Page 1 State: ............Postcode: ......Business Phone: ........Private Phone: ........Mobile: ........Email: .............. Registration Number: ......... Isuzu Truck Model: ..................Vehicle Indentification Number: ................. IAL Tag Number: ........Engine Number: ......... Transmission Serial Number: ........Differential Serial Number: ........
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Page 3 Symbols Used in This Manual DANGER Failure to follow these instructions identified by this symbol could result in death or serious injury to you and/or other people. WARNING Failure to follow these instructions identified by this symbol could result in a fire inside your vehicle in addition to death or serious injury to you and/or other people.
Page 4 Abbreviations This manual uses the following acronyms, as interpreted below. Abbreviations Description Anti-lock Brake System Association des Constructeurs Europeens d’Automobiles ACEA (Association of European Automobile Constructors) Automated Manual Transmission American Petroleum Institute Anti-Slip Regulator ASTM American Society for Testing and Materials British Standard Deutsche Industrie Normen Diesel Particulate Defuser...
Page 5 HOW TO USE THIS MANUAL AND HOW TO FIND A SPECIFIC TOPIC ● HOW TO USE THIS MANUAL ● HOW TO FIND A SPECIFIC TOPIC ● CHAPTER DESCRIPTION ● PICTORIAL INDEX ● WARNING/INDICATOR LIGHT INDEX 0-13 ● WARNING/CAUTION LABELS 0-18 2008N_sec00_print2.indd 1 3/09/2008 4:21:55 PM...
Page 6: How To Use This Manual
HOW TO USE THIS MANUAL Chapter/section titles Chapter index tab These titles are useful for getting the gist Use this for quick access of the content at a glance. to your desired chapter. 2-41 IMPORTANT INFORMATION Staying Safe When the Engine Coolant is Hot WARNING •...
Page 7: How To Find A Specific Topic
HOW TO FIND A SPECIFIC TOPIC Use chapter/section titles as keys Page 0-5 Search for the page describing the specific topic by using the general table of contents under CHAPTER DESCRIPTION, the CHAPTER INDEX, and/or the TABLE OF CONTENTS on the first page of each chapter.
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Page 9: Table Of Contents
CHAPTER DESCRIPTION PICTORIAL INDEX ··································· 0-6 VEHICLE INFORMATION ···························· 1 Chassis and Engine Numbers. Vehicle Identification. Change of ownership or address. IMPORTANT INFORMATION ······················ 2 Warranty statement. Customer assistance. What you should know before you can operate the vehicle safely and smoothly. DOORS, WINDOWS AND SEATS ···············...
Page 10 PICTORIAL INDEX NLR Model Equipment Page Equipment Page Air flow direction control lever Combination light control 4-64 switch Not used Heater / air conditioner Ashtray 5-23 Idling control knob 4-62 CD player (with AM/FM radio) 10 Cigarette lighter 5-22 Relay box 8-40 Small article storage 5-25...
Page 11 PICTORIAL INDEX Equipment Page Equipment Page Horn button 4-73 Instruments, warning lights and indicator lights 4-15 Driver's SRS airbag 4-143 Front fog light switch 4-67 DPD switch 4-154 Hazard warning flasher 4-68 AMT adjustment switch 4-93 switch AMT emergency switch 4-95 2008N_sec00_print2.indd 7 3/09/2008 4:21:58 PM...
Page 12: Pictorial Index
PICTORIAL INDEX NNR/NPR/NQR/NPS Models Equipment Page Equipment Page Air flow direction control lever Exhaust brake switch 4-69 Not used Windshield washer and wiper 4-71 switch Ventilator Heater/manual air Combination light control 4-64 conditioner switch Idling control knob 4-62 Automatic air 5-12 conditioner Cigarette lighter...
Page 13 PICTORIAL INDEX Model without Power Take-Off (PTO) Equipment Page Equipment Page Left rear window switch 3-11 Remote control mirror 4-73 switch Rear window lock switch 3-11 Right rear window switch 3-11 HSA OFF switch 4-98 Cruise control main switch 4-108 DPD switch 4-154 Transfer gear control switch 4-127...
Page 14 0-10 0-10 PICTORIAL INDEX Model with PTO Equipment Page Equipment Page Left rear window switch 3-11 Remote control mirror 4-73 switch Rear window lock switch 3-11 Right rear window switch 3-11 HSA OFF switch 4-98 Cruise control main switch 4-108 DPD switch 4-154 Transfer gear control switch 4-127...
Page 15 0-11 0-11 PICTORIAL INDEX Interior Equipment Page Equipment Page Coat hook 5-29 Back panel tray 5-28 (storage receptacle) Seat Belt 3-23 Dome light 5-20 Seat 3-17 Overhead tray 5-27 Centre console box 5-26 Sun visor 5-21 10 Parking brake lever 4-77 Inside mirror 3-22...
Page 16 0-12 0-12 PICTORIAL INDEX Exterior NLR/NNR/NPR/NQR/NPS Models Equipment Page Equipment Page Outside rearview mirrors 3-22 Tyres 7-80 Turn signal light 8-24 Headlight 8-24 Clearance light 8-24 Front fog light 8-24 Cornering light 8-24 2008N_sec00_print2.indd 12 3/09/2008 4:22:02 PM...
Page 17: Warning/Indicator Light Index
0-13 0-13 WARNING/INDICATOR LIGHT INDEX Warning/Indicator Light Index Multi-Information Display (MID) WARNING LIGHTS Message Display indication Color Page Low fuel Amber 4-50 Water separator (fuel filter) 4-43 Engine overheating 4-39 Meter failure 4-57 CAN system error 4-57 Over speed 4-38 Abnormal voltage 4-22 INDICATOR LIGHTS...
Page 18 0-14 0-14 WARNING/INDICATOR LIGHT INDEX Message Display indication Color Page Push DPD switch Amber 4-56 DPD PM level Green 4-27 Progress of DPD regeneration Amber 4-27 Engine oil level check Amber 4-41 Air cleaner check Amber 4-41 Engine oil and filter Green 4-40 Transmission oil...
Page 19 0-15 0-15 WARNING/INDICATOR LIGHT INDEX Message Display indication Color Page Calendar Green 4-23 Clock Green 4-24 Hour meter Green 4-14 Over speed Green 4-32 Nighttime dimmer Green 4-25 Instrument Panel WARNING LIGHTS Name Symbol Color Page Check engine warning light Amber 4-42 Engine oil pressure warning light...
Page 20 0-16 0-16 WARNING/INDICATOR LIGHT INDEX Name Symbol Color Page Water separator (fuel filter) warning light 4-43 Brake system warning light 4-35 Parking brake warning light 4-51 Brake booster warning light 4-36 Seat belt warning light 4-34 INDICATOR LIGHTS Name Symbol Color Page HSA indicator light...
Page 21 Mobile: ........Email: ........Amber 4-55 light Registration Number: ......... PTO indicator light 4-55 Isuzu Truck Model: ................Vehicle Indentifi cation Number: ............Low fuel warning light Amber 4-50 IAL Tag Number: ........Engine Number: ......... Transmission Serial Number: ........
Page 22: Warning/Caution Labels
Be sure to read them before using the vehicle. • If any of these labels are peeling or illegible due to wear or scratches, please contact your Isuzu Dealer for a replacement. • Some examples of warning/caution labels are indicated on the following pages, but there are many others not shown.
Page 23 0-19 0-19 WARNING/CAUTION LABELS Description Cab tilt instruction (model with cab tilt system) Engine periodic check DPD, AMT, HSA, driver's SRS airbag, passenger's SRS airbag Passenger's SRS airbag (model with passenger’s SRS airbag) Brake fluid 4WD - 2WD selection (4WD model) Free wheel hub (4WD model) Front propeller shaft lubrication (4WD model) Engine maintenance lid (model with engine maintenance lid)
Page 24 0-20 0-20 WARNING/CAUTION LABELS Warning/Caution Labels – Fuel Tank Description Diesel fuel (model with 63-liter fuel tank only) Warning/Caution Labels – Engine Compartment 4JJ1 engine 4HK1 engine Description Engine oil level check (4JJ1 engine) Fuel Filter Element (4JJ1 engine) Engine oil (4JJ1 engine) Radiator cap Engine coolant (4JJ1 engine) Engine control module...
Page 25: Vehicle Information
VEHICLE INFORMATION ● Chassis Number ● Vehicle Identification Number ● Engine Number ● Change of Ownership or Address 2008N_sec01_print2.indd 1 3/09/2008 4:28:11 PM...
Page 26 Chassis and Engine Numbers The chassis and engine numbers are necessary for registering your vehicle. They are also necessary when your vehicle undergoes official inspections. Provide your Isuzu Dealer with these numbers when you are having the vehicle repaired or are ordering replacement parts.
Page 27 75: 4HK1 Engine 85: 4JJ1 Engine Wheelbase code Model year code 8: 2008 model Production sequential number ADVICE • Interpretation of the VIN may differ depending on the market. For further details, please ask your Isuzu Dealer. 2008N_sec01_print2.indd 3 3/09/2008 4:28:18 PM...
Page 28: Your Vehicle
PTO with switch ADVICE • There are more option codes than those indicated above. Depending on the market, an option code may not be shown. For detailed specifications of your vehicle, please ask your Isuzu Dealer. 2008N_sec01_print2.indd 4 3/09/2008 4:28:18 PM...
Page 29 VEHICLE INFORMATION Engine Number 4JJ1 engine 4HK1 engine The engine number is stamped on the The engine number is stamped on the left-side rear part of the engine block. right-side front part of the engine block. 2008N_sec01_print2.indd 5 3/09/2008 4:28:18 PM...
Page 30 State: ............Postcode: ......Business Phone: ........Private Phone: ........Mobile: ........Email: .............. Registration Number: ......... Isuzu Truck Model: ..................Vehicle Indentification Number: ................. Sold To Date: ..........Copy this form and mail to: The Manager – Customer Care Department...
Page 31: Important Information
● Stopping and Parking 2-47 ● Staying Safe 2-53 ● Preventing Breakdowns 2-56 ● When to Visit Your Isuzu Dealer 2-58 ● Diesel Particulate Defuser (DPD) 2-60 ● Model with Speed Limit Device 2-63 ● Seat Belt with Pretensioner and...
Page 32 Subject to the exclusions below, this warranty covers the correction, during the warranty period, of any vehicle defect in materials or workmanship and advised to an Isuzu dealer or IAL authorised service dealer, by repair or at IAL’s option by replacement.
Page 33: Refer To
IMPORTANT INFORMATION fitted, engine hours are an approximate calculation depending on distance travelled and the type of operation. As an approximate guide only, 5,000 kilometres is equivalent to 100 hours of highway operation or 150 hours of suburban operation. In certain circumstances, extended periods of engine operation when a vehicle is stationary can cause excessive wear, and this warranty excludes such wear.
Page 34 • Cosmetic or surface corrosion resulting from scratches, stone chips, etc. • Any work carried out on the vehicle by someone other than an authorised Isuzu tuck dealer or authorised service dealer. • Deterioration due to normal use, exposure, wear and tear.
Page 35 Parts and Accessories purchased at retail or trade Parts and Accessories purchased at trade or retail and installed by other than an Isuzu dealer or IAL authorised service dealer are warranted for 12 months from the date of purchase.
Page 36: Your Vehicle
Isuzu dealer, the service (but only to the extent that it is necessary to enable the vehicle to be operated safely) may be performed by any other qualified mechanic or repairer.
Page 37: Your Vehicle
No. The tyres fitted to your vehicle are covered by a separate warranty provided by the tyre manufacturer. Any authorised Isuzu dealer will assist you by discussing queries that you might have with respect to the tyre manufacturer's warranty with the respective representative.
Page 38: Refer To
All parts and labour used in carrying out IAL warranty service at the premises of the servicing Isuzu dealer are free of charge. Whenever IAL warranty service is to be carried out by an Isuzu dealer it is your responsibility and cost to deliver the Vehicle to the servicing Isuzu dealer's premises.
Page 39: Your Vehicle
IMPORTANT INFORMATION Scheduled Maintenance NORMAL VEHICLE USE - The maintenance schedule in this section are based on the assumption that your vehicle will be used as designed: To carry passengers and cargo with the limitations indicated on the two vehicle identification plates affixed to every vehicle.
Page 40: Your Vehicle
IMPORTANT INFORMATION Customer Assistance We trust that you are delighted with your Isuzu truck and that it provides you with many years of safe and trouble free operation. However, in the event that you experience a problem with any aspect of your vehicle, be assured your Isuzu Dealer is well equipped to assist you.
Page 41 • Hydraulic hose repair Isuzu Assist covers you at the roadside 24 hours a day, 365 days a year for 36 months from the date of first registration. This free service is extended to you whether you are a private truck purchaser, a fleet, taxi truck or rental company, or a Commonwealth, State or Local Government customer.
Page 42 Lockout or lost keys If you have lost your keys, or inadvertently locked them in your truck cabin, Isuzu Assist will attempt to open the truck. However, the driver may be asked to sign an indemnity releasing the service provider from any liability should damage be caused by such forced entry.
Page 43 Isuzu Assist towing allowance. Accident Co-ordination Isuzu Assist with the assistance of the driver will proceed in the management of the incident. This could include advising the driver of their obligations at the scene of the accident, connecting the driver to an appropriate Service Provider, 000 Emergency services, or a vehicle recovery operator.
Page 44 Attempted Repairs If you request Isuzu Assist, the service provider will on arrival examine the truck. If it is found that a third party has attempted repairs causing further problems and the service provider considers in his/her opinion that the truck cannot be started or driven without risk of further damage, service may be refused.
Page 45 If you believe your truck has been damaged by a service person providing roadside assistance, you should contact Isuzu Assist on 1800 947 898. The truck in question must be inspected by a person authorised by Isuzu and agreement gained prior to any further repairs being undertaken.
Page 46 If an inspection reveals an abnormality or there was an abnormality the previous time the vehicle was driven, have the vehicle repaired by the nearest Isuzu Dealer before it is driven again. [1. Checking components that showed abnormalities during the previous operation]...
Page 47 2-17 IMPORTANT INFORMATION [3. Checks performed in the driver's seat] Check item Reference page Brake fluid level (and clutch fluid level 7-62 (7-100) Brake pedal free play 7-70 Clutch pedal free play 7-104 Operation of meters, gauges and warning/indicator lights 4-7, 4-15 Engine startability, abnormal noise and color of exhaust gases 7-20...
Page 48 2-18 IMPORTANT INFORMATION Use the Specified Fuel CAUTION • Always use only a low-sulfur diesel fuel (50 ppm or lower sulfur content) or super-low-sulfur diesel fuel (10 ppm or lower sulfur content). The use of a poor- quality diesel fuel, mixing such an additive as water remover to the fuel in the tank, or filling the tank with gasoline, kerosene or an alcohol-based fuel or its mixture with a diesel fuel will badly affect the fuel filter and result in lubrication problems in fuel-lubricated components of the injectors.
Page 49 He/she could pick up another charge of static electricity by doing so. • Do not use any fuel tank filler cap that is not an Isuzu genuine part. • Obey all cautions posted in filling stations.
Page 50 2-20 IMPORTANT INFORMATION Load Cargo Correctly WARNING • Overloading can result in an accident because it places too much strain on the wheel studs with the result that they break and the wheels come off. CAUTION • It is extremely dangerous to overload the vehicle or to load the vehicle with the cargo positioned on one side.
Page 51 2-21 IMPORTANT INFORMATION Cargo loading caution Incorrect Correct Do not place cargo only at the front or only at the rear. Distribute it evenly. When using supports under cargo, position them uniformly along the cargo. To the greatest extent possible, do not allow long cargo to protrude beyond the rear edge of the cargo bed.
Page 52 2-22 IMPORTANT INFORMATION Do Not Secure Cargo Too Tightly ADVICE • To prevent cargo from falling off the cargo bed, it is essential to secure it with ropes and tarpaulins. However, securing it too tightly can damage the cargo bed's gates and front guard frame.
Page 53 2-23 IMPORTANT INFORMATION Unloading Cargo CAUTION • When you load or unload cargo at the roadside and the cargo bed's gates or other body parts obscure the tail lights, stop lights, hazard warning flashers, turn signal lights and/or reflectors, be sure to warn other drivers and passersby by placing signs or emergency warning triangles where they are easy to...
Page 54 2-24 IMPORTANT INFORMATION Keep the Floor around the Driver's Seat Clean and Tidy WARNING • It is extremely dangerous to have empty cans, empty bottles or other items rolling around on the floor because they could get trapped under the brake pedal and prevent brake application.
Page 55 2-25 IMPORTANT INFORMATION Seat Adjustment Adjusting the seat for a correct driving Forward/ posture is a fundamental part of safe backward adjustment driving. Seat angle adjustment Fastening Your Seat Belt LNU720SH006901 Be sure to wear your seat belt. Sit up straight with your lower back pressed against the seat and the lap belt as low on your hips as possible.
Page 56 2-26 IMPORTANT INFORMATION Passengers and Seat Belts Only one person at a time should use each seat belt. WARNING • Be sure to adjust the seat before driving. Achieve the correct driving posture, gently rock the seat to make sure it is locked in place, and put on your seat belt before you start driving.
Page 57 2-27 IMPORTANT INFORMATION Carrying an Expecting Mother or a Person Who Is Ill WARNING • An expectant mother or a person who is ill riding in the vehicle must also wear a seat belt. In light of the risk that the seat belt will apply pressure to the abdomen, chest and shoulders in the event of a collision, however, an expectant mother or...
Page 58 2-28 IMPORTANT INFORMATION Carrying Children Using Seat Belts with Children WARNING • The vehicle's seat belts are designed for adults. If a seat belt touches a child's neck or chin, or does not rest across his/her hips, use a baby seat, child seat or junior seat.
Page 59 2-29 IMPORTANT INFORMATION Do not Allow a Child to Put His/Her Head or Hands Out of the Window WARNING • Regardless of whether the vehicle is moving or stationary, you must never allow a child to put his/her head, hands, or other body parts out of the window.
Page 60 Inspect the exhaust pipe from time to time. If you notice any defect (for example, a damaged joint, or a hole or crack caused by corrosion), have checks and maintenance performed by the nearest Isuzu Dealer. Continuing to use the vehicle without having the defect repaired would be dangerous because exhaust gases could get into the cab and cause carbon monoxide poisoning.
Page 61 2-31 IMPORTANT INFORMATION Starting the Engine CAUTION • Make sure that the parking brake lever is securely pulled. On a manual transmission model, make sure the gearshift lever is in the "N" position and then hold the clutch pedal down fully before starting the engine.
Page 62 2-32 IMPORTANT INFORMATION If the Vehicle Has not Been Used for a Long Period ADVICE • Before using a vehicle that has not been driven for a long period, check the engine, transmission and transfer case for oil leakage, and make sure the oil is at the required levels.
Page 63 2-33 IMPORTANT INFORMATION Do not Run the Engine in a Garage WARNING • Running the engine in a poorly ventilated place can lead to carbon monoxide poisoning. Choose a well ventilated place when starting and warming-up the engine. Also, do not perform manual diesel particulate defuser (DPD) regeneration indoors.
Page 64 2-34 IMPORTANT INFORMATION Appropriate Gearshifts ADVICE • Downshifts are performed for two main purposes: For engine braking on a steep and/or long downward slope For responsiveness and economy on an uphill slope [Cautions for downshifts] • Allowing the engine to overrun can result in engine damage.
Page 65 2-35 IMPORTANT INFORMATION Never Stop the Engine While Driving WARNING LOCK • Do not move the starter switch away from the "ON" position while the vehicle is being driven. If the engine stops while the vehicle is moving, the brakes would not work properly, and the steering wheel and clutch pedal would become extremely stiff and hard to operate.
Page 66 2-36 IMPORTANT INFORMATION Driving Down a Long Slope When driving down a long slope, use engine brake and the exhaust brake together with the foot brakes. Using the exhaust brake and low-gear engine brake reduces the work load on the foot brakes and yields greater braking force.
Page 67 2-37 IMPORTANT INFORMATION Driving in Bad Weather (Rain, Icy Roads, Snowy Roads, etc.) CAUTION • In bad weather, visibility is reduced and slippery road surfaces increase stopping distances. Drive more slowly than you would in good weather. Also, avoid sharp turns of the steering wheel and hard braking. Use engine brakes together with the foot brakes to decelerate.
Page 68 LNU720SH002201 the brakes. Otherwise, the moisture in the brakes may freeze and make the vehicle immovable. In addition, promptly have the nearest Isuzu Dealer perform water-ingress checks and, where necessary, lubricate brake, engine, electrical, transmission, differential and transfer case components.
Page 69 2-39 IMPORTANT INFORMATION Sidewinds ADVICE If the vehicle catches a sidewind and drifts sideways, firmly grip the steering wheel, decelerate to a speed that allows you to stay completely in control and make a directional correction. The vehicle may catch strong sidewinds in the following situations: •...
Page 70 If any part of the vehicle is damaged or broken, promptly have the vehicle inspected and repaired by the nearest Isuzu Dealer.
Page 71 2-41 IMPORTANT INFORMATION AMT Model On a AMT model, the driver does not use a clutch pedal when pulling away, changing gears or stopping; he/she uses only the gearshift lever, accelerator pedal, and brake pedal. In addition, a AMT model allows the driver to drive the vehicle with the gears changed automatically.
Page 72 2-42 IMPORTANT INFORMATION Operate the Brakes with Your Right Foot ADVICE • Sit in the correct driving position, and use your right foot to operate the brake and accelerator pedals. To avoid accidentally pressing the wrong pedal, check the pedal positions and practice putting your foot on the desired pedal.
Page 73 2-43 IMPORTANT INFORMATION ADVICE [Essential points for safety] • Even if you plan to move only a short distance, adopt the correct driving position and make sure you can firmly press the brake and accelerator pedals. • When you reverse, you twist to look rearward so pedal operation becomes difficult.
Page 74 2-44 IMPORTANT INFORMATION Four Wheel Drive (4WD) Model Four-wheel drive does not make it possible to drive a vehicle absolutely everywhere. Exercise caution when using the accelerator pedal, steering wheel and brake pedal. Concentrate on driving safely, paying attention to the condition and slope angle of the road surface.
Page 75 The vehicle is not completely impervious to water. Avoid driving through water. After driving through water, check the effectiveness of the brakes. Also, promptly have the nearest Isuzu dealer perform water-ingress checks and, where necessary, greasing on the engine, electrical components, transmission, propeller shaft, differential and transfer case.
Page 76 2-46 IMPORTANT INFORMATION Transfer Gear Control Switch Either the 4H or 4L gear can be selected with this switch when operating in 4WD mode. Select either gear appropriately depending on driving conditions. Gear Switching Method Use the transfer gear control switch to switch the gear from 2H-4H to 4L and vice versa.
Page 77 2-47 IMPORTANT INFORMATION Stopping and Parking Parking ADVICE • Choose a flat place where stopping and parking are permitted and where the vehicle will not obstruct traffic. Firmly apply the parking brake and make sure the vehicle does not move. •...
Page 78 2-48 IMPORTANT INFORMATION Do not Use the Hill-Start-Aid (HSA) for Parking CAUTION • HSA is a device to stop the vehicle temporarily and cannot replace the parking brake. When parking, be sure to firmly apply the parking brake. Hill-Start-Aid (HSA) →...
Page 79 2-49 IMPORTANT INFORMATION Keep Flammable Material Away from the Vehicle CAUTION • The exhaust pipe is extremely hot immediately after vehicle operation. Before parking, make sure the area is free of flammable material (for example, dry grass, waste paper, oil or old tyres).
Page 80 2-50 IMPORTANT INFORMATION Do not Touch the Gearshift Lever while the Vehicle is Stationary with the Engine Idling WARNING • Do not touch the gearshift lever while the vehicle is stationary with the engine idling. If you touch the gearshift lever at this time, a gear could be selected and the vehicle could move even with the parking brake applied.
Page 81 2-51 IMPORTANT INFORMATION Leaving the Vehicle WARNING • When leaving the vehicle, be sure to apply the parking brake, stop the engine and lock the doors. Do not leave valuables where they can be seen from outside the vehicle. • If you are traveling with a child, do not leave the child alone in the vehicle.
Page 82 2-52 IMPORTANT INFORMATION Reversing If you cannot see the area behind your vehicle well enough to confirm it is safe to back up, get out of the vehicle and check behind it. Pulling Away after a Temporary Stop CAUTION • Make it a habit to look around and confirm that it is safe to pull away after a temporary stop (at traffic...
Page 83 2-53 IMPORTANT INFORMATION Staying Safe When the Engine Coolant is Hot WARNING • Do not loosen or remove the radiator cap while the engine coolant is hot. Doing so would be dangerous because steam and hot air would shoot out. When the Engine Overheats →...
Page 84 2-54 IMPORTANT INFORMATION Do not Attach Accessories to the Windshield or Windows WARNING • Do not attach ornaments, films or other accessories to the windshield or windows. They would impair visibility. Also, any plastic suction cups used to attach accessories could cause a fire or other accident by acting as lenses.
Page 85 2-55 IMPORTANT INFORMATION Using the Jack WARNING • Jacking up a vehicle on slope or soft ground is extremely dangerous. Be sure to jack up the vehicle on a firm, level surface. • Set the jack in the correct position. Do not forget to first apply the parking brake and place chocks around the wheels.
Page 86 2-56 IMPORTANT INFORMATION Preventing Breakdowns Do not Rest Your Foot on the Clutch Pedal while Driving ADVICE • If you rest your foot on the clutch pedal while driving, the clutch could partially disengage without you realizing it, causing the clutch plates to wear and the clutch to slip.
Page 87 2-57 IMPORTANT INFORMATION Do not Climb onto the Engine ADVICE • Do not step on the engine or climb onto it. You could cause an engine failure by, for example, damaging the cylinder head cover or various connectors. Do not Leave the Steering Wheel Fully Turned for a Long Time WARNING •...
Page 88 For adjustments (for example, engine adjustments) and equipment installation, consult your Isuzu Dealer. • If you wish to attach accessories to the vehicle, consult your Isuzu Dealer. Have Engine Adjustments Made by Your Isuzu Dealer CAUTION •...
Page 89 Noise from the radio set could cause electromagnetic interference with the vehicle's electronic equipment and other systems, resulting in a vehicle breakdown or in a malfunction of electronic equipment. Consult your Isuzu Dealer if you wish to install radio equipment. 2008N_sec02_print2.indd 59 15/09/2008 10:36:59 AM...
Page 90 Otherwise, you could be burned. ADVICE • Use Isuzu genuine engine oil compatible with the DPD. Using oil other than Isuzu genuine engine oil compatible with the DPD would shorten the time between DPD filter cleaning and could increase fuel consumption.
Page 91 2-61 IMPORTANT INFORMATION NOTE • If the vehicle is stationary with the engine idling during DPD regeneration, the exhaust brake or exhaust throttle operates. Operating sounds will be heard when the exhaust brake or exhaust throttle is activated or deactivated. The sounds do not indicate a fault.
Page 92 If you are unable to perform a repair, the corrective action shown in the table does not eliminate a symptom or you can't locate a fault, contact the nearest Isuzu Dealer. Reference Symptom...
Page 93 • If the tyre size is changed, the speed limit device may not work normally. Have adjustments made by your Isuzu Dealer. NOTE • The speed limit device restricts the vehicle's speed by controlling the fuel injection volume.
Page 94 2-64 IMPORTANT INFORMATION Seat Belt with Pretensioner and SRS Airbag System If a vehicle that has a seat belt with pretensioner and supplemental restraint system (SRS) airbag system suffers a frontal impact above a certain level, the seat belt with pretensioner and airbag (assuming the vehicle has a passenger airbag in addition to a driver airbag) securely restrain the driver and passenger...
Page 95 • Replacing the steering wheel with a steering wheel other than an Isuzu- specified one or affixing a sticker to the steering wheel pad would be dangerous because it could result in defective operation and cause the sticker to be propelled toward you in the event of airbag deployment.
Page 96 Warning (Continued) • The actions listed below require special measures. Please consult your Isuzu Dealer. Unless the correct measures are taken, the seat belt with pretensioner or airbag could be activated unexpectedly such that the seat belt rewinds or the airbag deploys, causing injuries.
Page 97 Isuzu and its agents can obtain data recorded by the EDR and use them for the purpose of improving vehicle collision safety. Neither Isuzu nor its agents will show or provide the data to any third party except in the following situations: •...
Page 98 2-68 IMPORTANT INFORMATION 2008N_sec02_print2.indd 68 15/09/2008 10:37:02 AM...
Page 99 DOORS, WINDOWS AND SEATS ● Key ● Key with Immobilizer Transponder Chip ● Keyless Entry System ● Opening and Closing Doors ● Power Windows 3-11 ● Fuel Tank Filler Cap 3-13 ● Tool Box 3-16 ● Seats 3-17 ● Fully Adjustable Steering 3-21 ●...
Page 100 To prevent theft, store the metal plate with key code in a safe place other than the vehicle. • Should you lose the key, please give the key number to the nearest Isuzu Dealer. The Isuzu Dealer will be able to duplicate your key. •...
Page 101 • Another vehicle's transponder key is near your key. ADVICE • Should you lose your transponder key, contact the nearest Isuzu Dealer. • Do not leave the transponder key on the dashboard or any other surface where the key might be exposed to high temperatures (exceeding 60°C...
Page 102 DOORS, WINDOWS AND SEATS Keyless Entry System The keyless entry system allows you to Remote control operating range lock/unlock the doors by simply pressing 45° the remote control button rather than inserting the key into the lock. 10 m (33 ft) The remote control unit works within a 10 m (33 ft) radius of the cab center as indicated in the figure.
Page 103 DOORS, WINDOWS AND SEATS ADVICE • Should you lose the remote control unit, please contact your Isuzu Dealer. • After locking the doors using the remote control unit, be sure to check that they are locked by pulling the door handles.
Page 104 DOORS, WINDOWS AND SEATS Replacing the Battery in the Remote Control Unit 1. Remove the key ring from the remote control unit. Remove the cover by removing the screw with a small screwdriver. 2. Take out the battery holder, and then remove the battery from the holder.
Page 105 DOORS, WINDOWS AND SEATS CAUTION • When changing the battery, use only a battery of the same type as the original battery, or an equivalent. Otherwise, there is a risk of explosion. • Do not place the battery in direct sunlight, or near a fire or other sources of heat.
Page 106 DOORS, WINDOWS AND SEATS Front Doors (NLR/NNR/NPR/NQR/NPS Models) Locking and Unlocking the Door from Outside Using the Key Turn the key toward the front of the vehicle to lock the door and turn it toward the rear of the vehicle to unlock it. Locking the Door from Outside without Using the Key First, push the lock button on the inside...
Page 107 DOORS, WINDOWS AND SEATS Power Door Lock (Central Door Lock) How the Power Door Lock System Operates: When you lock or unlock the driver's door using the key or by operating the lock button, the power door lock system will automatically lock or unlock all doors simultaneously. Rear Doors (Crew Cab Model) Locking the Door from Outside NLR/NNR/NPR/NQR/NPS models...
Page 108 3-10 DOORS, WINDOWS AND SEATS Power Windows The power windows operate only when the starter switch is in the "ON" position. Open each door window by pressing the power window switch; close each one by raising the switch. WARNING • Before closing the windows, make sure that there is no risk of a hand, head or anything else being trapped in the moving window.
Page 109 3-11 DOORS, WINDOWS AND SEATS Window Switches on Passenger's Door and Rear Doors NLR/NNR/NPR/NQR/NPS models CAUTION (Passenger side) • Be sure to warn passengers, especially in the case of a child, not to let any part of the body become trapped or caught in a moving window.
Page 110 3-12 DOORS, WINDOWS AND SEATS Window Switches on center of dashboard (Crew Cab model) To Open a Rear Window The window glass will move downward while you are pushing the bottom part of the switch. To Close a Rear Window The window glass will move upward while you are pushing the top part of the switch.
Page 111 3-13 DOORS, WINDOWS AND SEATS Fuel Tank Filler Cap WARNING • Be sure to place the starter switch in the "ACC" or "LOCK" position to shut down the engine before refueling the vehicle. Refueling while the engine is running could cause a fire in your vehicle. •...
Page 112 3-14 DOORS, WINDOWS AND SEATS How to Open and Close the Fuel Tank Filler Cap (without Key Lock) 1. Eliminate static from your body before opening the fuel tank filler cap. 2. Slowly turn the cap counterclockwise to open it. 3.
Page 113 3-15 DOORS, WINDOWS AND SEATS Opening and Closing the Fuel Tank Filler Cap (with Key Lock) 1. Eliminate static from your body before opening the fuel tank filler cap. 2. Open the cover, then firmly insert the key and turn it to the "OPEN" position. 3.
Page 114 3-16 DOORS, WINDOWS AND SEATS Tool Box The tool box is located on the vehicle's outer chassis (either in the middle or near the rear). CAUTION • Securely close the tool box so the lid does not come open while the vehicle is moving.
Page 115 3-17 DOORS, WINDOWS AND SEATS Seats The driver's seat must be adjusted so that when you sit well back in the seat, you can fully depress the pedals without moving your back from the seatback, and you can operate the steering wheel easily and freely. After making adjustments, check that the seat is completely locked.
Page 116 3-18 DOORS, WINDOWS AND SEATS Driver's Seat Forward/backward Adjustment While raising the lever, move the seat forward or backward. Release the lever when the seat is in the desired position. After making adjustments, try to move the seat back and forth to check that it is fully locked.
Page 117 3-19 DOORS, WINDOWS AND SEATS Suspension Adjustment Before sitting on the seat, use the knob to adjust the suspension to suit your weight. Turn the knob clockwise to move the pointer down the scale and counterclockwise to move it up the scale. The pointer should be alongside your weight on the scale.
Page 118 3-20 DOORS, WINDOWS AND SEATS Rear Seats Do not remove the seat cushion except when taking out or stowing onboard tools. Tools→ Refer to Page CAUTION • Do not drive with the seat cushion removed. The seat would not be stable, which could lead to an accident.
Page 119 3-21 DOORS, WINDOWS AND SEATS Fully Adjustable Steering The steering wheel is adjustable up and down as well as forward and backward. WARNING • After adjusting the steering wheel, try moving it up and down to make sure it is fully locked before you drive the vehicle.
Page 120 3-22 DOORS, WINDOWS AND SEATS Mirrors Sit in the correct driving position on the properly adjusted seat, and then check each mirror to ensure that it provides a proper view of the rear, the sides, the area just in front of the vehicle, and the area directly opposite to the driver's seat. Make adjustments if necessary and clean any dirty mirrors.
Page 121 3-23 DOORS, WINDOWS AND SEATS CAUTION • Adjust the mirrors when the vehicle is stationary, not while the vehicle is in motion. • When checking the rear of the vehicle with mirrors, be careful that this does not distract your attention from the traffic ahead. •...
Page 122 • Have seat belts inspected and, if necessary, replaced by the nearest Isuzu Dealer when the webbing becomes frayed or worn and/or when the buckle or other mechanical parts fail to work properly.
Page 123 3-25 DOORS, WINDOWS AND SEATS WARNING (Continued) • Wearing seat belts is a legal requirement. The driver is responsible not only for wearing a seat belt himself/herself but also for prompting all passengers to wear their seat belts. It is necessary, however, to check with a doctor about the appropriateness of a seat belt for an expectant mother or a passenger with a chest/abdominal condition.
Page 124 3-26 DOORS, WINDOWS AND SEATS To Unfasten Push the button on the buckle. As the belt automatically retracts, let it be taken up slowly by holding on to the latch plate until the belt is fully retracted. ADVICE • While being automatically retracted, the seat belt could damage a nearby window or interior trim unless the latch plate is properly held.
Page 125 (and the passenger's seat belt, if the vehicle is equipped with a passenger's airbag) to unintentionally retracts or the driver's airbag (and the passenger's airbag, if equipped) to suddenly deploys, resulting in injury. Be sure to have any repair or installation done by your Isuzu Dealer. NOTE •...
Page 126 3-28 DOORS, WINDOWS AND SEATS Two-Point Seat Belt (Centre Seat) To Fasten 1. Sit on the seat in the correct position. 2. Pull out the latch plate side of the belt a little longer than necessary. (Placing the latch plate at right angles with the belt makes this easier.) 3.
Page 127: Doors, Windows And Seats
3-29 DOORS, WINDOWS AND SEATS To Unfasten Push the button on the buckle to unfasten the belt. NOTE [Centre seat belt design to prevent incorrect fastening] • The centre seat belt (length- adjustable two-point belt) is designed so that it cannot be connected with any of the window- side seat belts (three-point seat belts with ELR).
Page 128 3-30 DOORS, WINDOWS AND SEATS 2008N_sec03_print2.indd 30 3/09/2008 4:35:57 PM...
Page 129 CONTROLS AND INSTRUMENTS STARTING AND STOPPING THE ENGINE INSTRUMENTS, WARNING LIGHTS AND INDICATOR LIGHTS 4-59 SWITCHES 4-75 DRIVING CONTROLS 2008N_sec04-1_print2.indd 1 3/09/2008 5:27:55 PM...
Page 130 2008N_sec04-1_print2.indd 2 3/09/2008 5:27:57 PM...
Page 131 CONTROLS AND INSTRUMENTS STARTING AND STOPPING THE ENGINE ● Starting the Engine ● Stopping the Engine 2008N_sec04-1_print2.indd 3 3/09/2008 5:27:57 PM...
Page 132 CONTROLS AND INSTRUMENTS Starting the Engine Make sure that the switches, including those for the windshield wiper, light control and air conditioner, are in the "OFF" position. Turn the starter switch to the "ON" position to check that the warning and indicator lights turn on normally and the fuel level is proper.
Page 133 CONTROLS AND INSTRUMENTS Glow plug indicator light 1. If your vehicle is equipped with a manual transmission, fully press the clutch pedal. If your vehicle is equipped with a AMT system, make sure that the gearshift lever is in the "N" position and firmly press the brake pedal.
Page 134 CONTROLS AND INSTRUMENTS NOTE [Preheating] • Diesel engines are compression ignited, which makes them difficult to start when they are cold because the compression alone cannot create a temperature high enough for fuel to ignite. "Preheating" means warming the compressed air inside the combustion chambers to facilitate engine starting. Be sure to start the engine after the glow plug indicator light has gone out.
Page 135 CONTROLS AND INSTRUMENTS INSTRUMENTS, WARNING LIGHTS AND INDICATOR LIGHTS ● How to Read the Instruments (Instruments Layout) ● Speedometer ● Analog Tachograph 4-11 ● Tachometer 4-11 ● Engine Coolant Temperature Gauge 4-12 ● Fuel Gauge 4-13 ● Hour Meter 4-14 ●...
Page 136 CONTROLS AND INSTRUMENTS How to Read the Instruments (Instruments Layout) Reference Reference Name Name page page Tachometer 4-11 Shift indicator 4-79 Engine coolant Multi-Information 4-17 4-12 Display (MID) temperature gauge Speedometer Analog Tachograph 4-11 Fuel gauge 4-13 2008N_sec04-1_print2.indd 8 3/09/2008 5:28:02 PM...
Page 137 CONTROLS AND INSTRUMENTS Speedometer Model without multi-information The speedometer indicates the vehicle display (MID) speed in km/h or MPH. The speedometer is an integral unit with the odometer/trip meter. Each time you press the reset button lightly with the starter switch in the "ON"...
Page 138 4-10 CONTROLS AND INSTRUMENTS NOTE • When you turn the starter switch to the "ON" position, the odometer/trip meter shows what was displayed the last time you turned the switch to the "LOCK" or "ACC" position. • You can set the odometer to display on the odometer/trip meter each time you turn the starter switch to the "ON"...
Page 139: Controls And Instruments
4-11 CONTROLS AND INSTRUMENTS Tachometer The tachometer indicates the engine speed in revolutions per minute (r/min). (Graduation "1" on the scale indicates 1,000 r/min.) The red zone indicates a range of dangerous engine speeds beyond permissible levels. Do not drive your vehicle with the needle of the tachometer in the red zone.
Page 140 4-12 CONTROLS AND INSTRUMENTS Engine Coolant Temperature Gauge With the starter switch in the "ON" position, this gauge indicates the temperature of the engine coolant. "C" means cold while "H" means hot. If the engine overheats, the engine overheat warning light comes on (a model without multi-information display (MID)) or the warning message is indicated (a model with MID) and a warning buzzer...
Page 141 4-13 CONTROLS AND INSTRUMENTS Fuel Gauge With the starter switch in the "ON" position, this gauge indicates the quantity of fuel remaining in the fuel tank. "F" means the tank is full while "E" means the tank is almost empty. NOTE •...
Page 142 4-14 CONTROLS AND INSTRUMENTS Hour Meter Model with Multi-Information Display (MID) This meter indicates how many hours the engine has been run. The figure(s) on the left side of the decimal point indicate hours while the figure on the right side indicates 1/10 of an hour. This is displayed on the MID.
Page 143 4-15 CONTROLS AND INSTRUMENTS Warning and Indicator Lights Layout Model without multi-information display (MID) Model with MID 2008N_sec04-1_print2.indd 15 3/09/2008 5:28:08 PM...
Page 144 4-16 CONTROLS AND INSTRUMENTS Reference Reference Name Name page page 4-17 Cruise control main 4-54 indicator light 17 Generator warning light 4-42 PTO indicator light 4-55 Cruise control set 4-54 indicator light 19 High beam indicator light 4-51 HSA indicator light 4-52 ABS warning light 4-37...
Page 145 Otherwise, you will be in danger of vehicle breakdown or accident. Should any of the critical warning lights comes on, immediately contact the nearest Isuzu Dealer. 2008N_sec04-1_print2.indd 17 3/09/2008 5:28:09 PM...
Page 146 4-18 CONTROLS AND INSTRUMENTS Main Routine This page shows you the basic screens of the MID and what operations are necessary to access these screens. Use the MID select knob to select the desired screen or function. 2008N_sec04-1_print2.indd 18 3/09/2008 5:28:10 PM...
Page 147 4-19 CONTROLS AND INSTRUMENTS 2008N_sec04-1_print2.indd 19 3/09/2008 5:28:11 PM...
Page 148 4-20 CONTROLS AND INSTRUMENTS Warning and Indicator Lights Display Warning and indicator messages are shown on the display to alert you to system failures or to prompt you to necessary checks you should perform while operation- related information is being displayed. Use the MID select knob to select the desired screen page or function.
Page 149 4-21 CONTROLS AND INSTRUMENTS Reference Indication Color Description page Amber Air cleaner needs cleaning soon. 4-41 Operation-Related Information Display This function displays vehicle operation related information on such items as fuel economy, battery voltage, calendar and clock, which is useful for efficient management of your vehicle operation.
Page 150 The voltmeter shows the current status of the charge of the battery. Use the MID select knob to select the voltmeter. If a voltmeter sign appears with red, have the vehicle checked and serviced at the nearest Isuzu Dealer as soon as possible. Message Display indication...
Page 151 4-23 CONTROLS AND INSTRUMENTS Calendar and Clock Use the MID select knob to select the calendar or clock to display. CAUTION • The calendar and clock can be set only while the vehicle is stationary. When setting the calendar or clock, park your vehicle in a safe place where stopping or parking is permitted and is well clear of traffic.
Page 152 4-24 CONTROLS AND INSTRUMENTS 7. Turn the MID select knob clockwise to increase the day and counterclockwise to decrease the day. If you hold the switch after turning it clockwise or counterclockwise, the day continues to increase or decrease until the switch is released.
Page 153 4-25 CONTROLS AND INSTRUMENTS Nighttime Dimmer When the nighttime dimmer is set to ON, MID is dimmed while the headlights are on. Use the MID select knob to select the night time dimmer. If the MID is too dark when driving with the headlights on during daytime, set the nighttime dimmer to OFF.
Page 154 4-26 CONTROLS AND INSTRUMENTS Diesel Particulate Defuser (DPD) State This function displays the amount of particulate matter (PM) accumnlated by DPD. During DPD regeneration, the progress of the regeneration is displayed. Message Display indication Color Display condition DPD PM The current level of PM Green accumulation level accumulation in DPD is displayed.
Page 155 4-27 CONTROLS AND INSTRUMENTS DPD PM Accumulation Level The multi-information display (MID) shows the amount of PM accumulated in the DPD, using a total of six segments. As the amount of PM in the DPD increases, the number of the displayed segments increases one by one from the left side ("L"). Status Display Status...
Page 156 The maintenance data function indicates the distance remaining before the next scheduled maintenance. Scheduled maintenance time is approaching when the display turns from green to amber. Have the vehicle checked and serviced at the nearest Isuzu Dealer as soon as possible. CAUTION •...
Page 157 4-29 CONTROLS AND INSTRUMENTS Maintenance Reference Display indication Color Description Message page Distance remaining until Green the next engine oil and filter change is displayed. Engine oil and 4-40 This is displayed when filter the next engine oil and Amber filter change is near or has already been reached.
Page 158 4-30 CONTROLS AND INSTRUMENTS How to Set a New Change Interval (Odometer Reading) for Engine Oil and Filter 1. On the MID, go to ENG OIL & FILTER screen. 2. Enter the setting change screen by pressing and holding the MID select knob. NOTE • If you want to cancel the setting procedure, press the MID select knob once.
Page 159 4-31 CONTROLS AND INSTRUMENTS 3. Pressing and holding the MID select knob sets the new change interval (distance). Setting the Tyre Rotation Time (Odometer Reading) 1. On the MID, go to the TIRE ROTATION screen. 2. Enter the setting change screen by pressing and holding the MID select knob.
Page 160 4-32 CONTROLS AND INSTRUMENTS Hour Meter Hour Meter → Refer to page 4-14 Over Speed 1. On the multi-information display (MID), go to the SPEED WARNING screen. 2. Enter the speed warning setting screen by pressing and holding the MID select knob. NOTE • Your vehicle has been shipped from the factory with no warning speed set.
Page 161 If the system has not yet been able to access maintenance data, "ERROR" is shown on the multi-information display (MID). If "ERROR" does not change automatically to a distance or other maintenance indication, have your vehicle inspected / serviced at the nearest Isuzu Dealer. Per trip fuel Instantaneous fuel...
Page 162 CAUTION • If the warning light does not initially flash seven times, does not go out, or comes on while driving, promptly have your vehicle inspected / serviced at the nearest Isuzu Dealer. 2008N_sec04-1_print2.indd 34 3/09/2008 5:28:35 PM...
Page 163 → Refer to page 4-37 CAUTION • If this warning light comes on while the engine is running, immediately pull off to a safe place well clear of traffic and promptly contact the nearest Isuzu Dealer for inspection. 2008N_sec04-1_print2.indd 35 3/09/2008 5:28:36 PM...
Page 164 4-36 CONTROLS AND INSTRUMENTS Brake Booster Warning Light The warning light and buzzer will come on simultaneously whenever the brake booster's vacuum becomes insufficient either during driving or when the starter switch is in the "ON" position, whenever the hydraulic brake booster (HBB) system becomes faulty, or whenever a problem occurs with the exhaust brake while it is being used.
Page 165 If the warning light does not go out, the problem will be in the brake booster for the foot (main) brake. Have your vehicle inspected at the nearest Isuzu Dealer as soon as possible. • This light should come on to provide a bulb check when the engine control switch is turned to the "ON"...
Page 166 • If the indicator light does not go out, or comes on repeatedly, have the vehicle inspected/serviced at the nearest Isuzu Dealer as soon as possible. • Even if a problem has occurred in the ABS, the brakes will still work as normal brakes.
Page 167 4-39 CONTROLS AND INSTRUMENTS Engine Overheat Warning Light Model without MID This warning light comes on (a model without multi-information display (MID)) or appears on the display (a model with MID) when the engine has overheated. When the engine overheats, the engine coolant temperature gauge needle reaches the red zone, and the engine overheat warning light comes on (a model without MID) or...
Page 168 MID select knob is pressed once or the vehicle is started. When the engine oil and filter indicator light (amber) has come on, have the vehicle inspected / serviced at your Isuzu Dealer. NOTE [Checking the engine oil level] •...
Page 169 4-41 CONTROLS AND INSTRUMENTS Check Engine Oil Level Warning Light Model with Multi-Information Display (MID) This warning light appears on the display when the engine oil level is too low. NOTE • When the CHECK ENGINE oil level warning light is indicated on the screen, check the engine oil level using the oil dipstick. Multi-Information Display (MID) → Refer to page 4-17 Engine Oil...
Page 170 ADVICE • If this warning light comes on while the engine is running, immediately pull off to a safe place well clear of traffic and promptly contact the nearest Isuzu Dealer for inspection. Fan Belt → Refer to page 7-44 Handling the Battery →...
Page 171 The indicator light will go off after the engine starts. If the indicator light comes on during operation, immediately contact the nearest Isuzu dealer for inspection. Water Separator (Fuel Filter) Warning Light Model without MID This warning light comes on (a model...
Page 172 ADVICE • If this warning light comes on, have your vehicle inspected as soon as possible at the nearest Isuzu Dealer. • If this warning light flashes while driving, the AMT oil is abnormally hot. Pull off to a safe place well clear of traffic as soon as possible. Do not start driving again until the warning light goes out.
Page 173 MID select knob is pressed once or the vehicle is started. When the transmission oil indicator light (amber) has come on, have the vehicle inspected/serviced at your Isuzu Dealer. Multi-Information Display (MID) → Refer to page 4-17 When ERROR is Displayed → Refer to page 4-33...
Page 174 MID select knob is pressed once or the vehicle is started. When the AMT clutch oil indicator light (amber) appears on the display, have the vehicle inspected/serviced at your Isuzu Dealer. Multi-Information Display (MID) → Refer to page 4-17 When ERROR is Displayed → Refer to page 4-33...
Page 175 MID select knob is pressed once or the vehicle is started. When the fuel filter indicator light (amber) has come on, have the vehicle inspected / serviced at your Isuzu Dealer. Multi-Information Display (MID) → Refer to page 4-17 When ERROR is Displayed → Refer to page 4-33...
Page 176 MID select knob is pressed once or the vehicle is started. When the power steering fluid indicator light (amber) is displayed, have the vehicle inspected/serviced at your Isuzu Dealer. Multi-Information Display (MID) → Refer to page 4-17 When ERROR is Displayed → Refer to page 4-33...
Page 177 4-49 CONTROLS AND INSTRUMENTS Tyre Rotation Indicator Light Model with Multi-Information Display (MID) This message appears on the display when the tyre rotation maintenance screen is selected or when the next tyre (Comes on when the next tyre rotation interval is near or has already rotation interval is near or has been reached.
Page 178 4-50 CONTROLS AND INSTRUMENTS Low Fuel Warning Light Model without MID This warning light comes on (a model without multi-information display (MID)) or the message appears on the display (a model with MID) when the fuel level in the tank becomes too low while the engine is running.
Page 179 4-51 CONTROLS AND INSTRUMENTS High Beam Indicator Light This indicator light comes on when high beam is selected or the headlights are cycled between high and low beams (passing signal). Light Control Switch → Refer to page 4-64 Rear Fog Light Indicator Light This indicator light stays on while the rear fog lights are on.
Page 180 The exhaust brake indicator light flashes if there is a problem with the exhaust brake system. Have your vehicle inspected at the nearest Isuzu Dealer as soon as possible. Exhaust Brake Switch → Refer to page 4-69 HSA Indicator Light This indicator light comes on when the hill- start-aid (HSA) system is in operation.
Page 181 The ASR is operating satisfactorily. • If the indicator light does not go out, or comes on repeatedly, have the vehicle inspected/serviced at the nearest Isuzu Dealer as soon as possible. Anti-Slip Regulator (ASR) → Refer to page 4-120 Glow Plug Indicator Light This indicator light comes on when the starter switch is turned to the "ON"...
Page 182 4-54 CONTROLS AND INSTRUMENTS ECONO Mode Indicator Light This warning light should remain on for approximately 2 seconds after the starter switch is turned to the "ON" position, and then should go out. This indicator light comes on when the ECONO mode is selected.
Page 183 4-55 CONTROLS AND INSTRUMENTS PTO Indicator Light This indicator light comes on when the dump control or power take-off (PTO) lever is operated, or when the PTO switch is pressed. Power Take-Off (PTO) → Refer to page 4-128 4WD Indicator Light The 4WD indicator light comes on on the instrument panel when the 4WD switch is LNU740SH001201 used to select 4WD operation.
Page 184 4-56 CONTROLS AND INSTRUMENTS CAUTION • If your vehicle is a power take-off (PTO)-equipped model and when the PTO is operated for an extended time period, check that the DPD manual regeneration indicator light (amber) is not flashing. • During extended engine idling, the DPD manual regeneration indicator light (amber) may come on and the DPD may be automatically regenerated.
Page 185 Pull off to a safe place, stop the engine, and restart it. If the message still appears, contact the nearest Isuzu Dealer. CAN System Error Model with MID This message appears on the display when...
Page 186 ADVICE • The warning buzzer may not sound if there is a problem with the system. If this occurs, the system needs to be inspected. Please contact the nearest Isuzu Dealer. • At night, the buzzer back-up warning sound volume can be reduced by placing the light control switch in the "ON"...
Page 187: Horn Button
4-59 CONTROLS AND INSTRUMENTS SWITCHES ● Starter Switch 4-60 ● Idling Control Knob 4-62 ● Warm-Up Switch 4-63 ● Combination Light Control Switch 4-64 ● Headlight Leveling Switch 4-66 ● Front Fog Light Switch 4-67 ● Rear Fog Light Switch 4-68 ● Hazard Warning Flasher Switch 4-68 ●...
Page 188 4-60 CONTROLS AND INSTRUMENTS Starter Switch WARNING • While driving, never turn the starter switch to the "LOCK" position. The key could be removed from the switch, which then locks the steering wheel. This is extremely dangerous. ADVICE • After starting the engine, do not turn the starter switch to the "START" position. Otherwise, the starter motor may be damaged.
Page 189 4-61 CONTROLS AND INSTRUMENTS Starter Switch LOCK : In this position, the key can be inserted or removed. Remove the key and turn the steering wheel until it locks. The steering wheel will be locked to help prevent theft. To place the starter switch in the "LOCK"...
Page 190 4-62 CONTROLS AND INSTRUMENTS Idling Control Knob This knob is used to warm up the engine. You can increase the engine speed by turning the knob clockwise without the need to use the accelerator pedal. Turn the knob back fully counterclockwise after you have used it for engine warm-up and keep it in this position.
Page 191 4-63 CONTROLS AND INSTRUMENTS NOTE • Use the idling control knob to stabilize the engine speed at start when it runs rough. • Turn the idling control knob fully counterclockwise when the DPD is manually regenerated in order to reduce the engine speed if the knob has been turned clockwise to increase the engine speed.
Page 192 4-64 CONTROLS AND INSTRUMENTS Combination Light Control Switch Light Control Switch Turning the light control switch to the position indicated in the table causes the relevant lights to illuminate. ADVICE • The light control switch can be used when the starter switch is placed in the "LOCK"...
Page 193 4-65 CONTROLS AND INSTRUMENTS NOTE • Use low beam whenever there are vehicles ahead in the same lane or oncoming vehicles in the opposite lane. When the Bulb Does not Come On → Refer to page 8-24 Switching between High and Low Beams (Flash-to-Pass Signal) By lightly pulling the light control switch lever and releasing it, the high beam comes on and off.
Page 194 4-66 CONTROLS AND INSTRUMENTS NOTE • If the steering wheel is only turned a small amount, turn off the signal manually. Lightly press and hold the lever up or down when overtaking or changing lanes. The turn signal light continues flashing as long as the lever is held up or down. The lever moves back to neutral as soon as it is released.
Page 195 4-67 CONTROLS AND INSTRUMENTS Front Fog Light Switch With the light control switch positioned in NLR/NNR/NPR/NQR/NPS models , when this switch is pressed, the front fog lights come on and the front fog indicator light comes on. To turn off the lights, press the switch again.
Page 196 4-68 CONTROLS AND INSTRUMENTS Rear Fog Light Switch When the light control switch is placed in , the rear fog lights come on and the rear fog indicator light comes on. Use this feature in low visibility such as in fog. WARNING •...
Page 197 • If a warning buzzer sounds when the exhaust brake is in operation, promptly pull the vehicle over safely and contact the nearest Isuzu Dealer for inspection. • Even if the gearshift lever is placed in the "N" position, the exhaust brake does not disengage until the engine is warmed up if the warm-up system is on.
Page 198 4-70 CONTROLS AND INSTRUMENTS When you pull the exhaust brake switch toward you while driving, the exhaust brake indicator light on the instrument panel comes on and strong engine brake is applied. Under the following conditions, the exhaust brake does not engage even if the exhaust brake indicator light comes on.
Page 199 If the wiper frequently (Intermittent) stops operation, refrain from using (Off) it and contact the nearest Isuzu Dealer. • Before operating the wiper, ensure that the wiper rubber is not stuck MFU8Z0SH017801 on to the windshield.
Page 200 4-72 CONTROLS AND INSTRUMENTS Windshield Washer Switch Windshield washer fluid is sprayed over the windshield when this switch is pressed. At the same time, the windshield wiper operates. The windshield washer is used when wiping the windshield clean. CAUTION • At extremely low temperatures, washer fluid may freeze on the windshield after being sprayed,...
Page 201: Horn Button
4-73 CONTROLS AND INSTRUMENTS Horn Button To sound the horn, press the pad with a horn symbol on the steering wheel. Remote Control Mirror Switch The remote control mirror switch is active LNU740SH016401 only when the starter switch is in the "ACC" or "ON"...
Page 202 4-74 CONTROLS AND INSTRUMENTS Mirror Heater Switch Defrosting the Mirror Use the mirror heater to defrost the mirror surface. With the starter switch in the "ON" position, press the mirror heater switch to turn on the mirror heater. The mirror heater indicator light (amber) comes on. Press the switch again to turn it to "OFF".
Page 203 4-75 CONTROLS AND INSTRUMENTS DRIVING CONTROLS ● Pedals 4-76 ● Parking Brake Lever 4-77 ● Gear Shift Lever 4-78 ● Model with AMT 4-81 ● Hill-Start-Aid (HSA) 4-98 ● Cruise Control 4-108 ● Hydraulic Brake Booster (HBB) 4-113 ● Anti-lock Brake System (ABS) 4-115 ●...
Page 204 4-76 CONTROLS AND INSTRUMENTS Pedals M/T model Sit in a correct driving position on the seat and operate the brake pedal and accelerator pedal with your right foot. To avoid accidentally pressing the wrong pedal, check the pedal positions and practice putting your foot on the desired pedal.
Page 205 4-77 CONTROLS AND INSTRUMENTS Parking Brake Lever CAUTION • Although the parking brake warning light will come on if the parking brake is engaged while the starter switch is in the "ON" position, this does not mean the parking brake is fully engaged, so always make sure the lever is fully pulled up. •...
Page 206 4-78 CONTROLS AND INSTRUMENTS Gear Shift Lever Manual Transmission Model MYY model, 5-speed A manual transmission model requires fully depressing the clutch pedal when making a gearshift. When the gearshift lever is placed into "R (Reverse)", the back up lights come on and, in a model with back up warning, a buzzer will also sound.
Page 207 4-79 CONTROLS AND INSTRUMENTS Model with AMT Move the gearshift lever to make it shift into each gear. Reverse Push button (While pressing the push button) Neutral Upshift Switch between auto and manual modes Drive-Manual mode Drive-Auto mode (manual gearshift) (automatic gearshift) Downshift Shift is possible without depressing the brake pedal.
Page 208 4-80 CONTROLS AND INSTRUMENTS NOTE • While the engine is not running, you cannot shift gears by moving the gearshift lever. Start the engine before you can change the gear. • When the vehicle is stationary with the engine running, the shift lock function works for safety.
Page 209 4-81 CONTROLS AND INSTRUMENTS Model with AMT AMT is a transmission system that allows the driver to move the vehicle from a standstill, drive the vehicle with gears automatically changing and bring the vehicle to a stop by only using the gearshift lever, accelerator pedal and brake pedal, without needing to use the clutch pedal.
Page 210 4-82 CONTROLS AND INSTRUMENTS How to Use AMT CAUTION • Before starting the engine, place the gearshift lever into "N", make sure the shift indicator indicates "N", pull up the parking brake lever and fully depress the brake pedal. • When moving the gearshift lever from "N"...
Page 211 4-83 CONTROLS AND INSTRUMENTS NOTE • When starting the engine after parking with a gear engaged, make sure that the shift indicator indicates "N". Then, place the gearshift lever into "D" for forward movement and "R" for backward movement. • While the engine is not running, you cannot shift gears by moving the gearshift lever.
Page 212 4-84 CONTROLS AND INSTRUMENTS ADVICE • When the vehicle is stopped, do not keep depressing the accelerator pedal with the gearshift lever placed in the "D", "M" or "R" position while depressing the brake pedal. Doing so may cause a failure. •...
Page 213 4-85 CONTROLS AND INSTRUMENTS To Shift Gears - Manual Mode • When changing the gear in the manual mode, place the gearshift lever into the "M" position and move the lever towards the "+ (upshift)" or [6-speed transmission model] " – (downshift)" direction as necessary to select the desired gear.
Page 214 4-86 CONTROLS AND INSTRUMENTS NOTE • When it is necessary to keep the speed of the vehicle very low, as when reversing it onto a platform, you can utilize the creeping effect of the transmission to move the vehicle smoothly using only the brake pedal, not by using the accelerator pedal.
Page 215 4-87 CONTROLS AND INSTRUMENTS When Parking Your Vehicle 1. Set the parking brake while depressing the brake pedal with your right foot. 2. Place the gearshift lever into the "N" position, make sure that the shift indicator displays "N", and then slowly ease your right foot off the brake pedal.
Page 216 4-88 CONTROLS AND INSTRUMENTS 1st Start Mode The vehicle normally moves off from a standstill in second gear. Use the 1st start mode when you need powerful torque to start the vehicle, for example, when it is heavily loaded. When you press the 1st start switch in auto mode (i.e., when the vehicle is stopped and either the foot brake or parking brake is applied), the 1st start mode indicator light...
Page 217 4-89 CONTROLS AND INSTRUMENTS NOTE • The 1st start mode cannot be selected in the manual mode. If the manual mode is selected (the gearshift lever is moved from the "D" position to the "M" position) after the 1st start switch is pressed, the 1st start mode is suspended and the 1st start mode indicator light goes out.
Page 218 4-90 CONTROLS AND INSTRUMENTS NOTE • The ECONO mode cannot be selected while the transmission is in manual mode. When the transmission is changed to manual mode (the gearshift lever is moved from "D" to "M"), while ECONO mode is active, the ECONO mode indicator light will go out.
Page 219 The PTO is being used. — — beeps Continuous beep Stop the vehicle at a safe place and have your vehicle Short, The AMT system has failed. Comes on inspected at the nearest Isuzu repeated Dealer promptly. beeps — 2008N_sec04-2_print2.indd 91 3/09/2008 5:31:44 PM...
Page 220 4-92 CONTROLS AND INSTRUMENTS warning light Warning Condition and alarm type Corrective action buzzer Stop the vehicle at a safe place, place the gearshift lever AMT oil temperature is Flashes — into the "N" position and run abnormally high. the engine at idle until the AMT warning light goes out.
Page 221 4-93 CONTROLS AND INSTRUMENTS How to Adjust Partial Clutch Engagement of AMT With the AMT system, you can select the desired degree of partial clutch engagement from the 4 positions in both the fast and slow engagement directions from the default (standard) setting.
Page 222 Isuzu Dealer. • Make partial clutch engagement adjustments when the engine is running at idle. • Have the initial adjustment of the AMT system performed at your Isuzu Dealer. 2008N_sec04-2_print2.indd 94 3/09/2008 5:31:45 PM...
Page 223 Should the AMT warning light come on and remain on or flash during driving, stop the vehicle at a safe place. If the warning light does not go out, have the vehicle inspected at your nearest Isuzu Dealer. CAUTION •...
Page 224 4-96 CONTROLS AND INSTRUMENTS 1. Fully pull up the parking brake lever, turn the starter switch to the "LOCK" or "ACC" position while fully pressing the brake pedal and make sure that the gearshift lever is in "N". 2. Turn the starter switch to the "ON" position.
Page 225 4-97 CONTROLS AND INSTRUMENTS CAUTION • The AMT emergency switch must be used only in an emergency. Normally, the switch must be kept in the "OFF" position. Do not open the cover of the emergency switch. Never operate the AMT emergency switch while driving. •...
Page 226 4-98 CONTROLS AND INSTRUMENTS Hill-Start-Aid (HSA) When the HSA is not activated, the service brake system retains a certain level of hydraulic pressure (braking pressure) only while the brake pedal is being depressed. When HSA is activated, the system retains the braking pressure that is produced when the brake pedal is depressed during a stop even after the brake pedal is released.
Page 227 3 to 5 times Vehicle moves down on a slope. 3 to 5 times — CAUTION • If the brakes cannot be satisfactorily adjusted using the HSA adjustment switch, have the brakes adjusted at the nearest Isuzu Dealer. 2008N_sec04-2_print2.indd 99 3/09/2008 5:31:48 PM...
Page 228 If the HSA indicator light flashes or remains off or the buzzer continues to sound, the HSA system may have a problem. Deactivate the HSA and have your vehicle inspected at the nearest Isuzu Dealer as soon as possible. 2008N_sec04-2_print2.indd 100...
Page 229 • If the HSA system is not working normally, deactivate the HSA and have it inspected at the nearest Isuzu Dealer as soon as possible. Warning of HSA→ Refer to page 4-106 2008N_sec04-2_print2.indd 101 3/09/2008 5:31:49 PM...
Page 230 4-102 CONTROLS AND INSTRUMENTS To Deactivate the HSA The HSA cancels its operation and releases the brakes in any of the following cases. • When the gearshift lever is placed into a position other than "N" and the clutch is engaged while the engine is running.
Page 231 4-103 CONTROLS AND INSTRUMENTS Adjustment 1. Pull the parking brake lever, make sure the gearshift lever is placed in the "N" position and then start the engine. At this time make sure that the HSA OFF switch is placed in "OFF"...
Page 232 ADVICE • When a failure warning is issued, the HSA system is faulty. Have your vehicle inspected at the nearest Isuzu Dealer as soon as possible. Warning of HSA→ Refer to page 4-106 If your vehicle has a manual transmission, make an initial adjustment of the HSA in the following cases.
Page 233 4-105 CONTROLS AND INSTRUMENTS 5. Depress the clutch pedal, place the gearshift lever into any other position than "N", start the vehicle, and then make a fine adjustment using the HSA adjustment switch so that the brakes are released at the appropriate time. ADVICE •...
Page 234 CAUTION • When a failure warning is issued, the HSA system is faulty. Have your vehicle inspected at the nearest Isuzu Dealer as soon as possible. NOTE • A buzzer sounds when you open the door without pulling the parking brake lever with HSA activated.
Page 235 4-107 CONTROLS AND INSTRUMENTS CAUTION • When leaving the driver's seat, be sure to firmly set the parking brake. • Since the HSA no longer provides braking pressure if the starter switch is turned to the "ACC" or the "LOCK" position, the HSA OFF switch is pressed, or the fuse for the HSA circuit is removed while the HSA is activated, the vehicle will move down a slope and a very dangerous situation may result.
Page 236 4-108 CONTROLS AND INSTRUMENTS Cruise Control The cruise control function allows you to drive the vehicle at a constant speed without operating the accelerator pedal. The setting range for cruise control is approximately between 40 and 80 km/h (25 and 50 MPH). This function should only be used when driving without frequent starts and stops.
Page 237 4-109 CONTROLS AND INSTRUMENTS Cruise control set switch 2. Use the accelerator pedal to adjust the vehicle to a desired speed between approximately 40 and 80 km/h (25 and 50 MPH). Upon reaching the desired speed, operate the cruise control set switch. The vehicle speed at the moment you operate the switch is set in the system, enabling you to drive with the...
Page 238 4-110 CONTROLS AND INSTRUMENTS Accelerating during Cruise Control Driving If you want to accelerate temporarily to pass another vehicle while driving using the cruise control, depress the accelerator pedal. When you release the accelerator pedal, the speed returns to the original set vehicle speed. Changing the Cruise Control Speed Setting When Increasing Vehicle Speed Cruise control resume switch...
Page 239 4-111 CONTROLS AND INSTRUMENTS When Canceling Cruise Control Cruise control main switch Press the cruise control main switch again to set it to "OFF". The cruise control main indicator light will go out. The cruise control is canceled in the following cases.
Page 240 4-112 CONTROLS AND INSTRUMENTS When Returning to Cruise Control Driving If you have canceled cruise control under the following conditions, you can return to the cruise control driving condition before cancellation when you operate and release the cruise control resume switch. The moment the resume switch is released, the cruise control set indicator light comes on.
Page 241 HBB. If this warning light comes on while driving, immediately pull off to a safe place well clear of traffic and promptly contact the nearest Isuzu Dealer for inspection. Brake Booster Warning Light → Refer to page 4-36...
Page 242 4-114 CONTROLS AND INSTRUMENTS NOTE [HYDRAULIC BRAKE BOOSTER CHARACTERISTICS] In the HBB models, an unusual sound from under the instrument panel may be heard from the hydraulic system while brakes are used. It does not mean trouble. It is not a sign of malfunction. •...
Page 243 4-115 CONTROLS AND INSTRUMENTS Anti-lock Brake System (ABS) Wheels may be locked and slip during sudden braking or braking on a slippery road surface such as a snowy road. ABS is a device to prevent the wheels from by detecting a slippery condition during braking and to secure directional stability and handling stability of the vehicle.
Page 244 4-116 CONTROLS AND INSTRUMENTS NOTE [These are not signs of ABS malfunction] • Immediately after the engine is started, a motor sound may be heard from the rear of the vehicle or from the underside of the cab. This sound is from a self- check by the ABS.
Page 245 • If the ABS warning light does any of the following, the ABS may be faulty. Please contact the nearest Isuzu Dealer. If the ABS warning light comes on during driving The light does not come on when the starter switch is placed into the "ON"...
Page 246 4-118 CONTROLS AND INSTRUMENTS Precautions for Driving an ABS-Equipped Vehicle ABS is not a device that enables driving and stopping under conditions exceeding safe driving limits. Always drive safely. CAUTION • The braking distance on slippery road surfaces is longer than that on a normal dry paved road even with an ABS-equipped vehicle.
Page 247 • The rear wheels will lock more easily if there is a problem with the EBD function. Have it checked and serviced at the nearest Isuzu Dealer as soon as possible. NOTE •...
Page 248 4-120 CONTROLS AND INSTRUMENTS Anti-Slip Regulator (ASR) ASR is a device that helps prevent the drive wheels from spinning and improve vehicle motion stability when driving on a snowy or otherwise slippery road surface. The ASR is automatically activated when the engine is started. You may cancel the ASR operation using the ASR OFF switch.
Page 249 4-121 CONTROLS AND INSTRUMENTS ASR OFF Switch Use this switch when you want to cancel the ASR. When you press this switch while the ASR is active after starting the engine, the ASR is cancelled and the ASR indicator light (amber) in the instrument panel comes on.
Page 250 NOTE • If the ASR indicator light does any of the following, ASR may be faulty. Please contact the nearest Isuzu Dealer. When the ASR indicator light (green) remains on while driving on a firm, dry road. When the ASR indicator light (amber) comes on during driving (when the ASR OFF switch is not operated).
Page 251 4-123 CONTROLS AND INSTRUMENTS Precautions for Driving an ASR-equipped Vehicle ASR is not a device that enables driving under conditions exceeding safe limits. Always drive safely. CAUTION • The ASR does not increase the road grip of tyres although it improves the starting and accelerating performance on a slippery road surface when compared to a model without ASR.
Page 252 4-124 CONTROLS AND INSTRUMENTS Four Wheel Drive (4WD) Model CAUTION • Even a 4WD vehicle does not exempt you from safe driving practices. Operate the accelerator pedal, steering wheel and brake pedal with the same level of caution as when driving a standard rear-wheel drive vehicle. Part-time 4WD Model A part-time 4WD model can be switched between 2WD and 4WD operation using the 4WD switch.
Page 253 4-125 CONTROLS AND INSTRUMENTS "FREE" Position When a freewheel hub's knob is in the "FREE" position, the wheel is disconnected from the drive shaft. This position should be used for driving in 2WD mode. "LOCK" Position When a freewheel hub's knob is in the "LOCK"...
Page 254 4-126 CONTROLS AND INSTRUMENTS 4WD Switch Use the 4WD switch to select 2WD or 4WD. When using the switch, confirm in advance that the knobs on the freewheel hubs are in the "LOCK" position, and set the switch only when the vehicle is stopped or moving at low speed.
Page 255 4-127 CONTROLS AND INSTRUMENTS Transfer Gear Control Switch This switch is used to change between the "HIGH" range (high speed) and the "LOW" range (low speed) of the transfer case. 1. Make sure that the vehicle is stopped and depress the clutch pedal. NOTE •...
Page 256 4-128 CONTROLS AND INSTRUMENTS Power Take-Off (PTO) PTO is a device that is used to provide engine power to special equipment directly from the engine or through the transmission. This manual describes an operation of PTO, but for an operation of special equipment other than the PTO lever and PTO switch, consult [Instruction Manual for Special Equipment].
Page 257 4-129 CONTROLS AND INSTRUMENTS NOTE [Fast idle control] • A supplementary function to warm up the engine by automatically increasing the idling speed while the engine is cold. Lever-type PTO To Engage the PTO 1. Fully pull up the parking brake lever, and with the vehicle at a complete stop, set the gearshift lever in the "N"...
Page 258 4-130 CONTROLS AND INSTRUMENTS To Disengage the PTO Press the PTO switch. While the buzzer is making short, repeated beeps, press the lock button on the PTO lever and move the lever from the "ON" position to the "OFF" position. CAUTION •...
Page 259 4-131 CONTROLS AND INSTRUMENTS Lever-type PTO To Engage the PTO 1. Fully pull up the parking brake lever, and with the vehicle at a complete stop, set the gearshift lever in the "N" position. Then, start the engine. 2. Depress the clutch pedal fully, and after waiting for a short time, lower the PTO lever while pressing the lock button in order to engage the PTO.
Page 260 4-132 CONTROLS AND INSTRUMENTS Switch-type PTO To Engage the PTO 1. Fully pull up the parking brake lever, and with the vehicle at a complete stop, set the gearshift lever in the "N" position. Then, start the engine. 2. Press the PTO switch. The warning buzzer will begin making short, repeated beeps, and the PTO indicator light in the instrument panel...
Page 261 4-133 CONTROLS AND INSTRUMENTS Switch-type PTO To Engage the PTO 1. Fully pull up the parking brake lever, and with the vehicle at a complete stop, set the gearshift lever in the "N" position. Then, start the engine. 2. Depress the clutch pedal fully, and after waiting for a short time, press the PTO switch.
Page 262 4-134 CONTROLS AND INSTRUMENTS To Disengage the PTO 1. Press the PTO switch while depressing the clutch pedal. Then make sure that the PTO indicator light in the instrument panel goes out and PTO drive is stopped. 2. Slowly remove your foot from the clutch pedal.
Page 263 4-135 CONTROLS AND INSTRUMENTS Dump Control Lever The dump control lever is used to raise or lower the dump body. This section describes how to use the dump control lever of a dump truck. For operation of the controls other than the dump control lever, please refer to the separate "Instruction Manual for Dump Truck".
Page 264 4-136 CONTROLS AND INSTRUMENTS To Temporarily Stop the Dump Body Shown with a thick line in the drawing at left is the lever position to temporarily stop the dump body during raising or lowering. Never leave the driver's seat while placing the lever in this position.
Page 265 4-137 CONTROLS AND INSTRUMENTS When Operating the Dump Body CAUTION • When operating the dump control lever to raise or lower the dump body, make sure that there are no persons or objects near or above the vehicle. • Only raise or lower the dump body with the vehicle positioned on a level surface.
Page 266 4-138 CONTROLS AND INSTRUMENTS When Raising the Dump Body (Model with AMT) 1. Fully pull up the parking brake lever, and with the vehicle at a complete stop, set the gearshift lever in "N". Then, start the engine. 2. Press the PTO switch and make sure that the buzzer starts making short, repeated beeps.
Page 267 4-139 CONTROLS AND INSTRUMENTS When Raising the Dump Body (Manual Transmission Model) 1. Fully pull up the parking brake lever, and with the vehicle at a complete stop, set the gearshift lever in "N". Then, start the engine. 2. Depress the clutch pedal fully, and after waiting for a short time, move the dump control lever to the "UP"...
Page 268 4-140 CONTROLS AND INSTRUMENTS When Leaving the Dump Body Raised CAUTION • When the dump body is to be left in the raised position for cleaning, inspection or the like, always position the vehicle on a level surface, fully engage the parking brake, apply chocks to the wheels, ensure that the dump body is empty and support the dump body using a...
Page 269 4-141 CONTROLS AND INSTRUMENTS When Lowering the Dump Body (Model with AMT) 1. Press the lock button on the dump control lever, and move the lever from the "UP" position to the "DOWN" position. The dump body will lower by gravity.
Page 270 4-142 CONTROLS AND INSTRUMENTS CAUTION • Before starting the vehicle, you should confirm the following. The dump body has been fully lowered. The dump control lever has been securely locked in the "DOWN" position and cannot move the dump body. Each gate is firmly secured in place.
Page 271 CONTROLS AND INSTRUMENTS NOTE • Chains are available as special equipment. Please contact your Isuzu Dealer. Seat Belt with Pretensioner and SRS Airbag System The seat belt with pretensioner and supplemental restraint system (SRS) airbag system is activated in the event of a frontal collision when the impact energy exceeds a...
Page 272 Doing any of the following may require special precautions. Be sure to consult your Isuzu Dealer before doing any of the following. Failure to do so may cause the pretensioner seat belt and airbag to be unduly activated, causing the seat belt to be unexpectedly retracted or the airbag to be suddenly inflated, causing an injury to the occupant.
Page 273 ADVICE • Once activated during a collision, the seat belt with pretensioner cannot be reused. The seat belt must be replaced immediately at the nearest Isuzu Dealer. NOTE •...
Page 274 Immediately after the airbag is inflated, the metal portion that inflates the airbag gets hot. Do not touch it. • The airbag cannot be reused once it is inflated. Immediately replace it at the nearest Isuzu Dealer. NOTE • The airbag is quickly deflated after deployment and does not hinder visibility.
Page 275 4-147 CONTROLS AND INSTRUMENTS When and How the Seat Belt with Pretensioner and SRS Airbag System Operates The seat belt with pretensioner and airbag system are activated when the vehicle receives an impact exceeding a certain level in the event of a frontal collision. Because the vehicle body absorbs part of impact energy, the system may not be activated due to reduction in the force of the impact or the intensity or direction of the impact received.
Page 276 4-148 CONTROLS AND INSTRUMENTS When are the Seat Belt with Pretensioner and SRS Airbag System Not Likely to Be Activated? In the following cases, the seat belt with pretensioner and SRS airbag system are less likely to be activated even if they are working properly. When the vehicle collides against a When the vehicle gets under an utility pole or standing tree...
Page 277 4-149 CONTROLS AND INSTRUMENTS When are the Seat Belt with Pretensioner and SRS Airbag System Activated Other than in a Collision? • When the vehicle falls into a pothole or groove in the road • When the vehicle strongly collides against an obstacle such as a protruding object on the road •...
Page 278 4-150 CONTROLS AND INSTRUMENTS When are the Seat Belt with Pretensioner and SRS Airbag System not Activated? In the following cases, the seat belt with pretensioner and airbag system are not activated even if they are working properly. When the vehicle is hit from the rear When the vehicle is hit from the side When the vehicle rolls onto its side or upside down...
Page 279 (gas and so on) adheres to your eyes and skin, rinse them with water as soon as possible. Although it is rare, a person with delicate skin may suffer from irritation. • The airbag cannot be reused once it is inflated. Replace it at your Isuzu Dealer. 2008N_sec04-2_print2.indd 151 3/09/2008 5:32:17 PM...
Page 280 4-152 CONTROLS AND INSTRUMENTS Deployment of SRS Airbag When the vehicle collides head-on with an impact of a certain level or higher, the airbag system is activated and airbag instantly inflates. It is deflates quickly and does not hinder visibility. When Does An SRS Airbag Develop Its Full Effect? WARNING •...
Page 281 4-153 CONTROLS AND INSTRUMENTS When Carrying a Child in the Vehicle WARNING • Be sure to observe the following precautions when carrying a child in the vehicle. Otherwise the child may be fatally injured by the impact from an inflating airbag. Do not drive with a child standing in front of the passenger's airbag or held on your lap.
Page 282 4-154 CONTROLS AND INSTRUMENTS Diesel Particulate Defuser (DPD) The DPD purifies particulate matter (PM) in exhaust gases. The DPD collects PM in the DPD filter and when PM is collected in the filter to the predetermined level, the DPD automatically burns PM (regeneration the filter). We recommend that you observe the following instructions to keep the DPD in order.
Page 283 Continuing driving without performing the regeneration will cause the check engine warning light to come on. The DPD then must be repaired at the nearest Isuzu Dealer. NOTE • The DPD automatically burns PM (regenerates the filter) when a certain amount of PM is...
Page 284 4-156 CONTROLS AND INSTRUMENTS DPD Manual Regeneration Procedure 1. Stop the vehicle at a safe place free of flammable materials such as dead grass or wastepaper. CAUTION • To prevent a fire, make sure that there is no flammable material near the muffler, DPD and exhaust pipe.
Page 285 4-157 CONTROLS AND INSTRUMENTS 8. When the DPD manual regeneration indicator light (amber) or "MANUAL REGEN." massage (amber) goes out, regeneration is completed. Normal driving is then possible. WARNING • White smoke may be produced during manual regeneration; do not perform manual regeneration in a poorly ventilated indoor place.
Page 286 4-158 CONTROLS AND INSTRUMENTS Automatic Regeneration of DPD Model without MID The engine speed may increase and the exhaust brake may activate while the vehicle is stopped with the engine idling. When this occurs, the DPD is automatically regenerated. This does not indicate a failure.
Page 287 4-159 CONTROLS AND INSTRUMENTS Procedure for Selectable Regeneration of DPD Perform the selectable regeneration of the DPD when the engine (coolant temperature) and exhaust pipe are still warm such as when the day's operation is finished. CAUTION • Perform the selectable regeneration until it is completed without interruption. •...
Page 288 4-160 CONTROLS AND INSTRUMENTS 4. Press the DPD switch again. 5. If your vehicle is not equipped with MID, the DPD manual regeneration indicator light (amber) stops flashing and then stays on, and the engine speed automatically increases to start regeneration. If your vehicle is equipped with MID, the flashing "PUSH DPD SWITCH"...
Page 289 4-161 CONTROLS AND INSTRUMENTS NOTE • The time needed to complete regeneration differs depending on the outside temperature. • The exhaust brake or exhaust throttle is activated during DPD regeneration. The exhaust brake or exhaust throttle starting to operate or being disengaged will produce a sound, but this does not indicate a failure.
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Page 291: Comfort And Convenience
COMFORT AND CONVENIENCE ● Air Outlets ● Ventilator ● Heater/Manual Air Conditioner ● Automatic Air Conditioner 5-12 ● Interior Lights 5-20 ● Sun Visor 5-21 ● Cigarette Lighter 5-22 ● Ashtray 5-23 ● Small Article Storage Pocket 5-25 ● Card Holder 5-25 ●...
Page 292: Air Flow Direction Control Lever
COMFORT AND CONVENIENCE Air Outlets Outlet Features Air flow direction is adjustable with the Driver side outlet tab. Air flow direction is adjustable with the Passenger side outlet tab. Door windows outlet Air is delivered towards the door windows. Windshield outlet Air is delivered towards the windshield.
Page 293 COMFORT AND CONVENIENCE Ventilator How to Use the Controls Name Name Fan speed control knob Outlet selector knob Air selector lever 1. Outlet selector knob Knob position Air delivery Outlet Face Air flows through outlets 1 and 2. Bi-level Air flows through outlets 1, 2 and 5. Feet Air flows through outlets 5.
Page 294 COMFORT AND CONVENIENCE NOTE • The " " sign advises you to place the air selector lever in the outside air ventilation position when using the " ", " ", " " position to defog the windshield. 2. Air selector lever Lever Purpose position...
Page 295 COMFORT AND CONVENIENCE Heater/Manual Air Conditioner How to Use the Controls Name Name Outlet selector knob Fan speed control knob Air selector lever Air conditioning switch (A/C) Temperature control knob 1. Outlet selector knob Knob position Air delivery Outlet Face Air flows through outlets 1 and 2.
Page 296 COMFORT AND CONVENIENCE NOTE • The " " sign advises you to place the air selector lever in the outside air ventilation position when using the " ", " ", " " position to defog the windshield. 2. Air selector lever Lever Purpose position...
Page 297 COMFORT AND CONVENIENCE Ventilation Outside Air Ventilation Press the A/C switch (5) to the "OFF" position. Turn the outlet selector knob (1) to the preferred position. Move the air selector lever (2) to the " " position. Set the temperature control knob (3) to the desired position.
Page 298 COMFORT AND CONVENIENCE Maximum Heating Turn the outlet selector knob (1) to the " " position, set the air selector lever (2) to the " " position, and turn the temperature control knob (3) fully towards the high temperature direction. Set the fan speed control knob (4) to the maximum speed position.
Page 299 COMFORT AND CONVENIENCE Defogging and Defrosting the Windshield Defogging Set the outlet selector knob (1) to the " " position. Set the air selector lever (2) to the " " position. Turn the temperature control knob (3) to a high-temperature position according to your preference.
Page 300 5-10 COMFORT AND CONVENIENCE Defrosting Set the outlet selector knob (1) to the " " position. Set the air selector lever (2) to the " " position. Turn the temperature control knob (3) fully towards the high-temperature direction. Set the fan speed control knob (4) to the maximum speed position.
Page 301 5-11 COMFORT AND CONVENIENCE Maximum Cooling Set the outlet selector knob (1) to the " " position. Press the A/C switch (5) to the "ON" position. Move the air selector lever (2) to the " " position. Turn the temperature control knob (3) fully towards the low-temperature direction.
Page 302 5-12 COMFORT AND CONVENIENCE Automatic Air Conditioner How to Use the Controls Name Name Automatic air conditioning off switch Automatic air conditioning switch (OFF switch) (AUTO switch) Air selector switch Fan speed control dial Defroster switch Outside air temperature display switch (OUTSIDE switch) Air conditioning switch (A/C) Temperature control dial...
Page 303 5-13 COMFORT AND CONVENIENCE 2. Fan speed control dial Use this dial when manually selecting the fan speed. Turning the dial counterclockwise reduces the fan speed and turning it clockwise increases the fan speed. The fan speed can be adjusted through 8 levels. Fan speed Medium Fast...
Page 304: Comfort And Convenience Features
5-14 COMFORT AND CONVENIENCE 6. Air selector switch Use this switch to change between ventilation of outside air and recirculation of the interior air. The display will show the setting you have made by the corresponding symbol as follows. Displayed symbol Purpose Outside air This setting should normally be selected.
Page 305 5-15 COMFORT AND CONVENIENCE Automatic Air Conditioning Mode 1. Press the AUTO switch (1). The air conditioning system will turn on, and automatically select the air outlets and fan speed most suitable for the cab's interior condition. The selected air outlets will be those corresponding to either the "...
Page 306 5-16 COMFORT AND CONVENIENCE 3. To turn off the air conditioning system, press the A/C switch (8). To turn off both the fan and air conditioning system, press the OFF switch (5). NOTE • If you operate a certain control (excluding the temperature control dial) when the system is operating in the fully automatic mode, the "AUTO"...
Page 307 5-17 COMFORT AND CONVENIENCE Maximum Heating Turn the temperature control dial (4) to the maximum heating temperature (32°C (90° F)) and set the fan speed control dial (2) for the maximum setting. Select the desired air outlets with the MODE switch (9). Turn on the warm-up switch if necessary.
Page 308 5-18 COMFORT AND CONVENIENCE Defrosting Press defroster switch (7) to turn the defroster on. The display will show the " " sign. Turn the temperature control dial (4) to the maximum temperature position (32°C (90°F)). Press the air selector switch (6). The display will show the "...
Page 309 5-19 COMFORT AND CONVENIENCE NOTE • After prolonged parking in the direct sunlight, open the windows or doors to ventilate the cab's interior and release the heat before turning the air conditioning system on. • Prolonged use of the air conditioning system in the maximum cooling setting will make the interior air become stale.
Page 310 5-20 COMFORT AND CONVENIENCE Interior Lights Dome Light The dome light operates regardless of NLR/NNR/NPR/NQR/NPS models the starter switch position. To make the dome light be controlled by the "DOOR" operation, move the dome light switch in half way between the "ON" and "OFF" positions.
Page 311 5-21 COMFORT AND CONVENIENCE Sun Visor Driver's side The sun visor protects your eyes in strong sunlight. Use it when sunlight is too bright. To reduce side glare, unhook the sun visor and swing it around to the side. CAUTION •...
Page 312 Do not bend the cigarette lighter. A bent lighter does not function properly and is dangerous. CAUTION • Check with your Isuzu Dealer if you have no alternative to using the cigarette lighter socket as an accessory outlet. • If the cigarette lighter has to be replaced, use an Isuzu genuine replacement.
Page 313 5-23 COMFORT AND CONVENIENCE ADVICE • Do not use the cigarette lighter while the engine is not running. The cigarette lighter consumes a lot of electricity and could discharge the battery completely. Ashtray WARNING • Do not put any paper trash or other flammable material in the ashtray. •...
Page 314 5-24 COMFORT AND CONVENIENCE Driver's and Passenger's Ashtray (NLR/NNR/NPR/NQR/NPS Models) Open the lid to use. Put out lit cigarettes on the crush-out tab. To empty the ashtray, hold the lid and pull the ashtray up and out. Rear Ashtray (Crew Cab Model) Pull the ashtray towards you to use it.
Page 315 5-25 COMFORT AND CONVENIENCE Small Article Storage Pocket Use them for storing small articles. CAUTION • Do not leave eyeglasses or lighters inside the cab. Lighters may explode and plastic lenses or frames may deform or crack if the interior temperature becomes very hot.
Page 316 5-26 COMFORT AND CONVENIENCE Glove Compartment Press on the central mark to lock and unlock the lid. CAUTION • For safety, close the glove compartment during driving. There is a risk of injury from the open lid or Central mark items stored in the glove box.
Page 317 5-27 COMFORT AND CONVENIENCE Overhead Tray Use the overhead trays as shelves. CAUTION • Do not use either overhead tray to hold an object weighing more than 2 kg (71 oz) or an object that may fly out or fall down during vehicle Overhead tray operation.
Page 318 5-28 COMFORT AND CONVENIENCE Back Panel Tray (Storage Receptacle) Use them for storing small articles. They can be removed. Installation and Removal 1. Turn the knob to the "UNLOCK" position. 2. Lift the back panel tray upward to remove it from the three tabs. To install the back panel tray, perform this action in reverse.
Page 319 5-29 COMFORT AND CONVENIENCE Coat Hook Use this to hang clothing. Hook This can be used to hold plastic shopping bags. CAUTION • Do not hang anything weighing over 3 kg (106 oz) or that may fall off the hook while driving. Doing so may be dangerous.
Page 320 5-30 COMFORT AND CONVENIENCE Operating Tips for the Radio and CD Player CAUTION • Operate the radio or CD player only while the vehicle is stationary. Operating them while the vehicle is moving could cause an accident. • Adjust the volume so that sound outside of the vehicle can be heard. If outside sound cannot be heard, accidents may be harder to avoid.
Page 321 5-31 COMFORT AND CONVENIENCE Antenna Pull the antenna out to its full length when using it. ADVICE • To prevent breaking the antenna, shorten it when passing through areas with low clearance or through a carwash. NOTE [Radio reception] • Compared with AM signals, FM signals are of better quality and compatible with stereo broadcasting.
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Page 323: Tips On Safe And Smooth Operation
TIPS ON SAFE AND SMOOTH OPERATION ● Driving Safely and with Confidence ● On the Road ● Cautions for Parking 6-15 ● Cautions for Driving in Hot Regions 6-16 ● Cautions for Driving in Cold Regions 6-17 ● Using Tyre Chains 6-22 2008N_sec06_print2.indd 1 3/09/2008 5:42:18 PM...
Page 324 TIPS ON SAFE AND SMOOTH OPERATION Driving Safely and with Confidence Get Plenty of Rest If you drive when you are tired, you will get sleepy and lose concentration. Please get plenty of rest before you drive. Take Breaks during Long Journeys Driving long distances is tiring. Please take rest breaks from time to time.
Page 325 TIPS ON SAFE AND SMOOTH OPERATION On the Road Cautions for Driving • Concentrate on driving safely, obeying all legally designated speed limits, road signs and traffic signals. • Do not place the starter switch to any position other than the "ON" position while driving. The power steering would stop working, making steering extremely difficult. Also, the brakes would not work well, putting you in extreme danger.
Page 326 TIPS ON SAFE AND SMOOTH OPERATION Narrow or Congested Roads When passing or overtaking a vehicle on a narrow mountain road or on a narrow or congested urban road, pay careful attention to obstacles on either side and to the condition of the shoulder of the road. When Turning, the Rear Wheels will Follow Tighter Curves than the Front Wheels...
Page 327 TIPS ON SAFE AND SMOOTH OPERATION Driving Uphill or Downhill Uphill Shift down well ahead of time in order to avoid a heavy load to the engine. Downhill • Be careful not to drive too fast on a downhill road. • Use the same gear(s) that you used to drive up the hill. Also, use the exhaust brake in order to avoid going too fast. • Do not let the engine overrun. NOTE [Overrunning] • An engine overrun is an engine- speed increase that causes the tachometer needle to enter the red zone.
Page 328 TIPS ON SAFE AND SMOOTH OPERATION Brake Operation The brakes give strong braking force with only light pressure on the pedal. Do not press the brake pedal hard except in the event of an emergency. 1. Braking distances vary according to the vehicle speed and road conditions. First, slow down sufficiently using the engine brake and the exhaust brake.
Page 329 TIPS ON SAFE AND SMOOTH OPERATION Maintaining a Clear Field of View If the Windshield Fogs Up Use the heater to blow hot air on the windshield or dehumidify the cabin using the air conditioner and place the vent knob in the "...
Page 330 TIPS ON SAFE AND SMOOTH OPERATION Driving at Night Nighttime driving is more dangerous than daytime driving because the field of view is narrower. Keep your speed down, and maintain an ample headway distance. Driving in Fog Turn on the fog lights and drive slowly, using the road's center line as a guide. It is dangerous only to follow the lights of the preceding vehicle because they can cause optical illusions.
Page 331 TIPS ON SAFE AND SMOOTH OPERATION Highways 1. Speeds on highways are higher than • C heck that there is ample Tyres those on regular roads, so there is tread depth. more danger. Also, a breakdown • C heck that coolant is not on a highway represents a hazard leaking from the radiator to other vehicles and can cause and other parts of the cooling system.
Page 332 6-10 TIPS ON SAFE AND SMOOTH OPERATION 4. During high-speed driving, even a little turn of the steering wheel causes a big movement of the vehicle. Turn the steering wheel slowly. 5. Excessive use of the brake pedal is extremely dangerous because it rapidly wears the brake linings and causes brake fade.
Page 333 6-11 TIPS ON SAFE AND SMOOTH OPERATION Driving on Snowy or Frozen Roads CAUTION • On slippery roads, never accelerate rapidly, brake hard, decelerate rapidly or make sharp turns of the steering wheel. • There is a risk of reduced grip between the tyres and road surface and of increased braking distances.
Page 334 6-12 TIPS ON SAFE AND SMOOTH OPERATION Before Sitting in the Driver's Seat Remove snow and ice from your shoes when getting into the vehicle. If you try to drive with snow on your shoes, your shoes would slip on the pedals and you would not be able to press the pedals properly, meaning that your driving would be inconsistent. Also, the cabin could become...
Page 335 6-13 TIPS ON SAFE AND SMOOTH OPERATION Check the Brakes from Time to Time CAUTION • When the vehicle is driven or parked on a snowy surface, ice can form on the brakes, decreasing their effectiveness. From time to time while you are driving, press the brake pedal lightly and check the brake's effectiveness.
Page 336 6-14 TIPS ON SAFE AND SMOOTH OPERATION Driving on Poor Road Surfaces (Sand or Mud) If the vehicle gets stuck in mud, pressing the accelerator pedal more than necessary will simply dig the vehicle deeper into the mud and make it harder to extricate. Either put stones, tree branches or blankets under the tyres to gain traction or repeatedly drive forward and backward to use the vehicle's momentum to extricate it.
Page 337 6-15 TIPS ON SAFE AND SMOOTH OPERATION Cautions for Parking Parking in Cold Regions When snow collects around the wheels and lights, try to remove it before night falls. Do not apply the parking brake in cold regions. If you leave the parking brake applied, the wires and brake shoes could freeze up, making it impossible for you to release the parking brake. Be sure to park the vehicle in gear.
Page 338 6-16 TIPS ON SAFE AND SMOOTH OPERATION Cautions for Driving in Hot Regions The engine will be prone to overheating in an environment where the ambient temperature is high. To prevent the engine from overheating, pay attention to the following points: CAUTION •...
Page 339 • If you allow the engine to warm up but the coolant temperature does not rise, have the nearest Isuzu Dealer inspect the thermostat. • If you park in a place where there is a lot of snowfall, snow accumulating around the vehicle could limit ventilation.
Page 340 Changing the Engine Coolant → Refer to page 7-37 Preparing Coolant → Refer to page 7-43 Replacing the Engine Oil In all seasons, use Isuzu genuine low-ash engine oil. Changing the Engine Oil and Oil Filter → Refer to page 7-28 Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-172 2008N_sec06_print2.indd 18...
Page 341 6-19 TIPS ON SAFE AND SMOOTH OPERATION Fuel CAUTION • Always use only a low-sulfur diesel fuel (50 ppm or lower sulfur content) or super-low-sulfur diesel fuel (10 ppm or lower sulfur content). The use of a poor- quality diesel fuel, mixing such an additive as water remover to the fuel in the tank, or filling the tank with gasoline, kerosene or an alcohol-based fuel or its mixture with a diesel fuel will badly affect the fuel filter and result in lubrication problems in fuel-lubricated components of the injectors. In addition, this practice can also impair the operation of the engine and the diesel particulate defuser (DPD), the exhaust emission cleaning system, possibly leading to breakdown of the engine-related systems. If an incorrect fuel should accidentally be added, drain all fuel from the system.
Page 342 6-20 TIPS ON SAFE AND SMOOTH OPERATION When Ice Prevents You from Putting the Key in the Door or Opening the Door If you try to force the key into the door, you could bend it. And if you try to pull the door open with undue force, the rubber seal around the door could come unstuck or become damaged. Use warm water to melt the ice, then quickly wipe it away and open the door.
Page 343 6-21 TIPS ON SAFE AND SMOOTH OPERATION Cleaning the Vehicle after Driving on Snowy Roads CAUTION • Remove snow that has stuck to the inside of the fenders and to the brake hoses. Otherwise, it may damage components. After driving on a salted road, wash the underside of the vehicle as soon as possible to prevent the salt from causing rust. Spraying water under high pressure is an effective way to...
Page 344 CAUTION • Immediately after vehicle operation, the exhaust pipe and muffler are extremely hot. Be careful not to touch them. Also, do not change a tyre while diesel particulate defuser (DPD) regeneration is under way because the exhaust temperature then is very high. • Be careful not to hurt yourself on the edges of the vehicle while working with the tyre chains. ADVICE • Tyre chains cannot be fitted on the front wheels. Fit the rear tyres with chains suitable for the tyre size. For further details, please contact your Isuzu Dealer. • When the vehicle is fitted with tyre chains, drive at speeds below 30 km/h (19 MPH) and avoid driving on surfaces other than snowy or frozen roads. 2008N_sec06_print2.indd 22 3/09/2008 5:42:32 PM...
Page 345 6-23 TIPS ON SAFE AND SMOOTH OPERATION How to Fit a Tyre Chain 1. Making sure the tyre chain is not twisted, place it on the tyre so that the curled ends are on the outside (the side that will make contact with the ground). NOTE •...
Page 346 6-24 TIPS ON SAFE AND SMOOTH OPERATION 3. Retain any excess portion of chain with wire so it does not hit the vehicle's body or brake pipes. 4. Hook the clips over the chain band (with the clips pointing outward) such that the clips are evenly positioned around the band. 5. After fitting the tyre chains and driving for a while, check whether the chains are loose or they have come unfastened.
Page 347: Service And Maintenance
SERVICE AND MAINTENANCE BEFORE SERVICE AND MAINTENANCE 7-15 DAILY CHECKS ENGINE-RELATED SERVICE AND 7-19 MAINTENANCE CHASSIS-RELATED SERVICE AND 7-59 MAINTENANCE 7-127 OTHER SERVICE AND MAINTENANCE INTERIOR AND EXTERIOR 7-147 MAINTENANCE 7-157 MAINTENANCE DATA 2008N_sec07-1_print2.indd 1 3/09/2008 5:47:11 PM...
Page 348 2008N_sec07-1_print2.indd 2 3/09/2008 5:47:12 PM...
Page 349 SERVICE AND MAINTENANCE BEFORE SERVICE AND MAINTENANCE ● Precautions for Checking and Adjustments ● Discarded Parts, Oils and Other Liquids ● Isuzu Genuine Oils and Grease ● Tools ● Inspection Hatches 7-10 ● Tilting the Cab 7-12 2008N_sec07-1_print2.indd 3 3/09/2008 5:47:13 PM...
Page 350 CAUTION • Discarded parts, oil, grease and fluids could have an adverse effect on the environment. It is difficult to dispose of these, so have your Isuzu Dealer handle all checks and replacements. 2008N_sec07-1_print2.indd 4 3/09/2008 5:47:14 PM...
Page 351 SERVICE AND MAINTENANCE ADVICE • Use only appropriate tools. • Oils, brake fluid, battery fluid and engine coolant have lubrication, cooling and rust prevention functions. If these liquids deteriorate through loss or contamination, it will cause a decline in the performance of the parts and such problems as seizure or malfunctioning.
Page 352 Periodically replenishing and changing the oil and grease is extremely important for maintaining your vehicle's performance and preventing malfunctions. Isuzu Motors guarantees the quality and performance of the Isuzu genuine oils and grease. We recommend the use of Isuzu genuine oils and grease for maintenance and service of your vehicle. CAUTION •...
Page 353 SERVICE AND MAINTENANCE Tools Storage Location in Single Cab Model The tools are stored behind the driver's and passenger's seats. Tilt the seatbacks forward to take out the tools. ADVICE • If your vehicle has a back panel tray, the back panel tray must be removed before you can take out or store the tools.
Page 354 SERVICE AND MAINTENANCE Tools Carried in Your Vehicle Model with dual tyres Tool name (NLR/NNR/NPR/NQR/NPS models) Jack bar/Spare tyre removal bar Wheel nut wrench handle Wheel nut wrench Screwdriver (with switchable Phillips and flat heads) Crank handle for spare tyre removal Tool bag Jack ADVICE...
Page 355 SERVICE AND MAINTENANCE Inspection Hatches Engine Maintenance Lid Opening Lever Belt 1. Lift the catch levers located at the front of the passenger's seat cushion to release the lock. 2. Lift up the seat cushion and attach the belt extending from behind the seatback to the left catch lever to hold Seat cushion the cushion in the raised position.
Page 356 7-10 SERVICE AND MAINTENANCE Engine Maintenance Sub Lid Opening 1. Unlock the driver's seat cushion by lifting the lock lever (red) while pulling toward you. Then remove the cushion. 2. Lift up the mat, and then remove the engine maintenance sub lid by pulling the handle.
Page 357 7-11 SERVICE AND MAINTENANCE Rear Inspection Hatches (Crew Cab Model) All rear inspection hatches are located in the floor in the vicinity of the rear seat. To open an inspection hatch, lift the floor mat first, and then grip the handle on the hatch to raise the hatch.
Page 358 7-12 SERVICE AND MAINTENANCE Tilting the Cab WARNING • Do not touch the lock (E) on the cab support while the cab is tilted. If you touch it, the lock will release. Refer to Step 4 of the following "Tilting Up the Cab" section and be sure to follow the instructions given.
Page 359 7-13 SERVICE AND MAINTENANCE Tilting Up the Cab 1. Apply the parking brake firmly and make sure that the gearshift lever is in the "N" position. Close all doors fully. 2. Holding the grip (D) in your left hand, pull the lever (A) toward you using your finger, and then raise the handle (C) using your right hand.
Page 360 7-14 SERVICE AND MAINTENANCE Lowering the Cab WARNING • After lowering the cab, make sure the cab is securely locked. CAUTION • Note that when a load is present inside or outside the cab, it will lower faster. 1. If a lock pin is equipped, remove it and place it in the holder.
Page 361 7-15 SERVICE AND MAINTENANCE DAILY CHECKS ● Daily Checks (Preoperational Checks) 7-16 ● Checking Components that Showed Abnormalities during 7-18 Previous Operation 2008N_sec07-1_print2.indd 15 3/09/2008 5:47:25 PM...
Page 362 If the checks reveal an abnormality or if there are components that showed abnormalities during the previous operation, have the vehicle repaired by your Isuzu Dealer before using the vehicle. Daily Check (Preoperational Check) Items [1.
Page 363 Driving condition at low speeds and during acceleration 7-21 Checking Components that Showed Abnormalities during Previous Operation Check the components that showed abnormalities during the previous operation. Have any abnormalities repaired by your Isuzu Dealer before using the vehicle. 2008N_sec07-1_print2.indd 17 3/09/2008 5:47:26 PM...
Page 364 7-18 SERVICE AND MAINTENANCE 2008N_sec07-1_print2.indd 18 3/09/2008 5:47:26 PM...
Page 365 7-19 SERVICE AND MAINTENANCE ENGINE-RELATED SERVICE AND MAINTENANCE ● Engine Conditions 7-20 ● Engine Oil 7-22 ● Engine Coolant 7-34 ● Fan Belt 7-44 ● Air Cleaner 7-49 ● Fuel Filter 7-53 ● Diesel Particulate Defuser (DPD) 7-60 2008N_sec07-1_print2.indd 19 3/09/2008 5:47:26 PM...
Page 366 7-20 SERVICE AND MAINTENANCE Engine Conditions Checking the Engine for Startability and Abnormal Noises 1. Make sure the parking brake is securely engaged. Step firmly on the brake pedal. 2. Make sure the transmission is in neutral. CAUTION • If your vehicle is equipped with the AMT system, the engine will not start unless the transmission is actually in neutral.
Page 367 7-21 SERVICE AND MAINTENANCE Checking Condition of the Engine at Low Speeds and during Acceleration 1. Make sure the transmission is in neutral and the parking brake is securely engaged. 2. Turn the starter switch to start the engine, and run it to warm up. Starting the Engine →...
Page 368 7-22 SERVICE AND MAINTENANCE Engine Oil Engine oil is an important factor determining engine performance and longevity. Be sure to use only the specified oil and oil filters. The engine oil level must be checked and the oil should be changed regularly according to the Maintenance Schedule. NOTE •...
Page 369 7-23 SERVICE AND MAINTENANCE Checking the Engine Oil Level 1. Remove the oil dipstick and wipe off any oil on the oil dipstick. 2. Reinsert the oil dipstick fully and then gently remove it. If the oil level is between the "Inspection MAX" and "MIN"...
Page 370 7-24 SERVICE AND MAINTENANCE Adding the Engine Oil When the engine oil level is near the "MIN" mark on the oil dipstick, remove the oil filler cap and add the oil. Remove the oil dipstick at this time. Use only the specified engine oil.
Page 371 7-25 SERVICE AND MAINTENANCE WARNING • When adding oil, be careful not to spill any, but keep a workshop rag handy just in case there are any spills. If any oil should spill onto the engine, carefully wipe it away. If this precaution is not taken, the spilled oil could ignite and a fire could spread.
Page 372 7-26 SERVICE AND MAINTENANCE Changing the Engine Oil and Oil Filter Engine oil and the oil filter are important factors in engine performance and lifespan. Be sure to use only the specified oil and oil filters. The engine oil level must be checked and the oil should be changed regularly according to the Maintenance Schedule.
Page 373 7-27 SERVICE AND MAINTENANCE Changing the Oil (4JJ1 Engine Model) 1. Clean around the oil filler cap so that foreign matter does not enter. Remove the oil filler cap. 2. Place a container for receiving the oil beneath the oil pan and the oil filter. Remove the oil pan drain plug and the oil filter drain plug to discharge the oil into the container.
Page 374 7-28 SERVICE AND MAINTENANCE 6. Reinstall and tighten the oil pan drain plug and oil filter drain plug. Drain plug tightening torque Oil pan 83.3 N·m (8.5 kgf·m/61 lb·ft) Oil filter 25 N·m (2.5 kgf·m/18 lb·ft) ADVICE • The dirt on the plug must be wiped off before reinstalling it. 7.
Page 375 7-29 SERVICE AND MAINTENANCE Changing the Oil (4HK1 Engine model) 1. Clean around the oil filler cap so that foreign matter does not enter. Remove the oil filler cap. 2. Place a container for receiving the oil beneath the oil pan and the oil filter. 3.
Page 376 7-30 SERVICE AND MAINTENANCE 7. Make sure that the oil pan drain plug is securely tightened. Oil pan drain plug tightening torque 4HK1 engine 83 N·m model (8.5 kgf·m/61 lb·ft) ADVICE • The dirt on the plug must be wiped off before reinstalling it.
Page 377 7-31 SERVICE AND MAINTENANCE 10. Shut off the engine. Then, after waiting at least 30 minutes, check the oil level using the oil dipstick. WARNING • Bringing flames or other heat sources near spilled engine oil could cause a fire. Make sure to wipe it all up.
Page 378 7-32 SERVICE AND MAINTENANCE Engine Coolant The engine coolant must be changed according to the Maintenance Schedule. Maintenance Schedule → Refer to page 7-159 Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-172 WARNING • Check, replenish or change the engine coolant only after the engine has sufficiently cooled down.
Page 379 Also, check to make sure there are no leaks from the radiator or radiator hose. Check for fluid or stains on the ground showing leaks where the vehicle is parked. Contact your Isuzu Dealer when you discover leaks. CAUTION •...
Page 380 When the engine is still hot, take care to prevent engine coolant from contact with the exhaust manifold. Any such contact could result in exhaust manifold damage. • If the level of engine coolant changes rapidly, have your vehicle inspected at your Isuzu Dealer. 2008N_sec07-1_print2.indd 34 3/09/2008 5:47:34 PM...
Page 381 7-35 SERVICE AND MAINTENANCE Changing the Engine Coolant ADVICE • Drained coolant must be disposed of in a method conforming to the regulatory requirements in your country. Engine Coolant Level Engine model Coolant quantity [Reference value] 4JJ1 10.0 litres (2.64 US gal./2.20 Imp gal.) 18.0 litres (4.76 US gal./3.96 Imp gal.) 4HK1 Draining the Cooling System...
Page 382 7-36 SERVICE AND MAINTENANCE 4JJ1 engine model 5. For the 4JJ1 engine, apply sealant ® (LOCTITE 262 or equivalent) to the screw threads of the engine drain plug before installing it. For the 4HK1 engine, attach the gasket in the drain plug before installing it.
Page 383 7-37 SERVICE AND MAINTENANCE 4JJ1 engine model Cleaning the Coolant Passages 1. Remove the radiator cap, and fill the radiator with tap water to the top of the opening. Remove the air bleed plug from the water outlet pipe before filling the coolant.
Page 384 7-38 SERVICE AND MAINTENANCE Single cab model 4. Fill the surge tank with tap water to the "MAX" line. 5. Close the cap of the surge tank. 6. Start the engine and let it idle for 20 minutes. Stop the engine, wait until it cools down, and then drain out the water.
Page 385 7-39 SERVICE AND MAINTENANCE Filling the Cooling System 1. Confirm that the engine has fully cooled down before starting work. 2. Remove the radiator cap, and fill the 4JJ1 engine model radiator with coolant to the top of the filler opening. Remove the air bleed plug from the water outlet pipe before pouring coolant.
Page 386 7-40 SERVICE AND MAINTENANCE Single cab model 5. Fill the surge tank with coolant to the "MAX" line. Close the cap of the surge tank. 6. Close the water outlet pipe's air bleed plug. 7. Start the engine, let it idle for 2 or 3 minutes and then stop the engine.
Page 387 °F) lower than the expected outside temperature. When using an engine coolant other than the Isuzu genuine engine coolant (Isuzu specified product), use the following mixture ratios: When the outside temperature is above −40°C (−40°F): 50% engine coolant and 50% tap water When the outside temperature is −40°C (−40°F) or lower: 60% engine coolant and...
Page 388 Use tap water, not well water or river water, when preparing coolant for replenishing or changing. • If the coolant decreases rapidly, go immediately to the nearest Isuzu Dealer for a check or repair. • Tighten the radiator drain plug by hand. Tightening with pliers or some other tool could damage it.
Page 389 7-43 SERVICE AND MAINTENANCE Inspection 4JJ1 engine model 4JJ1 Engine Model Press the centre of the span between Engine with 50A alternator pulleys (see the figure) of the belt with a force of 98 N (10.0 kgf/22 lb) and check the amount of deflection.
Page 390 7-44 SERVICE AND MAINTENANCE Engine with 50A alternator 4HK1 Engine Model Press the centre of the span between pulleys (see the figure) of the belt with a force of 98 N (10.0 kgf/22 lb) and check the amount of deflection. The amount of deflection must fall within the standard value range indicated below.
Page 391 7-45 SERVICE AND MAINTENANCE Adjustment and Replacement 4JJ1 engine model 4JJ1 Engine Model or 4HK1 Engine Model with 50A Alternator Adjustment 1. Loosen the alternator's upper and lower nuts and bolts (1, 2). 2. Turn the adjusting bolt (3) until the belt tension falls within the standard value range.
Page 392 7-46 SERVICE AND MAINTENANCE 4HK1 engine model with 80A 4HK1 Engine Model with 80A Alternator alternator Adjustment 1. Loosen the tensioner's lock nut. 2. Adjust the belt tension with the adjusting bolt. 3. When the tension has been adjusted, securely fasten the tensioner's lock nut.
Page 393 7-47 SERVICE AND MAINTENANCE Air Cleaner Change the air cleaner element after cleaning 6 times, or in accordance with the Maintenance Schedule. Maintenance Schedule → Refer to page 7-159 Checking the Air Cleaner Remove the air cleaner element and check to see if it is blocked by dirt.
Page 394 7-48 SERVICE AND MAINTENANCE Changing the Air Cleaner Element 1. Unfasten the 3 clips and remove the air cleaner cover. Clip 2. Remove the air cleaner element by pulling it out toward you. LNU8Z0SH011301 3. Remove the dirt that has accumulated on the air cleaner cover and the air cleaner body.
Page 395 7-49 SERVICE AND MAINTENANCE 5. Push the element back into position in the air cleaner body. 6. Install the air cleaner cover. Line up the notch on the left side of the body with the claw on the cover. Secure the cover in position by fastening the 3 clips.
Page 396 7-50 SERVICE AND MAINTENANCE Cleaning the Air Cleaner Element Choose one of the following cleaning methods depending on how the element has become dirty. 1. When dry dust has adhered to the element a. Blow compressed air at a pressure of up to 690 kPa (7.0 kgf/cm /100 psi) against the inside of the...
Page 397 (fuel filter). Continuing to drive with the light remaining on could damage the fuel injection pump. If this happens, have the vehicle checked and serviced by the nearest Isuzu Dealer. Draining Water from the Fuel Filter →...
Page 398 7-52 SERVICE AND MAINTENANCE Changing the Fuel Filter 1. Loosen the drain plug at the bottom of the filter element case. Remove the rubber cap of the air bleed plug and then loosen the plug. This will allow the fuel in the filter element case to drain through the drain plug.
Page 399 7-53 SERVICE AND MAINTENANCE 4. Pull out the filter element downward and remove the O-ring. Use a clean cloth to wipe off any foreign matter that has accumulated on the inside surface of the filter body. ADVICE • Do not use compressed air to remove foreign matter.
Page 400 When fitting the element case, be careful not to let the O-ring become caught in the screw threads. This could cause a fuel leak and start a fire. ADVICE • Be sure to use an Isuzu genuine fuel filter element. • Replace the gaskets when replacing the filter element. •...
Page 401 7-55 SERVICE AND MAINTENANCE Draining Water from the Fuel Filter 1. Attach a plastic hose to the drain plug on the bottom of the engine-side fuel filter and put the other end of the hose in a container placed beneath the filter.
Page 402 Diesel Particulate Defuser (DPD) Checking and Cleaning the DPD Have the exhaust pressure check performed at your Isuzu Dealer in accordance with the Maintenance Schedule. The filter may need cleaning depending on the results of the check. If you cannot do the exhaust pressure check, clean the filter and inspect the exhaust differential pressure sensor rubber.
Page 403 7-57 SERVICE AND MAINTENANCE Notes 2008N_sec07-1_print2.indd 57 3/09/2008 5:47:49 PM...
Page 404 7-58 SERVICE AND MAINTENANCE Notes 2008N_sec07-1_print2.indd 58 3/09/2008 5:47:49 PM...
Page 405 7-59 SERVICE AND MAINTENANCE CHASSIS-RELATED SERVICE AND MAINTENANCE ● Brakes 7-60 ● Parking Brake 7-70 ● Brake Hoses and Pipes 7-72 ● Disc Brakes 7-73 ● Drum Brakes 7-75 ● Wheels and Tyres 7-77 ● Tyre Rotation 7-86 ● Changing Tyres 7-88 ●...
Page 406 If the brake fluid level decreases rapidly, there may be a problem in the brake system or brake pads or shoe linings may have worn out. Have your vehicle inspected by the nearest Isuzu Dealer immediately. 2008N_sec07-2_print2.indd 60 3/09/2008 5:53:08 PM...
Page 407 7-61 SERVICE AND MAINTENANCE Bleeding the Brake Hydraulic System If air is present in the brake hydraulic system, it adversely affects brake operations. Bleed the system if the brakes are used when the quantity of the brake fluid in the tank is extremely low or the brake piping is removed during maintenance operation.
Page 408 7-62 SERVICE AND MAINTENANCE 1. Fully apply the parking brake. CAUTION • In a model with an anti-lock brake system (ABS), remove the ABS fuse (10A) from the fuse box before starting an air-bleeding operation. Failure to observe this precaution will result in incomplete bleeding of air, and the ABS components may be damaged as a result.
Page 409 7-63 SERVICE AND MAINTENANCE 3. Remove the cap from the brake fluid tank, and then add brake fluid to the "MAX" level mark on the tank. Maintain this level throughout bleeding by adding brake fluid as necessary. 4. Bleed the brake hydraulic system part by part in the following sequence: Right-hand drive: Left rear wheel →...
Page 410 7-64 SERVICE AND MAINTENANCE 7. Loosen the bleeder screw to let the brake fluid containing air bubbles flow into the container and then tighten the bleeder screw immediately. 8. Release the brake pedal slowly. Repeat Steps 6 and 7 until the fluid from the tube no longer contains air bubbles.
Page 411 7-65 SERVICE AND MAINTENANCE Hydro-Booster Fluid WARNING • The HBB system has been designed to use Besco ATF-III as the hydro-booster ® fluid (DEXRON III fluids from different suppliers can also be used). If any other fluid is used with this system, rubber components may be damaged, oil may leak and the system may malfunction.
Page 412 7-66 SERVICE AND MAINTENANCE Checking the Hydro-booster Fluid Level Check the hydro-booster fluid level and change the fluid according to the Maintenance Schedule. The hydro-booster fluid level is correct if it is between the "MAX" and "MIN" lines. If the level is too low, add fluid up to the "MAX"...
Page 413 7-67 SERVICE AND MAINTENANCE 9. Repeat Step 6 through Step 8 until the fluid level has stabilized and no bubbles remain in the fluid. When bubbles are seen, wait until they have gone before repeating the above process. 10. After completing Step 9, start the engine and bleed air from the brake hydraulic system (including the master and wheel cylinders) with the...
Page 414 7-68 SERVICE AND MAINTENANCE Brake Pedal Stroke (Free Play) Shut off the engine and depress the brake pedal about 10 times strongly, then check the brake pedal for free play by lightly pushing it by hand until you feel resistance. Next, start the engine, and wait at least 1 Free play minute.
Page 415 If, after continued pressing of the brake pedal, the clearance slowly decreases or the pedal action feels spongy, air may be trapped in the brake hydraulic circuit. Have your vehicle inspected at the nearest Isuzu Dealer as soon as possible.
Page 416 7-70 SERVICE AND MAINTENANCE Parking Brake Inspection Pull the parking brake lever slowly from the fully released position while counting the clicks produced as the lever engages ratchet plate notches to check that it can be raised the proper amount and the lever is held firmly.
Page 417 7-71 SERVICE AND MAINTENANCE WARNING • Before going under the raised vehicle, make sure that the vehicle is securely supported with jack stands. • If your vehicle is equipped with a differential lock system, limited slip differential (LSD) or non-spin differential, it might start moving when the engine power is transmitted to the rear axle even when one of the wheels on the axle is raised clear of the ground.
Page 418 7-72 SERVICE AND MAINTENANCE Brake Hoses and Pipes Inspection With the steering wheel turned fully to the left, check the left front brake hose and pipe visually and by touch, making sure that they are free of scratches, cracks and bulging.
Page 419 The pad has an embedded wear indicator. A squeaking noise from the indicator means that the pad is approaching the usable limit. If the squeaking noise from the indicator can be heard, contact the nearest Isuzu Dealer for inspection or replacement.
Page 420 7-74 SERVICE AND MAINTENANCE 5. Check the pad and rotor as follows: Measure the pad thickness, rotor thickness and rotor runout. Rotor thickness LNU8Z0SH025101 Rotor thickness Pad thickness Brake size Standard Standard (Diameter x Thickness) Usable limit Usable limit value value φ265 x 35 mm 35.0 mm...
Page 421 Have the replacement carried out by the nearest Isuzu Dealer. Adjustment of Drum-to-Lining Gap (Model with Automatic Adjuster) 1. Press down the brake pedal as far as it goes.
Page 422 7-76 SERVICE AND MAINTENANCE Adjustment of Drum-to-Lining Gap (Model without Automatic Adjuster) 1. Apply the parking brake firmly and chock the wheels. 2. Raise the vehicle until the wheel is completely clear of the ground. 3. Support the raised vehicle with jack stands.
Page 423 WARNING • If you find anything abnormal with wheel bolts, wheel nuts or disc wheels when you check them, avoid driving the vehicle and contact the nearest Isuzu Dealer as soon as possible. • If you find anything abnormal on the left wheels, check the right wheels carefully for similar defects.
Page 424 7-78 SERVICE AND MAINTENANCE Tyre Air Pressure Tyre air pressure Tyre size Vehicle kPa (kgf/cm²/psi) model Front Rear Front Rear 195/75R16C 195/75R16C 475 (4.75/69) 475 (4.75/69) 7.00R15-8PR 7.00R15-8PR 450 (4.50/65) 450 (4.50/65) 7.00-15-10PR 7.00-15-10PR 500 (5.00/73) 500 (5.00/73) 7.00R15-10PR 7.00R15-10PR 525 (5.25/76) 525 (5.25/76) 7.00-16-8PR...
Page 425 7-79 SERVICE AND MAINTENANCE Tyre air pressure Tyre size Vehicle kPa (kgf/cm²/psi) model Front Rear Front Rear 7.50-16-10PR 7.50-16-10PR 525 (5.25/76) 525 (5.25/76) 7.50R16-10PR 7.50R16-10PR 575 (5.75/83) 575 (5.75/83) 7.50-16-12PR 7.50-16-12PR 600 (6.00/87) 600 (6.00/87) 7.50R16-12PR 7.50R16-12PR 650 (6.50/94) 650 (6.50/94) 7.50-16-14PR 7.50-16-14PR 650 (6.50/94)
Page 426 7-80 SERVICE AND MAINTENANCE Tyre air pressure Tyre size Vehicle kPa (kgf/cm²/psi) model Front Rear Front Rear 7.00-16-10PR 7.00-16-10PR 500 (5.00/73) 500 (5.00/73) 7.00R16-10PR 7.00R16-10PR 525 (5.25/76) 525 (5.25/76) 7.00-16-12PR 7.00-16-12PR 575 (5.75/83) 575 (5.75/83) 7.50-16- 8PR 7.50-16- 8PR 425 (4.25/62) 425 (4.25/62) NPR85F 7.50-16-10PR...
Page 427 7-81 SERVICE AND MAINTENANCE Tyre air pressure Tyre size Vehicle kPa (kgf/cm²/psi) model Front Rear Front Rear 7.50-16-14PR 7.50-16-14PR 650 (6.50/94) 650 (6.50/94) 7.50R16-14PR 7.50R16-14PR 700 (7.00/102) 700 (7.00/102) NQR75H 8.25-16-12PR 8.25-16-12PR 500 (5.00/73) 500 (5.00/73) 8.25-16-14PR 8.25-16-14PR 575 (5.75/83) 575 (5.75/83) 225/70R19.5F 225/70R19.5F...
Page 428 7-82 SERVICE AND MAINTENANCE WARNING • Insufficiently inflated or worn-out tyres are highly dangerous as they easily skid and can even burst. Should they burst, the tyres may burn and this could cause a fire in the vehicle. • If you drive on under-inflated or flat tyres, the wheel bolts will be placed under excessive stress.
Page 429 7-83 SERVICE AND MAINTENANCE Cracks and Other Damage Gap between inner Check the tread and sidewall surfaces and outer tires of each tyre for cracks or other damage. Sidewall surface Especially check the tread for nails or other metal pieces embedded in grooves and also the gap between the inner and outer tyres of a dual-tyre wheel for pebbles lodged in it.
Page 430 7-84 SERVICE AND MAINTENANCE Visual Checking of Wheel Installation Condition Visually check the condition of installation of each disc wheel. 1. Check that there are no missing wheel bolts and wheel nuts. 2. Check each disc wheel to see if there is any rust seepage from wheel bolts or nuts.
Page 431 7-85 SERVICE AND MAINTENANCE Spare Tyre Air Pressure Keep the air pressure of the spare tyre slightly higher than the standard pressure. Adjust the pressure correctly when you use Tyres heat up while driving, and their air pressures become higher accordingly. If you must wait until right after driving to adjust the air pressure, determine the target pressure for adjustment by adding...
Page 432 • If you find any abnormal condition on the wheel studs, wheel nuts or disc wheel, do not continue to use the wheel. Contact the nearest Isuzu Dealer as soon as possible. Tyres at different locations wear differently. For uniform tyre wear and longer tyre life, you should rotate the tyres on your vehicle regularly.
Page 433 7-87 SERVICE AND MAINTENANCE CAUTION • If differently sized tyres are used between the front and rear axles, do not exchange tyres between the front and rear axles; otherwise, the tyres get loaded beyond their limits. This is highly dangerous because the tyres and disc wheels could be break down under an excessive load.
Page 434 7-88 SERVICE AND MAINTENANCE Changing Tyres Change a tyre on a level and solid surface after checking safety in the surrounding area. Handling the Jack → Refer to page 7-128 Every stud or nut for right-hand wheels is marked "R" or " ", and each stud or nut for left-hand wheels is marked "L"...
Page 435 7-89 SERVICE AND MAINTENANCE Preparation When you park the vehicle to change tyres, choose a place where • Your vehicle does not hinder other traffic, • The surface is level, flat and solid, • You can change a tyre safely. When changing tyres on a road, use the hazard warning flasher and triangle reflectors to alert other traffic to the...
Page 436 7-90 SERVICE AND MAINTENANCE Removing a Wheel WARNING • Always apply the parking brake fully and correctly chock the wheels before raising the vehicle. Applying only the parking brake is insufficient to prevent the vehicle from moving. When a rear wheel is jacked up, the vehicle blocked only by the parking brake would move, creating a very dangerous situation.
Page 437 7-91 SERVICE AND MAINTENANCE 5. Jack up the vehicle so that the tyre is clear of the ground completely. 6. Remove all the wheel nuts that have been loosened, and then remove the wheel. Remove the wheel being careful to not damage the threads of the wheel studs.
Page 438 7-92 SERVICE AND MAINTENANCE CAUTION • Change wheels only when the tyre is clear of the ground. Otherwise, the wheel will be installed improperly and the operation of the vehicle will be affected adversely. • Remove mud and rust from the hub fitting surface or wheel-to-wheel mating surfaces.
Page 439 7-93 SERVICE AND MAINTENANCE CAUTION • Remove rust and dirt from a wheel stud and nut, lightly lubricate the threads with engine oil, gear oil or power steering fluid and turn the nut on the stud. If the nut does not turn smoothly, the threads are defective. •...
Page 440 7-94 SERVICE AND MAINTENANCE 5. Screw in each wheel nut by hand until it touches the nut seating surface on the disc wheel, and then finger tighten all wheel nuts until the wheel is held in position without any looseness. Face the tapered end of wheel nuts inward.
Page 441 After changing a tyre, turn the steering wheel in both directions to make sure that the wheels do not interfere with the surrounding components. If you are unclear about any of this, please contact the nearest Isuzu Dealer. • The tightening torque of the wheel nuts may decrease after tyre replacement due to their initial settlement.
Page 442 7-96 SERVICE AND MAINTENANCE Retightening Wheel Nuts Check the wheel nuts to make sure they are tightened to the specific torque by using a torque wrench. Use the following methods to check loose wheel nuts. The tightening torque of the wheel nuts may decrease after a tyre change or rotation due to their initial settlement.
Page 443 • If you find any abnormal conditions with the wheel nuts such as frequent loosening of retightened nuts, have your vehicle checked or serviced at the nearest Isuzu Dealer as soon as possible. CAUTION • Fully engage the wheel wrench on a wheel nut in order to tighten the nut to the specified torque.
Page 444 7-98 SERVICE AND MAINTENANCE Spare Tyre Removal Assemble the spare tyre removing bar and crank handle together, insert the bar into the hole in the spare tyre carrier, and turn the crank handle counterclockwise to remove the spare tyre. Spare tyre stored at rear of frame Spare tire removing crank handle...
Page 445 If you cannot retighten the tyre in the carrier, do not drive the vehicle but contact the nearest Isuzu Dealer. Air Pressure Check the air pressure of the spare tyre using a tyre air pressure gauge at the intervals specified in the Maintenance Schedule.
Page 446 • If clutch fluid decreases too rapidly, there might be a problem in the clutch system or the clutch disc might be worn beyond safe limit. Have your vehicle inspected by the nearest Isuzu Dealer immediately. Maintenance Schedule → Refer to page 7-159 Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-172...
Page 447 Changing Clutch Fluid Change the clutch fluid according to the Maintenance Schedule using the specified fluid. Since a clutch fluid change requires disassembly of the related components, have this service performed by your Isuzu Dealer. 2008N_sec07-2_print2.indd 101 3/09/2008 5:53:41 PM...
Page 448 7-102 SERVICE AND MAINTENANCE Bleeding the Clutch Hydraulic System If air is present in the clutch hydraulic system, the clutch may disengage incompletely. Bleed the system if the clutch is used when the quantity of the clutch fluid in the tank is extremely low or the clutch piping is disconnected during a maintenance operation.
Page 449 7-103 SERVICE AND MAINTENANCE 5. Press the clutch pedal several times and then keep it pressed. 6. Loosen the bleeder screw to let the clutch fluid containing air bubbles flow into the container and then tighten the bleeder screw immediately. 7.
Page 450 7-104 SERVICE AND MAINTENANCE Clutch Pedal The clutch disc wears down as the clutch is used, and this causes the free play of the clutch pedal to decrease. If you continue to use the clutch with reduced clutch pedal play, the clutch slips easily. On the other hand, if the pedal free play is too much, the clutch disengages poorly, making gearshifts difficult.
Page 451 7-105 SERVICE AND MAINTENANCE Transmission Oil Change the transmission oil according to the Maintenance Schedule. If your vehicle is equipped with AMT, you should follow the special procedures for level checking and changing of the AMT clutch oil. Maintenance Schedule → Refer to page 7-159 AMT Clutch Oil → Refer to page 7-109...
Page 452 7-106 SERVICE AND MAINTENANCE Checking the Oil Level 1. Remove the oil level plug. 2. Check whether the oil level is up to the lower edge of the oil level plug hole. The correct oil level range is between 0 and 10 mm (0 and 0.39 in) below the bottom of the level plug hole.
Page 453 7-107 SERVICE AND MAINTENANCE Changing the Oil 1. Place a container under the drain plug(s) to receive oil. 2. Remove both oil level plug and drain plug(s) to discharge the oil into the container. 3. After installing the drain plug(s) by tightening it to the specified torque, refill the transmission with new oil through the oil level plug hole up to...
Page 454 7-108 SERVICE AND MAINTENANCE 5. Install the oil level plug by tightening it to the specified torque. Oil level plug tightening torque 39 N·m (4.0 kgf·m/29 lb·ft) ADVICE • Any dirt on the plug should be wiped off before installing it. ADVICE •...
Page 455 Both quality and quantity of oil are important factors that have a significant influence on the performance and durability of AMT. Be sure to use only the Isuzu recommended oil for replenishment, and observe the specified oil level. Too much oil will cause oil leaks.
Page 456 7-110 SERVICE AND MAINTENANCE Checking the Oil Level 1. Park the vehicle on level ground, place the gearshift lever in the "N" position and firmly apply the parking brake. 2. Start the engine. Single cab model 3. Pull out the dipstick and wipe it with a clean cloth.
Page 457 7-111 SERVICE AND MAINTENANCE Changing the Oil Changing the AMT Clutch Oil Change the AMT clutch oil according to the Maintenance Schedule. Maintenance Schedule → Refer to page 7-159 ADVICE • After changing the AMT clutch oil, check that the oil level is correct by following the instructions in the preceding "Checking the Oil Level"...
Page 458 7-112 SERVICE AND MAINTENANCE Rear Axle Differential Gear Oil The rear axle differential gear oil level must be checked for its level and it must be changed according to the Maintenance Schedule. ADVICE • Use the oil quantities indicated later in this section only as guidelines when changing the rear axle differential gear oil.
Page 459 7-113 SERVICE AND MAINTENANCE Changing the Oil 1. Place a container under the drain plug to receive oil. 2. Remove the plugs indicated in the figure to discharge the oil into the container. 3. After installing the drain plug by tightening it to the specified torque, refill the rear axle differential with new oil through the oil level plug hole up to...
Page 460 7-114 SERVICE AND MAINTENANCE ADVICE • Use only the Isuzu recommended differential gear oil. Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-172 Front Axle Differential Gear Oil The front axle differential gear oil level must be checked and it must be changed according to the Maintenance Schedule.
Page 461 7-115 SERVICE AND MAINTENANCE Changing the Oil 1. Place a container under the drain plug to receive oil. ADVICE • Use the oil quantities indicated below only as guidelines when changing the front axle differential oil. After changing the oil, ensure that its level is as required.
Page 462 7-116 SERVICE AND MAINTENANCE ADVICE • Any dirt on the plug should be wiped off before installing it. Quantity of front axle differential gear oil to be changed Oil quantity [Reference value] 2.7 litres (0.71 US gal./0.59 Imp gal.) 2008N_sec07-2_print2.indd 116 3/09/2008 5:53:52 PM...
Page 463 7-117 SERVICE AND MAINTENANCE Transfer Gear Case Oil The transfer gear case oil level must be checked and it must be changed according to the Maintenance Schedule. Maintenance Schedule → Refer to page 7-159 Checking the Oil Level 1. Remove the oil level plug. 2.
Page 464 7-118 SERVICE AND MAINTENANCE Changing the Oil 1. Place a container under the drain plug to receive oil. 2. Remove both the oil level plug and the drain plug to discharge the oil into the container. ADVICE • Use the oil quantity indicated below only as a guideline when changing the transfer gear case oil.
Page 465 7-119 SERVICE AND MAINTENANCE ADVICE • Any dirt on the plug should be wiped off before installing it. Quantity of transfer gear case oil to be changed Oil quantity [Reference value] 1.8 litres (0.48 US gal./0.40 Imp gal.) 2008N_sec07-2_print2.indd 119 3/09/2008 5:53:54 PM...
Page 466 7-120 SERVICE AND MAINTENANCE Power Steering Fluid The power steering fluid level must be checked and it must be changed according to the Maintenance Schedule. Maintenance Schedule → Refer to page 7-159 Checking the Power Steering Fluid Level The fluid level is correct if it is between the "MAX"...
Page 467 7-121 SERVICE AND MAINTENANCE Changing the Power Steering Fluid Rack and pinion Draining 1. Apply the parking brake firmly and chock the rear wheels. 2. Firmly apply the head of the jack to the jacking point. 3. Raise the vehicle until the front wheels are completely clear of the ground.
Page 468 7-122 SERVICE AND MAINTENANCE Refilling 1. Securely connect the oil pipe and oil hose, and then refill the reserve tank with the specified power steering fluid. 2. When the reservoir tank is filled with the fluid up to the specified level, wait for 2 to 3 minutes to allow the fluid level to lower.
Page 469 Hub Bearing Grease As disassembly and reassembly will be required in order to replace front and rear bearing grease, have these operations performed by your Isuzu Dealer. 2008N_sec07-2_print2.indd 123 3/09/2008 5:53:57 PM...
Page 470 7-124 SERVICE AND MAINTENANCE Greasing Chassis Components The type (characteristics) of the grease specified for use with a chassis component differs from that of the grease specified for use with another component. Be sure to use only the specified grease for each component and perform greasing according to the Maintenance Schedule.
Page 471 7-125 SERVICE AND MAINTENANCE ADVICE • Each of propeller shaft universal joint must be greased heavily until grease oozes at the 4 needle bearing oil seal locations. After greasing, wipe off excess grease. 2008N_sec07-2_print2.indd 125 3/09/2008 5:54:00 PM...
Page 472 7-126 SERVICE AND MAINTENANCE 2008N_sec07-2_print2.indd 126 3/09/2008 5:54:00 PM...
Page 473 7-127 SERVICE AND MAINTENANCE OTHER SERVICE AND MAINTENANCE ● Handling the Jack 7-128 ● Windshield Washer Fluid 7-133 ● Windshield Wiper Blades 7-134 ● Headlights and Turn Signal Lights 7-137 ● Handling the Battery 7-138 ● Air Conditioning Filters 7-144 ●...
Page 474 7-128 SERVICE AND MAINTENANCE Handling the Jack WARNING • Raising the vehicle with a jack could lead to an accident when carried out on soft or inclined surfaces. Ensure that you always carry out this operation on flat, solid surfaces. •...
Page 475 7-129 SERVICE AND MAINTENANCE Operating the Jack Raising the Vehicle 1. Place the jack immediately below the jacking point and ensure that it is upright. The jack must be placed on a flat, solid surface. Front Wheel Jacking Points → Refer to page 7-130 Rear Wheel Jacking Points → Refer to page 7-131 Jacking When a Front Tyre Is Flat...
Page 476: Front Suspension
7-130 SERVICE AND MAINTENANCE Lowering the Vehicle 1. Line up the jack handle end notch with the bleeder screw. 2. Slowly turn the bleeder screw counterclockwise to lower the vehicle. 3. When the vehicle has been fully lowered, turn the bleeder screw as far as it will go in the clockwise direction.
Page 477 7-131 SERVICE AND MAINTENANCE Rear Wheel Jacking Points Over-slung Leaf Spring Suspension Model Leaf spring (single tyre model, dual tyre model, flat-low model) Apply the jack to the bottom of the leaf spring or axle case. Front of vehicle Under-slung Leaf Spring Suspension Model Leaf spring (some dual tyre models, standard full-flat...
Page 478 7-132 SERVICE AND MAINTENANCE Jacking When a Front Tyre Is Flat WARNING • Position the jack as close as possible to the front axle. • The wood block should be as thick as possible in order to improve stability. • As the bottom of the leaf spring is curved, special care must be taken during the jacking operation.
Page 479 7-133 SERVICE AND MAINTENANCE Windshield Washer Fluid Windshield Wiper/Washer Check the level of fluid in the windshield washer tank. In addition, spray windshield washer fluid and operate the windshield wipers to check for any areas not properly wiped. At this time, also check the windshield washer's spraying condition. Refilling Windshield Washer Fluid 1.
Page 480 7-134 SERVICE AND MAINTENANCE Windshield Wiper Blades Daily Checks Spray windshield washer fluid and then operate the windshield wipers to check for any poorly wiped areas. In addition, confirm that each of the " (intermittent)", "LO", and "HI" functions operate normally. Windshield Wiper Blade Replacement Removal 1.
Page 481 7-135 SERVICE AND MAINTENANCE Installation 1. Insert the blade while holding it almost perpendicular to the arm. 2. Then, with the blade and arm oriented in the same direction, push up the blade until it locks into place on the arm.
Page 482 7-136 SERVICE AND MAINTENANCE Replacement of Wiper Rubber Insert Removal Pull 1. Remove the wiper blade from the wiper arm. 2. Pull the wiper rubber insert in the direction indicated by the arrow and extract it from the wiper blade. Installation Insert 1.
Page 483 7-137 SERVICE AND MAINTENANCE Headlights and Turn Signal Lights Turn the starter switch to the "ON" position, and then check the way in which the headlights, turn signal lights, and other exterior lights come on and flash. In addition, depress the brake pedal to confirm whether the stop lights come on, and shift the transmission to "R"...
Page 484 • If the battery fluid level continues to drop at an unusually fast rate, have an inspection carried out immediately by the nearest Isuzu Dealer. 2008N_sec07-2_print2.indd 138 3/09/2008 5:54:10 PM...
Page 485 7-139 SERVICE AND MAINTENANCE Battery Handling Precautions Keep the battery clean. If the battery is left in a dirty condition, contaminants can get mixed into the battery fluid, the battery plates can be damaged, short circuits can occur on the top surface of the battery and the battery's service life can be reduced. When Performing Inspection or Maintenance Before starting inspection and maintenance...
Page 486: Charging The Battery
Using the Battery as a Direct Power Source The battery should not be used as a direct source of 12-volt power. If your battery must be used as a direct power source, please consult with your Isuzu Dealer. 2008N_sec07-2_print2.indd 140...
Page 487 • If the battery fluid level continues to drop at an unusually fast rate, have an inspection carried out immediately by the nearest Isuzu Dealer. 2008N_sec07-2_print2.indd 141 3/09/2008 5:54:11 PM...
Page 488 • If the battery fluid level continues to drop at an unusually fast rate, have an inspection carried out immediately by the nearest Isuzu Dealer. 2008N_sec07-2_print2.indd 142 3/09/2008 5:54:11 PM...
Page 489 7-143 SERVICE AND MAINTENANCE Checking the Specific Gravity of Battery Fluid 1. Check the specific gravity of the battery fluid using a hydrometer. If the specific gravity is too low, the Hydrometer battery should be charged. Specific gravity at a fluid temperature of 20°C (68°F) 1.27 - 1.29 Checking the Battery Terminals 1.
Page 490 7-144 SERVICE AND MAINTENANCE Air Conditioning Filters Removing the Inside Air Filter (All Models) 1. Loosen the screws at the centre of the 2 clips securing the cover and pull out the clips. 2. Remove the cover by pushing it upwards.
Page 491 7-145 SERVICE AND MAINTENANCE Installing the Inside Air Filter (All Models) 1. Install the filter in the reverse order to removal. CAUTION • Ensure that the filter is returned securely to its original position. Failure to observe this precaution can lead to rattling during travel, or should the filter become loose, to very dangerous situations.
Page 492 When refrigerant must be replaced, therefore, please contact your Isuzu Dealer or other service facility equipped with a gas recovery installation system. 2008N_sec07-2_print2.indd 146...
Page 493 7-147 SERVICE AND MAINTENANCE INTERIOR AND EXTERIOR MAINTENANCE ● Exterior Maintenance 7-148 ● Interior Maintenance 7-151 2008N_sec07-2_print2.indd 147 3/09/2008 5:54:13 PM...
Page 494 7-148 SERVICE AND MAINTENANCE Exterior Maintenance Washing If the vehicle is operated with foreign material adhering to the exterior, this material may react chemically with paint, resulting in staining, discoloration, rusting or corrosion of components. Also, the material may become trapped within mechanical components, adversely affecting their functions or forming an aerodynamic resistance.
Page 495 7-149 SERVICE AND MAINTENANCE ADVICE • If an automatic car or truck-wash is used with vehicles having dark or metallic coating, the painted surfaces can be damaged by the brushes, lose their luster or be very noticeably scratched. • Do not direct a large amount of water at the air inlet openings. •...
Page 496 7-150 SERVICE AND MAINTENANCE Vehicle Storage In order to maintain your vehicle's attractive appearance as long as possible, special consideration must be given to its storage location. If the vehicle is stored or kept for an extended period of time in any of the following locations, a chemical change may occur in the paintwork, resulting in staining, discoloration, rusting, and corrosion of components.
Page 497 Windshield Care If not fully cleaned by the windshield wipers, the windshield should be cleaned using Isuzu genuine glass cleaner. Interior Maintenance Remove dust and dirt from the interior of the cab using an automotive cleaner or vacuum cleaner, and gently wipe surfaces clean using a cloth wet with warm or cold water.
Page 498 Do not disassemble the seat belt mechanism in order to remove any foreign material or objects that may have entered the buckle. Instead, arrange for inspection and maintenance to be carried out by your Isuzu Dealer. Cleaning a Seat Belt's Fold-back Fitting Portion 1.
Page 499 In this case, arrange for inspection and maintenance to be carried out by your Isuzu Dealer. MFU770SH010801 • If the belt is not winding and unwinding correctly, or if inspection...
Page 500 7-154 SERVICE AND MAINTENANCE Notes 2008N_sec07-2_print2.indd 154 3/09/2008 5:54:15 PM...
Page 501 7-155 SERVICE AND MAINTENANCE Notes 2008N_sec07-2_print2.indd 155 3/09/2008 5:54:15 PM...
Page 502 7-156 SERVICE AND MAINTENANCE Notes 2008N_sec07-2_print2.indd 156 3/09/2008 5:54:15 PM...
Page 503 7-157 SERVICE AND MAINTENANCE MAINTENANCE DATA ● Inspection and Maintenance 7-159 ● Maintenance Schedule Validation 7-164 ● Recommended Lubricants and Diesel Fuels 7-172 2008N_sec07-3_print2.indd 157 4/09/2008 8:16:22 AM...
Page 504 2008N_sec07-3_print2.indd 158 4/09/2008 8:16:30 AM...
Page 505 Maintenance Schedule To drive your vehicle safely and at minimum cost, it is essential to have your vehicle regularly inspected and serviced at your Isuzu Dealer as per the specified maintenance schedule. Contact your Isuzu Dealer for inspection that requires disassembly and/or special equipment.
Page 506 7-160 SERVICE AND MAINTENANCE ISUZU NLR, NNR, NPR, NPS & NQR MAINTENANCE SCHEDULE I = Inspect, clean, correct, replace as necessary R = Replace T = Retighten to specified torque L = Lubricate A = Adjust * : Refer to “Maintenance schedule under severe operating conditions” on next page.
Page 507 All fluid levels. Cab suspension & tilt operation Operation of all electrical devices, A/C, heater & warning lights Connect Isuzu diagnostic tool, check, note and/or repair any codes recorded ROAD TEST Operation of steering, brakes, exhaust brake, engine, transmission, clutch *: Refer to “Maintenance schedule under severe operating conditions”...
Page 508 7-162 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE UNDER SEVERE OPERATING CONDITIONS Repeated short trips with extensive idling and/or where the engine does not reach normal operating temperature. Also applications involving descending or ascending steep gradients. (Examples may be Concrete Agitators, Tow trucks, Concrete Pumpers, Road Patchers, mine site trucks) Driving on rough/loose surface roads (More than 10% of operation) or operating in any harsh environment/application likely to cause accelerated wear and tear.
Page 509 ACEA E7 / API CJ-4 SM, SAE 10W40 Manual Transmission & Transfer Case ACEA E7 / API CJ-4 SM, SAE 10W40 Clutch – Automated Manual transmission Isuzu BESCO ATF III or equivalent Differential API GL5, SAE 85W-140 (plus additive for LSD) LLC (green), specification HN2217...
Page 510 7-164 SERVICE AND MAINTENANCE Maintenance Schedule Validation MAINTENANCE SCHEDULE VALIDATION Preparation carried out; New Vehicle at ……………………….. kilometres on (date)………………… Preparation Validation Delivering Dealer ………………………………………………... Service carried out; 5,000 kilometre at …………………...kilometres on (date)……………………… 0.1 year Servicing Dealer ………………………………………………... Service carried out; 15,000 kilometres at …………………...kilometres on (date)………………………...
Page 511 7-165 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE VALIDATION Service carried out; 105,000 kilometres at …………………...kilometres on (date)……………………… 3.5 years Servicing Dealer ………………………………………………... Service carried out; 120,000 kilometres at …………………...kilometres on (date)……………………… 4 years Servicing Dealer ………………………………………………... Service carried out; 135,000 kilometres at …………………...kilometres on (date)………………………...
Page 512 7-166 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE VALIDATION Service carried out; 225,000 kilometres at …………………...kilometres on (date)……………………… 7.5 years Servicing Dealer ………………………………………………... Service carried out; 240,000 kilometres at …………………...kilometres on (date)……………………… 8 years Servicing Dealer ………………………………………………... Service carried out; 255,000 kilometres at …………………...kilometres on (date)………………………...
Page 513 7-167 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE VALIDATION Service carried out; 345,000 kilometres at …………………...kilometres on (date)……………………… 11.5 years Servicing Dealer ………………………………………………... Service carried out; 360,000 kilometres at …………………...kilometres on (date)……………………… 12 years Servicing Dealer ………………………………………………... Service carried out; 375,000 kilometres at …………………...kilometres on (date)………………………...
Page 514 7-168 SERVICE AND MAINTENANCE INTERMEDIATE/SEVERE/ENGINE HOURS VALIDATION Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………...
Page 515 7-169 SERVICE AND MAINTENANCE INTERMEDIATE/SEVERE/ENGINE HOURS VALIDATION Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………...
Page 516 7-170 SERVICE AND MAINTENANCE INTERMEDIATE/SEVERE/ENGINE HOURS VALIDATION Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………...
Page 517 7-171 SERVICE AND MAINTENANCE INTERMEDIATE/SEVERE/ENGINE HOURS VALIDATION Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ………………………………………………...
Page 518 SERVICE AND MAINTENANCE Recommended Fluids, Lubricants and Diesel Fuels It is extremely important to select correct lubricants and diesel fuels so that your Isuzu vehicle demonstrates its full performance over years. Top up the lubricants in accordance with the Maintenance Schedule specified for your vehicle.
Page 519 7-173 SERVICE AND MAINTENANCE DIESEL FUEL / APPLICABLE STANDARD (Sulfur content below 50 ppm) Japanese Industrial Standards Based on K2204 Diesel Fuel Deutsche Industrie Normen (DIN) Based on EN590 : 2004 Based on D975-04c NO.1-D S15 or NO.2-D American Society for Testing and Materials (ASTM) S15 (below 15 ppm) British Standards (BS) Based on EN590 : 2004...
Page 520 7-174 SERVICE AND MAINTENANCE Notes 2008N_sec07-3_print2.indd 174 4/09/2008 8:16:33 AM...
Page 521: In Case Of Emergency
IN CASE OF EMERGENCY ● Troubleshooting ● When the Vehicle Breaks Down during Driving ● When the Tyre Goes Flat ● When the Engine Stops While Driving ● When the Engine Stalls and Cannot be Restarted 8-10 ● When the Brakes Do not Work 8-11 ●...
Page 522 Isuzu Dealer. ADVICE • Any item for which there is a in the "Corrective action" column requires repairs and adjustments. Contact the nearest Isuzu Dealer. 2008N_sec08_print2.indd 2 4/09/2008 8:14:17 AM...
Page 523 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page Flat batteries Recharge or replace 8-12 After repairing corroded Battery terminals detached, section, connect the loose or corroded terminals firmly Starter ground wire After repairing corroded terminal detached, loose section, connect the or corroded terminals firmly Engine oil viscosity too...
Page 524 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page Engine not sufficiently Allow engine to warm up 4-63 warmed up sufficiently Excessive engine oil Correct oil level 7-22 White or black 7-50 exhaust smoke Air cleaner clogged Clean or replace element 7-52 Fuel system is faulty DPD is faulty...
Page 525 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page Parking brake not fully Make sure it is fully released released Brake dragging Adjust clutch free play (Manual transmission 7-104 model) Clutch slipping Add clutch fluid 7-109 (AMT Model) Not enough engine 7-50 power Air cleaner clogged...
Page 526 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page Wheel studs and nuts Tighten to the specified 7-96 loose torque Unbalanced inflation Adjust to proper inflation 7-74 Excessive play in the pressure in the tyres pressure steering wheel Unbalanced tyres Excessive steering wheel play Poor lubrication in the...
Page 527 IN CASE OF EMERGENCY When the Vehicle Breaks Down during Driving 1. Operate the hazard warning flasher and pull the vehicle immediately over to a safe place that doesn't impede traffic (shoulder, verge). Place the triangle reflectors to alert other traffic to the presence of your vehicle.
Page 528 IN CASE OF EMERGENCY When the Tyre Goes Flat When the tyre gets flat while driving, avoid hard braking, hold on to the steering wheel firmly and stop the vehicle. The tyre should be changed on a flat space to prevent obstructing other vehicles or pedestrians.
Page 529 If the engine cannot be started, promptly have the vehicle inspected and repaired by the nearest Isuzu Dealer. If the engine stopped because the vehicle ran out of fuel while driving, refueling alone will not be enough to restart the engine.
Page 530 8-10 IN CASE OF EMERGENCY When the Engine Stalls and Cannot be Restarted • In manual transmission models, place the gearshift lever in the "N" position and push the vehicle to a safe place. • In AMT vehicles, place the gearshift lever in the "N" position, and if the shift indicator shows "N", push the vehicle to a safe place.
Page 531 8-11 IN CASE OF EMERGENCY When the Brakes Do not Work If the brakes become ineffective unexpectedly, reduce speed by quickly shifting down from third to second to first gear using the gearshift lever. Gradually pull the parking brake lever while firmly holding on to the steering wheel.
Page 532 When connecting the cables, under no circumstances should the clips be allowed to touch each other. • Ask the nearest Isuzu Dealer to recharge the battery. • Do not disconnect a battery terminal with the engine running. It could cause a breakdown in the electrical system.
Page 533 8-13 IN CASE OF EMERGENCY NOTE • When it is difficult to start the engine in a cold area, first start the engine of the vehicle with the booster batteries and a few minutes after that start the engine of the disabled vehicle. WARNING •...
Page 534 8-14 IN CASE OF EMERGENCY When the Fuel Runs Out When the fuel runs out, air will enter the fuel system, so refueling alone will not be enough to restart the engine. Use the following methods to bleed the fuel system. WARNING •...
Page 535 8-15 IN CASE OF EMERGENCY Bleeding the Fuel System Before starting the engine 1. Place a container beneath the air bleeder plug to receive fuel, and then fully loosen the plug. 2. Operate the priming pump up and down about 20 times until the fuel from the bleeder plug no longer contains air bubbles.
Page 536 With the engine still running, turn off the exhaust brake switch. A problem in the exhaust brake system will be confirmed if the buzzer stops sounding several seconds later. Have your vehicle inspected by the nearest Isuzu Dealer. If the warning buzzer continues to sound, the problem will be in the brake booster for the foot (main) brake.
Page 537 → Refer to page 4-37 CAUTION • If this warning light comes on while the engine is running, immediately stop the vehicle in a safe place well clear of traffic and promptly contact the nearest Isuzu Dealer for inspection. 2008N_sec08_print2.indd 17 4/09/2008 8:14:22 AM...
Page 538 2. If the fan belt is loose, adjust the tension. MFU740SH004701 3. If there is no abnormality in the fan belt, contact the nearest Isuzu Dealer. Fan Belt → Refer to page 7-45 CAUTION • Do not drive the vehicle when the warning light is on. The battery can be discharged.
Page 539 Replace the oil filter. 4. When the oil level is normal and the oil filter is not clogged, but there are oil leaks, contact the nearest Isuzu Dealer. Engine Oil → Refer to page 7-22 Changing the Engine Oil and Oil Filter → Refer to page 7-28...
Page 540 • If there is an abnormality in seat belts with a pretensioner and the SRS airbag system, they may not work normally. Have the system checked by the nearest Isuzu Dealer. NOTE • It is normal for the warning light to come on, flash seven times, and then go out when the starter switch is placed in the "ON"...
Page 541 Since checking and repairing the control system is required, immediately contact the nearest Isuzu Dealer. HSA Indicator Light HSA Indicator Light → Refer to page 4-52 ABS Warning Light ABS Warning Light → Refer to page 4-37...
Page 542 8-22 IN CASE OF EMERGENCY When the Engine Overheats If engine power drops and the needle on the engine coolant temperature gauge goes up above the upper limit of the safety zone and enters the "H" zone, the engine is overheating.
Page 543 (red) is indicated on the multi information display (MID), there may be excessive battery discharge or the alternator may not be working properly. When this occurs, contact the nearest Isuzu Dealer. Voltmeter → Refer to page 4-22 2008N_sec08_print2.indd 23 4/09/2008 8:14:25 AM...
Page 544 Rear 10W (1-light type) License plate light 5W (2-light type) Rear fog light Dome light Interior Rear dome light Roof Roof-mounted clearance light Contact the nearest Isuzu Dealer when replacing lights that aren't listed here. 2008N_sec08_print2.indd 24 4/09/2008 8:14:25 AM...
Page 545 • Do not replace a bulb with other than the specified wattage. This will cause abnormal flashing, particularly for turn signal lights. • When replacing headlight bulbs, have the headlight aim adjusted at your Isuzu Dealer. Bulb Wattage → Refer to page 8-24 2008N_sec08_print2.indd 25...
Page 546 8-26 IN CASE OF EMERGENCY Halogen Headlight (NLR/NNR/NPR/NQR/NPS Models) 1. Remove the screw from the centre of the grille. Push up on the tabs of the five clips on the upper side of the grille and pull the grille toward you to remove it.
Page 547 8-27 IN CASE OF EMERGENCY 4. Disconnect the connector for the turn signal light and then remove the light. 5. Disengage the rubber seals from the two projections at the bottom of the headlight. Remove the four bolts. Then disconnect the connector for the headlight, remove the clearance light unit, and disconnect the headlight leveling connector.
Page 548 8-28 IN CASE OF EMERGENCY 6. Remove the rubber boot. Then push the right side of the clip that holds the bulb in place and slide it upwards to disengage the clip. 7. Pull off the bulb and replace with a new one.
Page 549 8-29 IN CASE OF EMERGENCY Replacing Clearance Lights, Turn Signal Lights, and Cornering Lights Replacing a Clearance Light (NLR/NNR/NPR/NQR/NPS Models) 1. Refer to "Replacing the Headlights" and remove the headlight assembly. Replacing the Headlights → Refer to page 8-25 2. Pull the bulb out from the clearance light socket and replace with a new one.
Page 550 8-30 IN CASE OF EMERGENCY Replacing a Turn Signal Light (NLR/NNR/NPR/NQR/NPS Models) 1. While referring to "Replacing the Headlights", tilt the turn signal light unit down toward the front of the vehicle and remove it. Replacing the Headlights → Refer to page 8-25 2.
Page 551 8-31 IN CASE OF EMERGENCY Replacing a Cornering Light Side Turn Signal Light (NLR/NNR/NPR/NQR/NPS Models) 1. Open the front door, remove the rubber cap in the lower part of the door, and loosen the nut. 2. While sliding the cornering light or side turn signal light toward the front of the vehicle, turn it to expose the rear part of the light.
Page 552 8-32 IN CASE OF EMERGENCY 4. Loosen the socket by turning it counterclockwise. 5. Pull the bulb out from the socket and replace with a new one. 6. To install the lights, perform the same sequence of operations in reverse taking care of the following points: a.
Page 553 8-33 IN CASE OF EMERGENCY Replacing the Front Fog Light 1. Tilt and raise the cab. WARNING • Do not touch the lock on the cab support while the cab is tilted. If you touch it, the lock will release. CAUTION •...
Page 554 8-34 IN CASE OF EMERGENCY 3. Pull out the bulb and replace with a new one. ADVICE • Do not touch the glass of the bulb with your hand. Soiling the glass will cause the bulb to blow out. 4. To install the lights, perform the same sequence of operations in reverse taking care of the following points: •...
Page 555 8-35 IN CASE OF EMERGENCY Replacing the Rear Turn Signal Lights, Taillights, Stop Lights, and Back Up Lights 1. Loosen the screws and remove the lens. 2. Loosen the bulb by turning it counterclockwise while pressing on it. 3. To install the lights, follow the removal procedure in reverse.
Page 556 8-36 IN CASE OF EMERGENCY Replacing the Dome Light NLR/NNR/NPR/NQR/NPS Models 1. Remove the lens and pull out the bulb. 2. To install the lights, follow the removal procedure in reverse. Replacing the Roof-Mounted Clearance Light 1. Loosen the screws and remove the lens. 2.
Page 557 8-37 IN CASE OF EMERGENCY Replacing the Fuses and Relays When the lights won't come on or flash, or the equipment in the electrical system does not operate, check to see if a fuse has blown. The Location of Fuses and Relays The fuses and relays are located in the lower part of the instrument panel in the centre and in the left rear of the cab.
Page 558: Replacing Fuses
Do not use any other fuses than those designated. • Using fuses other than those specified could result in fire or damage to the equipment. • If the new fuses blow right away, contact the nearest Isuzu Dealer. 2008N_sec08_print2.indd 38 4/09/2008 8:14:33 AM...
Page 559 When the headlights and other devices in the electrical system do not work, but there is no problem with the fuses, check the slow-blow fuse. Replace the slow-blow fuse when it blows. Please contact the nearest Isuzu Dealer. Slow-blow fuses protect the electrical circuits, and they are installed so that they can be quickly replaced if there is a malfunction.
Page 560 8-40 IN CASE OF EMERGENCY Fuse and Relay Location Fuse locations: cab interior Description Rating Description Rating ELEC PTO (BATT) 18 IGNITION1 RR P/WINDOW 19 SRS ROOM LAMP, AUDIO 20 ECM DOOR LOCK 21 METER FOG LAMP 22 LAMPS (BATT) P/WINDOW 23 AUDIO, ACC 24 MIRROR...
Page 561 8-41 IN CASE OF EMERGENCY Relay locations: cab interior Description Description 12 POWER WINDOW STOP LAMP 13 HEAD LAMP (LOW) BLOWER MOTOR KEY ON 14 4WD DOOR LOCK (LOCK) 15 HEAD LAMP (HIGH) REAR FOG LAMP 16 TAIL LAMP WIPER MAIN 17 PTO SOLENOID, M/T HORN 18 PTO CUT...
Page 562 8-42 IN CASE OF EMERGENCY Fuse and relay locations: cab exterior Relay name Fuse name Rating STARTER MARKER LAMP ECM MAIN GLOW PLUG BATTERY A/C COMPRESSOR CONDENSER FAN STARTER CUTOFF MARKER LAMP GEARSHIFTER 4WD (4HK1 ENGINE MODEL) TRANSFER GEAR CONTROL 2008N_sec08_print2.indd 42 4/09/2008 8:14:35 AM...
Page 563 8-43 IN CASE OF EMERGENCY When Your Vehicle is Involved in an Accident Stay calm and take the following steps: 1. Avoid a chain of accidents Operate the hazard warning flasher, pull the vehicle immediately over to a safe place that doesn't impede traffic (shoulder, verge) and stop the engine. 2.
Page 564 8-44 IN CASE OF EMERGENCY When Towing To move a disabled vehicle, it is best to rely on someone in the wrecker or tow truck business. If that is not possible, follow these procedures. When towing, use appropriate equipment and comply with local legal requirements. Do not try to start the engine by towing or pushing the vehicle.
Page 565 8-45 IN CASE OF EMERGENCY When it is possible to operate the steering wheel, the vehicle can be towed with all wheels on the ground. However, the power steering will not be able to provide any power assist when the engine cannot be started.
Page 566 8-46 IN CASE OF EMERGENCY Front 1. If the vehicle is towing or being towed, firmly attach a rope to the front or rear towing hook on the same side. 2. During towing, carefully watch the stop lights of the towing vehicle in order to prevent the rope from becoming slack.
Page 567 8-47 IN CASE OF EMERGENCY ADVICE • In the case of a four wheel drive (4WD) model, set the 4WD switch to "OFF" before towing. Failure to do so could cause the brakes to activate during towing. [Contact a tow truck at these times] •...
Page 568 8-48 IN CASE OF EMERGENCY 2008N_sec08_print2.indd 48 4/09/2008 8:14:37 AM...
Page 569: Main Data
MAIN DATA ● Main Data and Specifications 2008N_sec09_print2.indd 1 4/09/2008 8:19:25 AM...
Page 570 MAIN DATA Main Data and Specifications Engine 4JJ1 Engine Model Specifications Water-cooled, overhead camshaft, direct injection engine with an inter-cooled turbocharger Compression ratio (to 1) 17.5 Displacement cc (cu. in) 2,999 (183.0) Firing order 1-3-4-2 Fuel injection timing (static) degree 0° Valve clearance mm (in) Both intake and exhaust valves: 0.15 (0.006) in cold engine Idling speed...
Page 571 MAIN DATA 4HK1 Engine Model Specifications Water-cooled, overhead camshaft, direct injection engine with an inter-cooled turbocharger Compression ratio (to 1) 17.5 Displacement cc (cu. in) 5,193 (317) Firing order 1-3-4-2 Fuel injection timing (static) degree 0° Valve clearance mm (in) Both intake and exhaust valves: 0.4 (0.016) in cold engine Idling speed r/min...
Page 572 MAIN DATA MYY6S Model (including AMT) Specifications Six-speed transmission (overdrive gear for 6th), synchromesh for 2nd to 6th Gear ratio (to 1) 5.979 3.434 1.862 1.297 1.000 0.759 Reverse 5.701 Transmission oil capacity [Reference value] Model without PTO: 3.5 (0.92/0.77) litres (US gal./lmp gal.) Model with PTO: 3.8 (1.00/0.84) AMT clutch oil capacity [Reference value] litres (US gal./lmp gal.)
Page 573 MAIN DATA ● Main Data and Specifications 2008N_sec09_print2.indd 1 4/09/2008 8:19:25 AM...
Page 574 MAIN DATA Main Data and Specifications Engine 4JJ1 Engine Model Specifications Water-cooled, overhead camshaft, direct injection engine with an inter-cooled turbocharger Compression ratio (to 1) 17.5 Displacement cc (cu. in) 2,999 (183.0) Firing order 1-3-4-2 Fuel injection timing (static) degree 0° Valve clearance mm (in) Both intake and exhaust valves: 0.15 (0.006) in cold engine Idling speed...
Page 575 MAIN DATA 4HK1 Engine Model Specifications Water-cooled, overhead camshaft, direct injection engine with an inter-cooled turbocharger Compression ratio (to 1) 17.5 Displacement cc (cu. in) 5,193 (317) Firing order 1-3-4-2 Fuel injection timing (static) degree 0° Valve clearance mm (in) Both intake and exhaust valves: 0.4 (0.016) in cold engine Idling speed r/min...
Page 576 MAIN DATA MYY6S Model (including AMT) Specifications Six-speed transmission (overdrive gear for 6th), synchromesh for 2nd to 6th Gear ratio (to 1) 5.979 3.434 1.862 1.297 1.000 0.759 Reverse 5.701 Transmission oil capacity [Reference value] Model without PTO: 3.5 (0.92/0.77) litres (US gal./lmp gal.) Model with PTO: 3.8 (1.00/0.84) AMT clutch oil capacity [Reference value] litres (US gal./lmp gal.)
Page 577: Combination Light Control Switch
10-1 INDEX Air Cleaner 7-47 Daily Checks (Preoperational Checks) 7-16 Diesel Particulate Defuser (DPD) Air Conditioning Filters 7-144 2-60, 4-154, 7-58 Air Outlets Disc Brakes 7-73 AMT Clutch Oil 7-109 Discarded Parts, Oils and Other Liquids 7-6 2.41 Driving 2-30 Antenna 5-31 Driving Safely and with Confidence...
Page 578: Idling Control Knob
5-20 Precautions for Checking and Interior Maintenance 7-151 Adjustments Interior (PICTORIAL INDEX) 0-11 Preventing Breakdowns 2-44 Isuzu Genuine Oils and Grease Rear Axle Differential Gear Oil 7-112 Rear Fog Light Switch 4-68 Key with Immobilizer Transponder Refrigerant 7-146 Chip Remote Control Mirror Switch...
Page 579: Airbag
Tools during Driving Transfer Gear Case Oil 7-117 When the Warning Light Comes On 8-16 Transmission Oil 7-105 When to Visit Your Isuzu Dealer 2-58 Troubleshooting When Towing 8-43 When Your Vehicle is Involved in an Accident 8-42 Using Tyre Chains...
Page 580 MEMO 2008N_sec10_print2.indd 4 4/09/2008 8:20:28 AM...

Isuzu N Series 2008 Owner's Manual

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