Isuzu Tilt Slide FYJ2000 Instruction Manual

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Owner and Vehicle Identification

This information fully identifies your vehicle. It will furnish all of the necessary

information in the event that warranty repairs are required. Be certain it is completely

and properly filled out and signed by your Selling Dealer.

Owner's Name: ...........................................................................................................

Business Name: ..........................................................................................................

Address: ......................................................................................................................

City / Town: ..................................................................................................

State: ......................................................... Postcode: .............................

Business Phone: ........................................ Private Phone: ....................................

Mobile: ......................................

Email: ..............................................................

Registration Number: .................................

Isuzu Truck Model: ......................................................................................

Vehicle Indentification Number: ................................................................................ .

IAL Tag Number: ........................................

Engine Number: .........................................

Transmission Serial Number: ..................................

Differential Serial Number: ......................................

Selling Dealer's Signature and Stamp:

Date: ...........................................

Table of Contents

Summary of Contents for Isuzu Tilt Slide FYJ2000

Page 1 State: ............Postcode: ......Business Phone: ........Private Phone: ........Mobile: ........Email: .............. Registration Number: ......... Isuzu Truck Model: ..................Vehicle Indentification Number: ................. IAL Tag Number: ........Engine Number: ......... Transmission Serial Number: ........Differential Serial Number: ........
Page 3 State: ............Postcode: ......Business Phone: ........Private Phone: ........Mobile: ........Email: .............. Registration Number: ......... Isuzu Truck Model: ..................Vehicle Indentification Number: ................. Sold To Date: ..........Mail this form to: The Manager – Customer Care Department Isuzu Australia Limited...
Page 5 State: ............Postcode: ......Business Phone: ........Private Phone: ........Mobile: ........Email: .............. Registration Number: ......... Isuzu Truck Model: ..................Vehicle Indentification Number: ................. Sold To Date: ..........Mail this form to: The Manager – Customer Care Department Isuzu Australia Limited...
Page 7 • : Market-/type-specific equipment (Your vehicle may not have the equipment with this symbol.) • : Vehicle equipped with Isuzu production transmission or axle • : Vehicle equipped with Arvin Meritor production axle • : Vehicle equipped with ZF production transmission •...
Page 8 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) The Australian Design Rules American Petroleum Institute ASTM American Society for Testing and Materials British Standard Controller Area Network Deutsche Industrie Normen...
Page 9 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 0-10 ● WARNING/CAUTION LABELS 0-14...
Page 10 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 11 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 12 HOW TO FIND A SPECIFIC TOPIC...
Page 13: 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 14: Pictorial Index
PICTORIAL INDEX Interior Equipment Page Equipment Page Air flow direction control lever Combination light control 4-55 switch Small article storage pocket 5-24 4-90 Cruise control SET/ Heater/manual air RESUME/CANCEL 4-91 conditioner switch 4-92 Automatic air conditioner 5-12 Front lid lever AM Radio 5-31 Cigarette lighter...
Page 15 PICTORIAL INDEX Equipment Page Equipment Page Cruise control MAIN 4-89 switch Horn button 4-65 Instruments, warning lights and indicator lights 4-14 Driver SRS airbag 4-105 Interior light switch 5-21 Remote control mirror 4-66 switch Differential lock switch 4-61 Mirror heater switch 4-67 Fog light switch 4-58...
Page 16 PICTORIAL INDEX Equipment Page Equipment Page Seats 3-17 Seat belts 3-29 Remote control mirror Interior light (fluorescent 5-21 4-66 switch light) Parking brake lever 4-71 Dome light 5-22 Center console box 5-26 Overhead shelf 5-27 Sun visor 5-22 Gearshift lever 4-74 12 Fully adjustable steering 3-25...
Page 17 PICTORIAL INDEX Exterior Equipment Page Equipment Page Outside mirrors 3-26 Fog light 8-24 Turn signal light 8-24 Clutch fluid 7-101 Wheels and tyres 7-60 Front end outline marker 8-24 light Headlight 8-24 Clearance light 8-24...
Page 18 0-10 WARNING/INDICATOR LIGHT INDEX Warning/Indicator Light Index Multi-Information Display (MID) Warning Lights Message Display indication Color Page Low fuel Amber 4-43 Water separator (fuel filter) 4-38 Engine overheat 4-33 Engine coolant level 4-34 Cab tilt 4-43 Meter failure 4-47 CAN system error 4-48 Over speed 4-38...
Page 19 0-11 WARNING/INDICATOR LIGHT INDEX Message Display indication Color Page Transmission oil Green 4-39 Fuel filter Green 4-40 Power steering fluid Green 4-41 Tyre rotation Green 4-42 Total fuel economy Green 4-19 Per trip fuel economy Green 4-19 Instantaneous fuel economy Green 4-19 Calendar...
Page 20 0-12 WARNING/INDICATOR LIGHT INDEX Instrument Panel Warning Lights Name Symbol Color Page Check engine warning light Amber 4-36 Engine oil pressure warning light 4-32 ABS warning light Amber 4-30 SRS airbag warning light 4-29 Alternator warning light 4-36 Air pressure warning light 4-30 Parking brake warning light 4-45...
Page 21 0-13 WARNING/INDICATOR LIGHT INDEX Indicator Lights Name Symbol Color Page Trailer ABS indicator light Amber 4-31 Cruise control MAIN indicator light Green 4-46 Cruise control SET indicator light Green 4-46 High beam indicator light Blue 4-44 Exhaust brake indicator light Green 4-45 Differential lock indicator light...
Page 22 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 23 0-15 WARNING/CAUTION LABELS Driver's sunvisor Driver supplemental restraint system (SRS) airbag Center console FXR/FXM/FXZ/FYH models GXR model Wheel parking brake Gearshift pattern Trailer hand brake...
Page 24 0-16 WARNING/CAUTION LABELS Warning/Caution Labels – Cab Exterior Inside the front lid Left rear side of the cab Windshield wiper Electric cab tilt Warning/Caution Labels – Chassis Air cleaner Brake chamber Air cleaner Brake chamber...
Page 25 0-17 WARNING/CAUTION LABELS Pre-fuel filter Spare tire carrier Rear of the vehicle Rear suspension Pre-fuel filter Spare wheel LSPV (Load sensing proportioning valve) Air suspension...
Page 26 0-18 WARNING/CAUTION LABELS Power steering fluid tank Power steering fluid tank FXR/FXM/FXZ/GXR models FYH model Power steering fluid tank Power steering fluid tank Warning/Caution Labels – Engine Compartment 6UZ1 engine Radiator sub-tank Engine tuning table and engine model Radiator sub-tank cap...
Page 27: Vehicle Information
VEHICLE INFORMATION ● Vehicle Identification Number (VIN) and Engine Numbers...
Page 28 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 29 GXR: 4 × 2 tractor Engine code 77: 6UZ1 Engine Wheelbase code Model year code A: 2010 MY B: 2011 MY Chassis number ADVICE • Interpretation of the VIN may differ depending on the market. For further details, please ask your Isuzu Dealer.
Page 30 60 km/h speed limit device 16.5-inch final drive 100 km/h speed limit device R130/RT210 type axle 17.5-inch final drive ADVICE • There are more option codes than those shown above. For detailed specifications of your vehicle, please ask your Isuzu Dealer.
Page 31 VEHICLE INFORMATION Engine Number The engine number is stamped on the back of the engine foot mounting on the left- hand side of the crank case.
Page 32 VEHICLE INFORMATION...
Page 33: Important Information
● RTO-11908LL Manual Transmission Model 2-41 ● Stopping and Parking 2-41 ● Staying Safe 2-47 ● Preventing Breakdowns 2-51 ● When to Visit an Isuzu Dealer 2-53 ● Turbocharger 2-55 ● Particulate Matter (PM) Catalytic Converter 2-57 ● Speed Limit Device 2-58 ●...
Page 34 Owners of Isuzu trucks purchased in Australia but operated overseas should consult their local Isuzu Dealer in the country of operation about any warranty or laws that are applicable to their trucks. This warranty does not apply to Isuzu trucks exported overseas.
Page 35 IAL are free of charge. IAL also has a grievance policy if an owner/operator is unsatisfied about any aspect of claiming under this warranty by calling Isuzu Customer Care on 1800 035 640 and discussing their grievance. Cancellation of warranty...
Page 36 •• Cosmetic or surface corrosion resulting from scratches, stone chips, etc. Any work carried out on the vehicle by someone other than an authorised Isuzu •• truck dealer or an authorised service dealer. Deterioration due to normal use, exposure, wear and tear.
Page 37 Parts and Accessories installed after new vehicle delivery by an Isuzu Dealer or IAL Authorised Service Dealer Parts and Accessories installed after delivery by an Authorised Isuzu dealer or IAL...
Page 38 “Legal” This warranty is given by Isuzu Australia Limited, ABN 97 006 962 572 whose business address is 858 Lorimer Street, Port Melbourne, Vic 3207. IAL’s telephone number is 1800 035 640.
Page 39 (as discussed above) is required to enable the Vehicle to be operated safely and it is not practical for you to go to an Isuzu Authorised Dealer, the service (but only to the extent that it is necessary to enable the Vehicle to be operated safely) may be performed by any other qualified mechanic or repairer.
Page 40 IAL warranty service at the premises of the servicing Isuzu Authorised Dealer are free of charge. Whenever IAL warranty service is to be carried out by an Isuzu Authorised Dealer it is your responsibility and cost to deliver the Vehicle to the servicing dealer’s premises.
Page 41 Subject to the Australian Consumer Law and any other relevant laws, this warranty contains all of IAL’s obligations to you in relation to the Vehicle. No Isuzu dealer or other person is authorised or permitted to give or make any statement, assertion or undertaking in relation to the quality, performance,...
Page 42 IMPORTANT INFORMATION Customer Assistance We trust that you are delighted with your Isuzu truck and that it provides you with many years of safe and trouble free operation. However, in the event that you experience a problem with any aspect of your vehicle, be assured your Isuzu Dealer is well equipped to assist you.
Page 43 • Hydraulic hose repair Isuzu Assist covers you at the roadside 24 hours a day, 365 days a year for 36 months from the date of first registration. This free service is extended to you whether you are a private truck purchaser, a fleet, taxi truck or rental company, or a Commonwealth, State or Local Government customer.
Page 44 Lockout or lost keys If you have lost your keys, or inadvertently locked them in your truck cabin, Isuzu Assist will attempt to open the truck. However, the driver may be asked to sign an indemnity releasing the service provider from any liability should damage be caused by such forced entry.
Page 45 Isuzu Assist towing allowance. Accident Co-ordination Isuzu Assist with the assistance of the driver will proceed in the management of the incident. This could include advising the driver of their obligations at the scene of the accident, connecting the driver to an appropriate Service Provider, 000 Emergency services, or a vehicle recovery operator.
Page 46 Truck Rescue If your truck has become disabled/Bogged off a 'legally' trafficable road in a situation such as a mining/construction site, beach, field or creek bed, Isuzu Assist will attempt recovery, however, this will be at the owners's expense. Remote Areas In remote or sparsely populated areas you may experience delays in obtaining Isuzu Assist due to your location, the availability of the service provider and accessibility.
Page 47 IMPORTANT INFORMATION Attempted Repairs If you request Isuzu Assist, the service provider will on arrival examine the truck. If it is found that a third party has attempted repairs causing further problems and the service provider considers in his/her opinion that the truck cannot be started or driven without risk of further damage, service may be refused.
Page 48 2-16 IMPORTANT INFORMATION Privacy Policy For information on the Isuzu Australia Limited privacy policy, please visit www.isuzu. com.au or call the Isuzu Customer Care Centre on 1800 035 640. Service provided by NTI TRUCKASSIST Before Driving Perform Daily (Pre-operation) Inspections ADVICE •...
Page 49 2-17 IMPORTANT INFORMATION [3. Checks performed in the driver's seat] Check item Reference page Operation of meters, gauges and warning/indicator lights 4-8, 4-14 Engine start ability, abnormal noise and color of exhaust emissions 7-20 Brake pedal free play 7-53 Exhaust sound from brake valve 7-53 Increase in air pressure 7-93...
Page 50 2-18 IMPORTANT INFORMATION Use the Specified Fuel CAUTION • Using fuel other than low sulfur diesel fuel (with sulfur content no higher than 50 ppm) or ultra-low sulfur diesel fuel (with sulfur content no higher than 10 ppm) would have a harmful effect on the engine, possibly resulting in a breakdown. If you accidentally put the wrong fuel in the tank, drain it all out.
Page 51 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 52 2-20 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 53 2-21 IMPORTANT INFORMATION Cargo loading caution Incorrect Correct Do not place cargo only at the front or only at the rear. Distribute it evenly. When using supports under cargo, position them uniformly along the cargo. To the greatest extent possible, do not allow long cargo to protrude beyond the rear edge of the cargo bed.
Page 54 2-22 IMPORTANT INFORMATION Do Not Secure Cargo Too Tightly ADVICE • To prevent cargo from falling off the cargo bed, it is essential to secure it with ropes and tarpaulins. However, retaining it too tightly can damage the cargo bed's gates and front guard frame.
Page 55 2-23 IMPORTANT INFORMATION Unloading Cargo CAUTION • When you load or unload cargo at the roadside and the cargo bed's gates or other body parts obscure the tail lights, stop lights, hazard warning flashers, turn signal lights and/or reflectors, be sure to warn other drivers and road users by placing signs or emergency warning triangles where they are easy to...
Page 56 2-24 IMPORTANT INFORMATION Keep the Floor around the Driver's Seat Clean and Tidy WARNING • It is extremely dangerous to have empty cans, empty bottles or other items rolling around on the floor because they could get trapped under the brake pedal and prevent brake application.
Page 57 2-25 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. Seat adjustment recommendations Make adjustments that allow you to easily turn the steering wheel with your elbows slightly bent.
Page 58 2-26 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 59 2-27 IMPORTANT INFORMATION Carrying an Expectant Mother or a Person Who is Ill WARNING • An expectant mother or a person who is ill riding in the vehicle must also wear a seat belt. In light of the risk that the seat belt will apply pressure to the abdomen, chest and shoulders in the event of a collision, however, an expectant mother or a...
Page 60 2-28 IMPORTANT INFORMATION Carrying Children Using Seat Belts with Children WARNING • The vehicle's seat belts are designed for adults. If a seat belt touches a child's neck or chin, or does not rest across his/her hips, use a baby seat, child seat or junior seat.
Page 61 2-29 IMPORTANT INFORMATION Do not Allow a Child to Put His/Her Head or Hands out of the Window WARNING • Regardless of whether the vehicle is moving or stationary, you must never allow a child to put his/her head, hands, or other body parts out of the window.
Page 62 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 63 If exhaust gases get into the cab, completely open all of the windows and place the inside/outside air selector of the heater or air conditioner to outside air. Promptly 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 64 2-32 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 65 2-33 IMPORTANT INFORMATION Do not Run the Engine in a Garage WARNING • Running the engine in a poorly ventilated place can lead to carbon monoxide poisoning. Start and warm up the engine only in places that have good ventilation. Do not Forget to Release the Parking Brake ADVICE •...
Page 66 2-34 IMPORTANT INFORMATION Appropriate Gearshifts ADVICE • Downshifts are performed for two main purposes: For engine braking on a steep and/or long downward slope For responsiveness and economy on an uphill slope [Cautions for downshifts] • Allowing the engine to overrun can result in engine damage.
Page 67 2-35 IMPORTANT INFORMATION Never Stop the Engine While Driving WARNING • Do not place the starter switch in any position other than "ON" while driving. If the engine stops while the vehicle is moving, the brakes would work poorly, and the steering wheel and clutch pedal would become extremely stiff and hard to operate.
Page 68 2-36 IMPORTANT INFORMATION Driving Down a Long Slope When driving down a long slope, select an appropriate gear to take advantage of engine brake and use the exhaust brake together with the foot brakes. Using the exhaust brake and low-gear engine brake reduces the workload on the foot brakes and yields greater braking force.
Page 69 2-37 IMPORTANT INFORMATION Driving in Bad Weather (Rain, Icy Roads, Snowy Roads, etc.) CAUTION • In bad weather, visibility is reduced and slippery road surfaces increase stopping distances. Drive more slowly than you would in good weather. Also, avoid sharp turns of the steering wheel and hard braking. Use engine brakes together with the foot brakes to decelerate.
Page 70 Isuzu Dealer. • Promptly have your Isuzu Dealer perform water-ingress checks and, where necessary, lubricate brake, engine, electrical, transmission and differential components.
Page 71 2-39 IMPORTANT INFORMATION Sidewinds ADVICE If the vehicle catches a sidewind and drifts sideways, firmly grip the steering wheel, decelerate to a speed that allows you to stay completely in control and make a directional correction. The vehicle may catch strong sidewinds in the following situations: •...
Page 72 If any part of the vehicle is damaged or broken, promptly have the vehicle inspected and repaired by the nearest Isuzu Dealer. If a Warning Light or Indicator Light Comes On or Flashes ADVICE •...
Page 73 2-41 IMPORTANT INFORMATION ZF9S1310 Manual Transmission Model The ZF9S1310 manual transmission differs from the 6 speed manual transmission in that it requires selection of low range or high range when the gearshift lever is used. Be sure to learn how to correctly use the gearshift lever. Model with ZF9S1310 Model Manual Transmission →...
Page 74 2-42 IMPORTANT INFORMATION Applying the Parking Brake CAUTION • Except in an emergency, do not apply the parking brake until the vehicle has come to a complete stop. Applying the parking brake before the vehicle has stopped can cause the tyres to lock or the vehicle to spin, possibly causing an accident.
Page 75 2-43 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 76 2-44 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 tyres).
Page 77 2-45 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 78 2-46 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 79 2-47 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 80 2-48 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 81 2-49 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 82 2-50 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 83 2-51 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 84 2-52 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 85 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 86 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 Tyres and Wheels CAUTION •...
Page 87 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. Turbocharger General Precaution...
Page 88 If you are unable to perform a repair, the corrective action shown in the table does not eliminate a symptom or you can't locate a fault, contact the nearest Isuzu Dealer. Reference Symptom...
Page 89 2-57 IMPORTANT INFORMATION Particulate Matter (PM) Catalytic Converter The PM catalytic converter uses an oxidation catalyst to reduce the unburnt portion of the exhaust particulate matter to water and carbon dioxide. Generally speaking, the temperature of the exhaust from diesel engines is low when the engine is idling, and as the oxidation catalyst is not activated in this condition, various types of emissions accumulate within the catalyst.
Page 90 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 tyre size is changed, the speed limit device may not work normally. Have adjustments made by the nearest Isuzu Dealer.
Page 91 2-59 IMPORTANT INFORMATION Seat Belt with Pretensioner and Supplemental Restraint System (SRS) Airbag System If a vehicle that has seat belt with pretensioner and an SRS airbag system suffers a frontal impact above certain level, seat belt with pretensioner and airbag securely restrain the driver in his/ her seat and lessen the physical shock to his/her head.
Page 92 • Replacing the steering wheel with a steering wheel other than an Isuzu-specified one or affixing a sticker to the steering wheel pad would be dangerous because it could result in defective operation and cause the sticker to be propelled toward you in the event of airbag deployment.
Page 93 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...
Page 94 2-62 IMPORTANT INFORMATION...
Page 95 DOORS, WINDOWS AND SEATS ● Key ● Keyless Entry System ● Opening and Closing Doors ● Getting In and Out of the Vehicle 3-10 ● Power Windows 3-12 ● Manually Operated Windows 3-13 ● Fuel Tank Filler Cap 3-14 ● Seats 3-17 ●...
Page 96: Doors, Windows And Seats
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 97 DOORS, WINDOWS AND SEATS Keyless Entry System The keyless entry system allows you to lock/unlock the doors by simply pressing the remote control button rather than inserting the key into the lock. The remote control unit works within a 10 m (33 ft) radius of the cab center as indicated in the figure (the actual distance over which the unit operates may vary depending on...
Page 98 DOORS, WINDOWS AND SEATS ADVICE • Should you lose the remote control unit, please contact your Isuzu Dealer. • After locking the doors using the remote control unit, be sure to check that they are locked by pulling the door handles.
Page 99 DOORS, WINDOWS AND SEATS Replacing the Battery in the Remote Control Unit When the battery runs down, replace it. Battery life is approximately 2 years. Battery used Number of battery Lithium battery Model number: CR2032 Voltage: DC3V Type 1 1. Remove the screw and pry open the cover by inserting a flat-blade screwdriver or similar tool into the notch of the cover.
Page 100 DOORS, WINDOWS AND SEATS Type 2 1. Remove the screw and pry open the cover by inserting a flat-blade screwdriver or similar tool into the notch of the cover. Wrap a piece of cloth or tape around the tip of the screwdriver so as not to damage the cover.
Page 101 DOORS, WINDOWS AND SEATS NOTE • Please comply with the collection system available in your country for the disposal of old batteries. In addition, take special care to prevent any danger to children. CAUTION • When changing the battery, use only a battery of the same type as the original battery, or an equivalent.
Page 102 DOORS, WINDOWS AND SEATS Locking and Unlocking the Front Doors Locking and Unlocking the Door from Outside Using the Key Firmly insert the key. Turn the key toward the rear of the vehicle to unlock the door and turn it toward the front of the vehicle to lock it.
Page 103 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 104 3-10 DOORS, WINDOWS AND SEATS Getting In and Out of the Vehicle Carefully check that the area around the Grip vehicle is safe, hold the grip, and place your foot on the step when getting in or out of the vehicle. Grip Step CAUTION...
Page 105 3-11 DOORS, WINDOWS AND SEATS ADVICE • Do not hold parts other than the grip when getting in or out of the vehicle. Doing so may cause damage to the vehicle or injuries to yourself or others. • When climbing into the cab, do not step on the plastic cover of the lower step;...
Page 106 3-12 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 107 3-13 DOORS, WINDOWS AND SEATS Window Switches on Passenger's Door 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 window. The window continues to lower while the window switch is being pressed and continues to rise while the switch is being...
Page 108 3-14 DOORS, WINDOWS AND SEATS Fuel Tank Filler Cap WARNING • Be sure to place the starter switch in the "ACC" or "LOCK" position to shut down the engine before refueling the vehicle. Refueling while the engine is running could cause a fire in your vehicle. •...
Page 109 3-15 DOORS, WINDOWS AND SEATS How to Open and Close the Fuel Tank Filler Cap (without Key Lock) 1. Eliminate static from your body before opening the fuel tank filler cap. 2. Slowly turn the cap counterclockwise to open it. 3.
Page 110 3-16 DOORS, WINDOWS AND SEATS Opening and Closing the Fuel Tank Filler Cap (with Key Lock) 1. Eliminate static from your body before opening the fuel tank filler cap. 2. Open the cover, then firmly insert the key and turn it to unlock the cap. 3.
Page 111 3-17 DOORS, WINDOWS AND SEATS Seats The driver's seat must be adjusted so that when you sit well back in the seat, you can fully depress the pedals without moving your back from the seatback, and you can operate the steering wheel easily and freely. After making adjustments, check that the seat is completely locked.
Page 112 3-18 DOORS, WINDOWS AND SEATS Driver's Seat (Except ISRI 6860/875 NTS Model) Forward/Backward Adjustment While raising the unlock 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 113 3-19 DOORS, WINDOWS AND SEATS Front Tilt Adjustment of Cushion The height of the front of the cushion can be adjusted by raising the front cushion tilt lever. Suspension Lock (Air Suspension Seat) Turn the lever up to lock the seat at the fixed height.
Page 114 3-20 DOORS, WINDOWS AND SEATS Driver's Seat (ISRI 6860/875 NTS Model) Horizontal Adjustment Pull the lever and move the seat forward or backward. Release the lever to lock the seat. After making adjustments, try to move the seat back and forth to check that it is fully locked.
Page 115 3-21 DOORS, WINDOWS AND SEATS Air Suspension On-off Switch Press the top of the switch to turn on the air suspension. To turn off the air suspension, press the bottom of the switch. Height Adjustment Pull or push the lever and adjust the seat to the desired height.
Page 116 3-22 DOORS, WINDOWS AND SEATS Damper Adjustment By adjusting the damper, the suspension characteristics of the seat can be optimally adapted to all types of roadways and drivers. Lever up: minimum damper force Lever down: maximum damper force NOTE • The damping force adjustment of the shock absorber does not work when the air suspension is turned...
Page 117 3-23 DOORS, WINDOWS AND SEATS Lower Lumbar Support Select the desired firmness for lumbar support that is provided at the bottom of the seatback. The appropriate setting will help alleviate fatigue during long-haul driving. Upper Lumbar Support Select the desired firmness for back support that is provided at the center of the seatback.
Page 118 3-24 DOORS, WINDOWS AND SEATS Passenger's Seat Reclining Adjustment Raise the reclining lever to adjust the seatback angle. 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 collision or sudden braking.
Page 119 3-25 DOORS, WINDOWS AND SEATS Fully Adjustable Steering The steering wheel is adjustable up and down as well as forward and backward. WARNING • After adjusting the steering wheel, try moving it up and down to make sure it is fully locked before you drive the vehicle.
Page 120 3-26 DOORS, WINDOWS AND SEATS Mirrors Sit in the correct driving position on the properly adjusted seat, and then check each mirror to ensure that it provides a proper view of the rear, the sides, the area just in front of the vehicle, and the area directly opposite to the driver's seat. Make adjustments if necessary and clean any dirty mirrors.
Page 121 3-27 DOORS, WINDOWS AND SEATS Outside Rearview Mirror Lateral-direction: Adjust the mirror so that you can see the vehicle's side including the cargo bed within the inner one-third of the mirror. Vertical-direction: Adjust the mirror so that you see the rear bottom corner of the vehicle halfway up the height of the mirror.
Page 122 3-28 DOORS, WINDOWS AND SEATS Pillar-mounted Mirrors After properly adjusting your seat for the correct 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 123 Instead, use an appropriate child restraint system available on the market. For further details, please contact your Isuzu Dealer. WARNING (Continued)
Page 124 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 125 3-31 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 126 (SRS) airbag system may be adversely affected, possibly causing the seat belt to unintentionally retract or the airbag to suddenly deploy, resulting in injury. Be sure to have any repair or installation done by your Isuzu Dealer. NOTE •...
Page 127 3-33 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.) 3.
Page 128 3-34 DOORS, WINDOWS AND SEATS To Unfasten Push the button on the buckle to unfasten the belt. NOTE [Center seat belt design to prevent incorrect fastening] • The center seat belt (length- adjustable two-point belt) is designed so that it cannot be connected with any of the window- side seat belts (three-point seat belts with ELR).
Page 129 CONTROLS AND INSTRUMENTS STARTING AND STOPPING THE ENGINE INSTRUMENTS, WARNING LIGHTS AND INDICATOR LIGHTS 4-51 SWITCHES 4-69 DRIVING CONTROLS...
Page 131 CONTROLS AND INSTRUMENTS STARTING AND STOPPING THE ENGINE ● Starting the Engine ● Stopping the Engine...
Page 132 CONTROLS AND INSTRUMENTS Starting the Engine Make sure that the switches, including those for the windshield wiper, light control and air conditioner, are in the "OFF" position. Turn the starter switch to the "ON" position to check that the warning and indicator lights turn on normally and the fuel level is proper.
Page 133 CONTROLS AND INSTRUMENTS ADVICE • At low ambient temperatures, a cold engine may emit more smoke (white smoke) than usual. Stopping the Engine Firmly apply the parking brake. With the accelerator pedal released, turn the starter switch to the "ACC" or "LOCK" position.
Page 134 CONTROLS AND INSTRUMENTS...
Page 135 CONTROLS AND INSTRUMENTS INSTRUMENTS, WARNING LIGHTS AND INDICATOR LIGHTS ● How to Read the Instruments (Instruments Layout) ● Speedometer ● Tachometer 4-10 ● Air Pressure Gauge 4-11 ● Engine Coolant Temperature Gauge 4-12 ● Fuel Gauge 4-13 ● Hour Meter 4-13 ●...
Page 136 CONTROLS AND INSTRUMENTS How to Read the Instruments (Instruments Layout) Reference Reference Name Name page page Engine coolant Air pressure gauge 4-12 4-11 (primary) temperature gauge Tachometer 4-10 Air pressure gauge 4-11 (secondary) Multi-information display 4-16 (MID) Fuel gauge 4-13 Speedometer...
Page 137 CONTROLS AND INSTRUMENTS Speedometer The speedometer indicates the vehicle 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 138 4-10 CONTROLS AND INSTRUMENTS NOTE • When you turn the starter switch to the "ON" position, the odometer / trip meter shows what was displayed the last time you turned the switch to the "LOCK" position. • You can set the odometer to display on the odometer / trip meter each time you turn the starter switch to the "ON"...
Page 139 Proper air pressure range contact the nearest Isuzu Dealer. 740 - 830 kPa Air Pressure Checking (7.5 - 8.5 kgf/cm²/107 - 121 psi) → Refer to page 7-93...
Page 140 4-12 CONTROLS AND INSTRUMENTS Engine Coolant Temperature Gauge With the starter switch in the "ON" position, this gauge indicates the temperature of the engine coolant. "C" means cold while "H" means hot. If the engine overheats, the warning message is indicated and a warning buzzer sounds.
Page 141 4-13 CONTROLS AND INSTRUMENTS Fuel Gauge With the starter switch in the "ON" position, this gauge indicates the quantity of fuel remaining in the fuel tank. "F" means the tank is full while "E" means the tank is almost empty. NOTE •...
Page 142 4-14 CONTROLS AND INSTRUMENTS Warning and Indicator Lights Layout Reference Reference Name Name page page Cruise control main Multi-information display 4-46 4-16 indicator light (MID) High beam indicator light 4-44 Cruise control set 4-46 indicator light Low accessory air 4-47 pressure warning light Differential lock 4-47...
Page 143 4-15 CONTROLS AND INSTRUMENTS Reference Reference Name Name page page Turn signal and hazard Inter-differential lock 4-46 warning flasher indicator 4-44 indicator light light - left Trailer ABS indicator Engine over run 4-31 4-38 light warning light 22 Seat belt warning light 4-29 Parking brake warning 4-45...
Page 144 Otherwise, you will be in danger of vehicle breakdown or accident. Should any of the critical warning lights comes on, immediately contact the nearest Isuzu Dealer. Main Routine The following chart shows you the basic screens of the MID and what operations are necessary to access these screens.
Page 145 4-17 CONTROLS AND INSTRUMENTS...
Page 146 4-18 CONTROLS AND INSTRUMENTS Warning and Indicator Lights Display Warning and indicator messages are shown on the display to alert you to system failures or prompt you to necessary checks you should perform while operation-related information is being displayed. Use the MID select knob to select the desired screen page or function. Reference Indication Color...
Page 147 4-19 CONTROLS AND INSTRUMENTS Operation-Related Information Display This function displays vehicle operation related information on such items as fuel economy, battery voltage, calendar and clock, which is useful for efficient management of your vehicle operation. Fuel Economy The system calculates and stores the distance traveled and fuel consumption while driving to encourage the operator to drive the vehicle economically.
Page 148 "L" level or rises to the "H" level. If a voltmeter sign appears with red, have the vehicle checked and serviced at the nearest Isuzu Dealer as soon as possible. Message...
Page 149 4-21 CONTROLS AND INSTRUMENTS Calendar and Clock Use the MID select knob to select the calender or clock to display. CAUTION • The calendar and clock can be set only while the vehicle is stationary. When setting the calendar or clock, park your vehicle in a safe place where stopping or parking is permitted and well clear of traffic.
Page 150 4-22 CONTROLS AND INSTRUMENTS 7. Turn the MID select knob clockwise to increase the day and counterclockwise to decrease the day. If you hold the knob after turning it clockwise or counterclockwise, the day continues to increase or decrease until the knob is released.
Page 151 The maintenance data function indicates the distance remaining before the next scheduled maintenance. A scheduled maintenance interval is approaching when the display turns from green to amber. Have the vehicle checked and serviced at your Isuzu Dealer as soon as possible. CAUTION •...
Page 152 4-24 CONTROLS AND INSTRUMENTS Maintenance Reference Display indication Color Descriptions message page Distance remaining until Green the next engine oil and filter change is displayed. Engine oil and 4-35 filter This is displayed when the Amber next engine oil and filter change is near or due.
Page 153 4-25 CONTROLS AND INSTRUMENTS How to Set a New Change Interval (Odometer Reading) for Engine Oil and Filter 1. On the MID, go to the ENG OIL & FILTER screen. 2. Enter the setting change screen by pressing and holding the MID select knob. NOTE • If you want to cancel the setting procedure, press the MID select knob momentarily.
Page 154 4-26 CONTROLS AND INSTRUMENTS Setting the Tire Rotation Interval (Odometer Reading) 1. On the MID, go to the TIRE ROTATION screen. 2. Enter the setting change screen by pressing and holding the MID select knob. NOTE • Your vehicle has been shipped from the factory with no tire rotation interval set.
Page 155 4-27 CONTROLS AND INSTRUMENTS Over Speed 1. On the MID, go to the SPEED WARNING screen. 2. Enter the speed warning setting screen by pressing and holding the MID select knob. NOTE • Your vehicle has been shipped from the factory with no warning speed set.
Page 156 If the system has not yet been able to access maintenance data, "ERROR" is shown on the MID. If "ERROR" does not change automatically to a distance or other maintenance indication, have your vehicle inspected / serviced at the nearest Isuzu Dealer. Per trip fuel Instantaneous fuel...
Page 157 CAUTION • If an error occurs, have your vehicle inspected/serviced at your Isuzu Dealer as soon as possible. [Error] If the warning light does not flash seven times when the starter switch is turned to the "ON"...
Page 158 • 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 159 If the warning light comes on again after it has gone out or while driving, the trailer ABS has a problem. Please contact the nearest Isuzu Dealer. This warning light does not come on when the trailer is not equipped with an ABS.
Page 160 If this warning light comes on while the engine is running, immediately pull off to a safe place well clear of traffic. • The lubrication system may be faulty. Promptly have your vehicle inspected at the nearest Isuzu Dealer. Engine Oil→ Refer to page 7-21...
Page 161 4-33 CONTROLS AND INSTRUMENTS Engine Overheat Warning Light This warning message appears on the display when the engine has overheated. When the engine overheats, the engine coolant temperature gauge needle moves to the red zone, and the engine overheat message appears on the display, and at the same time a buzzer sounds.
Page 162 4-34 CONTROLS AND INSTRUMENTS Engine Coolant Level Warning Light This warning message appears on the display when the engine coolant level is too low. At the same time, a buzzer sounds. Immediately pull off to a safe place, and check the vehicle and take necessary actions.
Page 163 When the engine oil and filter indicator light (amber) comes on, have the vehicle inspected / serviced at your Isuzu Dealer. Multi-Information Display (MID) → Refer to page 4-16 When ERROR is Displayed → Refer to page 4-28 Engine Oil → Refer to page 7-21...
Page 164 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 7-34 Handling the Battery → Refer to page 7-143...
Page 165 "ON" position. And the indicator light keeps lighting for 15 seconds, and then will go off after flashing three times. If the indicator light comes on during operation, immediately contact the nearest Isuzu Dealer for inspection.
Page 166 4-38 CONTROLS AND INSTRUMENTS Water Separator (Fuel Filter) Warning Light This warning light appears on the display 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.
Page 167 MID select knob is pressed momentarily or the vehicle is started. When the transmission oil indicator light (amber) has come on, have the vehicle inspected / serviced at your Isuzu Dealer. Multi-Information Display (MID) → Refer to page 4-16 When ERROR is Displayed → Refer to page 4-28...
Page 168 MID select knob is pressed momentarily or the vehicle is started. When the fuel filter indicator light (amber) has come on, have the vehicle inspected / serviced at your Isuzu Dealer. Multi-Information Display (MID) → Refer to page 4-16 When ERROR is Displayed → Refer to page 4-28...
Page 169 MID select knob is pressed momentarily or the vehicle is started. When the power steering fluid indicator light (amber) has come on, have the vehicle inspected / serviced at your Isuzu Dealer. Multi-Information Display (MID) → Refer to page 4-16 When ERROR is Displayed...
Page 170 4-42 CONTROLS AND INSTRUMENTS Tire Rotation Indicator Light This message appears on the MID when the tire rotation maintenance screen is selected or when the next tire rotation is approaching or due. The distance shown (Comes on amber when the next tire is the remaining distance to the next tire rotation is near or due.) rotation or the distance the vehicle traveled...
Page 171 4-43 CONTROLS AND INSTRUMENTS Low Fuel Warning Light This warning message appears on the MID when the fuel level in the tank becomes too low while the engine is running. ADVICE • If the low fuel warning message appears on the screen, add fuel at the earliest possible time.
Page 172 4-44 CONTROLS AND INSTRUMENTS Turn Signal and Hazard Warning Flasher Indicator Light Either of these indicator lights flashes when the turn signal switch is operated irrespective of the position of the starter switch. Both indicator lights flash when the hazard warning flasher switch is operated irrespective of the position of the starter switch.
Page 173 ADVICE • 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 4-60...
Page 174 4-46 CONTROLS AND INSTRUMENTS Cruise Control Main Indicator Light This indicator light comes on when the cruise control main switch is placed in the "ON" position. This indicator light comes on when the starter switch is turned to the "ON" position, and then goes out after approximately 5 seconds.
Page 175 While the message is displayed, the instrument panel does not function properly. Pull off to a safe place, stop the engine, and restart it. If the message still appears, contact the nearest Isuzu Dealer.
Page 176 If a CAN error has occurred, the engine coolant temperature gauge stops functioning and the alarming functions of the panel do not work properly. Pull off to a safe place, stop the engine, and restart it. If the message still appears, contact the nearest Isuzu Dealer.
Page 177 ADVICE • The warning buzzer may not sound if there is a problem with the system. If this occurs, the system needs to be inspected. Please contact the nearest Isuzu Dealer. • At night, the buzzer back-up warning sound level can be reduced by placing the...
Page 178 4-50 CONTROLS AND INSTRUMENTS...
Page 179 4-51 CONTROLS AND INSTRUMENTS SWITCHES ● Starter Switch 4-52 ● Idling Control Switch 4-54 ● Combination Light Control Switch 4-55 ● Headlight Leveling Switch 4-58 ● Fog Light Switch 4-58 ● Hazard Warning Flasher Switch 4-59 ● Exhaust Brake Switch 4-60 ● Differential Lock Switch 4-61 ●...
Page 180 4-52 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 181 4-53 CONTROLS AND INSTRUMENTS Starter Switch LOCK : In this position, the key can be inserted or removed. Remove the key, and turn the steering wheel until it locks. The steering wheel will be locked to help prevent theft. To place the starter switch in the "LOCK"...
Page 182 When the engine coolant temperature is low When the power take-off (PTO) is operating if your vehicle is equipped with a If the idling speed is not within the standard values, or the engine does not smoothly turn over, contact the nearest Isuzu Dealer.
Page 183 4-55 CONTROLS AND INSTRUMENTS Combination Light Control Switch Light Control Switch With the starter switch in any position, turning the light control switch to the positions indicated in the table below causes the relevant lights to illuminate. Position Name Headlight Clearance light Taillight License plate light...
Page 184 4-56 CONTROLS AND INSTRUMENTS Switching between High Beam and Low Beam With the headlights on, move the lever forward and rearward to switch between the high beam and low beam. Moving the lever forward selects high beam; moving the lever rearward selects low beam.
Page 185 4-57 CONTROLS AND INSTRUMENTS Turn Signal Light Switch When turning left or right, move the lever up or down to flash the turn signal light. ADVICE • The turn signal lights come on even when the starter switch is in the "ACC"...
Page 186 4-58 CONTROLS AND INSTRUMENTS Fog Light Switch With the light control switch positioned in " " or " ", when this switch is pressed, the fog lights come on and the fog indicator light comes on. To turn off the lights, press the switch again. The fog lights are useful when forward visibility is poor such as in fog.
Page 187 4-59 CONTROLS AND INSTRUMENTS Hazard Warning Flasher Switch The hazard warning flasher is used to signal other vehicles that your vehicle is stationary on the road because of accident or component failure. With the starter switch in any position, when this switch is pressed, all of the turn signal lights and the turn signal indicator lights flash to signal emergency.
Page 188 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. Conditions for Inoperable Exhaust Brake Under the following conditions, the exhaust brake does not engage. • The accelerator pedal or the clutch pedal is pressed.
Page 189 4-61 CONTROLS AND INSTRUMENTS Differential Lock Switch Use the differential lock only when one or more than one of the tyres on the drive axle is on a muddy or sandy road surface, frozen and sloped road surface, or other slippery road surfaces. To engage the differential lock, press the differential lock switch on the "ON"...
Page 190 4-62 CONTROLS AND INSTRUMENTS Inter-Differential Lock Switch Use the inter-differential lock when one or more than one of the tyres 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 191 If the wiper frequently 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 192 4-64 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 •...
Page 193 4-65 CONTROLS AND INSTRUMENTS Horn Button To sound the horn, press the pad with a horn symbol on the steering wheel. LNU740SH016401...
Page 194 4-66 CONTROLS AND INSTRUMENTS Remote Control Mirror Switch Model for non-Australian markets The remote control mirror switch is active only when the starter switch is in the "ACC" or "ON" position. Adjustment 1. Press the left/right selector switch on the "L" or "R" side to move the mirror to the desired position.
Page 195 4-67 CONTROLS AND INSTRUMENTS Mirror Heater Switch Defrosting the Mirror Use the mirror heater to defrost the mirror surface. With the starter switch in the "ON" position, press the mirror heater switch to turn on the mirror heater. The mirror heater indicator light (amber) comes on. Press the switch again to turn it to "OFF".
Page 196 4-68 CONTROLS AND INSTRUMENTS...
Page 197 4-69 CONTROLS AND INSTRUMENTS DRIVING CONTROLS ● Pedals 4-70 ● Parking Brake Lever 4-71 ● Gearshift Lever 4-74 ● Model with ZF9S1310 Model Manual Transmission 4-80 ● Model with RTO-11908LL Model Manual Transmission 4-84 ● Cruise Control 4-88 ● Antilock Brake System (ABS) 4-94 ●...
Page 198 4-70 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 199 Check the air pressure for correct level. • If the air pressure level is abnormal, immediately contact the nearest Isuzu Dealer. • If the parking brake cannot be released but the air pressure is normal and you...
Page 200 4-72 CONTROLS AND INSTRUMENTS NOTE • When you raise the parking brake lever, the spring force applies the rear wheel brakes, causing them to work as a parking brake. • When the air pressure in the brake chamber drops below the limit, the rear wheel brakes are automatically applied regardless of the parking brake lever position.
Page 201 4-73 CONTROLS AND INSTRUMENTS Semi-trailer Tractor When the parking brake lever is pulled up to the "PARKING" position, both trailer brakes and tractor parking brakes are set. The parking brake warning light will then come on. To release the parking brake lever, return it to the "RELEASE"...
Page 202 4-74 CONTROLS AND INSTRUMENTS Gearshift Lever Manual Transmission Model (7 Speeds) MJT7 model transmission Model with MJT7 Model Transmission shift pattern A manual transmission model requires you to fully depress the clutch pedal when making a gear shift. When the gearshift lever is placed into "R (Reverse)", the back up lights come on and, in a model with back up warning buzzer, the buzzer sounds as well.
Page 203 4-75 CONTROLS AND INSTRUMENTS Manual Transmission Model (9 Speeds) ZF9S1310 model transmission ZF9S1310 Model Transmission with Single-H Shift Pattern single-H shift pattern A total of 9 forward gears are available from Low range the low and high speed ranges, the low range providing 5 gears consisting of "1 (1st gear)"...
Page 204 4-76 CONTROLS AND INSTRUMENTS ZF9S1310 model transmission ZF9S1310 Model Transmission with Double-H Shift Pattern double-H shift pattern A total of 9 forward gears are available from the low and high speed ranges, the low range providing 5 gears consisting of "1 (1st gear)"...
Page 205 4-77 CONTROLS AND INSTRUMENTS Manual Transmission Model (8 Speeds) RTO-11908LL model transmission Model with RTO-11908LL Model Transmission shift pattern Change gears using the gearshift lever in combination with the range selector and deep reduction selector. Use the selector levers on the gearshift lever to select a range or a deep reduction.
Page 206 4-78 CONTROLS AND INSTRUMENTS Range Shift The range selector selects Lo or Hi range. It is used once during an upshift sequence and once during a downshift sequence. Preselect CAUTION • Always preselect all range shifts when upshifting or downshifting. Preselection requires that the range selector is moved to the needed position before starting the shift.
Page 207 4-79 CONTROLS AND INSTRUMENTS Driving Tips • Always use normal double-clutching procedures when making lever shifts. • Always select an initial starting gear that provides sufficient reduction for the load and terrain. • Never slam or jerk the shift lever to complete gear engagements. • Never coast with the shift lever in the neutral position. • Never downshift at too high of a road speed. • Never move the range lever with the shift lever in neutral while the vehicle is moving. • Never make a range shift while moving in reverse. • In most cases, depending on the engine and axle ratios, you can save valuable fuel by operating the vehicle at less than governed speed while cruising in 8th. • For models equipped with the dash-mounted deep reduction valve, NEVER move its lever to the IN position while the transmission is in Hi range. • Never more the shift lever to Lo speed gear position when the transmission is in Hi range.
Page 208 4-80 CONTROLS AND INSTRUMENTS Model with ZF9S1310 Model Manual Transmission The ZF9S1310 manual transmission requires selection of the low range or the high range when operating the gearshift lever, unlike the 6-speed transmission. Fully understand how to operate the gearshift lever and form a habit of operating it correctly.
Page 209 4-81 CONTROLS AND INSTRUMENTS CAUTION • You may shift into "C (crawler)" only when starting the vehicle from a standstill. Shifting into the "C" position during driving will cause damage to the transmission. • Shift into "C (crawler)" or "R (reverse)" only when the vehicle has come to a stop completely.
Page 210 If low-high range switching becomes impossible If low-to-high range switching is impossible, you can still drive the vehicle. Have your vehicle inspected at the nearest Isuzu Dealer promptly. If high-to-low range switching becomes impossible, you cannot drive the vehicle. Immediately stop your vehicle at a safe place and contact the nearest Isuzu Dealer.
Page 211 If low-high range switching becomes impossible If low-to-high range switching is impossible, you can still drive the vehicle. Have your vehicle inspected at the nearest Isuzu Dealer promptly. If high-to-low range switching becomes impossible, you cannot drive the vehicle. Immediately stop your vehicle at a safe place and contact the nearest...
Page 212 4-84 CONTROLS AND INSTRUMENTS Model with RTO-11908LL Model Manual Transmission In a vehicle with an RTO-11908LL model transmission, range (Hi/Lo) selection and deep reduction (In/Out) selection are necessary when the gearshift lever is operated. Fully understand how to operate the gearshift lever, and familiarize yourself to the correct operation.
Page 213 4-85 CONTROLS AND INSTRUMENTS 6. Make sure the deep reduction selector is in the "Out" position. OR, in the "In" position if you want to start in Lo-Lo under adverse conditions. 7. Depress the clutch pedal to the floor. 8. Move the shift lever to desired initial gear.
Page 214 4-86 CONTROLS AND INSTRUMENTS Downshift Procedure 1. Move the shift lever, double-clutching, to the next desired gear position in HI range. Range shift from HI Range to Lo Range (5th to 4th)… 2. While in 5th and ready for the next downshift, preselect Lo range, push the range preselection lever down.
Page 215 If you cannot shift from "Lo" to "Hi", the vehicle can still be driven. Promptly contact the nearest Isuzu Dealer to have the vehicle inspected. If you cannot shift from "Hi" to "Lo", the vehicle cannot be driven. Immediately stop the vehicle in a safe place and contact the nearest Isuzu Dealer.
Page 216 4-88 CONTROLS AND INSTRUMENTS Cruise Control The cruise control function allows you to drive the vehicle at a constant speed without operating the accelerator pedal. This function should only be used when driving where frequent starting and stopping is not required, such as highway driving. WARNING Do not use the cruise control function on the following roads, where using it could be dangerous.
Page 217 4-89 CONTROLS AND INSTRUMENTS Setting Your Desired Vehicle Speed Cruise control main switch 1. Press the cruise control main switch to the "ON" position. The cruise control main indicator light will come Cruise control main indicator light Cruise control set switch 2. Use the accelerator pedal to adjust the vehicle speed.
Page 218 4-90 CONTROLS AND INSTRUMENTS Accelerating during Cruise Control Driving If you want to accelerate the vehicle for passing, for example, while the cruise control is in use, simply depress the accelerator pedal. When you release the accelerator pedal, the speed returns to the set speed. Changing the Cruise Control Speed Setting Setting a Higher Speed Cruise control resume switch...
Page 219 4-91 CONTROLS AND INSTRUMENTS Cruise control set switch Setting a Lower Speed Turn the cruise control set switch; the vehicle speed continues to decrease while the switch is held. When the desired vehicle speed is reached, release the cruise control set switch. The speed at the moment you release the switch is set in the system.
Page 220 4-92 CONTROLS AND INSTRUMENTS ADVICE • When you are not using the cruise control, be sure to press the cruise control main switch to the "OFF" position. • When you turn the starter switch to "ACC", press the cruise control main switch to the "OFF"...
Page 221 4-93 CONTROLS AND INSTRUMENTS Cruise Control Coordinated with Auxiliary Braking Function Models with Auxiliary Brake-coordinated Cruise Control This type of cruise control system automatically engages the auxiliary braking function (exhaust brake) while it is in use to limit the increase in speed on a downhill slope. This helps lighten the driver's workload (reducing the need to use the brake pedal to prevent vehicle speed increase).
Page 222 4-94 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 223 4-95 CONTROLS AND INSTRUMENTS NOTE [These are not signs of ABS malfunction] • Soon after you start the engine and the vehicle starts moving, a motor sound 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 224 • 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 225 4-97 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 226 4-98 CONTROLS AND INSTRUMENTS Coupler Semi-trailer Tractor CAUTION • Firmly set the trailer parking brake and block the trailer tyres with chocks on level ground before coupling and decoupling the trailer. NOTE • Refer to the trailer manufacturer's Instruction Manual for detailed coupler handling instructions.
Page 227 4-99 CONTROLS AND INSTRUMENTS Tractor side 6. Connect the jumper cable. 7. If the trailer is also equipped with an antilock brake system (ABS), connect the ABS jumper cable. Trailer side 8. Detach the service line air hose (yellow) and emergency line air hose (red) from their hanger, open the covers and connect them to the couplings on the trailer.
Page 228 4-100 CONTROLS AND INSTRUMENTS 11. Check that there are no air leaks. Also check that the lights of the tractor and trailer operate correctly. 12. On a model equipped with trailer hand brake, with the brakes applied to the trailer wheels by pulling the trailer hand brake lever, slowly start the vehicle.
Page 229 4-101 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 230 4-102 CONTROLS AND INSTRUMENTS PTO Switch This is a switch to engage and disengage the PTO. When PTO is engaged, the PTO indicator light is displayed. When engaging the PTO, be sure to stop the vehicle before operating the switch. Engaging PTO 1.
Page 231 4-103 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 232 4-104 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. Mixer Control Lever Mixing, charging and discharging take place by placing the control lever into the relevant position. The drum rotation speed can be adjusted by changing the accelerator pedal position.
Page 233 CAUTION • If an error occurs, have your vehicle inspected/serviced at your Isuzu Dealer as soon as possible. [Error] If the warning light does not flash seven times when the starter switch is turned to the "ON"...
Page 234 Doing any of the following may require special precautions. Be sure to consult your Isuzu Dealer in advance. Failure to do so may cause the seat belt with pretensioner and airbag to be unduly activated, causing the seat belt to be unexpectedly retracted or the airbag to be suddenly inflated, causing an injury to the occupant.
Page 235 Do not remove or disassemble the seat belt. Accidental activation of the system may causes parts to fly off, injuring you or will cause the system to malfunction. ADVICE • Once activated in a collision, the seat belt with pretensioner cannot be reused. The seat belt must be replaced immediately at the nearest Isuzu Dealer.
Page 236 • Immediately after the airbag is inflated, the metal portion that inflates the airbag gets hot. Do not touch it. • The airbag cannot be reused once it is inflated. Immediately replace it at the nearest Isuzu Dealer.
Page 237 4-109 CONTROLS AND INSTRUMENTS NOTE • The airbag is quickly deflated after deployment and does not hinder visibility. • When the seat belt with pretensioner and airbag are activated in a collision, the SRS airbag warning light comes on. When and How the Seat Belt with Pretensioner and SRS Airbag System Operates The seat belt with pretensioner and SRS airbag system is activated when the vehicle receives an impact exceeding a certain level in the event of a frontal collision.
Page 238 4-110 CONTROLS AND INSTRUMENTS When is the Seat Belt with Pretensioner and SRS Airbag System not Likely to be Activated? In the following cases, the seat belt with pretensioner and SRS airbag system is less likely to be activated even if they are working properly. When the vehicle collides against a When the vehicle gets under an utility pole or standing tree...
Page 239: Controls And Instruments
4-111 CONTROLS AND INSTRUMENTS When is the Seat Belt with Pretensioner and SRS Airbag System Activated Other than in a Collision? • When the vehicle falls into a pothole or groove in the road • When the vehicle strongly collides against an obstacle such as a protruding object on the road • When the vehicle collides against a curb at high speed • When the vehicle becomes airborne and hits the ground, receiving a strong impact on the bottom of the vehicle...
Page 240 4-112 CONTROLS AND INSTRUMENTS When is the Seat Belt with Pretensioner and SRS Airbag System not Activated? In the following cases, the seat belt with pretensioner and SRS airbag system are not activated even if they are working normally. When the vehicle is hit from the rear When the vehicle is hit from the side When the vehicle rolls onto its side or upside down...
Page 241 (gas and so on) adheres to your eyes and skin, rinse them with water as soon as possible. Although it is rare, a person with delicate skin may suffer from irritation. • The airbag cannot be reused once it is inflated. Replace it at the nearest Isuzu Dealer.
Page 242 4-114 CONTROLS AND INSTRUMENTS Deployment of SRS Airbag When the vehicle collides head-on with an impact of a certain level or higher, the SRS airbag system is activated and instantly inflates. It deflates quickly and does not hinder visibility. When Does SRS Airbag Develop its Full Effect? WARNING •...
Page 243 4-115 CONTROLS AND INSTRUMENTS Handling of SRS Airbag WARNING • Do not remove or disassemble the airbag. Doing so may cause a malfunction or inadvertent activation. • Do not place anything near the airbag. You may suffer an injury when a thing is thrown by inflation force of the airbag. • Do not take a rest using the steering wheel as a pillow or with your arms or legs resting on it.
Page 244 4-116 CONTROLS AND INSTRUMENTS Particulate Matter (PM) Catalytic Converter The PM catalytic converter uses an oxidation catalyst to reduce the unburned material in PM in exhaust gases to water and carbon dioxide. As a general rule, while idling, diesel engines have low exhaust gas temperatures. The oxidation catalyst is not actively engaged, so the particles in the exhaust gases build up inside the catalyst.
Page 245 4-117 CONTROLS AND INSTRUMENTS...
Page 246 4-118 CONTROLS AND INSTRUMENTS...
Page 247: Comfort And Convenience
COMFORT AND CONVENIENCE ● Air Outlets ● Heater/Manual Air Conditioner ● Automatic Air Conditioner 5-12 ● Interior Lights 5-21 ● Sun Visor 5-22 ● Cigarette Lighter 5-22 ● Ashtray 5-24 ● Small Article Storage Pocket 5-24 ● Card Holder 5-25 ●...
Page 248 COMFORT AND CONVENIENCE Air Outlets Air outlets Features Driver side outlet Air flow direction is adjustable with the tab. Passenger side outlet Air flow direction is adjustable with the tab. Door windows Air is delivered towards the door window. Windshield Air is delivered towards the windshield.
Page 249 COMFORT AND CONVENIENCE Air Flow Direction Control Lever Use the tab to adjust the air flow direction from the outlet. To close the outlet, move the lever down.
Page 250 COMFORT AND CONVENIENCE Heater/Manual Air Conditioner How to Use the Controls Name Name Outlet selector knob Fan speed control knob Air source lever Air conditioning switch (A/C switch) Temperature control knob...
Page 251 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. Air flows through outlets 5 and some through outlets Feet and defroster 1 3 and 4.
Page 252 COMFORT AND CONVENIENCE 5. Air conditioning switch (A/C switch) Press this switch to use the air conditioning system. The indicator light inside the switch will come on to show that the air conditioning system is in operation. The air conditioning system can also be used for dehumidifying while the heater is being used.
Page 253 COMFORT AND CONVENIENCE How to Use the Heater Normal Heating Set the outlet selector knob (1) to the " " or " " " " position. Use the " " position for warming your feet while defogging the windshield. Set the air source lever (2) to the " "...
Page 254 COMFORT AND CONVENIENCE Bi-level Heating Set the outlet selector knob (1) to the " " position. Set the air source lever (2) to the " " position. Set the temperature control knob (3) to the middle position. Adjust the fan speed control knob (4) as desired.
Page 255 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 256 5-10 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 257 5-11 COMFORT AND CONVENIENCE Maximum Cooling Set the outlet selector knob (1) to the " " position. Press the A/C switch (5) to the "ON" position. Move the air source lever (2) to the " " position. Turn the temperature control knob (3) fully towards the low-temperature direction.
Page 258: Comfort And Convenience Features
5-12 COMFORT AND CONVENIENCE Automatic Air Conditioner How to Use the Controls Name Name Automatic air conditioning off switch Automatic air conditioning switch (AUTO switch) (OFF switch) Fan speed control dial Air source switch Defroster switch Outside temperature display switch (OUTSIDE switch) Air conditioning switch (A/C switch) Temperature control dial...
Page 259 5-13 COMFORT AND CONVENIENCE 2. Fan speed control dial Use this dial when manually selecting the fan speed. Turning the dial counterclockwise reduces the fan speed and turning it clockwise increases the fan speed. The fan speed can be adjusted through 8 levels. Fan speed Medium Fast...
Page 260 5-14 COMFORT AND CONVENIENCE 6. Air source switch Use this switch to change between ventilation of outside air and recirculation of the interior air. The display will show the setting you have made by the corresponding symbol as follows. Displayed symbol Air delivery Outside air This setting should normally be selected.
Page 261 5-15 COMFORT AND CONVENIENCE Automatic Air Conditioning Mode 1. Press the AUTO switch (1). The air conditioning system will turn on, and automatically select the air outlets and fan speed most suitable for the cab interior condition. The selected air outlets will be those corresponding to either the "...
Page 262 5-16 COMFORT AND CONVENIENCE 3. To turn off the air conditioning system, press the A/C switch (8). To turn off both the fan and air conditioning system, press the OFF switch (5). NOTE • If you operate a certain control (excluding the temperature control dial) when the system is operating in the fully automatic mode, the "AUTO"...
Page 263 5-17 COMFORT AND CONVENIENCE Maximum Heating Turn the temperature control dial (4) to the maximum heating temperature (32°C (90°F)) and set the fan speed control dial (2) for the maximum setting. Select the desired air outlets with the MODE switch (9). Defogging Press the defroster switch (7) to turn the defogger on.
Page 264 5-18 COMFORT AND CONVENIENCE Defrosting Press the defroster switch (7) to turn the defroster on. The display will show the " " sign. Turn the temperature control dial (4) to the maximum temperature position (32 °C (90°F)). Press the air source switch (6). The display will show the "...
Page 265 5-19 COMFORT AND CONVENIENCE Maximum Cooling Turn the temperature control dial (4) to the maximum cooling position (18°C (64 °F)) and turn the fan speed control dial (2) to the highest speed setting. Select the desired air outlets with the MODE switch (9) and press the air source switch (6).
Page 266 5-20 COMFORT AND CONVENIENCE Temperature Sensors The air conditioning system uses a sun sensor, room temperature sensor and outside temperature sensor to ensure effective and comfortable air conditioning. Do not place anything on the sensors or get them wet. Air conditioning control will become inaccurate.
Page 267 5-21 COMFORT AND CONVENIENCE Interior Lights Interior Light Switch Press the interior light switch to turn on the interior light. Press the switch again to turn off the interior light. ADVICE • Do not leave the interior light switch in the on position. Leaving the fluorescent light or dome light on for extended periods, especially with the engine shut off, will deplete the...
Page 268 5-22 COMFORT AND CONVENIENCE 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 269 • To use it once again as the cigarette lighter changing from the accessory socket, or to replace the broken cigarette lighter, use an Isuzu genuine part suitable for the vehicle. Do not use other cigarette lighters. •...
Page 270 5-24 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 271 5-25 COMFORT AND CONVENIENCE Card Holder Use this to hold your cards. Glove Compartment 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 272 5-26 COMFORT AND CONVENIENCE Center Console Box 2-seat model Squeeze the knobs on the lid to open. Use it for storing small articles. There are cup holders in the front section of the center console. CAUTION • Do not leave eyeglasses or lighters inside the cab.
Page 273 5-27 COMFORT AND CONVENIENCE Coin Holder Use the coin holder to keep coins and other small articles. 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.
Page 274 5-28 COMFORT AND CONVENIENCE Coat Hook Use this to hang clothing. Hook This can be used to hold plastic shopping bags. CAUTION • Do not hang anything on the hook weighing over 3 kg (106 oz) or that may fall off while driving. Doing so may be dangerous.
Page 275 5-29 COMFORT AND CONVENIENCE Operating Tips for the Radio and CD Player CAUTION • Operate the radio or CD player only while the vehicle is stationary. Operating them while the vehicle is moving could cause an accident. • Adjust the volume so that sound outside of the vehicle can be heard. If outside sound cannot be heard, accidents may be harder to avoid.
Page 276 5-30 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 277 5-31 COMFORT AND CONVENIENCE AM Radio AM radio can be used when the starter switch is in the "ACC" or "ON" position. Name Name Power switch Preset buttons Volume control (VOL control) Reset button (RESET button) Tuning buttons (TUNE buttons) Time adjusting button (T.ADJ button) Display Display selector button (DISP button)
Page 278 5-32 COMFORT AND CONVENIENCE Volume Adjustment Turn the "VOL" control to adjust the volume. ADVICE • Turning the power on or off with the volume set to maximum will have a bad effect on the equipment and your ears. Set the volume to a moderate level.
Page 279 5-33 COMFORT AND CONVENIENCE Radio Operation Seek-Tuning Pressing either "TUNE" button for 0.5 seconds will start the seek-tuning mode. It will stop at any receivable station. If there is no receivable station, the radio will search from the highest frequency to the lowest frequency or vice versa.
Page 280 5-34 COMFORT AND CONVENIENCE Adjusting the Time Press the "DISP" button to make the display show the time of day. Time is shown in the 12 hour clock. Setting the Clock to Time Signal Display (example) Press the "RESET" button to set your clock to time signal.
Page 281 5-35 COMFORT AND CONVENIENCE AM/FM Radio The AM/FM radio can be used when the starter switch is in the "ACC" or "ON" position. Name Name Tone control knob (TONE) Tuning buttons ( , ) Power switch (SW) Automatic storing button (AS) Volume control (VOL) Band selector button (AM/FM) Time adjusting button (CLOCK)
Page 282 5-36 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 Turn the "TONE" control knob. Turning clockwise emphasizes the treble, and turning it counterclockwise emphasizes the bass.
Page 283 5-37 COMFORT AND CONVENIENCE AM/FM Band Selection With the display indicating the time, press the "AM/FM" button. The display will change to the frequency indication. Press the "AM/FM" button again within 5 seconds to select the desired band. The display will cycle through the bands (AM1, AM2, FM1 and FM2) each time you press the button.
Page 284 5-38 COMFORT AND CONVENIENCE Programming Stations to Preset Flashes Buttons MEMO A maximum of 6 radio stations can be stored in the channels in each of the AM1, AM2, FM1 and FM2 bands. Preset memory No. 1. While receiving a radio station, press the "MEMO"...
Page 285 5-39 COMFORT AND CONVENIENCE Automatic Storing Function The automatic storing function selects the 6 regional radio stations with the strongest signals and stores them in memory, arranging them in the order of ascending frequency. 1. Press the "AS" button for more than 2 seconds.
Page 286 5-40 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 287 5-41 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 288 5-42 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 289 5-43 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 290 5-44 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 291 5-45 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 292 5-46 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 293 5-47 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 294 5-48 COMFORT AND CONVENIENCE Setting the Clock to Time Signal Press the reset 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 295 5-49 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 296 5-50 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 297 5-51 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 298 5-52 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 299 5-53 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 300 5-54 COMFORT AND CONVENIENCE...
Page 301 TIPS ON SAFE AND SMOOTH OPERATION ● Driving Safely and with Confidence ● On the Road ● Driving with a Trailer 6-15 ● Cautions for Parking 6-18 ● Cautions for Driving in Hot Regions 6-19 ● Cautions for Driving in Cold Regions 6-20 ●...
Page 302: Tips On Safe And Smooth Operation
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 303 TIPS ON SAFE AND SMOOTH OPERATION On the Road Cautions for Driving • Concentrate on driving safely, obeying all legally designated speed limits, road signs and traffic signals. • Do not place the starter switch to any position other than the "ON" position while driving. The power steering would stop working, making steering extremely difficult.
Page 304 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 305 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. Also, use the exhaust brake in order to avoid going too fast.
Page 306 TIPS ON SAFE AND SMOOTH OPERATION Braking Your vehicle has 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. Braking distances vary according to the vehicle speed and road conditions.
Page 307 TIPS ON SAFE AND SMOOTH OPERATION Stopping Distance The vehicle's stopping distance consists of a reaction distance (from the point where 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 308 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 (if equipped) and drive slowly, using the road's center line as a guide.
Page 309 TIPS ON SAFE AND SMOOTH OPERATION Highways 1. Speeds on highways are higher than • C heck that there is ample Tyres those on regular roads, so there is tread depth. more danger. Also, a breakdown • C heck that engine coolant on a highway represents a hazard is not leaking from the to other vehicles and can cause radiator and other parts of the cooling system.
Page 310 6-10 TIPS ON SAFE AND SMOOTH OPERATION 4. During high-speed driving, even a little turn of the steering wheel causes a big movement of the vehicle. Turn the steering wheel slowly. 5. Excessive use of the brake pedal is extremely dangerous because it rapidly wears the brake linings and causes brake fade.
Page 311 6-11 TIPS ON SAFE AND SMOOTH OPERATION Driving on Snowy or Frozen Roads 1. We recommend you use tire chains or winter tyres. 2. Use a low gear and use the engine brake. Use the brake pedal as little as possible. CAUTION • On slippery roads, never accelerate rapidly, brake hard, decelerate rapidly or make sharp turns of the steering wheel.
Page 312 6-12 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. If you try to drive with snow on your shoes, your shoes would slip on the pedals and you would not be able to press the pedals properly,...
Page 313 6-13 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 314 6-14 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. At this time, check whether the wiper blades are frozen onto the glass.
Page 315 6-15 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 height of the cargo's center of gravity and the weight of the cargo affect the trailer's...
Page 316 6-16 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...
Page 317 6-17 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 318 6-18 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, 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 319 6-19 TIPS ON SAFE AND SMOOTH OPERATION Cautions for Driving in Hot Regions The engine will be prone to overheating in an environment where the ambient temperature is high. To prevent the engine from overheating, pay attention to the following points: CAUTION •...
Page 320 • 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 321 Changing the Engine Coolant → Refer to page 7-42 Preparing Engine Coolant → Refer to page 7-39 Replacing the Engine Oil Outside temperatures vs. oil In all seasons, use Isuzu genuine "Besco viscosities Clean" engine oil. Changing the Engine Oil → Refer to page 7-25 Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7 -188...
Page 322 6-22 TIPS ON SAFE AND SMOOTH OPERATION Fuel CAUTION • Be sure to use ultra-low sulfur diesel fuel (with sulfur content no higher than 10 ppm) or low sulfur diesel fuel (with sulfur content no higher than 50 ppm). • If you supplied the vehicle with poor-quality fuel, water-removing 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 the engine, possibly resulting in a breakdown.
Page 323 • Winter tyres have wider contact areas, so they may interfere with other components. Consequently, it is necessary to adjust the steering angle. After putting winter tyres 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. When applying the brakes on snowy or frozen road, lightly press...
Page 324 6-24 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 325 • For dual tyres, use dual tyre chains. For triple chains, they may not be fitted depending on vehicle specifications, so please consult the nearest Isuzu Dealer for details. • For dual tyres, do not fit a single chain only on the outer tyre. The chain may interfere with other components and adversely affect driving.
Page 326 6-26 TIPS ON SAFE AND SMOOTH OPERATION How to Fit a Tyre Chain 1. Making sure the tyre chain is not Cross twisted, place it on the tyre such that chain the curled ends are on the outside (the side that will make contact with the ground). Connector (curled end) 2.
Page 327 6-27 TIPS ON SAFE AND SMOOTH OPERATION How to Remove a Tyre 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 MFU9Z0SH014201...
Page 328 6-28 TIPS ON SAFE AND SMOOTH OPERATION...
Page 329: Service And Maintenance
SERVICE AND MAINTENANCE BEFORE SERVICE AND MAINTENANCE 7-15 DAILY CHECKS ENGINE-RELATED SERVICE AND 7-19 MAINTENANCE CHASSIS-RELATED SERVICE AND 7-51 MAINTENANCE 7-133 OTHER SERVICE AND MAINTENANCE INTERIOR AND EXTERIOR 7-151 MAINTENANCE 7-161 MAINTENANCE DATA...
Page 331 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...
Page 332 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.
Page 333 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 334 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 •...
Page 335 SERVICE AND MAINTENANCE Tools Oil jack and handle Screwdriver (Phillips head) Tool bag 10 Screwdriver (Flat head) Pliers 11 Adjustable wrench Wheel nut wrench and handle 12 Bleeder hose Wrenches (8 × 10), (10 × 12), Socket wrench box, extension bar, (14 ×...
Page 336 SERVICE AND MAINTENANCE Front Lid To Open 1. Pull the lever at the bottom right 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 337 SERVICE AND MAINTENANCE ADVICE • Do not apply water directly to the air conditioning filter, or the connections for the air conditioning pipe or heater hose inside the front lid. This could cause water to enter the cab. Exterior Maintenance →...
Page 338 7-10 SERVICE AND MAINTENANCE Tilting the Cab Preparations for Tilting the Cab CAUTION • Tilt the cab only on a level surface. • Check the areas in front of and above the cab for sufficient clearance when tilting the cab indoors. (Particular care is required if your vehicle is equipped with an air deflector.) •...
Page 339 7-11 SERVICE AND MAINTENANCE Electrically Driven Hydraulic Cab Tilt...
Page 340 7-12 SERVICE AND MAINTENANCE To Tilt the Cab Up Securely apply the parking brake, set the gearshift lever in neutral, and then place chocks against the wheels. Do not tilt the cab when the gear is not in neutral. 1. Pull the lock lever (4) with your right hand and turn down the tilt lock lever (3) by pulling it toward you with your left hand to release the cab lock.
Page 341 7-13 SERVICE AND MAINTENANCE Lowering the Cab 1. Set the pump lever in the "lower (drive)" position (1). A buzzer will sound. WARNING • Do not stop lowering the cab mid- way except in an emergency. Doing so may cause the cab tilt mechanism to break down.
Page 342 Handle the pump lever as you would normally. • Insert a screwdriver into the manual pump socket and move the screwdriver up and down to operate the pump. WARNING • If you find anything abnormal about the buzzer tone, the tilt motor or the pump, contact the nearest Isuzu Dealer.
Page 343 7-15 SERVICE AND MAINTENANCE DAILY CHECKS ● Daily Check (Preoperational Checks) 7-16 ● Checking Components that Showed Abnormalities during 7-18 Previous Operation...
Page 344 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 345 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, 4-14 Engine startability, abnormal noise and exhaust emissions 7-20 Brake pedal free play 7-53 Exhaust sound from brake valve 7-53 Increase in air pressure 7-93...
Page 346 7-18 SERVICE AND MAINTENANCE Checking Components that Showed Abnormalities during Previous Operation Check the components that showed abnormalities during the previous operation. Have any abnormalities repaired by the nearest Isuzu Dealer before using the vehicle.
Page 347 7-19 SERVICE AND MAINTENANCE ENGINE-RELATED SERVICE AND MAINTENANCE ● Engine Conditions 7-20 ● Engine Oil 7-21 ● Engine Oil Filter 7-27 ● Engine Oil Separator Element 7-30 ● Air Cleaner 7-31 ● Fan Belt 7-34 ● Engine Coolant 7-38 ● Handling the Radiator and Intercooler 7-43 ●...
Page 348 7-20 SERVICE AND MAINTENANCE Engine Conditions Ease of Engine Startup, Abnormal Noises and Color of Exhaust Emissions 1. Make sure the parking brake is securely engaged. Step firmly on the brake pedal. 2. Confirm that the gearshift lever is in neutral ("N"). CAUTION •...
Page 349 7-21 SERVICE AND MAINTENANCE Engine Oil Engine oil is an important factor determining engine performance and longevity. Be sure to use the specified oil and oil filter, and keep them properly maintained. Checking the Engine Oil Level Tilt the cab and check the oil level with the oil dipstick.
Page 350 7-22 SERVICE AND MAINTENANCE ADVICE • Use the oil quantities indicated below only as guidelines when changing the engine oil. After changing the oil, ensure that its level is as required. • If the engine oil level is above the "MAX" mark on the oil dipstick, the engine may break down.
Page 351 7-23 SERVICE AND MAINTENANCE Adding the Engine Oil If the engine oil level is in the vicinity of the "MIN" mark on the oil dipstick, remove the oil filler cap from the filler hole, and replenish the engine oil after removing the oil dipstick.
Page 352 7-24 SERVICE AND MAINTENANCE ADVICE • Engine oil lubricates and cools the engine's internal components. The quality of the oil is degraded and the quantity of oil is reduced by evaporation, discharge and combustion during the engine's operation. Continually using the same oil without checking the level, or without replenishing and changing it could cause seizure or damage to the engine.
Page 353 7-25 SERVICE AND MAINTENANCE Changing the Engine Oil Oil Change Interval Replace the engine oil according to the maintenance schedule. Maintenance Schedule → Refer to page 7-163 Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-188 Changing the Engine Oil 1.
Page 354 7-26 SERVICE AND MAINTENANCE Capacity [Reference value] liters (US gal./Imp gal.) When changing oil only 19.0 - 24.0 (5.02 - 6.34 / 4.18 - 5.28) When changing oil and filter 25.5 - 30.5 (6.74 - 8.06 / 5.61 - 6.71) ADVICE •...
Page 355 Replace the element regardless of the mileage of the vehicle. ADVICE • When replacing the engine oil filter, use an Isuzu genuine oil filter. If you use another type of oil filter, a breakdown may occur. • Replace the oil filter when replacing the engine oil.
Page 356 7-28 SERVICE AND MAINTENANCE Changing the Oil Filter Main Oil Filter 1. Remove the oil filler cap. Remove the oil filter drain plug to discharge the oil into the container. 2. Loosen the center bolt, and remove the element together with the filter body.
Page 357 7-29 SERVICE AND MAINTENANCE Partial Oil Filter 1. Remove the oil filler cap. Remove the oil filter drain plug to discharge the oil into the container. 2. Loosen the center bolt, and remove the element together with the filter body. 3.
Page 358 7-30 SERVICE AND MAINTENANCE Engine Oil Separator Element Replace the oil separator element according to the maintenance schedule. Maintenance Schedule → Refer to page 7-163 Changing the Engine Oil Separator Element 1. Remove the cap, and secure it by hanging it into the space created among the EGR valve, priming pump bracket and PCV hose.
Page 359 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 360 7-32 SERVICE AND MAINTENANCE 3. Remove the air cleaner element. 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. Drain valve 6.
Page 361 8. Install the air cleaner cover, and securely lock the clips. ADVICE • Install the cover with its "ISUZU" mark facing upward and with the notches at both sides aligned with those on the case. 9. After cleaning the element, push the button at the end of the indicator to reset the signal.
Page 362 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 363 7-35 SERVICE AND MAINTENANCE Inspecting the Fan Belt Press the center of the span between pulleys (see the figure) of the belt with a force of 98 N (10.0 kgf/22 lb) and check the amount of deflection. The amount of deflection must fall within the standard value range indicated below.
Page 364 7-36 SERVICE AND MAINTENANCE Adjusting the Fan Belt 1. Loosen the mounting bolts and nuts at the top and bottom of the generator. 2. Turn the adjusting bolt until the belt tension is within the standard value range. 3. After adjustment, firmly tighten the loosened bolt and nuts.
Page 365 7-37 SERVICE AND MAINTENANCE Replacing the Fan Belt 1. Remove the air conditioning compressor belt. (Air conditioning equipped model) 2. Loosen the mounting bolts and nuts at the top and bottom of the alternator, and remove the belt from the pulleys. 3.
Page 366 7-38 SERVICE AND MAINTENANCE Engine Coolant The engine coolant must be changed according to the Maintenance Schedule. Maintenance Schedule → Refer to page 7-163 Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-188 WARNING • Check, replenish or change the engine coolant only after the engine has sufficiently cooled down.
Page 367 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 an appropriate concentration. Coolant concentration Usage region...
Page 368 30% or lower, anti-corrosion function is not provided sufficiently. • 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.
Page 369 Also, inspect the radiator hose for a crack and damage. When a water leakage or damage is found on the hose, contact the nearest Isuzu Dealer. Check the engine coolant concentration at an Isuzu Dealer. For concentration determination, refer to page 7-39.
Page 370 7-42 SERVICE AND MAINTENANCE Changing the Engine Coolant The engine coolant must be changed according to the Maintenance Schedule. When changing the engine coolant, also clean the radiator and engine coolant passages. Handling the Radiator and Intercooler → Refer to page 7-43 ADVICE •...
Page 371 7-43 SERVICE AND MAINTENANCE 9. Stop the engine and check the engine coolant level. If the engine coolant is insufficient, replenish it. Maintenance Schedule → Refer to page 7-163 Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-188 Handling the Radiator and Intercooler Cleaning the Radiator Core and Intercooler Core...
Page 372 • If stubborn dirt still remains even after the radiator core and intercooler core have been cleaned, have the vehicle inspected and serviced at your Isuzu Dealer. Fuel Filter • Replace the element and also discharge the water and sediment from inside the filter according to the maintenance schedule. • Drain the water from the pre-fuel filter when the water separator (fuel filter) warning message comes on.
Page 373 7-45 SERVICE AND MAINTENANCE Draining Water from the Fuel Filter Vehicle-side Pre-fuel Filter 1. Loosen the drain plug on the clear element case at the bottom of the fuel filter to drain out water. 2. Tighten the drain plug once all of the water has drained off.
Page 374 7-46 SERVICE AND MAINTENANCE Engine-side Main Fuel Filter 1. Loosen the air bleeder plug. 2. Loosen the drain plug to discharge water and sediment from inside the filter. 3. Tighten the drain plug, and then bleed off air in the filter. Air bleeder plug and drain plug 6.9 ±...
Page 375 Clean any foreign matter or dirt from the bottom of the clear 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. •...
Page 376 7-48 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. Engine-side Main Fuel Filter 1. Discharge water and sediment from inside the filter according to "Draining Water from the Fuel Filter"...
Page 377 4. Bleed the fuel system. Bleeding the Fuel System → Refer to page 8-13 Air Flow Sensor Have your Isuzu Dealer check the output characteristics according to the maintenance schedule. Depending upon the results of the check, it may be necessary to replace the air flow sensor.
Page 378 7-50 SERVICE AND MAINTENANCE...
Page 379 7-51 SERVICE AND MAINTENANCE CHASSIS-RELATED SERVICE AND MAINTENANCE ● Parking Brake ● Fuel Tank 7-52 7-97 ● Wheel Brake ● Clutch Pedal 7-52 7-98 ● Wheel Hub Bearing ● Clutch Fluid 7-59 7-101 ● Axle Shaft Bolts or Nuts 7-59 ●...
Page 380 7-52 SERVICE AND MAINTENANCE Parking Brake Checking the Braking Performance Fully return the parking brake lever to release the parking brake, and then gently operate it again and confirm that the lever moves smoothly and locks securely in the parking position. Also, check for a pressure release sound.
Page 381 7-53 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 Step on the brake pedal and check to see...
Page 382 2. Check the thickness of the lining. 3. If the thickness of the lining is 6.3 mm (0.25 in) or less, or has cracks or is flaking, the lining must be replaced. Contact the nearest Isuzu Dealer.
Page 383 (0.051 in). • No dragging is allowed (when the temperature of the drum is about the same as the outside temperature). ADVICE • If the drum-to-lining gap measurement is not as specified, have the brakes inspected by the nearest Isuzu Dealer.
Page 384 7-56 SERVICE AND MAINTENANCE Adjusting the Lining Gap FG941 (MFS66) /RS23/RT40 Type Axles 1. Prevent the vehicle from moving by applying chocks both in front of and behind the wheels. 2. Start the engine and release the parking brake. 3. Disengage a pull pawl or remove a conventional pawl.
Page 385 7-57 SERVICE AND MAINTENANCE 6. Move the slack adjuster using a lever to bring the lining into firm contact with the drum. In this position, repeat the measurement in Step 5 above. The difference between these two measurements is the free stroke. 7.
Page 386 7-58 SERVICE AND MAINTENANCE Checking the Slack Adjuster FG941 (MFS66) /RS23/RT40 Type Axles Camshaft Bushing ADVICE • It is recommended that when installing a new camshaft you also replace the camshaft bushing with a new one. 1. Inspect and grease the camshaft according to the maintenance schedule. CAUTION •...
Page 387 Wheel Hub Bearing HCU7C0SH009101 The bearing grease must be changed according to the maintenance schedule. This involves disassembly work, so ask your Isuzu Dealer to carry out a grease change. Maintenance Schedule → Refer to page 7-163 Recommended Fluids, Lubricants and Diesel Fuels →...
Page 388 WARNING • If you find anything abnormal in the wheel bolts, wheel nuts or disc wheels when you check them, avoid driving the vehicle, and contact the nearest Isuzu Dealer as soon as possible. • If you find anything abnormal on the left wheels, check the right wheels carefully for similar defects.
Page 389 7-61 SERVICE AND MAINTENANCE Tyre air pressure (cold tyre) kPa (kgf/cm²/ Tyre size psi) 295/80R22.5 152/148 825 (8.25/120) 11R22.5-16PR 148/145 825 (8.25/120) New Zealand Tyre air pressure (cold tyre) kPa (kgf/cm²/ Tyre size psi) 275/70R22.5 148/145 900 (9.00/131) 11R22.5-16PR 148/145 850 (8.50/123) ETRTO Tyre air pressure (cold tyre) kPa (kgf/cm²/...
Page 390 7-62 SERVICE AND MAINTENANCE WARNING • Insufficiently inflated or worn-out tyres are highly dangerous as they easily skid and can even burst. Should they burst, the tyres may burn and this could cause a fire in the vehicle. • If you drive on under-inflated or flat tyres, the wheel bolts will be placed under excessive stress.
Page 391 7-63 SERVICE AND MAINTENANCE Tread Depth and Abnormal Wear Using worn-out tyres is dangerous because they are punctured or burst more easily while you are driving than newer tyres in good condition. Check all tyres to see if tread wear indicators appear and also check the tread depth on the entire tyre with a depth gauge to make sure that the grooves are deeper than the specified...
Page 392 7-64 SERVICE AND MAINTENANCE Visual Checking of Wheel Installation Condition Too much Loose nut Visually check the installation condition of protrusion of bolt end each disc wheel. 1. Check that there are no missing wheel bolts and wheel nuts. Crack 2.
Page 393 • If you find any abnormal condition on the wheel bolts, wheel nuts or disc wheel, do not continue to use the wheel. Contact the nearest Isuzu Dealer as soon as possible. Tyres at different locations wear differently. For uniform tyre wear and longer tyre life, you should rotate the tyres on your vehicle regularly.
Page 394 7-66 SERVICE AND MAINTENANCE FXR/GXR models FXR/GXR models (different size tyres or tread patterns on both front and rear axles) FXZ model FXZ model (different size tyres or tread patterns on both front and rear axles) FXM model FXM model (different size tyres or tread patterns on both front and rear axles) FYH model...
Page 395 7-67 SERVICE AND MAINTENANCE Preparation for Changing a Tyre When you park the vehicle to change tyres, choose a place listed below. • Your vehicle does not hinder other traffic. • The surface is level, flat and solid. • You can change a tyre safely. When changing a tyre on a road, use the hazard warning flasher and triangle reflectors to alert other traffic to the presence of your vehicle.
Page 396 7-68 SERVICE AND MAINTENANCE Changing a Tyre (JIS 8-bolt Wheels) Change a tyre on a level and hard surface after checking safety in the surrounding area. Handling the Jack → Refer to page 7-134 Changing Aluminum Wheels to Steel Wheels and Vice Versa Steel wheels and aluminum wheels need their specific wheel bolts and nuts for installation.
Page 397 7-69 SERVICE AND MAINTENANCE Changing steel Changing aluminum Temporary use of steel wheel Wheel wheel to aluminum wheel to steel wheel in place of aluminum wheel *1 wheel Change nuts to Change nuts to Change nuts to those for steel Front those for aluminum those for steel wheel...
Page 398 7-70 SERVICE AND MAINTENANCE Identification Marks on Wheel Bolts/Nuts Single-tyre wheel Every wheel bolt or nut has a mark indicating the type of wheel to which the bolt or nut is applicable ("ST" for steel wheels; "AL" for aluminum wheels; or "S·A"...
Page 399 7-71 SERVICE AND MAINTENANCE Removing a Wheel WARNING • Before jacking up the vehicle, make sure to apply the parking brake firmly and fully chock the specified wheel. Applying only the parking brake is insufficient to prevent the vehicle from moving. When a rear wheel is jacked up, the vehicle blocked only by the parking brake would move, creating a very dangerous situation.
Page 400 7-72 SERVICE AND MAINTENANCE 5. Jack up the vehicle so that the tire clears the ground surface completely. 6. Remove all the wheel nuts that have been loosened and then remove the wheel. To tighten Remove the wheel being careful not to damage the threads of the wheel bolts.
Page 401 7-73 SERVICE AND MAINTENANCE 1. Check the disc wheel for the following: • Cracks or other damage around the bolt holes and decorative holes • Cracks or other damage or deformation on the wheel nut seating surfaces (tapered surfaces) • Cracks or other damage on welds • Wear or other damage on the hub fitting surface or wheel-to-wheel mating surface 2. Check the wheel bolts and wheel nuts for the following: • Cracks or other damage • Bolt elongation or excessive rust...
Page 402 7-74 SERVICE AND MAINTENANCE Single-tire wheel 3. Remove rust, dust and mud from the fitting surface, hub fitting surface or wheel-to-wheel mating surfaces, and wheel nut seating surfaces (tapered surfaces) of the disc wheel, and from the threads of the wheel bolts and nuts.
Page 403 7-75 SERVICE AND MAINTENANCE CAUTION • Do not use oils that contain molybdenum disulfide. When tightened to the same torque, the bolts and nuts coated with these oils produce a grip force much larger than those coated with other oils. Too much grip force could cause wheel bolts to be broken.
Page 404 After changing a tyre, turn the steering wheel in both directions to make sure that the wheels do not interfere with the surrounding components. If you are not sure about this, please contact the nearest Isuzu Dealer. • Tightening torque of the wheel nuts may decrease after tyre replacement due to their initial settlement.
Page 405 7-77 SERVICE AND MAINTENANCE Retightening Wheel Nuts (JIS 8-bolt Wheels) Check the wheel nuts to be sure they are tightened to the specific torque by using a torque wrench. Use the following methods to check for loose wheel nuts. Tightening torque of the wheel nuts may decrease after tire change or rotation due to their initial settlement.
Page 406 • If you find any abnormal conditions with the wheel nuts such as frequent loosening of retightened nuts, have your vehicle checked or serviced at the nearest Isuzu Dealer as soon as possible. CAUTION • Fully engage the wheel bolt wrench on a wheel nut to be able to tighten the nut to the specified torque.
Page 407 When changing a tyre, select a flat, solid surface. For the correct use of the jack, refer to "Handling the Jack" on Page 7-134. When replacing steel wheels, aluminum wheels, wheel bolts, or wheel nuts, use of Isuzu genuine parts is recommended. Changing Aluminum Wheels to Steel Wheels and Vice Versa Steel wheels and aluminum wheels need their specific wheel bolts for installation.
Page 408 7-80 SERVICE AND MAINTENANCE Example: Front wheel Example: Rear wheel (dual-tire wheel) ADVICE • When temporarily installing steel wheels on wheel bolts for aluminum wheel during winter or other occasions, apply grease or take some other preventive action on the sticking-out portion (exposed threaded portion) of the wheel bolt to protect the threaded portion from rusting.
Page 409 7-81 SERVICE AND MAINTENANCE Removing a Wheel WARNING • Always apply the parking brake fully and correctly chock the wheels before jacking up the vehicle. Applying only the parking brake is insufficient to prevent the vehicle from moving. When a rear wheel is jacked up, the vehicle blocked only by the parking brake could move, creating a very dangerous situation.
Page 410 7-82 SERVICE AND MAINTENANCE 1. Firmly apply the parking brake. When changing a front wheel, chock the rear wheel diagonally opposite to the front wheel. When changing a rear wheel, chock the front wheel diagonally opposite to the rear wheel. 2.
Page 411 7-83 SERVICE AND MAINTENANCE Installing a Wheel WARNING • A disc wheel, wheel bolts or wheel nuts in any abnormal condition could break later, causing the wheel to be detached from the vehicle while driving. • Do not repaint any mating surfaces, wheel nut seating surfaces and hub fitting surface of the disc wheel.
Page 412 Also, check to see if there is any noticeable rust. • Crushed, thinned or seized threads Replacement of the wheel bolts involves disassembly work, so ask the nearest Isuzu Dealer to do this. • Check to see if the washer rotates smoothly. If it doesn't, replace it. 3. Remove rust, dust and mud from the...
Page 413 7-85 SERVICE AND MAINTENANCE CAUTION • Remove rust and dirt from a wheel bolt and nut, lightly lubricate the threads with engine oil, gear oil or chassis grease and turn the nut on the bolt. If the nut does not turn smoothly, the threads are defective. •...
Page 414 After changing a tyre, turn the steering wheel in both directions to make sure that the wheels do not interfere with the surrounding components. If you are unclear about any of this, please contact the nearest Isuzu Dealer. • The tightening torque of the wheel nuts may decrease after tire replacement due to their initial settlement.
Page 415 • If you find any abnormal conditions with the wheel nuts such as frequent loosening of retightened nuts, have your vehicle checked or serviced at the nearest Isuzu Dealer as soon as possible. CAUTION • Fully engage the wheel nut wrench on a wheel nut in order to tighten the nut to the specified torque.
Page 416 7-88 SERVICE AND MAINTENANCE Spare Tyre Installation and Removal Removal Insert the spare tyre carrier handle in the spare tyre carrier and turn the handle counterclockwise. Installation 1. Place the tyre with the convex side of the disc wheel facing up and then fit the carrier hanger plate inside the disc wheel with its claws properly engaged.
Page 417 If you cannot tighten the tyre in the carrier, do not drive the vehicle and contact the nearest Isuzu Dealer. CAUTION • After storing the tyre in the carrier, check that the tyre is held firmly. If loosely retained, the tyre becomes loose while you are driving due to vibrations or shocks and the tyre might fall off;...
Page 418 7-90 SERVICE AND MAINTENANCE Directional Tyres Your vehicle may be equipped with special tyres whose direction of rotation is specified. A tyre of this type has a set of small arrows on the sidewall, showing the direction of rotation for forward movement of the vehicle.
Page 419 Aluminum Wheels 1. You must use wheel bolts specially produced for use with aluminum wheels. 2. Use only Isuzu genuine aluminum wheels. 3. After driving on a road where road chemicals are applied or on a coastal road, thoroughly wash the wheels with water and then apply wax to prevent corrosion.
Page 420 If a lot of water drains from an air tank, the desiccant of the air dryer may have deteriorated. When it is necessary to replace the desiccant, ask the nearest Isuzu Dealer to do this. WARNING • Water collecting in the air tank may...
Page 421 7-93 SERVICE AND MAINTENANCE Air Pressure Air Pressure Checking 1. Check the air pressure gauges to see that the primary and secondary air systems are charged with air to proper pressures. Proper air pressure range 740 - 830 kPa (7.5 - 8.5 kgf/cm²/107 - 121 psi) 2.
Page 422 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...
Page 423 If the trailer does not return to its normal height, a faulty leveling valve or spring damage is indicated. Drive the vehicle to the nearest Isuzu Dealer for repair. Maintenance Schedule → Refer to page 7-163...
Page 424 Have the replacement carried out by the nearest Isuzu Dealer. Also, it is necessary to periodically replace the rubber parts inside the air dryer. Have the replacement carried FYH model out by your Isuzu Dealer.
Page 425 7-97 SERVICE AND MAINTENANCE Fuel Tank Sediment and water collected in the fuel tank must be removed according to the Maintenance Schedule. ADVICE • The contaminant and fuel discharged from the tank must be disposed of in a method conforming to the regulatory requirements in your country. Maintenance Schedule →...
Page 426 7-98 SERVICE AND MAINTENANCE Clutch Pedal The clutch disc wears down as the clutch is used, and this causes the free play of the clutch pedal to decrease. If you continue to use the clutch with reduced clutch pedal play, the clutch slips easily. On the other hand, if there is too much free play, the clutch disengages poorly, making gearshifts difficult.
Page 427 7-99 SERVICE AND MAINTENANCE ADVICE • Release the clutch pedal carefully to prevent the vehicle from starting too suddenly. Adjustment of Clutch Pedal Free Play Adjustment of Clutch Booster (MJT7 Model Transmission) Clutch shaft If the free play of the clutch pedal is Push rod not within the specified range, make adjustments at the clutch booster and the...
Page 428 7-100 SERVICE AND MAINTENANCE Adjustment of Master Cylinder 7. Remove the return spring from the clutch pedal. 8. Loosen the master cylinder push rod lock nut. 9. Turn in the push rod until it makes contact with the piston. 10. Return the push rod from this position by 2/5 to 4/5 of a turn.
Page 429 If clutch fluid decreases too rapidly, there might be a problem in the clutch system or the clutch disc might be worn beyond safe limits. Have your vehicle inspected by the nearest Isuzu Dealer immediately. Maintenance Schedule → Refer to page 7-163...
Page 430 Changing the Clutch Fluid The clutch fluid must be changed according to the maintenance schedule. Since a clutch fluid change requires disassembly of the related components, have this service performed by your Isuzu Dealer. Maintenance Schedule → Refer to page 7-163...
Page 431 7-103 SERVICE AND MAINTENANCE 1. Chock the wheels and firmly apply the parking brake. 2. Check the level of the clutch fluid in the clutch fluid tank and add fluid as required. MJT7 model transmission 3. Detach the rubber cap from the bleeder screw on the clutch booster (MJT7 model transmission) or bleeder hose (ZF9S1310 or RTO-11908LL...
Page 432 7-104 SERVICE AND MAINTENANCE 5. Press the clutch pedal several times and then keep it pressed. 6. Loosen the bleeder screw to let the clutch fluid containing air bubbles flow into the container and then tighten the bleeder screw immediately. 7.
Page 433 7-105 SERVICE AND MAINTENANCE Transmission Oil MJT7 model transmission Change the transmission oil according to the maintenance schedule. CAUTION • The vehicle must be parked on a flat and level surface when changing the oil. On sloping ground, oil level cannot be checked correctly, and when the oil is not filled sufficiently, the transmission may be damaged.
Page 434 7-106 SERVICE AND MAINTENANCE RTO-11908LL model transmission Changing the Transmission Oil (MJT7 Model Transmission) ADVICE • Any dirt on the plug should be wiped off before removing or installing it. • Since the case of the MJT model transmission is made of aluminum, be extremely careful not to tighten the plug excessively when installing the level plug.
Page 435 7-107 SERVICE AND MAINTENANCE Oil strainer plug tightening torque 64 - 88 N·m (6.5 – 9.0 kgf·m/47 - 65 lb·ft) Drain plug tightening torque (other than above) 49 - 88 N·m (5.0 - 9.0 kgf·m/36 - 65 lb·ft) 3. After the drain plug is installed, add Level the oil from the level plug hole, up to plug hole...
Page 436 7-108 SERVICE AND MAINTENANCE Changing the Transmission Oil (ZF9S1310 Model Transmission) Transmission oil must be changed at the specified intervals. 1. Place a container under the drain plug to receive oil. 2. Remove the oil level plug and then the drain plugs 1 and 2 to discharge the oil into the container.
Page 437 7-109 SERVICE AND MAINTENANCE Changing the Transmission Oil (RTO-11908LL Model Transmission) WARNING • Before working on a vehicle, place transmission in neutral, set parking brake and block wheels. • Never mix engine oils and synthetic transmission oils in the same transmission. When switching between types of lubricants, all areas of each affected component must be thoroughly drained.
Page 438 7-110 SERVICE AND MAINTENANCE Check Transmission Oil Level ADVICE • Before checking level, engine must be idling in neutral for at least 2 minutes and lubricant temperature must be between 15.5 and 48.8°C (60 and 120°F). Check lubricant level using the fill hole or sight-glass usually located on the right side of the transmission.
Page 439 7-111 SERVICE AND MAINTENANCE Propeller Shaft Center Bearing Apply the recommended grease via the grease fitting according to the maintenance schedule. ADVICE • Avoid mixing the bearing grease with a different type of grease (chassis grease, for example). Be sure to use multi-purpose type grease.
Page 440 7-112 SERVICE AND MAINTENANCE Differential Gear Oil Change the differential gear oil according to the maintenance schedule. Level plug For the 17.5-inch forward rear axle (RT210 type), clean the oil strainer as well. ADVICE Drain plug • Use the oil quantities indicated later in this section only as guidelines 17.5-inch forward rear axle when changing the rear axle...
Page 441 7-113 SERVICE AND MAINTENANCE Changing the Differential Gear Oil R130/RT210 Type Axles 1. Remove both level plug and drain plug(s) to discharge the oil into the container. For the 17.5-inch forward rear axle, remove the oil strainer plug, and pull out the oil strainer. Wash the oil strainer with light oil, dry it, then reinstall it and tighten the oil strainer plug.
Page 442 7-114 SERVICE AND MAINTENANCE 3. After refilling, confirm that the oil level Level is up to the lower edge of the oil level plug hole plug hole. surface 4. Install the level plug. Oil level (bottom face of Plug tightening torque screw hole) Square head 29 - 59 N·m...
Page 443 7-115 SERVICE AND MAINTENANCE Rear axle, forward rear axle (FXM RS23/RT40 Type Axles model) and rearward rear axle (FXZ 1. Place a container under the drain model) plug(s) to receive oil. 2. Remove the filler plug to discharge the oil into the container. 3.
Page 444 6. Check the area around the filter for any oil leaks. CAUTION • Use only an Isuzu genuine oil filter. Any other oil filter has a projection, which will interfere with the carrier before the filter comes in contact with the seal. This will result in a...
Page 445 7-117 SERVICE AND MAINTENANCE Front Wheel Hub Bearing Oil The wheel hub bearing oil must be changed according to the Maintenance Schedule. Maintenance Schedule → Refer to page 7-163 Recommended Fluids, Lubricants and Diesel Fuels → Refer to page 7-188 Maintenance Schedule for FG941 (MFS66)/RS23/RT40 Type Axle →...
Page 446 Changing the Oil Changing the wheel hub bearing oil involves disassembly work, so have it done by your Isuzu Dealer.
Page 447 The fluid level should be between the "MAX" and "MIN" lines on the fluid tank. If the level is low, replenish the fluid up to the "MAX" line using Isuzu's recommended power steering fluid. ADVICE •...
Page 448 Changing the Power Steering Fluid Change the power steering fluid according to the maintenance schedule. Fluid replacement requires disassembling of the relevant components, so you should have it done by your Isuzu Dealer. Draining 1. Apply the parking brake firmly and chock the rear wheels.
Page 449 7-121 SERVICE AND MAINTENANCE FYH model 3. Without running the engine, fully turn the steering wheel in both directions a few times. 4. Lower the vehicle and start the engine. While running the engine at idle, fully turn the steering wheel in both directions a few times.
Page 450 7-122 SERVICE AND MAINTENANCE 4. Start the engine. Turn the steering wheel fully in both directions a few times. 5. Lower the vehicle. With the engine still running, fully turn the steering wheel in both directions a few times. If you do not hear abnormal sounds any more, the system has been properly bled.
Page 451 7-123 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 7-163 Cleaning the Power Steering Fluid Filter FXR/FXZ/FXM/GXR Models 1. Remove the cap from the power steering fluid tank.
Page 452 7-124 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 453 Change the cab tilt pump oil according to the maintenance schedule. Oil replacement requires disassembling of the relevant components, so you should have it done by your Isuzu Dealer. Maintenance Schedule → Refer to page 7-163 Recommended Fluids, Lubricants and Diesel Fuels →...
Page 454 7-126 SERVICE AND MAINTENANCE Steering Wheel Daily Check Check the steering wheel for the amount of play by turning the steering wheel in both directions until the tires begin to move with the engine running. Standard free play 10 - 60 mm (0.39 - 2.36 in) Also check the steering wheel for looseness in mount by moving it back and forth and sideways.
Page 455 Grease the following points using multi-purpose type grease or chassis grease according to the maintenance schedule. Coupler Wheel hub bearing (GXR model) Since disassembling is required for this greasing, have it performed by your Isuzu For details, refer to the instruction manual Dealer. for the coupler.
Page 456 7-128 SERVICE AND MAINTENANCE Apply multi-purpose type grease via the grease fitting to the following points according to the maintenance schedule. Propeller shaft Propeller shaft [Transmission universal joint] 1 point [Universal joint] 1 point [Sliding sleeve] 2 points (some models have 1 or no points) Propeller shaft Propeller shaft...
Page 457 7-129 SERVICE AND MAINTENANCE Clutch booster joint pin 1 position on the right side Lubricate directly around the pin (without grease fitting). (MJT7 transmission vehicles) ADVICE • At points where multi-purpose type grease is used, do not mix another type of grease (chassis grease.
Page 458 7-130 SERVICE AND MAINTENANCE Drag link [multi-purpose type grease] 2 points forward front axle (FYH model) 2 points rearward front axle (FYH model) Kingpin Kingpin/Kingpin bushing [multi-purpose type grease] [multi-purpose type grease] 4 points left and right 4 points left and right (F066/F075 type axles) (vehicles with FG941 (MFS66) type axle)
Page 459 7-131 SERVICE AND MAINTENANCE Tie rod end and ball stad on the Front wheel brake camshaft and slack steering arm adjuster [multi-purpose type grease] (vehicles with FG941 (MFS66) type axle) 4 points left and right (vehicles with FG941 (MFS66) type axle) Rear wheel brake camshaft and slack Front suspension adjuster...
Page 460 7-132 SERVICE AND MAINTENANCE Front suspension Air suspension [chassis grease] [Spring pin and shackle pin] 4 points When any grease remains on the air (FXR/FXZ/FXM/GXR models) or 8 points suspension bellows, use a cloth, etc. and (FYH model) on the rear area of front axle wipe it away.
Page 461 7-133 SERVICE AND MAINTENANCE OTHER SERVICE AND MAINTENANCE ● Handling the Jack 7-134 ● Windshield Wiper Blades 7-138 ● Windshield Washer Fluid 7-141 ● Exterior Lights 7-142 ● Handling the Battery 7-143 ● Air Conditioning Filters 7-147 ● Refrigerant 7-149 ●...
Page 462 7-134 SERVICE AND MAINTENANCE Handling the Jack WARNING • When jacking up the vehicle, select a flat, solid surface. • After raising the vehicle and before going underneath to perform work, make sure the vehicle is supported with jack stands. •...
Page 463 7-135 SERVICE AND MAINTENANCE 2. Turn the head of the jack to extend it to the height of the jacking point. Turn it counterclockwise to extend. 3. Insert the jack handle into the socket. When jacking up the vehicle, use the notched part of the jack handle and turn the release valve fully clockwise.
Page 464 7-136 SERVICE AND MAINTENANCE Jacking Points ADVICE • If the jack stroke is insufficient, place a thick piece of wood with ample width beneath the jack. • The jack cannot be placed under the front axle depending on the condition of the vehicle (flat tyre, etc.).
Page 465 7-137 SERVICE AND MAINTENANCE Jacking when a Front Tyre Is Flat WARNING • Position the jack as close as possible to the front axle. • The wood block should be as thick as possible in order to improve stability. • As the bottom of the leaf spring is curved, special care must be taken during the jacking operation.
Page 466 7-138 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 1.
Page 467 7-139 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 468 7-140 SERVICE AND MAINTENANCE Replacement of Wiper Rubber Element Removal 1. Remove the wiper blade from the Extract wiper arm. 2. Pull the wiper rubber element in the direction indicated by the arrow and extract it from the wiper blade. Installation 1.
Page 469 7-141 SERVICE AND MAINTENANCE Windshield Washer Fluid Windshield Washer Daily Check 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 470 7-142 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 471 7-143 SERVICE AND MAINTENANCE Handling the Battery DANGER • Usage or charging of the battery when the battery fluid is below the "LOWER LEVEL" can accelerate deterioration, and give rise to dangerous situations such as the generation of heat and even explosion. •...
Page 472 • If the battery fluid level continues to drop at an unusually fast rate, have an inspection carried out immediately by the nearest Isuzu Dealer. Checking the Battery Fluid Level 1. Check to see if the fluid surface is between the "UPPER"...
Page 473 7-145 SERVICE AND MAINTENANCE Cleaning the Terminals 1. Check the terminals for looseness and corrosion. 2. If a terminal is found to be corroded and coated in white powder, wash this away with warm water and then wipe fully dry. Subsequently, apply a light smear of grease to the terminals.
Page 474 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.
Page 475 7-147 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 476 7-148 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 477 The air conditioning system will not be able to cool the cab interior effectively if the refrigerant level is low. Accordingly, the refrigerant level must be topped up whenever necessary. Please contact your Isuzu Dealer whenever refrigerant must be added. ADVICE •...
Page 478 7-150 SERVICE AND MAINTENANCE Air Conditioning Compressor Belt If the air conditioning compressor belt becomes loose, cooling performance will be impaired. It is important to inspect belt tension to ensure proper cab interior cooling. Checking the Compressor Belt Check to see if the deflection of the belt is within the standard value range when the point mid-way between the pulleys is pressed with a force of approximately...
Page 479 7-151 SERVICE AND MAINTENANCE INTERIOR AND EXTERIOR MAINTENANCE ● Exterior Maintenance 7-152 ● Interior Maintenance 7-156...
Page 480 7-152 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 481 7-153 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 482 7-154 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 483 7-155 SERVICE AND MAINTENANCE Windshield Care If not fully cleaned by the windshield wipers, the windshield should be cleaned using glass cleaner.
Page 484 7-156 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 to fire if water should enter the audio system or other electrical components located underneath the floor carpet.
Page 485 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 at the nearest Isuzu Dealer. Cleaning a Seat Belt's Fold-back Fitting Portion 1.
Page 486 • Check to see if the seat belt fails to retract properly, the mounting part is loose, a metal part is deformed, or the belt is damaged, frayed, or faded. If you find an abnormality, contact the nearest Isuzu Dealer.
Page 487 7-159 SERVICE AND MAINTENANCE Fabric Seat Covering and Carpet Care Fabric Upholstery Remove dust and dirt using a household vacuum cleaner. 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 488 7-160 SERVICE AND MAINTENANCE...
Page 489 7-161 SERVICE AND MAINTENANCE MAINTENANCE DATA ● Inspection and Maintenance 7-163...
Page 491 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 492 7-164 SERVICE AND MAINTENANCE Maintenance Schedule ISUZU FXR, FXD, FXZ, GXD, FXL, FXY MAINTENANCE SCHEDULE I = Inspect, clean, correct, replace as necessary R = Replace T = Retighten to specified torque L = Lubricate A = Adjust * : Refer to “Maintenance schedule under severe operating conditions” on next page.
Page 493 7-165 SERVICE AND MAINTENANCE Maintenance Schedule SERVICE INTERVAL: Initial Every x 1,000 kilometres or years or hours 1200 1600 2400 Valve clearances * Power steering fluid - replace. Clean filter element * Exhaust pipes & mounting, exhaust brake operation Turbo charger, intercooler and intake system air duct connections and gaskets All coolant hoses &...
Page 494 7-166 SERVICE AND MAINTENANCE Maintenance Schedule SERVICE INTERVAL: Initial Every x 1,000 kilometres or years or hours 1200 1600 2400 Function of air compressor, govenor and unloader valve Gear control mechanism * Clutch pedal travel & free play * All grease points * Universal joints &...
Page 495 & exhaust systems for leaks. All fluid levels. Cab suspension & tilt operation Operation of all electrical devices, A/C, heater & warning lights Connect Isuzu diagnostic tool, check, note and/or repair any codes recorded ROAD TEST Operation of steering, brakes,...
Page 496 7-168 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE UNDER SEVERE OPERATING CONDITIONS A: Repeated short trips with extensive idling and/or where the engine does not reach normal operating temperature. Also applications involving descending or ascending steep gradients. (Examples may be Concrete Agitators, Tow trucks, Concrete Pumpers, Road Patchers, mine site trucks etc) B: Driving on rough/loose surface roads (More than 10% of operation) or operating in any harsh environment/application likely to cause accelerated wear and tear.
Page 497 7-169 SERVICE AND MAINTENANCE Inspect every 5,000 km Universal joints & splines (100hrs) Steering linkage for damage, Inspect every 5,000 km looseness and excessive play (100hrs) Change every 60,000 km Air dryer filter (1200hrs) Inspect every 5,000 km Brake lining/pad wear (100hrs) Brake drum/rotor for wear or Inspect every 5,000 km...
Page 498 7-170 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE VALIDATION Preparation carried out; New Vehicle at ……………………….. kilometres on (date)………………… Preparation Validation Delivering Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 5,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 20,000 kilometres Servicing Dealer ………………………………………………...
Page 499 7-171 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE VALIDATION Service carried out; at …………………...kilometres on (date)……………………… 140,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 160,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 180,000 kilometres Servicing Dealer ………………………………………………...
Page 500 7-172 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE VALIDATION Service carried out; at …………………...kilometres on (date)……………………… 300,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 320,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 340,000 kilometres Servicing Dealer ………………………………………………...
Page 501 7-173 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE VALIDATION Service carried out; at …………………...kilometres on (date)……………………… 300,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 320,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 340,000 kilometres Servicing Dealer ………………………………………………...
Page 502 7-174 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE VALIDATION Service carried out; at …………………...kilometres on (date)……………………… 620,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 640,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 660,000 kilometres Servicing Dealer ………………………………………………...
Page 503 7-175 SERVICE AND MAINTENANCE MAINTENANCE SCHEDULE VALIDATION Service carried out; at …………………...kilometres on (date)……………………… 780,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 800,000 kilometres Servicing Dealer ………………………………………………... Service carried out; at …………………...kilometres on (date)……………………… 820,000 kilometres Servicing Dealer ………………………………………………...
Page 504 7-176 SERVICE AND MAINTENANCE INTERMEDIATE/SEVERE/ENGINE HOURS VALIDATION Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………...
Page 505 7-177 SERVICE AND MAINTENANCE INTERMEDIATE/SEVERE/ENGINE HOURS VALIDATION Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………...
Page 506 7-178 SERVICE AND MAINTENANCE INTERMEDIATE/SEVERE/ENGINE HOURS VALIDATION Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………...
Page 507 7-179 SERVICE AND MAINTENANCE INTERMEDIATE/SEVERE/ENGINE HOURS VALIDATION Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………...
Page 508 7-180 SERVICE AND MAINTENANCE INTERMEDIATE/SEVERE/ENGINE HOURS VALIDATION Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………...
Page 509 7-181 SERVICE AND MAINTENANCE INTERMEDIATE/SEVERE/ENGINE HOURS VALIDATION Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………... Intermediate/Severe/Engine Hours Service carried out; at……………………kilometres or ………………..hours, on (date)……………………… Servicing Dealer ……………………………………………………………………………...
Page 510 SERVICE AND MAINTENANCE Recommended Fluids and Lubricants - Euro 4 & 5 only Component Description Package Part Number 5 Litres 92956060 Engine (Euro 4 & 5) NEXTGEN PLUS 20 Litres 92956061 205 Litres 92956062 5 Litres 92956072 Isuzu Manual Transmission - S-TRANS 75/90 MZX, MZW models only 20 Litres 92956073 5 Litres 92956060 Isuzu Manual Transmission MYY-5T, MYY-6S, MZZ 6F NEXTGEN PLUS 20 Litres 92956061 (N Series trucks only.) 205 Litres 92956062 Eaton Transmission...
Page 511 7-183 SERVICE AND MAINTENANCE Recommended Fluids and Lubricants - Euro 4 & 5 only 1 Litres 92955040 LONG LIFE Anti- 5 Litres 92955041 freeze 20 Litres 92955042 Coolant 5 Litres 92955193 PRE-MIX Anti- 20 Litres 92955194 freeze coolant 205 Litres 92955246 5 Litres 92956068 Power Steering Fluid ATF III 20 Litres 92956069 450gms 92956074 Wheel Bearings and Chassis Grease MP 2 20kg 92956075...
Page 512 7-184 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. Use Isuzu genuine lubricants or those recommended in the list below.
Page 513 7-185 SERVICE AND MAINTENANCE Recommended Fluids, Lubricants and Diesel Fuels DIESEL FUEL / APPLICABLE STANDARD Japanese Industrial Standards (JIS) Based on K2204 GAS OIL Deutsche Industrie Normen (DIN) Based on EN590 : 1997 SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) Based on SAE J-313C British Standards (BS) Based on EN590 : 1997 DIESEL FUEL / APPLICABLE STANDARD (Sulfur content below 50 ppm) Japanese Industrial Standards (JIS)
Page 514 7-186 SERVICE AND MAINTENANCE Engine Oil and Gear Oil Viscosity Charts Select appropriate engine and gear oils in accordance with the tables below. It is also important to select the viscosity appropriate for the temperature at which your vehicle operates. Use the following tables for making correct selections. °...
Page 515 7-187 SERVICE AND MAINTENANCE Lubrication Chart FXR Model (with F066/F075 and R130 Type Axles)
Page 516 7-188 SERVICE AND MAINTENANCE FXR Model with Leaf Spring Suspension (with FG941 (MFS66) and RS23 Type Axles)
Page 517 7-189 SERVICE AND MAINTENANCE FXR/GXR Models with Air Suspension (with FG941 (MFS66) and RS23 Type Axles)
Page 518 7-190 SERVICE AND MAINTENANCE FXZ Model with Leaf Spring Suspension (with F066/F075 and RT210 Type Axles)
Page 519 7-191 SERVICE AND MAINTENANCE FXZ Model with Leaf Spring Suspension (with FG941 (MFS66) and RT40 Type Axles)
Page 520 7-192 SERVICE AND MAINTENANCE FXZ Model with Air Suspension (with FG941 (MFS66) and RT40 Type Axles)
Page 521 7-193 SERVICE AND MAINTENANCE FXM Model...
Page 522 7-194 SERVICE AND MAINTENANCE Greasing Points FXR Model (with F066/F075 and R130 Type Axles)
Page 523 7-195 SERVICE AND MAINTENANCE FXR Model with Leaf Spring Suspension (with FG941 (MFS66) and RS23 Type Axles)
Page 524 7-196 SERVICE AND MAINTENANCE FXR/GXR Models with Air Suspension (with FG941 (MFS66) and RS23 Type Axles)
Page 525 7-197 SERVICE AND MAINTENANCE FXZ Model (with F066/F075 and RT210 Type Axles)
Page 526 7-198 SERVICE AND MAINTENANCE FXZ Model with Leaf Spring Suspension (with FG941 (MFS66) and RT40 Type Axles)
Page 527 7-199 SERVICE AND MAINTENANCE FXZ Model with Air Suspension (with FG941 (MFS66) and RT40 Type Axles)
Page 528 7-200 SERVICE AND MAINTENANCE FXM Model...
Page 529: In Case Of Emergency
IN CASE OF EMERGENCY ● Troubleshooting ● When the Vehicle Breaks Down during Driving ● When the Tyre Goes Flat ● When the Engine Stops While Driving ● When the Brakes Do not Work 8-10 ● When the Battery Goes Flat 8-11 ●...
Page 530 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 531 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page Adjust the idling speed Idling speed too low with the idling control 4-54 switch Drain the water and 7-45 Fuel filter clogged replace the filter 7-48 element with a new one Drain the water and Engine starts, but 7-45...
Page 532 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page No engine coolant Add engine coolant 7-41 Front of radiator is clogged Wash clean with water 7-43 with dirt Tighten it securely or Sub-tank cap not fully replace the cap with a ―...
Page 533 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page Clearances between the drum and lining are too ― large Brakes not effective Raise engine speed to Low air pressure 7-93 supply air Unbalanced air pressure Adjust to proper air 7-60 in tyres pressure...
Page 534 IN CASE OF EMERGENCY Reference Symptom Cause Corrective action page Insufficient transmission Add oil 7-105 From the transmission Transmission inner ― components faulty Insufficient differential Add oil 7-112 gear oil From Loud or differential abnormal Differential inner ― noises components faulty From the Spring pins, shackles or ―...
Page 535 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 536 IN CASE OF EMERGENCY When a Tyre Goes Flat When a tyre goes flat while driving, avoid hard braking, hold on to the steering wheel firmly and stop the vehicle. The tyre should be changed on a flat space to prevent obstructing other vehicles or pedestrians.
Page 537 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 538 When the vehicle operates properly with sufficient air pressure, you can drive the vehicle with the foot brake alone. In that case, contact the nearest Isuzu Dealer.
Page 539 8-11 IN CASE OF EMERGENCY When the Battery Goes Flat Sequence for connecting cable If the vehicle battery goes flat and you try to start the engine with a booster cable, use the following methods. 1. Stop the engine of the vehicle with the booster battery.
Page 540 When the air springs break or air leaks, avoid hard braking, hold on to the steering wheel firmly, and stop the vehicle in a safe place. Since repairing the air springs is required, stop driving and contact the nearest Isuzu Dealer.
Page 541 8-13 IN CASE OF EMERGENCY When the Fuel Runs Out When changing the fuel filter or when the fuel runs out, air will enter the fuel system, so refueling alone will not be enough to restart the engine. Use the following methods to bleed the fuel system.
Page 542 • When the air pressure 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, repair is required. Please contact the nearest Isuzu Dealer. Air Pressure Checking → Refer to page 7-93 WARNING •...
Page 543 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 7-34 CAUTION • Do not drive the vehicle when the warning light is on. The battery may drain.
Page 544 Replace the oil filter. 4. When the oil level is normal and the oil filter is not clogged, but there are oil leaks, contact the nearest Isuzu Dealer. Checking the Engine Oil Level → Refer to page 7-21 Changing the Engine Oil →...
Page 545 CAUTION • If there is an abnormality in the seat belt with pretensioner and airbag, they may not work normally. Have the system checked by the nearest Isuzu Dealer. NOTE • It is normal for the warning light to come on, flash seven times and then go out when the starter switch is placed in the "ON"...
Page 546 Antilock Brake System (ABS) Antilock Brake System (ABS) → Refer to page 4-94 Trailer ABS Trailer ABS Warning Light → Refer to page 4-31 If the indicator light comes on during operation, immediately contact the nearest Isuzu Dealer for inspection.
Page 547 8-19 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 548 6. If engine coolant is leaking, or the engine coolant level is proper and no engine coolant is leaking, contact the nearest Isuzu Dealer. ADVICE • Make sure that the needle on the engine coolant temperature gauge is below "C"...
Page 549 Voltmeter When the abnormal voltage display (red) is indicated on the multi-information display (MID), there may be excessive battery discharge or the generator may be deficient. When this occurs, contact the nearest Isuzu Dealer. Voltmeter → Refer to page 4-20...
Page 550 8-22 IN CASE OF EMERGENCY When the Parking Brake Cannot be Released Model with R130/RT210 Type Axle 1. Firmly chock the wheels. 2. Remove the cap and insert the release bolt, a tool carried on the vehicle, as far as it goes. Rotate it 90° Release bolt MFU780SH005401 clockwise and lock.
Page 551 8-23 IN CASE OF EMERGENCY Model with RS23/RT40 Type Axle 1. Firmly chock the wheels. 2. For easy removal and installation, the rear spring brake can be released manually. Remove the dust plug from the release tool keyhole in the center of the brake chamber.
Page 552 5/21W Turn signal light Rear Back up light 2-lights type License plate light 1-light type Dome light Interior Interior light (fluorescent light) Roof Front end outline marker light Contact the nearest Isuzu Dealer when replacing lights that aren't listed here.
Page 553 8-25 IN CASE OF EMERGENCY CAUTION • Using bulbs with a wattage other than that specified could cause the bulb or the wiring to become hot. This could result in the warping of the lens and case, leading to a fire. •...
Page 554 • When replacing headlight bulbs, have the headlight aim adjusted at the nearest Isuzu Dealer. Bulb Wattage→ Refer to page 8-24 1. Tilt the cab and work from front-sideways of the vehicle for the replacement.
Page 555 8-27 IN CASE OF EMERGENCY 2. Disconnect the headlight connector. ADVICE • When removing the headlight connector, pull out the connector while holding the center portion of the rubber boot. If the headlight connector is pulled out without holding the center portion of the rubber boot, the bulb will lift up and when the connector is removed, the bulb can hit the reflector by the...
Page 556 8-28 IN CASE OF EMERGENCY 3. Remove the rubber boot. Then push the right side of the clip that holds the bulb in place and slide it upwards to disengage the clip. 4. Pull off the bulb and replace with a new one.
Page 557 8-29 IN CASE OF EMERGENCY Replacing the Clearance Lights 1. Tilt the cab and work from front-sideways of the vehicle for the replacement. CAUTION • Tilt the cab only on a level surface. • Check the areas in front of and above the cab for sufficient clearance when tilting the cab indoors.
Page 558 8-30 IN CASE OF EMERGENCY 3. Pull off the bulb from the clearance light socket and replace with a new one. 4. To install the lights, perform the same sequence of operations in reverse taking care of the following point: • Turn the connector clockwise to Locked securely lock it.
Page 559 8-31 IN CASE OF EMERGENCY Replacing the Side Turn Signal Light 1. Loosen one screw and remove the side turn signal light by sliding it with the base toward the front of the vehicle. 2. Turn the socket counterclockwise to remove it. Pull off the bulb from the socket and replace with a new bulb.
Page 560 8-32 IN CASE OF EMERGENCY Replacing the 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 561 8-33 IN CASE OF EMERGENCY Replacing the Rear Turn Signal Light, Taillight, Stop Light and Backup Light 1. Loosen the screws and remove the lens. 2. Loosen the bulb by turning it counterclockwise while pushing it. 3. To install the lights, follow the removal procedure in reverse.
Page 562 8-34 IN CASE OF EMERGENCY Replacing the Dome Light 1. Remove the lens and pull out the bulb. 2. To install the lights, follow the removal procedure in reverse. Replacing the Interior Light (Fluorescent Light) 1. Open the cover and release the clip. Cover Cover Clip...
Page 563 8-35 IN CASE OF EMERGENCY Replacing the Front End Outline Marker Light 1. Loosen the screws and remove the lens. 2. Remove the bulb and replace it with a new one. 3. To install the lights, follow the removal procedure in reverse.
Page 564 8-36 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 are located in the lower part of the instrument panel in the center and in the left rear of the cab.
Page 565 Normal Open • If the new fuses blow right away, contact the nearest Isuzu Dealer. Changing Relays Before replacing relays, remove the cover. MFU8Z0SH080001 ADVICE • It is not necessary to open or close the cover unless trouble is found.
Page 566 Do not use any material other than designated slow-blow fuses. Using other materials could cause a serious malfunction or fire. • If the new slow-blow fuses blow right away, contact the nearest Isuzu Dealer. NOTE • If an overload exists in the circuit from the battery, the slow-blow fuse will melt...
Page 567 8-39 IN CASE OF EMERGENCY Fuse and Relay Location Fuse Location in the Cab...
Page 568 8-40 IN CASE OF EMERGENCY Description Rating Description Rating H/LAMP CLEANER 20 ECM TRAILER 21 METER ROOM LAMP, AUDIO 22 LAMPS (BATT) DOOR LOCK REMOTE CONTROL MIRROR FRT FOG LAMP POWER WINDOW 24 CIGAR LIGHTER 25 HORN BACK LAMP H/LAMP LEVELING 26 TURN, HAZARD WIPER 27 TAIL LAMP...
Page 569 8-41 IN CASE OF EMERGENCY Relay Location in the Cab Description Description STOP LIGHT 16 TAIL LIGHT BLOWER MOTOR 17 BLANK KEY ON 18 PARKING SWITCH DOOR LOCK (LOCK) 19 TRAILER STOP LIGHT 1 BLANK 20 TRAILER INFORMATION 2 WIPER MAIN 21 TRAILER INFORMATION 1 HORN 22 EXHAUST BRAKE...
Page 570 8-42 IN CASE OF EMERGENCY Fuse and relay location outside the cab Description Description Rating BLANK BLANK — ECM MAIN BLANK — BLANK 10 ECM MAIN MAGNETIC CLUTCH 11 EXHAUST BRAKE BUZZER CUT 12 VGS STARTER CUT 13 BLANK — BLANK 14 A/C 15 BLANK...
Page 571 8-43 IN CASE OF EMERGENCY When Driving on Bad Roads Pressing the accelerator pedal will simply dig the vehicle deeper into the mud and make it harder to extricate. Either put stones, tree branches or blankets under the tires to gain traction, or repeatedly drive forward and in reverse and use the vehicle's momentum to extricate it.
Page 572 When Towing If towing the vehicle is required due to a breakdown or accident, contact the nearest Isuzu Dealer. At that time, pay all due attention to the following. When towing, use appropriate equipment and comply with local legal requirements.
Page 573 8-45 IN CASE OF EMERGENCY 5. Use the towing hook when the vehicle is empty. When using a towing rope, make sure it is strong enough for the task, and secure it to the hook. 6. Attach the towing rope to the towing hook within the safety angle of use (30°...
Page 574 8-46 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 575 8-47 IN CASE OF EMERGENCY Towing Vehicles with ZF9S1310 Model Transmission On ZF9S1310 transmission vehicles, select high range and place the gearshift lever in the "N" position. For the towing speed, refer to the following chart. Do not tow more than 100 km (62 miles).
Page 576 8-48 IN CASE OF EMERGENCY Towing Vehicles with RTO-11908LL Model Transmission Towing Please 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 577: Main Data
MAIN DATA ● Specifications ● Others 9-12...
Page 578 MAIN DATA Specifications Engine 6UZ1 Specifications Water-cooled, overhead camshaft, direct injection engine with an inter-cooled turbocharger Compression ratio (to 1) 16.2 Displacement cc (cu. in) 9,839 (600.4) Firing order 1-5-3-6-2-4 Fuel injection timing (static) degree 0° Valve clearance mm (in) Intake valves: 0.2 (0.008) and exhaust valves: 0.5 (0.020) in cold engine Idling speed...
Page 579 MAIN DATA ZF9S1310 Model Specifications Nine-speed transmission (overdrive gear for 8th), synchromesh for 1st to 8th Gear ratio (to 1) Crawler 9.479 6.576 4.678 3.478 2.617 1.890 1.345 1.000 0.752 Rev. 8.967 Transmission oil capacity [Reference value] Model without PTO: 8.0 (2.11 / 1.76) litres (US gal./lmp gal.) Model with PTO: 8.5 (2.25 / 1.87) RTO-11908LL Model...
Page 580 MAIN DATA Service Specifications FXR/GXR Models Engine Model 6UZ1-TCC Engine oil capacity [Reference value] litres (US gal./lmp gal.) Refer to page 9-2 Engine coolant capacity [Reference value] litres (US gal./lmp gal.) Refer to page 9-2 Transmission Model ZF9S1310 Transmission oil capacity [Reference value] litres (US gal./lmp gal.) Refer to page 9-3 Clutch...
Page 581 MAIN DATA Steering Steering wheel free play mm (in) 10 - 60 (0.39 - 2.36) Power steering fluid capacity [Reference value] litres (US gal./lmp gal.) 4.5 (1.19 / 0.99) Service brakes Type Full-air, dual brake system Brake pedal free play mm (in) 10 - 18 (0.39 - 0.71) Parking brake...
Page 582 MAIN DATA FXZ Model Engine Model 6UZ1-TCC Engine oil capacity [Reference value] litres (US gal./lmp gal.) Refer to page 9-2 Engine coolant capacity [Reference value] litres (US gal./lmp gal.) Refer to page 9-2 Transmission Model MJT7 ZF9S1310 RTO-11908LL Transmission oil capacity [Reference value] litres (US gal./lmp gal.) Refer to page 9-2, 9-3 Clutch...
Page 583 MAIN DATA Steering Steering wheel free play mm (in) 10 - 60 (0.39 - 2.36) Power steering fluid capacity [Reference value] litres (US gal./lmp gal.) 4.5 (1.19 / 0.99) Service brakes Type Full-air, dual brake system Brake pedal free play mm (in) 10 - 18 (0.39 - 0.71) Parking brake...
Page 584 MAIN DATA FXM Model Engine Model 6UZ1-TCC Engine oil capacity [Reference value] litres (US gal./lmp gal.) Refer to page 9-2 Engine coolant capacity [Reference value] liters (US gal./lmp gal.) Refer to page 9-2 Transmission Model ZF9S1310 Transmission oil capacity [Reference value] litres (US gal./lmp gal.) Refer to page 9-3 Clutch...
Page 585 MAIN DATA Steering Steering wheel free play mm (in) 10 - 60 (0.39 - 2.36) Power steering fluid capacity [Reference value] litres (US gal./lmp gal.) 4.5 (1.19 / 0.99) Service brakes Type Full-air, dual brake system Brake pedal free play mm (in) 10 - 18 (0.39 - 0.71) Parking brake...
Page 586 9-10 MAIN DATA FYH Model Engine Model 6UZ1-TCC Engine oil capacity [Reference value] litres (US gal./Imp gal.) Refer to page 9-2 Engine coolant capacity [Reference value] litres (US gal./Imp gal.) Refer to page 9-2 Transmission Model ZF9S1310 Transmission oil capacity [Reference value] litres (US gal./Imp gal.) Refer to page 9-3 Clutch...
Page 587 9-11 MAIN DATA Steering Steering wheel free play mm (in) 10 - 60 (0.39 - 2.36) Power steering fluid capacity [Reference value] litres (US gal./Imp gal.) 7.5 (1.98 / 1.65) Service brakes Type Full-air, dual brake system Brake pedal free play mm (in) 10 - 18 (0.39 - 0.71) Parking brake...
Page 588 9-12 MAIN DATA Others Pneumatic Characteristic Data Compressor/unloader valve Market Model Pre-set pressure All market All models Max. cut-out Min. cut-in pressure = 8.3 bar pressure = 7.4 bar Four-circuit protection valve Market Model Pre-set pressure Australia, New Zealand FXR/FXM/FXZ/GXR Service brake Parking brake Others...
Page 589: Index
10-1 INDEX Air Cleaner 7-31 Cab Tilt Pump Oil 7-125 Air Conditioning Compressor Card Holder 5-25 Belt 7-150 Carrying Children 2-28 Air Conditioning Filters 7-147 Cautions for Driving in Cold Regions 6-20 Air Dryer 7-96 Cautions for Driving in Hot Regions 6-19 Air Flow Sensor 7-49...
Page 590 7-44 Interior Lights 5-21 Fuel Gauge 4-13 Interior Maintenance 7-156 Fuel Tank 7-97 Isuzu Genuine Oils and Grease Fuel Tank Filler Cap 3-14 Fully Adjustable Steering 3-25 Keyless Entry System Gearshift Lever 4-74 Getting In and Out of the Vehicle...
Page 591 10-3 INDEX On the Road Seat Belt with Pretensioner and Supplemental Restraint System (SRS) Opening and Closing Doors Airbag System 2-59, 4-105 Operating Tips for the Radio and Seat Belts 3-29 CD Player 5-29 Seats 3-17 Others 9-12 Small Article Storage Pocket 5-24 Overhead Shelf 5-27...
Page 592 Released 8-22 When the Tire Goes Flat When the Vehicle Breaks Down during Driving When the Warning Light Comes On 8-14 When to Visit an Isuzu Dealer 2-53 When Towing 8-44 Windshield Washer Fluid 7-141 Windshield Wiper and Windshield Washer Switch...
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Isuzu Tilt Slide FYJ2000 Instruction Manual

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