Isuzu FX FY Series Body Builders Guide 2022 – FXR FXM FXZ FYH Truck Body Mounting Manual PDF

Description

The Isuzu FX FY Series Body Builders Guide 2022 is the body-mounting reference published for the 2022 sales model year FX and FY forward-control truck range. It is written for the people who take the incomplete Isuzu cab chassis and mount the final rear body on it, and it collects every rule, clearance, torque figure, drawing and design guideline that the FX / FY platform requires to be finished correctly. The guide covers the FXR, FXM, FXZ and FYH models and the closely related FXD, FXL, FXY, FYJ and FYX variants listed in the MY22 model code chart.

File Details

• Manual type: Body Builders Guide (body mounting, chassis modification and rear body installation)
• Brand: Isuzu
• Model series: FX / FY Series (MY22)
• Covered models: FXR, FXM, FXZ, FYH and related variants
• Engine: 6UZ1-TCN / 6UZ1-TCC / 6Z1-TCC
• Language: English
• Page count: 396
• File format: PDF
• Sales model year: 2022
• Conformity reference: ADR and each state or territory regulation

Chapters Covered

The document is divided into two main parts. Part I lays down the general precautions that apply to every FX / FY build, and Part II delivers the model-specific data, drawings and precautions for the individual vehicle specifications.

• I. General Precautions
  • Chapter 1 General – precautions for installing the body, precautions at installing, precautions for bolt tightening
  • Chapter 2 Modification of Chassis – drilling or welding a chassis frame, reinforcing a chassis frame side member, modifying rear overhang, bolt and nut for cross member, precautions for welding, hydraulic or air piping, nylon air tubes and push-in connectors, nylon tube routing and fixing, air extraction, relocation and addition of a fuel tank, precautions for towing hook, electrical system modification, roof equipment installation, through holes inside a cab, painting precautions, emblems, decals
  • Chapter 3 Rear Body Mounting – consideration to proper load, clearance between cab chassis equipment and the rear body, sub frame and fixing of a rear body
• II. Specific Information
  • Chapter 1 Outline
  • Chapter 2 Principal specifications of various vehicle models
  • Chapter 3 Precautions for rear body mounting – SRS, ABS, ABS/ESC, fuel tank installation, air extraction, sub frame for vertical exhaust, exhaust system modification, pintle hook
  • 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 – piping diagrams

In practical terms the FX FY Series Body Builders Guide 2022 is the difference between a body that sits correctly on the chassis and one that fights it. It tells you which areas of the side member must never be drilled or welded, how long a weld bead should be and how far apart the beads should sit, how to size and space the sub frame mounts, how to keep the cab tilt envelope clear, how much clearance the propeller shafts, exhaust, retarder and air lines need, how to run nylon air tube without chafing or freezing, how to add a fuel tank without creating a fire risk, and how to tap standby power from the chassis without cooking the ABS or SRS circuits.

Model Coverage and Specifications

The MY22 model code reference in the guide maps the Isuzu Australia model names to the Isuzu Japan model codes and lists wheelbase, engine and ratings for each. FXR 165-350 LWB, FXD 165-350 LWB and XLWB, FXL 240-350 LWB, FXY 240-350, FYH 300-350, FYJ 300-350 and FYX 350-350 AUTO all appear with their GVM and GCM figures. The ratings run from 16,000 kg through 35,000 kg GVM and up to 38,000 kg or 45,000 kg GCM depending on the variant. The guide also carries the chassis frame section modulus charts, spring specifications, chassis frame top surface ground height formulas, rear and front tyre movement envelopes, and the frame section modulus diagrams for the FXR77, FXM77, FXZ77 and FYH77 model codes.

Electrical, PTO and Air Systems

The electrical section is unusually complete for a body builders guide. It includes power distribution, fuse load, ground distribution, ECM, starter and charging, ABS, ESC, air dryer, transmission (ZF, EATON and ALLISON), PTO, HVAC, SRS, headlamp, combination lamp, wiper, meter, CAN network diagrams, junction blocks, fuse blocks, chassis relay box and a full connector list. The PTO chapter covers the flywheel PTO, the external engine control lever, the harness routing for the external acceleration, dump and mixer control cable precautions, and the cover kit part numbers. Air extraction is covered in detail, including the multi protection valve layouts, the accessory tank routing, and the 690 kPa protection valve that must be fitted between the chassis extraction port and the rear body equipment.

Frame, Spring and Weight Data

Weight distribution formulas are given for 2-axle, 3-axle and 4-axle vehicles, along with the cab chassis weight and axle load capacity tables for each FXR, FXM, FXZ and FYH variant. Spring specifications are listed for leaf and air suspension, with the formula for calculating chassis frame top surface height above the front and rear axles. The rear axle and tyre movement envelope data gives the dimensions needed to position the rear fender and tyre housing with a reasonable clearance, and the same information is repeated for the front (rear) axle of the FYH.

Drawings and Diagrams

Cab chassis drawings are provided for the FXR77UU, FXR77VU, FXM77VU, FXZ77UU, FXZ77VU and the FYH77UU, FYH77VU range, and cab back detail drawings are included for both the ZF and ALLISON transmission variants. Chassis frame drawings cover the same range, and detailed cross member drawings are also included. Piping diagrams appear in the appendix for the FXR, FXM, FXZ and FYH, with ABS and ESC variants shown.

Who This Body Builders Guide Is For

This is written for body builders, chassis modifiers, fleet engineers and workshops that finish an Isuzu FX or FY cab chassis into a tipper, mixer, garbage compactor, agitator, crane truck, refrigerated van, fire appliance or any other rear body configuration. It assumes the reader is competent to weld, drill, bolt and wire a heavy vehicle chassis, and it sets the limits within which that work must stay so the finished vehicle remains ADR compliant, safe, durable and within warranty.

What the Isuzu FX FY Series Body Builders Guide 2022 Lets You Do

With this guide in hand you can design a sub frame that distributes body load along the chassis rather than concentrating it, position the outrigger or fish plate mounts so they stay clear of cross members, suspension brackets and reinforcement sections, choose the correct hole diameter for each chassis series, decide where reinforcement can and cannot be placed, and calculate the load distribution of the finished vehicle before the body is built. You can route nylon air tube and steel pipe without creating chafe points or freeze traps, extract air for accessories from the correct port, add a fuel tank without breaking the engine supply line, run standby power from the battery with correct fusing and grounding, install SRS and ABS-safe electrical work, and paint the chassis and cab without damaging the components that must not be painted.

Why Correct Body Mounting Procedures Matter

Getting a body mount wrong on an FX or FY chassis is not a cosmetic problem. An incorrectly positioned sub frame mount can crack a side member. Drilling in a prohibited area can start a fatigue crack that only shows up thousands of kilometres later. Extracting accessory air from the brake line instead of the accessory line can degrade braking performance. Tapping standby power from the wrong wire can upset the ABS or SRS circuit. Adding a fuel tank in the rear overhang area, or joining a fuel hose to the factory line, can create a fire risk. Every one of those errors is addressed in the guide with a specific prohibition, dimension, torque value or drawing, which is exactly why the document exists.

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Instant PDF Delivery

The Isuzu FX FY Series Body Builders Guide 2022 is supplied as a downloadable PDF. There is no shipping, no waiting for a courier and no physical book to keep track of. The file opens on any laptop, tablet or phone, and any page, diagram or table can be printed for use in the workshop or on the chassis. Because it is a PDF, the drawings and specification tables can be zoomed in on screen, which is the practical way to read a 396-page body building reference when you are working under a truck.