BBG10.indd (EN)

2010 GM/I suzu T ruck INTRODUCTION.......................................................................................................................................................................................... 1 FMVSS Chart....................................................................................................................................................................................... 2 EPA Requirements.............................................................................................................................................................................

4 INSTALLATION OF BODY AND SPECIAL EQUIPMENT........................................................................................................................... 6 Clearances.......................................................................................................................................................................................... 6 Engine..........................................................................................................................................................................................

6 Transmission................................................................................................................................................................................ 6 Front and Center Propeller Shafts................................................................................................................................................ 7 Rear Propeller Shaft.....................................................................................................................................................................

8 Exhaust System........................................................................................................................................................................... 8 Diesel Particulate Filter (DPF) Restrictions.......................................................................................................................... 9 No Modification Area...........................................................................................................................................................

9 Temporary Removal of DPF Unit....................................................................................................................................... 10 Exhaust Clearances........................................................................................................................................................... 10 Exhaust Pipe Heat.............................................................................................................................................................

11 Other Clearances....................................................................................................................................................................... 12 Rear Wheel and Axle................................................................................................................................................................. 12 Body Installations.............................................................................................................................................................................

13 Chassis...................................................................................................................................................................................... 13 Mirrors........................................................................................................................................................................................ 13 Special Equipment on the Chassis.............................................................................................................................................

13 Subframe Design and Mounting................................................................................................................................................ 13 Subframe Contour..................................................................................................................................................................... 14 Prohibited Attachment Areas..........................................................................................................................................................

15 Subframe Mounting......................................................................................................................................................................... 16 Bracket Installation..................................................................................................................................................................... 16 2010 GM/Isuzu Truck PAGE i

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2010 GM/I suzu T ruck INSTALLATION OF BODY AND SPECIAL EQUIPMENT – Subframe Mounting – (Continued) Modular Frame Hole Pattern..................................................................................................................................................... 17 U-bolt Installation....................................................................................................................................................................... 18 Modification of the Frame...............................................................................................................................................................

19 Working on Chassis Frame......................................................................................................................................................... 19 Drilling and Welding.................................................................................................................................................................... 19 Reinforcement of Chassis Frame..............................................................................................................................................

20 Welding...................................................................................................................................................................................... 20 Fluid Lines......................................................................................................................................................................................... 21 Preparation of Additional Lines...................................................................................................................................................

21 Installation of Additional Lines.................................................................................................................................................... 22 Electrical Wiring and Harnessing.................................................................................................................................................... 22 Wiring.........................................................................................................................................................................................

23 Wire Color Code......................................................................................................................................................................... 25 Maximum Allowable Current........................................................................................................................................................... 25 Electrical System Modifications..................................................................................................................................................

26 Exhaust System................................................................................................................................................................................ 26 Fuel System...................................................................................................................................................................................... 27 Rear Lighting....................................................................................................................................................................................

27 Serviceability.................................................................................................................................................................................... 27 Wheelbase Alteration...................................................................................................................................................................... 28 Shortening/Lengthening the Wheelbase without Altering the Frame........................................................................................

28 Altering the Wheelbase by Altering the Frame.......................................................................................................................... 28 Glossary of Terms – Chassis/Wheelbase Alteration.................................................................................................................. 28 BODY APPLICATION SUMMARY CHARTS............................................................................................................................................. 34 2010 Gas and 2010 Diesel Model Body Application Summary Chart....................................................................................... 34 2010 GM/Isuzu Truck PAGE ii

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2010 GM/I suzu T ruck BODY APPLICATION SUMMARY CHARTS – NPR/W3500, NPR HD/W4500 Gas – (Continued) NPR/W3500, NPR HD/W4500 Gas................................................................................................................................................... 36 2010 Model Year – Body & Payload Weight Distribution (% Front/% Rear).............................................................................. 36 NPR/W3500, NPR HD/W4500 Diesel...............................................................................................................................................

37 2010 Model Year – Body & Payload Weight Distribution (% Front/% Rear).............................................................................. 37 NQR/W5500 Diesel........................................................................................................................................................................... 38 2010 Model Year – Body & Payload Weight Distribution (% Front/% Rear).............................................................................. 38 NRR/W5500 HD Diesel.....................................................................................................................................................................

38 2010 Model Year – Body & Payload Weight Distribution (% Front/% Rear).............................................................................. 38 NPR/W3500, NPR HD/W4500 Gas Crew Cab, NPR HD/W4500 & NQR/W5500 Diesel Crew Cab.............................................. 39 2010 Model Year – Gas & Diesel Crew Cab Body & Payload Weight Distribution (% Front/% Rear)....................................... 39 MECHANICAL AND CAB SPECIFICATIONS...........................................................................................................................................

40 Engine Horsepower & Torque Chart............................................................................................................................................... 40 GVW/GCW Ratings.......................................................................................................................................................................... 40 Rear Frame Height Chart................................................................................................................................................................

41 Paint Code Chart.............................................................................................................................................................................. 42 N/W Series Towing Procedure........................................................................................................................................................ 44 Front End Towing (Front Wheels Off the Ground).......................................................................................................................

44 After Towing....................................................................................................................................................................... 45 Front End Towing (All Wheels On the Ground)........................................................................................................................... 45 After Towing.......................................................................................................................................................................

45 Rear End Towing (Rear Wheels Off the Ground)........................................................................................................................ 46 Special Towing Instructions ...................................................................................................................................................... 47 WEIGHT DISTRIBUTION CONCEPTS......................................................................................................................................................

48 Weight Restrictions......................................................................................................................................................................... 48 Gross Axle Weight Rating............................................................................................................................................................... 49 2010 GM/Isuzu Truck PAGE iii

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2010 GM/I suzu T ruck WEIGHT DISTRIBUTION CONCEPTS – (Continued) Weighing the Vehicle....................................................................................................................................................................... 49 Tire Inflation...................................................................................................................................................................................... 49 Center of Gravity..............................................................................................................................................................................

49 Weight Distribution.......................................................................................................................................................................... 50 Glossary of Dimensions.................................................................................................................................................................. 52 Weight Distribution Formulas.........................................................................................................................................................

53 Basic Formulas................................................................................................................................................................................ 54 Weight Distribution Formulas in Words.......................................................................................................................................... 54 Recommended Weight Distribution % of Gross Vehicle Weight by Axle...................................................................................

59 Conventional (2 Axle).................................................................................................................................................................. 59 COE (2 Axle)............................................................................................................................................................................... 59 Conventional (3 Axle).................................................................................................................................................................

60 COE (3 Axle)............................................................................................................................................................................... 60 Trailer Weight.................................................................................................................................................................................... 61 Payload at Kingpin.....................................................................................................................................................................

62 Payload at Rear Tandem............................................................................................................................................................ 62 Performance Calculations............................................................................................................................................................... 63 1. Speed Formula....................................................................................................................................................................... 63 2.

Grade Horsepower Formula................................................................................................................................................... 64 3. Air Resistance Horsepower Formula..................................................................................................................................... 65 4. Engine Horsepower Formula................................................................................................................................................. 66 5.

Gradeability Formula.............................................................................................................................................................. 67 6. Startability Formula................................................................................................................................................................ 68 7. Vertical Center of Gravity Formula......................................................................................................................................... 69 8.

Horizontal Center of Gravity Formula.................................................................................................................................... 71 2010 GM/Isuzu Truck PAGE iv

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