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2010
OWNER’S MANUAL
N-SERIES MEDIUM DUTY TRUCK
(LOW CAB FORWARD)
THIS MANUAL SHOULD BE CONSIDERED A PERMANENT PART OF
THIS TRUCK. IT SHOULD STAY WITH THE TRUCK WHEN SOLD TO
PROVIDE THE NEXT OWNER WITH IMPORTANT OPERATING,
SAFETY, AND MAINTENANCE INFORMATION.
Table of Contents
Section
page
0
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 1
1
Before Driving Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 1
2
Starting and Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1
Driving Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Steering Column Controls . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Instrument Panel and Controls . . . . . . . . . . . . . . . . . . . . . 2-33
3
In Case of Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1
Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
4
Appearance Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
5
Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4
6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
All information, illustrations and specifications in this manual are based
on the latest product information available at the time of printing. We
reserve the right to make changes at any time without notice.
Copyright Isuzu Motors Limited Dec., 2008
Printed in Japan
All Rights Reserved
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INTRODUCTION
This manual has been prepared to acquaint you with the operation
and maintenance of your 2010 Isuzu vehicle, and to provide important
safety information. It includes a Maintenance Schedule and is
supplemented with a Warranty and Owner Assistance Information
booklet. We urge you to read all these publications carefully. The
following recommendations will help ensure the most enjoyable, safe,
and trouble-free operation of your vehicle.
When it comes to service, keep in mind that your Isuzu commercial
truck dealer knows your vehicle best and is interested in your complete
satisfaction. Your dealer invites you to return for all of your service
needs both during and after the warranty period.
Remember, if you have a concern that has not been handled to your
satisfaction, follow the steps in the separate “Warranty and Owner
Assistance Information” booklet.
We thank you for choosing an Isuzu product, and want to assure you
of our continuing interest in your motoring pleasure and satisfaction.
CAUTION AND NOTICE
SAFETY WARNINGS
CAUTION: These cautions indicate something that could hurt you
or other people.
In the caution area, we tell you what the hazard is. Then we tell you
what to do to help avoid or reduce the hazard. Please read these
cautions. If you do not, you or others could be hurt.
VEHICLE DAMAGE WARNINGS
NOTICE: These warnings indicate something that could damage
your vehicle.
In the notice area, we tell you about something that can damage your
vehicle. Many times, this damage would not be covered by your
warranty, and it could be costly. But the notice will tell you what to do
to help avoid the damage.
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GRAPHIC SYMBOLS
Some of the following symbols are used to identify controls and
displays on your vehicle.
ENGINE
COOLANT
ENGINE OIL
PRESSURE
FUEL
MASTER LIGHTING
SWITCH
LIGHTS
PARKING
TURN SIGNALS
EXHAUST
BRAKE
CHECK ENGINE
WATER
SEPARATOR
ENGINE OIL LEVEL
WINDSHIELD
WIPER
WINDSHIELD
WASHER
INTERMITTENT
WIPER
BODY INTERIOR
LIGHT SWITCH
ILLUMINATION
CONTROL
IDLE SPEED
CONTROL
HAZARD WARNING
FLASHER
HIGH BEAM
GLOW PLUG
BATTERY CHARGING
CONDITION
FACE
BI-LEVEL
FOOT
FOOT AND
DEFROSTER
WINDSHIELD
DEFROSTER
AIR
RECIRCULATION
FRESH AIR
AIR
CONDITIONING
LIGHTER
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BRAKE
HORN
DAYTIME
RUNNING LIGHT
INDICATOR/BRAKE SYSTEM
WARNING LIGHT
BRAKE
BOOSTER
PARKING BRAKE
INDICATOR/BRAKE SYSTEM
WARNING LIGHT
PTO
(IF EQUIPPED)
CRUISE MAIN
CRUISE SET
CRUISE CONTROL
RESUME/
ACCEL
CRUISE CONTROL
SET/
COAST
BRAKE
BOOSTER
SERVICE VEHICLE
SOON LIGHT
OVERDRIVE
MILES CHECK
CHECK TRANS
DPF
AUTOMATIC
TRANSMISSION
FLUID TEMPERATURE
0-3
BRAKE
BOOSTER
ENGINE
OVERHEAT
ANTI-LOCK
BRAKE SYSTEM
ENGINE
SHUT DOWN
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IMPORTANT INFORMATION ON
VEHICLE LOADING
OVERLOADING
CAUTION: The components of your truck are designed to provide
satisfactory service if the vehicle is not loaded in excess of either
the gross vehicle weight rating (GVWR) or the maximum front and
rear gross axle weight ratings (GAWRs). These ratings are listed
on the Vehicle Identification Number (VIN) plate, which is located
on the left side rear pillar panel below the striker (single cab) or on
the left center pillar panel beside the shoulder seat belt anchor
(crew cab).
Overloading can result in loss of vehicle control and personal
injury, either by causing component failures or by affecting vehicle
handling. It can also shorten the service life of your vehicle.
Your dealer can advise you of the proper loading conditions for your
vehicle. Using selected heavier suspension components for added
durability may not increase any of the weight ratings shown on the
Vehicle Identification Number (VIN) and Weight Rating Plate.
Maximum GVWR Front GAWR Capacity Rear GAWR Capacity
lbs (kg)
lbs (kg)
lbs (kg)
NPR (HD) 14,500 (6577)
5,360 (2431)
9,880 (4482)
NQR
17,950 (8142)
6,830 (3098)
12,980 (5888)
NRR
19,500 (8845)
6,830 (3098)
13,660 (6196)
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MAXIMUM FRONT AND REAR AXLE WEIGHTS
The weight of the cargo load must be properly distributed over both
the front and rear axles. The VIN and Weight Rating Plate show the
maximum weight that the front axle can carry (front GAWR). It also
shows the maximum weight that the rear axle can carry (rear GAWR).
The GVWR is the maximum permissible loaded weight of the vehicle
and takes into account the capabilities of the engine, transmission,
frame, springs, brakes, axles and tires. Actual loads at the front and
the rear axles can only be determined by weighing the vehicle. This
can be done at highway weigh stations or other such places. See your
dealer for help. The cargo load should be distributed on both sides of
the center line as equally as possible.
EFFECT ON WARRANTY
Your new vehicle limited warranty does not cover any part or
component of your vehicle which has been subject to misuse or abuse.
Any part or component which malfunctions because of overloading will
be deemed to have been subject to misuse and/or abuse.
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VEHICLE IDENTIFICATION NUMBER
(VIN) AND WEIGHT RATING PLATE
Your VIN and Weight Rating Plate shows the GVWR (Gross Vehicle
Weight Rating) and the front and rear GAWRs for your vehicle.
Gross Vehicle Weight (GVW) is the weight of the originally equipped
vehicle and all items added to it after it has left the factory. This would
include bodies, liftgates, refrigeration systems, etc., winches, booms,
etc., the driver and all occupants, and the load the vehicle is carrying.
The GVW must not exceed the GVWR. Also, gross weight on each of
the front and rear axles must not exceed the front and rear GAWRs
respectively.
Your VIN and Weight Rating Plate will specify the following:
TIRES
The tires on your truck must be of the proper size and properly
inflated for the load that you are carrying. The VIN and Weight Rating
Plate shows the originally equipped tire size and recommended
inflation pressures.
The tire inflation tables in Section 6 show the load limits for various
size tires at various inflation pressures.
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MODEL REFERENCE
The models covered in this manual are, NPR-HD, NQR, NRR.
Single cab model
MODEL
NPR-HD
NQR
NRR
Crew cab model
MODEL
NPR-HD
NQR
0-7
A
L
Code Description
JAL ISUZU
J
Identifiers
C
0-8
6
A
0
Model
NPR HD
NRR
NQR
Code
0
3
9
1
0
0
Code Description Engine
6
Isuzu 4HK1-TC
Code Plant Location
7
Fujisawa
0
Sequential Numbers
: Bumper to Back of Cab
Code Description Cab Type
Steel Tilt Single Cab 71 inch BBC
W
J
Non-Tilt Crew Cab, 110 inch BBC
0
Model
Code
2010
7
Plant
Code
Code Description Chassis
1
4x2
1
Check
Digit
Code Series
4
ISUZU NPR HD
5
ISUZU NQR/NRR
W
Chassis
Type Code
Engine
Code
Model
Year Code
Code GVW/BRAKE
C
14001-16000 lbs.
E
16001-19500 lbs.
Hydraulic Brake System
4
Series
Code
GVWR and
Brake System
Cab
Type Code
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VIN INTERPRETATION
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Page 1
SECTION 1
BEFORE DRIVING YOUR VEHICLE
DRIVER DAILY CHECKLIST
Be sure you know how to use your truck and its equipment before
operating it.
BEFORE ENTERING THE TRUCK
1. See that windows, mirrors, lights and reflectors are undamaged,
clean and unobstructed.
2. Check tires for damage and proper air pressure. Check that all
wheel nuts are in place.
3. Look for fluid leaks.
4. Be sure that the tilt cab is securely locked in the lowered position
(crew cab models not applicable).
5. Inspect the exhaust system, checking that the tailpipe is clear.
START-UP
1. Check that all warning lights work (and that the brake alarm
buzzer works as described under that topic in this manual) when
the key is turned to “ON”, and hold until the glow plug indicator
light goes off, then “START”. The “BRAKE” system warning light
should stay on when the parking brake is applied.
2. Check all gauges (including the fuel gauge) and indicator lights.
3. Adjust the seat.
4. Be sure that the adjustable steering column is in the locked
position.
5. Check and adjust mirrors.
FINAL WALK-AROUND CHECK
Set the parking brake.
1. Look for leaks, now that the engine is running.
2. Check that all lights work.
3. Check that doors and covers are in place; and any emergency
equipment is complete.
4. Be sure everything is properly stowed.
5. Check the area under the truck, and behind it if you are about to
back up.
BEFORE DRIVING OFF
Do not drive the truck until the engine has had sufficient time to
circulate the lubricant oil. This usually requires 30 sec. to 2 minutes
depending on ambient conditions.
NOTICE: This will help reduce white start-up smoke.
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Page 2
1. Lock all doors.
2. Always properly fasten your seat belt. Check that the seat belt for
any other occupant is fastened properly. Never let anyone ride any
place in or on this vehicle where there is no lap belt or lapshoulder belt.
3. Push down on the brake pedal, release the parking brake, and
check that the “BRAKE” system warning light goes out. If the light
stays on, the vehicle should not be driven until the condition is
corrected.
These checks are in addition to, not instead of, the Bureau of Motor
Carrier Safety requirements. See related topics under “Maintenance
Schedule” in Section 5, especially if problems are found.
KEY
Spare key
Main key
Key code plate
One key can operate all the locks on the vehicle. Keep one of the
two keys provided as a spare. The key code is stamped on the tag.
For vehicle security:
• Record the key code numbers.
• Keep the key code plate in a safe place (such as your wallet), NOT
IN THE VEHICLE.
• Be sure to include the key code plate when the vehicle is transferred.
If the original keys are lost, duplicates can be made using the key
codes stamped on key code plate. Contact any authorized Isuzu dealer
or a locksmith.
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Page 3
Lock Button
Locked
Unlocked
Inside Handle
CAB DOOR LOCKS
ALWAYS LOCK THE DOORS
CAUTION: To help reduce the risk of personal injury in an
accident, always lock the doors when driving. Along with using the
seat belts properly, Iocking the doors helps prevent people from
being thrown from the vehicle. It also helps prevent unintended
opening of the doors and helps keep out intruders.
To lock the cab, Iock one door from the inside by turning the button
forward on the door interior lock button.
Lock the other door from the outside following the instructions under
“DOOR LOCKS” below. Or if desired, turn the interior lock button
forward, then close the door while lifting up on the outside handle.
Overriding door locks are a standard safety feature. When the doors
are locked, the inside handles will not open them. This is to prevent
accidental opening of the doors.
OUTSIDE DOOR HANDLES
A handle for opening each cab door from outside the cab is located
at the rear edge of the door’s outer panel. To open the door from
outside the vehicle, pull up on the handle.
INSIDE DOOR HANDLES
An inside handle for opening each cab door is located in the
recessed area at the front of the door. To open the door, pull on the
handle. If the door is locked, the lock mechanism overrides operation
of the door handle. The door must first be unlocked before the handle
can be used to open the door.
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Page 4
POWER DOOR LOCKS (IF EQUIPPED)
DOOR LOCK SWITCH
Both doors can be locked and unlocked by pressing the rocker lock
switch. Refer to Page 2-58 for switch location.
UPPER SIDE
LOCK
UNLOCK
DOOR LOCKS
• A door may be locked from outside of the vehicle, by inserting the
key into the door lock and turning it counterclockwise for the driver’s
door and clockwise for the passenger’s door.
• Locking the driver’s door will lock both driver’s and passenger’s
doors.
• To unlock the door, turn the key in the opposite direction.
FRONT
UNLOCK
LOCK
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LOCK BUTTON
• There is a lock button on each door. When the lock button on the
driver’s door is turned to “Locked”, it works for both the driver’s and
passenger’s doors. Otherwise it works only for its own door.
• Turn the button forward to lock the door, and turn it rearward to
unlock the door.
To lock the door automatically when it closes 1. Turn the button forward (the door must be opened).
2. Pull up on the outside door handle.
3. While holding the outside door handle up, close the door.
Lock Button
Locked
Unlocked
Inside Handle
WINDOW CONTROLS
WINDOW REGULATOR HANDLE (Manual window model)
Turn the window regulator handle to raise and lower the window.
POWER WINDOWS (IF EQUIPPED)
POWER WINDOW SWITCH (DRIVER’S DOOR)
The power window switch on the driver’s door can operate both
driver’s and passenger’s power windows.
NOTICE: The engine control switch must be in the “ON” position.
For driver’s power window
Press lightly on the switch to lower the window. The window
continues its downward motion until the switch is released (or the
window is fully opened).
Press firmly on the switch (until a click is heard) to lower the window
automatically. (To stop window movement, pull up on the switch.)
Pull up on the switch to close the window. The window continues its
upward motion until the switch is released (or the window is fully
closed).
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Page 6
CLOSE
Passenger Driver
side
side
OPEN
Driver
side
Passenger
side
POWER WINDOW SWITCH (PASSENGER’S DOOR)
The power window switch on the passenger’s door can raise and
lower the passenger’s side window only.
NOTICE: The engine control switch must be in the “ON” position.
Press lightly on the switch to lower the window. The window
continues its downward motion until the switch is released (or the
window is fully opened).
Pull up on the switch to close the window. The window continues its
upward motion until the switch is released (or the window is fully
closed).
CLOSE
OPEN
POWER WINDOW SWITCH (CREW CAB MODEL)
The power window switch on the instrument panel and rear door can
raise and lower the rear door window.
NOTICE: The engine control switch must be in the “ON” position.
The window cotinues to lower while the window switch is being
pressed and continues to rise while the switch is being raised. It will
stop moving at any position when the switch is released.
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Page 7
Left side
Right side
CLOSE
Rear door switch
OPEN
OPEN CLOSE
Rear
side
If you push the rear power window lock switch, only the driver’s
window and front passenger’s window will be openable and closable.
To cancel the rear power window lock, push the switch once more.
CAUTION: Use the rear power window lock switch to “lock” the
rear power windows when carrying a child in the vehicle. By doing
so, you can prevent the child from operating the rear power
windows and causing an accident.
UNLOCK
1-7
LOCK
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Page 8
MIRRORS
OUTSIDE REARVIEW MIRRORS
Adjust the outside rearview mirrors by hand before vehicle operation.
This helps you determine the location of objects seen in the mirror.
CAUTION: Do not adjust the outside mirrors while operating the
vehicle.
SUN VISORS
The sun visors may be swung down to prevent glare from the front.
They may also be swung to the side.
ASHTRAY
CAUTION:
• Do not put any paper trash or other flammable material in the
ashtray.
• 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.
• Put matches and cigarette butts in the ashtray only after they are
fully extinguished.
• Never throw lit cigarette butts out the window. They not only litter
the road and around but also can cause a roadside fire.
DRIVER’S AND PASSENGER’S ASHTRAY
Open the lid to use.
Put out lit cigarettes on the crush-out tab. To empty the ashtray, hold
the lid and pull the ashtray up and out.
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Page 9
REAR ASHTRAY (CREW CAB MODEL)
Pull the ashtray towards you to use it.
Pull out lit cigarettes on the crush-out tab. The ashtray cannot be
removed. To empty the ashtray, turn it down while pushing the crushout tab to remove cigarette butts into an appropriate container.
Crush-out tab
DRIVER’S SEAT CONTROLS
ADJUST DRIVER’S SEAT WHILE PARKED
CAUTION: Do not adjust the driver’s seat while the vehicle is
moving. The seat could move or jerk and cause a loss of control.
After adjustment, push the seat back and forth to be sure it is locked.
Take the vehicle to your dealer for servicing if the seat does not lock.
FORE-AND-AFT
The driver’s seat has a fore-and-aft adjustment and a seatback tilt
adjustment.
The fore-and-aft adjustment lever is located in front of the seat at the
base of the cushion. Move the lever to the upside, adjust the seat
position, and release the lever. The seat is designed to lock in position
when the lever is released. After adjustment, push the seat back and
forth to be sure it is locked. Take the vehicle to your dealer for
servicing if your seat does not lock.
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Page 10
Seatback
Tilt Lever
Fore-and-Aft Lever
SEATBACK LATCH (DRIVER)
The seatback latch of the driver seat is designed to limit forward
movement of the seatback during a sudden slowing of the vehicle. Tilt
the seatback to gain access to the area behind it.
The seatback latch release lever is located at the outboard side of
the seat at the base of the cushion. Raise the lever, adjust the
seatback, and release the lever.
After adjusting the seatback, push it back and forth to be sure it is
locked. Take the vehicle to your dealer for servicing if your seatback
does not lock.
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Page 11
Seatback Position When Moving
CAUTION: To reduce the risk of sliding under the lap belt during a
collision, an occupied reclining seat should not be reclined any
more than needed for comfort. The seatback and seat belts provide
best restraint only when the rider is sitting well back and straight
up in the seat. (The lap belt is designed to spread the force of a
collision over the hipbone. If you are reclined, the lap belt may slide
past your hips and apply restraint forces directly to the abdomen.
Therefore, in the event of a collision, the risk of personal injury will
increase with increasing recline of the seatback.)
Do not adjust the reclining seatback on the driver’s seat while the
vehicle is moving. The seatback could jerk and cause a loss of control.
SEAT BELT SYSTEMS
CAUTION: To help reduce the risk of personal injury in collisions or
sudden maneuvers, use the seat belts following these instructions
on their proper use, maintenance, and use with child restraint
systems. This applies to pregnant women. Pregnant women should
use a lap-shoulder belt whenever possible; the lap portion should
continue to be worn low and snug throughout the pregnancy.
Children small enough for child restraints (as indicated on the
label of such restraints), including booster seats, should always be
transported in them.
Children who have outgrown child restraint systems should use
the vehicle’s seat belts.
NEVER:
•
•
•
•
Put the lap portion of a seat belt over any armrest.
Wear a shoulder belt under your arm nearest the door.
Use a belt for more than one person at a time.
Wear the belts twisted or with a buckle release button facing
downward or inward.
• Let the belt system become damaged by the door or seat.
• Put anything into the opening where the seat belt passes through the
trim panel. (This may jam the retractor or damage the belt.)
Twisted Belt
Do not let the belt twist while it is rewinding: it may cause the
retractor to jam so it will not rewind further. If it is not fully rewound,
the belt cannot be pulled out. Should the belt jam, you may be able to
release it by working the belt in and out until the belt rewinds far
enough to unlock. However, if the belt remains jammed or other parts
of the restraint system do not work properly, have your dealer service
it.
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Page 12
LAP-SHOULDER BELT
1. Adjust the driver’s seat as needed and sit well back and straight up.
(The passenger seat does not adjust.) Grasp the latch plate and:
• Pull the belt as far as it will reach across your lap.
• Hold the latch plate at an angle to the webbing and slide it
further (toward the front of the truck).
• Then pull it slowly across your lap and push it into the buckle
until it clicks. If the retractor locks before the latch plate reaches
the buckle, let the belt retract slightly, then withdraw it slower
than before.
2. To reduce the risk of sliding under the belt during a collision,
position the belt across your lap as low on your hips as possible
and adjust it to a snug fit by pulling the “shoulder” portion upward
through the latch plate.
The lap-shoulder belt is designed to lock during a sudden stop or
impact. At other times it should move freely.
CAUTION: To help reduce the risk of personal injury or death in an
accident, if a child is using the vehicle’s seat belts because the
child has outgrown child restraints, including booster seats, and if
the shoulder belt is on or very close to the child’s face or neck,
move the child toward the center of the seat, away from the
shoulder belts.
W-01623
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Page 13
Take Up Slack
Keep Low
On Hip Bone
3. To unfasten the belt, push the button on the buckle. The belt
should retract when the buckle is unlatched, but hold the latch
plate while the belt is retracting, to keep it from hitting people or
nearby objects. To help prevent damage to the seat belt and
interior trim before closing the door, be sure the belt is fully
retracted and the latch plate is out of the way.
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CENTER LAP BELT
1 . The center seat lap belt has no retractor, but should be positioned,
worn and released as described above. The belt is adjusted to
snug fit by pulling on the free end of the webbing coming from the
latch plate.
2. To lengthen the center seat lap belt, place the latch plate at an
angle to the belt webbing and pull on the latch plate; the belt
should then slide easily through the latch plate adjustment feature.
Pull until
adjusted to
a snug fit
Adjustable
Latch Plate
SEAT BELT INSPECTION
Now and then check that the belts, buckles, latch plates, retractors,
anchorages and guide loops work properly; look for loose parts or
damage (without disassembly) that could keep the restraint system
from doing its job. Have a belt assembly replaced if the webbing has
been cut or otherwise damaged. Replace belts, retractors, and
hardware used in all but a minor collision. Also, restraint systems
should be replaced and anchorages properly repaired if they were in
areas damaged by a collision, whether the belt was in use or not. If
there is any question, replace the belt system. Damage, whether
visible or not, could result in a serious personal injury in the event of
an accident.
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Page 15
CHILD RESTRAINT
CAUTION: Children small enough for child restraints (as indicated
on the label of such restraints), including booster seats, should
always be transported in them. Children who have outgrown child
restraint systems should wear seat belts. The lap belt should be
snug and positioned low on the abdomen so that it is below the
top of the hipbone. Otherwise, the belt could intrude into the
child’s abdomen during an accident and cause personal injury.
When a child has grown enough so that the shoulder belt can be
worn, a seating position with a shoulder belt should be chosen
whenever possible. If the shoulder belt is on or very close to the
child’s face or neck, move the child toward the center of the seat,
away from the shoulder belt.
Any unrestrained child could be injured by striking the vehicle’s
interior or by ejection from the vehicle during an accident or
driving maneuver. Never allow a child to be held by another
occupant instead of being properly restrained. If not properly
restrained, the child could strike the vehicle interior or be crushed
by the person holding the child, or by other occupants.
Be sure to follow all installation and use instructions that come with
any child restraint system.
Child restraint systems are designed to be secured in vehicle seats
either by the lap belt, or the lap portion of the lap-shoulder belt at that
seating position. The child must also be secured within the restraint by
the means provided by the child restraint manufacturer. If the child or
the child restraint is not properly secured, the child risks personal
injury in the event of a collision.
Using a Lap Belt That Has No Retractor
When securing a child restraint with the center seat lap belt, pull the
excess webbing through the belt’s adjustment feature, then take these
steps:
• Once installed, push and pull the child restraint in all directions to be
sure it is secure. If it comes loose, flip the end of the belt with the
adjustment feature over before rebuckling.
• If the child restraint is still not secure, use the outboard seating
position in the vehicle and contact your dealer and the child restraint
manufacturer for help.
• Secure the child in the restraint in accordance with the child restraint
manufacturer’s instructions.
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Installation on Outboard Seat
A seat belt locking clip is required for installation of a child restraint
system on the outboard seat of this vehicle. A locking clip may usually
be obtained where child restraints are sold, or by contacting your
dealer for assistance. Make sure the locking clip is identical to the one
shown on page 1-17. Until you have the clip, use the child restraint
system only in the center seat.
CAUTION: To help avoid personal injury or death during a collision
or sudden maneuver, always thread both the lap and shoulder belt
through the locking clip when securing a child restraint on the
outboard seat. If the clip is not used or installed properly, the child
restraint may move or tip over when your vehicle turns or stops
abruptly.
Secure the child restraint with the lap belt portion of the seat belt in
accordance with the restraint manufacturer’s instructions. Then thread
both the lap and shoulder belt portions through the locking clip. Push
and pull the child restraint in all directions to be sure it is secure.
When your child restraint is not installed, remove the locking clip to
permit normal use of the lap-shoulder belt. Keep the locking clip in the
glove box to help prevent its loss.
Child Restraint With Top Strap
CAUTION: We do not recommend using a child restraint that
requires the use of a top strap. There is no appropriate place to
attach a top strap anchor behind the seat in this vehicle.
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Page 17
W-01621
SEAT BELT EXTENDER
If the vehicle’s seat belt will fasten around you, you should use it.
But if a seat belt isn’t long enough to fasten, your dealer will order you
an extender. When you go in to order it, take the heaviest coat you will
wear, so the extender will be long enough for you. The extender will be
just for you, and just for the seat in your vehicle that you choose. Do
not let someone else use it, and use it only for the seat it is made to fit.
To wear it, just attach it to the regular seat belt.
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DIESEL PARTICULATE FILTER (DPF)
The DPF is the system which traps Particulate Matter (PM) in
exhaust gas. This collects PM into the DPF and regenerates the filter
(burns PM) automatically. To prevent DPF failure, take the following
precautions.
CAUTION:
• Exhaust gas from the DPF, muffler, exhaust pipe and tail pipe is
extremely hot when the engine is running, during regeneration
(burning), or immediately after driving. Be very careful not to
touch them. You may get burned.
• When you service the vehicle, stop the engine to prevent burns.
• Take care not to stop or park vehicle nearby flammable material
such as grass or waste paper. It may catch fire.
NOTICE:
• Only use low ash engine oil. Use of oil other than those
designated by Isuzu that support the DPF may shorten the
cleaning intervals of the DPF and may lower fuel efficiency.
• The DPF automatically regenerates when a certain amount of PM
(Particulate Matter) accumulates in the filter. However, this may
not complete depending on driving conditions. In this situation,
the DPF indicator (amber) will come on. Perform switch
regeneration according to the procedure. This is not a system
failure, but is to restore the DPF function.
• Because of the exhaust gas purification system, the gas from the
exhaust pipe smells differently from that of conventional diesel
vehicles.
BEFORE DRIVING
Use the specified fuel (ultra low sulfur diesel fuel only)
NOTICE: Always use ultra low sulfur diesel fuel (15 ppm or less
sulfur content). Use of diesel fuel other than specified may
adversely affect the engine or emissions control systems.
If other than specified diesel fuel is used on the vehicle with the
DPF, the vehicle may not conform to specifications.
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Do not keep the engine running indoors
CAUTION: In a place with poor ventilation, carbon monoxide
poisoning may occur. Starting or warming-up the engine should be
performed in a well-ventilated place. White smoke may be
temporarily emitted due to PM combustion during the DPF switch
regeneration. Do not perform DPF switch regeneration indoors
with poor ventilation.
Be careful with flammable materials
CAUTION:
• Before starting the engine, make sure that there are no
flammable materials around the vehicle and grass does not wind
around the exhaust pipe. Be careful that the hot exhaust pipe and
hot exhaust gas does not catch fire after engine racing, or engine
running at high speed for long periods of time.
• Pay close attention to the heat of the exhaust gas during idling
especially when using the PTO (POWER TAKE-OFF) or
afterburning on the vehicle equipped with the DPF.
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SECTION 2
STARTING AND OPERATING
Engine Exhaust Gas Caution
(Carbon Monoxide)
CAUTION: Do not breathe exhaust gas because it contains carbon
monoxide, which by itself has no color or odor. Carbon monoxide is
a dangerous gas. It can cause unconsciousness and can be lethal.
If at any time you think exhaust fumes are entering the cab, have
the cause determined and corrected as soon as possible. If you must
drive under these conditions, drive only with all windows fully open.
Prevent carbon monoxide from entering the cab. The best way is
to keep the engine exhaust system, cab and cab ventilation system
properly maintained.
We recommend that the exhaust system and cab be inspected by
a competent technician:
• Each time the vehicle has an oil change.
• Whenever a change is noticed in the sound of the exhaust system.
• Whenever the exhaust system, underbody or cab is damaged or
becomes corroded.
See “Maintenance Schedule” in Section 5 of this manual for parts
requiring inspection.
To allow proper operation of your vehicle’s ventilation system, keep
the air inlet grille clear of snow, leaves or other obstructions at all times.
Do not park with the engine running or idle this vehicle for more than
10 minutes with the ventilation system control switch in the “OFF”
position. Even with the ventilation system on, running the engine while
parked or stopped for longer periods of time is not recommended. Entry
of carbon monoxide into the cab is possible with a poorly repaired,
damaged, or corroded exhaust system or cab.
Do not run the engine in confined areas (such as garages or next to a
building) any more than needed to move the vehicle. When the vehicle
has to be stopped in an unconfined area with the engine running for any
more than a few minutes, take the following steps:
A. Adjust the heating or cooling system to force outside air into
the cab. With temperature and select levers in any position:
• Set the air source lever to the fresh air position.
• Set the fan blower to the “3” or “4” position.
• See “Heating and Ventilation System Controls” later in this
section of the manual.
B. Keep the exhaust tailpipe area clear of snow and other material
to help reduce the buildup of exhaust gases under the vehicle.
This is particularly important when parked in blizzard conditions.
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Page 2
NEW VEHICLE BREAK-IN
Good vehicle care begins with proper break-in. While every new
vehicle goes through rigid factory and dealer inspection and tests
before delivery, the care you give your vehicle during the initial breakin period can pay off in longer life, better performance and more
economical operation. Follow the recommendations listed below:
• Warm up the engine by driving easily for the first few minutes before
placing it under load.
• Keep speeds below 50 MPH (80 km/h) for the first 500 miles (800
kilometers).
• Do not drive for extended periods at any one constant speed, either
fast or slow, during the first 500 miles (800 kilometers).
• Use the lowest gear ratio available when starting a loaded vehicle
and when climbing slopes to avoid lugging the engine.
• Use the correct gear to maintain the desired road speed without
lugging the engine.
• Avoid racing the engine, full-throttle starts and aggressive application
of brakes when stopping.
• Keep tires properly inflated for the load carried.
• Check lubricant levels in the engine and transmission frequently (at
least weekly).
• During the initial 2,000 miles (3,200 km), the maximum speed in
each gear should be held below the speed shown in the following
table for manual transmission vehicles.
Max. MPH (km/h)
GEAR
NPR-HD, NQR, NRR
1st
2nd
3rd
4th
5th
6th
5(8) 10(16) 20(32) 35(56) 55(88) 65(105)
MECHANICAL DRIVESHAFT BRAKE
BURNISH PROCEDURE
It is recommended that the driveshaft mounted parking brake be
burnished as part of the new vehicle break-in procedure. Increased
parking brake performance will result when the parking brake is
burnished according as specified below:
• Make 10 moderate stops, using the hand brake, from 10 MPH (16
km/h) while spacing the stops a minimum of 2.5 miles (4 km) apart.
• Operate the vehicle at 20 MPH (32 km/h) between stops.
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DIESEL FUEL REQUIREMENT
AND FUEL SYSTEM
Fuel Requirements
CAUTION: Use of fuels other than ultra low-sulfur fuel may not
conform to emission regulations.
NOTICE: The fuel supply pump, injector or other parts of the fuel
system and engine can be damaged if you use any fuel or fuel
additive other than those specifically recommended by Isuzu.
Such damage is not Isuzu’s responsibility, and is not covered by
the New Vehicle Limited Warranty. To help avoid fuel system or
engine damage, pay attention to the following:
• Some service stations mix used engine oil with diesel fuel. Some
manufacturers of large diesel engines allow this; however, for
your diesel engine, do not use diesel fuel which has been
contaminated with engine oil. Besides causing engine damage,
such fuel can also affect emission control. Before using any
diesel fuel, check with the service station operator to see if the
fuel has been mixed with engine oil.
• Do not use any fuel additive (other than as recommended under
“Biocides” in this section). At the time this manual was printed,
no other fuel additive was recommended. (See your authorized
dealer to find out if this has changed.)
• Take care not to run out of diesel fuel. If you do run out of fuel,
you may need to bleed air out of the supply pump to re-start the
engine after fuel has been filled.
Your vehicle is designed to use either Number 1-D or Number 2-D
diesel fuel. However, for better fuel economy, use Number 2-D diesel
fuel whenever possible. At temperatures below 20°F (–7°C), Number
2-D fuel may pose operating problems (see “Cold Weather Operation”
which follows). At colder temperatures, use Number 1-D fuel (if
available) or use a “winterized” Number 2-D (a blend of Number 1-D
and Number 2-D). This blended fuel is usually called Number 2-D also,
but can be used in colder temperatures than Number 2-D fuel which
has not been “winterized”. Check with the service station operator to
be sure you get the properly blended fuel.
NOTICE: Do not use fuels other than those listed below. Doing so
may adversely affect the engine.
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DIESEL FUEL/APPLICABLE STANDARD ( Sulfur content below 15ppm)
JIS (JAPANESE INDUSTRIAL
Based on K2204 Diesel Fuel
STANDARD)
DIN (DEUTSCHE INDUSTRIE
Based on EN590
NORMEN)
ASTM (AMERICAN SOCIETY
Based on D975 NO.1-D S15 or
FOR TESTING and MATERIALS)
NO.2-D S15 (below 15 ppm)
BS (BRITISH STANDARD)
Based on EN590
It is acceptable to use diesel fuel containing up to 5% biodiesel (B5),
but the final blended fuel must meet the same specification, ASTM D
975 (Grade Ultra Low Sulfur Diesel), as other fuels used in your
vehicle, and the biodiesel used for making this fuel must meet the
latest version of ASTM specification D 6751. Biodiesel is produced
from vegetable oils or animal fat that have been esterified to reduce
the possibility of damage to your fuel system and engine. Higher
concentration (i.e., greater than B5) biodiesel-containing fuels or the
use of unesterified bio-oils blended into diesel fuel at any
concentration is not recommended and could damage your fuel system
and engine. Such damage would not be covered by your warranty. If
there are questions about the biodiesel-containing fuels you are using,
contact your fuel supplier.
Cold Weather Operation
Diesel fuel is sensitive to temperature. All diesel fuel has a certain
amount of paraffin components, which are high in energy value and
help improve fuel economy. But, when temperatures are below 20°F
(–7°C), the paraffin components begin turning into wax flakes. If
temperatures are low enough, these flakes can obstruct the fuel filters
and stop fuel from reaching the engine.
At low temperatures, wax flakes are more likely to form in Number 2-D
fuel than in Number 1-D (or “winterized” Number 2-D) fuel. For best
operation at temperatures below 20°F (–7°C), use Number 1-D, or
Number 2-D which has been blended with Number 1-D for winter use.
When temperatures are consistently below (or near) 0°F (–18°C), use
Number 1-D if at all possible. Bear in mind, however, that even Number
1-D fuel will form wax flakes when temperatures are extremely low.
NOTICE: Do not use home heating oil or gasoline in your diesel
engine; either may cause engine damage.
The addition of kerosene will not unplug a filter plugged with wax.
Warming a “waxed” filter to a temperature of 32°F to 50°F (0°C to 10°C) will
return the wax to solution. Filter replacement is not normally required.
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Water in Fuel
During refueling, it is possible for water (and other contaminants) to
be pumped into your fuel tank along with the diesel fuel. This can
occur if a service station does not regularly inspect and clean its fuel
tanks, or if a service station receives contaminated fuel from its
supplier(s).
To protect your engine from contaminated fuel, there is a water
separator system on the engine which allows you to drain excess
water from the fuel.
CAUTION: The drained water/diesel fuel mixture is flammable, and
could be hot. To help avoid personal injury or death and/or
property damage, do not touch the fuel coming from the water
separator drain valve, and do not expose the fuel to open flames or
sparks.
Be sure you do not overfill the drain pan. Heat (such as from the
engine) can cause the fuel to expand. If the container is too full,
fuel could be forced out of the pan. This could lead to a fire and the
risk of personal injury and/or vehicle damage.
Biocides
In warm or humid weather, fungus, and/or bacteria may form in
diesel fuel if there is water in the fuel.
NOTICE: Fungus or bacteria can cause fuel system damage by
plugging the fuel lines, fuel filters or injector. They can also cause
fuel system corrosion.
If fungus or bacteria has caused fuel system problems, you should
have your authorized dealer correct these problems. Then, use a
diesel fuel biocide to sterilize the fuel system (follow the biocide
manufacturer’s instructions). Biocides are available from your dealer,
service stations, parts stores and other automotive places. See your
authorized dealer for advice on using biocides in your area and for
recommendations on which biocides you should use.
SMOKE SUPPRESSANTS
Because of extensive testing of treated fuel versus untreated fuel,
the use of a smoke suppressant additive is not recommended because
of the greater possibility of stuck rings and guttered valves, resulting
from excessive ash deposits.
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IMPORTANT FACTS YOU SHOULD KNOW ABOUT FUEL ECONOMY
AND HOW TO IMPROVE IT
How you drive, where you drive and when you drive all affect how
much distance you can achieve from the fuel. You can save fuel if you
avoid “Jackrabbit” starts, maintain as constant a throttle position as
traffic conditions allow once you have reached cruising speed, and
avoid sudden stops that waste energy in the form of heat generated in
braking. Frequent short trips, excessive idling and use of the air
conditioner in cool weather when “Vent” would provide adequate
comfort, can all lead to decreased fuel economy.
The careful attention you give your vehicle, as far as maintenance is
concerned, will also help fuel economy. Proper engine and air cleaner
maintenance, lubrication intervals, wheel alignment, and tire inflation
pressures will pay dividends in improved fuel economy as well as
longer vehicle life.
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STARTING THE ENGINE
ENGINE CONTROL SWITCH
The starting circuit, engine alarm circuits and accessory circuits are
all controlled by the engine control switch. The switch is located on the
right-hand side of the steering column.
A:LOCK—Lock is in the position fully counterclockwise. The key can
be inserted and removed in this position. To remove, keep pushing the
key while turning from “ACC” to “LOCK”.
B:ACC—Accessory is in the first position clockwise. Electrical
accessories can be operated without the engine control circuit being
energized.
C:ON—The engine “ON” position is in the second position clockwise.
Engine control, warning circuits, gauge circuits, and accessory circuits
are energized. The engine cylinder heaters or “glow plugs” are also
turned on when the switch is in the “ON” position. The glow plug
indicator light will come on and stay on until the glow plugs are heated
enough. When this light goes off, turn the switch to the “START”
position.
D:START—Start is in the position furthest clockwise. Turn the key
against spring pressure to energize the starter. When key is released,
spring pressure returns it to the “ON” position.
A
B
C
D
STARTING PROCEDURE
The following procedure is recommended for starting the truck’s
diesel engine.
1. Apply the parking brake, fully depress the clutch pedal and shift
transmission to neutral. If the vehicle has automatic transmission,
place the transmission selector in the “P” or “N” position (“P” is
preferred).
Do not depress the accelerator pedal with the key switch in the
“LOCK” or “ACC” position.
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2. Turn the key to the “ON” position and hold until the glow plug
indicator light goes off.
3. Turn the key switch to the “START” position (do not step on the
accelerator pedal). Release the key switch as soon as the engine
starts.
CAUTION: Do not keep the starter motor engaged for more than 10
seconds at a time, or the starter motor and the battery will be
adversely affected. Also, fire may occur due to overheating.
Repeat the steps 1 and above after 20 to 30 seconds break.
4. Do not crank the engine for more than 10 seconds at a time. If the
engine does not start, wait 20 to 30 seconds with the key switch in
the “LOCK” or “ACC” position before trying to start again.
NOTICE: Do not use starting “aids” such as ether in the air intake
system. Such aids can cause immediate engine damage.
It is normal for the vacuum warning buzzer to sound for a few
seconds after the engine has started.
After the engine has started, check to be sure the transmission is still
in Neutral, and release the clutch pedal (with manual transmission
models) or transmission is still in the “P” or “N” position (with automatic
transmission models).
Turn the idle speed control knob clockwise, if needed, to obtain a
smooth idle. This engine has an automatic warm-up system that
increases engine idle speed and applies the exhaust brake. Allow
sufficient time to let the engine circulate lubricant oil before driving. This
usually requires 30 sec. to 2 min. depending on ambient conditions.
DO NOT RACE THE ENGINE TO SPEED WARM-UP
Turn the idle speed control knob fully counterclockwise after the
engine has warmed up.
CAUTION: Do not use the idle speed control knob while the vehicle
is in motion. This could reduce your ability to stop in an
emergency, possibly resulting in increased brake wear, personal
injury and/or property damage.
Idle Speed Control Knob
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CHECKS BEFORE OPERATING
Allow the engine to warm up before placing the engine under heavy
load driving. While the engine is warming up under light load, the
following checks should be made:
1. Observe the red oil pressure warning light. The light should go out
when the engine is running. If it stays on, shut the engine off and
find the cause.
2. Look at the engine coolant temperature gauge. If the gauge
reaches the “H” (hot) area, stop the engine and find the cause of
the overheating.
3. Check that the generator warning light has gone out. The light
should go off and stay off at normal idle speeds. If the light does
not go out or comes on during normal operation, have the
charging system checked.
4. Check that the low vacuum warning light is out and that the
vacuum buzzer is not sounding. It is normal for the warning buzzer
to sound for a few seconds after the engine starts. If the light and
buzzer remain on, do not drive the vehicle until the cause has
been found and corrected.
5. Look at the “BRAKE” system warning light. It should be out when
the parking brake is released and the engine is running. If it stays
on, it could mean that the brake fluid level is low. Check the brake
fluid level indicator. This condition must be corrected before
moving the vehicle.
CAUTION: To reduce the chance of personal injury and/or vehicle
damage due to engine overheating, never leave the engine idling
without an alert driver present. If the engine should overheat, as
indicated by the engine coolant temperature gauge, immediate
action is required to correct the condition. Continued operation of
the engine, even for a short time, may result in a fire. Do not
engage the exhaust brake while the engine is idling as this may
cause engine overheating.
AVOID UNNECESSARY IDLING OF THE DIESEL ENGINE
If the engine idles too long, the engine coolant temperature will fall
below the operating range. Low engine operating temperature causes
several conditions that are harmful to engine operation and life.
Incomplete combustion of fuel in an engine that is not fully warmed-up
causes crankcase dilution and forms lacquer and gummy deposits on
valves, pistons, and rings. It also causes rapid accumulation of sludge
within the engine.
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SHUTTING DOWN THE
TURBOCHARGED DIESEL ENGINE
NOTICE: Let the engine run at idle for at least three (3) minutes
before stopping the engine to help prevent damage to the
turbocharger bearings.
1. Apply the parking brake and place the manual transmission lever
in the “NEUTRAL” position or the automatic transmission selector
in the “P” position.
2. Turn the engine control switch to the “ACC” or “LOCK” position.
CAUTION: DO NOT leave the vehicle in gear. If the vehicle rolls, the
engine may start. Always leave the manual transmission in the
“NEUTRAL” position or the automatic transmission selector in the
“P” position and apply the parking brake. When leaving the vehicle
parked on an incline, block the wheels or turn the front wheel into
the curb to prevent the vehicle from rolling.
KEY REMOVAL
To remove the key, turn the Engine Control Switch to the “LOCK” position.
COLD WEATHER STARTING
If you plan ahead for cold weather, starting and driving your vehicle
should be no problem. The following tips will help ensure good starting
in cold weather.
Oil gets thicker as it gets colder, which slows down the engine
cranking speed. Your diesel engine functions by the heat of
compression (and glow plugs when cold), rather than through the use
of spark plugs as in a gasoline engine. So, your engine must crank
faster than a gasoline engine before it will start.
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To be sure the engine can turn fast enough to start, use SAE 10W40 viscosity engine oil when prevailing temperatures drop below 32°F
(0°C). (See the oil quality and oil viscosity recommendations in Section
5 ) Using the proper viscosity oil will make starting easier down to
–10°F (–23°C). When prevailing temperatures drop below –10° F
(–23°C), the optional engine block heater may be needed for starting.
ENGINE WARM-UP SYSTEM
During cold ambient conditions, the automatic engine warm-up system
operates to reduce engine warm-up time during idling.
AUTOMATIC ENGINE WARM-UP
When the engine is idling with the engine coolant temperature below
144°F (62°C), the engine warm-up system automatically closes the
exhaust brake and increases engine idle speed so that the engine is
warmed more quickly. Warm-up is cancelled when the accelerator
pedal is depressed, and resumed when the pedal is released. Warmup is automatically cancelled entirely after the engine coolant
temperature rises above 149°F (65°C).
ENGINE BLOCK AND OIL PAN HEATER (IF EQUIPPED)
If the vehicle is parked in a garage, the block and pan heaters should
not be needed until the garage temperature drops below –10°F
(–23°C) regardless of outside temperature.
The engine block and oil pan heaters are designed to warm the block
and oil pan areas that will let the engine run faster. To use the heaters:
1. Tilt the cab (See Section 5).
2. Unwrap the electrical cord and remove the protective cap.
3. Plug the cord into any three-prong 110 volt outlet (normal
household current). It may require several hours to sufficiently
heat the engine.
Outside temperature, oil viscosity, etc., will affect how long the
block and oil pan heater should remain plugged in. Contact your
dealer for the conditions in your area.
4. After using the heater(s), be sure to restore the cord properly, to
help keep it away from moving engine parts.
NOTICE: If the cord is too short, use a heavy duty, three-prong
extension cord. Do not use an extension cord such as you would
use for a lamp, because the cord may overheat.
The engine should go through a warm-up period to warm up the
engine oil before placing engine under load. This will ensure proper
lubrication of the engine.
NOTICE: Do not use starting “aids” in the air intake system. Such
“aids” can cause immediate engine damage.
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ENGINE ALARM AND AUTOMATIC
SHUTDOWN
If the system senses any of the following conditions: high engine
temperature, low engine oil pressure or low engine coolant, the
corresponding warning light and engine alarm (shutdown) warning light
will come on. If the engine alarm (shutdown) warning light comes on,
you will also hear a tone alarm.
If your vehicle has the engine shutdown feature, your engine will
shut down in 30 seconds.
Pull off the road and shut off the engine. Do not start it until the
cause of the problem is known, and the problem is fixed. If the engine
shuts down when you are still in traffic, you can restart the engine and
get another 30 seconds of operation. Do this only if you have to, since
there is a problem that can harm the engine if it isn't fixed.
GUARD AGAINST THEFT
Your new vehicle has many features to help prevent theft of the
vehicle, its equipment and contents. But these anti-theft features
depend upon you to work.
The time to be most on guard is when leaving the vehicle:
1. Park in a lighted spot when you can.
2. Turn the engine control switch to “LOCK” and remove the key.
This locks the switch and the steering controls. The shift control
lever is not locked.
3. Keep items that may appear to be of value out of sight and locked
up when possible.
4. Fully close all windows and lock all doors.
PARKING, OR LEAVING DRIVER’S SEAT
CAUTION: It can be dangerous to get out of your vehicle if your
automatic transmission shift lever is not fully in “P” (Park) or the
parking brake is not applied all the way, or the shift lever for manual
transmission is not in neutral. Your vehicle can roll or move suddenly
if the engine is running. You or others could be injured or killed.
To be sure your vehicle won’t move, even when you are parking on
level ground, follow the steps below. (If you have to park on a hill, also
turn your front wheels so the vehicle would roll away from traffic.)
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1. Hold the regular brake pedal down with your right foot and apply the
parking brake all the way before shifting the transmission. Follow
the Parking Brake instructions in this manual for your vehicle.
2. To move the automatic transmission shift lever to “P” (Park), hold in
the button on the lever and push the lever all the way toward the
front of your vehicle. Or shift the manual transmission to Neutral.
3. Turn the key to “LOCK”.
4. Remove the key and take it with you.
5. Before you leave the driver’s seat, be sure the vehicle is not
moving, or check that your vehicle is in park by trying to pull the
automatic transmission shift lever out of “P” (Park) by pulling the
shift lever toward you without pushing the button. If you can do this,
it means that the shift lever wasn’t fully locked into “P” (Park).
CAUTION: To reduce the chance of personal injury and vehicle
damage due to engine overheating, never leave the engine idling
for any extended time. If the engine should overheat, as indicated
by the Engine Coolant Temperature gauge, action is required to
correct the condition. Continued operation of the engine with an
overheat condition, even for a short time, may result in a fire.
NOTICE: After high speed or heavy load operation, let the engine
run at idle for at least three (3) minutes before stopping engine to
prevent damage to the turbocharger.
Vehicle Operation
CAUTION: It is not recommended that this vehicle be parked, idled or
operated over combustible materials such as grass or leaves. They
could touch the hot exhaust system and start a fire. This is particularly
important if the exhaust system has not been properly maintained.
Combustible materials could catch fire from hot exhaust gases, soot,
or sparks that could escape through corrosion holes or cracks.
If operating, parking or idling your vehicle off-road is unavoidable,
such as in farming, lumbering, commercial or recreational use:
• The driver should be aware that combustible materials could
catch fire from the vehicle’s hot exhaust system.
• Carry a fire extinguisher with the vehicle at these times.
• Avoid driving your vehicle through or over combustible materials
such as leaves, grass vegetation or stubble high enough to
touch, catch or collect on its hot exhaust system.
• Parking or idling should be done only in an area where there are
no combustible materials under the vehicle.
Failure to follow these instructions could damage your vehicle or
nearby property.
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DRIVING TECHNIQUES
BRAKING AND STEERING TECHNIQUES
Always turn-off the manual engine idle control knob to the full counterclockwise position while driving to maintain proper braking performance
and reduce brake wear.
Excessive use of the brake pedal is extremely dangerous because it
could cause the brakes to get hot and not work as well. Also, it rapidly
wears the brake pads and linings. Make effective use of the engine brake
and the exhaust brake when you wish to decelerate.
To get maximum braking while maintaining vehicle control, use a
“squeeze” braking technique. Do this by pushing on the brake pedal with
steadily increasing pressure. If possible, steer around obstacles when there
is not enough room to stop. If the vehicle does not respond to steering or
changes direction when you are not steering, ease up on the brake pedal.
If the front wheels are not rolling to some extent, you cannot control the
direction of the vehicle by turning the steering wheel. To correct for a skid,
ease off the accelerator pedal or the brake and steer to keep the vehicle
pointing where you want it to go. Do not touch the brake.
WET BRAKES
CAUTION: After driving through water deep enough to wet brake
components or having the vehicle washed, the brakes may require
higher pedal effort. As a result, the vehicle will not slow down at
the usual rate, and it may pull to the right or left. After checking to
the rear for other vehicles, apply the brakes lightly to check
whether this has happened. To dry them quickly, lightly apply the
brakes. At the same time, keep a safe forward speed with plenty of
clear space ahead, to the rear, and to the sides. Do this until the
brakes return to normal. Always do this after driving through water
or washing the vehicle to help reduce the risk of personal injury.
RIDING THE BRAKE
CAUTION: “Riding the brake” by resting your foot on the pedal,
when you do not intend to brake, can overheat the brakes and wear
out the brake linings faster. This may also damage the brakes and
will waste fuel. It can also result in reduced braking performance.
DESCENDING A GRADE
CAUTION: To reduce the risk of personal injury, before going down
a steep or long grade, reduce speed, turn on the exhaust brake and
shift the transmission to the next lower gear. This will help control
your speed. Do not hold the brake pedal down too long or too
often while going down a steep or long grade. This could cause the
brakes to get hot and not to work as well. As a result, the truck will
not slow down at the usual rate. Failure to take these steps could
result in loss of vehicle control.
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NOTICE: The engine should never be allowed to exceed the governed
speed. Supplement the exhaust brake with vehicle service brakes
intermittently and/or shift to higher transmission gear to prevent
engine overspeed. A “rule-of thumb” for gear selection is that the
vehicle should be driven down a grade in the same gear that would be
used to climb that grade.
If the system fails to operate or shut off, check the electrical wiring,
wiring connections, and switch adjustment at pedals. Your dealer is
best qualified to adjust and service the exhaust brake system.
DRIVING ON SLIPPERY SURFACES
NOTICE: When inevitably driving on flooded road, it is advisable to
run slowly at a constant speed while confirming the depth of water.
Otherwise, water may intrude in the engine cylinder and cause
damage on the engine (due to water hammer phenomenon). It is
also advisable to slow down your vehicle and drive with care. After
driving on the flooded road, it is recommended to immediately
bring the vehicle to the Isuzu dealership and let them check
engine, electric parts, transmission, propeller shaft, differential
and transfer for water intrusion, and apply grease and oil to each
area.
Drive, steering and braking traction is reduced when water, snow, ice,
gravel or other material is on the road. Slow down and adjust your
driving to such conditions. It is important to slow down when it is slippery
because stopping distance will be longer and vehicle control more
limited. While driving on a surface with reduced traction, avoid
maneuvers involving sudden steering, acceleration or braking (including
engine braking by shifting to a lower gear), which could cause the tires
to skid. You may not realize the surface is slippery until the vehicle is
skidding. Learn to recognize warning clues—such as enough water or
ice on the road to make a “mirrored surface”—and slow down when
there is any doubt. Also, see “Tire Traction” under “Wheels and Tires” in
Section 5 of this manual.
USE OF THE EXHAUST BRAKE (ON SLIPPERY SURFACES)
The exhaust brake can be used effectively by selecting a higher than
normal transmission gear for the given road speed. The engine will
operate at a reduced rpm; therefore, reducing the retarding effect
when the system is operating.
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STOPPING THE VEHICLE IN THE EVENT OF SERVICE BRAKE
MALFUNCTION
The exhaust brake should be turned on as soon as service brake
malfunction is detected. This will slow the engine speed. With the
engine speed under control and providing the grade conditions permit,
the transmission can be progressively down-shifted using the exhaust
brake in each gear. Eventually the exhaust brake should slow the
vehicle to a controllable “crawl”. Stop the vehicle. The vehicle should
not be driven further until corrective measures are taken.
DRIVING AT LOW SPEEDS FOR SUSTAINED PERIODS (A/T ONLY)
Some vehicle applications such as Road Sweepers or Road Markers
may require operation at low speeds (less than 15 MPH (24 km/h)) for
sustained periods of time. In order to receive the best performance in
this condition, be sure the transmission selector is in the “1” position.
See Instrument Panel Control Section (Automatic Transmission Fluid
Temperature Warning Light) page 2-39 for additional information.
STEERING COLUMN CONTROLS
ANTI-THEFT STEERING COLUMN LOCK
CAUTION: If you need to turn the engine off while the vehicle is
moving, turn the key to “ACC” only.
Do not turn the key to “LOCK”. Do not remove the key when the
vehicle is moving. This will result in locking the steering wheel and
loss of steering control.
* Turning the engine off with the vehicle moving is dangerous as
braking efficiency will be reduced.
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LEFT-HAND CONTROL LEVER
The turn signal lever on the left side of the steering column also
controls headlight low beam and high beam.
Headlight
Turn Signal
TURN SIGNAL
Move the lever up to signal a right turn. Move it down to signal a left turn.
When the turn is completed, the signal will cancel and the lever will return
to horizontal. If the steering wheel was not turned enough to cancel the
signal automatically (such as when changing lanes on an expressway),
cancel the signal manually.
A green light on the instrument panel is designed to flash to tell you that
the front and rear turn signal lights are working. If the light stays on, but does
not flash, check for a burned-out turn signal bulb. If the green light does not
come on when you move the lever, check the fuse and indicator bulb.
HEADLIGHTS/CORNERING LIGHTS
The headlight switch has three positions. Rotate the switch to operate it.
• “
”—All lights are off.
• “
”—Taillights, license plate lights, instrument cluster lights,
identification lights and clearance lights (if equipped). Use for
parking only.
When taillights and a turn signal light are both turned on, the
cornering light will automatically come on.
• “
”—Headlights are on, plus all lights from“
”.
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HEADLIGHT DIMMER SWITCH
•
•
With the headlight switch set at “
” and the left-hand lever in the
center position, the headlights are at low beam. Always use low
beam when approaching or following other vehicles.
Push the multi-function lever toward you to engage high beam. An
indicator, located in the instrument panel lights when the high beam
is being used.
High Beam
Passing
PASSING LIGHT SWITCH
With the headlights on, you can repeatedly turn on and off the high
beams to signal your intention to pass. Even if the headlights are off,
pulling the switch up will momentarily turn on the high beams to signal
your intention to pass.
RIGHT-HAND CONTROL LEVER
The right-hand control lever controls the exhaust brake, windshield
wipers, and windshield washers.
WINDSHIELD WIPERS
NOTICE: Do not attempt to operate wipers if blades are frozen to
the windshield, since this could result in damage to the wiper
motor or wiper arm.
Turn the wiper switch to operate the windshield wipers. The switch
has four positions:
• “
”—Windshield wipers are off.
• “
”—Intermittent wiper operation, for use during periods of light
rain, mist, or fog where continuous wiping is not needed.
• “
”—Low-speed wiper operation.
• “
”—High-speed wiper operation.
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WINDSHIELD WASHER
To spray washer fluid on the windshield, push the button on the end
of the combination switch lever. The spray will continue as long as you
hold in the button. After using the windshield washer, turn the wipers
off by setting the switch to “
”.
Window Washer Switch
Window Wiper Switch
Operating Tips
•
•
•
•
Clear ice or packed snow from the wiper blades before using the
wipers. Carefully loosen or thaw wipers that are frozen to the
windshield.
Check the washer fluid level regularly. Do it often when the weather
is bad.
Use a good quality windshield antifreeze to help prevent freezing
damage, and for better cleaning. Be sure to add the fluid to the
proper reservoir.
Fill the washer fluid reservoir only 3/4 full during the winter to allow
for expansion if the temperature should fall low enough to freeze
the solution.
NOTICE: Do not use radiator antifreeze in the windshield washer, it
could cause paint damage and cloud the glass.
•
•
In cold weather, warm the windshield with the defrosters before using
the washer, to help prevent icing that may block the driver’s vision.
The washer fluid reservoir is located to the right of the glove box.
EXHAUST BRAKE OPERATION
The system, when turned on, increases the amount of power absorbed
by the engine while coasting in gear. Whenever slowing down the
vehicle, such as on down grades, in city traffic or approaching stop
signals, this brake system may be used.
Lift the right hand control lever up to turn the exhaust brake on. An
indicator in the instrument panel lights when the exhaust brake switch
is on. Pull the lever up again to turn the exhaust brake off during idling.
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After the vehicle is in motion, the exhaust brake system operates
when the driver's foot is removed from the accelerator pedal. On
manual transmission vehicles, the clutch must be engaged (foot off of
pedal) for the exhaust brake to operate.
The selection of transmission gears and engine speed when
operating the brake system is important. The exhaust brake is more
effective in the lower gears and at the higher engine speeds.
CAUTION: To reduce the risk of personal injury, do not operate the
exhaust brake on slippery roads (snow covered, frozen or wet
roads), because the tires may lock.
Descending a Grade
CAUTION: To reduce the risk of personal injury, before going down a
steep or long grade, reduce speed, turn on the exhaust brake, and
shift the transmission to the next lower gear. This will help control
your speed. Do not hold the brake pedal down too long or too often
while going downhill. This could cause the brakes to get hot and not
work as well. As a result, the truck will not slow down at the usual
rate. Failure to take these steps could result in loss of vehicle control.
ADJUSTABLE STEERING COLUMN
The steering column can be adjusted to different angles and the steering
wheel can be adjusted up or down. Before adjusting, position the seat as
desired.
Lock Lever
Unlock
Lock
STEERING COLUMN ADJUSTMENT
1. Release the steering column by pulling the lock lever all the way up.
2. Sit upright in your seat and move the steering wheel up or down and
the steering column back or forward as desired.
3. At the desired position, lock the column by pushing the lock lever all
the way down.
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CAUTION: To reduce the risk of personal injury, apply force to the
steering wheel to make certain the steering column is firmly locked
before driving. Also, do not try to tilt or adjust the steering wheel
while the vehicle is moving. If these steps are not followed, the
steering column could move suddenly while the vehicle is in
motion which could cause a temporary loss of steering control
which may result in personal injury or death.
HAZARD WARNING LIGHT FLASHER
Refer to “Hazard Warning Light Flasher” in Section 3.
ENGINE CONTROL SWITCH (KEY SWITCH)
Refer to “Starting the Engine” in Section 2.
HORN
The horn works by firmly pressing the pad in the steering wheel.
POWER STEERING
If the power assist steering system goes out because the engine has
stopped or the assist system has malfunctioned, the vehicle can still be
steered. However, much greater effort is needed, especially in sharp
turns or at low speeds.
CAUTION: Do not keep the steering wheel in a fully turned position
for a long period of time. This can heat the oil in the power steering
oil pump, causing poor lubrication, damage to the oil tank and
hose, and deterioration of the seals. This can result in damage to
the power steering oil pump, power steering unit, power steering
hose and other components, and the steering wheel could
suddenly become heavy, and an accident or fire could occur.
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BRAKE SYSTEM
7
6
1
2
3
4
5
1. Clutch pedal (M/T models)
2. Steering Column
3. Brake Pedal
4. Accelerator Pedal
5. Manual Transmission Shift Control Lever
6. Overdrive Switch (A/T models)
7. Automatic Transmission Selector
BRAKE PEDAL
For the most effective braking and for maximum life from brake
system components, follow these suggestions:
• Apply the brakes gradually as hard as road and load conditions
permit. Reduce pedal pressure as speed drops so that a very light
pressure is used at the end of the stop.
• If brake low vacuum warning light (NPR-HD model), brake booster
warning light (NQR, NRR models) or brake warning light comes on
during operation, have brake system checked immediately.
• Do not pump the brake pedal as this will only deplete the vacuum
reserve or hydraulic brake booster accumulator reserve.
• Always turn off the manual engine idle control knob to the full
counterclockwise position while driving to maintain proper braking
performance and reduce brake wear.
• Keep any obstructions from interfering with brake pedal travel.
• Keep tires properly inflated. Improperly inflated tires can reduce the
efficiency of the brakes.
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HYDRAULIC BRAKE BOOSTER (NQR, NRR models) CHARACTERISTICS
The NQR/NRR models are equipped with a “Hydraulic Brake Booster
(HBB)” system.
In the NQR/NRR, an unusual sound from under the instrument panel
may be heard from the hydraulic system while brakes are used. It does
not mean trouble. It is not a sign of malfunction.
• If you pump the brakes with the engine off, a squeaking sound can
be heard. This comes from the auxiliary accumulator. It is not a
malfunction.
With the engine running, a similar sound can be heard during
sudden braking.
• Another characteristic of the HBB system on NQR/NRR is that the
brake pedal may be depressed easily to the floor with the vehicle at
a stop. This is not a sign of malfunction.
• When the engine is running, the system automatically charges the
accumulator whenever pressure has been reduced after braking.
Auto charge may be activated without braking, depending on
temperature changes in the accumulator.
During auto charge, a hissing and clicking sound can be heard.
This is not a malfunction.
• With the engine running, a booming sound can be heard during
hard braking. This comes from the brake-fluid pump. It is not a
malfunction.
Applying continuous hard braking for a long time will lead to
considerable temperature rise in the hydraulic booster pump. Such
overworking of the brakes is best avoided.
VACUUM OR HYDRAULIC POWER ASSISTED BRAKES
If the engine stops, do not pump the brakes. The system is designed
to stop the vehicle with reserve power assist if the brake pedal is held
down. This reserve is greatly reduced each time you apply and release
the brakes. If, when you turn the steering wheel during braking, the
vehicle does not turn, do not push as hard on the brake pedal.
Without power assist the vehicle can still be stopped by pushing much
harder on the brake pedal, however, the stopping distance may be longer.
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ANTI-LOCK BRAKE SYSTEM (ABS)
Explanation of the ABS
The ABS is designed to prevent lock-up of the wheels during braking
by automatically changing the brake pressure. This occurs only during
braking which would have caused one or more wheels to lock.
CAUTION:
• Even with the ABS, do not get too close to vehicles in front of you.
Keep safe following distances, whether or not your vehicle has the
ABS.
The anti-lock feature is designed to help you maintain steering
control during braking, but there could still be some loss of steering
control under certain conditions.
Driving too fast around curves or turns (especially on slippery
pavement) might result in loss of control. Drive only as fast as
conditions permit; remember, loss of control can cause an accident.
To use anti-lock, do not "pump" your brakes. Just hold the pedal
down and let anti-lock work for you.
Even with the ABS, driving, steering and braking traction is
reduced on slippery surfaces. The operation of the ABS on gravel,
deep snow or bumpy roads, or if you are using tire chains, may
result in a longer stopping distance than for vehicles without ABS.
Slow down and adjust your driving to such conditions.
Do not use tires other than the manufacturer’s designated tires,
and do not mix tires or wheels of different sizes. By doing so, you
may prevent the ABS from operating at full effectiveness.
NOTICE: These symptoms are not abnormalities.
• When vehicle speed has reached 4MPH (6km/h) after engine
startup, an electric motor sound may be heard from the cab’s
underside. This is the automatic self check of the ABS. If you
happen to step on the pedal during self check, you may feel a
pedal vibration as well.
• When ABS is functioning, you may feel a vibration of the brake
pedal or steering wheel and hear the operation of the ABS pump.
These operating characteristics indicate normal ABS operation.
• If braking during turning or when hitting a bump, ABS may be
actuated. The reason is that the inside wheels or the wheels
hitting a bump may intermittently lock.
• ABS is not actuated until vehicle speed increases to 6MPH
(10km/h), and it stops working when vehicle speed has dropped
to 3MPH (5km/h).
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NOTICE:
• When you drive on sandy soil or in the mud, it may adversely
affect the brakes or the ABS sensor. If so, get the vehicle
washed and remove the mud or extraneous matter from it.
• On ABS equipped model, the vehicle speed sensors are fitted on
the wheels. When removing snow, ice and other incrustation,
take great care not to damage the components.
• Do not use a sharp implement to remove snow. Sharp edges
could damage rubber parts.
Explanation of Electronic Braking force Distribution (EBD)
The ABS has an EBD function.
The EBD uses the ABS system, and is a function that prevents early
stage rear wheel lock-up by adequately controlling the braking force
distribution of the front and rear wheels in accordance with load shift,
which is caused by changes to the load’s circumstance and
deceleration.
CAUTION:
• If the EBD system malfunctions, the ABS malfunction warning
light and “BRAKE” system warning light will come on
simultaneously.
• If the EBD system malfunctions, the rear wheels can easily lockup. Contact your Isuzu dealer immediately and have the system
repaired.
NOTICE: When the EBD is operated, it is not abnormal to feel a
clicking movement through the brake pedal or a noise resembling
ABS operation.
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PARKING BRAKE
•
•
•
The parking brake lever is located to the right of the driver’s seat.
To set the parking brake, completely stop the vehicle. Then hold
the brake pedal down while pulling the parking brake lever all the
way up. Before you leave the driver’s seat, follow the steps under
“Parking” in this Section.
To release the parking brake, hold the brake pedal down while
pushing the button in the tip of the brake lever and lower the lever.
The “BRAKE” system warning light is designed to remind you if the
parking brake is not released when the engine control switch is on.
Never drive the vehicle with the parking brake set as this will cause
excessive wear, reduce parking brake effectiveness and increase
fuel consumption.
If you notice the parking lever travel has increased over time, this
means the cable adjustment must be checked by a qualified
technician. Adjustment may be required due to parking brake shoe
wear.
“BRAKE” SYSTEM WARNING LIGHT (Refer to page 2-35)
BRAKE BOOSTER WARNING LIGHT (Refer to page 2-36)
EXHAUST BRAKE INDICATOR LIGHT (Refer to page 2-33)
PARKING “BRAKE” INDICATOR LIGHT (Refer to page 2-37)
BRAKE SYSTEM (Refer to page 5-37)
BRAKE MAINTENANCE (Refer to page 5-38)
DRIVING TECHNIQUES (Refer to page 2-14)
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MANUAL TRANSMISSION CONTROLS
AND OPERATION
It is the driver’s responsibility to be thoroughly familiar with the
transmission shift pattern and shifting procedure.
DESCENDING A GRADE
CAUTION: To reduce the risk of personal injury, before going down
a steep or long grade, reduce speed, turn on the exhaust brake and
shift the transmission into a lower gear to help control your vehicle
speed. Do not hold the brake pedal down too long or too often
while going down a steep or long grade. This could cause the
brakes to get hot and not work as well. As a result, the vehicle will
not slow down at the usual rate. Failure to take these steps could
result in loss of vehicle control which may result in personal injury
or death.
CLUTCH PEDAL
The clutch pedal is used to engage or disengage the clutch, thereby
connecting or disconnecting the engine from the transmission and
driveline to the rear wheels. When the pedal is fully released the clutch
is engaged, driving the transmission and the rear wheels.
Engaging the Clutch
When engaging the clutch from a standstill, always start in first gear.
With the engine speed at idle, start the clutch engagement and listen for
an engine speed drop of about 100 RPM. At this point, the clutch is
engaging and the engine speed can be increased and the clutch fully
engaged. Avoid excess slippage of the clutch from a standstill. Excess
slippage causes a reduction of clutch disc facing friction and clutch life. Do
not rest your foot on the clutch pedal while driving or to use the clutch to
hold the vehicle on an incline.
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Shifting Gears
•
•
•
•
•
•
Always depress the clutch pedal fully when shifting and release it fully
after shifting.
Always start moving in first gear and avoid slipping the clutch.
Select the gear which will maintain the desired road speed while
keeping the engine above two-thirds of the governed speed.
Do not overspeed the engine when shifting to a lower gear.
Do not rest your foot on the clutch pedal; this causes a partly
disengaged condition which could damage the clutch.
Hold your speed below the following maximum recommended speeds
for each gear position:
Max. MPH (km/h)
GEAR
NPR-HD, NQR, NRR
1st
2nd
3rd
4th
5th
6th
10(16) 18(29) 29(47) 45(72) 65(105) 75(121)
NOTICE: To prevent engine over-speed, confine your speed to the
range.
The speeds given are for a vehicle which has been “broken in”. See
“New Vehicle Break-In” earlier in this section.
• Do not use the engine by slipping clutch to hold the vehicle when
stopped on an upgrade.
• Never shift into reverse gear until the vehicle has completely
stopped moving.
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AUTOMATIC TRANSMISSION CONTROLS
AUTOMATIC TRANSMISSION SELECTOR
Button
Selector
Overdrive Switch
Indicator
SELECTING GEARS
Push the button located on the end of the selector when engaging
the “R” and “P” positions and when shifting from “2” to “1” as indicated
by the arrow “
”.
The selector can be shifted freely into any position without pushing
the button as indicated by the arrow “
”.
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AUTOMATIC TRANS. CONTROLS,
CONTINUED
STARTING
Start the engine in either the “P” or the “N” position. The engine
should not start in any other selector position. If it does, something is
wrong. Have your truck checked by your dealer as soon as possible.
Always apply either the foot brake or the parking brake before
shifting into any driving position. This will prevent creeping.
The engine should be running at idle speed when shifting from “P” or
“N” to one of the driving positions. Always rotate the manual idle speed
control knob fully counterclockwise before driving.
P: PARK
The “P” position is to be used with the parking brake.
The “P” position is one of the two positions (the other is “N”) in which
the engine can be started.
NEVER MOVE THE SELECTOR TO THE “P” POSITION WHEN THE
TRUCK IS IN MOTION.
R: REVERSE
Bring the truck to a complete stop before moving the selector to the
“R” position.
N: NEUTRAL
Automatic transmission — Driveshaft must be removed when towing
your truck.
The “N” position is used should it become necessary to tow your truck.
The engine may be started when the selector is in the “N” position.
D: DRIVE
The “D” position is for all normal forward driving.
If additional speed is required for passing, press the accelerator
pedal hard to the floor. The transmission will downshift at speeds
below about 55 MPH (88 km/h) to provide greater acceleration.
Push the overdrive switch to the “ON” position for greater fuel
economy. The automatic transmission will continue to select the best
speed range for the vehicle (1st, 2nd, 3rd, 4th, 5th and 6th).
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Push the overdrive switch to the OFF position at speeds below 65
MPH (105km/h) to increase engine braking action when traveling
downgrade.
If the automatic transmission fluid temperature is too low, the
transmission may not initially make automatic shift to the 4th, 5th and
6th gear. This condition is normal and will be resolved as the fluid
temperature rises.
2: SECOND
Select the “2” position at speeds below 25 MPH (40km/h) when
traveling down a moderate grade. The braking action of the engine will
hold your speed down. Continued use of the wheel brakes will not be
required. Use of the exhaust brake will also aid downhill braking.
Return the selector to the “D” position for normal driving.
1: FIRST
Use the “1” position for maximum engine braking on steep downhill
grades.
Return the selector to the “D” position for normal driving.
DRIVING TIPS
Before descending a long, steep grade, reduce speed and turn off the
overdrive switch. This is the safe way to control your truck’s speed.
Avoid continuous or frequent use of the wheel brakes over a long
period of time. Doing so will lead to brake overheating and
dangerously reduced braking efficiency.
NOTICE:
* Never move the selector from the “P” or “N” position to one of
the drive positions with the engine running at a high speed.
Damage to the automatic transmission will result.
* Never move the selector into the “P” position when the vehicle is
in motion. Damage to the automatic transmission will result.
* Do not operate the automatic transmission at or near stall
condition for more than five seconds.
Stall condition is when the transmission is in one of the driving
ranges, the engine is running at high speed, but the drive wheels
are unable to move. This condition might occur if the vehicle is
stuck in deep sand or is pushing against a fixed barrier.
NOTICE (Continued)
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NOTICE (Continued)
Operating the transmission at stall condition will result in
overheating and damage.
* Do not hold your vehicle on an upgrade by increasing engine
speed with the accelerator pedal. Doing so will result in
automatic transmission overheating and damage.
Use your wheel brakes to hold the vehicle on an upgrade.
Treatment for low speed applications.
Any low speed applications such as sweeper, highway striping or
moving, etc. require the following treatment to prevent the ATF
from overheating.
(1) Select “1”position during low speed operation under 11MPH (18km/h).
(2) Select “2”position during low speed operation under 22MPH (36km/h).
OVERDRIVE SWITCH
Overdrive Switch
The overdrive will not operate when the overdrive switch is in the
“OFF” position.
The indicator light on the instrument panel will be on when the
overdrive switch is in the “OFF” position.
When the overdrive switch is in the “ON” position, all six forward
speeds of the automatic transmission will operate.
If the automatic transmission fluid temperature is too low, the
transmission may not initially make automatic shift to the 4th, 5th and
6th gear.
If your vehicle is traveling at a speed exceeding 65 MPH (105km/h) it
is not possible to downshift from 6th gear to 5th gear.
When operating your vehicle on a slippery road, a winding road, or a
long downhill slope, you will want to take advantage of the engine’s
braking power. Push the overdrive switch to the “OFF” position at this time.
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Under normal operating conditions, the use of overdrive is
recommended. Road speed is increased, operating noise is reduced
and fuel economy is improved. Take advantage of overdrive whenever
possible.
INSTRUMENT PANEL AND CONTROLS
The instrument panels in this vehicle contain the gauges, warning
lights and controls necessary to run the vehicle and its systems. The
switches are designed to allow convenient driver access, and the
gauges and warning lights are designed to be read at a glance.
For safety reasons, do not place packages, tools or other items in the
driver’s area that may restrict access to the controls or sight of the gauges.
The following is a general guide to the instrument panel and controls
on these vehicles.
INDICATOR AND WARNING LIGHTS
The indicator and warning lights tell the driver about the status of
certain vehicle operations or systems. These indicator and warning
lights are located on the instrument panel.
By activating certain controls and switches, an indicator will light to
confirm the selection and operation of equipment or system. However,
a warning light should automatically turn on to visually alert the driver
when a vehicle system has or is about to have a malfunction, unless it
is during a bulb check or as otherwise described in the following
explanations.
Turn Signal Indicator Light
The indicator light flashes when the turn signal switch has
been activated, or when the hazard light circuit has been
activated.
Headlights High Beam Indicator Light
The indicator lights up when the headlight high beam circuit is
turned on.
Exhaust Brake Indicator Light
The indicator light comes on when the exhaust brake switch is
raised, and the engine is running.
NOTICE: During ABS operation, the exhaust brake may be inactive
even though the exhaust brake switch is in the “ON” position and
the indicator light is lit.
When traveling over an uneven road surface, the exhaust brake
may disengage for short intervals even though the brake pedal is
not depressed.
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Battery Discharge Warning Light
The warning light comes on when the battery is discharging.
This may mean that the generator has malfunctioned, the electrical
system is overloaded, or the generator drive belt is loose or broken. Have
the system repaired promptly.
Low Fuel Level Indicator Light
The fuel level warning light turns on when the amount of fuel
remaining in the fuel tank is approximately 4.0 U.S. gallons(15.0
liters). When the light comes on, fill the fuel tank as soon as possible. Ultra
low sulfur diesel fuel should be used.
1
2
3
20
4
5 7 9 11 13 15 17
6 8 10 12 14 16 18
21 23 25
22 24
1. Cruise Main Indicator Light
2. Cruise Set Indicator Light
3. Daytime Running Light (DRL)
Indicator Light
4. Water Separator Indicator
Light
5. Check Engine Malfunction
Indicator Light
6. Oil Level Indicator Light
7. Engine Oil Pressure Warning
Light
8. Glow Plug Indicator Light
9. Service Vehicle Soon (SVS)
Light
10. Parking Brake Indicator Light/
Brake System Warning Light
11. DPF Indicator Light (Green)
12. Engine Coolant Level
Warning Light
13. DPF Indicator Light (Amber,
Red)
14. Brake Low Vacuum Warning
Light (NPR-HD model)
Brake Booster Warning Light
(NQR, NRR models)
19
26
15. Battery Discharge Warning
Light
16. Headlights High Beam
Indicator Light
17. Engine Shut Down Warning
Light
18. Anti-Lock Brake System
Malfunction Warning Light
19. Exhaust Brake Indicator Light
20. Low Fuel Level Indicator Light
21. Overdrive Indicator Light (A/T
models)
22. A/T Oil Temperature Warning
Light (A/T models)
23. Turn Signal Indicator Light
24. “CHECK TRANS” Warning
Light (A/T models)
25. Turn Signal Indicator Light
26. Engine Overheating Warning
Light
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Glow Plug Indicator Light
Your diesel engine has a special starting system. Small heating
elements, called “glow plugs,” preheat the engine combustion
chambers to improve cold starting.
This light is designed to come on when the engine control switch is
turned to the “ON” position, and go off when the glow plugs are heated
enough. You should start the engine when this light goes out.
Check Engine Malfunction Indicator Light
Monitors operation of your electronic emission control system.
If the light flashes on while driving, it indicates that the engine
electronic emission control system may be malfunctioning. You should take
your vehicle in for servicing soon. When this light is on, avoid driving in a
manner that would apply load to the engine, such as accelerating hard.
Engine Alarm (Shutdown) Warning Light
This light will come on when the engine alarm and automatic
shutdown is active.
Refer to "ENGINE ALARM AND AUTOMATIC SHUTDOWN" on page
2-12.
“BRAKE” System Warning Light
BRAKE
The regular braking system is a split system designed so that one
part will provide some braking if there is a loss of hydraulic pressure
in the other part of the system. The system has a “BRAKE” system
warning light located on the instrument panel.
For a bulb check, the “BRAKE” light should come on when the
engine control switch is turned “ON” and the engine is not running. To
serve as a reminder, the light should stay on when the parking brake is
not fully released, and the engine control switch is on. Have the
system repaired if the light does not come on when it should. If this
warning light does not go away, brake inspection and maintenance
should be performed. The brake fluid level must be checked regularly.
Detach the inspection cover from the left side of the meter panel by
hand. Check that the fluid level in the reserve tank is between the MAX
line and the ADD line. Rock the vehicle if it is difficult to determine the
brake fluid's level. If the brake fluid has fallen below the ADD line,
open the cap and top up with DOT3. At this time, do not top up if the
brake fluid exceeds the MAX line. In addition, after topping up, close
the cap securely. See the “Maintenance Schedule” in Section 5 for
other brake checks.
If the Anti-lock brake system malfunctions, the ABS malfunction
warning light and the “BRAKE” system warning light come on
simultaneously. Refer to “ANTI-LOCK BRAKE SYSTEM (ABS)
Malfunction Warning Light” on page 2-41.
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If the light remains on after engine start up or comes on during
operation of the vehicle, it may mean that there is something wrong
with part of the brake system.
What to do:
1. Check to see that the parking brake has been released. If it has
been:
2. Turn on the exhaust brake to help slow the vehicle.
3. Pull off the road and stop carefully. Remember that:
• Stopping distances may be longer.
• You may have to push harder on the pedal.
• The pedal may go down farther than normal.
4. Check the brake fluid level indicator on the left side of the
instrument panel. If low, add fluid as needed.
If brake fluid level is not low:
5. Try out the brakes by starting and stopping on the road shoulder
then:
• If you judge it to be safe, drive cautiously at a safe speed to the
nearest dealer for repair.
• Have the vehicle towed to the nearest dealer for repair.
Continued driving without necessary repairs could be
dangerous.
BRAKE
BOOSTER
Brake Low Vacuum Warning Light (NPR-HD model)
Brake Booster Warning Light (NQR, NRR models)
This light should come on to provide a bulb check when the
engine control switch is turned to the “ON” position. It should go out
when the engine has started. If the light does not come on when the
engine control switch is turned to “ON”, it could indicate a burned out bulb
or a blown fuse. Have the system repaired if the light does not come on
during this check.
(NPR-HD model): The brake low vacuum warning light and warning
buzzer alarm should come on to indicate low vacuum reserve for brake
power assist. At the same time, the Buck up Electric Vacuum Pump
operates.
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(NQR, NRR models): When the hydraulic brake booster pressure is
low, and/or the hydraulic brake booster fluid (Dexron®-III) level is low,
the light and warning buzzer alarm should come on. Do not use brake
fluid in the brake booster reservoir. Use only Dexron ®-III ATF.
(NPR-HD, NQR, NRR models): If this happens while driving :
• Do not pump the brakes. The system is designed to stop the truck
with reserve power assist if the pedal is held down. This reserve is
greatly reduced each time you apply and release the brakes.
• Stopping distance may be longer.
• You may have to push much harder on the brake pedal.
Have the vehicle repaired before continue driving.
The buzzer stops when the parking brake lever with manual
transmission is pulled up or the automatic transmission selector is
shifted to the “N” or “P” positions.
Parking “BRAKE” Indicator Light
BRAKE
The “BRAKE” indicator light comes on when the parking brake
lever is pulled with the engine control switch “ON”. To serve as a
reminder, the light should stay on when the parking brake is not fully
released and the engine control switch is on.
Have the system repaired if the light does not come on when it
should. See the “Maintenance Schedule” in Section 5 for other brake
checks.
Engine Overheating Warning Light
The warning light comes on and the alarm buzzer rings when the
engine coolant temperature gauge goes into the red zone, indicating
overheat.
CAUTION: If this light comes on and stays on while you are
driving, your engine coolant might have overheated and your
engine may be too hot. You should pull off the road, stop your
vehicle and turn off the engine as soon as possible. When this
light comes on, you will also hear a warning tone.
CAUTION: Do not remove the radiator cap when the cooling water
inside the radiator has heated up. If it is removed without due
thought and caution, steam will spurt out, possibly scalding you.
Before removing the radiator cap, make sure that the temperature
of the cooling water has dropped.
CAUTION:
• Driving the vehicle while this lamp remains lit invites overheating
and may cause the engine to seize up.
• When this light comes on and stays on, stopping the engine
immediately may cause the engine to seize up.
CAUTION (Continued)
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CAUTION (Continued)
• This light will also activate the engine alarm and automatic
shutdown system. Refer to "ENGINE ALARM AND AUTOMATIC
SHUTDOWN" on page 2-12.
Low Coolant Warning Light
You have a low coolant warning light. If this light comes on, your
system is low on coolant and the engine may overheat. When it
comes on, you will also hear a warning tone.
Refer to “ENGINE COOLING SYSTEM” on page 5-32 and have your
vehicle serviced as soon as you can.
This light will also activate the engine alarm and automatic shutdown
system. Refer to “ENGINE ALARM AND AUTOMATIC SHUTDOWN” on
page 2-12.
CAUTION: If the warning light comes on while driving, stop the
vehicle immediately, check the cooling system for leaks, then
locate and correct the cause of the trouble.
Engine Oil Pressure Warning Light
The light comes on when the engine oil pressure has fallen below
the normal level. The light will also come on when the oil pressure
across the oil filter rises above the normal level.
If the indicator light comes on while driving, immediately stop the engine
and check the oil level in the engine crankcase. If the oil level is normal,
restrictions are in the oil filter or within the lubricating system. Do not run
the engine with this light on.
When this light comes on while driving, you will also hear a warning
tone.
NOTICE: The oil level varies while the engine is running, right after
it has stopped or if the vehicle is on uneven ground. As a result,
the "red Engine Oil Pressure Warning Light" may light up. When
checking the oil level, press the "Oil check switch" on level ground
while the engine is cool.
While driving, this light will also activate the engine alarm and
automatic shutdown system. Refer to "ENGINE ALARM AND
AUTOMATIC SHUTDOWN" on page 2-12.
The red Engine Oil Pressure Warning Light in combination with the green
Oil Level Indicator Light can indicate if the engine oil level is OK or low.
With the engine control switch in the “OFF” position, push the OIL CHECK
switch on the left-hand side of the instrument panel. The red Engine Oil
Pressure Warning Light will illuminate if the engine oil level is low. The
green Oil Level Indicator Light will illuminate if the engine oil level is OK.
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Overdrive Indicator Light (A/T models)
The indicator light comes on when the overdrive switch on the
transmission selector is in the “OFF” position. Overdrive will not
operate even when the automatic transmission is in the “D” position, unless
engine RPM is excessive.
“CHECK TRANS” Warning Light (A/T models)
When the engine control switch is turned on, the indicator light
comes on for approximately 2 seconds and then goes off
automatically.
If the indicator light starts to blink while driving, it indicates that there is a
malfunction in the automatic transmission’s electronic control system. If the
indicator light is found blinking, contact your authorized Isuzu medium duty
vehicle dealer promptly for repairs.
Automatic Transmission Fluid Temperature Warning Light
(A/T models)
The “A/T OIL TEMP” warning light warns that the automatic
transmission fluid temperature is high. This usually occurs when the
transmission is overfilled and may be accompanied by leakage of fluid from
the transmission breather hose.
The indicator light should turn on when the engine control switch is
turned to the “ON” position, but should go out after a few seconds.
If this light comes on while you are driving, slow down and pull off the road.
Stop the vehicle at a safe place and put the shift lever into the “P”
position. With the engine idling, wait until the light goes off. If the light
goes off, you can drive the vehicle again. If the light does not go off,
have the automatic transmission lubricating system checked as soon
as possible by your Isuzu dealer.
NOTICE: To avoid automatic transmission fluid overheating in
sustained low speed driving applications, be sure to use the “1”
position only. Examples of sustained low speed driving
applications are Road Sweepers, Road Marking Machinery, Trash
Collectors, etc.
CAUTION: Driving with the “A/T OIL TEMP” light constantly on can
cause serious mechanical damage to the automatic transmission.
Daytime Running Lights (DRL) Indicator Light
When you start the engine in daytime, with the lighting switch
off, and release the parking brake, the low beam headlights will
come on at a reduced brightness. This type of lighting is called “Daytime
Running Lights” or “DRL”.
When the DRL are on, a green indicator light with the DRL symbol will
be lit on the instrument panel. This is to indicate that the DRL are on.
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It will go out when the lighting switch is turned on.
The low beam lights will switch to full brightness and the exterior
lights will come on when the lighting switch is on. When the lighting
switch is off, the parking, side marker and tail lights will turn off and the
low beam lights will switch to the reduced brightness of DRL again.
Water separator indicator light
The indicator light comes on when the water level in the water
separator on the fuel line is beyond the specified level.
NOTICE: If the indicator light comes on while driving, stop the
vehicle and drain the water immediately. Refer to the “DRIVING”
section.
Service Vehicle Soon (SVS) Light
Monitors the operation of your vehicle control system. If the light
comes on while driving, it indicates that the vehicle control system
may be malfunctioning. You should take your vehicle in for servicing soon.
Oil Level Indicator Light
When the engine oil check switch is pushed with the engine
control switch “OFF”, the green oil level indicator light will come on if
the engine oil level is “OK”. The red engine oil pressure warning light will
come on if the engine oil level is low.
DPF Indicator Light (Green)
This light comes on during regeneration of the Diesel Particulate
Filter (DPF). It will go off when the regeneration is finished. The
DPF is operating normally if the indicator light comes on green when the
engine control switch is turned to the "ON" position and goes off after the
engine starts.
DPF Indicator Light (Amber/Red)
If the indicator light comes on amber or red, you must regenerate
the DPF. If the indicator changes from amber to red, the DPF
requires immediate regeneration.
If the DPF is not regenerated, the check engine malfunction indicator
will come on and engine power will be reduced.
CAUTION: While you operate the PTO (POWER TAKE-OFF) on a
vehicle fitted with a PTO, confirm that the DPF indicator light
(amber/red) does not come on.
If you continue the engine running without performing the
regeneration operation even after the red light comes on, the
check engine malfunction indicator light illuminates to indicate
that you must contact an Isuzu dealer to have the DPF repaired.
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BRAKE ALARM SYSTEM
See “Brake Booster Warning Light” above.
ANTI-LOCK BRAKE SYSTEM (ABS) Malfunction Warning Light
When the engine control switch is turned on, the indicator light
comes on for approximately 2 seconds and then goes off
automatically.
The ABS malfunction warning light comes on when there is a
problem with the ABS. Also, at this time, the “BRAKE” system warning light
comes on.
Until the ABS is fixed, you will have normal brakes, but you won't
have ABS.
The light should come on after the engine control switch is turned to
the "ON" position and, after the engine is started, blink twice and go out.
NOTICE: If the light comes on during vehicle operation, move the
vehicle to a safe spot which does not cause an obstruction to
traffic. Then take the following action:
(1) Stop the engine.
(2) Restart the engine. If the light comes on, and then goes out,
there is no problem with the ABS.
(3) Move the vehicle slowly forward. Gradually increase speed to
8MPH (13km/h). If the indicator light turns off, the ABS is normal.
If the light does not go out or comes on frequently, contact your
Isuzu dealer immediately and have the system repaired.
Cruise Main Indicator Light
The “CRUISE MAIN” indicator light will come on when the cruise
control switch is turned to the “ON” position.
Cruise Set Indicator Light
The “CRUISE SET” indicator light will come on when the cruise
control system is set to maintain a speed.
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CRUISE CONTROL
Cruise Control
Main Switch
Cruise Switch
Set Coast
Resume Accel
With cruise control, you can maintain a speed of between 30 and
75MPH (48 to 121 km/h) without keeping your foot on the accelerator
pedal. At speeds below 30 MPH (48 km/h), the cruise control does not
operate.
If you have an automatic transmission and you apply your brakes,
the cruise control will shut off.
If you have a manual transmission and you apply your brakes or
depress the clutch pedal, the cruise control will shut off.
CAUTION:
• Cruise control can be dangerous where you can’t drive safely at
a steady speed. Do not use cruise control on winding roads or in
heavy traffic.
• Cruise control can be dangerous on slippery roads. On such
roads, fast changes in tire traction can cause needless wheel
spinning, and you could lose control. Do not use cruise control
on slippery roads.
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1. OPERATION
SETTING CRUISE CONTROL
1.
2.
3.
Push the cruise control main switch “CRUISE MAIN” so that the
Cruise Main indicator light turns on.
Accelerate to your desired speed using the accelerator pedal.
Quickly turn the cruise switch to adjust to the “-SET” position and
release the cruise switch when the desired speed is reached.
The system is now set to maintain this cruise speed. The
“CRUISE SET” indicator light within the instrument panel turns on
and remains on while the cruise control system is in use.
RESUMING A SET SPEED
Should you set cruise control at a desired and then apply the brake, this
will shut off the cruise control but it does not need to be reset.
Once you are going about 30 MPH (48 km/h) or more, you can quickly turn
the cruise switch to adjust to the “+RES” position.
The vehicle will return to your chosen speed and stay there.
If you hold the switch at the “+RES” position, the vehicle will keep going
faster until you release the switch or apply the brake. So unless you want
to go faster, do not hold the switch at the “+RES” position.
INCREASING SPEED WHILE USING CRUISE CONTROL
There are two ways to go to a higher speed:
• Use the accelerator pedal to get to the higher speed. Turn the switch
to the “-SET” position, then release the switch and the accelerator
pedal. You will now cruise at the higher speed.
• Turn the cruise switch forward and adjust to the “+RES” position.
Hold it there until you get up to the speed you want, and then release
the switch. To increase your speed in very small amounts, turn to
adjust the switch to the “+RES” position quickly and release the
switch. Each time you do this, your vehicle will go about 1 MPH
(1.6km/h) faster. This operation can be performed ten times
consecutively.
REDUCING SPEED WHILE USING CRUISE CONTROL
Turn the switch to the “-SET” position until you reach the lower speed
you want, then release it.
To slow down in very small amounts, turn the switch to the “-SET”
position quickly. Each time you do this, your vehicle will go 1 MPH (1.6
km/h) slower. This operation can be performed ten times consecutively.
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PASSING ANOTHER VEHICLE WHILE USING CRUISE CONTROL
Use the accelerator pedal to increase your speed. When you take your
foot off the pedal, your vehicle will slow down to the cruise control speed
you set earlier.
USING CRUISE CONTROL ON HILLS
How well your cruise control will work on hills depends upon your speed,
load and the steepness of the hills. When going up steep hills, you may
want to step on the accelerator pedal to maintain your speed. When going
downhill, you may have to brake or shift to a lower gear to keep your speed
down. Of course, applying the brake or clutch takes you out of cruise
control. Many drivers find this to be too much trouble and do not use cruise
control on steep hills.
2. CLEARING
The cruise control system will be cancelled when any of the following
conditions apply:
1.
2.
3.*
4.*
5.*
6.*
When the brake pedal is depressed.
When the clutch pedal is depressed (manual transmission) or
when the automatic transmission is shifted to the "N" or "1st"
position.
When cruising speed is approximately 25 MPH (40 km/h) or lower.
When the cruise control main switch is turned off again.
When the key switch is turned to the "OFF" position.
When trouble develops in the system.
*: Memory speed is eliminated.
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SWITCHES AND CONTROLS
ENGINE CONTROL (KEY) SWITCH
The starting circuit, engine alarm circuits (if used) and accessory
circuits are all controlled by the engine control (key) switch. This
switch is located on the right-hand side of the steering column.
Refer to “Starting the Engine” previously in this section for
information about the Engine Control Switch.
LIGHTING CONTROL SWITCH
Check operation of all vehicle lights daily. Refer to “Steering Column
Controls” in this section.
IDLE SPEED CONTROL
The idle speed control knob is located to the left of the steering
column, mounted on a panel in the instrument panel. Engine RPM can
be increased by turning the idle speed control knob clockwise. To
return the engine to its normal idle speed, turn the idle speed control
knob counterclockwise.
CAUTION: Do not use the idle speed control knob while the vehicle
is in motion. This could reduce your ability to stop in an
emergency, possibly resulting in personal injury or death and/or
property damage.
Before the DPF regeneration, be sure to return the idling control
knob all the way to the left. Refer to "Switch regeneration" and
"Selectable regeneration procedure".
Refer to “STARTING PROCEDURE” on page 2-7 in this section for
further information on the idle speed control.
Idle Speed Control Knob
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INSTRUMENT PANEL LIGHT LEVEL CONTROL
The control will change the light level of the instrument panel.
Instrument Panel Light
Level Control
WINDSHIELD WIPER AND WASHER CONTROLS
Refer to “Steering Column Controls” earlier in this section.
OUTSIDE REARVIEW MIRROR HEATER SWITCH (IF EQUIPPED)
If the outside mirror fogs up, warm up the outside rearview mirror’s face to
defog. With the engine control switch in the “ON” position, press the outside
rearview mirror heater switch to operate, and the operation indicating light
will turn to orange. If the switch is pressed once again, it will switch to “OFF”,
and the operation indicating light will go out.
NOTICE:
• Do not use this switch while the engine is stopped. Due to high
power consumption, the battery can be discharged.
• Turn off the switch as soon as defogging is complete.
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MILES CHECK SWITCH
The “Miles Check Switch” will display the odometer and trip meter
mileages when depressed within five minutes after the key is turned off.
Also, while depressing this switch, the fuel gauge will operate to show the
fuel level in the fuel tank.
OIL CHECK SWITCH
Press the oil check switch. If the engine oil level is low, the red
engine oil pressure warning light will be turned on. If the engine oil level
is OK, the green oil level indicator light will turn on.
NOTICE: The oil level varies while the engine is running, right after
it is stopped, and on sloping ground. As a result, the "red Engine
Oil Pressure Warning Light" may light up. When checking the oil
level, press the "Oil check switch" on level ground while the
engine is cool.
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PTO (POWER TAKE-OFF) SWITCH (IF EQUIPPED)
For details about the PTO operation, refer to the separate instruction
manual provided by its maker.
CAUTION: If the optional PTO function is used for long periods of
time, make sure to regularly check the DPF indicator. Auto DPF
regeneration will not take place while the PTO function is active.
PTO Main Switch
PTO Engine Speed
Control Switch
CAUTION: In PTO mode, Cruise Set/Resume Switch can be used
exactly the same as PTO Engine Speed Control Switch. Improper
operation of these switches may cause personal injury or damage.
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DIESEL PARTICULATE FILTER (DPF)
Your vehicle has a Diesel Particulate Filter (DPF) as part of the
exhaust system to reduce vehicle emissions.
The exhaust pipe mixes air with the exhaust gas to lower its
temperature before it leaves the exhaust pipe.
Do not alter or block the airflow from the exhaust pipe. The DPF will
regenerate (self-clean) itself as part of normal operation.
The Engine Control Module (ECM) controls this function based on
several factors including amount of fuel consumed, hours of operation
and mileage.
Exhaust parts and gases become very hot when the DPF is being
regenerated.
Make sure the exhaust area is clear of material that could ignite or
burn.
CAUTION:
Parking over flammable items could allow them to touch hot
exhaust parts under your vehicle and cause them to ignite.
Do not park over papers, leaves, grass or other things that can
burn.
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The Diesel Particulate Filter (DPF) is the system which purifies
Particulate Matter (PM) in the exhaust gas. This collects PM into the
DPF and regenerates the filter (burns PM) automatically.
Always use ultra low sulfur diesel fuel. Use of low quality fuel may
adversely affect the engine parts and cause failure. Use of fuels other
than ultra low sulfur may adversely affect the engine or emission
control system and cause failure. Especially for the common rail type
engine, always use ultra low sulfur diesel fuel (15 ppm or less of sulfur
content). Refer to “DIESEL FUEL REQUIREMENT AND FUEL
SYSTEM” on page 2-3.
If fuels other than ultra low sulfur diesel fuel is used on a vehicle with
a DPF, the vehicle may not conform to emission regulations.
Do not modify the DPF or exhaust pipe.
Modification of the direction, length or diameter of the exhaust pipe
will adversely affect the exhaust gas purification system.
If modification to equipment is needed, contact your Isuzu dealer.
Automatic regeneration may not complete in some cases of
operating and driving patterns and conditions. In the event of this, the
DPF indicator (amber or red) will come on.
When the DPF indicator light lights in amber, perform regeneration
according to the Regeneration Procedures below as soon as possible.
When the DPF indicator light lights in red, perform regeneration
immediately. (This is to restore the DPF function and it is not a
malfunction.)
CAUTION: This content is to restore the function of the DPF and it
is not a malfunction.
However, the Check engine malfunction indicator light may come
on and the power output may be limited if driving or PTO (POWER
TAKE-OFF) operation is continued for a long time with the amber
or red DPF indicator on.
This is to prevent the DPF from being damaged.
When operating PTO during parking, check to ensure that the
amber or red DPF indicator on the instrument panel is not on.
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Automatic regeneration
The DPF automatically collects PM from exhaust gas into the filter,
and automatically regenerates the filter when a certain amount of PM
accumulates.
When automatic regeneration starts, the green DPF indicator in the
meter comes on.
During the idling mode when the vehicle is at a stop, the engine
speed increases and the exhaust gas control valve may be activated.
CAUTION: To prevent fire, ensure that there is no combustible
material near the muffler, the DPF or the exhaust pipe. Also, be
careful not to burn yourself on the hot exhaust gas.
NOTICE: Operating noise is emitted during automatic regeneration
and also when it is deactivated; this does not mean that a
breakdown has occurred.
During the DPF automatic regeneration, the engine speed may
increase accompanied by the action of the exhaust brake valve,
during the DPF automatic regeneration, which may occur when the
vehicle is stopped and idling; this is not a malfunction.
NOTICE: For vehicles equipped with DPF, Isuzu recommends
engine oil that supports DPF (low ash oil). Use of low ash oil
extends the maintenance interval of the DPF filter.
NOTICE: The DPF performs regeneration automatically when a
certain quantity of PM accumulates in the filter.
Depending upon running conditions, however, the regeneration
may sometimes not be completed. In this case, the DPF indicator
light (amber or red) will come on, so promptly operate the
emergency regeneration according to the "Emergency
regeneration procedure".
This operation recovers the function of the DPF. It does not
mean that a breakdown has occurred.
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Emergency regeneration procedure
If the DPF indicator light (Amber/Red) on the instrument panel turns
on, perform a regeneration operation in accordance with the following
procedures.
CAUTION: If you continue driving the vehicle without performing
regeneration, the check engine malfunction indicator light will
come on indicating that you must contact an Isuzu dealer to have
the DPF repaired.
Running regeneration
During running regeneration, in addition to the DPF indicator light
(Amber/Red), the indicator light (Green) will also turns on.
As a guideline, run the vehicle at 30MPH (48km/h) or above, and
make the accelerator pedal operation as less frequent as possible.
When the DPF indicator light (Amber/Red) and indicator light (Green)
go off, regeneration is complete.
NOTICE:
While the vehicle is at a stop with engine idling, the engine
speed increases if the shift lever is moved to the "N" position.
While the vehicle is at a stop with engine idling, regeneration
discontinues if the shift lever is moved to the "P" position and/or
the parking brake is set.
The amber DPF indicator light remains on when the green DPF
indicator light goes off until regeneration will complete.
Switch regeneration
If running regeneration is not possible, or if the vehicle brought to a
halt and parked during running regeneration, perform the following
switch regeneration.
1. Stop the vehicle in a safe place where there are no leaves, scraps
of paper or other substances that readily burn.
CAUTION: To prevent fire, ensure that there is no combustible
material near the muffler, the DPF or the exhaust pipe. Also, be
careful not to burn yourself on the hot exhaust gas.
2. Move to the gearshift lever in the "N" or "P" position, and set the
parking brake lever firmly.
3. Idle the engine.
If you used the idling control knob to increase the engine speed,
return it all the way to the left to reduce the engine speed.
4. In the case of a vehicle fitted with a PTO (POWER TAKE-OFF)
unit, stop operation of the PTO.
Return the PTO switch and the external acceleration control to
their initial positions.
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5. Press the DPF switch.
The DPF indicator light (green) comes on, the engine speed
automatically increases and the regeneration starts. Stay near the
vehicle during the regeneration.
The regeneration is normally completed in about 20 minutes.
When the DPF indicator light goes off, the regeneration is
complete, and the vehicle may be operated normally.
DPF Switch
This switch is to start the switch regeneration.
CAUTION: During regeneration, white smoke may be emitted.
Do not perform the regeneration in a poorly ventilated room.
CAUTION: When you wish to operate the PTO on a vehicle fitted
with a PTO unit for a long period, confirm that the DPF indicator
light (amber or red) is not on.
Once the emergency regeneration is started, it cannot be
switched to the running regeneration after regeneration is
discontinued.
When the emergency regeneration is selected, end regeneration
in a single operation if possible.
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NOTICE:
• The time it takes for the regeneration to complete depends upon
the external temperature.
• During DPF regeneration, the exhaust brake valve is in operation.
Operating noise is emitted while the exhaust brake valve is
operating and also when it is deactivated; this does not mean
that a breakdown has occurred.
• During the regeneration, the engine speed may temporarily
return to its initial speed, causing the exhaust brake valve to be
deactivated. However, while the DPF indicator light (green) is on,
regeneration is still taking place, so continue to perform
regeneration until the light goes off.
• White smoke may sometimes be emitted from the exhaust pipe
for a short period depending on PM combustion during
regeneration; this does not mean that a breakdown has occurred.
• Switch regeneration is completed more quickly after the vehicle
has just stopped driving, compared to when the engine is cold.
• During switch regeneration, the coolant temperature may
sometimes rise.
• When the DPF indicator light (red) is on, perform regeneration in
the same operation as switch regeneration procedure.
Interrupting switch regeneration
If you want to interrupt switch regeneration, press the DPF switch
once again.
The DPF indicator light (green) will go off and the indicator (amber or
red) will remain on, then the vehicle may be driven. In this case, it is
necessary to perform the switch regeneration once again. Repeat the
regeneration procedure from step 1 as quickly as possible.
NOTICE: Switch regeneration will be interrupted in the following
circumstances.
• Accelerator is ON.
• Gear-in (with Automatic Transmission)
• Vehicle speed is ON.
• Engine speed increases.
Operation noise caused by interruption is louder when depressing
the accelerator pedal than other operations.
This is not a failure.
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Selectable regeneration procedure
Your vehicle has the following selectable regeneration procedure in
case the driver is not able to perform the emergency regeneration for
some reasons when the DPF indicator light (amber/red) comes on.
Selectable regeneration may be performed when the engine (coolant
temperature) and exhaust pipe are warm after transport.
CAUTION: To prevent fire, ensure that there is no combustible
material near the DPF, exhaust pipe or muffler.
Be careful not to burn yourself on the hot exhaust gas.
CAUTION:
• Perform selectable regeneration without interruption.
• Stay near the vehicle during the regeneration.
1. Stop the vehicle in a safe place where there are no leaves, scraps
of paper or other substances that readily burn.
2. Idle the engine, then move the shift lever to the "N" or "P" position,
and pull the parking brake lever firmly. In the case of a vehicle
fitted with PTO (POWER TAKE-OFF) unit, confirm that operation
of the PTO has stopped.
NOTICE: If you used the idling control knob to increase the engine
speed, turn it all the way to the left to reduce the speed to normal
idling condition, and then perform the DPF regeneration.
Press until the DPF
Steady indication (amber)
indicator light comes on
(13 seconds)
Press
3. Confirm that the DPF indicator light (amber) is on for 3 seconds or
longer, then press the DPF switch again while the DPF indicator
light (amber) is on.
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NOTICE: Until a certain quantity of PM has accumulated in the DPF
filter, the DPF indicator light (amber) will go off after 3 seconds,
even if you continue to press the DPF switch. In this case, there is
no need to perform DPF regeneration, so regeneration will not start
even if you press the DPF switch.
4. The DPF indicator light (green) will come on with the DPF indicator
light (amber) remaining on, the engine speed automatically
increases, and DPF regeneration starts. Regeneration is normally
completed in about 20 minutes.
5. W h e n t h e D P F i n d i c a t o r l i g h t s ( a m b e r , g r e e n ) g o o f f , t h e
regeneration is completed, and the vehicle can be run normally.
CAUTION: During regeneration, white smoke may be emitted.
Do not perform the regeneration in a poorly ventilated room.
CAUTION: In the event that selectable regeneration is interrupted
due to the vehicle moving, for example, the DPF indicator light
(green) will go off, and the DPF indicator light (amber) will come
on. In this case, promptly stop the vehicle, press the DPF switch
again, and wait until the completion of selectable regeneration. Do
not continue to drive the vehicle while the indicator lights (amber)
remain on.
NOTICE:
• The time it takes for the regeneration to complete differs
depending upon the external temperature.
• During DPF regeneration, the exhaust brake valve operates.
Operating noise is emitted while the exhaust brake valve is
operating and also when it is deactivated; this does not mean
that a breakdown has occurred.
• White smoke may sometimes be emitted from the exhaust pipe
for a short period depending on PM combustion during
regeneration; this does not mean that a breakdown has occurred.
• Selectable regeneration is completed more quickly after the
vehicle has stopped driving than when the engine is cold.
• During selectable regeneration, the coolant temperature may
sometimes rise.
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SPEEDOMETER AND GAUGES
Tachometer
Warning/Indicator lights
Engine coolant
temperature gauge
Speedometer
Fuel gauge
A/T shift indicator
Warning/Indicator lights
(A/T shown)
Odometer and
Trip meter
Odometer and
Trip meter Knob
Odometer and Trip Meter
The odometer and the trip meter indicate mileage.
The odometer indicates total vehicle mileage, and the trip meter is
used when you want to know point-to-point distance and running
mileage reached in a certain period of time. Furthermore, the trip meter
can indicate two different point-to-point distances.
Change indicator and reset knob
Push the odometer and the trip meter knob for approximately 0.8
seconds or less, and the indicator will cycle through odometer, trip
meter A, trip meter B, and back to odometer. Continue to push the
knob for approximately 1 second or more when the meter (trip A, trip
B) is indicated, and the indicator will reset to 0 (zero). When the
battery is disconnected, trip meter A and B will be reset to 0 (zero).
With the engine control key removed, the odometer and trip meter
continue to indicate for around 5 minutes.
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1 23 4
5 6
7
8
9
10 11 4 12 13 14 15
16 17 18
4
33
19 20 21 22 23
24 25 26 27 28 29 30 31 32
1. Instrument Panel Light Level
Control
2. PTO Main Switch (If equipped)
3. PTO Engine Speed Control
Switch (If equipped)
4. Instrument Panel Vents
5. Rear body Interior Light Switch
6. Headlight Switch
Cruise Switch
7. Steering Wheel
8. Instrument Panel and Indicator
Light Panel
9. Horn Button
10. Windshield Wiper and Washer
Switch Lever
Exhaust Brake Switch Lever
11. Outside Rearview Mirror
Heater Switch (If equipped)
12. Cruise Control Main Switch
13. Rear Left Window Switch
(Crew cab model)
14. Rear Window Lock Switch
(Crew cab model)
15. Rear Right Window Switch
(Crew cab model)
16. Heater and Defroster Control
Panel
17. Card Holder
18. Beverage Holder
19. Door Lock Switch
(If equipped)
20. Miles Check Switch
Oil Check Switch
21. Idle Speed Control Knob
22. Clutch Pedal (M/T models)
23. Steering Column Adjusting
Lock Lever (Telescope/tilt)
24. Brake Pedal
25. DPF Switch
26. Accelerator Pedal
27. Hazard Lights Warning
Flasher Switch
28. Parking Brake Lever
29. Accessory Power Outlets
30. Transmission Gear Shift Lever
(M/T models)
31. Cigarette Lighter
32. Hook
33. Transmission Selector Lever
(A/T models)
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SPEEDOMETER
The speedometer is located directly in front of the steering column.
The speedometer hand indicates the vehicle speed in miles per hour
(MPH) on the outer scale and in kilometers per hour (km/h) on the
inner scale.
The odometer, located within the speedometer, records the miles
traveled up to 999,999.9 and stops, without returning to zero.
TACHOMETER
This gauge shows the engine speed in revolutions per minute (rpm).
FUEL GAUGE
The fuel gauge is located to the left of the instrument panel. The
gauge shows the approximate fuel level in the fuel tank(s).
To check the fuel level with the engine control switch in the “OFF”
position, press the “Miles check” switch.
ENGINE COOLANT TEMPERATURE (ECT) GAUGE
This gauge is located to the right of the instrument panel. If the engine
overheating warning light illuminates and the ECT gauge shows that an
overheat condition exists – as indicated by the pointer moving beyond
the white color line – immediate action by the driver is required. If an
overheat condition is shown, refer to “Engine Cooling System
Overheating” in Section 3. The ECT indicator will vary with air
temperature, vehicle load, grade of the road and other operating
conditions. The engine control switch must be on for accurate readings.
Prolonged driving or idling in very hot weather may cause the pointer to
move beyond the center of the ECT gauge. Make a practice of scanning
this and other gauges while driving, especially in hot weather and when
the vehicle is under heavy load.
CAUTION: If the ECT gauge shows an overheat condition or you
have any other reason to suspect the engine may be overheating,
continued operation of the engine (other than as explained in
Section 3) even for a short time may result in a fire and the risk of
personal injury and severe vehicle damage. Take immediate action
as outlined under “Engine Cooling System Overheating” in Section
3.
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DOME LIGHT
The dome light is located in the center of the ceiling. The switch has three
positions:
• “ON”—The light stays on regardless of the door position.
• “OFF”—The light stays off regardless of the door position.
• Between “ON” and “OFF”—The light comes on when the driver’s door is
opened.
CIGARETTE LIGHTER
The cigarette lighter is located in the right of the steering column in the
instrument panel.
To operate, push the knob in. The lighter is designed to “pop out” when the
correct temperature is reached.
ACCESSORY POWER OUTLET
Accessory power outlets are located beside the cigarette lighter in the
instrument panel. You can plug in auxiliary electrical equipment. Just flip the
outlet cover open from the left edge of the cover and follow the proper
installation instructions that are included with any electrical equipment you
install. These circuits are protected by a fuse and have maximum current
loads.
CAUTION: When using accessory power outlets, total maximum
electrical load must not exceed 120W. Always turn off any electrical
equipment when not in use.
Leaving electrical equipment on for extended periods will drain your
battery.
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HEATING AND VENTILATION SYSTEMS
CONTROLS
CAUTION: See “Engine Exhaust Gas Caution (Carbon Monoxide)”
in Section 2.
OPTIONAL AIR CONDITIONING
This system combines cooling capabilities for comfort in all weather
conditions.
During some air conditioning operating conditions, slight increases
and decreases of engine speed/power may be experienced. This
should be considered normal, as the system is designed to cycle the
compressor ON and OFF to maintain desired cooling. The reduced
compressor operation should benefit fuel economy.
1. Air Conditioning Switch.
2. Fan Control Knob.
3. Temperature Control Knob.
4. Air-source Selector Lever.
5. Air Selector Knob.
5
2
Use Bi-Level in this range
for giving cool air upward
and warm air downward.
4
1
3
1. AIR CONDITIONING SWITCH (If equipped)
Push this switch to operate the air conditioning system. The lightemitting diode in this switch lights up as the system is operating. To
turn off the air conditioning, push this switch in again.
Air conditioning will not operate without the fan control lever in one
of the “ON” positions.
2. FAN CONTROL KNOB
The fan control knob (OFF-1-2-3-4) provides speed control of the
blower fan in all Air Selector Knob positions.
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3. TEMPERATURE CONTROL KNOB
The Temperature Control Knob regulates the temperature of the air
entering the passenger compartment in all Air Selector Knob positions.
4. AIR-SOURCE SELECTOR LEVER
The intake of outside air and the circulation of inside air is controlled
by sliding this lever right or left.
Circulating only inside air for an extended period of time when the air
conditioning switch is in the “OFF” position may cause windshield
fogging. For good ventilation, switch to outside air as soon as possible.
5. AIR SELECTOR KNOB
The Air Selector Knob regulates air flow from the upper, floor and
defroster outlets.
…FACE- Air is conditioned as it passes through the system
and is discharged from the upper outlets.
This position is used for most air conditioning situations.
…BI-LEVEL- Air is conditioned and discharged from the upper
outlets and the floor outlets.
The air from the floor outlets is warmer than the air from the
upper outlets in this position.
However, when the temperature control lever is moved to
either the full “HOT” or the full “COLD” position, the air from
the floor outlets and the air from the upper outlets will be the
same temperature.
This position can give cool upper level air and warm floor
level air when the temperature control is adjusted in-between
“COLD” and “HOT”. This is useful in cool weather with bright
sunlight conditions.
…FOOT- Air is delivered from the floor outlets.
…FOOT/DEFROST 1- Air is blown out from the floor outlets
with a small amount from the windshield defroster outlets
and the side window defroster outlets.
…FOOT/DEFROST 2- Air is blown out from the floor outlets
with a larger amount than in the FOOT/DEFROST 1 above
from the windshield defroster outlets and the side window
defroster outlets.
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…DEFROST- Air is conditioned and delivered from the
windshield defroster outlets with a small amount delivered
from the side window defroster outlets. This position is
recommended for conditions of severe fogging and icing only.
To maximize defrosting operation, set the air-source selector
lever to the “Inside air” position. When the windshield is
defrosted, return the air-source selector lever to the
“Outside” position. If you keep the lever to the “Inside”
position, the windshield will tend to be foggy and disturb the
visibility.
Operating tips- The windshield defrosting and defogging system
assists in providing good visibility through critical areas of the
windshield under most inclement weather conditions. The windshield
should be scraped clear, if coated with ice or snow. When the
DEFROST mode is selected, the air conditioner compressor will be
ON.
MOBILE TELEPHONES
Mobile two-way radio units and mobile telephone equipment are
subject to federal rules and must be installed by trained personnel.
Isuzu is not responsible if add-on equipment interferes with engine
operation or picks up interference from vehicle components.
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SECTION 3
IN CASE OF EMERGENCY
HAZARD WARNING LIGHT FLASHER
Use the hazard warning light flasher to warn other drivers any time
your vehicle becomes a traffic hazard, day or night.
Avoid stopping on the roadway, if possible.
Turn on the hazard warning flashers by pushing in the switch located
on the right-hand side of the instrument panel.
The flasher will work with the engine control switch either “ON” or
“OFF” and the key removed. Right and left turn signal indicators should
flash together when the hazard flasher is turned on.
The individual turn signals do not work when the hazard flasher is
turned on.
To turn off the flasher, push the switch again.
EMERGENCY STARTING YOUR VEHICLE
DUE TO A DISCHARGED BATTERY
If your vehicle will not start due to discharged batteries, it can often
be started by using energy from another battery—a procedure called
“jump starting”.
This vehicle has a 12-volt starting system and a negative ground
electrical system. Make sure that the other vehicle also has a 12-volt
starting system, and that it is the negative (–) terminal which is
grounded (attached to the engine block, or frame rail). Its operator’s
manual may give you that information. Do not try to jump start if you
are unsure of the other vehicle’s voltage or ground (or if the other
vehicle’s voltage and ground are different from your vehicle).
Connect the positive cable from the good battery to either of the
positive terminals on the discharged batteries.
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Diesel engine vehicles have more than one battery because of the
higher torque required to start a diesel engine. This procedure can be
used to start a single-battery vehicle from any of the diesel vehicle’s
batteries. However, at low temperatures, it may not be possible to start
a diesel engine from a single battery from another vehicle.
CAUTION: Never tow the vehicle to start because a surge forward
when the engine starts could cause a collision with the tow vehicle.
Also, this vehicle has 12-volt batteries; be sure the vehicle or
equipment used to jump start your engine is also 12-volt. Use of
any other system may damage the vehicle’s electrical components.
JUMP STARTING INSTRUCTIONS
CAUTION: Batteries produce explosive gases, contain corrosive acid,
and supply levels of electrical current high enough to cause burns.
Therefore, to reduce the risk of personal injury when working near
a battery:
• Always shield your eyes and avoid leaning over a battery
whenever possible.
• Do not expose a battery to open flames or sparks.
• Be sure any batteries that have filler caps are properly filled with
fluid.
• Do not allow battery acid to contact eyes or skin. Flush any
contacted area with water immediately and thoroughly, and get
medical help.
• Follow each step in the jump starting instructions.
1.
2.
3.
4.
Position the vehicle with the good (charged) battery so that the
booster (jumper) cables will reach. But never let the vehicles touch.
Also, be sure the booster cables to be used do not have loose or
missing insulation.
In both vehicles:
• Turn off the ignition (engine control) switch and all lights and
accessories except the hazard flasher or any lights needed for
the work area.
• Apply the parking brake firmly and shift the automatic
transmission to Park or manual transmission to Neutral.
Make sure the cable clamps do not touch any other metal parts.
Clamp one end of the first booster cable to the positive (+)
terminal on the good battery. Clamp the other end either positive
terminal on the discharged battery. Never connect (+) to (–).
Clamp one end of the second cable to the negative (–) terminal of the
good (charged) battery. Make the final connection to the chassis
frame rail or to any solid, stationary metallic object on the engine at
least 18 inches from the discharged battery. Make sure the cables are
not on or near pulleys, fans or other parts that will move when the
engine is started.
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Make Connections in Numerical Order
Do Not Allow the Vehicles
To Touch
3
(-)
(+)
2
Charged
Battery
Make last connection
4
on frame away from
(+)
the battery
5.
6.
(-)
Discharged
Battery
1
Start the engine of the vehicle with the good (charged) battery.
Run the engine at a moderate speed for several minutes. Then,
start the engine of the vehicle that has the discharged battery.
Remove the jumper cables by reversing the above installation
sequence exactly. While removing each clamp, take care that it does
not touch any other metal while the other end remains attached.
ENGINE COOLING SYSTEM
OVERHEATING
CAUTION: If the Engine Coolant Temperature Gauge shows an
overheat condition or you have other reasons to suspect the
engine may be overheating, continued operation of the engine
(other than as described here) even for a short period of time may
result in a fire, and the risk of personal injury and severe vehicle
damage. Take immediate action as outlined.
If you see or hear escaping steam or have any other reason to
suspect there is a serious overheat condition, stop and park the
vehicle as soon as it is safe to do so and then turn off the engine
immediately and get out of the vehicle.
The engine cooling system may overheat if the engine coolant level
is too low, if there is a sudden loss of engine coolant (such as radiator
hose failure), or if other problems occur. It may also temporarily
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overheat during severe operating conditions such as:
• Climbing a long hill on a hot day
• Stopping after high-speed driving
• Idling for long periods in traffic
If the Engine Coolant Temperature gauge shows an overheat
condition, or you have reason to suspect the engine may be
overheating, take the following steps:
• If your air conditioner (if equipped) is on, turn it off. And turn on the
heater to help the engine expel heat.
• Pull over, stop, and park the vehicle as soon as it is safe to do so.
• Do not turn off your engine.
• Let the engine run at normal idle speed for two or three minutes.
If the engine coolant temperature does not start to drop, turn off the
engine and get out of the vehicle, then proceed as follows:
CAUTION: To help avoid being burned—
• Do not tilt the cab or open the engine access cover if you see or
hear steam or engine coolant escaping from the engine
compartment. Wait until no steam or engine coolant can be seen
or heard before tilting the cab or opening the engine cover.
• Do not remove the radiator cap or engine coolant reserve tank
cap if the engine coolant in the tank is boiling. Also do not
remove the radiator cap while the engine and radiator are still
hot. Scalding fluid and steam can be blown out under pressure if
either cap is taken off too soon.
If no steam or engine coolant can be seen or heard, tilt the cab or
open the engine access cover. If the engine coolant is boiling, wait
until it stops before proceeding. Look at the see-through reserve tank.
The engine coolant level should be between the “MAX” and “MIN”
marks on the reserve tank. If necessary, pour engine coolant (Engine
coolant is a mixture of ethylene glycol antifreeze and water. See
“Engine Cooling System” in Section 5 for the proper antifreeze and
water mixture.) into the reserve tank only, never directly into the
radiator. Also, do not check engine coolant level at the radiator.
Make sure the fan belts are not broken, or off the pulleys, and that
the fan turns when the engine is started.
If the engine coolant level in the reserve tank is low, look for leaks at
the radiator hoses and connections, heater hoses and connections,
radiator, and water pump. If you find major leaks, or spot other
problems that may have caused the engine to overheat, do not run the
engine until these problems have been corrected. If you do not find a
leak or other problem, carefully add engine coolant to the reserve tank.
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CAUTION: To help avoid being burned, do not spill antifreeze or
engine coolant on the exhaust system or hot engine parts. Under
some conditions, the ethylene glycol in engine coolant is
combustible.
If the engine coolant level in the reserve tank is at the correct level
but there is still an indication on the instrument panel of an overheat
condition:
• YOU MUST LET THE ENGINE COOL FIRST. You may then add
engine coolant directly to the radiator. See “Adding Engine Coolant”
under “Engine Cooling System” in Section 5.
Once the Engine Coolant Temperature Gauge no longer signals an
overheat condition, you can resume driving at a reduced speed. Return
to normal driving after about ten minutes if the gauge pointer does not
again show an overheat condition.
If no cause for the overheat condition was found, see a qualified
service technician.
DAMAGED TIRES
CAUTION: It is dangerous to mount the wrong size tire on a wheel. If
you do so, the tire/wheel can explode as air is being added. This
explosion may result in severe personal injury or death. To learn
which wheels and tires are correct, look at the “Vehicle Identification
Number (VIN) and Weight Rating Plate” on the left side rear pillar
panel below the striker (single cab) or on the left center pillar panel
beside the shoulder seat belt anchor (crew cab). Wheel size is also
stamped on the side of each wheel.
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CAUTION: To help avoid personal injury and property damage if a
wheel must be changed, seek expert tire services if you can. If you
must remove the wheel without any such help, do the following:
1. If the tire looks as if it may contain air under pressure, stand to
the side and check whether the wheel assembly appears normal
by comparing it to another wheel assembly on the vehicle.
2. Let the air out of the tire by taking out the valve core. If you
have a way to put air back in a tire, note that it is good safety
practice to let the air out of both tires of a dual assembly before
taking off the damaged tire and rim assembly from the vehicle.
After letting out the air, take off the tire and rim assembly and
install a spare tire and rim assembly.
If your vehicle is equipped with a differential lock system or
limited slip differential (LSD), it might start moving when the
engine power is transmitted to the rear axle even when one of
the wheels on the axle is raised clear of the ground. Do not start
the engine with any rear wheel in contact with the ground.
If you are not fully experienced on the procedures to follow,
and/or are not equipped with the proper tools and equipment,
again, do not attempt to raise the vehicle, or remove or install
the tire and wheel assembly—seek experts tire services.
3. Do not put air back in a tire that has been run flat, or is
seriously low on air, without first having the tire taken off the
wheel and the tire checked for damage.
4. Note that taking off and mounting tires on truck wheels requires
proper tools, safety equipment and special training. A person
can be severely injured or killed and damage can result from
using the wrong service methods. Truck tires and wheels
should be serviced only by trained people using the proper
equipment.
5. Never add air to your tires unless an accurate pressure gauge is
also used. When putting air in a tire on the vehicle, stand to the
side and use a clip-on chuck and hose extension. In choosing
the right tire pressure, be careful not to exceed the maximum
pressure capability shown on the tire; see the tire pressure
charts at the end of this manual.
6. Tire mounting or repair can result in serious personal injury or
death, if not performed correctly. This section has detailed
instructions for proper wheel and tire replacement, so be sure
to read and follow them.
Truck fleet owners and operators: You can get written
instructions on truck tire demounting, repair and mounting from
Rubber Manufacturers Association (RMA), 1400 K Street N.W.,
Washington, D.C. 20005, and also from many tire stores.
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WHEEL NUT TORQUE
CAUTION: Never use oil or grease on studs or nuts. Use the torque
specified for the type of wheels on the vehicle. Snug all wheel nuts
and then tighten to the specified torque in the numerical sequence
shown. Improperly tightened wheel nuts could eventually allow the
wheel to come off while the vehicle is moving, possibly causing
loss of control and personal injury and property damage.
When the vehicle, wheel or fasteners are new, have a technician
tighten wheel stud nuts and rim clamp nuts with a torque wrench
at 650 miles (1,040 kilometers). This is necessary because the
clamping system used on the wheels must seat before the fastener
will hold a uniform clamp load and remain fully tightened. Also
have a technician tighten wheel stud nuts and rim clamp nuts with
a torque wrench after installing any wheel.
In addition, nut tightness on all wheels should be set with a
torque wrench every 6,500 miles (10,400 kilometers).
WHEEL STUD NUT TORQUE
490 N·m (362 ft·lbs)
WHEEL TIGHTENING SEQUENCE
NOTICE: Some studs and nuts have left-hand threads. Those studs
are marked on their ends with the letter “L”.
Install valve stems of dual wheels 180 degrees opposite each other.
1. Finger-tighten the nuts.
2. Tighten all nuts to specified torque in order as shown. Never use oil
or grease on the studs or nuts.
3. If a wheel stud and nut has been replaced, stake the stud and nut.
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CAUTION: To help reduce the risk of losing vehicle control and
personal injury or death, if any stud has been damaged as a result
of a loose running wheel, all studs for that wheel should be
replaced. A Ioose running wheel may cause only one stud to break
but damage to other studs may not be noticeable. If stud holes in a
wheel have become elongated or distorted, replace the wheel.
TOWING YOUR ISUZU TRUCK
PROCEDURE
Proper equipment must be used to prevent damage to vehicles
during any towing. State and local laws which apply to vehicles in tow
must be followed. Vehicles should not be towed at speeds in excess of
55 MPH (88 km/h).
Connect to the main structural parts of the vehicle. DO NOT attach
to bumpers, tow hooks or brackets. Use only equipment designed for
this purpose. Follow the instructions of the wrecker manufacturer.
A safety chain system must be used.
The procedures below must be followed when towing to prevent
possible damage.
FRONT END TOWING (FRONT WHEELS OFF GROUND)
To prepare a disabled vehicle for front end towing with front wheels
raised off the ground, the following steps are necessary:
• Block the rear wheels of the disabled vehicle.
• Disconnect the driveshaft at the rear axle. Secure the driveshaft to
the frame or crossmember.
NOTICE: When towing, disconnect the driveshaft at the rear axle to
ensure the automatic transmission is not damaged.
If there is damage or suspected damage to the rear axle, remove the
axle shafts.
Cover the hub openings to prevent the loss of lubricant or entry of
dirt or foreign objects.
Place a 4” x 4” wood beam against the towing guide behind the
bumper. (If no 4” x 4” is available, then remove the bumper.) Ensure
towing chains do not come into contact with the horns or the bumper.
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1
2
1. Horns
2. Bumper (removed for towing)
After Towing
After towing the vehicle, block the rear wheels and install axle shafts
or driveshaft. Apply the parking brake before disconnecting from the
towing vehicle.
FRONT END TOWING (ALL WHEELS ON THE GROUND)
Your vehicle may be towed on all wheels provided the steering is
operable. Remember that power steering and brakes will not have
power assist. There must be a tow bar installed between the tow
vehicle and the disabled vehicle.
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Towing With All Wheels on the Ground
1.
2.
1. Bumper
2. Towing Chain
3.
3. Towing Guide
4.
5.
4. Front Axle
5. Tow Hook
To prepare a disabled vehicle for front end towing with all wheels on
the ground, the following steps are necessary:
• Block the wheels of the disabled vehicle.
• Disconnect the driveshaft at the rear axle. Secure the driveshaft to
the frame or crossmember.
NOTICE: When towing, disconnect the driveshaft at the rear axle to
ensure the automatic transmission is not damaged.
Provide wood blocking to prevent towing chains and bar from coming
into contact with the bumper.
If there is damage or suspected damage to the rear axle, remove the
axle shafts.
Cover the hub openings to prevent the loss of lubricant or entry of
dirt or foreign objects.
After Towing
After towing the vehicle, block the rear wheels and install axle shafts
or driveshaft. Apply the parking brake before disconnecting from the
towing vehicle. Check and fill rear axle with oil, if required.
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REAR END TOWING
When towing a vehicle with rear wheels raised, secure the steering
wheel to maintain straight-ahead position. Make certain that the front
axle is not loaded beyond the front axle Gross Axle Weight Rating
(GAWR) as indicated on the vehicle’s VIN and Weight Rating plate.
SPECIAL TOWING INSTRUCTIONS
1. All state and local laws regarding such items as warning signals,
night illumination, speed, etc., must be followed.
2. Safety chains must be used.
3. No vehicle should ever be towed over 55 MPH (88 km/h).
4. Loose or protruding parts of damaged vehicles should be secured
prior to moving.
5. A safety chain system completely independent of the primary lifting
and towing attachment must be used.
6. Operators should refrain from going under a vehicle which is being
lifted by the towing equipment unless the vehicle is adequately
supported by safety stands.
7. No towing operation which for any reason jeopardizes the safety of
the wrecker operator or any bystanders or other motorists should
be attempted.
FREEING THE VEHICLE
FROM SAND, MUD, SNOW AND ICE
CAUTION: Do not spin wheels faster than 20 MPH (32 km/h). Personal
injury or death and damage may result from excessive wheel
spinning, including tire, transmission and/or rear axle malfunction.
If your vehicle gets stuck in sand, mud, snow or ice, move the
gearshift lever from “Second” to “Reverse”. Apply a light pressure to the
accelerator pedal while the transmission is in gear. Remove your foot
from the accelerator and depress the brake pedal while shifting. DO
NOT RACE THE ENGINE. For best traction, avoid spinning the wheels.
USING THE ENGINE AS A BRAKE
CAUTION: To reduce the possibility of personal injury or death,
before going down a steep or long grade, reduce speed, turn on
the Exhaust Brake and shift the transmission to the next lower
gear. Try not to hold the brake pedal down too long or too often
while going down a steep or long grade. This could cause the
brakes to get hot and not work as well. As a result, the vehicle will
not slow down at the usual rate. Failure to take these steps could
result in loss of vehicle control.
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When going down a grade, the engine can be used as a brake to
slow vehicle speed, provided the transmission is shifted into a gear
which will slow the truck without overspeeding the engine.
THE ENGINE SHOULD NEVER BE ALLOWED TO EXCEED THE
GOVERNED SPEED. Supplement engine braking with vehicle service
brakes intermittently and/or shift to higher transmission gear to prevent
engine overspeed.
The exhaust brake system can also be used. This system, when
turned on, increases the amount of power absorbed by the engine
while coasting with the clutch engaged. Refer to “Exhaust Brake
System” in Section 2 for operating instructions.
STOPPING THE VEHICLE IN THE EVENT OF SERVICE BRAKE
MALFUNCTION
The exhaust brake should be turned on as soon as a service brake
malfunction is detected. This should slow the engine speed. With the
engine speed under control, and providing the grade conditions permit,
the transmission can be progressively downshifted using the exhaust
brake in each gear. Eventually the exhaust brake should slow the
vehicle to a controllable “crawl”. Stop the vehicle. The vehicle should
not be driven further until corrective measures are taken.
CAUTION: See “Engine Exhaust Gas Caution (Carbon Monoxide)”
in Section 2-1.
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CUSTOMER SATISFACTION
PROCEDURE
Your satisfaction and goodwill are important to your dealer and to
Isuzu. Normally, any problems with the sales transaction or the
operation of your Isuzu chassis, or upfitted rear body will be
resolved by your dealer’s Sales or Service Departments.
Sometimes, however, despite the best intentions of all concerned,
misunderstandings can occur. If your problem has not been
resolved to your satisfaction, we suggest you follow these steps:
STEP ONE – Discuss your problem with a member of dealership
management. Complaints can often be quickly resolved at that
level. If the problem has already been reviewed with the sales or
service manager, contact the owner of the dealership or the
General Manager.
STEP-TWO – If your problem cannot be quickly resolved by the
dealership, please contact Isuzu Commercial Truck of America
Customer Relations Department 13340 183 rd Street, Cerritos, CA
90702 in writing or call 1-866-441-9638. Our representatives will
review all available facts involved. Then, if it is felt that additional
action can be taken, our representative will further address your
concerns as soon as possible.
• Your name, address, and daytime phone number.
• The Vehicle Identification Number (VIN). This will be found on
registration or title, and on the VIN plate in the cab of the
vehicle.
• Your dealer’s name and location.
• Current mileage on the vehicle.
• Nature of the problem.
W h e n c o n t a c t i n g Isuzu Commercial Truck of America , p l e a s e
remember that your vehicle’s problem will likely be resolved at the
dealership, using the dealer’s facilities, equipment, and personnel.
Regardless of the review outcome, your contact will be
acknowledged and an explanation of our position in the matter will
be provided.
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REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect which could cause a
crash or could cause injury or death, you should immediately
inform the National Highway Traffic Safety Administration (NHTSA)
in addition to notifying Isuzu Commercial Truck of America, Inc.
If NHTSA receives similar complaints, it may open an investigation,
and if it finds that a safety defect exists in a group of vehicles, it
may order a recall and remedy campaign.
However, NHTSA cannot become involved in individual problems
between you, your dealer, or Isuzu Commercial Truck of America,
Inc.
To contact NHTSA, you may call the Vehicle Safety Hotline
toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to
http://www.safercar.gov ; or write to: Administrator, NHTSA, 1200
New Jersey Avenue, SE., Washington, DC, 20590. You can also
obtain other information about motor vehicle safety from
http://www.safercar.gov.
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SECTION 4
APPEARANCE CARE
CLEANING AGENTS
CAUTION: Follow the manufacturer’s advice whenever cleaning
agents or other chemicals are used, inside or outside the vehicle.
Some cleaners may be poisonous or flammable, and improper use
may cause personal injury or damage. When cleaning the inside or
outside of the vehicle, do not use volatile cleaning solvents, such
as acetone, lacquer thinners, enamel reducers, nail polish
removers; or such cleaning materials as laundry soaps, bleaches
or reducing agents, except as noted in the following fabric
cleaning advice on stain removal. Never use carbon tetrachloride,
gasoline, benzene or naphtha for any cleaning purpose.
Open all vehicle doors for ventilation when ANY cleaning agents
or other chemicals are used in the interior. Overexposure to some
vapors may result in a health problem that is more likely to occur
in small, unventilated spaces.
NOTICE: To avoid possible permanent discoloration of light colored
seats, DO NOT Iet materials with non-fast colors come into contact
with seat trim materials until these materials are totally dry. This
includes certain types of casual clothing, such as colored denims,
corduroys, leathers and suedes; also decorative paper, etc.
CARE AND CLEANING OF THE
INTERIOR
With the use of modern trim materials, it is VERY IMPORTANT that
you use proper cleaning techniques and cleaners. Failing to do this on
the first cleaning may result in water spots, spot rings or setting of
stains or soilage - all of which are more difficult to remove in a second
cleaning.
Dust and loose dirt that collect on interior fabric should be removed
often with a vacuum cleaner or soft bristle brush. Wipe vinyl or leather
trim regularly with a clean, damp cloth. Normal trim soils, spots or
stains can be cleaned with these cleaners.
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REMEMBER THESE BASIC STEPS BEFORE CLEANING:
1. Remove stains as quickly as possible before they become “set”.
2. Use a clean cloth or sponge, and change to a clean area often. A
soft brush may be used if stains persist.
3. Use solvent-type cleaners only in a well ventilated area: also, do
not saturate the stained area.
4. If a ring forms after spot cleaning, clean the entire area immediately.
5. Follow specific instructions on cleaner labels.
General Cleaning of Soiled or Water Spotted Fabric Type Trim With
Foam Type Cleaner
•
•
•
•
•
Vacuum the area thoroughly to remove any loose dirt.
Always clean a whole trim panel or section. Mask surrounding trim
along stitch or welt lines.
Use suds on a clean sponge. Do not brush wet suede. Do not
saturate the material or rub it harshly. Immediately after cleaning,
remove suds with a sponge and rinse with a clean wet sponge. Wipe
off remaining residue with a slightly damp absorbent towel or cloth.
Important — Immediately after wiping, force-dry the fabric with an
air hose. A heat dryer or heat lamp may be used. Use caution with
a heat dryer or lamp to help prevent damage.
When trim materials with a sheen or luster finish are dry, wipe the
fabric lightly with a soft, dry, clean cloth to restore its sheen or luster.
For suede, raise nap with dry scrub brush and vacuum to remove
any final traces of residue.
Spot Cleaning Fabric Type Trim With Solvent Type Cleaner
Before trying to remove a spot or stain from fabric, try to find out the
type and age of the spot or stain. Some spots or stains can be removed
with water or a mild soap solution (see “Removal of Specific Stains”).
Spots or stains should always be removed as soon as possible.
Some types of stains or soilage, such as lipstick, inks and grease,
are very difficult (sometimes impossible) to remove completely. When
cleaning this type of stain or soilage, be sure not to enlarge the soiled
area.
•
•
•
Gently scrape excess stain from the trim material with a clean, dull
knife or scraper. Use very little cleaner, light pressure, and clean
cloths (preferably cheesecloth). Cleaning should start at the outside
of the stain “feathering” towards the center. Keep changing to a
clean section of cloth.
When you clean a stain from fabric, immediately dry the area with
an air hose, heat dryer, or heat lamp to help prevent a cleaning ring.
(Use caution with heat dryer or lamp to help prevent fabric damage.)
If a ring forms, immediately repeat the cleaning operation over a
slightly larger area with emphasis on “feathering” towards its
center. If a ring still remains, mask off surrounding trim sections
and clean the entire soiled area with foam type cleaner.
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Removal of Specific Stains
Greasy or Oily Stains – Includes grease, oil, butter, margarine, shoe
polish, coffee with cream, chewing gum, cosmetic creams, vegetable
oils, wax crayon, tar and asphalts.
• Carefully scrape off excess stain; then use solvent type cleaner.
• Shoe polish, wax crayons, tar and asphalts will stain if left on trim;
they should be removed as soon as possible. Use care as cleaner
will dissolve them and may cause them to “bleed”.
Non-Greasy Stains – Includes catsup, coffee (black), egg, fruit, fruit
juice, milk, soft drinks, wine, vomit and blood.
• Carefully scrape off excess stain; then sponge the stain with cool
water.
• If a stain remains, use Multi-Purpose Powdered Cleaner (Foam
type) as previously described.
• If an odor lingers after cleaning vomit or urine, treat the area with a
water-baking soda solution: 5 milliliters (1 teaspoon) of baking soda
to 250 milliliters (1 cup) of lukewarm water.
• Finally, if needed, clean lightly with Fabric Cleaner (Solvent type).
Combination Stains – Includes candy, ice cream, mayonnaise, chili
sauce and unknown stains.
• Carefully scrape off excess stain; then clean with cool water and
allow to dry.
• If stain remains, clean it with Fabric Cleaner (Solvent type).
Cleaning Vinyl Trim
Ordinary soilage can be removed from vinyl or leather with warm
water and mild soap, such as saddle soap or oil soap, or an
equivalent.
• Apply a small amount of soap solution and let it soak for a few
minutes to loosen dirt; then, rub briskly with a clean, damp cloth to
remove dirt and traces of soap. This may be done several times, if
needed.
• Soilage such as tars, asphalts, shoe polish, etc., will stain if left on
trim. They should be wiped off as quickly as possible and the area
cleaned with a clean cloth dampened with solvent type vinyl leather
cleaner.
SEAT BELT CARE
CAUTION:
• Keep belts clean and dry.
• Clean safety belts only with mild soaps and lukewarm water.
• Do not bleach or dye belts since this may severely weaken them.
GLASS SURFACES
Glass surfaces should be cleaned on a regular basis. Use of glass
cleaner or a liquid household glass cleaner will remove normal tobacco
smoke and dust films sometimes caused by ingredients used in vinyls
and interior plastics.
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CLEANING OUTSIDE OF WINDSHIELD
If your windshield is not clear after using the windshield washer, or if
the wiper blade chatters when running, wax or other material may be
on the blade or windshield.
The windshield wipers on your truck can be pulled out from the
windshield to provide easier access for cleaning.
Clean the outside of the windshield with a non-abrasive cleaner.
Your windshield is clean if beads do not form when rinsing with water.
Clean the blade by wiping with a cloth soaked in a solution of onehalf water and one-half methanol alcohol. Then rinse the blade with
water.
CARE AND CLEANING OF EXTERIOR
EXTERIOR FINISH
The paint finish on your vehicle provides beauty, depth of color,
gloss retention and durability.
NOTICE: While cleaning the vehicle, do not grip the roof marker
lights to prevent damage or water leakage.
Washing Your Vehicle
The best way to preserve your vehicle’s finish is to keep it clean by
washing it often. Wash the vehicle in lukewarm or cold water.
Do not use hot water or wash your vehicle in the direct rays of the
sun. Do not use strong soap or chemical detergents. All cleaning
agents should be flushed promptly from the surface and not allowed to
dry on the finish.
Isuzu vehicles are designed to operate under normal environmental
conditions to withstand natural elements. However, unusual conditions
such as high-pressure car washers may cause water to enter inside
the vehicle.
Polishing and Waxing
Periodic polishing and waxing is recommended to remove built-up
residue and eliminate any “weathered” appearance.
Your authorized dealer offers several polishes and cleaners which
have proven value in maintaining original finish appearance and
durability.
Protecting Exterior Bright Metal Parts
Bright metal parts should be cleaned regularly to keep their luster.
Washing with water is all that is usually needed.
Use special care with aluminum trim. To avoid damaging protective
trim, never use auto or chrome polish, steam or caustic soap to clean
aluminum. A coating of wax, rubbed to a high polish, is recommended
for all bright metal parts.
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WEATHERSTRIP LUBRICATION
All weatherstrips should be periodically lubricated (minimum of every
six months) with a silicone grease lubricant. A thin film of silicone
grease lubricant should be applied using a clean cloth. Silicone grease
application will lengthen weatherstrip life, help sealing, and assist in
eliminating squeaks.
CORROSION PROTECTION
Your vehicle has been designed and built to resist corrosion. Special
materials and protective finishes were used on most parts of your
vehicle when it was built to help maintain good appearance, strength,
and reliable operation. However, some parts which normally are not
visible (such as those under the vehicle and under the hood) are such
that surface rust will not affect their reliability. So corrosion protection
is not needed or used on these parts.
Sheet Metal Damage
If your vehicle is damaged and requires sheet metal repair or
replacement, make sure the body repair shop applies anti-corrosion
material to the parts repaired or replaced so that corrosion protection
is restored. (Also see “Finish Damage” which follows.)
Foreign Material Deposits
Calcium chloride and other salts, ice-melting agents, road oil and tar,
tree sap, bird droppings, chemicals from industrial chimneys and other
foreign matter may damage vehicle finishes if left on painted surfaces.
Prompt washing may not completely remove all of these deposits.
Other cleaners may be needed. When using chemical cleaners, be
sure they are safe for use on painted surfaces.
Finish Damage
Any stone chips, fractures or deep scratches in the finish should be
repaired promptly. Bare metal will corrode quickly and may develop
into major repair expense.
Minor chips and scratches can be repaired with touchup materials
available from your authorized dealer or other service outlets. Larger
areas of finish damage can be corrected in your dealer’s body and
paint shop.
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UNDERBODY MAINTENANCE
Corrosive materials used for ice and snow removal, and dust control
can collect on the underbody. If these materials are not removed,
accelerated corrosion (rust) can occur on underbody parts such as fuel
lines, frames, floor pan and exhaust system even though they have
been provided with corrosion protection.
At least every spring, flush these materials from the underbody with
plain water. Take care to clean well any areas where mud and other
debris can collect. Sediment packed in closed areas of the frame
should be loosened before being flushed. If desired, your authorized
dealer can do this for you.
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Page 1
SECTION 5
SERVICE AND MAINTENANCE
Your authorized dealer has factory trained technicians and Genuine
Isuzu Parts to service your vehicle properly. For expert advice and
quality service, see your authorized dealer.
Vehicle Data Collection
Your vehicle, like other modern motor vehicles, has a number of
sophisticated computer systems that monitor and control several
aspects of the vehicle's performance. Your vehicle uses onboard
vehicle computers to monitor emission control components to
optimize fuel economy and, if so equipped, to provide anti-lock
braking and to help the driver control the vehicle in difficult driving
situations.
Some information may be stored during regular operations to
facilitate repair of detected malfunctions.
Isuzu may download and retrieve stored information for the
purpose of diagnosing, servicing or repairing your motor vehicle or
for improvement to future Isuzu motor vehicles.
OWNER MAINTENANCE
CAUTION: To help avoid personal injury, take care when doing any
maintenance or making any check or repair. Follow manufacturer’s
instructions for all materials used during service and maintenance
of this vehicle. If used or handled improperly, they may be
hazardous. Improper or incomplete service can also affect the
vehicle and result in personal injury, or damage to the vehicle or
its equipment. If you have any questions about carrying out some
service, have the work done by a skilled technician.
MAINTENANCE SCHEDULE
The Maintenance Schedule in this manual and a Warranty
Information Booklet are supplied with your vehicle. Read all
publications for a full understanding of your vehicle’s maintenance
needs.
The quality of maintenance your new vehicle receives is as important
as the regularity with which it is serviced. Isuzu, in cooperation with
authorized dealers, provides nationwide quality in customer service.
The program includes the training of dealer technicians at Training
Centers throughout the country and is supported with a continuous
follow-up of publications, films and other service information. The use
of genuine Isuzu parts and accessories, which have the same high
quality standards as original equipment parts, and the use of factory
approved tools developed and tested for use by the authorized dealer
also contribute to the high quality of service.
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Page 2
If you have any questions on how to keep your truck or chassis in
good condition, see your authorized dealer, the place many Isuzu truck
owners choose to have their maintenance work done. Your authorized
dealer can be relied upon to use proper parts and practices.
Some of these services can be complex, so unless you are
technically qualified and have the necessary equipment, you should let
your authorized dealer’s service department or another qualified
service center do these jobs.
CAUTION: Performing maintenance work on a truck or chassis can
be dangerous. In trying to do some jobs, you can be seriously
injured. Do your own maintenance work only if you have the
required know-how and the proper tools and equipment for the job.
If you have any doubts, have a qualified technician do the work.
The schedule includes general maintenance which you or a qualified
technician should perform periodically.
EXPLANATION OF VEHICLE
MAINTENANCE AND LOG
The following is a brief explanation of normal vehicle use.
NORMAL VEHICLE USE—The maintenance instructions contained in
this section are based on the assumption that your vehicle will be used
as designed:
• To carry passengers and cargo with the limitations indicated on the
vehicle VIN and GVW plate.
• On reasonable road surfaces within legal operating limits.
• On a daily basis, as a general rule, for at least several miles/kilometers.
Unusual operating conditions, such as driving in dusty areas (sweeper,
agricultural or off-road vehicles), extended idling (refrigeration vehicles),
or vehicles operated for frequent short trips, will require more frequent
vehicle maintenance.
The log groups items according to mile/kilometer service intervals.
Use the item codes (letter and number) to find the description of the
maintenance and the time intervals. Follow whichever interval comes
first, time or miles/kilometers.
After the maintenance services are performed, insert the month, day
and mileage/kilometers in the area provided next to the serviced item.
The services shown up to 110,000 miles (176,000 kilometers) are to
be repeated after the initial 110,000 miles (176,000 kilometers) at the
same intervals.
5-2
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Page 3
PREVENTIVE MAINTENANCE
As any mechanical device operates, a certain amount of wear
occurs. The amount of wear depends on certain variables – type and
method of operation and the schedule of maintenance. These variables
may be emphasized as critical to malfunction but each is dependent
upon the other. For example, if a vehicle is repeatedly overloaded,
driven at excessive speed or improperly shifted, no schedule of
maintenance can prevent malfunction. Also, if a preventive
maintenance schedule is not followed, or is improperly carried out, no
amount of correct vehicle operation will prevent malfunction. If vehicle
application, operation and preventive maintenance schedules and
procedures are followed and properly carried out, the life of the vehicle
will be greatly extended. For example, regular attention to the engine
oil is essential. The oil level must be periodically checked and oil
added whenever needed. Also, the oil should be changed at the
intervals specified with the proper quality and viscosity of oil. If your
engine should run excessively low on oil or if the oil has lost its
lubricating qualities because of old age, serious engine damage could
occur – damage that would not be covered under the New Vehicle
Warranty.
5-3
Item
Engine Noise Check
Valve Lash
Engine Oil & Oil Filter *1
Fuel Filter / Water Separator
Air Cleaner Filter
Air Intake system
Drive Belts
Engine Bolt Torques
Rotate Tires
Engine Cooling System
32,000 20,000
16,000 10,000
24,000 15,000
5-4
I
I
R
R
R
R
R
I
R
R
I
I
I
I
I
I
I
I
I
Every 6,500 miles (10,400 km)
I
I
I
I
I
I
I
I
R
72,000 45,000
I
I
R
120,000 75,000
I
R
R
I
I
I
I
I
A
R
R
168,000 105,000
I
48,000 30,000
R
64,000 40,000
R
80,000 50,000
R
96,000 60,000
I
112,000 70,000
I
A
R
128,000 80,000
I
144,000 90,000
I
160,000 100,000
I
I
I
R
I
176,000 110,000
I
or every 12 months
or every 12 months
or every 12 months
or every 12 months
indicator
*
Service Intervals
Months or Miles
(kilometers)
whichever
occurs first
*
*
2008.12.5 11:46 AM
(I): Inspect, replace or adjust if necessary (A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate (C): Clean
* In case this column is blank, follow miles (kilometers).
*1 When recommended oil is used, it conforms to this maintenance schedule.
Recommended oil: CJ-4 (API DESIGNATIONS) with viscosity W40.
Use of oils other than CJ-4 may require shorter maintenance intervals and may cause inconformity to regulations. Use of oils with
other viscosity than W-40 may also require shorter maintenance intervals and may cause a problem in engine durability.
No.
1
2
3
4
5
6
7
8
9
10
Interval (Miles)
Interval (kilometers)
Maintenance Schedule for the NPR-HD, NQR, NRR (Cont.)
58447_Sec05-1_'10
Page 4
5-5
72,000 45,000
24,000 15,000
(R): Replace
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
I
A
I
C
(T): Tighten to specified torque
I
I
I
I
R
120,000 75,000
(A): Adjust
I
R
I
I
I
168,000 105,000
(I): Inspect, replace or adjust if necessary
16,000 10,000
I
I
32,000 20,000
I
I
I
I
I
48,000 30,000
I
I
80,000 50,000
I
96,000 60,000
16
17
18
19
20
I
112,000 70,000
I
128,000 80,000
R
I
144,000 90,000
R
I
160,000 100,000
I
64,000 40,000
R
I
(C): Clean
or every 12 months
or every 12 months
or every 12 months
or every 12 months
or every 3,000 hours
or every 3,000 hours
or every 3,000 hours
(L): Lubricate
I
I
I
I
I
I
or every 24 months
Service Intervals
Months or Miles
(kilometers)
whichever
occurs first
2008.12.5 11:46 AM
15
Interval (Miles)
Item
Engine Coolant
Exhaust System
DPF (Clean filter)
DPF
(Pressure difference sensor 0 point adjustment)
DPF
(Pressure difference sensor hose)
Fuel Line System
Brake Lining and Pad for Wear
Brake Drum and Rotor for Wear and Damage
Brake Electric Vacuum Pump
Brake Fluid
176,000 110,000
14
No.
11
12
13
Interval (kilometers)
Maintenance Schedule for the NPR-HD, NQR, NRR (Cont.)
58447_Sec05-1_'10
Page 5
Item
Hydraulic Brake Booster Fluid
Brake Line and Hoses
Clutch Fluid
Clutch Pedal Free Travel
Manual Transmission Oil
Automatic Transmission Fluid
External Automatic Transmission Filter
Differential Gear Oil
Power Steering Fluid
32,000 20,000
24,000 15,000
16,000 10,000
5-6
I
72,000 45,000
I
R
I
R
R
R
R
R
I
I
I
I
I
I
(T): Tighten to specified torque
I
120,000 75,000
(R): Replace
I
I
I
I
I
R
168,000 105,000
(A): Adjust
I
64,000 40,000
I
80,000 50,000
I
I
I
I
112,000 70,000
R
I
R
R
R
R
R
128,000 80,000
I
I
I
I
I
160,000 100,000
I
I
I
I
48,000 30,000
R
I
R
I
R
R
R
R
R
96,000 60,000
I
I
I
I
I
144,000 90,000
R
(C): Clean
or every 24 months
or every 12 months
or every 12 months
or every 12 months
or every 24 months
or every 12 months
or every 24 months
or every 24 months
or every 24 months
(L): Lubricate
I
I
I
I
I
176,000 110,000
I
I
I
I
I
Service Intervals
Months or Miles
(kilometers)
whichever
occurs first
2008.12.5 11:46 AM
(I): Inspect, replace or adjust if necessary
No.
21
22
23
24
25
26
27
28
29
Interval (Miles)
Interval (kilometers)
Maintenance Schedule for the NPR-HD, NQR, NRR (Cont.)
58447_Sec05-1_'10
Page 6
Item
Power Steering Oil Hose
Steering Gear Box Torque
Driveshaft Flange Torque
Driveshaft Lubricate
Leaf Spring U-Bolt Torque*
Wheel Nut Torque*
King Pin
Wheel Bearing Grease**
Air Conditioner Blower Filter
T
L
T
32,000 20,000
L
T
L
T
L
128,000 80,000
120,000 75,000
112,000 70,000
96,000 60,000
80,000 50,000
72,000 45,000
64,000 40,000
16,000 10,000
5-7
L
R
T
L
T
144,000 90,000
L
R
T
T
L
T
160,000 100,000
R
T
T
T
T
T T T
T
L
L L L
L
T
T T T
T
Every 6,500 miles (10,400 km)
L
L L L
L
R
Cleaned once a month
168,000 105,000
24,000 15,000
(C): Clean
or every 12 months
or every 12 months
or every 24 months
or every 12 months
or every 12 months
or every 12 months
(L): Lubricate
L
T
L
T
176,000 110,000
L
R
48,000 30,000
T
T
L
T
Service Intervals
Months or Miles
(kilometers)
whichever
occurs first
2008.12.5 11:46 AM
(I): Inspect, replace or adjust if necessary (A): Adjust (R): Replace (T): Tighten to specified torque
Remarks; *Initial torque check at 650 miles (1,040 km) is required.
**Be sure to discard used grease seal, and always use new grease seal for installation.
No.
30
31
32
33
34
35
36
37
38
Interval (Miles)
Interval (kilometers)
Maintenance Schedule for the NPR-HD, NQR, NRR
58447_Sec05-1_'10
Page 7
58447_Sec05-1_'10
2008.12.5 11:46 AM
Page 8
RECOMMENDED FLUIDS AND LUBRICANTS
FLUIDS/LUBRICANTS
USAGE
Engine Oil
Quality recommended CJ4 (API designation).
To determine the viscosity required W-40
for your vehicle’s diesel engine, see
“CHOOSING OIL VISCOSITY” on page 5-23.
SAE 5W-30 SF below 90°F (32°C) or SAE 40
engine oil above 90°F (32°C)
Genuine ISUZU SCS Transmission Fluid.
(Do not use DEXRON®-III)
ATF DEXRON®-III
*
Manual Transmission Oil
Automatic Transmission
Fluid
Power Steering Fluid
Hydro Brake Booster Fluid
(NQR, NRR models)
Rear Axle
Multi purpose gear oil SAE90 GL-5
Rear Axle
Multi purpose gear oil SAE90 GL-5 for limited
(Limited slip differential)
slip differential together with limited slip
differential lubricant additive (Part No.
8-01052-358-0) or equivalent.
Multi purpose grease with high temperature,
Chassis Lubricant
good quality, lithium soap, extreme pressure
grease.
Petroleum Jelly (outer surfaces)
Battery Terminals
Brake fluid DOT 3 or equivalent
Brake and Clutch Fluid
A semi-fluid grease having extreme pressure
Cab-Door Hinges and
properties and containing zinc oxide
Latches Lubricant
(Lubricant or equivalent)
Mixture of water and good quality ethylene
Engine Coolant
glycol base type anti-freeze conforming to
Isuzu Factory Fill Long Life Coolant Part
No.2-90531-809-0
Washer solvent
Windshield Washer
Solvent
NLGI #1 or #2 multi-purpose type grease
Driveshaft, Universal
Joints and Sliding Sleeve
Lubricant
NLGI #2 or #3
Driveshaft Center
Bearing, When Hub
Bearing Lubricant
5-8
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Page 9
EXPLANATION OF COMPLETE
VEHICLE MAINTENANCE SCHEDULE
The following is a brief explanation of each of the services listed in
the preceding Complete Vehicle Maintenance Schedule.
NORMAL VEHICLE USE
The owner’s maintenance instructions in the Maintenance Schedule
are based on the assumption that your vehicle will be used as designed:
• to carry passengers and cargo within the limitations specified on
the tire placard.
• to be driven on reasonable road surfaces within legal operating limits.
• to be driven on a daily basis, as a general rule, for at least several
miles/kilometers; and
• to be driven with proper fuel (See Section 2 for details).
Unusual operating conditions, such as driving in dusty areas (sweeper,
agricultural or off-road vehicles), extended idling (refrigeration vehicles),
or vehicles operated for frequent short trips, will require more frequent
vehicle maintenance.
1. ENGINE NOISE — These components have an effect on the
control of noise emissions.
Engine (Every 10,000 miles
or 16,000 km)
Cooling system (Every
10,000 miles or 16,000 km)
Air intake system (Every
30,000 miles or 48,000 km)
Exhaust system (Every
10,000 miles or 16,000 km)
Cab (Every 10,000 miles or
16,000 km)
Inspect sound absorption materials for
tears, broken out sections or attachment.
Repair or replace as necessary.
Inspect fan, shroud and radiator for
attachment, tears or cleanliness. Repair or
replace as necessary.
Inspect all ducts, hoses and intake
silencers for leaks or chafing. Repair or
replace as necessary.
Inspect silencer, pipes, gaskets, clamps
and mounting for exhaust gas leaks or
looseness. Repair or replace as necessary.
Inspect sound absorption materials for
tears, broken out sections or attachment.
Repair or replace as necessary.
2. VALVE LASH — Incorrect valve clearance will result in increased
engine noise and lower engine output, thereby adversely affecting
engine performance. Retorque rocker shaft bracket nuts before
checking and adjusting valve clearance. Check and adjust valve
clearance every 50,000 miles (80,000 km).
5-9
58447_Sec05-1_'10
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Page 10
3. ENGINE OIL AND OIL FILTER — Change at interval noted below
depending upon driving conditions.
• NORMAL SERVICE — Change every 10,000 miles (16,000 km)
or 12 months whichever occurs first.
• SEVERE SERVICE — Change every 5,000 miles (8,000 km) or 3
months if you often drive under one or more of these conditions
(a) driving in dusty areas, (b) frequent idling or idling for long
periods, (c) driving 4 miles (6 km) or less in freezing weather, or
other short trips in cold weather, where the engine does not
thoroughly warm up. Change oil and filter as soon as you can
after driving in a dust storm.
When recommended oil is used, it conforms to this maintenance
schedule.
(Recommended oil: CJ-4 (API DESIGNATIONS))
4. FUEL FILTER/WATER SEPARATOR — Replace the fuel filter
every 15,000 miles (24,000 km) or more frequently if clogged. Drain
water from the water separator every 15,000 miles (24,000 km).
5. AIR CLEANER FILTER — The level of dirt in the air cleaner
element can be checked against the indicator.
Your dealer or service facility can be of assistance in determining
the proper replacement frequency for the conditions under which
you operate your vehicle.
6. AIR INTAKE SYSTEM — Check if air cleaner hoses and ducts are
connected and correctly installed every 30,000 miles (48,000 km).
7. DRIVE BELTS — Check belt driving the fan, generator or A/C
compressor every 10,000 miles (16,000 km). Look for cracks, fraying,
wear, and proper tension.
8. ENGINE BOLT TORQUES — Loosened bolts result in lower engine
output. Check and adjust manifold mounting, and injectors to
correct torque every 50,000 miles (80,000 km).
Specified tightening torque
INTAKE/EXHAUST MANIFOLD BOLTS
24/34 N·m
(17/25 ft·lbs)
INJECTOR FLANGE NUT
30 N·m
(22 ft·lbs)
9. ROTATE TIRES — To equalize wear, rotate tires as shown in the
figure and adjust tire pressures every 6,500 miles (10,400 km).
5-10
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2008.12.5 11:46 AM
Page 11
10. ENGINE COOLING SYSTEM — At 12 months or 10,000 miles
(16,000 km) intervals, wash radiator cap and filler neck with clean
water, pressure test system and radiator cap for proper pressure
holding capacity, tighten hose clamps and inspect condition of all
cooling and heater hoses. Replace hoses if cracked, swollen or
otherwise deteriorated.
Also each 12 months or 10,000 miles (16,000 km), clean exterior
of radiator core.
11. ENGINE COOLANT — Every 24 months or 30,000 miles (48,000
km), drain the engine coolant by opening the drain plug at the
bottom of the radiator core, flush and refill the engine cooling
system with a new 50/50 water / ethylene glycol solution.
12. EXHAUST SYSTEM — Check the complete exhaust system every
10,000 miles (16,000 km). Check body areas near the exhaust
system. Look for broken, damaged, missing, or out-of-position
parts. Also inspect for open seams, holes, loose connections, or
other conditions which could cause heat build-up at the rear body
floor pan, or could let exhaust fumes seep into the passenger
compartment. Dust or water in the cabin may indicate a leak in that
area. Required repairs should be made at once.
13. DPF(Clean Filter) — Clean the filter every 100,000 miles (160,000
km) or 3,000 hours whichever occurs first.
14. DPF(Pressure Difference Sensor 0 Point Adjustment) — Adjust
the sensor every 100,000 miles (160,000 km) or 3,000 hours
whichever occurs first.
15. DPF(Pressure Difference Sensor Hose) — Inspect the sensor
hose every 100,000 miles (160,000 km) or 3,000 hours whichever
occurs first.
16. FUEL LINE SYSTEM — Inspect the fuel tank, cap and lines for
damage which could cause leakage every 10,000 miles (16,000
km). Inspect fuel cap for correct sealing ability and indications of
physical damage. Replace any damaged or malfunctioning parts.
17. BRAKE LINING AND PAD FOR WEAR — Check drum brake lining
and disc brake pad for wear or cracks every 10,000 miles (16,000
km). Check brakes (including parking brake) more often if
operating conditions or driving habits result in frequent braking.
Front disc brakes have built-in wear noise indicators which are
designed to make a high pitched squeal or cricket-like warning
sound when the brake pads are worn to the point where new pads
are needed.
When the truck is in motion, the sound may be constant or it may come
and go. Pressing the brake pedal firmly may cause the sound to stop.
Have the brake linings or the brake pads replaced by your
authorized dealer as immediately as possible after the warning first
becomes evident.
Failure to do so can result in expensive damage to the brake
system or a serious accident.
5-11
58447_Sec05-1_'10
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Page 12
18. BRAKE DRUM AND ROTOR FOR WEAR AND DAMAGE — Check
brake drums (rear and parking) and rotors (front) for wear or
damage every 20,000 miles (32,000 km) or 12 months whichever
occurs first.
19. BRAKE ELECTRIC VACUUM PUMP (NPR-HD model) — Inspect
the brake electric vacuum pump operation every 10,000 miles
(16,000 km) or 12 months, whichever occurs first.
How to check: This operation could be difficult and you may choose
to have this done at your Isuzu dealer Service Department.
1. Turn the starter switch to the “ON” position (not to start the
engine), and depress the brake pedal several times.
2. Check for the noisy sound of the electric vacuum pump inside
the instrument panel at the same time as vacuum warning
buzzer sound, and check that the brake low vacuum warning
light comes on.
3. Then, after you start the engine, the main vacuum pump driven
by the engine will start running. If the electric vacuum pump
operation (noisy sound) and the vacuum warning buzzer stop,
and the brake low vacuum warning light goes off thereafter, the
operation is normal.
4. If you cannot hear the noisy sound of the electric vacuum pump,
check the electrical wiring and repair as necessary. If it cannot
be repaired, replace the electric vacuum pump.
20. BRAKE FLUID — Check the fluid in the brake fluid reservoir every
10,000 miles (16,000 km). Replace the fluid every 30,000 miles
(48,000 km).
The brake fluid reservoir is also used as the clutch fluid reservoir.
21. HYDRAULIC BRAKE BOOSTER FLUID (NQR, NRR models) —
Replace ATF Dexron ®-III fluid every 24 months or 30,000 miles
(48,000 km), whichever occurs first.
22. BRAKE LINE AND HOSES — Check lines and hoses for proper
hook-up, binding, leaks, cracks, chafing, etc. every 20,000 miles
(32,000 km). Any questionable parts should be replaced or
repaired at once. When rubbing or wear is noted on lines or hoses,
the cause must be corrected at once.
23. CLUTCH FLUID — Check the fluid in the clutch fluid reservoir
every 10,000 miles (16,000 km). Replace the fluid every 30,000
miles (48,000 km).
The clutch fluid reservoir is also used as the brake fluid reservoir.
24. CLUTCH PEDAL CONTROL — Check lines and hoses for proper
hook-up, binding leaks, cracks, chafing, etc. every 10,000 miles
(16,000 km). Any questionable parts should be replaced or
repaired.
25. MANUAL TRANSMISSION OIL — Replace lubricant every 30,000
miles (48,000 km). Check lubricant level every 10,000 miles
(16,000 km), and add lubricant to level of filler hole if necessary.
5-12
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Page 13
26. AUTOMATIC TRANSMISSION FLUID AND FILTER — Check the
automatic transmission fluid level at each engine oil change and
replace fluid and external filter every 30,000 miles (48,000 km). Do
not overfill.
27. EXTERNAL AUTOMATIC TRANSMISSION FILTER — Replace
external filter every 30,000 miles (48,000 km).
28. DIFFERENTIAL GEAR OIL — Replace lubricant every 30,000
miles (48,000 km). Check lubricant level every 10,000 miles
(16,000 km) or every 12 months, and add lubricant to within 0 to 10
mm (0 to 0.4 inch) of the bottom edge of the filler hole if necessary.
29. POWER STEERING FLUID — Replace power steering fluid every
24 months or 30,000 miles (48,000 km), whichever occurs first.
30. POWER STEERING OIL HOSE — Replace power steering oil hose
every 24 months or 50,000 miles (80,000 km), whichever occurs first.
31. STEERING GEAR BOX TORQUE — Retighten the attaching bolts
of the steering gear box to the specified torque every 12 months or
every 20,000 miles (32,000 km) whichever occurs first.
Specified tightening torque
STEERING GEAR BOX
103 N·m
(76 ft·Ibs)
32. DRIVESHAFT FLANGE TORQUE — Check the fixing bolts of
driveshaft flange for looseness or damage after the first 10,000
miles (16,000 km).
Specified tightening torque
DRIVESHAFT FLANGE
103 N·m
(76 ft·Ibs)
33. DRIVESHAFT — Lubricate the grease fitting on each universal
joint and spline coupling every 12 months or 10,000 miles (16,000
km) whichever occurs first.
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Page 14
34. LEAF SPRING U-BOLT TORQUE — Tighten the U-Bolt nuts to the
specified torque after the first 650 miles (1,040 km), thereafter
every 10,000 miles (16,000 km).
Specified tightening torque
LEAF SPRING U-BOLT
NPR-HD
NQR, NRR
Front
127 N·m
196 N·m
(94 ft·Ibs)
(145 ft·Ibs)
Rear
177 N·m
(131 ft·Ibs)
284 N·m
(209 ft·Ibs)
35. WHEEL NUT TORQUE — Check tires for excessive or abnormal
wear, or damage. Also check tire inflation pressures and adjust.
Be sure wheels are not bent or cracked and that wheel nuts have
been tightened to the specified torque after the first 650 miles
(1,040 km) and then every 6,500 miles (10,400 km). Note that there
are left and right hand threads.
Specified tightening torque
490 N·m
(362 ft·Ibs)
36. KING PIN — Lubricate the grease fitting on the king pins every 12
months or 10,000 miles (16,000 km) whichever occurs first.
37. WHEEL BEARING GREASE — Clean and repack front wheel
bearings every brake relining or 30,000 miles (48,000 km)
whichever comes first.
38. AIR CONDITIONER BLOWER FILTER — The air conditioner
blower filter should be removed and cleaned once a month.
Remove the 2 fasteners and 5 clips securing the panel and remove
the filter.
Use a vacuum cleaner to remove all dust and dirt adhering to the
filter surface.
• Do not use a stiff brush to clean the air conditioner blower filter.
Damage to the filter will result.
Filter (Inside)
Filter (Outside)
Fastener
5-14
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Page 15
OWNER SAFETY AND ROUTINE
MAINTENANCE
Listed below are vehicle checks which should be made periodically
by either the owner or a qualified technician to ensure proper
performance and safety of your vehicle. Take any problems promptly
to a technician for service advice.
For your safety and that of others, any of the safety-related
components that may have been damaged in an accident should
be checked and necessary repairs performed before operating
your vehicle.
At the minimum, these routine checks should be made every 6 months
or 10,000 miles (16,000 km), whichever comes first. Whenever repairs
are necessary, have them completed before operating the vehicle.
A
PARKING BRAKE — Park on a fairly steep hill and hold the vehicle
with the parking brake only. This checks holding ability.
Before checking item (B) below, be sure to have enough room
around the vehicle. Then firmly apply both the parking brake (see
“Parking Brake” Section 2 for procedure) and the regular brakes. Do
not use the accelerator pedal. If the engine starts, be ready to turn
off the ignition/engine control switch at once. Take these precautions
because the vehicle could move without warning and possibly cause
injury or property damage.
B
STARTER SAFETY SWITCH (A/T models) — Check by trying to
start the engine in each gear. The starter should crank only at
selector position “P” or “N”.
C
TRANSMISSION SHIFT INDICATOR (A/T models) — Check that the
indicator points to the gear chosen.
D
STEERING — Be alert for any changes in steering action. An
inspection or service is needed when: the steering wheel is harder to
turn or has too much free play, or when there are strange sounds
when turning or parking.
E
WHEEL ALIGNMENT, BALANCE, AND TIRES — Check tires for
abnormal wear or damage. Also, check for damaged wheels. A pull
right or left on a straight and level road may show the need for a
wheel alignment. A vibration of the steering wheel or seat at normal
highway speeds may mean a wheel balancing is needed. Check tire
pressure when the tires are “cold,” at least monthly, and whenever
the vehicle is serviced.
Check the pressure more often if daily checks show it’s needed.
(Refer to Driver daily checklist in Section 1.) Change tire pressure as
needed when changing loads.
5-15
58447_Sec05-1_'10
F
2008.12.5 11:46 AM
Page 16
BRAKES — Be alert to illumination of the brake warning light or brake
low vacuum warning light (NPR-HD model) or brake booster warning
light (NQR, NRR models), or the tone alarm, or changes in braking
action, such as repeated pulling to one side, unusual sounds when
braking, increased brake pedal travel or harder pedal. The front and
rear brakes are attached to an auto adjuster mechanism. If there are no
defects, as the pedal travel is properly maintained, adjustments are not
necessary. Check regularly that the brake fluid reservoir (left-hand side
of the instrument panel) or hydraulic brake booster reservoir (NQR,
NRR models: left side behind the cab) is properly filled and check for
fluid leaks. Any of these conditions could indicate the need for brake
system inspection and/or service.
G EXHAUST SYSTEM — Be alert for any changes in the sound of the
exhaust system or any smell of fumes. These are signs the system
may be leaking. Have it checked and/or repaired at once. (Refer to
“Engine Exhaust Gas Caution (Carbon Monoxide)” in Section 2-1.)
H
WINDSHIELD WIPERS AND WASHERS — Check operation and
condition of the wiper blades. Check the flow of the washer spray.
l
DEFROSTER — Turn the control lever to “Defrost” and the fan lever
to the fully clockwise position. Then check the airflow from the ducts
at the inside base of the windshield.
J
REARVIEW MIRRORS AND SUN VISORS — Check that friction
joints hold mirrors and sun visors in place.
K
HORN — Sound the horn, now and then, to be sure it works.
L
LAP-SHOULDER BELTS — Check the seat belt system (including
webbing, buckles, latch plates and anchors) for proper operation,
and for damage.
M SEAT ADJUSTERS — When adjusting the driver’s manual seat, be
sure the seat adjusters latch by pushing the seat forward and backward.
Do not attempt to adjust the seat when the vehicle is in motion.
N
LAMPS — Check panel lighting, warning lamps, indicator lamps and
interior lamps. On the outside, check: license plate lamps, side
marker lamps, reflectors on outside mirrors, headlamps, parking
lamps, identification and clearance lamps, taillights, brake lamps,
turn signals, cornering lamps, backup lamps and hazard warning
flashers.
Have headlamp aim checked immediately if beams seem improperly
aimed.
O GLASS, MIRRORS, LIGHTS AND/OR REFLECTORS CONDITION
— Look for broken, scratched, dirty or damaged glass, mirrors,
lamps or reflectors that could reduce the view or visibility, or cause
injury. Replace, clean or repair promptly.
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DOOR LATCHES — Check that doors close, latch and lock tightly.
Check for broken, damaged or missing parts that might prevent tight
latching.
Q TILT CAB (DRIVING POSITION) — Be sure the tilt lever is down
and locked.
R
FLUID LEAKS — Check for fuel, water, oil or other fluid leaks by
looking at the surface beneath the vehicle after it has been parked
for a while. If you notice diesel fumes or fluid at any time, have the
cause found and corrected at once.
S
UNDERBODY — Corrosive materials used for ice removal, snow
removal and dust control can collect on the underbody. If these
materials are not removed, accelerated corrosion (rust) can occur on
underbody parts such as fuel lines, frame, floor pan and exhaust
system. At least every spring, flush these materials from the
underbody with plain water. Take care to clean well any areas where
mud and other debris can collect. Sediment packed in closed areas
of the frame should be loosened before being flushed.
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NOISE EMISSION CONTROL
NOISE CONTROL SYSTEM
The following information relates to compliance with Federal noise
emission standards for vehicles with a Gross Vehicle Weight Rating
(GVWR) of more than 10,000 pounds (4,536 kilograms). The
Maintenance Schedule provides information on maintaining the noise
control system to minimize degradation of the noise emission control
system during the life of your vehicle. The noise control system
warranty is given in your Warranty and Owner Information book.
These standards apply only to vehicles sold in the United States.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof:
1 . The removal or rendering inoperative by any person other than for
purposes of maintenance, repair or replacement of any device or
element of design incorporated into any new vehicle for the
purpose of noise control, prior to its sale or delivery to the ultimate
purchaser or while it is in use, or;
2. The use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts
listed below.
Insulation
•
Removal of noise shields or undercab insulation.
Engine
•
Removal or rendering engine speed governor, if so equipped,
inoperative so as to allow engine speed to exceed manufacturer
specifications.
Fan and Drive
•
•
Removal of fan clutch or rendering clutch inoperative.
Removal of fan shroud.
Air Intake
•
•
Removal of air cleaner silencer.
Reversing air cleaner cover.
Exhaust
•
•
•
Removal of muffler, catalytic converter and/or resonator.
Removal of exhaust pipes and exhaust pipe clamps.
Removal or modification of Diesel Particulate Filter (DPF).
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REPLACEMENT FASTENERS
During vehicle maintenance, any fasteners used to replace older ones
must have the same measurements and strength as those removed,
whether metric or customary. Fasteners taken from the vehicle should
be saved for reuse in the same location when possible. Where a
fastener cannot be used again, take care to choose a replacement that
matches the old one. For information and help, see your authorized
dealer.
CAUTION: This vehicle is primarily dimensioned in the metric
system. Most fasteners are metric and many are very close in
dimension to well-known customary fasteners in the inch system.
Mismatched or incorrect fasteners can result in damage to the
vehicle or possibly personal injury.
FUEL CAP
If you need to replace the fuel filler cap, use only a genuine Isuzu fuel
filler cap.
CAUTION: The use of an improper fuel filler cap could cause fuel
spillage in the event of an accident.
The use of an improper fuel filler cap could also affect the fuel
system and the emission control system.
Since fueling with the engine running may cause a fire, be sure
to stop the engine before fueling.
Keep fire away when fueling. A fire may occur due to fuel or fuel
vapors catching fire.
Be sure to wipe off any fuel spilled during fueling.
Make sure that the fuel cap is tightly closed after fueling.
CAUTION: Fuel may be under pressure. Remove the fuel cap
slowly to prevent fuel from spraying out and causing injury.
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ENGINE OIL AND FILTER
RECOMMENDATIONS
The following engine oil recommendations are based on operating
your engine with the fuels recommended under “Diesel Fuel
Requirements and Fuel System” in Section 2 of this manual.
NOTICE: Engine damage due to improper maintenance, or using oil of
improper quality and/or viscosity is not covered by the new vehicle
warranty.
NOTICE: Engine oil change precaution
1. When adding oil, remove the dipstick.
2. After adding oil, wait for at least 5 minutes before starting the engine.
Be sure to reinstall the dipstick.
CHECK ENGINE OIL LEVEL
The DPF performs regeneration automatically when a certain
quantity of PM accumulates within the filter. To perform regeneration,
post-injection (fuel injection after the main fuel injection period) is
carried out. As a by-product of post-injection, it is possible for fuel to
gradually mix with the engine oil over a period of time which will
eventually increase the engine oil level up to the "Position A" level
mark on the oil level gauge rod (oil dipstick), once the oil level reaches
the "Position A" level mark the engine oil must be replaced.
Position "A"
Oil change is needed.
FULL
MIN
Oil adding is needed.
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Check procedure
CAUTION: If the engine has been running, wait at least 20 to 30
minutes before checking.
NOTICE: Engine oil level must be checked with the vehicle parked
on level ground.
The engine oil level must be kept at the right level to help assure
proper lubrication of your vehicle’s engine. It is the owner’s
responsibility to check the oil level at regular intervals (such as every
fuel stop), according to the following instructions. In order to get an
accurate reading, the oil must be warm, at operating temperature and
the vehicle must be on level ground.
1. Turn the engine off and give the oil 20 to 30 minutes to drain back
into the oil pan.
NOTICE: If you check the engine level when the oil is cold, do not
run the engine first. (A.M before starting) Cold oil will not drain
back to the pan fast enough to give an accurate reading.
2. Pull out the dipstick, wipe the dipstick clean, then push the dipstick
back down all the way.
3. Pull out the dipstick again and inspect the oil level on it.
4. If needed, add oil to keep the oil level above the "MIN" mark.
NOTICE: Be sure to add enough oil to put the level somewhere
between the "MIN" and "FULL" range. Never add oil above the
"FULL" mark.
5. If the oil level has increased above the "FULL" mark see "Dilution"
for additional information.
6. Push the dipstick all the way back in after checking the oil.
Dilution
Under normal engine operations the engine oil level may increase
above the "FULL" mark as a result of DPF regeneration. A small
increase in the oil level between the oil change interval is normal.
When checking the engine oil level, if the oil level exceeds the "FULL"
mark of the dipstick and reaches enlarged portion of the dipstick
(position "A") have your oil changed as soon as possible to avoid
engine damage.
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CAUTION:
• If the engine oil level is higher than the "Position A" level on the
oil level gauge, there is a possibility engine damage may occur. If
the oil level exceeds the "Position A" level, the engine oil must
be drained and refilled with oil of the correct grade and quality.
• It is possible for fuel to gradually mix with the engine oil, over a
period of time, which will eventually increase the engine oil level
up to the "Position A" level mark on the oil level gauge rod (oil
dipstick).
Ensure the engine oil is replaced at specified intervals with
engine oil of the correct grade and quality.
• After engine running, wait between 20 and 30 minutes after
stopping the engine before measuring the engine oil level.
CHOOSING THE RIGHT QUALITY OIL
CAUTION: If you do not use the oil intended for the DPF in a
vehicle fitted with a DPF, both the engine and the DPF may break
down and fuel economy may decrease. Be sure, therefore, to use
the oil intended for the DPF.
NOTICE: For vehicles equipped with a DPF, ISUZU recommends
engine oil that supports DPF (Low ash oil) with grades CJ-4 (API).
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CHOOSING OIL VISCOSITY
Engine oil viscosity (thickness) has an effect on fuel economy and
cold-weather starting. Lower viscosity engine oils can provide better
fuel economy; however, higher temperature weather conditions require
higher viscosity engine oils for satisfactory lubrication.
When choosing an oil, consider the range of temperature your
vehicle will be operated in before the next oil change. Then, select the
recommended oil viscosity from the chart.
Do not use any viscosity of oil which is not recommended. Such oils
could cause engine damage, and such damage is not covered by the
new vehicle warranty.
ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE
SAE 40
SAE 30
SAE 15W-40, 20W-40, 20W-50
SAE 10W-30
SAE 10W-40
F
C
20
30
0
20
20
10
40
0
60
10
80
20
100
30
This Engine Oil Viscosity Grade Chart shows general information.
For this vehicle, oil with W-40 viscosity is recommended.
*
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OIL IDENTIFICATION LOGO
A Iogo (symbol) is used on most oil containers to help you select the
oil you should use. The top portion of the logo shows the oil quality by
API designations such as CJ4 or others. The center portion of the logo
shows the SAE viscosity grade, such as SAE W-40 ( indicates
viscosity on the low temperature side.).
You should look for this logo on the oil container, and use ONLY oil
containing the logo.
*
*
SAE
*W-40
CHANGE INTERVALS
The oil and oil filter change intervals for your engine are based on
the use of recommended oil quality and viscosity, as well as highquality filters such as Isuzu genuine oil filters. Using oil other than
recommended, or oil and filter change intervals longer than
recommended, could reduce engine life. Damage to engines due to
improper maintenance or use of incorrect oil quality and/or viscosity is
not covered by the new vehicle warranty.
Your engine was filled with a high-quality engine oil when it was
built. You do not have to change this oil before the first recommended
change interval. Oil and filter change intervals depend on how you use
your vehicle. For information on the proper oil and filter change
intervals, refer to the maintenance schedule in this section.
ENGINE OIL ADDITIVES
Engine oils contain a variety of additives. Your engine should not
need any extra additives if you use the recommended oil quality and
change intervals.
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USED OIL DISPOSAL
Do not dispose of used engine oil (or any other oil) in a careless
manner such as pouring it on the ground, into sewers, or into streams
or bodies of water. Instead, recycle it by taking it to a used oil
collection facility which may be found in your community. If you have a
problem disposing of your used oil, it is suggested that you contact
your dealer or service station. (This also applies to diesel fuel which is
contaminated with water. See “Diesel Fuel Requirements and Fuel
System” in Section 2.)
Used Engine Oil
CAUTION: Used engine oil contains harmful contaminants that
have caused skin cancer in laboratory animals. Avoid prolonged
skin contact. Clean skin and nails thoroughly using soap and
water–not mineral oil, fuels or solvents. Launder or discard
clothing, shoes or rags containing used engine oil.
Discard used engine oil and other oils properly.
EXTERNAL DIESEL ENGINE CLEANING
NOTICE: Your diesel engine does not need periodic cleaning, nor
does Isuzu recommend it be cleaned. However, if you insist on
cleaning the engine, clean it only when it is cold, never when it is
warm or hot, and never when the engine is running. Spraying or
pouring water or other fluids on your engine when it is warm or
hot, or when it is running, can cause serious damage to the engine
and its components, particularly the fuel supply pump.
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DIESEL FUEL SYSTEM
Fuel system components which require periodic maintenance services
are the engine air cleaners and the fuel filters. Care must be taken when
filling the fuel tank to prevent entry of dirt and water. Fuel lines and
connections should be inspected regularly for evidence of leaks.
If by mistake gasoline is poured in the diesel fuel tank and the
engine is operated, the entire system must be drained; otherwise
damage to the fuel system may occur.
See your authorized dealer for servicing the fuel system.
Steps In Refueling
CAUTION: Before pulling up to a fuel pump, be sure that all
occupants in your vehicle stop smoking and extinguish any smoking
materials. Do not permit sparks or flames in the presence of fuel or
fumes, to help avoid personal injury or property damage due to fire.
Diesel fuel will ignite and burn as readily as gasoline if the fuel is
warm enough or additives have lowered its ignition temperature.
1. Follow all the steps under “Parking” in Section 2.
2. Select the correct fuel as referenced on page 2-3. Follow any posted
safety rules. Stand to the side, never above or opposite the filler opening.
3. Check that the fuel cap is tight, and see to it that engine oil, engine
coolant in the reservoir, and washer fluid, etc. are at proper levels.
Then do the Driver Daily Checklist in Section 1.
FUEL SYSTEM PRIMING (Air bleeding)
When The Fuel Has Run Out
The fuel system must be primed if your vehicle has run out of fuel.
The priming pump is located on the outboard side of the left frame rail,
in front of the batteries.
Before Starting The Engine
If your vehicle has run out of fuel, bleed the air out of the system
from the air bleeding plug on the side of the priming pump, because
otherwise the air would enter the fuel system and would cause starting
trouble.
1. Position a tray to collect the discharged fuel on the ground
underneath the air bleeding plug, then loosen the air bleeding plug
substantially.
2. Move the priming pump up and down for more than 20 pump cycles
until fuel with air bubbles stops coming from the air bleeding plug.
3. Tighten the air bleeding plug securely and wipe the fuel around the
plug clean.
4. Operate the priming pump for more than 10 pump cycles to send
the air in the fuel system to the fuel supply pump.
5. Turn the engine control switch to start the engine.
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After Starting The Engine
1. Turn the engine control switch without stepping on the accelerator
pedal and start the engine.
2. Allow the engine to idle for five seconds.
3. Slowly turn the idle control knob to the right as far as it will go, then
keep the knob in this position for three minutes.
4. Fully depress the accelerator pedal to obtain maximum RPM.
(Repeat this operation several times.)
5. Turn the idle control knob to the left so that the engine returns to
idle.
NOTICE:
Incomplete air bleeding can result in serious engine damage. Be
sure to follow the procedures outlined above carefully.
Priming pump
Air bleeding
CAUTION: The diesel engine in models covered by this manual will
operate on any fuel which enters the cylinders, whether it be from
the fuel injectors or the air inlet system. If any of the solvent which
may have been used in flushing out the air cleaner filter remains in
the filter, the engine could overspeed when started. In order to
prevent the engine from breaking apart and causing serious
personal injuries or death to anyone standing nearby, be sure that
no solvent remains in the air cleaner filter when starting the engine.
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FUEL FILTER
Always replace the fuel filter according to the manufacturer’s
recommended interval. Failure to replace the fuel filter when needed may
lead to fuel system damage. Your authorized Isuzu dealer can inspect
your fuel filter and replace your fuel filter, if needed.
WATER SEPARATOR
The purpose of the water separator is to clean the fuel of any dirt
particles that can cause wear on the fuel injector’s sliding surface; and
to separate any water from the fuel that may have formed in the fuel
tank due to condensation. The water separator is located on the
bottom of the fuel filter.
NOTICE: To help avoid engine damage,
• When the water separator indicator light comes on, loosen the
drain plug under the fuel filter and move the priming pump up
and down by hand from 10 to 20 times. When doing this, do not
loosen the air bleeding plugs of the fuel filter and the priming
pump.
• Make sure that there is no leak of fuel from the drain plug and
that the indicator light is off after the engine is started.
• If fuel is spilt on the vehicle body, etc., wipe it clean.
• Right after draining, it takes more time than usual to start the
engine. If the engine cannot be started within 10 seconds, wait
some time and restart.
Refer to “Used engine oil” in page 5-25 for proper disposal procedures.
Air bleeding
Drain plug
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REPLACEMENT WATER SEPARATOR FILTER ELEMENT
1. Disconnect the water separator switch electrical connector.
2. Loosen the fuel filter cover turning it counterclockwise with a filter
wrench.
3. Remove the fuel filter.
4. Wipe the fitting face on the upper cover clean with a rag so that the
new fuel filter can be seated properly.
5. Fill the new filter assembly with fuel in order to make air bleeding
easy.
6. Lightly oil the O-ring. Install and turn the filter assembly clockwise
carefully to prevent fuel spill until the O-ring is fitted against the
sealing face of the filter cover. Using the filter wrench, tighten the
filter an additional 1/3 to 2/3 turn.
7. Reconnect the water separator switch electrical connector.
8. Follow ‘Air bleeding’ instructions.
FUEL SYSTEM PRIMING (Air bleeding)
When The Fuel Filter Is Replaced
When the fuel filter is replaced, bleed the air out of the system from
the air bleeding plug on the side of the fuel filter, otherwise air will
enter the fuel system and cause starting trouble.
Before Starting The Engine
1. Sufficiently loosen the air bleeding plug on the side of the fuel filter.
Attach a vinyl hose, etc. to the plug in order to prevent the fuel from
splattering.
2. Move the priming pump up and down for more than 90 pump cycles
until fuel with air bubbles stops coming from the air bleeding plug
on the side of the fuel filter.
3. Tighten the air bleeding plug securely and wipe the fuel around the
plug clean.
4. Operate the priming pump for more than 10 pump cycles to send
the air in the fuel system to the fuel supply pump.
5. Turn the engine control switch to start the engine.
After Starting The Engine
1. Turn the engine control switch without stepping on the accelerator
pedal and start the engine.
2. Allow the engine to idle for five seconds.
3. Slowly turn the idle control knob to the right as far as it will go, then
keep the knob in this position for three minutes.
4. Fully depress the accelerator pedal to obtain maximum RPM.
(Repeat this operation several times.)
5. Turn the idle control knob to the left so that the engine returns to
idle.
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FUEL CAP
1. Follow all the steps under “Parking” in Section 2.
2. Follow any posted safety rules. Stand to the side, never above or
opposite the filler opening.
3. Check that the fuel cap is tight, and see to it that engine oil, engine
coolant in the reservoir, and washer fluid, etc., are at proper levels.
Then do the Driver Daily Checklist in Section 1.
NOTICE: Always use ultra low sulfur diesel fuel.
Use of low quality fuel may adversely affect the engine parts, and
cause failure.
Use of fuels other than ultra low sulfur diesel fuel may adversely
affect the engine or emission control system and cause failure.
Especially for the common rail type engine, always use ultra low
sulfur diesel fuel (15 ppm or less of sulfur content).
If other than specified diesel fuel is used, the vehicle may not
conform to specifications.
MAINTENANCE ITEMS TO AID COLD
WEATHER STARTING
Since the basic principle of diesel engine ignition is based on
compression, the diesel engine is somewhat harder to start than a
gasoline engine when the temperature is below freezing. To help
prevent hard starting problems, special attention should be given to
following normal maintenance items.
Refer to Section 2 for diesel fuel requirement.
1. Neglecting to have the fuel filter and water separator serviced can
be one of the major contributors to hard starting. If water is
permitted to accumulate in the primary filter, it will freeze and make
starting the engine impossible.
2. Make sure the fuel tank vent is open.
3. Always refuel at the end of a day’s operation. Moisture will
condense in an empty tank; therefore, the tank should be filled
before leaving the vehicle standing for an extended period.
If, by mistake, gasoline is poured into the diesel fuel tank and the
engine is operated, for a short period of time the entire system must be
drained; otherwise, damage to the fuel injector, fuel supply pump and
engine will occur.
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STARTING AIDS
NOTICE: Do not use starting “aids” in the air intake system . Such
“aids” can cause immediate engine damage.
WINDSHIELD WASHER
The windshield washer is equipped on the windshield wiper arm.
The windshield washer fluid supply reservoir is located to the right of
the glove box.
•
•
•
•
Inspect the washer fluid level regularly, especially during bad
weather conditions.
Use a high quality premixed solvent available at most dealers or
service stations. Avoid hard water when mixing Optikleen or other
windshield washer solvents. Hard water contaminants may plug
orifices in the washer system and reduce performance.
Do not use radiator antifreeze in the windshield washer; it could
cause cab paint damage.
In cold weather, warm the windshield with the defrosters before
using the washer – to help prevent icing that may block the driver’s
vision.
POWER STEERING SYSTEM
Check the fluid level in the power steering pump reservoir as
recommended in the Maintenance Schedule.
The power steering fluid should be changed and the filter should be
cleaned at intervals specified in the Maintenance Schedule.
Single cab model
Crew cab model
Forward
Power Steering
Reservoir Tank
M
AX
M
IN
Power Steering
Reservoir Tank
Right rear of cab
Right rear door area
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NOTICE: When replenishing power steering fluid or flushing the
power steering system, always use ATF Fluid (DEXRON® -III).
Failure to use the proper fluid may damage the power steering
system seals and hoses, leading to fluid leakage.
ENGINE COOLING SYSTEM
CAUTION: If your engine cooling system overheats, see “Engine
Cooling System Overheating” in Section 3. Continued operation of
the engine even for a short time may result in a fire and the
possibility of personal injury and/or severe vehicle damage.
Your vehicle has an engine coolant recovery system, expansion
bottle and/or a surge tank system. Engine coolant in the system
expands with heat and overflows into the recovery tank. When the
system cools, engine coolant is drawn back into the radiator.
The engine cooling system has been filled at the factory with a
quality engine coolant. It is important to use proper engine coolant to
prevent damage to engine cooling system components. The engine
cooling system is designed to use engine coolant (a mixture of
ethylene glycol, corrosion inhibitors and water) rather than plain water.
The 50/50 engine coolant solution must be used year round to provide:
• Freezing protection down to –31°F (–35°C).
• Boiling protection up to 262°F (128°C).
• Protection against rust and corrosion in the engine cooling system.
• The proper engine coolant temperature for efficient operation and
emission control.
• Proper operation of the engine coolant temperature gauge.
See the Maintenance Schedule in Section 5 to find out when the
engine coolant must be replaced. Note that changing the engine
coolant is needed to replenish the rust inhibitors to make certain that
all parts of the engine cooling system work well.
ENGINE COOLING SYSTEM CARE
Check the engine cooling system at regular intervals, such as during
fuel stops. You usually do not need to remove the radiator cap to
check the engine coolant level.
Single cab: Look at the see-through engine coolant reserve tank at
the back of the cab without tilting the cab.
Crew cab: Look under the inspection cover located beneath the rear
right seat or look from the lower part of the right side of vehicle. When
the engine is either hot or cold, engine coolant should be between the
“MAX” and “MIN” marks on the tank.
If the engine coolant level is low, remove the cap on the engine coolant
reserve tank. Add to the reserve tank enough of a 50/50 (48/52 For
Canada) mixture of water and Isuzu Long Life Coolant antifreeze to bring
the level up to the proper mark. Put the cap back on the reserve tank.
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CAUTION: Under some conditions the ethylene glycol in the
engine coolant is combustible. To help avoid being burned when
adding engine coolant, do not spill it on the exhaust system or
engine parts that may be hot. If there is any question, have this
service performed by a qualified technician.
Certain conditions, such as air trapped in the system, may affect the
engine coolant level in the radiator. You should check the engine
coolant level in the radiator at the time you change the engine oil and
when the engine is cold. Follow the steps under “Adding Engine
Coolant” for the correct way to remove the radiator cap and add engine
coolant.
If you have to add engine coolant more than four times a year either
to the reserve tank or to the radiator, see your authorized dealer for a
engine cooling system check.
NOTICE: If you use the proper quality antifreeze, there is no need to
add extra inhibitors or additives which claim to improve the system.
They may be harmful to the proper operation of the system.
ENGINE COOLING SYSTEM SERVICE
The engine cooling system should be serviced at the intervals
specified in the Maintenance Schedule as follows:
1. Wash the radiator tank cap and filler neck with clean water as
described in “Adding Engine Coolant”.
2. Remove the cap and check the engine coolant level and have it
tested for freeze protection. Add Isuzu Long Life Coolant antifreeze,
if needed, to maintain freeze protection at –33°F (–36°C).
3. Have the engine cooling system and radiator cap tested for a
pressure capacity of 108 kPa (16 psi). If a replacement cap is
needed, use an Isuzu genuine cap, or an equivalent cap, designed
for engine coolant recovery systems and specified for your model.
4. Tighten all radiator hose clamps and heater hose clamps and
inspect all hoses. Replace the hoses if they are swollen, “checked,”
or otherwise worn.
NOTICE: Take care when tightening the hose clamps at the radiator.
Overtightening could bend or collapse the radiator fittings.
5. Clean the front of the radiator core to remove dirt and other objects.
Adding Engine Coolant
CAUTION: To help avoid the danger of being burned, do not
remove the radiator cap or the reserve tank cap while the engine
and radiator are still hot. Scalding fluid and steam can be blown
out under pressure if either cap is taken off too soon.
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1. When the engine is cool, remove the radiator cap.
• Turn the cap slowly to the left until it reaches a “stop”. Do not
press down while turning the cap.
• Wait until any remaining pressure (indicated by a hissing sound) is
relieved, then press down on the cap and continue turning it to the left.
2. Fill the radiator to the base of the filler neck and fill the engine
coolant reserve tank to the “MAX” mark.
• Use a solution that is at least 50 percent antifreeze but no more
than 60 percent antifreeze.
• Add enough water and Isuzu Long Life Coolant antifreeze
solution to provide the required cooling, freezing and corrosion
protection. Install the radiator cap and reserve tank cap.
3. Run the engine until the engine coolant temperature rises to normal
level, and idle the engine for 10 minutes.
4. Turn off the engine. Make sure that the engine is cool. Remove the
radiator cap and add engine coolant to the radiator until it reaches
the bottom of the filler neck. Fill the engine coolant reserve tank to
the “MAX” mark.
5. Install the radiator cap and the reserve tank cap.
Engine Coolant Replacement and Cleaning
Draining:
NOTICE: Dispose of and handle the waste engine coolant in
accordance with the specified method.
1. Check the engine has sufficiently cooled.
2. Remove the radiator cap.
• Turn the cap slowly to the left until it comes to a stop. Do not
press down while turning the cap.
• Wait until any remaining pressure (indicated by a hissing sound)
is relieved, and then press down on the cap and continue turning
it to the left.
3. Open the radiator drain plug and engine drain plug, and drain the
engine coolant.
4. Close the drain plugs.
CAUTION: The engine must not be started after the engine coolant
has been drained. Doing so may cause engine burnout.
Cleaning the Radiator Core:
As a radiator core blocked with dirt and dust will result in a reduction
of cooling effectiveness and the corrosion of the radiator core, it is
necessary to periodically wash out the radiator core with water.
NOTICE: When washing out the radiator core, take care not to
crush or damage the fin, etc.
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Cleaning the Cooling Channel:
1. Fill the radiator to the mouth with clean tap water.
2. Check and clean the radiator cap. If an abnormality is found,
replace with a new radiator cap.
3. Securely fit the radiator cap.
4. Supply clean water to the engine coolant reserve tank up to the
"MAX" mark.
5. Close the reserve tank cap.
6. Start the engine and allow it to idle for 20 minutes. After doing so,
stop the engine and drain the water once it has cooled down.
(Refer to "Draining" in "Engine Coolant Replacement and
Cleaning" for the draining method.)
Supplying coolant:
1.
2.
3.
4.
Check the engine has sufficiently cooled.
Remove the radiator cap.
Open the engine outlet's air bleed bolt.
Fill the radiator up to the mouth with engine coolant.
• Use a solution that is at least 50 percent antifreeze and no more
than 60 percent antifreeze.
• Add enough water and Isuzu Long Life Coolant antifreeze
solution to provide the required cooling, freezing and corrosion
protection. Install the radiator cap and reserve tank cap.
5. Press the radiator upper hose 2 or 3 times. If, due to the hose
being pressed, air is released from inside the hose and the water
level goes down, replenish the radiator up to the mouth with
engine coolant.
6. Open the reserve tank cap, and fill to the "MAX" mark with engine
coolant, before closing.
7. Make sure the engine outlet's air bleed bolt is closed.
8. Securely fit the radiator cap.
After the engine has been started and left at normal idling
revolutions for approximately 2-3 minutes, turn the engine off.
9. After confirming that that engine has cooled down, remove the
radiator cap. If the level of engine coolant has been reduced, carry
out replenishment.
10. After fitting the radiator cap securely, warm up the engine at
approximately 2,000 rpm.
11. After the engine coolant temperature gauge's needle exceeds the
center line, allow the engine to idle for approximately 5 minutes,
before stopping it.
NOTICE: The engine alarm and automatic shutdown system may
be activated during the above step, but it is not malfunction.
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12. After confirming that the engine coolant has sufficiently cooled
down, remove the radiator cap. Be sure to top up the engine
coolant if the level has gone down. If the level of engine coolant is
dramatically reduced, check the coolant channel and reserve tank
hose for leaks.
CAUTION: If the above step is omitted, the engine alarm and
automatic shutdown system may be unexpectedly activated. Make
sure to perform this step.
13. Securely fit the radiator cap.
14. Open the reserve tank cap, and fill to the "MAX" mark with engine
coolant, before closing.
It is the owner’s responsibility to:
•
•
Maintain the engine cooling system freeze protection at –20°F
(–29°C) or in Canada at –40°F (–40°C) to ensure protection against
corrosion and loss of engine coolant from boiling. A 50/50 (48/52
for Canada) mixture of Isuzu Long Life Coolant antifreeze and
water will provide freeze protection to –33°F/–36°C (in Canada
–40°F/–40°C) and boil protection to 262°F (128°C). Periodic
replacement of engine coolant is needed to replenish the
anticorrosion additives that wear out with use.
Engine coolant that has become dark in color shows that it needs to
be changed.
Use only Isuzu Long Life Coolant antifreeze.
NOTICE: Do not use methanol-base antifreeze, alcohol or plain
water alone in your vehicle at any time. They will boil at a lower
point than that at which the engine coolant temperature gauge will
warn of overheating, and they do not provide proper protection
against corrosion.
THERMOSTAT
The engine coolant temperature is controlled by thermostat(s). The
thermostats stop engine coolant flow through the radiator until a preset
temperature is reached. The thermostats are installed in the engine
coolant outlet on the engine block. The same thermostats are used in
both winter and summer. When a replacement is needed, genuine
Isuzu parts are recommended.
RADIATOR PRESSURE CAP
The radiator cap, a 108 kPa (16 psi) pressure type, must be installed
tightly, otherwise engine coolant may be lost and damage to the
engine may result from overheating. Radiator pressure cap should be
checked periodically for proper operation. If a replacement is required,
an Isuzu genuine cap is recommended.
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AIR CLEANER/FLAME ARRESTOR
CAUTION: The air cleaner also functions as a flame arrestor in the
event of engine backfire. The air cleaner should be installed at all
times unless its removal is necessary for repair or maintenance.
To help reduce the risk of personal injury or death and/or property
damage, be sure that no one is near the engine compartment
before starting the engine with the air cleaner removed. If engine
backfire occurs with the air cleaner removed, there could be a
burst of flame and possibly other fire in the engine compartment.
RADIATOR GRILLE COVERS
CAUTION: Winter fronts or grille covers are not to be used. Radiator
shutters may cause the engine’s radiator cooling fan to fatigue from
the alternate unloading and loading of the blades as each passes
through the area masked by the cover, then the unmasked area.
After the fan has been fatigued, it may suddenly break apart while
rotating, possibly causing personal injury to anyone standing
nearby, and equipment damage.
RADIATOR COOLING FAN AND
GOVERNED SPEED
CAUTION: Increasing the governed speed of the engine or the fan
speed (by changing the fan drive ratio) may cause the engine’s
radiator cooling fan to fatigue, and then suddenly break apart while
rotating, possibly causing personal injury to anyone standing
nearby in addition to equipment damage. If it is felt the governed
speed must be changed, contact your dealer for information.
BRAKE SYSTEM
For the most effective braking and for maximum life from brake
system components, follow these suggestions:
• Keep any obstructions from interfering with brake pedal travel.
• Keep tires properly inflated. Improperly inflated tires can reduce the
efficiency of the brakes.
Follow the recommendations for brake checks in the Maintenance
Schedule. Refer to “Brake System” in Section 2 for details on brake
system operation. Refer to the explanation of the ABS in page 2-24.
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BRAKE MAINTENANCE
Isuzu replacement brake lining material is recommended for this
vehicle to maintain the balance between front and rear brake
performance. Isuzu replacement brake parts have been carefully
selected to provide the proper brake balance for purposes of both
stopping distance and controllability over the full range of operating
conditions. Installation of front or rear brake lining material with
performance different from that of the Isuzu replacement parts
recommended for this vehicle can change the intended brake balance
of this vehicle.
Brake fluid check
Check the brake fluid reservoir regularly. (DOT 3 brake fluid or
equivalent)
• When topping off, take care not to allow dirt or water to enter the
tank, as this may cause the brakes to malfunction.
• As the brake fluid needs to be replaced periodically, carry out
inspections and replacement in accordance with the Maintenance
Schedule.
• Take care not to allow brake fluid to adhere to painted surfaces or
to the skin. If adherence does occur or brake fluid is spilled, quickly
wipe off.
• As brake fluid is highly susceptible to moisture, be sure to close the
cap securely before storing.
• Do not mix the brake fluid with other brand name products.
• If the brake fluid reduces significantly, it could be brake system
failure or pad wear. Contact your Isuzu dealer immediately and
have the system inspected.
Hydraulic brake booster (HBB) fluid level check (NQR, NRR models)
By starting the engine, the hydraulic brake booster fluid charges the
accumulator.
Always inspect the hydraulic brake booster fluid reservoir level . The
brake booster (Dexron®-III) reservoir is located behind the cab on the
left side.
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MAX
MIN
ACCESS TO THE ENGINE
SINGLE CAB MODEL
Access to the engine coolant reserve tank cap and the engine oil
dipstick is located on the engine left side after tilting the cab.
Add engine coolant as described previously in this section “Engine
Cooling System Care”. Refer to “Engine Cooling System Overheating”
in Section 3.
Engine Oil Dipstick
Right rear cab
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CREW CAB MODEL
The engine coolant reserve tank is under the access panel beneath
the rear right seat. The engine oil dipstick is under the engine
inspection sub cover located beneath the driver’s seat.
Add engine coolant as described previously in this section “Engine
Cooling System Care”. Refer to “Engine Cooling System Overheating”
in Section 3.
Engine Oil Dipstick
Inspection Panel
MAX
MIN
Coolant Reserve
Tank
BEFORE TILTING THE CAB (Single cab model)
CAUTION: To help avoid personal injury and property damage,
• Park the vehicle on level ground and check that there is enough
space in front of and above the cab.
• Set the parking brake firmly and block the front wheels.
• Place the gearshift lever in the neutral position for manual
transmission or “P” (Park) for automatic transmission.
• Secure loose articles in the cab.
• Stop the engine.
• Close the cab door.
• Keep the area surrounding the cab clear.
TILTING THE CAB (Single cab model)
1.
2.
3.
4.
5.
Check that all personnel are clear of the cab.
Read the label on the rear of the cab.
Unlock the cab tilt lever (2) while pulling the lock lever (1).
Hold the assist handle (3) and pull the safety lever (4).
Raise the cab fully and be sure the cab support (5) is locked by the
support lock lever (7).
6. Insert the safety lock pin (6).
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Always be sure the safety lock pin is installed when the cab is tilted.
1
2
1. Lock Lever
2. Tilt Lever
3
4
3. Assist Handle
4. Safety Lever
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5
7
6
5.
Cab Support
6.
Lock Pin
7.
Support Lock Lever
CAUTION: To help avoid personal injury or death, keep hands,
tools, and clothing clear of the engine cooling fan when the engine
is running.
LOWERING THE CAB (Single cab model)
1. Have all personnel stand clear of the cab.
2. Be sure the gearshift lever is in Neutral (M/T models) or “P” PARK
(A/T models).
3. Remove the safety lock pin (6).
4. Hold the assist handle (3) and unlock the cab support by pulling the
support rearward while pressing the support lock lever (7).
5. Lower the cab and push the tilt lever (2) down firmly to lock.
CAUTION: To help avoid personal injury or death, be sure the tilt
cab is securely locked in the lowered position before operating the
vehicle.
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ENGINE INSPECTION COVER (Crew cab model)
To gain access to the engine, release the catch hooks and raise the
passenger’s seat cushion. The cover can be held up by a strap,
permitting engine inspection and adjustment.
Strap
Seat Cushion
Catch Hooks
ENGINE INSPECTION SUB COVER (Crew cab model)
To gain access to the engine compartment, pull the lock lever (red)
of the driver’s seat cushion to unlock it, raise the driver’s seat cushion
and remove the sub cover.
Seat Cushion
Lock Lever
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FUEL / WATER SEPARATOR AND RADIATOR SURGE TANK INSPECTION
COVER (Crew cab model)
To gain access to the fuel / water separator and radiator surge tank,
remove the inspection cover.
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DIESEL PARTICULATE FILTER (DPF)
DPF inspection and cleaning
Clean the DPF at every 100,000 miles (160,000 km) or every 3,000
hours at your Isuzu dealer. Refer to "Maintenance Schedule" in this
section.
NOTICE: Contact your Isuzu dealer for details of ash removal
equipment.
NOTICE: Pressure Difference Sensor 0 point Adjustment.
Every year, make a 0 point adjustment for the pressure difference
sensor that detects clogging in the DPF.
In addition, after every DPF inspection or DPF filter cleaning,
make a differential pressure sensor adjustment according to the
following procedure.
1. Turn the engine control switch to the "ON" position, and leave it for a
while. (Do not start the engine.)
2. Make sure that the DPF lamp comes on.
3. Make sure that the DPF lamp goes off in 30 seconds.
4. Turn the engine control switch to the "OFF" position, and leave it for
1 minute or more.
NOTICE: Perform zero point calibration of the pressure difference
sensor after the pressure difference sensor has cooled down to
the ambient temperature. After DPF regeneration, wait at least 2
hours before performing zero point calibration.
CAUTION:
• If you fail to clean the filter, the DPF and the engine may break
down or fuel economy may deteriorate.
• Contact your nearest Isuzu dealer for how to clean the filter.
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ACCESS TO THE WINDSHIELD
The windshield wiper arms may be swung out, away from the glass,
to provide easy access for cleaning.
NOTICE: Do not hang on to the roof marker lights while cleaning
the windshield or damage may occur (resulting in possible water
leakage).
AIR CONDITIONING (IF EQUIPPED)
A/C DRIVE BELT TENSION ADJUSTMENT
CAUTION: The air conditioning drive belt, if equipped, must be
adjusted after fan belt adjustment. If the required procedure is not
followed, the A/C belt may experience excessive tension, and
possible premature failure.
1
2
3
4
5
6
7
A/C compressor
A/C belt
Tension pulley
Generator
Fan belt
Fan pulley
Crank pulley
If your air conditioning system is functioning properly, it is not
necessary to remove and replace the refrigerant or compressor oil.
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ELECTRICAL SYSTEM
Following the after-delivery service, it is the owner’s responsibility to
check all wiring periodically for cracked, chafed or oil-soaked insulation
and maintain it in a clean and tight condition to ensure satisfactory
operation of the electrical system.
HEADLIGHT VERTICAL AIMING ADJUSTMENT
For vertical aiming, turn the two screws indicated by arrows in the
diagram.
1. Remove the rubber beneath the headlight.
2. Two screws should be turned in the same direction at the same
time to adjust aiming.
3. When the "Headlight aiming" is out of position, adjust it at an
authorized dealer.
TURN SIGNALS
The flasher unit activates both the turn signal circuits and the hazard
circuit. Should a light burn out, the flasher unit will continue to operate.
Therefore, check the turn signal lights visually before the vehicle is
used.
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HEADLIGHTS / PARKING LIGHTS
NOTICE: When replacing a bulb, make sure the light switch is
“OFF”.
Use only bulbs with the same wattage rating.
Removal
1. Remove the front grille (1).
• Remove the screw at the center of the front grille. Pushing up
the upper 5 clips, pull the front grille and remove it.
Clip
Clip
Screw
1
Clip
Nut
2. Remove the turn signal light.
• Remove the nut from the frontside turn signal light.
• Open the front door and unfasten the two screws through the
space between the door and the cab using a Phillips
screwdriver.
Forward
Door side
Inside
Screwdriver
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• Dismantle the entire turn signal light towards the front of the
vehicle in an obliquely downward direction.
• Remove the connectors of the turn signal light, followed by
removing the turn signal light.
3. Remove the headlight.
• Remove the seal rubber from the two protruding parts below the
headlight. Unfasten the four bolts. Remove the headlight
connectors and parking light connectors, followed by
dismounting the headlight unit.
Screw
Screw
Rubber
• Remove the headlight connector.
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Installation
1. Fix the headlight with bolts after positioning the guide pins on the
headlight and the holes of the cab panel.
2. Install the front corner panel clips and screw.
3. Install the front grille.
Headlight bulb
1. Remove the rubber cover, press the right side of the clip for
fastening the bulb and displace upwards to remove the clip.
2. Pull out the bulb and replace it with a new one.
CAUTION:
• Do not touch the glass portion of the bulb with your fingers.
• When installing the cap, firmly push in the cap's inner and outer
circumference, installing securely so that there is no float
between the cap, and the headlight body and bulb. If the cap is
not correctly installed, water may infiltrate the headlight resulting
in a breakdown.
Clip
Connector
Headlight Bulb
Cap
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Parking light bulb
1. Detach the parking light socket.
2. Remove the bulb from the socket, and replace with a new one.
Parking Light Bulb
3. When installing, proceed in the reverse order while paying
attention to the following points. Turn the connector to the right
and lock securely.
Lock
NOTICE: If the locking procedure is inadequate, water may
infiltrate the light resulting in a breakdown.
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FRONT TURN SIGNAL LIGHTS
1. Remove the bulb from the socket and replace it with a new one.
Bulb
Socket
2. During mounting, follow the procedures in the reverse order while
paying attention to the following.
• Turn the socket to the right to lock it firmly.
NOTICE: If the socket is not locked firmly, water may infiltrate the
light and cause malfunctioning.
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CORNERING LIGHT / SIDE TURN SIGNAL LIGHT / SIDE MARKER
LIGHT
Removal
1. Open the front door and remove the rubber cap at the bottom of
the door, followed by unfastening the nut.
Rubber Cap
Nut
2. Displace the cornering light and side indicator towards the front of
the vehicle to pull out the rear of the light, followed by removing
the tabs on the reverse side of the rear of the light from the door
panel.
Clip
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3. Upon removing the tabs, dismount the light by displacing it
towards the back of the vehicle and pulling it out.
Clip
Cornering light bulb / Side turn signal light bulb / Side marker light
bulb
1. Remove the bulb socket by turning counterclockwise.
2. Remove the bulb from the socket and replace it with a new one.
Cornering Light
Side Marker Light
Side Turn Signal Light
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3. Pay attention to the following when mounting.
• Turn the socket to the right to lock it firmly.
NOTICE: If the socket is not locked firmly, water may infiltrate the
light and cause malfunctioning.
Installation
1. Insert the tabs on the reverse side of the rear of the light into the
door panel.
2. Press the front of the light against the door panel to insert the tabs
on the reverse side of the front of the light into the door panel.
3. Open the front door, tighten the nut from the inner side, followed
by mounting the rubber cap.
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ROOF MARKER LIGHT (IDENTIFICATION LIGHT / CLEARANCE
LIGHT)
1. Unfasten the screws of the lens, and remove the lens.
2. Pull out the bulb and replace it with a new one.
3. Install the lens and screw.
NOTICE: If the screwing procedure is inadequate, water may
infiltrate into the light unit.
Screw
Lens
Bulb
Socket
WORKING NEAR BATTERY
CAUTION: Follow the precautions listed in the jump starting caution
(see “Emergency starting your vehicle due to a discharged battery”
in Section 3) when working on or near the battery. Personal injury
(particularly to eyes) or property damage may result from battery
explosion, battery fluid or electrical (short circuit) burns.
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1
1. Battery Cover
2. Latch
2
Battery
Your new vehicle is equipped with DELKOR batteries. They need no
periodic electrolyte level maintenance. Its top is permanently sealed
(except for two small vent holes) and has no filler caps. You will never
have to add water.
The hydrometer (green-eye test indicator) in the top of each battery
provides information for testing purposes only.
If the vehicle is not going to be driven for 30 days or longer,
disconnect the ground cable from the negative (–) terminal of the
batteries to prevent discharge.
For full power needs at replacement time, a DELKOR battery with
the same catalog number, as shown on the original DELKOR battery’s
label, is recommended.
CAUTION: Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the State of
California to cause cancer and reproductive harm. Wash hands after
handling.
ACCESS TO THE ELECTRICAL COMPONENTS
Batteries
The batteries are located on the outboard side of the left frame rail,
behind the cab. The batteries are in a carrier with the cover retained by
spring clips.
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Fuse Panel
The fuse panel is located at the lower side of the center of the
instrument. To gain access to the fuses, pull up the bottom of the cover
and remove the cover as shown below. The fuse designations are
printed on the inside of the panel. Replace a blown fuse with a fuse of
the correct rating and close the cover.
In addition, the relay and fuse box is mounted on the left frame at the
rear of the cab.
Fuse
Cover
Fuse Puller
Normal
Burnt Out
ELECTRICAL CIRCUIT PROTECTION
Your vehicle is equipped with fuses and fusible links to protect your
electrical wiring and equipment in case of electrical overload.
Fuses
In case of an electrical overload, the fuse will blow and stop the flow
of current in the circuit before electrical components become damaged.
The cause of the circuit overload must be identified and corrected
before the blown fuse is replaced, or else the new fuse will also blow.
Since different circuits handle different amounts of current, fuses of
various ampere ratings are used. Be sure to replace a blown fuse with
a fuse of the correct rating.
To know if a fuse is blown or not, remove the suspected fuse and
look at the wire for a break. If the wire is broken, replace the fuse with
one of equal amperage rating. The amperage rating of each fuse is
molded in its head.
Fuses are installed in the fuse panel.
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CLUTCH PEDAL FREE TRAVEL
CAUTION: Always use genuine Isuzu clutch replacement parts
whenever possible, for a more dependable operation.
As clutch facings wear, the amount of pedal-free travel is reduced,
but the NPR-HD/NQR/NRR models slave cylinder is equipped with
auto adjuster mechanism eliminating the need for adjustment.
W-01619
AUTOMATIC TRANSMISSION
CAUTION: Overfilling of the automatic transmission can cause the
fluid to be “PURGED” out of the breather hose onto the hot engine
parts and can cause a fire.
How to Check: This operation could be difficult and you may choose
to have this done at your Isuzu Dealership Service Department.
If you choose to do it yourself, then be sure to follow all the
instructions below or you could get a false reading on the dipstick.
CAUTION: Too much or too little transmission oil could damage
your transmission. Too much could cause your transmission to
overheat and fluid to spill out from the breather hose. Be sure to
get an accurate reading if you check your transmission fluid.
Park the vehicle on level ground and set parking brake. With engine
idling and the regular brakes applied, move the gear selector through
all gear positions and ending at “P”.
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NOTICE: Wait at least 30 minutes before checking the transmission
fluid if you have been driving at high speed for a long period of
time, in city/heavy traffic and or while pulling a trailer.
Single cab: Remove the dipstick located at the rear left of the engine.
Crew cab: Remove the dipstick located beneath the rear-of-engine
inspection panel.
After unlatching the A/T fluid inspection cover, the dipstick will be
visible.
Dipstick
Check fluid in Hot condition
The fluid should be checked while at normal operating temperature
(Hot) between 158°F and 176°F (70°C to 80°C). Pull, wipe and clean
the dipstick and reinsert all the way, wait at least 3 seconds then pull it
back out again for reading. If the level is not in the “H” range, then
adjust it accordingly.
NOTICE: The owner should use “H (Hot)” range. “C (Cold)” range
is used for the service technician only. “C (Cold)” range is
reference only for replacement of transmission or transmission
fluid.
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WHEELS AND TIRES
The operating load and cold inflation pressure on the rim and wheel
must not exceed the rim and wheel manufacturer’s recommendations
even though the tire may be approved for a higher load or inflation.
Rim and wheel may be identified (stamped) with maximum load and
maximum cold inflation rating. For rims and wheels not so identified or
for service conditions exceeding the rate capacities, consult the rim
and wheel manufacturer to determine rim and wheel capacities for the
intended service.
The factory-installed tires on this vehicle were selected to provide
the best all-around tire performance for normal operation. When
inflated, as shown on the vehicle, they have the load carrying capacity
to operate satisfactorily at all loads up to and including the full rated
load specified for the vehicle. For more information concerning the
differences in capacities of tires and rims, refer to the “Tire and Rim
Association Inc. Yearbook,” or your authorized dealer or tire dealer.
TIRE INFLATION
CAUTION: To reduce the risk of loss of vehicle control and
personal injury:
• Tires must be properly inflated, and your vehicle must not be
overloaded (see the information on “Inflation Pressure” in this
section and “Important Information on Vehicle Loading” in the
Introduction Section of this manual.).
CAUTION: Be sure to keep tires properly inflated. A tire that is run
while seriously underinflated will overheat to the point where the
tire may lose air suddenly and/or catch fire, possibly resulting in
personal injury and/or property damage.
In no case should the front or rear tire load exceed the maximum
recommended gross axle weight rating (front GAWR or rear GAWR).
The efficiency of the vehicle will be upset if air pressure in the tire is
not equal. Balanced inflation results when the tires on the same axle
carry the same air pressure. A difference in pressure between the front
and rear tires may be permissible within certain limitations, however,
there should not be a difference in pressures between the right and left
tires on the same axle.
Always use a truck tire pressure gauge (a pocket-type gauge is not
advised) when checking inflation pressures. Visual inspection of tires
for inflation pressures is not enough, especially in the case of radial
tires. Underinflated radial tires may look similar to correctly inflated
radial tires. If the inflation pressure on a tire is found to be low
frequently, have your dealer correct the cause.
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Be sure to install the tire inflation valve caps to prevent dirt and
moisture from getting into the valve core, which could cause air
leakage. An underinflated tire in a dual wheel assembly is harder to
notice than one in a single wheel assembly. The properly inflated dual
tire carries its own load plus that of the underinflated tire. Both tires
can overheat, which may result in property damage and/or personal
injury (see previous caution).
TIRES USED OR STORED FOR A LONG PERIOD OF TIME
Tires are a rubber product and degrade over time, even if they are
not being used. This is also true for spare tires.
If any of your tires is 5 to 7 years old or more, please have them
inspected for safe driving. For further information, please check with
the tire manufacturer.
DUAL TIRE OPERATION
The outer tire of a pair on dual wheel installations generally wears
faster than the inner tire. If this occurs, reverse the position of the tires
to equalize wear and get better tire life.
In addition, when trucks are driven continuously on high-crown
roads, an increase in air pressure of 35 kPa (5 psi) in the outer tire of a
dual tire operation will prolong outer tire life. Be sure not to exceed the
inflation pressure limits shown on the “VIN and Weight Rating Plate”.
The tire pressure should be adjusted to the recommended tire
pressure when high-crown roads are no longer driven on.
WHEEL AND TIRE BALANCING
Proper tire balancing provides the best riding comfort and helps to
reduce tire tread wear. Out-of-balance tires can cause annoying
vehicle vibration and uneven tire wear, such as cupping and flat spots.
See your authorized dealer for wheel balancing.
FRONT END ALIGNMENT
Proper front end alignment improves tire tread mileage. Your
vehicle’s front end suspension parts should be inspected often and
aligned when needed. (See the Maintenance Schedule for more
information). Improper alignment will not cause the vehicle to vibrate;
however, improper toe-in alignment will cause front tires to roll at an
angle that will result in faster tire wear. Incorrect caster or camber
alignment will cause your front tires to wear unevenly, and may cause
the vehicle to “pull” to the left or right.
5-62
58447_Sec05-2_'10 08.12.17 4:18 PM Page 63
TIRE TRACTION
A decrease in driving, cornering and braking traction occurs when
water, snow, ice, gravel or other material is on the road surface.
Driving practices and vehicle speed should be adjusted to the road
conditions. When driving on wet or slushy roads, it is possible for a
wedge of water to build up between the tire and road surface. This is
known as hydroplaning, and may cause partial or complete loss of
traction, vehicle control and stopping ability; this condition is also more
likely with worn tires.
To reduce the chance of traction loss, follow these tips:
1. Slow down during rainstorms or when roads are slushy.
2. Slow down if the road has standing water or puddles.
3. Replace tires when front tread depth is 3.2 mm (4/32 in.) and rear
tread depth is 1.6 mm (2/32 in.).
4. Keep tires properly inflated.
TIRE REPLACEMENT RECOMMENDATIONS
CAUTION: Do not mix different construction types of tires on your
vehicle such as radial, bias and bias-belted tires except in
emergencies, because vehicle handling could be affected and may
result in loss of vehicle control, or personal injury or death.
You should replace your tires when:
1. Your tires are worn to a point where 3.2 mm (4/32 in.) (front) and
1.6 mm (2/32 in.) (rear) or the cord or fabric is exposed.
2. Your tire tread or sidewall is cracked, cut or snagged deeply
enough to expose the core, fabric or steel components.
3. Your tire has a hump, bulge or split.
4. Your tire sustains a puncture, cut or other damage that can’t be
correctly repaired because of the size or location of the damage.
When replacing tires, you should use the same size, load range and
construction type (bias or radial) as the original tires on your vehicle.
Use of any other size or type tire may affect load carrying capacity, ride,
handling, speedometer/odometer calibration, vehicle ground clearance
and tire clearance to the chassis. If replacing only a single tire, it should
be put on the same axle with other tires of equal diameter.
When replacing or rotating tires, all tires on an axle should be of the
same tread design and should have the same outside diameter within
certain limitations, particularly on tandem rear axle models. Consult
your authorized dealer or tire dealer.
5-63
58447_Sec05-2_'10 08.12.17 4:18 PM Page 64
WHEEL REPLACEMENT RECOMMENDATIONS
Wheels must be replaced if they become damaged (for example:
bent, heavily rusted, leak air) or if wheel nuts often become loose. Do
not use bent wheels that have been straightened and do not use inner
tubes in leaking wheels which are designed for tubeless tires. Such
wheels may have structural damage and could fail without warning.
When replacing wheels for any reason, the new wheels should be
equal in load capacity, diameter, width, offset and mounting types to
those originally installed in your vehicle.
A wheel of the wrong size or type may adversely affect wheel and
bearing life, brake cooling, speedometer/odometer calibration, stopping
ability, headlight aim, bumper height, vehicle ground clearance and tire
or tire chain clearance on the body and chassis. Replacement with
“used” wheels is not advised. They may have been subjected to harsh
treatment or very high mileage and could fail without warning.
NOTICE: The use of wheels and/or tires with higher load carrying
limits than originally equipped on your vehicle does not in itself
increase the GAWR or the GVWR of the vehicle.
Replacement wheels can be obtained from the authorized dealer or
tire dealer.
TIRE WARRANTY
For the added convenience of owners, many dealers are equipped to
handle tire warranty adjustments on certain makes of tires provided on
your vehicle.
LUBRICATION
One of the most important items of good vehicle care is the
lubrication of all necessary points with the Right Lubricant, at the Right
Time and in the Right Way. It is the owner’s responsibility to maintain
proper lubrication practices as recommended on the following pages.
See the “Fluids/Lubrications Chart” in the Maintenance Schedule for
recommended lubricants.
See “GREASE POINTS CHART”.
MANUAL TRANSMISSION OIL AND AUTOMATIC TRANSMISSION
FLUID RECOMMENDATIONS
See the Maintenance Schedule to find out how often the lubricant level
should be checked and what type of lubricant should be used.
5-64
58447_Sec05-2_'10 08.12.17 4:18 PM Page 65
VEHICLE STORAGE
If the vehicle is to be placed in storage for a prolonged period of
time, certain precautions must be taken to prevent deterioration. It is
recommended that you write for detailed instructions on how to
prepare your truck for storage.
If the vehicle has been standing for an extended period of time, the
turbocharger bearings should be pre-lubricated prior to starting. See
your authorized dealer for more detailed information.
Or write to:
Isuzu Commercial Truck of America
Customer Relations Department
13340 183rd Street,
Cerritos, CA 90702
(1-866-441-9638)
5-65
58447_Sec05-2_'10 08.12.17 4:18 PM Page 66
LUBRICATION POINTS
GREASE POINTS
1. King Pins — 4 fittings
2. Driveshaft Universal Joints, Sliding Sleeve and Center
Bearing — 5 fittings
1
1
2
5-66
58447_Sec06_'10 08.12.10 10:21 AM Page 1
SECTION 6
SPECIFICATIONS
These specifications are given here for information only. Before
using them, see the Cautions and other instructions throughout this
manual – the index may help you locate such items. For more
information, see the Service Manual covering the chassis or body part
in question. Your authorized dealer may also be able to help.
DIESEL ENGINE SERIAL NUMBER
LOCATION
On the right-hand side, on a machined pad just above the oil pan.
VIN (VEHICLE IDENTIFICATION
NUMBER) AND WEIGHT RATING PLATE
The VIN and Weight Rating plate lists the manufacturer’s gross
vehicle weight for the vehicle, maximum front end weight at the ground,
maximum rear end weight at the ground, and the VIN (vehicle
identification number). This plate is located on the left side rear pillar
panel below the striker (single cab) or on the left center pillar panel
beside the shoulder seat belt anchor (crew cab).
The vehicle identification number is a legal identifier of your vehicle. It
not only appears on the VIN plate; but also on the Vehicle Certificates
of Title and Registration. The vehicle identification number specifically
identifies a vehicle by code. Refer to “INTRODUCTION” in Section 0 for
more information.
6-1
58447_Sec06_'10 08.12.10 10:21 AM Page 2
REPLACEMENT PARTS
Please contact your authorized dealer or parts supplier.
CAUTION: If part replacement is necessary, the part must be
replaced with one of the same part number or with an equivalent
part. Use of a replacement part of lesser quality may result in
personal injury or damage to the vehicle.
FACTORY-APPROVED ACCESSORIES
Your dealer can furnish a wide range of Comfort, Convenience, and
Safety Accessories, especially designed for you and your new truck.
They can install all of the Safety Accessories you will need to comply
with local, state and D.O.T. regulations and advise you how to comply
with these regulations.
Be sure to ask your authorized dealer about the accessories.
TIRE LOAD AND INFLATION TABLE
TIRES FOR VEHICLES IN HIGHWAY SERVICE
TIRE LOAD LIMITS AT VARIOUS COLD INFLATION PRESSURES
RADIAL PLY
Tire Size
Designation
(psi)
50 55 60
65
Dual
LT215/85R-16-E
Single (lbs)
Dual
225/70R 19.5-F
Single (lbs)
70 75
2210
2430
80 85
2470
2680
90
95
3245 3415
3450 3640
6-2
58447_Sec06_'10 08.12.10 10:21 AM Page 3
ENGINE DATA
Manufacturer
Model
Engine Type
Induction
Bore
Stroke
Displacement
Full Load RPM
Isuzu
4HK1-TC
Inline 4, Four Cycle
Turbocharged W/Charge Air Cooler
115 mm
125 mm
5.193L (317 CID)
2400
CAPACITIES
Capacities given are approximated original factory filling quantities.
Use this information for reference only. Actual refill quantities may
vary based on fluid temperature and drain time. Refer to the
appropriate section in this manual for proper fluid checking and refill
procedures.
ENGINE CRANKCASE
4HK1-TC ......................................................................13.0L (13.7 qts)
See section “ENGINE OIL AND FILTER RECOMMENDATIONS” on
page 5-20.
MANUAL TRANSMISSION
Transmission Oil............................................................4.4L (9.3 pints)
See section “MANUAL TRANSMISSION OIL” on page 5-12.
AUTOMATIC TRANSMISSION
Transmission fluid......................................................14.0L (29.6 pints)
See section “AUTOMATIC TRANSMISSION” on page 5-59.
REAR AXLE
Gear Oil.....................................................................10.0L (21.1 pints)
Limited Slip Differential Lubricant Additive..................0.6L (1.27 pints)*
See section “DIFFERENTIAL GEAR OIL” on page 5-13.
* Only for vehicles equipped with optional limited slip differential
FUEL TANK
The fuel tank capacity is stated on a metal plate attached to the fuel
tank body. Only fill the tank to 95 percent of its capacity; this allows
room for the expansion of the fuel.
6-3
58447_Sec06_'10 08.12.10 10:21 AM Page 4
ENGINE COOLING SYSTEM
CAPACITY......................................................................18L (19.0 qts)
THERMOSTAT (Starts to Open) .........................82, 85°C (180, 185°F)
RADIATOR PRESSURE .....................................................108 kPa (16 psi)
WHEEL
WHEEL STUD NUT TORQUE
Front and Rear ......................................................490 N·m (362 ft·Ibs)
Refer to Sections 3 and 5 for complete wheel changing and tire
information.
6-4
58447_Sec06_'10 08.12.10 10:21 AM Page 5
ELECTRICAL DATA
EXTERIOR LIGHTS
Light.................................................................................power
Headlight .......................................................................60/55W
Parking Light ........................................................................5W
Front Turn Signal Light .......................................................27W
Cornering Light ...................................................................27W
Side Turn Signal Light ..........................................................5W
Side Marker Light .................................................................5W
Stoplight / Taillight ...........................................................27/8W
Backup Light ......................................................................27W
Rear Turn Signal Light ........................................................27W
License Plate Light ............................................................7.5W
Identification Light / Clearance Light .....................................5W
Qty.
2
2
2
2
2
2
2
2
2
1
5
INTERIOR LIGHTS
Dome Light .........................................................................10W
Speedometer and Gauge Lights.........................................3.4W
Warning / Indicator Lights (M/T models)................................2W
Warning / Indicator Lights (A/T models) ................................2W
6-5
1
5
17
20
58447_Sec06_'10 08.12.10 10:21 AM Page 6
FUSE BLOCK : CAB
31
32
33
34
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
35 36 37 38
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
No
Circuit
1 RR POWER WINDOW
Fuse
25A
2 -
-
3 ROOM LIGHT, AUDIO
10A
4 DOOR LOCK
15A
5 -
-
6 POWER WINDOW
25A
7 ABS
10A
8 WIPER
25A
9 HEADLIGHT (LOW) (LH)
10A
10 LIGHTS (BATT)
10A
11 HEADLIGHT (LOW) (RH)
10A
12 BRAKE LIGHTS
10A
13 STARTER
10A
14 HEADLIGHT HI (LH)
10A
6-6
58447_Sec06_'10 08.12.10 10:21 AM Page 7
No
Circuit
Fuse
15 HEADLIGHT HI (RH)
10A
16 MIRROR HEATER
15A
17 IGNITION 2
10A
18 IGNITION 1
10A
19 -
-
20 ECM
10A
21 METER
10A
22 ECU (BATT)
10A
23 MIRROR
10A
24 AUDIO, ACCESSORIES
15A
25 HORN
15A
26 TURN, HAZARD
15A
27 TAILLIGHTS
10A
28 ILLUMINATIONS
10A
29 CORNERING LIGHT
10A
30 AIR CONDITIONER
10A
31 CIGAR
20A
32 ACCESSORIES SOCKET
15A
33 POWER SOURCE
20A
34 -
-
35 SPARE
10A
36 SPARE
15A
37 SPARE
25A
38 SPARE
20A
6-7
58447_Sec06_'10 08.12.10 10:21 AM Page 8
6
7
8
1
2
3
4
5
FUSE BLOCK : FRAME
No
Circuit
Fuse
1 MARKER LIGHT
20A
2 TAIL MAIN
20A
3 ECM MAIN
10A
4 -
-
5 -
-
6 RR DOME LIGHT
15A
7 CONDENSER FAN
20A
8 AIR CONDITIONER
10A
FILTER
Air Cleaner (Single cab model) .......................Isuzu
Air Cleaner (Crew cab model).........................Isuzu
Engine Oil ......................................................Isuzu
Fuel................................................................Isuzu
6-8
No.
No.
No.
No.
8-97062-294-0
8-97062-294-0
8-97148-270-1
8-98037-011-0
58447_Sec06_'10 08.12.10 10:21 AM Page 9
INDEX
A
B
ABS ..........................................2-24, 41
Accessory Power Outlet ................2-60
Access to the Electrical
Components ..............................5-57
Access to the Engine......................5-39
Before Tilting the Cab ..................5-40
Checking the Engine Oil ..............5-44
Crew Cab Model ..........................5-40
Engine Inspection Cover..............5-43
Engine Inspection Sub Cover ......5-43
Fuel/Water Separator and
Radiator Surge Tank Inspection
Cover ........................................5-44
Lowering the Cab ........................5-42
Single Cab Model ........................5-39
Tilting the Cab..............................5-40
Access to the Windshield ..............5-46
Acetone ............................................4-1
Adjustable Steering Column ..........2-20
Adjust Driver’s Seat While Parked....1-9
Air Bleeding ..............................5-26, 29
Air Cleaner Filter ....................5-10, 6-8
Air Cleaner/Flame Arrestor ............5-37
Air Conditioning ..............................5-46
Always Lock the Doors ....................1-3
Anti-lock Brake System ............2-24, 41
Appearance Care ............................4-1
Cleaning Agents ............................4-1
Ashtray ............................................1-8
Driver’s and Passenger’s Ashtray..1-8
Rear Ashtray (Crew Cab Model)....1-9
A/T OIL TEMP Warning Light ........2-39
ATF DEXRON-III ..............................5-8
Automatic Engine Warm-up............2-11
Automatic Trans. Controls,
Continued ..................................2-30
Driving Tips ..................................2-31
Overdrive Switch..........................2-32
Starting ........................................2-30
Automatic Transmission Capacity ....6-3
Automatic Transmission Controls ..2-29
Automatic Transmission Selector..2-29
Selecting Gears ..........................2-29
Avoid Unnecessary Idling
of the Diesel Engine ....................2-9
Battery Discharge Warning Light....2-34
Before Driving ................................1-18
Before Driving Off ............................1-1
Before Driving Your Vehicle ............1-1
Before Entering the Truck ................1-1
Before Tilting the Cab
(Single cab model) ....................5-40
Benzene ..........................................4-1
Biocides ........................................2-3, 5
Brake Alarm System ......................2-41
Brake Booster Warning Light..........2-36
Brake Maintenance ........................5-38
Brake System ........................2-22, 5-37
Anti-lock Brake System (ABS) ....2-24
Brake Pedal ................................2-22
Hydraulic Brake Booster (NQR,
NRR) Characteristics ................2-23
Parking Brake ..............................2-26
Vacuum Power Brakes and
Hydraulic Power Brakes ............2-23
Brake System Warning Light ..........2-35
C
Cab Door Locks................................1-3
Always Lock the Doors ..................1-3
Capacities ........................................6-3
Automatic Transmission Capacity..6-3
Engine Crankcase Capacity ..........6-3
Fuel Tank Capacity ........................6-4
Manual Transmission Capacity......6-3
Rear Axle Capacity ........................6-4
Carbon Monoxide ..........2-1, 3-12, 5-16
Care and Cleaning of Exterior ..........4-4
Exterior Finish ................................4-4
Polishing and Waxing ....................4-4
Weatherstrip Lubrication ................4-5
Care and Cleaning of the Interior ....4-1
Cleaning Outside of Windshield ....4-4
Glass Surfaces ..............................4-3
Seat Belt Care................................4-3
Caution and Notice ..........................0-1
Center Lap Belt ..............................1-14
Change Intervals ............................5-24
Check Engine Oil Level ..................5-20
Check Engine Malfunction
Indicator Light............................2-35
Checking the Engine Oil ................5-44
Checks Before Operating ................2-9
6-9
58447_Sec06_'10 08.12.10 10:21 AM Page 10
INDEX
Final Walk-Around Check ..............1-1
Start-up ..........................................1-1
Driver’s Seat Controls ......................1-9
Adjust Driver’s Seat While
Parked ........................................1-9
Fore-and-Aft ..................................1-9
Seatback Latch ............................1-10
Driver’s and Passenger’s Ashtray ....1-8
Driving Techniques ........................2-14
Braking Techniques ....................2-14
Descending a Grade ..............2-14, 20
Driving on Slippery Surfaces........2-15
Riding the Brake ..........................2-14
Steering Techniques ....................2-14
Stopping the Vehicle in the Event
of Service Brake Malfunction ....2-16
Use of the Exhaust Brake ............2-15
Wet Brakes ..................................2-14
Driving Tips ....................................2-31
DRL ................................................2-39
Dual Tire Operation ........................5-62
Check Trans Warning Light ............2-39
Child Restraint ................................1-15
Choosing Oil Viscosity....................5-23
Choosing the Right Quality Oil ......5-22
Cigarette Lighter ............................2-60
Cleaner ............................................4-2
Cleaning Outside of Windshield ......4-4
Clutch Pedal ..................................2-27
Clutch Pedal Free Travel................5-59
Cold Weather Starting ....................2-10
Cornering Light ..............................2-17
Cornering Light / Side Turn Signal
Light / Side Marker Light ..........5-53
Corrosion Protection ........................4-5
Crew Cab Model ............................5-40
Cruise Control ................................2-42
Cruise Main Indicator Light ............2-41
Cruise Set Indicator Light ..............2-41
Customer Satisfaction Procedure ..3-13
D
E
Damaged Tires ................................3-5
Wheel Nut Torque..........................3-7
Wheel Stud Nut Torque ................3-7
Wheel Tightening Sequence..........3-7
Daytime Running Light (DRL)
Indicator Light............................2-39
Defrost ............................................2-63
Descending a Grade ..........2-14, 20, 27
Diesel Engine Cleaning ..................5-25
Diesel Engine Serial Number
Location ......................................6-1
Diesel Fuel Requirement and Fuel
System ........................................2-3
Fuel Economy ................................2-6
Smoke Suppressants ....................2-5
Diesel Fuel System ........................5-26
Fuel Filter ....................................5-28
Fuel System Priming..............5-26, 29
Diesel Particulate Filter (DPF)
................................1-18, 2-49, 5-45
Before Driving ..............................1-18
Discharged Battery ..........................3-1
Dome Light ....................................2-60
Door Locks ......................................1-4
Door Lock Switch..............................1-4
DPF Indicator Light (Green) ..........2-40
DPF Indicator Light (Amber/Red) ..2-40
Driver Daily Checklist ......................1-1
Before Driving Off ..........................1-1
Before Entering the Truck ..............1-1
Effect on Warranty............................0-5
Electrical Data ..................................6-5
Exterior Lights ................................6-5
Fuse Block ....................................6-6
Interior Lights ................................6-5
Electrical System ............................5-47
Access to the Electrical
Components ..............................5-57
Cornering Light / Side Turn Signal
Light / Side Marker Light ..........5-53
Electrical Circuit Protection ..........5-58
Front Turn Signal Lights ..............5-52
Headlights / Parking Lights ..........5-48
Headlight Vertical Aiming
Adjustment ................................5-47
Roof Marker Light (Identification
Light / Clearance Light) ............5-56
Turn Signals ................................5-47
Working Near Battery ..................5-56
Emergency Starting Your
Vehicle due to a
Discharged Battery......................3-1
Enamel Reducers ............................4-1
Engaging the Clutch ......................2-27
Engine Alarm and Automatic
Shutdown ..................................2-12
Engine Alarm (Shutdown) Warning
Light ..........................................2-35
6-10
58447_Sec06_'10 08.12.10 10:21 AM Page 11
INDEX
Engine Block Heater ......................2-11
Engine Control Switch ..........2-7, 21, 45
Engine Coolant Temperature (ECT)
Gauge........................................2-59
Engine Cooling System ..........5-32, 6-4
Air Cleaner/Frame Arrestor..........5-37
Engine Cooling System Care ......5-32
Engine Cooling System Service ..5-33
Radiator Pressure Cap ................5-36
Thermostat ..................................5-36
Engine Cooling System
Capacity ......................................6-4
Engine Cooling System
Overheating ................................3-3
Engine Crankcase Capacity ............6-3
Engine Data......................................6-3
Engine Exhaust Gas Caution ..........2-1
Engine Inspection Cover
(Crew cab model) ......................5-43
Engine Inspection Sub Cover
(Crew cab model) ......................5-43
Engine Noise ....................................5-9
Engine Oil and Filter
Recommendations ....................5-20
Change Intervals..........................5-24
Check Engine Oil Level................5-20
Choosing Oil Viscosity ................5-23
Choosing the Right Quality Oil ....5-22
Engine Oil Additives ....................5-24
Oil Identification Logo ..................5-24
Used Oil Disposal ........................5-25
Engine Oil Pressure Warning
Light ..........................................2-38
Engine Overheating Warning
Light ..........................................2-37
Engine Warm-up System................2-11
Automatic Engine Warm-up ........2-11
Engine Block and Oil Pan
Heater........................................2-11
Exhaust Brake ................................2-19
Exhaust Brake Indicator
Light ..........................................2-33
Explanation of Complete Vehicle
Maintenance Schedule................5-9
Normal Vehicle Use ......................5-9
Explanation of Vehicle Maintenance
and Log ......................................5-2
Exterior Finish ..................................4-4
External Diesel Engine Cleaning ....5-25
F
Factory-Approved Accessories ........6-2
Filter..................................................6-8
Final Walk-Around Check ................1-1
Fore-and-Aft ....................................1-9
Freeing the Vehicle ........................3-11
Front Axle Weight ............................0-4
Front End Alignment ......................5-62
Front End Towing ........................3-8, 9
Front Turn Signal Lights ................5-52
Fuel Additive ....................................2-3
Fuel Cap ..................................5-19, 30
Fuel Economy ..................................2-6
Fuel Filter........................................5-28
Fuel Gauge ....................................2-60
Fuel System Priming ................5-26, 29
Fuel Tank Capacity ..........................6-3
Fuel/Water Separator and Radiator
Surge Tank Inspection Cover....5-44
Fuse Block........................................6-6
Fuses..............................................5-58
G
Gasoline ....................................2-4, 4-1
GAWR ..............................................0-4
Glass Surfaces ................................4-3
Glow Plug Indicator Light................2-35
Graphic Symbols ..............................0-2
Guard Against Theft ......................2-12
GVWR ..............................................0-4
H
Hazard Warning Flasher ........2-21, 3-1
HBB ......................................2-23, 5-38
Headlight Dimmer Switch ..............2-18
Headlights High Beam Indicator
Light ..........................................2-33
Headlights / Cornering Lights ........2-17
Headlights / Parking Lights ............5-48
Headlight Vertical Aiming
Adjustment ................................5-47
Heating and Ventilation Systems
Controls ....................................2-61
Optional Air Conditioning ............2-61
Windshield Defrosting and
Defogging Operating Tips ........2-63
Horn................................................2-21
6-11
58447_Sec06_'10 08.12.10 10:21 AM Page 12
INDEX
Parking Brake Indicator Light ......2-37
Service Vehicle Soon (SVS)
Light ..........................................2-40
Turn Signal Indicator Light ..........2-33
Water Separator Indicator Light ..2-40
Instrument Panel Light Level
Control ......................................2-46
Interior Lights....................................6-5
Introduction ......................................0-1
Hydraulic Brake Booster (NQR,
NRR) Characteristics ................2-23
I
Idle Speed Control..........................2-45
Important Information on
Vehicle Loading ..........................0-4
Effect on Warranty ........................0-5
Maximum Front and Rear
Axle Weights ..............................0-5
Overloading....................................0-4
In Case of Emergency ......................3-1
Discharged Battery ........................3-1
Jump Starting Instructions ............3-2
Hazard Warning Flasher ................3-1
Inside Door Handles ........................1-3
Instrument Panel and Controls ......2-33
Anti-Lock Brake System (ABS)
Malfunction Warning Light ........2-41
Automatic Transmission Fluid
Temperature Warning Light ......2-39
Battery Discharge Warning
Light ..........................................2-34
Brake Alarm System ....................2-41
Brake Booster Warning Light ......2-36
Brake System Warning Light ......2-35
Check Engine Malfunction
Indicator Light............................2-35
Check Trans Warning Light ........2-39
Cruise Main Indicator Light ..........2-41
Cruise Set Indicator Light ............2-41
Daytime Running Lights (DRL)
Indicator Light............................2-39
DPF Indicator Light (Green) ........2-40
DPF Indicator Light
(Amber/Red)..............................2-40
Engine Alarm (Shutdown) Warning
Light ..........................................2-35
Engine Oil Pressure Warning
Light ..........................................2-38
Engine Overheating Warning
Light ..........................................2-37
Exhaust Brake Indicator Light ......2-33
Glow Plug Indicator Light ............2-35
Headlights High Beam Indicator
Light ..........................................2-33
Indicator and Warning Lights ......2-33
Low Coolant Warning Light..........2-38
Low Fuel Level Indicator Light ....2-34
Oil Level Indicator Light ..............2-40
Overdrive Indicator Light..............2-39
J
Jump Starting Instructions ................3-2
K
Kerosene ..........................................2-4
Key ..................................................1-2
Key Removal ..................................2-10
L
Lacquer Thinner ..............................4-1
Lap-Shoulder Belt ..........................1-12
Left-hand Control Lever..................2-17
Cornering Lights ..........................2-17
Headlight Dimmer Switch ............2-18
Headlights ....................................2-17
Passing Light Switch....................2-18
Turn Signal ..................................2-17
Light Control Switch........................2-45
Lock Button ......................................1-5
Locking Clip-Full Size ....................1-17
Low Coolant Warning Light ............2-38
Low Fuel Level Indicator Light........2-34
Lowering the Cab
(Single cab model) ....................5-42
Lubrication ......................................5-64
Manual Transmission Oil and
Automatic Transmission
Fluid Recommendations............5-64
Lubrication Points ..........................5-66
M
Maintenance Items to Aid Cold
Weather Starting ......................5-30
Starting Aids ................................5-31
Maintenance Schedule ....................5-1
6-12
58447_Sec06_'10 08.12.10 10:21 AM Page 13
INDEX
Manual Transmission Controls
and Operation............................2-27
Clutch Pedal ................................2-27
Descending a Grade ....................2-27
Engaging the Clutch ....................2-27
Manual Transmission Oil and
Automatic Transmission
Fluid Recommendations............5-64
Maximum Front and Rear
Axle Weights ..............................0-5
Mechanical Driveshaft Brake Burnish
Procedure....................................2-2
Miles Check Switch ........................2-47
Mirrors ..............................................1-8
Outside Rearview Mirrors ..............1-8
Mobile Telephones ........................2-63
Model Reference ..............................0-7
P
Parking ..........................................2-12
Parking Brake ................................2-26
Parking Brake Indicator Light ..........2-37
Passing Light Switch ......................2-18
Power Door Locks
(If Equipped)................................1-4
Door Locks ....................................1-4
Door Lock Switch ..........................1-4
Lock Button ....................................1-5
Power Steering ..............................2-21
Power Steering System ..................5-31
Power Windows
(If Equipped)................................1-5
Power Window Switch
(Driver’s Door) ............................1-5
Power Window Switch
(Passenger’s Door) ....................1-6
Power Window Switch
(Crew cab model) ........................1-6
Preventive Maintenance ..................5-3
Maintenance Schedule ..................5-4
PTO (Power Take-Off) Switch ........2-48
N
Naphtha ............................................4-1
New Vehicle Break-in ......................2-2
NHTSA ..........................................3-14
Noise Emission Control ..................5-18
Noise Control System ..................5-18
Tampering with Noise Control
System Prohibited ....................5-18
Normal Vehicle Use..........................5-9
R
Radiator Cooling Fan and
Governed Speed ......................5-37
Radiator Grille Covers ....................5-37
Radiator Pressure ............................6-4
Radiator Pressure Cap ..................5-36
Rear Ashtray ....................................1-9
Rear Axle Capacity ..........................6-3
Rear Axle Weight..............................0-4
Rear End Towing............................3-11
Recommended Fluids and
Lubricants....................................5-8
Replacement Fasteners ................5-19
Fuel Cap ......................................5-19
Replacement Parts ..........................6-2
Reporting Safety Defects................3-14
Riding the Brake ............................2-14
Right-Hand Control Lever ..............2-18
Adjustable Steering Column ........2-20
Engine Control Switch..................2-21
Exhaust Brake..............................2-19
Hazard Warning Flasher ..............2-21
Horn ............................................2-21
Steering Column Adjustment ......2-20
Windshield Washer ......................2-19
Windshield Wipers ......................2-18
O
Odometer and Trip meter ..............2-57
Oil Check Switch ............................2-47
Oil Identification Logo ....................5-24
Oil Level Indicator Light ..................2-40
Oil Pan Heater ................................2-11
Oil Viscosity ....................................5-23
Optional Air Conditioning................2-61
Outside Door Handles ......................1-3
Outside Rearview Mirrors ................1-8
Outside Rearview Mirror Heater
Switch (If Equipped) ..................2-46
Overdrive Switch ............................2-32
Overloading ......................................0-4
Overdrive Indicator Light ................2-39
Overfilling Automatic
Transmission ............................5-59
Owner Maintenance ........................5-1
Owner Safety and Routine
Maintenance..............................5-15
6-13
58447_Sec06_'10 08.12.10 10:21 AM Page 14
INDEX
Sun Visors ........................................1-8
Switches and Controls....................2-45
Engine Control Switch..................2-45
Idle Speed Control ......................2-45
Instrument Panel Light Level
Control ......................................2-46
Lighting Control Switch ................2-45
Miles Check Switch......................2-47
Oil Check Switch..........................2-47
Outside Rearview Mirror Heater
Switch........................................2-46
PTO (Power Take-Off) Switch ....2-48
Windshield Wiper and Washer
Controls ....................................2-46
Roof Marker Light (Identification
Light / Clearance Light) ............5-56
S
Seat Belt Care ..................................4-3
Seat Belt Systems ..........................1-11
Center Lap Belt ............................1-14
Child Restraint ............................1-15
Lap-Shoulder Belt ........................1-12
Locking Clip-Full Size ..................1-17
Seat Belt Extender ......................1-17
Seat Belt Inspection ....................1-14
Seatback Latch ..............................1-10
Selecting Gears ..............................2-29
Service and Maintenance ................5-1
Maintenance Schedule ..................5-1
Owner Maintenance ......................5-1
Service Vehicle Soon (SVS) Light ..2-40
Shifting Gears ................................2-28
Shutting Down the Turbocharged
Diesel Engine ............................2-10
Single Cab Model ..........................5-39
Smoke Suppressants ......................2-5
Special Towing Instructions............3-11
Specifications ..................................6-1
Speedometer and Gauges ............2-57
Accessory Power Outlet ..............2-60
Cigarette Lighter ..........................2-60
Dome Light ..................................2-60
Engine Coolant Temperature
Gauge........................................2-59
Fuel Gauge ..................................2-59
Speedometer ..............................2-59
Tachometer..................................2-59
Start-up ............................................1-1
Starting ..........................................2-30
Starting Aids ..................................5-31
Starting and Operating ....................2-1
Engine Exhaust Gas Caution ........2-1
Starting Procedure............................2-7
Avoid Unnecessary Idling ..............2-9
Checks Before Operating ..............2-9
Starting the Engine ..........................2-7
Engine Control Switch....................2-7
Steering Column Adjustment..........2-20
Steering Column Controls ..............2-16
Anti-Theft Steering Column Lock 2-16
Steering Techniques ......................2-14
Stopping the Vehicle in the Event of
Service Brake
Malfunction ......................2-16, 3-12
T
Tachometer ....................................2-59
Tampering with Noise Control
System Prohibited ....................5-18
Thermostat ..............................5-36, 6-4
Thermostat (Starts to Open) ............6-4
Tilting the Cab
(Single cab model) ....................5-40
Tires..................................................0-6
Tire Inflation....................................5-61
Tire Load and Inflation Table............6-2
Tire Replacement
Recommendations ....................5-63
Tire Traction ..................................5-63
Tires Used or Stored for a Long
Period of Time ..........................5-62
Tire Warranty..................................5-64
Towing Your Isuzu Truck
Procedure....................................3-8
Front End Towing ......................3-8, 9
Rear End Towing ........................3-11
Special Towing Instructions ........3-11
Turn Signal ............................2-17, 5-47
Turn Signal Indicator Light..............2-33
U
Underbody Maintenance ..................4-6
Use of the Exhaust Brake
(on slippery surfaces) ................2-15
Used Oil Disposal ..........................5-25
Using the Engine as a Brake ..........3-11
Stopping the Vehicle in the Event
of Service Brake Malfunction ....3-12
6-14
58447_Sec06_'10 08.12.10 10:21 AM Page 15
INDEX
V
Vacuum or Hydraulic Power Assisted
Brakes ......................................2-23
Vehicle Identification Number ..........0-6
Vehicle Storage ..............................5-65
VIN and GVW Plate..........................5-2
VIN and Weight Rating
Plate ................................0-4, 6, 6-1
VIN Interpretation ............................0-8
W
Water Separator ............................5-28
Fuel Cap ......................................5-30
Fuel System Priming....................5-29
Replacement Water Separator
Filter Element ............................5-29
Water Separator Indicator Light......2-40
Weatherstrip Lubrication ..................4-5
Wet Brakes ....................................2-14
Wheel ..............................................6-4
Wheel Nut Torque ..................3-7, 5-14
Wheels and Tires............................5-61
Dual Tire Operation......................5-62
Front End Alignment ....................5-62
Tire Inflation ................................5-61
Tire Replacement
Recommendations ....................5-63
Tire Traction ................................5-63
Tires Used or Stored for a Long
Period of Time ..........................5-62
Tire Warranty ..............................5-64
Wheel and Tire Balancing............5-62
Wheel Replacement
Recommendations ....................5-64
Wheel Stud Nut Torque ............3-7, 6-4
Wheel Tightening Sequence ............3-7
Window Controls ..............................1-5
Window Regulator Handle
(Manual Window Model)..............1-5
Windshield Washer ..............2-19, 5-31
Windshield Wiper and Washer
Controls ....................................2-46
Windshield Wipers..........................2-18
Working Near Battery ....................5-56
6-15
DATE
MILEAGE
$
FUEL
$
OIL
$
REPAIRS
DATE
MILEAGE
OPERATING RECORD
$
FUEL
$
OIL
REPAIRS
$
58447_Sec07_'10 08.11.26 3:54 PM Page 1
DATE
MILEAGE
$
FUEL
$
OIL
$
REPAIRS
DATE
MILEAGE
OPERATING RECORD
$
FUEL
$
OIL
REPAIRS
$
58447_Sec07_'10 08.11.26 3:54 PM Page 2
58447_Sec07_'10 08.11.26 3:54 PM Page 3
SERVICE MANUALS
All Service Manuals are available from your local authorized Isuzu
dealer, and you are encouraged to order from them directly. In the
event that you are unable to contact your local dealer, use the below
website.
As a do-it-yourselfer, you’ll be glad to know that these Service Manuals
are the same manuals utilized by the professional technicians at your
Isuzu dealership.
WWW.ISUZUTRUCKSERVICE.COM
58447_Sec07_'10 08.11.26 3:54 PM Page 4
SERVICE PUBLICATIONS ORDER FORM
The publications listed covering the operation and servicing of your
Isuzu Truck can be obtained from Helm, Incorporated either by filling
out the reverse side of this form; or for credit card holders calling toll
free 1-800-782-4356, or FAXing to 313-865-5927.
Commercial Accounts should enclose a company check made payable
to Helm, Incorporated for the total amount of the order. Or, furnish us
with a Purchase Order and we will bill on Helm Open Account. (The
minimum P.O. amount is $100.00 and is subject to credit Approval.)
For purchases outside of the U.S.A. and for publications prior to the
year(s) shown, contact Helm, Incorporated at P.O. Box 07280, Detroit,
Michigan 48207 or call (313)865-5000 for availability.
The Service Manuals contain repair and overhaul information on engine,
transmission, axle, suspension, brakes, electrical, steering, body, etc.
PUBLICATION
NUMBER
DESCRIPTION
PRICE
EACH
Please contact Helm at 1-800-782-4356 for publication number and pricing
information.
NPD10-GBX-C01
2010 NPR-HD, NQR, NRR
GLOVE BOX PACKET
$24.95
* Prices are subject to change without notice and without incurring
obligation.
PLEASE SEE REVERSE SIDE FOR ORDERING INSTRUCTIONS.
58447_Sec07_'10 08.11.26 3:54 PM Page 5
ORDER TOLL FREE: 1-800-782-4356
(NOTE: For Credit Card Holders Only)
Monday-Friday 8:30 A.M. -6:00 P.M. EST
(MINIMUM CREDIT CARD PURCHASE $10.00)
—OR—
By completing this form you can order the materials desired. You can pay by check or
money order, or charge to your credit card. Mail to Helm, incorporated at the address
shown below.
VEHICLE MODEL
PUBLICATION FORM NUMBER
NAME
YEAR
QTY.
PRICE
EACH
TOTAL
PRICE
2
0
1
0
TOTAL MATERIAL
Orders are mailed within 10 days.
Please allow adequate time for delivery.
MICH. PURCHASERS
ADD 6% SALES TAX
HANDLING CHARGE
$6.95
GRAND TOTAL
S
H
I
P
NOTE: Dealers and Companies please provide dealer or company name, and also the name of the
person to whose attention the shipment should be sent. For purchases outside U.S.A. please write
to the above address for quotation.
(CUSTOMER NAME)
(ATTENTION)
(STREET ADDRESS-NO P.O. BOX NUMBERS)
T
O
P
A
Y
M
E
N
T
(CITY)
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payable to Helm, Inc.
(U.S. funds only —
do not send cash.)
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(APT. NO.)
(STATE)
AREA
CODE
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Check here if your billing address is different from
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Account
Number
Expiration
Mo-Yr
(CUSTOMER SIGNATURE)
(DATE)
Material cannot be returned for credit without receiving advance authorization within
14 days of delivery. On returns, a restocking fee may be applied against the original
order.
P.O. BOX 07280 • DETROIT, MICHIGAN 48207
58447_Sec07_'10 08.11.26 3:54 PM Page 6
58447_Sec07_'10 08.11.26 3:54 PM Page 7
58447_Sec07_'10 08.11.26 3:54 PM Page 8
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