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Isuzu FTR Manual

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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.
CAUTION
Failure to follow these instructions identified by this symbol could result in injuries
or an accident.
ADVICE
Failure to follow these instructions identified by this symbol could cause
malfunction or damage to your vehicle.
NOTE
This symbol identifies information that you need to know.
This symbol also identifies information that would be useful for operating the
vehicle.
The following symbols are also used in this manual.
•
: Market-/type-specific equipment (Your vehicle may not have the equipment
V
with this symbol.)
4612811̲sec00̲PICTORIAL INDEX.in1   1
4612811̲sec00̲PICTORIAL INDEX.in1   1
Symbols Used in This Manual
2016/03/16   11:36:56
2016/03/16   11:36:56

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Do you have a question about the FTR and is the answer not in the manual?

Questions and answers

Mike Davis
March 20, 2025

How does the two tank fuel system work on my 1999 FTR?

0
1 comments:
Mr. Anderson
March 20, 2025

The two-tank fuel system on a 1999 Isuzu FTR works by allowing fuel to move between tanks due to the difference in fuel levels. The system relies on gravity or pressure differences to balance fuel distribution. It is recommended to refill the tanks sufficiently or close the fuel tank taps before idling the engine or driving on steep slopes to ensure proper fuel flow and prevent issues.

This answer is automatically generated

0

Related Manuals for Isuzu FTR

Summary of Contents for Isuzu FTR

  • Page 1 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 2 Abbreviations This manual uses the following abbreviations, as interpreted below. Abbreviations Description Air Conditioner Antilock Brake System Association des Constructeurs Europeens d'Automobiles ACEA (Association of European Automobile Constructors) American Petroleum Institute ASTM American Society for Testing and Materials British Standards Deutsche Industrie Normen Emergency Locking Retractor ETRTO...
  • Page 3 HOW TO USE THIS MANUAL AND HOW TO FIND A SPECIFIC TOPIC ● HOW TO USE THIS MANUAL ● HOW TO FIND A SPECIFIC TOPIC ● CHAPTERS IN THIS MANUAL ● PICTORIAL INDEX ● WARNING/INDICATOR LIGHT INDEX 0-13 ● WARNING/CAUTION LABELS 0-15 4612811̲sec00̲PICTORIAL INDEX.in0-1   0-1 4612811̲sec00̲PICTORIAL INDEX.in0-1   0-1...
  • Page 4 HOW TO USE THIS MANUAL Chapter index tab Chapter/section titles Use this for quick access to These titles are useful for getting the gist of your desired chapter. the content descriptions that follow at a glance. 2-42 IMPORTANT INFORMATION Preventing Breakdowns Do not Rest Your Foot on the Clutch Pedal While Driving ADVICE •...
  • Page 5 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 CHAPTERS IN THIS MANUAL, the CHAPTER INDEX, and/or the TABLE OF CONTENTS on the first page of each chapter.
  • Page 6 4612811̲sec00̲PICTORIAL INDEX.in0-4   0-4 4612811̲sec00̲PICTORIAL INDEX.in0-4   0-4 2016/03/16   11:36:57 2016/03/16   11:36:57...

  • Page 7: Table Of Contents

    CHAPTERS IN THIS MANUAL PICTORIAL INDEX ··································· 0-6 VEHICLE INFORMATION ···························· 1 IMPORTANT INFORMATION ······················ 2 Describes what you should know before you can operate the vehicle safely and smoothly. DOORS, WINDOWS AND SEATS ··············· 3 Shows the proper way to open/close the doors, windows and fuel filler cap. Also explains how to adjust the mirrors and seats including how to correctly fasten the seat belts.

  • Page 8: Pictorial Index

    PICTORIAL INDEX Interior Right-hand drive 10 9 Equipment Page Equipment Page Idling control knob 4-30 Air flow direction control lever Small article storage pocket 5-19 Front lid lever Cigarette lighter 5-16 Manual air conditioner/ cooler Card holder 5-19 10 Hook 5-24 Windshield wiper and 4-39...
  • Page 9 PICTORIAL INDEX Left-hand drive Equipment Page Equipment Page Air flow direction control lever Combination light control 4-32 switch Small article storage pocket 5-19 Idling control knob 4-30 Manual air conditioner/ cooler Front lid lever AM/FM Radio 5-26 Cigarette lighter 5-16 10 Card holder 5-19 CD player...
  • Page 10 PICTORIAL INDEX Right-hand drive Equipment Page Equipment Page Horn button 4-41 Instruments, warning lights and indicator lights 4-15 Hazard warning flasher 4-35 switch Front fog light switch 4-35 PTO switch 4-58 Inter-differential lock 4-38 switch 4612811̲sec00̲PICTORIAL INDEX.in0-8   0-8 4612811̲sec00̲PICTORIAL INDEX.in0-8   0-8 2016/03/16   11:36:58 2016/03/16   11:36:58...
  • Page 11 PICTORIAL INDEX Left-hand drive Equipment Page Equipment Page Horn button 4-41 Instruments, warning lights and indicator lights 4-15 Hazard warning flasher 4-35 switch Front fog light switch 4-35 PTO switch 4-58 Headlight leveling 4-34 switch 4612811̲sec00̲PICTORIAL INDEX.in0-9   0-9 4612811̲sec00̲PICTORIAL INDEX.in0-9   0-9 2016/03/16   11:36:59 2016/03/16   11:36:59...
  • Page 12 0-10 PICTORIAL INDEX Equipment Page Equipment Page Seat belts 3-21 Seats 3-12 Center console box 5-21 Dome light 5-15 Overhead shelf 5-22 Parking brake lever 4-45 10 Gearshift lever 4-47 Sun visor 5-16 Inside mirror 3-18 Fully adjustable steering 3-17 Seatback pocket (driver's 5-19 side)
  • Page 13 0-11 PICTORIAL INDEX Exterior FTR/FVZ/FVM model Equipment Page Equipment Page Outside mirrors 3-19 Headlight 8-20 Turn signal light 8-20 Clearance light 8-20 Wheels and tires 7-62 Front fog light 8-20 4612811̲sec00̲PICTORIAL INDEX.in0-11   0-11 4612811̲sec00̲PICTORIAL INDEX.in0-11   0-11 2016/03/16   11:36:59 2016/03/16   11:36:59...
  • Page 14 0-12 PICTORIAL INDEX FVR model Equipment Page Equipment Page Outside mirrors 3-19 Headlight 8-20 Turn signal light 8-20 Clearance light 8-20 Wheels and tires 7-62 Front fog light 8-20 4612811̲sec00̲PICTORIAL INDEX.in0-12   0-12 4612811̲sec00̲PICTORIAL INDEX.in0-12   0-12 2016/03/16   11:36:59 2016/03/16   11:36:59...
  • Page 15 0-13 WARNING/INDICATOR LIGHT INDEX Warning/Indicator Light Index Instrument Panel Warning Lights Name Symbol Color Page Check engine warning light Amber 4-21 Engine overheat warning light 4-19 ABS warning light Amber 4-18 Generator warning light 4-20 Air pressure warning light 4-17 Water separator (fuel filter) warning light 4-22 Parking brake warning light...
  • Page 16 0-14 WARNING/INDICATOR LIGHT INDEX Indicator Lights Name Symbol Color Page High beam indicator light Blue 4-23 Exhaust brake indicator light Green 4-24 Inter-differential lock indicator light Amber 4-25 Turn signal and hazard warning flasher Green 4-23 indicator light – left Turn signal and hazard warning flasher Green 4-23...
  • Page 17 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. • These warning/caution labels only concern the vehicle, not any additional installation.
  • Page 18 0-16 WARNING/CAUTION LABELS Warning/Caution Labels – Cab Interior Driver's door Dashboard Towing Fuses and relays Center console Trailer hand brake 4612811̲sec00̲PICTORIAL INDEX.in0-16   0-16 4612811̲sec00̲PICTORIAL INDEX.in0-16   0-16 2016/03/16   11:37:01 2016/03/16   11:37:01...
  • Page 19 0-17 WARNING/CAUTION LABELS Warning/Caution Labels – Cab Exterior Inside the front lid Left rear side of the cab Windshield wiper Cab tilt 4612811̲sec00̲PICTORIAL INDEX.in0-17   0-17 4612811̲sec00̲PICTORIAL INDEX.in0-17   0-17 2016/03/16   11:37:02 2016/03/16   11:37:02...
  • Page 20 0-18 WARNING/CAUTION LABELS Warning/Caution Labels – Engine Compartment Radiator cap 4612811̲sec00̲PICTORIAL INDEX.in0-18   0-18 4612811̲sec00̲PICTORIAL INDEX.in0-18   0-18 2016/03/16   11:37:02 2016/03/16   11:37:02...

  • Page 21: Vehicle Information

    VEHICLE INFORMATION ● Vehicle Identification Number (VIN) and Engine Numbers 4612811̲sec01̲VEHICLE INFORMATIO1-1   1-1 4612811̲sec01̲VEHICLE INFORMATIO1-1   1-1 2016/03/04   10:35:12 2016/03/04   10:35:12...
  • Page 22 Vehicle Identification Number (VIN) and Engine Numbers The VIN and engine number 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 23 F T R 3 4 L G Section Description World Manufacturer Identifier (WMI) Vehicle model code FTR: 4 × 2 truck or tractor FVR: 4 × 2 truck FVZ: 6 × 4 truck FVM: 6 × 2 truck Engine code...
  • Page 24 6.143 (43/7) mounted 17.5-inch, 24V-90A generator gear ratio: 5.571 (39/7) 24V-60A generator ADVICE • There are more option codes than those indicated above. For detailed specifications of your vehicle, please ask your Isuzu Dealer. 4612811̲sec01̲VEHICLE INFORMATIO1-4   1-4 4612811̲sec01̲VEHICLE INFORMATIO1-4   1-4 2016/03/04   10:35:13 2016/03/04   10:35:13...
  • Page 25 VEHICLE INFORMATION Engine Number The engine number is stamped on the right top area of the cylinder block. Front 4612811̲sec01̲VEHICLE INFORMATIO1-5   1-5 4612811̲sec01̲VEHICLE INFORMATIO1-5   1-5 2016/03/04   10:35:13 2016/03/04   10:35:13...
  • Page 26 VEHICLE INFORMATION 4612811̲sec01̲VEHICLE INFORMATIO1-6   1-6 4612811̲sec01̲VEHICLE INFORMATIO1-6   1-6 2016/03/04   10:35:13 2016/03/04   10:35:13...

  • Page 27: Important Information

    2-17 ● Stopping and Parking 2-31 ● Staying Safe 2-37 ● Preventing Breakdowns 2-42 ● When to Visit an Isuzu Dealer 2-44 ● Speed Limit Device 2-47 ● Vehicle Data Collection 2-48 This chapter contains information and cautions that you should observe for safe and comfortable vehicle operation.
  • Page 28 Isuzu Dealer before it is driven again. [1. Checking where there was an abnormality the previous time the vehicle was...
  • Page 29 IMPORTANT INFORMATION [3. Checks to perform in the driver's seat] Check item Reference page Operation of meters, gauges and warning/indicator lights 4-8, 4-15 Engine start ability, abnormal noise and color of exhaust emissions 7-20 Brake pedal free play 7-58 Exhaust sound from brake valve 7-58 Increase in air pressure 7-56...
  • Page 30 IMPORTANT INFORMATION Use the Specified Fuel CAUTION • Be sure to use diesel fuel. If you supply the vehicle with poor-quality fuel, water-removal additive or other additive, gasoline, kerosene or alcohol-based fuel, it could harm the fuel filter, prevent proper movement of fuel-lubricated parts in the injectors and adversely affect engine components, possibly resulting in a breakdown.
  • Page 31 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 32 IMPORTANT INFORMATION Load Cargo Correctly WARNING • Overloading can result in an accident because it places too much strain on the wheel bolts 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 33 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 34 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, retaining it too tightly can damage the cargo bed's gates and front guard frame.
  • Page 35 IMPORTANT INFORMATION Economical Driving Driving too fast, driving so slowly that the engine knocks, driving with the exhaust brake switched on all the time, and frequently using the exhaust brake to adjust your speed lead to poor fuel economy. To the greatest extent possible, drive at a constant speed.
  • Page 36 2-10 IMPORTANT INFORMATION Do Not Carry Fuel and Spray Cans in the Cab WARNING • It is extremely dangerous to carry fuel and spray cans in the cab. If such a container were to ignite or rupture, it could cause a fire or explosion.
  • Page 37 2-11 IMPORTANT INFORMATION Correct Driving Posture WARNING • Before driving, be sure to adjust the seat, steering wheel and mirrors to positions that give you a correct driving posture. Make sure the seat is securely retained by trying to rock it forward and backward, and put on the seat belt. All other passengers must wear seat belts.
  • Page 38 2-12 IMPORTANT INFORMATION Fastening Your Seat Belt 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. Latch plate Buckle Keep as low on hips as possible Seat adjustment recommendations Make adjustments that allow you to...
  • Page 39 2-13 IMPORTANT INFORMATION Passengers and Seat Belts Only one person 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 40 2-14 IMPORTANT INFORMATION Carrying an Expectant Mother or a Person Who is Ill WARNING Shoulder belt portion • An expectant mother or a person who is ill riding in the vehicle must also wear a seat belt. In light of Lap belt portion the risk that the seat belt will apply pressure to the abdomen, chest and...
  • Page 41 2-15 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 42 2-16 IMPORTANT INFORMATION Do not Leave a Child Alone in the Vehicle WARNING • When you leave the vehicle, take the child with you. If you leave the child alone in the cab, the child could interfere with things, causing vehicle movement, a fire or some other accident.
  • Page 43 2-17 IMPORTANT INFORMATION An Adult must Open, Close, and Lock the Door for a Child WARNING • To protect the child from the danger of getting his/her hands and head trapped, an adult must open, close and lock the door for the child. Be careful that the child does not interfere with the power window switches and get his/her hands or...
  • Page 44 Inspect the exhaust pipe from time to time. If you notice any abnormality (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 45 2-19 IMPORTANT INFORMATION Starting the Engine CAUTION • Make sure the parking brake lever is firmly pulled, make sure the gearshift lever is in "N", and fully press the clutch pedal before starting the engine. • Be sure to sit in the driver's seat to start the engine.
  • Page 46 2-20 IMPORTANT INFORMATION If the Vehicle Has Not Been Driven for a Long Period ADVICE • Before using a vehicle that has not been driven for a long period, check the engine and transmission for oil leakage, and make sure the oil is at the required levels.
  • Page 47 2-21 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. Start and warm up the engine only in places that have good ventilation. Do not Forget to Release the Parking Brake ADVICE •...
  • Page 48 2-22 IMPORTANT INFORMATION Pulling Away in a Manual Transmission Model ADVICE • Pull away gently in the gear indicated below. Pulling away in a high gear, pulling away rapidly or slipping the clutch for a long time while pulling away would damage the clutch.
  • Page 49 2-23 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 50 2-24 IMPORTANT INFORMATION NOTE [What is engine brake?] • Engine brake is the braking effect that occurs when you release the accelerator pedal while driving. The lower the gear, the stronger the engine brake. Never Stop the Engine While Driving WARNING LOCK •...
  • Page 51 2-25 IMPORTANT INFORMATION Do not Use the Bed While the Vehicle is Moving CAUTION • It is not possible to hold a person's body in position on the bed. Using the bed while the vehicle is moving would be dangerous because the occupant of the bed could be thrown out of the bed in the event of a collision or hard braking.
  • Page 52 2-26 IMPORTANT INFORMATION NOTE [What is engine brake?] • Engine brake is the braking effect that occurs when you release the accelerator pedal while driving. The lower the gear, the stronger the engine brake. [What is the exhaust brake?] • The exhaust brake is a system that closes the exhaust pipe and uses the force of the exhaust emissions to enhance the effectiveness of engine brake.
  • Page 53 2-27 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 54 If the vehicle must be driven on a flooded road or is parked in an area that becomes flooded, promptly have your Isuzu Dealer perform a check for the following points: Effectiveness of the brakes Water-ingress or damage to drum...
  • Page 55 2-29 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 56 If any part of the vehicle is damaged or broken, promptly have the vehicle inspected and repaired by the nearest Isuzu Dealer.
  • Page 57 2-31 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 58 2-32 IMPORTANT INFORMATION Parking Safely on a Slope CAUTION • As much as possible, choose level places to park and avoid parking on slopes. If you cannot avoid parking on a slope, firmly apply the parking brake and make sure the vehicle does not move.
  • Page 59 2-33 IMPORTANT INFORMATION Napping in the Vehicle WARNING Before taking a nap in the vehicle, be sure to stop the engine and place the starter switch in the "LOCK" position. Otherwise, any unintended contact with the gearshift lever or accelerator pedal while you are asleep could cause the vehicle to move, resulting in an accident.
  • Page 60 2-34 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, grass, waste paper, oil or old tires).
  • Page 61 2-35 IMPORTANT INFORMATION Do not Touch the Gearshift Lever While the Vehicle is Stationary 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 parking brake applied.
  • Page 62 2-36 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 63 2-37 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 it is safe to pull away after a temporary stop (at traffic lights, for...
  • Page 64 2-38 IMPORTANT INFORMATION When the Muffler and Exhaust Pipe are Hot CAUTION • When the engine is running and immediately after vehicle operation, the muffler and exhaust pipe are extremely hot. Be careful not to inadvertently touch them when working near them (for example, tilting the cab or operating an attachment).
  • Page 65 2-39 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 66 2-40 IMPORTANT INFORMATION Using the Jack WARNING • Jacking up a vehicle on a 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 67 2-41 IMPORTANT INFORMATION If the Battery Goes Flat CAUTION • Do not try to start the engine by pushing or towing the vehicle. You could damage the engine. When the Battery Goes Flat → Refer to page 4612811̲sec02̲IMPORTANT INFORMAT2-41   2-41 4612811̲sec02̲IMPORTANT INFORMAT2-41   2-41 2016/03/10   14:35:26 2016/03/10   14:35:26...
  • Page 68 2-42 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 69 2-43 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 70 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 an Isuzu Dealer CAUTION •...
  • Page 71 Careless electric welding of vehicle parts can cause welding current to flow back through the vehicle's ground circuit and damage electrical and electronic parts so that they do not function normally. Whenever electric welding is necessary, consult your Isuzu Dealer. Replacing Tires and Wheels CAUTION •...
  • Page 72 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. 4612811̲sec02̲IMPORTANT INFORMAT2-46   2-46 4612811̲sec02̲IMPORTANT INFORMAT2-46   2-46 2016/03/10   14:35:28...
  • Page 73 The speed limit device does not control braking, so it is possible for the vehicle to exceed the set speed on downhill slopes. • If the tire size is changed, the speed limit device may not work normally. Have adjustments made by the nearest Isuzu Dealer. 4612811̲sec02̲IMPORTANT INFORMAT2-47   2-47 4612811̲sec02̲IMPORTANT INFORMAT2-47   2-47 2016/03/10   14:35:28...
  • Page 74 Some of the information may be stored during the regular operations to facilitate repair of detected malfunctions. Isuzu may download and retrieve stored information for the purpose of diagnosing, servicing, and repairing your motor vehicle or further improvement to future Isuzu motor vehicles.
  • Page 75 DOORS, WINDOWS AND SEATS ● Key ● Opening and Closing Doors ● Getting In and Out of the Vehicle ● Power Windows ● Manually Operated Windows ● Fuel Tank ● Seats 3-12 ● Fully Adjustable Steering 3-17 ● Mirrors 3-18 ●...
  • Page 76 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 your Isuzu Dealer. The Isuzu Dealer will be able to duplicate your key. •...
  • Page 77 DOORS, WINDOWS AND SEATS Opening and Closing Doors CAUTION • Be sure to do the following whenever you leave the vehicle: 1) Fully engage the parking brake. 2) Stop the engine. 3) Lock the doors. • When you close the door after sitting behind the steering wheel, check that the door is fully closed.
  • Page 78 DOORS, WINDOWS AND SEATS Locking and Unlocking the Door from Inside Push the lock button forward to lock the door; pull the lock button backward to unlock it. Lock button Lock Unlock Locking the Door from Outside without Using the Key Lock button First, push the lock button on the inside door handle forward and then close the...
  • Page 79 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. Opening and Closing the Front Doors Opening and Closing the Door from Outside...
  • Page 80 DOORS, WINDOWS AND SEATS Getting In and Out of the Vehicle Type 1 Carefully check that the area around the vehicle is safe, hold the grip, and place Grip your foot on the step or wheel step ring when getting in or out of the vehicle. CAUTION •...
  • Page 81 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 82 DOORS, WINDOWS AND SEATS Window Switch on Passenger's Door Passenger side CAUTION • 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 OPEN CLOSE window.
  • Page 83 DOORS, WINDOWS AND SEATS Fuel Tank 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 84 3-10 DOORS, WINDOWS AND SEATS Emergency Fuel Tank If the taps of the fuel tanks are open and Close only a small quantity of fuel remains in the tanks, you should be warned while idling the engine or driving on a steep slope. The engine can become starved of fuel because the fuel moves between tanks due Open...
  • Page 85 3-11 DOORS, WINDOWS AND SEATS Opening and Closing the Fuel Tank Filler Cap (with Key Lock) 1. Eliminate static from your body before Unlock opening the fuel tank filler cap. Open 2. Open the cover, then firmly insert the key and turn it to "OPEN" position. Cover 3.
  • Page 86 3-12 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 87 Take the vehicle to your Isuzu Dealer for service if you find that your seat adjusters do not latch. In addition, the seat belt will not operate properly if the seatback is not completely locked.
  • Page 88 3-14 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 89 3-15 DOORS, WINDOWS AND SEATS Passenger's Seat Reclining Adjustment To recline the seatback, raise the seatback Seatback tilt lever and gently lean back to the desired position. To move the seatback forward, lean forward with your back slightly clear of the seatback and raise the lever.
  • Page 90 3-16 DOORS, WINDOWS AND SEATS Center Seat If the center seat is not occupied, fold its seatback forward by using the lever positioned in the side of the center seat. CAUTION • As with the driver, the passenger must also have a correctly fastened seat belt during driving, in case his/her body should undergo dangerously strong force from a...
  • Page 91 3-17 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 92 3-18 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 93 3-19 DOORS, WINDOWS AND SEATS Outside Mirrors Door-mounted Mirrors After properly adjusting your seat for proper driving position, adjust the mirrors indicated below so that they provide adequate views for checking the rear, the side and the areas just in front and immediately to the side of the vehicle by moving each of the mirrors.
  • Page 94 3-20 DOORS, WINDOWS AND SEATS Pillar-mounted Mirrors After properly adjusting your seat for proper driving position, adjust the mirrors indicated below so that they provide adequate views for checking the rear, the side and the areas just in front and immediately to the side of the vehicle by moving each of the mirrors.
  • Page 95 Instead, use an appropriate child restraint system available on the market. For further details, please contact your Isuzu Dealer. WARNING (Continued) 4612811̲sec03̲DOORS, WINDOWS AND3-21   3-21 4612811̲sec03̲DOORS, WINDOWS AND3-21   3-21...
  • Page 96 If your vehicle has been involved in a collision, the seat belts worn at the time may have lost their original strength due to impact even if they appear intact. These seat belts must be inspected and, if necessary, replaced by your Isuzu Dealer.
  • Page 97 3-23 DOORS, WINDOWS AND SEATS Three-Point Seat Belts Every seat except the center seat on your vehicle is equipped with a three-point seat belt. The seat belt extends or retracts freely if the wearer moves slowly, but it locks and restrains the occupant during forward force caused in the occupant's body following a strong shock.
  • Page 98 3-24 DOORS, WINDOWS AND SEATS ADVICE • While being automatically retracted, the seat belt could damage a nearby window or interior trim unless the latch plate is properly held. Hold the latch plate to ensure that the belt is taken up slowly. •...
  • Page 99 3-25 DOORS, WINDOWS AND SEATS Two-Point Seat Belt (Center 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.) Right angle 3.

  • Page 100: Doors, Windows And Seats

    3-26 DOORS, WINDOWS AND SEATS To Unfasten Push the button on the buckle to unfasten the belt. NOTE [Center seat belt design to prevent Button incorrect fastening] Buckle • The center seat belt (length- adjustable two-point belt) is Latch plate Buckle designed so that it cannot be connected with any of the window-...
  • Page 101 CONTROLS AND INSTRUMENTS STARTING AND STOPPING THE ENGINE INSTRUMENTS, WARNING LIGHTS AND INDICATOR LIGHTS 4-27 SWITCHES 4-43 DRIVING CONTROLS 4612811̲sec04̲CONTROLS AND INSTR4-1   4-1 4612811̲sec04̲CONTROLS AND INSTR4-1   4-1 2016/03/04   10:58:13 2016/03/04   10:58:13...
  • Page 102 4612811̲sec04̲CONTROLS AND INSTR4-2   4-2 4612811̲sec04̲CONTROLS AND INSTR4-2   4-2 2016/03/04   10:58:14 2016/03/04   10:58:14...
  • Page 103 CONTROLS AND INSTRUMENTS STARTING AND STOPPING THE ENGINE ● Starting the Engine ● Stopping the Engine 4612811̲sec04̲CONTROLS AND INSTR4-3   4-3 4612811̲sec04̲CONTROLS AND INSTR4-3   4-3 2016/03/04   10:58:14 2016/03/04   10:58:14...
  • Page 104 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 105: Controls And Instruments

    CONTROLS AND INSTRUMENTS 1. Fully press the clutch pedal. 2. Turn the starter switch to the "ON" position. 3. Then turn the starter switch to the "START" position to start the engine. Use the idling control knob to stabilize the engine speed when the engine runs rough during warm-up.
  • Page 106 CONTROLS AND INSTRUMENTS Stopping the Engine Firmly apply the parking brake. With the accelerator pedal released, turn the starter switch to the "ACC" or "LOCK" position. ADVICE • Do not shut down the engine immediately after a driving the vehicle. Otherwise, seizure or other failures may result.
  • Page 107 CONTROLS AND INSTRUMENTS INSTRUMENTS, WARNING LIGHTS AND INDICATOR LIGHTS ● How to Read the Instruments (Instruments Layout) ● Speedometer ● Analog Tachograph 4-10 ● Tachometer 4-11 ● Air Pressure Gauge 4-12 ● Engine Coolant Temperature Gauge 4-13 ● Fuel Gauge 4-14 ●...
  • Page 108 CONTROLS AND INSTRUMENTS How to Read the Instruments (Instruments Layout) Reference Reference Name Name page page Tachometer 4-11 Fuel gauge 4-14 Speedometer Air pressure gauge 4-12 Odometer/Trip meter Engine coolant 4-13 temperature gauge Analog tachograph 4-10 4612811̲sec04̲CONTROLS AND INSTR4-8   4-8 4612811̲sec04̲CONTROLS AND INSTR4-8   4-8 2016/03/04   10:58:15 2016/03/04   10:58:15...
  • Page 109 CONTROLS AND INSTRUMENTS Speedometer The speedometer indicates the vehicle Speedometer speed in km/h. Each time you press the select / reset button lightly with the starter switch in the "ON" position, the odometer / trip meter shows "ODO", "TRIP A" and "TRIP B"...
  • Page 110 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" position. • You can set the odometer to display on the odometer / trip meter each time you turn the starter switch to the "ON"...
  • Page 111 4-11 CONTROLS AND INSTRUMENTS Tachometer The tachometer indicates the engine speed Green zone in revolution per minute (r/min). (Graduation "1" on the scale indicates 100 r/min.) The green zone indicates a range for economic Red zone driving. The red zone indicates a range of dangerous engine speeds beyond permissible levels.
  • Page 112 If air pressure will not increase, or there is a great difference between the readings of the two gauges, or it takes time for the needles to go up, contact the nearest Isuzu Dealer. Checking Air Pressure → Refer to page 7-56 WARNING •...
  • Page 113 4-13 CONTROLS AND INSTRUMENTS Engine Coolant Temperature Gauge With the starter switch in the "ON" position, Safety zone 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 and a warning buzzer sounds.
  • Page 114 4-14 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 115 4-15 CONTROLS AND INSTRUMENTS Warning and Indicator Lights Layout 15 17 4612811̲sec04̲CONTROLS AND INSTR4-15   4-15 4612811̲sec04̲CONTROLS AND INSTR4-15   4-15 2016/03/04   10:58:17 2016/03/04   10:58:17...
  • Page 116 4-16 CONTROLS AND INSTRUMENTS Reference Reference Name Name page page Check engine warning Low range indicator 4-21 4-25 light light PTO indicator light 4-25 Water separator (fuel 4-22 filter) warning light Exhaust brake indicator 4-24 light Engine overheat warning 4-19 light Trailer brake 4-21...
  • Page 117 4-17 CONTROLS AND INSTRUMENTS Warning and Indicator Lights Seat Belt Warning Light This warning light comes on when the driver is not wearing the seat belt while the starter switch is in the "ON" position. NOTE • This warning light goes out as soon as the driver buckles the seat belt.
  • Page 118 • If the warning light does not go out, or comes on repeatedly, have the vehicle inspected / serviced at the nearest Isuzu Dealer as soon as possible. • If the ABS has a problem, the brakes still function normally as ordinary service brakes.
  • Page 119 4-19 CONTROLS AND INSTRUMENTS Engine Overheat Warning Light This warning light comes on when the engine has overheated. When the engine overheats, the engine coolant temperature gauge needle moves to the red zone, and the engine overheat warning light comes on and at the same time a buzzer sounds.
  • Page 120 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 7-42 Handling the Battery →...
  • Page 121 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. Trailer Brake Warning Light Semi-tractor or Full-tractor When the trailer hand brake lever is pulled, the trailer brakes are applied.
  • Page 122 4-22 CONTROLS AND INSTRUMENTS Water Separator (Fuel Filter) Warning Light This warning light comes on when water in the water separator (fuel filter) needs draining. Drain water following the instructions in "Draining Water from the Fuel Filter" and make sure the warning light goes out. CAUTION •...
  • Page 123 4-23 CONTROLS AND INSTRUMENTS Turn Signal and Hazard Warning Flasher Indicator Light Either of these indicator lights flashes when the turn signal switch is operated with the starter switch in any position. Both indicator lights flash when the hazard warning flasher switch is operated irrespective of the position of the starter switch.
  • Page 124 • The exhaust brake indicator light flashes if there is a problem with the exhaust brake system. Have your vehicle inspected by the nearest Isuzu Dealer as soon as possible. Exhaust Brake Switch → Refer to page 4-36 4612811̲sec04̲CONTROLS AND INSTR4-24   4-24 4612811̲sec04̲CONTROLS AND INSTR4-24   4-24 2016/03/04   10:58:20...
  • Page 125 4-25 CONTROLS AND INSTRUMENTS PTO Indicator Light This indicator light comes on when the PTO switch is pressed. Power Take-Off (PTO) → Refer to page 4-57 Inter-Differential Lock Indicator Light This indicator light comes on when the inter-differential lock switch is placed in the "ON"...
  • Page 126 •: Long lasting alarm ×: No alarm * : Refer to "Condition" column. 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. 4612811̲sec04̲CONTROLS AND INSTR4-26   4-26 4612811̲sec04̲CONTROLS AND INSTR4-26   4-26 2016/03/04   10:58:21...
  • Page 127 4-27 CONTROLS AND INSTRUMENTS SWITCHES ● Starter Switch 4-28 ● Idling Control Knob 4-30 ● Combination Light Control Switch 4-32 ● Headlight Leveling Switch 4-34 ● Front Fog Light Switch 4-35 ● Hazard Warning Flasher Switch 4-35 ● Exhaust Brake Switch 4-36 ●...
  • Page 128 4-28 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 • Using a key sticking with dirt or dust, etc. may possibly damage the starter switch.
  • Page 129 4-29 CONTROLS AND INSTRUMENTS Starter Switch LOCK : Lock is in the position fully counterclockwise. 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.
  • Page 130 4-30 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 131 4-31 CONTROLS AND INSTRUMENTS Adjustment angle CAUTION • Do not use the idling control knob while the vehicle is in motion. This could cause a reduction in your ability to stop in an emergency, resulting in personal injury and/or property damage. ADVICE •...
  • Page 132 4-32 CONTROLS AND INSTRUMENTS Combination Light Control Switch Light Control Switch With the starter switch in the "ON" position, turning the light control switch to the positions indicated in the table below causes the relevant lights to illuminate. ADVICE • Placing the starter switch to a position other than the "ON"...
  • Page 133 4-33 CONTROLS AND INSTRUMENTS NOTE • Use low beam whenever there are vehicles ahead in the same lane or oncoming vehicles on the opposing lane. When the Bulb Does not Come On → Refer to page 8-20 High Beam Flash (Passing Signal) By lightly pulling the light control switch lever and releasing it, the high beam comes on and off.
  • Page 134 4-34 CONTROLS AND INSTRUMENTS NOTE • If the steering wheel is only turned a small amount, turn off the turn 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.
  • Page 135 4-35 CONTROLS AND INSTRUMENTS Front Fog Light Switch With the light control switch positioned in " " or " ", 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 136 ADVICE • If a warning buzzer sounds when the exhaust brake is in operation, promptly pull over the vehicle safely and contact the nearest Isuzu Dealer for inspection. 4612811̲sec04̲CONTROLS AND INSTR4-36   4-36 4612811̲sec04̲CONTROLS AND INSTR4-36   4-36 2016/03/04   10:58:24 2016/03/04   10:58:24...
  • Page 137 4-37 CONTROLS AND INSTRUMENTS Conditions for Inoperable Exhaust Brake Under the following conditions, the exhaust brake does not engage. • The accelerator pedal or the clutch pedal is pressed. • The gearshift lever is in the "N" position. • The vehicle is traveling at a speed of 5 km/h (3 MPH) or lower, or the engine speed drops to a value where the exhaust brake does not engage.
  • Page 138 4-38 CONTROLS AND INSTRUMENTS Inter-Differential Lock Switch Use the inter-differential lock when one or more than one of the tires on the drive axle is on a muddy or sandy road surface, frozen and sloped road surface, or other slippery road surfaces. Stop the vehicle.
  • Page 139 (Intermittent) operation. If the wiper frequently (Off) stops operation, refrain from using it and contact the nearest Isuzu Dealer. • Before operating the wiper, ensure that the wiper rubber is not stuck on to the windshield.
  • Page 140 4-40 CONTROLS AND INSTRUMENTS Windshield Washer Switch Windshield washer fluid is sprayed over the windshield when this switch is pressed. The wiper also operates if your vehicle features an intermittent windshield wiper function. The windshield washer is used when wiping the windshield clean. CAUTION Windshield •...
  • Page 141 4-41 CONTROLS AND INSTRUMENTS Horn Button To sound the horn, press the pad with a horn symbol on the steering wheel. 4612811̲sec04̲CONTROLS AND INSTR4-41   4-41 4612811̲sec04̲CONTROLS AND INSTR4-41   4-41 2016/03/04   10:58:26 2016/03/04   10:58:26...
  • Page 142 4-42 CONTROLS AND INSTRUMENTS 4612811̲sec04̲CONTROLS AND INSTR4-42   4-42 4612811̲sec04̲CONTROLS AND INSTR4-42   4-42 2016/03/04   10:58:26 2016/03/04   10:58:26...
  • Page 143 4-43 CONTROLS AND INSTRUMENTS DRIVING CONTROLS ● Pedals 4-44 ● Parking Brake Lever 4-45 ● Gearshift Lever 4-47 ● Model with ES11109 Model Manual Transmission 4-50 ● Antilock Brake System (ABS) 4-53 ● Power Take-Off (PTO) 4-57 4612811̲sec04̲CONTROLS AND INSTR4-43   4-43 4612811̲sec04̲CONTROLS AND INSTR4-43   4-43 2016/03/04   10:58:26 2016/03/04   10:58:26...
  • Page 144 4-44 CONTROLS AND INSTRUMENTS Pedals 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 145 4-45 CONTROLS AND INSTRUMENTS Parking Brake Lever CAUTION • When parking or stopping your vehicle, pull the parking brake lever and make sure that the vehicle does not start moving. • Avoid parking your vehicle on a slope as much as possible and choose a level and flat place.
  • Page 146 4-46 CONTROLS AND INSTRUMENTS Operation of the Parking Brake To set the parking brake, raise the parking Parking brake lever brake lever. The parking brake warning light will then come on. Make sure that you hear the air being released from the system.
  • Page 147 4-47 CONTROLS AND INSTRUMENTS Gearshift Lever 6 Speeds Manual Transmission Model Model with MZW Model Transmissions After fully pressing the clutch pedal and while pressing the brake pedal, place the gearshift lever into the "1" (1st gear) or "R" (reverse gear) position. In a model with back-up lights, the back- up lights come on when the gearshift lever is placed into "R"...
  • Page 148 4-48 CONTROLS AND INSTRUMENTS 9 Speeds Manual Transmission Model Model with ES11109 Model Transmission Models in this series provide nine forward speeds and one reverse speed, consisting of a five-speed front section and a two- speed auxiliary range section. Crawler gear (C) in the front section is used only as a starting gear.
  • Page 149 4-49 CONTROLS AND INSTRUMENTS High to Low Range Shifting WARNING • Never attempt to shift down at too high a vehicle speed as this will result in major damage to the driveline. Some vehicles are fitted with a range shift over-speed protection device in conjunction with the vehicle manufacturer.
  • Page 150 4-50 CONTROLS AND INSTRUMENTS Model with ES11109 Model Manual Transmission Fully understand how to operate the gearshift lever and form a habit of operating it correctly. Operation Method CAUTION • Never shift to crawler gear (C) while the vehicle is moving. Initial Start-Up Before starting the vehicle, always be seated in the driver’s seat, move the shift lever to neutral, and depress the master clutch fully.
  • Page 151 4-51 CONTROLS AND INSTRUMENTS Upshift 1. Fully depress the clutch pedal. Move the shift lever to the next desired speed. 2. Release the clutch pedal. 3. Accelerate the vehicle. 4. Continue upshifting to 4th speed. Range Shift Low to High (4th to 5th) 1.
  • Page 152 4-52 CONTROLS AND INSTRUMENTS Range Shift High to Low (5th to 4th) 1. When in the last HIGH range gear position (5th) release the accelerator. 2. Fully depress the clutch pedal. Move the shift lever to neutral. 3. Move the shift lever fully LEFT for a short period - doing this will trigger the range valve to automatically shift the transmission to LOW range.
  • Page 153 4-53 CONTROLS AND INSTRUMENTS Antilock Brake System (ABS) Wheels may lock causing a skid during sudden braking or when braking on a snowy or otherwise slippery road. The ABS prevents the wheels from locking during braking by sensing a skid and thus helps maintain directional and control stability of the vehicle. However, even with the ABS, difficulties resulting from driving and stopping exceeding safe limits cannot be avoided.
  • Page 154 4-54 CONTROLS AND INSTRUMENTS NOTE [These are not signs of ABS malfunction] • Soon after you start the engine, the sound of valve working may be heard from the rear of the vehicle or underside of the cab. This sound is from a self-check by the ABS system and is normal.
  • Page 155 • If the ABS warning light does any of the following, the ABS may be faulty. Please contact the nearest Isuzu Dealer. The ABS warning light comes on during driving. The light does not come on when the starter switch is placed into the "ON"...
  • Page 156 4-56 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. It is your responsibility to 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 157 4-57 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 operation of the PTO, but for operation of any special equipment other than the PTO switch, please consult the separate Instruction Manual for the Special Equipment.
  • Page 158 4-58 CONTROLS AND INSTRUMENTS PTO Switch This is a switch to engage and disengage the PTO. When PTO is engaged, the PTO indicator light comes on. When engaging the PTO, be sure to stop the vehicle before operating the switch. Engaging PTO 1.
  • Page 159 4-59 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 160 4-60 CONTROLS AND INSTRUMENTS To Lower the Dump Body Move the lever down while pressing the push button. NOTE • For handling and more detailed instructions about the dump body, please refer to the dump body manufacturer's Instruction Manual. 4612811̲sec04̲CONTROLS AND INSTR4-60   4-60 4612811̲sec04̲CONTROLS AND INSTR4-60   4-60 2016/03/04   10:58:31 2016/03/04   10:58:31...

  • Page 161: Comfort And Convenience

    COMFORT AND CONVENIENCE ● Air Outlets ● Ventilator ● Manual Air Conditioner/Cooler ● Interior Lights 5-15 ● Sun Visor 5-16 ● Cigarette Lighter 5-16 ● Ashtray 5-18 ● Seatback Pocket (Driver's Side) 5-19 ● Small Article Storage Pocket 5-19 ● Card Holder 5-19 ●...
  • Page 162 COMFORT AND CONVENIENCE Air Outlets Ram Air Vent Model Air outlets Features Driver side outlet Air flow direction is adjustable with the lever. Passenger side outlet Air flow direction is adjustable with the lever. Other Models Air outlets Features Driver side outlet Air flow direction is adjustable with the lever.
  • Page 163 COMFORT AND CONVENIENCE Air Flow Direction Control Lever Use the control lever to adjust the air flow direction from the outlet. To close the outlet, move the lever down. Ram air vent model Other models Air flow direction Air flow direction control lever control lever Down...
  • Page 164 COMFORT AND CONVENIENCE Ventilator How to Use the Controls Name Name Fan speed control knob Outlet selector knob Air source 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 165 COMFORT AND CONVENIENCE NOTE • The " " sign advises you to place the air source lever in the outside air ventilation position when using the " ", " ", " " position to defog the windshield. 2. Air source lever Lever Purpose position...
  • Page 166 COMFORT AND CONVENIENCE Manual Air Conditioner/Cooler How to Use the Controls Model without air conditioner and cooler Model with cooler Name Name Outlet selector knob Fan speed control knob Air source lever Air conditioning switch (A/C switch) Temperature control knob 4612811̲sec05̲COMFORT AND CONVEN5-6   5-6 4612811̲sec05̲COMFORT AND CONVEN5-6   5-6 2016/03/16   11:38:03...
  • Page 167 COMFORT AND CONVENIENCE 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. Feet, door windows Air flows through outlets 5 and some through outlets and windshield 3 and 4.
  • Page 168 COMFORT AND CONVENIENCE Blue color 3. Temperature control knob [Cooler] Use this knob to select the preferred cab interior temperature. Turn the knob the way counterclockwise to minimize cooler operation. And turn the knob the way clockwise to maximize cooler operation. 4.
  • Page 169 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 source lever (2) to the " " position. Set the temperature control knob (3) to the desired position.
  • Page 170 5-10 COMFORT AND CONVENIENCE Maximum Heating Turn the outlet selector knob (1) to the " " position, set the air source 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 171 5-11 COMFORT AND CONVENIENCE Defogging and Defrosting the Windshield Defogging Set the outlet selector knob (1) to the " " position. Set the air source lever (2) to the " " position. Turn the temperature control knob (3) to a high-temperature position according to your preference.
  • Page 172 5-12 COMFORT AND CONVENIENCE Defrosting Set the outlet selector knob (1) to the " " position. Set the air source 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 173 5-13 COMFORT AND CONVENIENCE Maximum Cooling [Manual A/C] Set the outlet selector knob (1) to the " " position. Press the A/C switch (5) to the "ON" position. Move the air source lever (2) to the " " position. Turn the temperature control knob (3) fully towards the low-temperature direction.
  • Page 174 5-14 COMFORT AND CONVENIENCE [Cooler] Set the outlet selector knob (1) to the " " position. Press the A/C switch (5) to the "ON" position. Move the air source lever (2) to the " " position. Turn the cooler control knob (3) fully towards the Max cool direction.
  • Page 175 5-15 COMFORT AND CONVENIENCE Interior Lights Dome Light The dome light operates regardless of the starter switch position. So that the dome light is controlled by "DOOR" operation, move the dome light switch in half way between the "ON" and "OFF" positions. : The light stays on regardless of the doors being open or closed.
  • Page 176 5-16 COMFORT AND CONVENIENCE Sun Visor Sun visor 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 177 • To use it once again as the cigarette lighter changing from the accessory power outlet, or to replace the broken cigarette lighter, use an Isuzu genuine part suitable for the vehicle. Do not use other cigarette lighters. •...
  • Page 178 5-18 COMFORT AND CONVENIENCE Ashtray WARNING • After using the ashtray, be sure to close it. If a cigarette butt has not been extinguished completely, other butts in the ashtray may catch fire. • Do not leave the ashtray full of cigarette butts. •...
  • Page 179 5-19 COMFORT AND CONVENIENCE Seatback Pocket (Driver's Side) Use it for storing items such as vehicle Seatback pocket registration documents or owner's manuals. Small Article Storage Pocket Use them for storing small articles. Storage CAUTION • Do not leave eyeglasses or lighters inside the cab.
  • Page 180 5-20 COMFORT AND CONVENIENCE Glove Compartment with Lid Press on the central mark to lock and unlock the lid. CAUTION • For safety, close the glove box while driving. There is a risk of injury from Central mark the open lid or from items stored in the glove box.
  • Page 181 5-21 COMFORT AND CONVENIENCE Glove Compartment without Lid CAUTION • Do not place a cup or something similar containing a beverage. • Do not place anything in the way blocking the vision. • Do not place anything that can fall when tilting the cab.
  • Page 182 5-22 COMFORT AND CONVENIENCE Overhead Shelf Hold down the knob on the lid to open. Use it for storing small articles. CAUTION • Do not leave eyeglasses or lighters inside the cab. If the cab became hot, a lighter left there could explode and plastic eyeglass lenses or frames could deform or crack.
  • Page 183 5-23 COMFORT AND CONVENIENCE Cup Holder Pull towards you to open. CAUTION • Do not place a too-full in the cup holder. Spills could cause damage to the radio or other electrical circuits. If there is a spill, wipe it up immediately with a dry cloth.
  • Page 184 5-24 COMFORT AND CONVENIENCE Hook This can be used to hold plastic shopping bags. CAUTION • Do not hang anything on the hook weighing over 3 kg (106 oz) or that may fall off while driving. Doing so Hook may be dangerous. Operating Tips for the Audio CAUTION •...
  • Page 185 5-25 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.
  • Page 186 5-26 COMFORT AND CONVENIENCE AM/FM Radio The AM/FM radio can be used when the starter switch is in the "ACC" or "ON" position. 2,3,4 SW/VOL TONE PULL BAL A /F CLOCK Name Name Tone control knob (TONE) Tuning buttons ( , ) Power switch (SW) Automatic storing button (AS) Volume control (VOL)
  • Page 187 5-27 COMFORT AND CONVENIENCE ADVICE • Turning the power on or off with the volume set to maximum may damage the equipment and your hearing. Set the volume to a moderate level. Tone Adjusting Tone control knob Turn the "TONE" control knob. Turning clockwise emphasizes the treble, and turning it counterclockwise emphasizes SW/VOL...
  • Page 188 5-28 COMFORT AND CONVENIENCE Display Selection [Time display] Each time you press the "AM/FM" button, the display toggles between the "time" indication and "frequency" indication. AM/FM C OCK NOTE • If the "AM/FM" button is not pressed [Frequency display] in 5 seconds, the display will return to the time indication.
  • Page 189 5-29 COMFORT AND CONVENIENCE Radio Operation Scan Tuning 1. Press the "AM/FM" button to select the band. 2. Pressing the "SCAN" button starts an automatic scan-seek tuning upwards through frequencies. If the radio tunes to a receivable station, it receives the station for 5 seconds before the radio starts another scan-seek tuning.
  • Page 190 5-30 COMFORT AND CONVENIENCE Programming Stations to Preset Buttons Flashes A maximum of 6 radio stations can be MEMO stored in the channels in each of the AM1, AM2, FM1 and FM2 bands. 1. While receiving a radio station, Preset memory No. press the "MEMO"...

  • Page 191: Comfort And Convenience Features

    5-31 COMFORT AND CONVENIENCE NOTE • The radio stations in memory will be erased when the power supply is interrupted to change the battery, for example. You must then reprogram the stations. • Use the automatic storing function if reception of the preset memory stations is poor.
  • Page 192 5-32 COMFORT AND CONVENIENCE Adjusting the Time Press the "CLOCK" button for more than 2 seconds. The "time-of-day" indication on the display will flash, indicating that the time adjusting mode is active. Time is shown in the 12 hour clock. Afternoon is identified by "PM". Setting the Clock to Time Signal Press the "MEMO"...
  • Page 193 5-33 COMFORT AND CONVENIENCE Setting the Alarm The alarm will sound at the time you have set. To set the alarm, you must press and hold the alarm button for 2 seconds or more to make the time display and the " " (For more than icon flash.
  • Page 194 5-34 COMFORT AND CONVENIENCE CD Player (with AM/FM Radio) The CD player can be used when the starter switch is in the "ACC" or "ON" position. Name Name Scan button Tuning button Eject button AM/FM button (Band selector/Clock adjust button) Preset buttons CD button 10 Power switch/Volume control knob...
  • Page 195 5-35 COMFORT AND CONVENIENCE Control Panel Turning the Power On Press the "Power switch" to turn the power Volume Decrease on. Press it again to turn the power off. Increase Volume Adjustment Turn the "Volume control knob" to adjust the volume. Turn the knob to the right to increase the volume, and to the left to decrease the Power...
  • Page 196 5-36 COMFORT AND CONVENIENCE Speaker Configuration Selection Press the preset button "2/RPT" while pressing the "AUDIO" button. You will hear the "beep", and the speaker configuration will switch between 2-channel and 4-channel systems. NOTE Output from Output from the front the front and •...
  • Page 197 5-37 COMFORT AND CONVENIENCE Listening to the Radio Tuning 1. Press the "Power switch" or AM/FM Changes button "AM/FM/CLOCK" to turn the upwards Displayed power on. frequency 2. Press the AM/FM button "AM/FM/ Changes downwards CLOCK" to select the band. Each time the AM/FM button is pressed, the band changes between, FM1, FM2 and AM.
  • Page 198 5-38 COMFORT AND CONVENIENCE Scan Tuning (Automatic Tuning) 1. Press the AM/FM button "AM/FM/ CLOCK" to select the band. 2. Pressing the "SCAN" button starts an SCAN button Blinks automatic scan-seek tuning upwards through frequencies. If the radio tunes to a receivable station, it receives the station for 5 seconds before the radio starts another scan-seek tuning again.
  • Page 199 5-39 COMFORT AND CONVENIENCE Setting the Time Adjusting the Time Press and hold the AM/FM button "AM/FM/ CLOCK" for 2 seconds or more to enter or exit the time adjustment mode. Time flashes When the time adjustment mode is switched on, you will hear the "beep", and the time display will flash.
  • Page 200 5-40 COMFORT AND CONVENIENCE Setting the Clock to Time Signal Press the preset button "6/RESET" while the time adjustment mode is active to set the time to the nearest hour. Time flashes If the minutes are less than 30, the hour will remain unchanged.
  • Page 201 5-41 COMFORT AND CONVENIENCE 3. Adjust the hour by pressing the preset button "4/HOUR" for less than 2 seconds. Time flashes Press and hold the preset button "4/HOUR" for 2 seconds or more to advance the hour continuously. 4. Adjust the minutes by pressing the preset button "5/MIN"...
  • Page 202 5-42 COMFORT AND CONVENIENCE NOTE • After setting the alarm, you can check the set time by pressing the alarm button " " for less than 2 seconds. • To cancel the alarm, press the alarm button " " for 2 seconds or more. Make sure the "...
  • Page 203 5-43 COMFORT AND CONVENIENCE Fast Forwarding/Fast Reversing Press and hold the tuning button " " during playback for 0.5 seconds or more to advance the track forwards or backwards quickly. : Fast forward : Fast reverse Replaying the Same Track Press the tuning button "...
  • Page 204 5-44 COMFORT AND CONVENIENCE Random Playback Press the preset button "1/RDM" during playback to play the CD tracks in random order. Press the button again to cancel random playback. Stopping CD Playback Press the AM/FM button "AM/FM/CLOCK" during CD playback to stop CD playback and listen to the radio.
  • Page 205 5-45 COMFORT AND CONVENIENCE If "Err" Appears in the Display If a problem occurs with the CD during playback, an error " " appears in the display. Cause Solution Insert the CD with the label (printed) side CD was inserted upside down facing upwards CD is scratched, bent, or dirty Replace with a different CD...
  • Page 206 5-46 COMFORT AND CONVENIENCE 4612811̲sec05̲COMFORT AND CONVEN5-46   5-46 4612811̲sec05̲COMFORT AND CONVEN5-46   5-46 2016/03/16   11:38:18 2016/03/16   11:38:18...
  • Page 207 TIPS ON SAFE AND SMOOTH OPERATION ● Driving Safely and with Confidence ● On the Road ● Driving with a Trailer 6-16 ● Cautions for Parking 6-19 ● Cautions for Driving in Hot Regions and Season 6-20 ● Cautions for Driving in Cold Regions and Season 6-21 ●...
  • Page 208 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.
  • Page 209 TIPS ON SAFE AND SMOOTH OPERATION • If you notice any abnormal noise, abnormal smell or abnormal vibration from any part of the vehicle, immediately stop the vehicle in a safe place and perform checks. • If a warning light comes on or a buzzer sounds while you are driving, immediately stop the vehicle in a safe place and perform checks.
  • Page 210 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 211 TIPS ON SAFE AND SMOOTH OPERATION Driving Uphill or Downhill Uphill Downshift 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.
  • Page 212 TIPS ON SAFE AND SMOOTH OPERATION Emergency Fuel Tank If the taps of the fuel tanks are open and Close only a small quantity of fuel remains in the tanks, you should be warned while idling the engine or driving on a steep slope. The engine can become starved of fuel because the fuel moves between tanks due Open...
  • Page 213 TIPS ON SAFE AND SMOOTH OPERATION Braking Your vehicle has air-over-hydraulic brakes or full-air brakes for strong braking force with only a light pressure on the brake pedal. Do not press the brake pedal hard except in the event of an emergency. 1.
  • Page 214 TIPS ON SAFE AND SMOOTH OPERATION Stopping Distance Stopping distance The vehicle's stopping distance consists of a reaction distance (from the point where Reaction distance Braking distance the driver senses danger and presses the pedal to the point where the brakes start to work) and a braking distance (from the point where the brakes start to work to the point where the vehicle comes to a halt).
  • Page 215 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.
  • Page 216 6-10 TIPS ON SAFE AND SMOOTH OPERATION Highways 1. Speeds on highways are higher than • Check that there is ample Tires those on regular roads, so there is tread depth. more danger. Also, a breakdown • Check that engine coolant on a highway represents a hazard is not leaking from the to other vehicles and can cause...
  • Page 217 6-11 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 218 6-12 TIPS ON SAFE AND SMOOTH OPERATION Driving on Snowy or Frozen Roads 1. We recommend you use tire chains or winter tires. 2. Use a low gear and use the engine brake. Use the brake pedal as little as possible.
  • Page 219 6-13 TIPS ON SAFE AND SMOOTH OPERATION Before Driving in Cold Regions Getting In and Out of the Vehicle The step can get icy in cold regions. Be careful not to slip when getting in and out of the vehicle. Before Sitting in the Driver's Seat Remove snow and ice from your shoes when getting into the vehicle.
  • Page 220 6-14 TIPS ON SAFE AND SMOOTH OPERATION Driving on Snowy or Frozen Roads (Fenders) Pay Attention to the Way the Steering Wheel Turns and Feels CAUTION • On snowy roads, water and snow splashed up by the tires can freeze and accumulate inside the fenders, making the steering wheel hard to turn.
  • Page 221 6-15 TIPS ON SAFE AND SMOOTH OPERATION Removing Snow from the Glass and Underbody To maintain an adequate field of view, use a plastic scraper to remove snow and frost from the glass surfaces. By using a plastic scraper, you can remove the snow and frost without scratching the glass.
  • Page 222 6-16 TIPS ON SAFE AND SMOOTH OPERATION Driving with a Trailer When you drive with a trailer, there are special considerations in addition to the cautions that you must take when driving without a trailer. Pay close attention to the following checks and driving methods: Cautions for Loading The balance of the cargo weight, the...
  • Page 223 6-17 TIPS ON SAFE AND SMOOTH OPERATION Effective Use of the Various Types of Brakes Use the various types of brakes appropriately to achieve stable braking. On slippery roads and curves, avoid using just one type of brake at a time. Particularly on a long downward slope, you should make effective use of the engine brake and the exhaust brake, additionally using the...
  • Page 224 6-18 TIPS ON SAFE AND SMOOTH OPERATION Turning with a Trailer When turning with a trailer hitched to the tractor, pay attention to the path followed by the trailer and to inclination of the trailer. CAUTION • The rear wheel of the trailer will run closer to the turning side of the road.
  • Page 225 6-19 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. CAUTION • When there is a risk that the parking brake will freeze in a cold region: With wheel parking brake model, dry the brake linings and drums by lightly pressing the brake pedal five or six times while driving at a speed of 30 km/h (19 MPH) before bringing the vehicle to a halt;...
  • Page 226 6-20 TIPS ON SAFE AND SMOOTH OPERATION Cautions for Driving in Hot Regions and Season 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: If the engine does not contain the appropriate concentration of engine...
  • Page 227 • If you allow the engine to warm up but the engine coolant temperature does not rise, have your 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 228 6-22 TIPS ON SAFE AND SMOOTH OPERATION Engine Coolant To prevent the engine damage due to freezing of the engine coolant, mix the coolant and water to be an appropriate concentration. Changing the Engine Coolant → Refer to page 7-34 Preparing Engine Coolant →...
  • Page 229 6-23 TIPS ON SAFE AND SMOOTH OPERATION Fuel CAUTION • Be sure to use diesel fuel. If you supply the vehicle with poor-quality fuel, water-removal additive or other additive, gasoline, kerosene or alcohol-based fuel, it could harm the fuel filter, prevent proper movement of fuel-lubricated parts in the injectors and adversely affect engine components, possibly resulting in a breakdown.
  • Page 230 • Winter tires have wider contact areas, so they may interfere with other components. Consequently, it is necessary to adjust the steering angle. After putting winter tires on the vehicle, have the adjustment made by your Isuzu Dealer. • Avoid sharp turns of the steering wheel and hard braking. Use the engine brake to decelerate.
  • Page 231 6-25 TIPS ON SAFE AND SMOOTH OPERATION CAUTION (Continued) • If you use the exhaust brake on a slippery road when the vehicle is not loaded, the resulting hard deceleration can cause the back of the vehicle to swing sideways. Exercise caution. •...
  • Page 232 • For triple chains, they may not be fitted depending on vehicle specifications, so please consult the nearest Isuzu Dealer for details. • For dual tires, do not fit a single chain only on the outer tire. The chain may interfere with other components and adversely affect driving.

  • Page 233: Tips On Safe And Smooth Operation

    6-27 TIPS ON SAFE AND SMOOTH OPERATION How to Fit a Tire Chain 1. Making sure the tire chain is not Cross twisted, place it on the tire such that chain the curled ends are on the outside (the side that will make contact with the Connector ground).
  • Page 234 6-28 TIPS ON SAFE AND SMOOTH OPERATION How to Remove a Tire Chain 1. Remove the chain band and wires, Clip and undo the outer hook first. 2. Move the vehicle and remove the chain. Chain band 4612811̲sec06̲SAFE AND SMOOTH OP6-28   6-28 4612811̲sec06̲SAFE AND SMOOTH OP6-28   6-28 2016/03/04   12:51:02 2016/03/04   12:51:02...

  • Page 235: Service And Maintenance

    SERVICE AND MAINTENANCE BEFORE SERVICE AND MAINTENANCE 7-15 DAILY INSPECTION ENGINE-RELATED SERVICE AND 7-19 MAINTENANCE CHASSIS-RELATED SERVICE AND 7-55 MAINTENANCE 7-111 OTHER SERVICE AND MAINTENANCE INTERIOR AND EXTERIOR 7-133 MAINTENANCE 7-143 MAINTENANCE DATA 4612811̲sec07̲SERVICE AND MAINTE7-1   7-1 4612811̲sec07̲SERVICE AND MAINTE7-1   7-1 2016/03/16   11:39:19 2016/03/16   11:39:19...
  • Page 236 4612811̲sec07̲SERVICE AND MAINTE7-2   7-2 4612811̲sec07̲SERVICE AND MAINTE7-2   7-2 2016/03/16   11:39:19 2016/03/16   11:39:19...
  • Page 237 SERVICE AND MAINTENANCE BEFORE SERVICE AND MAINTENANCE ● Precautions for Checking and Adjustments ● Discarded Parts, Oils and Other Liquids ● Isuzu Genuine Oils and Grease ● Tools ● Front Lid ● Tilting the Cab 7-10 4612811̲sec07̲SERVICE AND MAINTE7-3   7-3 4612811̲sec07̲SERVICE AND MAINTE7-3   7-3 2016/03/16   11:39:19 2016/03/16   11:39:19...
  • Page 238 Do not let the engine run in poorly ventilated garages or sheds. This could cause carbon monoxide poisoning. 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. 4612811̲sec07̲SERVICE AND MAINTE7-4   7-4 4612811̲sec07̲SERVICE AND MAINTE7-4   7-4 2016/03/16   11:39:19...
  • Page 239 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 parts and such problems as seizure or malfunctioning.
  • Page 240 Isuzu Motors guarantees the quality and performance of Isuzu genuine oils and grease. We recommend the use of Isuzu genuine oils and grease for maintenance and service of your vehicle. CAUTION • Flames or other heat sources near spilled oil can cause a fire.
  • Page 241 SERVICE AND MAINTENANCE Tools Tools Carried on Your Vehicle Hydraulic jack Tool bag Screwdriver (Phillips head and flat head) Wheel nut wrench Wrench Hammer Pliers Adjustable wrench Grease pump 10 Screwdriver (Phillips head/flat head interchangeable type) 11 Wrench handle 4612811̲sec07̲SERVICE AND MAINTE7-7   7-7 4612811̲sec07̲SERVICE AND MAINTE7-7   7-7 2016/03/16   11:39:20 2016/03/16   11:39:20...
  • Page 242 SERVICE AND MAINTENANCE Front Lid To Open 1. Pull the lever at the bottom right (right- hand drive model) or bottom left (left- hand drive model) of the instrument panel. 2. To hold the front lid open, take the end of the support rod and fit it Support rod securely into the bottom of the hole in the bracket.
  • Page 243 SERVICE AND MAINTENANCE CAUTION • Do not pull the lever while driving. This is extremely dangerous, because opening the front lid while driving blocks your view. • When opening the front lid, make sure to place the starter switch in the "LOCK" position.
  • Page 244 7-10 SERVICE AND MAINTENANCE Tilting the Cab CAUTION • Tilt the cab only on a level surface. • Make sure to apply the parking brake and set the gear in the neutral position. • Check the areas in front of and above the cab for sufficient clearance when tilting the cab indoors.
  • Page 245 7-11 SERVICE AND MAINTENANCE Cab Tilt Levers and Grip Handle Lever Lever Grip Tilting Up the Cab 1. Apply the parking brake firmly and make sure the transmission is in neutral. Close the doors completely. 2. Pull the lever (2) with your left hand and turn down the handle (1) by pulling it toward you with your right hand to release the cab lock.
  • Page 246 7-12 SERVICE AND MAINTENANCE 4. Fully lift up the cab, and lock the Tilt support tilt support while holding the part indicated by the arrow. When it is Lock locked, it makes a "click" sound. Confirm that the lock of tilt support is securely engaged.
  • Page 247 7-13 SERVICE AND MAINTENANCE Lowering the Cab WARNING • After lowering the cab, make sure the cab is securely locked. • When the starter switch is turned to the "ON" position with the lock being incompletely engaged. 1. Support the cab while gripping the grip (4) with your left hand.
  • Page 248 7-14 SERVICE AND MAINTENANCE 4. Confirm that the lock portion of lever is securely engaged after the cab has been lowered. Lock portion 5. Raise the handle (1) until the lever (2) catches. Place the starter switch in the "ON" position.
  • Page 249 7-15 SERVICE AND MAINTENANCE DAILY INSPECTION ● Daily Check (Preoperational Check) 7-16 ● Checking a Part Where there was an Abnormality the 7-18 Previous Time the Vehicle was Driven 4612811̲sec07̲SERVICE AND MAINTE7-15   7-15 4612811̲sec07̲SERVICE AND MAINTE7-15   7-15 2016/03/16   11:39:23 2016/03/16   11:39:23...
  • Page 250 If the checks reveal an abnormality or if there are components that showed abnormalities the last time the vehicle was driven, have the vehicle repaired by your Isuzu Dealer before using the vehicle. Daily Check (Preoperational Check) Items [1. Checking where there was an abnormality the previous time the vehicle was...
  • Page 251 7-17 SERVICE AND MAINTENANCE [3. Checks to perform in the driver's seat] Check item Reference page Operation of meters, gauges and warning/indicator lights 4-8, 4-15 Engine start ability, abnormal noise and color of exhaust emissions 7-20 Brake pedal free play 7-58 Exhaust sound from brake valve 7-58...
  • Page 252 Previous Time the Vehicle was Driven Check the components that showed abnormalities during the previous day's operation or the last time the vehicle was driven. Have any abnormalities repaired by your Isuzu Dealer before using the vehicle. 4612811̲sec07̲SERVICE AND MAINTE7-18   7-18 4612811̲sec07̲SERVICE AND MAINTE7-18   7-18 2016/03/16   11:39:23 2016/03/16   11:39:23...
  • Page 253 7-19 SERVICE AND MAINTENANCE ENGINE-RELATED SERVICE AND MAINTENANCE ● Engine Conditions 7-20 ● Engine Oil 7-21 ● Engine Coolant 7-29 ● Handling the Radiator and Intercooler 7-41 ● Fan Belt 7-42 ● Air Cleaner 7-45 ● Fuel Filter 7-48 4612811̲sec07̲SERVICE AND MAINTE7-19   7-19 4612811̲sec07̲SERVICE AND MAINTE7-19   7-19 2016/03/16   11:39:23 2016/03/16   11:39:23...
  • Page 254 7-20 SERVICE AND MAINTENANCE Engine Conditions Checking the Engine for Easy Starting 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 • For safety, firmly press the brake pedal before starting the engine.
  • Page 255 7-21 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. Maintenance Schedule →...
  • Page 256 7-22 SERVICE AND MAINTENANCE Checking the Engine Oil Level 1. Remove the oil dipstick and wipe off any oil on the gauge. 2. Reinsert the oil dipstick and then gently remove it. If the oil level is between the "MAX" and "MIN" marks, the oil is at the correct level.
  • Page 257 7-23 SERVICE AND MAINTENANCE NOTE • Perform all engine oil level checks on a level surface before starting the engine. • The oil level cannot be measured accurately when the engine is running. • Fuel will gradually become mixed with the engine oil, and the engine oil level will rise beyond the original level.
  • Page 258 7-24 SERVICE AND MAINTENANCE WARNING • When adding oil, keep a rag handy and be careful not to spill any. If any oil spills on the engine, wipe it all off. It could ignite and cause a fire. • Do not leave flammable items, such as rags or gloves in the engine compartment.
  • Page 259 7-25 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 260 7-26 SERVICE AND MAINTENANCE 6HK1-TCN engine model Changing the Oil 1. Clean around the oil filler cap so that foreign matter does not enter. Remove the oil filler cap. 2. Remove the inspection cover. (6HK1- TCS engine model) 3. Place a container to receive the oil beneath the oil pan and the oil filter.
  • Page 261 7-27 SERVICE AND MAINTENANCE 8. Check that the oil pan drain plug and the oil filter drain plug (if equipped) are firmly tightened. Oil pan drain plug tightening torque 78 N·m (8.0 kgf·m/58 lb·ft) Oil filter drain plug tightening torque (If equipped with an oil filter drain plug) 12 N·m (1.2 kgf·m/104 lb·in) ADVICE...
  • Page 262 7-28 SERVICE AND MAINTENANCE WARNING • Bringing flames or other heat sources near spilled engine oil could cause a fire. Make sure to wipe it all up. • Do not leave flammable items, such as rags or gloves in the engine compartment beneath the cab.
  • Page 263 7-29 SERVICE AND MAINTENANCE Engine Coolant The engine coolant must be changed according to the Maintenance Schedule. Maintenance Schedule → Refer to page 7-145 Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-158 WARNING • Check, replenish or change the engine coolant only after the engine has sufficiently cooled down.
  • Page 264 Preparing Engine Coolant To prevent the engine damage due to freezing of the engine coolant and to protect the cooling system from corrosion, mix the Isuzu recommended coolant and water to be at 50% concentration. For other than Isuzu genuine coolant (Caltex/Texaco/Chevron, etc.), it is recommended to use directly "50/50 Pre-diluted"...
  • Page 265 7-31 SERVICE AND MAINTENANCE Models confirming to EuroIII emission standards Engine coolant quantity [Reference value] Engine model liters (US gal./Imp gal.) 6HK1-TCN 29.0 (7.66/6.38) 6HK1-TCS 29.6 (7.82/6.51) Models confirming to EuroIV emission standards Engine coolant quantity [Reference value] Engine model liters (US gal./Imp gal.) 6HK1-TCN 29.6 (7.82/6.51)
  • Page 266 Using coolant at any coolant concentration other than that specified may reduce anti-freezing performance, and engine coolant may freeze. • If the engine coolant decreases rapidly, go immediately to the nearest Isuzu Dealer for a check or repair. 4612811̲sec07̲SERVICE AND MAINTE7-32   7-32 4612811̲sec07̲SERVICE AND MAINTE7-32   7-32 2016/03/16   11:39:26...
  • Page 267 MIN line Check for stains or fluid on the ground where the vehicle is parked that would indicate there is a leak. Contact your Isuzu Radiator reserve tank Dealer when you discover leaks. CAUTION •...
  • Page 268 7-34 SERVICE AND MAINTENANCE Changing the Engine Coolant Change the engine coolant according to the Maintenance Schedule. ADVICE • Drained engine coolant must be disposed of in a method conforming to the regulatory requirements in your country. Maintenance Schedule → Refer to page 7-145 Recommended Fluids, Lubricants and Diesel Fuels →...
  • Page 269 7-35 SERVICE AND MAINTENANCE Draining the Cooling System 1. Check that the engine has cooled Radiator cap sufficiently. 2. Remove the radiator cap. 3. Open the drain plugs on the radiator and the engine to let the engine coolant run out. Drain the engine coolant from the reserve tank as well.
  • Page 270 7-36 SERVICE AND MAINTENANCE Cleaning the Radiator Core and Intercooler Core Cooling efficiency is compromised when there is dirt or dust plugging air passages in the radiator core and intercooler core. It also could cause corrosion of the core. Periodically wash the core with water. Handling the Radiator and Intercooler →...
  • Page 271 7-37 SERVICE AND MAINTENANCE Cleaning the Engine Coolant Passages 1. Fill with tap water up to brim of the radiator inlet. CAUTION • The radiator cap is a double-action type that must be opened and closed in two turning motions. When removing the cap, take care not to damage the cap or filler.
  • Page 272 7-38 SERVICE AND MAINTENANCE Filling the Cooling System CAUTION • A failure to correctly fill the engine cooling system in changing or topping up engine coolant may sometimes cause the engine coolant to overflow from the filler neck even before the engine and radiator are completely full. •...
  • Page 273 7-39 SERVICE AND MAINTENANCE Radiator cap Radiator upper hose 4. Squeeze the radiator upper hose two or three times. If this action results in air being discharged from the hose and the level of engine coolant goes down, add engine coolant up to the top of the radiator filler opening from the radiator cap section.
  • Page 274 If the level is extremely low, inspect whether coolant is leaking from the radiator, coolant passages, or the reserve tank hose. If a leakage is found, contact your nearest Isuzu Dealer. 8. After firmly closing the radiator cap, idle the engine until the needle of the coolant temperature gauge reaches the center and the thermostat opens.
  • Page 275 7-41 SERVICE AND MAINTENANCE Handling the Radiator and Intercooler Cleaning the Radiator Core and Intercooler Core Cooling efficiency is compromised when there is dirt or dust plugging air passages in the radiator core and intercooler core. This can also cause corrosion of these cores. When replacing the engine coolant, wash the radiator core and intercooler core with tap water.
  • Page 276 To accurately check fan belt tension, use a sonic wave tension gauge, which will show you whether the belt's vibration frequency (representing the belt tension) is as listed below. Ask about the sonic wave tension gauge at your Isuzu Dealer. •...
  • Page 277 7-43 SERVICE AND MAINTENANCE CAUTION [Follow this to properly adjust belt tension] • Initial stretching takes place in any new belt after installation. Furthermore, an installed new or reused belt should be in good alignment with the pulley grooves. These require the following adjustments to be carried out. Align the belt and pulley grooves and adjust the belt tension using the indicated method.
  • Page 278 7-44 SERVICE AND MAINTENANCE Adjustments 1. Loosen the generator's upper and lower bolts or nuts (1, 2). 2. Turn the adjusting bolt (3) until the belt tension falls within the standard value range. 3. After adjustment, firmly tighten all the loosened bolts and nuts.
  • Page 279 It is always advisable to use Isuzu genuine elements for replacement. Otherwise its filtering efficiency will be lost and the engine will be damaged. Maintenance Schedule →...
  • Page 280 7-46 SERVICE AND MAINTENANCE 3. Remove the air cleaner element by pulling it out toward you. 4. Remove the dirt that has accumulated on the air cleaner cover and the air cleaner body. 5. Clean the drain valve at the bottom of the air cleaner.
  • Page 281 8. Install the air cleaner cover. When installing the cover, ensure that the "ISUZU" mark at the top and the notch on the left side are aligned with the claw on the body. Lock the cover securely using the 4 clips.
  • Page 282 (fuel filter). Continuing to drive with the light on could damage the fuel injection system. If this happens, have the vehicle checked and serviced by the nearest Isuzu Dealer. Draining Water from the Fuel Filter →...
  • Page 283 7-49 SERVICE AND MAINTENANCE Changing the Fuel Filter Engine-side Main Fuel Filter Air removal plug 1. Connect one end of a plastic hose to the drain plug at the bottom of the engine-side fuel filter and place the other end of the hose inside a container to receive the drained fluid.
  • Page 284 When fitting the element case, be careful not to let the O-ring be 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. • Replace the gasket when replacing the filter. •...
  • Page 285 7-51 SERVICE AND MAINTENANCE 10. Bleed the fuel system. How to Bleed Air → Refer to page 8-12 11. After restarting the engine, confirm that there is no fuel leakage from the area around the fuel filter. Vehicle-side Pre-fuel Filter 1.
  • Page 286 Float from the bottom of the filter element case and check that the float moves freely and smoothly. • Use only an Isuzu genuine fuel filter. • Replace the O-ring when replacing the filter. • Dispose of the replaced filter in compliance with the regulatory requirements in your country.
  • Page 287 7-53 SERVICE AND MAINTENANCE WARNING • After changing the fuel filter, operate the engine to check that there are no leaks around the filter. Fuel leaks could cause a fire. Draining Water from the Fuel Filter Vehicle-side Pre-fuel Filter 1. Connect one end of a plastic hose to the drain plug at the bottom of the vehicle-side pre-fuel filter (primary filter) and place the other end of the...
  • Page 288 7-54 SERVICE AND MAINTENANCE CAUTION • Clean off any fuel that has adhered to the vehicle body. • Starting the engine immediately after draining the water from the fuel filter requires a little more time than usual. If the engine doesn't start in 10 seconds, wait for a while and try again.
  • Page 289 7-55 SERVICE AND MAINTENANCE CHASSIS-RELATED SERVICE AND MAINTENANCE ● Brakes 7-56 ● Parking Brake 7-59 ● Drum Brakes 7-60 ● Wheels and Tires 7-62 ● Tire Rotation 7-68 ● Preparation for Changing a Tire 7-70 ● Changing a Tire (ISO 10-Bolt Wheels) 7-71 ●...
  • Page 290 7-56 SERVICE AND MAINTENANCE Brakes Air Pressure Checking Air Pressure Red zone 1. Check the air pressure gauges to Air gauge see that the primary and secondary air systems are charged with air to proper pressures. Optimum air pressure 780 - 890 kPa (8.0 - 9.1 kgf/cm²/114 - 129 psi) 2.
  • Page 291 The time taken before the air pressure warning light goes out may somewhat vary depending on the temperature and other environmental conditions. However, you should contact the nearest Isuzu Dealer if air pressure does not increase at all, the time taken before reaching a proper pressure is significantly different from that indicated in the table, or the needles of the two air pressure gauges indicate considerably different pressures.
  • Page 292 7-58 SERVICE AND MAINTENANCE Brake Pedal Free Play Press the brake pedal with two fingers to check that the pedal free play is proper and the pedal moves smoothly without abnormal interference. Free play (measured at the tip of pedal) 10 - 18 mm (0.39 - 0.71 in) Brake Valve Operation Release the brake pedal after stepping on...
  • Page 293 7-59 SERVICE AND MAINTENANCE Parking Brake NOTE • When you pull the parking brake lever, the wheel parking brake activates the rear wheel brakes to lock them. Checking the Parking Brake Lever Stroke Pull the parking brake lever from the fully released position to the wheel locked position to check that the air exhaust sound is heard and the lever stays in position.
  • Page 294 3. The lining must be replaced if the step is lost or there are cracks or flaking on the side surfaces. Have the replacement carried out by the nearest Isuzu Dealer. Step Step 4612811̲sec07̲SERVICE AND MAINTE7-60   7-60 4612811̲sec07̲SERVICE AND MAINTE7-60   7-60 2016/03/10   14:56:57...
  • Page 295 ADVICE Thickness gauge • If the drum-to-lining gap measurement is not as specified, have the brakes inspected by the nearest Isuzu Dealer. Standard drum-to-lining gap Gap* Remarks Brake shoe lining Within 1.3 mm (0.051 in) should not drag on the drum.
  • Page 296 WARNING • If you find anything abnormal in wheel bolts, wheel nuts or disc wheels as a result of checking, avoid driving the vehicle, and contact the nearest Isuzu Dealer as soon as possible. • If you find anything abnormal on left wheels, check the right wheels carefully for similar defects.
  • Page 297 7-63 SERVICE AND MAINTENANCE Standard air pressure kPa (kgf/cm²/psi) Tire size JATMA ETRTO Front Rear 10.00R20-14PR 725 (7.25/105) — 720 (7.20/104) 720 (7.20/104) 10.00-20-16PR — 750 (7.50/109) 790 (7.90/115) 720 (7.20/104) 10.00R20-16PR — — 830 (8.30/120) 830 (8.30/120) 11.00-20-16PR 725 (7.25/105) 675 (6.75/98) 790 (7.90/115) 720 (7.20/104) 11.00R20-16PR...
  • Page 298 7-64 SERVICE AND MAINTENANCE WARNING • Insufficiently inflated or worn-out tires are highly dangerous as they easily skid and can even burst. Should they burst, the tires may burn and this could cause a fire in the vehicle. • If you drive on under-inflated or flat tires, the wheel bolts will be placed under excessive stress.
  • Page 299 7-65 SERVICE AND MAINTENANCE Cracks and Other Damage Check the tread and sidewall surfaces of Gap between inner and outer tires tire for cracks or other damage. Especially Sidewall surface check the tread for nails or other metal pieces embedded in grooves. Also check the gap between the inner and outer tires of a dual-tire wheel for pebbles lodged in it.
  • Page 300 7-66 SERVICE AND MAINTENANCE NOTE • Hydroplaning occurs when a vehicle is running at high speeds on a wet road if a layer of water forms between the road surface and tires causing the tires to float on it. Hydroplaning prevents the driver from steering correctly and slowing down the vehicle with the brake pedal.
  • Page 301 7-67 SERVICE AND MAINTENANCE Checking Wheel Installation Condition with Inspection Hammer Place your fingers on the bottom of each wheel nut and tap the top of the nut with an inspection hammer or small hammer in the tightening direction. There may be some defect with a nut or its bolt if the vibration you feel is different from the other nuts or if the sound it produces is not clear.
  • Page 302 If you find any abnormal condition on the wheel bolts, wheel nuts or disc wheel, do not continue to use a wheel with such an abnormality, but contact the nearest Isuzu Dealer as soon as possible. Rear dual-tire wheel model (same Tires at different locations wear differently.
  • Page 303 7-69 SERVICE AND MAINTENANCE Rear single-tire wheel model (same CAUTION size wheels for front and rear axles) Rear wheel • If differently sized tires are used Front wheel Spare tire on the front and rear axles, do not exchange tires between the front and rear axles;...
  • Page 304 7-70 SERVICE AND MAINTENANCE Preparation for Changing a Tire When you park the vehicle to change tires, choose a place listed below. • Your vehicle does not hinder other traffic. • The surface is level, flat and solid. • You can change a tire safely. When changing a tire on a road, use the hazard warning flasher and triangle reflectors to alert other traffic to the...
  • Page 305 7-71 SERVICE AND MAINTENANCE Changing a Tire (ISO 10-Bolt Wheels) Select a level, flat and hard surface for changing a tire. Also, refer to "Handling the Jacks" on page 7-112 for the method of using a jack. Removing the Tire WARNING •...
  • Page 306 7-72 SERVICE AND MAINTENANCE CAUTION • All bolts and nuts from the wheels on both sides have right-hand screw threads. • Do not loosen wheel nuts more than necessary. Doing so could damage the wheel bolts. • An anti-lock brake system (ABS) The two disc wheels are tightened with equipped model must use tires of one rear nut, so be sure to jack up both...
  • Page 307 • Crushed, thinned or seized threads • Loose drum nuts Wheel bolt replacement involves component disassembly work, so have it done by your Isuzu Dealer. • Sticky washer rotation. Replace washers that do not turn smoothly. 3. Remove rust, dust and mud from the...
  • Page 308 7-74 SERVICE AND MAINTENANCE Do not grease If there is rust on the hub and the socket (disc wheel contact surface) portion surface (unpainted) of the disc wheel, remove the rust and apply a light coat of grease. Lightly grease 4.
  • Page 309 After changing a tire, turn the steering wheel in both directions to make sure that the wheels do not interfere with the surrounding components. If you are unsure of anything, please contact the nearest Isuzu Dealer. • Tightening torque of the wheel nuts may decrease after tire replacement due to initial settling.
  • Page 310 The bolts and nuts of both the left and right wheels have right-hand screw threads. WARNING • 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. 4612811̲sec07̲SERVICE AND MAINTE7-76   7-76 4612811̲sec07̲SERVICE AND MAINTE7-76   7-76 2016/03/10   14:57:03 2016/03/10   14:57:03...
  • Page 311 7-77 SERVICE AND MAINTENANCE CAUTION • Fully engage the wheel bolt wrench on a wheel nut to be able to tighten the nut to the specified torque. However, do not use a pipe as a handle extension or your foot to apply force to the wrench. This could tighten the nut more than necessary and damage the components.
  • Page 312 7-78 SERVICE AND MAINTENANCE Spare Tire Spare tire carrier – under rear part Removal of frame Insert the handle in the spare tire carrier Spare tire carrier and turn the handle counterclockwise. Spare tire carrier handle Storage 1. Place the tire with the convex side of the disc wheel facing up and then fit the hanger plate inside the disc wheel with its claws properly engaged.
  • Page 313 If you cannot tighten the tire in the carrier, do not continue driving but contact the nearest Isuzu Dealer. Air Pressure Check the air pressure of the spare tire using a tire air pressure gauge at the intervals specified in the Maintenance Schedule.
  • Page 314 After discharging water, check that air is not leaking from each drain tap. If a large volume of water drains from an air tank, the desiccant of the air dryer may have deteriorated. If desiccant replacement is necessary, have it performed by the nearest Isuzu Dealer. WARNING •...
  • Page 315 If clutch fluid decrease too rapidly, there might be a problem in the clutch system or the clutch disc might be worn out beyond safe limits. Have your vehicle inspected the nearest Isuzu Dealer immediately. Maintenance Schedule → Refer to page 7-145...
  • Page 316 Changing Clutch Fluid Change clutch fluid according to the Maintenance Schedule using the specified fluid. Since clutch fluid change requires disassembly of the related components, have this service performed by your Isuzu Dealer. 4612811̲sec07̲SERVICE AND MAINTE7-82   7-82 4612811̲sec07̲SERVICE AND MAINTE7-82   7-82 2016/03/10   14:57:05 2016/03/10   14:57:05...
  • Page 317 7-83 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 removed during a maintenance operation.
  • Page 318 7-84 SERVICE AND MAINTENANCE 5. Press the clutch pedal several times and keep it pressed the last time. 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 319 60 mm (2.36 in) or more. Position of fully pressed pedal ADVICE • If the clutch pedal stroke is not within the specified range, contact the nearest Isuzu Dealer. 4612811̲sec07̲SERVICE AND MAINTE7-85   7-85 4612811̲sec07̲SERVICE AND MAINTE7-85   7-85 2016/03/10   14:57:06 2016/03/10   14:57:06...
  • Page 320 7-86 SERVICE AND MAINTENANCE Adjustment of Clutch Pedal Free Play Adjustment of Clutch Booster Return spring If the free play of the clutch pedal is not within the specified range, make Clutch booster adjustments at the clutch booster and the clutch master cylinder with the engine stopped.
  • Page 321 7-87 SERVICE AND MAINTENANCE 7. If the free play value is out of the range, loosen the push rod lock nut and readjust the push rod accordingly by rotating either clockwise or counter clockwise until it is within the specified value.
  • Page 322 7-88 SERVICE AND MAINTENANCE Transmission Oil WARNING • If the level of transmission oil is extremely low, the transmission might become damaged and this could lead to an accident. Periodically check the oil level according to the Maintenance Schedule. • Do not touch the transmission oil when it is hot.
  • Page 323 7-89 SERVICE AND MAINTENANCE Quantity of transmission oil to be changed Oil quantity [Reference value] liters (US gal./Imp gal.) Transmission model Without power take-off (PTO) With PTO 6 speeds 5.3 (1.40/1.17) 6.0 (1.59/1.32) ES11109 9 speeds 8.5 (2.25/1.87) 9.0 (2.38/1.98) NOTE •...
  • Page 324 7-90 SERVICE AND MAINTENANCE Checking the Transmission Oil Level Before checking the oil level, be sure to Level or fill plug park the vehicle on a level surface. hole 1. Remove the level or fill plug. surface 2. Check that the oil level is up to the Oil level (lower edge of lower edge of the level or fill plug...
  • Page 325 7-91 SERVICE AND MAINTENANCE Changing the Transmission Oil – MZW Model Transmissions Level plug Transmission oil must be changed at the specified intervals. 1. Before changing the oil, make sure that the vehicle is on a level surface. 2. Place a container under the drain plug to receive oil.
  • Page 326 7-92 SERVICE AND MAINTENANCE ADVICE • Any dirt on the plug should be wiped off before installing it. • Because the cases of the MZW transmissions are made of aluminum, be extremely careful not to tighten the oil level plug and drain plug to an excessively large torque when installing them.
  • Page 327 7-93 SERVICE AND MAINTENANCE Changing the Transmission Oil – ES11109 Model Transmissions The transmission oil must be changed at the specified intervals. 1. Before changing the oil, make sure that the vehicle is on a level surface. 2. Make sure that the oil in the transmission is warm enough for draining.
  • Page 328 7-94 SERVICE AND MAINTENANCE 6. Clean the area around the fill plug hole and then add oil up to the lower edge of the fill plug hole. ADVICE • Avoid overfilling, which may result in oil leakage. Fill plug hole 7.
  • Page 329 7-95 SERVICE AND MAINTENANCE Differential Gear Oil The rear axle differential gear oil must be changed according to the Maintenance Schedule. ADVICE • Use the oil quantity indicated later in this section only as guidelines when changing the rear axle differential gear oil. •...
  • Page 330 7-96 SERVICE AND MAINTENANCE Checking the Oil Level FTR/FVR model, forward rear axle of 1. Remove the oil level plug. FVM model and rearward rear axle of FVZ model Oil level plug Drain plug Forward rear axle of FVZ model Oil level plug 2.
  • Page 331 7-97 SERVICE AND MAINTENANCE Changing the Oil FTR/FVR model, forward rear axle of 1. Place a container under the drain plug FVM model and rearward rear axle to receive oil. of FVZ model 2. Remove the plugs indicated in the figure to discharge the oil into the container.
  • Page 332 Forward rear axle 18.0 (4.76/3.96) 17.5 inch (tandem drive axle) Rearward rear axle 12.0 (3.17/2.64) ADVICE • Use only the Isuzu recommended differential gear oil. Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-158 4612811̲sec07̲SERVICE AND MAINTE7-98   7-98 4612811̲sec07̲SERVICE AND MAINTE7-98   7-98 2016/03/10   14:57:10 2016/03/10   14:57:10...
  • Page 333 7-99 SERVICE AND MAINTENANCE Power Steering Fluid The power steering fluid level must be checked and it should changed according to the Maintenance Schedule. Maintenance Schedule → Refer to page 7-145 Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-158 Checking the Power Steering Fluid Level The fluid level is correct if it is between the "MAX"...
  • Page 334 7-100 SERVICE AND MAINTENANCE Changing the Power Steering Fluid Draining 1. Apply the parking brake firmly and chock the rear wheels. 2. Apply the head of the jack to the jacking point firmly. 3. Raise the vehicle until the front wheels are completely clear of the ground.
  • Page 335 7-101 SERVICE AND MAINTENANCE Bleeding If you hear an abnormal sound when you turn the steering wheel, air has entered into the hydraulic system. Follow the steps below to bleed the system. 1. Apply the parking brake firmly and chock the rear wheels. 2.
  • Page 336 7-102 SERVICE AND MAINTENANCE Power Steering Fluid Filter The power steering fluid filter must be cleaned according to the Maintenance Schedule. Maintenance Schedule → Refer to page 7-145 Cleaning the Power Steering Fluid Filter 1. Remove the cap from the power steering fluid tank.
  • Page 337 7-103 SERVICE AND MAINTENANCE 8. Install the filter in the power steering fluid tank. 9. Install the strainer in the power steering fluid tank and fit the rubber cap in position. 10. Close the power steering fluid tank by installing the cap. ADVICE •...
  • Page 338 7-104 SERVICE AND MAINTENANCE Fuel Tank Sediment and water collected in the fuel tank must be removed according to the Maintenance Schedule. Maintenance Schedule → Refer to page 7-145 Removing Sediment and Water from the Fuel Tank 1. Remove the cap from the fuel tank and pump out the fuel.
  • Page 339 7-105 SERVICE AND MAINTENANCE Greasing Chassis Components ADVICE • 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. Multi-purpose type grease can generally be used for all greasing points, whereas chassis grease can be used only for the specified greasing points.
  • Page 340 7-106 SERVICE AND MAINTENANCE ADVICE • Each of propeller shaft universal joints must be greased heavily until grease oozes at the 4 needle bearing oil seal locations. After greasing, wipe excess grease off. Shift block Clutch booster joint pin 1 position on the lower side (ES11109 1 position on the right side transmission vehicles) Lubricate directly around the pin (without...
  • Page 341 Wheel hub bearings (left and right) Two-piece propeller shaft: 1 point; 4 points or 6 points Three-piece propeller shaft: 2 points; Since disassembling is required for this Four-piece propeller shaft: 3 points greasing, have it performed by your Isuzu Dealer. 4612811̲sec07̲SERVICE AND MAINTE7-107   7-107 4612811̲sec07̲SERVICE AND MAINTE7-107   7-107 2016/03/10   14:57:12 2016/03/10   14:57:12...
  • Page 342 King pins (left and right) Drag link 2 points each (top and bottom) 2 grease fittings (front and rear) (not required for types without grease FTR/FVR model fittings) Tie rod ends (left and right) Steering shaft sliding sleeve 1 point each...
  • Page 343 7-109 SERVICE AND MAINTENANCE Front spring shackle pins Rear spring pins (front end) (left and right) (left and right) 2 points each 1 point each Rear spring pad (front and rear, left Rear spring sliding shackles and right) (left and right) 2 points each 1 point each FVM/FVZ model...
  • Page 344 7-110 SERVICE AND MAINTENANCE 4612811̲sec07̲SERVICE AND MAINTE7-110   7-110 4612811̲sec07̲SERVICE AND MAINTE7-110   7-110 2016/03/10   14:57:14 2016/03/10   14:57:14...
  • Page 345 7-111 SERVICE AND MAINTENANCE OTHER SERVICE AND MAINTENANCE ● Handling the Jacks 7-112 ● Windshield Washer Fluid 7-116 ● Windshield Wiper Blades 7-117 ● Exterior Lights 7-120 ● Handling the Battery 7-121 ● Air Conditioning Filters 7-128 ● Refrigerant 7-130 ●...
  • Page 346 7-112 SERVICE AND MAINTENANCE Handling the Jacks WARNING • Raising the vehicle with a jack is extremely dangerous when carried out on soft or inclined surfaces. Ensure that you always carry out this operation on flat, hard surfaces. • Always apply the parking brake fully and correctly chock the wheels before raising the vehicle.
  • Page 347 7-113 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, hard surface. Jacking Points → Refer to page 7-114 2.
  • Page 348 • The jack cannot be placed under the front axle depending on the condition of the vehicle (flat tire, etc.). FTR/FVR model FVM/FVZ model Rear jacking point Rear jacking point Front jacking point 4612811̲sec07̲SERVICE AND MAINTE7-114   7-114 4612811̲sec07̲SERVICE AND MAINTE7-114   7-114 2016/03/10   14:57:14...
  • Page 349 7-115 SERVICE AND MAINTENANCE Jacking When a Front Wheel Tire Is Punctured 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. •...
  • Page 350 7-116 SERVICE AND MAINTENANCE Windshield Washer Fluid Windshield 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 that the windshield washer sprays correctly. Refilling Windshield Washer Fluid 1.
  • Page 351 7-117 SERVICE AND MAINTENANCE Windshield Wiper Blades Daily Check 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 Wiper blade...
  • Page 352 7-118 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 353 7-119 SERVICE AND MAINTENANCE Replacement of Wiper Rubber Element Removal Extract 1. Remove the wiper blade from the wiper arm. 2. Pull the wiper rubber element in the direction indicated by the arrow and extract it from the wiper blade. Installation Insert 1.
  • Page 354 7-120 SERVICE AND MAINTENANCE Exterior 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 355 7-121 SERVICE AND MAINTENANCE Handling the Battery DANGER • Usage or charging of the battery when the battery fluid is below the "LOWER LEVEL" line can accelerate deterioration and give rise to dangerous situations such as the generation of heat and even explosion. •...
  • Page 356 In winter months in particular, battery fluid can freeze and damage the battery case if you fail to recharge the battery. • If the battery fluid level continues to drop at an unusually fast rate, have an inspection carried out immediately by the nearest Isuzu Dealer. 4612811̲sec07̲SERVICE AND MAINTE7-122   7-122 4612811̲sec07̲SERVICE AND MAINTE7-122   7-122 2016/03/10   14:57:17...
  • Page 357 7-123 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 358 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. 4612811̲sec07̲SERVICE AND MAINTE7-124   7-124 4612811̲sec07̲SERVICE AND MAINTE7-124   7-124...
  • Page 359 In winter months in particular, battery fluid can freeze and damage the battery case if you fail to recharge the battery. • If the battery fluid level continues to drop at an unusually fast rate, have an inspection carried out immediately by the nearest Isuzu Dealer. 4612811̲sec07̲SERVICE AND MAINTE7-125   7-125 4612811̲sec07̲SERVICE AND MAINTE7-125   7-125 2016/03/10   14:57:17...
  • Page 360 7-126 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 battery ydrometer should be charged. Proper specific gravity at a fluid temperature of 20 °...
  • Page 361 7-127 SERVICE AND MAINTENANCE 3. When you have finished cleaning the Terminal mounting (type 2) terminals, apply a thin layer of grease Terminal mounting and securely connect the battery (type 1) cables, taking care to ensure that they are tightly connected. See "When the Battery Goes Flat"...
  • Page 362 7-128 SERVICE AND MAINTENANCE Air Conditioning Filters The air conditioning filters should be removed and cleaned once every month. Removing the Inside-air Filter 1. Open the front lid. Front Lid → Refer to page 2. While pressing in on both sides of the filter lock, pull out the filter.
  • Page 363 7-129 SERVICE AND MAINTENANCE Removing the Outside-air Filter 1. While pressing in on both sides of the filter lock, pull out the filter. 2. Use a vacuum cleaner or the like to clean dust and dirt from its surface. ADVICE •...
  • Page 364 No other type of refrigerant can be used. In order to protect the environment, care must be taken to ensure that refrigerant gas is never released into open air. When refrigerant must be replaced, therefore, please contact your Isuzu Dealer or another service facility equipped with a gas recovery system. 4612811̲sec07̲SERVICE AND MAINTE7-130   7-130 4612811̲sec07̲SERVICE AND MAINTE7-130   7-130...
  • Page 365 In order to accurately measure the belt tension, it will be necessary to use a sonic tension meter to confirm whether the vibration frequency is as set out below. For more information on sonic tension meters, please contact your Isuzu Dealer.
  • Page 366 7-132 SERVICE AND MAINTENANCE Adjustment 1. Loosen the idler pulley's lock nut. 2. Adjust the belt tension using the adjusting bolt. Deflection/ Vibration 3. After the belt tension has been frequency (Hz) adjusted, securely fasten the lock nut. Lock nut Replacement 1.
  • Page 367 7-133 SERVICE AND MAINTENANCE INTERIOR AND EXTERIOR MAINTENANCE ● Exterior Maintenance 7-134 ● Interior Maintenance 7-138 4612811̲sec07̲SERVICE AND MAINTE7-133   7-133 4612811̲sec07̲SERVICE AND MAINTE7-133   7-133 2016/03/10   14:57:20 2016/03/10   14:57:20...
  • Page 368 7-134 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, negatively affecting their functions or forming an aerodynamic resistance.
  • Page 369 7-135 SERVICE AND MAINTENANCE CAUTION • Do not apply water directly in order to clean the cab interior. Failure to observe this precaution can result in malfunction or breakdown of electronic control units and electrical components, or in rusting of the cab floor. •...
  • Page 370 7-136 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 371 7-137 SERVICE AND MAINTENANCE Windshield Care If not fully cleaned by the windshield wipers, the windshield should be cleaned using glass cleaner. CAUTION • When cleaning the windshield, do not place your feet or stand on the top of the bumper if it does not have a step.
  • Page 372 7-138 SERVICE AND MAINTENANCE 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. WARNING • When cleaning the interior of the cab, water should never be sprayed directly. Failure to observe this precaution can lead to vehicle malfunction and possibly fire if water should enter the audio system or other electrical components located underneath the floor carpet.
  • Page 373 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 374 In this case, arrange for inspection and maintenance to be carried out by your Isuzu Dealer. • If the belt is not winding and unwinding correctly, or if inspection...
  • Page 375 7-141 SERVICE AND MAINTENANCE Fabric Seat Covering and Carpet Care Remove dirt and dust using a home-use electric vacuum cleaner. Do not remove the carpet. Use standard household cleaning products and methods to remove stains from food, drink, and the like. Be sure to use neutral detergents or cleaning products indicated as higher alcohol based detergents.
  • Page 376 7-142 SERVICE AND MAINTENANCE 4612811̲sec07̲SERVICE AND MAINTE7-142   7-142 4612811̲sec07̲SERVICE AND MAINTE7-142   7-142 2016/03/10   14:57:22 2016/03/10   14:57:22...
  • Page 377 7-143 SERVICE AND MAINTENANCE MAINTENANCE DATA ● Inspection and Maintenance 7-145 4612811̲sec07̲SERVICE AND MAINTE7-143   7-143 4612811̲sec07̲SERVICE AND MAINTE7-143   7-143 2016/03/10   14:58:57 2016/03/10   14:58:57...
  • Page 378 4612811̲sec07̲SERVICE AND MAINTE7-144   7-144 4612811̲sec07̲SERVICE AND MAINTE7-144   7-144 2016/03/10   14:58:57 2016/03/10   14:58:57...
  • Page 379 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 380 7-146 SERVICE AND MAINTENANCE Maintenance Schedule (No. 1): I : Inspect then clean, repair or replace as necessary A: Adjust R: Replace T: Tighten to the specified torque L: Add lubricant Service interval x1,000 km x1,000 miles Engine startability and abnormal noise Idling speed and acceleration * Air cleaner element (models for Thailand) * Air cleaner element (models for Vietnam)
  • Page 381 Every 12 months : I First 200,000 km (120,000 miles) or 24 months : R Then every 600,000 km (370,000 miles) or 36 months : R (when isuzu recommended coolant is used) Every 12 months: I or every 3 months 4612811̲sec07̲SERVICE AND MAINTE7-147   7-147...
  • Page 382 7-148 SERVICE AND MAINTENANCE Maintenance Schedule (No. 2): I : Inspect then clean, repair or replace as necessary A: Adjust R: Replace T: Tighten to the specified torque L: Add lubricant Service interval x1,000 km x1,000 miles * Clutch fluid (models for Thailand) * Clutch fluid (models for Vietnam) Clutch system function Clutch pedal free play and stroke...
  • Page 383 7-149 SERVICE AND MAINTENANCE 95 100 105 Odometer reading or months, whichever comes first Every 10,000 km (6,000 miles) or 3 months: I Every 120,000 km (75,000 miles) or 12 months: R or every 3 months: I every 15 months: R or every 3 months or every 3 months or every 3 months...
  • Page 384 7-150 SERVICE AND MAINTENANCE Maintenance Schedule (No. 3): I : Inspect then clean, repair or replace as necessary A: Adjust R: Replace T: Tighten to the specified torque L: Add lubricant Service interval x1,000 km x1,000 miles Damaged disc wheels Loose front wheel hub bearings Loose rear wheel hub bearings Power steering fluid (models for Thailand)
  • Page 385 7-151 SERVICE AND MAINTENANCE 95 100 105 Odometer reading or months, whichever comes first or every 3 months or every 15 months or every 15 months or every 3 months: I every 12 months: R or every 3 months: I every 15 months: R or every 15 months Every 3 months: I...
  • Page 386 7-152 SERVICE AND MAINTENANCE Maintenance Schedule (No. 4): I : Inspect then clean, repair or replace as necessary A: Adjust R: Replace T: Tighten to the specified torque L: Add lubricant Service interval x1,000 km x1,000 miles Brake chamber piggy-bag Brake expander Worn parking brake lining (center parking brake model) Worn or damaged parking brake drum...
  • Page 387 7-153 SERVICE AND MAINTENANCE 95 100 105 Odometer reading or months, whichever comes first Every 36 months: R Every 12 months: I Every 36 months: overhaul or every 12 months or every 12 months or every 3 months or every 3 months or every 3 months or every 12 months or every 3 months...
  • Page 388 7-154 SERVICE AND MAINTENANCE Maintenance Schedule for Severe-condition Operations Driving condition A: Driving with a trailer B: Operation involving frequent starts and stops C: Driving on rough roads, mountain roads or uphill roads D: Driving in dusty areas E: Driving on snowy roads or along the seashore Condition Item Distance covered...
  • Page 389 7-155 SERVICE AND MAINTENANCE Maintenance Schedule - ES11109 Model Transmissions Carry out periodic maintenance on the transmission in order to maintain its original performance. It is particularly important to replace the transmission oil according to the Maintenance Schedule. The Maintenance Schedule varies according to the type of oil used. Mineral Oil Operating Replacement interval...
  • Page 390 7-156 SERVICE AND MAINTENANCE The multi information display provides information on the replacement interval assuming mineral oil is used. However, replacement intervals differ if synthetic oil or semi-synthetic oil is used, and the owner must therefore manage the replacement interval. Synthetic Oil Operating Replacement interval...
  • Page 391 7-157 SERVICE AND MAINTENANCE Semi-Synthetic Oil Operating Replacement interval Inspection and replacement item conditions Every 20,000 km Check oil level and inspect for leakage (12,000 miles) [All recommended oils] Highway Every 300,000 km Change transmission oil (180,000 miles) or [All recommended oils] 36 months Check oil level and inspect for leakage Every 40 hours...
  • Page 392 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 393 7-159 SERVICE AND MAINTENANCE GRADE LUBRICATION MAKE BRAND ACEA JASO ISUZU BESCO LSD (140) GL-5* ― ― Castrol Axle Limited Slip (85W-140) GL-5 ― ― Differential Chevron/Texaco/Caltex Gear Oil ZF (80W-90) GL-5 ― ― (Limited slip Tractelf BLS (80W-90) GL-5 ―...
  • Page 394 Glysantin G34 Total Glacelf Auto Supra Total Coolelf Auto Supra 37 *: Use Isuzu recommended coolant, or GENERAL MOTORS ENGINEERING STANDARDS GM6277M (Ethylene glycol based non-silicate and non-borate coolant) or equivalent. ADVICE • Mix the coolant and water at an appropriate concentration.
  • Page 395 7-161 SERVICE AND MAINTENANCE CAUTION • Be sure to use diesel fuel. If you supply the vehicle with poor-quality fuel, water-removal additive or other additive, gasoline, kerosene or alcohol-based fuel, it could harm the fuel filter, prevent proper movement of fuel-lubricated parts in the injectors and adversely affect engine components, possibly resulting in a breakdown.
  • Page 396 3: 5W-40 oil is specified as the recommended oil only for cold regions (Russia, China, etc.). 4: Use is possible at ambient temperatures up to 45°C (113°F) only in the case of Isuzu genuine oil. GEAR OIL VISCOSITY CHART (Isuzu production components)
  • Page 397 7-163 SERVICE AND MAINTENANCE Lubrication Chart FTR Model CHECK or SUPPLY ..ENGINE OIL ..BRAKE FLUID CHANGE ..GEAR OIL ..POWER STEERING FLUID ..AUTOMATIC TRANSMISSION FLUID ..MULTIPURPOSE TYPE GREASE ..MULTIPURPOSE TYPE GREASE or WHEEL BEARING GREASE Clutch fluid Drag link (Not required for types...
  • Page 398 7-164 SERVICE AND MAINTENANCE FVM/FVZ Model CHECK or SUPPLY ..ENGINE OIL ...BRAKE FLUID CHANGE ..GEAR OIL ...POWER STEERING FLUID ..AUTOMATIC TRANSMISSION FLUID ..MULTIPURPOSE TYPE GREASE ..MULTIPURPOSE TYPE GREASE or WHEEL BEARING GREASE Clutch fluid Drag link (Not required for types without grease fittings) Water pump bearing grease...
  • Page 399 7-165 SERVICE AND MAINTENANCE FVR Model CHECK or SUPPLY ..ENGINE OIL ...BRAKE FLUID CHANGE ..GEAR OIL ...POWER STEERING FLUID ..MULTIPURPOSE TYPE GREASE ..MULTIPURPOSE TYPE GREASE or WHEEL BEARING GREASE Clutch fluid Drag link (Not required for types without grease fittings) Water pump bearing grease Wheel hub bearing...
  • Page 400 7-166 SERVICE AND MAINTENANCE Greasing Points FTR/FVR Model Every month or every 5,000km (3,000miles) Steering shaft sliding sleeve Front spring pin Kingpin Front shackle pin Clutch booster joint pin Propeller shaft universal joint Propeller shaft center bearing Rear spring pin...
  • Page 401 7-167 SERVICE AND MAINTENANCE FVM/FVZ Model Every month or every 5,000km (3,000miles) : For FVZ model only Steering shaft sliding sleeve Front spring pin Kingpin Front spring pin and shackle pin Clutch booster joint pin Propeller shaft universal joint and sliding sleeve Propeller shaft center bearing Rear spring sliding pad Clutch shift block(ES11109 model transmission)
  • Page 402 7-168 SERVICE AND MAINTENANCE 4612811̲sec07̲SERVICE AND MAINTE7-168   7-168 4612811̲sec07̲SERVICE AND MAINTE7-168   7-168 2016/03/10   14:59:02 2016/03/10   14:59:02...

  • Page 403: In Case Of Emergency

    IN CASE OF EMERGENCY ● Troubleshooting ● When the Vehicle Breaks Down during Driving ● When the Tire Goes Flat ● When the Engine Stops While Driving ● When the Engine Stalls and Cannot be Restarted ● When the Brakes Do not Work ●...
  • Page 404 If you are unable to perform a repair, the corrective action shown in the table does not eliminate a symptom or you can not locate a fault, contact the nearest Isuzu Dealer. ADVICE •...
  • Page 405 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page Idling speed too low Adjust idling speed 4-30 Fuel filter clogged Replace filter 7-49 Engine starts, but Clean or replace immediately stops Air cleaner clogged 7-45 element Common rail system faulty ―...
  • Page 406 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page Parking brake not fully Make sure it is ― disengaged disengaged Brake dragging ― Adjust clutch control Clutch slipping 7-86 stroke Clean or replace Engine not powerful Air cleaner clogged 7-45 element enough...
  • Page 407 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page Poor lubrication in the Lubricate the 7-105 Poor steering wheel steering mechanisms mechanism return Poor wheel alignment ― Insufficient air Fill with air ― Clutch disengages Insufficient clutch fluid Add fluid 7-82 poorly Excessive clutch pedal...
  • Page 408 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 does not impede traffic (shoulder, verge). Place the triangle reflectors to alert other traffic to presence of your vehicle.
  • Page 409 IN CASE OF EMERGENCY When the Engine Stops While Driving Do not panic. Press the brake pedal to reduce speed, head immediately for a safe place, stop the vehicle and perform an inspection. If the engine stopped because the vehicle ran out of fuel while driving, refueling alone will not be enough to restart the engine.
  • Page 410 IN CASE OF EMERGENCY When the Brakes Do not Work When the brakes do not work unexpectedly, this can cause a serious accident. 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 411 When connecting the cables, under no circumstances allow the clips to touch each other. • Ask your 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 412 8-10 IN CASE OF EMERGENCY 3. Remove the battery cover and connect the booster cables in the numbered sequence in the drawing. Vehicle with booster battery Disabled vehicle Use the vehicle frame as the ground Negative side booster cable Positive side booster cable 4.
  • Page 413 8-11 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 booster battery and a few minutes after that start the engine of the disabled vehicle.
  • Page 414 8-12 IN CASE OF EMERGENCY How to Bleed Air 1. Remove the rubber cap of the air removal plug and then use a tool to loosen it. Attach a plastic hose to the Priming pump air removal plug so that fuel does not Air removal spray out.
  • Page 415 • When the warning light does not go out or when it takes longer than the specified time for the light to go out after an air pressure of 0 kPa (0 kgf/cm²/0 psi) is reached (refer to page 7-56), repair is required. Contact the nearest Isuzu Dealer. WARNING •...
  • Page 416 2. If the fan belt is loose, adjust the tension. 3. If there is no abnormality in the fan belt, contact the nearest Isuzu Dealer. Fan Belt → Refer to page 7-42 CAUTION • Do not drive the vehicle when the warning light is on. The battery may drain.
  • Page 417 Since checking and repairing the control system is required, immediately contact the nearest Isuzu Dealer. Antilock Brake System (ABS) → Refer to page 4-53 4612811̲sec08̲IN CASE OF EMERGEN8-15   8-15...
  • Page 418 8-16 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 419 If there is anything attached, clean and remove it. 6. After inspection, please contact the nearest Isuzu Dealer. ADVICE • Make sure that the needle on the engine coolant temperature gauge is below "C"...
  • Page 420 8-18 IN CASE OF EMERGENCY When the Meter Shows an Abnormality Air Pressure Gauge Red zone When the needle on this gauge moves into Air gauge the red zone, a warning light will come on at the same time. Air Pressure Gauge →...
  • Page 421 Do not release the brake manually, other than when the vehicle is being towed by a tow truck or the vehicle is being moved temporarily. • Contact the nearest Isuzu Dealer immediately after moving the vehicle. 1. Firmly chock the wheels. Mechanical release bolt 2.
  • Page 422 Turn signal light (side) 21W (Amber) Taillight and stop light 10/25W Turn signal light Rear Back up light License plate light Interior Dome light Contact the nearest Isuzu Dealer when replacing lights that aren't listed here. 4612811̲sec08̲IN CASE OF EMERGEN8-20   8-20 4612811̲sec08̲IN CASE OF EMERGEN8-20   8-20 2016/03/10   15:00:59 2016/03/10   15:00:59...
  • Page 423 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 the nearest Isuzu Dealer. Bulb Wattage → Refer to page 8-20 4612811̲sec08̲IN CASE OF EMERGEN8-21   8-21 4612811̲sec08̲IN CASE OF EMERGEN8-21   8-21 2016/03/10   15:00:59...
  • Page 424 8-22 IN CASE OF EMERGENCY Halogen Headlight 1. Tilt the cab and work from front- sideways of the vehicle for the replacement. WARNING • Do not touch the lock on the cab support while the cab is tilted. If you touch it, the lock will release.
  • Page 425 8-23 IN CASE OF EMERGENCY Rubber boot 2. Disconnect the headlight connector. Turn signal Headlight leveling connector Headlight bulb Clearance light connector Headlight connector Headlight connector ADVICE • When removing the headlight connector, pull out the connector while holding the center portion of the rubber boot.
  • Page 426 8-24 IN CASE OF EMERGENCY Retaining clip 3. Remove the rubber boot, grip the left and right sides of the bottom of the clip that secures the bulb, and unlock the clip by moving it upwards. 4. Pull off the bulb and replace with a new one.
  • Page 427 8-25 IN CASE OF EMERGENCY Replacing the Clearance Lights 1. Tilt the cab and work from front- sideways of the vehicle for the replacement. WARNING • Do not touch the lock on the cab support while the cab is tilted. If you touch it, the lock will release.
  • Page 428 8-26 IN CASE OF EMERGENCY Turn signal 2. Remove the clearance light socket from the headlight assembly. Headlight leveling connector Headlight connector Clearance light connector 3. Pull off the bulb from the clearance light socket and replace with a new one.
  • Page 429 8-27 IN CASE OF EMERGENCY Replacing the Turn Signal Lights 1. Remove the socket from the rear of the bumper by turning it counterclockwise. Socket 2. Pull off the bulb from the socket and replace with a new one. 3. To install, perform the same sequence of operations in reverse taking care of the following points: •...
  • Page 430 8-28 IN CASE OF EMERGENCY Replacing the Front Fog Light 1. Disconnect the connector, and Connector turn the cover counterclockwise to disconnect it. While pushing the clip that holds the bulb in place, slide it downward. 2. Disengage the terminal from the cover and replace with a new bulb.
  • Page 431 8-29 IN CASE OF EMERGENCY Replacing the Rear Turn Signal Light, Taillight, Stop Light and Backup Light Type 1 1. Loosen the screws and remove the lens. 2. Loosen the bulb by turning it counterclockwise while pushing it. 3. To install, follow the removal procedure in reverse.
  • Page 432 8-30 IN CASE OF EMERGENCY Replacing the Dome Light 1. Remove the lens and pull out the bulb. 2. To install, follow the removal procedure in reverse. Bulb 4612811̲sec08̲IN CASE OF EMERGEN8-30   8-30 4612811̲sec08̲IN CASE OF EMERGEN8-30   8-30 2016/03/10   15:01:02 2016/03/10   15:01:02...
  • Page 433 8-31 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 center and in the left rear of the cab.
  • Page 434 (The spare fuses are stored in the fuse box in the cab.) WARNING • Always use fuses specified by Isuzu. Using fuses with a rating other than that specified, or using wire or tin foil, etc., could result in fire or damage.
  • Page 435 8-33 IN CASE OF EMERGENCY Replacing Relays When replacing the relays, contact the nearest Isuzu Dealer. ADVICE • It is not necessary to open or close the cover unless trouble is found. • The relay box structure makes it difficult for water to enter. If you...
  • Page 436 8-34 IN CASE OF EMERGENCY Fuse and Relay Location Fuse Locations Fuse layout 22 23 24 Description Rating Description Rating 13 IGN1 & METER & ECU POWER WINDOW 14 DOOR LOCK HEAD LAMP HIGH BEAM RH 15 IGN2 & BLOWER & STARTER 16 RADIO &...
  • Page 437 8-35 IN CASE OF EMERGENCY Relay Locations (Type 1) Relay Description Description SIDE PTO 12 ABS SIDE PTO 13 ENG CONT FRT FOG LAMP 14 HVAC COOLER COMP & COND FAN HORN 15 HVAC BLOWER TRAILER 16 KEY ON POWER SUPPLY TRAILER STOP LAMP 17 STARTER CUT TRAILER BACK LAMP...
  • Page 438 8-36 IN CASE OF EMERGENCY Relay Locations (Type 2) Relay Description Description SIDE PTO 10 HVAC COOLER COMP & COND FAN SIDE PTO 11 HVAC BLOWER FRT FOG LAMP 12 KEY ON POWER SUPPLY HORN 13 STARTER CUT WIPER 14 HEAD LAMP HIGH BEAM WIPER 15 HEAD LAMP LOW BEAM POWER WINDOW...
  • Page 439 Immediately contact the nearest Isuzu Dealer. WARNING • Always use fuses specified by Isuzu when replacing the slow-blow fuse. Using fuses with a rating other than that specified, or using wire or tin foil, etc., could result in fire or damage. •...
  • Page 440 8-38 IN CASE OF EMERGENCY ADVICE • It is not necessary to open or close the cover unless trouble is found. • The relay box structure makes it difficult for water to enter. If you should spill water or a beverage on the cover, however, wipe it off before opening the cover. •...
  • Page 441 8-39 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 442 8-40 IN CASE OF EMERGENCY Towing Forward (All Wheels on the Ground, or the Front Wheels are off the Ground) When it is possible to operate the steering wheel, the vehicle can be towed with all wheels on the ground. If the engine cannot be started, the power steering system does not work, making steering difficult.
  • Page 443 8-41 IN CASE OF EMERGENCY Front 1. If the vehicle is towing or is 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 slack in the rope.
  • Page 444 8-42 IN CASE OF EMERGENCY Rear CAUTION • Do not tow a vehicle at an angle of greater than 15°. This could exert too much stress on the vehicle and damage it. • Attach a rope to the towing hook only.
  • Page 445 8-43 IN CASE OF EMERGENCY When Towing from the Rear (Rear Wheels off the Ground) Fix the steering wheel in a straight-ahead position. ADVICE [Contact a tow truck at these times] • When the vehicle will descend long hills (The brakes could overheat and become ineffective) •...
  • Page 446 8-44 IN CASE OF EMERGENCY Towing Vehicles with ES11109 Model Transmissions Towing Cut off the drive force from the rear axle to the transmission. If the vehicle is towed without cutting off the drive force, insufficient lubrication will occur inside the transmission and will result in damage such as mechanical seizure due to friction.

  • Page 447: Main Data

    MAIN DATA ● Main Data and Specifications ● Others 9-12 4612811̲sec09̲MAIN DATA.indd   9-1 4612811̲sec09̲MAIN DATA.indd   9-1 2016/03/16   11:40:49 2016/03/16   11:40:49...
  • Page 448 MAIN DATA Main Data and Specifications Engine 6HK1 Model Specifications Water-cooled, overhead camshaft, direct injection engine with an inter-cooled turbocharger Compression ratio (to 1) 17.5 Displacement cc (cu. in) 7,790 (475.3) Firing order 1-5-3-6-2-4 Fuel injection timing (static) degree 0° Valve clearance mm (in) Both intake and exhaust valves: 0.4 (0.016) in cold engine...
  • Page 449 MAIN DATA Transmission MZW6P Model Specifications Six-speed transmission (overdrive gear for 6th), synchromesh for 2nd to 6th Gear ratio (to 1) 6.615 4.095 2.358 1.531 1.000 0.722 Rev. 6.615 Transmission oil capacity [Reference value] Model without PTO: 5.3 (1.40 / 1.17) liters (US gal./Imp gal.) Model with PTO: 6.0 (1.59 / 1.32) ES11109 Model...
  • Page 450 MAIN DATA Service Specifications FVR Model Engine Model 6HK1-TCN Engine oil capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-2 Engine coolant capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-2 Transmission Model MZW6P Transmission oil capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-3 Clutch...
  • Page 451 MAIN DATA Steering Steering wheel free play mm (in) 10 - 60 (0.39 - 2.36) Power steering fluid capacity [Reference value] liters (US gal./Imp gal.) 3.0 (0.79 / 0.66) Service brakes Type Full air dual circuit Brake pedal free play mm (in) 10 - 18 (0.39 - 0.71) Parking brake...
  • Page 452 MAIN DATA FTR Model Engine Model 6HK1-TCN Engine oil capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-2 Engine coolant capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-2 Transmission Model MZW6P Transmission oil capacity [Reference value] liters (US gal./Imp gal.)
  • Page 453 MAIN DATA Steering Steering wheel free play mm (in) 10 - 60 (0.39 - 2.36) Power steering fluid capacity [Reference value] liters (US gal./Imp gal.) 3.0 (0.79 / 0.66) Service brakes Type Full air dual circuit Brake pedal free play mm (in) 10 - 18 (0.39 - 0.71) Parking brake...
  • Page 454 MAIN DATA FVM Model Engine Model 6HK1-TCS 6HK1-TCN Engine oil capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-2 Engine coolant capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-2 Transmission Model ES11109 Transmission oil capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-3 Clutch...
  • Page 455 MAIN DATA Steering Steering wheel free play mm (in) 10 - 60 (0.39 - 2.36) Power steering fluid capacity [Reference value] liters (US gal./Imp gal.) 3.0 (0.79 / 0.66) Service brakes Type Full air dual circuit Brake pedal free play mm (in) 10 - 18 (0.39 - 0.71) Parking brake...
  • Page 456 9-10 MAIN DATA FVZ Model Engine Model 6HK1-TCN Engine oil capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-2 Engine coolant capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-2 Transmission Model ES11109 Transmission oil capacity [Reference value] liters (US gal./Imp gal.) Refer to page 9-3 Clutch...
  • Page 457 9-11 MAIN DATA Steering Steering wheel free play mm (in) 10 - 60 (0.39 - 2.36) Power steering fluid capacity [Reference value] liters (US gal./Imp gal.) 3.0 (0.79 / 0.66) Service brakes Type Full air dual circuit Brake pedal free play mm (in) 10 - 18 (0.39 - 0.71) Parking brake...
  • Page 458 9-12 MAIN DATA Others Guidelines for Installation of Aftermarket Radio Frequency Transmitting Equipment Purpose This installation guidelines give requirement and recommendations for the installation in vehicles of • radio frequency (RF) transmitting equipment. • ancillary equipment associated with these. NOTE •...
  • Page 459 9-13 MAIN DATA 3. The installation shall comply with national legal requirements for the installation and use of RF-transmitting equipment in vehicles. 4. Full consideration shall be given to the positioning of RF-transmitting equipment such that electromagnetic interference (EMI) and radio frequency interference (RFI) is minimized between the RF-transmitting equipment being installed and the vehicle electrical and electronic systems.
  • Page 460 9-14 MAIN DATA 4. Care shall be taken when sitting an antenna next to an existing one or when mounting antennas with magnetic bases, as this could affect the accuracy or operation of the compass on vehicles so equipped. [Radiation patterns and ground planes] 1.
  • Page 461 9-15 MAIN DATA [Antenna position at vehicle] Installation and use of RF transmitters with antenna outside the vehicle is shown by Table 2. Table 2. Installation and use of RF transmitters with antenna outside the vehicle Frequency bands Max. output Antenna position Specific conditions for installation (MHz)
  • Page 462 9-16 MAIN DATA Antenna Cable 1. Use a high quality, one piece coaxial cable (at least 95% shield coverage) that is impedance matched for the RF-transmitting equipment (VSWR < 2.0). 2. Excess coaxial cable shall not be coiled, as this may affect the tuning of the antenna as well as producing electrical interference.
  • Page 463 9-17 MAIN DATA RF-transmitting Equipment [Mounting of RF-transmitting equipment] 1. Location of a RF-transmitting equipment should be selected that provides a solid mounting point which does not interfere with the vehicle operator controls and provides adequate ventilation. 2. RF-transmitting equipment shall not be able to be damaged or its ventilation restricted.
  • Page 464 9-18 MAIN DATA Power Supply for RF-transmitting Equipment [General] 1. A dedicated supply cable should be used for the RF-transmitting equipment installation which should be as short as possible to the battery positive and negative connections. Do not connect directly to the battery pillars, but use the battery terminals provided.
  • Page 465 1. A 12 V tap shall not be taken from 24 V vehicle batteries. NOTE • Most mobile RF-transmitting equipment operates from a 12 V supply. ISUZU FVR34/FTR34/FVM34/FVZ34 have a 24 V, so it is essential that a suitable regulator or converter be used which will provide the nominal supply voltage and current for which the RF-transmitting equipment is designed.
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  • Page 467 10-1 INDEX Air Cleaner 7-45 Card Holder 5-19 Carrying Children 2-15 Air Conditioning Compressor Belt 7-131 Cautions for Driving in Cold Regions and Season 6-21 Air Conditioning Filters 7-128 Cautions for Driving in Hot Regions and Air Dryer 7-81 Season 6-20 Air Outlets Cautions for Parking...
  • Page 468 Exhaust Brake Switch 4-36 Interior Lights 5-15 Exterior (PICTORIAL INDEX) 0-11 Interior Maintenance 7-138 Exterior Lights 7-120 Isuzu Genuine Oils and Grease Exterior Maintenance 7-134 Fan Belt 7-42 Front Fog Light Switch 4-35 Front Lid Main Data and Specifications Fuel Filter...
  • Page 469 10-3 INDEX Parking Brake 7-59 Tachometer 4-11 Parking Brake Lever 4-45 Tilting the Cab 7-10 Pedals 4-44 Tire Rotation 7-68 Power Steering Fluid 7-99 Tools Power Steering Fluid Filter 7-102 Transmission Oil 7-88 Troubleshooting Power Take-Off (PTO) 4-57 Power Windows Precautions for Checking and Adjustments Using Tire Chains 6-26...
  • Page 470 Released 8-19 When the Tire Goes Flat When the Vehicle Breaks Down during Driving When the Warning Light Comes On 8-13 When to Visit an Isuzu Dealer 2-44 When Towing 8-39 Windshield Washer Fluid 7-116 Windshield Wiper and Windshield Washer...
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