ISUZU NQR 2006 Service Manual

2006 W-SERIES (CHEVROLET & GMC) N-SERIES (ISUZU)

INDEX

Introduction

Installation of Body & Special Equipment

Body Application Summary Chart

Mechanical & Cab Specifications

Weight Distribution

Weights, Commodities & Materials

Vehicle Specifications

NPR/W3500, NPR HD/W4500 Gas

NPR/W3500, NPR HD/W4500 Diesel

NQR/W5500

NPR HD/W4500, NQR/W5500 Crew Cab

NRR/W5500 HD

Electrical

NPR/W3500, NPR HD/W4500 Gas

NPR/W3500, NPR HD/W4500, NQR/W5500 Diesel, NRR/W5500 HD Diesel 2005 PTO Section for the 4HK1-TC Engine (IL5)

Miscellaneous

Low Speed Applications for N & W-Series Chassis

Diesel Air Cleaner Canister Change Comparison Diagram

General Motors Isuzu Commercial Truck, LLC (GMICT) and American Isuzu Motors Inc. is striving to provide you with the most up-to-date and accurate information possible. If you have any suggestion to improve the Body Builder’s Guide, please call GMICT Application Engineering. In the West Coast call 1-562-229-5314 and in the East Coast call 1-678-240-9818.

Notice of Rights All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic, mechanical, recording or otherwise, without prior written permission.

Notice of Liability All specifications contained in this Body Builders Guide are based on the latest product information available at the time of publication. The manufacturer reserves the right to discontinue or change at any time, without prior notice, any parts, materials, colors, special equipment, specifications, designs and models.

2006 GM/Isuzu Truck

2006 W-SERIES (CHEVROLET & GMC) N-SERIES (ISUZU)

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i

INTRODUCTION.........................................................................................................................................................................................	1
FMVSS Chart...................................................................................................................................................................................	2-3
EPA Requirements ..........................................................................................................................................................................	4-5
INSTALLATION OF BODY AND SPECIAL EQUIPMENT ...........................................................................................................................	6
Clearances .........................................................................................................................................................................................	6
Engine .........................................................................................................................................................................................	6
Transmission ...............................................................................................................................................................................	6
Front and Center Propeller Shafts ...............................................................................................................................................	7
Rear Propeller Shaft ....................................................................................................................................................................	8
Exhaust System ..........................................................................................................................................................................	8
Rear Wheel and Axle ...................................................................................................................................................................	9
Other Clearances ........................................................................................................................................................................	9
Body Installations ............................................................................................................................................................................	10
Chassis .....................................................................................................................................................................................	10
Special Equipment on the Chassis ............................................................................................................................................	10
Subframe Design and Mounting ................................................................................................................................................	10
Subframe Contour .....................................................................................................................................................................	11
Prohibited Attachment Areas..........................................................................................................................................................	12
Subframe Mounting .........................................................................................................................................................................	13
Bracket Installation ....................................................................................................................................................................	13
U-bolt Installation ......................................................................................................................................................................	14
Crew Cab Body/Frame Requirements ...........................................................................................................................................	14
Modification of the Frame ...............................................................................................................................................................	15
Working on Chassis Frame ........................................................................................................................................................	15
Drilling and Welding ...................................................................................................................................................................	15
Reinforcement of Chassis Frame...............................................................................................................................................	16

2006 GM/Isuzu Truck

2006 W-SERIES (CHEVROLET & GMC) N-SERIES (ISUZU)

INSTALLATION OF BODY AND SPECIAL EQUIPMENT – Modification of the Frame – (Continued)

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ii

Welding .....................................................................................................................................................................................	16
Fluid Lines ........................................................................................................................................................................................	17
Preparation of Additional Lines ..................................................................................................................................................	17
Installation of Additional Lines ...................................................................................................................................................	18
Electrical Wiring and Harnessing ...................................................................................................................................................	18
Wiring ...................................................................................................................................................................................	19-20
Wire Color Code ........................................................................................................................................................................	21
Maximum Allowable Current ..........................................................................................................................................................	21
Electrical System Modifications .................................................................................................................................................	22
Exhaust System ...............................................................................................................................................................................	22
Fuel System .....................................................................................................................................................................................	23
Rear Lighting ...................................................................................................................................................................................	23
Serviceability ....................................................................................................................................................................................	23
Wheelbase Alteration ......................................................................................................................................................................	24
Shortening/Lengthening the Wheelbase Without Altering the Frame .........................................................................................	24
Altering the Wheelbase by Altering the Frame ...........................................................................................................................	24
Glossary of Terms – Chassis Wheelbase Alteration ...................................................................................................................	24
BODY APPLICATION SUMMARY CHART ..............................................................................................................................................	30
2006 Gas and 2006 Diesel Model Year Body Application Summary Chart ...........................................................................	30-31
NPR/W3500, NPR HD/W4500 Gas ..................................................................................................................................................	32
2006 Model Year – Body & Payload Weight Distribution (% Front/% Rear) – Automatic Transmission ......................................	32
NPR/W3500, NPR HD/W4500 Diesel ..............................................................................................................................................	33
2006 Model Year – Body & Payload Weight Distribution (% Front/% Rear) – Manual/Automatic Transmission .........................	33
NQR/W5500 Diesel ..........................................................................................................................................................................	34
2006 Model Year – Body & Payload Weight Distribution (% Front/% Rear) – Manual/Automatic Transmission .........................	34

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BODY APPLICATION SUMMARY CHART– NPR/W5500 HD Diesel – (Continued)

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NRR/W5500 HD Diesel ....................................................................................................................................................................	34
2006 Model Year – Body & Payload Weight Distribution (% Front/% Rear) – Manual/Automatic Transmission .........................	34
NPR HD/W4500, NQR/W5500 Crew Cab Diesel ............................................................................................................................	35
2006 Model Year – Diesel Crew Cab Body & Payload Weight Distribution (% Front/% Rear) ....................................................	35
MECHANICAL AND CAB SPECIFICATIONS...........................................................................................................................................	36
Engine Horsepower & Torque Chart ...............................................................................................................................................	36
GVW/GCW Ratings ..........................................................................................................................................................................	36
Rear Frame Height Chart ................................................................................................................................................................	37
Clutch Engagement Torque ............................................................................................................................................................	37
Paint Code Chart .............................................................................................................................................................................	38
CV Chart 2 ........................................................................................................................................................................................	39
N/W Series Towing Procedure ........................................................................................................................................................	40
Front End Towing (Front Wheels Off the Ground).......................................................................................................................	40
Front End Towing (All Wheels On the Ground) ...........................................................................................................................	41
Rear End Towing (Rear Wheels Off the Ground) ........................................................................................................................	42
Special Towing Instructions .......................................................................................................................................................	43
WEIGHT DISTRIBUTION CONCEPTS .....................................................................................................................................................	44
Weight Restrictions .........................................................................................................................................................................	44
Gross Axle Weight Rating ...............................................................................................................................................................	45
Weighing the Vehicle .......................................................................................................................................................................	45
Tire Inflation .....................................................................................................................................................................................	45
Center of Gravity..............................................................................................................................................................................	45
Weight Distribution .....................................................................................................................................................................	46-47
Glossary of Dimensions ..................................................................................................................................................................	48
Weight Distribution Formulas .........................................................................................................................................................	49

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2006 W-SERIES (CHEVROLET & GMC) N-SERIES (ISUZU)

WEIGHT DISTRIBUTION CONCEPTS – (Continued)

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Basic Formulas ..........................................................................................................................................................................		50
Weight Distribution Formulas in Words.....................................................................................................................................		50-55
Recommended Weight Distribution % of Gross Vehicle Weight by Axle .....................................................................................		55
Conventional (2 Axle) .................................................................................................................................................................		55
COE (2 Axle) ..............................................................................................................................................................................		55
Conventional (3 Axle) .................................................................................................................................................................		56
COE (3 Axle) ..............................................................................................................................................................................		56
Trailer Weight ...................................................................................................................................................................................		57
Payload at Kingpin ....................................................................................................................................................................		58
Payload at Rear Tandem ...........................................................................................................................................................		58
Performance Calculations ..............................................................................................................................................................		59
1. Speed Formula ......................................................................................................................................................................		59
2. Grade Horsepower Formula ..................................................................................................................................................		60
3.	Air Resistance Horsepower Formula .....................................................................................................................................	61
4.	Engine Horsepower Formula .................................................................................................................................................	62
5.	Gradeability Formula .............................................................................................................................................................	63
6.	Startability Formula................................................................................................................................................................	64
7.	Vertical Center of Gravity Formula ....................................................................................................................................	65-66
8.	Horizontal Center of Gravity Formula................................................................................................................................	67-68
Highway System Limits ...................................................................................................................................................................		69
Bridge Formula Definitions ........................................................................................................................................................		69
Exception to the Bridge Formula ...............................................................................................................................................		70
Other Federal Provisions ...........................................................................................................................................................		70
Federal Bridge Formula Table ....................................................................................................................................................		71-73
COMMODITY AND MATERIAL WEIGHTS ..............................................................................................................................................		74

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COMMODITY AND MATERIAL WEIGHTS – (Continued)
Approximate Weights of Commodities and Materials .............................................................................................................	74-80
VEHICLE SPECIFICATIONS INDEX .........................................................................................................................................................	81
NPR/W3500, NPR HD/W4500 Gas ..................................................................................................................................................	81
Specifications ..........................................................................................................................................................................	81
Vehicle Weights, Dimensions and Ratings.............................................................................................................................	82
Variable Chassis Dimensions.............................................................................................................................................	83
Dimension Constants 12,000 GVW ...................................................................................................................................	83
12,000-lb. GVWR with 4L80-E Hydra-Matic Transmission Model California ......................................................................	83
12,000-lb. GVWR with 4L80-E Hydra-Matic Transmission Model Federal .........................................................................	84
Dimension Constants 14,500 GVW ...................................................................................................................................	84
14,500-lb. GVWR with 4L30-E Hydra-Matic Transmission Model California/Federal .........................................................	84
Vehicle Weight Limits.........................................................................................................................................................	85
Frame and Crossmember Specifications ..............................................................................................................................	86
Frame Chart .............................................................................................................................................................................	87
Auxiliary Views .........................................................................................................................................................................	88
Body Builder Weight Information Chart .................................................................................................................................	89
Cab Tilt ..............................................................................................................................................................................	89
Center of Gravity ...............................................................................................................................................................	90
Front Axle Chart.......................................................................................................................................................................	91
Rear Axle Chart .......................................................................................................................................................................	92
Definitions .........................................................................................................................................................................	93
Formulas for Calculating Rear Width and Height Dimensions ...........................................................................................	93
Suspension Deflection Charts – NPR/W3500 Gas, NPR HD/W4500 Gas .............................................................................	94
Tire and Disc Wheel Chart – NPR/W3500 ..............................................................................................................................	95
Tire ....................................................................................................................................................................................	95

2006 GM/Isuzu Truck

2006 W-SERIES (CHEVROLET & GMC) N-SERIES (ISUZU)

VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500 Gas – (Continued)

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Disc Wheel ........................................................................................................................................................................	95
Tire and Disc Wheel Chart – NPR HD/W4500 ........................................................................................................................	96
Tire ....................................................................................................................................................................................	96
Disc Wheel ........................................................................................................................................................................	96
Propeller Shaft ....................................................................................................................................................................	97-98
Brake System Diagram, 12,000 GVW .....................................................................................................................................	99
Vacuum Over Hydraulic .....................................................................................................................................................	99
Brake System Diagram, 14,500 GVW ...................................................................................................................................	100
Vacuum Over Hydraulic ...................................................................................................................................................	100
Through the Rail Fuel Fill ......................................................................................................................................................	101
Installation Instructions ....................................................................................................................................................	101
Rear View Fuel Fill .........................................................................................................................................................	102
Top View Fuel Fill ...........................................................................................................................................................	103
Top View .........................................................................................................................................................................	104
Through the Rail Fuel Fill Frame Hole ..........................................................................................................................	105
Fuel Fill Parts Illustration ..............................................................................................................................................	106
Fuel Fill Parts List ..........................................................................................................................................................	107
NPR/W3500, NPR HD/W4500 Diesel ............................................................................................................................................	108
Specifications ........................................................................................................................................................................	108
Vehicle Weights, Dimensions and Ratings...........................................................................................................................	109
Variable Chassis Dimensions...........................................................................................................................................	110
Dimension Constants ......................................................................................................................................................	110
In-Frame Tank 12,000-lb. GVWR Manual Transmission Model ........................................................................................	110
In-Frame Tank 14,500-lb. GVWR Manual Transmission Model ........................................................................................	111
In-Frame Tank 12,000-lb. GVWR Automatic Transmission Model ...................................................................................	111

2006 GM/Isuzu Truck

2006 W-SERIES (CHEVROLET & GMC) N-SERIES (ISUZU)

VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500 Diesel – (Continued)

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In-Frame Tank 14,500-lb. GVWR Automatic Transmission Model ...................................................................................	111
Side-Mounted Tank 12,000-lb. GVWR Manual Transmission Model ................................................................................	112
Side-Mounted Tank 14,500-lb. GVWR Manual Transmission Model ................................................................................	112
Side-Mounted Tank 12,000-lb. GVWR Automatic Transmission Model ...........................................................................	112
Side-Mounted Tank 14,500-lb. GVWR Automatic Transmission Model ...........................................................................	113
Vehicle Weight Limits.......................................................................................................................................................	113
Frame and Crossmember Specifications ............................................................................................................................	114
Frame Chart ...........................................................................................................................................................................	115
Auxiliary Views .......................................................................................................................................................................	116
Body Builder Weight Information Chart ...............................................................................................................................	117
Cab Tilt ............................................................................................................................................................................	117
Center of Gravity .............................................................................................................................................................	118
Front Axle Chart.....................................................................................................................................................................	119
Rear Axle Chart .....................................................................................................................................................................	120
Definitions .......................................................................................................................................................................	121
Formulas for Calculating Rear Width and Height Dimensions .........................................................................................	121
Suspension Deflection Charts ..............................................................................................................................................	122
Tire and Disc Wheel Chart ....................................................................................................................................................	123
Tire ..................................................................................................................................................................................	123
Disc Wheel ......................................................................................................................................................................	123
Propeller Shaft ................................................................................................................................................................	124-125
PTO Location, Drive Gear and Opening Information ..........................................................................................................	126
Opening Diagram ............................................................................................................................................................	127
Brake System Diagram, 12,000 GVW ...................................................................................................................................	128
Vacuum Over Hydraulic ...................................................................................................................................................	128

2006 GM/Isuzu Truck

2006 W-SERIES (CHEVROLET & GMC) N-SERIES (ISUZU)

VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500 Diesel – (Continued)

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Brake System Diagram, 14,500 GVW ...................................................................................................................................	129
Vacuum Over Hydraulic ...................................................................................................................................................	129
In-Frame Diesel Fuel Filler ....................................................................................................................................................	130
Installation Instructions ....................................................................................................................................................	130
Rear View Fuel Fill .........................................................................................................................................................	131
Top View Fuel Fill ...........................................................................................................................................................	132
Hose Modification for Various Width Bodies ...............................................................................................................	133
Through the Rail Fuel Fill Frame Hole ..........................................................................................................................	134
Fuel Fill Parts Illustration ..............................................................................................................................................	135
Fuel Fill Parts List ..........................................................................................................................................................	136
NQR/W5500 Diesel ........................................................................................................................................................................	137
Specifications ........................................................................................................................................................................	137
Vehicle Weights, Dimensions and Ratings...........................................................................................................................	138
Variable Chassis Dimensions...........................................................................................................................................	139
Dimension Constraints ....................................................................................................................................................	139
In-Frame Tank 17,950-lb. GVWR Manual Transmission Model ........................................................................................	139
In-Frame Tank 17,950-lb. GVWR Automatic Transmission Model ...................................................................................	140
Side-Mounted Tank 17,950-lb. GVWR Manual Transmission Model................................................................................	140
Side-Mounted Tank 17,950-lb. GVWR Automatic Transmission Model ...........................................................................	140
Vehicle Weight Limits.......................................................................................................................................................	141
Frame and Crossmember Specifications ............................................................................................................................	142
Frame Chart ...........................................................................................................................................................................	143
Auxiliary Views .......................................................................................................................................................................	144
Body Builder Weight Information Chart ...............................................................................................................................	145
Cab Tilt ............................................................................................................................................................................	145

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2006 W-SERIES (CHEVROLET & GMC) N-SERIES (ISUZU)

VEHICLE SPECIFICATIONS INDEX – NQR/W5500 Diesel – (Continued)

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Center of Gravity .............................................................................................................................................................	146
Front Axle Chart.....................................................................................................................................................................	147
Rear Axle Chart .....................................................................................................................................................................	148
Definitions .......................................................................................................................................................................	149
Formulas for Calculating Rear Width and Height Dimensions .........................................................................................	149
Suspension Deflection Charts ..............................................................................................................................................	150
Tire and Disc Wheel Chart ....................................................................................................................................................	151
Tire ..................................................................................................................................................................................	151
Disc Wheel ......................................................................................................................................................................	151
Propeller Shaft ................................................................................................................................................................	152-153
PTO Location, Drive Gear and Opening Information ..........................................................................................................	154
Opening Diagram ............................................................................................................................................................	155
Brake System Diagram .........................................................................................................................................................	156
Hydraulic Brake Booster .................................................................................................................................................	156
Diesel Fuel Fill ........................................................................................................................................................................	157
Installation Instructions ....................................................................................................................................................	157
Rear View Fuel Fill .........................................................................................................................................................	158
Top View Fuel Fill ...........................................................................................................................................................	159
Hose Modification for Various Width Bodies ...............................................................................................................	160
Through the Rail Fuel Fill Frame Hole ..........................................................................................................................	161
NQR/W5500 Diesel Fuel Fill Parts Illustration..............................................................................................................	162
NQR/W5500 Diesel Fuel Fill Parts List .........................................................................................................................	163
NPR HD/W4500, NQR/W5500 Crew Cab Diesel ..........................................................................................................................	164
Specifications ........................................................................................................................................................................	164
Vehicle Weights, Dimensions and Ratings...........................................................................................................................	165

2006 GM/Isuzu Truck

2006 W-SERIES (CHEVROLET & GMC) N-SERIES (ISUZU)

VEHICLE SPECIFICATIONS INDEX – NPR HD/W4500, NQR/W5500 Crew Cab Diesel – (Continued)

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NPR HD/W4500 Variable Chassis Dimensions ................................................................................................................	166
NPR HD/W4500 Dimension Constants ...........................................................................................................................	166
NPR HD/W4500 In-Frame Tank 14,500-lb. GVWR Automatic Transmission Model .........................................................	166
NPR HD/W4500 Side-Mounted Tank 14,500-lb. GVWR Automatic Transmission Model.................................................	166
NQR/W5500 Variable Chassis Dimensions ......................................................................................................................	167
NQR/W5500 Dimension Constraints ...............................................................................................................................	167
NQR/W5500 In-Frame Tank 17,950-lb. GVWR Automatic Transmission Model ..............................................................	167
NQR/W5500 Side-Mounted Tank 17,950-lb. GVWR Automatic Transmission Model ......................................................	167
Vehicle Weight Limits.......................................................................................................................................................	168
Frame and Crossmember Specifications ............................................................................................................................	169
Frame Chart ...........................................................................................................................................................................	170
Auxiliary Views .......................................................................................................................................................................	171
Body Builder Weight Information Chart ...............................................................................................................................	172
NPR HD/W4500 ..............................................................................................................................................................	172
Center of Gravity .............................................................................................................................................................	172
NQR/W5500 ....................................................................................................................................................................	173
Center of Gravity .............................................................................................................................................................	173
Front Axle Chart NPR HD/W4500 .........................................................................................................................................	174
Front Axle Chart NQR/W5500 ...............................................................................................................................................	175
Rear Axle Chart NPR HD/W4500 ..........................................................................................................................................	176
Definitions .......................................................................................................................................................................	177
Formulas for Calculating Rear Width and Height Dimensions .........................................................................................	177
Rear Axle Chart NQR/W5500 ................................................................................................................................................	178
Definitions .......................................................................................................................................................................	179
Formulas for Calculating Rear Width and Height Dimensions .........................................................................................	179

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VEHICLE SPECIFICATIONS INDEX – NPR HD/W4500, NQR/W5500 Crew Cab Diesel – (Continued)
Suspension Deflection Charts NPR HD/W4500 ...................................................................................................................	180
Suspension Deflection Charts NQR/W5500.........................................................................................................................	181
Tire and Disc Wheel Chart NPR HD/W4500 .........................................................................................................................	182
Tire ..................................................................................................................................................................................	182
Disc Wheel ......................................................................................................................................................................	182
Tire and Disc Wheel Chart NQR/W5500 ...............................................................................................................................	183
Tire ..................................................................................................................................................................................	183
Disc Wheel ......................................................................................................................................................................	183
Propeller Shaft NPR HD/W4500 ............................................................................................................................................	184
Propeller Shaft NQR/W5500...........................................................................................................................................	185-186
PTO Location, Drive Gear and Opening Information ..........................................................................................................	187
Opening Diagram ............................................................................................................................................................	188
Brake System Diagram 14,500 GVW ....................................................................................................................................	189
Vacuum Over Hydraulic ...................................................................................................................................................	189
Brake System Diagram 17,950 GVW ....................................................................................................................................	190
Vacuum Over Hydraulic ...................................................................................................................................................	190
Diesel Fuel Fill ........................................................................................................................................................................	191
Installation Instructions ....................................................................................................................................................	191
Rear View Fuel Fill .........................................................................................................................................................	192
Top View Fuel Fill ...........................................................................................................................................................	193
Hose Modification for Various Width Bodies ...............................................................................................................	194
Through the Rail Fuel Fill Frame Hole ..........................................................................................................................	195
Fuel Fill Parts Illustration ..............................................................................................................................................	196
Fuel Fill Parts List ..........................................................................................................................................................	197
NRR/W5500-HD .............................................................................................................................................................................	198

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VEHICLE SPECIFICATIONS INDEX – NRR/W5500-HD – (Continued)

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Specifications ........................................................................................................................................................................	198
Vehicle Weights, Dimensions and Ratings...........................................................................................................................	199
Variable Chassis Dimensions...........................................................................................................................................	200
Dimension Constraints ....................................................................................................................................................	200
In-Frame Tank 19,500-lb. GVWR Manual Transmission Model ........................................................................................	200
In-Frame Tank 19,500-lb. GVWR Automatic Transmission Model ...................................................................................	201
Side-Mounted Tank 19,500-lb. GVWR Manual Transmission Model................................................................................	201
Side-Mounted Tank 19,500-lb. GVWR Automatic Transmission Model ...........................................................................	201
Vehicle Weight Limits.......................................................................................................................................................	202
Frame and Crossmember Specifications ............................................................................................................................	203
Frame Chart ...........................................................................................................................................................................	204
Auxiliary Views .......................................................................................................................................................................	205
Body Builder Weight Information Chart ...............................................................................................................................	206
Cab Tilt ............................................................................................................................................................................	206
Center of Gravity .............................................................................................................................................................	207
Front Axle Chart.....................................................................................................................................................................	208
Rear Axle Chart .....................................................................................................................................................................	209
Definitions .......................................................................................................................................................................	210
Formulas for Calculating Rear Width and Height Dimensions .........................................................................................	210
Suspension Deflection Charts ..............................................................................................................................................	211
Tire and Disc Wheel Chart ....................................................................................................................................................	212
Tire ..................................................................................................................................................................................	212
Disc Wheel ......................................................................................................................................................................	212
Propeller Shaft ................................................................................................................................................................	213-214
PTO Location, Drive Gear and Opening Information ..........................................................................................................	215

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VEHICLE SPECIFICATIONS INDEX – NRR/W5500-HD – (Continued)

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Opening Diagram ............................................................................................................................................................	216
Brake System Diagram .........................................................................................................................................................	217
Hydraulic Brake Booster .................................................................................................................................................	217
Diesel Fuel Fill ........................................................................................................................................................................	218
Installation Instructions ....................................................................................................................................................	218
Rear View Fuel Fill .........................................................................................................................................................	219
Top View Fuel Fill ...........................................................................................................................................................	220
Hose Modification for Various Width Bodies ...............................................................................................................	221
Through the Rail Fuel Fill Frame Hole ..........................................................................................................................	222
NRR/W5500-HD Diesel Fuel Fill Parts Illustration .......................................................................................................	223
NRR/W5500-HD Diesel Fuel Fill Parts List ...................................................................................................................	224
NPR/W3500, NPR HD/W4500 Gas Electrical................................................................................................................................	225
Symbols..................................................................................................................................................................................	225
Abbreviations .........................................................................................................................................................................	226
Wiring .....................................................................................................................................................................................	227
Wire Color .......................................................................................................................................................................	227
Distinction of Circuit by Wire Base Color .........................................................................................................................	228
Wire Size ..................................................................................................................................................................	228-229
Grounding Point Location (P-5, E-53, E-54) .........................................................................................................................	230
Grounding Point Location (E-55, E-56, E-38, E-106, E-39, E-129) ......................................................................................	231
Grounding Point Location (J-9, J-167) .................................................................................................................................	232
Grounding Point Location (E-39, E-129, E-38, E-106)..........................................................................................................	233
Reference Table of Grounding Points ..................................................................................................................................	234
NPR/W3500 Body Room Light, ID and Marker Lamp, and Back-Up Lamp Connector Location.....................................	235
NPR/W3500 Body Connectors LH Frame .......................................................................................................................	235

2006 GM/Isuzu Truck

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VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500 Gas Electrical – (Continued)

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NPR/W3500 Body Connectors EOF ................................................................................................................................	236
Fuse Location ........................................................................................................................................................................	237
Fuse Box ................................................................................................................................................................................	238
Relay Location .......................................................................................................................................................................	239
Diode Location ......................................................................................................................................................................	240
Headlights ..............................................................................................................................................................................	241
Marker Lights and Tail Lights ...............................................................................................................................................	242
Turn Signals ...........................................................................................................................................................................	243
Horn, Backup Light, Backup Buzzer Circuit ........................................................................................................................	244
Cab Interior Lights, Rear Body Interior Light Circuit...........................................................................................................	245
Radio and Cigar Lighter Circuit ............................................................................................................................................	246
Auxiliary Power Source Circuit Diagram ..............................................................................................................................	247
03 Model Year Fuel Tank Sending Unit Resistance Values .................................................................................................	248
04i Model Year Fuel Tank Sending Unit Resistance Values ................................................................................................	249
NPR/W3500, NPR HD/W4500, NQR/W5500 Diesel Electrical .....................................................................................................	250
Symbols..................................................................................................................................................................................	250
Abbreviations .........................................................................................................................................................................	251
Wiring .....................................................................................................................................................................................	252
Wire Color .......................................................................................................................................................................	252
Distinction of Circuit by Wire Base Color .........................................................................................................................	253
Wire Size .........................................................................................................................................................................	253
Grounding Point Location (P-5, E-136).................................................................................................................................	255
Grounding Point Location (B-1, B-7) ....................................................................................................................................	256
Grounding Point Location (J-9).............................................................................................................................................	257
Reference Table of Grounding Point ....................................................................................................................................	258

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VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500, NQR/W5500 Diesel Electrical – (Continued)
NPR/W3500, NQR/W5500 Body Room Light, ID and Marker Lamp, and Back-Up Lamp Connector Location	.............. 259
NPR/W3500, NQR/W5500 Body Connectors LH Frame .................................................................................................	259
NPR/W3500, NQR/W5500 Body Connectors EOF ..........................................................................................................	260
Fuse Location ........................................................................................................................................................................	261
Fuse Box ................................................................................................................................................................................	262
Relay Location .......................................................................................................................................................................	263
Diode Location ......................................................................................................................................................................	264
Headlights ..............................................................................................................................................................................	265
Marker Lights and Horns ......................................................................................................................................................	266
Turn Signals Front .................................................................................................................................................................	267
Turn Signals Rear and Back Buzzer Circuit .........................................................................................................................	268
Cab Interior Lights and Body Connectors ...........................................................................................................................	269
Radio and Cigar Lighter Circuits ..........................................................................................................................................	270
Auxiliary Power Source Circuit Diagram ..............................................................................................................................	271
Fuel Tank Sending Unit Resistance (In-Frame Tank), (Side-Mounted Tank) ...............................................................	272-273
NPR/W3500, NPR HD/W4500, NQR/W5500, NRR/W5500-HD, 2005 PTO Section for the 4HK1-TC Engine (IL5) ....................	274
Section Outline ......................................................................................................................................................................	274
Overview ................................................................................................................................................................................	275
Vocation/Modes.....................................................................................................................................................................	275
Factory Installed Equipment .................................................................................................................................................	276
Upfitter Installed Equipment .................................................................................................................................................	276
ECM Programmable PTO Functions ....................................................................................................................................	276
Operation ...............................................................................................................................................................................	276
PTO Switch Description ........................................................................................................................................................	277
Stationary Preset Mode .................................................................................................................................................	278-279

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VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500, NQR/W5500, NRR/W5500-HD – (Continued)
Stationary Variable Mode ...............................................................................................................................................	280-281
Mobile Variable Mode .....................................................................................................................................................	282-283
PTO Engine Shutdown ..........................................................................................................................................................	284
Remote Operation .................................................................................................................................................................	284
Location of PTO Switch and Indicator .................................................................................................................................	285
Location of Cruise Control Switches ...................................................................................................................................	286
PTO Switch Connector and Harness ...................................................................................................................................	287
PTO Switch Harness Connector...........................................................................................................................................	288
PTO Harness 1 Connector (10 Pin) & PTO Harness 2 Connector (8 Pin) ...........................................................................	289
PTO Switch Wiring Diagram .................................................................................................................................................	290
PTO Harness 1 & 2 Diagram .................................................................................................................................................	291
Low Speed Application for W and N-Series Chassis ..........................................................................................................	292
NPR/W3500, NPR HD/W4500, NQR/W5500, NRR/W5500 HD Diesel Air Cleaner Canister Change Comparison Diagram .... 293

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INTRODUCTION

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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 complete 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 cabchassis 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/W3500; NPR-HD/W4500 Gas; NPR/W3500; NPR-HD/W4500 Diesel; NQR/W5500, NPR-HD/W4500; NQR/W5500 Diesel Crew Cab; and NRR/W5500-HD Series 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 chart on the next page.

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FMVSS Chart

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List of Federal or Canadian Motor Vehicle Safety Standards applicable to Isuzu/GMC Truck product lines. Gasoline or diesel fueled vehicles with GVWR greater than 10,000 lbs. (4536 Kg)

	MVSS No.	Title	NPR/NPR HD	NQR/NRR
		Upper line FMVSS, Lower Line CMVSS	W3500/W4500	W5500/W5500-HD
	1106	N/A	1	1
		Exterior Noise
	101	Controls and Displays	1	1
		Location and Identification of controls and displays
	102	Transmission shift lever sequence, starter interlock and transmission braking effect	1	1
		Transmission control functions
	103	Windshield defrosting and defogging systems	1	1
		Windshield defrosting and defogging
	104	Windshield wiping and washing systems	1	1
		Windshield wiping and washing systems
	105	Hydraulic and electric brake systems	2	2
		Hydraulic and electric brake systems
	106	Brake hoses	1	1
		Brake hoses
	108	Lamps and reflective devices and associated equipment	2	2
		Lighting systems and reflective devices
	111	Rear view mirrors	1	1
		Mirrors
	113	Hood latch system	1	1
		Hood latch system
	115	N/A	1	1
		Vehicle identification system2
	116	Motor vehicle brake fluids	1	1
		Hydraulic brake fluids
	120	Tire selection and rims for vehicles other than passenger cars	2	2
		Tire selection and rims for vehicles other than passenger cars
	121	Air brake systems	3	3
		Air brake systems

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FMVSS Chart (continued)

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List of Federal or Canadian Motor Vehicle Safety Standards applicable to Isuzu/GMC Truck product lines. Gasoline or diesel fueled vehicles with GVWR greater than 10,000 lbs. (4536 Kg)

	MVSS No.	Title	NPR, NPR HD/	NQR/NRR
		Upper line FMVSS, Lower Line CMVSS	W3500, W4500	W5500/W5500-HD
	124	Accelerator control system	1	1
		Accelerator control system
	205	Glazing materials	1	1
		Glazing materials
	206	Door locks and door retention components	1	1
		Door locks and door retention components
	207	Seating systems	1	1
		Anchorage of seats
	208	Occupant crash protection	1	1
		Occupant restraint systems in frontal impacts
	209	Seatbelt assemblies	1	1
		Seatbelt assemblies
	210	Seatbelt assembly anchorages	1	1
		Seatbelt assembly anchorages
	213	Child restraint systems	3	3
	213.4	Built in child restraint systems and built in booster cushions
	302	Flammability of interior materials	1	1
		Flammability
		N/A	1, 3	1
		On road vehicle and engine emission regulations
		N/A	1	1
		ICES-002 Canadian Interference causing equipment standard

Type 1, 2 or 3 numbers to the right hand side of the table designate the appropriate paragraph in the Canadian Motor Vehicle Safety Standards (CMVSS), and Federal Motor Vehicle Safety Standards (FMVSS). Please see IVD (incomplete vehicle document) for full statements.

Type 1 A statement that the vehicle when completed will conform to the standard if no alterations are made in identified components of the incomplete vehicle.

Type 2 A statement of specific conditions of final manufacture under which the manufacturer specifies that the completed vehicle will conform to the standard.

Type 3 A statement that conformity with the standard cannot be determined based upon the components supplied on the incomplete vehicle, and that the incomplete vehicle manufacturer makes no representation to conformity

with the standard.

NOTE: This chart is only a guide. For complete information, please refer to “Document for Incomplete Vehicle” provided with each chassis.

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EPA Requirements

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NPR/W3500 Gas, NPR/W3500 Diesel, NQR/W5500 Diesel, NPR HD, NQR/W4500, W5500 Diesel Crew Cab and NRR/W5500-HD Series Chassis Cab

The following statement is applicable to all models of incomplete vehicles equipped with diesel engines. (Type 1)

This incomplete vehicle, when completed, will conform to the above standard providing no alterations are made which affect the function, physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components assemblies or systems including but not limited to those listed below:

-Injection Pump	-Exhaust Gas Re circulation System
-Injector and High Pressure Lines	-Engine Coolant Temperature
-Turbocharger	-Intake Manifold
-Charge Air Cooler and Charge Air Cooler Hoses	-Catalytic Converter and its location
-Engine Control Module (ECM)	-Variable Swirl System
-Engine Speed Sensor

The following statement is applicable to all models of incomplete vehicles equipped with gasoline engines. (TYPE 3)

Conformity with on road vehicle and emission regulations cannot be determined based upon the components supplied on the incomplete vehicle, and ISUZU Motors makes no representation to conformity with the standard

INTERFERENCE CAUSING EQUIPMENT STANDARD ICES –002

The following statement is applicable to NPR/W Series Chassis-Cab (Gasoline Engine Only). TYPE 1

This incomplete vehicle, when completed, will conform to the above regulations providing no alterations are made which affect the function, physical, chemical, or mechanical properties, environment, location or vital spatial clearances of the components assemblies or systems including but not limited to those listed below:

-Ignition coils

-Ignition Wires and plugs

-Spark Plug Wires

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 the incomplete vehicle document, especially the following instructions which relate to:

A.Exhaust emission related components

B.Specifications for fill pipes and openings of motor vehicle fuel tanks (applicable to California gasoline powered vehicles)

C.Labels

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A. EXHAUST EMISSION RELATED COMPONENTS

1.Compliance of this vehicle with EPA/California Emission certification requirements will be maintained providing no alterations (except where noted) are made to the components or systems identified below:

-Air Induction System	-Exhaust oxygen sensors (gasoline engine)
-Catalytic Converter System (if equipped)	-Exhaust system
-Coolant temperature Sensor	-Evaporative emission control system (gasoline engine) *
-Crankcase emission control System	-Fuel injection system
-Diesel fuel Injection components and controls	-Fuel system
-Engine Assembly	-Ignition System (gasoline engine)
-Engine electronics (ECM/PCM/VCM)	-Intake Manifold
-Engine Speed Sensor	-Turbocharger and associated equipment/controls
-Exhaust Gas Recalculation System

*All Federal/California gasoline powered heavy duty vehicles will have an evaporative emission control system that is certified for a fuel take capacity that is not to exceed the amount shown on the Vehicle Evaporative Emission Control Information Label. Persons wishing to add fuel tank capacity above the amount shown must contact CARB and/or submit a written statement to the EPA administrator that the hydrocarbon storage system has been upgraded according to the requirements of 40 CFR 86-095-35 (g) (2)

2. Compliance with applicable fuel evaporative emission regulations will be maintained if no alteration is made to the fuel filler neck(s).

Compliance with applicable fuel evaporative emission regulations will be maintained if no alteration is made to change material or increase the size or length of the following nonmetallic fuel and evaporative emission hoses.

-Fuel feed hose front and rear	-Fuel vapor lines at canister
-Fuel return hoses front and rear	-Fuel vapor lines from engine to chassis pipes
-Fuel tank filler hoses to filler neck	-Fuel vapor lines from fuel tank sender to chassis pipes
-Fuel tank vent hoses to filler neck

B.SPECIFICATIONS FOR FILL PIPES AND OPENINGS OF MOTOR VEHICLE FUEL TANKS (APPLICABLE ONLY TO CALIFORNIA GASOLINE POWERED VEHICLES

The incomplete vehicle when completed, will conform to Title 13 California Administrative Code Chapter 3 Air Resources Board Subchapter 7 “ Specifications for Fill Pipes and Openings of Motor Vehicle Fuel Tanks”, if no alterations are made to the fuel filler neck(s).

C.LABELS

The emission control related information labels that 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.

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2006 W-SERIES (CHEVROLET & GMC) N-SERIES (ISUZU)

INSTALLATION OF BODY AND SPECIAL EQUIPMENT

Clearances

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Engine

At least 1.6 inches of clearance should be maintained around the engine. No obstacles should be added in front of the radiator or intercooler.

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 of unrestricted movement of the transmission assembly. In addition, provide at least 2 inches of clearance around the control lever on the side of the transmission to allow free movement without any binding.

(Installation of Body and Special Equipment Section – continued on next page)

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(Installation of Body and Special Equipment Section – continued from previous page)

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At least 6 inches of clearance should be maintained above the transmission to allow easy removal of the upper cover for manual transmissions. At least 2 inches of clearance should be maintained above the automatic transmission to allow for transmission removal.

Front and Center Propeller Shafts

At least 1.25 inches of clearance should be maintained around front and center propeller shafts.

(Installation of Body and Special Equipment Section – continued on next page)

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(Installation of Body and Special Equipment Section – continued from previous page)

Rear Propeller Shaft

With the rear springs at maximum deflection, at least 1.25 inches of clearance should be provided over the rear propeller shaft.

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Exhaust System

If flammable materials such as wood are used in the body, provide at least 3.9 inches of 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.

(Installation of Body and Special Equipment Section – continued on next page)

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(Installation of Body and Special Equipment Section – continued from previous page) Rear Wheel and Axle

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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.

Note: For recommended clearances, please refer to the Rear Axle Chart in each model’s respective section.

Other Clearances

The transmission control cable may be broken if it is bent by or interferes with the body and its fixtures. To prevent this, 1 inch of minimum clearance should be provided. When cable is detached from 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.

	Parts	Minimum 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

(Installation of Body and Special Equipment Section – continued on next page)

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(Installation of Body and Special Equipment Section – continued from previous page)

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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.

(Installation of Body and Special Equipment Section – continued on next page)

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(Installation of Body and Special Equipment Section – continued from previous page) Subframe Contour

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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.

(Installation of Body and Special Equipment Section – continued on next page)

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(Installation of Body and Special Equipment Section – continued from previous page)

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

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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.

(Installation of Body and Special Equipment Section – continued on next page)

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(Installation of Body and Special Equipment Section – continued from previous page)

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

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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.”

(Installation of Body and Special Equipment Section – continued on next page)

2006 GM/Isuzu Truck