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01 Table of Contents - Isuzu Truck Service

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1. gt lt gt 4 A E 0000 im Tus gt FW e OAL gt cw lt CW ei VEHICLE WEIGHTS DIMENSIONS AND RATINGS e 18 000 GVW Variable Chassis Dimensions With 6 Speed Manual Transmission Model WB Unit Front Rear Total Payload Unit WB OAL AF SE1 148 in Ib 5027 2448 7475 10525 Inch 148 117 7 180 6 259 3 62 9 SE2 167 in Ib 5116 2414 7530 10470 SES 179 in Ib 5182 2403 7585 10415 nen 187 136 2 200 9 5 4 191 Ib 5171 2503 7674 10326 Inch 179 1260 22623049 78 1 5 218in Ib 5270 2547 7817 10183 Inch 191 159 8 243 9 322 6 84 1 Inch 218 1874 2833 3620 95 9 Chassis Curb amp Maximum Payload Weights 19 500 GVW Effective CA amp CE are 7 5 inch less for MT With Automatic Transmission Effective CA amp CE are 10 0 inch less for AT Model WB Unit Front Rear Total Payload SB1 148 in Ib 5045 2426 7471 12029 Dimensions Constants SB2 167 in Ib 5134 2392 7526 11974 SB3 179 in Ib 5189 2381 7570 11930 584 191 Ib 5178 2481 7659 11841 pede Inches 585 28 lb 5277 2525 7802 11698 8 2 D 18 000 GVW AW 70 5 m BA 47 8 With Automatic Transmission i Model WB Unit Front Rear Total Payload BBC 78 7 SF1 14811 Ib 5045 2426 7471 10529 BOC 7 5 MT 10 0 AT SF2 167in Ib 5134 2392 7526 10474 BW 85 3 5
2. SRA4E ROSE VAC LUM HOSE ICSF VACUUM F290 LOW FRESSURE H GH JRESZJRE 14 500 GVW April 2002 21 NQR W4500 W5500 Crew Cab Diesel BRAKE SYSTEM DIAGRAM Hydraulic Brake Booster PLEASE REFER TO INTRODUCTION SECTION OF BOOK FOR ANTI LOCK SYSTEM CAUTIONS AND WHEEL BASE MODIFICATION REQUIREMENTS ACTUATOR EXHAUST RETARDER CAB SIDE DIL TANK MAGNETIC VALVE FRONT REAR BRAKE LH LH 122220 TE Ex 2 BAKE VACUUM HOSE RAKE HISE IC ERAI PIPE FLOW PREBSKEEL HIGH PRESSUEEI HIGH SRESSUSEMELOR PRESSURE buten PRESSURE PRESSURE 17 950 GVW 22 April 2002 NQR W4500 W5500 Crew Cab Diesel DIESEL FUEL FILL Installation instructions Disconnect battery Loosen hose from the tie downs Remove caps from plate on rail Install hoses on to the plate Extend hose out from the driver side of the rail to body rail The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal see Figure 4 Cover with protector wrap and secure with tie wraps Filler hose is set for 96 inches outside width body Filler neck dimension A must be between 6 85 inches and 8 5 inches above frame Secure the filler plate to the bottom
3. A T Automatic Transmission TYPE AA TYPE BB TYPE ada XP XP SP SP SP TYPE DD Unit Inch CROSS MEMBER TYPE LOCATION Wheel Frame Base Thick A B C A T D A T E F G 109 0 24 37 0 28 3 11 1 AA DD 52 0 26 0 33 0 132 5 0 24 37 0 28 3 11 1 AA BB DD 52 0 59 4 26 0 33 0 150 0 0 24 37 0 28 3 11 1 AA BB DD 52 0 59 4 26 0 33 0 176 0 0 24 37 0 28 3 11 1 AA BB DD 52 0 59 4 26 0 33 0 April 2002 FRAME CHART FRAME FL NPR NPR HD W3500 W4500 Gas Front Axle Center 8 2 8 2 4 5 wu Qu 10 SECTIUN SECTION C C Unit Inch FRAME FL FRAME THICKNESS April 2002 HD W3500 W4500 Gas AUXILIARY VIEWS d 41 6 32 2 27 8 26 8 2 E Per SS 43 5 27 74 2 UNIT INCH 15 2 FRONT LH 9 2 t FRONT RHY 14 14 m Y VS iq 97 8 7 Nw Ce REAR 1220 she 20 2 Rear View Rear View Converters Muffler Side Veiw In Frame Tank lt 12 4 co 39 L
4. GOODYEAR TREAD RPO SIZE LOAD MINIMUM DIMENSIONS REVS LOAD R4A S4A CODE RANGE DUAL NO LOAD LOADED PER MAXPRESSURE PERTIRE TREAD DESIGN SPACING WIDTH DIA WIDTH SLR MILE SINGLE DUAL SINGLE DUAL G159 53 XTUYTI 245 70R19 5 2 11 00 9 90 33 00 10 90 15 30 629 95 95 4080 3860 159 53 XTY YTY 245 70R19 5 514 11 00 9 90 33 00 10 90 15 30 628 110 110 4540 4300 159 53 XWL YWL 11 22 5 G 14 12 60 10 90 41 50 12 00 19 40 501 105 95 6040 5300 G159 53 XWM YWM 11R22 5 H 16 12 60 10 90 41 50 12 00 19 40 501 120 110 6610 5800 G159 53 245 75R22 5 G 14 11 00 9 50 37 00 10 40 17 20 561 110 100 4675 4300 G159 R3C S3C XTU YTU 265 75822 5 6 14 11 60 9 90 38 70 10 80 18 00 537 110 100 5205 4805 5159 53 XRN YRN 295 75R22 5 G 14 12 90 11 20 40 40 12 30 18 70 514 110 100 6175 5675 5159 H3C S3C XTB YTB 255 70R22 5 H 16 11 30 9 80 36 40 10 70 17 00 571 120 115 5510 5070 G159 R3C S3C XWJ YWJ 10R22 5 2 11 40 10 10 40 10 11 00 18 80 518 100 100 5150 4875 5124 S3H YTI 245 70R19 5 F 12 11 00 9 90 33 20 10 90 15 40 622 95 95 4080 3875 6124 S3H 245 70819 5 G4 11 00 9 90 33 20 10 90 15 40 622 110 100 4540 4375 1124 S3H 265 75822 5 514 11 60 9 90 38 70 11 10 18 20 537 110 100 5205 4805 5124 S3H YTQ
5. 11 12 11 11 mie ug 17 vor AHBIT an April 2002 L abed Du 5 mee eweg TY Lv LOH 10 HD NQR W3500 W4500 W5500 Diesel Electrical FUSE LOCATION PUT UL TT Pay Py Pa Pd PTT Tilni i 1 H 1 1 e o a gt FUSE PULLER April 2002 11 HD NQR W3500 W4500 W5500 Diesel Electrical FUSE BOX 12 Fuse Number Fuse Name Circuit Protected Heater 2 Compressor Controls F 3 EXHAUST BRAKE Diesel Exhaust Brake System Diesel VCM IGN Gas Engine Controls Gas 4 D R L Diesel ENGINE IGN Gas Headlights Diesel Engine Controls Gas F 5 ECU BAT Diesel A T SOLENOID GAS Engine Controls Diesel Automatic Transmission Controls Gas F 6 DOME LIGHT Interior Lights Exterior Lights Sound System Gas Speedometer Gas F 7 TAIL LIGHT Dash Lights Exterior Lights F 8 STOP LIGHT Brake Lights F 9 HEAD LIGHT RH Headlights HEAD LIGHT LH Headlights WIPER WASHER Windshield Wiper Washer GENE
6. 15 x 5 25 25 Medium box 15 7 5 35 Large box 15 E 70 Cherries 2 56 bushel Stemmed bushel 64 bushel Lug box 5 63 x11 88 x19 75 17 Gh stn t l mber Sa 37 3080 Bd ft Chestnuts iii bushel 50 bushel Chickens Live broilers 20 avg standard crate 58 Fowl 12 avg standard crate 78 crate Standard crate empty 24 35 RTI ae 18 Cinder blocks 35 9302 Or tice obs 45 each Hato teer inp Pur e LIRE 50 1350 Cu yard Clay Dry P 85 2300 Cu yard Wet lumps i e ge eio 110 2970 yard Wet packed L u ua qa 135 3650 yard Fire pm cc 125 3375 Cu yard EEN EE EE 15 405 EO 35 bushel Shelled bushel
7. bd 5 DEFINITIONS DS DH DW EW HH HW 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 GROND LINE DUAL TIRE SPACING DISTANCE BETWEEN THE CENTER LINES OF THE When rear wheels on one side ride over a high spot When all of rear wheels ride over a high spot 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 DU
8. 19 SINGLE AND DUAL FUEL TANK DIMENSIONS AND LOCATION eene 20 EXHAUST SYSTEM DIMENSIONS AND LOCATIONS 21 AIR INTAKE SYSTEM DIMENSIONS AND LOCATIONS seen 22 CAB TILT AND CAB EXTERIOR DIMENSIONS eene nen nennen tenentes 23 INTERIOR DIMENSIONS A 24 25 TIRE DIMENSION CHARTS MIGHEEIN EPOR UO eaters RUMBO E EE 26 GOODYEAR 27 GENERAL Em 28 BRIDGESTONE et e eed deese an edie de dee ane 29 DISC WHEEL DIMENSION 30 April 2002 1 FSR 8 FVR CONDENSED BASE MODEL SPECIFICATIONS 23100 23100 23100 23100 FERONT GAWR 8100 8100 8100 8100 REAR GAWR 15000 15000 15000 15000 ENGINE 6HK1 TC 6HK1 TC 6HK1 TC 6HK1 TC HORSEPOWER 200 HP 200 HP 200 HP 200 HP TRANSMISSION MLD6Q AT545 MLD6Q 545 FRONT AXLE 8100 8100 8100 8100 FRONT SUSPENSION CAP 8100 8100 8100 8100 REAR AXLE CAP 15000 15000 15000 15000 REAR SUSPENSION CAP 15000 15000 15000 15000 REAR AXLE RATIO 5 29 3 7 5 57 4 11 TIRES 245 75R22 5 245 75R22 5 10R22 5F 10R22 5F BRAKES HYD HYD HYD HYD FRAME MAT 50000 PSI 50000 PSI 80000 PSI 80000 PSI FUEL CAPACITY 50 50 100 100 ALTERNATOR 110 AMP 110 110 AMP 110 AMP MODEL DESCRIPTION FTR 10
9. e AB AF OAL Glossary of Dimensions BBC Bumper to back of cab BA Bumper to axle CA Cab to axle AB Axle to back of cab BOC Back of cab clearance CE Cab to end of frame CG Center of gravity of body and payload from axle WB Wheelbase OAL Overall length AF Axle to end of frame FH Frame height 36 April 2002 Weight Restrictions amp Specifications WEIGHT DISTRIBUTION FORMULAS Front axle to back of cab B Distance between cab and or trailer C Front of body to C G or front of trailer to kingpin D Distance C G of body or fifth wheel is ahead of rear axle 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 W Portion of W transferred to front axle W Portion of W transferred to rear axle Basic Formulas WxD W x WB WB A B C 0 0 WxF W x d W W xW 1 W Wx D 5 W WxF WB WB 2 D W x WB 6 F W x WB 7 W W 4 W W x WB 8 W W x WB D F April 2002 37 Weight Restrictions amp Specifications WEIGHT DISTRIBUTION FORMULAS IN WORDS To find 1 Weight transferred to front axle 2 Distance C G must be placed ahead of rear axle 3 Wheelbase 4 Total Weight 5 Weight transferred t
10. HD NQR W4500 W5500 Crew Cab Electrical NOTE FOR FURTHER ELECTRICAL WIRING INFORMATION PLEASE REFER TO THE NPR NQR DIESEL ELECTRICAL SECTION April 2002 5 FRR FSR FTR amp FVR ELECTRICAL FRR FSR amp FVR Electrical PACKARD BODY PLUG FRR SERIES TAIL LIGHT CONNECTORS 2 April 2002 FRR FSR amp FVR Electrical FRR BODY CONNECTOR LOCATION FRR BODY CONNECTORS LH FRAME PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG LOCATION INSIDE LEFT HAND FRAME RAIL 26 TO 28 INCHES BOC CIRCUITS A REARDOME EN 20 MARKER LAMP BROWN BLACKELUE c p EN BODY CONNECTORS LH FRAME PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG LOCATION LH SIDE END OF FRAME CIRCUITS A REARDOME ege ES ee p GROUND ___ BLACKBLUE 1 BACK UP ALARM WIRING BULLET TYPE BODY PLUG LOCATION RH SIDE END OF FRAME e CIRCUITS A REAR DOME BLUE L p GROUND BLACK BLUE 0 x April 2002 3 FSR FTR amp FVR Electrical FSR FTR FVR SERIES RELAY LOCATION Located at Block 2 Body Builder Wire Harness 5 22 EG P I III IT 4 2002 FRR FSR FTR amp FVR Electrical FSR FTR amp FVR Body Builders Connector Cab interior location view amp
11. 56 bushel Sweet corn green bushel 43 bushel Grates etis 12 88 12 88 24 60 Cornmeal Zeg 44 bushel Keele EE 58 7 8 gallon 810114 114 ree db eT GE 86 11 5 gal Cotton 30 x 48 x 54 515 Standard bale 24 x 28 X 56 515 bale Comp 20 x 24 x 56 515 bale Gotton seed anal tid ed inia bushel 32 bushel Gottonseed Re LEET 58 7 8 gal Cottonwood t 37 3080 M Bd ft Cow Live feeder avg per 600 head Butcher avg per 800 head Butcher steer avg per 1100 head April 2002 55 Weight Restrictions amp Specifications Product Cranberries Cream Creosote Crude oil Cucumbers Earth Eggplant Eggs Elm Fertilizer Fir Douglas Fish fresh Flour Fuel oil Furniture Garbage Gasoline Glass Glue Glycerine Grapefruit Grapes Gravel Greens Groceries Hay 56 Lb Pe
12. HD W3500 W4500 Diesel FRAME amp CROSSMEMBER SPECIFICATIONS EN A E 1 2 Er W Unit Inch Unit Inch CROSS MEMBER TYPE LOCATION M T Manual Transmission A T Automatic Transmission April 2002 3 HD W3500 W4500 Diesel FRAME CHART FRAME FL Front Axle Center 8 2 8 2 4 QJ 5 N Qu 30 SECTIUN SECTIUN Unit Inch FRAME THICKNESS 4 April 2002 HD W3500 W4500 Diesel AUXILIARY VIEWS 37 4 64 75 30 7 7 6 Unit Inch Side View Battery Box 73 20 9 E 8 00 DIA Side View Side View Fuel Tank In Frame Tank DT Rear View ABS Controller 244 27 2 Frame mounted fuel tank available on 109 132 5 150 and 176 WB option replacing the in frame tank Allow 3 additional for battery box opening clearance April 2002 HD W3500 W4500 Diesel BODY BUILDER WEIGHT INF
13. 50 bushel Peaches ET E 48 bushel 412361 13 ia Cue de e huq s q 25 basket 10 5 x 11 25 x 24 50 crate Western box 5 5 x 12 25 x 19 75 22 Peanuts Unshelled tirer b she l_z 22 bushel dee eed alee 100 Peanubol maniro oium M enint iiia 57 7 6 gallon Pears Basket ted m car b sliel iit 50 bushel Western box 9 63 x 12 13 x 19 75 51 58 April 2002 Weight Restrictions amp Specifications APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS Lb Per Product Size Container Cu Ft Peas BAR EE Fresh hamper bushel 40 teres Large bag ER Peppers Basket nn a n bushel Pici 14 13 x 11 75 x 24 Petroleum h CEA 56 Phosphate Pe dr E PU ERR 200 Pine Long leaf North Carolina oe bn oe St ot oe
14. 5 9 3 Sek Ka one om ing NY9 03 amp a TIANYA WANLI ENGL 1000 Q3uNug BEDEIT i mu 038 NMO O3N 4 Wi vo ony 2011000 l TIV POWER DOOR LOCKS HD NQR W4500 W5500 Crew Cab Electrical DOME AND INTERIOR LIGHTS Rear Dome Light Diode 3 EL RY Right Rear Doar Switch GRY BLK BLK ig 8 AT ALL TIMES Wi GRY BLK GRYJBLK Front Dome Light Diode Console Lighis LT GRN BLK Dash and Console Lights Dash and LT GRN REO M 1469 REDIVEL 3 143 Connector Connecter Front REO YEL RED YEL 1 2002 3 HD NQR W4500 W5500 Crew Cab Electrical REAR HEATER 1H wma CH mung vs 068151597 Pag _ pios Dun 1 nai aaan 11 vot 331V3H swal ng SCH Ah sog 42 0 ma Bl BENT S3WI1 11 LOH vonnquisiQ BE 5 2002 iL ora Y voz zl 5301 TIV
15. EE 9 38 x19 x24 Cedalbv 30 54 APPROXIMATE WEIGHTS COMMODITIES AND MATERIALS No of Lb Per crate crate crate bushel cu yard cu yard cu yard bushel lt lt lt bushel crate bushel tub tub case pail bushel hamper crate crate crate head crate crate crate crate crate crate crate gallon bushel bushel crate gallon bushel crate M Bd ft April 2002 Weight Restrictions amp Specifications APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS Lb Per No of Product Size Container Cu Ft Lb Per Celery Standard crate 11 63 x22 x22 63 70 Half crate 10 75 x13 x20 38 35 Northern crate 16 5 21 25 22 85 Block en 8 x8 x16 42 BIOGK ttc 8 12 16 58 Portland ne nn 94 Portland barrel 4 sacks per barrel 376 barrel Chalk d eode 137 3700 Charcoal retur aunts 33 890 yard PINE ID 23 620 yard Cheese Small box
16. 18 April 2002 FSR 8 FVR BATTERY BOX AND COMPONENT BOX DIMENSIONS AND LOCATIONS 1489 8 58 6 TOP DIMENSION IS BOTTOM DIMENSION IS INCHES 19 April 2002 FSR 8 FVR SINGLE AND DUAL FUEL TANK DIMENSIONS AND LOCATIONS 1180 46 4T FRONT AXLE 18 29 Loss 9 SINGLE L H 50 GALLON 3 0 989 0 6 36 94 32 94 VEHICLE 1180 3 46 47 Si FRONT AXLE LU 281 0 10 28 155950 989 0 RIGHT amp 8 94 LEFT TANK pe 50 GALLON DUAL TANKS NL5 TOP DIMENSION IS MM BOTTOM DIMENSION IS INCHES 20 388 0 115 28 April 2002 FSR 8 FVR EXHAUST SYSTEM DIMENSIONS AND LOCATIONS 1567 4 278 8 61 7 11 0 21111 13 VEHICLE ____ P 192 3 7 6 a 1 IN ER N kt E is FRONT AXLE e 241 8 291 8 nz 9 5 01 5 103 7 2921 7 115 0 TOP DIMENSION IS BOTTOM DIMENSION IS INCHES April 2002 21 FSR 8 FVR AIR INTAKE SYSTEM DIMENSIONS TOP DIMENSION IS MM BOTTOM DIMENSION IS INCHES 22 April 2002 FSR 8 FVR CABTILT CAB EXTERIOR DIMENSIONS 30 1 WO LOS 301SN JHL WO SNOISNWIO DWOLLMSA TIV 30 xovg 375812 oN 3M1 193343 8 82 AS ds 900 Pen Z i 0 vi2 zm 0
17. Transmission At least 6 inches clearance should be maintained above the transmission to allow easy removal of the upper cover for manual transmissions At least 2 inches clearance should be maintained above the automatic transmission to allow for transmission removal E UA E ME TREND NES B MEE 150 Inches or More MIT 20 inches or More A T J 58 nches or More 5 D Transmission 2 April 2002 Installation of 8 Special Equipment Front and Center Propeller Shafts At least 1 25 inch clearance should be maintained around front and center propeller shafts 1 25 Inches or more 1 2 Inches or more Front Propellar Shaft Rear Propeller Shaft With the rear springs at maximum deflection at least 1 25 inch clearance should be provided over the rear propeller shaft 1 25 Inches or more Front Propellar Shaft Exhaust System If flammable materials such as wood are used in the 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 Tool Box Oil Pump 1 25 Inches or more Heat Shield 3 9 Inch Clerance Exhaust Pipe 2 K Muffler Front Propellar Sha
18. 2100 X 107 5 225 750 Ib in 3609 X 107 5 387 967 Ib in 1000 X 17 5 17 500 Ib in from vehicle specifications from body manufacturer GVWR Wv Wb We from equipment manufacturer from Body Builder s Guide NPR section page 6 from body manufacturer 1 2 of payload length distance from front axle to front of body from equipment manufacturer from 8 1 from 8 2 from 8 3 from 8 4 _ 224 338 225 750 387 967 17 500 5291 2100 3609 1000 859 998 _ 71 3 inches 12 000 71 3 lt 132 inches 132 inches 15 the wheelbase dimension Since the HCg for this truck is not greater than the WB or negative denotes HCg forward of front axle centerline it exists between the centerlines of the front and rear axles Hp and Hb dimensions are the same in this example because CG of body and payload happen to be at the same point 49 Weight Restrictions amp Specifications HIGHWAY SYSTEM LIMITS 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 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 spacings are setin order to keep axle loads and gross weight loads with the limits set by the Federal Government The Bridge Formula
19. 1 843 Ib in 14 500 GVW 12 000 GVW 0 1 2 3 4 5 VERTICAL SPRING DEFLECTION INCHES REAR LEAF SPRING LOAD VS DEFLECTION PER AXLE K 6 935 Ib in 14 500 GVW 12 000 GVW 1 926 Ib in 14 500 GVWR 12 000 GVWR 0 1 2 3 4 VERTICAL SPRING DEFLECTION INCHES HD W3500 W4500 Diesel TIRE AND DISC WHEEL CHART TIRE TIRE LOAD LIMIT AND COLD INFLATION PRESSURES SINGLE DUAL meer LB PS 215 85R 16 E 2430 70 2210 70 MAXIMUM TIRE LOAD LIMITS FRONT 2 SINGLE 4860 4 DUAL 8840 215 85R 16 E 2680 80 2470 80 TIRE RADIUS LOADED UNLOADED TIRE SIZE 215 85R 16 E 5360 9880 TIRE SECTION WIDTH Unit Inch DESIGN RIM WIDTH 215 85R 16 E DISC WHEEL NUT STUD WHEEL SIZE 16x6 00K O D Wrench Sizes TIRE SECTION _ WIDTH FT RR NUT SIZE 1 6142 41 mm BUD HEX REAR STUD SIZE 0 8268 21 mm SQUARE TIRE CLEARANCE TORQUE SPECS 289 ft Ib 392 OFFSET REFER TO DISC WHEEL SHOWN AT RIGHT G of DISC WHEEL 10 INNER CIRCLE 6 46 OUTSIDE OFFSET 5 0 Unit Inch MATERIAL MFG Steel TOPY OFFSET of DISC WHEEL April 2002 NPR HD W3500 W4500 Diesel PROPELLER SHAFT PLANE VIEW SIDE VIEW 132 5 in TYPICAL INSTALLATIONS SHOWING YOKES IN PHASE IN PHAS
20. 1313 uma ee tire tit eod ier RC Eae D 37 Kiln dried lumber averages 10 to 15 lighter and green lumber 40 to 50 heavier than air dried All weights in table 60 No of Lb 56 3670 1215 1350 280 2970 3375 2565 3240 3100 3970 2325 4645 2485 125 150 50 1350 39 60 3080 Per bushel cu yard cu yard cu yard barrel cu yard cu yard cu yard cu yard cu yard cu yard cu yard cu yard cu yard head bundle cu yard box box gallon bushel gallon bushel basket M Bd ft bushel cu yard cu yard cu yard bale bale cu yard cu yard bag barrel case case gallon cu yard gallon bushel crate M Bd ft April 2002 Tallow Tanks Acetylene Oxygen Tar Tile Tomatoes Turpentine Turnips Vetch seed Vinegar Walnuts Water Wheat Wool April 2002 Weight Restrictions amp Specifications APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS Lb Per Size Container Cu Ft IMs S a p EE LATA E 60 102 CU A RO MM DE 7 SAO CU TE sc le 7 150 G fU iiit UN CIE PEE 77 het ene empty 7 imt 65 Zaza qaqas ania animated REC 115 Partition 40 Bas
21. Hot Wire eB Marker Lamp Ground Dj EN BODY CONNECTORS PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG LOCATION CENTER OF CROSSMEMBER CIRCUITS 8 April 2002 HD W3500 W4500 Gas Electrical amp INTERIOR LIGHTS CIRCUIT DIAGRAM HOT AT ALL TIMES Box Detais 1 page 11 Diesel page 11 4 Gas d EE RED 4 12 6 22840 3i 1212 BLKRED EE REDIYEL GRY BLK Dash and 4 5 Console Lights GAS 4 8 645 LTGRNRED RED YEL RED YEL RED YEL ID 4 95 1 Body Body LT GRNIBLK Connector 4 GASE Front Dash and Console Lights GRYALK GAS GRY RED BLK See Ground Distribution 14 Diesel Page 14 5 Gas BLK 8 7 Diesel 5 Gas April 2002 9 PARK TAIL LICENSE 8 LIGHTS CIRCUIT DIAGRAM NPR NPR HD W3500 W4500 Gas Electrical April 2002 DIE mae Dog 2 4 junio as vg TM Er ven uo 1 1 n L IL _ x daha E _ D NOD ul al 9 wl i 02 n Ge 1 J a rafe 7 SE o mamen 1 1 aes qawsuo Com So 041 1 qe NN9I
22. 125 H Edited 1 0 i E E i H i ACC LINE 2 2 r PU 4 i E 5 ud r L AIR PIPE 06 35 AIR PIPE 98 AIR PIPE 810 AIR PIPE 012 AIR PIPE 015 NYLON TUBE 12 1 5 e NYLON 8X1 0 x RUBBER HOSE 011 PIPE 26 35 gt FLEX HOSE 14 April 2002 Allision Transmission Rating Guide General Severe Duty Specialty Transit Bus Transit Bus w Input Torque Gross Ib ft 740 545 740 545 740 545 576 425 630 465 Ib ft 705 520 705 520 705 520 542 400 603 445 Input Power Turbine Gross 12 Net kW hp 280 875 280 375 280 375 149 200 149 200 kW hp 254 340 254 340 254 340 134 180 134 180 Torque Ib ft 1152 850 1152 850 1152 850 1017 750 1017 750 GVW kg Ibs 9000 19 850 7500 16 540 9980 22 000 7500 16 540 7500 16 540 1 Gross Power and Torque ratings are included for reference only 2 Gross Power rating as defined by SAE J1995 3 Ratio of transmission output rpm to vehicle ground speed N V is only used to limit park pawl applications 4 SEM Engine controls with Shift Energy Management GCW kg 105 11 800 26 000 11 800 26 000 Note Consult Allison
23. Circuit breaker Right hand Cold start device Rear Direct ignition system Rear wheel anti lock brake system Electronic brake control module Start Electronic control gasoline injection Standard Electronic control module Switch Electronic control unit Short wheel base Early fuel evaporation Transmission control module 4 speed automatic transmission 3 speed automatic transmission Four wheel drive Volt Fusible link Vacuum switching valve Front Watt S Headlight Wide open throttle Integrated circuit With April 2002 Ignition Without HD W3500 W4500 Gas Electrical COLOR CODE FOR WIRING WIRING WIRE COLOR 1 Single Color Wire 2 Colored Stripe Wire Figure 18 Wire Color All wires have color coded insulation Wires belong ing 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 Red Stripe color Green Base color Wire size 0 5 mm2 Abbreviations are used to indicate wire color within a cirbuit diagram Refer to the following table Color Coding Meaning Color Coding Meaning Black Brown White Light Green Red Grey Green Pink Yellow Light Blue Blue Violet Orange
24. HEAD LIGHT LH Headlights WIPER WASHER Windshield Wiper Washer GENERATOR Charging System TURN S LIGHT Turn Lights ECU IGN Diese VCM ACC Gas Engine Controls AUDIO CIGAR LIGHTER Cigarette Lighter Engine Controls Sound System POWER SOURCE Engine Controls ENGINE STOP Diesel 4 Engine Stop System Diesel FUEL PUMP Gas Engine Controls Gauges Gas HAZARD HORN Engine Controls Gauges Horn Hazard Lights ABS BAT ABS 12 STARTER Starting System April 2002 HD W3500 W4500 Gas Electrical RELAY LOCATION Hidden Fuse Box RELAY BOX Install on the instrument panel RELAY BOX Installed on the left side rear of the cab April 2002 13 HD W3500 W4500 Gas Electrical CAB RELAY Diode Number Circuits Protected zi B 17 Brake warning system B 18 25 Compressor controls B 26 Exhaust brake system Diesel Relay Number Relay Relay Number Relay B 19 Charge relay B 34 Power source 20 Headlight 35 21 Heater 8 B 36 Exhaust brake cut Diesel B 22 Tail Vacuum pump Gas B 23 Buzzer control B 37 A C thermo
25. ee Rn 5 25 x 11 5 X 22 ie tees Unh ll d 5 eias Gr shed 2 2 erts 100 Romaine Crate a 13 88 x 18 88 x 24 5 Pici 12 25 x 18 x 15 25 Rubber g6048 94 RButabagas bushel 2002 No of Lb Per bushel hamper hamper bag bag basket crate gallon yard M Bd ft Bd ft Bd ft Bd ft Bd ft Bd ft Bd ft yard barrel bushel bushel bag barrel box box bushel bushel crate M Bd ft yard bushel box bushel yard crate crate yard bushel 59 Weight Restrictions amp Specifications APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS Lb Per Product Size Container Cu Ft uin RR v bushel Salt rock SOM a vr ci ee d e EE Eu da e 136 GOSE Rm 45 FID tede enis ooi red denne 50 peAa E TEAS E A E RO Sand Fine Bl E D ERE EN 110 Ne E 125 Coarse By aeo PE 95 Wet EE 120 Med 115 Sandstone SOlld eL 147 etico 86 Shale 29 Hi 172 Te M X 92 Sheep Live avg per head Shingles packed in bundles of 200 250 Size of bund
26. hamper 5 peck Slack barrel 21 30 stave 200 net Wood barrel 0 5 barrel 16 gal Wood barrel 0 25 barrel 8 gal Steel barrel 0 5 barrel 16 gal Steel barrel 0 25 barrel 8 gal DUTCHMAN 0 13 barrel 4 Regular bottles 17 25 x11 5 x9 88 Steinie bottles 18 38 12 13 7 38 TIR GPS rasen tein 16 13 11 5 13 Regular bottles 21 X19 5 A LA Steinie bottles 22 13 75 7 5 bushel Small crate 9 75 13 75 24 Western crate 14 19 24 5 Weight Restrictions amp Specifications No of Lb Per gallon gallon gallon bushel cu yard bushel box box barrel bushel bushel box box cu yard crate crate box bunch bushel cu yard cu yard bushel bushel bushel bushel bushel hamper barrel barrel barrel barrel barrel barrel
27. 5 Turn the stud clockwise one quarter of a turn 6 Using a 3 4 wrench turn the stud nut clockwise several turns to release the brakes Follow the same proce dure to release the other brake 7 Atthe repair facility apply air pressure of at least 70 psi 480 kPa to the brake chambers either from an external air supply or the vehicle s air system 8 Turn the stud nut counterclockwise several turns Remove the stud from the chamber 9 Put the stud into the side pocket of the chamber and replace the rubber cap April 2002 35 Weight Distribution Concepts Weight Restrictions amp Specifications Weight Restrictions The Gross Vehicle Weight Rating GVWR and the Gross Axle Weight Rating GAWR of each Incomplete Vehicle are specified on the cover of its Incomplete Vehicle Document in conformance to the requirements of Part 568 4 of the Federal Motor Vehicle Safety Regulations The final stage manufacturer is responsible under Part 567 5 to place the GVWR and the GAWR of each axle on the Final Vehicle Certification Label The regulation states that the appropriate rating shall not be less than the sum of the unloaded vehicle weight rated cargo load and 150 pounds times the vehicle s designated seating capacity Unloaded vehicle weight means the weight of a vehicle with maximum capacity of all fluids necessary for operation of the vehicle but without cargo or occupants During completion of this vehicle GVWR and GAWR m
28. 6 April 2002 5500 Diesel CURB POSITION DH TIRE DESIGN LOAD LOADED SS TRACK EE FORMULAS FOR CALCULATING HEIGHT DIMENSIONS 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 TIRE UNLOADED RADIUS DH D TIRE LOADED RADIUS Unit Inch TIRE GVWR GAWR CH TRACK Unload Load April 2002 7 5500 Diesel 2 50 MINIMUM TIRE CLEARANCE SECTION BETWEEN LW F BODYANDTIRES WHEEL OFFSET TIRE CLEARANCE TIRE RADIUS TIRE LOADED X j Y RADIUS DW Ge CW EW DEFINITIONS m gt DH DW EW HH 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
29. Body Application Summary Chart NPR NPR HD W3500 W4500 Gas NPR NPR HD W3500 W4500 Diesel NQR W5500 Diesel Weight Distribution Glossary of Dimensions Weight Distribution Formulas Recommended Weight Distribution Trailer Weight Performance Calculations Highway Limits Federal Bridge Formula Table Commodity amp Material Weights Approximate Weight of Commodites amp Materials Vehicle Specifications Index NPR NPR HD W3500 W4500 Gas NPR NPR HD W3500 W4500 Diesel NQR W5500 Diesel NPR NPR HD NQR W4500 W500 Crew Cab Diesel FRR WT FSR FTR amp FVR NPR NPR HD W3500 W4500 Gas Cab Chssis Electrical NPR NPR NQR W3500 W4500 Diesel Cab Chssis Electrical NPR NQR W4500 W500 Crew Cab Electrical NPR HD NQR W4500 W500 Crew Cab Diesel FRR WT FRR FSR FTR amp FVR Cab Chassis Electrical Note 2002 FSR FTR and FVR Mechanical amp Cab Specifications Engine Horsepower amp Torque Chart GVW GCW Ratings Rear Frame Height Chart Clutch Engagement Torque Paint Code Chart N W Series Towing Procedure FRR WT Series Towing Procedure FSR FTR amp FVR Series Towing Procedure Weight Distribution Concepts Weight Restriction Gross Axle Weight Rating Weighing the Vehicle Tire Inflation Center of Gravity Introduction This guide has been provided as an aid to final stage manufacturers in determining conformity to the applicable Emission Control and Federal Motor Vehicle Safety Standards Fi
30. Steel plate SATISFACTORY UNSATISFACTORY Cables should not be in contact with sharp edges or pierced holes fe Harness 7 Harness C 7 Theharnessreceives the adverse affect of dirt grit or water SATISFACTORY UNSATISFACTORY 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 Line Taping When parallel 0 4 in or more P di When across 0 8 in or more Y EM 12 April 2002 SATISFACTORY UNSATISFACTORY Installation of 8 Special Equipment Wire Color Code The electrical circuits of the N W and FRR WT Series Chassis Cab are connected with low voltage stranded wire for automotive applications The color coding standards are as follows for the N W and FRR WT Series Chassis Cab Refer to FSR FTR and FVR service manual for those vehicle wiring color codes Black B Starter circuits and grounds White W Generator alternator circuit Red Lighting circuit Signal circuit Instrument circuit Accessory circuit Other circuit Windshield wiper motor circuit 5 lt 0 2 Light Green 1 2 3 4 5 Yellow 6 7 8 Blue rr Maximum Allowable Current Harness Design AWG No of wires Cross sectional Maximum allowable Diameter mm equivalent wir
31. 10 75 x 8 75 x 10 5 Dall 3 cretion ale tidie Hamper 1 5 bushel B 12 75 x 18 5 x 19 Western crate 14 19 24 5 Barrel crate 12 75 x 18 75 x 37 38 Live average per Cantaloupe Crate PONY 11 75 11 75 23 5 Standard 12 75 12 75 23 5 JUMDO ss 13 75 13 75 23 5 PONY lal 4 75 12 75 23 5 Standard flat 25 14 25 23 5 Jumbo flat 5 75 15 25 23 5 Honeydew 6 38 x15 13 x23 5 G rbolic acid eet dei ef a P P dei ee 60 Carrots Bel DEE bushel With tops bushel LE 11 75 14 13 24 61 1 16 0 61 9
32. 5 31 4 72 8 86 8 86 Unit Inch SECTION A A SECTION B B SECTION C C SECTION C C 179 191 218in WB 148 amp 167 in WB at end of frame FRAME THICKNESS 4 April 2002 5500 AUXILIARY VIEWS AIR CLEANER Cab Mount Member Air Intake amp Rear Window Chassis 0 9 139 Brake Assembly 17 0 4 48 10 66 105 9 47 165 Side View Side View Unit Inch Fuel Tank Battery Box April 2002 5 FRR WT5500 BODY BUILDER WEIGHT INFORMATION CHART FRR Series ee ee one sono star me 7475 7420 7530 7475 7585 7519 7674 7608 7817 7751 2105 Manual Transmission Automatic Transmission Units z Lb CAB TILT GRID SCALE NOTE Roof marker lamps add Pd 97 One square is 1 575 to overall cab 5 x 5 in height 54 Pivot pointto topof frame 38 73 38 1 Unit Inch The center of gravity of the completed vehicle with a full load should not exceed 63 above ground level and must be located horizontally between the centerlines of the front and rear CENTER OF GRAVITY FH Unloaded Unit Inch Vertical Center of Gravity Horizontal Center of Gravity The center of gravity of the chassis cab Note The maximum dimensions for a body installed on the FRR are 96 inches wide outside by 90 inches high inside Any larger bod
33. 68 0 87 4 9 25 OW 78 5 FH 32 0 In Frame Tank 12 000 Ib GVWR Manual Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear NA1 109 0 in Ib 3472 1885 NA2 132 5 in Ib 3516 1907 NAS3 150 0 in Ib 3560 1929 NA4 176 0 in Ib 3605 1951 In Frame Tank 14 500 Ib GVWR Manual Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear NE1 109 0 in Ib 3483 1885 NE2 132 5 in Ib 3527 1907 150 0 Ib 3571 1929 NE4 176 0 in Ib 3616 1951 In Frame Tank 12 000 Ib GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear NB1 109 0 in Ib 3538 1929 NB2 132 5 in Ib 3582 1951 NB3 150 0 in Ib 3627 1973 NB4 176 0 in Ib 3671 1995 In Frame Tank 14 500 Ib GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear NF1 109 0 in Ib 3549 1929 NF2 132 5 Ib 3593 1951 150 0 Ib 3638 1973 NF4 176 0 in Ib 3682 1995 2 AF 43 1 43 1 43 1 43 1 Total 5357 5423 5489 5556 Total 5368 5434 5500 5567 Total 5467 5533 5600 5666 Total 5478 5544 5611 5677 Payload 6643 6577 6511 6444 Payload 9132 9066 9000 8933 Payload 6533 6467 6400 6334 Payload 9022 8956 8889 8823 Side Mounted Tank 12 000 Ib GVWR Manual Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear NA1 109 0 in Ib 36
34. Body Builder Connector F Series Body Builder Connector Exterior Location Body Builder View Harness Connector Ground Block Located Under Frame Flange Exterior Upfitter Connector p d j Mating female Connector Pin P N 12084872 April 2002 e 12065862 Connector Part 4 Metri Pack Information 280 Sealed BLK Wire Circuit Color No B 339 Fuse Output Ignition Dark Green Interior Upfitter Connector Dark Blue Interior Upfitter Connector FRR FSR FTR 8 FVR Electrical Body Chassis Electrical Connectors The wiring harness were designed for reliability durability and to simplify installation for body builders and customers All wires connectors and components are located for fast easy access The electrical circuits that may be available for connecting to and their locations are as follows Circuit Max Load Battery Fed Dedicated Body Builder Lead Dedicated Body Builder Lead d TN MES Auxiliary 7 0 Amps Marker Lamp Headlamp Availability Switch F Series 2 Pickup Loactions In Cab amp Under Cab Behind Engine Vehicles i Vehicle w o a Cigar Cigar Lt amp lighter or Auxiliary Aux Pwr Power Jacks Jacks 2 Speed Axle 200 Amps Vehicle w o 2 Speed Axle single axle only ale 20 0 Amps X Vehicle w o an Air spia Dryer Moisture ES Ejector In the above circuits the auxiliary marker lamp circuits are available on all vehicles the remainder
35. Equipment Sequential Port Fuel Injection SFI mass air flow meter powertrain control module VOM onboard diagnostics oxygen sensors catalytic convertor map sensor with external oil cooler TRANSMISSION 4L80 E Hydra Matic 4 speed automatic with lock up converter and overdrive STEERING Integral power steering 20 9 1 ratio Tilt and telescoping steering column FRONT AXLE Reverse Elliot beam rated 6 830 Ib Suspension Semi elliptical steel alloy leaf springs with stabilizer bar and shock absorbers GAWR 4 700 Ib REAR AXLE Full floating single speed with hypoid gearing rated at 11 020 Ib Suspension Semi elliptical steel alloy leaf springs and shock absorbers GAWR 7 950 Ib WHEELS 16 x 6 6 hole disc wheels painted white TIRES 215 85R 16E 10 pr tubeless steel belted radials all season tread Front Rear BRAKES 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 Anti lock brake system FUEL TANK 30 gal rectangular steel fuel tank Mounted between the frame rails with electric type fuel pump mounted in tank Through the rail fuel fill FRAME Ladder type channel section straight frame rail 33 5 inches wide through th
36. STEEL STEEL TYPE SAE J1392 SAE J1392 H T SAE 1027 GRADE 50 80 YIELD STRENGTH 50 000 80 000 110 000 WELDABILITY PERMITTED PERMITTED NOT PERMITTED RBM 479 000 1 378 300 1 760 000 SECTION MODULUS 9 58 12 53 16 00 OUTSIDE DEPTH 9 49 9 65 9 80 FLANGE WIDTH 3 00 3 00 3 00 MATERIAL THICKNESS 0 24 0 315 0 375 OPTIONAL REINFORCEMENT N A F08 F08 TYPE INVERTED L INVERTED L MATERIAL STEEL STEEL MATERIAL THICKNESS 0 24 0 24 COMBINED SECTION MODULUS 20 36 23 56 RATED COMBINED RBM MEASURED BEHIND THE April 2002 2 239 500 2 591 600 11 FSR 8 FVR FSR FVR FRONT AXLETRACK CHART AXLE FL1 FL2 FS7 CAPACITY 8100 LBS 11000 LBS 12000 LBS WHEELTYPE WHEEL BRAKES BRAKES BRAKES SIZE OFFSET HYD FULLAIR HYD FULLAIR FULL AIR STEEL DISK WHEEL 8 HOLE HUB PILOTED 19 5X6 75 N A N A ALUMINUM DISK WHEEL 8 HOLE HUB PILOTED 19 5X6 75 N A N A STEEL DISK WHEEL 10 HOLE HUB PILOTED 22 5 7 50 79 91 79 59 STEEL DISK WHEEL 10 HOLE HUB PILOTED 22 5X8 25 79 68 79 36 ALUMINUM DISK WHEEL 10 HOLE HUB PILOTED 22 5X8 25 N A N A DIMENSIONS ARE IN INCHES Formulas for Calculation Height Dimensions 6 WHEEL RADIUS CH CURB FOSITION DESIGN POSITION Tire loaded radius B Centerline of
37. Shortening the Wheelbase 16 April 2002 Installation of 8 Special Equipment 5 When welding the insert length AL for wheelbase lengthening to the original frame rail a continuous butt weld must be used at the splices When shortening the wheelbase weld the ends of the chassis frame together with a continuous butt weld over the junction of the frame ends Weld both the inside and outside of the frame rails using welding techniques prescribed by established welding standards ref SAE J1147 and in accordance with this guide An example of this weld is shown below NSW 40 in or more BUTT WELD 100 Weld can be inside or outside of member or as shown a combination of both C co 5 sss 110 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 placed over the extended or shortened section of the frame rail l1 C 3xD 22 Lengthened Wheelbase Shortened Wheelbase D Original frame rail web depth 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 reinforc
38. b Excessive overloading could result in steering component damage or failure 5 Unsafe operating and conditions a Poortraction onthe steering axle effects the safety of the driver and equipment particularly on wet icy and slippery surfaces Experience indicates that approximately 30 96 of the total weight at the ground on a truck or tractor should be on the front axle with a low cab forward vehicle b Whenatruckis overloaded a dangerous situation may existbecause minimum speeds cannot always be maintained directional control may not be precise and insufficient braking capacity can cause longer than normal braking distances 6 High maintenance costs a Improperweightdistribution and overloading cause excessive wear and premature failure of parts Additional stresses impose on the frame by the misapplication of wheel bases may be instrumental in causing the frame to crack or break April 2002 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 overthe rear axle This places all the payload on the rear axles
39. 11 FTR12 FTR13 50 51 20 FTR21 FTR22 FTR23 25950 25950 25950 25950 25950 25950 30000 30000 30000 30000 FERONT GAWR 9350 9350 9350 9350 11000 11000 11000 11000 11000 11000 REAR GAWR 17640 17640 17640 17640 17850 17850 19000 19000 19000 19000 ENGINE 6HK1 TC 6HK1 TC 6 1 6HK1 TC 6HK1 TC 6HK1 TC 6HK1 TC 6HK1 TC 6HK1 TC 6HK1 TC HORSEPOWER 200 HP 200 HP 200 HP 200 HP 200 HP 200 HP 200 HP 200 HP 200 HP 200 HP TRANSMISSION MLD6Q 545 MLD6Q AT545 MLD6Q AT545 MLD6Q 545 MLD6Q AT542 FRONT AXLE CAP 11000 11000 11000 11000 11000 11000 11000 11000 11000 11000 FRONT SUSPENSION CAP 12000 12000 12000 12000 12000 12000 12000 12000 12000 12000 REAR AXLE CAP 17850 17850 17850 17850 17850 17850 19000 19000 19000 19000 REAR SUSPENSION CAP 19000 19000 19000 19000 19000 19000 19000 19000 19000 19000 REAR AXLE RATIO 5 29 3 9 5 29 3 9 5 57 4 11 5 57 4 11 5 57 4 11 TIRES 245 75R22 5 245 75R22 5 245 75R22 5 245 75R22 5 11R22 5G 11R22 5G 11R22 5G 11R22 5G 11R22 5G 11R22 5G BRAKES HYD HYD AIR AIR HYD HYD HYD HYD AIR AIR FRAME MAT 80000PSI 80000PSI 80000PSI 80000PSI 80000PSI 80000PSI 80000 PSI 80000 PSI 80000 PSI 80000 PSI FUEL CAPACITY 50 50 50 50 100 100 50 50 50 50 ALTERNATOR 110 110 AMP 110 110 AMP 110 AMP 110 110 AMP 110 AMP 110 AMP 110 AMP MODEL DESCRIPTION FVR 10 FVR 50 GVW 33000 33000 FRONT GAWR 11000 11000 REAR GAWR 22000 22000 ENGINE 6HK1 TC
40. 8 5 x 12 75 x 16 75 54 2002 head gallon head bushel yard block block block can can can can bushel gallon head barrel bundle yard yard box box bushel bushel hamper basket crate 1 2 crate bushel barrel barrel box box gallon gallon bushel bushel bushel gallon M Bd ft M Bd ft bushel gallon can can crate crate 57 Weight Restrictions amp Specifications APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS Lb Per No of Product Size Container Cu Ft Lb Per 50 bushel IEN 90 12 gallon 20 25 head 34 stave 675 o EEN 110 2970 106 2860 Packed eset se e 125 3375 yard Muriatic acid 405 40 10 gallon Naptha Petroleum Len e ie 42 5 6 gallon Nitric acid EE Ee e ER 12 5 Black 3500 M Bd ft White en 4080 M Bd ft Oats 32 bushel Okra Hamper 1 2 bushel 18 hamper Hamper bushel B 34 bushel Oleomargarine mfg tub 21 head
41. Box Details Page 11 Diesel Page 11 4 Gas IN ACC ON Dash and Console See Fuse Lights om gt Box Details Page 11 2 Diesel RED YEL LT GRN RED Left Hand Speaker 18 Illumination Page 11 6 Gas ee 13 L Right Hand Speaker Antenna Radio input Solid State Do not check resistance See Ground Distribution Page 14 Diesel Page 14 5 625 ER 4 ai Diesel 54 Gas April 2002 HD NQR W3500 W4500 W5500 Diesel Electrical ENGINE STOP MOTORS CIRCUIT DIAGRAM L Stai n BLU RED BLUNEL BLU WHT 2 1 B 68 BLU YEL BLUANHT 10 BLU RED BLU YEL BLUWHT Ju Stop ES R Starter Switch 1 See Ground Distribution dads 14 2 April 2002 19 wa 19 p f 1 Em 710470811 puncig aag 1 jquiossy 2 4 abed 010 898 uni Aiquassy un uoneuquo 9 abed meng punolg 99 996 Aquassy un uopeuquo punoJ9 98 2002 10014 _ HD NQR W3500 W4500 W5500 Diesel Electrical TURN AND HAZARD LIGHTS CIRCUIT DIAGRAM Wm E 69 Aquassy s
42. DW 5 00 INCHES lt 1 00 INCH MINIMUM CLEARANCE BETWEEN TIRES AND SPRINGS NOTE TRACK AND OVERALL WIDTH MAY VARY WITH OPTIONAL EQUIPMENT Unit Inch Tire Track C E 8 4 2002 5500 Diesel SUSPENSION DEFLECTION CHARTS 2002 FRONT LEAF SPRING LOAD VS DEFLECTION PER AXLE S U S P E Ibs N 10 000 S 5 000 1 848 Ib in L 17 950 GVW 0 1 2 3 4 5 VERTICAL SPRING DEFLECTION INCHES REAR LEAF SPRING LOAD VS DEFLECTION PER AXLE 15 000 Ibs 10 000 10 610 Ib in 17 950 GVW 5 000 2 669 Ib in 17 950 GVW 3 4 VERTICAL SPRING DEFLECTION INCHES NQR W5500 Diesel TIRE AND DISC WHEEL CHART TIRE TIRE LOAD LIMIT AND COLD INFLATION PRESSURES SINGLE 2 LB PSI iB PS MAXIMUM TIRE LOAD LIMITS FRONT 2 SINGLE 225 70R 19 5F 3450 90 3245 90 6900 12980 17 950 TIRE 0 TRERADUS GVWR WIDTH TIRE SIZE Ib Unit Inch TIRE DESIGN SECTION CLEAR ANCE WIDTH 225708 19 5 17960 150 152 154 DISC WHEEL NUT STUD se 12 Unit Inch FT RR NUT SIZE 1 6142 41 mm BUD HEX REAR STUD SIZE 0 8268 21 mm SQUARE TORQUE SPECS 325 ft Ib 440 N M INNER CIRCLE OUTSIDE OFFSET 15 O
43. Page 144 4 Ri BLK See Ground Distribution Page 14 4 41 Switch Automatic Transmission Controls RED BLU 5 ARS Up Assembly ht See Ground Distribution Page 14 4 __ 1 2002 HD W3500 W4500 Gas Electrical TURN amp HAZARD LIGHTS CIRCUIT DIAGRAM HOT AT ALL TIMES HOT IN ON AND START 4 HAZARD HORN TURN SILIGHT LT GRN BLK LT GRN BLK 20A 10 ENS oJ flasher voltage punt di See Fuse Box Details Page 11 5 WHT BLU WHTIRED Dash and Console Lights LT GRN LT WHT BLU WHTIRED WHTIGRN BLK YELRED RED 3 4 8 30 Hazard Off Hazard LT GRN BLK Distribution Page 14 5 Dash and Comering Console Lights Lights 2 REDIBLK E 54 RED BLK Combination Switch Cornering PNKIBLK Gel m B 70 PNKIBLK cd Ground Lights Distribution Page 14 5 BLK 2 April 2002 19 HD W3500 W4500 Gas Electrical TURN amp HAZARD LIGHTS CIRCUIT DIAGRAM Tura Output GRAIBLK GRNIBLK Signal Light See Ground Distribution Page 14 5 Left Front Combination Light Assembly 7 Flasher Dutput GRN WHT GRN WHT Signal Light See Ground Distribution Right Front Combination Light Assembly GRNMWHT 77 Meter Right Turn As
44. VALVE MASTER VACUUM FRONT LH NG VACUUM TANK Line NAME BRAKE HOSE LOW PRESSURE VACUUM HOSE BRAKE HOSE VACUUM PIPE BRAKE PIPE HIGHT PRESSURE NPR HD W4500 GAS 14 500 GVW 15 HD W3500 W4500 Gas THROUGH THE RAIL FUEL FILL Installation instructions Disconnect battery Loosen hose from the tie downs Remove shipping plate from chassis Extend hose out from the driver side of the rail to body rail The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal see figure 1 Filler hose is set for 96 inches outside width body Filler neck Dimension A must be between 6 85 inches and 8 5 inches above frame Secure the filler plate to the bottom of the body and check for leaks Ensure that fill hose does not sag creating an area where the fuel could pool in the fill hose Reconnect battery 16 April 2002 HD W3500 W4500 Rear View Fuel Dimension A 6 85 8 5 inches 174 216mm Top View Fuel Fill Dimensions 28 85 inches 733mm C 34 00 inches 863mm D 39 29 inches 998mm 46 61 inches 1184mm 96 00 inches 2438mm 2002 17 HD W3500 W4500 Gas 1 Body Width Adjustment 90 inch Body Dim E 682 8mm 86
45. and WB new April 2002 15 Installation of amp Special Equipment 1 Determine the added length AL or shortened length SL required to lengthen or shorten chassis For added wheelbase New CA AL For shortened wheelbase New CA CA SL 2 Obtain the material to be used as the insert for the lengthened wheelbase in the correct length AL The insert must have the same cross sectional dimensions and yield strength as the original frame rail 3 Divide the new CA by two 2 Measure new 2 from the center of the rear axle forward and mark this point on the chassis frame see figure below 1 2 New CA 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 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 General Motors Isuzu Commercial Truck LLC GMICT and American Isuzu Motors Inc Application Section to be Added Cut Point Second Cut Point Section to be Removed First Cut Point
46. jud B L Page 14 April 2002 15 HD NQR W3500 W4500 W5500 Diesel Electrical HORNS CIRCUIT DIAGRAM HOT AT ALL TIMES LO 077 77 77 fuse F 18 Box HAZARD HORN 20A 4 GRN GRN WHT GRN WHTIGRN Gas GRN See Fuse WHT GRN Gas Details Page 11 1 Diesel Page 11 5 Gas GRN GRN WHTIGRN Gas WHTIGRN Gas T GRN WHT GRNANHT Right Hand Horn 16 April 2002 HD NQR W3500 W4500 W5500 Diesel Electrical BACK UP LIGHTS CIRCUIT DIAGRAM HOT IN ON OR START Hidden F 25 Fuse Box GAUGE BACK 10 BLKIYEL See Fuse Box Details 11 3 San BLKUYEL 2 FC ns Inhibitor Back Up AT Sh Shift Indicator Switch Light Switch Controls REDIBLU RED BLU used REDIBLU REDIBLU Automatic REDPLU REDIBLU Transmission 5 RED BLU 424146 5 RED BLU See Ground Distribution Page 14 2 RED BLU REDIBLU RED BLU T Left Taillight Assembly 69 m Up m Ground Distribution Page 142 CARE See Ground dE Distribution Page 14 2 April 2002 17 HD NQR W3500 W4500 W5500 Diesel Electrical SOUND SYSTEM CIRCUIT DIAGRAM HOT AT ALL TIMES F 6 DOME LIGHT RED See Fuse
47. 245 75822 5 6 14 11 00 9 50 37 30 10 50 17 40 557 110 110 4675 4410 5124 S3H YWL 11R22 5 6 14 12 60 10 80 41 70 11 90 19 50 498 105 115 6175 5250 5124 S3H YWM 11R22 5 H 16 12 60 10 80 41 70 11 90 19 50 498 120 110 6610 5800 124 S3H YRN 295 75822 5 6 14 12 90 11 10 40 60 12 30 18 90 512 110 100 6175 5675 5124 S3H YTB 255 70822 5 H6 11 30 9 80 36 80 10 70 17 20 564 115 115 5510 5070 5124 S3H 10R22 5 2 11 40 10 00 4040 11 00 1900 514 100 100 5150 4875 2167 530 YWJ 10R22 5 12 11 40 9 90 40 70 10 90 19 10 513 100 100 5150 4875 6167 530 YWL 11R22 5 6 14 12 60 10 70 42 00 11 80 19 70 497 105 115 6175 5250 167 530 YWM 11R22 5 H 16 12 60 10 70 42 00 11 80 19 70 497 120 110 6610 5800 G167 S3D YRN 295 75822 5 514 12 90 10 90 40 80 11 90 1900 512 110 100 6175 5675 144 S3E YWL 11R22 5 6 14 12 60 10 80 41 70 11 90 19 50 498 115 105 6175 5250 G144 5 YWM 11R22 5 H 16 12 60 10 80 41 70 11 90 19 50 498 120 110 6610 5800 5286 R3F S3F XWL YWL 11R22 5 G4 12 60 10 80 41 70 11 90 19 50 498 105 115 6040 5250 186 H3K S3K XWJ YWJ 10R22 5 2 11 40 10 00 40 40 11 00 18 90 514 100 100 5150 4875 G186 R3K S3K XWL YWL 11R22 5 6 14 12 60 11 00 41 80 12 10 19 50 497 105 115 6040 5250 5186 H3K S3K XWM YWM 118225 H 16 12 60 11 0 41 80 12 10 19 50 497 120 110 6610 5800 G177 R3L S3L XWL YWL 11 2
48. 34 stave s 70 tub URL 15 65 Iso 58 7 7 gallon Onions dry aaa Duebel 55 bushel Bag ctas mutent 17 X 32 50 Grate 20 5 x 11 5 x 10 5 58 crate Green with tops bushel 32 bushel Oranges Western box 11 5 x 11 5 x 24 80 Southern box 12 75 12 75 27 90 Bushel box 10 75 x 10 75 x 28 5 65 Oysters shucked or meats Crate with 5 1 gal cans 11 5 Ib per gal 18 x 127 24 67 With shells bags bushel 75 bushel Paint tead a en uma ebd mede etes 127 17 gallon Paper Average solid 58 1565 Cu yard Newspaper rolls 34 25 x 35 dia 500 roll ER 51 5 x 35 dia 1000 roll 9 64 25 x 35 dia 1300 roll Paraffin cu ee Fe er 56 1510 cu yard Parsley Bushel crate 12 75 x 12 75 x 17 30 SCC CEET bushel
49. AT CURB POSI TION 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 GROND LINE Normal rear axle center line HW CW REAR BODY 2 2 EN When rear wheels on one side ride over a high spot When all of rear wheels ride over a high spot 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 TIRE SECTION TIRE RADIUS TIRE LOADED RADIUS SEE TIRE CHART FOR VALUES TIRE CLEARANCE FORMULAS FOR CALCULATING REAR WIDTH AND HEIGHT DIMENSIONS CW CH DW EW HH JH KH KW LW lt TRACK lt TIRE LOADED RADIUS C lt TIRE LOADED RADIUS D TRACK 2 TIRE SECTIONS TIRE CLRARANCE TRACK 2 TIRE SECTIONS TIRE CLEARANCE TIRE LOADED RADIUS A KH B lt TIRE RADIUS 3 00 INCHES lt
50. B 24 Horn B 38 Exhaust brake Diesel Ignition Gas FUSE BOX Fuse Number Fuse Name Amps Circuit Protected F 23 ABS 1 15A ABS jus F 24 ABS2 10A ABS F 25 GAUGE BACK 10A ABS Back up Lights Diesel Brake Warning System Compressor Controls Engine Controls Exhaust Brake System Diesel Exterior Lights Starting System Transmission Controls Diesel RELAY BOX OUTSIDE Fuse Number Fuse Name Amps Circuit Protected 1 MAIN 80A Power distribution 2 KEY 50A Power distribution 3 ABS Gas 60A ABS Gas Engine controls Diesel GLOW Diesel 4 ABS Diesel 60A ABS 5 C HEATER Diesel 60A Ceramic heater F 21 Not used F 22 CONDENSER FAN Diesel 15A Condenser fan Relay Number Relay Relay Number Relay J 12 Starter J 16 Fuel pump Gas J 13 Glow 1 Diesel J 17 Condenser Diesel J 14 C Heater Diesel M T J 18 Exhaust brake control Diesel J 15 Warm cut 1 Diesel J 19 Engine warm cut 2 Diesel A T A C enable Gas J 20 1 0 light relay 14 April 2002 HD W3500 W4500 Gas Electrical AUXILIARY POWER SOURCE CIRCUIT DIAGRAM HOT IN ACC AND ON HOT AT ALL TIMES F 15 F 16 un CIGAR LIGHTER POWER SOURCE ES 20A RED YEL See Fuse m d Box Details Power source relay P N 8970609260 Must be installed in dash relay box Refer to page 13 relay B 34 for identification Cab Relay Power Source Relay RED BLU 1 AB 159 Service Termin
51. Brake fluid lines must not be cut and spliced under any circumstances We do not recommend the cutting or splicing of any fuel lines but if it is absolutely necessary be sure that the correct fitting and tools are used to form the joint and then pressure test the joint Steel lines are metric sizes Preparation of Additional Lines Where possible use only genuine Isuzu lines as supplied by authorized Isuzu dealers 2 Use the correct metric flaring and bending tools to form the lines 3 Avoid repeated bending Do not use heat for flaring and bending the lines Before and after forming the new lines examine them carefully for scratches distortion dents and the presence of any foreign matter 10 April 2002 Installation of 8 Special Equipment Installation of Additional Lines Install new lines away from adjacent parts and away from any sources of heat 1 A minimum clearance of 0 4 inch must be maintained between lines Where necessary clip the lines into position in order to maintain this minimum clearance Minimize any crossing between lines If a crossing is unavoidable use the following procedure a Atleast 0 4 inch clearance should be maintained between lines at the crossing point b Ifthe 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 lines to minimize vibration and the resulting fatigue Use rust proofed clips
52. Circuits Other Circuits April 2002 3500 4500 5500 Diesel Electrical 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 adul wire size and load capacity shown below are specificed by AWG American Wire Gauge Nominal size means approximate cross sectional area figure 24 4 3 Outside Diameter 4 Cross Sectional Area Figure 24 Wire Size Cross sectional area Allowable AWG size Nominal size mm Outside diameter mm current A cross reference 0 372 1 8 9 April 2002 5 HD NQR W3500 W4500 W5500 Diesel Electrical GROUNDING POINT LOCATION 1st Cross member LH Ft Spring 6 April 2002 HD NQR W3500 W4500 W5500 Diesel Electrical 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 Cable Harness Location Main Parts Load No Name harness Frame LH FRT Vehicle speed sensor Turn signal indicator light Meter High beam indicator light Body harness Headlight bracket LH Charge relay Exhaust brake relay ECM D R L unit Dome light Meter Brake fluid l
53. Fifth gear is direct Available Optional Transmission Aisin 450 43 LE 4 speed overdrive automatic transmission with lock up capability in 2nd 3rd and 4th and PTO capability STEERING Integral power steering 20 9 1 ratio Tilt and telescoping steering column FRONT AXLE Reverse Elliot I Beam rated at 6 830 Ib Suspension Semi elliptical steel alloy leaf springs with stabilizer bar and shock absorbers GAWR 4 700 Ib 5 360 Ib REAR AXLE Full floating single speed with hypoid gearing rated at 11 020 Ib Suspension Semi elliptical steel alloy leaf springs and shock absorbers GAWR 7 950 Ib 9 880 Ib WHEELS 16x6 0 6 hole disc wheels painted white TIRES 215 85R 16E 10 pr tubeless steel belted radials all season front and rear BRAKES 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 Anti lock brake system FUEL TANK 30 gal rectangular steel fuel tank mounted in frame rail behind rear axle Fuel water seperator mounted on rail FRAME Ladder type channel section straight frame rail 33 5 in wide through the total length of the f
54. Fuse Number Fuse Name Amps Circuit Protected F 23 ABS 1 15A ABS jus F 24 ABS2 10A ABS F 25 GAUGE BACK 10A ABS Back up Lights Diesel Brake Warning System Compressor Controls Engine Controls Exhaust Brake System Diesel Exterior Lights Starting System Transmission Controls Diesel RELAY BOX OUTSIDE Fuse Number Fuse Name Amps Circuit Protected 1 MAIN 80A Power distribution 2 KEY 50A Power distribution 3 ABS Gas 60A ABS Gas Engine controls Diesel GLOW Diesel 4 ABS Diesel 60A ABS 5 C HEATER Diesel 60A Ceramic heater F 21 Not used F 22 CONDENSER FAN Diesel 15A Condenser fan Relay Number Relay Relay Number Relay J 12 Starter J 16 Fuel pump Gas J 13 Glow 1 Diesel J 17 Condenser Diesel J 14 C Heater Diesel M T J 18 Exhaust brake control Diesel J 15 Warm cut 1 Diesel J 19 Engine warm cut 2 Diesel A T A C enable Gas J 20 1 0 light relay 14 April 2002 HD NQR W3500 W4500 W5500 Diesel Electrical AUXILIARY POWER SOURCE CIRCUIT DIAGRAM HOT AT ALL TIMES F 16 Box POWER SOURCE 20A See Fuse gt Box Details Power source relay P N 8970609260 Must be installed in dash relay box Refer to page 13 relay B 34 for identification REDIBLLU 1 AB 159 Service Terminal Auxillary power source wire located on left side underdash a en taped to body room light switch harness with green tape
55. OF THE REAR TIRES LW 1 00 INCH MINIMUM CLEARANCE BETWEEN TIRES AND HH REAR TIRE CLEARANCE SPRINGS MINIMUM CLEARANCE BETWEEN THE REAR AXLE AND THE GROND LINE NOTE TRACK AND OVERALL WIDTH MAY VARY HW DUAL TIRE SPACING WITH OPTIONAL EQUIPMENT DISTANCE BETWEEN THE CENTER LINES OF THE Unit Inch 12 April 2002 NQR W4500 W5500 Crew Cab Diesel SUSPENSION DEFLECTION CHARTS NPR HD W4500 April 2002 FRONT LEAF SPRING LOAD VS DEFLECTION PER AXLE S U S P E Ibs N 10 000 S 5 000 1 843 Ib in L 14 500 GVW D 0 1 2 3 4 5 VERTICAL SPRING DEFLECTION INCHES REAR LEAF SPRING LOAD VS DEFLECTION PER AXLE 15 000 6 935 Ib in 14 500 GVW zo ozmooco 5 000 K 1 926 Ib in 14 500 GVW 3 4 VERTICAL SPRING DEFLECTION INCHES 13 NQR W4500 W5500 Crew Cab Diesel SUSPENSION DEFLECTION CHARTS NQR W5500 FRONT LEAF SPRING LOAD VS DEFLECTION PER AXLE S U S P E Ibs N 10 000 S 5 000 1 848 bin L 17 950 GVW D 0 1 2 3 4 5 VERTICAL SPRING DEFLECTION INCHES REAR LEAF SPRING LOAD VS DEFLECTION PER AXLE 15 000 10 610 Ib in 17 950 GVW zo ozmuooco 2 5 000 2 669 Ib in 17 950 GVW 3 4 VERTICAL SPRING DEFLECTION INCHES 14 April 2002 NQR W4500 W5500 Crew Cab Diesel TIRE AND DISC WHEEL CHART NPR HD W4500 TIRE
56. Sot ee 44 Short leaf t tta eta tte tate ed lo tlt ut 38 Pineapples 36 Pitch Nr 70 Plums Western box 5 63 x 16 38 x 17 5 Pomegranates 6 5 x 12 x 24 63 Popcorn Ae ducat ted ped 1 Shelled r 27 150 Pork dressed Barrel 200 Ib net 18 head 29 stave Potatoes White or Irish zie tos ode etes 1 67 bushel z a oaa Susa s 17 13 head 28 5 stave BOX en 5 63 x 16 38 x 19 75 BOX 5 63 x 11 88 x 19 75 Radishes Bask6L c ee 9 75 x 13 75 x 24 Redwood ues ep 30 rrr HT LI TEN 68 Rhubarb pie plant bushel
57. Starter Circuit Instrument Circuit Charging Circuit Lighting Circuit Signal Circuits Other Circuits April 2002 HD W3500 W4500 Gas Electrical 512 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 specificed by AWG American Wire Gauge Nominal size means approximate cross sectional area figure 24 4 3 Outside Diameter 4 Cross Sectional Area Figure 24 Wire Size Cross sectional area Allowable AWG size Nominal size mm Outside diameter mm current A cross reference 0 372 1 8 9 April 2002 5 HD W3500 W4500 Gas Electrical GROUNDING POINT LOCATION April 2002 HD W3500 W4500 Gas Electrical 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 Cable Harness Location Main Parts Load No Name Frame LH FRT Turn signal indicator light Meter High beam indicator light Diagnostic connector Engine Harness Headlight bracket LH Charge relay Dome light switch Meter Meter Starter relay Inhibitor switch Lighti
58. 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 Governmenthas established the following formula to be used to determine the allowable weight limits and axle spacings for trucks W 500 LN 12N 36 N 1 Where W Thetotalgross weight that may be carried on any group of two or more consecutive axles to the nearest 500 Ib The distance spacing feet between the outer axles of any group of two or more consecutive axles N The number of axles in the group under consideration except that two consecutive sets oftandem 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 weightlimits on interstate highways and federal aid highways and reasonable access is 80 000 Ib 50 Single Axle Weight The total weight at the ground by all wheels of an axle whose centers may be included between parallel transverse planes forty inches apart extending across the width of the tru
59. W3500 DSL NPR HD W4500 DSL NPR W3500 DSL NPR HD W4500 DSL NPR W3500 DSL NPR HD W4500 DSL MODEL MANUAL AUTOMATIC TRANSMISSION NQR W5500 DSL NQR W5500 DSL NQR W5500 DSL NQR W5500 DSL BBC gt CE gt m CA gt 4 BOC M ll pc 1 s Q 5 BA med WB a AF OAL gt 2002 GAS amp 2003 DIESEL MODEL YEAR BODY amp PAYLOAD WEIGHT DISTRIBUTION FRONT REAR GVWR WB CA CE OAL BOC 10 12 14 16 12 000 109 88 4 131 5 199 5 9 25 18 82 7 93 14 050 109 88 4 131 5 199 5 9 25 18 82 7 93 12 000 132 5 111 9 155 223 9 25 14 86 14 050 132 5 111 9 155 223 9 25 14 86 12 000 150 129 4 172 5 2405 9 25 16 84 14 050 150 129 4 172 5 2405 9 25 16 84 12 000 176 155 4 198 5 266 3 9 25 14 050 176 155 4 198 5 266 3 9 25 GVWR WB CA CE OAL BOC 10 12 14 16 12 000 109 88 4 131 5 199 5 9 25 7 93 14 500 109 88 4 131 5 199 5 9 25 7 93 12 000 132 5 111 9 155 223 9 25 14 86 14 500 132 5 111 9 155 223 9 25 14 86 12 000 150 129 4 172 5 240 5 9 25 16 84 14 500 150 129 4 172 5 240 5 9 25 16 84 12 000 176 155 4 198 5 266 3 9 25 14 500 176 155 4 198 5 266 3 9 25 GVWR WB CA CE OAL BOC 10 12 14 16 17 950 109 88 4 131 5 199 5 9 25 7 93 17 950 132 5 111 9 155 223 9 25 14 86 17 950 150 129 4 172 5 2405 9 25 16 84 17 950 176 155 4 198 5 266 3 9 25 8 92 18 20 8 92 8 92 15 85 15 85 18 20 8 92 8 92 15 85 15 85 18 20 15 85 8 92 NPR NPR HD W3500 W4500 GAS and DIESEL 20 foot body requires Isuzu GM Application Enginee
60. WHEN REAR WHEELS ON ONE SIDE RIDE TIRE SECTION OVER A HIGH SPOT TIRE RADIUS CH DH DW EW HH 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 POSI TION 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 GROND LINE TIRE LOADED RADIUS SEE TIRE CHART FOR VALUES TIRE CLEARANCE FORMULAS FOR CALCULATING REAR WIDTH AND HEIGHT DIMENSIONS TRACK CH TIRE LOADED RADIUS C DH TIRE LOADED RADIUS D DW TRACK 2 TIRE SECTIONS TIRE CLRARANCE EW TRACK 2 TIRE SECTIONS TIRE CLEARANCE HH TIRE LOADED RADIUS A JH KH B KH TIRE RADIUS 3 00 INCHES KW DW 5 00 INCHES LW 1 00 INCH MINIMUM CLEARANCE BETWEEN TIRES AND SPRINGS NOTE TRACK AND OVERALL WIDTH MAY VARY WITH OPTIONAL EQUIPMENT Unit Inch E April 2002 NPR HD W3500 W4500 Diesel SUSPENSION DEFLECTION CHARTS April 2002 20 02 5 000 5 000 FRONT LEAF SPRING LOAD VS DEFLECTION PER AXLE
61. WT5500 MODEL FRR WT5500 GVWR GCWR 18 000 30 000 Ib 26 000 Ib with automatic 19 500 30 000 Ib 26 000 Ibs with automatic WB 148 in 167 in 179 in 191 in 218 in ENGINE Isuzu 6 oyl in line 4 cycle OHC turbocharged intercooled direct injection diesel Model Displacement 6HK1 TC 475 CID 7 8L HP Gross 200 HP 2 400 rpm Torque Gross 441 Ib ft torque 1 500 rpm Equipment 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 CLUTCH Single dry disc hydraulic actuation 14 in diameter cerametallic Spicer TRANSMISSION Optional Trans MLD 6Q Manual 6 Speed synchronized second through sixth sixth gear is overdrive Allison 1000 Series 5 Speed overdrive Automatic Transmission with lockup torque converter STEERING Integral power steering with variable ratio 18 8 16 1 1 FRONT AXLE Reverse Elliot l beam rated at 8 800 Ib Suspension Semi elliptical alloy steel leaf springs with stabilizer bar and shock absorbers GAWR 6 800 Ib 7 060 Ib REAR AXLE Full floating single speed with hypoid gearing rated at 14 330 Ib Ratio MT AT 4 11 1 4 33 1 Suspension Semi elliptical alloy steel leaf springs GAWR 13 000 Ib 13 680 Ib WHEELS 19 5 x 6 00 on 6 hole disc wheels pain
62. all chassis and wheelbases STEERING Integral power steering 20 9 1 ratio Tilt and telescoping steering column FRONT AXLE Reverse Elliot I Beam rated at 6 830 Ib Suspension Semi elliptical steel alloy leaf springs with stabilizer bar and shock absorbers GAWR 6 830 Ib REAR AXLE Full floating single speed with hypoid gearing rated at 14 550 Ib Suspension Semi elliptical steel alloy leaf springs and shock absorbers GAWR 12 980 Ib WHEELS 19 5x6 0 6 hole disc wheels painted white TIRES 225 70R 19 5F 12 pr tubeless steel belted radials highway tread front and rear BRAKES Dual circuit power 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 brake system FUEL TANK 30 gal rectangular steel fuel tank mounted in frame rail behind rear axle Fuel water separator mounted on rail FRAME Ladder type channel section straight frame rail 33 5 in wide through the total length of the frame Yield strength 44 000 psi section modulus 7 20 13 316 800 CAB All steel low cab forward BBC 68 0 in 45 mechanical tilt with torsion assist Equipment Jersey knit covered high back driver s seat with two occupant passenger seat Two way roof ventilator dual cab mounted exterior mirrors Tilt
63. amp CE are CA or CE less BOC Dimension Constants Code Inches Code Inches AH 8 6 BW 83 3 AW 65 6 CW 65 0 47 4 FW 33 5 BBC 68 0 OH 88 1 BOC 9 25 OW 78 5 FH 32 8 In Frame Tank 17 950 Ib GVWR Manual Transmission Model Chassis Cab and Maximum Payload Weights Model WB Unit Front Rear Total Payload NQ1 109 0in Ib 3704 2304 6008 11942 132 5in Ib 3748 2326 6074 11876 150 0in Ib 3781 2359 6140 11810 NQ4 176 0in 16 3825 2381 6206 11744 In Frame Tank 17 950 Ib GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights Model WB Unit Front Rear Total Payload NR1 109 0 in Ib 3737 2326 6063 11887 NR2 132 5 in Ib 3781 2348 6129 11821 150 0 Ib 3825 2370 6195 11755 NR4 176 0 in Ib 3869 2392 6261 11689 2 Model WB Unit Front Rear Total Payload NQ1 109 0 in Ib 3891 2039 5930 12020 NQ2 132 5 in Ib 3935 2061 5996 11954 NQ3 150 0 in Ib 3968 2094 6062 11888 NQ4 176 0 in Ib 4012 2116 6128 11822 Side Mounted Tank 17 950 Ib GVWR Automatic Transmission Model Chassis Cab and Maximum Payload Weights Model WB Unit Front Rear Total Payload NR1 109 0in Ib 3924 2061 5985 11965 NR2 1325 in 16 3968 2083 6051 11899 NR3 150 0 in Ib 4012 2105 6117 11833 NR4 176 0 in Ib 4056 2127 6183 11767 Vehicle Weight Limits GVWR Designed maximum 17 950 Ib GAWR Front 6 830 Ib GAWR Rear 12 980 Ib Technical Notes Chassis Curb Weight reflects standard equipment and fuel but no driver or payload Maximum Pay
64. are available depending on the option content of the vehicle And in some cases even when an air dryer moisture ejector has not been installed this circuit could have been used for factory installed special equipment options Therefore it is important to check the option content to each vehicle prior to making the body equipment wiring harnesses 10 April 2002 FRR FSR FTR amp FVR Electrical FSR FTR and FVR SERIES TAIL LIGHT CONNECTORS April 2002 11 FRR FSR FTR amp FVR Electrical FSR FTR FVR Series Tail Light Connectors Rear Chassis Harness and Tail Lamps eco Right Tail Stop and Turn Signal Lamp with Backup Lamp Rear Tail Light Harness s Left Tail Stop and Turn Signal Lamp with Backup Lamp Tail Stop and Turn Signal Lamp Left Tail Stop and Turn Signal Lamp Right Connector Part 12065862 Connector Part 12065862 Information ASM AE 280 BLK Information ASM AE 280 BLK Wire Circuit Color No EX Park Lamp Feed 1 Stop Turn Lamp Feed Right Rear ET A Park Lamp Feed B LT Green EX Left Rear 2 150 Joen 150 Ground 12 2002 FSR amp FVR Electrical FSR FTR FVR Series Wiring Diagram for exterior tail lights Exterior Lights Schematics Cell 110 Front and Rear Lighting IP Lights 1 25 LT BLU 136 1 25 YEL 134 1
65. axle to bottom of beam Centerline of axle to bottom inside of rail at curb position Centerline of axle to bottom inside of rail at design load H C Tire loaded radius D loaded radius Track Wheel offset at spindle Track at ground will vary with camber angle and tire wheel combination 12 April 2002 FSR 8 FVR 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 CHASSIS AND THE FORMULAS AND ILLUSTRATIONS FOR THE FRONT AXLE FRAME HEIGHT FDO 50 000 PSI STEEL FRAME FD5 80 000 PSI STEEL FRAME F03 110 000 PSI STEEL FRAME MODEL FRONTAXLE SUSPENSION FRAME STABILIZER LOWPRO DIMENSION CAPACITY CAPACITY 259 D F14 8100 TL 200 YES NO 7 32 8 03 6 26 NO NO 7 32 8 07 6 57 FD5 YES YES 7 28 6 89 5 12 YES NO 7 32 8 11 6 34 FSR FL1 8100 NO NO 7 32 8 15 6 65 F15 9000 TL 200 YES NO 7 32 807 6 57 NO NO 7 32 7 83 6 54 FD5 YES NO 7 32 8 15 6 65 NO NO 7 32 7 91 6 61 FK9 9000 200 7 32 7 64 6 42 205 7 32 7 72 6 50 F15 9000 TL FD5 YES NO 8 66 8 94 7 05 FTR NO NO 8 66 870 7 09 10 11 F03 YES NO 8 66 9 02 7 18 12 amp 13 FL2 11000 NO NO 8 66 8 78 7 17 FTR F26 12000 TL FD5 YES NO 8 6
66. between the hoses and the exhaust system Wiring harnesses and cables 3 9 in or more Steel fuel lines 3 1 in or more Rubber or vinyl fuel hoses 5 9 in or more 2 If a tool box is installed it should preferably be made from steel If a wooden tool box is installed at least 7 8 inches clearance should maintained between the tool box and any parts of the exhaust system 3 the exhaust system is modified it is the responsibility of those making the modification to ensure that the noise level meets appropriate standards Fuel System Relocation of the fuel tank or installation of additional fuel tanks is not recommended If modifications to the fuel system are unavoidable follow these recommendations 1 Maintain adequate clearance between the fuel tank and any other device or structure 2 Donoconnect an additional fuel hose Rear Lighting Brackets installed are temporary Please do not use these brackets for body installation Serviceability No matter what other modifications or changes are made access to components requiring daily preventive maintenance or other routine service must not be obstructed This includes 1 Inspection filling and draining of engine oil and cooling water 2 Inspection filling and draining of transmission fluid 14 April 2002 Installation of 8 Special Equipment Adjustment removal and installation of the fan belts Inspection filling and removal of the batter
67. cab mounted exterior mirrors Tilt and telescoping steering column Tinted glass ELECTRICAL 12 volt negative ground Delco maintenance free battery located under cab 600 CCA 80 Amp alternator with integral regulator OPTIONS Air conditioning AM FM cassette stereo radio spare wheel 6 stainless steel mirrors Power windows and Door Locks NOTE These selected specifications are subject to change without notice 2 April 2002 HD W3500 W4500 Gas VEHICLE WEIGHTS DIMENSIONS AND RATINGS CE BOC CA Dimension Constants 14 050 GVW Code BW CW FW OH OW FH Inches 84 0 65 0 33 5 88 1 78 5 32 8 14 050 Ib GVWR with 4L80 E Hydra Matic Transmission Chassis Cab and Maximum Payload Weights Front 3 230 3 274 3 296 AW AF OAL Variable Chassis Dimensions Unit WB CA CE OAL AF Code Inches Inch 109 0 88 4 131 5 199 5 43 1 8 6 Inch 132 5 111 9 155 0 223 0 43 1 65 6 Inch 150 0 129 4 172 5 240 5 43 1 47 4 Inch 176 0 155 4 198 5 266 3 43 1 68 0 Effective 8 CA CE less BOC 9 25 Dimension Constants 12 000 GVW Code Inches Code Inches d AU 79 BW 83 3 Model California Federal AW 65 6 Cw 65 0 47 4
68. case case case case case bushel crate crate 53 Weight Restrictions amp Specifications Lb Per Product Size Container Cu Ft Berries crate 24Ppint 9 75 x 9 97 x 20 24 quart 11 75 x 11 75 x 24 32 d 15 5 x 11 75 24 nenn Bluegrass seed bushel Bl eStOnes 120 SEN 115 nee 110 EE DUSNEL amate Le 2 25 x 4 8 25 COMMON 2 25 4 8 25 Hard lu 2 25 x 4 25 x 8 5 Klee DEE 2 38 x 4 8 38 Paving 2 25 ke Paving block 3 5 EE Ae eer Aer AN CM Bushel crate 12 75 x 12 75 x 17 Brussel sprouts Crate 7 75 x 10 5 x 21 38 Buckwheat Butter tub decidua d in 15 88 575 menden Standard echt 15 dia x 15 30 1 Ib bricks
69. constant GVWR Gross Vehicle Weight Rating r Loaded radius of tire Example NPR 12 000 GVWR manual transmission CET 260 Ib ft R 6 02 X 4 10 GVWR 12 000 Ib r 14 1 in 1200 X 260 X 0 9 X 0 9 X 6 02 X 4 10 Startability BE 1096 12 000 X 14 1 Startability 26 8696 April 2002 47 Weight Restrictions amp Specifications T 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 2 2 Equipment FH Frame Height 7 1 Wv X Vv Mv FLHT Floor Height 72 Wb X Vb Mb 7 3 X Vp Mp Ve CG Body 7 4 Mv Mb 7 5 VOg Wb We Definitions in formula VOg The total average vertical center of gravity of the completed vehicle vehicle body payload and equipment Wv Weight of Vehicle Wb Weight of Body Wp Weight of Payload We Weight of Equipment lt Distance from ground to center of gravity of the vehicle Vb Distance from ground to center of gravity of the body Vp lt Distance from ground to center of gravity of the payload Ve Distance from ground to center of gravity of the equi
70. d EY 45 Common windoW mua 0 25 plate eco Sana 80 reme 79 Western box 11 5 x 11 5 x 24 Southern box 12 757 12 15 liis 5 63 x 16 38 x 17 5 Western 15 5 dia x 14 5 12 BEC 95 125 d b shel ostro MISCHASSTr er ERES 30 Balearen 26 x 30 46 ee ats 17 3 22 KAS 52 teen APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS No of Lb Per box box gallon gallon gallon bushel crate case cu yard cu yard cu yard bushel crate crate M Bd ft M Bd ft bag M Bd ft barrel 1 2 barrel barrel gallon gallon cu yard yard cu yard gallon cu foot cu foot Sq foot cu yard gallon box box box box keg basket cu yard cu yard bushel cu yard bale bale bale April 2002 Weight Restrictions amp Specifications APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS Lb Per No of Product Size Co
71. exterior location view ET E L 3 E EC P April 2002 5 FRR FSR FTR amp FVR Electrical FSR FTR and FVR Series BODY BUILDER CONNECTOR CAB INTERIOR LOCATION VIEW DOG Dash Panel E Qi _ X gt 5 plug is attached ul 5 to the left hole of the Dash Panel center dash support Center Dash Support INTERIOR UP FITTER CONNECTOR Connector Part 6 Way Information Female Wire Circuit Color No Function Brown Exterior Lamps Fuse Output Battery Upfitter Connector Exterior Pin C Auxillary Connector Relay Center 2 Upfitter Connector Exterior Pin E EN Yellow Fuse Output Ignition Mating Male Connector Pin P N 894452 5650 6 April 2002 FRR FSR FTR 8 FVR Electrical FSR FTR FVR Series War Exterior Connector Location 1 Body Builder Connector 2 Body Clearance Light Connector Exterior Exterior Lights Schematics Cell 110 Tail Lamps Switch and Relay Upfitter Clearance Lamp Connector April 2002 7 FSR FTR amp FVR Electrical FSR FTR FVR Series Wiring Diagram for interior and exterior Body Builder Connector 1 2 BRN 317 D A w Upfitter Connector Interior 8 April 2002 FSR FTR FVR Series Engine Harness Transmission Harness FRR FSR FTR amp FVR Electrical
72. for transmission applications and approvals not listed above April 2002 N V Ratio rpm kMph rpm mph 24 38 38 62 24 38 38 62 24 38 38 62 24 38 38 62 24 38 38 62 FRR WT5500 Vocations One Way Rental School Bus General Purpose Refuse Vehicles On Highway Only Motorhome Transit Bus Transit Bus 15 FSR 8 FVR 5 CONDENSED MODEL SPECIFICATIONS 2 MODEL WEIGHTS t te eee at ide eda A 3 BODY PAYLOAD DISTRIBUTION 4 CHASSIS DEFINITION 5 GCW RATING FOR MAJOR COMPONENTS 6 CROSSMEMBER 8 FRAME REINFORCEMENT LOCATIONS AND FRAME RAIL 9 FULL TRUCK RQ2 FRAME RAIL 10 FRAME MATERIALS AND PHYSICAL PROPERTIES FRAME STRENGTH AND DIMENSIONS 0 11 FRONT AXLE TRACK 12 FRONT AXLE DIMENSION 13 REAR AXLE TRACK CHARTS a 14 REAR AXLE SUSPENSION DIMENSIONS ILLUSTRATION eene 15 REAR AXLE SUSPENSION 16 REAR AXLE TRACK 17 BATTERY BOX AND COMPONENT BOX DIMENSIONS AND LOCATION
73. harness can not be cut and spliced b only approved way to make the harness longer is to purchase the appropriate wheelbase harness from the Isuzu parts department c 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 fittings and steel lines AIR BRAKE SYSTEM 1 BEFORE WORK BEGINS a 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 front axle is changed the trim level of the ABS system must be readjusted per the instructions in the service manual An Authorized Isuzu dealer using the appropriate tools should do this reprogramming 3 ABS COMPUTER LOCATION a The ABS computer is located back of cab on the power steering bracket This component can not be relocated 15 ABS ELECTRICAL HARNESSES a The harness can not be cut and spliced b The only approved way to make the harness longer is to purchase the appropriate wheelbase harness from the Isuzu parts department c Extra wire resulting from a frame shortening can be coiled and secured to the frame 8 AIR BRAKE LINES a Air brake lines should be shortened or lengthened using appropriate fittings
74. in the East Coast call 1 404 257 3013 8 April 2002 NQR W4500 W5500 Crew Cab Diesel FRONT AXLE CHART NPR HD W4500 CH CURB POSITION DH TIRE DESIGN LOAD LOADED SS FORMULAS FOR CALCULATING HEIGHT DIMENSIONS 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 TIRE UNLOADED RADIUS DH D TIRE LOADED RADIUS Unit Inch TIRE GVWR GAWR c CH TRACK Unload Load April 2002 9 NQR W4500 W5500 Crew Cab Diesel FRONT AXLE CHART NQR W55000 CH CURB POSITION DH FORMULAS FOR CALCULATING HEIGHT DIMENSIONS 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 Radius TIRE GVWR GAWR CH TRACK EE 10 April 2002 HD NQR W4500 W5500 Crew Cab Diesel REAR AXLE CHART NPR HD W4500 2 50 MINIMUM TIRE CLEARANCE SECTION BETWEEN LW CS H BODY AND TIRES WHEEL OFFSET TIRE CLEARANCE IO T TIRE RADIUS 1 LOADED 5 RADIUS 7 2 REAR BODY 2 5 E 7 ECH HI 1 7 dg Z lt OS AND D Z 1 1 I CH p
75. inches 80 remove 8 inches NOTE Shorten Hose at A Area only Through the Rail Fuel Fill 1 34 Frame Hole End of Frame April 2002 17 NQR W5500 Diesel NQR DIESEL Fuel Fill Parts List KI d IR pa 1 man ___ __ 1 CLIP RUBBER HOSE 242 0240 2 3 MHOSEFUELFILLER 8971978750 sees 4 HOSEFUELFILER 897263 1400 972580 5 6944356760 97224873 6 SCREW FILLERHOSE 8948826060 3 7 BRACKELFILLERNECK 897116 62iY 1 8 eene se _ 76 smomems 1 10 CLIP 109707 1070 94062296 2 11 CAUTION PLATE 894414 3530 94414353 1 18 April 2002 NQR W4500 W5500 Crew Cab Diesel MODEL NPR HD Diesel W4500 Crew Cab GVWR 14 500 Ib WB 150 in 176 in ENGINE Isuzu 4 cylinder in line 4 cycle turbocharged intercooled direct injection diesel Model Displacement HP Gross Torque Gross 4 1 290 4 75 liters 175 HP 2700 RPM 347 Ib ft torque 2000 RPM Equipment Dry element air cleaner with vertical intake 2 rows 506 in radiator 6 blade 18 7 in diameter fan with viscous drive Cold weather starting device and an oil cooler Engine warning alarm for high wat
76. of the body and check for leaks Ensure that fill hose does not sag creating an area where the fuel could pool in the fill hose Reconnect battery April 2002 23 NQR W4500 W5500 Crew Cab Diesel Rear View Fuel Fill Dimension A 6 85 8 50 174 216mm Top View Fuel Fill Dimensions 29 75 in 756mm C 34 00 in 863mm D 39 29 in 998mm 30 86 in 784mm 56 6 in 1438mm 24 April 2002 NQR W4500 W5500 Crew Cab Diesel Hose Modification for Various Width Bodies 96 remove 0 inches 4 90 remove 3 inches 86 remove 5 inches 80 remove 8 inches NOTE Shorten Hose at A Area only Through the Rail Fuel Fill 4 34 Frame Hole End of Frame April 2002 25 NQR W4500 W5500 Crew Cab Diesel Fuel Fill Parts List 2 25 1 gu gegen 10 27 net Ie WW 897206 0420 art CLIP RUBBER HOSE 894242 0340 94242034 E HOSE FUEL FILLER 897187 8750 97187875 KS HOSE FUEL FILLER 897253 1400 97253140 5 CL FILLER HOSE 8944358760 977489 7 BRACKET FILLERNECK 897116 62iY 1 ore _ EE CLIP 109707 1070 94062296 11 CAUTION PLATE 894414 3530 94414353 26 April 2002 FRR
77. 0R 22 5 G 14 PLY 265 75R 22 5 G 14 PLY N A 275 80R 22 5 G 14 PLY N A 2 gt 295 75R 22 5 G 14 PLY AVAIL LYVHO 384 3 414 USS 9c MICHELINTIRES R4L S4L TREAD DESIGN H3C S3C XTN YTN MINIMUM DUAL SPACING DIMENSIONS NO LOAD LOADED MAXPRESSURE MAX LOAD PERTIRE SINGLE 85 SINGLE H3C S3C XTY YTY 245 70819 5 H3C S3C XTB YTB 255 70R22 5 H3C S3C XWL YWL 11R22 5 H3C S3C XWM YWM 11R22 5 R3C S3C XSH YSH 275 80R22 5 S3D YRL 235 80R22 5 S3D YSB 255 80R22 5 S3D YSH 275 80R22 5 S3D YWL 11R22 5 S3D 255 70822 5 530 YTN 225 70819 5 530 245 70819 5 531 YWL 11R22 5 531 YWM 11R22 5 S3H 11R22 5 93H 275 80822 5 GA 11R22 5 GA 11R22 5 93J 10R22 5 93J 275 80R22 5 R8K S3K 11R22 5 R8K S3K 11R22 5 838 538 10R22 5 838 538 11R22 5 R3B S3B 11R22 5 R3B S3B 245 70819 5 R3B S3B 245 70R19 5 R3B S3B XSH YSH 275 80R22 5 NOISNAWIG 38LLNIT3HOINW 414 USS 2002 44
78. 179 5189 2381 7570 10430 CW 65 4 SF4 191 Ib 5178 2481 7659 10341 FW 33 0 SF5 218 in Ib 5277 2525 7802 10198 OH 103 5 105 5 OW 86 3 Truck Weight Limits Unit FH 35 3 GVWR Designed Max Ib 18 000 19 500 FH 191 and 218 WB 37 3 GAWR Front Ib 6 800 7 060 GAWR Rear Ib 13 000 13 680 Chassis Curb amp Maximum Payload Weights 19 500 GVW Technical Notes With 6 Speed Manual Transmission Chassis Curb Weight reflects standard environment and Model WB Unit Front Rear Total Payload fuel but no driver or load SA1 148 in Ib 5027 2448 7475 12025 SA2 167 in Ib 5116 2414 7530 11970 Maximum Payload Weight is the allowed maximum for RAE i in e 2 SC 23 nn equipment body payload and driver and is calculated by in SAS 8110 Ib 5270 0847 7817 11683 subtracting chassis curb weight from the GVWR Frame is tapered at the rear of the 148 167 and 179 WB but straight on the 191 and 218 WB 2 April 2002 FRR WT5500 FRAME amp CROSSMEMBER SPECIFICATIONS 191 amp 218 in Wheelbase Unit Inch 145 27 April 2002 3 FRR WT5500 FRAME CHART FRAME FL Taper on 148 8 4 167 WB ONLY 2 36 2 76 2 76 2 36
79. 2 5 R3B S3B XWP YWP 12R22 5 H3B S3B XTQ YTQ 245 75R22 5 H3B S3B XTU YTU 265 75822 5 H3C S3C 295 75822 5 S3C YRV 285 75824 5 H3C S3C XWL YWL 11R22 5 14 NOISN3MWIQ 38 154901 8 3 414 us FSR 8 FVR STEEL ALUMINUM DISC WHEEL SPECIFICATIONS RPOOPTION OFFSET DISC RATING FRONT REAR THICKNESS LBS PSI 19 5 X 6 75 ACCURIDE 275 5000 115 22 5 X 7 50 ACCURIDE 285 75 MM 6200 120 22 5 X 8 25 ACCURIDE 285 75 MM 7300 120 19 5 X 6 75 ALCOA 275 MM 5500 120 22 5 X 8 25 ACCURIDE 285 75 MM 7300 120 30 April 2002 HD W3500 W4500 Gas Electrical HD W3500 W4500 Gas Electrical Symbol Symbol Meaning magnetic valve Switch Normal close type 9 o Battery f Electronic parts Light emitting diode p qwe DNE e xj en RE Circuit breaker Vacuum switching valve 2 April 2002 HD W3500 W4500 Gas Electrical ABBREVIATIONS Abbreviation Meaning of Abbreviation Abbreviation Meaning of Abbreviation Ampere S kilowatt Anti lock brake system Left hand Assemlby Long wheel base Alternating current Manual transmission Air Conditioner Over drive Accessories Option Automatic transmission Quick on start
80. 2 5 514 12 50 10 90 42 30 12 00 19 70 493 105 115 6040 5250 8177 R3L SSL XWM YWM 11822 5 H 16 12 50 10 90 42 30 12 00 19 70 493 120 110 6610 5800 NOISNAWIG 3Hl LHV3AqO09 3 414 us 8c GENERALTIRES 4 54 TREAD DESIGN AMERI STEELA R3B S3B XWL YWL 11R22 5 MINIMUM DUAL SPACING DIMENSIONS NO LOAD LOADED WIDTH DIA WIDTH SLR MAX PRESSURE MAX LOAD PERTIRE DUAL SINGLE AMERI STEELA R3B S3B XWJ YWJ 10R22 5 AMERI S380 H3C XRN 295 75822 5 AMERI S380 H3C S3C XWL YWL 11R22 5 AMERI LUG B S3D YWJ 10R22 5 AMERI MSL RADIAL H R3K S3K XWM YWM 11R22 5 NOISNAWIG JHI 1TVd3N39 414 us 2002 6c BRIDGESTONETIRES R4N S4N TREAD DESIGN TREAD CODE R3C S3C XTB YTB 255 70822 5 DUAL SPACING DIMENSIONS NO LOAD LOADED MAX PRESSURE MAX LOAD PERTIRE WIDTH DIA WIDTH SLR SINGLE DUAL SINGLE DUAL S3D YWL 11R22 5 530 295 75822 5 GA YTU 265 75822 5 GA YRN 295 75R22 5 H3M S3M XTY YTY 245 70R19 5 R3K S3K XWK YWK 10R22 5 H3B S3B XRN YRN 295 75822 5 H3B S3B XWJ YWJ 10R22 5 H3B S3B XWL YWL 11R2
81. 2002 15 FSR 8 FVR AXLE FORMULAS Definitions Centerline of axle to bottom of axle bowl B Centerline of axle to bottom inside rail at inf bump C Centerline of axle to bottom inside rail at curb pos D Centerline of axle to bottom inside rail at design load CH Rear Frame Height Distance between the bottom inside rail and the ground line through the vertical centerline of the rear axle at curb position DH Rear Frame Height Distance between the bottom inside rail and the ground line through the vertical centerline of the rear axle at design position HH Rear Axle Clearance Minimum clearance between the rear axle and the ground line JH 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 KH Chain Clearance LH Distance from the bottom inside rail to the top of rail CW Track Dual Wheel Vehicles Distance between the centerlines of the dual wheels as measured at the ground line DW Minimum distance between the inner surfaces of the rear tires EW Maximum Rear Width Over all width of vehicle measured at the outer most surface of the rear tires HW Dual Tire Spacing Distance between the centerlines of the tires in a set of dual tires KW Rear Body Width Maximum body width between rear tires See Tire Chart for values Tire Selection Tire Radius Tire Loaded Radius and Tire Clearance Formulas f
82. 25 135 40 C202 19 C200 20 C200 P100 0 8 LT BLU 17 0 8 BLU 18 3462 13 101 18 1YEL B JA Stop 3 AE Tun And S BLK ORN 160 Lamp RH April 2002 13 FSR FTR amp FVR Electrical FSR FTR and FVR SERIES BODY ROOM LIGHT DIAGRAMS 14 April 2002 FSR amp FVR Electrical FSR FTR and FVR chassis are equipped with a body room light switch mounted in the dash The body room light switch is located on the dash near the side window to the left of the fast idle switch This switch controls a relay illustration B that will allow current to flow the body room light The power wire from the relay runs down from the relay to cab frame connector box illustration C The body room light wiring should be connected to terminal number 36 Rear Body Light Switch Wiring Diagram CIRCUIT BREAKER 12 Alternate wiring to send power for Body Room light 35 to back of Cab Body Builder ES connector Attach jumper between the number 36 pin of the 202 connector and the number 51 pin of the 200 connector this will connect the body room light switch to body builders connector at the rear of the cab position April 2002 15 FSR FTR amp FVR Electrical Illustration B Legend 1 Engine Stop Relay 2 gnition amp 3 Relay 3 Ignition 2 Relay 4 Blower Relay 5 Ignition 41 Relay 6 Compressor Relay 7 Condenser Fan Relay 8 Accessory R
83. 25 0 985 6218 20 2 avd M 1 23543 18 85 9315 401 6 08 N 8 ELE 01 Boos d SC A KW se 8 21 29 227 1718 0 0902 291 0 0217 ML E LL 3 XV LNOYS 0 01 0 61 2 Ye sx I 8 0 96 8 20 989 r Orb 0 0E22 04407 6 76 OOvC 3391H34 TOP DIMENSION IS MM BOTTOM DIMENSION IS INCHES 23 April 2002 FSR 8 FVR CAB INTERIOR DIMENSIONS 3ONY J WO1L0E 3O0ISNI 33v SNO I SN3N10 1 LNOMJ SONY 05401 woow O L l O SE 1 10 dIH 583150 14 104 3A IS SI 0 0 fy 22 9 04S 93153315 3 089 37121H3A4 SO Y 1 1 TOP DIMENSION IS BOTTOM DIMENSION IS INCHES April 2002 24 2002 TIRE BRAND MICHELIN TIRES FRONT MICHELIN TIRES REAR TIRESIZE 10822 5 12 PLY N A 11R22 5 G 14 PLY AVAIL 11R22 5 H 16 PLY AVAIL 225 70R 19 5 12 PLY N A 245 70R 19 5 F 12 PLY N A 245 70R 19 5 G 14 PLY N A 235 80R 22 5 G 14 PLY N A 245 75R 22 5 G 14 PLY N A 255 70R 22 5 H 16 PLY N A N A 255 8
84. 3500 ML lt 28 2 lt lt lt lt lt 2 lt lt 2 DIMENSION IN INCHES REAR FRAME HEIGHT UNLOADED lt TIRE RADIUS C DIMENSION FRAME DIMENSION REAR FRAME HEIGHT LOADED LOADED TIRE RADIUS D DIMENSION FRAME DIMENSIONS April 2002 17 FSR 8 FVR 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 REAR AXLE SUSPENSION FRAME SHOCKABSORBER STABILIZER AUXSPRING DIMENSION CAPACITY CAPACITY RPO G68 RPOGNI 060 23000 TL 22000 LB 23500 ML 23000 TL 23000 LB 23500 ML 2 lt lt 2 REAR FRAME HEIGHT UNLOADED TIRE RADIUS C DIMENSION FRAME DIMENSION REAR FRAME HEIGHT LOADED LOADED TIRE RADIUS D DIMENSION FRAME DIMENSIONS FDO 50 000 PSI STEEL FRAME FD5 80 000 PSI STEEL FRAME 203 110 000 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 REARAXLE DIMENSION CAPACITY LBS SPEED BRAKES SINGLE HYD SINGLE HYD SINGLE HYD TWO HYD AIR SINGLE HYD AIR SINGLE HYD AIR SINGLE HYD AIR TWO HYD AIR SINGLE HYD AIR TWO HYD AIR TWO AIR SINGLE AIR SINGLE AIR TWO AIR SINGLE AIR
85. 3500 W4500 Gas FRONT AXLE CHART CH CURB POSITION DH FORMULAS FOR CALCULATING HEIGHT DIMENSIONS A TIRE LOADED RADIUS B C CENTERLINE OF AXLE TOP OF FRAME RAIL AT CURB POSITION D CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD CH TIRE UNLOADED RADIUS DH D TIRE LOADED RADIUS Unit Inch Tire Radius Radius TIRE TRACK 215 85R 16 11 050 Ib 4 700 Ib 225 70R 19 5 14 050 Ib 5 360 Ib 8 April 2002 HD W3500 W4500 REAR AXLE CHART 2 50 MINIMUM TIRE CLEARANCE SECTION BETWEEN LW TBODYANDTIRRES WHEEL OFFSET TIRE CLEARANCE TIRE RADIUS TIRE XLLD m RADIUS DW 2 2 2 7 7 REAR BODY 7 7 Aa 72 2 2 rw E 2 d 7 B C AND D B f LLL IL E CH leone d EET DH al of rear wheels bids te DEFINITIONS ride over a high spot A CENTER LINE OF AXLE TO BOTTOM OF AXLE BOWL KH BOUNCE B CENTER LINE OF AXLE TO TOP OF FRAME RAIL MINIMUM DISTANCE REQUIRED FOR TIRE BOUNCE AS METAL TO METAL POSITION MEASURED FROM THE CENTER LINE OF THE REAR C CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT CURB AXLE AND THE TOP OF THE REAR TIRE WHEN ONE POSITION WHEEL RIDES OVER A HIGH SPOT D CENTER OF AXLE TO TOP
86. 4 431 2 282 6 713 11 237 VEHICLE WEIGHT LIMITS NPR HD W4500 5500 GVWR Designed maximum 14 500 Ib 17 950 Ib GAWR Front 5 360 Ib 6 830 Ib GAWR Rear 9 880 Ib 12 980 Ib Technical Notes Chassis curb weight includes standard equipment and fuel Does not include driver passenger payload body or special equipment Maximum payload weight is the allowed maximum for equipment body payload driver and passengers and is calculated by subtracting chassis curb weight from the GVWR April 2002 NQR W4500 W5500 Crew Cab Diesel FRAME amp CROSSMEMBER SPECIFICATIONS ERR Unit Inch Unit Inch CROSS MEMBER TYPE LOCATION M T Manual Transmission A T Automatic Transmission 4 April 2002 NQR W4500 W5500 Crew Cab Diesel FRAME CHART FRAME FL Front Axle Center B 2 8 1 2 4 4111 QJ d e m Y e cu 6 4 8 5 6 9 018 pm SECTI A A e m 4 2 SECTION C C Unit Inch FRAME FRAME FL 0 24 0 18 0 24 0 18 On this model chassis GMICT will require that the body installed on the chassis have an understructure manufactured with
87. 6 9 29 6 69 10 11 12 NO NO 8 66 9 02 7 13 13 20 21 F03 YES NO 8 66 9 37 6 77 22 amp 23 NO NO 8 66 9 09 7 20 FTR F26 12000 TL FD5 YES NO 8 66 9 61 6 69 10 11 12 NO NO 8 66 941 728 13 20 21 F03 YES NO 8 66 9 69 6 77 22 amp 23 FS7 12000 NO NO 8 66 949 7 36 FTR 14600 TL FD5 YES NO 8 66 9 80 7 68 20 21 22 NO NO 8 66 9 37 7 56 amp 23 F03 YES NO 8 66 9 88 7 76 NO NO 8 66 945 7 64 F26 12000 TL FD5 YES NO 8 66 929 6 69 NO NO 8 66 9 02 7 13 FL2 11000 F03 YES NO 8 66 9 37 6 77 NO NO 8 66 9 09 7 20 F26 12000 TL FD5 YES NO 8 66 961 6 69 NO NO 8 66 941 728 F03 YES NO 8 66 9 69 6 77 FVR FS7 12000 NO NO 8 66 9 80 7 36 14600 TL FD5 YES NO 8 66 9 80 7 68 NO NO 8 66 9 37 7 56 F03 YES NO 8 66 9 88 7 76 NO NO 8 66 945 7 64 DIMENSIONS IN INCHES FRONT FRAME HEIGHT UNLOADED TIRE RADIUS C DIMENSION FRAME DIMENSION FRONT FRAME HEIGHT LOADED LOADED TIRE RADIUS D DIMENSION FRAME DIMENSION April 2002 13 FSR 8 FVR REAR AXLETRACK CHART FSR 10 11 AXLE 08 10 HWY CAPACITY 15000 LBS 15000 LBS 16900 LBS WHEELTYPE WHEEL BRAKES BRAKES BRAKES RPO SIZE OFFSET HYDRAULIC HYDRAULIC HYDRAULIC STEEL DISK WHEEL 8 HOLE HUB PILOTED Q83 19 5X6 75 5 6 72 30 72 30 ALUMINUM DISK WHEEL 8 HOLE HUB PILOTED RPW 19 5X6 75 6 5 72 18 72 18 STEEL DISK WHEEL 10 HOLE HUB P
88. 60 1620 NA2 132 5 in Ib 3704 1642 150 0 Ib 3748 1664 4 176 0 Ib 3792 1687 Side Mounted Tank 14 500 Ib GVWR Manual Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear NE1 109 0 in Ib 3671 1620 NE2 132 5 in Ib 3715 1642 150 0 Ib 3759 1664 4 176 0 Ib 3803 1687 Side Mounted Tank 12 000 Ib GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear NB1 109 0 in Ib 3726 1664 NB2 132 5 in Ib 3770 1687 NB3 150 0 in Ib 3814 1709 4 176 0 Ib 3858 1731 Side Mounted Tank 14 500 Ib GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear NF1 109 0 in Ib 3737 1664 NF2 132 5 in Ib 3781 1687 NF3 150 0 in Ib 3825 1709 NF4 176 0 in Ib 3869 1731 Vehicle Weight Limits GVWR Designed maximum 12 000 Ib GAWR Front 4 700 Ib GAWR Rear 7 950 Ib Technical Notes Total Payload 5280 6720 5346 6654 5412 6588 5479 6521 Total Payload 5291 9209 5357 9143 5423 9077 5490 9010 Total Payload 5390 6610 5457 6543 5523 6477 5589 6411 Total gt Payload 5401 9099 5468 9032 5534 8966 5600 8900 14 500 Ib 5 360 Ib 9 880 Ib 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 April 2002
89. 6HK1 TC HORSEPOWER 230 HP 230 HP TRANSMISSION MLD6Q MLD6Q FRONT AXLE CAP 11000 11000 FRONT SUSPENSION CAP 12000 12000 REAR AXLE CAP 22000 22000 REAR SUSPENSION CAP 23500 23500 REAR AXLE RATIO 5 57 5 57 TIRES 11R22 5G 11R22 5G BRAKES AIR AIR FRAME MAT 80000 PSI 80000 PSI FUEL CAPACITY 50 100 ALTERNATOR 110 AMP 110 AMP April 2002 FSR 8 FVR BASE MODEL WEIGHTS AND FRAME HEIGHTS TOTAL FRAME CHASSIS HEIGHT FRAME WEIGHT WEIGHT WEIGHT UNLOADED HEIGHT MODEL LB ED IN LB LB IN LOAD EE EE DEE E EE j i BASE MODEL WEIGHTS INCLUDE 15 GALLONS OF FUEL April 2002 3 FSR 8 FVR 86 BBC ISUZU FSR 8 FVR BODY PAYLOAD WEIGHT DISTRIBUTION Dimensions shown are nominal and with standard equipment BODY PAYLOAD WEIGHT DISTRIBUTION Front Rear DIMENSIONS INBODY LENGTHS FT 140 FQT 158 EG5 170 EH8 188 EK8 200 EM2 218 FPL 233 EQ8 248 ES5 CA CB 1 2 x Body Length WB percent body and payload weight at front axle Dimensions shown are nominal Percentages allow for 3 CB cab body clearance 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 Effective length in which fron
90. 860 8840 225 70R 19 5 3315 TIRE SIZE 215 85R 16 E 85 3115 TIRE RADIUS UNLOADED LOADED 85 6630 TIRE SECTION WIDTH 12460 Unit Inch DESIGN RIM WIDTH TIRE CLEAR ANCE 225 70R 19 5 DISC WHEEL FT RR NUT SIZE 1 6142 41mm BUD HEX REAR STUD SIZE 0 8268 21mm SQUARE NUT STUD TORQUE SPECS 289 ft Ib 892 N M INNER CIRCLE OUTSIDE OFFSET Unit Inch MATERIAL MFG 1 6142 41mm BUD HEX O D Wrench Sizes 0 8268 21mm SQUARE 325 ft lb 440 N M TIRE SECTION _ WIDTH TIRE CLEARANCE ce i E J Eur EI RIM OFFSET REFER TO DISC WHEEL SHOWN AT RIGHT G of DISC WHEEL 12 OFFSET of DISC WHEEL April 2002 HD W3500 W4500 PROPELLER SHAFT WB PLANE VIEW SIDE VIEW 1 Wo ice 11 06 i A B T 71 D 132 5 in 17 Jr es L VE I A B T 150 in T JL 176in B 1 0 4 D 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 132 5 in 150 in and 176 in WB 1 2 2 2 2 1 m Wn TRANSMISSION TRANSMISSION 8 1 UNIVERSAL JOINT 2 PROP
91. AL REAR WHEEL VEHICLES DISTANCE BETWEEN THE CENTER LINES OF THE DUAL WHEELS MEASURED AT THE GROUND LINE CW TIRE RADIUS TIRE LOADED RADIUS TIRE CLEARANCE SEE TIRE CHART FOR VALUES FORMULAS FOR CALCULATING REAR WIDTH AND HEIGHT DIMENSIONS TRACK CH TIRE LOADED RADIUS C DH TIRE LOADED RADIUS D DW TRACK 2 TIRE SECTIONS TIRE CLRARANCE EW TRACK 2 TIRE SECTIONS TIRE CLEARANCE HH TIRE LOADED RADIUS A JH KH B KH TIRE RADIUS 3 00 INCHES KW DW 5 00 INCHES LW 1 00 INCH MINIMUM CLEARANCE BETWEEN TIRES AND SPRINGS NOTE TRACK AND OVERALL WIDTH MAY VARY WITH OPTIONAL EQUIPMENT Unit Inch E April 2002 11 NQR W4500 W5500 Crew Cab Diesel REAR AXLE CHART NQR W5500 2 50 MINIMUM TIRE CLEARANCE SECTION BETWEEN LW WHEEL OFFSET KW TIRE CLEARANCE Claes _ L _ TIRE N RADIUS Hae AN TIRE d LOADED bd rd p RADIUS DW bea CW E 2 7 1 lt 2 1 2 7 4L Normal rear E N axle center sal line N VA E p When rear wheels on When all of wheels side ride over a high spot DEFINITIONS ride over a high spot A CENTER LINE OF AXLE TO BOTTOM OF AXLE BOWL MINIMUM DISTANCE REQUIRED FOR TIRE B
92. CHASSIS FRAME MODIFICATION WITH ANTILOCK BRAKES ON PAGES 27 AND 28 Working on 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 distribution If even distribution of load is not keptin mind when the equipmentis installed localization of stresses on specific areas of the frame could cause cracking of the chassis frame members or other problems even if the total weight of the equipment is within the design limit The chassis frame is designed as an integral unit Therefore we do not recommend cutting the chassis frame under any circumstances Drilling and Welding IMRORTANENOTE For vehicles equipped with electronic or hydra matic transmissions electric arc welding must be done with the negative battery cable disconnected 1 Do not drill or weld in the shaded portions of the chassis frame members Do not weld with 0 8 inch from th edges of any existing holes 2 Hold the length of any welding beads within 1 2 2 0 inch Allow at least 1 6 inch between adjacent welding beads 3 All holes must be drilled Do not use torch to make any holes 4 riveting must be done with cold rivets Do not use hot rivets 5 The flange of the chassis frame must not be cut under any circumstances 6 The subframe must be attached t
93. CS 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 Installation of amp Special Equipment Installation of amp Special Equipment Clearances Engine At least 1 6 inch clearance should be maintained around the engine No obstacles should be added in front of the radiator or intercooler 1 6 Inch 4 Clearance 1 6 Clearance 1 6 Inch Clearance 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 5 6 Inch Clearance Engine gt lo o lo
94. D Wrench Sizes TIRE SECTION _ WIDTH y TIRE CLEARANCE a Ze N ER N VA OFFSET REFER TO DISC WHEEL SHOWN AT RIGHT G of DISC WHEEL 10 OFFSET of DISC WHEEL April 2002 PROPELLER SHAFT PLANE VIEW NQR W5500 Diesel SIDE VIEW 132 5 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 109 in WB d TRANSMISSION 1 UNIVERSAL JOINT 2 PROPELLER SHAFT 3 CENTER CARRIER BEARING PLANE VIEW WHEEL BASE 109 in 132 5 in 150 and 176 in WB TRANSMISSION SIDE VIEW 132 5 in 150 176 in 2002 Manual Transmission Automatic Transmission NOTE ALL DRIVELINE ANGLES ARE AT UNLOADED CONDITION CURB POSITION WITH TYPICAL CARGO BODY 11 NQR W5500 Diesel PROPELLER SHAFT CONTINUED 10 1325 150 176 No of Shafts sss Trans Type orl Ar owt ewr Length 537 C Length 52 6 Oj j oS UNIT 1 shaft in 2 piece driveline Type B 15 shaft in 1 piece driveline 274 shaft in 2 piece driveline Type D Figure 2 5 NQR W Series Diesel Propeller Shaft Manual T
95. E MEANS THAT THE YOKES AT EITHER END OF A GIVEN PROPELLER SHAFT ASSEMBLY ARE IN THE SAME PLANE 109 in WB 132 5 in 150 and 176 in WB TRANSMISSION TRANSMISSION 1 UNIVERSAL JOINT 2 PROPELLER SHAFT 3 CENTER CARRIER BEARING PLANE VIEW SIDE VIEW WHEEL BASE 109 in 132 5 in 150 176 in Manual Transmission Automatic Transmission NOTE ALL DRIVELINE ANGLES ARE AT UNLOADED CONDITION CURB POSITION WITH TYPICAL CARGO BODY April 2002 11 NPR HD W3500 W4500 Diesel PROPELLER SHAFT CONTINUED cse n f Tran er swr Length Type 15 shaft in 2 piece driveline 1 shaft in 1 piece driveline 274 shaft in 2 piece driveline Manual Transmission Automatic Transmission 12 April 2002 HD W3500 W4500 Diesel PTO LOCATION DRIVE GEAR AND OPENING INFORMATION Manual Transmission Chassis Top of Frame i Center of Main Shaft Counter Shaft G of Front Axle Automatic Transmission Chassis Top of Frame KH 3 EO Opening Diagram TH B To Front Axle Unit Inch Ratio of PTO Opening Bolt PTO Drive Gear Spd Number Transmission Location Pattern Gear Location to Eng Sp
96. E 51 PIOOf SPINS 57 bushel 165 basket bushel Western box 11 5 12 20 New England box 11 25 x14 5 x17 5 Standard barrel 17 hd 28 5 stave DIled usnu a ar Minen Duebel tes ICSI bushel Western box 5 5 2 BOX nuit o Et 10 x11 5 x22 153 EEE E A let 11 5 high x 9 57 top BUNCHES 11 bottom x 19 38 long tete deen ctt 5 75 x11 25 x17 5 Single DUNC ittm 280 ROCK 185 White Peso beet bete ant bushel intet lu bushel EU bushel
97. EAR NUT SIZE STUD SIZE 1 6142 41 mm BUD HEX 325 ft Ib 440 O D Wrench Sizes RIM OFFSET REFER TO DISC WHEEL SHOWN AT RIGHT G of DISC WHEEL 16 INNER CIRCLE Unit Inch OUTSIDE OFFSET MATERIAL MFG 15 DC OFFSET of DISC WHEEL April 2002 NQR W4500 W5500 Crew Cab Diesel PROPELLER SHAFT NPR HD W4500 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 150 and 176 in WB TRANSMISSION 1 UNIVERSAL JOINT 2 PROPELLER SHAFT 3 CENTER CARRIER BEARING PLANE VIEW SIDE VIEW WHEEL BASE Automatic Transmission NOTE ALL DRIVELINE ANGLES ARE AT UNLOADED CONDITION CURB POSITION WITH TYPICAL CARGO BODY April 2002 17 NQR W4500 W5500 Crew Cab Diesel PROPELLER SHAFT NQR W5500 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 150 and 176 in WB Z er TRANSMISSION 3 1 1 UNIVERSAL JOINT 2 PROPELLER SHAFT 3 CENTER CARRIER BEARING PLANE VIEW SIDE VIEW WHEEL BASE Automatic Transmission NOTE ALL DRIVELINE ANGLES ARE AT UNLOADED CONDITION CURB POSITION
98. ELLER SHAFT 3 CENTER CARRIER BEARING PLANE VIEW SIDE VIEW WHEEL BASE 109 in 132 5 in 150 176 in Automatic Transmission NOTE ALL DRIVELINE ANGLES ARE AT UNLOADED CONDITION CURB POSITION WITH TYPICAL CARGO BODY April 2002 13 HD W3500 W4500 Gas PROPELLER SHAFT CONTINUED UNIT INCH 1 9 Shaft 1 0 0 Thickness Length Type Figure 1 2 NPR W SERIES GAS Propshaft Dimensions Description Illustration 15 shaft in 1 piece driveline 1 shaft in 2 piece driveline 274 shaft in 2 piece driveline 14 April 2002 HD W3500 W4500 Gas BRAKE SYSTEM DIAGRAM Vacuum Over Hydraulic MASTER ETERI VALVE MASTER VACUUM CYLINDER PLEASE REFER TO INTRODUCTION SECTION OF BOOK FOR ANTI LOCK SYSTEM CAUTIONS AND WHEEL BASE MODIFICATION REQUIREMENTS 3WAY CONNECTOR 2WAY CONNECTOR BRAKE AWAY ACTUATOR CONNECTOR ENGINE NG VACUUM TANK REAR Live ruru Ez NAME BRAKE HOSE VACUUM HOSE HOSE VACUUM PIPE LOW PRESSURE HIGHT PRESSURE NPR W3500 GAS 12 000 GVW April 2002 m 3wAY MASTER 4 OIL TANK 2WAY CYLINDER CONNECTOR BRAKE ACTUATOR AWAY CONNECTOR METERI
99. FW 33 5 17 TD BBC 68 0 OH 87 4 CE2 1325 in lb BOC 9 25 OW 78 5 150 0in Ib FH 32 0 CE4 176 0in Ib 12 000 Ib GVWR with 4L80 E Hydra Matic Transmission Model Federal Chassis Cab and Maximum Payload Weights Model WB Unit Front Rear Total Payload BB1 109 0 in Ib 3 160 1 799 4 959 7 041 BB2 132 5 in Ib 3 204 1 821 5 025 6 975 150 0 Ib 3 226 1 843 5 069 6 981 BB4 176 0 in Ib 3 270 1 865 5 135 6 865 12 000 Ib GVWR with 4180 Hydra Matic Transmission Model California Chassis Cab and Maximum Payload Weights Model WB Unit Front Rear Total Payload 1 109 0 Ib 3 160 1 799 4 959 7 041 2 1325 lb 3 204 1 821 5 025 6 975 150 0 lb 3 226 1 843 5 069 6 931 176 0 lb 3 270 1 865 5 135 6 865 2002 3 340 Vehicle Weight Limits GVWR Designed maximum GAWR Front GAWR Rear Technical Notes Chassis Curb Weight reflects standard equipment and fuel but no driver or payload Rear Total 1 874 5 104 1 896 5 170 1 918 5 214 1 940 5 280 12 000 Ib 4 700 Ib 7 950 Ib Payload 8 946 8 880 8 836 8 770 14 050 Ib 5 360 Ib 9 880 Ib Maximum Payload Weight is the allowed maximum for equipment body payload and driver and is calculated by subtracting chassis curb weight from the GVWR HD W3500 W4500 Gas FRAME amp CROSSMEMBER SPECIFICATIONS
100. ILDER WEIGHT INFORMATION CHART NPR Series Unit Ib Wheel Base 132 5 in Unsprung Weight Manual Transmission Automatic Transmission CAB TILT 16 94 430 3mm GRID SCALE ONE SQUARE 2 50 8mm X 2 50 8mm H 60 24 H 1530 1mm 2 76 70 1 mm o EE NES 28 0 711 1 869 95mm Unit Inch nit Inc CENTER OF GRAVITY The center of gravity of the chassis cab Unit Inch The center of gravity of the completed vehicle with a full load should not exceed 63 inches above ground level for the 17 950 GVWR and must be located horizontally between the centerlines of the front and rear axles Manual Transmission Automatic Transmission Vertical Center of Gravity Horizontal Center of Gravity 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 1 562 229 5314 and in the East Coast call 1 404 257 3013
101. ILOTED QH4 20 5 7 50 6 44 72 18 FTR10 11 12 amp 13 72 18 71 70 71 70 N A HPK HPM AXLE HZWIHZT H11 CAPACITY 17850 LBS 19000 LBS 19000 LBS WHEELTYPE WHEEL BRAKES BRAKES BRAKES RPO SIZE OFFSET HYD FULLAIR HYD FULLAIR HYD FULL AIR STEEL DISK WHEEL 10 HOLE HUB PILOTED 20 5 7 50 STEEL DISK WHEEL 10 PILOTED RPR 22 5X8 25 ALUMINUM DISK WHEEL 10 HOLE HUB PILOTEH RNF 22 5X8 25 FTR20 21 22 amp 23 15 AXLE H11 HPG HPH 4 STEEL DISK WHEEL 10 HOLE HUB PILOTED QH 22 5 7 50 22 5X8 25 N A 22 5X8 25 N A STEEL DISK WHEEL 10 HOLE HUB PILOTED RPR ALUMINUM DISK WHEEL 10 HOLE PILOTED RNF FVR10 AXLE HPG HPH HPQ H20 HNA ME 3P E m NNNM S STEEL DISK WHEEL 10 HOLE HUB PILOTED QH4 22 5X7 50 N A N A N A STEEL DISK WHEEL 10 HOLE HUB PILOTED RPR 22 5X8 25 N A N A N A ALUMINUM DISK WHEEL 10 HOLE HUB DIMENSIONS ARE IN INCHES 14 RNF 22 5X8 25 2002 REARAXLE SUSPENSION DIMENSIONS FSR FTR amp FVR TIRE SECTION gt mm 2 50 MINIMUM CLEARANCE BETWEEN BODY AND TIRES Ac Cw LW nu WHEEL OFFSET TIRE CLEARANCE TIRE RADIUS April
102. N A SET OF DUAL TIRES WITH OPTIONAL EQUIPMENT 215 85816 7950 8760 65 0 106 149 133 225 70R 19 5 9880 65 re 10 6 14 9 13 0 27 April 2002 HD W3500 W4500 Gas SUSPENSION DEFLECTION CHARTS FOR NPR GAS 10 FRONT LEAF SPRING LOAD VS DEFLECTION PER AXLE S U S P E Ibs N 10 000 S 5 000 1 508 Ib in L 12 000 GVW D 0 1 2 3 4 5 VERTICAL SPRING DEFLECTION INCHES REAR LEAF SPRING LOAD VS DEFLECTION PER AXLE S U S P E Ibs N 10 000 S 5 204 Ib in 5 000 12 000 GVW L 5 K 1 664 Ib in 12 000 GVW 0 1 2 3 4 5 VERTICAL SPRING DEFLECTION INCHES April 2002 HD W3500 W4500 Gas SUSPENSION DEFLECTION CHARTS FOR NPR HD GAS FRONT LEAF SPRING LOAD VS DEFLECTION PER AXLE S U S P E Ibs N 10 000 S 1 843 bin 5 000 14 050 GVW 0 1 2 3 4 5 VERTICAL SPRING DEFLECTION INCHES REAR LEAF SPRING LOAD VS DEFLECTION PER AXLE S U S P E Ibs N 10 000 5 K 6 935 Ib in 14 050 GVW 5 000 L 1 921 bin 14 050 0 2 3 4 5 VERTICAL SPRING DEFLECTION INCHES April 2002 11 HD W3500 W4500 Gas TIRE AND DISC WHEEL CHART TIRE TIRE LOAD LIMIT AND COLD INFLATION PRESSURES MAXIMUM TIRE LOAD LIMITS SINGLE DUAL FRONT TIRESIZE LB PSI PSI 2 SINGLE 4DUAL 215 85R 16 E 2430 70 2210 70 4
103. NG REFER TO COMPONENT BOX DRAWING REFER TO AIR INDUCTION DRAWING REFER TO BATTERY BOX DRAWING REFER TO CAB DRAWING April 2002 5 FSR 8 GCW RATINGS OF MAJOR COMPONENTS COMPONENTS RPO CODE MAXIMUM GCW RATING LB ENGINE ISUZU GCW MAY BE LIMITED BY PERFORMANCE RESTRICTIONS BASE ON ENGINE HP TRANSMISSION AXLE AND VEHICLE CONFIGURATION TRANSMISSION ISUZU MLD6Q 45 000 ALLISON AT545 30 000 AXLES DANA SPICER 150408 15 000 LB CAP DANA SPICER 5150 515 000 LB CAP DANA SPICER 190605 16 900 LB CAP DANA SPICER 190608 17 850 LB CAP DANA SPICER 190608 19 000 LB CAP DANA SPICER 19060T 19 000 LB CAP DANA SPICER 210608 21 000 LB CAP DANA SPICER 21060T 21 000 LB CAP DANA SPICER 220608 22 000 LB CAP DANA SPICER 22060T 22 000 LB CAP DANA SPICER 230805 23 000 LB CAP DANA SPICER 23080T 23 000 LB CAP DANA SPICER 231055 23 000 LB CAP HYDRAULIC BRAKE SYSTEM AIR BRAKE SYSTEM See Rating Page 6 April 2002 FSR 8 FVR AT 545 R Ratings Full Load Vocations Net Input Net Input Max Turbine Gov Speed N m Ib ft omen an Refuse 175 235 603 445 1032 761 Not 10 002 22 22 050 13 608 wa wa Note 1 500 Series retarder Diesel 24 40 Gas 32 44 AT 500R Series retarder Diesel 24 36 Gas 32 36 Transit B
104. NPR HD W3500 W4500 Diesel FUEL FILL EIL a A DREES 1 CLIP RUBBER HOSE 6942420340 9404204 2 3 891878750 ees 4 HOSEFUELFLER Leg e 5 84435876 07724373 6 SCREW FILLERHOSE 3 7 BRACKET FILLERNECK sormesziy eme 1 8 Lem o 7 S 10 CLIP 109707 1070 94062296 2 11 CAUTION PLATE 894414 3530 94414353 1 18 April 2002 5500 Diesel MODEL NQR W5500 GVWR 17 950 Ib WB 109 132 5 150in 176 ENGINE Isuzu 4 cylinder in line 4 cycle turbocharged intercooled direct injection diesel Model Displacement HP Gross Torque Gross 4 1 290 4 75 liters 175 HP 2700 RPM 347 Ib ft torque 2000 RPM Equipment Dry element air cleaner with vertical intake 2 rows 506 in radiator 6 blade 18 7 in diameter fan with viscous drive Cold weather starting device and an oil cooler CLUTCH Single dry plate 12 8 in dia ceramic actuated by self adjusting hydraulic master slave cylinder TRANSMISSION MZZ 6 speed manual all forward gears synchronized Sixth gear is overdrive Available Optional Transmission Aisin 450 43 LE 4 speed overdrive automatic transmission with lock up capability in 2nd 3rd and 4th PTO capability
105. NUAL 17 950 22 500 FRR WT5500 DIESEL AUTOMATIC 18 000 19 500 26 000 FRR WT5500 DIESEL MANUAL 18 000 19 500 30 000 1 The NPR W3500 NPR HD W4500 and NQR W500 are note approved for Hot Shot applications 2 GCWR 20 950 with addition of optional Isuzu Transmission Oil Cooler April 2002 27 Mechanical amp Cab Specifications e following chart proviaes the rear frame height for each mode with standard tires STANDARD FRAME HT in TIRE FH STD TIRES NPR W3500 GAS 11 050 215 85R 16E NPR HD W4500 GAS 14 050 225 70R 19 5F NPR W3500 DIESEL 12 000 215 85R 16E NPR HD W4500 DIESEL 14 050 215 85R 16E NQR W5500 DIESEL 17 950 225 70R 19 5F FRR WT5500 DIESEL 18 000 19 500 225 70R 19 5F FSR FTR FVR 2 2 1 191 and 218 WB have frame height of 37 3 inches 2 Refer to FSR FTR and FVR section CLUTCH ENGAGEMENT TORQUE CHART The following table provides the engagement torque of the engines currently in use in Isuzu medium duty trucks Torque at Ibs ft RPM ISUZU 4HE1 TC 142 HP ISUZU 1 175 HP ISUZU 6 1 200 HP ISUZU 6 1 230 HP 28 April 2002 ISUZU ISUZU ISUZU OPTION PAINT PAINT CODE COLOR CODE NAME 1985 KS22 N A Calm White 0133 P1 1986 95 NPR DIESEL 844 Glacier White 0172 1 1993 94 NPR EFI 844 Glacier White 0172 1 1995 5 03 DIESEL 729 Arc White 730 AdriaticBlue 302 801 0 Solid 1999 model on
106. O3N KEN 10 NYOY 104394102 4008 Ir 03 tt Ar 39934 NMOIC3U KERSCH 3016 995 11 TRI 11 Q3WNNO 17 EEN 8814 896 pL RS 17 mue Ir 9 11 E vol vi 3400 xal 94 inen S3NIL TY LY LOH TY 1v 10H 10 HD W3500 W4500 Gas Electrical FUSE LOCATION nm TU TY Py aay 7 wech a L amp 1 D 5 A FUSE PULLER April 2002 11 HD W3500 W4500 Gas Electrical FUSE BOX Fuse Number Fuse Name Circuit Protected 1 HEATER Heater 2 Compressor Controls F 3 EXHAUST BRAKE Diesel VCM IGN Gas Exhaust Brake System Diesel Engine Controls Gas F 4 D R L Diesel ENGINE IGN Gas Headlights Diesel Engine Controls Gas F 5 ECU BAT Diesel A T SOLENOID GAS Engine Controls Diesel Automatic Transmission Controls Gas DOME LIGHT Interior Lights Exterior Lights Sound System Gas Speedometer Gas TAIL LIGHT Dash Lights Exterior Lights STOP LIGHT Brake Lights HEAD LIGHT RH Headlights
107. OF FRAME RAIL CW TRACK DUAL REAR WHEEL VEHICLES DESIGN LOAD DISTANCE BETWEEN THE CENTER LINES OF THE E REAR TIRE CLEARANCE DUAL WHEELS MEASURED AT THE GROUND LINE MINIMUM CLEARANCE REQUIRED FOR TIRES AND CHAIN MEASURED FROM THE TOP OF THE FRAME AT THE VERTICAL CENTER LINE OF THE REAR AXLE SEE TIRE CHART FOR VALUES WHEN REAR WHEELS ON ONE SIDE RIDE OVER A TIRE LOADED RADIUS HIGH SPOT TIRE CLEARANCE CH FRAME HEIGHT VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF FORMULAS FOR CALCULATING REAR WIDTH FRAME RAIL AND THE GROUND LINE THROUGH THE AND HEIGHT DIMENSIONS CENTER LINE OF THE REAR AXLE AT CURB POSITION DH REAR FRAME HEIGHT CW TRACK VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF CH _ TIRE LOADED RADIUS FRAME RAIL AND THE GROUND LINE THROUGH THE DH _ TIRE LOADED RADIUS D CENTER LINE OF THE REAR AXLE AT DESIGN LOAD DW TRACK 2 TIRE SECTIONS TIRE CLRARANCE DW MINIMUM DISTANCE BETWEEN THE INNER SURFACES EW _ TRACK 2 TIRE SECTIONS TIRE CLEARANCE OF TRE EA TIRES HH TIRE LOADED RADIUS A EW MAXIMUM REAR WIDTH JH KH B OVERALL WIDTH OF THE VEHICLE MEASURED AT THE KH _ TIRE RADIUS 3 00 INCHES OUTER MOST SURFACE OF THE REAR TIRES KW DW 5 00 INCHES CRENEGTIBEGUEARANGE LW 1 00 INCH MINIMUM CLEARANCE BETWEEN TIRES AND MINIMUM CLEARANCE BETWEEN THE REAR AXLE AND SPRINGS THE GROND LINE HW DUAL TIRE SPACING DISTANCE BETWEEN THE CENTER LINES OF THE NOTE TRACK AND OVERALL WIDTH MAY VARY TIRES I
108. ORMATION CHART NPR Series Unit Ib Wheel Base 132 5 in Unsprung MT AT Weight Manual Transmission Automatic Transmission CAB TILT 16 94 430 3mm GRID SCALE ONE SQUARE 2 50 8mm X 2 50 8mm Unit Inch CENTER OF GRAVITY The center of gravity of the chassis cab Unit Inch The center of gravity of the completed vehicle with a full load should not exceed 54 inches above ground level for the 12 000 Ib GVWR 58 inches above ground level for the 14 500 GVWR and must be located horizontally between the centerlines of the front and rear axles Vertical Center of Gravity Horizontal Center of Gravity Manual Transmission Automatic Transmission Note The maximum dimensions for a body installed on the N W Series are 96 inches wide outside by 90 inches high inside Any larger body applications must be approved by GMICT Application Engineering In the West Coast call 1 562 229 5314 and in the East Coast call 1 404 257 3013 April 2002 HD W3500 W4500 Diesel FRONT AXLE CHART CH CURB POSITION DH TIRE DESIGN LOAD LOADED SS id _ TRACK E FORMULAS FOR CALCULATING HEIGHT DIMENSIONS 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 TI
109. OUNCE B CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT AS MEASURED FROM THE CENTER LINE OF THE METAL TO METAL POSITION REAR AXLE AND THE TOP OF THE REAR TIRE WHEN C CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT ONE WHEEL RIDES OVER A HIGH SPOT CURB POSITION CW TRACK DUAL REAR WHEEL VEHICLES D AXLE TO TOF OF ERAME RAIL AT DISTANCE BETWEEN THE CENTER LINES OF THE REAR TIRE CLEARANCE DUAL WHEELS MEASURED AT THE GROUND LINE 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 TIRE SECTION TIRE RADIUS TIRE LOADED RADIUS TIRE CLEARANCE SEE TIRE CHART FOR VALUES CH REAR FRAME HEIGHT VERTICAL DISTANCE BETWEEN THE NORMAL OF FORMULAS FOR CALCULATING REAR WIDTH FRAME RAIL AND THE GROUND LINE THROUGH THE CENTER LINE OF THE REAR AXLE AT CURB AND HEIGHT DIMENSIONS DH REAR FRAME HEIGHT CH TIRE LOADED RADIUS C VERTICAL DISTANCE BETWEEN THE NORMAL TOP OF DH TIRE LOADED RADIUS D FRAME RAIL AND THE GROUND LINE THROUGH THE DW TRACK 2 TIRE SECTIONS TIRE CLRARANCE CENTER LINE OF THE REAR AXLE AT DESIGN LOAD EW TRACK 2 TIRE SECTIONS TIRE CLEARANCE DW MINIMUM DISTANCE BETWEEN THE INNER SURFACES HH TIRE LOADED RADIUS A OF THE REAR TIRES JH EW MAXIMUM REAR WIDTH KH TIRE RADIUS 3 00 INCHES OVERALL WIDTH OF THE VEHICLE MEASURED AT THE KW DW 5 00 INCHES OUTER MOST SURFACE
110. RATOR Charging System TURN S LIGHT Turn Lights ECU IGN Diesel ACC Gas Engine Controls AUDIO CIGAR LIGHTER Cigarette Lighter Engine Controls Sound System POWER SOURCE Engine Controls ENGINE STOP Diesel Engine Stop System Diesel FUEL PUMP Gas Engine Controls Gauges Gas HAZARD HORN Engine Controls Gauges Horn Hazard Lights ABS BAT ABS STARTER Starting System April 2002 HD NQR W3500 W4500 W5500 Diesel Electrical RELAY LOCATION Hidden Fuse Box RELAY BOX Install on the instrument panel RELAY BOX Installed on the left side rear of the cab April 2002 13 NPR NPR HD NQR W3500 W4500 W5500 Diesel Electrical CAB RELAY Diode Number Circuits Protected 2 17 B 18 25 Compressor controls B 26 Exhaust brake system Diesel Relay Number Relay Relay Number Relay B 19 Charge relay B 34 Power source 20 Headlight 35 21 Heater 8 B 36 Exhaust brake cut Diesel B 22 Tail Vacuum pump Gas B 23 Buzzer control B 37 A C thermo B 24 Horn B 38 Exhaust brake Diesel Ignition Gas FUSE BOX
111. RE HIGH PRESSURE LOW PRESSURE INDICATION 5555555 BRAKE HOSE VACUUM HOSE BRAKE HOSE LOW PRESSURE HIGH PRESSURE VACUUM PIPE PIPE 14 April 2002 DIESEL FUEL FILL Installation instructions Disconnect battery Loosen hose from the tie downs Remove caps from plate on rail Install hoses on to the plate Extend hose out from the driver side of the rail to body rail The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal see Figure 4 Cover with protector wrap and secure with tie wraps Filler hose is set for 96 inches outside width body Filler neck dimension A must be between 6 85 inches and 8 5 inches above frame Secure the filler plate to the bottom of the body and check for leaks Ensure that fill hose does not sag creating an area where the fuel could pool in the fill hose Reconnect battery April 2002 NQR W5500 Diesel 15 NQR W5500 Diesel 16 Rear View Fuel Fill Dimension A 6 85 8 50 174 216mm Top View Fuel Fill Dimensions 29 75 in 756mm C 34 00 in 863mm D 39 29 in 998mm 30 86 in 784mm F 256 6 in 1438mm April 2002 5500 Diesel Hose Modification for Various Width Bodies 96 remove 0 inches 90 remove 3 inches 86 remove 5
112. RE UNLOADED RADIUS DH D TIRE LOADED RADIUS Unit Inch TIRE GVWR GAWR DH TRACK 12 000 5 4 70016 7 7 14 50010 5 36016 7 7 215 85R 16 E April 2002 7 HD W3500 W4500 Diesel REAR AXLE CHART 2 50 MINIMUM TIRE CLEARANCE SECTION BETWEEN w Bop WHEEL OFFSET F TIRE CLEARANCE yo TIRE RADIUS 1 i TIRE LOADED j 1 DQ D H 2 RADIUS C DW REAR BODY U SR LAA 7 Normal rear BL BN oh n Ss N N 1 d Dd D When rear wheels on one When all of rear wheels A DEFINITIONS ride over a high spot side ride over a high spot A CENTER LINE OF AXLE TO BOTTOM OF AXLE BOWL HW DUAL TIRE SPACING B CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT DISTANCE BETWEEN THE CENTER LINES OF THE METAL TO METAL POSITION MINIMUM DISTANCE REQUIRED FOR TIRE BOUNCE CENTER LINE OF FRAME RAIL AT AS MEASURED FROM THE CENTER LINE OF THE CURB POSITION REAR AXLE AND THE TOP OF THE REAR TIRE WHEN D DESIGN GAS AXLE TO TOP OF FRAME RAIL AT ONE WHEEL RIDES OVER A HIGH SPOT HEAR TIRE CLEARANCE CW TRACK DUAL REAR WHEEL VEHICLES MINIMUM CLEARANCE REQUIRED FOR TIRES AND N SECUN INE CHAIN MEASURED FROM THE TOP OF THE FRAME EINE AT THE VERTICAL CENTER LINE OF THE REAR AXLE
113. Safety Standards The information contained in this guide has been provided for the final stage manufacturer s information and guidance This guide contains information pertaining to the NPR W Gas NPR W Diesel NQR W Diesel NPR HD NQR W Diesel Crew Cab and FRR WT Series Chassis Cab and Janesville assembled FSR FTR and FVR Chassis Cab Following is a list of Federal Motor Vehicle Safety Standards applicable to those vehicles with a GVWR greater than 10 000 105 Please refer to the following chart FMVSS Chart NPRINPRHD NQR FRR FMVSS TITLE W3500 W4500 W5500 WT5500 FSR FTRIFVR 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 Number Motor Vehicle Brake Fluids Power Operated Window 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 43 Child Restraint Systems Flammability of Interior Materials NOTE This chart is only a guide for complete information please ref
114. TIRE LOAD LIMIT AND COLD INFLATION PRESSURES SINGLE TmESVE 18 PSI iB FS TIRE LOAD LIMITS FRONT 2 SINGLE MAXIMUM 4 DUAL 215 85R 16 2680 80 2470 80 5360 9880 14 500 TIRE RADIUS GVWR LOADED UNLOADED TIRESIZE 6 FRONT REAR FRONT Unit Inch TIRE DESIGN SECTION CLEAR ANCE WIDTH 1450 wi we wr ee DISC WHEEL FT RR NUT SIZE 1 6142 41 mm BUD HEX O D Wrench Sizes TIRE SECTION WIDTH REAR STUD SIZE 0 8268 21 mm SQUARE TIRE CLEARANCE NUT STUD TORQUE SPECS 289 ft Ib 892 N M RIM OFFSET REFER TO DISC WHEEL SHOWN AT RIGHT G of DISC WHEEL April 2002 INNER CIRCLE Unit Inch OUTSIDE OFFSET MATERIAL MFG 15 DC OFFSET of DISC WHEEL 15 NQR W4500 W5500 Crew Cab Diesel TIRE AND DISC WHEEL CHART NQR W5500 TIRE TIRE LOAD LIMIT AND COLD INFLATION PRESSURES SINGLE DUAL TRESVE LB PSI 8 FS MAXIMUM TIRE LOAD LIMITS FRONT 2SINGLE 4DUAL 225 70R 1956 3450 90 3245 90 6900 12980 17 950 TIRE RADIUS GVWR LOADED UNLOADED SECTION CLEAR TIRE SIZE 5 FRONT REAR FRONT REAR Unit Inch TIRE DESIGN ANCE WIDTH sron osr 17860 150 wa 12 60 DISC WHEEL NUT STUD TORQUE SPECS FT RR R
115. UM CLEARANCE BETWEEN TIRES AND SPRINGS NOTE TRACK AND OVERALL WIDTH MAY VARY WITH OPTIONAL EQUIPMENT Unit Inch A 225 70R19 5 12 19 500 Ib 14 330 Ib 13 680 Ib 8 1 April 2002 FRR WT5500 SUSPENSION DEFLECTION CHARTS FRONT LEAF SPRING LOAD VS DEFLECTION PER AXLE 10000 K 2 038 Ib in 19 500 Ib GVWR 8000 SUSPENSION LOAD Ib 6000 4000 2000 0 1 2 3 4 VERTICAL SPRING DEFLECTION inches REAR LEAF SPRING LOAD VS DEFLECTION PER AXLE 240004 200004 8 792 Ib in 19 500 Ib GVWR 160004 SUSPENSION LOAD Ib 12000 80007 2 632 Ib in 19 500 Ib GVWR 4000 0 1 2 3 4 VERTICAL SPRING DEFLECTION inches April 2002 9 FRR WT5500 TIRE AND DISC WHEEL CHART TIRE MAXIMUM RADIAL TIRE LOAD LIMITS SINGLE DUAL FRONT TIRE SIZE Ib ps Ib ps 2SINGLE 4DUAL ib 13 680 19 500 225 70R19 5F 12pr 13 640 3 420 95 7 280 TIRE RADIUS TIRE DESIGN GVWR SECTION CLEAR TIRE SIZE Ib LOADED UNLOADED RANCE WIDTH DISC WHEEL NUT STUD FT RR REAR TORQUE INNER OUTSIDE MATERIAL NUT SIZE STUD SIZE SPECS CIRCLE OFFSET MFG 19 5x6 00 1 6142 in 0 8268 in 400 ft Ib 15 DC 41 mm 21 mm 550 N M BUD HEX SQUARE O D Wrench Sizes TIRE SECTION WIDTH TIRE CLEARANCE RIM OFFSET REFER TO DISC WHEEL SHOWN AT RIGHT OFFSET of DISC WHEEL
116. URB POSITION DH 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 DW MINIMUM DISTANCE BETWEEN THE INNER SURFACES OF THE REAR TIRES EW MAXIMUM REAR WIDTH OVERALL WIDTH OF THE VEHICLE MEASURED AT THE OUTER MOST SURFACE OF THE REAR TIRES HH REAR TIRE CLEARANCE MINIMUM CLEARANCE BETWEEN THE REAR AXLE AND THE GROUND LINE HW DUAL TIRE SPACING DISTANCE BETWEEN THE CENTER LINES OF THE TIRES IN A SET OF DUAL TIRES KH 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 Tire Suspension Capacity Capacity Normal rear axle center REAR BODY When rear wheels on one When aot tear wheels side ride over a high spot ride over a high spot CW TRACK DUAL REAR WHEEL VEHICLES DISTANCE BETWEEN THE CENTER LINES OF THE DUAL WHEELS MEASURED AT THE GROUND LINE TIRE SECTION TIRE RADIUS TIRE LOADED RADIUS SEE TIRE CHART FOR VALUES TIRE CLEARANCE FORMULAS FOR CALCULATING REAR WIDTH AND HEIGHT DIMENSIONS CW TRACK CH TIRE LOADED RADIUS C DH TIRE LOADED RADIUS D DW TRACK 2 TIRE SECTIONS TIRE CLEARANCE EW TRACK 2 TIRE SECTIONS TIRE CLEARANCE HH TIRE LOADED RADIUS A JH KH B KH TIRE RADIUS 3 00 INCHES KW 5 00 INCHES LW 1 00 INCH MINIM
117. WITH TYPICAL CARGO BODY 18 April 2002 NQR W4500 W5500 Crew Cab Diesel PROPELLER SHAFT CONTINUED NPR HD W4500 NQR W5500 Trans Type 6M T AAT Shaft 1 O D 18 59 7 1 s Shaft 42 O D Thickness Length UNIT INCH Type Description Werer 15 shaft in 2 piece driveline 274 shaft in 2 piece driveline z Automatic Transmission April 2002 19 NQR W4500 W5500 Crew Cab Diesel PTO LOCATION DRIVE GEAR AND OPENING INFORMATION Automatic Transmission Chassis Top of Frame a o m To of Front Axle Ratio of PTO Maximum Opening Bolt PTO Drive Drv Gear Spd Number Helix Output Transmission Wa Gear Location to of Teeth Angle Torque Aisin Left Dr2 12 6 38 75 5 2 mI 4 48 PTO Gear 1 1 with turbine o pe lb ft 1000 RPM Unit Inch Opening Diagram 20 April 2002 NQR W4500 W5500 Crew Cab Diesel BRAKE SYSTEM DIAGRAM Vacuum Over Hydraulic PLEASE REFER TO INTRODUCTION SECTION OF BOOK FOR ANTI LOCK SYSTEM CAUTIONS AND WHEEL BASE MODIFICATION REQUIREMENTS B SWAY MASTFR CYLINGE ME TLR LAG
118. ach from GVWR These tables intended for reference and do not preclude the necessity for an accurate weight distribution calculation 26 April 2002 Applicaton Summary Chart BBC gt CE A q LH 3 GE u 9 AO O Le WB Sieg AF 3 OAL i 2003 MODEL YEAR BODY amp PAYLOAD WEIGHT DISTRIBUTION FRONT REAR Manual Transmission MODEL GVWR WB OAL 14 16 18 20 24 FRR WT5500 18000 19500 148 117 1 1806 259 3 7 5 16 841 10 90 FRR WT5500 18000 19500 167 136 2 206 5 285 2 7 5 12 88 FRR WT5500 18000 19500 179 148 0 226 2 304 9 75 11 89 FRR WT5500 18000 19500 191 159 8 243 9 322 2 75 FRR WT5500 18000 19500 218 187 4 283 3 362 0 10 0 15 85 Automatic Transmission MODEL GVWR WB OAL 14 16 18 20 24 FRR WT5500 18000 19500 148 117 1 180 6 2593 10 15 85 7 93 FRR WT5500 18000 19500 167 136 2 206 5 285 2 10 10 90 FRR WT5500 18000 19500 179 148 0 226 2 304 9 10 9 91 FRR WT5500 18000 19500 191 159 8 243 9 322 2 10 9 91 FRR WT5500 18000 19500 218 187 4 283 3 362 0 10 NOTES 1 10 0 Inches For MT 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
119. al Auxillary power source wire located on left side underdash taped to body room light switch T Distribution harness with green tape Page 14 5 wll April 2002 15 HD W3500 W4500 Gas Electrical SOUND SYSTEM CIRCUIT DIAGRAM F4 DOME LIGHT RED YEL Dash and RED See Fuse Console Box Detais See Fuse Lights Page 11 Diesel om Box Details 11 4 625 Ge RED YEL LT GRN RED BLK GRN TT zk Illumination Antenna input Solid State Do check resistance Right m Hand Speaker Speaker See Ground Distribution Page 14 Diesel Page 14 5 16 April 2002 HD W3500 W4500 Gas Electrical HORN CIRCUIT DIAGRAM HOT AT ALL TIMES Box HAZARD HORN 20A WHTIGRN WHTIGRN Gas See Fuse WHT GRN Gas Details Page 11 1 Diesel Page 11 5 Gas GRN GRN WHTIGRN Gas WHTIGRN 5 3 WHS GRNAWHT SRNRED LA April 2002 17 HD W3500 W4500 Gas Electrical BACK UP LIGHTS CIRCUIT DIAGRAM mes IN ON OR mes RE GAUGE zack P 10 BLK YEL See Fuse Details 7 7 inhibitor 18 RED BLU RED BLU RED BLU RED 8LU 4 REDIBLU 16 718 m 5 S 9 Back Up Assembly Light See Ground Distribution
120. al equipment on the chassis extra consideration must be given to the weight and construction ofthe 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 of the chassis frame as closely as possible Rear End of the Cab April 2002 5 Installation of amp Special Equipment Subframe Contour Contouring of the front end of the subframe members as shown the three illustrations below will prevent stresses from being concentrated on certain areas of the chassis frame Steel subframe 77 gt Steel subframe E H or more When using a steel subframe do not close the end of the subframe Steel subframe Chassis frame 6 April 2002 Installation of amp Special Equipment Prohibited Attachment Areas Do not attach the subframe with a bolt on brackettothe chassis frame atthe points indicated by shading inthe following illustrations 1 Atthe front end of the subframe The attaching bolt or bracket must be at least 2 inches behind the kick up point of the subframe 2 i
121. allation instructions Disconnect battery Loosen hose from the tie downs Remove caps from plate on rail Install hoses on to the plate Extend hose out from the driver side of the rail to body rail The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal see Figure 4 Cover with protector wrap and secure with tie wraps Filler hose is set for 96 inches outside width body Filler neck dimension A must be between 6 85 inches and 8 5 inches above frame Secure the filler plate to the bottom of the body and check for leaks Ensure that fill hose does not sag creating an area where the fuel could pool in the fill hose Reconnect battery April 2002 NPR NPR HD W3500 W4500 Diesel 15 HD W3500 W4500 Diesel 16 Rear View Fuel Fill Dimension 6 85 8 50 174 216mm Top View Fuel Fill Dimensions 29 75 in 756mm C 2 34 00 in 863mm D 39 29 in 998mm 30 86 in 784mm 56 6 in 1438mm April 2002 HD W3500 W4500 Diesel 1 NOTE Shorten Hose at A Area only Hose Modification for Various Width Bodies 96 remove 0 inches 90 remove 3 inches 86 remove 5 inches 80 remove 8 inches End of Frame Through the Rail Fuel Fill Frame Hole April 2002 17
122. alytic converter and its location Variable swirl system if equipped VII Conformity with CMVSS 1106 is not determined solely by the design 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 C LABELS 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 PART 3 Radio Noise CANADIAN RADIO INTERFERENCE REGULATIONS A The following statement is applicable to NPR W Series Chassis Cab Gasoline Engine Only This incomplete Vehicle when completed will conform to the above regulations providing no alterations or substi tutions are made which affect any parts or components identified below A Distributor B Ignition Wires C Spark Plug Wires FSR FTR amp 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 Exhaust emission related components B Labels D EXHAUST EMISSION RELATED COMPONENTS Compliance of this vehicle with EPA and California Certification Requirements wil
123. amp quessy 11146 ye 93 WENYI HANS t wipe W ert Wes yp DH H lt LHWNY9S 90100 pue useq 30 518180 880 896 NYOH 189118 Nini 8 4 TW 1v 14915 NO NI LOH 1 t ENER ane 1HWNY9 IINA 1 ME O Q38 N39 11 5181 908002 pue yseg EEGEN IHWNYD AHAVNYD DEER 024 YOURS udn Du 180615 un uopeuiquo v Memo 11 WANAD 91 2 eer e IHWINYD 5 HE 8 VEH uoynqusia punosg seg IT 1949214 punolg g day Bue NZ H 20 3500 4500 5500 Diesel Electrical FUEL TANK SENDING UNIT RESISTANCE April 2002 16 5 418 7 13 3in 337 6mm 92in 2327mml 8 8 in 224 5mm IN FRAME TANK 110273 Low fuel level warning switch SIDE MOUNTED TANK e 19 21 HD NQR W4500 W5500 Crew Cab Electrical NPR HD NQR W4500 Crew Cab Electrical HD NQR W4500 W5500 Crew Cab Electrical April 2002 DEI erm man 29g D I D I
124. 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 Vinyl Clip 2 0 4 Clip Electrical Wiring and Harnessing To increase the reliability of the wiring all frame harnesses are covered with corrugated vinyl tubing The follow ing instructions apply to extending or modifying these harnesses See the Electrical Section for information on commonly used circuits in the NPR NQR FRR and W Series The FSR and FVR wiring information can be found in the service manuals Wiring April 2002 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 sharp edges When cables must run near the exhaust system see the instructions in
125. and hose material April 2002 21 Installation of amp Special Equipment 22 April 2002 Body Application Summary Chart Body Application Summary Chart 24 2002 GAS amp 2003 DIESEL MODEL YEAR BODY APPLICATION SUMMARY CHART MODEL GVWR NPR W3500 GAS 12 000 16 NPR HD W4500 GAS 14 050 16 NPR W3500 DSL 12 000 16 NPR HD W4500 DSL 14 500 lbs NPR HD W4500 CREW CAB DSL 14 500 lbs NQR W5500 DSL 17 950 16 NQR W5500 CREW CAB DSL 17 950 16 FRR WT5500 DSL 18000 19 500 Notes 2 3 4 10 0 inches For MT 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 16 Dovetail landscape 12 deck plus 4 dovetail 18 Dovetail landscape 14 deck plus 4 dovetail 221 24 ft x UNIT INCH NPR NPR HD W3500 W4500 Diesel 20 ft body requires Isuzu GM Application Engineering Department approval April 2002 MODEL AUTOMATIC TRANSMISSION NPR W3500 GAS NPR HD W4500 GAS NPR W3500 GAS NPR HD W4500 GAS NPR W3500 GAS NPR HD W4500 GAS NPR W3500 GAS NPR HD W4500 GAS MODEL Body Applicaton Summary Chart MANUAL AUTOMATIC TRANSMISSION NPR W3500 DSL NPR HD W4500 DSL NPR
126. and telescoping steering column Tinted glass ELECTRICAL 12 Volt negative ground dual Delco maintenance free batteries 750 CCA each 110 Amp alternator with integral regulator OPTIONS 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 Power Windows and door Locks 33 gal fuel tank mounted on right hand rail in place of 30 gal in frame tank NOTE These selected specifications are subject to change without notice April 2002 NQR W5500 Diesel VEHICLE WEIGHTS DIMENSIONS AND RATINGS F lt BBC 1 1 7 LE La B H FH AH 21 AW gt FW gt CW 2 4 BW gt Figure 2 1 NQR W Series Diesel Cab Chassis Dimensions Variable Chassis Dimensions Side Mounted Tank 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 17 950 Ib GVWR Manual Transmission Model Chassis Cab and Maximum Payload Weights Effective CA
127. any of the following structural steel C channels 4 inch X 19 8 inch 7 25 Ib ft 5 inch X 19 inch 6 7 or 9 0 Ib ft 6 inch X 2 inch 8 2 10 5 or 13 lb ft April 2002 NQR W4500 W5500 Crew Cab Diesel AUXILIARY VIEWS Le 658 m 445 so 64 4 22 6 8 2 20 9 Ke Lk me y gt 57 81 E H TI 1 21 01 d AA es 1 li 5 i P ER CUE 1 161 Y 10 3 ET 5 Ape 65 8 Le 64 4 59 8 Sg 102 2 gt T SE 1 8 1 1 4 27 1577 v 0 TE Q O 13 75 10 8 11 5 s 73 L 209 eh ee 15 8 Side View Rear View In Frame Tank Fuel Tank 244 10 8 g 11 5 i 27 2 21 Rear View Rear View Rear View Battery Box ABS Controller In Frame Tank April 2002 NQR W4500 W5500 Crew Cab Diesel BODY BUILDER WEIGHT INFORMATION CHART NPR Series W4500 Wheel Base Unsprung Weight Automatic Transmission Unit Ib CENTER OF GRAVITY The center of gravity of the chassis cab GVWR V The center of gravity of the completed vehicle with a full load should not exceed 58 inches above ground level
128. arness must be extended in accordance with the ELECTRICAL WIRING AND HARNESSING section of this book The propeller shafts overall length will also needto be lengthened or shortened Ifthe 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 ofthe respective sections ofthis book Ifthe 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 lengths pin to pin for the respective models are shown in the table below Propeller Shaft Diameter in Maximum Propeller Shaft Length in April 2002 Installation of 8 Special Equipment B Propeller Shaft Angles The maximum propeller shaft angles with respect to the previous shaft are shown in the table below NPR W NPR W GAS NQR W FRR WT EE Propeller Shaft Angle C Thepropeller shaft angles must be designed such that the angles will cancel to avoid propeller shaft whip D The propeller shaft yokes must be assembled such that the propeller shaft yokes are in phase In phase means that the yokes at either end of a given propeller shaft assembly are in the same plane 10 Extending the frame will also require relocation and or addition of crossmembers If the extension is within the limits of the optional wheelbases of the respective mo
129. ation ahead Load of rear axle CL D W 227 Wheelbase WB Front axle Rear axle load load W W Front Axle Load Kingpin Load x 5th Wheel Location Wheelbase Rear Axle Load Kingpin Load Front Axle Load Example 4 Atractor has a wheelbase of 150 inches If the kingpin load is 20 000 Ib 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 Ib on the front axle and 4 400 Ib on the rear axle Front Axle Load 20 000 x 15 2 000 Ib 150 WB April 2002 Rear Axle Load 20 000 2 000 18 000 Ib Therefore Total Front Axle Weight 2 000 9 000 Ib Total Rear Axle Weight 4 400 18 000 Ib 22 400 Ib In calculating the weight distribution for a truck the same lever principle is applied however there is one change in the initial consideration of the method of loading the truck body Instead of the trailer kingpin location ahead of the rear axle 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 39 Weight Restrictions amp Specifications 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 a
130. ay be affected in various ways including but not limited to the following 1 The installation of a body or equipment that exceeds the rated capacities of the Incomplete Vehicle 2 The addition of designated seating positions which exceeds the rated capacities of this Incomplete Vehicle 3 Alterations or substitution of any components such as axles springs tires wheels frame steering and brake systems that may affect the rated capacities of this Incomplete Vehicle Use the following chart to assure compliance with the regulations Chassis curb weight and GVW rating is located on Page 2 in each vehicle section Always verify the results by weighing the completed vehicle on a certified scale Curb Weight of Chassis los From required vehicle section PLUS weight of added body components accessories or other permanently attached Body liftgate reefer etc components PLUS total weight of passengers air conditioning and all load or Driver passengers cargo accessories and load EQUALS Gross Vehicle Weight Ibs GVW of completed vehicle required vehicle section Should equal GVWR from 32 April 2002 Weight Restrictions amp Specifications 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 exc
131. ayload will be carried onthe front axle and how much will be carried on the rear axle onthetrailer 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 atractor trailer and the weight laws and regulations under which the truck will operate Improper weight distribution will cause problems in many areas 34 1 Excessive front end wear and failure a Tie rod and king pin wear b Front axle failure c Overloading of front suspension d Wheel bearing failure 2 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 Ifthe center ofthe payload is directly over or slightly behindthe 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 When loads beyond the capacity of the front axle are imposed upon it the steering mechanism is also overloaded and hard steering will result
132. by subtracting chassis wet weight including 200 Ib driver GVWR These tables are intended for reference and preclude the necessity for an accurate weight distribution calculation April 2002 27 Mechanical amp Cab Specifications Mechanical amp Cab Specifications The following table presents Net versus Gross Horsepower and Torque ratings for 2003 Isuzu W Series Truck Product Engines ENGINE NET HP NET TORQUE GROSS HP GROSS TORQUE MODEL APPLICATION HP RPM LBS FT RPM HP RPM LBS FT RPM GMPT NPR W3500 5 7L V8 NPR HD W4500 250 4400 330 2800 GAS NPR W3500 NPR HD W4500 137 2800 268 1300 142 2800 275 1300 DIESEL NPR W3500 NPR HD W4500 169 2700 339 2000 175 2700 347 2000 NQR W5500 DIESEL NQR W5500 169 2700 339 2000 175 2700 347 2000 DIESEL FRR WT5500 193 2400 426 1500 200 2400 441 1500 DIESEL FRR WT5500 193 2400 426 1500 200 2400 441 1500 DIESEL NOTE 1 Horsepower and Torque Ratings measured under SAE J1349 standards GVW GCW Ratings The following table presents GVW ratings and corresponding GCW ratings for each model truck TRUCK MODEL TRANSMISSION GVWR Ibs GCWR 105 NPR W3500 GAS AUTOMATIC 12 000 15 000 NPR HD W4500 GAS AUTOMATIC 14 050 17 050 NPR W3500 DIESEL AUTOMATIC 12 000 18 000 NPR W3500 DIESEL MANUAL 12 000 18 000 NPR HD W4500 DIESEL AUTOMATIC 14 500 19 500 NPR HD W4500 DIESEL MANUAL 14 500 20 500 NQR W5500 DIESEL AUTOMATIC 17 950 19 500 NQR W5500 DIESEL MA
133. ch clearance between rigid or stationary portions and at least 1 6 inch between moveable or flexible portions of the lines Subframe Fluide line SN 77 0 4 in or more N Chassis frame 1 6 in or more Z 212 V7 DCH Flexible portion H 2 N Reinforcement block Reinforcement blocks should be mounted securely in installed position For the installation positions of the U bolts refer to Prohibited Attachment Areas April 2002 Installation of 8 Special Equipment Crew Cab Body Frame Requirement The Crew Cab NPR HD W4500 and NQR W5500 will be available in two wheelbases 150 and 176 inches Effective CA will be 84 7 and 110 7 inches On this model chassis General Motors Isuzu Commercial Truck LLC GMICT and American Isuzu Motors Inc will require that the body installed on the chassis have an understructure manufactured with any of the following structural steel C channels 4 x1 5 8 7 25 Ibs ft ok 5 x1 3 4 6 7 or 9 0 Ibs ft ok 6 x2 8 2 10 5 13 0 Ibs ft ok Modification of the Frame Modification of chassis frame should be kept to an absolute minimum Modification work should be performed according the 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
134. ck The Federal single axle weight limit onthe Interstate system and reasonable access is 20 000 Ib Tandem Axle Weight Thetotal weightatthe ground of two or more consecu tive axles whose centers may be included between par allel 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 Ib 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 ofthe Federal Bridge Formula Two consecutive sets of tandem axles may carry a gross load of 34 000 Ib each providing the overall distance between the first and last axles of 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 doubletrailers 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 op
135. ctions of the wrecker manufacturer A safety chain system must be used The procedures below must be followed when towing to prevent possible damage FRONT END TOWING FRONT WHEELS OFF GROUND To prepare a disabled vehicle for front end towing with front wheels raised off the ground the following steps are necessary Block the rear wheels of the disabled vehicle Disconnect the propeller shafts at the rear axle Secure the propeller shafts to the frame or crossmember f there is damage or suspected damage to the rear axle remove the axle shafts Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects Place 4 x 4 wood beam against the towing guide behind the bumper If no 4 x 4 is available then remove the bumper Ensure towing chains do not contact the horns or the bumper 1 Horns 2 Bumper removed for towing 3 Filler AFTER TOWING After towing the vehicle block the rear wheels and install axle shafts or propeller shaft Apply the parking brake before disconnecting from the towing vehicle FRONT END TOWING ALL WHEELS ON THE GROUND Your vehicle may be towed on all wheels provided the steering is operable Remember that power steering and brakes will not have power assist There must be a tow bar installed between the towing vehicle and the disabled vehicle Bumper Towing Chain Towing GUide Front Axle Tow Hook Q b O N To prepare a disabled vehicle f
136. d SPECIAL TOWING INSTRUCTIONS 1 Call your local authorized dealership or professional towing service 2 state and local laws regarding such items as warning signals night illumination speed etc must be followed 3 Safety chains must be used 4 No vehicle should ever be towed over 55 mph 90 km h 5 Loose or protruding parts of damaged vehicles should be secured before moving 6 A safety chain system completely independent of the primary lifting and towing attachment must be used 7 Operators should refrain from going under a vehicle which is being lifted by the towing equipment unless the vehicle is adequately supported by safety stands 8 No towing operation which for any reason jeopardizes the safety of the wrecker operator or any bystanders or other motorists should be attempted FSR FTR amp FVR SERIES TOWING PROCEDURE CAUTION Never let passengers ride in a vehicle that is being towed Never tow faster than safe or posted speeds Never tow with damaged parts not fully secured Never get under your vehicle after it has been lifted Always use separate safety chains on each side when towing a vehicle Try to have GM Isuzu dealer or a professional towing service any tow your vehicle They can provide the right equipment and knowledge to tow it without damage Before you do anything turn on the hazard warning flashers if they have not been damaged When you call tell the towing s
137. d of Teeth 2nd Gear Trans 25 49 51 145 Ib ft 1000 RPM Countershaft PTO Gear 1 1 with turbine 134 Ib ft 1000 RPM Dr 2 AISIN pe zung 2 13 1 26 A 1 17 7 1 67 1 67 39 6 holes 2 54 2 54 April 2002 13 HD W3500 W4500 Diesel BRAKE SYSTEM DIAGRAM Vacuum Over Hydraulic PLEASE REFER TO INTRODUCTION SECTION OF BOOK FOR ANTI LOCK SYSTEM CAUTIONS AND WHEEL BASE MODIFICATION REQUIREMENTS FRONT 3 WAY OIL TANK VACUUM BRAKE MASTER ACTUATOR CYLINDER EXHAUST ENGINE VALVE RAN L4 Urt ba H N p MAGNETIC oe 3 WAY VALUE CONNECTOR CHAMBER VACUUM TANK CoS SS CZEZXEZIY REAR H Cine TO i NAME BRAKE HOSE LOW PRESSURE 12 000 GVW FRONT BT TY SON MASTER CYLINDER Gage ENGINE DENE 9 e N Lp MASTER METERING VALVE S VACUUM 9 MAGNETI POWER VALUE CHAMBER VACUUM N WAY TANK CONNECTOR TIT Se LH LINE 4 VACUUM BRAKE PIPE SSO Se 14 500 GVW 14 April 2002 IN FRAME DIESEL FUEL FILL Inst
138. del the exact cross member locations and dimensions are given in the respective model sections of this book If the modified wheelbase exceeds the optional wheelbases of the respective model the following guidelines must be adhered to A Thecross member location will largely be determined by the propeller shaft lengths and where the center carrier bearing locations are for the propeller shaft assembly B Across 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 these suspension cross members are to be located Thecross member must be constructed such that it supports both the upper and lower flange on each frame rail see drawing below cross member such as the one below may be constructed or Isuzu cross members may be obtained from your Isuzu parts dealer Additional crossmember Frame rails April 2002 19 Installation of amp Special Equipment D The maximum distance between crossmembers for the respective models is given in the table below NPR W NPR W GAS NOR W FRR WT Maximum Distance 35 7 35 7 35 7 49 8 Between Cross Members in E The drilling for any additional holes in the frame rails must comply to the DRILLING AND WELDING section of this book 11 All other aspects of lengthening or shortening the wheelbase must comply with the applicable section of this Body Builder s Guide For special applicatio
139. e Marker Lamp Ground 8 April 2002 HD NQR W3500 W4500 W5500 Diesel Electrical DOME amp INTERIOR LIGHTS CIRCUIT DIAGRAM HOT AT ALL TIMES Box Details 11 Diesel page 11 4 Gas EEE RED 4 7 St gt GRY 8LK 4 GRY BLK 4 GAS 6 GRY BLK GAS GRY RED 1 AN2 BLK April 2002 Dash and Console Lights LT GRN RED 3 LT GRN BLK Dash and Console Lights ON Indicator 2 5 RED YEL r GAS 4 H 8 GAS RED YEL RED YEL RED YEL 0 Connector Connector Rear Ground Distribution Page 14 Diesel Page 14 5 Gas 4 7 Diesel 54 Gas HD NQR W3500 W4500 W5500 Diesel Electrical LIGHTS CIRCUIT DIAGRAM D LICENSE amp TAIL PARK ti 1 1 wa D H 1 9 in 81 69 a 9 na uma a rJ a 81 Jean 8008 vot TW 1v LOH 0330007 i Pm rue pae RI punog 895 iquassy wore D d 24 n 3390889 LT ema
140. e diameter mm area mm current Amps 217 0 80 169 0 80 127 0 80 108 0 80 85 0 80 70 0 80 41 0 80 84 0 45 50 0 45 65 0 32 41 0 32 26 0 32 16 0 32 11 0 32 7 0 32 e 0 1 1 1 2 4 8 8 Reference The values given the allowable current column are based on the ambient temperature condition of 104 with temperature increase of 104 Electrical System Modifications Modifications add on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by reviewing system schematics wire routing paths harness connections etc Due to the wide range of modifications that may be required for vocational needs it is not feasible for the O E M to take into account all potential revisions For this reason any person modifying existing vehicle wiring must assume responsibility that the revisions have not degraded the electrical system performance Any add on wiring needs to be properly fused and routed to prevent cut pinch and chafe problems as well as avoid exposure to excessive heat Care must be exercised that existing vehicle interfaces do not have their current load capabilities exceeded and that the respective control devices are not overloaded Added wire size should be at least as large as the wire to which it is attaching in order for fuse protection to be maintained A Packard electric wiring repair kit is available
141. e total length of the frame Yield strength 44 000 psi section modulus 7 20 in RBM 316 800 CAB All steel low cab forward BBC 68 0 in 45 mechanical tilt with torsion assist Equipment Jersey knit covered high back driver s seat with two occupant passenger seat Two way roof ventilator dual cab mounted exterior mirrors Tilt and telescoping steering column Tinted glass ELECTRICAL 12 volt negative ground Delco maintenance free battery located under cab 600 CCA 80 Amp alternator with integral regulator OPTIONS Air conditioning AM FM cassette stereo radio spare wheel 6 stainless steel mirrors April 2002 Power windows and Door Locks NOTE These selected specifications are subject to change without notice HD W3500 W4500 Gas MODEL NPR HD GAS W4500 GAS GVWR 14 050 Ib WB 109 132 5 150in 176 in ENGINE GMPT 8 V Block 4 cycle water cooled Sequential Port Fuel Injection Model Displacement HP Gross Torque Gross GMPT V8 350 CID 5 7 liters 250 HP 4200 rpm 330 Ib ft torque 2800 rpm Equipment Sequential Port Fuel Injection SFI mass air flow meter powertrain control module VOM onboard diagnostics oxygen sensors catalytic convertor map sensor with external oil cooler TRANSMISSION 4L80 E Hydra Matic 4 speed automatic with lock up converter and overdrive STEERING I
142. 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 Weight Restrictions amp Specifications 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 centerline or too close to it will result inan unsafe handling situation by transferring too much weight to the rear axle and actually unloading the front axle April 2002 43 Weight Restrictions amp Specifications PERFORMANCE CALCULATIONS The following calculations have been included to help the users of this book determine the performance character istics required by their customers and to select the appropriate model vehicle 1 44 Speed Formula This formula can be used to determine 1 Top speed of the vehicle 2 Speed a given gear 3 Final ratio required for a given speed 60 X RPM MPH 500 X Gear Ratio Governed Speed Rev Mile X Gear Ratio Definitions in formulas RPM Revolutions per minute of the engine Rev Mile Tire revolutions per mile Gear Ratio The product of the axle ratio times the transmission ratio 60 E Time Consta
143. ece driveline 39 shaft in 3 piece driveline 6 speed manual and automatic 1 shaft in 3 piece driveline 6 speed manual and automatic 279 shaft in 3 piece driveline 6 speed manual and automatic Manual Transmission A T Automatic Transmission 12 April 2002 FRR WT5500 PTO LOCATION DRIVE GEAR AND OPENING INFORMATION Manual Transmission Top of Frame Rail PTO Output Opening G a Transmission H of Front Axle Automatic Transmission Top of Frame Rail PTO Output Opening Ratio of Maximum Opening Bolt PTO Drive Drv Gear Spd Output Transmission Location Pattern Gear Location to Eng Spd Torque 4th Gear 25 42 0 595 180 lb ft 1500 RPM Trans Countershaft Converter Driven 1 1 withturbine 250 Ib ft 1500 RPM PTOGear Counter Shaft 2 95 2 99 2 99 April 2002 13 FRR WT5500 BRAKE SYSTEM DIAGRAM Air Over Hydraulic PLEASE REFER TO INTRODUCTION SECTION OF BOOK FOR ANTI LOCK SYSTEM CAUTIONS AND WHEEL BASE MODIFICATION REQUIREMENTS 1 rm 17 xa o x 1 H d pis H 13017 ee P A 4 f H 1 1 7 SC a ad 2 Yexcnetensseninie gt H eg H j 12502 122223 mud
144. ed Rear View ABS Controller i 5 11 4 a 5 Tel co k 13 75 1 26 E _ 249 4 al Rear View Emission Canister Rear View In Frame Tank April 2002 HD W3500 W4500 BODY BUILDER WEIGHT INFORMATION CHART NPR NPR HD Series Unit Ib Wheel Base 109 in 132 5 150 176 in Unsprung Weight A T A T Automatic Transmission GRID SCALE ONE SQUARE 2 50 8mm X 2 50 8mm 60 24 1530 1mm 2 76 70 1mm 10 28 0 711 34 25 869 95mm CENTER OF GRAVITY The center of gravity of the chassis cab Unit Inch The center of gravity of the completed vehicle with a full load should not exceed 54 inches above ground level for the 12 000 Ib GVWR 58 inches above ground level for the 14 050 Ib GVWR and must be located horizontally between the centerlines of the front and rear axles Automatic Transmission Vertical Center of Gravity Horizontal Center of Gravity Note The maximum dimensions for 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 in the East Coast call 1 770 475 9195 extension 353 April 2002 7 NPR HD W
145. eeded 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 Weigh 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 o
146. el 38 Basket 8 5 x 11 75 x 21 38 17 Grale rin 18 75 17 5 X 24 5 75 Verrale ana nennen 9 5 x 13 5 x 24 5 40 Lime Hydrated 30 Barrel small 16 5 head 27 5 stave 62 210 Barrel large wu re Ran MES 62 320 Limes Western box X T3 X25 80 Southern box 12 75 12 75 27 52 90 Einseedi l 59 7 9 Eubricating en E 52 7 0 Malt Barley NEEN den DUSHEl 28 nenn bushel B 32 Brewer s grain bushel 40 Maple Syr p EEN gallon 82 11 Hard lumboer 44 3670 Ee 34 2830 Meal corn b sh l 44 Milk cond en tarde A eoe reete me pa Me E hao 64 8 6 5 gallon can 10 25 dia x 19 62 10 gallon can 13 dia Xx Ines 115 Crate 20 5 pt bottles 8 5 x 12 75 x 16 75 33 20 pt bottles
147. elay 9 Auxiliary Relay 10 Horn Relay 11 Stoplamp Relay 12 Body Room Light Relay 16 April 2002 FSR amp FVR Electrical 345545 HARNESS DASH PANEL Illustration Inline Connector C200 6263546368 6 5 54 3 52 726 2 Blessed 515065867 FPE EEN 48 015118 2111 Her 202 UE Garer GE 1917817 15151 6g65646364 9292967 28 pismak PSP DIR EI ERAEN een 615 b sbegscbe 418 1 0 833213 918 6 5 Body room light terminal April 2002 17
148. ement see figures below Application Engineering should be consulted for approval of such cases It 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 pe N N N NN N N N N NN N N OR NN N NN N N N N N N N N N i k N N N Snug fit inner channel Snug fit inner channel with Inverted L for Long Bridge wheelbases April 2002 17 Installation of amp Special Equipment 7 The reinforcements must fastened securely to only the web of the original chassis frame rail The reinforcement must be held rigidly in place using either HUC bolts GRADE 8 bolts and hardened steel washers at both the bolt head and nut or GRADE 8 flanged bolts and hardened steel washers at the nut Below are some suggested bolt patterns It should be noted that these bolt patterns must not align the bolts vertically i e the bolt pattern must be staggered 18 Lengthening 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 ofthe same diameter as the original lines and of the appropriate length The electrical h
149. er temperature low water level and low oil pressure TRANSMISSION Aisin 450 43 LE 4 speed overdrive automatic transmission with lock up capability in 2nd 3rd and 4th and PTO capability STEERING Integral power steering 20 9 1 ratio Tilt and telescoping steering column FRONT AXLE Reverse Elliot Beam rated at 6 830 Ib Suspension Semi elliptical steel alloy leaf springs with stabilizer bar and shock absorbers GAWR 5 360 Ib REAR AXLE Full floating single speed with hypoid gearing rated at 11 020 Ib Suspension Semi elliptical steel alloy leaf springs and shock absorbers GAWR 9 880 Ib WHEELS 16x6 0 6 hole disc wheels painted white TIRES 215 85R 16E 10 pr tubeless steel belted radials all season front and rear BRAKES 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 rear drum The parking brake is a mechanical cable actuated internal expanding drum type transmission mounted The exhaust brake is standard and is vacuum operated Four channel anti lock brake system FUEL TANK 30 gal rectangular steel fuel tank mounted in frame rail behind rear axle Fuel water seperator mounted on rail FRAME Ladder type channel section straight frame rail 33 5 in wide through the total length of the frame Yield strength 44 000 psi section modul
150. er to Document for Incomplete Vehicle provided with each chassis Chart Legend 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 Meets Canadian Motor Vehicle Safety Standards bearing same FMVSS number Canadian MVSS only Not applicable to truck or bus Not applicable to trucks with a GVWR greater than 10 000 LBS a 5 VI EPA Requirements NPR W Gas NPR W Diesel NQR W Diesel NPR HD NQR W Diesel Crew Cab and FRR WT Series Chassis Cab To assure that U S A and Canada Emission 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 Exhaust emission related components B Noise emission related components C Labels A 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 2 GASOLINE VEHICLES Injection Pump Vehicle Control Module VCM Injector and High Pressure Lines Fuel Management System Turbocharger Air Induction Syste
151. erating on Interstate highways andfederal aid highways designed by the Federal Highway Administration This also provides for reasonable access to the interstate highways April 2002 Weight Restrictions amp Specifications FEDERAL BRIDGE FORMULA TABLE MAXIMUM LOAD IN POUNDS ON ANY GROUP OF Distance in feet between the 2 OR MORE CONSECUTIVE AXLES extremes of any group of 2 or more consecutive axles 2 3 4 5 6 7 8 9 Axles Axles Axles Axles Axles Axles Axles Axles 4 34 000 5 34 000 6 34 000 34 000 8 and less 34 000 8 and more 38 000 39 000 40 000 Tandem Axle by Definition Exception to Federal Bridge Formula Table and Law See Text for Explanation Note All permissible load calculations to the nearest 500 Ib Maximum load on any single axle 20 000 Ib Weights over 80 000 Ib are in excess of the Federal GVW on the National Highway Network April 2002 51 Commodity amp Material Weights Alcohol Alfalfa seed Aluminum Apples Apricots Artichokes Asbestos Asparagus Avacados Bananas Barley Barytes Beans dry Fresh Beef Beer APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS Case carton 24 12 oz Wooden case 24 12 oz Beets Note Beer cases vary as to size and shape Suggest checking with local source April 2002 Lb Per Size Container Cu Ft bu eid EU NO UE I ILE 50 18111110 e EL
152. ering Department approval 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 Ib driver from GVWR These tables are intended for reference and not preclude the necessity for an accurate weight distribution calculation April 2002 25 Body Application Summary Chart AW BBC WB OAL 2003 MODEL YEAR DIESEL CREW CAB BODY amp PAYLOAD WEIGHT DISTRIBUTION MODEL NPR HD W4500 CREW CAB DSL NPR HD W4500 CREW CAB DSL MODEL NQR HD W5500 CREW CAB DSL NQR HD W5500 CREW CAB DSL IMPORTANT GVWR 14 500 14 500 GVWR 17 850 17 850 FRONT REAR WB CA CE 150 88 9 132 176 114 9 158 WB CA CE 150 88 9 132 176 114 9 158 OAL 240 5 266 5 OAL 240 5 266 5 BOC 10 12 14 16 4 2 8 92 4 2 15 85 BOC 10 12 14 16 4 2 16 84 8 92 4 2 15 85 8 92 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 Ib driver and a crew of 6 9200 Ibs e
153. ervice That your vehicle has rear wheel drive The make model and year of your vehicle Whether you can still move the shift lever An estimation of the total weight plus cargo so that the towing company can use the proper equipment If there was an accident what was damaged When the towing service arrives let the tow operator know that the owner s manual contains detailed towing instructions The operator may want to see them April 2002 33 Mechanical amp Cab Specifications Towing Your Vehicle From the Front Front Wheels Off the Ground BEFORE TOWING Block the rear wheels of the disabled vehicle On vehicles with air brakes release the emergency brake system by compressing brake chamber springs as outlined in this section Note This is to prevent the possibility of the emergency brake being applied during towing On vehicles with hydraulic brakes release the parking brake fully by moving the lever handle to the fully released position Towing the Vehicle with the Front Bumper Removed 1 Remove the front bumper 2 Connect and lock the lift chains to the front axle outside of the spring anchor plates as shown 3 Connect lift chains to the tow bar and raise the tow bar until lift chain slack has been taken up 4 Raise the vehicle to the required height Rear Axle Disconnect the propshaft at the rear axle Secure the propshaft to the frame crossmember After Towing Block the rear wheels a
154. et Cd Aerodynamic Drag Coefficient MPH Speed of vehicle in miles per hour 156 000 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 boat haulers Example NPR 12 000 GVWR van body with 96 inches wide 115 inches high 84 body height 31 frame height 96 115 Gay taa ES FA 73 47 0 70 55 73 47 0 70 55 3 156 000 Air Resistance HP 54 85 Air Resistance HP April 2002 45 Weight Restrictions amp Specifications 4 46 Engine Horsepower Formula This formula can be used to derive the output at a given RPM and torque Torque X RPM Horsepower 5252 Definitions in formula Torque Twisting output of engine given lb ft RPM Revolutions per minute of engine 5252 Constant Example NPR 12 000 GVWR automatic transmission Torque 347 lb ft RPM 2000 347 2000 132 5252 Gradeability Formula This formula can be used to determine how large of a grade a vehicle can climb 1200 X T X E X C X R RR Percent Grade Xr Definitions in formula 1200 C
155. evel switch Tail relay Cornering light Cornering light relay Wiper motor Washer motor intermittent relay Heater 8 AC relay Radio amp clock Cigar lighter Fan switch Blower resistor A C Switch Blower motor Electronic thermostat Accel switch Cab interior switch Flashe unit Clearance light ID light illumination control Kick down switch Electronic vacuum pump Power source relay Frame front harness 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 warming 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 April 2002 7 HD NQR W3500 W4500 W5500 Diesel Electrical NPR NQR BODY ROOM LIGHT ID 8 MARKER LAMP AND BACK UP LAMP CON NECTOR LOCATION NPR NQR BODY CONNECTORS LH FRAME W PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG LOCATION INSIDE LEFT HAND FRAME RAIL 28 TO 31 INCHES BOC CIRCUITS Rear Dome A Marker Lamp Ground A B C D NPR NQR BODY CONNECTORS EOF PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG LOCATION CENTER OF CROSSMEMBER CIRCUITS Rear Dom
156. f the center of gravity is not violated April 2002 33 Weight Restrictions amp Specifications Weight Destribution A truck as a commercial vehicle has but one purpose That purpose is to haul some commodity from one place to another Ashortdistance or along distance the weight to be hauled more than any other factor determines the size of the truck A small weight requires only a small truck a large weight requires a large truck A simple principle but it can easily be misapplied In any case selecting the right size truck for the load to be hauled will ensure that the job will be done and that 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 weight must also be properly distributed between the axles This is of extreme importance from both a functional and economic aspect truck consistently hauls less than its capacity the owner is not realizing full return on his investment and his operating costs will be higher than they should be If the truck is improperly loaded or overloaded profits will be reduced due to increased maintenance costs and potential fines resulting from overloading beyond legal limitations Careful consideration must be given to distribution of the load weight in order to determine how much of the total including chassis cab body and p
157. for the 14 500 GVWR and must be located horizontally between the centerlines of the front and rear axles 14 500 150 214 528 176 20 0 60 9 Unit Inch Automatic Transmission Vertical Center of Gravity Hz Horizontal Center of Gravity 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 1 562 229 5314 and in the East Coast call 1 404 257 3013 April 2002 7 NQR W4500 W5500 Crew Cab Diesel BODY BUILDER WEIGHT INFORMATION CHART NQR Series W5500 Wheel Base Unsprung Weight Automatic Transmission Unit Ib CENTER OF GRAVITY The center of gravity of the chassis cab mm The center of gravity of the completed vehicle with a full load should not exceed 63 inches above ground level for the 17 950 GVWR and must be located horizontally between the centerlines of the front and rear axles A T 17 950 150 21 3 57 0 176 19 9 66 0 Unit Inch Automatic Transmission Vertical Center of Gravity Horizontal Center of Gravity 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 1 562 229 5314 and
158. ft April 2002 3 Installation of amp Special Equipment Rear Wheel and Axle 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 For recomended clearances please refer to the Rear Axle Chart in each models respective section Rear of Body Rear Wheels Over High Spot Other Clearances Normal Rear Axle Center Line Rear Wheels Over Obstacle Transmission control cable may be broken if it is bent by or interferes with the body and its fixtures To preventthis 1 inch minimum clearance should be provided When cable is detached for body mounting be sure notto 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 PARTS Brake Hose Parking Brake Cable Fuel Hose Shock Absorber MINIMUM CLEARANCE 6 7 in 1 6 in 1 2in 1 6 in 2 4 in 1 2 in LOCATION Axle side Frame side Axle Side Frame Side April 2002 Installation of Body 8 Special Equipment Body Installation Chassis To maintain the performance of the truck chassis either a side member or subframe should always be used for body mounting Body mounting with low rigidity will often adversely affect riding comfort Special Equipment on the Chassis When installing speci
159. ide through the total length of the frame Yield strength 44 000 psi section modulus 11 89 in RBM 523 160 Ib ft in CAB EQUIPMENT ELECTRICAL All steel 7 passenger low cab forward BBC 108 6 in Jersey knit covered high back driver s seat with two occupant passenger seat Four passenger rear bench seat Two way roof ventilator dual cab mounted exterior mirrors Tilt and telescoping steering column Tinted glass 12 Volt negative ground dual Delco maintenance free batteries 750 CCA each 110 Amp alternator with integral regulator OPTIONS NOTE Air Conditioning AM FM cassette stereo radio PTO engine block heater engine oil pan heater 6 stainless steel convex mirrors Front power window and front rear power door locks 33 gal fuel tank mounted on right hand rail spare wheel Engine shutdown and alarm for high water temperature low water level and low oil pressure Rear cab heater cruise control and engine hour meter These selected specifications are subject to change without notice April 2002 NQR W4500 W5500 Crew Cab Diesel VEHICLE WEIGHTS DIMENSIONS AND RATINGS BBC ar CA SmE UU WB fom AF FW OAL La CW gt BW NPR HD W4500 Variable Chass
160. in the same terms as calculating full trucks OO The weight atthe center of the body and the load when applied is the same as the single point load of the kingpin on the fifth wheel TRAILER WEIGHT KP Kingpin 3 500 Ib Fill in L 40 feet RAS 48 inches KP 36 inches 396 0 2 204 42 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 C L Payload 45 b D 36 Lag WB NOTE Apply the same principles used with truck chassis A Payload at Kingpin PL WxD WB Calculate the dimension OAL 2 AF D 45 feet 2 48 inches 222 inches PL 50 000 Ib x 222 in 24 342 Ib 456 24 342 Ib B Payload at Rear Tandem PL W PL 50 000 Ib 24 342 Ib 25 658 Ib PL 25 658 Ib 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 April 2002 Due to variations in hauling wheelbase requirements from one truck application to another there is no one specific 5th wheel setting that will apply in all cases A of thumb which has proven satisfactory in many cases sets the 5th wheel one inch ahead of the rear axle for
161. inch Body Dim E 632 0mm 80 inch Body Dim E 555 8mm Through the Rail Fuel Fill Frame Hole End of Frame 18 April 2002 HD W3500 W4500 Gas HOSE FUEL FILLER 897213 6540 897213 6540 HOSE BREATHER 897214 2710 897214 2710 CLIP RUBBER HOSE 897177 5810 897177 5810 HOSE FUEL FILLER 897213 6540 897213 6540 E HOSE BREATHER 897229 9180 897229 9180 CLIP RUBBER HOSE 815699 8250 815699 8250 CLIP FILLER HOSE 802465 8140 802465 8140 2 ES 4 CLIP FILLER HOSE 8024658140 802465 8140 2 ES April 2002 19 HD W3500 W4500 Diesel MODEL NPR Diesel W3500 NPR HD Diesel W4500 GVWR 12 000 Ib 14 500 Ib WB 109 132 5 150in 176 ENGINE Isuzu 4 cylinder in line 4 cycle turbocharged intercooled direct injection diesel Model Displacement HP Gross Torque Gross 4 1 290 4 75 liters 142 HP 2800 RPM Manual Transmission 175 HP 2700 RPM Automatic Transmission 275 Ib ft torque 1300 RPM 347 Ib ft torque 2000 RPM Equipment Dry element air cleaner with vertical intake 2 rows 506 in radiator 6 blade 18 7 in diameter fan with viscous drive Cold weather starting device and an oil cooler CLUTCH Single dry plate 11 8 in dia actuated by self adjusting hydraulic master slave cylinder TRANSMISSION 5 speed manual all forward gears synchronized
162. is Dimensions NQR W5500 Variable Chassis Dimensions Unit WB CA CE OAL AF Unit WB CA CE OAL Inch 150 88 9 132 0 240 5 43 1 Inch 150 88 9 132 0 240 5 43 1 Inch 176 114 9 158 0 266 5 43 1 Inch 176 114 9 158 0 266 5 43 1 Effective CA amp CE are CA or CE less BOC NPR HD W4500 Dimension Constants Code Inches Code Inches NQR W5500 Dimension Constants AH 7 9 BW 83 3 Code Inches Code Inches AW 65 6 CW 65 0 8 6 BW 83 3 BA 47 4 FW 33 5 AW 65 6 65 0 108 6 87 4 47 4 FW 33 5 BOC 42 OW 78 5 BBC 108 6 88 1 FH 32 0 BOC 42 OW 78 5 FH 32 8 NPR HD W4500 In Frame Tank 14 500 Ib GVWR Automatic Transmission Model NQR W5500 In Frame Tank Chassis Cab and Maximum Payload Weights 17 950 Ib GVWR Automatic Transmission Model Model WB Unit Front Rear Total Payload Chassis Cab and Maximum Payload Weights NG3 150 in Ib 3 979 2 161 6 140 8 360 Model WB Unit Front Rear Total Payload NG4 176 in Ib 4 056 2149 6 205 8 295 NS3 150 in Ib 4 167 2 557 6 724 11 226 NSA 176 Ib 4 244 2 546 6 790 11 160 NPR HD W4500 Side Mounted Tank 14 500 Ib GVWR Automatic Transmission Model NQR W5500 Side Mounted Tank Chassis Cab and Maximum Payload Weights 17 950 Ib GVWR Automatic Transmission Model Model WB Unit Front Rear Total Payload Chassis Cab and Maximum Payload Weights 150 Ib 4 167 1 896 6 063 8 437 Model WB Unit Front Rear Total Payload NG4 176 in Ib 4 244 1885 6 129 8 371 NS3 150 in Ib 4 354 2293 6 647 11 303 54 176 Ib
163. ket ee bushel le DOK nee 7 25 x 14 x 17 5 Grate ii iia ide 10 5 x 11 25 x 24 8 5 x 8 75 x 20 Basket paper 4 25 x 8 5 x 16 25 Basket wood 5 5 x 7 25 x 16 5 ILE 54 BASKET aa kuna ama kuqa am 64 2 bushel Fresh 63 i iterum bushel 1 5 bushel RIESSOU EE 82 of Lb 1620 70 75 200 220 Per cu yard tank tank tank tank tank tank tank tank cu yard cu yard cu yard bushel box crate basket basket basket gallon bushel bushel gallon bushel bag gallon bushel bag cu yard 61 NPR HD W3500 W4500 Gas MODEL NPR GAS W3500 GAS GVWR 12 000 Ib WB 109 132 5 150in 176 in ENGINE GMPT 8 cylinder V Block 4 cycle OHV water cooled Sequential Port Fuel Injection Model Displacement GMPT V8 350 CID 5 7 liters HP Gross 250 HP 4200 rpm Torque Gross 330 Ib ft torque 2800 rpm
164. kin Tan FLNA80050 27406 15 0715 809 0172 P1 844 White FLNA40155 RM15602 844 WE9907 N A Medium Adriatic Blue FLNA90857 27426 N A B721 P801 0 801 Medium Blue FLNA50172 27403 801 N507 P901 0 845 Polar Silver FLNA91205 23664 845 22193 EPW3B 36658 56991 73192 845 R725 P801 0 810 Red Orange FLNA20079 27407 IS R725 B8250 KPL4B 56202 21881 810 WE9885 Rose Black FLNA90858 27428 15 27428 95057 N A G021 P801 0 Sunbelt Green FLNA60290 605301 989 401420 989 U716 P801 0 Tangier Orange FLNA20080 27409 15 0716 61785 815 Y719 P801 0 812 Wheatland Yellow FLNA10182 27408 IS Y719 B9042 KPL7B 83931 56144 21884 812 G705 P801 0 807 Woodland Green FLNA60181 27404 IS G705 B8046 KPL3B 48339 56201 64962 807 NOTES 1 STANDBOX uses paint code found in vehicle for paint identification 2 GM Based colors No Isuzu Option Code Mechanical amp Cab Specifications N W Series Towing Procedures NOTE When towing disconnect the propeller shaft at the rear axle to ensure the automatic transmission is not damaged Proper equipment must be used to prevent damage to vehicles during any towing State and local laws which apply to vehicles in tow must be followed Vehicles should not be towed at speeds in excess of 55 mph 90 km h Connect to the main structural parts of the vehicle DO NOT attach to bumpers tow hooks or brackets Use only equipment designed for this purpose Follow the instru
165. l 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 Charge Air Cooler and Charge Air Cooler Hoses Engine Control Module ECM Engine Speed Sensor Engine Coolant Temperature Sensor 6HE1 TC only Intake Manifold Catalytic converter and its location GHE1 TC only Air cylinder for variable swirl system GHE1 TCS only E LABELS The Emission control related information labels which are permanently affixed are required by government regula tion and must not be obstructed from view or defaced so as to impair its visibility or legibility VIII 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 GHE1 TC only Air cylinder for variable swirl system 6HE1 T
166. l 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 40 300 Ib 24 f x x 96 Front Rear Front Weight Rear Weight A W WxD A Total weight WB B 300 x 24 B 300 75 96 C 75 b C 225 lb The body manufacturer 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 W and W B L 3 96 L LL t LLL 3000 Ib 48 D SES N P S 2 60 132 60 3 48 9 inches W 205 W 2 795 April 2002 Weight Restrictions amp Specifications RECOMMENDED WEIGHT DISTRIBUTION OF GROSS VEHICLE WEIGHT BY AXLE 7 I CONVENTIONAL 2 Axle Front Axle Rear Axle 25 Desired 75 20 30 Permissible 70 80 COE 2 Axle C Front Axle Rear Axle 33 1 396 Desired 66 2 396 30 3596 Permissible 65 70 C CONVENTIONAL 3 Axle ww Front Axle Rear Axle 20 Desired 80 18 25 Permissible 75 82 COE 3 Axle Cre Front Axle Rear Axle 25 Desired 75 20 30 Permissible 70 80 April 2002 41 Weight Restrictions amp Specifications Calculating tractor trailer weight distribution can be thought of
167. le eed evel avg 24 x 20 x 10 Snow Moist packed AA 50 Soft drinks Half depth bottle box 24 6 to 8 oz bottles 12 25 18 75 8 5 Full depth bottle box 12 24 to 32 oz bottles EE 13 38 x 18 5 x 12 25 Sorgnum syrup aaa 86 ie Ve Soybeanoll 58 Spinach Hambper eornm bushel Basket bushel ei Kl Le 28 Squash EE bushel le 96 Stone Crushed 8vg 2 rictu tbe Han 100 HD De 65 Straw Bale 17 22 X 42 2 Bale anna 26 x 30 x 46 Street 32 100 Sugar 1006 Net eisen Barrel 22 Ib empty 19 13 head 30 stave Gase 24 5 cartons Case 60 2 16 cartons Sugar cane Peace apa e 85 2 125 Sulf ric acid 8796 uicta trt eode vd P VP Het 112 Sweet corn 2 en bushel
168. le with oil if required FRONT END TOWING ALL WHEELS ON THE GROUND Your vehicle may be towed on all wheels provided the steering is operable Remember that power steering will not have power assist If air pressure is exhausted the vehicle will not have brakes There must be a tow bar installed between the towing and the disabled vehicle BEFORE TOWING Block the wheels of the disabled vehicle Disconnect the propshaft at the rear axle Secure the propshaft to the frame or crossmember If there is damage or suspected damage to the rear axle drain oil and remove the axle shafts Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects AFTER TOWING After towing the vehicle block the rear wheels and install axle and propeller shafts Check for proper phasing of universal joints Apply the parking brake before disconnecting from the towing vehicle Check and fill rear axle with oil if required 32 April 2002 Mechanical amp Cab Specifications REAR END TOWING REAR WHEELS OFF THE GROUND BEFORE TOWING Secure the steering wheel to maintain straight ahead position Make certain that the front axle is not loaded above the front axle Gross Axle Weight Rating GAWR as indicated on the vehicle s VIN and Weight Rating plate AFTER TOWING Block the rear wheels and release the steering Apply the parking brake before disconnecting from the towing vehicle Check and fill the rear axle with oil as require
169. let passengers ride in a vehicle that is being towed Never tow faster than safe or posted speeds Never tow with damaged parts not fully secured Never get under your vehicle after it has been lifted Always use separate safety chains on each side when towing a vehicle April 2002 Mechanical amp Cab Specifications Before Towing Secure the steering wheel to maintain straight ahead position Make certain that the front axle is not loaded above the front axle Gross Axle Weight Rating GAWR as indicated on the vehicle s Certification Tire label After Towing Block the rear wheels and release the steering wheel Apply the parking brake system before disconnecting from the towing vehicle Check and fill the rear axle with oil as required Releasing Air Operated Parking Brakes If your vehicle has air brakes you could have a special towing problem If your vehicle has to be towed because you had a complete loss of air pressure from both systems the parking brakes may have applied The tow operator can release the brakes manually by using the following steps Then your vehicle can be with all wheels or just the rear wheels on the ground 1 Block the wheels of the vehicle 2 Remove the release stud and nut from the side pocket of the brake chamber Some chambers have studs that are visible at all times 3 Remove the rubber cap from the rear of the chamber 4 Put the release stud nut and flat washer into the chamber
170. load Weight is the allowed maximum for equipment body payload and driver and is calculated by subtracting chassis curb weight from the GVWR April 2002 5500 Diesel FRAME 8 CROSSMEMBER SPECIFICATIONS eh Unit Inch Unit Inch CROSS MEMBER TYPE LOCATION M T Manual Transmission A T Automatic Transmission April 2002 3 NQR W5500 Diesel FRAME CHART FRAME FL Front Axle Center 2 4 Qu NS SECTIUN 8 amp au in 55 0 24 SECTION C C Unit Inch April 2002 5500 Diesel LK ILI llan sz ET H Figure 9 oe 13 20 9 Side View Rear View In Frame Tank Fuel Tank 24 4 ET 10 8 27 2 23 Rear View Rear View Rear View Battery Box ABS Controller In Frame Tank Figure 10 NOTES Frame mounted fuel tank available on 109 132 5 150 and 176 WB as an option Allow 3 additional for battery box opening clearance April 2002 5 NQR W5500 Diesel BODY BU
171. long 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 18 In the case of a tractor trailer or a tractor with a set of doubles or triple trailers each units is handled as a separated unit and then combined to determine the total This simple example illustrates how the principles are applied Using the formulas find the weight distributed to each axle Payload 15 000 Ib 9 24 7 ENS 150 Example Front Axle Load Body Weight Payload x of location Wheelbase Rear Axle Load Body Weight Payload Front Axle Load Therefore Front Axle Load 15 000 x 24 2400 Ib 150 Rear Axle Load 15 000 2 400 12 600 Ib If the truck tare weight without the body is 5 000 Ib on the front axle and 2 400 Ib on the rear axle then Total Front Axle Weight 5 000 2 400 7 400 Ib and Total Rear Axle Weight 2 400 12 600 15 000 Ib 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 whee
172. ly 845 Polar Sil ver NPR only 989 Sunbelt Green G021 P801 0 N507 P901 0 1995 5 02 NPR GAS Arc White Wheels Only Polar Sil ver N507 P901 0 Sunbelt Green G021 P801 0 1989 94 NRR 844 Glacier White 0172 1 1995 03 FRR 844 Glacier White 0172 1 989 Sunbelt Green GO21 P801 0 April 2002 W301 P801 0 W301 P801 0 Accuride White 301 W 30102 Mechanical amp Cab Specifications ISUZU ISUZU ISUZU OPTION PAINT PAINT CODE COLOR CODE NAME 1987 02 FSR Glacier White 0172 1 1987 96 Arc White 1997 01 Sunbelt Green G021 P801 0 W301 P801 0 1988 02 FTR Glacier White 0172 1 1988 96 Arc White 1997 01 Sunbelt Green G021 P801 0 W301 P801 0 1988 02 FVR Glacier White 0172 P1 1988 96 Arc White 1997 01 Sunbelt Green G021 P801 0 301 801 0 1988 92 844 Glacier White 0172 1 NOTES 29 08 2 qe 5 2 ISUZU PPG SHERWIN OPTION DUPONT CODE WILLIAMS HECKER STANDOX CODE CODE MARTIN CODE SENOUR 301 W 30102 N A Accuride White FLNA40154 RM25319 301 W 30102 B302 P801 0 730 Adriatic Blue Solid FLNA50274 730 730 W9775 2NV9B 730 W301 P801 0 729 White FLNA40156 RM25318 729 Bright Red FLNA30252 27427 15 27427 N A Calm White FLNA40252 HS14391 15 820 0133 P1 Dark Green Gray FLNA90856 27425 15 27425 N A U715 P801 0 Does
173. m Charge Air Cooler and Charge Ignition System Air Cooler Hoses Catalytic Converter System Engine Control Module ECM Positive Crankcase Ventilation System Engine Speed Sensor Exhaust Gas Recirculation System Engine Coolant Temperature Sensor Evaporative Emission Control System Intake Manifold Miscellaneous Items Used in Above Systems Catalytic converter and its location Variable swirl system Exhaust Gas Recirculation System 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 or 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 Cat
174. n or more Kick up point of subframe N SS E Do not attach in this area 2 Within 8 inches of bends in the chassis frame or the attachment points of any cross members 8in 8 in 8 in 8 in Do not attach in these areas April 2002 7 Installation of amp Special Equipment Subframe Mounting Bracket Installation Mounting brackets should be clamped to the chassis frame using bolts For proper positions in which to install the bolts refer to the preceding section and the section Modifications to the Chassis Frame dd N N Subframe member M Bracket N ER SEI 7 N Cushioning material 2 Cushioning material Chassis frame lt mM gt frame U bolt Installation When U bolts are used to retain the subframe reinforcement blocks must be installed in the frame members This will prevent distortion of the frame flange as they are tightened The drawing indicates the correct placement of reinforcement blocks If you use wood blocks be sure that there is sufficient clearance between them and any parts of the exhaust system If any fluid lines or electric cables are located near the reinforcement blocks you must provide at least 0 4 in
175. nal 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 completed vehicle should be constantly alert to all effects direct or indirect on other components assemblies or systems caused by such alterations No alterations should be made to the incomplete vehicle that directly or indirectly results in any either component assembly or system being in nonconformance with applicable Emission Regulations or Federal Motor Vehicle Safety Standards General Motors Isuzu Commercial Truck LLC GMICT and 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 instruc tions contained in this guide with respect to the completion of the vehicle Otherwise the warranty becomes the responsibility of the final stage manufacturer The final stage manufacturer is solely responsible for the final certification of the vehicle and for compliance with Emission Control and Federal Motor Vehicle
176. nd install axle and propeller shafts Check for proper phasing of universal joints Apply the emergency brake system before disconnecting from the towing vehicle Check and fill the rear axle with oil as required Towing Your Vehicle From the Front All Wheels On the Ground Your vehicle may be towed on all wheels provided the steering is working Remember that the power brakes and power steering will not have power assist Vehicles with air brakes will not have brakes There must be a tow bar installed between the towing vehicle and the disabled vehicle Before Towing Block the wheels of the disabled vehicle On vehicles with air brakes release the emergency brake system by compressing brake chamber springs as outlined in this section Note This is to prevent the possibility of the emergency brake being applied during towing On vehicles with hydraulic brakes release the parking brake fully by moving the lever handle to the fully released position If there is damage or suspected damage to the axle s remove the axle shafts Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects After Towing Block the rear wheels and install axle and propshafts Check for proper phasing of universal joints Apply the parking brake system before disconnecting from the towing vehicle Check and fill rear axle with oil as required Towing Your Vehicle From the Rear Rear Wheels Off the Ground CAUTION Never
177. ng switch Ignition relay Front turn signal light Brake fluid switch Tail relay Cornering light switch Cornering light Cornering light relay Dimmer relay Wiper motor Washer motor Intermittent relay Heater amp A C relay Radio amp clock cigar lighter Fan switch Blower resistor A C Switch Blower motor Electronic Thermostat cab interior switch Flasher unit Clearance light ID light Illumination Power source relay hazard warning switch turn signal light switch diagnostic connector roof marker light illumination controller Frame front harness Frame RH CRT Fuel pump relay ID light relay license plate light tailight rear turn signal light stoplight backup light inhibitor switch rear oxygen sensor LH RH Frame rear harness HORN LH Fuel pump License plate light tailight rear turn signal light stoplight backup light inhibitor switch Front 025 LH RH Engine LH RR Mass air flow sensor Coil driver Vehicle control module Engine harness Purge solenoid vacuum switch Engine LH RR Vehicle control Module April 2002 7 HD W3500 W4500 Gas Electrical NPR BODY ROOM LIGHT ID amp MARKER LAMP AND BACK UP LAMP CONNECTOR LOCATION NPR BODY CONNECTORS LH FRAME PACKARD BODY PLUG 4PIN WEATHER SEAL CONNECTOR WITH MATING PLUG LOCATION INSIDE LEFT HAND FRAME RAIL 28 TO 31 INCHES BOC CIRCUITS Rear Dome
178. ns and longer than recommended body lengths GMICT Application Engineering must be consulted for approval In the West Coast call 1 562 229 5314 and in the East Coast call 1 404 257 3013 12 Please contact applications engineering for guidelines on N W 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 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 13 The Crew Cab NPR HD W4500 and NQR W5500 will be available in two wheelbases 150 and 176 inches Effective CA will be 84 7 and 110 7 inches On this model chassis General Motors Isuzu Commercial Trucks will require that the body installed on the chassis have an understructure manufactured with any ofthe following structural steel C channels 4 x1 5 8 7 25 Ibs ft ok 5 x1 3 4 6 7 or 9 0 Ibs ft ok 6 x2 8 2 10 5 or 13 0 Ibs ft ok 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 disc
179. nt Example NPR 12 000 GVWR automatic transmission RPM 3 000 Rev Mile 674 Gear Ratio 703 x 5 375 60 X 3000 MPH Governed Speed 674 X 703 X 5 375 MPH Governed Speed 70 MPH Grade Horsepower Formula This formula can be used to determine horsepower required for a given grade and speed GVWR X Grade X Speed Horsepower Req d for a given grade 37 500 X Efficiency Factor AHP Definitions in formula GVWR Gross Vehicle Weight Rating Grade Grade anticipated in percent Speed Speed in miles per hour 37 500 Constant Efficiency Factor Factor for losses in drivetrain due to friction use 0 9 for a 90 efficient driveline AHP Resistance Horsepower required to overcome wind force April 2002 Weight Restrictions amp Specifications Example NPR 11 050 GVWR automatic transmission with a van GVWR 12 000 105 Grade 1 55 37 500 Constant Efficiency Factor 0 9 AHP Resistance 53 6 See following formula 3 for calculation 12 000 1 55 Required for Grade 37 500 X 0 9 53 67 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 FA X Cd X MPH Air Resistance Horsepower 156 000 Definitions in formula FA Frontal area of vehicle square fe
180. ntainer Cu Ft Lb Hog Live average per 225 250 Honey 90 12 0 Live average per 1200 1500 Horseradish 35 rrr TEE E TERES 57 1540 Ice mfg Block nee 222X382 rauhen 250 tee 14 x 14 x 40 255 Block nenn 115X22 X een 440 2 5 gal can Eule 9 Ah eec 18 Empty i cett ait e 6 5 gal RUE 9 35 11 LEE bushel 25 Kerosene ek Dr de ege done 50 6 6 Lamb AVG u per 75 85 Lard 18 head 30 stave 425 Lath standard length 29 in Packed in bundles of 50 Avg bundle diameter 9 inches 25 Leather Diye G TET 55 1485 WO dte a 65 1755 Lemons Western box 10 x 13 x 25 80 Southern box 12 75 12 75 27 90 Lents 22241555 4 254 bushel 60 Lettuce tens o 2 25 Hamper 1 5 bush
181. ntegral power steering 20 9 1 ratio Tilt and telescoping steering column FRONT AXLE Reverse Elliot I beam rated 6 830 Ib Suspension Semi elliptical steel alloy leaf springs with stabilizer bar and shock absorbers GAWR 5 360 Ib REAR AXLE Full floating single speed with hypoid gearing rated at 11 020 Ib Suspension Semi elliptical steel alloy leaf springs and shock absorbers GAWR 9 880 Ib WHEELS 19 5 x 6 0 6 hole disc wheels painted white TIRES 225 70R 19 5F 12 ply tubeless steel belted radials premium highway tread Front Rear BRAKES 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 Anti lock brake system FUEL TANK 30 gal rectangular steel fuel tank Mounted between the frame rails with electric type fuel pump mounted in tank Through the rail fuel fill FRAME Ladder type channel section straight frame rail 33 5 inches wide through the total length of the frame Yield strength 44 000 psi section modulus 7 20 in RBM 316 800 CAB All steel low cab forward BBC 68 0 in 45 mechanical tilt with torsion assist Equipment Jersey knit covered high back driver s seat with two occupant passenger seat Two way roof ventilator dual
182. o the chassis frame with bolts Do not weld Dimensions A not more than 0 51 in in diameter B must be more than 0 8 in C mustbe more than 1 0 in April 2002 9 Installation of amp Special Equipment 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 W3500 NPR GAS W4500 and NQR W5500 is made of SAPH440 mild steel The frame of the FRR is made of HT540A See the FSR FTR and FVR section for frame material specifications The drawings below illustrates correct and incorrect methods of frame reinforcement Welding Keep reinforcement plates and chassis frame free from moisture and water 2 Avoid cooling with water after welding 3 Use 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 5 Remove coat of paint completely when welding painted areas SATISFACTORY Frame rail 0 0 9 4 4 0 0 A Reinforcement Plug weld or rivet L Frame p UNSATISFACTORY 27 Reinforcement Fluid Lines V Welding is prohibited 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
183. o the rear axle 38 Distance C G must be placed behind the front axle Wheelbase Total weight Remember Total weight x Distance C G is ahead of the rear axle Wheelbase Weight transferred to the front axle x Wheelbase Total weight Total weight x Distance C G is ahead of the rear axle Weight to be transferred to the front axle Weight to be transferred to the front axle x Wheelbase Distance C G is ahead of the rear axle Total weight x Distance C G is behind the front axle Wheelbase Weight transferred to the rear axle x Wheelbase Total weight Total weight x Distance C G is behind the front axle Weight to be transferred to the rear axle Weight to be transferred to the rear axle x Wheelbase Distance C G is behind the front axle Total weight must always equal weight transferred to the rear the weight transferred to the front axle axle plus April 2002 Weight Restrictions amp Specifications 100 Ib Pivot 20 P Ib To find the value of P the leverages must be equal for balance This same approach is used to determine axle loadings on a tractor or truck chassis Assuming the i e rear axle serves as a pivot point the front axle load can 100 Ib x 8 P x 20 in be determined by applying the lever principle T 100 Ib x 8 in 20 in Therefore E 40 Ib Kingpin 5th wheel loc
184. of DISC WHEEL 10 April 2002 FRR WT5500 PROPELLER SHAFT 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 FRR 148 in 167 in 179 in amp 191 in WB 218 in WB TRANSMISSION TRANSMISSION 1 UNIVERSAL JOINT AXLE 2 PROPELLER SHAFT 3 CENTER CARRIER BEARING PLAN VIEW UNLOADED LOADED WHEELBASE 148 in 167 in 179 in 191 in 218 in SIDE VIEW UNLOADED LOADED WHEELBASE 148 in 167 in 179 in 191 in 218 in Engine install at 2 5 degree angle from horizontal frame Side view angles are measured from 2 5 degree angle Positive angles are in addition to 2 5 angle Negative angles are in subtraction from 2 5 angle MOTA EEEN EE EE at Design Load 6 210 at Curb Position With typical cargo body April 2002 11 FRR WT5500 PROPELLER SHAFT CONTINUED a Neo 2 2 2 T 2 s asr 2 o D 4 0 0 134 4844 su 6008 8085 me oe i M ob G 1 shaft in 2 piece driveline 6 speed manual and automatic 2 shaft in 2 pi
185. onnection 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 from 140 FQT 158 EG5 170 inches B is for the FL2 axle and covers wheelbase from 140 FQT 158 EG5 170 EH8 188 EK8 200 EM2 inches 20 April 2002 Installation of 8 Special Equipment C is for the FL1 axle and covers wheelbase from 188 8 200 218 FPL 233 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 crossmember and is an integral part of the brake fluid modulation system These components can not be relocated 4 ABSELECTRICAL HARNESSES a The
186. onstant T Maximum Torque of Engine E lt Engine Efficiency 0 9 C Driveline Efficiency 0 9 Transmission X Axle Ratio RR Rolling Resistance see chart on following page GVWR Gross Vehicle Weight Rating r Loaded radius of tire Example NPR 12 000 GVWR automatic transmission on concrete highway T 347 lb ft 0 9 0 9 703 X 5 375 in overdrive RR 1 0 GVWR 12 000 r E 14 1 in April 2002 Weight Restrictions amp Specifications Percent Grade 1200 X 347 X 0 9 X 0 9 X 703 X 5 375 BP 12 000 14 1 6 53 1 Gradeability 5 53 ROAD ROLLING RESISTANCE Road Rolling Resistance Expressed in Percent Grade Road Surface Concrete excellent Cobbles ordinary 5 5 Concrete good Cobbles poor 8 5 Concrete poor Snow 2 inch 2 5 Asphalt good Snow 4 inch 3 75 Asphalt fair Dirt smooth 2 5 Asphalt poor Dirt sandy 3 75 Macadam good 3 75 10 15 0 fair Sand level soft 6 0 to 15 0 Macadam poor Sand dune 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 1200 X CET X E X X R Startability 1096 GVWR X r Definitions in formula 1200 Constant CET Clutch Engagement Torque E 0 9 0 9 Transmission X Axle Ratio 10 Average break away resistance and static inertia
187. or calculating rear width and height dimensions CH Tire loaded radius C LH DH Tire loaded radius D LH HH Tire loaded radius A JH KH B LH KH Tire radius 3 00 inches Track DW Track 1 Tire section HW EW Track 1 Tire section HW KW DW 5 00 inches LW 1 00 inch minimum clearance between tires and springs NOTE Track and width may vary with optional equipment 16 April 2002 FSR 8 FVR REARAXLE 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 REAR AXLE SUSPENSION FRAME SHOCK ABSORBER STABILIZER AUXSPRING DIMENSION CAPACITY 068 RPOGN1 RPO G60 C 15000 TL z 15000 ML 15000 LB 16900 TL 19000 TL 19000 ML 16900 LB 16900 TL z zz 2 2 212 22 19000 TL 19000 ML lt lt zz lt z lt lk lt ziz lt mz lt lt 19000 AIR 19000 ML gt 17850 19000 TL 19000 19000 lt 2 2 2 19000 21000 gt 190001 21000 TL 23000 TL 23500 ML 21000 ML 21000 TL 21000 LB 23000 TL 23500 ML 23000 TL 22 000 2
188. or front end towing with all wheels on the ground the following steps are necessary Block the wheels of the disabled vehicle Disconnect the propeller shafts at the rear axle Secure the propeller shafts to the frame or crossmember Provide wood blocking to prevent towing chains and bar from contacting the bumper f there is damage or suspected damage to the rear axle remove the axle shafts Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects April 2002 31 Mechanical amp Cab Specifications After Towing After towing the vehicle block the rear wheels and install axle shafts or propeller shaft Apply the parking brake before disconnecting from the towing vehicle Check and fill rear axle with oil if required REAR END TOWING When towing a vehicle with rear wheels raised secure the steering wheel to maintain straight ahead position Make certain that the front axle is not loaded above the front axle Gross Axle Weight Rating GAWR as indicated on the vehicle s VIN and Weight Rating plate SPECIAL TOWING INSTRUCTIONS 1 state and local laws regarding such items as warning signals night illumination speed etc must be followed 2 Safety chains must be used 3 No vehicle should ever be towed over 55 mph 90 km h 4 Loose or protruding parts of damaged vehicles should be secured prior to moving 5 A safety chain system completely independent of the primary lifting and
189. pension and suspension crossmembers rivet holes left in the frame rail flange must be filled with GRADE 8 bolts and hardened steel washers at both the bolt head and nut HUC bolts or GRADE 8 flanged bolts and hardened steel washers at the nut When shortening lengthening the wheelbase in this manner the following guidelines must be adhered to All frame drilling must comply with the DRILLING AND WELDING section of this book 2 All rivet holes left in the frame rail flange from the suspension and suspension crossmembers must be either filled with GRADE 8 bolts and hardened steel washers at both the bolt head and nut HUC bolts or GRADE 8 flanged bolts and hardened steel washers at the nut 3 The components required to be slid forward or aft are the suspension and suspension hangers suspension crossmembers and suspension frame liner 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 Added length case of a lengthened wheelbase Difference between WB new and WB old SL Shortened length in case of shortened wheelbase Difference between WB old
190. pment Mv Moment of vehicle Mb Moment of Mp Moment of payload Me Moment of equipment Example 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 5291 lbs from vehicle specifications Wb lt 2100 165 4609 105 GVWR Wv Wb Well Vv 24 9 in from Body Builder s Guide NPR section page 6 Vb 80 62 1 2 of payload height height height from frame to flooring Mv 5291 X 24 9 131 746 Ib in from 7 1 Mb E 2100 X 80 168 000 Ib in from 7 2 Mp 4609 X 62 285 758 Ib in from 7 3 We Ve Me None this example 285 198 5291 2100 4609 VOg Eu 48 8 inches 12 000 48 8 54 0 inches 54 inches is maximum allowable VCg per mfg specifications from Body Builder s Guide NPR section page 6 Since maximum VOg for this truck is not exceeded 48 stack height above flooring is acceptable 48 April 2002 Weight Restrictions amp Specifications 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 reefe
191. pre D Body Builders Guide Body Builders Guide General Motors Isuzu Commercial Truck LLC GMICT and American Isuzu Motors Inc Is striving to provide you with the most up to date and accurate information possible If you have any suggestion to improve the Body Builder s Guide please call GMICT Application Engineering In the West Coast call 1 562 229 5314 and in the East Coast call 1 404 257 3013 Notice of Rights All rights reserved No part of this book may be reproduced or transmitted in any form or by any means electronic mechanical recording or otherwise without the prior written permission Notice of Liability All specifications contained in this Body Builders Guide are based on the latest product information available at the time of publication The manufacturer reserves the right to discontinue or change at anytime without prior notice parts material colors special equipment specifications designs and models Made and printed in the USA Contents Introduction FMVSS EPA Requirements Installation of Body amp Special Equipment Clearances Installations Prohibited Attachment Areas Subframe Mounting Crew Cab Body Frame Requirements Modification of the Frame Fluid Lines Electrical Wiring amp Harnessing Maximum Allowable Current Exhaust System Fuel System Rear Lighting Servicability Wheelbase Alteration Hydraulic Brake System
192. r Size Container Cu Ft 0 25 barrel box 0 25 barrel box 12 25 14 75 X 22 Toce ERR 64 fare rv eR ux 68 ME 56 A e Dee EN b shel ee 9 75 x 13 75 24 tw tet DFX 13 25 X KEE Loose dry 76 ee da Otra d cera 95 MODO E 125 bushel EC 14 x 11 75 x 24 30 crate 127 12 26 SOL coim ana 44 rd m 38 utut 45 Commercial burlap bag 207 0 Easter 25 19 head 29 stave 0 5 barrel 18 5 head 23 5 stave 19 13 head 30 stave Furnace grade ee eei aii 56 Di sel 52 Household EE 7 Dry paper wrapped 15 30 uud 50 bete le gw ttd ert Ad dr
193. r unit snow plow etc is installed on either extremes along the completed vehicle s overall length 8 1 Wv X Hv 8 2 Wb X Hb Mb 21 27 83 COR Mad 8 4 Complete Vehicle Mb Mp Me 5 85 WV Wb Wp We Definitions in formula Wheelbase HCg The total average horizontal center of gravity of the completed vehicle vehicle body payload and equipment Wv Weight of Vehicle Wb Weight of Wp Weight of Payload We Weight of Equipment Hv Distance from front axle to center of gravity of the vehicle Hb Distance from front axle to center of gravity of the body Hp Distance from front axle to center of gravity of the payload He Distance from front axle to center of gravity of the equipment Mv Moment of vehicle Mb Moment of Mp Moment of payload Me Moment of equipment Example Overall Outside Body Length NPR 12 000 GVWR automatic transmission 132 WB 14 body length full payload of boxes stacked and distributed evenly throughout the flooring 1 000 Ib reefer unit attached in front of body NOTE April 2002 Wv Wb Hb Hp He Mv Mb Mp Me HCg HCg lt 5291 16 2100 Ibs 3609 105 1000 Ibs 42 4 in 107 5 in 107 5 in 17 5 in 5291 X 42 4 224 338
194. rame Yield strength 44 000 psi section modulus 7 20 316 800 CAB All steel low cab forward BBC 68 0 in 45 mechanical tilt with torsion assist Equipment Jersey knit covered high back driver s seat with two occupant passenger seat Two way roof ventilator dual cab mounted exterior mirrors Tilt and telescoping steering column Tinted glass ELECTRICAL 12 Volt negative ground dual Delco maintenance free batteries 750 CCA each 110 Amp alternator with integral regulator OPTIONS Air Conditioning AM FM cassette stereo radio PTO engine block heater engine oil pan heater Fuel Tank mounted on right hand rail 33 gal spare wheel 6 stainless steel convex mirrors Power windows and door locks NOTE These selected specifications are subject to change without notice April 2002 Transmissions have gear in all wheelbases HD W3500 W4500 Diesel VEHICLE WEIGHTS DIMENSIONS AND RATINGS ke ow me lt BOC SCH Variable Chassis Dimensions Unit WB CA CE OAL Inch 109 0 88 4 131 5 199 5 Inch 132 5 111 9 155 0 223 0 Inch 150 0 129 4 172 5 240 5 Inch 176 0 155 4 198 5 266 3 Effective CA amp CE are CA or CE less BOC Dimension Constants Code Inches Code Inches AH 7 9 BW 83 3 AW 65 6 65 0 47 4 33 5
195. ransmission Automatic Transmission 12 April 2002 LOCATION DRIVE GEAR AND OPENING INFORMATION Manual Transmission Automatic Transmission NQR W5500 Diesel Chassis Top of Frame It se m T F A Output Shaft dees To of Front Axle Bolt Location Opening Transmission Pattern PTO Drive 3 7 w 14 angle Countershaft Gear Location 4th Gear Trans Ratio of PTO Drv Gear Spd to Eng Spd No 25 46 0 543 of Teeth 3 Degrees 5 RH Maximum Output Torque 180 lb ft Torque 1000 RPM Counter Shaft 2 95 3 94 PTO Opening April 2002 4 48 PTO Gear 111 with turbine N A 09 134 Ib ft Torque 1000 RPM Unit Inch 13 NQR W5500 Diesel Brake System Diagram Hydraulic Brake Booster PLEASE REFER TO INTRODUCTION SECTION OF BOOK FOR ANTI LOCK SYSTEM CAUTIONS AND WHEEL BASE MODIFICATION REQUIREMENTS LSPV FRONT BRAKE RH PIPE CONNECTOR BRAKE OIL TANK ACTUATOR 01 PUMP EXHAUST ENGINE RETARDER a A a A H MAGNETIC VALVE REAR BRAKE LH HYDRAULIC HOSE HYDRAULIC HOSE HYDRAULIC PIPE PIPE HIGH PRESSURE LOW PRESSU
196. resulting in overloading the rear tires rear April 2002 Weight Restrictions amp Specifications axle springs and wheel bearings and potentially exceeding the rear axle legal weight limit The front axle is then carrying no part of the payload and is easily lifted off the ground when going over rough terrain creating a very rough ride and temporary loss of steering control If the body is too short for the wheelbase used frame stress may be increased and may result in excessive loads on the front axle Excessive front axle loads increase wear on the 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 35 Weight Restrictions amp Specifications Weightdistribution 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 15 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 CE CA
197. sembly amp Indicator Light amp Page 14 5 NHIEU See Ground See Ground Distribution Distribution Page 14 5 14 5 BLK p 20 April 2002 HD W3500 W4500 Gas Electrical FUEL TANK SENDING UNIT RESISTANCE Float Position Standard Resistance 110 Empty stop Full stop 12 549455 in Full Stop Position E E 9 0 April 2002 21 NPR NPR HD NQR W3500 W4500 W5500 Diesel Electrical HD NQR W3500 W4500 W5500 Diesel Electrical Symbol Fusible link Double filament bulb 07 Switch Coil Inductor solenoid magnetic valve Switch Normal close type 9 o Battery EC Electronic parts ej ap e Circuit breaker Vacuum switching valve 2 April 2002 Light emitting diode 3500 4500 5500 Diesel Electrical ABBREVIATIONS Abbreviation Meaning of Abbreviation Abbreviation Meaning of Abbreviation Ampere S Ignition Anti lock brake system kilowatt Assemlby Left hand Alternating current Long wheel base Air Conditioner Manual transmission Accessories Over drive Automatic transmission Option Circuit breaker Quick on start Cold start device Right hand Direct ignition sys
198. t axle load is 696 or less is normally poor distribution 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 Ib driver GVWR These are intended for reference and does not preclude the necessity for an accurate weight distribution calculation 4 April 2002 FSR 8 FVR CHASSIS DEFINITION REFERENCE DRAWING REFER TO BATTERY BOX DRAWING 1249 7 49 2 MAINTAIN THIS CLEARANCE FOR SUSPENSION AND REFER TO FRAME BODY CROSS BARS OVER 34 0 IN IN THIS AREA AND CROSSMEMBER DIMENSION ARE WITH LARGEST TIRE AND 3 00 IN ARRANGEMENT CHAIN CLEARANCE HL 19 mem 2 1 RE LE H 41 00 AUST IF LENS IS REMOVED MUST f Vw wine REFER d FUEL TANK THE WIRING MUST NOT BE CUT OR SPL ICED FORWARD OF TH BOOT REAR LAMPS ARE RELOCATED le NEW LAMP POSITION MUST REFER TO COMPONENT RATING COMPLY WITH FMVSS 108 BOX EFFECTIVE BACK OF CENTERLINE OF BOO DRAGIN FRONT AXLE REFER REFER TO AIR INDUCTION CA BODY DRAWING DRAWING REAR AXLE MEM TOP DIMENSION IS MM BOTTOM DIMENSION IS INCHES REFER TO EFFECTIVE BACK OF CAB DRAWING REFER TO FUEL TANK DRAWING REFER TO FRAME AND CROSSMEMBER DRAWING REFER TO EXHAUST DRAWI
199. ted white TIRES 225 70R19 5F low profile tubeless radial FUEL TANK 42 gal rectangular steel mounted on LH frame rail fuel water separator frame mounted Fuel filter BRAKES Anti Lock Brake system with dual circuit air over hydraulic self adjusting service brakes Mechanical cable actuated internal expanding drum parking brake transmission mounted An exhaust brake is also standard FRAME Ladder type channel section 33 in width at load platform area section modulus of 7 63 in and RBM 412 200 Ib ft in per rail CAB All steel low cab forward BBC 78 7 in 45 mechanical tilt with torsion assist Equipment Dual exterior rear view mirrors electrically operated wipers and window washer Steering column tilts and telescopes Includes 2 3 point seat belts and retractors and a 2 point seat belt Right hand power window ELECTRICAL 12 Volt dual Delco maintenance free batteries 750 CCA each 110 Amp alternator with integral regulator Right hand power window OPTIONS 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 NOTE These selected specifications are subject to change without notice April 2002 Transmissions have a gear in all wheelbases FRR WT5500 VEHICLE WEIGHTS DIMENSIONS AND RATINGS
200. tem Rear Daytime running lights Rear wheel anti lock brake system Electronic brake control module Start Electronic control gasoline injection Standard Electronic control module Switch Electronic control unit Short wheel base Early fuel evaporation Transmission control module 4 speed automatic transmission 3 speed automatic transmission Four wheel drive Volt Fusible link Vacuum switching valve Front Watt S Hydro brake booster Wide open throttle Headlight With April 2002 Integrated circuit Without NPR NPR HD NQR W3500 W4500 W5500 Diesel Electrical COLOR CODE FOR WIRING WIRING WIRE COLOR 1 Single Color Wire 2 Colored Stripe Wire Figure 18 Wire Color All wires have color coded insulation Wires belong ing 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 Red Stripe color Green Base color Wire size 0 5 mm2 Abbreviations are used to indicate wire color within a cirbuit diagram Refer to the following table Color Coding Meaning Color Coding Meaning Brown Light Green Grey Pink Light Blue Violet Starter Circuit Instrument Circuit Charging Circuit Lighting Circuit Signal
201. 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 points should be set up according to the table less than 0 2 in less than 11 8 in 0 2 in 0 4 in approx 15 7 in 0 4 in 0 8 in approx 19 7 in 11 Installation of amp Special Equipment 7 When changing the length of the battery cable do not cut or splice the existing cable Make up a new cable of the correct length and wire gauge for the load and distance without splices 8 When using connectors use a socket female connector on the electrical source side and a plug male connector on the electrical load side to lower the possibility of a short circuit when disconnected 9 When connecting cables to moving or vibrating parts such as the engine or transmission be sure to maintain sufficient slack in the wiring to absorb the vibration Follow the example of existing cables connected by Isuzu Keep flexible cables clear of other parts 10 Do not use vinyl tape in the engine compartment The heat will tend to make it peel off Use plated steel clips coated with rubber or vinyl Vinyl tube 2 Direct contact SATISFACTORY UNSATISFACTORY Rubber grommet Electric wire
202. through Kent Moore P N J38125 B Phone 1 800 345 2233 This kit contains instructions tools and components for making repairs to wiring harness components This kit would also greatly assist in accomplishing necessary add on wiring such as body marker lamps so that system April 2002 13 Installation of amp Special Equipment reliability durability is maintained Electrical wiring components can be obtained through your authorized Isuzu GM dealers Packard Electric components are also available through Pioneer Standard Company 1 00 PACKARD Pioneer may also be able to assist in making necessary wiring additions by providing custom wiring stubs or jumpers to your specifications Exhaust System Modification of the exhaust system should be avoided If modifications are absolutely necessary the following points should be maintained 1 Maintain the clearance specified in the 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 Brake Lines 2 4 in or more If the combined section of a group of parallel brake lines is more than 7 8 in a clearance of 7 in or more should be provided Flexible brake hoses 3 9 in or more Thetemperature of flexible brake hoses should not exceed 158 F If the highest temperature is not measurable a clearance of more than 15 7 in should be maintained
203. towing attacment must be used 6 Operators should refrain from going under a vehicle which is being lifted by the towing equipment unless the vehicle is adequately supported by safety stands 7 No towing operation which for any reason jeopardizes the safety of the wrecker operator or any bystanders or other motorists should be attempted FRR WT TOWING PROCEDURE Your vehicle should be towed by an authorized dealership or professional towing service to prevent damage Proper equipment must be used and state Provincial in Canada and local laws which apply to vehicles in tow must be followed Vehicles should not be towed in excess of 55 mph 90 km h Connect to the main structural parts of the vehicle Do not attach to bumpers tow hooks or brackets Use only equipment designed for this purpose Follow the instructions of the wrecker manufacturer A safety chain system must be used FRONT END TOWING FRONT WHEELS OFF THE GROUND BEFORE TOWING Block the rear wheels of the disabled vehicle Release the parking brake as described under Air Operated Parking Brake in this section Drain rear axle oil and remove the axle shafts Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects AFTER TOWING After towing the vehicle block the rear wheels remove the covers from the hub openings and install the axle shafts Apply the parking brake before disconnecting from the towing vehicle Check and fill rear ax
204. us Shuttle E a Gs DE 12 020 E EES Note Consult Allison for transmission applications and approvals not listed above Reprint from Allison Transmission Watch 32 Rev March 1999 April 2002 7 FSR 8 FVR CROSS MEMBERLOCATIONS 851 0 33 5 INSIDE TOP DIMENSION IS MM BOTTOM DIMENSION IS INCHES DIMENSIONS ARE IN INCHES 8 April 2002 FSR 8 FVR FRAME REINFORCEMENT LOCATIONS FRAME RAIL DIMENSIONS FRAME FL 400 0 5 7 amp 385 0 115 2 F08 REAR AXLE WB WB WHEELBASE REAR AXLE WB AUX VIEW FOR LOw PROFILE PACKAGE GPG 7546 0 29 208 1251 149 3 76 0 SE 234 0 273 0 SS Ol 5 AN 9 13 0 R 248 0 249 0 0 66 0 Loan Lee SECTION SECTION ER SECTION FRAME FDS 8 RAM FRAME FDO REINFORCEMENT F08 REINFORCEMENT FOB TOP DIMENSION IS MM BOTTOM DIMENSION IS INCHES April 2002 9 FSR 8 FVR FULLTRUCK OVERALL FRAME RAIL LENGTHS WB INCHES FRAME LENGTH 140 200 50000 PSI FRAME FD5 80000 PSI FRAME F03 110000 PSI FRAME HEAT TREATED 10 240 9 April 2002 FSR 8 FVR FRAME MATERIALS AND PHYSICAL PROPERTIES MODEL DIMENSION FSR FTR FVR FTR FVR FRAME RAIL RPO CODE 200 205 203 MATERIAL STEEL
205. us 11 89 in RBM 523 160 CAB EQUIPMENT ELECTRICAL All steel 7 passenger low cab forward BBC 108 6 in Jersey knit covered high back driver s seat with two occupant passenger seat Four passenger rear bench seat Two way roof ventilator dual cab mounted exterior mirrors Tilt and telescoping steering column Tinted glass 12 Volt negative ground dual Delco maintenance free batteries 750 CCA each 110 Amp alternator with integral regulator OPTIONS NOTE April 2002 Air Conditioning AM FM cassette stereo radio PTO engine block heater engine oil pan heater 6 stainless steel convex mirrors Front power window and front rear power door locks 33 gal fuel tank mounted on right hand rail spare wheel Engine shutdown and alarm for high water temperature low water level and low oil pressure Rear cab heater cruise control and engine hour meter These selected specifications are subject to change without notice Transmissions have gear in all wheelbases NQR W4500 W5500 Crew Cab Diesel MODEL NGR Diesel W5500 Crew Cab GVWR 17 950 Ib WB 150 in 176 in ENGINE Isuzu 4 cylinder in line 4 cycle turbocharged intercooled direct injection diesel Model Displacement HP Gross Torque Gross 4 1 290 4 75 liters 175 HP 2700 RPM 347 Ib ft torque 2000 RPM Equipment Dry element air cleaner with
206. vertical intake 2 rows 506 in radiator 6 blade 18 7 in diameter fan with viscous drive Cold weather starting device and an oil cooler Engine warning alarm for high water temperature low water level and low oil pressure TRANSMISSION Aisin 450 43 LE 4 speed overdrive automatic transmission with lock up capability in 2nd 3rd and 4th and PTO capability STEERING Integral power steering 20 9 1 ratio Tilt and telescoping steering column FRONT AXLE Reverse Elliot I Beam rated at 6 830 Ib Suspension Semi elliptical steel alloy leaf springs with stabilizer bar and shock absorbers GAWR 6 830 Ib REAR AXLE Full floating single speed with hypoid gearing rated at 14 550 Ib Suspension Semi elliptical steel alloy leaf springs and shock absorbers GAWR 12 980 Ib WHEELS 19 5x6 0 6 hole disc wheels painted white TIRES 225 70R 19 5F 12 pr tubeless steel belted radials all season front and rear BRAKES Dual circuit power 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 Four channel anti lock brake system FUEL TANK 30 gal rectangular steel fuel tank mounted in frame rail behind rear axle Fuel water seperator mounted on rail FRAME Ladder type channel section straight frame rail 33 5 in w
207. y and battery cover Inspection and filling of brake fluid Inspection and bleeding of the brake system and servo unit Maintenance of clearance for tightening of check bolt on brake safety cylinder Operation 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 accomplishing 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 shortening lengthening the wheelbase on some models itis possible to do so without cutting the frame This is possible on models which have a straight frame rail If the chassis does not have a straight frame rail it may still be necessary to cutthe frame For instructions on shortening lengthening these chassis referto the ALTERING THE WHEELBASE BY ALTERING THE FRAME section of this book Otherwise the wheelbase may be shortened lengthened by removing the rear suspension drilling new suspension mounting holes at the appropriate spot in the frame and sliding the rear suspension suspension liner and suspension crossmembers forward or aft The sus
208. y applications must be approved by Isuzu Application Engineering In the West Coast call 1 562 229 5314 and in the East Coast call 1 404 257 3013 Manual Transmission Automatic Transmission 6 April 2002 FRR WT5500 FRONT AXLE CHART FORMULAS FOR CALCULATING HEIGHT DIMENSIONS TIRE LOADED RADIUS B C CENTERLINE OF AXLE TOP OF FRAME RAIL CURB POSITION D CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD CH TIRE UNLOADED RADIUS DH D TIRE LOADED RADIUS Unit Inch AXLE auer CAPACITY CAPACITY 225 70R19 5 19 500 8 800 Ib 7 06010 8 9 11 39 27 52 26 41 2002 7 FRR WT5500 REAR AXLE CHART 2 50 in MINIMUM TIRE CLEARANCE SECTION BETWEEN LW BODY AND TIRES WHEEL OFFSET J TIRE CLEARANCE f TIRE RADIUS line DEFINITIONS A CENTER LINE OF AXLE TO BOTTOM OF AXLE BOWL B 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 D CENTER LINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD E 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 CH 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 C

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