FRAMES - Navistar
Contents
1. Y x 185 195 19 _ 335 BETWEEN 4700 5000 494 851 FRAME RAILS 197 211 28 _ S AN 5050 5350 718 6 H J 213 224 37 _ 5400 5700 942 CENTER LINE TO CENTER LINE 942 FRONT AXLE FRONT SPRING EYE CENTER LINE 226 236 55 REAR AXLE 5750 6100 1390 238 254 19 6150 6450 494 30 256 266 37 44 770 6500 6750 942 1120 268 280 46 6800 7100 1166 282 293 53 213 7150 7450 55 1344 uU L NE _ 295 321 1390 62 52 uy ien 7500 8150 1568 KICK UP RAIL 763 744 LP MODELS ddcrossmember DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 123 INTERMEDIATE CROSSMEMBER LOCATION 4x2 CREW CAB WITH STAGGERED FUEL TANKS SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 124 INTERMEDIATE CROSSMEMBER LOCATION 6x4 STANDARD CAB INTERMEDIATE CROSSMEMBER LOCATION 6x4 Standard Cab Wheelbase Range AX BX CX Min Max Inches Millimeters up to 158 4000 160 197 _ _ 4050 5000 199 211 _ _ 5050 5350 213 224 _ _ 5400 5700 226 238 35 _ 5750 6050 896 240 252 6100 6400 44 254 266 1120 6450 6750 268 280 53 _ 6800 7100 1344 282 293 62 26 7150 7450 1568 672 295 307 35 7500 7800 896 53 309 321 44 1344 7850 812. _ 53 TOUS 82 2 1338 3 25 0 209 31 800 69 0339 TO BACK OF i comerune JOE CENTER UNE FRONT AXLE WE PEAR AXLE 10 6 WITH LP RAILS STRAIGHT RAIL CUM d lt lt 28 30 9 7j 29 3 Crossmember Inches Millimeters KICK UP RAIL 84 29 9 G AXB C SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE UP AND WEB FORWARD 0 REAR SUSPENSION CROSSMEMBER WITH STRAIGHT RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE DOWN AND WEB FORWARD WITH KICK UP RAILS C CHANNEL AF CROSSMEMBER OO WITH STRAIGHT RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE DOWN AND WEB FORWARD 01_0060 AF CROSSMEMBER LOCATIONS 6x4 WITH 52 SPREAD SUSPENSION AF Range Min Max Crossmember WITH 55 AND 60 SPREAD SUSPENSION STRAIGHT RAIL 921 _ 2340 TO CENTER LINE FRONT SPRING EYE CENTER LINE FRONT AXLE TO BACK OF CAB 851 BETWEEN FRAME RAILS CENTER LINE REAR SUSPENSION WB AF Crossmember Min Max Inches Millimeters 1 2 30 750 3 DURASTAR SERIES BUILDE
3. Aftermarket Modifications Cutting the frame behind the rear axle to shorten the frame is acceptable Mechanical cutting or sawing is preferred to torch cutting Whenever it is necessary to cut the frame the sidemember should be cut at an angle of 90 to the longitudinal axis For information on cutting of the frames to lengthen the frames or modify the wheelbase refer to Wheelbase Alterations Where mounting angles are to be welded to fifth wheel assemblies refer to fifth wheel manufacturer s recommendations In some cases specialized equipment such as hoists winches lifts snowplows pusher and tag axles are added to the vehicle by distributors installers or dealers Unless otherwise specified by the customer at the time of assembly the vehicle is generally equipped with a standard chassis frame and the manufacturer has not made special allowances for the special equipment which is being added The addition or installation of this special equipment on the vehicle can significantly affect the loading of the chassis frame In some cases it may be necessary to reinforce the frame Care must be exercised to insure that the gross vehicle weight rating GVWR and or the gross axle weight ratings GAWR are not exceeded Installation of this special equipment may involve State and Federal requirements which affect vehicle certification for noise emissions exhaust emissions brake requirements lighting system requirements etc The specialized
4. L 54 4 8 _ 3 0 17 137 5 3 12 122 135 76 30 1 2 29 CHANNEL REAR SUSPENSION CROSSMEMBER C CHANNEL AF CROSSMEMBER 01 0067 DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 133 CROSSMEMBERS WITH TAPERED RAILS LP 9 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 134 FRAME DRILLING GUIDELINES ALL MODELS FRAME DRILLING GUIDELINES All Models The drilling of the frame sidemember presents no unusual difficulty Standard high speed steel drills of good quality will serve provided they are sharpened properly and not overheated during sharpening or use Hole Location Guidelines Never drill holes into the restricted areas of the frame rails Refer to diagrams on the following pages Use existing holes whenever possible Maintain a minimum of 0 75 inch 19 mm of material between holes There should not be more than three holes located on a vertical line Bolt holes should be no larger than is required for the size of bolts being used in no instance larger than 11 16 688 inch If reinforcements are used avoid drilling holes closer than 2 0 inches 51 mm from the ends of the reinforcement Bolts must be periodically checked to insure that the proper torque and clamping force is maintained Qy E EDU ME Never drill any holes in the flanges of the frame rail FRAME DRILLING RE
5. 2 Improper modification or repair of frame components 3 Equipment which is susceptible to resonant vibration due to excess flexibility of its mounting Frame damage may also be caused by corrosion resulting from the contact between dissimilar metals Damage to the chassis frame which is not associated with impact damage should not be repaired until the cause of the damage has been determined and corrective actions taken to prevent re occurrence of the non impact damage DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 85 GENERAL FRAME INFORMATION ALL MODELS DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 86 GENERAL FRAME INFORMATION ALL MODELS Welding and Reinforcement The guidelines below deal with the general procedures for weld repair and reinforcement Because of the many variables associated with these repairs it is recommended that your field service representative be consulted prior to undertaking the repair This will also help to determine whether a specific set of recommendations has already been developed for the case in question The essential elements of repairing the sidemembers are the restoring of BOTH the shape and local strength so that the load capacity is at least as good as before the damage occurred The sidemembers may like new but may have local strength reduction due to small cracks or material strength reduction Even if the frame has acceptable alignment and there is no
6. 5700 942 226 236 55 _ 5750 6100 1390 238 254 19 6150 6450 494 256 266 37 44 6500 6750 942 1120 268 280 46 6800 7100 1166 282 293 53 7150 7450 55 1344 295 321 1390 62 7500 8150 1568 1 3455 TO CENTER LINE FRONT SPRING EYE 136 0 L 8 0 204 TO BACK OF CAB CENTER LINE CENTER LINE REAR AXLE FRONT AXLE WB _ AF 10 6 STRAIGHT RAIL m wo uu f UU Bg 30 9 29 3 10 6 8 4 KICK UP RAIL LP MODELS E 2 fat fat TED E EE E M 299 r 2334 G 33 5 851 BETWEEN FRAME RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE UP AND WEB FORWARD D REAR SUSPENSION CROSSMEMBER WITH STRAIGHT RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE DOWN AND WEB FORWARD WITH KICK UP RAILS C CHANNEL AF CROSSMEMBER F WITH STRAIGHT RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE DOWN AND WEB FORWARD 01_0062 INTERMEDIATE CROSSMEMBER LOCATION 4x2 Crew Cab with Staggered Fuel Tanks Wheelbase Range BX Min Max BX CX Inches Millimeters up to 183 4650
7. Incorrect Grind Direction Correct Grind Depth Incorrect Grind Direction Incorrect Grind Depth Figure 2 25 Cross sectional Views Showing Correct and Incorrect Methods of Finishing the Joint 01 0035 Wheelbase Alterations Shortening or lengthening a wheelbase is an added expense for the customer Therefore it is often to the customer s benefit to order a chassis from the factory with the desired wheelbase rather than to alter the wheelbase of the chassis on site The preferred method for altering the wheelbase is to slide the rear axle forward or rearward as required Invariably this requires the lengthening or shortening of air lines brake lines electrical lines and driveline Extreme care should be taken in the modification of the air lines brake lines electrical lines and driveline to insure that they operate as reliably as those with which the vehicle was manufactured If the wheelbase is lengthened a reinforcement may be required Consult your International dealer before lengthening the wheelbase In those instances when it is necessary to cut and weld the frame to alter the wheelbase the frame must be reinforced with a channel type reinforcement of the same strength as the original frame material in the area where the frame has been cut extending at least two feet on either side of the cut and bolted as specified in Figure 2 5 D shown earlier in this section If the frame was built with both a main frame and a reinforcement the
8. 14 600 Ib 7 58 6 1 X of standard frame model Adjust dimensions for optional frame reinforcements See Frame Section Frame Rail Height F 01CAA 5 16 x 9 1 8 Tapered Rail 80 psi Yield Strength 9 125 01CAB 5 16 x 9 1 8 Straight Rail 80 psi Yield Strength 9 125 01CAC 5 16 x 10 1 8 Straight Rail 50 psi Yield Strength 10 125 01CAD 3 8 x 10 1 4 Straight Rail 80 psi Yield Strength 10 250 01CAE 01CEK 5 16 x 10 1 8 Straight Rail 120 psi Yield Strength 10 125 01CAG 01CEL 3 8 x 10 1 4 Straight Rail 120 psi Yield Strength 10 250 01CAH 01CEM 7 16 x 10 3 8 Straight Rail 120 psi Yield Strength 10 375 DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 139 FRAME HEIGHT DATA FRONT ALL MODELS 9 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 140 FRAME HEIGHT CALCULATION AT CENTERLINE OF REAR AXLE ALL MODELS FRAME HEIGHT CALCULATION AT CENTERLINE OF REAR AXLE All Models The rear frame height the centerline of the rear axle may be calculated using the following equations Refer to the illustration for a visual explanation of the symbols used in these calculations Wheel axis to bottom of frame in unladen position Refer to tabulated data Wheel axis to bottom of frame in loaded position Refer to tabulated qata F Frame rail height Refer to tabulated data Static Loaded Radius The distance
9. 7850 8150 791 1266 323 331 59 62 8200 8400 1490 1568 DURASTAR SERIES BUILDER BX CX Aa p 335 BETWEEN 851 FRAME RAILS 24 8 630 CENTER LINE TO CENTER LINE FRONT FRONT SPRING EYE CENTER LINE REAR AXLE AF T Bo 19 m 30 3 STRAIGHT RAIL 770 84 213 LS Ravi o 55 a L KICK DE 300 295 744 LP MODELS 63 744 G ddcrossmember FRAMES FEBRUARY 2015 PAGE 125 INTERMEDIATE CROSSMEMBER LOCATION 6x4 STANDARD CAB WITH STAGGERED FUEL TANKS 9 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 126 INTERMEDIATE CROSSMEMBER LOCATION 6x4 EXTENDED CAB INTERMEDIATE CROSSMEMBER LOCATION 6x4 Extended Cab Wheelbase Range BX CX Min Max Inches Millimeters up to 197 5000 m 199 211 11 _ _ 5050 5350 277 213 224 20 _ _ 5400 5700 501 7 8 197 33 5 226 238 35 TO BACK OF CAB 851 m BETWEEN 5750 6050 11 896 T FRAME RAILS 240 252 277 _ 3000 6100 6400 44 TO CENTER LINE FRONT SPRING EYE 254 266 1120 6450 6750 268 280 20 53 _ 6800 7100 501 1344 CENTER LINE CENTER LINE 282 293 62 26 FRONTAXLE REAR SUSPENSION 7150 74
10. Depth Width Thickness Nominal ps Maximum Nominal Maximum Design Straight Channel Side Rail Kick Up at Rear Suspension Rearward 01CAA 9 125 3 062 0 312 80 000 B 11 47 10 74 917 600 859 200 Straight Channel Side Rail 01CAB 9 125 3 062 0 312 80 000 B 11 47 10 74 917 600 859 200 01CAC 10 125 3 062 0 312 50 000 B 13 31 12 64 665 500 632 000 01CAD 10 250 3 092 0 375 80 000 B 15 94 15 14 1 275 200 1 211 200 01CAE 01 10 125 3 580 0 312 120 000 C 14 85 14 18 1 782 000 1 701 600 01CAG 01CEL 10 250 3 610 0 375 120 000 17 79 16 98 2 134 800 2 037 600 01CAH 01 10 375 3 705 0 438 120 000 C 21 05 20 11 2 526 000 2 413 200 Straight Channel Side Rail with Outer C Channel Reinforcement a 2 UT NETS NOTES B High Strength Low Alloy Steel C Heat Treated Alloy Steel 1 Section Modulus Nominal Calculated using design dimensions indicates the design load capacity of the frame Maximum Tolerance All frame dimensions are at maximum tolerance used by some competitors as advertised values 2 Reinforcement dimensions and specifications are shown in italics 3 Rail depth given is for base rail depth of kick up in AF section is 6 495 4 33 000 Ib GVWR only DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 117 FRAME RAIL CROSS SECTIONS ALL MODELS 9 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 118 INTERMEDIATE CROSSMEMBER LOCATION LP AND 4x2 STAN
11. FLAT FLANGE DOWN AND WEB FORWARD 01 0061 INTERMEDIATE CROSSMEMBER LOCATION 4x2 Extended Cab with Staggered Fuel Tanks Wheelbase Range BX Cx Min Max Inches Millimeters 4 y 5 up to 169 4300 E 171 195 _ HB 335 BETWEEN 4350 4950 A 851 FRAME RAILS 197 211 32 5000 5350 818 L 21 P36 20 CENTER LINE TO CENTER LINE 5400 6000 1266 FRONTAXLE FRONT SPRING EYE 238 254 67 ni 6050 6450 1714 256 266 14 41 PETEA 8 6500 6750 355 1042 44 STRAIGHT RAIL 770 268 280 1120 6800 7100 50 282 293 1266 51 7150 7450 62 T ate 295 307 59 1568 7500 7800 1490 UP RAL 300 295 309 311 68 53 6 7850 7900 1714 1344 durastar ddcrossmember DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 121 INTERMEDIATE CROSSMEMBER LOCATION 4x2 EXTENDED CAB WITH STAGGERED FUEL TANKS 9 SERIES BODY BUILDER INTERMEDIATE CROSSMEMBER LOCATION LP AND 4x2 CREW CAB FRAMES FEBRUARY 2015 PAGE 122 INTERMEDIATE CROSSMEMBER LOCATION LP and 4x2 Crew Cab Wheelbase Range AX BX Min Max Inches Millimeters up to 183 4650 185 195 19 _ 4700 5000 494 197 211 28 _ 5050 5350 718 213 224 37 _ 5400
12. Figure 2 5 The length and height of the plate will vary with the size of the weld repair area In general it should be such that it will accommodate an array of reinforcement attachment bolts at a typical 3 to 5 inch 76 to 127 mm spacing all around the weld repair area 2 The plate should generally be installed on the side opposite the component which transferred the local bending load into the web 3 The edges of the plate should be staggered with respect to the edges of other relatively stiff web mounted components to avoid the creation of stress concentrations Bolt and Torque Information Most frames are assembled with bolts and nuts Others are riveted BOLTS MUST ALWAYS BE USED WHEN ATTACHING A REINFORCEMENT Rivets should be replaced by bolts as required when the frame is repaired and reinforced In bolted joints the majority of the load is transferred by frictional force or clamping force between the members of the joint The bolts must be properly tightened to develop and maintain the desired clamping force Operation of the joint with loose or improperly tightened bolts can lead to failure of the joint The bolts and nuts should be inspected periodically to insure that proper torque is maintained Bolts of high strength material conforming to SAE Grade 8 bolts should be used on all frames For installation of reinforcements 0 5 inch 13 mm diameter flange head bolts are recommended The SAE Grade 8 bolt is identified by six radial
13. HEIGHT AT THE RAIL ENDS ARE THE REAR END gt Y gt 7 THEN THE TRUCK IS SAID TO HAVE A NEGATIVE THIS SITUATION THE EQUATIONS FOR DETERMINING THE FRAME HEIGHT AT THE RAIL ENDS ARE Frame Height Front End of Rail Frame Height Front End of Rail FOR UNLOADED CONDITION FOR UNLOADED CONDITION FG Y Z x BA FG Y x BA FOR LOADED CONDITION FOR LOADED CONDITION 2227155 raw Ez Y FG Y WEE x BA Fa Y x Ba Frame Height Rear End of Rail Frame Height Rear End of Rail FOR UNLOADED CONDITION FOR UNLOADED CONDITION RG z 4 x ar RG z 2 x ar WB FOR LOADED CONDITION FOR LOADED CONDITION RG z x AF RG 27 E x AF DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 145 FRAME HEIGHT CALCULATION AT FRONT AND REAR RAIL ENDS ALL MODELS 9 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 146 FRONT BUMPER AND TOW HOOKS 4300 AND LP FRONT BUMPER AND Tow Hooks 4300 and LP Front Aero Bumper 01LLD and Front Tow Hooks 01570 7 5 2 8 190 70 RIGHT SIDE LEFT SIDE 463 STD AERO PA BUMPER 01LLD FRONT SPRING EYE 381 01 0076 FRONT BUMPER AND Tow Hooks 4400 Front Aero Bumper 01LLD and Front Tow Hooks 01570 7 5 190 RIGHT SIDE FRONT XMBR FRONT SPRING EYE 381 01 0237 DuRASTAR SERIES BODY BUI
14. HEIGHT DATA REAR ALL MODELS FEBRUARY 2015 PAGE 143 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 144 FRAME AND BuMP HEIGHT DATA REAR ALL MODELS FRAME AND BUMP HEIGHT DATA REAR CONTINUED Frame Rail Height Rear Suspension Spindle to Bottom of Sidemember Model Frame Code F Capacity Unloaded D Loaded D Bump D 01CAD 10 250 10 18 6 24 4 24 01 10 125 10 06 6 12 4 12 4x2 non LP Vari Rate 31 000 01CAG 10 250 10 18 6 24 4 24 01CAH 10 375 10 43 6 49 4 49 4x2 non LP 10 125 Chalmers 1030 30 000 10 125 6x4 10 250 Multileaf 34 000 10 375 10 125 10 88 50 9 50 50 8 10 50 6 4 10 250 40 000 11 03 50 9 63 50 8 23 50 10 375 11 15 50 9 75 50 8 35 50 40 000 46 000 6x4 10 125 Walking Beam FRAME HEIGHT CALCULATION AT FRONT AND REAR RAIL ENDS All Models Now that we have learned to calculate the frame height at both the front and rear axle centerlines we can determine the frame height values at both rail ends FRONT AXLE REAR AXLE FRAME RAIL AF FIRST WE MUST DETERMINE THE RAKE OF THE FRAME THE SLOPE OF THE FRAME FOR SITUATIONS WHERE THE RAKE IS POSITIVE I E lt 2 OR Y lt Z THE EQUATIONS FROM FRONT END TO REAR END THE FRONT END OF THE FRAME IS HIGHER THAN FOR DETERMINING FRAME
15. THIS WOULD BE CLIMBING OVER A CURB WHEN TURNING A CORNER THE COCKED BUMP HEIGHT CHARTS PRESENTED HERE ASSUME A 7 DEFLECTION FROM HORIZONTAL BUMP BUMP HE I GHT SIDEMEMBER SIDEMEMBER 6 REAR AXLE STRAIGHT BUMP HEIGHT COCKED BUMP HEIGHT 9 7 DEFLECTION 01 0073 01 0074 Wheel Axis to bottom of frame in straight bump position Refer to tabulated data Tire radius one half of tire outside diameter NOT mounted on the vehicle To obtain tire dimensions contact the tire manufacturer Frame Rail Height Straight Bump Height R4 D F Cocked Bump Height Straight Bump Height 3 5 In DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 141 BUMP HEIGHTS REAR ALL MODELS DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 142 FRAME AND BUMP HEIGHT DATA REAR ALL MODELS FRAME AND BUMP HEIGHT DATA REAR All Models Frame Rail Height Rear Suspension Spindle to Bottom of Sidemember Moge Type Capacity Unloaded D Loaded D Bump D r r r 12 000 LP 01CAA 9 125 i 15 500 4 31 25 18 500 10 125 9 26 25 9 26 25 10 250 9 38 25 9 38 25 4x2 non LP 10 125 20 000 to 23 000 9 26 25 9 26 25 10 250 9 38 25 9 38 25 10 375 9 51 25 9 51 25 10 125 9 26 25 9 26 25 6x4 10 250 Ai
16. account for the lateral shift if either of these factors apply Overhang Limit L in P Ib LP 80 000 PSI Steel Leaf Springs Air Suspension gt 6 000 95 90 l p DUMCBODY 504 8 000 82 71 10 000 68 61 I 2 12 000 59 53 gt ra 14 000 52 47 kd B P Maximum Static Vertical L Lead During Dumping 168 L Overhang in 01 0079 DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 151 OVERHANG LIMITS FOR REFUSE RECYCLER BODIES LP SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 152 OVERHANG LIMITS FOR REFUSE RECYCLER BobiEs LP INTERNATIONAL ANAYVISTAR COMPANY
17. bent or buckled sufficiently to show cracks or weakness after straightening should be replaced or reinforced HEAT TREATED FRAME MEMBERS MUST NOT BE INTERMIXED WITH NON HEAT TREATED MEMBERS If one sidemember is to be replaced the new member must match the former frame member in both cross section and material strength Repair and Reinforcement Recommended Procedures In some cases of frame damage the sidemembers must be replaced rather than repaired Examples of this are 1 When sidemember cracks caused complete separation or a visible deformation of the section 2 When the sidemembers are extensively deformed Consult with your field service representative and frame repair specialists if in doubt Preparation of Frame for Repair Bevel Crack to Weld To assure complete weld penetration bevel the crack from one side when welding from one side Bevel the crack from both sides when welding from both sides The existing crack in the sidemember must be entirely removed Figure 2 3 Widen the crack its full length to 1 8 inch 3 mm If required a rubber backed disc grinder or high speed steel burr may be used Clean Surface to Weld Surfaces to be welded and surfaces adjacent to the weld must be free of loose scale slag rust grease moisture paint or other material that could contribute to poor quality welds 1 FRAME RAIL 2 WIDEN CRACK 3 BEVEL EDGES Figure 2 3 Preparing For Weld Repair 01 0013 DuRASTAR SERIES BODY BUILDER F
18. equipment installer is responsible for the safety and durability of their product and in addition is responsible to insure that the equipment and its installation comply with all applicable State and Federal Department of Transportation requirements and OSHA regulations Addition of specialized equipment may have a significant effect on other vehicle components such as the brake system steering system suspension system etc Simple reinforcement of the chassis frame may not be adequate to provide safe operation of the vehicle In any modification of the chassis frame the addition of holes reinforcements welds clamps splices etc may cause an increase in the local stress in the frame at the point of the modification These local stress concentrations can significantly affect the life of the chassis frame The specific effect which the stress concentrator will have on the life of the chassis frame is influenced by the location of the stress concentration the frequency and severity of the loading and the type of stress concentration Any modification of the frame may void the manufacturer s warranty Refer to Welding and Reinforcement information DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 113 GENERAL FRAME INFORMATION ALL MODELS 9 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 114 GENERAL FRAME INFORMATION ALL MODELS 450 Figure 2 24 Frames Preparation of Joint for Welding Extension 01 0034
19. from the wheel axis to the ground for a properly inflated fully loaded loaded to its maximum capacity tire To obtain tire dimensions contact the tire manufacturer Tire Radius half of tire outside diameter mounted on the AXLE vehicle To obtain tire dimensions contact the tire manufacturer 01 0072 2 Calculated Tire Radius on an unloaded chassis The value of is calculated using the following method R R 2 R SLR Rear Frame Height at the rear axle centerline in unloaded condition Rear Frame Height at the rear axle centerline in loaded condition Z D R F for unloaded condition Z D SLR F for loaded condition NOTE Values calculated for Z and Z are strictly for the frame height at the rear axle centerline For frame heights at the rear of the frame rail refer to HEIGHTS All Models Bump Height refers to the maximum distance of the tires above the side rails as the rear axle of the truck travels over an object Bump Heights are important in the selection of truck bodies since it may be necessary to incorporate wheelwells into the body floor to allow adequate clearance for tire travel STRAIGHT BUMP HEIGHT IS USED WHEN BOTH SETS OF WHEELS TRAVEL OVER AN CockED BUMP HEIGHT REFERS TO THE CONDITION THAT EXISTS WHEN ONLY ONE SET OBJECT AT THE SAME TIME SUCH AS A PARKING LOT SPEED BUMP OF REAR WHEELS TRAVELS OVER AN OBJECT AN EXAMPLE OF
20. gross deformation local deformations may reduce the strength in the area to be weld repaired Examples of this are local bulges in the web vertical portion of the section and buckling of the flanges These local deformations must be repaired by straightening before proceeding with the weld repair Welding Precautions When welding on any vehicle care must be taken to prevent damage to the electronic components Vehicles with ELECTRONIC ENGINE CONTROL SYSTEMS require additional precautions CAUTION vehicle disconnect both the positive and negative battery cables from the battery before welding on the vehicle Attach the welder ground cable as close as possible to the part being welded TO AVOID SERIOUS PERSONAL INJURY DEATH OR POSSIBLE ENGINE DAMAGE WHEN WELDING OR USING AN ACETYLENE TORCH ALWAYS WEAR WELDING GOGGLES AND GLOVES INSURE THAT ACETYLENE AND OXYGEN TANKS ARE SEPARATED A METAL SHIELD AND ARE CHAINED TO A CART DO WELD OR HEAT AREAS NEAR FUEL TANKS OR FUEL LINES UTILIZE PROPER SHIELDING AROUND HYDRAULIC LINES With an electronic engine controller such as Celect do not connect the ground cable to the control module s or the cooling plate To protect the control module s it is mandatory to remove all connectors going to the control modules The following is a general guideline for the steel frames Welding of the HSLA 50 000 60 000 and 80 000 PSI yield strength steel side member and
21. line markings on the head of the bolt Figure 2 6 Nuts must be Grade 8 flange type SAE GRADE 5 BOLTS ARE IDENTIFIED BY 3 RADIAL LINES SAE GRADE 8 BOLTS ARE IDENTIFIED BY 6 RADIAL LINES Figure 2 6 Bolt Identification 01 0016 These bolts 0 5 inch 13 mm diameter flange head type should be tightened to 110 to 120 ft Ibs 149 to 163 Nm based on new bolts and nuts lubricated with engine oil Whenever possible hold the bolt and tighten the nut If frame components are aluminum flange head bolts and nuts or bolts with hardened flat washers must be used If modification or repair requires replacement of existing bolts with new bolts or bolts of a greater length the old flange head nuts should not be used with new standard bolts Careful consideration is given to the number location and sizes of frame bolt holes in the design of a vehicle The number location and sizes of additional bolt holes put in the frame subsequent to manufacture of the vehicle can adversely affect frame strength The adverse effect of additional bolt holes can be minimized by following the guidelines DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 101 GENERAL FRAME INFORMATION ALL MODELS FEBRUARY 2015 PAGE 102 9 SERIES BODY BUILDER FRAMES GENERAL FRAME INFORMATION ALL MODELS Huckbolt Fasteners HP 8 Huckbolt HP 8 fasteners are used in various positions in frame rail construction Advantages to this style fastener ar
22. reinforcement should be removed before cutting the main frame IT IS ESSENTIAL THAT A NEW ONE PIECE OUTER CHANNEL REINFORCEMENT BE OBTAINED RATHER THAN CUTTING AND RE USING THE ORIGINAL REINFORCEMENT The original frame should also be reinforced with an inner channel reinforcement extending at least two feet beyond the cut s on either side of the cut s The reinforcement must be of the same material as the original frame Blank and pre punched chassis channel reinforcements are available through your dealer parts department On both medium and high strength aluminum frames RE WELDING TO LENGTHEN THE FRAME IS NOT RECOMMENDED Refer to Reinforcement and Reinforcement Attachment for additional information DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 115 GENERAL FRAME INFORMATION ALL MODELS DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 116 FRAME RAIL CROSS SECTIONS ALL MODELS FRAME RAIL CROSS SECTIONS ALL MODELS 3 062 3 062 3 092 3 580 3 610 lo 3 892 9 125 10 125 10 250 10 250 10 375 312 312 375 312 375 01CAA 01CAB 01CAC 01CAD O1CEK 01CAG O1CEL 01CAH 01 01CAE 01GBP 01 0054 01 0055 01 0056 01 0057 01 0058 01 0059 01 0086 01 0053 Side Rail amp Reinforcement Descriptions 1 Dimensions inches Strength Moment
23. reinforcements installed to the inside of the sidemember Contact your International Truck dealer regarding the required type of reinforcement Depending on model application there will be other parts affected such as spring brackets for example which are bolted to the flange as well as the web of the sidemember To maintain proper alignment of the springs these brackets may require replacement with new brackets designed to accept the reinforcements These brackets are available through your International Truck dealer parts department When an inside reinforcement is added the lengths of the crossmembers will be affected DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 87 GENERAL FRAME INFORMATION ALL MODELS DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 88 GENERAL FRAME INFORMATION ALL MODELS Reinforcement Attachment THE REINFORCEMENTS MUST NEVER BE WELDED TO THE ORIGINAL CHASSIS SIDEMEMBERS High strength SAE Grade 8 bolts are to be used to fasten the reinforcement to the sidemember Existing bolt holes in the sidemembers should be used whenever possible The reinforcements should be bolted to the chassis frame using high strength SAE Grade 8 bolts not less than 0 5 inch 13 mm in diameter refer to Bolt and Torque Information Corrosion If aluminum and steel are allowed to come into direct contact with each other a galvanic cell can be formed In order for the cell to form the dissimila
24. the heat treated 110 000 and 120 000 PSI yield strength steel sidemember involves a significant reduction in the strength of the frame in the heat affected zones of the weldment This means that the frame in the welded region is no longer capable of carrying the same load or stress as the original section To restore the strength of the frame rails after welding the welded area must be reinforced using reinforcements as indicated in Repair and Reinforcement Recommended Procedures Welding must be done properly to make an effective repair Therefore only those who are properly trained and qualified should perform the welding repairs in this section Reinforcement Reinforcements Figure 2 1 to increase load capacity are generally full length The actual length of the reinforcement varies with the model Shorter approximately 7 rear suspension tandem liner reinforcements are available for some tractor models Inverted L and C channel reinforcements are available for most models For models which do not have reinforcements necessary to contact Sales Engineering to obtain reinforcement recommendations 1 2 3 4 STANDARD HEAVY DUTY L REINFORCEMENT C REINFORCEMENT SIDEMEMBER SECTION SIDEMEMBER SECTION SIDEMEMBER SECTION SIDEMEMBER SECTION Figure 2 1 Frame Rails and Reinforcements Typical 01 0011 These reinforcements are generally installed on the outside of the sidemember although certain models require C channel
25. 00 PSI Yield Strength When welding Heat Treated Frames 110 000 PSI and 120 000 Yield Strength use low hydrogen electrodes which have superior crack resistance and notch toughness similar to AWS E 11018 This type electrode should be stored in a moisture free container to avoid porosity during welding Amperage and voltage recommendations for welding are shown in Table 2 4 Table 2 4 SMAW Method Heat treated Frames POSITION VOLTAGE Downhand 130 140 21 23 Overhead 130 140 21 23 Vertical Up 110 120 22 24 A heavy copper chill strip should be clamped to the rail side away from the groove to help control the temperature and cooling rate during welding Figure 2 4 Short lengths of discarded heavy copper electrical bus bars make suitable chill strips Preheat the frame rail along the crack area to 500 600 F 260 316 C Either alternating current or direct current reversed polarity combined with a short arc and a beading or narrow weave technique may be used Direct current reversed polarity is recommended Slag should be removed after each pass and an interpass temperature of 200 F 93 C should be maintained Grind smooth and flush with surrounding sidemember material in a direction that is parallel to the longitudinal axis of the sidemember Figure 2 4 D A V groove is ground from the side opposite the repair and the procedure outlined above repeated Chill strips should be used whenever possible The V groove ground on
26. 50 1120 323 331 53 62 8200 8400 1344 1568 Q9 AX cx 25 0 END 33 5 635 209 851 G J TO BACK OF CAB 851 BETWEEN FRAME 92 1 RAILS 2340 TO CENTER LINE FRONT SPRING EYE CENTER LINE CENTER LINE FRONT AXLE REAR SUSPENSION WB AF STRAIGHT RAIL 11 6 295 Ec m OOO OOG t g 53 8 49 2 1367 1249 SINGLE CROSSMEMBER MOUNTED WITH FLANGE UP AND WEB FORWARD REAR SUSPENSION CROSSMEMBER DOUBLE STAMPED CROSSMEMBER STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE UP 01 0063 INTERMEDIATE CROSSMEMBER LOCATION 6x4 Standard Cab with Staggered Fuel Tanks Wheelbase Range AX BX CX Min Max Inches Millimeters 157 4000 E _ 160 197 23 _ _ 4050 5000 567 199 211 31 _ _ 5050 5350 791 213 224 40 _ 5400 5700 1015 226 238 41 _ 5750 6050 1042 240 252 791 _ 6100 6400 50 254 266 1266 _ 6450 6750 268 280 40 59 _ 6800 7100 1015 1490 282 293 67 26 7150 7450 1714 672 295 307 41 7500 7800 1042 53 309 321 31 50 1344
27. 50 1568 672 WB AF 295 307 35 11 6 7500 7800 896 53 295 x STRAIGHT RAIL 309 321 11 44 1344 7850 8150 277 1120 E Tao A 5 g 323 331 53 62 8200 8400 1344 1568 53 8 49 2 1367 1249 A8 c SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE UP AND WEB FORWARD p REAR SUSPENSION CROSSMEMBER DOUBLE STAMPED CROSSMEMBER STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE UP 01 0064 INTERMEDIATE CROSSMEMBER LOCATION 6x4 Extended Cab with Staggered Fuel Tanks Wheelbase Range AX BX CX Inches Millimeters up to 224 _ _ 5700 226 238 32 _ one 5750 6050 818 630 240 252 41 _ 6100 6400 1042 CENTER LINE TO CENTER LINE FRONTAXLE FRONT SPRING EYE 254 266 50 _ 6450 6750 1266 268 280 59 _ 6800 7100 1490 282 293 67 26 7150 7450 1714 672 295 307 32 7500 7800 818 53 309 321 41 1344 7850 8150 1042 323 331 50 62 KICK UP RAIL 8200 8400 1266 1568 ICK UP RAI DURASTAR SERIES BODY BUILDER BX FRAMES CX 3 335 BETWEEN 851 FRAME RAILS G H J CENTER LINE REAR AXLE AF 30 0 29 3 763 744 durastar ddcrossmember FEBRUARY 2015 PAGE 127 INTERMEDIATE CROSSMEMBER LOCATION 6x4 EXTENDED CAB WITH STAGGERED FUEL TANKS 9 SER
28. 85 10 000 260 32 900 12 000 171 10 000 811 j 12 000 272 01CAD 3 8 x 10 1 4 Straight Rail 80 psi Yield Strength 10 000 260 12 000 171 50 000 10 000 283 5 16 x 10 1 8 Straight Rail 01 01 52 000 12 000 238 54 000 14 000 167 50 000 10 000 311 3 8 x 10 1 4 Straight Rail 01CAG 01CEL ath 52 000 12 000 266 54 000 14 000 230 50 000 10 000 311 01CAH 01CEM 10 AB Slant ai 52 000 12 000 293 120 psi Yield Strength 54 000 14 000 256 5 16 x 10 1 8 Straight Rail with 5 16 x 10 13 16 01 w 01GBP Outer C Channel Reinforcement 54 000 14 000 311 120 psi Yield Strength Contact your local International dealer for approval if your wheelbase or axle load exceeds the values given See General Frame information Aftermarket Modifications earlier in this section DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 137 MAXIMUM WHEELBASE FRAME STRETCHING ALL MODELS SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 138 FRAME HEIGHT CALCULATION AT CENTERLINE OF FRONT AXLE ALL MODELS FRAME HEIGHT CALCULATION AT CENTERLINE OF FRONT AXLE All Models The front frame height the centerline of the front axle be calculated using the following equations Refer to the illustration for a visual explanation of the symbols used in these calculations f Wheel axis to bottom of frame in unladen position Refer to tabulated data f Wheel axis to bott
29. BODY BUILDER FRAMES FEBRUARY 2015 PAGE 149 FRONT BUMPER TOW HOOKS AND EXTENSIONS 4400 9 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 150 TiRE CARRIER ALL MODELS TIRE CARRIER All Models q REAR AXLE 31 5 800 e 1 o oH m 20 9 1 1 530 14 6 116 cm em F 1 2 37 6 J 47 0 954 1194 01 0078 Dimensions From Rear Axle Centerline Suspension A All 4x2 40 6 1030 6x4 52 Air 4 Spring 59 8 1520 6x4 55 60 Air 63 9 1622 OVERHANG LIMITS FOR REFUSE RECYCLER BODIES LP Dump and other similar pivoting bodies impose a great deal of stress on the frame rails in the rear suspension area The body installer has the responsibility for determining the pivot pin load and for establishing operating guidelines to prevent exceeding this load The limits shown in this chart are for equal loading on both sidemembers i e the center of gravity of the raised body is ideally centered and the chassis is on solid level ground If the center of gravity is laterally offset due either to uneven loading uneven ground or both the bending moment on one of the rails could increase substantially For this reason the body installer should derate the overhang limits to
30. DARD CAB INTERMEDIATE CROSSMEMBER LOCATION LP and 4x2 Standard Cab Wheelbase Range AX BX 3 CX 33 5 Min Max 851 Inches Millimeters Me BETWEEN FRAME up to 138 3500 _ BX 140 156 19 a 8550 3950 489 i 158 169 28 m 82 gt 25 0 209 4000 4300 713 635 Bhi x M 171 183 37 _ es 185 195 43 0 M 4700 4950 19 489 2 35 896 21 106 197 211 35 STRAIGHT RAIL 5000 5350 896 Eg 95 e Hl ac 213 224 30 9 29 3 5400 5700 53 226 236 1344 5750 6000 KICK UP RAIL 067 84 LP MODELS 238 254 46 1161 1 62 1568 P TELA 7 i i 6050 6450 28 713 21 35 896 2 44 1120 21 29 9 28 3 256 266 44 6500 6750 1120 44 1120 SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE UP AND WEB FORWARD 282 293 D REAR SUSPENSION CROSSMEMBER 7150 7450 62 E WITH STRAIGHT RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE 295 307 1568 DOWN AND WEB FORWARD WITH KICK UP RAILS C CHANNEL AF CROSSM
31. ELMET WITH DARK COLORED FILTER LENSES OF THE PROPER DENSITY MUST BE USED GTAW TIG WELDING WILL PRODUCE INTENSE RADIATION THEREFORE FILTER PLATE LENSES OF THE DEEPEST SHADE PROVIDING ADEQUATE VISIBILITY ARE RECOMMENDED IS STRONGLY RECOMMENDED THAT PERSONS WORKING IN THE WELD AREA WEAR FLASH SAFETY GOGGLES ALSO WEAR PROTECTIVE CLOTHING 9 Electrodes Only low hydrogen electrodes should be used These should be purchased in hermetically sealed containers or dried for two hours at a temperature between 450 F 232 C and 500 F 260 C After drying the electrodes should be stored in an oven at a temperature of at least 250 F 121 C If exposed to the atmosphere for more than four 4 hours the electrodes should be dried before use ANY MOISTURE INTRODUCED INTO THE WELD COULD DEVELOP POROSITY OR EMBRITTLEMENT LEADING TO FURTHER CRACKING Welding procedures will vary among different frame materials Outlined below are recommendations for welding of the various types of frames 1 Preheat the frame member along the prepared weld joint to 500 to 600 F 260 to 316 C Insure the area is clean and any moisture present is eliminated 2 Permit heated area to cool to 200 F 93 C or below before welding is started The weld repair area must be clean before welding 3 Either alternating current or direct current reversed polarity combined with a short arc and beading or narrow weave technique may be used Direct current reve
32. EMBER 7500 7800 WITH STRAIGHT RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE 309 321 DOWN AND WEB FORWARD 7850 8150 71 01 0060 323 331 1792 8200 8400 1 With l6 Engines 2 With V8 Engines 4x2 Models only INTERMEDIATE CROSSMEMBER LOCATION 4x2 Standard Cab with Staggered Fuel Tanks Wheelbase Range AX BX 3 CX Min Max Inches Millimeters vm BX 6 B up to 138 3500 pae 140 169 _ 5 ET 1 17 T 171 183 ee a 4350 4650 7 248 6 177 TS 1 e 650 SUAE AF 185 195 _ Sis B gi Te 197 211 41 _ OW 5000 5350 1042 STRAIGHT RAIL 212 236 59 _ 5400 6000 1490 238 254 67 213 1714 6050 6450 ae 256 266 1266 30 0 29 3 6500 6750 44 KICK UP RAIL 763 744 268 280 1120 6800 7100 59 282 293 1490 7150 7450 62 295 307 1568 7500 7800 309 321 67 7850 8150 1714 71 323 331 1792 8200 8400 1 With O4WZA durastar ddcrossmember DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 119 INTERMEDIATE CROSSMEMBER LOCATION 4x2 STANDARD CAB WITH STAGGERED FUEL TANKS 9 SERIES BODY BUILDER FRAMES INTERMEDIATE CROSSMEMBER LOCATION LP AND 4x2 EXTENDED CAB FEBRUARY 2015 PAGE 120 INTERMEDIATE CROSSM
33. EMBER LOCATION 33 5 851 BETWEEN FRAME RAILS LP and 4x2 Extended Cab Wheelbase Range G AX BX CX Min Max Inches Millimeters cx up to 169 4300 2 171 183 2 _ 4350 4650 185 195 250 IE 7 T 118 1 4700 4950 635 3000 G H TO CENTER LINE 197 211 35 FRONT SPRING EYE 5000 5350 896 CENTER LINE za 224 p O 5400 5700 53 E 106 226 236 1344 STRAIGHT RAIL 5750 6000 TX TERM SEPR d fi E a 238 254 62 1568 11 _ 309 293 6050 6450 44 1120 21 256 266 44 KICK UP RAIL 10 6 8 4 6500 6750 1120 44 LP MODELS 268 280 1120 mc ERA NEC d 6800 7100 53 E 282 293 1344 299 t 28 3 7150 7450 62 G 295 307 1568 7500 7800 62 CA B CO SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE UP AND WEB FORWARD 309 311 1568 53 D REAR SUSPENSION CROSSMEMBER 7850 7900 1344 1 With l6 Engines 2 With V8 Engines WITH STRAIGHT RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE DOWN AND WEB FORWARD WITH KICK UP RAILS C CHANNEL AF CROSSMEMBER WITH STRAIGHT RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH
34. FRAMES GENERAL FRAME INFORMATION All Models Introduction The frame is the structure that carries and supports the rated load under anticipated driving conditions and secures the major components of a vehicle in their relative positions The frame assembly consists of two sidemembers and depending upon the length of the frame five or more crossmembers u01 General Frame Recommendations It is very important that the frame be inspected periodically for cracks buckling crossmember loosening or other damage that may cause eventual failure of the frame Additional inspections should be made whenever the chassis has been overloaded or involved in an accident An alignment check IS NOT SUFFICIENT since local cracks crossmember loosening or sidemember buckling will not necessarily cause misalignment On reinforced sidemember sections when cracks exist in either of the sidemember sections the members must be separated for repair After separation follow the procedures for non reinforced sections The two sidemember sections MUST NOT be welded together After the weld repairs the sections should be reinforced with the appropriate section and re assembled with mounting bolts tightened to SAE Grade 8 torque levels Drilling or Notching Sidemembers should not be drilled or notched without approval from Navistar Engineering Do not exceed the maximum allowable sidemember hole size in the unrestricted zones For illustrations see the Frame Drilling Re
35. IES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 128 INTERMEDIATE CROSSMEMBER LOCATION 6x4 CREW INTERMEDIATE CROSSMEMBER LOCATION 6x4 Crew Cab Wheelbase Range AX BX Min Max 851 Inches Millimeters T FRAME RAILS up to 211 5350 ded a 213 224 9 Ji 5400 5700 e T M 28 8 0 226 238 718 635 136 0 204 G HL 5750 6050 3455 TO BACK OF TO CENTER LINE 240 252 37 FRONT SPRING EYE 6100 6400 942 CENTER LINE CENTER LINE REAR AXLE 254 266 46 _ FRONTAXLE WB AF 6450 6750 1166 268 280 55 26 108 6800 7100 1390 672 STRAIGHT RAIL _ 282 293 44 uA B UC UC gd 7150 7450 28 1120 NE ae 295 307 718 7500 7800 53 309 321 37 1344 nm 10 6 1 84 7850 8150 942 LP MODELS Eg X E 299 234 WGE SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE UP AND WEB FORWARD SUSPENSION CROSSMEMBER WITHSTRAIGHT RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE DOWN AND WEB FORWARD WITH KICK UP RAILS C CHANNEL AF CROSSMEMBER e WI
36. LDER FRAMES FEBRUARY 2015 PAGE 147 FRONT BUMPER AND Tow Hooks 4400 FEBRUARY 2015 PAGE 148 FRAMES DURASTAR SERIES BODY BUILDER FRONT BUMPER TOW HOOKS AND EXTENSIONS 4300 AND LP Front Bumper Tow Hooks and Extensions 4300 and LP Swept Back Front Bumper 01LLA Front Tow Hook 01570 and Bolt On Front Frame Extension 01WDR 30 7 25 9 i sag 659 42 659 526 2 8 105 1 70 uf E AE 43 9 1115 CHASSIS 2 8 o 772 70 2 8 30 4 072 RIGHT SIDE LEFT SIDE 346 879 cm 30D Swept Back 22 212 Bumper OLLA T L I 1047 6 9 265 175 o M 35 3 FRONT SPRING EYE 89 6 01 0077 FRONT BUMPER TOW HOOKS AND EXTENSIONS 4400 Swept Back Front Bumper 01LLA Front Tow Hook 01570 and Bolt On Front Frame Extension 01WDR 30 7 E 779 42 vp Wl ters i Jp E ILL se 30 DEGREE SWEPT BACK BUMPER 01LLA 01 0238 DuRASTAR SERIES
37. N THE INSIDE IS PREFERRED FOR STRENGTH D RAIL HEIGHT LOCAL FLAT PLATE REINFORCEMENT M MINIMUM LOCATION BOLTS ADDED TO SECURE REIN FORCEMENT EE B MINIMUM IN SPECIFIC MODEL BOOKS FOR MINIMAL VALUE FORAAND B ZONE OF APPLICATION FOR FLAT PLATE APPLICATICN d WELD REPAIR MUST NOT EXTEND BEYOND THIS ZONE E RUN OFF BLOCK FOR WELDING SIDEMEMBER EDGE HOLE DRILLED AT CRACK TIP ZONES Y amp Z ARE DRILL RESTRICTED ZONES SEE FRAME DRILLING DIAGRAMS IN SPECIFIC MODEL BOOKS FOR MINIMAL VALUE FORAAND B GROOVE BLOCK TO MATCH FLANGE GROOVE RUN OFF BLOCK CLAMP TO SIDEMEMBER DO NOT TACK WELD TO SIDEMEMRER Reinforcement Application FRAMES GENERAL FRAME INFORMATION ALL MODELS 01 0015 FEBRUARY 2015 PAGE 97 DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 98 GENERAL FRAME INFORMATION ALL MODELS Cracks which occur in the critical zones have a greater probability of growing vertically through the section and the reduced strength after weld repair necessitates a more substantial reinforcement These guidelines potentially affect the structural integrity of the frame assembly and are intended for those who have the equipment and experience required to qualify as frame repair specialists General Weld Repair Reinforcement Procedures 1 The thickness and material strength of the local plate L and channel reinforcements should match the section bein
38. R 11 6 295 i 538 1367 49 2 1 amp 6 1249 SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE UP AND WEB FORWARD REAR SUSPENSION CROSSMEMBER DOUBLE STAMPED CROSSMEMBER STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE UP FRAMES AF CROSSMEMBER LOCATIONS 6X4 01_0063 FEBRUARY 2015 PAGE 131 SERIES BODY BUILDER DURASTAR FRAMES FEBRUARY 2015 PAGE 132 CROSSMEMBERS ALL MODELS CROSSMEMBERS All Models 3 2 81 5 8 147 E 1 22 SINGLE STAMPED CROSSMEMBER 1 DE 10 1 257 170 REAR CAB MOUNTING CROSSMEMBER 8 1 206 DOUBLE STAMPED CROSSMEMBER 1 7 42 2 4 61 4 8 6 8 122 173 END FACE FLAT AREA 9 19 4 8 7 6 192 01 0066 Crossmembers With Tapered Rails LP 6H 127 1 2 84 6 0 213 Res 4 Li A aa m a e 9j 1 ES 33 5 7 4 56 76 851 33 5 188 851 8 T 26 7 _ 173 4 800 O 6 678 L g Oi 20 9 pups I ka
39. RAMES FEBRUARY 2015 PAGE 91 GENERAL FRAME INFORMATION ALL MODELS DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 92 GENERAL FRAME INFORMATION ALL MODELS Welding Electric arc welding is recommended for repair of steel frames The shielded arc method should be used because the heat generated during welding is localized and burning of material is minimized using this method Additional advantages are that the finished weld can be ground flush and drilled as necessary Shielded metal arc welding SMAW gas metal arc welding GMAW also known as metal inert gas MIG welding gas tungsten arc welding GTAW also known as tungsten inert gas TIG welding or flux cored arc welding FCAW are recommended methods for repair of steel frame members TO AVOID SERIOUS PERSONAL INJURY DEATH OR POSSIBLE ENGINE DAMAGE WHEN WELDING OR USING AN ACETYLENE TORCH ALWAYS WEAR WELDING GOGGLES AND GLOVES INSURE THAT ACETYLENE AND OXYGEN TANKS ARE SEPARATED A METAL SHIELD AND ARE CHAINED A CART DO WELD OR HEAT AREAS NEAR FUEL TANKS OR FUEL LINES UTILIZE PROPER SHIELDING AROUND HYDRAULIC LINES General Recommendations IMPORTANT To properly perform the repair procedure the following rules must be observed Steel Sidemembers 1 Welding should not be performed when surfaces are wet or exposed to rain snow high wind or when repair personnel are exposed to inclement conditions Frames exposed to incle
40. STRICTIONS 4300 4x2 4400 4x2 and 6x4 Straight Rails Straight Trucks 1 6 41 c CENTERLINE REAR SUSPENSION E ml E E eu E e E E e A 254 51 DURASTAR SERIES BODY BUILDER FRAMES 1 6 41 NO DRILL ZONE CENTERLINE OF DRILLED HOLES 2 0 51 SECTION C C 01_0068 FEBRUARY 2015 PAGE 135 FRAME DRILLING RESTRICTIONS 4300 4x2 4400 4X2 AND 6x4 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 136 FRAME DRILLING RESTRICTIONS LP FRAME DRILLING RESTRICTIONS LP Tapered Rails 1 5 38 NO DRILL ZONE 0 4 CENTERLINE 15 CENTERLINE 38 REAR SUSPENSION OF DRILLED HOLES Se zF T L rin 1 5 C 20 38 BORC B 51 lt SECTION D D 01 0069 WHEELBASE FRAME STRETCHING All Models Frames Maximum Wheelbase Figures For Changing Wheelbase NM Maximum Frame Maximum Front Axle Susp Frame Code Frame Description GVW Rating Lbs Capacity Lbs Maximum Wheelbase 5 16 x 9 1 8 Tapered Rail 01CAA 80 psi Yield Strength 29 000 8 000 254 i i 8 000 285 01CAB 5 16 x9 1 8 Straight Rail 25 999 80 psi Yield Strength 10 000 12 000 262 8 000 311 25 999 10 000 12 000 293 5 16 x 10 1 8 Straight Rail 01CAC coped am 29 000 8 000 2
41. TH STRAIGHT RAILS SINGLE STAMPED CROSSMEMBER MOUNTED WITH FLAT FLANGE DOWN AND WEB FORWARD 01 0060 INTERMEDIATE CROSSMEMBER LOCATION 6x4 Crew Cab with Staggered Fuel Tanks Wheelbase Range BX Min Max AX BX CX Inches Millimeters 6 6 up to 211 5350 Ka 213 224 _ 335 BETWEEN 226 238 718 5750 6050 i 248 TO BACK OF CAB 630 240 252 37 _ G H J 6100 6400 942 CENTER LINE TO CENTER LINE CENTER LINE 254 266 46 _ FRONT AXLE FRONT SPRING EYE REAR AXLE 6450 6750 1166 AF 268 280 55 26 6800 7100 1390 672 282 293 44 30 3 7150 7450 1120 770 295 307 718 7500 7800 53 309 321 37 1344 a 7850 8150 942 sia 30 0 29 3 KICK UP RAIL 763 744 LP MODELS durastar_ddcrossmember DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 129 INTERMEDIATE CROSSMEMBER LOCATION 6X4 CREW CAB WITH STAGGERED FUEL TANKS 9 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 130 AF CROSSMEMBER LOCATIONS LP AND 4x2 AF CROSSMEMBER LOCATIONS LP and 4x2 WITH STRAIGHT RAILS 33 5 AF Range 6 j 851 Crossmember Min Max A B 9 e BETWEEN FRAME Inches Millimeters AX BX cx RAILS
42. ck installation tool over the HP 8 fastener pintail See Figure 2 10 Figure 2 10 Place Installation Tool 01 0020 Over Fastener Pintail 4 Activate the Huck installation tool The Huck installation tool creates a pulling force on the fastener seating the bolt head and closing the gap between the mating surfaces The collar is swaged into the pintail locking grooves developing clamping force See Figure 2 11 As pulling forces further increase the body of the fastener separates at the breakneck See Figure 2 12 completing installation Figure 2 11 Clamping Force is Developed 01 0021 Figure 2 12 Body of Fastener Separates at Breakneck 01 0022 Huck Spin Fasteners Description Huck Spin fasteners are used in various positions in frame rail construction The installed fastener has a collar that is cold worked or swaged over the grooved pin Figure 2 13 Advantages to this style fastener are consistent clamp load and a high resistance to loosening due to vibration The need to recheck fastener torque is eliminated SWAGED SECTION Figure 2 13 Huck Spin Collar 01 0023 DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 105 GENERAL FRAME INFORMATION ALL MODELS 9 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 106 GENERAL FRAME INFORMATION ALL MODELS Remove The collar cannot be removed by twisting or hammering The collar must be cut longitudinally to the extent of the swaged sec
43. cle Their advantage in this case is their availability A disadvantage of this type is that it is likely to affect more of the components which mount to the frame In some cases this disadvantage may be offset by cutting the full length reinforcement to create a local reinforcement Recommended Applications 1 Cases of repair of vertical cracks in either the top or bottom flanges at very low mileage 2 Casesin which the weld repair is accompanied by extensive straightening of heat treated sidemembers Full Length 1 Weld Repair Reinforcements Steps 1 and 2 above also apply to the full length 1 reinforcements available from International All of these are the inverted L type and are designed for installation on the outside of the sidemember section except 9000 Series Figure 2 5 A Recommended Applications This type of reinforcement is recommended for cases of cracking at very low mileage where a web crack has extended beyond the range for a flat plate reinforcement but ends short of the bend radius It is also applicable to cases in which the cracking is accompanied by flange buckling Application Procedures 1 For custom fabricated full length L reinforcements the section should be oriented up or down so that the flange is on the same side as the damaged area 2 Formaximum strength the flange should be on the outside of the section 3 Follow the general recommendations above for attachment of the reinforcement Local Cha
44. e consistent clamp load and a high resistance to loosening due to vibration The need to recheck fastener torque is eliminated BREAKNECK PINTAIL LOCK GROOVES PULL GROOVES Figure 2 7 Huckbolt Fasteners 01_0017 Removal The swaged collar cannot be unscrewed due to the locking grooves on the HP 8 fastener Removal requires a Huck Collar Cutter or the collar can be split with an air chisel while supporting the opposite side of the collar When the collar is split the fastener can be driven out with a punch CHISEL Figure 2 8 Collar Can Be 01_0018 Split With an Air Chisel CAUTION The HP 8 fastener is not intended for re use To do so can result in damage to the vehicle frame or components attached to the frame CAUTION In the eventthat Huck fasteners are removed in order to retain the same joint integrity it is strongly recommended that new Huck fasteners be used for attachment reattachment of components Installation NOTE Huckbolt HP 8 fasteners cannot be installed without Huck installation equipment 1 Install the HP 8 fastener into the component and frame hole 2 Place the collar over the fastener pintail See Figure 2 9 Figure 2 9 Place Collar Over 01 0019 Fastener Pintail DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 103 GENERAL FRAME INFORMATION ALL MODELS 9 SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 104 GENERAL FRAME INFORMATION ALL MODELS 3 Place the Hu
45. elding flame cutting or the addition of holes in critical zones These practices are restricted for all frame rails however HEAT TREATED rails are much more sensitive to these alterations Frame Damage The major sources of frame damage are accidents overloading the vehicle and local overstressing due to a variety of causes In accident cases the reasons for the damage are readily apparent Such damage may often be repaired by Straightening and reinforcing the frame e Repairing the damaged area and reinforcing the frame sidemember e Replacing the frame sidemembers and crossmembers Damage to the chassis frame such as a crack in the frame sidemember or crossmember which is not associated with impact damage may be an indication of overloading the vehicle Damage to the chassis frame may also be an indication of the creation of locally high stresses due to operating conditions or equipment mounting practices Examples of overloading are 1 Exceeding either the gross vehicle weight rating GVWR or the gross axle weight rating GAWR loading the frame beyond its design capacity 2 Uneven load distribution 3 Improper fifth wheel settings 4 Using the vehicle in operating conditions or with equipment it was not designed for Examples of creation of locally high stresses are 1 Mounting bodies or equipment in a manner that causes stress concentrations and or abrasive wear in either the flange or web portion of the sidemember
46. frame the addition of holes reinforcements welds clamps splices etc may cause an increase in the local stress in the frame at the point of the modification THEREFORE CAUSING A STRESS CONCENTRATION IN THE FRAME SIDEMEMBER S These local stress concentrations can significantly affect the life of the chassis frame The specific effect which the stress concentrator will have on the life of the chassis frame is influenced by the location of the stress concentration the frequency and severity of the loading and the magnitude of stress concentration Deviation from the repair procedures in this section may void manufacturer s warranty Identification of Frame Rail Material International amp chassis are manufactured with frame rails of different alloy steels and some are heat treated Each material must be handled in a specific manner to assure maximum service life therefore the frame material must be determined before attempting repair or modification International chassis are presently manufactured with frame rails of e High strength low alloy HSLA steel 50 000 60 000 and 80 000 PSI yield strength e Heat treated steel 110 000 and 120 000 psi yield strength Each type has different repair procedures The frame rail material can be determined by inspecting the frame and consulting the dealer vehicle lineset ticket and the sales data book Heat treated rails are marked on the inside of the section with a decal which cautions against w
47. g reinforced 2 The corners of the reinforcements which will be in contact with the sidemember along the reinforcement edges must be chamfered to prevent damage to the sidemember 3 All sidemember reinforcements must be bolted to the web section within the zone shown in the frame drilling guidelines in the specific model body builder book The bolts must be of SAE Grade 8 or better with integral flanges or with hardened flat washers and must be tightened to Grade 8 levels 4 Crossmember modification or replacement may be required if the reinforcement is on the same side as the crossmember 5 Consider the potential effects of the reinforcements on the various components mounted to the frame Check clearances for suspension wiring plumbing and other controls 6 For attachment of reinforcements use existing bolts wherever this is practical 7 The weld repaired area of the sidemember and all of the reinforcement should be primed and painted before reinforcement installation For corrosive environments additional treatment of the interface may be needed Full Length Channel Weld Repair Reinforcements Full length channel reinforcements are available through International dealers for most models The actual length starting location and ending location vary from model to model Different length reinforcements may also be available When applied as a repair reinforcement these reinforcements DO NOT increase the load capacity of the vehi
48. ment weather must be thoroughly cleaned and dried before the repair is made 2 Surface areas and edges to be joined must be clean and free of oil grease loose scale rust moisture paint or other material that could contribute to poor quality welds 3 Always avoid craters notching and undercutting 4 Peennew welds prior to grinding to relieve stresses caused by shrinkage 5 Grind all welds flush with the surrounding surfaces Use a coarse grinder followed by smooth grind at 90 to the crack direction to remove all of the coarse grind marks 6 Inspect the weld repaired area carefully after grinding Grind out any remaining cracks notches or undercuts and repeat the finishing and inspections 7 For welding cracks to the edge of the sidemember flange locate a run off block at the edge as in to obtain a continuous weld without undercuts After welding the run off block should be cut off and the weld should be ground and inspected as in steps 5 and 6 above 8 Weld to the edges of the holes The weld should continue into the hole to form a plug weld with a copper chill block on the opposite side to help form the plug The weld should then be finished as in steps 5 and 6 above and redrilled Chamfer the hole edges If the hole was open and unused install a Grade 8 bolt to help attach the weld repair reinforcement NVISIBLE ULTRAVIOLET AND INFRARED RAYS EMITTED IN WELDING CAN INJURE UNPROTECTED EYES AND SKIN PROTECTION SUCH AS WELDER S H
49. n Figure 2 4 is the preferred welding method Table 2 1 Recommended Electrodes and Wires RECOMMENDED ELECTRODE AND WIRE MATERIAL STRENGTH PSI SMAW GMAW 50 000 E7018 705 3 60 000 705 1 80 000 8018 805 02 Amperage and voltage recommendations for welding are shown Table 2 2 and Table 2 3 Table 2 2 SMAW Method HSLA Frames WELDING CURRENT POSITION ELECTRODE SIZES SPEED INCH AMPERES VOLTS INCH MIN Flat Horizontal and Vertical 110 140 20 14 24 Table 2 3 GMAW Method HSLA Frames wes vos _ Flat 350 400 Horizontal and Vertical 190 220 20 30 350 400 7 Preheat frame rail along the weld joint to 500 to 600 F 260 to 316 C to insure any moisture present is eliminated and to prevent too rapid cooling of weld metal 8 Direct current reversed polarity is preferred Weld using a short arc and a beading or narrow weave technique B Slag should be removed after each pass and an interpass temperature of 200 F 93 C should be maintained 10 Grind smooth and flush with surrounding sidemember material Grind the weld in a direction that is at 90 to crack direction Figure 2 4 D 11 Add reinforcement DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 95 GENERAL FRAME INFORMATION ALL MODELS DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 96 GENERAL FRAME INFORMATION ALL MODELS Heat Treated Frames 110 000 and 120 0
50. nnel Weld Repair Reinforcements This type of reinforcement must be custom fabricated either by cutting lengths from full length reinforcements or by forming from flat stock Figure 2 5 B Recommended Applications 1 Casesin which the weld repair extends into the sidemember flange after substantial service life 2 Cases accompanied by extensive abrasive wear of the sidemember section In these cases the length of the wear area should be added to the length recommendations below Application Procedures 1 The channel should be installed on the outside of the section for greater strength 2 Figure 2 5 B gives recommended dimensional data and attachment specifications for a typical installation Holes drilled for the attachment must be within the frame drilling guidelines in the specific model body builder book DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 99 GENERAL FRAME INFORMATION ALL MODELS DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 100 GENERAL FRAME INFORMATION ALL MODELS Local L or Inverted L Weld Repair Reinforcements This type of reinforcement is also generally custom fabricated It has a greater tendency to loosen than a channel reinforcement because for vertical deflections of the frame assembly it tends to bend about an axis different from that of the main sidemember section Because of this its length and or attachment specifications are typically greater than for the channel
51. ob positioned against bare metal 2 Tack or tape pieces of paper to the floor directly under each point of measurement on the chassis as indicated by the letter K in Figure 2 2 Figure 2 2 Centerline of Chassis 01 0012 Method of Checking After each measurement point has been carefully marked on the floor proceed as follows 1 Locate centerline of chassis by measuring front and rear end widths using marks on floor If frame widths are within specification draw centerline on floor the full length of the chassis and continue with step 2 If frame widths are out of specification lay out centerline as follows DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 89 GENERAL FRAME INFORMATION ALL MODELS DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 90 GENERAL FRAME INFORMATION ALL MODELS Centerline can be drawn through the intersection of any one pair of equal diagonals A A B B C C D D and center point of one end of frame or through points of intersection of any two pairs of equal diagonals 2 Measure distance from centerline to opposite points marked over entire length of frame Measurements should not vary more than 0 12 inch 3 0 mm at any point 3 Measuring diagonals A A B B C C D D will indicate point where misalignment occurs If diagonals in each pair are within 0 12 inch 3 0 mm that part of the frame included between points of measurement may be considered in satisfac
52. om of frame in loaded position Refer to tabulated data Frame rail height Refer to tabulated data Static Loaded Radius The distance from the wheel axis to the ground for a properly inflated fully loaded loaded to its maximum capacity tire To obtain tire dimensions contact the tire manufacturer Tire Radius one half of tire outside diameter NoT mounted on the vehicle To obtain tire dimensions contact the tire manufacturer 2 Calculated Tire Radius on an unloaded chassis The value of is FRONT AXLE calculated using the following method CENTER LINE R 2 R SLR 01 0071 Front Frame Height at the front axle centerline unloaded condition Front Frame Height at the front axle centerline in loaded condition Y De R F for unloaded condition Y D SLR F for loaded condition Values calculated for Y and Y are strictly for the frame height at the front axle centerline For frame heights at the front of the frame rail refer to FRAME HEIGHT DATA FRONT All Models Front Suspension Spindle To Bottom Of Frame Model Type Capacity Code Unloaded D Loaded D LP 4x2 6x4 5 5 4 5 X X 8 000 Ib 0 12 4 12 2 9 000 Ib 03AGW 6 6 5 6 X X 74 5 5 X X 10 000 Ib 12 4 11 5 Parabolic 11 000 Ib 0 7 1 5 5 X 12 000 Ib 7 5 5 6 X 13 000 Ib 03AGS 7 1 5 5 X 14 000 Ib 7 4 5 7 X
53. r 40 000 9 38 25 9 38 25 10 375 9 51 25 9 51 25 9 125 7 31 50 10 125 8 31 50 4x2 non LP Vari Rate 13 500 10 125 8 31 50 10 250 8 43 50 10 375 8 56 50 9 125 6 37 3 79 1 59 10 125 7 37 4 79 2 59 10 250 7 49 4 92 2 72 4 2 non LP Vari Rate 10 125 7 37 4 79 2 59 10 250 7 49 4 92 2 72 10 375 7 62 5 04 2 84 FRAME AND BUMP HEIGHT DATA REAR CONTINUED Frame Rail Height Rear Suspension Spindle to Bottom of Sidemember Model Frame Code F Unloaded D Loaded D Bump D LP 01CAA 9 125 Vari Rate 18 500 7 78 4 48 2 2 9 125 7 81 5 03 2 83 10 125 8 81 6 03 3 83 10 250 8 93 6 16 3 96 4x2 non LP Vari Rate 10 125 8 81 6 03 3 83 10 250 8 93 6 16 3 96 10 375 9 06 6 28 4 08 LP 01CAA 9 125 Vari Rate 20 000 8 125 4 75 2 5 9 125 8 26 50 5 31 3 13 10 125 9 26 50 6 31 4 13 10 250 9 38 50 6 44 4 26 4x2 non LP Vari Rate 10 125 9 26 50 6 31 4 13 10 250 9 38 50 6 44 4 26 10 375 9 51 50 6 56 4 38 01CAB 9 125 01CAC 10 125 9 68 6 13 3 93 10 250 9 81 6 26 4 06 4x2 non LP Vari Rate 10 125 9 68 6 13 3 93 10 250 9 81 6 26 4 06 10 375 9 93 6 38 4 18 DURASTAR SERIES BUILDER FRAMES FRAME AND BUNP
54. r and then automatically disengages from the fastener Figure 2 20 L Figure 2 20 Huck Spin Installation 01 0030 DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 109 GENERAL FRAME INFORMATION ALL MODELS SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 110 GENERAL FRAME INFORMATION ALL MODELS Special Service Tools Hydraulic Unit Model No 940 Used for removal and installation of the Huck Bolt Figure 2 21 Hydraulic Unit 01 0031 Nose Assembly Tool NOSE ASSEMBLY TOOL Figure 2 22 Nose Assembly Tool 01 0032 Table 2 5 Nose Assembly Tool DESCRIPTION TOOL NUMBER For 1 2 Dia Fastener 99 1484 For 5 8 Dia Fastener 99 1481 DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 111 GENERAL FRAME INFORMATION ALL MODELS FEBRUARY 2015 PAGE 112 SERIES BODY BUILDER FRAMES GENERAL FRAME INFORMATION ALL MODELS Hydraulic Installation Tool Figure 2 23 Hydraulic 01 0033 Installation Tool Table 2 6 Hydraulic Installation Tool TOOL NUMBER 557 585 DESCRIPTION For 1 2 Dia Fasteners For 5 8 Dia Fasteners Collar Removal Tool Table 2 7 Collar Removal Tool TOOL NUMBER 516 520 DESCRIPTION For 1 2 Dia Fasteners For 5 8 Dia Fasteners ORDER TOOLS FROM Phone 800 431 3091 Phone 914 331 7300 Huck International Inc Box 2270 One Corporate Drive Kingston NY 12401 Fax 914 334 7333
55. r metals must be in direct contact and an electrolyte such as moisture must be present Aluminum is anodic with respect to steel and will corrode when in the presence of steel Corrosion of aluminum frame crossmembers will reduce the load carrying capacity of the frame member and may eventually lead to the failure of the frame To prevent the formation of a galvanic cell isolation techniques such as non conductive or barrier type spacers or sealers must be used so that the steel and aluminum are not in direct contact It is recommended that a sealer such as Tectyl 400C or equivalent be painted onto the surface of both the aluminum and steel as well as on the washers under the head of the bolts and nuts Frame Alignment The frame must be properly aligned as this affects body axle and suspension mounting If the vehicle has been involved in an accident or has been overloaded it is recommended that the frame be checked for proper alignment Pre Alignment Inspection Before checking alignment park vehicle on level ground and set parking brake Inspect frame assembly for loose parts welds cracks and bends Be sure to make all necessary repairs before attempting to check frame alignment Method of Checking Frame Alignment A satisfactory method of checking the frame and axle alignment particularly when a body and cab is on a chassis is to 1 Place a plumb bob against the point of measurement All measurements must be taken with the plumb b
56. rsed polarity is recommended 4 Slag should be removed after each pass and an interpass temperature of 200 F 93 C should be maintained 5 Grind smooth and flush with surrounding sidemember material Grind the weld in a direction that is 90 to crack direction Figure 2 4 D 6 Addreinforcement DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 93 GENERAL FRAME INFORMATION ALL MODELS DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 94 GENERAL FRAME INFORMATION ALL MODELS LAA 5590 Nd Nw V 5 XXX V GROOVE INTO SOUND METAL COPPER CHILL STRIP FRAME RAIL V GROOVE CRACK WELD GROUND FLUSH WITH FRAME GRIND IN LONGITUDINAL DIRECTION OF SIDEMEMBER Figure 2 4 Use of Chill Strip 01 0014 High Strength Low Alloy Steel Frames 50 000 60 000 and 80 000 PSI Yield Strength Any of the electric arc methods previously described may be used The choice of a suitable electrode or wire depends somewhat upon the equipment available for welding and the method selected The SMAW and the GMAW methods are preferred for welding the HSLA frames The use of low hydrogen electrodes is recommended Refer to Table 2 1 for selection of recommended electrodes and wires or refer to A W S A 5 standard available from www aws org for equivalent strength electrodes wires or rods and power leads to be used in the welding methods The double V notch weld preparation using the weld procedure shown i
57. strictions later in this book Welding or Flame Cutting Welding or flame cutting of the frame components is unacceptable because of the associated loss of fatigue strength This restriction applies not only to the heat treated components but also the high strength low alloy HSLA and low carbon steel components DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 83 GENERAL FRAME INFORMATION ALL MODELS DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 84 GENERAL FRAME INFORMATION ALL MODELS Exceptions to this are cases with Navistar Engineering approval or for repair operations as described in this service manual section TO AVOID SERIOUS PERSONAL INJURY DEATH OR POSSIBLE ENGINE DAMAGE WHEN WELDING OR USING AN ACETYLENE TORCH ALWAYS WEAR WELDING GOGGLES AND GLOVES INSURE THAT ACETYLENE AND OXYGEN TANKS ARE SEPARATED BY A METAL SHIELD AND ARE CHAINED TO A CART DO WELD OR HEAT AREAS NEAR FUEL TANKS OR FUEL LINES UTILIZE PROPER SHIELDING AROUND HYDRAULIC LINES Reinforcement to Increase Capacity Reinforcement of the chassis frame to support either additional loading or concentrated loading does not increase vehicle load carrying capacity unless it has been fully verified that all other vehicle components such as the brake system steering system suspension system etc can properly and safely support the increased loading Increase in Local Stress In any modification of the chassis
58. the opposite side of the repair should be deep enough to enter the sound metal of the first weld repair as shown in Figure 2 4 C Reinforcement The strength of the sidemember in the weld joint repair region has been reduced by welding and this region must be reinforced sufficiently to insure that the service life of the frame is not shortened Reinforcement of the frame after welding is intended to reduce the stresses in the weld repair region to a lower level than was previously permitted Improper drilling will also reduce the strength of the sidemembers Refer to Drilling or Notching THE TYPE LENGTH MATERIAL AND ATTACHMENT TECHNIQUES FOR REINFORCEMENTS VARY WITH THE TYPE AND LOCATION OF THE CRACK AND WITH THE LOADING CONDITIONS ASSOCIATED WITH THE CRACK It is not practical to give specific recommendations for all cases of frame cracking therefore the various types of reinforcements are identified with general descriptions of their applications and installation procedures To aid in making the distinctions between the more critical flange area and the less critical web area critical zones are defined as shown Figure 2 5 D Figure 2 5 DURASTAR SERIES BODY BUILDER A LOCAL REINFORCEMENT CRACK LOCATION 30 MINIMUM NOTE NOT TO BE USED FOR MINIMUM ap CRACKS BELOW START OF BEND B LOCAL C REINFORCEMENT LOCATION 2D MINIMUM REINFORCEMENT 20 MINIMUM NOTE INSTALLATION OF THE REINFORCEMENT AI TYPICAL O
59. tion This can be accomplished with a small wheel grinder Figure 2 14 Figure 2 14 Cutting Collar 01 0024 with Wheel Grinder Drilling on opposite sides of the collar may also be used Figure 2 15 Figure 2 15 Drilling 01 0025 the Collar Another method of splitting the collar is to chisel the walls of the collar Figure 2 16 Figure 2 16 Using 01 0026 Chisel to Split the Collar DuRASTAR SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 107 GENERAL FRAME INFORMATION ALL MODELS SERIES BODY BUILDER FRAMES FEBRUARY 2015 PAGE 108 GENERAL FRAME INFORMATION ALL MODELS When the collar has been opened over the length of the swaged portion on two opposite sides Figure 2 17 the fastener can be removed The fastener may need to be hammered to remove the collar Figure 2 17 Collar 01 0027 with Reliefs for Removal In the event the collar doesn t come loose use a chisel or suitable tool to peel the collar sections back Figure 2 18 Figure 2 18 Collar Peeled 01 0028 Back to Assist Removal The fastener will come free when sufficient collar material has been pulled away Figure 2 19 t nM es lt gt gt Figure 2 19 Fastener Removed 01 0029 Install The Huck Spin is installed by spinning the collar onto the fastener The pulling action of the Huck Spin installation tool swages the collar into the grooves of the fastene
60. tory alignment These diagonals should intersect within 0 12 inch 3 0 mm of the centerline If the diagonals are not within specification try loosening and re tightening all cross members Then re check alignment Refer to the Bolt Torque Chart Phosphate and Oil Coated If frame is still out of alignment the vehicle must be taken to a suitable frame alignment establishment to confirm frame misalignment If misalignment is confirmed suitable measures must be taken to repair the damage ELEVATION DIMENSIONS Dimensions for side elevation of the frame should be checked at the points indicated and should not vary more than 0 12 inch 3 0 mm from side to side They will differ fore and aft due to typical frame rake Axle Alignment With Frame After determining that the frame is properly aligned the axle alignment with the frame should be checked by comparing diagonals If necessary adjust axle to frame alignment Frame Straightening Frame straightening should only be performed by a qualified frame alignment facility Under no circumstance should frame alignment be performed by inexperienced or unqualified service personnel DO NOT USE HEAT TO STRAIGHTEN Use of heat is not recommended when straightening heat treated frame sidemembers Heat will weaken these frame members consequently all straightening should be done at room temperature Add reinforcement per section if heat straightening is done Frame members which are
61. type Recommended Applications This type of reinforcement is recommended for cases in which the weld repair is confined to the web of the section but extends beyond the application zone of the flat plate reinforcements shown in Figure 2 5 D Application Procedures 1 Figure 2 5 A shows a typical installation for an L reinforcement on the inside of a sidemember section along with minimum recommended dimensions 2 The flange of the reinforcement should be oriented up or down so that flange is on the same side as the damaged area 3 Formaximum strength the reinforcement should be installed on the outside of the sidemember section Flat Plate Weld Repair Reinforcements This reinforcement is intended for the less critical web portion of the sidemember section where typical cracking is due to local stresses which tend to diaphragm or dish the web without creating appreciable stresses for overall bending of the section Typical crack patterns radiate out from the edge of a mounting bracket or crossmember or from a hole in the web Cracks which radiate from a web hole occupied by a fastener are frequently an indication of a defective joint whether by the loosening of the fastener or poor joint design Figure 2 5 C Recommended Applications The flat plate reinforcements are recommended for weld repairs in which the weld does not extend beyond the zone defined in Figure 2 5 D Application Procedures 1 A typical installation is shown in
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