Isuzu 3CH1-NGZG01 Reference manual

i
TNV Operation Manual
INTRODUCTION
To help you enjoy your Isuzu C series engine for
many years to come, please follow these
recommendations:
• Read and understand this Operation Manual
before you operate the machine to ensure that
you follow safe operating practices and
maintenance procedures.
• Keep this Operation Manual in a convenient place
for easy access.
• If this Operation Manual is lost or damaged, order
a new one from your Isuzu Distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should be
considered a permanent part of the engine and
remain with it.
• Constant efforts are made to improve the quality
and performance of Isuzu products, so some
details included in this Operation Manual may
differ slightly from your engine. If you have any
questions about these differences, please contact
your Isuzu Distributor.
• The specifications and components (instrument
panel, fuel tank, etc.) described in this manual
may differ from ones installed on your machine.
Please refer to the manual provided by the
manufacturer of these components.
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INTRODUCTION
ii
RECORD OF OWNERSHIP
Take a few moments to record the information you need when you contact Isuzu for service, parts or
literature.
Engine model:________________________________________________________________________
Engine serial No.: _____________________________________________________________________
Date purchased: ______________________________________________________________________
Dealer: ______________________________________________________________________________
Dealer phone: ________________________________________________________________________
SYMBOL EXPLANATION
The following symbols are used throughout this manual to identify specific engine model information
This symbol indicates information pertaining to the following indirect injection engines:
• 3CH1-NGZG01
• 3CH1-SDZP01
• 3CJ1-NGZG01
• 3CJ1-SDZP01
All of the models conform to the engine emission regulations (EPA 2013 rules).
This symbol indicates information pertaining to the following direct injection engines:
•3CE1
This model conform to the engine emission regulations (EPA 2013 rules).
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iii
TABLE OF
CONTENTS
Introduction............................................................................................... i
Record of Ownership........................................................................... ii
Symbol Explanation............................................................................. ii
Table of Contents ................................................................................... iii
Isuzu Engine After Service .................................................................... 1
Isuzu Genuine Parts........................................................................... 2
Emission-Related Installation Instructions (REF) ............................... 2
Installation of Nonroad Engines into Equipment........................... 2
Allowable Air Intake Restriction and Exhaust Back Pressure....... 2
Allowable Air Intake Restriction.................................................... 2
Allowable Exhaust Back Pressure................................................ 2
Safety....................................................................................................... 3
Safety Statements .............................................................................. 3
Safety Precautions.............................................................................. 4
Before You Operate...................................................................... 4
During Operation and Maintenance.............................................. 4
Product Overview................................................................................. 13
Isuzu C series Engine Features and Applications............................ 13
Component Identification.................................................................. 14
Location of Labels............................................................................. 17
Function of Major Engine Components ............................................ 18
Function of Cooling System Components ........................................ 20
Electronic Control System ................................................................ 21
Main Electronic Control Components and Features......................... 24
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TABLE OF CONTENTS
iv
Gauges and Indicators...................................................................... 26
Gauges........................................................................................ 26
Indicators..................................................................................... 27
Gauges and Indicators of Electronic Control System........................ 28
Gauges........................................................................................ 28
Indicators..................................................................................... 28
Controls............................................................................................. 29
Key Switch................................................................................... 29
Glow Plugs.................................................................................. 30
Governor Lever ........................................................................... 30
Engine Stop Solenoid (IDI Engines)............................................ 31
Speed Control of Electronically Controlled Engines.................... 31
Electronic Engine Speed Control ................................................ 32
Before You Operate .............................................................................. 35
Diesel Fuel ........................................................................................ 36
Diesel Fuel Specifications........................................................... 36
Filling the Fuel Tank.................................................................... 41
Priming the Fuel System............................................................. 42
Engine Oil.......................................................................................... 43
Engine Oil Specifications............................................................. 43
Engine Oil Viscosity..................................................................... 44
Checking Engine Oil.................................................................... 44
Adding Engine Oil........................................................................ 44
Engine Oil Capacity (Typical)...................................................... 45
Engine Coolant.................................................................................. 46
Engine Coolant Specifications..................................................... 47
Filling Radiator with Engine Coolant ........................................... 47
Daily Check of the Cooling System............................................. 48
Engine Coolant Capacity (Typical).............................................. 48
Daily Checks ..................................................................................... 49
Visual Checks.............................................................................. 49
Check Diesel Fuel, Engine Oil and Engine Coolant Levels......... 49
Check Engine Speed Control...................................................... 49
Check Operator’s Console.......................................................... 50
Check Indicators.......................................................................... 50
Engine Operation .................................................................................. 53
Starting Engine.................................................................................. 54
Cold Start Device .............................................................................. 56
High-altitude Injection Control Device............................................... 56
Checking the Engine During Operation............................................ 57
Adjust Engine Speed......................................................................... 59
Shutting Down the Engine................................................................. 60
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TABLE OF CONTENTS
v
Periodic Maintenance........................................................................... 61
Precautions....................................................................................... 62
The Importance of Periodic Maintenance................................... 62
Performing Periodic Maintenance............................................... 62
The Importance of Daily Checks................................................. 62
Keep a Log of Engine Hours and Daily Checks.......................... 62
Isuzu Replacement Parts............................................................ 62
Tools Required ........................................................................... 62
Ask Your Isuzu Distributor For Help ........................................... 62
Required EPA/ARB Maintenance USA Only.............................. 62
EPA/ARB Installation Requirements USA Only.......................... 63
Tightening Fasteners.................................................................. 63
Standard Torque Chart..................................................................... 63
Periodic Maintenance Schedule....................................................... 64
Periodic Maintenance Chart ....................................................... 64
Periodic Maintenance Procedures.................................................... 66
After Initial 50 Hours of Operation .............................................. 66
Every 50 Hours of Operation...................................................... 71
Every 250 Hours of Operation.................................................... 75
Every 500 Hours of Operation.................................................... 79
Every 1000 Hours of Operation.................................................. 83
Every 1500 Hours of Operation.................................................. 85
Every 2000 Hours of Operation.................................................. 86
Every 3000 Hours of Operation.................................................. 87
Troubleshooting ................................................................................... 89
Troubleshooting Chart...................................................................... 90
Troubleshooting of Electronic Control System.................................. 92
Fault Detection Capability........................................................... 92
Troubleshooting Information............................................................. 94
List of Possible Faults of Electronically Controlled Engines............. 95
Long-Term Storage .............................................................................. 99
Before You Place the Engine In Long-Term Storage ..................... 100
Returning the Engine to Service..................................................... 101
Specifications ..................................................................................... 103
Engine General Specifications........................................................ 104
Principal Engine Specifications....................................................... 105
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TABLE OF CONTENTS
vi
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1
TNV Operation Manual
ISUZU ENGINE
AFTER SERVICE
Please feel free to contact your Isuzu distributor for
periodical inspection and maintenance.
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ISUZU ENGINE AFTER SERVICE
2
ISUZU GENUINE PARTS
The Isuzu genuine parts are identical with those of used in the
engine production, and accordingly, they are warranted by Isuzu
Motors Limited.
The Isuzu genuine parts are supplied by the Isuzu distributors or
the authorized parts suppliers. Please designate "Isuzu Genuine
Parts" when you need engine parts.
EMISSION-RELATED INSTALLATION INSTRUCTIONS (REF)
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment
violates Federal Law (40 CFR1068.105(B)), subject to fines or other penalties as described in the clean air
act.
Installation of Nonroad Engines into Equipment
To ensure engines operate under the certified configurations, Isuzu has established defined application
requirements when installing any certified engine into a piece of equipment. The instructions outlined below
are included in our certification process and any failure to comply will be considered tampering.
Isuzu certifies engines to operate under variable speed or constant speed conditions. Engines certified as
constant speed are prohibited from installation into variable speed applications. The emission control
information label will identify an engine certified as constant speed.
Allowable Air Intake Restriction and Exhaust Back Pressure
Resistance to intake airflow and exhaust gas flow is generated in the intake and exhaust systems.
Exceeding the limitations will affect the operation of an engine and its certified configuration. Refer to the
installation requirements and limitations of the Isuzu C series Application Manual for the engine being
equipped with these systems.
Allowable Air Intake Restriction
Allowable Exhaust Back Pressure
Engine model Allowable air intake restriction kPa (mmAq)
Initial upper limit Upper limit for air cleaner replacement
All models 2.94 (300) 6.23 (635)
Engine model Allowable exhaust back pressure kPa (mmAq)
Initial upper limit Upper limit for exhaust system cleaning
3CH1, 3CJ1 9.81 (1000) 11.77 (1200)
3CE1 12.75 (1300) 15.30 (1560)
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3
TNV Operation Manual
SAFETY
SAFETY STATEMENTS
Isuzu is concerned for your safety and your
machine’s condition. Safety statements are one of
the primary ways to call your attention to the
potential hazards associated with Isuzu C series
engine operation. Follow the precautions listed
throughout the manual before operation, during
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the
labels from becomingdirty or torn and replace them
if they are lost or damaged. Also, if you need to
replace a part that has a label attached to it, make
sure you order the new part and label at the same
time.
DANGER
DANGER indicates a hazardous situation which,
if not avoided, will result in death or serious
injury.
WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION
CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE
NOTICE indicates a situation which can cause
damage to the machine, personal property and/or
the environment or cause the equipment to operate
improperly.
This safety alert symbol appears with
most safety statements. It means
attention, become alert, your safety is
involved! Please read and abide by the
message that follows the safety alert
symbol.
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SAFETY
4
SAFETY PRECAUTIONS
Before You Operate
NOTICENOTICE
• Never permit anyone to operate the
engine or driven machine without
proper training.
• Read and understand this Operation Manual
before you operate or service the machine to
ensure that you follow safe operating practices
and maintenance procedures.
• Machine safety signs and labels are additional
reminders for safe operating and maintenance
techniques.
• See your Isuzu Distributor for additional training.
During Operation and Maintenance
DANGER
Scald Hazard!
• Never remove the radiator cap if
the engine is hot. Steam and hot
engine coolant will spurt out and
seriously burn you. Allow the
engine to cool down before you
attempt to remove the radiator
cap.
• Tighten the radiator cap securely after you
check the radiator. Steam can spurt out during
engine operation if the cap is loose.
• Always check the level of the engine coolant
by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
DANGER
Explosion Hazard!
• Keep the area around the battery
well-ventilated. While the engine
is running or the battery is
charging, hydrogen gas is
produced which can be easily
ignited.
• Keep sparks, open flame and any other form
of ignition away while the engine is running or
battery is charging.
• Never short out the battery terminals,
including when checking the remaining
battery charge. This will result in a spark and
may cause an explosion or fire. Use a
hydrometer to check the remaining battery
charge.
• If the electrolyte is frozen, slowly warm the
battery before you recharge it.
• Failure to comply will result in death or
serious injury.
Sudden Movement Hazard!
• Never start the engine by
shorting out the starter terminal
and the battery terminal
(Jump-start). The machine may
move suddenly if the machine
safety circuit is released, but
the gear is still engaged.
• Failure to comply will result in death or
serious injury.
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SAFETY
5
DANGER
Fire and Explosion Hazard!
• Diesel fuel is extremely
flammable and explosive under
certain conditions.
• When you remove any fuel system component
to perform maintenance (such as changing
the fuel filter) place an approved container
under the opening to catch the fuel.
• Never use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
remove any fuel system component.
• Only use the key switch to start the engine.
• Never jump-start the engine. Sparks caused
by shorting the battery to the starter terminals
may cause a fire or explosion.
• If the unit has an electric fuel pump, in the
case of DI engine, since air is automatically
bled, by keeping the key of the starter switch
in the ON position for 10 to 15 seconds, the
fuel system can be primed. If this is an IDI
engine, keep the key in the ON position
(within 15 seconds) until fuel without bubbles
comes out from the air bleeding bolt. Here, do
not turn the key to the START position.
• If the unit has a mechanical fuel pump, when
you prime the fuel system, operate the fuel
priming lever of the mechanical fuel pump
several times until the fuel filter cup is filled
with fuel. On top of that, operate the fuel feed
pump for several times until fuel without
bubbles comes out from the air bleeding bolt.
• Never use diesel fuel as a cleaning agent.
• Never remove the fuel cap with the engine
running.
DANGER
(Continued)
• Only fill the fuel tank with diesel fuel. Filling
the fuel tank with gasoline may result in a fire
and will damage the engine.
• Never refuel with the engine running.
• Keep sparks, open flames or any other form of
ignition (match, cigarette, static electric
source) well away when refueling.
• Never overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated area, away
from any combustibles or sources of ignition.
• Be sure to place the diesel fuel container on
the ground when transferring the diesel fuel
from the pump to the container. Hold the hose
nozzle firmly against the side of the container
while filling it. This prevents static electricity
buildup which could cause sparks and ignite
fuel vapors.
• Never place diesel fuel or other flammable
material such as oil, hay or dried grass close
to the engine during engine operation or
shortly after shutdown.
• Before you operate the engine, check for fuel
leaks. Replace rubberized fuel hoses every
two years or every 2000 hours of engine
operation, whichever comes first, even if the
engine has been out of service. Rubberized
fuel lines tend to dry out and become brittle
after two years or 2000 hours of engine
operation, whichever comes first.
• When you prime the fuel system, operate the
fuel priming lever of the mechanical fuel pump
several times until the fuel filter cup is filled
with fuel.
• Failure to comply will result in death or
serious injury.
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SAFETY
6
DANGER
Crush Hazard!
• When you need to transport an
engine for repair, have a helper
assist you to attach it to a hoist
and load it on a truck.
• Never stand under a hoisted engine. If the
hoist mechanism fails, the engine will fall on
you, causing death or serious injury.
• Failure to comply will result in death or
serious injury.
WARNING
Sever Hazard!
• Keep hands and other body parts
away from moving/rotating parts
such as the cooling fan, flywheel
or PTO shaft.
• Wear tight-fitting clothing and keep your hair
short or tie it back while the engine is running.
• Remove all jewelry before you operate or
service the machine.
• Never start the engine in gear. Sudden
movement of the engine and/or machine
could cause death or serious personal injury.
• Never operate the engine without the guards
in place.
• Before you start the engine make sure that all
bystanders are clear of the area.
• Keep children and pets away while the engine
is operating.
• Check before starting the engine that any
tools or shop rags used during maintenance
have been removed from the area.
• Failure to comply could result in death or
serious injury.
WARNING
Exhaust Hazard!
• Never operate the engine in an
enclosed area such as a garage,
tunnel, underground room,
manhole or ship’s hold without
proper ventilation.
• Never block windows, vents, or other means
of ventilation if the engine is operating in an
enclosed area. All internal combustion
engines create carbon monoxide gas during
operation. Accumulation of this gas within an
enclosure could cause illness or even death.
• Make sure that all connections are tightened
to specifications after repair is made to the
exhaust system.
• Failure to comply could result in death or
serious injury.
WARNING
Alcohol and Drug Hazard!
• Never operate the engine while
you are under the influence of
alcohol or drugs.
• Never operate the engine when you are feeling
ill.
• Failure to comply could result in death or
serious injury.
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SAFETY
7
WARNING
Exposure Hazard!
• Wear personal protective
equipment such as gloves, work
shoes, eye and hearing
protection as required by the
task at hand.
• Never wear jewelry, unbuttoned cuffs, ties or
loose-fitting clothing when you are working
near moving/rotating parts such as the
cooling fan, flywheel or PTO shaft.
• Always tie back long hair when you are
working near moving/rotating parts such as a
cooling fan, flywheel, or PTO shaft.
• Never operate the engine while wearing a
headset to listen to music or radio because it
will be difficult to hear the alert signals.
• Failure to comply could result in death or
serious injury.
WARNING
Burn Hazard!
• Wait until the engine cools before
you drain the engine coolant. Hot
engine coolant may splash and
burn you.
• If you must drain the engine oil while it is still
hot, stay clear of the hot engine oil to avoid
being burned.
• Always wear eye protection.
• Keep your hands and other body parts away
from hot engine surfaces such as the muffler,
exhaust pipe, turbocharger (if equipped) and
engine block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the engine is
operating and could seriously burn you.
• Failure to comply could result in death or
serious injury.
WARNING
Burn Hazard!
• Batteries contain sulfuric acid.
Never allow battery fluid to come
in contact with clothing, skin or
eyes. Severe burns could result.
Always wear safety goggles and
protective clothing when
servicing the battery. If battery
fluid contacts the eyes and/or
skin, immediately flush the
affected area with a large amount
of clean water and obtain prompt
medical treatment.
• Failure to comply could result in death or
serious injury.
WARNING
High-Pressure Hazard!
• Avoid skin contact with the
high-pressure diesel fuel spray
caused by a fuel system leak
such as a broken fuel injection
line. High-pressure fuel can
penetrate your skin and result in
serious injury. If you are exposed
to high-pressure fuel spray,
obtain prompt medical treatment.
• Never check for a fuel leak with your hands.
Always use a piece of wood or cardboard.
Have your Isuzu Distributor repair the
damage.
• Failure to comply could result in death or
serious injury.
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SAFETY
8
WARNING
Shock Hazard!
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.
• Check the electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors. Always keep the connectors and
terminals clean.
• Failure to comply could result in death or
serious injury.
WARNING
Entanglement Hazard!
• Stop the engine before you begin
to service it.
• Never leave the key in the key switch when
you are servicing the engine. Someone may
accidentally start the engine and not realize
you are servicing it. This could result in a
serious injury.
• If you must service the engine while it is
operating, remove all jewelry, tie back long
hair, and keep your hands, other body parts
and clothing away from moving/rotating parts.
• Failure to comply could result in death or
serious injury.
WARNING
Sudden Movement Hazard!
• Engaging the transmission or PTO at an
elevated engine speed could result in
unexpected movement of the equipment.
• Failure to comply could result in death or
serious injury.
CAUTION
Coolant Hazard!
• Wear eye protection
and rubber gloves
when you handle
long life or extended
life engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water.
• Failure to comply may result in minor or
moderate injury.
CAUTION
Flying Object Hazard!
• Always wear eye protection when
servicing the engine and when
using compressed air or
high-pressure water. Dust, flying
debris, compressed air,
pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or
moderate injury.
CAUTION
• When using a 120 V system only, push the
change-over switch to the right (120 V).
• The main switch should always be kept in the
ON position during operation.
• Before starting the engine, always turn the
switches on the working instruments (lighting
apparatus, motor, etc.) to their OFF position. If
the switches are not OFF, the sudden
application of load when the engine is started
could be very dangerous.
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SAFETY
9
NOTICE
• Only use diesel fuels recommended by Isuzu for
the best engine performance, to prevent engine
damage and to comply with EPA/ARB warranty
requirements.
• Only use clean diesel fuel.
• Never remove the primary strainer (if equipped)
from the fuel tank filler port. If removed, dirt and
debris could get into the fuel system causing it to
clog.
• Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause internal
engine components to seize and/or shorten
engine life.
• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick and
the surrounding area before you remove the cap.
• Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
engine oil.
• Never overfill the engine with engine oil.
• Always keep the oil level between the upper and
lower lines on the oil cap/dipstick.
• Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
damage.
• Only use the engine coolant specified. Other
engine coolants may affect warranty coverage,
cause an internal buildup of rust and scale and/or
shorten engine life.
• Prevent dirt and debris from contaminating the
engine coolant. Carefully clean the radiator cap
and the surrounding area before you remove the
cap.
• Never mix different types of engine coolants. This
may adversely affect the properties of the engine
coolant.
NOTICE
Never attempt to adjust the low or high idle speed
limit screw. This may impair the safety and
performance of the machine and shorten its life. If
adjustment is ever required, contact your Isuzu
Distributor.
If any problem is noted during the visual check, the
necessary corrective action should be taken before
you operate the engine.
New engine break-in:
• On the initial engine start-up, allow the engine to
idle for approximately 15 minutes while you check
for proper engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for proper
operation of the indicators and/or gauges.
• During the first hour of operation, vary the engine
speed and the load on the engine. Short periods
of maximum engine speed and load are
desirable. Avoid prolonged operation at minimum
or maximum engine speeds and loads for the next
four to five hours.
• During the break-in period, carefully observe the
engine oil pressure and engine temperature.
• During the break-in period, check the engine oil
and coolant levels frequently.
If any indicator fails to illuminate when the key
switch is in the ON position, see your Isuzu
Distributor for service before operating the engine.
Never hold the key in the START position for longer
than 15 seconds or the starter motor will overheat.
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SAFETY
10
NOTICE
If the engine fails to start:
Wait until the engine comes to a complete stop
before you attempt to start it again. Engaging the
starter while the engine is still rotating will result in
damage to the starter and flywheel.
Never use an engine starting aid such as ether.
Engine damage will result.
Never engage the starter motor while the engine is
running. This may damage the starter motor pinion
and/or ring gear.
Make sure the engine is installed on a level surface.
If a continuously running engine is installed at an
angle greater than (30°) in any direction or if an
engine runs for short periods of time (less than
three minutes) at an angle greater than (35°) in any
direction, engine oil may enter the combustion
chamber causing excessive engine speed and
white exhaust smoke. This may cause serious
engine damage.
If any indicator illuminates during engine operation,
stop the engine immediately. Determine the cause
and repair the problem before you continue to
operate the engine.
The illustrations and descriptions of optional
equipment in this manual, such as the operator’s
console, are for a typical engine installation. Refer
to the documentation supplied by the optional
equipment manufacturer for specific operation and
maintenance instructions.
NOTICE
Observe the following environmental operating
conditions to maintain engine performance and
avoid premature engine wear:
• Avoid operating in extremely dusty conditions.
• Avoid operating in the presence of chemical
gases or fumes.
• Avoid operating in a corrosive atmosphere such
as salt water spray.
• Never install the engine in a floodplain unless
proper precautions are taken to avoid being
subject to a flood.
• Never expose the engine to the rain.
• The standard range of ambient temperatures for
the normal operation of Isuzu engines is from
-15 °C (+5 °F) to +45 °C (+113 °F).
• If the ambient temperature exceeds +45 °C
(+113 °F) the engine may overheat and cause
the engine oil to break down.
• If the ambient temperature is below -15 °C (+5 °F)
the engine will be hard to start and the engine oil
may not flow easily.
• Contact your Isuzu Distributor if the engine will be
operated outside of this standard temperature
range.
• Contact your Isuzu Distributor if the engine will be
operated at high altitude. High altitude reduces
engine power, de-stabilizes operation and
generates exhaust gas that exceeds the
specification amount in design.
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SAFETY
11
NOTICE
• When the engine is operated in dusty conditions,
clean the air cleaner element more frequently.
• Never operate the engine with the air cleaner
element(s) removed. This may allow foreign
material to enter the engine and damage it.
The maximum air intake restriction, in terms of
differential pressure measurement, must not
exceed 0.90 psi (6.23 kPa; 635 mmAq). Clean or
replace the air cleaner element if the air intake
restriction exceeds the above mentioned value.
For maximum engine life, Isuzu recommends that
when shutting the engine down, you allow the
engine to idle, without load, for five minutes. This
will allow the engine components that operate at
high temperatures, such as the turbocharger (if
equipped) and exhaust system, to cool slightly
before the engine itself is shut down.
• Never attempt to modify the engine’s design or
safety features such as defeating the engine
speed limit control or the diesel fuel injection
quantity control.
• Modifications may impair the engine’s safety and
performance characteristics and shorten the
engine’s life. Any alterations to this engine may
void its warranty. Be sure to use Isuzu genuine
replacement parts.
Protect the air cleaner, turbocharger (if equipped)
and electric components from damage when you
use steam or high-pressure water to clean the
engine.
Never use high-pressure water or compressed air
at greater than 28 psi (193 kPa; 19686 mmAq) or a
wire brush to clean the radiator fins. Radiator fins
damage easily.
NOTICE
Establish a periodic maintenance plan according to
the engine application and make sure you perform
the required periodic maintenance at intervals
indicated. Failure to follow these guidelines will
impair the engine’s safety and performance
characteristics, shorten the engine’s life and may
affect the warranty coverage on your engine.
Consult your Isuzu Distributor for assistance when
checking items marked with a
● .
Make it a habit to perform daily checks. See Daily
Checks in the Before You Operate Section of this
manual.
Periodic maintenance prevents unexpected
downtime, reduces the number of accidents due to
poor machine performance and helps extend the
life of the engine.
The tightening torque in the Standard Torque Chart
in the Periodic Maintenance Section of this manual
should be applied only to the bolts with a “7” head.
(JIS strength classification: 7T)
• Apply 60 % torque to bolts that are
not listed.
• Apply 80 % torque when tightened to
aluminum alloy.
TNV_OperationManual_T4(under 19kW).book Page 11 Wednesday, June 17, 2015 11:23 AM

SAFETY
12
NOTICE
• Always be environmentally
responsible.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
NOTICE
Precautions for handling desiccant
Disposal:
This material is disposable as non-flammable.
however, the bag is flammable and if it is necessary,
then tear the bag and discard the bag and the
contents separately.
It is desirable to bury the contents in the bag under
ground.
Dispose in accordance with the disposal standards
for industrial waste defined by local laws and
regulations.
Handling:
The contents of the bag do not leak out in the
normal use.
Take the following emergency measures, however,
if the contents leak out.
• If the contents get on the skin, rinse thoroughly
with running water.
• If the contents get in the eyes, rinse thoroughly
with water. Consult with doctors when any
abnormalities are found.
• If the contents get in the mouth, rinse thoroughly
with water. Drink water to dilute if the content is
swallowed, though a small amount is harmless.
Consult with doctors when any abnormalities are
found.
Characteristics of materials:
• Calcium Chloride (CaCl2) Approx. 57 %
• Grain Polysaccharide Approx. 28 %
• Grain Skins Approx. 9 %
• Ethylene Polymer (Bag) Approx. 5 %
Hazard information:
• Explosiveness None
• Inflammability Inflammable
• Combustibility None
• Oxidation None
TNV_OperationManual_T4(under 19kW).book Page 12 Wednesday, June 17, 2015 11:23 AM

13
TNV Operation Manual PRODUCT
OVERVIEW
ISUZU C SERIES ENGINE
FEATURES AND APPLICATIONS
Isuzu C series engine is environmentally friendly
and is designed to:
• Lower the amount of exhaust gas emissions.
• Reduce engine noise and vibration.
• Be easy to start thanks to the specially designed
fuel injection pump and combustion system.
• Be economical to run because diesel fuel and
engine oil consumption are reduced.
• Be easy to operate due to the minimum amount of
required maintenance and their compact design.
• Be durable and reliable due in part to the newly
designed fuel injection valve and fuel injection
pump.
Isuzu C series engine is designed to supply power
to a wide variety of driven machines including:
• Construction
• Agriculture
• Power generation
We are sure that you will agree these features
provide excellent value in an industrial diesel
engine.
These engines are designed to deliver power to
driven machines by means of a “direct coupled
drive” or “belt drive.” In direct coupled drive engine
applications, the engine’s flywheel housing or end
plate is coupled directly to the driven machine. In
belt drive engine applications, a belt drive is used to
power the driven machine. If you have applications
that require a belt drive and/or front power take-off
(PTO), please contact your Isuzu Distributor.
The engine is designed for a wide range of
applications. Options, such as fuel tank, control
panel, indicators, gauges and alarms, are available
to customize the application.
Since designing the application and installing the
engine require special knowledge and skill, always
consult your Isuzu Distributor for these services.
They will help you:
• Select optional equipment. Optional equipment
should be selected to match the work conditions
and environment.
• Maximize engine performance with a minimum
amount of downtime and safety related incidents
by carefully matching the characteristics of the
engine with the driven machine.
• Plan for safe fuel piping, exhaust piping, electrical
wiring, ventilation and accurate engine installation.
• Design your applications so they meet
requirements of the local authorities.
TNV_OperationManual_T4(under 19kW).book Page 13 Wednesday, June 17, 2015 11:23 AM

PRODUCT OVERVIEW
14
COMPONENT IDENTIFICATION
Figure 1 shows where major indirect injection engine components are located.
1 –Lifting eye (flywheel end)
2 –Engine coolant pump
3 –Lifting eye (engine cooling fan end)
4 –Engine cooling fan
5 –V-belt
6 –Crankshaft V-pulley
7 –Side filler port (engine oil)
8 –Drain plug (engine oil)*
9 –Fuel inlet
10–Mechanical fuel pump
11–Dipstick (engine oil)
12– Fuel priming lever
13– Engine oil filter
14–Governor lever
15–Fuel injection pump
16–Intake manifold
17–Air intake port (from air cleaner)
18–Fuel filter
19–Fuel return to fuel tank
20–Top filler port (engine oil)
21–Rocker arm cover
22–Flywheel
23–Starter motor
24–Exhaust manifold
25–Alternator
Figure 1
* Engine oil drain plug location may vary based on oil pan options.
3CH1-NGZG01, 3CH1-SDZP01, 3CJ1-NGZG01
12 3
4
5
67891011
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20 21
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045080-00X00
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