MY2000 Body Builders Guide

MY2000 Body Builder's Guide
Introduction
Introduction
This guide is furnished 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 alteration. No alterations should be made to the incomplete vehicle which either directly or indirectly results in any component, assembly or system being in nonconformance with applicable Emission Regulations or Federal Motor Vehicle Safety Standards. American Isuzu Motors, Inc. 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 the guide with respect to the completion of the vehicle. Other wise, 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 Motor vehicle Safety standards. The information contained in this guide is furnished for the final stage manufacturer's information and guidance. This guide contains information pertaining to the Isuzu built NPR, NPR GAS, NQR, FRR and Janesville assembled FSR, FTR and FVR. NOTE: All information and specifications contained in this book are based on the latest information available at the time of the publication. The manufacturer reserves the right to discontinue or change, at any time, without prior notice, specifications, options, materials, equipment, design and models. 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 following chart.
Isuzu 2000 Body Builder's Guide
Page 1
FMVSS Chart
FMVSS TITLE NPR/ W3500 NPR HD/ NQR/ W550 0 FRR W5 FSR F6 FTR/ FVR F7
101 102
Controls and Displays Transmission Shift Lever Sequence Starter Interlock, and Transmission Braking Effect. Windshield Defrosting and Defogging Systems Windshield Wiping and Washing Systems Hydraulic Brake Systems Brake Hoses Reflecting Surfaces Lamps, Reflective Devices, and Associated Equipment Rear View Mirrors Headlamp Concealment Devices Hood Latch System Vehicle Identification Number3 Motor Vehicle Brake Fluids Power Operated Windows System 5 Tire Selection and Rims Air Brake Systems Accelerator Control Systems Glazing Materials Door Locks and Door Retention Components Seating Systems Occupant Crash Protection Seat Belt Assemblies Seat Belt Assembly Anchorages Wheel Nuts, Wheel Discs, and Hub Caps. 4,3 Child Restraint Systems Flammability of Interior Materials
A+ A+
A+ A+
A+ A+
A A+
A A+
103 104 105 106 107 108 111 112 113 115 116 118 120 121 124 205 206 207 208 209 210 211 213 302
A+ A+ A+ A+ A+ A+ A A A A+ A A+ B A+ A+ A+ A+ A+ A+ A+ A A A+
A+ A+ A+ A+ A+ A+ A A A A+ A A+ B A+ A+ A+ A+ A+ A+ A+ A A A+
A+ A+ B A+ A+ A+ A A A A+ A A+ A A+ A+ A+ A+ A+ A+ A+ A A A+
A A A+ A+ A A A A A+ A+ A+ A+ A+ A+ A+ A A A A A A A
A A A+ A+ A A A A A+ A+ A+ A+ A+ A+ A+ A A A A A A A
NOTE: Above chart is a guide. For complete information please refer to "Document for Incomplete Vehicle" porridge with each chassis. Isuzu 2000 Body Builder's Guide Page 2
1.A = Incomplete vehicle; when completed will conform providing no alterations have been made affecting items covered by FMVSS regulations and "Document for Incomplete Vehicle." B = Incomplete vehicle; when completed by the final manufacturer will conform providing it is completed in compliance with FMVSS regulations and "Document for Incomplete Vehicle." 2. 3. 4. 5. + =Meets Canadian Motor Vehicle Safety Standards bearing same FMVSS number 3 =Canadian MVSS only. Not applicable to tuck or bus. Not applicable to trucks with a GVWR greater than 10,000 LBS.
EPA Requirements
Emission Statement NPR Gas HD, NPR NPRHD, NQR, FRR
To assure that U.S.A. and Canada Emission Requirements are met, this Incomplete Vehicle must be competed in strict accordance with all instructions contained in this document, especially the following instructions which relate to: A. B. C. [A] Exhaust emission related components Noise emission related components Labels
EXHAUST EMISSION RELATED COMPONENTS Compliance of this vehicle with EPA, California and Canada Requirements will be maintained providing no alterations are made to the components or systems identified below: 1.) DIESEL VEHICLES Injection Pump Injector and High Pressure Lines Turbocharger Change Air Cooler and Charge Air Cooler Hoses Engine Control Module (ECM) Engine Speed Sensor Engine Coolant Temperature Sensor 2.) GASOLINE VEHICLES Vehicle Control Module VCM Fuel Management System Air Induction System Ignition System Catalytic Converter System Positive Crankcase Ventilation System Exhaust Gas Recirculation System Evaporative Emission Control System Page 3
1.)
DIESEL VEHICLES Intake Manifold Catalytic converter and its location Variable swirl system Exhaust Gas Recirculation System
2.)
GASOLINE VEHICLES Miscellaneous Items Used in Above Systems
ADDITIONAL CANADA MOTOR VEHICLE SAFETY STANDARD CMVSS NO. 1101-EMISSION DEVICE CMVSS NO. 1102-CRANKCASE EMISSION (GASOLINE ENGINE ONLY) CMVSS NO. 1103-EXHAUST EMISSIONS CMVSS NO. 1104-OPACITY (DIESEL ENGINE ONLY) CMVSS NO. 1105-EVAPORATIVE EMISSION (GASOLINE ENGINE ONLY) [B] NOISE
Compliance of this vehicle with EPA and Canada requirements will be maintained providing no alterations are made to the components of systems. CMVSS NO. 1106-NOISE This incomplete vehicle, when completed, will conform to the above standards except CMVSS-1106 providing no alterations are made which effect the function, physical or mechanical properties, environment, locations or vital spatial clearances of the components identified below: * Engine assembly Exhaust emission control system P.C.V. system (if equipped) * * Intake system Exhaust system Fuel system (if equipped) * * * * Transmission assembly Axle Tires Fan and drive Diesel fuel injection controls (if equipped) Turbocharger and associated controls (if equipped * Catalytic converter and its location Variable swirl system (if equipped) Conformity with CMVSS 1106 is not determined solely by the design of the incomplete vehicle. When Isuzu 2000 Body Builder's Guide Page 4
completed, it should conform to CMVSS 1106 providing no alterations are made to the noise attenuation components identified thus * in the above list. [C] Labels
The Emission control related information labels which are permanently affixed ate required by government regulation and must not be obstructed from view or defaced so as to impair its visibility or legibility. PART 3: Radio Noise CANADIAN RADIO INTERFERENCE REGULATIONS [A] The following statements applicable to NPR/W3500/W4500 Chassis-Cab Gasoline Engine Only).
Emissions Statement FSR FTR FVR

U.S. ENVIRONMENTAL PROTECTION AGENCY AND STATE OF CALIFORNIA EMISSION REQUIREMENTS To assure that EPA and California Emission Certificate Requirements are met, this incomplete vehicle must be completed in strict accordance with all instructions contained in this document, especially the following instructions which relate to: A. B. [D] Exhaust emission related components Labels
EXHAUST EMISSION RELATED COMPONENTS
Compliance of this vehicle with EPA and California Certification Requirements will be maintained providing no alterations are made to the components or systems identified below: 1.) DIESEL VEHICLES Injection Pump Injection and High Pressure Lines Turbocharger Charge Air Cooler and Change Air Cooler Hoses Engine Control Module (ECM) Engine Speed Sensor Engine Coolant Temperature Sensor (6HE1-TC only) Intake Manifold Catalytic converter and its location (6HE1-TC only) Air cylinder for variable swirl system (6HE1-TCS only)
[E]
LABELS Page 5
The Emission control related information labels which 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. CANADIAN MOTOR VEHICLE SAFETY STANDARDS CMVSS NO. 1101-EMISSION DEVICE CMVSS NO. 1103-EXHAUST EMISSIONS CMVSS NO. 1104-OPACITY CMVSS NO. 1106-NOISE This incomplete vehicle, when completed, will conform to the above standards except CMVSS 1106 providing no alterations are made which affect the function, physical or mechanical properties, environment, locations or vital spatial clearances of the components identified below: Engine assembly * Exhaust emission control system P.C.V. system Intake system* Exhaust system* Fuel system Transmission assembly* Axle* Tires* Fan and drive Diesel fuel injection controls* Turbocharger and associated controls Catalytic converter and its location (6HE1-TC only)* Air Cylinder for variable swirl system (6HE`-TCS only) Conformity with CMVSS 1106 is not determined solely by the design of the incomplete vehicle. When completed, it should conform to CMVSS 1106 providing no alterations are made to the noise attenuation components identified thus * in the above list. Compliance of this vehicle with EPA and California Certification Requirements will be maintained providing no alterations are made to the components or systems identified below: Air Inlet System Diesel Fuel Injection Controls Engine Assembly with all Components of Exhaust Emission Control System Exhaust System Fuel System Turbocharger and Associated Controls Isuzu 2000 Body Builder's Guide Page 6
Weight Restrictions
Regulations and Requirements
The Gross Vehicle Weight Rating (GVWR) and the Gross Axle Weight Rating (GAWR) or 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) 2) 3) The installation of a body or equipment that exceeds the rated capacities of the Incomplete Vehicle. The addition of designated seating positions which exceeds the rated capacities of this Incomplete Vehicle Alterations or substitutions 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.
Figure 1 Isuzu 2000 Body Builder's Guide Page 7
Gross Axle Weight Rating

The Gross Vehicle Weight is further restricted by the Gross Axle Weight Rating (GAWR). The maximum GAWR for both front and rear axles is listed in each Vehicle Section. Weight distribution calculations must be performed to ensure GAWR is not exceeded. Always verify the results by weighing the completed vehicle on a certified scale. 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 GAWR's allow the second stage manufacturer some flexibility in the design of the weight distribution of the attached unit.
Weighing the Vehicle

Front and rear GAWR's and total GVWR should be verified by weighing a completed loaded vehicle. Weight the front and rear of the vehicle separately and combine the weights for the total GVWR. All three weights must be less than the respective maximum shown in the vehicle sections.
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.
Installation of Body and Special Equipment

Clearance Around Engine, Driveline and Others
Isuzu 2000 Body Builder's Guide Page 8
Engine
At least 1.6 inch clearance should be maintained around the engine. No obstacles should be added in front of the radiaton or intercooler.
Figure 2
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 unrestricted movement of the transmission assembly. In addition, provide at least 2 inches clearance around the control lever on the side of the transmission to allow free movement without any binding.
Page 9
Figure 3 At least 6 inches clearance should be maintained above the transmission to allow easy removal of the upper cover for manual transmission. At least 2 inches clearance should be maintained above the automatic transmission to allow for transmission removal
Figure 4
Front and Center Propeller Shafts

At least 1.25 inch clearance should be maintained around front and center propeller shafts.
Figure 5
Rear Propeller Shaft

With the rear springs at maximum deflection, at least 1.25 inch clearance should be provided over the Isuzu 2000 Body Builder's Guide Page 10
rear propeller shaft.
Figure 6
Exhaust System Clearance

If flammable materials such as wood are used int he body, provide at least 3.9 inches clearance between the body and any parts of the exhaust pipe, muffler and catalytic converter. If it is impossible to maintain this 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.
Figure 7
Page 11
Rear Wheel and Axle Clearance

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.
Figure 8 Recommended clearance (dimension E) is given in each model section. Oversize tire requires correspondingly greater clearance.
Other Clearances
Transmission control cable may be broken if it is bent by or interferes with the body and its fixtures. To prevent this, 1 inch minimum clearance should be provided. When cable is detached for 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.
MINIMUM CLEARANCE
PARTS
LOCATION
Brake Hose Parking Brake Cable Fuel Hose Shock Absorber
6.7in 1.6 in 1.2 in. 1.6 in. 2.4 in 1.2 in
Axle Side Frame Side ----------Axle Side Frame Side
Page 12
Body Installation
To maintain the performance of the truck chassis, eighteen a side member or subframe should always be used for body mounting. Body mounting with low rigidity will often adversely affect riding comfort.
Installation of Special Equipment on the Chassis

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.
Subframe Design and Mounting

The subframe assembly should be mounted as close to the cab as possible. It should be contoured to match the shape and dimensions the chassis frame as closely as possible.
Figure 9
Page 13
Contouring of the Subframe

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.
Figure 10
Figure 11
Page 14
Figure 12 Drawing (1) A 0.2 in B
(2) (3)
0.2 in
H or more H or more
When using a steel subframe, do not close the end of the subframe.
Page 15
Figure 13
Prohibited Attachment Areas

Do not attach the subframe with a bolt on bracket to the chassis frame at the point indicated by shading in the following illustrations. 1. At the front end of the subframe. The attaching bolt or bracket must be at least 2 inches behind the kid up pint of the subframe.
Page 16
Figure 14 2. Within 8 inches of bend in the chassis frame or the attachment points of any cross members.
Figure 15
Subframe Mounting Bracket Installation

Mounting brackets should be clamped to the chassis frame using bolts. For proper positions in which to Isuzu 2000 Body Builder's Guide Page 17
install the bolts, refer to the preceding section and the section "Modifications to the Chassis Frame."
Figure 16
Figure 17
Subframe Mounting U-bolt

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 Isuzu 2000 Body Builder's Guide Page 18
clearance between them and any parts of the exhaust system. If any fluid lines or electric cables are located near the reinforcement blocks, you must provide at least 0.4 inch clearance between rigid or stationary portions, and at least 1.6 inch between moveable or flexible portions of the lines.
Figure 18 For the installation position of the U-bolts, refer to "Prohibited Attachment Areas."
Modification of the Chassis Frame

Modifications of the chassis frame should be held to an absolute minimum. Modification work should be performed according to eh instructions in the following paragraphs. 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.
Working on the Chassis Frame

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 distributions. If even distribution of load is not keep 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 Isuzu 2000 Body Builder's Guide Page 19
limit. The chassis frame is designed as an integral unit. Therefore, we do not recommend cutting the chassis frame under any circumstances.
Drilling and Welding

IMPORTANT NOTE: VEHICLES EQUIPPED WITH ELECTRONIC OR HYDRA-MATIC TRANSMISSIONS Any electric arc welding performed upon the vehicle must be done with the negative battery cable disconnected. 1. 2. Do not drill or weld in the shaded portions of the chassis frame members. Do not weld within 0.8 inch from the edges of any existing holes. Hold the length of any welding beads within 1.2-2.0 inch. Allow at least 1.6 inch between adjacent welding beads.
Figure 19 3. 4. 5. 6. All holes must be drilled. Do not use a torch to make any holes. All riveting must be done with cold rivers. Do not use hot rivets. The flange of the chassis frame must not be cut under any circumstances. The subframe must be attached to the chassis frame with bolts. Do not weld.
Page 20
Reinforcement of Chassis Frame

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 NPR, NPR GAS and NQR is made of SAPH440 mild steel. The frame of the FRR is made of HT54A. See FSR, FTR and FVR section for frame material specifications. The drawings below illustrates correct and incorrect methods of frame reinforcement.
Figure 20
Welding
1. 2. 3. 4. 5. Keep reinforcement plates and chassis frame free from moisture and water. Avoid cooling with water after welding. Use a suitable means to protect pipes, wires, rubber parts, leaf springs, etc.. against heat and affect of sputtering. Remove fuel tank assembly when welding portions near the fuel tank. Remove coat of paint completely when welding painted areas.
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 Isuzu 2000 Body Builder's Guide Page 21
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.
Preparation of Additional Lines

1. 2. 3. When possible, use only genuine Isuzu lines ans supplies by authorized Isuzu dealers. Use the correct metric flaring and bending tools to form the liens. 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, distorting, dents and the presence of any foreign matter.
Installation of Additional Lines

Install new lines away from adjacent parts and away from any sources of heat. 1. 2. A minimum clearance of 0.4 inch must be maintained between lines. Where necessary, clip the lines into position in order ot maintain this minimum clearance. Minimize any crossing between lines. If a crossing is unavoidable, use the following procedure: a. b. 3. 4. 5. At least 0.4 inch clearance should be maintained between lines at the crossing point. If the 0.4 inch clearance cannot be maintained, or if the lines are subject to vibration, clip them securely.
Plan the bends and clipping points of the lins to minimize vibration and the resulting fatigue. Use rust-proofed clips and apply vinyl coating to the portions of the lines to be clipped. 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.
Figure 21
Page 22
Electrical Wiring and Harnessing

To increase the reliability of the wiring, all frame harnesses are covered with corrugated vinyl tubing. The following instructions apply to extending or modifying these harnesses. See the Electrical Section for information on commonly used circuits in the NPR, NQR, and FRR. The FSR, FTR and FVR wiring information can be found in the service manuals.
Wiring
1. 2. 3. Most wiring connections on Isuzu vehicles are made with terminals. We recommend the use of terminals when splicing cables and wires. When splicing, use new wire of the same gauge, and do not make splices inside the corrugated tubing. 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. 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 shard edges. When cables must run near the exhaust system, see the instructions in the "Exhaust System" section. 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. To minimize the vibration of the harness, clipping pings should be set up according to the table. Harness Diameter less than 0.2 in. 0.2 in. ~ 0.4 in. 0.4 in. ~ 0.8 in. 7. Clip Distance less than 11.8 in approx. 15.7 in. approx. 19.7 in.
4.
5. 6.
When changing the lengths of the battery cable, do not cut or splice the exciting cable. Make us a new cable of the correct length and wire gauge for the load and distance, without splices. When using connectors, use a socket (female) connector on the electrical source side and a plug (male0 connector on the electrical load side to lower the possibility of a short circuit when disconnected. 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 Isuzu. Keep flexible cables clear of other parts. Do not use vinyl tape in the engine compartment. The heat will tend to make it peel off. Use plated steel clops coated with rubber or vinyl.
8.
9.
10.
Page 23
Figure 22
Figure 23 * Cables should not be contact with sharp edges or pierced holes.
* Harnesses should not be installed on inside lower face of the chassis frame. * Harnesses should not be taped to fuel lines or other lines. A sufficient clearance should be maintained between harness and pipe lines.
Figure 25
Wire Color Code

The electrical circuits of Isuzu vehicles NPR, NPR GAS and FRR are connected with low-voltage stranded wire for automotive applications. The color coding standards are as follow for NPR, NPR GAS and FRR. Refer to FSR, FTR and FVR service manual for those vehicle wiring color codes. (1) Black (2) White (3) Red (4) Green (5) Yellow (6) Brown (7) Light Green (8) Blue B W R G Y Br Lg L Starter circuits and grounds Generator (alternator) circuit Lighting circuit Signal circuit Instrument circuit Accessory circuit Other circuit Windshield wiper motor circuit
Maximum Current Allowable in Low Voltage Wiring

Harness Design Diameter (mm) AWG equivalent No. of wires/ wire diameter (mm) Cross sectional area (mm2) Maximum allowable current (amps)
100 85 60 50 40 30 20 Isuzu 2000 Body Builder's Guide
00 0 1 1 1 2 4
217/0.80 169/0.80 127/0.80 108/0.80 85/0.80 70/0.80 41/0.80
109.1 84.96 63.84 54.29 42.73 35.19 20.61
363 305 248 223 191 171 123 Page 25
Harness Design Diameter (mm)
AWG equivalent
No. of wires/ wire diameter (mm)
Cross sectional area (mm2)
Maximum allowable current (amps)
15 8 5 3 2 1.25 0.85 0.5
6 8 8 12 14 16 18 20
84/0.45 50/0.45 65/0.32 41/0.32 26/0.32 16/0.32 11/0.32 7/0.32
13.36 7.952 5.228 3.297 2.091 1.287 0.8846 0.5629
93 68 51 39 29 21 17 13
Reference: The values given in the "maximum allowable current" column are based on the ambient temperature condition of 104o F with temperature increase of 104oF.
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 int eh table on the next page 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 in more than 7.8 in., a clearance of 7 in. or more should be provided.) 3.9 in. or more. (The temperature of flexible brake hoses should not exceed 158o F. if the highest temperature is not measurable, a clearance of more than 15.7 in. should be maintained between the hoses and the exhaust system.) 3.9 in. or more.
Flexible brake hoses
Wiring harnesses and cables Steel fuel lines Rubber or vinyl fuel hoses
3.1 in. or more. 5.9 in. or more.
Page 26
2.
If a tool box is installed, it should preferable be made from steel. If a wooden tool box is installed, at least 7.8 inches clearance should maintained between the tool box and any parts of the exhaust system. If the exhaust system is modified, it is the responsibility of those making the modification to ensure that the noise level meets appropriate standards.
3.
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. 2. Maintain adequate clearance between the fuel tank and any other device or structure. Do not connect any additional fuel hose.
Rear Comb. Lamp / License Plate Lamp Mounting Bracket

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 included: 1. 2. 3. 4. 5. 6. 7. 8. 9. Inspection, filling and draining of engine oil and cooling water. Inspection, filling and draining of transmission fluid. Adjustment, removal and installation of the fan belts. Inspection, filling and removal of the battery and battery cover. Inspection and filling of brake fluids. Inspection and bleeding of the brake system and servo unit. Maintenance of clearance for tightening of check bolt on brake safety cylinder. Operating of the spare tire carrier, including mounting and dismounting of the spare tire Adjustment, removal and installation of distributor and/or cover. .
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 accomplishment either shortening or lengthening of the wheelbase.
Shortening / Lengthening the Wheelbase Without Altering the Frame

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 lengthening the wheelbase on some models, it is possible to do so without Isuzu 2000 Body Builder's Guide Page 27
cutting the frame. This is possible on models which have a straight frame rail. If the chassis does not have a straights frame rail, it may still be necessary to cut the frame. For instructions on shortening 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 real 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 the wheelbase in this manner, the following guidelines must be adhered to: 1. 2. All frame drilling must comply with the DRILLING AND WELDING section of this book. 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. The components required to be slid forward or aft are the suspension and suspension hangers, suspension crossmembers and suspension frame liner.
3.
Altering the Wheelbase by Altering the Frame

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.
Glossary of Terms - Chassis Wheelbase Alteration

CA - Length from back-of-cab to rear axle center line in inches. AL SL 1. Added length (in case of a lengthened wheelbase). Difference between WB (new) and WB (old). Shortened length (in case of shortened wheelbase). Difference between WB (old) and WB (new).
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). Obtain the material to be sued 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. 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).
2.
3.
Page 28
Figure 26 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 Application Engineering.
Figure 27 Lengthening the Wheelbase
Figure 28 Shortening the Wheelbase 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 and wheelbase, weld the ends of the chassis frame together with a continuous butt weld over the junction of t the Page 29
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.
Figure 29 6. Determine the appropriate additional internal reinforcements which are required using this equation: Reinforcement Length = AL + 6 x (original frame rail web depth). The figure below shows how this reinforcement is to be places over the extended or shortened section of the frame rail.
Figure 30 The suggested cross section of this reinforcement is a snug fit inner channel. If the new wheelbase exceeds the upper limit of the optional wheelbases of this model, i.e.; a "long bridge", it may be necessary to use an "inverted L" reinforcement in addition to the snug fit channel reinforcement (see figures below). Isuzu Application Engineering should be consulted for approval of such cases. If should be noted that these methods of reinforcements, and any other methods which may be used, require a 45 degree angled cut at both ends to avoid stress concentrations in the frame (note the figures under item 7).
Page 30
Figure 31 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 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 pattens must not align the bolts vertically, i.e.: the bolt pattern must be staggered.
Figure 32 8. Leathering the frame will also require extending the brake lines, basic chassis electrical harnesses, excluding ABS wiring 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 electrical harness must be extended in accordance with the ELECTRICAL WIRING AND HARNESSING section of this book. 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: A. Propeller Shaft Length The maximum propeller shaft angles, with respect to the pervious shaft, are shown in the table below. NPR Isuzu 2000 Body Builder's Guide NPR GAS NQR FRR Page 31
9.
NPR
NPR GAS
NQR
FRR
B.
Propeller Shaft Angles The maximum propeller shaft angles, with respect to the previous shaft, are shown in the table below. NPR NPR GAS NQR FRR
Maximum Propeller Shaft Angle
5.7
5.1
5.7
5.5
C. D.
The propeller shaft angels must be designed such that the angles will cancel to avoid propelled shaft whip. 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 place.
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 repetitive 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 cross member location will largely be determined by the propeller shaft lengths and where the center carrier bearing locations are for the propeller shaft assembly. A cross member 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 there suspension cross members are to be located). The cross member must be constructed such that it supports both the upper and lower flange on each frame rail (see drawing below). A cross member such as ths one below may be constructed, or Isuzu cross members may be obtained from your ISUZU parts dealer.
B.
C.
Page 32
Figure 33 D. The maximum distance between cross members for the respective models is given in the table below. NPR Maximum Distance Between Cross Members (in) NPR GAS NQR FRR
35.7
35.7
35.7
49.8
E. 11.
The drilling for any additional holes in the frame rails must comply to the DRILLING AND WELDING section of this book.
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, Isuzu Application Engineering must be consulted for approval. In the West Coast call 1-562-229-5314 and in the East Coast call 1-770-475-9195 extension 353. N SERIES CHASSIS NPR NPR HD NPR GAS NPR HD GAS
Page 33
Please contact applications engineering for guidelines on N SERIES CHASSIS frame modifications when the vehicle is equipped with an Antilock Brake System. FRR SERIES CHASSIS Please contact applications engineering for guidelines on FRR SERIES CHASSIS frame modifications when the vehicle is equipped with an Antilock Brake System. F SERIES CHASSIS FSR FTR FVR WHEN MAKING WHEELBASE MODIFICATIONS TO THE 1997, MODEL YEAR AND ABOVE FSR, FTR, AND FVR HYDRAULIC BRAKE CHASSIS AND AIR BRAKE CHASSIS THE FOLLOWING SHOULD BE STRICTLY OBSERVED.
Brake System Hydraulic Brake System

1. BEFORE WORK BEGINS As with any electrical work on the chassis the battery should be disconnected before electrical work is started. 2. ABS PROGRAM
THE Antilock Brake System (ABS) computer will hold its codes when disconnected and reprogramming as a result of battery disconnection will not be necessary. If the wheelbase is changed the trim level of the ABS system must be readjusted per the instructions in the service manual. An Authorized Isuzu dealer should do this reprogramming using appropriate tools. For your reference and to help you determine if the system needs to be reprogrammed the following provisions apply to all ABS systems with hydraulic brakes. The ABS module has four (4) programs: A, B, C, and D. These programs are tied to the wheelbase and axle combination of the chassis. (The axle and wheel base codes can be found on the passenger's visor.) A is for the FL1 axle and covers wheelbase fro 140 (GQT), 158 (EG5), 170 (EH8) inches. B is for the FL2 axle and covers wheelbase for 140 (FQT), 158 (EG5), 170 (EH8), 188 (EK8), 200 (EM2) inches. C is for the FL1 axle and covers wheelbase from 188 (EK8), 200 (EM2), 218 (FPL), 23 (EQ8), 248 (ES5) inches. D is for the FL2 axle and covers wheelbase from 218 (FPL), 233 (EQ8), 248 (ES5) inches. Moving between program/wheelbase groups A, B, C or D will require that the system be reprogrammed. Moving wheelbase within a program group will not require reprogramming. 3. ABS COMPUTER LOCATION a. The ABS computer is located under the cab on the front crossmembers and is an integral part of the brake fluid modulation system. These components can not be relocated. Page 34
4.
ABS ELECTRICAL HARNESSES a. b. c. The harness can not be cut and spliced The only approved way to make the harness longer is to purchase the appropriate wheelbase harness from the Isuzu parts department Extra wire resulting from a frame shortening can be coiled and secured to the frame.
5.
HYDRAULIC BRAKE LINES a. Hydraulic brake lines should be shortened or lengthened using appropriate fitting and steel lines.
Air Brake ABS Equipped Chassis

1. BEFORE WORK BEGINS a. 2. As with any electrical work on the chassis the battery should be disconnected before electrical work is started.
ABS PROGRAM
The antilock brake system (ABS) computer will hold its codes when disconnected and reprogramming as a result of battery disconnection will not be necessary. If the front axle is changed the trim level of the ABS system must be readjusted per the instruction in the service manual. An Authorized Isuzu dealer using the appropriate tools should do this reprogramming. 3. ABS COMPUTER LOCATION a. 15. The ABS computer is located back of cab on the power steering bracket. This component can not be relocated.
ABS ELECTRICAL HARNESSES a. b. c. The harness can not be cut and spliced The only approved way to make the harness longer is to purchase the appropriate wheelbase harness from the Isuzu parts department Extra wire resulting from a frame shortening can be coiled and secure to the frame.
8.
AIR BRAKE LINES a. Air brake lines should be shortened or lengthened using appropriate fittings and hose material.
Body Application Summary Charts

2000 Model Year Body Application Summary Chart
MODEL/GVWR WB BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft.
Page 35
MODEL/GVWR
WB
BOC
10 ft.
12 ft.
14 ft.
16 ft.
18 ft.
20 ft.
22 ft.
24 ft.
1 BOC 10.0 Inches.
NOTES: * NPR, NPR HD GAS and DIESEL 20 foot body requires Isuzu Application Engineering Department approval. 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.
NPR EFI Gas / NPR
Figure 34
1999 Model Year* Body & Payload Weight Distribution (% Front / % Rear) Automatic Transmission
MODEL NPR/ W3500 GAS NPR HD/W4500 GAS GVWR 11,050 14,050 WB 109 109 CA 88.4 88.4 CE 131.5 131.5 OAL 199.5 199.5 BOC 9.25 9.25 10 18/82 18/82 12 7/93 7/93 14 16 18 20 AUTOMATIC TRANSMISSION
Page 36
MODEL NPR/W3500 GAS NPR HD/W4500 GAS NPR/W3500 GAS NPR HD/W4500 GAS NPR/W3500 GAS NPR HD/W4500 GAS
GVWR 11,050 14,050
WB 132 .5 132 .5 150 150
CA 111.9 111.9
CE 155 155
OAL 223 223
BOC 9.25 9.25
10
12
14 14/86 14/86
16
18
20
11,050 14,050
129.4 129.4
172.5 172.5
240.5 240.5
9.25 9.25
16/84 16/84
8/92 8/92
11,050 14,050
176 176
155.4 155.4
198.5 198.5
266.3 266.3
9.25 9.25
15/85 15/85
Manual / Automatic Transmission

MODEL NPR/ W3500 DSL NPR HD/W4500 DSL NPR/W3500 DSL NPR/HD/W45 00 DSL NPR/W3500 DSL NPR HD/W4500 DSL NPR/W3500 DSL NPR HD/W4500 DSL GVWR 12,000 14,500 0 12,000 14,500 0 12,000 14,500 WB 109 109 CA 88.4 88.4 CE 131.5 131.5 OAL 199.5 199.5 BOC 9.25 9.25 10 12 7/93 7/93 14 16 18 20 MANUAL / AUTOMATIC TRANSMISSION
132 .5 132 .5 150 150
111.9 111.9 129.4 129.4
155 155 172.5 172.5
223 223 240.5 240.5
9.25 9.25 9.25 9.25
14/86 14/86 16/84 16/84 8/92 8/92
12,000 14,500
176 176
155.4 155.4
198.5 198.5
266.3 266.3
9.25 9.25
15/85 15/85
Manual / Automatic Transmission

MODEL NQR/ W5500 DSL NQR/W5500 DSL NQR/W5500 DSL NQR/W5500 DSL GVWR 17,950 17,950 17,950 17,950 WB 109 132 .5 150 176 CA 88.4 111.9 129.4 155.4 CE 131.5 155 172.5 198.5 OAL 199.5 223 240.5 266.3 BOC 9.25 9.25 9.25 9.25 10 12 7/93 14/86 16.84 8/92 15/85 8/95 14 16 18 20 22 MANUAL / AUTOMATIC TRANSMISSION
Page 37
* NPR, NPR HD/W3500, W4500 GAS and DIESEL IMPORTANT: Weight distribution percentages listed do not included 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.
FRR/W
Figure 35
2000 Model Year Body & Payload Weight Distribution (% Front / % Rear) Manual Transmission
MODEL FRR/ WT5500 FRR/ W T5500 FRR WT5500/ FRR WT5500/ FRR WT5500/ GVWR 18000/ 19500 18000/ 19500 18000/ 19500 18000/ 19500 18000/ 19500 WB 148 167 179 191 218 CA 117.1 136.2 148.0 159.8 187.4 CE 180.6 206.5 226.2 243.9 283.3 OAL 259.3 285.2 304.9 322.2 362.0 BOC 7.5 7.5 7.5 7.5 10.0 14 16/84 * 16 10/90 12/88 11/89 11/89 15/85 18 20 22 24
Page 38
* BOC 10.0 Inches.
Automatic Transmission
MODEL FRR/ WT5500 FRR/ WT5500 FRR/ WT5500 FRR/ WT5500 FRR/ WT5500 GVWR 18000/ 19500 18000/ 19500 18000/ 19500 18000/ 19500 18000/ 19500 WB 148 167 179 191 218 CA 117.1 136.2 148.0 159.8 187.4 CE 180.6 206.5 226.2 243.9 283.3 OAL 259.3 285.2 304.9 322.2 362.0 BOC 11.3 11.3 11.3 11.3 11.3 14 15/85 16 7/93 10/90 9/91 9/91 15/85 18 20 22 24
IMPORTANT: Weight distribution percentage listed do not include added accessories. liftgate or refrigeration units. Percentage 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 does not preclude the necessity for an accurate weight distribution calculation.
Engine Horsepower / Torque Chart

The following table presents Net versus Gross Horsepower and Torque ratings for 1999 Isuzu/W-Series Truck Product Engines:
ENGINE MODEL APPLICATION NET HP1 HP/RPM NET TORQUE1 LBS-FT/RPM GROSS HP1 HP/RPM GROSS TORQUE1 LBS-FT/RPM
GMPT5.7L-V8
NPR, NPR HD/W3500, W4500 GAS NPR, NPR HD/ W3500, W4500 DIESEL NPR, NPR HD, NQR/W3500, W4500, W5500 DIESEL NQR/W5500 DIESEL
N/A
N/A
250/4400
330/2800
ISUZU 4HE1-T C M/T
137/2800
268/1300
142/2800
275/1300
ISUZU 4HE1-T C A/T
169/2700
339/2000
175/2700
347/2000
ISUZU 4HE1-T C M/T
169/2700
339/2000
175/2700
347/2000
Page 39
ENGINE MODEL
APPLICATION
NET HP1 HP/RPM
NET TORQUE1 LBS-FT/RPM
GROSS HP1 HP/RPM
GROSS TORQUE1 LBS-FT/RPM
ISUZU 6HK1-T C M/T ISUZU 6HK1-T C A/T
FRR/WT550 0 DIESEL
193/2400
426/1500
200/2400
441/1500
FRR/WT550 0 DIESEL
193/2400
426/1500
200/2400
441/1500
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 NPR/W3500 GAS NPR HD/W4500 GAS NPR/W3500 DIESEL NPR/W3500 DIESEL NPR HD/W4500 DIESEL NPR HD/W45000 DIESEL NQR/W5500 DIESEL NQR/W5500 DIESEL FRR/WT5500 DIESEL FRR/WT5500 DIESEL TRANSMISSION AUTOMATIC AUTOMATIC AUTOMATIC MANUAL AUTOMATIC MANUAL AUTOMATIC MANUAL AUTOMATIC MANUAL GVWR (lbs) 11,050 14,050 12,000 12,000 14,500 14,500 17,950 17,950 18,000/19,50 0 18,000/19,50 0 GCWR (LBS)1 14,050 17,050 18,000 18,000 19,500 20,500 20,950 20,500 22,050 30,000
(1)
The NPR, NPR HD, NQR/W3500, W4500, W5500 are note approved for Hot Shot applications.
Rear Frame Height Chart

The following chart provides the rear frame height for each model/GVWR with standard tires:
TRUCK MODEL NPR/W3500 GAS GVWR (lbs) 11,050 STANDARD TIRE 215/85R-16E FRAME HT (In) FH STD. TIRES 32
Page 40
TRUCK MODEL NPR HD/W4500 GAS NPR/W3500 DIESEL NPR HD/W4500 DIESEL NQR/W5500 DIESEL FRR/WT5500 DIESEL FSR/FTR/FVR
GVWR (lbs) 14,050 12,000 14,050 17,950 18,000 (2)
STANDARD TIRE 225/70R-19. 5F 215/85R-16E 215/85R-16E 225/70R-19. 5F 225/70R-19. 5F (2)
FRAME HT (In) FH STD. TIRES 32.75 32 32 32.75 32.25 (1) (2)
(1) (2)
191 and 218 WB have frame height of 35.2 inches. Refer to FSR, FTR, and FVR section.
Clutch Engagement Torque

The following table provides the engagement torque of the engines currently in use in Isuzu medium duty truck:
ENGINE ISUZU 4HE1-TC (142 HP) ISUZU 4HE1-TC (175 HP) ISUZU 6HK1-TC (200 HP) ISUZU 6HK1-TC (230 HP) Torque (lbs-ft) 260 265 331 368 at (RPM) 1,000 1,000 1,000 1,000
Paint Code Chart

ISUZU OPTION CODE ISUZU PAINT COLOR NAME 1985 KS22
N/A Calm White 0133-P1
ISUZU PAINT CODE
ISUZU OPTION CODE
ISUZU PAINT COLOR NAME 1986-95 NPR Diesel

Glacier White
ISUZU PAINT CODE
844 Isuzu 2000 Body Builder's Guide
0172-P1 Page 41
ISUZU OPTION CODE
ISUZU PAINT COLOR NAME 1993-94 NPR EFI

Glacier White
ISUZU PAINT CODE
844
0172-P1
ISUZU OPTION CODE
ISUZU PAINT COLOR NAME 1995.5-99 NPR/NQR Diesel

Arc White W301-P801-0 Adriatic Blue Solid (1999 model only)
ISUZU PAINT CODE
729 730
B302-P801-0
ISUZU OPTION CODE
ISUZU PAINT COLOR NAME 1995.5-99 NPR EFI

Arc White W301-P801-0 Accuride White (Wheels Only)
ISUZU PAINT CODE
729 N/A
301-W-30102
ISUZU OPTION CODE
ISUZU PAINT COLOR NAME 1989-94 NRR

Glacier White
ISUZU PAINT CODE
844
0172-P1
ISUZU OPTION CODE
ISUZU PAINT COLOR NAME 1995-98 FRR

Glacier White
ISUZU PAINT CODE
844
0172-P1
ISUZU OPTION CODE
ISUZU PAINT COLOR NAME 1987-99 FSR

Glacier White (1987-96) Arc White (1997-99)
ISUZU PAINT CODE
844 729
0172-P1 W301-P801-0
ISUZU OPTION CODE

ISUZU PAINT COLOR NAME
ISUZU PAINT CODE

Page 42
ISUZU OPTION CODE
ISUZU PAINT CODE
ISUZU OPTION CODE
ISUZU PAINT COLOR NAME 1988-99 FVR

Glacier White (1988-96) Arc White (1997-99)
ISUZU PAINT CODE
844 729
0172-P1 W301-P801-0
ISUZU OPTION CODE
ISUZU PAINT COLOR NAME 1988-92 EVR

Glacier White (1988-96)
ISUZU PAINT CODE
844
0172-P1
ISUZU OPTION CODE
ISUZU PAINT CODE
1997-99 F-Series (FSR, FTR, FVR) (ZY1-Solid Exterior Paint Scheme)

729 801 807 809 810 812 815 Arc White Medium Blue Woodland Green Doeskin Tan Red Orange Wheatland Yellow Tangier Orange W301-P801-0 B721-P801-0 G705-P801-0 U715-P801-0 R725-P801-0 Y719-P801-0 U716-P801-0
GM OPTION CODE (UPPER)
GM OPTION CODE (LOWER)
ISUZU PAINT CODE
1997-99 F-Series (FSR, FTR, FVR) (ZY2-Two Tone Exterior Paint Scheme)
16U 16U 16U 16U 18L 30L 73L 81L Dark Green Gray Medium Adriatic Blue Rose Black Bright Red WE5398 WE9907 WE9885 WE8774
NOTE: A ZY2 paint scheme has a cab painted Arc White (16U) with fenders and bumper painted one of the four colors listed above. These four colors are GM-based colors. There are no Isuzu 2000 Body Builder's Guide Page 43
corresponding Isuzu Option Codes for these colors.
CV Chart 2
ISUZU PAINT CODE

B301-P801-0 0133-P1 0172-P1 301-W-30102 B721-P801-0 WE9907 G705-P801-0 WE5398 WE8774 R725-P801-0 U715-P801-0 U716-P801-0 W301-P801-0 Y719-P801-0 WE9885
ISUZU OPTION CODE

730 N/A 844 N/A 801 N/A 807 N/A N/A 810 809 815 729 812 N/A
ISUZU COLOR NAME

Adriatic Blue (Solid) Calm White Glacier White Accuride White Medium Blue *Medium Adriatic Blue Woodland Green *Dark Green Gray *Bright Red Red Orange Doeskin Tan Tangier Orange Arc White Wheatland Yellow *Rose Black
DUPONT CODE
W9775 G8477 H8620 F2499 B8041 B9321 B8046 B9329 C8508 B8250 B8462 B9043 W9774 B9042 B9218
BASF R-M CODE

730 HS14391 RM15602 RM25319 27403 27426 27404 27425 27427 27407 27406 27409 RM25318 27408
BASF GLASS CODE

730 IS-820 IS-844 IS-25319 IS-B721 IS-27426 IS-G705 IS-27425 IS-27427 IS-R725 IS-U715 IS-U716 IS-25318 IS-Y719 IS-27428
27428
SHERWIN WILLIAMS/ MARTIN SENOUR CODE

57541 34657 35478 51548 56143 46829
PPG CODE
AKZO NOBEL CODE

FLNA50274 FLNA40252 FLNA40155 FLNA40154 FLNA50172 FLNA90857
SPIES HECKER CODE

50287 1622 10281 15593 55934 56120
ICI AUTO COLOR CODE

2NV9B KK27 ND92 8AR8 KPL2B 2NY4B
19320 91522 90330 91513 190217 190401
Page 44
SHERWIN WILLIAMS/ MARTIN SENOUR CODE

56201 47155 34983 56202 56203 56204 51400 56144 45738
PPG CODE
AKZO NOBEL CODE

FLNA60181 FLNA90856 FLNA30252 FLNA20079 FLNA80050 FLNA20080 FLNA40156 FLNA10182 FLNA90858
SPIES HECKER CODE

64962 65071 34169 21881 21882 21883 10280 21884 74223
ICI AUTO COLOR CODE

KPL3B 2NP9B TC78B KPL4B KPL5B KPL6B 2NV8 KPL7B 1AB2B
48339 36575 75057 61784 28613 61785 91512 83931 95057
NOTE: STANDBOX uses paint code found in vehicle for paint identification. * GM-Based colors. No Isuzu Option Code.
NPR and NPR Gas Towing Procedure

Should it become necessary to tow the NPR, NPR GAS and NQR the following procedure should be followed: 1) 2) For manual transmission models, disconnect the propshaft at the rear axle or transmission. Secure the propshaft to the frame of crossmember. For automatic transmission models, move the selector into "N" position, vehicles can be towed at speeds below 30 mph and up to distances less than 50 miles. If it is necessary to exceed theses speeds or distances, the rear axle shafts must be removed or utilize rear end towing procedures. Attach "J" hooks to the front axle inboard of the front spring. Position a 4" x 4" timber or spacer under the front bumper reinforcement and another 4" x 4" timber with spacer blocks (illustrated below) under the front spring. Position the tow bar under the bumper. Attach safety chains to the front springs. If the truck is loaded, the front bumper should also be removed. Refer to Owner1 Manual in glove box for additional information.
3) 4) 5) 6) 7) 8)
Page 45
Figure 36
Weight Distribution
A truck as a commercial vehicle has but one purpose. That purpose is to haul some commodity form 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 misapplies, In any case, selecting the right size truck for the load to be hauled will ensure that the job will be done and that is 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 that 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 form 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: 1. Excessive front end wear and failure Page 46
a. b. c. d. 2.
Tie-rod and king pin wear Front axle failure Overloading of front suspension Wheel bearing failure
Rapid tire wear a. When the weight on a tire exceeds its rating capacity, accelerated wear will result and could result in tire failure.
3.
Rough, erratic ride 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 up hill.
4.
Hard steering a. b. When loads beyond the capacity of the front axle are imposed upon it, the steering mechanism is also overloaded and hard steering will result. Excessive overloading could result in steering component damage or failure.
5.
Unsafe operating and conditions. 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. 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.
b.
6.
High maintenance costs a. Improper weight distribution and overloading cause excessive wear and premature failure of parts. Additional stresses impose on the frame by the misapplication of wheelbases, may be instrumental in causing the frame to crack or break.
7.
Noncompliance with weight laws and regulations 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. The 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 axel. Excessive front axle loads increase wear Isuzu 2000 Body Builder's Guide Page 47
on the king pins and bushings, wheel bearings and steering gear. Excessive front axle loads also over stress the front axle, springs, tires and wheels. All of these contribute directly to higher maintenance costs and hard steering, both of which are undesirable.
Glossary of Dimensions
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.
Figure 37 BBC Bumper to back of cab BA CA AB Bumper to axle Cab to axle Axle to back of cab Page 48
BOC Back of cab clearance CE CG WB Cab to end of frame Center of gravity of body and payload from axle Wheelbase
OAL Overall length AF FH Axle to end of frame Frame height
Weight Distribution Formulas and Examples
Figure 38
Page 49
Figure 39 A= B= C= D= F= Front axle to back of cab Distance between cab and body or trailer Front of body to C.G. or front of trailer to kingpin Distance between cab and body or trailer (A + B + C) or distance C.G. of weight of fifth wheel is behind front axle
WB = Wheelbase W= Weight of body plus payload, or kingpin load
Wf = Portion of W transferred to front axle Wr= Portion of W transferred to rear axle
Basic Formulas: (a) W x D = W1 x WB or (b) W x F = Wr x WB (d) W = Wf x Wr (c) WB = (A+B+C+D) = (F+D)
1.
2.
3.
4.
5.
6.
7.
8. Weight Distribution Formulas in Words
Page 50
To find:
1.
2.
3.
4.
5.
6.
7.
8. 9. Remember - Total weight must aways equal weight transferred to the rear axle plus the weight transferred to the front axle.
Figure 40 To find the value of "P", the leverages must be equal for balance. i.e. 100 lb x 8 in = "P" x 20 in or
Therefore: "P" =
40 lb Page 51
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.
Figure 41 Front Axle Load:
= Rear Axle Load: = Example: (4) A tractor has a wheelbase of 150 inches. If the kingpin load is 20,000 lb 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 lb on the front axle and 4,4000 lb on the rear axle. Front Axle = Load Kingpin Load - Front Axle Load
= 2,000 lb Rear Axle Load = 20,000 - 2,000 18,000 lb Therefore: Total Front Axle Weight = 2,000 + 9,000 lb Total Rear Axle Weight = 4,400 + 18,000 lb = 22,400 lb Isuzu 2000 Body Builder's Guide Page 52
In calculating the weight distribution for a truck, the same lever principle is applies; 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 center line, we must determine the position of the center of gravity of the payload and body weight in relation to the rear axle center line. 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.
Figure 42 Example: Front Axle Load =
Rear Axle Load = (Body Weight + Payload) - Front Axle Load Therefore, Front Axle Load =
Rear Axle Load = 15,000 -2,400 =12,600 lb If the truck tare weight without the body is 5,000 lb on the front axel and 2,4000 lb on the rear axle, then Total Front Axle Weight = 5,000 + 2,4000 = 7,400 lb Isuzu 2000 Body Builder's Guide Page 53
and Total Rear Axle Weight = 2,400 + 12,600 = 15,000 lb 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 doubles or tripe trailer, each units is handled as a separated unit and then combined to determine the total. This simple example illustrates how the principle are applied. Using the formulas, find the weight distributed to each axle.
Figure 43 Front Weight A.
B. C. = 75 lb.
Rear Weight A. Total weight B. C. 300 - 75 = 225 lb.
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. Find (D) and then solve for Wf and Wr.
Page 54
Fiugre 44 D = 60-3-48 = 9 inches Wf = 205 Wr = 2,795
Recommended Weight Distribution % of Gross Vehicle Weight By Axle

CONVENTIONAL (2 Axle)
Page 55
Figure 45
COE (2 Axle)
Figure 46
CONVENTIONAL (3 Axle)
Page 56
Figure 47
COE (3 Axle)
Figure 48
Trailer Weight Calculation

Calculating tractor/trailer weight distribution can be thought of in the same terms as calculating full trucks.
Page 57
Figure 49 The weight at the center of the body and the load when applied is the same a the single point load of the kingpin on the fifth wheel.
Figure 50 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.
Page 58
Figure 51
NOTE: Apply the same principles used with truck chassis
TRAILER WEIGHT
Page 59
Figure 52
Fill in: L = 40 feet RAS = 48 inches KP = 36 inches WB = ? 396 D = ? 204
A. Payload at Kingpin
Calculate the "D" dimension OAL/2 - AF = D 45 feet/2 - 48 inches = 222 inches
PLkp = 24,342 lb B. Payload at Rear Tandem
Page 60
PLrt = W - PLkp PLrt = 50,000 lb - 24,342 lb = 25,658 lb PLrt =25,658 LB 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 5th wheel setting that will apply in all cases. A "rule of thumb" which has proven satisfactory in many cases sets the 5th wheel one inch ahead of the rear axle for each 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 5th 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. A tractor on a hill with the 5th 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.
Figure 53
Performance Calculations
The following calculations have been included to help the users of this book determine the performance characteristics required by their customers and to select the appropriate model vehicle:
Page 61
1.
Speed Formula This formula can be used to determine: 1. 2. 3. Top speed of the vehicle Speed in a given gear Final ratio required for a given speed
Definitions in formulas: RPM Rev/Mile Gear Ratio 60 Example: NPR 12,000 GVWR automatic transmission. RPM = Rev/Mile = Gear/Ratio = 3,000 674 .703 x 5.375 = = = = Revolutions per minute of the engine Tire revolutions per mile The product of the axle ratio times the transmission ratio Time Constant
MPH @ Governed Speed = 70 MPH 2. Grade Horsepower Formula This formula can be used to determine horsepower required for a given grade and speed.
Definitions in formula: GVWR = Grade = Speed = 37,500 Efficiency Factor AHP Resistance Example: NPR 11,050 GVWR automatic transmission with a van body. GVWR Grade = = 12,000 lbs. 1 percent Page 62 Gross Vehicle Weight Rating Grade anticipated in percent Speed in miles per hour Constant = Factor for losses in drivetrain due to friction (use 0.9% efficient driveline) = Horsepower required to overcome wind force
Speed = 37,500 = Efficiency Factor AHP Resistance
55 MPH Constant = 0.9 = 53.6 HP (See following formula (3) for calculation)
HP Required for Grade = 73.22 3. Air Resistance Horsepower Formula This formula is used to determine the horsepower required to overcome air resistance at a given speed.
Definitions in formula: FA Cd MPH 156,000 = = = = Frontal area of vehicle in square feet Aerodynamic Drag Coefficient Speed of vehicle in miles per hour Constant
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. Aerodynamic Drag Coefficients (Source Material: Motor Truck Engineering Handbook). 0.70 for most trucks, semitrailer combinations with tanks or van bodies 0.77 for double and triple trailers and flatbeds with loads 1.00 car and boat haulers Example: NPR 12,000 GVWR van body with 96 inches wide, 115 inches high (84" body height + 31" frame height).
FA Cd Speed
= = =
73.47 FT2 0.70 55 MPH
Air Resistance HP = 54.85 4. Engine Horsepower Formula
Page 63
This formula can be used to derive the output at a given RPM and torque
Definitions in formula: Torque RPM 5252 Example: NPR 12,000 GVWR automatic transmission Torque RPM = = 347 lb-ft 2000 = = = Twisting output of engine given in lb-ft Revolutions per minute of engine Constant
5.
Gradability Formula This formula can be used to determine how large of a grade a vehicle can climb.
Definitions in formula: 1200 T E C R RR GVWR r Example: NPR 12,000 GVWR automatic transmission on concrete highway. T E C R RR GVWR r = = = = = = = 347 lb-ft 0.9 0.9 .703 x 5.375 (in overdrive 1.0 12,000 14.1 in = = = = = = = = Constant Maximum Torque of Engine Engine Efficiency (0.9) Driveline Efficiency (0.9) Transmission Ratio X Axle Ratio Rolling Resistance (see chart on following page) Gross Vehicle Weight Rating Loaded radius of tire
Page 64
Percent Grade = 6.53 - 1 Gradability = 5.53% ROAD ROLLING RESISTANCE: Road Rolling Resistance - Expressed in Percent Grade. Road Surface Concrete, excellent Concrete, good Concrete, poor Asphalt, good Asphalt, fair Asphalt, poor Macadam, good Macadam, fair Macadam, poor 1.0 1.5 2.0 1.25 1.75 2.25 1.5 2.25 3.75 Cobbles, ordinary Cobbles, poor Snow, 2 inch Snow, 4 inch Dirt, smooth Dirt, sandy Mud Sand, level soft Sand, dune 5.5 8.5 2.5 3.75 2.5 3.75 3.75 to 15.0 6.0 to 15.0 16.0 to 30.0
6.
Startability Formula This formula is used to determine what type of a grade a vehicle can be started on.
Definitions in formula: 1200 CET E C R 10% GVWR r E Example: NPR 12,000 GVWR manual transmission CET R GVWR r = = = = 260 lb-ft 6.02 x 4.10 12,000 lb 14.1 in = = = = = = = = = Constant Clutch Engagement Torque 0.9 0.9 Transmission X Axle Ratio Average break away resistance and static inertia constant Gross Vehicle Weight Rating Loaded radius of tire
Page 65
Startability = 7.
26.86%
Vertical Center of Gravity Formula 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 7.2 7.3 7.4 Wv X (Vv) = Mv Wb X (Vb) = Mb Wp X (Vp) = Mp W3 X (Ve) = Me
7.5
Figure 54 Definitions in formula: VCg Wv Wb Wp We Vv Vb Vp Ve Mv Mb Mp Me Example: Isuzu 2000 Body Builder's Guide Page 66 = = = = = = = = = = = = = The total average vertical center of gravity of the completed vehicle (vehicle, body, payload and equipment) Weight of Vehicle Weight of Body Weight of Payload Weight of Equipment Distance from ground to center of gravity of the vehicle Distance from ground to center of gravity of the body Distance from ground to center of gravity of the payload Distance from ground to center of gravity of the equipment Moment of vehicle Moment of Body Moment of Payload Moment of Equipment
NPR 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. Wv Wb Wp Vv Vb Vp Mv Mb Mp = = = = = = = = = 5291 lbs (from vehicle specifications) 2100 lbs (from body manufacturer) 4609 lbs (GVWR - (Wv + Wb + We)) 24.9 in (from Body Builder's Guide, NPR section, page 6) 80 in (from body manufacturer) 62 in (1/2 of payload height + frame height + height from frame to flooring) 5291 X 24.9 =131,746 lb-in (from 7.1) 2100 X 80 = 168,000 lb-in (from 7.2) 4609 X 62 = 285,758 lb-in (from 7.3) None in this example
We,Ve,Me =
48.8 < 54.0 inches (54 inches is maximum allowable VCg per mfg. specifications - from Body Builder's Guide, NPR section, page 6) Since maximum VCg for this truck is not exceeded, 48" stack height above flooring is acceptable. 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, snow plow, etc. ) is installed on either extremes along the completed vehicle's overall length. 8.1 8.2 8.3 8.4 Wv X (Hv) = Mv Wb X (Hb) = Mb Wp X (Hp) = Mp We X (He) = Me
8.5
Page 67
Figure 55 Definitions in formula: Hcg Wv Wb Wp We Vv Vb Vp Ve Mv Mb Mp Me Example: NPR 12,000 GVWR automatic transmission, 132" WB, 14' body length, full payload of boxes stacked and distributed evenly throughout the following, 1,000 lb refer unit attached in front of body. 5291 lbs (from vehicle specifications) Wb = 2100 lbs (from body manufacturer) Wp = 3609 lbs (GVWR - (Wv + Wb + We)) We = 1000 lbs (from equipment manufacturer) Isuzu 2000 Body Builder's Guide Wv = = = = = = = = = = = = = = The total average horizontal center of gravity of the completed vehicle vehicle, body, payload and equipment) Weight of Vehicle Weight of Body Weight of Payload Weight of Equipment Distance from ground to center of gravity of the vehicle Distance from ground to center of gravity of the body Distance from ground to center of gravity of the payload Distance from ground to center of gravity of the equipment Moment of Vehicle Moment of Body Moment of Payload Moment of Equipment
Page 68
Hv Hb Hp* He Mv Mb Mp Me
= = = = = = = =
42.4 in (from Body Builder's Guide, NPR section, page 6) 107.5 in (from body manufacturer) 107.5 in (1/2 of payload length + distance from front axle to front of body) 17.5 in (from equipment manufacturer) 5291 X 42.4 = 224,338 lb-in (from 8.1) 2100 X 107.5 = 225,750 lb-in (from 8.2) 3609 X 107.5 = 387.967 lb-in (from 8.3) 1000 X 17.5 = 17,500 lb-in (from 8.4)
71.3 < 132 inches
(132 inches is the wheelbase dimension)
Since the HCg for this truck is not greater than the WB or negative (-) (denotes HCg forward to 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 body and payload happen to be at the same point.
Highway Limits
Interstate Highway System Limits Bridge Gross Weight Formula
The Federal Government established the Federal Bridge Gross Weight Formula to provide a standard to control the spacing of truck axles on trucks that use highway bridges. This is intended to space loads out over a distance to avoid too high a concentration in one area that could cause damage. The truck's gross weights, axle weight and axle spacing are set in order to keep axle loads and gross weight loads with the limits set by the Federal Government. The Bridge Formula Table is used to check trucks to make sure that Federal weight limit requirements are met and that the allowable gross and axle weights are in the correct relationship with the spacing of axles to prevent high load concentrations on highway bridges. The Federal Government has established the following formula to be used to determine the allowable weight limits and axle spacing for trucks
Page 69
Where: W= L= N= The total gross weight that may be carried on any group of two or more consecutive axles to the nearest 500 lb. The distance (spacing) in feet between the outer axle of any group of two or more consecutive axles. 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 lb each provided the overall distance between the first and last axles of such consecutive sets of axles in 36 feet or more.
Bridge Formula Definitions

The following definitions are used for bridge formula calculations.
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 lb.
Single Axle Weight

The total weight at the ground by al wheels of an axle whose centers may be included between parallel transverse planes forty 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 lb.
Tandem Axle Weight

The total weight at the ground of two or more consecutive or more axles whose centers may be included between parallel vertical planes spaced more than forty inches but not more than ninety-six 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 lb.
Consecutive Axle Weight

The Federal law states that any two consecutive or more 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.
Exception to the Bridge Formula

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 lb each, providing the overall distance between the first and last axles of Isuzu 2000 Body Builder's Guide Page 70
such consecutive sets of tandem axles is 36 feet or more.
Other Federal Provisions

Maximum Width: 102" Overall 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 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.
Federal Bridge Formula Table

MAXIMUM LOAD IN POUNDS ON ANY GROUP OF 2 OR MORE CONSECUTIVE AXLES
Distance in feet between the extremes of any group of 2 or more consecutive axles
4 5 6 7 8 and less 8 and more 9 10 11 12 13 14 15 16 17 18 19 20 21 22
2 Axles 34,000* 34,000* 34,000* 34,000* 34,000* 38,000 39,000 40,000
3 Axles
4 Axles
5 Axles
6 Axles
7 Axles
8 Axles
9 Axles
34,000 42,000 42,500 43,500 44,000 45,000 45,500 46,500 47,000 48,000 48,500 49,500 50,000 51,000 51,500 52,500 50,000 50,500 51,500 52,000 52,500 53,500 54,000 54,500 55,500 56,000 56,500 58,000 58,500 59,000 60,000 60,500 61,000 61,500 66,000 66,500 67,000 Page 71

2 Axles
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 Isuzu 2000 Body Builder's Guide
3 Axles 53,000 54,000 54,500 55,500 56,000 57,000 57,500 58,500 59,000 60,000
4 Axles 57,500 58,000 58,500 59,500 60,000 60,500 61,500 62,000 62,500 63,500 64,000 64,500 65,500 66,000+ 66,500+ 67,500+ 68,000 68,500 69,500 70,000 70,500 71,500 72,000 72,500 73,500 74,000 74,500 75,500 76,000 76,500 77,500 78,000 78,500 79,500 80,000
5 Axles 62,500 63,000 63,400 64,000 65,000 65,500 66,000 66,500 67,500 68,000 68,500 69,000 70,000 70,500 71,000 72,000 72,500 73,000 73,500 74,000 75,000 75,500 76,000 76,500 77,500 78,000 78,500 79,000 80,000 80,500 81,000 81,500 82,500 83,000 83,500 84,000 85,000
6 Axles 68,000 68,500 69,000 69,500 70,000 71,000 71,500 72,000 72,520 73,000 74,000 74,500 75,000 75,500 76,000 77,000 77,500 78,000 78,500 79,000 80,000 80,500 81,000 81,500 82,000 83,000 83,500 84,000 84,500 85,000 86,000 86,500 87,000 87,500 88,000 89,000 89,500
7 Axles 74,000 74,500 75,000 75,500 76,500 77,000 77,500 78,000 78,500 79,000 80,000 80,500 81,000 81,500 82,000 82,500 83,500 84,000 84,500 85,000 85,500 86,000 87,000 87,500 88,000 88,500 89,000 89,500 90,500 91,000 91,500 92,000 92,500 93,000 94,000 94,500
8 Axles
9 Axles
82,000 82,500 83,000 83,500 84,500 85,000 85,500 86,000 86,500 87,000 87,500 88,500 89,000 89,500 90,000 90,500 91,000 91,500 92,500 93,000 93,500 94,000 94,500 95,000 95,500 96,500 97,000 97,500 98,000 98,500 99,000 99,500 Page 72 90,000 90,500 91,000 91,500 92,000 93,000 93,500 94,000 94,500 94,500 95,000 95,500 96,000 96,500 97,500 98,000 98,500 99,000 99,500 100,000 100,500 101,000 102,000 102,500 103,000 103,500 104,000 104,500 105,000

2 Axles
3 Axles
4 Axles
60
5 Axles 85,500
6 Axles 90,000
7 Axles 95,000
8 Axles 100,500
9 Axles 105,500
* Tandem Axle by Definition + Exception to Federal Bridge Formula Table and Law. See Text for Explanation. Note: All permissible load calculations are to the nearest 500 lb Maximum load on any single axle, 20,000 lb. Weights over 80,000 lb are in excess of the Federal GVW on the National Highway Network.
Approximate Weights of Commodities and Materials
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NPR Diesel / NPR HD Diesel

-- WARNING -VEHICLES EQUIPPED WITH AISIN AUTOMATIC TRANSMISSION:
In order to aviod POSSIBLE TRANSMISSION FAILURE, when modifying chassis electrical wiring harness, care must be taken not to eliminate existing ground connections or wiring. Any electric arc welding performed upon the vehicle must be done with the negative battery cable disconnected.
Page 82
Specifications
MODEL GVWR WB ENGINE Model/ Displacement HP (Gross) Torque (Gross) Equipment NPR Diesel/W3500 12,000 lb NPR HD Diesel/W4500 14,500 lb
109 in, 132.5 in, 176 in Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel. 4HE1-TC/290 CID (4.75 liters) 142 HP/2800 RPM (Manual Transmission) 275 lb ft torque/1300 RPM 175 HP/2700 RPM (Automatic Transmission) 347 lb ft torque/2000 RPM
Dry element air cleaner with vertical intake; 2 rows 506 in2 radiator; 6 blade 18.7 in diameter fan with viscous drive. Cold weather starting device and an oil cooler. Single, dry plate, 11.8 in dia, actuated by self adjusting hydraulic master/slave cylinder. MXA5C 5-speed manual, all forward gears syncronized. Fifth gear is direct. Integral power steering 20.9:1 ratio. Tilt and telescoping steering column. Reverse Elliott "I" -Beam rated at 6,830 lb. Semi-elliptical steel alloy leaf springs with stabilizer bar and shock absorbers. 4,700 lb. 5,360 lb Full floating single speed with hypoid gearing rated at 11,020 lb. Semi-elliptical steel allow leaf springs and shock absorbers. 7,950 lb 9,880 lb 16x6.0 6 hole disc wheels, painted white. 215/85R-16E (10 pr) tubeless steel belted radials, all season front and rear. Dual circuit vacuum assisted hydraulic service brakes with load sensing proportioning valve in rear brake circuit and a metering valve between the master cylinder and 6-way joint on the front brake lines. Disc front 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. Antilock Brakes system 33 gal. cylindrical steel fuel tank mounted on right hand rail with fuel water separator mounted on rail. Page 83
CLUTCH TRANSMISSION STEERING FRONT AXLE Suspension GAWR REAR AXLE Suspension GAWR WHEELS TIRES BRAKES
FUEL TANK Isuzu 2000 Body Builder's Guide
MODEL FRAME
NPR Diesel/W3500
NPR HD Diesel/W4500
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. All steel low cab forward, BBC 68.0 in, 45 mechanical tilt with torsion assist. Jersey knit covered high back driver's seat with two occupant passenger seat. Two way roof ventilator, dual cab mounted exterior mirrors. Tilt and telscoping steering column. Tinted glass. 12 Volt, negative ground, dual Delco maintenance free batteries, 750 CCA each, 80 Amp alternator with integral regulator Air Conditioning; AM/FM cassette stereo radio; PTO; engine block heater; engine oil pan heater; heated fuel/water separator; spare wheel; 6" stainless steel convex mirrors. Aisin 450-43 LE 4-speed overdrive transmission with lock-up capability in 2nd, 3rd and 4th and PTO capability.
CAB Equipment
ELECTRICAL
OPTIONS
Transmissions
NOTE: These selected specifications are subject to change without notice.
Vehicle Weights, Dimensions and Ratings
Figure 56 NPR Chassis Dimensions
Variable Chassis Dimensions:

Unit Inch Inch Inch WB 109.0 132.5 150.0 CA* 88.4 111.9 129.4 CE* 131.5 155.0 172.5 OAL 199.5 223.0 240.5 AF 43.1 43.1 43.1 Page 84
Unit Inch
WB 176.0
CA* 155.4
CE* 198.5
OAL 266.3
AF 43.1
* Effective CA & CE are CA or CE less BOC.
Dimension Constraints:
Code AH AW BA BBC BOC Inches 7.9 65.6 47.4 68.0 9.25 Code BW CW FW OH OW FH Inches 83.3 65.0 33.5 87.4 78.5 32.0
12,000 lb GVWR Manual Transmission Model Chassis Cab and Maximum Payload Weights
Model NA1 NA2 NA3 NA4 WB 109.0 in 132.5 in 150.0 in 176.0 in Unit lb lb lb lb Front 3,638 3,682 3,726 3,770 Rear 1,587 1,609 1,631 1,653 Total 5,225 5,291 5,357 5,423 Payload 6,775 6,709 6,643 6,577
Model NE1 NE2 NE3 NE4 WB 109.0 in 132.5 in 150.0 in 176.0 in Unit lb lb lb lb Front 3,649 3,693 3,737 3,781 Rear 1,587 1,609 1,631 1,653 Total 5,236 5,302 5,368 5,434 Payload 9,264 9,198 9,132 9,066
12,000 lb GVWR with Aisin Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model WB Unit Isuzu 2000 Body Builder's Guide Front Rear Total Payload Page 85
Model
WB
Unit
Front
Rear
Total
Payload
14,500 lb GVWR with Aisin Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model NF1 NF2 NF3 NF4 WB 109.0 in 132.5 in 150.0 in 176.0 in Unit lb lb lb lb Front 3,715 3,759 3,803 3,847 Rear 1,631 1,653 1,675 1,698 Total 5,346 5,412 5,478 5,545 Payload 9,154 9,088 9,022 8,955
Vehicle Weight Limits:

GVWR Designed maximum GAWR, Front GAWR, Rear 12,000 lb 4,700 lb 7,950 lb 14,500 lb 5,360 lb 9,880 lb
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.
Frame and Crossmember Specifications
Page 86
Figure 57 Unit: Inch
Figure 58 Unit: Inch Model Wheel Base Frame Thick CROSS MEMBER TYPE/LOCATION A B C-M/T C-A/T D-M/T D-A/T E F Page 87 G
Model
Wheel Base 109 132.5 150.0 176.0
Frame Thick 0.24 0.24 0.24 .024
CROSS MEMBER TYPE/LOCATION A 37.0 37.0 37.0 37.0 B 28.3 28.3 28.3 28.3 C-M/T 8.4 8.4 8.4 8.4 C-A/T 8.4 8.4 8.4 8.4 D-M/T AA 40.5 AA 40.5 AA 40.5 40.5 D-A/T AA 44.7 AA 44.7 AA 44.7 44.7 E -BB 59.4 BB 59.4 59.4 F CC 26.0 CC 26.0 CC 26.0 26.0 G DD 33.0 DD 33.0 DD 33.0 33.0
NPR NPR NPR NPR
M/T = Manual Transmission A/T = Automatic Transmission
Frame Chart
Figure 59
Page 88
Figure 60
Page 89
Figure 61
Figure 62 Unit: Inch VEHICLE MODEL NPR NPR NPR NPR WB 109.0 132.5 150.0 176.0 FRAME FL 186.0 209.6 227.4 253.4 FRAME THICKNESS 0.24 0.24 0.24 0.24
Auxillary Views
Page 90
Figure 64 Side View Battery Box
Page 91
Figure 65 Side View Fuel Tank
Figure 66 Side View Aux. Battery Tray
Page 92
Figure 67 Rear View ABS Controller
Figure 68 Side View In Frame Tank
Page 93
Figure 69 Side View In Frame Tank NOTE: Frame mounted fuel tank available on 109", 132.5", 150" and 176" WB: In frame mounted tank available as optional replacement for frame mounted tank on 109", 132.5", 150" and 176" WB. * Allow 3" additional for battery box opening clearance.
Body Builder Weight Information Chart

NPR Series
Unit: lb Wheel Base GVWR Axle 109 in M/T 12,000 Front Rear Total 14,500 Front Rear Total 3,638 1,587 5,225 3,649 1,587 5,236 A/T 3,704 1,631 5,335 3,715 1,631 5,346 132.5 in M/T 3,682 1,609 5,291 3,693 1,609 5,302 A/T 3,748 1,653 5,401 3,759 1,653 5,412 150 in M/T 3,729 1,631 5,357 3,737 1,631 5,368 A/T 3,792 1,675 5,467 3,803 1,675 5,478 176 in M/T 3,770 1,653 5,423 3,781 1,653 5,434 A/T 3,836 1,698 5,534 3,847 1,698 5,545 573 871 1,444 573 904 1,477 Unsprun g Weight
M/T = Manual Transmission Isuzu 2000 Body Builder's Guide Page 94
A/T = Automatic Transmission
Cab Tilt
Center of Gravity
The center of gravity of the chassis cab. Unit: Inch WB GVWR M/T 12,000 109 132.5 150 176 14,500 109 132.5 150 176 22.1 20.6 20.5 18.9 22.1 20.6 20.5 18.9 33.1 40.3 45.7 53.6 33.0 40.2 45.6 53.5 A/T 33.3 40.6 46.5 54.0 33.3 40.5 45.9 53.6 Page 95 V H
Figure 71 NOTE: The maximum dimensions for a body installed on the NPR are 96 inches wide (outside) by 90 inches high (inside). Any larger body applications must be approved by Isuzu Application Engineering. In the West Coast call 1-562-699-0500, extension 2385 and in the East Coast call 1-770-475-9195 extension 353.
Front Axle Chart
Figure 72 FORMULAS FOR CALCULATING HEIGHT DIMENSIONS Isuzu 2000 Body Builder's Guide Page 96
A = TIRE LOADED RADIUS - B C = CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT CURB POSITION D = CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD CH = C + TIRE UNLOADED RADIUS DH = D + TIRE LOADED RADIUS Unit: Inch Tire Radius TIRE GVWR GAWR A B C D CH DH TRACK Unloa d 14.3 14.3 Loa 14.1 14.1
215/85R 16-E
11,050 lb 14,500 lb
4,700 lb 5,360 lb
7.7 7.7
6.4 6.4
13.0 13.0
12.5 12.5
27.3 27.3
26.6 26.6
65.6 65.6
Rear Axle Chart
Page 97
Figure 73
Figure 74
Definitions
A B C D E CENTER LINE OF AXLE TO BOTTOM OF AXLE BOWL. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT METAL TO METAL POSITION. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT CURB POSITION. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD. REAR TIRE CLEARANCE: MINIMUM CLEARANCE REQUIRED FOR TIRES AND CHAIN MEASURED FROM THE TOP OF THE FRAME AT THE VERTICAL CENTER LINE OF THE REAR AXLE, WHEN REAR WHEELS ON ONE SIDE RIDE OVER A HIGH SPOT. REAR FRAME HEIGHT: VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF FRAME RAIL AND THE GROUND-LINE THROUGH THE CENTER LINE OF THE REAR AXLE AT CURB POSITION. REAR FRAME HEIGHT: VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF FRAME RAIL AND THE GROUND-LINE THROUGH THE CENTER LINE OF THE REAR AXLE AT DESIGN LOAD. MINIMUM DISTANCE BETWEEN THE INNER SURFACES OF THE REAR TIRES.
CH
DH
DW
Page 98
EW
MAXIMUM REAR WIDTH: OVERALL WIDTH OF THE VEHICLE MEASURED AT THE OUTER MOST SURFACE OF THE REAR TIRES. REAR TIRE CLEARANCE: MINIMUM CLEARANCE BETWEEN THE REAR AXLE AND THE GROUND-LINE. DUAL TIRE SPACING: DISTANCE BETWEEN THE CENTER LINES OF THE MINIMUM DISTANCE REQUIRED FOR TIRE BOUNCE AS MEASURED FROM THE CENTER LINE OF THE REAR AXLE AND THE TOP OF THE REAR TIRE WHEN ONE WHEEL RIDES OVER A HIGH SPOT. TRACK DUAL REAR WHEEL VEHICLES: DISTANCE BETWEEN THE CENTER LINES OF THE DUAL WHEELS MEASURED AT THE GROUND-LINE.
HH
HW
CW
SEE TIRE CHART FOR THE FOLLOWING VALUES: TIRE SECTION TIRE RADIUS TIRE LOADED RADIUS TIRE CLEARANCE
FORMULAS FOR CALCULATING REAR WIDTH AND HEIGHT DIMENSIONS

CW CH DH DW EW HH JH KH KW LW = TRACK = TIRE LOADED RADIUS + C = TIRE LOADED RADIUS + D = TRACK + 2 TIRE SECTIONS - TIRE CLEARANCE = TRACK + 2 TIRE SECTIONS + TIRE CLEARANCE = TIRE LOADED RADIUS - A = KH - B = TIRE RADIUS + 3.00 INCHES = DW - 5.00 INCHES = 1.00 INCH MINIMUM CLEARANCE BETWEEN TIRES AND SPRINGS
NOTE: TRACK AND OVERALL WIDTH MAY VARY WITH OPTIONAL EQUIPMENT. Unit: Inch TIRE 215/85R16-E GAWR 7950/9880 lb Track CW 65.0 A 10.6 B 10.6 C 14.9 D 13.3 E 7.8 Page 99
Suspension Deflection Charts
Figure 75
Page 100
Figure 76
Tire and Disc Wheel Chart

TIRE
TIRE LOAD LIMIT AND COLD INFLATION PRESSURES SINGLE TIRE SIZE 215/85R 16-E 215/85R 16-E LB 2430 2680 PSI 70 80 LB 2210 2470 DUAL PSI 70 80 MAXIMUM TIRE LOAD LIMITS FRONT 2 SINGLE 4860 5360 REAR 4 DUAL 8840 9880 12,000 14,500
GVWR (lb)
Unit: Inch TIRE RADIUS TIRE SIZE GVWR (lb) 12,000 LOADED FRONT 215/85R 16-E 14.1 REAR 14.1 UNLOADED FRONT 14.3 REAR 14.7 8.2 1.8 Page 101 6.0 TIRE SECTION WIDTH TIRE CLEARANCE DESIGN RIM WIDTH
TIRE RADIUS TIRE SIZE GVWR (lb) 14,500 LOADED FRONT 215/85R 16-E 14.1 REAR 14.1 UNLOADED FRONT 14.3 REAR 14.7 8.2 1.8 6.0 TIRE SECTION WIDTH TIRE CLEARANCE DESIGN RIM WIDTH
DISC WHEEL
WHEEL SIZE BOLT HOLES BOLT CIRCLE DIA FT/RR NUT SIZE+ REAR STUD SIZE+ NUT/ STUD TORQUE SPECS. 289 ft-lb (392 N-M) INNER CIRCLE OUTSIDE OFFSET DISC THK RIM TYPE MATERIA L MFG.
16x6.00K
6 JIS
8.75
1.6142 (41 mm) BUD HEX
0.8268 (21 mm) SQUAR E
6.46
5.0
0.35
5 DC
Steel TOPY
+ O.D. Wrench Sizes
Figure 77
Page 102
Figure 78
Propeller Shaft
WB PLANE VIEW SIDE VIEW
109 in
132.5 in
150 in
Page 103
WB
PLANE VIEW
SIDE VIEW
176 in
TYPICAL INSTALLATIONS SHOWING YOKES "IN PHASE". "IN PHASE" MEANS THAT THE YOKES AT EITHER END OF A GIVEN PROPELLER SHAFT ASSEMBLY ARE IN THE SAME PLANE.
NPR
(109 in WB)
Figure 79 (132.5 in, 150 and 176 in WB)
Figure 80 1. 2. 3. UNIVERSAL JOINT PROPELLER SHAFT CENTER CARRIER BEARING Page 104
PLANE VIEW WHEEL BASE A M/T A A/T B M/T B A/T C M/T
SIDE VIEW C A/T D M/T D A/T
M/T = Manual Transmission A/T = Automatic Transmission NOTE: ALL DRIVELINE ANGLES ARE AT UNLOADED CONDITION (CURB POSITION WITH TYPICAL CARGO BODY) WB No. of Shafts Trans. Type Shaft #1 O.D. Thickness Length Type Shaft #2 O.D. Thickness Length Type N/A N/A N/A N/A 38.3 B B 44.5 B 39.1 B 29.7 A A 3.25 0.091 38.3 38.3 B 38.3 B 38.3 B 38.3 B 5M/T 109 1 4A/T 5M/T 132.5 2 4A/T 5M/T 3.25 0.091 24.3 47.4 A 41.9 A 59.1 A 53.7 A 150 2 4A/T 5M/T 176 2 4A/T
Type Type A
Description 1st shaft in 2 piece driveline
Illustration
Type B
1st shaft in 1 piece driveline 2nd shaft in 2 piece driveline
M/T = Manual Transmission A/T = Automatic Transmission Figure 81 NPR/W Series Deisel Propeller Shaft
Page 105
PTO Location, Drive Gear and Opening Information

Manual Transmission
Figure 82
Figure 83
Page 106
Unit: Inch
Transmissio n MXA 5C Opening Locatio n Left PTO DriveGear Location 2nd Gear Trans Countershaft PTO Gear Ratio of PTO Drv Gear Spd to Eng Spd 25/49=.51 Number of Teeth 20 Helix Angl e 15 Ma Outp Torq 14 lb@ 10 RP 13 lb@ 15 RP
Bolt Pattern
Pitch
(Dr 1)
13.2
39
3.4
11.2
7.1
2.5
4.1
3.175
Aisin1
Left
(Dr 2)
12.6
38.5 9
7.5
2.5
4.48
1:1 with tubine
58
N/A
Opening Diagram (Dr 1) MXA 5C (Dr 2) AISIN
Brake System Diagram

Vacuum Over Hydraulic
PLEASE REFER TO INTRODUCTION SECTION OF BOOK FOR ANTI-LOCK SYSTEM CAUTIONS AND WHEEL BASE MODIFICATION REQUIREMENTS
Page 107
Figure 84
Page 108
Figure 85
2000 Model Diesel Fuel Filler Installation Instructions

DISCONNECT BATTERY Take out hoses, clips, pipe joint support bracket (3), filler neck, fuel filler cap and protective wrap from storage box. Mount support bracket on rail per drawing #1. Bracket location is at 20.55 inches. Remove the temporary filler cap from the tank. Install 90 degree hose (1) on the fuel tank. Secure with clip (9) hose lengths are set for 96 inch wide body to adjust for narrower body see drawing #2. Place pipe joint (11) in open end of hose and clamp with clip (9). See drawing #3. Place other piece of filler hose and vent hose tube through the protective wrap and join with 90 degree hose at the pipe joint use clips to secure hose. Make sure the vent tube hose is placed on top of the filler hose inside the protective wrap. This will allow Isuzu 2000 Body Builder's Guide Page 109
the fuel tank to vent properly. The hose must be covered with the protective wrap. See drawing #4. Secure the fuel filler hose and fuel vent hose that is surrounded by the protective wrap to the support bracket with two tie wraps. The filler neck must be mounted at 35 degrees from the frame horizontal. See drawing #5. Secure the filler plate to the bottom of the body. Filler instructions for the gasoline fuel tank are the same as above except that the filler neck plate is offset from the frame bracket due to the bend in the outer hose that prevents fuel splash back. The different hose makes the attaching location on the bosy different between the diesel and the gasoline tank. See drawing #1. Secure cap and cap tether to the filler plate. See drawing #1. Check for leaks. Reconnect battery.
Installation Drawings of Fuel Filler Hose

Drawing #1
Diesel A = 20.55 inches
Page 110
Figure 86 (1) (2) (9) (10) Filler Hose Breather Hose Clip Filler Hose Clips Breather Hose
Drawing #2
Page 111
Figure 87
Drawing #3
Page 112
Figure 88 (9) (11) Clip Filler Hose Clips Breather Hose
Drawing #4
Page 113
Figure 89 Torque for Bolts 280 ~ 450 in/lbs. (8) (3) (12) (4) Clip Band Protector Bracket Filler Hose Bolt Protector
The hose shall be routed as shown. The breather tube sshall be routed above the filler hose. There shall be no slack in breather hose when routed.
Drawing #5
Page 114
Figure 90 (4) (9) (10) (5) (E) Fill Hose Protector Fill Hose Clip Breather Hose Clip Fill Hose Neck Asm. See Drawing #3
Drawing #3
Page 115
Figure 91 (6) (7) (13) Fill Neck Cap Fill Neck Bracket Fill Hose Screw
NO. 1 2 3 4 5 6 7 8 9 10 11
P. NAME FILLER HOSE BREATHER HOSE BRKT; FILLER HOSE PROTECTOR; FILLER HOSE NECK ASM; FILLER HOSE CAP; FILLER NECK BRKT; FILLER NECK CLIP; BAND / PROTECTOR CLIP; FILLER HOSE CLIP; BREATHER HOSE JOINT PIPE
P. NO. 897108 251 894462 403 897127 344 897114 063 897116 622 897116 431 897116 621 109707 107 894435 876 894242 034 121431 134
QTY 001 001 001 002 001 001 001 002 004 002 001
Page 116
NO. 12 13
P. NAME BOLT SCREW; FILLER HOSE
P. NO. 02868 1035 894381 646
QTY 002 003
NPR Gas / NPR HD Gas

-- WARNING -VEHICLES EQUIPPED WITH HYDRA-MATIC TRANSMISSION:
Specifications
MODEL GVWR WB ENGINE Model/ Displacement HP (Gross) Torque (Gross) Equipment NPR GAS/W3500 GAS 12,000 lb 109 in, 132.5 in, 150 in, 176 in GMPT 8-cylinder, V Block 4-cycle, OHV, water cooled, Sequential Port Fuel Injection GMPT-V8/350 CID (5.7 liters) 250 HP @ 4200 rpm 330 lb-ft torque @ 2800 RPM Sequential Port Fuel Injection (SFI), mass air flow meter, powertrain control module (VCM), onboard diagnostics, oxygen sensors, catalytic converter, map sensor, with external oil cooler. 4L30-E Hydra-Matic 4-speed automatic with lock-up converter and overdrive.. Integral power steering 20.9:1 ratio. Tilt and telescoping steering column. Page 117
TRANSMISSION STEERING Isuzu 2000 Body Builder's Guide
MODEL FRONT AXLE Suspension GAWR REAR AXLE Suspension GAWR WHEELS TIRES BRAKES
NPR GAS/W3500 GAS Reverse Elliott "I" -Beam rated at 6,830 lb. Semi-elliptical steel alloy leaf springs with stabilizer bar and shock absorbers. 4,700 lb. Full floating single speed with hypoid gearing rated at 11,020 lb. Semi-elliptical steel allow leaf springs and shock absorbers. 7,950 lb 16x6.0 6 hole disc wheels, painted white. 215/85R-16E (10 pr) tubeless steel belted radials, all season front and rear. Dual circuit vacuum assisted hydraulic service brakes with load sensing proportioning valve in rear brake circuit and a metering valve between the master cylinder and 6-way joint on the front brake lines. Disc front and self-adjust outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal expanding drum type, transmission mounted. Antilock Brakes system 32.1 gal. rectangular steel fuel tank. Mounted between the frame rails with electric type fuel pump (mounted in tank). 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. All steel, low cab forward, BBC 68.0 in, 45 mechanical tilt with torsion assist. Jersey knit covered high back driver's seat with two occupant passenger seat. Two way roof ventilator, dual cab mounted exterior mirrors. Tilt and telscoping steering column. Tinted glass. 12 Volt, negative ground, Delco maintenance free battery (located under cab), 630 CCA each, 80 Amp alternator with integral regulator Air Conditioning; AM/FM cassette stereo radio; spare wheel; 6" stainless steel mirrors.
FUEL TANK FRAME
CAB Equipment
ELECTRICAL
OPTIONS
MODEL GVWR WB ENGINE Model/Displacement Isuzu 2000 Body Builder's Guide
NPR HD GAS/W4500 GAS 14,050 lb 109 in, 132.5 in, 150 in, 176 in GMPT 8-cylinder, V Block 4-cycle, OHV, water cooled, Sequential Port Fuel Injection GMPT-V8/350 CID (5.7 liters) Page 118
MODEL HP (Gross) Torque (Gross) Equipment
NPR HD GAS/W4500 GAS 250 HP @ 4200 rpm 330 lb-ft torque @ 2800 RPM Sequential Port Fuel Injection (SFI), mass air flow meter, powertrain control module (VCM), onboard diagnostics, oxygen sensors, catalytic converter, map sensor, with external oil cooler. 4L30-E Hydra-Matic 4-speed automatic with lock-up converter and overdrive.. Integral power steering 20.9:1 ratio. Tilt and telescoping steering column. Reverse Elliott "I" -Beam rated at 6,830 lb. Semi-elliptical steel alloy leaf springs with stabilizer bar and shock absorbers. 5,360 lb. Full floating single speed with hypoid gearing rated at 11,020 lb. Semi-elliptical steel allow leaf springs and shock absorbers. 9,880 lb 16x6.0 6 hole disc wheels, painted white. 225/70R-19.5F (12 ply) tubeless steel belted radials, premium highway tread Front/Rear. Antilock Brake System, dual circuit vacuum assisted hydraulic service brakes with load sensing proportioning valve in rear brake circuit and a metering valve between the master cylinder and 6-way joint on the front brake lines. Disc front and self-adjust outboard mounted drum rear. The parking brake is a mechanical, cable actuated, internal expanding drum type, transmission mounted. 32.1 gal. rectangular steel fuel tank. Mounted between the frame rails with electric type fuel pump (mounted in tank). 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. All steel, low cab forward, BBC 68.0 in, 45 mechanical tilt with torsion assist. Jersey knit covered high back driver's seat with two occupant passenger seat. Two way roof ventilator, dual cab mounted exterior mirrors. Tilt and telscoping steering column. Tinted glass. 12 Volt, negative ground, Delco maintenance free battery (located under cab), 630 CCA each, 80 Amp alternator with integral regulator Air Conditioning; AM/FM cassette stereo radio; spare wheel; 6" stainless steel mirrors.
TRANSMISSION STEERING FRONT AXLE Suspension GAWR REAR AXLE Suspension GAWR WHEELS TIRES BRAKES
FUEL TANK FRAME
CAB Equipment
ELECTRICAL
OPTIONS
NOTE: These selected specifications are subject to change without notice. Isuzu 2000 Body Builder's Guide Page 119
MODEL
NPR HD GAS/W4500 GAS
Figure 92
Figure 93
Page 120
Figure 94 NPR/W-Series Gas Cab Chassis Dimensions

Unit Inch Inch Inch Inch WB 109.0 132.5 150.0 176.0 CA* 88.4 111.9 129.4 155.4 CE* 131.5 155.0 172.5 198.5 OAL 199.5 223.0 240.5 266.3 AF 43.1 43.1 43.1 43.1
Dimension Constraints: 11,050 GVW

Code AH AW BA BBC BOC Inches 7.9 65.6 47.4 68.0 9.25 Code BW CW FW OH OW FH Inches 83.3 65.0 33.5 87.4 78.5 32.0*
* 32.75 for 14,050 GVWR
11,050 lb GVWR with 4L30-E Hydra-Matic Transmission Model Federal Chassis Cab and Maximum Payload Weights
Model WB Unit Front 3,153 Rear 1,742 Total 4,895 Payload 6,155 Page 121 JB1 109.0 in lb Isuzu 2000 Body Builder's Guide
Model JB2 JB3 JB4
WB 132.5 in 150.0 in 176.0 in
Unit lb lb lb
Front 3,197 3,219 3,263
Rear 1,764 1,786 1,808
Total 4,961 5,005 5,071
Payload 6,089 6,045 5,979
11,050 lb GVWR with 4L30-E Hydra-Matic Transmission Model California Chassis Cab and Maximum Payload Weights
Model HB1 HB2 HB3 HB4 WB 109.0 in 132.5 in 150.0 in 176.0 in Unit lb lb lb lb Front 3,153 3,197 3,219 3,263 Rear 1,742 1,764 1,786 1,808 Total 4,895 4,961 5,005 5,071 Payload 6,155 6,089 6,045 5,979
Dimension Constraints: 14,050 GVW

Code AH AW BA BBC BOC Inches 8.6 65.6 47.4 68.0 9.25 Code BW CW FW OH OW FH Inches 84.0 65.0 33.5 88.1 78.5 32.7
14,050 lb GVWR with 4L30-E Hydra-Matic Transmission Model California/Federal Chassis Cab and Maximum Payload Weights
Model KE1 KE2 KE3 KE4 WB 109.0 in 132.5 in 150.0 in 176.0 in Unit lb lb lb lb Front 3,230 3,274 3,296 3,340 Rear 1,874 1,896 1,918 1,940 Total 5,104 5,170 5,214 5,280 Payload 8,946 8,880 8,836 8,770

GVWR 11,050 lb Designed maximum Isuzu 2000 Body Builder's Guide 14,050 lb Page 122
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.
Figure 95
Page 123
Figure 96 Unit: Inch Model Wheel Base 109 132.5 150.0 176.0 Frame Thick 0.24 0.24 0.24 .024 CROSS MEMBER TYPE/LOCATION A 37.0 37.0 37.0 37.0 B 28.3 28.3 28.3 28.3 C-A/T 11.1 11.1 11.1 11.1 D-A/T AA 52.0 AA 52.0 AA 52.0 52.0 E -BB 59.4 BB 59.4 59.4 F CC 26.0 CC 26.0 CC 26.0 26.0 G DD 33.0 DD 33.0 DD 33.0 33.0
NPR/ NPR HD NPR/ NPR HD NPR/ NPR HD NPR/ NPR HD
Frame Chart
Page 124
Figure 97
Figure 98
Page 125
Figure 99
Figure 100 Unit: Inch VEHICLE MODEL Isuzu 2000 Body Builder's Guide WB FRAME FL FRAME THICKNESS
Page 126
Auxillary Views
Page 127
Figure 102 Rear View Catalitic Converters
Figure 103 Rear View Muffler
Page 128
Figure 104 Side View In Frame Tank
Figure 106 Rear View Emission Canister Isuzu 2000 Body Builder's Guide Page 129
Figure 107 Rear View In Frame Tank

NPR/NPR HD Series
Unit: lb Wheel Base GVWR Axle 109 in A/T 11,050 Front Rear Total 14,050 Front Rear Total 3,153 1,742 4,895 3,230 1,874 5,104 132.5 in A/T 3,197 1,764 4,961 3,274 1,896 5,170 150 in A/T 3,219 1,786 5,005 3,296 1,918 5,214 176 in A/T 3,263 1,808 5,071 3,340 1,940 5,280 573 871 1,444 705 1,134 1,839 Unsprun g Weight
A/T = Automatic Transmission Isuzu 2000 Body Builder's Guide Page 130
Cab Tilt
Center of Gravity
The center of gravity of the chassis cab. Unit: Inch WB GVWR A/T 11,050 109 132.5 150 176 21.7 20.1 19.7 18.1 38.8 47.1 53.5 62.8 V H
Page 131
WB GVWR
H A/T
14,050
109 132.5 150 176
21.7 20.0 19.7 18.1
40.0 48.6 55.2 64.7
Figure 109 NOTE: The maximum dimensions for a body installed on the NPR are 96 inches wide (outside) by 90 inches high (inside). Any larger body applications must be approved by Isuzu Application Engineering. In the West Coast call 1-562-699-0500, extension 2385 and in the East Coast call 1-770-475-9195 extension 353.
Front Axle Chart
Page 132
Figure 110 FORMULAS FOR CALCULATING HEIGHT DIMENSIONS A = TIRE LOADED RADIUS - B C = CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT CURB POSITION D = CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD CH = C + TIRE UNLOADED RADIUS DH = D + TIRE LOADED RADIUS Unit: Inch Tire Radius TIRE GVWR GAWR A B C D CH DH TRACK Unloa d 15.2 15.4 Loa 14.1 15
215/85R 16-E 225/70R 19.5
11,050 lb 14,050 lb
4,700 lb 5,360 lb
7.7 8.4
6.4 7.0
13.0 13.6
12.5 13.1
27.3 29
26.6 28.1
65.6 65.6
Rear Axle Chart
Page 133
Figure 111
Page 134
Figure 112
Definitions
A B C D E CENTER LINE OF AXLE TO BOTTOM OF AXLE BOWL. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT METAL TO METAL POSITION. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT CURB POSITION. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD. REAR TIRE CLEARANCE: MINIMUM CLEARANCE REQUIRED FOR TIRES AND CHAIN MEASURED FROM THE TOP OF THE FRAME AT THE VERTICAL CENTER LINE OF THE REAR AXLE, WHEN REAR WHEELS ON ONE SIDE RIDE OVER A HIGH SPOT. REAR FRAME HEIGHT: VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF FRAME RAIL AND THE GROUND-LINE THROUGH THE CENTER LINE OF THE REAR AXLE AT CURB POSITION. REAR FRAME HEIGHT: VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF FRAME RAIL AND THE GROUND-LINE THROUGH THE CENTER LINE OF THE REAR AXLE AT DESIGN LOAD. MINIMUM DISTANCE BETWEEN THE INNER SURFACES OF THE REAR TIRES. MAXIMUM REAR WIDTH: OVERALL WIDTH OF THE VEHICLE MEASURED AT THE OUTER MOST SURFACE OF THE REAR TIRES. REAR TIRE CLEARANCE: MINIMUM CLEARANCE BETWEEN THE REAR AXLE AND THE GROUND-LINE. DUAL TIRE SPACING: DISTANCE BETWEEN THE CENTER LINES OF THE TIRES IN A SET OF DUAL TIRES. TIRE BOUNCE CLEARANCE: MINIMUM DISTANCE REQUIRED FOR TIRE BOUNCE AS MEASURED FROM THE CENTER LINE OF THE REAR AXLE AND THE TOP OF THE REAR TIRE WHEN ONE WHEEL RIDES OVER A HIGH SPOT. TRACK DUAL REAR WHEEL VEHICLES: DISTANCE BETWEEN THE CENTER LINES OF THE DUAL WHEELS MEASURED AT THE GROUND-LINE.
CH
DH
DW EW
HH
HW
KH
CW
SEE TIRE CHART FOR THE FOLLOWING VALUES: Isuzu 2000 Body Builder's Guide Page 135
TIRE SECTION TIRE RADIUS TIRE LOADED RADIUS TIRE CLEARANCE

NOTE: TRACK AND OVERALL WIDTH MAY VARY WITH OPTIONAL EQUIPMENT. Unit: Inch TIRE 215/85R16-E 225/70R 19.5 GAWR 7950/8760 lb 9880 Track CW 65.0 65 A 6.5 11.6 B 10.6 10.6 C 14.9 14.9 D 13.3 13.0 E 7.8 8.4
Suspension Deflection Charts - NPR GAS
Page 136
Figure 113
Figure 114
Suspension Deflection Charts - NPR HD GAS

Figure 115
Figure 116

TIRE
TIRE LOAD LIMIT AND COLD INFLATION PRESSURES SINGLE TIRE SIZE 215/85R 16-E 225/70R 19.5 LB 2430 3315 PSI 70 85 LB 2210 3115 DUAL PSI 70 85 MAXIMUM TIRE LOAD LIMITS FRONT 2 SINGLE 4860 6630 REAR 4 DUAL 8840 12460 11,050 14,050
GVWR (lb)
Unit: Inch TIRE RADIUS TIRE SIZE GVWR (lb) 11,050 14,050 LOADED FRONT 215/85R 16-E 225/70R 19.5 14.05 15.00 REAR 14.05 15.20 UNLOADED FRONT 15.21 15.40 REAR 15.21 15.80 8.54 8.8 1.46 1.2 6.0 6.0 TIRE SECTION WIDTH TIRE CLEARANCE DESIGN RIM WIDTH
DISC WHEEL
WHEEL SIZE BOLT HOLES BOLT CIRCLE DIA FT/RR NUT SIZE+ REAR STUD SIZE+ NUT/ STUD TORQUE SPECS. 289 ft-lb (392 N-M) INNER CIRCLE OUTSID E OFFSET DISC THK RIM TYPE M AL
16x6.00K
6 JIS
8.75
1.6142 (41 mm) BUD HEX 1.6142 (41 mm) BUD HEX
0.8268 (21 mm) SQUARE
6.46
5.0
0.35
5 DC T
19.5x6.00
6 JIS
8.75
0.8268 (21 mm) SQUARE
325 ft-lb (440 N-M)
6.46
5.0
0.35
5 DC T
+ O.D. Wrench Sizes
Page 139
Figure 117
Figure 118
Propeller Shaft
WB
PLANE VIEW
SIDE VIEW
NPR EFI
(109 in WB)
Figure 119 (132.5 in, 150 and 176 in WB)
Figure 120 1. 2. 3. UNIVERSAL JOINT PROPELLER SHAFT CENTER CARRIER BEARING PLANE VIEW WHEEL BASE A A/T -2.1 B A/T 3.5 0 C A/T -1.5 SIDE VIEW D A/T 6.4 2.4 Page 141
109 in 132.5 in
PLANE VIEW WHEEL BASE A A/T 0 0 B A/T 2.7 1.8 C A/T 0.7 4.0
SIDE VIEW D A/T 5.3 6.0
150 in 176 in
A/T = Automatic Transmission NOTE: ALL DRIVELINE ANGLES ARE AT UNLOADED CONDITION (CURB POSITION WITH TYPICAL CARGO BODY) WB No. of Shafts Trans. Type Shaft #1 O.D. Thickness Length Type Shaft #2 O.D. Thickness Length Type N/A N/A 33.46 C 34.05 A 24.10 B 3.0 0.083 33.46 C 49.2 C 109 1 A/T 132.5 2 A/T 3.0 0.083 41.85 B 52.1 B 3.5 150 2 A/T 176 2 A/T 3.0
Figure 121 NPR/W-Series Gas Propshaft Dimensions Type Description Illustration
Type A
1st shaft in 1 piece driveline
Type B
Page 142
Type C
2nd shaft in 2 piece driveline

Figure 122
Page 143
Figure 123
1999 Model Gasoline Fuel Filler Installation Instructions (Revised)

DISCONNECT BATTERY Loosen hose from tie downs. Remove replacement hoses from cab and install in place of original hoses. Discard old hoses. Place 2" rubber block on frame with hoses inserted through the block to determine minimum thickness of wood filler to be used. Extend hose out from passenger side of rail to body rail. The filler neck must be mounted at 35 degrees from the frame horizontal. See drawing #A and B. Filler hose is set for 96 inch outside width body. Minimum floor height is 250 mm from rail to floor. Secure the filler plate to the bottom of the body. Isuzu 2000 Body Builder's Guide Page 144
Check for leaks. Reconnect battery.
Fuel Filler Installation Drawings

Gas Filler Neck Installation Rear View 96" Wide Body
Figure 124
Top View 96" Wide Body
Page 145
Figure 125 BODY WIDTH 90 inch BODY 86 inch BODY 80 inch BODY CUT HOSE Remove 3 inches Remove 5 inches Remove 8 inches
NQR
-- WARNING -VEHICLES EQUIPPED WITH AISIN TRANSMISSION:
Specifications
MODEL GVWR WB ENGINE Model/ Displacement HP (Gross) Torque (Gross) Equipment NQR/W5500 17,950 lb 109 in, 132.5 in, 150 in, 176 in Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel. 4HE1-TC/290 CID (4.75 liters) 175 HP/2700 RPM 347 lb ft torque/2000 RPM Dry element air cleaner with vertical intake; 2 rows 511.2 in2 radiator; 6 blade 18.7 in diameter fan with viscous drive. Cold weather starting device and an oil cooler. Single, dry plate, 12.8 in dia ceramic, actuated by self adjusting hydraulic master/slave cylinder. MBP6P 6-speed manual, all forward gears syncronized. Sixth gear is overdrive. Integral power steering 20.9:1 ratio. Tilt and telescoping steering column. Reverse Elliott "I" -Beam rated at 6,830 lb. Semi-elliptical steel alloy leaf springs with stabilizer bar and shock absorbers. 6,830 lb. Full floating single speed with hypoid gearing rated at 14,550 lb. Semi-elliptical steel allow leaf springs and shock absorbers. 12,980 lb 19.5x6.0 6 hole disc wheels, painted white. 225/70R-19.5F (12 pr) tubeless steel belted radials, highway tread front and rear. Dual circuit vacuum assisted hydraulic service brakes with load sensing proportioning valve in rear brake circuit. Disc front 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. Antilock Brakes system 33 gal. cylindrical steel fuel tank mounted on right hand rail with fuel water separator mounted on rail.
CLUTCH TRANSMISSION STEERING FRONT AXLE Suspension GAWR REAR AXLE Suspension GAWR WHEELS TIRES BRAKES
FUEL TANK
Page 147
MODEL FRAME
NQR/W5500 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. All steel low cab forward, BBC 68.0 in, 45 mechanical tilt with torsion assist. Jersey knit covered high back driver's seat with two occupant passenger seat. Two way roof ventilator, dual cab mounted exterior mirrors. Tilt and telscoping steering column. Tinted glass. 12 Volt, negative ground, dual Delco maintenance free batteries, 750 CCA each, 80 Amp alternator with integral regulator Air Conditioning; AM/FM cassette stereo radio; PTO; engine block heater; engine oil pan heater; heated fuel/water separator; spare wheel; 6" stainless steel convex mirrors. Auxillary transmission oil cooler, mandatory for 20,950 GCWR. Aisin 450-43 LE 4-speed overdrive transmission with lock-up capability in 2nd, 3rd and 4th and PTO capability.
CAB Equipment
ELECTRICAL
OPTIONS
Transmissions
Figure 126
Page 148
Figure 127
Figure 128 NQR/W Series Diesel Cab Chassis Dimensions

Unit Inch Inch Inch Inch WB 109.0 132.5 150.0 176.0 CA* 88.4 111.9 129.4 155.4 CE* 131.5 155.0 172.5 198.5 OAL 199.5 223.0 240.5 266.3 AF 43.1 43.1 43.1 43.1
Code AH Inches 8.6 Code BW Inches 83.3 Page 149
Code AW BA BBC BOC
Inches 65.6 47.4 68.0 9.25
Code CW FW OH OW FH
Inches 65.0 33.5 88.1 78.5 32.8
Model NQ1 NQ2 NQ3 NQ4 WB 109.0 in 132.5 in 150.0 in 176.0 in Unit lb lb lb lb Front 3,891 3,935 3,979 4,023 Rear 2,028 2,050 2,072 2,094 Total 5,919 5,985 6,051 6,117 Payload 12,031 11,965 11,899 11,833
17,950 lb GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights
Model NR1 NR2 NR3 NR4 WB 109.0 in 132.5 in 150.0 in 176.0 in Unit lb lb lb lb Front 3,880 3,924 3,968 4,012 Rear 2,028 2,050 2,072 2,094 Total 5,908 5,974 6,040 6,106 Payload 12,042 11,976 11,910 11,844

GVWR Designed maximum GAWR, Front GAWR, Rear 17,950 lb 6,830 lb 12,980 lb
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 Isuzu 2000 Body Builder's Guide Page 150
calculated by subtracting chassis curb weight from the GVWR.
Figure 129
Figure 130 Unit: Inch Wheel Frame Base Thick Isuzu 2000 Body Builder's Guide Model CROSS MEMBER TYPE/LOCATION Page 151
Model
Wheel Base
Frame Thick
CROSS MEMBER TYPE/LOCATION A B C-M/T C-A/T D-M/T D-A/T E F G
Frame Chart
Figure 131
Figure 132
Page 152
Figure 133
Figure 134 Unit: Inch VEHICLE MODEL Isuzu 2000 Body Builder's Guide WB FRAME FL FRAME THICKNESS Page 153
NQR NQR NQR NQR
109.0 132.5 150.0 176.0
186.0 209.6 227.4 253.4
0.24 0.24 0.24 0.24
Auxillary Views
Page 154
Figure 136 Side View Battery Box
Figure 137 Side View Fuel Tank
Figure 138 Side View Aux. Battery Tray ID1
Page 155

NPR Series
Unit: lb Wheel Base GVWR Axle 109 in M/T 16,500 Front Rear Total 3,891 2,028 5,919 A/T 3,880 2,028 5,908 132.5 in M/T 3,935 2,050 5,985 A/T 3,924 2,050 5,974 150 in M/T 3,979 2,072 6,051 A/T 3,968 2,072 6,040 176 in M/T 4,023 2,094 6,117 A/T 4,012 2,094 6,106 705 1366 2,071 Unsprun g Weight
Cab Tilt
Page 156
Center of Gravity
The center of gravity of the chassis cab. Unit: Inch WB GVWR M/T 16,500 109 132.5 150 176 22.1 20.6 20.4 18.9 36.8 44.7 50.6 59.4 A/T 37.4 44.8 50.7 59.5 V H
Page 157
Figure 141 NOTE: The maximum dimensions for a body installed on the NQR are 96 inches wide (outside) by 90 inches high (inside). Any larger body applications must be approved by Isuzu Application Engineering. In the West Coast call 1-562-699-0500, extension 2385 and in the East Coast call 1-770-475-9195 extension 353.
Front Axle Chart
Figure 142 FORMULAS FOR CALCULATING HEIGHT DIMENSIONS Isuzu 2000 Body Builder's Guide Page 158
A = TIRE LOADED RADIUS - B C = CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT CURB POSITION D = CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD CH = C + TIRE UNLOADED RADIUS DH = D + TIRE LOADED RADIUS Unit: Inch Tire Radius TIRE GVWR GAWR A B C D CH DH TRACK Unloa d 15.4 Loa 15.0
225/70R 19.5
16,500 lb
6,830 lb
8.4
7.0
13.6
13.1
29
28.1
66.1
Rear Axle Chart
Page 159
Figure 143
Page 160
Figure 144
Definitions
A B C D E CENTER LINE OF AXLE TO BOTTOM OF AXLE BOWL. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT METAL TO METAL POSITION. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT CURB POSITION. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD. REAR TIRE CLEARANCE: MINIMUM CLEARANCE REQUIRED FOR TIRES AND CHAIN MEASURED FROM THE TOP OF THE FRAME AT THE VERTICAL CENTER LINE OF THE REAR AXLE, WHEN REAR WHEELS ON ONE SIDE RIDE OVER A HIGH SPOT. REAR FRAME HEIGHT: VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF FRAME RAIL AND THE GROUND-LINE THROUGH THE CENTER LINE OF THE REAR AXLE AT CURB POSITION. REAR FRAME HEIGHT: VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF FRAME RAIL AND THE GROUND-LINE THROUGH THE CENTER LINE OF THE REAR AXLE AT DESIGN LOAD. MINIMUM DISTANCE BETWEEN THE INNER SURFACES OF THE REAR TIRES. MAXIMUM REAR WIDTH: OVERALL WIDTH OF THE VEHICLE MEASURED AT THE OUTER MOST SURFACE OF THE REAR TIRES. Page 161
CH
DH
DW EW
HH
REAR TIRE CLEARANCE: MINIMUM CLEARANCE BETWEEN THE REAR AXLE AND THE GROUND-LINE. DUAL TIRE SPACING: DISTANCE BETWEEN THE CENTER LINES OF THE MINIMUM DISTANCE REQUIRED FOR TIRE BOUNCE AS MEASURED FROM THE CENTER LINE OF THE REAR AXLE AND THE TOP OF THE REAR TIRE WHEN ONE WHEEL RIDES OVER A HIGH SPOT. TRACK DUAL REAR WHEEL VEHICLES: DISTANCE BETWEEN THE CENTER LINES OF THE DUAL WHEELS MEASURED AT THE GROUND-LINE.
HW
CW

NOTE: TRACK AND OVERALL WIDTH MAY VARY WITH OPTIONAL EQUIPMENT. Unit: Inch TIRE 225/70R19.5 GAWR 12980 lb Track CW 65.0 A 11.6 B 10.6 C 14.9 D 13.0 E 8.4
Page 162
Figure 145

TIRE
TIRE LOAD LIMIT AND COLD INFLATION PRESSURES SINGLE TIRE SIZE 225/70R 19.5F LB 3450 PSI 90 LB 3245 DUAL PSI 90 MAXIMUM TIRE LOAD LIMITS FRONT 2 SINGLE 6900 REAR 4 DUAL 12980 16,500
GVWR (lb)
Unit: Inch TIRE RADIUS TIRE SIZE GVWR (lb) 16,500 LOADED FRONT 225/70R 19.5F 15.0 REAR 15.2 UNLOADED FRONT 15.4 REAR 15.8 8.8 1.2 6.0 TIRE SECTION WIDTH TIRE CLEARANCE DESIGN RIM WIDTH
DISC WHEEL
19.5x6.00 K
6 JIS
8.75
1.6142 (41 mm) BUD HEX
0.8268 (21 mm) SQUARE
6.46
5.0
0.39
15 DC
+ O.D. Wrench Sizes
Page 164
Figure 147
Figure 148
Propeller Shaft
WB PLANE VIEW SIDE VIEW
Page 165
WB
PLANE VIEW
SIDE VIEW
109 in
132.5 in
150 in
176 in
NPR
(109 in WB)
Figure 139
Page 166
(132.5 in, 150 and 176 in WB)
Figure 140 1. 2. 3. UNIVERSAL JOINT PROPELLER SHAFT CENTER CARRIER BEARING PLANE VIEW WHEEL BASE A M/T -0 0 0 A A/T -0 0 0 B M/T 3.1 3.1 3.1 2.3 B A/T 3.1 3.1 3.1 2.3 C M/T -4.9 2.6 2.8 SIDE VIEW C A/T -5.0 2.6 2.8 D M/T 9.4 7.3 7.7 4.8 D A/T 9.4 7.3 7.7 4.8
109 in 132.5 in 150 in 176 in
M/T = Manual Transmission A/T = Automatic Transmission NOTE: ALL DRIVELINE ANGLES ARE AT UNLOADED CONDITION (CURB POSITION WITH TYPICAL CARGO BODY) WB No. of Shafts Trans. Type Shaft #1 O.D. Thickness Length Type Shaft #2 O.D. Thickness Length 6M/T 3.54 0.126 38.7 D 3.54 0.126 N/A 109 1 4A/T 3.25 0.091 38.6 C 3.25 0.091 N/A 6M/T 3.54 0.126 24.5 B 3.54 0.126 38.3 D 132.5 2 4A/T 3.25 0.091 24.3 A 3.25 0.091 38.3 C 6M/T 3.54 0.126 41.9 B 3.54 0.126 38.3 D 150 2 4A/T 3.25 0.091 41.9 A 3.25 0.091 38.3 C 6M/T 3.54 0.126 53.7 B 3.54 0.126 52.6 D 176 2 4A/T 3.25 0.091 53.7 A 3.25 0.091 52.6 C Page 167
N/A N/A Type Isuzu 2000 Body Builder's Guide
WB No. of Shafts Trans. Type
109 1 6M/T 4A/T
132.5 2 6M/T 4A/T
150 2 6M/T 4A/T
176 2 6M/T 4A/T
Type
Description
Model
Illustration
Type A
P20
Type B
P30
Type C 1st shaft in 1 piece driveline 2nd shaft in 2 piece driveline Type D
P20
P30
M/T = Manual Transmission A/T = Automatic Transmission Figure 141 NQR/W Series Deisel Propeller Shaft

Manual Transmission
Page 168
Figure 142
Figure 143
Ratio of PTO Drv Gear Spd to Eng Spd 20/38=.52 6
Transmissio n MBP 6P
Opening Locatio n Left
Bolt Pattern
PTO DriveGear Location 3rd Gear Trans Countershaft PTO Gear
Number of Teeth
Pitch
Helix Angl e 22 RH
Ma Outp Torq 18 lb@ 15 RP 13 lb@ 10 RP
(Dr 1)
10.9
36.9
5.2
13.1
7.7
2.5
3.9
28
3.5
Aisin1
Left
(Dr 2)
12.6
38.5 9
7.5
2.5
4.48
1:1 with tubine
58
N/A
Page 169
1) No PTO gear in the 150" WB models.
Opening Diagram (Dr 1) MBP 6P (Dr 2) AISIN

Page 170
Figure 144
FRR
Specifications
MODEL GVWR/GCWR WB ENGINE Model/ Displacement Isuzu 2000 Body Builder's Guide NPR Diesel/W3500 NPR HD Diesel/W4500 18,000/30,000 lb (22,050 lb with automatic) 19,500/30,000 lb (22,050 lbs with automatic) 148 in, 167 in, 176 in, 218 in Isuzu 6-cyl., in-line 4-cycle, turbocharged, intercooled, direct injection diesel. 6HK1-TC/475 CID (7.8 L) Page 171
MODEL HP (Gross) Torque (Gross) Equipment
NPR Diesel/W3500
NPR HD Diesel/W4500
200 HP @ 2,400 rpm 441 lb ft torque @ 1,500 rpm Dry element air cleaner with vertical inlet. Spin-on paper element type fuel and oil filters. Cold weather starting device. Fuel water separator, common rail type electronic fuel injection system and an oil cooler. Single dry disc, hydraulic actuation, 14 in diameter, cerametallic Spicer. MLD 6Q Manual 6-Speed syncronized second through sixth, sixth gear is overdrive. Allison AT542, 4-Speed, automatic transmission. Integral power steering with variable ratio (18.8-16.1:1). Reverse Elliott "I" -Beam rated at 8,800 lb. Semi-elliptical alloy steel leaf springs with stabilizer bar and shock absorbers. 6,800 lb. 7,060 lb Full floating single speed with hypoid gearing rated at 14,330 lb. 3.900:1 Semi-elliptical alloy steel leaf springs. 13,000 lb 13,680 lb 19.5x6.00 on 6-hole disc wheels, painted white. 225/70R 19.5F low profile tubeless radial Anti-Lock Brake System with dual circuit air over hydraulic self adjusting service brakes. Mechanical cable actuated internal expanding drum parking brake, transmission mounted. Disc front and self-adjust outboard mounted drum rear. An exhaust brake is standard on manual transmission models. 42 gal. rectangular steel, mounted on LH frame rail, fuel/water separator mounted. Fuel filter. Ladder type channel section 33 in width at load platform area, section modulus 7.63 in3 and RBM 412,200 lb-ft/in per rail. All steel, low cab forward, BBC 78.2 in, 45 mechanical tilt with torsion assist. Dual exterior rear view mirrors, electrically operated wipers and window washer. Steering column tilts and telscopes. Includes 2-3 point seat belts and retractors, and a 2 point seat belt. 12 Volt, dual Delco maintenance free batteries, 750 CCA each. 110 Amp alternator with integral regulator 2nd fuel tank on 167", 179, 191 and 218 WB, transmission mounted PTO, Air Conditioning, block heater; oil pan heater, AM/FM Cassette Stereo Radio, rear traction tread tires, spare wheel, spare tire carrier, spare tire. Page 172
CLUTCH TRANSMISSION Optional Trans. STEERING FRONT AXLE Suspension GAWR REAR AXLE Ratio Suspension GAWR WHEELS TIRES BRAKES
FUEL TANK FRAME CAB Equipment
ELECTRICAL OPTIONS
MODEL
NPR Diesel/W3500
NPR HD Diesel/W4500
Figure 145
Figure 146
Page 173
Figure 147

Unit Inch Inch Inch Inch Inch WB+ 148 167 179 191 218 CA* 117.1 136.2 148.0 159.8 187.4 CE* 180.3 206.5 226.2 243.9 283.3 OAL 259.1 285.2 304.9 322.6 362.0 AF 62.9 70.3 78.1 84.1 95.9
* Effective CA & CE are 7.5 inches less for MT. * Effective CA & CE are 11.3 inch less for AT.
+
Frame is tapered at the rear of the 148", 167" and 179" WB, but straight on the 191" WB.
Code AH HH AW BA BBC Inches 8.2 6.7 70.5 47.8 78.7 7.5 MT/ 11.3 AT Code BW CW FW OH OW FH FH 191 and 218 WB Inches 85.3 65.4 33.0 100.9 86.3 33.2 35.2
BOC
Page 174
Indicates change.
Chassis Curb and Maximum Payload Weights 19,500 GVW With 6-Speed Manual Transmission
Model SA1 SA2 SA3 SA4 SA5 WB+ 148 in 167 in 179 in 191 in 218 in Unit lb lb lb lb lb Front 5,027 5,116 5,182 5,171 5,270 Rear 2,448 2,414 2,403 2,503 2,547 Total 7,475 7,530 7,585 7,674 7,817 Payload 12,025 11,970 11,915 11,826 11,683
18,000 GVW With 6-Speed Manual Transmission

Model SE1 SE2 SE3 SE4 SE5 WB+ 148 in 167 in 179 in 191 in 218 in Unit lb lb lb lb lb Front 5,027 5,116 5,182 5,171 5,270 Rear 2,448 2,414 2,403 2,503 2,547 Total 7,475 7,530 7,585 7,674 7,817 Payload 10,525 10,470 10,415 10,326 10,183
Chassis Curb & Maximum Payload Weights 19,500 GVW With Automatic Transmission
Model SB1 SB2 SB3 SB4 SB5 WB+ 148 in 167 in 179 in 191 in 218 in Unit lb lb lb lb lb Front 4,994 5,083 5,138 5,127 5,226 Rear 2,426 2,392 2,381 2,481 2,525 Total 7,420 7,475 7,519 7,608 7,751 Payload 12,080 12,025 11,981 11,892 11,749
Frame is tapered at the rear of the 148", 167" and 179" WB, but straight on the 191" WB. Page 175
18,000 GVW With Automatic Transmission

Model SF1 SF2 SF3 SF4 SF5 WB+ 148 in 167 in 179 in 191 in 218 in Unit lb lb lb lb lb Front 4,994 5,083 5,138 5,127 5,226 Rear 2,426 2,392 2,381 2,481 2,525 Total 7,420 7,475 7,519 7,608 7,751 Payload 10,580 10,525 10,481 10,392 10,249
Truck Weight Limits:

Unit GVWR Designed max GAWR, Front GAWR, Rear lb lb lb 18,000 lb 6,800 lb 13,000 lb 19,500 lb 7,060 lb 13,680 lb
Technical Notes:
Chassis Curb Weight reflects standard environment 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.

191 & 218 in Wheelbase
Page 176
Figure 148
148, 167 & 179 in Wheelbase
Figure 149
Page 177
Figure 150 Unit: Inch Model Wheel Base 148 167 179 191 218 Frame FL 253.9 279.5 299.2 316.9 356.3 Frame Thick 0.24 0.24 0.24 0.24 0.24 CROSS MEMBER TYPE/LOCATION A AA 24.3 AA 24.3 AA 24.3 AA 24.3 AA 24.3 B AA 39.6 AA 39.6 AA 39.6 AA 39.6 AA 39.6 C BB 77.9 BB 77.9 BB 77.9 BB 77.9 BB 77.9 D C2 106.2 8 DD C2 96.1 C1 106.3 C3 106.3 C1 117.7 C1 145.27 E DD 125.4 DD 143.9 DD 155.7 DD 167.5 DD 195.0 F DD 175.0 DD 193.5 DD 205.3 DD 217.1 DD 244.6 G EE 212.0 EE 237.6 EE 257.3 EE 267.1 EE 314.3
FRR FRR FRR FRR FRR
Frame Chart
Page 178
Figure 151
Figure 152
Page 179
Figure 153
Figrue 154
Page 180
Figure 155 Unit: Inch VEHICLE MODEL FRR FRR FRR FRR FRR WB 148 167 191 179 218 FRAME FL 253.9 279.5 299.2 316.9 356.3 CA 117.7 132.2 148 159.8 187.4 CE 180.6 206.5 226.2 243.9 283.3 FRAME THICKNESS 0.24 0.24 0.24 0.24 0.24
Auxillary Views
Page 181
Figure 156
Figure 157
Page 182

FRR Series
GVWR 19500 19500 19500 19500 Front Rear Total Axle 148 in M/T 5027 2448 7475 A/T 4994 2426 7420 167 in M/T 5116 2414 7530 A/T 5083 2392 7475 179 in M/T 5182 2403 7585 A/T 5138 2381 7519 191 in M/T 5171 2503 7674 A/T 5127 2481 7608 218 in M/T 5270 2547 7817 A/T 5226 2525 7751 U sp We 7 1 2
M/T = Manual Transmission A/T = Automatic Transmission Units = Lb
Page 183
Cab Tilt
Center of Gravity
The center of gravity of the chassis cab. Unit: Inch GVWR 19,500 WB 148 167 179 191 218 V 27.5 27.5 27.5 28.3 28.3 M/T 48.7 53.7 56.8 62.3 71.2 A/T 48.6 53.6 56.7 62.3 71.2
Page 184
Figure 160 NOTE: The maximum dimensions for a body installed on the FRR are 96 inches wide (outside) by 90 inches high (inside). Any larger body applications must be approved by Isuzu Application Engineering. In the West Coast call 1-562-699-0500, extension 2385 and in the East Coast call 1-770-475-9195 extension 353.
Front Axle Chart
Figure 161 FORMULAS FOR CALCULATING HEIGHT DIMENSIONS A = TIRE LOADED RADIUS - B C = CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT CURB POSITION Isuzu 2000 Body Builder's Guide Page 185
D = CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD CH = C + TIRE UNLOADED RADIUS DH = D + TIRE LOADED RADIUS Unit: Inch
TIRE 225/70R 19.5 GVWR 19,500 lb
AXLE CAPACIT Y SUSP CAPACIT Y
A 8.2
B 6.9
C 12.3
D 11.3 9
CH 27.5 2
DH 26.4 1
TRAC K 70.5
Tire Radius Unload 15.4 Lo 15
8,800 lb
7,060 lb
Rear Axle Chart
Page 186
Figure 162
Page 187
Figure 163
Definitions
A B C D E CENTER LINE OF AXLE TO BOTTOM OF AXLE BOWL. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT METAL TO METAL POSITION. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT CURB POSITION. CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD. REAR TIRE CLEARANCE: MINIMUM CLEARANCE REQUIRED FOR TIRES AND CHAIN MEASURED FROM THE TOP OF THE FRAME AT THE VERTICAL CENTER LINE OF THE REAR AXLE, WHEN REAR WHEELS ON ONE SIDE RIDE OVER A HIGH SPOT. REAR FRAME HEIGHT: VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF FRAME RAIL AND THE GROUND-LINE THROUGH THE CENTER LINE OF THE REAR AXLE AT CURB POSITION. REAR FRAME HEIGHT: VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF FRAME RAIL AND THE GROUND-LINE THROUGH THE CENTER LINE OF THE REAR AXLE AT DESIGN LOAD. MINIMUM DISTANCE BETWEEN THE INNER SURFACES OF THE REAR TIRES.
CH
DH
DW EW
MAXIMUM REAR WIDTH: OVERALL WIDTH OF THE VEHICLE MEASURED AT THE OUTER MOST SURFACE OF THE REAR TIRES. Isuzu 2000 Body Builder's Guide
Page 188
HH
REAR TIRE CLEARANCE: MINIMUM CLEARANCE BETWEEN THE REAR AXLE AND THE GROUND-LINE. DUAL TIRE SPACING: DISTANCE BETWEEN THE CENTER LINES OF THE TIRES IN A SET OF DUAL TIRES. TIRE BOUNCE CLEARANCE MINIMUM DISTANCE REQUIRED FOR TIRE BOUNCE AS MEASURED FROM THE CENTER LINE OF THE REAR AXLE AND THE TOP OF THE REAR TIRE WHEN ONE WHEEL RIDES OVER A HIGH SPOT. TRACK DUAL REAR WHEEL VEHICLES: DISTANCE BETWEEN THE CENTER LINES OF THE DUAL WHEELS MEASURED AT THE GROUND-LINE.
HW
KH
CW

NOTE: TRACK AND OVERALL WIDTH MAY VARY WITH OPTIONAL EQUIPMENT. Unit: Inch TIRE GVWR
Axle Capacity Susp Capacity
A 8.1
B 11.2
C 17.4
D 15.1
E 9.8
Track CW 65.3
225/70R19.5 19,500 lb (12 pr) Isuzu 2000 Body Builder's Guide
14,330 lb
13,680 lb
Page 189
TIRE
GVWR
Axle Capacity
Susp Capacity
Track CW
Figure 164
Page 190
Figure 165

TIRE
RADIAL SINGLE TIRE SIZE 225/70R 19.5 (12 pr) LB 13,640 PSI 95 LB 3,420 DUAL PSI 95 MAXIMUM TIRE LOAD LIMITS FRONT 2 SINGLE 7,280 REAR 4 DUAL 13,680 19,500
GVWR (lb)
TIRE SIZE 225/70R 19.5F
GVWR (lb) 19,500
TIRE RADIUS LOADED 15.0 in UNLOADED 15.4 in
TIRE SECTION WIDTH 8.8 in
TIRE CLEARANCE 1.20 in
DESIGN RIM WIDTH 6.0 in
Page 191
DISC WHEEL
19.5x6.00
6 JIS
8.75
1.6142 in (41 mm) BUD HEX
0.8268 in (21 mm) SQUARE
6.46 in
5.3 in
0.35 in
15 DC
+ O.D. Wrench Sizes
Figure 166
Page 192
Figure 167
Propeller Shaft
WB 148 in 167 in 179 in 191 in PLANE VIEW SIDE VIEW
148 in 218 in
FRR
(148 in, 167 in, 179 in & 191 in WB)
Page 193
Figure 168 (218 in WB)
Figure 169 1. 2. 3. UNIVERSAL JOINT PROPELLER SHAFT CENTER CARRIER BEARING PLANE VIEW A B UNLOADED WHEEL BASE 148 in 167 in 179 in 191 in 218 in M/T 0.0 0.0 0.0 0.0 0.0 A/T 0.0 0.0 0.0 0.0 0.0 0.0 0.0 M/T A/T M/T 4.8 3.5 2.6 2.6 2.6 A/T 4.9 3.5 2.7 2.6 2.6 4.8 3.5 2.6 2.6 2.6 4.9 3.5 2.7 2.6 2.6 C LOADED
SIDE VIEW D E UNLOADED WHEEL BASE M/T A/T M/T A/T M/T A/T F LOADED M/T A/T Page 194
SIDE VIEW D E UNLOADED WHEEL BASE 148 in 167 in 179 in 191 in 218 in M/T 1.7 1.2 1.2 2.0 1.2 A/T 1.8 1.3 1.3 2.1 1.3 1.6 1.6 M/T A/T M/T 7.1 4.2 2.5 2.2 0.7 A/T 7.2 4.2 2.5 2.2 0.7 F LOADED M/T 2.4 0.7 -0.1 -0.2 -1.8 A/T 2.4 0.7 -0.1 -0.3 -1.8
Engine install at 2.5 degree angle from horizontal frame. Side view angles are measured from 2.5 degree angle. Positive angles are in additional to 2.5 angle. Negative angles are in subtraction from 2.5 angle. NOTE: Loaded Unloaded WB No. of Shafts Trans. Type Shaft #1 O.D. Thickness Length Type Shaft #2 O.D Thickness Length Type Shaft #3 O.D. Thickness Length Type 38.2 B 37.61 B 48.44 B 47.85 B B 4.0 0.134 60.65 B 60.65 B 37.89 A 36.59 A 46.16 A 44.86 A A 4.0 0.134 60.06 59.46 B 60.65 B 60.06 B 42.89 D 42.89 D M/T at Design Load at Curb Position (With typical cargo body) 148 2 A/T M/T 167 2 A/T M/T 4.0 0.134 46.16 44.86 A 57.57 A 56.28 A 42.37 C 41.07 C 179 2 A/T M/T 191 2 A/T M/T 218 3 A/T
Type
Description
Illustration
Page 195
Type A
1st shaft in 2 piece driveline 6-speed manual and automatic
Type B
2nd shaft in 2 piece driveline 3rd shaft in 3 piece driveline 6-speed manual and automatic
Type C
1st shaft in 3 piece driveline 6-speed manual and automatic
Type D
2nd shaft in 3 piece driveline 6-speed manual and automatic

Manual Transmission
Page 196
Figure 170
Figure 171
Ratio of PTO Drv Gear Spd to Eng Spd 25/ 42-0.595
Transmissio n MLD6Q
Open ing Locatio n Left
Bolt Pattern
PTO DriveGear Location 4th Gear Trans Countershaft Counter Driven PTO Gear
No. of Teeth
Pitch
Helix Angl e 24 RH
(Dr 1)
11.3
43.2
5.1
12.9
7.3
2.5
5.6
36
6.629 9
AT 542
Right
SAE-6
8.2
40.0
0.0
7.6
7.3
2.5
5.7
1:1 with tubine
55
6.000
Page 197
(Dr 1) MLD 6Q
AT 542

Page 198
Figure 172
FSR, FTR & FVR
Base Model Specifications

CONDENSED BASE MODEL SPECIFICATIONS
MODEL DESCRIP GVW (LBS) FRONT GAWR* (LBS) REAR GAWR* (LBS) FSR 10 23100 8100 FSR 11 23100 8100 FTR 10 25950 9350 FTR 11 25950 9350 FTR 12 25950 9350 FTR 13 25950 9350 FTR 20 30000 11000 FTR 21 30000 11000 FTR 22 30000 11000 FTR 23 30000 11000
15000
15000
17640
17640
17640
17640
19000
19000
19000
19000
Page 199
MODEL DESCRIP ENGINE HORSEP OWER TRANSMI SSION FRONT AXLE CAP* (LBS) FRONT SUSP CAP* (LBS) REAR AXLE CAP* (LBS) REAR SUSP CAP* (LBS) REAR AXLE RATIO* (LBS) TIRES*
FSR 10
6HK1-T C
FSR 11
6HK1-T C
FTR 10
6HK1-T C
FTR 11
6HK1-T C
FTR 12
6HK1-T C
FTR 13
6HK1-T C
FTR 20
6HK1-T C
FTR 21
6HK1-T C
FTR 22
6HK1-T C
FTR 23
6HK1-T C
200 HP MLD6Q 8100
200 HP AT545 8100
200 HP MLD6Q 11000
200 HP AT545 11000
200 HP MLD6Q 11000
200 HP AT545 11000
200 HP MLD6Q 11000
200 HP AT545 11000
200 HP MLD6Q 11000
200 HP AT545 11000
8100
8100
12000
12000
12000
12000
12000
12000
12000
12000
15000
15000
17850
17850
17850
17850
19000
19000
19000
19000
15000
15000
19000
19000
19000
19000
19000
19000
19000
19000
4.88
3.90
4.88
3.90
4.88
3.90
5.57
4.33
5.57
4.33
235/ 80R22.5 G
235/ 80R22.5 G
235/ 80R22.5 G
235/ 80R22.5 G
235/ 80R22.5 G
235/ 80R22.5 G
11R22.5 G
11R22.5 G
11R22.5 G
11R22.5 G
BRAKES FRAME MATERIA L* FUEL CAPACIT Y* ALTERNA TOR
HYD 50,000 PSI 50
HYD 50,000 PSI 50
HYD 80,000 PSI 50
HYD 80,000 PSI 50
AIR 80,000 PSI 50
AIR 80,000 PSI 50
HYD 80,000 PSI 50
HYD 80,000 PSI 50
AIR 80,000 PSI 50
AIR 80,000 PSI 50
110 AMP
110 AMP
110 AMP
110 AMP
110 AMP
110 AMP
110 AMP
110 AMP
110 AMP
110 AMP
* MAY CHANGE BASED ON SPECIFICATION REQUIREMENT OF THE APPLICATION
Base Model Weights

MODEL FRONT AXLE WEIGHT (LB.) 5760 REAR AXLE WEIGHT (LB.) 2394 TOTAL CHASSIS WEIGHT (LB.) 8154 Page 200
FSR 10 Isuzu 2000 Body Builder's Guide
MODEL
FRONT AXLE WEIGHT (LB.) 5765 5918 5922 6019 6023 6076 5990 6094 6021 6371
REAR AXLE WEIGHT (LB.) 2374 2590 2588 2992 2989 2837 2798 3188 3164 3380
TOTAL CHASSIS WEIGHT (LB.) 8139 8508 8510 9011 9012 8913 8788 9282 9185 9751
FSR 11 FTR 10 FTR 11 FTR 12 FTR 13 FTR 20 FTR 21 FTR22 FTR 23 FVR 10
BASE MODEL WEIGHTS INCLUDE 15 GALLONS OF FUEL.
Body Payload Distribution

86" BBC Isuzu FSR, FTR & FVR
Page 201
Figure 173
BODY-PAYLOAD WEIGHT DISTRIBUTION (% Front/Rear)

DIMENSIONS - INBODY LENGTHS - FT.
WB 140"/FQT 158"/EG5 170"/EH8 188"/EK8 200"/EM2 218"/FPL 233"/EQ8 248"/ES5 CA* 108 126 138 156 168 186 201 216 CE 159.6 195.2 207.2 249.3 261.3 279.3 294.3 309.3 OL 245.6 281.2 293.2 335.2 347.2 365.2 380.2 395.2 12 24/76 14 15/85 25/75 30/70 17/83 23/77 30/70 35/65 9/91 16/84 24/76 29/71 34/66 39/61 9/91 18/82 23/77 29/71 33/67 37/63 11/89 17/83 23/77 28/72 33/67 11/89 18/82 23/77 28/72 12/88 18/82 23/77 7/93 13/87 18/82 8/92 13/8 16 18 20 22 24 26 28 30
* Dimensions shown are nominal. * Percentages allow for 3" CB (cab/body clearance) *All Ca. dimensions are measured above frame; Consult Body Builder pages for fuel tank and battery box locations on frame. Recommended (Wheelbase/Body Length) combinations are shown in bold font. 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 are intended for reference and does not preclude the necessity for an accurate weight distribution calculation.
Chassis Definition Drawing
Page 202
Figure 174
GCW Rating for Major Components

COMPONENTS ENGINE ISUZU 6HK1-TC RPO CODE MAXIMUM GCW RATING (LB.)
LQB LQC
GCW MAY BE LIMITED BY PERFORMANCE RESTRICTIONS BASE ON ENGINE HP, TRANSMISSION, AXLE AND VEHICLE CONFIGURATION
TRANSMISSION ISUZU MLD6Q ALLISON AT545 ALLISON AT542 Isuzu 2000 Body Builder's Guide M54 MF1 MT9 45,000 30,000 22,050 Page 203
COMPONENTS ENGINE AXLES EATON 15040S 15,000 LB. CAP. DANA S150-S15,000 LB. CAP EATON 19050S 16,900 LB. CAP. EATON 19050S 17,850 LB. CAP. EATON 19050T 17,850 LB. CAP EATON 19050S 19,000 LB. CAP EATON 19060S 19,000 LB. CAP. EATON 19060T 19,000 LB. CAP. EATON 21060S 21,000 LB. CAP. EATON 21060T 21,000 LB. CAP. EATON 22060S 22,000 LB. CAP. EATON 22060T 22,000 LB. CAP. EATON 23080S 23,000 LB. CAP. EATON 23080T 23,000 LB. CAP. EATON 23105S 23,000 LB. CAP. HYDRAULIC BRAKE SYSTEM AIR BRAKE SYSTEM
RPO CODE
MAXIMUM GCW RATING (LB.)
H10 H08 HWY HZW HZT H11 HPK HPM HPP H15 HPG HPH HPQ H20 HNA JE3 JE4
40,000 40,000 50,000 50,000 50,000 50,000 55,000 55,000 65,000 65,000 65,000 65,000 70,000 70,000 105,000 30,000 45,000
Crossmember Locations
Page 204
Figure 175 TOP DIMENSION IS MM (BOTTOM DIMENSION IS INCHES) RPO CODE FQT EG5 EH8 EK8 EM2 FPL EQ8 ES5 WB 140 158 170 188 200 218 233 248 A -103.8 103.8 103.8 115.8 103.8 103.8 103.8 B -----133.8 148.8 133.8 C -------163.8 D -213.9 225.9 267.9 279.9 297.9 312.9 327.9
DIMENSIONS ARE IN INCHES.
Frame Reinforcement Locations and Frame Rail Dimensions
Page 205
Figure 176 TOP DIMENSION IS MM (BOTTOM DIMENSION IS INCHES)
Full Truck (RQ2) Frame Rail Lengths

FULL TRUCK (RQ2) OVERALL FRAME RAIL LENGTHS
MODEL WB CODE WB (INCHES) FRAME CODE FRAME REINF. FRAME LENGTH
Page 206
MODEL
WB CODE FQT
WB (INCHES) 140
FRAME CODE FD0 FD5 F03
FRAME REINF. F08
FRAME LENGTH 240.9
EG5
158
FD0 FD5 F03
276.5
EH8
170
FD0 FD5
288.5
FSR FTR FVR EM2 200 EK8 188
F03 FD5 F03 FD5 F03 FPL 218 FD5 F03 EQ8 233 FD5 F03 ES5 248 FD5 F03 390.5 375.5 360.5 342.5 330.5
FD0 = 50000 PSI FRAME FD5 = 80000 PSI FRAME F03 = 110000 PSI FRAME HEAT TREATED
Frame Materials and Physical Properties, Frame Strength and Dimensions

FRAME MATERIALS AND PHYSICAL PROPERTIES

MODEL FRAME RAIL RPO CODE MATERIAL TYPE GRADE YIELD STRENGTH WELDABILITY RBM SECTION MODULUS* OUTSIDE DEPTH FLANGE WIDTH MATERIAL THICKNESS OPTIONAL REINFORCEMENT TYPE MATERIAL MATERIAL THICKNESS COMBINED SECTION MODULUS* RATED COMBINED RBM INCH IN-LBS IN-LBS IN
3
DIMENSION
FSR FD0 STEEL SAE J1392 50
FTR/FVR FD5 STEEL SAE J1392 80 80,000 PERMITTED 1,378,300 12.53 9.65 3.00 0.315 F08 INVERTED L STEEL 0.24 20.36
FTR/FVR F03 STEEL H.T. SAE 1027 ---110,000 NOT PERMITTED 1,760,000 16.00 9.80 3.00 0.375 F08 INVERTED L STEEL 0.24 23.56
PSI
50,000 PERMITTED 479,000 9.58 9.49 3.00 0.24 N/A -----
INCH INCH INCH
IN
--
2,239,500
2,591,600
* MEASURED BEHIND THE CAB.
Front Axle Track Chart

FSR, FTR, FVR FRONT AXLE TRACK CHART
AXLE CAPACITY FL1 8100 LBS FL2 11000 LBS F 120
Page 208
FSR, FTR, FVR FRONT AXLE TRACK CHART

AXLE CAPACITY WHEEL TYPE RPO STEEL DISK WHEEL 8 HOLE HUB PILOTED ALUMINUM DISK WHEEL 8 HOLE HUB PILOTED STEEL DISK WHEEL 10 HOLE HUB PILOTED STEEL DISK WHEEL 10 HOLE HUB PILOTED ALUMINUM DISK WHEEL 10 HOLE HUB PILOTED Q82 RPM WHEEL SIZE 19.5X6.75 19.5X6.75 OFFSET 5.60 6.50 FL1 8100 LBS BRAKES HYD 81.35 82.33 FULL AIR N/A N/A FL2 11000 LBS BRAKES HYD N/A N/A FULL AIR N/A N/A F 120 BR FUL
QH3
22.5X7.50
6.44
79.66
79.56
79.86
79.91
RPQ
22.5X8.25
6.62
79.43
79.32
79.63
79.68
RNE
22.5X8.25
6.59
N/A
80.26
N/A
80.61
DIMENSIONS ARE IN INCHES
Front Axle Formulas and Dimensions Illustration

Formulas for Calculation Height Dimensions
Page 209
Figure 177 A = Tire loaded radius - B B = Centerline of axle to bottom of beam C = Centerline of axle to bottom inside of of rail at curb position. D = Centerline of axle to bottom inside of rail at design load CH = C+ Tire loaded radius DH = D+ Tire loaded radius
Track = Wheel offset at spindle. Track at ground will vary with camber angle and tire/wheel combination.
Front Axle Dimension Charts

THIS CHART IS USED TO FIND FRONT FRAME HEIGHT BY COMBINING THE INFORMATION IN THE CHART WITH THE TIRE INFORMATION FOR THE TIRES USED ON THE CAHSSIS AND THE FORMULAS AND ILLUSTRATIONS FOR THE FRONT AXLE FRAME HEIGHT FD0 = 50,000 PSI STEEL FRAME Isuzu 2000 Body Builder's Guide Page 210
FD5 = 80,000 PSI STEEL FRAME F03 = 110,000 PSI STEEL FRAME
MODEL FRONT AXLE RPO CAPACITY SUSPENSION RPO F14 CAPACITY 8100 TL FRAME RPO FD0 FD5 STABILIZER F59 YES NO YES YES NO FSR FL1 8100 F15 9000 TL FD0 FD5 FK9 F15 FTR 10, 11, 12 & 13 FL2 FTR 10, 11, 12, 13, 20, 21, 22 & 23 FTR 10, 11, 12, 13, 20, 21, 22 & 23 FS7 FTR 20, 21, 22 & 23 F26 FL2 11000 12000 TL 12000 11000 F26 12000 TL 9000 ML 9000 TL FD0 FD5 FD5 F03 FD5 F03 F26 12000 TL FD5 F03 FM4 14600 TL FD5 F03 FD5 F03 F26 FVR FS7 12000 12000 TL FD5 F03 FM4 14600 TL FD5 F03 YES NO YES NO NO NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO LOW PRO GPG NO NO YES NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO B 7.32 7.32 7.28 7.32 7.32 7.32 7.32 7.32 7.32 7.32 7.32 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 8.66 DIMENSION C 8.03 8.07 6.89 8.11 8.15 8.07 7.83 8.15 7.91 7.64 7.72 8.94 8.70 9.02 8.78 9.29 9.02 9.37 9.09 9.61 9.41 9.69 9.49 9.80 9.37 9.88 9.45 9.29 9.02 9.37 9.09 9.61 9.41 9.69 9.80 9.80 9.37 9.88 9.45 D 6. 6. 5. 6. 6. 6. 6. 6. 6. 6. 6. 7. 7. 7. 7. 6. 7. 6. 7. 6. 7. 6. 7. 7. 7. 7. 7. 6. 7. 6. 7. 6. 7. 6. 7. 7. 7. 7. 7.
DIMENSIONS IN INCHES
Page 211
FRONT FRAME HEIGHT UNLOADED = TIRE RADIUS + C DIMENSION + FRAME DIMENSION FRONT FRAME HEIGHT LOADED = LOADED TIRE RADIUS + D DIMENSION + FRAME DIMENSION
Rear Axle Dimension Charts

REAR AXLE TRACK CHART FSR 10, 11
AXLE CAPACITY WHEEL TYPE RPO STEEL DISK WHEEL 8 HOLE HUB PILOTED ALUMINUM DISK WHEEL 8 HOLE HUB PILOTED STEEL DISK WHEEL 10 HOLE HUB PILOTED Q83 RPW WHEEL SIZE 19.5X6.75 19.5X6.75 OFFSET 5.6 6.5 H08 15000 LBS BRAKES HYDRAULIC 72.30 72.18 H10 15000 LBS BRAKES HYDRAULIC 72.30 72.18 HWY 16900 LBS BRAKES HYDRAULIC 71.70 71.70
QH4
22.5X7.50
6.44
72.18
72.18
N/A
FTR 10, 11, 12, & 13

AXLE CAPACITY WHEEL TYPE RPO STEEL DISK WHEEL 10 HOLE HUB PILOTED STEEL DISK WHEEL 10 HOLE HUB PILOTED ALUMINUM DISK WHEEL 10 HOLE HUB PILOTED QH4 WHEEL SIZE 22.5X7.50 OFFSET 6.44 HZW/HZT 17850 LBS BRAKES HYD 71.57 FULL AIR 71.81 HPK/HPM 19000 LBS BRAKES HYD 71.57 FULL AIR 71.81 H11 19000 LBS BRAKES HYD 71.57 FULL AIR 71.81
RPR
22.5X8.25
6.62
71.69
71.94
71.69
71.94
71.69
71.94
RNF
22.5X8.25
6.59
71.57
71.94
71.57
71.94
71.57
71.94
Page 212
FTR 20, 21, 22 & 23

AXLE CAPACITY WHEEL TYPE RPO STEEL DISK WHEEL 10 HOLE HUB PILOTED STEEL DISK WHEEL 10 HOLE HUB PILOTED ALUMINUM DISK WHEEL 10 HOLE HUB PILOTED QH4 WHEEL SIZE 22.5X7.50 OFFSET 6.44 H11 19000 LBS BRAKES HYD 71.57 FULL AIR 71.81 HPP/H15 21000 LBS BRAKES HYD 71.46 FULL AIR 72.02 HPG/HPH 22000 LBS BRAKES HYD N/A FULL AIR 72.02
RPR
22.5X8.25
6.62
71.69
71.94
71.58
72.14
N/A
72.14
RNF
22.5X8.25
6.59
71.57
71.94
71.46
72.14
N/A
72.14
FVR 10
AXLE CAPACITY WHEEL TYPE RPO STEEL DISK WHEEL 10 HOLE HUB PILOTED STEEL DISK WHEEL 10 HOLE HUB PILOTED ALUMINUM DISK WHEEL 10 HOLE HUB PILOTED QH4 WHEEL SIZE 22.5X7.50 OFFSET 6.44 HPG/HPH 22000 LBS BRAKES HYD N/A FULL AIR 72.02 HPQ/H20 23000 LBS BRAKES HYD N/A FULL AIR 72.02 HNA 23000 LBS BRAKES HYD N/A FULL AIR 72.02
RPR
22.5X8.25
6.62
N/A
72.14
N/A
72.14
N/A
72.14
RNF
22.5X8.25
6.59
N/A
72.14
N/A
72.14
N/A
72.14
Rear Axle/Suspension Dimensions Illustration
Page 213
Figure 178
Page 214
Figure 179
Rear Axle/Suspension Formulas

REAR AXLE FORMULAS
A B C D CH Centerline of axle to bottom of axle bowl. Centerline of axle to bottom inside rail at inf. bump. Centerline of axle to bottom inside rail at curb pos. Centerline of axle to bottom inside rail at design load. Rear Frame Height. Distance between the bottom inside rail and the ground-line through the vertical centerline of the rear axle at curb position. Rear Frame Height Distance between the bottom inside rail and the ground-line through the vertical centerline of the rear axle at design position. Rear Axle Clearance Minimum clearance between the rear axle and the ground-line. Rear Tire Clearance Minimum clearance required for tires and chains measured from the top of the frame at the vertical centerline of the rear axle. Chain clearance Distance from the bottom inside rail to the top of rail. Track Dual Wheel Vehicles Distance between the centerlines of the dual wheels as measured at the ground-line. Minimum distance between the inner surfaces of the rear tires. Maximum Rear Width Over-all width of vehicle measured at the outer most surface of the rear tires. Dual Tire Spacing Distance between the centerlines of the tires in a set of dual tires. Rear Body Width Maximum body width between rear tires.
DH
HH JH
KH LH CW
DW EW
HW KW
See Tire Chart for values: Tire Selection, Tire Radius, Tire Loaded Radius and Tire Clearance.
Formulas for calculating rear width and height dimensions: CH = Tire loaded radius + C + LH
Page 215
DH HH JH KH CW DW EW KW LW
= Tire loaded radius + D + LH = Tire loaded radius - A = KH - B - LH = Tire radius + 3.00 inches = Track = Track - 1 Tire section - HW = Track + 1 Tire section + HW = DW - 5.00 inches = 1.00 inch minimum clearance between tires and springs
NOTE: Track and overall width may vary with optional equipment.
Rear Axle Track Dimensions

REAR AXLE DIMENSION CHART
THIS CHART IS USED TO FIND REAR FRAME HEIGHT BY COMBINING THE INFORMATION IN THE CHART WITH THE TIRE INFORMATION FOR THE TIRES USED ON THE CHASSIS AND THE FORMULAS AND ILLUSTRATIONS FOR THE REAR AXLE FRAME HEIGHT.
MODE L REAR AXLE SUSPENSION FRAME SHOCK ABSORBE R RPO G68 STABILIZE R RPO GN1 AUX. SPRING RPO G60 B DIMENSION
RPO
CAPACIT Y
RPO
CAPACIT Y
RPO
Page 216
MODE L
REAR AXLE
SUSPENSION
FRAME
SHOCK ABSORBE R RPO G68 Y OR N Y OR N Y Y Y Y
STABILIZE R RPO GN1 Y Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y Y OR N Y OR N Y OR N N/A Y OR N Y OR N Y Y OR N Y OR N Y OR N Y Y OR N N/A Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y OR N Y Y OR N Y OR N Y OR N Y Y OR N Y OR N Y OR N
AUX. SPRING RPO G60 N Y Y N Y N N Y Y N Y N N Y Y N N/A N Y N Y N Y N Y N/A N Y N Y N Y N Y N Y N Y N Y N Y N Y N Y B 4.15 4.15 4.86 4.86 N/A 2.46 4.35 4.35 5.77 5.77 N/A 2.58 4.47 4.47 5.10 5.10 5.30 5.10 5.10 4.47 4.47 5.10 5.10 4.47 4.44 5.30 5.20 5.20 4.69 4.69 4.54 4.54 6.03 6.03 5.23 5.22 4.69 4.69 4.54 4.56 6.03 6.03 4.54 4.54 6.03 6.03
DIMENSION
RPO
CAPACIT Y
RPO GQ0 GG0
CAPACIT Y 15000 TL 15000 ML 16900 TL 19000 TL 19000 ML 16900 TL 19000 TL 19000 ML 19000 AIR 19000 ML 19000 TL 19000 ML 19000 ML 19000 AIR 21000 ML 21000 TL 23000 TL
RPO
C 9.91 9.91 10.93 10.93 N/A 6.94 10.51 10.51 11.83 11.84 N/A 7.06 10.63 10.63 11.17 11.17 8.71 11.17 11.17 10.63 10.63 11.17 11.17 10.63 11.24 8.31 11.35 11.35 10.84 10.84 10.69 10.69 12.26 12.26 11.36 11.35 10.84 10.84 10.69 10.72 12.26 12.26 10.69 10.69 12.26 12.26
D 6.68 7.00 7.79 7.64 N/A 5.04 7.73 7.89 9.28 9.14 N/A 4.94 7.66 7.89 8.45 8.29 8.31 8.16 8.35 7.46 7.74 7.99 8.21 7.23 7.50 8.31 8.15 8.35 7.72 7.96 7.96 7.95 9.21 9.35 7.91 8.14 7.44 7.73 7.54 7.76 9.00 9.18 7.40 7.63 8.89 9.08
15000 LB
GG7 GN2
FSR
H08 H10 16900 LB
GN0 GG7 GN2 GN0 G40
FD0 FD5
Y Y Y OR N Y OR N Y Y Y Y Y OR N Y OR N N/A Y OR N Y OR N Y Y Y OR N Y OR N Y Y N/A Y OR N Y OR N Y Y
HZT HZW
17850 LB
GN0 GN2 GN0 GN2 G40
HPK HPM H11
GN8 19000 LB GR9 GP0
FTR
FD5 F03
Y Y Y OR N Y OR N Y OR N Y OR N Y Y Y Y Y OR N Y OR N Y Y Y OR N Y OR N
GP1 GN8
23500 ML 21000 ML
GR9 GP0 GP1 GP0 GP1
21000 TL 23000 TL 23500 ML 23000 TL 23500 ML
Page 217
DIMENSION IN INCHES REAR FRAME HEIGHT UNLOADED = TIRE RADIUS + C DIMENSION + FRAME DIMENSION REAR FRAME HEIGHT LOADED = LOADED TIRE RADIUS + D DIMENSION + FRAME DIMENIONS
REAR AXLE DIMENSION CHART

THIS CHART IS USED TO FIND REAR FRAME HEIGHT BY COMBINING THE INFORMATION IN THE CHART WITH THE TIRE INFORMATION FOR THE TIRES USED ON THE CHASSIS AND THE FORMULAS AND ILLUSTRATIONS FOR THE REAR AXLE FRAME HEIGHT.
MODE L REAR AXLE SUSPENSION FRAME SHOCK ABSORBE R RPO G68 Y Y Y OR N Y OR N Y Y Y OR N Y OR N STABILIZE R RPO GN1 Y Y OR N Y OR N Y OR N Y Y OR N Y OR N Y OR N AUX SPRING RPO G60 N Y N Y N Y N Y B 4.54 4.54 6.03 6.03 4.74 4.73 6.22 6.03 DIMENSION
RPO HPG HPH
CAPACIT Y 22000 LB
RPO GP0
CAPACIT Y 23000 TL
RPO
C 10.69 10.69 12.26 12.26 10.89 10.89 12.45 12.45
D 7.40 7.63 8.89 9.08 7.49 7.73 9.00 9.20
GP1 FVR HNA HP0 H20 GP0 GP1
23500 ML 23000 TL 23500 ML FD5 F03
23000 LB
REAR FRAME HEIGHT UNLOADED = TIRE RADIUS + C DIMENSION + FRAME DIMENSION REAR FRAME HEIGHT LOADED = LOADED TIRE RADIUS + D DIMENSION + FRAME DIMENSIONS FD0 = 50,000 PSI STEEL FRAME FD5 = 80,000 PSI STEEL FRAME F03 = 110,000 PSI STEEL FRAME
REAR AXLE "A" DIMENSION CHART

THIS CHART IS USED TO FIND THE "A" DIMENSION A = CENTERLINE OF AXLE TO BOTTOM OF AXLE BOWL.
MODEL RPO REAR AXLE CAPACITY (LBS) SPEED BRAKES DIMENSION A
Page 218
MODEL RPO H08 H10 HWY HZT HZW H11 FSR FTR FVR HPK HPM HPP H15 HPH HPG HPQ H20 HNA
REAR AXLE CAPACITY (LBS) 15000 15000 16900 17850 17850 19000 19000 19000 21000 21000 22000 22000 23000 23000 23000 SPEED SINGLE SINGLE SINGLE TWO SINGLE SINGLE SINGLE TWO SINGLE TWO TWO SINGLE SINGLE TWO SINGLE BRAKES HYD HYD HYD HYD/AIR HYD/AIR HYD/AIR HYD/AIR HYD/AIR HYD/AIR HYD/AIR AIR AIR AIR AIR AIR
DIMENSION A 8.50 8.46 8.82 9.53 8.82 8.82 9.24 10.35 9.24 10.35 10.35 9.24 10.23 10.74 10.99
Battery Box and Component Box Dimensions and Locations
Page 219
Page 220
Single and Dual Fuel Tank Dimensions and Location
Exhaust System Dimensions and Locations

Air Intake System Dimensions and Locations
Page 222
Cab Tilt and Cab Exterior Dimensions
Page 223
Cab Interior Dimensions
Page 224
Figure 185
Tire Availability Chart

TIRE AVAILABILITY CHART
TIRE BRAND MICHELIN TIRES FRONT MICHELIN TIRES REAR TIRE SIZE FSR 10 STD STD FSR 11 STD STD FTR 10 STD STD FTR 11 STD STD FTR 12 STD STD FTR 13 STD STD FTR 20 STD STD FTR 21 STD STD FTR 22 STD STD FTR 23 STD STD FVR 10 STD STD
Page 225
TIRE BRAND MICHELIN TIRES FRONT MICHELIN TIRES REAR TIRE SIZE 10R22.5 F (12 PLY) 11R22.5 G (14 PLY) 11R22.5 H (16 PLY) 225/70R 19.5 F (12 PLY) 245/70R 19.5 F (12 PLY) 245/70R 19.5 G (14 PLY) 235/80R 22.5 G (14 PLY) 245/75R 22.5 G (14 PLY) 255/70R 22.5 H (16 PLY) 255/80R 22.5 G (14 PLY) 265/75R 22.5 G (14 PLY) 275/80R 22.5 G (14 PLY) 295/75R 22.5 G (14 PLY)
FSR 10 STD STD
FSR 11 STD STD
FTR 10 STD STD
FTR 11 STD STD
FTR 12 STD STD
FTR 13 STD STD
FTR 20 STD STD
FTR 21 STD STD
FTR 22 STD STD
FTR 23 STD STD
FVR 10 STD STD
AVAIL N/A N/A AVAIL AVAIL AVAIL AVAIL AVAIL N/A N/A N/A N/A N/A
AVAIL N/A N/A AVAIL AVAIL AVAIL AVAIL AVAIL N/A N/A N/A N/A N/A
AVAIL AVAIL N/A N/A N/A N/A AVAIL AVAIL AVAIL AVAIL AVAIL AVAIL N/A
N/A AVAIL N/A N/A N/A N/A N/A N/A AVAIL AVAIL AVAIL AVAIL AVAIL
N/A AVAIL AVAIL N/A N/A N/A N/A N/A AVAIL N/A N/A N/A AVAIL
Tire Dimension Charts

Michelin
MICHELIN TIRE DIMENSION CHART
MICHELIN TIRES R4L/S4L TREAD DESIGN PXZA TREAD CODE RPO SIZE LOAD RANG E MIN DUAL SPACI NG 9.90 DIMENSIONS NO LOAD WIDTH 8.80 DIA 32.30 LOADED WIDTH 9.60 SLR 14.90 646 REVS PER MILE MAX PRESSURE SINGLE 85 DUAL 85 M
SIN 3
R3C/S3 C
XTN/YT N
225/ 70R 19.5
F/12
Page 226
MICHELIN TIRES R4L/S4L TREAD DESIGN PXZA PXZA XAZ-2 XAZ-2 XZA-2 PXDU PXDU XDA2 XDA2 XDA+ PXZT XDY-1 XDHT PXDHT XM+S4 XM+S4 XM+S4 PXM+S4 XYZ-1 XYZ-1 XZE XZE XZE XZE XZE XZE
TREAD CODE
RPO
SIZE
LOAD RANG E
MIN DUAL SPACI NG 10.90 11.0 12.50 12.50 12.30 10.40 11.30 12.30 12.00 11.10 9.90 12.80 12.60 12.20 11.10 12.20 10.80 12.30 12.80 12.80 11.50 12.40 12.40 10.90 10.90 12.40
DIMENSIONS NO LOAD WIDTH 9.70 9.70 11.10 11.10 10.90 9.30 10.00 11.00 10.90 9.60 8.80 11.30 11.10 10.90 11.10 11.20 10.80 11.00 11.30 11.30 10.20 10.60 10.60 8.90 8.90 11.10 DIA 33.40 36.60 41.30 41.30 40.00 37.40 38.40 40.40 41.70 36.90 32.50 42.00 41.90 40.70 41.70 41.80 40.20 40.40 41.60 41.60 40.10 41.10 41.10 33.50 33.50 39.70 LOADED WIDTH 10.60 10.70 12.00 12.00 12.00 10.20 10.90 11.90 11.90 10.60 9.60 12.50 12.00 12.00 12.10 12.10 10.50 12.00 12.50 12.50 N/A N/A N/A N/A N/A N/A SLR 15.50 17.00 19.30 19.30 18.60 17.40 17.80 18.90 19.40 17.30 15.00 19.60 19.50 18.90 19.40 19.40 18.60 18.80 19.50 19.50 18.70 19.30 19.30 15.10 15.10 18.40 624 567 501 501 518 554 540 516 501 561 639 493 500 515 499 500 517 516 497 497 517 501 501 619 619 517 REVS PER MILE MAX PRESSURE SINGLE 110 115 100 115 100 90 95 100 100 115 85 100 100 100 100 115 95 100 100 115 95 100 115 90 110 100 DUAL 110 115 100 115 100 90 95 100 100 115 85 100 100 100 100 115 95 100 100 115 95 100 115 90 110 100
SIN 4 5 6 6 6 4 5 6 6 5 3 6 6 6 6 6 5 6 6 6 5 6 6 4 4 6
R3C/S3 C R3C/S3 C R3C/S3 C R3C-S3 C R3C-S3 C S3D S3D S3D S3D S3D S3D S3T S3H S3H S3J S3J S3J S3J R3K/S3 K R3K/S3 K R3B/S3 B R3B/S3 B R3B/S3 B R3B/S3 B R3B/S3 B R3B/S3 B
XTY/YT Y XTB/YT B XWL/YW L XWM/Y WM XSH/YS H YRL YSB YSH YWL YTB YTN YWL YWL YSH YWL YWM YWJ YSH XWL/YW L XWM/Y WM XWKYW J XWL/YW L XWM/Y WM XTI/YTI XTY/YT Y XSH/YS H
245/ 70R19.5 255/ 70R22.5 11R22.5 11R22.5 275/ 80R22.5 235/ 80R22.5 255/ 80R22.5 275/ 80R22.5 11R22.5 255/ 70R22.5 225/ 70R19.5 11R22.5 11R22.5 275/ 80R22.5 11R22.5 11R22.5 10R22.5 275/ 80R22.5 11R22.5 11R22.5 10R22.5 11R22.5 11R22.5 245/ 70R19.5 245/ 70R19.5 275/ 80R22.5
G/14 H/16 G/14 H/16 G/14 G/14 G/14 G/14 G/14 H/16 F/12 G/14 G/14 G/14 G/14 H/16 F/12 G/14 G/14 H/16 F/12 G/14 H/16 F/12 G/14 G/14
Goodyear
GOOD YEAR TIRE DIMENSION CHART

MICHELIN TIRES R4L/S4L TREAD DESIGN G159 G159 G159 G159 G159 G159 G159 G159 G159 G124 G124 G124 G124 G124 G124 G124 G124 G124 G167 G167 G167 G167 G186 G186 G186 G177 G177 TREAD CODE RPO SIZE LOAD RANG E MINIM UM DUAL SPACI NG 11.00 11.00 12.60 12.60 11.00 11.60 12.90 11.30 11.40 11.00 11.00 11.60 12.60 12.60 12.90 11.30 11.40 11.40 12.60 12.60 12.60 12.60 11.40 12.60 12.60 12.50 12.50 DIMENSIONS NO LOAD WIDTH 9.90 9.90 10.90 10.90 9.50 9.90 11.20 9.80 10.10 9.90 9.90 9.90 10.80 10.80 11.10 9.80 10.00 9.90 10.70 10.80 10.80 10.80 10.00 11.00 11.0 10.90 10.90 DIA 33.00 33.00 41.50 41.50 37.00 38.70 40.40 36.40 40.10 33.20 33.20 38.70 41.70 41.70 40.60 36.80 40.40 40.70 42.00 41.70 41.70 41.70 40.40 41.80 41.80 42.30 42.30 11.90 11.90 11.90 11.00 12.10 12.10 12.00 12.00 19.50 19.50 19.50 18.90 19.50 19.50 19.70 19.70 498 498 498 514 497 497 493 493 115 120 105 100 105 120 105 120 105 110 115 100 115 110 115 110 6 6 6 5 6 6 6 6 LOADED WIDTH 10.90 10.90 12.00 12.00 10.40 10.80 12.30 10.70 11.00 10.90 10.90 11.10 11.90 11.90 12.30 10.70 11.00 10.90 SLR 15.30 15.30 19.40 19.40 17.20 18.00 18.70 17.00 18.80 15.40 15.40 18.20 19.50 19.50 18.90 17.20 19.00 19.10 629 628 501 501 561 537 514 571 518 622 622 537 498 498 512 564 514 513 REVS PER MILE MAX PRESSURE SINGLE 95 110 105 120 110 110 110 120 100 95 110 110 105 120 110 115 100 100 DUAL 95 110 95 110 100 100 100 115 100 95 100 100 115 110 100 115 100 100 M
SIN 4 4 6 6 4 5 6 5 5 4 4 5 6 6 6 5 5 5
R3C/S3 C R3C/S3 C R3C/S3 C R3C/S3 C R3C-S3 C R3C-S3 C R3C/S3 C R3C/S3 C R3C/S3 C S3H S3H S3H S3H S3H S3H S3H S3H S3H S3D S3E S3E R3F/S3F R3K/S3 K R3K/S3 K R3K/S3 K R3L/S3L R3L/S3L
XTI/ YTI XTY/ YTY XWL/ YWL XWM/ YWM XTQ/ YTQ XTU/ YTU XRN/ YRN XTB/ YTB XWJ/ YWJ YTI YTY YTU YWL YWM YRN YTB YWJ YWJ YRN YWL YWM XWL/ YWL XWJ/ YWJ XWL/ YWL XWM/ YWM XWL/ YWM XWM/ YWM
245/ 70R19.5 245/ 70R19.5 11R22.5 11R22.5 245/ 75R22.5 265/ 75R22.5 295/ 75R22.5 255/ 70R22.5 10R22.5 245/ 70R19.5 245/ 70R19.5 265/ 75R22.5 11R22.5 11R22.5 295/ 75R22.5 255/ 70R22.5 10R22.5 10R22.5 295/ 75R22.5 11R22.5 11R22.5 11R22.5 10R22.5 11R22.5 11R22.5 11R22.5 11R22.5
F/12 G/14 G/14 H/16 G/14 G/14 G/14 H/16 F/12 F/12 G/14 G/14 G/14 H/16 G/14 H/16 F/12 F/12 H/16 G/14 H/16 G/14 F/12 G/14 H/16 G/14 H/16
Page 228
General
GENERAL TIRE DIMENSION CHART
GENERAL TIRES R4H/S4H TREAD DESIGN AMERI-STEE LA AMERI-STEE LA AMERI-S380 AMERI-S380 AMERI-LUG B AMERI-MSL RADIAL H TREAD CODE RPO SIZE LOAD RANG E MINIM UM DUAL SPACI NG 12.60 11.40 13.20 12.60 11.40 12.60 DIMENSIONS NO LOAD WIDTH 10.80 10.00 11.10 11.00 10.00 10.70 DIA 41.30 40.30 40.20 41.40 40.30 41.40 LOADED WIDTH 12.20 11.30 12.00 12.00 11.30 12.20 SLR 19.20 18.70 18.70 19.30 18.70 19.30 501 514 515 500 511 500 REVS PER MILE MAX PRESSURE SINGLE 115 100 110 105 95 120 DUAL 105 90 N/A 105 90 120 M
SIN 4 5 6 6 5 6
R3B/S3 B R3B/S3 B R3C R3C/S3 C S3D R3K/S3 K
XWL/YW L XWJ/YW J XRN XWL/YW L S3D R3K/S3 K
11R22.5 10R22.5 295/ 75R22.5 11R22.5 10R22.5 11R22.5
G/14 F/12 G/14 G/14 F/12 H/16
Bridgestone
BRIDGESTONE TIRE DIMENSION CHART
BRIDGESTONE TIRES R4N/S4N TREAD DESIGN R294 M711 M711 M716 M716 M724 M857 R250F R250F TREAD CODE RPO SIZE LOAD RANG E MINIM UM DUAL SPACI NG 11.50 12.60 13.20 11.60 13.20 11.10 11.40 13.20 11.40 DIMENSIONS NO LOAD WIDTH 9.90 10.70 11.10 10.10 11.10 9.70 9.80 10.90 9.80 DIA 36.70 41.90 40.60 38.60 40.40 33.50 40.30 40.20 40.00 LOADED WIDTH 10.90 11.80 12.20 11.10 12.20 10.40 10.80 12.00 10.70 SLR 17.40 19.70 19.10 18.20 19.10 15.70 19.00 18.80 18.70 568 498 513 541 519 622 519 519 519 REVS PER MILE MAX PRESSURE M
SINGLE 120 105 110 110 110 110 115 110 100
DUAL 115 105 100 100 100 110 105 100 90
SIN 5 6 6 5 6 4 5 6 5
R3C/ S3C S3D S3D S3J S3J R3M/ S3M R3K/ S3K R3B/ S3B R3B/ S3B
XTB/ YTB YWL YRN YTU YRN XTY/ YTY XWK/ YWK XRN/ YRN XWJ/ YWJ
255/ 70R22.5 11R22.5 295/ 75R22.5 265/ 75R22.5 295/ 75R22.5 245/ 70R22.5 10R22.5 295/ 75R22.5 10R22.5
H/16 G/14 G/14 G/14 G/14 G/14 G/14 G/14 F/12
Page 229
R250F R250F R250F R250F R299LP R299LP R293
R3B/ S3B R3B/ S3B R3B/ S3B R3B/ S3B R3C/ S3C S3C R3C/ S3C
XWL/ YWL XWP/ YWP XTQ/ YTQ XTU/ YTU XRN/ YRN YRV XWL/ YWL
11R22.5 12R22.5 245/ 75R22.5 265/ 75R22.5 295/ 75R22.5 285/ 75R24.5 11R22.5
G/14 H/16 G/14 G/14 G/14 G/14 G/14
12.60 13.50 11.00 11.60 13.20 12.50 12.60
10.70 11.60 9.70 10.20 10.90 10.60 10.60
41.30 42.70 37.40 38.40 40.20 41.40 41.30
11.80 12.60 10.50 11.10 12.00 11.70 11.70
19.30 19.80 17.60 18.00 18.80 19.40 19.30
502 487 555 541 526 499 519
105 120 110 110 110 110 105
105 110 100 100 100 100 105
6 7 4 5 6 6 6
Wheel Dimension Chart

STEEL AND ALUMINUM DISC WHEEL SPECIFICATIONS
WHEEL SIZE 19.5 X 6.75 22.5 X 7.50 22.5 X 8.25 19.5 X 6.75 22.5 X 8.25 RPO OPTION MFG. FRONT Q82 QH3 RPQ RPM QM3 REAR Q83 QH4 RPR RPW QM4 ACCURIDE ACCURIDE ACCURIDE ALCOA ACCURIDE 5.60 6.44 6.62 5.55 6.62 OFFSET DISC THICKNESS 0.437 0.375 0.437 0.812 0.437 RIM TYPE DCT DCT DCT DCT DCT BC DIA. 275 MM 285.75 MM 285.75 MM 275 MM 285.75 MM NO. STUD S 8 10 10 8 10 RATINGS LBS @ PSI 5000 @ 115 6200 @ 120 7300 @ 120 5500 @ 120 7300 @ 120
Electrical
Diesel Cab Chassis 2000 Model Year

Symbols
Symbol. Meaning
Page 230
Symbol. Fuse
Meaning
Fusible Link
Fusible Link Wire
Switch
Switch
Switch (Normal close type)
Contact wiring
Battery
Diode
Electronic parts
Page 231
Symbol. Resistor
Meaning
Speaker
Buzzer
Circuit Breaker
Bulb
Double filament bulb
Motor
Variable resistor rheostat
Coil (Inductor), solenoid magnetic valve
Page 232
Symbol.
Meaning
Relay
Connector
Light emitting diode
Reed switch
Condensor
Horn
Vacuum switching valve
Abbreviations
Abbreviation Meaning of Abbreviation Ampere (S) Anti-lock brake system Assembly Abbreviation Meaning of Abbreviation Ignition kilowatt
A ABS
IG kW
ASM Isuzu 2000 Body Builder's Guide
LH
Left hand Page 233
Abbreviation
Meaning of Abbreviation Alternating current Air Conditioner Accessories Automatic transmission Circuit breaker Cold start device Direct ignition system Daytime running lights Electronic brake control module Electronic control gasoline injection Electronic control module Electronic control unit Early fuel evaporation
Abbreviation
Meaning of Abbreviation Long wheel base Manual transmission Over drive Option
AC A/C ACC A/T
LWB M/T OD OPT
C/B CSD DIS DRL
QOS RH RR RWAL
Quick on start Right hand Rear Rear wheel anti-lock brake system Start
EBCM
ST
ECGI
STD
Standard
ECM
SW
Switch
ECU EFE
SWB TCM
Short wheel base Transmission control module 3-speed automatic transmission Volt Vacuum switching valve Watt (S) Wide open throttle With Without
4 A/T
4-speed automatic transmission Four-wheel drive Fusible link
3A/T
4X4 FL
V VSV
FRT HBB H/L IC
Front Hydro brake booster Headlight Integrated circuit
W WOT W/ W/O
Page 234
Color Code for Wiring

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 R - Red (Stripe color) Green - (Base color) Wire size (0.5 mm2) Abbreviations are used to indicate wire color within a circuit diagram. Refer to the following table.
Figure 186 Wire Color Color-Coding B W R Isuzu 2000 Body Builder's Guide Meaning Black White Red Color-Coding BR LG GR Meaning Brown Light Green Grey Page 235
Color-Coding G Y L O
Meaning Green Yellow Blue Orange
Color-Coding P LB V
Meaning Pink Light Blue Violet
Distinction of Circuit by Wire Color

Base Color B W R G Circuits Starter Circuit Charging Circuit Lighting Circuit Signal Circuits Base Color Y L, O, BR, LG, GR, P, LB, V Other Circuits Circuits Instrument Cluster
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, shown below, are specified by AWG (American Wire Gauge) (Nominal size means approximate cross sectional area) (figure 24).
Page 236
Figure 187 Wire Size Nominal size Cross sectional area (mm2) 0.372 0.563 0.885 1.287 2.091 3.296 5.227 7.952 13.36 20.61 Outside diameter (mm) 1.8 2.0 2.2 2.5 2.9 3.6 4.4 5.5 7.0 8.2 Allowable current (A) 9 12 16 21 28 37.5 53 67 75 97 AWG size (cross reference) 22 20 18 16 14 12 10 8 6 4
0.3 0.5 0.85 1.25 2 3 5 8 15 20
Grounding Point and Reference of Grounding Point

Grounding Point
Page 237
Figure 188
Figure 190
Reference Table of Grounding Point

NOTICE: Abnormal phenomena of electrical components are considered resulted from defective grounding. In repair, be sure to inspect grounding points and to tighten all fastening parts surrounding the grounding points. Connector No. Cable Harness Name Body harness Location Main Parts (Load)
B-1
Frame-LH (FRT)
Vehicle speed sensor, Turn signal indicator light, Meter, High beam indicator light. Change relay, Exhaust brake relay, ECM, D.R.L. unit, Dome light, Meter, Brake fluid level switch, Tail relay, TCM, Cornering light, Cornering light relay, Washer motor intermittent relay, Heater & A/C relay, Radio & clock, Cigar lighter, Fan switch, Blower resistor, A/C switch, Blower motor, Electronic thermostat, Accel switch, Cab interior switch, Flasher unit, Clearance light, ID light, illumination control, Kick down switch, Electronic vacuum pump, Power source relay Page 239
B-7
Body harness
Headlight bracket-LH
Connector No.
Cable Harness Name Frame front harness
Location
Main Parts (Load)
J-9
Frame-LH (CTR)
Fuel tank unit, Starter relay, Neutral switch, Pressure switch, Exhaust brake control relay, Exhaust brake magnetic valve, Accel switch, Clutch switch, Engine stop motor Inhibitor switch, Engine warnimg cut relay, ID relay, Condenser fan relay, Condenser fan, License plate light, Taillight, Rear turn signal light, Stoplight, Backup light, Air magnetic valve, VSV 2 EXH (FULL), VSV F1CD Engine warming up switch
NPR NQR Body Room Light, I.D. and Marker Lamp and Back Up Lamp Connector Location
NPR/NQR BODY CONNECTORS LH FRAME
Figure 191 PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG LOCATION: INSIDE LEFT HAND FRAME RAIL 28 TO 31 INCHES BOC Page 240
CIRCUITS: Isuzu 2000 Body Builder's Guide
BLACK = GROUND RED/GREEN = MARKER LAMP GREEN = STOP LAMP RED/YELLOW = CARGO ROOM LIGHT (KEYED) RED BULLET CONNECTOR = HOT WIRE
NPR/NQR BODY CONNECTORS EOF
Figure 192 PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG LOCATION: CENTER OF CROSSMEMBER CIRCUITS: BLACK = GROUND RED/GREEN = MARKER LAMP GREEN = STOP LAMP RED/YELLOW = CARGO ROOM LIGHT (KEYED)
Schematic Body Room Light
Page 241
Figure 193
Schematic Body I.D. and Marker Lamps
Page 242
Page 243
Figure 194
Fuse and Fusible Link Location
Figure 195
Figure 196
Page 244
Fuse Label
25A (1) 10A (2) 10A (3) 15A (4) 20A (5) 20A (6) 15A (7) 15A (8) 10A (9) 10A (10) HEATER AIR CON STARTER RADIO, CIGAR HEAD LAMP (RH) HEAD LAMP (LH) MEMORY HAZARD, HORN TAIL LAMP STOP LAMP 15A (11) 10A (12) 10A (13) 15A (14) 10A (15) 10A (16) (17) (18) 10A (19) 20A (20) PCM/BAT P/SOURCE WIPER, WASHER METER, BACK TURN LAMP FUEL HEATER EXH. BRAKE ECU (BAT) 10A (F-21) 15A (F-22) ---------CONDENSER FAN
NOTICE: The fuse numbers (1) ~ (20) indicated on the fuse labels are expressed as (F-1) ~ (F-20) in the circuit diagrams of this manual.
Schematic Fuse Block
Page 245
Page 246
Figure 197
Reference Table of Fuse Panel

REFERENCE TABLE OF FUSE
Fuse No. Capacity Indication on label HEATER Main Parts (Load)
F-1
20A
Blower motor, Blower resistor, A/C thermo relay, Electronic thermostat A/C switch, Pressure switch, magnetic clutch, Condenser fan relay Starter relay Cigar lighter, Radio, Power source relay
F-2
10A
AIR CON
F-3 F-4
10A 15A
STARTER AUDIO, CIGAR LIGHTER HEAD LIGHT (RH) HEAD LIGHT (LH) MEMORY HAZARD/HO RN TAIL LIGHT
F-5
15A
Headlight (RH), High beam indicator light
F-6
15A
Headlight (LH), Cornering light
F-7 F-8
10A 15A
Radio & clock, Dome light, ID light Horn, Horn relay, Flasher unit
F-9
15A
Tail relay, illumination light(s), Clearance light(s), Tail light(s), Illumination control, ID light relay, license plate light Stoplight, TCM Wiper motor, Washer motor, Intermittent relay
F-10 F-11
10A 15A
STOP LAMP WIPER, WASHER
Page 247
Fuse No.
Capacity
Indication on label GAUGE, BACK
Main Parts (Load)
F-12
10A
Exhaust brake control relay, TCM, Backup light, Glow relay, Glow indicator (Meter), Engine coolant temperature gauge, thermo unit, vehicle speed sensor (installed on the meter assembly & transmission), meter assembly, cornering light relay, thermo switch (fuel throttle), vacuum pump relay, electronic vacuum pump, VSV; EGR, VSV; Anecom, VSV; VSS Engine warming cut 2 ECM ----------
F-13 F-14
10A 15A
ECM (IGN) FUEL HEATER EXH. BRAKE
F-15
10A
Exhaust brake magnetic valve, Engine warming cut relay 1, Thermo switch (Eng. warm) ECM Flasher unit, Front turn signal light, Rear turn signal light, Turn signal indicator light Generator
F-16 F-17
10A 10A
ECM (BAT) TURN S/LIGHT GENERATO R ENG. STOP P/SOURCE -----CONDENSE R FAN
F-18
15A
F-19 F-20 F-21 F-22
10A 20A ---15A
Engine stop motor Power source relay, Service terminal -------Condenser fan
Relay Location and Reference List
Page 248
Figure 198
RELAY LIST
Connector No. Relay name B-9 Intermittent B-19 Charge B-20 Head light B-21 Heater & A/C B-22 Tail
Connector No.
B-23
B-24
B-34
B-35
B-37 Page 249
Connector No. Relay name
B-38 Exh. brake
J-12 Starter
J-13 Glow-1
J-14 Glow-2
J-16 Eng. warming out
J-17 Condenser fan
J-18 Exh. brake control
J-20 ID light
Schematic Auxiliary Power Source
Page 250
Page 251
Figure 199
Schematic Accessory Wiring
Page 252
Figure 200
Schematic Horn and Back-up Light
Page 253
Figure 201
Page 254
Schematic Engine Stop Motor
Page 255
Page 256
Figure 202
Schematic Turn Signal, Hazard and Stop Lamp
Page 257
Page 258
Figure 203
Schematic Instrument Panel
Page 259
Page 260
Figure 204
Fuel Tank Sending Unit Resistance
Figure 205
Page 261
Figure 205
Gas Cab Chassis 2000 Model Year

Symbols
Symbol. Fuse Meaning
Fusible Link
Page 262
Symbol.
Meaning
Fusible Link Wire
Switch
Switch
Switch (Normal close type)
Contact wiring
Battery
Diode
Electronic parts
Resistor
Page 263
Symbol.
Meaning
Speaker
Buzzer
Circuit Breaker
Bulb
Double filament bulb
Motor
Variable resistor rheostat
Coil (Inductor), solenoid magnetic valve
Relay
Page 264
Symbol.
Meaning
Connector
Light emitting diode
Reed switch
Condensor
Horn
Vacuum switching valve
Abbreviations
Abbreviation Meaning of Abbreviation Ampere (S) Anti-lock brake system Assembly Alternating current Air Conditioner Accessories Abbreviation Meaning of Abbreviation kilowatt Left hand
A ABS
kW LH
ASM AC A/C ACC
LWB M/T OD OPT
Long wheel base Manual transmission Over drive Option
Page 265
Abbreviation
Meaning of Abbreviation Automatic transmission Circuit breaker Cold start device Direct ignition system
Abbreviation
Meaning of Abbreviation Quick on start
A/T
QOS
C/B CSD DIS
RH RR RWAL
Right hand Rear Rear wheel anti-lock brake system Start
EBCM
Electronic brake control module Electronic control gasoline injection Electronic control module Electronic control unit Early fuel evaporation
ST
ECGI
STD
Standard
ECM
SW
Switch
ECU EFE
SWB TCM
Short wheel base Transmission control module 3-speed automatic transmission Volt Vacuum switching valve Watt (S) Wide open throttle With Without
4A/T
4-speed automatic transmission Four-wheel drive Fusible link
3A/T
4X4 FL
V VSV
FRT H/L IC IG
Front Headlight Integrated circuit Igniton
W WOT W/ W/O
Color Code for Wiring

All wires have color-coded insulation. Wires belonging to a system's main harness will have a single Isuzu 2000 Body Builder's Guide Page 266
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 R - Red (Stripe color) Green - (Base color) Wire size (0.5 mm2) Abbreviations are used to indicate wire color within a circuit diagram. Refer to the following table.
Figure 206 Wire Color Color-Coding B W R G Y L O Isuzu 2000 Body Builder's Guide Meaning Black White Red Green Yellow Blue Orange Page 267 Color-Coding BR LG GR P LB V Meaning Brown Light Green Grey Pink Light Blue Violet
Color-Coding
Meaning
Color-Coding
Meaning
Distinction of Circuit by Wire Color

Base Color B W R G Circuits Starter Circuit Charging Circuit Lighting Circuit Signal Circuits Base Color Y L, O, BR, LG, GR, P, LB, V Other Circuits Circuits Instrument Cluster
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, shown below, are specified by AWG (American Wire Gauge) (Nominal size means approximate cross sectional area) (figure 24).
Figure 207 Wire Size Nominal size Cross sectional area (mm2) Outside diameter (mm) Allowable current (A) AWG size (cross reference)
Page 268
Nominal size
Cross sectional area (mm2) 0.372 0.563 0.885 1.287 2.091 3.296 5.227 7.952 13.36 20.61
Outside diameter (mm) 1.8 2.0 2.2 2.5 2.9 3.6 4.4 5.5 7.0 8.2
Allowable current (A) 9 12 16 21 28 37.5 53 67 75 97
AWG size (cross reference) 22 20 18 16 14 12 10 8 6 4
0.3 0.5 0.85 1.25 2 3 5 8 15 20
Grounding Point and Reference of Grounding Point

Grounding Point Location
Figure 208
Page 269
Figure 209
Figure 210
Page 270
Figure 211
Figure 212
Reference Table of Grounding Point

NOTICE: Abnormal phenomena of electrical components are considered resulted from defective grounding. In repair, be sure to inspect grounding points and to tighten all fastening parts surrounding the grounding points. Connector No. Cable Harness Name Location Main Parts (Load)
Page 271
Connector No.
Cable Harness Name
Location
Main Parts (Load)
E-55
Frame-LH (FRT)
Turn signal indicator light, Meter, High beam indicator light
E-55 E-53 Headlight bracket-LH
Diagnostic connector Charge relay, Dome light switch, Meter, Meter Starter relay, Inhibitor switch, Lighting switch, Ignition relay, Front turn sigal light, Brake fluid switch, Tail relay, Cornering light switch, Cornering light, Cornering light relay, Dimmer relay, Wiper motor, Washer motor, Intermittent relay, Heater & A/C relay, Radio & clock, cigar lighter, Fan switch, Blower resistor, A/C switch, Blower motor, Electronic Thermostat, cab interior switch, Flasher unit, Clearance light, ID light, Illumiination, Power source relay, hazard warning switch, turn signal light switch, diagnostic connector, roof marker light, illuination controller Fuel pump relay, ID light relay license plate light, taillight, rear turn signal light, stoplight, backup light inhibitor switch, rear oxygen sensor, (LH, RH) Fuel pump License plate light, taillight, rear turn signal light, stoplight, backup light inhibitor switch Engine-LH (RR) Front O2S (LH, RH) Mass air flow sensor Coil driver, Vehicle control module Purge solenoid vacuum switch
Engine Harness
J-9
Frame front harness
Frame-RH (CRT)
J-61
Frame rear harness
HORN (LH)
E-38
Engine harness
E-39
Engine-LH (RR)
Vehicle control Module
NPR Body Room Light, I.D. and Marker Lamp and (Back Up
Lamp Connector Location)

NPR BODY CONNECTORS LH FRAME
Figure 213 PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG LOCATION: INSIDE LEFT HAND FRAME RAIL 28 TO 31 INCHES BOC CIRCUITS: BLACK = GROUND RED/GREEN = MARKER LAMP GREEN = STOP LAMP RED/YELLOW = CARGO ROOM LIGHT (KEYED) RED BULLET CONNECTOR = HOT WIRE
NPR BODY CONNECTORS EOF
Page 273
Figure 214 PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG LOCATION: CENTER OF CROSSMEMBER CIRCUITS: BLACK = GROUND RED/GREEN = MARKER LAMP GREEN = STOP LAMP RED/YELLOW = CARGO ROOM LIGHT (KEYED)
Schematic Body Room Light
Page 274
Figure 215
Schematic Body I.D. and Marker Lamps
Page 275
Page 276
Figure 216
Fuse and Fusible Link Location
Figure 217
Figure 218
Fuse Label
25A (1) HEATER 20A (11) WIPER, WASHER (F-21) ---------Page 277
10A (2) 10A (3) 20A (4) 20A (5) 20A (6) 10A (7) 15A (8) 15A (9) 10A (10)
AIR CON STARTER RADIO, CIGAR HEAD LIGHT (RL) HEAD LIGHT (LH) MEMORY HAZARD, HORN TAIL LAMP STOP LIGHT
10A (12) 10A (13) 10A (14) 20A (15) 20A (16) 10A (17) 10A (18) 20A (19) 20A (20)
METER, BACK TURN S/LIGHT GENERATOR VCM (IGN) ENGINE (IGN) A/T SOLENOID VCM (ACC) FUEL PUMP P/SOURCE
(F-22)
----------
20A
BREAKE R
NOTICE: The fuse numbers (1) ~ (20) indicated on the fuse labels are expressed as (F-1) ~ (F-20) in the circuit diagrams of this manual.
Schematic Fuse Block
Page 278
Page 279
Figure 219
Location of Fusible Links
Figure 220
Reference Table of Fuse Panel
Page 280
REFERENCE TABLE OF FUSE

Fuse No. Capacity Indication on label HEATER Main Parts (Load)
F-1
25A
Blower motor, Blower resistor, Fan switch, A/C switch, A/C thermo relay, Electronic thermostat A/C switch, A/C thermo relay, Pressure switch, magnetic clutch, Electronic thermostat, A/C enable relay Starter relay, Inhibitor switch Cigar lighter, Radio, Power source relay
F-2
10A
AIR CON
F-3 F-4
10A 15A
STARTER RADIO, CIGAR HEAD LAMP (RH) HEAD LAMP (LH) MEMORY
F-5
15A
Headlight (RH), Dimmer Relay, High Beam Indicator light Headlight (LH), Dimmer relay, Cornering light relay, Cornering light, Cornering light switch Radio & clock, Dome light switch, Dome light, Door switch (LH), ID light relay, ID light, cab interior switch, roof marker light Hazard warning switch, Horn, Horn relay, Horn switch, Flasher unit Tail relay, illumination lights(s), Lighting switch, Clearance light(s), Tail light(s), illlumination controller, ID light relay, license plate light Stoplight switch, Flasher unit Wiper & Washer switch, Wiper motor, Washer motor, Intermittent relay Backup light, Inhibitor Switch, Meter assembly, Cornering light relay, A/C enable relay, ignition relay Hazard warning SW, Flasher Unit
F-6
15A
F-7
10A
F-8
15A
HAZARD, HORN TAIL LAMP
F-9
15A
F-10 F-11
10A 15A
STOP LAMP WIPER, WASHER METER, BACK
F-12
15A
F-13
10A
TURN S/LAMP GENERATO R
F-14
15A
Generator, Charge relay, heater & A/C relay Page 281
Fuse No.
Capacity
Indication on label VCM (IGN)
Main Parts (Load)
F-15
20A
VCM, CKP sensor, Central MFI, Coil driver, Ignition coil Automatic transmission, IAT sensor, MAP sensor, Linear EGR, CMP sensor, EVAP canister purge solenoid, Mass airflow sensor, Front O2S (LH, RH), Rear O2S (LH, RH) Automatic transmission (Tcc pwn control solenoid, Shift A solenoid, Shift B solenoid ---------
F-16
15A
Engine (IGN)
F-17
10A
A/T Solenoid
F-18
20A
Spare (for 97 model) Fuel Pump
F-19
20A
Fuel pump relay, Fuel pump & fuel gauge sender, Oil pressure switch Power source relay, Service terminal -----------
F-20 F-21 F-22
20A ----------
P/SOURCE -----------
Relay Location and Reference List
Page 282
Figure 221
RELAY LIST
Connector No. Relay name B-9 Intermittent B-19 Charge B-20 Head light B-21 Heater & A/C B-22 Tail
Connector No.
B-24
B-34
B-35
B-36
B-37 Page 283
B-38 Ignition
J-12 Starter
J-15 A/C Enable
J-16 Fuel Pump
J-20 ID Light
Schematic Auxiliary Power Source
Page 284
Page 285
Figure 222
Schematic Accessory Wiring
Page 286
Figure 223
Page 287
Schematic Horn and Back-up Light
Figure 224
Page 288
Schematic Turn Signal, Hazard and Stop Lamp
Page 289
Page 290
Figure 225
Schematic Instrument Panel
Page 291
Page 292
Figure 226
Fuel Tank Sending Unit Resistance
Page 293
Page 294
Figure 227
FRR, FSR, FTR & FVR Series Cab Chassis 2000 Model Year
FRR Body Room Light, I.D. Marker Lamp and Back Up Lamp Connector Location
FRR BODY CONNECTORS
Figure 228 BULLET TYPE BODY PLUG LOCATION: RH AND LH END OF FRAME CIRCUITS: BROWN = MARKER LAMP BLUE = BODY ROOM LIGHT
FRR BACK-UP ALARM WIRING
Page 295
Figure 229 BULLET TYPE BODY PLUG LOCATION: CENTER END OF FRAME CIRCUITS: BLACK/BLUE = GROUND RED = POWER BACK-UP ALARM
FSR FTR FVR-Series Relay Location
Figure 230
Page 296
Figure 231
Figure 232
Page 297
Figure 233
Dedicated Body Builder Electrical Circuits Behind Engine for F Series

FSR FTR FVR CONNECTORS
Figure 234
Page 298
PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG
LOCATION: AT REAR OF ENGINE BLOCK CIRCUITS: ORANGE = BATTERY LEAD PINK = IGNITION LEAD BLUE = SPARE LEAD GREEN = SPARE LEAD CIRCUITS: YELLOW = ACCESSORY BROWN = BODY LIGHTS/TAIL LIGHTS
Body Chassis Electrical Connections

Diagnostic Information and Procedures
Uplifter Provision System Check Diagnosis Body Builder Harness
1. 2. 3. Inspect circuit Breakers 2, 6, 12 and 13 to determine if any circuit is open. If an open condition exists, locate and repair the overload condition and replace the circuit breaker. Inspect ground G 105 to assure that it is clean and tight. Inspect for broken (or partially broken) wire in the insulation. This condition could cause a system malfunction but prove to test good in continuity or voltage test with the system disconnected. These circuits may be intermittent or resistive when in operation. If possible test for a voltage drop when the system is operational. Inspect for proper installation of aftermarket electronic equipment which may affect the integrity of other systems.
4.
Page 299
Figure 235
Connector Part Information Pin

A B C D E F
6 Way Female
Wire Color
BRN ORN GRN YEL PNK BLU
Circuit No.
317 319 322 318 320 323
Function
Exterior Lamps Fuse Output-Battery Uplifter Connector (Exterior) Pin-C Fuse Output-Ignition Auxillary Relay Contact (Relay Center 2) Uplifter Connector (Exterior) Pin-E
Figure 236
Connector Part Information
12065862 4 Way Metri Pack 280 Sealed (BLK)
Pin
A B C D E
Wire Color
ORN PNK DK GRN --DK BLU
Circuit No.
640 339 909 --910
Function
Fuse Output-Battery Fuse Output-Ignition Interior Uplifter Connector Not Used - Sealed Interior Uplifter Connector
Wiring Diagram Body Mounting Circuits
Page 300
Figure 237
Metric Information
Metric Information
Throughout the Isuzu/GM W-Series Body Builder's Guide, you will find the dimensions, weights, and power ratings that are presented in both customary United States measurements and in metric measurements that conform to standards of Systems International d'Unites (S.I. metric). Many of the customary measurements are conversions from metric based information while some information is based on U.S. measurements. Some figures have been rounded for clarity and are thus not exact equivalents. For your inormation, here are some of the more common measurements and their conversion factors.
Page 301
METRIC CONVERSIONS
Length 1 inch 1 foot 1 yard 1 mile 1 centimeter 1 meter 1 meter 1 kilometer Equals 2.54 cm 30.48 0.9144 meters 1.6093 km 0.3937 inches 39.37 inches 3.2808 feet 0.6214 mile
Volume 1 cubic inch 1 cubic foot 1 cubic yard 1 gallon (U.S.) 1 gallon (Imp.) 1 centimeter3 1 meter3 1 liter 1 liter
Equals 16.39 cm3 0.0283 m3 0.7646 m3 3.785 liters 4.534 liters 0.061 cu in 35.31 cu ft 61.02 cu in 0.264 U.S. gal.
Area 1 square inch 1 square foot 1 square yard 1 centimeter2 1 meter2
Equals 6.452 cm2 0.0929 m2 0.8361 m2 0.155 sq in 10.76 sq ft
Speed (Velocity) 1 mile/hour (mph) 1 kilometer/hour
Equals 1.6093 km/h 0.6214 mph
Weight(Mass) 1 pound 1 kilogram
Equals 0.4536 kg 2.205 lbs
Force 1 pound 1 kilogram
Equals 4.448 Newtons 9.807 Newtons
Page 302
Power
Equals
Torque 1 lb-ft 1 Newton-meter
Equals 1.3558 Nm 0.7376 lb-ft
We are striving to provide you with the most up-to-date and accurate information possible. If you have any recommendations to improve the Body Builder Guide, please call Isuzu Application Engineering. In the West Coast call 1-562-229-5000 extension 2385 and in the East Coast call 1-770-475-9195 extension 353.
Page 303

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Isuzu 2000 Body Builder's Guide

Isuzu 2000 Body Builder's Guide

GASOLINE VEHICLES Miscellaneous Items Used in Above Systems

Emissions Statement FSR FTR FVR

EXHAUST EMISSION RELATED COMPONENTS

Isuzu 2000 Body Builder's Guide

Figure 1 Isuzu 2000 Body Builder's Guide Page 7

Gross Axle Weight Rating

Weighing the Vehicle

Installation of Body and Special Equipment

Isuzu 2000 Body Builder's Guide

Front and Center Propeller Shafts

Rear Propeller Shaft

rear propeller shaft.

Exhaust System Clearance

Isuzu 2000 Body Builder's Guide

Rear Wheel and Axle Clearance

Brake Hose Parking Brake Cable Fuel Hose Shock Absorber

6.7in 1.6 in 1.2 in. 1.6 in. 2.4 in 1.2 in

Axle Side Frame Side ----------Axle Side Frame Side

Isuzu 2000 Body Builder's Guide

Installation of Special Equipment on the Chassis

Subframe Design and Mounting

Isuzu 2000 Body Builder's Guide

Contouring of the Subframe

Isuzu 2000 Body Builder's Guide

Figure 12 Drawing (1) A 0.2 in B

Isuzu 2000 Body Builder's Guide

Prohibited Attachment Areas

Isuzu 2000 Body Builder's Guide

Subframe Mounting Bracket Installation

Subframe Mounting U-bolt

Modification of the Chassis Frame

Working on the Chassis Frame

Drilling and Welding

Isuzu 2000 Body Builder's Guide

Reinforcement of Chassis Frame

Preparation of Additional Lines

Installation of Additional Lines

Isuzu 2000 Body Builder's Guide

Electrical Wiring and Harnessing

Isuzu 2000 Body Builder's Guide

Figure 24 Isuzu 2000 Body Builder's Guide Page 24

Wire Color Code

Maximum Current Allowable in Low Voltage Wiring

100 85 60 50 40 30 20 Isuzu 2000 Body Builder's Guide

217/0.80 169/0.80 127/0.80 108/0.80 85/0.80 70/0.80 41/0.80

109.1 84.96 63.84 54.29 42.73 35.19 20.61

363 305 248 223 191 171 123 Page 25

Harness Design Diameter (mm)

No. of wires/ wire diameter (mm)

Cross sectional area (mm2)

Maximum allowable current (amps)

15 8 5 3 2 1.25 0.85 0.5

84/0.45 50/0.45 65/0.32 41/0.32 26/0.32 16/0.32 11/0.32 7/0.32

13.36 7.952 5.228 3.297 2.091 1.287 0.8846 0.5629

Flexible brake hoses

3.1 in. or more. 5.9 in. or more.

Isuzu 2000 Body Builder's Guide

Rear Comb. Lamp / License Plate Lamp Mounting Bracket

Shortening / Lengthening the Wheelbase Without Altering the Frame

Altering the Wheelbase by Altering the Frame