2009/2010MY

WORKSHOP MANUAL

FRAME

No.LGFRM-WE-1091
59657_Maegaki 2009.2.20 3:38 PM 1

This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
2 SUSPENSION 2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D1 Transfer Case (Part Time)
4 BRAKES 4B Brake
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME 11A Frame
59657_Maegaki 2009.2.20 3:38 PM 2
LGFRM-WE-1091.book 1

Frame 11A-1

FRAME AND FRAME ACCESSORIES

Frame
TABLE OF CONTENTS
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2
Minimizing Frame Service . . . . . . . . . . . . . . . . 11A-2
Reinforcements . . . . . . . . . . . . . . . . . . . . . . . . 11A-2
Drilling and Welding . . . . . . . . . . . . . . . . . . . . . 11A-3
LGFRM-WE-1091.book 2

11A-2 Frame

Frame
Minimizing Frame Service 2. Follow recommended practices when repairing a
frame or when mounting a body or equipment on a
Generally, frame service can be minimized or
frame.
eliminated by minimizing the concentration of stress in
small areas of the frame: a. Avoid sudden changes in the section modulus.
1. Vehicles should be used only for those purposes b. Do not drill holes in the frame rail flanges.
for which they were designed. c. Space holes in the web section of a rail at least
a. They should not be overloaded. 25 mm (0.98 in.) from one another.
b. They should be loaded evenly; localized d. Use existing holes whenever possible.
overloads should be avoided. e. Do not cut holes with a torch.
c. Dump trucks should not be used to spread f. Do not cut notches in the rails.
loads. g. Do not overheat the frame rails.
d. Use baffles in tank trucks. h. Avoid welding on the flanges.
e. Do not operate the vehicle on extremely rough i. Do not allow four or more holes to exist on the
terrain. same vertical line of the web.
f. Take into account the forces that will be placed j. Holes made in a reinforcement should be
on the frame from the operation of equipment placed at least two times the material thickness
such as snow plows when picking a frame for a from the edge of the reinforcement.
new vehicle or reinforcing a frame.

Satisfactory
2

While welding,be sure to take off electric wiring and fuel pipe from the frame.

Unsatisfactory Welding isprohibited

HCW8BAMF000101

Legend
1. More than 45 4. Side member
2. Plug weld or rivet 5. Reinforcement
3. Reinforcement 6. Side member

Reinforcements installing reinforcement materials on the chassis frame.

The following points should be carefully noted when
LGFRM-WE-1091.book 3

Frame 11A-3
1. Reinforcement materials should be so installed to 8. On tandem rear axle models (with trunnion type
prevent a considerable variation in the section rear suspension) cutting or machining of gusset
modulus and so welded to avoid localized angles is strictly prohibited.
stresses.
2. High-tensile steel reinforcement plates should be
used on the main frame members which are made
up of high-tensile steel.

Drilling and Welding

1. Welding and drilling is strictly prohibited in the
shaded area of the chassis frame members.
Any portions within 20 mm (0.79 in.) from the edge 1
20 mm (0.79 in.) or more
of holes should not be welded.
2
2. Length of welding beads should be held within 30 - 3
50 mm (1.2 - 2.0 in.) and at least 25 mm (0.98 in.)
of distance should be maintained between
adjacent welding beads. For high- tensile steel
chassis frames, refer to special instructions.

HCW8BASH000101
mm (in.)
Legend
a b c 1. Cutting or machining strictly prohibited
Not more than 2. Gusset angle
20 (0.79) 25 (0.98) or more 3. Crossmember
11 (0.43)

WELDING
General Precautions
1. Disconnect negative battery cable prior to welding.
If you do not this, electrical parts could be
2
damaged.
b
2. Connect the welder ground cable as close to the
H
working area as possible.
3. Keep reinforcement plates and chassis frame
b members free from moisture and water.
4. Avoid cooling with water after welding.
a 5. Use a suitable means to protect pipes, wires,
c rubber parts, leaf springs, etc. against heat and
1 affect of sputtering.
6. Remove fuel tank assembly when welding portions
near the fuel tank.
HCW8BASH000201
7. Remove coat of paint completely when welding
painted areas.
Legend
1. Side member Carefully Note the Following Points When Welding
2. Range of prohibition Chassis Frame Members Made of High-Tensile
Steel:
3. To make a hole, do not use gas flame. Be sure to
1. Weld with extreme care to prevent cracking.
use drill.
2. Hold hardness of material from increasing beyond
4. Always chamfer the edges after drilling.
the limit (not higher than 350 in terms of Vickers
5. In case of rivet fixing, use cold riveting. hardness).
6. Cutting the flange of the chassis frame is 3. The face of welding beads should be smoothed as
prohibited. the notch effect of high- tensile steel is relatively
7. In case of fixing the sub frame to the chassis higher than ordinary mild steel.
frame, use bolt fixing. (Welding beads must be smoothed carefully where
fatigue strength is of important consideration).
LGFRM-WE-1091.book 4

11A-4 Frame
4. Welding methods Use a suitable means to protect the chassis
Recommended welding rods frame against sputtering. If part of the chassis
(JIS)-D5316 (Insulated arc-welding rod for mild frame is exposed to sputtering inadvertently,
steel) grind finish affected area.
D4303 is to be used only for welding fillet
portions.
Welding rods should be dried completely before
using.
Drying: 30 - 60 minutes at 70-100C (158-
212F).
Slightly concaved
Dry welding rod for about 1 hour using indirect Satisfactory
heat from gas burner or charcoal. Convexed
Preheat chassis frame members made up of Unsatisfactory
high- tensile steel sufficiently before welding.
Preheating temperature: 100-150C (212- Grind finish is recommendable
302F).
(Preheating temperature should be such that
drops of water evaporate with sizzling sound in
contact with heated area.)
The length of welding beads should not be HCW8BASH000401
shorter than 30 mm (1.2 in.). Where length of
welding beads are to be limited, preheat the Face of all welding beads should preferably be
chassis frame members sufficiently. smoothed with a pointed hammer.
Smooth face of all welding beads.
Avoid undercut-like welding as illustrated in the
drawing.
Avoid leaving excess metal (increase in
thickness should be held around 10 percent of
the thickness of the frame member).

The thickness of excess metal should be held

around 10 percent of the chassis frame thickness

Satisfactory

Undercut-like welding
HCW8BASH000501
Unsatisfactory

HCW8BASH000301

Avoid welding of portions subject to high

stresses unless absolutely necessary.
Carefully grind finish welded portions. Grind
finish welded portions in direction in line with
longitudinal direction of the chassis frame using
a fine abrasive wheel.
LGFRM-WE-1091.book 5

Frame 11A-5
After butt-welding angles, grind-finish the edges
carefully moving abrasive wheel in the direction
in line with the longitudinal direction.

Grind finish to
smooth curvature

Grind finish edge

carefully

HCW8BASH000601
LGFRM-WE-1091.book 1

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Published: Sep., 2009 All rights reserved.
Second Edition

WORKSHOP MANUAL
FRAME

Issued by ISUZU MOTORS LIMITED

E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
59657_LGFRM-WE-1091_ 2009.2.20 3:40 PM 2
 2010MY
2010MY

WORKSHOP MANUALFRAME
WORKSHOP MANUAL

FRAME

No.LGFRM-WE-1091