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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.

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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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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
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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.

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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

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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

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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

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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

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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.

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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.

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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.

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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

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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.

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Figure 22

Figure 23 * Cables should not be contact with sharp edges or pierced holes.

Figure 24 Isuzu 2000 Body Builder's Guide Page 24

* 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.

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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.

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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

Isuzu 2000 Body Builder's Guide

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).

Isuzu 2000 Body Builder's Guide

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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.

Isuzu 2000 Body Builder's Guide

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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

Isuzu 2000 Body Builder's Guide

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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

Isuzu 2000 Body Builder's Guide

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.

Isuzu 2000 Body Builder's Guide

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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

Isuzu 2000 Body Builder's Guide

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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

Isuzu 2000 Body Builder's Guide

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* 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

Isuzu 2000 Body Builder's Guide

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* 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

Isuzu 2000 Body Builder's Guide

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

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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 2000 Body Builder's Guide

ISUZU PAINT COLOR NAME

ISUZU PAINT CODE


Page 42

ISUZU OPTION CODE

ISUZU PAINT COLOR NAME

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 COLOR NAME

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 COLOR NAME

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

Isuzu 2000 Body Builder's Guide

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)

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

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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

Isuzu 2000 Body Builder's Guide

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.

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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)

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Figure 45

COE (2 Axle)

Figure 46

CONVENTIONAL (3 Axle)

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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.

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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.

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Figure 51
NOTE: Apply the same principles used with truck chassis

TRAILER WEIGHT

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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

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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:

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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

Isuzu 2000 Body Builder's Guide

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

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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

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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

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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

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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

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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

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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

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

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

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.

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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

Isuzu 2000 Body Builder's Guide

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

14,500 lb GVWR Manual Transmission Model Chassis Cab and Maximum Payload Weights
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

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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

Isuzu 2000 Body Builder's Guide

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

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Figure 60

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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

Isuzu 2000 Body Builder's Guide

Page 90

Figure 63 Unit: Inch

Figure 64 Side View Battery Box

Isuzu 2000 Body Builder's Guide

Page 91

Figure 65 Side View Fuel Tank

Figure 66 Side View Aux. Battery Tray

Isuzu 2000 Body Builder's Guide

Page 92

Figure 67 Rear View ABS Controller

Figure 68 Side View In Frame Tank

Isuzu 2000 Body Builder's Guide

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

Figure 70 Unit: Inch

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

Isuzu 2000 Body Builder's Guide

M/T = Manual Transmission A/T = Automatic Transmission

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Suspension Deflection Charts

Figure 75

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 102

Figure 78

Propeller Shaft
WB PLANE VIEW SIDE VIEW

109 in

132.5 in

150 in

Isuzu 2000 Body Builder's Guide

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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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 105

PTO Location, Drive Gear and Opening Information


Manual Transmission

Figure 82

Automatic Transmission

Figure 83

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 107

Figure 84

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 110

Figure 86 (1) (2) (9) (10) Filler Hose Breather Hose Clip Filler Hose Clips Breather Hose

Drawing #2

Isuzu 2000 Body Builder's Guide

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Figure 87

Drawing #3

Isuzu 2000 Body Builder's Guide

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Figure 88 (9) (11) Clip Filler Hose Clips Breather Hose

Drawing #4

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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:
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.

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

NOTE: These selected specifications are subject to change without notice.

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

Vehicle Weights, Dimensions and Ratings

Figure 92

Figure 93

Isuzu 2000 Body Builder's Guide

Page 120

Figure 94 NPR/W-Series Gas Cab Chassis Dimensions

Variable 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

* Effective CA & CE are CA or CE less BOC.

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

Vehicle Weight Limits:


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.

Frame and Crossmember Specifications

Figure 95

Isuzu 2000 Body Builder's Guide

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

A/T = Automatic Transmission

Frame Chart

Isuzu 2000 Body Builder's Guide

Page 124

Figure 97

Figure 98

Isuzu 2000 Body Builder's Guide

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

Figure 101 Unit: Inch

Isuzu 2000 Body Builder's Guide

Page 127

Figure 102 Rear View Catalitic Converters

Figure 103 Rear View Muffler

Isuzu 2000 Body Builder's Guide

Page 128

Figure 104 Side View In Frame Tank

Figure 105 Rear View ABS Controller

Figure 106 Rear View Emission Canister Isuzu 2000 Body Builder's Guide Page 129

Figure 107 Rear View In Frame Tank

Body Builder Weight Information Chart


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

Figure 108 Unit: Inch

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

Isuzu 2000 Body Builder's Guide

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

A/T = Automatic Transmission

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 133

Figure 111

Isuzu 2000 Body Builder's Guide

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

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 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

Isuzu 2000 Body Builder's Guide

Page 136

Figure 113

Figure 114

Suspension Deflection Charts - NPR HD GAS


Isuzu 2000 Body Builder's Guide Page 137

Figure 115

Figure 116

Tire and Disc Wheel Chart


Isuzu 2000 Body Builder's Guide Page 138

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

Isuzu 2000 Body Builder's Guide

Page 139

Figure 117

Figure 118

Propeller Shaft
Isuzu 2000 Body Builder's Guide Page 140

WB

PLANE VIEW

SIDE VIEW

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 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

Isuzu 2000 Body Builder's Guide

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

1st shaft in 2 piece driveline

Isuzu 2000 Body Builder's Guide

Page 142

Type C

2nd shaft in 2 piece driveline

Brake System Diagram


Vacuum Over Hydraulic
PLEASE REFER TO INTRODUCTION SECTION OF BOOK FOR ANTI-LOCK SYSTEM CAUTIONS AND WHEEL BASE MODIFICATION REQUIREMENTS

Figure 122

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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:
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.
Isuzu 2000 Body Builder's Guide Page 146

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

Isuzu 2000 Body Builder's Guide

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

NOTE: These selected specifications are subject to change without notice.

Vehicle Weights, Dimensions and Ratings

Figure 126

Isuzu 2000 Body Builder's Guide

Page 148

Figure 127

Figure 128 NQR/W Series Diesel Cab Chassis Dimensions

Variable 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

* Effective CA & CE are CA or CE less BOC.

Dimension Constraints:
Code AH Inches 8.6 Code BW Inches 83.3 Page 149

Isuzu 2000 Body Builder's Guide

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

17,950 lb GVWR Manual Transmission Model Chassis Cab and Maximum Payload Weights
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

Vehicle Weight Limits:


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.

Frame and Crossmember Specifications

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

M/T = Manual Transmission A/T = Automatic Transmission

Frame Chart

Figure 131

Figure 132

Isuzu 2000 Body Builder's Guide

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

Figure 135 Unit: Inch

Isuzu 2000 Body Builder's Guide

Page 154

Figure 136 Side View Battery Box

Figure 137 Side View Fuel Tank

Figure 138 Side View Aux. Battery Tray ID1

Isuzu 2000 Body Builder's Guide

Page 155

Figure 139 Rear View ABS Controller

Body Builder Weight Information Chart


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

M/T = Manual Transmission A/T = Automatic Transmission

Cab Tilt

Isuzu 2000 Body Builder's Guide

Page 156

Figure 140 Unit: Inch

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

M/T = Manual Transmission A/T = Automatic Transmission

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 159

Figure 143

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

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 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

Isuzu 2000 Body Builder's Guide

Page 162

Suspension Deflection Charts

Figure 145

Figure 146 Isuzu 2000 Body Builder's Guide Page 163

Tire and Disc Wheel Chart


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
WHEEL SIZE BOLT HOLES BOLT CIRCLE DIA FT/RR NUT SIZE+ REAR STUD SIZE+ NUT/ STUD TORQUE SPECS. 325 ft-lb (440 N-M) INNER CIRCLE OUTSID E OFFSET DISC THK RIM TYPE M AL

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

Isuzu 2000 Body Builder's Guide

Page 164

Figure 147

Figure 148

Propeller Shaft
WB PLANE VIEW SIDE VIEW

Isuzu 2000 Body Builder's Guide

Page 165

WB

PLANE VIEW

SIDE VIEW

109 in

132.5 in

150 in

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 139

Isuzu 2000 Body Builder's Guide

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

1st shaft in 2 piece driveline

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

PTO Location, Drive Gear and Opening Information


Manual Transmission

Isuzu 2000 Body Builder's Guide

Page 168

Figure 142

Automatic Transmission

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

Isuzu 2000 Body Builder's Guide

Page 169

1) No PTO gear in the 150" WB models.

Opening Diagram (Dr 1) MBP 6P (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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

MODEL

NPR Diesel/W3500

NPR HD Diesel/W4500

NOTE: These selected specifications are subject to change without notice.

Vehicle Weights, Dimensions and Ratings

Figure 145

Figure 146

Isuzu 2000 Body Builder's Guide

Page 173

Figure 147

Variable Chassis Dimensions:


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.

Dimension Constraints:
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

Isuzu 2000 Body Builder's Guide

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

Frame is tapered at the rear of the 148", 167" and 179" WB, but straight on the 191" WB.

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

Frame is tapered at the rear of the 148", 167" and 179" WB, but straight on the 191" WB.

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

Isuzu 2000 Body Builder's Guide

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

Frame is tapered at the rear of the 148", 167" and 179" WB, but straight on the 191" WB.

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.

Frame and Crossmember Specifications


191 & 218 in Wheelbase

Isuzu 2000 Body Builder's Guide

Page 176

Figure 148

148, 167 & 179 in Wheelbase

Figure 149

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 178

Figure 151

Figure 152

Isuzu 2000 Body Builder's Guide

Page 179

Figure 153

Figrue 154

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 181

Figure 156

Figure 157

Isuzu 2000 Body Builder's Guide

Page 182

Figure 158 Unit: Inch

Body Builder Weight Information Chart


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

Isuzu 2000 Body Builder's Guide

Page 183

Cab Tilt

Figure 159 Unit: Inch

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

M/T = Manual Transmission A/T = Automatic Transmission

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 186

Figure 162

Isuzu 2000 Body Builder's Guide

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

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 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

Suspension Deflection Charts

Figure 164

Isuzu 2000 Body Builder's Guide

Page 190

Figure 165

Tire and Disc Wheel Chart


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

Isuzu 2000 Body Builder's Guide

Page 191

DISC WHEEL
WHEEL SIZE BOLT HOLES BOLT CIRCLE DIA FT/RR NUT SIZE+ REAR STUD SIZE+ NUT/ STUD TORQUE SPECS. 400 ft-lb (550 N-M) INNER CIRCLE OUTSID E OFFSET DISC THK RIM TYPE M AL

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

Isuzu 2000 Body Builder's Guide

Page 192

Figure 167

Propeller Shaft
WB 148 in 167 in 179 in 191 in PLANE VIEW SIDE VIEW

148 in 218 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.

FRR
(148 in, 167 in, 179 in & 191 in WB)

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

M/T = Manual Transmission A/T = Automatic Transmission

PTO Location, Drive Gear and Opening Information


Manual Transmission

Isuzu 2000 Body Builder's Guide

Page 196

Figure 170

Automatic Transmission

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

Isuzu 2000 Body Builder's Guide

Page 197

(Dr 1) MLD 6Q

AT 542

Brake System Diagram


Vacuum Over Hydraulic
PLEASE REFER TO INTRODUCTION SECTION OF BOOK FOR ANTI-LOCK SYSTEM CAUTIONS AND WHEEL BASE MODIFICATION REQUIREMENTS

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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


Isuzu 2000 Body Builder's Guide Page 207

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

DIMENSIONS ARE IN INCHES.

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

DIMENSIONS ARE IN INCHES.

Isuzu 2000 Body Builder's Guide

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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

DIMENSIONS ARE IN INCHES.

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

DIMENSIONS ARE IN INCHES.

Rear Axle/Suspension Dimensions Illustration

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Figure 178

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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

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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

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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

Isuzu 2000 Body Builder's Guide

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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

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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

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Figure 180 TOP DIMENSION IS MM (BOTTOM DIMENSION IS INCHES)

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Single and Dual Fuel Tank Dimensions and Location

Figure 181 TOP DIMENSION IS MM (BOTTOM DIMENSION IS INCHES)

Exhaust System Dimensions and Locations


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Figure 182 TOP DIMENSION IS MM (BOTTOM DIMENSION IS INCHES)

Air Intake System Dimensions and Locations

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Figure 183 TOP DIMENSION IS MM (BOTTOM DIMENSION IS INCHES)

Cab Tilt and Cab Exterior Dimensions

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Figure 184 TOP DIMENSION IS MM (BOTTOM DIMENSION IS INCHES)

Cab Interior Dimensions

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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

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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

AVAIL AVAIL N/A N/A N/A N/A AVAIL AVAIL AVAIL AVAIL AVAIL AVAIL N/A

AVAIL AVAIL N/A N/A N/A N/A AVAIL AVAIL AVAIL AVAIL AVAIL AVAIL 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 N/A N/A N/A N/A N/A N/A AVAIL AVAIL AVAIL AVAIL AVAIL

N/A AVAIL N/A N/A N/A N/A N/A N/A AVAIL AVAIL AVAIL AVAIL AVAIL

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

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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
Isuzu 2000 Body Builder's Guide Page 227

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

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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

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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

Isuzu 2000 Body Builder's Guide

Page 230

Symbol. Fuse

Meaning

Fusible Link

Fusible Link Wire

Switch

Switch

Switch (Normal close type)

Contact wiring

Battery

Diode

Electronic parts

Isuzu 2000 Body Builder's Guide

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Symbol. Resistor

Meaning

Speaker

Buzzer

Circuit Breaker

Bulb

Double filament bulb

Motor

Variable resistor rheostat

Coil (Inductor), solenoid magnetic valve

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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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).

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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

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Figure 188

Figure 189 Isuzu 2000 Body Builder's Guide Page 238

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

Isuzu 2000 Body Builder's Guide

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

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Figure 193

Schematic Body I.D. and Marker Lamps

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Page 242

Isuzu 2000 Body Builder's Guide

Page 243

Figure 194

Fuse and Fusible Link Location

Figure 195

Figure 196

Isuzu 2000 Body Builder's Guide

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

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Isuzu 2000 Body Builder's Guide

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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

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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

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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

Isuzu 2000 Body Builder's Guide

Connector No. Relay name

B-38 Exh. brake

J-12 Starter

J-13 Glow-1

J-14 Glow-2

J-16 Eng. warming out

Connector No. Relay name

J-17 Condenser fan

J-18 Exh. brake control

J-20 ID light

Schematic Auxiliary Power Source

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Isuzu 2000 Body Builder's Guide

Page 251

Figure 199

Schematic Accessory Wiring

Isuzu 2000 Body Builder's Guide

Page 252

Figure 200

Schematic Horn and Back-up Light

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Page 253

Figure 201

Isuzu 2000 Body Builder's Guide

Page 254

Schematic Engine Stop Motor

Isuzu 2000 Body Builder's Guide

Page 255

Isuzu 2000 Body Builder's Guide

Page 256

Figure 202

Schematic Turn Signal, Hazard and Stop Lamp

Isuzu 2000 Body Builder's Guide

Page 257

Isuzu 2000 Body Builder's Guide

Page 258

Figure 203

Schematic Instrument Panel

Isuzu 2000 Body Builder's Guide

Page 259

Isuzu 2000 Body Builder's Guide

Page 260

Figure 204

Fuel Tank Sending Unit Resistance

Figure 205

Isuzu 2000 Body Builder's Guide

Page 261

Figure 205

Gas Cab Chassis 2000 Model Year


Symbols
Symbol. Fuse Meaning

Fusible Link

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Page 262

Symbol.

Meaning

Fusible Link Wire

Switch

Switch

Switch (Normal close type)

Contact wiring

Battery

Diode

Electronic parts

Resistor

Isuzu 2000 Body Builder's Guide

Page 263

Symbol.

Meaning

Speaker

Buzzer

Circuit Breaker

Bulb

Double filament bulb

Motor

Variable resistor rheostat

Coil (Inductor), solenoid magnetic valve

Relay

Isuzu 2000 Body Builder's Guide

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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

Isuzu 2000 Body Builder's Guide

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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)

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 269

Figure 209

Figure 210

Isuzu 2000 Body Builder's Guide

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)

Isuzu 2000 Body Builder's Guide

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
Isuzu 2000 Body Builder's Guide Page 272

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 274

Figure 215

Schematic Body I.D. and Marker Lamps

Isuzu 2000 Body Builder's Guide

Page 275

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 278

Isuzu 2000 Body Builder's Guide

Page 279

Figure 219

Location of Fusible Links

Figure 220

Reference Table of Fuse Panel

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Connector No. Relay name

B-38 Ignition

J-12 Starter

J-15 A/C Enable

J-16 Fuel Pump

J-20 ID Light

Schematic Auxiliary Power Source

Isuzu 2000 Body Builder's Guide

Page 284

Isuzu 2000 Body Builder's Guide

Page 285

Figure 222

Schematic Accessory Wiring

Isuzu 2000 Body Builder's Guide

Page 286

Figure 223

Isuzu 2000 Body Builder's Guide

Page 287

Schematic Horn and Back-up Light

Figure 224

Isuzu 2000 Body Builder's Guide

Page 288

Schematic Turn Signal, Hazard and Stop Lamp

Isuzu 2000 Body Builder's Guide

Page 289

Isuzu 2000 Body Builder's Guide

Page 290

Figure 225

Schematic Instrument Panel

Isuzu 2000 Body Builder's Guide

Page 291

Isuzu 2000 Body Builder's Guide

Page 292

Figure 226

Fuel Tank Sending Unit Resistance

Isuzu 2000 Body Builder's Guide

Page 293

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

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

Isuzu 2000 Body Builder's Guide

Page 296

Figure 231

Figure 232

Isuzu 2000 Body Builder's Guide

Page 297

Figure 233

Dedicated Body Builder Electrical Circuits Behind Engine for F Series


FSR FTR FVR CONNECTORS

Figure 234

Isuzu 2000 Body Builder's Guide

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.

Isuzu 2000 Body Builder's Guide

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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

Isuzu 2000 Body Builder's Guide

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.

Isuzu 2000 Body Builder's Guide

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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

Isuzu 2000 Body Builder's Guide

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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.

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