2009 BodyBuilderGuide
2009 BodyBuilderGuide
2009 BodyBuilderGuide
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INTRODUCTION
This guide has been provided as an aid to final stage manufacturers in determining conformity to the applicable Emission Control and Federal Motor Vehicle
Safety Standards. Final stage manufacturers should maintain current knowledge of all Emission Regulations and Federal Motor Vehicle Safety Standards and be
aware of their specific responsibility in regards to each standard.
Any manufacturer making material alterations to this incomplete vehicle during the process of manufacturing the complete vehicle should be constantly alert to
all effects, direct or indirect, on other components, assemblies or systems caused by such alterations. No alterations should be made to the incomplete vehicle
that directly or indirectly results in any either component, assembly or system being in nonconformance with applicable Emission Regulations or Federal Motor
Vehicle Safety Standards.
Isuzu Commercial Trucks of America, Inc. (ICTA) will honor its warranty commitment (for the cab-chassis only), to the ultimate
consumer, provided: (1) the final stage manufacturer has not made any alterations or modifications which do not conform to any
applicable laws, regulations or standards, or adversely affect the operation of the cab-chassis; and (2) the final stage manufacturer complied with the instructions
contained in this guide with respect to the completion of the vehicle. Otherwise, the warranty becomes the responsibility of the final stage manufacturer.
The final stage manufacturer is solely responsible for the final certification of the vehicle and for compliance with Emission Control and Federal Motor Vehicle
Safety Standards. The information contained in this guide has been provided for the final stage manufacturer’s information and guidance.
This guide contains information pertaining to the: NPR/W3500; NPR-HD/W4500 Gas, NPR/W3500; NPR-HD/W4500 Gas Crew Cab; NPR/W3500; NPR-HD/
W4500 Diesel; NQR/W5500, NPR-HD/W4500; NQR/W5500 Diesel Crew Cab; and NRR/W5500-HD Series Chassis Cab.
Following is a list of Federal Motor Vehicle Safety Standards applicable to those vehicles with a GVWR greater than 10,000 lbs. Please refer to the chart on the
next page.
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FMVSS Chart
List of Federal or Canadian Motor Vehicle Safety Standards applicable to Isuzu/GMC Truck product lines. Gasoline or diesel fueled vehicles with GVWR greater
than 10,000 lbs. (4536 Kg)
1106 N/A
Exterior Noise 1 1
102 Transmission shift lever sequence, starter interlock and transmission braking effect
Transmission control functions 1 1
115 N/A
Vehicle identification system 1 1
120 Tire selection and rims for vehicles other than passenger cars
Tire selection and rims for vehicles other than passenger cars 2 2
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FMVSS Chart (continued)
List of Federal or Canadian Motor Vehicle Safety Standards applicable to Isuzu/GMC Truck product lines. Gasoline or diesel fueled vehicles with GVWR greater
than 10,000 lbs. (4536 Kg)
N/A 1, 3 1
On road vehicle and engine emission regulations
N/A
ICES-002 Canadian Interference causing equipment standard 1 1
Type 1, 2 or 3 numbers to the right hand side of the table designate the appropriate paragraph in the Canadian Motor Vehicle Safety Standards (CMVSS), and Federal Motor Vehicle Safety Standards (FMVSS).
Please see IVD (incomplete vehicle document) for full statements.
Type 1 A statement that the vehicle when completed will conform to the standard if no alterations are made in identified components of the incomplete vehicle.
Type 2 A statement of specific conditions of final manufacture under which the manufacturer specifies that the completed vehicle will conform to the standard.
Type 3 A statement that conformity with the standard cannot be determined based upon the components supplied on the incomplete vehicle, and that the incomplete vehicle manufacturer makes no representation to conformity
with the standard.
NOTE: This chart is only a guide. For complete information, please refer to “Document for Incomplete Vehicle” provided with each chassis.
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EPA Requirements
NPR/W3500 Gas, NPR/W3500 Gas Crew Cab, NPR/W3500 Diesel, NQR/W5500 Diesel, NPR HD, NQR/W4500, W5500 Diesel Crew
Cab and NRR/W5500-HD Series Chassis Cab
The following statement is applicable to all models of incomplete vehicles equipped with diesel engines. (Type 1)
This incomplete vehicle, when completed, will conform to the above standard providing no alterations are made which affect the function, physical, chemical, or mechanical properties, environment,
location or vital spatial clearances of the components, assemblies or systems including but not limited to those listed below:
-Injection Pump -Engine Coolant Temperature Sensor
-Injector and High Pressure Lines -Intake Manifold
-Turbocharger -Catalytic converter and its location
-Charger Air Cooler and Charge Air Cooler Hoses -Exhaust Gas Recirculation System
-Engine Control Module (ECM) -MAF Sensor
-Engine Speed Sensor -DPD (Diesel Particulate Defuser) and its location
The following statement is applicable to all models of incomplete vehicles equipped with diesel engines. (Type 2)
This incomplete vehicle, when completed with the vertical exhaust system, will conform to the above standard providing it is completed by the final stage manufacturer
in accordance with the following specific conditions:
a. the incomplete vehicle manufacturer‘s vertical exhaust system kit is used, and
b. the vertical exhaust system kit is installed to the vehicle in accordance with the incomplete vehicle manufacturer‘s instructions
For more information on the kit and instructions, please call 678-240-9818 or 562-229-5374
The following statement is applicable to all models of incomplete vehicles equipped with gasoline engines . (Type 3)
Conformity with On-Road Vehicle and Engine Emission Regulations cannot be determined based upon the components supplied on the incomplete vehicle, and ISUZU Motors makes no representation
to conformity with the standard.
Applies to all models of incomplete vehicles except vehicles equipped with diesel engines contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles except vehicles equipped with diesel engines (unless otherwise noted on the cover of this document)
This incomplete vehicle, when completed, will conform to the above regulations providing no alterations are made which affect the function, physical, chemical, or
mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but not limited to those listed below:
-Ignition Wires & plugs -Ignition coil(s) -Spark plug wires
U.S. ENVIRONMENTAL PROTECTION AGENCY AND STATE OF CALIFORNIA EMISSION EQUIREMENTS AND ON-BOARD DIAGNOSTIC SYSTEM (OBDII) REQUIREMENTS
To assure that EPA and California emission certificate requirements and OBDII requirements are met, this incomplete vehicle (except where noted) must be completed
in strict accordance with all instructions contained in this document, especially the following instructions which relate to:
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(A) EXHAUST EMISSION RELATED COMPONENTS
1. Compliance of this vehicle with EPA/California emission certification requirements and OBDII requirements will be maintained providing no alterations (except where noted) are made to the
components identified below:
* All Federal/California gasoline powered heavy duty vehicles will have an evaporative emission control system that is certified for a fuel tank capacity not to exceed
the amount shown on Vehicle Evaporative Emission Control Information Label. Persons wishing to add fuel tank capacity above the amount shown must contact
California Air Resources Board and/or submit a written statement to the EPA Administrator that the Hydrocarbon Storage System has been upgraded according to
the requirements of 40 CFR 86-095-35 (g) (2).
2. Compliance with applicable fuel evaporative emission regulations will be maintained if no alterations are madeto the fuel filler neck(s).
Compliance with applicable fuel evaporative emission regulations will be maintained if no alterations are made to change material or increase the size or length of the following nonmetallic fuel and
evaporative emission hoses.
-Fuel feed hoses front and rear -Fuel vapor lines at canister
-Fuel return hoses front and rear -Fuel vapor lines from engine to chassis pipes
-Fuel tank filler hoses to filler neck -Fuel vapor lines from fuel tank sender to chassis pipes
-Fuel tank vent hoses to filler neck
(B) SPECIFICATION FOR FILL PIPES AND OPENINGS OF MOTOR VEHICLE FUEL TANKS (APPLICABLE ONLY TO CALIFORNIA GASOLINE POWERED VEHICLES)
This incomplete vehicle, when completed, will conform to Title 13, California Administrative Code Chapter 3 Air Resources Board Subchapter 7, “Specifications for
Fill Pipes and Openings of Motor Vehicle Fuel Tanks”, if no alterations are made to the fuel filler neck(s).
(C) LABELS
The emission control related information labels and ultra low sulfur diesel fuel label that are permanently affixed are required by government regulation and must not
be obstructed from view or defaced so as to impair its visibility or legibility.
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INSTALLATION OF BODY AND SPECIAL EQUIPMENT
Clearances
Engine
At least 1.6 inches of clearance should be maintained around the engine. No obstacles should be added in front of the radiator or intercooler.
Transmission
The transmission is removed from the rear. Enough clearance must be provided to allow rearward movement of the transmission assembly. Clearance should
be sufficient to allow 5 to 6 inches of unrestricted movement of the transmission assembly. In addition, provide at least 2 inches of clearance around the control
lever on the side of the transmission to allow free movement without any binding.
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At least 6 inches of clearance should be maintained above the transmission to allow easy removal of the upper cover for manual transmissions.
At least 2 inches of clearance should be maintained above the automatic transmission to allow for transmission removal.
At least 1.25 inches of clearance should be maintained around front and center propeller shafts.
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With the rear springs at maximum deflection, at least 1.25 inches of clearance should be provided over the rear propeller shaft.
Exhaust System
The exhaust system has a crucial role in meetig 07EPA regulations. In order to maintain compliance withthe 07EPA emissions levels the Diesel Particulate Filter
(DPF) must not be moved. The distance between the engine exhaust manifold down pipe and DPF must be maintained and the pressure in the system must be
sustained at a constant level. Due to increased temperatures in the exhaust
system during the regeneration cycle and the heat stress caused by these temperatures, body builders should closely evaluate the
placement of equipment and provide protection to these added components as needed.
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Diesel Particulate Filter (DPF) Restrictions
The front section before the DPF unit cannot be modified/relocated. The silencer and exhaust cooler can not be modified or removed.
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EXHAUST CLEARANCES
If flammable materials such as wood are ised in the body, provide at least 3.9 inches of clearance between the body and any parts of the exhaust pipe, muffler
and Diesel Particulate Filter. If it is impossible to maintain the minimum clearance, use a heat shield. Also use a heat shield if an oil pump or line is located above
the exhaust pipe, muffler or catalytic converter.
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The design and installation of the body should allow sufficient clearance for full vertical movement of the rear wheels and axle when the vehicle travels over rough
or unlevel surfaces.
Note: For recommended clearances, please refer to the Rear Axle Chart in each model’s respective section.
Other Clearances
The transmission control cable may be broken if it is bent by or interferes with the body and its fixtures. To prevent this, 1 inch of minimum clearance should be
provided. When cable is detached from body mounting, be sure not to bend the cable.
Accessibility to the grease nipple on the rear spring bracket/shackle should be provided so that serviceability with a grease gun is not hampered.
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Body Installation
Chassis
To maintain the performance of the truck chassis, either a side member or subframe should always be used for body mounting. Body mounting with low rigidity
will often adversely affect riding comfort.
Mirrors
The Isuzu N/W series chasis will accomodate up to 96 inch wide bodies without modification to the mirror brackets. Bodies from 97 to 102 inches wide will
require that the mirror brackets be modified. This Modification can be made at the port and the vehicle order/label will indicate a Regular Product Option of IU3
indicating “Mirror Bracket for 102 wide body”. The brackets can also be modified by the N/W Dealer or the Body Company by installing mirror brackets ordered
from Isuzu Parts.
When installing special equipment on the chassis, extra consideration must be given to the weight and construction of the equipment to assure proper
distribution of the load. Localization of the load should be prevented. All special equipment should be properly secured into position. We recommend the use of
subframe members when installing special equipment.
The subframe assembly should be mounted as close to the cab as possible. It should be contoured to match the shape and dimensions of the chassis frame as
closely as possible.
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Subframe Contour
Contouring of the front end of the subframe members as shown in the three illustrations below will prevent stresses from being concentrated on certain areas of
the chassis frame.
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When using a steel subframe, do not close the end of the subframe.
1. At the front end of the subframe. The attaching bolt or bracket must be at least 2 inches behind the kick up point of the subframe.
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2. Within 8 inches of bends in the chassis frame or the attachment points of any crossmembers.
Subframe Mounting
Bracket Installation
Mounting brackets should be clamped to the chassis frame using bolts. For proper positions in which to install the bolts, refer to the
preceding section and the section “Modifications to the Chassis Frame.” In addition to the illustrated bracket and U -bolts a shear plate
may be required for adequatley body mounting. The body company will be responsible for engineering their own mounting system.
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The fame material is a heat treated carbon manganese, and low alloy steel with good welding characteristics. The frame has an
80/40mm modular hole spacing standard. This standard pattern will assist with body mounting.
Depending on model, wheelbase and Note: Retighten all attaching parts that are
chassis specification some holes are in use loosened during body installation.
and some holes are intentionally missing.
(Subject to change without notice).
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U-bolt Installation
When U-bolts are used to retain the subframe, reinforcement blocks must be installed in the frame members. This will prevent distortion of
the frame flange as they are tightened. The drawing indicates the correct placement of reinforcement blocks. If you use wood blocks, be sure
that there is sufficient clearance between them and any parts of the exhaust system. The use of J-bolts to retain the subframe is strictly
prohibited.
If any fluid lines or electric cables are located near the reinforcement blocks, you must provide at least 0.4 inches of clearance between rigid
or stationary portions, and at least 1.6 inches between moveable or flexible portions of the lines.
CAUTION:
U-Bolt placement is critical with new emission systems
and controls. Extra care must be taken when
placing bodies on chassis so as not to damage these
components.
For the installation positions of the U-bolts, refer to “Prohibited Attachment Areas.”
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When modification is complete, chassis frame members should be carefully inspected to eliminate the possibility of any safety-related defects.
NOTE: PLEASE REFER TO NOTES ON CHASSIS FRAME MODIFICATION WITH ANTILOCK BRAKES.
The chassis frame is designed and built with consideration for proper load distribution. Sufficient physical strength is provided when the load is evenly
distributed. Installation of special equipment on the chassis frame can cause variations in load distribution. If even distribution of load is not kept in mind when
the equipment is installed, localization of stresses on specific areas of the frame could cause cracking of the chassis frame members or other problems, even if
the total weight of the equipment is within the design limit.
The chassis frame is designed as an integral unit. Therefore, we do not recommend cutting the chassis frame under any circumstances.
IMPORTANT NOTE: For vehicles equipped with electronic engines and or electronic or hydra-matic transmissions, electric arc welding must be done
with the negative battery cable disconnected.
1. Do not drill or weld in the shaded portions of the chassis frame members. Do not weld within 0.8 inches from the edges of any existing holes.
2. Hold the length of any welding beads within 1.2-2.0 inches. Allow at least 1.6 inches between adjacent welding beads.
3. All holes must be drilled. Do not use a torch to make any holes.
4. All riveting must be done with cold rivets. Do not use hot rivets.
5. The flange of the chassis frame must not be cut under any circumstances.
6. The subframe must be attached to the chassis frame with bolts. Do not weld.
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Reinforcements must be installed to prevent the considerable variation in the section modulus. They must be welded so as to avoid localized stresses.
The frame of the N and W Series gas and diesel is made of SAPH440 mild steel.
The drawing on the following page illustrates correct and incorrect methods of frame reinforcement.
Welding
1. Keep reinforcement plates and chassis frame free from moisture and water.
3. Use a suitable means to protect pipes, wires, rubber parts, leaf springs, etc. against heat and effect of sputtering.
4. Remove fuel tank assembly when welding portions near the fuel tank.
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Fluid Lines
Do not disturb the layout of any brake lines or fuel lines unless absolutely necessary. When modification is needed, follow the instructions below carefully to
ensure safety. Brake fluid lines must not be cut and spliced under any circumstances. We do not recommend the cutting or splicing of any fuel lines, but if it is
absolutely necessary, be sure that the correct fitting and tools are used to form the joint, and then pressure test the joint. Steel lines are metric sizes.
1. Where possible, use only genuine GM/Isuzu lines as supplied by authorized GM/Isuzu dealers.
2. Use the correct metric flaring and bending tools to form the lines.
3. Avoid repeated bending. Do not use heat for flaring and bending the lines. Before and after forming the new lines, examine them carefully for scratches,
distortion, dents and the presence of any foreign matter.
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Installation of Additional Lines
Install new lines away from adjacent parts and away from any sources of heat.
1. A minimum clearance of 0.4 inches must be maintained between lines. Where necessary, clip the lines into position in order to maintain this minimum
clearance.
2. Minimize any crossing between lines. If a crossing is unavoidable, use the following procedure:
a. At least 0.4 inches of clearance should be maintained between lines at the crossing point.
b. If the 0.4 inches of clearance cannot be maintained, or if the lines are subject to vibration, clip them securely.
3. Plan the bends and clipping points of the lines to minimize vibration and the resulting fatigue.
4. Use rust-proofed clips and apply vinyl coating to the portions of the lines to be clipped.
5. Install new lines in positions where they are protected against water, dirt, grit, sand, rocks and other foreign matter that can come from above or below, or
can be flung up by the wheels.
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Wiring
1. Most wiring connections on GM/Isuzu vehicles are made with terminals. We recommend the use of terminals when splicing cables and wires.
2. When splicing, use new wire of the same gauge, and do not make splices inside the corrugated tubing.
3. When making connections to the end of the harness, make sure the connections are electrically perfect. Use insulating tape as needed to prevent the
entry of water, which results in short circuits and/or corrosion.
4. When making new circuits, or modifying circuits already installed, make the cables only just taut enough to remove any slack. Use clips or grommets
where required to protect cables from heat or sharp edges. When cables must run near the exhaust system, see the instructions in the “Exhaust System”
section.
5. Always use rustproof clips, and apply vinyl coating to that portion of the clips in direct contact with the harnesses. No scotch clips or connectors.
6. To minimize the vibration of the harness, clipping points should be set up according to the table.
7. When changing the length of the battery cable, do not cut or splice the existing cable. Make up a new cable of the correct length and wire gauge for the
load and distance, without splices.
8. When using connectors, use a socket (female) connector on the electrical source side and a plug (male) connector on the electrical load side to lower the
possibility of a short circuit when disconnected.
9. When connecting cables to moving or vibrating parts such as the engine or transmission, be sure to maintain sufficient slack in the wiring to absorb the
vibration. Follow the example of existing cables connected by GM/Isuzu. Keep flexible cables clear of other parts.
10. Do not use vinyl tape in the engine compartment. The heat will tend to make it peel off. Use plated steel clips coated with rubber or vinyl.
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The electrical circuits of the N/W and W Series Chassis Cab are connected with low-voltage stranded wire for automotive applications. The color coding
standards are as follows for the N/W Series Chassis Cab:
(1) Black B Starter circuits and grounds (5) Yellow Y Instrument circuit
(2) White W Generator (alternator) circuit (6) Brown Br Accessory circuit
(3) Red R Lighting circuit (7) Light Green Lg Other circuit
(4) Green G Signal circuit (8) Blue L Windshield wiper motor circuit
Reference: The values given in the “maximum allowable current” column are based on the ambient temperature condition of 104oF with temperature increase
of 1040F.
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Modifications/add-on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by reviewing system schematics, wire routing paths,
harness connections, etc. Due to the wide range of modifications that may be required for vocational needs, it is not feasible for the O.E.M. to take into account
all potential revisions. For this reason, any person modifying existing vehicle wiring must assume responsibility that the revisions have not degraded the electrical
system performance. Any add-on wiring needs to be properly fused and routed to prevent cut, pinch, and chafe problems, as well as avoid exposure to
excessive heat. Care must be exercised that existing vehicle interfaces do not have their current load capabilities exceeded, and that the respective control
devices are not overloaded. Added wire size should be at least as large as the wire to which it is attaching in order for fuse protection to be maintained
A Packard electric wiring repair kit is available through Kent-Moore (P/N J38125-B) (Phone # 1-800-345-2233). This kit contains instructions, tools and
components for making repairs to wiring harness components. This kit would also greatly assist in accomplishing necessary add-on wiring such as body marker
lamps, so that system reliability/durability is maintained.
Electrical wiring components can be obtained through your authorized GM/Isuzu dealers. Packard Electric components are also available through Power and
Signal (www.powerandsignal.com). Power and Signal may also be able to assist in making necessary wiring additions by providing custom wiring stubs or
jumpers to your specifications.
Exhaust System
Modification of the exhaust system should be avoided. If modifications are absolutely necessary, the following points should be maintained.
1. Maintain the clearance specified in the “Exhaust System” table between all parts of the exhaust system and any fuel lines, brake
lines, brake hoses, electrical cables, etc. The exhaust outlet should not point toward any of these parts.
Clearance
Brake lines 2.4 in. or more. (If the combined section of a group of parallel brake lines is more than 7.8 in., a clearance of 7 in. or more
should be provided.)
Flexible brake hoses 3.9 in. or more. (The temperature of flexible brake hoses should not exceed 158oF. If the highest temperature is not measur
able, a clearance of more than 15.7 in. should be maintained between the hoses and the exhaust system.)
Wiring harnesses and cables 3.9 in. or more.
Steel fuel lines 3.1 in. or more.
Rubber or vinyl fuel hoses 5.9 in. or more.
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2. If a tool box is installed, it should preferably be made from steel. If a wooden tool box is installed, at least 7.8 inches of clearance should be maintained
between the tool box and any parts of the exhaust system.
3. If the exhaust system is modified, it is the responsibility of those making the modification to ensure that the noise level meets appropriate standards.
4. If the exhaust system is modified it is the responsibility of those making the modification to ensure that the emission levels meet appropriate standards.
Fuel System
Relocation of the fuel tank, or installation of additional fuel tanks, is not recommended. If modifications to the fuel system are unavoidable, follow these
recommendations:
1. Maintain adequate clearance between the fuel tank and any other device or structure.
Rear Lighting
Brackets installed are temporary. Please do not use these brackets for body installation.
Serviceability
No matter what other modifications or changes are made, access to components requiring daily preventive maintenance or other routine service must not be
obstructed. This includes:
8. Operation of the spare tire carrier, including mounting and dismounting of the spare tire.
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Wheelbase Alteration
With certain applications, it may become necessary to alter the wheelbase of the chassis. The next two sections provide the suggested
guidelines for accomplishing either shortening or lengthening of the wheelbase.
Since the frame is an integral part of the chassis, it is recommended that the frame not be cut if it is possible to avoid it. When shortening/lengthening the
wheelbase on some models, it is possible to do so without cutting the frame. This is possible on models which have a straight frame rail. If the chassis does not
have a straight frame rail, it may still be necessary to cut the frame. For instructions on shortening/lengthening these chassis, refer to the “Altering the Wheelbase
by Altering the Frame” section of this book. Otherwise, the wheelbase may be shortened/lengthened by removing the rear suspension, drilling new suspension
mounting holes at the appropriate spot in the frame, and sliding the rear suspension, suspension liner, and suspension crossmembers forward or aft.
The suspension and suspension crossmembers’ rivet holes left in the frame rail flange must be filled with GRADE 8 bolts and hardened steel washers at both the
bolt head and nut, HUC bolts or GRADE 8 flanged bolts and hardened steel washers at the nut. When shortening/lengthening the wheelbase in this manner, the
following guidelines must be adhered to:
1. All frame drilling must comply with the DRILLING AND WELDING section of this book.
2. All rivet holes left in the frame rail flange from the suspension and suspension crossmembers must be either filled with GRADE 8 bolts and hardened
steel washers at both the bolt head and nut, HUC bolts or GRADE 8 flanged bolts and hardened steel washers at the nut.
3. The components required to be slid forward or aft are the suspension and suspension hangers, suspension crossmembers and suspension frame liner.
Even on a straight frame rail, it may be desirable to cut the frame and lengthen or shorten the wheelbase rather than simply sliding the rear
suspension back or forward. The following section offers some guidelines and suggestions for cutting and lengthening or shortening the frame.
AL – Added length (in case of a lengthened wheelbase). Difference between WB (new) and WB (old).
SL – Shortened length (in case of shortened wheelbase). Difference between WB (old) and WB (new).
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1. Determine the added length (AL) or shortened length (SL) required to lengthen or shorten chassis. (For added wheelbase: New CA = CA + AL; For shortened
wheelbase: New CA = CA – SL.)
2. Obtain the material to be used as the insert for the lengthened wheelbase in the correct length (AL). The insert must have the same cross sectional
dimensions and yield strength as the original frame rail.
3. Divide the new CA by two (2). Measure (new CA)/2 from the center of the rear axle forward and mark this point on the chassis frame (see figure below).
4. Cut the chassis frame at this point. If the wheelbase is to be lengthened, addition of the previously obtained insert (of length AL determined in step 1) will be
made at this time. If the wheelbase is to be shortened, measure the distance (SL) forward of this cut and remove a length (SL) section from the chassis frame
(see figure below). Insure that an adequate area on the frame remains for the required addition of the necessary reinforcements. These are the only suggested
places for cutting the frame and reinforcements but may be changed upon the advice of Isuzu Commercial Trucks of America, Inc. Application Engineering.
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5. When welding the insert (length AL for wheelbase lengthening) to the original frame rail, a continuous butt weld must be used at the splices. When
shortening the wheelbase, weld the ends of the chassis frame together with a continuous butt weld over the junction of the frame ends. Weld both the inside
and outside of the frame rails using welding techniques prescribed by established welding standards (ref. SAE J1147) and in accordance with this guide. An
example of this weld is shown below.
6. Determine the appropriate additional internal reinforcements which are required using this equation:
The figure below shows how this reinforcement is to be placed over the extended or shortened section of the frame rail.
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7. The reinforcements must be fastened securely to only the web of the original chassis frame rail. The reinforcement must be held rigidly in place using either
HUC bolts, GRADE 8 bolts and hardened steel washers at both the bolt head and nut, or GRADE 8 flanged bolts and hardened steel washers at the nut.
Below are some suggested bolt patterns. It should be noted that these bolt patterns must not align the bolts vertically, i.e.: the bolt pattern must be
staggered.
8. Lengthening the frame will also require extending the brake lines, basic chassis electrical harness. It is recommended that the original brake lines be removed
and replaced with brake lines of the same diameter as the original lines and of the appropriate length. The extended ABS brake lines must be supported
back to the frame to prevent vibration. The electrical harness must be extended in accordance with the ELECTRICAL WIRING AND HARNESSING section of
this book. ICTA offers an electrical extension harnesses for the N and W series chassis when a wheelbase is lengthened. One wheelbase longer is the
recommended maximum wheelbase extension (please refer to the drive line section and particular models for number of drivelines and their maximum
lengths). The extension of a wheelbase will require an extension harnesses (pn 8980626380)and 12 clips (5097003230).
9. The propeller shafts’ overall length will also need to be lengthened or shortened. If the extension is within the limits of the optional wheelbases of the
respective model, the exact propeller shaft lengths and angles are given on or about Page 12 of the respective sections of this book. If the modified
wheelbase exceeds the optional wheelbases of the respective model, the following guidelines must be adhered to:
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The maximum propeller shaft lengths (pin to pin) for the respective models are shown in the table below.
The maximum propeller shaft angles, with respect to the previous shaft, are shown in the table below.
c. The propeller shaft angles must be designed such that the angles will cancel to avoid propeller shaft whip.
d. The propeller shaft yokes must be assembled such that the propeller shaft yokes are “in phase.” “In phase” means that the yokes at either end of a given
propeller shaft assembly are in the same plane.
10. Extending the frame will also require relocation and/or addition of crossmembers. If the extension is within the limits of the optional wheelbases of the
respective model, the exact crossmember locations and dimensions are given in the respective model sections of this book. If the modified wheelbase
exceeds the optional wheelbases of the respective model, the following guidelines must be adhered to:
a. The crossmember location will largely be determined by the propeller shaft lengths and where the center carrier bearing locations are for the propeller
shaft assembly.
b. A crossmember must be located at the front and rear spring hangers of the rear suspension (refer to the appropriate section of this book to see where
these suspension crossmembers are to be located).
c. The crossmember must be constructed such that it supports both the upper and lower flange on each frame rail (see drawing on next page).
A crossmember such as the one on the next page may be constructed, or GM/Isuzu crossmembers may be obtained from your GM/Isuzu parts dealer.
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d. The maximum distance between crossmembers for the respective models is given in the table below.
e. The drilling for any additional holes in the frame rails must comply with the DRILLING AND WELDING section of this book.
11. All other aspects of lengthening or shortening the wheelbase must comply with the applicable section of this Body Builder’s Guide. For special applications
and longer than recommended body lengths, ICTA Application Engineering must be consulted for approval. In the West Coast call 1-562-229-5314 and in the
East Coast call 1-770-740-1670 x262.
12. Please contact applications engineering for guidelines on N/W SERIES CHASSIS frame modifications when the vehicle is equipped with an Antilock Brake
System.
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BODY APPLICATION SUMMARY CHART
2009 Gas and 2009 Diesel Model Body Application Summary Chart
Model/GVWR WB BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft.
109 6.5 X X
NPR/W3500 Gas 132.5 6.5 X
12,000 lbs. 150 6.5 X X
176 6.5 X
109 6.5 X X
NPR HD/W4500 Gas 132.5 6.5 X
14,500 lbs. 150 6.5 X X
176 6.5 X
109 6.5 X X
NPR/W3500 Diesel 132.5 6.5 X
12,000 lbs. 150 6.5 X X
176 6.5 X
109 6.5 X X
NPR HD/W4500 Diesel 132.5 6.5 X
14,500 lbs. 150 6.5 X X
176 6.5 X
IMPORTANT: Body selection recommendations are based on water-level weight distribution and no accessories, liftgate or refrigeration units. This table is
intended for reference and does not preclude the necessity for an accurate weight distribution calculation.
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2009 Gas and 2009 Diesel Model Body Application Summary Chart (Chart continued from previous page)
Model/GVWR WB BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft.
109 6.5 X
NQR/W5500 Gas 132.5 6.5 X X
17,500 lbs. 150 6.5 X X
176 6.5 X
200 6.5 X
NQR/W5500 Crew Cab Diesel 150 5.0 X1
17,950 lbs. 176 5.0 X2
109 6.5 X
NRR/W5500-HD Diesel 132.5 6.5 X X
19,500 lbs. 150 6.5 X
176 6.5 X X
200 6.5 X
212 6.5 X
IMPORTANT: Body selection recommendations are based on water-level weight distribution and no accessories, liftgate or refrigeration units. This table is
intended for reference and does not preclude the necessity for an accurate weight distribution calculation.
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2009 Model Year - Body & Payload Weight Distribution (% Front/% Rear)
Model GVWR WB CA CE OAL BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft.
AUTOMATIC TRANSMISSION
NPR/W3500 Gas 12,000 109 86.5 129.6 200.5 6.5 18/82 7/93
NPR HD/W4500 Gas 14,500 109 86.5 129.6 200.5 6.5 18/82 7/93
NPR/W3500 Gas 12,000 132.5 110 153.1 224 6.5 14/86
NPR HD/W4500 Gas 14,500 132.5 110 153.1 224 6.5 14/86
NPR/W3500 Gas 12,000 150 127.5 170.6 241.5 6.5 16/84 8/92
NPR HD/W4500 Gas 14,500 150 127.5 170.6 241.5 6.5 16/84 8/92
NPR/W3500 Gas 12,000 176 153.5 196.6 267.5 6.5 15/85
NPR HD/W4500 Gas 14,500 176 153.5 196.6 267.5 6.5 15/85
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2009 Model Year - Body & Payload Weight Distribution (% Front/% Rear)
Model GVWR WB CA CE OAL BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft.
AUTOMATIC TRANSMISSION & MANUAL TRANSMISSION
NPR/W3500 Diesel 12,000 109 86.5 129.6 200.5 6.50 18/82 7/93
NPR HD/W4500 Diesel 14,500 109 86.5 129.6 200.5 6.50 18/82 7/93
NPR/W3500 Diesel 12,000 132.5 110 153.1 224 6.50 15/85
NPR HD/W4500 Diesel 14,500 132.5 110 153.1 224 6.50 15/85
NPR/W3500 Diesel 12,000 150 127.5 170.6 241.5 6.50 17/83 9/91
NPR HD/W4500 Diesel 14,500 150 127.5 170.6 241.5 6.50 17/83 9/91
NPR/W3500 Diesel 12,000 176 153.5 196.6 267.5 6.50 15/85
NPR HD/W4500 Diesel 14,500 176 153.5 196.6 267.5 6.50 15/85
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NQR/W5500 Diesel
2009 Model Year - Body & Payload Weight Distribution (% Front/% Rear)
Model GVWR WB CA CE OAL BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft.
AUTOMATIC TRANSMISSION & MANUAL TRANSMISSION
NQR/W5500 Diesel 17,950 109 86.5 129.6 200.5 6.5 18/82 7.93
NQR/W5500 Diesel 17,950 132.5 110 153.1 224 6.5 15/85
NQR/W5500 Diesel 17,950 150 127.5 170.6 241.5 6.5 17/83 9/91
NQR/W5500 Diesel 17,950 176 153.5 196.6 267.5 6.5 15/85
NQR/W5500 Diesel 17,950 200 177.5 220.6 291.5 6.5 19/81
IMPORTANT: Weight distribution percentages listed do not include added accessories, liftgate or refrigeration units. Percentages based on water-level
distribution of body and payload weight which is determined by subtracting chassis wet weight (including 200 lb. driver) from GVWR.
These tables are intended for reference and do not preclude the necessity for an accurate weight distribution calculation.
NRR/W5500 HD Diesel
2009 Model Year - Body & Payload Weight Distribution (% Front/% Rear)
Model GVWR WB CA CE OAL BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft.
AUTOMATIC TRANSMISSION & MANUAL TRANSMISSION
NRR/W5500-HD Diesel 19,500 109 86.5 129.6 200.5 6.5 18/82 7.93
NRR/W5500-HD Diesel 19,500 132.5 110 153.1 224 6.5 15/85
NRR/W5500-HD Diesel 19,500 150 127.5 170.6 241.5 6.5 17/83 9/91
NRR/W5500-HD Diesel 19,500 176 153.5 196.6 267.5 6.5 15/85
NRR/W5500-HD Diesel 19,500 200 177.5 200.6 291.5 6.5 19/81
NRR/W5500-HD Diesel 19,500 212 189.5 232.6 303.5 6.5 18/82
IMPORTANT: Weight distribution percentages listed do not include added accessories, liftgate or refrigeration units. Percentages based on water-level
distribution of body and payload weight which is determined by subtracting chassis wet weight (including 200 lb. driver) from GVWR.
These tables are intended for reference and do not preclude the necessity for an accurate weight distribution calculation.
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NPR/W3500, NPR-HD/W4500 Gas Crew Cab & NPR-HD/W4500, NQR/W5500 Diesel Crew Cab
2009 Model Year - Gas and Diesel Crew Cab Body & Payload Weight Distribution (% Front/% Rear)
IMPORTANT: Weight distribution percentages listed do not include added accessories, liftgate or refrigeration units. Percentages based on water-level
distribution of body and payload weight which is determined by subtracting chassis wet weight (including 200 lb. driver and a crew of 6 @ 200 lbs.
each) from GVWR. These tables are intended for reference and do not preclude the necessity for an accurate weight distribution calculation.
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MECHANICAL AND CAB SPECIFICATIONS
Engine Horsepower and Torque Chart
The following table presents Net versus Gross Horsepower and Torque ratings for Isuzu/W-Series Truck Product Engines:
Engine Model Application Net Hp1 Net Torque1 Gross Hp1 Gross Torque1
hp/rpm lbs.-ft./rpm hp/rpm lbs.-ft./rpm
GMPT 6.0L-V8 NPR/W3500, NPR-HD/W4500 Gas N/A N/A 300/4400 360/4000
Isuzu 4HK1-TC Automatic Transmission NPR/W3500, NPR-HD/W4500, NQR/W5500, 193/2400 414/1850 205/2400 441/1850
NRR/W5500-HD Diesel
MANUAL TRANSMISSION
Isuzu 4HK1-TC NPR-HD/W4500, NQR/W5500, NRR/W5500-HD Diesel 169/2400 379/1850 175/2400 387/1850
NOTE: 1 Horsepower and Torque Ratings measured under SAE J1349 standards.
GVW/GCW Ratings
The following table presents GVW ratings and corresponding GCW ratings for each model truck:
Truck Model Transmission GVWR (lbs.) GCWR (lbs.)1 Truck Model Transmission GVWR (lbs.) GCWR (lbs.)1
NPR/W3500 Gas Automatic 12,000 18,000 NPR-HD/W4500 Diesel Manual 14,500 20,500
NPR-HD/W4500Gas Automatic 14,500 20,500
NPR/W3500 Diesel Automatic 12,000 18,000 NQR/W5500 Diesel Manual 17,950 23,950
NPR-HD/W4500 Diesel Automatic 14,500 20,500
NQR/W5500 Diesel Automatic 17,950 23,950 NRR/W5500-HD Diesel Manual 19,500 25,550
NRRW5500-HD Diesel Automatic 19,500 25,500
1
The NPR, NPR HD, NQR, NRR/W3500, W4500, W5500, W5500-HD are not approved for Hot Shot applications.
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To prepare a disabled vehicle for front end towing with front wheels raised off the ground, the following steps are necessary:
• Disconnect the diveshafts at the rear axle. Secure the driveshafts to the frame or crossmember.
• If there is damage or suspected damage to the rear axle, remove the axle shafts.
• Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects.
• Place 4” x 4” wood beam against the towing guide behind the bumper. (If no 4” x 4” is available, then remove the bumper.) Ensure the towing chains do not
contact the horns or the bumper.
Legend:
1. Bumper
2. Towing Chain
3. Towing Guide
4. Front Axle
5. Tow Hook
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After Towing
After towing the vehicle, block the rear wheels and install axle shafts or propeller shaft. Apply the parking brake before disconnecting from the towing vehicle.
Your vehicle may be towed on all wheels provided the steering is operable. Remember that power steering and brakes will not have power assist. There must be
a tow bar installed between the towing vehicle and the disabled vehicle.
To prepare a disabled vehicle for front end towing with all wheels on the ground, the following steps are necessary:
• Disconnect the propeller shafts at the rear axle. Secure the propeller shafts to the frame or crossmember.
• Provide wood blocking to prevent towing chains and bar from contacting 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 propeller shaft. Apply the parking brake before disconnecting from the towing vehicle.
Check and fill rear axle with oil if required.
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Legend:
1.Horns
2.Bumper
(removed for towing)
When towing a vehicle with rear wheels raised, secure the steering wheel to maintain straight-ahead position. Make certain that the front axle is not loaded above
the front axle Gross Axle Weight Rating (GAWR) as indicated on the vehicle’s VIN and Weight Rating plate.
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WEIGHT DISTRIBUTION CONCEPTS
Weight Restrictions
The Gross Vehicle Weight Rating (GVWR) and the Gross Axle Weight Rating (GAWR) of each Incomplete Vehicle are specified on the cover of its Incomplete
Vehicle Document in conformance to the requirements of Part 568.4 of the Federal Motor Vehicle Safety Regulations. The final stage manufacturer is responsible
under Part 567.5 to place the GVWR and the GAWR of each axle on the Final Vehicle Certification Label. The regulation states that the appropriate rating “shall
not be less than the sum of the unloaded vehicle weight, rated cargo load, and 150 pounds times the vehicle’s designated seating capacity.”
Unloaded vehicle weight means the weight of a vehicle with maximum capacity of all fluids necessary for operation of the vehicle, but without cargo or
occupants.
During completion of this vehicle, GVWR and GAWR may be affected in various ways, including but not limited to the following:
1. The installation of a body or equipment that exceeds the rated capacities of this Incomplete Vehicle.
2. The addition of designated seating positions which exceeds the rated capacities of this Incomplete Vehicle.
3. Alterations or substitution of any components such as axles, springs, tires, wheels, frame, steering and brake systems that may affect the rated capacities of
this Incomplete Vehicle.
Use the following chart to assure compliance with the regulations. Chassis curb weight and GVW rating is located on Page 2 in each vehicle section. Always
verify the results by weighing the completed vehicle on a certified scale.
PLUS weight of added body components, accessories or other permanently attached components. +
(Body, liftgate, reefer, etc.)
PLUS total weight of passengers, air conditioning and all load or cargo. +
(Driver, passengers, accessories and load)
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NOTE: Although the Front Gross Axle Weight Rating (FGAWR) plus the Rear Gross Axle Weight Rating (RGAWR) may exceed the Gross Vehicle Weight Rating
(GVWR), the total GVW may not exceed the respective maximum GVWR.
The variation in the GAWRs allow the second stage manufacturer some flexibility in the design of the weight distribution of the attached unit.
Tire Inflation
Tire inflation must be compatible with GAWR and GVWR as specified on the cover of the Incomplete Vehicle Document for each vehicle.
Center of Gravity
The design of the truck body should be such that the center of gravity of the added load does not exceed the guidelines as listed in each Vehicle Section. If the
body is mounted in such a way that the center of gravity height exceeds the maximum height of the center of gravity designated for each model, the directional
stability at braking and roll stability at cornering will be adversely affected. A vertical and/or horizontal center of gravity calculation must be performed if a
question in stability arises to ensure the designed maximum height of the center of gravity is not violated.
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Weight Distribution
A truck as a commercial vehicle has but one purpose. That purpose is to haul some commodity from one place to another. A short distance or a long distance,
the weight to be hauled, more than any other factor, determines the size of the truck. A small weight requires only a small truck; a large weight requires a large
truck. A simple principle, but it can easily be misapplied. In any case, selecting the right size truck for the load to be hauled will ensure that the job will be done
and that it will be able to be done with some degree of reliability and within the legal limitations of total gross weight and axle gross weights.
Not only must a truck be selected that will handle the total load, but the weight must also be properly distributed between the axles. This is of extreme
importance from both a functional and economic aspect. If a truck consistently hauls less than its capacity, the owner is not realizing full return on his investment
and his operating costs will be higher than they should be. If the truck is improperly loaded or overloaded, profits will be reduced due to increased maintenance
costs and potential fines resulting from overloading beyond legal limitations. Careful consideration must be given to distribution of the load weight in order to
determine how much of the total, including chassis, cab, body and payload, will be carried on the front axle and how much will be carried on the rear axle, on the
trailer axles and the total. Moving a load a few inches forward or backward on the chassis can mean the difference between acceptable weight distribution for
the truck or an application that will not do the job satisfactorily.
Every truck has a specific capacity and should be loaded so that the load distribution is kept within Gross Axle Weight Ratings (GAWR) and the truck’s Gross
Vehicle Weight Rating (GVWR) or Gross Combination Weight Rating (GCWR) for a tractor/trailer and the weight laws and regulations under which the truck will
operate. Improper weight distribution will cause problems in many areas:
a. When the weight on a tire exceeds its rating capacity, accelerated wear will result and could result in tire failure.
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a. If the center of the payload is directly over or slightly behind the rear axle, the lack of sufficient weight on the front axle will create a bobbing effect, very
rough ride, and erratic steering. This condition will be magnified when the truck is going uphill.
4. Hard steering
a. When loads beyond the capacity of the front axle are imposed upon it, the steering mechanism is also overloaded and hard steering will result.
a. Poor traction on the steering axle effects the safety of the driver and equipment, particularly on wet, icy and slippery surfaces. Experience indicates that
approximately 30% of the total weight at the ground on a truck or tractor should be on the front axle with a low cab forward vehicle.
b. When a truck is overloaded, a dangerous situation may exist because minimum speeds cannot always be maintained, directional control may not be
precise and insufficient braking capacity can cause longer than normal braking distances.
a. Improper weight distribution and overloading cause excessive wear and premature failure of parts. Additional stresses imposed on the frame by the
misapplication of wheelbases may be instrumental in causing the frame to crack or break.
a. When there is the possibility that axle loads will exceed existing weight laws and regulations, careful weight distribution is necessary to provide a correct
balance between front and rear axle loads and total load within legal limitations.
In this way, maximum payloads may be carried without exceeding legal limits. If the body is too long for a wheelbase, the center of the body and payload is
placed directly over the rear axle. This places all the payload on the rear axles, resulting in overloading the rear tires, rear axle springs and wheel bearings and
potentially exceeding the rear axle legal weight limit. The front axle is then carrying no part of the payload and is easily lifted off the ground when going over
rough terrain, creating a very rough ride and temporary loss of steering control. If the body is too short for the wheelbase used, frame stress may be increased
and may result in excessive loads on the front axle. Excessive front axle loads increase wear on the kingpins and bushings, wheel bearings and steering gear.
Excessive front axle loads also overstress the front axle, springs, tires and wheels. All of these contribute directly to higher maintenance costs and hard steering,
both of which are undesirable.
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Weight distribution analysis involves the application of basic mathematical principles to determine the proper positioning of the payload and body weight in
relation to the wheelbase of the truck chassis.
It is much less expensive to work all of this out on paper, make mistakes on paper and correct them there than to set up the truck incorrectly and either have it
fail to do the job or, much worse, fail completely.
It is important to become familiar with the dimensions of the truck, as these will be needed to perform the necessary calculations.
Glossary of Dimensions
BBC – Bumper to back of cab CG – Center of gravity of body and payload from axle
BA – Bumper to axle WB – Wheelbase
CA – Cab to axle OAL – Overall length
AB – Axle to back of cab AF – Axle to end of frame
BOC – Back of cab clearance FH – Frame height
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Basic Formulas
(a) W x D = Wf x WB (c) WB = (A + B + C + D) = (F + D)
or
(b) W x F = Wr x WB (d) W = Wf x Wr
1. Wf = WxD 5. Wr = WxF
WB WB
2. D = Wf x WB 6. F = Wr x WB
W W
3. WB = WxD 7. WB = WxF
Wf Wr
4. W = Wf x WB 8. W = Wr x WB
D F
1. Weight transferred to front axle = (Total weight) x (Distance C.G. is ahead of the rear axle)
(Wheelbase)
2. Distance C.G. must be placed ahead of rear axle = (Weight transferred to the front axle) x (Wheelbase)
(Total weight)
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1. Weight transferred to rear axle = (Total weight) x (Distance C.G. is behind the front axle)
(Wheelbase)
2. Distance C.G. must be placed behind the front axle = (Weight transferred to the rear axle) x (Wheelbase)
(Total weight)
To find the value of “P”, the leverages must be equal for balance.
This same approach is used to determine axle loadings on a tractor or truck chassis. Assuming the rear axle serves as a pivot point, the front axle load can be
determined by applying the lever principle.
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Example: (4) A tractor has a wheelbase of 150 inches. If the kingpin load is 20,000 lbs. and the fifth wheel location is 15 inches, find the total weight on the front
and rear axles. The tare weight of the tractor is 7,000 lbs. on the front axle and 4,400 lbs. on the rear axle.
Therefore:
Total Front Axle Weight = 2,000 + 9,000 lbs. = 11,000 lbs.
Total Rear Axle Weight = 4,400 + 18,000 lbs. = 22,400 lbs.
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In calculating the weight distribution for a truck, the same lever principle is applied; however, there is one change in the initial consideration of the method of
loading the truck body. Instead of the trailer kingpin location ahead of the rear axle centerline, we must determine the position of the center of gravity of the pay-
load and body weight in relation to the rear axle centerline.
For our calculations, we assume that the payload is distributed in the truck body so that the load is supported evenly over the truck body floor (water-level
distribution). The weight of the body itself is also considered to be evenly distributed along the truck frame. In this manner, we can add the payload and body
weights together and calculate the distribution on the vehicle chassis as an evenly distributed load on the truck frame rails.
So that we can make the necessary calculation in a simple manner, the total body and payload weight is considered to act at the center of gravity which will be at
the center of the body length.
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If the truck tare weight without the body is 5,000 lbs. on the front axle and 2,400 lbs. on the rear axle, then
Total Front Axle Weight = 5,000 + 2,400 = 7,400 lbs. and
Total Rear Axle Weight = 2,400 + 12,600 = 15,000 lbs.
This same lever principle is applied in all calculations of weight distribution, whether we are dealing with concentrated loads as with a kingpin load acting on a
fifth wheel or if it be with an evenly distributed load as with a truck body. The same approach is made in calculating an evenly distributed load on a trailer.
In the case of a tractor/trailer or a tractor with a set of double or triple trailers, each unit is handled as a separated unit and then combined to determine the total.
This simple example illustrates how the principles are applied. Using the formulas, find the weight distributed to each axle.
A. Wf = W x D A. Total Weight –
WB
B. 300 x 24 B. 300 – 75
96
The body manufacturer can provide the body length and weight, or actual measurements of the body may be taken with a tape.
Generally, (D) is unknown. This you must find logically, or with a tape measure.
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Find (D) and then solve for Wf and Wr.
D = 60–3–48 = 9 in.
Wf = 205
Wr = 2,795
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Calculating tractor/trailer weight distribution can be thought of in the same terms as calculating full trucks.
The weight at the center of the body and the load when applied is the same as the single point load of the kingpin on the fifth wheel.
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Trailer Weight
In the following example, a 50,000-pound payload at water-level loading. Calculate the payload (PL) weight transfer to kingpin and the rear axle.
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Payload at Kingpin
PLkp = W x D
WB
OAL/2 – AF = D
45 feet/2 – 48 inches – 36 inches = 186 inches
PLrt = W – PLkp
Once the weight on the kingpin is determined, it can then be treated on the tractor the same as a weight on a straight truck.
Due to the variations in hauling and wheelbase requirements from one truck application to another, there is no one specific fifth wheel setting that will apply
in all cases.
A “rule of thumb” which has proven satisfactory in many cases sets the fifth wheel one inch ahead of the rear axle for every 10 inches of wheelbase. In the case
of tandem axles, the wheelbase is measured from the center line of the front axle to the midpoint between the tandem rear axles. The location of the fifth wheel
fixes the load distribution between the front and rear axles. Too far forward and the front axle is overloaded. If too far back, the front axle may be too lightly
loaded and cause an unsafe steering and braking control situation at the front axle.
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A tractor on a hill with the fifth wheel set at the axle center line or too close to it will result in an unsafe handling situation by transferring too much weight to the
rear axle and actually unloading the front axle.
Performance Calculations
The following calculations have been included to help you determine the performance characteristics required by your customers and to select the appropriate
model vehicle:
1. Speed Formula
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Definitions in formula:
RPM = 3,000
Rev/Mile = 674
Gear Ratio = .703 x 5.375
This formula can be used to determine horsepower required for a given grade and speed.
Definitions in formula:
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Example: NPR/W3500 11,050 GVWR automatic transmission with a van body.
12,000 x 1 x 55
HP Required for Grade = + 53.67
37,500 x 0.9
This formula is used to determine the horsepower required to overcome air resistance at a given speed.
Definitions in formula:
Frontal area is calculated by multiplying the height of the vehicle by the width of the vehicle and subtracting the open area under the vehicle from the total.
0.70 for most trucks, semitrailer combinations with tanks or van bodies
0.77 for double and triple trailers and flatbeds with loads
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Example: NPR/W3500 12,000 GVWR van body with 96” wide, 115” high (84” body height + 31” frame height).
FA = (96) x (115)
– 3.2
(12) x (12)
FA = 73.47 ft.2
Cd = 0.70
Speed = 55 mph
This formula can be used to derive the output at a given RPM and torque.
Definitions in formula:
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5. Gradeability Formula
This formula can be used to determine how large of a grade a vehicle can climb.
Definitions in formula:
1,200 = Constant
T = Maximum Torque of Engine
E = Engine Efficiency (0.9)
C = Driveline Efficiency (0.9)
R = Transmission Ration x Axle Ratio
RR = Rolling Resistance (see following chart)
GVWR = Gross Vehicle Weight Rating
r = Loaded radius of tire
T = 347 lbs.-ft.
E = 0.9
C = 0.9
R = .703 x 5.375 (in overdrive)
RR = 1.0
GVWR = 12,000
r = 14.1 in.
Gradeability = 5.53%
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6. Startability Formula
This formula is used to determine what type of a grade a vehicle can be started on.
1,200 = Constant
CET = Clutch Engagement Torque
E = 0.9
C = 0.9
R = Transmission x Axle Ratio
10% = Average break away resistance and static inertia constant
GVWR = Gross Vehicle Weight Rating
r = Loaded radius of tire
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Example: NPR/W3500 12,000 GVWR manual transmission.
Startability = 26.86%
These formulas are used to estimate the vertical center of gravity of a completed vehicle in order to determine whether maximum allowable limits have been
exceeded. This formula should be used when encountering high center of gravity loads.
7.1 Wv x (Vv) = Mv
7.2 Wb x (Vb) = Mb
7.3 Wp x (Vp) = Mp
7.4 We x (Ve) = Me
(Mv+ Mb+Mp+Me)
7.5 VCg =
(Wv + Wb + Wp + We)
Definitions in formula:
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Example: NPR/W3500 12,000 GVWR automatic transmission, 132” WB, 14’ body length, 84” high body, full payload of boxes stacked to a maximum height of
48” above the flooring.
(131,746+168,000+285,758)
VCg =
(5,291 + 2,100 + 4,609)
(528,504)
VCg = = 48.8 inches
(12,000)
48.8 < 54.0 inches (54 inches is maximum allowable VCg per mfg. specifications from Body Builder’s Guide, NPR/W3500 section)
Since maximum VCg for this truck is not exceeded, 48” stack height above flooring is acceptable.
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8. Horizontal Center of Gravity Formula
These formulas are used to estimate the horizontal center of gravity of a completed vehicle in order to determine whether it exists between the centerlines of
the front and rear axles. This formula should be used when a load and/or permanent equipment (liftgate, reefer unit, snowplow, etc.) is installed on
either extreme along the completed vehicle’s overall length.
8.1 Wv x (Hv) = Mv
8.2 Wb x (Hb) = Mb
8.3 Wp x (Hp) = Mp
8.4 We x (He) = Me
(Mv+Mb+Mp+Me)
8.5 HCg =
(Wv + Wb + Wp + We)
Definitions in formula:
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Example: NPR/W3500 Diesel 12,000 GVWR automatic transmission, 132” WB, 14’ body length, full payload of boxes stacked and distributed evenly throughout
the flooring, 1,000 lb. reefer unit attached in front of body.
Since HCg for this truck is not greater than the WB or negative (–) (denotes HCg forward of front axle centerline), it exists between the centerlines of the front and
rear axles.
NOTE: Hp and Hb dimensions are the same in this example because CG of body and payload happen to be at the same point.
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The Federal Government has established the following formula to be used to determine the allowable weight limits and axle spacings for trucks.
Where:
W = The total gross weight that may be carried on any group of two or more consecutive axles to the nearest 500 lbs.
L = The distance (spacing) in feet between the outer axles of any group of two or more consecutive axles.
N = The number of axles in the group under consideration; except that two consecutive sets of tandem axles may carry a gross load of
34,000 lbs. each provided the overall distance between the first and last axles of such consecutive sets of axles is 36 feet or more.
Gross Weight
The total weight of a truck (and/or trailer) combined with the weight of the load being hauled. The Federal gross weight limits on interstate highways and federal-
aid highways and reasonable access is 80,000 lbs.
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The total weight at the ground by all wheels of an axle whose centers may be included between parallel transverse planes 40 inches apart, extending across
the width of the truck. The Federal single axle weight limit on the interstate system and reasonable access is 20,000 lbs.
The total weight at the ground of two or more consecutive axles whose centers may be included between parallel vertical planes spaced more than 40 inches
but not more than 96 inches apart, extending across the full width of the truck. The Federal tandem axle weight limit on the interstate system and reasonable
access is 34,000 lbs.
The Federal law states that any two or more consecutive axles may not exceed the weight as computed by the formula even though the single axles, tandem
axles, and gross weights are within the legal requirements.
There is one exception to the use of the Federal Bridge Formula: two consecutive sets of tandem axles may carry a gross load of 34,000 lbs. each, providing
the overall distance between the first and last axles of such consecutive sets of tandem axles is 36 feet or more.
Length: States cannot set overall length limits on tractor, semitrailer or tractor-semitrailer, trailer combinations. States must allow tractors with double trailers.
States must allow semitrailers of up to 48 feet in length for doubles combinations. There is also not a limitation on overall length for semitrailer or doubles
combinations.
These width and length dimensions apply to trucks operating on interstate highways and federal-aid highways designed by the Federal Highway Administration.
This also provides for reasonable access to the interstate highways.
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COMMODITY AND MATERIAL WEIGHTS
Approximate Weights of Commodities and Materials
Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per
Acetone ——— 50 6.6 / gallon Beef, Slack barrel 21” x 30” stave (200 lbs. net) —— 254 / barrel
Alcohol, Commercial ——— 51 6.8 / gallon Beer, Wood barrel .5 barrel (16 gal.) —— 205 / barrel
Proof spirits ——— 57 7.6 / gallon Wood barrel .25 barrel (8 gal.) —— 105 / barrel
Alfalfa seed bushel —— 60 / bushel Steel barrel .5 barrel (16 gal.) —— 190 / barrel
Aluminum, Pure (cast) ——— 165 4,450 / cu. yard Steel barrel .25 barrel (8 gal.) —— 95 / barrel
Western, box 11.5” x 12” x 20” —— 50 / box Case carton,* Regular bottles 17.25” x 11.5” x 9.88” —— 45 / case
New England, box 11.25” x 14.5” x 17.5” —— 56 / box 24, 12 oz. Steinie bottles 18.38” x 12.13” x 7.38” —— 40 / case
Standard barrel 17” head, 28.5” stave —— 160 / barrel Tin cans 16.13” x 11” x 5.13” —— 28 / case
Dried bushel —— 24 / bushel Wooden case,* Regular bottles 21” x 13.5” x 10” —— 35 / case
Apricots, Fresh bushel —— 48 / bushel 24, 12 oz. Steinie bottles 22” x 13.75” x 7.5” —— 46 / case
Western, box 5.5” x 12” x 20” —— 23 / box Beets bushel —— 50-60 / bushel
Artichokes, Box 10” x 11.5” x 22” —— 44 / box Small crate 9.75” x 13.75” x 24” —— 50 / crate
Asbestos ——— 153 4,130 / cu. yard Western crate 14” x 19” x 24.5” —— 95 / crate
Asparagus, crate, Loose 11.5” high x 9.75” top —— 38 / crate Berries, crate, 24 pint 9.75” x 9.97” x 20” —— 25 / crate
Bunches 11” bottom x 19.38” long —— 31 / crate 24 quart 11.75” x 11.75” x 24” —— 48 / crate
Avocados, Box 5.75” x 11.25” x 17.5” —— 16 / box 32 quart 15.5” x 11.75” x 24” —— 63 / crate
Bananas, Single stem bunch —— 45-65 / bunch Bluegrass seed bushel —— 44 / bushel
Barytes, Mineral ——— 280 7,560 / cu. yard Bone ——— 115 3,110 / cu. yard
Basalt, Rock ——— 185 5,000 / cu. yard Borax ——— 110 2,970 / cu. yard
Beans, fresh, Lima bushel —— 39 / bushel Hard 2.25” x 4.25” x 8.5” —— 6,480 / thousand
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Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per
Broccoli, Bushel crate 12.75” x 12.75” x 17” —— 30 / bushel Cement, Block 8” x 8” x 16” —— 42 / each
Brussels sprouts, Crate 7.75” x 10.5” x 21.38” —— 26 / crate Block 8” x 12” x 16” —— 58 / each
Buckwheat bushel —— 49 / bushel Portland sack —— 94 / sack
Butter, tub, Small 15” dia. x 5.75” —— 25 / tub Portland barrel (4 sacks per) —— 376 / barrel
Standard 15” dia. x 15” —— 70 / tub Chalk ——— 137 3,700 / cu. yard
Butter, case, 30 – 1-lb. bricks 10.75” x 8.75” x 10.5” —— 32 / case Charcoal, Oak ——— 33 890 / cu. yard
9-lb. pail pail —— 10 / pail Pine ——— 23 620 / cu. yard
Cabbage bushel —— 38 / bushel Cheese, Small box 15” dia. x 5.25” —— 25 / box
Hamper 1.5 bushel —— 58 / hamper Medium box 15” dia. x 7.5” —— 35 / box
Crate 12.75” x 18.5” x 19” —— 60 / crate Large box 15” dia. x 15” —— 70 / box
Western crate 14” x 19” x 24.5” —— 85 / crate Cherries, Unstemmed bushel —— 56 / bushel
Barrel crate 12.75” x 18.75” x 37.38” —— 110 / crate Stemmed bushel —— 64 / bushel
Calf, Live (average) per head —— 140-160 / head Lug box 5.63” x 11.88” x 19.75” —— 17 / box
Cantaloupe, crate, Pony 11.75” x 11.75” x 23.5” —— 58 / crate Chestnut* (lumber) ——— 37 3,080 / M. Bd. ft.
Standard 12.75” x 12.75” x 23.5” —— 68 / crate Chestnuts bushel —— 50 / bushel
Jumbo 13.75” x 13.75” x 23.5” —— 78 / crate Chickens, Live, broilers (20 avg.) standard crate —— 58 / crate
Pony flat 4.75” x 12.75” x 23.5” —— 26 / crate Fowl (12 avg.) standard crate —— 78 / crate
Standard flat 5.25” x 14.25” x 23.5” —— 28 / crate Standard crate, empty 24” x 35” x 13” —— 18 / crate
Jumbo flat 5.75” x 15.25” x 23.5” —— 32 / crate Cinder blocks 8” x 8” x 16” —— 35 / each
Honeydew (Casaba) 6.38” x 15.13” x 23.5” —— 35 / crate 8” x 12” x 16” —— 45 / each
Carbolic acid ——— 60 8.0 / gallon Cinders ——— 50 1,350 / cu. yard
Carrots, Topped bushel —— 55 / bushel Clay, Dry lumps ——— 85 2,300 / cu. yard
With tops bushel —— 40 / bushel Wet lumps ——— 110 2,970 / cu. yard
Crate 11.75” x 14.13” x 24” —— 60 / crate Wet packed ——— 135 3,650 / cu. yard
Castor oil ——— 61 8.1 / gallon Fire ——— 125 3,375 / cu. yard
Cauliflower bushel —— 30 / bushel Cork ——— 15 405 / cu. yard
Crate 9.38” x 19” x 24” —— 50 / crate Corn, Ear bushel —— 35 / bushel
Cedar* (lumber) ——— 30 2,500 / M. Bd. ft. Shelled bushel —— 56 / bushel
Celery, Standard crate 11.63” x 22” x 22.63” —— 70 / crate Sweet corn (green) bushel —— 43 / bushel
Half crate 10.75” x 13” x 20.38” —— 35 / crate Crate 12.88” x 12.88” x 24” —— 60 / crate
Northern crate 16.5” x 21.25” x 22” —— 85 / crate Corn meal bushel —— 44 / bushel
*Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried.
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Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per
Corn oil ——— 58 7.8 / gallon Fish, fresh, Barrel 19” head, 29” stave —— 300 / barrel
Corn syrup ——— 86 11.5 / gallon 1/2 Barrel 18.5” head, 23.5” stave —— 160 / 1/2 barrel
Cotton, Gin bale 30” x 48” x 54” —— 515 / bale Flour, Barrel 19.13” head, 30” stave —— 215 / barrel
Standard bale 24” x 28” x 56” —— 515 / bale Fuel oil, Furnace grade ——— 56 7.5 / gallon
Comp. bale 20” x 24” x 56” —— 515 / bale Diesel engine ——— 52 7.0 / gallon
Cotton seed bushel —— 32 / bushel Furniture, Household ——— 7 1,915 / cu. yard
Cottonseed oil ——— 58 7.8 / gallon Garbage, Dry, paper wrapped ——— 15-30 405-810 / cu. yard
Cottonwood* (lumber) ——— 37 3,080 / M. Bd. ft. Wet ——— 50 1,240 / cu. yard
Cow, Live-Feeder (average) per head —— 600 / head Gasoline ——— 45 6.0 / gallon
Butcher (average) per head —— 800 / head Glass, Common window ——— —— 162 / cu. foot
Butcher steer (average) per head —— 1100 / head Plate or crown ——— —— 161 / cu. foot
Cranberries, 1/4 barrel box 9.5” x 11” x 14” —— 28 / box 1/4” plate ——— —— 3.3 / sq. foot
1/2 barrel box 12.25” x 14.75” x 22” —— 60 / box Glue ——— 80 2,160 / cu. yard
Cream ——— 64 8.5 / gallon Glycerine ——— 79 10.5 / gallon
Creosote ——— 68 9.2 / gallon Grapefruit, Western box 11.5” x 11.5” x 24” —— 68 / box
Crude oil ——— 56 7.5 / gallon Southern box 12.75” x 12.75” x 27” —— 90 / box
Cucumbers bushel —— 55 / bushel Grapes, Basket bushel —— 48 / box
Crate 9.75” x 13.75” x 24” —— 75 / crate Lug box 5.63” x 16.38” x 17.5” —— 30 / box
Case 5” x 13.25” x 19” —— 26 / case Western keg 15.5” dia. x 14” —— 45 / keg
Earth, Loose, dry loam ——— 76 2,050 / cu. yard Basket 12 quart —— 18 / basket
Packed ——— 95 2,565 / cu. yard Gravel, Dry ——— 95 2,565 / cu. yard
Wet ——— 125 3,375 / cu. yard Wet ——— 125 3,375 / cu. yard
Eggplant, Hamper bushel —— 40 / bushel Greens bushel —— 25 / bushel
Crate 14” x 11.75” x 24” —— 54 / crate Groceries, Misc. assorted ——— 30 810 / cu. yard
Eggs, 30 dozen crate 12” x 12” x 26” —— 55 / crate Hay, Bale 26” x 30” x 46” —— 210 / bale
Elm,* Soft ——— 38 3,170 / M. Bd. ft. Bale 17” x 22” x 43” —— 115 / bale
Rock ——— 45 3,750 / M. Bd. ft. Bale 14” x 16” x 43” —— 85 / bale
Fertilizer, Commercial burlap bag —— 100-200 / bag Hog, Live (average) per head —— 225-250 / head
Fir,* Douglas ——— 32 2,670 / M. Bd. ft. Honey ——— 90 12.0 / gallon
Eastern ——— 25 2,080 / M. Bd. ft. Horse, Live (average) per head —— 1,200-1,500 / head
*Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried.
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Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per
Ice ——— 57 1,540 / cu. yard Lubricating oil ——— 52 7.0 / gallon
Ice (mfg.), Block 11” x 22” x 32” —— 250 / block Malt, Barley bushel —— 28 / bushel
Rye bushel —— 32 / bushel
Block 14” x 14” x 40” —— 255 / block
Brewer’s grain bushel —— 40 / bushel
Block 11” x 22” x 56” —— 440 / block
Maple syrup gallon 82 11.0 / gallon
Ice Cream, 2.5 gallon can, Full 9” dia. x 11” —— 18 / can
Maple,* Hard (lumber) ——— 44 3,670 / M. Bd. ft.
Empty ——— —— 6 / can
Soft ——— 34 2,830 / M. Bd. ft.
5 gallon can, Full 9” dia. x 21” —— 35 / can
Meal-corn bushel —— 44 / bushel
Empty ——— —— 11 / can
Milk, Bulk ——— 64 8.6 / gallon
Kale bushel —— 25 / bushel
5 gallon can 10.25” dia. x 19” —— 62 / can
Kerosene ——— 50 6.6 / gallon 10 gallon can 13” dia. x 23” —— 115 / can
Lamb, Live (average) per head —— 75-85 / head Crate, 20.5 pt. bottles 8.5” x 12.75” x 16.75” —— 33 / crate
Lard, Barrel 18” head, 30” stave —— 425 / barrel 20 pt. bottles 8.5” x 12.75” x 16.75” —— 54 / crate
Lath, Standard length 29” Packed in bundles of 50 —— 25 / bundle Millet bushel —— 50 / bushel
Leather, Dry ——— 55 1,485 / cu. yard Barrel 20.25” head, 34” stave —— 675 / barrel
Wet ——— 65 1,755 / cu. yard Mortar, Lime ——— 110 2,970 / cu. yard
Mud, Flowing ——— 106 2,860 / cu. yard
Lemons, Western box 10” x 13” x 25” —— 80 / box
Packed ——— 125 3,375 / cu. yard
Southern box 12.75” x 12.75” x 27” —— 90 / box
Muriatic acid, 40% ——— 40 10.0 / gallon
Lentils bushel —— 60 / bushel
Naptha, Petroleum ——— 42 5.6 / gallon
Lettuce, Hamper bushel —— 25 / bushel
Nitric acid, 91% ——— 94 12.5 / gallon
Hamper 1.5 bushel —— 38 / hamper
Oak-red,* Black ——— 42 3,500 / M. Bd. ft.
Basket 8.5” x 11.75” x 21.38” —— 17 / basket
White ——— 48 4,080 / M. Bd. ft.
Crate 18.75” x 17.5” x 24.5” —— 75 / crate
Oats bushel —— 32 / bushel
1/2 crate 9.5” x 13.5” x 24.5” —— 40 / 1/2 crate Okra, Hamper 1/2 bushel —— 18 / hamper
Lime, Hydrated bushel —— 30 / bushel Hamper bushel —— 34 / bushel
Barrel (small) 16.5” head, 27.5” stave 62 210 / barrel Oleomargarine, (mfg.-tub) 21” head, 34” stave —— 70 / tub
Barrel (large) 62 320 / barrel Cases ——— —— 15-65 / case
*Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried.
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Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per
Olive oil ——— 58 7.7 / gallon Pecans, Large bag ——— —— 100 / bag
Onions, dry, Basket bushel —— 55 / bushel Small bag ——— —— 50 / bag
Bag 17” x 32” —— 50 / bag Peppers, Basket bushel —— 25 / basket
Crate 20.5” x 11.5” x 10.5” —— 58 / crate Crate 14.13” x 11.75” x 24” —— 45 / crate
Green (with tops) bushel —— 32 / bushel Petroleum ——— 56 7.5 / gallon
Oranges, Western box 11.5” x 11.5” x 24” —— 80 / box Phosphate rock ——— 200 5,400 / cu. yard
Southern box 12.75” x 12.75” x 27” —— 90 / box Pine,* Long leaf ——— 44 3,670 / M. Bd. ft.
Bushel box 10.75” x 10.75” x 23.5” —— 65 / box North Carolina ——— 36 3,000 / M. Bd. ft.
Oysters (shucked or meats) Oregon ——— 32 2,670 / M. Bd. ft.
Crate with 5.1 gal. cans 18” x 12” x 24” (11.5 lbs. per gal.) 67 / crate Red ——— 30 2,500 / M. Bd. ft.
With shells (bags) bushel —— 75 / bushel White ——— 26 2,170 / M. Bd. ft.
Paint, Lead and oil ——— 127 17 / gallon Yellow, long leaf ——— 44 3,670 / M. Bd. ft.
Paper, Average solid ——— 58 1,565 / cu. yard Short leaf ——— 38 3,170 / M. Bd. ft.
Newspaper rolls 34.25” x 35” dia. —— 500 / roll Pineapples, Crate 11” x 12.5” x 36” —— 85 / crate
51.5” x 35” dia. —— 1,000 / roll Pitch ——— 70 1,900 / cu. yard
64.25” x 35” dia. —— 1,300 / roll Plums, Basket bushel —— 56 / bushel
Paraffin ——— 56 1,510 / cu. yard Western box 5.63” x 16.38” x 17.5” —— 25 / box
Parsley, Bushel crate 12.75” x 12.75” x 17” —— 30 / crate Pomegranates, Box 6.5” x 12” x 24.63” —— 30 / box
Parsnips bushel —— 50 / bushel Popcorn, Ear bushel —— 70 / bushel
Peaches, Basket bushel —— 48 / bushel Shelled bushel —— 56 / bushel
1/2 bushel ——— —— 25 / basket Poplar* ——— 27 2,250 / M. Bd. ft.
Crate 10.5” x 11.25” x 24” —— 50 / crate Porcelain ——— 150 4,050 / cu. yard
Western box 5.5” x 12.25” x 19.75” —— 22 / box Pork (dressed), Barrel (200 lbs. net) 18” head, 29” stave —— 240 / barrel
Peanuts, Unshelled bushel —— 22 / bushel Potatoes, Sweet bushel —— 55 / bushel
Bag ——— —— 100 / bag White or Irish bushel —— 60 / bushel
Peanut oil ——— 57 7.6 / gallon Bag 1.67 bushel —— 102 / bag
Pears, Basket bushel —— 50 / bushel Barrel 17.13” head, 28.5” stave —— 185 / barrel
Western box 9.63” x 12.13” x 19.75” —— 51 / box Prunes, Box 5.63” x 16.38” x 19.75” —— 25 / box
Peas, Dry bushel —— 60 / bushel Box 5.63” x 11.88” x 19.75” —— 22 / box
Fresh hamper bushel —— 35 / hamper Quinces bushel —— 50 / bushel
Hamper 40 quarts —— 45 / hamper
*Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried.
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Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per
Radishes, Basket bushel —— 34 / bushel Soft drinks, Half depth bottle box
Crate 9.75” x 13.75” x 24” —— 40 / crate 24-6 to 8 oz. bottles 12.25” x 18.75” x 8.5” —— 39 / box
Redwood* ——— 30 2,500 / M. Bd. ft. Full depth bottle box
Resin ——— 68 1,835 / cu. yard 12-24 to 32 oz. bottles 13.38” x 18.5” x 12.25” —— 60 / box
Rhubarb (pie plant) bushel —— 50 / bushel Sorghum syrup ——— 86 11.5 / gallon
Box 5.25” x 11.5” x 22” —— 24 / box Soybeans bushel —— 60 / bushel
Rice, Unhulled bushel —— 43 / bushel Soybean oil ——— 58 7.7 / gallon
Rock, Crushed (average) ——— 100 2,700 / cu. yard Spinach, Hamper bushel —— 20 / bushel
Romaine, Crate 13.88” x 18.88” x 24.5” —— 64 / crate Basket bushel —— 27 / bushel
Crate 12.25” x 13” x 15.25” —— 27 / crate Spruce* ——— 28 2,330 / M. Bd. ft.
Rubber goods ——— 94 2,540 / cu. yard Squash bushel —— 46 / bushel
Rutabagas bushel —— 56 / bushel Starch ——— 96 2,590 / cu. yard
Rye bushel —— 56 / bushel Stone, Crushed, (average) ——— 100 2,700 / cu. yard
Salt, rock, Solid ——— 136 3,670 / cu. yard Rip-rap ——— 65 1,755 / cu. yard
Coarse ——— 45 1,215 / cu. yard Straw, Bale 17” x 22” x 42” —— 110 / bale
Fine ——— 50 1,350 / cu. yard Bale 26” x 30” x 46” —— 180 / bale
Barrel (average) ——— —— 280 / barrel Street sweepings ——— 32 865 / cu. yard
Sand, fine, Dry ——— 110 2,970 / cu. yard Sugar ——— 100 2,700 / cu. yard
Wet ——— 125 3,375 / cu. yard Sugar, Bag (100 lbs. net) —— 101 / bag
Sand, coarse, Dry ——— 95 2,565 / cu. yard Barrel (22 lbs. empty) 19.13” head, 30” stave —— 345 / barrel
Wet ——— 120 3,240 / cu. yard Case 24 – 5-lb. cartons —— 135 / case
Sand, Mixed ——— 115 3,100 / cu. yard Case 60 – 2-lb. cartons —— 135 / case
Sandstone, Solid ——— 147 3,970 / cu. yard Sugar cane syrup ——— 85 11.3 / gallon
Crushed ——— 86 2,325 / cu. yard Sulphur ——— 125 3,375 / cu. yard
Shale, Solid ——— 172 4,645 / cu. yard Sulfuric acid, 87% ——— 112 15 / gallon
Crushed ——— 92 2,485 / cu. yard Sweet corn, Basket bushel —— 45 / bushel
Sheep, Live (average) per head —— 125-150 / head Crate 13” x 13” x 24” —— 60 / crate
Shingles, Bundle Pkg. in bndls. of 200-250 —— 50 / bundle Sycamore* ——— 37 3,080 / M. Bd. ft.
Size (avg.) 24” x 20” x 10” Tallow ——— 60 1,620 / cu. yard
Snow, Moist-packed ——— 50 1,350 / cu. yard
*Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried.
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Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per
Tanks, Acetylene, 102 cu. foot empty —— 70 / tank
filled —— 75 / tank
310 cu. foot empty —— 200 / tank
filled —— 220 / tank
Tanks, Oxygen, 150 cu. foot empty —— 80 / tank
filled —— 92 / tank
300 cu. foot empty —— 133 / tank
filled —— 153 / tank
Tar ——— 65 1755 / cu. yard
Tile, Solid ——— 115 3,100 / cu. yard
Partition (construction) ——— 40 1,080 / cu. yard
Tomatoes, Basket bushel —— 55 / bushel
Lug box 7.25” x 14” x 17.5” —— 35 / box
Crate 10.5” x 11.25” x 24” —— 48 / crate
Basket 8.5” x 8.75” x 20” —— 18 / basket
Basket (paper) 4.25” x 8.5” x 16.25” —— 9 / basket
Basket (wood) 5.5” x 7.25” x 16.5” —— 10 / basket
Turpentine ——— 54 7.2 / gallon
Turnips, Basket bushel —— 54 / bushel
Vetch seed bushel —— 60 / bushel
Vinegar ——— 64 8.5 / gallon
Walnuts, Bulk bushel —— 50 / bushel
Bag 2 bushel —— 100 / bag
Water, Fresh ——— 63 8.4 / gallon
Wheat, Bulk bushel —— 60 / bushel
Bag 1.5 bushel —— 90 / bag
Wool, Pressed ——— 82 2,215 / cu. yard
*Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried.
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VEHICLE SPECIFICATIONS INDEX
NPR/W3500, NPR HD/W4500 GAS
Specifications
Model NPR/W3500 Gas NPR HD/W4500 Gas
GVWR 12,000 lbs. 14,500 lbs.
WB 109 in., 132.5 in., 150 in., 176 in.
Engine GMPT 8-cylinder, V Block 4-cycle, OHV, water-cooled, Sequential Port Fuel Injection
Model/Displacement GMPT-V8/365 CID (6.0 liters)
HP (Gross) 325 HP @ 5,000 RPM
Torque (Gross) 360 lbs.-ft. torque @ 4,400 RPM
Sequential Port Fuel Injection (SFI), mass air flow meter, powertrain control module (PCM),
Equipment onboard diagnostics, oxygen sensors, catalytic convertor, map sensor, with external oil cooler,
engine cruise control, rear engine cover.
Transmission 4L80-E Hydra-Matic 4-speed automatic w/lock-up converter and overdrive
Steering Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column.
Front Axle Reverse Elliot “I”-Beam rated at 6,830 lbs.
Suspension Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers.
GAWR 4,700 lbs. 5,360 lbs.
Rear Axle Full-floating single speed with hypoid gearing rated at 11,020 lbs.
Suspension Semi-elliptical steel alloy multi-leaf springs and shock absorbers.
GAWR 7,950 lbs. 9,880 lbs.
Wheels 16 x 6.0 6-hole disc wheels, painted white. 19.5 x 6.0 6-hole disc wheels, painted white.
Tires 215/85R 16-E (10 pr) tubeless steel-belted radials, 225/70R-19.5F (12 ply) tubeless steel-belted radials,
all-season tread front and rear. all-season tread front and rear.
Dual-circuit, vacuum-assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system
Brakes for load proportioning of the brake system. Disc front and self-adjusting outboard mounted drum rear.
The parking brake is a mechanical, cable-actuated, internal expanding drum type, transmission mounted.
Four-channel antilock brake system.
Fuel Tank 30-gallon rectangular steel fuel tank. Mounted between the frame rails
with electric type fuel pump (mounted in tank). Through the rail fuel fill.
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Model NPR/W3500 Gas NPR HD/W4500 Gas
GVWR 12,000 lbs. 14,500 lbs.
Frame Ladder type channel section straight frame rail 33.5 in. wide through the total length of the frame.
Yield strength 44,000 psi section modulus 7.20 in.3, RBM 316,800 lbs.-ft./in. per rail.
Cab All-steel, low cab forward, BBC 70.9 in., 45o mechanical tilt with torsion assist.
TRICOT and JERSEY KNIT combination cloth covered high back driver’s seat with two occupant passenger seat.
Equipment Dual cab-mounted exterior mirrors. With integral convex mirrors.Tilt and telescoping steering column.
Tinted glass, air conditioning.
Electrical 12-volt, negative ground, maintenance-free battery located on frame,
750 CCA each, 145-amp alternator with integral regulator.
Options AM/FM CD stereo radio, wheel simulators, air deflector, back up alarm,mirror brackets for 102” wide body,
fire extinguisher and triangle kit mounted in rear organizer, , heated mirrors, Limited Slip Differential, and Chrome Grille
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In Frame Tank 12,000-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
DB1 109 LB. 3212 1790 5003 6997
DB2 132.5 LB. 3310 1769 5079 6921
DB3 150 LB. 3366 1750 5116 6884
DB4 176 LB. 3432 1739 5171 6829
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In Frame Tank 14,500-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
FE1 109 LB. 3261 1828 5089 9411
FE2 132.5 LB. 3332 1815 5147 9353
FE3 150 LB. 3384 1791 5175 9325
FE4 176 LB. 3445 1776 5221 9279
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GVWR
Technical Notes:
Chassis Curb Weight reflects standard equipment and fuel but no driver or payload.
Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb
weight from the GVWR.
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Frame Chart
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Frame Chart
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Cab Tilt
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Center of Gravity
63
63
NOTE: The maximum dimensions for a body installed on the N/W Series are 102 inches wide (outside) with 102” wide mirror brackets installed 90 inches high
(inside). Any larger body applications must be approved by ICTA Application Engineering. On the West Coast call 1-562-229-5314 and on the East Coast
call 1-770-740-1620 x 262.
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Definitions
A Centerline of axle to bottom of axle bowl. DW Minimum distance between the inner surfaces of the rear tires.
B Centerline of axle to top of frame rail at metal-to-metal position.
C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width:
Overall width of the vehicle measured at the outermost surface of the rear tires.
D Centerline of axle to top of frame rail at design load. HH Rear Tire Clearance:
Minimum clearance between the rear axle and the ground-line.
Rear Tire Clearance: Minimum clearance required for tires
E and chain measured from the top of the frame at the vertical HW Dual Tire Spacing:
centerline of the rear axle, when rear wheels on one side ride Distance between the centerlines of the tires in a set of dual tires.
over a high spot.
Rear Frame Height: Tire Bounce Clearance:
CH Vertical distance between the normal top of frame rail and KH Minimum distance required for tire bounce as measured from the centerline of
the ground-line through the centerline of the rear axle the rear axle and the top of the rear tire when one wheel rides over a high spot.
at curb position.
Rear Frame Height: Track Dual Rear Wheel Vehicles:
DH Vertical distance between the normal top of frame rail and CW Distance between the centerlines of the dual wheels measured at the ground-line.
the ground-line through the centerline of the rear axle at
design load.
Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Tire Chart for Values
NOTE: Track and overall width may vary with optional equipment.
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Tire
Tire and Disc Wheel Chart – NPR/W3500
Tire Load Limit and Cold Inflation Pressures Maximum Tire Load Limits
Tire Size Single Dual Front Rear GVWR (Lb.)
Lb. PSI Lb. PSI 2 Single 4 Dual
215/85R 16-E 2,430 70 2,210 70 4,860 8,840 12,000
Tire Radius
Tire Size GVWR (Lb.) Loaded Unloaded Tire Section Tire Clearance Design Rim
Front Rear Front Rear Width Width
215/85R 16-E 12,000 14.05 14.05 14.6 14.6 8.54 1.46 6.0
Disc Wheel
Nut/Stud
Wheel Size Bolt Holes Bolt Circle Ft./Rr. Nut Rear Stud Torque Inner Circle Outside Disc Rim Type Material Mfg.
Dia. Size* Size* Specs. Offset Thickeness
1.6142 0.8268
16 X 6 K 6 JIS 8.75 (41 mm) (21 mm) 325 ft-lb. 6.46 5.0 0.35 50 DC Steel
BUD HEX SQUARE (440 N•m) TOPY
*O.D. Wrench Sizes
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Tire
Tire and Disc Wheel Chart – NPR HD/W4500
Tire Load Limit and Cold Inflation Pressures Maximum Tire Load Limits
Tire Size Single Dual Front Rear GVWR (Lb.)
Lb. PSI Lb. PSI 2 Single 4 Dual
225/70R 19.5-F 3,315 85 3,115 85 6,630 12,460 14,500
Tire Radius
Tire Size GVWR (Lb.) Loaded Unloaded Tire Section Tire Clearance Design Rim
Front Rear Front Rear Width Width
225/70R 19.5-F 14,500 15.24 15.28 16.10 16.10 8.9 1.1 6.0
Disc Wheel
Nut/Stud
Wheel Size Bolt Holes Bolt Circle Ft./Rr. Nut Rear Stud Torque Inner Circle Outside Disc Rim Type Material Mfg.
Dia. Size* Size* Specs. Offset Thickeness
1.6142 0.8268
19.5 x 6.00 RW 6 JIS 8.75 (41 mm) (21 mm) 325 ft-lb. 6.46 5.0 0.37 150 DC Steel
BUD HEX SQUARE (440 N•m) ACCURIED
*O.D. Wrench Sizes
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Propeller Shaft
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1. Disconnect battery.
2. Remove the short filler hose and the short breather hose from the breather and fuel filler pipes and the filler neck bracket assembly.
3. Filler kit hoses are designed for the 96 inch wide body width. Modify the hoses as required to fit dimension “E” of the desired body width (see page 104)
4. Install flexible filler hose (item 2) to fuel filler pipe and filler neck bracket assembly using existing screw clamps.
5. Install flexible breather hose (item 3) to fuel breather pipe and filler neck bracket assembly using new clamps (item 4)
6. The filler neck must be mounted to allow the filler neck bracket to be parallel to the frame horizontal.
7. Filler neck (Dimension A) must be between 6.85 inches and 8.85 inches above frame.
8. Secure the filler plate to the bottom of the body and check for leaks.
9. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose.
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Dimensions:
B = 29.75 inches (756 mm) B
C = 34.00 inches (863 mm)
D = 39.29 inches (998 mm) C
E = 33.86 inches (860 mm) D
F = 59.60 inches (1,514 mm)
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AUX.
DRAWING
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AUX.
DRAWING
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NPR/W3500, NPR HD/W4500, Crew Cab Gas
Specifications
Model NPR GAS/W3500 GAS NPR HD GAS/W4500 GAS
GVWR 12,000 lb 14,500 lbs.
WB 150 in, 176 in.
Engine GMPT 8-cylinder, V Block 4-cycle, OHV, water cooled, Sequential Port Fuel Injection
Model/Displacement GMPT-V8/365 CID (6.0 liters)
HP (Gross) 325 HP @ 5000 rpm
Torque (Gross) 360 lb-ft torque @ 4400 rpm
Equipment Sequential Port Fuel Injection (SFI), mass air flow meter, powertrain control module
(PCM), onboard diagnostics, oxygen sensors, catalytic convertor, map sensor, withexternal oil cooler, engine cruise control.
Transmission 4L80-E Hydra-Matic 4-speed automatic with lock-up converter and overdrive. No PTO opening
Steering Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column.
Front Axle Reverse Elliot “I”-Beam rated at 6,380 lbs.
Suspension Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers.
GAWR 4,700 lbs. 5,360 lbs.
Rear Axle Full-floating single speed with hypoid gearing rated at 11,020 lb.
Suspension Semi-elliptical steel alloy multi-leaf springs and shock absorbers.
GAWR 7,950 lbs. 9,880 lbs.
Wheels 16 x 6.0 6-hole disc wheels, painted white. 19.5 x 6.0
Tires 215/85R 16-E (10 pr) tubeless steel-belted radials, all-season front and rear. 225/70R-19.5F (12 ply)
Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load
BRAKES proportioning of the brake system front disc and self-adjust outboard mounted drum rear. The parking brake is a
mechanical, cable actuated, internal expanding drum type, transmission mounted. 4 channel anti-lock brake system.
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Model NPR GAS/W3500 GAS NPR HD GAS/W4500 GAS
Fuel Tank 30 gal. rectangular steel fuel tank. Mounted between the frame rails with electric type fuel pump (mounted in tank).
Through the rail fuel fill.
Frame Ladder type channel section straight frame rail 33.5 inches wide through the total length of the frame.
Yield strength 44,000 psi, section modulus 7.20 in3., RBM 316,800.
Cab All-steel, low cab forward BBC 109.9 in. All-steel, low cab forward7 passenger, BBC 109.9 in.
TRICOT and JERSEY KNIT combination cloth covered high back driver’s seat with two-occupant passenger seat.
Equipment Four passenger rear bench seat. Dual cab mounted exterior mirrors with integral convex mirror.
Tilt and telescoping steering column. Power windows and door locks, front floor mats, tinted glass.
Electrical 12-volt, negative ground, dual Delco maintenance free batteries, 750 CCA each, 145-Amp alternator with integral regulator.
AM/FM CD stereo radio, spare wheel, wheel simulators, back up alarm,mirror brackets for
Options 102” wide body, fire extinguisher and triangle kit mounted under rear seat, heated mirrors, and chrome grille.
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NPR /W3500 In-Frame Tank 12,000-lb. Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
HB3 150 LB. 3776 1980 5756 6244
HB4 176 LB. 3852 1959 5811 6189
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In Frame Tank 14,500-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
HE3 150 LB. 3794 2021 5815 8185
HE4 176 LB. 3865 1996 5861 8139
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Technical Notes:
Chassis Curb Weight includes standard equipment and fuel. Does not include driver, passenger, payload, body or special equipment.
Maximum Payload Weight is the allowed maximum for equipment, body, payload, driver and passengers and is calculated by subtracting
chassis curb weight from the GVWR.
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Frame Chart
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63
12,000
NOTE: The maximum dimensions for a body installed on the NPR / W3500 are 102 inches wide (outside)wide with 102” wide mirror brackets by 90 inches high
(inside). Any larger body applications must be approved by Isuzu Commercial Trucks of America Application Engineering. In the West Coast call
1-562-229-5314 and in the East Coast call 1-770-740-1620 X262.
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63
14,500
NOTE: The maximum dimensions for a body installed on the NPR-HD / W4500 are 102 inches wide (outside) with 102” wide mirror brackets by 90 inches high
(inside). Any larger body applications must be approved by Isuzu Commercial Trucks of America Application Engineering. In the West Coast call 1-562-229-5314
and in the East Coast call 1-770-740-1620 X262.
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Definitions
Rear Frame Height:
A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line
through the centerline of the rear axle at design load.
B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires.
C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width:
Overall width of the vehicle measured at the outermost surface of the rear tires.
D Centerline of axle to top of frame rail at design load. Rear Tire Clearance:
HH Minimum clearance between the rear axle and the ground-line.
Rear Tire Clearance: Dual Tire Spacing:
Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce
E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when
wheels on one side ride over a high spot. one wheel rides over a high spot.
Rear Frame Height: Track Dual Rear Wheel Vehicle:
CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line.
ground-line through the centerline of the rear axle at curb
position.
Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Chart for values.
NOTE: Track and overall width may vary with optional equipment.
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Definitions
Rear Frame Height:
A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line
through the centerline of the rear axle at design load.
B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires.
C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width:
Overall width of the vehicle measured at the outermost surface of the rear tires.
D Centerline of axle to top of frame rail at design load. Rear Tire Clearance:
HH Minimum clearance between the rear axle and the ground-line.
Rear Tire Clearance: Dual Tire Spacing:
Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce
E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when
wheels on one side ride over a high spot. one wheel rides over a high spot.
Rear Frame Height: Track Dual Rear Wheel Vehicle:
CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line.
ground-line through the centerline of the rear axle at curb
position.
Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Chart for values.
NOTE: Track and overall width may vary with optional equipment.
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Tire
Tire and Disc Wheel Chart – NPR / W3500
Tire Load Limit and Cold Inflation Pressures Maximum Tire Load Limits
Tire Size Single Dual Front Rear GVWR (Lb.)
Lb. PSI Lb. PSI 2 Single 4 Dual
215/85R 16E 2,430 70 2,210 70 4,860 8,840 12,000
Tire Radius
Tire Size GVWR (Lb.) Loaded Unloaded Tire Section Tire Clearance Design Rim
Front Rear Front Rear Width Width
215/85R 16E 12,000 14.05 14.05 14.6 14.6 8.54 1.46 6.0
Disc Wheel
Nut/Stud
Wheel Size Bolt Holes Bolt Circle Ft./Rr. Nut Rear Stud Torque Inner Circle Outside Disc Rim Type Material Mfg.
Dia. Size* Size* Specs. Offset Thickeness
1.6142 0.8268
16.6 x 6 K 6 JIS 8.75 (41 mm) (21 mm) 325 ft-lb. 6.46 5.0 0.35 50 DC Steel
BUD HEX SQUARE (440 N•m) TOPY
*O.D. Wrench Sizes
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Tire
Tire and Disc Wheel Chart – NPR HD / W4500
Tire Load Limit and Cold Inflation Pressures Maximum Tire Load Limits
Tire Size Single Dual Front Rear GVWR (Lb.)
Lb. PSI Lb. PSI 2 Single 4 Dual
225/70R 19.5F 3,315 85 3,115 85 6,630 12,460 14,500
Tire Radius
Tire Size GVWR (Lb.) Loaded Unloaded Tire Section Tire Clearance Design Rim
Front Rear Front Rear Width Width
225/70R 19.5F 14,500 15.24 15.28 16.10 15.10 8.9 1.1 6.0
Disc Wheel
Nut/Stud
Wheel Size Bolt Holes Bolt Circle Ft./Rr. Nut Rear Stud Torque Inner Circle Outside Disc Rim Type Material Mfg.
Dia. Size* Size* Specs. Offset Thickeness
1.6142 0.8268
19.5 x 6.00 6 JIS 8.75 (41 mm) (21 mm) 325 ft-lb. 6.46 5.0 0.37 150 DC Steel
BUD HEX SQUARE (440 N•m) TOPY
*O.D. Wrench Sizes
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NOTE: All driveline angles are at unloaded condition (curb position with typical cargo body).
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NOTE: All driveline angles are at unloaded condition (curb position with typical cargo body).
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THIS
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LEFT
BLANK
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LEFT
BLANK
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Please refer to introduction section of book for antilock system cautions and wheelbase modification requirements.
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Please refer to introduction section of book for antilock system cautions and wheelbase modification requirements.
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1. Disconnect battery.
2. Remove the short filler hose and the short breather hose from the breather and fuel filler pipes and the filler neck bracket assembly.
3. Filler kit hoses are designed for the 96 inch wide body width. Modify the hoses as required to fit dimension “E” of the desired body width (see page 104)
4. Install flexible filler hose (item 2) to fuel filler pipe and filler neck bracket assembly using existing screw clamps.
5. Install flexible breather hose (item 3) to fuel breather pipe and filler neck bracket assembly using new clamps (item 4)
6. The filler neck must be mounted to allow the filler neck bracket to be parallel to the frame horizontal.
7. Filler neck (Dimension A) must be between 6.85 inches and 8.85 inches above frame.
8. Secure the filler plate to the bottom of the body and check for leaks.
9. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose.
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Dimensions:
B = 29.75 inches (756 mm)
C = 34.00 inches (863 mm) B
D = 39.29 inches (998 mm) C
E = 33.86 inches (860 mm)
D
F = 59.60 inches (1,514 mm)
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NPR/W3500, NPR HD/W4500 Diesel
Specifications
Model NPR/W3500 Diesel NPR HD/W4500 Diesel
GVWR 14,500 lbs. 14,500 lbs.
WB 109 in., 132.5 in., 150 in., 176 in.
Engine Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel
Model/Displacement 4HK1-TC/317 CID (5.19 liters)
HP (Gross) 12,000/14,500 GVWR 205HP @ 2400 RPM w/ Automatic Trans 14,500 GVWR 175HP @ 2400 RPM w/ Manual Trans
Torque (Gross) 12,000/14,500 GVWR 441 lb/ft torque @ 1850 RPM w/ Automatic Trans 14,500 GVWR 387 lb/ft torque @ 1850 RPM w/ Manual Trans
Dry element air cleaner with vertical intake; 2 rows 569 in.2 radiator; 7-blade 20.1 in. diameter fan with viscous drive.
Equipment Cold weather starting device and an oil cooler. Engine oil level check switch and light. Engine warning system with
audible warning for low oil pressure, high coolant temperature andlow coolant level. Engine cruise control
and idle up function Rear engine cover.
Transmission Aisin A465 6 speed automatic transmission with fifth and sixth gear overdrive with lock up in 2nd, 3rd, 4th,5th, and 6th.
PTO capability. Optional MZZ 6 speed manual transmission.
(information available in manual transmission section for 14500 GVWR chassis)
Steering Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column.
Front Axle Reverse Elliot “I”-Beam rated at 6,380 lbs.
Suspension Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers.
GAWR 5,360 lbs. 5,360 lbs.
Rear Axle Full-floating single speed with hypoid gearing rated at 14,550 lb.
Suspension Semi-elliptical steel alloy multi-leaf springs and shock absorbers.
GAWR 8,840 lbs. 9,880 lbs.
Wheels 16 x 6.0-K 6-hole disc wheels, painted white.
Tires 215/85R 16-E (10 pr) tubeless steel-belted radials, all-season front and rear.
Dual-circuit, vacuum-assisted hydraulic service brakes with EBD (Electronic Brake Distribution)
Brakes system for load proportioning of the brake system front disc and self-adjust outboard mounted drum
The parking brake is a mechanical, cable-actuated, internal expanding drum type, transmission mounted.
The exhaust brake is standard and is vacuum-operated. 4 channel antilock brake system
NOTE: These selected specifications are subject to change without notice. *All Transmissions have a PTO gear in all wheelbases.
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Dimension Constants
Code Inches Code Inches Code Inches
AH 7.5 BW 83.3 FH (in frame tank) 31.8
AW 65.6 CW 65.0 FH (side tank) 32.0
BA 48.4 FW 33.5
BBC 70.9 OH 90.0
BOC 6.5 OW 81.4
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In-Frame Tank 12,000-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NB1 109.0 in. lb. 3,752 1,967 5,719 6,281
NB2 132.5 in. lb. 3,827 1,932 5,759 6,241
NB3 150.0 in. lb. 3,876 1,920 5,796 6,204
NB4 176.0 in. lb. 3,939 1,912 5,851 6,149
In-Frame Tank 14,500-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NF1 109.0 in. lb. 3,704 2,004 5,708 8,792
NF2 132.5 in. lb. 3,805 1,978 5,783 8,717
NF3 150.0 in. lb. 3,858 1,962 5,820 8,680
NF4 176.0 in. lb. 3,927 1,948 5,875 8,625
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Side-Mounted Tank 12,000-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NB1 109.0 in. lb. 3,960 1,712 5,672 6,328
NB2 132.5 in. lb. 4,015 1,733 5,748 6,252
NB3 150.0 in. lb. 4,052 1,747 5,799 6,201
NB4 176.0 in. lb. 4,095 1,765 5,860 6,140
Side-Mounted Tank 14,500-lb. GVWR Automatic Transmission ModelChassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NF1 109.0 in. lb. 3,982 1,773 5,755 8,745
NF2 132.5 in. lb. 4,043 1,788 5,831 8,669
NF3 150.0 in. lb. 4,083 1,799 5,882 8,618
NF4 176.0 in. lb. 4,130 1,813 5,943 8,557
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GVWR
Technical Notes:
Chassis Curb Weight reflects standard equipment and fuel but no driver or payload.
Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb
weight from the GVWR.
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Crossmember Type/Location
Wheelbase Frame
Thickness
B C D E F G
109 0.24 28.3 7.9 AA 46.5 - CC 24.2 DD 33.8
132.5 0.24 28.3 7.9 AA 46.5 BB 57.5 CC 24.2 DD 33.8
150 0.24 28.3 7.9 AA 46.5 BB 57.9 CC 24.2 DD 33.8
176 0.24 28.3 7.9 AA 46.5 BB 74.4 CC 24.2 DD 33.8
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Frame Chart
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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Cab Tilt
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H
GVWR WB V IN FRAME TANK SIDE TANK
109 23.8 37.5 32.9
12,000 132.5 23.7 44.5 39.9
150 23.6 49.7 45.2
176 23.6 57.5 53.0
109 23.8 38.3 33.6
14,500 132.5 23.7 45.3 40.6
150 23.7 50.6 45.9
176 23.6 58.4 53.7
63
63
NOTE: The maximum dimensions for a body installed on the N/W Series are 102 inches wide (outside*) by 90 inches high (inside). Any larger body applications
must be approved by Isuzu Commercial Trucks of America (ICTA) Application Engineering. In the West Coast call 1-562-229-5314 and in the
East Coast call 1-770-740-1620 x262. (* with 102 inches wide mirror brackets installed)
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215/85R 16-E
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Definitions
A Centerline of axle to bottom of axle bowl. DW
Minimum distance between the inner surfaces of the rear tires.
B Centerline of axle to top of frame rail at metal-to-metal position. EW
Maximum Rear Width:
C Centerline of axle to top of frame rail at curb position. Overall width of the vehicle measured at the outermost surface of the rear tires.
D Centerline of axle to top of frame rail at design load. HH
Rear Tire Clearance:
Minimum clearance between the rear axle and the ground-line.
Rear Tire Clearance: Dual Tire Spacing:
E Minimum clearance required for tires and chain measured from the HW Distance between the centerlines of the minimum distance required for tire
top of the frame at the vertical centerline of the rear axle, when bounce as measured from the centerline of the rear axle and the top of the
rear wheels on one side ride over a high spot. rear tire when one wheel rides over a high spot.
Rear Frame Height:
CH Vertical distance between the normal top of frame rail and CW Track Dual Rear Wheel Vehicles:
the ground-line through the centerline of the rear axle Distance between the centerlines of the dual wheels measured at the ground-line.
at curb position.
Rear Frame Height:
DH Vertical distance between the normal top of frame rail and
the ground-line through the centerline of the rear axle at
design load.
Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Tire Chart for Values
NOTE: Track and overall width may vary with optional equipment.
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Tire
Tire and Disc Wheel Chart – NPR HD/W4500
Tire Load Limit and Cold Inflation Pressures Maximum Tire Load Limits
Tire Size Single Dual Front Rear GVWR (Lb.)
Lb. PSI Lb. PSI 2 Single 4 Dual
225/70R 19.5-F 3,315 85 3,115 85 6,630 12,460 14,500
Tire Radius
Tire Size GVWR (Lb.) Loaded Unloaded Tire Section Tire Clearance Design Rim
Front Rear Front Rear Width Width
215/85R 16-E 12,000 14.1 14.1 14.6 14.6 8.2 1.8 6.0
215/85R 16-E 14,500 14.1 14.1 14.6 14.6 8.2 1.8 6.0
Disc Wheel
Nut/Stud
Wheel Size Bolt Holes Bolt Circle Ft./Rr. Nut Rear Stud Torque Inner Circle Outside Disc Rim Type Material Mfg.
Dia. Size* Size* Specs. Offset Thickeness
1.6142 0.8268
16 x 6 K 6 JIS 8.75 (41 mm) (21 mm) 325 ft-lb. 6.46 5.0 0.37 50 DC Steel
BUD HEX SQUARE (440 N•m) TOPY
*O.D. Wrench Sizes
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Propeller Shaft
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Trans. Opening Bolt A B C D E F H PTO Drive Gear Ratio of PTO Drv. No. of Pitch Helix Max. Output Torque
Location Pattern Location Gear Spd. to Eng. Spd. Teeth Angle
Aisin 465 Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 5.16 PTO Gear 1:1 with turbine 69 N/A 0 134 lbs.-ft. @ 1,700 RPM
Opening Diagram
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Please refer to Introduction Section of book for antilock system cautions and wheelbase modification requirements.
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Please refer to Introduction Section of book for antilock system cautions and wheelbase modification requirements.
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1. Disconnect battery.
2. Loosen hose from the tie downs. Remove caps from plate on rail.
4. Extend hose out from the driver side of the rail to body rail.
5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal (see figure 4).
8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame.
9. Secure the filler plate to the bottom of the body and check for leaks.
10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose.
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Dimensions:
B = 29.75 inches (756 mm)
C = 34.00 inches (863 mm)
D = 39.29 inches (998 mm)
E = 33.86 inches (860 mm)
F = 59.60 inches (1,514 mm)
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NQR/W5500 Diesel
Specifications
Model NQR/W5500
GVWR 17,950 lbs.
WB 109 in., 132.5 in., 150 in., 176 in.
Engine Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel.
Model/Displacement 4HK1-TC/317 CID (5.19 liters)
HP (Gross) 205HP/2400 RPM w/Automatic Trans
175HP/2400 RPM w/Manual Trans
Torque (Gross) 441 lb ft torque/1850 RPM w/ Automatic Trans
387 lb ft torque/1850 RPM w/ Manual Trans
Equipment Dry element air cleaner with vertical intake; 2 rows 569 square in. radiator; 7 blade 20.1 in diameter fan with viscous drive.
Cold weather starting device and an oil cooler. Engine oil level check switch and light. Engine warning system with audible
warning for low oil pressure, high coolant temperature, and low coolant level. Engine cruise control and engine idle up function.
Rear engine cover.
Transmission Aisin A465 6 speed automatic transmission with fifth and sixth gear overdrive with lock up in 2nd, 3rd, 4th, 5th and 6th,
PTO capability. Optional MZZ 6 speed manual transmission.
Steering Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column.
Front Axle Reverse Elliot I” -Beam rated at 6,830 lb.
Suspension Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers.
GAWR 6,830 lb.
Rear Axle Full floating single speed with hypoid gearing rated at 14,550 lb.
Suspension Semi-elliptical steel alloy multi-leaf springs and shock absorbers.
GAWR 12,980 lb
Wheels 19.5x6.0-K 6 hole disc wheels, painted white.
Tires 225/70R-19.5E (12 pr) tubeless steel belted radials, all season tread front and rear.
Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning
Brakes of the brake system front disc and self-adjust outboard mounted drum rear. The parking brake is a mechanical,
cable actuated, internal expanding drum type, transmission mounted. The exhaust brake is standard and is vacuum operated.
4 channel anti-lock brake system.
Fuel Tank 30 gal. rec fuel tank mounted in frame rail behind rear axle. Fuel water separator with dash mounted indicator light.
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Model NQR/W5500
GVWR 17,950 lbs.
Frame Ladder type channel section straight frame rail 33.5 in wide through the total length of
the frame. Yield strength 44,000 psi, section modulus 7.20 in3. RBM 316,800.
Cab All steel low cab forward, BBC 70.9 in, 45o mechanical tilt with torsion assist.
TRICOT and JERSEY KNIT combination cloth covered high back driver’s seat with two occupant passenger seat.
Equipment Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column.
Power windows and door locks, floor mats, tinted glass.
Electrical 12 Volt, negative ground, dual Delco maintenance free batteries, 750 CCA each, 110 Amp alternator with integral regulator.
Options AM/FM CD stereo radio, engine block heater; engine oil pan heater fuel tank mounted on right hand rail (33 gal), spare wheel,
wheel simulators, air deflector, air conditioning, PTO enable switches, back up alarm, heated mirrors, engine shutdown,
mirror bracket for 102” wide body, fire etinguisher and triangle kit mounted in rear organizer, cross rail horizontal DPF
with vertical exhaust, and hour meter, (2nd fuel tank 33 gal), Limited Slip Differential, and Chrome Grille.
*200 wheelbase chassis (NR5) will require you to add the following options to your order:
White cab/Side mounted fuel tank with power windows and door locks, air conditioning (OCC 74) AM/FM CD Stereo radio (IL7),
Air Deflector (IF4), Back up Alarm (UZF) N/A w M/T.
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Dimension Constants
Code Inches Code Inches Code Inches
AH 8.3 BW 83.3 FH 33.0
AW 65.6 CW 65.0
BA 48.4 FW 33.5
BBC 70.9 OH 90.0
BOC 6.50 OW 81.4
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In-Frame Tank 17,950-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NR1 109.0 in. lb. 3,936 2,317 6,253 11,697
NR2 132.5 in. lb. 4,063 2,266 6,329 11,621
NR3 150.0 in. lb. 4,129 2,236 6,365 11,585
NR4 176.0 in. lb. 4,214 2,206 6,420 11,530
Side -Mounted 17,950-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NR1 109 lb. 4,167 2,034 6,201 11,749
NR2 132.5 lb. 4,249 2,028 6,277 11,673
NR3 150 lb. 4,301 2,027 6,328 11,622
NR4 176 lb. 4,362 2,027 6,389 11,561
NR5 200 lb. 4,423 2,021 6,444 11,506
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Technical Notes:
Chassis Curb Weight reflects standard equipment and fuel but no driver or payload.
Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb
weight from the GVWR.
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Frame Chart
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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Cab Tilt
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Center of Gravity
GVWR WB V H
IN FRAME TANK SIDE TANK
109 25.0 40.4 35.8
17,950 132.5 24.9 47.4 42.8
150 24.9 52.7 48.1
176 24.8 60.5 55.9
200 24.8 n/a 55.9
The center of gravity of the completed vehicle with a full load should
not exceed 63 inches above ground level for the 17,950 lb. GVWR,
and must be located horizontally between the centerlines of the front
and rear axles.
NOTE: The maximum dimensions for a body installed on the NQR/W5500 are 102 inches wide (outside) by 90inches high (inside).
Any larger body applications must be approved by Isuzu Application Engineering. In the West Coast call 1-562-229-5314 and in the East
Coast call 1-770-740-1620 X 262.
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Definitions
Rear Frame Height:
A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line
through the centerline of the rear axle at design load.
B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires.
C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width:
Overall width of the vehicle measured at the outermost surface of the rear tires.
D Centerline of axle to top of frame rail at design load. Rear Tire Clearance:
HH Minimum clearance between the rear axle and the ground-line.
Rear Tire Clearance: Dual Tire Spacing:
Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce
E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when
wheels on one side ride over a high spot. one wheel rides over a high spot.
Rear Frame Height: Track Dual Rear Wheel Vehicle:
CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line.
ground-line through the centerline of the rear axle at curb
position.
Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Chart for values.
NOTE: Track and overall width may vary with optional equipment.
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Tire
Tire and Disc Wheel Chart
Tire Load Limit and Cold Inflation Pressures Maximum Tire Load Limits
Tire Size Single Dual Front Rear GVWR (Lb.)
Lb. PSI Lb. PSI 2 Single 4 Dual
225/70R 19.5F 3,450 90 3,245 90 6.900 12,980 17,950
Tire Radius
Tire Size GVWR (Lb.) Loaded Unloaded Tire Section Tire Clearance Design Rim
Front Rear Front Rear Width Width
225/70R 19.5F 17,950 14.93 14.98 16.00 16.00 8.7 1.3 6.0
Disc Wheel
Nut/Stud
Wheel Size Bolt Holes Bolt Circle Ft./Rr. Nut Rear Stud Torque Inner Circle Outside Disc Rim Type Material Mfg.
Dia. Size* Size* Specs. Offset Thickeness
1.6142 0.8268
19.5 x 6.00 RW 6 JIS 8.75 (41 mm) (21 mm) 325 ft-lb. 6.46 5.0 0.35 150 DC Steel
BUD HEX SQUARE (440 N•m) TOPY
*O.D. Wrench Sizes
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Propeller Shaft
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Trans. Opening Bolt A B C D E F H PTO Drive Gear Ratio of PTO Drv. No. of Pitch Helix Max. Output Torque
Location Pattern Location Gear Spd. to Eng. Spd. Teeth Angle
Aisin Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 5.16 PTO Gear 1:1 with turbine 69 N/A 00 134 lbs.-ft. @ 1,700 RPM
Opening Diagram
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1. Disconnect battery.
2. Loosen hose from the tie downs. Remove caps from plate on rail.
4. Extend hose out from the driver side of the rail to body rail.
5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal (see figure 4).
8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame.
9. Secure the filler plate to the bottom of the body and check for leaks.
10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose.
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Dimensions:
B = 29.75 inches (756 mm)
C = 34.00 inches (863 mm)
D = 39.29 inches (998 mm)
E = 33.86 inches (860 mm)
F = 59.60 inches (1,514 mm)
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Hose Modification for Various Width Bodies and fuel fill vent Orientation and Protection
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NRR/W5500 HD Diesel
Specifications
Model NRR/W5500 HD
GVWR 19,500 lbs.
WB 109 in., 132.5 in., 150 in., 176 in., 200 in., 212 in
Engine Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel.
Model/Displacement 4HK1-TC/317 CID (5.19 liters)
HP (Gross) 205HP/2400 RPM w/Automatic Trans
175HP/2400 RPM w/Manual Trans
Torque (Gross) 441 lb ft torque/1850 RPM w/ Automatic Trans
387 lb ft torque/1850 RPM w/ Manual Trans
Equipment Dry element air cleaner with vertical intake; 2 rows 569 square in. radiator; 7 blade 20.1in diameter fan with viscous drive.
Cold weather starting device and an oil cooler. Engine oil level check switch and light. Engine warning system with audible
warning for low oil pressure, high coolant temperature, and low coolant level. Engine cruise control and engine idle up function.
Rear engine cover.
Transmission Aisin A465 6 speed automatic transmission with fifth and sixth gear overdrive with lock up in 2nd, 3rd, 4th, 5th and 6th,
PTO capability. Optional MZZ 6 speed manual transmission.
Steering Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column.
Front Axle Reverse Elliot “I” -Beam rated at 6,830 lb.
Suspension Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers.
GAWR 6,830 lb.
Rear Axle Full floating single speed with hypoid gearing rated at 14,550 lb.
Suspension Semi-elliptical steel alloy multi-leaf springs and shock absorbers.
GAWR 13,660 lb
Wheels 19.5x6.0-K 6 hole disc wheels, painted white.
Tires 225/70R-19.5E (12 pr) tubeless steel belted radials, all season tread front and rear.
Dual circuit power assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of
the brake system front disc and self-adjust outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal
expanding drum type, transmission mounted. The exhaust brake is standard and is vacuum operated. 4 channel anti-lock brake system.
Fuel Tank 30 gal. rectangular steel fuel tank mounted in frame rail behind rear axle. Fuel water separator with dash mounted indicator light.
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Model NRR/W5500 HD
GVWR 19,500 lbs.
Frame Ladder type channel section straight frame rail 33.5 in wide through the total length of the frame. Yield strength 44,000 psi,
section modulus 7.20 in3. RBM 316,800.
Cab All steel low cab forward, BBC 70.9 in, 45o mechanical tilt with torsion assist.
TRICOT and JERSEY KNIT combination cloth covered high back driver’s seat with two occupant passenger seat.
Equipment Dual cab mounted exterior mirrors with integral convex mirror. Tilt and telescoping steering column.
Power windows and door locks, floor mats, tinted glass.
Electrical 12 Volt, negative ground, dual Delco maintenance free batteries, 750 CCA each, 110 Amp alternator with integral regulator.
Options AM/FM CD stereo radio, engine block heater; engine oil pan heater fuel tank mounted on right hand rail (33 gal), spare wheel,
wheel simulators, air deflector, air conditioning, PTO enable switches, back up alarm, heated mirrors, hour meter, engine
shutdown, mirror brackets for 102” widebody, fire extinguisher and triangle kit mounted in rear organizer,
cross rail horizontal DPF with vertical exhaust, 2nd fuel tank (33 gal), Limited Slip Differential and chrome grille.
*200 and 212 wheelbase chassis (NU5 NU6) will require you to add the following options to your order:
White cab/Side mounted fuel tank with power windows and door locks, air conditioning (OCC 74)
AM/FM CD Stereo radio (IL7), Air Deflector (IF4), Back up Alarm (UZF)
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Dimension Constants
Code Inches Code Inches Code Inches
AH 8.3 BW 83.3 FH 33.0
AW 65.6 CW 65.0
BA 48.4 FW 33.5
BBC 70.9 OH 91.1
BOC 6.5 OW 81.3
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In-Frame Tank 19,500-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NU1 109 in. lb. 3,997 2,319 6,316 13,184
NU2 132.5 in. lb. 4,121 2,270 6,391 13,109
NU3 150 in. lb. 4,186 2,242 6,428 13,072
NU4 176 in. lb. 4,125 2,412 6,537 12,963
Side-Mounted Tank 19,500-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NU1 109 lb. 4,231 2,035 6,266 13,234
NU2 132.5 lb. 4,310 2,032 6,342 13,158
NU3 150 lb. 4,359 2,033 6,392 13,108
NU4 176 lb. 4,419 2,035 6,454 13,046
NU5 200 lb. 4,479 2,037 6,516 12,984
NU6 212 lb. 4,527 2,039 6,566 12,934
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Technical Notes:
Chassis Curb Weight reflects standard equipment and fuel, but no driver or payload.
Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb
weight from the GVWR.
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Crossmember Type/Location
Wheelbase Frame
Thickness
B C D E E2 F G
109 0.24 28.3 7.9 AA 46.5 - - CC 24.2 DD 33.8
132.5 0.24 28.3 7.9 AA 46.5 BB 57.5 - CC 24.2 DD 33.8
150 0.24 28.3 7.9 AA 46.5 BB 57.9 - CC 24.2 DD 33.8
176 0.24 28.3 7.9 AA 46.5 BB 74.4 - CC 24.2 DD 33.8
200 0.24 28.3 7.9 AA 46.5 BB 98.4 BB 74.4 CC 24.2 DD 33.8
212 0.24 28.3 7.9 AA 46.5 BB 110.4 BB 74.4 CC 24.2 DD 33.8
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Frame Chart
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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NOTE: Frame-mounted fuel tank available on 109”, 132.5”, 150” and 176” WB as an option replacing the In-Frame Tank.
* Allow 3” additional for battery box opening clearance.
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Cab Tilt
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Center of Gravity
GVWR WB V H
IN FRAME TANK SIDE TANK
109 24.9 40.0 35.4
132.5 24.9 47.1 42.5
19,500 150 24.9 52.3 47.7
176 24.9 64.9 55.5
200 24.9 N/A 55.5
212 24.9 N/A 55.5
19,500 LB.
NOTE: The maximum dimensions for a body installed on the NRR/W5500-HD are 102 inches wide (outside) by 90 inches high (inside). Any
larger body applications must be approved by Isuzu Commercial Trucks of America Application Engineering. In the West Coast call 1-562-229-5314 and in the
East Coast call 1-770-740-1620 x 262.
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Definitions
Rear Frame Height:
A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line
through the centerline of the rear axle at design load.
B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires.
C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width:
Overall width of the vehicle measured at the outermost surface of the rear tires.
D Centerline of axle to top of frame rail at design load. Rear Tire Clearance:
HH Minimum clearance between the rear axle and the ground-line.
Rear Tire Clearance: Dual Tire Spacing:
Minimum clearance required for tires and chain measured from the HW Distance between the centerlines of the tires in a set of dual tires.
E top of the frame at the vehicle centerline of the rear axle, when rear KW Tire Bounce Clearance:
wheels on one side ride over a high spot. Minimum distance required for tire bounce as measured from the centerline of the
rear axle and the top of the rear tire when one wheel rides over a high spot.
Rear Frame Height: Track Dual Rear Wheel Vehicle:
CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line.
ground-line through the centerline of the rear axle at curb position.
Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Tire Chart for values.
NOTE: Track and overall width may vary with optional equipment.
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Tire
Tire and Disc Wheel Chart
Tire Load Limit and Cold Inflation Pressures Maximum Tire Load Limits
Tire Size Single Dual Front Rear GVWR (Lb.)
Lb. PSI Lb. PSI 2 Single 4 Dual
225/70R 19.5F 3,640 95 3,415 95 7,280 13,660 19,500
Tire Radius
Tire Size GVWR (Lb.) Loaded Unloaded Tire Section Tire Clearance Design Rim
Front Rear Front Rear Width Width
225/70R 19.5F 19,500 14.91 14.96 16.00 16.00 8.7 1.3 6.0
Disc Wheel
Nut/Stud
Wheel Size Bolt Holes Bolt Circle Ft./Rr. Nut Rear Stud Torque Inner Circle Outside Disc Rim Type Material Mfg.
Dia. Size* Size* Specs. Offset Thickeness
1.6142 0.8268
19.5 x 6.00 K 6 JIS 8.75 (41 mm) (21 mm) 325 ft.-lb. 6.46 5.0 0.35 150 DC Steel
BUD HEX SQUARE (440 N•m) TOPY
*O.D. Wrench Sizes
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Trans. Opening Bolt A B C D E F H PTO Drive Gear Ratio of PTO Drv. No. of Pitch Helix Max. Output Torque
Location Pattern Location Gear Spd. to Eng. Spd. Teeth Angle
Aisin 1) Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 5.16 PTO Gear 1:1 with turbine 69 N/A 00 134 lbs.-ft. @ 1,700 RPM
Opening Diagram
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Please refer to Introduction Section of book for antilock system cautions and wheelbase modification requirements.
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1. Disconnect battery.
2. Loosen hose from the tie downs. Remove caps from plate on rail.
4. Extend hose out from the driver side of the rail to body rail.
5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal (see figure 4).
8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame.
9. Secure the filler plate to the bottom of the body and check for leaks.
10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose.
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Dimensions:
B = 29.75 inches (756 mm)
C = 34.00 inches (863 mm)
D = 39.29 inches (998 mm)
E = 33.86 inches (860 mm)
F = 59.60 inches (1,514mm)
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Hose Modification for Various Width Bodies and fuel fill vent Orientation and Protection
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NPR/W3500, NPR HD/W4500 Gas Electrical
Symbols
Symbol Meaning Symbol Meaning Symbol Meaning
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Abbreviations
Abbreviation Definition Abbreviation Definition
3A/T 6-Speed Automatic Transmission IG Ignition
4A/T 4-Speed Automatic Transmission kW kilowatt
A/T Automatic Transmission LH Left hand
ABS Anti-lock brake system LO Low
APP Accelerator pedal position LWB Long wheelbase
ATF Automatic Transmission Fluid M/T Manual Transmission
AUTO Automatic M/V Magnetic valve
BRKT Bracket MAF Mass airflow
C/B Circuit breaker MIL Check engine light
CKP Crankshaft position OD Over drive
CMP Camshaft position OPT Option
COMB Combination PTO Power Take Off
CONT Control RH Right hand
D.R.L. Day time running light RR Rear
DC Direct current SCV Suction control valve
ECM Electronic control module ST Start
ECT Engine coolant temperature STD Standard
ECU Electronic control unit SW Switch
EGR Exhaust gas reticulation SWB Short wheelbase
EHCU Electronic and hydraulic control unit TCM Transmission control module
FL Fusible link V Volt
FRT Front VSV Vacuum switching valve
FT Fuel Temperature W Watt (S)
H/L Headlight W/ With
HI High W/O Without
IAT Intake air temperature W/S Weld splice
IC Integrated circuit WOT Wide-open throttle
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Wiring
Wire Color
All wires have color-coded insulation. Wires belonging to a system’s main harness will have a single color. Wires belonging to a system’s
sub-circuits will have a colored stripe. Striped wires use the following code to show wire size and colors.
Example: 0.5 G / R
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Abbreviations are used to indicate wire color within a circuit diagram. Refer to the following table.
Wire Size
The size of wire used in a circuit is determined by the amount of current (amperage), the length of the circuit, and the voltage drop allowed. The
following wire size and load capacity are specified by AWG (American Wire Gauge). (Nominal size means approximate cross sectional area.)
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B-52 J-7
B-244 J-6
J-11
B-53
B-54
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Fuse Location
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Fuse Chart
Fuse
No. Capacity Indication on Label Main Parts (Load)
F-1 25A RR P/WINDOW Rear Power Window Switch RH, Rear Power Window Switch LH
Rear Power Window Relay
F-2 — — —
F-3 10A ROOM LAMP, AUDIO Radio, Data Link Connector, Room Light
F-4 15A DOOR LOCK Door Lock Relay
F-5 — — —
F-6 25A P/WINDOW Front Power Window RH Switch, Front Power Window LH
Switch Power Window Relay
F-7 10A BACK UP LAMP Shift Lever Switch
F-8 25A WIPER Wiper Main Relay, Wiper High Low Relay, Key On Relay, Front
Wiper Motor, Front Washer Motor
F-9 10A H/LAMP LO (LH) Headlight LH, Headlight Low Relay, DRL Control Unit
F-10 10A LAMPS (BATT) DRL Relay, Headlight High Relay, Headlight Low Relay, Tail Relay
F-11 10A H/LAMP LO (RH) Headlight RH, Headlight Low Relay, DRL Control Unit
F-12 10A BRAKE LAMPS Stoplight Relay
F-13 10A STARTER PIM.B, P/N Start Relay
F-14 10A H/LAMP HI (LH) Headlight LH, Meter, Headlight High Relay
F-15 10A H/LAMP HI (RH) Headlight RH, Headlight High Relay
F-16 15A MIRROR HEATER Mirror Heater Switch, Blower Relay, Power Window Relay
F-17 10A IGNITION2 Rear Window Lock Switch
F-18 10A IGNITION1 Intermittent Relay, Vacuum Pump Relay
F-19 — — —
F-20 10A ECM Stoplight Switch, PIM. B, Cruise Main Switch ,TCM Relay
F-21 10A METER Key On Relay, P/N Start Relay, Vacuum Pump Relay, Meter,
Shift Lever Switch, Charge Relay, EHCU, Flasher Unit, DRL Relay
F-22 10A ECU (BATT) Check Miles Switch, TCM Relay, Meter, Power train Control Module, PIM.B
F-23 10A MIRROR —
F-24 15A AUDIO, ACCESSORIES Radio, Cigarette Lighter Relay, Power ACC Relay, PIM.A, PIM.B
F-25 15A HORN Horn Relay
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Tail Relay, Meter, Mirror Heater Switch, Blower Switch, Door Lock Switch,
F-28 10A ILLUMINATIONS Cruise Main Switch, Rear Dome Light Switch, Hazard Switch,
Check Miles Switch, Shift Lever Switch, Radio, Illumination Control Switch
F-33 20A PCM1 PCM Main Relay, Power train Control Module Ignition Coil 1, Ignition Coil 3,
Ignition Coil 5, Ignition Coil 7, Injector 1, Injector 3, Injector 5, Injector 7
F-34 20A PCM2 PCM Main Relay, Ignition Coil 2, Ignition Coil 4, Ignition Coil 6, Ignition Coil 8,
Injector 2, Injector 4, Injector 6, Injector 8
F-35 20A PCM3 PCM Main Relay, Front Heater O2 Sensor LH, Front Heater O2 Sensor RH,
Rear Heater O2 Sensor LH, Rear Heater O2 Sensor RH, Canister Purge Solenoid
F-36 15A POWER SOURCE Rear Dome Light Relay, Front Manufacture Connector, Rear Manufacture Connector
F-37 20A CONDENSER FAN Condenser Fan Relay
F-38 10A AIR CONDITIONER Magnetic Clutch Relay
F-39
(D-1) 20A CIGAR Cigarette Lighter Relay, Cigarette Lighter
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F-40
(D-2) 10A ACCESSORIES
SOCKET Power ACC Relay, ACC Socket
F-41
(D-3) 20A POWER SOURCE Power Source
Relay Chart
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Relay Locations
1, 2
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Tailights
The connectors that match the end
of frame tail and stop lamp harness
can now be ordered through
Isuzu & W-Series dealers.
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Radio Circuits
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Abbreviations
Abbreviation Definition Abbreviation Definition
6A/T 6-speed automatic transmission IG Ignition
4A/T 4-speed automatic transmission kW Kilowatt
A/T Automatic transmission LH Left Hand
ABS Anti-lock brake system LWB Long Wheelbase
APP Accelerator pedal position M/T Manual Transmission
ATF Automatic transmission fluid M/V Magnetic valve
AUTO Automatic MAF Mass air flow
BRKT Bracket MIL Check engine light
C/B Circuit breaker OD Overdrive
CKP Crankshaft position OPT Option
CMP Camshaft position RWAL Rear Wheel Anti-lock Brake System
COMB Combination PTO Power Take Off
CONT Control RH Right Hand
D.R.L. Day time running light RR Rear
DC Direct Current SCV Suction control valve
ECM Electronic control module ST Start
ECT Engine coolant temperature STD Standard
ECU Electronic control unit SW Switch
EGR Exhaust gas reticulation SWB Short Wheelbase
EHCU Electronic and hydraulic control unit TCM Transmission Control Module
FL Fusible link V Volt
FRT Front VSV Vacuum Switching Valve
FT Fuel temperature W Watt (S)
H/L Headlight W/ With
HI High W/O Without
IAT Intake air temperature W/S Weld splice
IC Integrated circuit WOT Wide-open Throttle
LO Low
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Wiring
Wire Color
All wires have color-coded insulation. Wires belonging to a system’s main harness will have a single color. Wires belonging to a system’s
sub-circuits will have a colored stripe. Striped wires use the following code to show wire size and colors.
Example: 0.5 G / R
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Abbreviations are used to indicate wire color within a circuit diagram. Refer to the following table.
Wire Size
The size of wire used in a circuit is determined by the amount of current (amperage), the length of the circuit, and the voltage drop allowed. The
following wire size and load capacity are specified by AWG (American Wire Gauge). (Nominal size means approximate cross sectional area.)
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Fuse Location
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Fuse Box
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Relay Location
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Relay Location
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Taillights
The connectors that match the end
of frame tail and stop lamp harness
can now be ordered through
Isuzu & W-Series dealers.
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Radio Circuits
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PTO SECTION FOR THE 4HK1-TC ENGINE
System Operating Instructions
PTO – Power Take Off Option – Electrical Requirements
SECTION OUTLINE
• Overview
• Vocation/Modes
• Factory Installed Equipment
• Upfitter Installed Equipment
• ECM Programmable PTO Functions
• Operation *
Stationary Preset Mode
Stationary Variable Mode
Mobile Variable Mode
• Appendix
Illustrations:
Location of PTO Switch and Indicator ILL#1
Location of Cruise Control Switches ILL#2
PTO Switch Connector and Harness ILL#3
PTO Switch Harness ILL#4
PTO Harness Connector H104 (8 pin) ILL#5
PTO Harness Connector H105 (10 pin) ILL#6
Power Take-Off Switch and Vehicle Speed Sensor 2 ILL#7
Resume, PTO Disable and Set Switch ILL#8
Brake clutch override, IP disable, Set A and B Switches ILL#9
Power Take-Off Enable Relay ILL#10
Power Take-Off Throttle Sensor ILL#11
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OVERVIEW
A Power Take Off (PTO) is a gearbox or mechanical device used to transmit mechanical power from the power train, through gears or a transmission, to another
mechanical or hydraulic device. Examples of PTO applications are: salt spreaders; refuse equipment, plows, pumps, drills, lifts, wrecker equipment,
dump bodies, fire/rescue equipment.
PTO Advantages
• PTO’s are inexpensive, convenient, safe and reliable.
• PTO’s bolt on to the transmission, engine, transfer case or can be incorporated into the accessory belt drive system.
• PTO’s eliminate the need for a complex array of levers, controllers, electric motors, which would be required to duplicate the operation of a PTO.
Scope
The Upfitter or Specialty Vehicle Assembler installs the PTO unit itself on the vehicle. The (PTO) option described here is the necessary electrical and electronic
content to control the PTO unit. Responsibility for proper and safe operation remains with the Upfitter.
(PTO) Option
The (PTO) option allows for increased engine speed for increased power to the PTO unit.
VOCATION/MODES
The primary difference in PTO operation is whether the vehicle is stationary or moving. Stationary operation can have either preset or variable PTO speeds.
Some examples of modes and vocations are:
• Stationary Preset – Two preset high idle speeds – Refuse & Wrecker equipment, Fire truck pumpers
• Stationary Variable – Variable high idle speeds – Drills, Lifts
• Mobile Variable – Allows variable PTO speeds while the vehicle is moving – Salt Spreaders, Plows, Street Cleaners
Note: The ECM (ENGINE CONTROL MODULE) can be programmed to only one of these modes at any given time.
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FACTORY INSTALLED EQUIPMENT
The factory PTO option includes the PTO Enable Switch, PTO Engine Speed Control switch,Cruise Control Switches, and upfitter connectors to allow optional
upfitter installed switches, and wiring.
OPERATION
Description
The PTO controls allow the user to raise the engine speed through the use of designated switches and ECM programming.
The ECM can be programmed to one of the following three PTO modes:
• Stationary Preset mode – Two preset high idle speeds. Vehicle must be stationary. (Factory standard mode)
• Stationary Variable mode – Variable high idle speeds. Vehicle must be stationary.
• Mobile Variable mode – Allows variable PTO speeds while vehicle is moving.
These PTO modes are addressed separately and in detail in the following pages.
Please note the ECM can be programmed to only one of the three modes at any one time.
PTO Switches
Vehicles ordered with the PTO switch option (IL9, IL10) come with instrument panel mounted switches, which allows the user to enable the PTO function and
control the engine speed. These PTO switches are located on the left of the dash as shown in the illustration 1. An indicator in the PTO enabled switch
illuminates to show PTO mode is active. The engine speed can then be changed with either the PTO Engine Speed Control switch or upfitter installed remote
PTO switches. Cruise Control Switches come standard with the 2008 GM/Isuzu W and N series chassis as shown in illustration 2. The following chart illustrates
switch operation.
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PTO SWITCH DESCRIPTION
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STATIONARY PRESET MODE
Description
The Stationary Preset Mode allows the user to select from two high idle speeds that are programmed in the ECM. The user can toggle between 2 preset speeds
using the PTO Engine Speed Control switch, Cruise Control switch, Cruise Resume/Set switch, or the Remote PTO Switches.
How To Operate
Prior to enabling the Stationary Preset PTO Mode, the following conditions must be met:
1. Engine must be running.
2. Transmission must be in Park or Neutral.
3. Vehicle speed must be less than 5 mph.
4. Brake or Clutch must not be depressed.
When the above conditions are met, the operator can activate the Stationary Preset PTO mode by the following sequence:
Upon Completion of the above steps, the PTO Stationary Preset Mode will be enabled and the engine speed will increase to the PTO Standby speed. Toggling
the PTO Engine Speed Control Switch or Cruise Resume/Set switch will cause the engine RPM to change from PTO standby speed to either the PTO Preset #1
or PTO Preset #2 speed depending on which switch is pressed first.
Any changes in the above conditions, including depressing the brake or clutch pedals or shifting an automatic transmission in gear, will disable the Stationary
Preset Mode causing the engine to return to normal base idle speed.
Note:
4HK1-TC engine will be governed to PTO Max engine speed with throttle activation. Engine speed will return to pre-activation value after the pedal is released.
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The factory preset and minimum and maximum programmable speeds are shown in the table below for the 4HK1-TC engine:
Note: The values shown in the above chart are accurate at the time of publication, but may change in time for various reasons including running changes made
to the ECM, ECM software calibrations, or Isuzu Diagnostic Service System (IDSS) software.
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STATIONARY VARIABLE MODE
Description
The Stationary Variable Mode allows the user to retain the engine speed at a desired value through the use of the accelerator pedal and PTO Engine Speed
Control switch or Cruise Resume/Set switch. The engine speed must be greater than the PTO standby speed and lower than the maximum engine speed.
How To Operate
Prior to enabling the Stationary Variable PTO Mode, the following conditions must be met:
1. Engine must be running
2. Transmission must be in Park or Neutral
3. Vehicle speed must be less than 5 mph
4. Brake or Clutch must not be depressed.
When the above conditions are met, the operator can activate the Stationary Variable PTO Mode by the following sequence:
The PTO Engine Speed Control switch or the Cruise Resume/Set switch can then be used to adjust the engine speed within the Maximum and Minimum RPM
values shown in the following table. The adjustment increments are 25 RPM. This function will also work with the remote switches.
Any changes in the above conditions, including depressing the brake or clutch pedals or shifting an automatic transmission in gear, will disable the Stationary
Variable Mode causing the engine to return to normal base idle.
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STATIONARY VARIABLE MODE (con’t)
ADDITIONAL FUNCTIONS
Default Allowable
Parameter Units
setting Range
PTO ENGAGE RELAY YES/NO NO
PTO MAX ENGAGE SPEED RPM 1050 750-1500
PTO FEEDBACK YES/NO NO
PTO ENGINE SHUTDOWN YES/NO NO
PTO SHUTDOWN TIME DELAY SECONDS 0 0-255
PTO BRAKE/CLUTCH OVERRIDE YES/NO NO
PTO TAP DOWN RATE RPM 25 25-500
PTO TAP UP RATE RPM 25 25-500
PTO ACCEL RATE RPM/128ms 20 25-500
PTO REMOTE SET/RESUME SWITCH YES/NO NO
PTO REMOTE THROTTLE YES/NO NO
PTO REMOTE THROTTLE MAX ENGINE SPEED RPM 2100 0-2300
PTO REMOTE THROTTLE 0% VOLTS 0.85 0.25-4.75
PTO REMOTE THROTTLE 100% VOLTS 3.75 0.25-4.75
Note: The values shown in the above chart are accurate at the time of publication, but may change in time for various reasons including running changes made
to the ECM, ECM software calibrations, or Isuzu Diagnostic Service System (IDSS) software.
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MOBILE VARIABLE MODE
Description
The PTO Mobile Variable Mode allows the driver to maintain a desired engine speed (not vehicle speed) while the vehicle is moving. This feature is available with
both manual and automatic transmissions. The engine speed must be greater than the PTO Standby Speed and lower than the PTO Maximum Engine Speed.
The Vehicle speed must be less than the Maximum Vehicle Speed Value.
How To Operate
To engage the PTO Mobile Variable Mode, the following conditions must be met in the following order:
1. Engine must be running
2. Transmission must be in gear.
3. Vehicle speed must be less than the Maximum Vehicle Speed
4. Brake or Clutch must not be depressed.
5. PTO Enable Switch must be set to the On position
When the above conditions are met, the operator can activate the Mobile Variable mode by the following sequence:
7. Depress the Accelerator Pedal to obtain the desired engine speed.
8. Press the PTO Engine Speed Control switch (-) side or set the Cruise Resume/Set switch to Set position to hold engine at the desired high idle speed.
The PTO Engine Speed Control switch or the Cruise Resume/Set switch can then be used to adjust the engine speed within the Maximum
and Minimum RPM values shown in the Engine calibration table. The adjustment increments are 25 RPM
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MOBILE VARIABLE MODE (con’t)
ADDITIONAL FUNCTIONS
Default Allowable
Parameter Units
setting Range
PTO ENGAGE RELAY YES/NO NO
PTO MAX ENGAGE SPEED RPM 1050 750-1500
PTO FEEDBACK YES/NO NO
PTO ENGINE SHUTDOWN YES/NO NO
PTO SHUTDOWN TIME DELAY SECONDS 0 0-255
PTO BRAKE/CLUTCH OVERRIDE YES/NO NO
PTO TAP DOWN RATE RPM 25 25-500
PTO TAP UP RATE RPM 25 25-500
PTO ACCEL RATE RPM/128ms 20 25-500
PTO REMOTE SET/RESUME SWITCH YES/NO NO
PTO REMOTE THROTTLE YES/NO NO
PTO REMOTE THROTTLE MAX ENGINE SPEED RPM 2100 0-2300
PTO REMOTE THROTTLE 0% VOLTS 0.85 0.25-4.75
PTO REMOTE THROTTLE 100% VOLTS 3.75 0.25-4.75
Note: The values shown in the above chart are accurate at the time of publication, but may change in time for various reasons including running changes made
to the ECM, ECM software calibrations, or Isuzu Diagnostic Service System (IDSS) software.
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PTO ENGINE SHUTDOWN
Description
The PTO option includes provisions for PTO engine shutdown. This feature allows the operator to stop the engine while in PTO mode with an aftermarket
installed switch. If the truck is not in PTO mode, pressing the switch will have no effect on engine operation. The PTO Upfitter Connector (located on the left hand
frame rail) has been provided for installation of remote PTO controls. The upfitter can access the PTO engine fault shutdown circuits through this connector.
The upfitter must provide the mating connector, wiring, and remote switches. To install this feature see the upfitter provisions schematics. Important. If the PTO
engine shutdown feature is to be used, it must be turned on in the ECM. If this feature is not turned on it will have no effect engine operation.
The above parameters can be reprogrammed with a Isuzu Diagnostic Service System (IDSS) Diagnostic tool or the service programming system.
REMOTE OPERATION
Description
The PTO Upfitter Connector (located on the left hand frame rail) has been provided for installation of remote PTO idle controls. The upfitter can access the PTO
high idle circuits through this connector. The upfitter must provide the mating connector, wiring, and remote switches shown on the Upfitter (PTO) Connector.
Two momentary switches are required to duplicate the operation of the PTO Engine Speed Control Switch or the Cruise Resume/Set switch in the cab.
The schematics showing the switches can be found on the following diagrams. The PTO UP switch duplicates c + c side of PTO Engine Speed Control switch
or the Cruise Resume operation.The PTO Down switch duplicates c - c side of the PTO Engine Speed Control switch or the Cruise Set operation.
Please note that the PTO high idle must still be enabled from the PTO enable switch in the cab or the remote PTO enable switch.
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Location of PTO Switch and Indicator
Illustration #1
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Location of Cruise Control Switches
Illustration #2
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PTO Switch Connector and Harness
Illustration #3
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PTO Switch Harness 1 & 2
Illustration #4
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PTO HARNESS CONNECTOR
H104
Illustration #5
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PTO HARNESS CONNECTOR
H105
Illustration #6
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Power Take-Off Switch and Vehicle Speed Sensor2
Illustration #7
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PTO Resume, Disable and Set Switch
Illustration #8
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Brake clutch override, IP disable, Set a and b switches
Illustration #9
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Power Take-Off Enable Relay
Illustration #10
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Power Take-Off Throttle Sensor
Illustration #11
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Low Speed Applications for N and W Series Chassis
Any low speed vehicle applications using the Aisin Transmission such as sweeper, highway striping and road side mowing airport service must adhere to the
following guidelines in order to prevent the over heating of the automatic transmission fluid.
Factory Recommendation:
Select Range 1 for low speed operations under 11 mph, (18km/h).
Select Range 2 for low speed operation under 22 mph, (36km/h).
Affected Vehicle:
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This bulletin is being revised to further clarify DPF Regeneration Modes. Please disgard Information Bulletin IB07-L-002.
Service Information:
The quick reference information below is provided to assist dealer personnel in better understanding the DPF Emission System Operation. Additional
information regarding DPF Regeneration can be found in the Owner’s Manual, Service manual, the driver side sunvisor label or on the Emission System Operation
video (available in vehicles delivered from Port after 09/01/20x07). For your convenience, this video may be downloaded from the following websites;
WWW.ISUZUTRUCKSERVICE.COM, WWW.ISUZUCV.COM, WWW.ISUZUCV.ORG and WWW.ISUZUDIESELENGINE.COM
Green DPF Lamp: When illuminated this lamp indicates the DPF is actively regenerating.
No action is required.
Amber/Orange or Red DPF Lamp: (One indicator with two possible colors)
When this lamp is Amber/Orange the DPF filter is dirty. Filter regeneration is necessary
or at this time. When driving continues without regeneration, this DFP lamp will change from
Amber/Orange to RED. Continuing to drive the vehicle with the red lamp illuminated can
cause filter damage.
Malfunction Indicator Lamp ( MIL): This lamp indicates a possible concern with engine
and/ or emissions performance.
Reduced Engine Power Lamp: (F/T/C-Series Only) This lamp indicates when a
noticeable change in vehicle performance may occur.
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N/W-Series F/T-Series C-Series
DPF Switch
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Mode Name Description
• Set the parking brake, engine running and transmission in Park or Neutral Position
• Press DPF switch
Emergency Regeneration Switched • Green DPF lamp comes “ON”
Option 2 • Engine RPM increases and exhaust brake activation for about 20 minutes
• If this is interrupted must press DPF switch to restart process
Important: Once Emergency Switched or Selectable Regeneration Modes have been selected the Automatic and Emergency Running Modes are no longer
available. Automatic and Emergency running modes will become available after Switched or Selectable DPF regeneration is completed.
Note: For quickest possible regeneration, be sure the vehicle is at operating temperature before performing selectable
regeneration.
• Engine running and in “Park” Position
• Parking brake is applied
Selectable • Press and hold the DPF switch until the amber DPF lamp turns “ON”
Regeneration • If amber DPF lamp goes “Off”, regeneration is not necessary.
• If the amber DPF lamp stays on “ON”, it means that regeneration is possible
• Press the DPF switch again to start regeneration
• The green DPF lamp and then the amber DPF lamp will turn “ON” indicating that regeneration is taking place. This will
take about 20 minutes.
• Engine RPM will increase and the exhaust brake will activate
Caution: The following actions will interrupt the stationary type regeneration. Failure to restart and complete the regeneration cycle will result in filter clogging.
• Applying the accelerator pedal.
• Shifting into gear (with Automatic Transmission)
• Pressing the clutch pedal (Manual Transmission)
• Engine speed increases.
This condition should only be diagnosed and repaired by an Isuzu trained technician.
• MIL lamp is on, vehicle speed is reduced
Limp Home Mode • Technician diagnosis required
• IDSS induced regeneration (fast or slow) based on diagnosis
• Slow process takes 2 hours
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F/T/C-Series Regeneration Modes
• Set the parking brake, engine running and transmission in Park or Neutral Position
• Press DPF switch
Switched • Green DPF lamp comes “ON”
Option 2 • Engine RPM increases and exhaust brake activation for about 20 minutes
• If this is interrupted must press DPF switch to restart process
Important: Once Emergency Switched or Selectable Regeneration Modes have been selected the Automatic and Emergency Running Modes are no longer
available. Automatic and Emergency running modes will become available after Switched or Selectable DPF regeneration is completed.
Note: For quickest possible regeneration be sure the vehicle is at operating temperature before performing selectable
regeneration.
• Engine running and in “Park” Position
• Parking brake is applied
Selectable • Press and hold the DPF switch until the DPF switch jewel lamp comes “ON”
Regeneration • If the jewel lamp goes “Off”, regeneration is not necessary.
• If the jewel lamp blinks, it means that regeneration is possible
• Press the DPF switch again to start regeneration
• The orange DPF lamp, green DPF lamp and then the jewel lamp will turn “ON” indicating that regeneration is taking place.
This will take about 20 minutes.
• Engine RPM will increase and the exhaust brake will activate
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Mode Name Description
Caution: The following actions will interrupt the stationary type regeneration. Failure to restart and complete the regeneration cycle will result in filter clogging.
• Applying the accelerator pedal.
• Shifting into gear (with Automatic Transmission)
• Pressing the clutch pedal (Manual Transmission)
• Engine speed increases
• Releasing the parking brake
This condition should only be diagnosed and repaired by an Isuzu trained technician.
• MIL and/ or Reduced Engine Power Lamp is “ON”, vehicle speed is reduced
Limp Home Mode • Technician diagnosis required
• IDSS induced regeneration (fast or slow) based on diagnosis
• Slow process takes 2 hours
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Diesel Air Cleaner Canister
07/08/09 M/Y
Air Cleaner
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368
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MECHANICAL SPECIFICATIONS
Engine Horsepower and Torque Chart
The following table presents Net versus Gross Horsepower and Torque ratings for Isuzu/W-Series Truck Product Engines:
ENGINE APPLICATION TRANSMISSION NET HP(1) NET TORQUE(1) GROSS HP(1) GROSS TORQUE(1)
4HK1-TC HP/RPM LBS.-FT./RPM HP/RPM LBS.-FT./RPM
Isuzu NPR HD/W4500 Manual 169/2400 379/1850 175/2400 387/1850
NQR/W5500
NRR/W5500 HD
MECHANICAL SPECIFICATIONS
GVW/GCWR Chart
The following table presents GCWR Ratings ratings for Isuzu/W-Series Truck Product:
1 The NPR HD, NQR, NRR/W3500, W4500, W5500 HD are not approved for Hot Shot applications.
PAGE
370
PAGE
371
NPR-HD/W4500,NQR/W5500, NRR/W5500 HD
Diesel Manual Transmission Chassis Weight Supplement
NPR-HD/W4500 NPR-HD/W4500
In-Frame Tank 14,500-lb. GVWR Manual Transmission Model Side Mounted Tank 14,500-lb. GVWR Manual Transmission Model
Chassis Curb and Maximum Payload Weights Chassis Curb and Maximum Payload Weights
Model WB+ Unit Front Rear Total Payload Model WB+ Unit Front Rear Total Payload
NE1 109 in. lb. 3611 1974 5585 8915 NE1 109 in. lb. 3889 1743 5632 8868
NE2 132.5 in. lb. 3712 1948 5660 8840 NE2 132.5 in. lb. 3950 1758 5708 8792
NE3 150 in. lb. 3765 1932 5697 8803 NE3 150 in. lb. 3990 1769 5759 8741
NE4 176 in. lb. 3834 1918 5752 8748 NE4 176 in. lb. 4037 1783 5820 8680
NQR/W5500 NQR/W5500
In-Frame Tank 17,950-lb. GVWR Manual Transmission Model Side Mounted Tank 17,950-lb. GVWR Manual Transmission Model
Chassis Curb and Maximum Payload Weights Chassis Curb and Maximum Payload Weights
Model WB+ Unit Front Rear Total Payload Model WB+ Unit Front Rear Total Payload
NQ1 109 in. lb. 3843 2287 6130 11820 NQ1 109 in. lb. 4074 2004 6078 11872
NQ2 132.5 in. lb. 3970 2236 6206 11744 NQ2 132.5 in. lb. 4156 1998 6154 11796
NQ3 150 in. lb. 4036 2206 6242 11708 NQ3 150 in. lb. 4208 1997 6205 11745
NQ4 176 in. lb. 4121 2176 6297 11653 NQ4 176 in. lb. 4269 1997 6266 11684
NRR/W5500-HD NRR/W5500-HD
In-Frame Tank 19,500-lb. GVWR Manual Transmission Model Side Mounted Tank 19,500-lb. GVWR Manual Transmission Model
Chassis Curb and Maximum Payload Weights Chassis Curb and Maximum Payload Weights
Model WB+ Unit Front Rear Total Payload Model WB+ Unit Front Rear Total Payload
NT1 109 in. lb. 3904 2289 6193 13307 NT1 109 in. lb. 4138 2005 6143 13357
NT2 132.5 in. lb. 4028 2240 6268 13232 NT2 132.5 in. lb. 4217 2002 6219 13281
NT3 150 in. lb. 4093 2212 6305 13195 NT3 150 in. lb. 4266 2003 6269 13231
NT4 176 in. lb. 4032 2382 6414 13086 NT4 176 in. lb. 4326 2005 6331 13169
PAGE
372
NPR-HD/W4500,NQR/W5500, NRR/W5500 HD
Diesel Manual Transmission Frame and Crossmember Specifications
PAGE
373
NPR-HD/W4500,NQR/W5500, NRR/W5500 HD
Diesel Manual Transmission PTO Location, Drive Gear and Opening Information
PAGE
374
NPR-HD/W4500,NQR/W5500, NRR/W5500 HD
Diesel Manual Transmission PTO Location, Drive Gear and Opening Information
Opening Bolt PTO Drive Gear Ratio of PTO Drv. Gear No. of Helix
Trans. Location Pattern A B C D E F H Location Spd. to Eng. Spd. Teeth Pitch Angle Max. Output Torque
MZZ 6U Left (Dr 1) 11.6 37.57 5.2 12.8 7.7 2.5º 3.7 Countershaft 25/46=.543 37 3 25º 180 lbs.-ft.@1,000 RPM
PAGE
375
NPR-HD/W4500,NQR/W5500, NRR/W5500 HD
Diesel Manual Transmission Body Builder Weight Information Chart
PAGE
376
NPR-HD/W4500,NQR/W5500, NRR/W5500 HD
Diesel Manual Transmission Center of Gravity
The center of gravity of the completed vehicle with a full load should not exceed 63
inches above ground level for the 14,500 lb., 17,950 lb., and 19,500 lb. GVWR, and
must be located horizontally between the centerlines of the front and rear axles.
NOTE: The maximum dimensions for a body installed on the NPR-HD/W4500, NQR/W5500, NRR/W5500 HD are 96 inches wide (outside) by 90 inches high (inside). Any larger body
applications must be approved by ICTA Application Engineering. In the West Coast call 1-562-229-5314 and in the East Coast call 1-678-240-9818.
PAGE
377
NPR-HD/W4500,NQR/W5500, NRR/W5500 HD
Diesel Manual Transmission Propeller Shaft
Plane View Side View
A B C D
WHEELBASE MANUAL TRANS. MANUAL TRANS. MANUAL TRANS. MANUAL TRANS.
109 in. – 3.1º – 8.1º
132.5 in. 0º 3.1º 2.5º 2.5º
150 in. 0º 3.1º 0º 5.3º
176 in. 0º 2.3º 0.3º 2.0º
PAGE
378
NPR-HD/W4500,NQR/W5500, NRR/W5500 HD
Diesel Manual Transmission Propeller Shaft
No. of Shafts 1 2 2 2
Shaft #1 O.D. 3.54 3.54 3.54 3.54
Thickness 0.126 0.126 0.126 0.126
Length 39.9 27.0 44.4 53.8
Type B A A A
Shaft #2 O.D. N/A 3.54 3.54 3.54
Thickness N/A 0.126 0.126 0.126
Length N/A 36.2 36.4 53.0
Type N/A B B B
PAGE
DOCUMENT FOR INCOMPLETE VEHICLE
DO NOT REMOVE
THIS DOCUMENT MUST REMAIN
WITH THIS VEHICLE UNTIL IT IS
CERTIFIED AS A COMPLETED VEHICLE.
PLACE
LABEL
HERE
This document is furnished as required by the Canada Motor Vehicle Safety Act and Federal Motor Vehicle Safety Regulations (FMVSR) to aid intermediate and final stage
manufacturers in their determination of conformity of the completed vehicle with applicable Canada Motor Vehicle Safety Standards (CMVSS), Federal Motor Vehicle Safety
Standards (FMVSS), Canadian On-Road Vehicle and Engine Emission Regulations and Canada Interference Causing Equipment Standard – ICES-002. Also included
are instructions which must be followed in order to assure that Environmental Protection Agency (EPA) and California emission certification requirements are met.
This document is not a substitute for knowledge and understanding of the requirements of the Canada Motor Vehicle Safety Act, Federal Motor Vehicle Safety Regulations
(FMVSR); or applicable Canada Motor Vehicle Safety Standards (CMVSS) and Federal Motor Vehicle Safety Standards (FMVSS). Intermediate and final stage manufacturers should
be familiar with the Regulations and Standards referred to above to be aware of their specific responsibilities.
Any manufacturer making alterations to this incomplete vehicle during the process of manufacturing the complete vehicle should be constantly vigilant to recognize all effects,
either direct or indirect, on other components, assemblies or systems caused by each such alteration. No alteration should be made to the incomplete vehicle that either directly
or indirectly results in any component, assembly or system being in nonconformance with any applicable Canada Motor Vehicle Safety Standard, Federal Motor Vehicle Safety
Standard or Emission Regulation.
The statements contained in this Incomplete Vehicle Document are accurate as of the date of manufacture of the Incomplete Vehicle and can be relied on by any intermediate and/
or final stage manufacturer as a basis for certification.
PAGE
INTRODUCTION
This document contains information relative to conformance of this incomplete vehicle with the following:
Part I – FEDERAL MOTOR VEHICLE SAFETY STANDARDS, CANADA MOTOR VEHICLE SAFETY STANDARDS, CANADIAN ON-ROAD VEHICLE AND ENGINE EMISSION
REGULATIONS, AND CANADA INTERFERENCE CAUSING EQUIPMENT STANDARD
Part II – U.S. ENVIRONMENTAL PROTECTION AGENCY AND STATE OF CALIFORNIA EMISSION REQUIREMENTS
PART 1
This section contains a list of Canada Motor Vehicle Safety Standard (CMVSS), Federal Motor Vehicle Safety Standards (FMVSS), Canadian On-Road Vehicle and Engine Emission
Regulations, and Canada Interference Causing Equipment Standard – ICES-002 followed by a section entitled “Statements Regarding Canada Motor Vehicle Safety Standards
(CMVSS), Federal Motor Vehicle Safety Standards (FMVSS), Canadian On-Road Vehicle and Engine Emission Regulations, and Canada Interference Causing Equipment Standard”.
An appropriate statement of applicability is made for each standard, and by vehicle model as it relates to the incomplete vehicle.
If supplemental technical information is required to support this document, go to the Body Builder website shown below, or
contact to following telephone information.
Telephone
East coast : 1-678-240-9818
West coast : 1-562-229-5314
PAGE
The identifiers TYPE 1, TYPE 2 or TYPE 3 prefix statements (of applicability) regarding Canada Motor Vehicle Safety Standards (CMVSS), and Federal Motor Vehicle Safety Standards (FMVSS).
“Examples” of these statements follow:
TYPE 1 A statement that the vehicle when completed will conform to the standard if no alterations are made in identified components of the incomplete vehicle. EXAMPLE: This vehicle
when complete will conform to CMVSS 104 and FMVSS No. 104, Windshield Wiping and Washing Systems, if no alterations are made in the windshield wiper components.
TYPE 2 A statement of specific conditions of final manufacture under which the manufacturer specifies that the completed vehicle will conform to the standard. EXAMPLE: This vehicle
when completed will conform to CMVSS 121 and FMVSS 121, Air Brake Systems, if it does not exceed any of the gross axle weight ratings, if the center of gravity at GVWR is not higher than
## feet above the ground, and if no alterations are made to any brake system component.
TYPE 3 A statement that conformity with the standard cannot be determined based upon the components supplied on the incomplete vehicle, and that the incomplete vehicle manufacturer
makes no representation to conformity with the standard.
In accordance with the requirements of Canada Motor Vehicle Safety Regulations, and Federal Motor Vehicle Safety Regulations Part 568.4, the following information is included on the label affixed to
the front cover of this document:
• the month and year the incomplete vehicle manufacturer performed its last manufacturing operation on the incomplete vehicle;
• the Gross Vehicle Weight Rating (GVWR) expressed in kg (lb.), intended for the vehicle when it is a completed vehicle;
• the Gross Axle Weight Rating (GAWR) expressed in kg (lb.), intended for each axle of the vehicle when it is a completed vehicle, listed in order from front to rear.
In addition, the final stage manufacturer is responsible under of Canada Motor Vehicle Safety Regulations, and Federal Motor Vehicle Safety Regulations Part 567.5, to place the GVWR and the GAWR
of each axle, on the Final Vehicle Certification Label. The regulation states that the appropriate rating “shall not be less than the sum of the Unloaded Vehicle Weight, rated cargo load, and 68 kg (150 lb.)
times the vehicle’s designed seating capacity”.
Unloaded Vehicle Weight means the weight of a vehicle with maximum capacity of all fluids necessary for operation of the vehicle, but without cargo or occupants.
During the completion of this vehicle, GVWR and GAWR may be affected in various ways, including but not limited to the following:
• The installation of a body or equipment that exceeds the rated capacities of the incomplete vehicle.
• The addition of designated seating positions that exceed the rated capacities of the incomplete vehicle.
• Alterations or substitution of any components such as axles, springs, tires, wheels, frames, steering and brake systems that may affect the rated capacities of the incomplete vehicle.
PAGE
PART I - CHART A
LIST OF CANADA MOTOR VEHICLE SAFETY STANDARDS (CMVSS),
FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS), CANADIAN ON-ROAD VEHICLE AND ENGINE
EMISSION REGULATIONS, AND CANADA INTERFERENCE CAUSING EQUIPMENT STANDARD, APPLICABLE TO
GASOLINE OR DIESEL – FUELED TRUCKS WITH A GVWR OF GREATER THAN 4536 kg. (10,000 lb.)
• TYPE 1, 2 or 3 numbers to the right hand side of the table above designate the appropriate paragraph in the CMVSS or FMVSS standards that follow.
PAGE
CANADA U.S. NPR NQR
TITLE NPR-HD NRR
W3500 W5500
W4500 W5500-HD
’ – On-Road Vehicle and Engine Emission Regulations 1, 3 1
’ – ICES-002 Canada interference causing equipment standard 1 1
• TYPE 1, 2 or 3 numbers to the right hand side of the table above designate the appropriate paragraph in the CMVSS or FMVSS standards that follow.
PAGE
Statements Regarding Canada Motor Vehicle Safety Standards (CMVSS),
Federal Motor Vehicle Safety Standards (FMVSS), Canadian On-Road
Vehicle and Engine Emission Regulations, and Canada Interference
Causing Equipment Standard.
TYPE 1 The following statement is applicable to all models of incomplete vehicles (unless otherwise noted on the cover of this document).
A. This incomplete vehicle, when completed, will conform to the above standards providing no alterations are made which affect the function, physical,
chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but not limited
to those listed below:
B. Final compliance with CMVSS 1106 is the responsibility of the final stage manufacturer for any modifications, or added material, components,
or systems.
PAGE
CMVSS 101 and FMVSS 101 – CONTROLS AND DISPLAYS
Applies to all models of incomplete vehicles contained in this book
with a 4536 kg. (10,000 lb.) GVWR or more
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book with a GVWR of more than 4536 kg.
(10,000 lb.) (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 101 and FMVSS 101 providing no alterations are made which affect this location,
identification, or illumination of the controls and displays identified below or the location, travel and type of seat. If the seat is installed by the final stage
manufacturer, the visibility and operation of the controls and displays listed below must meet the requirements of the standard:
If the intermediate or final stage manufacturer installs any of the above controls and displays, those controls and displays will also have to meet the
requirements of this standard.
PAGE
CMVSS 102 and FMVSS 102 – TRANSMISSION SHIFT LEVER SEQUENCE,
STARTER INTERLOCK AND TRANSMISSION BRAKING EFFECT
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all incomplete vehicle models contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 102 and FMVSS 102 providing no alterations are made which affect the function,
physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems
including but not limited to those listed below (if equipped):
Transmission control and identification system, including but not limited to:
PAGE
CMVSS 103 and FMVSS 103 – WINDSHIELD DEFROSTING AND DEFOGGING SYSTEMS
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 103 and FMVSS 103 providing no alterations are made which affect the function,
physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including
but not limited to those listed below (if equipped):
Windshield defrosting and defogging systems, including but not limited to:
Chassis and instrument panel wiring harness assembly
Defroster air distributor assembly (manifold)
Defroster air duct assembly
Defroster air hoses – manifold to nozzle
Defroster air to windshield outlet assembly (nozzle)
Defroster outlet to heater assembly adapter
Engine water outlet thermostat assembly
Heater & defroster assembly – including motor & blower
Heater & defroster control (mechanical)
Heater blower motor resistor assembly (blower speed control)
Heater & water hoses and hose assemblies
Heater water inlet valve control
Windshield assembly
PAGE
CMVSS 104 and FMVSS 104 – WINDSHIELD WIPING AND WASHER SYSTEMS
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 104 and FMVSS 104 providing no alterations are made which affect the function,
physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but
not limited to those listed below (if equipped):
Windshield defrosting and defogging systems, including but not limited to:
Chassis wiring harness Windshield wiper linkage assembly
Washer reservoir cap Windshield wiper and washer control
Water reservoir filler assembly Windshield wiper and washer motor and pump assembly
Windshield assembly Windshield washer fluid reservoir
Windshield wiper arm assembly Windshield washer system hoses
Windshield wiper blade assembly Windshield washer nozzle
PAGE
CMVSS 105 and FMVSS 105 – HYDRAULIC BRAKE SYSTEMS
Applies to all models of incomplete vehicles contained in this book
TYPE 2 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, if equipped with hydraulic brakes, when completed, will conform to CMVSS 105 and FMVSS 105 providing no alterations are
made which affect the function, physical or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or
systems identified below. In addition, the maximum vertical center of gravity specified below must not be exceeded at maximum GVWR and rated front
and rear GAWR.
Center of Gravity:
Maximum Center of Gravity
Application millimeter (inches) above ground
NPR/NPR-HD/W3500/W4500 Chassis-Cab 1600 mm (63”)
NQR/NRR/W5500/W5500-HD Chassis-Cab 1600 mm (63”)
PAGE
CMVSS 106 and FMVSS 106 – BRAKE HOSES
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all incomplete vehicle models contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 106 and FMVSS 106 providing no alterations are made which affect the function,
physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems
including but not limited to those listed below:
Hydrauric Air, and Vacuum Brake Hoses Brake Hose Assemblies – and Brake Hose
Hoses and hose end fittings End Fittings
Labeling requirements
PAGE
CMVSS 108 and FMVSS 108 – LAMPS, REFLECTIVE DEVICES
AND ASSOCIATED EQUIPMENT
Applies to all models of incomplete vehicles contained in this book
TYPE 2 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 106 and FMVSS 106 providing no alterations are made which affect the function, physical, chemical,
or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but not limited to those listed below:
This incomplete vehicle, when completed, will conform to CMVSS 108 and FMVSS 108 providing it is completed in accordance with the following specific conditions by
the final stage manufacturer:
1) Body width must be between 2.032 m (80”) and 2.438 m (96”). (2.184 m (86”) MIN Body Width For Crew Cab).
2) Each of these devices must be properly installed on the completed vehicle and meet all the requirements of CMVSS 108 and FMVSS 108:
a. The following devices, when provided, located and/or wired by ISUZU MOTORS meet the requirements of this standard.
Cab roof clearance and ID lamps (front)
Headlamps (Headlamps or Daytime running lamps)
Side marker lamp (Front)
Side reflex reflectors (front)
Turn signal flasher
Turn signal lamps (front)
Turn signal operating unit
Vehicle hazard warning signal operating unit
Vehicle hazard warning signal flasher
b. The following lamps and reflective devices are temporarily mounted on this incomplete vehicle as required for transportation. When relocating them, intermediate or
final stage manufacturers must refer to the Isuzu Body Builders Manual and assure conformance with the location, visibility, and operational requirements of CMVSS
108 and FMVSS 108.
License plate lamp
Rear combination lamps (tail lamps, stop lamps, turn signal lamps and back-up lamps)
Reflex reflectors (rear)
PAGE
(CMVSS 108 and FMVSS 108 – continued from previous page)
c. No part of the completed vehicle shall be installed so as to prevent any of the devices listed in (a) or (b) above from meeting their required photometric output at the
specified test points. If such interference exists, the applicable devices may have to be relocated or additional devices added to meet the requirements of CMVSS
108 and FMVSS 108:
Any CMVSS 108 and FMVSS 108 part shall not be painted.
d. The following devices are not installed on this incomplete vehicle or supplied by ISUZU MOTORS. When added by intermediate or final stage manufacturers, they
must also meet the requirements of CMVSS 108 and FMVSS 108:
e. The following additional devices must be installed on the van body and meet all requirements of this standard if the overall vehicle length is 9.1 m (30 feet) or greater.
3) No alterations (other than any relocation of Items in 2) b.) which may be necessary for conformance to CMVSS 108 and FMVSS 108 should be made which affect the
location, mounting surfaces, function, environment or visibility clearance of the above listed devices which have been installed on this incomplete vehicle.
PAGE
CMVSS 111 and FMVSS 111 – REARVIEW MIRRORS
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover of this
document).
This incomplete vehicle, when completed, will conform to FMVSS 111 providing no alterations or substitutions are made to the outside rearview mirrors,
the driver’s seat location is not altered, and the body is installed symmetrical about the vehicle centerline. The overall width should be no greater than;
Width Limit
Model millimeter (inches)
NPR/NPR-HD/W3500/W4500 2438 mm (96”)
NQR/NRR/W5500/W5500-HD 2438 mm (96”)
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 113 and FMVSS 113 providing no alterations are made which affect the function,
physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including
but not limited to those listed below:
PAGE
CMVSS 115 – VEHICLE IDENTIFICATION NUMBER
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 115 providing no alterations are made which affect the function, physical, chemical,
or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but not limited
to those listed below:
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when equipped with approved hydraulic brake fluid will conform to CMVSS 116 and FMVSS 116 providing no alterations are
made which affect the physical or chemical properties of the brake fluid.
PAGE
CMVSS 120 and FMVSS 120 – TIRE SELECTION AND RIMS FOR VEHICLES
OTHER THAN PASSENGER CARS
Applies to all models of incomplete vehicles contained in this book
TYPE 2 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 120 and FMVSS 120 providing:
A. No alterations are made which affect the function, physical or mechanical properties, environment, location or vital spatial clearances
of the components, assemblies or systems including but not limited to:
Wheels Tires
B. GVWR, GAWR front and rear weight ratings as listed on the incomplete vehicle label affixed to the front cover of this document
must not be exceeded.
C. The tire and wheel information shown on the incomplete vehicle label must be transferred to the final stage manufacturer’s Certification
label or Tire Information Label providing no equipment changes are made.
TYPE 3 The following statement is applicable to NPR/NPR-HD/W3500/W4500 and NQR/NRR/W5500/W5500-HD of incomplete vehicles contained in
this book (unless otherwise noted on the cover).
Conformity with CMVSS 121 and FMVSS 121 cannot be determined based upon the components supplied on the incomplete vehicle,
and ISUZU MOTORS makes no representation to the conformity with the standard.
PAGE
CMVSS 124 and FMVSS 124 – ACCELERATOR CONTROL SYSTEMS
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 124 and FMVSS 124 providing no alterations are made which affect the function,
physical chemical, or mechanical properties, environment, location, or vital spatial clearances of the components, assemblies or systems including but
not limited to those listed below:
{
Accelerator lever and supporting bracket assembly
DIESEL Accelerator cable, support brackets, and seals
VEHICLES Accelerator return spring(s)
Attachment to injection pump lever - pin, hole, or ball stud
Downshift switch
Idling control cable assembly
{
GASOLINE Accelerator pedal and attachments
VEHICLES Accelerator lever and supporting bracket assembly
Accelerator return spring(s)
PAGE
CMVSS 205 and FMVSS 205 – GLAZING MATERIALS
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 205 and FMVSS 205 providing no alterations are made which affect the function,
physical chemical, or mechanical properties, environment, location, or vital spatialclearances of the components, assemblies or systems including but
not limited to those listed below:
Final compliance with CMVSS 205 and FMVSS 205 is the responsibility of the final stage manufacturer for any modifications, or added material, parts,
components, or systems.
CMVSS 206 and FMVSS 206 – DOOR LOCKS AND DOOR RETENTION COMPONENTS
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover of this
document).
This incomplete vehicle, when completed, will conform to CMVSS 206 and FMVSS 206 providing no alterations are made which affect the function,
physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but
not limited to those listed below:
Door lock
Door latch
Door latch striker plate
Door hinge
Inside lock control linkage
Exterior door handles
If the intermediate or final stage manufacturer installs any additional doors, they must also meet the requirements of this standard.
PAGE
CMVSS 207 and FMVSS 207 – ANCHORAGE OF SEATS
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover of this
document).
This incomplete vehicle, when completed, will conform to CMVSS 207 and FMVSS 207 providing no alterations are made which affect the function,
physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but
not limited to those listed below:
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This vehicle, when completed, will conform to the seat belt provision sections of CMVSS 208 and FMVSS 208 providing no alterations are made which
affect the function, physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or
systems installed by Isuzu Motors including but not limited to the location or configuration of the designated seats/seating positions or to the number,
placement, installation or model number of the seat belt assemblies of this incomplete vehicle.
PAGE
CMVSS 209 and FMVSS 209 – SEAT BELT ASSEMBLIES
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
The seat belt assembly provided by ISUZU Motors when mounted to its original attachments locations, at any designated seating position,
will conform to CMVSS 209 and FMVSS 209 providing no alterations are made which affect the function, physical, chemical, or mechanical
properties environment, location or vital spatial clearances of the components, assemblies or systems including but not limited to those listed below:
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 210 and FMVSS 210 providing no alterations are made which affect the function,
physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including
but not limited to those listed below:
TYPE 3 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
Conformity with CMVSS 213.4 and FMVSS 213 cannot be determined based upon the components supplied on the incomplete vehicle, and
ISUZU Motors makes no representation to conformity with the standard.
PAGE
CMVSS 302 and FMVSS 302 – FLAMMABILITY OF INTERIOR MATERIALS
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to CMVSS 302 and FMVSS 302 providing no alterations are made which affect the function,
physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including
but not limited to those listed below, and installed by ISUZU Motors:
Seat assemblies
Seat cushions
Seat backs
Seat belts
Headlining
Arm rests
Compartment shelves
Head restraints
Floor coverings
Sun visors
Shades
Wheel housing covers
Engine compartment covers
Instrument panel
Console
All trim panels including door, front, rear and side panels
Any other interior materials, including padding and crash deployed elements that are designed to absorb energy on contact by occupants
in the event of a crash.
PAGE
ON-ROAD VEHICLE AND ENGINE EMISSION REGULATIONS
Applies to all models of incomplete vehicles contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles equipped with diesel engines and contained in this book
(unless otherwise noted on the cover).
This incomplete vehicle, when completed, will conform to the above standard providing no alterations are made which affect the function, physical,
chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including
but not limited to those listed below:
TYPE 2 The following statement is applicable to all models of incomplete vehicles contained in this book (unless otherwise noted on the cover).
This incomplete vehicle, when completed with the vertical exhaust system, will conform to the above standard providing it is completed by the final
stage manufacturer in accordance with the following specific conditions:
a. the incomplete vehicle manufacturer‘s vertical exhaust system kit is used, and
b. the vertical exhaust system kit is installed to the vehicle in accordance with the incomplete vehicle manufacturer‘s instructions
For more information on the kit and instructions, please call the telephone number shown on page 1.
TYPE 3 The following statement is applicable to all models of incomplete vehicles equipped with gasoline engines and contained in this book
(unless otherwise noted on the cover).
Conformity with On-Road Vehicle and Engine Emission Regulations cannot be determined based upon the components supplied on the incomplete
vehicle, and ISUZU Motors makes no representation to conformity with the standard.
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INTERFERENCE CAUSING EQUIPMENT STANDARD – ICES-002
Applies to all models of incomplete vehicles except vehicles equipped with diesel engines contained in this book
TYPE 1 The following statement is applicable to all models of incomplete vehicles except vehicles equipped with diesel engines
(unless otherwise noted on the cover of this document).
This incomplete vehicle, when completed, will conform to the above regulations providing no alterations are made which affect the function, physical,
chemical, or mechanical properties, environment, location or vital spatial clearances of the components, assemblies or systems including but not limited
to those listed below:
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PART 2
U.S. ENVIRONMENTAL PROTECTION AGENCY AND STATE OF CALIFORNIA EMISSION REQUIREMENTS AND ON-BOARD DIAGNOSTIC SYSTEM
(OBDII) REQUIREMENTS
To assure that EPA and California emission certificate requirements and OBDII requirements are met, this incomplete vehicle (except where noted) must be
completed in strict accordance with all instructions contained in this document, especially the following instructions which relate to:
* All Federal/California gasoline powered heavy duty vehicles will have an evaporative emission control system that is certified for a fuel tank capacity not to
exceed the amount shown on Vehicle Evaporative Emission Control Information Label. Persons wishing to add fuel tank capacity above the amount shown must
contact California Air Resources Board and/or submit a written statement to the EPA Administrator that the Hydrocarbon Storage System has been upgraded
according to the requirements of 40 CFR 86-095-35 (g) (2).
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2. Compliance with applicable fuel evaporative emission regulations will be maintained if no alterations are made to the fuel filler neck(s).
Compliance with applicable fuel evaporative emission regulations will be maintained if no alterations are made to change material or increase the size or
length of the following nonmetallic fuel and evaporative emission hoses.
(B) SPECIFICATION FOR FILL PIPES AND OPENINGS OF MOTOR VEHICLE FUEL TANKS
(APPLICABLE ONLY TO CALIFORNIA GASOLINE POWERED VEHICLES)
This incomplete vehicle, when completed, will conform to Title 13, California Administrative Code Chapter 3 Air Resources Board Subchapter 7,
“Specifications for Fill Pipes and Openings of Motor Vehicle Fuel Tanks”, if no alterations are made to the fuel filler neck(s).
(C) LABELS
The emission control related information labels and ultra low sulfur diesel fuel label that are permanently affixed are required by government regulation
and must not be obstructed from view or defaced so as to impair its visibility or legibility.
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N/W Series Vertical Exhaust
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NPR HD/W4500, NQR/W5500, Crew Cab Diesel
Specifications
Model NPR HD Diesel/W4500 Crew Cab NQR Diesel/W5500 Crew Cab
GVWR 14,500 lb 17,950 lbs.
WB 150 in, 176 in.
Engine Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel.
Model/Displacement 4HK1-TC/317 CID (5.19 liters)
HP (Gross) 205 HP @ 2,400 rpm
Torque (Gross) 441 lb-ft torque @ 1,850 rpm
Equipment Dry element air cleaner with vertical intake; 2 rows 569 square in. radiator; 7 blade 20.1 in diameter fan with viscous drive.
Cold weather starting device and an oil cooler. Engine oil level check switch and light. Engine warning system with audible
warning for low oil pressure, high coolant temperature, and low coolant level. Engine cruise control and engine idle up function.
Transmission Aisin A465 6 speed automatic transmission with fifth and sixth gear overdrive with lock up in
2nd, 3rd, 4th, 5th and 6th, PTO capability.
Steering Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column.
Front Axle Reverse Elliot “I”-Beam rated at 6,830 lbs.
Suspension Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers.
GAWR 5,360 lbs. 6,830 lbs.
Rear Axle Full-floating single speed with hypoid gearing rated at 14,550 lb.
Suspension Semi-elliptical steel alloy multi-leaf springs and shock absorbers.
GAWR 9,880 lbs. 12,980 lbs.
Wheels 16 x 6.0 6-hole disc wheels, painted white. 19.5 x 6.0
Tires 215/85R 16-E (10 pr) tubeless steel-belted radials, all-season front and rear. 225/70R-19.5E (12 ply)
Dual circuit vacuum assisted hydraulic service brakes with EBD (Electronic Brake Distribution) system for load proportioning of
Brakes the brake system front disc and self-adjust outboard mounted drum rear. The parking brake is a mechanical,
cable actuated, internal expanding drum type, transmission mounted. The exhaust brake is standard and is vacuum operated.
4 channel anti-lock brake system.
NOTE: These selected specifications are subject to change without notice.
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NPR HD/W4500 In-Frame Tank 14,500-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NG3 150.0 in. lb. 4,264 2,189 6,453 8,047
NG4 176.0 in. lb. 4,347 2,174 6,521 7,979
NPR HD/W4500 Side-Mounted Tank 14,500-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NG3 150.0 in. lb. 4,426 1,969 6,395 8,105
NG4 176.0 in. lb. 4,481 1,982 6,463 8,037
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NQR/W5500 In-Frame Tank 17,950-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NS3 150.0 in. lb. 4,422 2,447 6,869 11,081
NS4 176.0 in. lb. 4,499 2,434 6,933 11,017
NQR/W5500 Side-Mounted Tank 17,950-lb. GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
NS3 150.0 in. lb. 4,599 2,220 6,819 11,131
NS4 176.0 in. lb. 4,646 2,237 6,883 11,067
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Technical Notes:
Chassis Curb Weight includes standard equipment and fuel. Does not include driver, passenger, payload, body or special equipment.
Maximum Payload Weight is the allowed maximum for equipment, body, payload, driver and passengers and is calculated by subtracting
chassis curb weight from the GVWR.
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Frame Chart
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Center of Gravity
GVWR WB V H
in frame tank side tank
63
14,500
NOTE: The maximum dimensions for a body installed on the NPR-HD/W4500 are 102 inches wide (outside) by 90 inches high (inside). Any larger body
applications must be approved by Isuzu Commercial Trucks of America Application Engineering. In the West Coast call 1-562-229-5314 and in the
East Coast call 1-770-740-1620 X262.
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Center of Gravity
GVWR WB V H
in frame tank side tank
63
17,950
NOTE: The maximum dimensions for a body installed on the NQR/W5500 are 102 inches wide (outside) by 90 inches high (inside). Any larger
body applications must be approved by Isuzu Commercial Trucks of America Application Engineering. In the West Coast call 1-562-229-5314 and in the
East Coast call 1-770-740-1620 X262.
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Definitions
Rear Frame Height:
A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line
through the centerline of the rear axle at design load.
B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires.
C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width:
Overall width of the vehicle measured at the outermost surface of the rear tires.
D Centerline of axle to top of frame rail at design load. Rear Tire Clearance:
HH Minimum clearance between the rear axle and the ground-line.
Rear Tire Clearance: Dual Tire Spacing:
Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce
E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when
wheels on one side ride over a high spot. one wheel rides over a high spot.
Rear Frame Height: Track Dual Rear Wheel Vehicle:
CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line.
ground-line through the centerline of the rear axle at curb
position.
Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Tire Chart for values.
NOTE: Track and overall width may vary with optional equipment.
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Definitions
Rear Frame Height:
A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line
through the centerline of the rear axle at design load.
B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires.
C Centerline of axle to top of frame rail at curb position. EW Maximum Rear Width:
Overall width of the vehicle measured at the outermost surface of the rear tires.
D Centerline of axle to top of frame rail at design load. Rear Tire Clearance:
HH Minimum clearance between the rear axle and the ground-line.
Rear Tire Clearance: Dual Tire Spacing:
Minimum clearance required for tires and chain measured from the Distance between the centerlines of the minimum distance required for tire bounce
E top of the frame at the vehicle centerline of the rear axle, when rear HW as measured from the centerline of the rear axle and the top of the rear tire when
wheels on one side ride over a high spot. one wheel rides over a high spot.
Rear Frame Height: Track Dual Rear Wheel Vehicle:
CH Vertical distance between the normal top of frame rail and the CW Distance between the centerlines of the dual wheels measured at the ground-line.
ground-line through the centerline of the rear axle at curb
position.
Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Chart for values.
NOTE: Track and overall width may vary with optional equipment.
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Tire
Tire and Disc Wheel Chart NPR HD/W4500
Tire Load Limit and Cold Inflation Pressures Maximum Tire Load Limits
Tire Size Single Dual Front Rear GVWR (Lb.)
Lb. PSI Lb. PSI 2 Single 4 Dual
215/85R 16E 2,680 80 2,470 80 5,360 9,880 14,500
Tire Radius
Tire Size GVWR (Lb.) Loaded Unloaded Tire Section Tire Clearance Design Rim
Front Rear Front Rear Width Width
215/85R 16E 14,500 14.1 14.1 14.6 14.6 8.2 18 6.0
Disc Wheel
Nut/Stud
Wheel Size Bolt Holes Bolt Circle Ft./Rr. Nut Rear Stud Torque Inner Circle Outside Disc Rim Type Material Mfg.
Dia. Size* Size* Specs. Offset Thickeness
1.6142 0.8268
16.6 x 6 K 6 JIS 8.75 (41 mm) (21 mm) 289 ft.-lb. 6.46 5.0 0.39 50 DC Steel
BUD HEX SQUARE (392 N•m) TOPY
*O.D. Wrench Sizes
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Tire
Tire and Disc Wheel Chart NQR/W5500
Tire Load Limit and Cold Inflation Pressures Maximum Tire Load Limits
Tire Size Single Dual Front Rear GVWR (Lb.)
Lb. PSI Lb. PSI 2 Single 4 Dual
225/70R 19.5F 3,450 90 3,245 90 6,900 12,980 17,950
Tire Radius
Tire Size GVWR (Lb.) Loaded Unloaded Tire Section Tire Clearance Design Rim
Front Rear Front Rear Width Width
225/70R 19.5F 17,950 14.93 14.98 16 16 8.7 1.3 6.0
Disc Wheel
Nut/Stud
Wheel Size Bolt Holes Bolt Circle Ft./Rr. Nut Rear Stud Torque Inner Circle Outside Disc Rim Type Material Mfg.
Dia. Size* Size* Specs. Offset Thickeness
1.6142 0.8268
19.5 x 6.00 6 JIS 8.75 (41 mm) (21 mm) 325 ft.-lb. 6.46 5.0 0.35 150 DC Steel
BUD HEX SQUARE (440 N•m) TOPY
*O.D. Wrench Sizes
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NOTE: All driveline angles are at unloaded condition (curb position with typical cargo body).
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NOTE: All driveline angles are at unloaded condition (curb position with typical cargo body).
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Trans. Opening Bolt A B C D E F H PTO Drive Gear Ratio of PTO Drv. No. of Pitch Helix Max. Output Torque
Location Pattern Location Gear Spd. to Eng. Spd. Teeth Angle
Aisin 465 Left (Dr 2) 12.35 36.89 0 7.85 7.31 2.50 5.16 PTO Gear 1:1 with turbine 69 N/A 00 134 lbs.-ft. @ 1,700 RPM
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Opening Diagram
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Please refer to introduction section of book for antilock system cautions and wheelbase modification requirements.
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Please refer to introduction section of book for antilock system cautions and wheelbase modification requirements.
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1. Disconnect battery.
2. Loosen hose from the tie downs. Remove caps from plate on rail.
4. Extend hose out from the driver side of the rail to body rail.
5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal (see figure 4).
8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame.
9. Secure the filler plate to the bottom of the body and check for leaks.
10. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose.
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Dimensions:
B = 29.75 inches (756 mm)
C = 34.00 inches (863 mm)
D = 39.29 inches (998 mm)
E = 33.86 inches (784 mm)
F = 59.60 inches (1,438 mm)
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Hose Modification for Various Width Bodies and fuel fill vent Orientation and Protection
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N/W Series Upfitter
LED Brake Light Caution
Affected Vehicles
Body Upfitter installed LED lights with 2008-2009 Model Year
Isuzu N-Series and GMC/Chevrolet W-Series equipped with 6.0L V8 gasoline engine
Information
Isuzu has determined that some up-fitter applications, which include the use of LED brake lights, may cause the factory cruise control to become inoperative. This
condition is created when the factory filament style brake lamp bulbs is replaced with LED type bulbs.
The engine control module (ECM) uses the brake lamp circuit to detect the position of the brake pedal for correct operation of the cruise control system. The ECM
monitors the condition of the brake lamp circuit by continuously measuring the brake lamp circuit voltage. This voltage is dependant upon the correct operation of
the factory filament type brake lamp bulbs. If the filament type bulbs are replaced with LED type bulbs, the circuit resistance value will increase causing the brake
lamp circuit voltage to remain high with the brake pedal released. Therefore, the ECM “thinks” the brake pedal is applied at all times inhibiting the cruise control
system from functioning properly. In this case, the MIL may not illuminate to identify this concern.
If a customer calls a body company with this complaint and the vehicle is equipped with LED brake lights, the following diagnostic steps have been provided for
your reference and can be used to determine if the condition is caused by the LED style bulbs. Should this diagnosis confirm LED style bulbs are the cause of this
condition, the repair procedure outlines below can be completed as a customer pay repair at an Isuzu Dealer. The repair procedures also provides the necessary
information for location and installation of the Isuzu LED load resistor. The resistor will correctly replace the resistance value in the brake lamp circuit provided
previously by the factory brake lamp bulbs and allow the cruise feature to operate properly.
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Diagnosis
1. Confirm only LED style bulbs are installed in the Brake lamp circuit.
2. Connect IDSS and select the appropriate vehicle information.
3. Using IDSS, monitor the Brake Pedal Position (BPP) Circuit Signal in the Engine - Cruise Data list.
4. With the ignition key “ON” and the engine “OFF” press and release the brake pedal while monitoring the BPP signal in the IDSS as listed in step 3. The data
should switch from “Released” to “Applied” as you press and release the pedal.
5. If the signal does not switch and indicates “Applied” all the times, the LED style bulbs are affecting this circuit.
Follow the Repair Procedure below to correct this condition.
6. If the signal switches as indicated in step 4, refer to the service manual for additional diagnosis.
Repair Procedure
1. Disconnect the negative battery terminal.
2. Locate connector H-66 at the center rear of the last cross member.
3. Cut down the extension harness to 100mm and strip away 15mm of
insulation.
4
4. Splice the extension harness together with the chassis harness near
connector H-66 at the solid green wire from pin # 2 and the solid black
wire from pin # 7.
Note: Follow the splicing method as outlined in the appropriate
service manual.
6. Connect the resistor to the extension harness. Secure the resistor to the
chassis harness with vinyl tape.
Note: Be sure the new connection and resistor are properly 1
waterproofed and secured. 2
7. Connect the negative battery terminal
3
8. Using IDSS, confirm the Brake Pedal Position (BPP) Circuit Signal is Identification for Repair Procedure:
switching from “Released” to “Applied” when the brake pedal is 1. H-66 connector
depressed and released. 2. Extension harness
9. Test drive the vehicle to confirm cruise control operation is normal. 3. Resistor
4. Chassis harness
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Parts Information
The following parts are available from AIPDN (American Isuzu Parts Distribution Network)