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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