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ISUZU ENGINE AFTER SERVICE

2

ISUZU GENUINE PARTS

The Isuzu genuine parts are identical with those of used in the
engine production, and accordingly, they are warranted by Isuzu
Motors Limited.
The Isuzu genuine parts are supplied by the Isuzu distributors or
the authorized parts suppliers. Please designate "Isuzu Genuine
Parts" when you need engine parts.

EMISSION-RELATED INSTALLATION INSTRUCTIONS (REF)

Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment
violates Federal Law (40 CFR1068.105(B)), subject to fines or other penalties as described in the clean air
act.

Installation of Nonroad Engines into Equipment

To ensure engines operate under the certified configurations, Isuzu has established defined application
requirements when installing any certified engine into a piece of equipment. The instructions outlined below
are included in our certification process and any failure to comply will be considered tampering.

Isuzu certifies engines to operate under variable speed or constant speed conditions. Engines certified as
constant speed are prohibited from installation into variable speed applications. The emission control
information label will identify an engine certified as constant speed.

Allowable Air Intake Restriction and Exhaust Back Pressure

Resistance to intake airflow and exhaust gas flow is generated in the intake and exhaust systems.
Exceeding the limitations will affect the operation of an engine and its certified configuration. Refer to the
installation requirements and limitations of the Isuzu C series Application Manual for the engine being
equipped with these systems.

Allowable Air Intake Restriction

Allowable Exhaust Back Pressure

Engine model

Allowable air intake restriction



kPa (mmAq)

Initial upper limit

Upper limit for air cleaner replacement

All models

2.94 (300)

6.23 (635)

Engine model

Allowable exhaust back pressure



kPa (mmAq)

Initial upper limit

Upper limit for exhaust system cleaning

3CH1, 3CJ1

9.81 (1000)

11.77 (1200)

3CE1

12.75 (1300)

15.30 (1560)

TNV_OperationManual_T4(under 19kW).book Page 2 Wednesday, June 17, 2015 11:23 AM

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Содержание 3CH1-NGZG01

Страница 1: ...s transferred to subsequent owners This manual should be considered a permanent part of the engine and remain with it Constant efforts are made to improve the quality and performance of Isuzu products...

Страница 2: ..._______________ Dealer phone ________________________________________________________________________ SYMBOL EXPLANATION The following symbols are used throughout this manual to identify specific engi...

Страница 3: ...ir Intake Restriction 2 Allowable Exhaust Back Pressure 2 Safety 3 Safety Statements 3 Safety Precautions 4 Before You Operate 4 During Operation and Maintenance 4 Product Overview 13 Isuzu C series E...

Страница 4: ...e Oil Viscosity 44 Checking Engine Oil 44 Adding Engine Oil 44 Engine Oil Capacity Typical 45 Engine Coolant 46 Engine Coolant Specifications 47 Filling Radiator with Engine Coolant 47 Daily Check of...

Страница 5: ...l 50 Hours of Operation 66 Every 50 Hours of Operation 71 Every 250 Hours of Operation 75 Every 500 Hours of Operation 79 Every 1000 Hours of Operation 83 Every 1500 Hours of Operation 85 Every 2000 H...

Страница 6: ...TABLE OF CONTENTS vi This Page Intentionally Left Blank TNV_OperationManual_T4 under 19kW book Page vi Wednesday June 17 2015 11 23 AM...

Страница 7: ...ation Manual ISUZU ENGINE AFTER SERVICE Please feel free to contact your Isuzu distributor for periodical inspection and maintenance TNV_OperationManual_T4 under 19kW book Page 1 Wednesday June 17 201...

Страница 8: ...ered tampering Isuzu certifies engines to operate under variable speed or constant speed conditions Engines certified as constant speed are prohibited from installation into variable speed application...

Страница 9: ...it make sure you order the new part and label at the same time DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a ha...

Страница 10: ...t by observing the reserve tank Failure to comply will result in death or serious injury DANGER Explosion Hazard Keep the area around the battery well ventilated While the engine is running or the bat...

Страница 11: ...iesel fuel as a cleaning agent Never remove the fuel cap with the engine running DANGER Continued Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and...

Страница 12: ...ets away while the engine is operating Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or s...

Страница 13: ...ck during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or se...

Страница 14: ...uld result in unexpected movement of the equipment Failure to comply could result in death or serious injury CAUTION Coolant Hazard Wear eye protection and rubber gloves when you handle long life or e...

Страница 15: ...u remove the cap Never mix different types of engine coolants This may adversely affect the properties of the engine coolant NOTICE Never attempt to adjust the low or high idle speed limit screw This...

Страница 16: ...allation Refer to the documentation supplied by the optional equipment manufacturer for specific operation and maintenance instructions NOTICE Observe the following environmental operating conditions...

Страница 17: ...rts Protect the air cleaner turbocharger if equipped and electric components from damage when you use steam or high pressure water to clean the engine Never use high pressure water or compressed air a...

Страница 18: ...ose in accordance with the disposal standards for industrial waste defined by local laws and regulations Handling The contents of the bag do not leak out in the normal use Take the following emergency...

Страница 19: ...ine applications the engine s flywheel housing or end plate is coupled directly to the driven machine In belt drive engine applications a belt drive is used to power the driven machine If you have app...

Страница 20: ...oil 12 Fuel priming lever 13 Engine oil filter 14 Governor lever 15 Fuel injection pump 16 Intake manifold 17 Air intake port from air cleaner 18 Fuel filter 19 Fuel return to fuel tank 20 Top filler...

Страница 21: ...er port engine oil 10 Drain plug engine oil 11 Engine oil filter 12 Mechanical fuel pump 13 Fuel injection pump 14 Dipstick engine oil 15 Governor lever 16 Top filler port engine oil 17 Rocker arm cov...

Страница 22: ...injection pump 10 Engine oil filter 11 Intake manifold 12 Dipstick engine oil 13 Fuel filter 14 Fuel return to fuel tank 15 Fuel inlet 16 Top filler port engine oil 17 Rocker arm cover 18 EGR valve 19...

Страница 23: ...ocation of regulatory and safety labels on Isuzu C series indirect injection model engine 1 K0000585A 2 Figure 5 shows the location of regulatory and safety labels on Isuzu C series direct injection m...

Страница 24: ...lps to keep the engine oil cool Engine coolant from the cooling system is circulated by the coolant pump through an adapter at the base of the engine to the oil cooler and then to the cylinder block a...

Страница 25: ...uel pump primes the fuel system The fuel system needs to be primed before you start the engine for the first time if you run out of fuel or if fuel system service is performed To prime the fuel system...

Страница 26: ...the heat is transferred to the air Radiator cap The radiator cap controls the cooling system pressure The cooling system is pressurized to raise the boiling point of the engine coolant As the engine...

Страница 27: ...NING Replacing the fuel injection pump involves rewriting the fuel injection data in the E ECU Be sure to contact your Isuzu Distributor before replacing the fuel injection pump Failure to rewrite the...

Страница 28: ...nit has been turned on or off Do not touch connector pins of the E ECU with bare hands Doing so may result in corrosion of the connector pins and or damage to the internal circuits of the E ECU due to...

Страница 29: ...the electronic engine control system include Engine speed control schemes Droop control Low idling speed up Auto deceleration High idling speed down Black smoke suppression Starting aid Auto preheati...

Страница 30: ...of the exhaust manifold Accelerator sensor Unlike mechanical governors the Eco governor has no governor lever The accelerator sensor serves as the governor lever to provide the speed command signal vo...

Страница 31: ...ng speed up Increases the low idling speed to up to 1000 min 1 rpm depending on the engine coolant temperature When the coolant temperature reaches a predetermined value this feature returns the engin...

Страница 32: ...uges are located on a typical operator s console Some operator s consoles may not have the gauges described here or may have different gauges Figure 7 Figure 8 Tachometer The tachometer display Figure...

Страница 33: ...cator turns off is when to start the operation In the case of 3CE1 DI the indicator goes off after 15 seconds Battery charge Figure 9 2 or Figure 10 2 When the key is turned to the ON position the cha...

Страница 34: ...hart on page 90 Auxiliary Figure 11 2 Reserved as an optional fault indicator HEAT Figure 11 3 This indicator will come on when the glow plugs are energized when cold starting the engine For the elect...

Страница 35: ...en the engine is not running use this position to energize the gauges indicators electric fuel pump and auxiliary devices NOTICE Never hold the key in the START position for longer than 15 seconds or...

Страница 36: ...ne starting sequence the glow plugs are activated for approximately 4 seconds 15 seconds in case of 3CE1 After the pre heat indicator goes out the engine can be started These plugs are installed in th...

Страница 37: ...ine causing the engine to stop Speed Control of Electronically Controlled Engines 3CE1 The electronically controlled engines have no governor lever For these engines the position signal of the throttl...

Страница 38: ...of isochronous design engines the speed of which is kept constant from no load to full rated load See curves 2 in Figure 19 below Some VM series engines for general use may be custom engineered and h...

Страница 39: ...g speed depending on the engine coolant temperature When the coolant temperature falls to a predetermined value this feature returns the engine speed to the normal high idle setting thus minimizing th...

Страница 40: ...PRODUCT OVERVIEW 34 This Page Intentionally Left Blank TNV_OperationManual_T4 under 19kW book Page 34 Wednesday June 17 2015 11 23 AM...

Страница 41: ...ction of the Operation Manual describes the diesel fuel engine oil and engine coolant specifications and how to replenish them It also describes the daily engine checkout TNV_OperationManual_T4 under...

Страница 42: ...5 by volume Less than 30 is preferred PAH Polycyclic Aromatic Hydrocarbons content should be below 10 by volume Metal content of Mg Si and Al should be equal to or lower than 1 mass ppm Test analysis...

Страница 43: ...ve an adverse affect on the engine s performance its integrity and or durability The risk of problems occurring in the engine increases as the level of biodiesel blend increases The following negative...

Страница 44: ...g the bio diesel fuel of B10 or higher replace the following parts Fuel hose The hose must be replaced every 2 years or 2000 hours regardless of the bio fuel type O ring of fuel filter O ring of water...

Страница 45: ...el injection nozzle Part No No need 5 8640 1423 0 5 8640 0112 0 Part name CAP CLIP Number 1 1 Fuel injection nozzle Fuel injection nozzle No No need 13 Length 115 Part No 5 8640 1791 0 Part name FO T...

Страница 46: ...051 00X B 033050 00X 033042 00X D C E Part number A 5 8640 2246 0 P44 B 5 8640 2246 0 P44 C 5 8640 2251 0 G75 D 5 8640 1755 0 P16 E 5 8640 2252 0 P7 TNV_OperationManual_T4 under 19kW book Page 40 Wedn...

Страница 47: ...shutdown Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out...

Страница 48: ...After fuel system maintenance such as changing the fuel filter and draining the water separator or replacing a fuel system component To prime the fuel system if an electric fuel pump is installed 1 Tu...

Страница 49: ...ponents to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap Never mix...

Страница 50: ...oil viscosity based on the ambient temperature and use the SAE service grade viscosity chart in Figure 3 Figure 3 Checking Engine Oil 1 Make sure engine is level 2 Remove dipstick Figure 4 1 and wipe...

Страница 51: ...vary dependent upon which optional oil pan is used Refer to the operation manual provided by the driven machine manufacturer for the actual engine oil capacity of your machine The following are the e...

Страница 52: ...you Failure to comply could result in death or serious injury CAUTION Coolant Hazard Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the...

Страница 53: ...commends that soft distilled or demineralized water be used to mix with coolants Never mix extended or long life coolants and conventional green coolants Never mix different types and or colors of ext...

Страница 54: ...L HOT mark Figure 5 6 If the coolant is not at the FULL HOT mark add coolant to the reserve tank to bring the coolant level to the FULL HOT mark Daily Check of the Cooling System 1 Check the level of...

Страница 55: ...nt leaks 4 Check for damaged or missing parts 5 Check for loose missing or damaged fasteners 6 Check the electrical harnesses for cracks abrasions and damaged or corroded connectors 7 Check hoses for...

Страница 56: ...to START position and start the engine In the case of 3CE1 DI the indicator goes off after 15 seconds Figure 7 shows an indicator arrangement with the specification for ON glow As you turn the key swi...

Страница 57: ...engine overheats Auxiliary Figure 7 5 or Figure 9 2 Stays on momentarily Used for special applications Here is a summary of how these indicators function The table shows what happens when you turn th...

Страница 58: ...F Stays on until alternator is supplying charging current Remains on if there is a problem in the charging system This indicator does not indicate whether the battery is discharged Engine oil pressure...

Страница 59: ...This section of the Operation Manual describes the procedures for starting the engine checking engine performance during operation and shutting the engine down TNV_OperationManual_T4 under 19kW book...

Страница 60: ...on once before starting the engine The E ECU has usually been initialized before the driven machine is delivered From the second power up make sure the fault indicator is on for 2 sec when turning the...

Страница 61: ...ure 2 2 or Figure 3 5 Note The starter of electronically controlled engines 3CE1 will start with a delay of approx 0 5 sec after the key switch has been turned to the ON position This is because the E...

Страница 62: ...is assembled on the implement side The output control solenoid actuates at engine start It does not actuate during engine operation At engine start the starter operates and the engine starts running 4...

Страница 63: ...cardboard Have your Isuzu Distributor repair the damage Failure to comply could result in death or serious injury NOTICE Make sure the engine is installed on a level surface If a continuously running...

Страница 64: ...the gauges for normal indications The gauges shown in Figure 6 and Figure 5 are provided for illustrative purposes only Figure 5 Figure 6 Tachometer Figure 6 1 or Figure 5 1 Make sure the engine speed...

Страница 65: ...engine coolant or engine oil leaks If any leaks are found shut down the engine and have the necessary repairs performed 6 Check the fuel level during operation If the fuel level runs low stop the engi...

Страница 66: ...steps to shut down the engine 1 Disengage the PTO and or set the transmission to NEUTRAL if equipped 2 Set the engine speed control to its lowest setting 3 Run the engine at low idle speed for at leas...

Страница 67: ...Manual PERIODIC MAINTENANCE This section of the Operation Manual describes the procedures for proper care and maintenance of the engine TNV_OperationManual_T4 under 19kW book Page 61 Wednesday June 1...

Страница 68: ...ks are performed on a regular basis Make it a habit of performing daily checks before the start of each shift See Daily Checks on page 49 Keep a Log of Engine Hours and Daily Checks Keep a log of the...

Страница 69: ...lying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure NOTICE The tightening torque in the Standard Torque Chart in the Periodic Mainte...

Страница 70: ...ten the engine s life and may affect the warranty coverage on your engine Consult your Isuzu Distributor for assistance when checking items marked with a Periodic Maintenance Chart Check Replace Conta...

Страница 71: ...nk level Drain fuel tank Drain water separator Check water separator Clean water separator Replace fuel filter Hoses Check and replace fuel hoses and engine coolant hoses or every 2 years Intake and e...

Страница 72: ...components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap Never...

Страница 73: ...oil pan is used Drain the engine oil as follows 1 Make sure the engine is level 2 Start the engine and bring it up to operating temperature 3 Stop the engine 4 Remove one of the oil filler caps Figur...

Страница 74: ...to 14 17 ft lb 19 6 23 5 N m 2 0 2 4 kgf m or one additional turn using the oil filter wrench Consult the operation manual for the driven machine for applicability of the dust proof filter 4 Add new...

Страница 75: ...Press the V belt down with your thumb with a force of approximately 22 ft lb 98 N m 10 kgf m to check the deflection There are three positions to check for V belt tension Figure 4 A B and C You can c...

Страница 76: ...on Then tighten the adjusting bolts and or nuts Figure 5 3 Tighten the V belt to the proper tension There must be clearance Figure 6 1 between the V belt and the bottom of the pulley groove If there i...

Страница 77: ...er use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when y...

Страница 78: ...ater separators are equipped with a sensor to detect the amount of contaminants This sensor sends a signal to an indicator to alert the operator Figure 7 1 Position an approved container under the wat...

Страница 79: ...pen the fuel valve 8 Be sure to prime the diesel fuel system See Priming the Fuel System on page 42 9 Check for fuel leaks Check battery and recharge DANGER Explosion Hazard Never short out the batter...

Страница 80: ...t start recharge the battery Use a specialized battery charger to recharge the battery with a voltage of 8 volts or less Charging the battery by booster even with a voltage of 8 bolts or less will gen...

Страница 81: ...serious injury NOTICE Always be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fu...

Страница 82: ...se procedures may seriously harm the environment Change the engine oil every 250 hours of operation after the initial change at 50 hours Replace the engine oil filter at the same time See Replace engi...

Страница 83: ...ine and shorten its life If the idle speed limit screws require adjustment see your Isuzu Distributor 1 Check that the governor lever Figure 12 1 makes firm contact with the high idle stop Figure 12 2...

Страница 84: ...double element only remove and replace the inner element Figure 14 1 if the engine lacks power or the dust indicator actuates if equipped Note The inner element should not be removed when cleaning or...

Страница 85: ...r place an approved container under the opening to catch the fuel Never use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protect...

Страница 86: ...uel filter using a filter wrench to turn it to the left Figure 16 1 When removing the fuel filter carefully hold it to prevent the fuel from spilling Wipe up all spilled fuel Figure 16 4 Clean the fil...

Страница 87: ...sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 1 Position an approved container under the cup Figure 17 1 of the water sep...

Страница 88: ...arefully hold the cup to prevent fuel from spilling If you spill any fuel clean up the spill completely Figure 18 6 Remove the float ring Figure 18 8 from the cup Pour the contaminants into the contai...

Страница 89: ...life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury NOTICE Alw...

Страница 90: ...reinstall and tighten the drain plug or close the drain valve in the radiator Reinstall and tighten the engine block drain plug 6 Fill radiator and engine with engine coolant See Filling Radiator wit...

Страница 91: ...ilure to comply could result in death or serious injury Proper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine performance The EPA ARB requires that...

Страница 92: ...rd Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failur...

Страница 93: ...mponent for cleaning exhaust gas To prevent the valve from deteriorating in exhaust gas recirculation performance due to carbon accumulation inspect clean and test the valve at least every 3000 hours...

Страница 94: ...PERIODIC MAINTENANCE 88 This Page Intentionally Left Blank TNV_OperationManual_T4 under 19kW book Page 88 Wednesday June 17 2015 11 23 AM...

Страница 95: ...indicator fails to illuminate when the key switch is in the ON position see your Isuzu Distributor for service before operating the engine If any indicator illuminates during engine operation stop the...

Страница 96: ...See Isuzu Distributor Faulty engine coolant pump Battery Indicator V belt loose or damaged Adjust V belt or replace Check and adjust cooling fan V belt on page 69 Battery failure Check battery conditi...

Страница 97: ...cable connection at battery terminals Clean terminals retighten Faulty starter switch See Isuzu Distributor Faulty starter motor Engine cannot be manually turned Inner parts seized or damaged White or...

Страница 98: ...ore replacing the E ECU will void the engine warranty Improper use or misuse of the E ECU may result in death or serious injury due to an abrupt and unexpected increase in engine speed Fault Detection...

Страница 99: ...rger number of flashes Figure 2 NOTICE If the fault indicator comes on check and note the flashing pattern shut down the engine without delay and contact your Isuzu Distributor Flashing repeated Power...

Страница 100: ...has been in service the number of engine hours or the number of calendar months Operating conditions when problem occurs Engine RPM Color of exhaust smoke Type of diesel fuel Type of engine oil Flashi...

Страница 101: ...sition relative to rack actuator is without specified limits Continues to run without rack position sensing at up to 150 of low idling speed or 80 of high idling speed whichever is lower Key switch is...

Страница 102: ...ion can be selected Temperature returns to normal under 100 C other optional setting is allowed Optional 2 5 14 Oil pressure Oil pressure switch is not turned off while engine is running Continues to...

Страница 103: ...r failed Continues to run normally 22 ECU mapping format Mapping format is invalid Is shut down 23 ECU temperatu re sensor Sensor voltage is over 4 6 V or under 1 0 V Continues to run normally Tempera...

Страница 104: ...TROUBLESHOOTING 98 This Page Intentionally Left Blank TNV_OperationManual_T4 under 19kW book Page 98 Wednesday June 17 2015 11 23 AM...

Страница 105: ...ection of the Operation Manual describes the procedures necessary to place the engine into long term storage six months or longer and how to place it back into operation TNV_OperationManual_T4 under 1...

Страница 106: ...air cleaner turbocharger if equipped and electric components from damage when you use steam or high pressure water to clean the engine Perform the next Preventive Maintenance procedure For example if...

Страница 107: ...e minute This will circulate the oil in the engine s lubrication system 3 Prime the fuel system See Priming the Fuel System on page 42 4 Start the engine Allow the engine to idle for approximately 15...

Страница 108: ...LONG TERM STORAGE 102 This Page Intentionally Left Blank TNV_OperationManual_T4 under 19kW book Page 102 Wednesday June 17 2015 11 23 AM...

Страница 109: ...103 TNV Operation Manual SPECIFICATIONS TNV_OperationManual_T4 under 19kW book Page 103 Wednesday June 17 2015 11 23 AM...

Страница 110: ...and muffler installed to the engine With cooling fan air cleaner muffler Isuzu standard After the engine break in period Output allowable deviation 3 1 PS 0 7355 kW 1 hp SAE Society of Automotive Engi...

Страница 111: ...end Speed governor Mechanical centrifugal type all speed governor Cooling system Liquid cooled with radiator Lubricating system Forced lubrication with trochoid pump Normal oil pressure at rated engi...

Страница 112: ...al governor all speed governor Cooling system Liquid cooled with radiator Lubricating system Forced lubrication with trochoid pump Normal oil pressure at rated engine speed MPa 0 294 Normal oil pressu...

Страница 113: ...nor Mechanical centrifugal type all speed governor Cooling system Liquid cooled with radiator Lubricating system Forced lubrication with trochoid pump Normal oil pressure at rated engine speed MPa 0 3...

Страница 114: ...l centrifugal type all speed governor Cooling system Liquid cooled with radiator Lubricating system Forced lubrication with trochoid pump Normal oil pressure at rated engine speed MPa 0 34 Normal oil...

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