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TNV_OperationManual_T4(under 19kW).book Page i Wednesday, June 17, 2015 11:23 AM
TNV Operation Manual
INTRODUCTION
To help you enjoy your Isuzu C series engine for
many years to come, please follow these
recommendations:
• Read and understand this Operation Manual
before you operate the machine to ensure that
you follow safe operating practices and
maintenance procedures.
• Keep this Operation Manual in a convenient place
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.
i

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Do you have a question about the 3CH1-NGZG01 and is the answer not in the manual?

Questions and answers

Carlos Moreno chavarin
March 11, 2025

Solicito kit de reparacion para motor 3CH1- NGZG1

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2 comments:
Carlos Moreno chavarin
March 11, 2025

@Carlos Moreno chavarin

User image 67d04ad37f5e8
Mr. Anderson
May 14, 2025

Yes, the Isuzu 3CH1-NGZG01 engine has repair kit parts available. The parts list includes items such as fuel oil tank (Part No. 5-8640-2241-0), fuel feed pump (Part No. 5-8640-2242-0), fuel oil filter (Part No. 5-8640-2243-0), fuel injection pump (Part No. 5-8640-2244-0), and fuel injection nozzle (Part No. 5-8640-1791-0).

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Summary of Contents for Isuzu 3CH1-NGZG01

  • Page 1 TNV_OperationManual_T4(under 19kW).book Page i Wednesday, June 17, 2015 11:23 AM TNV Operation Manual INTRODUCTION To help you enjoy your Isuzu C series engine for many years to come, please follow these recommendations: • Read and understand this Operation Manual before you operate the machine to ensure that you follow safe operating practices and maintenance procedures.
  • Page 2: Introduction

    TNV_OperationManual_T4(under 19kW).book Page ii Wednesday, June 17, 2015 11:23 AM 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.: _____________________________________________________________________...
  • Page 3: Table Of Contents

    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 ........
  • Page 4 TNV_OperationManual_T4(under 19kW).book Page iv Wednesday, June 17, 2015 11:23 AM 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 ..................
  • Page 5 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 ..............
  • Page 6 TNV_OperationManual_T4(under 19kW).book Page vi Wednesday, June 17, 2015 11:23 AM TABLE OF CONTENTS This Page Intentionally Left Blank...
  • Page 7: Isuzu Engine After Service

    TNV_OperationManual_T4(under 19kW).book Page 1 Wednesday, June 17, 2015 11:23 AM ISUZU ENGINE TNV Operation Manual AFTER SERVICE Please feel free to contact your Isuzu distributor for periodical inspection and maintenance.
  • Page 8: Isuzu Genuine Parts

    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.
  • Page 9: Safety

    TNV Operation Manual SAFETY SAFETY STATEMENTS DANGER Isuzu is concerned for your safety and your DANGER indicates a hazardous situation which, machine’s condition. Safety statements are one of if not avoided, will result in death or serious the primary ways to call your attention to the injury.
  • Page 10: Safety Precautions

    • See your Isuzu Distributor for additional training. • If the electrolyte is frozen, slowly warm the battery before you recharge it. • Failure to comply will result in death or serious injury.
  • Page 11 TNV_OperationManual_T4(under 19kW).book Page 5 Wednesday, June 17, 2015 11:23 AM SAFETY DANGER DANGER (Continued) Fire and Explosion Hazard! • Only fill the fuel tank with diesel fuel. Filling the fuel tank with gasoline may result in a fire • Diesel fuel is extremely and will damage the engine.
  • Page 12 TNV_OperationManual_T4(under 19kW).book Page 6 Wednesday, June 17, 2015 11:23 AM SAFETY DANGER WARNING Crush Hazard! Exhaust Hazard! • When you need to transport an • Never operate the engine in an engine for repair, have a helper enclosed area such as a garage, assist you to attach it to a hoist tunnel, underground room, and load it on a truck.
  • Page 13 Always use a piece of wood or cardboard. • If you must drain the engine oil while it is still hot, stay clear of the hot engine oil to avoid Have your Isuzu Distributor repair the damage. being burned. • Failure to comply could result in death or •...
  • Page 14 TNV_OperationManual_T4(under 19kW).book Page 8 Wednesday, June 17, 2015 11:23 AM SAFETY CAUTION WARNING Shock Hazard! Coolant Hazard! • Turn off the battery switch (if • Wear eye protection equipped) or disconnect the and rubber gloves negative battery cable before when you handle servicing the electrical system.
  • Page 15 TNV_OperationManual_T4(under 19kW).book Page 9 Wednesday, June 17, 2015 11:23 AM SAFETY • Only use diesel fuels recommended by Isuzu for Never attempt to adjust the low or high idle speed the best engine performance, to prevent engine limit screw. This may impair the safety and damage and to comply with EPA/ARB warranty performance of the machine and shorten its life.
  • Page 16 • Contact your Isuzu Distributor if the engine will be If any indicator illuminates during engine operation, operated outside of this standard temperature stop the engine immediately.
  • Page 17 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.
  • Page 18 TNV_OperationManual_T4(under 19kW).book Page 12 Wednesday, June 17, 2015 11:23 AM SAFETY • Always be environmentally Precautions for handling desiccant responsible. Disposal: This material is disposable as non-flammable. however, the bag is flammable and if it is necessary, then tear the bag and discard the bag and the •...
  • Page 19: Product Overview

    • Select optional equipment. Optional equipment should be selected to match the work conditions Isuzu C series engine is designed to supply power and environment. to a wide variety of driven machines including: • Maximize engine performance with a minimum •...
  • Page 20: Component Identification

    TNV_OperationManual_T4(under 19kW).book Page 14 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW COMPONENT IDENTIFICATION 3CH1-NGZG01, 3CH1-SDZP01, 3CJ1-NGZG01 Figure 1 shows where major indirect injection engine components are located. 045080-00X00 1 – Lifting eye (flywheel end) 14 – Governor lever 2 – Engine coolant pump 15 –...
  • Page 21 TNV_OperationManual_T4(under 19kW).book Page 15 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW 3CJ1-SDZP01 Figure 2 shows where major indirect injection engine components are located. 16 17 044905-00X00 1 – Air intake port (from air cleaner) 12 – Mechanical fuel pump 2 –...
  • Page 22 TNV_OperationManual_T4(under 19kW).book Page 16 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW 3CE1 Figure 3 shows where major direct injection engine components are located. 045002-00X00 1 – Lifting eye (flywheel end) 12 – Dipstick (engine oil) 2 – Lifting eye (engine cooling fan end) 13 –...
  • Page 23: Location Of Labels

    TNV_OperationManual_T4(under 19kW).book Page 17 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW 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 information label is shown (Figure 4, (1)).
  • Page 24: Function Of Major Engine Components

    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 Maintenance Schedule on page 64 for the replacement frequency.
  • Page 25 TNV_OperationManual_T4(under 19kW).book Page 19 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW Components Functions The mechanical fuel pump is a diaphragm-type of pump and is installed on Mechanical fuel pump the fuel injection pump body. The mechanical fuel pump is driven by a cam on the camshaft of the fuel injection pump.
  • Page 26: Function Of Cooling System Components

    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 driven by a V-belt which is powered by the crankshaft V-pulley.
  • Page 27: Electronic Control System

    • Replacing the fuel injection pump involves intended or in other ways than specified by rewriting the fuel injection data in the E-ECU. Isuzu. Doing so could result in the violation of Be sure to contact your Isuzu Distributor emission control regulations and will void the before replacing the fuel injection pump.
  • Page 28 TNV_OperationManual_T4(under 19kW).book Page 22 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW Shut down the engine if the fault indicator comes • Do not plug or unplug the E-ECU for a period of at least 6 seconds after power to the unit has been turned on or off.
  • Page 29 TNV_OperationManual_T4(under 19kW).book Page 23 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW Model 3CE1 engine come with the Exhaust Gas • Engine speed control schemes Recirculation (EGR) system to conform to the Droop control/Low-idling speed up/Auto engine emission regulations (EPA 2013 rules). deceleration/High-idling speed down/Black smoke The EGR system and an electronic governor suppression...
  • Page 30: Main Electronic Control Components And Features

    TNV_OperationManual_T4(under 19kW).book Page 24 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES 3CE1 Component/feature Description Engine controller (E-ECU) Adjusts the rack position of the fuel injection pump depending on the speed command signal from the accelerator sensor, thus regulating the engine speed and power.
  • Page 31 TNV_OperationManual_T4(under 19kW).book Page 25 Wednesday, June 17, 2015 11:23 AM 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 seconds. The duration of energization depends on the engine coolant temperature.
  • Page 32: Gauges And Indicators

    Since the operator’s console 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. The illustrations and descriptions of optional MC-704HP-G4 equipment in this manual, such as the operator’s...
  • Page 33: Indicators

    TNV_OperationManual_T4(under 19kW).book Page 27 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW Indicators HEAT indicator (Figure 9, (1)) - For the “ON-glow” type of the starter switch that does not have the The following indicators are located on a typical HEAT position in the counterclockwise direction of operator’s console.
  • Page 34: Gauges And Indicators Of Electronic Control System

    TNV_OperationManual_T4(under 19kW).book Page 28 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW GAUGES AND INDICATORS OF ELECTRONIC CONTROL SYSTEM Fault (Figure 11, (1)) (optional) - This indicator will 3CE1 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.
  • Page 35: Controls

    The key switch for the operator’s console illustrated in Figure 13 has four positions - OFF, ON, START, and HEAT. For maximum engine life, Isuzu recommends that when shutting the engine down, you allow the engine to idle, without load, for five minutes. This...
  • Page 36: Glow Plugs

    DI engines. Governor Lever K0000021A Figure 13 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...
  • Page 37: Engine Stop Solenoid (Idi Engines)

    TNV_OperationManual_T4(under 19kW).book Page 31 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW Engine Stop Solenoid (IDI Engines) Figure 16 045045-00X00 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 Figure 17 the engine, allowing the engine to be started.
  • Page 38: Electronic Engine Speed Control

    TNV_OperationManual_T4(under 19kW).book Page 32 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW Electronic Engine Speed Control 3CE1 120 % 110 % ■ Start and stop of electronic controlled 100 % engines The electronic controlled engines have no engine stop solenoid. The ECU controls the engine start/stop sequence.
  • Page 39 TNV_OperationManual_T4(under 19kW).book Page 33 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW 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.
  • Page 40 TNV_OperationManual_T4(under 19kW).book Page 34 Wednesday, June 17, 2015 11:23 AM PRODUCT OVERVIEW This Page Intentionally Left Blank...
  • Page 41: Before You Operate

    TNV_OperationManual_T4(under 19kW).book Page 35 Wednesday, June 17, 2015 11:23 AM BEFORE YOU TNV Operation Manual 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.
  • Page 42: Diesel Fuel

    Especially in U.S.A. and additives may cause poor engine performance. Canada, Ultra Low Sulfur fuel must be used. Consult your Isuzu representative for more • Use the fuel that can be used where the information. temperature is 12 °C (53.6 °F) lower than the expected lowest temperature to prevent the fuel from freezing.
  • Page 43 93 % conventional diesel fuel. Approved engines The unprocessed vegetable oil is not Isuzu C series engine can be operated with considered as diesel fuel. biodiesel with concentrations up to B20. In case of using biodiesel fuel up to B7 concentrations, no 2.
  • Page 44 (from B8 to B20) • Please daily check the water level of the water When operating your applicable Isuzu C series separator. If the water level rises above the engine with biodiesel blends concentrated above “max” indicator, an immediate drain of the B8, we seriously recommend observing the water separator is required.
  • Page 45 TNV_OperationManual_T4(under 19kW).book Page 39 Wednesday, June 17, 2015 11:23 AM BEFORE YOU OPERATE ■ KIT parts list for B10 through B 20 3CH1, 3CJ1 3CE1 5-8640-2407-0 5-8640-2408-0 Length 2000 2000 Fuel oil tank - Part No. 5-8640-2241-0 5-8640-2241-0 / - Fuel oil tank Part name FO-T CMP FO-T CMP...
  • Page 46 TNV_OperationManual_T4(under 19kW).book Page 40 Wednesday, June 17, 2015 11:23 AM BEFORE YOU OPERATE Part number 5-8640-2246-0 (P44) 5-8640-2246-0 (P44) 5-8640-2251-0 (G75) 5-8640-1755-0 (P16) 5-8640-2252-0 (P7) 033042-00X 033051-00X 033050-00X...
  • Page 47: Filling The Fuel Tank

    TNV_OperationManual_T4(under 19kW).book Page 41 Wednesday, June 17, 2015 11:23 AM BEFORE YOU OPERATE Filling the Fuel Tank DANGER • Only use diesel fuels recommended by Isuzu for the best engine performance, to prevent engine Fire and Explosion Hazard! damage and to comply with EPA/ARB warranty •...
  • Page 48: Priming The Fuel System

    TNV_OperationManual_T4(under 19kW).book Page 42 Wednesday, June 17, 2015 11:23 AM BEFORE YOU OPERATE Priming the Fuel System To prime the fuel system if an electric fuel pump is installed: DANGER 1. Turn the key to the ON position for 10 to 15 Fire and Explosion Hazard! seconds.
  • Page 49: Engine Oil

    TNV_OperationManual_T4(under 19kW).book Page 43 Wednesday, June 17, 2015 11:23 AM BEFORE YOU OPERATE ENGINE OIL The fuel system needs to be primed under certain conditions: • Only use the engine oil specified. Other engine • Before starting the engine for the first time oils may affect warranty coverage, cause internal •...
  • Page 50: Engine Oil Viscosity

    5. Fully reinsert dipstick. See the SAE Service Grade Viscosity Chart (Figure 3). Adding Engine Oil • Isuzu does not recommend the use of engine oil 1. Make sure engine is level. “additives.” 2. Remove oil cap (Figure 4, (4)).
  • Page 51: Engine Oil Capacity (Typical)

    The following are the engine oil capacities for various Isuzu C series engine. Engine oil capacity (typical) Dipstick Engine model upper limit/lower limit 3CH1-NGZG01 3.6/1.9 qt (3.4/1.8 ℓ)
  • Page 52: Engine Coolant

    TNV_OperationManual_T4(under 19kW).book Page 46 Wednesday, June 17, 2015 11:23 AM BEFORE YOU OPERATE ENGINE COOLANT CAUTION Coolant Hazard! DANGER • Wear eye protection Scald Hazard! and rubber gloves • Never remove the radiator cap if when you handle the engine is hot. Steam and long life or extended hot engine coolant will spurt life engine coolant.
  • Page 53: Engine Coolant Specifications

    • 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 K0000029A demineralized water be used to mix with coolants. Figure 5 •...
  • Page 54: Daily Check Of The Cooling System

    7. Run the engine until it reaches operating The following are the engine coolant capacities for temperature. Check the level of engine coolant various Isuzu C series engine. in the reserve tank When the engine is running and the engine coolant is at normal...
  • Page 55: Daily Checks

    DAILY CHECKS Visual Checks 1. Check for engine oil leaks. Before you begin any job, make sure the Isuzu C series engine is in good operating condition. Make 2. Check for fuel leaks. sure you check the following items before you start 3.
  • Page 56: Check Operator's Console

    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.
  • Page 57 TNV_OperationManual_T4(under 19kW).book Page 51 Wednesday, June 17, 2015 11:23 AM BEFORE YOU OPERATE 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.
  • Page 58 TNV_OperationManual_T4(under 19kW).book Page 52 Wednesday, 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 Note that, for electronic Glow...
  • Page 59: Engine Operation

    TNV_OperationManual_T4(under 19kW).book Page 53 Wednesday, June 17, 2015 11:23 AM 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: Starting Engine

    TNV_OperationManual_T4(under 19kW).book Page 54 Wednesday, June 17, 2015 11:23 AM ENGINE OPERATION STARTING ENGINE 4. Set the transmission (if equipped) in the NEUTRAL position. Use the following procedure to start the engine. 5. Disengage the PTO (if equipped). Note that two typical operator’s consoles are shown 6.
  • Page 61 TNV_OperationManual_T4(under 19kW).book Page 55 Wednesday, June 17, 2015 11:23 AM ENGINE OPERATION 10. If the engine fails to start: 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.
  • Page 62: Cold Start Device

    TNV_OperationManual_T4(under 19kW).book Page 56 Wednesday, June 17, 2015 11:23 AM ENGINE OPERATION HIGH-ALTITUDE INJECTION CONTROL DEVICE COLD START DEVICE 3CH1, 3CJ1 WARNING This series has a high-altitude injection control device installed. It suppresses black smoke when Sudden Movement Hazard! operating at high altitudes and at the same time •...
  • Page 63: Checking The Engine During Operation

    • 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.
  • Page 64 TNV_OperationManual_T4(under 19kW).book Page 58 Wednesday, 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 minutes while you check x100 for proper engine oil pressure, diesel fuel leaks, engine oil leaks, coolant leaks, and for proper operation of the indicators and/or gauges.
  • Page 65: Adjust Engine Speed

    • During the first hour of operation, vary the engine Isuzu Distributor. speed and the load on the engine. Short periods 4. Check for abnormal sounds or vibration. In...
  • Page 66: Shutting Down The Engine

    4. Turn the key to the OFF position (Figure 7, (1)) or (Figure 8, (1)) and remove it from the key switch. For maximum engine life, Isuzu recommends that when shutting the engine down, you allow the engine to idle, without load, for five minutes. This...
  • Page 67: Periodic Maintenance

    TNV_OperationManual_T4(under 19kW).book Page 61 Wednesday, June 17, 2015 11:23 AM PERIODIC TNV Operation Manual MAINTENANCE This section of the Operation Manual describes the procedures for proper care and maintenance of the engine.
  • Page 68: Precautions

    Isuzu Replacement Parts manhole or ship’s hold without proper ventilation. Isuzu recommends that you use "Isuzu genuine parts" when replacement parts are needed. • Never block windows, vents, or other means Genuine replacement parts help ensure long of ventilation if the engine is operating in an engine life.
  • Page 69: Epa/Arb Installation Requirements Usa Only

    TNV_OperationManual_T4(under 19kW).book Page 63 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE EPA/ARB Installation Requirements Note: EGR-equipped engines have a range of allowable intake and exhaust restrictions; a USA Only minimum and a maximum value. The following are the installation requirements for the EPA/ARB.
  • Page 70: Periodic Maintenance Schedule

    Consult your Isuzu Distributor for assistance when checking items marked with a ●. Periodic Maintenance Chart : Check : Replace ●: Contact your Isuzu Distributor...
  • Page 71 TNV_OperationManual_T4(under 19kW).book Page 65 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE : Check : Replace ●: Contact your Isuzu Distributor Periodic maintenance interval Every Every Every Every Every Every Every System Check item Daily 1000 1500 2000 3000 hours...
  • Page 72: Periodic Maintenance Procedures

    TNV_OperationManual_T4(under 19kW).book Page 66 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE PERIODIC MAINTENANCE PROCEDURES • Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal After Initial 50 Hours of Operation engine components to seize and/or shorten engine life.
  • Page 73 TNV_OperationManual_T4(under 19kW).book Page 67 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE 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.
  • Page 74 TNV_OperationManual_T4(under 19kW).book Page 68 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE 6. Remove the oil drain plug (Figure 2, (1)) from the engine oil pan. Allow oil to drain. • Never overfill the engine with engine oil. 7. After all oil has been drained from the engine, reinstall the oil drain plug (Figure 2, (1)) and tighten •...
  • Page 75 TNV_OperationManual_T4(under 19kW).book Page 69 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE ■ Check and adjust cooling fan V-belt 9. Reinstall the oil filler cap (Figure 3, (4)). If any engine oil is spilled, wipe it away with a clean The V-belt will slip if it does not have the proper cloth.
  • Page 76 TNV_OperationManual_T4(under 19kW).book Page 70 Wednesday, June 17, 2015 11:23 AM 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.
  • Page 77: Every 50 Hours Of Operation

    TNV_OperationManual_T4(under 19kW).book Page 71 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE Every 50 Hours of Operation After you complete the initial 50 hour maintenance procedures, perform the following procedures every 50 hours thereafter. • Drain water separator • Check battery K0000584 ■...
  • Page 78 TNV_OperationManual_T4(under 19kW).book Page 72 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE Drain the water separator as follows: • 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.
  • Page 79 TNV_OperationManual_T4(under 19kW).book Page 73 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE 9. Reinstall the cup to the mounting flange 1 - 2 N·m (Figure 7, (8)) and turn the retaining ring Tightening torque (0.1 - 0.2 kgf·m) (Figure 7, (4)) to the right (Figure 7, (5)). hand-tighten only.
  • Page 80 • If the engine still will not start after charging, have • Failure to follow these procedures may seriously your Isuzu Distributor check the battery and the harm the environment. engine’s starting system.
  • Page 81: Every 250 Hours Of Operation

    TNV_OperationManual_T4(under 19kW).book Page 75 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE Every 250 Hours of Operation • Always be environmentally responsible. Perform the following maintenance every 250 hours of operation. • Drain fuel tank • Replace engine oil and engine oil filter •...
  • Page 82 TNV_OperationManual_T4(under 19kW).book Page 76 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE ■ Replace engine oil and engine oil filter ■ Check and clean radiator fins CAUTION • Only use the engine oil specified. Other engine Flying Object Hazard! oils may affect warranty coverage, cause internal •...
  • Page 83 See Check and adjust cooling fan V-belt on page 69. ■ Check and adjust the governor lever and See your Isuzu Distributor for the adjustment engine speed control (except electronically procedures for your specific engine or machine. controlled engines) The governor lever and engine speed control (throttle lever, accelerator pedal etc.), are...
  • Page 84 TNV_OperationManual_T4(under 19kW).book Page 78 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE ■ Clean air cleaner element 1. Unlatch and remove the air cleaner cover (Figure 13, (1)). CAUTION 2. Remove the element (Figure 13, (2)) (outer element if equipped with two elements). Flying Object Hazard! •...
  • Page 85: Every 500 Hours Of Operation

    When replacing the element, clean the inside of the air cleaner case (Figure 13, (4)). For maximum engine life, Isuzu recommends that If the air cleaner is equipped with a double element, when shutting the engine down, you allow the only remove and replace the inner element engine to idle, without load, for five minutes.
  • Page 86 TNV_OperationManual_T4(under 19kW).book Page 80 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE Replace the fuel filter element at Replace the fuel filter at specified specified intervals to prevent intervals to prevent contaminants from contaminants from adversely affecting adversely affecting the diesel fuel flow. the diesel fuel flow.
  • Page 87 TNV_OperationManual_T4(under 19kW).book Page 81 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE ■ Clean water separator Periodically clean the water separator DANGER element and inside cup. Fire and Explosion Hazard! • Diesel fuel is flammable and 1. Position an approved container under the cup explosive under certain (Figure 17, (1)) of the water separator to collect conditions.
  • Page 88 TNV_OperationManual_T4(under 19kW).book Page 82 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE 9. Put the float (Figure 17, (7)) and retaining 7. Clean the element (Figure 18, (9)) and inside spring (Figure 17, (6)) inside the cup. cup. Replace the element if it is damaged. 10.
  • Page 89: Every 1000 Hours Of Operation

    TNV_OperationManual_T4(under 19kW).book Page 83 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE CAUTION Every 1000 Hours of Operation Coolant Hazard! • Wear eye protection Perform the following maintenance every 1000 and rubber gloves hours of operation. when you handle • Change coolant long life or extended life engine coolant.
  • Page 90 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. K0000074A Figure 19 4.
  • Page 91: Every 1500 Hours Of Operation

    The EPA/ARB requires that you have the injectors inspected, cleaned and tested every Perform the following maintenance every 1500 1500 hours. See your Isuzu Distributor for this hours of operation. service. • Inspect, clean and test fuel injection nozzle, if...
  • Page 92: Every 2000 Hours Of Operation

    • Failure to comply could result in death or system hoses. If they are cracked or degraded, serious injury. 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: Every 3000 Hours Of Operation

    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. EGR valve 045050-00X00 Figure 21...
  • Page 94 TNV_OperationManual_T4(under 19kW).book Page 88 Wednesday, June 17, 2015 11:23 AM PERIODIC MAINTENANCE This Page Intentionally Left Blank...
  • Page 95: Troubleshooting

    Refer to the SYMPTOM column in the Troubleshooting Chart to identify the problem. 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.
  • Page 96: Troubleshooting Chart

    Coolant on page 47 Check and clean radiator Dirty radiator fins Clean the radiator fins fins on page 76 Engine coolant leaking See Isuzu Distributor – Engine coolant indicator Check and adjust cooling V-belt loose or damaged Adjust V-belt or replace...
  • Page 97 Replace fuel filter (element) Clogged fuel filter Replace fuel filter on page 79 Poor fuel injection – Compressed air leakage See Isuzu Distributor – from intake/exhaust valves Faulty engine stop solenoid – Check battery and recharge Battery needs charging Check electrolyte, recharge...
  • Page 98: Troubleshooting Of Electronic Control System

    Isuzu. Doing so could result in the violation of emission control regulations and will void the product warranty. Shut down the engine if the fault indicator comes •...
  • Page 99 EGR valve fault One 1.5 sec. flash Three 0.5 sec. flashes Power up 1.5s 0.5s Flashing repeated Figure 2 If the fault indicator comes on, check and note the flashing pattern, shut down the engine without delay and contact your Isuzu Distributor.
  • Page 100: 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...
  • Page 101: List Of Possible Faults Of Electronically Controlled Engines

    TNV_OperationManual_T4(under 19kW).book Page 95 Wednesday, June 17, 2015 11:23 AM TROUBLESHOOTING LIST OF POSSIBLE FAULTS OF ELECTRONICALLY CONTROLLED ENGINES 3CE1 Availability No. of Fault (alarm) flashes/flashing Fault/alarm condition Engine status Reset condition location detection pattern of fault features indicator Coolant Sensor voltage is over 4.8 V or Continues to run at a coolant Voltage returns to...
  • Page 102 TNV_OperationManual_T4(under 19kW).book Page 96 Wednesday, June 17, 2015 11:23 AM TROUBLESHOOTING Availability No. of Fault (alarm) flashes/flashing Fault/alarm condition Engine status Reset condition location detection pattern of fault features indicator Relay returns to normal. This fault Power cannot be turned off Main relay Continues to run normally will persist even if...
  • Page 103 TNV_OperationManual_T4(under 19kW).book Page 97 Wednesday, June 17, 2015 11:23 AM TROUBLESHOOTING Availability No. of Fault (alarm) flashes/flashing Fault/alarm condition Engine status Reset condition location detection pattern of fault features indicator Flash ROM checksum error ECU-ROM Is shut down occurred Reading/writing error occurred ECU-EEPROM Continues to run normally Checksum error occurred...
  • Page 104 TNV_OperationManual_T4(under 19kW).book Page 98 Wednesday, June 17, 2015 11:23 AM TROUBLESHOOTING This Page Intentionally Left Blank...
  • Page 105: Long-Term Storage

    TNV_OperationManual_T4(under 19kW).book Page 99 Wednesday, June 17, 2015 11:23 AM LONG-TERM TNV Operation Manual STORAGE This section of the Operation Manual describes the procedures necessary to place the engine into long-term storage (six months or longer) and how to place it back into operation.
  • Page 106: Before You Place The Engine In Long-Term Storage

    TNV_OperationManual_T4(under 19kW).book Page 100 Wednesday, June 17, 2015 11:23 AM LONG-TERM STORAGE BEFORE YOU PLACE THE ENGINE IN LONG-TERM STORAGE DANGER Explosion Hazard! Protect the air cleaner, turbocharger (if equipped) and electric components from damage when you • Never short out the battery use steam or high-pressure water to clean the terminals, including when engine.
  • Page 107: Returning The Engine To Service

    TNV_OperationManual_T4(under 19kW).book Page 101 Wednesday, June 17, 2015 11:23 AM LONG-TERM STORAGE RETURNING THE ENGINE TO SERVICE 1. Perform the Daily Checks on page 49. 2. The engine should be pre-oiled before startup. Crank the engine, leaving the fuel system shut off so the engine will not start, for 15 seconds.
  • Page 108 TNV_OperationManual_T4(under 19kW).book Page 102 Wednesday, June 17, 2015 11:23 AM LONG-TERM STORAGE This Page Intentionally Left Blank...
  • Page 109: Specifications

    TNV_OperationManual_T4(under 19kW).book Page 103 Wednesday, June 17, 2015 11:23 AM TNV Operation Manual SPECIFICATIONS...
  • Page 110: Engine General Specifications

    • Fuel feeding pressure: 20 ± 10 kPa (net) after engine break-in has been performed with the cooling fan, air cleaner and muffler installed to the engine. • With cooling fan, air cleaner, muffler: Isuzu standard • After the engine break-in period. Output allowable deviation: ± 3 % •...
  • Page 111: Principal Engine Specifications

    TNV_OperationManual_T4(under 19kW).book Page 105 Wednesday, June 17, 2015 11:23 AM SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS ■ 3CH1-NGZG01, 3CH1-SDZP01 Engine model 3CH1-NGZG01 3CH1-SDZP01 Type Vertical in-line 4-cycle diesel engine Combustion system Ball-type swirl chamber (IDI) Aspiration Naturally aspiration No. of cylinders Bore × stroke ø80 ×...
  • Page 112 TNV_OperationManual_T4(under 19kW).book Page 106 Wednesday, June 17, 2015 11:23 AM SPECIFICATIONS ■ 3CE1 Engine model 3CE1 Type Vertical in-line 4-cycle diesel engine Combustion system Direct injection (DI) Aspiration Naturally aspiration No. of cylinders Bore × stroke ø88 × 90 Displacement 1.642 Engine rotation speed 1500...
  • Page 113 TNV_OperationManual_T4(under 19kW).book Page 107 Wednesday, June 17, 2015 11:23 AM SPECIFICATIONS ■ 3CJ1-NGZG01 Engine model 3CJ1-NGZG01 Type Vertical in-line 4-cycle diesel engine Combustion system Ball-type swirl chamber (IDI) Aspiration Naturally aspiration No. of cylinders Bore × stroke ø74 × 77 Displacement 0.993 Engine rotation speed...
  • Page 114 TNV_OperationManual_T4(under 19kW).book Page 108 Wednesday, June 17, 2015 11:23 AM SPECIFICATIONS ■ 3CJ1-SDZP01 Engine model 3CJ1-SDZP01 Type Vertical in-line 4-cycle diesel engine Combustion system Ball-type swirl chamber (IDI) Aspiration Naturally aspiration No. of cylinders Bore × stroke ø74 × 77 Displacement 0.993 Engine rotation speed...

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