Manual Carrocero

Page Section Contents
Introduction
General
05 >>>> 1-1 General precautions concerning body installation

(1) Running speed of bare chassis in transportation
(2) Leveling of chassis frame
(3) Prevention of damage to chassis
07 >>>> 1-2 Preparation for chassis
(1) Confirmation of specification sheet
(2) Confirmation of outermost dimensions of front/rear tires
against vehicle width
(3) Leaf spring of rear suspension
08 >>>> 1-3 Main data and specifications
(1) Specifications
(2) Running performance curve
25 >>>> 1-4 Four orthogonal views
29 >>>> 1-5 Allowable loads
(1) Allowable loads to axles
(2) Allowable loads to tires
(3) Allowable load ratio of front axle
30 >>>> 1-6 Layout around driving device
2 Precautions for Body Installation
38 >>>> 2-1 General precautions

(1) Basic bus body structures
(2) Advantages of the bus chassis with frame (reason of ISUZU
MOTORs recommendation)
(3) Chassis frame
39 >>>> 2-2 Balance of weight
39 >>>> 2-3 Ideal method for connecting body and chassis frame IMPORTANT
(1) Prohibited structure
(2) Recommended structure
(3) Fitting a support bracket
1) Fitting a support bracket on a side member by welding
2) Fitting a support bracket by bolting
3) Contact by support bracket
(4) Connecting front and rear outriggers to body
43 >>>> 2-4 Layout of floor boards and opening
(1) Position of drivers door
(2) Position of passenger steps
(3) Requirements for opening for engine check and
neighboring parts and equipment
1) Size of opening
2) Requirements for engine hood
3) Oil tank for power steering
(4) Requirements for wheelhouse
Contents 1
3 Remodeling Chassis and Chassis Frame
46 >>>> 3-1 Remodeling chassis frame

(1) Drilling and welding chassis frame
(2) Extending or shortening front or rear end of chassis frame
1) Extending front or rear end
2) Shortening front or rear end
3) Extending or shortening the region between wheelbases of
chassis frame
49 >>>> 3-2 Remodeling chassis
(1) Displacing or modifying fuel tank
(2) Relocating or modifying battery and battery relay
(3) Remodeling exhaust pipe
(4) Remodeling rear suspension
(5) Piping for brake system
1) Fitting equipment and laying pipes
2) Material and processing of pipes
(6) Precautions for modifying chassis harness
1) Cables and harnesses
2) Harness connector
3) Extending chassis harnesses
4 Requirements for Body Installation
59 >>>> 4-1 Outline of engine air intake system and remodeling of

the system IMPORTANT
(1) Engine intake system on the NPR/NQR bus chassis
(2) Remodeling air intake system
1) Remodeling rear vertical intake system
2) Remodeling front intake system
63 >>>> 4-2 Requirements for vicinity of engine
(1) Radiator
1) Replacing the original radiator
2) Changing position and angle of radiator
3) Placing a body component in front of radiator core
4) Placing a shield around radiator
5) Radiator surge tank
6) Radiator grill
(2) Exhaust system and measure against heat damage
(3) Clearance around engine
(4) Vehicle noise
1) Measure against vehicle exterior noise
1. Sound insulation panel (side cover)
2. Tire noise
3. Exhaust noise
2) Measure against vehicle interior noise
1. How to reduce penetrating noise
2. How to reduce knocking and contact sound caused by
body vibration or resonance of body structural sections
69 >>>> 4-3 Requirements for engine control
(1) Position of accelerator pedal
(2) Fixing flexible shaft
(3) Displacing flexible shaft
2 Contents
70 >>>> 4-4 Drive line and operating devices
(1) Requirements for driveline and its vicinity
1) Checking and maintaining clutch and transmission
2) Checking and maintaining the area above transmission
3) Clearance around front and center propeller shafts
4) Vicinity of rear propeller shaft
(2) Requirements for transmission control
1) Change lever
2) Temporarily removing flexible shaft
3) Arranging flexible shaft
72 >>>> 4-5 Parking brake and operating devices
(1) Fitting parking brake lever
(2) Temporarily removing flexible shaft
(3) Arranging flexible shaft
73 >>>> 4-6 Changing specification of electric components on bus body or
adding new electric components
73 >>>> 4-7 Spare tire carrier
5 Air Conditioning System Procured and Installed by Body Builder
74 >>> 5-1 Power generating capacity of AC generator

74 >>>> 5-2 Installing air conditioning system on chassis
76 >>> 5-3 Laying pipes on chassis for air conditioning system
6 Hot-water Heating System Procured and Installed by Body Builder
77 >>> 6-1 Inlet and outlet for hot water for heating system
77 >>>> 6-2 Laying pipes on chassis for heating system
Contents 3
Introduction 1
General
This body builders guide contains common methods for installing bus body on an
ISUZU NPR/NQR bus chassis with frame.
When installing bus bodies, please refer to the general explanations in this
installation manual.
In order to earn a good reputation for diesel engine buses with ISUZU NPR/NQR
2
frames in your country, it is first important to pay full attention to build a bus body
Installation
Precautions for Body
on chassis so as to obtain true performance, safety, and reliability of the chassis.
In addition, dimensional accuracy, execution, and quality of the body are also
reflected in customer appraisals.
Therefore, it is important to conduct verification in each installation process so that
occurrence of various kinds of defects related to bus body installation can be
prevented. 3
Chassis Frame
Remodeling Chassis and
We ask that, in addition to maximizing your special experience and know-how,
installers provide appropriate instructions so that workers at the worksite are
familiar with the contents of this installation manual, and thereby ensure that the
bodies to be installed are of high quality and high performance and do not cause
any defects.
Installation
Requirements for Body
5
Body Builder
Procured and Installed by
Air Conditioning System
6
Body Builder
Hot-water Heating System
Introduction 4
General 1
General
1-1 General precautions concerning body installation
This body manual sets out guidelines for the installation of a bus body onto the
chassis. Even in the case of the buses installed in accordance with this installation
manual, the responsibility for the body installation shall be borne by the body
builder. Furthermore, if the body builder does not comply with this manual, ISUZU
MOTORS shall not respond to any warranty claims. Also, if the chassis is modified 2
by the body builder, the responsibility for such modifications shall also be borne by
Installation
the body builder.
(1) Running speed of bare chassis in transportation

When a bare chassis is transported by being driven, it is preferable that the
chassis is driven at 40 km/h or under considering unbalanced weight, and
prevention of residual torsion of frame, loosening of rivet, etc. Especially on
3
uneven or punishing roads, driving at 20 km/h or under in as short distance as
Chassis Frame
possible is preferable.
(2) Leveling of chassis frame
When installing the body, it is important to keep the chassis frame horizontal.
Generally, the chassis frame carried into a body installation site is twisted and
bended in many cases. Therefore, it is essential, before the installation, to
4
correct the torsion on the upper surface of the frame so as to assure evenness.
Installation
If a body is installed on the frame with any bends or twists, it will not be possible
to finish a high-precision and high-quality bus due to the effect of frame flexure,
regardless of whether a completed body is mounted on the chassis or the body
is built up on the chassis.
Fig.1-1 shows an example of the method for leveling the chassis frame.
The leveling is done by setting 6 jacks or height-adjustable stands, under the
lower surface of the frame side rail, at each of the right and left sides of the 5
following: The front overhang, rear overhang, and center of wheel base.
Body Builder
Position the jacks or stands so that they do not come into contact with any
chassis equipment parts except the frame.
6
Body Builder
NPR/NQR1 General 5
1 (3) Prevention of damage to chassis
General
During body installation, pay sufficient attention so that any mechanical,

chemical or heat damage to chassis equipment or functional parts occurs.
Examples of damage
Damage to chassis parts while punching holes on the frame
Melting or functional damage to rubber and plastic parts caused by spatters
when welding the body structure
2
Damage to electric parts caused by overcurrent or overvoltage in electric
Installation
welding
Trapping of foreign matter in revolving parts, sealed parts and joined parts
Clogging of radiator caused by paint
Deterioration of rubber and plastic parts while drying paint
Fig. 1-1 Leveling of chassis frame

3
Chassis Frame
4
Installation
5
Body Builder
6
Body Builder
6 NPR/NQR1 General
1-2 Preparation for chassis 1
General
(1) Confirmation of specification sheet
(Confirmation of allowable gross vehicle weight, allowable front/rear axle
weights, and load capacity of tires)
Totalized value of overall weight of a bus body and the riding capacity weight,
etc. may exceed the above allowable load. Therefore, in designing bus body, be
careful not to exceed each tolerance by referring to the past results of body
2
installation and calculating estimated weight.
Installation
Especially when extending front overhang so as to create an entrance door
according to users requirements, pay full attention to increasing possibility of
excess over allowable front axle weight.
ISUZU MOTORS does not recommend the extension of front overhang,
because it may cause excessive load on front axle and may require modification
of steering gear, which may lower the running stability.
3
(2) Confirmation of outermost dimensions of front/rear tires against vehicle width
Chassis Frame
If outermost sides of the tires are recessed by 150 mm or more against overall
width of bus body or protrude, in any degree, from the neighboring outer surface
of the body, reselection of chassis or review of body dimensions is preferable,
because, such locations of tires may cause problems in body appearance,
running stability, safety, etc.
4
(3) Leaf spring of rear suspension
Installation
If a bus body is installed on the chassis adopting the sub spring for truck as rear
suspension, when the sub spring comes into contact with stopper, spring
constant drastically increases and impact reaches inside to reduce riding
comfort. Accordingly, it is permissible to adopt the spring especially intended for
bus which is commensurate with possible load without any sub spring.
5
Body Builder
6
Body Builder
NPR/NQR1 General 7
1-3 Main data and specifications 1
General
(1) Specifications
Tab. 1-1
Vehicle type NPR66LL-5LYB NPR66PBL-5LVY NPR66PBU-5LVY NPR66PU-5LXYMW NQR66PU-5NVXY NQR70PBL-5LYRJ NQR71PBL-5NVY NQR71RBL-5LVYB NQR75RBU-5NXYZJ
Destination Egypt Universal Universal Malaysia Universal Taiwan Universal Egypt South Africa
Original shape of cab Wide, single Skeleton Wide, single (manual tilt) Skeleton Wide, single Skeleton
(tilt cab) (w/Ft. bumper) (w/o back panel) (w/Ft. bumper) (w/o back panel) (w/Ft. bumper) (w/o back panel)
2
Steering position LH RH LH RH
Installation
Allowable gross vehicle weight
7,000 8,000 7,500 8,000 7,500 8,500
(kg)
Weight
(kg) Allowable front axle weight (kg) 3,100
Allowable rear axle weight (kg) 5,000 6,600
Overall length of chassis 5,955 (Ft. bumper) 6,540 (Ft. panel) 6,610 (Ft. bumper) 6,540 (Ft. panel) 7,320 (Ft. bumper) 7,250 (Ft. panel)
3
Wheelbase 3,365 3,815 4,175
Chassis Frame
Front overhang 1,035 1,015 1,035 1,015 1,035 1,015
Rear overhang 1,505 1,710 2,060

Dimensions
Front axle
(mm) center
Ground height
from frame Rear axle
center
4
Front wheel 1,680 1,665 1,680
Installation
Tread
Rear wheel 1,525 1,650 1,525 1,650
4HF1 4HE1-TCS 4HG1 4HK1-TCS

Type
(EURO-I) (US98EPA) (EURO-I) (EURO-III)
Turbocharging Turbocharging
Air intake system Naturally-aspirated Naturally-aspirated
(w/intercooler) (w/intercooler)
Engine
Overall displacement (cc) 4,334 4,751 4,570 5,200 5
Builder
Procured and Installed by Body
Max. output kw/rpm (ps/rpm) 88 (120)/3,200 175HP (177)/2,700 89(121)/3,200 128(175)/2,600
Max. torque Nm/rpm 347ftlb (47.9)

285 (29.0)/1,800 (ISO-gross) 304(31)/1,600 500(51)/1,500
(kg-m/rpm) /1800 (SAE-gross)
Vertical
Air intake duct type Vertical Front grill Vertical
(Opt: Front grill)
Type MYY5T MZZ6U MYY5T MZZ6U

6
1st 5.315 6.369 5.315 6.369
Builder
2nd 3.053 3.767 3.053 3.767
Transmission 3rd 1.655 2.234 1.655 2.234
Gear ratio 4th 1.000 1.442 1.000 1.442
5th 0.721 1.000 0.721 1.000
6th 0.782 0.782
Reverse 5.068 6.369 5.068 6.369
NPR/NQR1 General 8
Vehicle type NPR66LL-5LYB NPR66PBL-5LVY NPR66PBU-5LVY NPR66PU-5LXYMW NQR66PU-5NVXY NQR70PBL-5LYRJ NQR71RBL-5NVY NQR71RBL-5LVYB NQR75RBU-5NXYZJ 1
General
Destination Egypt Universal Universal Malaysia Universal Taiwan Universal Egypt South Africa
Drive Base 6.142 6.833 5.125 6.833 4.777

Final gear Gear ration
system Option 5.857 or 5.571 6.142 or 5.857 4.777 6.142 or 5.857
Braking Hydraulic Hydraulic Hydraulic Hydraulic
Control method
system (vacuum servo) (hydraulic servo) (vacuum servo) (hydraulic servo)
Type Variation of width Straight (w/o upper rivet) Variation of width Straight (w/o upper rivet) Straight, extension frame (w/o upper rivet)
2
Width Front: 935 Front: 935
Frame Dimensions after 850 850
Installation
Center: 820 Center: 820
of side frame assembly Rear: 750 Rear: 750
(mm)
Height 173 216 173 216
Base 7.50-16-10 7.50-16-10 7.50-16-14
Tire 8.25-16-14 8.25-16-14

Option 7.50-16-12 7.50-16-10
(Base) (Base)
Option 7.50-16-14 8.25-16-12 8.25-16-12
3
Disk Size - offset (mm) 6.00GSx16-127 6.00GSx16-127 (7.50-16 tire), 6.00GSx16135 (8.25-16 tire)
Chassis Frame
wheel No. of studs 6
Semi-elliptic leaf Semi-elliptic leaf spring Semi-elliptic leaf
Semi-elliptic leaf
Type spring w/auxiliary Semi-elliptic leaf spring Semi-elliptic leaf spring spring w/auxiliary
w/auxiliary spring on rear axle spring
Suspen- spring on rear axle spring on rear axle
sion Front axle Option Option Standard Option
Stabilizer
Chassis Rear axle Option Option Standard Option
Power assist Option Standard Option Standard Option Standard 4
Tilt & telescopic column Option
Installation
Driving 15mm extension of
gear
column shaft
Knuckle Outer race 42.5 42.5 (36.5) 42.5 42.5 (36.5) 42.5
angle () Inner race 32.7 32.7 (30.0) 32.7 32.7 (30.0) 32.7
100
100
Tank capacity (lit.) Two-piece capsule 100 100 100 100
Two-piece capsule
Tank shape type (Square Two-piece capsule type Square winding type Two-piece capsule type Square winding type 5
type
Fuel winding type)
Builder
system Water separator Standard (w/sensor)
Dual filter Option
Position on chassis RH (Opt: LH) RH LH RH
Exhaust
Pigtail pipe Standard Standard
system
Front Standard Standard Standard Standard Standard
Others Tow hook
Rear Standard Standard Standard 6
Builder
Base 75D23R2 65D23R2 75D23R2 80D26R2 75D23R2 80R26R2
Option 80D26R2 75D23R2 (Base) 80D26R2 115I41R2 80D26R2 115I41R2
Battery
Electric Option 65D23R2 80D26R2 65D23R2 65D23R2
com-
ponent Position on chassis LH (Opt: RH) LH RH LH
AC Base 24V50A 24V60A 24V50A 24V60A 24V50A

generator Option 24V60A 24V35A 24V60A 24V60A, 24V80A 24V60A
NPR/NQR1 General 9
(2) Running performance curve 1
General
Running performance curves according to engine output are shown on the
following pages. (Refer to Fig. 1-2 through Fig. 1-13.)
The curves are reference data to be used in prediction of the running
performance within allowable gross vehicle weight.
To draw a running performance curve for the gross weight of the bus to be
completed by body builder, running resistance (R) curve can be approximately
2
calculated by using the formula below.
Installation
R = rVW + sinW + lAV
R: Total running resistance (kg)
W: Gross vehicle weight (kg)
V: Running speed (km/h)
A: Vehicle frontal area (m2) 3
Chassis Frame
: Road gradient (%)
r: Rolling resistance coefficient (=0.010)
l: Air resistance coefficient (=0.003)
Installation
5
Body Builder
6
Body Builder
NPR/NQR1 General 10
Fig. 1-2 Running performance curves 1: NPR66L/P (T/M:MYY5T) bus
NPR/NQR1 General
Air Conditioning System Hot-water Heating System
Precautions for Body Remodeling Chassis and Requirements for Body
11
General Procured and Installed by Procured and Installed by
6
1
Installation Chassis Frame Installation
Body Builder Body Builder
12
2
6
1

NPR/NQR1 General
Fig. 1-3 Running performance curves 2: NPR66P (T/M:MYY5T) bus
Fig. 1-4 Running performance curves 3: NPR66P (T/M:MYY5T) bus
NPR/NQR1 General
13
6
1
14
2
6
1

NPR/NQR1 General
Fig. 1-5 Running performance curves 4: NQR70P (T/M:MZZ6U) bus
Fig. 1-6 Running performance curves 5: NQR70P (T/M:MZZ6U) bus
NPR/NQR1 General
15
6
1
16
2
6
1

NPR/NQR1 General
Fig. 1-7 Running performance curves 6: NQR66P (T/M:MYY5T) bus
NPR/NQR1 General
17
6
1
18
2
6
1

NPR/NQR1 General
NPR/NQR1 General
19
6
1
20
2
6
1

NPR/NQR1 General
Fig. 1-11 Running performance curves 10: NQR71R (T/M:MYY5T) bus
NPR/NQR1 General
21
6
1
22
2
6
1

NPR/NQR1 General
NPR/NQR1 General
23
6
1
24
2
6
1

NPR/NQR1 General
Fig. 1-15 Running performance curves 14: NQR75R (T/M:MZZ6U) bus
1 1-4 Four orthogonal views
General
Four orthogonal views are attached as a reference for designing bus bodies.
(1) Fig. 1-16 through Fig. 1-18 show four orthogonal views (external views) of
NPR/NQR bus chassis.
(2) Section 1-3 Main data and specifications shows chassis weights and
suspension spring constants of NPR/NQR bus chassis. The weights are the
2 reference values of the weights before shipment.
Before installing the body, measure front/rear wheel loads of right/left sides,
Installation
and if any installed equipment such as fuel tank is to be relocated, calculate the
chassis weight based on the weight of the equipment and the relocation
distance.
3
Chassis Frame
4
Installation
5
Body Builder
6
Body Builder
25 NPR/NQR1 General
Procured and Installed by Procured and Installed by Body
26
General
2
6
1

Body Builder Builder
NPR/NQR1 General
Fig. 1-16 Four orthogonal views: NPR66PBU bus chassis
27
General
2
6
1

NPR/NQR1 General
Fig. 1-17 Four orthogonal views: NPR66PBL bus chassis
28
General
2
6
1

NPR/NQR1 General
Fig. 1-18 Four orthogonal views: NQR70PBL bus chassis
1-5 Allowable loads 1
General
(1) Allowable loads to axles
Maximum allowable loads of NPR/NQR bus are shown on Table 1-2.
Tab. 1-2 Allowable loads Unit: kg

Vehicle Allowable front axle Allowable rear axle Allowable gross vehicle
type weight (maximum) weight (maximum) weight (maximum)
NPR 3,100 5,000 7,000 2
Installation
NQR 3,100 6,600 7,500
(2) Allowable loads to tires

Maximum allowable loads of NPR/NQR bus are shown on Table 1-3.
Tab. 1-3 Allowable load rating based on tire size Unit: kg

Allowable front Allowable rear Allowable gross
Vehicle 3
Tire size axle weight axle weight vehicle weight
type
(maximum) (maximum) (maximum)
Chassis Frame
7.50-16-10 (Standard) 2,660 5,060
NPR 7.50-16-12 2,880 5,480 7,000
7.50-16-14 3,020 5,760
7.50-16-10 2,660 5,060
7.50-16-12 2,880 5,480
NQR 7.50-16-14 (Standard) 3,020 5,760 7,500 4
Installation
8.25-16-12 3,150 6,000
8.25-16-14 (Standard) 3,420 6,520
(3) Allowable load ratio of front axle

Front axle weight distribution is calculated by the following formula, and should
be within the following tolerance, which is applied to both laden and unladen
5
vehicle weights
Body Builder
WF
40 x100 25
W
Legend WF Front axle weight
WR Rear axle weight
W WF + WR = Gross vehicle weight
6
Body Builder
NPR/NQR1 General 29
1 1-6 Layout around driving device
(Diversion of the peripheral parts/devices of truck cab)
General
Major ways to divert truck cab may include the following. The merits and demerits
of the diversion are shown on Table 1-4.
Please take reference to the following in selecting the most suitable way for the
manufacturing technology and methods unique to each body builder.
Tab. 1-4
2
Case Diversion methods of truck cab Major merits and demerits
Installation
Divert the whole truck cab assembly Merits:

(Applicable to all types of NPR/NQR 1. Assures assembly quality equal to
completed truck cab.
2. Diverts main parts.
3. Reduces investment and assembly man-
hour for front section of bus body.
4. Assures appropriate driving position and
3 view.
1
Demerits:
Chassis Frame
1. Tends to cause defects in quality and

strength of the joint between cab and bus
body.
2. Requires many manual works as a whole to
tend to cause defective appearance of joint
with rear section of bus body.
4 Remove the parts unnecessary for bus Merits:

body installation from truck cab 1. Assures assembly quality equal to
Installation
assembly. completed truck cab.

(Skeleton cab) 2. Diverts main parts.
3. Reduces investment and assembly man-
hour for front section of bus body.
4. Reduces chassis cost by removal of
unnecessary parts.
2 5. Assures appropriate driving position.
Demerits:
5
1. Tends to cause defects in quality and
Body Builder
strength of the joint between bus body and

diverted parts from truck cab.
2. If the main body of cab is repaired before
diversion, requires many manual works as a
whole to tend to cause defective
appearance.
6
Body Builder
30 NPR/NQR1 General
Case Diversion methods of truck cab Major merits and demerits 1
General
Use the truck cab equipped with the Merits:
temporary device frame with the whole 1. Assures the assemble quality of the whole
driving device and instrument panel on driving device and parts.
each original position 2. Assures appropriate driving position.
(Currently applicable to NPR/NQR) 3. Drastically reduces chassis cost by
removal of unnecessary parts. (Cab tilt
mechanism is also unnecessary.)
4. Allows various shapes and mechanisms of
bus body to be installed. 2
3 5. Assures the same appearance around
Installation
drivers seat including diverted instrument
panel as that of the truck.
Demerits:
1. Increases in weight due to the addition of
temporary device frame.
2. Lowers the appearance after installation of
bus body because of the temporary device
frame.
3
Chassis Frame
Parts of the whole driving device are Merits:
supplied separately from the cab , and 1. Allows the change in driving position as
body builder assembles the parts onto requested by body builder.
a bus body. 2. Allows the whole driving device to be
(Applicable to all types of NRP/NQR) assembled in accordance with body
structure.
In this method, however, measurement 3. Allows the design around driving device
of the coordinates on actual vehicle is flexible to the needs of body builder.
4 required, because it is preferable to 4
Demerits:
locate each parts of the whole driving 1. May lack in rigidity of the joints between
Installation
device on the same position as that of instrument panel, brake/clutch assembly,
the truck. steering column, etc. and body.
2. May cause defective piping and wiring
around drivers seat.
3. Not allow the transportation of bare
chassis by driving it.
Note: For Case 1 and Case 2, ISUZU MOTORS assumes that there will be 5
generally no change from original parts to alternatives..

Body Builder
6
Body Builder
NPR/NQR1 General 31
1 1) Precaution for Case 2
General
When adopting skeleton cab, the following 2 types of cabs are available.
(Refer to Table 1-5.)
Tab. 1-5Composition of skeleton cab

1. Standard specification
Main components
2
Related parts of outer panels Trim parts
Installation
1) Front panel 1) Instrument panel

2) Floor panel 2) Drivers seat
3) Roof panel
4) Post A and post B
Main parts to be removed
Related parts of outer panels Trim parts
1) Windshield 1) Assistant seat
3
2) Door assembly 2) Sound insulation mat
Chassis Frame
3) Frontal side panel 3) Melting sheet

4) Back panel 4) Trim
5) Radiator grill 5) Head lining
6) Front bumper 6) Roof mirror
7) Rearview mirror 7) Sun visor
8) Tilt mechanism 8) Grip
9) Ornament 9) Blower unit and duct
10) Wiper and washer
4
2. Optional specification
Installation
Following parts are excluded from the main components of

standard specification.
1) Roof panel
2) Post A and post B (Refer to the drawing on the right.)
5
Body Builder
When optionally adopting the reinforcement to fix skeleton cab as shown in

the following Fig. 1-19, remove the reinforcement before installing bus body
according to the following procedure.
Fig. 1-19 Fixing procedure of skeleton cab reinforcement

6
Body Builder
32 NPR/NQR1 General
The reinforcement is L-shaped steel (L40 x 40 3.2t and has bolt-holes at 1
both ends.
General
The reinforcement is fixed by the screws for door hinge on the front portion
and by that for door striker on the rear portion.
Accordingly, the reinforcement can be removed only by removing the fixing
bolts at both ends.
2) Precaution for Case 3 and Case 4
2
Assemble the whole driving device (steering wheel/shaft, meters, switches,
Installation
pedal A/B/C, change lever, parking brake lever, etc.) onto the bus body
without any change in original parts, equipment, and their relative positions.
For assembling the whole driving device, it is recommended to divert the
following original parts of truck cab (instrument panel and related parts).
The following shows composition of instrument panel and related parts for
reference. However, please note that the components, their parts numbers,
3
required numbers of them, etc. are subject to change according to vehicle
Chassis Frame
type and model year. For detail information, please contact dealers of ISUZU
MOTORS.
Fig. 1-20 Composition of instrument panel and box
Installation
5
Body Builder
6
Body Builder
NPR/NQR1 General 33
1 No. Part name No. Part name
General
1 Instrument panel 323 Screw for glove box lid

4 Instrument panel cover 335 Grommet for glove box lid
7 Support bolt for instrument panel 336 Side cover of instrument panel
11 Bolt for instrument panel 378 Instrument panel seal
16 Bracket for instrument panel 495 Bezel for switch
33 Inspection lid for brake/clutch fluids 500 Instrument panel center cluster
2
34 Oil tank lid 513 Bracket for relay
Installation
40 Air duct for side cluster bezel 520 Screw for spring clip
42 Glove box for instrument panel 521 Cover for solar sensor
46 Stopper cap for glove box 522 Lid for relay box
48 Spring for glove box lid 524 Cup holder for instrument panel
49 Glove box lid 525 Screw for cup holder
50 Stopper for glove box lid 526 Pocket guide for instrument panel
3
61 Screw for glove box 527 Clip for instrument panel cluster
Chassis Frame
62 Knob for glove box lid 528 Cover for power takeoff lever
66 Reinforcement of instrument panel 529 Coin pocket
69 Grill of side air outlet 530 Clip for glove box
109 Upper side-grill of instrument panel 531 Main body of ash tray
133 Screw for instrument panel cover 532 Screw for ash tray
142 Instrument panel stay 533 Spring clip for center cluster
4
145 Instrument panel side stay 534 Bracket clip
Installation
146 Tap screw 566 Hole plug

154 Nut 581 Screw
167 Bolt to joint instrument panel and
598 Screw for grommet
reinforcement
179 Bolt for instrument panel stay 624 Cup holder cover
182 Bolt for instrument panel bracket
5
211 Fixing nut for instrument panel bracket
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219 Shaft for glove box lid

235 Screw for grill
274 Nut for glove box
6
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34 NPR/NQR1 General
Fig. 1-21 Under cover and ash tray: Composition of instrument panel assembly 1
General
2
Installation
3
Chassis Frame
No. Part name No. Part name
3 Ash tray inner 42 Bracket for under cover
4 Ash tray outer 48 Nut for under cover
6 Screw for ash tray 53 Clip for undercover
8 Ash tray 58 Screw for under cover
11 Bulb for Ash tray 67 Under cover for instrument panel 4
88 Under cover for side of instrument panel
Installation
Fig 1-22 shows the example drawing of the NQR71RBL bus chassis
adopting case 3.
Fig. 1-23 shows the example drawing of the temporary driving device frame
equipped on the truck cab to be diverted to the NQR71RBL bus chassis
5
adopting Case 3.
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If drivers view point should be relocated from where it should be as truck cab
due to the layout of the bus body to be installed, move the whole driving
device in parallel to keep relative position.
6
Body Builder
NPR/NQR1 General 35
General Procured and Installed by Body Procured and Installed by Body
36
1

Builder Builder
NPR/NQR1 General
Fig. 1-22 Drawing of NQR71RBL bus chassis (Engine: 4HG1)
General Procured and Installed by Body Procured and Installed by Body
37
1

Builder Builder
NPR/NQR1 General
Fig. 1-23 Example drawing of the temporary driving device frame equipped on the truck cab to be diverted
2 Precautions for Body Installation 1
General
2-1 General precautions
Note that the definition of the term original herein is either base truck chassiss
or as described in dictionary.
(1) Basic bus body structures
1. Skeleton structure
2
With body frame only, this structure ensures strength and rigidity of entire
Installation
bus.
Features: This structure realizes a variety of body shapes such as large
windows and square body. However, it requires large-scale jigs
and facilities.
2. Monocoque structure
This structure ensures its strength and rigidity when outer panels are fitted 3
on it.
Chassis Frame
Features: Lightweight but it requires a large number of jigs and facilities
because this stressed-skin structure places limitation on body
shape.
3. Built-up structure
A body is built up on chassis with frame.
4
Features: This structure realizes a variety of body shapes, and it requires
Installation
only a few assembly jigs and facilities. However, it is not suitable
for volume production because body is heavy and it requires a
considerable number of man-hours.
(2) Advantages of the bus chassis with frame (reason of ISUZU MOTORs
recommendation)
1. After being landed at a port, chassis themselves can be driven to plant for
5
body installation.
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2. Since the structure of this chassis is originally of a mass-produced truck, a

fair percentage of the chassis components can be used without modification.
3. Chassis frame allows to build up a bus body on it, resulting in reduction of
the investment in assembly jigs and facilities.
(3) Chassis frame

6
The structure of the NPQ/NQR bus chassis frame is Ladder Structure, which
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is the same as truck structure. Since its strength and rigidity are assured only
when it is joined to a body, chassis frame and body structure must firmly be
connected so that they mutually supplement each others strength and rigidity,
creating a powerful, strong bus. Take sufficient care when connecting a body
and cross members of chassis frame.
NPR/NQR2 Precautions for Body Installation 38

1 2-2 Balance of weight
General
Variance in weight between the left and right sides of unladen bus should be no
more than 100kg. Weight imbalance causes inclination of bus body, and gives
adverse effect on steering performance.
2-3 Ideal method for connecting body and chassis frame IMPORTANT
The way of installing bus bodies on chassis varies depending on the body builder.
2 As mentioned in Section 2-1, ISUZU MOTORS bus chassis frames are not so rigid
and they are designed to be strong when they are joined to hexahedron bodies
Installation
that firmly withstand bending and twisting. To avoid stress concentration,

deformation, and crack, you must be very careful when joining a body to a chassis
frame.
(1) Prohibited structure
As shown in Figure 2-1, vertical motion of body (W) is transmitted via Stay A,
3
creating force (F) applied to the connecting point (P) of Stay B and chassis
Chassis Frame
frame.
Because the force (F) works to separate Stay B from the chassis frame, the
chassis frame may crack. Therefore, the outrigger structure shown in Figure 2-1
should not be adopted.
Fig. 2-1 Outrigger (1)

4
Installation
5
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6
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39 NPR/NQR2 Precautions for Body Installation

(2) Recommended structure (See Figure 2-2) 1
General
1. Fit Stay C in order to avoid direct force application to the web of chassis
frame.
2. Use a cross sill whose section is strong enough to bear load without Stay A,
while allowing vertical force application to the web of chassis frame.
Installation
3
Chassis Frame
(3) Fitting a support bracket 4
Installation
We recommend that you use a support bracket when connecting a cross sill of
body floor to chassis frame. If there is limitation on the location of support
bracket on chassis frame, changing the shape of the bracket may help.
1) Fitting a support bracket on a side member by welding

When connecting outrigger fitted on cross sill of body floor, stay or support
5
bracket to side members, do not weld them if there are on the base truck
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chassis any pipes or cables within 200mm from them because doing so will
cause heat damage to the pipes or cables.
Figure 2-3 shows how to fit a support bracket on a side member by welding.
6
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1 Note: Be aware that pipes and cables laid along side members are
vulnerable to heat damage since they are clamped by plastic clips.
General
When installing a body on chassis, do not remove these plastic clips

because once they are removed, it will be very hard to clamp the pipes
or the cables again in the original manner.
Fig. 2-3 How to fit a support bracket by welding
2
Installation
3
Chassis Frame
2) Fitting a support bracket by bolting

We recommend that you use bolts when fitting a support bracket on a side
member. Knurled bolt is preferable for its tightening performance. As side
members have a lot of holes, use these holes for bolting and do not make
additional holes as much as possible. Figure 2-4 shows how to bolt a
4 support bracket.
Installation
Fig. 2-4 How to fit a support bracket by bolting
5
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3) Contact by support bracket

6
Fit a support bracket in an appropriate position so that it will not contact with
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chassis components or clips clamping pipes and cables on chassis.

42
1
6
NPR/NQR2 Precautions for Body Installation

As shown in Figure 2-5, at the front and rear ends of body, securely connect
(4) Connecting front and rear outriggers to body
outriggers to chassis.

1 2-4 Layout of floor boards and opening
General
The NPR/NQR bus chassis is for the front-engine buses. You must follow through
the following instructions:
Layout of floor boards on the front side of body needs to carefully be designed
since in this area, there are a lot of components that necessitate consideration
such as driving devices, passenger seats, drivers door, engine room and front
wheel fender. If you use a truck cab (See Section 1-6 Layout around driving
device), leave the layout of the floor boards and the opening on the front side of the
2 body as they are because they have appropriately been arranged.
Installation
To prevent quality deterioration of body, carefully examine the method for

connecting floor structures of base truck cab and a body so that problems such as
strength poverty of joints, corrosion, dust intrusion, and leakage of noise and heat
from under floor can be prevented.
If you do not use a truck cab, we recommend that you minutely measure positions
and distances between the base truck cab and chassis frame, and then design
floor based on this data. Always be careful with the floor structure on the front side
3 of body.
Chassis Frame
(1) Position of drivers door

Considering drivers convenience, we recommend that you provide a door
beside drivers seat. Since drivers door, driver steps and their vicinity on base
truck cab are qualitatively usable without modification, it is possible to use the
drivers door as long as it does not impair the appearance of entire bus.
If you would like a drivers door that further matches body design, you should
4 know that designing such a door while considering its strength and quality
requires a lot of work.
Installation
(2) Position of passenger steps

The layout of the NPQ/NQR chassis does not permit to place front entrance
steps in front overhang area. It is possible to place middle entrance steps on the
front side between wheelbases. It is also possible to place rear entrance steps
in rear overhang area, but in this case, make sure that the rear overhang area
5
has sufficient width and you comply with the vehicle law regarding the ratio of
the width of rear overhang to the distance between wheelbases.
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For smooth boarding and alighting, give sufficient consideration to the floor
structure of body, and design each step to be low and have deep depth.
In accordance with the position of the steps, fuel tank, battery, etc may need to
be relocated. If there is any vehicle law regarding the entrance steps, comply
with it.
To ensure passengers safety, for entrance steps and floorboards near the
6
steps, it is preferable to use boards to which antislip and antiwear undercoat are
applied. Since these steps are prone to corrode, apply rust retardant on the
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bottom of the lowest steps by two or three millimeters thick.

Take extra care when placing cross members and side window pillars near the
entrance steps. Use floorboards of appropriate thickness so that the floor would
be flat and smooth. If floor is approximately at 20mm above the top surface of
approximately 350mm and 250mm respectively.

(3) Requirements for opening for engine check and neighboring parts and 1
equipment
General
1) Size of opening
To check and maintain engine and radiator, an opening should be provided
above them. Determine the size of the opening according to the position of
the engine and the radiator and the layout of floorboards on the front side of
body. This opening should appropriately be sized to enable the following
works:
2
1. Checking and replacing cooling fan and drive belts for cooler compressor
Installation
and AC generator
2. Removing/replacing filler cap of radiator upper tank, and feeding cooling
water
3. Removing air from injection pump
4. Checking engine oil level and feeding engine oil
5. Checking piping for cooler compressor and its gas leakage, and
removing/replacing union 3
6. Checking, removing and laying cables and pipes for AC generator and
Chassis Frame
vacuum pump
2) Requirements for engine hood
For the opening mentioned in the above (1), provide a hood that meets the
following requirements:
1. The engine hood is made of the materials that do not allow noise and
heat leakage from engine compartment into passenger area. Securely 4
apply sealing on the parts of the hood that come in contact with floor.
Installation
As shown in Figure 2-6, we recommend that you doubly apply heat and
weather resistant rubber sealing on the entire circumference of the
engine hood.
Fig. 2-6 How to apply soundproof sealing on engine hood
5
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6
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2. The engine hood can be opened and closed easily. As for a device to fix
the engine hood, choose the one that allows easy open/close operation
and is resistant to aging. It is a matter of course that bolting securely fixes
the hood, however, for its poor removability, it does not suit for the hood
used for daily check.

1 3) Oil tank for power steering
General
Do not displace oil tank for power steering from the original position. On a
body outer panel close to the tank, provide an access panel for oil tank
check. If the layout permits, this access panel should be common use
between the oil tank and radiator surge tank.
(4) Requirements for wheelhouse
2 For free movement of tires, there should be reasonable space between wheel
houses and tires. The tires must not contact with the wheelhouses when
Installation
steering or axles move. Figure 2-7 shows the minimum clearance between
wheelhouses and tires of a completed unladen bus.
Note that the above-mentioned space should be larger for the busses used in
such areas that service under any of the following conditions is expected:
1. Tires need to be chained for snow.
3
2. Road conditions are poor.
3. Bus is fully packed.
Chassis Frame
4. Baggage are loaded on the roof.

If you will use reinforcement to increase rigidity of wheelhouses, fit them in
appropriate positions so that they will not damage tires.
Fig. 2-7 Minimum clearance between wheelhouse and tire
4
Installation
5
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6
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3 Remodeling Chassis and Chassis Frame 1
General
When designing layout of a bus body, modification of chassis frame may be
required accordingly. However, such modification shall be minimized as much as
possible, and implemented with great care to safety, reliability and quality of the
chassis.
2
Installation
3-1 Remodeling chassis frame
(1) Drilling and welding chassis frame
When you drill holes in chassis frame members, follow Figure 3-1. Do not make
holes in the shaded area in the figure. Make sure to appropriately locate these
holes so that they will not cause static or dynamic interference with parts on
chassis. To securely fit parts in these holes, remove burr on the edge of the
3
holes. When welding chassis frame, follow Figure 3-1 again. Do not weld the
Chassis Frame
shaded area in the figure.
Fig. 3-1 Drilling and welding a chassis frame member
Installation
5
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Location hole
If you assemble a body before mounting it on chassis, to increase alignment
accuracy, location holes may be provided, for example, in the front, rear, left or
right part of flanges at the top face of side members. Follow the above 6
instructions when making such holes.
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NPR/NQR3 Remodeling Chassis and Chassis Frame 46

1 (2) Extending or shortening front or rear end of a chassis frame
General
1) Extending front or rear end

(Extension of front or rear end of chassis frame in accordance with shapes
and dimensions of front and rear sides of a body)
If you extend front end of a chassis frame, you should not displace cross
member at the front end and neighboring parts and change their shapes.
Instead, extend side member by using extension material whose material is
2 the same as the side member or equivalent.
On the front side of chassis frame, there are a lot of important equipment
Installation
such as front suspension system, steering devices, and the engine mount.
Great care must be taken when modifying this area.
Rear end of chassis frame should not be extended by more than 500mm. If
there is a cross member at the rear end, displace it according to need, and
then connect it to side member in the original manner. Rear end of chassis
frame cannot be extended excessively because there may be a vehicle law
3
on the ratio of the width of rear overhang to the distance between
wheelbases.
Chassis Frame
When the overall length of a bus is determined, select an appropriate

wheelbase considering the balance in the front and rear axle load.
Prerequisites for connecting extension material (See Figures 3-2, 3-3 and 3-
4)
a) Sectional shape and thickness of extension material shall be the same
as side members.
4 b) Material of extension material shall be the same as side members or
equivalent (material of side member: SAPH440.
Installation
c) Connect extension material by butt welding, and use reinforcement if

needed. Material of such reinforcement shall be the same as side
members or equivalent. To securely weld the reinforcement, before
welding, flatten beads on the inner side of side member by grinding.
Fig. 3-2 Pre-welding treatment
5
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Fig. 3-3 Appearance of connected part

6
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47 NPR/NQR3 Remodeling Chassis and Chassis Frame

Fig. 3-4 Reinforcement 1
General
2
Installation
2) Shortening front or rear end
(Shortening of front or rear end of chassis frame in accordance with shapes 3
and dimensions of front and rear sides of a body)
Chassis Frame
Do not shorten front end of chassis frame because it forces modification of
steering devices and suspension system. Rear end can be shortened for a
certain extent as long as it does not affect suspension system. If there is a
cross member on the rear end, displace it according to need, and then
connect it to side member in the original manner.
(3) Extending or shortening the region between wheelbases of chassis frame 4
Installation
Extending or shortening the region between wheelbases of chassis frame due
to layout change of bus body must be avoided because it forces modification of
the frame, propeller shaft, brake pipes, electric wiring, etc., and results in loss of
safety reliability and abnormal oscillation of the propeller shaft.
5
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6
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1 3-2 Remodeling chassis
On the NPR/NQR bus bodies, entrances will be provided on the opposite side of
General
drivers seat, between the wheelbases. If you use a truck chassis, fuel tank and
battery may have to be relocated because their positions overlap with these
entrances. As for the current truck chassis, especially LHD models, relocation of
the fuel tank is unavoidable.
Table 3-1 shows the currently available truck cab-mounted chassis with relocated
fuel tank and battery. These models are also equipped with suspension systems
2
modified for bus use.
Installation
Tab. 3-1 Chassis for NPR/NQR bus

Max. GVW Wheelbase
Model Engine Handle Frame Destination
(ton) (mm)
NPR66PBU-5LVY 4HF1 7.0 RH WIDE & STRAIGHT 3.815 General
NPR66PBL-5LVY 4HF1 7.0 LH WIDE & STRAIGHT 3.815 General
NQR70PBL-5LYRJ 4HE1-TCS 7.5 LH WIDE & STRAIGHT 3.815 Taiwan

3
NQR71RBL-5NVY 4HG1 8.0 LH WIDE & STRAIGHT 4.175 General
Chassis Frame
NQR71RBL-5LVYB 4HG1 7.5 LH WIDE & STRAIGHT 4.175 Egypt

NQR75RBU-5NXYZJ 4HK1-TCS 8.0 RH WIDE & STRAIGHT 4.175 South Africa
(1) Displacing or modifying a fuel tank

There are two types of fuel tanks: square tank and two-piece capsule type tank.
The capacity of these tanks is both 100 liters. The type of the tank to be
4
installed depends on the destination.
Installation
Parts required for tank installation such as mounting brackets and clip bands
differ between two types.
When relocating a fuel tank, we recommend that you use the original mounting
brackets, clip bands, etc. without modification. In terms of strength, the clip
bands on the fuel tank must not be displaced from the original position. They
must be placed right over the beads on the tank body made by spot welding,
5 which are the markings for the partitioning panels inside the tank.
When you extend fill opening of a fuel tank closer to body outer panel for ease
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of oil feeding, bolt steel spacers between chassis frame and mounting brackets,
that are strong and rigid enough to support the overall weight of the filled tank
(See Figure 3-5). Make sure that the bolted parts do not contact with adjacent
pipes, cables or parts.
Fig. 3-5 Fixing a fuel tank (Method 1)
6
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In Figure 3-6, fuel tank is supported by using a cross sill of body floor. 1
General
Fig. 3-6 Fixing a fuel tank (Method 2)
Installation
Do not extend filler neck of fuel tank by welding because strength of the welded 3
part and the base of the filler neck may decrease, and foreign substances such
Chassis Frame
as welding spatters may get inside the tank.
When displacing a fuel sedimenter due to relocation of fuel tank or body
installation on chassis, the fuel sedimemter must be fitted between the fuel tank
and engine. In addition, an access panel for checking water intrusion and
drainage shall be provided on side panel of body. See Figure 3-7 for the
appearance of the fuel sedimemter. Refer to drawing for correct connection of 4
the sedimemter to the fuel tank and the engine.
Installation
Fig. 3-7 Fuel sedimemter
5
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6
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1 When you use fuel pipes that are different from the original ones, make sure
that their materials and dimensions are the same as the original or equivalent.
General
Such pipes should be connected in the original manner as much as possible. It

is possible to use rust-proofed steel pipes and light oil resistant rubber hoses.
Clamp or support the pipes by using clips so that they will not improperly be
bended, squashed or contact adjacent parts.
On the side of body, provide a fill opening near filler neck of fuel tank, which is
2
appropriately sized to allow easy removal/replacement of the filler cap and
Installation
easy fueling (See Figure 3-8).
Fig. 3-8 Dimension and position of fill opening
3
Chassis Frame
4 It is preferable that outer panels near the fuel tank, located at the lower part of
body are removable so that the fuel tank unit and its pipe connection can easily
Installation
be checked.
(2) Displacing or modifying battery and battery relay
Table 3-2 shows the types of the batteries installed on chassis.
Fig. 3-2 Batteries

5
Bus model Standard Option Destination
Body Builder
NPR66LL-5LYB 75D23R 65D23R or 80D26R Egypt
NPR66PBL-5LVY 75D23R 65D23R or 80D26R General
NPR66PBU-5LVY 75D23R 65D23R or 80D26R General
NPR66PU-5LXMW 75D23R 65D23R or 80D26R Malaysia
NQR66PU-5NVXY 75D23R 65D23R or 80D26R General

6 NQR71RBL-5NVY 75D23R 65D23R or 80D26R General
NQR71RBL-5LVYB 75D23R 65D23R or 80D26R Egypt
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NQR70PBL-5LYRJ 80D26R 115E41R Taiwan

NQR75RBU-5NXYZJ 80D26R 115E41R South Africa

52
1
6
NPR/NQR3 Remodeling Chassis and Chassis Frame

Figures 3-9 through 3-12 show examples of appearance of the batteries.
Fig. 3-11 80D26RR battery

Fig. 3-10 65R23R battery
Fig. 3-9 75R23R battery
Fig. 3-12 115E41R battery
1
General
2
Installation
When you relocate battery or battery relay, we recommend that you use the
original mounting brackets and clips without modification.
3
When you relocate battery closer to a body outer panel for ease of battery
Chassis Frame
check, bolt steel spacers between chassis frame and mounting brackets. Such
spacers should be strong and rigid enough to support the weight of the battery
and battery carrier (See Figure 3-13).
Make sure that the bolted parts do not contact with adjacent pipes, cables or
parts on chassis. If there is possibility of contact with the pipes or the cables,
provide protection (e.g. adhesive tape) on such contact-anticipated part of the
4
pipes and the cables.
Installation
Fig. 3-13 Fixing a battery carrier
5
Body Builder
It is preferable that outer panels near the battery, located at the lower part of
body can be opened or removed so that the cable connection to battery
terminals can easily be checked.
6
If you use battery cables different from the original ones, make sure that their
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diameter is the same as the original or equivalent.

Clamp or support the cables by using clips so that they will not improperly be
bended, squashed, or contact with adjacent parts. If there is possibility of
contact with frame or brackets, provide protection on such contact-anticipated
part of the frame and the brackets.

(3) Remodeling exhaust pipe 1
General
If you bend or extend exhaust pipe in accordance with the shape of body or in
order to comply with vehicle law of your country, perform such modification as
instructed below:
a) Modification of exhaust pipe is only allowed for the region on the tail side,
posterior to silencer.
b) If you bend an exhaust pipe, bend the pipe in bending radius which is, 2
relative to the center axis of the pipe, at least 1.5 times the pipe diameter.
Installation
Make sure that the bended part is not considerably wrinkled or squashed.
c) Diameter and thickness of extension material should be the same as exhaust
pipes. Connect the extension material to the exhaust pipe by butt welding.
Galvanized extension material is preferable, but if it is not available, after
welding the extension material, apply heat resistant paint on it.
3
d) If rear end of the exhaust pipe badly vibrates after extending, provide a
Chassis Frame
vibration deadening support which is the same the one used on the base
truck chassis.
e) Table 3-3 shows minimum clearance required between exhaust pipe and
adjacent parts.
Tab. 3-3 Minimum clearance between exhaust pipe and adjacent parts
Part Clearance
4
60mm.
Installation
Brake pipe If a part of the brake pipe which is parallel to the exhaust pipe is more than
200mm, separate the exhaust pipe and the brake pipe by at least 180mm.
100mm.
Temperature of the flexible hose should not exceed 70 degrees C.
Flexible brake hose
If the maximum temperature cannot be measured, leave at least 400mm
between the hose and the exhaust pipe.
Harness and cable 100mm

5
Fuel pipe 80mm
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Fuel hose 150mm
Spare tire 100mm
f) If you fit a body component near exhaust pipe, provide a heat insulation
panel in a position 30mm away from the exhaust pipe (See Figure 3-14).
Fig. 3-14 Heat insulation panel for exhaust pipe

6
Body Builder

1 g) If you fit a tool box near exhaust pipe, we recommend that such tool box is
made of firesafe steel. If you prefer a wooden tool box, leave at least 200mm
General
between the box and exhaust muffler or exhaust pipe.
(4) Remodeling rear suspension

Comparing a bus with bus chassis and a bus with truck chassis, difference in
weight of the latter between unladen and laden conditions is larger. For that
reason, except for specific light load models, rear suspension on truck chassis
2 is equipped with sub springs that work under loaded condition.
When truck chassis with sub springs is used as bus chassis, and then the bus
Installation
bounces, the sub springs contact with a stopper, considerably impairing ride
comfort. Therefore, we recommend that you replace the sub springs with
different ones dedicated to the bus models without sub springs. Make sure to
choose adequate springs according to the bus weight.
Some body builders procure and fit such new springs on chassis by
themselves. When you replace the sub springs with springs of your own choice,
3 do not forget to remove the original sub springs. If they are left unremoved, they
may damage adjacent parts. If you cannot procure replacement springs, please
Chassis Frame
contact our Overseas Sales Department.

(5) Piping for brake system
Do not modify piping of brake system because it is a very important safety part.
If modification or replacement is unavoidable, for safety assurance, carefully
measure the length of the pipes and the interval between clips on the base truck
chassis, and then execute such modification based on this data. After
4
modification or replacement, conduct reliability check on strength and vibration.
Installation
1) Fitting equipment and laying pipes

Install a body on chassis in such a manner that brake servo system, brake
pipeand brake hose can be checked and removed without effort, and the
air inside them can easily be removed. Provide sufficient spaces between
each of the brake pipe, vacuum pipe, brake hose, braking device and
connectors.
5
2) Material and processing of pipes
Body Builder
No pipes are allowed except for new ISUZU MOTORS genuine pipes
supplied by ISUZU MOTORS.
When bending pipes or performing flare processing for them, make sure that
you only use the tools supplied by ISUZU MOTORS, and perform them in
exactly the same way as that for the pipes on the base truck chassis. Do not
bend more than once or perform flare processing while heating pipes.
6 Before and after processing, assure safety of pipes by checking for damage,
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dent, squashing, and foreign substances.

Do not remove plastic clips from chassis frame. Use them as much as
possible. Once you remove them, they will be unusable.
After processing, clean inside of the pipes.
See Figure 3-15 for clearance between a steel pipe and adjacent parts.

Fig. 3-15 Clearance between a steel pipe and adjacent parts
1
General
Min. 10mm
Installation
3
Chassis Frame
(6) Precautions for modifying chassis harness
1) Cables and harnesses (See Figure 3-16)
4
Most of the electric cables arranged inside ISUZU MOTORS busses are
Installation
connected by using terminals. We recommend using terminals when you
need to adjust cable length.
When you add electric circuit or modify the circuits already laid on chassis,
make sure to securely fit cables so that they will not sag. If necessary, to
prevent short circuit, use grommets or clips to protect the harnesses from
heat source or sharp objects. See (e) under Section 3-2 (3) for details on the
protection of cables against heat from exhaust pipe. 5
Body Builder
Use rust-proofed clips, and apply vinyl coating to the part of the clips that
come in contact with harnesses. Appropriately locate the clips so that the
vibration of harnesses can be minimized.
When you need a longer battery cable, do not attempt to extend the cable by
cutting it and then connecting an extension cable between the cut cables. Do
not use connected cables.
6
When connecting cables to moving equipments such as engine and
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transmission, such cables should have sufficient length so that they absorb
vibration that possibly be transferred to the parts which ISUZU MOTORS
has already fitted on chassis. These cables should appropriately be
arranged so that they will not contact with adjacent parts.
Since inside of engine room is hot, vinyl tape may come off due to heat.
Make sure that you use rubber- or vinyl-coated steel clips.

Fig. 3-16 Harnesses and cables on body and chassis
NPR/NQR3 Remodeling Chassis and Chassis Frame

57
6
2) Harness connector 1
General
When using a connector, insert a harness into its plug whose pole is
opposite to that of power source, otherwise short circuit may occur when the
connected harness is disconnected.
When installing a body, before disconnecting harnesses on the body and
chassis, which are connected to driving devices, mark up these harnesses
so that they will correctly be reconnected after body installation.
2
If foreign substances such as dust adhere to the contact point of
Installation
disconnected connectors, contact failure may occur after reconnecting them.
Do not forget to cover disconnected connecters with dust cover. After
reconnecting the connectors, check whether they are securely connected.
Note that such contact failure can cause engine start error, AT control error,
and other electrical problems, and it may take long time to identify the cause
and solve the problem. 3
Chassis Frame
Basically, connectors used inside truck cabs are not water-proofed. Before
installing a body, check the location of the connectors and protect them from
water intrusion, otherwise water (e.g. rain) may gets inside the connectors,
causing electrical failures.
3) Extending chassis harnesses
If you need to extend chassis harnesses in order to use lighting equipment of 4
your own choice or to change the position of the original lighting equipment,
Installation
make sure that extension harness has the same diameter and color as the
original or equivalent.
When connecting wires, do not connect them inside corrugated tube. When
connecting ends of harnesses, make sure that they are securely connected,
and to prevent short circuit and water intrusion, apply insulation tape on them
according to need. Body Builder
5
When extending harnesses, use quality-guaranteed connectors and make
sure that the extended harnesses are securely clamped by using clips.
Check the power consumption of changed or added lighting equipment and
other electrical components, and make sure that the harnesses and fuse
have enough capacity for serving them.
6
Body Builder

4 Requirements for Body Installation 1
General
4-1 Outline of engine air intake system and remodeling of the system IMPORTANT
(1) Engine intake system on the NPR/NQR bus chassis

The following two engine intake systems are available for the NPR/NQR 2
chassis. The layout of these systems vary depending on the engine model and
Installation
the bus model.
Before installing a bus body, check which of the following will be installed:
1. Rear vertical intake system vertically mounted on the back of the cab
2. Front intake system (front grill intake system) with a long duct, that requires -
an underfloor opening at the lower part of the front side of the cab
3
(2) Remodeling air intake system
Chassis Frame
As for both of the above two systems, do not make any changes to their air
cleaner and duct hose which is connected to the air cleaner and engine.
Provide a hinged access panel on the side of body (skirt) to install, remove
and check air cleaner elements.
Modification or change of intake duct connected to the air cleaner and arranged
toward the outside the vehicle shall be executed according to body structure 4
and on body builders own responsibility.
Installation
1) Remodeling rear vertical intake system
Rear vertical intake system mounted on the base truck cab will cause a
problem when you install a bus body. We recommend either of the following
solutions:
1. Modify its vertical intake duct so as to mount it between outer panel and 5
inner panel at the side of body.
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2. Fabricate a new side vertical intake system.

Since remodeling and change of air intake system may seriously affect
performance and reliability of engine, be sure to follow through the following
instructions. It is preferable that no change is made to air intake duct and the
way how it is connected.
6
Figure 4-1 shows an example of a side vertical intake duct. To prevent
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resonance in whole revolution area of engine, a reinforcement rib is required

because if rigidity of the intake duct is insufficient, the duct may resonate
with intake pulsation of the engine.
The inner sectional area of air duct connected to air intake opening and air
cleaner should be the same as the original or larger. Excessive narrowing
and improper change in sectional area are not allowed.
NPR/NQR4Requirements for Bus Installation 59

Fig. 4-1 Side vertical intake duct
1
General
2
Installation
3
Chassis Frame
Figure 4-2 shows a recommended position of an opening for taking in

outside air, which will be provided on the side of body. Placing the opening
here prevents suction of droplets, dust, etc.
To prevent intake of foreign substances, cover the above-mentioned opening
4
with a metallic mesh, punching metal screen or expand-metal screen. Such
Installation
cover should appropriately be sized so as not to reduce total effective area of

the opening. Apply antirust treatment on the cover by zinc galvanizing,
painting, etc.
To prevent intrusion of rain, etc., as shown in Figure 4-2, the lower edge of
the intake duct opening should be located at least 100mm above the upper
edge of the opening in body outer panel.
5
Prohibited matters
Body Builder
In terms of layout, it is easy to make an opening near air cleaner, in the side
of body (skirt), and then connect intake duct to this opening and the air
cleaner. However, this method must not be adopted because it will suck in a
considerable amount of droplets and dust raised by front wheel.
6
Body Builder
60 NPR/NQR4Requirements for Bus Installation

Fig. 4-2 Opening for side air intake system (Engine: 4HF1 or 4HG1)
1
General
2
Installation
3
Chassis Frame
2) Remodeling front intake system
Basically, you do not have to make any change to intake duct connected to
air cleaner and arranged toward the outside the vehicle. However, since air
intake opening is generally located low, in such areas that have high rainfall, 4
we recommend taking measures against water hammering due to water
Installation
intrusion.
If end of the above duct is placed in front of an opening at the front side of
body (in front of radiator grill), it will suck in water. Therefore, as shown in
Figure 4-3, it is preferable to extend the duct up to immediately below tow
board or relocate it to an upper position.
5
Duct for the front intake system is long and complicatedly bended, and
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consequently its intake resistance is relatively high. If you modify or extend
the end of the duct, assure sufficient effective area of that part. To prevent
intake of foreign substances, provide a metallic mesh, etc. on the end of the
duct.
6
Body Builder

Fig. 4-3 Duct end of front intake system
NPR/NQR4Requirements for Bus Installation

62
6
4-2 Requirements for vicinity of engine 1
General
(1) Radiator
Body installation in such a way that worsens radiators performance to radiate
engine cooling water can cause serious problems such as overheat of engine.
Therefore, you must follow through the following instructions:
1) Replacing the original radiator
2
Do not replace the original genuine radiator installed on chassis.
Installation
2) Changing position and angle of radiator
Do not change the position and angle of the original radiator installed on
chassis. Changing relative positions of radiator core and engine cooling fan
may considerably reduce cooling efficiency.
3) Placing a body component in front of radiator core
3
Do not place any parts or equipment in front of radiator core or they will block
Chassis Frame
the intake of cooling air.
4) Placing a shield around radiator
In tropical, subtropical or other areas requiring engine to work at full load on
a long upward slope, to increase cooling performance of radiator, as shown
in Figure 4-4, provide a rubber shield around the radiator, covering its left,
right, top and space between the radiator and body. 4
Installation
Fig. 4-4 Shield around radiator
5
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6
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1 5) Radiator surge tank
General
Surge tank (See Figure 4-5) is an essential and important functional

component that stops outflow of cooling water due to temperature change,
and protects engine from overheating. When installing a body, make sure to
fit it in an appropriate position.
We recommend not moving surge tank from the original position. However, if
body structure forces relocation of the tank, execute it according to Figure 4-
2
6.
Installation
Leave sufficient space around the radiator surge tank, and provide an
access panel near it in order for feeding cooling water and checking the
amount of cooling water.
Fig. 4-5 Surge tank
3
Chassis Frame
4
Installation
5
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Fig. 4-6 Installing a surge tank
6
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6) Radiator grill 1
General
Since engine room of front engine buses is relatively small, to prevent
engine from overheating, you need to provide a radiator grill and, depending
on circumstances, a guide plate.
The total area of radiator grill opening should not be smaller than 50% of the
total area of radiator core. If bus has to service in an environment that the
temperature of cooling water exceeds normal value, provide an appropriately
2
sized guide plate under the radiator (the guide plate is fitted to chassis frame.
Installation
See Figure 4-7 for detail) in order to take in more cooling air from the lower
part of body.
Fig. 4-7 Guide plate for radiator cooling air
Chassis Frame
4
Installation
(2) Exhaust system and measure against heat damage
The inside of engine compartment can partially be over 100 degrees C due to 5
heat radiation from exhaust manifold and turbo charger of engine. Be careful
Body Builder
about the areas subject to the radiant heat and rear upper corner inside the
engine compartment where hot air tends to stagnate.
Countermeasures against the above problems :
1. To prevent heat damage due to radiation heat from the exhaust manifold and
the turbo charger, do not place any parts, pipes and cables near these
equipments, or provide shield panels around them. 6
Body Builder
2. To prevent stagnation of hot air inside engine compartment, provide an air

flow guide plate or an air outlet. If both of them cannot be provided, try not to
place any parts, pipes and cables in this area.

1 (3) Clearance around engine
General
To prevent contact between engine and neighboring body members due to

engine vibration, at least 30mm of clearance should be provided around the
engine in a resting state.
Fig. 4-8 Clearance around engine
2
Installation
3
Chassis Frame
4
Installation
5
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6
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(4) Vehicle noise 1
General
If your country has any regulation regarding vehicle exterior noise, you must
comply with it. Even if there is no particular regulation at the present time,
needless to say, buses with low exterior noise are preferable, and bus crew and
passengers would think the same way.
Engine, transmission, cooling fan, tires, exhaust system, etc. for the NPR/NQR
bus chassis are designed to ensure top-level low noise level. However, we
should make every effort to further reduce vehicle interior/exterior noise by 2
improving body structure, and to win the admiration of customers for entire bus.
Installation
1) Measure against vehicle exterior noise
Sources of vehicle exterior noise are engine, transmission, cooling fan, tire,
exhaust system, etc. As for bus bodies, thanks to the skirt on their entire
circumference, the level of exterior noise is relatively low. However, take the
following sound isolation measure to further reduce exterior noise:
3
1. Sound insulation panel (side cover)
Chassis Frame
Provide steel or plastic sound insulation panels (side covers) on both
sides of major sound sources that are engine, transmission and cooling
fan. Material of such insulation panel should be rigid and of large mass.
Its cover area should be as large as possible, and clearance between (1)
panels placed next to each other, and (2) a panel and a part sandwiched
by the panel and the other panel should be small. In consideration of 4
maintainability of engine and transmission, these panels should be
Installation
removable (See Figure 4-9).
Fig. 4-9 Side cover for engine compartment
5
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6
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1 2. Tire noise
Certain tread patterns make noise. We recommend using rib tires rather
General
than lug tires.

3. Exhaust noise
Exhaust system for the NPR/NQR chassis is designed not to make large
noise unless it is improperly remodeled (extension/shortening of its tail
pipe previously mentioned is excluded).
2 2) Measure against vehicle interior noise
Installation
There are two types of interior noise. One of them is penetrating noise
emitted from underfloor equipment such as engine, transmission, and
cooling fan. The other is knocking sound, contact sound, squeaking or
rattling sound and booming sound, caused by factors such as body vibration
and resonance of body structural sections.
1. How to reduce penetrating noise:
3 a. Select materials of large mass for floor boards above engine.
b. To reduce high frequency noise, apply glass wool wrapped with
Chassis Frame
aluminum foil on the entire surface of underfloor area and a side of

engine hood facing the engine. Make sure to securely fix the glass wool
by using rivets, clips, etc.
c. If there is gap between joints of floor boards, joints at stepped part of
floor, or joints at engine hood, sound from underfloor source leaks into
the inside of the bus. Fully apply sealant over these joints, and then
4 cover them with coaming material.
Installation
d. To further reduce and make noise lower and softer, put down sound
proof mats on the above-mentioned floor boards, the stepped part on
the floor, and the engine hood.
2. How to reduce knocking and contact sound caused by body vibration or
resonance of body structural sections:
a. One of the ways of reducing vibration transfer from chassis to body floor
5 structure is to insert rubber vibration insulation material when
connecting chassis frame and body. Note that measure against
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vibration transfer varies depending on the connecting method employed

by body builder.
b. When the basic cross-sectional shape of body is consisted of four lines
(top, bottom, left and right sides) each of which is nearly a straight line,
rigidity of side faces is low and the body often resonates with frequency
of vibration transferred from chassis. If specification and design permit,
6 we recommend that the body is made up of side faces of large curvature.
Body Builder
c. If there is space between body outer panels and skeleton structure, the
outer panels may warp or vibrate. In this case, we recommend inserting
fillers for tensing the panels.
d. If vibration of a certain part of body cannot be prevented by any means
including insertion of fillers, application of rubber vibration deadening
material on such part may work.

4-3 Requirements for engine control 1
General
(1) Position of accelerator pedal
Do not displace accelerator pedal from the original position. However, if body
layout forces relocation of all driving devices, make sure that you do not change
relative positions of the driving devices, clutch pedal, brake pedal, steering shaft,
meter cluster, etc.
(2) Fixing flexible shaft 2
Installation
When you need to temporarily remove flexible shaft of engine control for body
installation, make sure to replace it after body installation. Do not forget to
securely clamp both ends of outer casing of the shaft.
(3) Displacing flexible shaft
Do not displace flexible shaft of engine control. However, if body structure
forces relocation of the shaft, make sure that its bend radius is no smaller than 3
300mm and it is not improperly bended or twisted.
Chassis Frame
4
Installation
5
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6
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1 4-4 Drive line and operating devices
General
(1) Requirements for drive line and its vicinity

1) Checking and maintaining clutch and transmission
For the purpose of replacing clutch driven plate (clutch facing) or checking
transmission, the transmission should be removable. When removing the
transmission, support engine from beneath and remove bolts fixing engine
2 rear mount and the transmission. To move the transmission behind and
remove top gear shaft from pilot bearing on the engine side, at least 70mm of
Installation
free space is required (See Figure 4-10).
Fig. 4-10 Space required for removing transmission
3
Chassis Frame
4
2) Checking and maintaining the area above transmission
Installation
For the purpose of checking and maintaining reverse lamp switch, select
lever and shift lever located above transmission, provide a space necessary
for such works and an access panel above these devices.
3) Clearance around front and center propeller shafts
Front and center propeller shafts are supported by transmission and center
5
bearing. If you place a body component or equipment near them, to prevent
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contact, at least 30mm of clearance is required around the front and center
propeller shafts (See Figure 4-11)
Fig. 4-11 Clearance around front and center propeller shafts
6
Body Builder

4) Vicinity of rear propeller shaft 1
Because traveling distance of rear propeller shaft is large as it moves in
General
conjunction with the movement of rear axle, do not place any body
component or equipment in the area below the top surface of chassis frame,
around the propeller shaft (See Figure 4-12).
Fig. 4-12 Clearance around rear propeller shaft
Installation
3
Chassis Frame
(2) Requirements for transmission control
1) Change lever
Position of change lever assembly differs depending on the type of the base
truck chassis. See each case in Section 1-6 Layout around driving device. 4
Installation
a. Case 1 or Case 2 (using or partially remodeling a truck cab body): You do
not have to change the position of the lever assembly on the cab floor.
b. Case 3 (Using a truck cab with a temporary drivers platform equipped
with all the driving devices and facia): Stability, rigidity and operability of
the change lever on the temporary drivers platform have been assured.
You do not have to change its position for body installation.
c. Case 4 (Body builder fits parts they procured during CKD phase on their 5
own bus body) or in case that the layout of driving devices forces
Body Builder
relocation of the change lever: Make sure that the lever is stable and the
part on which the lever is fitted does not deform when applying control
effort of 25kg to the grip of the change lever assembly.
2) Temporarily removing flexible shaft
When temporarily removing flexible shaft of transmission control in order for
body installation, make sure you replace it after body installation. Not to
6
impair gear maneuverability, make sure to securely clamp both ends of outer
Body Builder
cover of the cable.

3) Arranging flexible shaft
Do not displace flexible shaft of transmission control. However, if body
structure forces relocation of the shaft, not to impair maneuvering feeling,
make sure that its bend radius is no smaller than 300mm, and it is not
improperly bended or twisted.

1 4-5 Parking brake and operating devices
General
(1) Fitting parking brake lever

Position of parking brake lever differs depending on the type of the base truck
chassis. See each case in Section 1-6 Layout around driving device.
a. Case 1 or Case 2 (using or partially remodeling a truck cab body): You do
not have to change the position of the parking brake lever on the cab floor.
2
b. Case 3 (Using a truck cab with a temporary drivers platform equipped
Installation
with all the driving devices and facia): Stability, rigidity and operability of
the parking brake lever on the temporary drivers platform have been
assured. You do not have to change its position for body installation.
c. Case 4 (Body builder fits parts they procured during CKD phase on their
own bus body) or in case that the layout of the driving devices forces
relocation of the parking brake lever: Make sure that the parking brake
3
lever is stable and the part on which the lever is fitted does not deform
Chassis Frame
when applying control effort of 50kg to the grip of the parking brake lever.
(2) Temporarily removing flexible shaft

When temporarily removing flexible shaft of parking brake control in order for
body installation, make sure to replace it after body installation. Not to impair
maneuverability, make sure to clamp both ends of outer cover of the cable.
4 (3) Arranging flexible shaft
Installation
Do not displace flexible shaft of parking brake control. However, if body

structure forces replacement of the shaft, not to impair maneuvering feeling,
make sure that its bend radius is no smaller than 300mm, and it is not
improperly bended or twisted.
5
Body Builder
6
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4-6 Changing specification of electric components on bus body or adding new 1
electric components
General
If you need to change the original specifications to comply with vehicle law of your
country, customers use conditions, or requests from customer, such change must
be made on your own responsibility. Especially, if you add equipments such as air
conditioning system, combustion-type heating system, TV, VCR, KARAOKE
machine, illumination, and rear combination lamps, make sure that the power
generating capacity of AC generator, capacity of relay and fuse, and harness 2
diameter do not exceed their limit. If there is possibility that the AC generator
Installation
provided as a standard equipment does not have enough generation capacity to
serve such additional air conditioning system, please contact our sales department.
4-7 Spare tire carrier

Spare tire carrier should be fitted at the rear end of chassis frame. To remotely 3
operate the spare tire carrier by using a clank handle, connect an extension rod to
Chassis Frame
the spare tire carrier and body panel (See Figure 4-13).
Fig. 4-13 Connecting a spare tire carrier
Installation
5
Body Builder
6
Body Builder

5 Air Conditioning System Procured and Installed by Body Builder 1
General
5-1 Power generating capacity of AC generator
Passenger capacity of a bus body mounted on the NPR/NQR chassis is around 30

persons at maximum. The maximum power consumption of air conditioning system
installed on such a bus is 24V-60A, which can be served by an ordinary AC
generator.
2
An AC generator of 24V-60A can optionally be installed on the NPR/NQR chassis.
Installation
If you would like to install an air conditioning system, you need to install this
genuine AC generator.
5-2 Installing air conditioning system on chassis

When you install an air conditioning system of your own choice on chassis, be
3
careful of the weight balance between left and right sides of the bus. If you equip
Chassis Frame
engine with a cooler compressor of your own choice, to get instructions necessary
for the installation, provide technical information on the compressor including
drawings and specifications to our Sales Department. We can then furnish you with
information regarding the compressor, including brackets, belt tensioner, pulley
grooves, etc. Figures 5-1 and 5-2 and Table 5-1 show examples of modification
parts for the cooler compressor that can be equipped on 4HF1 and 4HG1 engines.
4
Fig. 5-1 Fitting a bracket on the cooler compressor that can be supplied by ISUZU MOTORS
Installation
5
Body Builder
6
Body Builder
NPR/NQR5Air Conditioning System Procured and Installed by Body Builder 74

Fig. 5-2 Fitting a belt tensioner that can be supplied by ISUZU MOTORS
1
General
2
Installation
3
Tab. 5-1 List of modification parts for compressor
Chassis Frame
Number in
Part Part Number Quantity
Figure 5-2
1 Tensioner assembly 897065641Y 1
2 Belt for cooler compressor 897224430Y 1
3 Bolt for fixing a tensioner 0280808160 3
4
4 Bracket for cooler compressor 897115710Y 1
5 Spacer for bracket 897065515Y 2
Installation
6 Washer 9091646100 2
7 Nut for fixing a bracket 0911502100 2
8 Bolt for fixing a bracket 0281910900 2
9 Bracket for tensioner 897162776Y 1
10 Bolt for fixing a bracket 0281860110 1
5 11 Bolt for fixing a bracket 894399863Y 2
Body Builder
Make sure that the above modification parts do not contact with the existing parts
on chassis or body and impair maintainability of of these parts (See Figure 5-3).
6
Body Builder
75 NPR/NQR5Air Conditioning System Procured and Installed by Body Builder

Fig. 5-3 Precaution for drive belt for cooler compressor
1
General
2
Installation
5-3 Laying pipes on chassis for air conditioning system
3
Do not clamp refrigerant pipe together with the other pipes such as brake pipe. By
Chassis Frame
using support brackets, fit individual piping alone on chassis frame. Doing so
makes check and maintenance of these piping easy.
Make sure that the pipes do not contact with the existing parts on chassis or body
and impair maintainability of these parts.
Installation
5
Body Builder
6
Body Builder
NPR/NQR5Air Conditioning System Procured and Installed by Body Builder 76

6 Hot-water Heating System Procured and Installed by Body Builder 1
General
6-1 Inlet and outlet for hot water for heating system
Hot water inside engine room can be used for defroster and heating system. At the
time of shipment, caps are attached to hot water inlet and outlet. When installing a
body, remove these caps and then determine the piping layout.
2
6-2 Laying pipes on chassis for heating system
Installation
Do not clamp hot water pipes for the heating system together with the other
existing pipes such as brake pipe. By using support brackets, fit individual piping
alone on chassis frame. Doing so makes check and maintenance of these piping
easy.
Make sure that the pipes do not contact with the existing parts on chassis or body
3
and impair maintainability of these parts.
Chassis Frame
4
Installation
5
Body Builder
6
Body Builder
NPR/NQR6Hot-water Heating System Procured and Installed by Body Builder 77

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Page Section Contents

05 >>>> 1-1 General precautions concerning body installation

2 Precautions for Body Installation

38 >>>> 2-1 General precautions

46 >>>> 3-1 Remodeling chassis frame

4 Requirements for Body Installation

59 >>>> 4-1 Outline of engine air intake system and remodeling of

5 Air Conditioning System Procured and Installed by Body Builder

74 >>> 5-1 Power generating capacity of AC generator

6 Hot-water Heating System Procured and Installed by Body Builder

(1) Running speed of bare chassis in transportation

During body installation, pay sufficient attention so that any mechanical,

Fig. 1-1 Leveling of chassis frame

(2) Confirmation of outermost dimensions of front/rear tires against vehicle width

Allowable rear axle weight (kg) 5,000 6,600

Rear overhang 1,505 1,710 2,060

4HF1 4HE1-TCS 4HG1 4HK1-TCS

Max. torque Nm/rpm 347ftlb (47.9)

Type MYY5T MZZ6U MYY5T MZZ6U

Drive Base 6.142 6.833 5.125 6.833 4.777

Tire 8.25-16-14 8.25-16-14

Tilt & telescopic column Option

AC Base 24V50A 24V60A 24V50A 24V60A 24V50A

Installation Chassis Frame Installation

Installation Chassis Frame Installation

Installation Chassis Frame Installation

Installation Chassis Frame Installation

Installation Chassis Frame Installation

Installation Chassis Frame Installation

Installation Chassis Frame Installation

Installation Chassis Frame Installation

Installation Chassis Frame Installation

Installation Chassis Frame Installation

Tab. 1-2 Allowable loads Unit: kg

(2) Allowable loads to tires

Tab. 1-3 Allowable load rating based on tire size Unit: kg

(3) Allowable load ratio of front axle

Divert the whole truck cab assembly Merits:

1. Tends to cause defects in quality and

4 Remove the parts unnecessary for bus Merits:

assembly. completed truck cab.

strength of the joint between bus body and

generally no change from original parts to alternatives..

Tab. 1-5Composition of skeleton cab

1) Front panel 1) Instrument panel

3) Frontal side panel 3) Melting sheet

Following parts are excluded from the main components of

When optionally adopting the reinforcement to fix skeleton cab as shown in

Fig. 1-19 Fixing procedure of skeleton cab reinforcement

Fig. 1-20 Composition of instrument panel and box

1 Instrument panel 323 Screw for glove box lid

146 Tap screw 566 Hole plug

219 Shaft for glove box lid

Installation Chassis Frame Installation

Installation Chassis Frame Installation

2. Since the structure of this chassis is originally of a mass-produced truck, a

(3) Chassis frame

NPR/NQR2 Precautions for Body Installation 38

that firmly withstand bending and twisting. To avoid stress concentration,

Fig. 2-1 Outrigger (1)

39 NPR/NQR2 Precautions for Body Installation

1) Fitting a support bracket on a side member by welding

NPR/NQR2 Precautions for Body Installation 40

When installing a body on chassis, do not remove these plastic clips