Truck

2004 GM/ISUZU TRUCK
INDEX
W Series:
Introduction
Installation of Body & Special Equipment
Body Application Summary Chart
Mechanical & Cab Specifications
Weight Distribution
Weights, Commodities & Materials
Vehicle Specifications
NPR/W3500, NPR HD/W4500 Gas
NPR/W3500, NPR HD/W4500 Diesel
NQR/W5500
NPR HD/W4500, NQR/W5500 Crew Cab
FRR/WT5500
Electrical
NPR/W3500, NPR HD/W4500 Diesel, NQR/W5500 Diesel
NPR HD/W4500, NQR/W5500 Crew Cab
FRR/WT5500 Electrical
General Motors Isuzu Commercial Truck, LLC (GMICT) and American Isuzu Motors Inc. is striving to provide you with the most up-to-date and accurate information possible. If you
have any suggestion to improve the Body Builder’s Guide, please call GMICT Application Engineering. In the West Coast call 1-562-229-5314 and in the East Coast call 1-404-257-3013.
Notice of Rights
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic, mechanical, recording or otherwise, without prior written permission.
Notice of Liability
All specifications contained in this Body Builders Guide are based on the latest product information available at the time of publication. The manufacturer reserves the right to discontinue
or change at any time, without prior notice, any parts, materials, colors, special equipment, specifications, designs and models.
Made and printed in the USA.
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2004 GM/ISUZU TRUCK
PAGE
i
INTRODUCTION......................................................................................................................................................................................... 1
FMVSS Chart ...................................................................................................................................................................................... 2
EPA Requirements ............................................................................................................................................................................. 4
INSTALLATION OF BODY AND SPECIAL EQUIPMENT ........................................................................................................................... 6
Clearances ......................................................................................................................................................................................... 6
Engine ......................................................................................................................................................................................... 6
Transmission ............................................................................................................................................................................... 6
Front and Center Propeller Shafts ............................................................................................................................................... 7
Rear Propeller Shaft .................................................................................................................................................................... 8
Exhaust System .......................................................................................................................................................................... 8
Rear Wheel and Axle ................................................................................................................................................................... 9
Other Clearances ........................................................................................................................................................................ 9
Body Installations ............................................................................................................................................................................ 10
Chassis ..................................................................................................................................................................................... 10
Special Equipment on the Chassis ............................................................................................................................................ 10
Subframe Design and Mounting ................................................................................................................................................ 10
Subframe Contour ..................................................................................................................................................................... 11
Prohibited Attachment Areas.......................................................................................................................................................... 12
Subframe Mounting ......................................................................................................................................................................... 13
Bracket Installation .................................................................................................................................................................... 13
U-bolt Installation ...................................................................................................................................................................... 14
Crew Cab Body/Frame Requirements ........................................................................................................................................... 14
Modification of the Frame ............................................................................................................................................................... 15
Working on Chassis Frame ........................................................................................................................................................ 15
Drilling and Welding ................................................................................................................................................................... 15
Reinforcement of Chassis Frame............................................................................................................................................... 16
Welding ..................................................................................................................................................................................... 16
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INSTALLATION OF BODY AND SPECIAL EQUIPMENT – Modification of the Frame – (Continued)
Fluid Lines ........................................................................................................................................................................................ 17
Preparation of Additional Lines .................................................................................................................................................. 17
Installation of Additional Lines ................................................................................................................................................... 18
Electrical Wiring and Harnessing ................................................................................................................................................... 18
Wiring ........................................................................................................................................................................................ 19
Wire Color Code ........................................................................................................................................................................ 21
Maximum Allowable Current .......................................................................................................................................................... 21
Electrical System Modifications ................................................................................................................................................. 22
Exhaust System ............................................................................................................................................................................... 22
Fuel System ..................................................................................................................................................................................... 23
Rear Lighting ................................................................................................................................................................................... 23
Serviceability .................................................................................................................................................................................... 23
Wheelbase Alteration ...................................................................................................................................................................... 24
Shortening/Lengthening the Wheelbase Without Altering the Frame ......................................................................................... 24
Altering the Wheelbase by Altering the Frame ........................................................................................................................... 24
Glossary of Terms – Chassis Wheelbase Alteration ................................................................................................................... 24
FRR/WT Series Chassis ............................................................................................................................................................ 29
Hydraulic Brake System .................................................................................................................................................................. 30
Before Work Begins ................................................................................................................................................................... 30
ABS Program ............................................................................................................................................................................ 30
ABS Computer Location............................................................................................................................................................ 31
ABS Electrical Harness .............................................................................................................................................................. 31
Hydraulic Brake Lines ................................................................................................................................................................ 31
Air Brake System ............................................................................................................................................................................. 31
Before Work Begins ................................................................................................................................................................... 31
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INSTALLATION OF BODY AND SPECIAL EQUIPMENT – Modification of the Frame – (Continued)
ABS Program ............................................................................................................................................................................ 31
ABS Computer Location............................................................................................................................................................ 31
ABS Electrical Harness .............................................................................................................................................................. 32
Air Brake Lines .......................................................................................................................................................................... 32
BODY APPLICATION SUMMARY CHART .............................................................................................................................................. 33
2004 Gas and 2004 Diesel Model Year Body Application Summary Chart ................................................................................ 33
NPR/W3500, NPR HD/W4500 Gas .................................................................................................................................................. 35
2004 Model Year – Body & Payload Weight Distribution (% Front/% Rear) – Automatic Transmission ...................................... 35
NPR/W3500, NPR HD/W4500 Diesel .............................................................................................................................................. 36
2004 Model Year – Body & Payload Weight Distribution (% Front/% Rear) – Manual/Automatic Transmission ......................... 36
NQR/W5500 Diesel .......................................................................................................................................................................... 37
2004 Model Year – Body & Payload Weight Distribution (% Front/% Rear) – Manual/Automatic Transmission ......................... 37
NPR HD/W4500, NQR/W5500 Crew Cab Diesel ............................................................................................................................ 38
2004 Model Year – Diesel Crew Cab Body & Payload Weight Distribution (% Front/% Rear) .................................................... 38
FRR/WT5500 .................................................................................................................................................................................... 39
2004 Model Year – Body & Payload Weight Distribution (% Front/% Rear) ............................................................................... 39
MECHANICAL AND CAB SPECIFICATIONS........................................................................................................................................... 41
Engine Horsepower & Torque Chart ............................................................................................................................................... 41
GVW/GCW Ratings .......................................................................................................................................................................... 41
Rear Frame Height Chart ................................................................................................................................................................ 42
Clutch Engagement Torque ............................................................................................................................................................ 42
Paint Code Chart ............................................................................................................................................................................. 43
CV Chart 2 ........................................................................................................................................................................................ 44
N/W Series Towing Procedure ........................................................................................................................................................ 46
Front End Towing (Front Wheels Off the Ground) ....................................................................................................................... 46
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MECHANICAL AND CAB SPECIFICATIONS – (Continued)
Front End Towing (All Wheels On the Ground) ........................................................................................................................... 47
Rear End Towing (Rear Wheels Off the Ground) ........................................................................................................................ 48
FRR/WT5500 Series Towing Procedure ......................................................................................................................................... 49
Front End Towing (Front Wheels Off the Ground) ....................................................................................................................... 49
Front End Towing (All Wheels On the Ground) ........................................................................................................................... 49
Rear End Towing (Rear Wheels Off the Ground) ........................................................................................................................ 50
WEIGHT DISTRIBUTION CONCEPTS ..................................................................................................................................................... 51
Weight Restrictions ......................................................................................................................................................................... 51
Gross Axle Weight Rating ............................................................................................................................................................... 52
Weighing the Vehicle ....................................................................................................................................................................... 52
Tire Inflation ..................................................................................................................................................................................... 52
Center of Gravity.............................................................................................................................................................................. 52
Weight Distribution .......................................................................................................................................................................... 53
Glossary of Dimensions .................................................................................................................................................................. 55
Weight Distribution Formulas ......................................................................................................................................................... 56
Basic Formulas .......................................................................................................................................................................... 57
Weight Distribution Formulas in Words.......................................................................................................................................... 57
Recommended Weight Distribution % of Gross Vehicle Weight by Axle ..................................................................................... 62
Conventional (2 Axle) ................................................................................................................................................................. 62
COE (2 Axle) .............................................................................................................................................................................. 62
Conventional (3 Axle) ................................................................................................................................................................. 63
COE (3 Axle) .............................................................................................................................................................................. 63
Trailer Weight ................................................................................................................................................................................... 64
Payload at Kingpin .................................................................................................................................................................... 65
Payload at Rear Tandem ........................................................................................................................................................... 65
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v
WEIGHT DISTRIBUTION CONCEPTS – Performance Calculations – (Continued)
Performance Calculations .............................................................................................................................................................. 66
1. Speed Formula ...................................................................................................................................................................... 66
2. Grade Horsepower Formula .................................................................................................................................................. 67
3. Air Resistance Horsepower Formula ..................................................................................................................................... 68
4. Engine Horsepower Formula ................................................................................................................................................. 69
5. Gradeability Formula ............................................................................................................................................................. 70
6. Startability Formula................................................................................................................................................................ 71
7. Vertical Center of Gravity Formula ......................................................................................................................................... 72
8. Horizontal Center of Gravity Formula ..................................................................................................................................... 74
Highway System Limits ................................................................................................................................................................... 76
Bridge Formula Definitions ........................................................................................................................................................ 76
Exception to the Bridge Formula ............................................................................................................................................... 77
Other Federal Provisions ........................................................................................................................................................... 77
Federal Bridge Formula Table ......................................................................................................................................................... 78
COMMODITY AND MATERIAL WEIGHTS .............................................................................................................................................. 81
Approximate Weights of Commodities and Materials .................................................................................................................. 81
VEHICLE SPECIFICATIONS INDEX ......................................................................................................................................................... 88
NPR/W3500, NPR HD/W4500 Gas .................................................................................................................................................. 88
Specifications .......................................................................................................................................................................... 88
Vehicle Weights, Dimensions and Ratings ............................................................................................................................. 89
Variable Chassis Dimensions ............................................................................................................................................. 90
Dimension Constraints 12,000 GVW ................................................................................................................................. 90
12,000-lb. GVWR with 4L80-E Hydra-Matic Transmission Model California ...................................................................... 90
12,000-lb. GVWR with 4L80-E Hydra-Matic Transmission Model Federal ......................................................................... 91
Dimension Constraints 14,500 GVW ................................................................................................................................. 91
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VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500 Gas – (Continued)
14,500-lb. GVWR with 4L30-E Hydra-Matic Transmission Model California/Federal ......................................................... 91
Vehicle Weight Limits......................................................................................................................................................... 92
Frame and Crossmember Specifications .............................................................................................................................. 93
Frame Chart ............................................................................................................................................................................. 94
Auxiliary Views ......................................................................................................................................................................... 95
Body Builder Weight Information Chart ................................................................................................................................. 96
Cab Tilt .............................................................................................................................................................................. 96
Center of Gravity ............................................................................................................................................................... 97
Front Axle Chart....................................................................................................................................................................... 98
Rear Axle Chart ....................................................................................................................................................................... 99
Definitions ....................................................................................................................................................................... 100
Formulas for Calculating Rear Width and Height Dimensions ......................................................................................... 100
Suspension Deflection Charts – NPR/W3500 Gas, NPR HD/W4500 Gas ........................................................................... 101
Tire and Disc Wheel Chart – NPR/W3500 ............................................................................................................................ 102
Tire .................................................................................................................................................................................. 102
Disc Wheel ...................................................................................................................................................................... 102
Tire and Disc Wheel Chart – NPR HD/W4500 ...................................................................................................................... 103
Tire .................................................................................................................................................................................. 103
Disc Wheel ...................................................................................................................................................................... 103
Propeller Shaft ....................................................................................................................................................................... 104
Brake System Diagram, 12,000 GVW ................................................................................................................................... 106
Vacuum Over Hydraulic ................................................................................................................................................... 106
Through the Rail Fuel Fill ...................................................................................................................................................... 108
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VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500 Gas – (Continued)
Installation Instructions.................................................................................................................................................... 108
Rear View Fuel Fill ......................................................................................................................................................... 109
Top View Fuel Fill ........................................................................................................................................................... 110
Top View ......................................................................................................................................................................... 111
Through the Rail Fuel Fill Frame Hole .......................................................................................................................... 112
Fuel Fill Parts Illustration .............................................................................................................................................. 113
Fuel Fill Parts List .......................................................................................................................................................... 114
NPR/W3500, NPR HD/W4500 Diesel ............................................................................................................................................ 115
Specifications ........................................................................................................................................................................ 115
Vehicle Weights, Dimensions and Ratings ........................................................................................................................... 116
Variable Chassis Dimensions ........................................................................................................................................... 117
Dimension Constants ...................................................................................................................................................... 117
In-Frame Tank 12,000-lb. GVWR Manual Transmission Model ........................................................................................ 117
In-Frame Tank 14,500-lb. GVWR Manual Transmission Model..........................................................................................118
In-Frame Tank 12,000-lb. GVWR Automatic Transmission Model ................................................................................... 118
Side-Mounted Tank 12,000-lb. GVWR Manual Transmission Model ................................................................................ 119
Side-Mounted Tank 12,000-lb. GVWR Automatic Transmission Model ........................................................................... 119
Vehicle Weight Limits....................................................................................................................................................... 120
Frame and Crossmember Specifications ............................................................................................................................ 121
Frame Chart ........................................................................................................................................................................... 122
Auxiliary Views ....................................................................................................................................................................... 123
Body Builder Weight Information Chart ............................................................................................................................... 124
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VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500 Diesel – (Continued)
Cab Tilt ............................................................................................................................................................................ 124
Center of Gravity ............................................................................................................................................................. 125
Front Axle Chart..................................................................................................................................................................... 126
Rear Axle Chart ..................................................................................................................................................................... 127
Definitions ....................................................................................................................................................................... 128
Suspension Deflection Charts .............................................................................................................................................. 129
Tire and Disc Wheel Chart .................................................................................................................................................... 130
Tire .................................................................................................................................................................................. 130
Disc Wheel ...................................................................................................................................................................... 130
Propeller Shaft ....................................................................................................................................................................... 131
PTO Location, Drive Gear and Opening Information .......................................................................................................... 133
Opening Diagram ............................................................................................................................................................ 134
In-Frame Diesel Fuel Filler .................................................................................................................................................... 137
Installation Instructions .................................................................................................................................................... 137
Hose Modification for Various Width Bodies ............................................................................................................... 140
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VEHICLE SPECIFICATIONS INDEX – (Continued)
NQR/W5500 Diesel ........................................................................................................................................................................ 144
Specifications ........................................................................................................................................................................ 145
Dimension Constraints .................................................................................................................................................... 146
In-Frame Tank 17,950-lb. GVWR Manual Transmission Model ........................................................................................ 146
Frame Chart ........................................................................................................................................................................... 150
Auxiliary Views ....................................................................................................................................................................... 151
Cab Tilt ............................................................................................................................................................................ 152
Front Axle Chart..................................................................................................................................................................... 154
Rear Axle Chart ..................................................................................................................................................................... 155
Definitions ....................................................................................................................................................................... 156
Tire .................................................................................................................................................................................. 158
Disc Wheel ...................................................................................................................................................................... 158
Propeller Shaft ....................................................................................................................................................................... 159
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VEHICLE SPECIFICATIONS INDEX – NQR/W5500 Diesel – (Continued)
Opening Diagram ............................................................................................................................................................ 162
Brake System Diagram ......................................................................................................................................................... 163
Diesel Fuel Fill ........................................................................................................................................................................ 164
NQR/W5500 Diesel Fuel Fill Parts Illustration .............................................................................................................. 169
NQR/W5500 Diesel Fuel Fill Parts List ......................................................................................................................... 170
NPR HD/W4500, NQR/W5500 Crew Cab Diesel .......................................................................................................................... 171
Specifications ........................................................................................................................................................................ 171
NPR HD/W4500 Variable Chassis Dimensions ................................................................................................................ 173
NPR HD/W4500 Dimension Constants ........................................................................................................................... 173
NPR HD/W4500 In-Frame Tank 14,500-lb. GVWR Automatic Transmission Model ......................................................... 173
NPR HD/W4500 Side-Mounted Tank 14,500-lb. GVWR Automatic Transmission Model................................................. 173
NQR/W5500 Variable Chassis Dimensions ...................................................................................................................... 174
NQR/W5500 Dimension Constraints ............................................................................................................................... 174
NQR/W5500 In-Frame Tank 17,950-lb. GVWR Automatic Transmission Model .............................................................. 174
NQR/W5500 Side-Mounted Tank 17,950-lb. GVWR Automatic Transmission Model ...................................................... 174
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VEHICLE SPECIFICATIONS INDEX – NPR HD/W4500, NQR/W5500 Crew Cab Diesel – (Continued)
Frame Chart ........................................................................................................................................................................... 177
Auxiliary Views ....................................................................................................................................................................... 178
NPR HD/W4500 .............................................................................................................................................................. 179
NQR/W5500 .................................................................................................................................................................... 180
Front Axle Chart NPR HD/W4500 ......................................................................................................................................... 181
Front Axle Chart NQR/W5500 ............................................................................................................................................... 182
Rear Axle Chart NPR HD/W4500 .......................................................................................................................................... 183
Definitions ....................................................................................................................................................................... 184
Rear Axle Chart NQR/W5500 ................................................................................................................................................ 185
Definitions ....................................................................................................................................................................... 186
Suspension Deflection Charts NPR HD/W4500 ................................................................................................................... 187
Suspension Deflection Charts NQR/W5500......................................................................................................................... 188
Tire and Disc Wheel Chart NPR HD/W4500 ......................................................................................................................... 189
Tire .................................................................................................................................................................................. 189
Disc Wheel ...................................................................................................................................................................... 189
Tire and Disc Wheel Chart NQR/W5500 ............................................................................................................................... 190
Tire .................................................................................................................................................................................. 190
Disc Wheel ...................................................................................................................................................................... 190
Propeller Shaft NPR HD/W4500 ............................................................................................................................................ 191
Propeller Shaft NQR/W5500.................................................................................................................................................. 192
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VEHICLE SPECIFICATIONS INDEX – NPR HD/W4500, NQR/W5500 Crew Cab Diesel – (Continued)
Opening Diagram ............................................................................................................................................................ 195
Brake System Diagram 14,500 GVW .................................................................................................................................... 196
Brake System Diagram 17,950 GVW .................................................................................................................................... 197
Diesel Fuel Fill ........................................................................................................................................................................ 198
FRR/WT5500 .................................................................................................................................................................................. 205
Specifications ........................................................................................................................................................................ 205
Dimension Constants ...................................................................................................................................................... 207
19,500-lb. GVW With 6-Speed Manual Transmission ...................................................................................................... 207
18,000-lb. GVW With 6-Speed Manual Transmission ...................................................................................................... 208
19,500-lb. GVW With Automatic Transmission ................................................................................................................ 208
18,000-lb. GVW With Automatic Transmission ................................................................................................................ 208
Truck Weight Limits ......................................................................................................................................................... 209
Technical Notes ............................................................................................................................................................... 209
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VEHICLE SPECIFICATIONS INDEX – FRR/WT5500 – (Continued)
Frame Chart ........................................................................................................................................................................... 211
Auxiliary Views ....................................................................................................................................................................... 212
Cab Tilt ............................................................................................................................................................................ 213
Front Axle Chart..................................................................................................................................................................... 215
Rear Axle Chart ..................................................................................................................................................................... 216
Definitions ....................................................................................................................................................................... 217
Tire .................................................................................................................................................................................. 219
Disc Wheel ...................................................................................................................................................................... 219
Propeller Shaft ....................................................................................................................................................................... 220
Opening Diagram ............................................................................................................................................................ 224
Brake System Diagram ......................................................................................................................................................... 225
Air Over Hydraulic ........................................................................................................................................................... 225
Allison Transmission Rating Guide ....................................................................................................................................... 226
NPR/W3500, NPR HD/W4500 Gas Electrical................................................................................................................................ 227
Symbols.................................................................................................................................................................................. 227
Abbreviations ......................................................................................................................................................................... 228
Wiring ..................................................................................................................................................................................... 229
Wire Color ....................................................................................................................................................................... 229
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VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500 Gas Electrical – (Continued)
Distinction of Circuit by Wire Base Color ......................................................................................................................... 230
Wire Size ......................................................................................................................................................................... 230
Grounding Point Location (E-55, E-56) ................................................................................................................................. 232
Grounding Point Location (J-9)............................................................................................................................................. 236
Reference Table of Grounding Point .................................................................................................................................... 237
NPR/W3500 Body Room Light, ID and Marker Lamp, and Back-Up Lamp Connector Location..................................... 238
NPR/W3500 Body Connectors LH Frame ....................................................................................................................... 238
NPR/W3500 Body Connectors EOF ................................................................................................................................ 239
Dome and Interior Lights Circuit Diagram ........................................................................................................................... 240
Park, Tail, License and I.D. Lights Circuit Diagram ............................................................................................................. 241
Fuse Location ........................................................................................................................................................................ 242
Fuse Box ................................................................................................................................................................................ 243
Relay Location ....................................................................................................................................................................... 244
Cab Relay ............................................................................................................................................................................... 245
Fuse Box ................................................................................................................................................................................ 245
Relay Box Outside Cab ......................................................................................................................................................... 246
Auxiliary Power Source Circuit Diagram .............................................................................................................................. 247
Sound System Circuit Diagram ............................................................................................................................................ 248
Horn Circuit Diagram ............................................................................................................................................................ 249
Back-Up Lights Circuit Diagram .......................................................................................................................................... 250
Turn and Hazard Lights Circuit Diagram .............................................................................................................................. 251
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VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500 Gas Electrical – (Continued)
03i Model Year Fuel Tank Sending Unit Resistance Values ................................................................................................ 253
03i Model Year Fuel Tank Sending Unit Resistance Values ................................................................................................ 254
NPR/W3500, NPR HD/W4500, NQR/W5500 Diesel Electrical ..................................................................................................... 255
Symbols.................................................................................................................................................................................. 255
Abbreviations ......................................................................................................................................................................... 256
Wiring ..................................................................................................................................................................................... 257
Wire Color ....................................................................................................................................................................... 257
Distinction of Circuit by Wire Base Color ......................................................................................................................... 258
Wire Size ......................................................................................................................................................................... 258
Grounding Point Location (B-1) ............................................................................................................................................ 260
Grounding Point Location (B-7) ............................................................................................................................................ 261
Grounding Point Location (J-9)............................................................................................................................................. 262
Reference Table of Grounding Point .................................................................................................................................... 263
NPR/W3500, NQR/W5500 Body Room Light, ID and Marker Lamp, and Back-Up Lamp Connector Location .............. 264
NPR/W3500, NQR/W5500 Body Connectors LH Frame ................................................................................................. 264
NPR/W3500, NQR/W5500 Body Connectors EOF .......................................................................................................... 265
Park, Tail, License and I.D. Lights Circuit Diagram ............................................................................................................. 267
Fuse Location ........................................................................................................................................................................ 268
Fuse Box ................................................................................................................................................................................ 269
Relay Location ....................................................................................................................................................................... 270
Cab Relay ............................................................................................................................................................................... 271
Fuse Box ................................................................................................................................................................................ 271
Relay Box Outside Cab ......................................................................................................................................................... 272
Auxiliary Power Source Circuit Diagram .............................................................................................................................. 273
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VEHICLE SPECIFICATIONS INDEX – NPR/W3500, NPR HD/W4500, NQR/W5500 Diesel Electrical – (Continued)
Horn Circuit Diagram ............................................................................................................................................................ 274
Back-Up Lights Circuit Diagram .......................................................................................................................................... 275
Sound System Circuit Diagram ............................................................................................................................................ 276
Engine Stop Motor Circuit Diagram ..................................................................................................................................... 277
Fuel Tank Sending Unit Resistance (In-Frame Tank) ........................................................................................................... 279
Fuel Tank Sending Unit Resistance (Side-Mounted Tank) .................................................................................................. 280
NPR HD/W4500, NQR/W5500 Crew Cab Electrical ..................................................................................................................... 281
Power Door Locks Circuit Diagram ..................................................................................................................................... 281
Rear Heater Circuit Diagram ................................................................................................................................................ 283
FRR/WT5500 Electrical.................................................................................................................................................................. 285
FRR/WT5500 Series Taillight Connectors ............................................................................................................................ 285
FRR/WT5500 Body Room Light, I.D. and Marker Lamp, and Back-Up Lamp Connector Location ................................. 286
FRR/WT5500 Body Connectors LH Frame...................................................................................................................... 286
FRR/WT5500 Series Relay Location ..................................................................................................................................... 289
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1
INTRODUCTION
This guide has been provided as an aid to final stage manufacturers in determining conformity to the applicable Emission Control and
Federal Motor Vehicle Safety Standards. Final stage manufacturers should maintain current knowledge of all Emission Regulations and
Federal Motor Vehicle Safety Standards and be aware of their specific responsibility in regards to each standard.
Any manufacturer making material alterations to this incomplete vehicle during the process of manufacturing the complete vehicle should be
constantly alert to all effects, direct or indirect, on other components, assemblies or systems caused by such alterations. No alterations
should be made to the incomplete vehicle that directly or indirectly results in any either component, assembly or system being in nonconfor-
mance with applicable Emission Regulations or Federal Motor Vehicle Safety Standards.
General Motors Isuzu Commercial Truck, LLC (GMICT) and American Isuzu Motors Inc. will honor its warranty commitment (for the cab-
chassis only), to the ultimate consumer, provided: (1) the final stage manufacturer has not made any alterations or modifications which do
not conform to any applicable laws, regulations or standards, or adversely affect the operation of the cab-chassis; and (2) the final stage
manufacturer complied with the instructions contained in this guide with respect to the completion of the vehicle. Otherwise, the warranty
becomes the responsibility of the final stage manufacturer.
The final stage manufacturer is solely responsible for the final certification of the vehicle and for compliance with Emission Control and
Federal Motor Vehicle Safety Standards. The information contained in this guide has been provided for the final stage manufacturer’s
information and guidance.
This guide contains information pertaining to the: NPR/W3500 Gas; NPR/W3500 Diesel; NQR/W5500 Diesel; NPR HD, NQR/W4500, W5500
Diesel Crew Cab; and FRR/WT5500 Series Chassis Cab.
Following is a list of Federal Motor Vehicle Safety Standards applicable to those vehicles with a GVWR greater than 10,000 lbs. Please refer
to the chart on the next page.
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2
FMVSS Chart
List of Federal or Canadian Motor Vehicle Safety Standards applicable to Isuzu/GMC Truck product lines. Gasoline or diesel fueled vehicles
with GVWR greater than 10,000 lbs. (4536 Kg)
Title NPR, NPR HD/

MVSS No. Upper line FMVSS, Lower Line CMVSS W3500, W4500 NQR/W5500 FRR/WT5500 FSR FTR/FTV
Controls and displays
101 Location and identification of controls and displays A A A A A
Transmission shift lever sequence, starter interlock and transmission braking effect
102 Transmission control functions A A A A A
Windshield defrosting and defogging systems
103 Windshield defrosting and defogging A A A A A
Windshield wiping and washing systems
104 Windshield wiping and washing systems A A A A A
Hydraulic and electric brake systems
105 Hydraulic and electric brake systems A A A A A
Brake hoses
106 Brake hoses A A A A A
Lamps and reflective devices and associated equipment
108 Lighting systems and reflective devices A A A A A
Rear view mirrors
111 Mirrors A A A A A
Hood latch system
113 Hood latch system A A A A A
N/A
115 Vehicle identification system2 A A A A A
Motor vehicle brake fluids
116 Hydraulic brake fluids A A A A A
Power operated window, partition, and roof panel systems
118 N/A A A A A A
1 = The letter A or B designates the lettered statement regarding FMVSS / CMVSS.
2 = Canadian MVSS Only.
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3
FMVSS Chart (continued)
List of Federal or Canadian Motor Vehicle Safety Standards applicable to Isuzu/GMC Truck product lines. Gasoline or diesel fueled vehicles
with GVWR greater than 10,000 lbs. (4536 Kg)
Title NPR, NPR HD/

MVSS No. Upper line FMVSS, Lower Line CMVSS W3500, W4500 NQR/W5500 FRR/WT5500 FSR FTR/FTV
Tire selection and rims for vehicles other than passenger cars
120 Tire selection and rims for vehicles other than passenger cars A A A A A
Air brake systems
121 Air brake systems B B A A A
Accelerator control system
124 Accelerator control system A A A A A
Glazing materials
205 Glazing materials A A A A A
Door locks and door retention components
206 Door locks and door retention components A A A A A
Seating systems
207 Anchorage of seats A A A A A
Occupant crash protection
208 Occupant restraint systems in frontal impacts A A A A A
Seatbelt assemblies
209 Seatbelt assemblies A A A A A
Seatbelt assembly anchorages
210 Seatbelt assembly anchorages A A A A A
Child restraint systems
213 Built in child restraint systems and built in booster cushions A A A A A
Flammability of interior materials
302 Flammability A A A A A
1 = The letter A or B designates the lettered statement regarding FMVSS / CMVSS.
2 = Canadian MVSS Only.
NOTE: This chart is only a guide. For complete information, please refer to “Document for Incomplete Vehicle” provided with each chassis.
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EPA Requirements
NPR/W3500 Gas, NPR/W3500 Diesel, NQR/W5500 Diesel, NPR HD, NQR/W4500, W5500 Diesel Crew Cab and FRR/WT5500 Series
Chassis Cab
To assure that U.S.A. and Canada Emission Requirements are met, this Incomplete Vehicle must be completed in strict accordance with all
instructions contained in this document, especially the following instructions which relate to:
A Exhaust emission related components

B Noise emission related components
C Labels
A. EXHAUST EMISSION RELATED COMPONENTS
Compliance of this vehicle with EPA, California and Canada Requirements will be maintained providing no alterations are made to the
components or systems identified below:
1. DIESEL VEHICLES 2. GASOLINE VEHICLES
Injection Pump Vehicle Control Module (VCM)
Injector and High Pressure Lines Fuel Management System
Turbocharger Air Induction System
Charge Air Cooler and Charge Air Cooler Hoses Ignition System
Engine Control Module (ECM) Catalytic Converter System
Engine Speed Sensor Positive Crankcase Ventilation System
Engine Coolant Temperature Sensor Exhaust Gas Recirculation System
Intake Manifold Evaporative Emission Control System
Catalytic Converter and Its Location Miscellaneous Items Used in Above Systems
Variable Swirl System
Exhaust Gas Recirculation System
CMVSS NO. 1100–VEHICLE EMISSIONS

This incomplete vehicle when completed, will conform to CMVSS 1100 providing no alterations are made which affect the
function, physical or mechanical properties environment, locations or vital spatail clearance of the components identified below:
(EPA Requirements – continued on next page)

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(EPA Requirements – continued from previous page)
B. NOISE EMISSION RELATED COMPONENTS
Compliance of this vehicle with EPA and Canada requirements will be maintained providing no alterations are made to the
components or systems.
CMVSS NO. 1106–NOISE EMISSIONS
This incomplete vehicle, when completed, will conform to CMVSS-1106 providing no alterations are made which effect the function,
physical or mechanical properties, environment, locations or vital spatial clearances of the components identified below:
* Engine assembly * Axle
* Intake system * Tires
* Exhaust system * Fan and drive
* Transmission assembly * Catalytic converter and its location
C. LABELS
The emission control related information labels which are permanently affixed are required by government regulation and must not be
obstructed from view or defaced so as to impair its visibility or legibility.
PART 3: RADIO NOISE
CANADIAN RADIO INTERFERENCE REGULATIONS
A. The following statement is applicable to NPR/W Series Chassis-Cab (Gasoline Engine Only).
This incomplete vehicle, when completed, will conform to the above regulations providing no alterations or substitutions are made
which affect any parts or components identified below:
A. Distributor
B. Ignition Wires
C. Spark Plug Wires
2004 GM/Isuzu Truck

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INSTALLATION OF BODY AND SPECIAL EQUIPMENT
Clearances
Engine
At least 1.6 inches of clearance should be maintained around the engine. No obstacles should be added in front of the radiator or intercooler.
Transmission
The transmission is removed from the rear. Enough clearance must be provided to allow rearward movement of the transmission
assembly. Clearance should be sufficient to allow 5 to 6 inches of unrestricted movement of the transmission assembly. In addition, provide
at least 2 inches of clearance around the control lever on the side of the transmission to allow free movement without any binding.
(Installation of Body and Special Equipment Section – continued on next page)

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(Installation of Body and Special Equipment Section – continued from previous page)
At least 6 inches of clearance should be maintained above the transmission to allow easy removal of the upper cover for manual transmis-
sions. At least 2 inches of clearance should be maintained above the automatic transmission to allow for transmission removal.
Front and Center Propeller Shafts
At least 1.25 inches of clearance should be maintained around front and center propeller shafts.

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Rear Propeller Shaft
With the rear springs at maximum deflection, at least 1.25 inches of clearance should be provided over the rear propeller shaft.
Exhaust System
If flammable materials such as wood are used in the body, provide at least 3.9 inches of clearance between the body and any parts of the
exhaust pipe, muffler and catalytic converter. If it is impossible to maintain this minimum clearance, use a heat shield. Also use a heat shield
if an oil pump or line is located above the exhaust pipe, muffler or catalytic converter.

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Rear Wheel and Axle
The design and installation of the body should allow sufficient clearance for full vertical movement of the rear wheels and axle when the
vehicle travels over rough or unlevel surfaces.
Note: For recommended clearances, please refer to the Rear Axle Chart in each model’s respective section.
Other Clearances
The transmission control cable may be broken if it is bent by or interferes with the body and its fixtures. To prevent this, 1 inch of minimum
clearance should be provided. When cable is detached from body mounting, be sure not to bend the cable.
Accessibility to the grease nipple on the rear spring bracket/shackle should be provided so that serviceability with a grease gun is not
hampered.
Parts Minimum Clearance Location

6.7 in. Axle Side
Brake Hose 1.6 in. Frame Side
Parking Brake Cable 1.2 in. —
Fuel Hose 1.6 in. —
2.4 in. Axle Side
Shock Absorber 1.2 in. Frame Side
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Body Installation
Chassis
To maintain the performance of the truck chassis, either a side member or subframe should always be used for body mounting. Body
mounting with low rigidity will often adversely affect riding comfort.
Special Equipment on the Chassis
When installing special equipment on the chassis, extra consideration must be given to the weight and construction of the equipment to
assure proper distribution of the load. Localization of the load should be prevented. All special equipment should be properly secured into
position. We recommend the use of subframe members when installing special equipment.
Subframe Design and Mounting
The subframe assembly should be mounted as close to the cab as possible. It should be contoured to match the shape and dimensions of
the chassis frame as closely as possible.

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

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

Do not attach the subframe with a bolt on bracket to the chassis frame at the points indicated by shading in the following illustrations.
1. At the front end of the subframe. The attaching bolt or bracket must be at least 2 inches behind the kick up point of the subframe.

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2. Within 8 inches of bends in the chassis frame or the attachment points of any crossmembers.
Subframe Mounting
Bracket Installation
Mounting brackets should be clamped to the chassis frame using bolts. For proper positions in which to install the bolts, refer to the
preceding section and the section “Modifications to the Chassis Frame.”

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U-bolt Installation
When U-bolts are used to retain the subframe, reinforcement blocks must be installed in the frame members. This will prevent distortion of
the frame flange as they are tightened. The drawing indicates the correct placement of reinforcement blocks. If you use wood blocks, be sure
that there is sufficient clearance between them and any parts of the exhaust system.
If any fluid lines or electric cables are located near the reinforcement blocks, you must provide at least 0.4 inches of clearance between rigid
or stationary portions, and at least 1.6 inches between moveable or flexible portions of the lines.
For the installation positions of the U-bolts, refer to “Prohibited Attachment Areas.”
Crew Cab Body/Frame Requirement

The Crew Cab NPR HD/W4500 and NQR/W5500 will be available in two wheelbases, 150 and 176 inches. Effective CA will be 84.7 and
110.7 inches. On this model chassis, General Motors Isuzu Commercial Truck, LLC (GMICT) and American Isuzu Motors Inc. will require that
the body installed on the chassis have an understructure manufactured with any of the following structural steel “C” channels:
4” x 1-5/8”, 7.25 lbs./ft. = ok

5” x 1-3/4”, 6.7 or 9.0 lbs./ft. = ok
6” x 2”, 8.2, 10.5 or 13.0 lbs./ft. = ok
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Modification of the Frame

Modifications of the chassis frame should be held to an absolute minimum. Modification work should be performed according to the
instructions in the following paragraphs.
When modification is complete, chassis frame members should be carefully inspected to eliminate the possibility of any safety-related
defects.
NOTE: PLEASE REFER TO NOTES ON CHASSIS FRAME MODIFICATION WITH ANTILOCK BRAKES.
Working on Chassis frame
The chassis frame is designed and built with consideration for proper load distribution. Sufficient physical strength is provided when the load
is evenly distributed. Installation of special equipment on the chassis frame can cause variations in load distribution. If even distribution of
load is not kept in mind when the equipment is installed, localization of stresses on specific areas of the frame could cause cracking of the
chassis frame members or other problems, even if the total weight of the equipment is within the design limit.
The chassis frame is designed as an integral unit. Therefore, we do not recommend cutting the chassis frame under any circumstances.
Drilling and Welding
IMPORTANT NOTE: For vehicles equipped with electronic or hydra-matic transmissions,

electric arc welding must be done with the negative battery cable disconnected.
1. Do not drill or weld in the shaded portions of the chassis frame members. Do not weld within 0.8 inches from the edges of any
existing holes.
2. Hold the length of any welding beads within 1.2-2.0 inches. Allow at least 1.6 inches between adjacent welding beads.
3. All holes must be drilled. Do not use a torch to make any holes.
4. All riveting must be done with cold rivets. Do not use hot rivets.
5. The flange of the chassis frame must not be cut under any circumstances.
6. The subframe must be attached to the chassis frame with bolts. Do not weld.

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Reinforcement of Chassis Frame
Reinforcements must be installed to prevent the considerable variation in the section modulus. They must be welded so as to avoid localized
stresses.
The frame of the NPR/W3500, NPR GAS/W4500 and NQR/W5500 is made of SAPH440 mild steel. The frame of the FRR/WT5500 is made
of HT540A.
The drawing on the following page illustrates correct and incorrect methods of frame reinforcement.
Welding
1. Keep reinforcement plates and chassis frame free from moisture and water.
2. Avoid cooling with water after welding.
3. Use a suitable means to protect pipes, wires, rubber parts, leaf springs, etc. against heat and effect of sputtering.
4. Remove fuel tank assembly when welding portions near the fuel tank.
5. Remove coat of paint completely when welding painted areas.
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Fluid Lines
Do not disturb the layout of any brake lines or fuel lines unless absolutely necessary. When modification is needed, follow the instructions
below carefully to ensure safety. Brake fluid lines must not be cut and spliced under any circumstances. We do not recommend the cutting
or splicing of any fuel lines, but if it is absolutely necessary, be sure that the correct fitting and tools are used to form the joint, and then
pressure test the joint. Steel lines are metric sizes.
Preparation of Additional Lines
1. Where possible, use only genuine GM/Isuzu lines as supplied by authorized GM/Isuzu dealers.
2. Use the correct metric flaring and bending tools to form the lines.
3. Avoid repeated bending. Do not use heat for flaring and bending the lines. Before and after forming the new lines, examine them
carefully for scratches, distortion, dents and the presence of any foreign matter.

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Installation of Additional Lines
Install new lines away from adjacent parts and away from any sources of heat.
1. A minimum clearance of 0.4 inches must be maintained between lines. Where necessary, clip the lines into position in order to
maintain this minimum clearance.
2. Minimize any crossing between lines. If a crossing is unavoidable, use the following procedure:
a. At least 0.4 inches of clearance should be maintained between lines at the crossing point.
b. If the 0.4 inches of clearance cannot be maintained, or if the lines are subject to vibration, clip them securely.
3. Plan the bends and clipping points of the lines to minimize vibration and the resulting fatigue.
4. Use rust-proofed clips and apply vinyl coating to the portions of the lines to be clipped.
5. Install new lines in positions where they are protected against water, dirt, grit, sand, rocks and other foreign matter that can come
from above or below, or can be flung up by the wheels.
Electrical Wiring and Harnessing

To increase the reliability of the wiring, all frame harnesses are covered with corrugated vinyl tubing. The following instructions apply
to extending or modifying these harnesses. See the Electrical Section for information on commonly used circuits in the NPR, NPR HD, NQR,
FRR and W-series.

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Wiring
1. Most wiring connections on GM/Isuzu vehicles are made with terminals. We recommend the use of terminals when splicing
cables and wires.
2. When splicing, use new wire of the same gauge, and do not make splices inside the corrugated tubing.
3. When making connections to the end of the harness, make sure the connections are electrically perfect. Use insulating tape as
needed to prevent the entry of water, which results in short circuits and/or corrosion.
4. When making new circuits, or modifying circuits already installed, make the cables only just taut enough to remove any slack. Use
clips or grommets where required to protect cables from heat or sharp edges. When cables must run near the exhaust system,
see the instructions in the “Exhaust System” section.
5. Always use rustproof clips, and apply vinyl coating to that portion of the clips in direct contact with the harnesses. No scotch clips
or connectors.
6. To minimize the vibration of the harness, clipping points should be set up according to the table.
Harness Diameter Clip Distance

less than 0.2 in. less than 11.8 in.
0.2 in. ~ 0.4 in. approx. 15.7 in.
0.4 in. ~ 0.8 in. approx. 19.7 in.
7. When changing the length of the battery cable, do not cut or splice the existing cable. Make up a new cable of the correct length
and wire gauge for the load and distance, without splices.
8. When using connectors, use a socket (female) connector on the electrical source side and a plug (male) connector on the
electrical load side to lower the possibility of a short circuit when disconnected.
9. When connecting cables to moving or vibrating parts such as the engine or transmission, be sure to maintain sufficient slack in
the wiring to absorb the vibration. Follow the example of existing cables connected by GM/Isuzu. Keep flexible cables clear of
other parts.
10. Do not use vinyl tape in the engine compartment. The heat will tend to make it peel off. Use plated steel clips coated with rubber
or vinyl.

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Wire Color Code
The electrical circuits of the N/W and FRR/WT Series Chassis Cab are connected with low-voltage stranded wire for automotive
applications. The color coding standards are as follows for the N/W and FRR/WT Series Chassis Cab:
(1) Black B Starter circuits and grounds (5) Yellow Y Instrument circuit
(2) White W Generator (alternator) circuit (6) Brown Br Accessory circuit
(3) Red R Lighting circuit (7) Light Green Lg Other circuit
(4) Green G Signal circuit (8) Blue L Windshield wiper motor circuit
Maximum Allowable Current
Harness Design Diameter (mm) AWG Equivalent No. of Wires/Wire Diameter (mm) Cross Sectional Area (mm2) Maximum Allowable Current (Amps)
100 00 217/0.80 109.1 363
85 0 169/0.80 84.96 305
60 1 127/0.80 63.84 248
50 1 108/0.80 54.29 223
40 1 85/0.80 42.73 191
30 2 70/0.80 35.19 171
20 4 41/0.80 20.61 123
15 6 84/0.45 13.36 93
8 8 50/0.45 7.952 68
5 8 65/0.32 5.228 51
3 12 41/0.32 3.297 39
2 14 26/0.32 2.091 29
1.25 16 16/0.32 1.287 21
0.85 18 11/0.32 0.8846 17
0.5 20 7/0.32 0.5629 13
Reference: The values given in the “maximum allowable current” column are based on the ambient temperature condition of 104ºF with
temperature increase of 104ºF.
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Electrical System Modifications
Modifications/add-on wiring must be carefully reviewed to ensure compatibility with the base vehicle wiring by reviewing system
schematics, wire routing paths, harness connections, etc. Due to the wide range of modifications that may be required for vocational needs,
it is not feasible for the O.E.M. to take into account all potential revisions. For this reason, any person modifying existing vehicle wiring must
assume responsibility that the revisions have not degraded the electrical system performance. Any add-on wiring needs to be properly fused
and routed to prevent cut, pinch, and chafe problems, as well as avoid exposure to excessive heat. Care must be exercised that existing
vehicle interfaces do not have their current load capabilities exceeded, and that the respective control devices are not overloaded. Added
wire size should be at least as large as the wire to which it is attaching in order for fuse protection to be maintained
A Packard electric wiring repair kit is available through Kent-Moore (P/N J38125-B) (Phone # 1-800-345-2233). This kit contains instructions,
tools and components for making repairs to wiring harness components. This kit would also greatly assist in accomplishing necessary
add-on wiring such as body marker lamps, so that system reliability/durability is maintained.
Electrical wiring components can be obtained through your authorized GM/Isuzu dealers. Packard Electric components are also
available through Pioneer Standard Company (1-800-PACKARD). Pioneer may also be able to assist in making necessary wiring additions
by providing custom wiring stubs or jumpers to your specifications.
Exhaust System
Modification of the exhaust system should be avoided. If modifications are absolutely necessary, the following points should be
maintained.
1. Maintain the clearance specified in the “Exhaust System” table between all parts of the exhaust system and any fuel lines, brake
lines, brake hoses, electrical cables, etc. The exhaust outlet should not point toward any of these parts.
Clearance
Brake lines 2.4 in. or more. (If the combined section of a group of parallel brake lines is more than 7.8 in., a clearance of 7 in. or more should be provided.)
Flexible brake hoses 3.9 in. or more. (The temperature of flexible brake hoses should not exceed 158ºF. If the highest temperature is not measurable,
a clearance of more than 15.7 in. should be maintained between the hoses and the exhaust system.)
Wiring harnesses and cables 3.9 in. or more.
Steel fuel lines 3.1 in. or more.
Rubber or vinyl fuel hoses 5.9 in. or more.
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2. If a tool box is installed, it should preferably be made from steel. If a wooden tool box is installed, at least 7.8 inches of clearance
should be maintained between the tool box and any parts of the exhaust system.
3. If the exhaust system is modified, it is the responsibility of those making the modification to ensure that the noise level meets
appropriate standards.
Fuel System
Relocation of the fuel tank, or installation of additional fuel tanks, is not recommended. If modifications to the fuel system are unavoidable,
follow these recommendations:
1. Maintain adequate clearance between the fuel tank and any other device or structure.
2. Do not connect any additional fuel hose.
Rear Lighting
Brackets installed are temporary. Please do not use these brackets for body installation.
Serviceability
No matter what other modifications or changes are made, access to components requiring daily preventive maintenance or other routine
service must not be obstructed. This includes:
1. Inspection, filling and draining of engine oil and cooling water.
2. Inspection, filling and draining of transmission fluid.
3. Adjustment, removal and installation of the fan belts.
4. Inspection, filling and removal of the battery and battery cover.
5. Inspection and filling of brake fluid.
6. Inspection and bleeding of the brake system and servo unit.
7. Maintenance of clearance for tightening of check bolt on brake safety cylinder.
8. Operation of the spare tire carrier, including mounting and dismounting of the spare tire.
9. Adjustment, removal and installation of distributor and/or cover.
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Wheelbase Alteration
With certain applications, it may become necessary to alter the wheelbase of the chassis. The next two sections provide the suggested
guidelines for accomplishing either shortening or lengthening of the wheelbase.
Shortening/Lengthening the Wheelbase Without Altering the Frame
Since the frame is an integral part of the chassis, it is recommended that the frame not be cut if it is possible to avoid it. When shortening/
lengthening the wheelbase on some models, it is possible to do so without cutting the frame. This is possible on models which have a
straight frame rail. If the chassis does not have a straight frame rail, it may still be necessary to cut the frame. For instructions on shortening/
lengthening these chassis, refer to the “Altering the Wheelbase by Altering the Frame” section of this book. Otherwise, the wheelbase may
be shortened/lengthened by removing the rear suspension, drilling new suspension mounting holes at the appropriate spot in the frame, and
sliding the rear suspension, suspension liner, and suspension crossmembers forward or aft. The suspension and suspension crossmembers’
rivet holes left in the frame rail flange must be filled with GRADE 8 bolts and hardened steel washers at both the bolt head and nut, HUC bolts
or GRADE 8 flanged bolts and hardened steel washers at the nut. When shortening/lengthening the wheelbase in this manner, the following
guidelines must be adhered to:
1. All frame drilling must comply with the DRILLING AND WELDING section of this book.
2. All rivet holes left in the frame rail flange from the suspension and suspension crossmembers must be either filled with GRADE 8
bolts and hardened steel washers at both the bolt head and nut, HUC bolts or GRADE 8 flanged bolts and hardened steel washers
at the nut.
3. The components required to be slid forward or aft are the suspension and suspension hangers, suspension crossmembers and
suspension frame liner.
Altering the Wheelbase by Altering the Frame
Even on a straight frame rail, it may be desirable to cut the frame and lengthen or shorten the wheelbase rather than simply sliding the rear
suspension back or forward. The following section offers some guidelines and suggestions for cutting and lengthening or shortening the frame.
Glossary of Terms – Chassis Wheelbase Alteration
CA – Length from back-of-cab to rear axle centerline in inches.

AL – Added length (in case of a lengthened wheelbase). Difference between WB (new) and WB (old).
SL – Shortened length (in case of shortened wheelbase). Difference between WB (old) and WB (new).
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1. Determine the added length (AL) or shortened length (SL) required to lengthen or shorten chassis. (For added wheelbase: New CA = CA
+ AL; For shortened wheelbase: New CA = CA – SL.)
2. Obtain the material to be used as the insert for the lengthened wheelbase in the correct length (AL). The insert must have the same cross
sectional dimensions and yield strength as the original frame rail.
3. Divide the new CA by two (2). Measure (new CA)/2 from the center of the rear axle forward and mark this point on the chassis frame (see
figure below).
4. Cut the chassis frame at this point. If the wheelbase is to be lengthened, addition of the previously obtained insert (of length AL determined
in step 1) will be made at this time. If the wheelbase is to be shortened, measure the distance (SL) forward of this cut and remove a length
(SL) section from the chassis frame (see figure below). Insure that an adequate area on the frame remains for the required addition of the
necessary reinforcements. These are the only suggested places for cutting the frame and reinforcements but may be changed upon the
advice of General Motors Isuzu Commercial Truck, LLC (GMICT) and American Isuzu Motors Inc. Application Engineering.

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5. When welding the insert (length AL for wheelbase lengthening) to the original frame rail, a continuous butt weld must be used at the
splices. When shortening the wheelbase, weld the ends of the chassis frame together with a continuous butt weld over the junction of
the frame ends. Weld both the inside and outside of the frame rails using welding techniques prescribed by established welding
standards (ref. SAE J1147) and in accordance with this guide. An example of this weld is shown below.
6. Determine the appropriate additional internal reinforcements which are required using this equation:
Reinforcement Length = AL + 6 x (original frame rail web depth).
The figure below shows how this reinforcement is to be placed over the extended or shortened section of the frame rail.
D = Original frame rail web depth
The suggested cross section of this reinforcement is a snug fit inner channel. If the new wheelbase exceeds the upper limit of the optional
wheelbases of this model, i.e.; a “long bridge”, it may be necessary to use an “inverted L” reinforcement in addition to the snug fit channel
reinforcement (see figures on next page). Application Engineering should be consulted for approval of such cases. It should be noted that
these methods of reinforcements, and any other methods which may be used, require a 45º angled cut at both ends to avoid stress
concentrations in the frame (note the figures under item 7).
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7. The reinforcements must be fastened securely to only the web of the original chassis frame rail. The reinforcement must be held rigidly
in place using either HUC bolts, GRADE 8 bolts and hardened steel washers at both the bolt head and nut, or GRADE 8 flanged bolts
and hardened steel washers at the nut. Below are some suggested bolt patterns. It should be noted that these bolt patterns must not
align the bolts vertically, i.e.: the bolt pattern must be staggered.
8. Lengthening the frame will also require extending the brake lines, basic chassis electrical harness, excluding ABS wiring harness. It is
recommended that the original brake lines be removed and replaced with brake lines of the same diameter as the original lines and of
the appropriate length. The electrical harness must be extended in accordance with the ELECTRICAL WIRING AND HARNESSING
section of this book.
9. The propeller shafts’ overall length will also need to be lengthened or shortened. If the extension is within the limits of the optional
wheelbases of the respective model, the exact propeller shaft lengths and angles are given on or about Page 12 of the respective
sections of this book. If the modified wheelbase exceeds the optional wheelbases of the respective model, the following guidelines
must be adhered to:
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a. Propeller Shaft Length
The maximum propeller shaft lengths (pin to pin) for the respective models are shown in the table below.
NPR/W3500, W4500 Diesel NPR/W3500, W4500 Gas NQR/W5500 FRR/WT5500

Propeller Shaft Diameter (in.) 3.25 3.0 3.0 4.0
Maximum Propeller Shaft Length (in.) 50.8 50.8 50.8 62.0
b. Propeller Shaft Angles
The maximum propeller shaft angles, with respect to the previous shaft, are shown in the table below.

Maximum Propeller Shaft Angle 5.7º 5.1º 5.7º 5.5º
c. The propeller shaft angles must be designed such that the angles will cancel to avoid propeller shaft whip.
d. The propeller shaft yokes must be assembled such that the propeller shaft yokes are “in phase.” “In phase” means that the yokes at
either end of a given propeller shaft assembly are in the same plane.
10. Extending the frame will also require relocation and/or addition of crossmembers. If the extension is within the limits of the optional
wheelbases of the respective model, the exact crossmember locations and dimensions are given in the respective model sections of
this book. If the modified wheelbase exceeds the optional wheelbases of the respective model, the following guidelines must be
adhered to:
a. The crossmember location will largely be determined by the propeller shaft lengths and where the center carrier bearing locations are
for the propeller shaft assembly.
b. A crossmember must be located at the front and rear spring hangers of the rear suspension (refer to the appropriate section of this
book to see where these suspension crossmembers are to be located).
c. The crossmember must be constructed such that it supports both the upper and lower flange on each frame rail (see drawing on next
page). A crossmember such as the one on the next page may be constructed, or GM/Isuzu crossmembers may be obtained from
your GM/Isuzu parts dealer.
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d. The maximum distance between crossmembers for the respective models is given in the table below.

Maximum Distance Between Crossmembers (in.) 35.7 35.7 35.7 49.8
e. The drilling for any additional holes in the frame rails must comply with the DRILLING AND WELDING section of this book.
11. All other aspects of lengthening or shortening the wheelbase must comply with the applicable section of this Body Builder’s Guide. For
special applications and longer than recommended body lengths, GMICT Application Engineering must be consulted for approval. In
the West Coast call 1-562-229-5314 and in the East Coast call 1-404-257-3013.
12. Please contact applications engineering for guidelines on N/W SERIES CHASSIS frame modifications when the vehicle is equipped
with an Antilock Brake System.
FRR/WT Series Chassis
Please contact applications engineering for guidelines on FRR/WT SERIES CHASSIS frame modifications when the vehicle is equipped with
an Antilock Brake System.
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13. The Crew Cab NPR HD/W4500 and NQR/W5500 will be available in two wheelbases, 150 and 176 inches. Effective CA will be 84.7 and
110.7 inches. On this model chassis, General Motors Isuzu Commercial Trucks will require that the body installed on the chassis have
an understructure manufactured with any of the following structural steel “C” channels:
4" x 1-5/8", 7.25 lbs./ft. = ok
5" x 1-3/4", 6.7 or 9.0 lbs./ft. = ok
6" x 2", 8.2, 10.5 or 13.0 lbs./ft. = ok
Hydraulic Brake System

Before Work Begins
As with any electrical work on the chassis, the battery should be disconnected before electrical work is started.
ABS Program
The Antilock Brake System (ABS) computer will hold its codes when disconnected and reprogramming as a result of battery disconnection
will not be necessary. If the wheelbase is changed, the trim level of the ABS system must be readjusted per the instructions in the service
manual. An authorized GM/Isuzu dealer should do this reprogramming using appropriate tools.
For your reference, and to help you determine if the system needs to be reprogrammed, the following provisions apply to all ABS systems
with hydraulic brakes. The ABS module has four (4) programs: A, B, C and D. These programs are tied to the wheelbase and axle combina-
tion of the chassis. (The axle and wheelbase codes can be found on the passenger’s visor.)
A is for the FL1 axle and covers wheelbase from 140 (FQT), 158 (EG5), and 170 (EH8) inches.
B is for the FL2 axle and covers wheelbase from 140 (FQT), 158 (EG5), 170 (EH8), 188 (EK8), and 200 (EM2) inches.
C is for the FL1 axle and covers wheelbase from 188 (EK8), 200 (EM2), 218 (FPL), 233 (EQ8), and 248 (ES5) inches.
D is for the FL2 axle and covers wheelbase from 218 (FPL), 233 (EQ8), and 248 (ES5) inches.
Moving between program/wheelbase groups A, B, C or D will require that the system be reprogrammed. Moving wheelbase within a
program group will not require reprogramming.

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ABS Computer Location
a. The ABS computer is located under the cab on the front crossmember and is an integral part of the brake fluid modulation system.
These components cannot be relocated.
ABS Electrical Harness
a. The harness cannot be cut and spliced.
b. The only approved way to make the harness longer is to purchase the appropriate wheelbase harness from the GM/Isuzu parts
department.
c. Extra wire resulting from a frame shortening can be coiled and secured to the frame.
Hydraulic Brake Lines
a. Hydraulic brake lines should be shortened or lengthened using appropriate fitting and steel lines.
Air Brake System

Before Work Begins
As with any electrical work on the chassis, the battery should be disconnected before electrical work is started.
ABS Program
The antilock brake system (ABS) computer will hold its codes when disconnected and reprogramming as a result of battery disconnection
will not be necessary. If the front axle is changed, the trim level of the ABS system must be readjusted per the instructions in the service
manual. An authorized GM/Isuzu dealer using the appropriate tools should do this reprogramming.
ABS Computer Location
a. The ABS computer is located back of cab on the power steering bracket. This components cannot be relocated.

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ABS Electrical Harness
a. The harness cannot be cut and spliced.
b. The only approved way to make the harness longer is to purchase the appropriate wheelbase harness from the GM/Isuzu parts
department.
c. Extra wire resulting from a frame shortening can be coiled and secured to the frame.
Air Brake Lines
a. Air brake lines should be shortened or lengthened using appropriate fittings and hose material.
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BODY APPLICATION SUMMARY CHART
2004 Gas and 2004 Diesel Model Year Body Application Summary Chart
Model/GVWR WB BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft.
109 9.25 X X
NPR/W3500 Gas 132.5 9.25 X
12,000 lbs. 150 9.25 X X
176 9.25 X1
109 9.25 X X
NPR HD/W4500 Gas 132.5 9.25 X
14,050 lbs. 150 9.25 X X
176 9.25 X1
109 9.25 X
NPR/W3500 Diesel 132.5 9.25 X
12,000 lbs. 150 9.25 X X
176 9.25 X1
109 9.25 X
NPR HD/W4500 Diesel 132.5 9.25 X
14,500 lbs. 150 9.25 X X
176 9.25 X1
NPR HD/W4500 Crew Cab Diesel 150 4.2 X4
14,500 lbs. 176 4.2 X5
109 9.25 X
NQR/W5500 Diesel 132.5 9.25 X
17,950 lbs. 150 9.25 X X
176 9.25 X X2
(2004 Model Year Body Application Summary Chart continued on next page)
1 = NPR/W3500, NPR HD/W4500 and Diesel 20-foot body requires GM/Isuzu Application Engineering Department approval.
2 = NQR/W5500 22-foot body requires GM/Isuzu Application Engineering Department approval.
3 = BOC 10.0 inches for MT.
4 = 16' Dovetail landscape (12' deck plus 4' dovetail).
IMPORTANT: Body selection recommendations are based on water-level weight distribution and no accessories, liftgate or refrigeration units. This table is intended
for reference and does not preclude the necessity for an accurate weight distribution calculation.
(Body Application Summary Chart Section – continued on next page)
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(Body Application Summary Chart Section – continued from previous page)
2004 Gas and 2004 Diesel Model Year Body Application Summary Chart (Chart continued from previous page)
Model/GVWR WB BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft. 24 ft.
NQR/W5500 Crew Cab Diesel 150 4.2 X4
17,950 lbs. 176 4.2 X5
MT/AT
148 7.5/10 X3 X
FRR/WT5500 Diesel 167 7.5/10 X
18,000/19,500 lbs. 179 7.5/10 X
191 7.5/10 X
218 10.0/10 X
1 = NPR/W3500, NPR HD/W4500 and Diesel 20-foot body requires GM/Isuzu Application Engineering Department approval.
2 = NQR/W5500 22-foot body requires GM/Isuzu Application Engineering Department approval.
3 = BOC 10.0 inches for MT.
IMPORTANT: Body selection recommendations are based on water-level weight distribution and no accessories, liftgate or refrigeration units. This table is intended
for reference and does not preclude the necessity for an accurate weight distribution calculation.

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2004 Model Year – Body & Payload Weight Distribution (% Front/% Rear) – Automatic Transmission
Model GVWR WB CA CE OAL BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft.
NPR/W3500 Gas 12,000 109 88.4 131.5 199.5 9.25 18/82 7/93
NPR HD/W4500 Gas 14,500 109 88.4 131.5 199.5 9.25 18/82 7/93
NPR/W3500 Gas 12,000 132.5 111.9 155 223 9.25 14/86
NPR HD/W4500 Gas 14,500 132.5 111.9 155 223 9.25 14/86
NPR/W3500 Gas 12,000 150 129.4 172.5 240.5 9.25 16/84 8/92
NPR HD/W4500 Gas 14,500 150 129.4 172.5 240.5 9.25 16/84 8/92
NPR/W3500 Gas 12,000 176 155.4 198.5 266.3 9.25 15/85*
NPR HD/W4500 Gas 14,500 176 155.4 198.5 266.3 9.25 15/85*
*NPR/W3500, NPR HD/W4500 Gas and Diesel 20-foot body requires GM/Isuzu Application Engineering Department approval.
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(Body Application Summary Chart – continued from previous page)
2004 Model Year – Body & Payload Weight Distribution (% Front/% Rear) – Manual/Automatic Transmission
NPR/W3500 Diesel 12,000 109 88.4 131.5 199.5 9.25 7/93
NPR HD/W4500 Diesel 14,500 109 88.4 131.5 199.5 9.25 7/93
NPR/W3500 Diesel 12,000 132.5 111.9 155 223 9.25 14/86
NPR HD/W4500 Diesel 14,500 132.5 111.9 155 223 9.25 14/86
NPR/W3500 Diesel 12,000 150 129.4 172.5 240.5 9.25 16/84 8/92
NPR HD/W4500 Diesel 14,500 150 129.4 172.5 240.5 9.25 16/84 8/92
NPR/W3500 Diesel 12,000 176 155.4 198.5 266.3 9.25 15/85*
NPR HD/W4500 Diesel 14,500 176 155.4 198.5 266.3 9.25 15/85*
*NPR/W3500, NPR HD/W4500 Gas and Diesel 20-foot body requires GM/Isuzu Application Engineering Department approval.
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NQR/W5500 Diesel
2004 Model Year – Body & Payload Weight Distribution (% Front/% Rear) – Manual/Automatic Transmission
Model GVWR WB CA CE OAL BOC 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 22 ft.
NQR/W5500 Diesel 17,950 109 88.4 131.5 199.5 9.25 7/93
NQR/W5500 Diesel 17,950 132.5 111.9 155 223 9.25 14/86
NQR/W5500 Diesel 17,950 150 129.4 172.5 240.5 9.25 16/84 8/92
NQR/W5500 Diesel 17,950 176 155.4 198.5 266.3 9.25 15/85 8/92
IMPORTANT: Weight distribution percentages listed do not include added accessories, liftgate or refrigeration units. Percentages based on water-level distribution of
body and payload weight which is determined by subtracting chassis wet weight (including 200 lb. driver) from GVWR. These tables are intended for
reference and do not preclude the necessity for an accurate weight distribution calculation.

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(Body Application Summary Chart – continued from previous page)
NPR HD/W4500, NQR/W5500 Crew Cab Diesel
2004 Model Year – Diesel Crew Cab Body & Payload Weight Distribution (% Front/% Rear)
Model GVWR WB CA CE OAL BOC 10 ft. 12 ft. 14 ft. 16 ft.

NPR HD/W4500 Crew Cab Diesel 14,500 150 88.9 132 240.5 4.2 8/92
NPR HD/W4500 Crew Cab Diesel 14,500 176 114.9 158 266.5 4.2 15/85
NQR/W5500 Crew Cab Diesel 17,850 150 88.9 132 240.5 4.2 16/84 8/92
NQR/W5500 Crew Cab Diesel 17,850 176 114.9 158 266.5 4.2 15/85 8/92
IMPORTANT: Weight distribution percentages listed do not include added accessories, liftgate or refrigeration units. Percentages based on water-level distribution of
body and payload weight which is determined by subtracting chassis wet weight (including 200 lb. driver and a crew of 6 @ 200 lbs. each) from GVWR.
These tables are intended for reference and do not preclude the necessity for an accurate weight distribution calculation.

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FRR/WT5500
2004 Model Year – Body & Payload Weight Distribution (% Front/% Rear)
Manual Transmission
FRR/WT5500 18,000/19,500 148 117.1 180.6 259.3 7.5 16/84* 10/90
FRR/WT5500 18,000/19,500 167 136.2 206.5 285.2 7.5 12/88
FRR/WT5500 18,000/19,500 179 148.0 226.2 304.9 7.5 11/89
FRR/WT5500 18,000/19,500 191 159.8 243.9 322.2 7.5 11/89
FRR/WT5500 18,000/19,500 218 187.4 283.3 362.0 10.0 15/85
* BOC 10.0 inches. (2004 Model Year Body & Payload Weight Distribution Chart continued on next page)

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2004 Model Year – Body & Payload Weight Distribution (% Front/% Rear) (Chart continued from previous page)
Automatic Transmission
FRR/WT5500 18,000/19,500 148 117.1 180.6 259.3 10 15/85 7/93
FRR/WT5500 18,000/19,500 167 136.2 206.5 285.2 10 10/90
FRR/WT5500 18,000/19,500 179 148.0 226.2 304.9 10 9/91
FRR/WT5500 18,000/19,500 191 159.8 243.9 322.2 10 9/91
FRR/WT5500 18,000/19,500 218 187.4 283.3 362.0 10 15/85
IMPORTANT: Weight distribution percentages listed do not include added accessories, liftgate or refrigeration units. Percentages based on water-level
distribution of body and payload weight which is determined by subtracting chassis wet weight (including 200 lb. driver) from GVWR. These tables
are intended for reference and do not preclude the necessity for an accurate weight distribution calculation.
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MECHANICAL AND CAB SPECIFICATIONS
Engine Horsepower and Torque Chart
The following table presents Net versus Gross Horsepower and Torque ratings for 2004 Isuzu/W-Series Truck Product Engines:
Net Hp1 Net Torque1 Gross Hp1 Gross Torque1

Engine Model Application hp/rpm lbs.-ft./rpm hp/rpm lbs.-ft./rpm
GMPT 6.0L-V8 NPR/W3500, NPR HD/W4500 Gas N/A N/A 300/4400 358/2800
Isuzu 4HE1-TC Manual Transmission NPR/W3500, NPR HD/W4500 Diesel 137/2800 268/1300 142/2800 275/1300
Isuzu 4HE1-TC Automatic Transmission NPR/W3500, NPR HD/W4500, NQR/W5500 Diesel 169/2700 339/2000 175/2700 347/2000
Isuzu 4HE1-TC Manual Transmission NQR/W5500 Diesel 169/2700 339/2000 175/2700 347/2000
Isuzu 6HK1-TC Manual Transmission FRR/WT5500 Diesel 193/2400 426/1500 200/2400 441/1500
Isuzu 6HK1-TC Automatic Transmission FRR/WT5500 Diesel 193/2400 426/1500 200/2400 441/1500
1
NOTE: Horsepower and Torque Ratings measured under SAE J1349 standards.
GVW/GCW Ratings
The following table presents GVW ratings and corresponding GCW ratings for each model truck:
Truck Model Transmission GVWR (lbs.) GCWR (lbs.)1 Truck Model Transmission GVWR (lbs.) GCWR (lbs.)1
NPR/W3500 Gas Automatic 12,000 18,000 NPR HD/W4500 Diesel Manual 14,500 20,500
NPR HD/W4500 Gas Automatic 14,500 20,500 NQR/W5500 Diesel Automatic 17,950 19,5002
NPR/W3500 Diesel Automatic 12,000 18,000 NQR/W5500 Diesel Manual 17,950 22,500
NPR/W3500 Diesel Manual 12,000 18,000 FRR/WT5500 Diesel Automatic 18,000/19,500 26,000
NPR HD/W4500 Diesel Automatic 14,500 19,500 FRR/WT5500 Diesel Manual 18,000/19,500 30,000
1
The NPR, NPR HD, NQR/W3500, W4500, W5500 are not approved for Hot Shot applications.
2
GCWR 20,950 with addition of optional Isuzu Transmission Oil Cooler.
(Mechanical and Cab Specifications Section – continued on next page)

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(Mechanical and Cab Specifications Section – continued from previous page)
Rear Frame Height Chart

The following table provides the rear frame height for each model/GVWR with standard tires:
Model GVWR (lbs.) Standard Tire Frame HT (in.) FH Std. Tires

NPR/W3500 Gas 12,000 215/85R-16E 31.4
NPR HD/W4500 Gas 14,500 225/70R-19.5F 32.3
NPR/W3500 Diesel 12,000 215/85R-16E 32
NPR HD/W4500 Diesel 14,500 215/85R-16E 32
NQR/W5500 Diesel 17,950 225/70R-19.5F 32.8
FRR/WT5500 Diesel 18,000 225/70R-19.5F 35.31
1
191-inch and 218-inch WB have frame height of 37.3 inches.
Clutch Engagement Torque

The following table provides the engagement torque of the engines currently is use in GM/Isuzu medium duty trucks:
Engine Torque (lbs.-ft.) at (RPM)

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

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Paint Code Chart
GM/ISUZU OPTION CODE GM/ISUZU PAINT COLOR NAME GM/ISUZU PAINT CODE
1985 KS22
N/A Calm White 0133-P1
1986-95 NPR/W3500, W4500 Diesel
844 Glacier White 0172-P1
1993-94 NPR/W3500, W4500 EFI
1995.5-04 NPR, NQR/W3500, W4500, W5500 DIESEL
729 Arc White W301-P801-0
730 Adriatic Blue Solid (1999 Model Only) B302-P801-0
845 Polar Silver (NPR only) N507-P901-0
989 Sunbelt Green G021-P801-0
1995.5-04 NPR/W3500, W4500 GAS
729 Arc White W301-P801-0
N/A Accuride White (Wheels Only) 301-W-30102
845 Polar Silver N507-P901-0
1989-94 NQR/W5500
1995-03 FRR/WT5500

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CV Chart 2
GM/ISUZU PAINT CODE GM/ISUZU OPTION CODE GM/ISUZU COLOR NAME AKZO NOBEL CODE BASF R-M CODE BASF GLASS CODE
301-W-30102 N/A Accuride White FLNA40154 RM25319 IS-25319
B302-P801-0 730 Adriatic Blue (Solid) FLNA50274 730 730
W301-P801-0 729 Arc White FLNA40156 RM25318 IS-25318
WE8774 N/A *Bright Red FLNA30252 27427 IS-27427
0133-P1 N/A Calm White FLNA40252 HS14391 IS-820
WE5398 N/A *Dark Green Gray FLNA90856 27425 IS-27425
U715-P801-0 809 Doeskin Tan FLNA80050 27406 IS-U715
0172-P1 844 Glacier White FLNA40155 RM15602 IS-844
WE9907 N/A *Medium Adriatic Blue FLNA90857 27426 IS-27426
B721-P801-0 801 Medium Blue FLNA50172 27403 IS-B721
N507-P901-0 845 Polar Silver FLNA91205 23664 845
R725-P801-0 810 Red Orange FLNA20079 27407 IS-R725
WE9885 N/A *Rose Black FLNA90858 27428 IS-27428
G021-P801-0 989 Sunbelt Green FLNA60290 605301 989
U716-P801-0 815 Tangier Orange FLNA20080 27409 IS-U716
Y719-P801-0 812 Wheatland Yellow FLNA10182 27408 IS-Y719
G705-P801-0 807 Woodland Green FLNA60181 27404 IS-G705
* GM-based colors. No Isuzu Option Code.

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CV Chart 2 (Continued)
SHERWIN WILLIAMS/
DUPONT CODE AUTO COLOR PPG CODE MARTIN SENOUR SPIES HECKER CODE STANDOX
F2499 8AR8 91513 51548 15593 301-W-30102
W9775 2NV9B 19320 57541 50287 730
W9774 2NV8 91512 51400 10280 729
C8508 TC78B 75057 34983 34169 WE8774
G8477 KK27 91522 34657 16222 0133-P1
B9329 2NP9B 36575 47155 65071 WE5398
B8462 KPL5B 28613 56203 21882 809
H8620 ND92 90330 35478 10281 844
B9321 2NY4B 190401 46829 56120 WE9907
B8041 KPL2B 190217 56143 55934 801
F2193 EPW3B 36658 56991 73192 845
B8250 KPL4B 61784 56202 21881 810
B9218 1AB2B 95057 45738 74223 WE9885
M6682 WMK4 401420 61559 67847 989
B9043 KPL6B 61785 56204 21883 815
B9042 KPL7B 83931 56144 21884 812
B8046 KPL3B 48339 56201 64962 807

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N/W Series Towing Procedure

NOTE: When towing, disconnect the propeller shaft at the rear axle to ensure the automatic transmission is not damaged.
Proper equipment must be used to prevent damage to vehicles during any towing. State and local laws which apply to vehicles in tow must
be followed. Vehicles should not be towed at speeds in excess of 55 mph (90 km/h). Connect to the main structural parts of the vehicle. DO
NOT attach to bumpers, tow hooks or brackets. Use only equipment designed for this purpose. Follow the instructions of the wrecker
manufacturer. A safety chain system must be used. The procedures below must be followed when towing to prevent possible damage.
Front End Towing (Front Wheels Off the Ground)
To prepare a disabled vehicle for front end towing with front wheels raised off the ground, the following steps are necessary:
• Block the rear wheels of the disabled vehicle.
• Disconnect the propeller shafts at the rear axle. Secure the propeller shafts to the frame or crossmember.
• If there is damage or suspected damage to the rear axle, remove the axle shafts.
• Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects.
• Place 4" x 4" wood beam against the towing guide behind the bumper. (If no 4" x 4" is available, then remove the bumper.) Ensure
the towing chains do not contact the horns or the bumper.
Legend:
1. Horns
2. Bumper
(removed for towing)
3. Filler

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After Towing
After towing the vehicle, block the rear wheels and install axle shafts or propeller shaft. Apply the parking brake before disconnecting from
the towing vehicle.
Front End Towing (All Wheels On the Ground)
Your vehicle may be towed on all wheels provided the steering is operable. Remember that power steering and brakes will not have power
assist. There must be a tow bar installed between the towing vehicle and the disabled vehicle.
Legend:
1. Bumper
2. Towing Chain
3. Towing Guide
4. Front Axle
5. Tow Hook
To prepare a disabled vehicle for front end towing with all wheels on the ground, the following steps are necessary:
• Block the wheels of the disabled vehicle.
• Disconnect the propeller shafts at the rear axle. Secure the propeller shafts to the frame or crossmember.
• Provide wood blocking to prevent towing chains and bar from contacting the bumper.
• If there is damage or suspected damage to the rear axle, remove the axle shafts.
• Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects.
After Towing
After towing the vehicle, block the rear wheels and install axle shafts or propeller shaft. Apply the parking brake before disconnecting from
the towing vehicle. Check and fill rear axle with oil if required.

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Rear End Towing (Rear Wheels Off the Ground)
When towing a vehicle with rear wheels raised, secure the steering wheel to maintain straight-ahead position. Make certain that the front axle
is not loaded above the front axle Gross Axle Weight Rating (GAWR) as indicated on the vehicle’s VIN and Weight Rating plate.
Special Towing Instructions:

1. All state and local laws regarding such items as warning signals, night illumination, speed, etc., must be followed.
2. Safety chains must be used.
3. No vehicle should ever be towed over 55 mph (90 km/h).
4. Loose or protruding parts of damaged vehicles should be secured prior to moving.
5. A safety chain system completely independent of the primary lifting and towing attachment must be used.
6. Operators should refrain from going under a vehicle which is being lifted by the towing equipment unless the vehicle is
adequately supported by safety stands.
7. No towing operation which for any reason jeopardizes the safety of the wrecker operator or any bystanders or other motorists
should be attempted.

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FRR/WT5500 Series Towing Procedure

Your vehicle should be towed by an authorized dealership or professional towing service to prevent damage. Proper equipment must be
used and state (Provincial in Canada) and local laws, which apply to vehicles in tow, must be followed. Vehicles should not be towed in
excess of 55 mph (90 km/h).
Connect to the main structural parts of the vehicle. Do not attach to bumpers, tow hooks or brackets. Use only equipment designed for this
purpose. Follow the instructions of the wrecker manufacturer.
A safety chain system must be used.
Front End Towing (Front Wheels Off the Ground)
Before Towing
Block the rear wheels of the disabled vehicle. Release the parking brake as described under “Air-Operated Parking Brake” in this section.
Drain rear axle oil and remove the axle shafts. Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects.
After Towing
After towing the vehicle, block the rear wheels, remove the covers from the hub openings and install the axle shafts. Apply the parking brake
before disconnecting from the towing vehicle. Check and fill rear axle with oil if required.
Front End Towing (All Wheels On the Ground)
Your vehicle may be towed on all wheels provided the steering is operable. Remember that power steering will not have power assist. If air
pressure is exhausted, the vehicle will not have brakes. There must be a tow bar installed between the towing and the disabled vehicle.
Before Towing
Block the wheels of the disabled vehicle. Disconnect the propshaft at the rear axle. Secure the propshaft to the frame or crossmember. If
there is damage or suspected damage to the rear axle, drain oil and remove the axle shafts. Cover the hub openings to prevent the loss of
lubricant or entry of dirt or foreign objects.
After Towing
After towing the vehicle, block the rear wheels and install axle and propeller shafts. Check for proper phasing of universal joints. Apply the
parking brake before disconnecting from the towing vehicle. Check and fill rear axle with oil if required.

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Rear End Towing (Rear Wheels Off the Ground)
Before Towing
Secure the steering wheel to maintain straight-ahead position. Make certain that the front axle is not loaded above the front axle Gross Axle
Weight Rating (GAWR) as indicated on the vehicle’s VIN and Weight Rating plate.
After Towing
Block the rear wheels and release the steering. Apply the parking brake before disconnecting from the towing vehicle. Check and fill the rear
axle with oil as required.
Special Towing Instructions:

1. Call your local authorized dealership or professional towing service.
2. All state and local laws regarding such items as warning signals, night illumination, speed, etc. must be followed.
3. Safety chains must be used.
4. No vehicle should ever be towed over 55 mph (90 km/h).
5. Loose or protruding parts of damaged vehicles should be secured before moving.
6. A safety chain system completely independent of the primary lifting and towing attachment must be used.
7. Operators should refrain from going under a vehicle, which is being lifted by the towing equipment unless the vehicle is adequately
supported by safety stands.
8. No towing operation, which for any reason jeopardizes the safety of the wrecker operator or any bystanders or other motorists,
should be attempted.
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WEIGHT DISTRIBUTION CONCEPTS
Weight Restrictions
The Gross Vehicle Weight Rating (GVWR) and the Gross Axle Weight Rating (GAWR) of each Incomplete Vehicle are specified on the cover
of its Incomplete Vehicle Document in conformance to the requirements of Part 568.4 of the Federal Motor Vehicle Safety
Regulations. The final stage manufacturer is responsible under Part 567.5 to place the GVWR and the GAWR of each axle on the Final
Vehicle Certification Label. The regulation states that the appropriate rating “shall not be less than the sum of the unloaded vehicle weight,
rated cargo load, and 150 pounds times the vehicle’s designated seating capacity.”
Unloaded vehicle weight means the weight of a vehicle with maximum capacity of all fluids necessary for operation of the vehicle, but
without cargo or occupants.
During completion of this vehicle, GVWR and GAWR may be affected in various ways, including but not limited to the following:
1. The installation of a body or equipment that exceeds the rated capacities of this Incomplete Vehicle.
2. The addition of designated seating positions which exceeds the rated capacities of this Incomplete Vehicle.
3. Alterations or substitution of any components such as axles, springs, tires, wheels, frame, steering and brake systems that may
affect the rated capacities of this Incomplete Vehicle.
Use the following chart to assure compliance with the regulations. Chassis curb weight and GVW rating is located on Page 2 in each vehicle
section. Always verify the results by weighing the completed vehicle on a certified scale.
Curb Weight of Chassis (lbs.)

(From required vehicle section)
PLUS weight of added body components, accessories or other permanently attached components. +
(Body, liftgate, reefer, etc.)
PLUS total weight of passengers, air conditioning and all load or cargo. +
(Driver, passengers, accessories and load)
EQUALS Gross Vehicle Weight (lbs.) (GVW) of completed vehicle. =

(Should equal GVWR from required vehicle section)
(Weight Distribution Concepts Section – continued on next page)

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(Weight Distribution Concepts Section – continued from previous page)
Gross Axle Weight Rating

The Gross Vehicle Weight is further restricted by the Gross AxIe Weight Rating (GAWR). The maximum GAWR for both front and rear axles
is listed in each Vehicle Section. Weight distribution calculations must be performed to ensure GAWR is not exceeded. Always verify the
results by weighing the completed vehicle on a certified scale.
NOTE: Although the Front Gross Axle Weight Rating (FGAWR) plus the Rear Gross Axle Weight Rating (RGAWR) may exceed the Gross
Vehicle Weight Rating (GVWR), the total GVW may not exceed the respective maximum GVWR.
The variation in the GAWRs allow the second stage manufacturer some flexibility in the design of the weight distribution of the attached unit.
Weighing the Vehicle

Front and rear GAWRs and total GVWR should be verified by weighing a completed loaded vehicle. Weigh the front and rear of the vehicle
separately and combine the weights for the total GVWR. All three weights must be less than the respective maximum shown in the vehicle
sections.
Tire Inflation
Tire inflation must be compatible with GAWR and GVWR as specified on the cover of the Incomplete Vehicle Document for each vehicle.
Center of Gravity
The design of the truck body should be such that the center of gravity of the added load does not exceed the guidelines as listed in each
Vehicle Section. If the body is mounted in such a way that the center of gravity height exceeds the maximum height of the center of gravity
designated for each model, the directional stability at braking and roll stability at cornering will be adversely affected. A vertical and/or
horizontal center of gravity calculation must be performed if a question in stability arises to ensure the designed maximum height of the
center of gravity is not violated.

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Weight Distribution
A truck as a commercial vehicle has but one purpose. That purpose is to haul some commodity from one place to another. A short distance
or a long distance, the weight to be hauled, more than any other factor, determines the size of the truck. A small weight requires only a small
truck; a large weight requires a large truck. A simple principle, but it can easily be misapplied. In any case, selecting the right size truck for
the load to be hauled will ensure that the job will be done and that it will be able to be done with some degree of reliability and within the legal
limitations of total gross weight and axle gross weights.
Not only must a truck be selected that will handle the total load, but the weight must also be properly distributed between the axles. This is
of extreme importance from both a functional and economic aspect. If a truck consistently hauls less than its capacity, the owner is not
realizing full return on his investment and his operating costs will be higher than they should be. If the truck is improperly loaded or
overloaded, profits will be reduced due to increased maintenance costs and potential fines resulting from overloading beyond legal limita-
tions. Careful consideration must be given to distribution of the load weight in order to determine how much of the total, including chassis,
cab, body and payload, will be carried on the front axle and how much will be carried on the rear axle, on the trailer axles and the total.
Moving a load a few inches forward or backward on the chassis can mean the difference between acceptable weight distribution for the
truck or an application that will not do the job satisfactorily.
Every truck has a specific capacity and should be loaded so that the load distribution is kept within Gross Axle Weight Ratings (GAWR) and
the truck’s Gross Vehicle Weight Rating (GVWR) or Gross Combination Weight Rating (GCWR) for a tractor/trailer and the weight laws and
regulations under which the truck will operate. Improper weight distribution will cause problems in many areas:
1. Excessive front end wear and failure

a. Tie-rod and kingpin wear
b. Front axle failure
c. Overloading of front suspension
d. Wheel bearing failure
2. Rapid tire wear

a. When the weight on a tire exceeds its rating capacity, accelerated wear will result and could result in tire failure.

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3. Rough, erratic ride
a. If the center of the payload is directly over or slightly behind the rear axle, the lack of sufficient weight on the front axle will
create a bobbing effect, very rough ride, and erratic steering. This condition will be magnified when the truck is going uphill.
4. Hard steering
a. When loads beyond the capacity of the front axle are imposed upon it, the steering mechanism is also overloaded and hard
steering will result.
b. Excessive overloading could result in steering component damage or failure.
5. Unsafe operating and conditions

a. Poor traction on the steering axle effects the safety of the driver and equipment, particularly on wet, icy and slippery surfaces.
Experience indicates that approximately 30% of the total weight at the ground on a truck or tractor should be on the front axle
with a low cab forward vehicle.
b. When a truck is overloaded, a dangerous situation may exist because minimum speeds cannot always be maintained, direc-
tional control may not be precise and insufficient braking capacity can cause longer than normal braking distances.
6. High maintenance costs

a. Improper weight distribution and overloading cause excessive wear and premature failure of parts. Additional stresses
imposed on the frame by the misapplication of wheelbases may be instrumental in causing the frame to crack or break.
7. Noncompliance with weight laws and regulations

a. When there is the possibility that axle loads will exceed existing weight laws and regulations, careful weight distribution is
necessary to provide a correct balance between front and rear axle loads and total load within legal limitations.
In this way, maximum payloads may be carried without exceeding legal limits. If the body is too long for a wheelbase, the center of the body
and payload is placed directly over the rear axle. This places all the payload on the rear axles, resulting in overloading the rear tires, rear axle
springs and wheel bearings and potentially exceeding the rear axle legal weight limit. The front axle is then carrying no part of the payload
and is easily lifted off the ground when going over rough terrain, creating a very rough ride and temporary loss of steering control. If the body
is too short for the wheelbase used, frame stress may be increased and may result in excessive loads on the front axle. Excessive front axle
loads increase wear on the kingpins and bushings, wheel bearings and steering gear. Excessive front axle loads also overstress the front
axle, springs, tires and wheels. All of these contribute directly to higher maintenance costs and hard steering, both of which are undesirable.

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Weight distribution analysis involves the application of basic mathematical principles to determine the proper positioning of the payload and
body weight in relation to the wheelbase of the truck chassis.
It is much less expensive to work all of this out on paper, make mistakes on paper and correct them there than to set up the truck incorrectly
and either have it fail to do the job or, much worse, fail completely.
It is important to become familiar with the dimensions of the truck, as these will be needed to perform the necessary calculations.
Glossary of Dimensions
BBC – Bumper to back of cab CG – Center of gravity of body and payload from axle
BA – Bumper to axle WB – Wheelbase
CA – Cab to axle OAL – Overall length
AB – Axle to back of cab AF – Axle to end of frame
BOC – Back of cab clearance FH – Frame height
CE – Cab to end of frame

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Weight Distribution Formulas
A – Front axle to back of cab

B – Distance between cab and body or trailer
C – Front of body to C.G. or front of trailer to kingpin
D – Distance C.G. of body or fifth wheel is ahead of rear axle
F – (A + B + C) or distance C.G. of weight of fifth wheel is behind front axle
WB – Wheelbase
W – Weight of body plus payload, or kingpin load
Wf – Portion of W transferred to front axle
Wr – Portion of W transferred to rear axle

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Basic Formulas
(a) W x D = Wf x WB (c) WB = (A + B + C + D) = (F + D)
or
(b) W x F = Wr x WB (d) W = Wf x Wr
1. Wf = WxD 5. Wr = WxF
WB WB
2. D = Wf x WB 6. F = Wr x WB
W W
3. WB = WxD 7. WB = WxF
Wf Wr
4. W = Wf x WB 8. W = Wr x WB
D F
Weight Distribution Formulas in Words

To find:
1. Weight transferred to front axle = (Total weight) x (Distance C.G. is ahead of the rear axle)
(Wheelbase)
2. Distance C.G. must be placed ahead of rear axle = (Weight transferred to the front axle) x (Wheelbase)
(Total weight)
3. Wheelbase = (Total weight) x (Distance C.G. is ahead of the rear axle)

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

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

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

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

(Distance C.G. is behind the front axle)
9. Remember = Total weight must always equal weight transferred to the

rear axle plus the weight transferred to the front axle
To find the value of “P”, the leverages must be equal for balance.
Example: 100 lbs. x 8 in. = “P” x 20 in.
or “P” = 100 lbs. x 8 in.

20 in.
Therefore: “P” = 40 lbs.
This same approach is used to determine axle loadings on a tractor or truck chassis. Assuming the rear axle serves as a pivot point, the front
axle load can be determined by applying the lever principle.
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Front Axle Load: = Kingpin Load x 5th Wheel Location

Wheelbase
Rear Axle Load: = Kingpin Load – Front Axle Load
Example: (4) A tractor has a wheelbase of 150 inches. If the kingpin load is 20,000 lbs. and the fifth wheel location is 15 inches, find the total
weight on the front and rear axles. The tare weight of the tractor is 7,000 lbs. on the front axle and 4,400 lbs. on the rear axle.
Front Axle = Load

20,000 x 15 = 2,000 lbs.
150
WB
Rear Axle Load = 20,000 – 2,000 lbs. = 18,000 lbs.
Therefore:
Total Front Axle Weight = 2,000 + 9,000 lbs. = 11,000 lbs.
Total Rear Axle Weight = 4,400 + 18,000 lbs. = 22,400 lbs.

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In calculating the weight distribution for a truck, the same lever principle is applied; however, there is one change in the initial consideration
of the method of loading the truck body. Instead of the trailer kingpin location ahead of the rear axle centerline, we must determine the
position of the center of gravity of the payload and body weight in relation to the rear axle centerline.
For our calculations, we assume that the payload is distributed in the truck body so that the load is supported evenly over the truck body
floor (water-level distribution). The weight of the body itself is also considered to be evenly distributed along the truck frame. In this manner,
we can add the payload and body weights together and calculate the distribution on the vehicle chassis as an evenly distributed load on the
truck frame rails.
So that we can make the necessary calculation in a simple manner, the total body and payload weight is considered to act at the center of
gravity which will be at the center of the body length.
Example: Front Axle Load =

(Body Weight + Payload) x C of G location
Wheelbase
Rear Axle Load =

(Body Weight + Payload) – Front Axle Load
Therefore, Front Axle Load =

15,000 x 24 = 2,400 lbs.
150
Rear Axle Load = 15,000 – 2,400 = 12,600 lbs.

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If the truck tare weight without the body is 5,000 lbs. on the front axle and 2,400 lbs. on the rear axle, then
Total Front Axle Weight = 5,000 + 2,400 = 7,400 lbs. and
Total Rear Axle Weight = 2,400 + 12,600 = 15,000 lbs.
This same lever principle is applied in all calculations of weight distribution, whether we are dealing with concentrated loads as with a kingpin
load acting on a fifth wheel or if it be with an evenly distributed load as with a truck body. The same approach is made in calculating an evenly
distributed load on a trailer.
In the case of a tractor/trailer or a tractor with a set of double or triple trailers, each unit is handled as a separated unit and then combined to
determine the total.
This simple example illustrates how the principles are applied. Using the formulas, find the weight distributed to each axle.
Front Weight Rear Weight
A. Wf = W x D A. Total Weight –
WB
B. 300 x 24 B. 300 – 75
96
C. = 75 lbs. C. = 225 lbs.
The body manufacturer can provide the body length and weight, or actual measurements of the body may be taken with a tape.
Generally, (D) is unknown. This you must find logically, or with a tape measure.

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Find (D) and then solve for Wf and Wr.
D = 60–3–48 = 9 in.
Wf = 205
Wr = 2,795
Recommended Weight Distribution % of Gross Vehicle Weight by Axle

Conventional (2 Axle) COE (2 Axle)

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Conventional (3 Axle) COE (3 Axle)
Calculating tractor/trailer weight distribution can be thought of in the same terms as calculating full trucks.
The weight at the center of the body and the load when applied is the same as the single point load of the kingpin on the fifth wheel.

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Trailer Weight
Fill in: L = 40 feet

RAS = 48 inches
KP = 36 inches
WB = ? 396
D = ? 204
In the following example, a 50,000-pound payload at water-level loading. Calculate the payload (PL) weight transfer to kingpin and the rear
axle.
NOTE: Apply the same principles used with truck chassis.

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Payload at Kingpin
PLkp = W x D
WB
Calculate the “D” dimension.
OAL/2 – AF = D
45 feet/2 – 48 inches – 36 inches = 186 inches
PLkp =50,000 lbs. x 186 in. = 20,394 lbs.

456 in.
PLkp =20,394 lbs.
Payload at Rear Tandem
PLrt = W – PLkp
PLrt = 50,000 lbs. – 20,394 lbs. = 29,606 lbs.
PLrt = 29,606 lbs.
Once the weight on the kingpin is determined, it can then be treated on the tractor the same as a weight on a straight truck.
Due to the variations in hauling and wheelbase requirements from one truck application to another, there is no one specific fifth wheel setting
that will apply in all cases.
A “rule of thumb” which has proven satisfactory in many cases sets the fifth wheel one inch ahead of the rear axle for every 10 inches of
wheelbase. In the case of tandem axles, the wheelbase is measured from the center line of the front axle to the midpoint between the tandem
rear axles. The location of the fifth wheel fixes the load distribution between the front and rear axles. Too far forward and the front axle is
overloaded. If too far back, the front axle may be too lightly loaded and cause an unsafe steering and braking control situation at the front axle.

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A tractor on a hill with the fifth wheel set at the axle center line or too close to it will result in an unsafe handling situation by transferring too
much weight to the rear axle and actually unloading the front axle.
Performance Calculations
The following calculations have been included to help you determine the performance characteristics required by your customers and to
select the appropriate model vehicle:
1. Speed Formula
This formula can be used to determine:
1. Top speed of the vehicle.

2. Speed in a given gear.
3. Final ratio required for a given speed.
MPH @ Governed Speed = _______________________

(60) x (RPM)
(Rev/Mile) x (Gear Ratio)

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Definitions in formula:
RPM = Revolutions per minute of the engine at Governed Speed

Rev/Mile = Tire revolutions per mile
Gear Ratio = The product of the axle ratio times the transmission ratio
60 = Time Constant
Example: NPR/W3500 12,000 GVWR automatic transmission.
RPM = 3,000
Rev/Mile = 674
Gear Ratio = .703 x 5.375
MPH @ Governed Speed = ___________________

(60) x (3,000)
(674) x (.703 x 5.375)
MPH @ Governed Speed = 70 MPH
2. Grade Horsepower Formula
This formula can be used to determine horsepower required for a given grade and speed.
Horsepower Req’d. for a given grade = _________________________

GVWR x Grade x Speed
+ AHP
37,500 x Efficiency Factor
GVWR = Gross Vehicle Weight Rating

Grade = Grade anticipated in percent
Speed = Speed in miles per hour
37,500 = Constant
Efficiency Factor = Factor for losses in drivetrain due to friction
(use 0.9 for a 90% efficient driveline)
AHP Resistance = Horsepower required to overcome wind force

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Example: NPR/W3500 11,050 GVWR automatic transmission with a van body.
GVWR = 12,000 lbs.

Grade = 1 percent
Speed = 55 MPH
37,500 = Constant
Efficiency Factor = 0.9
AHP Resistance = 53.6 HP (see the following formula for calculation)
12,000 x 1 x 55
______________
HP Required for Grade = + 53.67
37,500 x 0.9
HP Required for Grade = 73.22
3. Air Resistance Horsepower Formula
This formula is used to determine the horsepower required to overcome air resistance at a given speed.
Air Resistance Horsepower = FA x Cd x (MPH)3

________________
156,000
FA = Frontal area of vehicle in square feet

Cd = Aerodynamic Drag Coefficient
MPH = Speed of vehicle in miles per hour
156,000 = Constant
Frontal area is calculated by multiplying the height of the vehicle by the width of the vehicle and subtracting the open area under the
vehicle from the total.
Aerodynamic Drag Coefficients (Source Material: Motor Truck Engineering Handbook):
0.70 for most trucks, semitrailer combinations with tanks or van bodies
0.77 for double and triple trailers and flatbeds with loads
1.00 car and boat haulers
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Example: NPR/W3500 12,000 GVWR van body with 96" wide, 115" high (84" body height + 31" frame height).
FA = (96) x (115)
__________ – 3.2
(12) x (12)
FA = 73.47 ft.2
Cd = 0.70
Speed = 55 mph
Air Resistance HP = 73.47 x 0.70 x (55)3

__________________
156,000
Air Resistance HP = 54.85
4. Engine Horsepower Formula
This formula can be used to derive the output at a given RPM and torque.
Horsepower = Torque x RPM

_____________
5,252
Torque = Twisting output of engine given in lbs.-ft.

RPM = Revolutions per minute of engine
5,252 = Constant
Example: NPR/W3500 12,000 GVWR automatic transmission.
Torque = 347 lbs.-ft.

RPM = 2,000
132 HP = (347) x (2,000)
____________
5,252

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5. Gradeability Formula
This formula can be used to determine how large of a grade a vehicle can climb.
Percent Grade = ________________________

1,200 x (T) x (E) x (C) x (R)
– RR
GVWR x r
1,200 = Constant
T = Maximum Torque of Engine
E = Engine Efficiency (0.9)
C = Driveline Efficiency (0.9)
R = Transmission Ration x Axle Ratio
RR = Rolling Resistance (see following chart)
r = Loaded radius of tire
Example: NPR/W3500 12,000 GVWR automatic transmission on concrete highway.
T = 347 lbs.-ft.
E = 0.9
C = 0.9
R = .703 x 5.375 (in overdrive)
RR = 1.0
GVWR = 12,000
r = 14.1 in.
1,200 x (347) x (0.9) x (0.9) x (.703) x (5.375)

________________________________________
Percent Grade = – 1.0
12,000 x 14.1
Percent Grade = 6.53 – 1
Gradeability = 5.53%

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Road Rolling Resistance

Road Rolling Resistance – Expressed in Percent Grade
Road Surface Grade Road Surface Grade
Concrete, excellent 1.0 Cobbles, ordinary 5.5
Concrete, good 1.5 Cobbles, poor 8.5
Concrete, poor 2.0 Snow, 2 inches 2.5
Asphalt, good 1.25 Snow, 4 inches 3.75
Asphalt, fair 1.75 Dirt, smooth 2.5
Asphalt, poor 2.25 Dirt, sandy 3.75
Macadam, good 1.5 Mud 3.75 to 15.0
Macadam, fair 2.25 Sand, level soft 6.0 to 15.0
Macadam, poor 3.75 Sand, dune 16.0 to 30.0
6. Startability Formula
This formula is used to determine what type of a grade a vehicle can be started on.
(1,200) x (CET) x (E) x (C) x (R)

Startability = ____________________________ – 10%
(GVWR x r)
1,200 = Constant
CET = Clutch Engagement Torque
E = 0.9
C = 0.9
R = Transmission x Axle Ratio
10% = Average break away resistance and static inertia constant
r = Loaded radius of tire

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Example: NPR/W3500 12,000 GVWR manual transmission.
CET = 260 lbs.-ft.

R = 6.02 x 4.10
GVWR = 12,000 lbs.
r = 14.1 in.
(1,200) x (260) x (0.9) x (0.9) x (6.02 x 4.10)

_____________________________________
Startability = – 10%
(12,000 x 14.1)
Startability = 26.86%
7. Vertical Center of Gravity Formula
These formulas are used to estimate the vertical center of gravity of a completed vehicle in order to determine whether maximum
allowable limits have been exceeded. This formula should be used when encountering high center of gravity loads.
7.1 Wv x (Vv) = Mv
7.2 Wb x (Vb) = Mb
7.3 Wp x (Vp) = Mp
7.4 We x (Ve) = Me
(Mv + Mb + Mp + Me)
____________________
7.5 VCg =
(Wv + Wb + Wp + We)
VCg = The total average vertical

center of gravity of the
completed vehicle (vehicle,
body, payload and equipment)
Wv = Weight of vehicle
Wb = Weight of body
Wp = Weight of payload
We = Weight of equipment
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Definitions in formula (continued):
Vv = Distance from ground to center of gravity of the vehicle

Vb = Distance from ground to center of gravity of the body
Vp = Distance from ground to center of gravity of the payload
Ve = Distance from ground to center of gravity of the equipment
Mv = Moment of vehicle
Mb = Moment of body
Mp = Moment of payload
Me = Moment of equipment
Example: NPR/W3500 12,000 GVWR automatic transmission, 132" WB, 14' body length, 84" high body, full payload of boxes
stacked to a maximum height of 48" above the flooring.
Wv = 5,291 lbs. (from vehicle specifications)

Wb = 2,100 lbs. (from body manufacturer)
Wp = 4,609 lbs. (GVWR – (Wv + Wb + We))
Vv = 24.9 in. (from Body Builder’s Guide, NPR Section)
Vb = 80 in. (from body manufacturer)
Vp = 62 in. (1/2 of payload height + frame height + height from frame to flooring)
Mv = 5,291 x 24.9 = 131,746 lbs.-in. (from 7.1)
Mb = 2,100 x 80 = 168,000 lbs.-in. (from 7.2)
Mp = 4,609 x 62 = 285,758 lbs.-in. (from 7.3)
We, Ve, Me = None in this example
VCg = (131,746 + 168,000 + 285,758)
___________________________
(5,291 + 2,100 + 4,609)
VCg = (528,504)
_________ = 48.8 inches
(12,000)
48.8 < 54.0 inches (54 inches is maximum allowable VCg per mfg. specifications from Body Builder’s Guide, NPR/W3500 section)
Since maximum VCg for this truck is not exceeded, 48" stack height above flooring is acceptable.
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8. Horizontal Center of Gravity Formula
These formulas are used to estimate the horizontal center of gravity of a completed vehicle in order to determine whether it exists
between the centerlines of the front and rear axles. This formula should be used when a load and/or permanent equipment (liftgate,
reefer unit, snowplow, etc.) is installed on either extreme along the completed vehicle’s overall length.
8.1 Wv x (Hv) = Mv
8.2 Wb x (Hb) = Mb
8.3 Wp x (Hp) = Mp
8.4 We x (He) = Me
(Mv + Mb + Mp + Me)
8.5 HCg = ____________________
(Wv + Wb + Wp + We)
HCg = The total average horizontal center

of gravity of the completed vehicle
(vehicle, body, payload and equipment)
Wv = Weight of vehicle
Wb = Weight of body
Wp = Weight of payload
We = Weight of equipment
Hv = Distance from front axle to
center of gravity of the vehicle
Hb = Distance from front axle to
center of gravity of the body
Hp = Distance from front axle to
center of gravity of the payload
He = Distance from front axle to
center of gravity of the equipment
Mv = Moment of vehicle
Mb = Moment of body
Mp = Moment of payload
Me = Moment of equipment
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Example: NPR/W3500 Diesel 12,000 GVWR automatic transmission, 132" WB, 14' body length, full payload of boxes stacked and
distributed evenly throughout the flooring, 1,000 lb. reefer unit attached in front of body.
Wv = 5,291 lbs. (from vehicle specifications)

Wb = 2,100 lbs. (from body manufacturer)
Wp = 3,609 lbs. (GVWR – (Wv + Wb + We))
We = 1,000 lbs. (from equipment manufacturer)
Hv = 42.4 in. (from Body Builder’s Guide, NPR Section)
Hb = 107.5 in. (from body manufacturer)
Hp* = 107.5 in. (1/2 of payload length + distance from front axle to front of body)
He = 17.5 in. (from equipment manufacturer)
Mv = 5,291 x 42.4 = 224,338 lbs.-in. (from 8.1)
Mb = 2,100 x 107.5 = 225,750 lbs.-in. (from 8.2)
Mp = 3,609 x 107.5 = 387,967 lbs.-in. (from 8.3)
Me = 1,000 x 17.5 = 17,500 lbs.-in. (from 8.4)
HCg = (224,338 + 225,750 + 387,967 + 17,500)

____________________________________
(5,291 + 2,100 + 3,609 + 1,000)
HCg = (855,555)
_________ = 71.3 inches
(12,000)
71.3 < 132 inches (132 inches is the wheelbase dimension)

Since HCg for this truck is not greater than the WB or negative (–) (denotes HCg forward of front axle centerline), it exists between the
centerlines of the front and rear axles.
NOTE: Hp and Hb dimensions are the same in this example because CG of body and payload happen to be at the same point.

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Highway System Limits

The Federal Government established the Federal Bridge Gross Weight Formula to provide a standard to control the spacing of truck axles on
trucks that use highway bridges. This is intended to space loads out over a distance to avoid too high a concentration in one area that could
cause damage. The truck’s gross weights, axle weight and axle spacings are set in order to keep axle loads and gross weight loads within
the limits set by the Federal Government. The Bridge Formula Table is used to check trucks to make sure that Federal weight limit require-
ments are met and that the allowable gross and axle weights are in the correct relationship with the spacing of axles to prevent high load
concentrations on highway bridges.
The Federal Government has established the following formula to be used to determine the allowable weight limits and axle spacings for
trucks.
W = 500 LN (
N-1+ 12N = 36 )
Where:
W = The total gross weight that may be carried on any group of two or more consecutive axles to the nearest 500 lbs.
L = The distance (spacing) in feet between the outer axles of any group of two or more consecutive axles.
N = The number of axles in the group under consideration; except that two consecutive sets of tandem axles may carry a gross load of
34,000 lbs. each provided the overall distance between the first and last axles of such consecutive sets of axles is 36 feet or more.
Bridge Formula Definitions
The following definitions are used for bridge formula calculations.
Gross Weight
The total weight of a truck (and/or trailer) combined with the weight of the load being hauled. The Federal gross weight limits on
interstate highways and federal-aid highways and reasonable access is 80,000 lbs.

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Single Axle Weight
The total weight at the ground by all wheels of an axle whose centers may be included between parallel transverse planes 40 inches
apart, extending across the width of the truck. The Federal single axle weight limit on the interstate system and reasonable access is
20,000 lbs.
Tandem Axle Weight
The total weight at the ground of two or more consecutive axles whose centers may be included between parallel vertical planes
spaced more than 40 inches but not more than 96 inches apart, extending across the full width of the truck. The Federal tandem axle
weight limit on the interstate system and reasonable access is 34,000 lbs.
Consecutive Axle Weight
The Federal law states that any two or more consecutive axles may not exceed the weight as computed by the formula even though
the single axles, tandem axles, and gross weights are within the legal requirements.
Exception to the Bridge Formula
There is one exception to the use of the Federal Bridge Formula: two consecutive sets of tandem axles may carry a gross load of
34,000 lbs. each, providing the overall distance between the first and last axles of such consecutive sets of tandem axles is 36 feet or more.
Other Federal Provisions
Maximum Width: 102 inches overall
Length: States cannot set overall length limits on tractor, semitrailer or tractor-semitrailer, trailer combinations. States must allow trac-
tors with double trailers. States must allow semitrailers of up to 48 feet in length for doubles combinations. There is also not a
limitation on overall length for semitrailer or doubles combinations.
These width and length dimensions apply to trucks operating on interstate highways and federal-aid highways designed by the Federal
Highway Administration. This also provides for reasonable access to the interstate highways.

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Federal Bridge Formula Table
Distance in feet between the Maximum Load in Pounds on Any Group of 2 or More Consecutive Axles
extremes of any group of 2 or
more consecutive axles 2 Axles 3 Axles 4 Axles 5 Axles 6 Axles 7 Axles 8 Axles 9 Axles
4 34,000*
5 34,000*
6 34,000*
7 34,000*
8 and less 34,000* 34,000
8 and more 38,000 42,000
9 39,000 42,500
10 40,000 43,500
11 44,000
12 45,000 50,000
13 45,500 50,500
14 46,500 51,500
15 47,000 52,000
16 48,000 52,500 58,000
17 48,500 53,500 58,500
18 49,500 54,000 59,000
19 50,000 54,500 60,000
20 51,000 55,500 60,500 66,000
21 51,500 56,000 61,000 66,500
22 52,500 56,500 61,500 67,000
* Tandem Axle by Definition. NOTE: All permissible load calculations are to the nearest 500 lbs. Maximum load on any single axle, 20,000 lbs.
+ Exception to Federal Bridge Formula Table and Law. See Text for Explanation. Weights over 80,000 lbs. are in excess of the Federal GVW on the National Highway Network.

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Federal Bridge Formula Table (Continued)
23 53,000 57,500 62,500 68,000
24 54,000 58,000 63,000 68,500 74,000
25 54,500 58,500 63,500 69,000 74,500
26 55,500 59,500 64,000 69,500 75,000
27 56,000 60,000 65,000 70,000 75,500
28 57,000 60,500 65,500 71,000 76,500 82,000
29 57,500 61,500 66,000 71,500 77,000 82,500
30 58,500 62,000 66,500 72,000 77,500 83,000
31 59,000 62,500 67,500 72,500 78,000 83,500 90,000
32 60,000 63,500 68,000 73,000 78,500 84,500 90,500
33 64,000 68,500 74,000 79,000 85,000 91,000
34 64,500 69,000 74,500 80,000 85,500 91,500
35 65,500 70,000 75,000 80,500 86,000 92,000
36 66,000+ 70,500 75,500 81,000 86,500 93,000
37 66,500+ 71,000 76,000 81,500 87,000 93,500
38 67,500+ 72,000 77,000 82,000 87,500 94,000
39 68,000 72,500 77,500 82,500 88,500 94,500
40 68,500 73,000 78,000 83,500 89,000 94,500
41 69,500 73,500 78,500 84,000 89,500 95,000
42 70,000 74,000 79,000 84,500 90,000 95,500

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Federal Bridge Formula Table (Continued)
43 70,500 75,000 80,000 85,000 90,500 96,000
44 71,500 75,500 80,500 85,500 91,000 96,500
45 72,000 76,000 81,000 86,000 91,500 97,500
46 72,500 76,500 81,500 87,000 92,500 98,000
47 73,500 77,500 82,000 87,500 93,000 98,500
48 74,000 78,000 83,000 88,000 93,500 99,000
49 74,500 78,500 83,500 88,500 94,000 99,500
50 75,500 79,000 84,000 89,000 94,500 100,000
51 76,000 80,000 84,500 89,500 95,000 100,500
52 76,500 80,500 85,000 90,500 95,500 101,000
53 77,500 81,000 86,000 91,000 96,500 102,000
54 78,000 81,500 86,500 91,500 97,000 102,500
55 78,500 82,500 87,000 92,000 97,500 103,000
56 79,500 83,000 87,500 92,500 98,000 103,500
57 80,000 83,500 88,000 93,000 98,500 104,000
58 84,000 89,000 94,000 99,000 104,500
59 85,000 89,500 94,500 99,500 105,000
60 85,500 90,000 95,000 100,500 105,500
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COMMODITY AND MATERIAL WEIGHTS
Approximate Weights of Commodities and Materials
Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per
Acetone ——— 50 6.6 / gallon Beef, Slack barrel 21" x 30" stave (200 lbs. net) —— 254 / barrel
Alcohol, Commercial ——— 51 6.8 / gallon Beer, Wood barrel .5 barrel (16 gal.) —— 205 / barrel
Proof spirits ——— 57 7.6 / gallon Wood barrel .25 barrel (8 gal.) —— 105 / barrel
Alfalfa seed bushel —— 60 / bushel Steel barrel .5 barrel (16 gal.) —— 190 / barrel
Steel barrel .25 barrel (8 gal.) —— 95 / barrel
Aluminum, Pure (cast) ——— 165 4,450 / cu. yard Dutchman .13 barrel (4 gal.) —— 51 / barrel
Apples, Fresh basket-bushel —— 48 / bushel Case carton,* Regular bottles 17.25" x 11.5" x 9.88" —— 45 / case
Western, box 11.5" x 12" x 20" —— 50 / box 24, 12 oz. Steinie bottles 18.38" x 12.13" x 7.38" —— 40 / case
New England, box 11.25" x 14.5" x 17.5" —— 56 / box Tin cans 16.13" x 11" x 5.13" —— 28 / case
Standard barrel 17" head, 28.5" stave —— 160 / barrel Wooden case,* Regular bottles 21" x 13.5" x 10" —— 35 / case
Dried bushel —— 24 / bushel 24, 12 oz. Steinie bottles 22" x 13.75" x 7.5" —— 46 / case
Apricots, Fresh bushel —— 48 / bushel Beets bushel —— 50-60 / bushel
Western, box 5.5" x 12" x 20" —— 23 / box Small crate 9.75" x 13.75" x 24" —— 50 / crate
Western crate 14" x 19" x 24.5" —— 95 / crate
Artichokes, Box 10" x 11.5" x 22" —— 44 / box
Berries, crate, 24 pint 9.75" x 9.97" x 20" —— 25 / crate
Asbestos ——— 153 4,130 / cu. yard 24 quart 11.75" x 11.75" x 24" —— 48 / crate
Asparagus, crate, Loose 11.5" high x 9.75" top —— 38 / crate 32 quart 15.5" x 11.75" x 24" —— 63 / crate
Bunches 11" bottom x 19.38" long —— 31 / crate Bluegrass seed bushel —— 44 / bushel
Avocados, Box 5.75" x 11.25" x 17.5" —— 16 / box Bluestone ——— 120 3,240 / cu. yard
Bananas, Single stem bunch —— 45-65 / bunch Bone ——— 115 3,110 / cu. yard
Barley bushel —— 48 / bushel Borax ——— 110 2,970 / cu. yard
Barytes, Mineral ——— 280 7,560 / cu. yard Bran bushel —— 20 / bushel
Basalt, Rock ——— 185 5,000 / cu. yard Brick, Soft 2.25" x 4" x 8.25" —— 4,320 / thousand
Beans, dry, Lima bushel —— 56 / bushel Common 2.25" x 4" x 8.25" —— 5,400 / thousand
White bushel —— 60 / bushel Hard 2.25" x 4.25" x 8.5" —— 6,480 / thousand
Castor bushel —— 46 / bushel Pressed 2.38" x 4" x 8.38" —— 7,500 / thousand
Beans, fresh, Lima bushel —— 39 / bushel Paving 2.25" x 4" x 8.5" —— 6,750 / thousand
String bushel —— 36 / bushel Paving block 3.5" x 4" x 8.5" —— 8,750 / thousand
hamper, 5 peck —— 45 / hamper Fire 2.5" x 4.5" x 9" —— 7,000 / thousand
* Note: Beer cases vary as to size and shape. Suggest checking with local source.
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Broccoli, Bushel crate 12.75" x 12.75" x 17" —— 30 / bushel Cement, Block 8" x 8" x 16" —— 42 / each
Brussels sprouts, Crate 7.75" x 10.5" x 21.38" —— 26 / crate Block 8" x 12" x 16" —— 58 / each
Portland sack —— 94 / sack
Buckwheat bushel —— 49 / bushel Portland barrel (4 sacks per) —— 376 / barrel
Butter, tub, Small 15" dia. x 5.75" —— 25 / tub Chalk ——— 137 3,700 / cu. yard
Standard 15" dia. x 15" —— 70 / tub
Butter, case, 30 – 1-lb. bricks 10.75" x 8.75" x 10.5" —— 32 / case Charcoal, Oak ——— 33 890 / cu. yard
9-lb. pail pail —— 10 / pail Pine ——— 23 620 / cu. yard
Cabbage bushel —— 38 / bushel Cheese, Small box 15" dia. x 5.25" —— 25 / box
Hamper 1.5 bushel —— 58 / hamper Medium box 15" dia. x 7.5" —— 35 / box
Crate 12.75" x 18.5" x 19" —— 60 / crate Large box 15" dia. x 15" —— 70 / box
Western crate 14" x 19" x 24.5" —— 85 / crate Cherries, Unstemmed bushel —— 56 / bushel
Barrel crate 12.75" x 18.75" x 37.38" —— 110 / crate Stemmed bushel —— 64 / bushel
Calf, Live (average) per head —— 140-160 / head Lug box 5.63" x 11.88" x 19.75" —— 17 / box
Cantaloupe, crate, Pony 11.75" x 11.75" x 23.5" —— 58 / crate Chestnut* (lumber) ——— 37 3,080 / M. Bd. ft.
Standard 12.75" x 12.75" x 23.5" —— 68 / crate Chestnuts bushel —— 50 / bushel
Jumbo 13.75" x 13.75" x 23.5" —— 78 / crate Chickens, Live, broilers (20 avg.) standard crate —— 58 / crate
Pony flat 4.75" x 12.75" x 23.5" —— 26 / crate Fowl (12 avg.) standard crate —— 78 / crate
Standard flat 5.25" x 14.25" x 23.5" —— 28 / crate Standard crate, empty 24" x 35" x 13" —— 18 / crate
Jumbo flat 5.75" x 15.25" x 23.5" —— 32 / crate
Honeydew (Casaba) 6.38" x 15.13" x 23.5" —— 35 / crate Cinder blocks 8" x 8" x 16" —— 35 / each
8" x 12" x 16" —— 45 / each
Carbolic acid ——— 60 8.0 / gallon
Cinders ——— 50 1,350 / cu. yard
Carrots, Topped bushel —— 55 / bushel
With tops bushel —— 40 / bushel Clay, Dry lumps ——— 85 2,300 / cu. yard
Crate 11.75" x 14.13" x 24" —— 60 / crate Wet lumps ——— 110 2,970 / cu. yard
Wet packed ——— 135 3,650 / cu. yard
Castor oil ——— 61 8.1 / gallon Fire ——— 125 3,375 / cu. yard
Cauliflower bushel —— 30 / bushel Cork ——— 15 405 / cu. yard
Crate 9.38" x 19" x 24" —— 50 / crate
Corn, Ear bushel —— 35 / bushel
Cedar* (lumber) ——— 30 2,500 / M. Bd. ft. Shelled bushel —— 56 / bushel
Celery, Standard crate 11.63" x 22" x 22.63" —— 70 / crate Sweet corn (green) bushel —— 43 / bushel
Half crate 10.75" x 13" x 20.38" —— 35 / crate Crate 12.88" x 12.88" x 24" —— 60 / crate
Northern crate 16.5" x 21.25" x 22" —— 85 / crate Corn meal bushel —— 44 / bushel
*Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried.
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Corn oil ——— 58 7.8 / gallon Fish, fresh, Barrel 19" head, 29" stave —— 300 / barrel
Corn syrup ——— 86 11.5 / gallon 1/2 Barrel 18.5" head, 23.5" stave —— 160 / 1/2 barrel
Cotton, Gin bale 30" x 48" x 54" —— 515 / bale Flour, Barrel 19.13" head, 30" stave —— 215 / barrel
Standard bale 24" x 28" x 56" —— 515 / bale Fuel oil, Furnace grade ——— 56 7.5 / gallon
Comp. bale 20" x 24" x 56" —— 515 / bale Diesel engine ——— 52 7.0 / gallon
Cotton seed bushel —— 32 / bushel Furniture, Household ——— 7 1,915 / cu. yard
Cottonseed oil ——— 58 7.8 / gallon Garbage, Dry, paper wrapped ——— 15-30 405-810 / cu. yard
Cottonwood* (lumber) ——— 37 3,080 / M. Bd. ft. Wet ——— 50 1,240 / cu. yard
Cow, Live-Feeder (average) per head —— 600 / head Gasoline ——— 45 6.0 / gallon
Butcher (average) per head —— 800 / head Glass, Common window ——— —— 162 / cu. foot
Butcher steer (average) per head —— 1100 / head Plate or crown ——— —— 161 / cu. foot
Cranberries, 1/4 barrel box 9.5" x 11" x 14" —— 28 / box 1/4" plate ——— —— 3.3 / sq. foot
1/2 barrel box 12.25" x 14.75" x 22" —— 60 / box Glue ——— 80 2,160 / cu. yard
Cream ——— 64 8.5 / gallon Glycerine ——— 79 10.5 / gallon
Creosote ——— 68 9.2 / gallon Grapefruit, Western box 11.5" x 11.5" x 24" —— 68 / box
Crude oil ——— 56 7.5 / gallon Southern box 12.75" x 12.75" x 27" —— 90 / box
Cucumbers bushel —— 55 / bushel Grapes, Basket bushel —— 48 / box
Crate 9.75" x 13.75" x 24" —— 75 / crate Lug box 5.63" x 16.38" x 17.5" —— 30 / box
Case 5" x 13.25" x 19" —— 26 / case Western keg 15.5" dia. x 14" —— 45 / keg
Basket 12 quart —— 18 / basket
Earth, Loose, dry loam ——— 76 2,050 / cu. yard
Packed ——— 95 2,565 / cu. yard Gravel, Dry ——— 95 2,565 / cu. yard
Wet ——— 125 3,375 / cu. yard Wet ——— 125 3,375 / cu. yard
Eggplant, Hamper bushel —— 40 / bushel Greens bushel —— 25 / bushel
Crate 14" x 11.75" x 24" —— 54 / crate Groceries, Misc. assorted ——— 30 810 / cu. yard
Eggs, 30 dozen crate 12" x 12" x 26" —— 55 / crate Hay, Bale 26" x 30" x 46" —— 210 / bale
Elm,* Soft ——— 38 3,170 / M. Bd. ft. Bale 17" x 22" x 43" —— 115 / bale
Rock ——— 45 3,750 / M. Bd. ft. Bale 14" x 16" x 43" —— 85 / bale
Fertilizer, Commercial burlap bag —— 100-200 / bag Hog, Live (average) per head —— 225-250 / head
Fir,* Douglas ——— 32 2,670 / M. Bd. ft. Honey ——— 90 12.0 / gallon
Eastern ——— 25 2,080 / M. Bd. ft. Horse, Live (average) per head —— 1,200-1,500 / head
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Horseradish roots bushel —— 35 / bushel Linseed oil ——— 59 7.9 / gallon
Ice ——— 57 1,540 / cu. yard Lubricating oil ——— 52 7.0 / gallon
Ice (mfg.), Block 11" x 22" x 32" —— 250 / block Malt, Barley bushel —— 28 / bushel
Block 14" x 14" x 40" —— 255 / block Rye bushel —— 32 / bushel
Block 11" x 22" x 56" —— 440 / block Brewer’s grain bushel —— 40 / bushel
Ice Cream, 2.5 gallon can, Full 9" dia. x 11" —— 18 / can Maple syrup gallon 82 11.0 / gallon
Empty ——— —— 6 / can Maple,* Hard (lumber) ——— 44 3,670 / M. Bd. ft.
5 gallon can, Full 9" dia. x 21" —— 35 / can Soft ——— 34 2,830 / M. Bd. ft.
Empty ——— —— 11 / can
Meal-corn bushel —— 44 / bushel
Kale bushel —— 25 / bushel
Milk, Bulk ——— 64 8.6 / gallon
Kerosene ——— 50 6.6 / gallon 5 gallon can 10.25" dia. x 19" —— 62 / can
Lamb, Live (average) per head —— 75-85 / head 10 gallon can 13" dia. x 23" —— 115 / can
Lard, Barrel 18" head, 30" stave —— 425 / barrel Crate, 20.5 pt. bottles 8.5" x 12.75" x 16.75" —— 33 / crate
20 pt. bottles 8.5" x 12.75" x 16.75" —— 54 / crate
Lath, Standard length 29" Packed in bundles of 50 —— 25 / bundle
Average bundle, dia. 9" Millet bushel —— 50 / bushel
Leather, Dry ——— 55 1,485 / cu. yard Molasses ——— 90 12.0 / gallon
Wet ——— 65 1,755 / cu. yard Barrel 20.25" head, 34" stave —— 675 / barrel
Lemons, Western box 10" x 13" x 25" —— 80 / box Mortar, Lime ——— 110 2,970 / cu. yard
Southern box 12.75" x 12.75" x 27" —— 90 / box Mud, Flowing ——— 106 2,860 / cu. yard
Lentils bushel —— 60 / bushel Packed ——— 125 3,375 / cu. yard
Lettuce, Hamper bushel —— 25 / bushel Muriatic acid, 40% ——— 40 10.0 / gallon
Hamper 1.5 bushel —— 38 / hamper Naptha, Petroleum ——— 42 5.6 / gallon
Basket 8.5" x 11.75" x 21.38" —— 17 / basket Nitric acid, 91% ——— 94 12.5 / gallon
Crate 18.75" x 17.5" x 24.5" —— 75 / crate
1/2 crate 9.5" x 13.5" x 24.5" —— 40 / 1/2 crate Oak-red,* Black ——— 42 3,500 / M. Bd. ft.
White ——— 48 4,080 / M. Bd. ft.
Lime, Hydrated bushel —— 30 / bushel
Barrel (small) 16.5" head, 27.5" stave 62 210 / barrel Oats bushel —— 32 / bushel
Barrel (large) 62 320 / barrel Okra, Hamper 1/2 bushel —— 18 / hamper
Limes, Western box 10" x 13" x 25" —— 80 / box Hamper bushel —— 34 / bushel
Southern box 12.75" x 12.75" x 27" —— 90 / box Oleomargarine, (mfg.-tub) 21" head, 34" stave —— 70 / tub
*Kiln dried lumber averages 10% to 15% lighter, and green lumber 40% to 50% heavier, than air dried. Cases ——— —— 15-65 / case
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Olive oil ——— 58 7.7 / gallon Pecans, Large bag ——— —— 100 / bag
Onions, dry, Basket bushel —— 55 / bushel Small bag ——— —— 50 / bag
Bag 17" x 32" —— 50 / bag Peppers, Basket bushel —— 25 / basket
Crate 20.5" x 11.5" x 10.5" —— 58 / crate Crate 14.13" x 11.75" x 24" —— 45 / crate
Green (with tops) bushel —— 32 / bushel Petroleum ——— 56 7.5 / gallon
Oranges, Western box 11.5" x 11.5" x 24" —— 80 / box Phosphate rock ——— 200 5,400 / cu. yard
Southern box 12.75" x 12.75" x 27" —— 90 / box
Bushel box 10.75" x 10.75" x 23.5" —— 65 / box Pine,* Long leaf ——— 44 3,670 / M. Bd. ft.
North Carolina ——— 36 3,000 / M. Bd. ft.
Oysters (shucked or meats) Oregon ——— 32 2,670 / M. Bd. ft.
Crate with 5.1 gal. cans 18" x 12" x 24" (11.5 lbs. per gal.) 67 / crate Red ——— 30 2,500 / M. Bd. ft.
With shells (bags) bushel —— 75 / bushel White ——— 26 2,170 / M. Bd. ft.
Paint, Lead and oil ——— 127 17 / gallon Yellow, long leaf ——— 44 3,670 / M. Bd. ft.
Paper, Average solid ——— 58 1,565 / cu. yard Short leaf ——— 38 3,170 / M. Bd. ft.
Newspaper rolls 34.25" x 35" dia. —— 500 / roll Pineapples, Crate 11" x 12.5" x 36" —— 85 / crate
51.5" x 35" dia. —— 1,000 / roll Pitch ——— 70 1,900 / cu. yard
64.25" x 35" dia. —— 1,300 / roll
Plums, Basket bushel —— 56 / bushel
Paraffin ——— 56 1,510 / cu. yard Western box 5.63" x 16.38" x 17.5" —— 25 / box
Parsley, Bushel crate 12.75" x 12.75" x 17" —— 30 / crate Pomegranates, Box 6.5" x 12" x 24.63" —— 30 / box
Parsnips bushel —— 50 / bushel Popcorn, Ear bushel —— 70 / bushel
Peaches, Basket bushel —— 48 / bushel Shelled bushel —— 56 / bushel
1/2 bushel ——— —— 25 / basket Poplar* ——— 27 2,250 / M. Bd. ft.
Crate 10.5" x 11.25" x 24" —— 50 / crate
Western box 5.5" x 12.25" x 19.75" —— 22 / box Porcelain ——— 150 4,050 / cu. yard
Peanuts, Unshelled bushel —— 22 / bushel Pork (dressed), Barrel (200 lbs. net) 18" head, 29" stave —— 240 / barrel
Bag ——— —— 100 / bag Potatoes, Sweet bushel —— 55 / bushel
Peanut oil ——— 57 7.6 / gallon White or Irish bushel —— 60 / bushel
Bag 1.67 bushel —— 102 / bag
Pears, Basket bushel —— 50 / bushel Barrel 17.13" head, 28.5" stave —— 185 / barrel
Western box 9.63" x 12.13" x 19.75" —— 51 / box
Prunes, Box 5.63" x 16.38" x 19.75" —— 25 / box
Peas, Dry bushel —— 60 / bushel Box 5.63" x 11.88" x 19.75" —— 22 / box
Fresh hamper bushel —— 35 / hamper
Hamper 40 quarts —— 45 / hamper Quinces bushel —— 50 / bushel
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Radishes, Basket bushel —— 34 / bushel Soft drinks, Half depth bottle box
Crate 9.75" x 13.75" x 24" —— 40 / crate 24-6 to 8 oz. bottles 12.25" x 18.75" x 8.5" —— 39 / box
Redwood* ——— 30 2,500 / M. Bd. ft. Full depth bottle box
12-24 to 32 oz. bottles 13.38" x 18.5" x 12.25" —— 60 / box
Resin ——— 68 1,835 / cu. yard
Sorghum syrup ——— 86 11.5 / gallon
Rhubarb (pie plant) bushel —— 50 / bushel
Box 5.25" x 11.5" x 22" —— 24 / box Soybeans bushel —— 60 / bushel
Rice, Unhulled bushel —— 43 / bushel Soybean oil ——— 58 7.7 / gallon
Rock, Crushed (average) ——— 100 2,700 / cu. yard Spinach, Hamper bushel —— 20 / bushel
Basket bushel —— 27 / bushel
Romaine, Crate 13.88" x 18.88" x 24.5" —— 64 / crate
Crate 12.25" x 13" x 15.25" —— 27 / crate Spruce* ——— 28 2,330 / M. Bd. ft.
Rubber goods ——— 94 2,540 / cu. yard Squash bushel —— 46 / bushel
Rutabagas bushel —— 56 / bushel Starch ——— 96 2,590 / cu. yard
Rye bushel —— 56 / bushel Stone, Crushed, (average) ——— 100 2,700 / cu. yard
Rip-rap ——— 65 1,755 / cu. yard
Salt, rock, Solid ——— 136 3,670 / cu. yard
Coarse ——— 45 1,215 / cu. yard Straw, Bale 17" x 22" x 42" —— 110 / bale
Fine ——— 50 1,350 / cu. yard Bale 26" x 30" x 46" —— 180 / bale
Barrel (average) ——— —— 280 / barrel Street sweepings ——— 32 865 / cu. yard
Sand, fine, Dry ——— 110 2,970 / cu. yard Sugar ——— 100 2,700 / cu. yard
Wet ——— 125 3,375 / cu. yard Sugar, Bag (100 lbs. net) —— 101 / bag
Sand, coarse, Dry ——— 95 2,565 / cu. yard Barrel (22 lbs. empty) 19.13" head, 30" stave —— 345 / barrel
Wet ——— 120 3,240 / cu. yard Case 24 – 5-lb. cartons —— 135 / case
Sand, Mixed ——— 115 3,100 / cu. yard Case 60 – 2-lb. cartons —— 135 / case
Sandstone, Solid ——— 147 3,970 / cu. yard Sugar cane syrup ——— 85 11.3 / gallon
Crushed ——— 86 2,325 / cu. yard
Sulphur ——— 125 3,375 / cu. yard
Shale, Solid ——— 172 4,645 / cu. yard
Crushed ——— 92 2,485 / cu. yard Sulfuric acid, 87% ——— 112 15 / gallon
Sheep, Live (average) per head —— 125-150 / head Sweet corn, Basket bushel —— 45 / bushel
Crate 13" x 13" x 24" —— 60 / crate
Shingles, Bundle Pkg. in bndls. of 200-250 —— 50 / bundle
Size (avg.) 24" x 20" x 10" Sycamore* ——— 37 3,080 / M. Bd. ft.
Snow, Moist-packed ——— 50 1,350 / cu. yard Tallow ——— 60 1,620 / cu. yard
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Product Size of Container Lbs. Per Cu. Ft. No. of Lbs. / Per
Tanks, Acetylene, 102 cu. foot empty —— 70 / tank
filled —— 75 / tank
310 cu. foot empty —— 200 / tank
Tanks, Oxygen, 150 cu. foot empty —— 80 / tank
300 cu. foot empty —— 133 / tank
Tar ——— 65 1755 / cu. yard
Tile, Solid ——— 115 3,100 / cu. yard
Partition (construction) ——— 40 1,080 / cu. yard
Tomatoes, Basket bushel —— 55 / bushel
Lug box 7.25" x 14" x 17.5" —— 35 / box
Crate 10.5" x 11.25" x 24" —— 48 / crate
Basket 8.5" x 8.75" x 20" —— 18 / basket
Basket (paper) 4.25" x 8.5" x 16.25" —— 9 / basket
Basket (wood) 5.5" x 7.25" x 16.5" —— 10 / basket
Turpentine ——— 54 7.2 / gallon
Turnips, Basket bushel —— 54 / bushel
Vetch seed bushel —— 60 / bushel
Vinegar ——— 64 8.5 / gallon
Walnuts, Bulk bushel —— 50 / bushel
Bag 2 bushel —— 100 / bag
Water, Fresh ——— 63 8.4 / gallon
Wheat, Bulk bushel —— 60 / bushel
Bag 1.5 bushel —— 90 / bag
Wool, Pressed ——— 82 2,215 / cu. yard
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VEHICLE SPECIFICATIONS INDEX
NPR/W3500, NPR HD/W4500 GAS
Specifications
Model NPR/W3500 Gas NPR HD/W4500 Gas
GVWR 12,000 lbs. 14,500 lbs.
WB 109 in., 132.5 in., 150 in., 176 in.
Engine GMPT 8-cylinder, V Block 4-cycle, OHV, water-cooled, Sequential Port Fuel Injection
Model/Displacement GMPT-V8/365 CID (6.0 liters)
HP (Gross) 300 HP @ 4,400 RPM
Torque (Gross) 358 lbs.-ft. torque @ 4,000 RPM
Sequential Port Fuel Injection (SFI), mass air flow meter, powertrain control module (PCM), onboard diagnostics, oxygen sensors,
Equipment catalytic convertor, map sensor, with external oil cooler.
Transmission 4L80-E Hydra-Matic 4-speed automatic w/lock-up converter and overdrive
Steering Integral power steering 18.8-20.9:1 ratio. Tilt and telescoping steering column.
Front Axle Reverse Elliot “I”-Beam rated at 6,830 lbs.
Suspension Semi-elliptical steel alloy tapered leaf springs with stabilizer bar and shock absorbers.
GAWR 4,700 lbs. 5,360 lbs.
Rear Axle Full-floating single speed with hypoid gearing rated at 11,020 lbs.
Suspension Semi-elliptical steel alloy multi-leaf springs and shock absorbers.
GAWR 7,950 lbs. 9,880 lbs.
Wheels 16 x 6.0 6-hole disc wheels, painted white. 19.5 x 6.0 6-hole disc wheels, painted white.
215/85R 16-E (10 pr) tubeless steel-belted radials, 225/70R-19.5F (12 ply) tubeless steel-belted radials,
Tires all-season tread front and rear. all-season tread front and rear.
Dual-circuit, vacuum-assisted hydraulic service brakes with load sensing proportioning valve in rear brake circuit and a metering valve
Brakes between the master cylinder and 6-way joint on the front brake lines. Disc front and self-adjusting outboard mounted drum rear.
The parking brake is a mechanical, cable-actuated, internal expanding drum type, transmission mounted. Four-channel antilock brake system.
Fuel Tank 30-gallon rectangular steel fuel tank. Mounted between the frame rails with electric type fuel pump (mounted in tank). Through the rail fuel fill.
NOTE: These selected specifications are subject to change without notice.
(Vehicle Specifications Index Section – NPR/W3500, NPR HD/W4500 Gas – continued on next page)
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(Vehicle Specifications Index Section – NPR/W3500, NPR HD/W4500 Gas – continued from previous page)
Model NPR/W3500 Gas NPR HD/W4500 Gas

Ladder type channel section straight frame rail 33.5 in. wide through the total length of the frame.
Frame Yield strength 44,000 psi section modulus 7.20 in.3, RBM 316,800 lbs.-ft./in. per rail.
Cab All-steel, low cab forward, BBC 68.0 in., 45º mechanical tilt with torsion assist.
Jersey knit covered high back driver’s seat with two-occupant passenger seat. Two-way roof ventilator, dual cab-mounted exterior mirrors.
Equipment Tilt and telescoping steering column. Tinted glass.
Electrical 12-volt, negative ground, Delco maintenance-free battery located on frame, 750 CCA each, 145-amp alternator with integral regulator.
Options Air conditioning; AM/FM cassette stereo radio; spare wheel; 6" stainless steel mirrors. Power windows and door locks, wheel simulators and air deflector.
Vehicle Weights, Dimensions and Ratings
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Variable Chassis Dimensions

Unit WB CA* CE* OAL AF
Inch 109.0 88.4 131.5 199.5 43.1
Inch 132.5 111.9 155.0 223.0 43.1
Inch 150.0 129.4 172.5 240.5 43.1
Inch 176.0 155.4 198.5 266.3 43.1
* Effective CA & CE are CA or CE less BOC.
Dimension Constants: 12,000 GVW

Code Inches Code Inches Code Inches
AH 7.9 BW 83.3 FH 31.4
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
AW 65.6 CW 65.0 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
BA 47.4 FW 33.5 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
BBC 68.0 OH 87.4 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
BOC 9.25 OW 78.5 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
12,000-lb. GVWR with 4L80-E Hydra-Matic Transmission California, Maine, Massachusetts California Emission System
Chassis Cab and Maximum Payload Weights
Model WB Unit Front Rear Total Payload
DB1 109.0 in. lb. 3,119 1,819 4,938 7,062
DB2 132.5 in. lb. 3,164 1,841 5,005 6,995
DB3 150.0 in. lb. 3,186 1,863 5,049 6,951
DB4 176.0 in. lb. 3,230 1,885 5,115 6,885
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12,000-lb. GVWR with 4L80-E Hydra-Matic Transmission Federal Emission System Except CA, MMA and ME
EB1 109.0 in. lb. 3,119 1,819 4,938 7,062
EB2 132.5 in. lb. 3,164 1,841 5,005 6,995
EB3 150.0 in. lb. 3,186 1,863 5,049 6,951
EB4 176.0 in. lb. 3,230 1,885 5,115 6,885
Dimension Constants: 14,500 GVW

AH 8.6 BW 84.0 FH 32.3
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1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
AW 65.6 CW 65.0 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
BA 47.4 FW 33.5 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
BBC 68.0 OH 88.1 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
BOC 9.25 OW 78.5 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
14,500-lb. GVWR with 4L30-E Hydra-Matic Transmission Model California/Federal/Federal CCFV 50 State Emission System
FE1 109.0 in. lb. 3,219 1,984 5,203 9,297
FE2 132.0 in. lb. 3,263 2,006 5,269 9,231
FE3 150.0 in. lb. 3,285 2,028 5,313 9,187
FE4 176.0 in. lb. 3,329 2,050 5,379 9,121
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Vehicle Weight Limits:
GVWR
Designed Maximum 12,000 lbs. 14,500 lbs.
GAWR, Front 4,700 lbs. 5,360 lbs.
GAWR, Rear 7,950 lbs. 9,880 lbs.
Technical Notes:
Chassis Curb Weight reflects standard equipment and fuel but no driver or payload.
Maximum Payload Weight is the allowed maximum for equipment, body, payload and driver and is calculated by subtracting chassis curb
weight from the GVWR.
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Frame and Crossmember Specifications
Frame Crossmember Type/Location

Wheelbase
Thick A B C-A/T D-A/T E F G
109.0 0.24 37.0 28.3 10.6 AA 50.6 — CC 25.4 DD 33.5
132.5 0.24 37.0 28.3 10.6 AA 50.6 BB 58.9 CC 25.4 DD 33.5
150.0 0.24 37.0 28.3 10.6 AA 50.6 BB 58.9 CC 25.4 DD 33.5
176.0 0.24 37.0 28.3 10.6 AA 50.6 BB 58.9 CC 25.4 DD 33.5
A/T = Automatic Transmission
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Frame Chart
Wheelbase Frame FL Frame Thickness

109.0 186.0 0.24
132.5 209.6 0.24
150.0 227.4 0.24
176.0 253.4 0.24
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Auxiliary Views
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Body Builder Weight Information Chart
Wheelbase
Unsprung
GVWR Axle 109 in. 132.5 in. 150 in. 176 in.
Weight
Auto. Trans. Auto. Trans. Auto. Trans. Auto. Trans.
Front 3,119 3,164 3,186 3,230 573
12,000 Rear 1,819 1,841 1,863 1,885 871
Total 4,938 4,961 5,049 5,115 1,444
Front 3,219 3,263 3,285 3,329 705
14,500 Rear 1,984 2,006 2,028 2,050 1,135
Total 5,203 5,269 5,313 5,379 1,840
Cab Tilt
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Center of Gravity
The center of gravity of the chassis cab.
GVWR WB V H Auto. Trans.

109 21.7 38.8
132.5 20.1 47.1
12,000
150 19.7 53.5
176 18.1 62.8
109 21.7 40.0
132.5 20.0 48.6
14,500
150 19.7 55.2
176 18.1 64.7
NOTE: The maximum dimensions for a body installed on the NPR/W3500, NPR HD/W4500 are 96 inches wide (outside) by 90 inches high
(inside). Any larger body applications must be approved by GM/Isuzu Application Engineering. In the West Coast call 1-562-699-
0500 and in the East Coast call 1-770-475-9195, extension 353.
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Front Axle Chart
Formulas for calculating height dimensions:
A = Tire Loaded Radius – B

C = Centerline of Axle to Top of Frame Rail at Curb Position
D = Centerline of Axle to Top of Frame Rail at Design Load
CH = C + Tire Unloaded Radius
DH = D + Tire Loaded Radius
Tire Radius
Tire GVWR GAWR A B C D CH DH Track
Unload Load
215/85R 16-E 12,000 lbs. 4,700 lbs. 8.1 6.4 13.0 12.4 27.5 26.9 66.2 14.5 14.5
225/70R 19.5 14,500 lbs. 5,360 lbs. 8.1 6.4 13.0 12.2 28.3 27.6 66.2 15.2 15.2
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Rear Axle Chart
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Definitions
A Centerline of axle to bottom of axle bowl. DW Minimum distance between the inner surfaces of the rear tires.
B Centerline of axle to top of frame rail at metal-to-metal position. Maximum Rear Width:
EW
C Centerline of axle to top of frame rail at curb position. Overall width of the vehicle measured at the outermost surface of the rear tires.
Rear Tire Clearance:
D Centerline of axle to top of frame rail at design load. HH
Minimum clearance between the rear axle and the ground-line.
Rear Tire Clearance: Minimum clearance required for tires and chain measured
E from the top of the frame at the vertical centerline of the rear axle, when rear HW Dual Tire Spacing:
wheels on one side ride over a high spot. Distance between the centerlines of the tires in a set of dual tires.
Rear Frame Height: Tire Bounce Clearance:
CH Vertical distance between the normal top of frame rail and the ground-line KH Minimum distance required for tire bounce as measured from the centerline of
through the centerline of the rear axle at curb position. the rear axle and the top of the rear tire when one wheel rides over a high spot.
Rear Frame Height: Track Dual Rear Wheel Vehicles:
DH Vertical distance between the normal top of frame rail and the ground-line CW Distance between the centerlines of the dual wheels measured at the
through the centerline of the rear axle at design load. ground-line.
Tire Section, Tire Radius, Tire Loaded Radius, Tire Clearance See Tire Chart for Values
Formulas for Calculating Rear Width and Height Dimensions

CW = Track HH = Tire loaded radius – A
CH = Tire loaded radius + C JH = KH – B
DH = Tire loaded radius + D KH = Tire radius + 3.00 inches
DW = Track + 2 tire sections – tire clearance KW = DW – 5.00 inches
EW = Track + 2 tire sections + tire clearance LW = 1.00-inch minimum clearance between tires and springs
NOTE: Track and overall width may vary with optional equipment.
Tire GAWR Track CW A B C D E

215/85R 16-E 7,950/8,760 lbs. 65.0 6.5 9.0 15.3 13.1 7.8
225/70R 19.5-F 9,880 lbs. 65.0 6.5 9.0 15.4 12.9 8.4
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Suspension Deflection Charts – NPR/W3500 Gas, NPR HD/W4500 Gas
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Tire and Disc Wheel Chart – NPR/W3500

Tire
Tire Load Limit and Cold Inflation Pressures Maximum Tire Load Limits
Tire Size Single Dual Front Rear GVWR (Lb.)
Lb. PSI Lb. PSI 2 Single 4 Dual
215/85R 16-E 2,430 70 2,210 70 4,860 8,840 12,000
Tire Radius
Tire Size GVWR (Lb.) Loaded Unloaded Tire Section Tire Clearance Design Rim
Width Width
Front Rear Front Rear
215/85R 16-E 12,000 14.05 14.05 15.21 15.21 8.54 1.46 6.0
Disc Wheel
Nut/Stud
Bolt Circle Ft./Rr. Nut Rear Stud Outside Disc
Wheel Size Bolt Holes Torque Inner Circle Rim Type Material Mfg.
Dia. Size* Size* Offset Thickness
Specs.
1.6142 0.8268
325 ft.-lb. Steel
16 x 6 K 6 JIS 8.75 (41 mm) (21 mm) 6.46 5.0 0.35 5º DC
(440 N•m) TOPY
BUD HEX SQUARE
* O.D. Wrench Sizes
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Tire and Disc Wheel Chart – NPR HD/W4500

Tire
225/70R 19.5-F 3,315 85 3,115 85 6,630 12,460 14,500
Tire Radius
Width Width
225/70R 19.5-F 14,500 15.24 15.28 16.10 16.10 8.9 1.1 6.0
Disc Wheel
Nut/Stud
Specs.
1.6142 0.8268
325 ft.-lb. Steel
19.5 x 6.00 RW 6 JIS 8.75 (41 mm) (21 mm) 6.46 5.0 0.37 15º DC
(440 N•m) ACCURIDE
BUD HEX SQUARE
* O.D. Wrench Sizes
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Propeller Shaft
Plane View Side View

Wheelbase A B C D
Auto. Trans. Auto. Trans. Auto. Trans. Auto. Trans.
109 in. — 3.5º — 6.4º
132.5 in. 2.1º 0º 1.5º 2.4º
150 in. 0º 2.7º 0.7º 5.3º
176 in. 0º 1.8º 4.0º 6.0º
NOTE: All driveline angles are at unloaded condition (curb position with typical cargo body).
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Wheelbase 109 132.5 150 176

No. of Shafts 1 2 2 2
Trans. Type Automatic Transmission Automatic Transmission Automatic Transmission Automatic Transmission
Shaft #1 O.D. 3.0
Thickness 0.083
Length 34.05 24.10 41.85 52.1
Type A B B B
Shaft #2 O.D. 3.0 3.5
Thickness 0.083
Length N/A 33.46 33.46 49.2
Type N/A C C C
Type Description Illustration
Type A 1st shaft in 1-piece driveline
Type B 1st shaft in 2-piece driveline
Type C 2nd shaft in 2-piece driveline
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Brake System Diagram, 12,000 GVW

Vacuum Over Hydraulic
Please refer to Introduction Section of book for antilock system cautions and wheelbase modification requirements.
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Through the Rail Fuel Fill

Installation Instructions
1. Disconnect battery.
2. Loosen hose from the tie downs.
3. Remove shipping plate from chassis.
4. Extend hose out from the driver’s side of the rail to body rail.
5. The filler neck must be mounted to allow the fill plate bracket to be parallel to the frame horizontal (see figure 1).
6. Filler hose is set for 96 inches outside width body.
7. Filler neck (Dimension A) must be between 6.85 inches and 8.5 inches above frame.
8. Secure the filler plate to the bottom of the body and check for leaks.
9. Ensure that fill hose does not sag, creating an area where the fuel could pool in the fill hose.
10. Reconnect battery.
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Rear View Fuel Fill
Dimension A = 6.85-8.5 inches (174-216 mm)

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Top View Fuel Fill
Dimensions:
B = 28.85 inches (733 mm)
C = 34.00 inches (863 mm)
D = 39.29 inches (998 mm)
E = 46.61 inches (1,184 mm)
F = 48.00 inches (1,219 mm)
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Top View
Body Width Adjustment:

90-inch Body Dim E = 682.8 mm
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Through the Rail Fuel Fill Frame Hole
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Fuel Fill Parts Illustration
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Fuel Fill Parts List
Number Description Part Number – Isuzu Part Number – GM Quantity

FEDERAL PARTS
1 Hose, Fuel Filler 897213-6540 897213-6540 1
2 Hose, Breather 897214-2710 897214-2710 1
3 Clip, Rubber Hose 897177-5810 897177-5810 2
4 Clip, Filler Hose 802465-8140 802465-8140 2
CALIFORNIA PARTS
1 Hose, Fuel Filler 897213-6540 897213-6540 1
2 Hose, Breather 897229-9180 897229-9180 1
3 Clip, Rubber Hose 815699-8250 815699-8250 2
4 Clip, Filler Hose 802465-8140 802465-8140 2
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Specifications
Model NPR/W3500 Diesel NPR HD/W4500 Diesel
GVWR 12,000 lbs. 14,500 lbs.
WB 109 in., 132.5 in., 150 in., 176 in.
Engine Isuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel
Model/Displacement 4HE1-TC/290 CID (4.75 liters)
HP (Gross) 142 HP @ 2,800 RPM (Manual Transmission) 175 HP @ 2,700 RPM (Automatic Transmission)
Torque (Gross) 275 lbs.-ft. torque @ 1,300 RPM 347 lbs.-ft. torque @ 2,000 RPM
2
Dry element air cleaner with vertical intake; 2 rows 506 in. radiator; 6-blade 18.7 in. diameter fan with viscous drive.
Equipment Cold weather starting device and an oil cooler.
Clutch Single, dry plate, 11.8 in. dia., actuated by self-adjusting hydraulic master/slave cylinder.
MXA5C 5-speed manual, all forward gears synchronized. Fifth gear is direct. Available Optional Transmission: Aisin 450-43 LE 4-speed
Transmission* overdrive automatic transmission with lock-up capability in 2nd, 3rd and 4th and PTO capability.
GAWR 4,700 lbs. 5,360 lbs.
GAWR 7,950 lbs. 9,880 lbs.
Wheels 16 x 6.0 6-hole disc wheels, painted white.
Tires 215/85R 16-E (10 pr) tubeless steel-belted radials, all-season front and rear.
Dual-circuit, vacuum-assisted hydraulic service brakes with load-sensing proportioning valve in rear brake circuit and a metering valve between
Brakes the master cylinder and 6-way joint on the front brake lines. Disc front and self-adjusting outboard mounted drum rear.
The parking brake is a mechanical, cable-actuated, internal expanding drum type, transmission mounted.
The exhaust brake is standard and is vacuum-operated. Four channel antilock brake system
NOTE: These selected specifications are subject to change without notice. *All Transmissions have a PTO gear in all wheelbases.
(Vehicle Specifications Index Section – NPR/W3500, NPR HD/W4500 Diesel – continued on next page)
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(Vehicle Specifications Index Section – NPR/W3500, NPR HD/W4500 Diesel – continued from previous page)
Model NPR/W3500 Diesel NPR HD/W4500 Diesel

Fuel Tank 30-gallon rectangular steel fuel tank mounted in frame rail behind rear axle. Fuel/water separator mounted on rail.
Jersey knit covered high back driver’s seat with two-occupant passenger seat. Two-way roof ventilator, dual cab mounted exterior mirrors.
Electrical 12-volt, negative ground, dual Delco maintenance free batteries, 750 CCA each, 110-amp alternator with integral regulator.
Air conditioning; AM/FM cassette stereo radio; PTO; engine block heater; engine oil pan heater; fuel tank mounted on right hand rail (33 gallon);
Options spare wheel; 6" stainless steel convex mirrors. Power windows and door locks, wheel simulators, second 33-gallon tank,
air deflector, cruise control, engine shutdown system, engine shutdown system with hourmeter.
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Inch 109.0 88.4 131.5 199.5 43.1
Inch 132.5 111.9 155.0 223.0 43.1
Inch 150.0 129.4 172.5 240.5 43.1
Inch 176.0 155.4 198.5 266.3 43.1
Dimension Constants
AH 7.9 BW 83.3 FH 32.0
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
AW 65.6 CW 65.0 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
BA 47.4 FW 33.5 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
BBC 68.0 OH 87.4 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
BOC 9.25 OW 78.5 1234567890123456789012345678901212345678901234567890123456789012123456789
1234567890123456789012345678901212345678901234567890123456789012123456789
In-Frame Tank 12,000-lb. GVWR Manual Transmission Model

NA1 109.0 in. lb. 3,472 1,885 5,357 6,643
NA2 132.5 in. lb. 3,516 1,907 5,423 6,577
NA3 150.0 in. lb. 3,560 1,929 5,489 6,511
NA4 176.0 in. lb. 3,605 1,951 5,556 6,444
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NE1 109.0 in. lb. 3,483 1,885 5,368 9,132
NE2 132.5 in. lb. 3,527 1,907 5,434 9,066
NE3 150.0 in. lb. 3,571 1,929 5,500 9,000
NE4 176.0 in. lb. 3,616 1,951 5,567 8,933
In-Frame Tank 12,000-lb. GVWR Automatic Transmission Model

NB1 109.0 in. lb. 3,538 1,929 5,467 6,533
NB2 132.5 in. lb. 3,582 1,951 5,533 6,467
NB3 150.0 in. lb. 3,627 1,973 5,600 6,400
NB4 176.0 in. lb. 3,671 1,995 5,666 6,334

NF1 109.0 in. lb. 3,549 1,929 5,478 9,022
NF2 132.5 in. lb. 3,593 1,951 5,544 8,956
NF3 150.0 in. lb. 3,638 1,973 5,611 8,889
NF4 176.0 in. lb. 3,682 1,995 5,677 8,823
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Side-Mounted Tank 12,000-lb. GVWR Manual Transmission Model

NA1 109.0 in. lb. 3,660 1,620 5,280 6,720
NA2 132.5 in. lb. 3,704 1,642 5,346 6,654
NA3 150.0 in. lb. 3,748 1,664 5,412 6,588
NA4 176.0 in. lb. 3,792 1,687 5,479 6,521

NE1 109.0 in. lb. 3,671 1,620 5,291 9,209
NE2 132.5 in. lb. 3,715 1,642 5,357 9,143
NE3 150.0 in. lb. 3,759 1,664 5,423 9,077
NE4 176.0 in. lb. 3,803 1,687 5,490 9,010
Side-Mounted Tank 12,000-lb. GVWR Automatic Transmission Model

NB1 109.0 in. lb. 3,726 1,664 5,390 6,610
NB2 132.5 in. lb. 3,770 1,687 5,457 6,543
NB3 150.0 in. lb. 3,814 1,709 5,523 6,477
NB4 176.0 in. lb. 3,858 1,731 5,589 6,411
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NF1 109.0 in. lb. 3,737 1,664 5,401 9,099
NF2 132.5 in. lb. 3,781 1,687 5,468 9,032
NF3 150.0 in. lb. 3,825 1,709 5,534 8,966
NF4 176.0 in. lb. 3,869 1,731 5,600 8,900
GVWR
Designed Maximum 12,000 lbs. 14,500 lbs.
Technical Notes:
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Wheelbase
Thick A B C-M/T C-A/T D-M/T D-A/T E F G
109.0 0.24 37.0 28.3 8.4 8.4 AA 40.5 AA 44.7 — CC 26.0 DD 33.0
132.5 0.24 37.0 28.3 8.4 8.4 AA 40.5 AA 44.7 BB 59.4 CC 26.0 DD 33.0
150.0 0.24 37.0 28.3 8.4 8.4 AA 40.5 AA 44.7 BB 59.4 CC 26.0 DD 33.0
176.0 0.24 37.0 28.3 8.4 8.4 AA 40.5 AA 44.7 BB 59.4 CC 26.0 DD 33.0
M/T = Manual Transmission A/T = Automatic Transmission
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Frame Chart

109.0 186.0 0.24
132.5 209.6 0.24
150.0 227.4 0.24
176.0 253.4 0.24
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Auxiliary Views
NOTE: Frame-mounted fuel tank available on 109", 132.5", 150" and 176" WB as an option replacing the In-Frame Tank.
* Allow 3" additional for battery box opening clearance.
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Wheelbase
Unsprung
Weight
Man. Trans. Auto. Trans. Man. Trans. Auto. Trans. Man. Trans. Auto. Trans. Man. Trans. Auto. Trans.
Front 3,472 3,538 3,516 3,582 3,560 3,627 3,605 3,671 573
12,000 Rear 1,885 1,929 1,907 1,951 1,929 1,973 1,951 1,995 871
Total 5,357 5,467 5,423 5,533 5,489 5,600 5,556 5,666 1,444
Front 3,483 3,549 3,527 3,593 3,571 3,638 3,616 3,682 573
14,500 Rear 1,885 1,929 1,907 1,951 1,929 1,973 1,951 1,995 904
Total 5,368 5,478 5,434 5,544 5,500 5,611 5,567 5,677 1,477
Cab Tilt
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Center of Gravity
H
GVWR WB V
Manual Trans. Auto. Trans.
109 22.1 33.1 33.3
132.5 20.6 40.3 40.6
12,000
150 20.5 45.7 46.5
176 18.9 53.6 54.0
109 22.1 33.0 33.3
132.5 20.6 40.2 40.5
14,500
150 20.5 45.6 45.9
176 18.9 53.5 53.6
NOTE: The maximum dimensions for a body installed on the N/W Series are 96 inches wide (outside) by 90 inches high (inside). Any larger
body applications must be approved by GMICT Application Engineering. In the West Coast call 1-562-229-5314 and in the East
Coast call 1-404-257-3013.
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Front Axle Chart

Tire Radius
Unload Load
12,000 lbs. 4,700 lbs. 8.1 6.4 13.0 12.4 27.5 26.9 65.2 14.5 14.5
215/85R 16-E
14,500 lbs. 5,360 lbs. 8.1 6.4 13.0 12.4 27.5 26.9 65.2 14.5 14.5
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Rear Axle Chart
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Definitions
A Centerline of axle to bottom of axle bowl. DW Minimum distance between the inner surfaces of the rear tires.
B Centerline of axle to top of frame rail at metal-to-metal position. Maximum Rear Width:
EW
C Centerline of axle to top of frame rail at curb position. Overall width of the vehicle measured at the outermost surface of the rear tires.
D Centerline of axle to top of frame rail at design load. HH
Minimum clearance between the rear axle and the ground-line.
Rear Tire Clearance: Dual Tire Spacing:
Minimum clearance required for tires and chain measured from the top of the Distance between the centerlines of the minimum distance required for tire
E frame at the vertical centerline of the rear axle, when rear wheels on one side HW bounce as measured from the centerline of the rear axle and the top of the
ride over a high spot. rear tire when one wheel rides over a high spot.
CH Vertical distance between the normal top of frame rail and the ground-line CW Distance between the centerlines of the dual wheels measured at the
through the centerline of the rear axle at curb position. ground-line.
Rear Frame Height:
DH Vertical distance between the normal top of frame rail and the ground-line
through the centerline of the rear axle at design load.


215/85R 16-E 7,950/9,880 lbs. 65.0 10.6 10.6 14.9 13.3 7.8
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Suspension Deflection Charts
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Tire and Disc Wheel Chart

Tire
215/85R 16-E 2,430 70 2,210 70 4,860 8,840 12,000
215/85R 16-E 2,680 80 2,470 80 5,360 9,880 14,500
Tire Radius
Width Width
215/85R 16-E 12,000 14.1 14.1 14.3 14.7 8.2 1.8 6.0
215/85R 16-E 14,500 14.1 14.1 14.3 14.7 8.2 1.8 6.0
Disc Wheel
Bolt Circle Ft./Rr. Nut Rear Stud Nut/Stud Outside Disc
Wheel Size Bolt Holes Dia. Size* Size* Torque Specs. Inner Circle Offset Thickness Rim Type Material Mfg.
1.6142 0.8268
325 ft.-lb. Steel
16 x 6 K 6 JIS 8.75 (41 mm) (21 mm) 6.46 5.0 0.35 5º DC
(440 N•m) TOPY
BUD HEX SQUARE
* O.D. Wrench Sizes
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Propeller Shaft

Wheelbase A A B B C C D D
Manual Trans. Auto. Trans. Manual Trans. Auto. Trans. Manual Trans. Auto. Trans. Manual Trans. Auto. Trans.
109 in. — — 2.0º 2.3º — — 8.3º —
132.5 in. 0º 0º 2.4º 2.4º 4.4º 5º 6.2º 6.1º
150 in. 0º 0º 2.4º 2.4º 2.5º 2.6º 6.4º 6.4º
176 in. 0º 0º 1.7º 1.7º 2.8º 2.8º 4.5º 4.5º
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Wheelbase 109 132.5 150 176

Trans. Type 5 Manual Trans. 4 Auto. Trans. 5 Manual Trans. 4 Auto. Trans. 5 Manual Trans. 4 Auto. Trans. 5 Manual Trans. 4 Auto. Trans.
Shaft #1 O.D. 3.25
Thickness 0.091
Length 44.5 39.1 29.7 24.3 47.4 41.9 59.1 53.7
Type B B A A A A A A
Shaft #2 O.D. 3.25
Thickness 0.091
Length N/A N/A 38.3 38.3 38.3 38.3 52.6 52.6
Type N/A N/A B B B B B B
Type A 1st shaft in 2-piece driveline
1st shaft in 1-piece driveline

Type B 2nd shaft in 2-piece driveline
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PTO Location, Drive Gear and Opening Information
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Opening Bolt PTO Drive Gear Ratio of PTO Drv. No. of Helix
Trans. Location Pattern A B C D E F H Location Gear Spd. to Eng. Spd. Teeth Pitch Angle Max. Output Torque
2nd Gear Trans.
MXA 5C Left (Dr 1) 13.2 39 3.4 11.2 7.1 2.5º 4.1 Countershaft 25/49 = .51 20 3.175 15º 145 lbs.-ft. @ 1,000 RPM
Aisin1) Left (Dr 2) 12.6 38.59 0 8 7.5 2.5º 4.48 PTO Gear 1:1 with turbine 58 N/A 0 134 lbs.-ft. @ 1,000 RPM
1) No PTO gear in the 150" WB models.
Opening Diagram
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In-Frame Diesel Fuel Fill

2. Loosen hose from the tie downs. Remove caps from plate on rail.
3. Install hoses onto the plate.
4. Extend hose out from the driver side of the rail to body rail.
6. Cover with protector wrap and secure with tie wraps.
8. Filler neck (dimension A) must be between 6.85 inches and 8.5 inches above frame.
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Rear View Fuel Fill

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Top View Fuel Fill
Dimensions:
B = 29.75 inches (756 mm)
C = 34.00 inches (863 mm)
D = 39.29 inches (998 mm)
E = 30.86 inches (784 mm)
F = 56.60 inches (1,438 mm)
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Hose Modification for Various Width Bodies
96 remove 0 inches
90 remove 3 inches
86 remove 5 inches
80 remove 8 inches
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Number Part Name Isuzu Part Number GM Part Number Quantity

1 Breather Hose 897206-0420 N/A 1
2 Clip, Rubber Hose 894242-0340 94242034 2
3 Hose, Fuel Filler 897187-8750 97187875 1
4 Hose, Fuel Filler 897253-1400 97253140 1
5 Clip, Filler Hose 894435-8760 97724373 4
6 Screw, Filler Hose 894384-6460 N/A 3
7 Bracket, Filler Neck 897116-621Y 97116621 1
8 Cap, Filler 897118-7020 N/A 1
9 Protector 897114-0630 97114063 1
10 Clip 109707-1070 94062296 2
11 Caution Plate 894414-3530 94414353 1
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NQR/W5500 Diesel
Specifications
Model NQR/W5500
GVWR 17,950 lbs.
WB 109 in., 132.5 in., 150 in., 176 in.
Engine lsuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel.
Dry element air cleaner with vertical intake; 2 rows 506 in.2 radiator; 6-blade 18.7 in. diameter fan with viscous drive.
Equipment Cold weather starting device and an oil cooler.
Clutch Single, dry plate, 12.8 in. dia. ceramic, actuated by self-adjusting hydraulic master/slave cylinder.
Transmission MZZ 6-speed manual, all forward gears synchronized. Sixth gear is overdrive. Available Optional Transmission:
Aisin 450-43 LE 4-speed overdrive automatic transmission with lock-up capability in 2nd, 3rd and 4th. PTO capability all chassis and wheelbases.
GAWR 6,830 lbs.
Rear Axle Full-floating, single speed with hypoid gearing rated at 14,550 lbs.
GAWR 12,980 lbs.
Wheels 19.5 x 6.0 6-hole disc wheels, painted white.
Tires 225/70R 19.5F (12 pr) tubeless steel-belted radials, all season tread front and rear.
Dual-circuit, power-assisted hydraulic service brakes with load-sensing proportioning valve in rear brake circuit. Disc front and self-adjusting
Brakes outboard mounted drum rear. The parking brake is a mechanical, cable-actuated, internal expanding drum type,
transmission mounted. The exhaust brake is standard and is vacuum-operated. Four channel antilock brake system.
(Vehicle Specifications Index Section – NQR/W5500 Diesel – continued on next page)
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(Vehicle Specifications Index Section – NQR/W5500 Diesel – continued from previous page)
Model NQR/W5500
Jersey knit covered high back driver’s seat with two-occupant passenger seat. Two-way roof ventilator, dual cab mounted exterior mirrors.
Electrical 12-volt, negative ground, dual Delco maintenance free batteries, 750 CCA each, 110-amp alternator with integral regulator.
Air conditioning, AM/FM cassette stereo radio, PTO, engine block heater, engine oil pan heater, spare wheel, 6' stainless steel convex mirrors.
Options Auxilliary transmission oil cooler, mandatory for 20,950 GCWR. Power windows and door locks. 33-gallon fuel tank mounted on right hand rail,
in place of 30-gallon in frame tank, wheel simulators, second 33-gallon fuel tank mounted on left hand rail in addition to the 30-gallon in rail tank,
engine shutdown system, engine shutdown system with hourmeter and cruise control.

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Inch 109.0 88.4 131.5 199.5 43.1
Inch 132.5 111.9 155.0 223.0 43.1
Inch 150.0 129.4 172.5 240.5 43.1
Inch 176.0 155.4 198.5 266.3 43.1
Dimension Constants
AH 8.6 BW 83.3 FH 32.8
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AW 65.6 CW 65.0 1234567890123456789012345678901212345678901234567890123456789012123456789
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BA 47.4 FW 33.5 1234567890123456789012345678901212345678901234567890123456789012123456789
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BBC 68.0 OH 88.1 1234567890123456789012345678901212345678901234567890123456789012123456789
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NQ1 109.0 in. lb. 3,704 2,304 6,008 11,942
NQ2 132.5 in. lb. 3,748 2,326 6,074 11,876
NQ3 150.0 in. lb. 3,781 2,359 6,140 11,810
NQ4 176.0 in. lb. 3,825 2,381 6,206 11,744

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NR1 109.0 in. lb. 3,737 2,326 6,063 11,887
NR2 132.5 in. lb. 3,781 2,348 6,129 11,821
NR3 150.0 in. lb. 3,825 2,370 6,195 11,755
NR4 176.0 in. lb. 3,869 2,392 6,261 11,689

NQ1 109.0 in. lb. 3,891 2,039 5,930 12,020
NQ2 132.5 in. lb. 3,935 2,061 5,996 11,954
NQ3 150.0 in. lb. 3,968 2,094 6,062 11,888
NQ4 176.0 in. lb. 4,012 2,116 6,128 11,822

NR1 109.0 in. lb. 3,924 2,061 5,985 11,965
NR2 132.5 in. lb. 3,968 2,083 6,051 11,899
NR3 150.0 in. lb. 4,012 2,105 6,117 11,833
NR4 176.0 in. lb. 4,056 2,127 6,183 11,767

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GVWR
Designed Maximum 17,950 lbs.
GAWR, Front 6,830 lbs.
GAWR, Rear 12,980 lbs.
Technical Notes:

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Wheelbase
109.0 0.24 37.0 28.3 8.4 8.4 AA 40.5 AA 44.7 — CC 26.0 DD 33.0
132.5 0.24 37.0 28.3 8.4 8.4 AA 40.5 AA 44.7 BB 59.4 CC 26.0 DD 33.0
150.0 0.24 37.0 28.3 8.4 8.4 AA 40.5 AA 44.7 BB 59.4 CC 26.0 DD 33.0
176.0 0.24 37.0 28.3 8.4 8.4 AA 40.5 AA 44.7 BB 59.4 CC 26.0 DD 33.0

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Frame Chart

109.0 186.0 0.24
132.5 209.6 0.24
150.0 227.4 0.24
176.0 253.4 0.24
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Auxiliary Views
NOTE: Frame-mounted fuel tank available on 109", 132.5", 150" and 176" WB as an option. Allow 3" additional for battery box opening
clearance.
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Wheelbase
Unsprung
Weight
Man. Trans. Auto. Trans. Man. Trans. Auto. Trans. Man. Trans. Auto. Trans. Man. Trans. Auto. Trans.
Front 3,704 3,737 3,748 3,781 3,781 3,825 3,825 3,869 573
17,950 Rear 2,304 2,326 2,326 2,348 2,359 2,370 2,381 2,392 871
Total 6,008 6,063 6,074 6,129 6,140 6,195 6,206 6,261 1,444
Cab Tilt

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Center of Gravity
H
GVWR WB V
Manual Trans. Auto. Trans.
109 22.1 36.8 37.4
132.5 20.6 44.7 44.8
17,950
150 20.4 50.6 50.7
176 18.9 59.4 59.5
NOTE: The maximum dimensions for a body installed on the NQR/W5500 are 96 inches wide (outside) by 90 inches high (inside). Any larger
body applications must be approved by GM/Isuzu Application Engineering. In the West Coast call 1-562-229-5314 and in the East
Coast call 1-404-257-3013.

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Front Axle Chart

Tire Radius
Unload Load
225/70R 19.5F 17,950 lbs. 6,830 lbs. 8.8 6.4 13.0 12.2 28.3 27.6 66.2 15.2 15.2
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Rear Axle Chart

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Definitions
Rear Frame Height:
A Centerline of axle to bottom of axle bowl. DH Vertical distance between the normal top of frame rail and the ground-line
B Centerline of axle to top of frame rail at metal-to-metal position. DW Minimum distance between the inner surfaces of the rear tires.
Maximum Rear Width:
C Centerline of axle to top of frame rail at curb position. EW Overall width of the vehicle measured at the outermost surface of the rear tires.
D Centerline of axle to top of frame rail at design load. HH Minimum clearance between the rear axle and the ground-line.
Minimum clearance required for tires and chain measured from the top of Distance between the centerlines of the minimum distance required for tire
E the frame at the vertical centerline of the rear axle, when rear wheels on HW bounce as measured from the centerline of the rear axle and the top of the
one side ride over a high spot. rear tire when one wheel rides over a high spot.


225/70R 19.5F 12,980 lbs. 65.0 11.6 10.6 14.9 13.0 8.4

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Tire
225/70R 19.5F 3,450 90 3,245 90 6,900 12,980 17,950
Tire Radius
Width Width
225/70R 19.5F 17,950 15.24 15.28 16.10 16.10 8.9 1.1 6.0
Disc Wheel
Nut/Stud
Specs.
1.6142 0.8268
325 ft.-lb. Steel
19.5 x 6.00 RW 6 JIS 8.75 (41 mm) (21 mm) 6.46 5.0 0.37 15º DC
(440 N•m) ACCURIDE
BUD HEX SQUARE
* O.D. Wrench Sizes

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Propeller Shaft

Wheelbase A A B B C C D D
Manual Trans. Auto. Trans. Manual Trans. Auto. Trans. Manual Trans. Auto. Trans. Manual Trans. Auto. Trans.
109 in. — — 3.1º 3.1º — — 10.3º 9.4º
132.5 in. 0º 0º 3.1º 3.1º 4.9º 5.0º 7.8º 7.3º
150 in. 0º 0º 3.1º 3.1º 2.5º 2.6º 8.2º 7.7º
176 in. 0º 0º 2.3º 2.3º 2.8º 2.8º 4.8º 4.8º
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Wheelbase 109 132.5 150 176

Trans. Type 6 Manual Trans. 4 Auto. Trans. 6 Manual Trans. 4 Auto. Trans. 6 Manual Trans. 4 Auto. Trans. 6 Manual Trans. 4 Auto. Trans.
Shaft #1 O.D. 3.54 3.25 3.54 3.25 3.54 3.25 3.54 3.25
Thickness 0.126 0.091 0.126 0.091 0.126 0.091 0.126 0.091
Length 38.3 38.6 18.4 24.3 36.1 41.9 47.9 53.7
Type D C B A B A B A
Shaft #2 O.D. 3.54 3.25 3.54 3.25 3.54 3.25 3.54 3.25
Thickness 0.126 0.091 0.126 0.091 0.126 0.091 0.126 0.091
Length N/A N/A 37.8 38.3 37.8 38.3 51.9 52.6
Type N/A N/A D C D C D C
Type Description Model Illustration
Type A P20
Type B P30
Type C P20

2nd shaft in 2-piece driveline
Type D P30

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3.7 w/ 4th Gear Trans.
MZZ 6U Left (Dr 1) 11.6 37.57 4.6 12.8 7.7 2.5º 14º angle Countershaft 25/46 = 0.543 37 3º 25º RH 180 lbs.-ft. @ 1,000 RPM
Aisin1) Left (Dr 2) 12.6 38.59 0 8 7.5 2.5º 4.48 PTO Gear 1:1 with turbine 58 N/A 0º 134 lbs.-ft. @ 1,000 RPM
Opening Diagram

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Brake System Diagram, Hydraulic Brake Booster

Please refer to introduction section of book for antilock system cautions and wheelbase modification requirements.

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Diesel Fuel Fill


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Rear View Fuel Fill

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Top View Fuel Fill
Dimensions:
B = 29.75 inches (756 mm)
C = 34.00 inches (863 mm)
D = 39.29 inches (998 mm)
E = 30.86 inches (784 mm)
F = 56.60 inches (1,438 mm)
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96 remove 0 inches
90 remove 3 inches
86 remove 5 inches
80 remove 8 inches
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NQR/W5500 Diesel Fuel Fill Parts Illustration

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NQR/W5500 Diesel Fuel Fill Parts List

2 Clip, Rubber Hose 894242-0340 94242034 2
3 Hose, Fuel Filler 897187-8750 97187875 1
4 Hose, Fuel Filler 897253-1400 97253140 1
5 Clip, Filler Hose 894435-8760 97724373 4
8 Cap, Filler 897118-7020 N/A 1
9 Protector 897114-0630 97114063 1
10 Clip 109707-1070 94062296 2
11 Caution Plate 894414-3530 94414353 1
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NPR HD/W4500, NQR/W5500 Crew Cab Diesel
Specifications
Model NPR HD/W4500 Crew Cab Diesel NQR/W5500 Crew Cab Diesel
GVWR 14,500 lbs. 17,950 lbs.
WB 150 in., 176 in.
Engine lsuzu 4-cylinder, in-line 4-cycle, turbocharged, intercooled, direct injection diesel.
Dry element air cleaner with vertical intake; 2 rows 506 in.2 radiator; 6-blade 18.7 in. diameter fan with viscous drive.
Equipment Cold weather starting device and an oil cooler. Engine warning alarm for high water temperature, low water level and low oil pressure.
Transmission* Aisin 450-43 LE 4-speed overdrive automatic transmission with lock-up capability in 2nd, 3rd and 4th. PTO capability.
Steering Integral power steering 18.8-20.9:1 ratio. Tilt & telescoping steering column. Integral power steering 20.9:1 ratio. Tilt & telescoping steering column.
Suspension Semi-elliptical steel alloy tapered leaf springs with Semi-elliptical steel alloy leaf springs with
stabilizer bar and shock absorbers. stabilizer bar and shock absorbers.
GAWR 5,360 lbs. 6,830 lbs.
Rear Axle Full-floating single-speed with hypoid gearing rated at 11,020 lbs. Full-floating single-speed with hypoid gearing rated at 14,550 lbs.
Suspension Semi-elliptical steel alloy multi-leaf springs and shock absorbers. Semi-elliptical steel alloy leaf springs and shock absorbers.
GAWR 9,880 lbs. 12,980 lbs.
Wheels 16 x 6.0 6-hole disc wheels, painted white. 19.5 x 6.0 6-hole disc wheels, painted white.
Tires 215/85R 16E (10 pr) tubeless steel-belted radials, all-season front/rear. 225/70R 19.5F (12 pr) tubeless steel-belted radials, all-season front/rear.
Dual-circuit, vacuum-assisted hydraulic service brakes with load-sensing
proportioning valve in rear brake circuit and a metering valve between Dual-circuit, power-assisted hydraulic service brakes with
Brakes the master cylinder and 6-way joint on the front brake lines. load sensing proportioning valve in rear brake circuit.
Disc front and self-adjusting outboard mounted rear drum. The parking brake is a mechanical, cable-actuated, internal expanding drum type,
transmission mounted. The exhaust brake is standard and is vacuum-operated. Four channel antilock brake system.
NOTE: These selected specifications are subject to change without notice. *All Transmissions have a PTO gear in all wheelbases.
(Vehicle Specifications Index Section – NPR HD/W4500, NQR/W5500 Crew Cab Diesel – continued on next page)
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(Vehicle Specifications Index Section – NPR HD/W4500, NQR/W5500 Crew Cab Diesel – continued from previous page)
Model NPR HD/W4500 Crew Cab Diesel NQR/W5500 Crew Cab Diesel
Cab All-steel, 7-passenger, low cab forward, BBC 108.6 in.
Jersey knit covered high back driver’s seat with two-occupant passenger seat. Four passenger rear bench seat.
Equipment Two-way roof ventilator, dual cab mounted exterior mirrors. Tilt and telescoping steering column. Tinted glass.
Electrical 12-volt, negative ground, dual Delco maintenance-free batteries, 750 CCA each, 110-amp alternator with integral regulator.
Air Conditioning, AM/FM cassette stereo radio, PTO, engine block heater, engine oil pan heater, 6" stainless steel convex mirrors.
Options Front power window and front/rear power door locks. 33-gallon fuel tank mounted on right-hand rail, spare wheel. Engine shutdown
and alarm for high water temperature, low water level and low oil pressure.
Rear cab heater, cruise control, engine hour meter and wheel simulators. Rear cab heater, cruise control, engine hour meter.
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NPR HD/W4500 Variable Chassis Dimensions

Inch 150.0 88.9 132.0 240.5 43.1
Inch 176.0 114.9 158.0 266.5 43.1
NPR HD/W4500 Dimension Constants

AH 7.9 BW 83.3 FH 32.0
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AW 65.6 CW 65.0 1234567890123456789012345678901212345678901234567890123456789012123456789
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BA 47.4 FW 33.5 1234567890123456789012345678901212345678901234567890123456789012123456789
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BBC 108.6 OH 87.4 1234567890123456789012345678901212345678901234567890123456789012123456789
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BOC 4.2 OW 78.5 1234567890123456789012345678901212345678901234567890123456789012123456789
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NPR HD/W4500 In-Frame Tank 14,500-lb. GVWR Automatic Transmission Model

NG3 150.0 in. lb. 3,979 2,161 6,140 8,360
NG4 176.0 in. lb. 4,056 2,149 6,205 8,295
NPR HD/W4500 Side-Mounted Tank 14,500-lb. GVWR Automatic Transmission Model

NG3 150.0 in. lb. 4,167 1,896 6,063 8,437
NG4 176.0 in. lb. 4,244 1,885 6,129 8,371
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NQR/W5500 Variable Chassis Dimensions

Inch 150.0 88.9 132.0 240.5 43.1
Inch 176.0 114.9 158.0 266.5 43.1
NQR/W5500 Dimension Constants

AH 8.6 BW 83.3 FH 32.8
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AW 65.6 CW 65.0 1234567890123456789012345678901212345678901234567890123456789012123456789
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BA 47.4 FW 33.5 1234567890123456789012345678901212345678901234567890123456789012123456789
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BBC 108.6 OH 88.1 1234567890123456789012345678901212345678901234567890123456789012123456789
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BOC 4.2 OW 78.5 1234567890123456789012345678901212345678901234567890123456789012123456789
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NQR/W5500 In-Frame Tank 17,950-lb. GVWR Automatic Transmission Model

NS3 150.0 in. lb. 4,167 2,557 6,724 11,226
NS4 176.0 in. lb. 4,244 2,546 6,790 11,160
NQR/W5500 Side-Mounted Tank 17,950-lb. GVWR Automatic Transmission Model

NS3 150.0 in. lb. 4,354 2,293 6,647 11,303
NS4 176.0 in. lb. 4,431 2,282 6,713 11,237
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NPR HD/W4500 NQR/W5500
GVWR Designed Maximum 14,500 lbs. 17,950 lbs.
Technical Notes:
Chassis Curb Weight includes standard equipment and fuel. Does not include driver, passenger, payload, body or special equipment.
Maximum Payload Weight is the allowed maximum for equipment, body, payload, driver and passengers and is calculated by subtracting
chassis curb weight from the GVWR.
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Wheelbase
150.0 0.24 37.0 +0.18 28.3 8.1 8.1 AA 40.5 AA 44.7 BB 59.4 CC 26.0 DD 33.0
176.0 0.24 37.0 +0.18 28.3 8.1 8.1 AA 40.5 AA 44.7 BB 59.4 CC 26.0 DD 33.0
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Frame Chart

150.0 227.4 0.24 + 0.18
176.0 253.4 0.24 + 0.18
Note: On this model chassis, GMICT will require that the body installed on the chassis have an understructure manufactured with any of
the following structural steel “C” channels: 4" x 1-5/8", 7.5 lb./ft.; 5" x 1-3/4", 6, 7 or 9.0 lb./ft.; 6" x 2", 8.2, 10.5 or 13 lb./ft.
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Auxiliary Views
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NPR/W4500 Series
Wheelbase
GVWR Axle Unsprung Weight
150 in. – Automatic Trans. 176 in. – Automatic Trans.
Front 3,979 4,056 573
14,500 Rear 2,161 2,149 904
Total 6,140 6,205 1,477
Center of Gravity
H
GVWR WB V
150 21.4 52.8
14,500
176 20.0 60.9
Coast call 1-404-257-3013.
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NQR/W5500 Series
Wheelbase
GVWR Axle Unsprung Weight
150 in. – Automatic Trans. 176 in. – Automatic Trans.
Front 4,167 4,244 705
17,950 Rear 2,557 2,546 1,366
Total 6,724 6,790 2,071
Center of Gravity
The center of gravity of the chassis-cab.
H
GVWR WB V
150 21.3 57.0
17,950
176 19.9 66.0
Coast call 1-404-257-3013.
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Front Axle Chart NPR HD/W4500

Tire Radius
Unload Load
215/85R 16E 14,500 lbs. 5,360 lbs. 8.1 6.4 13.0 12.4 27.5 26.9 65.2 14.5 14.5
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Front Axle Chart NQR/W5500

Tire Radius
Unload Load
225/70R 19.5F 17,950 lbs. 6,830 lbs. 8.8 6.4 13.0 12.2 28.3 27.6 66.2 15.2 15.2
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Rear Axle Chart NPR HD/W4500
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Definitions
Rear Frame Height:
Maximum Rear Width:


215/85R 16E 9,880 lbs. 65.0 10.6 10.6 14.9 13.3 7.8
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Rear Axle Chart NQR/W5500
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Definitions
Rear Frame Height:
Maximum Rear Width:


225/70R 19.5F 12,980 lbs. 65.0 11.6 10.6 14.9 13.0 8.4
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Suspension Deflection Charts NPR HD/W4500
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Suspension Deflection Charts NQR/W5500
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Tire and Disc Wheel Chart NPR HD/W4500

Tire
215/85R 16E 2,680 80 2,470 80 5,360 9,880 14,500
Tire Radius
Width Width
215/85R 16E 14,500 14.1 14.1 14.3 14.7 8.2 18 6.0
Disc Wheel
Nut/Stud
Specs.
1.6142 0.8268
289 ft.-lb. Steel
16.6 x 6.00K 6 JIS 8.75 (41 mm) (21 mm) 6.46 5.0 0.39 15º DC
(392 N•m) TOPY
BUD HEX SQUARE
* O.D. Wrench Sizes
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Tire and Disc Wheel Chart NQR/W5500

Tire
225/70R 19.5F 3,450 90 3,245 90 6,900 12,980 17,950
Tire Radius
Width Width
225/70R 19.5F 17,950 15.0 15.2 15.4 15.8 8.8 1.2 6.0
Disc Wheel
Nut/Stud
Specs.
1.6142 0.8268
325 ft.-lb. Steel
19.5 x 6.00K 6 JIS 8.75 (41 mm) (21 mm) 6.46 5.0 0.39 15º DC
(440 N•m) TOPY
BUD HEX SQUARE
* O.D. Wrench Sizes
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Propeller Shaft NPR HD/W4500

Wheelbase A B C D
Automatic Transmission Automatic Transmission Automatic Transmission Automatic Transmission
150 in. 0º 2.4º 2.6º 6.4º
176 in. 0º 1.7º 2.8º 4.5º
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Propeller Shaft NQR/W5500

Wheelbase A B C D
Automatic Transmission Automatic Transmission Automatic Transmission Automatic Transmission
150 in. 0º 3.1º 2.6º 7.7º
176 in. 0º 2.3º 2.8º 4.8º
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Wheelbase 150 176

Number of Shafts 1 2
Transmission Type 6 Manual Transmission 4 Automatic Transmission
Shaft #1 O.D. 3.25 3.25
Thickness 0.091 0.091
Length 41.9 53.7
Type A A
Shaft #2 O.D. 3.25 3.25
Thickness 0.091 0.091
Length 38.3 52.6
Type C C
Type Description Model Illustration
Type A 1st shaft in 2-piece driveline P20
Type C 2nd shaft in 2-piece driveline P20
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Aisin1) Left (Dr 2) 12.6 38.59 0 8 7.5 2.5º 4.48 PTO Gear 1:1 with turbine 58 N/A 0º 134 lbs.-ft. @ 1,000 RPM
1) No PTO gear in the 150” WB models
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Opening Diagram
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Brake System Diagram 14,500 GVW

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Brake System Diagram 17,950 GVW

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Diesel Fuel Fill

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Rear View Fuel Fill

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Top View Fuel Fill
Dimensions:
B = 29.75 inches (756 mm)
C = 34.00 inches (863 mm)
D = 39.29 inches (998 mm)
E = 30.86 inches (784 mm)
F = 56.60 inches (1,438 mm)
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96 remove 0 inches
90 remove 3 inches
86 remove 5 inches
80 remove 8 inches
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2 Clip, Rubber Hose 894242-0340 94242034 2
3 Hose, Fuel Filler 897187-8750 97187875 1
4 Hose, Fuel Filler 897253-1400 97253140 1
5 Clip, Filler Hose 894435-8760 97724373 4
8 Cap, Filler 897118-7020 N/A 1
9 Protector 897114-0630 97114063 1
10 Clip 109707-1070 94062296 2
11 Caution Plate 894414-3530 94414353 1
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FRR/WT5500
Specifications
Model FRR/WT5500
GVWR/GCWR 18,000/30,000 lbs. (26,000 lbs. with automatic) 19,500/30,000 lbs. (26,000 lbs. with automatic)
WB 148 in., 167 in., 176 in., 191 in., 218 in.
Engine GM/lsuzu 6-cylinder, in-line 4-cycle, OHC, turbocharged, intercooled, direct injection diesel.
Model/Displacement 6HK1-TC/475 CID (7.8 liters)
Dry element air cleaner with vertical intake. Spin-on paper element type fuel and oil filters.
Equipment Cold weather starting device. Fuel/water separator, common rail type electronic fuel injection system and an oil cooler.
Clutch Single dry disc, hydraulic actuation, 14-inch diameter, cerametallic Spicer.
Transmission* MLD 6Q Manual 6-Speed synchronized second through sixth, sixth gear is overdrive.
Optional Allison 1000 Series, 5-speed overdrive, automatic transmission with lockup torque converter.
Steering Integral power steering with variable ratio (18.8-16.1:1).
Suspension Semi-elliptical alloy steel leaf springs with stabilizer bar and shock absorbers.
GAWR 6,800 lbs. 7,060 lbs.
Ratio MT/AT 4.11:1/4.33:1
Suspension Semi-elliptical alloy steel leaf springs.
GAWR 13,000 lbs. 13,680 lbs.
Wheels 19.5 x 6.00 on 6-hole disc wheels, painted white.
Tires 225/70R 19.5F low profile tubeless radial, all-season tread front and rear.
Fuel Tank 42-gallon rectangular steel, mounted on left hand frame rail, fuel/water separator frame mounted. Fuel filter.
Brakes Antilock brake system with dual circuit air over hydraulic self-adjusting service brakes.
Mechanical cable-actuated internal expanding drum parking brake, transmission mounted. An exhaust brake is also standard.
NOTE: These selected specifications are subject to change without notice. *All transmissions have a PTO gear in all wheelbases.
(Vehicle Specifications Index Section – FRR/WT5500 – continued on next page)
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(Vehicle Specifications Index Section – FRR/WT5500 – continued from previous page)
Model FRR/WT5500
Frame Ladder type channel section, 33-inch width at load platform area, section modulus 7.63 in.3, and RBM 412,200 lbs.-ft./in. per rail.
Dual exterior rearview mirrors, electrically operated wipers and window washer. Steering column tilts and telescopes.
Equipment Includes two 3-point seat belts and retractors, and a 2-point seat belt. Right hand power window.
Electrical 12-volt, dual Delco maintenance-free batteries, 750 CCA each. 110-amp alternator with integral regulator. Right hand power window.
Second fuel tank on 167 in., 179 in., 191 in., and 218 in. wheelbase; transmission mounted PTO; air conditioning; block heater; oil pan heater; AM/FM
Options cassette stereo radio; spare wheel; Federal FV/CCFV Certification available; wheel simulators; rear axle stabilizer bar (mandatory with 102" wide bodies).

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Unit WB+ CA* CE* OAL AF
Inch 148 117.7 180.6 259.3 62.9
Inch 167 136.2 206.5 285.2 70.3
Inch 179 148.0 226.2 304.9 78.1
Inch 191 159.8 243.9 322.6 84.1
Inch 218 187.4 283.3 362.0 95.9
* Effective CA & CE are 7.5 inches less for MT. Effective CA & CE are 10 inches less for AT.
Dimension Constants
AH 8.2 BW 85.3 HH 6.7
AW 70.5 CW 65.4 OH 103.5/105.5
BA 47.8 FH 35.3 OW 86.3
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BBC 78.7 FH** 37.3 1234567890123456789012345678901212345678901234567890123456789012123456789
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** 191" and 218" WB.
19,500-lb. GVW With 6-Speed Manual Transmission

Chassis Curb and Maximum Payload Weights
Model WB+ Unit Front Rear Total Payload
SA1 148 in. lb. 5,027 2,448 7,475 12,025
SA2 167 in. lb. 5,116 2,414 7,530 11,970
SA3 179 in. lb. 5,182 2,403 7,585 11,915
SA4 191 in. lb. 5,171 2,503 7,674 11,826
SA5 218 in. lb. 5,270 2,547 7,817 11,683
+
Frame is tapered at the rear of the 148", 167" and 179" WB, but straight on the 191" and 218" WB.

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18,000-lb. GVW With 6-Speed Manual Transmission

SE1 148 in. lb. 5,027 2,448 7,475 10,525
SE2 167 in. lb. 5,116 2,414 7,530 10,470
SE3 179 in. lb. 5,182 2,403 7,585 10,415
SE4 191 in. lb. 5,171 2,503 7,674 10,326
SE5 218 in. lb. 5,270 2,547 7,817 10,183
19,500-lb. GVW With Automatic Transmission

SB1 148 in. lb. 5,045 2,426 7,471 12,029
SB2 167 in. lb. 5,134 2,392 7,526 11,974
SB3 179 in. lb. 5,189 2,381 7,570 11,930
SB4 191 in. lb. 5,178 2,481 7,659 11,841
SB5 218 in. lb. 5,277 2,525 7,802 11,698
18,000-lb. GVW With Automatic Transmission

SF1 148 in. lb. 5,045 2,426 7,471 10,529
SF2 167 in. lb. 5,134 2,392 7,526 10,474
SF3 179 in. lb. 5,189 2,381 7,570 10,430
SF4 191 in. lb. 5,178 2,481 7,659 10,341
SF5 218 in. lb. 5,277 2,525 7,802 10,198
+
Frame is tapered at the rear of the 148", 167" and 179" WB, but straight on the 191" and 218" WB.

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Truck Weight Limits:
GVWR Designed Maximum 18,000 lbs. 19,500 lbs.
Technical Notes:
Chassis Curb Weight reflects standard equipment and fuel, but no driver or payload.

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Frame Frame Crossmember Type/Location

Wheelbase
FL Thick A B C D DD E F G
148 253.9 0.24 AA 24.3 AA 39.6 BB 77.9 — C2 96.1 DD 125.4 DD 175.0 EE 212.0
167 279.5 0.24 AA 24.3 AA 39.6 BB 77.9 — C1 106.3 DD 143.9 DD 193.5 EE 237.6
179 299.2 0.24 AA 24.3 AA 39.6 BB 77.9 — C3 106.3 DD 155.7 DD 205.3 EE 257.3
191 316.9 0.24 AA 24.3 AA 39.6 BB 77.9 — C1 117.7 DD 167.5 DD 217.1 EE 267.1
218 356.3 0.24 AA 24.3 AA 39.6 BB 77.9 C2 106.28 C1 145.27 DD 195.0 DD 244.6 EE 314.3
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Frame Chart
Wheelbase Frame FL CA CE Frame Thickness

148 253.9 117.7 180.6 0.24
167 279.5 132.2 206.5 0.24
179 299.2 148.0 226.2 0.24
191 316.9 159.8 243.9 0.24
218 356.3 187.4 283.3 0.24

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Auxiliary Views

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Wheelbase
Unsprung
GVWR Axle 148 in. 167 in. 179 in. 191 in. 218 in.
Weight
Man. Trans. Auto. Trans. Man. Trans. Auto. Trans. Man. Trans. Auto. Trans. Man. Trans. Auto. Trans. Man. Trans. Auto. Trans.
Front 5,027 4,994 5,116 5,083 5,182 5,138 5,171 5,127 5,270 5,226 770
19,500 Rear 2,448 2,426 2,414 2,392 2,403 2,381 2,503 2,481 2,547 2,525 1,335
Total 7,475 7,420 7,530 7,475 7,585 7,519 7,674 7,608 7,817 7,751 2,105
Cab Tilt

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Center of Gravity
H
GVWR WB V
Manual Transmission Automatic Transmission
148 27.5 48.7 48.6
167 27.5 53.7 53.6
19,500 179 27.5 56.8 56.7
191 28.3 62.3 62.3
218 28.3 71.2 71.2
NOTE: The maximum dimensions for a body installed on the FRR/WT5500 are 96 inches wide (outside) by 90 inches high (inside). Any larger
Coast call 1-404-257-3013.

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Front Axle Chart

AXLE SUSP. Tire Radius

Tire GVWR A B C D CH DH Track
CAPACITY CAPACITY Unload Load
225/70R 19.5 19,500 lbs. 8,800 lbs. 7,060 lbs. 8.2 6.9 12.3 11.39 27.52 26.41 70.5 15.4 15.0
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Rear Axle Chart

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Definitions
Rear Frame Height:
Maximum Rear Width:
Minimum clearance required for tires and chain measured from the top of the HW Distance between the centerlines of the tires in a set of dual tires.
E frame at the vertical centerline of the rear axle, when rear wheels on one side Tire Bounce Clearance:
ride over a high spot. KH Minimum distance required for tire bounce as measured from the centerline of the
Rear Frame Height: rear axle and the top of the rear tire when one wheel rides over a high spot.
CH Vertical distance between the normal top of frame rail and the ground-line
through the centerline of the rear axle at curb position. CW Track Dual Rear Wheel Vehicles:
Distance between the centerlines of the dual wheels measured at the ground-line.

Tire GVWR Axle Capacity Susp. Capacity A B C D E Track CW

225/70R 19.5 (12 pr) 19,500 lbs. 14,330 lbs. 13,680 lbs. 8.1 11.2 17.4 15.1 9.8 65.3

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Tire
225/70R 19.5F (12 pr) 13,640 95 3,420 95 7,280 13,680 19,500
Tire Radius Design Rim

Tire Size GVWR (Lb.) Tire Section Width Tire Clearance
Loaded Unloaded Width
225/70R 19.5F 19,500 15.0 in. 15.4 in. 8.8 in. 1.20 in. 6.0 in.
Disc Wheel
Nut/Stud
Specs.
1.6142 in. 0.8268 in.
400 ft.-lb. Steel
19.5 x 6.00 6 JIS 8.75 (41 mm) (21 mm) 6.46 in. 5.3 in. 0.35 in. 15º DC
(550 N•m) TOPY
BUD HEX SQUARE
* O.D. Wrench Sizes

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Propeller Shaft

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C F
Wheelbase A B D E
Unloaded Loaded Unloaded Loaded
M/T A/T M/T A/T M/T A/T M/T A/T M/T A/T M/T A/T M/T A/T M/T A/T
148 in. 0.0º 4.4º — — 4.8º 9.6º 9.6º 4.9º 1.7º 1.9º — — 7.1º 7.1º 2.4º 2.4º
167 in. 0.0º 3.8º — — 3.5º 6.6º 6.6º 3.2º 1.2º 1.3º — — 4.2º 4.1º 0.7º 0.7º
179 in. 0.0º 3.8º — — 2.6º 5.0º 5.0º 2.4º 1.2º 1.3º — — 2.5º 2.5º -0.1º -0.1º
191 in. 0.0º 4.6º — — 2.6º 4.8º 4.8º 2.2º 2.0º 2.1º — — 2.2º 2.3º -0.2º -0.3º
218 in. 0.0º 3.7º 0.0º 4.2º 2.6º 3.2º 3.2º 0.7º 1.2º 1.2º 1.6º 1.7º 0.7º 0.7º -1.8º -1.8º
Engine install at 2.5º angle from horizontal frame. Side view angles are measured from 2.5º angle. Positive angles are in addition to 2.5º angle. Negative angles are in subtraction from 2.5º angle.
NOTE: Loaded = at Design Load. Unloaded = at Curb Position (with typical cargo body).
Wheelbase 148 in. 167 in. 179 in. 191 in. 218 in.
No. of Shafts 2 2 2 2 3
Trans. Type M/T A/T M/T A/T M/T A/T M/T A/T M/T A/T
Shaft #1 O.D. 4.0
Thickness 0.134
Length 37.89 35.80 46.16 44.07 46.16 44.07 57.57 55.49 42.37 40.28
Type A A A A A A A A C C
Shaft #2 O.D. 4.0
Thickness 0.134
Length 38.20 38.20 48.44 48.44 60.05 60.05 60.65 60.65 42.89 42.89
Type B B B B B B B B D D
Shaft #3 O.D. 4.0
Thickness 0.134
Length — — — — — — — — 60.65 60.65
Type — — — — — — — — B B

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Type A 6-speed manual and automatic

Type B 3rd shaft in 3-piece driveline
6-speed manual and automatic

Type C 6-speed manual and automatic

Type D 6-speed manual and automatic

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Trans. Location Pattern A B C D E F G H Location Gear Spd. to Eng. Spd. Teeth Pitch Angle Max. Output Torque
4th Gear Trans.
MLD6Q Left (Dr 1) 11.3 43.2 5.1 12.9 7.3 2.5º 0º 5.6 Countershaft 25/42 - 0.595 36 6.6299 24º RH 180 lbs.-ft. @ 1,500 RPM
Converter Driven
S1000 Right SAE-6 11.94 43.7 0.0 7.8 7.3 2.5º 0º 5.67 PTO Gear 1:1 with turbine 64 6.865 0º 250 lbs.-ft. @ 1,500 RPM
Opening Diagram

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Brake System Diagram

Air Over Hydraulic

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Allison Transmission Rating Guide
Input Torque Input Power Turbine

1 1,2
Gross Net Gross Net Torque GVW GCW N/V Ratio3
N•m (lbs./ft.) N•m (lbs./ft.) (kW) (hp) (kW) (hp) N•m (lbs./ft.) kg (lbs.) kg (lbs.) rpm/kMph Vocations
(rpm/mph)
One-Way Rental,
General 740 (545) 705 (520) 280 (375) 254 (340) 1,152 (850) 9,000 (19,850) 11,800 (26,000) 24-38 (38-62) School Bus,
General Purpose
Refuse Vehicles
Severe Duty 740 (545) 705 (520) 280 (375) 254 (340) 1,152 (850) 7,500 (16,540) N/A 24-38 (38-62) (On-Highway
Only)
Specialty 740 (545) 705 (520) 280 (375) 254 (340) 1,152 (850) 9,980 (22,000) 11,800 (26,000) 24-38 (38-62) Motorhome
Transit Bus 576 (425) 542 (400) 149 (200) 134 (180) 1,017 (750) 7,500 (16,540) N/A 24-38 (38-62) Transit Bus
Transit Bus
w/SEM4 630 (456) 603 (445) 149 (200) 134 (180) 1,017 (750) 7,500 (16,540) N/A 24-38 (38-62) Transit Bus
1. Gross Power and Torque ratings are included for reference only.
2. Gross Power rating as defined by SAE J1995.
3. Ratio of transmission output rpm to vehicle ground speed. N/V is only used to limit park pawl applications.
4. SEM = Engine controls with Shift Energy Management.
NOTE: Consult Allison for transmission applications and approvals not listed above.
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2003i NPR/W3500, NPR HD/W4500 Gas Electrical
Symbols
Symbol Meaning Symbol Meaning Symbol Meaning
Coil (Inductor),
Fuse Electronic Parts
Solenoid Magnetic Valve
Fusible Link Resistor

Relay
Fusible Link Wire Speaker
Switch Buzzer Connector
Switch Circuit Breaker Light-Emitting Diode
Switch (Normal Close Type) Bulb Reed Switch
Contact Wiring Double-Filament Bulb Condenser
Battery Motor Horn
Diode Variable Resistor Rheostat Vacuum Switching Valve
(Vehicle Specifications Index Section – NPR/W3500, NPR HD/W4500 Gas Electrical – continued on next page)
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(Vehicle Specifications Index Section – NPR/W3500, NPR HD/W4500 Gas Electrical – continued from previous page)
Abbreviations
Abbreviation Definition Abbreviation Definition

A Ampere (S) kW Kilowatt
ABS Anti-lock Brake System LH Left Hand
ASM Assembly LWB Long Wheelbase
AC Alternating Current M/T Manual Transmission
A/C Air Conditioner OD Overdrive
ACC Accessories OPT Option
A/T Automatic Transmission QOS Quick on Start
C/B Circuit Breaker RH Right Hand
CSD Cold Start Device RR Rear
DIS Direct Ignition System RWAL Rear Wheel Anti-lock Brake System
EBCM Electronic Brake Control Module ST Start
ECGI Electronic Control Gasoline Injection STD Standard
ECM Electronic Control Module SW Switch
ECU Electronic Control Unit SWB Short Wheelbase
EFE Early Fuel Evaporation TCM Transmission Control Module
4 A/T 4-Speed Automatic Transmission 3 A/T 3-Speed Automatic Transmission
4X4 Four-Wheel Drive V Volt
FL Fusible Link VSV Vacuum Switching Valve
FRT Front W Watt (S)
H/L Headlight WOT Wide Open Throttle
IC Integrated Circuit W/ With
IG Ignition W/O Without
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Wiring
Wire Color
All wires have color-coded insulation. Wires belonging to a system’s main harness will have a single color. Wires belonging to a system’s
sub-circuits will have a colored stripe. Striped wires use the following code to show wire size and colors.
Example: 0.5 G / R
Red (Stripe Color)
Green (Base Color)
Wire Size (0.5 mm2)
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Abbreviations are used to indicate wire color within a circuit diagram. Refer to the following table.
Color-Coding Meaning Color-Coding Meaning

B Black BR Brown
W White LG Light Green
R Red GR Grey
G Green P Pink
Y Yellow LB Light Blue
L Blue V Violet
O Orange
Distinction of Circuit by Wire Base Color
Base Color Circuits Base Color Circuits

B Starter Circuit Y Instrument Circuit
W Charging Circuit L, O, BR,
R Lighting Circuit LG, GR, Other Circuits
G Signal Circuits P, LB, V
Wire Size
The size of wire used in a circuit is determined by the amount of current (amperage), the length of the circuit, and the voltage drop allowed. The
following wire size and load capacity are specified by AWG (American Wire Gauge). (Nominal size means approximate cross sectional area.)
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Nominal Cross Sectional Outside Allowable AWG Size

Size Area (mm2) Diameter (mm) Current (A) (Cross reference)
0.3 0.372 1.8 9 22
0.5 0.563 2.0 12 20
0.85 0.885 2.2 16 18
1.25 1.287 2.5 21 16
2 2.091 2.9 28 14
3 3.296 3.6 37.5 12
5 5.227 4.4 53 10
8 7.952 5.5 67 8
15 13.36 7.0 75 6
20 20.61 8.2 97 4
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Grounding Point Location (E-55, E-56)
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Grounding Point Location (J-9)
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Reference Table of Grounding Point

NOTICE: Abnormal phenomena of electrical components are considered resulted from defective grounding. In repair, be sure to inspect
grounding points and to tighten all fastening parts surrounding the grounding points.
Connector No. Cable Harness Name Location Main Parts (Load)

E-55
Frame-LH (FRT) Turn signal indicator light, Meter, High beam indicator light.
E-56
Charge relay, Dome light switch, Meter, Meter starter relay, Inhibitor switch, Lighting switch, Ignition relay,
Front turn signal light, Brake fluid switch, Tail relay, Cornering light switch, Cornering light, Cornering light
relay, Dimmer relay, Wiper motor, Washer motor, Intermittent relay, Heater and A/C relay, Radio and clock,
E-53 Headlight bracket-LH Cigar lighter, Fan switch, Blower resistor, A/C switch, Blower motor, Electronic thermostat, Cab interior
Engine harness switch, Flasher unit, Clearance light, I.D. light, Illumination, Power source relay, Hazard warning switch,
Turn signal light switch, Roof marker light, Illumination controller.
E-38 Mass air flow sensor, Diagnostics connector, Coil driver, Powertrain control module.
Engine-LH (RR)
E-39 Powertrain control module.
Engine-RH (RR)
Fuel pump relay, I.D. light relay, Oxygen sensor (LH, RH), Fuel pump, License plate light, Taillight,
J-9 Frame front harness Frame-RH (FRT) Rear turn signal light, Stoplight, Backup light.
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NPR/W3500 Body Room Light, I.D. and Marker Lamp,

and Back-Up Lamp Connector Location
NPR/W3500 Body Connectors LH Frame Packard Body Plug Connector Parts
NPR/NQR
Chassis Housing ASM ....................................... 1201-0974
Terminal ............................................................. 1208-9040
Terminal ............................................................. 1212-4587
Seal ................................................................... 1208-9679
Seal ................................................................... 1201-5193
Body Housing ASM ........................................... 1201-5797

Housing ............................................................. 1201-5787
Connector Seal.................................................. 1201-0492
Dummy Seal ...................................................... 1201-0300
• Packard Body Plug

• 4-Pin Weather Seal Connector with Mating Plug
• Location:
Inside left-hand frame rail 28 to 31 inches BOC
• Circuits:
Rear Dome = A
Hot Wire =B
Marker Lamp = C
Ground =D
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NPR/W3500 Body Room Light, I.D. and Marker Lamp,

and Back-Up Lamp Connector Location (continued)
NPR/W3500 Body Connectors EOF Packard Body Plug Connector Parts
NPR/NQR
Terminal ............................................................. 1208-9040
Terminal ............................................................. 1212-4587
Seal ................................................................... 1208-9679
Seal ................................................................... 1201-5193
Body Housing ASM ........................................... 1201-5797

Housing ............................................................. 1201-5787
Connector Seal.................................................. 1201-0492
Dummy Seal ...................................................... 1201-0300

• Location:
Center of Crossmember
• Circuits:
Rear Dome = A
Hot Wire =B
Marker Lamp = C
Ground =D
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Dome and Interior Lights Circuit Diagram
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241
Park, Tail, License and I.D. Lights Circuit Diagram
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242
Fuse Location
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Fuse Box
Fuse No. Fuse Name Amps Circuit Protected

F-1 HEATER 25A Heater
F-2 AIR CON 10A Compressor controls
EXHAUST BRAKE (Diesel) Exhaust brake system (Diesel)
F-3 10A
PCM (IGN 1) (Gas) Engine controls (Gas)
D.R.L. (Diesel) Headlights (Diesel)
F-4 10A
PCM (IGN) (Gas) Engine controls (Gas)
ECU (BAT) (Diesel) Engine controls (Diesel)
F-5 10A
A/T SOLENOID (Gas) Automatic transmission controls (Gas)
F-6 DOME LIGHT 10A Interior lights, Exterior lights
F-7 TAIL LIGHT 10A Dash lights, Exterior lights
F-8 STOP LIGHT 10A Brake lights
F-9 HEAD LIGHT (RH) 20A Headlights
F-10 HEAD LIGHT (LH) 20A Headlights
F-11 WIPER, WASHER 20A Windshield wiper/washer
F-12 GENERATOR 20A Charging system
F-13 TURN SIGNAL LIGHT 10A Turn lights
ECU (IGN) (Diesel)
F-14 10A Engine controls
PCM (ACC) (Gas)
F-15 AUDIO, CIGAR LIGHTER 20A Cigarette lighter, Engine controls, Sound system
F-16 POWER SOURCE 20A Engine controls
F-17 ENGINE STOP (Diesel) 10A Engine stop system (Diesel)
FUEL PUMP (Gas) Engine controls (Gas)
F-18 HAZARD, HORN 20A Horn, Hazard lights
F-19 AUDIO (Gas) 10A Audio
F-20 STARTER 10A Starting system
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Relay Location
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245
Cab Relay
Diode Number Circuits Protected Diode Number Circuits Protected

B-17 Brake warning system B-25 Compressor controls
B-18 —— B-26 Exhaust brake system (Diesel)
Relay Number Relay Relay Number Relay

B-19 Charge relay B-35 Cornering
B-20 Headlight Exhaust brake cut (Diesel)
B-36
B-21 Heater and A/C Vacuum pump (Gas)
B-22 Tail B-37 A/C thermo
B-23 Buzzer control Exhaust brake (Diesel)
B-38
B-24 Horn Ignition (Gas)
B-34 Power source
Fuse Box

F-23 ABS-1 15A ABS
F-24 ABS-2 10A ABS
ABS, Back-up lights (Diesel), Brake warning system, Compressor controls, Engine controls,
F-25 GAUGE, BACK 10A Exhaust brake system (Diesel), Exterior lights, Starting system, Transmission controls (Diesel)
F-26 TAC 15A TAC
F-27 TAC 15A IGN COIL (Gas)
F-28 TAC SPARE 15A SPARE
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Relay Box Outside Cab

80A (D)
1 MAIN Power Distribution
100A (G)
2 KEY 50A Power Distribution
ABS (Gas)
3 60A ABS (Gas), Engine Controls (Diesel)
GLOW (Diesel)
ABS (Diesel) 60A (D) ABS (Diesel)
4
RR DOME LIGHT (Gas) 40A (G) RR Dome Light (Gas)
CAB HEATER (Diesel) Ceramic Heater (Diesel)
5 60A
POWER SOURCE (Gas) Power Source (Gas)
F-21 MARKER LAMPS (Gas) 20A Marker Lamps
F-22 CONDENSER FAN (Diesel) 15A Condenser Fan (Diesel)

J-12 Starter J-17 Condenser (Diesel)
J-13 Glow-1 (Diesel) J-18 Exhaust brake control (Diesel)
J-14 C/Heater (Diesel/MT) Engine warm cut 2 (Diesel/AT)
J-19
Warm cut 1 (Diesel) Rear dome light (Gas)
J-15
A/C enable (Gas) J-20 I.D. light relay
J-16 Fuel pump (Gas)
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Auxiliary Power Source Circuit Diagram
Power source relay

P/N 8970609260.
Must be installed in dash relay box.
Refer to page 244, relay B-34
for identification.
Auxiliary power source wire

located on left side underdash
taped to body room light switch
harness with green tape.
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Sound System Circuit Diagram
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249
Horn Circuit Diagram
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250
Back-Up Lights Circuit Diagram
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251
Turn and Hazard Lights Circuit Diagram
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252
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03i Model Year Fuel Tank Sending Unit Resistance Values
Float Position Standard Resistance (Ω)

Empty Stop 248.5
Full Stop 40
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03i Model Year Fuel Tank Sending Unit Resistance Values
Float Position Standard Resistance (Ω)

Empty Stop 248.5
Full Stop 40
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NPR/W3500, NPR HD/W4500, NQR/W5500 Diesel Electrical
Symbols
Symbol Meaning Symbol Meaning Symbol Meaning
Coil (Inductor),
Fuse Electronic Parts
Solenoid Magnetic Valve
Fusible Link Resistor

Relay
Fusible Link Wire Speaker
Switch Buzzer Connector
Switch Circuit Breaker Light-Emitting Diode
Switch (Normal Close Type) Bulb Reed Switch
Contact Wiring Double-Filament Bulb Condenser
Battery Motor Horn
Diode Variable Resistor Rheostat Vacuum Switching Valve
(Vehicle Specifications Index Section – NPR/W3500, NPR HD/W4500, NQR/W5500 Diesel Electrical – continued on next page)
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(Vehicle Specifications Index Section – NPR/W3500, NPR HD/W4500, NQR/W5500 Diesel Electrical – continued from previous page)
Abbreviations
Abbreviation Definition Abbreviation Definition

A Ampere (S) IG Ignition
ABS Anti-lock Brake System kW Kilowatt
ASM Assembly LH Left Hand
AC Alternating Current LWB Long Wheelbase
A/C Air Conditioner M/T Manual Transmission
ACC Accessories OD Overdrive
A/T Automatic Transmission OPT Option
C/B Circuit Breaker QOS Quick on Start
CSD Cold Start Device RH Right Hand
DIS Direct Ignition System RR Rear
DRL Daytime Running Lights RWAL Rear Wheel Anti-lock Brake System
EBCM Electronic Brake Control Module ST Start
ECGI Electronic Control Gasoline Injection STD Standard
ECM Electronic Control Module SW Switch
ECU Electronic Control Unit SWB Short Wheelbase
EFE Early Fuel Evaporation TCM Transmission Control Module
4 A/T 4-Speed Automatic Transmission 3 A/T 3-Speed Automatic Transmission
4X4 Four-Wheel Drive V Volt
FL Fusible Link VSV Vacuum Switching Valve
FRT Front W Watt (S)
HBB Hydro Brake Booster WOT Wide-open Throttle
H/L Headlight W/ With
IC Integrated Circuit W/O Without
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Wiring
Wire Color
All wires have color-coded insulation. Wires belonging to a system’s main harness will have a single color. Wires belonging to a system’s
sub-circuits will have a colored stripe. Striped wires use the following code to show wire size and colors.
Example: 0.5 G / R
Red (Stripe Color)
Green (Base Color)
Wire Size (0.5 mm2)
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Abbreviations are used to indicate wire color within a circuit diagram. Refer to the following table.
Color-Coding Meaning Color-Coding Meaning

B Black BR Brown
W White LG Light Green
R Red GR Grey
G Green P Pink
Y Yellow LB Light Blue
L Blue V Violet
O Orange
Distinction of Circuit by Wire Base Color
Base Color Circuits Base Color Circuits

B Starter Circuit Y Instrument Circuit
W Charging Circuit L, O, BR,
R Lighting Circuit LG, GR, Other Circuits
G Signal Circuits P, LB, V
Wire Size
The size of wire used in a circuit is determined by the amount of current (amperage), the length of the circuit, and the voltage drop allowed. The
following wire size and load capacity are specified by AWG (American Wire Gauge). (Nominal size means approximate cross sectional area.)
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Nominal Cross Sectional Outside Allowable AWG Size

Size Area (mm2) Diameter (mm) Current (A) (Cross reference)
0.3 0.372 1.8 9 22
0.5 0.563 2.0 12 20
0.85 0.885 2.2 16 18
1.25 1.287 2.5 21 16
2 2.091 2.9 28 14
3 3.296 3.6 37.5 12
5 5.227 4.4 53 10
8 7.952 5.5 67 8
15 13.36 7.0 75 6
20 20.61 8.2 97 4
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260
Grounding Point Location (B-1)
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261
Grounding Point Location (B-7)
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262
Grounding Point Location (J-9)
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263
Reference Table of Grounding Point

NOTICE: Abnormal phenomena of electrical components are considered resulted from defective grounding. In repair, be sure to inspect
grounding points and to tighten all fastening parts surrounding the grounding points.
Connector No. Cable Harness Name Location Main Parts (Load)

B-1 Body harness Frame-LH (FRT) Vehicle speed sensor, Turn signal indicator light, Meter, High beam indicator light.
Charge relay, Exhaust brake relay, ECM, D.R.L. unit, Dome light, Meter, Brake fluid level switch, Tail relay,
TCM, Cornering light, Cornering light relay, Wiper motor, Washer motor intermittent relay, Heater and A/C
B-7 Body harness Headlight bracket-LH relay, Radio and clock, Cigar lighter, Fan switch, Blower resistor, A/C switch, Blower motor, Electronic
thermostat, Accel switch, Cab interior switch, Flasher unit, Clearance light, I.D. light, Illumination control,
Kick-down switch, Electronic vacuum pump, Power source relay.
Fuel tank unit, Starter relay, Neutral switch, Pressure switch, Exhaust brake control relay, Exhaust brake
magnetic valve, Accel switch, Clutch switch, Engine stop motor, Inhibitor switch, Engine warming cut
J-9 Frame front harness Frame-LH (CRT) relay, I.D. relay, Condenser fan relay, Condenser fan, License plate light, Taillight, Rear turn signal light,
Stoplight, Back-up light, Air magnetic valve, VSV 2 EXH (FULL), VSV F1CD Engine warming-up switch.
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NPR/W3500, NQR/W5500 Body Room Light, I.D. and Marker Lamp,

NPR/W3500, NQR/W5500 Body Connectors LH Frame Packard Body Plug Connector Parts
NPR/NQR
Terminal ............................................................. 1208-9040
Terminal ............................................................. 1212-4587
Seal ................................................................... 1208-9679
Seal ................................................................... 1201-5193
Body Housing ASM ........................................... 1201-5797

Housing ............................................................. 1201-5787
Connector Seal.................................................. 1201-0492
Dummy Seal ...................................................... 1201-0300

• Location:
• Circuits:
Rear Dome = A
Hot Wire =B
Marker Lamp = C
Ground =D
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NPR/W3500, NQR/W5500 Body Room Light, I.D. and Marker Lamp,

NPR/W3500, NQR/W5500 Body Connectors EOF Packard Body Plug Connector Parts
NPR/NQR
Terminal ............................................................. 1208-9040
Terminal ............................................................. 1212-4587
Seal ................................................................... 1208-9679
Seal ................................................................... 1201-5193
Body Housing ASM ........................................... 1201-5797

Housing ............................................................. 1201-5787
Connector Seal.................................................. 1201-0492
Dummy Seal ...................................................... 1201-0300

• Location:
Center of Crossmember
• Circuits:
Rear Dome = A
Hot Wire =B
Marker Lamp = C
Ground =D
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
266
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
267
Park, Tail, License and I.D. Lights Circuit Diagram
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
268
Fuse Location
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
269
Fuse Box

F-1 HEATER 25A Heater
F-2 AIR CON 10A Compressor controls
EXHAUST BRAKE (Diesel) Exhaust brake system (Diesel)
F-3 10A
D.R.L. (Diesel) Headlights (Diesel)
F-4 10A
ECU (BAT) (Diesel) Engine controls (Diesel)
F-5 10A
A/T SOLENOID (Gas) Automatic transmission controls (Gas)
F-6 DOME LIGHT 10A Interior lights, Exterior lights
F-7 TAIL LIGHT 10A Dash lights, Exterior lights
F-8 STOP LIGHT 10A Brake lights
F-9 HEAD LIGHT (RH) 20A Headlights
F-10 HEAD LIGHT (LH) 20A Headlights
F-11 WIPER, WASHER 20A Windshield wiper/washer
F-12 GENERATOR 20A Charging system
F-13 TURN SIGNAL LIGHT 10A Turn lights
ECU (IGN) (Diesel)
F-14 10A Engine controls
PCM (ACC) (Gas)
F-15 AUDIO, CIGAR LIGHTER 20A Cigarette lighter, Engine controls, Sound system
F-16 POWER SOURCE 20A Engine controls
ENGINE STOP (Diesel) Engine stop system (Diesel)
F-17 10A
FUEL PUMP (Gas) Engine controls (Gas)
F-18 HAZARD, HORN 20A Horn, Hazard lights
F-19 NOT USED (Diesel) 10A AUDIO
F-20 STARTER 10A Starting system
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
270
Relay Location
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
271
Cab Relay
Diode Number Circuits Protected Diode Number Circuits Protected

B-17 Brake warning system B-25 Compressor controls
B-18 —— B-26 Exhaust brake system (Diesel)

B-19 Charge relay B-35 Cornering
B-20 Headlight Exhaust brake cut (Diesel)
B-36
B-21 Heater and A/C Vacuum pump (Gas)
B-22 Tail B-37 A/C thermo
B-23 Buzzer control Exhaust brake (Diesel)
B-38
B-24 Horn Ignition (Gas)
B-34 Power source
Fuse Box

F-23 NOT USED
F-24 NOT USED
ABS, Back-up lights (Diesel), Brake warning system, Compressor controls, Engine controls,
F-25 GAUGE, BACK 10A Exhaust brake system (Diesel), Exterior lights, Starting system, Transmission controls (Diesel)
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
272
Relay Box Outside Cab

1 MAIN 80A Power distribution
2 KEY 50A Power distribution
ABS (Gas)
3 60A ABS (Gas), Engine controls (Diesel)
GLOW (Diesel)
4 ABS (Diesel) 60A ABS
5 C/HEATER (Diesel) 60A Ceramic heater
F-21 —— —— Not used
F-22 CONDENSER FAN (Diesel) 15A Condenser fan

J-12 Starter J-16 Fuel pump (Gas)
J-13 Glow-1 (Diesel) J-17 Condenser (Diesel)
J-14 C/Heater (Diesel/MT) J-18 Exhaust brake control (Diesel)
Warm cut 1 (Diesel) J-19 Engine warm cut 2 (Diesel/AT)
J-15
A/C enable (Gas) J-20 I.D. light relay
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
273
Auxiliary Power Source Circuit Diagram
Power source relay

P/N 8970609260.
Must be installed in dash relay box.
Refer to page 271, relay B-34
for identification.
Auxiliary power source wire

located on left side underdash
taped to body room light switch
harness with green tape.
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
274
Horn Circuit Diagram
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
275
Back-Up Lights Circuit Diagram
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
276
Sound System Circuit Diagram
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
277
Engine Stop Motor Circuit Diagram
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
278
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
279
Fuel Tank Sending Unit Resistance (In-Frame Tank)
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
280
Fuel Tank Sending Unit Resistance (Side-Mounted Tank)
2004 GM/Isuzu Truck

2004 GM/ISUZU TRUCK
PAGE
281
NPR HD/W4500, NQR/W5500 Crew Cab Electrical
Power Door Locks Circuit Diagram
(Vehicle Specifications Index Section – NPR HD/W4500, NQR/W5500 Crew Cab Electrical – continued on next page)
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
282
(Vehicle Specifications Index Section – NPR HD/W4500, NQR/W5500 Crew Cab Electrical – continued from previous page)
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
283
Rear Heater Circuit Diagram
2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
284
NOTE:
For further Electrical Wiring Information please refer to the
NPR/W3500, NPR HD/W4500, NQR/W5500 Diesel Electrical Section
2004 GM/Isuzu Truck

2004 GM/ISUZU TRUCK
PAGE
285
FRR/WT5500 Electrical
FRR/WT5500 Series Taillight Connectors
(Vehicle Specifications Index Section – FRR/WT5500 Electrical – continued on next page)

2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
286
(Vehicle Specifications Index Section – FRR/WT5500 Electrical – continued from previous page)
FRR/WT5500 Body Room Light, I.D. and Marker Lamp,

FRR/WT5500 Body Connectors LH Frame Packard Body Plug Connector Parts

NPR/NQR
Terminal ............................................................. 1208-9040
Terminal ............................................................. 1212-4587
Seal ................................................................... 1208-9679
Seal ................................................................... 1201-5193
Body Housing ASM ........................................... 1201-5797

Housing ............................................................. 1201-5787
Connector Seal.................................................. 1201-0492
Dummy Seal ...................................................... 1201-0300
• Location:
• Circuits:
A = Rear Dome Blue
B=–– ––
C = Marker Lamp Brown
D = Ground Black/Blue

2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
287

FRR/WT5500 Body Connectors LH Frame Packard Body Plug Connector Parts
NPR/NQR
Terminal ............................................................. 1208-9040
Terminal ............................................................. 1212-4587
Seal ................................................................... 1208-9679
Seal ................................................................... 1201-5193
Body Housing ASM ........................................... 1201-5797

Housing ............................................................. 1201-5787
Connector Seal.................................................. 1201-0492
Dummy Seal ...................................................... 1201-0300
• Location:
Left-hand side, end of frame
• Circuits:
A = Rear Dome Blue
B=–– ––
C = Marker Lamp Brown
D = Ground Black/Blue

2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
288

FRR/WT5500 Body Connectors LH Frame
• Bullet Type Plug
• Location:
Right-hand side, end of frame
• Circuits:

2004 GM/Isuzu Truck
2004 GM/ISUZU TRUCK
PAGE
289
FRR/WT5500 Series Relay Location
2004 GM/Isuzu Truck

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2004 GM/ISUZU TRUCK

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

2004 GM/Isuzu Truck

Title NPR, NPR HD/

Title NPR, NPR HD/

A Exhaust emission related components

A. EXHAUST EMISSION RELATED COMPONENTS

CMVSS NO. 1100–VEHICLE EMISSIONS

(EPA Requirements – continued on next page)

PART 3: RADIO NOISE

CANADIAN RADIO INTERFERENCE REGULATIONS

2004 GM/Isuzu Truck

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

Front and Center Propeller Shafts

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

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

Parts Minimum Clearance Location

Special Equipment on the Chassis

Subframe Design and Mounting

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

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

Prohibited Attachment Areas

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

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

Crew Cab Body/Frame Requirement

4” x 1-5/8”, 7.25 lbs./ft. = ok

Modification of the Frame

Working on Chassis frame

Drilling and Welding

IMPORTANT NOTE: For vehicles equipped with electronic or hydra-matic transmissions,

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

Reinforcement of Chassis Frame

Preparation of Additional Lines

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

Electrical Wiring and Harnessing

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

Harness Diameter Clip Distance

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

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

Maximum Allowable Current

Shortening/Lengthening the Wheelbase Without Altering the Frame

Altering the Wheelbase by Altering the Frame

Glossary of Terms – Chassis Wheelbase Alteration

CA – Length from back-of-cab to rear axle centerline in inches.