2007 Owner'S Manual N-Series Medium Duty Truck (Low Cab Forward)
2007 Owner'S Manual N-Series Medium Duty Truck (Low Cab Forward)
2007 Owner'S Manual N-Series Medium Duty Truck (Low Cab Forward)
2007
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
3 In Case of Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1
4 Appearance Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 3
6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
INTRODUCTION
This manual has been prepared to acquaint you with the operation
and maintenance of your 2007 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.
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GRAPHIC SYMBOLS
Some of the following symbols are used to identify controls and
displays on your vehicle.
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BRAKE
BRAKE
BOOSTER
SERVICE VEHICLE DPF BRAKE ANTI-LOCK
MILES CHECK LOW VACUUM BRAKE SYSTEM
SOON LIGHT
AUTOMATIC ENGINE
OVERDRIVE CHECK TRANS TRANSMISSION ENGINE
FLUID TEMPERATURE OVERHEAT SHUT DOWN
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IMPORTANT INFORMATION ON
VEHICLE LOADING
OVERLOADING
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.
Front GAWR Capacity . . . . . . . 5,360 lbs (2431 kg) Rear GAWR Capacity . . . . . . 8,840 lbs (4010 kg)
Front Curb . . . . . . . . . . . . . . . . 3,451 lbs (1565 kg) Rear Curb . . . . . . . . . . . . . . . 1,918 lbs ( 870 kg)
Front Body and Cargo Load . . . . 622 lbs (282 kg) Rear Body and Cargo Load . . 6,009 lbs (2726 kg)
. . . . . . . . . . . . . . . . . . . . . . . . 4,073 lbs (1847 kg) . . . . . . . . . . . . . . . . . . . . . . . .7,927 lbs (3596 kg)
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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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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 model covered in this manual is NPR.
MODEL
NPR
0-7
Cab Model
Type Code Year Code
GVWR and Engine
Brake System Code
J A L B 4 W 1 6 7 7 0 0 0 0 0 1
2007
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Code Description
0-8
JAL ISUZU Code Description Code Plant Location
1 4x2 7 Fujisawa
SECTION 1
BEFORE DRIVING YOUR VEHICLE
DRIVER DAILY CHECKLIST
Be sure you know how to use your truck and its equipment before
operating it.
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.
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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
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.
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Lock Button
Locked
Unlocked
Inside Handle
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.
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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
LOCK UNLOCK
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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.
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Passenger
side
CLOSE OPEN
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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.
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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.
Seatback
Tilt Lever
Fore-and-Aft Lever
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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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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.
W-01623
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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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Pull until
adjusted to
a snug fit
Adjustable
Latch Plate
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CHILD RESTRAINT
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.
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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.
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W-01621
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CAUTION:
• Exhaust gas from the DPF, muffler, exhaust pipe and tailpipe is
extremely hot when the engine is running, during regeneration
(burning), or immediately after driving.
Nearby flammable materials such as dried grass and wastepaper
may catch fire.
Be very careful not to touch them by accident. You may get
burned.
When you service the vehicle, stop the engine to prevent burns.
• Always use diesel fuel. Use of low quality fuel may adversely
affect the engine parts, and cause failure.
• Use of other than specified fuel may adversely affect the engine
or emission control system and cause failure. Especially for
common rail type engines, always use ultra low sulfur diesel fuel
(15 ppm or less of sulfur content).
• If other than specified diesel fuel is used on a vehicle with DPF,
the vehicle may not conform to specifications.
• 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 is needed according to equipment type, contact
your Isuzu dealer.
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NOTICE:
• For engine oil, use low ash engine oil. Use of others 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 manual
regeneration according to the procedure. This is not a system
failure, but is to restore the DPF function.
• The exhaust brake valve is activated while the vehicle is idling in
the DPF regeneration (burning) mode. Sound occurs when the
exhaust brake valve is activated and deactivated. This is not a
failure.
• A small amount of white smoke may be emitted from the exhaust
pipe with Particulate Matter (PM) burned during DPF
regeneration. This is not a failure. Also, do not perform the
emergency regeneration indoors with poor ventilation.
• White smoke may be emitted during the DPF regeneration after
the new vehicle runs for a certain distance.
This is not a failure. White smoke may not necessarily be emitted
when the vehicle is new.
• Because of the exhaust gas purification system, the gas from the
exhaust pipe smells differently from that of conventional diesel
vehicles.
• With long continuous idling, the exhaust brake valve may be
activated to prevent white smoke after a certain period of time.
• Use of low ash oil lengthens the maintenance interval of the DPF.
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BEFORE DRIVING
Use the specified fuel (ultra low sulfur diesel fuel only)
CAUTION: Always use diesel fuel.
Use of low quality fuel may adversely affect the engine parts, and
cause failure.
Use of other than specified 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 on the vehicle with the
DPF, the vehicle may not conform to specifications.
CAUTION:
• Before starting the engine, make sure that there are no
flammable materials around the vehicle and dried 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.
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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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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.
Biocides
In warm or humid weather, fungus, and/or bacteria may form in
diesel fuel if there is water in the fuel.
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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.
FUEL SELECTION
Use Number 2-D diesel fuel whenever possible; it will give better fuel
economy than Number 1-D. Use Number 1-D in weather below 20°F
(–7°C). See “Diesel Fuel Requirement and Fuel System” in this section
for guidelines on selecting the proper fuel.
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STARTING PROCEDURE
The following procedure is recommended for starting the truck’s
diesel engine.
1. Apply the parking brake, 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 the “P” or “N” position.
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.
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CAUTION: DO NOT leave the vehicle in gear. If the vehicle rolls, the
engine may start. Always leave 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.
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To be sure the engine can turn fast enough to start, use SAE 10W-
40 viscosity engine oil when prevailing temperatures drop below 32°F
(0°C). (See the oil quality and oil viscosity recommendations in Section
5 ) Using your 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.
NOTICE: Do not use starting “aids” in the air intake system. Such
“aids” can cause immediate engine damage.
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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.
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).
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
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DRIVING TECHNIQUES
BRAKING AND STEERING TECHNIQUES
Always turn-off the manual engine idle control knob to the full counter-
clockwise position while driving to maintain proper braking performance
and reduce brake wear.
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, Iightly 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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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.
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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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High Beam
Passing
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
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.
• 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.
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Descending a Grade
Lock
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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.
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BRAKE SYSTEM
1 2 3 4 5
1. Steering Column
2. Brake Pedal
3. Accelerator Pedal
4. Overdrive Switch
5. 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 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.
• 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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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.
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Selector
Button
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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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.
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.
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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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.
1: FIRST
Use the “1” position for maximum engine braking on steep downhill
grades.
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.
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.
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NOTICE (Continued)
Operating the transmission at stall condition will result in
overheating and damage.
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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1 3 5 7 9 11 13 15 17 19
2 4 6 8 10 12 14 16 18
21 23 25
20 22 24 26
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BRAKE
Brake Low Vacuum Warning Light
BOOSTERThis 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.
The brake low vacuum warning light and warning buzzer alarm should
come on to indicate low vacuum reserve for brake power assist.
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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.
• Stopping the engine immediately may cause it to seize up.
• This light will also activate the engine alarm and automatic
shutdown system. Refer to "ENGINE ALARM AND AUTOMATIC
SHUTDOWN" on page 2-12.
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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.
CAUTION: Driving with the “A/T OIL TEMP” light constantly on can
cause serious mechanical damage to the automatic transmission.
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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.
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.
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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 lock-
up. Contact your Isuzu dealer immediately and have the system
repaired.
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CRUISE CONTROL
Cruise Control
Main Switch
Cruise Switch
Set Coast
Resume Accel
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. Push the cruise control main switch “CRUISE MAIN” so that the
Cruise Main indicator light turns on.
2. Accelerate to your desired speed using the accelerator pedal.
3. 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.
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2. CLEARING
The cruise control system will be cancelled when any of the following
conditions apply:
1. When the brake pedal is depressed.
2. When the automatic transmission is shifted to the "N" or "1st"
position.
3.* When cruising speed is approximately 25 MPH (40 km/h) or lower.
4.* When the cruise control main switch is turned off again.
5.* When the key switch is turned to the "OFF" position.
6.* When trouble develops in the system.
*: Memory speed is eliminated.
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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 "Manual regeneration
procedure" and "Selectable regeneration procedure".
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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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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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CAUTION: If you activate the PTO on the vehicle with PTO for a
long time, make sure that the DPF indicator light does not come
on.
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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, dry grass or other things that
can burn.
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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.
NOTICE:
During the idling mode when the vehicle is at a stop, switching
the shift button to the "N" position increases the engine speed.
Automatic regeneration may not complete in some cases of
operating patterns and conditions. The DPF indicator light (amber
or red) will then come on.
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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.
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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DPF Switch
This switch is to start the emergency regeneration.
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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.
• Manual regeneration is completed more quickly after the vehicle
has just stopped driving, compared to when the engine is cold.
• During manual regeneration, the coolant temperature may
sometimes rise.
• When the DPF indicator light (red) is on, perform regeneration in
the same operation as manual regeneration procedure.
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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 dead 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.
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55698_Sec02-2_'07 08.2.8 11:47 AM Page 54
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.
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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1 23 4 5 6 7 8 9 10 11 4 12 13 14 15 16 4
17 1819 20 21 22 23 24 25 26 27 28
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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.
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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.
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5 2 1 3
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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.
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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.
1. 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.
2. 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.
3. 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 (–).
4. 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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2
3 (-) (+)
Charged
Battery
5. 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.
6. 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.
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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. Wheel size is also stamped on the side of
each wheel.
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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).
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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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.
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1.
2.
1. Bumper
2. Towing Chain 3.
3. Towing Guide
4.
4. Front Axle 5.
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.
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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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.
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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:
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SECTION 4
APPEARANCE CARE
CLEANING AGENTS
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• 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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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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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.
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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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.
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.
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.
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EXPLANATION OF VEHICLE
MAINTENANCE AND LOG
The following is a brief explanation of normal vehicle use.
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.
5-2
Maintenance Schedule for the NPR (Cont.)
16 000 10,000
24 000 15,000
32 000 20,000
48 000 30,000
64 000 40,000
72 000 45,000
80 000 50,000
96 000 60,000
112 000 70,000
120 000 75,000
128 000 80,000
144 000 90,000
160 000 100,000
168 000 105,000
176 000 110,000
No. Item
1 Engine Noise Check I I I I I I I I I I I *
2 Valve Lash A A
3 Engine Oil & Oil Filter *1 R R R R R R R R R R R or every 12 months
4 Fuel Filter / Water Separator R R R R R R R or every 12 months
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5-3
6 Air Intake system I I I
7 Drive Belts I I I I I I I I I I I or every 12 months
8 Engine Bolt Torques I I
9 Rotate Tires Every 6,500 miles (10,400 km)
10 Engine Cooling System I I I I I I I I I I I or every 12 months
(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.
*
Maintenance Schedule for the NPR (Cont.)
16 000 10,000
24 000 15,000
32 000 20,000
48 000 30,000
64 000 40,000
72 000 45,000
80 000 50,000
96 000 60,000
112 000 70,000
120 000 75,000
128 000 80,000
144 000 90,000
160 000 100,000
168 000 105,000
176 000 110,000
No. Item
11 Engine Coolant R R R or every 24 months
12 Exhaust System I I I I I I I I I I I
13 DPF (Clean filter) C or every 3,000 hours
DPF
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5-4
DPF
15 (Pressure difference sensor hose) I or every 3,000 hours
16 Fuel Line System I I I I I I I I I I I or every 12 months
17 Brake Pedal Free Travel I I I I I I I I I I I or every 12 months
18 Brake Lining and Pad for Wear I I I I I I I I I I I
19 Brake Drum and Rotor for Wear and Damage I I I I I I or every 12 months
20 Brake Fluid I I R I I R I I R I I or every 12 months
(I): Inspect, replace or adjust if necessary (A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate (C): Clean
Maintenance Schedule for the NPR (Cont.)
16 000 10,000
24 000 15,000
32 000 20,000
48 000 30,000
64 000 40,000
72 000 45,000
80 000 50,000
96 000 60,000
112 000 70,000
120 000 75,000
128 000 80,000
144 000 90,000
160 000 100,000
168 000 105,000
176 000 110,000
No. Item
21 Brake Line and Hoses I I I I I or every 12 months
22 Automatic Transmission Fluid I I R I I R I I R I I or every 12 months
23 External Automatic Transmission Filter R R R or every 24 months
24 Differential Gear Oil I I R I I R I I R I I or every 24 months
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5-5
26 Power Steering Oil Hose R R or every 24 months
27 Steering Gear Box Torque T T T T T or every 12 months
28 Driveshaft Flange Torque T T T T T T T T T T T or every 12 months
29 Driveshaft Lubricate L L L L L L L L L L L or every 12 months
(I): Inspect, replace or adjust if necessary (A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate (C): Clean
Maintenance Schedule for the NPR
16 000 10,000
24 000 15,000
32 000 20,000
48 000 30,000
64 000 40,000
72 000 45,000
80 000 50,000
96 000 60,000
112 000 70,000
120 000 75,000
128 000 80,000
144 000 90,000
160 000 100,000
168 000 105,000
176 000 110,000
No. Item
30 Leaf Spring U-Bolt Torque* T T T T T T T T T T T
31 Wheel Nut Torque* Every 6,500 miles (10,400 km)
32 King Pin L L L L L L L L L L L or every 12 months
33 Wheel Bearing Grease** R R R or every 12 months
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5-6
34 Air Conditioner Blower Filter Cleaned once a month
(I): Inspect, replace or adjust if necessary (A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate (C): Clean
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.
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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.
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19. 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.
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).
21. 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.
22. 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.
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”.
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.
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Filter (Inside)
Filter (Outside)
Fastener
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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.
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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.
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P DOOR LATCHES — Check that doors close, latch and lock tightly.
Check for broken, damaged or missing parts that might prevent tight
latching.
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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.
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
CAUTION: If you need to replace the fuel filler cap, use only a
genuine Isuzu fuel filler cap. 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.
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FULL
MIN
Oil adding is needed.
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Check procedure
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.
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.
NOTICE: The engine oil level must be checked with the vehicle
parked on level ground.
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.
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SAE 40
SAE 30
SAE 10W-30
SAE 10W-40
°F −20 0 20 40 60 80 100
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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 high-
quality 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.
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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.
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NOTICE:
Incomplete air bleeding can result in serious engine damage. Be
sure to follow the procedures outlined above carefully.
Priming pump
Air bleeding
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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.
Refer to “Used engine oil” in page 5-24 for proper disposal procedures.
Air bleeding
Drain plug
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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.
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.
Forward
Power Steering
Reservoir Tank
M
AX
M
IN
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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: 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.
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CAUTION: The engine must not be started after the engine coolant
has been drained. Doing so may cause engine burnout.
NOTICE: When washing out the radiator core, take care not to
crush or damage the fin, etc.
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Supplying coolant:
1. Check the engine has sufficiently cooled.
2. Remove the radiator cap.
3. Open the engine outlet's air bleed bolt.
4. 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.
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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.
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.
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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 ABS in page 2-37.
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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.
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5-38
55698_Sec05-2_'07 08.2.8 11:53 AM Page 39
Always be sure the safety lock pin is installed when the cab is tilted.
1. Lock Lever
2. Tilt Lever
3. Assist Handle
4. Safety Lever
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55698_Sec05-2_'07 08.2.8 11:53 AM Page 40
7
6
5. Cab Support
6. Lock Pin
7. Lock Lever
5-40
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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 the enlarged portion of dipstick
(position "A") have your oil changed as soon as possible to avoid
engine damage.
FULL
MIN
Oil adding is needed.
CAUTION: If the engine oil level is above the "FULL" mark of the
dipstick, it may cause engine damage. Replace the engine oil if the
oil level exceeds the "FULL" mark.
Replace the engine oil always at the specified period as the fuel
gradually mixes with the engine oil and dilutes the engine oil.
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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.
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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55698_Sec05-2_'07 08.2.8 11:53 AM Page 43
1 A/C compressor
2 A/C belt
3 Tension pulley
4 Generator
5 Fan belt
6 Fan pulley
7 Crank pulley
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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.
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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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
Forward
Door side
Inside
Screwdriver
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55698_Sec05-2_'07 08.2.8 11:53 AM Page 46
• Dismantle the entire turn signal light towards the front of the
vehicle in an obliquely downward direction.
Screw
Screw
Rubber
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55698_Sec05-2_'07 08.2.8 11:53 AM Page 47
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
5-47
55698_Sec05-2_'07 08.2.8 11:53 AM Page 48
Lock
5-48
55698_Sec05-2_'07 08.2.8 11:53 AM Page 49
Bulb
Socket
NOTICE: If the socket is not locked firmly, water may infiltrate the
light and cause malfunctioning.
5-49
55698_Sec05-2_'07 08.2.8 11:53 AM Page 50
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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55698_Sec05-2_'07 08.2.8 11:53 AM Page 51
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
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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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55698_Sec05-2_'07 08.2.8 11:53 AM Page 53
Screw
Lens
Bulb
Socket
5-53
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1. Battery Cover
2. Latch
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.
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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
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OVERFILLING 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.
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.).
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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.
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).
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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.
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55698_Sec05-2_'07 08.2.8 11:53 AM Page 59
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.
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.
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.
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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”.
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
46401 Commerce Center Drive
Plymouth, MI 48170
(1-866-441-9638)
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LUBRICATION POINTS
GREASE POINTS
1
1
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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.
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.
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.
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55698_Sec06_'07 08.2.8 3:50 PM Page 2
REPLACEMENT PARTS
Please contact your authorized dealer or parts supplier.
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.
6-2
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ENGINE DATA
Manufacturer Isuzu
Model 4HK1-TC
Engine Type Inline 4, Four Cycle
Induction Turbocharged W/Charge Air Cooler
Bore 115 mm
Stroke 125 mm
Displacement 5.193L (317 CID)
Full Load RPM 2400
CAPACITIES
ENGINE CRANKCASE
Capacities are for normal refill. Capacities given may be approximate
– keep level as close as possible to the full mark without overfilling. Do
not operate with the level below the low mark.
4HK1-TC .........................................................................13L (13.7 qts)
This figure includes the oil filter, which should be changed at each oil
change.
AUTOMATIC TRANSMISSION
See “EXPLANATION OF COMPLETE TRUCK MAINTENANCE
SCHEDULE” for correct fluid level checking procedure.
Transmission fluid......................................................14.0L (29.6 pints)
REAR AXLE
Gear Oil .............................................................................10.0L (21.1 pints)
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.
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WHEEL
WHEEL STUD NUT TORQUE
Front and Rear ......................................................490 N·m (362 ft·Ibs)
6-4
55698_Sec06_'07 08.2.8 3:50 PM Page 5
ELECTRICAL DATA
EXTERIOR LIGHTS
Light.................................................................................power Qty.
Headlight .......................................................................60/55W 2
Parking Light ........................................................................5W 2
Front Turn Signal Light .......................................................27W 2
Cornering Light ...................................................................27W 2
Side Turn Signal Light ..........................................................5W 2
Side Marker Light .................................................................5W 2
Stoplight / Taillight ...........................................................27/8W 2
Backup Light ......................................................................27W 2
Rear Turn Signal Light ........................................................27W 2
License Plate Light ............................................................7.5W 1
Identification Light / Clearance Light .....................................5W 5
INTERIOR LIGHTS
Dome Light .........................................................................10W 1
Speedometer and Gauge Lights.........................................3.4W 5
Warning / Indicator Lights .....................................................2W 20
6-5
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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 Fuse
1 RR POWER WINDOW 25A
2 - -
3 ROOM LIGHT, AUDIO 10A
4 DOOR LOCK 15A
5 - -
6 POWER WINDOW 25A
7 BACKUP LIGHT 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
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55698_Sec06_'07 08.2.8 3:50 PM 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
55698_Sec06_'07 08.2.8 3:50 PM Page 8
3
4
5
2
6
7
8
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 .....................................................Isuzu No. 8-97062-294-0
Engine Oil ......................................................Isuzu No. 8-97148-270-1
Fuel................................................................Isuzu No. 8-98037-011-0
6-8
55698_Sec06_'07 08.2.8 3:50 PM Page 9
INDEX
Brake Low Vacuum
A Warning Light ............................2-32
Brake Maintenance ........................5-37
ABS ................................................2-37 Brake System ........................2-22, 5-36
Accessory Power Outlet ................2-58 Brake Pedal ................................2-22
Access to the Electrical Parking Brake ..............................2-24
Components ..............................5-54 Vacuum Power Brakes ................2-23
Access to the Engine......................5-38 Brake System Warning Light ..........2-31
Before Tilting the Cab ..................5-38
Checking the Engine Oil ..............5-41
Lowering the Cab ........................5-40 C
Tilting the Cab..............................5-38
Access to the Windshield ..............5-43 Cab Door Locks................................1-3
Acetone ............................................4-1 Always Lock the Doors ..................1-3
Adjustable Steering Column ..........2-20 Capacities ........................................6-3
Adjust Driver’s Seat While Parked....1-8 Automatic Transmission Capacity..6-3
Air Bleeding ..............................5-25, 28 Engine Crankcase Capacity ..........6-3
Air Cleaner Filter ......................5-9, 6-8 Fuel Tank Capacity ........................6-3
Air Cleaner/Flame Arrestor ............5-36 Rear Axle Capacity ........................6-3
Air Conditioning ..............................5-43 Carbon Monoxide ..........2-1, 3-12, 5-15
Always Lock the Doors ....................1-3 Care and Cleaning of Exterior ..........4-4
Anti-lock Brake System ..................2-37 Exterior Finish ................................4-4
Appearance Care ............................4-1 Polishing and Waxing ....................4-4
Cleaning Agents ............................4-1 Weatherstrip Lubrication ................4-5
A/T OIL TEMP Warning Light ........2-35 Care and Cleaning of the Interior ....4-1
ATF DEXRON-III ..............................5-7 Cleaning Outside of Windshield ....4-4
Automatic Engine Warm-up............2-11 Glass Surfaces ..............................4-3
Automatic Trans. Controls, Seat Belt Care................................4-3
Continued ..................................2-26 Caution and Notice ..........................0-1
Driving Tips ..................................2-27 Center Lap Belt ..............................1-13
Overdrive Switch..........................2-28 Change Intervals ............................5-23
Starting ........................................2-26 Check Engine Oil Level ..................5-19
Automatic Transmission Capacity ....6-3 Check Engine Malfunction
Automatic Transmission Controls ..2-25 Indicator Light............................2-31
Automatic Transmission Selector..2-25 Checking the Engine Oil ................5-41
Selecting Gears ........................2-25 Checks Before Operating ................2-9
Automatic Transmission Check Trans Warning Light ............2-35
Fluid Recommendations............5-60 Child Restraint ................................1-14
Avoid Unnecessary Idling Choosing Oil Viscosity....................5-22
of the Diesel Engine ....................2-9 Choosing the Right Quality Oil ......5-21
Cigarette Lighter ............................2-58
Cleaner ........................................4-2, 3
B Cleaning Outside of Windshield ......4-4
Cold Weather Starting ....................2-10
Battery Discharge Warning Light....2-30 Cornering Light ..............................2-17
Before Driving ................................1-19 Cornering Light / Side Turn Signal
Before Driving Off ............................1-1 Light / Side Marker Light ..........5-50
Before Driving Your Vehicle ............1-1 Corrosion Protection ........................4-5
Before Entering the Truck ................1-1 Cruise Control ................................2-40
Before Tilting the Cab ....................5-38 Cruise Main Indicator Light ............2-39
Benzene ..........................................4-1 Cruise Set Indicator Light ..............2-39
Biocides ........................................2-3, 5 Customer Satisfaction Procedure ..3-13
Brake Alarm System ......................2-36
6-9
55698_Sec06_'07 08.2.8 3:50 PM Page 10
INDEX
Dual Tire Operation ........................5-57
D
Damaged Tires ................................3-5 E
Wheel Nut Torque..........................3-7
Wheel Stud Nut Torque ................3-7 Effect on Warranty............................0-5
Wheel Tightening Sequence..........3-7 Electrical Data ..................................6-5
Daytime Running Light (DRL) Exterior Lights ................................6-5
Indicator Light............................2-35 Fuse Block ....................................6-6
Defrost ............................................2-61 Interior Lights ................................6-5
Descending a Grade ................2-14, 20 Electrical System ............................5-44
Diesel Engine Cleaning ..................5-24 Access to the Electrical
Diesel Engine Serial Number Components ..............................5-54
Location ......................................6-1 Cornering Light / Side Turn Signal
Diesel Fuel Requirement and Fuel Light / Side Marker Light ..........5-50
System ........................................2-3 Electrical Circuit Protection ..........5-55
Fuel Economy ................................2-6 Front Turn Signal Lights ..............5-49
Fuel Selection ................................2-6 Headlights / Parking Lights ..........5-45
Smoke Suppressants ....................2-6 Headlight Vertical Aiming
Diesel Fuel System ........................5-25 Adjustment ................................5-44
Fuel Filter ....................................5-27 Roof Marker Light (Identification
Fuel System Priming..............5-25, 28 Light / Clearance Light) ............5-53
Diesel Particulate Filter (DPF) Turn Signals ................................5-44
................................1-17, 2-47, 5-42 Working Near Battery ..................5-53
Before Driving ..............................1-19 Emergency Starting Your
Discharged Battery ..........................3-1 Vehicle due to a
Dome Light ....................................2-58 Discharged Battery......................3-1
Door Locks ......................................1-4 Enamel Reducers ............................4-1
Door Lock Switch..............................1-4 Engine Alarm and Automatic
DPF Indicator Light (Green) ..........2-36 Shutdown ..................................2-12
DPF Indicator Light (Amber/Red) ..2-36 Engine Alarm (Shutdown) Warning
Driver Daily Checklist ......................1-1 Light ..........................................2-31
Before Driving Off ..........................1-1 Engine Block Heater ......................2-11
Before Entering the Truck ..............1-1 Engine Control Switch ..........2-7, 21, 43
Final Walk-Around Check ..............1-1 Engine Coolant Temperature (ECT)
Start-up ..........................................1-1 Gauge........................................2-57
Driver’s Seat Controls ......................1-8 Engine Cooling System ..........5-31, 6-4
Adjust Driver’s Seat While Air Cleaner/Frame Arrestor..........5-36
Parked ........................................1-8 Engine Cooling System Care ......5-31
Fore-and-Aft ..................................1-8 Engine Cooling System Service ..5-32
Seatback Latch ..............................1-9 Radiator Pressure Cap ................5-35
Driving Techniques ........................2-14 Thermostat ..................................5-35
Braking Techniques ....................2-14 Engine Cooling System
Descending a Grade ..............2-14, 20 Capacity ......................................6-4
Driving on Slippery Surfaces........2-15 Engine Cooling System
Riding the Brake ..........................2-14 Overheating ................................3-3
Steering Techniques ....................2-14 Engine Crankcase Capacity ............6-3
Stopping the Vehicle in the Event Engine Data......................................6-3
of Service Brake Malfunction ....2-16 Engine Exhaust Gas Caution ..........2-1
Use of the Exhaust Brake ............2-15 Engine Noise ....................................5-8
Wet Brakes ..................................2-14 Engine Oil and Filter
Driving Tips ....................................2-27 Recommendations ....................5-19
DRL ................................................2-35 Change Intervals..........................5-23
6-10
55698_Sec06_'07 08.2.8 3:50 PM Page 11
INDEX
Check Engine Oil Level................5-19 Glass Surfaces ................................4-3
Choosing Oil Viscosity ................5-22 Glow Plug Indicator Light................2-31
Choosing the Right Quality Oil ....5-21 Graphic Symbols ..............................0-2
Engine Oil Additives ....................5-23 Guard Against Theft ......................2-12
Oil Identification Logo ..................5-23 GVWR ..............................................0-4
Used Oil Disposal ........................5-24
Engine Oil Pressure Warning
Light ..........................................2-34 H
Engine Overheating Warning
Light ..........................................2-33 Hazard Warning Flasher ........2-21, 3-1
Engine Warm-up System................2-11 Headlight Dimmer Switch ..............2-18
Automatic Engine Warm-up ........2-11 Headlights High Beam Indicator
Engine Block and Oil Pan Light ..........................................2-29
Heater........................................2-11 Headlights / Cornering Lights ........2-17
Exhaust Brake ................................2-19 Headlights / Parking Lights ............5-45
Exhaust Brake Indicator Headlight Vertical Aiming
Light ..........................................2-29 Adjustment ................................5-44
Explanation of Complete Vehicle Heating and Ventilation Systems
Maintenance Schedule................5-7 Controls ....................................2-59
Normal Vehicle Use ......................5-8 Optional Air Conditioning ............2-59
Explanation of Vehicle Maintenance Windshield Defrosting and
and Log ......................................5-2 Defogging Operating Tips ........2-61
Exterior Finish ..................................4-4 Horn................................................2-21
External Diesel Engine Cleaning ....5-24
I
F Idle Speed Control..........................2-43
Factory-Approved Accessories ........6-2 Important Information on
Filter..................................................6-8 Vehicle Loading ..........................0-4
Final Walk-Around Check ................1-1 Effect on Warranty ........................0-5
Fore-and-Aft ....................................1-8 Maximum Front and Rear
Freeing the Vehicle ........................3-11 Axle Weights ..............................0-5
Front Axle Weight ............................0-4 Overloading....................................0-4
Front End Alignment ......................5-58 In Case of Emergency ......................3-1
Front End Towing ........................3-8, 9 Discharged Battery ........................3-1
Front Turn Signal Lights ................5-49 Jump Starting Instructions ............3-2
Fuel Additive ....................................2-3 Hazard Warning Flasher ................3-1
Fuel Cap ..................................5-18, 29 Inside Door Handles ........................1-3
Fuel Economy ..................................2-6 Instrument Panel and Controls ......2-29
Fuel Filter........................................5-27 Anti-Lock Brake System (ABS)
Fuel Gauge ....................................2-57 Malfunction Warning Light ........2-37
Fuel Selection ..................................2-6 Automatic Transmission Fluid
Fuel System Priming ................5-25, 28 Temperature Warning Light ......2-35
Fuel Tank Capacity ..........................6-3 Battery Discharge Warning
Fuse Block........................................6-6 Light ..........................................2-30
Fuses..............................................5-55 Brake Alarm System ....................2-36
Brake Low Vacuum
Warning Light ............................2-32
G Brake System Warning Light ......2-31
Check Engine Malfunction
Gasoline ....................................2-5, 4-1 Indicator Light............................2-31
GAWR ..............................................0-4 Check Trans Warning Light ........2-35
6-11
55698_Sec06_'07 08.2.8 3:50 PM Page 12
INDEX
Cruise Main Indicator Light ..........2-39 Turn Signal ..................................2-17
Cruise Set Indicator Light ............2-39 Light Control Switch........................2-43
Daytime Running Lights (DRL) Lock Button ......................................1-5
Indicator Light............................2-35 Locking Clip-Full Size ....................1-16
DPF Indicator Light (Green) ........2-36 Low Coolant Warning Light ............2-34
DPF Indicator Light Low Fuel Level Indicator Light........2-30
(Amber/Red)..............................2-36 Lowering the Cab ..........................5-40
Engine Alarm (Shutdown) Warning Lubrication ......................................5-60
Light ..........................................2-31 Automatic Transmission
Engine Oil Pressure Warning Fluid Recommendations............5-60
Light ..........................................2-34 Lubrication Points ..........................5-61
Engine Overheating Warning
Light ..........................................2-33
Exhaust Brake Indicator Light ......2-29 M
Glow Plug Indicator Light ............2-31
Headlights High Beam Indicator Maintenance Items to Aid Cold
Light ..........................................2-29 Weather Starting ......................5-29
Indicator and Warning Lights ......2-29 Starting Aids ................................5-30
Low Coolant Warning Light..........2-34 Maintenance Schedule ....................5-1
Low Fuel Level Indicator Light ....2-30 Maximum Front and Rear
Oil Level Indicator Light ..............2-36 Axle Weights ..............................0-5
Overdrive Indicator Light..............2-34 Mechanical Driveshaft Brake Burnish
Parking Brake Indicator Light ......2-33 Procedure....................................2-2
Service Vehicle Soon (SVS) Miles Check Switch ........................2-45
Light ..........................................2-36 Mirrors ..............................................1-7
Turn Signal Indicator Light ..........2-29 Outside Rearview Mirrors ..............1-7
Water Separator Indicator Light ..2-36 Mobile Telephones ........................2-61
Instrument Panel Light Level Model Reference ..............................0-7
Control ......................................2-44
Interior Lights....................................6-5
Introduction ......................................0-1
N
Naphtha ............................................4-1
New Vehicle Break-in ......................2-2
J NHTSA ..........................................3-14
Jump Starting Instructions ................3-2 Noise Emission Control ..................5-17
Noise Control System ..................5-17
Tampering with Noise Control
K System Prohibited ....................5-17
Normal Vehicle Use..........................5-8
Kerosene ..........................................2-4
Key ..................................................1-2
Key Removal ..................................2-10 O
Odometer and Trip meter ..............2-55
L Oil Check Switch ............................2-45
Oil Identification Logo ....................5-23
Lacquer Thinner ..............................4-1 Oil Level Indicator Light ..................2-36
Lap-Shoulder Belt ..........................1-11 Oil Pan Heater ................................2-11
Left-hand Control Lever..................2-17 Oil Viscosity ....................................5-22
Cornering Lights ..........................2-17 Optional Air Conditioning................2-59
Headlight Dimmer Switch ............2-18 Outside Door Handles ......................1-3
Headlights ....................................2-17 Outside Rearview Mirrors ................1-7
Passing Light Switch....................2-18
6-12
55698_Sec06_'07 08.2.8 3:50 PM Page 13
INDEX
Outside Rearview Mirror Heater Adjustable Steering Column ........2-20
Switch........................................2-44 Engine Control Switch..................2-21
Overdrive Switch ............................2-28 Exhaust Brake..............................2-19
Overloading ......................................0-4 Hazard Warning Flasher ..............2-21
Overdrive Indicator Light ................2-34 Horn ............................................2-21
Overfilling Automatic Steering Column Adjustment ......2-20
Transmission ............................5-56 Windshield Washer ......................2-19
Owner Maintenance ........................5-1 Windshield Wipers ......................2-18
Owner Safety and Routine Roof Marker Light (Identification
Maintenance..............................5-14 Light / Clearance Light) ............5-53
P S
Parking ..........................................2-12 Seat Belt Care ..................................4-3
Parking Brake ................................2-24 Seat Belt Systems ..........................1-10
Parking Brake Indicator Light ..........2-33 Center Lap Belt ............................1-13
Passing Light Switch ......................2-18 Child Restraint ............................1-14
Power Door Locks Lap-Shoulder Belt ........................1-11
(If Equipped)................................1-4 Locking Clip-Full Size ..................1-16
Door Locks ....................................1-4 Seat Belt Extender ......................1-16
Door Lock Switch ..........................1-4 Seat Belt Inspection ....................1-13
Lock Button ....................................1-5 Seatback Latch ................................1-9
Power Steering ..............................2-21 Selecting Gears ..............................2-25
Power Steering System ..................5-30 Service and Maintenance ................5-1
Power Windows Maintenance Schedule ..................5-1
(If Equipped)................................1-5 Owner Maintenance ......................5-1
Power Window Switch Service Vehicle Soon (SVS) Light ..2-38
(Driver’s Door) ............................1-5 Shutting Down the Turbocharged
Power Window Switch Diesel Engine ............................2-10
(Passenger’s Door) ....................1-6 Smoke Suppressants ......................2-6
Preventive Maintenance ..................5-2 Special Towing Instructions............3-11
Maintenance Schedule ..................5-3 Specifications ..................................6-1
PTO (Power Take-Off) Switch ........2-46 Speedometer and Gauges ............2-55
Accessory Power Outlet ..............2-58
Cigarette Lighter ..........................2-58
R Dome Light ..................................2-58
Radiator Cooling Fan and Engine Coolant Temperature
Governed Speed ......................5-36 Gauge........................................2-57
Radiator Grille Covers ....................5-36 Fuel Gauge ..................................2-57
Radiator Pressure ............................6-4 Speedometer ..............................2-57
Radiator Pressure Cap ..................5-35 Tachometer..................................2-57
Rear Axle Capacity ..........................6-3 Start-up ............................................1-1
Rear Axle Weight..............................0-4 Starting ..........................................2-26
Rear End Towing............................3-11 Starting Aids ..................................5-30
Recommended Fluids and Starting and Operating ....................2-1
Lubricants....................................5-7 Engine Exhaust Gas Caution ........2-1
Replacement Fasteners ................5-18 Starting Procedure............................2-7
Fuel Cap ......................................5-18 Avoid Unnecessary Idling ..............2-9
Replacement Parts ..........................6-2 Checks Before Operating ..............2-9
Reporting Safety Defects................3-14 Starting the Engine ..........................2-7
Riding the Brake ............................2-14 Engine Control Switch....................2-7
Right-Hand Control Lever ..............2-18 Steering Column Adjustment..........2-20
6-13
55698_Sec06_'07 08.2.8 3:50 PM Page 14
INDEX
Steering Column Controls ..............2-16 Stopping the Vehicle in the Event
Anti-Theft Steering Column Lock 2-16 of Service Brake Malfunction ....3-12
Steering Techniques ......................2-14
Stopping the Vehicle in the Event of
Service Brake V
Malfunction ......................2-16, 3-12
Sun Visors ........................................1-7 Vacuum Power Assisted Brakes ....2-23
Switches and Controls....................2-43 Vehicle Identification Number ..........0-6
Engine Control Switch..................2-43 Vehicle Storage ..............................5-60
Idle Speed Control ......................2-43 VIN and GVW Plate..........................5-2
Instrument Panel Light Level VIN and Weight Rating
Control ......................................2-44 Plate ................................0-4, 6, 6-1
Lighting Control Switch ................2-43 VIN Interpretation ............................0-8
Miles Check Switch......................2-45
Oil Check Switch..........................2-45
Outside Rearview Mirror Heater
W
Switch........................................2-44 Water Separator ............................5-27
PTO (Power Take-Off) Switch ....2-46 Fuel Cap ......................................5-29
Windshield Wiper and Washer Fuel System Priming....................5-28
Controls ....................................2-44 Replacement Water Separator
Filter Element ............................5-28
Water Separator Indicator Light......2-36
T Weatherstrip Lubrication ..................4-5
Tachometer ....................................2-57 Wet Brakes ....................................2-14
Tampering with Noise Control Wheel ..............................................6-4
System Prohibited ....................5-17 Wheel Nut Torque ..................3-7, 5-13
Thermostat ..............................5-35, 6-4 Wheels and Tires............................5-56
Thermostat (Starts to Open) ............6-4 Dual Tire Operation......................5-57
Tilting the Cab ................................5-38 Front End Alignment ....................5-58
Tires..................................................0-6 Tire Inflation ................................5-56
Tire Inflation....................................5-56 Tire Replacement
Tire Load and Inflation Table............6-2 Recommendations ....................5-58
Tire Replacement Tire Traction ................................5-58
Recommendations ....................5-58 Tire Warranty ..............................5-59
Tire Traction ..................................5-58 Wheel and Tire Balancing............5-57
Tire Warranty..................................5-59 Wheel Replacement
Towing Your Isuzu Truck Recommendations ....................5-58
Procedure....................................3-8 Wheel Stud Nut Torque ............3-7, 6-4
Front End Towing ......................3-8, 9 Wheel Tightening Sequence ............3-7
Rear End Towing ........................3-11 Window Controls ..............................1-5
Special Towing Instructions ........3-11 Window Regulator Handle
Turn Signal ............................2-17, 5-44 (Manual Window Model)..............1-5
Turn Signal Indicator Light..............2-29 Windshield Washer ..............2-19, 5-30
Windshield Wiper and Washer
Controls ....................................2-44
U Windshield Wipers..........................2-18
Working Near Battery ....................5-53
Underbody Maintenance ..................4-6
Use of the Exhaust Brake
(on slippery surfaces) ................2-15
Used Oil Disposal ..........................5-24
Using the Engine as a Brake ..........3-11
6-14
OPERATING RECORD
DATE MILEAGE FUEL OIL REPAIRS DATE MILEAGE FUEL OIL REPAIRS
$ $ $ $ $ $
55698_Sec07_'07 08.2.8 11:58 AM Page 1
OPERATING RECORD
DATE MILEAGE FUEL OIL REPAIRS DATE MILEAGE FUEL OIL REPAIRS
$ $ $ $ $ $
55698_Sec07_'07 08.2.8 11:58 AM Page 2
55698_Sec07_'07 08.2.8 11:58 AM 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.
WWW.ISUZUTRUCKSERVICE.COM
55698_Sec07_'07 08.2.8 11:58 AM Page 4
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.
PUBLICATION PRICE
DESCRIPTION
NUMBER EACH
Please contact Helm at 1-800-782-4356 for publication number and pricing
information.
2
0
0
7
GRAND TOTAL
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
S to the above address for quotation.
H
I (CUSTOMER NAME) (ATTENTION)
P
(STREET ADDRESS-NO P.O. BOX NUMBERS) (APT. NO.)
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
55698_Sec07_'07 08.2.8 11:58 AM Page 6
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