ISUZU 2003 User Manual

Body Builders Guide

General Motors Isuzu Commercial Truck, LLC (GMICT) and American Isuzu Motors Inc.

Is striving to provide you with the most upto-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

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, any parts, material, colors, special equipment, specifications, designs and models.

Made and printed in the USA.

Contents

Introduction FMVSS EPA Requirements

Installation of Body & Special Equipment

Clearances Body Installations Prohibited Attachment Areas Subframe Mounting Crew Cab Body/Frame Requirements Modification of the Frame Fluid Lines Electrical Wiring & Harnessing Maximum Allowable Current Exhaust System Fuel System Rear Lighting Servicability Wheelbase Alteration Hydraulic Brake System

Body Application Summary Chart

NPR, NPR HD/W3500 W4500 Gas NPR, NPR HD/W3500 W4500 Diesel NQR/W5500 Diesel NPR HD, NQR/W4500 W500 Crew Cab Diesel FRR/WT

Mechanical & Cab Specifications

Engine Horsepower & 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 & FVR Series Towing Procedure

Weight Distribution Glossary of Dimensions Weight Distribution Formulas Recommended Weight Distribution Trailer Weight Performance Calculations Highway Limits Federal Bridge Formula Table

Commodity & Material Weights

Approximate Weight of Commodites & 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 & FVR

NPR, NPR HD/W3500 W4500 Gas Cab Chssis Electrical NPR, NPR HD NQR/W3500 W4500 Diesel Cab Chssis Electrical NPR HD NQR/W4500 W500 Crew Cab Electrical FRR, FSR, FTR & FVR Cab Chassis Electrical

*Note: 2002 FSR, FTR and FVR

Weight Distribution Concepts

Weight Restriction Gross Axle Weight Rating Weighing the Vehicle Tire Inflation Center of Gravity

III

Introduction

This guide has been provided as an aid to final stage manufacturers in determining conformity to the applicable Emission Control and Federal Motor Vehicle Safety Standards. Final stage manufacturers should maintain current knowledge of all Emission Regulations and Federal Motor Vehicle Safety Standards and be aware of their specific responsibility in regards to each standard.

Any manufacturer making material alterations to this incomplete vehicle during the process of manufacturing the 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 instructions contained in this guide with respect to the completion of the vehicle. Otherwise, the warranty becomes the responsibility of the final stage manufacturer.

The final stage manufacturer is solely responsible for the final certification of the vehicle and for compliance with Emission Control and Federal Motor Vehicle Safety Standards. The information contained in this guide has been provided for the final stage manufacturer’s information and guidance.

This guide contains information pertaining to the NPR/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 lbs. Please refer to the following chart.

FMVSS Chart

NOTE: This chart is only a guide, for complete information please refer 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. 3 Canadian MVSS only. 4 Not applicable to truck or bus. 5 Not applicable to trucks with a GVWR greater than 10,000 LBS.

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 RELA TED COMPONENTS

Compliance of this vehicle with EP A, 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 System Charge Air Cooler and Charge Ignition System Air Cooler Hoses Catalytic Converter System Engine Control Module (ECM) Positive Crankcase V entilation System Engine Speed Sensor Exhaust Gas Recirculation System Engine Coolant T emperature Sensor Evaporative Emission Control System Intake Manifold Miscellaneous Items Used in Above Systems Catalytic converter and its location V ariable swirl system Exhaust Gas Recirculation System

ADDITIONAL CANADA MOTOR VEHICLE SAFETY ST ANDARD

CMVSS NO. 1 101-EMISSION DEVICE CMVSS NO. 1 102-CRANKCASE EMISSION (GASOLINE ENGINE ONLY) CMVSS NO. 1 103-EXHAUST EMISSIONS CMVSS NO. 1 104-OPACITY (DIESEL ENGINE ONL Y) CMVSS NO. 1 105- EVAPORATIVE EMISSION (GASOLINE ENGINE ONLY)

[B] NOISE

Compliance of this vehicle with EP A and Canada requirements will be maintained providing no alterations are made to the components or systems.

CMVSS NO. 1 106-NOISE

This incomplete vehicle, when completed, will conform to the above standards except CMVSS-1106 providing no alterations are made which effect the function, physical or mechanical properties, environment, locations or vital spatial clearances of the components identified below:

* Engine assembly Exhaust emission control system P.C.V. system (if equipped) * Intake system * Exhaust system Fuel system (if equipped) * Transmission assembly * Axle * Tires * Fan and drive Diesel fuel injection controls (if equipped) Turbocharger and associated controls (if equipped) * Catalytic converter and its location V ariable swirl system (if equipped)

VII

Conformity with CMVSS 1 106 is not determined solely by the design of the incomplete vehicle. When completed, it should conform to CMVSS 1 106 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 .

P A R T 3 : Radio Noise CANADIAN RADIO INTERFERENCE REGULA TIONS [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 substitutions are made which affect any parts or components identified below:

A. Distributor B. Ignition Wires C. Spark Plug Wires

FSR, FTR & FVR

U.S. ENVIRONMENT AL PROTECTION AGENCY AND STA TE 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 EP A and California Certification Requirements will be maintained providing no alterations are made to the components or systems identified below:

1. DIESEL VEHICLES Injection Pump

Injector and High Pressure Lines Turbocharger 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 (6HE1-TC only) Air cylinder for variable swirl system (6HE1-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. 1 101-EMISSION DEVICE CMVSS NO. 1 103-EXHAUST EMISSIONS CMVSS NO. 1 104-OPACITY CMVSS NO. 1 106-NOISE

This incomplete vehicle, when completed, will conform to the above standards except CMVSS 1106 providing no alterations are made which affect the function, physical or mechanical properties, environment, locations or vital spatial clearances of the components identified below:

Engine assembly* Exhaust emission control system P.C.V . system Intake system* Exhaust system* Fuel system Transmission assembly* Axle* Tires* Fan and drive* Diesel fuel injection controls Turbocharger and associated controls Catalytic converter and its location (6HE1-TC only) * Air cylinder for variable swirl system (6HE1- TCS only)

Compliance of this vehicle with EP A 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 Body & Special Equipment

Installation of Body

Special Equipment

April 2002 1

Installation of Body & 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

Clearance

1.6 Inch

Clearance

Engine

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

Engine

Clearance

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.

5.9 Inches or More M/T

(150)

2.0 Inches or More A/T

(58)

Transmission

2 April 2002

Installation of Body & 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

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

1.25 Inches or more

3.9 Inch

Clerance

Oil Pump

Heat Shield

Front Propellar Shaft

April 2002 3

Exhaust Pipe

Muffler

Installation of Body & 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.

Rear of Body

*NOTE: For recomended clearances

please refer to the Rear Axle Chart in each models respective section.

Normal Rear

Axle Center Line

Rear Wheels

Over High Spot

Rear Wheels

Over Obstacle

Other Clearances

Transmission control cable may be broken if it is bent by or interferes with the body and its fixtures. To prevent this, 1 inch minimum clearance should be provided. When cable is detached for body mounting, be sure not to bend the cable.

Accessibility to the grease nipple on the rear spring bracket/shackle should be provided so that serviceability with a grease gun is not hampered.

MINIMUM

PARTS CLEARANCE LOCATION

Brake Hose 6.7 in. Axle side

1.6 in. Frame side Parking Brake Cable 1.2 in. -------Fuel Hose 1.6 in. -------Shock Absorber 2.4 in. Axle Side

1.2 in. Frame Side

4 April 2002

Installation of Body & 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 special equipment on the chassis, extra consideration must be given to the weight and construction of the equipment to assure proper distribution of the load. Localization of the load should be prevented. All special equipment should be properly secured into position. We recommend the use of subframe members when installing special equipment.

Subframe Design and Mounting

The subframe assembly should be mounted as close to the cab as possible. It should be contoured to match the shape and dimensions of the chassis frame as closely as possible.

Rear End of the Cab

April 2002 5

Installation of Body & Special Equipment

Subframe Contour

Contouring of the front end of the subframe members as shown in the three illustrations below will prevent stresses from being concentrated on certain areas of the chassis frame.

Wooden subframe

Steel subframe

Drawing A B

1 0.2 in. H

2 0.2 in. H or more

3 H H or more

2 ~ H

When using a steel subframe, do not close the end of the subframe.

Steel subframe

Chassis frame

6 April 2002

Installation of Body & Special Equipment

Prohibited Attachment Areas

Do not attach the subframe with a bolt on bracket to the chassis frame at the points indicated by shading in the following illustrations.

1. At the front end of the subframe. The attaching bolt or bracket must be at least 2 inches behind the kick up point of the subframe.

2. Within 8 inches of bends in the chassis frame or the attachment points of any cross members.

3.3

8 in. 8 in

6.1

8 in. 8 in

3.1

Do not attach in these areas.

3.12.9

2.8

April 2002 7

Installation of Body & 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.”

Bolster

Subframe member

Cushioning material

Chassis frame

Bracket

Cushioning material

Chassis 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 inch clearance between rigid or stationary portions, and at least 1.6 inch between moveable or flexible portions of the lines.

Reinforcement block (Reinforcement blocks should be mounted securely in installed position)

For the installation positions of the U-bolts, refer to “Prohibited Attachment Areas.”

8 April 2002

Installation of Body & 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 lbs/ft = ok 5"x1-3/4", 6.7 or 9.0 lbs/ft = ok 6"x2", 8.2, 10.5 or 13.0 lbs/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 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 kept in mind when the equipment is installed, localization of stresses on specific areas of the frame could cause cracking of the chassis frame members or other problems, even if the total weight of the equipment is within the design limit.

The chassis frame is designed as an integral unit. Therefore, we do not recommend cutting the chassis frame

under any circumstances.

Drilling and Welding

IMPORTANT NOTE

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 a torch to make any holes.

4. All riveting must be done with cold rivets. Do not use hot rivets.

5. The flange of the chassis frame must not be cut under any circumstances.

6. The subframe must be attached to the chassis frame with bolts. Do not weld.

Dimensions: A - not more than 0.51 in. in diameter

April 2002 9

B - must be more than 0.8 in. C - must be more than 1.0 in.

Installation of Body & 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

1. Keep reinforcement plates and chassis frame free from moisture and water.

2. Avoid cooling with water after welding.

3. Use a suitable means to protect pipes, wires, rubber parts, leaf springs, etc. against heat and affect of sputtering.

4. Remove fuel tank assembly when welding portions near the fuel tank.

5. Remove coat of paint completely when welding painted areas.

SATISFACTORY

Fluid Lines

Reinforcement

Plug weld or rivet

UNSATISFACTORY

Frame rail

Reinforcement

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. 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

1. 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 Body & 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.

2. Minimize any crossing between lines. If a crossing is unavoidable, use the following procedure: a. At least 0.4 inch clearance should be maintained between lines at the crossing point. b. If the 0.4 inch clearance cannot be maintained, or if the lines are subject to vibration, clip

them securely.

3. Plan the bends and clipping points of the lines to minimize vibration and the resulting fatigue.

4. Use rust-proofed clips and apply vinyl coating to the portions of the lines to be clipped.

5. Install new lines in positions where they are protected against water, dirt, grit, sand, rocks and other foreign matter that can come from above or below, or can be flung up by the wheels.

Lines

Clip

0.4 in. or more

Vinyl

Clip

Electrical Wiring and Harnessing

To increase the reliability of the wiring, all frame harnesses are covered with corrugated vinyl tubing. The following instructions apply to extending or modifying these harnesses. See the Electrical Section for information on commonly used circuits in the NPR, NQR, FRR and W-Series. The FSR, FTR and FVR wiring information can be found in the service manuals.

Wiring

1. Most wiring connections on Isuzu vehicles are made with terminals. We recommend the use of terminals when splicing cables and wires.

2. When splicing, use new wire of the same gauge, and do not make splices inside the corrugated tubing.

3. When making connections to the end of the harness, make sure the connections are electrically perfect. Use insulating tape as needed to prevent the entry of water, which results in short circuits and/or corrosion.

4. When making new circuits, or modifying circuits already installed, make the cables only just taut enough to remove any slack. Use clips or grommets where required to protect cables from heat or sharp edges. When cables must run near the exhaust system, see the instructions in the “Exhaust System” section.

5. Always use rustproof clips, and apply vinyl coating to that portion of the clips in direct contact with the harnesses. No scotch clips or connectors.

6. To minimize the vibration of the harness, clipping points should be set up according to the table.

Harness Diameter Clip Distance

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.

April 2002 11

Installation of Body & 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

Clip

Harness

Direct contact*

SATISFACTORY

Rubber grommet

Steel plate

SATISFACTORY

Electric wire

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

Harness

SATISFACTORY UNSATISFACTORY

UNSATISFACTORY

Harness*

The harness receives the adverse affect of dirt, grit, or water

* 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

When parallel: 0.4 in. or more When across: 0.8 in. or more

Harness

12 April 2002

UNSATISFACTORYSATISFACTORY

Taping*

Installation of Body & 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.

(1) Black B Starter circuits and grounds (2) White W Generator (alternator) circuit (3) Red R Lighting circuit (4) Green G Signal circuit (5) Yellow Y Instrument circuit (6) Brown Br Accessory circuit (7) Light Green Lg Other circuit (8) Blue L Windshield wiper motor circuit

Maximum Allowable Current

Harness Design AWG No. of wires/ Cross sectional Maximum allowable

Diameter (mm) equivalent wire diameter (mm) area (mm2) current (Amps)

100 00 217/0.80 109.1 363

85 0 169/0.80 84.96 305 60 1 127/0.80 63.84 248 50 1 108/0.80 54.29 223 40 1 85/0.80 42.73 191 30 2 70/0.80 35.19 171 20 4 41/0.80 20.61 123 15 6 84/0.45 13.36 93

8 8 50/0.45 7.952 68 5 8 65/0.32 5.228 51 3 12 41/0.32 3.297 39 2 14 26/0.32 2.091 29

1.25 16 16/0.32 1.287 21

0.85 18 11/0.32 0.8846 17

0.5 20 7/0.32 0.5629 13

Reference: The values given in the “maximum allowable current” column are based on the ambient temperature condition of 104o F with temperature increase of 104o F.

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 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 Body & 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.

CLEARANCE

Brake Lines 2.4 in. or more. (If the combined section of a group of parallel brake lines is

more than 7.8 in., a clearance of 7 in. or more should be provided.)

Flexible brake hoses 3.9 in. or more. (The temperature of flexible brake hoses should not exceed

158o F. If the highest temperature is not measurable, a clearance of more than 15.7 in. should be maintained between the hoses and the exhaust system.

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. If 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. Do no connect 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 Body & Special Equipment

3. Adjustment, removal and installation of the fan belts.

4. Inspection, filling and removal of the battery and battery cover.

5. Inspection and filling of brake fluid.

6. Inspection and bleeding of the brake system and servo unit.

7. Maintenance of clearance for tightening of check bolt on brake safety cylinder.

8. Operation of the spare tire carrier, including mounting and dismounting of the spare tire.

9. 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, it is possible to do so without cutting the frame. This is possible on models which have a straight frame rail. If the chassis does not have a straight frame rail, it may still be necessary to cut the frame. For instructions on shortening/lengthening these chassis, refer to the ALTERING THE WHEELBASE BY ALTERING THE FRAME section of this book. Otherwise, the wheelbase may be shortened/ lengthened by removing the rear suspension, drilling new suspension mounting holes at the appropriate spot in the frame, and sliding the rear suspension, suspension liner, and suspension crossmembers forward or aft. The suspension and suspension crossmembers' rivet holes left in the frame rail flange must be filled with GRADE 8 bolts and hardened steel washers at both the bolt head and nut, HUC bolts or GRADE 8 flanged bolts and hardened steel washers at the nut. When shortening/lengthening the wheelbase in this manner, the following guidelines must be adhered to:

1. All frame drilling must comply with the DRILLING AND WELDING section of this book.

2. All rivet holes left in the frame rail flange from the suspension and suspension crossmembers must be either filled with GRADE 8 bolts and hardened steel washers at both the bolt head and nut, HUC bolts or GRADE 8 flanged bolts and hardened steel washers at the nut.

3. The components required to be slid forward or aft are the suspension and suspension hangers, suspension crossmembers and suspension frame liner.

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 (in case of a lengthened wheelbase). Difference between WB (new) and WB (old). SL - Shortened length (in case of shortened wheelbase). Difference between WB (old) and WB (new).

April 2002 15

Installation of Body & Special Equipment

1. Determine the added length (AL) or shortened length (SL) required to lengthen or shorten chassis. (For added wheelbase: New CA = CA + AL; For shortened wheelbase: New CA = CA - SL)

2. Obtain the material to be used as the insert for the lengthened wheelbase in the correct length (AL). The insert must have the same cross sectional dimensions and yield strength as the original frame rail.

3. Divide the new CA by two (2). Measure (new CA)/2 from the center of the rear axle forward and mark this point on the chassis frame (see figure below).

Cut Point

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 at this time. If the wheelbase is to be shortened, measure the distance (SL) forward of this cut and remove a length (SL) section from the chassis frame (see figure below). Insure that an adequate area on the frame remains for the required addition of the necessary reinforcements. These are the only suggested places for cutting the frame and reinforcements but may be changed upon the advice of General Motors Isuzu Commercial Truck, LLC (GMICT) and American Isuzu Motors Inc. Application Engineering.

Section to be Added

Cut Point

Lengthening the Wheelbase

New CA 2

Second Cut Point

Section to be Removed

First Cut Point

New CA 2

Shortening the Wheelbase

16 April 2002

Installation of Body & 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.

BUTT WELD 100 % - Weld can be inside or outside of member or, as shown, a combination of both

1.0 in. or more

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.

AL3 x D 3 x D

6 x D + AL

Lengthened Wheelbase

3 x D

Shortened Wheelbase

3 x D

6 x D

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 reinforcement (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).

Snug fit inner channel with "Inverted L" for "Long Bridge" wheelbasesSnug fit inner channel

April 2002 17

Installation of Body & Special Equipment

7. The reinforcements must be fastened securely to only the web of the original chassis frame rail. The reinforcement must be held rigidly in place using either HUC bolts, GRADE 8 bolts and hardened steel washers at both the bolt head and nut, or GRADE 8 flanged bolts and hardened steel washers at the nut. Below are some suggested bolt patterns. It should be noted that these bolt patterns must not align the bolts vertically, i.e.: the bolt pattern must be staggered.

8. Lengthening the frame will also require extending the brake lines, basic chassis electrical harnesses, excluding ABS wiring harness. It is recommended that the original brake lines be removed and replaced with brake lines of the same diameter as the original lines and of the appropriate length. The electrical harness must be extended in accordance with the ELECTRICAL WIRING AND HARNESSING section of this book.

9. The propeller shafts’ overall length will also need to be lengthened or shortened. If the extension is within the limits of the optional wheelbases of the respective model, the exact propeller shaft lengths and angles are given on or about Page 12 of the respective sections of this book. If the modified wheelbase exceeds the optional wheelbases of the respective model, the following guidelines must be adhered to:

A. Propeller Shaft Length The maximum propeller shaft lengths (pin to pin) for the respective models are shown in the table below.

NPR NPR GAS NQR FRR

Propeller

Shaft 3.25 3.0 3.0 4.0 Diameter (in)

Maximum Propeller Shaft 50.8 50.8 50.8 62.0 Length (in)

18 April 2002

Installation of Body & 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

Maximum Propeller

Shaft Angle 5.7

5.1

5.7

5.5

C. The propeller shaft angles must be designed such that the angles will cancel to avoid propeller shaft whip. D. The propeller shaft yokes must be assembled such that the propeller shaft yokes are “in phase.” “In

phase” means that the yokes at either end of a given propeller shaft assembly are in the same plane.

10. Extending the frame will also require relocation and/or addition of crossmembers. If the extension is within the limits of the optional wheelbases of the respective model, the exact 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. The cross member location will largely be determined by the propeller shaft lengths and where the center

carrier bearing locations are for the propeller shaft assembly.

B. A cross member must be located at the front and rear spring hangers of the rear suspension (refer to the

appropriate section of this book to see where these suspension cross members are to be located).

C. The cross member must be constructed such that it supports both the upper and lower flange on each

frame rail (see drawing below). A cross member such as 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 Body & Special Equipment

D. The maximum distance between crossmembers for the respective models is given in the table below.

NPR/W NPR/W GAS NQR/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 applications 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 of the following structural steel "C" channels:

4"x1-5/8", 7.25 lbs/ft = ok 5"x1-3/4", 6.7 or 9.0 lbs/ft = ok 6"x2", 8.2, 10.5 or 13.0 lbs/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 disconnection will not be necessary. If the wheelbase is changed the trim level of the ABS system must be readjusted per the instructions in the service manual. An Authorized Isuzu dealer should do this reprogramming using appropriate tools.

For your reference and to help you determine if the system needs to be reprogrammed the following provisions apply to all ABS systems with hydraulic brakes. The ABS module has four (4) programs: A, B, C, and D. These programs are tied to the wheelbase and axle combination of the chassis. (The axle and wheel base codes can be found on the passenger’s visor.)

A is for the FL1 axle and covers wheelbase from 140 (FQT), 158 (EG5), 170 (EH8) 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 Body & Special Equipment

C is for the FL1 axle and covers wheelbase from 188 (EK8), 200 (EM2), 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. 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.

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 and hose material.

April 2002 21

Installation of Body & Special Equipment

22 April 2002

Body Applicaton Summary Chart

Body Application

Summary Chart

April 2002 23

Body Application Summary Chart

2002 GAS & 2003 DIESEL MODEL YEAR BODY APPLICA TION SUMMARY CHART

MODEL/GVWR WB BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft.

NPR/W3500 GAS 109 9.25 X X

12,000 lbs 132.5 9.25 X

150 9.25 X X 176 9.25 X

NPR HD/W4500 GAS 109 9.25 X X

14,050 lbs 132.5 9.25 X

150 9.25 X X 176 9.25 X

NPR/W3500 DSL 109 9.25 X

12,000 lbs 132.5 9.25 X

150 9.25 X X 176 9.25 X

NPR HD/W4500 DSL 109 9.25 X

14,500 lbs 132.5 9.25 X

150 9.25 X X 176 9.25 X

(1)

NPR HD/W4500 CREW CAB DSL 150 4.2 X

14,500 lbs 176 4.2 X

(3)

(4)

NQR/W5500 DSL 109 9.25 X

17,950 lbs 132.5 9.25 X

150 9.25 X X 176 9.25 X

NQR/W5500 CREW CAB DSL 150 4.2 X

17,950 lbs 176 4.2 X

(3)

(4)

MT/AT

FRR/WT5500 DSL 14 8 7.5/10 X

(2)

18000/19,500 167 7.5/10 X

179 7.5/10 X 191 7.5/10 X 218

10.0/10

Notes:

1. NPR, NPR HD/W3500 W4500 Diesel 20’ ft. body requires Isuzu/GM Application Engineering Department approval.

2. BOC 10.0 inches. For MT

UNIT: INCH

3. 16’ Dovetail landscape (12’ deck plus 4’ dovetail).

4. 18’ Dovetail landscape (14’ deck plus 4’ dovetail).

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.

24 April 2002

Body Applicaton Summary Chart

2002 GAS & 2003 DIESEL MODEL YEAR*

BODY & PAYLOAD WEIGHT DISTRIBUTION

(% FRONT/% REAR)

MODEL GVWR WB CA CE OAL BOC 10 12 14 16 18 20

AUTOMATIC TRANSMISSION NPR/W3500 GAS 12,000 109 88.4 131.5 199.5 9.25 18/82 7/93 NPR HD/W4500 GAS 14,050 109 88.4 131.5 199.5 9.25 18/82 7/93 NPR/W3500 GAS 12,000 132.5 111.9 155 223 9.25 14/86 NPR HD/W4500 GAS 14,050 132.5 111.9 155 223 9.25 14/86 NPR/W3500 GAS 12,000 150 129.4 172.5 240.5 9.25 16/84 8/92 NPR HD/W4500 GAS 14,050 150 129.4 172.5 240.5 9.25 16/84 8/92 NPR/W3500 GAS 12,000 176 155.4 198.5 266.3 9.25 15/85 NPR HD/W4500 GAS 14,050 176 155.4 198.5 266.3 9.25 15/85

MODEL GVWR WB CA CE OAL BOC 10 12 14 16 18 20

MANUAL/AUTOMATIC TRANSMISSION NPR/W3500 DSL 12,000 109 88.4 131.5 199.5 9.25 7/93 NPR HD/W4500 DSL 14,500 109 88.4 131.5 199.5 9.25 7/93 NPR/W3500 DSL 12,000 132.5 111.9 155 223 9.25 14/86 NPR HD/W4500 DSL 14,500 132.5 111.9 155 223 9.25 14/86 NPR/W3500 DSL 12,000 150 129.4 172.5 240.5 9.25 16/84 8/92 NPR HD/W4500 DSL 14,500 150 129.4 172.5 240.5 9.25 16/84 8/92 NPR/W3500 DSL 12,000 176 155.4 198.5 266.3 9.25 15/85 NPR HD/W4500 DSL 14,500 176 155.4 198.5 266.3 9.25 15/85

MODEL GVWR WB CA CE OAL BOC 10 12 14 16 18 20

MANUAL/AUTOMATIC TRANSMISSION NQR/W5500 DSL 17,950 109 88.4 131.5 199.5 9.25 7/93 NQR/W5500 DSL 17,950 132.5 111.9 155 223 9.25 14/86 NQR/W5500 DSL 17,950 150 129.4 172.5 240.5 9.25 16.84 8/92 NQR/W5500 DSL 17,950 176 155.4 198.5 266.3 9.25 15/85 8/92

*NPR, NPR HD/W3500, W4500 GAS and DIESEL 20 foot body requires Isuzu/GM Application Engineeering 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 lb. driver) from GVWR. These tables are intended for reference and do not preclude the necessity for an accurate weight distribution calculation.

April 2002 25

Body Application Summary Chart

2003 MODEL YEAR DIESEL CREW CAB BODY & PAYLOAD WEIGHT DISTRIBUTION

(% FRONT/% REAR)

MODEL GVWR WB CA CE OAL BOC 10 12 14 16

NPR HD/W4500 CREW CAB DSL 14,500 150 88.9 132 240.5 4.2 8/92 NPR HD/W4500 CREW CAB DSL 14,500 176 114.9 158 266.5 4.2 15/85

MODEL GVWR WB CA CE OAL BOC 10 12 14 16

NQR HD/W5500 CREW CAB DSL 17,850 150 88.9 132 240.5 4.2 16/84 8/92 NQR HD/W5500 CREW CAB DSL 17,850 176 114.9 158 266.5 4.2 15/85 8/92

IMPORTANT:

Weight distribution percentages listed do not include added accessories, liftgate or refrigeration units. Percentages based on water-level distribution of body and payload weight which is determined by subtracting chassis wet weight (including 200 lb. driver and a crew of 6 @200 lbs each) from GVWR. These tables are intended for reference and do not preclude the necessity for an accurate weight distribution calculation.

26 April 2002

Manual Transmission

Body Applicaton Summary Chart

2003 MODEL YEAR

BODY & PAYLOAD WEIGHT DISTRIBUTION

(% FRONT/% REAR)

MODEL GVWR WB CA CE OAL BOC 14 16 18 20 22 24

FRR/WT5500 18000/19500 148 117.1 180.6 259.3 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 7.5 11/89 FRR/WT5500 18000/19500 191 159.8 243.9 322.2 7.5 11/89 FRR/WT5500 18000/19500 218 187.4 283.3 362.0 10.0 15/85

Automatic Transmission

MODEL GVWR WB CA CE OAL BOC 14 16 18 20 22 24

FRR/WT5500 18000/19500 148 117.1 180.6 259.3 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 15/85

NOTES:

1. BOC 10.0 Inches. For MT

IMPORTANT:

April 2002 27

Mechanical & Cab Specifications

Mechanical

Cab Specifications

26 April 2002

Mechanical & 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

MODEL APPLICATION HP/RPM LBS-FT/RPM HP/RPM LBS-FT/RPM

GMPT- NPR/W3500,

5.7L-V8 NPR HD/W4500

N/A N /A 250/4400 330/2800

GAS

ISUZU NPR/W3500, 4HE1-TC NPR HD/W4500 137/2800 268/1300 142/2800 275/1300 M/T DIESEL

ISUZU NPR/W3500, 4HE1-TC NPR HD/W4500, 169/2700 339/2000 175/2700 347/2000 A/T NQR/W5500

DIESEL

ISUZU NQR/ 4HE1-TC W5500 169/2700 339/2000 175/2700 347/2000 M/T DIESEL

GROSS HP

GROSS TORQUE

ISUZU FRR/ 6HK1-TC WT5500 193/2400 426/1500 200/2400 441/1500 M/T DIESEL

ISUZU FRR/ 6HK1-TC WT5500 193/2400 426/1500 200/2400 441/1500 A/T 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 (lbs) GCWR (lbs)

NPR/W3500 GAS AUTOMATIC 12,000 15,000 NPR HD/W4500 GAS AUTOMATIC 14,050 17,050 NPR/W3500 DIESEL AUTOMATIC 12,000 18,00 0 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 MANUAL 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 & Cab Specifications

The following chart provides the rear frame height for each model/GVWR with standard tires:

GVWR STANDARD FRAME HT (in)

MODEL (lbs) TIRE FH STD. TIRES

NPR/W3500 GAS

NPR HD/W4500 GAS

NPR/W3500 DIESEL

NPR HD/W4500 DIESEL

NQR/W5500 DIESEL 17,950

FRR/WT5500 DIESEL 18,000/19,500

FSR/FTR/FVR (2) (2) (2)

(1) 191 and 218 WB have frame height of 37.3 inches (2) Refer to FSR, FTR, and FVR section

11,050 215/85R-16E 32 14,050 225/70R-19.5F 32.75 12,000 215/85R-16E 32 14,050 215/85R-16E 32

225/70R-19.5F 32.8 225/70R-19.5F 35.3 (1)

CLUTCH ENGAGEMENT TORQUE CHART

The following table provides the engagement torque of the engines currently in use in Isuzu medium duty trucks:

Torque at

Engine (lbs-ft) (RPM)

ISUZU 4HE1-TC (142 HP) 260 1,000 ISUZU 4HE1-TC (175 HP) 265 1,000 ISUZU 6HK1-TC (200 HP) 331 1,000 ISUZU 6HK1-TC (230 HP) 368 1,000

28 April 2002

Mechanical & Cab Specifications

April 2002 29

30 April 2002

CV CHART 2

ISUZU

PAINT

CODE

301-W-30102 N/A Accuride White B302-P801-0 730 Adriatic B lue ( Soli d) W301-P801-0 729 Arc White WE8774 N/A *Bright Red 0133-P1 N/A Calm White WE5398 N/A *Dark Green Gray U715-P801-0 809 Doeskin Tan 0172-P1 844 Glacier White WE9907 N/A *Medium Adriatic Blue B721-P801-0 801 Medium Blue N507-P901-0 845 Polar Silver R725-P801-0 810 Red Orange WE9885 N/A *Rose Black G021-P801-0 989 Sunbelt Green U716-P801-0 815 Tangier Orange Y719-P801-0 812 Wheatland Yellow G705-P801-0 807 Woodland Green

ISUZU

OPTION

CODE

ISUZU

COLOR

NAME

AKZO

NOBEL

CODE

FLNA40154 FLNA50274 FLNA40156 FLNA30252 FLNA40252 FLNA90856 FLNA80050 FLNA40155 FLNA90857 FLNA50172 FLNA91205 FLNA20079 FLNA90858 FLNA60290 FLNA20080 FLNA10182 FLNA60181

BASF

R-M

CODE

RM25319 IS-25319

730 730

RM25318 IS-25318

27427 IS-27427

HS14391 IS-820

27425 IS-27425 27406 IS-U715

RM15602 IS-844

27426 IS-27426 27403 IS-B721 23664 845 27407 IS-R725 27428 IS-27428

605301 989

27409 IS-U716 27408 IS-Y719 27404 IS-G705

BASF GLAS CODE

DUPONT

CODE

F2499 8AR8 91513 W9775 2NV9B 19320 W9774 2NV8 91512

C8508 TC78B 75057

G8477 KK27 91522

B9329 2NP9B 36575

B8462 KPL5B 28613

H8620 ND92 90330

B9321 2NY4B 190401

B8041 KPL2B 190217

F2193 EPW3B 36658

B8250 KPL4B 61784

B9218 1AB2B 95057 M6682 WMK4 401420

B9043 KPL6B 61785

B9042 KPL7B 83931

B8046 KPL3B 48339

ICI

AUTO

COLOR

PPG

CODE

SHERWIN

WILLIAMS/

MARTIN

SENOUR

51548 15593 57541 50287 51400 10280 34983 34169 34657 16222 47155 65071 56203 21882 35478 10281 46829 56120 56143 55934 56991 73192 56202 21881 45738 74223 61559 67847 56204 21883 56144 21884 56201 64962

SPIES

HECKER

CODE

STANDOX

301-W-30102

730 729 N/A

0133-P1

N/A 809 844 N/A 801 845 810 N/A 989 815 812 807

Mechanical & Cab Specifications

NOTES:

1. ST ANDBOX uses paint code found in vehicle for paint identification.

2. GM-Based colors. No Isuzu Option Code.

Mechanical & 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 instructions 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.

• If there is damage or suspected damage to the rear axle, remove the axle shafts.

• Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects.

• Place 4” x 4” wood beam against the towing guide behind the bumper. (If no 4” x 4” is available, then remove the bumper.) Ensure 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.

1. Bumper

2. Towing Chain

3. Towing GUide

4. Front Axle

5. Tow Hook

To prepare a disabled vehicle for 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.

• If there is damage or suspected damage to the rear axle, remove the axle shafts.

• Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects.

April 2002 31

Mechanical & 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. All 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 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

Y our 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 axle with oil if required.

FRONT END TOWING (ALL WHEELS ON THE GROUND)

Y our 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 & 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 required.

SPECIAL TOWING INSTRUCTIONS

1 . Call your local authorized dealership or professional towing service.

2. All 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 & 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 a 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 service:

• 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 & Cab Specifications

T owing 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.

T owing 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 or crossmember.

After T owing

Block the rear wheels and 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.

T owing 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 T owing

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 T owing

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.

T owing Your Vehicle From the Rear (Rear Wheels Off the Ground)

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.

34 April 2002

Mechanical & Cab Specifications

Before T owing

After T owing

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.

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 procedure to release the other brake.

7. At the 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 Restrictions & Specifications

Weight Distribution

Concepts

April 2002 31

Weight Restrictions & 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 may be affected in various ways, including but not limited to the following:

1) The installation of a body or equipment that exceeds the rated capacities of 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 lbs.

From required vehicle section

PLUS weight of added body components, accessories or other permanently attached components.

Body, liftgate, reefer, etc.

PLUS total weight of passengers, air conditioning and all load or cargo.

EQUALS Gross Vehicle Weight lbs (GVW) of completed vehicle.

Driver, passengers, accessories and load.

Should equal GVWR from required vehicle section

32 April 2002

Weight Restrictions & 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 exceeded. Always verify the results by weighing the completed vehicle on a certified scale.

Note: Although the Front Gross Axle Weight Rating (FGAWR) plus the Rear Gross Axle Weight Rating

(RGAWR) may exceed the Gross Vehicle Weight Rating (GVWR), the total GVW may not exceed the respective maximum GVWR.

The variation in the GAWR's allow the second stage manufacturer some flexibility in the design of the weight distribution of the attached unit.

Weighing the Vehicle

Front and rear GAWR's and total GVWR should be verified by weighing a completed loaded vehicle. 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 of the center of gravity is not violated.

April 2002 33

Weight Restrictions & 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. A short distance or a long distance, the weight to be hauled, more than any other factor, determines the size of the truck. A small weight requires only a small truck; a large weight requires a large truck. A simple principle, but it can easily be misapplied. In any case, selecting the right size truck for the load to be hauled will ensure that the job will be done and that is will be able to be done with some degree of reliability and within the legal limitations of total gross weight and axle gross weights.

Not only must a truck be selected that will handle the total load, but the weight must also be properly distributed between the axles. This is of extreme importance from both a functional and economic aspect. If a truck consistently hauls less than its capacity, the owner is not realizing full return on his investment and his operating costs will be higher than they should be. If the truck is improperly loaded or overloaded, profits will be reduced due to increased maintenance costs and potential fines resulting from overloading beyond legal limitations. Careful consideration must be given to distribution of the load weight in order to determine how much of the total, including chassis, cab, body and payload, will be carried on the front axle and how much will be carried on the rear axle, on the trailer axles and the total. Moving a load a few inches forward or backward on the chassis can mean the difference between acceptable weight distribution for the truck or an application that will not do the job satisfactorily.

Every truck has a specific capacity and should be loaded so that the load distribution is kept within Gross Axle Weight Ratings (GAWR) and the truck’s Gross Vehicle Weight Rating (GVWR) or Gross Combination Weight Rating (GCWR) for a tractor/trailer and the weight laws and regulations under which the truck will operate. Improper weight distribution will cause problems in many areas:

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. If the center of the payload is directly over or slightly

behind the rear axle, the lack of sufficient weight on the front axle will create a bobbing effect, very rough ride, and erratic steering. This condition will be magnified when the truck is going up hill.

4. Hard steering a. When loads beyond the capacity of the front axle

are imposed upon it, the steering mechanism is also overloaded and hard steering will result.

b. Excessive overloading could result in steering

component damage or failure.

5. Unsafe operating and conditions. a. Poor traction on the steering axle effects the safety

of the driver and equipment, particularly on wet, icy and slippery surfaces. Experience indicates that approximately 30 % of the total weight at the ground on a truck or tractor should be on the front axle with a low cab forward vehicle.

b. When a truck is overloaded, a dangerous situation

may exist because minimum speeds cannot always be maintained, directional control may not be precise and insufficient braking capacity can cause longer than normal braking distances.

6. High maintenance costs a. Improper weight distribution and overloading cause

excessive wear and premature failure of parts. Additional stresses impose on the frame by the misapplication of wheel bases, may be instrumental in causing the frame to crack or break.

34 April 2002

Weight Restrictions & Specifications

7. Noncompliance with weight laws and regulations a. When there is the possibility that axle loads will

exceed existing weight laws and regulations, careful weight distribution is necessary to provide a correct balance between front and rear axle loads, and total load within legal limitations.

In this way, maximum payloads may be carried without exceeding legal limits. If the body is too long for a wheelbase, the center of the body and payload is placed directly over the rear axle. This places all the payload on the rear axles, resulting in overloading the rear tires, rear

axle springs and wheel bearings and potentially exceeding the rear axle legal weight limit. The front axle is then carrying no part of the payload and is easily lifted off the ground when going over rough terrain, creating a very rough ride and temporary loss of steering control. If the body is too short for the wheelbase used, frame stress may be increased and may result in excessive loads on the front axle. Excessive front axle loads increase wear on the 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.

April 2002 35

Weight Restrictions & Specifications

Weight distribution analysis involves the application of basic mathematical principles to determine the proper positioning of the payload and body weight in relation to the wheelbase of the truck chassis.

It is much less expensive to work all of this out on paper, make mistakes on paper and correct them there

BBC

BOC

than to set up the truck incorrectly and either have it fail to do the job or much worse, fail completely.

It is important to become familiar with the dimensions of the truck as these will be needed to perform the necessary calculations.

Glossary of Dimensions

OAL

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 DISTRIBUTION FORMULAS

Weight Restrictions & Specifications

L/2

CoG

A = Front axle to back - of - cab B = Distance between cab and body 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

F = (A + B + C) or distance C.G. of weight of fifth wheel is behind front axle

WB = Wheelbase

W = Weight of body plus payload, or kingpin load

Wf= Portion of W transferred to front axle

Wr= Portion of W transferred to rear axle

Basic Formulas: (a) W x D = Wf x WB (c) WB = (A + B + C + D) = (F + D)

(b) W x F = Wr x WB (d) W=Wf x W

L/2

1. Wf= W x D 5. Wr=W x F

WB WB

2. D=Wf x WB 6. F=Wr x WB W W

3. WB = W x D 7. WB = W x F W

4. W=Wf x WB 8. W=Wr x WB D F

April 2002 37

Weight Restrictions & Specifications

WEIGHT DISTRIBUTION FORMULAS IN WORDS

To find:

1. Weight transferred to front axle = (Total weight) x (Distance C.G. is ahead of the rear axle) (Wheelbase)

2. Distance C.G. must be placed = (Weight transferred to the front axle) x (Wheelbase)

ahead of rear axle (T otal weight)

3. Wheelbase = (Total weight) x (Distance C.G. is ahead of the rear axle)

(Weight to be transferred to the front axle)

4. Total Weight = (Weight to be transferred to the front axle) x (Wheelbase)

(Distance C.G. is ahead of the rear axle)

5. Weight transferred to the rear axle = (Total weight) x (Distance C.G. is behind the front axle) (Wheelbase)

6. Distance C.G. must be placed = (Weight transferred to the rear axle) x (Wheelbase)

behind the front axle (T otal weight)

7. Wheelbase = (Total weight) x (Distance C.G. is behind the front axle)

(Weight to be transferred to the rear axle)

8. Total weight = (Weight to be transferred to the rear axle) x (Wheelbase)

(Distance C.G. is behind the front axle)

9. Remember - Total weight must always equal weight transferred to the rear axle plus

the weight transferred to the front axle.

38 April 2002

100 lb.

Weight Restrictions & Specifications

P lb.

To find the value of "P", the leverages must be

equal for balance.

i.e.

100 lb x 8 in = "P" x 20 in

"P" = 100 lb x 8 in

20 in

Therefore:

"P" = 40 lb

20"

Pivot

This same approach is used to determine axle loadings on a tractor or truck chassis. Assuming the rear axle serves as a pivot point, the front axle load can be determined by applying the lever principle.

Kingpin

Load

(W)

5th wheel location (ahead of rear axle CL) (D)

Wheelbase (WB)

Front axle

load (WF)

Front Axle Load:

= Kingpin Load x 5th Wheel Location

Wheelbase

Rear Axle Load:

= Kingpin Load - Front Axle Load

Example: (4) A tractor has a wheelbase of 150 inches.

If the kingpin load is 20,000 lb and the fifth wheel location is 15 inches, find the total weight on the front and rear axles. The tare weight of the tractor is 7,000 lb on the front axle and 4,400 lb on the rear axle.

Front Axle = Load 20,000 x 15 = 2,000 lb 150 WB

Rear axle

load (WR)

Rear Axle Load = 20,000 - 2,000

= 18,000 lb

Therefore: Total Front Axle Weight = 2,000 + 9,000 lb Total Rear Axle Weight = 4,400 + 18,000 lb

= 22,400 lb

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.

April 2002 39

Weight Restrictions & 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 along the truck frame. In this manner we can add the payload and body weights together and calculate the distribution on the vehicle chassis as an evenly distributed load on the truck frame rails.

So that we can make the necessary calculation in a simple manner, the total body and payload weight is considered to act at the center of gravity which will be at the center of the body length.

18'

Body + Payload = 15,000 lb.

150"

7'24"

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.

300 lb.

24"

96"

Front

Front Weight Rear Weight A. WF = W x D A. Total weight -

B. 300 x 24 B. 300 - 75

C. = 75 lb. C . = 225 lb.

Rear

Example:

Front Axle Load =

(Body Weight + Payload) x C of G location

Wheelbase

Rear Axle Load =

(Body Weight + Payload) - Front Axle Load

Therefore, Front Axle Load =

15,000 x 24 = 2400 lb

150

Rear Axle Load = 15,000-2,400 = 12,600 lb

If the truck tare weight without the body is 5,000 lb on the front axle and 2,400 lb on the rear axle, then Total Front Axle Weight =

5,000 + 2,400 = 7,400 lb

and Total Rear Axle Weight =

2,400 + 12,600 = 15,000 lb

This same lever principle is applied in all calculations of weight distribution, whether we are dealing with concentrated loads as with a kingpin load acting on a fifth wheel or if it be with an evenly distributed load as with a truck body. The same approach is made in calculating an evenly distributed load on a trailer.

The body manufacturer can provide the body length and weight, or actual measurements of the body may be taken with a tape. Generally, (D) is unknown. This you must find logically, or with a tape measure.

Find (D) and then solve for Wf and Wr.

48" D

60"

132"

96"

3000 lb

D = 60-3-48 = 9 inches Wf = 205

Wr = 2,795

40 April 2002

Weight Restrictions & Specifications

RECOMMENDED WEIGHT DISTRIBUTION % OF GROSS VEHICLE WEIGHT BY AXLE

CONVENTIONAL (2 Axle)

Front Axle Rear Axle

25% Desired 75%

20-30% Permissible 70-80%

COE (2 Axle)

Front Axle Rear Axle

33 1/3% Desired 66 2/3%

30-35% Permissible 65-70%

Front Axle Rear Axle

20% Desired 80%

18-25% Permissible 75-82%

CONVENTIONAL (3 Axle)

COE (3 Axle)

Front Axle Rear Axle

25% Desired 75%

20-30% Permissible 70-80%

April 2002 41

Weight Restrictions & Specifications

Calculating tractor/trailer weight distribution can be

thought of in the same terms as calculating full trucks.

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

The weight at the center of the body and the load when applied is the same as the single point load of the kingpin on the fifth wheel.

TRAILER WEIGHT

45'

48"36"

NOTE: Apply the same principles

used with truck chassis

A. Payload at Kingpin

PLkp = W x D

Calculate the “D” dimension

OAL/2 - AF = D 45 feet/2 - 48 inches = 222 inches

RAS

PLkp = 50,000 lb x 222 in = 24,342 lb

456 in

PLkp = 24,342 lb

B. Payload at Rear Tandem

PLrt = W - PL

Kingpin 3,500 lb.

Rear

Tandem

6,500 lb.

PLrt = 50,000 lb - 24,342 lb = 25,658 lb

PLrt = 25,658 lb

Fill in:

L = 40 feet

RAS = 48 inches

KP = 36 inches

WB = ? 396

D = ? 204

42 April 2002

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.

Weight Restrictions & Specifications

Due to the variations in hauling and wheelbase requirements from one truck application to another, there is no one specific 5th wheel setting that will apply in all cases.

A “rule of thumb” which has proven satisfactory in many cases sets the 5th wheel one inch ahead of the rear axle for each 10 inches of wheelbase. In the case of tandem axles, the wheelbase is measured from the center line of the front axle to the midpoint between the

tandem rear axles. The location of the 5th wheel fixes the load distribution between the front and rear axles. Too far forward and the front axle is overloaded. If too far back, the front axle may be too lightly loaded and cause an unsafe steering and braking control situation at the front axle.

A tractor on a hill with the 5th wheel set at the axle center line or too close to it will result in an unsafe handling situation by transferring too much weight to the rear axle and actually unloading the front axle.

April 2002 43

Weight Restrictions & Specifications

PERFORMANCE CALCULATIONS

The following calculations have been included to help the users of this book determine the performance characteristics required by their customers and to select the appropriate model vehicle:

1. Speed Formula

This formula can be used to determine:

1. Top speed of the vehicle.

2. Speed in a given gear .

3. Final ratio required for a given speed.

(60) X (RPM)

MPH @ Governed Speed =

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 = Time Constant

(Rev/Mile) X (Gear Ratio)

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.

Horsepower Req'd. for a given grade =

GVWR X Grade X Speed

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

44 April 2002

Weight Restrictions & Specifications

Example: NPR 11,050 GVWR automatic transmission with a van body. GVWR = 12,000 lbs.

Grade = 1 percent Speed = 55 MPH 37,500 = Constant Efficiency Factor = 0.9 AHP Resistance = 53.6 HP (See following formula (3) for calculation)

HP Required for Grade =

12,000 X 1 X 55

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.

Air Resistance Horsepower =

F A X Cd X (MPH)

Definitions in formula:

FA = Frontal area of vehicle in square feet 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)

37,500 X 0.9

156,000

+ 53.67

0.70 for most trucks, semitrailer combinations with tanks or van bodies

0.77 for double and triple trailers and flatbeds with loads

1.00 car and boat haulers Example: NPR 12,000 GVWR van body with 96 inches wide, 115 inches high (84" body height + 31"

frame height).

(96) (115)

FA = - 3.2 FA = 73.47 FT

(12) (12)

Cd = 0.70 Speed = 55 MPH

73.47 X 0.70 X (55)

Air Resistance HP =

156,000

Air Resistance HP = 54.85

April 2002 45

Weight Restrictions & Specifications

4. Engine Horsepower Formula

This formula can be used to derive the output at a given RPM and torque. Horsepower =

Torque X RPM

Definitions in formula:

Torque = Twisting output of engine given in lb-ft RPM = Revolutions per minute of engine

5252 = Constant Example: NPR 12,000 GVWR automatic transmission.

Torque = 347 lb-ft

RPM = 2000

132 HP =

( 347) X (2000)

5. Gradeability Formula

This formula can be used to determine how large of a grade a vehicle can climb.

5252

Percent Grade =

1200 X (T) X (E) X (C) X (R)

GVWR X r

- RR

Definitions in formula:

1200 = Constant

T = Maximum Torque of Engine

E = Engine Efficiency (0.9)

C = Driveline Efficiency (0.9)

R = Transmission Ratio 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

E = 0.9

C = 0.9

R = .703 X 5.375 (in overdrive)

RR = 1.0

GVWR= 12,000

r = 14.1 in

46 April 2002

Weight Restrictions & Specifications

Percent Grade =

Percent Grade = 6.53 - 1 Gradeability = 5.53%

6. Startability Formula

This formula is used to determine what type of a grade a vehicle can be started on. Startability = Definitions in formula:

1200 X (347) X (0.9) X (0.9) X (.703) X (5.375)

12,000 X 14.1

ROAD ROLLING RESIST ANCE:

Road Rolling Resistance - Expressed in Percent Grade.

Road Surface

Concrete, excellent 1.0 Cobbles, ordinary 5.5 Concrete, good 1.5 Cobbles, poor 8.5 Concrete, poor 2.0 Snow, 2 inch 2.5 Asphalt, good 1.25 Snow, 4 inch 3.75 Asphalt, fair 1.75 Dirt, smooth 2.5 Asphalt, poor 2.25 Dirt, sandy 3.75 Macadam, good 1.5 Mud 3.75 to 15.0 Macadam, fair 2.25 Sand, level soft 6.0 to 15.0 Macadam, poor 3.75 Sand, dune 16.0 to 30.0

(1200) X (CET) X (E) X (C) X (R)

(GVWR X r)

- 10%

- 1.0

1200 = Constant CET = Clutch Engagement Torque E=0.9 C=0.9 R = Transmission X Axle Ratio 10% = Average break away resistance and static inertia constant GVWR = Gross Vehicle Weight Rating

r = Loaded radius of tire Example: NPR 12,000 GVWR manual transmission.

CET = 260 lb-ft

R = 6.02 X 4.10

GVWR = 12,000 lb

r = 14.1 in

Startability =

(1200) X (260) X (0.9) X (0.9) X (6.02 X 4.10)

(12,000 X 14.1)

Startability = 26.86%

- 10%

April 2002 47

Weight Restrictions & Specifications

7. Vertical Center of Gravity Formula

These formulas are used to estimate the vertical center of gravity of a completed vehicle in order to determine whether maximum allowable limits have been exceeded. This formula should be used when encountering high center of gravity loads.

7.1 Wv X (Vv) = Mv

7.2 Wb X (Vb) = Mb

7.3 Wp X (Vp) = Mp

7.4 We X (Ve) = Me

7.5 VCg = Definitions in formula:

VCg = The total average vertical center of gravity of the completed vehicle ( vehicle, Wv = Weight of Vehicle

Wb = Weight of Body Wp = Weight of Payload We = Weight of Equipment Vv = Distance from ground to center of gravity of the vehicle Vb = Distance from ground to center of gravity of the body Vp = Distance from ground to center of gravity of the payload V e = Distance from ground to center of gravity of the equipment Mv = Moment of vehicle Mb = Moment of Body Mp = Moment of payload Me = Moment of equipment

(Mv + Mb + Mp + Me)

(Wv + Wb + Wp + We)

body , payload and 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 Wb = 2100 lbs Wp = 4609 lbs Vv = 24.9 in Vb = 80 in Vp = 62 in

(from vehicle specifications) (from body manufacturer) (GVWR - (Wv + Wb + We))

(from Body Builder 's Guide, NPR section, page 6)

(from body manufacturer) (1/2 of payload height + frame height + height from frame to flooring)

Mv = 5291 X 24.9 = 131,746 lb-in Mb = 2100 X 80 = 168,000 lb-in Mp = 4609 X 62 = 285,758 lb-in

We, Ve, Me = None in this example

VCg =

VCg = = 48.8 inches

48.8 < 54.0 inches (54 inches is maximum allowable VCg per mfg. specifications

(131,746 + 168,000 + 285,758)

(5291 + 2100 + 4609)

(528,504)

(12,000)

- from Body Builder's Guide, NPR section, page 6)

(from 7.1) (from 7.2) (from 7.3)

Since maximum VCg for this truck is not exceeded, 48" stack height above flooring is acceptable.

48 April 2002

8. Horizontal Center of Gravity Formula

These formulas are used to estimate the horizontal center of gravity of a completed vehicle in order to determine whether it exists between the centerlines of the front and rear axles. This formula should be used when a load and/or permanent equipment (liftgate, reefer unit, snow plow, etc.) is installed on either extremes along the completed vehicle's overall length.

8.1 Wv X (Hv) = Mv

8.2 Wb X (Hb) = Mb

8.3 Wp X (Hp) = Mp

8.4 We X (He) = Me

(Mv + Mb + Mp + Me)

8.5 HCg =

(Wv + Wb + Wp + We)

Definitions in formula:

HCg = The total average horizontal 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 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 Body Mp = Moment of payload Me = Moment of equipment

Weight Restrictions & Specifications

Example: NPR 12,000 GVWR automatic transmission, 132" WB, 14' body length, full payload of boxes stacked and

distributed evenly throughout the flooring, 1,000 lb reefer unit attached in front of body.

Wv = 5291 lbs Wb = 2100 lbs Wp = 3609 lbs We = 1000 lbs Hv = 42.4 in Hb = 107.5 in Hp* = 107.5 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)

He = 17.5 in Mv = 5291 X 42.4 = 224,338 lb-in Mb = 2100 X 107.5 = 225,750 lb-in Mp = 3609 X 107.5 = 387,967 lb-in Me = 1000 X 17.5 = 17,500 lb-in

HCg =

(224,338 + 225,750 + 387,967 + 17,500)

(from equipment manufacturer) (from 8.1) (from 8.2) (from 8.3) (from 8.4)

(5291 + 2100 + 3609 + 1000)

HCg = = 71.3 inches

(855,555) (12,000)

71.3 < 132 inches(132 inches is the wheelbase dimension) Since the HCg for this truck is not greater than the WB or negative (-) (denotes HCg forward of front

axle centerline), it exists between the centerlines of the front and rear axles.

NOTE: Hp and Hb dimensions are the same in this example because CG of body and payload happen to be at the same point.

April 2002 49

Weight Restrictions & 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 to space loads out over a distance to avoid too high a concentration in one area that could cause damage. The truck’s gross weights, axle weight and axle spacings are set in order to keep axle loads and gross weight loads with the limits set by the Federal Government. The Bridge Formula Table is used to check trucks to make sure that Federal weight limit requirements are met and that the allowable gross and axle weights are in the correct relationship with the spacing of axles to prevent high load concentrations on highway bridges.

The Federal Government has established the following formula to be used to determine the allowable weight limits and axle spacings for trucks.

W = 500 ( LN + 12N = 36)

N-1 Where: W = The total gross weight that may be carried on any

group of two or more consecutive axles to the nearest 500 lb.

L = The distance (spacing) in feet between the outer

axles of any group of two or more consecutive axles.

N = The number of axles in the group under

consideration; except that two consecutive sets of tandem axles may carry a gross load of 34,000 lb each provided the overall distance between the first and last axles of such consecutive sets of axles in 36 feet or more.

BRIDGE FORMULA DEFINITIONS

The following definitions are used for bridge formula calculations.

Gross Weight:

The total weight of a truck (and/or trailer) combined with the weight of the load being hauled. The Federal gross weight limits on interstate highways and federal-aid highways and reasonable access is 80,000 lb.

Single Axle Weight:

The total weight at the ground by all wheels of an axle whose centers may be included between parallel transverse planes forty inches apart, extending across the width of the truck. The Federal single axle weight limit on the Interstate system and reasonable access is 20,000 lb.

Tandem Axle Weight:

The total weight at the ground of two or more consecutive axles whose centers may be included between parallel vertical planes spaced more than forty inches but not more than ninety-six inches apart, extending across the full width of the truck. The Federal tandem axle weight limit on the interstate system and reasonable access is 34,000 lb.

CONSECUTIVE AXLE WEIGHT:

The Federal law states that any two consecutive or more axles may not exceed the weight as computed by the formula even though the single axles, tandem axles, and gross weights are within the legal requirements.

EXCEPTION TO THE BRIDGE FORMULA:

There is one exception to the use of the Federal Bridge Formula: Two consecutive sets of tandem axles may carry a gross load of 34,000 lb each, providing the overall distance between the first and last axles of such consecutive sets of tandem axles is 36 feet or more.

OTHER FEDERAL PROVISIONS:

Maximum Width: 102" Overall Length: States cannot set overall length limits on tractor,

semitrailer or tractor - semitrailer, trailer combinations. States must allow tractors with double trailers. States must allow semitrailers of up to 48 feet in length for doubles combinations. There is also not limitation on overall length for semitrailer or doubles combinations.

These width and length dimensions apply to trucks operating on Interstate highways and federal-aid highways designed by the Federal Highway Administration. This also provides for reasonable access to the interstate highways.

50 April 2002

Weight Restrictions & Specifications

FEDERAL BRIDGE FORMULA TABLE

Distance in feet between the 2 OR MORE CONSECUTIVE AXLES

MAXIMUM LOAD IN POUNDS ON ANY GROUP OF

extremes of any group of 2 or more consecutive axles 2 3456789

Axles Axles Axles Axles Axles Axles Axles Axles 4 34,000 5 34,000 6 34,000 7 34,000

* * * *

8 and less 34,000*34,000 8 and more 38,000 42,000 9 39,000 42,500 10 40,000 43,500 11 44,000 12 45,000 50,000 13 45,500 50,500 14 46,500 51,500 15 47,000 52,000 16 48,000 52,500 58,000 17 48,500 53,500 58,500 18 49,500 54,000 59,000 19 50,000 54,500 60,000 20 51,000 55,500 60,500 66,000 21 51,500 56,000 61,000 66,500 22 52,500 56,500 61,500 67,000 23 53,000 57,500 62,500 68,000 24 54,000 58,000 63,000 68,500 74,000 25 54,500 58,500 63,500 69,000 74,500 26 55,500 59,500 64,000 69,500 75,000 27 56,000 60,000 65,000 70,000 75,500 28 57,000 60,500 65,500 71,000 76,500 82,000 29 57,500 61,500 66,000 71,500 77,000 82,500 30 58,500 62,000 66,500 72,000 77,500 83,000 31 59,000 62,500 67,500 72,500 78,000 83,500 90,000 32 60,000 63,500 68,000 73,000 78,500 84,500 90,500 33 64,000 68,500 74,000 79,000 85,000 91,000 34 64,500 69,000 74,500 80,000 85,500 91,500 35 65,500 70,000 75,000 80,500 86,000 92,000 36 66,000+ 70,500 75,500 81,000 86,500 93,000 37 66,500+ 71,000 76,000 81,500 87,000 93,500 38 67,500+ 72,000 77,000 82,000 87,500 94,000 39 68,000 72,500 77,500 82,500 88,500 94,500 40 68,500 73,000 78,000 83,500 89,000 94,500 41 69,500 73,500 78,500 84,000 89,500 95,000 42 70,000 74,000 79,000 84,500 90,000 95,500 43 70,500 75,000 80,000 85,000 90,500 96,000 44 71,500 75,500 80,500 85,500 91,000 96,500 45 72,000 76,000 81,000 86,000 91,500 97,500 46 72,500 76,500 81,500 87,000 92,500 98,000 47 73,500 77,500 82,000 87,500 93,000 98,500 48 74,000 78,000 83,000 88,000 93,500 99,000 49 74,500 78,500 83,500 88,500 94,000 99,500 50 75,500 79,000 84,000 89,000 94,500 100,000 51 76,000 80,000 84,500 89,500 95,000 100,500 52 76,500 80,500 85,000 90,500 95,500 101,000 53 77,500 81,000 86,000 91,000 96,500 102,000 54 78,000 81,500 86,500 91,500 97,000 102,500 55 78,500 82,500 87,000 92,000 97,500 103,000 56 79,500 83,000 87,500 92,500 98,000 103,500 57 80,000 83,500 88,000 93,000 98,500 104,000 58 84,000 89,000 94,000 99,000 104,500 59 85,000 89,500 94,500 99,500 105,000 60 85,500 90,000 95,000 100,500 105,500

* Tandem Axle by Definition + Exception to Federal Bridge Formula Table and Law. See Text for Explanation. Note: All permissible load calculations are to the nearest 500 lb Maximum load on any single axle, 20,000 lb.

Weights over 80,000 lb are in excess of the Federal GVW on the National Highway Network.

April 2002 51

Weight Restrictions & Specifications

Commodity

Material Weights

52 April 2002

Weight Restrictions & Specifications

APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS

Lb. Per No. of

Product Size Container Cu. Ft. Lb. Per

Acetone .................................................................................................50 6.6 gallon

Alcohol, Commercial ..............................................................................51 6.8 gallon

Proof spirits............................................................................... 57 7.6 gallon

Alfalfa seed .........................................................bushel ............................. -- 60 bushel

Aluminum, Pure (cast) ..............................................................................165 4450 cu. yard

Apples, Fresh .......................................... basket-bushel ....................... -- 48 bushel

Western, box .............................. 11.5"x12"x20" ....................... -- 50 box

New England, box................... 11.25"x14.5"x17.5" ................... -- 56 box

Standard barrel ....................... 17" hd., 28.5" stave ................... -- 160 barrel

Dried ................................................. bushel ............................. -- 24 bushel

Apricots, Fresh ................................................ bushel ............................. -- 48 bushel

Western, box ............................... 5.5"x12"x20" ........................ -- 23 box

Artichokes, Box ............................................. 10"x11.5"x22" ....................... -- 44 box

Asbestos ............................................................................................... 153 4130 cu. yard

Asparagus, Crate......................................................

Loose.................................... 11.5" high x 9.57" top ................. -- 38 crate

Bunches.............................. 11" bottom x 19.38" long............... -- 31 crate

Avacados, Box ......................................... 5.75"x11.25"x17.5" ................... -- 16 box

Bananas, Single stem....................................... bunch ............................. -- 45-65 bunch

Barley ......................................................... bushel ............................. -- 48 bushel

Barytes, Mineral....................................................................................280 7560 cu. yard

Basalt, Rock ....................................................................................... 185 5000 cu. yard

Beans, dry Lima.................................................. bushel ............................. -- 56 bushel

White ................................................bushel ............................. -- 60 bushel

Castor ............................................... bushel ............................. -- 46 bushel

Fresh Lima.................................................. bushel ............................. -- 39 bushel

String ................................................ bushel ............................. -- 36 bushel

..................................................hamper, 5 peck ...................... -- 45 hamper

Beef, Slack barrel....................... 21"x30" stave (200 lb. net) ............. -- 254 barrel

Beer, Wood barrel.............................0.5 barrel (16 gal.).................... -- 205 barrel

Wood barrel .............................0.25 barrel (8 gal.) .................... -- 105 barrel

Steel barrel ..............................0.5 barrel (16 gal.).................... -- 190 barrel

Steel barrel ..............................0.25 barrel (8 gal.).................... -- 95 barrel

Dutchman ................................0.13 barrel (4 gal.).................... -- 51 barrel

Case carton-24, 12 oz.

Regular bottles........................ 17.25"x11.5"x9.88" ................... -- 45 case

Steinie bottles ........................ 18.38"x12.13"x7.38" .................. -- 40 case

Tin cans ....................................16.13"x11"x5.13"..................... -- 28 case

Wooden case-24, 12 oz.

Regular bottles............................ 21"x13.5"x10" ....................... -- 35 case

Steinie bottles ............................22"x13.75"x7.5"...................... -- 46 case

Beets .........................................................bushel ............................. -- 50-60 bushel

Small crate................................9.75"x13.75"x24"..................... -- 50 crate

Western crate ............................. 14"x19"x24.5" ....................... -- 95 crate

Note: Beer cases vary as to size and shape. Suggest checking with local source.

April 2002 53

Weight Restrictions & Specifications

APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS

Lb. Per No. of

Product Size Container Cu. Ft. Lb. Per

Berries-crate 24 pint......................................9.75" x 9.97" x 20".................... -- 25 crate

24 quart .................................11.75" x 11.75" x 24".................. -- 48 crate

32 quart ..................................15.5" x 11.75" x 24"................... -- 63 crate

Bluegrass seed ......................................................... bushel ............................. -- 44 bushel

Bluestone ............................................................................................... 120 3240 cu. yard

Bone ............................................................................................... 115 3110 cu. yard

Borax ...............................................................................................110 2970 cu. yard

Bran .........................................................bushel ............................. -- 20 bushel

Brick-

Soft ............................................ 2.25" x 4" 8.25"...................... -- 4320 M

Common ...................................2.25" x 4" x 8.25"..................... -- 5400 M

Hard........................................ 2.25" x 4.25" x 8.5"................... -- 6480 M

Pressed ................................... 2.38" x 4" x 8.38" .................... -- 7500 M

Paving......................................... 2.25" x 4" 8.5" ....................... -- 6750 M

Paving block ...............................3.5" x 4" x 8.5"....................... -- 8750 M

Fire .............................................2.5" x 4.5" x 9"....................... -- 7000 M

Broccoli- Bushel crate...........................12.75" x 12.75" x 17" .................. -- 30 bushel

Brussel sprouts, Crate .................................... 7.75" x 10.5" x 21.38" ................. -- 26 crate

Buckwheat ......................................................... bushel ............................. -- 49 bushel

Butter-tub, Small.......................................... 15" dia. x 5.75" ...................... -- 25 tub

Standard ......................................15" dia. x 15"........................ -- 70 tub

Case, 30 - 1-lb. bricks .................... 10.75" x 8.75" x 10.5" ................. -- 32 case

9-lb. pail .............................................. pail ............................... -- 10 pail

Cabbage ......................................................... bushel ............................. -- 38 bushel

Hamper.......................................... 1.5 bushel .......................... -- 58 hamper

Crate.......................................12.75" x 18.5" x 19"................... -- 60 crate

Western crate ........................... 14" x 19" x 24.5" ..................... -- 85 crate

Barrel crate ........................ 12.75" x 18.75" x 37.38" ............... -- 110 crate

Calf, Live (average).................................per head........................... -- 140-160 head

Cantaloupe, Crate-

Pony ...................................... 11.75"x11.75"x23.5" .................. -- 58 crate

Standard ................................ 12.75"x12.75"x23.5" .................. -- 68 crate

Jumbo.....................................13.75"x13.75"x23.5................... -- 78 crate

Pony flat.................................. 4.75"x12.75"x23.5" ................... -- 26 crate

Standard flat ........................... 5.25"x14.25"x23.5" ................... -- 28 crate

Jumbo flat ............................... 5.75"x15.25"x23.5" ................... -- 32 crate

Honeydew (Casaba) ............... 6.38"x15.13"x23.5" ................... -- 35 crate

Carbolic acid ................................................................................................. 60 8.0 gallon

Carrots, Topped ............................................. bushel ............................. -- 55 bushel

With tops .......................................... bushel ............................. - - 40 bushel

Crate........................................11.75"x14.13"x24".................... -- 60 crate

Castor oil ................................................................................................. 61 8.1 gallon

Cauliflower ......................................................... bushel ............................. -- 30 bushel

Crate........................................... 9.38"x19"x24" ....................... -- 50 crate

Cedar* .................................................................................................30 2500 M. Bd. ft.

54 April 2002

Weight Restrictions & 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 crate

Half crate ................................. 10.75"x13"x20.38 .................... -- 35 crate

Northern crate...........................16.5"x21.25"x22"..................... -- 85 crate

Cement Block...............................................8"x8"x16"........................... -- 42 each

Block..............................................8"x12"x16".......................... -- 58 each

Portland ............................................. sack .............................. -- 94 sack

Portland ............................. barrel (4 sacks per barrel) .............. -- 376 barrel

Chalk ............................................................................................... 137 3700 cu. yard

Charcoal, Oak ........................................................................................... 33 890 cu. yard

Pine .......................................................................................... 23 620 cu. yard

Cheese, Small box................................... 15" dia. x 5.25" ...................... -- 25 box

Medium box .................................15" dia x 7.5"........................ -- 35 box

Large box..................................... 15" dia. x 15" ........................ -- 70 box

Cherries, Un-stemmed ..................................... bushel ............................. -- 56 bushel

Stemmed .......................................... bushel ............................. -- 64 bushel

Lug box.................................. 5.63:x11.88"x19.75" .................. -- 17 box

Chestnut (lumber)...............................................................................................37 3080 M. Bd. ft.

Chestnuts ......................................................... bushel ............................. -- 50 bushel

Chickens- Live, broilers (20 avg.) ................standard crate....................... -- 58 crate

Fowl (12 avg.) .............................standard crate....................... -- 78 crate

Standard crate (empty) .................24"x35"x13"......................... -- 18 crate

Cinder blocks, 8"x8"x16" ................................................................................... -- 35 each

8"x12"x16" ................................................................................. -- 45 each

Cinders .................................................................................................50 1350 cu. yard

Clay, Dry lumps .................................................................................85 2300 cu. yard

Wet lumps .............................................................................. 110 2970 cu. yard

Wet packed ............................................................................ 135 3650 cu. yard

Fire ......................................................................................... 125 3375 cu. yard

Cork ................................................................................................. 15 405 cu. yard

Corn, Ear.................................................... bushel ............................. -- 35 bushel

Shelled.............................................. bushel ............................. -- 56 bushel

Sweet corn (green) ........................... bushel ............................. -- 43 bushel

Crate........................................12.88"x12.88"x24".................... -- 60 crate

Corn meal ......................................................... bushel ............................. -- 44 bushel

Corn oil .................................................................................................58 7.8 gallon

Corn syrup .................................................................................................86 11.5 gal.

Cotton, Gin bale ......................................30" x 48" x 54"....................... -- 515 bale

Standard bale .............................24" x 28" x 56"....................... -- 515 bale

Comp. bale .................................20" x 24" x 56"....................... -- 515 bale

Cotton seed ......................................................... bushel ............................. -- 32 bushel

Cottonseed oil .................................................................................................58 7.8 gal.

Cottonwood (lumber)

Cow, Live-feeder (avg.)............................per head........................... -- 600 head

............................................................................................................................................................

37 3080 M. Bd. ft.

Butcher (avg.) .................................per head........................... -- 800 head

Butcher steer (avg.) ........................per head........................... -- 1100 head

April 2002 55

Weight Restrictions & Specifications

APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS

Lb. Per No. of

Product Size Container Cu. Ft. Lb. Per

Cranberries- 0.25 barrel box ........................... 9.5" x 11" x 14" ...................... -- 28 box

0.25 barrel box.......................12.25" x 14.75" x 22" .................. -- 60 box

Cream .................................................................................................64 8.5 gallon

Creosote .................................................................................................68 9.2 gallon

Crude oil .................................................................................................56 7.5 gallon

Cucumbers ......................................................... bushel ............................. -- 55 bushel

Crate.......................................9.75" x 13.75" x 24"................... -- 75 crate

Case ......................................... 5" x 13.25" x 19" ..................... -- 26 case

Earth, Loose, dry loam .......................................................................76 2050 cu. yard

Packed......................................................................................95 2565 cu. yard

Wet .........................................................................................125 3375 cu. yard

Eggplant, Hamper............................................. bushel ............................. -- 40 bushel

Crate........................................ 14" x 11.75" x 24" .................... -- 54 crate

Eggs, 30 doz. crate ..............................12" x 12" x 26"....................... -- 55 crate

Elm, Soft

Fertilizer, Commercial ................................... burlap bag .......................... -- 100-200 bag

Fir,Douglas ............................................................ 32 ........................... 2670 M. Bd. ft.

Fish, fresh- Barrel ......................................19" head, 29" stave................... -- 300 barrel

Flour, Barrel ................................... 19.13" head, 30" stave ................ -- 215 barrel

Fuel oil, Furnace grade ..........................................................................56 7.5 gallon

Furniture, Household ..................................................................................7 1915 cu. yard

Garbage, Dry, paper wrapped .............................................................15-30 405-810 cu. yard

Gasoline .................................................................................................45 6.0 gallon

Glass, Common window ....................................................................... -- 162 cu. foot

Glue ................................................................................................. 80 2160 cu. yard

Glycerine .................................................................................................79 10.5 gallon

Grapefruit, Western box ............................11.5" x 11.5" x 24".................... -- 68 box

Grapes, Basket............................................... bushel ............................. -- 48 box

Gravel, Dry ............................................................................................ 95 2565 cu. yard

Greens .........................................................bushel ............................. -- 25 bushel

Groceries, Misc. asst’d ............................................................................... 30 810 cu. yard

Hay, Bale .............................................26" x 30" 46" ........................ -- 210 bale

..............................................................................................................................................................

...........................................................................................................................................................

Rock

38 3170 M. Bd. ft. 45 3750 M. Bd. ft.

Eastern ..................................................................................... 25 2080 M. Bd. ft.

0.5 barrel ............................. 18.5" head, 23.5" stave................ -- 160 1/2 barrel

Diesel engine ............................................................................ 52 7.0 gallon

Wet ...........................................................................................50 1240 cu. yard

Plate or crown............................................................................ -- 161 cu. foot

0.25" plate.................................................................................. -- 3.3 sq. foot

Southern box .......................... 12.75" x 12.75" 27" ................... -- 90 box

Lug box................................. 5.63" x 16.38" x 17.5" ................. -- 30 box

Western keg .............................. 15.5" dia. x 14" ...................... -- 45 keg

Basket..............................................12 quart............................ -- 18 basket

Wet .........................................................................................125 3375 cu. yard

Bale ............................................17" x 22" x 43"....................... -- 115 bale

Bale ............................................. 14" x 16" 43" ........................ -- 85 bale

56 April 2002

Weight Restrictions & Specifications

APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS

Lb. Per No. of

Product Size Container Cu. Ft. Lb. Per

Hog, Live (average).................................per head........................... -- 225-250 head

Honey .................................................................................................90 12.0 gallon

Horse, Live (average).................................per head........................... -- 1200-1500 head

Horseradish roots ....................................................... bushel ............................. -- 35 bushel

Ice .................................................................................................57 1540 cu. yard

Ice (mfg.), Block...........................................11" x 22" x 32"....................... -- 250 block

Block...........................................14" x 14" x 40"....................... -- 255 block

Block...........................................11" x 22" x 56"....................... -- 440 block

Ice Cream, 2.5 gal. can,

Full................................................ 9" dia. x 11"......................... -- 18 can

Empty ........................................................................................ -- 6 can

5 gal. can,

Full................................................ 9" dia. x 21"......................... -- 35 can

Empty ........................................................................................ -- 11 can

Kale ......................................................... bushel ............................. -- 25 bushel

Kerosene ................................................................................................. 50 6.6 gallon

Lamb, Live (avg.).......................................per head........................... -- 75-85 head

Lard, Barrel ...................................... 18" head, 30" stave................... -- 425 barrel

Lath-standard length 29 in. Packed in bundles of 50.

...................................... Avg. bundle-diameter 9 inches .......... -- 25 bundle

Leather, Dry ............................................................................................55 1485 cu. yard

Wet ...........................................................................................65 1755 cu. yard

Lemons, Western box ...............................10" x 13" x 25"....................... -- 80 box

Southern box ......................... 12.75" x 12.75" x 27".................. -- 90 box

Lentils .........................................................bushel ............................. -- 60 bushel

Lettuce, Hamper............................................. bushel ............................. -- 25 bushel

Hamper.......................................... 1.5 bushel .......................... -- 38 hamper

Basket................................... 8.5" x 11.75" x 21.38" ................. -- 17 basket

Crate..................................... 18.75" x 17.5" x 24.5" ................. -- 75 crate

1/2 crate.................................. 9.5" x 13.5" x 24.5" ................... -- 40 1/2 crate

Lime, Hydrated ........................................... bushel ............................. -- 30 bushel

Barrel (small) .......................16.5" head, 27.5" stave ............... 62 210 barrel

Barrel (large)............................................................................62 320 barrel

Limes, Western box ...............................10" x 13" x 25"....................... -- 80 box

Southern box ......................... 12.75" x 12.75" x 27".................. -- 90 box

Linseed oil ................................................................................................. 59 7.9 gallon

Lubricating oil ................................................................................................. 52 7.0 gallon

Malt, Barley ............................................... bushel ............................. -- 28 bushel

Rye ................................................... bushel ............................. -- 32 bushel

Brewer’s grain................................... bushel ............................. -- 40 bushel

Maple syrup ......................................................... ga llon ............................82 11 gallon

Maple, Hard (lumber)* ..........................................................................44 3670 M. Bd. ft.

Meal-corn ......................................................... bushel ............................. -- 44 bushel

Milk, Bulk ..........................................................................................64 8.6 gallon

Soft

..............................................................................................................................................................

34 2830 M. Bd. ft.

5 gallon can .............................. 10.25" dia. x 19" ..................... -- 62 can

10 gallon can ...............................13" dia. x 23"........................ -- 115 can

Crate-20.5 pt. bottles ............ 8.5" x 12.75" x 16.75" ................. -- 33 crate

20 pt. bottles ......................... 8.5" x 12.75" x 16.75" ................. -- 54 crate

April 2002 57

Weight Restrictions & Specifications

APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS

Lb. Per No. of

Product Size Container Cu. Ft. Lb. Per

Millet ......................................................... bushel ............................. -- 50 bushel

Molasses ................................................................................................. 90 12 gallon

Barrel ................................... 20.25" head, 34" stave ................ -- 675 barrel

Mortar, Lime........................................................................................110 2970 cu. yard

Mud, Flowing ................................................................................... 106 2860 cu. yard

Packed.................................................................................... 125 3375 cu. yard

Muriatic acid, 40% ..........................................................................................40 10 gallon

Naptha, Petroleum ................................................................................. 42 5.6 gallon

Nitric acid, 91% .......................................................................................... 94 12.5 gallon

Oak-red, Black

Oats ......................................................... bushel ............................. -- 32 bushel

Okra, Hamper.......................................... 1/2 bushel .......................... -- 18 hamper

Oleomargarine (mfg.-tub) ................................ 21" head, 34" stave................... -- 70 tub

Olive oil .................................................................................................58 7.7 gallon

Onions dry, Basket............................................... bushel ............................. -- 55 bushel

Oranges, Western box ............................11.5" x 11.5" x 24".................... -- 80 box

Oysters (shucked or meats)

Paint, Lead and oil ............................................................................ 127 17 gallon

Paper, Average solid............................................................................58 1565 cu. yard

Paraffin .................................................................................................56 1510 cu. yard

Parsley, Bushel crate...........................12.75" x 12.75" x 17".................. -- 30 crate

Parsnips ......................................................... bushel ............................. -- 50 bushel

Peaches, Basket............................................... bushel ............................. -- 48 bushel

Peanuts, Unshelled.......................................... bushel ............................. -- 22 bushel

Peanut oil ................................................................................................. 57 7.6 gallon

Pears, Basket...............................................bushel ............................. -- 50 bushel

..........................................................................................................................................................

.........................................................................................................................................................

White

42 3500 M. Bd. ft. 48 4080 M. Bd. ft.

Hamper.............................................bushel ............................. -- 34 bushel

Cases ........................................................................................ -- 15-65 case

Bag ................................................. 17" x 32" ........................... -- 50 bag

Crate...................................... 20.5" x 11.5" x 10.5" .................. -- 58 crate

Green (with tops) .............................. bushel ............................. -- 32 bushel

Southern box ......................... 12.75" x 12.75" x 27".................. -- 90 box

Bushel box ........................... 10.75" x 10.75" x 23.5" ................ -- 65 box

Crate-with 5.1 gal. cans

(11.5 lb. per gal.).........................18" x 12" x 24"....................... -- 67 crate

With shells (bags) ............................. bushel ............................. -- 75 bushel

Newspaper rolls ........................ 34.25" x 35" dia. ..................... -- 500 roll

.................................................. 51.5" x 35" dia. ...................... -- 1000 roll

................................................. 64.25" x 35" dia. ..................... -- 1300 roll

1/2 bushel .................................................................................. -- 25 basket

Crate.......................................10.5" x 11.25" x 24"................... -- 50 crate

Western box ......................... 5.5" x 12.25" x 19.75" ................. -- 22 box

Bag ............................................................................................ -- 100 bag

Western box ........................ 9.63" x 12.13" x 19.75" ................ -- 51 box

58 April 2002

Weight Restrictions & Specifications

APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS

Lb. Per No. of

Product Size Container Cu. Ft. Lb. Per

Peas, Dry ....................................................bushel ............................. -- 60 bushel

Fresh hamper ................................... bushel ............................. -- 35 hamper

Hamper.............................................40 qts.............................. -- 45 hamper

Pecans, Large bag .................................................................................. -- 100 bag

Small bag................................................................................... -- 50 bag

Peppers, Basket............................................... bushel ............................. -- 25 basket

Crate......................................14.13" x 11.75" x 24" .................. -- 45 crate

Petroleum .................................................................................................56 7.5 gallon

Phosphate rock ...............................................................................................200 5400 cu. yard

Pine, Long leaf

North Carolina

Oregon

Red

White

Yellow-long leaf

Short leaf

Pineapples, Crate......................................... 11" x 12.5" x 36" ..................... -- 85 crate

Pitch ................................................................................................. 70 1900 cu. yard

Plums, Basket............................................... bushel ............................. -- 56 bushel

Western box ......................... 5.63" x 16.38" x 17.5" ................. -- 25 box

Pomegranates, Box ..........................................6.5" x 12" x 24.63".................... -- 30 box

Popcorn, Ear ....................................................bushel ............................. -- 70 bushel

Shelled.............................................. bushel ............................. -- 56 bushel

Poplar

.................................................................................................27 2250 M. Bd. ft.

Porcelain ...............................................................................................150 4050 cu. yard

Pork (dressed), Barrel (200 lb. net) ..................18" head, 29" stave ................... -- 240 barrel

Potatoes, Sweet................................................ bushel ............................. -- 55 bushel

White or Irish .................................... bushel ............................. -- 60 bushel

Bag ............................................... 1.67 bushel ......................... -- 102 bag

Barrel .................................. 17.13" head, 28.5" stave ............... -- 185 barrel

Prunes, Box ...................................... 5.63" x 16.38" x 19.75" ................ -- 25 box

Box ...................................... 5.63" x 11.88" x 19.75" ................ -- 22 box

Quinces ......................................................... bushel ............................. -- 50 bushel

Radishes, Basket............................................... bushel ............................. -- 34 bushel

Crate.......................................9.75" x 13.75" x 24"................... -- 40 crate

Redwood

.................................................................................................30 2500 M. Bd. ft.

Resin ................................................................................................. 68 1835 cu. yard

Rhubarb (pie plant)..................................................... bushel ............................. -- 50 bushel

Box ..........................................5.25" x 11.5" x 22".................... -- 24 box

Rice, Unhulled ...........................................bushel ............................. -- 43 bushel

Rock, Crushed (avg.) ........................................................................100 2700 cu. yard

Romaine, Crate.................................... 13.88" x 18.88" x 24.5" ................ -- 64 crate

Crate......................................12.25" x 13" x 15.25" .................. -- 27 crate

Rubber goods .................................................................................................94 2540 cu. yard

Rutabagas .........................................................bushel ............................. -- 56 bushel

................................................................................................................................................

.....................................................................................................................................................

..............................................................................................................................................................

.........................................................................................................................................................

.................................................................................................................................

..............................................................................................................................

...............................................................................................................................................

44 3670 M. Bd. ft. 36 3000 M. Bd. ft. 32 2670 M. Bd. ft. 30 2500 M. Bd. ft. 26 2170 M. Bd. ft. 44 3670 M. Bd. ft. 38 3170 M. Bd. ft.

April 2002 59

Weight Restrictions & Specifications

APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS

Lb. Per No. of

Product Size Container Cu. Ft. Lb. Per

Rye .........................................................bushel ............................. -- 56 bushel

Salt-rock, Solid........................................................................................ 136 3670 cu. yard

Coarse ...................................................................................... 45 1215 cu. yard

Fine...........................................................................................50 1350 cu. yard

Barrel (avg.) ............................................................................... -- 280 barrel

Sand-

Fine, Dry .......................................................................................... 110 2970 cu. yard

Wet .........................................................................................125 3375 cu. yard

Coarse, Dry ............................................................................................95 2565 cu. yard

Wet .........................................................................................120 3240 cu. yard

Mixed ............................................................................................... 115 3100 cu. yard

Sandstone, Solid........................................................................................147 3970 cu. yard

Crushed .................................................................................... 86 2325 cu. yard

Shale, Solid........................................................................................172 4645 cu. yard

Crushed .................................................................................... 92 2485 cu. yard

Sheep, Live (avg.) ....................................... per head ........................... -- 125-150 head

Shingles-packed in bundles of 200-250. Size of bundle

..............................................(avg.) 24" x 20" x 10".................. -- 50 bundle

Snow, Moist-packed ............................................................................ 50 1350 cu. yard

Soft drinks, Half depth bottle box 24-6 to 8 oz. bottles

............................................. 12.25" x 18.75" x 8.5" ................. -- 39 box

Full depth bottle box 12-24 to 32 oz. bottles

............................................ 13.38" x 18.5" x 12.25" ................ -- 60 box

Sorghum syrup ................................................................................................. 86 11.5 gallon

Soybeans .........................................................bushel ............................. -- 60 bushel

Soybean oil .................................................................................................58 7.7 gallon

Spinach, Hamper............................................. bushel ............................. -- 20 bushel

Spruce

Squash .........................................................bushel ............................. -- 46 bushel

Starch ................................................................................................. 96 2590 cu. yard

Stone, Crushed (avg.) ........................................................................ 100 2700 cu. yard

Straw, Bale ............................................17" x 22" x 42"....................... -- 110 bale

Street sweepings ................................................................................................ 32 865 cu. yard

Sugar ............................................................................................... 100 2700 cu. yard

Sugar, Bag (100 lb. net) ........................................................................ -- 101 bag

Sugar cane syrup ...............................................................................................85 11.3 gallon

Sulphur ............................................................................................... 125 3375 cu. yard

Sulfuric acid, 87%.............................................................................................112 15 gallon

Sweet corn, Basket............................................... bushel ............................. -- 45 bushel

Sycamore

Basket............................................... bushel ............................. -- 27 basket

.................................................................................................28 2330 M. Bd. ft.

Rip-rap......................................................................................65 1755 cu. yard

Bale ............................................26" x 30" x 46"....................... -- 180 bale

Barrel (22 lb. empty) ............ 19.13" head, 30" stave ................ -- 345 barrel

Case .........................................24 - 5-lb. cartons ..................... -- 135 case

Case 60 - 2-lb. cartons............................................................... -- 135 case

Crate...........................................13" x 13" x 24"....................... -- 60 crate

.................................................................................................37 3080 M. Bd. ft.

Kiln dried lumber averages 10% to 15% lighter and green lumber 40% to 50% heavier than air dried. All weights

in table.

60 April 2002

Weight Restrictions & Specifications

APPROXIMATE WEIGHTS OF COMMODITIES AND MATERIALS

Lb. Per No. of

Product Size Container Cu. Ft. Lb. Per

Tallow ................................................................................................. 60 1620 cu. yard

Tanks,

Acetylene 102 cu. ft. .......................................... empty ............................. -- 70 tank

...........................................................filled............................... -- 75 tank

310 cu. ft........................................... empty ............................. -- 200 tank

...........................................................filled............................... -- 220 tank

Oxygen 150 cu. ft. .......................................... empty ............................. -- 80 tank

...........................................................filled............................... -- 92 tank

300 cu. ft........................................... empty ............................. -- 133 tank

...........................................................filled............................... -- 153 tank

Tar .................................................................................................65 1755 cu. yard

Tile, Solid........................................................................................115 3100 cu. yard

Partition (construction) .............................................................. 40 1080 cu. yard

Tomatoes, Basket...............................................bushel ............................. -- 55 bushel

Lug box....................................7.25" x 14" x 17.5".................... -- 35 box

Crate.......................................10.5" x 11.25" x 24"................... -- 48 crate

Basket.......................................8.5" x 8.75" x 20"..................... -- 18 basket

Basket (paper) ....................... 4.25" x 8.5" x 16.25" .................. -- 9 basket

Basket (wood)......................... 5.5" x 7.25" x 16.5" ................... -- 10 basket

Turpentine .................................................................................................54 7.2 gallon

Turnips, Basket............................................... bushel ............................. -- 54 bushel

Vetch seed ......................................................... bushel ............................. -- 60 bushel

Vinegar .................................................................................................64 8.5 gallon

Walnuts, Bulk .................................................. bushel ............................. -- 50 bushel

Bag ................................................. 2 bushel ........................... -- 100 bag

Water, Fresh ........................................................................................63 8.4 gallon

Wheat, Bulk .................................................. bushel ............................. -- 60 bushel

Bag ................................................ 1.5 bushel .......................... -- 90 bag

Wool, Pressed ....................................................................................82 2215 cu. yard

April 2002 61

NPR NPR HD/W3500 W4500 Gas

MODEL NPR GAS/W3500 GAS GVWR 12,000 lb WB 109 in, 132.5 in, 150 in, 176 in. ENGINE GMPT 8-cylinder, V Block 4-cycle, OHV, water cooled, Sequential Port Fuel Injection

Model/Displacement GMPT-V8/350 CID (5.7 liters) HP (Gross) 250 HP @ 4200 rpm Torque (Gross) 330 lb-ft torque @ 2800 rpm Equipment Sequential Port Fuel Injection (SFI), mass air flow meter, powertrain control module

(VCM), 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 "I" -beam rated at 6,830 lb.

Suspension Semi-elliptical steel alloy leaf springs with stabilizer bar and shock absorbers. GAWR 4,700 lb

REAR AXLE Full floating single speed with hypoid gearing rated at 11,020 lb.

Suspension Semi-elliptical steel alloy leaf springs and shock absorbers.

GAWR 7,950 lb 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 the total length

of the frame. Yield strength 44,000 psi, section modulus 7.20 in3., RBM 316,800.

CAB All steel, low cab forward, BBC 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.

Power windows and Door Locks.

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

April 2002 1

NPR NPR HD/W3500 W4500 Gas

MODEL NPR HD GAS/W4500 GAS GVWR 14,050 lb WB 109 in, 132.5 in, 150 in, 176 in. ENGINE GMPT 8-cylinder, V Block 4-cycle, OHV, water cooled, Sequential Port Fuel Injection

(VCM), onboard diagnostics, oxygen sensors, catalytic convertor, map sensor, with external oil cooler.

Suspension Semi-elliptical steel alloy leaf springs with stabilizer bar and shock absorbers. GAWR 5,360 lb

REAR AXLE Full floating single speed with hypoid gearing rated at 11,020 lb.

Suspension Semi-elliptical steel alloy leaf springs and shock absorbers.

GAWR 9,880 lb 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

FUEL TANK 30 gal. rectangular steel fuel tank. Mounted between the frame rails with electric type fuel

pump (mounted in tank). Through the rail fuel fill.

FRAME Ladder type channel section straight frame rail 33.5 inches wide through the total length of

the frame. Yield strength 44,000 psi, section modulus 7.20 in3., RBM 316,800.

CAB All steel, low cab forward, BBC 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.

Power windows and Door Locks.

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

2 April 2002

VEHICLE WEIGHTS, DIMENSIONS AND RATINGS

NPR NPR HD/W3500 W4500 Gas

Variable Chassis Dimensions: Unit WB CA* CE* OAL AF

Inch 109.0 88.4 131.5 199.5 43.1 Inch 132.5 111.9 155.0 223.0 43.1 Inch 150.0 129.4 172.5 240.5 43.1 Inch 176.0 155.4 198.5 266.3 43.1

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

Dimension Constants: 12,000 GVW Code Inches Code Inches

AH 7.9 BW 83.3 AW 65.6 CW 65.0 BA 47.4 FW 33.5 BBC 68.0 OH 87.4 BOC 9.25 OW 78.5

FH 32.0*

12,000 lb 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 lb 3,160 1,799 4,959 7,041 BB2 132.5 in lb 3,204 1,821 5,025 6,975 BB3 150.0 in lb 3,226 1,843 5,069 6,931 BB4 176.0 in lb 3,270 1,865 5,135 6,865

Dimension Constants: 14,050 GVW Code Inches Code Inches

AH 8.6 BW 84.0 AW 65.6 CW 65.0 BA 47.4 FW 33.5 BBC 68.0 OH 88.1 BOC 9.25 OW 78.5

FH 32.8

14,050 lb GVWR with 4L80-E Hydra-Matic Transmission Model California/Federal Chassis Cab and Maximum Payload Weights

Model WB Unit Front Rear Total Payload

CE1 109.0 in lb 3,230 1,874 5,104 8,946 CE2 132.5 in lb 3,274 1,896 5,170 8,880 CE3 150.0 in lb 3,296 1,918 5,214 8,836 CE4 176.0 in lb 3,340 1,940 5,280 8,770

Vehicle Weight Limits:

GVWR Designed maximum 12,000 lb 14,050 lb

GAWR, Front 4,700 lb 5,360 lb GAWR, Rear 7,950 lb 9,880 lb

12,000 lb GVWR with 4L80-E Hydra-Matic Transmission Model California Chassis Cab and Maximum Payload Weights

Model WB Unit Front Rear Total Payload

AB1 109.0 in lb 3,160 1,799 4,959 7,041 AB2 132.5 in lb 3,204 1,821 5,025 6,975 AB3 150.0 in lb 3,226 1,843 5,069 6,931 AB4 176.0 in lb 3,270 1,865 5,135 6,865

April 2002 3

Technical Notes: Chassis Curb Weight reflects standard equipment and

fuel, but no driver or payload. Maximum Payload Weight is the allowed maximum for

equipment, body, payload and driver and is calculated by subtracting chassis curb weight from the GVWR.

NPR NPR HD/W3500 W4500 Gas

FRAME & CROSSMEMBER SPECIFICATIONS

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 -- CC DD

52.0 26.0 33.0

132.5 0.24 37.0 28.3 11.1 AA BB CC DD

52.0 59.4 26.0 33.0

150.0 0.24 37.0 28.3 11.1 AA BB CC DD

52.0 59.4 26.0 33.0

176.0 0.24 37.0 28.3 11.1 AA BB CC DD

52.0 59.4 26.0 33.0

A/T=A/T=

Automatic TransmissionAutomatic Transmission

A/T=

Automatic Transmission

A/T=A/T=

Automatic TransmissionAutomatic Transmission

4 April 2002

FRAME CHART

NPR NPR HD/W3500 W4500 Gas

WB FRAME FRAME

FL THICKNESS

109 186.0 0.24

132.5 209.6 0.24

150.0 227.4 0.24

176.0 253.4 0.24

Unit: Inch

April 2002 5

NPR NPR HD/W3500 W4500 Gas

AUXILIARY VIEWS

7.1 9.8

8.1

UNIT: INCH

Rear View

Catalitic Converters

12.4

Rear View

Muffler

.39

7.3

Side Veiw

In Frame Tank

Rear View

ABS Controller

11.4

13.75

Rear View

Emission Canister

Rear View

In Frame Tank

6 April 2002

BODY BUILDER WEIGHT INFORMATION CHART

NPR/NPR HD Series

Wheel Base

GVWR Axle 109 in 132.5 in 150 in 176 in

A/T A/T A/T A/T

12,000 Front 3153 3197 3219 3263 573

Rear 1742 1764 1786 1808 871 Total 4895 4961 5005 5071 1444

14,050 Front 3230 3274 3296 3340 705

Rear 1874 1896 1918 1940 1134 Total 5104 5170 5214 5280 1839

A/T =A/T =

A/T =

A/T =A/T =

CAB TILTCAB TILT

CAB TILT

CAB TILTCAB TILT

16.94"

(430.3mm)

NPR NPR HD/W3500 W4500 Gas

Unit: lb

Unsprung

Weight

Automatic TransmissionAutomatic Transmission

Automatic Transmission

Automatic TransmissionAutomatic Transmission

GRID SCALE: ONE SQUARE= 2" (50.8mm) X 2" (50.8mm)

28.0"

(711.1mm)

34.25"

(869.95mm)

CENTER OF GRAVITY

The center of gravity of the chassis-cab.

Unit: Inch

GVWR WB V H A/T

12,000 109 21.7 38.8

132.5 20.1 47.1 150 19.7 53.5 176 18.1 62.8

14,050 109 21.7 40.0

132.5 20.0 48.6 150 19.7 55.2 176 18.1 64.7

A/T = Automatic Transmission

60.24"

(1530.1mm)

2.76"

(70.1mm)

The center of gravity of the completed vehicle with a full load should not exceed 54 inches above ground level for the 12,000 lb GVWR, 58 inches above ground level for the 14,050 lb GVWR, and must be located horizontally between the centerlines of the front and rear axles.

32.0 in32.0 in

32.0 in

32.0 in32.0 in

V = Vertical Center of Gravity H = Horizontal Center of Gravity

Note: The maximum dimensions for a body installed on the NPR are 96 inches wide (outside) by 90 inches

high (inside). Any larger body applications must be approved by Isuzu Application Engineering. In the West Coast call 1-562-699-0500; in the East Coast call 1-770-475-9195 extension 353.

April 2002 7

NPR NPR HD/W3500 W4500 Gas

FRONT AXLE CHARTFRONT AXLE CHART

FRONT AXLE CHART

FRONT AXLE CHARTFRONT AXLE CHART

FORMULAS FOR CALCULATING HEIGHT DIMENSIONS A = TIRE LOADED RADIUS - B

C = CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT CURB POSITION D = CENTERLINE OF AXLE TO TOP OF FRAME RAIL AT DESIGN LOAD CH = C + TIRE UNLOADED RADIUS DH = D + TIRE LOADED RADIUS

Unit: Inch

Tire Radius Tire Radius

Tire Radius

Tire Radius Tire Radius

TIRETIRE

TIRE

TIRETIRE

215/85R 16-E 11,050 lb 4,700 lb 7.7 6.4 13.0 12.5 27.3 26.6 65.6 15.2 14.1 225/70R 19.5 14,050 lb 5,360 lb 8.4 7.0 13.6 13.1 29 28.1 65.6 15.4 15

GVWRGVWR

GVWR

GVWRGVWR

GAWRGAWR

GAWR

GAWRGAWR

CHCH

DHDH

TRACKTRACK

TRACK

TRACKTRACK

UnloadUnload

Unload

UnloadUnload

LoadLoad

Load

LoadLoad

8 April 2002

REAR AXLE CHARTREAR AXLE CHART

REAR AXLE CHART

REAR AXLE CHARTREAR AXLE CHART

2.50 MINIMUM2.50 MINIMUM

2.50 MINIMUM

2.50 MINIMUM2.50 MINIMUM CLEARANCECLEARANCE

CLEARANCE

TIRE TIRE

TIRE

TIRE TIRE SECTIONSECTION

SECTION

SECTIONSECTION

HWHW

KHKH

CLEARANCECLEARANCE BETWEENBETWEEN

BETWEEN

BETWEENBETWEEN BODY AND TIRESBODY AND TIRES

BODY AND TIRES

BODY AND TIRESBODY AND TIRES

KWKW

DWDW

DWDW CWCW

CWCW EWEW

EWEW

HHHH

LWLW

WHEEL OFFSETWHEEL OFFSET

WHEEL OFFSET

WHEEL OFFSETWHEEL OFFSET

TIRE CLEARANCETIRE CLEARANCE

TIRE CLEARANCE

TIRE CLEARANCETIRE CLEARANCE

TIRE TIRE

TIRE

TIRE TIRE RADIUSRADIUS

RADIUS

RADIUSRADIUS

TIRE TIRE

TIRE

TIRE TIRE

LOADEDLOADED

LOADED

LOADEDLOADED

RADIUS RADIUS

RADIUS

RADIUS RADIUS

B, C B, C

B, C

B, C B, C AND DAND D

AND D

AND DAND D

CHCH

DHDH

Normal rear axle center line

NPR NPR HD/W3500 W4500 Gas

REAR BODYREAR BODY

REAR BODY

REAR BODYREAR BODY

DEFINITIONSDEFINITIONS

DEFINITIONS

DEFINITIONSDEFINITIONS

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.

C 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 CURB 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 GROND-LINE.

HW DUAL TIRE SPACING:

DISTANCE BETWEEN THE CENTER LINES OF THE TIRES IN A SET OF DUAL TIRES.

When all of rear wheels ride over a high spot.

KH TIRE BOUNCE CLEARANCE:

MINIMUM DISTANCE REQUIRED FOR TIRE BOUNCE AS MEASURED FROM THE CENTER LINE OF THE REAR AXLE AND THE TOP OF THE REAR TIRE WHEN ONE WHEEL RIDES OVER A HIGH SPOT.

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 TIRE CLEARANCE

FORMULAS FOR CALCULATING REAR WIDTHFORMULAS FOR CALCULATING REAR WIDTH

FORMULAS FOR CALCULATING REAR WIDTH

FORMULAS FOR CALCULATING REAR WIDTHFORMULAS FOR CALCULATING REAR WIDTH AND HEIGHT DIMENSIONSAND HEIGHT DIMENSIONS

AND HEIGHT DIMENSIONS

AND HEIGHT DIMENSIONSAND HEIGHT DIMENSIONS

CW = 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

NOTE:NOTE:

NOTE: TRACK AND OVERALL WIDTH MAY VARY

NOTE:NOTE:

SPRINGS

SEE TIRE CHART FOR VALUES

}

When rear wheels on one side ride over a high spot.

WITH OPTIONAL EQUIPMENT.

TireTire

Tire

TireTire

GAWRGAWR

GAWR

GAWRGAWR

TrackTrack

Track

TrackTrack

CWCW

Unit: Inch

215/85R16-E 7950/8760 65.0 6.5 10.6 14.9 13.3 7.8 225/70R 19.5 9880 65 11.6 10.6 14.9 13.0 8.4

April 2002 9

NPR NPR HD/W3500 W4500 Gas

SUSPENSION DEFLECTION CHARTS FOR NPR GASSUSPENSION DEFLECTION CHARTS FOR NPR GAS

SUSPENSION DEFLECTION CHARTS FOR NPR GAS

SUSPENSION DEFLECTION CHARTS FOR NPR GASSUSPENSION DEFLECTION CHARTS FOR NPR GAS

FRONT LEAF SPRING LOAD VS. DEFLECTIONFRONT LEAF SPRING LOAD VS. DEFLECTION

FRONT LEAF SPRING LOAD VS. DEFLECTION

FRONT LEAF SPRING LOAD VS. DEFLECTIONFRONT LEAF SPRING LOAD VS. DEFLECTION (PER AXLE)(PER AXLE)

(PER AXLE)

(PER AXLE)(PER AXLE)

S U S P E (lbs) N

10,000

S I O N

5,000 L O A D

K = 1,508 lb/in 12,000 GVW

S U S P E (lbs) N S I O N

L O A D

10,000

5,000

REAR LEAF SPRING LOAD VS. DEFLECTIONREAR LEAF SPRING LOAD VS. DEFLECTION

REAR LEAF SPRING LOAD VS. DEFLECTION

REAR LEAF SPRING LOAD VS. DEFLECTIONREAR LEAF SPRING LOAD VS. DEFLECTION (PER AXLE)(PER AXLE)

(PER AXLE)

(PER AXLE)(PER AXLE)

VERTICAL SPRING DEFLECTION

K = 5,204 lb/in 12,000 GVW

K = 1,664 lb/in 12,000 GVW

(INCHES)

10 April 2002

VERTICAL SPRING DEFLECTION

(INCHES)

NPR NPR HD/W3500 W4500 Gas

SUSPENSION DEFLECTION CHARTS FOR NPR HD GASSUSPENSION DEFLECTION CHARTS FOR NPR HD GAS

SUSPENSION DEFLECTION CHARTS FOR NPR HD GAS

SUSPENSION DEFLECTION CHARTS FOR NPR HD GASSUSPENSION DEFLECTION CHARTS FOR NPR HD GAS

FRONT LEAF SPRING LOAD VS. DEFLECTIONFRONT LEAF SPRING LOAD VS. DEFLECTION

FRONT LEAF SPRING LOAD VS. DEFLECTION

FRONT LEAF SPRING LOAD VS. DEFLECTIONFRONT LEAF SPRING LOAD VS. DEFLECTION (PER AXLE)(PER AXLE)

(PER AXLE)

(PER AXLE)(PER AXLE)

S U S P E (lbs)

10,000

N S I O N

5,000 L O A D

K = 1,843 lb/in 14,050 GVW

S U S P E (lbs) N S I O N

L O A D

10,000

5,000

REAR LEAF SPRING LOAD VS. DEFLECTIONREAR LEAF SPRING LOAD VS. DEFLECTION

REAR LEAF SPRING LOAD VS. DEFLECTION

REAR LEAF SPRING LOAD VS. DEFLECTIONREAR LEAF SPRING LOAD VS. DEFLECTION (PER AXLE)(PER AXLE)

(PER AXLE)

(PER AXLE)(PER AXLE)

VERTICAL SPRING DEFLECTION

K = 6,935 lb/in 14,050 GVW

K = 1,921 lb/in 14,050 GVW

(INCHES)

April 2002 11

VERTICAL SPRING DEFLECTION

(INCHES)

NPR NPR HD/W3500 W4500 Gas

TIRE AND DISC WHEEL CHARTTIRE AND DISC WHEEL CHART

TIRE AND DISC WHEEL CHART

TIRE AND DISC WHEEL CHARTTIRE AND DISC WHEEL CHART

TIRETIRE

TIRE

TIRETIRE

SINGLE SINGLE

SINGLE

SINGLE SINGLE

TIRE SIZETIRE SIZE

TIRE SIZE

TIRE SIZETIRE SIZE

TIRE LOAD LIMIT AND TIRE LOAD LIMIT AND

TIRE LOAD LIMIT AND

TIRE LOAD LIMIT AND TIRE LOAD LIMIT AND COLD INFLATION PRESSURESCOLD INFLATION PRESSURES

COLD INFLATION PRESSURES

COLD INFLATION PRESSURESCOLD INFLATION PRESSURES

DUAL DUAL

DUAL

DUAL DUAL

LBLB

PSIPSI

PSI

PSIPSI

LBLB

MAXIMUM MAXIMUM

MAXIMUM

MAXIMUM MAXIMUM

TIRE LOAD LIMITS TIRE LOAD LIMITS

TIRE LOAD LIMITS

TIRE LOAD LIMITS TIRE LOAD LIMITS

FRONTFRONT

FRONT

FRONTFRONT

PSIPSI

PSI

PSIPSI

2 SINGLE2 SINGLE

2 SINGLE

2 SINGLE2 SINGLE

REARREAR

REAR

REARREAR

4 DUAL4 DUAL

4 DUAL

4 DUAL4 DUAL

215/85R 16-E 2430 70 2210 70 4860 8840 12,000

225/70R 19.5 3315 85 3115 85 6630 12460 14,050

TIRE SIZETIRE SIZE

TIRE SIZE

TIRE SIZETIRE SIZE

GVWRGVWR

GVWR

GVWRGVWR

(lb)(lb)

(lb)

(lb)(lb)

TIRE RADIUS TIRE RADIUS

TIRE RADIUS

TIRE RADIUS TIRE RADIUS

LOADED LOADED

LOADED

LOADED LOADED

FRONTFRONT

FRONT

FRONTFRONT

REARREAR

REAR

REARREAR

UNLOADED UNLOADED

UNLOADED

UNLOADED UNLOADED

FRONTFRONT

FRONT

FRONTFRONT

REARREAR

REAR

REARREAR

TIRETIRE

TIRE

TIRETIRE

SECTIONSECTION

SECTION

SECTIONSECTION

WIDTHWIDTH

WIDTH

WIDTHWIDTH

TIRETIRE

TIRE

TIRETIRE

CLEAR-CLEAR-

CLEAR-

CLEAR-CLEAR-

ANCEANCE

ANCE

ANCEANCE

215/85R 16-E 12 ,000 14.05 14.05 15.21 15.21 8.54 1.46 6.0

225/70R 19.5 14,0 50 15.00 15. 20 15.4 0 15.80 8.8 1 .2 6.0

DISC WHEELDISC WHEEL

DISC WHEEL

DISC WHEELDISC WHEEL

WHEELWHEEL

WHEEL

WHEELWHEEL

SIZESIZE

SIZE

SIZESIZE

BOLTBOLT

BOLT

BOLTBOLT

HOLESHOLES

HOLES

HOLESHOLES

BOLTBOLT

BOLT

BOLTBOLT

CIRCLECIRCLE

CIRCLE

CIRCLECIRCLE

DIADIA

DIA

DIADIA

FT/RRFT/RR

FT/RR

FT/RRFT/RR

NUT SIZENUT SIZE

NUT SIZE

NUT SIZENUT SIZE

REARREAR

REAR

REARREAR

STUD SIZESTUD SIZE

STUD SIZE

STUD SIZESTUD SIZE

NUT/STUDNUT/STUD

NUT/STUD

NUT/STUDNUT/STUD

TORQUETORQUE

TORQUE

TORQUETORQUE

SPECSSPECS

SPECS

SPECSSPECS

INNERINNER

INNER

INNERINNER

CIRCLECIRCLE

CIRCLE

CIRCLECIRCLE

OUTSIDEOUTSIDE

OUTSIDE

OUTSIDEOUTSIDE

OFFSETOFFSET

OFFSET

OFFSETOFFSET

DISC DISC

DISC

DISC DISC

THK THK

THK

THK THK

GVWRGVWR

GVWR

GVWRGVWR

RIMRIM

RIM

RIMRIM

TYPETYPE

TYPE

TYPETYPE

(lb)(lb)

(lb)

(lb)(lb)

Unit: Inch

DESIGNDESIGN

DESIGN

DESIGNDESIGN

WIDTHWIDTH

WIDTH

WIDTHWIDTH

Unit: Inch

MATERIALMATERIAL

MATERIAL

MATERIALMATERIAL

RIMRIM

RIM

RIMRIM

MFG.MFG.

MFG.

MFG.MFG.

16x6.00K 6JIS 8.75 1.6142 0.8268 289 ft-lb 6.46 5.0 0.35 5o DC Steel

(41mm) (21mm) (392 N-M) TOPY

BUD HEX SQUARE

19.5x6.00 6JIS 8.75 1.6142 0.8268 325 ft-lb 6.46 5.0 0.39 5

DC Steel

(41mm) (21mm) (440 N-M) TOPY

BUD HEX SQUARE

+ O.D. Wrench Sizes

TIRE TIRE

TIRE

TIRE TIRE SECTIONSECTION

SECTION

SECTIONSECTION WIDTH WIDTH

WIDTH

WIDTH WIDTH

of DISC WHEELof DISC WHEEL

of DISC WHEEL

of DISC WHEELof DISC WHEEL

TIRE CLEARANCETIRE CLEARANCE

TIRE CLEARANCE

TIRE CLEARANCETIRE CLEARANCE

RIM OFFSET - REFER TO DISCRIM OFFSET - REFER TO DISC

RIM OFFSET - REFER TO DISC

RIM OFFSET - REFER TO DISCRIM OFFSET - REFER TO DISC

WHEEL SHOWN AT RIGHTWHEEL SHOWN AT RIGHT

WHEEL SHOWN AT RIGHT

WHEEL SHOWN AT RIGHTWHEEL SHOWN AT RIGHT

OFFSETOFFSET

OFFSET

OFFSETOFFSET

of DISC WHEELof DISC WHEEL

of DISC WHEEL

of DISC WHEELof DISC WHEEL

12 April 2002

PROPELLER SHAFTPROPELLER SHAFT

PROPELLER SHAFT

PROPELLER SHAFTPROPELLER SHAFT

NPR NPR HD/W3500 W4500 Gas

WBWB

109 in

132.5 in

PLANE VIEW PLANE VIEW

PLANE VIEW

PLANE VIEW PLANE VIEW

SIDE VIEW SIDE VIEW

SIDE VIEW

SIDE VIEW SIDE VIEW

150 in

176 in

TYPICAL INSTALLATIONS SHOWING YOKES "IN PHASE". "IN PHASE" MEANS THAT THE YOKES AT EITHER END OF A GIVEN PROPELLER SHAFT ASSEMBLY ARE IN THE SAME PLANE.

NPR EFINPR EFI

NPR EFI

NPR EFINPR EFI

(109 in WB) (132.5 in, 150 in and 176 in WB)

TRANSMISSIONTRANSMISSION

TRANSMISSION

TRANSMISSIONTRANSMISSION

AXLEAXLE

AXLE

AXLEAXLE

TRANSMISSIONTRANSMISSION

TRANSMISSION

TRANSMISSIONTRANSMISSION

AXLEAXLE

AXLE

AXLEAXLE

1. UNIVERSAL JOINT

2. PROPELLER SHAFT

3. CENTER CARRIER BEARING

PLANE VIEW PLANE VIEW

PLANE VIEW

PLANE VIEW PLANE VIEW

WHEEL BASEWHEEL BASE

WHEEL BASE

WHEEL BASEWHEEL BASE

109 in -- 3.5

132.5 in 2.1 150 in 0 176 in 0

A/TA/T

A/T

A/TA/T

A/T

A/TA/T

2.7

1.8

NOTE: ALL DRIVELINE ANGLES ARE AT UNLOADED CONDITION (AT CURB POSITION WITH TYPICAL

CARGO BODY).

April 2002 13

SIDE VIEW SIDE VIEW

SIDE VIEW

SIDE VIEW SIDE VIEW

A/TA/T

A/T

A/TA/T

-- 6.4

1.5

0.7

4.0

A/T =A/T =

A/T =

Automatic TransmissionAutomatic Transmission

Automatic Transmission

A/T =A/T =

Automatic TransmissionAutomatic Transmission

A/TA/T

A/T

A/TA/T

2.4

5.3

6.0

NPR NPR HD/W3500 W4500 Gas

PROPELLER SHAFT (CONTINUED)PROPELLER SHAFT (CONTINUED)

PROPELLER SHAFT (CONTINUED)

PROPELLER SHAFT (CONTINUED)PROPELLER SHAFT (CONTINUED)

WBWB

No. of ShaftsNo. of Shafts

No. of Shafts 1222

No. of ShaftsNo. of Shafts

Trans. TypeTrans. Type

Trans. Type

Trans. TypeTrans. Type

Shaft #1 O.D.Shaft #1 O.D.

Shaft #1 O.D. 3.0 3.0

Shaft #1 O.D.Shaft #1 O.D.

ThicknessThickness

Thickness 0.083

ThicknessThickness

LengthLength

Length 34.05 24.10 41.85 52.1

LengthLength

TypeType

Type ABBB

TypeType

Shaft #2 O.D.Shaft #2 O.D.

Shaft #2 O.D. 3.0 3.5

Shaft #2 O.D.Shaft #2 O.D.

ThicknessThickness

Thickness 0.083

ThicknessThickness

LengthLength

Length N/A 33.46 33.46 49.2

LengthLength

TypeType

Type N/A C C C

TypeType

109109

109

109109

A/TA/T

A/T

A/TA/T

132.5132.5

132.5

132.5132.5

A/TA/T

A/T

A/TA/T

150150

150

150150

A/TA/T

A/T

A/TA/T

UNIT: INCH

176176

176

176176

A/TA/T

A/T

A/TA/T

Figure 1.2 NPR/W-SERIES GAS Propshaft Dimensions

TypeType

Type

TypeType

Type

A 1st shaft in 1 piece driveline.

Type

B 1st shaft in 2 piece driveline.

Type

C 2nd shaft in 2 piece driveline.

DescriptionDescription

Description

DescriptionDescription

IllustrationIllustration

Illustration

IllustrationIllustration

Length

14 April 2002

BRAKE SYSTEM DIAGRAMBRAKE SYSTEM DIAGRAM

BRAKE SYSTEM DIAGRAM

BRAKE SYSTEM DIAGRAMBRAKE SYSTEM DIAGRAM

Vacuum Over HydraulicVacuum Over Hydraulic

Vacuum Over Hydraulic

Vacuum Over HydraulicVacuum Over Hydraulic

NPR NPR HD/W3500 W4500 Gas

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

NPR/W3500 GAS 12,000 GVW

NPR HD/W4500 GAS 14,500 GVW

April 2002 15

NPR NPR 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

NPR NPR HD/W3500 W4500 Gas

Rear View Fuel Fill

Dimension A = 6.85 - 8.5 inches (174-216mm)

Top View Fuel Fill

Dimensions:

B = 28.85 inches (733mm) C = 34.00 inches (863mm) D = 39.29 inches (998mm) E = 46.61 inches (1 184mm) F = 96.00 inches (2438mm)

April 2002 17

NPR NPR HD/W3500 W4500 Gas

Top View

Body Width Adjustment:

90 inch Body Dim E = 682.8mm 86 inch Body Dim E = 632.0mm 80 inch Body Dim E = 555.8mm

Through the Rail Fuel Fill Frame Hole

18 April 2002

NPR NPR HD/W3500 W4500 Gas

No.

1 2 3 4

Description

FEDERAL P ARTS

HOSE, FUEL FILLER HOSE , BREATHER CLIP, RUBBER HOSE CLIP, FILLER HOSE

CALIFORNIA P ARTS

HOSE, FUEL FILLER HOSE , BREATHER CLIP, RUBBER HOSE CLIP, FILLER HOSE

Part Number

ISUZU

897213-6540 897214-2710 897177-5810 802465-8140

897213-6540 897229-9180 815699-8250 802465-8140

Part Number

897213-6540 897214-2710 897177-5810 802465-8140

897213-6540 897229-9180 815699-8250 802465-8140

Qty.

1 1 2 2

April 2002 19

NPR NPR HD/W3500 W4500 Diesel

MODEL NPR Diesel/W3500 NPR HD Diesel/W4500 GVWR 12,000 lb 14,500 lb WB 109 in, 132.5 in, 150 in, 176 in ENGINE Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel.

Model/Displacement 4HE1-TC/290 CID (4.75 liters) HP (Gross) 142 HP/2800 RPM (Manual Transmission) 175 HP/2700 RPM (Automatic Transmission) Torque (Gross) 275 lb ft torque/1300 RPM 347 lb ft torque/2000 RPM Equipment Dry element air cleaner with vertical intake; 2 rows 506 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 MXA5C 5-speed manual, all forward gears synchronized. 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 lb.

Suspension Semi-elliptical steel alloy leaf springs with stabilizer bar and shock absorbers. GAWR 4,700 lb 5,360 lb

radiator; 6 blade 18.7 in

REAR AXLE Full floating single speed with hypoid gearing rated at 11,020 lb.

Suspension Semi-elliptical steel alloy leaf springs and shock absorbers.

GAWR 7,950 lb 9,880 lb 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 circui t vac u um ass ist ed hyd rau li c servic e brake s with lo ad sensing proportioning

valve in rear brake circuit and a metering valve between the master cyl ind er and 6- way join t on the fron t b r a ke lines. D i s c f ro n t a nd sel f -adju s t outbo a r d m ounted drum re a r. 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

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 modulus 7.20 in3. RBM 316,800.

CAB All steel low cab forward, BBC 68.0 in, 45o 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.

*All Transmissions have a PTO gear in all wheelbases.

April 2002 1

NPR NPR HD/W3500 W4500 Diesel

VEHICLE WEIGHTS, DIMENSIONS AND RATINGS

Variable Chassis Dimensions: Unit WB CA* CE* OAL AF

Inch 109.0 88.4 131.5 199.5 43.1 Inch 132.5 111.9 155.0 223.0 43.1 Inch 150.0 129.4 172.5 240.5 43.1 Inch 176.0 155.4 198.5 266.3 43.1

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

Dimension Constants: Code Inches Code Inches

AH 7.9 BW 83.3 AW 65.6 CW 65.0 BA 47.4 FW 33.5 BBC 68.0 OH 87.4 BOC 9.25 OW 78.5

FH 32.0

In-Frame Tank 12,000 lb GVWR Manual Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear Total Payload

NA1 109.0 in lb 3472 1885 5357 6643 NA2 132.5 in lb 3516 1907 5423 6577 NA3 150.0 in lb 3560 1929 5489 6511 NA4 176.0 in lb 3605 1951 5556 6444

In-Frame Tank 14,500 lb GVWR Manual Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear Total Payload

NE1 109.0 in lb 3483 1885 5368 9132 NE2 132.5 in lb 3527 1907 5434 9066 NE3 150.0 in lb 3571 1929 5500 9000 NE4 176.0 in lb 3616 1951 5567 8933

In-Frame Tank 12,000 lb GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights

Model WB Unit Front Rear Total Payload NB1 109.0 in lb 3538 1929 5467 6533 NB2 132.5 in lb 3582 1951 5533 6467 NB3 150.0 in lb 3627 1973 5600 6400 NB4 176.0 in lb 3671 1995 5666 6334

In-Frame Tank 14,500 lb GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights Model WB Unit Front Rear Total Payload

NF1 109.0 in lb 3549 1929 5478 9022 NF2 132.5 in lb 3593 1951 5544 8956 NF3 150.0 in lb 3638 1973 5611 8889 NF4 176.0 in lb 3682 1995 5677 8823

Side Mounted Tank 12,000 lb GVWR Manual Transmission Model Chassis Curb and Maximum Payload Weights

Model WB Unit Front Rear Total Payload

NA1 109.0 in lb 3660 1620 5280 6720 NA2 132.5 in lb 3704 1642 5346 6654 NA3 150.0 in lb 3748 1664 5412 6588 NA4 176.0 in lb 3792 1687 5479 6521

Side Mounted Tank 14,500 lb GVWR Manual Transmission Model Chassis Curb and Maximum Payload Weights

Model WB Unit Front Rear Total Payload

NE1 109.0 in lb 3671 1620 5291 9209 NE2 132.5 in lb 3715 1642 5357 9143 NE3 150.0 in lb 3759 1664 5423 9077 NE4 176.0 in lb 3803 1687 5490 9010

Side Mounted Tank 12,000 lb GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights

Model WB Unit Front Rear Total Payload NB1 109.0 in lb 3726 1664 5390 6610 NB2 132.5 in lb 3770 1687 5457 6543 NB3 150.0 in lb 3814 1709 5523 6477 NB4 176.0 in lb 3858 1731 5589 6411

Side Mounted Tank 14,500 lb GVWR Automatic Transmission Model Chassis Curb and Maximum Payload Weights

Model WB Unit Front Rear Total Payload

NF1 109.0 in lb 3737 1664 5401 9099 NF2 132.5 in lb 3781 1687 5468 9032 NF3 150.0 in lb 3825 1709 5534 8966 NF4 176.0 in lb 3869 1731 5600 8900

Vehicle Weight Limits:

GVWR Designed maximum 12,000 lb 14,500 lb

GAWR, Front 4,700 lb 5,360 lb GAWR, Rear 7,950 lb 9,880 lb

Technical Notes: Chassis Curb Weight reflects standard equipment and

fuel, but no driver or payload. Maximum Payload Weight is the allowed maximum for

equipment, body, payload and driver and is calculated by subtracting chassis curb weight from the GVWR.

2 April 2002

FRAME & CROSSMEMBER SPECIFICATIONSFRAME & CROSSMEMBER SPECIFICATIONS

FRAME & CROSSMEMBER SPECIFICATIONS

FRAME & CROSSMEMBER SPECIFICATIONSFRAME & CROSSMEMBER SPECIFICATIONS

NPR NPR HD/W3500 W4500 Diesel

Unit: Inch

CROSS MEMBER TYPE/LOCATION CROSS MEMBER TYPE/LOCATION

CROSS MEMBER TYPE/LOCATION

CROSS MEMBER TYPE/LOCATION CROSS MEMBER TYPE/LOCATION

WheelWheel

Wheel

WheelWheel BaseBase

Base

BaseBase

109 0.24 37.0 28.3 8.4 8.4 AA AA -- CC DD

132.5 0.24 37.0 28.3 8.4 8.4 AA AA BB CC DD

150.0 0.24 37.0 28.3 8.4 8.4 AA AA BB CC DD

176.0 .024 37.0 28.3 8.4 8.4 AA AA BB CC DD

April 2002 3

FrameFrame

Frame

FrameFrame

ThickThick

Thick

ThickThick

C-M/TC-M/T

C-M/T

C-M/TC-M/T

C-A/TC-A/T

C-A/T

C-A/TC-A/T

D-M/TD-M/T

D-M/T

D-M/TD-M/T

40.5 44.7 26.0 33.0

40.5 44.7 59.4 26.0 33.0

D-A/TD-A/T

D-A/T

D-A/TD-A/T

M/T=M/T=

Manual TransmissionManual Transmission

M/T=

Manual Transmission

M/T=M/T=

Manual TransmissionManual Transmission

A/T=A/T=

Automatic TransmissionAutomatic Transmission

A/T=

Automatic Transmission

A/T=A/T=

Automatic TransmissionAutomatic Transmission

ISUZU 2003 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

FMVSS Chart

EPA Requirements

NPR/W Gas, NPR/W Diesel, NQR/W Diesel, NPR HD/NQR/W Diesel Crew Cab and FRR/WT Series Chassis Cab

FSR, FTR & FVR

Installation of Body & Special Equipment

Clearances

Engine

Transmission

Front and Center Propeller Shafts

Exhaust System

Rear Wheel and Axle

Other Clearances

Body Installation

Chassis

Special Equipment on the Chassis

Subframe Design and Mounting

Subframe Contour

Prohibited Attachment Areas

Subframe Mounting

Bracket Installation

U-bolt Installation

Crew Cab Body/Frame Requirement

Modification of the Frame

Working on Chassis Frame

Drilling and Welding

Reinforcement of Chassis Frame

Welding

Fluid Lines

Preparation of Additional Lines

Installation of Additional Lines

Electrical Wiring and Harnessing

Wiring

Wire Color Code

Maximum Allowable Current

Electrical System Modifications

Exhaust System

Fuel System

Rear Lighting

Serviceability

WHEELBASE ALTERATION

SHORTENING/LENGTHENING THE WHEELBASE WITHOUT ALTERING THE FRAME

ALTERING THE WHEELBASE BY ALTERING THE FRAME

GLOSSARY OF TERMS-CHASSIS WHEELBASE ALTERATION

HYDRAULIC BRAKE SYSTEM

AIR BRAKE SYSTEM

2002 GAS & 2003 DIESEL MODEL YEAR BODY APPLICA TION SUMMARY CHART

2003 MODEL YEAR DIESEL CREW CAB BODY & PAYLOAD WEIGHT DISTRIBUTION

Mechanical & Cab Specifications

GVW/GCW Ratings

CLUTCH ENGAGEMENT TORQUE CHART

N/W Series Towing Procedures

FRONT END TOWING (FRONT WHEELS OFF GROUND)

FRONT END TOWING (ALL WHEELS ON THE GROUND)

REAR END TOWING

SPECIAL TOWING INSTRUCTIONS

FRR/WT TOWING PROCEDURE

FRONT END TOWING (FRONT WHEELS OFF THE GROUND)

FRONT END TOWING (ALL WHEELS ON THE GROUND)

REAR END TOWING (REAR WHEELS OFF THE GROUND)

SPECIAL TOWING INSTRUCTIONS

FSR, FTR & FVR SERIES TOWING PROCEDURE

T owing Your Vehicle From the Front (Front Wheels Off the Ground)

T owing the Vehicle with the Front Bumper Removed

T owing Your Vehicle From the Front (All Wheels On the Ground)

T owing Your Vehicle From the Rear (Rear Wheels Off the Ground)

Releasing Air-Operated Parking Brakes

Weight Restrictions

Gross Axle Weight Rating

Weighing the Vehicle

Tire Inflation

Center of Gravity

Glossary of Dimensions

WEIGHT DISTRIBUTION FORMULAS

RECOMMENDED WEIGHT DISTRIBUTION % OF GROSS VEHICLE WEIGHT BY AXLE

TRAILER WEIGHT