed and white exhaust smoke. This may cause serious engine damage.

Page 64

NOTICE

K0000023B

100

180

220

250

x100

RPM

VDO

PSI

bar

100

120

AUX

MC-704HP-G4

K0000024C

TNV_OperationManual_T4(under 19kW).book Page 58 Wednesda y, June 17, 2015 11:23 AM

ENGINE OPERATION

New engine break-in:

• On the initial engine start-up, allow the engine to idle for approximately 15 min utes while you 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 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.

Never engage the starter motor while the engine is running. This may damage the starter motor pinion and/or ring gear.

1. While the engine is running, check the gauges

for normal indications. The gauges shown in Figure 6 and Figure 5 are provided for illustrative purposes only.

Figure 5

Figure 6

• Tachometer (Figure 6, (1)) or (Figure 5, (1))

-Make sure the engine speed is wi thin normal limits.

• Engine oil pressure (Figure 6, (2)) or (Figure 5, (3)) - Make sure the engine oil pressure is within normal limits. See Principal

Engine Specifications on page 105.

• Engine coolant temperature (Figure 6, (3)) or (Figure 5, (2)) - Make sure the engine coolant temperature is within normal limits.

• Hour meter - The hour meter display (Figure 6, (4)) or (Figure 5, (4)) shows the total number of hours the engine has run. This is useful for planning periodic maintenance operations. See Periodic Maintenance Schedule on page 64.

• If any of the gauges shows an out of normal limits condition, shut down the engine and have the necessary repairs performed.

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NOTICE

TNV_OperationManual_T4(under 19kW).book Page 59 Wednesda y, June 17, 2015 11:23 AM

ENGINE OPERATION

2. After the engine has reached operating temperature, all of the indicators (Figure 6, (5)) or (Figure 5, (5)) should be off. If any of the indicators are on, shut down the engine and have the necessary repairs performed.

3. Check for white or black smoke from the exhaust system. A small amount of white exhaust smoke is normal on start-up of a cold engine. Black exhaust smoke could mean the engine is overloaded or is being over-fueled. If either of these conditions persists, contact your Isuzu Distributor.

4. Check for abnormal sounds or vibration. In some applications the engine and its mounting may start to resonate and cause unusual vibrations at certain engine speeds. Avoid running the engine at these speeds. If the abnormal sounds or vibration cannot be resolved, shut down the engine and have the necessary repairs performed. Contact your Isuzu Distributor.

5. Check for any fuel, engine coolant or engine oil leaks. If any leaks are found shut down the engine and have the necessary repairs performed.

6. Check the fuel level during operation. If the fuel level runs low, stop the engine and refuel.

ADJUST ENGINE SPEED

New engine break-in:

• 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.

Use the engine speed control to adjust the engine speed for the task that will be performed.

Page 66

NOTICE

AUX

K0000009C

K0000025D

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ENGINE OPERATION

SHUTTING DOWN THE ENGINE

Follow these steps to shut down the engine:

1. Disengage the PT O and/or set the tr ansmission to NEUTRAL (if equipped).

2. Set the engine speed control to its lowest setting.

3. Run the engine at low idle speed for at least fiv e minutes before you shut it down.

4. Turn the key to the OFF position (Figure 7, (1)) or (Figure 8, (1)) and remove it from the key switch.

Figure 8

5. If the engine will not be used for six months or longer, follow the additional instructions in Long-Term Storage on page 99.

Figure 7

Page 67

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TNV Operation Manual

PERIODIC

MAINTENANCE

This section of the Operation Manual describes the procedures for proper care and maintenance of the engine.

Page 68

WARNING

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PERIODIC MAINTENANCE

PRECAUTIONS

The Importance of Periodic Maintenance

Engine deterioration and wear occurs in proportion to length of time the engine has been in s ervice and the conditions the engine is subject to during operation. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor machine performance and helps extend the life of the engine.

Performing Periodic Maintenance

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.

• 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.

Perform periodic maintenance procedures in an open, level area free from traffic. If possible, perform the procedures indoors to prevent environmental conditions, such as rain, wind, or snow, from damaging the machine.

The Importance of Daily Checks

Periodic Maintenance Schedules assume that the daily checks are performed on a regular basis. Make it a habit of performing daily checks before the start of each shift. See Daily Checks on

page 49.

Keep a Log of Engine Hours and Daily Checks

Keep a log of the number of hours the engine is run each day and a log of the daily checks performed. Also note the date, type of repair (e.g., replaced alternator), and parts needed for any service needed between the periodic maintenance intervals. Periodic maintenance intervals are every 50, 250, 500, 1000, 1500, 2000 and 3000 engine hours. Failure to perform periodic maintenance will shorten the life of the engine.

Isuzu Replacement Parts

Isuzu recommends that you use "Isuzu genuine parts" when replacement parts are needed. Genuine replacement parts help ensure long engine life.

Tools Required

Before you start any periodic maintenance procedure make sure you have the tools you need to perform all of the required tasks.

Ask Your Isuzu Distributor For Help

Our professional service technicians have the expertise and skills to help you with any maintenance or service related procedures you need help with.

Required EPA/ARB Maintenance USA Only

To maintain optimum engine performance and compliance with the Environmental Protection Agency (EPA) Regulations Non-Road Engines and the California Air Resources Board (ARB, California), it is essential that you follo w the Periodic

Maintenance Schedule on page 64 and Periodic Maintenance Procedures on page 66.

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NOTICE

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PERIODIC MAINTENANCE

EPA/ARB Installation Requirements USA Only

The following are the installation requirements for the EPA/ARB. Unless these requirements are met, the exhaust gas emissions will not be within the limits specified by the EPA and ARB.

Therefore, periodically perform the maintenance and cleaning of air cleaner and muffler.

Maximum Exhaust Gas Restriction shall be:

• 3CH1, 3CJ1: 1.71 PSI (11.8 kPa; 1200 mm Aq) or less

• 3CE1: 2.22 PSI (15.3 kPa, 1560 mm Aq) or less

Maximum air intake restriction shall be 0.90 PSI (6.23 kPa; 635 mmAq) or less. Cl ean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value.

Note: EGR-equipped engines have a range of

allowable intake and exhaust restrictions; a minimum and a maximum value.

Tightening Fasteners

Use the correct amount of torque when you tighten fasteners on the machine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure.

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.

STANDARD TORQUE CHART

Thread Size × Pitch mm M6 × 1.0 M8 × 1.25 M10 × 1.5 M12 × 1.75 M14 × 1.5 M16 × 1.5

in.-lb96.0 ± 9.0–––––

Tightening torque

Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise

specified.

ft-lb – 19.0 ± 2.0 36.0 ± 4.0 65.0 ± 7.0 101.0 ± 7.0 167.0 ± 7.0

N·m 10.8 ± 1.0 25.5 ± 2.9 49.0 ± 4.9 88.3 ± 9.8 137.0 ± 9.8 226.0 ± 9.8

kgf/m 1.1 ± 0. 1 2. 6 ± 0. 3 5.0 ± 0.5 9.0 ± 1.0 14.0 ± 1.5 23.0 ± 2.0

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NOTICE

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PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Daily and periodic maintenance is important to keep the engine in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively. The following should be treated only as a general guideline.

Consult your Isuzu Distributor for assistance when checking items marked with a

Periodic Maintenance Chart

: Check : Replace ●: Contact your Isuzu Distributor

Periodic maintenance in terval

Every

System Check item Daily

Check and refill engine coolant  Check and clean radiator fins

Check and adjust cooling fan V-belt

Cooling system

Change coolant

Cylinder head

Electrical equipment

Engine oil

Check and adjust intake/exhau st va lve clearance ●

Check indicators  Check battery and recharge  Check engine oil level  Drain and fill engine oil

Replace engine oil filter

hours



1st

time



1st

time

250

hours



2nd and

after



2nd and

after

Every

500

hours

●

Every

1000

hours

 or

every 1 year which-

ever

comes

first

Every

1500

hours

Every

2000

hours

Every

3000

hours

Page 71

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System Check i t em Daily

Engine speed control

Emission control warranty

Check and adjust governor lever and engine speed control

Inspect, clean and test fuel injection nozzle, if necessary

Inspect, clean and test EGR valve



PERIODIC MAINTENANCE

: Check : Replace ●: Contact your Isuzu Distributor

Periodic maintenance i nterval

Every

hours

250

hours

500

hours

1000 hours

1500

hours

●

2000

hours

Every

3000

hours

●

Inspect crankcase breather system Check and refill fuel tank level  Drain fuel tank 

Fuel

Hoses

Intake and exhaust

Complete engine

Note: These procedures ar e considered normal maintenance and are performed at the ow ner’s expense.

Drain water separator  Check water separator  Clean water separator  Replace fuel filter 

Check and replace fuel hoses and engine coolant hoses

Clean or replace air cleaner element 

Overall visual check daily 

●



every

years.

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WARNING

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PERIODIC MAINTENANCE

PERIODIC MAINTENANCE PROCEDURES

After Initial 50 Hours of Operation

Perform the following maintenance after the initial 50 hours of operation.

• Replace engine oil and engine oil filter

• Check and adjust cooling fan V-belt

■ Replace engine oil and engine oil filter

Burn Hazard!

• 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.

• 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.

NOTICE

• 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. Overfilling may result in white exhaust smoke, engine overspeed or internal damage.

NOTICE

• Always be environmentally responsible.

• 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.

Page 73

K0000587D

045048-00X01

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The engine oil on a new engine becomes contaminated from the initial break-in of internal parts. It is very important that the initial oil change is performed as scheduled.

Note: The oil drain plug may be in another location

if an optional oil pan is used.

Drain the engine oil as follows:

1. Make sure the engine is level.

2. Start the engine and bring it up to operating temperature.

3. Stop the engine.

4. Remove one of the oil filler caps (Figure 1, (1)) to vent the engine crankcase and allow the engine oil to drain more easily.

5. Position a container under the engine to collect waste oil.

PERIODIC MAINTENANCE

Figure 1

Page 74

CAUTION

NOTICE

K0000651A

045049-00X01

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PERIODIC MAINTENANCE

6. Remove the oil drain plug (Figure 2, (1)) from the engine oil pan. Allow oil to drain.

7. After all oil has been drained from the engine, reinstall the oil drain plug

(Figure 2, (1))

and tighten

to 40 - 47 ft-lb (53.9 - 63.7 N·m, 5.5 - 6.5 kgf/m).

• Never ov erfill the engine with engine oil.

• Always k eep the oil le v el between the upper and lower lines on the oi l cap/dipstick.

8. Dispose of used oil properly.

■ Replace the engine oil filter

1. T urn the engine oil filter

(Figure 2, (3))

using an oil filter wrench.

(Figure 2, (2))

counterclockwise

2. Clean the engine oil filter mounting face.

3. Lightly coat the gasket on the new oil filter with engine oil. Install the new engine oil filter manually by turning it clockwise (Figure 2, (4)) until it contacts the mounting surface. Tighten to 14 - 17 ft-lb (19.6 - 23.5 N·m, 2.0 - 2.4 kgf/m) or one additional turn using the oil filter wrench.

Engine oil filter part No.

Engine model Part No.

3CH1, 3CJ1

Engine oil filter part No.

Engine model

3CE1

* Consult the operation manual for the driven machine for

applicability of the dust proof filter.

5-8640-1515-0

5-8640-0632-0

(68×65L)

Part No.

Standard Dust proof*

5-8640-1495-0

(80×80L)

(80×100L)

4. Add new engine oil to the engine through either of the oil filler ports as specified in Adding Engine Oil on page 44.

Figure 2

5. Warm up the engine by running it for 5 minutes and check for any engine oil leaks.

6. After engine is warm, shut it off and let it sit for 10 minutes.

7. Recheck the engine oil level.

8. Add engine oil to engine oil filler port (Figure 3, (5)) as needed until the level is between the upper (Figure 3, (2)) and lower lines (Figure 3, (3)) shown on the dipstick

(Figure 3, (1)).

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K0000587AX

045046-00X01

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PERIODIC MAINTENANCE

9. Reinstall the oil filler cap (Figure 3, (4)). If any engine oil is spilled, wipe it away with a clean cloth.

■ Check and adjust cooling fan V-belt

The V-belt will slip if it does not have the proper tension. This will prevent the alternator from generating sufficient power. Also, the engine will overheat due to the engine coolant pump pulley slipping.

Check and adjust the V-belt tension (deflection) as follows:

1. Press the V-belt down with your thumb with a force of approximately 22 ft-lb (98 N·m, 10 kgf/m) to check the deflection.

There are three positions to check f or V - belt tension (Figure 4, (A), (B) and (C)). Y ou can check the tension at whichever position is the most accessible. The proper defl ection of a used V -belt at each position is:

Used V-belt tension

ABC

3/8 - 1/2 in.

(10 - 14 mm)

1/4 - 3/8 in.

(7 - 10 mm)

5/16 - 1/2 in.

(9 - 13 mm)

Note: A “Used V-Belt” refers to a V-belt which

has been used on a running engine for five minutes or more.

Figure 3

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K0000652A

K0000063AX

K0000653A

K0000064AX

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PERIODIC MAINTENANCE

2. If necessary, adjust the V-belt tension. Loosen the adjusting bolt (Figure 5, (1)) and related bolts and/or nuts, then move the alternator (Figure 5, (2)) with a pry bar (Figure 5, (3)) to tighten the V-belt to the desired tension. Then tighten the adjusting bolts and/or nuts.

Figure 4

Figure 5

3. Tighten the V-belt to the proper tension. There must be clearance (Figure 6, (1)) between the V-belt and the bottom of the pulley groove. If there is no clearance (Figure 6, (2)) between the V-belt and the bottom of the pulley groove, replace the V-belt.

Page 77

DANGER

NOTICENOTICE

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Every 50 Hours of Operation

After you complete the initial 50 hour maintenance procedures, perform the following procedures e very 50 hours thereafter.

• Drain water separator

•Check battery

PERIODIC MAINTENANCE

Figure 6

4. Check the V-belt for crack s, oil or wear. If any of these conditions exist, replace the V-belt.

5. Install the new V-belt. Refer to the table for proper tension.

New V-belt tension

ABC

5/16 - 7/16 in.

(8 - 12 mm)

3/16 - 5/16 in.

(5 - 8 mm)

1/4 - 7/16 in.

(7 - 11 mm)

6. After adjusting, run the engine for 5 minutes or more. Check the tension again using the specifications for a used V-belt.

Used V-belt tension

ABC

3/8 - 1/2 in.

(10 - 14 mm)

1/4 - 3/8 in.

(7 - 10 mm)

5/16 - 1/2 in.

(9 - 13 mm)

■ Drain water separator

Fire and Explosion Hazard!

• Diesel fuel is 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 pr otection. The fuel system is under pressure and fuel could spray out when you remove any fuel system component.

• Failure to comply will result in death or serious injury.

If no water drips when the water separator drain valve is opened, loosen the air vent screw on the top of the water separator by using a screwdriver to turn it counterclockwise 2 - 3 turns.

This may occur if the water separator is positioned higher than the fuel lev el in t he fuel tank. After draining the water separator, be sure to tighten the air vent screw.

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NOTICE

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PERIODIC MAINTENANCE

• Always be environmentally responsible.

• 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.

Drain the water separator whenever there are contaminants, such as water, collected in the bottom of the cup. Never wait until the scheduled periodic maintenance if contaminants are discovered.

The separator cup is made from semi-transparent material. In the cup is a red-colored float ring. The float ring will rise to the surface of the water to show how much needs to be drained. Also, some optional water separators are equipped with a sensor to detect the amount of contaminants. This sensor sends a signal to an indicator to alert the operator.

Drain the water separator as follows:

Figure 7

1. Position an approved container under the water separator (Figure 7, (1)) to collect the contaminants.

2. Close (Figure 7, (2)) the fuel valve (Figure 7, (3)).

3. Turn the retaining ring (Figure 7, (4)) to the left (Figure 7, (9)).

4. Carefully remove the cup (Figure 7, (1)). Remove the retaining spring (Figure 7, (6)) and float (Figure 7, (7)) from the cup. Pour the fuel into an approved container and dispose of waste properly. Hold the bottom of the cup with a shop towel to prevent the fuel from dripping. Wipe up any spills immediately.

5. Clean the inside of the cup.

6. Inspect the condition of the mesh filter (Figure 7, (10)). Clean the mesh filter if necessary.

7. Inspect the condition of the O-ring (Figure 7, (11)). Replace the O-ring if necessary.

8. Put the float (Figure 7, (7)) and retaining spring

(Figure 7, (6)) inside the cup.

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WARNING

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PERIODIC MAINTENANCE

9. Reinstall the cup to the mounting flange

(Figure 7, (8)) and turn the retaining ring (Figure 7, (4)) to the right (Figure 7, (5)).

hand-tighten only.

10. Open the fuel valve (Figure 7, (3)).

11. Be sure to prime the diesel fuel system when you are done. See Priming the Fuel System on page 42.

12. Check for fuel leaks.

Drain the water separator as follows:

Tightening torque

1 - 2 N·m

(0.1 - 0.2 kgf·m)

6. Be sure to tighten the air v ent scre w if it i s loosened.

7. Open the fuel valve.

8. Be sure to prime the diesel fuel system. See Priming the Fuel System on page 42.

9. Check for fuel leaks.

■ Check battery and recharge

Explosion Hazard!

• If the electrolyte is frozen, slowly warm the battery before you recharge it.

• Failure to comply will result in death or serious injury.

Figure 8

1. Position an approved container under the water separator (Figure 8, (1)) to collect water and contaminants drained from the water separator.

2. Close (Figure 8, (2)) the fuel valve (Figure 8, (3)).

3. Open the drain valve (Figure 8, (4)) at the bottom of the water separator. Drain any water collected inside. If no water comes out, loosen the air vent screw (Figure 8, (5)) at the top of the water separator by turning it counterclockwise 2 - 3 turns.

4. If still no water comes out, open the fuel valve (Figure 8, (3)).

5. After draining the water separator, hand-tighten the drain valve.

Burn Hazard!

• Failure to comply could result in death or serious injury.

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NOTICE

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PERIODIC MAINTENANCE

• If the engine cranking speed is so slow that the engine does not start, recharge the battery.

• Always be environmentally responsible.

Use a specialized battery charger to recharge the battery with a voltage of 8 volts or less. Charging the battery by booster even with a voltage of 8 bolts or less will generate an abnormally high voltage and destroy electrical

• 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.

equipment. Further, in the electronic control engine, when unavoidab ly using a rapid charger to recharge, do not insert and turn the starter key to ON position while the battery is being charged. Avoid using a charger equipped with a boost function (cell start support) to start the engine. The ECU may be damaged by applied excessive voltage.

• If the engine still will not start after charging, have your Isuzu Distributor check the battery and the engine’s starting system.

Figure 9

• When the amount of fluid nears the lower limit

(Figure 9, (3)), fill with distilled water (Figure 9, (2)) so it is at the upper limit (Figure 9, (1)). If operation continues with

insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode. During the summer, check the fluid level more often than specified.

• If operating the machine where the ambient temperature could drop to -15 °C (5 °F) or less, remove the battery from the machine at the end of the day. Store the battery in a warm place until the next use. This will help start the engine easily at low ambient temperatures.

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NOTICE

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Every 250 Hours of Operation

Perf orm the foll owing maintenance e v ery 250 hours of operation.

• Drain fuel tank

PERIODIC MAINTENANCE

• Always be environmentally responsible.

• Replace engine oil and engine oil filter

• Check and clean radiator fins

• Check and adjust cooling fan V-belt

• Check and adjust the governor lever and engine speed control

• Clean air cleaner element

■ Drain fuel tank

DANGER

Fire and Explosion Hazard!

• Diesel fuel is 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.

• Failure to comply will result in death or serious injury.

• 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.

Note that a typical fuel tank is illustrated.

1. Position an appro ved container under the dies el

fuel tank (Figure 10, (1)) to collect the contaminants.

Figure 10

2. Remove the fuel cap (Figure 10, (3)).

3. Remove the drain plug (Figure 10, (2)) to drain

the contaminants (water, dirt, etc.) from the bottom of the tank.

4. Drain the tank until clean diesel fuel with no

water or dirt flows out. Reinstall and tighten the drain plug firmly.

5. Reinstall the fuel cap.

6. Check for leaks.

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NOTICE

FULL

LOW

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PERIODIC MAINTENANCE

■ Replace engine oil and engine oil filter

• 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. Overfilling may result in white exhaust smoke, engine overspeed or internal damage.

• Always be environmentally responsible.

■ Check and clean radiator fins

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.

Dirt and dust adhering to the radiator fins reduce the cooling performance, causing overheating. Make it a rule to check the radiator fins daily and clean as needed.

Note that a typical radiator is shown in Figure 11 for illustrative purposes only.

• Blow off dirt and dust from fins and radiator with 28 PSI (0.19 MPa, 2 kgf/cm compressed air (Figure 11, (1)). Be careful not to damage the fins with the compressed air.

) or less of

• 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.

Change the engine oil ev ery 250 hours of operation after the initial change at 50 hours. Replace the engine oil filter at the same time.

See Replace engine oil and engine oil filter on page 66.

• If there is a large amount of contamination on the fins, apply detergent, thoroughly clean and rinse with tap water.

Figure 11

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NOTICE

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PERIODIC MAINTENANCE

NOTICE

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.

■ Check and adjust cooling fan V-belt

Check and adjust the cooling fan V-belt every 250 hours of operation after the initial 50 hour V-belt maintenance. See Check and adjust cooling fan

V-belt on page 69.

■ Check and adjust the governor lever and engine speed control ( controlled engines

The governor lever and engine speed control (throttle lever, accelerator pedal etc.), are connected together by a cable or linkage. If the cable becomes stretched, or the linkage wears or loosens, the governor lever may not respond to a change in the position of the engine speed control.

)

except electronically

NOTICE

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 the idle speed limit screws require adjustment, see your Isuzu Distributor.

Note: Do not force the throttle cable or linkage

to move. This may damage the the governor lever, the throttle cable or linkage and cause irregular operation of the engine speed control.

The engine speed control (throttle lev er , accelerator pedal etc.), should be equipped with stops to prevent the application of excessiv e pressure by the governor lever to either the high idle stop or low idle speed limit scre w .

See your Isuzu Distributor for the adjustment procedures for your specific engine or machine.

Figure 12

1. Check that the governor lever (Figure 12, (1))

makes firm contact with the high idle stop (Figure 12, (2)) and the low idle speed limit screw (Figure 12, (3)) when the engine speed control is in the full speed or low idle speed positions.

2. If the governor lever does not make proper

contact with the high idle stop or the low idle speed limit screw, adjust the throttle cable or linkage as necessary.

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CAUTION

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PERIODIC MAINTENANCE

■ Clean air cleaner element

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.

Note that a typical air cleaner is sho wn in Figure 13 and Figure 14 for illustrative purposes only.

Figure 13

1. Unlatch and remove the air cleaner cover (Figure 13, (1)).

2. Remove the element (Figure 13, (2)) (outer element if equipped with two elements).

3. Blow air (Figure 13, (3)) through the element from the inside out using 42 - 71 PSI (0.29 -

0.49 MPa, 3.0 - 5.0 kgf/cm

) compressed air to remove the particulates. Use the lowest possible air pressure to remov e the dust without damaging the element.

4. If the air cleaner is equipped with a double element, only remove and replace the inner element (Figure 14, (1)) if the engine lacks power or the dust indicator actuates (if equipped).

Note: The inner element should not be

removed when cleaning or replacing the outer element. The inner element is used to prevent dust from entering the engine while servicing the outer element.

5. Replace the element with a new one if the element is damaged, excessively dirty or oily.

6. Clean inside of the air cleaner cover.

7. Reinstall the element into the air cleaner case (Figure 13, (4)).

Note: If there is a red line (Figure 14, (2)) in

the outer element, reinsert the element until the overlap position of red line and end face of the air cleaner case.

8. Reinstall the air cleaner cover making sure you

match the arrow (Figure 13, (5)) on the cover with the arrow on the case (Figure 13, (6)).

9. Latch the air cleaner cover to the case.

NOTICE

• When the engine is operated in dusty conditions,

clean the air cleaner element more frequently.

K0000071A-01X

• Never operate the engine with the air cleaner

element(s) removed. This may allow foreign

Figure 14

material to enter the engine and damage it.

The engine performance is adversely affec ted when the air cleaner element is clogged with dust. Be sure to clean the air filter element periodically.

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DANGER

NOTICE

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PERIODIC MAINTENANCE

Every 500 Hours of Operation

Perf orm the foll owing maintenance e v ery 500 hours of operation.

• Replace air cleaner element

• Replace fuel filter (element)

• Clean water separator

■ Replace air cleaner element

NOTICE

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.

Replace the air cleaner element (Figure 13, (2)) every 500 hours even if it is not damaged or dirty.

When replacing the element, clean the inside of the air cleaner case (Figure 13, (4)).

If the air cleaner is equipped with a double element, only remove and replace the inner element

(Figure 14, (1)) if the engine lacks power or the dust indicator actuates (if equipped). This is in

addition to replacing the outer element.

■ Replace fuel filter (element)

Fire and Explosion Hazard!

• Diesel fuel is 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 pr otection. The fuel system is under pressure and fuel could spray out when you remove any fuel system component.

• Failure to comply will result in death or serious injury.

• Always be environmentally responsible.

• 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.

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PERIODIC MAINTENANCE

Replace the fuel filter element at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow.

1. Stop the engine and allow it to cool.

2. Close the fuel valve of the water separator.

3. Turn the retaini ng ring (Figure 15, (1)) to the left (Figure 15, (5)).

Figure 15

4. Carefully remove the cup (Figure 15, (3)). Pour the fuel into an approved container and dis pose of waste properly. Hold the bottom of the cup with a shop towel to prevent the fuel from dripping. Wipe up any spills immediately.

5. Remove the fuel filter element (Figure 15, (4)) by pulling it down.

6. Replace the fuel filter element with a new one.

Applicable fuel filter element par t No.

Engine model

3CH1, 3CJ1 5-8640-0778-0 5-8 640-1510-0

* This is a fuel filter for DI, and should be installed with a

different filter br ac ket. Consult the operatio n manu al for the driven machine for applicability of the dust proof filter.

Standard Dust proof*

Part No.

7. Wash the inside of the cup.

8. Check the condition of the O-ring (Figure 15, (6)). Replace if necessary.

9. Install the cup to the mounting flange and turn the retaining ring (Figure 15, (1)) to the right (Figure 15, (2)). Hand-tighten only.

10. Open the fuel valve of the water separator.

11. Prime the fuel system. See Priming the Fuel

System on page 42.

12. Check for fuel leaks.

Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow.

1. Stop the engine and allow it to cool.

2. Close the fuel valve of the water separator.

3. Remove the fuel filter using a filter wrench to turn it to the left (Figure 16, (1)). When removing the fuel filter, carefully hold it to prevent the fuel from s pilling. Wipe up all spilled fuel.

Figure 16

4. Clean the filter mounting surface and apply a small amount of diesel fuel to the gasket of the new fuel filter.

5. Install the new fuel filter. Hand-tighten it to the right (Figure 16, (2)) until it comes in contact with the mounting surface. Use a filter wrench and tighten to 14 - 17 ft-lb (19.6 - 23.5 N·m, 2.0

- 2.4 kgf/m) or one additional turn using the fil ter wrench.

Applicable fuel filter part No.

Engine model

3CE1 5-8640-1510-0 5-8640-1496-0

* Consult the operation manual for the driven machine for

applicability of the dust proof filter.

Standard Dust proof*

Part No.

6. Open the fuel valve of the water separator.

7. Prime the fuel system. See Priming the Fuel

System on page 42.

8. Check for fuel leaks.

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■ Clean water separator

DANGER

Fire and Explosion Hazard!

• Diesel fuel is flammable and

1. Position an approved container under the cup

explosive under certain conditions.

• Never use diesel fuel as a cleaning agent.

• 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.

• Failure to comply will result in death or

2. Close (Figure 17, (2)) the fuel valve

serious injury.

3. T urn the retaining ring (Figure 17, (4)) to the left

NOTICE

• Always be environmentally responsible.

• 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.

4. Carefully remove the cup (Figure 17, (1)).

5. Remove the element by pulling it down

6. Wash the inside of the element and cup with

PERIODIC MAINTENANCE

Periodically clean the water separator element and inside cup.

(Figure 17, (1)) of the w ater separator to collect the contaminants.

Figure 17

(Figure 17, (3)).

(Figure 17, (9)).

Remove the retaining spring (Figure 17, (6)) and float (Figure 17, (7)) from the cup. P our the fuel into an approved container and dispose of waste properly. Hold the bottom of the cup with a shop towel to prevent the fuel from dripping. Wipe up any spills immediately.

(Figure 17, (10)).

new fuel. If the element is damaged or broken, replace with a new one.

Applicable mesh filter part No.

Engine model Part No.

3CH1, 3CJ1 5-8640-0832-0

7. Attach the element to the main body.

8. Inspect condition of the O-ring

(Figure 17, (11)). Replace if necessary.

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PERIODIC MAINTENANCE

9. Put the float (Figure 17, (7)) and retaining spring (Figure 17, (6)) inside the cup.

10. Install the cup to the mounting flange

(Figure 17, (8)) and turn the retaining ring (Figure 17, (4)) to the right (Figure 17, (5)).

Hand-tighten only.

11. Open the fuel valve (Figure 17, (3)).

12. Prime the fuel system. See Priming the Fuel

System on page 42.

13. Check for fuel leaks.

Periodically clean the water separator element and inside the cup.

1. Position an approved container under the cup (Figure 18, (1)) of the w ater separator to collect the contaminants.

2. Close (Figure 18, (2)) the fuel valve (Figure 18, (3)).

3. Loosen the drain valve (Figure 18, (4)) and drain the contaminants. See Drain water

separator on page 71.

4. Turn the cup (Figure 18, (1)) to the left (Figure 18, (10)) and remove the cup (Figure 18, (1)). If equipped, disconnect the

sensor wire from the cup before removing the cup.

5. Carefully hold the cup to prevent fuel from spilling. If you spill any fuel, clean up the spill completely.

7. Clean the element (Figure 18, (9)) and inside cup. Replace the element if it is damaged.

Applicable element part No.

Engine model Part No.

3CE1 5-8640- 2106-0

8. Install the element into the top of body.

9. Position the float ring in the cup.

10. Check the condition of the O-ring. Replace if necessary.

11. Install the cup to the body by tightening the cup to the right (Figure 18, (6)) to 18 - 22 N·m (1.8 -

2.2 kfg·m).

12. Close the drain valve. Reconnect the sensor wire if equipped.

13. Open the fuel valve (Figure 18, (3)).

14. Prime the fuel system. See Priming the Fuel

System on page 42

15. Check for leaks.

Figure 18

6. Remove the float ring (Figure 18, (8)) from the cup. Pour the contaminants into the container and dispose of it properly.

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CAUTION

NOTICE

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Every 1000 Hours of Operation

Perform the following maintenance every 1000 hours of operation.

• Change coolant

• Check and adjust intake/exhaust valve clearance

DANGER

Scald Hazard!

• Tighten the radiator cap securely after you check the radiator. Steam 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.

• Failure to comply may result in minor or moderate injury.

PERIODIC MAINTENANCE

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.

• Always be environmentally responsible.

WARNING

Burn Hazard!

• Wait until the engine cools before you drain the engine coolant. Hot engine coolant may splash and burn you.

• Failure to comply could result in death or serious injury.

• 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.

■ Change coolant

Engine coolant contaminated with rust or water scale reduces the cooling effect. Even when extended life engine coolant is properly mixed, the engine coolant gets contaminated as its ingredients deteriorate. Drain, flush and refill the cooling system with new coolant every 1000 hours or once a year, whichever comes first.

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PERIODIC MAINTENANCE

1. Allow engine and coolant to cool.

2. Remove the radiator cap (Figure 19, (1)).

3. Remove the drain plug or open the drain valve (Figure 19, (2)) at the bottom of the radiator and drain the engine coolant.

FULL

LOW

Figure 19

4. Drain the coolant from the engine block.

• On models not equipped with an oil cooler ,

remove the coolant dr ain plug (Figure 20, (1)) from the engine block.

5. After draining the engine coolant, flush the radiator and engine block to remove any rust, scale and contaminants. Then reinstall and tighten the drain plug or close the drain valve in the radiator. Reinstall and tighten the engine block drain plug.

6. Fill radiator and engine with engine coolant.

See Filling Radiator with Engine Coolant on page 47.

■ Check and adjust intake/exhaust valve

clearance

Improper intake/exhaust valve clearance will cause the engine to run noisily, resulting in poor engine performance and engine damage. Proper adjustment is necessary to maintain the correct timing for opening and closing the valves. See your Isuzu Distributor to inspect and adjust the intake/exhaust valve clearance.

Figure 20

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PERIODIC MAINTENANCE

Every 1500 Hours of Operation

Perform the following maintenance every 1500 hours of operation.

• Inspect, clean and test fuel injection nozzle, if necessary

• Inspect crankcase breather system

■ Inspect, clean and test fuel inject ion nozzle

WARNING

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 exposed to high-pressure fuel spray, obtain prompt medical treatment.

• Never check for a fuel leak with your hands. 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.

Proper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine performance. The EPA/ARB requires that you have the injectors inspected, cleaned and tested every 1500 hours. See your Isuzu Distributor for this service.

This procedure is considered normal maintenance and is performed at the owner’s expense. This procedures is not covered by the Isuzu Mortors Limited Warranty.

■ Inspect crankcase breather system

Proper operation of the crankcase breather system is required to maintain the emission requirements of the engine. The EPA/ARB requires that you have the crankcase breather system inspected every 1500 hours. See your Isuzu Distributor for this service.

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DANGER

WARNING

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PERIODIC MAINTENANCE

Every 2000 Hours of Operation

Perform the following maintenance every 2000 hours of operation.

• Check and replace fuel hoses and engine coolant hoses

■ Check and replace fuel hoses and engine

coolant hoses

Scald Hazard!

• 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.

Burn Hazard!

• 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.

• Failure to comply could result in death or serious 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.

• Failure to comply may result in minor or moderate injury.

NOTICE

• Always be environmentally responsible.

• 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.

■ Check and replace fuel hoses and engine

coolant hoses

Regularly check the fuel system and engine coolant system hoses. If they are cracked or degraded, replace them. Replace the hoses at least every two years. See your Isuzu Distributor to replace fuel hoses and engine coolant system hoses.

Page 93

045050-00X00

EGR valve

TNV_OperationManual_T4(under 19kW).book Page 87 Wednesda y, June 17, 2015 11:23 AM

Every 3000 Hours of Operation

Perform the following maintenance every 3000 hours of operation.

• Inspect, clean and test EGR valve 3CE1

■ Inspect, clean and test EGR valve

3CE1

The EGR valve is a key component for cleaning exhaust gas.

To prevent the valve from deteriorating in exhaust gas recirculation performance due to carbon accumulation, inspect, clean and test the valve at least every 3000 hours.

Consult your Isuzu Distributor for this service.

PERIODIC MAINTENANCE

Figure 21

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PERIODIC MAINTENANCE

This Page Intentionally Left Blank

Page 95

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TNV Operation Manual

TROUBLESHOOTING

If a problem occurs, stop the engine immediately. Refer to the SYMPTOM column in the Troubleshooting Chart to identify the problem.

NOTICE

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.

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.

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TROUBLESHOOTING

TROUBLESHOOTING CHART

Symptom Probable cause Action Refer to

Indicator turns ON - engine running

Low level of engine oil

Engine oil pressure indicator

Engine coolant indicator

Battery Indicator

Indicator does not turn ON - key switch is turned to ON (OFF  ON) - engine no t running

Indicator stays ON - k ey sw i t ch i s turned from start to ON (START  ON) - engine not running

Battery indicator stay s O N Faulty alternator

Engine oil pressure indicator stays ON

Too high an oil level Clogged engine oil filter Replace engine oil filter

Low engine coolant lev el Add engine coolan t

Dirty radiator fins Clean the radiator fins Engine coolant leaking See Isuzu Distributor – V-belt loose or damaged Ad just V -b elt o r repl ace Contaminated engine

coolant Faulty engine coolant pump –

V-belt loose or damaged Ad just V -b elt o r repl ace

Battery fa i l ure Check battery condition Faulty alternator See Isuzu Distributor –

Faulty electrical wiring or faulty indicator

Faulty engine oil pressur e switch

No or low level of engine oil

Clogged engine oil filter Replace engine oil filter

Check and adjust oil level as necessary

See Isuzu Distributor

See Isuzu Distributor –

See Isuzu Distributor

Check and adjust oil level as necessary

Checking Engine Oil on page 44

Replace engine oil and engine oil filter on page 66

Filling Radiator with Engine Coolant on page 47

Check and clean radiator fins on page 76

Check and adjust coo lin g fan V-belt on page 69

Check battery and recharge on page 73

Checking Engine Oil on page 44

Replace engine oil and engine oil filter on page 66

–

– –

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Symptom Probable cause Action Refer to

Engine does not Start

No diesel fuel

Air in fuel system Prime fuel system

Starter motor operates but engine does not start

Starter motor does not operate or rotates too slowly (engine can be turned manually)

Engine cannot be manually turned

White or black exhaust s m oke

Black exhaust smoke

White exhaust smok e

Improper diesel fuel

Clogged fuel filter Replace fuel filter Poor fuel injection

Compressed air leaka ge from intake/exhaust valves

Faulty engine stop solenoid – Battery needs charging Check electrolyte, recharge Faulty cable connection at

battery terminals Faulty starter switch Faulty starter motor – Inner parts seized or

damaged

Engine overloaded Reduce load – Clogged air cleaner

element Improper diesel fuel Faulty spraying of fuel

injection Excessive i ntake/exhaust

valve clearance Faulty EGR valve –

Improper diesel fuel Faulty spray pattern of fuel

injection Fuel injection timing delay – Engine burning oil –

Refuel and prime fuel system

Replace with recommended diesel fuel

See Isuzu Di stributor

Clean terminals, retighten –

See Isuzu Di stributor

Clean element or replace Replace with

recommended diesel fuel

See Isuzu Di stributor

Replace with recommended diesel fuel

See Isuzu Di stributor

TROUBLESHOOTING

Filling the Fuel Tank on page 41

Priming the Fuel System on page 42

Diesel Fuel Specification s on page 36

Replace fuel filter (element) on page 79

– –

Check battery and recharge on page 73

–

Clean air cleaner elem ent on page 78

Diesel Fuel Specification s on page 36

–

Diesel Fuel Specification s on page 36

–

Page 98

WARNING

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TROUBLESHOOTING

TROUBLESHOOTING OF ELECTRONIC CONTROL SYSTEM

3CE1

• 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.

Fault Detection Capability

The E-ECU has a fault detection capability. See List of Possible Faults of Electronically Controlled Engines on page 95.

A fault indicator (Optional) is located on the operator’s console as shown in Figure 1.

This indicator comes on at power up of the E-ECU and goes out after 2 sec.

Once a fault is detected, then the indicator flashes in certain patterns, providing fault information to the operator.

NOTICE

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.

1 – Fault indicator

Figure 1

Figure 1 Typical Operator’s Console

Page 99

Flashing repeated

Power up

Off

3s 0.5s

Five 0.5 sec. flashes

Accelerator sensor fault

Flashing repeated

Power up

Off

3s 1.5s 0.5s

One 1.5 sec. flash Three 0.5 sec. flashes

EGR valve fault

0.5s

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TROUBLESHOOTING

Figure 2 exemplifies flashing patterns that represent an accelerator fault (5 flashes) or EGR valv e f ault (1 to

3 flashes) occurring at power up. If multiple faults occur simultaneously, the indicator indicates all the faults in order of smaller to larger number of flashes.

Figure 2

NOTICE

If the fault indicator comes on, check and note the flashing pattern, shut down the engine without delay and contact your Isuzu Distributor.

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TROUBLESHOOTING

TROUBLESHOOTING INFORMATION

If your engine does not operate properly, refer to the troubleshooting chart or consult your Isuzu Distributor.

Supply the Isuzu Distributor with the following information:

• Model name and serial number of your engine

• The driven machine type (tractor, generator, skid steer loader), manufacturer’s name, model and serial number

• How long the engine has been in service (the number of engine hours or the number of calendar months)

• Operating conditions when problem occurs:

• Engine RPM

• Color of exhaust smoke

• T ype of diesel fuel

• T ype of engine oil

• Flashing patterns of indicators (When an electronically controlled engine and the f ault indicator are used)

• Any abnormal noises or vibration

• Operating environment such as high altitude or extreme ambient temperatures , etc.

• Engine maintenance history and previous problems

• Other factors that contribute to the problem

Isuzu 3CH1-NGZG01, 3CJ1-NGZG01, 3CH1-SDZP01, 3CJ1-SDZP01 Introduction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

RECORD OF OWNERSHIP

SYMBOL EXPLANATION

Table of Contents ................................................................................... iii

ISUZU GENUINE PARTS

EMISSION-RELATED INSTALLATION INSTRUCTIONS (REF)

Installation of Nonroad Engines into Equipment

Allowable Air Intake Restriction and Exhaust Back Pressure

Allowable Air Intake Restriction

Allowable Exhaust Back Pressure

SAFETY

SAFETY STATEMENTS

SAFETY PRECAUTIONS

Before You Operate

During Operation and Maintenance

ISUZU C SERIES ENGINE FEATURES AND APPLICATIONS

COMPONENT IDENTIFICATION

LOCATION OF LABELS

■ Location of labels/nameplates on direct injection model engines

FUNCTION OF MAJOR ENGINE COMPONENTS

FUNCTION OF COOLING SYSTEM COMPONENTS

ELECTRONIC CONTROL SYSTEM

MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES

GAUGES AND INDICATORS

Gauges

Indicators

GAUGES AND INDICATORS OF ELECTRONIC CONTROL SYSTEM

Gauges

Indicators

CONTROLS

Key Switch

Glow Plugs

Governor Lever

Engine Stop Solenoid (IDI Engines)

Speed Control of Electronically Controlled Engines

Electronic Engine Speed Control

■ Start and stop of electronic controlled engines

■ Engine performance curves

DIESEL FUEL

Diesel Fuel Specifications

■ Additional technical fuel requirements

■ Bio-diesel fuels

Filling the Fuel Tank

Priming the Fuel System

ENGINE OIL

Engine Oil Specifications

■ Service categories

■ Definitions

Engine Oil Viscosity

Checking Engine Oil

Adding Engine Oil

Engine Oil Capacity (Typical)

ENGINE COOLANT

Engine Coolant Specifications

■ Alternative engine coolant

Filling Radiator with Engine Coolant

Daily Check of the Cooling System

Engine Coolant Capacity (Typical)

DAILY CHECKS

Visual Checks

Check Diesel Fuel, Engine Oil and Engine Coolant Levels

Check Engine Speed Control

Check Operator’s Console

Check Indicators

ENGINE OPERATION

STARTING ENGINE

HIGH-ALTITUDE INJECTION CONTROL DEVICE

COLD START DEVICE

CHECKING THE ENGINE DURING OPERATION

ADJUST ENGINE SPEED

SHUTTING DOWN THE ENGINE

PRECAUTIONS

The Importance of Periodic Maintenance

Performing Periodic Maintenance

The Importance of Daily Checks

Keep a Log of Engine Hours and Daily Checks