Beruflich Dokumente
Kultur Dokumente
INTRODUCTION
Ⅰ. GENERAL PRECAUTIONS
Chapter 1 GENERAL
Ⅱ. SPECIFIC INFORMATION
Chapter 1 OUTLINE
Chapter 8 PAINTING
Chapter 11 APPENDIX
INTRODUCTION
The purpose of this Body Builder’s Guide (hereinafter referred to as “guide”) is to provide
information and guidance to the body builders that take charge of the final stage of vehicle
manufacture by mounting their vehicle bodies on the cab chassis (incomplete vehicles) provided
by ISUZU MOTORS LIMITED. The body builders are encouraged to refer to the information in this
guide in order to perform rear body mounting at suitable conditions with good use of their own
experiences.
• This guide is a summary of a technical content for body mounting and remodeling
according to mounting of ISUZU MOTORS incomplete vehicles.
• It is not that ISUZU MOTORS guarantee the quality of construction or the safety and
running performance of the modified complete vehicle which remodeling done according
to this guide.
• For body mounting and remodeling according to mounting, the body builders must design
and manufacture so that there is no influence on safety, the running performance, and the
function of genuine devices.
• The body builders are to comply with the national regulations with respect to their vehicle
bodies, cab chassis modification incidental to rear body mounting, and completed
vehicles after body mounting.
• The manufacturing responsibility of completed vehicles after body mounting is in the body
builders. ISUZU MOTORS does not owe the obligation.
• ISUZU MOTORS is not responsible for any human injury or instrument damage due to
using this guide.
Note: ・ This guide is made commonly for various destination. There may be equipment or
function described which is not developed depending on destination.
・ Follow the owner’s manual for handling the vehicle or the equipments on vehicle.
・ The content of this guide might change without a previous notice. Contact ISUZU
MOTORS LIMITED, ISUZU distributor or ISUZU dealership for exact details of latest
information.
Ⅰ. GENERAL PRECAUTIONS
Chapter 1
GENERAL Ⅰ GENERAL PRECAUTIONS
Chapter 1 GENERAL
・Design the rear body to evenly distribute the load of rear body on chassis frame.
- Installation of special equipments on a chassis frame can change the said load distribution.
Therefore, such special equipments must be installed, taking load distribution into account,
otherwise stress concentration in particular part of the chassis frame may occur, possibly
resulting in cracks in chassis frame members or other problems even if the total weight of
these special equipments falls within allowable range. Confirm that there is no problem in
safety in chassis frame member before the examination.
・If there is any equipment addition (e.g. fuel tank addition) or weight trend to one side (e.g.
side door installation of the van body), adjust right and left weight difference on rear body.
・ When adding equipments on front overhang, rear overhang or lower part between axles, note
that the approach angle, departure angle, and ramp angle do not go below the position of
existing equipments.
Approach angle
Departure angle
Ramp angle
Chapter 1
GENERAL Ⅰ GENERAL PRECAUTIONS
③ Cab
・Give appropriate rust prevention treatment to the inside and surrounding the hole when
drilling hole the inside or outside of the cab. Do similar processing when the surface of the
cab is mistakenly damaged.
・ When installing lever or switch to control rear body in the cab, maintain enough clearance
from other levers and switches of existing and install it in the cab so as not to come in contact
at operation.
・ Place a plate or a label on the lever and the switch newly added to distinguish the purpose of
use.
・ When installing warning buzzer of the rear body device in the cab, install one with a buzzer
sound different from the safe warning sound of other warning buzzers such as buzzers for the
brake.
⑤ Other
・Make sure the rear body does not obstruct forward and the side views, nor the views such as
rearview mirrors and under mirrors.
・ Do not install components likely to drop out by the vibration of the vehicle in the vicinity of the
driver's seat, since it might obstruct the driving operation.
・ Do not install rear body (especially, components impact or the outside force may be applied
such as side guard) on to chassis accessories such as fuel tank support and air tank support,
etc.
・ No projection or sharp edges on iron plates of rear body which may give scratch.
Chapter 1
GENERAL Ⅰ GENERAL PRECAUTIONS
・ Stop the engine, apply the parking brake, and set sprag on the tire, to prevent the vehicle
from moving.
・ When installing, make sure no inclination of rear body at horizontal place.
・ Observe the instruction of the caution plate stuck on the cab chassis strictly.
・ When you disconnect the battery cables, to prevent short circuit, do according to the following
procedure. Connect battery cables following the procedure for cable disconnection in reverse
order.
- Turn off all the switches.
②
①
- After turning off the starter switch, wait about 1
minute and disconnect the negative cable ①. If
disconnect negative cable within 1 minute, ECM
may malfunction.
- Disconnect the positive cable ②.
③
- Disconnect the battery cable ③.
- When you connect the battery cable, to prevent
battery terminals from corroding, clean them and
lightly apply grease on them.
・ Depending on the mounting equipment (e.g. UREA SCR), the time before being able to
disconnect the negative cable after turning off the starter switch may become long. Refer to
"SPECIFIC INFORMATION" for details.
・ After disconnecting negative terminal, wait more than 15 seconds before starting to work.
・ When all the work is done, restore (connect) the battery negative terminal. The terminal
should be tightened with specific torque. (Refer to "SPECIFIC INFORMATION" for tightening
torque.)
・ Partially protect the chassis if necessary.
② At work
・Do not get on valves and equipments related to the brake, the brake pipes, the fuel tanks, the
fuel pipes, the air tanks, the brake boosters, the batteries, wire harnesses, the transmission
control cable and the relay boxes, etc. to lead to damage and the breakdown of the
equipment.
・Use the grip and the step, etc. to prevent from slipping and falling when getting on and off of
the cab.
Chapter 1
GENERAL Ⅰ GENERAL PRECAUTIONS
・ When tilting the cab, give a necessary safety precaution like certain fixation of the cab
stopper stay etc.
・ In the case of the tilt cab vehicle, when heavy load is installed on the cab roof or inside the
cab, descending speed quicken. Be careful not to get caught in between.
・ When installing additional components, be careful not to damage the harness due to jamming
or smashing. If the harness is damaged, have it repaired.
・ Do not leave tools or waste cloth, etc. behind in the engine room.
・ Do not touch the vent plug of electronic unit (control Example Vent plug
unit).
・ The vent plug might come off from the unit when
external force is applied.
・ If the vent plug came off, replace unit with new one.
・ If the vent plug is reused or left off, foreign
Cont. unit
substance (water, waste, etc.) may enter inside the
electronic unit.
③ Starting up engine
・Confirm whether the gear shift lever is in neutral or parking (when there is parking range).
・Start up an engine while pressing the clutch pedal.
・Turn off PTO if there is.
・ Do not put the combustible in the direction of the exhaust and the vicinity of the hot section.
・ If starting engine inside, install exhaust device to release the exhaust gas outdoor.
・Do not work in the direction of the exhaust or place where the exhaust gas collect easily.
・ When the engine is on, be careful with the rotation part and the high temperature section, and
not to touch, get caught in, or get burnt.
etc.
Chapter 1
GENERAL Ⅰ GENERAL PRECAUTIONS
・ When storing the vehicle for long term, do not leave the key in starter switch. Small amount of
electric current is flowing to each system while the key is in, and keeping this for long term
will cause flat battery.
Chapter 1
GENERAL Ⅰ GENERAL PRECAUTIONS
・ Do not fix together the accessories and equipments for rear body with same bolt.
・ Use the bolts of the same strength class when using the bolt with same size and different
length.
・ Follow the tightening torque on next page when re-installing each part on the chassis.
・ Follow the work book when re-use prohibition and tightening torque are specified.
Chapter 1
GENERAL Ⅰ GENERAL PRECAUTIONS
8 8 9 8 8 9
・ ・
・ ・ ・ ・ ・ ・
Nominal of thread
(Diameter×Pitch)
5.6 to 11.2 6.6 to 12.2
M6×1 ― ―
{0.6 to 1.1} {0.7 to 1.2}
13.4 to 25.7 16.7 to 30.4 15.3 to 28.4 18.1 to 33.6
M8×1.25
{1.4 to 2.6} {1.7 to 3.1} {1.6 to 2.9} {1.8 to 3.4}
31.3 to 52.5 37.3 to 62.8 35.4 to 58.9 42.3 to 70.5
M10×1.25
{3.2 to 5.4} {3.8 to 6.4} {3.6 to 6.0} {4.3 to 7.2}
31.3 to 51.4 36.3 to 59.8 34.5 to 57.5 40.1 to 66.9
*M10×1.5
{3.2 to 5.2} {3.7 to 6.1} {3.5 to 5.9} {4.1 to 6.8}
69.3 to 104.0 75.5 to 113.8 77.7 to 116.5 85.0 to 127.5
M12×1.25
{7.1 to 10.6} {7.7 to 11.6} {7.9 to 11.9} {8.7 to 13.0}
64.8 to 96.1 71.6 to 106.9 71.4 to 107.2 79.5 to 119.2
*M12×1.75
{6.6 to 9.8} {7.3 to 10.9} {7.3 to 10.9} {8.1 to 12.2}
106.2 to 158.8 113.8 to 170.6 114.9 to 172.3 123.4 to 185.1
M14×1.5
{10.8 to 16.2} {11.6 to 17.4} {11.7 to 17.6} {12.6 to 18.9}
100.6 to 149.8 106.9 to 160.0 108.2 to 162.2 115.5 to 173.3
*M14×2
{10.3 to 15.3} {10.9 to 16.3} {11.0 to 16.5} {11.8 to 17.7}
154.3 to 232.5 160.0 to 240.3 171.1 to 256.7 176.9 to 265.3
M16×1.5
{15.7 to 23.7} {16.3 to 24.5} {17.4 to 26.2} {18.0 to 27.1}
147.6 to 221.4 153.0 to 229.5 162.5 to 243.8 168.5 to 252.7
*M16×2
{15.1 to 22.6} {15.6 to 23.4} {16.6 to 24.9} {17.2 to 25.8}
222.5 to 334.3 229.5 to 345.2
M18×1.5 ― ―
{22.7 to 34.1} {23.4 to 35.2}
223.6 to 335.4 230.5 to 346.2
*M18×2.5 ― ―
{22.8 to 34.2} {23.5 to 35.3}
307.4 to 461.7 293.2 to 440.3
M20×1.5 ― ―
{31.3 to 47.1} {29.9 to 44.9}
284.0 to 472.1 293.2 to 440.3
*M20×2.5 ― ―
{29.0 to 48.1} {29.9 to 44.9}
413.6 to 620.5 424.6 to 636.5
M22×1.5 ― ―
{42.2 to 63.3} {43.3 to 64.9}
385.7 to 578.0 394.2 to 592.3
*M22×2.5 ― ―
{39.3 to58.9} {40.2 to 60.4}
490.8 to 810.5 554.1 to 830.6
M24×2 ― ―
{50.0 to 82.6} {56.5 to 84.7}
462.8 to 693.1 520.7 to 781.6
*M24×3 ― ―
{47.2 to 70.7} {53.1 to 79.7}
b
Prohibited area
b
a
c
d
d Prohibited area
H
Prohibited area
d
d
Side member
a c
b Side member
Welding bead
“a” in the above figure “b” in the above figure “c” in the above figure “d” in the above figure
(Allowable maximum (Working-prohibited (Minimum required (Minimum required
hole diameter) area) distance) distance)
② Cross member
・ For alligator type, hole drilling, notch making and welding are prohibited.
Alligator type cross member
・ For channel type, allowable maximum hole diameter “a” is 9mm, and this hole should be used
only for piping or harness routing. “b: Working-prohibited area” and “c: Minimum required
distance” shown in figure above depend on the side member.
Channel type cross member
b
a H
③ Gusset
・ Hole drilling and notch making are prohibited.
Working on gusset
Prohibited Gusset
Prohibited
Good example
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Prohibited
Side member
Reinforcement
Zigzag alignment
Rivet or plug weld (14 to 20mm)
④ Size of rivet
Rivet size detail
Unit ; mm
Vehicle type Rivet Diameter(d) Diameter (D) Height (H)
Light duty vehicle 10 16 7
Medium duty vehicle 11 18 7.7
Heavy duty vehicle 13 21 11
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
① Extension material
・ The extension material should be equivalent to that of side members. Refer to " SPECIFIC
INFORMATION " of the object vehicle model.
・ Thickness and bending radius of the extension material should be the same as that of side
members. Refer to " SPECIFIC INFORMATION " of the object vehicle model.
Extension material
Chassis frame
1.5 to 2mm
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Unit: mm
Identification
Nominal of thread Tightening torque
(Bolt head shape and Target location
(Diameter ×Pitch) N・m {kgf・m}
strength class)
Good example
Welding current does not flow through electronic unit and return to welder.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ Do not attach the ground cable to a chassis spring, otherwise the spring may break.
・ Remove the paint coating and dry the area where welding is to be performed.
・ To prevent the following components from being damaged by welding spatters or heat, cover
them up or temporarily relocate them to somewhere reasonably distant. In particular, if
welding any area within 200mm from a fuel tank, remove the fuel tank beforehand.
- Plastic parts - Rubber parts - Electric harnesses
- Air intake duct - Radiator hose - Radiator
- Intercooler - Pipes - Chassis springs
- Tire
・ To minimize impact of heat on peripheral area and to assure welding quality, select a suitable
welding torch and perform welding at suitable welding conditions.
・ No weld defect such as undercuts, overlaps, and pin holes.
② After welding
・Welded area must not be rapidly cooled.
・ Apply rust-proof paint with the same color, if the paint is removed from chassis frame or cab.
・ After welding, put the disconnected electronic units such as control unit connectors and fuses
back in place exactly as before. After that, connect negative battery terminal securely.
・ Check operation of equipments. Contact ISUZU distributor or ISUZU dealership for checking
method.
③ Welding electrode
・ Use welding electrode depending on parts in following chart.
Nominal S
D A B T C
Diameter (at minimum)
4.76 4.76 6.6 to 7.1 3.0 to 3.7 0.7 1.4 1.0
6.35 6.35 8.6 to 9.1 4.5 to 5.2 0.7 1.4 1.0
8 8 10.5 to11.0 6.2 to 6.9 0.7 1.4 1.6
±0.2
10 10 13.0 to13.5 8.2 to 8.9 0.7 1.4 1.6
12 12 15.0 to15.7 9.8 to 10.5 0.9 1.8 1.6
15 15 18.1 to18.8 12.7 to 13.4 1.0 2.0 1.6
Remarks: ・ The decentering with the center of the seat side and the tube is assumed to be
0.15mm or less.
・ For the double walled steel pipe, peeling in the inside part of the flare must be 1/3 or
less of the dimension “S”.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Tightening torque
Nominal Flare nut
Diameter Width Tightening torque value
Joint type Screw size Remarks
of applied across flats N・m{kgf・m}
pipe (mm)
A-type flare nut Tightening torque
values selected
Iron:13 to18 {1.3 to 1.8}
Pipe depending on mating
Flare nut 4.76 10 M10 x 1.0 Non-iron:9 to 15
materials.
{0.9 to1.5}
Non-iron: Aluminum
and brass
6.35 12 M12 x 1.0 25 to 35 {2.6 to 3.6}
8 14 M14 x 1.5 29 to 39 {3.0 to 4.0}
10 17 M16 x 1.5 45 to 55 {4.6 to 5.6}
C-type flare nut 4.76 14 M10 x 1.0 13 to 18 {1.3 to 1.8}
Pipe Flare nut 6.35 17 M12 x 1.5 25 to 35 {2.6 to 3.6} Mating materials: iron
8 17 M14 x 1.5 25 to 39 {2.6 to 4.0} Mating materials: iron
10 19 M16 x 1.5 45 to 80 {4.6 to 8.2} Mating materials: iron
12 24 M20 x 1.5 65 to 115 {6.6 to 11.7} Mating materials: iron
15 30 M22 x 1.5 80 to 130 {8.2 to 13.3} Mating materials: iron
a≧2d b≧2 d
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Unit: mm
Pipe diameter P
4.76 / 6.35 400 or less
8 / 10 500 or less
For floating joints 12 / 15 600 or less
・ For piping between air compressor and air dryer, do not fix by shape that moisture collects
because moisture in the tube might freeze.
10mm or more
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ Secure the distance between steel pipes or a pipe and other components according to the
following Fig.
Distance between steel pipe and other components
Bolt head or Hole in the panel
rivet head on 10mm 10mm
chassis frame at or more
minimum 10mm or more
10mm
member or more
at minimum
Rivet head
Bolt head
Edge Moving components such lever, link and arm: 30mm (moving
10mm or more
range +30mm)
30mm
30mm以上or more
80mm or more
10mm or more
Flare nut
200mm or more
20mm or more
There may be individual values provided.
Refer to "Ⅱ SPECIFIC INFORMATION" of target vehicle
type.
・ Do not route pipes over, under or outside the frame. Pipes may be damaged due to , stepping
on, flying gravels, etc.
・ Do not route pipes in lower part inside the frame. Pipes may be damaged due to piled up or
freezing mud or water.
Piping location
Frame Frame
Good example Poor example
Brake piping
Mud and water
Prohibited area
Brake piping
10mm
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Outer Diameter (mm) Inner Diameter (mm) Minimum bending Radius (mm) Purpose example
6 4 50 Air suspension seat
8 6 80 Accessory line
12 9 100 Brake line
・ To disconnect nylon tube, push the release collar and pull out the nylon tube.
・ If the nylon tube is frequently connected and disconnected, purchase genuine ISUZU
products from ISUZU distributor or ISUZU dealership.
・ When using steel connector, use connectors with following treatment to prevent pipes from
corrosion.
- Surface treatment: Zinc chromate plating (Product name: Dacromet treatment)
- Plating thickness: 4μm (MIN)
- Rust proofing test with salt water spray: no rust for 240 hours
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ Check the inside of the connector. If there is any extraneous substance, blow air into it to
remove it.
・If there is friction marks from connector on nylon tube, cut off that portion. Confirm there is no
scratch on tube after cutting. If there is, cut off that part.
・ Check the insertion length before inserting the nylon tube. Paint the position and insert to the
mark. Insertion depth differs by connector makers. Firmly insert the nylon tube to the end.
Connecting nylon tubes
・ Check the inserted part of the removed nylon tube for adhesion
of dirt. If there is any, remove it. Thoroughly blow air into the
connector to remove extraneous substance.
・ Cover the removed nylon tube and connector with vinyl bags
(lint-free bag) to protect them from scratches and dirt.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ After completing the tube insertion, hold the connector and at the
same time pull the tube to confirm secure connection.
・ Confirm that there is no air leakage.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
③ Band clips
・ When nylon tube contacts chassis frame or other components, cover the nylon tube with
corrugated tube.
・ Wrap tape on both end of corrugated tube to prevent from moving.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ Cover the tube with corrugated tube and clip fix the tube to avoid corrugate tube to be
scratched.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ When passing the tube through a hole of chassis frame member, protect the tube in the
corrugated tube, and fix the nylon tube so that the tube does not contact with the edge of the
hole.
Measure through holes (2)
・The tube near the movable component such as the lever, the drag links, and arms must be
fixed with distance of 30mm or more from them.
Distance between tube and movable components
30mm or more
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
⑤ Freeze proofing
・ Do not fix by shape that moisture collects because moisture in the tube might freeze.
Loose nylon tube
⑥ Installation length
・The tube expands and contracts according to the temperature change. Install it with enough
length.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Contact with a bracket (1) Wrap the pipe with rubber sleeve and fix with
band clip to a bracket.
Provide
Provide aa minimum
minimum of of 10mm
10mm clearance
clearance
between
between the nylon tube and
the nylon tube and the
the bracket,
chassis
or wrapmember,
frame the nylonortube
wrapwith
theanylon
corrugated
tube
tube.
with a corrugated tube and secure it at
both sides point within 50mm from
contact part with clip.
300mm 300mm
or less or less
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Others
Contact between vibrating nylon tubes
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Example 1
① Without multi protection valve (MPV)
air extraction
・ Extract air from accessory line including
main tank.
Example 2
② With multi protection valve
without accessory tank
・ Extract air from accessory line down
stream of low pressure switch.
air extraction
Example 3
③ With multi protection valve
with accessory tank
・ Extract air from accessory line down
stream of accessory tank.
air extraction
For the vehicles with air extraction details, refer to "SPECIFIC INFORMATION".
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ When lowering the position of the fuel tank, carefully determine the ground height of a fuel
tank not to contact the ground with particular attention to the conditions of use.
・ Be sure that the breather opening of the relocated fuel tank will not be subjected to water.
There are two types of the breather: One of them is fitted on a fuel tank body, which can be
opened with a hose, and the other type is at a filler cap.
・ Maintain sufficient clearances between the hoses for a fuel tank ("A" in the figure below) and
the object to be mounted on a chassis frame such as sub frame, U-bolt and double ended
bracket. If contact is anticipated, wrap the hoses with corrugated tubes or protectors.
Hose for fuel tank
・ Be sure that the relocated tank is sufficiently apart from any movable or projecting object.
・ The fill opening of a fuel tank should be easily accessible so that its cap can be removed or
attached and fuel can be fed without problems.
・ Maintain a reasonable clearance between an exhaust system component (front pipe, silencer
and tail pipe) and a fuel tank or a fuel hose.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
50mm or less
Note: Make sure that adding the new bracket does
not make the fuel tank or the fuel tank bracket
protrude outward from the outmost side of the vehicle.
Note: Form hose referring to above chart, without wrinkles at inner bent or blockage.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Hose Hose
D A B D A B
Nominal Size Nominal Size
05/06 6.35 7.40.3 6.10.3 05/06 6.35 7.40.3 6.35
08 8 9.30.3 7.90.3 08 8 9.30.3 8
10 10 11.50.3 10.00.3 10 10 11.50.3 10
12 12 13.50.3 12.00.3 12 12 13.50.3 12
Note: * Corrosion resistance: 2,500hrs. at minimum before reddish brown corrosion appears
after salt spray test.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Unit: mm
・ Insert this connecting pipe into hoses by more than 30mm, and secure with clips.
Unit: mm
Hose Nominal Size Clip part number
05 898150-3580
06 898150-3570
08 898150-3570
09 898008-0980
10 109704-1020
12 898150-3560
・ If bulge forming and spool forming are impossible, the insertion depth should be 35mm or
more.
・ Secure the hoses on a chassis frame or something else by using clips.
Hose fixing
① Location
・ For straight frame: locate towing hook leveled with frame.
・ For kick-up frame: locate towing hook incline 15°downward from frame to avoid effect to
rear body or poor operativity from the hook located higher.
② Installation
・ For drilling holes on frame, refer to "Ⅰ-2-1 DRILLING OR WELDING A CHASSIS FRAME".
・ Hole diameter and tightening torque is as follows.
The rear body posterior of towing hook must not be in range of towing rope.
15°
Range of towing rope
15°
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ How to extract power from the positive battery terminal (when electrical load of rear body
exceed the allowable capacity of standby power supply)
- Provide a fuse in each power extraction circuit.
- Fuses must be a minimum of 300mm apart from the battery (volatile gas may come out of
the battery) and protected from water.
- Do not put a fuse directly on the battery body or on the reverse side of the battery cover,
otherwise the battery will be damaged or explode.
- Use the ring terminal to extract from battery, fix it together with battery terminal to prevent
loosening.
- Only one terminal may be added to prevent loosening.
- Do not connect ground circuit of additional power supply with the existing harness.
Connect it with negative terminal of the battery.
- When using a cable of 5mm2 or larger, solder the pressured part of the wire terminal, and
then wrap the area with a heat shrink tubing.
- Extracted power from battery is always energized, does not depend on the state of the key
switch on the underbody. This can cause the battery go flat. Take the necessary measures
such as appending to the caution label or the owner’s manual.
Connecting an additional cable
Factory-installed circuit
Additional circuit
Fuse
Additional
load 300 at min
Ring terminal
12mm
Battery terminal
③ Ground circuit
Careless modification may result in fire or equipment breakdown.
Relocating the ground points of the factory-installed ground circuit and lengthening or
shortening these wires or cables is prohibited, because doing any of these may result in
breakdown of electrical equipments or electronics devices due to surge, etc.
Follow the below instructions when adding ground circuit for bodies or additional equipments.
・ How to connect the ground circuit to a chassis frame
- The ground point of an additional equipment should be connected to the chassis frame
member to which the negative battery cable is connected.
- Do not secure the ground circuit of additional equipment together with a factory installed
ground point because the fixing bolt will loosen and contact failure will occur.
- Use ring terminal and secure it without looseness. Jamming foreign substance at
connecting will be a cause of looseness.
- Bolt for fixing ground circuit on frame and cab panel is exclusive use. When the bolt is
damaged at work, replace it with specified exclusive ground bolt.
- Weld a mating nut on the chassis frame or directly tap the chassis frame. To drill holes for
directly tapping chassis frame, follow "Ⅰ-2-1 DRILLING OR WELDING A CHASSIS
FRAME".
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
(Good)
Harness A Harness B
Center stopper
Cu sleeve
Harness B
Heat the tube with a heat gun or the like to shrink it.
Heat gun Keep heating until translucent plastic ooze out whole
circumference from both ends of tube.
Joint terminal
Roughly heating temperature ; 120℃
Note: For the additional wire, consider the overlap length of splicing area to the wire cut off. If
there is recommended length for the used crimped-type terminal, prepare additional wire
with the length added.
Splicing of wire harness (Solder or crimped-type terminal)
・ For repairing damaged wires, cutoff the damaged portion, add wire, and perform splicing.
- Below figure shows joint terminal method. Follow the same procedure for solder or
crimped-type terminal method.
- When using specific joint terminal for splicing, the length of wire cutoff and added must be
the same (L mm).
- When splicing with soldering or using crimping terminal, length of the additional wire must
be the total of length of wire cutoff and overlap of joint potion (2 places) added. If there is
recommended length for used crimping terminal, add the overlap length (2 places) to it.
・ When rerouting the damaged circuit due to working space etc., follow the above directions
except for the additional wire length.
- For the rerouted wires, perform damage prevention treatment.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ When the connector or the wire close to connector is damaged, prepare connector ASM for
replenishment and perform splicing.
- Below figure shows joint terminal method. Follow the same procedure for solder or
crimped-type terminal method.
- When using specific joint terminal for splicing, the length of wire cutoff and connector ASM
for replenishment must be the same (L mm).
- When splicing with soldering or using crimping terminal, length of the additional wire must
be the total of length of connector ASM and overlap of joint potion added. If there is
recommended length for used crimping terminal, add the overlap length to it.
・ Additional wires and connector ASM for replenishment must be the same size (diameter of
copper wire). Considering re-repairing, use of same color wire is recommended.
・ When splicing 4 or more wires, adjust splice position by shifting back and forth to avoid
overlapping to keep the harness diameter enlargement in minimum. Do the above same with
3 or less, if they do not fit in the protective material with splicing at the same position.
・ Do not splice in the following area; bent location of harness, area of large vibration, and area
of high temperature.
- Since the flexibility is reduced at splicing portion as compared with other portions, it is
possible that harness route may not return to the original.
- Possibility of disconnection occurrence will be higher, because flutter increases due to
larger weight.
- Decide the position of the splice carefully
・ In case of performing the splicing in the middle of the connecting route to the relative motion
part (cab to frame, engine/mission to frame), there is a risk of breakage caused by bending
input. Perform the splicing out of the connection area by replacing the lengthened wire all
spans the area.
Splicing in the middle of the connecting route to the relative motion part
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
⑦ Wrapping tapes
Wrapping tapes
①Partial taping
Wrapping repeatedly at the same position.
Purpose; Temporary bundling together wires, Marking tape, etc.
②Spiral taping
Wrapping by aparting width of tape.
Purpose; Bundling together wires in corrugated tube,
prevent slit opening of corrugated tube, etc.
Corrugated tube
⑧ Connectors
・ Use water-proof connectors for the harnesses placed outside a cab.
・ Do not unnecessarily disconnect these waterproof connectors, otherwise continuity failure will
occur.
・ When disconnecting waterproof connectors, to prevent foreign substances such as water and
metal chips from getting into the joint, or to protect the sealed part from being damaged, cover
the disconnected connectors with vinyl bags or something. If water or any foreign substance
get into the joint, dry up the joint or remove such foreign substance before connecting the
connectors.
A variety of connectors
Giboshi Standard connector Joint connector Water proof type connector
・ As for the area where connectors may be subjected to vibration, use connectors with a
detach-safe lock.
・ When using a “GIBOSHI” type plug, be sure that its socket connector (female) with insulation
cover is connected to the wire from the power source, to prevent it from shorting when the
plug comes off and contacts with vehicle body.
・ Disconnecting connectors
- Certain types of connectors have a tang lock that prevents these connectors from coming
off when vehicle is running.
- Some tang locks can be released by pulling (①) while the others by pushing in (②).
Check which type of tang lock the connectors have.
- To prevent harnesses from coming off from the connector or breaking, when disconnecting
connectors, do not pull the harnesses but securely hold both connectors (male and female),
release the tang lock, and then separate the connectors with care.
Disconnecting connectors
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ Connecting connectors
- Securely hold both connectors (male and
female) and check whether the connector pins
and the cavities match. Also, check whether the
connectors are aligned.
- Securely hold the connectors and carefully
engage them by pushing until the connectors
click.
⑨ Harness routing
・ When laying additional wires, be sure that they will not restrict inspection or maintenance of
the vehicle components.
・ To increase reliability of wires, protect all additional wires and harnesses with corrugated
tubes or polyvinyl chloride tubes.
・ When handling the wires, do not pull them hard.
・ Additional harnesses should be laid along and secured on rear body members or on chassis
frame. Do not pass them in the air.
・ Securely fix the harnesses in place so that they will not contact with moving parts or sharp
objects.
・ Fix the harnesses so there is no jamming at rear body mounting.
Distance between harness and object
Object Required distance between harness and object
Moving part most approached 10mm or more
Sharp object minimum distance 10mm or more
・ If there is possibility that a harness contacts with a sharp edge of a metal part, protect the
harness with corrugated tubes and clip fix to avoid contact the sharp edge, or cover the sharp
edge with a protector, otherwise vibration will damage the harness coating.
Harness routing (1)
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ To prevent harness coating from being damaged, attach grommets to the through holes in
steel plates.
Harness routing (2)
・ Do not put any harness on top, underside or outer side of chassis frame members because
someone may step on it or flying gravels may damage it.
・ Do not put any harness in the lower part of the inner side of chassis frame members because
harness may be damaged or freeze due to mud, snow, water, etc. that may be built up in this
area.
Harness routing of chassis frame members
・ If there are factory-installed harnesses nearby, secure additional harness on them with tapes
or nylon clips. Do not tape wrap an additional harness directly on a metal pipe or a rubber
hose including the brake pipe and the fuel pipe.
・Provide sufficient clearance between such pipe, hose and a harness.
Distance between harness and pipe/hose
Positional relation Clearance between harness and pipe/hose
Parallel 10mm or more
Intersecting 20mm or more
・ When the Corrugated tube and the air tube vibrate while interfering, the air tube will damage.
Arrange the tube maintaining enough space.
Harness routing of near the pipe/hose
・Note the following when fixing together to factory-installed harness with band clips.
- Put the additional harness in the vinyl chloride tube or the corrugate tube, use nylon clip to
fix along the wire harness for the vehicle.
Fixing of additional harness
No-clipping area
Existing harness
(with COT-TUBE)
・Moving harness
- When connecting an additional harness to any equipment that produces relative vibration
against chassis frame, such as engine and transmission, reasonably slacken the harness
and lay it along the factory-installed harnesses so as to absorb the relative vibration. Be
sure that the additional harness does not contact with adjacent parts or equipments.
- As for the factory-installed harnesses connected to the equipments that produce relative
vibration against chassis frame, such as engine and transmission, do not change the way
how they are secured, the clipping points, and the sagging volume.
Harness root of moving
・ Heat protection
- Harnesses must sufficiently be distant from heat source (e.g. Exhaust pipe). Be sure that
the temperature of the harnesses does not exceed their allowable temperature limit (80°C
in principle). There may be for an individual value provided according to the auto vehicle
exhaust emission device kind. Refer to "SPECIFIC INFORMATION".
・ Clip
- Use plastic clips, or vinyl-coated or rubber-coated plate clips whose base material is rust-
proofed.
A variety of clips
Plate clip P-type plate clip Plastic clip
Vinyl tube
or
Vinyl coating
- Adhesive clips should be used only as supplemental parts. (Do not use at places with
relative displacement or vibration)
- Especially, in such a place like the engine room where ambient temperature is high, use
vinyl- or rubber-coated plate clips or band clips. Do not use non-heat-proof vinyl tape or
adhesive clips to bind additional harnesses to the factory-installed harnesses because
they will come unstuck due to heat aging.
- Seal with grommet so the water dripping along the wire does not enter the case, and route
the harness so the terminals become higher than the harness entrance. Consider that
water from tire splash or at cleaning does not enter.
Water proof of case
Grommet
0.5 G / R
Red (stripe color)
Green (base color)
Wire size (0.5mm2)
Wire size
Cross sectional area External diameter Allowable current
Wire size (*)
(mm2) (mm) (A)
0.3 0.372 1.8 9
0.5 0.563 2.0 12
0.85 0.885 2.2 16
1.25 1.287 2.5 21
2.0 2.091 2.9 28
3.0 3.296 3.6 37.5
5.0 5.227 4.4 53
8.0 7.952 5.5 67
15.0 13.36 7.0 75
20.0 20.61 8.2 97
・ Do not use the factory-installed dummy bolts on the roof for installing equipments.
・The drip channel of C&E cab does not have the structure for the heavy load. Do not install
equipments.
② Precaution(NKR/QKR/1X cab)
・ For installation of equipments (e.g. Air deflector), use rain gutters on the left and right sides of
the cab.
・ To install equipments on the rain gutter, fit a bracket (e.g. L-shaped bracket) on the
undersurface of the rain gutter, and bolt them from their lateral sides to secure them in
between. When installing any equipments, avoid making a hole in the rain gutter; otherwise it
may cause rust. (See the figure.)
Rain gutter
③ Precaution(2X/3X/4X/5X/C&E cab)
・ For installation of equipments (e.g. Air deflector), welded installation nuts are available on the
left and right edges of the roof. See the following figure for the location of the nuts.
・ Before installing equipments on the roof, remove the factory-installed dummy bolts from nuts.
Do not use the removed dummy bolts for installing equipments because they do not have
sufficient strength.
・ When installing equipments, be careful not to damage the roof, and for rust proofing, be sure
to insert packing between the equipments and the roof.
・ To prevent crack in the packing due to ozone, the material of such packing should be
neoprene rubber or EPDM rubber.
・ Use rust proofing M8 nickel chrome stainless steel bolts, and washers.
・ After tightening bolts, to prevent water leakage, apply silicone sealant on the entire
circumference of the bolts.
Equipment attachment with M8 bolt on the roof
Silicone sealant
Equipment
Bolt
Rubber packing
Nut
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Cab roof
Dummy bolt
θ
Cab body side
B
a(boss) d(boss)
b(boss) c(boss)
Section view of the boss
95 E 95
F
G
Front axle
Cab back
I
Unit: mm
Chassis
Cab back Cab roof Front axle frame top
Gradient angle of to to to surface
Distance between bosses
Cab type E bosses ( °) d(boss) d(boss) Cab back to
Cab roof
A B C D a b c d F G H I
2X 1,535 1,535 1,535 1,535 252 Refer to ″Ⅱ-9-1 CAB
468 9 8 5 5 44 CHASSIS DRAWINGS ″
3X 1,760 1,760 1,760 1,760 372
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Cab roof
Dummy bolt
θ
Cab body side
B
a(boss) d(boss)
b(boss) c(boss)
Section view of the boss
95 E 95
F
G
Front axle
Cab back
I
Unit: mm
Chassis
Cab back Cab roof Front axle frame top
Gradient angle of to to to surface
Distance between bosses
Cab type E bosses ( °) d(boss) d(boss) Cab back to
Cab roof
A B C D a b c d F G H I
4X 678 489.5
4X 1,854.5 1,858 1,876 1,880
468 359.5
(Bed less) Refer to ″Ⅱ-9-1 CAB
9 8 5 5 119.5
5X 678 489.5 CHASSIS DRAWINGS ″
5X 2,054.5 2,058 2,076 2,080
468 359.5
(Bed less)
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Dummy bolt
29.5°
C
Section view of the boss
95 600 95 a(boss)
F
High roof
G
E
D
STD roof
G
E
D
I
Front axle
Cab back
I
Unit:mm
Chassis
Cab back Cab roof Front axle frame under
Distance between bosses to to to surface
Roof height D E a(boss) Cab back to
a(boss) Cab roof
A B C F G H I
STD roof 2,086 2,093 2,111 2.5 6.5 467 84.5 Refer to ″Ⅱ-9-1 CAB
High roof 1,989 1,997 2,024 4.0 4.0 467 51.5 CHASSIS DRAWINGS ″
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Cab roof
Dummy bolt
θ
Cab body side
C
D
B
F
2X cab G
5.5
3X cab
9
G
Cab back
I
I
Unit: mm
Chassis
Cab back Cab roof Front axle frame top
Gradient angle of to to to surface
Distance between bosses
Cab type E bosses ( °) d(boss) d(boss) Cab back to
Cab roof
A B C D a b c d F G H I
2X 1,535 1,535 1,535 1,535 108.5 Refer to ″Ⅱ-9-1 CAB
1,225 9 8 5 5 606.5
3X 1,760 1,760 1,760 1,760 44 CHASSIS DRAWINGS ″
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Cab roof
Dummy bolt
θ
Cab body side
B
a(boss) d(boss)
Front axle
Unit: mm
Chassis
Cab back Cab roof Front axle frame top
Gradient angle of to To to surface
Distance between bosses
Cab type E bosses ( °) d(boss) d(boss) Cab back to
Cab roof
A B C D a b c d F G H I
4X 1,854.5 1,858 1,905 1,909 Refer to “Ⅱ-9-1 CAB
1,224.5 9 8 5 5 634.5 221
5X 2,054.5 2,058 2,105 2,109 CHASSIS DRAWINGS “
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
(Cab front)
Through hole
2X
3X
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
4X
Through hole
Through hole
(Cab front) (46mm)
(46mm)
(Cab front)
5X
Through hole
Through hole (46mm)
(Cab front) (46mm)
(Cab front)
C&E
Through hole
(Cab front)
(46mm)
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
NKR
QKR
1X
2X
3X
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Location of through hole for an antenna cable (vertical surface of the bed panel)
4X
5X
(Cab front)
Rubber
Bed panel
Through hole(28mm)
C&E
(Cab front)
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
① Cab painting
・ Precautions before and after painting
- When cleaning a cab, do not use thinner and gasoline but IPA (isopropyl alcohol).
- To enhance coating adhesion, thoroughly sand undercoat surface. Be sure that the
sanding pattern is uniform, and the sealant at the joints of steel plates must not be
removed.
Good and poor sanded surface conditions
② Paint
・ Urethane paint is recommended for its high luster and distinctness-of-image gloss, and it
allows low-temperature baking.
・ Contact ISUZU distributor or ISUZU dealership for cab color.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ The United States’ Ziebart’s rust-proofing agent is globally popular in protection from road
snow melting agent, salty wind, etc. Apply this Ziebart’s rust-proofing agent on cab under floor
area, inner sides of fenders, outer side of a front panel, lower parts of doors, and joints of
panels. Follow the instructions below.
- Before applying the agent, cover the drain holes in the doors and in other areas with tape
in order to prevent them from being plugged up with the agent. Also cover the air bleeding
holes in air valves, etc. with tape to protect them from blockage.
- After completion of the agent application, remove the tapes and check the drain holes for
blockage. Since a cab is made from thin steel plates, if the drain holes are plugged up by
something such as rust-proofing agent, water or salty water may consequently rust the
panels, in the worst case making holes in them or weakening the strength of the members
that are assuring the strength of the cab.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
⑤ Paint boundary
・ The range shown in the figure below is recommended as a range of the painting boundary.
・ Shaded areas indicate the areas to be painted.
A B A B
A A
A A B
A A B
⑥ Paint drying
・ When conducting high temperature forced drying, be sure that the atmospheric temperature
of painted surface does not exceed 80°C.
- Drying temperature over 80°C may deform rubber and plastic parts, and result in separation
of adhesive-bonded joints.
・ Remove bed mat.
・ If the air cylinder for cab suspension is equipped, protect them from high temperature with
heat insulation sheet, blanket, etc.
・ If the drying temperature inevitably exceeds 80°C, follow the instructions below.
- Remove components or protect them from high temperature with heat insulation sheet,
blanket, etc.
- Remove all the control units.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
⑥ Allowable
No. Component name Material temperature
limit (°C)
⑨
① Head lamp PC
② Front bumper PP
④ ⑤ ③ Radiator grill ASA/ABS 80
④ Front ornament ABS
⑤ Door handle PP-GF25
①
⑥ Door garnish PP 90
⑦ Support step PP-GF40 80
②
⑧ Air duct PP 90
③
⑨ Emblem ABS 80
⑦
Note: This is a simplified image of a vehicle (cab).
Allowable
No. Component name Material temperature
limit (°C)
① Meter cluster
② Glove box
PPF
Instrument panel
③
cover
80
④ Trim cover PP
⑤ Headlining TPE/PEF/PP
⑥ Seat cloth
PVC
⑦ Floor mat
Note: This is a simplified image of a cab interior.
Above Fig. shows right handle vehicle.
Left handle is mirrored image.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Allowable
No. Component name Material temperature
limit (°C)
① Head lamp PC
⑤ Fog lamp PP (housing)
②
Front combination
③ lamp PMMA 80
①
④ Side reflector
② ⑤ Corner panel ABS
⑥ ⑥ Grill ASA
⑧ ⑦ Air duct PP 90
③
④ ⑧ Emblem ABS 80
⑤
Allowable
④ No. Component name Material temperature
limit (°C)
① ① Meter cluster
② Tray
PPF
② Instrument panel 80
⑥ ③
cover
③ ④ Trim cover PP or PPF
⑤ Headlining PET 90
⑥ Seat assembly PP or Other 80
(Cab back
right side) Allowable
No. Component name Material temperature
limit (°C)
Turn signal lamp
① PMMA 80
(front)
② Head lamp PC
③ Fog lamp PP (housing)
90
Turn signal lamp
④ PC
(side)
⑤ Flank reflector PMMA
⑥ Corner panel ABS 80
⑦ Grill ASA
⑧ Step closing
PP 90
⑨ Air duct
⑩ Emblem ABS 80
Note: This is a simplified image of a vehicle (cab).
Allowable
No. Component name Material temperature
limit (°C)
① Meter cluster
② Tray
PPF
Instrument panel
③
cover
④ Header shelf
PP or PPF
⑤ Trim cover 80
PET-PP
⑥ Headlining or
PET-PUR
Note: This is a simplified image of a cab interior.
Above Fig. shows right handle vehicle. ⑦ Seat assembly PP or Other
Left handle is mirrored image.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Allowable
No. Component name Material temperature
limit (°C)
① Meter cluster
② Tray
PPF
Instrument panel
③
cover
④ Header shelf
PP or PPF
⑤ Trim cover
80
⑥ Steering cowl PP-PVC
Instrument panel
⑦ PPF
pad
⑧ Headlining PET-PUR
Allowable
No. Component name Material temperature
limit (°C)
① Meter cluster
② Tray
PPF
Instrument panel
③
cover
④ Header shelf
PP or PPF
⑤ Trim cover
80
⑥ Steering cowl PP-PVC
Instrument panel
⑦ PPF
pad
⑧ Headlining PET-PUR
Allowable
No. Component name Material temperature
⑨(cab back right side)
limit (°C)
⑦ ②
⑮ ⑪ ① Front lid SMC 100
② Front corner panel
80
④ ③ Blister fender ABS
④ Door ornament
⑥
⑩ Door outer handle 90
⑤
⑤ base plate
ASA
① ⑰ ⑥ Rear quarter bent grill 80
③
⑦ Roof ornament ASA + PC 90
⑲ ⑭
⑧ Step closing
⑧
⑫ ⑨ Air duct
PP 80
⑩ Front grip and hinge
⑬
⑪ Roof assist grip
⑯ ⑫ Head lamp
Turn signal lamp
⑬
(front) PC 90
Turn signal lamp
⑭
(side)
⑮ Roof marker lamp
PMMA
⑯ Side reflector
⑰ Fender ABS 80
⑱ Bumper grill PP
⑲ Emblem ABS
Note: This is a simplified image of a vehicle (cab).
④ Allowable
⑧ ③
No. Component name Material temperature
limit (°C)
① Meter cluster PPF
②
⑤ ② Fuse lid PPF
Instrument panel
⑦ ③ PPF
cover
④ Header shelf PP or PPF
⑨
⑤ Trim cover PP or PPF
① ⑥ Steering cowl PP 80
JEC270C/PU
Instrument panel
⑩ ⑦ R/PVC+ABS
pad
⑥ or PPF
⑧ Headlining PET
⑦ Laminated glass
・ A laminated glass consists of two thermal-bonded glasses between which a polyvinyl butyral
film is sandwiched. In hot and humid conditions during paint drying, follow the instructions
below. Failure to follow these instructions may result in problems such as peeling of the
polyvinyl butyral film and bubbles between the glasses.
- When conducting forced infrared drying, work limit within 30 minutes at temperature no
higher than 120°C.
- If the temperature during such forced drying inevitably exceeds 120°C, before starting the
forced drying, cover the glass to prevent the temperature of the glass surface from
exceeding 120°C, or remove it.
- Laminated glasses can be identified by “LP”, “LS”, “L”, “AS1” or “LAMINATE” printed at the
lower left corner. Partially tempered glasses have a “Z” print.
A
Flat surface
・ Components related to braking system such as brake hose and brake booster
・ Rubber hose, vinyl hose or connectors
・ Wire harness and connectors
・ Components and equipments related to suspension, steering, such as these made of rubber
or plastic. Especially painting on the air bellows is strictly prohibited.
・ Cab power tilt related components
・ Caution plates and number plates
・ Door sealing
・ Rubber and plastic components around window
・ Sliding part of check arm
・ Inside the door lock (Be careful not to have painting in mechanism part.)
・ Wiper blade and washer nozzle
・ Reserve tanks for coolant and washer tank
・ Regenerator such as condenser, radiator, and inter cooler
・ Condenser fan
・ Movable components such as compressor clutch
・ Lattice part in radiator grill (black part)
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
2-16 EMBLEMS
① Precautions before affixing emblems
・ If there is any extraneous substance on a bonding surface(cab, panel) such as water, oil and
dust, emblems will not firmly stick to the surface. If there is any, wipe them off completely with
a clean cloth soaked in IPA (isopropyl alcohol). Remove wax if the wax has adhered.
・ The ideal ambient temperature for adhesion is 30°C to 50°C. Make the temperature of the
bonding surface fall within this temperature range.
・ Follow the below instructions when using an organic solvent.
- Work in an airy place.
- Fire strictly prohibited.
- Be careful do not get into eyes.
- Stop working immediately when the physical condition worsens.
- Follow instructions of the organic solvent used in detail.
② Precautions at affixing emblems
・ As for affixing emblem, set the alignment that came with a chassis on the front lid of a cab,
and then stick each letter sticker by using cut-outs of the alignment as a guide.
・ The sticky side of emblem requires pressurization for bonding. To firmly stick the stickers,
apply sufficient and uniform pressure on the emblem. Use of a roller is recommended as they
provide uniform pressurization. The pressure of the roller should be no less than 5kg.
・ Exposing the sticky side of emblem to the air for long hours weakens their adhesivity due to
adhesion of dust, etc. To protect the sticky side, do not remove a release-paper until
immediately before use.
・ Since this sticky-side has very strong adhesive property, once emblems are affixed, peeling
them off is not easy. Before sticking them, carefully check sticking position.
Location of emblem for various cab is described in “Ⅰ-2-17 DECALS“, together with location of
decal.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
2-17 DECALS
The base material of a decal is thin, soft and stretchable vinyl chloride. Therefore, strictly follow
the procedure to firmly affix decals without making wrinkles, bubbles or stretching.
Dry type (Use paper carrier tape) Wet type (Use neutral detergent solution)
Small area 300 X 300mm or less Large area 300 X 300mm or more
Decal size
Narrow width 50mm or less Wide width 50mm or more
Note: *1 When it is not possible to wipe off with IPA (iso-propyl alcohol) etc. used for the
cleaning, it is necessary to prepare lacquer thinner.
*2 Tape is used for alignment. Prepare NITTO paper adhesive tape No.720 or equivarent.
*3 Use home liquid neutral detergent for the neutral detergent solution.
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
・ Dry type (For sheet decals such as signature, mark, and stickers)
- Prepare decal with paper carrier tape pasted to the printing surface.
Sectional view of sheet decal
- Without removing a release paper, temporarily place the decal in position, and mark the
position with tape.
- Peel off the release paper from the edge approximately 20mm, and then fold down the
paper 180°.
- Align to the positioning tape, press and paste up the 20mm area with squeegee first.
Temporarily fix the other edges with tape so that the decal will not move.
- Slowly peel off the release paper, and press the decal carefully.
- Basically , move the squeegee in same direction, downward or right to left.
- When you are sure with no meandering or mis-positioning, remove the positioning tapes.
- If there are bubbles trapped inside the decal, pop it with needle and press them out to
flatten.
- Press the entire surface hard for the last time, and then carefully remove the paper carrier
tape in 180° angle.
How to affix decal
Tape
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Decal Decal
Dryer
10mm at minimum
Squeegee
Squeegee
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
B C
1 2
y
1: Edge of panel
3 2: Decal
D 3: Emblem (ISUZU)
Distance
A: 23mm B: 26mm C: 23mm D:18.5mm
y 1
Sectiony-y
B C
1 2
1: Edge of panel
2: Decal
3: Emblem (ISUZU)
Distance
D A: 25mm B: 26mm C: 23mm D:20mm
1 3
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Z 1
B
B
Z
A 2
Section Z-Z
3
3
C 1: Edge of panel
2: Decal
3: Emblem (ISUZU)
1 4: Radiator grill
4
Distance
A: 16mm B: 19mm C: 39mm
Grill shape
Type(a)
Type(b)
1: Edge of panel
5 2: Decal (“N*”/”REWARD-N*”/”REWARD”)
3: End of panel curve
4: Edge of emblem
5: Emblem(ISUZU)
4 Distance
A: 30mm(“NL””NM”)/34mm(“NN””NP””NQ”)/
C 18mm(“REWARD-N*”)/18mm(“REWARD”)
B: 19mm
3
C: 43mm(Grill shape type(a))
58mm(Grill shape type(b))
Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Grill shape
Type(a)
Type(b)
“FORWARD” Decal
2
5 A
4 Distance
E A: 45mm B: 21mm
3
The decal shown here is one example.
Z
1 Z
a
c
b B
e d a,
c,b
A
d
2 Z Z 1
2
Section Z-Z
5
1. Decal
4 a, b: End of panel curve
C c: Upper left corner of the decal
3 d: Upper right corner of the decal
e: Edge of panel
2. Front lid
3: End of panel curve
4: Edge of emblem
5: Emblem (ISUZU)
Distance
A: 53mm B: 21.5mm C: 40mm
Blister fender
C
Right
side
Emblem (ISUZU)
Edge of front lid Blister fender End of fender curve
Edge of emblem
D
Distance
A: 31mm B: 29mm C: 28mm D: 49mm
Note: The table is at 1G reaction force. A peculiar value to the frame tensile strength and the
permissible stress value might be indicated according to the vehicle type and destination.
Confirm the frame section coefficient diagram etc. of "SPECIFIC INFORMATION" of the
vehicle type targeted without fail.
・ Chassis frame is designed assuming uniformly distributed load. Frame stress may become
maximum other than maximum load due to rear body feature, shipment, or rear body
characteristics. Built suitable sub-frame or add reinforcement so the frame stress do not
exceed limits referring to below examples.
Load concentrates on rear over hang for hopper weight. Further more,
Garbage compactor truck
the load concentrates on tare meter load cell installation part.
Concrete mixer truck Load concentrates on front and rear drum support.
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
② Transmission
・ Since transmission moves in unison with the engine, maintain a minimum of 40mm clearance
around it.
・ Transmission is to be retreated when removed. Therefore, not to contact anything, the
transmission assembly must have a minimum of 150mm clearance behind it.
・ Provide a minimum of 150mm clearance above the transmission assembly for check-ups and
maintenance.
Clearance between transmission assembly and rear body
・ There should be the following minimum clearance around rear propeller shaft and rear axle.
Clearance between rear propeller shaft/rear axle and rear body
・ Clearance between rear axle and chassis frame from spring deflection differs in each vehicle
model. Refer to "SPECIFIC INFORMATION" of target vehicle model.
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
⑤ Exhaust system
・If a rear body is partially made of combustible materials such as wood and rubber, provide
100mm of clearance between the rear body and an exhaust pipe, a silencer or catalytic
converter.
・ If such clearance cannot be assured, provide a heat insulation between them.
・ An oil pump or its piping for the equipments or the hydraulic system on a rear body must not
be placed near exhaust system components such as a silencer or catalytic converter.
- Smoking and the ignition when the leakage occurs in the hydraulic system.
Clearance of exhaust components
Exhaust pipe
c
b
Spare tire
Prohibited
a, b, c = sufficient clearance to prevent heat damage
・ The condition of exhaust emission device may be individually shown by the form and the
vehicle type, and refer to "SPECIFIC INFORMATION" of the targeted vehicle type.
A=250mm
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
Note: When above condition is difficult to be satisfied, clip fix to avoid contact with rear body.
・ Corrosion of pipes and cables promotes on tank truck, vacuum truck, etc. due to water and
dew condensation at low-temperature part. Place protection board or keep pipes , cables and
wires away from water dripping or dew condensation part.
⑧ Cab
・When the vehicle is moving, the whole cab moves in various directions in conjunction with
cab suspension. Also, when a cab tilts, rear body may contact with the cab or cab chassis
components such as an air inlet duct attached to the cab. Taking these into account, provide
sufficient clearances between them as shown below to prevent the cab from contacting with
anything.
Clearance of cab
C
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
⑨ Retarder
・ The retarder generate heat higher than 200°C. Maintain clearance of 100mm for both A and
B from combustible materials such as wood and rubber.
Clearance between retarder and rear body
A
B
A
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
(a) (b)
(c) (d)
Unit: mm
A B R
(a) 5 H/2 to H
(b) 5 H or more
(c) H/3 H or more
(d) H/4 to H/5 H to 1.5 times H 15 to 20
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
Reference shape
200mm or less
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
1,000mm or less
1,000mm or less
・Area from the front end of a sub frame side members to 50mm posterior to a kick-up point.
Prohibited areas of fixing (1)
Prohibited area
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
・ Areas within 50mm anterior or posterior to the point where the width between chassis frame
side members begin to change.
Prohibited areas of fixing (2)
Prohibited area
Prohibited area
・ Areas within 50mm anterior or posterior to the point where height of chassis member changes
(frame kick point).
Prohibited areas of fixing (3)
Prohibited area
・ Areas within 100mm anterior or posterior to each cross member, gusset or spring bracket.
Prohibited areas of fixing (4)
Prohibited area
100mm 100mm
Cross member
- Check “SPECIFIC INFORMATION“ of target vehicle for cross member shapes and details.
・ Areas within 100mm anterior or posterior to rear suspension components or edge of its
reinforcement.
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
Chassis frame
100mm (Prohibited area)
100mm 100mm
Reinforcement
Reinforcement Prohibited area
Chassis frame
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
Installing of reinforcement
Wooden reinforcement
Sub frame
Pipes, harnesses,
and wires
Reinforcement
Chassis frame
side member 10mm or more
U-bolt
Steel reinforcement
Sub frame
Pipes, harnesses,
and wires
Reinforcement
Chassis frame
side member 10mmor more
U-bolt
Example of reinforcement
U-bolt
Sub frame
r<R
Poor example
Reinforcement
Chassis frame
side member
r>R
Spacer
Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
Installation of anti-sifting
"V" "I" type anti-sifting bracket for ・Bolt fix to chassis frame.
forward and backward direction ・Tightening with the body cannot be expected. Use U-bolt as well for
installing body.
Anti-sifting bracket for right and left ・Bolt fix to chassis frame.
direction ・Tightening with the body cannot be expected. Use U-bolt as well for
installing body.
Ⅱ. SPECIFIC INFORMATION
Chapter 1
OUTLINE Ⅱ SPECIFIC INFORMATION
"Ⅱ. SPECIFIC INFORMATION" is a summery of vehicle development for each shipment, main
technical data, and precautions at mounting rear body for each vehicle specification, to examine
at body building.
It is recommended to refer to "Ⅰ. GENERAL PRECAUTIONS“ as well at examination and
working on body building.
The content of this guide might change without a previous notice. If the contents differs from the
vehicle, contact ISUZU MOTORS LIMITED, ISUZU distributor or ISUZU dealership for exact
details of latest information.
Chapter 2
PRINCIPAL SPECIFICATIONS OF VARIOUS VEHICLE MODELS Ⅱ SPECIFIC INFORMATION
NKR/QKR 1,695
STD
1X 1,695
STD
2X 1,770
STD
3X 1,995
STD
4X 2,120
STD
5X 2,320
STD
C&E-series 2,420
High roof
The specifications given herein are based on the latest information available at the time this guide is released, and may be changed at any time without prior notice. For inquiry of latest information, contact ISUZU distributor or ISUZU dealership.
The specifications given herein are based on the latest information available at the time this guide is released, and may be changed at any time without prior notice. For inquiry of latest information, contact ISUZU distributor or ISUZU dealership.
② Precaution
・ Provide sufficient clearance between the fuel tank and the exhaust pipe and the silencer.
・ Install a heat protector to protect the fuel tank from heat.
・ For the fuel tank installing, refer to drawing shown later. The dimension between the fuel tank
brackets, observe L dimension strictly. After relocate the fuel tank, tighten band nut by
specific torque securely.
Chapter 3
PRECAUTIONS FOR REAR BODY MOUNTING Ⅱ SPECIFIC INFORMATION
③ Band tightening
Z
L
BRACKET
DETAIL
PLAN VIEW
VIEW Z
Protection valve
(Intenal thread Rc1/4)
Rear body
Chassis
equipment
Chapter 3
PRECAUTIONS FOR REAR BODY MOUNTING Ⅱ SPECIFIC INFORMATION
Front
Air extraction mouth
CONNECTOR CONNECTOR
109660-9570 109661-0250
(Tube diameter 8mm) (Tube diameter 8mm x2)
R3/8
Front
Air extraction mouth
CONNECTOR CONNECTOR
109660-9570 109661-0250
(Tube diameter 8mm) (Tube diameter 8mm x2)
R3/8
Chapter 3
PRECAUTIONS FOR REAR BODY MOUNTING Ⅱ SPECIFIC INFORMATION
① Precaution
・ Provide a 210mm or more clearance for cartridge replacement and working space.
Air dryer
① Prohibition
・ Using the he U-bolt near the rear axle
- The rear axle parts and the U-bolt may interfere due to the movement of rear axle. Do not
use the U-bolt within the areas below.
- When using the fixing bracket except the U-bolt, follow the instructions in "Ⅰ-3-4 FIXING
OF A REAR BODY".
REAR AXLE
C/L
Front
TRUNNION
C/L
Front
② Precaution
・ The recommended position of the first position of the U-bolt is shown below.
- When inserting the U-bolt into the chassis frame, detach the exhaust pipe and the under
cover as necessary.
- After inserting the U-bolt, restore the removed parts by all means. Do not to restore the
parts may cause law nonconformity and adversely affect running performance.
・ Use anti-shifting bracket described in "Ⅰ-3-4 ⑤ Precautions of using anti-shifting bracket"
together.
Front
Unit: mm
Specification
Vehicle model A B
Engine Transmission Flywheel PTO
FVR34L (N)
FVR34P (N)
FVR34PD (N)
6HK1-TCNH EATON ES9306ADD ― 1,448 1,461
FVR34S (N)
FVM34N (N)
FVM34U (N)
FVR34P HP (N)
FVR34P HPD (N)
FVR34S HP (N)
FVM34U HP5.1 (N)
― 1,391 1,461
FVM34U HP5.8 (N) 6HK1-TCS EATON ES11109DD
FVZ34N HP6.1 (N)
FVZ34N HP6.4 (N)
FVZ34U HP (N)
FVZ34L HPMX (N) ○ 1,448 1,486
・ For the clearance between U-bolt and chassis parts, refer to "Ⅰ-3-4 ③ Precautions at
fixing with U-bolts", and secure a necessary clearance.
・ When cannot secure a necessary clearance, follow the instruction below.
- Change the direction of the nylon tube clip and the harness clip for securing a necessary
clearance. But do not change the direction of that clip, if a nylon tube and harness are
connected to the parts that produce relative movement (e.g. Transmission). Because that
cannot absorb the movement.
- Refer to the following example, wrap the nylon tube and harness with rubber sleeve, and
fix it to the U-bolt or reinforcement by the band clip.
・ When using the fixing bracket except U-bolt, follow the instruction in "Ⅰ-3-4 FIXING OF A
REAR BODY".
HARNESS
BAND CLIP
109707-1830 or equivalent
RUBBER SLEEVE
※Fix the 2 band clips to the cross 109369-0061 or equivalent
U-BOLT
Chapter 3
PRECAUTIONS FOR REAR BODY MOUNTING Ⅱ SPECIFIC INFORMATION
REAR AXLE
C/L
Front
TRUNNION
C/L
CROSS MEMBER;TRUNNION
Front
Vehicle model FVR34L (N) FVR34P (N) FVR34PD (N) FVR34S (N)
Cab Front axle CAWf 2,980 3,050 3,070 3,125
chassis
Rear axle CAWr 2,410 2,470 2,510 2,545
weight
(kg) Total 5,390 5,520 5,580 5,670
Axle load Front axle 7,500
capacity
(kg) Rear axle 13,000
Tire size 10.00-20-16PR
Tire load
capacity Front axle 6,000
(kg)
Rear axle 10,900
GVW (kg) 16,000
FVR(2/2)
FVM
Vehicle model FVM34N (N) FVM34U (N) FVM34U HP5.1 (N) FVM34U HP5.8 (N)
Front axle CAWf 3,150 3,275 3,260 3,260
Cab Rear axle CAWr 3,940 4,065 4,060 4,060
chassis
Rr axle (front) CAWfr 2,030 2,095 2,060 2,060
weight
(kg) Rr axle (rear) CAWrr 1,910 1,970 2,000 2,000
Total 7,090 7,340 7,320 7,320
Axle load Front axle 7,500
capacity
(kg) Rear axle 21,000(2axles total)
Tire size 11.00-20-16PR
Tire load
capacity Front axle 6,500
(kg)
Rear axle 21,800(2axles total)
GVW (kg) 26,000
FVZ
Vehicle model FVZ34L HPMX (N) FVZ34N HP6.1 (N) FVZ34N HP6.4 (N) FVZ34U HP (N)
Front axle CAWf 3,260 3,130 3,130 3,390
Cab Rear axle CAWr 4,010 4,300 4,300 4,560
chassis
Rr axle (front) CAWfr 1,970 2,160 2,160 2,290
weight
(kg) Rr axle (rear) CAWrr 2,040 2,140 2,140 2,270
Total 7,270 7,430 7,430 7,950
Axle load Front axle 7,500
capacity
(kg) Rear axle 21,000(2axles total)
Tire size 11.00-20-16PR
Tire load
capacity Front axle 6,500
(kg)
Rear axle 21,800(2axles total)
GVW (kg) 26,000
L/2 L/2
OS
WB
CAWf CAWr
GAWf GAWr
3 axle vehicle
CW
CP
CPa BW+PL
L/2 L/2
OS
d/2 d/2
CAWfr CAWrr
GAWfr GAWrr
DAC
CAWf CAWr
GAWf GAWr
DAC: Distance from the front axle center to the rear tandem center (mm)…Refer to "Ⅱ-9-1 "
OS: Offset of the combined center of gravity of the rear body and cargo from the rear
tandem center (mm)
CP: Distance from occupant to the rear tandem center (mm)
CPa: Distance from occupant to the front axle center (mm)
L/2: Half length of the cargo bed (mm) Vehicle model CPa(mm)
BW: Rear body weight (kg) FVM
57
PL: Cargo weight (kg) FVZ
CW: Occupants weight (kg)
CAWf: Chassis front axle weight (kg)
CAWr: Gross chassis rear axle weight (kg) Refer to "Ⅱ-4-1"
CAWfr: Chassis rear axle (front) weight (kg)
CAWrr: Chassis rear axle (rear) weight (kg)
GAWf: Vehicle front axle weight (kg)
GAWr: Gross vehicle rear axle weight (kg)
GAWfr: Vehicle rear axle (front) weight (kg)
GAWrr: Vehicle rear axle (rear) weight (kg)
GVW: Gross vehicle weight (kg)
Chapter 4
WEIGHT DATA AND FRAME STRENGTH CALCULATION Ⅱ SPECIFIC INFORMATION
Basic formula
(a) GVW =GAWf+GAWr
=CAWf+CAWr+BW+PL+CW
=CAWf+(CAWfr+CAWrr)+BW+PL+CW
(b) GAWf =CAWf+{(BW+PL)xOS/DAC}+(CWxCP/DAC)
=CAWf+{(BW+PL)xOS/DAC}+{CWx(CPa+DAC)/DAC}
(c) GAWr =GVW-GAWf
(d) GAWfr ={(GAWr-A)x1/2}+B
(e) GAWrr ={(GAWr-A)x1/2}+C
Chapter 4
WEIGHT DATA AND FRAME STRENGTH CALCULATION Ⅱ SPECIFIC INFORMATION
1 FVR34L (N)
2 FVR34P (N)
3 FVR34PD (N)
4 FVR34P HP (N) Fig.4-3-1
5 FVR34P HPD (N)
6 FVR34S (N)
7 FVR34S HP (N)
8 FVM34N (N)
9 FVM34U (N)
10 FVM34U HP5.1 (N)
11 FVM34U HP5.8 (N) Fig.4-3-2
12 FVZ34L HPMX (N)
13 FVZ34N HP6.1 (N)
14 FVZ34N HP6.4 (N)
15 FVZ34U HP (N) Fig.4-3-3
Chapter 4
WEIGHT DATA AND FRAME STRENGTH CALCULATION Ⅱ SPECIFIC INFORMATION
Fig. 4-3-1 Frame Section Modulus FVR34
Unit: mm
Section module (Main frame on both sides)
Rear
axle
Front axle
Section A - A
L1 L2
Vehicle model a b c d e f g h i j k l m n o
(Wheelbase) (Rear Over Hang)
FVR34L (N) 4,300 2,000 2,355 2,555 2,570 2,710 2,770 3,080 3,350 4,272 4,287 4,391 4,406 5,200 5,290 5,340 6,300
FVR34P (N)
FVR34PD (N)
5,060 2,490 2,775 2,975 3,400 3,540 3,600 3,840 4,110 5,032 5,047 5,151 5,166 5,960 6,050 6,100 7,550
FVR34P HP (N)
FVR34P HPD (N)
FVR34S (N)
6,160 3,185 2,975 3,175 3,745 3,885 3,945 4,940 5,210 6,132 6,147 6,251 6,266 7,060 7,150 7,200 9,345
FVR34S HP (N)
Chapter 4
WEIGHT DATA AND FRAME STRENGTH CALCULATION Ⅱ SPECIFIC INFORMATION
Fig. 4-3-2 Frame Section Modulus FVM34, FVZ34 (Except FVZ34U HP (N))
Unit: mm
Section module (Main frame on both sides)
Rear tandem
Front axle
center
Section A - A
L1 L2
Vehicle model a b c d e f
(Wheelbase) (Rear Over Hang)
FVM34N (N) 4,800 2,850 2,513 2,713 3,014 3,134 3,214 7,650
FVM34U (N)
FVM34U HP5.1 (N) 6,510 4,140 2,975 3,175 3,425 3,545 3,525 10,650
FVM34U HP5.8 (N)
FVZ34L HPMX (N) 4,250 2,015 2,355 2,555 2,914 3,034 3,114 6,265
FVZ34N HP6.1 (N)
4,800 2,545 2,513 2,713 3,014 3,134 3,214 7,345
FVZ34N HP6.4 (N)
Chapter 4
WEIGHT DATA AND FRAME STRENGTH CALCULATION Ⅱ SPECIFIC INFORMATION
Fig. 4-3-3 Frame Section Modulus FVZ34U HP (N)
Unit: mm
Section module (Main frame on both sides)
Rear tandem
Front axle
center
Section A - A
Main: 1,4509014-2
1,4708013-2
Span (mm) Width (mm) 15-7
14-2
Thickness (mm) - No. of leaves Helper: 9808013-3
13-3
14-3
② FVM
FVM34 front and rear springs
Spring specification
Spring dimension Front Rear
Multi-leaf Multi-leaf
1,4708013-2
Span (mm) Width (mm) 1,3709018-3
14-2
Thickness (mm) - No. of leaves 20-9
13-3
③ FVZ
FVZ34 front and rear springs
Spring specification
Spring dimension Front Rear
Multi-leaf Multi-leaf
2 axle vehicle
X Y
Z
L1 L2
Wf Wr
3 axle vehicle
Y
X
Z
L1 L2
Wf Wr
Z = Y+(YX)L2/L1
X: Ground height of chassis frame top surface above front axle (mm)
Y: Ground height of chassis frame top surface above rear axle (mm)
Z: Ground height of chassis frame rear end (mm)
L1: Calculational wheelbase (mm)
L2: Chassis frame rear overhang (mm)
Wf: Front axle load (kg)
Wr: Rear axle load (kg)
Chapter 5
CHARACTERISTICS OF THE SPRINGS Ⅱ SPECIFIC INFORMATION
Unit: mm
Chassis frame depth
Vehicle model Tire A B C D
at rear axle
FVR34 275 10.00-20 195 115 590 155
FVM34 305 11.00-20 170 90 565 200
FVZ34 305/307 11.00-20 170 90 565 200
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
FVR34L (N)
— — — — — — —
FVR34P (N)
EATON
○ — 350N・m
ES9306ADD With Clockwise when
FVR34PD (N) ○ — — {36kgf・m} 0.720
Flange viewed from rear
/2,500rpm
FVR34S (N) — — — — — — —
FVR34P HP (N) — — — — — — —
380N・m
EATON With Clockwise when
FVR34P HPD (N) — ○ ○ — — {39kgf・m} 0.940
ES11109DD Flange viewed from rear
/1,500rpm
FVR34S HP (N) — — — — — — —
FVM34N (N)
EATON
○ — — — — — — — —
ES9306ADD
FVM34U (N)
353N・m Counter-clockwise
With
FVZ34L HPMX (N) — — ○ {36kgf・m} 0.700 when viewed from
EATON Flange
— ○ /2,400rpm rear
ES11109DD
FVZ34N HP6.1 (N) 380N・m
With Clockwise when
○ — — {39kgf・m} 0.940
Flange viewed from rear
FVZ34N HP6.4 (N) /1,500rpm
FVZ34U HP (N) — — — — — — —
② Side PTO
FRONT
Main shaft
center
PTO output
From front axle center
shaft center
SIDE VIEW REAR VIEW
Note: ・ This figure is an example of transmission. The dimensions from engine datum point
varies in each vehicle. Confirm the side view of "Ⅱ-9-1 CAB CHASSIS DRAWINGS".
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
Unit: mm
35
35
35
35
6 - 3/8“-16 UNC-3B
Screwing depth: 18
Pilot hole depth: 26
52.4 52.4
Unit: mm
112.3 REF
7.9
Φ 84
1.9
Φ 100
Φ 57
6X Φ 8.1
197.3
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
FRONT
Note: ・ This figure is an example of transmission. The dimensions from engine datum point
varies in each vehicle. Confirm the side view of "Ⅱ-9-1 CAB CHASSIS DRAWINGS".
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
Unit: mm
35
35
35
35
6 – M10 x 1.5
Screwing depth: 20
Pilot hole depth: 24
52.4 52.4
10 77.4 Unit: mm
Φ 88
60
4X Φ 8.5
114 35
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
③ Flywheel PTO
・ 6HK1 Engine
Unit: mm
Note: ・ The dimensions from engine datum point varies in each vehicle. Confirm the side view of
"Ⅱ-9-1 CAB CHASSIS DRAWINGS".
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
・ When connecting the PTO drive shaft, follow the instructions below to keep it from vibration
and noise out of the power train.
- The shaft angle is recommended 7˚ at maximum.
- For installation of the driven equipments such as pumps, the shaft angles (β1, β2) should
be the same.
- The shaft must be in proper balance, and confirm that there is no harmful vibration or noise
by driving the driven equipments after mounting.
PTO
Driven equipment
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
Accelerator throttle position and engine output of electronic controlled engine have two types of
mode of Running Characteristic (drive) and Working Characteristic (work). When the
conditions of each mode are satisfied, the ECM determines fuel injection quantity, and mode is
switched. Refer to “Ⅱ-6-3 GOVERNOR CHARACTERISTICS CURVES FOR WORK MODE"
for engine output characteristic curves of work mode.
・ Prohibition
- Directly input the electric signal to the external engine control signal terminal
- Any modification which may influence control, e.g. adding interlock mechanism
・ Precaution
- After completing any work with use of PTO, be sure to return the external engine control
lever to IDLE. Leaving the external engine control lever opened may cause unexpected
increase in the engine speed.
・ Switching to work mode
After satisfy following conditions, mode switches to work mode when the external engine
control lever is opened from idle position.
- When stopping the engine while using an external control, to drive in the work mode after
re-starting, the switch condition to the work mode should be satisfied again.
Conditions for switch to work mode
External engine control Connected
External engine control lever position IDLE
Stop
Status of vehicle
(Vehicle speed: 0km/h)
Engine speed Higher than the idle speed
Shift lever position Neutral
Acceleration pedal position Released
When push the PTO switch, PTO connection is indicated on meter panel as shown below.
The figure shows location and indication contents of PTO indicator. Other indications may
differ according to specification of each vehicle.
with Multi-Information display
PTO indicator
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
External engine control of electronic controlled engine is electrically performed. The cable for
external engine control is to be installed on the rear body, and the movements of the cable are
converted into electrical signals by lever. Engine speed is controlled by the signals.
To prevent the malfunction of the engine and the damage to ECM, observe the following
descriptions when installing the external engine control lever and the harness.
・ Prohibition
- Harness extension by modification is prohibited. Wiring resistance increase of power
supply, ground harness and signal wire or exogenous noises due to modification may
cause defective output or unexpected engine blow.
・ Precaution
- Work while engine stopped.
- Parts ① and ② of following table must be used in pairs for the external engine control
lever.
- Refer to "Precautions for routing of the extension harness" on the later pages for harness
routing.
Required parts
No. Part number Part name Quantity Remarks
① 897219-4664 LEVER ASM; ENGINE CONTROL 1 -
② 182675-8980 HARNESS; ALL SPEED ACCEL SENSOR 1 Length: 5.2m approx.
Note: ・ Part numbers may be changed without notice due to specification change, etc.
Contact ISUZU distributor or ISUZU dealership when you order.
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
Unit: mm
Acceleration
IDLE FULL OPEN
Lever 4.9 N・m 20.6 N・m
reaction {0.5kgf・m} {2.1kgf・m}
2-M8x1.25
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
- Install control lever in a place that is not affected by dust, grease, moisture and chemical.
- Control lever can be used at temperature in the range from -30 to 75C. The ambient
temperature must fall within this range. Do not install the control lever on the place subject
to heat from engine, exhaust pipe, or rear body.
- Securely install the bracket in order to protect the control lever from large vibration (e.g.
Running vibration).
- Do not install the control lever in such a place where it may receive any shock from falling
objects, flying gravels, etc.
- Since the position sensor had been adjusted before shipment, do not loosen its fixing bolt
or disassemble it.
- Handle the control lever with extra care not to drop or give a shock to it, which may result
in malfunction or breakdown of the sensor.
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
- Tie the extension harness and the harnesses laid on the chassis frame together by using
nylon band clips so that the extension harness will not contact with neighboring objects
such as cables, pipes and equipments.
- Secure the harness so as for none of the electric wires to be damaged by vibration.
- Distance between clips for securing harnesses should be 400mm or less.
- Do not twist or excessively bend the harness, and ensure to avoid high temperature area
for routing harnesses.
- To avoid interference from electric currents or signals on rear body, do not tie the harness
with any harnesses laid on rear body (e.g. Power harness and signal harness) together.
- For further precautions of harness routing, refer to "Ⅰ-2-12 PRECAUTIONS FOR
MODIFICATION OF THE ELECTRICAL SYSTEM" and "Ⅱ-7 ELECTRICAL SYSTEM".
Routing of harness
Connect to
FRONT ① LEVER ASM
- For clearance with all parts except above, refer to "Ⅰ-3-2 CLEARANCE BETWEEN AN
EQUIPMENT OR A COMPONENT ON A CAB CHASSIS AND A REAR BODY".
- Route the cable so that the cable is higher than the lower end of front axle I-beam.
- Route the cable with slack, in consideration of cab tilt.
- Route the cable with consideration for heat damage from exhaust pipe and others.
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
・ Cover kit
When using the existing floor holes to install dump / mixer control lever, be sure to use
special cover kit. The cover kit is set as water infiltration prevention in the cab.
- For the vehicle with the dump / mixer control lever installed at shipment, the cover kit listed
on below table is bundled. Install it as shown in below figure.
- For the vehicle installing the dump / mixer control lever at rear body mounting using
existing floor holes, purchase the cover kit in the below table and install it.
Details of cover kit
COVER KIT
Handle Vehicle model ① COVER x1 ② BOLT x2 ③ NUT x2 ④ RIVET x2 Remarks
ASM
Note : ・ Part numbers may be changed without notice due to specification change, etc.
Contact ISUZU distributor or ISUZU dealership when you order.
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
Note : ・ Part numbers may be changed without notice due to specification change, etc.
Contact ISUZU distributor or ISUZU dealership when you order.
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
100
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 100
7-1 LAMPS
Lamps perform the installation and adjustment in accordance with the following precautions.
60
50
OUTPUT CURRENT (A)
40
30
20
10
Relay Switch
Buzzer Speaker
Diode Motor
③ Circuit diagrams
At the end of this chapter, this guide provides circuit diagrams of the following equipments, that
are involved in rear body mounting.Electrical work, refer to "Ⅰ-2-12 PRECAUTIONS FOR
MODIFICATION OF THE ELECTRICAL SYSTEM".
Factory-installed circuit
Additional circuit
Fuse
300mm Additional
or more load
12mm
④ Service terminals
Local PTO (PTO) 1 1 BR/Y or B/G 10 (A) Terminal for PTO power source.
Left side near the third cross member of a chassis frame
(Refer to Fig.3)
―
Local PTO (Lamp) 1 1 W/L or V/W Terminal for PTO ind. lamp.
(Ind. lamp)
Stop lamps ( + ) 2 G
Back of rear combination lamp Circuit for adding stop lamps.
2 (A)
(Refer to Fig.3) * Required waterproof branch.
Stop lamps ( - ) 6 B/L
View A
FRONT
・ When installing additional turn signal lamps, replace the flasher unit with new one according
to figure shown in below. (To retain the number of flashings.)
Flasher unit
Note: ・ Part numbers may be changed without notice due to specification change, etc.
Contact ISUZU distributor or ISUZU dealership when you order.
・ When adding turn signal lamps, connect an additional ground circuit to the free cavity 4 of the
flasher unit connector as shown in below figure.
Type A Type B
Battery Battery Battery
terminal terminal cable
Battery cable
②
① Radio harness
Stud bolt
Stud bolt ③
Type A Type A
ー +
ー
+
Type B Type A
① Prohibition
・ Using harness which dose not include a fuse
- When an overcurrent applied, the harness does not be protected.
・ Putting fuse part of the harness directly on the battery body or inside of the battery cover
- It may cause damage or explosion of the battery.
② Precaution
・ Secure distance more than 300mm between fuse part of the harness and the battery
(volatile gas may come out of the battery) and protect from water.
Example of the case which battery is on the right side of the vehicle
FRONT
Battery cable
Chapter 8
PAINTING Ⅱ SPECIFIC INFORMATION
Chapter 8 PAINTING
8-1 PAINTING-PROHIBITED AREA ON COMPONENTS OR EQUIPMENTS
Chapter 8
PAINTING Ⅱ SPECIFIC INFORMATION
When paint may attach by the painting of the outskirts part, mask it by all means.
This chapter mainly describes about particular part of this vehicle. For other parts, confirm "Ⅰ-2-
15 PRECAUTIONS FOR PAINTING".
① Disc wheel
Do not apply additional painting on the contact faces of a mating disc wheel and a hub, and the
portions with which wheel nuts contact because thickening the painting may eventually loosen
or damage wheel nuts.
A
A
Section A-A
Paint prohibited area
② Brake chamber
【Front axle】
【Rear axle】
Note: ・ X,Y and Z dimensions of drawing are calculated to "Ⅱ-4-1 CAB CHASSIS WEIGHT AND
AXLE LOAD CAPACITY" and "Ⅱ-5-2 FORMULA FOR CALCULATING GROUND
HEIGHT OF CHASSIS FRAME TOP SURFACE".
The dimension may be different from the actual size. Confirm by actual measurement
before conducting rear body mounting, if required.
・ The outer most measurement of rear tire is a reference dimension.
The dimension may be different from the actual size. Confirm by actual measurement
before conducting rear body mounting, if required.
Chapter 9
CAB CHASSIS DRAWINGS Ⅱ SPECIFIC INFORMATION
Fig. 9-1-5 Cab Chassis Drawing FVR34P HP (N)
X Y Z
X Y Z
X Y Z
1 FVR34L (N)
2 FVR34P (N)
3 FVR34PD (N)
Fig.9-2-1
4 FVR34S (N)
5 FVM34N (N)
6 FVM34U (N)
7 FVR34P HP (N)
8 FVR34P HPD (N)
9 FVR34S HP (N)
10 FVM34U HP5.1 (N)
Fig.9-2-2
11 FVM34U HP5.8 (N)
12 FVZ34N HP6.1 (N)
13 FVZ34N HP6.4 (N)
14 FVZ34U HP (N)
15 FVZ34L HPMX (N) Fig.9-2-3
Chapter 9
CAB CHASSIS DRAWINGS Ⅱ SPECIFIC INFORMATION
Engine : 6HK1-TCNH
T/M : EATON ES9306ADD
Unit : mm
Chapter 9
CAB CHASSIS DRAWINGS Ⅱ SPECIFIC INFORMATION
Fig. 9-2-2 FVR34* HP* (N), FVM34* HP* (N), FVZ34* HP* (N) 【Except FVZ34L HPMX (N)】
Engine : 6HK1-TCS
T/M : EATON ES11109DD
Unit : mm
Chapter 9
CAB CHASSIS DRAWINGS Ⅱ SPECIFIC INFORMATION
Engine : 6HK1-TCS
With Flywheel PTO
T/M : EATON ES11109DD
Unit : mm
Chapter 10
CHASSIS FRAME DRAWINGS Ⅱ SPECIFIC INFORMATION
A1 A2
A3
B1 B2
Chapter 10
CHASSIS FRAME DRAWINGS Ⅱ SPECIFIC INFORMATION
C1 C2
C3
E1 E2
Chapter 10
CHASSIS FRAME DRAWINGS Ⅱ SPECIFIC INFORMATION
E3 E4
F1
G1 G2
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
Chapter 11 APPENDIX
11-1 LOCATION OF CONTROL UNIT
11-2 PIPING DIAGRAMS
11-3 LOCATION OF AIR INTAKE DUCT
11-4 LOCATION OF VARIOUS COMPONENTS
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
Front
ECM
1 FVR34 Fig.11-2-1 ― ―
Full Air
FVM34
2 Fig.11-2-2 ― ○
FVZ34
LEGEND
SYMBOL NAME SYMBOL NAME
RELAY VALVE
MODULATOR
with DOUBLE CHEK VALVE
REDUCING VALVE
・ The referred number of piping apparatus expresses the use of port. (The second column
shows the serial number of the port.)
1: Supply
2: Delivery
3: Exhaust
4: Control
・ The symbol of piping and wiring shown below. The referred number expresses the outer
diameter.
Air piping
Wiring
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
Fig. 11-2-1 Piping Diagram FVR34
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
Fig. 11-2-2 Piping Diagram FVM34 / FVZ34
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
334
REAR BODY
FRONT AXLE
760
149
660
PLAN VIEW
697
686
SIDE VIEW
Φ 290 Φ 290
CHASSIS FRAME TOP SURFACE
181
381
80
185 320
VIEW A
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
149
660
PLAN VIEW
869
858
SIDE VIEW
Φ 290 Φ 290
CHASSIS FRAME TOP SURFACE
181
381
80
185 320
VIEW A
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
1,635
134
794
1,100
PLAN VIEW
65
134
714
SIDE MEMBER LH
89
54
CHASSIS FRAME
9
TOP SURFACE
TANK TOP SURFACE
85 85
322
REAR VIEW
389
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
65D26R battery
321
190
262
2,603
320
430
350
PLAN VIEW
SIDE MEMBER RH
47
30
275
234
REAR VIEW
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
65D26R battery
451
320
262
2,665
382
430
350
PLAN VIEW
SIDE MEMBER RH
53
30
281
240
REAR VIEW
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
Unit: mm
CHASSIS FRAME
CENTER LINE
W
PLAN VIEW
FRONT
SIDE VIEW
Note: Spare tire of FVZ34L HPMX (N) is temporarily installed on the chassis frame at shipment.