1 page

INDEX1
Models FA, FB, FD, FE, FF and SG CHASSIS FRAME 18-1

18-28E-09

CHAPTER 18
CHASSIS FRAME
Models FA, FB, FD, FE, FF and SG

TROUBLESHOOTING ................................................................ 18- 2

CHASSIS FRAME ...................................................................... 18- 3

18
 1 page 1
18-2 CHASSIS FRAME Models FA, FB, FD, FE, FF and SG

TROUBLESHOOTING

Symptom Possible cause Remedy

Frame distortion Weakened or broken springs on .............. Replace springs
(Vehicle inclination) one side

Incorrect mounting ................................... Correct mounting

(Attachment of heavy unit on one side of the vehicle)

Bent frame Overloading or load concentrate on ........ Correct load

...
rear end of frame ........Correct with frame correction
device

Cracked frame or Inappropriate method of body mounting .. Correct mounting

...
broken rivets .. Improvement of the usage
Overloading .............................................. Reinforce with stiffener
 1 page 1
Models FA, FB, FD, FE, FF and SG CHASSIS FRAME 18-3

CHASSIS FRAME

INSPECTION
1. CLEAN THE FRAME.
NOTE: While inspecting or repairing, stop the engine
and block the wheels. When cleaning with a
steam cleaner, use safety goggles.

Fig.18-1 SM18-1
2. PLACE THE VEHICLE ON A FLAT SURFACE, HANG A
WEIGHT FROM EACH MEASURING POINT ON THE
FRAME, AND MARK THE FLOOR BELOW THE
WEIGHT.

Fig.18-2 SM18-2
3. INSPECT THE FRAME FOR BENDING, TWISTING OR
OTHER DEFORMATION.

Fig.18-3 SM18-3
4. CHECK THE TIGHTNESS OF THE RIVETS, AND BOLTS.

Fig.18-4 SM18-4
 1 page 1
18-4 CHASSIS FRAME Models FA, FB, FD, FE, FF and SG

REPAIRS
1. FRAME ALIGNMENT
Correct the frame alignment.

Fig.18-5 SM18-5
2. REPLACEMENT OF LOOSENED RIVETS
1. Drill out the head of the loosened rivet with a drill.
NOTE: When drilling, do not use gloves. They can
get caught up in the drill.

Fig.18-6 SM18-7
2. Ream the hole with a reamer.

Fig.18-7 SM18-8
3. Strike the rivet with the proper amount of force using
a pneumatic riveter
Unit: mm (in.)
Rivet hole
Rivet
Standard Limit
ø10 ø11(ø0.43) ø11.5(ø0.45)
(ø0.39)
ø13 ø14(ø0.55) ø14.5(ø0.57)
(ø0.51)
ø16 ø17(ø0.67) ø17.5(ø0.69)
(ø0.63)
Fig.18-8 SM18-9 SM18-10
4. If it is impossible to tighten with rivets, finish the rivet
GOOD BAD hole with a reamer and tighten with reamer bolts.
NOTE: The tensile strength of the bolts must be
above 90 kg/mm2 (127,998 psi).
Tightening torque Unit: kg·cm (lb·ft)
12 mm dia bolt 870 – 1,100 (63 – 79)
14 mm dia bolt 1,500 – 1,800 (109 – 130)
16 mm dia bolt 2,300 – 2,900 (167 – 209)
Fig.18-9 SM18-022
 1 page 1
Models FA, FB, FD, FE, FF and SG CHASSIS FRAME 18-5

5. Arc weld nut and bolt to prevent loosening after

WHIRL–STOP WELDING tighten the bolts to the specified torque.

Fig.18-10 SM18-12
3. CRACKING OF THE FRAME
1. Clean the area around the cracks with a steam
cleaner, soap and water, or a solvent.
NOTE: When cleaning with a steam cleaner, use
safety goggles.

Fig.18-11 SM18-1
2. Drill a 6 mm hole at the extreme end of the crack to
DRILLING POSITION
prevent the cracks from progressing.

INCORRECT CORRECT

Fig.18-12

a)
3. Grind the frame to make a V-shaped groove along
the crack.
a) Without the inner stiffener
Unit: mm (in.)
t t s α°
s 4.5 (0.18) 1.0 (0.039) 90o

Fig.18-13
b) With the inner stiffener
b)
In the case of cracked main frame (t=4.5)
Unit: mm (in.)
t s a α°
t 4.5 (0.18) 1.0 (0.039) 3.2 (0.13) 90°
a

Fig.18-14 SM18-018
 1 page 1
18-6 CHASSIS FRAME Models FA, FB, FD, FE, FF and SG

c) With the inner stiffener.

s
In the case of cracked inner stiffener (a=3.2)
Unit: mm (in.)
t t s a α°

a 4.5 (0.18) 1.0 (0.039) 3.2 (0.13) 90°

Fig.18-15 SM18-019
4. Arc weld the groove with the proper welding rod.

Fig.18-16
5. Smooth both the surface of the welded section and
the face of the flange, then reinforce the repaired
section with a patch-plate of the same thickness as
the frame.

Fig.18-17

6. After welding, shake the grinder crosswise the bead

CORRECT WRONG
line A, along direction B, to polish the welded area
illustrated as C.
Grind and polish the bead line A so that the frame
surface becomes even.
A

C B

Fig.18-18 ASM18-001
 1 page 1
Models FA, FB, FD, FE, FF and SG CHASSIS FRAME 18-7

WARNING
● Perform the electric welding after conforming
the following procedures, as it may occur that
the reverse current come from the ground line
drivers electronic instruments to malfunctions.
1) Set the starter switch to [OFF] position.
2) Be sure to disconnect the negative terminal
of the battery cable.
3) Be sure to ground of the welder to the place
near the welding spots.
● Be sure to cover the piping lines, harnesses,
rubber (resin) parts, fuel tank, and the like with
the fireproofing sheets, it the above parts locate
around the welding spots.
● Heat up to the welding area by using a burner,
soon after performing the welding, and then leave
them as they are.
 1 page 1
18-8 CHASSIS FRAME Models FA, FB, FD, FE, FF and SG

4. REINFORCEMENT PATCHING METHOD

CORRECT WRONG
1. Sudden sectional change at the end of the reinforcing
material may become a cause of damage.
Patching plate thckness should be the same as the
frame.
LESS
THAN 30º

Fig.18-19 ASM18-002

CORRECT WRONG

Fig.18-20 ASM18-003

CORRECT WRONG

Fig.18-21 ASM18-004
2. Be sure to fasten the bolts at the hole locations of
CORRECT WRONG
ups and downs (other wise, use rivets or perform plug
welding.).

Fig.18-22 ASM18-005
3. Diameter of plug Welding hole.
NOTE: Prohibit plug welding of flange.
25 PLUG WELDING

t dø
d
t 3.2 15
4.5 15
6 18

Fig.18-23 ASM18-006
 1 page 1
Models FA, FB, FD, FE, FF and SG CHASSIS FRAME 18-9

4. Interval of hales
a ≥ 50+d/2
e1 e1
b ≥ 3d
a d c ≥ 70+d/2
b d
e2 b d ≤ 20
e1e2 ≥ 701+a

Fig.18-24 ASM18-007

CORRECT WRONG 5. Method of fixing on the flange.

RIVETS OR
REAMER BOLT PLUG WELDING

Fig.18-25 ASM18-008
6. Method of welding on the flange.
CORRECT WRONG

DO NOT WELD HEAR

40 20

30
25
30

Fig.18-26 ASM18-009

CORRECT WRONG

PROHIBIT WELDING
OF BRACKET
AROUND THE HOLE

OVER 30 (1,2)

Fig.18-27 ASM18-010
7. In welding, be sure that there is no undercut A or
CORRECT WRONG
the overlap B of the bead and a pin hole.
A NOTE: An experienced professional welder should
always perform the welding since a bad
welding job may damage the frame.
B

Fig.18-28 ASM18-011
 1 page 1
18-10 CHASSIS FRAME Models FA, FB, FD, FE, FF and SG

5. WELDING CONDITION (WHEN WELDING ROD IS

USED)

Electric current (Unit: A)

Rod dia ø
3.2 mm {0.126 in.} 4 mm {0.157 in.} 5 mm {0.197 in.}
Welding
Mechanical position Vertical Vertical Vertical
Flat Flat Flat
property of weld metal & rod overhead overhead overhead
Weld Metal (Hot roll plate)
Tensile strength;
441.29 kPa {45 kgf/mm2, 63.990 lbf/in.2}
Welding Rod
80 – 130 60 – 110 120 – 180 100 – 150 170 – 250 130 – 200
Tensile strength;
421.69 kPa {43 kgf/mm2, 61.146 lbf/in.2}
Illuminate type (JIS D4301 AWS E6019)
Coated electrode

Weld Metal (Hot roll plate)

Tensile strength;
539.37 kPa {55 kgf/mm2, 78.210 lbf/in.2}
Welding Rod
90 – 140 80 – 130 141 – 190 110 – 160 180 – 250 –
Tensile strength;
490.33 kPa {50 kgf/mm2, 71.1 lbf/in.2}
Illuminate type (JIS D4301 AWS E6019)
Coated electrode

NOTE: ‡ Diameter of welding rod ø3.2 mm {0.126 in.} or ø4 mm {0.157 in.} - plate thinner than 5
mm {0.197 in.}
‡ Diameter of welding rod ø4 mm {0.157 in.} or ø5 mm {0.197 in.} - plate thicker than 6
mm {0.236 in.}