Chapter 6

INSTRUCTIONS FOR BUILDING UP OF REAR BODY

MAIN SILL (OR SUB-FRAME) ••••••••••••••••••••••••••••••••••••••••••••••••••• 1

REAR AXLE • •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6
REAR BODY LENGTH AND MAIN SILL (SUB-FRAME) •••••••••••• 7
DIMENSIONS
U-BOLTS ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7
MOUNTING SUB-FRAME WITH U-BOLT •••••••••••••••••••••••••••••••••••• 11
MOUNTING OF REAR FENDER AND MUDGUARD •••••••••••••••••••• 12

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Chapter 6 INSTRUCTIONS FOR BULDING UP OF REAR BODY

Main Sill (OR SUB-FRAME)

When mounting a body or equipment, always fit a main sill

(sub-frame) on the top surface of the side rail of the
chassis frame.

(1) When mounting the main sill on top of the side rail, make sure that you position it so as to
disperse the stress placed on the side rail by loading.
Also be sure to secure all mechanisms of the body equipment unit to the main sill, except
for the combination parts between the main sill and the side rail.

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Shape of front end

The front end of the main sill, which comes into contact with the side rail, should be shaped as
illustrated below in order to disperse the concentrated load.
The following illustrations show the shapes of the main sill (or sub-frame) in the case of ordi-
nary cargo body, van body and the like. In case of other special types of trucks, appropriate
considerations should be given in reference to these illustrations.
When fixing the main sill to the side rail, no welding and no bolting is recommended even
though the sill is made of steel.

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Chapter 6 INSTRUCTIONS FOR BULDING UP OF REAR BODY

Relation of concentrated stress to forward end shape of main sill.

Preventing concentrated stress around the forward end of the main sill (sub-frame).

If the section modulus at the forward end of the main sill (sub-frame) changes suddenly, this
will place concentrated stress on the side rail and may lead to cracks in the side rail.
When mounting a body, make sure that the section modulus at the forward end of the main sill
(sub-frame) does not change suddenly.

The front end of the main sill (sub-frame), which used pressed or shaped steel material, must
not be closed as shown in the drawing below to avoid stress concentration.

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Chapter 6 INSTRUCTIONS FOR BULDING UP OF REAR BODY

Assembly width of main sill

Assembly width of main sill (sub-frame) of the mounted body or equipment should be same
with the chassis frame as following figure.

RIGHT MAIN SILL WRONG

(SUB-FRAME)

CHASSIS FRAME

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Chapter 6 INSTRUCTIONS FOR BULDING UP OF REAR BODY

Reinforcement of main sill

When reinforcing the main sill by steel plate, its end must be more than 100 mm (4.0 in.) apart
from the bolt of crossmember and fitted with main sill.

When the superstructure has a high rigidity as in the case van body (particularly refrigerator
van body), care must be taken in choosing the vehicle type and in designing the superstruc-
ture so that the main sill may be as close to the rear of cab as possible. The superstructure
and the main sills should be linked as close as possible by use of stays if there is an exces-
sive gap between the superstructure and the rear of cab.

Pay due attention to the following points in the relations between the rear of cab and the main
sill when abnormal vibration will happen on vehicle.

Unit : mm (in.)
CAB A
SINGLE 558 (22)
DOUBLE 1568 (61.7)

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Chapter 6 INSTRUCTIONS FOR BULDING UP OF REAR BODY

When body mounting brackets are used instead of U-bolts to mount the body, following points
must be observed.
• Body mounting bracket shall be 200 mm (8.0 in.) or more apart from the bolt of crossmem-
ber.

• If the mounting brackets must be mounted within 200 mm ( 8.0 in. ) of the bolt of No.2 cross-
member, they should be positioned at the central nearby existing hole of crossmember.

• Body mounting brackets must be fitted to the side rail with bolts.
You should use existing holes for brackets.
When drilling holes for brackets, do not damage brake pipes and harness wires.

Avoiding Sudden Change of Rigidity around No.2 Crossmember

• The part around No.2 crossmember is easy to occur stress concentration due to constantly
receiving the high bending and torsional force under operation of the vehicle.
• Be sure to avoid such structure around No.2 crossmember of the main sill (sub-frame) and
body or equipment as sudden change of section modulus or rigidity.

Rear Axle

As the brake hose is fitted over the rear axle, sufficient clearance between the hose and the
fittings of rear body is required so that the hose does not contact with the fittings when the
axle contacts with the frame.

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Chapter 6 INSTRUCTIONS FOR BULDING UP OF REAR BODY

Rear Body Length and Main Sill (SUB-FRAME) Dimensions

In the case of a vehicle with a long rear body, the sectional dimensions of the rear body main
sill should be at least as indicated below.

Unit: mm (in.)

If wooden main sills are used for a long cargo body, the chassis frame and rear body may
deflect unusually resulting the side gate of the rear body cannot be opened freely. Therefore,
steel sills should be used for the long wheelbase vehicles.
In the case of heavy-load or concentrated load vehicles with the long wheelbase, consider the
use of the standard pressure-rolled structural steel material SS400 (Min. 120 mm (4.7 in.) high
by 50 mm (2.0 in.) wide by 3.2 mm (0.1 in.) thick) or the like.

When lip shape steel (     -shape) is used for the main or cross sill, provide a drain hole at a
place where it will not affect its­ strength, for accumulation of water inside the steel shape will
cause rusting.

U-Bolts

The main sill and the U-bolts fastening, it must be given sufficient clearance to prevent them
from contacting brakes pipes, hoses, fuel tube, cables and harness wires.
When it is difficult to ensure the required clearance between them and the chassis parts, use
flat U-bolts as a remedy.
Use an appropriate prop to support the side rail to which the U-bolt is hooked so that the lower
flange may not be deformed.
Pay due attention to the clearance between the prop and the brake pipes, hoses, fuel tube,
cables and harness wires etc.
In an area close to the muffler, use a steel prop to prevent burning.

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[EXAMPLE STRUCTURE OF PROPS]

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Chapter 6 INSTRUCTIONS FOR BULDING UP OF REAR BODY

Pay special attention to the rubber hose. As for the rear of the cab and around the rear axles,
reference should be made to the instructions for their mounting.
Ensure a clearance of 50 mm (2.0 in.) or more between the U-bolts and rubber hose.

[INSTALLATION METHOD OF U-BOLT]

Unit: mm (in.)

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Chapter 6 INSTRUCTIONS FOR BULDING UP OF REAR BODY

It is desirable to install the U-bolts at the U-bolt mounting positions (standard positions) shown
on the below. Installing U-bolts at other positions will impair the frame strength. As a rule, do
not install U-bolts at the positions listed below. If it is unavoidable to install U-bolts at prohib-
ited positions, carefully verify the frame strength.

• Point where there is a difference in level on the chassis frame (frame kick point).
The U-bolt mounting position must be 50 mm ( 2.0 in. ) or more away from the frame kick
point.

• Existing hole in the flange of the side rail

The U-bolt mounting position must be 40 mm ( 1.6 in. ) or more away from the existing
hole.

• Break point of the side rail inner or outer reinforcement (the section modulus change greatly)
The U-bolt mounting position must be 100 mm ( 4.0 in. ) or more away from the break
point of the inner or outer reinforcement.

• Near the crossmember

As a rule, the U-bolt mounting position must be 200 mm ( 8.0 in. ) or more away from the
bolt of crossmember. If impossible, the U-bolt must be at least 100 mm ( 4.0 in. ) away from
the bolt of crossmember.

• Stress release point at front end of main sill (sub-frame).

• The details where U-bolt should be installed, see the next page.

[U-BOLT SHOULD NOT BE INSTALLED AT FOLLOWING RANGE]

Unit : mm (in.)

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Chapter 6 INSTRUCTIONS FOR BULDING UP OF REAR BODY

MOUNTING SUB-FRAME WITH U-BOLT

The setting positions of U-bolts should be observed according to the figure shown below.

Unit : mm (in.)
Wheelbase SIDE U-BOLT POSITION
Model Cab
mm (in.) RAIL L1 L2 L3 L4 L5 L6
2900 RH 1930 (76.0) 780 (30.7) 230 (9.1) 1275 (50.2)
700 SINGLE
(114) LH 1890 (74.4) 830 (32.7) 230 (9.1) 1275 (50.2)
3500 RH 2530 (99.6) 1375 (54.1) 275 (10.8) 1275 (50.2)
710 SINGLE
(138) LH 2490 (98.0) 1425 (56.1) 275 (10.8) 1275 (50.2)
RH 2830 (111.4) 1675 (65.9) 825 (32.5) 275 (10.8) 1275 (50.2)
SINGLE
XJC 3800 LH 2790 (109.8) 1725 (67.9) 825 (32.5) 275 (10.8) 1275 (50.2)
720
XFC (150) RH 1675 (65.9) 825 (32.5) 275 (10.8) 1275 (50.2)
DOUBLE
LH 1725 (67.9) 825 (32.5) 275 (10.8) 1275 (50.2)
RH 3430 (135.0) 2275 (89.6) 1375 (54.1) 275 (10.8) 1275 (50.2)
SINGLE
4400 LH 3390 (133.5) 2325 (91.5) 1375 (54.1) 275 (10.8) 1275 (50.2)
740
(173) RH 2275 (89.6) 1375 (54.1) 275 (10.8) 1275 (50.2)
DOUBLE
LH 2325 (91.5) 1375 (54.1) 275 (10.8) 1275 (50.2)

NOTE : When you do not extend rear overhang, the dimensions of L6 recommend 1025mm (40.4in).

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Chapter 6 INSTRUCTIONS FOR BULDING UP OF REAR BODY

MOUNTING OF REAR FENDER AND MUDGUARD

Recommendable Mounting Position of Rear Fender

When mounting of rear fenders, determine dimensions of fenders so as not to interfere tires
making reference to the following figures.

Unit : mm (in.)
MODEL TIRE SIZE A B C D E F
XJC7 0L -HKTQMA3
XJC7 0L -QKTQMA3
215/85R16 2130 (83.9) 2150 (84.6) 1660 (65.4) 490 (19.3) 166 (6.5) 166.1 (6.5)
XFC7 0L -HKTQMA3
XFC7 0L -QKTQMA3
XJC7 0L -CKTTMA3
XJC7 0L -DKTTMA3
225/70R19.5 2137 (84.1) 2157 (84.9) 1665 (65.6) 492 (19.4) 168 (6.6) 184.8 (7.3)
XFC7 0L -CKTTMA3
XFC7 0L -DKTTMA3

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Deflection of Rear Tires

Measurements for the maximum deflection for one side tire and for simultaneous left and right
deflection are shown blow.
When you mount the body, allow a clearance at least 30 mm (1.2 in.) so as not to obstruct tire
deflection.

DEFLECTION OF REAR TIRES

A : MAXIMUM DEFLECTION FOR B,C : MAXIMUM SIMULTANEOUS DEFLECTION

ONE SIDE WHEELS RIGHT AND LEFT WHEELS

Unit : mm (in.)
MODEL TIRE SIZE A B C
XJC7 0L -HKTQMA3
XJC7 0L -QKTQMA3
215/85R16 116 (4.6) 80 (3.1) 119 (4.7)
XFC7 0L -HKTQMA3
XFC7 0L -QKTQMA3
XJC700L -CKTTMA3 225/70R19.5 114 (4.5) 80 (3.1) 142 (5.6)
XJC7 0L -CKTTMA3
(Except XJC700L)
XJC7 0L -DKTTMA3
225/70R19.5 135 (5.3) 99 (3.9) 123 (4.8)
XFC7 0L -CKTTMA3
XFC7 0L -DKTTMA3

[NOTE]
• When tire chain to be equipped, dimensions A and B are to be added 63.5mm (2.5 in.).

Installing Mudguard for Rear Wheel

The mudguard for rear wheel is under the obligation to install on the vehicle by each State’s
law. Since contents of the obligation differ by each State, observe each State’s law.

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