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Isuzu NPR 2008 Owner's Manual

N-series medium duty truck (low cab forward)
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55702_Sec00_'08 08.2.12 9:41 AM Page A-1
N-SERIES MEDIUM DUTY TRUCK
THIS MANUAL SHOULD BE CONSIDERED A PERMANENT PART OF
THIS TRUCK. IT SHOULD STAY WITH THE TRUCK WHEN SOLD TO
PROVIDE THE NEXT OWNER WITH IMPORTANT OPERATING,
SAFETY, AND MAINTENANCE INFORMATION.
Section
0
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 1
1
Before Driving Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 1
2
Starting And Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1
Driving Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Steering Column Controls . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Instrument Panel And Controls . . . . . . . . . . . . . . . . . . . . . 2-29
3
In Case Of Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1
Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
4
Appearance Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
5
Service And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 3
6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
All information, illustrations and specifications in this manual are based
on the latest product information available at the time of printing. We
reserve the right to make changes at any time without notice.
Copyright Isuzu Motors Limited Feb., 2008
Printed in Japan
All Rights Reserved
2008
OWNER'S MANUAL
( LOW CAB FORWARD )

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Summary of Contents for Isuzu NPR 2008

  • Page 1 All information, illustrations and specifications in this manual are based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. Copyright Isuzu Motors Limited Feb., 2008 Printed in Japan All Rights Reserved...

  • Page 2: Introduction

    Remember, if you have a concern that has not been handled to your satisfaction, follow the steps in the separate “Warranty and Owner Assistance Information” booklet. We thank you for choosing an Isuzu product, and want to assure you of our continuing interest in your motoring pleasure and satisfaction. CAUTION AND NOTICE...
  • Page 3 55702_Sec00_'08 08.2.12 9:41 AM Page 2 GRAPHIC SYMBOLS Some of the following symbols are used to identify controls and displays on your vehicle. ENGINE ENGINE OIL MASTER LIGHTING FUEL LIGHTS COOLANT PRESSURE SWITCH EXHAUST WATER CHECK ENGINE PARKING TURN SIGNALS BRAKE SEPARATOR WINDSHIELD...
  • Page 4 55702_Sec00_'08 08.2.12 9:41 AM Page 3 BRAKE PARKING BRAKE DAYTIME INDICATOR/BRAKE SYSTEM BRAKE HORN INDICATOR/BRAKE SYSTEM WARNING LIGHT LOW VACUUM RUNNING LIGHT WARNING LIGHT CRUISE CONTROL CRUISE CONTROL CRUISE MAIN CRUISE SET RESUME/ SET/ (IF EQUIPPED) ACCEL COAST BRAKE BOOSTER SERVICE VEHICLE BRAKE ANTI-LOCK...

  • Page 5: Vehicle Loading

    55702_Sec00_'08 08.2.12 9:41 AM Page 4 IMPORTANT INFORMATION ON VEHICLE LOADING OVERLOADING CAUTION: The components of your truck are designed to provide satisfactory service if the vehicle is not loaded in excess of either the gross vehicle weight rating (GVWR) or the maximum front and rear gross axle weight ratings (GAWRs).
  • Page 6 55702_Sec00_'08 08.2.12 9:41 AM Page 5 MAXIMUM FRONT AND REAR AXLE WEIGHTS The weight of the cargo load must be properly distributed over both the front and rear axles. The VIN and Weight Rating Plate show the maximum weight that the front axle can carry (front GAWR). It also shows the maximum weight that the rear axle can carry (rear GAWR).
  • Page 7 55702_Sec00_'08 08.2.12 9:41 AM Page 6 VEHICLE IDENTIFICATION NUMBER (VIN) AND WEIGHT RATING PLATE Your VIN and Weight Rating Plate shows the GVWR (Gross Vehicle Weight Rating) and the front and rear GAWRs for your vehicle. Gross Vehicle Weight (GVW) is the weight of the originally equipped vehicle and all items added to it after it has left the factory.

  • Page 8: Model Reference

    55702_Sec00_'08 08.2.12 9:41 AM Page 7 MODEL REFERENCE The model covered in this manual is NPR. Single cab model MODEL...
  • Page 9 55702_Sec00_'08 08.2.12 9:41 AM Page 8 VIN INTERPRETATION...

  • Page 10: Before Driving Your Vehicle

    55702_Sec01_'08 08.2.12 9:43 AM Page 1 SECTION 1 BEFORE DRIVING YOUR VEHICLE DRIVER DAILY CHECKLIST Be sure you know how to use your truck and its equipment before operating it. BEFORE ENTERING THE TRUCK 1. See that windows, mirrors, lights and reflectors are undamaged, clean and unobstructed.
  • Page 11 • Be sure to include the key code plate when the vehicle is transferred. If the original keys are lost, duplicates can be made using the key codes stamped on key code plate. Contact any authorized Isuzu dealer or a locksmith.

  • Page 12: Outside Door Handles

    55702_Sec01_'08 08.2.12 9:43 AM Page 3 Lock Button Locked Unlocked Inside Handle CAB DOOR LOCKS ALWAYS LOCK THE DOORS CAUTION: To help reduce the risk of personal injury in an accident, always lock the doors when driving. Along with using the seat belts properly, Iocking the doors helps prevent people from being thrown from the vehicle.
  • Page 13 55702_Sec01_'08 08.2.12 9:43 AM Page 4 POWER DOOR LOCKS (IF EQUIPPED) DOOR LOCK SWITCH Both doors can be locked and unlocked by pressing the rocker lock switch. Refer to Page 2-56 for switch location. UPPER SIDE LOCK UNLOCK DOOR LOCKS •...

  • Page 14: Window Controls

    55702_Sec01_'08 08.2.12 9:43 AM Page 5 LOCK BUTTON • There is a lock button on each door. When the lock button on the driver’s door is turned to “Locked”, it works for both the driver’s and passenger’s doors. Otherwise it works only for its own door. •...
  • Page 15 55702_Sec01_'08 08.2.12 9:43 AM Page 6 CLOSE OPEN Passenger Driver side side Driver side Passenger side POWER WINDOW SWITCH (PASSENGER’S DOOR) The power window switch on the passenger’s door can raise and lower the passenger’s side window only. NOTICE: The engine control switch must be in the “ON” position. Press lightly on the switch to lower the window.

  • Page 16: Sun Visors

    55702_Sec01_'08 08.2.12 9:43 AM Page 7 MIRRORS OUTSIDE REARVIEW MIRRORS Adjust the outside rearview mirrors by hand before vehicle operation. This helps you determine the location of objects seen in the mirror. CAUTION: Do not adjust the outside mirrors while operating the vehicle.
  • Page 17 55702_Sec01_'08 08.2.12 9:43 AM Page 8 DRIVER’S SEAT CONTROLS ADJUST DRIVER’S SEAT WHILE PARKED CAUTION: Do not adjust the driver’s seat while the vehicle is moving. The seat could move or jerk and cause a loss of control. After adjustment, push the seat back and forth to be sure it is locked. Take the vehicle to your dealer for servicing if the seat does not lock.
  • Page 18 55702_Sec01_'08 08.2.12 9:43 AM Page 9 SEATBACK LATCH (DRIVER) The seatback latch of the driver seat is designed to limit forward movement of the seatback during a sudden slowing of the vehicle. Tilt the seatback to gain access to the area behind it. The seatback latch release lever is located at the outboard side of the seat at the base of the cushion.

  • Page 19: Seat Belt Systems

    55702_Sec01_'08 08.2.12 9:43 AM Page 10 SEAT BELT SYSTEMS CAUTION: To help reduce the risk of personal injury in collisions or sudden maneuvers, use the seat belts following these instructions on their proper use, maintenance, and use with child restraint systems.
  • Page 20 55702_Sec01_'08 08.2.12 9:43 AM Page 11 LAP-SHOULDER BELT 1. Adjust the driver’s seat as needed and sit well back and straight up. (The passenger seat does not adjust.) Grasp the latch plate and: • Pull the belt as far as it will reach across your lap. •...
  • Page 21 55702_Sec01_'08 08.2.12 9:43 AM Page 12 Take Up Slack Keep Low On Hip Bone 3. To unfasten the belt, push the button on the buckle. The belt should retract when the buckle is unlatched, but hold the latch plate while the belt is retracting, to keep it from hitting people or nearby objects.
  • Page 22 55702_Sec01_'08 08.2.12 9:43 AM Page 13 CENTER LAP BELT 1 . The center seat lap belt has no retractor, but should be positioned, worn and released as described above. The belt is adjusted to snug fit by pulling on the free end of the webbing coming from the latch plate.
  • Page 23 55702_Sec01_'08 08.2.12 9:43 AM Page 14 CHILD RESTRAINT CAUTION: Children small enough for child restraints (as indicated on the label of such restraints), including booster seats, should always be transported in them. Children who have outgrown child restraint systems should wear seat belts. The lap belt should be snug and positioned low on the abdomen so that it is below the top of the hipbone.
  • Page 24 55702_Sec01_'08 08.2.12 9:43 AM Page 15 Installation on Outboard Seat A seat belt locking clip is required for installation of a child restraint system on the outboard seat of this vehicle. A locking clip may usually be obtained where child restraints are sold, or by contacting your dealer for assistance.
  • Page 25 55702_Sec01_'08 08.2.12 9:43 AM Page 16 W-01621 SEAT BELT EXTENDER If the vehicle’s seat belt will fasten around you, you should use it. But if a seat belt isn’t long enough to fasten, your dealer will order you an extender. When you go in to order it, take the heaviest coat you will wear, so the extender will be long enough for you.

  • Page 26: Specifications

    • Do not modify the DPF or exhaust pipe. Modification of the direction, length or diameter of the exhaust pipe will adversely affect the exhaust gas purification system. If modification is needed according to equipment type, contact your Isuzu dealer. 1-17...
  • Page 27 NOTICE: • For engine oil, use low ash engine oil. Use of others than those designated by Isuzu that support the DPF may shorten the cleaning intervals of the DPF and may lower fuel efficiency. • The DPF automatically regenerates when a certain amount of PM (Particulate Matter) accumulates in the filter.
  • Page 28 55702_Sec01_'08 08.2.12 9:43 AM Page 19 BEFORE DRIVING Use the specified fuel (ultra low sulfur diesel fuel only) CAUTION: Always use diesel fuel. Use of low quality fuel may adversely affect the engine parts, and cause failure. Use of other than specified fuel may adversely affect the engine or emission control system and cause failure.

  • Page 29: Starting And Operating

    55702_Sec02-1_'08 08.2.12 9:45 AM Page 1 SECTION 2 STARTING AND OPERATING Engine Exhaust Gas Caution (Carbon Monoxide) CAUTION: Do not breathe exhaust gas because it contains carbon monoxide, which by itself has no color or odor. Carbon monoxide is a dangerous gas. It can cause unconsciousness and can be lethal. If at any time you think exhaust fumes are entering the cab, have the cause determined and corrected as soon as possible.
  • Page 30 55702_Sec02-1_'08 08.2.12 9:45 AM Page 2 NEW VEHICLE BREAK-IN Good vehicle care begins with proper break-in. While every new vehicle goes through rigid factory and dealer inspection and tests before delivery, the care you give your vehicle during the initial break- in period can pay off in longer life, better performance and more economical operation.
  • Page 31 Isuzu. Such damage is not Isuzu’s responsibility, and is not covered by the New Vehicle Limited Warranty. To help avoid fuel system or engine damage, pay attention to the following: •...
  • Page 32 55702_Sec02-1_'08 08.2.12 9:45 AM Page 4 DIESEL FUEL/APPLICABLE STANDARD ( Sulfur content below 15ppm) JIS (JAPANESE INDUSTRIAL Based on K2204 Diesel Fuel STANDARD) DIN (DEUTSCHE INDUSTRIE Based on EN590 NORMEN) ASTM (AMERICAN SOCIETY Based on D975 NO.1-D S15 or FOR TESTING and MATERIALS) NO.2-D S15 (below 15 ppm) BS (BRITISH STANDARD) Based on EN590...
  • Page 33 55702_Sec02-1_'08 08.2.12 9:45 AM Page 5 NOTICE: Do not use home heating oil or gasoline in your diesel engine; either may cause engine damage. The addition of kerosene will not unplug a filter plugged with wax. Warming a “waxed” filter to a temperature of 32°F to 50°F (0°C to 10°C) will return the wax to solution.
  • Page 34 55702_Sec02-1_'08 08.2.12 9:45 AM Page 6 SMOKE SUPPRESSANTS Because of extensive testing of treated fuel versus untreated fuel, the use of a smoke suppressant additive is not recommended because of the greater possibility of stuck rings and guttered valves, resulting from excessive ash deposits.

  • Page 35: Starting The Engine

    55702_Sec02-1_'08 08.2.12 9:45 AM Page 7 STARTING THE ENGINE ENGINE CONTROL SWITCH The starting circuit, engine alarm circuits and accessory circuits are all controlled by the engine control switch. The switch is located on the right-hand side of the steering column. A:LOCK—Lock is in the position fully counterclockwise.
  • Page 36 55702_Sec02-1_'08 08.2.12 9:45 AM Page 8 2. Turn the key to the “ON” position and hold until the glow plug indicator light goes off. 3. Turn the key switch to the “START” position (do not step on the accelerator pedal). Release the key switch as soon as the engine starts.
  • Page 37 55702_Sec02-1_'08 08.2.12 9:45 AM Page 9 CHECKS BEFORE OPERATING Allow the engine to warm up before placing the engine under heavy load driving. While the engine is warming up under light load, the following checks should be made: 1. Observe the red oil pressure warning light. The light should go out when the engine is running.

  • Page 38: Key Removal

    55702_Sec02-1_'08 08.2.12 9:45 AM Page 10 SHUTTING DOWN THE TURBOCHARGED DIESEL ENGINE NOTICE: Let the engine run at idle for at least three (3) minutes before stopping the engine to help prevent damage to the turbocharger bearings. 1. Apply the parking brake and place the automatic transmission selector in the “P”...
  • Page 39 55702_Sec02-1_'08 08.2.12 9:45 AM Page 11 To be sure the engine can turn fast enough to start, use SAE 10W- 40 viscosity engine oil when prevailing temperatures drop below 32°F (0°C). (See the oil quality and oil viscosity recommendations in Section 5 ) Using your proper viscosity oil will make starting easier down to –10°F (–23°C).

  • Page 40: Guard Against Theft

    55702_Sec02-1_'08 08.2.12 9:45 AM Page 12 ENGINE ALARM AND AUTOMATIC SHUTDOWN If the system senses any of the following conditions: high engine temperature, low engine oil pressure or low engine coolant, the corresponding warning light and engine alarm (shutdown) warning light will come on.
  • Page 41 55702_Sec02-1_'08 08.2.12 9:45 AM Page 13 1. Hold the regular brake pedal down with your right foot and apply the parking brake all the way before shifting the transmission. Follow the Parking Brake instructions in this manual for your vehicle. 2.

  • Page 42: Driving Techniques

    55702_Sec02-1_'08 08.2.12 9:45 AM Page 14 DRIVING TECHNIQUES BRAKING AND STEERING TECHNIQUES Always turn-off the manual engine idle control knob to the full counter- clockwise position while driving to maintain proper braking performance and reduce brake wear. To get maximum braking while maintaining vehicle control, use a “squeeze”...
  • Page 43 After driving on the flooded road, it is recommended to immediately bring the vehicle to the Isuzu dealership and let them check engine, electric parts, transmission, propeller shaft, differential and transfer for water intrusion, and apply grease and oil to each area.

  • Page 44: Steering Column Controls

    55702_Sec02-1_'08 08.2.12 9:45 AM Page 16 STOPPING THE VEHICLE IN THE EVENT OF SERVICE BRAKE MALFUNCTION The exhaust brake should be turned on as soon as service brake malfunction is detected. This will slow the engine speed. With the engine speed under control and providing the grade conditions permit, the transmission can be progressively down-shifted using the exhaust brake in each gear.
  • Page 45 55702_Sec02-1_'08 08.2.12 9:45 AM Page 17 LEFT-HAND CONTROL LEVER The turn signal lever on the left side of the steering column also controls headlight low beam and high beam. Headlight Turn Signal TURN SIGNAL Move the lever up to signal a right turn. Move it down to signal a left turn. When the turn is completed, the signal will cancel and the lever will return to horizontal.
  • Page 46 55702_Sec02-1_'08 08.2.12 9:45 AM Page 18 HEADLIGHT DIMMER SWITCH • With the headlight switch set at “ ” and the left-hand lever in the center position, the headlights are at low beam. Always use low beam when approaching or following other vehicles. •...
  • Page 47 55702_Sec02-1_'08 08.2.12 9:45 AM Page 19 WINDSHIELD WASHER To spray washer fluid on the windshield, push the button on the end of the combination switch lever. The spray will continue as long as you hold in the button. After using the windshield washer, turn the wipers off by setting the switch to “...
  • Page 48 55702_Sec02-1_'08 08.2.12 9:45 AM Page 20 After the vehicle is in motion, the exhaust brake system operates when the driver's foot is removed from the accelerator pedal. The selection of transmission gears and engine speed when operating the brake system is important. The exhaust brake is more effective in the lower gears and at the higher engine speeds.

  • Page 49: Power Steering

    55702_Sec02-1_'08 08.2.12 9:45 AM Page 21 CAUTION: To reduce the risk of personal injury, apply force to the steering wheel to make certain the steering column is firmly locked before driving. Also, do not try to tilt or adjust the steering wheel while the vehicle is moving.

  • Page 50: Brake System

    55702_Sec02-1_'08 08.2.12 9:45 AM Page 22 BRAKE SYSTEM 1. Steering Column 2. Brake Pedal 3. Accelerator Pedal 4. Overdrive Switch 5. Automatic Transmission Selector BRAKE PEDAL For the most effective braking and for maximum life from brake system components, follow these suggestions: •...
  • Page 51 55702_Sec02-1_'08 08.2.12 9:45 AM Page 23 NOTICE: A small amount of white smoke may be emitted from the exhaust pipe with PM (Particulate Matter) burned during DPF regeneration. This is not a failure. Also, do not perform regeneration indoors with poor ventilation. White smoke may be emitted during DPF regeneration after the new vehicle has run a certain distance.
  • Page 52 55702_Sec02-1_'08 08.2.12 9:45 AM Page 24 PARKING BRAKE The parking brake lever is located to the right of the driver’s seat. • To set the parking brake, completely stop the vehicle. Then hold the brake pedal down while pulling the parking brake lever all the way up.
  • Page 53 55702_Sec02-2_'08 08.2.12 9:46 AM Page 25 AUTOMATIC TRANSMISSION CONTROLS AUTOMATIC TRANSMISSION SELECTOR Selector Button Overdrive Switch Indicator SELECTING GEARS Push the button located on the end of the selector when engaging the “R” and “P” positions and when shifting from “2” to “1” as indicated by the arrow “...
  • Page 54 55702_Sec02-2_'08 08.2.12 9:46 AM Page 26 AUTOMATIC TRANS. CONTROLS, CONTINUED STARTING Start the engine in either the “P” or the “N” position. The engine should not start in any other selector position. If it does, something is wrong. Have your truck checked by your dealer as soon as possible. Always apply either the foot brake or the parking brake before shifting into any driving position.
  • Page 55 55702_Sec02-2_'08 08.2.12 9:46 AM Page 27 Push the overdrive switch to the OFF position at speeds below 65 MPH (105km/h) to increase engine braking action when traveling downgrade. If the automatic transmission fluid temperature is too low, the transmission may not initially make automatic shift to the 4th, 5th and 6th gear.
  • Page 56 55702_Sec02-2_'08 08.2.12 9:46 AM Page 28 NOTICE (Continued) Operating the transmission at stall condition will result in overheating and damage. * Do not hold your vehicle on an upgrade by increasing engine speed with the accelerator pedal. Doing so will result in automatic transmission overheating and damage.

  • Page 57: Instrument Panel And Controls

    55702_Sec02-2_'08 08.2.12 9:46 AM Page 29 U n d e r n o r m a l o p e r a t i n g c o n d i t i o n s , t h e u s e o f o v e r d r i v e i s recommended.
  • Page 58 55702_Sec02-2_'08 08.2.12 9:46 AM Page 30 Battery Discharge Warning Light The warning light comes on when the battery is discharging. This may mean that the generator has malfunctioned, the electrical system is overloaded, or the generator drive belt is loose or broken. Have the system repaired promptly.
  • Page 59 55702_Sec02-2_'08 08.2.12 9:46 AM Page 31 Glow Plug Indicator Light Your diesel engine has a special starting system. Small heating elements, called “glow plugs,” preheat the engine combustion chambers to improve cold starting. This light is designed to come on when the engine control switch is turned to the “ON”...
  • Page 60 55702_Sec02-2_'08 08.2.12 9:46 AM Page 32 If the light remains on after engine start up or comes on during operation of the vehicle, it may mean that there is something wrong with part of the brake system. What to do: 1.
  • Page 61 55702_Sec02-2_'08 08.2.12 9:46 AM Page 33 If this happens while driving : • Do not pump the brakes. The system is designed to stop the truck with reserve power assist if the pedal is held down. This reserve is greatly reduced each time you apply and release the brakes. •...
  • Page 62 55702_Sec02-2_'08 08.2.12 9:46 AM Page 34 Low Coolant Warning Light You have a low coolant warning light. If this light comes on, your system is low on coolant and the engine may overheat. When it comes on, you will also hear a warning tone. Refer to “ENGINE COOLING SYSTEM”...
  • Page 63 If the indicator light starts to blink while driving, it indicates that there is a malfunction in the automatic transmission’s electronic control system. If the indicator light is found blinking, contact your authorized Isuzu medium duty vehicle dealer promptly for repairs.
  • Page 64 Isuzu dealer to have the DPF repaired. BRAKE ALARM SYSTEM See “Brake Low Vacuum Warning Light” above.
  • Page 65 8MPH (13km/h). If the indicator light turns off, the ABS is normal. If the light does not go out or comes on frequently, contact your Isuzu dealer immediately and have the system repaired. Explanation of the ABS The ABS is designed to prevent lock-up of the wheels during braking by automatically changing the brake pressure.
  • Page 66 “BRAKE” system warning light will come on simultaneously. • If the EBD system malfunctions, the rear wheels can easily lock- up. Contact your Isuzu dealer immediately and have the system repaired. NOTICE: When the EBD is operated, it is not abnormal to feel a clicking movement through the brake pedal or a noise resembling ABS operation.
  • Page 67 Some information may be stored during regular operations to facilitate repair of detected malfunctions. Isuzu may download and retrieve stored information for the purpose of diagnosing, servicing or repairing your motor vehicle or for improvement to future Isuzu motor vehicles.

  • Page 68: Cruise Control

    55702_Sec02-2_'08 08.2.12 9:46 AM Page 40 CRUISE CONTROL Cruise Control Main Switch Cruise Switch Set Coast Resume Accel With cruise control, you can maintain a speed of between 30 and 75MPH (48 to 121 km/h) without keeping your foot on the accelerator pedal.
  • Page 69 55702_Sec02-2_'08 08.2.12 9:46 AM Page 41 1. OPERATION SETTING CRUISE CONTROL Push the cruise control main switch “CRUISE MAIN” so that the Cruise Main indicator light turns on. Accelerate to your desired speed using the accelerator pedal. Quickly turn the cruise switch to adjust to the “-SET” position and release the cruise switch when the desired speed is reached.
  • Page 70 55702_Sec02-2_'08 08.2.12 9:46 AM Page 42 PASSING ANOTHER VEHICLE WHILE USING CRUISE CONTROL Use the accelerator pedal to increase your speed. When you take your foot off the pedal, your vehicle will slow down to the cruise control speed you set earlier. USING CRUISE CONTROL ON HILLS How well your cruise control will work on hills depends upon your speed, load and the steepness of the hills.
  • Page 71 55702_Sec02-2_'08 08.2.12 9:46 AM Page 43 SWITCHES AND CONTROLS ENGINE CONTROL (KEY) SWITCH The starting circuit, engine alarm circuits (if used) and accessory circuits are all controlled by the engine control (key) switch. This switch is located on the right-hand side of the steering column. R e f e r t o “...
  • Page 72 55702_Sec02-2_'08 08.2.12 9:46 AM Page 44 INSTRUMENT PANEL LIGHT LEVEL CONTROL The control will change the light level of the instrument panel. Instrument Panel Light Level Control WINDSHIELD WIPER AND WASHER CONTROLS Refer to “Steering Column Controls” earlier in this section. OUTSIDE REARVIEW MIRROR HEATER SWITCH (IF EQUIPPED) If the outside mirror fogs up, warm up the outside rearview mirror’s face to defog.
  • Page 73 55702_Sec02-2_'08 08.2.12 9:46 AM Page 45 MILES CHECK SWITCH The “Miles Check Switch” will display the odometer and trip meter mileages when depressed within five minutes after the key is turned off. Also, while depressing this switch, the fuel gauge will operate to show the fuel level in the fuel tank.
  • Page 74 55702_Sec02-2_'08 08.2.12 9:46 AM Page 46 PTO (POWER TAKE-OFF) SWITCH (IF EQUIPPED) For details about the PTO operation, refer to the separate instruction manual provided by its maker. CAUTION: If you activate the PTO on the vehicle with PTO for a long time, make sure that the DPF indicator light does not come PTO Main Switch PTO Engine Speed...
  • Page 75 55702_Sec02-2_'08 08.2.12 9:46 AM Page 47 DIESEL PARTICULATE FILTER (DPF) Your vehicle has a Diesel Particulate Filter (DPF) as part of the exhaust system to reduce vehicle emissions. The exhaust pipe mixes air with the exhaust gas to lower its temperature before it leaves the exhaust pipe.
  • Page 76 If modification to equipment is needed, contact your Isuzu dealer. A u t o m a t i c r e g e n e r a t i o n m a y n o t c o m p l e t e i n s o m e c a s e s o f operating and driving patterns and conditions.
  • Page 77 DPF automatic regeneration, which may occur when the vehicle is stopped and idling; this is not a malfunction. CAUTION: For vehicles equipped with DPF, Isuzu recommends engine oil that supports DPF (low ash oil). Use of low ash oil extends the maintenance interval of the DPF filter.
  • Page 78 CAUTION: If you continue driving the vehicle without performing regeneration, the check engine malfunction indicator light will come on indicating that you must contact an Isuzu dealer to have the DPF repaired. Emergency running regeneration During running regeneration, in addition to the DPF indicator light (Amber/Red), the indicator light (Green) will also turns on.
  • Page 79 55702_Sec02-2_'08 08.2.12 9:46 AM Page 51 5. Press the DPF switch. The DPF indicator light (green) comes on, the engine speed automatically increases and the regeneration starts. Stay near the vehicle during the regeneration. The regeneration is normally completed in about 20 minutes. When the DPF indicator light goes off, the regeneration is complete, and the vehicle may be operated normally.
  • Page 80 55702_Sec02-2_'08 08.2.12 9:46 AM Page 52 NOTICE: • The time it takes for the regeneration to complete depends upon the external temperature. • During DPF regeneration, the exhaust brake valve is in operation. Operating noise is emitted while the exhaust brake valve is operating and also when it is deactivated;...
  • Page 81 55702_Sec02-2_'08 08.2.12 9:46 AM Page 53 Selectable regeneration procedure Your vehicle has the following selectable regeneration procedure in case the driver is not able to perform the emergency regeneration for some reasons when the DPF indicator light (amber/red) comes on. Selectable regeneration may be performed when the engine (coolant temperature) and exhaust pipe are warm after transport.
  • Page 82 55702_Sec02-2_'08 08.2.12 9:46 AM Page 54 NOTICE: Until a certain quantity of PM has accumulated in the DPF filter, the DPF indicator light (amber) will go off after 3 seconds, even if you continue to press the DPF switch. In this case, there is no need to perform DPF regeneration, so regeneration will not start even if you press the DPF switch.
  • Page 83 55702_Sec02-2_'08 08.2.12 9:46 AM Page 55 SPEEDOMETER AND GAUGES Engine coolant Warning/Indicator lights for Tachometer temperature gauge U.S.A models Speedometer Fuel gauge Odometer and A/T shift indicator Odometer and Trip meter Knob Warning/Indicator lights for Trip meter U.S.A models Odometer and Trip Meter The odometer and the trip meter indicate mileage.
  • Page 84 55702_Sec02-2_'08 08.2.12 9:46 AM Page 56 10 11 12 13 14 1. Instrument Panel Light Level 15. Card Holder Control 16. Beverage Holder 2. PTO Main Switch (If equipped) 17. Door Lock Switch 3. PTO Engine Speed Control (If equipped) Switch (If equipped) 18.
  • Page 85 55702_Sec02-2_'08 08.2.12 9:46 AM Page 57 SPEEDOMETER The speedometer is located directly in front of the steering column. The speedometer hand indicates the vehicle speed in miles per hour (MPH) on the outer scale and in kilometers per hour (km/h) on the inner scale.
  • Page 86 55702_Sec02-2_'08 08.2.12 9:46 AM Page 58 DOME LIGHT The dome light is located in the center of the ceiling. The switch has three positions: • “ON”—The light stays on regardless of the door position. • “OFF”—The light stays off regardless of the door position. •...
  • Page 87 55702_Sec02-2_'08 08.2.12 9:46 AM Page 59 HEATING AND VENTILATION SYSTEMS CONTROLS CAUTION: See “Engine Exhaust Gas Caution (Carbon Monoxide)” in Section 2. OPTIONAL AIR CONDITIONING This system combines cooling capabilities for comfort in all weather conditions. During some air conditioning operating conditions, slight increases and decreases of engine speed/power may be experienced.
  • Page 88 55702_Sec02-2_'08 08.2.12 9:46 AM Page 60 3. TEMPERATURE CONTROL KNOB The Temperature Control Knob regulates the temperature of the air entering the passenger compartment in all Air Selector Knob positions. 4. AIR-SOURCE SELECTOR LEVER The intake of outside air and the circulation of inside air is controlled by sliding this lever right or left.
  • Page 89 MOBILE TELEPHONES Mobile two-way radio units and mobile telephone equipment are subject to federal rules and must be installed by trained personnel. Isuzu is not responsible if add-on equipment interferes with engine operation or picks up interference from vehicle components. 2-61...

  • Page 90: In Case Of Emergency

    55702_Sec03_'08 08.2.12 9:47 AM Page 1 SECTION 3 IN CASE OF EMERGENCY HAZARD WARNING LIGHT FLASHER Use the hazard warning light flasher to warn other drivers any time your vehicle becomes a traffic hazard, day or night. Avoid stopping on the roadway, if possible. Turn on the hazard warning flashers by pushing in the switch located on the right-hand side of the instrument panel.
  • Page 91 55702_Sec03_'08 08.2.12 9:47 AM Page 2 Diesel engine vehicles have more than one battery because of the higher torque required to start a diesel engine. This procedure can be used to start a single-battery vehicle from any of the diesel vehicle’s batteries.
  • Page 92 55702_Sec03_'08 08.2.12 9:47 AM Page 3 Make Connections in Numerical Order Do Not Allow the Vehicles To Touch Charged Battery Make last connection Discharged on frame away from Battery the battery Start the engine of the vehicle with the good (charged) battery. Run the engine at a moderate speed for several minutes.
  • Page 93 55702_Sec03_'08 08.2.12 9:47 AM Page 4 overheat during severe operating conditions such as: • Climbing a long hill on a hot day • Stopping after high-speed driving • Idling for long periods in traffic If the Engine Coolant Temperature gauge shows an overheat c o n d i t i o n , o r y o u h a v e r e a s o n t o s u s p e c t t h e e n g i n e m a y b e overheating, take the following steps: •...
  • Page 94 55702_Sec03_'08 08.2.12 9:47 AM Page 5 CAUTION: To help avoid being burned, do not spill antifreeze or engine coolant on the exhaust system or hot engine parts. Under some conditions, the ethylene glycol in engine coolant is combustible. If the engine coolant level in the reserve tank is at the correct level but there is still an indication on the instrument panel of an overheat condition: •...
  • Page 95 55702_Sec03_'08 08.2.12 9:47 AM Page 6 CAUTION: To help avoid personal injury and property damage if a wheel must be changed, seek expert tire services if you can. If you must remove the wheel without any such help, do the following: 1.
  • Page 96 55702_Sec03_'08 08.2.12 9:47 AM Page 7 WHEEL NUT TORQUE CAUTION: Never use oil or grease on studs or nuts. Use the torque specified for the type of wheels on the vehicle. Snug all wheel nuts and then tighten to the specified torque in the numerical sequence shown.
  • Page 97 A Ioose running wheel may cause only one stud to break but damage to other studs may not be noticeable. If stud holes in a wheel have become elongated or distorted, replace the wheel. TOWING YOUR ISUZU TRUCK PROCEDURE Proper equipment must be used to prevent damage to vehicles during any towing.
  • Page 98 55702_Sec03_'08 08.2.12 9:47 AM Page 9 1. Horns 2. Bumper (removed for towing) After Towing After towing the vehicle, block the rear wheels and install axle shafts or driveshaft. Apply the parking brake before disconnecting from the towing vehicle. FRONT END TOWING (ALL WHEELS ON THE GROUND) Your vehicle may be towed on all wheels provided the steering is operable.
  • Page 99 55702_Sec03_'08 08.2.12 9:47 AM Page 10 Towing With All Wheels on the Ground 1. Bumper 2. Towing Chain 3. Towing Guide 4. Front Axle 5. Tow Hook To prepare a disabled vehicle for front end towing with all wheels on the ground, the following steps are necessary: •...
  • Page 100 55702_Sec03_'08 08.2.12 9:47 AM Page 11 REAR END TOWING When towing a vehicle with rear wheels raised, secure the steering wheel to maintain straight-ahead position. Make certain that the front axle is not loaded beyond the front axle Gross Axle Weight Rating (GAWR) as indicated on the vehicle’s VIN and Weight Rating plate.
  • Page 101 55702_Sec03_'08 08.2.12 9:47 AM Page 12 When going down a grade, the engine can be used as a brake to slow vehicle speed, provided the transmission is shifted into a gear which will slow the truck without overspeeding the engine. THE ENGINE SHOULD NEVER BE ALLOWED TO EXCEED THE GOVERNED SPEED.

  • Page 102: Customer Satisfaction Procedure

    • Nature of the problem. W h e n c o n t a c t i n g Isuzu Commercial Truck of America , p l e a s e remember that your vehicle’s problem will likely be resolved at the dealership, using the dealer’s facilities, equipment, and personnel.

  • Page 103: Reporting Safety Defects

    National Highway Traffic Safety Administration (NHTSA) in addition to notifying Isuzu Commercial Truck of America, Inc. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.

  • Page 104: Appearance Care

    55702_Sec04_'08 08.2.12 9:48 AM Page 1 SECTION 4 APPEARANCE CARE CLEANING AGENTS CAUTION: Follow the manufacturer’s advice whenever cleaning agents or other chemicals are used, inside or outside the vehicle. Some cleaners may be poisonous or flammable, and improper use may cause personal injury or damage.
  • Page 105 55702_Sec04_'08 08.2.12 9:48 AM Page 2 REMEMBER THESE BASIC STEPS BEFORE CLEANING: 1. Remove stains as quickly as possible before they become “set”. 2. Use a clean cloth or sponge, and change to a clean area often. A soft brush may be used if stains persist. 3.
  • Page 106 55702_Sec04_'08 08.2.12 9:48 AM Page 3 Removal of Specific Stains Greasy or Oily Stains – Includes grease, oil, butter, margarine, shoe polish, coffee with cream, chewing gum, cosmetic creams, vegetable oils, wax crayon, tar and asphalts. • Carefully scrape off excess stain; then use solvent type cleaner. •...
  • Page 107 Isuzu vehicles are designed to operate under normal environmental conditions to withstand natural elements. However, unusual conditions such as high-pressure car washers may cause water to enter inside the vehicle.

  • Page 108: Corrosion Protection

    55702_Sec04_'08 08.2.12 9:48 AM Page 5 WEATHERSTRIP LUBRICATION All weatherstrips should be periodically lubricated (minimum of every six months) with a silicone grease lubricant. A thin film of silicone grease lubricant should be applied using a clean cloth. Silicone grease application will lengthen weatherstrip life, help sealing, and assist in eliminating squeaks.

  • Page 109: Underbody Maintenance

    55702_Sec04_'08 08.2.12 9:48 AM Page 6 UNDERBODY MAINTENANCE Corrosive materials used for ice and snow removal, and dust control can collect on the underbody. If these materials are not removed, accelerated corrosion (rust) can occur on underbody parts such as fuel lines, frames, floor pan and exhaust system even though they have been provided with corrosion protection.

  • Page 110: Service And Maintenance

    The quality of maintenance your new vehicle receives is as important as the regularity with which it is serviced. Isuzu, in cooperation with authorized dealers, provides nationwide quality in customer service. The program includes the training of dealer technicians at Training Centers throughout the country and is supported with a continuous follow-up of publications, films and other service information.

  • Page 111: Maintenance Schedule

    55702_Sec05-1_'08 08.2.12 9:49 AM Page 2 EXPLANATION OF VEHICLE MAINTENANCE AND LOG The following is a brief explanation of normal vehicle use. NORMAL VEHICLE USE—The maintenance instructions contained in this section are based on the assumption that your vehicle will be used as designed: •...
  • Page 112 55702_Sec05-1_'08 08.2.12 9:49 AM Page 3 176 000 110,000 168 000 105,000 160 000 100,000 144 000 90,000 128 000 80,000 120 000 75,000 112 000 70,000 96 000 60,000 80 000 50,000 72 000 45,000 64 000 40,000 48 000 30,000 32 000 20,000...
  • Page 113 55702_Sec05-1_'08 08.2.12 9:49 AM Page 4 176 000 110,000 168 000 105,000 160 000 100,000 144 000 90,000 128 000 80,000 120 000 75,000 112 000 70,000 96 000 60,000 80 000 50,000 72 000 45,000 64 000 40,000 48 000 30,000 32 000 20,000...
  • Page 114 55702_Sec05-1_'08 08.2.12 9:49 AM Page 5 176 000 110,000 168 000 105,000 160 000 100,000 144 000 90,000 128 000 80,000 120 000 75,000 112 000 70,000 96 000 60,000 80 000 50,000 72 000 45,000 64 000 40,000 48 000 30,000 32 000 20,000...
  • Page 115 55702_Sec05-1_'08 08.2.12 9:49 AM Page 6 176 000 110,000 168 000 105,000 160 000 100,000 144 000 90,000 128 000 80,000 120 000 75,000 112 000 70,000 96 000 60,000 80 000 50,000 72 000 45,000 64 000 40,000 48 000 30,000 32 000 20,000...

  • Page 116: Recommended Fluids And Lubricants

    Latches Lubricant properties and containing zinc oxide (Lubricant or equivalent) Engine Coolant Mixture of water and good quality ethylene glycol base type anti-freeze conforming to Isuzu Factory Fill Long Life Coolant Part No.2-90531-809-0 Windshield Washer Washer solvent Solvent Driveshaft, Universal...
  • Page 117 55702_Sec05-1_'08 08.2.12 9:49 AM Page 8 NORMAL VEHICLE USE The owner’s maintenance instructions in the Maintenance Schedule are based on the assumption that your vehicle will be used as designed: • to carry passengers and cargo within the limitations specified on the tire placard.
  • Page 118 55702_Sec05-1_'08 08.2.12 9:49 AM Page 9 • SEVERE SERVICE — Change every 5,000 miles (8,000 km) or 3 months if you often drive under one or more of these conditions (a) driving in dusty areas, (b) frequent idling or idling for long periods, (c) driving 4 miles (6 km) or less in freezing weather, or other short trips in cold weather, where the engine does not thoroughly warm up.
  • Page 119 55702_Sec05-1_'08 08.2.12 9:49 AM Page 10 10. ENGINE COOLING SYSTEM — At 12 months or 10,000 miles (16,000 km) intervals, wash radiator cap and filler neck with clean water, pressure test system and radiator cap for proper pressure holding capacity, tighten hose clamps and inspect condition of all cooling and heater hoses.
  • Page 120 30,000 miles (48,000 km). Do not overfill. How to Check: This operation could be difficult and you may choose to have this done at your Isuzu Dealership Service Department. If you choose to do it yourself, then be sure to follow all the instructions below or you could get a false reading on the dipstick.
  • Page 121 55702_Sec05-1_'08 08.2.12 9:49 AM Page 12 NOTICE: The owner should use “H (Hot)” range. “C (Cold)” range is used for the service technician only. “C (Cold)” range is reference only for replacement of transmission or transmission fluid. 22. EXTERNAL AUTOMATIC TRANSMISSION FILTER — Replace external filter every 30,000 miles (48,000 km).
  • Page 122 55702_Sec05-1_'08 08.2.12 9:49 AM Page 13 28. DRIVESHAFT — Lubricate the grease fitting on each universal joint and spline coupling every 12 months or 10,000 miles (16,000 km) whichever occurs first. 29. LEAF SPRING U-BOLT TORQUE — Tighten the U-Bolt nuts to the specified torque after the first 650 miles (1,040 km), thereafter every 10,000 miles (16,000 km).
  • Page 123 55702_Sec05-1_'08 08.2.12 9:49 AM Page 14 OWNER SAFETY AND ROUTINE MAINTENANCE Listed below are vehicle checks which should be made periodically by either the owner or a qualified technician to ensure proper performance and safety of your vehicle. Take any problems promptly to a technician for service advice.
  • Page 124 55702_Sec05-1_'08 08.2.12 9:49 AM Page 15 BRAKES — Be alert to illumination of the brake warning light or brake low vacuum warning light, or the tone alarm, or changes in braking action, such as repeated pulling to one side, unusual sounds when braking, increased brake pedal travel or harder pedal.
  • Page 125 55702_Sec05-1_'08 08.2.12 9:49 AM Page 16 DOOR LATCHES — Check that doors close, latch and lock tightly. Check for broken, damaged or missing parts that might prevent tight latching. Q TILT CAB (DRIVING POSITION) — Be sure the tilt lever is down and locked.
  • Page 126 55702_Sec05-1_'08 08.2.12 9:49 AM Page 17 NOISE EMISSION CONTROL NOISE CONTROL SYSTEM The following information relates to compliance with Federal noise emission standards for vehicles with a Gross Vehicle Weight Rating ( G V W R ) o f m o r e t h a n 1 0 , 0 0 0 p o u n d s ( 4 , 5 3 6 k i l o g r a m s ) . T h e Maintenance Schedule provides information on maintaining the noise control system to minimize degradation of the noise emission control system during the life of your vehicle.
  • Page 127 FUEL CAP CAUTION: If you need to replace the fuel filler cap, use only a genuine Isuzu fuel filler cap. The use of an improper fuel filler cap could cause fuel spillage in the event of an accident. The use of an improper fuel filler cap could also affect the fuel system and the emission control system.
  • Page 128 55702_Sec05-1_'08 08.2.12 9:49 AM Page 19 ENGINE OIL AND FILTER RECOMMENDATIONS The following engine oil recommendations are based on operating y o u r e n g i n e w i t h t h e f u e l s r e c o m m e n d e d u n d e r “ D i e s e l F u e l Requirements and Fuel System”...
  • Page 129 55702_Sec05-1_'08 08.2.12 9:49 AM Page 20 Check procedure CAUTION: If the engine has been running, wait at least 20 to 30 minutes before checking. NOTICE: Engine oil level must be checked with the vehicle parked on level ground. The engine oil level must be kept at the right level to help assure p r o p e r l u b r i c a t i o n o f y o u r v e h i c l e ’...
  • Page 130 DPF, both the engine and the DPF may break down and fuel economy may decrease. Be sure, therefore, to use the oil intended for the DPF. NOTICE: For vehicles equipped with a DPF, ISUZU recommends engine oil that supports DPF (Low ash oil) with grades CJ-4 (API). 5-21...
  • Page 131 55702_Sec05-1_'08 08.2.12 9:49 AM Page 22 CHOOSING OIL VISCOSITY Engine oil viscosity (thickness) has an effect on fuel economy and cold-weather starting. Lower viscosity engine oils can provide better fuel economy; however, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. When choosing an oil, consider the range of temperature your vehicle will be operated in before the next oil change.
  • Page 132 Isuzu genuine oil filters. Using oil other than r e c o m m e n d e d , o r o i l a n d f i l t e r c h a n g e i n t e r v a l s l o n g e r t h a n recommended, could reduce engine life.
  • Page 133 EXTERNAL DIESEL ENGINE CLEANING NOTICE: Your diesel engine does not need periodic cleaning, nor does Isuzu recommend it be cleaned. However, if you insist on cleaning the engine, clean it only when it is cold, never when it is warm or hot, and never when the engine is running. Spraying or...

  • Page 134: Diesel Fuel System

    55702_Sec05-1_'08 08.2.12 9:49 AM Page 25 DIESEL FUEL SYSTEM Fuel system components which require periodic maintenance services are the engine air cleaners and the fuel filters. Care must be taken when filling the fuel tank to prevent entry of dirt and water. Fuel lines and connections should be inspected regularly for evidence of leaks.
  • Page 135 55702_Sec05-1_'08 08.2.12 9:49 AM Page 26 After Starting The Engine 1. Turn the engine control switch without stepping on the accelerator pedal and start the engine. 2. Allow the engine to idle for five seconds. 3. Slowly turn the idle control knob to the right as far as it will go, then keep the knob in this position for three minutes.

  • Page 136: Water Separator

    Always replace the fuel filter according to the manufacturer’s recommended interval. Failure to replace the fuel filter when needed may lead to fuel system damage. Your authorized Isuzu dealer can inspect your fuel filter and replace your fuel filter, if needed.
  • Page 137 55702_Sec05-2_'08 08.2.12 9:51 AM Page 28 REPLACEMENT WATER SEPARATOR FILTER ELEMENT 1. Disconnect the water separator switch electrical connector. 2. Loosen the fuel filter cover turning it counterclockwise with a filter wrench. 3. Remove the fuel filter. 4. Wipe the fitting face on the upper cover clean with a rag so that the new fuel filter can be seated properly.
  • Page 138 55702_Sec05-2_'08 08.2.12 9:51 AM Page 29 FUEL CAP 1. Follow all the steps under “Parking” in Section 2. 2. Follow any posted safety rules. Stand to the side, never above or opposite the filler opening. 3. Check that the fuel cap is tight, and see to it that engine oil, engine coolant in the reservoir, and washer fluid, etc., are at proper levels.

  • Page 139: Windshield Washer

    55702_Sec05-2_'08 08.2.12 9:51 AM Page 30 STARTING AIDS NOTICE: Do not use starting “aids” in the air intake system . Such “aids” can cause immediate engine damage. WINDSHIELD WASHER The windshield washer is equipped on the windshield wiper arm. The windshield washer fluid supply reservoir is located to the right of the glove box.
  • Page 140 Add to the reserve tank enough of a 50/50 (48/52 For Canada) mixture of water and Isuzu Long Life Coolant antifreeze to bring the level up to the proper mark. Put the cap back on the reserve tank.
  • Page 141 3. Have the engine cooling system and radiator cap tested for a pressure capacity of 108 kPa (16 psi). If a replacement cap is needed, use an Isuzu genuine cap, or an equivalent cap, designed for engine coolant recovery systems and specified for your model.
  • Page 142 • Use a solution that is at least 50 percent antifreeze but no more than 60 percent antifreeze. • Add enough water and Isuzu Long Life Coolant antifreeze solution to provide the required cooling, freezing and corrosion protection. Install the radiator cap and reserve tank cap.
  • Page 143 • Use a solution that is at least 50 percent antifreeze and no more than 60 percent antifreeze. • Add enough water and Isuzu Long Life Coolant antifreeze solution to provide the required cooling, freezing and corrosion protection. Install the radiator cap and reserve tank cap.
  • Page 144 (–29°C) or in Canada at –40°F (–40°C) to ensure protection against corrosion and loss of engine coolant from boiling. A 50/50 (48/52 for Canada) mixture of Isuzu Long Life Coolant antifreeze and water will provide freeze protection to –33°F/–36°C (in Canada –40°F/–40°C) and boil protection to 262°F (128°C).
  • Page 145 55702_Sec05-2_'08 08.2.12 9:51 AM Page 36 AIR CLEANER/FLAME ARRESTOR CAUTION: The air cleaner also functions as a flame arrestor in the event of engine backfire. The air cleaner should be installed at all times unless its removal is necessary for repair or maintenance. To help reduce the risk of personal injury or death and/or property damage, be sure that no one is near the engine compartment before starting the engine with the air cleaner removed.
  • Page 146 • Do not mix the brake fluid with other brand name products. • If the brake fluid reduces significantly, it could be brake system failure or pad wear. Contact your Isuzu dealer immediately and have the system inspected. 5-37...
  • Page 147 55702_Sec05-2_'08 08.2.12 9:51 AM Page 38 ACCESS TO THE ENGINE Access to the engine coolant reserve tank cap and the engine oil dipstick is located on the engine left side after tilting the cab. Add engine coolant as described previously in this section “Engine Cooling System Care”.
  • Page 148 55702_Sec05-2_'08 08.2.12 9:51 AM Page 39 Always be sure the safety lock pin is installed when the cab is tilted. 1. Lock Lever 2. Tilt Lever 3. Assist Handle 4. Safety Lever 5-39...
  • Page 149 55702_Sec05-2_'08 08.2.12 9:51 AM Page 40 5. Cab Support 6. Lock Pin 7. Lock Lever CAUTION: To help avoid personal injury or death, keep hands, tools, and clothing clear of the engine cooling fan when the engine is running. LOWERING THE CAB 1.
  • Page 150 55702_Sec05-2_'08 08.2.12 9:51 AM Page 41 CHECKING THE ENGINE OIL The oil dipstick is located on the left-hand side of the engine. Check the oil level daily. Make the check preferably after a day’s run and after the engine has been stopped for at least five minutes. Remove the dipstick, wipe it clean with a cloth, reinsert it and remove it again.
  • Page 151 CAUTION: • If you fail to clean the filter, the DPF and the engine may break down or fuel economy may deteriorate. • Contact your nearest Isuzu dealer for how to clean the filter. 5-42...
  • Page 152 55702_Sec05-2_'08 08.2.12 9:51 AM Page 43 ACCESS TO THE WINDSHIELD The windshield wiper arms may be swung out, away from the glass, to provide easy access for cleaning. NOTICE: Do not hang on to the roof marker lights while cleaning the windshield or damage may occur (resulting in possible water leakage).

  • Page 153: Electrical System

    55702_Sec05-2_'08 08.2.12 9:51 AM Page 44 ELECTRICAL SYSTEM Following the after-delivery service, it is the owner’s responsibility to check all wiring periodically for cracked, chafed or oil-soaked insulation and maintain it in a clean and tight condition to ensure satisfactory operation of the electrical system.
  • Page 154 55702_Sec05-2_'08 08.2.12 9:51 AM Page 45 HEADLIGHTS / PARKING LIGHTS NOTICE: When replacing a bulb, make sure the light switch is “OFF”. Use only bulbs with the same wattage rating. Removal 1. Remove the front grille (1). • Remove the screw at the center of the front grille. Pushing up the upper 5 clips, pull the front grille and remove it.
  • Page 155 55702_Sec05-2_'08 08.2.12 9:51 AM Page 46 • Dismantle the entire turn signal light towards the front of the vehicle in an obliquely downward direction. • Remove the connectors of the turn signal light, followed by removing the turn signal light. 3.
  • Page 156 55702_Sec05-2_'08 08.2.12 9:51 AM Page 47 Installation 1. Fix the headlight with bolts after positioning the guide pins on the headlight and the holes of the cab panel. 2. Install the front corner panel clips and screw. 3. Install the front grille. Headlight bulb 1.
  • Page 157 55702_Sec05-2_'08 08.2.12 9:51 AM Page 48 Parking light bulb 1. Detach the parking light socket. 2. Remove the bulb from the socket, and replace with a new one. Parking Light Bulb 3. When installing, proceed in the reverse order while paying attention to the following points.
  • Page 158 55702_Sec05-2_'08 08.2.12 9:51 AM Page 49 FRONT TURN SIGNAL LIGHTS 1. Remove the bulb from the socket and replace it with a new one. Bulb Socket 2. During mounting, follow the procedures in the reverse order while paying attention to the following. •...
  • Page 159 55702_Sec05-2_'08 08.2.12 9:51 AM Page 50 CORNERING LIGHT / SIDE TURN SIGNAL LIGHT / SIDE MARKER LIGHT Removal 1. Open the front door and remove the rubber cap at the bottom of the door, followed by unfastening the nut. Rubber Cap 2.
  • Page 160 55702_Sec05-2_'08 08.2.12 9:51 AM Page 51 3. Upon removing the tabs, dismount the light by displacing it towards the back of the vehicle and pulling it out. Clip Cornering light bulb / Side turn signal light bulb / Side marker light bulb 1.
  • Page 161 55702_Sec05-2_'08 08.2.12 9:51 AM Page 52 3. Pay attention to the following when mounting. • Turn the socket to the right to lock it firmly. NOTICE: If the socket is not locked firmly, water may infiltrate the light and cause malfunctioning. Installation 1.
  • Page 162 55702_Sec05-2_'08 08.2.12 9:51 AM Page 53 ROOF MARKER LIGHT (IDENTIFICATION LIGHT / CLEARANCE LIGHT) 1. Unfasten the screws of the lens, and remove the lens. 2. Pull out the bulb and replace it with a new one. 3. Install the lens and screw. NOTICE: If the screwing procedure is inadequate, water may infiltrate into the light unit.
  • Page 163 55702_Sec05-2_'08 08.2.12 9:51 AM Page 54 1. Battery Cover 2. Latch Battery Your new vehicle is equipped with DELKOR batteries. They need no periodic electrolyte level maintenance. Its top is permanently sealed (except for two small vent holes) and has no filler caps. You will never have to add water.
  • Page 164 55702_Sec05-2_'08 08.2.12 9:51 AM Page 55 Fuse Panel The fuse panel is located at the lower side of the center of the instrument. To gain access to the fuses, pull up the bottom of the cover and remove the cover as shown below. The fuse designations are printed on the inside of the panel.

  • Page 165: Wheels And Tires

    55702_Sec05-2_'08 08.2.12 9:51 AM Page 56 OVERFILLING AUTOMATIC TRANSMISSION CAUTION: Overfilling of the automatic transmission can cause the fluid to be “PURGED” out of the breather hose onto the hot engine parts and can cause a fire. WHEELS AND TIRES The operating load and cold inflation pressure on the rim and wheel must not exceed the rim and wheel manufacturer’s recommendations even though the tire may be approved for a higher load or inflation.
  • Page 166 55702_Sec05-2_'08 08.2.12 9:51 AM Page 57 In no case should the front or rear tire load exceed the maximum recommended gross axle weight rating (front GAWR or rear GAWR). The efficiency of the vehicle will be upset if air pressure in the tire is not equal.
  • Page 167 55702_Sec05-2_'08 08.2.12 9:51 AM Page 58 FRONT END ALIGNMENT Proper front end alignment improves tire tread mileage. Your vehicle’s front end suspension parts should be inspected often and aligned when needed. (See the Maintenance Schedule for more information). Improper alignment will not cause the vehicle to vibrate; however, improper toe-in alignment will cause front tires to roll at an angle that will result in faster tire wear.
  • Page 168 55702_Sec05-2_'08 08.2.12 9:51 AM Page 59 When replacing tires, you should use the same size, load range and construction type (bias or radial) as the original tires on your vehicle. Use of any other size or type tire may affect load carrying capacity, ride, handling, speedometer/odometer calibration, vehicle ground clearance and tire clearance to the chassis.

  • Page 169: Vehicle Storage

    If the vehicle has been standing for an extended period of time, the turbocharger bearings should be pre-lubricated prior to starting. See your authorized dealer for more detailed information. Or write to: Isuzu Commercial Truck of America Customer Relations Department 46401 Commerce Center Drive Plymouth, MI 48170...

  • Page 170: Lubrication Points

    55702_Sec05-2_'08 08.2.12 9:51 AM Page 61 LUBRICATION POINTS GREASE POINTS 1. King Pins — 4 fittings 2. Driveshaft Universal Joints, Sliding Sleeve and Center Bearing — 5 fittings 5-61...
  • Page 171 55702_Sec06_'08 08.2.12 9:56 AM Page 1 SECTION 6 SPECIFICATIONS These specifications are given here for information only. Before using them, see the Cautions and other instructions throughout this manual – the index may help you locate such items. For more information, see the Service Manual covering the chassis or body part in question.

  • Page 172: Replacement Parts

    55702_Sec06_'08 08.2.12 9:56 AM Page 2 REPLACEMENT PARTS Please contact your authorized dealer or parts supplier. CAUTION: If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part. Use of a replacement part of lesser quality may result in personal injury or damage to the vehicle.

  • Page 173: Engine Data

    55702_Sec06_'08 08.2.12 9:56 AM Page 3 ENGINE DATA Manufacturer Isuzu Model 4HK1-TC Engine Type Inline 4, Four Cycle Induction Turbocharged W/Charge Air Cooler Bore 115 mm Stroke 125 mm Displacement 5.193L (317 CID) Full Load RPM 2400 CAPACITIES ENGINE CRANKCASE Capacities are for normal refill.
  • Page 174 55702_Sec06_'08 08.2.12 9:56 AM Page 4 ENGINE COOLING SYSTEM CAPACITY..............18L (19.0 qts) THERMOSTAT (Starts to Open) ......82, 85°C (180, 185°F) RADIATOR PRESSURE .............108 kPa (16 psi) WHEEL WHEEL STUD NUT TORQUE Front and Rear ............490 N·m (362 ft·Ibs) Refer to Sections 3 and 5 for complete wheel changing and tire information.

  • Page 175: Electrical Data

    55702_Sec06_'08 08.2.12 9:56 AM Page 5 ELECTRICAL DATA EXTERIOR LIGHTS Light.................power Qty. Headlight ...............60/55W Parking Light ................5W Front Turn Signal Light ............27W Cornering Light ..............27W Side Turn Signal Light ............5W Side Marker Light ..............5W Stoplight / Taillight ............27/8W Backup Light ..............27W Rear Turn Signal Light ............27W License Plate Light ............7.5W Identification Light / Clearance Light ........5W...
  • Page 176 55702_Sec06_'08 08.2.12 9:56 AM Page 6 FUSE BLOCK : CAB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 35 36 37 38 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Circuit Fuse 1 RR POWER WINDOW...
  • Page 177 55702_Sec06_'08 08.2.12 9:56 AM Page 7 Circuit Fuse 15 HEADLIGHT HI (RH) 16 MIRROR HEATER 17 IGNITION 2 18 IGNITION 1 19 - 20 ECM 21 METER 22 ECU (BATT) 23 MIRROR 24 AUDIO, ACCESSORIES 25 HORN 26 TURN, HAZARD 27 TAILLIGHTS 28 ILLUMINATIONS 29 CORNERING LIGHT...
  • Page 178 55702_Sec06_'08 08.2.12 9:56 AM Page 8 FUSE BLOCK : FRAME Circuit Fuse 1 MARKER LIGHT 2 TAIL MAIN 3 ECM MAIN 6 RR DOME LIGHT 7 CONDENSER FAN 8 AIR CONDITIONER FILTER Air Cleaner .............Isuzu No. 8-97062-294-0 Engine Oil ............Isuzu No. 8-97148-270-1 Fuel..............Isuzu No. 8-98037-011-0...
  • Page 179 55702_Sec06_'08 08.2.12 9:56 AM Page 9 INDEX Brake Low Vacuum Warning Light ......2-32 Brake Maintenance ......5-37 ABS ..........2-37 Brake System ......2-22, 5-36 Accessory Power Outlet ....2-58 Brake Pedal ........2-22 Access to the Electrical Parking Brake ......2-24 Components ......5-54 Vacuum Power Brakes ....2-23 Access to the Engine......5-38 Brake System Warning Light ..2-31 Before Tilting the Cab ....5-38...
  • Page 180 55702_Sec06_'08 08.2.12 9:56 AM Page 10 INDEX Dual Tire Operation ......5-57 Damaged Tires ........3-5 Wheel Nut Torque......3-7 Effect on Warranty......0-5 Wheel Stud Nut Torque ....3-7 Electrical Data ........6-5 Wheel Tightening Sequence..3-7 Exterior Lights ........6-5 Daytime Running Light (DRL) Fuse Block ........6-6 Indicator Light......2-35 Interior Lights ........6-5 Defrost ..........2-61...
  • Page 181 55702_Sec06_'08 08.2.12 9:56 AM Page 11 INDEX Check Engine Oil Level....5-19 Glass Surfaces ........4-3 Choosing Oil Viscosity ....5-22 Glow Plug Indicator Light....2-31 Choosing the Right Quality Oil ..5-21 Graphic Symbols ......0-2 Engine Oil Additives ....5-23 Guard Against Theft ......2-12 Oil Identification Logo ....5-23 GVWR ..........0-4 Used Oil Disposal ......5-24 Engine Oil Pressure Warning...
  • Page 182 55702_Sec06_'08 08.2.12 9:56 AM Page 12 INDEX Cruise Main Indicator Light ..2-39 Turn Signal ........2-17 Cruise Set Indicator Light ....2-39 Light Control Switch......2-43 Daytime Running Lights (DRL) Lock Button ........1-5 Indicator Light......2-35 Locking Clip-Full Size ....1-16 DPF Indicator Light (Green) ..2-36 Low Coolant Warning Light ....2-34 DPF Indicator Light Low Fuel Level Indicator Light..2-30...
  • Page 183 55702_Sec06_'08 08.2.12 9:56 AM Page 13 INDEX Outside Rearview Mirror Heater Adjustable Steering Column ..2-20 Switch (If Equipped) ....2-44 Engine Control Switch....2-21 Overdrive Switch ......2-28 Exhaust Brake......2-19 Overloading ........0-4 Hazard Warning Flasher ....2-21 Overdrive Indicator Light ....2-34 Horn ..........2-21 Overfilling Automatic Steering Column Adjustment ..2-20 Transmission ......5-56 Windshield Washer ......2-19...
  • Page 184 Recommendations ....5-58 Wheel and Tire Balancing....5-57 Tire Traction ........5-58 Wheel Replacement Tire Warranty........5-59 Recommendations ....5-58 Towing Your Isuzu Truck Wheel Stud Nut Torque ....3-7, 6-4 Procedure........3-8 Wheel Tightening Sequence ....3-7 Front End Towing ......3-8, 9 Window Controls ......1-5 Rear End Towing ......3-11 Window Regulator Handle Special Towing Instructions ..3-11...
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  • Page 187: Service Manuals

    55702_Sec07_'08 08.2.12 9:57 AM Page 3 SERVICE MANUALS All Service Manuals are available from your local authorized Isuzu dealer, and you are encouraged to order from them directly. In the event that you are unable to contact your local dealer, use the below website.
  • Page 188 SERVICE PUBLICATIONS ORDER FORM The publications listed covering the operation and servicing of your Isuzu Truck can be obtained from Helm, Incorporated either by filling out the reverse side of this form; or for credit card holders calling toll free 1-800-782-4356, or FAXing to 313-865-5927.
  • Page 189 55702_Sec07_'08 08.2.12 9:57 AM Page 5 ORDER TOLL FREE: 1-800-782-4356 (NOTE: For Credit Card Holders Only) Monday-Friday 8:30 A.M. -6:00 P.M. EST (MINIMUM CREDIT CARD PURCHASE $10.00) —OR— By completing this form you can order the materials desired. You can pay by check or money order, or charge to your credit card.
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