Isuzu giga руководство по эксплуатации

Isuzu C-Series / E-Series / Giga / Giga Max: owner’s, service, repair and maintenance manuals PDF, electrical wiring diagrams, scheduled maintenance, operating instructions free download

See also:

Title File Size Download Links
Isuzu C- & E-Series Brochure [PDF] 3.4Mb Download
Isuzu C-Series CYZ51 / EXZ51 / EXR51 (Euro-3) Maintenance and Owner’s Manual [PDF] 6.1Mb Download
Isuzu C-Series CYZ52, EXZ52, EXR52 (Euro-4) Maintenance and Owner’s Manual [PDF] 5.8Mb Download
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Isuzu Giga CXZ415 / Giga CXY415 Specifications [PDF] 349.6kb Download
Isuzu GIGA FRR Parts Catalog [PDF] 15.7Mb Download
Isuzu GIGA Spare Parts Catalog [PDF] 7.6Mb Download
Isuzu Giga Workshop Manual – General Information [PDF] 5.9Mb Download

Isuzu Giga background information

Isuzu Giga / Isuzu C-Series / Isuzu E-Series are trucks manufactured by Isuzu since 1994.

Outside of Japan, the truck series is called “C” and “E”, respectively, which means Comfort and Economic, respectively.

The first generation

In 1994, the Isuzu 810 was replaced by the first generation Isuzu Giga. Compared to its predecessor, the model received a new cabin and equipment.

In 2007, the Isuzu Giga was upgraded to change its appearance, including the radiator grille.

In 2010, the model received new headlights, bumpers and grille. Now it is distinguished by a massive bumper with solid main optics, a brutal front grille and the presence of a front anti-roll power element under the bumper. It should be noted and an additional steel bumper under the main. It protects the crankcase pallet, attachments for which no standard protection is provided. The engines meet the Euro-5 standard.

The second generation

At the end of 2015, the second generation Isuzu Giga with a completely new cab was presented at the Tokyo Motor Show.

The new trucks are available in the form of 4×2, 6×2, 6×4 wheeled tractors, 8×4 chassis and 4×2 vans. Giga received Isuzu 9.8-liter 6U and 15.6-liter 6W engines from 350 to 520 hp. Moreover, the first engines are equipped with cars with wheel formula 4×2 and 8×4, and tractors are equipped with more than 15.6 liters.

All trucks are equipped with a new generation ZF Ecosplit4 transmission with 16 gears for tractors and 8 gears for chassis.

Model range

C-Series

  • CVR (4 x 2)
  • FRR (4×2)
  • FTR (4×2)
  • FVR (4×2)
  • FVM (6×2)
  • CXM (6 x 2)
  • CYM (6 x 2), gross vehicle weight: more than 20 tons
  • CYL (6 x 2), gross vehicle weight: 20 tonnes
  • CXG (6 x 2 with 2 front axles), gross vehicle weight: 20 tonnes
  • CXE (6 x 2 with 2 front axles)
  • CYG (6 x 2 with 2 front axles), gross vehicle weight: 20 tonnes
  • CYE (6 x 2 with 2 front axles), gross vehicle weight: 20 tonnes
  • CXZ (6 x 4)
  • FVZ (6×4)
  • CYZ (6 x 4), gross vehicle weight: 20 tonnes
  • CYY (6 x 4), gross vehicle weight: 20 tonnes
  • CVZ (Low 6 x 4), gross vehicle weight: 18 tons
  • CXZ-J (Low 6 x 4)
  • CYZ-J (Low 6 x 4), Gross Vehicle Weight: 20 Ton
  • CYY-J (Low 6 x 4), Gross Vehicle Weight: 20 Ton
  • CXH (Low 8 x 4)
  • CYH (Low 8 x 4), Gross Vehicle Weight: 20 Ton
  • CYJ (Low 8 x 4), Gross Vehicle Weight: 20 Ton

E-Series

  • Isuzu EXR (4×2)
  • Isuzu EXD (4×2)
  • Isuzu FVR TH (4×2)
  • Isuzu FVM TH (6×2)
  • Isuzu FVZ TH (6×4)
  • Isuzu EXZ (6×4)
  • Isuzu EXY (6×4)

Isuzu Giga Owner's and Maintenance Manuals PDF

Isuzu Giga

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2008-2011MY

WORKSHOP MANUAL

GENERAL INFORMATION

This Workshop Manual deals only with the screen toned section(s) in the table below.

Section

Sub Section

0

GENERAL INFORMATION

0A

General Information

1

ENGINE

1A

Engine Control System

1B

Engine Mechanical

1C

Engine Cooling

1D

Engine Fuel

1E

Engine Electrical

1F

Emission Control

1G

Engine Exhaust

1H

Engine Lubrication

1I

Engine Speed Control System

1J

Induction

1K

Pre-Heating System

1L

Power Take-Off (PTO)

2

SUSPENSION

2A1

Air Suspension Control System

2B

Front Suspension

2C

Rear Suspension

2D

Wheel and Tire System

3

DRIVELINE/AXLE

3A1

Front Differential

3A2

Rear Differential

3C1

Propeller Shaft

3C2

Front Axle

3C3

Rear Axle

3D

Transfer Case

4

BRAKES

4A2

Brake Control System (Air Over)

4A3

Brake Control System (Full Air)

4B2

Brake (Air Over)

4B3

Brake (Full Air)

4C

Anti-Lock Brake (ABS)

4C1

Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)

4D

Parking Brake

4E

Hill Start Aid (HSA)

4F

Speed Retarder System

4G

Trailer Brake

5

TRANSMISSION/TRANSAXLE

5A

Transmission Control System

5B

Automatic Transmission

5C

Manual Transmission

5E

Clutch

5G

Power Take-Off (PTO)

5G1

Side Power Take-Off

6

STEERING

6B

Power Steering

7

HVAC

7A

Heating and Ventilation

7B

Manual Air Conditioning

7C

Automatic Air Conditioning

8

RESTRAINTS

8A

Seat Belt

8B

Supplemental Restraint System (SRS)

8C

SRS Control System

9

BODY, CAB AND ACCESSORIES

9A

Lighting System

9B

Wiper/Washer System

9C

Entertainment

9D

Wiring System

9E

Instrumentation/Driver Info.

9F

Body Structure

9G

Cab

9H

Seats

9I

Security and Lock

9K

Exterior/Interior Trim

9L

Cab Mounting

10

CONTROL SYSTEMS

10B

Vehicle Control

11

FRAME AND FRAME ACCESSORIES

11A

Frame

General Information 0A-1

GENERAL INFORMATION

General Information

TABLE OF CONTENTS

General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2 General Repair Instructions . . . . . . . . . . . . . . . 0A-2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3

Chassis Number/Engine Number Stamping

Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 Option Code List . . . . . . . . . . . . . . . . . . . . . . . . 0A-4 Vehicle Identification Number (VIN) . . . . . . . . 0A-11 General Precaution . . . . . . . . . . . . . . . . . . . . . . 0A-15 General Precautions . . . . . . . . . . . . . . . . . . . . 0A-15 Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . . 0A-17 Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . 0A-17 Caution for The Maintenance of Electrical Parts 0A-20 Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . 0A-20 Connector Handling Requirements . . . . . . . . . 0A-20 Handling Electronic Parts . . . . . . . . . . . . . . . . 0A-23 Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . 0A-23 Regarding The Scan Tool. . . . . . . . . . . . . . . . . . 0A-25 Trouble Diagnosis Using The Scan Tool . . . . . 0A-25 Recommended Liquid Gasket . . . . . . . . . . . . . . 0A-31 Recommended Liquid Gasket. . . . . . . . . . . . . 0A-31 Recommended Thread Locking Agent. . . . . . . . 0A-33 Recommended Thread Locking Agent . . . . . . 0A-33 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . 0A-34 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-34

Maintenance Schedule

(for Euro4 specification except Europe) . . . . . 0A-35 Maintenance Schedule

(for Euro2, Euro3 specification). . . . . . . . . . . . 0A-41 Maintenance Schedule (for Europe) . . . . . . . . 0A-45 Maintenance Schedule

(CNG engine for Australia) . . . . . . . . . . . . . . . 0A-50 Maintenance Schedule

(CNG engine for Thailand) . . . . . . . . . . . . . . . 0A-54 Transmission Oil — ZF6S1000/ZF9S1110 Type 0A-58 Transmission Oil — FS8209A/FSO5206B Type 0A-65 RS23/RS40 Type Axle . . . . . . . . . . . . . . . . . . 0A-67 RS25 Type Axle . . . . . . . . . . . . . . . . . . . . . . . 0A-68

Maintenance Schedule for Severe-condition . . . 0A-69 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-69 Maintenance Schedule for Severe-condition . 0A-69

Recommended Fluids, Lubricants and

Diesel Fuels (except Europe). . . . . . . . . . . . . . . 0A-73 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-73 Diesel Engine Crankcase with DPD

(Low Ash Oil). . . . . . . . . . . . . . . . . . . . . . . . . . 0A-73 Diesel Engine Crankcase without DPD. . . . . . 0A-74 CNG Engine Crankcase (for Australia) . . . . . . 0A-74 CNG Engine Crankcase (for Thailand) . . . . . . 0A-74 Manual Transmission (MZX/MZW/MLD

models), Transfer Case, Differential

(without LSD) and Oil Lubricated Hub

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-75

Manual Transmission (MZZ models). . . . . . . . 0A-75 Differential (with LSD) . . . . . . . . . . . . . . . . . . . 0A-75 Smoother Clutch Oil (Smoother) . . . . . . . . . . . 0A-75 Automatic Transmission, Power Steering . . . . 0A-76 Center Bearing, Clutch Shift Block,

Grease Lubricated Hub, Water Pump,

Propeller Shaft Sliding Yoke, Universal

Joint (Multi Purpose Grease) . . . . . . . . . . . . . 0A-76 Multi-Purpose Grease Containing

Molybdenum . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-76 Engine Cooling System. . . . . . . . . . . . . . . . . . 0A-76 Electric-hydraulic Cab Tilt Pump . . . . . . . . . . . 0A-77 Clutch and Brake Fluid Reservoir . . . . . . . . . . 0A-77 Diesel Fuel / Applicable Standard . . . . . . . . . . 0A-77 Diesel Fuel / Applicable Standard

(Sulfur content below 50 ppm) . . . . . . . . . . . . 0A-78 Recommended Fluids, Lubricants and

Diesel Fuels (for Europe) . . . . . . . . . . . . . . . . . . 0A-79 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-79 Diesel Engine Crankcase with DPD

(Low Ash Oil). . . . . . . . . . . . . . . . . . . . . . . . . . 0A-79 Diesel Engine Crankcase without DPD. . . . . . 0A-79 Manual Transmission (MZX/MZW/MZZ/MLD

models), Differential (without LSD) and Oil Lubricated Hub Bearing . . . . . . . . . . . . . . . . . 0A-80

Differential (with LSD) . . . . . . . . . . . . . . . . . . . 0A-80 Smoother Clutch Oil (Smoother) . . . . . . . . . . . 0A-80 Power Steering . . . . . . . . . . . . . . . . . . . . . . . . 0A-80 Center Bearing, Clutch Shift Block,

Grease Lubricated Hub, Water Pump,

Propeller Shaft Sliding Yoke, Universal

Joint (Multi Purpose Grease) . . . . . . . . . . . . . 0A-81 Engine Cooling System. . . . . . . . . . . . . . . . . . 0A-81 Electric-hydraulic Cab Tilt Pump . . . . . . . . . . . 0A-81 Clutch and Brake Fluid Reservoir . . . . . . . . . . 0A-82 Diesel Fuel / Applicable Standard . . . . . . . . . . 0A-82 Diesel Fuel / Applicable Standard

(Sulfur content below 50 ppm) . . . . . . . . . . . . 0A-82 Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . . 0A-83 Oil Viscosity Chart. . . . . . . . . . . . . . . . . . . . . . 0A-83 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . 0A-84 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . 0A-84 Greasing Point . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-97 Greasing Point . . . . . . . . . . . . . . . . . . . . . . . . 0A-97

0A-2 General Information

General Information

General Repair Instructions

1.Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle.

2.Use covers on the vehicle body, seats, and floor to prevent damage and/or contaminations.

3.Disconnect the grounding cable from the battery before performing service operations.

This will prevent cable damage or burning due to shortcircuiting.

4.Raise the vehicle with a jack set against the axle or the frame.

5.Support the vehicle on chassis stands.

6.Handle brake fluid and antifreeze solution with great care.

Spilling these liquids on painted surfaces will damage the paint.

7.The use of the proper tool(s) and special tool(s) where specified is efficient, reliable, and safe service operations.

8.Always use genuine ISUZU replacement parts.

9.Discard used cotter pins, gasket, O-rings, oil seals, lock washers, and self-locking nuts at disassembly. Normal function of these parts cannot be guaranteed if they are reused.

10.Keep the disassembled parts neatly in groups. This will facilitate smooth and correct reassembly.

11.Keep fixing nuts and bolts separate.

Fixing nuts and bolts vary in hardness and design according to installation positions.

12.Clean all parts before inspection or reassembly.

13.Clean the oil ports and other openings with compressed air to make certain that they are free of dirt and obstructions.

14.Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.

15.Use the recommended liquid gasket to prevent leakage.

16.Be sure to tighten nuts and bolts to the specified torque, using a properly maintained torque wrench.

17.When service operation is completed, male a final check to be sure service has been done properly and problem has been corrected.

18.When removing or replacing parts that require refrigerant to the discharged from the Air conditioning system, be sure to use the ACR4 or equivalent to recover and recycle Refrigerant — 134a (HFC-134a), to promote the movement for the protection of the ozone layer covering the earth.

19.To assure safety, always slowly release air pressure from the air tanks before disconnecting pipes, hoses or other parts from any unit under pressure.

20.Prior to start the welding work, the following operations are required:

Disconnect all connectors of electronic control unit.

Disconnect battery ground terminal.

Welding machine ground cable must be connected near the welding point.

Turn off the all switches.

ISUZU Giga Service Manual

General Information 0A-3

Identification

Chassis Number/Engine Number Stamping Position

Chassis number

It is stamped on the front right-hand side face of the chassis side member.

MFW70ASH000101

Engine number (4HK1 Engine)

The engine number is stamped on the right side of the cylinder body.

LNWB0ASH000101

Engine number (6HF1 Engine)

The engine number (1) is stamped on the right side of the cylinder body.

1

MFW90ASH000101

Engine number (6HK1 Engine)

The engine number is stamped on the right side of the cylinder body.

MFW80ASH000401

Service Parts ID Plate

The service parts ID plate is attached to the passenger side lower dashboard.

The service parts ID plate has the following information;

Vehicle identification number (VIN)

Wheelbase dimensions

Paint information

Production options or special equipment installed on the vehicle at the factory

0A-4 General Information

Refer to the service parts ID plate when ordering replacement parts.

MFU8Z0SH043301

Option Code List

Option

Option Description

Code

AJ3

Driver side air bag

AK3

Front seat belt & shoulder

with retractor

AK5

Driver and passenger side air bag

AU4

Automatic door lock

A31

Power window — front & rear door

A32

Power window — front door

A56

Driver seat — air suspension

A83

Vinyl seat with reclining

BDM

Power take off — transmission rear

BFK

Transfer TF56

BHW

Power take off — engine rear,

electromagnetic clutch

BJR

Brake adjuster — manual

B02

South Africa equipment

B03

Thailand equipment

B04

Taiwan equipment

B1S

Parking brake drum — 8.5 inch

B1T

Parking brake drum — 10 inch

B10

Malaysia equipment

B12

Russia equipment

B13

Australia equipment

Option

Option Description

Code

B14

Hong Kong equipment

B3A

Rear wheel parking brake — air

control

B30

Floor carpet — vinyl

B84

Body side molding

CB7

Colombia equipment

CE4

Head lamp washer

CGA

Morocco equipment

CJ6

Country — Ireland

CK1

Pakistan equipment

CL1

Kenya equipment

CT6

Country — Italy

CU9

Country — United Kingdom

CV4

Country — Israel

CX6

Country — New Zealand

C13

Wiper with intermittent

C2C

Transmission oil cooler

C2M

Propeller shaft — P60 type

C3N

Final differential lock

C3U

Air suspension — high control

C4M

Air breather with flex hose

C4Z

Propeller shaft — P46 type

C41

Heater & defroster

C5K

Hub lubrication — oil bath

C5T

Propeller shaft — P90 type

C60

Manual air conditioning

C65

Manual air conditioning

without heater core

C68

Automatic air conditioning

DH2

O/S rear view mirror — long arm

DL8

O/S rear view mirror — remote control

with heated

DNB

O/S rear view mirror — pillar mounted

D20

Assist side sun visor

D31

Rear view mirror

D37

Mirror — Outside rear view

D6M

User — export government

D8T

Iran equipment

D94

Touch-up paint

General Information 0A-5

Option

Option Description

Code

EAK

Disc wheel — 6 studs 19.5×6.75

(136-12)

EBB

Digital tachograph

EBE

Front under run protector

ECF

Speed limiter — 60km/h

ECY

Speed limiter — 70km/h

EDG

Header console — driver & assist

EDH

Round curtain rail

EDW

Speed limiter — 80km/h

EDX

Speed limiter — 85km/h

EFE

Regulation ECE R29

EFK

Floor mat — vinyl mat Var.2

E09

Europe equipment

E11

Mexico equipment

E13

New Zealand equipment

E2N

Fuel pipe — steel

E29

Auxiliary steps

E40

Sleeper cab with mattress

E46

Ecuador equipment

FJC

Disc wheel — 10 studs 20×8.50V

(138-13)

F59

Front stabilizer

GH3

Saudi Arabia equipment

GL6

Rear shock absorber

GN1

Rear stabilizer

G86

Limited slip differential — no spin

JAQ

Lighting system — Saudi Arabia

JBF

Tire — KD special

JBZ

Lighting system — Japanese standard

JCA

Anti-noise equipment — ECE R51.02

JDN

Compartment — I/P assist side with lid

JDP

Compartment — I/P assist side without lid

JE5

Anti-lock brake system

J55

Brake system — heavy duty Var.1

J91

Trailer brake control

KC5

Receptacle — accessory

KE1

Chile equipment

KF0

Fuel filter — low quality

KG2

Generator 24V60A

Option

Option Description

Code

K30

Auto cruise

K44

Generator 24V-90A

K89

Generator 24V-50A

M9A

Owners manual — Not required

NCR

Memory system — Runnig condition

NF7

Fuel tank 200L + 200L

NJW

Ireland KD special

NMJ

Speed limiter — 90km/h

NMU

Speed limiter — 100km/h

NNR

3 speaker system

NT2

Emission system — Euro2

NT3

Emission system — Euro3

NT4

Emission system — Euro4

N02

Fuel tank 100L — frame side mount

N05

Fuel tank cap with key lock

N19

Fuel tank — 140L frame side

N20

Fuel tank 200L — frame side mount

N79

Spare disc wheel

PM1

Rear hook — double

PP7

Pintle hook

PR2

Driving position — wide leg space

PS7

Air dryer

PT1

Disc wheel — 8 studs 22.5×6.75

(145-11)

PT6

Thailand KD special

P10

Spare tire carrier — frame rear mount

P13

Spare tire carrier — frame side mount

P38

Tire delete

QM8

Disc wheel — 10 studs 22.5 x 8.25

(165-13)

Q47

Disc wheel — 8 studs 20×6.50T

(145-10)

Q87

Disc wheel — 10 studs 22.5×7.50

(162-12)

Q5T

Turbo — conventional

Q50

Disc wheel — 8 studs 20×6.50T

(152-11)

Q54

Disc wheel — 8 studs 20×7.00T

(162-12)

Q58

Disc wheel — 10 studs 20×7.00T

0A-6 General Information

Option

Option Description

Code

Q62

Disc wheel — 8 studs 20×7.50V

(165-13)

Q64

Disc wheel — 10 studs 20 x 7.50V

Q87

Disc wheel — 10 studs 22.5×7.50

(162-12)

RC4

Dump control lever

RC5

Tool box with key lock

RE3

Spare tire fixing

RE9

Clutch — 15 inch single plate

strap drive

RDV

4HK1-TCC engine

RJS

4HK1-TCS engine

RQZ

G.V.W. — 8.0-11.0 ton

RRA

G.V.W. — 11.0-14.0 ton

RR9

O/S rear view mirror — under

RSA

Manual transmission — MZZ6W

RSW

Manual transmission — MZX6P

RSZ

Manual transmission — MZW6P

RWE

Chevrolet brand

R32

KD frame

R46

Spare tire & disc wheel

R9A

Service cab with electric

R9B

Service cab without electric

R9C

Deletion — service cab with electric

R9D

Deletion — service cab without electric

R9E

Service cab conversion with electric

R9F

Deletion — service cab conversion

without electric

R9Z

Thailand localization spec.

SAQ

Front suspension — multi leaf spring

SAR

Front suspension — taper leaf spring

SAS

Rear suspension — multi leaf spring

SAU

Rear helper suspension — taper leaf

spring

SAY

Standard cab

SAZ

Ventilator & defroster

SBB

Disc wheel — 8 studs 20×6.00S

(135-10)

SBG

Disc wheel — 6 studs 17.5×6.00

(135-9)

Option

Option Description

Code

SDF

Room lamp with all door switch

SDH

Fuel tank 400L

SDK

Cab suspension — semi floating type

SDP

Disc wheel — 8 studs 20×7.00T

(152-12)

SEG

Disc wheel — 8 studs 205×7.50V

(130-13)

SFC

Disc wheel — 6 studs 17.5×6.75

(137-10)

SFT

Electric outlet — one

SGA

Front under spoiler delete

SGX

Vietnam equipment

SG4

Tire inflator device

SG7

Disc wheel — 6 studs 16×6.00GS

(135-9)

SH5

Power take off — transmission side

without lever

SJA

Driver seat — Isringhausen

SKU

Disc wheel — 8 studs 22.5×7.50

(162-13)

SKV

Disc wheel — 8 studs 22.5 x 8.25

(165-13)

SK4

Engine overrun buzzer

SLB

Front bumper with headlamp

SLC

Lighting system — ECE

SLK

Anti-noise equipment — ECE

SMS

Rear bumper — steel wide

SP9

Assist seat without center seat

SR6

Rearward double tire

SV6

Power take off control

SY8

Spare tire carrier — lifting type

TAF

O/S rear view mirror — under & side

under

TAK

Anti-noise equipment — Var.2

TAZ

Driver seat — rigid without arm rest

TDU

Brake regulation — ADR

TDV

Brake regulation — ECE

TEC

Roof marker lamp

TEE

Disc wheel — 8 studs 19.5×6.75

(147-12)

TFD

Cab all painting

General Information 0A-7

Option

Option Description

Code

TFN

Driver’s seat belt with pre-tension

reducer

TGL

Anti corrosion package

TM1

Battery — 80D26L

TR6

Headlamp leveling system — manual

TR7

Headlamp leveling system — automatic

TT5

Halogen headlamp

TT6

High intensity discharge headlamp

T1A

Injection pump Q set — special

+5%Q

T62

Battery — dry

T64

Battery delete

T79

Rear fog lamp

T87

Cornering lamp

T96

Front fog lamp

UC1

Speedometer — miles per hour (MPH)

UC9

TachographKienzle

UF3

Map lamp

UG3

Engine oil temperature gauge

UL5

Radio delete

UT3

AM/FM radio with CD player

U01

Roof marker — 5 lamps

U18

Speedometer — kilometer

U69

AM/FM radio

U95

2 speaker system

VG7

Front bumper reinforcement

— heavy duty

VP1

Front under spoiler

VR7

Two eye rear hook

VTK

Owners manual — Arabic language

VTL

Owners manual — French language

VTS

Owners manual — Spanish language

VT7

Owners manual — English language

VZA

VIN model year — 2010

VZB

VIN model year — 2011

V22

Radiator grille — chrome

V4F

Chassis for fire car

V76

Hook — tow

WB7

Electrical horn

Option

Option Description

Code

WC7

Tachograph — 140km/h

WF6

Clutch — 14 inch single plate

strap drive

WG3

Brake system — heavy duty Var.2

WH2

Spare tire — front tire

WJ7

Cautions — Arabian

WJ8

Cautions — French

WL5

Inspection lamp

WM3

Interior trim — full trimming

WV2

Automatic cab tilt

WX8

Shift control — assister

W02

Highland zone package

W1G

Final drive gear ratio — 6.143 (43/7)

14.5 inch hypoid

W1H

Final drive gear ratio — 5.571 (39/7)

14.5 inch hypoid

W1J

Final drive gear ratio — 6.500 (39/6)

14.5 inch hypoid

W1K

Final drive gear ratio — 6.833 (41/6)

14.5 inch hypoid

W1L

Final drive gear ratio — 6.500 (39/6)

16.5 inch hypoid

W1R

Final drive gear ratio — 6.143 (43/7)

15.5 inch hypoid

W1T

Final drive gear ratio — 6.500 (39/6)

15.5 inch hypoid

W1U

Final drive gear ratio — 4.875 (39/8)

14.5 inch hypoid

W12

Front locking hub — manual

W14

Deluxe cab

W16

Cab suspension — full floating

W18

Transfer TF36

W20

Disc wheel special painted (white)

W3B

Final drive gear ratio — 5.571 (39/7)

16.5 inch hypoid

W3D

Final drive gear ratio — 4.875 (39/8)

18.5 inch hypoid

W3F

Final drive gear ratio — 6.167 (37/6)

18.5 inch hypoid

W3G

Final drive gear ratio — 6.667 (40/6)

18.5 inch hypoid

W3K

Final drive gear ratio — 5.571 (39/7)

15.5 inch hypoid

0A-8 General Information

Option

Option Description

Code

W3L

Final drive gear ratio — 6.143 (43/7)

16.5 inch hypoid

W3M

Final drive gear ratio — 5.125 (41/8)

18.5 inch hypoid

W3N

Final drive gear ratio — 4.556 (41/9)

18.5 inch hypoid

W3P

Final drive gear ratio — 5.125 (41/8)

16.5 inch hypoid

W3S

Final drive gear ratio — 5.857 (41/7)

15.5 inch hypoid

W3U

Final drive gear ratio — 7.167 (43/6)

17.5 inch hypoid

W3X

Final drive gear ratio — 6.429 (45/7)

17.5 inch hypoid

W3Y

Final drive gear ratio — 6.143 (43/7)

17.5 inch hypoid

W3Z

Final drive gear ratio — 5.571 (39/7)

17.5 inch hypoid

W4A

Final drive gear ratio — 5.125 (41/8)

17.5 inch hypoid

W4B

Final drive gear ratio — 4.875 (39/8)

17.5 inch hypoid

W4C

Final drive gear ratio — 4.556 (41/9)

17.5 inch hypoid

W4F

Final drive gear ratio — 5.125 (41/8)

14.5 inch hypoid

W4H

Final drive gear ratio — 5.125 (41/8)

15.5 inch hypoid

W4T

Final drive gear ratio — 4.333 (39/9)

18.5 inch hypoid

W4W

Final drive gear ratio — 6.833 (41/6)

17.5 inch hypoid

W4X

Final drive gear ratio — 4.333 (39/9)

14.5 inch hypoid

W5M

Final drive gear ratio — 4.100 (41/10)

14.5 inch hypoid

W5V

Final drive gear ratio — 6.833 (41/6)

16.5 inch hypoid Rockwell

W5Z

Final drive gear ratio — 4.89 (44/9)

18.0 inch hypoid Rockwell

W6A

Final drive gear ratio — 5.38 (43/8)

18.0 inch hypoid Rockwell

W6B

Final drive gear ratio — 5.63 (45/8)

18.0 inch hypoid Rockwell

W6C

Final drive gear ratio — 6.14 (43/7)

18.0 inch hypoid Rockwell

Option

Option Description

Code

W6M

Final drive gear ratio — 6.43 (45/7)

18.0 inch hypoid Rockwell

W6N

Final drive gear ratio — 6.83 (41/6)

18.0 inch hypoid Rockwell

W6R

Final drive gear ratio — 4.30 (43/10)

18.0 inch hypoid Rockwell

W6S

Final drive gear ratio — 6.14 (43/7)

15.0 inch hypoid Rockwell

W66

Disc wheel with step

W71

Cab suspension — rigid type

W8C

Final drive gear ratio — 4.56 (41/9)

18.0 inch hypoid Rockwell

W8D

Final drive gear ratio — 6.43 (45/7)

15.0 inch hypoid Rockwell

W8F

Final drive gear ratio — 4.555 (41/9)

14.5 inch hypoid

W8L

Final drive gear ratio — 6.83 (41/6)

15.0 inch hypoid Rockwell

X5J

Manual transmission — MLD6Q

X7W

Manual transmission — MLD6S

X9C

Transmission — manual

X9D

Transmission — automatic

YC4

Injection pump — high altitude

compensator, aneroid type

YK3

Rearward single tire

YM9

Reversing warning buzzer

YN1

Caution — Spanish

YS1

O/S rear view mirror — flat type

YT9

Pakistan KD special

Y2C

Manual transmission — MLD6W

Y21

Light duty package truck

Y3A

Manual transmission

— Fuller FS8209

Y3B

Automatic transmission

— Allison MD3560P

Y4F

Automatic transmission

— Allison LCT2000

Y4G

Automatic transmission

— Allison MD3060P

Y4V

Manual transmission

— Fuller FSO5206B

Y48

Heavy duty package truck

Y5D

Manual transmission — ZF 6S1000

General Information 0A-9

Option

Option Description

Code

Y5E

Manual transmission — ZF 9S1110

Z05

Brake system — air over hydraulic

dual circuit

Z06

Brake system — full air dual circuit

Z1V

Equipment — additional key

01D

KD package — South Africa

01R

Tire — front & rear 8.25-20-14 lug

02E

KD package — Taiwan

05R

Tire — front & rear 8.25R20-14 rib

09X

Tire — front 8.25-20-14 rib,

rear 8.25-20-14 lug

1D7

6HF1-TCN engine

1D9

6HF1-TCC engine

10T

Tire — front & rear 9.00-20-14 rib

10X

Tire — front 9.00-20-14 rib,

rear 9.00-20-14 lug

11X

Tire — front 10.00-20-14 rib,

rear 10.00-20-14 lug

12X

Tire — front 10.00-20-16 rib,

rear 10.00-20-16 lug

15N

Tire — front & rear 9R22.5-14 rib

155

Interior color — Charcoal gray

2G0

Singapore equipment

20D

Thailand KD deletion parts

21R

Tire — front & rear 9.00-20-14 lug

25R

Tire — front & rear 9.00R20-14 rib

27X

Tire — front 11.00-20-16 rib,

rear 11.00-20-16 lug

30T

Tire — front & rear 10.00-20-14 rib

34W

Wheel base 3,400mm

35N

Tire — front & rear 10R22.5-14 rib

36W

Wheel base 3,600mm

37W

Wheel base 3,700mm

38W

Wheel base 3,800mm

39W

Wheel base 3,900mm

40S

Tire — front & rear 8.25-16-14 rib

40T

Tire — front & rear 10.00-20-16 rib

40W

Wheel base 4,000mm

41R

Tire — front & rear 10.00-20-14 lug

41W

Wheel base 4,100mm

Option

Option Description

Code

42W

Wheel base 4,200mm

43P

Tire — front & rear 9R22.5-14

43W

Wheel base 4,300mm

45N

Tire — front & rear 11R22.5-14 rib

45P

Tire — front & rear 275/70R22.5

45R

Tire — front & rear 10.00R20-14 rib

46W

Wheel base 4,600mm

48W

Wheel base 4,800mm

49W

Wheel base 4,900mm

49P

Tire — front & rear 8.25R20-14

exp block

5D9

Tire — front & rear

295/80R22.5-152/148K rib/lug

5E0

Tire — front & rear

295/80R22.5-152/148J rib

5E1

Tire — front & rear 10R22.5-14

5G2

Tire — front 295/80R22.5,

rear 11R22.5-16

5H1

Tire — front 10.00-20-16 rib,

rear 10.00-20-16 lug

5J6

Tire — front 9.5R17.5 129/127L rib,

rear 9.5R17.5 129/127L traction

5J7

Tire — front & rear 11R22.5 148/145L

rib

5J8

Tire — front & rear 245/70R19.5 rib

5J9

Tire — front & rear 235/75R17.5 rib

5K0

Tire — front & rear 265/70R19.5 rib

5K4

Tire — front & rear 11R22.5 148/145K

rib/lug

5K5

Tire — front & rear 12R22.5 152/148K

rib/lug

5L1

Tire — front & rear 12.00R20-18

5L4

Tire — front & rear 275/70R22.5

148/145M rib

5L7

Tire — front & rear 9.00R-20-14

exp lug

5L8

Tire — front & rear 10.00R-20-16 lug

5N5

Tire — front & rear

265/70R19.5

140/

138M rib (BS brand)

5N6

Tire — front & rear

235/75R17.5

132/

130M rib (BS brand)

5P0

Tire — front & rear

235/75R17.5

132/

130M rib (BS brand)

0A-10 General Information

Option

Option Description

Code

5P1

Tire — front 295/80R22.5,

rear 11R22.5-16 (6×2, BS brand)

5P2

Tire — front 295/80R22.5,

rear 11R22.5-16 (BS brand)

5P3

Tire — front & rear 10R22.5-14

exp rib/lug (BS brand)

5P6

Tire — front & rear 225/70R19.5

5P7

Tire — front & rear 8.25R16 128/126L

exp rib/lug

50W

Wheel base 5,000mm

51R

Tire — front & rear 10.00-20-16 lug

51W

Wheel base 5,100mm

517

Body color — AL. gray

53W

Wheel base 5,300mm

538

Body color — Tool-IPEC yellow

55N

Tire — front & rear 11R22.5-16 rib

55P

Tire — front & rear 295/80R22.5

152/148M rib

55R

Tire — front & rear 10.00R20-16 rib

55W

Wheel base 5,500mm

58N

Tire — front & rear 11.00R20-16 rib

58W

Wheel base 5,800mm

59W

Wheel base 5,900mm

6DY

Rear under run protector

6EP

HSA system

6HF

KD preparatory package

6KK

Horn — heavy duty (dual)

6ND

OK window

6NF

Remote control door lock

6PH

LSPV — Load sensing proportioning

valve

6SZ

Power take off — flywheel

6UC

Fluorescent lamp

6UH

O/S rear view mirror — assist side short

stay

6VE

O/S rear view mirror — door mount

6WX

Floor mat — vinyl

6XH

ASR system

60W

Wheel base 6,000mm

609

Body color — FT orange

Option

Option Description

Code

61P

Tire — front & rear 225/90R17.5

63E

KD package — Italy

63W

Wheel base 6,300mm

64E

KD package — Vietnam

64N

Tire — front & rear 8.25R20-14 rib

65W

Wheel base 6,500mm

668

Body color — Purplish blue

681

Body color — Geranium red

695

Body color — Dark blue

7BC

Assist seat with center seat

7DM

Tuner band — Latin America

7FL

Seat material — cloth

7HZ

Rear bumper

7KC

Immobilizer system

7NY

Multi information display

7SV

O/S rear view mirror — heated

7TV

KD preparatory package

70T

Tire — front & rear 11.00-20-14 rib

71R

Tire — front & rear 11.00-20-14 lug

71S

Tire — front & rear 7.50-20-12 lug

71W

Wheel base 7,100mm

729

Body color — Arc white

736

Body color — Cardinal red

78N

Tire — front & rear 8.25R16

79R

Tire — front & rear 11.00R20-14

8AA

Good quality ethylene glycol

antifreeze 50%

8AC

Good quality ethylene glycol

antifreeze 30%

8EJ

Battery — 65D23L

8GF

Transmission with Smoother

8GJ

Transmission without Smoother

8JM

Diesel particulate diffuser

8LF

Rear window glass

8LX

Ash tray — assist side

8MA

Battery 115E41L

8MH

Fuel tank 370L

8ML

O/S rear view mirror — middle arm

General Information 0A-11

Option

Option Description

Code

8MV

O/S rear view mirror — extended long

arm

8NG

Decal — vehicle & pet name

8NH

Decal — pet name

8NV

Bio diesel fuel B10

80L

6HK1-TCS engine

80R

Tire — front & rear 11.00-20-16 rib

800

Body color — In white

807

Body color — Woodland green

81L

6HK1-TCC engine

81R

Tire — front & rear 11.00-20-16 lug

81U

Tire — front & rear 8.25-16-14 lug

812

Body color — Wheatland yellow

82L

6HK1-TCN engine

829

Body color — Sahara beige

83N

Tire — front & rear 9.5R17.5

84D

Colombia Var.2

85N

Tire — front & rear 11R22.5-16

85R

Tire — front & rear 11.00R20-16 rib

85U

Tire — front & rear 8.25R16-14 rib

87N

Tire — front & rear 10.00R20-14PR rib

89N

Tire — front & rear 9.00R20-14PR rib

89R

Tire — front & rear 11.00R20-16PR

89T

Tire — front & rear 11.00R20-16

890

Body color — Marine blue

90S

Tire — front & rear 8.25-20-14 rib

904

Body color — golden yellow

91D

KD package — Philippine Var.2

915

Body color — fire red

92N

Tire — front & rear 8.25R16-14PR rib

93N

Tire — front 12.00R20-18,

rear 12.00R20-18 lug

94K

Tire — front & rear 10.00R20-16

94N

Tire — front & rear 12.00R20-16

944

Body color — Highway orange

95D

KD package — Ireland

951

Body color — arc white

97N

Tire — front 295/80R22.5,

rear 11R22.5-16

Option

Option Description

Code

982

Body color — Polar white

989

Body color — Sunbelt green

99D

KD package — United Kingdom

99N

Tire — front & rear 11R22.5-16

909

Body color — middle bronze green

919

Body color — olive drab

999

Body color — trans blue

Vehicle Identification Number (VIN)

The ID plate indicates the vehicle identification number (VIN).

This single number contains multiple pieces of information including the vehicle and engine model codes as shown below.

0A-12 General Information

Type 1

J A L F R R 3 4 L 8 7 0 0 0 0 0 1

1 2 3 4 5 6

MFW80ASF000201

Legend

1. World manufacturer identifier (WMI)

2.

Vehicle model code

3.

Engine code

4. Wheel base code

5.

Model year code

6.

Chassis number

1. World manufacturer identifier (WMI)

4. Wheel base code

Code

Code

ISUZU BRAND

H

3,201 — 3,500 mm

JAL

Medium & Heavy Duty

(126.02 — 137.80 in)

Incomplete Vehicle

J

3,501 — 3,800 mm

2. Vehicle model code

(137.83 — 149.61 in)

K

3,801 — 4,100 mm

Code

(149.65 — 161.42 in)

FRR

4×2 Truck FRR model

L

4,101 — 4,400 mm

(161.46 — 173.23 in)

FSR

4×2 Truck FSR model

4,401 — 4,700 mm

FTR

4×2 Truck FTR model

M

(173.27 — 185.04 in)

FVR

4×2 Truck FVR model

N

4,701 — 5,000 mm

FVZ

6×4 Truck FVZ model

(185.08 — 196.85 in)

FVM

6×2 Truck FVM model

P

5,001 — 5,300 mm

(196.89 — 208.66 in)

GVR

4×2 Tractor GVR model

5,301 — 5,600 mm

FSS

4×4 Truck FSS model

7

(208.70 — 220.47 in)

FTS

4×4 Truck FTS model

R

5,601 — 5,900 mm

(220.51 — 232.28 in)

3. Engine code

S

5,901 — 6,200 mm

Code

(232.32 — 244.09 in)

34

6HK1 Engine

T

6,201 — 6,500 mm

86

6HF1 Engine

(244.13 — 255.91 in)

90

4HK1 Engine

General Information 0A-13

5. Model year code

Code

U

6,501 — 6,800 mm

Code

(255.94 — 267.72 in)

8

2008MY

6,801 — 7,100 mm

V

9

2009MY

(267.76 — 279.53 in)

A

2010MY

W

7,101 — 7,400 mm

B

2011MY

(279.57 — 291.34 in)

Type 2

J A L

H

5

K

1

6

8

7

7 0 0 0 0 1

1

2

3

4

5

6

7

8

9

10

MFW80ASF000301

Legend

6.

Engine code

1.

World manufacturer identifier (WMI)

2.

Gross vehicle weight (GVW) and brake system

7.

Check digit

3.

Series code

8.

Model year code

4.

Line/Cab type code

9.

Plant code

5.

Chassis code

10.

Production sequential number

1. World manufacturer identifier (WMI)

3. Series code

Code

Code

ISUZU BRAND

5

FRR

JAL

Medium & Heavy Duty

6

FSR

Incomplete Vehicle

7

FTR, FTS, FVR

2. Gross vehicle weight (GVW) and brake system

4. Line/Cab type code

Code

Code

H

8,846 — 10,659 kg

(19,501 — 23,500 lb)

Tilt cab,

K

BBC = 1,726 mm (67.95 in),

10,660 — 11,793 kg

K

Narrow Cab

(23,501 — 26,000 lb)

Tilt cab,

11,794 — 14969 kg

M

M

BBC = 2,066 mm (81.34 in),

(26,001 — 33,000 lb)

Narrow Cab

14,970 — 18,370 kg

P

Tilt cab,

(33,001 — 40,500 lb)

S

BBC = 2,066 mm (81.34 in),

Wide Cab

0A-14 General Information

5. Chassis code

Code

1

4×2, 2 Axles, 1 driving

2

4×4, 2 Axles, 1 driving

4

6×4, 3 Axles, 2 driving

6. Engine code

Code

3

6HK1-TC

6

4HK1-TC

Type 3

8. Model year code

Code

8

2008MY

9

2009MY

A

2010MY

B

2011MY

9. Plant code

3 M G F R R 9 0 A M 6 5 4 3 2 1

1

2

3

4

5

6

MFWB0ASF000101

Legend

1.

World manufacturer identifier (WMI)

4.

Model year code

2.

General attributes

5.

Plant code

3.

Check digit

6.

Production sequential number

1. World manufacturer identifier (WMI)

4. Model year code

Code

ISUZU BRAND

3MG Medium & Heavy Duty

Incomplete Vehicle

2. General attributes

5. Plant code

Code

Code

M

Mexico (IMEX)

FRR90

FRR90

FTR34

FTR34

FVR34

FVR34

General Information 0A-15

General Precaution

General Precautions

2

1

3

MFW70AMF000201

Legend

1. Clean and safe costume 3. Support by stand after jack up 2. Installation of Chock blocks

Work preparations

Prepare the tools, instruments, and special tools in advance.

Prepare the parts that require replacement and parts that cannot be re-used in advance.

Clothing

The service technician must wear a clean service technician uniform, hat, and safety footwear.

Protect the vehicle.

Make sure to use a seat cover, etc.

Disconnect the terminal of the battery (–) in advance.

Always focus on safety

Make sure to use chock block when the vehicle is jacked up.

After jacking up, make sure to support the specified position using a stand.

When lifting up the vehicle using a lift, make sure to set the safety device.

When performing a procedure with two or more people, make sure to ensure each other’s safety before performing an action.

Do not leave the engine running for an extended period of time or perform painting in a poorly ventilated working environment.

Make sure to use only the special tools if the procedure requires them for the work. Performing the procedure using other tools may cause damage to parts or personal injury.

Do not use tools such as a wrench that has lost its edges, a hammer with frayed edges, or a chipped chisel.

When performing work using a device such as a grinder, crane, or welder, make sure that a qualified technician performs the procedure while paying sufficient attention to the handling precautions.

0A-16 General Information

When performing maintenance on fuel systems, make sure that there is no fuel leakage. (may possibly catch fire)

When handling volatile materials, take care that they do not catch fire.

Also make sure to wipe away any oil that sticks to rubber parts, as it can cause deterioration.

Work Precaution

Arrange removed parts in the correct order and ensure they do not get mixed up with parts that cannot be re-used.

Perform sufficient cleaning and washing when performing assembly / installation.

Also perform sufficient grease removal for areas to apply liquid gasket, etc.

After-procedure check

After completing the procedure, perform a final check to confirm that the problem has been solved.

Check that there is no fuel, oil, or coolant leakage.

General Information 0A-17

Lifting Instruction

Lifting Instruction

If it necessary to use a lifting device other than the original equipment jack, see illustration for acceptable lifting points.

Lifting should only be done at the positions indicated to prevent possible damage to the vehicle.

CAUTION:

Failure to observe the acceptable lift points may result in unsatisfactory vehicle performance or a durability failure which may result in loss of control of the vehicle.

Garage Jack and Safety Stand

Lifting Point and Supportable Point Location

MFW70ASH000201

Legend

1.Front axle

2.Rear axle center

3.Side member front side

4.Side member rear side

Lifting Point Positions — Front side

CAUTION:

Do not lift or support on engine oil pan.

F*R/FVM/FVZ/GVR models

MFW80ASH000101

FSS model

MFU770SH015801

0A-18 General Information

FTS model

MFU8Z0SH025501

Lifting Point Positions — Rear side

CAUTION:

Do not lift or support on rear axle tube.

FRR/FSR models (with air suspension)

MFU770SH002801

FRR/FSR/FTR/FVR/GVR models (with leaf spring suspension), FSS/FTS models (except rear singletire model)

MFW80ASH000201

FSS/FTS models (rear single-tire model)

MFU9Z0SH015301

General Information 0A-19

NOTE:

Let the tire run over a piece of block, etc., and apply the jack.

FTS model(rear single-tire model)

MFU9Z0SH015401

FVR/FVM/FVZ/GVR models (with air suspension, except Europe)

MFU8Z0SH037501

FVR model (with air suspension, for Europe)

MFU8Z0SH077401

FVM/FVZ models (with leaf spring suspension)

MFW80ASH000301

0A-20 General Information

Caution for The Maintenance of Electrical Parts

Battery Cable

Disconnecting the battery cables

1.Turn all the switches «OFF».

2.Disconnect the battery ground cable (1).

3.Disconnect the battery plus cable (3).

4.Disconnect the battery cable (2).

CAUTION:

Make sure to disconnect the battery ground cable first. Disconnecting the plus cable first may cause a short circuit.

3

1

2

MFW70ASH000401

Connecting the battery cables

Connect the battery cables in the reverse order of the disconnection procedure.

CAUTION:

Clean the area surrounding the battery terminal, and apply a thin layer of grease to the terminal to prevent corrosion.

Connector Handling Requirements

Visual inspection

With the male and female connectors connected

Gently pull the connector and check whether the connector becomes disconnected or partially disconnected, and that the lock is properly set.

If a problem is found, reconnect the connectors.

Check that there is no damage to the connector

housing.

If a problem is found, perform replacement. With the male and female connectors disconnected

Check that no foreign material or water has entered the inside of the connectors.

Remove any foreign material or water that has entered the connector using an air brush, etc. If the material cannot be removed, replace them.

Check that no foreign material is stuck to the terminals, and there is no corrosion or deformation.

Remove any foreign material by cleaning with an air brush, or clean rag, etc. If the material cannot be removed by cleaning, or there is corrosion or deformation, replace them.

Gently pull the wires to check that no terminals are missing from the connector and there is no breakage in the terminal area.

If a terminal is missing, reinsert it until it locks into place. If you find a disconnection, replace them.

Insert the male connector into the same female connector, and check that there is no abnormality in the terminal contact pressure.

If you find an abnormality, replace them.

For waterproof connectors, check that there is no damage or foreign material stuck to the seal parts (wire seal of wiring, O-ring or waterproofing seal of connector, etc.) or seal area of the connector housing.

Remove any foreign material by cleaning with an air brush, or clean rag, etc. If the material cannot be removed by cleaning, or there is damage, replace them.

CAUTION:

Do not perform polishing that would remove the plating of the terminals, nor wash the inside of the connector. If there is dirt that requires washing, replace them.

Be careful when attaching the seal areas of waterproof connectors, as some have specific positions and directions they must be attached. Also do not attach them in a twisted state.

Regarding vehicle washing

Even for electric parts that are installed outside the cab and are waterproofed, try to avoid exposing them directly to high pressure water when washing the vehicle (cover them with plastic sheets, etc.) as much as possible.

General Information 0A-21

Disconnecting the connector

Many connectors have a lock to ensure secure connections.

The two types of locks generally used are those that open by lifting the release area of the lock (1), and those that open by pressing the release area (2). Before disconnecting the connector, determine in advance which type of lock the connector is using.

12

LNW20ASH001201

When disconnecting the connector, first securely grasp the male side and female side of the connector. Release the lock, and carefully disconnect the connector.

Do not pull the harness when disconnecting the connector, as this may cause wires to come out or break.

OK

NO

LNW20ASH001301

Connecting the connector

Securely grasp the female side and male side of the connector, and align them correctly.

Firmly push them together until both sides click into place.

OK

NO

LNW20ASH001401

Connector circuit inspection requirements

Check the continuity of the connector using a circuit tester. Insert the probes (1) of the tester from the harness side of the connector, as indicated in the diagram.

OK

1

LNW20ASH001501

0A-22 General Information

Never insert the probes (1) from the connection closure area of the connector, as this will cause the connector terminals to break.

NO

1

LNW20ASH001601

Inspection requirements for waterproof connector circuit

For waterproof connectors, the probes of the tester cannot be inserted from the wiring side, due to the structure of the connectors.

Therefore, perform the continuity inspection as indicated in the diagram, by connecting a testing connector (1) prepared in advance to the connector (2) to test, and connect the probes (3) of the tester to the harness of the testing connector.

1

2

3

LNW20ASH001701

Disconnecting connector terminals —Built-in lock type

1.As indicated in the diagram, insert a thin screwdriver-shaped metal rod (1) from the connector closure area (5).

2.Push the lock (2) up in the direction of the arrow using the metal rod to release the lock. In that state, pull out the harness (3) together with the terminal (4).

1

2

5

4

3

LNW20ASH001801

—Terminal lock type

1.Insert a metal rod (1) from the connector closure area (5).

2.As indicated in the diagram, release the terminal lock (2) by pushing it to the harness side, pull out the harness (3) together with the terminal (4).

1

2

3

54

LNW20ASH001901

Connecting connector terminals

1.Check that the terminal lock (1) area is raised fully and can be locked.

2.Insert the terminal (3) from the harness (2) side of the connector, and push it in until the lock area clicks.

General Information 0A-23

3.Gently pull the harness and check whether the terminal is completely locked inside the connector.

Replacing the fuse

WARNING:

If a fuse melts down, make sure to replace it with a nondefective fuse of the same capacity, after identifying the cause of the melt down.

If you use a fuse with high capacity, the fuse will not perform its function when excess current flows. This may cause parts or wires, etc. to burn, and can result in a vehicle fire.

LNW20ASH002101

Handling Electronic Parts

Handle electronic parts with sufficient care, and do not damage the parts by dropping or throwing them.

LNW20ASH002201

Cable Harness

1.When installing electronic parts, take care to ensure the harness does not get stuck and do not forcibly push the harness in.

LNW20ASH002301

2.Make sure that all connections are clean and secure.

0A-24 General Information

3.When the harness will be contacting sharp edges or surfaces of other parts, protect the harness using a grommet or tube to prevent damage due to the contact.

NO

OK

LNW20ASH002401

4.When wiring the harness by diverting it around other parts, give the harness a sufficient amount of free length, and use a protective tube (2) and clip

(1) to ensure it does not contact surrounding parts.

5.For wiring between the engine and chassis, give the wiring sufficient free length to prevent wear and damage caused by vibrations.

NO

OK

LNW20ASH002601

General Information 0A-25

Regarding The Scan Tool

Trouble Diagnosis Using The Scan Tool

Regarding the scan tool (Tech2) / Tech2 24 volt adaptor 2 /CAN-di module

This tool is effective for diagnosing electrical failures in electronic control units and performing system checks. If you connect the Tech2 to the DLC installed in the vehicle, it performs communication with the control units of the vehicle, and enables various diagnoses and tests to be performed.

Legend

1. PCMCIA card (dedicated) 3. DLC cable

2. Tech2 (body)

0A-26 General Information

12

4

3

LNW7Z0SF000101

Legend

1.

Tech2 24V adaptor 2 (body)

3.

Tech2 connecting cable

2.

Signal change switch

4.

DLC connecting cable

[Euro4 specification]

1

2

3

LNW7Z0SF000401

Legend

1. CAN-di module (body) 3. DLC connecting cable 2. Tech2 connecting cable

Features and cautions regarding the scan tool (Tech2) / Tech2 24 volt adaptor 2 / CAN-di module [Euro4 specification]

The Tech2 has a 12 V power system. Do not directly use 24 V power. Do not directly supply power from the cigar lighter.

Remove/install the PCMCIA card after turning the power off.

The Tech2 has the capacity for two snapshots.

As the PCMCIA card is sensitive to magnetism and static electricity, take care when handling it.

The Tech2 is able to draw graphs of snapshots.

To select a menu, press the selection key or choose a menu with a function key and press the ENTER key.

You can return to the main menu at any time by pressing the EXIT key.

To clear the diagnostic trouble codes (DTC), open the application menu and select «Clear DTC Information».

The Tech2 adaptor 2 has a built-in DC to DC converter (that converts 24 V to 12 V).

General Information 0A-27

The Tech2 adaptor 2 has a selector for switching signals (the signals for each electronic control unit (ECU)).

The CAN-di module has a built-in signal converter (that converts CAN serial data to keyword serial data)

Parts of the Tech2

1

2

3

13

4

8

14

3

5

6

15

16

7

12

11

9

10

HCW35ALF001401

Legend

10.

VCI module fastening bar

1.

Soft key

2.

Selection key (arrow key)

11.

DLC cable connecting connector

3.

Action keys (YES, NO, ENTER, EXIT)

12.

AC adaptor connector

4.

Function key (F0 – F9)

13.

PCMCIA card insertion opening (with cover)

5.

Help key (?)

14.

PCMCIA card release (removal) button

6.

Control key (PWR or SHIFT)

15.

Connector for external communication (RS-485

7.

Wide stand

port)

8.

Display (liquid crystal display)

16.

Connector for external communication (RS-232

9.

Vehicle communication interface (VCI) Module

port)

1. Soft keys

displayed on the screen.

When operating the Tech2, the selection box is

2. Selection key (arrow key)

displayed on the top of the screen. The soft keys

Selects menu items on the Tech2 screen, and

correspond to that selection box. The soft keys

switches the display. The highlighted area of the

cannot be used unless the selection box is

screen display indicates what is being selected.

0A-28 General Information

3.Action keys (YES, NO, ENTER, EXIT)

Confirm Tech2 operations, respond to screen instructions/questions, switch/move to the various menu screens.

4.Function keys (F0 — F9)

Confirm menu functions displayed on the screen. Also when «F0» etc., is displayed on the menus on the screen, the keys correspond to that display.

5.Help key (?)

Displays a screen explaining the Tech2 function being used.

6.Control key (PWR or SHIFT)

The PWR key turns the power of the Tech2 ON/ OFF. The SHIFT key is used when adjusting the screen contrast. The LED (orange) lights up when the SHIFT key is available. At this time, the key and functions other than the selection key are locked. The LED (green) lights up when the power is turned ON.

7.Wide stand

Used as a stand. The operating angle of the stand is 0 to 180°.

8.Display (liquid crystal display)

The liquid crystal display has a contrast adjustment function. Displays the ECM information and the various instruction screens.

9.Vehicle communication interface (VCI) module The module that enables communication between the vehicle and Tech2.

Parts of the Tech2 24 V adaptor 2

10.VCI module fastening bar

Operate the bar to attach/fix, or remove the VCI.

11.DLC cable connecting connector

Connector for using (connecting) the Tech2 with the vehicle. Connect the DLC cable.

12.AC adaptor connector

Connector for connecting the included AC adaptor. Enables the Tech2 to be used away from the vehicle.

13.PCMCIA card insertion opening (with cover) Open the cover to insert a PCMCIA card into the Tech2. Insert the PCMCIA card with the cover opened. Never insert/remove the PCMCIA card with the Tech2 turned ON.

14.PCMCIA card release (removal) button

Used when removing the PCMCIA card from the Tech2. The PCMCIA card can be removed when the button is pressed. Never remove the PCMCIA card with the Tech2 turned ON.

15.Connector for external communication (RS-485 port)

This port is for connecting to a telephone line, but is currently not used for the Tech2. Do not connect a telephone line, etc., to this port.

16.Connector for external communication (RS-232 port)

This port is for connecting the Tech2 to another computer.

1.Signal change switch

The Tech2 adaptor 2 has a selector for switching signals (the signals for each electronic control unit (ECU)).

(The position of the switch is free for other than the following device)

“1” : —

“2” : HSA

“3” : —

2.DLC connecting cable

Connects the Tech2 adaptor 2 to the vehicle DLC (pole 16, blue).

3.Tech2 connecting cable

Connects the Tech2 adaptor 2 to the Tech2.

General Information 0A-29

Parts of the CAN-di module [Euro4 specification]

1

2

LNW7Z0SF000501

1.Tech2 connecting cable

Connects the CAN-di module to the Tech2.

2.DLC connecting cable

Connects the CAN-di module to the Tech2 adaptor 2.

Connection method

1.Insert the ISUZU system PCMCIA card into the Tech2 unit.

2.Connect the DLC cable to the Tech2 unit.

3.Connect the CAN-di module to the DLC cable. [Euro4 specification]

4.Connect the Tech2 24 V adaptor 2 to the CAN-di module. [Euro4 specification]

Connect the Tech2 24 V adaptor 2 to the DLC cable. [Except Euro4 specification]

5.Confirm that the ignition is turned «OFF».

6.Connect the Tech2 24 V adaptor 2 to the vehicle side DLC connector (pole 16, blue).

RHD model

9

1

10

2

11

3

12

4

13

5

14

6

15

7

16

8

LHD model

9

1

10

2

11

3

12

4

13

5

14

6

15

7

16

8

MFW82ASH000401

NOTE:

The CNG engine becomes sensitive to fluctuation of the power voltage when the temperature of ECM unit is high while or after driving, and communication failures may occur.

To avoid this situation, input 12 V power supply from a 12 V battery using a battery power cable, separately from the power for the Tech2 24 V adaptor 2.

Do not input 24 V battery power supply to the Tech2 unit. Do not use the cigar lighter power supply on the vehicle side, which is also 24 V.

MFA7Z0SH000201

0A-30

General Information

1

2

3

4

5

MFW90ASH000401

Legend

1.Tech2

2.Battery power cable

3.3 A fuse

4.Clip (black)

5.Clip (red)

If the power supply is not input, check the 3 A fuse.

7.Turn the ignition «ON», and press the «PWR» key of the Tech2.

8.Confirm the display of the Tech2.

Press (ENTER) To Continue

HCW46ESH001901

CAUTION:

Remove/install the PCMCIA card after confirming that power is not being supplied to the Tech2.

General Information 0A-31

Recommended Liquid Gasket

Recommended Liquid Gasket

Type

Product name

Manufacturer name

Area used (reference)

ThreeBond 1207B

ThreeBond

Engine oil seal retainer

Silicon type

ThreeBond 1207C

ThreeBond

Engine oil pan

(Room temperature

ThreeBond 1215

ThreeBond

Timing gear case

vulcanization process)

ThreeBond 1216

ThreeBond

Cylinder head cover

ThreeBond 1281

ThreeBond

Fuel pump

Water pump

Water Base

ThreeBond 1141E

ThreeBond

Rear axle

ThreeBond 1102

ThreeBond

Etc.

Solvent

ThreeBond 1104

ThreeBond

ThreeBond 1194

ThreeBond

LOCTITE 515

LOCTITE

Engine oil seal retainer

Anaerobic

LOCTITE 518

LOCTITE

Water pump

LOCTITE 17430

LOCTITE

Transaxle

FMD127

LOCTITE

Etc.

Make sure to use a liquid gasket with the above product name or equivalent.

Do not use LOCTITE 515, 518 or FMD 127, as they are anaerobic, and do not provide sufficient effect when there is a gap larger than 0.25 mm (0.010 in) between the contact surfaces of metals.

Use an appropriate amount of liquid gasket. Follow the handling precautions for the product.

Application method

1.Wipe any water or oil from the contact surface. Make sure the contact surface is dry.

2.Apply liquid gasket of the specified bead width to one side of the contact surface. Make sure there are no cuts in the beads.

1. Completely remove lubricant and moisture from the connecting surfaces.The surfaces must be perfectly dry.

2. Apply specified bead width of liquid gasket to one of the connecting surfaces.There must be no gaps in the bead.

mm (in)

SCREW

DEPRESSION

JUDGE

HOLE

MENT

1˜3

(0.04˜0.12)

OK

1˜3

More than

(0.04˜0.12)

2 (0.08)

OK

Depression

Apply liquid gasket to

the bolt hole interior

Specified

bead width

NG

Example

Anaerobic Type :2-3 mm (0.08-0.12 in)

Others

:2-6 mm (0.08-0.24 in)

MFW70AMF000101

0A-32 General Information

NOTE:

If the repair manual specifies an application method, follow that method.

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Книга: ISUZU GIGA 1996-2003 г.в., дизель эксплуатация, техническое обслуживание

Руководство по эксплуатации грузовых автомобилей Isuzu Giga / Giga Max / Isuzu C/E 1996-2003 годы выпуска, оборудованных дизельными двигателями 6WF1-TC, 6WF1-TC, 6WG1-TC, 8TD1, 8PE1, 10PE1.

Книга: ISUZU ELF / N-SERIES дизель с 1993 г.в., ремонт, эксплуатация, техническое обслуживание
Руководство по эксплуатации, ремонту и техническому обслуживанию заднеприводных и полноприводных автомобилей Isuzu ELF / N-Series с правым и левым рулем, оборудованных дизельными двигателями серии 4H (4,3; 4,6; 4,8 л), а так же серии 4J (2,8; 3,0).

Книга: ISUZU ELF / N-series дизель 1993-2004 г.в., NISSAN ATLAS дизель 1999-2004 г.в., ремонт, эксплуатация, техническое обслуживание

Руководство по эксплуатации, ремонту и техническому обслуживанию заднеприводных и полноприводных автомобилей Isuzu ELF / N-Series и Nissan Atlas с правым и левым рулем, оборудованных дизельными двигателями 4JG2 (3,1 л), 4HF1/4HF1 -2 (4,3 л), 4HG1/4HG1-T (4,6 л).

Книга: ISUZU TROOPER / ISUZU BIGHORN / OPEL MONTEREY бензин / дизель 1991-2002 г.в., ремонт, эксплуатация, техническое обслуживание

Руководство по ремонту, устройству и техническому обслуживанию автомобилей Isuzu Trooper / Isuzu Bighorn / Opel Monterey 1991-2002 годы выпуска с левым и правым рулем, с бензиновыми 6VD1 (3,2 л.), 6VE1 (3,5 л.) и дизельными 4JG2 (3,1 л.), 4JX1 (3,0 л.) двигателями.

Книга: ISUZU RODEO / AMIGO / HONDA PASSPORT бензин 1989 -1997 г.в., ремонт, эксплуатация, техническое обслуживание
Руководство по ремонту, техническому обслуживанию и эксплуатации автомобилей Isuzu Rodeo & Amigo / Honda Passport в пяти- и трехдверном исполнении кузова с бензиновыми 4-цилиндровыми двигателями 2.3 и 2.6 л., а также двигателями V6 3.1 и 3.2 л., оборудованные 4- или 5-ступенчатой РКПП, либо 4-ступенчатой АТ, с задним или полным приводом.

Книга: ISUZU FORWARD дизель 1985-2000 г.в., ремонт, эксплуатация, техническое обслуживание
Данная книга содержит подробные сведения об устройстве, эксплуатации, техобслуживанию и ремонту грузовых автомобилей Isuzu Forward, которые выпускались с 1985 по 2000 год, оснащались дизельными двигателями 6HH1 (объем 8,2 л) и 6BG1 (объем 6,5 л), 6HE1 (объем 7,1 л) и 6SA1 (объем 8,4 л) и оборудовались автоматической коробкой передач либо коробкой отбора мощности.

Книга: OPEL MONTEREY / ISUZU TROOPER BIGHORN AMIGO (MU) бензин c 1981 — 1992 / с 1988 — 1997 г.в., ремонт, экс
Руководство по ремонту  автомобилей Opel Monterey/Isuzu Trooper, Bighorn, Amigo(MU) c 1981 по 1992 и с 1988 по 1997 годы выпуска  для моделей с бензиновыми двигателями объемом 1,8; 2,0; 2,3; 2,6; 2,8; 3,1 л.

Книга: Двигатели ISUZU (4HF1 / 4HG1 / 4BB1 / 6BB1 / 4BD1 / 4BD1-T / 6BD1 / 6BD1-T / 4BG1 / 4BG1-T / 6BG1 / 6BG1-T) дизель ремонт, эксплуатация, техническое обслуживание
Подробное руководство по ремонту и техобслуживанию двигателей ISUZU (4HF1 / 4HG1 / 4BB1 / 6BB1 / 4BD1 / 4BD1-T / 6BD1 / 6BD1-T / 4BG1 / 4BG1-T / 6BG1 / 6BG1-T).

Книга: Двигатели ISUZU (6HK1-TC / 6HL1 / 6HH1 / 4HK1-T / 4HK1-TC / 4HL1 / 4HL1-TC) дизель ремонт, эксплуатация, техническое обслуживание

Подробное руководство по ремонту и техобслуживанию двигателей ISUZU (6HK1-TC / 6HL1 / 6HH1 / 4HK1-T / 4HK1-TC / 4HL1 / 4HL1-TC).


Книга: ISUZU ELF дизель до 1993 г.в., ремонт, эксплуатация, техническое обслуживание
Руководство по ремонту, эксплуатации и техническому обслуживанию, устройство автомобилей Isuzu Elf до 1993 года выпуска, с дизельными двигателями 4JA1 (2,5 л), 4JB1 (2,8 л), 4JB1-T (2,8 л, Turbo), 4BC2 (3,3 л), 4BE1 / 4BE2 (3,6 л), 4BD1 (3,9 л), 4BD1-T (3,9 л, Turbo).

Книга: CHEVROLET S-10 /BLAZER GMC SONOMA OLDSMOBILE BRAVADA ISUZU HOMBRE бензин с 1994 г.в., ремонт, эксплуатация,
Руководство по ремонту и техническому обслуживанию автомобилей Chevrolet S-10 / Blazer, GMC Sonoma, Oldsmobile Bravada, Isuzu Hombre  1994-2001 гг. выпуска, с бензиновыми двигателями рабочим объемом 2,2, 4,3 л.



Isuzu Giga / Giga Max / Isuzu C-Series / Isuzu E-Series owner’s, operators, service and maintenance manuals, error codes list, DTC, spare parts manuals & catalogues, wiring diagrams, schematics free download PDF

See also:

Title File Size Download Links
ISUZU C- & E-series Owner’s Maintenance Manual rus [PDF] 6Mb Download
ISUZU C-series Truck Service Manual [PDF] 6Mb Download
ISUZU CYZ/EXR Service Manual [PDF] 7.8Mb Download
Isuzu GIGA Parts Catalog [PDF] 7.4Mb Download
ISUZU Giga Workshop Manual – General information [PDF] 5.6Mb Download
ISUZU Specifications [PDF] 161.9kb Download

The Japanese company Isuzu is the world’s largest manufacturer of trucks, buses, and SUVs. These Isuzu Giga / Giga Max / Isuzu C-Series / Isuzu E-Series trucks are rightfully considered one of the most reliable, comfortable, powerful, and ready to cope with any feasible task. However, any vehicle needs proper handling by the user and regular preventive inspections.

Isuzu Giga / Giga Max / Isuzu C/E manuals have been issued for everyone who is engaged in the maintenance of trucks or driving them, as well as car owners.

The manuals also contain maintenance information for these trucks manufactured between 1996 and 2022. Models on a diesel engine 6WF1-TC, 6WF1-TC, 6WG1-TC, 8TD1, 8PE1, and 10PE1 are considered.

The Isuzu Giga manuals contain the most necessary information for drivers and specialists, without orientation in which, it is impossible to successfully use vehicles and keep them running for as long as possible.

Due to the abundance of thoughtful drawings, the Isuzu Giga / Giga Max / Isuzu C / E manuals have become easier to learn and practice new skills in competent handling of the machine and maintenance procedures. In the presented manuals, the external and internal structure of the Isuzu Giga truck is fully considered, and all devices, assemblies, components, and systems of the machine are described – their location, purpose, operating functionality, technical characteristics, and control methods. Thus, even a novice user will not get confused about the design features of this high-tech vehicle.

In addition, this manual contains a complete, illustrated owner’s manual for Isuzu Giga / Giga Max / Isuzu C/E, with which the driver can quickly and comprehensively study the truck and learn new information for himself. For example, learn about the working potential of a truck or how to use a truck with minimal environmental impact.

To ensure that the truck does not let you down on the road and is always on the move, ready to help the driver in any business, regular maintenance of the Isuzu Giga / Giga Max / Isuzu C / E should not be overlooked. So, this manual describes the course of all the main regulated checks and their frequency, from annual inspections to the necessary preventive procedures before each trip.

Isuzu Giga /C-E-Series Service Manuals PDF

Isuzu Giga

The Isuzu C-Series / Isuzu E-Series manuals provide descriptions of various works and a list of the required tools and materials. The Isuzu Giga / C-Series / Isuzu E-Series repair manual, however, has a handy summary table describing the main problems that can happen along the way, their possible causes, and the best ways to eliminate these problems. This information will help the driver solve the problem as soon as possible. Thus, this manual will become a competent guide to the world of trucks and will provide the caring user with new theoretical knowledge and applied skills that will help him use the car for a long time, comfortably and without problems.

Полезный тюнинг от RollingTruck для грузовых автомобилей: фары, дефлекторы, грязеотсекатели, расширители арок и многое другое

Руководство по ремонту ISUZU GIGA ⇐ Giga (C/E-Series)

Модератор: RANGER

Аватара пользователя

Автор темы

Войтенко Александр

Новичок
Всего сообщений: 6
Зарегистрирован: 09.09.2013
Откуда: Россия, Красноярск
Возраст: 43

 

Руководство по ремонту ISUZU GIGA

У кого есть — поделитесь пожалуйста, уж больно редкий вид.
Если есть каталожные номера — пожалуйста тоже.

Аватара пользователя

Автор темы

Войтенко Александр

Новичок
Всего сообщений: 6
Зарегистрирован: 09.09.2013
Откуда: Россия, Красноярск
Возраст: 43

 

Re: Руководство по ремонту ISUZU GIGA

Сообщение

Войтенко Александр »

Он японец, у него в сртс указан № шасси: CXG50X3000040,
а в кабине указан VIN: CXG50X3000040

Руководство по ремонту ISUZU GIGA - 22092013034.jpg

А VIN везде требуется 17 знаков а у меня 13.
И кстати, поиском естественно пользовался. Пересмотрены все ссылки до 10 — 15 страниц по разным поисковым запросам.

Сам грузовик вот такой:

Руководство по ремонту ISUZU GIGA - 21092013032.jpg

Гость

 

Re: Руководство по ремонту ISUZU GIGA

Сообщение

Гость »

момент затяжки ДВС-10РЕ1

Гость

 

Re: Руководство по ремонту ISUZU GIGA

Сообщение

Гость »

Гость: момент затяжки ДВС-10РЕ1[/q

Гость: момент затяжки ДВС-10РЕ1

привет
нашел что нибудь по Исузу своему, у меня двигатель 12PD1, вообще по нему ничего найти не могу

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