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CONFIDENTIAL

N-Series for Mexico

BODY BUILDERS GUIDE


March 2009

ISUZU MOTORS LIMITED


LA04-2009-00007
Page Chapter Contents

1 Outline
04 >>>> 1-1 Introduction
05 >>>> 1-2 Identifying a cab chassis
(1) ID plate
(2) ID code components of various vehicle models
(3) VIN (Vehicle Identification Number)
(4) Location for carving a vehicle number
(5) Vehicle model code chart

2 Principal Specifications of Various Vehicle Models

12 >>>> 2-1 Principal Specifications of Cab Chassis for Mexico

3 Precautions for Rear Body Mounting

18 >>>> 3-1 General precautions


(1) Prohibited modification
(2) Maintainability
(3) Clearance between an equipment/component on a cab chassis
and a rear body
(4) Precautions for an exhaust system
(5) Relation between rear view mirror and rear body width
(6) Painting a disc wheel
30 >>>> 3-2 Precautions for mounting of a rear body
(1) Precautions for fixing bolts
(2) Designing and fitting a sub frame
(3) Areas from which fixing bolts are kept away
(4) Fitting a sub frame on a chassis frame
(5) Fastening U-bolts for fitting a sub frame on a chassis frame
(6) Fitting double-ended brackets for fitting a sub frame on a chassis frame
(7) Recommended sub frame
(8) Precautions for a fender
(9) Rubber mud guard fitted on a rear fender
46 >>>> 3-3 Precautions for modification of a chassis frame
(1) Load on a chassis frame side member
(2) Drilling or welding a chassis frame
(3) Reinforcing a chassis frame side member
(4) Modifying rear overhang of a chassis frame
(5) Rivet plate
(6) Precautions for installation or relocation of a heavy object
on/to the lateral side of a chassis frame
(7) Holes in a chassis frame

1
57 >>>> 3-4 Precautions for modification of chassis components
(1) Modifying an exhaust system
(2) Modifying a fueling system
64 >>>> 3-5 General precautions for brake-related components
(1) Precautions for rear body mounting on a chassis with ABS or EBD
(2) Outline of Load Sensing Proportioning Valve (LSPV)
(3) Adjusting LSPV
(4) Modifying a brake pipe or a clutch pipe
(5) Hydraulic steel pipes
74 >>>> 3-6 Precautions for cab modification
(1) Modification or addition to a cab
(2) Installing equipment(s) on a roof
(3) Load limit on a roof
(4) Through holes inside a cab for harnesses or an antenna cable
(5) Precautions for the works performed on a cab roof panel
80 >>>> 3-7 Precautions for cab painting
(1) Top coat
(2) Precautions for cab painting
(3) Paint boundary
(4) Precautions for paint drying
(5) Removing control units with built-in computers during baking coating
(6) Laminated glass
(7) Affixing an emblem and decals on the front face of a cab
(8) Rust prevention with Ziebart’s rust-proofing agent

4 Weight Distribution and Weight Data

92 >>>> 4-1 Weight distribution


95 >>>> 4-2 Weight data
96 >>>> 4-3 Weight distribution calculation
98 >>>> 4-4 Front axle load rate
99 >>>> 4-5 Allowable load on axles and tires

5 PTO and Engine Control

100>>>> 5-1 PTO variation


101>>>> 5-2 Side PTO
107>>>> 5-3 Side PTO control
110>>>> 5-4 Installing a control cable
113>>>> 5-5 Engine control
118>>>> 5-6 Governor characteristics

2
6 Various Issues Regarding Electrical Equipments

122>>>> 6-1 Working voltage and output characteristics of AC generators


123>>>> 6-2 Precautions for modification of electrical components
135>>>> 6-3 Electric wiring
138>>>> 6-4 Fuses
146>>>> 6-5 Relays
149>>>> 6-6 How to add power sources and precautions for such addition
155>>>> 6-7 Adjusting the position of lamps
156>>>> 6-8 Symbols and abbreviations in circuit diagrams
158>>>> 6-9 Circuit diagrams

7 Characteristics of the Springs

202>>>> 7-1 Specifications of springs


207>>>> 7-2 Formula for calculating ground height of chassis frame top surface
210>>>> 7-3 Margin for movement of the rear axle and tires

8 Cab Chassis Drawings


212>>>> 8-1 Cab chassis drawings

9 Chassis Frame Drawings


226>>>> 9-1 Chassis frame drawings
234>>>> 9-2 Detailed drawings of cross members

10 Annex
238>>>> 10-1 Piping diagrams
242>>>> 10-2 Location of various components
(1) Location of the fuel tank
(2) Location of the battery and the carrier
(3) Location of the spare tire and the carrier

3
1
1 Outline

Outline
1-1 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 2

Models
Various Vehicle
Specifications of
Principal
stage of vehicle manufacture by mounting their vehicle bodies on the cab
chassises (incomplete vehicles) provided by ISUZU MOTORS. Such 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. 3

Mounting
Rear Body
Precautions for
This guide provides information about rear body mounting on N-series truck
chassis for Mexico.
Basically, the cab chassises provided by ISUZU MOTORS are designed to ensure
appropriate balance between functions and performance. Therefore, modification 4

Weight Data
Distribution and
Weight
of the chassis frame should be avoided as much as possible. However, if
modification is unavoidable, such modification must be performed according to the
instructions in this guide.
The body builders are fully responsible to comply with the official regulations of 5

Control
PTO and Engine
their own countries with respect to their vehicle bodies, cab chassis modification
incidental to rear body mounting, and completed vehicles after body mounting.
ISUZU MOTORS will not be responsible for any problems in performance,
functions or characteristics of completed vehicles, which are resulted in rear body 6

Equipments
Electrical
Regarding
Various Issues
mounting or modification performed without following the instructions in this guide.
ISUZU MOTORS strictly prohibits modification of equipments, systems,
components, parts, and materials, which may violate the regulations including
FMVSS (Federal Motor Vehicle Safety Standards) and domestic regulations in 7

of the Springs
Characteristics
Mexico, with which the cab chassis provided by ISUZU MOTORS comply.

Note: Information and specifications provided in this guide are based on the latest
information available at the time this guide is released. The cab chassis 8
Drawings
Cab Chassis

manufacturer (ISUZU MOTORS) reserves the right to, at any time, without
prior notice, discontinue or change specifications, optional parts, materials,
equipments, design, or model of the cab chassis.

9
Drawings
Chassis Frame

10
Annex

4
1
1-2 Identifying a cab chassis

Outline
This section provides information necessary to identify vehicle models and basic
specifications of the cab chassises subject to rear body mounting. For optional
parts and equipments for Mexico, please consult the ISUZU MOTORS dealership.
2
(1) ID plate

Models
Various Vehicle
Specifications of
Principal
The following figures show a sample ID plate with vehicle model information
and basic specifications of a cab chassis, and location of the ID plate in a cab.
3
ID plate

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
See the following pages for details of the fields Ⓐ through Ⓝ. Option codes are
entered in the OPTION fields Ⓛ. 7

of the Springs
Characteristics
Location of the ID plate

8
Drawings
Cab Chassis

9
ID plate
Drawings
Chassis Frame

10
Annex

5
1
(2) ID code components of various vehicle models

Outline
Cab chassis for Mexico
Drive
Cab system Cab GVM Engine Wheelbase
No. Vehicle model Rear wheel Model and Handle
width suspen- type (kg) model (mm)
2
sion

Models
Various Vehicle
Specifications of
Principal
Single axle
with single 4,100 2,490
1 NLR85AL -EE1AYMX tires
Leaf
E 24W
suspension 2X LHD 4JJ1-TCC
2 NMR85L -EH5AYMX M 6 5,000 RDU/4JJ1 2,475 24W
3
3 NMR85L -HH5AYMX N 3,345 33W

Mounting
Rear Body
Precautions for
4 NPR75L -FL6AYMXC Single axle Light 6,577 2,765 28W
5 NPR75L -HL6AYMXC with dual duty N 3,365 34W
6 NPR75L -KL6AYMXC tire truck 4×2 SINGLE 3,815 38W
7 NQR75L -FN6AYMXC Leaf N R CAB 2,765 28W
8 NQR75L -HN6AYMXC suspension 3X LHD S 7,257 4HK1-TCC 3,365 34W
9 NQR75L -KN6AYMXC P 7 S RDV/4HK1 3,815 38W 4
10 NQR75L -MN6AYMXC 4,475 45W

Weight Data
Distribution and
Weight
11 NQR75L -HQ6AYMXC 8,865 3,365 34W
12 NQR75L -KQ6AYMXC S 3,815 38W
13 NQR75L -MQ6AYMXC 4,475 45W

Ⓐ Ⓐ -1 Ⓑ-1 Ⓑ-2 Ⓑ-3 Ⓑ-4 Ⓑ-5 Ⓑ-6 Ⓓ/Ⓜ 5

Control
PTO and Engine
ID code components

Ⓐ 6-character vehicle descriptor section “VDS”


6
A VDS is made up by the first five characters of Ⓐ and the first character of

Equipments
Electrical
Regarding
Various Issues
Ⓐ-1 that indicates a wheelbase type.
(Example 1)
NMR85L-EH5AYMX (Vehicle model) ⇒ NMR85E (VDS)
7

of the Springs
Characteristics
(Example 2)
NQR75L-MQ6AYMXC (Vehicle model) ⇒ NQR75M (VDS)
For the string composition of a VIN (Vehicle Identification Number), see the
next subsection (3) VIN (Vehicle Identification Number). 8
Drawings
Cab Chassis

Ⓑ 6-character model designator “MD”


Ⓑ-1 through Ⓑ-6 are consecutively arranged. (Example) NPR7SN
Ⓒ Manufacture month and year
9
Manufacture date is alphabetized as follows and stated in the order of year
Drawings
Chassis Frame

(2-character) and month (2-character).

0 1 2 3 4 5 6 7 8 9 (Example 1) May 1999 (05/ 99) →JJ/AF


A B C D E F G H I J (Example 2) March 2009 (03/09) →AJ/AD
10
Annex

6
Ⓓ 3-character engine option code (Example) “RDU”, “RDV” 1

Outline
Ⓔ 3-character rear axle option code (Example) “G73”, “6CP”
Ⓕ 3-character transmission option code (Example)“RSM”, “RST”
Ⓖ 3-character final gear option code (Example) “GV1”,“R41” 2

Models
Various Vehicle
Specifications of
Principal
Ⓗ 3-character tire option code (Example) “BQU”, “CSA”
Ⓙ 3-character destination option code
(Example) “E11” for Mexico, “CB7” for Columbia 3

Mounting
Rear Body
Precautions for
Ⓚ Cab exterior/interior color option code (3-character each)

(Example) “729” for ARC WHITE, “155” for MED CHARCOAL GRAY
Ⓛ 3-character regular option code 4

Weight Data
Distribution and
Weight
(Example) “AU4” for AUTO DOOR LOCK, “JE5” for ABS
Ⓜ 4-character engine model code (Example) “4JJ1”, “4HK1”
Ⓝ 1-character wheelbase code (First character of Ⓐ-1)
5

Control
PTO and Engine
(Example) “H” for 3,201-3,500mm

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

7
1
(3) VIN (Vehicle Identification Number)

Outline
The following is an example of a VIN to be entered in the field Ⓐ of ID plate:

WMI (World VDS


VIS 2
Manufacturer (Vehicle Descriptor

Models
Various Vehicle
Specifications of
Principal
Identifier) Section) (Vehicle Indicator Section)

J A M N M R 8 5 E — 9 7 0 0 0 0 0 1
3
Sequence No.

Mounting
Rear Body
Precautions for
Model Year
7: 2007 8: 2008 9: 2009
A: 2010 B: 2011 C: 2012
Wheel Base (mm) 4
D: 2,301 to 2,450 P: 5,001 to 5,300

Weight Data
Distribution and
Weight
E: 2,451 to 2,600 Q: 5,301 to 5,600
F: 2,601 to 2,900 R: 5,601 to 5,900
G: 2,901 to 3,200 S: 5,901 to 6,200
H: 3,201 to 3,500 T: 6,201 to 6,500
J: 3,501 to 3,800 U: 6,501 to 6,800 5

Control
PTO and Engine
K: 3,801 to 4,100 V: 6,801 to 7,100
L: 4,101 to 4,400 W: 7,101 to 7,400
M: 4,401 to 4,700 X: 7,401 to 7,700
N: 4,701 to 5,000 Y: 7,701 to 8,000
Engine Model 6
55: 4JB1-TC 71: 4HG1

Equipments
Electrical
Regarding
Various Issues
75: 4HK1-TCN/TCS… For vacuum pump
85: 4JJ1-TCC/TCS
Driving System
R: 4×2 (Rear wheel drive)
S: 4×4 (All wheel drive) 7

of the Springs
Characteristics
M: 6×2 (Rear wheel drive)
Z: 6×4 (Rear wheel drive)
GVM range or cab type
H: 3.0 to 4.0 ton (1.7m width cab)
L: 3.5 to 5.0 ton (1.8m width cab) 8
M: 5.0 to 7.5 ton (1.8m width cab)
Drawings
Cab Chassis

N: 3.5 to 5.0 ton (2.0m width cab)


P: 5.0 to 7.5 ton (2.0m width cab)
Q: 7.5 to 9.0 ton (2.0m width cab)
R: 9.0 to 11.0 ton (2.0 to 2.2m width cab)
S: 11.0 to 14.0 ton (2.2m width cab) 9
Drawings
Chassis Frame

T: 14.0 to 15.5 ton (2.3m width cab)


V: 15.0 to 16.0 ton (2.3m width cab)
W: 16.0 to 26.0 ton (2.3m width cab)
Model Line
N: Light duty forward control truck 10
Annex

World Manufacturer Identifier


JAM: Light duty incomplete vehicle

Note: When VDS is “NQR”, “N1R” is indicated instead of “NQR” on ID plate.

8
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

10

9
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight Data
Models Equipments
A vehicle number is carved on the right side member of a chassis frame, above
(4) Location for carving a vehicle number

a front axle.
1
(5) Vehicle model code chart

Outline
If there is no applicable code, truncate the blank.

Basic Model Code Model Code Suffix


2

Models
Various Vehicle
Specifications of
Principal
N M R 85 A L — H E 5 V W D Y U N
① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ⑪ ⑫ ⑬ ⑭ ⑮

① Model Line ⑤ Suspension Type and Main Brake System


3
F Medium duty forward control chassis cab — FRT and RR rigid axle and hydraulic

Mounting
Rear Body
Precautions for
(No code) vacuum brake
G Medium duty forward control semi-tractor
A FRT independent suspension, RR rigid
N Light duty forward control chassis cab
axle and hydraulic vacuum brake
S FRT and RR rigid axle and air over
hydraulic brake
② GVM Rating or Cab Type 4
T FRT and RR rigid axle, RR air

Weight Data
Distribution and
Weight
H 3.0 to 4.0 ton (1.7m width cab) suspension and air over hydraulic
L 3.5 to 5.0 ton (1.8m width cab) brake
M 5.0 to 7.5 ton (1.8m width cab) U FRT and RR rigid axle and full air
N 3.5 to 5.0 ton (2.0m width cab) brake
P 5.0 to 7.5 ton (2.0m width cab) V FRT and RR rigid axle, RR air
suspension and full air brake 5
Q 7.5 to 9.0 ton (2.0m width cab)

Control
PTO and Engine
R 9.0 to 11.0 ton (2.0 to 2.2m width cab)
S 11.0 to 14.0 ton (2.2m width cab) ⑥ Steering Location
T 14.0 to 15.5 ton (2.3m width cab) L Left hand drive (LHD)
V 15.0 to 16.0 ton (2.3m width cab) U Right hand drive (RHD)
X 16.0 to 26.0 ton (2.3m width cab) 6

Equipments
Electrical
Regarding
Various Issues
⑦ Wheel Base (mm)
③ Driving System C 2,151 to 2,300 P 5,001 to 5,300
R 4×2 (Rear wheel drive) D 2,301 to 2,450 Q 5,301 to 5,600
S 4×4 (All wheel drive) E 2,451 to 2,600 R 5,601 to 5,900
7
M 6×2 (Rear wheel drive) F 2,601 to 2,900 S 5,901 to 6,200

of the Springs
Characteristics
Z 6×4 (Rear wheel drive) G 2,901 to 3,200 T 6,201 to 6,500
H 3,201 to 3,500 U 6,501 to 6,800
J 3,501 to 3,800 V 6,801 to 7,100
④ Engine Type
K 3,801 to 4,100 W 7,101 to 7,400
34 6HK1-TCC/TCN/TCS
L 4,101 to 4,400 X 7,401 to 7,700 8
55 4JB1-TC
Drawings
Cab Chassis

M 4,401 to 4,700 Y 7,701 to 8,000


71 4HG1-∗∗∗ N 4,701 to 5,000 Z 8,001 and over
75 4HK1-TCN/TCS for vacuum pump
77 6UZ1-TCC/TCN
82 4HV1-∗∗∗ for CNG ⑧ GVM (ton) [N series]
9
85 4JJ1-TCC/TCS A 3.0 H 5.0 to 5.5
Drawings
Chassis Frame

90 4HK1-TCS for air compressor B 3.2 J 6.0 to 6.5


C 3.3 to 3.5 L 7.0 to 7.5
D 3.5 to 4.0 N 8.0 to 8.5
E 4.0 to 4.5
10
Annex

10
1

Outline
⑨ Tire [N series]  ⑬ Rear Body Configuration [N series]
1 Rear wheel single tire (High deck) A Flat bed (wooden bed and gate or
wooden bed+aluminum gate)
4 RR small dual tire: Radial (Flat-low)
D Standard dump
5 Rear dual tire (High deck)
R Three way incline dump 2
FRT small tire and RR small dual tire (Full

Models
Various Vehicle
Specifications of
Principal
6 Y Cab chassis (w/o rear body)
flat low/low deck)
FRT and RR small size single tire (Full flat
7
low)
⑭ Destination
⑩ Frame Type —
General export 3
(No code)

Mounting
Rear Body
Precautions for
— C China
Standard frame
(No code)
CH Chile
J F series low deck, all wheel drive
chassis frame CL Columbia
M N series kick up frame E Europe
U F series kick down frame ED Ecuador 4
G Turkey

Weight Data
Distribution and
Weight
V N series 850mm width straight frame
H Australia
I India
⑪ Cab Configuration IN Indonesia
— IR Iran
Single cab (w/o bed, w/o tilt)
(No code) 5
IS Israel

Control
PTO and Engine
A Single cab (w/o bed, w/ tilt)
K Hong Kong
B Single cab (w/o bed, w/ tilt) F wide cab
ME East Malaysia
C Single cab (w/ bed, w/ tilt)
MO Morocco
D Single cab (w/ bed, w/ tilt) F wide cab
MW West Malaysia
W Double cab (w/o tilt)
MX Mexico 6
V Double cab (w/ tilt)

Equipments
Electrical
Regarding
Various Issues
P Thailand
Y Double cab (w/ tilt) F wide cab
PA Pakistan
PH Philippines
⑫ Chassis Configuration [N series] R Taiwan
— S Gulf countries
Standard chassis 7
(No code) SP Singapore

of the Springs
Characteristics
B Export bus chassis U Russia
D Dump chassis (w/ side PTO and dump V New Zealand
lever)
VT Vietnam
F Fire truck chassis (Special PTO)
X Venezuela
5F Chemical fire truck chassis (side PTO)
Y Kenya 8
6F Ladder fire truck chassis (Fly wheel
Drawings
Cab Chassis

PTO+side PTO) Z South Africa


G Fire truck chassis (Fly wheel PTO)
M Mixer chassis (Fly wheel PTO)
⑮ Engine horse power version
H High place work truck chassis (side
N Multiple horse power/Low horse power
PTO) 9
N Concrete pump chassis (side full C Multiple horse power/Medium horse power
Drawings
Chassis Frame

power PTO) S Multiple horse power/High horse power


P Garbage truck chassis (side PTO)

10
Annex

11
1
2 Principal Specifications of Various Vehicle Models

Outline
2-1 Principal Specifications of Cab Chassis for Mexico (I/III-1/2)

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.
2

Models
Various Vehicle
Specifications of
Principal
Vehicle Model NLR85AL-EE1AYMX NMR85L-EH5AYMX NMR85L-HH5AYMX NPR75L-FL6AYMXC NPR75L-HL6AYMXC Remarks
GVW kg 4,100 5,000 5,000 6,577 6,577
GAW FRT kg 2,600 2,900 2,900 2,431 2,431
RR kg 3,600 5,000 5,000 4,482 4,482 3

Mounting
Rear Body
Precautions for
Wheelbase mm 2,490 2,475 3,345 2,765 3,365
Engine Type 4JJ1-TCC 4JJ1-TCC 4JJ1-TCC 4HK1-TCC 4HK1-TCC
Emission 04 EPA 04 EPA 04 EPA 04 EPA 04 EPA
Displacement cc 2,999 2,999 2,999 5,193 5,193
Max Power kw/rpm 102/2,600 102/2,600 102/2,600 136/2,600 136/2,600
4
Max Torque Nm/rpm 375/1,800-2,600 375/1,800-2,600 375/1,800-2,600 500/1,500 500/1,500

Weight Data
Distribution and
Weight
Air Intake RR VERTICAL RR VERTICAL RR VERTICAL RR VERTICAL RR VERTICAL
Frame STANDARD (Width: 700mm) STANDARD (Width: 700mm) STANDARD (Width: 700mm) STRAIGHT (Width: 850mm) STRAIGHT (Width: 850mm)
Transmission MYY5T MYY5T MYY5T MZZ6U MZZ6U
AMT — — — — —
Final Gear Ratio 5.125 5.125 5.125 4.300 4.300 5

Control
PTO and Engine
Clutch mm φ300 φ300 φ300 φ325 φ325
Axle FRT INDEPENDENT RIGID RIGID RIGID RIGID
RR mm Full-Floating φ292 Full-Floating φ292 Full-Floating φ292 Full-Floating φ320 Full-Floating φ320
P/Shaft 1st mm φ82.6 φ82.6 φ82.6 φ90 φ90
2nd mm — — φ82.6 — φ90
6
Tire FRT Tire 205/75R16C 205/75R16C 205/75R16C 215/85R16 (10PR) 215/85R16 (10PR)

Equipments
Electrical
Regarding
Various Issues
Disc Wheel 16X5.5J-85 16X5.5J-116.5 16X5.5J-116.5 16X6K-128 (WHITE) 16X6K-128 (WHITE)
RR Tire 205/75R16C 205/75R16C 205/75R16C 215/85R16 (10PR) 215/85R16 (10PR)
Disc Wheel 16X5.5J-85 16X5.5J-85 16X5.5J-85 16X6K-128 (WHITE) 16X6K-128 (WHITE)
Brake FRT mm φ265×35V (DISC) φ293×40V (DISC) φ293×40V (DISC) φ293×40V (DISC) φ293×40V (DISC)
RR mm φ290×75 D2L (DRUM) φ320×75 D2L (DRUM) φ320×75 D2L (DRUM) φ320×100 D2L (DRUM) φ320×100 D2L (DRUM) 7

the Springs
Characteristics of
ABS (with EBD) — — — STD STD
ASR — — — — —
EXH Brake STD STD STD STD STD
LSPV STD STD STD — —
HBB — — — — — 8
HSA (Except Models with AMT) — — — — —

Drawings
Cab Chassis
Steering P/Steering P/Steering P/Steering P/Steering P/Steering
Fuel Tank L 75L 75L 100L 125L Cylindrical shape 140L Box shape
(OPT. 113L Box shape) (OPT. 113L Box shape)
EXH Silencer Elongated Round−Entire Length mm φ200−550 φ200−550 φ200−550 φ202.4−780 φ202.4−780
EXH Emission Purifier “DPD” inch — — — — — 9

Drawings
Chassis Frame
ACG 24V×50A (OPT. 24V×80A) 24V×50A (OPT. 24V×80A) 24V×50A (OPT. 24V×80A) 12V×110A 12V×110A
Battery Size STD 65D23L×2 65D23L×2 65D23L×2 750CCA 750CCA
OPT 75D23L×2 or 80D26L×2 75D23L×2 or 80D26L×2 75D23L×2 or 80D26L×2 — —
Starter Size 24V×4.0kw 24V×4.0kw 24V×4.0kw 12V×3.0kw 12V×3.0kw
10

Annex
12
1
Principal Specifications of Cab Chassis for Mexico (I/III-2/2)

Outline
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.

Vehicle Model NLR85AL-EE1AYMX NMR85L-EH5AYMX NMR85L-HH5AYMX NPR75L-FL6AYMXC NPR75L-HL6AYMXC Remarks 2


Interior Seatbelt Three-Point Fastening STD STD STD STD STD

Models
Various Vehicle
Specifications of
Principal
Equipment Two-Point Fastening (Center Seat) STD STD STD STD STD
SRS Airbag Driver’s Seat — — — — —
Passenger’s Seat — — — — —
Seat Skin Vinyl STD STD STD — —
3
Flameproof Cloth OPT OPT OPT STD STD

Mounting
Rear Body
Precautions for
Folding Center Seat — — — STD STD
Sun Visor Driver’s Seat STD STD STD STD STD
Passenger’s Seat OPT OPT OPT STD STD
Assist. Grip Driver’s Seat OPT OPT OPT STD STD
Passenger’s Seat OPT OPT OPT STD STD 4
Header Tray OPT OPT OPT — —

Weight Data
Distribution and
Weight
Full Trim Pad — — — OPT OPT
Cup Holder OPT OPT OPT STD STD
Ash Tray Driver Side STD STD STD STD STD
Passenger’s Door Side OPT OPT OPT STD STD
5
Power Window FRT Door Only OPT OPT OPT OPT OPT

Control
PTO and Engine
FRT and RR Doors — — — — —
Central Door Locking System OPT OPT OPT OPT OPT
Key Less Entry — — — — —
Tachometer STD STD STD STD STD
Tachograph (Digital) — — — — —
6
Tilt/Telescoping Steering STD STD STD STD STD

Equipments
Electrical
Regarding
Various Issues
Intermittent Windshield Wiper OPT OPT OPT STD STD
Radio with AM (Antenna/One Speaker) — — — — —
Alarm Clock AM/FM (Antenna/Two Speakers) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT)
AM/FM/CD (Antenna/Two OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT)
Speakers) 7

the Springs
Characteristics of
Heater and Defroster STD STD STD STD STD
Air Conditioning Manual (Heater Equipped) — — — OPT OPT
System Full Automatic — — — — —
Exterior Sun Shade Band — — — — —
Equipment Under Mirror OPT OPT OPT — —
8
Fog lamp FRT OPT OPT OPT — —

Drawings
Cab Chassis
RR — — — —
Cornering Lamp STD STD STD STD STD
Halogen Head Lamp STD STD STD STD STD
Head Lamp Leveling (Manual) — — — — —
Horn Normal Single Horn — — — — — 9

Drawings
Chassis Frame
Heavy Duty Single Horn STD STD STD — —
Heavy Duty Dual Horn OPT OPT OPT STD STD
Chassis Anticorrosion Wax OPT OPT OPT STD STD
Back Buzzer OPT OPT OPT — —
Long Life Coolant 30% STD STD STD — —
10
50% OPT OPT OPT STD STD

Annex
Stabilizer FRT — — — STD STD
RR — — — — —
Fuel Tank Cap with Lock OPT OPT OPT — STD

13
1
Principal Specifications of Cab Chassis for Mexico (II/III-1/2)

Outline
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.

Vehicle Model NPR75L-KL6AYMXC NQR75L-FN6AYMXC NQR75L-HN6AYMXC NQR75L-KN6AYMXC NQR75L-MN6AYMXC Remarks 2

Models
Various Vehicle
Specifications of
Principal
GVW kg 6,577 7,257 7,257 7,257 7,257
GAW FRT kg 2,431 2,812 2,812 2,812 2,812
RR kg 4,482 5,443 5,443 5,443 5,443
Wheelbase mm 3,815 2,765 3,365 3,815 4,475
Engine Type 4HK1-TCC 4HK1-TCC 4HK1-TCC 4HK1-TCC 4HK1-TCC
3
Emission 04 EPA 04 EPA 04 EPA 04 EPA 04 EPA

Mounting
Rear Body
Precautions for
Displacement cc 5,193 5,193 5,193 5,193 5,193
Max Power kw/rpm 136/2,600 136/2,600 136/2,600 136/2,600 136/2,600
Max Torque Nm/rpm 500/1,500 500/1,500 500/1,500 500/1,500 500/1,500
Air Intake RR VERTICAL RR VERTICAL RR VERTICAL RR VERTICAL RR VERTICAL
Frame STRAIGHT (Width: 850mm) STRAIGHT (Width: 850mm) STRAIGHT (Width: 850mm) STRAIGHT (Width: 850mm) STRAIGHT (Width: 850mm) 4

Weight Data
Distribution and
Weight
Transmission MZZ6U MZZ6U MZZ6U MZZ6U MZZ6U
AMT — — — — —
Final Gear Ratio 4.300 4.555 4.555 4.555 4.555
Clutch mm φ325 φ325 φ325 φ325 φ325
Axle FRT RIGID RIGID RIGID RIGID RIGID
5
RR mm Full-Floating φ320 Full-Floating φ320 Full-Floating φ320 Full-Floating φ320 Full-Floating φ320

Control
PTO and Engine
P/Shaft 1st mm φ90 φ90 φ90 φ90 φ90
2nd mm φ90 — φ90 φ90 φ90
Tire FRT Tire 215/85R16 (10PR) 225/70R19.5 (12PR) 225/70R19.5 (12PR) 225/70R19.5 (12PR) 225/70R19.5 (12PR)
Disc Wheel 16X6K-128 (WHITE) 19.5X6.00-127 (WHITE) 19.5X6.00-127 (WHITE) 19.5X6.00-127 (WHITE) 19.5X6.00-127 (WHITE)
RR Tire 215/85R16 (10PR) 225/70R19.5 (12PR) 225/70R19.5 (12PR) 225/70R19.5 (12PR) 225/70R19.5 (12PR) 6

Equipments
Electrical
Regarding
Various Issues
Disc Wheel 16X6K-128 (WHITE) 19.5X6.00-127 (WHITE) 19.5X6.00-127 (WHITE) 19.5X6.00-127 (WHITE) 19.5X6.00-127 (WHITE)
Brake FRT mm φ293×40V (DISC) φ363×42V (DISC) φ363×42V (DISC) φ363×42V (DISC) φ363×42V (DISC)
RR mm φ320×100 D2L (DRUM) φ320×120 D2L (DRUM) φ320×120 D2L (DRUM) φ320×120 D2L (DRUM) φ320×120 D2L (DRUM)
ABS (with EBD) STD STD STD STD STD
ASR — — — — —
7
EXH Brake STD STD STD STD STD

the Springs
Characteristics of
LSPV — — — — —
HBB — STD STD STD STD
HSA (Except Models with AMT) — — — — —
Steering P/Steering P/Steering P/Steering P/Steering P/Steering
Fuel Tank L 140L Box shape 125L Cylindrical shape 140L Box shape 140L Box shape 140L Box shape 8

Drawings
Cab Chassis
(OPT. 113L Box shape) (OPT. 113LBox shape) (OPT. 113L Box shape) (OPT. 113L Box shape) (OPT. 113L Box shape)
EXH Silencer Elongated Round−Entire Length mm φ202.4−780 φ202.4−780 φ202.4−780 φ202.4−780 φ202.4−780
EXH Emission Purifier “DPD” inch — — — — —
ACG 12V×110A 12V×110A 12V×110A 12V×110A 12V×110A
Battery Size STD 750CCA 750CCA 750CCA 750CCA 750CCA
9
OPT — — — — —

Drawings
Chassis Frame
Starter Size 12V×3.0kw 12V×3.0kw 12V×3.0kw 12V×3.0kw 12V×3.0kw

10

Annex
14
1
Principal Specifications of Cab Chassis for Mexico (II/III-2/2)

Outline
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.

Vehicle Model NPR75L-KL6AYMXC NQR75L-FN6AYMXC NQR75L-HN6AYMXC NQR75L-KN6AYMXC NQR75L-MN6AYMXC Remarks 2


Interior Seatbelt Three-Point Fastening STD STD STD STD STD

Models
Various Vehicle
Specifications of
Principal
Equipment Two-Point Fastening (Center Seat) STD STD STD STD STD
SRS Airbag Driver’s Seat — — — — —
Passenger’s Seat — — — — —
Seat Skin Vinyl — — — — —
Flameproof Cloth STD STD STD STD STD 3

Mounting
Rear Body
Precautions for
Folding Center Seat STD STD STD STD STD
Sun Visor Driver’s Seat STD STD STD STD STD
Passenger’s Seat STD STD STD STD STD
Assist. Grip Driver’s Seat STD STD STD STD STD
Passenger’s Seat STD STD STD STD STD
4
Header Tray — — — — —

Weight Data
Distribution and
Weight
Full Trim Pad OPT OPT OPT OPT OPT
Cup Holder STD STD STD STD STD
Ash Tray Driver Side STD STD STD STD STD
Passenger’s Door Side STD STD STD STD STD
Power Window FRT Door Only OPT OPT OPT OPT OPT 5

Control
PTO and Engine
FRT and RR Doors — — — — —
Central Door Locking System OPT OPT OPT OPT OPT
Key Less Entry — — — — —
Tachometer STD STD STD STD STD
Tachograph (Digital) — — — — —
6
Tilt/Telescoping Steering STD STD STD STD STD

Equipments
Electrical
Regarding
Various Issues
Intermittent Windshield Wiper STD STD STD STD STD
Radio with AM (Antenna/One Speaker) — — — — —
Alarm Clock AM/FM (Antenna/Two Speakers) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT)
AM/FM/CD (Antenna/Two OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT)
Speakers) 7

the Springs
Characteristics of
Heater and Defroster STD STD STD STD STD
Air Conditioning Manual (Heater Equipped) OPT OPT OPT OPT OPT
System Full Automatic — — — — —
Exterior Sun Shade Band — — — — —
Equipment Under Mirror — — — — —
8
Fog lamp FRT — — — — —

Drawings
Cab Chassis
RR — — — — —
Cornering Lamp STD STD STD STD STD
Halogen Head Lamp STD STD STD STD STD
Head Lamp Leveling (Manual) — — — — —
Horn Normal Single Horn — — — — — 9
Heavy Duty Single Horn — — — — —

Drawings
Chassis Frame
Heavy Duty Dual Horn STD STD STD STD STD
Chassis Anticorrosion Wax STD STD STD STD STD
Back Buzzer — — — — —
Long Life Coolant 30% — — — — —
10
50% STD STD STD STD STD

Annex
Stabilizer FRT STD STD STD STD STD
RR — — — — —
Fuel Tank Cap with Lock STD — STD STD STD

15
1
Principal Specifications of Cab Chassis for Mexico (III/III-1/2)

Outline
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.

Vehicle Model NQR75L-HQ6AYMXC NQR75L-KQ6AYMXC NQR75L-MQ6AYMXC Remarks 2

Models
Various Vehicle
Specifications of
Principal
GVW kg 8,865 8,865 8,865
GAW FRT kg 3,098 3,098 3,098
RR kg 6,196 6,196 6,196
Wheelbase mm 3,365 3,815 4,475
Engine Type 4HK1-TCC 4HK1-TCC 4HK1-TCC
3
Emission 04 EPA 04 EPA 04 EPA

Mounting
Rear Body
Precautions for
Displacement cc 5,193 5,193 5,193
Max Power kw/rpm 136/2,600 136/2,600 136/2,600
Max Torque Nm/rpm 500/1,500 500/1,500 500/1,500
Air Intake RR VERTICAL RR VERTICAL RR VERTICAL
Frame STRAIGHT (Width: 850mm) STRAIGHT (Width: 850mm) STRAIGHT (Width: 850mm) 4

Weight Data
Distribution and
Weight
Transmission MZZ6U MZZ6U MZZ6U
AMT — — —
Final Gear Ratio 4.555 4.555 4.555
Clutch mm φ325 φ325 φ325
Axle FRT RIGID RIGID RIGID
5
RR mm Full-Floating φ320 Full-Floating φ320 Full-Floating φ320

Control
PTO and Engine
P/Shaft 1st mm φ90 φ90 φ90
2nd mm φ90 φ90 φ90
Tire FRT Tire 225/70R19.5 (12PR) 225/70R19.5 (12PR) 225/70R19.5 (12PR)
Disc Wheel 19.5X6.00-127 (WHITE) 19.5X6.00-127 (WHITE) 19.5X6.00-127 (WHITE)
RR Tire 225/70R19.5 (12PR) 225/70R19.5 (12PR) 225/70R19.5 (12PR) 6

Equipments
Electrical
Regarding
Various Issues
Disc Wheel 19.5X6.00-127 (WHITE) 19.5X6.00-127 (WHITE) 19.5X6.00-127 (WHITE)
Brake FRT mm φ363×42V (DISC) φ363×42V (DISC) φ363×42V (DISC)
RR mm φ370×150 D2L (DRUM) φ370×150 D2L (DRUM) φ370×150 D2L (DRUM)
ABS (with EBD) STD STD STD
ASR — — —
7
EXH Brake STD STD STD

the Springs
Characteristics of
LSPV — — —
HBB STD STD STD
HSA (Except Models with AMT) — — —
Steering P/Steering P/Steering P/Steering
Fuel Tank L 140L Box shape 140L Box shape 140L Box shape 8
φ202.4−780 φ202.4−780 φ202.4−780

Drawings
Cab Chassis
EXH Silencer Elongated Round−Entire Length mm
EXH Emission Purifier “DPD” inch — — —
ACG 12V×110A 12V×110A 12V×110A
Battery Size STD 750CCA 750CCA 750CCA
OPT — — —
9
Starter Size 12V×3.0kw 12V×3.0kw 12V×3.0kw

Drawings
Chassis Frame
10

Annex
16
1
Principal Specifications of Cab Chassis for Mexico (III/III-1/2)

Outline
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.

Vehicle Model NQR75L-HQ6AYMXC NQR75L-KQ6AYMXC NQR75L-MQ6AYMXC Remarks 2


Interior Seatbelt Three-Point Fastening STD STD STD

Models
Various Vehicle
Specifications of
Principal
Equipment Two-Point Fastening (Center Seat) STD STD STD
SRS Airbag Driver’s Seat — — —
Passenger’s Seat — — —
Seat Skin Vinyl — — —
Flameproof Cloth STD STD STD 3

Mounting
Rear Body
Precautions for
Folding Center Seat STD STD STD
Sun Visor Driver’s Seat STD STD STD
Passenger’s Seat STD STD STD
Assist. Grip Driver’s Seat STD STD STD
Passenger’s Seat STD STD STD
4
Header Tray — — —

Weight Data
Distribution and
Weight
Full Trim Pad OPT OPT OPT
Cup Holder STD STD STD
Ash Tray Driver Side STD STD STD
Passenger’s Door Side STD STD STD
Power Window FRT Door Only OPT OPT OPT 5

Control
PTO and Engine
FRT and RR Doors — — —
Central Door Locking System OPT OPT OPT
Key Less Entry — — —
Tachometer STD STD STD
Tachograph (Digital) — — —
6
Tilt/Telescoping Steering STD STD STD

Equipments
Electrical
Regarding
Various Issues
Intermittent Windshield Wiper STD STD STD
Radio with AM (Antenna/One Speaker) — — —
Alarm Clock AM/FM (Antenna/Two Speakers) OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT)
AM/FM/CD (Antenna/Two OPT (STD/OPT) OPT (STD/OPT) OPT (STD/OPT)
Speakers) 7

the Springs
Characteristics of
Heater and Defroster STD STD STD
Air Conditioning Manual (Heater Equipped) OPT OPT OPT
System Full Automatic — — —
Exterior Sun Shade Band — — —
Equipment Under Mirror — — —
8
Fog lamp FRT — — —

Drawings
Cab Chassis
RR — — —
Cornering Lamp STD STD STD
Halogen Head Lamp STD STD STD
Head Lamp Leveling (Manual) — — —
Horn Normal Single Horn — — — 9
Heavy Duty Single Horn — — —

Drawings
Chassis Frame
Heavy Duty Dual Horn STD STD STD
Chassis Anticorrosion Wax STD STD STD
Back Buzzer — — —
Long Life Coolant 30% — — —
10
50% STD STD STD

Annex
Stabilizer FRT STD STD STD
RR — — —
Fuel Tank Cap with Lock STD STD STD

17
1
3 Precautions for Rear Body Mounting

Outline
3-1 General precautions

(1) Prohibited modification


2
Modification incidental to rear body mounting must be avoided as much as

Models
Various Vehicle
Specifications of
Principal
possible. Especially, from the viewpoint of compliance with applicable laws and
regulations and safety assurance, modification to the following components
must be avoided:
3
• Air inlet system

Mounting
Rear Body
Precautions for
• Diesel fuel injection controls
• Engine assembly with all components of exhaust emission control system
• Exhaust system
4
• Fuel system

Weight data
Distribution and
Weight
• Engine cooling system
• Turbocharger and associated controls
• Brake and brake control system
• Steering system 5

Control
PTO and Engine
• Noise insulation materials
• Transmission and final gear
• Front and rear axles
• Disc wheel
6
(2) Maintainability

Equipments
Electrical
Regarding
Various Issues
Rear bodies must be designed or mounted on chassises so as not to obstruct
inspection of, feeding to, or removal of the chassis components that require
regular maintenance. Such regular maintenance includes the following: 7

of the Springs
Characteristics
• Checking, feeding and evacuating engine oil and cooling water
• Checking, feeding and evacuating transmission oil
• Adjusting, removing and fitting a fan belt
• Checking and removing battery or battery cover, and feeding battery fluid 8
• Checking and feeding brake oil
Drawings
Cab Chassis

• Checking and air bleeding from braking system and clutch system, and
checking their servo unit
• Operation of spare tire carrier including fitting and removing spare tire
9
• Feeding to fuel tank, and checking and maintaining fuel tank area
Drawings
Chassis Frame

• Checking lamps on rear body and replacing their valves

10
Annex

18
1
(3) Clearance between an equipment/component on a cab chassis and a rear body

Outline
1) Engine
When installing any equipment/component around an engine, provide the
following clearances to such equipment/component. Do not place any object
2
that may impair cooling efficiency of the radiator and the inter cooler in front

Models
Various Vehicle
Specifications of
Principal
of them.
An engine control link/cable must be installed in such a manner that absorbs
vibration of the engine.
3

Mounting
Rear Body
Precautions for
4
Above and below 40mm or more

Weight data
Distribution and
Weight
Left and right 40mm or more
Front and back 25mm or more

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
2) Transmission
Since transmission is removed backward, to move a transmission assembly 7
without contacting anything, provide a minimum of 150mm clearance behind

of the Springs
Characteristics
it. For easy access to and maintenance of the upper cover of transmission,
provide a minimum of 150mm clearance above the transmission. Since
transmission moves in unison with the engine, for free movement of the
8
control lever on the side of the transmission, maintain a minimum of 40mm
Drawings
Cab Chassis

clearance around it.

9
Drawings
Chassis Frame

Periphery 40mm or more


Above and back 150mm or more

10
Annex

19
1
3) Front and center propeller shafts

Outline
Provide a minimum of 30mm clearance around front and center propeller
shafts. Equipments that emit high heat should be distant from the propellers.
If such equipment has to be placed near a propeller, provide a heat
2
insulation between them.

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
4) Rear propeller shaft and rear axle
With a rear spring bent to a practically maximum extent, there should be a
minimum of 30mm clearance around rear propeller shaft and rear axle.
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

20
5) Exhaust system 1

Outline
If a rear body is partially made of combustible materials such as wood and
rubber, give a minimum of 100mm clearance between the rear body and an
exhaust pipe, a muffler or a catalytic converter. If such clearance cannot be
assured, provide a heat insulation between them. If an oil pump or its piping 2

Models
Various Vehicle
Specifications of
Principal
has to be located above an exhaust pipe, a muffler or a catalytic converter,
provide a heat insulation between them.

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6) Brake hose
With wheels cut to a maximum extent at full bump or rebound, there should
be a minimum of 50mm clearance around the brake hoses connected to the
6
wheels.

Equipments
Electrical
Regarding
Various Issues
7) Front and rear suspensions
When a vehicle runs, the main spring and the shackle of suspension move
accordingly. With the spring and the shackle moved vertically or laterally to a 7

of the Springs
Characteristics
maximum extent, there should be a minimum of 20mm clearance around a
spring bracket.

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

21
1
8) Others

Outline
The control cable for transmission may possibly be bent or damaged by rear
body, fasteners, or accessories. To prevent this situation, the control cable
should have a minimum of 25mm clearance to such contact-anticipated
2
objects.

Models
Various Vehicle
Specifications of
Principal
When disconnecting a control cable in order to mount a rear body on a
chassis, be sure not to bend the cable.
Clearances between various components and a rear body, fasteners or
3
accessories are as follows:

Mounting
Rear Body
Precautions for
Component Minimum clearance Location
170 mm Axle side
Brake hose 4
40 mm Frame side

Weight data
Distribution and
Weight
Parking brake cable 30 mm —
Fuel hose and battery cable 40 mm —
60 mm Axle side
Shock absorber
30 mm Frame side 5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

22
1
9) Tilt cab

Outline
When a vehicle is running, its entire cab moves because of the factors such
as the cushioning material fitted on a cab locking device. Even if the vehicle
is in a resting state, when its cab tilts, rear body may contact with cab
2
chassis components such as a cab back panel, rear part of the engine, and

Models
Various Vehicle
Specifications of
Principal
an air inlet duct. To prevent it, provide such clearances between them as
shown below.

Mounting
Rear Body
Precautions for
Unit: mm

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
Unit: mm 8
Drawings
Cab Chassis

High cab
Vehicle model A B
Cab tilt radius
NLR85AL 50 911 1880
NMR85L 50 921 1880
NPR75L 90 924 1949 9
Drawings
Chassis Frame

NQR75L 90 924 1949

Note: Crew cabs do not tilt. No vehicle models for Mexico have crew cab.
10
Annex

23
1
(4) Precautions for an exhaust system

Outline
1) Relation of components layout and heat damage
The exhaust temperature differs between the two vehicle statuses in the
following table. Since the surface temperature of exhaust system 2
components gets very high, when installing a rear body, to prevent heat

Models
Various Vehicle
Specifications of
Principal
damage, follow the instructions ① through ⑤ below.

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
Vehicle status and temperature of exhaust system components (Unit: °C)
A B C D E
5
(During DPD regeneration) (*1) (350 to 450) (250 to 300) (400 to 450) (350 to 400 ) (350 to 400)

Control
PTO and Engine
At full load (*2) 500 to 600 250 to 300 450 to 500 350 to 400 400 to 450

Note : - The above data was obtained when outside air temperature was 6

Equipments
Electrical
Regarding
Various Issues
35°C.
- (*1) Vehicle is either stopped or running. This is shown as
reference.
- (*2) Vehicle is running.
7
- The above temperature data defers depending on outside air

of the Springs
Characteristics
temperature and load condition.

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

24
① Clearance between an exhaust system component and a neighboring 1

Outline
component

• In accordance with the following table, provide sufficient clearances


between an exhaust system component and a rear body or a chassis
2
component.

Models
Various Vehicle
Specifications of
Principal
•If the following clearances cannot be assured, install a heat shield panel
or an insulator between them, and then according to need, to assure
safety, measure the temperature of ambient areas.
3

Mounting
Rear Body
Precautions for
Rear body or chassis
Distance from an exhaust system component
components
200mm at minimum. Temperature of flexible hose must not exceed 70°C.
Flexible hose for brake,
If the maximum temperature of flexible hose cannot be measured, give a
electric harness and cable, 4
minimum of 400mm clearance between the hose and an exhaust system

Weight data
Distribution and
Weight
and resin
component.
60mm at minimum. If the length of a part of brake pipes, which is parallel
Brake pipe to each other is longer than 200mm, give a minimum of 180mm
clearance between these pipes.
Wood and rubber 100mm at minimum 5

Control
PTO and Engine
Steel fuel pipe 80mm at minimum

• If a tool box needs to be fitted, a steel box is recommended. If a wooden


one is preferable, such wooden tool box must be a minimum of 200mm 6

Equipments
Electrical
Regarding
Various Issues
away from any exhaust system component.

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

25
1
- Distance from a heat shield panel

Outline
When a 1mm-thick aluminum heat shield panel is installed 25mm away
from a heat source, the following distances (A) should be maintained
between the heat source and the equipment/component that are being
2
protected from heat damage.

Models
Various Vehicle
Specifications of
Principal
Allowable temperature limit of an
Distance from a heat shield panel (A)
equipment/component
100°C 20mm
3
80°C 30mm

Mounting
Rear Body
Precautions for
70°C 40mm
60°C 60mm

- Width of a heat shield panel 4

Weight data
Distribution and
Weight
The heat shield panel extend a minimum of 50mm out from the central
intersection of the line connecting the outermost point of the heat source
and the outermost edge of equipment/component protected from the
heat source. 5

Control
PTO and Engine
<Example>

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
If rear body mounting constrains exhaust emission to blow on workers or
passersby, or constrains any exhaust system component such as
silencer and DPD main body to be located in places where workers or 8
passersby possibly come nearby, to alert these people, make caution
Drawings
Cab Chassis

plates as shown below and prominently affix them in adequate places.

Unit: mm
9
Drawings
Chassis Frame

10
Annex

26
② Clearance between an exhaust system component and a fueling 1

Outline
component

•A fuel tank and fuel hoses should have a minimum of 200mm clearance
to an exhaust system component.
2
•Take preventive measure against fuel leakage from a fuel pipe in order

Models
Various Vehicle
Specifications of
Principal
to prevent leaked fuel from spilling on or adhering to exhaust system
components.

③ Pumps, hoses and pipes for the equipments or the hydraulic system on a 3

Mounting
Rear Body
Precautions for
rear body must not be placed above exhaust system components such as
DPD and silencer. Failure to follow this instruction may result in vehicle
fire. Since fuel leakage from these pumps, hoses and pipes may start
vehicle fire even if they are not placed above exhaust components, take
4
preventive measure against fuel leakage in order to prevent leaked fuel

Weight data
Distribution and
Weight
from spilling on or adhering to exhaust system components.
④ If a part of a rear body comes posterior to the outlet of a tail pipe, or if you
changed the direction of a tail pipe, be sure that any combustible
5
components such as resin parts, oil hoses, brake hoses, tires and electric

Control
PTO and Engine
harnesses are not placed within the shaded area in the figure below. For
details, see 3-4 (1) Modifying an exhaust system.
After making any change to a tail pipe, be sure that, on an actual vehicle,
6
exhaust emission does not blow on a rear body or any chassis

Equipments
Electrical
Regarding
Various Issues
components.

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

27
⑤ When fitting a side guard or a tool box on a rear body, follow the 1

Outline
instructions below.
• Since exhaust pipe emits very hot exhaust gas during DPD
regeneration,when installing a rear body, to prevent heat damage and
2
burns, be sure that any part of the rear body is not placed within the

Models
Various Vehicle
Specifications of
Principal
shaded areas in the figures below and within gas-affected area.

Areas affected by exhaust gas heat


3
Unit: mm

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
[Reference] Installing a side guard
6
• The ground height of a side guard bar should be higher than that of the

Equipments
Electrical
Regarding
Various Issues
outlet of a tail pipe.

Side guard bar should be placed a minimum of 70mm 7

of the Springs
Characteristics
above the exhaust pipe outlet.

8
Drawings
Cab Chassis

9
Side guard bar should be placed a
Drawings
Chassis Frame

minimum of 100m anterior to the front


edge of the exhaust pipe outlet.

10
Annex

28
1
(5) Relation between rear view mirror and rear body width

Outline
Since the size and position of the rearview mirror outside the cab limits the width
of rear body, be sure that the entire width of rear body complies with FMVSS
(Federal Motor Vehicle Safety Standards) and domestic regulations in Mexico.
2

Models
Various Vehicle
Specifications of
Principal
(6) Painting a disc wheel
Some body builders may provide custom-painting on disc wheels upon request
of users. When painting a disc wheel, follow the instructions below. If disc
wheels are painted inappropriately, paint film may loosen wheel nuts. 3

Mounting
Rear Body
Precautions for
1) How to paint a disc wheel in a user-requested color
• Painting a disc wheel before mounting it on a chassis

Before painting a disc wheel, apply masking tape to the contact faces of a 4

Weight data
Distribution and
Weight
mating disc wheel and a brake drum, and the portions with which wheel
nuts contact.

Control
PTO and Engine
R

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
• Painting a disc wheel after mounting it on a chassis
8
If a custom-painted disc wheel mounted with wheel nuts on a chassis look
Drawings
Cab Chassis

like it needs a touch-up, paint it as thin as possible in the same user-


requested color.
When rotating tires, follow the instructions below to prevent wheel nuts
9
from loosening because of custom-painting on the disc wheel.
Drawings
Chassis Frame

2) Precautions for tire rotation


In the event of tire rotation, if any portion of custom-coating on a disc wheel
contacts with a mating disc wheel, peel off the coating from the contact face,
clean the surface with a wire brush, etc., and then lightly apply anti-rust 10
Annex

coating. Before applying anti-rust coating, apply masking tape to the portions
with which wheel nuts contact when they are fastened.

29
1
3-2 Precautions for mounting of a rear body

Outline
To preserve the performance of chassises, provide the rear bodies to be mounted
on the chassises with side members, or mount a sub frame on the chassises. Such
sub frame prevents load concentration in chassis frame. Since load stress tends to
2
concentrate in the area near the cross member located right behind cab back,

Models
Various Vehicle
Specifications of
Principal
appropriately shape the ends of sub frame side members so that the sub frame
produces no acute change in the section modulus.
Mounting a rear body not on a sub frame but directly on a chassis frame and poor
rigidity of a rear body may result in large chassis frame displacement, and 3

Mounting
Rear Body
Precautions for
deteriorate ride comfort and driveability.
If mounting a special equipment on a chassis frame, pay attention to the
equipment’s weight and structure in order to ensure appropriate load distribution.
Excess load concentration in particular part of a chassis frame must be avoided. 4

Weight data
Distribution and
Weight
Special equipments must be placed appropriately. Mounting these special
equipments not on a chassis frame but on a sub frame is recommended.
(1) Precautions for fixing bolts
5
1) It is recommended that the first fixing bolts (U-bolts) are located near the

Control
PTO and Engine
front end of sub frame side members. However, note that these bolts must
not be fastened within the area from the front end to the kick-up point of the
sub frame. Be sure that the bolts are posteriorly distant to the kick-up point
by approximately 50mm. 6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

30
1
2) Fixing bolts, except for those fitted in the rear axle area, should be spaced

Outline
no longer than 1,000mm apart. Securely fasten them on a chassis frame.
3) As for the low-floor vehicles that have their rear bodies mounted not on a sub
frame but directly on a chassis frame, weld or rivet BRKT; RR BODY MTG in
2
the parts of chassis frame web where bolsters of the rear body are to be

Models
Various Vehicle
Specifications of
Principal
attached. When bolting bolsters to a chassis frame, put cushioning material
between the bolsters and brackets.
Be sure that rear bodies are sufficiently rigid, otherwise traveling
3
performance will deteriorate.

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
(2) Designing and fitting a sub frame
6
1) A sub frame assembly should be mounted as close as to a cab. Form the

Equipments
Electrical
Regarding
Various Issues
sub frame so as to have much the same shape and dimensions as those of a
chassis frame.
2) Front end of a sub frame
7

of the Springs
Characteristics
Mislocation of the front end of a sub frame may result in cracks in a chassis
frame in that area, or deterioration in ride comfort.
The distance between a CAB MTG; RR at the lower part of cab back or the
rear face of a BRKT;CAB MTG.RR on a chassis frame and the front end of a 8
Drawings
Cab Chassis

sub frame should be no longer than 200mm.

9
Drawings
Chassis Frame

10
Annex

31
1
3) Shape of the front ends of sub frame side members

Outline
Shaping the front ends of sub frame side members as follows prevents
stress concentration in particular part of a chassis frame. Select an end
shape that suits to a rear body from the following options:
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
Unit: mm

A B R

(1) 5 H/2 to H ⎯
(2) 5 Longer than H ⎯ 7

of the Springs
Characteristics
(3) H/3 Longer than H ⎯
(4) H/4 to H/5 H to 1.5 times H 15 to 20

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

32
1
4) Simplifying the shape of the front ends of sub frame side members

Outline
Load is relatively evenly distributed on flat bed bodies and aluminum van
bodies. As for the sub frames to be mounted on these types of rear bodies,
the front ends of sub frame side members (square pipes or trilateral
2
members) do not have to be shaped as the figures in the previous clause 3).

Models
Various Vehicle
Specifications of
Principal
In this case, however, to absorb shock from the ground, make a rectangle
spacer from resin waste material or a belt-like cushion from canvas, and then
insert it between the sub frame and the chassis frame. Thickness of such
resin spacer is approximately 50mm to 100mm while the canvas cushion is 3

Mounting
Rear Body
Precautions for
approximately 5mm to 10mm. Cut the resin spacer to appropriate lengths
before insertion. As for the spacer to be inserted in the foremost part, to
effectively reduce stress concentration in the chassis frame, cut its lower part
as shown in the figure (1) in the previous clause 3).
4
5) Contouring a sub frame

Weight data
Distribution and
Weight
When fitting a sub frame on a chassis frame by covering the area where the
width between chassis frame side members begin to change, sub frame side
members need to carefully be formed so that they will follow the shape and 5
the dimensions of the bending portion of the chassis frame side members.

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

The point in the fore part of sub frame side members where its section area
begins to change should not overlap with the bending point of chassis frame
side members.
10
Annex

33
1
(3) Areas from which fixing bolts are kept away

Outline
When fitting a sub frame on a chassis frame, do not install fixing bolts and
double-ended brackets in the following areas:

1) Area from the front end of a sub frame side member to the first U-bolt located 2

Models
Various Vehicle
Specifications of
Principal
approximately 50mm posterior to a kick-up point

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
2) Areas within 50mm anterior or posterior to the point where the width
between chassis frame side members begin to change
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
3) Areas within 100mm anterior or posterior to each cross member Characteristics
8
Drawings
Cab Chassis

Unit: mm

9
Drawings
Chassis Frame

10
Annex

34
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

35
10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight data
Models Equipments
4) Areas within 100mm anterior or posterior to the end of a reinforcement fitted

Unit: mm
on the inner side or outer side of a chassis frame
1
(4) Fitting a sub frame on a chassis frame

Outline
The following are the common methods of fitting a sub frame on a chassis
frame:

2
Method Feature

Models
Various Vehicle
Specifications of
Principal
Method 1: Fitting with U-bolts • Most common method. Quick application
and does not require chassis modification.
• Used for wooden and steel sub frames.
• Requires a reasonable clearance to a 3

Mounting
Rear Body
Precautions for
chassis component such as pipe, hose and
harness.

Weight data
Distribution and
Weight
Method 2: Fitting with double-ended brackets • Used for the area where U-bolt cannot be
used because of the components on the
inner side of a chassis frame side member
such as silencer
5
• Double-ended brackets must always be

Control
PTO and Engine
fitted in pairs. When fitting a pair of brackets,
be sure they are not in parallel on frame
members.
• Basically brackets should be fitted by
welding. If it is impossible, bolt them.
6

Equipments
Electrical
Regarding
Various Issues
• Absorbs cross-directional movement of a
rear body.

Method 3: Fitting with anti-slip brackets • I-shaped brackets must always be fitted in
pairs. When fitting a pair of brackets, make 7
sure they are not in parallel on frame

of the Springs
Characteristics
members.
• Used for wooden and steel sub frames.
• Fit both of V-shaped and I-shaped brackets
by bolting.
8
• U-bolt fixing (Method 1) is required at the
Drawings
Cab Chassis

same time.
• Absorbs cross-directional movement of a
rear body.

9
Drawings
Chassis Frame

Method 4: Fitting with anti-lateral vibration • Fit this bracket on a sub frame by welding,
brackets and on a chassis frame by bolting. Do not fit
this bracket on a chassis frame by welding.
• U-bolt fitting (Method 1) is required at the
same time.
10
• Absorbs cross-directional movement of a
Annex

rear body.

36
1
(5) Fastening U-bolts for fitting a sub frame on a chassis frame

Outline
When using U-bolts to fit a sub frame on a chassis frame, to prevent the flanges
of the chassis frame and the sub frame from deforming when the U-bolts are
tightened, fit a reinforcement block on the inner side of chassis frame side
2
members.

Models
Various Vehicle
Specifications of
Principal
The following figures show typical reinforcement blocks and the way how they
are fitted:

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
• The fitting direction of U-bolts can be downward or upward.
• It is recommended to use steel blocks for the area near exhaust system
components. If wooden blocks are preferable, be sure to provide a sufficient
8
clearance between a wooden block and an exhaust system component.
Drawings
Cab Chassis

• If any pipe or harness is located near a reinforcement block, maintain a


minimum of 10mm clearance between the block and fixed part or unmoving
part of such pipe or harness, and a minimum of 40mm between the block
9
and moving part of the pipe or the harness.
Drawings
Chassis Frame

• The U-bolt used to secure the leaf spring of a suspension cannot be used to
fit a sub frame on a chassis frame because it is different type of U-bolt even
though it looks very much like.
10
• For the fitting location of U-bolts, see the section 3-2 (3) Areas from which
Annex

fixing bolts are kept away.

37
1
When fitting a sub frame on a chassis frame by using U-bolts, follow the

Outline
instructions below.

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
Insert a spacer as shown below if a U-bolt and a chassis frame side member
cannot be in contact because the bending radius of the U-bolt is larger than that
6
of the bottom flange of the chassis frame side member.

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

38
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

39
10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight data
Models Equipments
U-bolt is most commonly used for connecting a sub frame to a chassis frame,
but it is also possible to use stud bolts or rod bolts as follows.
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

40
10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight data
Models Equipments
The following figures show various types of steel reinforcement blocks and the
ways how they are fitted:
1
(6) Fitting double-ended brackets for fitting a sub frame on a chassis frame

Outline
Use double-ended brackets for the areas where U-bolts cannot be used. Note
that double-ended brackets must always be fitted in pairs. Be sure that brackets
of each pair are not arranged in parallel. Fit double-ended brackets by welding,
2
however, if welding is not practical, bolt or rivet them. For the location of such

Models
Various Vehicle
Specifications of
Principal
bolts and rivets, see the section 3-2 (3) Areas from which fixing bolts are kept
away and (2) Drilling or welding a chassis frame under the section 3-3
Precaution for modification of a chassis frame.
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

41
1
(7) Recommended sub frame

Outline
Chassises tend to vibrate when they have long wheelbase. Especially, crew
cabs have that tendency. In this case, before mounting a rear body on it,
reinforce the chassis frame by the following procedure:
2
1. Fabricate a sub frame by referring to the table below.

Models
Various Vehicle
Specifications of
Principal
2. Fit the sub frame on a chassis frame from the cab back to the rear end.
3. Secure the sub frame on the chassis frame by using U-bolts or fixing
brackets. For details, see the section 3-2 (2) Designing and fitting a sub 3

Mounting
Rear Body
Precautions for
frame.

Weight data
Distribution and
Weight
5

Control
PTO and Engine
Examples of reinforcement sub frame
Section
Shape of sub Yield strength Web length Flange Thickness (mm) Sub frame
6
length modulus overall

Equipments
Electrical
Regarding
Various Issues
frame member (Mpa) (mm)
(mm) Web Flange (mm3) length
Structural
1 248 101.6 40.1 4.7 4.7 39.8×106 From the
C-Channel cab back to
Formed
2 248 127.0 63.5 3.6 3.6 45.1×10 the rear end
6
C-Channel of the 7

of the Springs
Characteristics
3 I-Beam 414 101.6 57.2 2.3 3.0 35.3×106 chassis
frame
4 Square pipe 345 50.8 76.2 6.4 6.4 40.9×106

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

42
1
(8) Precautions for a fender

Outline
1) Clearance between a rear fender and a tire
Consult the following figure and 7-3 Margin for movement of the rear axle
and tires to determine the height of a rear fender and a rear deck based on 2
“h” in the figure, which indicates the difference in height between a tire on

Models
Various Vehicle
Specifications of
Principal
the ground and that at its highest position.

3
Rear body

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
L≥C
5

Control
PTO and Engine
2) To ensure safety and strength, bend the outer edge of the rear fender inward
as shown in the figure below. Also, bend the inner edge inward to prevent
cracks.
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

43
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

44
10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight data
Models Equipments
4) Both edges of the rear fender should cover the areas 30° anteriorly and 50°
3) Both edges of the rear fender should be located exterior to tires.

posteriorly from the top of the tire as shown below.


1
(9) Rubber mud guard fitted on a rear fender

Outline
1) To protect the rear part of a tire from mud splash or to prevent the rear end
of a fender from being sucked in between a tire and the fender itself, fit such
a rubber mud guard that has the following dimension:
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
Unit: mm
A 130 to 200
B 200 to 300
5

Control
PTO and Engine
2) When fitting a long mud guard, take the following preventive measure so that
the guard will not be sucked in between a tire and a fender.
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

45
1
3-3 Precautions for modification of a chassis frame

Outline
Modification of a chassis frame should be avoided as much as possible. Only in
the circumstances that modification cannot be avoided, modify the chassis frame
according to the instructions below. When modification is complete, chassis frame
2
members should be carefully inspected to eliminate the possibility of any safety-

Models
Various Vehicle
Specifications of
Principal
related defects.
(1) Load on a chassis frame side member
The chassis frame is designed and built with consideration of appropriate load
3
distribution. Evenly-distributed load allows sustainable and sufficient physical

Mounting
Rear Body
Precautions for
strength. Installation of special equipments on a chassis frame can change the
said load distribution. When installing such equipments, make sure that load is
evenly distributed. Otherwise, stress concentrates on specific area of the frame
even if the total weight of the equipment is within the design limit, and 4

Weight data
Distribution and
Weight
eventually problems such as deformation or cracking of the chassis frame
members can be caused.
The chassis frame is designed as an integral structure. Therefore, cutting the
chassis frame is not recommended under any circumstances. 5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

46
1
(2) Drilling or welding a chassis frame

Outline
Chassis frame is designed to accommodate any load on various vehicle types
(e.g. Cargo transport vehicle, service vehicle). Installation of any special
equipment on a chassis frame negates the frame’s load condition. Even a small
2
cargo can fluctuate stresses on various areas of a chassis frame, possibly

Models
Various Vehicle
Specifications of
Principal
resulting in deformation or cracks. Therefore, drilling holes and welding chassis
frame members are basically prohibited. However, if such works are
unavoidable, follow the instructions below.
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
1) Side member 6

Equipments
Electrical
Regarding
Various Issues
Do not drill, notch, or weld on the shaded areas (flange) in the figure shown
above .

“a” in the above figure 7


“b” in the above figure “c“ in the above figure

of the Springs
Characteristics
(Allowable maximum
(Work-prohibited area) (Minimum required distance)
hole diameter)
Heavy duty φ17mm
H/5 (Welding) H/7 (Hole) 40mm
Medium duty φ15mm
Light duty φ11mm 20 25mm 8
Drawings
Cab Chassis

2) Cross member
• Alligator type: Hole drilling, notch making and welding are prohibited.
9
Drawings
Chassis Frame

• Trilateral ([-shaped) type: “b” and “c” depend on the side member. The
hole “a” should be a maximum of 9mm in diameter, which can be used
only for piping or harness routing.

10
Annex

47
1
3) Gusset

Outline
Hole drilling, notch making and welding are prohibited. If a hole needs to be
made, follow the instructions below.
• Use a drilling machine to make a hole. Do not use gas.
2

Models
Various Vehicle
Specifications of
Principal
• Length of any welding beads should be 30mm to 50mm. Allow at least 40
mm between adjacent welding beads.
• Weld beads must not protrude over holes. Do not weld within the distance
“c”, which is shown in the table on the previous page, from the edges of 3

Mounting
Rear Body
Precautions for
any existing holes.
• When using gas for notching, grind to finish the notch.
• All riveting must be done by cold rivets. Do not use hot rivets.
4

Weight data
Distribution and
Weight
4) Precautions for welding of a chassis frame
• Overcurrent generated in welding can damage electric devices equipped
in a vehicle. Therefore, to start welding, be sure to disconnect the
negative battery terminal and turn off the starter key switch. 5

Control
PTO and Engine
• To prevent ABS EHCU (electro-hydraulic control unit) from being
damaged, disconnect the connector of the ABS EHCU prior to welding.
• Keep chassis frames dry, free from moisture.
6
• Attach welder’s ground cable to a plated bolt or a metallic part of a

Equipments
Electrical
Regarding
Various Issues
chassis frame in the vicinity of welding site or to the chassis frame itself.

- Before attaching the ground cable on a chassis frame, peel off the
paint film on the area of the chassis frame suitable for attaching the 7

of the Springs
Characteristics
ground cable till its metallic base appears. After welding, apply the
same colored anticorrosion paint on the area.
- Do not attach the ground cable to a chassis spring, otherwise the
spring may break. 8
Drawings
Cab Chassis

• To prevent the following components from being damaged by welding


spatters or heat, cover them up or temporarily relocate them to
somewhere reasonably distant:
9
- Plastic parts - Rubber parts - Electric harnesses
Drawings
Chassis Frame

- Air intake duct - Radiator hose - Radiator - Intercooler


- Pipes - Chassis springs - Tire
In particular, if welding any area within 200mm from a fuel tank, remove
10
the fuel tank prior to welding.
Annex

48
1
• Before welding, remove the paint coating on the area to be welded. After

Outline
welding, apply anticorrosion paint in the same color.
• Welding rod
When the material of the chassis frame side member to be welded is 2
either one of the following, use a 55kgf/mm2 illuminite welding rod (KOBE

Models
Various Vehicle
Specifications of
Principal
STEEL, LTD.’s BW-52 or equivalent).

- High tensile steel HT540 (ISUZU MOTORS standard) in tensile strength


540Mpa{55kgf/mm2} 3

Mounting
Rear Body
Precautions for
Avoid welding problems such as undercut, overlap and pin holes.
- General steel plate for frame JSH440 (ISUZU MOTORS standard) in
tensile strength 440Mpa{45kgf/mm2}
4

Weight data
Distribution and
Weight
(3) Reinforcing a chassis frame side member
When reinforcing a chassis frame side member, to prevent an acute change in
rigidity, follow the instructions below.
5
1) Preventing an acute change in the section modulus and stress concentration

Control
PTO and Engine
due to welding
• Ends of outer reinforcement and inner reinforcement should not overlap.
• An end of outer reinforcement and cross member should not overlap. 6

Equipments
Electrical
Regarding
Various Issues
• An end of outer reinforcement and spring bracket should not overlap.

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

49
1
2) Welding on a flange

Outline
When fitting a reinforcement on a chassis frame, secure it by riveting or plug
welding. For plug welding, electrical components such as electric harnesses
on the inner side of a chassis frame side member should be kept a minimum
2
of 50mm apart from welding site.

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
Heavy duty/Medium duty Light duty
b H/5 20mm

3) Reinforcement material
6

Equipments
Electrical
Regarding
Various Issues
Heavy/Medium/Light duty
Outer reinforcement Same as side member’s
Inner reinforcement General steel plate for frame
7

of the Springs
Characteristics
Determine the thickness and the dimensions of reinforcements in due
consideration of rear body mounting conditions and vehicle use conditions.

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

50
1
4) Shape of reinforcements

Outline
Difference in shape between a trilateral reinforcement and a chassis frame
side member results in insufficient strength and reinforcing effect. For this
reason, use of L-shaped reinforcement material is recommended.
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
5) Inserting a new rivet in a hole from which another rivet was removed
When inserting a rivet in a hole from which another rivet was previously
6
removed, the rivet should be 1 or 2mm larger in diameter than the removed

Equipments
Electrical
Regarding
Various Issues
one. Cold rivet only.

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

51
1
(4) Modifying rear overhang of a chassis frame

Outline
If a rear body constrains a sub frame to necessarily protrude outward from the
rear end of a chassis frame by 300mm or more, lengthen rear overhang of the
chassis frame according to need.
2

Models
Various Vehicle
Specifications of
Principal
1) In case that extension material is 300mm or shorter:
Join an extension material and a chassis frame by continuous butt welding.
After welding, grind weld surface.
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
2) In case that extension material is longer than 300mm:
Join an extension material and a chassis frame by butt welding, and then fit
a reinforcement on the inner side of them. 8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

52
1

Outline
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
Thickness of reinforcement material (Unit: mm)
Side member Reinforcement material 4

Weight data
Distribution and
Weight
8.0 or thicker 6.0
4.0 to 6.0 4.5

• The thickness of extension material should be the same as that of side 5

Control
PTO and Engine
members.
• The material of extension material should be equivalent to that of side
members.
6
(5) Rivet plate

Equipments
Electrical
Regarding
Various Issues
Attaching parts/components on a chassis frame flange by welding is basically
prohibited, not to deform or crack the chassis frame. However, if a rivet plate is
required to offset a rivet on the upper flange of a chassis frame side member in
order to enhance rear body mountability, such a rivet plate should be properly 7

of the Springs
Characteristics
shaped and attached so that it will not adversely affect the chassis frame.
1) Precautions for attachment of a rivet plate

8
• To prevent an acute change in rigidity of a chassis frame, ends of a rivet
Drawings
Cab Chassis

plate should be formed as shown in the figure on the next page.


• Remove burrs and sharp edges from rivet plates.
• Attach a rivet plate on a chassis frame by plug welding. Do not weld the 9
Drawings
Chassis Frame

longitudinal edges of the rivet plate and a chassis frame flange together.
• After attaching a rivet plate, to prevent the rivet plate and a chassis frame
from corroding, apply anticorrosion paint on them.
10
• Rivet plates should not factor into strength calculation.
Annex

• When rivet plates need to be welded on a chassis frame due to rear body
mounting, consult us if necessary.

53
1

Outline
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
(6) Precautions for installation or relocation of a heavy object on/to the lateral side
of a chassis frame 4

Weight data
Distribution and
Weight
As for a standard or a high cab (frame thickness: 4mm) chassis, installation or
relocation of any heavy object on/to the lateral side of a chassis frame requires
a reinforcement as shown below. The following figure shows how a bracket for
a 100L fuel tank is to be attached on the part of the chassis frame inner side 5

Control
PTO and Engine
where no inner reinforcement is provided. This method is also available for
installing any object as heavy as the said 100L fuel tank. If there is a
reinforcement already provided, no additional reinforcing is required.

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

• Precautions for equipment relocation


Some brackets for the equipments (e.g. Fuel tank and battery) may have 10
Annex

been secured together with a chassis frame cross member and a side
member. If relocation of the equipments on such brackets is required. Make
sure of securely fix the cross members and the side members together, after
removing the brackets.

54
1
Bolt and nut

Outline
Size M10 x 1.25
Bolt: 8.8
Strength
Nut: 9N

2
Note: Use brand new bolts and nuts.

Models
Various Vehicle
Specifications of
Principal
Tightening torque
44 to 59N⋅m (4.5 to 6.1kgf⋅m)
3

Mounting
Rear Body
Precautions for
Note: Before tightening bolts and nuts, do not apply grease on them or on
mounting surfaces.

(7) Holes in a chassis frame


4

Weight data
Distribution and
Weight
1) Position of the holes in a chassis frame of various types of vehicles
Vehicle type: Standard cab vehicle and high cab vehicle (except for a kick-up
frame vehicle)
5
Overall chassis frame width: 700mm

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PTO and Engine
Side member thickness (mm) A B
4.0 180 30
5.3 182.6 31.3
6

Equipments
Electrical
Regarding
Various Issues
Side member

Unit: mm

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

55
1
Vehicle type: Wide cab vehicle

Outline
Overall chassis frame width: 750mm or 850mm

Overall chassis frame width (mm) Side member thickness (mm) A B


2
750 5.0 214 32

Models
Various Vehicle
Specifications of
Principal
850 6.0 216 32

Side member

3
Unit: mm

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
2) Precautions for use of module holes
6
• In chassis frame side members between wheelbase, some module holes

Equipments
Electrical
Regarding
Various Issues
(40mm pitch) are available for installing accessories, mounting bracket,
etc. These holes can also be used for relocation of equipments such as
fuel tank and battery, etc. Some of the holes may have already been used.
Check free holes on actual vehicle. 7

of the Springs
Characteristics
• The following modifications are prohibited:
- Drilling a new hole between module holes
- Enlarging a module hole 8
Drawings
Cab Chassis

- When relocating an equipment installed on a standard or a high cab


vehicle with 4mm thick side members, or installing any heavy object on
it, patches may need to be attached on the inner side of a chassis frame.
See 3-3 (6) for details. 9
Drawings
Chassis Frame

- When drilling new holes, follow the instructions under 3-3 (2) Drilling or
welding a chassis frame.

10
Annex

56
3-4 Precautions for modification of chassis components 1

Outline
(1) Modifying an exhaust system
1) Modification of an exhaust system is basically prohibited. Especially,
modification to the following area is strictly prohibited because it will 2
adversely affects exhaust gas purification system (DPD) and engine.

Models
Various Vehicle
Specifications of
Principal
2) Modification-prohibited area

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
Note: No vehicles for Mexico are equipped with DPD.

Equipments
Electrical
Regarding
Various Issues
3) If modification of a tail pipe cannot be avoided, follow the instructions below. 7

of the Springs
Characteristics
• Diameter and material of the pipe to be used for tail pipe modification
should be equivalent to those of the factory-installed tail pipe. When
performing welding, use a welding wire appropriate for the base metal of
8
the pipe.
Drawings
Cab Chassis

• Lengthening or bending a tail pipe is not recommended because doing so


increases exhaust resistance. If bending cannot be avoided, bend the
pipe so as to make its inside bending radius become at least 1.5 times the
9
pipe diameter, and be sure that exhaust pressure does not exceed a
Drawings
Chassis Frame

specified value.
• Tail pipe support should be the same as the factory-installed one or a
genuine ISUZU MOTORS pipe support with equivalent specification.
10
Support a tail pipe by means of rubber elasticity. Do not reduce the
Annex

number of supporting points.

57
1
• For the clearances between a modified tail pipe and a neighboring

Outline
equipment/component on a chassis, see ① through ⑤ under 1) Relation
of components layout and heat damage under the section 3-1 (5)
Precautions for an exhaust system.
2
• The angle and the position of a tail pipe opening shall be as follows, and

Models
Various Vehicle
Specifications of
Principal
they shall comply with applicable laws and regulations of body builders’
country.

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5
A B θ1*1 θ2 *1 C

Control
PTO and Engine
・It should not protrude outward
from vehicle’s outermost side. 200mm or 25° or
200mm or
Recommendation 0° to 15° smaller
・It should not protrude outward longer (*2) angle
longer
from the side guard.
6
Japanese safety 30° or smaller
・It should not protrude outward

Equipments
Electrical
Regarding
Various Issues
standard ⎯ angle to the ⎯ ⎯
from vehicle’s outermost side.
(For reference) left and right

*1: If the angle θ1 exceeds 15° and θ2 exceeds 25°, consult the ISUZU
7
MOTORS dealership. A tail pipe opening should be located a minimum of

of the Springs
Characteristics
450mm by extension away from the bold line in the above figure, which is
100mm outside from the outermost side of a vehicle. The dimensions θ1, θ2,
and C apply to both rear emission and side emission.
8
*2: Be sure that exhaust gas does not directly blow on a rear tire.
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

58
1
(2) Modifying a fueling system

Outline
If it is hard to mount a rear body with a fuel tank placed in the current position, it
is permitted to relocate the fuel tank by following the instructions below.
Adding an extra fuel tank is not recommended. 2

Models
Various Vehicle
Specifications of
Principal
1) Relocating a fuel tank
• When relocating a fuel tank forward or rearward, check the area to where
the fuel tank will be relocated for free holes in a chassis frame side
member, that can be used for fitting a bracket. Using these holes is 3

Mounting
Rear Body
Precautions for
recommended rather than making new holes. If more holes are required,
then drill them in the chassis frame side member. For details, see the
section 3-3 (2) Drilling or welding a chassis frame.
• When relocating a fuel tank upward or downward, fabricate a bracket as 4

Weight data
Distribution and
Weight
shown below.
• The pitch of the holes for mounting the fabricated bracket should be the
same as that of the holes for the factory-installed bracket.
5
• Do not fit the bracket together with other equipment by sharing same hole.

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

• Height “A” should be 250mm or more.


• The fill opening of a fuel tank must be a minimum of 300mm apart from
9
the opening of an exhaust pipe and a minimum of 200mm from any
Drawings
Chassis Frame

uncovered electrical terminal.


• Be sure that the relocated tank is sufficiently apart from any movable or
projecting object.
10
Annex

• 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.

59
2) Changing a fuel pipe 1

Outline
• If a fuel pipe that is different than the factory-installed one is preferable,
use a genuine ISUZU MOTORS rubber fuel hose. Poor quality hose will
possibly cause a fire. Please purchase a genuine ISUZU MOTORS hose
from the ISUZU MOTORS dealership. 2

Models
Various Vehicle
Specifications of
Principal
The following part numbers are the latest available at the time this guide
is released. Prior to placing an order, please check the stock.

Feed side fuel hose (general type) Unit: mm


3
Nominal Part number

Mounting
Rear Body
Precautions for
Inner diameter Outer diameter
diameter Length: 3,000 Length: 1,500 Length: 1,150
09 9.3±0.4 17.0±0.7 0012593000 0012591500 0012591150

Return side fuel hose (general type) Unit: mm 4


Part number

Weight data
Distribution and
Weight
Nominal
Inner diameter Outer diameter
diameter Length: 3,000 Length: 2,000 Length: 1,050
10 9.5±0.4 14.5±0.7 0012603000 0012602000 0012601050

• In the engine compartment, use steel pipes with anti-corrosion treatment 5

Control
PTO and Engine
on their surface and whose nominal diameter is 10mm.

Inner surface Copper plating (Thickness: 3µ at minimum)


Outer surface Galvanization (Thickness: 13µ at minimum)
6

Equipments
Electrical
Regarding
Various Issues
Perform bulge forming or spool forming on both ends of the said steel
pipes as follows:

Unit: mm 7

of the Springs
Characteristics
Bulge forming Spool forming

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

3) Precautions for piping


Do not connect two or more hoses to lengthen a single hose. When 10
Annex

connecting hoses, follow the instructions below.

• Fabricate a connecting pipe from a steel pipe. Perform bulge forming or


spool forming on both ends of this pipe.

60
1
Unit: mm

Outline
2

Models
Various Vehicle
Specifications of
Principal
• Insert this connecting pipe into hoses by more than 30mm, and secure
with clips. 3

Mounting
Rear Body
Precautions for
Unit: mm
Nominal diameter 9 P.No. 894122-6790
Nominal diameter 10 P.No. 109704-1020
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
• If bulge forming and spool forming is impossible, the insertion depth 6

Equipments
Electrical
Regarding
Various Issues
should be 35mm or more.
• Secure the hoses on a chassis frame or something with clips.

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

• Hose joints must not be located above an exhaust system.


• After completing the hose connection, confirm that there is no fuel
leakage.
10
Annex

61
1
4) Clearance around a fuel tank

Outline
• 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,
2
wrap the hoses with corrugated tubes or protectors.

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6
• In the engine compartment, use steel fuel tubes.

Equipments
Electrical
Regarding
Various Issues
• The fill opening of a fuel tank should easily be accessed so that its cap
can be removed/attached and fuel can be fed without problems.
• Do not join a fuel hose to the factory-installed one to take out fuel. Fuel 7

of the Springs
Characteristics
must not be taken out from a branched hose.
• When installing a steel tube, follow the instructions under ③ Precautions
for piping in this section.
8
• Maintain a reasonable clearance between an exhaust system component
Drawings
Cab Chassis

(front pipe, muffler and tail pipe) and a fuel tank or a fuel tube.
• When fitting any equipment (e.g. Side guard and marker lamp) near a fuel
tank, maintain a minimum of 25mm clearance front and back of the fuel
9
tank and a minimum of 40mm on its outer side.
Drawings
Chassis Frame

• In cold regions, when installing a sub tank on a vehicle, to prevent a fuel


hose from sagging due to snow, secure the fuel hose on any retaining
component (e.g. Stay) attached to a tank hanger bracket.
10
Annex

62
1
5) Location of a fuel tank

Outline
Place a fuel tank somewhere between wheelbase. Do not place it in rear
overhang area.

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
6) Precautions for relocation or addition of a fuel tank 5

Control
PTO and Engine
When relocating or adding a fuel tank, follow the instructions below.
• When changing a fuel hose, use a fuel hose of the same material as the
factory-installed one’s or a steel pipe.
6
- Rubber hose

Equipments
Electrical
Regarding
Various Issues
Rubber hose is used on the feed side as a hose that supplies fuel from
a fuel tank to the engine, and on the return side as a hose that returns
fuel from the engine to a fuel tank.
7

of the Springs
Characteristics
Side Part name Dimension
Inner diameter: 9.3mm
Feed side Rubber hose
Outer diameter: 17mm
Inner diameter: 9.5mm 8
Return side Rubber hose
Outer diameter: 14.5mm
Drawings
Cab Chassis

• Since use of low quality rubber hoses may cause fire, please purchase
genuine ISUZU MOTORS products from the ISUZU MOTORS dealership.
9
• When installing an additional fuel tank, use of a genuine ISUZU
Drawings
Chassis Frame

MOTORS fuel tank is recommended.


- The factory-installed fuel tank should be a main tank. Fuel must be
supplied from this main tank.
10
- If the Fire Defense Law of body builders’ country imposes regulation on
Annex

the amount of fuel that a vehicle can carry, when installing an additional
fuel tank, be sure that the total amount of fuel does not exceed the
regulation.

63
1
3-5 General precautions for brake-related components

Outline
(1) Precautions for rear body mounting on a chassis with ABS or EBD
• Anti-Lock Brake System (ABS)
ABS prevents the wheels from being locked or slipping when a vehicle is 2

Models
Various Vehicle
Specifications of
Principal
braked, in order to assure safety and steering performance of the vehicle.
• Electronic Brake force Distribution (EBD)
When the slip ratio of rear wheels exceeds specified value, EBD actuates the
3
holding valve of ABS to prevent increase in brake fluid pressure. By doing

Mounting
Rear Body
Precautions for
this, EBD prevents the slip ratio from rising and ensures sufficient braking
force and stability. Since EBD has usual effects of LSPV, no LSPV is
provided on a vehicle with EBD. On every chassis without EBD, LSPV is
provided. 4

Weight data
Distribution and
Weight
EBD is incorporated in the ABS controller and its brake pressure sensor is
fitted on the brake master cylinder.

Control
PTO and Engine
ABS-EBD configuration

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

64
1
1) When welding a chassis or a rear body, not to damage ABS components,

Outline
follow the instructions below.
• Disconnect the negative battery terminal.
• Disconnect the cable connector of the electro-hydraulic control unit. 2

Models
Various Vehicle
Specifications of
Principal
• If possible, disconnect the cable connector of the speed sensor.
• Surely secure the ground cable of electric welder on chassis frame.
Avoid that large current is accidentally supplied to the electro-hydraulic
3
control unit via brake pipe or something.

Mounting
Rear Body
Precautions for
• Be sure that welding spatters do not adhere to harnesses and the electro-
hydraulic control unit.

4
2) Using tires in desired diameter

Weight data
Distribution and
Weight
• Do not use tires with different specifications than those of the factory-
installed ones.
• If tires in desired diameter is preferable, consult the ISUZU MOTORS 5

Control
PTO and Engine
dealership.
3) Components layout

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Note: Location of the components may change depending on the vehicle
Drawings
Chassis Frame

model.

10
Annex

65
1
4) Relocating the electro-hydraulic control unit

Outline
Do not relocate the electro-hydraulic control unit, otherwise the following
problems may occur:

• Incorrect connection of a brake pipe or harnesses may result in breakdown 2

Models
Various Vehicle
Specifications of
Principal
of ABS or deterioration of braking performance.
• Changing the routing of a brake pipe or harnesses may result in contact
with neighboring objects or damage of the pipe or the harnesses.
3
5) ABS-EBD system configuration

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

66
1
(2) Outline of Load Sensing Proportioning Valve (LSPV)

Outline
LSPV controls braking force according to load. Do not relocate or modify LSPV.
Since it moves in conjunction with an rear axle, mount a rear body and other
equipments (e.g. Oil pump) with care so that LSPV will not contact them.
2
When temporarily removing LSPV for rear body mounting, after the rear body

Models
Various Vehicle
Specifications of
Principal
mounting, adjust the LSPV according to the instructions under Adjusting LSPV
that appears later in this section.

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
Maintain a minimum of 50mm clearance between the moving part of LSPV and
a rear body.
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

Note: The above figure is a major example. The appearance of LSPV may differ
depending on the vehicle model.

67
1
(3) Adjusting LSPV

Outline
1) Measuring fluid pressure
1. Adjusting rear axle load
Adjust rear axle load by using an axle load scale. 2

Models
Various Vehicle
Specifications of
Principal
With a person in a driver’s seat and a weight on a rear body, adjust
the rear axle load.
For the reference axle load value, see the “WS” column of the Table 1
3
showing LSPV adjustment values on the following page.

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
2. Connecting a fluid pressure gauge
Connect a fluid pressure gauge to a vehicle, and remove air from the
gauge. 6

Equipments
Electrical
Regarding
Various Issues
Remove air bleeding plugs from front and rear left wheels, and then
connect measuring hoses of the fluid pressure gauge to these
wheels in order to remove air from them.
7
Special tool

of the Springs
Characteristics
Brake fluid pressure gauge: part number 5-8840-2190-0

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

68
1
3. Measuring fluid pressure of a rear wheel cylinder

Outline
Press a brake pedal so as to make the fluid pressure of a front wheel
cylinder “P2” become 7.85Mpa {80kg/cm2}, and then measure the fluid
pressure of a rear wheel cylinder.
2
Two seconds after the above fluid pressure value of the front wheel

Models
Various Vehicle
Specifications of
Principal
cylinder started to be stable, read the fluid pressure value of the rear
wheel cylinder. When measuring the fluid pressure of LSPV, be sure
not to fully or halfway release the brake pedal but keep pressing it.
3
For the fluid pressure of the rear wheel cylinder, see the “P1” column of

Mounting
Rear Body
Precautions for
the following Table 1 showing LSPV adjustment values.

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6
2) LSPV adjustment values

Equipments
Electrical
Regarding
Various Issues
Table 1 Unit: (WS)=kg, (P2) and (P1)=Mpa{kg/cm2}
Front cylinder fluid Rear cylinder fluid
Rear axle load
GVW pressure during pressure during 7
Vehicle model during adjustment
(ton) adjustment adjustment

of the Springs
Characteristics
(WS)
(P2) (P1)
NLR85AL-EE1AYMX 4.1 800
NMR85L-EH5AYMX 7.85 {80} 3.69±0.59 {37.6±6}
5.0 900
NMR85L-HH5AYMX
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

69
1
3) Adjusting LSPV

Outline
If the reference value cannot be obtained, loosen two adjustment nuts “A” on
the main body of LSPV, and then move the LSPV up or down until you get
the reference fluid pressure value.
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
After completing the adjustment of LSPV, tighten the LSPV adjustment nuts.
5
Unit: N⋅m{kg⋅m}(lb⋅in)

Control
PTO and Engine
Adjustment nut tightening torque 13{1.33}(116)

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

70
1
(4) Modifying a brake pipe or a clutch pipe

Outline
Brake pipe and clutch pipe must not be modified unless absolutely necessary. If
these pipes must need to be modified, for safety assurance, follow the
instructions below.
2

Models
Various Vehicle
Specifications of
Principal
• Brake pipe must not be cut and reconnected. No exceptions.
• Cutting and reconnecting a clutch pipe is not recommended.
If the modification of the clutch pipe cannot be avoided, fabricate a connecting
3
pipe using appropriate tools, and then connect cut pipes by using this

Mounting
Rear Body
Precautions for
connecting pipe. After the pipe connection, conduct a pressure test on joints.
Note that a steel pipe used to make the connecting pipe is in metric size.

(5) Hydraulic steel pipes


4

Weight data
Distribution and
Weight
1) Precautions
• Pipe materials and forming
- Use brand new genuine ISUZU MOTORS pipes.
5
- When flare-forming or bending a pipe, use the tools specified by ISUZU

Control
PTO and Engine
MOTORS, and do such works according to ISUZU MOTORS’ standards.
- Do not bend the same portion of a pipe more than once. Do not perform
heat flare forming and heat bending. Before and after forming a pipe, for
6
safety assurance, check the surface of the pipe for damage, deformation

Equipments
Electrical
Regarding
Various Issues
or dent, or foreign substance inside.
- Leave factory-installed clips unremoved and use them as much as
possible when securing pipes.
7

of the Springs
Characteristics
- After forming a pipe, clean up the inside of the pipe.
• Clearance between a steel pipe and other components

Steel pipes must not contact with rear body components, and must not be
8
subjected to heat and vibration.
Drawings
Cab Chassis

- If there is possibility that a pipe Fig.1

may contact with a rear body


component, secure the pipe with
9
clips.
Drawings
Chassis Frame

Allow a minimum of 10mm (0.39


in.) clearance between pipes
(See the Fig.1).
10
Annex

71
1
- No metal pipes should be placed Fig.2

Outline
intersecting each other. If such
intersection cannot be avoided,
provide a minimum of 10mm (0.39
in.) clearance between the 2

Models
Various Vehicle
Specifications of
Principal
intersecting pipes (See the Fig.1).
If vibration of a pipe is anticipated,
secure such pipe with clips so that
it will not contact with neighboring Fig.3
3

Mounting
Rear Body
Precautions for
components (See the Fig. 2).
- Location of clips
To prevent pipes from being
damaged by vibration, locate clips 4
at such distances that absorb

Weight data
Distribution and
Weight
vibration. Place bended pipes at
appropriate angles.

5
- Use rust-proofed clips. Apply vinyl coating to the part of the clips where

Control
PTO and Engine
pipes may contact (See the Fig.2).
- Protect pipes from dust, sand, water and other foreign objects raised
from road. Water accumulation inside pipes must be avoided (See the
6
Fig.3).

Equipments
Electrical
Regarding
Various Issues
- If some clips were removed due to rear body mounting, after the body
mounting, put these clips back in place. If piping cannot be restored to
its original state, secure pipes with clips according to the Table 2.
7

of the Springs
Characteristics
Table 2 Distance between clips Unit: mm
Pipe diameter
φ 6.35 φ 8 to 10 φ 12
8
Drawings
Cab Chassis

Small 500 600 800


vibration at maximum at maximum at maximum

9
Drawings
Chassis Frame

Large
400 to 500 500 to 600 600 to 800 10
vibration
Annex

72
1
• After any modification to a pipe, check whether the following clearances

Outline
have been maintained.

Table 3 Clearance between a steel pipe and other components


2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
Moving components such as lever, link and
arm: 30mm (moving range +30mm)

Weight data
Distribution and
Weight
5
Silencer and exhaust pipe

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

73
1
3-6 Precautions for cab modification

Outline
(1) Modification or addition to a cab
1) Cab modification is prohibited except for drilling holes. Do not deform or weld
cab panels. 2

Models
Various Vehicle
Specifications of
Principal
2) After making holes in the inner or outer surface of a cab for installing
equipments, thoroughly apply rust-proofing agent on the inner surface and
the circumference of such holes. If a hole of more than 10mm diameter is
made in a strength-critical area such as floor, be sure to reinforce the area 3
around the hole.

Mounting
Rear Body
Precautions for
3) When installing levers or switches for controlling a rear body from a cab, to
avoid contact, they must be sufficiently apart from the other levers and
switches that have already been fitted in the cab.
4

Weight data
Distribution and
Weight
4) Affix plates or labels on such newly-added levers and switches so as to tell
what these devices are for.
5) When installing a warning buzzer in a cab for a rear body equipment, be
sure that the sound of the buzzer is different than the safety-alerting sounds 5

Control
PTO and Engine
of other warning buzzers such as the one for brake.
6) Since every cab had undergone thorough anticorrosion treatment, when
making any additional works on a cab such as drilling holes, or when a cab
surface was falsely scratched, apply rust-proofing treatment on such portions. 6

Equipments
Electrical
Regarding
Various Issues
(2) Installing equipment(s) on a roof
1) For installation of equipment(s) (e.g. Air deflector), a total of eight welded
mounting nuts as shown in the Fig.1 are available on the left and right edges
7
of a cab roof (four each). See the Fig.2 (High cab) and Fig.3 (wide cab) for

of the Springs
Characteristics
the location of the nuts.
2) Before fitting equipment(s) on a roof, remove the factory-installed dummy
bolts from nuts. Do not use the removed dummy bolts for fitting equipments
8
because they do no have sufficient strength.
Drawings
Cab Chassis

3) When fitting a rear body, be careful not to damage the roof, and for rust-
proofing, be sure to insert a packing between the rear body and the roof. To
prevent crack in the packing due to ozone, the material of such packing
9
should be neoprene rubber or EPDM rubber.
Drawings
Chassis Frame

4) Use anticorrosive M8 nickel chrome stainless steel bolts, and washers.


5) After tightening bolts, to prevent water leakage, apply silicone sealant on the
entire circumference of the bolts. 10
Annex

74
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

75
10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight data
Models Equipments
Unit: mm
Fig.2 Location of the nuts on a high cab roof
Fig.1 Attachment with M8 bolt
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

76
10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight data
Models Equipments
Unit: mm
Fig.3 Location of the nuts on a wide cab roof
1
(3) Load limit on a roof

Outline
Load on a roof must not exceed the following weight:

Table 1 Load limit on a roof


2
Light duty vehicle Medium duty vehicle Heavy duty vehicle

Models
Various Vehicle
Specifications of
Principal
45kg 75kg 80kg

A hanging-type header tray can optionally be fitted on the forefront part of cab
3
ceiling. The maximum loading capacity of the header tray is 2 kg.

Mounting
Rear Body
Precautions for
The Fig.4 shows how the header tray is fitted on the ceiling. Note that the
tightening torque of the screws with “∗” is 0.75±0.2Kgf⋅m.

Weight data
Distribution and
Weight
Fig.4 Fitting a header tray over the head (RHD is shown. LHD is symmetrical.)

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

77
1
(4) Through holes inside a cab for harnesses or an antenna cable

Outline
1) Through hole for harnesses
As shown in the Fig.5, in a dashboard panel in a cab there is a through
hole for harnesses. 2

Models
Various Vehicle
Specifications of
Principal
Fig.5 Through hole in a dashboard panel in a cab

(Cab front)
3

Mounting
Rear Body
Precautions for
Through hole

Weight data
Distribution and
Weight
5

Control
PTO and Engine
2) Through hole for an antenna cable
As shown in the Fig.6, in the upper part of the rear mounting rail behind 6
driver’s seat in a cab there is a through hole (φ25) for an antenna cable.

Equipments
Electrical
Regarding
Various Issues
Fig.6 Through hole in the upper part of the rear mounting rail

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

78
1
(5) Precautions for the works performed on a cab roof panel

Outline
In view of the strength of a roof, any works and walking on a roof panel are
basically prohibited. If you must need to get on a roof, gently put your feet on a
sunken area of a roof panel. At this time, get on the roof not with rigid-soled
2
shoes like safety shoes but with bare feet or soft-soled shoes. Never get on a

Models
Various Vehicle
Specifications of
Principal
risen area. Since roof is made of thin steel plate, getting on the risen area may
buckle the roof. When performing any major works on a roof, do them on
wooden boards placed over a spread blanket.
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

79
1
3-7 Precautions for cab painting

Outline
(1) Top coat
To enhance coating adhesion, thoroughly sand undercoat surface (See the
Fig.7). Be sure that the sanding pattern is uniform, and not to remove the 2
sealant at the joints of steel plates.

Models
Various Vehicle
Specifications of
Principal
Fig.7 Good and poor sanded surface conditions

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
Urethane paint is recommended for its high luster and distinctness-of-image
gloss, and it allows low-temperature baking. Compared to lacquer composition,
urethane paint provides better finish quality and has lower fading property. Top 5

Control
PTO and Engine
coat thickness should be 30µ or thicker.
When cleaning a cab, do not use thinner and gasoline but IPA (isopropyl
alcohol).
6
(2) Precautions for cab painting

Equipments
Electrical
Regarding
Various Issues
1) Painting-prohibited components

The following are the major components against which painting is prohibited.
Apply masking to them when painting a cab. 7

of the Springs
Characteristics
- Brake hose and brake-related components such as brake booster
- Rubber hoses and vinyl hoses
- Electric harnesses and connectors 8
Drawings
Cab Chassis

- Cab suspension and rubber or plastic steering components (In no


circumstances should the air bellows be painted.)
- Cab power tilt-related components
9
Drawings
Chassis Frame

- Wiper blades and washer nozzles


- Reservoir tank for coolant water and washer tank
- Caution plates and other identification plates
10
- Rubber or resin parts around windows
Annex

80
1
2) Components that should be removed before painting

Outline
Remove the following components before painting:
- Assist grip on front panel (Since the assist grip is made of polycarbonate, it
is weak against chemical solvent.) 2

Models
Various Vehicle
Specifications of
Principal
- Mirrors (Stay not included)
- Air intake duct
- Fender step covers
3

Mounting
Rear Body
Precautions for
- Fender rubber
- Side panel covers
3) Precautions for re-attachment of removed components
4

Weight data
Distribution and
Weight
When re-attaching components after completion of painting, follow the
instructions below.

- Do not re-attach the components until paint completely hardens.


5
- With a brush soaked in clear lacquer, etc., touch up the scratches made

Control
PTO and Engine
during unfastening or fastening screws, bolts or nuts.
- See the Fig.8 for the tightening torque of left and right mirrors. Securely
attach the mirrors with specified torque.
6

Equipments
Electrical
Regarding
Various Issues
Fig.8 Tightening torque of left and right mirrors

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

81
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

82
10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight data
Models Equipments
) indicate the areas to
The Fig.9 shows paint boundary.

Fig.9 Paint boundary

Note: Shaded areas (


(3) Paint boundary

be painted.
1
(4) Precautions for paint drying

Outline
There is no temperature restriction on the air seasoning. When conducting high
temperature forced drying, be sure that the atmospheric temperature of painted
surface does not exceed 80°C.
2
Due consideration must be given to the drying temperature. Drying temperature

Models
Various Vehicle
Specifications of
Principal
over 80°C may deform rubber and resin parts, and result in separation of
adhesive-bonded joints.
If the drying temperature inevitably exceeds 80°C, referring to the allowable
3
temperature limits in the Table 2 through Table 5, remove components or

Mounting
Rear Body
Precautions for
protect them from high temperature with tinfoil, blanket, etc. The Fig.10 through
Fig.13 show the location of the components in the Table 2 through Table 5
respectively.
4
The above-mentioned heat protection is imperative for the air cylinder for cab

Weight data
Distribution and
Weight
suspension because the temperature over 80°C degrades its durability.

Material of the roof of high roof vehicles is FRP. Be sure to keep the
temperature below 80°C.
5

Control
PTO and Engine
Table 2 Allowable temperature limit of interior components of a high cab
No. Component name Material Allowable temperature limit (°C)
1 Meter cluster PPF 90
2 Fuse lid PC 80 6

Equipments
Electrical
Regarding
Various Issues
3 Instrument panel cover PP or PPF 80
4 — — —
5 Trim cover PP or PPF 80
6 Steering cowl PP or PPF 80
7 Grid PET 80 7

of the Springs
Characteristics
8 Head lining PET 90

Fig.10 Location of the interior components of a high cab

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

83
1
Table 3 Allowable temperature limit of interior components of a wide cab

Outline
No. Component name Material Allowable temperature limit (°C)
1 Meter cluster PPF 90
2 Fuse lid PC 80
3 Instrument panel cover PP or PPF 80
2
4 Header tray PP or PPF 80

Models
Various Vehicle
Specifications of
Principal
5 Trim cover PP or PPF 80
6 Steering cowl PP or PPF 80
7 Grid PET 80
8 Head lining PET 90 3

Mounting
Rear Body
Precautions for
Fig.11 Location of the interior components of a wide cab

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

84
1
Table 4 Allowable temperature limit of exterior components of a high/wide cab

Outline
No. Component name Material Allowable temperature limit (°C)
1 Front turn signal lamp PMMA 80
2 Headlamp PC 90
3 Fog lamp PP (Housing) 90 2
Side turn signal lamp

Models
Various Vehicle
Specifications of
Principal
4 PC 90
Cornering lamp
5 Side reflector PMMA 80
6 Corner panel ABS 80
7 Grille ASA 80
3
8 Step closing PP 90

Mounting
Rear Body
Precautions for
9 Air duct PP 90
10 “ISUZU” emblem PET 90

Fig.12 Location of the exterior components of a high/wide cab (RHD is shown. LHD is 4

Weight data
Distribution and
Weight
symmetrical)

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

85
1
(5) Removing control units with built-in computers during baking coating

Outline
The allowable temperature limit of various control units with built-in computers is
80°C. If the ambient temperature inside a cab, specifically the area 5mm above
a floor, exceeds 80°C during baking coating on the outer panels, or if such
2
situation is expected, remove the control units.

Models
Various Vehicle
Specifications of
Principal
(6) Laminated glass
A laminated glass consists of two thermal-bonded glasses between which a
polyvinyl butyral film is sandwiched. There is nothing to worry about the
3
laminated glasses under normal use conditions. However, in hot and humid

Mounting
Rear Body
Precautions for
conditions during paint drying, you must 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.
4
When conducting forced infrared drying, do it within 30 minutes at temperature

Weight data
Distribution and
Weight
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
5
glass surface from exceeding 120°C, or remove it.

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PTO and Engine
Laminated glasses can be identified by “LP”, “LS” or “LAMINATE” printed below
a JIS mark in the lower left corner (See the Fig.13). Partially tempered glasses
have a “Z” print.
6

Equipments
Electrical
Regarding
Various Issues
Fig.13 Location of the print on a laminated glass

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

86
1
(7) Affixing an emblem and decals on the front face of a cab

Outline
1) Emblem and decals
The Fig.14 and Fig.15 show “ISUZU” emblem and “ELF” decal. The Fig.15
also shows “Custom” decal. 2

Models
Various Vehicle
Specifications of
Principal
2) Location of the emblem and decals
The Fig.14 and Fig.15 show the location of an “ISUZU” emblem and vehicle
model decals on the front face of a high/wide cab of a non-custom vehicle
and a high/wide cab of a custom vehicle respectively. 3

Mounting
Rear Body
Precautions for
Fig.14 Location of an “ISUZU” emblem and vehicle model decal on a high/wide cab of a non-
custom vehicle

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

1. Edge of the panel


2. “ELF” decal
3. Bottom edge of the panel
4. Bottom edge of the emblem
10
5. “ISUZU” emblem
Annex

Distance
A: 20mm B: 19mm C: 43mm

87
Fig.15 Location of an “ISUZU” emblem and vehicle model decal on a high/wide cab of a custom 1
vehicle

Outline
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7
1. Edge of the panel

of the Springs
Characteristics
2. “ELF” decal
3. End of panel curve
4. Bottom edge of the emblem
5. End of panel curve
6. End of panel curve
8
7. “Custom” decal
Drawings
Cab Chassis

8. “ISUZU” emblem

Distance
A: 20mm B: 19mm C: 18mm D: 2mm
9
Drawings
Chassis Frame

10
Annex

88
1
3) How to affix an “ISUZU” emblem

Outline
Set the jig that came with a chassis on the front lid of a cab, and then stick
each letter sticker by using cut-outs of the jig as a guide.
[Precautions for an “ISUZU” emblem] 2

Models
Various Vehicle
Specifications of
Principal
- If there is any extraneous matter on a bonding surface such as water, oil
and dust, letter stickers will not firmly stick to the surface. If there is any,
wipe them off completely with a clean cloth soaked in non-leaded gasoline.
- An ideal ambient temperature for adhesion is 30°C to 40°C. Make the 3

Mounting
Rear Body
Precautions for
temperature of the bonding surface fall within this temperature range as
much as possible.
- The sticky side of stickers requires pressurization for bonding. To firmly
stick the stickers, apply sufficient and uniform pressure on the stickers. Use 4

Weight data
Distribution and
Weight
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 the stickers to the air for long hours weakens
their adhesivity due to adhesion of dust, etc. To protect the sticky side, do 5

Control
PTO and Engine
not remove a release-paper until immediately before use.
- Since this sticky-side has very strong adhesive property, once you stick
stickers, you will not be able to peel them off easily. Before sticking them,
carefully check sticking position. 6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

89
1
4) How to affix a vehicle model decal

Outline
- The ambient temperature should be no lower than 20°C.
- If there is any extraneous matter on a bonding surface, wipe it off with
ethanol. If the matter cannot be removed, completely wipe it off with lacquer 2
thinner, etc., and then wipe the surface again with ethanol.

Models
Various Vehicle
Specifications of
Principal
- To protect printed matters on a decal, as shown in the Fig.16, cover the
front face of the decal with a paper carrier tape before pressing the decal.
3
Fig.16 Composition of a decal

Mounting
Rear Body
Precautions for
4

Weight data
Distribution and
Weight
- With a release paper unremoved, temporarily place the decal in position,
5
and as shown in the Fig.17, fix the two corners of the decal with adhesive

Control
PTO and Engine
tape.

Fig.17 Positioning with adhesive tape

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
- Peel off the release paper from the upper edge of the decal by Characteristics
8
approximately 20mm, and then fold down the paper at 180°.
Drawings
Cab Chassis

- Press and paste up the area 20mm from the upper edge of the decal.
Temporarily fix the lower corners with adhesive tape so that the decal will
not move. 9
Drawings
Chassis Frame

- Slowly peel off the release paper, and press the decal carefully.
- When you finished sticking the entire area, remove the positioning tapes.
- If there are bubbles trapped inside the decal, pop and press them out.
10
Annex

- Press the entire surface hard, and then carefully remove the paper carrier
tape.

90
1
[Precautions for vehicle model decals]

Outline
- The base material of a decal is thin, soft and stretchable vinyl chloride.
Strictly following the above procedures will enable you to firmly affix decals
without making wrinkles, bubbles or stretching.
2
- Decals can be affixed directly on the front face of the ISUZU MOTORS’

Models
Various Vehicle
Specifications of
Principal
cabs with no problem. However, if you intend to put any decor made of
polypropylene, polyethylene, Teflon, Noryl, urethane, etc. underneath a
decal, there is possibility that the decal may not stick at all or may come off
shortly after being affixed. 3

Mounting
Rear Body
Precautions for
5) How to remove a decal
- If a decal has been affixed not more than one week, raise the edge of the
decal with a fingernail, and then peel it off. If adhesive agent remains on a
4
bonding surface, wipe it off with toluene and wipe again with isopropyl

Weight data
Distribution and
Weight
alcohol.
- If the decal has been affixed more than one week, coat the decal with
toluene, and then peel it off with a spatula.
5

Control
PTO and Engine
(8) Rust prevention with Ziebart’s rust-proofing agent
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 underfloor area, inner sides of fenders, outer side of front panel, 6

Equipments
Electrical
Regarding
Various Issues
lower parts of doors, and joints of panels. Before applying the agent, cover the
weep holes in the doors and other areas with tape in order to prevent them from
being plugged up with the agent. After completion of the agent application,
remove the tapes and check the weep holes for blockage. Since a cab is made
7
from thin steel plates, if the weep holes are plugged up by something such as

of the Springs
Characteristics
rust-proofing agent, water or salty water consequently colleted may corrode 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. In addition to the above
weep holes, also cover the air bleeding holes in air valves, etc. with tape to 8
Drawings
Cab Chassis

protect them from blockage.

9
Drawings
Chassis Frame

10
Annex

91
1
4 Weight Distribution and Weight Data

Outline
4-1 Weight distribution
The only purpose of a truck as a commercial vehicle is to transport products from
one place to another. Regardless of transport distance, the weight of cargo to be 2

Models
Various Vehicle
Specifications of
Principal
transported should determine the size of a truck. Light cargo needs a small truck
and heavy cargo needs a big truck. Many drivers do not pay much attention to this
simple logic. Choosing a truck of a right size according to shipping weight
guarantees the completion of transport task. In other words, choosing a truck of a
3
right size ensures a certain degree of reliability for transport, and guarantees that

Mounting
Rear Body
Precautions for
the total vehicle weight and the total axle load within legally allowable ranges are
transported.
It is certainly important to choose a truck that can support the total weight
4
composed of a cab chassis, a rear body and cargo. However, from viewpoint of

Weight Data
Distribution and
Weight
vehicle function and economy, it is also very important to appropriately distribute
load between front and rear axles.
If a truck always transports cargo which is lighter than its maximum loading
capacity, it is obvious that the owner of this truck has never given ‘return on 5

Control
PTO and Engine
investment’ a thought. He must realize that his truck is wasting a lot of money.
Inappropriate load distribution and excessive loading increase maintenance cost,
and illegal overloading imposes a fine on the truck, in any case decreasing profit.
When determining gross weight composed of a cab chassis, a rear body and
6
maximum payload, give careful consideration to the load distribution.

Equipments
Electrical
Regarding
Various Issues
The other reason why the load distribution needs to be considered is because how
load is distributed determines how the total weight composed of a cab chassis, a
rear body and maximum payload will be applied on each of a front axle, a rear axle,
a trailer axle and an entire vehicle. Moving cargo on a truck a few inches to the 7

of the Springs
Characteristics
front or to the back can negate the truck’s allowable load distribution rate, making
optimal transport impossible.
Every truck has its maximum loading capacity. When determining load distribution,
be sure that it satisfies the vehicle’s gross axle weight ratings (GAWR), gross 8
Drawings
Cab Chassis

vehicle weight ratings (GVWR), and gross combination weight ratings (GCWR,
applicable to trailer/tractor), and ensures that the vehicle complies with applicable
weight regulations when in service.
Inappropriate load distribution contributes to the following problems: 9
Drawings
Chassis Frame

(1) Excessive wear and problems of the components located in fore part of a
chassis
• Wear of tie-rods and king pins
• Malfunction of a front axle 10
Annex

• Overload on a front suspension


• Malfunction of a wheel bearing

92
1
(2) Rapid wear of tires

Outline
Applying weight that is exceeding a specified limit on a tire results in rapid tire
wear and other tire problems.
(3) Uncomfortable ride 2

Models
Various Vehicle
Specifications of
Principal
When the center of cargo is located right above a rear axle or slightly behind it,
a front axle does not have much load upon it. This results in vertical vibration,
poor ride quality, and unstable steering control. These problems worsen when a
truck is going up a hill.
3

Mounting
Rear Body
Precautions for
(4) Uncontrollable steering
When load beyond the loading capacity of a front axle is loaded above the front
axle, the load also overloads a steering mechanism, making steering control
difficult. 4

Weight Data
Distribution and
Weight
Overloading results in damage or failure of steering components.
(5) Dangerous driving
Insufficient vertical load of an steering axle on the ground compromises safety 5

Control
PTO and Engine
of a driver and vehicle equipments especially when a road is wet, icy or slippery.
Experience tells that approximately 30 percent of the total shipping weight
measured at the truck/tractor-ground interface should be applied on a front axle.
Since overloading does not allow a vehicle to always maintain its minimum load 6
ratio, this vehicle may fall into such dangerous situations that it becomes out of

Equipments
Electrical
Regarding
Various Issues
directional control or cannot stop at its original braking distance due to poor
braking performance.
(6) High maintenance cost 7

of the Springs
Characteristics
Inappropriate load distribution and overloading result in excessive wear and
early breakdown of parts. Inappropriate modification of wheelbase causes
excess stress on a chassis frame, resulting in cracks in and break of the chassis
frame. 8
Drawings
Cab Chassis

(7) Noncompliance with weight regulations


If there is possibility that axle load may exceed weight regulations, determine
load distribution with extra care so as to keep front and rear axle load and total
of them within specified ranges. 9
Drawings
Chassis Frame

By following all of the above instructions, drivers will be able to transport maximum
payload without going over a statutory limit.
10
Annex

93
1
When a rear body of a truck is too long for its wheelbase, the rear body and cargo

Outline
are necessarily placed right above a rear axle or behind it. This means that entire
load is applied on the rear axle, overloading rear driveline, a rear axle spring and a
wheel bearing, and possibly exceeding a statutory limit on rear axle load. Since
very little load is applied on a front axle at this time, on rough terrain, the front axle 2

Models
Various Vehicle
Specifications of
Principal
may lift up, impairing ride quality and temporarily nullifying steering control.
On the other hand, when the rear body is too short for the wheelbase, high stress is
applied on the chassis frame, and the front axle is overloaded. Such overload on
the front axle wears king pins, bushings, wheel bearings, steering gear, front axle 3
itself, front axle springs, tires, and wheels.

Mounting
Rear Body
Precautions for
Note that mounting a rear body in an inappropriate length increases maintenance
cost and makes steering control difficult.
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

94
1
4-2 Weight data

Outline
The following table shows the weight data of the cab chassis for Mexico, that
should be referenced at the time of rear body mounting. Since the data are the
design values, the weight of the actual cab chassises may be different. Measure
2
the weight of the cab chassises before conducting rear body mounting, if required.

Models
Various Vehicle
Specifications of
Principal
N*R series for Mexico
Cab chassis weight (kg) GAW (kg) GVW
Vehicle model
Front axle Rear axle Total Front axle Rear axle (kg) 3

Mounting
Rear Body
Precautions for
NLR85AL-EE1AYMX 1,330 535 1,865 2,600 3,600 4,100
NMR85L-EH5AYMX 1,370 630 2,000 2,900 5,000 5,000
NMR85L-HH5AYMX 1,395 675 2,070 2,900 5,000 5,000
NPR75L-FL6AYMXC 1,725 775 2,500 2,431 4,482 6,577
NPR75L-HL6AYMXC 1,770 810 2,580 2,431 4,482 6,577 4

Weight Data
Distribution and
Weight
NPR75L-KL6AYMXC 1,785 815 2,600 2,431 4,482 6,577
NQR75L-FN6AYMXC 1,820 895 2,715 2,812 5,543 7,257
NQR75L-HN6AYMXC 1,880 930 2,810 2,812 5,543 7,257
NQR75L-KN6AYMXC 1,890 940 2,830 2,812 5,543 7,257
NQR75L-MN6AYMXC 1,920 940 2,860 2,812 5,543 7,257 5

Control
PTO and Engine
NQR75L-HQ6AYMXC 1,880 980 2,860 3,098 6,196 8,865
NQR75L-KQ6AYMXC 1,890 990 2,880 3,098 6,196 8,865
NQR75L-MQ6AYMXC 1,920 990 2,910 3,098 6,196 8,865

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

95
1
4-3 Weight distribution calculation

Outline
In weight distribution calculation, the basic mathematical principle is used to
determine appropriate load distribution and rear body weight on a truck chassis
wheelbase.
2
In terms of cost efficiency, it is better to do this calculation on paper because

Models
Various Vehicle
Specifications of
Principal
miscalculations can be corrected right away. Omission of this desk calculation may
end up in suspensions of truck building work due to mistakes or in worse case--
cessation due to complete failure.
3
Being familiar with truck dimensions is important in doing the weight distribution

Mounting
Rear Body
Precautions for
calculations.
This section provides the formulas for calculating load distribution on the completed
N-series vehicles. See the previous section 4-2 Weight data for the weight of the
4
axles on the cab chassises.

Weight Data
Distribution and
Weight
(1) Formula for determining load distribution on NLR, NMR, NPR, or NQR vehicle
model (Single cab)
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

96
1
WB: Wheelbase (mm)

Outline
OS: Offset of the combined center of gravity of the rear body and cargo
from the rear axle center (mm)
CP: Distance from occupant to the rear axle center (mm)
L/2: Half length of the cargo bed (mm) 2

Models
Various Vehicle
Specifications of
Principal
BW: Rear body weight (kg)
PL: Cargo weight (kg)
CW: Occupants weight (kg)
CAWf: Chassis front axle weight (kg)
3
CAWr: Chassis rear axle weight (kg)

Mounting
Rear Body
Precautions for
GAWf: Vehicle front axle weight (kg)
GAWr: Vehicle rear axle weight (kg)
GVW: Gross vehicle weight (kg)
4

Weight Data
Distribution and
Weight
Basic formula
(a) GVW =GAWf+GAWr
=CAWf+CAWr+BW+PL+CW
5
(b) GAWf=CAWf+{(BW+PL)×OS/WB}+(CW×CP/WB)

Control
PTO and Engine
(c) GAWr= CAWr+{(BW+PL)×(WB−OS)/WB}+{CW×(WB−CP)/WB}

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

97
1
4-4 Front axle load rate

Outline
To ensure optimal and safe driving, calculate load distribution on the front axle
through the following formula. Be sure that the axle load is within the allowable
range. This formula applies to both loaded and unladen vehicles.
2
40% > WF/W × 100 > 25%

Models
Various Vehicle
Specifications of
Principal
WF: Total weight of the front axles
WR: Total weight of the rear axles
W: WF+WR=Gross vehicle weight
3

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

98
1
4-5 Allowable load on axles and tires

Outline
The following table shows the allowable load on the axles and tires. These data will
be essential to determine allowable live load on a completed vehicle that went
through rear body mounting.
2

Models
Various Vehicle
Specifications of
Principal
N*Series for Mexico
Tire size
GAW (kg)
(○: STD △: OPT)

Front & Rear: 225/70R19.5


Front & Rear: 215/85R16
3

Mounting
Rear Body
Precautions for
205/75R16C-113/111

205/75R16C-113/111
GVW
Vehicle model
(kg) Front Rear
Front & Rear:

Front & Rear:


axle axle

Weight Data
Distribution and
Weight
NLR85AL-EE1AYMX 4,100 ○ 2,600 3,600
NMR85L-EH5AYMX 5,000 ○ 2,900 5,000
NMR85L-HH5AYMX 5,000 ○ 2,900 5,000 5

Control
PTO and Engine
NPR75L-FL6AYMXC 6,577 ○ 2,431 4,482
NPR75L-HL6AYMXC 6,577 ○ 2,431 4,482
NPR75L-KL6AYMXC 6,577 ○ 2,431 4,482
NQR75L-FN6AYMXC 7,257 ○ 2,812 5,443
NQR75L-HN6AYMXC 7,257 ○ 2,812 5,443 6

Equipments
Electrical
Regarding
Various Issues
NQR75L-KN6AYMXC 7,257 ○ 2,812 5,443
NQR75L-MN6AYMXC 7,257 ○ 2,812 5,443
NQR75L-HQ6AYMXC 8,865 ○ 3,098 6,196
NQR75L-KQ6AYMXC 8,865 ○ 3,098 6,196
NQR75L-MQ6AYMXC 8,865 ○ 3,098 6,196 7

of the Springs
Characteristics
Single Single Single Single
Front axle: axle: axle: axle:
Maximum allowable 2,300 2,300 3,007 3,302
tire load (kg)* Single Single Single Single
Rear axle: axle: axle: axle:
2,300 4,360 5,651 6,196 8
Drawings
Cab Chassis

Note*: The tires are with the air pressure specified by ETRO or TRA.

9
Drawings
Chassis Frame

10
Annex

99
1
5 PTO and Engine Control

Outline
5-1 PTO variation

PTO main body Engine PTO control


Trans- 2
PTO Allowable
Vehicle model Speed mission Lever Electric

Models
Various Vehicle
Specifications of
Principal
availability Type Output maximum increasing 4JJ1- 4HK1- with
shaft TCC TCC model switch
torque ratio cable
NLR85AL-EE1AYMX △ 196N・m ○ — MYY5T — ○
NMR85L-EH5AYMX (20kgf・m) 0.760
△ ○ — MYY5T ○ —
NMR85L-HH5AYMX Side Flange /1000rpm
PTO type 3
245N・m

Mounting
Rear Body
Precautions for
NPR75L-*******
× (25kgf・m) 0.773 — ○ MZZ6U ○ —
NQR75L-*******
/1000rpm

Legend ○: Standard equipment △: Option ×: Not available 4

Weight Data
Distribution and
Weight
Note: Factory option may not be available in some cases. Please consult the
ISUZU MOTORS dealership for details.
A speed sensor is located on the left side of vehicle. Install a drive shaft with
5
careful regard to the position of the sensor.

Control
PTO and Engine
MZZ6U transmission side PTO is not available for NPR75 and NQR75 as
factory option, and genuine ISUZU MOTORS side PTO is also not available.
For a reference for manufacturing or purchasing PTO, specifications of
6
MZZ6U transmission side PTO are indicated in 5-2 (2). Please be advised

Equipments
Electrical
Regarding
Various Issues
that the PTO of equivalent or superior performance should be used
accordingly.

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

100
1
5-2 Side PTO

Outline
(1) Side PTO for MYY transmission

Allowable maximum Expected Transmission PTO output


Speed increasing ratio
Output shaft torque (output life in rated power take off shaft rotating 2
compared to the engine

Models
Various Vehicle
Specifications of
Principal
shaft) operation gear direction

196N・m (20kgf・m) Clockwise


28/45×33/31×31/27=0.760
Flange type 600 hours 3rd when viewed
/1000rpm (MYY5T)
from rear

Mounting
Rear Body
Precautions for
1) Transmission side view (4JJ1-TC)

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
Unit: mm

Note 1: The angle of the drive shaft against the side PTO output shaft shall
be 4° at maximum. 7

of the Springs
Characteristics
Note 2: For the following dimensions, see 5-5 Engine Control.
• θ : Engine inclination angle
• A: Distance from front axle center to engine datum point
8
• B: Distance from chassis frame top surface to engine datum point
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

101
1
2) PTO-connecting part of transmission

Outline
Unit: mm

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
Specification of the counter gear
Model MYY5T
Module 2.77
Pressure angle 20° 6

Equipments
Electrical
Regarding
Various Issues
Number of teeth 33
Addendum modification coefficient +0.072
Tooth height 7.828
Outer diameter 105 +0.1
−0.1
Helical angle and direction 20°, Right 7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

102
1
3) Power takeoff elements

Outline
Flange PTO for MYY5T [196N⋅m (20kgf⋅m)/1000rpm]

Outline of the PTO


2

Models
Various Vehicle
Specifications of
Principal
Unit: mm

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
MYY5T 5
A 28

Control
PTO and Engine
B 45

Specification of the serration “H”


Tooth shape Involute 6

Equipments
Electrical
Regarding
Various Issues
(Module) (0.591)
Number of teeth 36
Pressure angle 42.3145°
Tip circle diameter φ21.775±0.1
Pitch circle diameter φ21.276 7
φ15.733

of the Springs
Characteristics
Base circle diameter
Over pin diameter φ22.718±0.033
Measuring pin diameter φ1.0227

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

103
1
4) Parts for flange PTO

Outline
Parts name Qty Part No.
① FLANGE; OUTPUT 1 8980466240
② WASHER; PLAIN 1 0916105140 2

Models
Various Vehicle
Specifications of
Principal
③ WASHER; SPRING 1 0915108140
④ NUT; FLANGE FIX 1 0911115140
⑤ BOLT; COVER 4 0280508200
⑥ COVER ASM; SEAL 1 8980299680
3

Mounting
Rear Body
Precautions for
Note: ⑥ is not included in the flange PTO assembly kit.

Unit: mm
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7
5) PTO gear arrangement

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

104
1
(2) Side PTO for MZZ transmission

Outline
Allowable maximum Speed increasing ratio Transmission power PTO output shaft
Output shaft
torque (output shaft) compared to the engine take off gear rotating direction

245N・m (25kgf・m) Clockwise when 2


Flange type 0.773 4th counter gear

Models
Various Vehicle
Specifications of
Principal
/1000rpm viewed from rear

1) Location of PTO
3
Unit: mm

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
A
Manual transmission 170 6

Equipments
Electrical
Regarding
Various Issues
Note: The angle of the drive shaft against the PTO output shaft shall be 4°
7
at maximum.

of the Springs
Characteristics
2) PTO output shaft end
8
Drawings
Cab Chassis

Unit: mm

9
Drawings
Chassis Frame

10
Annex

105
1
3) PTO output flange

Outline
Unit: mm

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
Note: Flange is not installed even if PTO is factory-installed.
Therefore, referring to the above figure, body builders
are encouraged to fabricate flange by themselves.

Weight Data
Distribution and
Weight
4) Detailed drawing of PTO-connecting part of a MZZ transmission and PTO
power take off gear specification

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Unit: mm Characteristics
8
Drawings
Cab Chassis

Transmission model MZZ6U


PTO power take off gear 4th counter gear
9
Outer diameter 131.1
Drawings
Chassis Frame

Helical angle against reference pitch circle 25°, Right


Module 3.0
Pressure angle 20°
Number of teeth 37
10
Addendum modification coefficient +0.073
Annex

Reference pitch diameter 122.47


Tooth height 8.3749
Over ball diameter 132.92
Measuring over ball diameter 6.0

106
1
5-3 Side PTO control

Outline
(1) Fitting the main body of a side PTO (MYY)

Side PTO
Transmission Fastening Fastening Distance 2
main body Bolt Stud bolt/Nut
model position position plate

Models
Various Vehicle
Specifications of
Principal
(Cable-type)
Flange type
Side 897286-908Y 04401-10250/
[196N・m MYY5T 02875-10300 ③, ④, ⑤ ①, ②, ⑥ ―
PTO 898092-476Y 09118-02100
(20kgf・m)]

3
Fitting a cable-type side PTO

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6
Precautions for installation of a side PTO

Equipments
Electrical
Regarding
Various Issues
• Remove grease and apply fluid packing (ThreeBond 1215 or equivalent) on
the contact surface between the transmission casing and PTO. Also, apply
fluid packing (LOCKTITE 242 or equivalent) on the fastened bolts and stud
7
bolts ①, ② and ⑥.

of the Springs
Characteristics
• Tightening torque is 27.5 to 45.1 N⋅m.
Note: Consult the ISUZU MOTORS dealership for details.
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

107
1
(2) Side PTO control (MYY)

Outline
Control of PTO Control device
Figure Applicable vehicle model
main body in cab
Electric Switch (Button) Fig.1 NLR85AL-EE1AYMX Only
PTO control All vehicle models
Cable Lever Fig.2 2
except the above

Models
Various Vehicle
Specifications of
Principal
Fig.1
3
Cabling PTO control lever

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
PTO switch

Fig.2
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
RHD shown. LHD is symmetrical. Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

108
Principal Various Issues
Precautions for Weight

109
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight Data
Models Equipments
Note: For genuine ISUZU MOTORS side PTO control, as a standard equipment,
there is a PTO indicator on the upper right side of the meter panel, that
indicates engagement of side PTO.

(3) Location of a PTO control lever (MZZ)


1
5-4 Installing a control cable

Outline
(1) 4JJ1-TCC LHD RIGID AXLE (NMR85L用)

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

the Springs
Characteristics of
Note:
1. These figures show installation of PTO cable.
2. When securing a cable, place marking on the cable in the center
between clips.
8
3. For tightening torque of the bolts and nuts, see ISA-M-003Y Table B.

Drawing
Cab-Chassis
4. Install PTO on/off lever while it is in off position.
5. Secure each bracket while they are in contact with adjacent part when
turned to the right.

Parts list
No. Part name UPC FNA Part number Qty Remarks No. Part name UPC FNA Part number Qty Remarks 9

Drawings
Chassis Frame
1 BRACKET ; PTO CONT CBL FRT 7A 4634B 898086 263Y 1 13 NUT ; PTO CONT CBL BRKT 7A 4635E 09118 01080 1
2 BOLT/SCREW ; PTO CONT CBL BRKT 7A 4635C 02865 14300 1 14 BRACKET ASM ; PTO CONT CBL 7A 4635A 898032 829Y 1 4JJ1 MT
3 NUT ; PTO CONT CBL BRKT 7A 4635E 09118 01140 1 15 CABLE ASM ; PTO CONT 937A 4630A 898117 185Y 1 4JJ1 MT
4 BRACKET ; PTO CONT CBL CTR 7A 4634H 898086 266Y 1 A/C 16 PIN ; PTO CONT CBL SWIV COT 7A 4640F 894111 137Y 1
5 BOLT/SCREW ; PTO CONT CBL BRKT 7A 4635C 02865 06200 1 A/C 17 WASHER ; PTO CONT CBL SWIV 7A 4640D 09161 47080 1
6 NUT ; PTO CONT CBL BRKT 7A 4635E 09118 01060 1 A/C 18 WASHER ; PTO CONT CBL SWIV 7A 4640D 50950 90010 1
7 BRACKET ; PTO CONT CBL CTR 7A 4634H 898086 265Y 1 A/C Less 19 BUSHING ; PTO CONT CBL LVR 7A 4700H 894367 367Y 1 10

Annex
8 BOLT/SCREW ; PTO CONT CBL BRKT 7A 4635C 02865 08250 1 A/C Less 20 SWIVEL;PTO CONT CBL 7A 4640B 894366 842Y 1
9 STRAP ; PTO CONT CBL 7A 4630S 897040 812Y 1 21 NUT ; PTO CONT CBL SWIV 7A 4640E 09111 05060 2
10 BRACKET ; PTO CONT CBL RR 7A 4634Q 898117 131Y 1
11 BRACKET ; PTO CONT CBL RR 7A 4634Q 898117 132Y 1
12 BOLT/SCREW ; PTO CONT CBL BRKT 7A 4635C 02865 08250 1

110
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
111
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Remarks
Qty
1
1
2
1
898050 126Y
09111 05060

89732 96100
09118 01060
Part number
463AC

464AC
4630G

4635E
FNA
937A
937A
937A
937A
UPC

BOLT/SCREW ; PTO CONT CBL BRKT


NUT ; PTO CONT CBL BRKT
RETAINER;PTO CONT CBL
NUT;PTO CONT CBL BRKT
Part name
Parts list
No.
1
2
3
4
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
112
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
(2) 4HK1-TCC LHD MZZ
1
5-5 Engine control

Outline
(1) Engine datum point
1) 4JJ1-TC
2
Unit: mm

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
Side D
Vehicle Drive
Transmission Engine Suspension member A B C Manual θ
model system
thickness T/M
5
NLR85A MYY5T 4JJ1-TCC 4×2 Independent 4.0 470 193.5 85 386 3°

Control
PTO and Engine
NMR85L MYY5T 4JJ1-TCC 4×2 Rigid 4.0 460 193.5 85 386 2.5°

6
2) 4HK1-TC

Equipments
Electrical
Regarding
Various Issues
MZZ6U transmission
Unit: mm
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

Side D
Vehicle Drive
Transmission Engine Suspension member A B C Manual θ
model system
thickness T/M 10
Annex

NPR75L-****
MZZ6U 4HK1-TCC 4×2 Rigid 6.0 493 185 148.6 294 2.5°
NQR75L-****

113
1
(2) External engine control lever

Outline
Movements of the cable connected to the rear body control device selected and
installed by body builder are converted into electrical signals, and these signals
are used for acceleration control. Since the external engine control lever is
2
connected to ECU with a harness, it can be installed in desired location.

Models
Various Vehicle
Specifications of
Principal
1) External engine control lever and harness
The external engine control lever must be connected to ECU. Connect the
above-mentioned harness to the connector of the harness laid on the 3
chassis frame as shown below.

Mounting
Rear Body
Precautions for
Note: When ordering a chassis with optional PTO, you need to check if
LEVER & BRKT ASM; ENG. CONT and HARNESS; EXT. PTO TPS will come
with it. If they do not come bundled, please order them along with the
4
chassis.

Weight Data
Distribution and
Weight
Connect the one end of the harness ② to the external engine control lever ①
and the other end to the connector located on the left side at the rear of the
3rd cross member.
5

Control
PTO and Engine
Required parts
No. Part No. Part name Qty Remarks
① 897219-4663 LEVER & BRKT ASM; ENG. CONT 1
② 897223-5780 HARNESS; EXT. PTO TPS 1 Length: 2.0m approx.
6

Equipments
Electrical
Regarding
Various Issues
The number or “Y” in the suffix position of each part number indicates the
level of product improvement. When placing an order, to get the latest suffix
number, replace suffix with “0”.
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

Note: To prevent ECU from being destroyed or the engine from


malfunctioning, strictly observe the following instructions:
10
• Before installing external engine control lever and harness, kill the
Annex

engine.
• When connecting harness, be sure that it is securely connected to
the connector and the lever.

114
Principal Various Issues
Precautions for Weight

115
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight Data
Models Equipments
Unit: mm

FULL OPEN

(2.1 kgf⋅m)
20.6 N⋅m
Lever opening
2) Detail view of external engine control lever

(0.5 kgf⋅m)
4.9 N⋅m
IDLE

Lever reaction
<Precautions for installation of an external engine control lever> 1

Outline
• Install external engine control lever in a place that is barely affected by
dust, grease, moisture, chemical and vibration. If the lever simply has to
be subjected to them, protect it with cover, rubber mount, etc.
2
• Do not place lever in such a place where it may receive a shock from

Models
Various Vehicle
Specifications of
Principal
falling objects, flying gravels, etc.

• Lever can be used at temperature in the range from −30°C to 75°C. The
ambient temperature must fall within this range.
3

Mounting
Rear Body
Precautions for
• When viewing a lever from above, the harness connected to the lever
must be installed within the area 90 degrees to the left and right from the
lever.
• To avoid interference from electric currents or signals on rear body, do 4

Weight Data
Distribution and
Weight
not tie the harness connected to the external engine control lever and any
harnesses laid on rear body (e.g. Power harness and signal harness)
together.
• Be sure that the installed harness is not twisted or excessively bent. To 5

Control
PTO and Engine
protect it from high temperature and vibration, secure it with band clips.
• Since the position sensor had been adjusted before shipment, do not
loosen its fixing bolt or disassemble it. Dropping or giving a shock to it will
result in malfunction or breakdown of the sensor. 6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

116
1
3) Harness route

Outline
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
Connect the one end of the harness ② to the external engine control lever ①
and the other end to the connector located on the left side at the rear of the
3rd cross member.
5

Control
PTO and Engine
Required parts
No. Part No. Part name Qty Remarks
① 897219-4663 LEVER & BRKT ASM; ENG. CONT 1
② 897223-5780 HARNESS; EXT. PTO TPS 1 Length: 2.0m approx.
6

Equipments
Electrical
Regarding
Various Issues
The number or “Y” in the suffix position of each part number indicates the
level of product improvement. When placing an order, to get the latest suffix
number, replace suffix with “0”.
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

117
1
5-6 Governor characteristics

Outline
(1) Outline of PTO control
For convenience and safety in rear body operation, the following settings can be
made through the PTO control: 2

Models
Various Vehicle
Specifications of
Principal
• Setting driving conditions that enable rear body operation while activating
PTO
• Switching between Rear Body Operation Governor Characteristic and
Running Governor Characteristic 3

Mounting
Rear Body
Precautions for
1) Switching acceleration modes
An input to the acceleration pedal position sensor enables the control by the
acceleration pedal, while an input to the external acceleration sensor enables
4
the control by the external engine control lever. When vehicle is in the

Weight Data
Distribution and
Weight
external engine control mode, both of the acceleration pedal and the external
engine control lever can be used.
2) Conditions for enabling the use of the external engine control lever, i.e.
5
conditions under which both of the engine control lever and the acceleration

Control
PTO and Engine
pedal are usable
All of the following conditions must be satisfied:

- None of the external acceleration sensor, transmission and acceleration 6

Equipments
Electrical
Regarding
Various Issues
pedal position sensor is defective.
- Status of vehicle: Stopped (Vehicle speed 20km/h or lower).
- Shift lever position: Neutral
7
- Acceleration pedal position: Released

of the Springs
Characteristics
- The engine speed is higher than the idle speed.
- External engine control lever position: IDLE
8
<Precautions>
Drawings
Cab Chassis

- If the starter key switch is turned off and back on while the external control
is in use, all of the conditions in the above 2) must be satisfied again.
- After completing any work with use of PTO, be sure to return the external 9
Drawings
Chassis Frame

engine control lever to IDLE. Keep this in mind because leaving the
external engine control lever opened may cause unexpected increase in
the engine speed. For instance, if a work with use of PTO is terminated by
shifting gear into a non-neutral position or if the PTO switch is turned off
10
while the lever is opened, the use of the external engine control lever is
Annex

disabled and the engine speed decreases, however, shifting gear back into
neutral switches to Rear Body Operation governor, increasing the engine
speed.

118
1
3) Conditions for disabling the use of the external engine control lever

Outline
Any of the following conditions is satisfied:
- Any of the external acceleration sensor, transmission or the acceleration
pedal position sensor is defective.
2

Models
Various Vehicle
Specifications of
Principal
- Shift lever position: Non-neutral
- Vehicle speed: 25km/h or higher
- Engine stall
3

Mounting
Rear Body
Precautions for
4) Switching the governor characteristics between Running Governor
Characteristic and Rear Body Operation Governor Characteristic
Satisfying all the conditions for enabling the use of the external engine
control lever and then opening the lever from IDLE switches to Rear Body 4

Weight Data
Distribution and
Weight
Operation Governor. When the acceleration pedal and the external engine
control lever happen to be operated at the same time, the ECU determines
which output (amount of fuel consumption) is larger, and reflects the
determination result on the engine.
5

Control
PTO and Engine
Fuel consumption amount
- External engine control lever > Acceleration pedal
⇒ Rear Body Operation Governor Characteristic
6
- Acceleration pedal > External engine control lever

Equipments
Electrical
Regarding
Various Issues
⇒ Running Governor Characteristic
5) Lengthening a signal harness for external engine control
7
When lengthening the harnesses for external engine control, be sure that the

of the Springs
Characteristics
resistance of the power harness, the ground harness and the signal harness
do not increase. Especially, high resistance of the ground harness increases
the voltage of the external control signal, creating a condition as if the
external engine control lever is being opened. This may result in malfunction 8
Drawings
Cab Chassis

of PTO or sudden increase in the engine speed.


Protect the harnesses from external noise. Just like the harness for the
acceleration pedal, appropriately route and secure the harnesses.
9
Drawings
Chassis Frame

10
Annex

119
1
6) Effect of a PTO electromagnetic clutch on a crank sensor

Outline
When using an electromagnetic clutch to supply or cut the power from PTO,
noise from the electromagnetic clutch may be superimposed on the crank
sensor, possibly causing engine control problems such as unstable engine
2
rotation, torque down in response to the detection of engine troubles, and

Models
Various Vehicle
Specifications of
Principal
engine stop.
7) Acceleration interlocking
Do not perform any modification to make the acceleration pedal unusable
3
when working rear body with use of PTO. Such prohibited modification

Mounting
Rear Body
Precautions for
includes interrupting an acceleration pedal sensor signal and inputting it to a
dummy sensor. Vehicles that undergo prohibited modifications will be
shipped without safety evaluation of safety-critical components, and may
possibly cause runaway accidents. 4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

120
Principal Various Issues
Precautions for Weight

121
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight Data
Models Equipments
4HK1-TCC (Mexico regulations) Rear Body Operation Governor Characteristic curve
4JJ1-TCC (Mexico regulations) Rear Body Operation Governor Characteristic curve
1
6 Various Issues Regarding Electrical Equipments

Outline
6-1 Working voltage and output characteristics of AC generators
(1) The following tables show the working voltages and the capacity of the AC
generators for the standard vehicle models: 2

Models
Various Vehicle
Specifications of
Principal
24V
AC generator output
Vehicle model Engine model Working voltage
Standard Option
NLR 4JJ1-TCC 24V 50A 80A 3

Mounting
Rear Body
Precautions for
NPR 4JJ1-TCC 24V 50A 80A

12V
AC generator output
Vehicle model Engine model Working voltage 4
Standard Option

Weight Data
Distribution and
Weight
NPR 4HK1-TCC 12V 110A —
NQR 4HK1-TCC 12V 110A —

Control
PTO and Engine
(2) The output characteristics of the AC generators are as follows:

ACG AC generator output 24(V)/50(A) AC generator output 24(V)/80(A) 6

Equipments
Electrical
Regarding
Various Issues
Engine speed (r/m) Engine speed (r/m)
Engine 500 1500 500 1500
4J type 10 (A) 50 (A) 30 (A) 80 (A)

of the Springs
Characteristics
ACG AC generator output 12(V)/110(A)
Engine speed (r/m)
Engine 500 1500
4H type 40 (A) 110 (A)
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

122
1
6-2 Precautions for modification of electrical components

Outline
• Basically, modification to the factory-installed electrical components such as
harnesses, fuses and relays are prohibited. Do not tear protective corrugated
tubes and pull out inside harnesses to connect add-on equipments because this
2
may damage the remaining harnesses inside the corrugated tubes.

Models
Various Vehicle
Specifications of
Principal
• If the shape of the rear body of a completed vehicle constrains rain or vehicle
washing water to concentrate into particular portions of the vehicle, be sure to
keep connectors, relay box, and other factory-installed/add-on electric
equipments away from such water. In this case, attach panels, gutters, etc. to 3

Mounting
Rear Body
Precautions for
disperse and let out water to the outside of the vehicle. Be fully aware that
exposing connectors, relay box, and electric equipments to such water may
cause water intrusion into electric components or internal condensation,
resulting in problems such as operational malfunction, and in the worst case, a 4
vehicle fire.

Weight Data
Distribution and
Weight
• When lengthening or modifying electric harnesses, follow the instructions below.
The section 6-9 Circuit diagrams shows the electrical circuits on the ISUZU
MOTORS’ chassises. 5

Control
PTO and Engine
[Lengthening or shortening an electric wire or a cable]
(1) Do not change the length of a battery cable by splicing a different cable to it or
cutting it. If the length of a battery cable needs to be changed, replace it with a
6
new solid cable in length and diameter that satisfy required electrical load and

Equipments
Electrical
Regarding
Various Issues
distance. As for the harness connected to the starter, in consideration of the
relative movement between the starter and a chassis frame, changing its
clipping points, the way how it is secured, and the sagging volume are strictly
prohibited. 7

of the Springs
Characteristics
(2) Disconnecting or connecting battery
cables
1) Disconnecting battery cables
8
Drawings
Cab Chassis

a) Turn off all the switches.


b) Disconnect the ground cable ①.
c) Disconnect the positive cable ②.
d) Disconnect the battery cable ③.
9
Drawings
Chassis Frame

! Caution
Disconnect the ground cable first. If disconnecting the positive cable before
the ground cable, during disconnecting a terminal with a tool, such tool may
contact with battery casing, etc. and cause a short circuit. 10
Annex

123
1
2) Connecting battery cables

Outline
Connect battery cables following the procedure for cable disconnection in
reverse order.

! Caution 2

Models
Various Vehicle
Specifications of
Principal
To prevent battery terminals from corroding, clean them and lightly apply
grease on them.

(3) When lengthening a harness, splice a new harness with the same section area
and color as those of the harness to be lengthened. Do not splice them inside 3

Mounting
Rear Body
Precautions for
corrugated tube.

(4) When splicing a harness to an end of another harness, for secure connection,
twist them together and then solder the area or clamp with a crimping terminal
by using a specified crimping tool. After that, to insulate the area, remove burrs 4

Weight Data
Distribution and
Weight
and wrap with an adhesive lined heat shrink tubing.

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
Covering the splice with butyl rubber 7

of the Springs
Characteristics
Butyl rubber 182698-263Y

8
Drawings
Cab Chassis

9
As for the area where spliced harnesses may be subjected to vibration, splicing
Drawings
Chassis Frame

with crimping terminals is recommended rather than by soldering because there


is possibility that solder may seep into the inside of the harnesses, making them
harden and lose flexibility, and consequently resulting in harness separation.
10
Do not splice harnesses by only twisting them together without soldering.
Annex

124
1
(5) When splicing harnesses outside a cab, for example on the chassis frame,

Outline
apply appropriate coating (e.g. Epoxy resin coating) on the splice in order for
waterproofing and insulation.
(6) Since there is possibility of separation, do not splice harnesses in such an area
2
where the harnesses may produce relative vibration.

Models
Various Vehicle
Specifications of
Principal
(7) When shortening a harness, do not cut it but tie its redundancy with a vinyl tape,
and then bind it to the factory-installed harnesses or something else.
[Connectors]
3

Mounting
Rear Body
Precautions for
(1) Waterproof connector
Use waterproof connectors for the
harnesses placed outside a cab. Do
not unnecessarily disconnect these 4

Weight Data
Distribution and
Weight
waterproof connectors, otherwise
continuity failure will occur. When
disconnecting waterproof connectors,
to prevent foreign substances such as 5
water and metal chips from getting into

Control
PTO and Engine
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 got into the joint, remove such foreign substance or dry up the joint 6

Equipments
Electrical
Regarding
Various Issues
before connecting the connectors.

Note: As for the area where connectors may be subjected to vibration, use
connectors with a detach-safe lock.
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

125
(2) Disconnecting connectors 1

Outline
Certain types of connectors have a
tang lock that prevents these
connectors from coming off when
vehicle is running. 2

Models
Various Vehicle
Specifications of
Principal
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. 3

Mounting
Rear Body
Precautions for
To prevent harnesses from coming off
from the connector or breaking, when
disconnecting connectors, do not pull
the harnesses but securely hold both 4

Weight Data
Distribution and
Weight
connectors (male and female), release
the tang lock, and then separate the
connectors with care.
5

Control
PTO and Engine
(3) Connecting connectors
Securely hold both connectors (male
6
and female) and check whether the

Equipments
Electrical
Regarding
Various Issues
connector pins and the cavities match.
Also, check whether the connectors are
aligned. Securely hold the connectors
and carefully engage them by pushing 7

of the Springs
Characteristics
until you hear the connectors click.

(4) Checking connectors


8
Use a circuit tester to check the
Drawings
Cab Chassis

continuity of a connector. Insert test


probes of the circuit tester from the
harness side. This continuity check
9
should be avoided unless absolutely
Drawings
Chassis Frame

necessary.
When doing a continuity check, do not
insert the test probes into the cavities of
10
the connector. This will deform the
Annex

connecter terminal and cause continuity


failure.

126
1
(5) Removing a connector pin

Outline
1) Built-in tang lock

a) Insert a slender shaft into the


opening of the connector housing. 2

Models
Various Vehicle
Specifications of
Principal
b) Push up the tang lock in the
direction of arrow in the figure.
Remove the harness and the
connector pin from the harness 3

Mounting
Rear Body
Precautions for
side.
2) Pin-type tang lock
a) Insert a slender shaft into the
4
opening of the connector housing.

Weight Data
Distribution and
Weight
b) Push the tang lock toward the
harness side so as to make it flat.
Remove the harness and the
5
connector pin from the harness

Control
PTO and Engine
side.
(6) Inserting a connector pin
a) Check if the tang lock is upright.
6

Equipments
Electrical
Regarding
Various Issues
b) Insert a connector pin from the
harness side. Push the pin until
the tang lock is securely engaged.
c) Gently pull the harness to check if 7

of the Springs
Characteristics
the pin is securely in place.
(7) Using a “GIBOSHI” type plug
When using a “GIBOSHI” type plug, be sure that its socket connector (female)
8
with insulation cover is on the power source side and its plug connector (male)
Drawings
Cab Chassis

on the electric load side. This prevents disconnected “GIBOSHI” type plug from
shorting when it comes off and contacts with vehicle body.
[Harness routing]
9
<General note>
Drawings
Chassis Frame

• When laying additional harnesses, be sure that they will not restrict
inspection or maintenance of vehicle components.
10
• To increase reliability of the harnesses, protect all add-on harnesses with
Annex

corrugated tubes or PVC tubes.


• When handling the harnesses, do not pull them hard.

127
1
<Routing>

Outline
• Add-on 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 2
parts or sharp objects.

Models
Various Vehicle
Specifications of
Principal
Object Required distance between harness and object
Moving part 10mm (0.4 in.) at minimum ( at closest approach)
Sharp object 10mm (0.4 in.) at minimum 3

Mounting
Rear Body
Precautions for
• If there is possibility that a harness contacts with a sharp edge of a metal
part, secure the harness somewhere distant from the sharp edge by using
clips, or cover the sharp edge with a protector, otherwise vibration will 4

Weight Data
Distribution and
Weight
damage the harness coating. To prevent harness coating from being
damaged, attach grommets to the through holes in steel plates.

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
• 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. 8
Drawings
Cab Chassis

• 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.
9
Drawings
Chassis Frame

10
Annex

128
1
• If there are factory-installed harnesses nearby, secure add-on harness on

Outline
them with tapes or nylon clips.

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
• Do not tape wrap an add-on harness directly on a metal pipe or a rubber
hose including the brake pipe and the fuel pipe. Provide sufficient clearance 5

Control
PTO and Engine
between such pipe/hose and the harness.

Positional relation Clearance between harness and pipe/hose


Parallel 10mm (0.4 in.) at minimum
Intersecting 20mm (0.8 in.) at minimum 6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

129
1
<Moving harness>

Outline
• When connecting an additional harness to any equipment that produces
relative vibration against chassis frame, such as an engine and transmission,
reasonably slacken the harness and lay it along the factory-installed
2
harnesses so as to absorb the relative vibration. Be sure that the add-on

Models
Various Vehicle
Specifications of
Principal
harness does not contact with neighboring parts/equipments.

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
• As for the factory-installed harnesses connected to the equipments that 5
produce relative vibration against chassis frame, such as an engine and

Control
PTO and Engine
transmission, do not change the way how they are secured, the clipping
points, and the sagging volume.

<Heat protection> 6

Equipments
Electrical
Regarding
Various Issues
• 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). For details, see the
subsection 1) ① Clearance between an exhaust system component and a 7

of the Springs
Characteristics
neighboring component under 3-1 (4) Precautions for an exhaust system,
and the “Allowable temperature” column of the table under the next section
6-3 (3) Harness size.
• Most of the harnesses placed inside the engine room should be wrapped in 8
Drawings
Cab Chassis

heatproof vinyl tape, and laid along and bound to the factory-installed
chassis harnesses with band clips.

<Clip>
9
Drawings
Chassis Frame

• Use resin clips, or vinyl- or rubber-coated clips whose base material is


rustproofed. Use clips and connectors manufactured for automobiles.
• To minimize vibration of the harnesses, space clips as follows:
10
Annex

Harness diameter Distance between clips


Smaller than 5mm (0.2 in.) 300mm (11.8 in. ) at maximum
5mm to 10mm (0.2 in. to 0.4 in.) 400mm (15.7 in.) approx.
10mm to 20mm (o.4 in. to 0.8 in.) 500mm (19.7 in.) approx.

130
1
• Adhesive clips should be used only as supplemental parts. Especially, in

Outline
such a place like the engine room where ambient temperature is high, use
rubber- or vinyl-coated plate clips or band clips. Do not use non-heatproofed
vinyl tape or adhesive clips to bind add-on harnesses to the factory-installed
harnesses because they will come unstuck due to heat aging. 2

Models
Various Vehicle
Specifications of
Principal
<Others>
• To prevent water intrusion through wires into equipments, securely seal the
inlet ports of the equipment with grommets and make sure that the wire
3
terminals are placed above such inlet ports.

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6
• If it is inevitable to disconnect chassis harnesses due to rear body mounting,

Equipments
Electrical
Regarding
Various Issues
after the body mounting, be sure to put them back in place exactly as before
the disconnection.
• When installing equipments on a chassis, be sure that they do not crush 7
harnesses.

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

131
[Precautions for electric welding] 1

Outline
Improper welding causes welding current to flow back from the ground circuit,
possibly damaging electrical equipments and components. When performing
electric welding, follow the instructions below:
2
<Welding procedure>

Models
Various Vehicle
Specifications of
Principal
1. Turn off the starter key switch.
2. Disconnect the negative battery terminal.
3
3. Disconnect the fuse for the airbag. For the location of the fuse, see the

Mounting
Rear Body
Precautions for
section 6-4 (1).

Welding current flow direction (Reference)


4

Weight Data
Distribution and
Weight
Poor example: Performing welding without following the procedure 1 through 4

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
Good example: Performing welding following the procedure 1 through 4

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

132
1
4. Secure the ground cable of the electric welder in the vicinity of welding site.

Outline
• Cab welding
Attach the welder’s ground cable to a plated bolt or metallic part of the
cab in the vicinity of welding site. Before securing the ground cable on
2
such a metallic part, peel off the paint on the area to reveal its metallic

Models
Various Vehicle
Specifications of
Principal
base.
• Chassis welding
Attach the welder’s ground cable to a plated bolt or a chassis frame 3

Mounting
Rear Body
Precautions for
member in the vicinity of welding site. Before securing the cable on the
chassis frame member, peel off the paint on the area to reveal its base.
Do not attach the ground cable on the chassis spring, otherwise the
spring may break.
4

Weight Data
Distribution and
Weight
5. Precautions for welding
• Keep the chassis frame dry.
• To prevent welding spatters from adhering to any components located
5
near welding site such as rubber hoses, electric harnesses, pipes,

Control
PTO and Engine
chassis spring, tires, radiator and resin parts, cover them up before
welding. Especially, when performing welding in the area within 200mm
from a fuel tank, remove the fuel tank before welding.
6
• To minimize impact of heat on peripheral area and to assure welding

Equipments
Electrical
Regarding
Various Issues
quality, select a suitable welding torch and perform welding at suitable
welding conditions.

6. After completing welding, put the disconnected components such as fuses


7
and negative battery terminal back in place exactly as before the

of the Springs
Characteristics
disconnection. If you peeled off the paint on the chassis frame or the cab,
apply anticorrosion paint in the same color on them.
7. After reconnecting the above components, check if the equipments work
8
normally.
Drawings
Cab Chassis

8. Do not cool down welds rapidly.

9
Drawings
Chassis Frame

10
Annex

133
1
[Precautions for other works]

Outline
1. When drilling or cutting a chassis frame, see the section 3-3 (2) Drilling or
welding a chassis frame. Be sure not to damage electric harnesses and
pipes.
2
2. When fitting any additional components, be sure that they do not squeeze or

Models
Various Vehicle
Specifications of
Principal
crush the harnesses.
3. If you removed clips for doing some works, put these clips back in place after
such works. If harnesses cannot be clipped because more harnesses have
3
been added by add-on equipment(s), use appropriately-sized clips.

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

134
1
6-3 Electric wiring

Outline
(1) Harnesses
• Improper use of harnesses may result in fire or equipment breakdown. If
additional harnesses are required, select appropriate harnesses according to 2
the load current to be added, the circuit length, and the harness route.

Models
Various Vehicle
Specifications of
Principal
• Use the following JIS-certified electric harnesses for automobiles, or
equivalent:
- For common area: AV (Low-voltage harness for automobile) or AVS (Thin- 3
walled low-voltage harness for automobile)

Mounting
Rear Body
Precautions for
- For the area that needs heat protection: AVX (Cross-linked vinyl insulated
heat resistant low-voltage harness for automobile) or AEX (Cross-linked
polyethylene insulated heat resistant low-voltage harness for automobile)
4
• When using an AEX harness, parts used with it such as protection tube,

Weight Data
Distribution and
Weight
corrugated tube, vinyl tape, etc. should also be heatproofed.
• When using a harness whose size is 5sq or larger, solder the pressured
part inside the harness terminal to prevent it from heating.
5

Control
PTO and Engine
(2) Harness color
Every harness is covered with insulation
material with specific color code. The
main harnesses used for electric 6

Equipments
Electrical
Regarding
Various Issues
systems are in solid color (1) while the
sub harnesses are with tracers (2).
The following is an example of a color
code of a harness with tracer: 7

of the Springs
Characteristics
0.5 G / R
Red (tracer color)
Green (base color)
Diameter (0.5mm2)
8
Drawings
Cab Chassis

The harness colors are abbreviated in circuit diagrams as follows:

Color code Color Color code Color Color code Color


B Black L Blue P Pink
W White O Orange LB Light Blue 9
Drawings
Chassis Frame

R Red BR Brown V Violet


G Green LG Light Green
Y Yellow GR Grey

Application of each harness is as follows: 10


Annex

Code B W R G Y L Br Lg
Harness color Black White Red Green Yellow Blue Brown Light green
Starting,
Application Charger Light Signal Meter Wiper Auxiliary Others
Grounding

135
1
(3) Harness size

Outline
The size of each harness to be used in a

circuit is determined by the current
amount (ampere) that will flow into the
2
harness, the circuit length, the allowable

Models
Various Vehicle
Specifications of
Principal
voltage drop amount, etc.
The following table shows sizes,

allowable temperature and allowable
current of AV, AVS, AVX and AEX 3
harnesses. AWG (American Wire

Mounting
Rear Body
Precautions for
Gauge) also specifies harness sizes and
allowable current. The nominal size of a
harness means its section area.
4

Weight Data
Distribution and
Weight
Harness Allowable Allowable current (ampere)
Remarks
type temperature 0.5sq 0.85sq 1.25sq 2sq 3sq 5sq 8sq
AV 80° 9A 11A 14A 20A 27A 36A 47A
No
AVS 80° 8A 11A 14A 19A 26A 35A
spec. 5

Control
PTO and Engine
AVX 90° 8A 10A 13A 17A 24A 33A 43A
AEX 110° 7A 9A 12A 17A 23A 32A 42A
External diameter (mm) ③ 2.0 2.2 2.5 2.9 3.6 4.4 5.5
Section area (mm2) ④ 0.563 0.885 1.287 2.091 3.296 5.227 7.952
AWG size 20 18 16 14 12 10 8 6

Equipments
Electrical
Regarding
Various Issues
Note: “Allowable temperature” means “Ambient temperature” + “Self-heating
temperature”.
7
“Allowable current” is a current that is allowed to flow into a harness when

of the Springs
Characteristics
the “Self-heating temperature” is approximately 20°C.

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

136
1
(4) Harness size and circuit length

Outline
Fuse value on the power source side determines usable harness size and circuit
length. Select appropriate harness size in consideration of the fuse value on the
power source side and the harness route.
2

Models
Various Vehicle
Specifications of
Principal
Fuse Harness size and circuit length
Allowable
Rating
Type continuous 0.5sq 0.85sq 1.25sq 2sq 3sq 5sq 8sq
capacity
current
5A 3.5A Max.25m Max.40m – – – – –
3
7.5A 5.2A Max.15m Max.25m Max.40m – – – –

Mounting
Rear Body
Precautions for
Blade 10A 7.0A Max.10m Max.20m Max.30m – – – –
fuse 15A 10.5A Max.5m Max.10m Max.15m Max.30m Max.45m – –
20A 14.0A × Max.5m Max.10m Max.20m Max.30m – –
25A 17.5A × × Max.10m Max.15m Max.25m Max.40m –
4
30A 15.0A × × × Max.10m Max.15m Max.30m Max.45m

Weight Data
Distribution and
Weight
SBF 40A 20.0A × × × × Max.10m Max.20m Max.30m
(Slow- 50A 25.0A × × × × × Max.15m Max.25m
blow 60A 30.0A × × × × × Max.15m Max.20m
fuse)
80A 40.0A × × × × × × Max.15m
5
100A 50.0A × × × × × × Max.10m

Control
PTO and Engine
Legend: ×: Cannot be used –: 50m at maximum
If a harness is connected to an equipment that produces relative movement, to
prevent wire breaking, the size of the harness should be 0.85sq or larger. 6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

137
1
6-4 Fuses

Outline
(1) Purpose of use
Fuse is a most common device for
circuit protection. Improper use of fuses Normal Blown
2
may result in fire or equipment

Models
Various Vehicle
Specifications of
Principal
breakdown. When fitting an additional
equipment, select an appropriate fuse
for it taking its load current and
maximum capacity of the fuse into 3

Mounting
Rear Body
Precautions for
account.
A fuse consists of a thin wire piece or a
metal piece contained in a glass or a
plastic housing. 4

Weight Data
Distribution and
Weight
Each fuse is placed in series with a circuit that the fuse protects. If overcurrent
flows into the circuit due to factors such as short-circuit of a ground harness, the
said wire/metal piece burns out, blocking the current flow. Thus each fuse
protects the equipment connected to it and also other equipments connected in 5

Control
PTO and Engine
the circuit from being damaged by overcurrent.
(2) Location of the fuses in a cab
As shown in the Fig.1, the fuses 1 through 30 are located in the central part of
6
the dashboard.

Equipments
Electrical
Regarding
Various Issues
Fig.1 Location of the fuses and relays in a cab (RHD is shown. LHD is same position.)

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

138
Principal Various Issues
Precautions for Weight

139
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight Data
Models Equipments
(3) Location of the fuses in the fuse box and equipments connected to them
The Fig.2 shows the location of the 30 fuses in the fuse box.

Fig.2 Location of the fuses in the fuse box


24V (85L-4JJ1) 1

Outline
1 20A ELEC PTO (BATT) 16 15A ELEC PTO (KEY ST)
TOMA DE POTENCIA ELECTRICA TOMA DE POTENCIA ELECTRICA
(BAT) (ARR LLAVE)
2 15A RR P/WINDOW 17 15A STARTER
VENTANIILLA AUTO.TR MOTOR DE ARRANQUE 2

Models
Various Vehicle
Specifications of
Principal
3 15A ROOM LAMP, AUDIO 18 15A IGNITION 1
LAMPARA INTERIOR, AUDIO ENCENDIDO 1
4 15A DOOR LOCK 19 10A SRS
BLOQUEO DE LAS PUERTAS SISTEMA DE SEGURIDAD
SUPLEMENTARIO 3
5 10A FOG LIGHT 20 10A ECM

Mounting
Rear Body
Precautions for
LUCES ANTINIEBLA ECM
6 20A P/WINDOW 21 10A METER
VENTANIILLA AUTO MEDIDOR
7 10A ABS 22 10A LAMPS (BATT) 4

Weight Data
Distribution and
Weight
ABS LUCES (BATERIA)
8 20A WIPER 23 15A AUDIO ACC
LIMPIAPARABRISAS ACCESORIOS AUDIO
9 10A H/LAMP LO (LH) 24 15A MIRROR
LUZ DE CRUCE DEL FARO(IZQ) ESPEJOS RETROVISORES 5

Control
PTO and Engine
10 10A ECU (BATT) 25 15A HORN
ECU(BATERIA) BOCINA
11 10A H/LAMP LO (RH) 26 15A TURN, HAZARD
LUZ DE CRUCE DEL FARO (DER) LUCES DE GIRO, AVISO DE
PELIGRO
6
12 10A BRAKE LAMP 27 10A TAIL LAMPS

Equipments
Electrical
Regarding
Various Issues
LUCES DEL FRENO LUCES DE COLA
13 10A IGNITION 2 28 10A ILLUMINATION
ENCENDIDO 2 ILUMINACION
14 10A H/LAMP HI (LH) 29 10A CORNERING LAMPS/FF FOG LAMP
7
LUZ DE CARRETERA DEL FARO LUZ DE GIRO

of the Springs
Characteristics
(IZQ)
15 10A H/LAMP HI (RH) 30 20A BLOWER MOTOR
LUZ DE CARRETERA DEL FARO MOTOR DE SOPLADOR
(IDER)
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

140
24V (85L-4JJ1) 1
Electric equipments connected to the fuses

Outline
Fuse Current Major equipments that produce
Label
No. capacity electrical load
F-1 20A ELEC PTO (BATT) Electric power take off (Battery)
F-2 15A RR P/WINDOW Rear power window 2
F-3 15A ROOM LAMP, AUDIO Doom lamp

Models
Various Vehicle
Specifications of
Principal
F-4 15A DOOR LOCK Door lock actuator
F-5 15A FT FOG LAMP Front fog lamp
F-6 20A P/WONDOW Power window
F-7 10A ABS Antilock brake system 3

Mounting
Rear Body
Precautions for
F-8 20A WIPER Front wiper, washer
F-9 10A H/LAMP LO (LH) Head lamp low left side
F-10 10A ECU (BATT) Engine control unit (Battery)
F-11 10A H/LAMP LO (RH) Head lamp low (Right side)
F-12 10A STOP LAMP 4

Weight Data
Distribution and
Weight
F-13 10A IGNITION 2 Starter key switch 2
F-14 10A H/LAMP HI (LH) Head lamp high (Left side)
F-15 10A H/LAMP HI (RH) Head lamp high (Right side)
F-16 15A ELEC PTO (KEY ST) Electric power take off (Starter key switch)
F-17 15A STARTER 5

Control
PTO and Engine
F-18 15A IGNITION 1 Starter key switch 1
F-19 10A SRS Supplement restraint system
F-20 10A ECM Engine control module
F-21 10A METER Meter, tachograph, pilot lamp
F-22 10A LAMPS (BATT) Lamps (Battery) 6

Equipments
Electrical
Regarding
Various Issues
F-23 15A AUDIO, ACC Audio, accessory
F-24 15A MIRROR Side mirror
F-25 15A HORN
F-26 15A TURN, HAZARD Turn signal lamp, hazard signal lamp
F-27 10A TAIL LAMPS 7

of the Springs
Characteristics
F-28 10A ILLUMINASION Illumination lamp
F-29 10A CORNERING LAMPS/RR FOG LIGHT Cornering lamp, rear fog lamp
F-30 20A BLOWER MOTOR Air conditioner blower motor

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

141
12V (75L-4HK1) 1

Outline
1 25A RR P/WINDOW 16 10A BLOWER (IG)
VENTANIILLA AUTO.TR. SOPLADOR (ENCENDIDO)
2 15A FOG LAMP 17 10A IGNITION 2
LUCES ANTINIEBLA ENCENDIDO 2
3 10A ROOM LAMP, AUDIO 18 10A IGNITION 1 2
LAMPARA INTERIOR, AUDIO ENCENDIDO 1

Models
Various Vehicle
Specifications of
Principal
4 15A DOOR LOCK 19 — —
BLOQUEO DE LAS PUERTAS
5 10A EXAUST BRAKE (4JB1) 20 10A ECM
FRENO DE ESCAPE ECM
3
6 25A P/WINDOW 21 10A METER

Mounting
Rear Body
Precautions for
VENTANIILLA AUTO. MEDIDOR
7 10A ABS 22 10A ECU (BATT)
ABS ECU (BATERIA)
8 25A WIPER 23 10A MIRROR
LIMPIAPARABRISAS ESPEJOS RETROVISORES 4

Weight Data
Distribution and
Weight
9 10A H/LAMP LO (LH) 24 15A ACCESSORY, AUDIO
LUZ DE CRUCE DEL FARO (IZQ) ACCESORIOS AUDIO
10 10A LAMPS (BATT) 25 15A HORN
LUCES (BATERIA) BOCINA
11 10A H/LAMP LO (RH) 26 15A TURN, HAZARD 5

Control
PTO and Engine
LUZ DE CRUCE DEL FARO (DER) LUCES DE GIRO, AVISO DE
PELIGRO
12 10A BRAKE LAMP 27 10A TAIL LAMPS
LUCES DEL FRENO LUCES DE COLA
13 10A STARTER 28 10A ILLUMINATION
6
MOTOR DE ARRANQUE ILUMINACION

Equipments
Electrical
Regarding
Various Issues
14 10A H/LAMP HI (LH) 29 10A CORNERING LAMPS
LUZ DE CARRETERA DEL FARO LUZ DE GIRO
(IZQ)
15 10A H/LIGHT HI (RH) 30 20A AIR CONDITIONER
LUZ DE CARRETERA DEL FARO AIRE ACONDICIONADO 7
(DER)

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

142
12V (75L-4HK1) 1

Outline
Electric equipments connected to the fuses
Fuse Current Major equipments that produce
Label
No. capacity electrical load
F-1 25A RR P/WINDOW Rear power window
F-2 15A FOG LAMP Front fog lamp 2
F-3 10A ROOM LAMP, AUDIO Doom lamp, audio

Models
Various Vehicle
Specifications of
Principal
F-4 15A DOOR LOCK Door lock actuator
F-5 10A EXHAUST BRAKE (4JB1) Exhaust brake (4JB1 engine)
F-6 25A P/WINDOW Power window
F-7 10A ABS Anti lock brake system 3

Mounting
Rear Body
Precautions for
F-8 25A WIPER Front wiper, washer
F-9 10A H/LAMP LO (LH) Head lamp low left side
F-10 10A LAMPS (BATT) Lamps (Battery)
F-11 10A H/LAMP LO (RH) Head lamp low (Right side)
F-12 10A BRAKE LAMP Stop lamp 4

Weight Data
Distribution and
Weight
F-13 10A STARTER Starter key switch 2
F-14 10A H/LAMP HI (LH) Head lamp high (Left side)
F-15 10A H/LAMP HI (RH) Head lamp high (Right side)
F-16 10A BLOWER (IG) Blower motor (IG)
F-17 10A IGNITION 2 Starter key switch 12 5

Control
PTO and Engine
F-18 10A IGNITION 1 Starter key switch 1
F-19 — — —
F-20 10A ECM Engine control module
F-21 10A METER Meter, tachograph, pilot lamp
F-22 10A ECU (BATT) Engine control unit (Battery) 6

Equipments
Electrical
Regarding
Various Issues
F-23 10A MIRROR Side mirror
F-24 15A ACCESSORY, AUDIO Accessory, audio
F-25 15A HORN Horn
F-26 15A TURN, HAZARD Turn signal lamp, hazard signal lamp
F-27 10A TAIL LAMPS Tail lamps 7

of the Springs
Characteristics
F-28 10A ILLUMINASION Illumination lamp
F-29 10A CORNERING LAMPS Cornering lamp
F-30 20A AIR CONDITIONER Air conditioner blower motor

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

143
1
(4) Location of the relay box attached in the cab back area

Outline
The Fig.3 shows the location of the relay box that is housing the slow-blow
fuses 17 through 28 and the fuses 29 and 36.

Fig.3 Location of the outside relay box 2

Models
Various Vehicle
Specifications of
Principal
3
Relay box

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
(5) Location of the fuses in the relay box attached on a chassis frame and
5
equipments connected to them

Control
PTO and Engine
The Fig.4 shows the location of the slow-blow fuses 17 through 28 and the
fuses 29, 31, 35 and 36 in the relay box.

Fig.4 Location of the slow-blow fuses and fuses 6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

Location of the slow-blow fuses (24V)


17 ECM 23 AMT 9
Drawings
Chassis Frame

18 Starter 24 Headlamp
19 Power source 25 HAB
20 Glow 26 Wiper, HVAC
21 Ignition 27 ABS
22 B/Ignition-1 28 Junction block 10
Annex

Location of the fuses (24V)


29 Marker lamp 35 A/C
31 ECM main 36 Radiator fan

144
Principal Various Issues
Precautions for Weight

145
Specifications of PTO and Engine Regarding Characteristics Cab Chassis Chassis Frame

10
Outline Rear Body Distribution and Annex
3

9
1

5
4

Various Vehicle Control Electrical of the Springs Drawings Drawings


Mounting Weight Data
Models Equipments
35 Air conditioner
28 Junction block
26 HVAC, Wiper

36 Radiator fan
24 Headlamp
23 —

25 —

27 —
Location of the slow-blow fuses (12V)

Location of the fuses (12V)


29 Marker lamp

31 ECM main
30 Tail main
18 Starter

20 Glow
17 ECM

21 AM2
22 AM1
19 —
1
6-5 Relays

Outline
(1) Purpose of use
In order for flexibility in mounting location, to prevent drop in voltages that are
input to equipments, that is caused by shorting a load current circuit, and to 2
reduce the load on switches, most of the control switches have relays installed

Models
Various Vehicle
Specifications of
Principal
in their circuits. When adding an equipment or lengthening a circuit, be sure to
install an additional relay to protect switches and to prevent voltage drop.
(2) Location
3

Mounting
Rear Body
Precautions for
Relays are installed in the fuse box and the relay box which is located on the left
side of the outside cab back area, respectively shown in the Fig.1 and Fig.3 in
the previous section.
To preserve the functions of the factory-installed circuits, modifying the inside of 4

Weight Data
Distribution and
Weight
relay box and installing additional components (e.g. Harness) in relay box are
prohibited. If you need to add a relay, install it in one of the free cavities
provided for extra relays inside the relay box, or place a waterproofed box and
install the relay in it.
5

Control
PTO and Engine
(3) Location of the relays and equipments connected to them
The Fig.5 and Fig.6 show the location of the relays in the fuse box inside a cab
and in the relay box in the cab back area respectively. Relays 17 to 20 in Fig.5
are only used for 75L (4HK1, 12V) model. 6

Equipments
Electrical
Regarding
Various Issues
Fig.5 Location of the relays in the fuse box for cab

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

146
24V 1

Outline
1 STOP LAMP 9 FOG LAMP
2 BLOWER MOTOR 10 PTO MAIN
3 KEY ON (ACCESSORY) 11 DOOR LOCK (UNLOCK)
4 DOOR LOCK (LOCK) 12 POWER WINDOW
5 RR FOG LAMP 13 HEAD LAMP (LOW) 2

Models
Various Vehicle
Specifications of
Principal
6 WIPER MAIN 14 —
7 HORN 15 HEAD LAMP (HI)
8 WIPER (HI/LOW) 16 TAIL

3
12V

Mounting
Rear Body
Precautions for
1 STOP LAMP 11 BATTERY CHARGE
2 — 12 POWER WINDOW
3 KEY ON (ACCESSORY) 13 HEAD LAMP (LOW)
4 — 14 VACUUM PUMP 4
5 CORNERLING LAMP 15 HEAD LAMP (HI)

Weight Data
Distribution and
Weight
6 WIPER MAIN 16 TAIL
7 HORN 17 —
8 WIPER (HI/LOW) 18 CIGER LIGHTER
9 EXHAUST BRAKE 19 POWER ACC 5

Control
PTO and Engine
10 — 20 BLOWER

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

147
1
Fig.6 Location of the relays in the relay box

Outline
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
24V 4

Weight Data
Distribution and
Weight
1 STARTER 6 STARTER CUT OFF
2 ECM MAIN 7 EXHAUST BRAKE
3 GLOW 8 SHIFT CONTROL SOLENOID
4 A/C COMPRESSOR 11 TRANSFER CASE 2/4 DRIVE
5 A/C CONDENSER FAN MOTOR 12 TRANSFER CASE H/L SHIFT 5

Control
PTO and Engine
12V
1 STARTER 6 STARTER CUT OFF, EXHAUST BRAKE
2 ECM MAIN 7 EXHAUST BRAKE, MARKER LAMP 6

Equipments
Electrical
Regarding
Various Issues
3 GLOW 8 SHIFT CONTROL SOLENOID
4 A/C COMPRESSOR 14 MARKER LAMP
5 A/C CONDENSER FAN MOTOR

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

148
1
6-6 How to add power sources and precautions for such addition

Outline
(1) Location of the service terminals and how to connect equipments with them
For convenience in connecting additional equipments and to prevent various
problems during equipment connection, ELF series for Mexico, except for 75L 2
(4HK1, 12V) have the following service terminals near the outside relay box and

Models
Various Vehicle
Specifications of
Principal
the third cross member of a chassis frame. See the Fig.7, 8, 9 and 10 for details.
• External idle-up signal input terminal for vehicle models with PTO
→See the Fig.7, 8 and 10.
3

Mounting
Rear Body
Precautions for
• External idle-up signal input terminal for vehicle models with refrigerating
machine
→See the Fig.7, 9 and 10.

4
Fig.7 Location of the idle-up signal input terminals for PTO and refrigerating machine

Weight Data
Distribution and
Weight
Idle-up signal input terminal for refrigerating 5

Control
PTO and Engine
vehicle

Idle-up signal input terminal for PTO

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
Outside relay box

8
The Fig.8 shows a circuit including an external acceleration signal input terminal
Drawings
Cab Chassis

and an external controlling resistor. Connect the terminal and the resistor to the
connector attached to a harness (harness assembly). This connector must be
YAZAKI Corporation’s connector (SWP-3P-M). The terminal is also YAZAKI’s
(part no.: 7114-1471 or 7114-1472), which is in size suitable for the harness 9
Drawings
Chassis Frame

size. Properly attach a waterproof part (e.g. Waterproof plug) for the connector.

10
Annex

149
1
Fig.8 Idle-up circuit for PTO-installed vehicle model

Outline
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
The Fig.9 shows the connection circuit of ECU and the compressor on a vehicle
model with refrigerating machine.

5
Fig.9 External idle-up signal input terminal/circuit on a vehicle model with refrigerating

Control
PTO and Engine
machine

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
Use YAZAKI Corporation’s RFW-M type connector.

Fig.10 Location of the service terminals (RHD is shown. LHD is same position.)

8
Drawings
Cab Chassis

Main harness
・Idle-up signal input terminal for refrigerating vehicle
・Idle-up signal input terminal for PTO

9
Drawings
Chassis Frame

10
Outside relay box
Annex

150
1
(Reference) Location of the PTO and the idle-up signal input terminal for refrigerating vehicle

Outline
Idle-up signal input terminal for refrigerating 2
vehicle

Models
Various Vehicle
Specifications of
Principal
Idle-up signal input terminal for PTO

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
Outside relay box

• Circuit that includes add-on side turn signal lamps and how to connect these
5
lamps

Control
PTO and Engine
If additional side turn signal lamps are required, referring to the Fig.11,
connect such additional lamps directly to the harnesses coming out of the
rear combination lamp connector. Connect the left lamp to the 0.5GB green
and black power source wire, the right lamp to the 0.5GW green and white 6

Equipments
Electrical
Regarding
Various Issues
power source wire, and both lamps to the 1.25 black ground wires. For
secure connection, see Lengthening or shortening an electric wire or a cable
under 6-2 Precautions for modification of electrical components.
Since the above connections are made at the rear end of the chassis frame, 7

of the Springs
Characteristics
harnesses may be subjected to water and vibration. Therefore, it is
recommended to splice the wires by using crimping terminals and to take
protective measures such as protecting the splice with epoxy resin coating or
waterproof cover. 8
Drawings
Cab Chassis

Connect the ground harnesses of the add-on lamps to the chassis frame.

9
Drawings
Chassis Frame

10
Annex

151
1
Fig.11 Circuit that includes add-on side turn signal lamps

Outline
2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
(2) Precautions for connecting of additional equipments
8
When connecting any additional equipment to the power terminal for additional
Drawings
Cab Chassis

marker lamp, be sure that the load produced by such add-on equipment is
within the capacity of the wire and the fuse. Besides, load produced by all the
equipments on the vehicle should be within the capacity of the power generator.
9
When adding any other equipments or using a large-load equipment for a short
Drawings
Chassis Frame

time within the capacity of the power generator, connect such equipment(s)
directly to the battery as instructed under (3) How to connect a large-load
equipment to the positive battery terminal.
10
When fitting add-on equipments, always follow the instructions in this guide
Annex

because failure to follow these instructions will impair the functions of the
vehicle and cause serious problems such as vehicle fire.

152
1
(3) How to connect a large-load equipment to a positive battery terminal

Outline
When fitting an additional large-load equipment, extract power directly from the
battery as shown in the Fig.12.

Fig.12 Fitting an additional harness to the battery terminal 2

Models
Various Vehicle
Specifications of
Principal
3

Mounting
Rear Body
Precautions for
4

Weight Data
Distribution and
Weight
To extract power from the positive battery terminal, attach a ring terminal or
other type terminal to the harness of add-on equipment, and then secure it on
5
the battery terminal.

Control
PTO and Engine
• To prevent the stud bolt from loosening, do not add more than one harness
on the battery terminal.
• Provide a fuse in each power extraction circuit. Fuses must be a minimum of 6

Equipments
Electrical
Regarding
Various Issues
300mm apart from 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.
• When using a harness of 5mm2 or larger, solder the pressured part of the 7

of the Springs
Characteristics
harness terminal, and then wrap the area with a heat shrink tubing.

8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

153
1
(4) How to connect the ground wire or cable of an add-on large-load equipment to a

Outline
chassis frame

• The ground wire or cable of an add-on equipment should be connected to


the chassis frame member to which the negative battery cable is connected.
2

Models
Various Vehicle
Specifications of
Principal
• Attach a ring terminal to the ground wire or cable. Be sure to firmly secure
the terminal on the chassis frame.
• Use a ground bolt to secure the ring terminal.
3
• Weld a mating nut on the chassis frame or directly tap the chassis frame.

Mounting
Rear Body
Precautions for
• Relocating the ground points of the factory-installed ground wire or cable and
lengthening/shortening these wires and cables should be avoided as much
as possible because doing any of these may result in breakdown of electrical
4
equipments or electronics devices due to surge, etc.

Weight Data
Distribution and
Weight
• Do not secure the ground wire or cable of add-on equipment together with
factory-installed ground wire or cable because the fixing bolt will loosen and
contact failure will occur.
5

Control
PTO and Engine
6

Equipments
Electrical
Regarding
Various Issues
7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

154
1
6-7 Adjusting the position of lamps

Outline
At the rear end of a chassis frame, you will find temporarily fitted triple rear
combination lamps consisted of a tail lamp/a stop lamp, a turn signal lamp and a
back-up lamp.
2
After fitting a rear body and its components on a chassis, fit these rear lamps on

Models
Various Vehicle
Specifications of
Principal
the rear body or on the chassis frame following the precautions below.
• The Fig.13 shows the appearance of the rear combination lamps.

• There is a drain hole in the bottom of each lens. For convenience in 3

Mounting
Rear Body
Precautions for
shipment, these holes have temporarily been turned up and covered with
waterproof tape. Before fitting rear combination lamps on a rear body or on a
chassis frame, remove this tape. Since the bulb of the back-up lamp is
removed backward for replacement, to permit ease of replacement, provide 4
sufficient space behind the lamp.

Weight Data
Distribution and
Weight
• To prevent the bulb filaments from breaking due to vibration of the lamp
housing, after fitting the lamps on a rear body or on a chassis frame, to
absorb vibration, fit a stay with its one end fixed to the bottom center of the 5
lamp housing and the other on the rear body or on the chassis frame.

Control
PTO and Engine
• Note that the position and the height of the rear combination lamps relative to
the outermost side of vehicle must comply with applicable laws and
regulations of body builder’s country.
6

Equipments
Electrical
Regarding
Various Issues
Fig.13 Rear combination lamps (RH is shown. LH is symmetrical)

Unit: mm

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

155
1
6-8 Symbols and abbreviations in circuit diagrams

Outline
The following are the symbols and abbreviations that appear in the circuit diagrams
provided in this guide:

2
Symbol

Models
Various Vehicle
Specifications of
Principal
Symbol Meaning Symbol Meaning

Fuse Bulb

Mounting
Rear Body
Precautions for
Slow-blow fuse Double filament bulb

Fusible link wire Motor

Weight Data
Distribution and
Weight
Switch (Normally open) Variable resister rheostat

Coil (inductor), solenoid, magnetic


Switch
valve
5

Control
PTO and Engine
Switch (Normally closed) Relay (Normally open)

Wire connection
6

Equipments
Electrical
Regarding
Various Issues
Relay (Normally closed)
Battery

Diode Connector 7

of the Springs
Characteristics
Electronic parts Light emitting diode

Resistor Lead switch 8


Drawings
Cab Chassis

Speaker Condenser

Buzzer Horn 9
Drawings
Chassis Frame

Circuit breaker Vacuum switching valve

Light emitting diode Grounding point 10


Annex

156
Abbreviation 1

Outline
Abbr. Full spelling Abbr. Full spelling
3A/T 3-speed automatic transmission IAT Intake air temperature
4×4 Four-wheel drive IC Integrated circuit
4A/T 4-speed automatic transmission IG Ignition
2
A Ampere J/T Joint terminal

Models
Various Vehicle
Specifications of
Principal
A/C Air conditioner kW kilowatt
A/T Automatic transmission LH Left hand
ABS Anti-lock brake system LHD Left hand driver side
AC Alternating current LO Low
3
ACC Accessories LWB Long wheelbase

Mounting
Rear Body
Precautions for
ACCEL Accelerator M/T Manual transmission
APP Accelerator pedal position M/V Magnetic valve
ASM Assembly MAF Mass air flow
ATF Automatic transmission fluid MIL Engine check light
4
AUTO Automatic OD Overdrive

Weight Data
Distribution and
Weight
BRKT Bracket OPT Option
C/B Circuit breaker PTO Power Take Off
CKP Crankshaft position QOS Quick on start
CMP Camshaft position R/L Relay
5
COMB Combination RH Right hand

Control
PTO and Engine
CONN Connector RHD Right hand driver side
CONT Control RR/Rr Rear
CSD Cold start device RWAL Rear wheel anti-lock brake system
CTR Center RWD Rearward
6
C/U Control unit SCV Suction control valve

Equipments
Electrical
Regarding
Various Issues
DCL Data link connector SEN Sensor
Steering power emergency
DIS Direct ignition system S/P
changeover valve
ECGI Electronic control gasoline injection ST Start
7
ECM Electronic control module STD Standard

of the Springs
Characteristics
ECT Engine coolant temperature SW Switch
ECU Electronic control unit SWB Short wheelbase
EFE Early fuel evaporation TCM Transmission control module
EHGU Electronic and hydraulic control unit V Volt
8
EGR Exhaust gas recirculation VSV Vacuum switching valve
Drawings
Cab Chassis

FL Fusible link W Watt


FRT Front W/ With
FT Fuel temperature W/O Without
FWD Forward WOT Wide open throttle
9
HI High W/S Weld splice
Drawings
Chassis Frame

H/L Head lamp

10
Annex

157
1
6-9 Circuit diagrams

Outline
At the end of this chapter, this guide provides circuit diagrams of the following
equipments, that are involved in rear body mounting.
You might need to shorten or lengthen the harnesses or add circuits for the 2
following equipments. For such harness modification, follow the instructions under

Models
Various Vehicle
Specifications of
Principal
the sections 6-2 and 6-3.

24V (85L-4JJ1)
Circuits Circuits 3
01 HEADLAMP, FOG LAMP & LEVELING 14 ROOM LAMP

Mounting
Rear Body
Precautions for
02 TAIL, STOP, TURN, CORNERING LAMP 15 ENGINE CONT MODULE
03 VOICE WARNING 16 NEW ECONOMY EASY DRIVE SYSTEM
04 METER 17 ANTILOCK BRAKE SYSTEM & ANTISLIP
REGULATOR
4
05 HEATER, VENTILATION & AIR CON. 18 HILL START AID

Weight Data
Distribution and
Weight
06 COMPUTER AREA NETWORK 19 POWER DISTRIBUTION CHASSIS
07 IMMOBILIZER & HORN 20 POWER DISTRIBUTION CAB
08 WIPER & WASHER 21 SUB JUNCTION BLOCK 1
09 POWER WINDOW & DOOR LOCK 22 SUB JUNCTION BLOCK 2
5
10 RETRACTABLE DOOR MIRROR 23 EARTH-B

Control
PTO and Engine
11 SUPPLEMENTAL RESTRAINT SYSTEM 24 EARTH-A
12 CIGAR LIGHTER & AUDIO 25 POWER TAKE OFF & POWER CAB TILT
13 CHECK CONN. & SERVICE TERMINAL

Equipments
Electrical
Regarding
Various Issues
12V (75L-4HK1 )
Circuits Circuits
01 HEADLAMP, FOG LAMP & LEVELING 10 ROOM LAMP
02 TAIL, STOP, TURN, CORNERING LAMP 11 SPEED SENSOR 7

of the Springs
Characteristics
03 VOICE WARNING 12 POWER DISTRIBUTION CHASSIS
04 METER 13 POWER DISTRIBUTION CAB
05 HEATER, VENTILATION & AIR CON. 14 SUB JUNCTION BLOCK 1
06 WIPER & WASHER 15 EARTH-B
07 POWER WINDOW & DOOR LOCK 16 EARTH-A 8
Drawings
Cab Chassis

08 CIGAR LIGHTER & AUDIO 17 EGR & QOS


09 SERVICE TERMINAL

9
Drawings
Chassis Frame

10
Annex

158
We do not permit modification of the other factory-installed electrical equipments in 1

Outline
order to preserve their functions. Therefore, this guide does not provide the circuit
diagrams of these electrical equipments. Modifying these equipments may
contribute to the following problems:

• Recently, many electrical circuits have built-in microcomputers. Since these 2

Models
Various Vehicle
Specifications of
Principal
microcomputers are controlled by digital signals, they are susceptible to
noise. Even very weak pulse noise can cause these computers to
malfunction, and in the worst case, the control unit overruns. Therefore, it is
not permitted to modify the harnesses or install additional equipments in
3
these microcomputer-embedded circuits. Also, it is better to avoid to

Mounting
Rear Body
Precautions for
disconnect the connectors installed in these circuits because disconnecting
them may fluctuate the impedance (alternating resistance such as inductance
and capacitance), and consequently you may need to readjust the entire
equipment. 4

Weight Data
Distribution and
Weight
• Computer circuits and microcomputer-embedded equipments produce
massive amount of signal transmissions. Each single harness transmits and
receives multiple currents to and from multiple circuits. If you connect an
additional equipment to any of these circuits, the existing circuits may 5

Control
PTO and Engine
malfunction due to circuit interference.
• Most of the digital circuits are electrically shielded. Do not modify these
circuits because once you modify them, you will not be able to bring them
back to the former state. 6

Equipments
Electrical
Regarding
Various Issues
• Use waterproof connectors outside a cab. Note that terminals cannot be
added to these waterproof connectors, and that only harness manufacturers
can fabricate harnesses with waterproof connectors. To assure reliability of
harnesses, it is better not to modify them. 7

of the Springs
Characteristics
8
Drawings
Cab Chassis

9
Drawings
Chassis Frame

10
Annex

159
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
160
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-1 HEADLAMP, FOGLAMP, LEVELING HEAD LAMP
< 24V (85U-4JJ1, 75U-4HK1 ) >
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
161
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-2 TAIL, STOP, TURN, CORNERING LAMP
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
162
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-3 VOICE WARNING
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
163
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-4 METER
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
164
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-5 HEATER VENTILATION AIRCON
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
165
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-6 CONTROLLER AREA NETWORK
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
166
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-7 IMMOBI & HORN
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
167
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-8 WIPER & WASHER
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
168
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-9 POWER WINDOW & DOOR LOCK
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
169
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-10 RETRACTABLE DOOR MIRROR
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
170
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-11 SUPPLEMENTAL RESTRAIN SYSTEM
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
171
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-12 CIGAR LIGHTER & AUDIO
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
172
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-13 CHECK CONN & SERVICE TERMINAL
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
173
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-14 ROOM LAMP
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
174
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-15 ENGINE CONT MODULE
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
175
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight Data
Models Equipments
Fig. 6-16 NEW ECONOMY EASY DRIVE SYSTEM
Principal Various Issues
Precautions for Weight
Specifications of PTO and Engine Regarding Characteristics of Cab-Chassis Chassis Frame
176
10

Outline Rear Body Distribution and Annex


3

9
1

5
4

Various Vehicle Control Electrical the Springs Drawing Drawings


Mounting Weight D