Body Builders Guide MY22 FY Series IAL BBG Apr2022

FX221_601
v2
FXFY-Series for Australia
BODY BUILDERS GUIDE

April 2022
Sales model year 2022

Vehicle model FXR, FXM, FXZ, FYH
Conformity regulation ADR and each state or territory regulations

Important Notice
This guide has been supplied by Isuzu Motors Japan Limited. The latest information
available from Isuzu Australia Limited (IAL) such as specification sheets, technical
bulletins, etc. should also be used in conjunction with this guide. Information is also
available at http://body.isuzu.com.au.
If further technical assistance is required please call IAL on (03) 96446837 or email to
[email protected].
IAL recommends that modifications to truck chassis be avoided wherever possible. If

modifications can not be avoided they must be conducted in accordance with this
guide, the Industry Code of Practice for Heavy Vehicle Modifications VSB6 and all
National Heavy Vehicle Regulator (NHVR) requirements, unless specific alternative
information or instruction is provided by IAL.
The latest issue of VSB6 is available from the following website:

https://www.nhvr.gov.au/safety-accreditation-compliance/vehicle-standards-and-
modifications/vehicle-standards-bulletin-6
Note that any modifications outside the recommendations in this notice may affect
vehicle ADR compliance, safety, durability and warranty.
Isuzu, in accordance with ADR Circular 0-4-11, Certification of Chassis-Cab Vehicles,

and clause 4.1 supplies a PCV (Partially Complete Vehicle) in the nature of a cab-
chassis that may not fully comply with certain ADRs, as follows:
4.4.1 The “Position” requirements of ADR 13/00 for the following Lighting and Light
Signalling devices:
• Reversing Lamp (ADR 1/00) – as per ADR 13/00
• Rear Direction Indicators (ADR 6/00) – as per ADR 13/00
• Reflex Reflectors (ADR 47/00) – as per ADR 13/00
• Devices for Illumination of Rear Registration Plates (ADR 48/00) – as per ADR
13/00
• Rear Position (Side Lamps) (ADR 49/00) – as per ADR 13/00
• Stop Lamps (ADR 49/00) – as per ADR 13/00 Appendix A clause 6.7.4
•
4.1.2 Wheel Guards (Mudguards) for the rearmost wheels as per ADR 42/04 clause
14.2
4.1.3 Provision for Rear Registration Plate as per ADR 61/02 clause 9.1.1.1
Body builders are responsible to ensure the completed body installations include
components complying with the number, design and location specified in the above
ADRs.
Throughout this guide reference is made to various Isuzu Japan model names. The
following table is provided to cross reference these to the model names used by IAL
locally.
ISUZU AUSTRALIA LIMITED
ABN 97 006 962 572
Office: 66 Foundation Road, Truganina, Victoria 3029
Correspondence: PO Box 328, Altona North, Victoria 3025
T: (03) 9644 6666 F: (03) 9644 6622
isuzu.com.au
MY22 FX FY Series Model Code Reference
Vehicle Ratings
Isuzu Australia Isuzu Australia Isuzu Japan Wheelbase
Engine (kgs)
Model Name Model Code Model Code (mm)
GVM GCM
FXR 165-350 LWB FH-FXRJJ-D22 (C7CA) FXR77UU-RDSH 5,740 6UZ1-TCN 16,500 38,000
FXR 165-350 LWB FH-FXRJJ-D22 (C7C) FXR77UU-RDSH 5,740 6UZ1-TCN 16,000 38,000
FXD 165-350 LWB FH-FXDJJ-D22 (C7CA) FXR77VU-RDSH 5,740 6UZ1-TCN 16,500 38,000
FXD 165-350 LWB FH-FXDJJ-D22 (C7C) FXR77VU-RDSH 5,740 6UZ1-TCN 16,000 38,000
FXD 165-350 AUTO LWB FH-FXDJJ-N22 (C7CA) FXR77VU-RDSH-P 5,740 6UZ1-TCN 16,500 38,000
FXD 165-350 AUTO LWB FH-FXDJJ-N22 (C7C) FXR77VU-RDSH-P 5,740 6UZ1-TCN 16,000 38,000
FXD 165-350 XLWB FH-FXDJJ-E22 (C7CA) FXR77VU-SDSH 6,200 6UZ1-TCN 16,500 38,000
FXD 165-350 XLWB FH-FXDJJ-E22 (C7C) FXR77VU-SDSH 6,200 6UZ1-TCN 16,000 38,000
FXL 240-350 LWB FH-FXLJJ-D22 (C7UA) FXM77VU-UDSH 6,010 6UZ1-TCN 24,000 38,000
FXZ 240-350 AUTO MLWB FH-FXZJJ-L22 (C7UA) FXZ77UU-PDSH-P 4,540 6UZ1-TCN 24,000 38,000
FXZ 240-350 LWB FH-FXZJJ-D22 (C7UA) FXZ77UU-UDSH 6,010 6UZ1-TCN 24,000 38,000
FXZ 240-350 AUTO LWB FH-FXZJJ-N22 (C7UA) FXZ77UU-UDSH-P 6,010 6UZ1-TCN 24,000 38,000
FXY 240-350 AUTO MLWB FH-FXYJJ-L22 (C7UA) FXZ77VU-PDSH-P 4,540 6UZ1-TCN 24,000 38,000
FXY 240-350 LWB FH-FXYJJ-D22 (C7UA) FXZ77VU-UDSH 6,010 6UZ1-TCN 24,000 38,000
FXY 240-350 AUTO LWB FH-FXYJJ-N22 (C7UA) FXZ77VU-UDSH-P 6,010 6UZ1-TCN 24,000 38,000
FYH 300-350 AUTO MWB FH-FYHJJ-L22 (C7Q) FYH77UU-TDSH-P 5,770 6UZ1-TCN 30,000 45,000
FYH 300-350 AUTO LWB FH-FYHJJ-N22 (C7Q) FYH77UU-UDSH-P 6,010 6UZ1-TCN 30,000 45,000
FYJ 300-350 AUTO MWB FH-FYJJJ-L22 (C7Q) FYH77VU-TDSH-P 5,770 6UZ1-TCN 30,000 45,000
FYJ 300-350 LWB FH-FYJJJ-D22 (C7Q) FYH77VU-UDSH 6,010 6UZ1-TCN 30,000 45,000
FYJ 300-350 AUTO LWB FH-FYJJJ-N22 (C7Q) FYH77VU-UDSH-P 6,010 6UZ1-TCN 30,000 45,000
FYJ 300-350 XLWB FH-FYJJJ-E22 (C7Q) FYH77VU-WDSH 6,700 6UZ1-TCN 30,000 45,000
FYJ 300-350 AUTO XLWB FH-FYJJJ-P22 (C7Q) FYH77VU-WDSH-P 6,700 6UZ1-TCN 30,000 45,000
FYJ 300-350 AUTO AGITATOR FH-FYJJJ-K22 (C7Q) FYH77VU-RDSH-P 5,080 6UZ1-TCN 30,000 45,000
FYX 350-350 AUTO FH-FYXJJ-L22 (C7QA) FYH77VU-TDSH-P 6,425 6UZ1-TCN 35,000 45,000
CONTENTS
INTRODUCTION
Ⅰ. GENERAL PRECAUTIONS
Chapter 1 GENERAL
Chapter 2 MODIFICATION OF CHASSIS
Chapter 3 REAR BODY MOUNTING
Ⅱ. SPECIFIC INFORMATION
Chapter 1 OUTLINE
Chapter 2 PRINCIPAL SPECIFICATIONS OF VARIOUS VEHICLE MODELS
Chapter 3 PRECAUTIONS FOR REAR BODY MOUNTING
Chapter 4 WEIGHT DATA AND FRAME STRENGTH CALCULATION
Chapter 5 CHARACTERISTICS OF THE SPRINGS
Chapter 6 PTO AND ENGINE CONTROL
Chapter 7 ELECTRICAL SYSTEM
Chapter 8 PAINTING
Chapter 9 CAB CHASSIS DRAWINGS
Chapter 10 CHASSIS FRAME DRAWINGS
Chapter 11 APPENDIX
INTRODUCTION
The purpose of this Body Builder’s Guide (hereinafter referred to as “guide”) is to provide
information and guidance to the body builders that take charge of the final stage of vehicle
manufacture by mounting their vehicle bodies on the cab chassis (incomplete vehicles) provided
by ISUZU MOTORS LIMITED. The body builders are encouraged to refer to the information in this
guide in order to perform rear body mounting at suitable conditions with good use of their own
experiences.
• This guide is a summary of a technical content for body mounting and remodeling
according to mounting of ISUZU MOTORS incomplete vehicles.
• It is not that ISUZU MOTORS guarantee the quality of construction or the safety and
running performance of the modified complete vehicle which remodeling done according
to this guide.
• For body mounting and remodeling according to mounting, the body builders must design
and manufacture so that there is no influence on safety, the running performance, and the
function of genuine devices.
• The body builders are to comply with the national regulations with respect to their vehicle
bodies, cab chassis modification incidental to rear body mounting, and completed
vehicles after body mounting.
• The manufacturing responsibility of completed vehicles after body mounting is in the body
builders. ISUZU MOTORS does not owe the obligation.
• ISUZU MOTORS is not responsible for any human injury or instrument damage due to
using this guide.
Note: ・This guide is revised “Ⅱ-7-3 CIRCUIT DIAGRAMS”(to full colord edition) and “Ⅱ-9-
1 CAB CHASSIS DRAWINGS”(FUP height dimension of FXZ77VU-PDSH-P) from
the guide published in September 2021 (document number: FX220_601). All the
contents of FX220_601 are included.
・ This guide is made commonly for various destination. There may be equipment or
function described which is not developed depending on destination.
・ Follow the owner’s manual for handling the vehicle or the equipments on vehicle.
・ The content of this guide might change without a previous notice. Contact ISUZU
MOTORS LIMITED, ISUZU distributor or ISUZU dealership for exact details of latest
information.
Ⅰ. GENERAL PRECAUTIONS
Chapter 1
GENERAL Ⅰ GENERAL PRECAUTIONS
Chapter 1 GENERAL
1-1 PRECAUTIONS FOR INSTALLING BODY
1-2 PRECAUTIONS AT INSTALLING
1-3 PRECAUTIONS FOR BOLT TIGHTENING

Chapter 1
1-1 PRECAUTIONS FOR INSTALLING BODY

When designing and examining body, consider regulation control in use country and agreement to
standard, and safety and prevention of accidents of vehicle, and follow instructions below.
① Weight of body
・Design the rear body to evenly distribute the load of rear body on chassis frame.
- Installation of special equipments on a chassis frame can change the said load distribution.
Therefore, such special equipments must be installed, taking load distribution into account,
otherwise stress concentration in particular part of the chassis frame may occur, possibly
resulting in cracks in chassis frame members or other problems even if the total weight of
these special equipments falls within allowable range. Confirm that there is no problem in
safety in chassis frame member before the examination.
・If there is any equipment addition (e.g. fuel tank addition) or weight trend to one side (e.g.
side door installation of the van body), adjust right and left weight difference on rear body.
② Approach angle, departure angle, and ramp angle.
・ When adding equipments on front overhang, rear overhang or lower part between axles, note
that the approach angle, departure angle, and ramp angle do not go below the position of
existing equipments.
Approach angle, departure angle, and ramp angle
Approach angle
Departure angle
Ramp angle
Chapter 1
③ Cab
・Give appropriate rust prevention treatment to the inside and surrounding the hole when
drilling hole the inside or outside of the cab. Do similar processing when the surface of the
cab is mistakenly damaged.
・ When installing lever or switch to control rear body in the cab, maintain enough clearance
from other levers and switches of existing and install it in the cab so as not to come in contact
at operation.
・ Place a plate or a label on the lever and the switch newly added to distinguish the purpose of
use.
・ When installing warning buzzer of the rear body device in the cab, install one with a buzzer
sound different from the safe warning sound of other warning buzzers such as buzzers for the
brake.
④ Consideration to chassis maintenance
・ Rear bodies must be designed or mounted on chassis so as not to obstruct maintenance.
- Checking, feeding and draining engine oil

- Level checking, feeding and draining coolant
- Checking, feeding and draining transmission oil
- Checking, feeding and draining differential oil
- Adjustment and detaching of fan belt
- Checking and replenishment of battery fluid, detaching of battery or battery cover
- Refueling to fuel tank, check and maintenance around fuel tank
- Draining of air tank
- Checking and replenishment of air dryer, relay valve, brake booster, and other valves
related to brake system and accessories
- Checking and air bleeding from brake system, clutch system, and servo unit
- Operation of spare tire carrier including detaching spare tire
- Detaching of DPD filter and piping
- Checking of lamps of rear body and exchange of valves
- Other check work
Chapter 1
⑤ Other
・Make sure the rear body does not obstruct forward and the side views, nor the views such as
rearview mirrors and under mirrors.
・ Do not install components likely to drop out by the vibration of the vehicle in the vicinity of the
driver's seat, since it might obstruct the driving operation.
・ Do not install rear body (especially, components impact or the outside force may be applied
such as side guard) on to chassis accessories such as fuel tank support and air tank support,
etc.
・ No projection or sharp edges on iron plates of rear body which may give scratch.
Chapter 1
1-2 PRECAUTIONS AT INSTALLING

Note the following instructions when installing, and work safely. Please refer to the owner’s
manual of a vehicle concerned for the handling of the vehicle and devices.
① Preparation
・ Stop the engine, apply the parking brake, and set sprag on the tire, to prevent the vehicle
from moving.
・ When installing, make sure no inclination of rear body at horizontal place.
・ Observe the instruction of the caution plate stuck on the cab chassis strictly.
・ When you disconnect the battery cables, to prevent short circuit, do according to the following
procedure. Connect battery cables following the procedure for cable disconnection in reverse
order.
- Turn off all the switches.
②
①
- After turning off the starter switch, wait about 1
minute and disconnect the negative cable ①. If
disconnect negative cable within 1 minute, ECM
may malfunction.
- Disconnect the positive cable ②.
③
- Disconnect the battery cable ③.
- When you connect the battery cable, to prevent
battery terminals from corroding, clean them and
lightly apply grease on them.
・ Depending on the mounting equipment (e.g. UREA SCR), the time before being able to
disconnect the negative cable after turning off the starter switch may become long. Refer to
"SPECIFIC INFORMATION" for details.
・ After disconnecting negative terminal, wait more than 15 seconds before starting to work.
・ When all the work is done, restore (connect) the battery negative terminal. The terminal
should be tightened with specific torque. (Refer to "SPECIFIC INFORMATION" for tightening
torque.)
・ Partially protect the chassis if necessary.
② At work
・Do not get on valves and equipments related to the brake, the brake pipes, the fuel tanks, the
fuel pipes, the air tanks, the brake boosters, the batteries, wire harnesses, the transmission
control cable and the relay boxes, etc. to lead to damage and the breakdown of the
equipment.
・Use the grip and the step, etc. to prevent from slipping and falling when getting on and off of
the cab.
Chapter 1
・ When tilting the cab, give a necessary safety precaution like certain fixation of the cab
stopper stay etc.
・ In the case of the tilt cab vehicle, when heavy load is installed on the cab roof or inside the
cab, descending speed quicken. Be careful not to get caught in between.
・ When installing additional components, be careful not to damage the harness due to jamming
or smashing. If the harness is damaged, have it repaired.
・ Do not leave tools or waste cloth, etc. behind in the engine room.
・ Do not touch the vent plug of electronic unit (control Example Vent plug
unit).
・ The vent plug might come off from the unit when
external force is applied.
・ If the vent plug came off, replace unit with new one.
・ If the vent plug is reused or left off, foreign
Cont. unit
substance (water, waste, etc.) may enter inside the
electronic unit.
③ Starting up engine
・Confirm whether the gear shift lever is in neutral or parking (when there is parking range).
・Start up an engine while pressing the clutch pedal.
・Turn off PTO if there is.
・ Do not put the combustible in the direction of the exhaust and the vicinity of the hot section.
・ If starting engine inside, install exhaust device to release the exhaust gas outdoor.
・Do not work in the direction of the exhaust or place where the exhaust gas collect easily.
・ When the engine is on, be careful with the rotation part and the high temperature section, and
not to touch, get caught in, or get burnt.
Example of rotation part and high temperature section

Rotation part High temperature section
Cooling fan and belt Exhaust manifold

Pulley Turbo-charger
PTO output shaft and flange Intake manifold
Alternator and belt Intercooler
Cooler compressor, and belt Oil pan
Radiator and radiator cap
etc. Water hose
Exhaust pipe and exhaust silencer/DPD
Brake drum and retarder immediately after running
etc.
Chapter 1
④ Moving the vehicle

・ Do not put anything obstacle of the driving operation such as tools and parts.
・ Idle rotate the engine, and move the vehicle after confirming all the warning lamps have gone
off.
・ Follow the instruction of owner’s manual when warning lamp does not go off.
⑤ Storing the vehicle
・ When storing the vehicle for long term, do not leave the key in starter switch. Small amount of
electric current is flowing to each system while the key is in, and keeping this for long term
will cause flat battery.
Chapter 1
1-3 PRECAUTIONS FOR BOLT TIGHTENING

① Fixing with bolt
・ Do not fix together the accessories and equipments for rear body with same bolt.
・ Use the bolts of the same strength class when using the bolt with same size and different
length.
・ Follow the tightening torque on next page when re-installing each part on the chassis.
・ Follow the work book when re-use prohibition and tightening torque are specified.
Chapter 1
Bolt tightening torque unit：N・m {kgf・m}

Bolt head shape Hexagon head bolts Hexagon bolt with flange
Strength class 8.8 8.8
None- 9.8 None- 9.8
Thermal Thermal
thermal thermal
refining refining
refining refining
Bolt head
8.8 8.8 9.8 8.8 8.8 9.8

・・
8 8 9 8 8 9
・・
・・・・・・
Nominal of thread
(Diameter×Pitch)
5.6 to 11.2 6.6 to 12.2
M6×1 ― ―
{0.6 to 1.1} {0.7 to 1.2}
13.4 to 25.7 16.7 to 30.4 15.3 to 28.4 18.1 to 33.6
M8×1.25
{1.4 to 2.6} {1.7 to 3.1} {1.6 to 2.9} {1.8 to 3.4}
31.3 to 52.5 37.3 to 62.8 35.4 to 58.9 42.3 to 70.5
M10×1.25
{3.2 to 5.4} {3.8 to 6.4} {3.6 to 6.0} {4.3 to 7.2}
31.3 to 51.4 36.3 to 59.8 34.5 to 57.5 40.1 to 66.9
*M10×1.5
{3.2 to 5.2} {3.7 to 6.1} {3.5 to 5.9} {4.1 to 6.8}
69.3 to 104.0 75.5 to 113.8 77.7 to 116.5 85.0 to 127.5
M12×1.25
{7.1 to 10.6} {7.7 to 11.6} {7.9 to 11.9} {8.7 to 13.0}
64.8 to 96.1 71.6 to 106.9 71.4 to 107.2 79.5 to 119.2
*M12×1.75
{6.6 to 9.8} {7.3 to 10.9} {7.3 to 10.9} {8.1 to 12.2}
106.2 to 158.8 113.8 to 170.6 114.9 to 172.3 123.4 to 185.1
M14×1.5
{10.8 to 16.2} {11.6 to 17.4} {11.7 to 17.6} {12.6 to 18.9}
100.6 to 149.8 106.9 to 160.0 108.2 to 162.2 115.5 to 173.3
*M14×2
{10.3 to 15.3} {10.9 to 16.3} {11.0 to 16.5} {11.8 to 17.7}
154.3 to 232.5 160.0 to 240.3 171.1 to 256.7 176.9 to 265.3
M16×1.5
{15.7 to 23.7} {16.3 to 24.5} {17.4 to 26.2} {18.0 to 27.1}
147.6 to 221.4 153.0 to 229.5 162.5 to 243.8 168.5 to 252.7
*M16×2
{15.1 to 22.6} {15.6 to 23.4} {16.6 to 24.9} {17.2 to 25.8}
222.5 to 334.3 229.5 to 345.2
M18×1.5 ― ―
{22.7 to 34.1} {23.4 to 35.2}
223.6 to 335.4 230.5 to 346.2
*M18×2.5 ― ―
{22.8 to 34.2} {23.5 to 35.3}
307.4 to 461.7 293.2 to 440.3
M20×1.5 ― ―
{31.3 to 47.1} {29.9 to 44.9}
284.0 to 472.1 293.2 to 440.3
*M20×2.5 ― ―
{29.0 to 48.1} {29.9 to 44.9}
413.6 to 620.5 424.6 to 636.5
M22×1.5 ― ―
{42.2 to 63.3} {43.3 to 64.9}
385.7 to 578.0 394.2 to 592.3
*M22×2.5 ― ―
{39.3 to58.9} {40.2 to 60.4}
490.8 to 810.5 554.1 to 830.6
M24×2 ― ―
{50.0 to 82.6} {56.5 to 84.7}
462.8 to 693.1 520.7 to 781.6
*M24×3 ― ―
{47.2 to 70.7} {53.1 to 79.7}
* Used for internal thread of soft material such as casting.

Chapter 2
MODIFICATION OF CHASSIS Ⅰ GENERAL PRECAUTIONS
Chapter 2 MODIFICATION OF CHASSIS

2-1 DRILLING OR WELDING A CHASSIS FRAME
2-2 REINFORCING A CHASSIS FRAME SIDE MEMBER
2-3 MODIFYING REAR OVERHANG OF A CHASSIS FRAME
2-4 BOLT AND NUT FOR CROSS MEMBER
2-5 PRECAUTIONS FOR WELDING
2-6 PRECAUTIONS FOR HYDRAULIC OR AIR PIPING
2-7 NYLON AIR TUBES AND PUSH-IN CONNECTOR
2-8 NYLON TUBE ROUTING AND FIXING
2-9 AIR EXTRACTION
2-10 RELOCATION AND ADDITION OF A FUEL TANK
2-11 PRECAUTIONS FOR TOWING HOOK
2-12 PRECAUTIONS FOR MODIFICATION OF THE ELECTRICAL SYSTEM
2-13 INSTALLATION OF EQUIPMENTS ON THE ROOF
2-14 THROUGH HOLES INSIDE A CAB FOR HARNESSES OR AN ANTENNA
CABLE
2-15 PRECAUTIONS FOR PAINTING
2-16 EMBLEMS
2-17 DECALS
Chapter 2
2-1 DRILLING OR WELDING A CHASSIS FRAME

Drilling holes and welding fluctuate stresses in various parts of a chassis frame and negate the
frame’s load condition, possibly resulting in deformation or cracks. To install any special
equipment, follow the instructions below.
① Side member
・ Do not drill a hole or make a notch in or weld the shaded areas in the below figure.
・ Use drill to drill holes. Gas cut is prohibited.
Working prohibited areas of side member (1)
b
Prohibited area
b
a
c
d
d Prohibited area
H
Prohibited area
d
d
Side member
Working prohibited areas of side member (2)
a c
b Side member
Welding bead
・ Maintain the following measurements at working.
“a” in the above figure “b” in the above figure “c” in the above figure “d” in the above figure
(Allowable maximum (Working-prohibited (Minimum required (Minimum required
hole diameter) area) distance) distance)
Heavy duty vehicle 17mm H/5

H/7 (Hole) 40mm
Medium duty vehicle 15mm (Welding) 30mm
Light duty vehicle 11mm 20mm 25mm
Note: Measure “d” from end of bending radius.

Chapter 2
② Cross member
・ For alligator type, hole drilling, notch making and welding are prohibited.
Alligator type cross member
・ For channel type, allowable maximum hole diameter “a” is 9mm, and this hole should be used
only for piping or harness routing. “b: Working-prohibited area” and “c: Minimum required
distance” shown in figure above depend on the side member.
Channel type cross member
b
a H
③ Gusset
・ Hole drilling and notch making are prohibited.
Working on gusset
Prohibited Gusset
Cutting or machining strictly prohibited Cross member
④ Other cautions at work

・When making a hole, use drilling machine.
・Length of a weld should be 30 to 50mm, and welds should be spaced a minimum of 40mm.
・ Be sure that weld beads do not protrude over holes. Welding should be done away from the
edge of holes by the distance “c” in the table in previous page.
・ When making a notch by using gas, finish the cut surface by grinding.
・ Cold rivet only.
・ Apply rust proofing after drilling hole, making notch or welding.
Chapter 2
2-2 REINFORCING A CHASSIS FRAME SIDE MEMBER

When reinforcing a chassis frame side member, follow the instructions below to prevent an acute
change in the section modulus and stress concentration due to welding, since it might cause
deform or crack.
① Reinforcement material
・The reinforcement material should be equivalent to that of side members. Refer to "SPECIFIC
INFORMATION" of the target vehicle model.
・ Thickness and shape of the reinforcement material should be selected according to rear body
mounting and vehicle usage condition.
・ Use L-shaped reinforcement material.
・ Channel-shaped reinforcement is not recommended.
- It is difficult to match the dimension of a channel-shaped reinforcement with a chassis
frame side member, and difference in shape between a reinforcement and a side member
results in slacking and reinforcing effect.
Reinforcement shape
Poor example
Prohibited
Poor reinforcement forming makes

a gap at the upper or the lower part.
Good example
Chapter 2
② Installation position of reinforcement material

・ Ends of outer reinforcement and inner reinforcement should not overlap.
・ An end of outer reinforcement and cross member should not overlap.
・ An end of outer reinforcement and spring bracket should not overlap.
Prohibited areas for installing reinforcement
Cross member location

Inner reinforcement end
Prohibited
Inner reinforcement end
Cross member location
Spring BRKT Cross member location
③ Installing reinforcement material

・ Install a reinforcement by riveting or plug welding. Place them in zigzag alignment.
・ When performing plug welding, be sure that electrical components such as electric harnesses
on the inner side of a chassis frame side member are a minimum of 50mm apart from welding
site.
・ When inserting a rivet in a hole from which another rivet has previously been removed, the
rivet should be 1 or 2mm larger in diameter than the removed one. Cold rivet only.
Example of installing reinforcement
45°or larger
Side member
Reinforcement
Zigzag alignment
Rivet or plug weld (14 to 20mm)
④ Size of rivet
Rivet size detail
Unit ; mm
Vehicle type Rivet Diameter（d) Diameter (D) Height (H)
Light duty vehicle 10 16 7
Medium duty vehicle 11 18 7.7
Heavy duty vehicle 13 21 11
Chapter 2
2-3 MODIFYING REAR OVERHANG OF A CHASSIS FRAME

If a rear body constrains a sub frame to necessarily protrude outward from the rear end of a
chassis frame by 300mm or more, lengthen rear overhang of the chassis frame according to need.
If it is absolutely necessary to cut a side member of a chassis frame for modification, make sure
that the cut line does not split existing holes.
① Extension material
・ The extension material should be equivalent to that of side members. Refer to " SPECIFIC
INFORMATION " of the object vehicle model.
・ Thickness and bending radius of the extension material should be the same as that of side
members. Refer to " SPECIFIC INFORMATION " of the object vehicle model.
② Installing extension material
・ In case that extension material is 300mm or shorter:

- Join an extension material and a chassis frame by continuous butt welding on the entire
circumference. After welding, grind finish weld surface.
Installing extension material (1)
Extension material
Chassis frame
Butt welding on the entire circumference and

grinding finish in lengthwise direction
Outer side of the chassis frame
60°approx.
1.5 to 2mm
Chapter 2
・ In case that extension material is longer than 300mm:

- Join an extension material and a chassis frame by butt welding, and then fit a
reinforcement on the inner side of them.
Installing extension material (2)
Unit: mm
Reinforcement material thickness

Side member thickness
(recommendation value)
8.0 at minimum 7.0
7.5 5.5 to 7.0
7.0 4.5 to 6.0
4.0 to 6.0 4.5
Chapter 2
2-4 BOLT AND NUT FOR CROSS MEMBER

When the bolt and nut fixing cross member to side member is removed, re-fix with tightening
torque in following chart.
Identification
Nominal of thread Tightening torque
(Bolt head shape and Target location
(Diameter ×Pitch) N・m {kgf・m}
strength class)
Hexagon bolt with flange

M10×1.25 44 to 59 {4.5 to 6.0}
8 or 8.8
Hexagon head bolts

M10×1.25 39 to 53 {4.0 to 5.4} Bolt and nut fixing
8 or 8.8
cross member ,
Hexagon head bolts including those
M12×1.25 85 to 104 {8.7 to 10.6}
8 or 8.8 fixing fuel tanks,
battery, etc.
Hexagon head bolts together
M12×1.25 93 to 114 {9.5 to 11.6}
9 or 9.8
Hexagon head bolts

M14×1.5 139 to 171 {14.2 to 17.4}
9 or 9.8
Chapter 2
2-5 PRECAUTIONS FOR WELDING

Be cautious of following when electric welding. Welding current may damage electronic devices
installed in a vehicle.
① Before welding
・ Turn off a starter key switch.
・ Disconnect a negative battery terminal.
・ Disconnect fuse for air bag. (Confirm the fuse label for location of fuse.)
・ Disconnect all wire harnesses from electronic unit (control unit).
・ Cab welding
- Attach the welder’s ground cable to a plated bolt or metallic part of the cab in the vicinity of
welding site. Before securing the ground cable on such a metallic part, peel off the paint on
the area to reveal its base.
・ Chassis welding
- Attach the welder’s ground cable to a plated bolt or a chassis frame member in the vicinity
of welding site. Before securing the cable on the chassis frame member, peel off the paint
on the area to reveal its base.
Welding current flow direction (Reference)
Poor example
Welding current flows through

electrode → cab → electronic unit → battery → welder ground cable
cab ground
and damage the electronic unit.
Good example
Welding current does not flow through electronic unit and return to welder.
Chapter 2
・ Do not attach the ground cable to a chassis spring, otherwise the spring may break.
・ Remove the paint coating and dry the area where welding is to be performed.
・ To prevent the following components from being damaged by welding spatters or heat, cover
them up or temporarily relocate them to somewhere reasonably distant. In particular, if
welding any area within 200mm from a fuel tank, remove the fuel tank beforehand.
- Plastic parts - Rubber parts - Electric harnesses
- Air intake duct - Radiator hose - Radiator
- Intercooler - Pipes - Chassis springs
- Tire
・ To minimize impact of heat on peripheral area and to assure welding quality, select a suitable
welding torch and perform welding at suitable welding conditions.
・ No weld defect such as undercuts, overlaps, and pin holes.
② After welding
・Welded area must not be rapidly cooled.
・ Apply rust-proof paint with the same color, if the paint is removed from chassis frame or cab.
・ After welding, put the disconnected electronic units such as control unit connectors and fuses
back in place exactly as before. After that, connect negative battery terminal securely.
・ Check operation of equipments. Contact ISUZU distributor or ISUZU dealership for checking
method.
③ Welding electrode
・ Use welding electrode depending on parts in following chart.
Welding part Details Recommended welding electrode
HT540 (ISUZU standard)

High tensile steel
Tensile strength: 540MPa {55kgf/mm2} JIS Z3211 E4916 / AWS A5.1 E7016
or
JIS Z3211 E4316 / AWS A5.1 E7016
JSH440 (ISUZU standard) equivalent
Steel for general frame
Tensile strength: 440MPa {45kgf/mm2}
Chapter 2
2-6 PRECAUTIONS FOR HYDRAULIC OR AIR PIPING

Since the air pressure and the hydraulic piping of the brake system and the steering system are
important parts, modification is prohibited. If there is necessity to add pipes for body building,
follow the instructions below for safety assurance.
① Working efficiency
・ Checking and detaching of equipment (hydro master, air master, brake oil tank, etc.) installed
at remodeling area should not be obstructed.
・ Do not interfere with movable body of special purpose vehicle.
② Pipe forming
・ Use one full pipe to form, do not connect pipes.

・ When damaged, do not repair, use new pipe.
・ Do not bend the same portion of a pipe more than once. Do not perform heat flare forming
and heat bending.
・ Before and after forming a pipe, for safety assurance, check the surface of the pipe for
damage, deformation, or dent, and make sure of no foreign substance inside.
・ Clean inside the pipe after forming.
Flare forming and dimensions Unit: mm

Type Double flare
Dimension ‘S’ is the

width of flat seat (inside
Shape flare face) coming into
contact with mating seat
Nominal S
D A B T C
Diameter (at minimum)
4.76 4.76 6.6 to 7.1 3.0 to 3.7 0.7 1.4 1.0
6.35 6.35 8.6 to 9.1 4.5 to 5.2 0.7 1.4 1.0
8 8 10.5 to11.0 6.2 to 6.9 0.7 1.4 1.6
±0.2
10 10 13.0 to13.5 8.2 to 8.9 0.7 1.4 1.6
12 12 15.0 to15.7 9.8 to 10.5 0.9 1.8 1.6
15 15 18.1 to18.8 12.7 to 13.4 1.0 2.0 1.6
Remarks: ・ The decentering with the center of the seat side and the tube is assumed to be
0.15mm or less.
・ For the double walled steel pipe, peeling in the inside part of the flare must be 1/3 or
less of the dimension “S”.
Chapter 2
Tightening torque
Nominal Flare nut
Diameter Width Tightening torque value
Joint type Screw size Remarks
of applied across flats N・m{kgf・m}
pipe (mm)
A-type flare nut Tightening torque
values selected
Iron:13 to18 {1.3 to 1.8}
Pipe depending on mating
Flare nut 4.76 10 M10 x 1.0 Non-iron:9 to 15
materials.
{0.9 to1.5}
Non-iron: Aluminum
and brass
6.35 12 M12 x 1.0 25 to 35 {2.6 to 3.6}
8 14 M14 x 1.5 29 to 39 {3.0 to 4.0}
10 17 M16 x 1.5 45 to 55 {4.6 to 5.6}
C-type flare nut 4.76 14 M10 x 1.0 13 to 18 {1.3 to 1.8}
Pipe Flare nut 6.35 17 M12 x 1.5 25 to 35 {2.6 to 3.6} Mating materials: iron
8 17 M14 x 1.5 25 to 39 {2.6 to 4.0} Mating materials: iron
・ Minimum bending radius should be as shown below.

Unit: mm
Pipe Nominal Size 4.76 6.35 8 10 12 15
Bending Radius 15 20 25 30 35 40
Straight portion of the pipe
ａ≧2ｄｂ≧2 d
Chapter 2
③ Routing steel pipes

・ Pipes should be considered not to contact with other components, heat influence, and
vibration.
・ Protect pipes from sand, water, and other foreign substances fly up from road.
・ Clip fix pipes at straight piping line. Refer to following
Clip distance
Unit： mm
Pipe diameter P
4.76 / 6.35 400 or less
8 / 10 500 or less
For floating joints 12 / 15 600 or less
・ For piping between air compressor and air dryer, do not fix by shape that moisture collects
because moisture in the tube might freeze.
Poor example of fixing pipe
・ Apply rust-proofing on clips. Apply vinyl or rubber

vinyl
coating to the part of the clips where pipes may
contact. (Usage of genuine ISUZU clips is
recommended.) clip
・ When the steel pipes intersect, secure 10mm or

more at crossing point, and clip fix at straight part
and point off the bending radius.
10mm or more
Chapter 2
・ Secure the distance between steel pipes or a pipe and other components according to the
following Fig.
Distance between steel pipe and other components
Bolt head or Hole in the panel
rivet head on 10mm 10mm
chassis frame at or more
minimum 10mm or more
10mm
member or more
at minimum
Rivet head
Bolt head
Edge Moving components such lever, link and arm: 30mm (moving
10mm or more
range +30mm)
30mm
30mm以上or more
Pipes arranged in parallel Silencer and exhaust pipe
80mm or more
10mm or more
Flare nut
200mm or more
20mm or more
There may be individual values provided.
Refer to "Ⅱ SPECIFIC INFORMATION" of target vehicle
type.
・ Do not route pipes over, under or outside the frame. Pipes may be damaged due to , stepping
on, flying gravels, etc.
・ Do not route pipes in lower part inside the frame. Pipes may be damaged due to piled up or
freezing mud or water.
Piping location
Frame Frame
Good example Poor example
Brake piping
Mud and water
Prohibited area
Brake piping
10mm
Chapter 2
2-7 NYLON AIR TUBES AND PUSH-IN CONNECTOR

Since the air pressure piping of the brake system is important parts, remodeling is prohibited. If
there is necessity to add piping for body building, note the instructions below.
① Nylon air tube
・ Nylon tube is weak to heat (100°C). Remove before welding.

・ Nylon tube is weak to acid. Do not use waste cloth or globes with battery fluid.
・ Keep distance from high-pressure cleaner nozzle (MIN 100mm).
・ When removing it, make sure not to bend the tube. When damaged, use new tube.
・ Do not use any nylon tubes other than the genuine ISUZU nylon tubes.
Followings are specifications of nylon tubes for reference.
Standard Manufacturer Type

DIN Standard Nitta Moore or Reflex & Allen Push-in type
Outer Diameter (mm) Inner Diameter (mm) Minimum bending Radius (mm) Purpose example
6 4 50 Air suspension seat
8 6 80 Accessory line
12 9 100 Brake line
② Nylon tube connector
・ To disconnect nylon tube, push the release collar and pull out the nylon tube.
・ If the nylon tube is frequently connected and disconnected, purchase genuine ISUZU
products from ISUZU distributor or ISUZU dealership.
Part name Part number

Nylon tube remover 185239-0080
・ When using steel connector, use connectors with following treatment to prevent pipes from
corrosion.
- Surface treatment: Zinc chromate plating (Product name: Dacromet treatment)
- Plating thickness: 4μm (MIN)
- Rust proofing test with salt water spray: no rust for 240 hours
Chapter 2
・ Check the inside of the connector. If there is any extraneous substance, blow air into it to
remove it.
・If there is friction marks from connector on nylon tube, cut off that portion. Confirm there is no
scratch on tube after cutting. If there is, cut off that part.
・ Check the insertion length before inserting the nylon tube. Paint the position and insert to the
mark. Insertion depth differs by connector makers. Firmly insert the nylon tube to the end.
Connecting nylon tubes
Disconnecting nylon tube

・ Before removing a tube, check a joint for adhesion of dirt, and
remove it if there is any.
Note: If the joint is so dirty that a release collar is stuck, replace
both the tube and the connector with new ones.
・ Push the release collar by using a dedicated tool (nylon tube
remover) to pull out the nylon tube by hand.
・ When using a tool other than the above dedicated tool, be sure
to use a tool that does not scratch the nylon tube (e.g. Monkey
wrench).
Dedicated tool (nylon tube remover)

part number: 185239-0080
・ Check the inserted part of the removed nylon tube for adhesion
of dirt. If there is any, remove it. Thoroughly blow air into the
connector to remove extraneous substance.
・ Cover the removed nylon tube and connector with vinyl bags
(lint-free bag) to protect them from scratches and dirt.
Chapter 2
Assembling new nylon tube

・ Confirm that the part of a nylon tube, which is to be inserted into a
connector is free of scratches, warping and dirt.
・ Lightly apply lubricant (e.g. Engine oil) on the outer surface of the
end of the nylon tube.
・ Mark up an insertion depth on the tube with paint or something,
and then insert the tube into the connector up to the marking.
Note: Some resistance may be encountered when the tube
passes the O-ring and the retainer inside the connector.
Be sure to insert the tube up to the marking.
・ After completing the tube insertion, hold the connector and at the
same time pull the tube to confirm secure connection.
・ Confirm that there is no air leakage.
Chapter 2
Connecting nylon tube and connector

Combination of tube and connector How to connect
Check inside for cleanness.

Remove dirt by blowing air onto it.
Check inside for cleanness.

Remove dirt by blowing air onto it.
③ Band clips
・ Use 66-nylon band clip.

・ Use clips only to hold nylon tube, not to restrict the direction of nylon tube.
・ Fix the clip directly on to chassis frame. Brackets are allowed.
・ Do not use galvanized zinc brackets. Otherwise, chemical change will damage nylon clips.
④ Protection corrugated tube
・ When nylon tube contacts chassis frame or other components, cover the nylon tube with
corrugated tube.
・ Wrap tape on both end of corrugated tube to prevent from moving.
Chapter 2
2-8 NYLON TUBE ROUTING AND FIXING

① Precaution
・ To prevent wearing and damaging, nylon tube should not interfere with other tube or
component.
・ At routing, prevent the nylon tube from twisting and note to suppress the vibration of the nylon
tube to the minimum.
・ Ambient temperature of nylon tube routing area should be from -40°C to +100°C.
・ When nylon tube is needed to be routed in areas where mechanical damage, heat damage,
chemical damage may be received, provide a protector in this area to protect the tube.
・ When routing around high temperature are such as engine, place heat insulator and confirm
that the ambient temperature is in between tolerance temperature. Areas enclosed for such a
noise insulation requires extra attention because the temperature of these areas tend to be
high.
・ Route the nylon tube where exhaust emission would not hit even when the gas leaked from
exhaust pipe by corrosion or damage.
・ Maintain sufficient clearance from vibrating components such as transmission.
・ Do not bundle nylon tube with starter cable.
・ When nylon tube is clipped together with harness, consider the clip distance so tube and
harness would not be rubbed by vibration.
・ Clip distance to be 600mm or less.
・ Do not cross nylon tube and wire harness as possible.
・ When routing nylon tube around battery, be sure that battery fluid (or leaked battery fluid)
does not adhere to them while checking the vehicle is running.
・ Multiple tubes bundled together can control the vibration effectively than single tube.
・ When single tube branches out from a bundle, fix the bundle at branch point to prevent from
rubbing.
・ When nylon tubes intersect, clip fix each tube individually to avoid interference.
Chapter 2
② Measure around sharp edges

Do measure appropriately by referring to the following example.
Measure around sharp edges (1)
・ Cover the sharp edge with protection.

・ Use F-clip to avoid from contact.

・ Cover the tube with corrugated tube and clip fix the tube to avoid corrugate tube to be
scratched.
Chapter 2
③ Measure through holes

・ Prevent the tube from interfering the edge of the hole when you pass the tube through the
hole of the cross member.
Measure through holes (1)
・ When passing the tube through a hole of chassis frame member, protect the tube in the
corrugated tube, and fix the nylon tube so that the tube does not contact with the edge of the
hole.
Measure through holes (2)
300mm or less 300mm or less
④ Distance between tube and movable components
・The tube near the movable component such as the lever, the drag links, and arms must be
fixed with distance of 30mm or more from them.
Distance between tube and movable components
30mm or more
Chapter 2
⑤ Freeze proofing
・ Do not fix by shape that moisture collects because moisture in the tube might freeze.
Loose nylon tube
⑥ Installation length
・The tube expands and contracts according to the temperature change. Install it with enough
length.
Chapter 2
⑦ Example of defective installation

・Poor example is shown below. Do necessary preventive measures referring to the example of
measures.
Poor example Preventive measures
Wrap the nylon tubes with the rubber sleeve,

and clamp a with band clip.
Wrap the steel pipe with a rubber sleeve, and

clamp with band clip.
Wrap the nylon tube with a rubber sleeve and

clamp it with a band clip, provide a minimum of
30mm clearance between the nylon tube and
the rubber hose.
Provide a minimum of 10mm clearance

between the nylon tube and the cable, or clamp
the nylon tube with band clips.

between the nylon tube and the air tank, or
wrap the nylon tube with a rubber sleeve and
clamp with a band clip.
Chapter 2

between the nylon tube and the bolt or the nut,
or wrap the nylon tube with a corrugated tube.
Contact with a bracket (1) Wrap the pipe with rubber sleeve and fix with
band clip to a bracket.
Contact with a bracket (2) Provide a minimum of 10mm clearance

between the nylon tube and the bracket or
connector, or wrap the nylon tube with a
corrugated tube.
Provide
Provide aa minimum
minimum of of 10mm
10mm clearance
clearance
between
between the nylon tube and
the nylon tube and the
the bracket,
chassis
or wrapmember,
frame the nylonortube
wrapwith
theanylon
corrugated
tube
tube.
with a corrugated tube and secure it at
both sides point within 50mm from
contact part with clip.
300mm 300mm
or less or less
Chapter 2

and fix with clip.
Otherwise, place pipes in another route.
Others
Contact between vibrating nylon tubes
Chapter 2
2-9 AIR EXTRACTION

For air to accessories, branch from accessory (ACC) line. Branching from other lines (especially
from brake line) is prohibited, since it may affect braking performance. Accessory line differs in
vehicle specifications. Refer to the followings.
Example 1
① Without multi protection valve (MPV)
air extraction
・ Extract air from accessory line including
main tank.
Example 2
② With multi protection valve
without accessory tank
・ Extract air from accessory line down
stream of low pressure switch.
air extraction
Example 3
③ With multi protection valve
with accessory tank
・ Extract air from accessory line down
stream of accessory tank.
air extraction
For the vehicles with air extraction details, refer to "SPECIFIC INFORMATION".
Chapter 2
2-10 RELOCATION AND ADDITION OF A FUEL TANK

When relocating or adding a fuel tank is necessary, follow the local regulations.
When installing an additional fuel tank, be sure that the total amount of fuel does not exceed the
regulation.
① Location of a fuel tank
・ Place a fuel tank somewhere between wheelbase. Do not place it in rear overhang area.
Location of fuel tank
・ When lowering the position of the fuel tank, carefully determine the ground height of a fuel
tank not to contact the ground with particular attention to the conditions of use.
・ Be sure that the breather opening of the relocated fuel tank will not be subjected to water.
There are two types of the breather: One of them is fitted on a fuel tank body, which can be
opened with a hose, and the other type is at a filler cap.
・ Maintain sufficient clearances between the hoses for a fuel tank ("A" in the figure below) and
the object to be mounted on a chassis frame such as sub frame and double ended
bracket. If contact is anticipated, wrap the hoses with corrugated tubes or protectors.
Hose for fuel tank
・ Be sure that the relocated tank is sufficiently apart from any movable or projecting object.
・ The fill opening of a fuel tank should be easily accessible so that its cap can be removed or
attached and fuel can be fed without problems.
・ Maintain a reasonable clearance between an exhaust system component (front pipe, silencer
and tail pipe) and a fuel tank or a fuel hose.
Chapter 2
② Installation of fuel tank

Individual method such as the reinforcement of the intraframe might be provided by the vehicle
type. Confirm "SPECIFIC INFORMATION" of the targeted vehicle type.
・ When relocating a fuel tank, make sure whether there are free holes in a chassis frame side
member adjacent to the area to which the fuel tank is to be relocated, so that these holes can
be used for installing a bracket. Using these holes is recommended rather than making new
holes.
・ If more holes are required, follow "Ⅰ-2-1 DRILLING OR WELDING A CHASSIS FRAME".
・ When moving the fuel tank vertically, make bracket referring below drawing.
- Do not install the bracket together with other equipment by sharing same hole.
- Do not make hole pitch smaller than the original bracket hole pitch vertically or horizontally.
Additional bracket for relocating fuel tank
additional new bracket

Fuel tank bracket
50mm or less
Note: Make sure that adding the new bracket does
not make the fuel tank or the fuel tank bracket
protrude outward from the outmost side of the vehicle.
・ Be sure to air bleed after detaching tank or hose.

・ If nylon lock nut is used for band fixing fuel tank, do not reuse it, change to new one. Refer to
" SPECIFIC INFORMATION" for cautions at installing fuel tank.
・ When installing an additional fuel tank, follow the instructions below to prevent vehicle fire.
- Use a genuine ISUZU fuel tank.
- Fuel must be supplied from the main tank.
- In cold regions, to prevent a fuel hose from sagging due to snow, secure the fuel hose on
any retaining component such as stay attached to a tank hanger bracket.
- Never branch from engine supply line. It may affect fuel supply to engine.
Chapter 2
③ Fuel hoses and pipes

Follow the below cautions when relocating or adding fuel tank.
・ When changing a fuel hose and pipe, use a fuel hose of the same material and size as the
genuine fuel hose or steel pipe. Use genuine ISUZU rubber hose. Use of non-genuine hose
may cause problems such as fire.
Feed side fuel hose Unit: mm
Vehicle type Nominal size Inner diameter Outer diameter
Light duty vehicle 09 9.30.4 17.00.7
09 9.30.5 17.00.7
Medium duty vehicle
10 9.50.4 14.50.7
12 11.3±0.5 19.0±0.8
Heavy duty vehicle
12 11.30.5 19.50.8
Return side fuel hose Unit: mm

Vehicle type Nominal size Inner diameter Outer diameter
Light duty vehicle 05 5.80.4 12.20.7
Light duty vehicle (Q-Series) 06 5.80.4 13.50.7
08 7.50.3 13.50.7
Medium duty vehicle
09 9.30.4 17.00.7
09 9.30.4 17.00.7
Heavy duty vehicle
10 9.50.4 14.50.7
・ The hose diameter mentioned above is a example.

・ Contact ISUZU distributor or ISUZU dealership for hose specification of actual vehicle,
・ Follow the below chart for hose bending radius.
Unit: mm
Hose diameter 12.2 13.5 14.5 17.0 19.0/19.5
Minimum bending Radius 70 75 80 95 105
Note: Form hose referring to above chart, without wrinkles at inner bent or blockage.
Chapter 2
・Use steel pipes in engine room.

・ Use fuel pipes size shown below.
Detail of end portion

Bulge forming Spool forming Unit: mm
Hose Hose
D A B D A B
Nominal Size Nominal Size
05/06 6.35 7.40.3 6.10.3 05/06 6.35 7.40.3 6.35
08 8 9.30.3 7.90.3 08 8 9.30.3 8
09/10 10 11.50.3 10.00.3 09/10 10 11.50.3 10
12 12 13.50.3 12.00.3 12 12 13.50.3 12
Inner surface Copper plating (Thickness: 3 at minimum)

Outer surface Galvanization (Thickness: 13 at minimum) and Organic coating (*)
Note: * Corrosion resistance: 2,500hrs. at minimum before reddish brown corrosion appears
after salt spray test.
Chapter 2
④ Precautions for connecting pipes

・ Do not connect two or more hoses to lengthen a single hose.
・ Fabricate a connecting pipe from a steel pipe. Perform bulge forming or spool forming on both
ends of this pipe.
Length of connecting pipe
Unit: mm
・ Insert this connecting pipe into hoses by more than 30mm, and secure with clips.
Connecting hose and pipe
Unit: mm
Hose Nominal Size Clip part number
05 898150-3580
06 898150-3570
08 898150-3570
09 898008-0980
10 109704-1020
12 898150-3560
・ If bulge forming and spool forming are impossible, the insertion depth should be 35mm or
more.
・ Secure the hoses on a chassis frame or something else by using clips.
Hose fixing
・ Hose joints must not be located above an exhaust system.

・ After completing the hose connection, confirm that there is no fuel leakage.
・ Do not join a fuel hose to the factory-installed one to take out fuel. Fuel must be taken out
directly from the fuel tank.
Chapter 2
2-11 PRECAUTIONS FOR TOWING HOOK

Follow the instructions below when relocating towing hook installed at delivery.
① Location
・ For straight frame: locate towing hook leveled with frame.
・ For kick-up frame: locate towing hook incline 15°downward from frame to avoid effect to
rear body or poor operativity from the hook located higher.
② Installation
・ For drilling holes on frame, refer to "Ⅰ-2-1 DRILLING OR WELDING A CHASSIS FRAME".
・ Hole diameter and tightening torque is as follows.
Hole diameter Torque

Vehicle type Location Remarks
mm N・m {kgf・m}
Lower 11 51±7 {5.2±0.7} ━
Light duty vehicle
Side 15 157±32 {16.0±3.3} ━
15 133±26 {13.6±2.7} FR, FS series
Medium duty vehicle Side
17 193±39 {19.7±4.0} FT, FV series
Heavy duty vehicle Side 17 193±39 {19.7±4.0} ━
The rear body posterior of towing hook must not be in range of towing rope.
Range of towing rope
Chassis frame 15°

Towing hook 15°
15°
15°
Chapter 2
2-12 PRECAUTIONS FOR MODIFICATION OF THE ELECTRICAL SYSTEM

① General Precautions
・ Careless modification may result in fire or equipment breakdown. Follow the below cautions.
- Modification to the factory-installed electrical components such as wires, fuses and relays
are prohibited.
- Do not tear protective corrugated tubes and pull out inside wires to connect additional
equipments because this may damage the remaining harnesses.
- Be careful not to damage the wire harness and other components. When they are
damaged, have, them repaired.
- Never modify the harness around electric unit (control unit).
- Restore the terminals, connectors, clips, and harnesses removed at work where they were
originally. If the terminal polarity or connector partner is confused, it may lead to defect or
damage the component.
- If the original clip cannot be used due to additional components, add alternative clip to fix
harness.
- When a clip for fixing harness is broken, replace it with new clip same as the broken one.
Metallic clip has coating (rubber or vinyl chloride) at harness converging part. Clip with tear
on coating, hole, crack is considered damaged, and replace it with new clip.
- Exposing connectors, relay box, and electric equipments to such water may cause water
intrusion into electric components or internal condensation, resulting in problems such as
operational malfunction, erosion, and in the worst case, a vehicle fire.
- When mounting rear body on chassis frame, be careful not to have harness jammed.
- When there is melting fuse, investigate the cause, repair it, and change it with new one of
specified capacity. Never increase the fuse capacity, it will burnout components and wires,
and lead to fire.
② Additional power supply (standby power supply) and ground circuit
Sizes and shapes of terminals and electric wires used for the increase must use the one that
corresponded to the increased load. Select the battery and ACG that corresponds to the
electric load when installing body with high electric load (fire engine and refrigerated vehicle,
etc.). Refer to "SPECIFIC INFORMATION".
・ How to extract power from the factory-installed wires (when the electrical load of rear body
does not exceed the allowable capacity of standby power supply)
- Do not extract power other than from the extraction of the standby power supply prepared
in the vehicle.
- Maintain the power below the ratings capacity of the standby power supply.
- Refer to "SPECIFIC INFORMATION" of the targeted vehicle type for the position and the
rating capacity of the standby power supply.
- Do not connect ground circuit of additional power supply with the existing harness.
Connect it with either the ground circuit for standby power supply, negative terminal of the
battery, or the frame.
Chapter 2
・How to extract power from the positive battery terminal (when electrical load of rear body
exceed the allowable capacity of standby power supply)
- Provide a fuse in each power extraction circuit.
- Fuses must be a minimum of 300mm apart from the battery (volatile gas may come out of
the battery) and protected from water.
- Do not put a fuse directly on the battery body or on the reverse side of the battery cover,
otherwise the battery will be damaged or explode.
- Use the ring terminal to extract from battery, fix it together with battery terminal to prevent
loosening.
- Only one terminal may be added to prevent loosening.
Connect it with negative terminal of the battery.
- When using a cable of 5mm2 or larger, solder the pressured part of the wire terminal, and
then wrap the area with a heat shrink tubing.
- Extracted power from battery is always energized, does not depend on the state of the key
switch on the chassis. This can cause the battery go flat. Take the necessary measures
such as appending to the caution label or the owner’s manual.
Connecting an additional cable
Factory-installed circuit
Additional circuit
(Switching circuit such as

relay is included.)
Fuse
Additional
load 300 at min
Replace with the ones with capacity that

suits the additional load.
Installing an additional cable to the battery terminal
Battery cable Nut

Additional Battery terminal Battery cable
cable
Ring terminal
Nut Ring terminal Additional cable
12mm
Battery terminal
Terminal added to right figure shall be 12mm or smaller in size.

Chapter 2
③ Ground circuit
Careless modification may result in fire or equipment breakdown.
Relocating the ground points of the factory-installed ground circuit and lengthening or
shortening these wires or cables is prohibited, because doing any of these may result in
breakdown of electrical equipments or electronics devices due to surge, etc.
Follow the below instructions when adding ground circuit for bodies or additional equipments.
・ How to connect the ground circuit to a chassis frame
- The ground point of an additional equipment should be connected to the chassis frame
member to which the negative battery cable is connected.
- Do not secure the ground circuit of additional equipment together with a factory installed
ground point because the fixing bolt will loosen and contact failure will occur.
- Use ring terminal and secure it without looseness. Jamming foreign substance at
connecting will be a cause of looseness.
- Bolt for fixing ground circuit on frame and cab panel is exclusive use. When the bolt is
damaged at work, replace it with specified exclusive ground bolt.
- Weld a mating nut on the chassis frame or directly tap the chassis frame. To drill holes for
directly tapping chassis frame, follow "Ⅰ-2-1 DRILLING OR WELDING A CHASSIS
FRAME".
Chapter 2
Addition of ground point
Weld nut or Tapped hole
Refer to the below table the

dimensions of each symbol.
Ground bolt part list

Nominal
Part No. Pitch a (Max) Length Spring washer Plane washer Lock length Lock position Tightening torque
Diameter mm L mm T1×D1 T2×D2 d mm La mm N・m {kgf・m}
898164-8360 M6 1 2.6 14 None 1.6×12 4 5 7.8±2.0 {0.8±0.2}
897086-8220 M6 1 3.9 14 1.2×11.3 1.6×12 3.5 6 7.8±2.0 {0.8±0.2}
897086-8230 M6 1 5.4 16 1.2×11.3 1.6×12 4 7.5 7.8±2.0 {0.8±0.2}
897086-8240 M6 1 5.4 20 1.2×11.3 1.6×12 4 10 7.8±2.0 {0.8±0.2}
897087-2010 M6 1 5.4 25 1.2×11.3 1.6×12 4 16.5 7.8±2.0 {0.8±0.2}
897087-6170 M6 1 5.4 40 1.2×11.3 1.6×12 4 31 7.8±2.0 {0.8±0.2}
897119-4790 M6 1 3.9 14 1.2×11.3 1.6×12 3.5 6 7.8±2.0 {0.8±0.2}
897206-4070 M6 1 3.9 14 1.2×11.3 1.6×12 3.5 6 7.8±2.0 {0.8±0.2}
898164-8370 M8 1.25 3 14 None 1.6×16 4 5 18.6±4.9 {1.9±0.5}
898141-2550 M8 1.25 3 18.5 None 1.6×16 6.5 6 18.6±4.9 {1.9±0.5}
897086-8250 M8 1.25 6.5 20 1.6×14.3 1.6×16 4 10 18.6±4.9 {1.9±0.5}
898141-2561 M8 1.25 3 24 None 1.6×16 10 7 18.6±4.9 {1.9±0.5}
897087-0550 M8 1.25 4.7 16 1.6×14.3 1.6×16 4 6 18.6±4.9 {1.9±0.5}
897087-2030 M8 1.25 6.5 25 1.6×14.3 1.6×16 4 15 18.6±4.9 {1.9±0.5}
897087-2040 M8 1.25 6.5 30 1.6×14.3 1.6×16 4 20 18.6±4.9 {1.9±0.5}
None
897264-7660 M8 1.25 2 23 None (flange diameter 5 4 18.6±4.9 {1.9±0.5}
16mm)
898164-8380 M10 1.25 4.5 20 None 2×20 6.5 6 40.2±5.9 {4.1±0.6}
897087-2050 M10 1.25 5.9 25 1.8×17.4 2×20 5 10 40.2±5.9 {4.1±0.6}
897087-2060 M10 1.25 7.2 30 1.8×17.4 2×20 5 17.5 40.2±5.9 {4.1±0.6}
Chapter 2
④ Wire size and fuse capacity

・ Improper use of wire harnesses may result in fire or equipment breakdown.
・ If additional wire harnesses are required, select appropriate wires according to the load
current to be added, the circuit length, and the harness route.
・ Use electric wires for automobiles (JIS-certified wires such as AV, AVS, AVX, AEX, or
equivalent).
・ When using an AEX wire, parts used with it such as protection tube, corrugated tube, vinyl
tape, etc. should also be heat-proofed.
・ When using a wire whose size is 5mm2 or larger, solder the pressured part inside the wire
terminal to prevent it from heating.
Permissible temperature and current of electric wire
Allowable current
Allowable
Wire type 0.5 0.85 1.25 2 3 5 8 Remarks
temperature
mm2 mm2 mm2 mm2 mm2 mm2 mm2
AV 80℃ 9A 11A 14A 20A 27A 36A 47A Standard
AVS 80℃ 8A 11A 14A 19A 26A 35A No spec. Standard
AVX 90℃ 8A 10A 13A 17A 24A 33A 43A for high temp.
AEX 110℃ 7A 9A 12A 17A 23A 32A 42A for high temp.
・Fuse capacity, wire size and circuit length

- Fuse capacity on the power source side determines usable wire size and circuit length.
- Select appropriate wire size in consideration of the fuse capacity on the power source side
and the wire route. If a wire is connected to an equipment that produces relative
movement, the size of the wire should be 0.85mm2 or larger so as to prevent wire breaking.
Permissible current of fuse, wire size and circuit length
Fuse Wire size and circuit length
Allowable
Rating 0.5 0.85 1.25 2 3 5 8
Type continuous
capacity mm2 mm2 mm2 mm2 mm2 mm2 mm2
current
5A 3.5A Max.25m Max.40m – – – – –
7.5A 5.2A Max.15m Max.25m Max.40m – – – –
10A 7.0A Max.10m Max.20m Max.30m – – – –
Blade fuse
15A 10.5A Max.5m Max.10m Max.15m Max.30m Max.45m – –
20A 14.0A  Max.5m Max.10m Max.20m Max.30m – –
25A 17.5A   Max.10m Max.15m Max.25m Max.40m –
30A 15.0A    Max.10m Max.15m Max.30m Max.45m
40A 20.0A     Max.10m Max.20m Max.30m
SBF (Slow- 50A 25.0A      Max.15m Max.25m
blow fuse) 60A 30.0A      Max.15m Max.20m
80A 40.0A       Max.15m
100A 50.0A       Max.10m
Legend: : Cannot be used –: 50m at max.

Chapter 2
⑤ Lengthening or shortening an electric wire or a cable

・ Splicing of battery cable is prohibited. When high current is energized, it may generate heat at
splicing point and cause fire. (Replace it with new cable.)
・ When lengthening a wire, splice a new wire with the same section area and color as those of
the wire to be lengthened.
・ When splicing a wire (adding a wire to an end of another wire), use specified joint terminals,
soldering or crimping terminal for secure connection.
・ Do not splice the wires by only twisting them together.
・ For the area where wires may be subject to vibration such as above engine or transmission,
splicing using specified joint terminals or with crimping terminals is recommended rather than
soldering because solder may seep into the inside of the wires, making them harden and lose
flexibility, resulting in separation.
・ When splicing a wire with soldering or crimping terminals, remove burrs and wrap with vinyl
tape to insulate the area. If the insulation is insufficient, it might short or cause vehicle fire.
・ When splicing wires with soldering or crimping terminal outside a cab or on the chassis frame
where water proofing is necessary, wrap butyl rubber at splicing point for waterproofing. If the
water proofing is insufficient, the conductor (copper wire) will corrode and lead to
disconnection or conduction defective.
Chapter 2
Parts used for wire splicing (joint terminal)

Wire size Wire strip length
Joint terminal Color
mm2 mm
897169-4730 Yellow 0.3 to 0.5 6.0 to 7.0
897169-4740 Red 0.75 to 1.25 7.0 to 8.0
897169-4750 Blue 2.0 7.0 to 8.0
Note: Use specialized tool (587410-6470) for crimping tool.

For wires with size larger than 2mm2, follow the instruction on next page.
Splicing of wire harness (joint terminal)
① Crimping ② Crimping
position position
(Good)
Harness A Harness B
Crimping center of Tip of the tool is protruding

Cu sleeve. from the sleeve.
Cu sleeve Insulator (Poor)
Center stopper
Crimping wires set in place Harness

Insulator
Cu sleeve
Harness B
Heat the tube with a heat gun or the like to shrink it.
Heat gun Keep heating until translucent plastic ooze out whole
circumference from both ends of tube.
Joint terminal
Roughly heating temperature ； 120℃
* At the crimping work, the tube(insulator) of the joint terminal

may be damaged and leave a hole. However, when it is possible
Harness A to cover the entire hole with the heated translucence plastic,
rework is not needed. Because it is considered to satisfy the
waterproof performance.
Chapter 2
Parts used for wire splicing (Solder or crimped-type terminal)

Purpose Parts name Parts number Remarks
Crimped-type Work with tools and working methods that are
(Commercially)
Splice terminal recommended in the used crimping terminal.
Solder (Commercially) －
Not required in waterproof unnecessary area(such as
Water proof Butyl rubber 182698-2630
area with out water splash).
Insulator Vinyl tape (Commercially) －
Note: For the additional wire, consider the overlap length of splicing area to the wire cut off. If
there is recommended length for the used crimped-type terminal, prepare additional wire
with the length added.
Splicing of wire harness (Solder or crimped-type terminal)
Use the soldering or crimped-type terminal for harness splicing.

Overlap area
* Wire size of 2mm2 or larger is recommended to splice by soldering.
* Splicing of the soldering at the area with large vibration such as engine and
mission is not recommended.
Winding butyl rubber, do

waterproof treatment.
Cover up wire coating.
Remove the burr of solder and
copper wire.
Wrap in vinyl tape, to the

insulation treatment.
Cover up butyl rubber.
・When splicing wires, do not splice at vibrating position. It may be disconnected

・ When shortening a wire or a harness, do not cut it but tie its redundancy with a vinyl tape, and
then bind it to the factory-installed harnesses or something else.
Chapter 2
⑥ Repairment of damaged wires
・ For repairing damaged wires, cutoff the damaged portion, add wire, and perform splicing.
- Below figure shows joint terminal method. Follow the same procedure for solder or
crimped-type terminal method.
- When using specific joint terminal for splicing, the length of wire cutoff and added must be
the same (L mm).
- When splicing with soldering or using crimping terminal, length of the additional wire must
be the total of length of wire cutoff and overlap of joint potion (2 places) added. If there is
recommended length for used crimping terminal, add the overlap length (2 places) to it.
Splicing wires (joint terminal method)
・ When rerouting the damaged circuit due to working space etc., follow the above directions
except for the additional wire length.
- For the rerouted wires, perform damage prevention treatment.
Chapter 2
・ When the connector or the wire close to connector is damaged, prepare connector ASM for
replenishment and perform splicing.
- Below figure shows joint terminal method. Follow the same procedure for solder or
crimped-type terminal method.
- When using specific joint terminal for splicing, the length of wire cutoff and connector ASM
for replenishment must be the same (L mm).
- When splicing with soldering or using crimping terminal, length of the additional wire must
be the total of length of connector ASM and overlap of joint potion added. If there is
recommended length for used crimping terminal, add the overlap length to it.
Splicing wires close to connector (joint terminal method)
・ Additional wires and connector ASM for replenishment must be the same size (diameter of
copper wire). Considering re-repairing, use of same color wire is recommended.
・ When splicing 4 or more wires, adjust splice position by shifting back and forth to avoid
overlapping to keep the harness diameter enlargement in minimum. Do the above same with
3 or less, if they do not fit in the protective material with splicing at the same position.
Splicing 4 or more wires in the same area

Chapter 2
・ Do not splice in the following area; bent location of harness, area of large vibration, and area
of high temperature.
- Since the flexibility is reduced at splicing portion as compared with other portions, it is
possible that harness route may not return to the original.
- Possibility of disconnection occurrence will be higher, because flutter increases due to
larger weight.
- Decide the position of the splice carefully
・ In case of performing the splicing in the middle of the connecting route to the relative motion
part (cab to frame, engine/mission to frame), there is a risk of breakage caused by bending
input. Perform the splicing out of the connection area by replacing the lengthened wire all
spans the area.
Splicing in the middle of the connecting route to the relative motion part
Chapter 2
⑦ Wrapping tapes
Wrapping tapes
①Partial taping
Wrapping repeatedly at the same position.
Purpose; Temporary bundling together wires, Marking tape, etc.
②Spiral taping
Wrapping by aparting width of tape.
Purpose; Bundling together wires in corrugated tube,
prevent slit opening of corrugated tube, etc.
③Half wrap taping

Wrapping by overlapping half of tape of width.
Bundling together wires in location without protective material,
fixing corrugated tube end, prevent slit opening of corrugated tube, etc.
Wrapping tapes at branch
Bundling together wires in corrugated tube.

(①Partial taping)
Corrugated tube outer diameter ; 11mm or less
Bundling together wires of branch. Fixing corrugated tube end.

(③Half wrap taping) (③Half wrap taping)
Bundling together wires

Bundling together wires in corrugated tube.
in corrugated tube. (②Spiral taping)
(②Spiral taping)
Corrugated tube
Fixing corrugated tube end.

Prevent slit opening of corrugated tube
(③Half wrap taping) Electrical wire
(①Partial taping or ②spiral taping or ③half wrap taping)
Chapter 2
⑧ Connectors
・ Use water-proof connectors for the harnesses placed outside a cab.
・ Do not unnecessarily disconnect these waterproof connectors, otherwise continuity failure will
occur.
・ When disconnecting waterproof connectors, to prevent foreign substances such as water and
metal chips from getting into the joint, or to protect the sealed part from being damaged, cover
the disconnected connectors with vinyl bags or something. If water or any foreign substance
get into the joint, dry up the joint or remove such foreign substance before connecting the
connectors.
A variety of connectors
Giboshi Standard connector Joint connector Water proof type connector
・ As for the area where connectors may be subjected to vibration, use connectors with a
detach-safe lock.
・ When using a “GIBOSHI” type plug, be sure that its socket connector (female) with insulation
cover is connected to the wire from the power source, to prevent it from shorting when the
plug comes off and contacts with vehicle body.
・ Disconnecting connectors
- Certain types of connectors have a tang lock that prevents these connectors from coming
off when vehicle is running.
- Some tang locks can be released by pulling (①) while the others by pushing in (②).
Check which type of tang lock the connectors have.
- To prevent harnesses from coming off from the connector or breaking, when disconnecting
connectors, do not pull the harnesses but securely hold both connectors (male and female),
release the tang lock, and then separate the connectors with care.
Disconnecting connectors
Chapter 2
・ Connecting connectors
- Securely hold both connectors (male and
female) and check whether the connector pins
and the cavities match. Also, check whether the
connectors are aligned.
- Securely hold the connectors and carefully
engage them by pushing until the connectors
click.
・ Checking connectors GOOD
- When using circuit tester to test conduction of

connector, insert test probes of circuit tester
from harness side of the connector.
Test probes
- Do not insert test probes of the tester in female POOR

terminal of connector. It may deform the Test
terminal and lead to poor contacting. probes
- For the water proof connector, the test probes GOOD

cannot be inserted from the harness side Testing
structurally. Use testing connector prepared connector
beforehand to check. Connect test connector to
the vehicle side connector and connect test
probes to the harness of the testing connector.
Vehicle side
connector Test
probes
- Do not insert test probes to protection rubber of POOR Test

water proof connector. It may decrease the probes
water proof performance and became cause of
corrosion.
Chapter 2
- Do not use tester type to prick needles to cover

POOR tester type to
of harness. It may become cause of corrosion of
prick needles
wires and short.
- Confirm there is no damage to lead line or
connector from test probes after checking.
Wire
・ Removing a connector pin (Built-in tang lock)

- In case of dual lock, unlock.
- Insert a slender shaft into the opening of the Housing open pad
connector housing. Pin Lock
- Push down the tang lock in the direction of an
arrow in the figure. Pull out the wire and the
connector pin from connector.
Tang lock
Wire
Slender shaft
・ Pin-type tang lock

- Insert a slender shaft into the opening of the
connector housing.
- Push the tang lock toward the wire so as to
make it flat. Pull out the wire and the connector
pin from the connector.
・ Inserting a connector pin

- Check if the tang lock is upright.
- Insert a connector pin into the connector
housing for wires. Push the pin until the tang
lock is securely engaged.
- Gently pull the wire to check if the pin is
securely in place.
・ Using a “GIBOSHI” type plug

- When using a “GIBOSHI” type plug, be sure that its socket connector (female) with
insulation cover is connected to the wire from the power source and its plug connector
(male) to the wire from the electric load. This prevents disconnected “GIBOSHI” type plug
from shorting when it comes off and contacts with vehicle body.
Chapter 2
⑨ Harness routing
・ When laying additional wires, be sure that they will not restrict inspection or maintenance of
the vehicle components.
・ To increase reliability of wires, protect all additional wires and harnesses with corrugated
tubes or polyvinyl chloride tubes.
・ When handling the wires, do not pull them hard.
・ Additional harnesses should be laid along and secured on rear body members or on chassis
frame. Do not pass them in the air.
・ Securely fix the harnesses in place so that they will not contact with moving parts or sharp
objects.
・ Fix the harnesses so there is no jamming at rear body mounting.
Distance between harness and object
Object Required distance between harness and object
Moving part most approached 10mm or more
Sharp object minimum distance 10mm or more
・ If there is possibility that a harness contacts with a sharp edge of a metal part, protect the
harness with corrugated tubes and clip fix to avoid contact the sharp edge, or cover the sharp
edge with a protector, otherwise vibration will damage the harness coating.
Harness routing (1)
Chapter 2
・ To prevent harness coating from being damaged, attach grommets to the through holes in
steel plates.
Harness routing (2)
・ Do not put any harness on top, underside or outer side of chassis frame members because
someone may step on it or flying gravels may damage it.
・ Do not put any harness in the lower part of the inner side of chassis frame members because
harness may be damaged or freeze due to mud, snow, water, etc. that may be built up in this
area.
Harness routing of chassis frame members
・ If there are factory-installed harnesses nearby, secure additional harness on them with tapes
or nylon clips. Do not tape wrap an additional harness directly on a metal pipe or a rubber
hose including the brake pipe and the fuel pipe.
・Provide sufficient clearance between such pipe, hose and a harness.
Distance between harness and pipe/hose
Positional relation Clearance between harness and pipe/hose
Parallel 10mm or more
Intersecting 20mm or more
・ When the Corrugated tube and the air tube vibrate while interfering, the air tube will damage.
Arrange the tube maintaining enough space.
Harness routing of near the pipe/hose
Parallel: 10mm at min.

Intersecting: 20mm at min.
Chapter 2
・Note the following when fixing together to factory-installed harness with band clips.
- Put the additional harness in the vinyl chloride tube or the corrugate tube, use nylon clip to
fix along the wire harness for the vehicle.
Fixing of additional harness
- If an additional harness is to be laid along the factory-installed harnesses, it should be

firmly secured so as to avoid flip-flop movement induced by vibration of engine and vehicle,
protecting factory-installed harnesses from being damaged. Fix clips at a the portion of the
factory-installed harness which is protected by the materials such as COT-TUBE, polyvinyl
chloride tube, hard tube, and protector, should be chosen to do so.
Fixing of additional harness (branching area)
Do not attach the clip

around the wrapped
in tape of the branch Existing harness
harness. (branching area wrapped in tape)
No-clipping area
Existing harness
(with COT-TUBE)
Band clip for Additional harness

additional harness
Chapter 2
・Moving harness
- When connecting an additional harness to any equipment that produces relative vibration
against chassis frame, such as engine and transmission, reasonably slacken the harness
and lay it along the factory-installed harnesses so as to absorb the relative vibration. Be
sure that the additional harness does not contact with adjacent parts or equipments.
- As for the factory-installed harnesses connected to the equipments that produce relative
vibration against chassis frame, such as engine and transmission, do not change the way
how they are secured, the clipping points, and the sagging volume.
Harness root of moving
There is a possibility that the

Poor example terminal and connector are
disconnected in vibration. Fix
Good example the harness in the proper
location.
・ Heat protection
- Harnesses must sufficiently be distant from heat source (e.g. Exhaust pipe). Be sure that
the temperature of the harnesses does not exceed their allowable temperature limit (80°C
in principle). There may be for an individual value provided according to the auto vehicle
exhaust emission device kind. Refer to "SPECIFIC INFORMATION".
・ Clip
- Use plastic clips, or vinyl-coated or rubber-coated plate clips whose base material is rust-
proofed.
A variety of clips
Plate clip P-type plate clip Plastic clip
Vinyl tube
or
Vinyl coating
- Clip distance are as follows:

Distance of harness clip Unit: mm
Harness diameter Clip distance
5 or less 300 or less
5 to 10 400 or less
10 or more 500 or less
- If the wire vibrate due to engine or driving vibration, shorten the clipping distances.
Chapter 2
- Adhesive clips should be used only as supplemental parts. (Do not use at places with
relative displacement or vibration)
- Especially, in such a place like the engine room where ambient temperature is high, use
vinyl- or rubber-coated plate clips or band clips. Do not use non-heat-proof vinyl tape or
adhesive clips to bind additional harnesses to the factory-installed harnesses because
they will come unstuck due to heat aging.
- Seal with grommet so the water dripping along the wire does not enter the case, and route
the harness so the terminals become higher than the harness entrance. Consider that
water from tire splash or at cleaning does not enter.
Water proof of case
Terminal Case or cover
Grommet
⑩ Wire color and size

Every wire is covered with insulation material with specific color code. The main wires used for
systems are in solid color ① while the sub wires are with stripe ②.
0.5 G / R
Red (stripe color)
Green (base color)
Wire size (0.5mm2)
Color code of wire harness

Color code Color Color code Color Color code Color
B Black L Blue P Pink
W White O Orange SB Sky Blue
R Red BR Brown V Violet
G Green LG Light Green
Y Yellow GY Grey
・ Use the JIS-certified electric wires for automobiles, or equivalent

- For common area: AV (Low-voltage wire for automobile) or AVS (Thin-walled low-voltage
wire for automobile)
- For high temperature area: AVX (Cross-linked vinyl insulated heat resistant low-voltage
wire for automobile) or AEX (Cross-linked polyethylene
insulated heat resistant low-voltage wire for automobile)
Chapter 2
・ The size of each wire to be used in a circuit is

Diameter
determined by the current amount (ampere) that will
flow into the wire, the circuit length, the allowable
voltage drop amount, etc.
・ The following table shows sizes and allowable current
of AVS, AV wires.
Cross
section
Wire size
Cross sectional area External diameter Allowable current
Wire size (*)
(mm2) (mm) (A)
0.3 0.372 1.8 9
0.5 0.563 2.0 12
0.85 0.885 2.2 16
1.25 1.287 2.5 21
2.0 2.091 2.9 28
3.0 3.296 3.6 37.5
5.0 5.227 4.4 53
8.0 7.952 5.5 67
15.0 13.36 7.0 75
20.0 20.61 8.2 97
Note： * Rough sectional area

Chapter 2
2-13 INSTALLATION OF EQUIPMENTS ON THE ROOF

① Prohibition
・In view of the strength of the roof and work safety, any works and walking on the roof panel
are basically prohibited.
・ The installing load to the roof must not exceed the following weight including carriers. Refer to
"SPECIFIC INFORMATION" for cab specifications.
Unit: kg
Cab type NKR/QKR/1X 2X/3X 4X/5X C&E
Load limit 45 45 75 80
・ Do not use the factory-installed dummy bolts on the roof for installing equipments.
・The drip channel of C&E cab does not have the structure for the heavy load. Do not install
equipments.
② Precaution(NKR/QKR/1X cab)
・ For installation of equipments (e.g. Air deflector), use rain gutters on the left and right sides of
the cab.
・ To install equipments on the rain gutter, fit a bracket (e.g. L-shaped bracket) on the
undersurface of the rain gutter, and bolt them from their lateral sides to secure them in
between. When installing any equipments, avoid making a hole in the rain gutter; otherwise it
may cause rust. (See the figure.)
Location of rain gutter
Rain gutter
Example of equipment installation on rain gutter

Chapter 2
③ Precaution(2X/3X/4X/5X/C&E cab)
・ For installation of equipments (e.g. Air deflector), welded installation nuts are available on the
left and right edges of the roof. See the following figure for the location of the nuts.
・ Before installing equipments on the roof, remove the factory-installed dummy bolts from nuts.
Do not use the removed dummy bolts for installing equipments because they do not have
sufficient strength.
・ When installing equipments, be careful not to damage the roof, and for rust proofing, be sure
to insert packing between the equipments and the roof.
・ To prevent crack in the packing due to ozone, the material of such packing should be
neoprene rubber or EPDM rubber.
・ Use rust proofing M8 nickel chrome stainless steel bolts, and washers.
・ After tightening bolts, to prevent water leakage, apply silicone sealant on the entire
circumference of the bolts.
Equipment attachment with M8 bolt on the roof
Silicone sealant
Equipment
Bolt
Rubber packing
Nut
Chapter 2
Location of the M8 bolts on the roof (2X/3X Single cab)
A (Distance between bosses)
Cab roof
Dummy bolt
θ
Cab body side
B
a(boss) d(boss)
b(boss) c(boss)
Section view of the boss
95 E 95
F
G
Front axle
Cab back
I
Unit: mm
Chassis
Cab back Cab roof Front axle frame top
Gradient angle of to to to surface
Distance between bosses
Cab type E bosses （ °） d(boss) d(boss) Cab back to
Cab roof
A B C D a b c d F G H I
2X 1,535 1,535 1,535 1,535 252 Refer to ″Ⅱ-9-1 CAB
468 9 8 5 5 44 CHASSIS DRAWINGS ″
3X 1,760 1,760 1,760 1,760 372
Chapter 2
Location of the M8 bolts on the roof (4X/5X Single cab)
Cab roof
Dummy bolt
θ
Cab body side
B
a(boss) d(boss)
b(boss) c(boss)
95 E 95
F
G
Front axle
Cab back
I
Unit: mm
Chassis
Cab roof
4X 678 489.5
4X 1,854.5 1,858 1,876 1,880
468 359.5
(Bed less) Refer to ″Ⅱ-9-1 CAB
9 8 5 5 119.5
5X 678 489.5 CHASSIS DRAWINGS ″
5X 2,054.5 2,058 2,076 2,080
468 359.5
(Bed less)
Chapter 2
Location of the M8 bolts on the roof (C&E Single cab)

Dummy bolt
29.5°
Cab body side

B
C
95 600 95 a(boss)
F
High roof
G
E
D
STD roof
G
E
D
I
Front axle
Cab back
I
Unit:mm
Chassis
Cab back Cab roof Front axle frame under
Distance between bosses to to to surface
Roof height D E a(boss) Cab back to
a(boss) Cab roof
A B C F G H I
STD roof 2,086 2,093 2,111 2.5 6.5 467 84.5 Refer to ″Ⅱ-9-1 CAB
High roof 1,989 1,997 2,024 4.0 4.0 467 51.5 CHASSIS DRAWINGS ″
Chapter 2
Location of the M8 bolts on the roof (2X/3X Crew cab)

Cab roof
Dummy bolt
θ
Cab body side
C
D
B
a(boss) b(boss) d(boss)

c(boss)
95 E 95
Front axle
F
2X cab G
5.5
3X cab
9
G
Cab back
I
I
Unit: mm
Chassis
Cab roof
2X 1,535 1,535 1,535 1,535 108.5 Refer to ″Ⅱ-9-1 CAB
1,225 9 8 5 5 606.5
3X 1,760 1,760 1,760 1,760 44 CHASSIS DRAWINGS ″
Chapter 2
Location of the M8 bolts on the roof (4X/5X Crew cab)
A (Distance between bosses
Cab roof
Dummy bolt
θ
Cab body side
B
a(boss) d(boss)
Front axle
b(boss) c(boss) Section view of the boss

95 E 95
Ｆ
G
Cab back
Unit: mm
Chassis
Gradient angle of to To to surface
Cab roof
4X 1,854.5 1,858 1,905 1,909 Refer to “Ⅱ-9-1 CAB
1,224.5 9 8 5 5 634.5 221
5X 2,054.5 2,058 2,105 2,109 CHASSIS DRAWINGS “
Chapter 2
2-14 THROUGH HOLES INSIDE A CAB FOR HARNESSES OR AN ANTENNA CABLE

① Through hole for harnesses
There is a through hole for harnesses in the cab at the floor panel and at the dash panel.
Refer to "SPECIFIC INFORMATION" for cab specifications.
Location of through hole for harnesses (Floor panel)
Cab type RHD LHD
(Cab front) Through hole

(Cab front)
NKR Through hole
QKR
１X
(Cab front)
Through hole
2X
3X
Chapter 2
Location of through hole for harnesses (Dash panel)
Cab type RHD LHD
4X
Through hole
Through hole
(Cab front) (46mm)
(46mm)
(Cab front)
5X
Through hole
Through hole (46mm)
(Cab front) (46mm)
(Cab front)
C&E
Through hole
(Cab front)
(46mm)
Chapter 2
② Through hole for an antenna cable

There is a through hole for an antenna cable in the cab at the upper part of the rear mounting
rail behind driver’s seat and at the vertical surface of the bed panel. Refer to "SPECIFIC
INFORMATION" for cab specifications.
Location of through hole for an antenna cable (Upper part of the rear mounting rail behind driver’s seat)
Cab type RHD only
Through hole (25mm)
NKR
QKR
1X
2X
3X
Chapter 2
Location of through hole for an antenna cable (vertical surface of the bed panel)
Cab type RHD and LHD
Through hole(28mm) Bed panel
4X
5X
(Cab front)
Rubber
Bed panel
Through hole(28mm)
C&E
(Cab front)
Chapter 2
2-15 PRECAUTIONS FOR PAINTING

There are cab and the chassis component which marketability is dropped due to the heat from
painting and drying, and likely to become the cause of a serious accident.
① Cab painting
・ Precautions before and after painting
- When cleaning a cab, do not use thinner and gasoline but IPA (isopropyl alcohol).
- To enhance coating adhesion, thoroughly sand undercoat surface. Be sure that the
sanding pattern is uniform, and the sealant at the joints of steel plates must not be
removed.
Good and poor sanded surface conditions
② Paint
・ Urethane paint is recommended for its high luster and distinctness-of-image gloss, and it
allows low-temperature baking.
・ Contact ISUZU distributor or ISUZU dealership for cab color.
Chapter 2
③ Components that should be removed before painting

・ Remove the following components before painting to secure painting quality. Be sure to re-
attach them after painting.
・ For the components installed with the bolt with the adhesive such as assist grip, do not reuse
the bolts because it causes slacking.
- Assist grip on front panel
- Mirrors (except for Stay)
- Air intake duct
- Fender step covers
- Fender rubber
- Radiator grill
- Side panel covers
- Wiper
- Nozzle
- Turn signal lamp (side)
・ When re-attaching components after completion of painting, follow the instructions below.
- Re-attach the components after the paint completely hardens.
- For the scratches that can be made during unfastening and fastening screws, bolts, or
nuts, touch them up with a brush soaked in clear lacquer, etc.
- When re-attaching removed mirror, be sure to tighten the bolt with appropriate torque.
④ Rust prevention with Ziebart’s
・ The United States’ Ziebart’s rust-proofing agent is globally popular in protection from road
snow melting agent, salty wind, etc. Apply this Ziebart’s rust-proofing agent on cab under floor
area, inner sides of fenders, outer side of a front panel, lower parts of doors, and joints of
panels. Follow the instructions below.
- Before applying the agent, cover the drain holes in the doors and in other areas with tape
in order to prevent them from being plugged up with the agent. Also cover the air bleeding
holes in air valves, etc. with tape to protect them from blockage.
- After completion of the agent application, remove the tapes and check the drain holes for
blockage. Since a cab is made from thin steel plates, if the drain holes are plugged up by
something such as rust-proofing agent, water or salty water may consequently rust the
panels, in the worst case making holes in them or weakening the strength of the members
that are assuring the strength of the cab.
Chapter 2
⑤ Paint boundary
・ The range shown in the figure below is recommended as a range of the painting boundary.
・ Shaded areas indicate the areas to be painted.
Paint boundary (example of light duty vehicle)

B
B
A B A B
A A
Note: Shaded areas ( ) indicates the areas

to be painted.
Note: This is a simplified image of a vehicle.
Paint boundary (example of medium duty vehicle)
A A B

to be painted.

Chapter 2
Paint boundary (example of Heavy duty vehicle)
A A B

to be painted.

Chapter 2
⑥ Paint drying
・ When conducting high temperature forced drying, be sure that the atmospheric temperature
of painted surface does not exceed 80°C.
- Drying temperature over 80°C may deform rubber and plastic parts, and result in separation
of adhesive-bonded joints.
・ Remove bed mat.
・ If the air cylinder for cab suspension is equipped, protect them from high temperature with
heat insulation sheet, blanket, etc.
・ If the drying temperature inevitably exceeds 80°C, follow the instructions below.
- Remove components or protect them from high temperature with heat insulation sheet,
blanket, etc.
- Remove all the control units.
Chapter 2
・ Allowable temperature limit of the main plastic components

Light duty vehicle (NKR/QKR series) cab exterior
⑧ (Cab back right side)
⑥ Allowable
No. Component name Material temperature
limit (°C)
⑨
① Head lamp PC
② Front bumper PP
④ ⑤ ③ Radiator grill ASA/ABS 80
④ Front ornament ABS
⑤ Door handle PP-GF25
①
⑥ Door garnish PP 90
⑦ Support step PP-GF40 80
②
⑧ Air duct PP 90
③
⑨ Emblem ABS 80
⑦
Note: This is a simplified image of a vehicle (cab).
Light duty vehicle (NKR/QKR series) cab interior
Allowable
limit (°C)
① Meter cluster
② Glove box
PPF
Instrument panel
③
cover
80
④ Trim cover PP
⑤ Headlining TPE/PEF/PP
⑥ Seat cloth
PVC
⑦ Floor mat
Note: This is a simplified image of a cab interior.
Above Fig. shows right handle vehicle.
Left handle is mirrored image.
Chapter 2
Light duty vehicle (standard cab) cab exterior
⑦ (Cab back right side)
Allowable
limit (°C)
① Head lamp PC
⑤ Fog lamp PP (housing)
②
Front combination
③ lamp PMMA 80
①
④ Side reflector
② ⑤ Corner panel ABS
⑥ ⑥ Grill ASA
⑧ ⑦ Air duct PP 90
③
④ ⑧ Emblem ABS 80
Light duty vehicle (standard cab) cab interior
⑤
Allowable
④ No. Component name Material temperature
limit (°C)
① ① Meter cluster
② Tray
PPF
② Instrument panel 80
⑥ ③
cover
③ ④ Trim cover PP or PPF
⑤ Headlining PET 90
⑥ Seat assembly PP or Other 80

Chapter 2
Light duty vehicle (high cab) cab exterior
(Cab back
right side) Allowable
limit (°C)
Turn signal lamp
① PMMA 80
(front)
② Head lamp PC
③ Fog lamp PP (housing)
90
Turn signal lamp
④ PC
(side)
⑤ Flank reflector PMMA
⑥ Corner panel ABS 80
⑦ Grill ASA
⑧ Step closing
PP 90
⑨ Air duct
⑩ Emblem ABS 80
Light duty vehicle (high cab) cab interior
Allowable
limit (°C)
① Meter cluster
② Tray
PPF
Instrument panel
③
cover
④ Header shelf
PP or PPF
⑤ Trim cover 80
PET-PP
⑥ Headlining or
PET-PUR
Above Fig. shows right handle vehicle. ⑦ Seat assembly PP or Other
Chapter 2
Medium duty vehicle cab exterior
(Cab back right side)

Allowable
limit (°C)
Turn signal lamp PMMA or
① 80
(front) PC
② Head lamp PC
③ Fog lamp PP
Turn signal lamp 90
④ (side) or flank signal PC
lamp
⑦ Grill ASA
⑧ Step closing
PP 90
⑨ Air duct
⑩ Emblem ABS 80
Medium duty vehicle cab interior
Allowable
limit (°C)
① Meter cluster
② Tray
PPF
Instrument panel
③
cover
④ Header shelf
PP or PPF
⑤ Trim cover
80
⑥ Steering cowl PP-PVC
Instrument panel
⑦ PPF
pad
⑧ Headlining PET-PUR
⑨ Seat assembly PP or Other

Above Fig. shows right handle vehicle. ⑩ Bed mattress PP or Other 70
Chapter 2
Heavy duty vehicle (FX/GX/FY series) cab exterior
⑨(Cab back right side)

Allowable
limit (°C)
Turn signal lamp PMMA or
① 80
(front) PC
⑥
② Head lamp PC
③ Fog lamp PP
⑩
Turn signal lamp 90
④ (side) or flank signal PC
⑦ lamp
②
① ⑦ Grill ASA
⑧ Step closing
③ PP 90
⑨ Air duct
④ ⑤ ⑧ ⑩ Emblem ABS 80
Heavy duty vehicle (FX/GX/FY series) cab interior
Allowable
limit (°C)
① Meter cluster
② Tray
PPF
Instrument panel
③
cover
④ Header shelf
PP or PPF
⑤ Trim cover
80
⑥ Steering cowl PP-PVC
Instrument panel
⑦ PPF
pad
⑧ Headlining PET-PUR
Note: This is a simplified image of a cab interior. ⑩ Bed mattress PP or Other 70

Chapter 2
Heavy duty vehicle (C&E series) cab exterior
Allowable
⑨(cab back right side)
limit (°C)
⑦ ②
⑮ ⑪ ① Front lid SMC 100
② Front corner panel
80
④ ③ Blister fender ABS
④ Door ornament
⑥
⑩ Door outer handle 90
⑤
⑤ base plate
ASA
① ⑰ ⑥ Rear quarter bent grill 80
③
⑦ Roof ornament ASA + PC 90
⑲ ⑭
⑧ Step closing
⑧
⑫ ⑨ Air duct
PP 80
⑩ Front grip and hinge
⑬
⑪ Roof assist grip
⑯ ⑫ Head lamp
Turn signal lamp
⑬
(front) PC 90
Turn signal lamp
⑭
(side)
⑮ Roof marker lamp
PMMA
⑯ Side reflector
⑰ Fender ABS 80
⑱ Bumper grill PP
⑲ Emblem ABS
Heavy duty vehicle (C&E series) cab interior
④ Allowable
⑧ ③
limit (°C)
① Meter cluster PPF
②
⑤ ② Fuse lid PPF
Instrument panel
⑦ ③ PPF
cover
④ Header shelf PP or PPF
⑨
⑤ Trim cover PP or PPF
① ⑥ Steering cowl PP 80
JEC270C/PU
Instrument panel
⑩ ⑦ R/PVC+ABS
pad
⑥ or PPF
⑧ Headlining PET

Above Fig. shows right handle vehicle. ⑩ Bed mattress PP or Other 70
Chapter 2
⑦ Laminated glass
・ A laminated glass consists of two thermal-bonded glasses between which a polyvinyl butyral
film is sandwiched. In hot and humid conditions during paint drying, follow the instructions
below. Failure to follow these instructions may result in problems such as peeling of the
polyvinyl butyral film and bubbles between the glasses.
- When conducting forced infrared drying, work limit within 30 minutes at temperature no
higher than 120°C.
- If the temperature during such forced drying inevitably exceeds 120°C, before starting the
forced drying, cover the glass to prevent the temperature of the glass surface from
exceeding 120°C, or remove it.
- Laminated glasses can be identified by “LP”, “LS”, “L”, “AS1” or “LAMINATE” printed at the
lower left corner. Partially tempered glasses have a “Z” print.
Location of the print on a laminated glass

Chapter 2
⑧ Painting-prohibited components or equipments

Following describes the common items that doesn't depend on the vehicle type and destination.
There may be other prohibited components or equipments other than the following depending
on the destination or specification, confirm "SPECIFIC INFORMATION" of the targeted vehicle
type.
・ Disc wheel
- Do not apply additional painting on the contact faces of a mating disc wheel and a hub,
and the portions with which wheel nuts contact because thickening the painting possibly
slack or damage wheel nuts.
Painting prohibited areas of disc wheel
Cover the outer and

inner flat surfaces.
(Masking)
Section A-A
R
A
Flat surface
Cover the portions with

which the wheel nuts
contact. (Masking)
(The JIS disc wheel)
The disc wheel shown here is one example.
・ Components related to braking system such as brake hose and brake booster
・ Rubber hose, vinyl hose or connectors
・ Wire harness and connectors
・ Components and equipments related to suspension, steering, such as these made of rubber
or plastic. Especially painting on the air bellows is strictly prohibited.
・ Cab power tilt related components
・ Caution plates and number plates
・ Door sealing
・ Rubber and plastic components around window
・ Sliding part of check arm
・ Inside the door lock (Be careful not to have painting in mechanism part.)
・ Wiper blade and washer nozzle
・ Reserve tanks for coolant and washer tank
・ Regenerator such as condenser, radiator, and inter cooler
・ Condenser fan
・ Movable components such as compressor clutch
・ Lattice part in radiator grill (black part)
Chapter 2
2-16 EMBLEMS
① Precautions before affixing emblems
・ If there is any extraneous substance on a bonding surface(cab, panel) such as water, oil and
dust, emblems will not firmly stick to the surface. If there is any, wipe them off completely with
a clean cloth soaked in IPA (isopropyl alcohol). Remove wax if the wax has adhered.
・ The ideal ambient temperature for adhesion is 30°C to 50°C. Make the temperature of the
bonding surface fall within this temperature range.
・ Follow the below instructions when using an organic solvent.
- Work in an airy place.
- Fire strictly prohibited.
- Be careful do not get into eyes.
- Stop working immediately when the physical condition worsens.
- Follow instructions of the organic solvent used in detail.
② Precautions at affixing emblems
・ As for affixing emblem, set the alignment that came with a chassis on the front lid of a cab,
and then stick each letter sticker by using cut-outs of the alignment as a guide.
・ The sticky side of emblem requires pressurization for bonding. To firmly stick the stickers,
apply sufficient and uniform pressure on the emblem. Use of a roller is recommended as they
provide uniform pressurization. The pressure of the roller should be no less than 5kg.
・ Exposing the sticky side of emblem to the air for long hours weakens their adhesivity due to
adhesion of dust, etc. To protect the sticky side, do not remove a release-paper until
immediately before use.
・ Since this sticky-side has very strong adhesive property, once emblems are affixed, peeling
them off is not easy. Before sticking them, carefully check sticking position.
Location of emblem for various cab is described in “Ⅰ-2-17 DECALS“, together with location of
decal.
Chapter 2
2-17 DECALS
The base material of a decal is thin, soft and stretchable vinyl chloride. Therefore, strictly follow
the procedure to firmly affix decals without making wrinkles, bubbles or stretching.
① Precautions before affixing decals

・ Confirm the material of bonding surface. There is possibility that the decals may not stick at
all or may come off shortly after being affixed on following materials.
- Low polarity plastic such as polyethylene, polypropylene, and teflon
- Rough surfaces such as cloth, whetstone, sandpapers, and plastic emboss finished goods
- When a mold lubricant, a plasticizer, and other additives to the surface of the plastic
molding.
- Hygroscopicity plastic such as ABS, noryl, and urethanes
・ Remove wax if the wax has adhered.
・ If there is any extraneous substance on a bonding surface (cab, panel) such as water, oil and
dust, decals will not firmly stick to the surface. If there is any, wipe them off completely with a
clean cloth soaked in IPA (isopropyl alcohol). If the substance cannot be removed, completely
wipe it off with lacquer thinner, etc., and then wipe the surface again with IPA.
② Precautions at affixing decals

・ The ambient temperature should be 10°C or more
・ Begin working after leaving in atmosphere above 10°C for one hour or more, when the decal
or the bonding body was kept at 10°C or less.
③ How to affix a decal
Dry type (Use paper carrier tape) Wet type (Use neutral detergent solution)
Small area 300 X 300mm or less Large area 300 X 300mm or more
Decal size
Narrow width 50mm or less Wide width 50mm or more
squeegee (spatula) squeegee (spatula)

cutter knife cutter knife
waste cloth waste cloth
needle needle
Prepared apparatus and IPA (isopropyl alcohol) ＊1 IPA (isopropyl alcohol) ＊1
material dryer for heating dryer for heating
tape ＊2 tape ＊2
neutral detergent solution ＊3
spray bottle
Note: *1 When it is not possible to wipe off with IPA (iso-propyl alcohol) etc. used for the
cleaning, it is necessary to prepare lacquer thinner.
*2 Tape is used for alignment. Prepare NITTO paper adhesive tape No.720 or equivarent.
*3 Use home liquid neutral detergent for the neutral detergent solution.
Chapter 2
・ Dry type (For sheet decals such as signature, mark, and stickers)
- Prepare decal with paper carrier tape pasted to the printing surface.
Sectional view of sheet decal
- Without removing a release paper, temporarily place the decal in position, and mark the
position with tape.
- Peel off the release paper from the edge approximately 20mm, and then fold down the
paper 180°.
- Align to the positioning tape, press and paste up the 20mm area with squeegee first.
Temporarily fix the other edges with tape so that the decal will not move.
- Slowly peel off the release paper, and press the decal carefully.
- Basically , move the squeegee in same direction, downward or right to left.
- When you are sure with no meandering or mis-positioning, remove the positioning tapes.
- If there are bubbles trapped inside the decal, pop it with needle and press them out to
flatten.
- Press the entire surface hard for the last time, and then carefully remove the paper carrier
tape in 180° angle.
How to affix decal
Tape
Chapter 2
・ Dry type (decals with cut characters or stripes)

- Same way with the sheet decal.
By putting half pulling out slit in the released paper beforehand, it becomes easier to
temporary fix the decal. Moreover, note that loosening is not caused in the decal when it
puts on pressure by the squeegee enough when it is long. Press and stick the loosen
decal, wrinkle and the bubble may occur.
・ Dry type (fitting on corner area)
- Cut or roll it inside. Make it 1mm shorter from the corner when cutting, or bend it 10mm or
more when rolling it in, and press it heating with dryer.
How to affix decal (at corner)
Decal Decal
Dryer
Bonding body Bonding body
10mm at minimum
・ Dry type (fitting on uneven part)

- Press-fit concave part by using the edge of the squeegee. Please move right and left and
work about the squeegee. Note that the decal does not loosen.
- Press- fit toward next concave part by the squeegee. Note that the decal does not stretch.
- Press-fit the convex part by using the squeegee as shown in figure. Press enough so that
the squeegee deforms.
- Fitting on a globular uneven part is impossible.
How to affix decal (at uneven part)
Squeegee
Squeegee
Chapter 2
・ Wet type (fitting on other than corner area)

- Stretch prevention and the alignment of the decal become easy by using neutral detergent
solution, the paper carrier tape is not needed. Fitting on a uneven part is impossible with
wet type.
- Put neutral detergent solution in spray bottle.
- Without removing a release paper, temporarily place the decal in position, and fix the two
corners of the decal with adhesive tape.
- Spray neutral detergent solution evenly on adherence face and adhesive coated surface of
decal after removing released paper.
- Place the entire decal on the adherence body at the same time. Remove tape after
confirming position.
- To improve sliding of the squeegee, and to prevent the friction scar, spray the neutral
detergent solution on the decal surface evenly.
- Press-fit while pushing the spray liquid out from the center toward the edge by squeegee.
- When the convex part is found after pushing out with the squeegee, the spray liquid
remaining in the part. Make hole with a needle and push out the spray liquid.
How to affix decal (wet type)
・ Wet type (fitting on corner area)

- Same way with the dry type.
Chapter 2
④ Precautions for peeling off a decal

・ How to peel off a decal (affixed less than one week)
- Lift the edge of the decal with a spatula and pull it gradually.
- After peeling the edge about 2cm, pull the decal slowly and gently.
- Wipe with toluene to remove remaining adhesive agent on a bonding surface.
- Wipe again with isopropyl alcohol after it dry, and wipe with waste cloth at the last.
・ How to peel off a decal (affixed more than one week)

- The degree of adhesion rises as for the decal that passes one week or more after affixing,
peeling off is considerably difficult. Proceed work carefully.
- Coat the decal with toluene to expand the decal.
- Shave off the decal with a spatula.
- Wipe with toluene to remove remaining adhesive agent on a bonding surface.
- Wipe again with isopropyl alcohol after it dry, and wipe with waste cloth at the last.
Chapter 2
Location of decal and emblem for various cab.

Light duty vehicle (NKR series)
B C
1 2
y
1: Edge of panel
3 2: Decal
D 3: Emblem (ISUZU)
Distance
A: 23mm B: 26mm C: 23mm D:18.5mm
y 1
Sectionｙ-ｙ
Light duty vehicle (QKR series)
B C
1 2
1: Edge of panel
2: Decal
3: Emblem (ISUZU)
Distance
D A: 25mm B: 26mm C: 23mm D:20mm
1 3
Chapter 2
Light duty vehicle (standard cab)
Z 1
B
B
Z
A 2
Section Z-Z
3
3
C 1: Edge of panel
2: Decal
3: Emblem (ISUZU)
1 4: Radiator grill
4
Distance
A: 16mm B: 19mm C: 39mm
Light duty vehicle (high cab)
Grill shape
Type(a)
Type(b)
1: Edge of panel
5 2: Decal (“N＊”/”REWARD-N＊”/”REWARD”)
3: End of panel curve
4: Edge of emblem
5: Emblem(ISUZU)
4 Distance
A: 30mm(“NL””NM”)/34mm(“NN””NP””NQ”)/
C 18mm(“REWARD-N＊”)/18mm(“REWARD”)
B: 19mm
3
C: 43mm(Grill shape type(a))
58mm(Grill shape type(b))
Chapter 2
Medium duty vehicle
Grill shape
Type(a)
Type(b)
“FORWARD” Decal
2
5 A
4 Distance
E A: 45mm B: 21mm
3
The decal shown here is one example.
“Model name” decal

1. “FORWARD” decal and “Model name” decal
a: End of panel curve Z
a Z
b: Upper left corner of the decal b a
c: Upper right corner of the decal d c
d: Edge of panel C D
2. Front lid Z Z
4: Edge of emblem
5: Emblem (ISUZU) Distance
C: 46mm:STD cab / 53mm:Wide cab
Distance D: 14mm:STD cab / 21.5mm:Wide cab
E: 40mm(Grill shape type(a))
55mm(Grill shape type(b)) The decal shown here is one example.
Chapter 2
Heavy duty vehicle (FX/GX/FY series)
Grill shape
Type(a)
Type(b)
1
Z
Z
a
c B
b
e a,
d
c,b
A d
2
Z Z 1
2
5 Section Z-Z
4 1. Decal
C a, b: End of panel curve
3 c: Upper left corner of the decal
d: Upper right corner of the decal
e: Edge of panel
2. Front lid
4: Edge of emblem
5: Emblem (ISUZU)
Distance
A: 53mm B: 21.5mm
C: 40mm(Grill shape type(a))
55mm(Grill shape type(b))

Chapter 2
Heavy duty vehicle (C&E series)
Blister fender
A End of panel curve
Model name decal
Turn signal lamp Decal: pet name

End of panel curve
C
Left
side
End of fender curve Blister fender

Decal: pet name Turn signal lamp
C
Right
side
Emblem (ISUZU)
Edge of front lid Blister fender End of fender curve
Edge of emblem
D
Distance
A: 31mm B: 29mm C: 28mm D: 49mm

Chapter 3
REAR BODY MOUNTING Ⅰ GENERAL PRECAUTIONS
Chapter 3 REAR BODY MOUNTING

3-1 CONSIDERATION TO PROPER LOAD
3-2 CLEARANCE BETWEEN ANY EQUIPMENT OR A COMPONENT ON A
CAB CHASSIS AND A REAR BODY
3-3 SUB FRAME AND FIXING OF A REAR BODY
Chapter 3
3-1 CONSIDERATION TO PROPER LOAD

① Partial load and concentrated load
・ When generation of partial load and concentric load in chassis frame is assumed due to
structure of rear body or users loading, distribute the load by adding sub frame or main sill
structure to prevent the transformation and the crack of chassis frame.
・ When load is assumed to be concentrated partially such as at cab back crane, add
reinforcements as needed to reduce stress.
・ When installing a sub frame, allot the generated bend stress by calculating the combination
beam. When installing reinforcement, do calculation same as the combination beam.
② Stress of chassis frame
・Follow the table below about the stress generated in chassis frame at time when the
maximum payload was installed. 2 Unit：MPa {kgf/mm }
Light duty Medium duty Heavy duty

Smooth road use
64{6.5} or less 78{8.0} or less
Flat bed, van, etc.
Rough road use 64{6.5} or less

44{4.5} or less
Tipper, mixer, garbage, etc. 44{4.5} or less (Tipper)
Condition of frame tensile strength 440{45} or more 540{55} or more
Note: The table is at 1G reaction force. A peculiar value to the frame tensile strength and the
permissible stress value might be indicated according to the vehicle type and destination.
Confirm the frame section coefficient diagram etc. of "SPECIFIC INFORMATION" of the
vehicle type targeted without fail.
・ Chassis frame is designed assuming uniformly distributed load. Frame stress may become
maximum other than maximum load due to rear body feature, shipment, or rear body
characteristics. Built suitable sub-frame or add reinforcement so the frame stress do not
exceed limits referring to below examples.
Rear body type Load tendency

Load concentrate on one part depending to the construction machine
Construction equipment carrier
mounted.
When the shipment exceed in front or rearward, the load concentrates

Lengthy cargo carrier
on front axles or rear over hang.
Load concentrates on rear over hang for hopper weight. Further more,
Garbage compactor truck
the load concentrates on tare meter load cell installation part.
Aerial work platform

Load concentrates in front (cab back) part for bucket/boom weight.
Earth auger
Concrete mixer truck Load concentrates on front and rear drum support.
Chapter 3
3-2 CLEARANCE BETWEEN ANY EQUIPMENT OR A COMPONENT ON A CAB

CHASSIS AND A REAR BODY
① Engine
・ When installing any equipment or component around an engine, provide the following
clearances from the engine.
・ Do not place any object in front of the radiator or the inter cooler, otherwise cooling efficiency
of the radiator or the inter cooler may be impaired.
Clearance between engine and rear body
Above and below 40mm or more

Left and right 40mm or more
Front and back 25mm or more
② Transmission
・ Since transmission moves in unison with the engine, maintain a minimum of 40mm clearance
around it.
・ Transmission is to be retreated when removed. Therefore, not to contact anything, the
transmission assembly must have a minimum of 150mm clearance behind it.
・ Provide a minimum of 150mm clearance above the transmission assembly for check-ups and
maintenance.
Clearance between transmission assembly and rear body
Periphery 40mm or more

Above and back 150mm or more
Chapter 3
③ Front and center propeller shafts

・ Provide a minimum of 30mm clearance around front and center propeller shafts.
・Equipment that emits high heat should be distant from the propeller shafts. If such equipment
has to be placed near a propeller shaft, provide a heat insulation between them.
Clearance between front/center propeller shaft and rear body
Front propeller shaft
Center propeller shaft
④ Rear propeller shaft and rear axle
・ There should be the following minimum clearance around rear propeller shaft and rear axle.
Clearance between rear propeller shaft/rear axle and rear body
・ Clearance between rear axle and chassis frame from spring deflection differs in each vehicle
model. Refer to "SPECIFIC INFORMATION" of target vehicle model.
Chapter 3
⑤ Exhaust system
・If a rear body is partially made of combustible materials such as wood and rubber, provide
100mm of clearance between the rear body and an exhaust pipe, a silencer or catalytic
converter.
・ If such clearance cannot be assured, provide a heat insulation between them.
・ An oil pump or its piping for the equipments or the hydraulic system on a rear body must not
be placed near exhaust system components such as a silencer or catalytic converter.
- Smoking and the ignition when the leakage occurs in the hydraulic system.
Clearance of exhaust components
Rubber mud guard

a
Exhaust pipe
c
b
Spare tire
Prohibited
a, b, c = sufficient clearance to prevent heat damage
・ The condition of exhaust emission device may be individually shown by the form and the
vehicle type, and refer to "SPECIFIC INFORMATION" of the targeted vehicle type.
⑥ Slide shackle rear suspension

・ As for slide shackle rear suspension, the rear end of the spring stretches out. Therefore, the
rear body must not be mounted on the portion ‘A ‘ shown in the drawing below:
Clearance between slide shackle rear suspension and rear body
A=250mm
Chapter 3
⑦ Pipes, cables, and wire harness

・ Maintain the following clearance.
Between rear body and movable (engine, mission, etc.) wire
40mm or more (most approached)
harness and piping
Between rear body and half fixed wiring and piping (wire 10mm or more from most approached
harnesses cables, fuel piping) position
battery cables: 15mm or more

Between rear body and fixed wire harnesses and piping
other wire harnesses: 10mm or more
Note： When above condition is difficult to be satisfied, clip fix to avoid contact with rear body.
・ Corrosion of pipes and cables promotes on tank truck, vacuum truck, etc. due to water and
dew condensation at low-temperature part. Place protection board or keep pipes , cables and
wires away from water dripping or dew condensation part.
⑧ Cab
・When the vehicle is moving, the whole cab moves in various directions in conjunction with
cab suspension. Also, when a cab tilts, rear body may contact with the cab or cab chassis
components such as an air inlet duct attached to the cab. Taking these into account, provide
sufficient clearances between them as shown below to prevent the cab from contacting with
anything.
Clearance of cab
Vehicle type A B C D Unit: mm
Heavy duty vehicle

40 50 60 50
Medium duty vehicle
Light duty vehicle 20 50 50 50
C
Chapter 3
⑨ Retarder
・ The retarder generate heat higher than 200°C. Maintain clearance of 100mm for both A and
B from combustible materials such as wood and rubber.
Clearance between retarder and rear body
A
B
A
Chapter 3
3-3 SUB FRAME AND FIXING OF A REAR BODY

Fitment of a subframe between the rear body and the vehicle chassis is mandatory. The
purpose of the subframe is to evenly distribute the body load along the length of the chassis
as well as contributing to overall chassis strength.
3.3.1 SUB FRAME DESIGN CONSIDERATIONS
The subframe must be designed in such a manner that stress concentrations induced in the
truck chassis are minimised. Incorrect design or positioning of the sub frame may result in
chassis failure.
Guidelines for sub frame design
• The subframe must be continuous and follow the contours of the chassis
• The subframe must be in continuous contact with the chassis rail flange throughout
its length. A suitable spacer in continuous contact with both the chassis and
subframe can be used to clear any rivet heads. It is not permissible for the
subframe to contact any rivets which may be located along the top flange of the
chassis
Chapter 3
• The front of the subframe must be tapered or otherwise designed so that there is a
gradual transference of load from the subframe to the chassis. Acceptable designs
are:
Unit: mm
A B R
(a) 5 H or more —
(b) H/3 H or more —
(c) H/4 to H/5 H to 1.5 times H 15 to 20
• The width of the subframe section should be between 70-100% of the width of the
chassis rail section.
Chapter 3
• The subframe should extend forward to a distance no greater than 200mm from the
rear cab face. Distances greater than 200mm may cause excessive chassis flex
between the cab and body resulting in poor ride comfort and chassis failure
• The front end of a subframe must contact the chassis no less than 200mm from any
major change in chassis section (eg, crossmember mounting, reinforcement section,
suspension mounting)
Chapter 3
• The start or end of any subframe reinforcement should contact the chassis no less
than 200mm from any major change in chassis section (eg, crossmember mounting,
reinforcement section, suspension mounting)
• Timber is not a suitable subframe material nor should timber be used as a material
for a spacer between the subframe and chassis.
Chapter 3
3.3.2 SUB FRAME MOUNTING DESIGN CONSIDERATIONS

The purpose of the subframe mountings is to secure the sub frame to the vehicle chassis
whilst still allowing the chassis to flex.
Ideally the sub frame should be mounted rigidly at the rear of chassis and less rigidly toward
the front. This is particularly important if the body is very rigid in structure (e.g a tanker). This
will allow the chassis to remain flexible in the areas it is designed to be flexible.
The mountings must be both designed and positioned to minimise the amount of stress
induced in the chassis. High stress areas in the chassis are locations where there is a
significant change in section caused by a change in shape or added reinforcement and/or
where there are high loadings, for example where the suspension mountings are attached.
Incorrect design or positioning of mountings may result in chassis failure
Guidelines for mounting design

The preferred mounting methods are outrigger mounts or fish plates bolted to the chassis
web. Welding of mounts to the chassis is not permitted. “U” bolt mounting is not
recommended for the following reasons:
• “U” bolts need to be frequently checked for tightness

• The load is transferred to the flange of the chassis rather than the web
• There is a localised stiffening of the chassis near the mounting which causes frame
stress
• There is a risk of chassis buckling occurring due to overtightening.
Outrigger Mounting Flexible Outrigger Mounting
Fish Plate Mounting U-Bolt Mounting

Chapter 3
Mountings should be spaced a maximum of 1000mm apart along the length of the sub
frame and the first mounting should be located a maximum of 1000mm from back of cab
The edge of any mounting should not be placed in the following areas:
• Within 100mm of a chassis crossmember attachment point
Notes:
(1) On some truck model chassis where there is lack of clear space available to place
mounts adequately at spacing less than the maximum stated, a 10% dimension
tolerance is acceptable.
(2) If a choice must be made between placing a mount within 100mm of a crossmember
and complying with the body mount maximum spacing dimension, preference is given
to achieve optimal spacing between mounts. Outrigger mounts are permitted in the
vicinity of crossmembers under these circumstances.

Chapter 3
• Within 100mm of a suspension mounting attachment point
• Within 100mm of the start or finish of a chassis reinforcement

Chapter 3
• Within 50mm of the transition area at the front of the subframe where load is being
progressively applied to the chassis
• Within 50mm of the area where the chassis may change direction (steps up, down
or sideways)
Chapter 3
Bolt holes used to secure mountings should meet the following requirements:
• Where possible existing holes in the chassis should be used

• Where possible holes should be drilled on the same horizontal plane as existing
adjacent holes. Note the centre of the web is the neutral axis and therefore has the
lowest stress.
• Holes should be de-burred and chamfered after drilling to reduce potential stress
points
Maximum permissible hole diameters as follows:
• N-series: 11mm
• FR, FS, FT, FV: 15mm
• FX, FY, Giga: 17mm
All fasteners should be ISO Grade 8.8 (SAE Class 5) or higher and torqued to the
recommended figure. Refer to the fastener supplier for recommended torque specifications
or in the absence of information the table in Chapter 1 “General”.
Washers having a hardness no less than 200HV should be used under bolt and nut heads.
Alternatively, flanged bolts and nuts can be used.
The stem of the bolt should pass through as far as possible both the mounting and chassis
frame. Clearance between the bolt stem and hole should be a maximum of 0.8mm. Fully
threaded bolts should not be used.
Chapter 3
Holes should not be drilled in the following areas:
• Top or bottom flanges of the chassis side rail

• In the web within (0.2xH) mm of the top or bottom flanges where H = side rail depth
• Within 50mm of an area where the chassis side rail may change direction (steps up,
down or sideways)
• Closer than 25mm to an existing chassis hole (N-series) or closer than 40mm to an
existing chassis hole (all except N-series) measured from hole edge to hole edge.
• Such that the edge of any hole is located a distance less than 25mm from any weld
(N-series) or 40mm from any weld (all other models)
Chapter 3
• Such that there are more than 3 holes aligned together in a vertical plane
• It is prohibited to mount a body or subframe to the chassis by bolting to the top or

bottom flanges, or welding to any part of the chassis. It is also prohibited to notch the
chassis or crossmember flanges to facilitate body fitment.
• Mounting holes should not be created by using a blowtorch. Drilling using a twist drill
only is permitted.
Ⅱ. SPECIFIC INFORMATION
Chapter 1
OUTLINE Ⅱ SPECIFIC INFORMATION
"Ⅱ. SPECIFIC INFORMATION" is a summery of vehicle development for each shipment, main
technical data, and precautions at mounting rear body for each vehicle specification, to examine
at body building.
It is recommended to refer to "Ⅰ. GENERAL PRECAUTIONS" as well at examination and
working on body building.
The content of this guide might change without a previous notice. If the contents differs from the
vehicle, contact ISUZU MOTORS LIMITED, ISUZU distributor or ISUZU dealership for exact
details of latest information.
Chapter 2
PRINCIPAL SPECIFICATIONS OF VARIOUS VEHICLE MODELS Ⅱ SPECIFIC INFORMATION
Chapter 2 PRINCIPAL SPECIFICATIONS OF VARIOUS VEHICLE

MODELS
2-1 VEHICLE MODEL CODE CHART
2-2 CAB NAME AND BASIC SPECIFICATIONS
2-3 PRINCIPAL SPECIFICATIONS OF THE CAB CHASSIS
Chapter 2
2-1 VEHICLE MODEL CODE CHART

The following is the definition of vehicle model code. If there is no applicable code, truncate the
blank.
Note: Model code shown below is an example.

Basic Model Code Model Code Suffix
(Example) F X R 77 V U — N D M S H -P
① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ⑪ ⑫
① Model Line ⑦ Wheelbase (mm)

F Medium duty forward control truck H 3,201 to 3,500 S 5,901 to 6,200
G Medium duty forward control semi-tractor J 3,501 to 3,800 T 6,201 to 6,500
K 3,801 to 4,100 U 6,501 to 6,800
② GVW/GVM Range L 4,101 to 4,400 V 6,801 to 7,100
X 16.0 to 26.0 ton M 4,401 to 4,700 W 7,101 to 7,400
Y 20.0 ton or over N 4,701 to 5,000 X 7,401 to 7,700
P 5,001 to 5,300 Y 7,701 to 8,000
③ Driving System Q 5,301 to 5,600 Z 8,001 or over
4×2 (Rear wheel drive) R 5,601 to 5,900

D
E 6×2 Front double axle (Rear wheel drive)
G 6×2 Front double axle (Rear wheel drive) ⑧ Cab Configuration
H 8×4 (Rear wheel drive) —
Single cab (w/o bed, w/o tilt)
(No code)
J 8×4 (Rear wheel drive)
A Single cab (w/o bed, w/ tilt)
L 6×2 (Rear wheel drive)
B Single cab (w/o bed, w/ tilt) F wide cab
M 6×2 (Rear wheel drive)
C Single cab (w/ bed, w/ tilt)
R 4×2 (Rear wheel drive)
D Single cab (w/ bed, w/ tilt) F wide cab
Y 6×4 (Rear wheel drive)
W Double cab (w/o tilt)
Z 6×4 (Rear wheel drive)
V Double cab (w/ tilt)
Y Double cab (w/ tilt) F wide cab
④ Engine Type
34 6HK1
⑨ Chassis Configuration
51 6WF1
—
52 6WG1 Standard chassis
(No code)
77 6UZ1
B Export bus chassis
D Dump chassis (w/ side PTO and dump lever)
⑤ Suspension Type and Main Brake System F Fire truck chassis (w/ special PTO)
S FRT/RR rigid axle and air over hydraulic brake 5F Chemical fire truck chassis (w/ side PTO)
FRT/RR rigid axle, RR air suspension and air over Ladder fire truck chassis (w/ flywheel PTO and
T hydraulic brake 6F
side PTO)
U FRT/RR rigid axle and full air brake G Fire truck chassis (w/ flywheel PTO)
FRT/RR rigid axle, RR air suspension and full air M Mixer chassis (w/ flywheel PTO)
V brake H High place work truck chassis (w/ side PTO)
N Concrete pump chassis (w/ side full power PTO)
⑥ Steering Location P Garbage truck chassis (w/ side PTO)
U Right hand drive (RHD)
L Left hand drive (LHD)
Chapter 2
⑩ Engine horse power version ⑪ Destination 2/2

N Multiple horse power/ Low horse power N Canada
C Multiple horse power/ Medium horse power P Thailand
S Multiple horse power/ High horse power PA Pakistan
H Multiple horse power/ Ultimate horse power PE Peru
PH Philippines
R Taiwan
⑪ Destination 1/2
RG Argentine
—
General export S Gulf countries
(No code)
B Egypt [Budget (US only)] SP Singapore
BA Bangladesh U Russia
BR Brazil UZ Uzbekistan
C China V New Zealand
CH Chile VT Vietnam
CL Colombia X Venezuela
Y Kenya
CO Costa Rica
Z South Africa
D California
E Europe
ED Ecuador ⑫ Others
F USA (including its dependencies) -E Rear overhang-lengthened vehicle
G Turkey -P Automatic transmission
H Australia -V Delivery van base vehicle
I India
IN Indonesia
IR Iran
IS Israel
K Hong Kong
L Algeria
ME East Malaysia
MO Morocco
MW West Malaysia
MX Mexico
Chapter 2
2-2 CAB NAME AND BASIC SPECIFICATIONS
CAB * SINGLE CAB

CAB TYPE WIDTH CREW CAB
(mm) Bed less Sleeper
NKR/QKR 1,695
STD
1X 1,695
STD
2X 1,770
STD
3X 1,995
STD
4X 2,120
STD
5X 2,320
STD
C&E-series 2,420
High roof
*: CAB WIDTH shows most outer width of cab panel.

Confirm "Ⅱ-9-1 CAB CHASSIS DRAWINGS" for overall width of the vehicle.
Chapter 2
2-3 PRINCIPAL SPECIFICATIONS OF THE CAB CHASSIS

The specifications given herein are based on the latest information available at the time this guide is released, and may be changed at any time without prior notice. For inquiry of latest information, contact the ISUZU distributor or ISIZU dealership.
Main specification table (1/6)

Vehicle Model FXR77UU-RDSH FXR77VU-RDSH FXR77VU-RDSH-P FXR77VU-SDSH Remarks
GVM kg 16,500 16,500 16,500 16,500
GCM kg (36,000) (36,000) (36,000) (36,000) GCM is a reference value.
FRT kg 6,600 6,600 6,600 6,600 Refer to “Ⅱ-4-1” as for
Axle Capacity
RR kg 10,400 10,400 10,400 10,400 GALR details.
Wheelbase mm 5,740 5,740 5,740 6,200 Refer to "Ⅱ-9-1"
FRT mm 2,025 2,025 2,025 2,025
Tread
RR mm 1,840 1,840 1,840 1,840
Steering Angle Inner (Outer) 40°(33°) 40°(33°) 40°(33°) 40°(33°)
Type 6UZ1-TCC 6UZ1-TCC 6UZ1-TCC 6UZ1-TCC
Emission EuroV EuroV EuroV EuroV
(Exh depurator) (DOC) (DOC) (DOC) (DOC)
Engine
Displacement cc 9,839 9,839 9,839 9,839
Max Power kW/rpm 257 / 2,000 257 / 2,000 257 / 2,000 257 / 2,000
Max Torque N･m/rpm 1,422 / 1,400 1,422 / 1,400 1,422 / 1,400 1,422 / 1,400
Frame width mm 950-850 950-850 950-850 950-850 Refer to "Ⅱ-10-1"
Transmission ZF9S1310TO ZF9S1310TO ALLISON4430 ZF9S1310TO
AMT －－－－
PTO N/A N/A N/A N/A
Final Gear Ratio 4.555 4.555 4.888 4.555
FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149
Tire FRT&RR
RR:11R22.5-148/145 RR:11R22.5-148/145 RR:11R22.5-148/145 RR:11R22.5-148/145
Disc Wheel FRT&RR 22.5x8.25-165(Steel) 22.5x8.25-165(Steel) 22.5x8.25-165(Steel) 22.5x8.25-165(Steel)
System Full Air Full Air Full Air Full Air
Park Brake Wheel Park Wheel Park Wheel Park Wheel Park
ABS STD STD STD STD
Brake ASR N/A N/A N/A N/A
EXH Brake STD STD STD STD
LSPV N/A N/A N/A N/A
HSA N/A N/A N/A N/A
Driver STD STD STD STD
SRS
Driver and Passenger N/A N/A N/A N/A
Safety&Economy Device
FUP STD STD STD STD
ESC (Including ABS/ASR system) N/A N/A N/A N/A
Air Tank Capacity (L) x Quantity (27)x4+(5)x1 (27)x4+(5)x1 (27)x4+(5)x1 (27)x4+(5)x1
FRT Taper-Leaf Taper-Leaf Taper-Leaf Taper-Leaf
Suspension Main:Multi-Leaf Refer to "Ⅱ-5-1"
RR 2-Bag Air 2-Bag Air 2-Bag Air
Helper:Multi-Leaf
Fuel Tank Capacity L 400 400 400 400 Refer to "Ⅱ-3-4"
Between Ft and Rr Axles Between Ft and Rr Axles Between Ft and Rr Axles Between Ft and Rr Axles
EXH Tail Position / Direction Refer to "Ⅱ-9-1"
(Right) / Outside frame (Right) / Outside frame (Right) / Outside frame (Right) / Outside frame
ACG 24V-90A 24V-90A 24V-90A 24V-90A
Battery Capacity 115E41Lx2 115E41Lx2 115E41Lx2 115E41Lx2
Crew 3 3 3 3
Cab Type 5X 5X 5X 5X Refer to "Ⅱ-2-2"
Note: N/A is short for "Not available".

Chapter 2

Vehicle Model FXM77VU-UDSH FXZ77UU-PDSH-P FXZ77UU-UDSH FXZ77UU-UDSH-P Remarks
GVM kg 24,000 24,000 24,000 24,000
FRT kg 6,600 6,600 6,600 6,600 Refer to “Ⅱ-4-1” as for
Axle Capacity
RR kg 20,400(2axles total) 18,100(2axles total) 18,100(2axles total) 18,100(2axles total) GALR details.
FRT mm 2,025 2,025 2,025 2,025
Tread
RR mm 1,840 1,840 1,840 1,840
Steering Angle Inner (Outer) 40°(33°) 40°(33°) 40°(33°) 40°(33°)
Engine
Displacement cc 9,839 9,839 9,839 9,839
Max Power kW/rpm 257 / 2,000 257 / 2,000 257 / 2,000 257 / 2,000
Max Torque N･m/rpm 1,422 / 1,400 1,422 / 1,400 1,422 / 1,400 1,422 / 1,400
Transmission ZF9S1310TO ALLISON4430 ZF9S1310TO ALLISON4430
AMT －－－－
PTO N/A N/A N/A N/A
Final Gear Ratio 4.888 5.285 4.875 4.875
FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149
Tire FRT&RR
RR:11R22.5-148/145 RR:11R22.5-148/145 RR:11R22.5-148/145 RR:11R22.5-148/145
Disc Wheel FRT&RR 22.5x8.25-165(Steel) 22.5x8.25-165(Steel) 22.5x8.25-165(Steel) 22.5x8.25-165(Steel)
ABS STD STD STD STD
Brake ASR N/A N/A N/A N/A
HSA N/A N/A N/A N/A
SRS
FUP STD STD STD STD
ESC (Including ABS/ASR system) N/A N/A N/A N/A
Air Tank Capacity (L) x Quantity (27)x5+(5)x1 (27)x4+(5)x1 (27)x5+(5)x1 (27)x5+(5)x1
FRT Taper-Leaf Taper-Leaf Taper-Leaf Taper-Leaf
Suspension Refer to "Ⅱ-5-1"
RR 2-Bag Air Taper-Leaf Taper-Leaf Taper-Leaf
Between Ft and Rr Axles Between Ft and Rr Axles Between Ft and Rr Axles Between Ft and Rr Axles
(Right) / Outside frame (Right) / Outside frame (Right) / Outside frame (Right) / Outside frame
ACG 24V-90A 24V-90A 24V-90A 24V-90A
Battery Capacity 115E41Lx2 115E41Lx2 115E41Lx2 115E41Lx2
Crew 3 3 3 3

Chapter 2

Vehicle Model FXZ77VU-PDSH-P FXZ77VU-UDSH FXZ77VU-UDSH-P Remarks
GVM kg 24,000 24,000 24,000
GCM kg (42,500) (42,500) (42,500) GCM is a reference value.
FRT kg 6,600 6,600 6,600 Refer to “Ⅱ-4-1” as for
Axle Capacity
RR kg 18,100(2axles total) 18,100(2axles total) 18,100(2axles total) GALR details.
Wheelbase mm 4,540 6,010 6,010 Refer to "Ⅱ-9-1"
FRT mm 2,025 2,025 2,025
Tread
RR mm 1,840 1,840 1,840
Steering Angle Inner (Outer) 40°(33°) 40°(33°) 40°(33°)
Type 6UZ1-TCC 6UZ1-TCC 6UZ1-TCC
Emission EuroV EuroV EuroV
(Exh depurator) (DOC) (DOC) (DOC)
Engine
Displacement cc 9,839 9,839 9,839
Max Power kW/rpm 257 / 2,000 257 / 2,000 257 / 2,000
Max Torque N･m/rpm 1,422 / 1,400 1,422 / 1,400 1,422 / 1,400
Frame width mm 950-850 950-850 950-850 Refer to "Ⅱ-10-1"
Transmission ALLISON4430 ZF9S1310TO ALLISON4430
AMT －－－
PTO N/A N/A N/A
Final Gear Ratio 5.285 4.875 4.875
FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149
Tire FRT&RR
RR:11R22.5-148/145 RR:11R22.5-148/145 RR:11R22.5-148/145
Disc Wheel FRT&RR 22.5x8.25-165(Steel) 22.5x8.25-165(Steel) 22.5x8.25-165(Steel)
System Full Air Full Air Full Air
Park Brake Wheel Park Wheel Park Wheel Park
ABS STD STD STD
Brake ASR N/A N/A N/A
EXH Brake STD STD STD
LSPV N/A N/A N/A
HSA N/A N/A N/A
Driver STD STD STD
SRS
Driver and Passenger N/A N/A N/A
FUP STD STD STD
ESC (Including ABS/ASR system) N/A N/A N/A
Air Tank Capacity (L) x Quantity (27)x5+(5)x1 (27)x5+(5)x1 (27)x5+(5)x1
FRT Taper-Leaf Taper-Leaf Taper-Leaf
RR 2-Bag Air 2-Bag Air 2-Bag Air
Fuel Tank Capacity L 400 400 400 Refer to "Ⅱ-3-4"
Between Ft and Rr Axles Between Ft and Rr Axles Between Ft and Rr Axles
(Right) / Outside frame (Right) / Outside frame (Right) / Outside frame
ACG 24V-90A 24V-90A 24V-90A
Battery Capacity 115E41Lx2 115E41Lx2 115E41Lx2
Crew 3 3 3
Cab Type 5X 5X 5X Refer to "Ⅱ-2-2"

Chapter 2

Vehicle Model FYH77UU-TDSH FYH77UU-UDSH-P Remarks
GVM kg 30,000 30,000
GCM kg (42,500) (42,500) GCM is a reference value.
FRT kg 6,600x2 6,600x2 Refer to “Ⅱ-4-1” as for
Axle Capacity
RR kg 18,100(2axles total) 18,100(2axles total) GALR details.
Wheelbase mm 5,770 6,010 Refer to "Ⅱ-9-1"
FRT mm 2,025 2,025
Tread
RR mm 1,840 1,840
FRT:40°(33°) FRT:40°(33°)
Steering Angle Inner (Outer)
RR:34°(29°) RR:34°(29°)
Type 6UZ1-TCC 6UZ1-TCC
Emission EuroV EuroV
(Exh depurator) (DOC) (DOC)
Engine
Displacement cc 9,839 9,839
Max Power kW/rpm 257 / 2,000 257 / 2,000
Max Torque N･m/rpm 1,422 / 1,400 1,422 / 1,400
Frame width mm 950-850 950-850 Refer to "Ⅱ-10-1"
Transmission ALLISON4430 ALLISON4430
AMT －－
PTO N/A N/A
Final Gear Ratio 5.285 5.285
FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149
Tire FRT&RR
RR:11R22.5-148/145 RR:11R22.5-148/145
Disc Wheel FRT&RR 22.5x8.25-165(Steel) 22.5x8.25-165(Steel)
System Full Air Full Air
Park Brake Wheel Park Wheel Park
ABS STD STD
Brake ASR N/A N/A
EXH Brake STD STD
LSPV N/A N/A
HSA N/A N/A
Driver STD STD
SRS
Driver and Passenger N/A N/A
FUP STD STD
ESC (Including ABS/ASR system) N/A N/A
Air Tank Capacity (L) x Quantity (27)x4+(13+26.8)x1 (27)x4+(13+26.8)x1
FRT Taper-Leaf (With Equalizer) Taper-Leaf (With Equalizer)
RR Taper-Leaf Taper-Leaf
Fuel Tank Capacity L 400 400 Refer to "Ⅱ-3-4"
Between Ft and Rr Axles Between Ft and Rr Axles
(Right) / Outside frame (Right) / Outside frame
ACG 24V-90A 24V-90A
Battery Capacity 115E41Lx2 115E41Lx2
Crew 3 3
Cab Type 5X 5X Refer to "Ⅱ-2-2"

Chapter 2

Vehicle Model FYH77VU-RDSH-P FYH77VU-TDSH-P FYH77VU-UDSH FYH77VU-UDSH-P Remarks
GVM kg 30,000 30,000 30,000 30,000
FRT kg 6,600x2 6,600x2 6,600x2 6,600x2 Refer to “Ⅱ-4-1” as for
Axle Capacity
RR kg 18,100(2axles total) 18,100(2axles total) 18,100(2axles total) 18,100(2axles total) GALR details.
FRT mm 2,050 2,045 2,025 2,025
Tread
RR mm 1,860 1,860 1,840 1,840
FRT:40°(33°) FRT:40°(33°) FRT:40°(33°) FRT:40°(33°)
RR:34°(24°) RR:34°(29°) RR:34°(29°) RR:34°(29°)
Engine
Displacement cc 9,839 9,839 9,839 9,839
Max Power kW/rpm 257 / 2,000 257 / 2,000 257 / 2,000 257 / 2,000
Max Torque N･m/rpm 1,422 / 1,400 1,422 / 1,400 1,422 / 1,400 1,422 / 1,400
Transmission ALLISON4430 ALLISON4430 ZF9S1310TO ALLISON4430
AMT －－－－
PTO N/A N/A N/A N/A
Final Gear Ratio 5.285 5.285 4.875 5.285
FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149
Tire FRT&RR 11R22.5-148/145
RR:11R22.5-148/145 RR:11R22.5-148/145 RR:11R22.5-148/145
Disc Wheel FRT&RR 22.5x7.50-162(Aluminum) 22.5x8.25-165(Aluminum) 22.5x8.25-165(Steel) 22.5x8.25-165(Steel)
ABS Included ESC STD STD STD
Brake ASR Included ESC N/A N/A N/A
HSA N/A N/A N/A N/A
SRS
FUP STD STD STD STD
ESC (Including ABS/ASR system) STD N/A N/A N/A
Air Tank Capacity (L) x Quantity (27)x4+(13+26.8)x1 (27)x4+(13+26.8)x1 (27)x4+(13+26.8)x1 (27)x4+(13+26.8)x1
FRT Taper-Leaf (With Equalizer) Taper-Leaf (With Equalizer) Taper-Leaf (With Equalizer) Taper-Leaf (With Equalizer)
RR 2-Bag Air 2-Bag Air 2-Bag Air 2-Bag Air
Between Ft and Rr Axles Between Ft and Rr Axles Between Ft and Rr Axles
EXH Tail Position / Direction Cab back (Left) / Vertical Refer to "Ⅱ-9-1"
(Right) / Outside frame (Right) / Outside frame (Right) / Outside frame
ACG 24V-90A 24V-90A 24V-90A 24V-90A
Battery Capacity 80D26Lx2 115E41Lx2 115E41Lx2 115E41Lx2
Crew 3 3 3 3

Chapter 2

Vehicle Model FYH77VU-WDSH FYH77VU-WDSH-P Remarks
GVM kg 30,000 30,000
GCM kg (42,500) (42,500) GCM is a reference value.
FRT kg 6,600x2 6,600x2 Refer to “Ⅱ-4-1” as for
Axle Capacity
RR kg 18,100(2axles total) 18,100(2axles total) GALR details.
Wheelbase mm 6,700 6,700 Refer to "Ⅱ-9-1"
FRT mm 2,025 2,025
Tread
RR mm 1,840 1,840
FRT:40°(33°) FRT:40°(33°)
RR:34°(29°) RR:34°(29°)
Type 6UZ1-TCC 6UZ1-TCC
Emission EuroV EuroV
(Exh depurator) (DOC) (DOC)
Engine
Displacement cc 9,839 9,839
Max Power kW/rpm 257 / 2,000 257 / 2,000
Max Torque N･m/rpm 1,422 / 1,400 1,422 / 1,400
Frame width mm 950-850 950-850 Refer to "Ⅱ-10-1"
Transmission ZF9S1310TO ALLISON4430
AMT －－
PTO N/A N/A
Final Gear Ratio 4.875 5.285
FRT:295/80R22.5-152/149 FRT:295/80R22.5-152/149
Tire FRT&RR
RR:11R22.5-148/145 RR:11R22.5-148/145
Disc Wheel FRT&RR 22.5x8.25-165(Steel) 22.5x8.25-165(Steel)
System Full Air Full Air
Park Brake Wheel Park Wheel Park
ABS STD STD
Brake ASR N/A N/A
EXH Brake STD STD
LSPV N/A N/A
HSA N/A N/A
Driver STD STD
SRS
Driver and Passenger N/A N/A
FUP STD STD
ESC (Including ABS/ASR system) N/A N/A
Air Tank Capacity (L) x Quantity (27)x4+(13+26.8)x1 (27)x4+(13+26.8)x1
FRT Taper-Leaf (With Equalizer) Taper-Leaf (With Equalizer)
RR 2-Bag Air 2-Bag Air
Fuel Tank Capacity L 400 400 Refer to "Ⅱ-3-4"
Between Ft and Rr Axles Between Ft and Rr Axles
(Right) / Outside frame (Right) / Outside frame
ACG 24V-90A 24V-90A
Battery Capacity 115E41Lx2 115E41Lx2
Crew 3 3
Cab Type 5X 5X Refer to "Ⅱ-2-2"

Chapter 3
PRECAUTIONS FOR REAR BODY MOUNTING Ⅱ SPECIFIC INFORMATION
Chapter 3 PRECAUTIONS FOR REAR BODY MOUNTING

3-1 SRS
3-2 ABS
3-3 ABS/ESC
3-4 INSTALLATION OF THE FUEL TANK
3-5 AIR EXTRACTION
3-6 SUB FRAME FOR VERTICAL EXHAUST
3-7 MODIFICATION OF EXHAUST SYSTEM
3-8 MOUNTING THE PINTLE HOOK
Chapter 3
3-1 SRS
SRS(Supplemental Restraint System) airbag is an auxiliary seatbelt equipment which deploys to
reduce and disperse a shock to occupants’ bodies when the front end of a vehicle gets such a
strong jolt that may seriously harm the driver or the passenger.
For vehicles equipped with SRS airbag, “SRS AIRBAG” is indicated on the center pad of the
steering wheel.
① System components
SRS airbag system consists of SRS control unit, airbag assembly, SRS coil assembly,
pretensioner seatbelt, satellite sensor, SRS airbag warning lamp, and SRS harness that
connects these components. This SRS harness is either wrapped with yellow tube or partially
wrapped with yellow tape.
Location of SRS airbag components
Pretensioner seatbelt
(Attached to the seat)
SRS airbag
SRS coil assembly
SRS warning lamp
SRS control unit Satellite sensor

Chapter 3
WARNING
When mounting a rear body or modifying a chassis, follow the instructions below strictly. Any
works without following these instructions will result in malfunction of airbag when in collision
or unexpected deployment of airbag. Be extremely cautious because such failures can
seriously harm vehicle occupants or plant workers or put their lives at risk.
② Prohibition
・ Disabling or modifying SRS control unit, airbag assembly, SRS coil assembly, pretensioner
seatbelt, satellite sensor, and SRS harness
・ Modifying meter cluster assembly, steering column shaft assembly, floor panels, and side
panels
・ Using an electric tester for diagnosing SRS circuit
・ Connecting a power harness of any other equipment to the airbag fuse
・ Modifying bumper (e.g. Relocating a bumper forward or extending its length)

・ Fitting and protrusion of any components in fore part of a vehicle
- Fitting :Snow plow, winch, spare tire and bush bar, etc.
- Protrusion :Basket of high-place work vehicle and crane boom, etc.
Chapter 3
③ Precaution
・ Before applying heat higher than 85C to a cab in order for welding, painting, etc., remove
airbag assembly, pretensioner seatbelt and SRS control unit. Contact ISUZU distributor or
ISUZU dealership for details on removal of the components.
・ Before modifying any electrical equipments, cab, steering area and steering support bracket
area, detaching SRS control unit, be sure to disconnect the negative battery terminal to cut a
power supply and wait for a minimum of 15 seconds. After completing the work, reconnect
the battery cable.
・ Removed airbag assembly must be put with its horn pad side up at all times.
・ When carrying pretensioner seatbelt, be sure to turn the gas generator part outside the body.
・ Do not drop or give a shock to airbag assembly, SRS control unit, pretensioner seatbelt, and
satellite sensor. If these SRS airbag components are dropped or given any shock, replace
them with new ones even if they do not look damaged.
・ When reconnecting the SRS harness connector, be sure to connect it securely.
・ Do not unnecessarily turn the SRS coil assembly, regardless of whether it is fitted on the
steering wheel or not, because doing so may damage a harness inside the assembly. Even
when it needs to be turned, do not turn it either way more than three times from neutral point.
・ Before disconnecting the joint of the steering shaft from the steering unit in order to mount or
dismount a cab or for other reasons, be sure to lock the starter key switch. If the joint is
disconnected without locking the starter key switch and with the steering wheel unremoved,
the steering shaft turns due to the self weight of the steering wheel, possibly breaking the
SRS coil assembly.
・ Before putting the steering wheel back in place, be sure that the front wheels are facing
straight forward, and to align the turning part of the SRS coil assembly with the neutral point.
- To align the adjustment mark (△) with the neutral point mark (◇), fully turn the turning part
of the SRS coil assembly clockwise and then turn it counterclockwise approximately 3.3
times.
SRS coil assembly with the neutral point
neutral point mark (◇) adjustment mark (△)

Chapter 3
・ Since every SRS airbag component is paired with a vehicle number, if you remove any SRS
airbag component, be sure to put it back on its mating vehicle.
・ For replacing or disposing of the airbag assembly, or dismantling the SRS airbag installed
vehicle, contact ISUZU distributor or ISUZU dealership at all times.
・ For detailed information on SRS airbag system, refer to the instruction manual or the repair
manual, or contact ISUZU distributor or ISUZU dealership.
・ When putting SRS airbag components back in place, tighten their bolts with the following
tightening torque.
SRS control unit
Fixing nut:SRS control unit
Tightening torque:
10.0±2.0Nm{1.0±0.2kgfm}
Airbag for driver’s seat
Airbag
Driver’s seat airbag is fitting type.

Confirm after installation that the
airbag is fit firmly.
Steering wheel
Note: The airbag shown here is an example.

Chapter 3
3-2 ABS
ABS (Anti-lock Brake System) prevents the wheels from being locked or slipping when a vehicle
is braked, so as to assure safety and steering performance of the vehicle. (Refer to "Ⅱ-2-3
PRINCIPAL SPECIFICATIONS OF THE CAB CHASSIS" for development on each vehicle of this
equipment.)
① Prohibition
・ Modifying pipes between modulator and brake
(extending/shortening/changing inner diameter)
・ Modifying electrical harness and connector of ABS
・ Modifying ABS control unit and valves
・ Running with combination of tires other than ISUZU factory specification
- ABS is controlled based on the rotational speed difference of front and rear tires under
braking, and a set value of the tire diameter is memorized in the control unit.
- When the diameter of tire change greatly or the difference between front and rear tire
differs from the set value, necessary braking power may not be demonstrated or ABS may
not operate normally.
- Contact ISUZU distributor or ISUZU dealership when changing the tire.
・ Extracting power of accessories and ground cable from ABS apparatus wires
Chapter 3
② Precaution
・When performing electrical welding at body mounting, follow the instructions in "Ⅰ-2-5
PRECAUTIONS FOR WELDING".
・ When installing following components in the vicinity of ABS apparatus (ABS control unit,
modulator, speed sensor, etc.), maintain more than 100mm clearance from them.
- Radio machine and its antenna
- Motor, relay, and other devices which generate noise
・ Circuit for ABS apparatus is in vehicle harness. Do not place cable for wireless antenna along
with vehicle harness, since it might affect the ABS circuit.
・ ABS control unit is located close to center console. Do not pour water directly on to the unit
while cleaning cab interior.
・ABS does not operate normally when the exhaust port of the modulator is closed. Note that
the exhaust port of the modulator might not be closed with the body equipment.
- When installing the body equipment in the vicinity of the modulator, do not arrange it
where snow, ice, and the extraneous material collect. (Secure the space between the
modulator and the lower part of the inner side of chassis frame as the factory shipment.)
- When the sediment occurs in the vicinity of the modulator and the exhaust port might be
closed, properly install the covers.
・When installing the body equipment which generates heat at work in the vicinity of the
modulator, install the body equipment apart from the modulator or install the cover board.
(80°C or less on the surface of the modulator.)
Chapter 3
ABS system (FXR)
ABS control unit

Air tank
Brake valve
Air tank
Relay valve Speed sensor
Speed sensor
Quick release
valve
Do not change Do not change

the pipe length and the pipe length and
inner diameter. Modulator Modulator inner diameter.
Air piping
Electric circuit Speed sensor Speed sensor
Front wheel brake Rear wheel brake
Component layout (FXR)
Quick release Front speed Rear speed

valve Modulator Modulator
sensor sensor
Relay valve
ABS control unit Front speed Rear speed

Modulator Modulator
(Inside the cab) sensor sensor
This system location is one example.

Chapter 3
ABS system (FXM/FXZ)
ABS control unit

Air tank
Brake valve
Air tank
Relay valve Speed sensor
Speed sensor
Quick release
valve

Air piping
Electric circuit Speed sensor Relay valve
Speed sensor
Front wheel brake
Rear wheel brake
Component layout (FXM/FXZ)
Quick release Front speed Rear speed

Modulator Relay valve x2
valve sensor sensor

Modulator Modulator x２

Chapter 3
ABS system (FYH)
ABS control unit

Air tank
Air piping
Brake valve
Electric circuit
Air tank
Speed sensor Relay valve Speed sensor
Relay valve

Relay valve
Speed sensor
Speed sensor
Component layout (FYH)

Modulator Relay valve Relay valve x2
Front speed Rear speed

Modulator Relay valve Modulator x2
sensor sensor

Chapter 3
3-3 ABS/ESC
ABS (Anti-lock Brake System) prevents the wheels from being locked or slipping when a vehicle
is braked, so as to assure safety and steering performance of the vehicle. ESC (Electronic
Stability Control) suppresses the wheel spin by electronically controlling the engine power and the
brake power when running and accelerating in a slippery road, and contributes to the prevention
of slipping sideways. (Refer to "Ⅱ-2-3 PRINCIPAL SPECIFICATIONS OF THE CAB CHASSIS"
for development on each vehicle of this equipment.)
① Prohibition
・ Modifying pipes between relay valve and brake

(extending/shortening/changing inner diameter)
・ Modifying electrical harness and connector of ABS/ESC
・ Modifying ABS/ESC control unit and valves
・Running with combination of tires other than ISUZU factory specification
- ABS/ESC is controlled based on the rotational speed difference of front and rear tires
under braking, and a set value of the tire diameter is memorized in the control unit.
- When the diameter of tire change greatly or the difference between front and rear tire
differs from the set value, necessary braking power may not be demonstrated or ABS/ESC
may not operate normally.
- Contact ISUZU distributor or ISUZU dealership when changing the tire.
・Setting final gear ratio other than ISUZU factory specification
- The set value of the final gear ratio is memorized in the ABS/ESC control unit. When the
final gear ratio is changed, ABS/ESC may not operated normally.
・ Extracting power of accessories and ground wiring from ABS/ESC apparatus wirings
・ Relocation and changing installation direction of yaw rate sensor
- Position of yaw rate sensor has restriction between the wheelbase and the vehicle center
of gravity position, and has directionality. Normal operation of ESC might be ruined when
relocating it.
・ Changing wheelbase
- Changing wheelbase may impair the ESC control.
・ Modifying to the full tractor
- The movement of the vehicle might be disturbed at the time of ESC operation.
Chapter 3
② Precaution
・When performing electrical welding at body mounting, follow the instructions in "Ⅰ-2-5
PRECAUTIONS FOR WELDING".
・ When installing following components in the vicinity of ABS/ESC apparatus (ABS/ESC
control unit, modulator, relay valve, ASR valve, speed sensor, yaw rate sensor, etc.),
maintain more than 100mm clearance from them.
- Radio machine and its antenna
- Motor, relay, and other devices which generate noise
・ Circuit for ABS/ESC apparatus is in vehicle harness. Do not place wiring for wireless antenna
along with vehicle harness, since it might affect the ABS/ESC wiring.
・ ABS/ESC control unit is located close to center console. Do not pour water directly on to the
unit while cleaning cab interior.
・ ABS/ESC does not operate normally when the exhaust port of the modulator/relay valve is
closed. Brakes might drag it when the exhaust port of the ASR valve is closed. Note that the
exhaust port of the modulator/relay valve/ASR valve might not be closed with the body
equipment.
- When installing the body equipment in the vicinity of the modulator/relay valve/ASR valve,
do not arrange it where snow, ice, and the extraneous material collect. (Secure the space
between the modulator/relay valve/ASR valve and the lower part of the inner side of the
chassis frame as the factory shipment.)
- When the sediment occurs in the vicinity of the modulator/relay valve/ASR valve and the
exhaust port might be closed, properly install the cover.
・When installing the body equipment which generates heat at work in the vicinity of the
modulator/relay valve/ASR valve, install the body equipment apart from the modulator/relay
valve/ASR valve or install the cover board. (80°C or less on the surface of the modulator/relay
valve/ASR valve.)
・ The calibration of the ESC is needed when replacing and removing the following
components. Contact ISUZU distributor or ISUZU dealership for details.
- Replacing ABS/ESC control unit and yaw rate sensor
- Replacing steering sensor and steering related components
- Removing steering wheel
Chapter 3
ABS/ESC system
Pressure sensor ABS/ESC control unit

Air tank Air piping
Brake valve Electric circuit
ASR valve
Air tank
Speed sensor Relay valve Speed sensor
Relay valve

Yaw rate sensor Relay valve

Speed sensor
Speed sensor
Component layout
ASR valve ASR valve Modulator x2

ABS/ESC control unit Front speed Rear speed
(Inside the cab) sensor Modulator Relay valve
sensor
Front speed Rear speed

sensor Modulator Relay valve
sensor
Yaw rate sensor Relay valve

Chapter 3
3-4 INSTALLATION OF THE FUEL TANK

When the fuel tank is detached for body installation, follow the below instruction for restoration.
For relocating the fuel tank, refer to "Ⅰ-2-10 RELOCATION AND ADDITION OF A FUEL TANK ".
(Refer to "Ⅱ-2-3 PRINCIPAL SPECIFICATIONS OF THE CAB CHASSIS" for development on
each vehicle of this equipment.)
① Prohibition
・ Installing any components on the fuel tank bracket, such as a stay or a side guard for rear
body
② Precaution
・ Secure sufficient clearance of the fuel tank from the exhaust pipe and the silencer.
・ If sufficient clearance of the fuel tank from the exhaust pipe and the silencer can not be
secured, install a heat protector to protect the fuel tank from heat.
・ For the fuel tank installing, refer to drawing shown later. The dimension between the fuel tank
brackets, observe L dimension strictly. After relocate the fuel tank, tighten band nut by
specific torque securely.
Chapter 3
③ Band tightening
・400L fuel tank
Detail of band tightening
L 275
PLAN VIEW
As shown in the figure, locate the band
edge so as to be hide the 333 mark.
TIGHTENING NUT BRACKET
LOCK NUT BOLT

(BAND ASM)
Note: This is a simplified image of a fuel tank.
Fuel tank capacity L (mm) Nut size Tightening torque

Tightening nut : 35.5 to 39.5 N・m
400L 470 M14 (Double nut)
Lock nut : 95.0 to 115.0 N・m
Note: ・ Nut can be reused.

・ Hold the band to prevent from turning, and tighten the nut. After tightening the nut, hold
the nut with spanner and tighten the locknut.
Chapter 3
・200L fuel tank
Detail of band tightening
L 148
As shown in the figure, locate the band edge

so as not to be hide the two marks.
TIGHTENING NUT BRACKET
LOCK NUT BOLT

(BAND ASM)
Note: This is a simplified image of a fuel tank.
Fuel tank capacity L (mm) Nut size Tightening torque

Tightening nut : 14.7 to 19.6N・m
200L 218 M10 (Double nut)
Lock nut : 17.6 to 23.5N・m
Note: ・ Nut can be reused.

・ Hold the band to prevent from turning, and tighten the nut. After tightening the nut, hold
the nut with spanner and tighten the locknut.
Chapter 3
④ Breather hose
・200L fuel tank
- The oblique section end of breather hose should be inserted inside the chassis frame side
member through the same hole as the fuel hose.
- As shown below, align the breather hose along with fuel hose, and fasten them together
with band clips outside the chassis frame side member. Likewise, inside the chassis frame
side member, fasten the breather hose with harness or nylon tube.
- The end of breather hose on the inside of chassis frame should be turned below.
- The end of breather hose should not contact lower part of the inner side of chassis frame.
Location of breather hose
Front
Breather hose
Clip;band
Chapter 3
3-5 AIR EXTRACTION

Extract air to use in a rear body from the air tank for accessory which connects to the port 24 of
the multi protection valve.
① Prohibition
・Extracting air from any other than the air tank for accessory
② Precaution
・The air pressure can be used in the range of 690 to 784 kPa.
・The recommended connector in case of the use of nylon tube, use the part number as
shown in the drawing.
・ For prevention of air leak, apply a sealant (LOCTITE575 or equivalent) to the taper threaded
end of the connector.
- For prevention of air leak, do not fill air for more than 2 hours after tightening connector.
Location of air extraction (FXR/FXM/FXZ)
Front
A
Front
Air extraction mouth VIEW A

plugged with R3/8
Part No. of connectors recommended
for used of nylon tube
109660-9590 (φ12)
109660-9570 (φ8)
109661-2340 (φ6)
Chapter 3
Location of air extraction (FYH77UU-R/T/U,FYH77VU-R/T/U)
Front Front
Air extraction mouth

VIEW A
Example of air extract connector modifying (FYH77UU-R)

CONNECTOR
Part No. of connectors recommended
109660-9560 (φ 8)
for used of nylon tube
CONNECTOR CONNECTOR
109660-9560 (φ 8) 109661-1320(φ12 )
CONNECTOR CONNECTOR
109661-1320(φ12 ) 109661-3000
CONNECTOR CONNECTOR
109650-4941 109660-9650 (φ12)
PACKING 109660-9640 (φ8)
909571-4220 109661-1340 (φ6)
M22×1.5 CONNECTOR
109650-4941
PACKING
909571-4220
Example of air extract connector modifying (FYH77UU-T/U,FYH77VU-R/T/U)

Part No. of connectors recommended CONNECTOR
for used of nylon tube 109660-9580 (φ12)
109660-9560 (φ 8)
109661-0670 (φ6 )
CONNECTOR CONNECTOR
109661-4970(φ12 ) 109661-1320(φ12 )
CONNECTOR
109650-4941
M22×1.5 PACKING
909571-4220
Chapter 3
Location of air extraction (FYH77VU-W)

A
Front
Front
Air extraction mouth
VIEW A
Example of air extract connector modifying

CONNECTOR
109660-9580 (φ12)
Part No. of connectors recommended 109660-9560 (φ 8)
for used of nylon tube 109661-0670 (φ6 )
CONNECTOR CONNECTOR
109661-4970(φ12 ) 109661-1320(φ12 )
CONNECTOR
109650-4941
M22×1.5
PACKING
909571-4220
Chapter 3
・For safety purpose, provide a 690kPa limited protection valve somewhere between the air
extraction port on the chassis side and the mating equipment on a rear body. (protection
valve Part number： 148110-1841)
- Install the protection valve so that the exhaust port faces downward as shown below, so
that water does not enter.
Addition of protection valve
Protection valve
(Intenal thread Rc1/4)
Rear body
Chassis
equipment
＜Detail of protection valve＞

Air outlet
Rear body
equipment
31 33 Rc1/4 70
8.5 Tightening torque:
5 to 16 N・m
2-Φ8.5
29
30
Air inlet
Chassis
Approx. 170
Exhaust port
Chapter 3
3-6 SUB FRAME FOR VERTICAL EXHAUST

To avoid contact with the vertical exhaust silencer installation stay, end shape of the sub frame is
recommended to be examined with (c) type in "Ⅰ-3-3 SUB FRAME SIDE MEMBERS“.
Chapter 3
3-7 MODIFICATION OF EXHAUST SYSTEM

Modification of exhaust system is basically prohibited in consideration of adverse influence to
noise regulation, engine performance and fire prevention.
If change related to the exhaust is necessary at mounting rear body, follow the local regulations.
Contact ISUZU distributor or ISUZU dealership for details.
Chapter 3
3-8 MOUNTING THE PINTLE HOOK

When mounting the pintle hook to use the vehicle as a full tractor, follow the instructions below.
① Precaution
・ Overall length and weight of the vehicle, follow the local regulations.
・ Decide the mounting location and the specifications of pintle hook, in consideration of the
specifications of the trailer.
・ The frame rear end does not consider mounting the pintle hook. When mounting pintle hook,
add enough reinforcement to rear end of the frame.
Chapter 4
WEIGHT DATA AND FRAME STRENGTH CALCULATION Ⅱ SPECIFIC INFORMATION
Chapter 4 WEIGHT DATA AND FRAME STRENGTH CALCULATION

4-1 CAB CHASSIS WEIGHT AND AXLE LOAD CAPACITY
4-2 WEIGHT DISTRIBUTION
4-3 FRAME SECTION MODULUS
Chapter 4
4-1 CAB CHASSIS WEIGHT AND AXLE LOAD CAPACITY
FXR
Vehicle model FXR77UU-RDSH FXR77VU-RDSH FXR77VU-RDSH-P FXR77VU-SDSH
Disc wheel Steel Steel Steel Steel

Cab Front axle CAWf 4,135 4,145 4,320 4,195
chassis
Rear axle CAWr 2,145 2,010 2,035 1,985
weight
(kg) Total 6,280 6,155 6,355 6,180
Axle load Front axle 6,600
capacity
(kg) Rear axle 10,400
FRT:295/80R22.5-152/149
Tire size
Tire load RR:11R22.5-148/145
capacity Front axle 6,940 *
(kg)
Rear axle 11,330 *
GVM (kg) 16,500
GCM (kg) (36,000)
GALR Front axle 6,600

(kg) Rear axle 10,400
・ GCM is a reference value.

・ GALR is the lightest load capacity determined by comparing the axle load capacity and the tire
load capacity.
・ The cab chassis weight depends on the following conditions.
- The weight includes specified amount of fluid (fuel, coolant, oil), spare tire and required
tools.
・ The cab chassis weight listed above may be different from the actual weight of each vehicle
specification. Measure the weight before conducting rear body mounting, if required.
・ Tire load capacity comply with ETRTO (The European Tyre and Rim Technical Organisation).
・ The maximum inflation pressure of the tire is limited to 825kPa by ADR. * is the value of the
tire load capacity at setting tire air pressure in 825kPa.
Chapter 4
FXM/FXZ(1/2)
Vehicle model FXM77VU-UDSH FXZ77UU-PDSH-P FXZ77UU-UDSH FXZ77UU-UDSH-P

Front axle CAWf 4,125 4,370 4,160 4,355
Cab Rear axle CAWr 3,190 3,470 3,660 3,685
chassis
Rr axle (front) CAWfr 1,740 1,795 1,895 1,905
weight
(kg) Rr axle (rear) CAWrr 1,450 1,675 1,765 1,780
Total 7,315 7,840 7,820 8,040
capacity
(kg) Rear axle 20,400(2axles total) 18,100(2axles total)
FRT:295/80R22.5-152/149
Tire size
Tire load RR:11R22.5-148/145
(kg)
Rear axle 22,660(2axles total) *
GVM (kg) 24,000
GCM (kg) (36,000) (42,500)

(kg) Rear axle 20,400(2axles total) 18,100(2axles total)

load capacity.
tools.
Chapter 4
FXZ(2/2)
Vehicle model FXZ77VU-PDSH-P FXZ77VU-UDSH FXZ77VU-UDSH-P
Disc wheel Steel Steel Steel

Front axle CAWf 4,305 4,145 4,330
Cab Rear axle CAWr 3,255 3,430 3,460
chassis
Rr axle (front) CAWfr 1,690 1,780 1,795
weight
(kg) Rr axle (rear) CAWrr 1,565 1,650 1,665
Total 7,560 7,575 7,790
capacity
(kg) Rear axle 18,100(2axles total)
FRT:295/80R22.5-152/149
Tire size
Tire load RR:11R22.5-148/145
(kg)
GVM (kg) 24,000
GCM (kg) (42,500)

(kg) Rear axle 18,100(2axles total)

load capacity.
tools.
Chapter 4
FYH(1/3)
Vehicle model FYH77UU-TDSH-P FYH77UU-UDSH-P
Disc wheel Steel Steel

Front axle CAWf 5,855 5,885
Ft axle (front) CAWff 2,930 2,945
Cab Ft axle (rear) CAWrf 2,925 2,940
chassis
Rear axle CAWr 2,930 3,100
weight
(kg) Rr axle (front) CAWfr 1,530 1,615
Rr axle (rear) CAWrr 1,400 1,485
Total 8,785 8,985
Front axle 13,200
Axle load Ft axle (front) 6,600
capacity
(kg) Ft axle (rear) 6,600
Rear axle 18,100(2axles total)
FRT:295/80R22.5-152/149
Tire size
RR:11R22.5-148/145
Tire load Front axle 13,880 *
capacity Ft axle (front) 6,940 *
(kg)
Ft axle (rear) 6,940 *
GVM (kg) 30,000
GCM (kg) (42,500)
Front axle 13,200
GALR Ft axle (front) 6,600


load capacity.
tools.
Chapter 4
FYH(2/3)
Vehicle model FYH77VU-RDSH-P FYH77VU-TDSH-P
Disc wheel Aluminum Aluminum

Front axle CAWf 5,870 5,820
Ft axle (front) CAWff 2,940 2,915
Cab Ft axle (rear) CAWrf 2,930 2,905
chassis
Rear axle CAWr 2,415 2,655
weight
(kg) Rr axle (front) CAWfr 1,270 1,395
Rr axle (rear) CAWrr 1,145 1,260
Total 8,285 8,475
Front axle 13,200
capacity
FRT:295/80R22.5-152/149
Tire size 11R22.5-148/145
RR:11R22.5-148/145
Tire load Front axle 12,320 * 13,880 *
capacity Ft axle (front) 6,160 * 6,940 *
(kg)
Ft axle (rear) 6,160 * 6,940 *
GVM (kg) 30,000
GCM (kg) (42,500)
Front axle 12,320 13,200
GALR Ft axle (front) 6,160 6,600

(kg) Ft axle (rear) 6,160 6,600

load capacity.
tools.
Chapter 4
FYH(3/3)
Vehicle model FYH77VU-UDSH FYH77VU-UDSH-P FYH77VU-WDSH FYH77VU-WDSH-P

Front axle CAWf 5,655 5,865 5,620 5,825
Ft axle (front) CAWff 2,830 2,940 2,815 2,915
Cab Ft axle (rear) CAWrf 2,825 2,925 2,805 2,910
chassis
Rear axle CAWr 2,870 2,860 2,955 2,950
weight
(kg) Rr axle (front) CAWfr 1,500 1,495 1,540 1,540
Rr axle (rear) CAWrr 1,370 1,365 1,415 1,410
Total 8,525 8,725 8,575 8,775
Front axle 13,200
capacity
FRT:295/80R22.5-152/149
Tire size
RR:11R22.5-148/145
Tire load Front axle 13,880 *
capacity Ft axle (front) 6,940 *
(kg)
Ft axle (rear) 6,940 *
GVM (kg) 30,000
GCM (kg) (42,500)
Front axle 13,200
GALR Ft axle (front) 6,600


load capacity.
tools.
Chapter 4
4-2 WEIGHT DISTRIBUTION

① Formula for determining load distribution (2 axle vehicle・single cab)
The assumption condition of this calculating formula is as follows.
・ Assume that the center of gravity of the total weight of the rear body and cargo is located in
the center of the overall length of the rear body.
2 axle vehicle ・ single cab

CW
CPa CP
BW+PL
L/2 L/2
OS
WB
CAWf CAWr
GALf GALr
WB: Wheelbase (mm)…Refer to "Ⅱ-9-1"

OS: Offset of the combined center of gravity of the rear body and cargo
from the rear axle center (mm)
CP: Distance from occupant to the rear axle center (mm)
CPa: Distance from occupant to the front axle center (mm)
L/2: Half length of the cargo bed (mm) Vehicle model CPa(mm)
BW: Rear body weight (kg) FXR 323
PL: Cargo weight (kg)
CW: Occupants weight (kg)
CAWf: Chassis front axle weight (kg) Refer to "Ⅱ-4-1"
CAWr: Chassis rear axle weight (kg)
GALf: Vehicle front axle load (kg)
GALr: Vehicle rear axle load (kg)
GVM: Gross vehicle mass (kg)
Basic formula
(a) GVM =GALf+GALr
=CAWf+CAWr+BW+PL+CW
(b) GALf =CAWf+{(BW+PL)xOS/WB}+(CWxCP/WB)
=CAWf+{(BW+PL)xOS/WB}+{CWx(CPa+WB)/WB}
(c) GALr =GVM-GALf
Chapter 4
② Formula for determining load distribution (3 axle vehicle)

・The load on the spring to front and rear axle of the rear axles is distributed in 1:1.
・Assume that the center of gravity of the total weight of rear body and cargo is located in the
center of the overall length of rear body.
3 axle vehicle
CW
CP
CPa BW+PL
L/2 L/2
OS
d/2 d/2
CAWfr CAWrr
GALfr GALrr
DAC
CAWf CAWr
GALf GALr
DAC: Distance from the front axle center to the rear tandem center (mm)…Refer to "Ⅱ-9-1 "
OS: Offset of the combined center of gravity of the rear body and cargo from the rear
tandem center (mm)
CP: Distance from occupant to the rear tandem center (mm)
L/2: Half length of the cargo bed (mm) Vehicle model CPa(mm)
BW: Rear body weight (kg) FXM
323
PL: Cargo weight (kg) FXZ

CAWf: Chassis front axle weight (kg)
CAWr: Gross chassis rear axles weight (kg) Refer to "Ⅱ-4-1"
CAWfr: Chassis rear axle (front) weight (kg)
CAWrr: Chassis rear axle (rear) weight (kg)
GALf: Vehicle front axle load (kg)
GALr: Gross vehicle rear axles load (kg)
GALfr: Vehicle rear axle (front) load (kg)
GALrr: Vehicle rear axle (rear) load (kg)
Chapter 4
A: Total of unsprung weight of rear 2 axles (B+C=A) (kg)

B: Unsprung weight of rear axle (front) (kg)
C: Unsprung weight of rear axle (rear) (kg)
Vehicle model Tire Disc Wheel A (kg) B (kg) C (kg)

FXM77VU 11R22.5 Steel 1,890 1,090 800
FXZ77UU 11R22.5 Steel 2,185 1,155 1,030
FXZ77VU 11R22.5 Steel 2,385 1,255 1,130
Basic formula
(a) GVM =GALf+GALr
=CAWf+CAWr+BW+PL+CW
=CAWf+(CAWfr+CAWrr)+BW+PL+CW
(b) GALf =CAWf+{(BW+PL)xOS/DAC}+(CWxCP/DAC)
=CAWf+{(BW+PL)xOS/DAC}+{CWx(CPa+DAC)/DAC}
(c) GALr =GVM-GALf
(d) GALfr ={(GALr-A)x1/2}+B
(e) GALrr ={(GALr-A)x1/2}+C
Chapter 4
③ Formula for determining load distribution (4 axle vehicle with the equalized suspension in the
previous 2axles.)

・The load on the spring to front and rear axle of the front and rear axles is distributed in 1:1.
・Assume that the center of gravity of the rear body and cargo is located in the center of the
overall length of the cargo bed.
4 axle vehicle
CW
CP
CPa BW+PL
L/2 L/2
OS
s/2 s/2 d/2 d/2

CAWff CAWrf CAWfr CAWrr
GALff GALrf GALfr GALrr
DCC
CAWf CAWr
GALf GALr
DCC: Distance from the center between the front axles to the center between the rear
axles (mm) …Refer to "Ⅱ-9-1"
OS: Offset of the combined center of gravity of the rear body and cargo from the center
between the rear axles (mm)
CP: Distance from occupant to the center between the rear axles (mm)
L/2: Half length of the cargo bed (mm)
s/2: Half length of the distance between the center of the front axles (mm) ) …Refer to
"Ⅱ-9-1"
Vehicle model CPa(mm)
BW: Rear body weight (kg)
FYH 323
PL: Cargo weight (kg)
CAWf: Gross chassis front axles weight (kg)
CAWff: Chassis front axle (front) weight (kg)
CAWrf: Chassis front axle (rear) weight (kg)
CAWr: Gross chassis rear axles weight (kg) Refer to "Ⅱ-4-1"
CAWfr: Chassis rear axle (front) weight (kg)
CAWrr: Chassis rear axle (rear) weight (kg)
GALf: Gross vehicle front axles load (kg)
GALff: Vehicle front axle (front) load (kg)
GALrf: Vehicle front axle (rear) load (kg)
Chapter 4
GALr: Gross vehicle rear axles load (kg)

GALfr: Vehicle rear axle (front) load (kg)
GALrr: Vehicle rear axle (rear) load (kg)
Af: Total of unsprung weight of front 2 axles (Bf+Cf=Af) (kg)

Bf: Unsprung weight of front axle (front) (kg)
Cf: Unsprung weight of front axle (rear) (kg)
Vehicle model Tire Disc Wheel Af (kg) Bf (kg) Cf (kg)

FYH77UU 295/80R22.5 Steel 1,540 775 765
11R22.5 Aluminum 1,430 720 710
FYH77VU Steel 1,540 775 765
295/80R22.5
Aluminum 1,500 755 745
Note：Af,Bf,Cf is a value with standard specification.
Ar: Total of unsprung weight of rear 2 axles (Br+Cr=Ar) (kg)

Br: Unsprung weight of rear axle (front) (kg)
Cr: Unsprung weight of rear axle (rear) (kg)
Vehicle model Tire Disc Wheel Ar (kg) Br (kg) Cr (kg)

FYH77UU 11R22.5 Steel 2,230 1,180 1,050
Steel 2,205 1,170 1,035
FYH77VU 11R22.5
Aluminum 2,115 1,125 990
Note：Ar,Br,Cr is a value with standard specification.
Basic formula
(a) GVM =GALf+GALr
=CAWf+CAWr+BW+PL+CW
=(CAWff+CAWrf)+(CAWfr+CAWrr)+BW+PL+CW
(b) GALf =CAWf+{(BW+PL)OS/DCC}+(CWCP/DCC)
=CAWf+{(BW+PL)OS/DCC}+{ CWx(CPa+(s/2)+DCC)/DCC)}
(c) GALr =GVM-GALf
(d) GALff ={(GALf-Af)1/2}+Bf
(e) GALrf ={(GALf-Af)1/2}+Cf
(f ) GALfr ={(GALr-Ar)1/2}+Br
(g) GALrr ={(GALr-Ar)1/2}+Cr
Chapter 4
4-3 FRAME SECTION MODULUS

FXR
Rear suspension
No. Vehicle model Drawing
Leaf Air
1 FXR77UU-RDSH ○ — Fig.4-3-1
2 FXR77VU-RDSH — ○
Fig.4-3-2
3 FXR77VU-RDSH-P — ○
4 FXR77VU-SDSH — ○ Fig.4-3-3
FXM/FXZ
Rear suspension
Leaf Air
5 FXZ77UU-PDSH-P ○ — Fig.4-3-4
6 FXZ77UU-UDSH ○ —
Fig.4-3-5
7 FXZ77UU-UDSH-P ○ —
8 FXZ77VU-PDSH-P — ○ Fig.4-3-6
9 FXM77VU-UDSH — ○
10 FXZ77VU-UDSH — ○ Fig.4-3-7
11 FXZ77VU-UDSH-P — ○
FYH
Rear suspension
Leaf Air
Fig.4-3-9
14 FYH77UU-TDSH-P ○ —
15 FYH77UU-UDSH-P ○ — Fig.4-3-10
16 FYH77VU-RDSH-P — ○ Fig.4-3-11
Fig.4-3-12
18 FYH77VU-TDSH-P — ○
19 FYH77VU-UDSH — ○
Fig.4-3-13
20 FYH77VU-UDSH-P — ○
21 FYH77VU-WDSH — ○
Fig.4-3-14
22 FYH77VU-WDSH-P — ○
Chapter 4
Fig. 4-3-1 Frame section modulus FXR77UU-RDSH
Tensile strength Yield strength

Parts name Material
(MPa) (MPa)
Side member HT540 540 390
Unit: mm
7t
93 103
686 733
Section module (Main frame on both sides)
Rear axle
Front axle
Distance from front axle (mm)

Chapter 4
Fig. 4-3-2 Frame section modulus FXR77VU-RDSH, FXR77VU-RDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Rear
axle
Front axle

Chapter 4
Fig. 4-3-3 Frame section modulus FXR77VU-SDSH

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Rear
axle
Front axle

Chapter 4
Fig. 4-3-4 Frame section modulus FXZ77UU-PDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Tandem
center
Rear
Front axle

Chapter 4
Fig. 4-3-5 Frame section modulus FXZ77UU-UDSH, FXZ77UU-UDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Tandem
center
Rear
Front axle

Chapter 4
Fig. 4-3-6 Frame section modulus FXZ77VU-PDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Tandem
center
Rear
Front axle

Chapter 4
Fig. 4-3-7 Frame section modulus FXM77VU-UDSH, FXZ77VU-UDSH, FXZ77VU-UDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Tandem
center
Rear
Front axle

Chapter 4
Fig. 4-3-9 Frame section modulus FYH77UU-TDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Tandem
center
Rear
Front axle

Chapter 4
Fig. 4-3-10 Frame section modulus FYH77UU-UDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Tandem
center
Rear
Front axle

Chapter 4
Fig. 4-3-11 Frame section modulus FYH77VU-RDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Tandem
center
Rear
Front axle

Chapter 4
Fig. 4-3-12 Frame section modulus FYH77VU-TDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Tandem
center
Rear
Front axle

Chapter 4
Fig. 4-3-13 Frame section modulus FYH77VU-UDSH, FYH77VU-UDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Tandem
center
Rear
Front axle

Chapter 4
Fig. 4-3-14 Frame section modulus FYH77VU-WDSH, FYH77VU-WDSH-P

Parts name Material
(MPa) (MPa)
Unit: mm
7t
Tandem
center
Rear
Front axle

Chapter 5
CHARACTERISTICS OF THE SPRINGS Ⅱ SPECIFIC INFORMATION
Chapter 5 CHARACTERISTICS OF THE SPRINGS

5-1 SPECIFICATIONS OF THE SPRINGS
5-2 FORMULA FOR CALCULATING GROUND HEIGHT OF CHASSIS FRAME TOP
SURFACE
5-3 MARGIN FOR MOVEMENT OF THE AXLES AND THE TIRES
Chapter 5
5-1 SPECIFICATIONS OF THE SPRINGS

① FXR
FXR77UU front and rear springs
Spring specification
Front Rear
Spring dimension
Main:Multi-Leaf
Taper-Leaf
Helper:Multi-Leaf
Main: 1,420x100x12-8
Span (mm)  Width (mm)  1,600x80x21-1
Helper: 980x100x10-2
Thickness (mm) - No. of leaves 24-2
11-4
Spring constant (N/mm)
Main 285 358
Main + Helper － 1,010
Legend Main: Main spring Helper: Helper spring
FXR77VU front and rear springs

Front Rear
Spring dimension
Air suspension
Taper-Leaf
(Hendrickson 2-Bag Air)
Span (mm)  Width (mm) 
Thickness (mm) - No. of leaves 1,600x80x21-1
325x307-2
or 24-2
Diameter (mm)  Height (mm) - No. of pieces
Spring constant (N/mm) 285 Omitted
② FXM/FXZ
FXZ77UU front and rear springs
Spring dimension Front Rear
Taper-Leaf Taper-Leaf
Span (mm)  Width (mm)  1,600x80x21-1
1,310x90x32-5
Thickness (mm) - No. of leaves 24-2
Spring constant (N/mm) 285 3,408
FXM77VU/FXZ77VU front and rear springs

Front Rear
Spring dimension
Air suspension
Taper-Leaf
(Hendrickson 2-Bag Air)
Thickness (mm) - No. of leaves 1,600x80x21-1 Front:325x310-2
or 24-2 Rear:325x310-2
Spring constant (N/mm) 285 Omitted
Chapter 5
③ FYH
FYH77UU front and rear springs
Front Rear
Spring dimension
Taper-Leaf
Taper-Leaf
(With Equalizer)
Front:1,600x80x24-1
25-2
Rear:1,450x80x17.5-1 1,310x90x32-5
Thickness (mm) - No. of leaves
20.5-2
16-1
Front:342
Spring constant (N/mm) 3,408
Rear:354
FYH77VU front and rear springs

Front Rear
Spring dimension
Taper-Leaf Air suspension
(With Equalizer) (Hendrickson 2-Bag Air)
Front:1,600x80x24-1
25-2
Thickness (mm) - No. of leaves Front:325x308-2
Rear:1,450x80x17.5-1
or Rear:325x308-2
20.5-2
16-1
Front:342
Spring constant (N/mm) Omitted
Rear:354
Chapter 5
5-2 FORMULA FOR CALCULATING GROUND HEIGHT OF CHASSIS FRAME TOP

SURFACE
To calculate ground height of the chassis frame top surface above front axle and rear axle, find an
applicable formula on next page.
Use the following formula to calculate ground height of rear end chassis frame top surface.
2 axle vehicle
Y
X
Z
L1 L2
Wf Wr
3 axle vehicle
Y
X
Z
L1 L2
Wf Wr
4 axle vehicle
L1 L2
Z = Y+(Y−X)L2/L1
X: Ground height of chassis frame top surface above front axle (mm)
Y: Ground height of chassis frame top surface above rear axle (mm)
Z: Ground height of chassis frame rear end (mm)
L1: Calculational wheelbase (mm)
L2: Chassis frame rear overhang (mm)
Wf: Front axle load (kg)
Wr: Rear axle load (kg)
Chapter 5
Formula for calculating ground height of chassis frame top surface

Leaf suspension: Front axle
Conditions
Vehicle model Spring Formula
Axle load Tire size
FXR77UU/VU Taper-Leaf X=1,112-0.0217Wf — 295/80R22.5
FXM77VU Taper-Leaf X=1,112-0.0217Wf — 295/80R22.5
FXZ77UU/VU Taper-Leaf X=1,111-0.0217Wf — 295/80R22.5
Taper-Leaf
FYH77UU X=1,078-0.0093Wf — 295/80R22.5
(With Equalizer)
Taper-Leaf X=1,100-0.0093Wf — 295/80R22.5

FYH77VU
(With Equalizer) X=1,104-0.0094Wf — 11R22.5
Leaf suspension: Rear axle

Conditions
Axle load Tire size
Main:Multi-Leaf Y=1,152-0.0160Wr Wr ≦ 5,997
FXR77UU 11R22.5
Helper:Multi-Leaf Y=1,096-0.0072Wr Wr ＞ 5,997
FXZ77UU Taper-Leaf Y=1,100-0.0026Wr — 11R22.5
FYH77UU Taper-Leaf Y=1,100-0.0026Wr — 11R22.5
Air suspension: Rear axle

Conditions
Axle load Tire size
FXR77VU 2-Bag Air Y=1,029-0.0023Wr — 11R22.5
FXM77VU 2-Bag Air Y=1,040-0.0012Wr — 11R22.5
FXZ77VU 2-Bag Air Y=1,041-0.0012Wr — 11R22.5
FYH77VU 2-Bag Air Y=1,038-0.0012Wr — 11R22.5
Chapter 5
5-3 MARGIN FOR MOVEMENT OF THE REAR AXLE AND TIRES

① Movement of the rear tires
Based on the dimensional data in the table below, determine position and dimension of the
rear fender and the tire housing with reasonable clearances to the tires.
For chained tires, add 50mm to "A", "B" and subtract 50mm from "C".
Rear tire
Leaf suspension Unit: mm

Chassis frame depth
Vehicle model Tire A B C
at rear axle
FXR77UU 285 11R22.5 219 130 546
FXZ77UU 285 11R22.5 169 78 517
FYH77UU 285 11R22.5 169 78 517
Air suspension Unit: mm

Chassis frame depth
Vehicle model Tire A B C
at rear axle
FXR77VU 285 11R22.5 139 103 602
FXM77VU 285 11R22.5 191 110 505
FXZ77VU 285 11R22.5 139 103 602
FYH77VU 285 11R22.5 139 103 602
Chapter 5
② Movement of the front tires (for front (rear) axle of FYH)

Based on the dimensional data in the table below, determine position and dimension of the
fender and the tire housing with reasonable clearances to the tires on the front (rear) axle.
Front (rear) tire
Unit: mm
Chassis frame depth
Vehicle model Tire A B
at front(rear) axle
FYH77UU 285 295/80R22.5 241 169

FYH77VU 285 11R22.5 245 173
Note: ・To prevent contact, the objects placed above the front (rear) axle including the PTO drive
shaft should be maximum 200mm distant from the chassis frame bottom surface.
Chapter 6
PTO AND ENGINE CONTROL Ⅱ SPECIFIC INFORMATION
Chapter 6 PTO AND ENGINE CONTROL

6-1 PTO VARIATION AND SPECIFICATION
6-2 PTO CONTROL
6-3 GOVERNOR CHARACTERISTICS CURVES FOR WORK MODE
Chapter 6
6-1 PTO VARIATION AND SPECIFICATION

① PTO variation
FXR
Transmission Engine PTO variation
model PTO type
Vehicle Speed PTO output
model 6UZ1 Fly- Output Allowable
increasing shaft rotating
Side Rear
MT AT -TCC wheel shaft maximum torque ratio direction
PTO PTO
PTO
FXR77UU ZF9S1310
— — — — — — — —
-RDSH TO
FXR77VU ZF9S1310
— — — — — — — —
-RDSH TO
○
FXR77VU ALLISON
— — — — — — — —
-RDSH-P 4430
FXR77VU ZF9S1310
— — — — — — — —
-SDSH TO
FXM/FXZ
model PTO type
increasing shaft rotating
Side Rear
MT AT -TCC wheel shaft maximum torque ratio direction
PTO PTO
PTO
FXM77VU ZF9S1310
— — — — — — — —
-UDSH TO
FXZ77UU ALLISON
— — — — — — — —
-PDSH-P 4430
FXZ77UU ZF9S1310
— — — — — — — —
-UDSH TO
FXZ77UU ALLISON
-UDSH-P
—
4430
○ — — — — — — —
FXZ77VU ALLISON
— — — — — — — —
-PDSH-P 4430
FXZ77VU ZF9S1310
— — — — — — — —
-UDSH TO
FXZ77VU ALLISON
— — — — — — — —
-UDSH-P 4430
Legend ○: Standard specification △: Option —: Not installed at shipment

Chapter 6
FYH
model PTO type
Side Rear increasing shaft rotating
MT AT -TCC wheel shaft maximum torque
PTO PTO ratio direction
PTO
FYH77UU ALLISON
— — — — — — — —
-TDSH-P 4430
FYH77UU ALLISON
— — — — — — — —
-UDSH-P 4430
FYH77VU ALLISON
— — — — — — — —
-RDSH-P 4430
FYH77VU ALLISON
— — — — — — — —
-TDSH-P 4430
FYH77VU ZF9S1310
— — — — — — — —
-UDSH TO
FYH77VU ALLISON
— — — — — — — —
-UDSH-P 4430
FYH77VU ZF9S1310
— — — — — — — —
-WDSH TO
FYH77VU ALLISON
— — — — — — — —
-WDSH-P 4430
Legend ○: Standard specification △: Option —: Not installed at shipment

Chapter 6
② Flywheel PTO
・ 6UZ1 Engine
Location of the flywheel PTO

Flywheel PTO Flywheel PTO output shaft Unit: mm
B rotating direction
C
FRONT
Engine datum point
D
Chassis frame
bottom surface
Housing Flywheel A
Chassis center
From front axle center
SIDE VIEW REAR VIEW
Note: ・This figure is an example of flywheel housing. The dimensions from engine datum point
varies in each vehicle. Confirm the side view of "Ⅱ-9-1 CAB CHASSIS DRAWINGS".
Dimensions
C D
A B
PTO flange Engine crank
Housing Flywheel Engine datum point
Engine rear surface shaft center
rear surface to PTO flange
to Housing Flywheel to Flywheel PTO
to Engine datum point rear surface
rear surface flange center
6UZ1-TCC 116.5 123 6.5 348.7
Chapter 6
Detailed drawing of the flywheel PTO output flange
Unit: mm
Involute spline hole specification (Flywheel PTO)

Code JIS 45162.5
Addendum modification coefficient +0.800
Tooth shape Stub tooth
Tool Module 2.5
Pressure angle 20°
Reference pitch diameter 40.0
Number of teeth 16
+0.085
Over pin diameter 35.168 0
Tooth Pin diameter 5.0
thickness (notch) (4.26)
+0.030
Displacement over 3 teeth 20.379 −0.009
Finishing Broaching
Centering Tooth flank
Tooth flank / roughness 3.2Ra
Chapter 6
6-2 PTO CONTROL

① Engine output characteristic (PTO work output) and control
Accelerator throttle position and engine output of electronic controlled engine have two types of
mode of Running Characteristic (drive) and Working Characteristic (work). When the
conditions of each mode are satisfied, the ECM determines fuel injection quantity, and mode is
switched. Refer to "Ⅱ-6-3 GOVERNOR CHARACTERISTICS CURVES FOR WORK MODE"
for engine output characteristic curves of work mode.
Mode Fuel injection quantity

Drive mode = External engine control lever operation < Accelerator pedal operation
Work mode = External engine control lever operation > Accelerator pedal operation
・ Prohibition
- Directly input the electric signal to the external engine control signal terminal
- Any modification which may influence control, e.g. adding interlock mechanism
・ Precaution
- After completing any work with use of PTO, be sure to return the external engine control
lever to IDLE. Leaving the external engine control lever opened may cause unexpected
increase in the engine speed.
・Switching to work mode
After satisfy following conditions, mode switches to work mode when the external engine
control lever is opened from idle position.
- When stopping the engine while using an external control, to drive in the work mode after
re-starting, the switch condition to the work mode should be satisfied again.
Conditions for switch to work mode
External engine control Connected
External engine control lever position IDLE
Stop
Status of vehicle
(Vehicle speed: 0km/h)
Engine speed Higher than the idle speed
Shift lever position Neutral
Acceleration pedal position Released
・Switching to drive mode

When the following conditions are satisfied, mode switches to drive mode.
Conditions for return to drive mode
Shift lever position Except Neutral
Vehicle speed signal Detecting
Chapter 6
② External engine control
External engine control of electronic controlled engine is electrically performed. The cable for
external engine control is to be installed on the rear body, and the movements of the cable are
converted into electrical signals by lever. Engine speed is controlled by the signals. To prevent
the malfunction of the engine and the damage to ECM, observe the following descriptions
when installing the external engine control lever and the harness.
・ Prohibition
- Harness extension by modification is prohibited. Wiring resistance increase of power
supply, ground harness and signal wire or exogenous noises due to modification may
cause defective output or unexpected engine blow.
・ Precaution
- Work while engine stopped.
- Parts ① and ② of following table must be used in pairs for the external engine control
lever.
- Refer to " Precautions for routing of the extension harness" on the later pages for harness
routing.
Required parts
No. Part number Part name Quantity Remarks
① 897219-4664 LEVER ASM; ENGINE CONTROL 1 -
② 898163-0950 HARNESS; ALL SPEED ACCEL SENSOR 1 Length: 10.7m approx.
Note: ・Part numbers may be changed without notice due to specification change, etc.
Contact ISUZU distributor or ISUZU dealership when you order.
Chapter 6
・ External engine control lever

The lever assembly and ECM must be connected with harness. Appropriate adjustment in
harness routing allows installation of lever at a required place. (There are vehicles without
lever installed. Contact ISUZU distributor or ISUZU dealership for details of specification.)
Detail of external engine control lever
Unit: mm
Acceleration
IDLE FULL OPEN
Lever 4.9 N･m 20.6 N･m
reaction {0.5kgf･m} {2.1kgf･m}
2-M8x1.25
Chapter 6
・Precautions for installation of the external engine control lever

- Install the control lever in the direction as shown below figure. The sides indicated with
arrows must not be turned up, otherwise foreign objects (e.g. Water) will collect in the
connector, resulting in breakdown of the control lever.
Direction of control lever
- Install control lever in a place that is not affected by dust, grease, moisture and chemical.
- Control lever can be used at temperature in the range from -30 to 75C. The ambient
temperature must fall within this range. Do not install the control lever on the place subject
to heat from engine, exhaust pipe, or rear body.
- Securely install the bracket in order to protect the control lever from large vibration (e.g.
Running vibration).
- Do not install the control lever in such a place where it may receive any shock from falling
objects, flying gravels, etc.
- Since the position sensor had been adjusted before shipment, do not loosen its fixing bolt
or disassemble it.
- Handle the control lever with extra care not to drop or give a shock to it, which may result
in malfunction or breakdown of the sensor.
Chapter 6
・Precautions for routing of the extension harness
- Tie the extension harness and the harnesses laid on the chassis frame together by using
nylon band clips so that the extension harness will not contact with neighboring objects
such as cables, pipes and equipments.
- Secure the harness so as for none of the electric wires to be damaged by vibration.
- Distance between clips for securing harnesses should be 400mm or less.
- Do not twist or excessively bend the harness, and ensure to avoid high temperature area
for routing harnesses.
- To avoid interference from electric currents or signals on rear body, do not tie the harness
with any harnesses laid on rear body (e.g. Power harness and signal harness) together.
- For further precautions of harness routing, refer to "Ⅰ-2-12 PRECAUTIONS FOR
MODIFICATION OF THE ELECTRICAL SYSTEM" and "Ⅱ-7 ELECTRICAL SYSTEM".
Routing of harness
② HARNESS for external engine

control lever (Entire length: 10.7m)
4pin connector for

external acceleration Connect to
① LEVER ASM
Note: ・ Four pin connector of chassis frame harness is bound with green tape to the frame harnesses laid on the
first cross member. Remove this green tape and waterproof cap, and then connect the harness to the
connector. Make sure that the connector is securely fitted.
Chapter 6
③ Dump / Mixer control
・Precautions for routing of the control cable
- Do not change the routing of transmission cable, as the cable become to break.
- For clearances with all parts when routing additional cables, refer to "Ⅰ-3-2 CLEARANCE
BETWEEN AN EQUIPMENT OR A COMPONENT ON A CAB CHASSIS AND A REAR
BODY".
- Route the cable so that the cable is higher than the lower end of front axle I-beam.
- Route the cable with slack, in consideration of cab tilt.
- Route the cable with consideration for heat damage from exhaust pipe and others.
Chapter 6
・ Cover kit
When using the existing floor holes to install dump / mixer control lever, be sure to use
special cover kit. The cover kit is set as water infiltration prevention in the cab.
- For the vehicle with the dump / mixer control lever installed at shipment, the cover kit listed
on below table is bundled. Install it as shown in below figure.
- For the vehicle installing the dump / mixer control lever at rear body mounting using
existing floor holes, purchase the cover kit in the below table and install it.
Details of cover kit
Cover kit part No.

COVER KIT
Handle Vehicle model ① COVER x1 ② BOLT x2 ③ NUT x2 ④ RIVET x2 Remarks
ASM
FXR/FXM
RHD 898083-5770 898076-2710 109980-4950 894197-1990 109987-2481 —
/FXZ/FYH
Note : ・ Part numbers may be changed without notice due to specification change, etc.
Chapter 6
(Reference) Dump control lever related components

Part number Part name Quantity Remarks
179996-0920 DUMP LEVER 1
894279-2070 BOLT 3
897465-1380 TRIM COVER 1 RH of the right hand drive cab
(Reference) Mixer control lever related components

Part number Part name Quantity Remarks
179907-0481 MIXER LEVER 1
898060-6210 BRACKET ASM; PTO CONT LEVER 1
894279-2070 BOLT 6
897407-4143 TRIM COVER 1 RH of the right hand drive cab
Note : ・ Part numbers may be changed without notice due to specification change, etc.
Chapter 6
6-3 GOVERNOR CHARACTERISTICS CURVES FOR WORK MODE
Max power Max torque

Emission Engine Drawing
(kW / rpm) (N•m / rpm)
Euro Ⅴ 6UZ1-TCC Fig.1 257 / 2,000 1,422 / 1,400
Fig.1 Governor Characteristics Curves (6UZ1-TCC)
Do not use under 600 rpm or less.

Chapter 7
ELECTRICAL SYSTEM Ⅱ SPECIFIC INFORMATION
Chapter 7 ELECTRICAL SYSTEM

7-1 LAMPS
7-2 WORKING VOLTAGE AND OUTPUT CHARACTERISTICS OF ACG
7-3 CIRCUIT DIAGRAMS
7-4 POWER SUPPLY FOR REAR BODY
7-5 LOCATION OF CONTROL UNIT
7-6 FMS-CAN INTERFACE
Chapter 7
7-1 LAMPS
Perform the lamps installation and adjustment in accordance with the following precautions.
① Adjusting light axis of head lamp
・The light axis of the headlamp at shipment is fixed by the definite value on the assumption of
the adjustment after body mounting (before certification).
- By installing rear body, the vehicle posture changes. Follow the local regulations for
adjusting the light axis of the head lamp.
② Rear combination lamp
・ Near the rear end of a chassis frame, there are temporarily installed rear combination lamp as
the rear lamp.
- Install the lamps at location where water, snow, mud, etc. does not splash on to the rear
combination lamp, or apply cover.
- When applying paint on the vehicle, be sure not to paint the rear combination lamp.
- There is a drain hole in the bottom of rear combination lamp’s each lens. If these holes
were covered with waterproof tape, remove this tape, and locate the lamp so that the drain
hole is facing downward.
- To prevent the bulb filaments from breaking due to vibration of the lamp housing, take
antivibration measure to the lamp fixation department.
・ For install location, follow the local regulations.
③ Installing lamp to rear body
・ There are occasions when installation of lamps to rear body is required.

- Body builders should install lamps to rear body with the following local regulations.
Chapter 7
7-2 WORKING VOLTAGE AND OUTPUT CHARACTERISTICS OF ACG

The following table shows the working voltages and the output current of ACG for shipping
vehicles.
Vehicle model Engine Working voltage Output current Drawing

FXR77UU
FXR77VU
FXM77VU
FXZ77UU 6UZ1 24V 90A Fig.1
FXZ77VU
FYH77UU
FYH77VU
Fig.1 Output characteristics of ACG (24V-90A)
90
80
70
60
OUTPUT CURRENT (A)
50
40
30
20
10
0 1000 2000 3000 4000 5000 6000 7000

ALTERNATOR SPEED (r/min)
6UZ1 0 385 770 1150 1535 1920 2305 2685
ENGINE SPEED (r/min)
Chapter 7
7-3 CIRCUIT DIAGRAMS

① Symbols in circuit diagrams
Symbol Meaning of Symbol Symbol Meaning of Symbol
Battery HID bulb
Fuse Solenoid valve,Magnetic valve,etc.
Slow blow fuse Resistor
Fusible link (wire) Horn
Relay Switch
Buzzer Speaker
Diode Motor
Light emitting diode Magnetic clutch
Single filament bulb Pressure sensor,etc.
Double filament bulb Temperature sensor
Pulse sensor Twisted pair
Other sensors,etc. Shield
Intermediate connector Ground point
Joint connector/junction block Connection between pages
Joint Connection within a pages
Pair Dedicated line

Chapter 7
② Abbreviation in circuit diagrams

For commonization of material, there may be descriptions of device without development.
Abbr. Full spelling Abbr. Full spelling

# Cylinder or number indicator FFR Frame Front Right
CAB Cab Fr Front
CBL Cab Back Left FSL Frame Side Left
CBR Cab Back Right FSR Frame Side Right
CFC Cab Front Center HBL Hybrid unit Box Lower
CFL Cab Floor Left HBM Hybrid unit Box Middle
CFR Cab Floor Right HBU Hybrid unit Box Upper
CHASS Chassis Hi High
CSD Cold Start Device L/H Left Hand
E/B Electric Box Lo Low
EBL Engine Block Left P/W Power Window
ECL Engine Compartment Left R/B Relay Block/Relay Box
ECR Engine Compartment Right R/H Right Hand
EHL Engine Head Left RL Relay
FCB Frame Center Battery S/B Switch Box
FFC Frame Front Center VGS Variable Geometry System
FFL Frame Front Left
Chapter 7
③ Circuit diagrams
Circuit diagrams of the following equipments that are involved in rear body mounting are
shown on following pages. Electrical work, also refer to "Ⅰ-2-12 PRECAUTIONS FOR
MODIFICATION OF THE ELECTRICAL SYSTEM".
Circuit diagrams
Drawing Circuits Drawing Circuits
Fig.7-3-1 Power Distribution Fig.7-3-23 Meter
Fig.7-3-2 Fuse Load Fig.7-3-24 Horn
Fig.7-3-3 Ground Distribution Fig.7-3-25 Pulse Adjuster (MT)
Fig.7-3-4 ECM Fig.7-3-26 Pulse Adjuster (AT)
Fig.7-3-5 Starter&Charging (MT) Fig.7-3-27 Power Cab Tilt
Fig.7-3-6 Starter&Charging (AT) Fig.7-3-28 Power Door Lock

Axle Differential Lock
Fig.7-3-7
(FXR/FXM/FXZ/FYH)
Inter-axle Differential Lock
Fig.7-3-8 Fig.7-3-30 Heated and Remote Control Mirror
(FXZ/FYH)
Fig.7-3-9 ABS Fig.7-3-31 Power Window
Fig.7-3-10 ESC Fig.7-3-32 Body Control
Fig.7-3-11 Air Dryer Fig.7-3-33 DRM
Fig.7-3-12 AT(ALLISON) Fig.7-3-34 CAN (MT)
Fig.7-3-13 MT(ZF/EATON) Fig.7-3-35 CAN (AT Except ESC)
Fig.7-3-14 PTO Fig.7-3-36 CAN (AT ESC)
Fig.7-3-15 Heating, Ventilation, Air Conditioning Fig.7-3-37 Check Connector
Fig.7-3-16 SRS Fig.7-3-38 Cab Junction Block
Fig.7-3-17 Headlamp Fig.7-3-39 Junction Block
Fig.7-3-18 Front Fog Lamp Fig.7-3-40 Fuse Block
Fig.7-3-19 Combination Lamp Fig.7-3-41 Chassis Relay Box
Fig.7-3-20 Room Lamp Fig.7-3-42 Relay Block
Fig.7-3-21 Wiper, Washer Fig.7-3-43 Connector List
Fig.7-3-22 Cigar Lighter
Note: ・There may be descriptions of device without development in the circuit diagrams.
・ Refer to “Ⅱ-2-3 PRINCIPAL SPECIFICATIONS OF THE CAB CHASSIS” for
development on each vehicle of ESC, AT, MT, PTO.
Chapter 7
Circuit diagrams Fig.7-3-1 Power Distribution (1/3)

Chapter 7

Chapter 7
TURBO CONTROL
Chapter 7
Circuit diagrams Fig.7-3-2 Fuse Load (1/4)
Check Connector
Chapter 7

Chapter 7

Chapter 7
TURBO CONTROL
Chapter 7
Circuit diagrams Fig.7-3-3 Ground Distribution (1/3)
Check Connector
Check Connector
Chapter 7

Chapter 7

Chapter 7
Circuit diagrams Fig.7-3-4 ECM (1/7)
TURBO CONTROL
Turbo control
Transmission Control
Chapter 7
OF5
TURBO
CONTROL
10A
Chapter 7
Chapter 7
External engine control

Chapter 7

Chapter 7
Cruise control
Speed control Speed control

Chapter 7
Check Connector
Chapter 7
Circuit diagrams Fig.7-3-5 Starter&Charging (MT) (1/2)

Chapter 7
Circuit diagrams Fig.7-3-5 Starter&Charging (AT) (2/2)

Chapter 7

Chapter 7
Chapter 7
Circuit diagrams Fig.7-3-7 Axle Differential Lock (FXR/FXM/FXZ/FYH)

Chapter 7
Circuit diagrams Fig.7-3-8 Inter-axle Differential Lock (FXZ/FYH)

Chapter 7
Circuit diagrams Fig.7-3-9 ABS (1/2)
Check Connector
Chapter 7
Circuit diagrams Fig.7-3-9 ABS (2/2)

Chapter 7
Circuit diagrams Fig.7-3-10 ESC (1/3)

Chapter 7
Check Connector
Chapter 7

Chapter 7
Circuit diagrams Fig.7-3-11 Air Dryer

Chapter 7
Circuit diagrams Fig.7-3-12 AT (ALLISON) (1/2)
Chapter 7
Circuit diagrams Fig.7-3-12 AT (ALLISON) (2/2)
Chapter 7
Circuit diagrams Fig.7-3-13 MT (ZF/EATON)
Speed control Transmission control

Chapter 7
Circuit diagrams Fig.7-3-14 PTO

Chapter 7
Circuit diagrams Fig.7-3-15 Heating, Ventilation, Air Conditioning (1/2)

Chapter 7
Circuit diagrams Fig.7-3-15 Heating, Ventilation, Air Conditioning (2/2)

Chapter 7
Circuit diagrams Fig.7-3-16 SRS
Check Connector
Chapter 7
Circuit diagrams Fig.7-3-17 Headlamp

Chapter 7
Circuit diagrams Fig.7-3-18 Front Fog Lamp

Chapter 7
Circuit diagrams Fig.7-3-19 Combination Lamp (1/5)

Chapter 7

Chapter 7

Chapter 7

Chapter 7
Chapter 7
Circuit diagrams Fig.7-3-20 Room Lamp

Chapter 7
Circuit diagrams Fig.7-3-21 Wiper, Washer

Chapter 7
Circuit diagrams Fig.7-3-22 Cigar Lighter

Chapter 7
Circuit diagrams Fig.7-3-23 Meter (1/8)

Chapter 7
EATON(Austraria)
EATON (Expect Austraria)
Speed control
Chapter 7
Check Connector
Chapter 7

Chapter 7

Chapter 7

Chapter 7
Chapter 7

Chapter 7
Circuit diagrams Fig.7-3-24 Horn

Chapter 7
Circuit diagrams Fig.7-3-25 Pulse Adjuster (MT)
EATON
Speed control Transmission control
Check Connector
Chapter 7
Circuit diagrams Fig.7-3-26 Pulse Adjuster (AT)
Speed control
Check Connector
Chapter 7
Circuit diagrams Fig.7-3-27 Power Cab Tilt

Chapter 7
Circuit diagrams Fig.7-3-28 Power Door Lock

Chapter 7
Circuit diagrams Fig.7-3-30 Heated and Remote Control Mirror (1/2)

Chapter 7
Circuit diagrams Fig.7-3-30 Heated and Remote Control Mirror (2/2)

Chapter 7
Circuit diagrams Fig.7-3-31 Power Window

Chapter 7
Circuit diagrams Fig.7-3-32 Body Control (1/2)
Body control
Chapter 7
Circuit diagrams Fig.7-3-32 Body Control (2/2)
Service CAN Check Connector

Chapter 7
Circuit diagrams Fig.7-3-33 DRM

Chapter 7
Circuit diagrams Fig.7-3-34 CAN (MT)
Check Connector
Chapter 7
Circuit diagrams Fig.7-3-35 CAN (AT Except ESC)
Check Connector
Body Control
Chapter 7
Circuit diagrams Fig.7-3-36 CAN (AT ESC) (1/2)
Body Control
Chapter 7
Circuit diagrams Fig.7-3-36 CAN (AT ESC) (2/2)
Check Connector
Chapter 7
Circuit diagrams Fig.7-3-37 Check Connector
Check
Connector
Speed control Body Control

Chapter 7
Circuit diagrams Fig.7-3-38 Cab Junction Block (1/3)

Chapter 7

Chapter 7

Chapter 7
Circuit diagrams Fig.7-3-39 Junction Block (1/2)

Chapter 7
Circuit diagrams Fig.7-3-39 Junction Block (2/2)

Chapter 7
Circuit diagrams Fig.7-3-40 Fuse Block

Chapter 7
Circuit diagrams Fig.7-3-41 Chassis Relay Box (1/2)
TURBO
CONTROL
Chapter 7
Circuit diagrams Fig.7-3-41 Chassis Relay Box (2/2)

Chapter 7
Circuit diagrams Fig.7-3-42 Relay Block (1/2)

Chapter 7
Circuit diagrams Fig.7-3-42 Relay Block (2/2)

Chapter 7
Circuit diagrams Fig.7-3-43 Connector List (1/23)

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7

Chapter 7
7-4 POWER SUPPLY FOR REAR BODY

This section describes the electrical work for rear body, such as rear body power supply and
linking the rear body with the chassis. When performing the work for rear body, modification of the
existing harness without following instructions in this guide may cause serious problems such as
vehicle fires and other malfunctions. When performing electrical work for rear body, always follow
the instructions in this guide and "Ⅰ-2-12 PRECAUTIONS FOR MODIFICATION OF THE
ELECTRICAL SYSTEM".
① Extracting power supply for rear body

The power supply for operating the rear body should be extract directly from the battery. At that
time, be sure to put a fuse in the power supply extraction circuit. When extracting power supply,
follow the prohibitions and precautions below because vehicle fire and flat battery may occur.
・ Prohibition
- Do not put a fuse inside of the battery cover, otherwise the battery will be damaged or
explode.
- Do not add multiple terminal. A nut might loosen when piling terminals more than two
pieces by result of without enough length of the stud.
・ Precaution
- Secure distance more than 300mm between fuses and the battery (volatile gas may come
out of the battery) and protect from water.
Connect it with negative terminal of the battery or the frame to which the negative cable is
connected. In addition, replace the existing ground wire with the ones with capacity that
- Pay attention so that battery and ACG specification corresponds to electric load (fire
engine and refrigerated vehicle, etc.). Refer to "Ⅱ-2-3 PRINCIPAL SPECIFICATIONS
OF THE CAB CHASSIS".
- Extracted power from battery is always energized, does not depend on the state of the key
switch on the chassis. This can cause the battery go flat. Take the necessary measures
such as appending to the caution label or the owner’s manual.
- Use the ring terminal to extract from battery. Sizes and shapes of terminals and electric
wires used for the increase must use the one that corresponded to the increased load.
- When using a cable of 5mm2 or larger, solder the pressured part of the wire terminal, and
then wrap the area with a heat shrink tubing.
- Tighten the nut according to the example next page to prevent loosening. Refer to
"⑥ Tightening torque of battery terminal" and tighten the nut by appropriate torque so
that no looseness.
Chapter 7
Example of extracting power from battery
Factory-installed circuit
Additional circuit
(Switching circuit such as

relay is included.)
Fuse
Connect to the negative terminal of
the battery or the frame to which the
negative cable is connected.
Additional
load 300㎜ or more
Replace with the ones with capacity that

Example of installing an additional harness
Battery terminal Battery cable
Nut Ring terminal Additional cable
12mm or less
Chapter 7
② Terminal location of vehicle

The location of various service terminals and the connected terminals that are related to work
for rear body that are set on vehicle are shown below. Terminal details are shown in “③
Service terminals" and "④ Connected terminals", so use the terminal according to the work for
rear body.
Fig.1 Location of service terminals and connected terminals (On chassis)
Ⅰ
Ⅲ
B Ⅱ
C
【Service terminals】【Connected terminals】

A ： External engine control Ⅰ ： Rear combination lamp RH
B ： Trailer ABS Ⅱ ： Rear combination lamp LH
C ： Trailer ABS Ⅲ ： License lamp
Chapter 7
Fig.2 Location of service terminal (Inside cab)
【Service terminals】
Z ： Service CAN (Inside the cover)
Chapter 7
③ Service terminals
Various service terminals of existing harness provide power and signals by connected to the
suitable terminals according to the work for rear body. For the location of the service terminals,
refer to "② Terminal location of vehicle".
・ Prohibition
- Modification of connector and terminal
- Extracting power supply from other than the extracting part (terminal) prepared to the
vehicle
Connector and terminal modification is prohibited
・ Precaution
- The current extracted from the service terminal should be less than the allowable current
value in the terminal list on the next page. The current that can be used by the bodybuilder
is shown as the allowable current.
Chapter 7
Service terminals (On chassis)

Terminal
Sym. Service terminal Location Connector type Wire color Allowable current Remarks
position
1 W ー
2 R ー
Near the 1st cross member 1 2 Use for external engine speed control terminal.
A External engine control Use a waterproof terminal.
(Refer to Fig.1)
3 4 3 B ー
(Refer to Ⅱ-6-2 ② External engine control)
4 B ー
Trailer ABS
１ BR
・TR.ABS indicator
B
Trailer ABS １２２ V/W
・Key on
Trailer ABS Near the 2nd cross member

３
３ B ー Trailer ABS connector
・Earth (Refer to Fig.1)
Trailer ABS
１ B
・Earth
C
１
Trailer ABS
・Key on
２２ W
Chapter 7
Service terminals (Inside cab)

Terminal
Sym. Service terminal Location Connector type Wire color Allowable current Remarks
position
Service CAN
1 BR/W ー Follow SAE J1939/11 for CAN communication.
CAN bus (Hi)
Yazaki Corporation The FCG (FMS CAN Gateway) and the extension harness that
Inside the cover (Cab) connects the vehicle and the FCG are not installed in the shipping
Z Part number 7323-8326
(Refer to Fig.2) state. So if only connecting rear body FMS to this terminal, CAN
ISUZU Part number 894363-3640 communication can not be performed. When communication with
Service CAN Mating connector 2 BR ー CAN is necessary, contact ISUZU distributor or ISUZU dealership.
CAN bus (Lo)
Yazaki Corporation
Part number 7322-8326 (SDL2P)
Chapter 7
④ Connected terminals
The terminals described in this section are already connected to existing equipment and
cannot be connected to additional equipment.
If it is necessary to extract power supply for additional lamps in the case of without service
terminal of existing harness, blanch from the wire connected to the rear combination lamp. For
the location of the connected terminal including rear combination lamp, refer to "② Terminal
location of vehicle". The terminals other than the rear combination lamp are reference
information when relocating.
・Prohibition
- Modification of connector and terminal
Connector and terminal modification is prohibited
・ Precaution
- The current extracted from the existing harness should be less than the allowable current
value in the list shown next page. The current that can be used by the bodybuilder is
shown as the allowable current.
- When modifying the electric harness to extract the power supply, take appropriate
measures according to "Ⅰ-2-12 Precautions when modifying the electrical system". Make
sure to waterproof the harness splicing point. (ex. Use the crimp terminal and wrap with
butyl rubber, etc.).
- When adding turn signal lamps, replace the flasher unit by referring to
"⑤ Replacement of flasher unit when installing additional turn signal lamps".
Chapter 7
Connected terminals (Rear combination lamp)

Sym. Terminal Terminal Wire color Allowable current
Connector type
RH LH RH LH position RH LH (RH/LH total)
Tail lamp Tail lamp
1 G/R G/R 0.8 (A)
(+) (+)
Stop lamp Stop lamp
2 G G 2.1 (A)
(+) (+)
Turn signal Turn signal
3 G/W G/B 2.0 (A)
lamp ( + ) lamp ( + )
Ⅰ Ⅱ
Back buzzer
No circuit 4 R/L ー
(+)
ー
Back lamp Back lamp
5 R/L R/L
(+) (+)
Earth Earth
6 B/L B/L ー
(-) (-)
Connected terminals (Except rear combination lamp)
Terminal
Sym. Terminal Connector type Wire color
position
License lamp ( + ) 1 G/R

Ⅲ
1 2
License lamp ( - ) 2 B/L
Chapter 7
⑤ Replacement of flasher unit when installing additional turn signal lamps

・ When installing additional turn signal lamps, replace the flasher unit with new one according
to figure shown in below. (To retain the number of flashings.)
Location of flasher unit
Flasher unit
Flasher unit parts number for replace

ISUZU MOTORS LIMITED Number of the lamps added on
Working voltage Addition of ground wire
Part number one side of a vehicle
897613-9681 24V 21W, One Not required
897613-9701 24V 21W, Two Required
897613-9691 24V 21W, Three Required
Note: ・Part numbers may be changed without notice due to specification change, etc.
・ When adding turn signal lamps, it may be necessary to add a ground wire. In that case, add a
ground wire to the free cavity 4 of the flasher unit connector as shown in below figure.
Ground terminal of flasher unit connector
Connecting an additional ground circuit

No.4: Free
Chapter 7
⑥ Tightening torque of battery terminal

When the battery terminal is detached for body installation, connect and tighten the battery
terminal with specific torque following the figure.
Vehicle model Working voltage Battery capacity Drawing

FYH77UU-R
24V 80D26Lx2 Fig.1
FYH77VU-R
FXR77UU
FXR77VU
FXM77VU
FXZ77UU 24V 115E41Lx2 Fig.2
FXZ77VU
FYH77UU-T/U
FYH77VU-T/U/W
Fig.1 Tightening of battery terminal (24V 80D26Lx2)
Frame side
＋－
－＋
Tightening torque
No. Nut size Part name Tightening torque (N・m)
① M6 CABLE ASM; BAT POS CBL 5 to 7
② M6 CABLE ASM; BAT TO BAT (NEG) 5 to 7
③ M6 CABLE ASM; BAT TO BAT (POS) 5 to 7
④ M6 CABLE ASM; BAT NEG CBL 5 to 7
Chapter 7
Fig.2 Tightening of battery terminal (24V 115E41Lx2)
Frame side
＋－
－＋
Tightening torque
No. Nut size Part name Tightening torque (N・m)
① M6 CABLE ASM; BAT POS CBL 5 to 7
② M6 CABLE ASM; BAT TO BAT (NEG) 5 to 7
③ M6 CABLE ASM; BAT TO BAT (POS) 5 to 7
④ M6 CABLE ASM; BAT NEG CBL 5 to 7
Chapter 7
7-5 LOCATION OF CONTROL UNIT

The control unit may be instructed to disconnect the harness or remove the unit itself before work.
As a reference for the disconnecting or the removing, location of the control unit is shown below.
(The contents is just a location information of the control unit, and part shape in the illustration
may differ from the actual one.)
Location of control unit (Cab rear member)
Front
Turbo control
(left side of cab rear member)
Location of control unit (Cab floor)
Front Engine control

(installed behind the passenger seat)
Chapter 7
Location of control unit (Instrument panel)
ABS control
ABS/ESC control Body control Keyless entry control Speed control
Transmission control Cruise control SRS control Transmission control

(ZF) (ALLISON)
Shift selector (ALLISON)

(installed at the center console)
Note: ・ Refer to “Ⅱ-2-3 PRINCIPAL SPECIFICATIONS OF THE CAB CHASSIS” for

development on each vehicle of ABS, ABS/ESC, ZF, ALLISON.
Chapter 7
7-6 FMS-CAN INTERFACE

FMS (Fleet Management System) standard, an open common interface produced by many
manufacturers of trucks, is adopted in CAN (Controller Area Network) of this vehicle. This is
provided in "SAE J1939".
When communicating with CAN from outside of the vehicle, connect to the network with CAN
service connector. An incorrect connection could cause the normal functions of vehicles to
behave irrationally. The bodybuilder is responsible for ensuring that the external control unit is
used correctly.
Since the FCG (FMS CAN Gateway) shown below and the extension harness that connects the
vehicle and the FCG are not installed in the shipping state, CAN communication can not be
performed. If communication with CAN is necessary, contact ISUZU distributor or ISUZU
dealership.
① General guidelines
• Control units connected to a CAN bus must be able to handle up to 100% CAN bus load with
the correct messages with no significant functional limitations or malfunctions.
• The CAN bus load should not generally exceed 50%.
• If closed control loops over the CAN are required, they must be fully capable of sending the
necessary CAN messages even using twice the transmission period, with paying attention to
bus load.
Note: CAN bus is exclusive cable for CAN communication.
② Cables
・ Set the cable colors of the CAN bus of external control unit as follows to match the colors of
the vehicle harness. In order to avoid misconnection, unify the cables colors.
CAN-HI: BR/W, CAN-LO: BR
・ CAN low should be marked as CAN-LO and CAN high as CAN-HI.
③ CAN service connector

CAN service connector
※1
※1：Since the FCG and extension harness are not installed at the time of shipment, communication is not
possible even if it is connected to the CAN service connector set in the cab. If communication with CAN
is necessary, contact ISUZU distributor or ISUZU dealership.
・ For location of CAN service connector, refer to "Ⅱ-7-4 POWER SUPPLY FOR REAR BODY".
Chapter 7
④ Cable connections
・ The length of the cables must not exceed 30 m (main cable) between CAN service connector
and ECU X. If more than one control unit (ECU Y, ECU Z, etc.) is connected, the length of the
cables between the main cable and control unit should not exceed 1 m.
・ When connecting nodes to cables of the CAN bus, keep at least 0.1 m between each node.
・ The cables should be as short as possible to minimize the effect of electromagnetic
interference.
・ The number of control units in the FMS network of external control unit should not exceed 9.
・ The figure shows the principle of the external FMS network topology.
Principle of the external FMS network topology

CAN service
connector
Note: FCG is short for "FMS CAN Gateway".

R is short for "Resistor".
Chapter 7
⑤ CAN bus cable

・ The CAN bus cable must be connected using a 120 Ω termination resistor at each end in
accordance with "SAE J1939-15 Physical Layer".
・ Depending on the other control units connected to the CAN bus of external control unit, there
must be a termination resistor in the control unit.
・ When connecting a number of different control unit to the cable harness of the CAN bus of
external control unit, confirm the termination resistor in control unit to connect, and set one
termination resistor. (The other terminal is already connected to the vehicle.)
・ If the control unit is not equipped with an internal termination resistor, an external termination
resistor must be connected as close to the control unit as possible.
When using termination resistors inside the ECU X
CAN service
connector
FCG
When connecting termination resistors to the outside of the ECU X

CAN service
connector
FCG
⑥ Fault validation of communication

・ Avoid CAN communication when the starter key is in the lock or accessory. Also avoid CAN
communication during the start sequence of the control units connected to the CAN bus of
external control unit.
・ During the engine start sequence, when the starter motor is turning, the supply voltage can
be extremely low. Because of this, communication from the FCG control unit cannot be
guaranteed during this sequence.
・ No fault codes related to CAN communication with the FCG control unit should be set when
the system voltage is under 18V.
・ When the starter key is turned ON, the FCG control unit starts sending messages within a few
seconds.
For further information of FMS-CAN interface, contact ISUZU distributor or ISUZU dealership.
Chapter 8
PAINTING Ⅱ SPECIFIC INFORMATION
Chapter 8 PAINTING
8-1 PAINTING-PROHIBITED AREA ON COMPONENTS OR EQUIPMENTS
Chapter 8
8-1 PAINTING-PROHIBITED AREA ON COMPONENTS OR EQUIPMENTS

Painting in following areas are prohibited.
When paint may attach by the painting of the outskirts part, mask it by all means.
This chapter mainly describes about particular part of this vehicle. For other parts, confirm "Ⅰ-2-
15 PRECAUTIONS FOR PAINTING".
① Disc wheel
Do not apply additional painting on the contact faces of a mating disc wheel and a hub, and the
portions with which wheel nuts contact because thickening the painting may eventually loosen
or damage wheel nuts.
Painting prohibited areas of disc wheel
Paint prohibited area
A
A
Section A-A
Paint prohibited area
The disc wheel shown here is one example.
② Brake chamber (rear axle)
Check valve under brake chamber
Check valve in the lower part

of the brake chamber
Chapter 8
③ Components related to braking system
Do not apply paint on air outlet or silencer.

・ Governor
・ Servo unit
・ Relay valve
・ Multi protection valve
・Air dryer
・Brake valve
・Parking brake valve
・Modulator
・ Quick release valve
・ LSPV
・ Trailer control valve
・ Trailer hand control valve
・ Electro hydraulic control unit
・ Proportional valve
・ASR valve
・HSA valve
・Reducing valve
④ Others
・Piston rod for cab power tilt cylinder

・Bellows for air suspension
Chapter 9
CAB CHASSIS DRAWINGS Ⅱ SPECIFIC INFORMATION
Chapter 9 CAB CHASSIS DRAWINGS

9-1 CAB CHASSIS DRAWINGS
9-2 CAB BACK DETAIL DRAWINGS
Chapter 9
9-1 CAB CHASSIS DRAWINGS

FXR
Rear suspension
No. Vehicle model Transmission Drawing
Leaf Air
1 FXR77UU-RDSH ZF ○ — Fig.9-1-1
2 FXR77VU-RDSH ZF — ○ Fig.9-1-2
3 FXR77VU-RDSH-P ALLISON — ○ Fig.9-1-3
4 FXR77VU-SDSH ZF — ○ Fig.9-1-4
FXM/FXZ
Rear suspension
Leaf Air
5 FXM77VU-UDSH ZF — ○ Fig.9-1-5
6 FXZ77UU-PDSH-P ALLISON ○ — Fig.9-1-6
7 FXZ77UU-UDSH ZF ○ — Fig.9-1-7
8 FXZ77UU-UDSH-P ALLISON ○ — Fig.9-1-8
9 FXZ77VU-PDSH-P ALLISON — ○ Fig.9-1-9
10 FXZ77VU-UDSH ZF — ○ Fig.9-1-10
11 FXZ77VU-UDSH-P ALLISON — ○ Fig.9-1-11
FYH
Rear suspension
Leaf Air
14 FYH77UU-TDSH-P ALLISON ○ — Fig.9-1-14

15 FYH77UU-UDSH-P ALLISON ○ — Fig.9-1-15
16 FYH77VU-RDSH-P ALLISON — ○ Fig.9-1-16
18 FYH77VU-TDSH-P ALLISON — ○ Fig.9-1-18

19 FYH77VU-UDSH ZF — ○ Fig.9-1-19
20 FYH77VU-UDSH-P ALLISON — ○ Fig.9-1-20
21 FYH77VU-WDSH ZF — ○ Fig.9-1-21
22 FYH77VU-WDSH-P ALLISON — ○ Fig.9-1-22
Note: ・ X,Y and Z of drawings, refer to "Ⅱ-5-2 FORMULA FOR CALUCULATING GROUND
HEIGHT OF CHASSIS FRAME TOP SURFACE".
・The outer most measurement of rear tire is a reference and may be different from actual
size. Confirm by actual measurement.
Chapter 9
Fig. 9-1-1 Cab chassis drawing FXR77UU-RDSH
Chapter 9
Fig. 9-1-2 Cab chassis drawing FXR77VU-RDSH
Chapter 9
Fig. 9-1-3 Cab chassis drawing FXR77VU-RDSH-P
Chapter 9
Fig. 9-1-4 Cab chassis drawing FXR77VU-SDSH
Chapter 9
Fig. 9-1-5 Cab chassis drawing FXM77VU-UDSH
Chapter 9
Fig. 9-1-6 Cab chassis drawing FXZ77UU-PDSH-P
Chapter 9
Fig. 9-1-7 Cab chassis drawing FXZ77UU-UDSH
Chapter 9
Fig. 9-1-8 Cab chassis drawing FXZ77UU-UDSH-P
Chapter 9
Fig. 9-1-9 Cab chassis drawing FXZ77VU-PDSH-P
Chapter 9
Fig. 9-1-10 Cab chassis drawing FXZ77VU-UDSH
Chapter 9
Fig. 9-1-11 Cab chassis drawing FXZ77VU-UDSH-P
Chapter 9
Fig. 9-1-14 Cab chassis drawing FYH77UU-TDSH-P
Chapter 9
Fig. 9-1-15 Cab chassis drawing FYH77UU-UDSH-P
Chapter 9
Fig. 9-1-16 Cab chassis drawing FYH77VU-RDSH-P
Chapter 9
Fig. 9-1-18 Cab chassis drawing FYH77VU-TDSH-P
Chapter 9
Fig. 9-1-19 Cab chassis drawing FYH77VU-UDSH
Chapter 9
Fig. 9-1-20 Cab chassis drawing FYH77VU-UDSH-P
Chapter 9
Fig. 9-1-21 Cab chassis drawing FYH77VU-WDSH
Chapter 9
Fig. 9-1-22 Cab chassis drawing FYH77VU-WDSH-P
Chapter 9
9-2 CAB BACK DETAIL DRAWINGS

FXR
No. Vehicle model Transmission Flywheel PTO Drawing
1 FXR77UU-RDSH
2 FXR77VU-RDSH ZF — Fig.9-2-1
3 FXR77VU-SDSH
4 FXR77VU-RDSH-P ALLISON — Fig.9-2-2
FXM/FXZ
5 FXM77VU-UDSH
6 FXZ77UU-UDSH ZF — Fig.9-2-1
7 FXZ77VU-UDSH
8 FXZ77UU-PDSH-P
9 FXZ77UU-UDSH-P
ALLISON — Fig.9-2-2
10 FXZ77VU-PDSH-P
11 FXZ77VU-UDSH-P
FYH
12 FYH77VU-UDSH
ZF — Fig.9-2-3
13 FYH77VU-WDSH
17 FYH77VU-RDSH-P Fig.9-2-6
18 FYH77UU-TDSH-P
19 FYH77UU-UDSH-P
ALLISON —
20 FYH77VU-TDSH-P Fig.9-2-7
21 FYH77VU-UDSH-P
22 FYH77VU-WDSH-P
Chapter 9
Fig. 9-2-1 FXR, FXM, FXZ
Engine : 6UZ1-TCC
T/M : ZF9S1310TO
Frame height : 285mm
Unit : mm
Chapter 9
Fig. 9-2-2 FXR, FXZ
Engine : 6UZ1-TCC
T/M : ALLISON4430
Unit : mm
Chapter 9
Fig. 9-2-3 FYH (1)
Engine : 6UZ1-TCC
T/M : ZF9S1310TO
Unit : mm
Chapter 9
Fig. 9-2-6 FYH (4)
Engine : 6UZ1-TCC
T/M : ALLISON4430
Unit : mm
Chapter 9
Fig. 9-2-7 FYH (5)
Engine : 6UZ1-TCC
T/M : ALLISON4430
Unit : mm
Chapter 10
CHASSIS FRAME DRAWINGS Ⅱ SPECIFIC INFORMATION
Chapter 10 CHASSIS FRAME DRAWINGS

10-1 CHASSIS FRAME DRAWINGS
10-2 DETAILED DRAWINGS OF CROSS MEMBERS
Chapter 10
10-1 CHASSIS FRAME DRAWINGS

FXR
Rear suspension
Leaf Air
1 FXR77UU-RDSH ○ — Fig.10-1-1
2 FXR77VU-RDSH — ○
Fig.10-1-2
3 FXR77VU-RDSH-P — ○
4 FXR77VU-SDSH — ○ Fig.10-1-3
FXM/FXZ
Rear suspension
Leaf Air
5 FXM77VU-UDSH — ○ Fig.10-1-4
6 FXZ77UU-PDSH-P ○ — Fig.10-1-5
7 FXZ77UU-UDSH ○ —
Fig.10-1-6
8 FXZ77UU-UDSH-P ○ —
9 FXZ77VU-PDSH-P — ○ Fig.10-1-7
10 FXZ77VU-UDSH — ○
Fig.10-1-8
11 FXZ77VU-UDSH-P — ○
FYH
Rear suspension
Leaf Air
Fig.10-1-10
14 FYH77UU-TDSH-P ○ —
15 FYH77UU-UDSH-P ○ — Fig.10-1-11
16 FYH77VU-RDSH-P — ○ Fig.10-1-12
Fig.10-1-13
18 FYH77VU-TDSH-P — ○
19 FYH77VU-UDSH — ○
Fig.10-1-14
20 FYH77VU-UDSH-P — ○
21 FYH77VU-WDSH — ○
Fig.10-1-15
22 FYH77VU-WDSH-P — ○
Chapter 10
Fig. 10-1-1 Chassis frame drawing FXR77UU-RDSH
Chapter 10
Fig. 10-1-2 Chassis frame drawing FXR77VU-RDSH, FXR77VU-RDSH-P
Chapter 10
Fig. 10-1-3 Chassis frame drawing FXR77VU-SDSH
Chapter 10
Fig. 10-1-4 Chassis frame drawing FXM77VU-UDSH
Chapter 10
Fig. 10-1-5 Chassis frame drawing FXZ77UU-PDSH-P
Chapter 10
Fig. 10-1-6 Chassis frame drawing FXZ77UU-UDSH, FXZ77UU-UDSH-P
Chapter 10
Fig. 10-1-7 Chassis frame drawing FXZ77VU-PDSH-P
Chapter 10
Fig. 10-1-8 Chassis frame drawing FXZ77VU-UDSH, FXZ77VU-UDSH-P
Chapter 10
Fig. 10-1-10 Chassis frame drawing FYH77UU-TDSH-P
Chapter 10
Fig. 10-1-11 Chassis frame drawing FYH77UU-UDSH-P
Chapter 10
Fig. 10-1-12 Chassis frame drawing FYH77VU-RDSH-P
Chapter 10
Fig. 10-1-13 Chassis frame drawing FYH77VU-TDSH-P
Chapter 10
Fig. 10-1-14 Chassis frame drawing FYH77VU-UDSH, FYH77VU-UDSH-P
Chapter 10
Fig. 10-1-15 Chassis frame drawing FYH77VU-WDSH, FYH77VU-WDSH-P
Chapter 10
10-2 DETAILED DRAWINGS OF CROSS MEMBERS

Unused cross members are also shown, because drawings are common to FXGX-Series and
C&E-Series. Confirm "Ⅱ-10-1 CHASSIS FRAME DRAWINGS" for cross member symbol of
shipment vehicle.
A1
B1 B2
Chapter 10
B3 B4
B5
Chapter 10
C1 C2
C3 C4
Chapter 10
C5 C6
C7 C8
Chapter 10
C9
C10
Chapter 10
C11
C12 C13
Chapter 10
C14
D1 D2
Chapter 10
D3 D4
D5
Chapter 10
E1
E2 E3
Chapter 10
E4
Chapter 10
F1 F2
F3 F4
Chapter 10
F5 F6
Chapter 11
APPENDIX Ⅱ SPECIFIC INFORMATION
Chapter 11 APPENDIX
11-1 PIPING DIAGRAMS
Chapter 11
11-1 PIPING DIAGRAMS

Specification
System ABS ESC
FXR77UU
1 Fig.11-1-1 ○ ―
FXR77VU
FXM77VU
2 FXZ77UU Fig.11-1-2 ○ ―
FXZ77VU Full Air
FYH77UU
3 Fig.11-1-3 ○ ―
FYH77VU-TD,UD,WD
4 FYH77VU-RD Fig.11-1-4 ― ○
Legend ○: Standard equipment ―: Not equipped
LEGEND
SYMBOL NAME SYMBOL NAME
DUAL RELAY VALVE PROPORTIONAL RELAY VALVE
MAIN…MAIN AIR TANK

PRI …PRIMARY AIR TANK
MODULATOR SEC …SECONDARY AIR TANK
W/P …WHEEL PARK AIR TANK
ACC …ACCESSORY AIR TANK
MULTI PROTECTION VALVE TRAILER CONTROL VALVE
RELAY VALVE with

REDUCING VALVE
DOUBLE CHECK VALVE
LOAD SENSING
ANTI SPIN REGULATOR VALVE
PROPORTION VALVE
・ The referred number of piping apparatus expresses the use of port. (The second column
shows the serial number of the port.)
1: Supply
2: Delivery
3: Exhaust
4: Control
・ The symbol of piping and wiring shown below. The referred number expresses the outer
diameter.
Air piping
Wiring
Chapter 11
Fig. 11-1-1 Piping Diagram FXR77UU / FXR77VU (With ABS)
Chapter 11
Fig. 11-1-2 Piping Diagram FXM77VU / FXZ77UU / FXZ77VU (With ABS)
Chapter 11
Fig. 11-1-3 Piping Diagram FYH77UU / FYH77VU-TD,UD,WD (With ABS)
Chapter 11
Fig. 11-1-4 Piping Diagram FYH77VU-RD (With ESC)
MY22 FYJ 300-350 Agitator Cab Chassis Outriggers Details
MY22 FYX 350-350 AUTO CHASSIS DRAWING

Body Builders Guide MY22 FY Series IAL BBG Apr2022

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FX221_601

FXFY-Series for Australia

BODY BUILDERS GUIDE

Sales model year 2022

Conformity regulation ADR and each state or territory regulations

IAL recommends that modifications to truck chassis be avoided wherever possible. If

The latest issue of VSB6 is available from the following website:

Isuzu, in accordance with ADR Circular 0-4-11, Certification of Chassis-Cab Vehicles,

Chapter 2 MODIFICATION OF CHASSIS

Chapter 3 REAR BODY MOUNTING

Chapter 2 PRINCIPAL SPECIFICATIONS OF VARIOUS VEHICLE MODELS

Chapter 3 PRECAUTIONS FOR REAR BODY MOUNTING

Chapter 4 WEIGHT DATA AND FRAME STRENGTH CALCULATION

Chapter 5 CHARACTERISTICS OF THE SPRINGS

Chapter 6 PTO AND ENGINE CONTROL

Chapter 7 ELECTRICAL SYSTEM

Chapter 9 CAB CHASSIS DRAWINGS

Chapter 10 CHASSIS FRAME DRAWINGS

1-1 PRECAUTIONS FOR INSTALLING BODY

1-2 PRECAUTIONS AT INSTALLING

1-3 PRECAUTIONS FOR BOLT TIGHTENING

1-1 PRECAUTIONS FOR INSTALLING BODY

② Approach angle, departure angle, and ramp angle.

Approach angle, departure angle, and ramp angle

④ Consideration to chassis maintenance

・ Rear bodies must be designed or mounted on chassis so as not to obstruct maintenance.

- Checking, feeding and draining engine oil

1-2 PRECAUTIONS AT INSTALLING

Example of rotation part and high temperature section

Cooling fan and belt Exhaust manifold

④ Moving the vehicle

⑤ Storing the vehicle

1-3 PRECAUTIONS FOR BOLT TIGHTENING

Bolt tightening torque unit：N・m {kgf・m}

8.8 8.8 9.8 8.8 8.8 9.8

* Used for internal thread of soft material such as casting.

Chapter 2 MODIFICATION OF CHASSIS

2-1 DRILLING OR WELDING A CHASSIS FRAME

Working prohibited areas of side member (1)

Working prohibited areas of side member (2)

・ Maintain the following measurements at working.

Heavy duty vehicle 17mm H/5

Note: Measure “d” from end of bending radius.

Cutting or machining strictly prohibited Cross member

④ Other cautions at work

2-2 REINFORCING A CHASSIS FRAME SIDE MEMBER

Poor reinforcement forming makes

② Installation position of reinforcement material

Cross member location

Inner reinforcement end

Cross member location

Spring BRKT Cross member location

③ Installing reinforcement material

2-3 MODIFYING REAR OVERHANG OF A CHASSIS FRAME

② Installing extension material

・ In case that extension material is 300mm or shorter:

Installing extension material (1)

Butt welding on the entire circumference and

・ In case that extension material is longer than 300mm:

Installing extension material (2)