BM1503A5ECAFIG1

HINO 500 SERIES

Body Mounting Manual

BM1503A5ECA

APPLICATION

TRUCK CHASSIS

TRUCK CHASSIS

FC9J

GD8J

GH8J

FM8J

FM2P

COPYRIGHT

No part of this manual may be reproduced or transmitted in any form without the express

written permission of Hino Motors, Ltd.

© 2015, Hino Motors, Ltd. All rights reserved. Printed in Japan.

3-1-1, HINO-DAI, HINO-SHI, TOKYO, 191-8660 JAPAN

PUBLISHING INFOMATION

MANUAL No. : BM1503A5ECA

PUBLISHING INFOMATION

We have published the new revised edition of Body Mounting Manual with the following changes. Consequently, please discard the current Body Mounting Manual

CD-ROM NO. KK-FC210A, KK-GD206A, KK-GH209B, KK-FM111C, KK-FM231A and KK-FM231B and use the new CD-ROM NO. BM1503A5ECA from now on.

CONTENTS OF CHANGES

Purpose

This manual is provided to Body and Equipment Manufacturers, including inter-mediate and/or final stage manufacturers (hereinafter collectively referred to as Body and Equipment Manufacturers), to provide;

• Technical instructions for Hino truck chassis with cab for modification and mounting of bodies,

• An aid to Body and Equipment Manufacturers for producing safe vehicles under their own discretion and responsibility,

• Other general advice for installation, modification or alteration,

when Body and Equipment Manufacturers install any body or other equipment or device on Hino truck chassis with cab (hereinafter collectively referred to as Hino Chassis), or modify or alter a Hino Chassis.

Content

This manual contains chassis specifications and instructions particular to HINO 500 series medium duty trucks.

Important

• The Common Manual is available in this CD-R.

• For more information on mounting of bodies and equipments or on chassis modifications, refer to the appropriate workshop manuals, parts catalogs, and maintenance guides and owner's or driver's manual.

• The information in this manual is accurate to the best of Hino's knowledge at the time of going to press.

Hino reserves the right to modify any and all information without notice and without obligation.

• Should more detailed data or information be needed, please contact authorized Hino distributor.

ABOUT THIS MANUAL

This instruction manual must be used in combination with

the Common Manual, No. KC-AA201A.

Warning

• It is the responsibility of Body and Equipment Manufacturers or modification companies to make sure that the completed vehicle with body and equipment, or after

modification, conforms to all applicable laws and regulations of the country in which the vehicle is to be used (e. g. regulations on lighting, tilt, overall size, axle load, external noise control etc).

• This manual does not guarantee the safety of a Hino chassis once a body or equipment has been mounted or modification has been made by a Body and Equipment Manufacturer or a modification company.

• This manual does not affect that ultimate responsibility for the manufacture and mounting of the body, installation, modification or alteration on Hino Chassis devolves upon the Body and Equipment Manufacturer.

• Each individual Body and Equipment Manufacturer has the sole responsibility for the design, functions, materials and work concerning the body and equipment.

• Hino Motors, Ltd. does not assume any liability whatsoever for any injury to persons or damage to property caused as a result of the utilization of this manual.

• About chassis mass

The chassis mass of chapter 1 and 3 shows standard specification of vehicle. (It is not included mass of option equipment.)

When consider the mounting of body, should include mass of option equipment. • About SRS air bag and ABS system

The vehicle with SRS air bag and ABS system, be sure to comply with the remarks bellow.

The SRS air bag may inflate incorrectly according to wrong operations of body mounting or unexpected cause.

The function of ABS system fall remarkably according to incorrect body mounting. Therefore it is strictly prohibited that the following operations, modification or provision of equipments install to the vehicle.

- Removing the steering wheel, steering system and parts of cab. - Wheelbase modification

- Front bumper modification

(Stay extension, Bumper thickness change, Shape modification) - Provide snow plough (Snow removal)

- Mounted spare tire in front - Provide grille guard - Provide winch - Provide kangaroo bar

- Mounted crane behind cab (front boom rest type) - Mounted aerial platform (front boom rest type)

Before starting work, be sure to refer to Chapter 2.1 PRECAUTION FOR SRS AIR BAG or please consult Hino sales dealer or distributor.

• About VEHICLE CONTROL ECU

The vehicle with VEHICLE CONTROL ECU, the vehicle is controlled by the ECU. Therefore, don't change the specification of vehicle. (Ex. Tire size, Final gear ratio, etc.)

ABOUT THIS MANUAL

• In normal operation, the chassis frame and body frame provide sufficient strength for the mounting of a standard cargo, van and dump body.

However, if body or equipment such as a small crane at the back of the cab, concrete pump, areal platform, tank supported reg type or a mixer are fitted, the chassis frame will be subject to concentrated loads and the chassis frame alone will not give sufficient strength. To help spread the load, you must strengthen the body structure (especially strengthening members corresponding to the sub frame=longitudinal main floor member of body or equipment) or the chassis frame itself, using L-shaped stiffeners to achieve sufficient strength for the mounting of the rear body or equipment.

More detailed information will be needed, please contact to authorized Hino distributor or sales outlet.

1. VEHICLE SUMMARY

2. GENERAL PRECAUTIONS

3. CHASSIS MASS & FRAME SECTION MODULUS

4. SPRINGS & REAR AXLES

5. P.T.O. AND CONTROL

6. ELECTRICAL SYSTEMS

7. PAINTING

8. CHASSIS DRAWINGS

9. MOUNTING OF CHASSIS EQUIPMENT

10. TRACTOR EQUIPMENT

11. REGULATION

CONTENTS

(THIS CHAPTER IS NOT APPLICABLE TO YOUR MODEL SERIES.)

(THIS CHAPTER IS NOT APPLICABLE TO YOUR MODEL SERIES.)

Chapter

1

VEHICLE SUMMARY

1. PRODUCTION CODE

2. IDENTIFICATION NUMBER

3. CHASSIS SPECIFICATIONS

VEHICLE SUMMARY

1

1. PRODUCTION CODE

F

G

8J

K

1

A

–

GVMR DRIVE CODE MODEL CODE WHEELBASE_(mm) CODE STEERING_{POSITION MODIFY CODE} BODY TYPE_ETC.

C 3000 D 3000 3249 E 3250 3499 G 3750 3999 H 4000 4249 J 4250 4499 K 4500 4749 L 4750 4999 M 5000 5249 N 5250 5499 P 5500 5749 R 5750 5999 S 6000 6249 T 6250 6499 W 7000 7249 Q U H M

FIRE ENGINE with LEAF SUSPENSION T 10,000 13,000kg_CLASS 4 x 4 17,000kg CLASS 26,000kg CLASS 26,000kg CLASS 4 x 2 6 x 2 6 x 4 L M 7J J07E 8J J08E 9J J05E 1A A09C 2P P11C G VEHICLE TYPE

ENGINE CODE WHEELBASE CODE MODIFICATION CODE

10,400kg CLASS 10,000 12,000kg CLASS D C APPLICABLE CODE GVMR & (DRIVE) CODE

4 x 6J F G CAB-OVER TRUCK CAB-OVER TRUCK

GENERAL CARGO with LEAF SUSPENSION

GENERAL CARGO with REAR AIR

SUSPENSION GENERAL CARGO

with REAR AIR SUSPENSION DUMP with LEAF SUSPENSION DUMP with LEAF SUSPENSION MIXER with LEAF SUSPENSION DUMP with REAR AIR

SUSPENSION MIXER with REAR AIR

SUSPENSION GENERAL CARGO with

LEAF SUSPENSION A D 4 x 2 12,000 14,000kg CLASS E 4 x 2 2 B 4 x 2 J05D 1J J08C G E F S SEMI-TRACTOR 14,000 15,500kg CLASS H

OTHER SPECIFICATION CODE

CAB, T/M TYPE ETC.

AAA

VEHICLE SUMMARY

1

2. IDENTIFICATION NUMBER

CHASSIS NUMBER

ENGINE NUMBER

Located at the side member of chassis frame.

RIGHT

VEHICLE MANUFACTURED STAMPING POSITION ( ) LOCAL

ORIGIN (JAPAN) LOCAL or ORIGIN (JAPAN)

LEFT LEFT

TAIWAN, and VENEZUELA DESTINATION EXCEPT ABOVE

A

C

B

: ENGINE NUMBER

J08E (FOR INDONESIA EURO2) J08E (EXCEPT ABOVE)

A09C P11C STAMPING POSITION B A B A A B B C

VEHICLE SUMMARY

1

3. CHASSIS SPECIFICATIONS

Detail of specifications refer to following.

WARNING

• Permissible axle capacity and GVM or GCM capacity must not be exceeded.

• The front axle load must exceed 30% of the gross vehicle mass under full loaded

condition for 4x2, 8x4 and 4x4 drive vehicle.

• The front axle load must exceed 20% of the gross vehicle mass under full loaded

condition for 6x2 and 6x4 drive vehicle.

• The rear axle load must exceed 25% of the gross combination mass under full

loaded condition of semi-tractor vehicle.

• Mass distribution on the left and right wheels should be balanced.

• Both front axle and rear axle loads must not exceed the permissible load based on

the tire load capacity according to the tire standards in your country.

• The mass and dimension of tires mentioned in chassis specification shows design

figure according to ETRTO or JATMA standard.

VEHICLE SUMMARY

1

BODY MOUNTING MANUAL NUMBER BM1503A5ECA

MODEL NAME HINO 51018 HINO 51226 HINO 51726 HINO 52626 HINO 52635 PRODUCTION CODE FC9JJSA-NNB GD8JLSA-PAB GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX FM2PLSD-ZGL FM2PRSA-ZGL BODY APPLICATION GENERAL CARGO GENERAL CARGO DUMP GENERAL CARGO DUMP GENERAL CARGO DUMP GENERAL CARGO

EMISSION CONTROL EURO3 EURO3 EURO3 EURO3 EURO3

ENGINE J05E-TC J08E-UD J08E-UD J08E-UD P11C-VR

MAX. OUTPUT ISO NET 129kW {175PS} at 2,500r/min 184kW {251PS} at 2,500rpm 184kW {251PS} at 2,500rpm 184kW {251PS} at 2,500rpm 257kW {350PS} at 2,100rpm MAX. TORQUE ISO NET 500N·m {51kgf·m} at 1,500r/min 739N·m {75.4kgf·m} at 1,500rpm 739N·m {75.4kgf·m} at 1,500rpm 739N·m {75.4kgf·m} at 1,500rpm 1,275N·m {130kgf·m} at 1,500rpm TRANSMISSION LX06S (6MT) LJ06S (6MT) EATON ES11109 (9MT) EATON ES11109 (9MT) M009 (9MT) SUSPENSION Fr & Rr LEAF SPRING Fr & Rr LEAF SPRING Fr & Rr LEAF SPRING Fr & Rr LEAF SPRING Fr & Rr LEAF SPRING CAB SHORT CAB SINGLE CAB SINGLE CAB, WIDE TYPE SINGLE CAB, WIDE TYPE SINGLE CAB, WIDE TYPE

VEHICLE CONTROL ECU LESS LESS LESS LESS LESS

SRS AIR BAG LESS LESS LESS LESS LESS

ABS WITH WITH WITH WITH WITH

HEADLIGHT AUTOLEVELING LESS LESS LESS LESS LESS

FRONT UNDERRUN PROTECTION DEVICE (FUPD) LESS LESS LESS LESS LESS

REAR UNDERRUN PROTECTION DEVICE (RUPD) LESS LESS LESS LESS LESS

WHEEL BASE (mm) 4,350 4,850 3,760 5,030 3,590+1,300 4,600+1,300 3,590+1,300 4,600+1,300

TREAD FRONT (mm) 1,770 1,750 1,925 1,925 1,925

REAR (mm) 1,660 1,720 1,840 1,860 1,860

MAX. GVM/GCM CAPACITY (REGAL LIMIT) (kg) 10,400/ --- 11,900/ --- 17,000/ --- 26,000/ --- 26,000/ ---PERMISSIBLE AXLE CAPACITY FRONT (kg) 3,600 4,500 6,500 6,500 6,500

(GAM. RATING) REAR (kg) 7,000 8,500 10,500 20,000 20,000

TIRE CAPACITY SIZE 8.25-16-14PR 8.25-20-14PR 11.00-20-16PR 11.00-20-14PR 11.00-20-14PR

ON STD SPECIFICATIONS FRONT (kg) 3,600 4,120 6,500 6,000 6,000

REAR (kg) 6,800 7,800 11,600 21,800 21,800

CHASSIS MASS ON STD SPECIFICATIONS

(INCLUDING WATER, OIL AND FULL FUEL) (kg) Refer to 3, 1 Refer to 3, 1 Refer to 3, 1 Refer to 3, 1 Refer to 3, 1 HEIGHT OF CENTER OF GRAVITY (CHASSIS) (mm) Refer to 3, 1 Refer to 3, 1 Refer to 3, 1 Refer to 3, 1 Refer to 3, 1 RECOMMENDED HEIGHT OF GRAVITY CENTER

OF VEHICLE (UNLOADED CONDITION) (mm) 1,090 1,100 1,100 1,220 1,220 RECOMMENDED BODY WIDTH (mm) MAX. 2,320 MAX. 2,320 MAX. 2,500 MAX. 2,500 MAX. 2,500

8.25-16-14PR S – – – – – – – 8.25R16-14PR P – – – – – – – 9.5R17.5(129/127) P – – – – – – – 235/75R17.5(130/128) P – – – – – – – 225/70R19.5(130/128) P – – – – – – – 8.25-20-14PR – S – – – – – – 8.25R20-14PR – P – – – – – – 10.00-20-16PR – – – – P P P P 10.00R20-16PR – – – – P P P P 11.00-20-14PR – – – – S S S S 11.00-20-16PR – – S S – – – – 11.00R20-14PR – – – – P P P P 11.00R20-16PR – – P P P P P P 11R22.5-16PR – – – – P P P P 12R22.5-16PR – – P P – – – – 255/70R22.5(143/140) – P – – – – – – 275/70R22.5(148/145) – – P P P P – P 275/80R22.5(149/146) – – P P – – – – 295/80R22.5(152/148) – – – – P P P P 16x6.00GS-offset135mm S – – – – – – – 17.5x6.75-offset135mm P – – – – – – – 19.5x6.75-offset136mm P – – – – – – – 20x6.50T-offset145mm – S – – – – – – 20x7.50V-offset165mm – – S S S S S S 22.5x7.50-offset162mm – P – – P P P P 22.5x8.25-offset165mm – – P P P P P P 100L S – – – – – – – 200L P S S S S S S S 200Lx2 – – – – – P – P 65AH S S S S S S S S 120AH P P P P P P – – 24V-50A S S S S S S S S

FOR DETAILS OF DIMENSIONS & MASS, REFER TO EACH SECTIONS AS BELOW .

3.1. CHASSIS MASS M1 M2 M3 M4 M5 M6 M7 M8

3.2. MASS OF THE OPTION EQUIPMENT EQ1 EQ2 EQ3 EQ3 EQ4 EQ4 EQ4 EQ4

3.3. FRAME SECTION MODULUS Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8

4.1. SPRING CHARACTERISTICS FRONT STD F1(FRT) F3(FRT) F5(FRM) F5(FRM) F7(FRM) F7(FRM) F7(FRM) F7(FRM) OPT1 F2(FRM) F4(FRM) - - F8(FRT) F8(FRT) F9(FRT) F9(FRT) REAR  　 STD R1(RRM) R3(RRM) R5(RRM) R6(RRM) R7(RRM) R7(RRM) R7(RRM) R7(RRM) 5.2. TRANSMISSION SIDE POWER TAKE OFF TP-1d TP-2e TP-7 TP-7 TP-7 TP-7 TP-5 TP-5

5.3. ENGINE REAR END POWER TAKE OFF – – – – – – – –

5.4. TRANSFER POWER TAKE OFF – – – – – – – –

5.5. ENGINE CONTROL FOR BODY OR EQUIPMENT U-2b U-2b U-2b U-2b U-2b U-2b U-2c U-2c

5.6. REAR BODY CONTROL LEVER – – DL-2 – DL-2 – DL-2 –

8.1. CAB DRAWINGS C-1 C-2 C-3 C-3 C-4 C-4 C-5 C-5

8.2. CAB BACK DRAWINGS CB-1 CB-2 CB-3 CB-3 CB-4 CB-4 CB-5 CB-5

8.3. CHASSIS DRAWINGS CH-1 CH-2 CH-3 CH-4 CH-5 CH-6 CH-7 CH-8

8.4. CHASSIS FRAME DRAWINGS CF-1 CF-2 CF-3 CF-4 CF-5 CF-6 CF-7 CF-8 9.1. AIR TANK & AIR BOOSTER STD AT-1 AT-2 AT-3 AT-3 AT-4, AT-6 AT-4, AT-6 AT-5, AT-6 AT-5, AT-6 9.2. BRAKE PIPING DIAGRAM STD PD-1 PD-2 PD-3 PD-3 PD-4 PD-4 PD-5 PD-5

9.3. BATTERY STD BAT-1 BAT-1 BAT-1 BAT-1 BAT-1 BAT-1 BAT-1 BAT-1

OPT BAT-3 BAT-3 BAT-3 BAT-3 BAT-3 BAT-3 – –

9.4. FUEL TANK STD FT-1 FT-3 FT-4 FT-4 FT-5 FT-5 FT-5 FT-5

OPT FT-2 – – – – FT-6 – FT-6

9.5. FUEL COOLER STD – – – – – – – –

9.6. AUTO CLUTCH UNIT STD – – – – – – – –

9.7. EXHAUST SYSTEM STD EX-1 EX-3 EX-6 EX-6 EX-7 EX-7 EX-9 EX-9

OPT EX-2 EX-4 EX-5 EX-5 EX-8 EX-8 – –

9.8. LICENSE PLATE BRACKET STD LPB-C LPB-C LPB-C LPB-C LPB-C LPB-C LPB-C LPB-C P.T.O. AND CONTROL SPRINGS & REAR AXLES CHASSIS MASS & FRAME SECTION MODULUS MAJOR SPECIFICATIONS DIMENSIONS & MASS TIRE WHEEL DISC FUEL TANK BATTERY ALTERNATOR Ch3 Ch4 Ch5 Ch8 Ch9 MOUNTING OF CHASSIS EQUIPMENT CHASSIS DRAWINGS

Chapter

2

GENERAL PRECAUTIONS

1. PRECAUTION FOR SRS AIR BAG

2. ELECTRIC WELDING WORK

3. NOTES ON SYSTEM CONTROL COMPUTERS

4. PRECAUTION FOR ENGINE ECU

5. PRECAUTION FOR EXHAUST SYSTEM

6. PRECAUTION FOR VEHICLE TO BE PROVIDED HID LIGHT AXIS

SENSOR

7. PRECAUTION FOR AUTO CLUTCH UNIT (ACU)

8. PRECAUTION FOR MOUNTING OF BODY WITH AIR

SUSPENSION

9. FIRE SHIELD

10. NOTES ON ADDITIONAL WIRING IN THE ENGINE

COMPARTMENT

11. PRECAUTION FOR FUEL COOLER

12. CLEARANCE BETWEEN CAB AND REAR BODY OR

EQUIPMENT

13. RECOMMENDED POSITIONS OF U-BOLTS

14. RECOMMENDED POSITIONS OF REAR FENDERS AND

MUDGUARDS

15. PRECAUTION OF THE ANTENNA POSITION

16. ADJUSTMENT OF LIGHT AXIS OF HEADLIGHT

17. PRECAUTION FOR FRONT UNDERRUN PROTECTION DEVICE

(FUPD)

18. FOR INSTALLATION OF REAR UNDERRUN PROTECTION

DEVICE (RUPD)

19. PRECAUTION FOR ADDITIONAL FUEL TANK

20. PRECAUTION FOR THE FUEL HOSE

GENERAL PRECAUTIONS

2

1. PRECAUTION FOR SRS AIR BAG

(If equipped)

Be sure to observe the following precautions.

* SRS stands for Supplemental Restraint System, a device to supplement the protection of the crews.

* The vehicle with SRS air bag has marked "SRS AIRBAG" on the steering wheel horn button.

1.1 Precaution for Alteration or Body Mounting

When body mounting or alteration of cab body especially cab floor structure, be sure to take the following cautions securely.

* Do not make any reinforcement not modification at a part of cab floor.

Otherwise, an impact to be conveyed to a sensor of SRS air bag computer will change, by which SRS air bag will not function correctly.

* Do not cover over the pad of steering wheel with something like a sticker, a cover, etc.

At the same time, at an opening space for the air bag to be inflated, do not install any attachment or do not place anything thereon.

Otherwise, SRS air bag will not function correctly. * Do not make any modification of the suspension.

A change of vehicle height or a change of the suspension hardness may lead to a malfunction of SRS air bag computer.

* An electric wave of wireless device may affect badly to the computer, by which SRS air bag functions.

Take care to the following points for its installation. - Install an antenna, away possibly from the computer. - Install an antenna cord, 200 mm away from the computer. - Do not install a high power wireless device.

- As the installation of the said device may affect to other electronic apparatus, install it securely in accordance with a "Installation Manual" by the manufacturer of the devices.

When body mounted, observe following cautioning points securely. Otherwise, at the collision (accident), SRS air bag does not operate correctly or inflates incorrectly, which may result in a serious injury.

GENERAL PRECAUTIONS

2

* Strictly prohibited the following modification or provision of equipment.

Because the SRS air bag will not function correctly by change of impact to be conveyed to SRS air bag sensor.

- Front bumper modification

(Stay extension, Bumper thickness change, Shape modification) - Provide snow plough (Snow removal)

- Mounted spare tire in front - Provide grille guard - Provide winch - Provide kangaroo bar

- Mounted crane behind cab (front boom rest type) - Mounted aerial platform (front boom rest type) * Before work

Turn the starter switch to "LOCK" position, wait more than 60 seconds, and disconnect the negative terminal of battery.

Wait more than 90 seconds and start the work.

The SRS air bag may explode if giving shock to the SRS air bag sensor after removing negative terminal of battery until 90 seconds by storage in control computer.

If you weld, take off fuses of the SRS air bag.

Refer to Chapter 2. 2 of ELECTRIC WELDING WORK for detail. * After work

If fuses of SRS air bag are taken off, put back them original position. Connect the negative terminal of battery.

Leave from driver's seat for your safety, turn the starter switch to "ON" position, and check that function of SRS air bag will not operate until 10 seconds, then turn starter switch to "LOCK" position.

After that, turn the starter switch to "ON" position again, and then check that warning lamp of SRS air bag in combination meter will be ON then OFF after approximately 6 seconds. (See the following figure.)

If the warning lamp dose not light up or remains light up, bring the vehicle to your nearest authorized Hino dealer or distributor for an inspection.

GENERAL PRECAUTIONS

2

1.2 Precautions for electric wiring harness

Never alter or modify electric wiring harness of SRS air bag system.

(wiring harness and connectors of SRS air bag system are unified with yellow color.) Also, never try to check SRS air bag system by a general purpose tester, which may lead to a malfunction of SRS air bag system.

Do not take out power source of the mounting body or accessories from fuses of SRS air bag system, which may lead to a malfunction of it.

If you damage or cut harness of SRS air bag system accidentally, exchange harness assembly including SRS air bag system.

1.3 Precautions for working inside of cab

Be sure to observe the following precautions' when working inside of cab. The SRS air bag will not function correctly or may abnormally explode. * Do not remove or scratch the installing floor reinforcement of front

and do not remain the goods such as bolt or nut between floor plate and floor reinforcement of front.

* Do not remove or scratch the rubber mat under floor mat on the cab floor. * The SRS air bag is installed in the pad of steering wheel.

Do not scratch and force to pad such as hitting strongly. * Do not remove the stay where installed steering post.

1.4 Precautions for remove the cab or steering parts

When remove and reinstall the cab or steering parts, please consult with distributor.

1.5 Precautions for electric welding

Cover with a heat resisting sheet the resin parts of SRS air bag and an instrument panel. Remove the SRS air bag and the SRS air bag computer, in the case of the ambient temperature of them exceed 80°C during welding work.

Consult with your nearest Hino dealer or distributor when removing work. Refer to Chapter 2. 2 for detail of ELECTRIC WELDING WORK.

SRS air bag and chassis numbers are recorded for manufacturer's control. When removed off the SRS air bag, install it to the original chassis

GENERAL PRECAUTIONS

2

1.6 Precautions for cab sheet metal repair etc.

The acceleration sensor is built in the SRS air bag computer and the computer is installed to the pedal bracket.

(see the following figure)

Take care to the following points.

Otherwise, the SRS air bag will not function correctly or lead to a malfunction.

Remove the computer, when the sheet metal work of the surroundings (less than 500mm in radius) of it.

Do not to impact the surroundings (less than 500mm in radius) of the computer. Do not to impact the cab floor under the computer.

Do not to impact the pedal bracket which is installed the computer.

Do not use an air impact wrench when installation and removal of the computer and other parts of the surroundings.

GENERAL PRECAUTIONS

2

1.7 Precautions for cab paint

When heating the cab (ex. painting jobs) and it's temperature exceeds 80°C, remove off SRS air bag and SRS air bag computer.

Consult with your nearest Hino sales dealer or distributor When needed a removing work.

1.8 Precautions for installing off the computer

Install the removed SRS air bag computer in the position and direction of origin. Tighten installing bolts with regular torque.

If an installing position or direction is different from origin or tightening torque is outside regulation, the SRS air bag may not work normally.

Do not use an air impact wrench when tightening bolts. Tightening torque : 5.9±1.2 N·m {58±12 kgf·cm}

Do not drop a computer.

Do not provide an impact by a tool etc.

Exchange the computer witch got a shock by fall etc. or damp in water for a new article.

If an accident etc., cannot be re-used if a SRS air bag inflated. Consult with your nearest Hino sales dealer or distributor.

GENERAL PRECAUTIONS

2

1.9 Precautions for Seat Belt with Pre-tensioner

(If equipped)

When doing a heating job around anchor of the seat belt at driver seat side (ex. welding, painting work, etc.), remove off the belt assy with pre-tensioner without fail.

The possibility is that it may lead to incorrect explosion if heated up to high temperature (more than 80°C).

When handling the seat belt with pre-tensioner and keeping it, do not turn an exhaust outlet of the seat belt with pretensioner to a person.

Otherwise, high pressure gas will blow up in a case, which may be very dangerous. Do not give such strong shock as dropping down the seat belt assy with pre-tensioner. Once dropped it down, replace it with Hino genuine new parts.

1.10 Others

When SRS air bag inflates at accidents, etc., it can not be usable again. Change it at your nearest Hino sales dealer or distributor.

When the vehicle or SRS air bag is scrapped, consult with your nearest Hino sales dealer or distributor.

GENERAL PRECAUTIONS

2

2. ELECTRIC WELDING WORK

Internal clocks in the tachograph and the radio and all the electronic instruments are directly connected to the battery, and are cab body-earthed at one end.

Under these conditions, electric welding will cause damage to these electrical units as the welding current flow back along the earth circuit.

When welding, take following step of manner.

2.1 Procedure before welding

(Step of manner before welding.)

Step 1. Turn the starter switch to "LOCK" position. Step 2. Wait more than 60 seconds.

Step 3. Disconnect the negative terminal of the battery. Step 4. Wait more than 90 seconds.

Step 5. Take off fuses of SRS air bag, Engine ECU, and Vehicle ECU. (If equipped. See fig. 1.)

2.2 Ground of the welding equipment

* Ground the welding equipment securely, near the place where to be welded. (Ground to the plating parts is strictly prohibited.)

* Peel off the paint where to be welded.

* Connecting the ground to the chassis spring is strictly prohibited to prevent damage of the spring.

* In the case to weld to the cab body, connect the ground to the fixing bolt of cab hinge or to the cab body near the place where to be welded.

2.3 Other precautions of welding

* To protect ancillary equipment from sparks during welding, place fire-resistant covers over the DPR system, rubber hoses, wire harness, pipes, chassis spring and tires, etc.. Remove the SRS air bag and the SRS air bag computer, in the case of the

ambient temperature of them exceed 80°C during welding work.

Consult with your nearest Hino dealer or distributor when removing SRS device. * perform to weld under most suitable conditions of the welding, and minimize the heat

influence to the circumference where to be welded, and as far as possible to keep the welding quality.

2.4 After welding

* Put back fuses of SRS air bag, Engine ECU, and Vehicle ECU in original position. * Make sure to connect the ground terminal of the batery.

And the terminal should be horizontally setting.

* Re-paint the place where to be peeled off the paint for grounding the welding equipment by same color.

2.5 After restored

* Check the warning lamp of SRS air bag. (If equipped)

See 2.1 PRECAUTION FOR SRS AIR BAG for detail, for your safety. If the warning lamp dose not light up or remains light up, bring the vehicle to your nearest authorized Hino dealer or distributor for an inspection.

* Inspect the operation and function of each electronic instrument and equipment. Consult to each Hino dealer or distributor for details of inspection's procedure.

TAKE OFF THESE FUSES

EX.1 : FULL EQUIPPED LAYOUT EX.2 : ENGINE ECU ONLY LAYOUT

POSITION OF SRS AIR BAG, ENGINE ECU, AND VHECLE ECU FUSE fig. 1.

NOTE

• The figure mentioned above is example, consequently for various particular items, check them on the actual vehicle caution plate.

GENERAL PRECAUTIONS

2

2.6 FOR REFERENCE

CURRENT FLOW OF ELECTRIC WELDING WHEN WELD CAB BODY

BATTERY ARC WELDING MACHINE ELECTRIC EQUIPMENTS EARTH OF EQUIPMENTS EARTH WIRE OF CAB

Disconnect the negative terminal of BATTERY. Do not disconnect at CHASSIS FRAME. Turn the STARTER SWITCH to LOCK position. Do not turn on the STARTER SWITCH when the earth wire is disconnected.

CHASSIS FRAME

+ –

GOOD

WELDING ROD BATTERY CHASSIS FRAME ELECTRIC EQUIPMENTS STARTER SWITCH EARTH WIRE OF CAB

WELDING ROD CAB ELECTRIC EQUIPMENTS BATTERY EARTH of ARC WELDING MACHINE

<The electric current of welding>

EARTH WIRE OF CAB

ELECTRIC EQUIPMENTS will be damaged.

+ – EARTH OF EQUIPMENTS ARC WELDING MACHINE

NG

GENERAL PRECAUTIONS

2

3. NOTES ON SYSTEM CONTROL COMPUTERS

Vehicle control and brake ABS computers or ENGINE ECU, are installed left or right part, inside of the instrument panel as described following figure.

Therefore, give great care to the computer when performing any body mounting work or modification as following points.

• Be sure to cover the computer to protect the water penetration when performing cleaning up the inside of cab.

• When mounting such devices as a radiophone, a wireless communication device, be sure to use the devices that conforms to the electric control act and install the devices on the places which are as far as possible from the computers and it’s harness.

Do not install any high output (over 50W) device.

Be sure to check that no abnormal electric wave or electromagnetic wave is found, after having installed the device, which affects on the electronic signals passing through in computer harness.

• Do not alter the computer, harness wire or sensors (ex. acceleration sensor). • As you will see on the following Fig. Various kind of computers are

installed inside the cab, when fitting and modifying the inside of the cab, be careful not to give any shock to the vicinity of the computer.

[LAYOUT EXAMPLE]

GENERAL PRECAUTIONS

2

4. PRECAUTION FOR ENGINE ECU

(If equipped)

• In the case of following engine models,ENGINE ECU is installed on the engine. (Refer to the following figure)

When mounting the body, should not give any shock to ECU.

• Strictly prohibited following manner to ENGINE ECU and related part when body mounting. To given shock.

To perform electrical welding. To apply paint and removal.

• The parts which to be generated heat do not provide near ECU.

• ECU has air bent valve, therefor do not perform body mounting and modification which to be closed bent valve, and also do not always splash water and oil to the bent valve. • Do not remove connector of ECU to avoid malfunction of ENGINE CONTROL SYSTEM.

ENGINE ECU CONNECTOR ENGINE ECU CONNECTOR CONNECTOR ENGINE ECU

J07E

J08E

A09C

GENERAL PRECAUTIONS

2

5. PRECAUTION FOR EXHAUST SYSTEM

(if equipped EXHAUST GAS AFTER TREATMENT SYSTEM)

Modifying the exhaust system has a major effect on vehicle performance, gaseous emission and external noise. As a rule, the exhaust system must not be modified. Do not modify any part within the range shown in the drawing below.

• Do not install spark arrester to avoid bad influence at the DPR SYSTEM and the ENGINE.

• For the detail of exhaust gas differential pressure sensor attachment position, refer to exhaust system of Chapter 9.

ABOUT THE DPR MUFFLER

(DPR = Diesel Particulate active Reduction system) (1) Outline of DPR Muffler

Structure of DPR muffler is shown following figure.

The DPR filter collects particulate matter found in exhaust gas and automatically burns them.

(2) Working condition while running

The DPR automatically purifies particulate matter during normal operation. This system does not negatively effect the vehicle operation.

Do not modify any part of exhaust system within this range.

{Muffler (DPR), EXHAUST GAS DIFFERENTIAL PRESSURE SENSOR, Tail pipe etc.}

Exhaust tail pipe

FOR J07E & J08E E/G

FOR A09C E/G

(3) Working condition while under operation Purification of particulate matter

: When the vehicle stops for a traffic signal, the DPR may enter filter mode.

At this time the engine idle speed may temporarily increase causing the exhaust brake to actuate.

When idling long time

: To prevent emission of white smoke, when vehicle is left idling for certain time (approx. 1 hour), idling speed will increase causing exhaust brake to work. (4) Precautions

1) An exhaust pressure outlet pipe and an exhaust temperature sensor are installed on muffler and a harness is attached to the sensor. At the time of mounting the body, take extra care with these system.

If these parts are damaged, purification of particulate matter may not be performed sufficiently.

2) Muffler may be removed and remounted for maintenance.

Place the parts of the body so that it is easy to remove and mount the muffler. 3) Depending on how vehicle is operated, DPR indicator light may be flashing.

If the DPR indicator light is flashing, follow the instruction below within 150km. To prevent fire, make sure there is no flammable matter near the exhaust pipe.

1. Park vehicle in safe place. 2. Do not stop the engine.

3. Press the DPR switch shown below.

Confirm that the flashing DPR indicator light turns on and idle speed increases, and turn on the exhaust brake.

Wait for 15 to 20 minutes.

When the DPR indicator light goes off and the idle speed returns to normal, you can drive normally.

This instruction is to reproduce the function of DPR filter and it does not mean there is a problem.

However, if the vehicle is left with the flashing DPR indicator light on and engine runs long time, the check engine light will turn on and output power will be restricted in order to prevent damage to the DPR. If vehicle is used in one spot for body operation for a long time, it is necessary to make sure the DPR indicator light does not turn on. (5) Paint application

Never paint the muffler (DPR) or exhaust gas differential pressure sensor. Indicator

lamp

Position of DPR switch

GENERAL PRECAUTIONS

2

EXHAUST GAS AFTER TREATMENT SYSTEM ( DPR )

1. Moving of the muffler Do not move the muffler.

It may be affect the capability of the exhaust gas after treatment if moved the muffler with the exhaust gas after treatment system. If obliged to move the DPR muffler, please contact authorized Hino distributor.

2. Moving of the sensor

Do not move the pressure sensor for the exhaust gas after treatment system (DPR) which installed the chassis side.

If obliged to move it, be sure to observe the following precaution for routing the hose.

1) Secure a sufficient clearance between sensor and muffler or piping with high temperature and check the temperature if need, then make sure that it is no problem for safety.

　2) Regarding the routing of hose, there will be problem such as 　 malfunction of pressure sensing if the water gathered in the hose with the looseness as shown the following figure. Also If the hose was too much tense, it may be the cause of came off the hose by vibration of vehicle.

　3) When reinstall the hose after moved sensor, make sure that the hose routing is correct.

(Should matched back and forth direction)

3. Painting

Do not paint the muffler and pressure sensor.

Muffler Pressure sensor

Pressure sensor hose

Pressure sensor _{Pressure sensor hose}

Do not too much tense the hose

D o not too m uch looseness t he hose (○ : correct installation) (× : wrong installation)

GENERAL PRECAUTIONS

2

PRESSURE SENSOR OF DPR SYSTEM

It is a precision instrument part, therefore, be sure to observe the following precautions for mounted body or equipment.

1. Do not give any shock with something hard goods or hammering to the sensor.

2. Use hand tools to tighten or loosen the installing bolt and nut. Do not use impact wrenches.

3. Do not drop the sensor unit.

4. Do not disassembly the sensor unit.

Do not use the sensor which is not handled according to these precautions above.

SENSOR UNIT ASSEMBLY SCREWS AND NUTS

GENERAL PRECAUTIONS

2

Clearances between exhaust parts and other parts

The exhaust system becomes very hot during driving. Observe the following procedures to prevent vehicle fires. Clearances from body parts

When mounting a body or equipment, observe the precautions given in this section. Clearances from fuel system parts

• Maintain a clearance of at least 200mm between the fuel tank, fuel hose or pipes, etc. and the hot parts of the exhaust system.

If you cannot maintain a clearance of 200mm, fit heat insulators to protect the fuel tank and fuel pipes.

When arranging fuel piping, make sure that even if a fuel line ruptures and fuel leaks out, no fuel will come into contact with the hot parts of the exhaust system.

• Never make joints in the fuel piping above the hot parts of the exhaust system, etc. • When moving the fuel tank or installing an additional tank, make sure that the filling

port is at least 300mm away from the mouth of the tail pipe and at least 200mm away from exposed electrical terminals.

Clearances from other chassis parts

Maintain the clearances shown in the table below. If you cannot maintain these clearances, fit heat insulators.

The effect and interference of the heat from the exhaust pipe, muffler, etc. of the exhaust system have a significant influence to safety. Maintain adequate clearances between components such as the exhaust pipe, muffler and a body or equipment, measure the temperature of these components as necessary to check for safe operation.

GENERAL PRECAUTIONS

2

6. PRECAUTION FOR VEHICLE TO BE PROVIDED HID LIGHT AXIS SENSOR

(If equipped)

GENERAL PRECAUTION

• The light axis adjustment system (HEADLIGHT AUTOLEVERING) is controlled with autoleveling ECU.

• Vehicle speed signal to be output by the speed sensor as well as vehicle height signal to be output by the vehicle height sensors installed on the LH front and LH rear wheels of the vehicle are inputted the autoleveling ECU.

• The ECU will control the light axis of the headlight by computing a change of pitch angle of the vehicle posture with these signals and also wheelbase information memorized in the ECU, and activating headlight actuator to respond against changing amount of the vehicle posture.

• Therefore, any alteration or modification are strictly prohibited at the time of rear body or equipment to be mounted as following manner.

• DO NOT LOAD CARRING GOODS UNDER ABNORMAL LOADED CONDITION AS ONE SIDE MASS DISTRIBUTION ON FRONT OR REAR WHEELS.

• USE THE TIRE WITH STANDARD INFLATION PRESSURE. • DO NOT ALTER OR MODIFY THE SUSPENSION.

• DO NOT MAKE ANY ALTERATION OR MODIFICATION TO BE CONSEQUENTLY OCCURED WITH WHEELBASE CHANGE.

• DO NOT INSTALL ANY TIRES EXCEPT TIRES TO BE PROVIDED WITH OPTION SPECIFICATION.

PRECAUTION AT THE TIME OF REAR BODY OR EQUIPMENT MOUNTING

• Make sure to observe the following manner strictly.

• DO NOT DISASSEMBLE THE VEHICLE HEIGHT SENSOR UNIT DUE TO PRECISION PARTS.

• DO NOT GIVE ANY SHOCK TO THE HEIGHT SENSOR DUE TO PRECISION PARTS.

• DO NOT CHANGE THE LENGTH OF LINK ROD TO AVOID ABNORMAL ADJUSTMENT OF LIGHT AXIS.

GENERAL PRECAUTIONS

2

7. PRECAUTION FOR AUTO CLUTCH UNIT (ACU)

(If equipped)

• The Auto clutch unit (ACU) has the function which automatically control the clutch.

It may not be properly operation by changed layout of piping or wiring of the ACU,

therefore, do not move the ACU.

If need to move ACU, please contact authorized Hino distributor.

• For detail of ACU installation position, refer to CHASSIS DRAWINGS of Chapter 8 and

MOUNTING OF CHASSIS EQUIPMENT of Chapter 9.

• If temporarily remove the ACU and the clutch piping, to observe the following instructions.

• Make sure that there is no dust and water in piping and inside ACU when removed them.

It may be cause of abnormal operation of ACU or damaged of related equipments,

if there is something inside the piping.

• When air bleeding of piping, can be done by operation of the change lever after changed

proper mode of the vehicle control system ECU.

For more details, please contact authorized Hino distributor.

• The ACU has a reserve tank for clutch oil.

Be sure to do not step on the reserve tank.

It may not be driving because it doesn't work clutch for leaking out clutch oil if the reserve

tank has broken.

• Make sure to avoid obstructing the visibility of oil level on clutch reserve tank for checking

from the side all the time when mounting of body.

And it need work space when changing clutch oil.

Therefore, make sure that secure a sufficient space upper of the reserve tank for changing

clutch oil as the following figure.

• FOR MAINTENANCE WORK SPACE OF AUTO CULTCH UNIT (ACU)

Do not obstruct the ACU for maintenance work space when mounting of body.

To avoid obstructing the visibility of oil level The nozzle head of oil container

More than 150

Need space upper of the tank for filling the oil

GENERAL PRECAUTIONS

2

8. PRECAUTION FOR MOUNTING OF BODY WITH AIR SUSPENSION

(If equipped)

Be sure to observe the following precaution when considering a mount of body for vehicle with air suspension.

If compare air suspension's vehicle with leaf suspension's vehicle, the roll of air suspension is large, and so it may not proper vehicle with air suspension by a use. The following are example of vehicles.

• Bulk tank truck for feed • Truck for carrying wood • Dump truck

• Mixer truck

• Truck for carrying livestock (structure of double-decker) • Truck for carrying vehicle (structure of double-decker) • Truck for carrying fish in water

• Refrigerated van truck with meat hook

If Body manufacture is received such as above vehicle request, please use a vehicle with leaf suspension or ask HINO sale dealer and authorized HINO distributor.

Also the vehicle with the high center of gravity beside above vehicles, it may not proper vehicle with air suspension when running at winding road such as a mountain road.

GENERAL PRECAUTIONS

2

9. FIRE SHIELD

GAP BETWEEN CAB REAR END AND BODY

If the vehicle has a flat bed or similar body, a fire shield should be fitted across the gap between the rear arch cover and the front end of the rear body (header board of rear body) on the chassis frame to prevent fires that may be caused by flammable materials falling off from the load platform onto the exhaust pipe. (See the illustration below.) A fire shield is not necessary when the body is fitted with a sheet carrier attached directly to the top of header board.

A fire shield is also not necessary for such bodies as dump trucks, concrete mixer, tankers and aluminum vans, where there is no danger of falling - off of flammable materials.

FITTING THE FIRE SHIELD

CAB REAR ARCH RUBBER

BOLT & NUT BODY OR EQUIPMENT FIRE SHIELD • For approximately 50mm from the front

end (vehicle front), use rubber to match the shape of the fire shield to that of the rear arch.

• The clearance between the engine and fire shield material must be not less than 40mm.

• You may also install the fire shield so that it covers only the exhaust pipe.

WARNING

• When you mount the fire shield, use bolts, etc., that can be taken out to allow for replacement of the chassis parts which are located at the rear part of cab.

GENERAL PRECAUTIONS

2

10. NOTES ON ADDITIONAL WIRING IN THE ENGINE COMPARTMENT

Since the engines in HINO trucks are covered with sound arrest plates, the engine compartment tends to heat up.

Avoid wiring in the engine compartment if possible.

Additional wiring harness or cable should be kept away from heated elements, and should be wired along the main harness.

GENERAL PRECAUTIONS

2

11. PRECAUTION FOR FUEL COOLER

(If equipped)

When mounting the body or equipment, pay attention to the following point. Around fuel cooler and fuel cooler bracket opening area should not be blocked. Bad influence on vehicle performance if blocked the parts.

• For detail of FUEL COOLER installation position, refer to CHASSIS DRAWINGS of Chapter 8 and MOUNTING OF CHASSIS EQUIPMENT of Chapter 9.

GENERAL PRECAUTIONS

2

12. CLEARANCE BETWEEN CAB AND REAR BODY OR EQUIPMENT

MINIMUM CLEARANCE WITH CAB REAR END

The rear part of the cab contains the cab lock mechanism and the tilt mechanism, as well as the engine cylinder block or other various equipment as trailer brake connector stand and etc.

When mounting the body or equipment, allow at least the minimum clearance between the rear end of the cab or some of the chassis component and the front end of the rear body or swept radius of the trailer front end to avoid obstructing the operation and maintenance of these mechanisms or various equipments, and to avoid damage due to contact.

Unit : mm

MINIMUM CLEARANCE FROM THE FRONT END OF THE REAR BODY TO THE CAB REAR END OR THE EXHAUST PIPE

PRODUCTION CODE APPLICATION CAB MOUNT TYPE REAR ARCH COVER A B

FC9JJSA-NNB FC RIGID LESS 625 50

- FC RIGID TYPE A 650 50

GD8JLSA-PAB FD, FE, GD, FT, GT RIGID LESS 875 50

- FD, FE RIGID TYPE A 900 50 - GD RIGID TYPE D 905 50 - FG, GT RIGID LESS 825 50 - FG, GT RIGID TYPE C 860 50 - FG FLOATING LESS 851 50 - FG FLOATING TYPE B 864 50 GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX GH, FL, FM1J,

FM8J, FM1A RIGID LESS 805 50

- GH, FL, FM8J, FM1A RIGID TYPE C 840 50 - GH, FL, FM8J, FM1A FLOATING LESS 831 50 - GH, FL, FM8J, FM1A FLOATING TYPE B 844 50 FM2PLSD-ZGL

FM2PRSA-ZGL FM2P RIGID LESS 885 50

- FM2P(TRACTOR) - - 1,255 50

- SG2P(TRACTOR) - - 1,000 100

• Refer to following page "MEASUREMENT DETAIL OF REAR ARCH COVER" for rear arch cover type.

MINIMUM CLEARANCE WITH DOUBLE CAB REAR END

MEASUREMENT DETAIL OF RADIATOR HEADER TANK

Unit : mm Unit : mm PRODUCTION CODE APPLICATION A B FC9JJSA-NNB FC 755 80 - FD - -GD8JLSA-PAB GD 1,005 80 - FT, GT - -- FG 955 80 GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX GH, FL, FM1J, FM8J 935 80 - FM2P 1,075 80 - FM2P(TRACTOR) 1,255 80 - SG2P 1,000 175 PRODUCTION CODE APPLICATION A B - SG2P 180 6.5° - FM1A, FM2P 175 4° PRODUCTION CODE APPLICATION A - FD, FT 1,600 - FG 1,575 - GT 1,550

GENERAL PRECAUTIONS

2

MEASUREMENT DETAIL OF CAB TILT MECHANISM

(FOR SINGLE CAB, RIGID CAB MOUNT TYPE)

PRODUCTION CODE APPLICATION A

FC9JJSA-NNB FC 613

GD8JLSA-PAB FD,GD,FE 863

PRODUCTION CODE APPLICATION A B

– FG 813 564 GH8JGSD-TGB GH8JMSA-TGB GH 793 564 FM8JLSD-TGX FM8JRSA-TGX FL1J, FM1J, FM8J 793 534 FM2PLSD-ZGL _{SG2P, FM2P 793 694}

GENERAL PRECAUTIONS

2

MEASUREMENT DETAIL OF POWER CAB TILT MECHANISM

(FOR SINGLE CAB, RIGID CAB MOUNT TYPE)

Unit : mm PRODUCTION CODE A

GENERAL PRECAUTIONS

2

MEASUREMENT DETAIL OF POWER CAB TILT MECHANISM

(FOR SINGLE CAB, FLOATING CAB MOUNT TYPE)

Unit : mm

PRODUCTION CODE APPLICATION A

– FG 851

GENERAL PRECAUTIONS

2

MEASUREMENT DETAIL OF POWER CAB TILT MECHANISM

(FOR DOUBLE CAB)

SIDE VIEW REAR VIEW

CAB TILT PUMP INSTALLATION

OPERATION RANGE, MANUAL TILT PUMP LEVER, DETAIL

UPPER VIEW

SIDE VIEW

PRODUCTION CODE APPLICATION A B C D E F

– FD 1,570 483 749 382 1,007.5 205

– FG 1,520 477 759 447 928 216

GENERAL PRECAUTIONS

2

MEASUREMENT DETAIL OF REAR ARCH COVER

180

192 ₁₆₇

128 147

30

CHASSIS CENTER LINE TO FRONT AXLE DATUM LINE

REAR BODY

FRAME UPPER SURFACE

B 387 198 29

[TYPE A]

[TYPE B]

[TYPE C]

PRODUCTION CODE APPLICATION A

– FC 650

– FD,FE 900

PRODUCTION CODE APPLICATION B

– FG 864

– GH,FL,FM 844

PRODUCTION CODE APPLICATION A B C

– FG 860 143 49 – GH,FM 840 143 49 – GT 860 172 78

[TYPE D]

GENERAL PRECAUTIONS

2

MEASUREMENT DETAIL OF ENGINE AIR INTAKE PORT

(FOR SINGLE CAB)

Unit : mm APPLICATION A B C D FC 1,032.5 762.5 625 1,541.5 FD,GD,FE 1,032.5 762.5 875 1,541.5 FG 1,122.5 772.5 825 1,551.5 GH 1,122.5 772.5 805 1,551.5 FL,FM1J,FM8J 1,122.5 742.5 805 1,521.5 SG2P,FM1A,FM2P 1,122.5 902.5 805 1,681.5 FT 1,122.5 827.5 875 1,606.5 GT 1,122.5 801.5 825 1,580.5

WARNING

The blocking of the smooth flow of air into the air intake pipe caused by any materials such as ropes, pieces of cloth, etc. leads to the increase of exhaust temperature if driven long intervals. The increase in exhaust temperature is caused by the decreased efficiency in the combustion process, as the proportion of air in the combustion chamber is also decreased by the above mentioned factor. This situation will lead to major malfunctions such as the cracking of the exhaust manifold and the breaking down of the turbocharger. To avoid such malfunctions, please keep the air intake pipe free from any blocking materials at all times.

GENERAL PRECAUTIONS

2

MEASUREMENT DETAIL OF ENGINE AIR CLEANER

(FOR SINGLE CAB)

PRODUCTION CODE APPLICATION L W H

FC9JJSA-NNB FC 434.5 988.5 246.5

GD8JLSA-PAB FD,GD,FE 684.5 988.5 246.5

– FT 684.5 988.5 311.5

PRODUCTION CODE APPLICATION L W H

– FG,GT 634.5 1078.5 256.5 GH8JGSD-TGB GH8JMSA-TGB GH 614.5 1078.5 256.5 FM8JLSD-TGX FM8JRSA-TGX FL,FM1J,FM8J 614.5 1078.5 226.5 L H W

PRODUCTION CODE APPLICATION

WARNING

If equipped Diesel Particulate Active Reduction ( DPR ) System, be sure to install both primary ( outer ) and secondary ( inner ) HINO genuine element to avoid engine performance and fuel-efficiency being affected.

Use of non-genuine element may result in the malfunction of DPR System, and

W L 260 215 H DUAL ELEMENT SINGLE ELEMENT

GENERAL PRECAUTIONS

2

MEASUREMENT DETAIL OF VERTICAL EXHAUST PIPE

(OPT)

Unit : mm

PRODUCTION CODE APPLICATION A B

FC9JJSA-NNB FC 755 536 GD8JLSA-PAB GD 1005 536 – FG 955 561 GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX GH,FL,FM1J,FM8J 935 561 – FM2P 1075 563 Unit : mm

PRODUCTION CODE APPLICATION

GENERAL PRECAUTIONS

2

13. RECOMMENDED POSITIONS OF U-BOLTS

• The U-bolts to be fastened on the body sub-frame and the chassis frame must be provided sufficient clearance to prevent contact with the brake pipes, hoses, and harness wires etc.

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

L2 L5

L4 L3

B A

REAR AXLE DATUM LINE OR TRUNNION SHAFT CENTER

No.1 U-BOLT No.2 U-BOLT No.3 U-BOLT

L1f L1r

No.2 CROSSMEMBER DATUM LINE

PROHIBITION RANGE OF THE U-BOLT SETTING ON BOTH SIDE. (FOR FL, FM, MODEL ONLY)

No.5 U-BOLT No.4 U-BOLT PRODUCTION CODE _{L1f L1r L2 L3 L4 L5 A B} FC9JJSA-NNB RH 520 – 1,550 220 1,405 – – – FC9JJSA-NNB LH 520 – 1,550 220 1,405 – – – GD8JLSA-PAB RH 330 – 1,600 220 1,670 – – – GD8JLSA-PAB LH 330 – 1,600 220 1,670 – – – GH8JGSD-TGB RH 885 – – 150 – – – – GH8JGSD-TGB LH 335 – – 150 – – – – GH8JMSA-TGB RH 885 – 1,560 150 2,120 – – – GH8JMSA-TGB LH 335 – 1,560 150 2,120 – – – FM8JLSD-TGX RH 500 – – – 1,445 – 1,370 955 FM8JLSD-TGX LH 315 – – – 1,445 – 1,370 955 FM8JRSA-TGX RH 500 – 1,755 – 1,260 – 1,755 1,260 FM8JRSA-TGX LH 315 – 1,755 – 1,260 – 1,755 1,260 FM2PLSD-ZGL RH 575 – – – 1,450 – 1,370 955 FM2PLSD-ZGL LH 315 – – – 1,450 – 1,370 955 FM2PRSA-ZGL RH 575 – 1,755 – 1,260 – 1,755 1,260 FM2PRSA-ZGL LH 315 – 1,755 – 1,260 – 1,755 1,260 Unit : mm

MOUNTING POSITION

WARNING

• When mounting only with U-bolts, use props.

When the sub-frame is open section steel also use this props.

• With respect to how to mount them, refer to the chapter 12, item 3 Body mounting manual common version issued by HINO.

• Make sure to control tightening torque of the U-bolts. Apply double nut system to prevent slackening of the nuts.

• When delivering the vehicle, securely carry out PDI and check to it there is any slackening of the U-bolts.

GENERAL PRECAUTIONS

2

DRILLING PROCESS FOR INSTALLING

THE MOUNTING BRACKET AROUND TANDEM REAR AXLE

EXAMPLE DETAIL OF MOUNTING BRACKET

Unit : mm

Unit : mm

NOTE

• For more information on drilling process of the chassis frame to install the mounting bracket, refer to the Common Manual, No.KC-AA201A of Body Mounting Manual.

GENERAL PRECAUTIONS

2

14. RECOMMENDED POSITIONS OF REAR FENDERS AND MUDGUARDS

When mounting rear fenders and mudguards, determine required clearances with reference to the following table and figures of “MAXIMUM VERTICAL DEFLECTION OF REAR WHEELS” in 4 - 2.

PRODUCTION

CODE WHEEL REAR TIRE A B C D

FC9J 16x6.00GS-offset135mm 8.25-16 2,160 2,180 1,660 160 FC9J 16x6.00GS-offset135mm 8.25R16 2,155 2,175 1,660 163 FC9J 17.5x6.75-offset135mm 9.5R17.5 2,170 2,190 1,660 155 FC9J 17.5x6.75-offset135mm 235/75R17.5 2,165 2,185 1,660 158 FC9J 19.5x6.75-offset136mm 225/70R19.5 2,160 2,180 1,660 160 GD8J 20x6.50T-offset145mm 8.25-20 2,245 2,265 1,720 178 GD8J 20x6.50T-offset145mm 8.25R20 2,240 2,260 1,720 180 GD8J 22.5x7.50-offset162mm 255/70R22.5 2,300 2,320 1,720 150 GH8J 20x7.50V-offset165mm 11.00-20 2,455 2,475 1,840 168 GH8J 20x7.50V-offset165mm 11.00R20 2,450 2,470 1,840 170 GH8J 22.5x8.25-offset165mm 12R22.5 2,460 2,480 1,840 165 GH8J 22.5x8.25-offset165mm 275/70R22.5 2,445 2,465 1,840 173 GH8J 22.5x8.25-offset165mm 275/80R22.5 2,445 2,465 1,840 173

(FOR REAR SINGLE AXLE)

NOTE

• When mounting the fenders (shaded in the figure) make a drain hole at E to allow water to escape.

• The dimension of tire to be mentioned in below table shows design figure according to ETRTO or JATMA standard.

PRODUCTION

CODE WHEEL REAR TIRE A B C D

FM8J,FM2P 20x7.50V-offset165mm 10.00-20 2,465 2,485 1,860 183 FM8J,FM2P 20x7.50V-offset165mm 10.00R20 2,465 2,485 1,860 183 FM8J,FM2P 20x7.50V-offset165mm 11.00-20 2,475 2,495 1,860 178 FM8J,FM2P 20x7.50V-offset165mm 11.00R20 2,470 2,490 1,860 180 FM8J,FM2P 22.5x7.50-offset162mm 11R22.5 2,455 2,475 1,860 188 FM8J,FM2P 22.5x7.50-offset162mm 275/70R22.5 2,450 2,470 1,860 190 FM8J,FM2P 22.5x8.25-offset165mm 295/80R22.5 2,480 2,500 1,860 175

(FOR TANDEM REAR AXLE)

16 or 17.5 or 19.5 _~150 ₂₀₀ 200 20 or 22.5 _~200 ₂₅₀ 300 F TIRE WHEEL

GENERAL PRECAUTIONS

2

15. PRECAUTION OF THE ANTENNA POSITION

• The antenna which is installed on roof corner top of the cab use right angle position in normal operation.

• Make sure that not to obstruct the moving range of the antenna in described following figure when perform to mount body or equipment.

• It may cause the noise or poor receiving of the radio if occur an interference with the antenna and body part.

APPLICATION A B C FC 1,869~2,446 -270~1,263 933~1,244 FD,GD,FE 1,869~2,446 -230~1,303 933~1,244 FG 1,879~2,456 -180~1,353 1,023~1,334 GH 1,879~2,456 -160~1,373 1,023~1,334 FL,FM1J,FM8J 1,849~2,426 -160~1,373 1,023~1,334 SG2P,FM1A,FM2P 2,009~2,586 -160~1,373 1,023~1,334 FT 1,933~2,510 -230~1,303 1,023~1,334 GT 1,908~2,485 -180~1,353 1,023~1,334 Unit : mm

RIGHT HAND DRIVE IS SHOWN IN THIS FIGURE, LEFT HAND DRIVE IS SYMMETRICAL TO THIS FIGURE.

GENERAL PRECAUTIONS

2

16. ADJUSTMENT OF LIGHT AXIS OF HEADLIGHT

(If equipped)

HALOGEN OR DISCHARGE (HID) HEADLAMP

Light axis of headlight will be changed due to vehicle posture change to be influenced by the rear body or equipment to be mounted.

Therefore, consult the adjustment of light axis after rear body or equipment to be mounted to authorized Hino distributor or sales dealer.

WARNING

• Make sure that the light axis of headlamp of the completed vehicle with rear body or equipment, conforms to all applicable laws and regulations of the country in which the vehicle is to be operated.

• Should more detailed information be needed, please contact authorized Hino distributor or sales dealer.

GENERAL PRECAUTIONS

2

17. PRECAUTION FOR FRONT UNDERRUN PROTECTION DEVICE (FUPD)

(If equipped)

(1) REGULATION

This vehicle in compliance with a regulation (ECE R93) of FUPD has equipped. Make sure following precautions at the time of body mounting.

• Don't perform body mounting which prevents the function of FUPD, and modification. • The ground-height of FUPD should satisfy a

regulation.

After performing body mounting, the ground height of FUPD should satisfy a regulation. If the ground height of FUPD does not satisfy a regulation after performing body mounting, adjust in the following manner.

Adjustment method of the ground height of FUPD

• The bracket of attachment by a standard, please check by the current vehicles. Please alter the position of the adjustment hole of a bracket and adjust height of FUPD.

• If a paint is peeling off when installing, should repaint it. • Tightening torque refer to the following page.

ECE R93

EXCEPT OFF-ROAD MAX. 400mm

OFF-ROAD

Inapplicable

(There are variatiions of type by vehicle.)

ARM SUB-ASSY, FR BUMPER

[TYPE A]

APPLICATION : FC,FD,GD,FE

[TYPE B]

APPLICATION : FG,SG,GH,FL,FM

BRACKET, SIDE STEP, No.1

GENERAL PRECAUTIONS

2

(2) ABOUT THE STRUCTURE OF AROUND FUPD

[TYPE A] APPLICATION : FC,FD,GD,FE

ARM SUB-ASSY, FUP

[EXAMPLE]

Installation position of bracket

for adjusting height

Shape of bracket

for adjusting height

FUPD

Installation position of FUPD

: 197mm (lower frame ~ lower FUPD)

Installation position of FUPD

: 219mm (lower frame ~ lower FUPD)

Installation position of FUPD

: 244mm (lower frame ~ lower FUPD)

Installation position of FUPD

: 269mm (lower frame ~ lower FUPD)

Parts Number : 52011-E0070 (RH)

: 52012-E0070 (LH)

Parts Number : 52011-E0080 (RH)

: 52012-E0080 (LH)

With four steps front of the vehicle

ARM SUB-ASSY, FR BUMPER, RH/LH BOLT Tightening torque :125±16.3N·m NUT, BOLT Tightening torque :63±18.9N·m ARM SUB-ASSY, FR BUMPER, RH/LH BOLT Tightening torque :125±16.3N·m NUT, BOLT Tightening torque :63±18.9N·m ARM SUB-ASSY, FR BUMPER, RH/LH BOLT Tightening torque :125±16.3N·m NUT, BOLT Tightening torque :63±18.9N·m ARM SUB-ASSY, FR BUMPER, RH/LH BOLT Tightening torque :125±16.3N·m

FUPD

FUPD

GENERAL PRECAUTIONS

2

[TYPE B] APPLICATION : FG,SG,GH,FL,FM

ARM SUB-ASSY, FUP

[EXAMPLE]

[EXAMPLE]

Installation position of bracket

for adjusting height

Shape of bracket

for adjusting height

Installation position of FUPD

: 300mm (lower frame ~ lower FUPD)

Installation position of FUPD

: 325mm (lower frame ~ lower FUPD)

Installation position of FUPD

: 350mm (lower frame ~ lower FUPD)

Installation position of FUPD

: 375mm (lower frame ~ lower FUPD)

FUPD

FUPD

FUPD

GENERAL PRECAUTIONS

2

[TYPE B] APPLICATION : FG,SG,GH,FL,FM

BRACKET SIDE STEP

[EXAMPLE]

Installation position of bracket

for adjusting height

Shape of bracket

for adjusting height

If changed installation height for FUP, should change bracket for installation step. BRACKET, SIDE STEP, No.1 RH/LH NUT Tightening torque :63±18.9N·m BRACKET, SIDE STEP, No.1 RH/LH NUT Tightening torque :63±18.9N·m BRACKET, SIDE STEP, No.1 RH/LH NUT Tightening torque :63±18.9N·m BRACKET, SIDE STEP, No.1 RH/LH NUT Tightening torque :63±18.9N·m

Parts Number : 51793-E0081 (RH)

: 51794-E0071 (LH)

Parts Number : 51793-E0071 (RH)

: 51794-E0061 (LH)

GENERAL PRECAUTIONS

2

(3) Precaution for removing and reinstalling of the FUPD (FC,FD,GD,FE ONLY)

A sim may be installed between the FUPD stay and a bracket for adjusting FUPD height for improving effect of tightening.

Be sure to observe the following precautions, if removing or replacement a bracket for adjusting FUPD height with the vehicle concerned.

1. When removed a bracket for adjusting FUPD height. • Be sure to reinstall a sim when installing the FUPD.

(If there is no sim, do not need to install it) • Tightening torque refer to the previous page. 2. When replace a bracket for adjusting FUPD height.

• Be sure to install a sim between the FUPD stay and a bracket for adjusting FUPD height. (Sim parts number : 38123-E0030)

• If a sim will not be able to insert between the FUPD stay and a bracket

for adjusting FUPD height by pounding with hammer, do not need to insert a sim. (Do not need a sim when the clearance less than 1.2mm between the FUPD stay and a bracket for adjusting FUPD height.)

• Make sure that there is no shaking / moving a bracket for adjusting FUPD height when installed FUPD without sim.

• If a paint is peeling off when installing, should repaint it. • Tightening torque refer to the previous page.

Parts Number : 38123-E0030

UP

RH

GENERAL PRECAUTIONS

2

18. FOR INSTALLATION OF REAR UNDERRUN PROTECTION DEVICE (RUPD)

(If equipped)

The vehicle has the Rear Under-run Protection ( RUPD ) and the Stay with satisfied the capability of safety and the requirement of

strength according to ECE regulation.

Therefore, do not alter the RUP with the mount of body. There are installation holes on chassis frame.

If there is no issue when mounted of body, install the RUPD as that location. Make sure that the installation position is satisfied the dimension as below after installed the RUPD.

Tightening torque

• Frame and stay (φ16 bolt, equivalent to 8.8T) : 200±30 N·m • Stay and rear bumper (φ12 bolt, equivalent to 8.8T) : 63±18.9 N·m

For mounted of the special body and others, if it not satisfied the required dimension as below even properly installation position, must move the RUPD as the following instructions.

• Should use the original bolts on installed of chassis when install the RUPD and Stay. • The stay should install on chassis frame.

• To avoid obstruct the number plate and indication of lamps by the RUPD.

• Should take a maximum departure angle within satisfied the following dimension. • A light device ord the reflector, please satisty law requirements.

It need to submit that satisfied the ECE REGULATION No.58 (2) of the capability and the requirement of strength in such cases as follows.

• When repaired the original RUPD or Stay with chassis. • When made new RUPD or Stay.

• When fixed the RUPD and Stay by welding instead of original bolts. • When use a spacer between RUPD and Stay.