BM1503A5ECAFIG1

BM1503A5ECA

HINO 500 SERIES

Body Mounting Manual

TRUCK CHASSIS

APPLICATION

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

Feb. 2015

BM1503A5ECA

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 1. Vehicle specifications changed for complying of Ecuador safety regulations.

BM1503A5ECA

ABOUT THIS MANUAL 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 This instruction manual must be used in combination with the Common Manual, No. KC-AA201A. • 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.

BM1503A5ECA

ABOUT THIS MANUAL 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.)



To be continued next page. BM1503A5ECA

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.

BM1503A5ECA

CONTENTS



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

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

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

BM1503A5ECA

Chapter 1 VEHICLE SUMMARY

1. PRODUCTION CODE

2. IDENTIFICATION NUMBER

3. CHASSIS SPECIFICATIONS

BM1503A5ECA

1

VEHICLE SUMMARY

1. PRODUCTION CODE

F

G

8J

GVMR & (DRIVE) CODE VEHICLE TYPE

K

ENGINE CODE

GVMR

DRIVE

CODE

MODEL

F

CAB-OVER TRUCK

C

10,400kg CLASS

4x2

1J

J08C

G

CAB-OVER TRUCK

D

10,000 12,000kg CLASS

4x2

6J

J05D

S

SEMI-TRACTOR

E

12,000 14,000kg CLASS

4x2

7J

J07E

G

14,000 15,500kg CLASS

4x2

8J

J08E

H

17,000kg CLASS

4x2

9J

J05E

L

26,000kg CLASS

6x2

1A

A09C

M

26,000kg CLASS

6x4

T

10,000 13,000kg CLASS

4x4

Y

OVER 30,000kg CLASS

8x4

2P

P11C

1

A

WHEELBASE CODE CODE C D E G H J K L M N P R S T W

WHEELBASE (mm) 3000 3000 3249 3250 3499 3750 3999 4000 4249

–

AAA

MODIFICATION CODE CODE

STEERING MODIFY CODE POSITION

K R ,

RH

FIRST

1

4250 4499 4500 4749 4750 4999 5000 5249 5250 5499 5500 5749

S Z , 7

5750 5999 6000 6249 6250 6499 7000 7249

APPLICABLE CODE

LH

FIRST

BODY TYPE ETC.

A

GENERAL CARGO with LEAF SUSPENSION

B

GENERAL CARGO with LEAF SUSPENSION

D

DUMP with LEAF SUSPENSION

E

DUMP with LEAF SUSPENSION

F

FIRE ENGINE with LEAF SUSPENSION

G H

OTHER SPECIFICATION CODE

CAB, T/M TYPE ETC.

GENERAL CARGO with REAR AIR SUSPENSION GENERAL CARGO with REAR AIR SUSPENSION

M

MIXER with LEAF SUSPENSION

Q

DUMP with REAR AIR SUSPENSION

U

MIXER with REAR AIR SUSPENSION

NOTE

• Refer to chassis specification for GVMR (Gross vehicle mass rating). BM1503A5ECA

1

1

VEHICLE SUMMARY

2. IDENTIFICATION NUMBER CHASSIS NUMBER

Located at the side member of chassis frame.

VEHICLE MANUFACTURED STAMPING POSITION ( LOCAL

RIGHT

ORIGIN (JAPAN)

LEFT

LOCAL or ORIGIN (JAPAN)

LEFT

)

DESTINATION TAIWAN, and VENEZUELA EXCEPT ABOVE

ENGINE NUMBER : ENGINE NUMBER Right side of cylinder block

B

A

C STAMPING POSITION ENGINE MODEL B J05D A J05E B J07E A J08C A J08E (FOR INDONESIA EURO2) B J08E (EXCEPT ABOVE) B A09C C P11C BM1503A5ECA

2

1

VEHICLE SUMMARY

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.

BM1503A5ECA

3

1

VEHICLE SUMMARY BODY MOUNTING MANUAL NUMBER

BM1503A5ECA

MODEL NAME

HINO 51018

HINO 51226

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

EURO3

EURO3

EURO3

EURO3

EURO3

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

SUSPENSION CAB

M009 (9MT)

Fr & Rr LEAF SPRING

Fr & Rr LEAF SPRING

SINGLE CAB, WIDE TYPE

SINGLE CAB, WIDE TYPE

SINGLE CAB, WIDE TYPE

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

(mm)

4,350

4,850

FRONT (mm)

1,770

1,750

(GAM. RATING)

5,030

3,590+1,300

1,925

3,590+1,300

1,925

4,600+1,300 1,925

1,720

1,840

1,860

1,860

11,900/ -----

17,000/ -----

26,000/ -----

26,000/ -----

FRONT (kg)

3,600

4,500

6,500

6,500

6,500

REAR (kg)

7,000

8,500

10,500

20,000

20,000 11.00-20-14PR

SIZE

S : STANDARD EQUIPMENT P : OPTION EQUIPMENT

LESS 4,600+1,300

1,660

TIRE CAPACITY ON STD SPECIFICATIONS

3,760

10,400/ -----

(kg)

8.25-16-14PR

8.25-20-14PR

11.00-20-16PR

11.00-20-14PR

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)

ALTERNATOR

EATON ES11109 (9MT)

Fr & Rr LEAF SPRING

SINGLE CAB

PERMISSIBLE AXLE CAPACITY

BATTERY

EATON ES11109 (9MT)

LESS

REAR (mm)

FUEL TANK

LJ06S (6MT) Fr & Rr LEAF SPRING

SHORT CAB

MAX. GVM/GCM CAPACITY (REGAL LIMIT)

WHEEL DISC

LX06S (6MT) Fr & Rr LEAF SPRING

VEHICLE CONTROL ECU

TREAD

TIRE

HINO 52635

ENGINE

WHEEL BASE

DIMENSIONS & MASS

HINO 52626

EMISSION CONTROL

TRANSMISSION MAJOR SPECIFICATIONS

HINO 51726

(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 .

Ch3

CHASSIS MASS & FRAME SECTION MODULUS

Ch4

SPRINGS & REAR AXLES

3.1. CHASSIS MASS 3.2. MASS OF THE OPTION EQUIPMENT 3.3. FRAME SECTION MODULUS 4.1. SPRING CHARACTERISTICS

FRONT STD

Ch5

M6

M7

M8

EQ4

EQ4

EQ4

Z1

Z2

Z3

Z4

Z5

Z6

Z7

Z8

F1(FRT)

F3(FRT)

F5(FRM)

F5(FRM)

F7(FRM)

F7(FRM)

F7(FRM)

F7(FRM)

F4(FRM)

-

-

F8(FRT)

F8(FRT)

F9(FRT)

F9(FRT)

R3(RRM)

R5(RRM)

R6(RRM)

R7(RRM)

R7(RRM)

R7(RRM)

R7(RRM)

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

–

–

–

–

–

–

–

–

U-2b

U-2b

U-2b

U-2b

U-2b

U-2b

U-2c

U-2c

–

–

DL-2

–

DL-2

–

DL-2

–

C-1

C-2

C-3

C-3

C-4

C-4

C-5

C-5

5.5. ENGINE CONTROL FOR BODY OR EQUIPMENT

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

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 BAT-1

9.3. BATTERY

Ch9

M5 EQ4

F2(FRM)

8.4. CHASSIS FRAME DRAWINGS

MOUNTING OF CHASSIS EQUIPMENT

M4 EQ3

R1(RRM)

8.1. CAB DRAWINGS CHASSIS DRAWINGS

M3 EQ3

OPT1

5.6. REAR BODY CONTROL LEVER

Ch8

M2 EQ2

REAR  　 STD 5.2. TRANSMISSION SIDE POWER TAKE OFF

P.T.O. AND CONTROL

M1 EQ1

9.4. FUEL TANK

CF-1

CF-2

CF-3

STD

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

–

–

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

9.8. LICENSE PLATE BRACKET

OPT

EX-2

EX-4

EX-5

EX-5

EX-8

EX-8

–

–

STD

LPB-C

LPB-C

LPB-C

LPB-C

LPB-C

LPB-C

LPB-C

LPB-C

BM1503A5ECA

4

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 21. PRECAUTION FOR REMOVE NYLON TUBE FROM CONNECTOR BM1503A5ECA

2

GENERAL PRECAUTIONS

1. ‌PRECAUTION FOR SRS AIR BAG (If equipped) Be sure to observe the following precautions. 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. * 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.

BM1503A5ECA

1

2

GENERAL PRECAUTIONS * ‌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.

BM1503A5ECA

2

2

GENERAL PRECAUTIONS 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 without fail.

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GENERAL PRECAUTIONS 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.

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GENERAL PRECAUTIONS 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.

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GENERAL PRECAUTIONS 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.

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GENERAL PRECAUTIONS

2. ELECTRIC WELDING WORK

fig. 1.

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.

TAKE OFF THESE FUSES

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. EX.1 : FULL EQUIPPED LAYOUT

2.5 After restored

EX.2 : ENGINE ECU ONLY LAYOUT

POSITION OF SRS AIR BAG, ENGINE ECU, AND VHECLE ECU FUSE

* ‌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.

NOTE

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

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GENERAL PRECAUTIONS 2.6 F ‌ OR REFERENCE CURRENT FLOW OF ELECTRIC WELDING WHEN WELD CAB BODY Case of disconnecting the negative terminal of BATTERY Turn the STARTER SWITCH to LOCK position. Do not turn on the STARTER SWITCH when the earth wire is disconnected.

EARTH OF EQUIPMENTS

ELECTRIC EQUIPMENTS

ARC WELDING MACHINE

+

–

EARTH WIRE OF CAB

GOOD

CHASSIS FRAME

BATTERY

Disconnect the negative terminal of BATTERY. Do not disconnect at CHASSIS FRAME.

Case of connecting the negative terminal of BATTERY ELECTRIC EQUIPMENTS will be damaged. WELDING ROD EARTH OF EQUIPMENTS

ELECTRIC EQUIPMENTS

ARC WELDING MACHINE

STARTER SWITCH

+

–

NG

CHASSIS FRAME

EARTH WIRE OF CAB BATTERY

WELDING ROD

CAB

ELECTRIC EQUIPMENTS

BATTERY

EARTH of ARC WELDING MACHINE

EARTH WIRE OF CAB

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GENERAL PRECAUTIONS

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]

The figure shows RHD VEHICLE, LHD VEHICLE's figure is symmetrical. BM1503A5ECA

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GENERAL PRECAUTIONS

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.

J07E ENGINE ECU

CONNECTOR

J08E

ENGINE ECU

CONNECTOR

A09C

ENGINE ECU CONNECTOR

AIR BENT VALVE BM1503A5ECA

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GENERAL PRECAUTIONS

5. ‌PRECAUTION FOR EXHAUST SYSTEM (if equipped EXHAUST GAS AFTER TREATMENT SYSTEM)

(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.

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.

(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.

Do not modify any part of exhaust system within this range. {Muffler (DPR), EXHAUST GAS DIFFERENTIAL PRESSURE SENSOR, Tail pipe etc.}

Exhaust tail pipe

• 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.



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.

ABOUT THE DPR MUFFLER (DPR = Diesel Particulate active Reduction system)

Position of DPR switch • The figure shows RHD vehicle, LHD vehicle is symmetry

(1) ‌Outline of DPR Muffler Structure of DPR muffler is shown following figure.

FOR J07E & J08E E/G

FOR A09C E/G Indicator lamp ‌ 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.

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.

(5) ‌Paint application Never paint the muffler (DPR) or exhaust gas differential pressure sensor. BM1503A5ECA

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GENERAL PRECAUTIONS 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. Do not too much looseness the hose

2

Pressure sensor

Muffler

Pressure sensor hose

Do not too much tense the hose

　3) When reinstall the hose after moved sensor, make sure that the hose routing is correct. (Should matched back and forth direction) Pressure sensor

Pressure sensor hose

(× : wrong installation)

(○ : correct installation)

3. Painting Do not paint the muffler and pressure sensor.

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GENERAL PRECAUTIONS 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.

SENSOR UNIT ASSEMBLY SCREWS AND NUTS Do not loosen or re-tighten it.

INSTALLING BOLTS AND NUTS

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

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GENERAL PRECAUTIONS 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.

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GENERAL PRECAUTIONS

6. ‌PRECAUTION FOR VEHICLE TO BE PROVIDED HID LIGHT AXIS SENSOR (If equipped)

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.

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



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

• 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.



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

GENERAL PRECAUTION

• 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.

• Location of components are described as following figure.

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GENERAL PRECAUTIONS

7. ‌PRECAUTION FOR AUTO CLUTCH UNIT (ACU) (If equipped)

• ‌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. More than 150

• 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.

Need space upper of the tank for filling the oil The nozzle head of oil container To avoid obstructing the visibility of oil level

• 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. • FOR MAINTENANCE WORK SPACE OF AUTO CULTCH UNIT (ACU) Do not obstruct the ACU for maintenance work space when mounting of body.

• 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. Do not step on the reserve tank.

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GENERAL PRECAUTIONS

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.

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GENERAL PRECAUTIONS

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.

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.

FITTING THE 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. CAB REAR ARCH RUBBER FIRE SHIELD BOLT & NUT BODY OR EQUIPMENT

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GENERAL PRECAUTIONS

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.

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GENERAL PRECAUTIONS

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.

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GENERAL PRECAUTIONS

12. CLEARANCE BETWEEN CAB AND REAR BODY OR EQUIPMENT

MINIMUM CLEARANCE WITH DOUBLE CAB REAR END PRODUCTION CODE -

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.

APPLICATION FD, FT FG GT

Unit : mm

A 1,600 1,575 1,550

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 PRODUCTION CODE

APPLICATION

REAR ARCH COVER

A

FC9JJSA-NNB GD8JLSA-PAB -

CAB MOUNT TYPE

FC FC FD, FE, GD, FT, GT FD, FE GD FG, GT FG, GT FG FG

RIGID RIGID RIGID RIGID RIGID RIGID RIGID FLOATING FLOATING

LESS TYPE A LESS TYPE A TYPE D LESS TYPE C LESS TYPE B

625 650 875 900 905 825 860 851 864

50 50 50 50 50 50 50 50 50

GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX

GH, FL, FM1J, FM8J, FM1A

LESS

805

50

TYPE C LESS TYPE B

840 831 844

50 50 50

FM2PLSD-ZGL FM2PRSA-ZGL -

RIGID

GH, FL, FM8J, FM1A RIGID GH, FL, FM8J, FM1A FLOATING GH, FL, FM8J, FM1A FLOATING FM2P

RIGID

FM2P(TRACTOR) SG2P(TRACTOR)

LESS

-

-

B

885

50

1,255 1,000

50 100

MEASUREMENT DETAIL OF RADIATOR HEADER TANK

PRODUCTION CODE FC9JJSA-NNB GD8JLSA-PAB GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX -

APPLICATION FC FD GD FT, GT FG GH, FL, FM1J, FM8J FM2P FM2P(TRACTOR) SG2P

A

PRODUCTION CODE -

B

755 1,005 955

80 80 80

935

80

1,075 1,255 1,000

80 80 175

-

APPLICATION

A

Unit : mm

B

SG2P

180

6.5°

FM1A, FM2P

175

4°

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

• Refer to following page "MEASUREMENT DETAIL OF REAR ARCH COVER" for rear arch cover type. BM1503A5ECA

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GENERAL PRECAUTIONS 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 FM2PRSA-ZGL

SG2P, FM2P

793

694

–

FT

863

619

–

GT

813

564

BM1503A5ECA

Unit : mm

22

2

GENERAL PRECAUTIONS MEASUREMENT DETAIL OF POWER CAB TILT MECHANISM (FOR SINGLE CAB, RIGID CAB MOUNT TYPE) PRODUCTION CODE

A

–

813

Unit : mm

BM1503A5ECA

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GENERAL PRECAUTIONS MEASUREMENT DETAIL OF POWER CAB TILT MECHANISM (FOR SINGLE CAB, FLOATING CAB MOUNT TYPE) PRODUCTION CODE

APPLICATION

A

–

FG

851

–

GH,FL8J,FM8J

831

BM1503A5ECA

Unit : mm

24

2

GENERAL PRECAUTIONS MEASUREMENT DETAIL OF POWER CAB TILT MECHANISM (FOR DOUBLE CAB) Unit : mm

SIDE VIEW

REAR VIEW

UPPER VIEW

SIDE VIEW

OPERATION RANGE, MANUAL TILT PUMP LEVER, DETAIL

CAB TILT PUMP INSTALLATION 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

–

GT

1,520

506

788

447

928

216

BM1503A5ECA

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GENERAL PRECAUTIONS MEASUREMENT DETAIL OF REAR ARCH COVER

[TYPE C]

[TYPE A] PRODUCTION CODE

APPLICATION

A

–

FC

650

–

FD,FE

900

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 B] PRODUCTION CODE

[TYPE D] PRODUCTION CODE CHASSIS CENTER LINE

B

–

TO FRONT AXLE DATUM LINE

29

198

147

128

192

167

387

REAR BODY

2

FRAME UPPER SURFACE 180

30

BM1503A5ECA

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GENERAL PRECAUTIONS 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. BM1503A5ECA

27

GENERAL PRECAUTIONS MEASUREMENT DETAIL OF ENGINE AIR CLEANER (FOR SINGLE CAB)

Unit : mm

L

W

H

DUAL ELEMENT

L

W

215

PRODUCTION CODE – GH8JGSD-TGB GH8JMSA-TGB

H

2

260

FM8JLSD-TGX FM8JRSA-TGX

SINGLE ELEMENT

PRODUCTION CODE FC9JJSA-NNB GD8JLSA-PAB –

APPLICATION FC FD,GD,FE FT

L 434.5 684.5 684.5

W 988.5 988.5 988.5

APPLICATION FG,GT

L 634.5

W 1078.5

H 256.5

GH

614.5

1078.5

256.5

FL,FM1J,FM8J

614.5

1078.5

226.5

H 246.5 246.5 311.5

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 may damage engine parts and DPR system.

PRODUCTION CODE FM2PLSD-ZGL FM2PRSA-ZGL

BM1503A5ECA

APPLICATION SG2P,FM1A,FM2P

28

2

GENERAL PRECAUTIONS MEASUREMENT DETAIL OF VERTICAL EXHAUST PIPE (OPT)

Unit : mm

PRODUCTION CODE

Unit : mm

APPLICATION

A

B

PRODUCTION CODE

APPLICATION

FC9JJSA-NNB

FC

755

536

–

FT,GT

GD8JLSA-PAB

GD

1005

536

FG

955

561

GH,FL,FM1J,FM8J

935

561

FM2P

1075

563

– GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX –

BM1503A5ECA

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GENERAL PRECAUTIONS

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.

MOUNTING POSITION

L1f

L2

L1r

L5 L3

A No.1 U-BOLT

No.2 U-BOLT

PRODUCTION CODE

REAR AXLE DATUM LINE OR TRUNNION SHAFT CENTER

No.2 CROSSMEMBER DATUM LINE

No.3 U-BOLT

L4

B No.4 U-BOLT

No.5 U-BOLT

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

WARNING

FC9JJSA-NNB FC9JJSA-NNB GD8JLSA-PAB GD8JLSA-PAB GH8JGSD-TGB GH8JGSD-TGB GH8JMSA-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JLSD-TGX FM8JRSA-TGX FM8JRSA-TGX FM2PLSD-ZGL FM2PLSD-ZGL FM2PRSA-ZGL FM2PRSA-ZGL

RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH

Unit : mm

L1f

520 520 330 330 885 335 885 335 500 315 500 315 575 315 575 315

L1r – – – – – – – – – – – – – – – –

L2

1,550 1,550 1,600 1,600 – – 1,560 1,560 – – 1,755 1,755 – – 1,755 1,755

L3

220 220 220 220 150 150 150 150 – – – – – – – –

L4

1,405 1,405 1,670 1,670 – – 2,120 2,120 1,445 1,445 1,260 1,260 1,450 1,450 1,260 1,260

L5 – – – – – – – – – – – – – – – –

A

– – – – – – – – 1,370 1,370 1,755 1,755 1,370 1,370 1,755 1,755

B

– – – – – – – – 955 955 1,260 1,260 955 955 1,260 1,260

• 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.

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30

2

GENERAL PRECAUTIONS DRILLING PROCESS FOR INSTALLING THE MOUNTING BRACKET AROUND TANDEM REAR AXLE 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.

EXAMPLE DETAIL OF MOUNTING BRACKET

BM1503A5ECA

Unit : mm

31

2

GENERAL PRECAUTIONS

14. RECOMMENDED POSITIONS OF REAR FENDERS AND MUDGUARDS

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.

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.

(FOR REAR SINGLE AXLE) PRODUCTION CODE FC9J FC9J FC9J FC9J FC9J

GD8J GD8J GD8J

GH8J GH8J GH8J GH8J GH8J

WHEEL 16x6.00GS-offset135mm 16x6.00GS-offset135mm 17.5x6.75-offset135mm 17.5x6.75-offset135mm 19.5x6.75-offset136mm

20x6.50T-offset145mm 20x6.50T-offset145mm 22.5x7.50-offset162mm

20x7.50V-offset165mm 20x7.50V-offset165mm 22.5x8.25-offset165mm 22.5x8.25-offset165mm 22.5x8.25-offset165mm

(FOR TANDEM REAR AXLE)

Unit : mm REAR TIRE 8.25-16 8.25R16 9.5R17.5 235/75R17.5 225/70R19.5

8.25-20 8.25R20 255/70R22.5

11.00-20 11.00R20 12R22.5 275/70R22.5 275/80R22.5

TIRE WHEEL SIZE (in)

A

B

2,160 2,155 2,170 2,165 2,160

2,245 2,240 2,300

2,455 2,450 2,460 2,445 2,445

E 150

C

2,180 2,175 2,190 2,185 2,180

2,265 2,260 2,320

2,475 2,470 2,480 2,465 2,465

1,720 1,720 1,720

1,840 1,840 1,840 1,840 1,840

FM8J,FM2P FM8J,FM2P FM8J,FM2P FM8J,FM2P FM8J,FM2P FM8J,FM2P FM8J,FM2P

160 163 155 158 160

178 180 150

WHEEL 20x7.50V-offset165mm 20x7.50V-offset165mm 20x7.50V-offset165mm 20x7.50V-offset165mm 22.5x7.50-offset162mm 22.5x7.50-offset162mm 22.5x8.25-offset165mm

REAR TIRE 10.00-20 10.00R20 11.00-20 11.00R20 11R22.5 275/70R22.5 295/80R22.5

A 2,465 2,465 2,475 2,470 2,455 2,450 2,480

B 2,485 2,485 2,495 2,490 2,475 2,470 2,500

C 1,860 1,860 1,860 1,860 1,860 1,860 1,860

D 183 183 178 180 188 190 175

168 170 165 173 173

F

16 or 17.5 or 19.5

~ 200

200

20 or 22.5

~ 250

300

200

1,660 1,660 1,660 1,660 1,660

PRODUCTION CODE

D

Unit : mm

BM1503A5ECA

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GENERAL PRECAUTIONS

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. Unit : mm

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

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

BM1503A5ECA

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2

GENERAL PRECAUTIONS

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.

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34

2

GENERAL PRECAUTIONS

17. ‌PRECAUTION FOR FRONT UNDERRUN PROTECTION DEVICE (FUPD) (If equipped)

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

(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.

ECE R93 EXCEPT OFF-ROAD MAX. 400mm OFF-ROAD Inapplicable

FRAME LOWER SURFACE FUPD ATTACHMENT HEIGHT

FUPD GROUND HEIGHT

UPPER STAY

FUPD

GROUND

BRACKET FOR ADJUSTING HEIGHT (There are variatiions of type by vehicle.)

ARM SUB-ASSY, FR BUMPER 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.

[TYPE B]

Adjustment method of the ground height of FUPD

APPLICATION : FG,SG,GH,FL,FM

BRACKET, SIDE STEP, No.1

• 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.

ARM SUB-ASSY, FR BUMPER BM1503A5ECA

35

2

GENERAL PRECAUTIONS (2) ABOUT THE STRUCTURE OF AROUND FUPD [TYPE A] APPLICATION : FC,FD,GD,FE

ARM SUB-ASSY, FUP Installation position of bracket for adjusting height Installation position of FUPD : 197mm (lower frame ~ lower FUPD)

Shape of bracket for adjusting height

ARM SUB-ASSY, FR BUMPER, RH/LH

Parts Number : 52011-E0070 (RH) : 52012-E0070 (LH)

BOLT Tightening torque :125±16.3N·m

[EXAMPLE] FUPD Installation position of FUPD : 219mm (lower frame ~ lower FUPD)

NUT,

BOLT

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

BOLT Tightening torque :125±16.3N·m

FUPD Installation position of FUPD : 244mm (lower frame ~ lower FUPD)

NUT,

BOLT

Tightening torque :63±18.9N·m

Parts Number : 52011-E0080 (RH) : 52012-E0080 (LH)

ARM SUB-ASSY, FR BUMPER, RH/LH

With four steps front of the vehicle BOLT Tightening torque :125±16.3N·m

FUPD Installation position of FUPD : 269mm (lower frame ~ lower FUPD)

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

BOLT

Tightening torque :125±16.3N·m

FUPD BM1503A5ECA

NUT,

BOLT

Tightening torque :63±18.9N·m

36

2

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

ARM SUB-ASSY, FUP [EXAMPLE]

Installation position of bracket for adjusting height

Shape of bracket for adjusting height

Installation position of FUPD : 300mm (lower frame ~ lower FUPD)

FUPD Installation position of FUPD : 325mm (lower frame ~ lower FUPD)

FUPD

[EXAMPLE]

Installation position of FUPD : 350mm (lower frame ~ lower FUPD)

FUPD Installation position of FUPD : 375mm (lower frame ~ lower FUPD)

FUPD BM1503A5ECA

37

2

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

BRACKET SIDE STEP Installation position of bracket for adjusting height

Shape of bracket for adjusting height

BRACKET, SIDE STEP, No.1 RH/LH NUT Tightening torque :63±18.9N·m

Parts Number : 51793-E0071 (RH) : 51794-E0061 (LH)

[EXAMPLE]

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

If changed installation height for FUP, should change bracket for installation step.

Parts Number : 51793-E0081 (RH) : 51794-E0071 (LH)

BRACKET, SIDE STEP, No.1 RH/LH

NUT Tightening torque :63±18.9N·m

BM1503A5ECA

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2

GENERAL PRECAUTIONS (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.

UP RH Parts Number : 38123-E0030

FR

BM1503A5ECA

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2

GENERAL PRECAUTIONS

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. • When structure that a structure part of the body rear prevents a plange.

BM1503A5ECA

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2

GENERAL PRECAUTIONS

19. PRECAUTION FOR ADDITIONAL FUEL TANK When install additional fuel tank, make sure to check if the fuel sender works correctly as following. 1) ‌The meter of this vehicle incorporates a computer that calculates the input signals and displays on different meters and gauges. In the case of a fuel gauge, in order to prevent it from moving of float of the fuel sender with vehicle posture change, its movement is intentionally dull, consequently if move float from [E] to [F] (or [F] to [E]) it will not follow. (The indicator moves only 2 degrees per minute.) 2) How to check if the fuel sender works correctly. a. ‌Disconnect battery negative connecter and wait for more than 30 seconds. b. Move ‌ the float of the fuel sender to the position corresponding to [F]. (The highest position of raised float.) c. ‌Connect battery negative connecter and turn on starter switch to [ON] position. ( The fuel gauge indicates [F] position.) d. ‌Disconnect battery negative connecter again and wait for more than 30 seconds. e. ‌Move the float of the fuel sender to the position corresponding to 1/2 position. (Move float to mid position between the highest and the lowest position of the float.) f. Connect ‌ battery negative connecter and turn on starter switch to [ON] position. ( The fuel gauge indicates 1/2 position.) As the result if the fuel gauge indicates [F] position in step c. and further indicate 1/2 position in step f., there is no problem.

BM1503A5ECA

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2

GENERAL PRECAUTIONS

20. PRECAUTION FOR THE FUEL HOSE Be sure to observe the following notes, if it will be changed a fuel hose by a movement or an addition of a fuel tank. Always use the fuel hose of the HINO genuine parts. The following figure is an example of genuine parts. (The material and quality of each component are based on the standard of HINO.)

Unit : mm

ØA

ØB

INNER RUBBER (FLUORIDE COATED)

OUTER RUBBER BRAID INTERMEDIATE RUBBER

DIAMETER NOMINAL 8 10

INNER A 7.5 9.5

OUTER B 15 17

If genuine parts cannot be obtained, please get the following rubber hoses as a substitute. • The rubber hoses which dose not contain a metal element. or • The rubber hoses which a metal element does not melt into fuel. (For example : The rubber hose which give the fluoride coat to the inside.) The quality of the rubber hoses of a substitute should be more than equivalent to genuine, or equivalent. Use of unsuitable rubber hose may cause serious faults of engine, such as the decline of an exhaust gas purification function. For more detailed information, please consult your nearest HINO sales outlet.

BM1503A5ECA

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GENERAL PRECAUTIONS

21. ‌PRECAUTION FOR REMOVE NYLON TUBE FROM CONNECTOR (VOSS type, If equipped) Removal procedures a. ‌When removing the whole coupling with the nylon tube press fitted into the connector Make sure that there are no adherents such as dirt and stains around. If adherents are recognized, remove all of them with air blow. Fix the nylon tube near the press fit area so that it does not turn together and is twisted, and turn only the coupling at the base with a tool to remove. b. ‌When removing the connector from the coupling Tilt the tool with the special tool for removal fitted into the groove of the fixing ring of the coupling as shown in the illustration, and remove the resin ring. Or break the fixing ring with nippers to remove. Pull out two clips using the hook area of the special tool as shown in the illustration, remove the clip holding ring, and then remove the connector. It is not permissible to reuse a coupling from which a fixing ring is removed. Special tool for disassembling coupling (VOSS made) (S0911-E0030)

NOTICE • ‌In the case of both a. and b. , store them so that no dirt, stain and flaw adhere to either inner or outer surface of the connector. • ‌It is not permissible to remove the press fitted nylon tube from the connector and to reuse the connector because it cannot be guaranteed against air leak.

BM1503A5ECA

43

Chapter 3 CHASSIS MASS & FRAME SECTION MODULUS

1. CHASSIS MASS

2. MASS OF THE OPTION EQUIPMENT 3. FRAME SECTION MODULUS

BM1503A5ECA

3

CHASSIS MASS & FRAME SECTION MODULUS

Refer to CHASSIS MASS (STD & OPT) or FRAME SECTION MODULUS based on following. MODEL NAME HINO 51018 HINO 51226 HINO 51726 HINO 51726 HINO 52626 HINO 52626 HINO 52635 HINO 52635

PRODUCTION CODE

FC9JJSA-NNB GD8JLSA-PAB GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX FM2PLSD-ZGL FM2PRSA-ZGL

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

BM1503A5ECA

3.2. MASS OF THE 3.3. FRAME SECTION OPTION EQUIPMENT MODULUS EQ1 EQ2 EQ3 EQ3 EQ4 EQ4 EQ4 EQ4

Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8

1

3

CHASSIS MASS & FRAME SECTION MODULUS

1. CHASSIS MASS No. PRODUCTION CODE

M1 FC9JJSA-NNB

26 305 26 40 32 4 130 5 2 13 179 23 494 8 45 15 38 35 108 43 376 3 -

(m) -1.100 -0.935 -0.935 -0.600 -0.435 0.400 0.115 0.200 0.200 0.435 0.565 0.565 0.590 0.490 1.375 0.500 1.960 2.395 1.735 2.775 2.715 5.600 -

( kg·m ) -28.600 -285.175 -24.310 -24.000 -13.920 1.600 14.950 1.000 0.400 5.655 101.135 12.995 291.460 3.920 61.875 7.500 74.480 83.825 187.380 119.325 1,020.840 16.800 -

Gravity height from frame upper surface (m) -0.125 0.715 0.100 0.045 0.430 0.100 -0.150 0.050 0.080 0.245 0.715 0.230 -0.150 -0.050 -0.210 -0.100 -0.315 -0.170 -0.215 -0.355 -0.120 -0.195 -

1,950 347 667 2,964

0.835 0.000 4.350 1.529

1,629.135 0.000 2,901.450 4,530.585

0.084 -0.385 -0.470 -0.096

FRONT SPRUNG MASS ( kg ) 1,575 UNSPRUNG MASS ( kg ) 347 CHASSIS MASS ( kg ) 1,922 GRAVITY POSITION FROM F.A.C GRAVITY HEIGHT FROM FRAME UPPER SURFACE

REAR 375 667 1,042 (m) (m)

TOTAL 1,950 1,014 2,964 1.529 -0.096

ITEMS

( kg )

Front Bumper Cab Front Cab Front Mtg. Steering Step Radiator Steering Control Engine Front Control Engine Room Air Cleaner Cab Rear Cab Rear Mtg. Engine Rear Rear Splash Brake System Electric System Exhaust System Stack Tail Battery Fuel Tank Transfer Propeller Shaft Frame etc. Platform Coupler Tire Carrier Rear Bumper Tool Box Rear Spring SUB TOTAL

UNSPRUNG MASS TOTAL

Mass

FRONT REAR

Gravity position from F.A.C

Moment from F.A.C

Moment from frame upper surface ( kg·m ) -3.250 218.075 2.600 1.800 13.760 0.400 -19.500 0.250 0.160 3.185 127.985 5.290 -74.100 -0.400 -9.450 -1.500 -11.970 -5.950 -23.220 -15.265 -45.120 -0.585 163.195 -133.595 -313.490 -283.890

NOTE

• The mass of tire follows design figure according to ETRTO or JATMA standard. • The chassis mass 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. BM1503A5ECA

2

3

CHASSIS MASS & FRAME SECTION MODULUS No. PRODUCTION CODE

M2 GD8JLSA-PAB

26 334 26 40 40 5 271 5 12 184 23 512 6 48 15 30 35 215 48 459 7 -

(m) -1.130 -0.975 -0.975 -0.830 -0.475 0.720 0.080 0.200 0.685 0.815 0.815 0.815 0.600 1.335 1.740 1.880 2.355 2.185 3.160 3.110 6.145 -

( kg·m ) -29.380 -325.650 -25.350 -33.200 -19.000 3.600 21.680 1.000 8.220 149.960 18.745 417.280 3.600 64.080 26.100 56.400 82.425 469.775 151.680 1,427.490 43.015 -

Gravity height from frame upper surface (m) -0.125 0.740 0.100 0.045 -0.020 -0.110 -0.090 0.050 0.245 0.740 0.230 -0.090 -0.100 -0.210 -0.100 -0.345 -0.170 -0.205 -0.360 -0.120 -0.195 -

2,341 525 972 3,838

1.073 0.000 4.850 1.883

2,512.470 0.000 4,714.200 7,226.670

0.075 -0.422 -0.489 -0.136

FRONT SPRUNG MASS ( kg ) 1,823 UNSPRUNG MASS ( kg ) 525 CHASSIS MASS ( kg ) 2,348 GRAVITY POSITION FROM F.A.C GRAVITY HEIGHT FROM FRAME UPPER SURFACE

REAR 518 972 1,490 (m) (m)

TOTAL 2,341 1,497 3,838 1.883 -0.136

ITEMS

( kg )

Front Bumper Cab Front Cab Front Mtg. Steering Step Radiator Steering Control Engine Front Control Engine Room Air Cleaner Cab Rear Cab Rear Mtg. Engine Rear Rear Splash Brake System Electric System Exhaust System Stack Tail Battery Fuel Tank Transfer Propeller Shaft Frame etc. Platform Coupler Tire Carrier Rear Bumper Tool Box Rear Spring SUB TOTAL

UNSPRUNG MASS TOTAL

Mass

FRONT REAR

Gravity position from F.A.C

Moment from F.A.C

Moment from frame upper surface ( kg·m ) -3.250 247.160 2.600 1.800 -0.800 -0.550 -24.390 0.250 2.940 136.160 5.290 -46.080 -0.600 -10.080 -1.500 -10.350 -5.950 -44.075 -17.280 -55.080 -1.365 174.850 -221.603 -475.308 -522.061

NOTE

• The mass of tire follows design figure according to ETRTO or JATMA standard. • The chassis mass 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. BM1503A5ECA

3

3

CHASSIS MASS & FRAME SECTION MODULUS No. PRODUCTION CODE

M3 GH8JGSD-TGB

34 343 31 61 22 40 7 327 7 15 187 26 479 15 103 15 67 36 213 59 646 5 -

(m) -1.200 -1.045 -1.045 -0.820 -0.750 -0.485 0.650 0.030 0.080 0.595 0.745 0.745 0.870 0.580 2.440 1.670 1.410 1.250 2.315 2.560 2.335 3.098 -

( kg·m ) -40.800 -358.435 -32.395 -50.020 -16.500 -19.400 4.550 9.810 0.560 8.925 139.315 19.370 416.730 8.700 251.320 25.050 94.470 45.000 493.095 151.040 1,508.410 15.490 -

Gravity height from frame upper surface (m) -0.200 0.725 0.031 0.010 -0.500 -0.014 -0.024 -0.170 0.045 0.255 0.725 0.422 -0.170 -0.090 -0.185 -0.130 -0.370 -0.185 -0.225 -0.395 -0.140 0.000 -

2,738 791 1,429 4,958

0.977 0.000 3.760 1.623

2,674.285 0.000 5,373.040 8,047.325

0.011 -0.495 -0.530 -0.226

FRONT SPRUNG MASS ( kg ) 2,027 UNSPRUNG MASS ( kg ) 791 CHASSIS MASS ( kg ) 2,818 GRAVITY POSITION FROM F.A.C GRAVITY HEIGHT FROM FRAME UPPER SURFACE

REAR 711 1,429 2,140 (m) (m)

TOTAL 2,738 2,220 4,958 1.623 -0.226

ITEMS

( kg )

Front Bumper Cab Front Cab Front Mtg. Steering Step Radiator Steering Control Engine Front Control Engine Room Air Cleaner Cab Rear Cab Rear Mtg. Engine Rear Rear Splash Brake System Electric System Exhaust System Stack Tail Battery Fuel Tank Transfer Propeller Shaft Frame etc. Platform Coupler Tire Carrier Rear Bumper Tool Box Rear Spring SUB TOTAL

UNSPRUNG MASS TOTAL

Mass

FRONT REAR

Gravity position from F.A.C

Moment from F.A.C

Moment from frame upper surface

M4 GH8JMSA-TGB

( kg·m ) -6.800 248.675 0.961 0.610 -11.000 -0.560 -0.168 -55.590 0.315 3.825 135.575 10.972 -81.430 -1.350 -19.055 -1.950 -24.790 -6.660 -47.925 -23.305 -90.440 0.000 29.910 -391.545 -757.370 -1,119.005

Mass

( kg )

34 343 31 61 22 40 7 327 7 15 187 26 479 15 103 15 67 36 213 71 701 7 -

2,807 791 1,435 5,033

( kg·m ) -40.800 -358.435 -32.395 -50.020 -16.500 -19.400 4.550 9.810 0.560 8.925 139.315 19.370 416.730 8.700 251.320 25.050 94.470 45.000 493.095 231.460 2,330.825 44.870 -

Gravity height from frame upper surface (m) -0.200 0.725 0.031 0.010 -0.500 -0.014 -0.024 -0.170 0.045 0.255 0.725 0.422 -0.170 -0.090 -0.185 -0.130 -0.370 -0.185 -0.225 -0.395 -0.140 -0.230 -

1.285 3,606.500 0.000 0.000 5.030 7,218.050 2.151 10,824.550

0.006 -0.495 -0.550 -0.231

Gravity position from F.A.C (m) -1.200 -1.045 -1.045 -0.820 -0.750 -0.485 0.650 0.030 0.080 0.595 0.745 0.745 0.870 0.580 2.440 1.670 1.410 1.250 2.315 3.260 3.325 6.410 -

FRONT 2,090 791 2,881

Moment from F.A.C

REAR 717 1,435 2,152

Moment from frame upper surface ( kg·m ) -6.800 248.675 0.961 0.610 -11.000 -0.560 -0.168 -55.590 0.315 3.825 135.575 10.972 -81.430 -1.350 -19.055 -1.950 -24.790 -6.660 -47.925 -28.045 -98.140 -1.610 15.860 -391.545 -789.250 -1,164.935

TOTAL 2,807 2,226 5,033 2.151 -0.231

NOTE

• The mass of tire follows design figure according to ETRTO or JATMA standard. • The chassis mass 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. BM1503A5ECA

4

3

CHASSIS MASS & FRAME SECTION MODULUS No. PRODUCTION CODE

ITEMS

Front Bumper Cab Front Cab Front Mtg. Steering Step Radiator Steering Control Engine Front Control Engine Room Air Cleaner Cab Rear Cab Rear Mtg. Engine Rear Rear Splash Brake System Electric System Exhaust System Stack Tail Battery Fuel Tank Transfer Propeller Shaft Frame etc. Trunnion Bracket Coupler Tire Carrier Rear Bumper Tool Box Rear Spring SUB TOTAL

UNSPRUNG MASS TOTAL

FRONT REAR

M5 FM8JLSD-TGX Mass

( kg )

27 338 31 61 27 7 327 7 17 185 26 479 15 122 21 34 36 213 60 822 160 515

3,530 837 2,500 6,867

( kg·m ) -32.400 -353.210 -32.395 -50.020 -12.690 4.550 9.810 0.560 11.560 137.825 19.370 416.730 8.700 251.930 35.070 61.200 89.460 377.010 142.500 2,437.230 678.400 2,183.600

Gravity height from frame upper surface (m) -0.230 0.725 0.080 -0.220 0.120 -0.055 -0.170 0.040 0.430 0.725 0.180 -0.680 -0.070 0.165 0.160 -0.420 -0.130 -0.225 -0.335 -0.180 -0.327 -0.559

1.809 6,384.790 0.000 0.000 4.240 10,600.000 2.473 16,984.790

-0.158 -0.536 -0.553 -0.348

Gravity position from F.A.C (m) -1.200 -1.045 -1.045 -0.820 -0.470 0.650 0.030 0.080 0.680 0.745 0.745 0.870 0.580 2.065 1.670 1.800 2.485 1.770 2.375 2.965 4.240 4.240

FRONT SPRUNG MASS ( kg ) 2,024 UNSPRUNG MASS ( kg ) 837 CHASSIS MASS ( kg ) 2,861 GRAVITY POSITION FROM F.A.C GRAVITY HEIGHT FROM FRAME UPPER SURFACE

Moment from F.A.C

REAR 1,506 2,500 4,006 (m) (m)

Moment from frame upper surface

M6 FM8JRSA-TGX

( kg·m ) -6.210 245.050 2.480 -13.420 3.240 -0.385 -55.590 0.280 7.310 134.125 4.680 -325.720 -1.050 20.130 3.360 -14.280 -4.680 -47.925 -20.100 -147.960 -52.320 -287.885 -556.870 -448.632 -1,383.500 -2,389.002

TOTAL 3,530 3,337 6,867 2.473 -0.348

Mass

( kg )

27 338 31 61 27 7 327 7 17 185 26 479 15 122 21 34 36 213 109 904 160 515

3,661 837 2,500 6,998

( kg·m ) -32.400 -353.210 -32.395 -50.020 -12.690 4.550 9.810 0.560 11.560 137.825 19.370 416.730 8.700 251.930 35.070 61.200 89.460 377.010 327.000 3,114.280 840.000 2,703.750

Gravity height from frame upper surface (m) -0.230 0.725 0.080 -0.220 0.120 -0.055 -0.170 0.040 0.430 0.725 0.180 -0.680 -0.070 0.165 0.160 -0.420 -0.130 -0.225 -0.335 -0.180 -0.327 -0.559

2.166 7,928.090 0.000 0.000 5.250 13,125.000 3.008 21,053.090

-0.161 -0.534 -0.553 -0.346

Gravity position from F.A.C (m) -1.200 -1.045 -1.045 -0.820 -0.470 0.650 0.030 0.080 0.680 0.745 0.745 0.870 0.580 2.065 1.670 1.800 2.485 1.770 3.000 3.445 5.250 5.250

FRONT 2,151 837 2,988

Moment from F.A.C

REAR 1,510 2,500 4,010

Moment from frame upper surface ( kg·m ) -6.210 245.050 2.480 -13.420 3.240 -0.385 -55.590 0.280 7.310 134.125 4.680 -325.720 -1.050 20.130 3.360 -14.280 -4.680 -47.925 -36.515 -162.720 -52.320 -287.885 -588.045 -446.791 -1,383.500 -2,418.336

TOTAL 3,661 3,337 6,998 3.008 -0.346

NOTE

• The mass of tire follows design figure according to ETRTO or JATMA standard. • The chassis mass 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. BM1503A5ECA

5

3

CHASSIS MASS & FRAME SECTION MODULUS No. PRODUCTION CODE

ITEMS

Front Bumper Cab Front Cab Front Mtg. Steering Step Radiator Steering Control Engine Front Control Engine Room Air Cleaner Cab Rear Cab Rear Mtg. Engine Rear Rear Splash Brake System Electric System Exhaust System Battery Fuel Tank Propeller Shaft Frame etc. Trunnion Bracket Rear Spring

SUB TOTAL

UNSPRUNG MASS TOTAL

FRONT REAR

M7 FM2PLSD-ZGL Mass

( kg )

27 338 31 66 63 7 654 7 17 185 26 753 15 134 21 33 36 213 60 839 160 515

4,200 837 2,436 7,473

( kg·m ) -32.400 -353.210 -32.395 -54.120 -24.570 4.550 -9.810 0.560 11.560 137.825 19.370 760.530 8.700 276.710 35.070 59.400 90.180 377.010 142.500 2,278.724 678.400 2,183.600

Gravity height from frame upper surface (m) -0.230 0.855 0.161 -0.220 0.020 -0.055 -0.127 0.040 0.430 0.855 0.552 -0.127 -0.070 -0.165 -0.160 -0.420 -0.130 -0.225 -0.335 -0.160 -0.327 -0.559

1.561 6,558.184 0.000 0.000 4.240 10,328.640 2.260 16,886.824

-0.074 -0.525 -0.555 -0.281

Gravity position from F.A.C (m) -1.200 -1.045 -1.045 -0.820 -0.390 0.650 -0.015 0.080 0.680 0.745 0.745 1.010 0.580 2.065 1.670 1.800 2.505 1.770 2.375 2.716 4.240 4.240

FRONT SPRUNG MASS ( kg ) 2,653 UNSPRUNG MASS ( kg ) 837 CHASSIS MASS ( kg ) 3,490 GRAVITY POSITION FROM F.A.C GRAVITY HEIGHT FROM FRAME UPPER SURFACE

Moment from F.A.C

REAR 1,547 2,436 3,983 (m) (m)

Moment from frame upper surface

M8 FM2PRSA-ZGL

( kg·m ) -6.210 288.990 4.991 -14.520 1.260 -0.385 -83.058 0.280 7.310 158.175 14.352 -95.631 -1.050 -22.110 -3.360 -13.860 -4.680 -47.925 -20.100 -134.240 -52.320 -287.885

-311.976 -439.425 -1,351.980 -2,103.381

TOTAL 4,200 3,273 7,473 2.260 -0.281

Mass

( kg )

27 338 31 66 63 7 654 7 17 185 26 753 15 134 21 33 36 213 109 974 160 515

4,384 837 2,436 7,657

( kg·m ) -32.400 -353.210 -32.395 -54.120 -24.570 4.550 -9.810 0.560 11.560 137.825 19.370 760.530 8.700 276.710 35.070 59.400 90.180 377.010 327.000 3,262.900 840.000 2,703.750

Gravity height from frame upper surface (m) -0.230 0.855 0.161 -0.220 0.020 -0.055 -0.127 0.040 0.430 0.855 0.552 -0.127 -0.070 -0.165 -0.160 -0.420 -0.130 -0.225 -0.335 -0.160 -0.327 -0.559

1.918 8,408.610 0.000 0.000 5.250 12,789.000 2.768 21,197.610

-0.080 -0.525 -0.555 -0.280

Gravity position from F.A.C (m) -1.200 -1.045 -1.045 -0.820 -0.390 0.650 -0.015 0.080 0.680 0.745 0.745 1.010 0.580 2.065 1.670 1.800 2.505 1.770 3.000 3.350 5.250 5.250

FRONT 2,782 837 3,619

Moment from F.A.C

REAR 1,602 2,436 4,038

Moment from frame upper surface ( kg·m ) -6.210 288.990 4.991 -14.520 1.260 -0.385 -83.058 0.280 7.310 158.175 14.352 -95.631 -1.050 -22.110 -3.360 -13.860 -4.680 -47.925 -36.515 -155.840 -52.320 -287.885

-349.991 -439.425 -1,351.980 -2,141.396

TOTAL 4,384 3,273 7,657 2.768 -0.280

NOTE

• The mass of tire follows design figure according to ETRTO or JATMA standard. • The chassis mass 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. BM1503A5ECA

6

3

CHASSIS MASS & FRAME SECTION MODULUS

2. MASS OF THE OPTION EQUIPMENT

P : OPT. EQUIPMENT - : NOT PROVIDED

PRODUCTION CODE : FC9J

-

-

-

The table of option mass shows the difference mass with standard specifications.

FC9JJSA-NNB

No. EQ1

AIR CONDITIONER

16

-0.440

-7.040

P

-

-

-

BATTERY (120Ah)

33

2.170

71.610

P

-

-

-

108

1.985

214.380

P

-

-

-

26

0.220

5.720

P

-

-

-

3

0.600

1.800

P

-

-

-

T/M PTO

14

1.270

17.780

P

-

-

-

FRONT SUS. (REINFORCED MULTI)

26

0.000

P

-

-

-

CONTENT OF OPTION

FUEL TANK (100L –> 200L) HORIZONTAL TO STACK TAIL PIPE T/M POWER SHIFT

GRAVITY POSITION FROM MASS F.A.C. (kg) (m)

MOMENT FROM F.A.C. (kg·m)

BM1503A5ECA

REMARKS

0.000 UNSPRUNG MASS

7

CHASSIS MASS & FRAME SECTION MODULUS P : OPT. EQUIPMENT - : NOT PROVIDED

PRODUCTION CODE : GD8J

-

-

The table of option mass shows the difference mass with standard specifications.

-

No. EQ2

GD8JLSA-PAB

3

AIR CONDITIONER

16

-0.600

-9.600

P

-

-

-

BATTERY (120Ah)

33

2.130

70.290

P

-

-

-

BED LESS

-3

0.450

-1.350

P

-

-

-

6

-1.100

-6.600

P

-

-

-

40

1.370

54.800

P

-

-

-

3

0.830

2.490

P

-

-

-

T/M PTO

14

1.270

17.780

P

-

-

-

FRONT SUS. (REINFORCED MULTI)

24

0.000

0.000 UNSPRUNG MASS

P

-

-

-

FRONT SUS. (REINFORCED MULTI W/STB.)

49

-0.650

-31.850 UNSPRUNG MASS

P

-

-

-

CONTENT OF OPTION

FRONT AIR SPOILER HORIZONTAL TO STACK TAIL PIPE T/M POWER SHIFT

GRAVITY POSITION FROM MASS F.A.C. (kg) (m)

MOMENT FROM F.A.C. (kg·m)

BM1503A5ECA

REMARKS

8

CHASSIS MASS & FRAME SECTION MODULUS P : OPT. EQUIPMENT - : NOT PROVIDED

PRODUCTION CODE : GH8J

-

-

The table of option mass shows the difference mass with standard specifications.

GH8JMSA-TGB

No. EQ3

GH8JGSD-TGB

3

AIR CONDITIONER

16

-0.510

-8.160

P

P

-

-

BATTERY (120Ah)

33

1.280

42.240

P

P

-

-

BED LESS

-3

0.430

-1.290

P

P

-

-

CENTER SEAT LESS

-4

-0.215

0.860

P

P

-

-

-37

1.135

-41.995

P

P

-

-

17

1.350

22.950

P

P

-

-

CONTENT OF OPTION

STACK TO HORIZONTAL TAIL PIPE T/M PTO

GRAVITY POSITION FROM MASS F.A.C. (kg) (m)

MOMENT FROM F.A.C. (kg·m)

BM1503A5ECA

REMARKS

9

CHASSIS MASS & FRAME SECTION MODULUS P : OPT. EQUIPMENT - : NOT PROVIDED

PRODUCTION CODE : FM8J, FM2P

FM2PLSD-ZGL

FM2PRSA-ZGL

The table of option mass shows the difference mass with standard specifications.

FM8JRSA-TGX

No. EQ4

FM8JLSD-TGX

3

AIR CONDITIONER

16

-0.510

-8.160

P

P

-

-

AIR CONDITIONER

22

-0.510

-11.220

-

-

P

P

8

-0.170

-1.360

P

P

-

-

33

2.520

83.160

P

P

-

-

3

0.430

1.290

P

P

P

P

CENTER SEAT LESS

-4

-0.215

0.860

P

P

P

P

CHASSIS STEP

22

-0.750

-16.500

P

P

P

P

6

-1.200

-7.200

P

P

P

P

213

3.325

708.225

-

P

-

P

38

1.175

44.650

P

P

-

-

4

1.395

5.580

-

-

P

P

T/M PTO

17

1.350

22.950

P

P

-

-

T/M PTO

14

1.465

20.510

-

-

P

P

TIRE CARRIER

15

7.140

107.100

-

P

-

P

-20

0.000

0.000 UNSPRUNG MASS

P

P

P

P

-3

0.000

0.000 UNSPRUNG MASS

P

P

P

P

CONTENT OF OPTION

AIR SUSPENSION SEAT (DRIVER'S SEAT) BATTERY (120Ah) BED

FRONT AIR SPOILER FUEL TANK (200L -> 200L x 2) HORIZONTAL TO STACK TAIL PIPE T/M POWER SHIFT

FRONT SUS MULTI –> TAPER WHEEL STEP LESS

GRAVITY POSITION FROM MASS F.A.C. (kg) (m)

MOMENT FROM F.A.C. (kg·m)

BM1503A5ECA

REMARKS

10

3

CHASSIS MASS & FRAME SECTION MODULUS

3. FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) No. Z1

Unit : mm

PRODUCTION CODE : FC9JJSA-NNB

BM1503A5ECA

11

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) No. Z2

Unit : mm

PRODUCTION CODE : GD8JLSA-PAB

BM1503A5ECA

12

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) No. Z3

Unit : mm

PRODUCTION CODE : GH8JGSD-TGB

BM1503A5ECA

13

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) No. Z4

Unit : mm

PRODUCTION CODE : GH8JMSA-TGB

BM1503A5ECA

14

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) No. Z5

Unit : mm

PRODUCTION CODE : FM8JLSD-TGX

BM1503A5ECA

15

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) No. Z6

Unit : mm

PRODUCTION CODE : FM8JRSA-TGX

BM1503A5ECA

16

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) No. Z7

Unit : mm

PRODUCTION CODE : FM2PLSD-ZGL

BM1503A5ECA

17

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) No. Z8

Unit : mm

PRODUCTION CODE : FM2PRSA-ZGL

BM1503A5ECA

18

Chapter 4 SPRINGS & REAR AXLES

1. SPRING CHARACTERISTICS

2. CALCULATION FOR HEIGHT OF FRAME UPPER SURFACE FROM GROUND

3. MAXIMUM VERTICAL DEFLECTION OF REAR WHEELS

4. MAXIMUM VERTICAL TRAVEL RANGE OF REAR AXLE AND SUSPENSION

5. MAXIMUM VERTICAL TRAVEL RANGE OF REAR LATERAL ROD 6. MAXIMUM LONGTUDINAL TRAVEL RANGE OF REAR SUSUPENSION

7. PRECAUTION FOR LEVELING VALVE LEVER 8. REAR SHOCK ABSORBER

9. PRECAUTION WHEN WELDING OPERATIONS AROUND THE SUSPENSION PARTS

BM1503A5ECA

4

SPRINGS & REAR AXLES

1. SPRING CHARACTERISTICS

SPRING COMBINATION Refer to SPRING CHARACTERISTICS CHART based on following table.

SPRING COMBINATION TABLE MODEL NAME HINO 51018 HINO 51226 HINO 51726 HINO 51726 HINO 52626 HINO 52626 HINO 52635 HINO 52635

PRODUCTION CODE

FC9JJSA-NNB GD8JLSA-PAB GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX FM2PLSD-ZGL FM2PRSA-ZGL

STD F1(FRT) F3(FRT) F5(FRM) F5(FRM) F7(FRM) F7(FRM) F7(FRM) F7(FRM)

FRONT OPT1 OPT2 F2(FRM) F4(FRM) F8(FRT) F8(FRT) F9(FRT) F9(FRT) -

OPT3 -

REAR STD OPT1 R1(RRM) R3(RRM) R5(RRM) R6(RRM) R7(RRM) R7(RRM) R7(RRM) R7(RRM) -

NOTE SYMBOL

SPECIFICATION

FTL

TAPER LEAF SPRING

FML

MULTI LEAF SPRING

FRT

REINFORCED TAPER LEAF SPRING

FRM

REINFORCED MULTI LEAF SPRING

RML

MULTI LEAF SPRING

RTL

TAPER LEAF SPRING

RRM

REINFORCED MULTI LEAF SPRING

AIR

AIR SPRING

BM1503A5ECA

1

SPRINGS & REAR AXLES



PRODUCTION CODE : FC9J





• SPRING CHARACTERISTICS CHART "F1"



kgf x 103 (kN) 40 4

FRONT

a b c

• SPRING CHARACTERISTICS CHART "R1" kgf x 103 (kN)

0.226kN/mm {23.0kgf/mm} 21.130kN {2154.6kgf} 29.340kN {2991.8kgf}

8

CONTACTING POINT OF BUFFER RUBBER

10

129.8

0

50

FRONT

b

2

20

c

0

0

50

121.7

128

100

150 (mm)

VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING LOAD VS. DEFLECTION

FFC4 4J SPG CHARA "C"

FFC4 4J SPG CHARA "F"

0.232kN/mm {23.7kgf/mm} 19.600kN {1998.6kgf} 31.740kN {3236.5kgf}

30

2

20

1

10

a

0

0

50

CONTACTING POINT OF BUFFER RUBBER

b

HORIZONTAL POINT

SPRING LOAD ON ONE SIDE

40

60

a b c

c

3

4

150 (mm)

100

• SPRING CHARACTERISTICS CHART "F2" kgf x 103 (kN) 40 4

60

a

VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING LOAD VS. DEFLECTION



6

HORIZONTAL POINT

SPRING LOAD ON ONE SIDE

HORIZONTAL POINT

SPRING LOAD ON ONE SIDE

0

93.5

20

a 1

a 0.245kN/mm {25.0kgf/mm} b 0.245+0.722=0.967kN/mm {25.0+73.6=98.6kgf/mm} c 14.700kN {1499.0kgf} d 74.370kN {7583.5kgf} e 80.460kN {8204.5kgf}

d

30 b

2

e

80

c 3

REAR

CONTACTING POINT OF BUFFER RUBBER

4

84.5

136.8 100

150 (mm)

VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING LOAD VS. DEFLECTION

FFC4 4J SPG CHARA "D"

BM1503A5ECA

2

4

SPRINGS & REAR AXLES



PRODUCTION CODE : GD8J





• SPRING CHARACTERISTICS CHART "F3"



kgf x 103 (kN) 40 4

FRONT

a b c

• SPRING CHARACTERISTICS CHART "R3" kgf x 103 (kN) 15 150

0.226kN/mm {23.0kgf/mm} 21.130kN {2154.7kgf} 30.670kN {3127.5kgf}

REAR a 0.263kN/mm {26.8kgf/mm} b 0.263+0.771=1.034kN/mm {26.8+78.6=105.4kgf/mm c 15.780kN {1609.1kgf} e 86.096kN {8778.7kgf}

30

2

0

93.5

135.7

20

a 1

CONTACTING POINT OF BUFFER RUBBER

b

10

0

50

FRONT

c

a

0

50

128.0 100

150 (mm) FGD4 1J SPG CHARA "F"

0.232kN/mm {23.7kgf/mm} 19.600kN {1998.6kgf} 31.710kN {3233.5kgf}

30

2

20

1

10

a

0

0

50

CONTACTING POINT OF BUFFER RUBBER

b

HORIZONTAL POINT

SPRING LOAD ON ONE SIDE

b

a b c

c

3

50

e

VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING LOAD VS. DEFLECTION

FGD4 1J SPG CHARA "C"

• SPRING CHARACTERISTICS CHART "F4" kgf x 103 (kN) 40 4

5

0

VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING LOAD VS. DEFLECTION



100

60 150 (mm)

100

10

HORIZONTAL POINT

SPRING LOAD ON ONE SIDE

3

HORIZONTAL POINT

SPRING LOAD ON ONE SIDE

c

84.5

136.7 100

150 (mm)

VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING LOAD VS. DEFLECTION

FGD4 1J SPG CHARA "D"

BM1503A5ECA

3

SPRINGS & REAR AXLES



PRODUCTION CODE : GH8J





• SPRING CHARACTERISTICS CHART "F5"



kgf x 103 (kN)

40

3

30

15

2

0

101.0

147.1

20 a

1

CONTACTING POINT OF BUFFER RUBBER

b

10

0

50

100

150

a 0.516kN/mm {52.6kgf/mm} b 0.516+0.997=1.513kN/mm {52.6+101.7=154.3kgf/mm} c 25.280kN {2577.8kgf} d 99.420kN {10138.0kgf} e 134.220kN {13686.6kgf}

150

e 10

100 d

5

50 c a 49.0

0

200 (mm)

VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING LOAD VS. DEFLECTION

98.0

121

b

0

50

100

150 (mm)

VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING LOAD VS. DEFLECTION

FGH4 4J SPG CHARA "D"





FGH4 1J SPG CHARA "F"

• SPRING CHARACTERISTICS CHART "R6"

SPRING LOAD ON ONE SIDE

kgf x 103 (kN) 20

200

15

150

10

100

a 0.516kN/mm {52.6kgf/mm} b 0.516+0.997=1.513kN/mm {52.6+101.7=154.3kgf/mm} c 25.280kN {2577.8kgf} d 99.420kN {10138.0kgf} e 164.480kN {16772.3kgf}

e

b

CONTACTING POINT OF BUFFER RUBBER

4

HORIZONTAL POINT

SPRING LOAD ON ONE SIDE

c

0.282kN/mm {28.8kgf/mm} 28.480kN {2905.0kgf} 41.480kN {4231.0kgf} SPRING LOAD ON ONE SIDE

a b c

CONTACTING POINT OF BUFFER RUBBER

FRONT

HORIZONTAL POINT

kgf x 103 (kN) 50 5

• SPRING CHARACTERISTICS CHART "R5"

HORIZONTAL POINT

4

49.0

98.0

141

d

5

50

c a

0

0

50

100

150 (mm)

VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING LOAD VS. DEFLECTION

BM1503A5ECA

FGH4 1J SPG CHARA "H"

4

4

SPRINGS & REAR AXLES



PRODUCTION CODE : FM8J, FM2P





• SPRING CHARACTERISTICS CHART "F7"



• SPRING CHARACTERISTICS CHART "F9"



• SPRING CHARACTERISTICS CHART "R7"

4

40

3

30

2

20

FRONT

a b c

c

0.282kN/mm {28.8kgf/mm} 28.480kN {2905.0kgf} 44.300kN {4518.6kgf}

a

1

0

10

0

50

CONTACTING POINT OF BUFFER RUBBER

b

HORIZONTAL POINT

SPRING LOAD ON ONE SIDE

kgf x 103 (kN) 50 5

101.0

157.1

100

200 (mm)

150

VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING LOAD VS. DEFLECTION

• SPRING CHARACTERISTICS CHART "F8" kgf x 103 (kN) 50 5

4

40

3

30

2

20

FRONT a b c

c

0

10

0

50

CONTACTING POINT OF BUFFER RUBBER

a 1

0.322kN/mm {32.8kgf/mm} 33.170kN {2905.0kgf} 51.230kN {5225.5kgf}

b

HORIZONTAL POINT

SPRING LOAD ON ONE SIDE



FFL4 4J SPG CHARA B

103.0

159.1

100

150

200 (mm)

VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING LOAD VS. DEFLECTION

FFL4 4J SPG CHARA A

BM1503A5ECA

5

4

SPRINGS & REAR AXLES

2. ‌CALCULATION FOR HEIGHT OF FRAME UPPER SURFACE FROM GROUND

CALCULATION FORMULA OF Hf1 & Hr1 SPRING CONSTANT (kg/mm)

When installing body or equipment on chassis, must be calculating height of frame upper surface from ground. In order to confirm the vehicle posture as frame end upper surface from ground slightly higher than front end to ensure vehicle stability during operation. Following are as formula how to calculate. [FOR 4x2 DRIVE MODEL ONLY] L1

HIGHT OF FRAME UPPER SURFACE FROM GROUND (mm)

MASS DISTRIBUTION OF BODY OR EQUIPMENT(kg) Mass of payload should also be calculated mass distribution, Front and Rear, if necessary.

Wf

Hf

Hr

Wr

W : BODY (EQUIPMENT) MASS Wf : FRONT DISTRIBUTION MASS OF BODY (EQUIPMENT) Wr : REAR DISTRIBUTION MASS OF BODY (EQUIPMENT) L3 : GRAVITY CENTER OF BODY (EQUIPMENT) MASS L4 : WHEELBASE

L4

Wf Wr W x L3 Wr = W - Wf Wf = L4 For more details if needed, refer to the Chapter 1 of Common Manual, No.KC-AA201A.

L2





Hro

Hr1

Hf1

Tr

CALCULATION FORMULA OF MASS DISTRIBUTION W L3

Wr

[FOR 6x2, 6x4 DRIVE MODEL ONLY] L1

CHASSIS DRAWING

Tf

ELEMENT FRONT REAR

ITEM

Hro

Hr1

Hf1

8

ELEMENT FRONT REAR



L2

Wf

CHAPTER TO BE REFERED CHAPTER NAME OF CLAUSE SPRING CHARAC4 TERISTICS CHART

ITEM

Hf1 = Hf - ( Wf 2

Hr1 = Hr - ( Wr 2

÷ Tf )

÷ Tr )

FOR INSTANCE OF CALCULATION This is the calculation of "Hro" of the vehicle to be mounted rear body or equipment. When calculate "Hro" under the condition of GVM, mass of the payload also be calculated to mass distribution on front and rear separately, and it should be added to mass distribution on ,Front and Rear, of body or equipment.

Wf Wr Wf Wr Hf1 Hr1 Hfo L1 L2

Since, the deflection of tire due to loaded do not be considered in calculation formula. Therefore, figure of the tire deflection has to be added in Hf and Hr according to ETRTO or JATMA standard.

: Load on front axle (kg) : Load on rear axle (kg) : Height of frame upper surface from ground on front axle datum line (mm) : Height of frame upper surface from ground on rear axle datum line (mm) : Height of frame upper surface from ground on frame end (mm) : Distance from front axle datum line to rear axle loading center (mm) : Frame rear overhung (mm) · · · From rear loading center to frame end. Hro = Hr1 +

Hr1 - Hf1 L1

SPRING CONSTANT : HIGHT OF FRAME UPPER SURFACE FROM GROUND : BODY MASS :

Wf = W x L3 = 6000x1500 = 1800 kg

x L2

L4

Hf1 = Hf - (

NOTE

5000

Wf 2

÷ Tf )

1800 ÷ 34.7 ) 2 = 1010 mm

Hro = Hr1 + (Hr1 - Hf1) x L2 L1

BM1503A5ECA

FRONT : 1036 mm, REAR : 1098 mm • BODY MASS : 6000 kg • GRAVITY CENTER OF BODY MASS : 1500 mm • WHEELBASE : 5000 mm • REAR OVER HANG : 3000 mm Wr = W - Wf = 6000 - 1800 = 4200 Hr1 = Hr - (

Wr 2

÷ Tr )

4200 ÷ 255.8 ) 2 = 1090 mm

= 1036 - (

• Refer to the next page how to calculate the figure Hf1 and Hr1. • The deflection of tire due to loaded do not be considered in calculation formula. Therefore, figure of the tire deflection has to be added in Hf1 and Hr1 according to ETRTO or JATMA standard.

FRONT : 34.7 kgf/mm, REAR : 255.8 kgf/mm

= 1098 - (

= 1090 +

(1090 - 1010) 5000

x 3000 = 1138 mm

6

4

SPRINGS & REAR AXLES

3. MAXIMUM VERTICAL DEFLECTION OF REAR WHEELS Measurements for the maximum deflection for one side tire and for simultaneous left and right deflection are shown below. When you mount the body, allow a clearance of at least 30mm so as not to obstruct tire deflection.

C

B

A

DEFLECTION OF REAR TIRES

A : MAXIMUM DEFLECTION FOR ONE SIDE WHEELS

B,C : MAXIMUM SIMULTANEOUS DEFLECTION RIGHT AND LEFT WHEELS

Unit : mm PRODUCTION CODE TIRE SIZE

8.25-16 8.25R16 9.5R17.5 235/75R17.5 225/70R19.5 265/70R19.5 8.25-20 8.25R20 9.00-20 9.00R20 10.00-20 10.00R20 11.00-20 11.00R20 9R22.5 9.5R22.5 10R22.5 11R22.5 12R22.5 235/70R22.5 255/70R22.5 275/70R22.5 275/80R22.5 295/80R22.5

A

195 195 190 170 175 -

FC9J B 185 185 180 160 165 -

C

50 50 50 50 50 -

A

250 250 225 -

GD8J B 235 235 210 -

C

34 34 34 -

A

255 250 250 180 210 -

GH8J B 175 170 170 100 105 -

C

115 115 115 115 115 -

FM8J/FM2P A B C

235 235 245 245 235 190 225

170 170 180 180 170 125 160

-

NOTE

• When snow chains are fitted, add 50mm to measurements A and B. • The dimension of tire to be mentioned in above table shows design figure according to ETRTO or JATMA standard. BM1503A5ECA

7

4

SPRINGS & REAR AXLES

4. ‌MAXIMUM VERTICAL TRAVEL RANGE OF REAR AXLE AND SUSPENSION Measurement for maximum vertical travel range of the rear torque rod is shown below. When you mount a body or equipment, allow a clearance of at least 30mm so as not to interfere with rear torque rod.

VERTICAL TRAVEL RANGE OF REAR AXLE AND SUSPENSION (FOR REAR TANDEM AXLE)

Unit : mm

PRODUCTION CODE

FM8JLSD-TGX FM8JRSA-TGX FM2PLSD-ZGL FM2PRSA-ZGL

A

B

C

-

701

645

30

35

-

-

697

645

30

35

-

BM1503A5ECA

D

E

F

8

4

SPRINGS & REAR AXLES

5. ‌MAXIMUM VERTICAL TRAVEL RANGE OF REAR LATERAL ROD (For rear air spring series) Measurement for maximum vertical travel range of the rear lateral rod is shown below. When you mount a body or equipment, allow a clearance of at least 30mm so as not to interfere with rear lateral rod.

VERTICAL TRAVEL RANGE OF REAR LATERAL ROD 4x2 DRIVE MODEL

Unit : mm

PRODUCTION CODE

A

–

37

–

34

6x2, 6x4 DRIVE MODEL

PRODUCTION CODE

FORWARD

–

–

BM1503A5ECA

A

Unit : mm

REARWARD –

9

4

SPRINGS & REAR AXLES

6. MAXIMUM LONGTUDINAL TRAVEL RANGE OF REAR SUSUPENSION During driving, the shackle of the main spring or shock absorber moves beyond the end of the rear bracket. Do not mount any parts of body inside of the hatching range.

LEAF SPRING SUSUPENSHON

Unit : mm

PRODUCTION CODE APRICATION

A

FC9JJSA-NNB GD8JLSA-PAB

FC4J FC7J FC9J FD7J GD8J FE7J FT1J

727.3

GH8JGSD-TGB GH8JMSA-TGB

FG1J FG8J SG2P GH1J GH8J

775.2

GT1J GT8J

875

–

AIR SUSUPENSHON PRODUCTION CODE APRICATION

BM1503A5ECA

A

–

FD7J

610

–

FE7J

663.3

10

4

SPRINGS & REAR AXLES

7. PRECAUTION FOR LEVELING VALVE LEVER Rear air suspension model installed leveling valve to keep vehicle height. When mounting body or equipment on the vehicle, must be kept 30mm clearance between lever and body or equipment.

PRODUCTION CODE APRICATION

A

–

FD7J

0

–

FE7J

20

• The adjustment of Leveling Valve has already been made under the chassis condition before deliver the chassis to body or equipment manufacturer. Therefore, do not re-adjust and disassembly the Leveling Valve at the time or after rear body mounted. (Should more detailed data or information regarding adjust ment of Leveling Valve be needed, please contact your nearest HINO sales dealer.) • Do not change the length of link rod.

BM1503A5ECA

11

4

SPRINGS & REAR AXLES

8. REAR SHOCK ABSORBER

PRODUCTION CODE : NOT PROVIDED

BM1503A5ECA

12

4

SPRINGS & REAR AXLES

9. ‌PRECAUTION WHEN WELDING OPERATIONS AROUND THE SUSPENSION PARTS GENERAL PRECAUTION • Suspension parts absorb shocks from the road surface received while driving and are always changing shape. • Accordingly, the parts are manufactured from very special metal materials or other materials. • Accordingly, if subjected to the effects of heat or other environmental factors, this is danger that the material hardness may easily drop or suffer damage. • Therefore, do not use electrical welding of the suspension parts or a gas torch to apply heat. • The ground used during electrical welding must not make connect with the suspension parts. • During welding operations around the periphery of suspension parts, be sure to protect the suspension parts using a cover or similar item so the parts are not subjected to welding sparks. • Because in the peripheral portion of the bracket where the suspension parts are installed constantly a large amount of stress is generated while the vehicle is driving, heat must not be applied to this portion by electrical welding or a gas torch. • The above sentences only describe a multi-leaf suspension. The same precautions also apply to air bag type rear suspension as well.

Installation of suspension parts (For example)

BM1503A5ECA

13

Chapter 5 P.T.O. AND CONTROL

1. PROVISION OF P.T.O. AND CONTROL

2. TRANSMISSION SIDE POWER TAKE OFF 3. ENGINE REAR END POWER TAKE OFF 4. TRANSFER POWER TAKE OFF

5. ENGINE CONTROL FOR BODY OR EQUIPMENT 6. REAR BODY CONTROL LEVER

7. THE INSTRUCTIONS FOR INSTALLING T/M PTO

NOTE

• Mark to be mentioned in each table of production code shows applicable specification.

BM1503A5ECA

5

P.T.O. AND CONTROL

1. PROVISION OF P.T.O. AND CONTROL

ENGINE CONTROL FOR BODY OR EQUIPMENT•••••••••••••••••••• chapter 5, 5. PRODUCTION CODE

When the body require transmission Power Take Off (P.T.O.) and Control, genuine P.T.O. and control should be supplied as option equipment. Refer to details for P.T.O. and CONTROL based on following table.

– – – – – – – FC9JJSA-NNB – GD8JLSA-PAB GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX – – FM2PLSD-ZGL FM2PRSA-ZGL – – – – – – – – – – – – – – – –

TRANSMISSION SIDE POWER TAKE OFF••••••••••••••••••••••••••••• chapter 5, 2. PRODUCTION CODE

– – – FC9JJSA-NNB – – – – GD8JLSA-PAB – – – FM2PLSD-ZGL FM2PRSA-ZGL – GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX – – –

T/M MODEL

T/M P.T.O.

PROVISION OF P.T.O. UNIT

MF06S HK06S

TP-1a TP-1b TP-1c TP-1d TP-2a TP-2b TP-2c TP-2d TP-2e TP-2f TP-3 TP-4

PROVIDED NOT PROVIDED

M009

TP-5

PROVIDED

EATON RT-8908LL / RTO-11909ALL

TP-6

NOT PROVIDED

TP-7

PROVIDED

TP-8 TP-9 TP-10

PROVIDED NOT PROVIDED NOT PROVIDED

LX06S

LJ06S

EATON ES11109 FS-8209BBE FS-6109A ZF 9S1310 ALLISON 2500 ALLISON 3000 / 3500

PROVIDED

PROVIDED

ENGINE REAR END POWER TAKE OFF••••••••••••••••••••••••••••••• chapter 5, 3. PRODUCTION CODE

– – – – – – –

ENGINE MODEL J05E J07E J08E A09C P11C-VP P11C-UB J08E

APPLICATION FC9J FC7J FM8J FM1A, FY1A GY2P FM2P GT8J

GENERAL USE & CONCRETE MIXER FIRE ENGINE

PROVISION OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT STANDARD EQUIPMENT

TRANSFER SERIES

APPLICATION

–

MA12C

–

MA12C

GENERAL USE FIRE ENGINE GENERAL USE

PROVISION OF ENGINE ACCELERATOR OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT

J08E-UD

U-2b

OPTION EQUIPMENT

J08E-UE P11C-UV

U-2b U-2c

OPTION EQUIPMENT OPTION EQUIPMENT

P11C-VR

U-2c

OPTION EQUIPMENT

J05D-TG J08E-UB J08E-UC J08E-TE A09C-TE J05E-TE J08C-F J08C-TS J08C-TG J08E-UG J08E-UF J05C-TF J08C-TT (1 COMP.) J08C-TT (2 COMP.) J08C-UL P11C-UB

U-2 U-2 U-2 U-2 U-2 MECHA.(R901) MECHA.(R901) MECHA.(R901) MECHA.(R901) MECHA.(R901) MECHA.(R901) MECHA.(BOSCH RLD-J, FRONT) MECHA.(BOSCH RLD-J, FRONT) MECHA.(BOSCH RLD-J, FRONT) MECHA.(BOSCH RLD-J, FRONT) MECHA.(RLD-J、REAR)

OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT OPTION EQUIPMENT

REAR BODY CONTROL LEVER•••••••••••••••••••••••••••••••••••••••••• chapter 5, 6. PRODUCTION CODE

– GH8JGSD-TGB FM8JLSD-TGX FM2PLSD-ZGL – –

TRANSFER POWER TAKE OFF••••••••••••••••••••••••••••••••••••••••••• chapter 5, 4. PRODUCTION CODE

J07E-TR J07E-TP J07E-TN J08E-VD J08E-VE A09C-UK A09C-TT J05E-TC J05E-TD

ENGINE CONTROL TYPE U-2a U-2a U-2a U-2a U-2a U-2a U-2a U-2b U-2b

ENGINE MODEL

REAR BODY CONTROL LEVER DL-1

DUMP LEVER (RHD, OPTION EQUIPMENT)

DL-2

DUMP LEVER (LHD, OPTION EQUIPMENT)

ML-1 ML-2

MIXER LEVER (RHD, STANDARD EQUIPMENT) MIXER LEVER (RHD, OPTION EQUIPMENT)

DETAILS

THE INSTRUCTIONS FOR INSTALLING T/M PTO•••••••••••••••••••• chapter 5, 7. APPLICATION : The vehicle with ALLISON AUTO Transmission, TP-9, TP-10, in chapter 5, 2. BM1503A5ECA

1

5

P.T.O. AND CONTROL

2. TRANSMISSION SIDE POWER TAKE OFF [T/M P.T.O. : TP-1]

When the body require transmission Power Take Off (P.T.O.) , genuine P.T.O. equipment and related parts should be supplied as shown below. WARNING

• Not install direct pump of transmission P.T.O..

• Data of the P.T.O. output shaft TRANSMISSION MODEL

PERMISSIBLE TORQUE (N·m {kgf·m} at r/min)

LX06S

245 {25} / 1,000

P.T.O. CONTROL DIRECTION OF TYPE ROTATION Pneumatic Reverse to control engine

• Necessary parts

TP-1a

T/M P.T.O. TRANSMISSION MODEL TRANSMISSION GEAR RATIO 1ST 2ND 3RD 4TH 5TH 6TH REV P.T.O. CONTROL TYPE

6.098 3.858 2.340 1.422 1.000 0.744 5.672

TP-1b

6.098 3.858 2.340 1.422 1.000 0.761 5.672

PARTS NAME

Parts No.

POWER TAKE OFF ASSY POWER TAKE OFF SUB ASSY ADAPTER, P.T.O. CASE

36610-E0382 36610-E0391 36125-E0030 36125-E0040 36125-E0050 SL512-01030 SZ170-10064 SZ116-10086 SZ116-10079 SZ116-10172 SZ119-10170

LOCK WASHER NUT BOLT, STUD (REAMER BOLT) BOLT, STUD BOLT, STUD BOLT, W/WASHER

• Tightening torque

BOLT / NUT

or or

61±7 N·m

Q'ty/ unit 01 01 01 01 or 01 or 06 06 02 02 02 02

LX06S

TP-1c

6.098 6.515 3.858 4.122 2.340 2.500 1.422 1.718 1.000 1.261 0.761 1.000 5.672 6.060 Pneumatic Q'ty/ Parts No. Parts No. unit 36610-E0621 01 36610-E0581 01 36610-E0591 36610-E0631 01 36125-E0090 36125-E0030 01 or 36125-E0100 36125-E0040 01 or 36125-E0110 36125-E0050 08 SL512-01030 SL512-01030 08 SZ170-10064 SZ170-10064 02 SZ116-10086 SZ116-10086 06 SZ116-10079 SZ116-10079 -

TP-1d

6.098 3.858 2.340 1.422 1.000 0.744 5.672

61±7 N·m

7.818 4.957 2.992 1.866 1.312 1.000 7.445 Q'ty/ unit 01 01 01 01 or 01 or 08 08 02 06 -

8.190 5.072 2.981 1.848 1.343 1.000 7.619

Parts No. 36610-E0601 36610-E0611 36125-E0120 36125-E0130 36125-E0140 SL512-01030 SZ170-10064 SZ116-10084 SZ116-10085 -

61±7 N·m

Q'ty/ unit 01 01 01 01 01 08 08 02 06 -

61±7 N·m

NOTE

• Parts mentioned above table shows transmission P.T.O. unit only. • Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.

BM1503A5ECA

2

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-1]

DETAIL OF P.T.O., TRANSMISSION MODEL HINO LX06S • P.T.O. Installation procedure • Drain the transmission oil. (Do not remove the drain plug while the oil is hot, or you will scald yourself.) • Remove the P.T.O. cover which is at the left of the transmission. ( Do not reuse the bolts and gasket that you remove at this time.) • Clean the P.T.O. mounting surface on the transmission side. • Prepare the necessary parts, referring to table of necessary parts. • Apply liquid packing to all fitting surfaces, such as the P.T.O. mounting surface of the transmission case and installation gasket, adaptor and P.T.O. body. • Fit the P.T.O. on the P.T.O. mounting and secure the mounting position by means of the reamer bolts (See the part described with marked "R" in the section Transmission P.T.O. mounting for pneumatic control type) and tighten the other fitting bolts.Tightening torque for bolts : Please refer the chart before page. • After attaching the P.T.O., turn the output shaft coupling a few revolutions to be sure that it turns freely. • When you refill the transmission oil, increase the amount by 0.4 liters to allow for the P.T.O..

• Gear layout and gear ratio

Gear ratio : i = N2/N1xN4/N3xN5/N4 TRANSMISSION GEAR RATIO MODEL 6.098 ~ 0.744 6.098 ~ 0.761 LX06S 6.515 ~ 1.000 7.818 ~ 1.000 8.190 ~ 1.000

N1

N2

N3

N4

N5

i

25 25 24 21 21

39 39 40 43 44

26 26 26 26 26

35 31 31 31 31

21 21 20 16 16

1.260 1.260 1.282 1.260 1.289

NOTE

• Number of revolutions of P.T.O. output shaft = number of revolutions of engine x1/ i • The P.T.O. output shaft turns in the opposite direction to the engine.

BM1503A5ECA

3

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-1]

• How to check the gear backlash The gear backlash of the P.T.O. is important factor to prolong the P.T.O. gear life. The bigger backlash causes the noise from gears on the contrary the smaller backlash causes the damage of gears. When installing the P.T.O. measure and check the backlash according to the following procedures. • Measurement of backlash (a) (between gear A and B) Attach a fuse (Ø1x10mm), with grease on the tooth surface of the P.T.O. gear B (3 places of gear tooth). After rotating gear B, measure the thickness of crashed fuses with a micro-meter. • Adjustment of backlash (a) (between gear A and B) When the backlash is not within the following standard backlash adjust the backlash by selecting an appropriate adapter.

TRANSMISSION GEAR POSITION MODEL LX06S

Between gear A and gear B (a)

STANDARD BACKLASH 0.08 ~ 0.21mm

If specified gear backlash value cannot be obtained, check whether all the parts have been installed correctly. If the specified gear backlash value cannot be obtained despite correct installation, use another P.T.O. assembly. BM1503A5ECA

4

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-1]

• P.T.O. mounting location on transmission case

Unit : mm

TRANSMISSION MODEL

LX06S

T/M GEAR RATIO

6.098 - 0.744 6.098 - 0.761 6.515 - 1.000

7.818 - 1.000 8.190 - 1.000

(A) GEAR SPECIFICATION NUMBER OF TEETH

26

26

110.0 +0.8 +0.6

OUTSIDE DIAMETER

(D)

108.1

FACE WIDTH

(B)

30.5

30.5

OFFSET

(C)

3

3

PITCH DIAMETER

98.859

98.859

CHORDAL THICKNESS (5 TEETH)

48.763

COEFFICIENT OF PROFILE SHIFT

+0.28628

OVER BALL DIAMETER / BALL DIAMETER MODULE

110.018

0 - 0.087

+0.8 +0.6

0 -0.04

/ 6.350

3.5

49.549 +0.5798

113.661 - 00.080 / 7.000 3.5

PRESSURE ANGLE OF CUTTING TOOL

22° 30'

22° 30'

HELIX ANGLE & DIRECTION

23° RH

23° RH

BM1503A5ECA

0 -0.04

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-1a]

• ‌Transmission P.T.O. mounting for pneumatic control type

Unit : mm

R : REAMER BOLT WARNING

• The devises on the body or equipment side (e. g. oil pump) must be mounted at the same angle as engine to the body. (Direct mounting the devices to the P.T.O. output flange is strictly prohibited.) • The three-dimensional angle of the universal joint of the drive shaft must be a Min. 1° to Max. 6°.

TAPER DETAIL OF P.T.O. SHAFT

MAIN SHAFT CENTER

8

R

R1

5

COUNTER SHAFT CENTER

FILLER PRUG

R

OUTPUT FLANGE

P.T.O. HOLE CENTER ø18 COUNTER BORED

46

END OF T/M CASE

A (ADAPTOR) T/M GEAR RATIO PARTS No. 36125-E0030 6.098 ~ 0.744 6.098 ~ 0.961 36125-E0040 36125-E0050

BM1503A5ECA

t (mm) 10.46 10.34 10.24

ADAPTOR A Apply liquid packing on the both faces of adapter. (Equivalent of ThreeBond 1216.)

6

P.T.O. AND CONTROL [T/M P.T.O. : TP-1b, 1c, 1d]

• ‌Transmission P.T.O. mounting for pneumatic control type

Unit : mm

R : REAMER BOLT

MAIN SHAFT CENTER

8

R

COUNTER SHAFT CENTER

FILLER PRUG

3.0

P.T.O. HOLE CENTER

20

50 ±0.1

66

+0.2 0

25 ±0.1 4 - ø8

OUTPUT FLANGE R

45

°

70

123

7 6

R

ø34H9 91.5

+0.2 0

ø18 COUNTER BORED

11

46

END OF T/M CASE

(124)

A

65

16 14.5 13

TAPER1/8 28

ø21.5

7

12

• The devises on the body or equipment side (e. g. oil pump) must be mounted at the same angle as engine to the body. (Direct mounting the devices to the P.T.O. output flange is strictly prohibited.) • The three-dimensional angle of the universal joint of the drive shaft must be a Min. 1° to Max. 6°.

ø25

WARNING

3

14

M14x1.5

DETAIL OF P.T.O. SHAFT

BM1503A5ECA

130

ADAPTOR A Apply liquid packing on the both faces of adapter. (Equivalent of ThreeBond 1216.)

215.5

7

5

A (ADAPTOR) T/M GEAR RATIO PARTS No. 36125-E0030 6.098 ~ 0.744 36125-E0040 6.098 ~ 0.761 36125-E0050 36125-E0090 6.515 ~ 1.000 36125-E0100 36125-E0110 36125-E0120 7.818 ~ 1.000 36125-E0130 8.190 ~ 1.000 36125-E0140

t (mm) 10.46 10.34 10.24 8.42 8.31 8.21 2.25 2.14 2.04

7

P.T.O. AND CONTROL [T/M P.T.O. : TP-1]

• Layout of power line

CRANKCASE

A

SIDE RAIL UPPER FACE TRANSMISSION

D

CLUTCH HOUSING

FLYWHEEL HOUSING

C

B R ENGINE CENTE

FRONT AXLE DATUM LINE

5

CASE

DRIVE SHAFT C

ENTER

E

124

F 215.5

Unit : mm TRANSMISSION MODEL

LX06S

APPLICATION

A

B

C

FC7J

186

170

4.0°

331 173.5 577

FC4J FC9J

249

175

4.0°

268 173.5 577

402.9 171.3 3.5°

331 173.5 577

FD7J

D

E

F

FT1J

340

83

3.5°

394 173.5 577

GT1J GT8J

290

138

3.5°

394 173.5 577

BM1503A5ECA

8

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-2]

When the body require transmission Power Take Off (P.T.O.) , genuine P.T.O. equipment and related parts should be supplied as shown below. WARNING

• Not install direct pump of transmission P.T.O..

• Data of the P.T.O. output shaft TRANSMISSION MODEL

PERMISSIBLE TORQUE (N·m {kgf·m} at r/min)

LJ06S

245 {25} / 1,000

• Necessary parts

T/M P.T.O. TRANSMISSION MODEL TRANSMISSION GEAR RATIO 1ST 2ND 3RD 4TH 5TH 6TH REV P.T.O. CONTROL TYPE

P.T.O. CONTROL DIRECTION OF TYPE ROTATION Pneumatic Reverse to control engine

TP-2a

6.477 4.016 2.450 1.470 1.000 0.723 6.064

6.477 4.382 2.450 1.470 1.000 0.723 6.064

PARTS NAME

Parts No.

POWER TAKE OFF ASSY POWER TAKE OFF SUB ASSY ADAPTER, P.T.O. CASE

36610-E0181 36610-E0191 S3662-81490 S3662-81670 S3662-81680 33162-E0050 SL512-01030 SZ101-10165 SZ119-10105

GASKET, P.T.O. CASE LOCK WASHER REAMER BOLT BOLT

• Tightening torque

BOLT

or or

61±7 N·m

TP-2b

6.893 4.274 2.607 1.564 1.000 0.770 6.453 Q'ty/ unit 01 01 01 01 or 01 or 02 02 02 06

6.893 4.274 2.607 1.564 1.000 0.770 6.453

TP-2c

8.189 4.847 2.912 1.858 1.294 1.000 7.666

Parts No. 36610-E0A10 36610-E0A20 S3662-81490 S3662-81670 S3662-81680 33162-E0050 SL512-01030 SZ101-10165 SZ119-10105

Q'ty/ unit 01 01 01 01 or 01 or 02 02 02 06

61±7 N·m

7.663 4.751 2.898 1.844 1.288 1.000 7.173

LJ06S

TP-2d

TP-2e

TP-2f

6.746 4.190 2.451 1.474 1.000 0.823 6.453

6.746 4.190 2.451 1.474 1.000 0.823 6.453

6.893 4.274 2.607 1.564 1.000 0.770 6.453

36610-E0A40 36610-E0A20 S3662-82711 S3662-82721 S3662-82731 33162-E0050 SL511-01025 SZ101-10151 SH782-01030

Pneumatic Q'ty/ Parts No. unit 01 36610-E0A30 01 36610-E0A20 01 S3662-82380 01 or S3662-82390 01 or S3662-82400 02 33162-E0050 02 SL511-01025 02 SZ101-10152 06 SH782-01035

49±4.5 N·m

49±4.5 N·m

Parts No.

Q'ty/ unit 01 01 01 01 or 01 or 02 02 02 06

Parts No. 36610-E0081 36610-E0A50 S3662-82380 S3662-82390 S3662-82400 33162-E0050 SL511-01025 SZ101-10152 SH782-01035

49±4.5 N·m

Q'ty/ unit 01 01 01 01 or 01 or 02 02 02 06

Parts No. 36610-E0A60 36610-E0A50 S3662-81490 S3662-81670 S3662-81680 33162-E0050 SL511-01025 SZ101-10152 SH782-01035

Q'ty/ unit 01 01 01 01 01 02 02 02 06

61±7 N·m

NOTE

• Parts mentioned above table shows transmission P.T.O. unit only. • Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.

BM1503A5ECA

9

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-2]

DETAIL OF P.T.O., TRANSMISSION MODEL HINO LJ06S • P.T.O. Installation procedure • Drain the transmission oil. (Do not remove the drain plug while the oil is hot, or you will scald yourself.) • Remove the P.T.O. cover which is at the left of the transmission. ( Do not reuse the bolts and gasket that you remove at this time.) • Clean the P.T.O. mounting surface on the transmission side. • Prepare the necessary parts, referring to table of necessary parts. • Apply liquid packing to all fitting surfaces, such as the P.T.O. mounting surface of the transmission case and installation gasket, adaptor and P.T.O. body. • Fit the P.T.O. on the P.T.O. mounting and secure the mounting position by means of the reamer bolts (See the part described with marked "R" in the section "P.T.O. mounting location on transmission case") and tighten the other fitting bolts.Tightening torque for bolts : Please refer the chart before page. • After attaching the P.T.O., turn the output shaft coupling a few revolutions to be sure that it turns freely. • When you refill the transmission oil, increase the amount by 0.5 liters to allow for the P.T.O..

• Gear layout and gear ratio

Gear ratio : i = N2/N1xN4/N3xN5/N4 TRANSMISSION GEAR RATIO MODEL 6.477 ~ 0.723 6.893 ~ 0.770 LJ06S 8.189 ~ 1.000 7.663 ~ 1.000 6.746 ~ 0.823

N1

N2

N3

N4

N5

i

26 25 22 23 25

43 44 46 45 44

36 36 36 35 37

26 26 26 26 26

23 23 23 23 23

1.056 1.124 1.335 1.285 1.094

NOTE

• Number of revolutions of P.T.O. output shaft = number of revolutions of engine x1/ i • The P.T.O. output shaft turns in the opposite direction to the engine.

BM1503A5ECA

10

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-2]

• How to check the gear backlash The gear backlash of the P.T.O. is important factor to prolong the P.T.O. gear life. The bigger backlash causes the noise from gears on the contrary the smaller backlash causes the damage of gears. When installing the P.T.O. measure and check the backlash according to the following procedures. • Measurement of backlash (a) (between gear A and B) Attach a fuse (ø1 X 10mm), with grease on the tooth surface of the P.T.O. gear B (3 places of gear tooth). After rotating gear B, measure the thickness of crashed fuses with a micro-meter. • Adjustment of backlash (a) (between gear A and B) When the backlash is not within the following standard backlash adjust the backlash by selecting an appropriate adapter.

TRANSMISSION GEAR POSITION MODEL LJ06S

Between gear A and gear B (a)

STANDARD BACKLASH 0.09 ~ 0.25mm

If specified gear backlash value cannot be obtained, check whether all the parts have been installed correctly. If the specified gear backlash value cannot be obtained despite correct installation, use another P.T.O. assembly. BM1503A5ECA

11

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-2]

• P.T.O. Mounting location on transmission case

TRANSMISSION MODEL

LJ06S

T/M GEAR RATIO

6.477 - 0.723 6.893 - 0.770 8.189 - 1.000

7.663 - 1.000

6.746 - 0.823

(A) GEAR SPECIFICATION NUMBER OF TEETH

36

35

37

OUTSIDE DIAMETER

(D)

150.6 +0.8 +0.6

146.8 +0.8 +0.6

154.3 +0.8 +0.6

FACE WIDTH

(B)

27.0

27.0

27.0

OFFSET

(C)

6.5

6.5

6.5

PITCH DIAMETER

142.704

138.740

146.668

CHORDAL THICKNESS (5 TEETH)

49.550

COEFFICIENT OF PROFILE SHIFT

+0.10787

OVER BALL DIAMETER / BALL DIAMETER MODULE

151.726

0 - 0.096

0 -0.04

/ 6.000

3.5

49.543

0 -0.04

+0.14162 147.832

0 - 0.095

/ 6.000

3.5

49.578

+0.08149 155.388 - 00.097 / 6.000 3.5

PRESSURE ANGLE OF CUTTING TOOL

22° 30'

22° 30'

22° 30'

HELIX ANGLE & DIRECTION

28° RH

28° RH

28° RH

BM1503A5ECA

0 -0.04

12

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-2]

• Transmission P.T.O. mounting for pneumatic control type

Unit : mm

A (ADAPTOR) T/M GEAR RATIO PARTS No. t (mm) 6.477 - 0.723 S3662-81490 6.12 6.893 - 0.770 S3662-81670 5.99 8.189 - 1.000 S3662-81680 5.86 S3662-82711 4.26 7.663 - 1.000 S3662-82721 4.13 S3662-82731 4.00 S3662-82380 8.02 6.746 - 0.823 S3662-82390 7.89 S3662-82400 7.76

WARNING

• The devises on the body or equipment side (e. g. oil pump) must be mounted at the same angle as engine to the body. (Direct mounting the devices to the P.T.O. output flange is strictly prohibited.) • The three-dimensional angle of the universal joint of the drive shaft must be a Min. 1° to Max. 6°. BM1503A5ECA

13

P.T.O. AND CONTROL [T/M P.T.O. : TP-2]

• Layout of power line

CRANKCASE

A

SIDE RAIL UPPER FACE TRANSMISSION

D

E

CLUTCH HOUSING

FLYWHEEL HOUSING

C

B R ENGINE CENTE

FRONT AXLE DATUM LINE

5

CASE

DRIVE SHAFT C

ENTER

275

F

G

Unit : mm TRANSMISSION MODEL

LJ06S

APPLICATION

A

B

C

D

E

F

G

FD7J

402.9 171.3 3.5°

331 173.5 108

446

FE7J

402.9 171.3 3.5°

331 173.5 120

446

GD1J GD8J

340 167.5 3.5°

394 173.5 108

446

FG1J

290 187.6 3.5°

394 173.5 108

446

BM1503A5ECA

14

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-3]

When the body require transmission Power Take Off (P.T.O.) , genuine P.T.O. equipment and related parts should be supplied as shown below. WARNING

• Not install direct pump of transmission P.T.O..

• Data of the P.T.O. output shaft

TRANSMISSION MODEL

PERMISSIBLE TORQUE (N·m {kgf·m} at r/min)

MF06S

245 {25} / 1,000

P.T.O. CONTROL DIRECTION OF TYPE ROTATION Pneumatic Reverse to control engine

• Necessary parts

T/M P.T.O. TRANSMISSION MODEL TRANSMISSION GEAR RATIO 1ST 2ND 3RD 4TH 5TH

6TH REV P.T.O. CONTROL TYPE PARTS NAME POWER TAKE OFF ASSY GASKET, P.T.O. CASE LOCKWASHER REAMER BOLT STUD NUT BOLT BRACKET, ELEC. PARTS

TP-3 MF06S 8.189 5.340

7.395 4.758

1.000 7.142

1.000 7.142

3.076 1.936 1.341

3.076 1.936 1.341

Pneumatic Parts No.

36610-E0A90 S3663-51030 SL511-01025 SZ101-10151 SJ182-01022 SL113-01008 SH782-01030 S5591-24450

Q'ty / unit 01 01 03 02 01 01 05 01

NOTE

• Parts mentioned above table shows transmission P.T.O. unit only. • Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.

BM1503A5ECA

15

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-3]

DETAIL OF P.T.O., TRANSMISSION MODEL HINO MF06S • P.T.O. Installation procedure • Drain the transmission oil. (Do not remove the drain plug while the oil is hot, or you will scald yourself.) • Remove the P.T.O. cover which is at the left of the transmission. ( Do not reuse the bolts and gasket that you remove at this time.) • Clean the P.T.O. mounting surface on the transmission side. • Prepare the necessary parts, referring to table of necessary parts. • Apply liquid packing to all fitting surfaces, such as the P.T.O. mounting surface of the transmission case, installation gasket and P.T.O. body. • Fit the P.T.O. on the P.T.O. mounting and secure the mounting position by means of the reamer bolts (See the part described with marked "R" in the section "P.T.O. mounting location on transmission case") and tighten the other fitting bolts.Tightening torque for bolts and nut : 49±4.5 N·m {500±45 kgf·cm} • After attaching the P.T.O., turn the output shaft coupling a few revolutions to be sure that it turns freely. • When you refill the transmission oil, increase the amount by 0.3 liters to allow for the P.T.O..

• Gear layout and gear ratio

Gear ratio : i = N2/N1xN4/N3xN5/N4 TRANSMISSION MODEL

N1

N2

N3

N4

N5

i

MF06S

22

47

21

29

12

1.220

NOTE

• Number of revolutions of P.T.O. output shaft = number of revolutions of engine x1/ i • The P.T.O. output shaft turns in the opposite direction to the engine.

BM1503A5ECA

16

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-3]

• How to check the gear backlash The gear backlash of the P.T.O. is important factor to prolong the P.T.O. gear life. The bigger backlash causes the noise from gears on the contrary the smaller backlash causes the damage of gears. When installing the P.T.O. measure and check the backlash according to the following procedures. • Measuring the backlash at the output flange • Measure the free play of the P.T.O. gear (gear A; the transmission P.T.O. unit gear) and the shaft spline. Fix the P.T.O. gear so that it will not turn when the P.T.O. is on, and use a dial gauge or similar to measure the change in position of one of the output flange bolt holes. This value is a 1. • Fix the reverse idler gear (gear B) such that it will not turn, and attach the P.T.O. to the transmission. With the P.T.O. on, use a dial gauge or similar to measure the change in position of one of the output flange bolt holes. This value is a 2. • Calculate the backlash using the formula below:

• Measuring the backlash caused with a fuse Use grease to paste a fuse (ø1X10mm) to the surface of a tooth of P.T.O. gear B. Make the teeth interlock over the fuse, then measure the thickness of the crushed fuse with a micrometer (at three points on the perimeter). This value is the backlash.

If specified gear backlash value cannot be obtained, check whether all the parts have been installed correctly. If the specified gear backlash value cannot be obtained despite correct installation, use another P.T.O. assembly. BM1503A5ECA

17

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-3]

• P.T.O. Mounting location on transmission case

TRANSMISSION MODEL T/M GEAR RATIO NUMBER OF TEETH

Unit : mm

MF06S (A) GEAR SPECIFICATION

8.189 - 1.000 / 7.395 - 1.000 29

OUTSIDE DIAMETER

(D)

150.6 +1.2 +0.8

FACE WIDTH

(B)

27.0

OFFSET

(C)

23.7

PITCH DIAMETER

145

CHORDAL THICKNESS / TEETH COEFFICIENT OF PROFILE SHIFT OVER BALL DIAMETER / BALL DIAMETER MODULE

37.457 - 00.032 / 3 - 0.4313

153.151 - 00.096 / 8.731 5.0

PRESSURE ANGLE OF CUTTING TOOL

20°

HELIX ANGLE & DIRECTION

0°

BM1503A5ECA

18

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-3]

• Transmission P.T.O. mounting for pneumatic control type

Unit : mm

WARNING

• The devises on the body or equipment side (e. g. oil pump) must be mounted at the same angle as engine to the body. (Direct mounting the devices to the P.T.O. output flange is strictly prohibited.) • The three-dimensional angle of the universal joint of the drive shaft must be a Min. 1° to Max. 6°. BM1503A5ECA

19

P.T.O. AND CONTROL [T/M P.T.O. : TP-3]

• Layout of power line

CRANKCASE

A

SIDE RAIL UPPER FACE TRANSMISSION

D

E

CLUTCH HOUSING

FLYWHEEL HOUSING

C

B R ENGINE CENTE

FRONT AXLE DATUM LINE

5

CASE

DRIVE SHAFT C

ENTER

121

F

G

Unit : mm TRANSMISSION MODEL MF06S

APPLICATION FG1J FG8J GH1J GH8J

A

B

C

D

E

F

G

290 187.6 3.5°

394 173.5 136

490

270 187.6 3.5°

394 173.5 136

490

BM1503A5ECA

20

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-4]

Do not provide transmission Power Take Off (P.T.O.) as option equipment, consult with authorized Hino distributor when the mounted body require transmission P.T.O.. WARNING

• Not install direct pump of transmission P.T.O..

• Data of the P.T.O. output shaft TRANSMISSION MODEL HK06S

PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF (N·m {kgf·m} at r/min) TYPE ROTATION ——— ( 245 {25} / 1,000 ) ——— ——— ( CAPACITY OF OUTPUT GEAR OF T/M. )

• Necessary parts TRANSMISSION MODEL TRANSMISSION GEAR RATIO 1ST 2ND

HK06S 7.028 4.389

3RD 4TH 5TH

2.495 1.592 1.000

6TH REV

0.743 6.987

PARTS NAME

Parts No.

Q'ty / unit

POWER TAKE OFF ASSY Power take off sub assy Knob sub assy,shift Cap, shift lever Booster assy, T/M Gasket, P.T.O. case

BM1503A5ECA

21

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-4] • P.T.O. Installation procedure • Remove the drain plug to drain transmission oil. (Do not remove the drain plug while the oil is hot, as you may be burned.) Remove the P.T.O. cover which is at the left of the transmission. Do not reuse bolts and gasket that you remove at this time. Clean the P.T.O. mounting surface on the transmission side. • Prepare the necessary parts. • Insert reamer bolts on the P.T.O. mounting surface of the transmission. (see part marked “R” In the section “P.T.O. mounting location on transmission case” ) • Apply liquid packing to all fitting surfaces, such as the P.T.O. mounting surface of the transmission case and installation gasket, shim and P.T.O. body. • Tightening torque for bolts : 44.1 ~ 53.9 N·m {450 ~ 550 kgf·cm} • After attaching the P.T.O., turn the output shaft coupling a few revolutions to be sure that it turns freely. • When you refill the transmission with oil, increase the amount by 0.5 liters,to allow for the P.T.O..

• Gear layout and gear ratio INPUT SHAFT

N1 N2

N3 N4 N5 P.T.O. OUT UNIT P.T.O. UNIT

Gera ratio : i = N2/N1xN4/N3xN5/N4 TRANSMISSION MODEL

N1

N2

N3

N4

N5

N6

i

HK06S

24

43

20

30

—

—

—

NOTE

• Number of revolutions of P.T.O. output shaft = number of revolutions of engine x1/ i • The P.T.O. output shaft turns in the opposite direction to the engine.

BM1503A5ECA

22

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-4]

• How to check the gear backlash The gear backlash of the P.T.O. is important factor to prolong the P.T.O. gear life. The bigger backlash causes the noise from gear, on the contrary the smaller backlash causes the damage of gear. When installing the P.T.O., measure and check the backlash according to the following procedures. • Measuring the backlash at the output flange • Measure the free play of the P.T.O. gear (gear A; the transmission P.T.O. unit gear) and the shaft spline. Fix the P.T.O. gear so that it will not turn when the P.T.O. is on, and use a dial gauge or similar to measure the change in position of one of the output flange bolt holes. The value is a 1. • Fix the reverse idler gear (gear B) such that it will not turn, and attach the P.T.O. to the transmission. With the P.T.O. on, use a dial gauge or similar to measure the change in position of the output flange bolt holes. This value is a 2. • Calculate the backlash using the formula below:

• Measuring the backlash caused with a fuse Use grease to paste a fuse (ø1 x 10 mm) to the surface of a tooth of P.T.O. gear B. Make the teeth interlock over the fuse, then measure the thickness of the crushed fuse with a micrometer (at three points on the perimeter). This value is the backlash

BM1503A5ECA

23

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-4]

• P.T.O. mounting location of transmission case

Unit : mm

WARNING

• Hold the reverse idler adjust screw using a power take-off to avoid it coming loose. • Change HINO recommended gear oil to set level. • Use reamer bolts at all points embossed with "R".

BM1503A5ECA

24

P.T.O. AND CONTROL [T/M P.T.O. : TP-4]

• Layout of power line

CRANKCASE

A

SIDE RAIL UPPER FACE TRANSMISSION FLYWHEEL HOUSING

CLUTCH HOUSING

C

B R ENGINE CENTE

FRONT AXLE DATUM LINE

5

E

F

D

CASE

DRIVE SHAFT C

ENTER

G

Unit : mm TRANSMISSION MODEL HK06S

APPLICATION

A

B

C

D

E

F

G

FM1A

270 217.6 3.5° 438.5 197.5 147.5 468

FM2P

323

BM1503A5ECA

175

4.0° 438.5 138 147.5 468

25

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-5]

When the body require transmission Power Take Off (P.T.O.) , genuine P.T.O. equipment and related parts should be supplied as shown below.

• Data of the P.T.O. output shaft TRANSMISSION MODEL

PERMISSIBLE TORQUE (N·m {kgf·m} at r/min)

M009

345 {35} / 1,000

P.T.O. CONTROL DIRECTION OF TYPE ROTATION Electric pneumatic Reverse to control engine

• Necessary parts

TRANSMISSION MODEL TRANSMISSION GEAR RATIO

M009

1ST 2ND

10.178 6.986

6TH

1.921

3RD 4TH 5TH

5.063 3.636 2.633

7TH 8TH

9TH REV P.T.O. CONTROL TYPE PARTS NAME POWER TAKE-OFF ASSY SWITCH ASSY, TRANSMISSION POSITION IND CONNECTOR SUB ASSY GASKET, PTO CASE BRACKET SUB-ASSY, SWITCH BOLT, FLANGE BOLT STUD NUT NUT, FLANGE LOCKWASHER CLIP BOLT

1.392 1.000

0.724 9.874 Pneumatic Parts No.

Q'ty / unit

36610-E0300 84220-E0150 S3480-12380 33162-E0030

1 1 2

S840Z-E0120 SH552-11020 SH782-01025 SJ172-01022 SL113-01008 SL151-00809 SL511-01025 SN231-01001 SZ101-10154

1 1 1 5 1

1 1 3 1 2

NOTE

• Parts mentioned above table shows transmission P.T.O. unit only. • Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.

BM1503A5ECA

26

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-5]

DETAIL OF P.T.O., TRANSMISSION MODEL HINO M009 • PTO Installation Procedure • Drain the transmission oil. (Do not remove the drain plug while the oil is hot, or you will scaled yourself.) • Remove the PTO cover which is at the left of the transmission. (Do not reuse the bolts and gasket that you remove at this time.) • Clean the PTO mounting surface on the transmission side. • Prepare the necessary parts, referring to table of Necessary parts. • Install the stud bolts to the PTO mounting of the transmission case. • Fit the gasket and PTO on the PTO mounting position and tighten the fitting bolts and nuts. Tightening torque for stud bolts : 44 ~ 54 N·m {432 ~ 530 kgf·cm} • After attaching the PTO, turn the output shaft coupling a few revolutions to be sure that it turns freely.

• Gear Layout and Gear Ratio INPUT SHAFT

N1 N3

N2

N4 N5

PTO OUTPUT PTO unit

Gear ratio : i =N2/N1xN4/N3xN5/N4 TRANSMISSION MODEL

N1

N2

N3

N4

N5

i

M009

29

30

16

31

16

1.034

NOTE

• Number of revolutions of P.T.O. output shaft = number of revolutions of engine x1/ i • The P.T.O. output shaft turns in the opposite direction to the engine.

BM1503A5ECA

27

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-5]

• How to check the gear backlash The gear backlash of the P.T.O. is important factor to prolong the P.T.O. gear life. The bigger backlash causes the noise from gears on the contrary the smaller backlash causes the damage of gears. When installing the P.T.O. measure and check the backlash according to the following procedures. • Measurement of backlash (between gear A and B) Attach a fuse (Ø1x10mm), with grease on the tooth surface of the P.T.O. gear B (3 places of gear tooth). After rotating gear B, measure the thickness of crashed fuses with a micro-meter. • Adjustment of backlash (between gear A and B) When the backlash is not within the following standard backlash, take following measures. 1. ‌If specified gear backlash value cannot be obtained, check whether all the parts have been installed correctly. 2. ‌If the specified gear backlash value cannot be obtained in despite of correct installation, use another P.T.O. assembly. 3. ‌Please consult with Hino sales dealer, if the backlash cannot be adjusted within proper limit.

TRANSMISSION GEAR POSITION MODEL M009

Between gear A and gear B

BM1503A5ECA

STANDARD BACKLASH 0.08 ~ 0.300mm

28

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-5]

• P.T.O. mounting location on transmission case

TRANSMISSION MODEL T/M GEAR RATIO

Unit : mm

M009

(A) GEAR SPECIFICATION

NUMBER OF TEETH

10.178 ~ 0.724 31

STANDARD PITCH CIRCLE OUTSIDE DIAMETER

139.500

DISPLACEMENT OVER A GIVEN NUMBER OF TEETH

62.073 - 00.04 / 5

ADDENDUM MODIFICATION COEFFICICENT

0.1527

OVER BALL / BALL DIAMETER

152.094 - 00.09 / 8.000

MODULE

NORMAL PRESSURE ANGLE HELIX ANGLE

4.50

22° 30' 0°

BM1503A5ECA

29

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-5]

• Transmission P.T.O. mounting for pneumatic control type

Unit : mm

WARNING

• The devises on the body or equipment side (e. g. oil pump) must be mounted at the same angle as engine to the body. (Direct mounting the devices to the P.T.O. output flange is strictly prohibited.) • The three-dimensional angle of the universal joint of the drive shaft must be Min. 1° to Max. 6°.

BM1503A5ECA

30

P.T.O. AND CONTROL [T/M P.T.O. : TP-5]

• Layout of power line

CRANKCASE

A

SIDE RAIL UPPER FACE TRANSMISSION CLUTCH HOUSING

D

FLYWHEEL HOUSING

C

B R ENGINE CENTE

FRONT AXLE DATUM LINE

5

E

F

CASE

DRIVE SHAFT C

ENTER

G

Unit : mm TRANSMISSION APPLICATION MODEL M009

FM1A FM2P

A

B

C

323

175

4.0°

BM1503A5ECA

D

E

394 181.6 438.5 138

F

G

302.5 419.7

31

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-6]

Do not provide transmission Power Take Off (P.T.O.) as option equipment, consult with authorized Hino distributor when the mounted body require transmission P.T.O..

• Data of the P.T.O. output shaft TRANSMISSION MODEL EATON RT-8908LL RTO-11909ALL

PERMISSIBLE OUTPUT TORQUE IN ACCORDANCE WITH SAE STD HEAVY DUTY P.T.O.

• Necessary parts

TRANSMISSION MODEL TRANSMISSION GEAR RATIO LL1 Lo LL2 1ST 2ND 3RD 4TH 5TH 6TH 7TH 8TH

9TH 10TH LL Rev. Low Rev. high Rev.

EATON RT-8908LL

EATON RTO-11909ALL

– – – 19.577 12.668

26.078 16.299 11.853 7.408 5.234

3.404 2.464 1.829

1.379 1.000 0.730

8.390 6.229 4.578

3.794 2.770 1.952

– – 20.848

1.344 1.000 20.467

13.030 3.434

13.243 3.889 Parts No.

PARTS NAME POWER TAKE OFF ASSY SWITCH ASSY, T/M POSITUION ELBOW CONNECTOR GASKET, P.T.O. CASE BOLT LOCK WASHER BOLT STUD NUT BRACKET, ELEC. PARTS

Q'ty / unit

NIL (IN ACCORDANCE WITH SAE STD HEAVY DUTY P.T.O.)

BM1503A5ECA

32

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-6]

DETAIL OF P.T.O., TRANSMISSION MODEL EATON RT-8908LL / RTO-11909ALL • Gear layout and gear ratio NO. OF GEAR TRANSMISSION MODEL EATON RT-8908LL RTO-11909ALL

BM1503A5ECA

N1

N2

N3

48

69

47

33

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-6]

• P.T.O. mounting location on transmission case

Unit : mm

NOTE

• Gear data and backlash are specified by gear box manufacturer. • More detail information if needed, please contact with "EATON CORPORATION (TRANSMISSION DIVISION)". BM1503A5ECA

34

P.T.O. AND CONTROL [T/M P.T.O. : TP-6]

• Layout of power line

CRANKCASE

A

SIDE RAIL UPPER FACE TRANSMISSION FLYWHEEL HOUSING

CLUTCH HOUSING

C

B R ENGINE CENTE

FRONT AXLE DATUM LINE

5

E

F

D

CASE

DRIVE SHAFT C

ENTER

G

Unit : mm TRANSMISSION MODEL

EATON RT-8908LL / RTO-11909ALL

APPLICATION

A

B

C

D

FM1A

323

175

4°

394

BM1503A5ECA

E

F

G

181.6 203.28 761.5

35

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-7]

When the body require transmission Power Take Off (P.T.O.) , genuine P.T.O. equipment and related parts should be supplied as shown below.

• Data of the P.T.O. output shaft TRANSMISSION MODEL EATON ES11109 FS-8209BBE FS-6109A

PERMISSIBLE TORQUE (N·m {kgf·m} at r/min)

• Necessary parts TRANSMISSION MODEL TRANSMISSION GEAR RATIO LOW 1ST 2ND 3RD 4TH 5TH 6TH 7TH 8TH REV

P.T.O. CONTROL TYPE PARTS NAME POWER TAKE OFF ASSY ADAPTER, SUB ASSY HARNESS SUB ASSY, TRANSMISSION BRACKET, ELEC. PARTS ELBOW CONNECTOR

P.T.O. CONTROL DIRECTION OF TYPE ROTATION Pneumatic control

235 {24} / 1,000

Same to engine

EATON ES11109 FS-8209BBE FS-6109A 12.637 8.806 6.550 4.768 3.548 2.481 1.845 1.343 1.000 13.210 Pneumatic 36610-E0460 S3190-61230

Q'ty / unit 01 01

S8206-51121

01

S5591-23920

01

Parts No.

SZ407-10059 SZ404-14004

01 01

NOTE

• Parts mentioned above table shows transmission P.T.O. unit only. • Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.

BM1503A5ECA

36

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-7]

DETAIL OF P.T.O. TRANSMISSION MODEL EATON ‌ES11109 FS-8209BBE FS-6109A • P.T.O. Installation procedure • Remove the drain plug to the transmission oil. (Do not remove the drain plug while the oil is hot, or you maybe burned.) Remove the P.T.O. cover which is at the left forward of the transmission. Do not reuse the bolts and gasket that you remove at this time. Clean the P.T.O. mounting surface on the transmission side. • Prepare the necessary parts, referring to table of last page. • Tighten the elbow and connector to the P.T.O., after binding up a sealing tape at 1.5 to 2 times on the taper thread and make sure air do not leak from the taper thread. (When binding up a sealing tape on the taper thread, two thread from top of screw should not be binded and bind up counter direction of the taper thread. And also make sure a foreign material do not came into joint and control cylinder.) • Installation angle of the elbow should be adjusted the tightening direction of the taper thread. • Adjust the backlash of each gears, between transmission counter shaft gear and adapter gear, adapter gear and P.T.O. gear as described with paragraph "How to check the gear backlash". • Apply liquid packing to all fitting surfaces, such as the P.T.O. mounting surface of the transmission case, adapter and P.T.O. body. (Do not apply liquid packing between contact surface of each other of the gasket.) • Install the adapter with proper bolts (furnished with adapter) in the P.T.O. aperture of the transmission case and the P.T.O. with proper studs and nuts (furnished with P.T.O.) in the adapter. • Tightening torque of bolt : 41 - 47 N·m {418 - 484 kgf·cm} • Tightening torque of stud and nut : 48 - 54 N·m {490 - 551 kgf·cm} • After attaching the P.T.O., turn the output shaft coupling a few revolutions to be sure that it turns freely. • When you refill the transmission with oil, increase the amount by 0.5 liters, to allow for the P.T.O.. And check the oil level of the transmission case with filler plug of main case. • More detail information if needed, please contact with "DANA CORPORATION".

BM1503A5ECA

37

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-7]

• Gear layout and gear ratio

Gear ratio : i = N2/N1xN4/N3xN6/N5xN8/N7 TRANSMISSION MODEL EATON ES11109 FS-8209BBE FS-6109A

N1

N2

N3

N4

N5

N6

N7

N8

i

33

43

32

18

24

22

21

37

1.183

NOTES

• Number of revolutions of P.T.O. output shaft = number of revolutions of engine x1/ i • The P.T.O. output shaft turns in the opposite direction to the engine.

BM1503A5ECA

38

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-7]

• How to check the gear backlash The gear backlash of the P.T.O. is important factor to prolong the P.T.O. gear life. The bigger backlash causes the noise from gears, on the contrary the smaller backlash causes the damage of gears. When installing the P.T.O. measure and check the backlash according to the following procedures. • Remove the P.T.O. shaft housing and/or inspection plate. • Mount the dial indicator so that it registers movement of the input gear (driven gear) of the P.T.O.. (See Fig. 1.)

NOTES

• See figure 2 for proper location of dial indicator contact point. (Two common type dial indicators shown.)

• Hold the P.T.O. driver gear in transmission with a screwdriver or bar and rock the P.T.O. input gear (driven gear) back and forth with your hand. Note the total movement on the dial indicator. • Establish backlash at 0.15mm - 0.30mm by adding or subtracting gaskets. General rule -- A CHELSEA'S 0.25mm gasket will change backlash approx. 0.15mm, a 0.51mm gasket changes backlash approx. 0.30mm. • Replace the shift housing and/or inspection plate and retorque four capscrews to 22 27 N·m {221 - 276 kgf·cm}. • Use same procedure for mounting the adapter and checking backlash as was used when mounting the P.T.O. to transmission as described above.

• Pouring gear oil When pouring gear oil into the transmission, add more oil (0.5L) for the lubrication of P.T.O. gears.

• Other notices After finishing P.T.O. installation, check whether the output shaft can be smoothly rotated when P.T.O. is in the neutral position.

BM1503A5ECA

39

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-7]

• P.T.O. mounting location on transmission case

Unit : mm

NOTE

• Gear data and backlash are specified by gear box manufacturer. BM1503A5ECA

40

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-7]

• Transmission P.T.O. mounting

Unit : mm

BM1503A5ECA

41

P.T.O. AND CONTROL [T/M P.T.O. : TP-7]

• Layout of power line

CRANKCASE

A

SIDE RAIL UPPER FACE TRANSMISSION FLYWHEEL HOUSING

CLUTCH HOUSING

C

B R ENGINE CENTE

FRONT AXLE DATUM LINE

5

E

F

D

CASE

DRIVE SHAFT C

ENTER

G

Unit : mm TRANSMISSION MODEL

EATON ES11109 FS-8209BBE FS-6109A

APPLICATION FG1J FG8J

GH1J GH8J FL1J FL8J FM1J FM8J

BM1503A5ECA

A

B

C

D

E

F

G

290 187.6 3.5°

394 173.5 176

567

270 187.6 3.5°

394 173.5 176

567

270 217.6 3.5°

394 173.5 176

567

42

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-8]

When the body require transmission Power Take Off (P.T.O.), genuine P.T.O. equipment and related parts should be supplied as shown below. This vehicle is mounted the ZF 9S1310 transmission. Therefore, consult with the technical staff of ZF authorized dealer in your country if need more detail information and data concerning ZF transmission and P.T.O..

• Data of the P.T.O. output shaft TRANSMISSION SERIES

PERMISSIBLE TORQUE (N·m {kgf·m})

ZF 9S1310

800 {81.5}

P.T.O. CONTROL DIRECTION OF TYPE ROTATION Pneumatic Reverse to control engine

• Necessary parts

TRANSMISSION MODEL TRANSMISSION GEAR RATIO CRAWLER GERA 1ST 2ND 3RD 4TH 5TH 6TH 7TH

8TH REV. P.T.O. CONTROL TYPE PARTS NAME POWER TAKE OFF ASSY SHAFT SET, POWER TAKE OFF

ZF 9S1310 9.479 6.576 4.678 3.478 2.617 1.890 1.345 1.000

0.752 8.967 Pneumatic 36610-E0370

Q'ty / unit 01

S3601-E0050

01

Parts No.

NOTE

• Parts mentioned above table shows transmission P.T.O. unit only. • Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.

BM1503A5ECA

43

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-8] • P.T.O. Installation procedure • P.T.O. units is installed in place of the rear end plate of the layshaft. The adapter shaft required for driving the P.T.O. is engaged with the reverse intermediate gear of the main gearbox. The adapter shaft is included in the P.T.O. delivery specification. • When installing the P.T.O., it is important to ensure that the temperature of the gearbox oil is not greatly affected by ambient conditions on the vehicle (e. g. exhaust pipe etc.). Check the oil temperature and if necessary provide forced cooling(e.g.a fan) so that an operating temperature of 110ºC is not exceeded. Brief temperature peaks of up to 130ºC are permissible(lasting not more than 30 minutes).

• Gear layout and gear ratio

Gera ratio : i = N2/N1xN4/N3xN5/N4 TRANSMISSION

N1

N2

N3

N4

N5

N6

i

ZF 9S1310

32

33

14

21

14

—

1.031

NOTES

• Number of revolutions of P.T.O. output shaft = number of revolutions of engine x1/ i • The P.T.O. output shaft turns in the opposite direction to the engine.

BM1503A5ECA

44

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-8]

• Technical data of P.T.O. NH/1

Model

Outputtorque Continuous operation

[Nm]

800

Input

Layshaft

Output speed for transmission ratio 9S1310 9.479-0.752

Speed factor f 0.97

Direction of output rotation

Reverse to engine

Required air pressure for pneumatic engagement

[bar]

6.2 to max. 10.0bar

Weight

[kg]

3-5

Gravity torque

[kg]

50

Output power The permissible output power depends on permissible output torque and output speed. It is calculated by the following formula : perm. output torque X noutput [kw] 9552

Pperm. =

Speed noutput = f X nengine [rpm] Output torque 15.92 X Q X p T= [Nm] nX or 9552 X Pperm. T= [Nm] n Perm. pump gravity torque

P.T.O. calculation P= T= n= Q= p= f = M= s =

Power [kw] Torque [Nm] Speed [rpm] Delivery volume [l] Pressure [bar] Speed factor Gravity torque [Nm] Distance between the center of gravity of the flange mounting face [m] G = Pump weight [kg] = Efficiency

Mperm. = s X G [Nm]

CENTER OF GRAVITY

s G

BM1503A5ECA

45

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-8]

• P.T.O. Mounting location of transmission case

BM1503A5ECA

46

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-8]

• P.T.O. Mounting on transmission case

BM1503A5ECA

47

P.T.O. AND CONTROL [T/M P.T.O. : TP-8]

• Layout of power line

CRANKCASE

A

SIDE RAIL UPPER FACE TRANSMISSION FLYWHEEL HOUSING

CLUTCH HOUSING

C

B R ENGINE CENTE

FRONT AXLE DATUM LINE

5

E

F

D

CASE

DRIVE SHAFT C

ENTER

G

Unit : mm TRANSMISSION MODEL

APPLICATION

A

B

ZF 9S1310

SG2P

323

180

BM1503A5ECA

C

D

E

6.5° 438.5 138

F

G

216

598

48

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-9]

There is no provision of transmission Power Take Off (P.T.O.) as option equipment, consult with authorized Hino distributor when the mounted body require transmission P.T.O..

• Data of the P.T.O. output shaft TRANSMISSION MODEL ALLISON 2500

PERMISSIBLE TORQUE (N·m {kgf·m} at r/min)

P.T.O. CONTROL DIRECTION OF TYPE ROTATION

See ALLISON's specifications section of the tech data book.

• Necessary parts

TRANSMISSION MODEL TRANSMISSION GEAR RATIO

ALLISON 2500

1ST 2ND 3RD 4TH 5TH

3.512 1.896 1.439 1.000 0.737

REV

5.086

PARTS NAME POWER TAKE OFF ASSY ADAPTER, SUB ASSY HARNESS SUB ASSY, TRANSMISSION ELBOW CONNECTOR

Parts No.

Q'ty / unit

NIL (See ALLISON's specifications section of the tech data book.)

BM1503A5ECA

49

P.T.O. AND CONTROL [T/M P.T.O. : TP-9]

• Layout of power line

CRANKCASE

A

SIDE RAIL UPPER FACE TRANSMISSION

303.3

D

CASE

DRIVE SHAFT C

ENTER

FLYWHEEL HOUSING

C

B R ENGINE CENTE

FRONT AXLE DATUM LINE

5

E

Unit : mm TRANSMISSION MODEL ALLISON 2500

APPLICATION FE7J GT8J

A

B

C

402.9 171.3 3.5° 290

BM1503A5ECA

138

3.5°

D

E

331 173.5 394 273.5

50

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-9]

• Mounting position of transmission P.T.O. ass'y for ALLISON 2500

Unit : mm (in.)

POWER TAKE OFF DRIVE GEAR RATINGS TRANSMISSION CONFIGURATION

VALUE

UNIT

With PTO on One Pad (Continuous)

339 (250)

N·m (pound-foot)

With a PTO on Both Pads Simultaneously – Each, Continuous

271 (200)

N·m (pound-foot)

BM1503A5ECA

51

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-10]

Do not provide transmission Power Take Off (P.T.O.) as option equipment, consult with authorized Hino distributor when the mounted body require transmission P.T.O..

• Data of the P.T.O. output shaft TRANSMISSION MODEL ALLISON 3000 ALLISON 3500

PERMISSIBLE TORQUE (N·m {kgf·m} at r/min)

P.T.O. CONTROL DIRECTION OF TYPE ROTATION

See ALLISON's specifications section of the tech data book.

• Necessary parts

T/M P.T.O. TRANSMISSION MODEL TRANSMISSION GEAR RATIO 1ST 2ND 3RD 4TH 5TH 6TH REV

PARTS NAME POWER TAKE OFF ASSY ADAPTER, SUB ASSY HARNESS SUB ASSY, TRANSMISSION ELBOW CONNECTOR

TP-10 ALLISON 3500

ALLISON 3000

4.593 2.257 1.535 1.000 0.749 0.651 4.999

3.487 1.864 1.409 1.000 0.750 – 5.027 Parts No.

Q'ty / unit

NIL (See ALLISON's specifications section of the tech data book.)

BM1503A5ECA

Parts No.

Q'ty / unit

NIL (See ALLISON's specifications section of the tech data book.)

52

P.T.O. AND CONTROL [T/M P.T.O. : TP-10]

• Layout of power line

CRANKCASE

A

SIDE RAIL UPPER FACE 182.8

C

B

DRIVE SHAFT C

ENTER

FLYWHEEL HOUSING SPACER

R ENGINE CENTE

FRONT AXLE DATUM LINE

5

D

E

TRANSMISSION

CASE

F

Unit : mm TRANSMISSION MODEL ALLISON 3000

ALLISON 3500

APPLICATION

A

B

C

D

E

F

FG8J

290

187.6

3.5°

394

173.5

29

GH8J

270

187.6

3.5°

394

173.5

29

FM8J

270

217.6

3.5°

394

173.5

29

FM1A

323

175

4°

394

181.6

20

BM1503A5ECA

53

5

P.T.O. AND CONTROL [T/M P.T.O. : TP-10]

• Mounting position of transmission P.T.O. ass'y for ALLISON 3000 / ALLISON 3500

Unit : mm

See “Layout of power line”

• Provision of P.T.O. must only be left side. • Torques shown for customer-furnished fasteners and threaded components are for plain (non-plated) threads. Torque requirements should be reviewed if plated items will be used. Consult the supplier. P.T.O. output speed (rpm) : Engine speed x

Drive gear x Driven gear

P.T.O. input gear P.T.O. output gear

• For P.T.O. gear torque ratings. See transmission specifications section of the tech data book. BM1503A5ECA

54

5

P.T.O. AND CONTROL

3. ENGINE REAR END POWER TAKE OFF

3.1 APPRICATION : FOR GENERAL USE & CONCRETE MIXER FRONT AXLE DATUM LINE

MOUNTING PARTICULARS

Unit : mm

B

A

E

CRANKSHAFT CENTER LINE

D

Y

CHASSIS CENTER LINE

FRAME ASSEMBLED WIDTH

C

FRAME UPPER SURFACE DATUM LINE

VIEW Y

COUPLING PARTICULARS

SECTION ENGINE MODEL

APPRICATION

J05E J07E J08E A09C P11C-VP P11C-UB

FC9J FC7J FM8J FM1A, FY1A GY2P FM2P

E13C

FS1E, ZS1E, FY1E

A

D

E

F

Refer to 8.2 Refer to 8.2 Refer to 8.2 Refer to 8.2 Refer to 8.2 Refer to 8.2

120 120 120 130.3 7 73

351 351 351 391.6 365.4 344.5

13 13 13 14 14 14

PERMISSIBLE TORQUE N·m {kgf·m} 343{35} 343{35} 343{35} 441{45} 392{40} 441{45}

Refer to 8.2

235

457.6

14

637{65}

B

C

REV. RATIO

REV. DIRECTION (See from engine rear)

0.722 0.722 0.722 1.000 1.000 0.896

Counter clock wise rotation Counter clock wise rotation Counter clock wise rotation Counter clock wise rotation Counter clock wise rotation Counter clock wise rotation

1.000

Clock wise rotation

WARNING

• The devices on the body or equipment side (e.g.oil pump) must be mounted at the same angle as engine to the body. Direct mounting the devices to the P.T.O. output flange is strictly prohibited. • The three-dimensional angle of the universal joint of the drive shaft must be Min. 1° to Max. 6°. BM1503A5ECA

55

5

P.T.O. AND CONTROL 3.2 APPLICATION : GT8J FOR FIRE ENGINE PRODUCTION CODE : NOT PROVIDED

1) ‌When turn on or off the PTO switch, there is time lag to start PTO according to structure of hydraulic PTO. The span of time lag will be different according to inertia mass of driving goods (water pump etc.) and engine condition (hot or cold). 2) ‌High loading with PTO and operation at full speed right after engine start, is may be the cause of damage and malfunction of PTO, therefore, must warm up the engine, especially the engine is cold. 3) ‌The devices on the body or equipment side (e.g. oil pump) must be mounted at the same angle as engine to the body.(Direct mounting the devices to the PTO output flange is strictly prohibited.) 4) The three-dimensional angle of the universal joint of the drive shaft must be a Min. 1° to Max. 6°. 5) Meeting conditions of PTO clutch.

BM1503A5ECA

56

5

P.T.O. AND CONTROL

BM1503A5ECA

57

P.T.O. AND CONTROL • Layout of power line

427.5

CRANKCASE

D

TRANSMISSION

321.8

SIDE RAIL UPPER FACE

FLYWHEEL HOUSING

ENGINE CENTER

C

B

A

FRONT AXLE DATUM LINE

5

CASE

DRIVE SHAFT CE

NTER

E

F J

Unit : mm CHASSIS MODEL

A

B

C

GT8J

290

138

3.5°

BM1503A5ECA

D

E

F

394 273.5 752.3

58

5

P.T.O. AND CONTROL

4. TRANSFER POWER TAKE OFF When the body require transfer Power Take Off (P.T.O.) , genuine P.T.O. equipment and related parts should be supplied as shown below.

• Transfer series

• Data of the standard P.T.O. output shaft

• Necessary parts PRODUCTION CODE TRANSFER MODEL TRANSFER GEAR RATIO LOW HIGH PARTS NAME TRANSFER ASSY, W/P.T.O. POWER TAKE OFF ASSY

–

–

MA12C

MA12C

2.224 1.000

2.224 1.000

Parts No. 36300-E0031 S3622-01060

BM1503A5ECA

Q'ty/ unit 01 01

Parts No. S3620-E0051 S3622-01060

Q'ty/ unit 01 01

59

5

P.T.O. AND CONTROL • Transfer P.T.O. mounting

Unit : mm

BM1503A5ECA

60

5

P.T.O. AND CONTROL • Transfer P.T.O. particulars

Unit : mm

BM1503A5ECA

61

5

P.T.O. AND CONTROL • Cautions for Transfer P.T.O. Example layout of P.T.O. drive shaft is shown following figure. Make sure to details of cautions to be installed P.T.O. drive shaft as following page.

BM1503A5ECA

Unit : mm

62

5

P.T.O. AND CONTROL Caution when installing the propeller shaft for T/F P.T.O. Be sure to observe the following indications. • Fitting a pulley or a sprocket directly to the output shaft of transfer P.T.O. is strictly prohibited. • An oil pump, a pulley or a sprocket wheel should be supported properly with the support bracket which is fixed firmly to the mounted body. • Indications for power taking out should be followed as the indicated below.

Length of drive shaft To reduce the vibration of drive shaft during operation, HINO recommend that the drive shaft length should be less than the value shown in the table. If body builder must make the shaft which is longer than the value shown in the table, fit a center bearing for the reduction of excessive vibration.

NOTE

• The support bracket for center bearing should be fixed on the mounted body.

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5

P.T.O. AND CONTROL

5. ENGINE CONTROL FOR BODY OR EQUIPMENT 5.1. ENGINE CONTROL TYPE : U-2a U-2 FUEL INJECTION TYPE ENGINE MODEL

ENGINE MODEL

J07E-TR

J05D-TG

J07E-TP

A09C-TE

J07E-TN J08E-VD J08E-VE A09C-UK A09C-TT

ENGINE CONTROL Hino engine is controlled by computer (hereinafter termed E/G ECU). Take following measure when engine speed to be controlled for body or equipment installation.

• KIND OF METHOD Device

Range to be controlled engine speed

Provision of device

Idle up switch

Idle to 980 rpm (Can be controlled constant revo. Only)

Related parts to be provided by standard equipment

Engine accelerator

Idle to Max. revolution (Can be controlled variable revo.)

Related parts to be provided by optional equipment

Idle to Max. revolution Engine Control ECU (Can be controlled constant (CUSTOMIZE) revo. Only)

BM1503A5ECA

Hino Diagnostic Explore

64

P.T.O. AND CONTROL 5.1. ENGINE CONTROL TYPE : U-2a

• ELECTRIC CIRCUIT OF ENGINE CONTROL FOR BODY OR EQUIPMENT Whatever P.T.O. control system is mechanical or pneumatic or electric, the signal of P.T.O. switched on should be always connected to E/G ECU.

IDLE UP SW

PTO SW2

PTO CUT RLY

PTO SW

ENGINE STOP SW

ENGINE ECU

PTO ACCEL SSR

5

A ENGINE SIDE CAB SIDE

In case of ENGINE ECU customize.

ECU CONNECTOR P.T.O. SW

P.T.O. ACCEL SSR

DETAIL OF A

WARNING

• ALTERATION OF ENGINE SPEED CUSTOMIZE INCLUDING PROVISION OF P.T.O. UNIT ETC. MUST BE PROVIDED OWN RESPONSIBILITY OF BODY OR EQUIPMENT MANUFACTURER. • SET OF ENGINE SPEED BY MEANS OF REWRITING OF THE PROGRAM OF E/G ECU CAN BE MADE BY "HINO DIAGNOSTIC EXPLORE". • STANDARD FUNCTION OF ENGINE ACCELERATION CONTROL BY ACCELERATOR PEDAL INSIDE OF CABIN IS CANCELLED DURING OPERATION OF BODY OR EQUIPMENT. • CONSULT TO HINO SALES DEALER WHEN CUSTOMIZE ENGINE SPEED.

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5

P.T.O. AND CONTROL 5.1. ENGINE CONTROL TYPE : U-2a • Engine accelerator

a. Related parts, Engine accelerator unit and extension harness, are packed in cabin as optional equipment. b. Connect the connector of Engine accelerator unit with spare connector which is provided forward No.2 crossmember at chassis frame LH side member.

Details of how to connect the connectors, see following figure.

OUTLET POSITION OF CHASSIS SIDE For details, refer to chapter 6.2.

• Other precautions a. Conditions of change of E/G ECU to body or equipment control mode as following.

• Vehicle speed is Max. 20km/h or less. • Transmission shift position is neutral. • Engine speed is idling revolution. • Engine accelerator unit is idle position. • P.T.O. switch on signal is connected.



E/G ECU will be changed as body or equipment control mode with fully completed above conditions.



If a condition is loss, engine will run under normal vehicle operation to be controlled by accelerate pedal.

b. Details of installation of Engine accelerator to be controlled for body and equipment, refer to following page. BM1503A5ECA

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5

P.T.O. AND CONTROL 5.1. ENGINE CONTROL TYPE : U-2a

[HOW TO INSTALL ENGINE ACCELERATOR FOR BODY OR EQUIPMENT]

• When fitting the cable on the accelerator sensor lever, define the direction by pulling the cable parallelly to the direction of lever stroke so that an imbalanced load may not be imposed on the sensor shaft. (See the following illustration.)

• Be sure to provide the body control lever with the full speed stopper for controlling the stroke of the sensor lever. In that case, adjust the body side stroke in such a way that the body side stopper comes in contact earlier than the sensor side stopper. The standard for adjustment is 1mm clearance between the sensor side lever and stopper under the condition than the body side lever touches the stopper. (See the following illustration.) • Be sure to set the accelerator sensor lever that sensor lever should be contacted with idling stopper by adjusting body control lever while body or equipment do not operate (while vehicle is driving).

• Cautiones when installing the Engine accelerator sensor (hereinafter termed the sensor). • Never attempt to disassemble the sensor. Do not drop the sensor or do not impact it. Each above thing may lead malfunction and failure. • The sensor is not integral waterproof type. Therefore, when installing it, pay attention to avoid the direct projection of vehicle washing water, tire splash etc. • The temperature range for use is -30~80°C. • Avoid such places where there is risk of receiving falling matters or stones that give impact. • Install the sensor where there is no possibility of exposing dust, oil mist, humidity, chemical product or vibration. If it is impossible to find such place, protect it with a cover. • Install the wire harness certainly so that it may not twist or not bend extremely. • For fitting and clipping the harness wires,refer to the COMMON manual. • If the length of the sub-harness wire is too short, try to abtain the same kind of the harness wire for extension.

The clearance indicated for the stroke stopper of accelerator sensor is just for reference. If the sensor side stopper comes into contact earlier, a forcible stress will be imposed on the sensor shaft and it may result in the damage of the part in cause. Moreover if sensor lever do not came into contact with idling stopper may result in a bad condition of the engine while vehicle to be driving.

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P.T.O. AND CONTROL 5.2. ENGINE CONTROL TYPE : U-2b U-2 FUEL INJECTION TYPE ENGINE MODEL

ENGINE MODEL

J05E-TC

J08E-UC

J05E-TD

J08E-TE

J08E-UB J08E-UD J08E-UE

ENGINE CONTROL Hino engine is controlled by computer (hereinafter termed E/G ECU). Take following measure when engine speed to be controlled for body or equipment installation.

• KIND OF METHOD Device

Range to be controlled engine speed

Idle up switch

Idle to 980 rpm (Can be controlled constant revo. Only)

To be provided by body manufacturer

Engine accelerator

Idle to Max. revolution (Can be controlled variable revo.)

Related parts to be provided by optional equipment

BM1503A5ECA

Provision of device

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5

P.T.O. AND CONTROL 5.2. ENGINE CONTROL TYPE : U-2b

• ELECTRIC CIRCUIT OF ENGINE CONTROL FOR BODY OR EQUIPMENT

• Idle up switch a. Install idle up switch and connect electric circuit as follows.

• Input the signal of P.T.O. switched on to E/G ECU Whatever P.T.O. control system is mechanical or pneumatic or electric, the signal of P.T.O. switched on should be always connected to E/G ECU. Recommended electric circuit is as follows.

U2 - ECU (ENGINE CONTROL ECU)

A

K4F

U2 - ECU (ENGINE CONTROL ECU)

LINKED STARTER S/W ON

ECU CONNECTOR

IDLE VOL

ACCEL SSR

IDLE VOL

%E5 (IUP1)

IDLE UP1

CAB SIDE

PTO SW

P.T.O. S/W P.T.O.

THE CIRCUIT OF P.T.O. SWITCHED ON TO BE CONNECTED. [NOTE] • THIS ALTERATION INCLUDING PROVISION OF P.T.O. UNIT ETC. MUST BE PROVIDED OWN RESPONSIBILITY OF BODY OR EQUIPMENT MANUFACTURER. • STANDARD FUNCTION OF ENGINE ACCELERATION CONTROL BY ACCELERATOR PEDAL INSIDE OF CABIN IS CANCELLED DURING OPERATION OF BODY OR EQUIPMENT.

IDLE UP S/W

IDLE VOL

ACCEL SSR

IDLE VOL

#PK #PL #PM

CAB SIDE BODY SIDE

DETAIL OF A

%E5 (IUP1)

PTO SW

K31 (GND )

POWER SUPPLY CONNECTOR

IDLE UP1

SIGNAL CIRCUIT OF P.T.O.

[NOTE] • THIS ALTERATION INCLUDING PROVISION OF P.T.O. UNIT ETC. MUST BE PROVIDED OWN RESPONSIBILITY OF BODY OR EQUIPMENT MANUFACTURER. • STANDARD FUNCTION OF ENGINE ACCELERATION CONTROL BY ACCELERATOR PEDAL INSIDE OF CABIN IS CANCELLED DURING OPERATION OF BODY OR EQUIPMENT.

b. Set engine speed by means of rewriting the program of E/G ECU by "Hino Diagnostic Explore".

Consult to Hino sales dealer when set engine speed.

WARNING

• No signal of P.T.O. switched on, engine speed will be fluctuated high and low due to torque fluctuation of P.T.O.. • Consult to Hino sales dealer with regard to Electrical Wiring Diagram.

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5

P.T.O. AND CONTROL 5.2. ENGINE CONTROL TYPE : U-2b • Engine accelerator

a. Related parts, Engine accelerator unit and extension harness, are packed in cabin as optional equipment. b. Connect the connector of Engine accelerator unit with spare connector which is provided forward No.2 crossmember at chassis frame LH side member.

Details of how to connect the connectors, see following figure.

OUTLET POSITION OF CHASSIS SIDE For details, refer to chapter 6.2.

• Other precautions a. Conditions of change of E/G ECU to body or equipment control mode as following.

• Vehicle speed is Max. 20km/h or less. • Transmission shift position is neutral. • Engine speed is idling revolution. • Engine accelerator unit is idle position. • P.T.O. switch on signal is connected.



E/G ECU will be changed as body or equipment control mode with fully completed above conditions.



If a condition is loss, engine will run under normal vehicle operation to be controlled by accelerate pedal.

b. Details of installation of Engine accelerator to be controlled for body and equipment, refer to following page. BM1503A5ECA

70

5

P.T.O. AND CONTROL 5.2. ENGINE CONTROL TYPE : U-2b

[HOW TO INSTALL ENGINE ACCELERATOR FOR BODY OR EQUIPMENT]

• When fitting the cable on the accelerator sensor lever, define the direction by pulling the cable parallelly to the direction of lever stroke so that an imbalanced load may not be imposed on the sensor shaft. (See the following illustration.)

• Be sure to provide the body control lever with the full speed stopper for controlling the stroke of the sensor lever. In that case, adjust the body side stroke in such a way that the body side stopper comes in contact earlier than the sensor side stopper. The standard for adjustment is 1mm clearance between the sensor side lever and stopper under the condition than the body side lever touches the stopper. (See the following illustration.) • Be sure to set the accelerator sensor lever that sensor lever should be contacted with idling stopper by adjusting body control lever while body or equipment do not operate (while vehicle is driving).

• Cautiones when installing the Engine accelerator sensor (hereinafter termed the sensor). • Never attempt to disassemble the sensor. Do not drop the sensor or do not impact it. Each above thing may lead malfunction and failure. • The sensor is not integral waterproof type. Therefore, when installing it, pay attention to avoid the direct projection of vehicle washing water, tire splash etc. • The temperature range for use is -30~80°C. • Avoid such places where there is risk of receiving falling matters or stones that give impact. • Install the sensor where there is no possibility of exposing dust, oil mist, humidity, chemical product or vibration. If it is impossible to find such place, protect it with a cover. • Install the wire harness certainly so that it may not twist or not bend extremely. • For fitting and clipping the harness wires,refer to the COMMON manual. • If the length of the sub-harness wire is too short, try to abtain the same kind of the harness wire for extension.

The clearance indicated for the stroke stopper of accelerator sensor is just for reference. If the sensor side stopper comes into contact earlier, a forcible stress will be imposed on the sensor shaft and it may result in the damage of the part in cause. Moreover if sensor lever do not came into contact with idling stopper may result in a bad condition of the engine while vehicle to be driving.

BM1503A5ECA

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5

P.T.O. AND CONTROL 5.3. ENGINE CONTROL TYPE : U-2c U-2 FUEL INJECTION TYPE ENGINE MODEL P11C-UV P11C-VR

ENGINE CONTROL Hino engine is controlled by computer (hereinafter termed E/G ECU). Take following measure when engine speed to be controlled for body or equipment installation.

• KIND OF METHOD Device Idle up switch Engine accelerator

Range to be controlled engine speed

Idle to 850 rpm (Can be controlled constant revo. Only) Idle to Max. revolution (Can be controlled variable revo.)

BM1503A5ECA

Provision of device To be provided by body manufacturer Related parts to be provided by optional equipment

72

5

P.T.O. AND CONTROL 5.3. ENGINE CONTROL TYPE : U-2c

• ELECTRIC CIRCUIT OF ENGINE CONTROL FOR BODY OR EQUIPMENT

• Idle up switch a. Install idle up switch and connect electric circuit as follows.

• Input the signal of P.T.O. switched on to E/G ECU Whatever P.T.O. control system is mechanical or pneumatic or electric, the signal of P.T.O. switched on should be always connected to E/G ECU. Recommended electric circuit is as follows.

U2 - ECU (ENGINE CONTROL ECU)

A

K4F

U2 - ECU (ENGINE CONTROL ECU)

LINKED STARTER S/W ON

ECU CONNECTOR

IDLE VOL

ACCEL SSR

IDLE VOL

%E5 (IUP1)

IDLE UP1

CAB SIDE

PTO SW

P.T.O. S/W P.T.O.

THE CIRCUIT OF P.T.O. SWITCHED ON TO BE CONNECTED. [NOTE] • THIS ALTERATION INCLUDING PROVISION OF P.T.O. UNIT ETC. MUST BE PROVIDED OWN RESPONSIBILITY OF BODY OR EQUIPMENT MANUFACTURER. • STANDARD FUNCTION OF ENGINE ACCELERATION CONTROL BY ACCELERATOR PEDAL INSIDE OF CABIN IS CANCELLED DURING OPERATION OF BODY OR EQUIPMENT.

IDLE UP S/W

IDLE VOL

ACCEL SSR

IDLE VOL

#PK #PL #PM

CAB SIDE BODY SIDE

DETAIL OF A

%E5 (IUP1)

PTO SW

K31 (GND )

POWER SUPPLY CONNECTOR

IDLE UP1

SIGNAL CIRCUIT OF P.T.O.

[NOTE] • THIS ALTERATION INCLUDING PROVISION OF P.T.O. UNIT ETC. MUST BE PROVIDED OWN RESPONSIBILITY OF BODY OR EQUIPMENT MANUFACTURER. • STANDARD FUNCTION OF ENGINE ACCELERATION CONTROL BY ACCELERATOR PEDAL INSIDE OF CABIN IS CANCELLED DURING OPERATION OF BODY OR EQUIPMENT.

b. Set engine speed by means of rewriting the program of E/G ECU by "Hino Diagnostic Explore".

Consult to Hino sales dealer when set engine speed.

WARNING

• No signal of P.T.O. switched on, engine speed will be fluctuated high and low due to torque fluctuation of P.T.O.. • Consult to Hino sales dealer with regard to Electrical Wiring Diagram.

BM1503A5ECA

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5

P.T.O. AND CONTROL 5.3. ENGINE CONTROL TYPE : U-2c • Engine accelerator

a. Related parts, Engine accelerator unit and extension harness, are packed in cabin as optional equipment. b. Connect the connector of Engine accelerator unit with spare connector which is provided forward No.2 crossmember at chassis frame LH side member.

Details of how to connect the connectors, see following figure.

OUTLET POSITION OF CHASSIS SIDE For details, refer to chapter 6.2.

• Other precautions a. Conditions of change of E/G ECU to body or equipment control mode as following.

• Vehicle speed is Max. 20km/h or less. • Transmission shift position is neutral. • Engine speed is idling revolution. • Engine accelerator unit is idle position. • P.T.O. switch on signal is connected.



E/G ECU will be changed as body or equipment control mode with fully completed above conditions.



If a condition is loss, engine will run under normal vehicle operation to be controlled by accelerate pedal.

b. Details of installation of Engine accelerator to be controlled for body and equipment, refer to following page. BM1503A5ECA

74

5

P.T.O. AND CONTROL 5.3. ENGINE CONTROL TYPE : U-2c

[HOW TO INSTALL ENGINE ACCELERATOR FOR BODY OR EQUIPMENT]

• When fitting the cable on the accelerator sensor lever, define the direction by pulling the cable parallelly to the direction of lever stroke so that an imbalanced load may not be imposed on the sensor shaft. (See the following illustration.)

• Be sure to provide the body control lever with the full speed stopper for controlling the stroke of the sensor lever. In that case, adjust the body side stroke in such a way that the body side stopper comes in contact earlier than the sensor side stopper. The standard for adjustment is 1mm clearance between the sensor side lever and stopper under the condition than the body side lever touches the stopper. (See the following illustration.) • Be sure to set the accelerator sensor lever that sensor lever should be contacted with idling stopper by adjusting body control lever while body or equipment do not operate (while vehicle is driving).

• Cautiones when installing the Engine accelerator sensor (hereinafter termed the sensor). • Never attempt to disassemble the sensor. Do not drop the sensor or do not impact it. Each above thing may lead malfunction and failure. • The sensor is not integral waterproof type. Therefore, when installing it, pay attention to avoid the direct projection of vehicle washing water, tire splash etc. • The temperature range for use is -30~80°C. • Avoid such places where there is risk of receiving falling matters or stones that give impact. • Install the sensor where there is no possibility of exposing dust, oil mist, humidity, chemical product or vibration. If it is impossible to find such place, protect it with a cover. • Install the wire harness certainly so that it may not twist or not bend extremely. • For fitting and clipping the harness wires,refer to the COMMON manual. • If the length of the sub-harness wire is too short, try to abtain the same kind of the harness wire for extension.

The clearance indicated for the stroke stopper of accelerator sensor is just for reference. If the sensor side stopper comes into contact earlier, a forcible stress will be imposed on the sensor shaft and it may result in the damage of the part in cause. Moreover if sensor lever do not came into contact with idling stopper may result in a bad condition of the engine while vehicle to be driving.

BM1503A5ECA

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5

P.T.O. AND CONTROL 5.4. ENGINE CONTROL TYPE : MECHA.(R901) / (RLD-J,FRONT)

• ENGINE CONTROL FOR BODY If you intend to fit a device to control engine revolutions when working with a body or equipment, make sure that the device is able to absorb the relative movement between the engine and the chassis (mounting of control lever for body or equipment, etc.). If the mechanism cannot absorb the relative motion, the control lever of the injection pump may be moved by the normal vibration of the engine (displacement) and abnormal vibrations may arise.

FUEL INJECTION PUMP WITH MECHNICAL GOVERNOR TYPE • Governor model : Mechanical, all speed control type. (DENSO R901) Unit : mm

RELATIVE MOVEMENT OF ENGINE AND CHASSIS ABSORBED

ENGINE MODEL

A

J05E-TE

183.5

J08C-F J08C-TG J08C-TS J08E-UG

120.5

J08E-UF

105.5

RELATIVE MOVEMENT OF ENGINE AND CHASSIS NOT ABSORBED

• Governor model : Mechanical, all speed control type. (BOSCH RLD-J, FRONT)

ENGINE MODEL

A

J05C–TF

185

J08C-UL

131

J08C-TT (1 COMP.) J08C-TT (2 COMP.)

131

WARNING

220

Precautions for installation of engine control device of the body or equipment. • Make sure that the devices (as control cable) do not interfere with engine parts while control devices to be installed. • If use the bolts or nuts of the engine parts for installing the devices, make sure that the bolt or nut can be properly tightened and confirm the tightening torque. • Should more detailed data or information regarding the engine control be needed, please contact authorized Hino distributor or sales dealer.

BM1503A5ECA

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5

P.T.O. AND CONTROL 5.4. ENGINE CONTROL TYPE : MECHA.(R901) • Governor lever for body control

ENGINE MODEL

Unit : mm

J05E-TE

BM1503A5ECA

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5

P.T.O. AND CONTROL 5.4. ENGINE CONTROL TYPE : MECHA.(R901) • Governor lever for body control

SPEED CONTROL LEVER REACTION LOW IDLE FULL SPEED

ENGINE MODEL

A

B

J08C-F

12.5°±5°

40°±3°

14.4N {1.47kgf}

23.5N {2.40kgf}

J08C-TS

12.5°±5°

39.5°±3°

15.7N {1.6kgf}

25.5N {2.6kgf}

J08E-UG

13.5°±5°

37°±3°

14.4N {1.47kgf}

23.5N {2.40kgf}

J08E-UF

12.5°±5°

39°±3°

14.4N {1.47kgf}

23.5N {2.40kgf}

BM1503A5ECA

Unit : mm

78

5

P.T.O. AND CONTROL 5.4. ENGINE CONTROL TYPE : MECHA.(R901) • Governor lever for body control

ENGINE MODEL

Unit : mm

J08C-TG FOR BODY CONTROL (ø6.3

) LOW IDLE

165

113

+0.1 -0.2

40

3 FULL SPEED

6

0

R5

CONTROL DIRECTION OF CABLE FOR BODY OR EQUIPMENT

6

R4

SPEED CONTROL LEVER REACTION 58

159.7 BM1503A5ECA

LOW IDLE

14.4N {1.47kg}

FULL SPEED

23.5N {2.40kg}

79

5

P.T.O. AND CONTROL 5.4. ENGINE CONTROL TYPE : MECHA.(RLD-J,FRONT) • Governor lever for body control

SPEED CONTROL LEVER REACTION LOW IDLE FULL SPEED

ENGINE MODEL

A

B

J05C-TF

5°±5°

34.5°±3°

7.8N {0.8kgf}

15.7N {1.6kgf}

J08C-TT

8.5°±5°

40.5°±3°

12.7N {1.3kgf}

36.3N {3.7kgf}

J08C-UL

8.5°±5°

36.5°±3°

6.8N {0.7kgf}

14.2N {1.4kgf}

BM1503A5ECA

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5

P.T.O. AND CONTROL 5.5. ENGINE CONTROL TYPE : MECHA.(RLD-J, REAR)

• HOW TO INSTALL THE ENGINE CONTROL LINKAGES FROM ENGINE INJECTION PUMP If body builder wants to install the engine control cable or linkage to engine, prepare the following parts. • Speed meter cable (or the like) • Flared nuts for fixing the outer sheath of above control cable • Cable holder (clip) for holding outer sheath of above cable • Cable end connectors (crevice pins or the like) • Steel sheet (or small brackets) for supporting brackets of above cable • Etc.

ENGINE MODEL : P11C-UB • Governor model : Mechanical, all speed control type. (BOSCH RLD-J) Unit : mm

WARNING

Precautions for installation of engine control device of the body or equipment. • Make sure that the devices (as control cable) do not interfere with engine parts while control devices to be installed. • If use the bolts or nuts of the engine parts for installing the devices, make sure that the bolt or nut can be properly tightened and confirm the tightening torque. • Should more detailed data or information regarding the engine control be needed, please contact authorized Hino distributor or sales dealer.

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5

P.T.O. AND CONTROL 5.5. ENGINE CONTROL TYPE : MECHA.(RLD-J, REAR) • Governor lever for body control

Engine Model : P11C-UB

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5

P.T.O. AND CONTROL

6. REAR BODY CONTROL LEVER DUMP LEVER : DL-1, DL-2

MIXER LEVER : ML-1, ML-2

NOTE

NOTE

• LEVER RATIO 250/65=3.8

• LEVER RATIO 330/65=5.1

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

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

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P.T.O. AND CONTROL

7. THE INSTRUCTIONS FOR INSTALLING T/M PTO The wire harness for PTO control are provided as standard to install T/M PTO in local market. Be sure to observe the following instructions when installing PTO control by own responsibility of Body and Equipment Manufactures.

1) The application model The vehicle with ALLISON AUTO Transmission.

2) Necessary Parts Body and Equipment Manufactures should prepare necessary parts such as T/M PTO assembly and PTO control switch by own responsibility.

3) Diagram for PTO control circuit

PTO CONTROL SWITCH

T/M PTO

NOTE

APPRICATION OF T/M MODEL.

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P.T.O. AND CONTROL 4) The instructions for installing PTO control (1) Installation of switch for PTO There is a connector for switch in Instrument Panel. Should use the connector when installing switch for PTO. See figure below for detail and position of the connector.

Detail of the connector position for switch

CONNECTOR - K

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P.T.O. AND CONTROL (2) Connecting wire harness for T/M PTO assembly control A connector for controlling T/M PTO assembly is provided at the side of T/M on chassis frame left side. Connect the connector after installed T/M PTO assembly. See figure below for detail and position of the connector.

Detail of the connector position for T/M PTO

CONNECTOR - L

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P.T.O. AND CONTROL

5) Detail of connector CONNECTOR POLE MARK CODE

CIRCUIT (MAIN APPLICATION)

TRANSMISSION PTO SW INDICATOR TRANSMISSION PTO SW U1M INDICATOR + TRANSMISSION PTO SW U1H PTO+ TRANSMISSION PTO SW U1J PTOU1N

CAB SIDE

K

CONNECTOR POLE MARK CODE

TRANSMISSION PTO MAGNETIC VALVE POWER TRANSMISSION PTO NUD PRESSURE SW OPERATION SIGNAL INPUT TRANSMISSION PTO NUC MAGNETIC VALVE GROUND TRANSMISSION PTO NUE PRESSURE SW OPERATION SIGNAL NUB

CHASSIS SIDE

L

CIRCUIT (MAIN APPLICATION)

COUPLING MAX. WIRE CONNECTOR CONNECTOR CAPACITY SIZE PARTS No. (SPARE (A) & COLOR PARTS) 0.5 B 0.5 L 82824-E0U80 S8258-08050 0.5 W-R 0.5 L-B

COUPLING MAX. WIRE CONNECTOR CONNECTOR CAPACITY SIZE PARTS No. (SPARE (A) & COLOR PARTS) 4A ※1 0.5 7A ※2 L -

0.5 G

4A ※1 7A ※2

0.5 B

-

0.5 R-B

S8258-09000

S8258-08990

APPLICABLE MODEL

REMARKS -

AUTOMATIC TRANSMISSION MODEL

-

APPLICABLE MODEL

REMARKS -

AUTOMATIC TRANSMISSION MODEL

CONNECT WITH METER INDICATOR & ENGINE ECU.

※1　FOR GT FIRE FIGHTING MODEL. ※2　FOR OTHER MODELS EXCEPT MODEL ※1.

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Chapter 6 ELECTRICAL SYSTEMS

1. FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK 2. SPARE POWER TERMINALS

3. RECOMMENDED ELECTRIC WIRING OF SPARE CIRCUIT 4. PRECAUTION FOR INSTALLING WIRES, etc., TO CAB 5. REAR COMBINATION LAMP 6. OTHER LAMPS

7. BACK-UP BUZZER

8. ELECTRICAL WIRING DIAGRAMS

BM1503A5ECA

6

ELECTRICAL SYSTEMS

1. FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK

Fuse block [ EXAMPLE ]

LOCATION OF THE CAB SIDE The fuse block and the relay panel are located inside the instrument panel as shown below. (The figure shown below is for RHD vehicle. LHD vehicle is symmetrical to this figure.)

WARNING

• The figure mentioned above is example, consequently, for various particular items, check them on the actual vehicle. • Be sure to use each capacity fuse designated in the actual vehicle caution plate. Never use the capacity fuse exceeding the designated one in the above, otherwise over current may damage the harness wires, and fusible linkage wires are in the same.

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ELECTRICAL SYSTEMS Relay panel

RHD VEHICLE POLE NUMBER OF CONNECTOR No.

WARNING

• The figure mentioned above is example, consequently, for various particular items, check themon the actual vehicle.

BM1503A5ECA

1

4/5

2 3

4 4

4

4

5

5/5/4

6

4

7

4

8 9 10 11 12

4/5 4 – 4 5

13

4

14

5

15

4

16 17 18 19 20 21

4 4 4 4 4 4

22 23 24 25 26 27 28 29 30

4/5 4 4 4 4 4 4 5 4

31 32 33 34 35

4 4 4 4 4

36 37 A B E F G H

4/5 4 4 4 – 4 4 4

DESCRIPTION LAMP CHECK RLY / ABS EXHAUST BRAKE CUT RLY PTO RLY / ABS WARNING LAMP RLY M009 BUZZER RLY PTO SIG REV RLY / M009 POWER SIFT CUT RLY LO-HI IND RLY / AMT STARTER RLY / M009 OVER RUN RLY RR P/W RLY / BACK-UP LAMP RLY ENG VNT PWR RLY / M009 SELECT RLY AT NTRL RLY / AMT NTRL RLY HORN RLY

– BACK LAMP RLY ABS IG CUT RLY IMMO PWR RLY / PTO RLY STARTER CUT RLY / LO-HI INDICATOR RLY IMMO 12VDMY RLY / M009 THROTTLE RLY ES MAIN RLY / TRAILER RLY

POWER RLY No.1 POWER RLY No.3 POWER RLY No.2 TAIL LAMP RLY 1 TAIL LAMP RLY 2 U2 ACT PWR RLY / ACTUATOR POWER OUTLET RLY

POWER RLY No.4 POWER RLY ACC. ECU MAIN RLY AIR CON RLY A/C COS RLY HEATER RLY ABS EXH CUT RLY U2 T-CUT DMY RLY VSS ACT RLY / HORN RLY FR FOG LP RLY H-LP DIM RLY H-LP MAIN RLY ABS MOTOR RLY ABS SOL RLY / ONE-KEY RLY STOP LAMP RLY TILT UP RLY TILT DOWN RLY ABS SOL RLY MIR HTR RLY

–

–

LHD VEHICLE POLE NUMBER OF CONNECTOR No.

DESCRIPTION

1

4

HEATER RLY

2 3

4 4

A/C RLY A/C CONDENSER RLY

4

4

HORN RLY

5

4

U2 PCV RLY

6

4

BACK-UP LAMP RLY

7

4

HEAD LAMP RLY (MAIN)

8 9 10 11 12

4 4 4 4 4

HEAD LAMP RLY (DIMMER) FOG LAMP RLY ABS VALVE RLY ECU MAIN RLY REAR FOG LAMP RLY

13

5

ABS WARNING LAMP RLY

14

5

ABS EXHAUST BRAKE CUT RLY

15

4

ACTUATOR POWER RLY

16 17 18 19 20 21

5 4 4 4 4 4

LO-HI INDICATOR RLY POWER RLY No.1 POWER RLY No.3 POWER RLY No.2 TAIL LAMP RLY 1 TAIL LAMP RLY 2

22 23 24 25 26 27 28 29 30

– 4 4 5 5 4 4 4 5

– POWER RLY No.4 POWER RLY ACC. PTO RLY M009 BZR RLY M009 OVER RUN RLY M009 PWR-S CUT RLY BACK-UP LAMP RLY M009 RANGE RLY

31 32 33 34 35

4 – – 4 4

M009 SELECT RLY – – M009 THROTTLE RLY ABS MOTOR RLY

36 37 A B E F G H

5 4 – – 4 – – –

ONE-KEY RLY STOP LAMP RLY

– – ABS SOLENOID RLY – – –

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6

ELECTRICAL SYSTEMS LOCATION OF THE FUSIBLE LINK BLOCK The fusible link block is located on left side of the cab rear arch as shown below.

DETAILS OF FUSIBLE LINK BLOCK, LARGE TYPE

SMALL TYPE

WARNING

• The figure mentioned above is example, consequently, for various particular items, check them on the actual vehicle. • Be sure to use each capacity fusible link designated in the actual vehicle caution plate. Never use the capacity fusible link exceeding the designated one, otherwise over current may damage the harness wires. BM1503A5ECA

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ELECTRICAL SYSTEMS

2. SPARE POWER TERMINALS

OUTLET POSITION INSIDE CAB

CAB SIDE SPARE POWER SUPPLIES AND POSITIONS

If you must take an electrical power supply for the body from the chassis, take it from the spare power supply. TERMINAL POLE MARK CODE

CIRCUIT (MAIN APPLICATION)

AGH POWER SUPPLY

MAX. WIRE SIZE CAPACITY & COLOR (A) *1

AGM POWER SUPPLY IGNITION KEY ON

A

AGP POWER SUPPLY LIGHTING

7A

1.25 Y-

7A

0.85 W-R

*2 7A

AGM POWER SUPPLY IGNITION KEY ON

7A

APPLICATION

NOT PROVIDED

0.85 O

0.85 W-R

CONNECTOR VEHICLE SIDE P1 AGH

PIG1 PTL1 AGM AGP

COMPANION SIDE

4

3

2

1

PARTS No. 82824 - E0K70 PARTS No. 82824 - E0K60

AGM

ALL MODEL

PARTS No. SZ591 - 04002 PARTS No. SZ591 - 04001

B

&06

PTO CUT RLY

–

0.5 W

NOT PROVIDED

ARLI &06

1

PARTS No. 82824 - E0U30 PARTS No. S8258 - 06160

C

&07

ENGINE STOP SW

–

0.5 L-W

NOT PROVIDED

EGST &07

GROUND

1

E

PARTS No. 82824 - E0U30 PARTS No. S8258 - 06160

D

CAB SIDE



• Center of instrument panel

E

*1 7A

1.25 Y-

*3

7A

0.85 R-

7A

1.25 O-

GROUND

30A

2.0 B-

I0P

POWER SUPPLY, BATTERY

10A

1.25 W-

I0Q

POWER SUPPLY, ACC

7A

0.85 W-G

I0K

POWER SUPPLY, LIGHTING

10A

0.85 W-L

I0S

GROUND

19A

2.0 B-

AQK GROUND

30A

3.0 B-

I0P

POWER SUPPLY, BATTERY

I0Q

POWER SUPPLY, ACC

I0K

POWER SUPPLY, LIGHTING

I0S

*2

NOT PROVIDED

ENGINE STOP SW ACC ILL I0Q I0K GND +B I0S I0P

2

1

4

3

C

A

PTO SW1

NOT PROVIDED

F

–

• The permissible current to be taken from spare power terminal is determined from the capacity of the fuse and wire size. • Make sure that the maximum load (current) of the installed equipment must be kept lower current than the permissible capacity to be able to take from spare power terminal. • Total current of 12V POWER SUPPLY (OPT) and POLE CODE AGH and l0P should be within 7A. (MARK *1) • Total current of 12V POWER SUPPLY (OPT) and POLE CODE AGP and AGQ should be within 7A. (MARK *2) • Total current of 12V POWER SUPPLY (OPT) and POLE CODE I0Q should be within 7A. (MARK *3) • Be sure to keep the lower current value than the alternator generated capacity when switched on the original and additional equipment same time to avoid over discharging electricity of the battery.

1

%E5

ALL MODEL PARTS No. 82824 - E0U30 or PARTS No. S8258 - 06160 S8258 - 06170

&05

PTO SW2

NOT PROVIDED

BUSW &05

PARTS No. 82824 - E0U30 G

–

1

0.5 Y-W %E6

%E6 IDLE-UP SENSOR (INPUT)

F

WARNING

0.5 G-

%E5 IDLE-UP SENSOR (INPUT)

PTO SW1 or IDLE-UP SENSOR

This figure is for RHD vehicle. LHD vehicle is symmetrical this figure.

F:UP &04

PARTS No. 82824 - E0U30

G

1

PARTS No. S8256 - 02970 PARTS No. S8256 - 02960

&04

PTO SW2 or IDLE-UP SENSOR

POWER SUPPLY POWER SUPPLY, IGNITION KEY ON POWER SUPPLY, LIGHTING

PARTS No. 82824 - E0U70 PARTS No. S8258 - 08380 or S8258 - 06920

AQK

D

PTO CUT RLY

B

ALL MODEL

NOT PROVIDED

POWER SUPPLY, BATTERY POWER SUPPLY, ACC POWER SUPPLY, LIGHTING GROUND

ALL MODEL PARTS No. 82824 - E0U30 or PARTS No. S8258 - 06160 S8258 - 06170

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ELECTRICAL SYSTEMS OUTLET POSITION OF CHASSIS SIDE CHASSIS SIDE SPARE POWER SUPPLIES AND POSITIONS

FRAME SIDE RAIL

If you must take an electrical power supply for the body from the chassis, take it from the spare power supply. TERMINAL POLE MARK CODE

CIRCUIT (MAIN APPLICATION)

MAX. WIRE SIZE CAPACITY & COLOR (A)

APPLICATION

ACCEL SENSOR

CONNECTOR VEHICLE SIDE

J

COMPANION SIDE

POWER SUPPLY, DUMP-UP S/W

H H

U39 or POWER SUPPLY, DUMP-UP SWITCH UEO

5A

0.85 W-B

DUMP

+ U39

1

No.2 CROSSMEMBER

PARTS No. S8258 - 04240 PARTS No. S8258 - 04230

*2

7A

*4 0.85 or 1.25 NOT PROVIDED O-

PTL2 AGQ

POWER SUPPLY, LIGHTING

4

I PARTS No. 82824 - E0M10 PARTS No. 82824 - E0M00

FOR FIRE ENGINE CHASSIS SIDE



FRONT

FRONT FRAME SIDE RAIL ACCEL SENSOR

J

POWER SUPPLY, LIGHTING

AGQ

I

AGQ POWER SUPPLY, LIGHTING

7A

I

1

NOT PROVIDED

No.2 CROSSMEMBER

PARTS No. S8258 - 06570 PARTS No. S8258 - 06580

0.85 W-L

ALL MODEL

1

AGQ

HOW TO TAKE ELECTRICITY FROM POWER SUPPLY CIRCUIT PARTS No. S8258 - 04240 PARTS No. S8258 - 04230

J

K95

POWER SUPPLY

–

0.5 R or LG -

K96

ACCEL SENSOR

–

0.5 Y

K97

GROUND

–

0.5 B

FOR U-2 E/G ONLY FOR HINO GENUINE P.T.O. ACCEL SENSOR

VCC K95 GND K97

SIG K96

2

1

4

3

PARTS No. S8256 - 01260 PARTS No. S8256 - 01250

WARNING

• Total current of 12V POWER SUPPLY (OPT) and POLE CODE AGP, AGQ and I0K should be within 7A. (MARK *2) • 0.85 for all models except tractor, 1.25 for tractor only. (MARK *4)

WARNING

• As far as possible take power using sub-harness type. • If you must take power using direct connecting type, be sure to observe the precautions in described item “ELECTRICAL EQUIPMENT AND WIRING” of Common Manual.

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ELECTRICAL SYSTEMS

3. RECOMMENDED ELECTRIC WIRING OF SPARE CIRCUIT STANDARD WIRING CONFIGURATION

WIRING CONFIGURATION FOR INCREASED LOAD

TAKING POWER DIRECTLY FROM THE BATTERY If you intend to take power for the body directly from the battery, secure the battery cable and the body power supply terminal together with the same nut (see drawing). In this case, you must install a fuse at a suitable point in the circuit and take precautions to prevent short circuits as these may lead vehicle fires. When securing the cable and power terminal, make sure you tighten the nut properly.

Battery cable TIGHTENING TORQUE 11 ~ 14 N·m {108 ~ 137 kgf·cm} To body Should be added an adequate fuse.

Terminal

Battery positive terminal

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ELECTRICAL SYSTEMS INSTALLATION OF ADDITIONAL EQUIPMENT AND SWITCHES Layout of switches

NOTE

• Standard layout of switches include option equipment are as following figure. • If you intend to install additional switches at instrument panel for the convenience of body mounting, be sure to install it at empty space after confirmation of original condition on the actual vehicle.

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

Avoid using additional switches with existing switches • If you install additional switches, fit a caution plate showing the purpose of each switch, etc., to prevent accidental operation or confirmation.

LHD VEHICLE

RHD VEHICLE

• Instrument panel

• Instrument panel

DESCRIPTION No. 1 IDLE VOLUME SWITCH 2 RR POWER WINDOW SWITCH (RH) RR POWER WINDOW SWITCH (LH) 3 CRUISE MAIN SWITCH 4 HEAD LAMP LEVELING SWITCH

No. 1 FR FOG LAMP SWITCH 2 T/M PTO SWITCH -3 4 H/L LEVELING SWITCH 5 RR FOG LAMP SWITCH 6 PARK LAMP SWITCH 7 -8 -9 HI/LO SWITCH 10 2WD/4WD SWITCH OR DIFF. LOCK SWITCH 11 IDLE VOLUME SWITCH 12 CIGARETTE LIGHTER 13 ES START SWITCH 14 -15 CONVENIENCE HOOK

5 6 7

HEAD LAMP WASHER SWITCH FRONT FOG LAMP SWITCH

INFORMATION DISPLAY CONTROL SWITCH ECO RUN SWITCH FRONT DRIVE SWITCH 9 ASR OFF SWITCH 10 EXHAUST BRAKE CHECK SWITCH 11 T/M PTO SWITCH 12 8

13

DIFF LOCK SWITCH 2-SPEED HI/LO SWITCH

14 CIGAR LIGHTER ES START SWITCH 15

• Floor console

16 ECO RUN SWITCH 17 DPR MANUAL REGENERATION SWITCH BRAKE LOCK SWITCH 18 AIR SUSPENSION SWITCH 19 HOOK

• Floor console MT

AT

No. DESCRIPTION 16 POWER MIRROR STAY SWITCH 17 FLUORESCENT LIGHT SWITCH ---

DESCRIPTION No. 1 2 3 REMOTE CONTROL MIRROR SWITCH 4 POWER MIRROR SWITCH 5 MIRROR HEATER SWITCH 6

AMT

BM1503A5ECA

FLUORESCENT LIGHT SWITCH

7 8 9 10 11 12 ATM MODE SW 13 MANEUVER SWITCH 14 T/M POWER SWITCH

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ELECTRICAL SYSTEMS

4. PRECAUTION FOR INSTALLING WIRES, etc.,TO CAB

USING THROUGH HOLE OF BACK PANEL FOR WIRING When using through hole of back panel for wiring, to secure the rust prevention and water proof before carry out fitting and wiring according to the following instructions.

USING THE THROUGH HOLE FOR HARNESS WIRE, etc. (CABLE) ON THE FLOOR

• A through hole of ø 36 is provided on the back panel but it is closed with a grommet. Make a slit on this grommet and, after the wiring, sufficiently seal its periphery with a sealing agent. • In order to secure the water proofness, lower the wiring once as shown on “ Section A A ” to drain the water and after that bring the wiring into the cab. • It is prohibited to fix the wiring with a tapping screw etc., because this can be a cause of penetration of rust.

When using the through hole for harness wire, etc. (cable) on the floor, at the front part of the floor panel through hole is provided for mounting harnesses or cables. When installing, remove the plug hole and then carry out wiring with using the harness grommets.

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ELECTRICAL SYSTEMS

5. REAR COMBINATION LAMP When chassis with cab are shipped, the rear combination lamp assembly is temporarily installed onto the end of the frame. Therefore, they should be relocated by subsequent manufacturer to conform to your country laws and regulations. Install the rear combination lamp directly such that the direction indicator lamp (amber) is outside and the back-up lamp (white) is inside of the vehicle. Do not install the rear combination lamps vertically so as not to affect the performance of reflectors and water drain holes. When installing the rear combination lamps onto the rear body, install reinforcing stays to prevent breakage, deflection and vibration of rear combination lamp body.

• REAR CONBINATION LAMP

• BRACKET FOR REAR COMBINATION LAMP Unit : mm

Unit : mm

NOTE

• Drawing shows rear combination lamp, LH side. And, RH side is symmetrical this drawing. BM1503A5ECA

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ELECTRICAL SYSTEMS

6. ‌OTHER LAMPS (If equipped) BACK-UP LAMP

LICENSE PLATE LAMP

The back-up lamps are temporarily installed on the chassis frame, when shipped out the chassis. Therefore, should install the back-up lamp with satisfied your country laws and regulations by own responsibility of Body and Equipment Manufactures.

MOLD TYPE

Unit : mm

Unit : mm

STEEL TYPE

NOTE

• When install the back-up lamp, mark “TOP” on the lens must always be up side. • Installation angle must be kept 4˚ • Above drawing shows right side lamp, left side lamp is symmetry shape.

RECOMMENDED MOUNTING HOLE PATTERN BM1503A5ECA

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ELECTRICAL SYSTEMS

7. ‌BACK-UP BUZZER (If equipped) If move the back-up buzzer or modify the around parts of back-up buzzer on the chassis, be sure to observe the following precautions.

Installation angle • Must be kept the permissible range of installing angles shown in the figure below. • If the installing angle is not within range, water will accumulate inside the buzzer and may lead to failure.

Installation area • Should install the buzzer the area which is the muddy water, rainwater and stone do not splash.

Precaution for painting • Should put a cover on the buzzer during painting to prevent the paint into it for avoiding failure of no sound.

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ELECTRICAL SYSTEMS

8. ELECTRICAL WIRING DIAGRAMS This manual does not contain electrical wiring diagrams. The electrical wiring diagrams are in the WORKSHOP MANUAL. For more details, please contact authorized Hino distributor.

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Chapter 7 PAINTING

1. GENERAL PRECAUTIONS FOR PAINTING 2. NOTE ON THE TOP COAT OF PAINT

3. HOW TO REMOVE THE PARTS OF CAB

4. PROCEDURE FOR ADHERING ORNAMENTS

5. MOUNTING AND STICKING OF DOOR WEATHER STRIP 6. HOW TO MOUNT THE MAIN AND SUB SEAL

7. CAUTIONS FOR PAINTING TILT CYLINDER ROD 8. HANDLING OF LAMINATED WINDSHIELD 9. HANDLING OF COMPUTERS (ECU)

10. PRECAUTIONS FOR FITTING AND STORING THE CAUTION PLATE

11. CAUTIONS FOR PAINTING THE TIRE DISC WHEELS

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PAINTING

1. GENERAL PRECAUTIONS FOR PAINTING When you apply finish paint to the cab etc. observe the following precautions. Some parts of the cab and chassis are sensitive to the drying heat, some parts must not be painted and so require masking, etc.

GENERAL PRECAUTIONS FOR PAINTING • Parts to be masked: Parts that must not be painted-ornaments, name plates (model names, Hino logo mark chassis number), caution plate, etc. must all be masked. (It is possible to take off the top mark.) Never paint the rubber hoses and nylon tubes or valves, the brake booster, or hoses or valves of the brake fluid reservoir. • If the body of the air cleaner has been taken out, seal off the engine intake port completely so that paint and dirt do not get in. When you replace the body of the air cleaner, make sure that the hose is properly fitted and securely clamped. • Cover the battery, wiring connections and hoses to protect them from paint. • If you get paint on the cab shell, wipe it clean with gasoline. Never use thinner. • When cleaning inside of the cab, must use a neutral detergent. Never use gasoline nor paint thinner. • In the case of the vehicle with the SRS air bag. When adhering paint etc. on the SRS air bag, consult with your nearest Hino sales dealer or distributor. • Pay attention when dismounting and removing the cab exterior fittings. The bolts that thread diameter exceeds 6mm to be tighten the exterior parts of the cab body have been modified from “+ type screw bolt” to “hexalobular internal type bolt (TORX® bolt)” in order to improve stabilization of tightening torque and avoiding the damage of tool groove. Use proper tools to fit with “TORX® bolt”. • Precaution for preventing to paint the fuel pre-filter If the fuel pre-filter is painted, it may deteriorate the function of fuel prefilter, and there will be a crack at resin parts. Therefore, be sure to observe the following manner. - Should put a musk completely on the fuel pre-filter when painting. - If the fuel pre-filter is painted, it need replace a new one. ［EXAMPLE］

RESIN COVER DRAIN PLUG

FOR 300 SERIES

FOR 500 SERIES BM1503A5ECA

Do not paint this range

［EXAMPLE］ Do not paint this range

Do not paint this range

［EXAMPLE］

RESIN COVER DRAIN PLUG

FOR 500/700 SERIES

1

7

PAINTING GENERAL PRECAUTIONS FOR FORCED DRYING • When you use forced drying, a temperature on the surface of any parts to be painted must be 80°C as an upper limit. Removing off any plastic parts, rubber parts from the vehicle, paint them when you use a forced drying at over 80°C. (Refer to the figure as shown in after.) Take care to those as plastic parts like fender, air cleaner, etc. are much used. • When a vehicle with air-conditioning whose piping and hosing are heated at abnormal temperature (more than 100°C), a pressure safety valve may function and come out refrigerant gas. • When removing off a air-cleaner assy, seal completely the inlet port side of engine to prevent any penetration of dirt, paint or etc. • Remove off the parts shown below, when you use forced drying at over 80°C.

NON-HEAT RESISTING PARTS AT THE HEATED AIR OR MORE THAN 80°C

• The figure shows RHD vehicle, LHD vehicle is the same with above figure, except location of ANTENNA FITTING which is symmetrical.

WARNING

• When drying with heated air more than 80°C these parts described above must be removed. • Detail of outside mirror to be equipped is shown following page. BM1503A5ECA

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7

PAINTING DETAIL OF OUTSIDE MIRROR TO BE EQUIPPED PRODUCTION CODE

– – – ALL

SYMBOL

SPECIFICATION

TYPE A TYPE B TYPE C TYPE D

FLAT MIRROR, FIXED STAY TYPE, RHD FLAT MIRROR, ADJUSTABLE STAY TYPE, LHD CONVEX MIRROR TYPE, RHD CONVEX MIRROR TYPE, LHD

TYPE C SPECIFICATION : CONVEX MIRROR TYPE, RHD

TYPE A SPECIFICATION : FLAT MIRROR, FIXED STAY TYPE, RHD

TYPE D SPECIFICATION : CONVEX MIRROR TYPE, LHD

DOOR UNDER NIRROR (if equipped) MAIN MIRROR (RH)

MAIN MIRROR (LH)

LONG STAY TYPE SIDE UNDER MIRROR (RH)

SIDE UNDER MIRROR (LH) SHORT STAY TYPE

TYPE B SPECIFICATION : FLAT MIRROR, ADJUSTABLE STAY TYPE, LHD

The figure shown above is for LHD vehicle. RHD vehicle is symmetrical to this figure.

FRONT UNDER MIRROR DOOR UNDER MIRROR MAIN MIRROR (RH)

SIDE UNDER MIRROR (RH)

MAIN MIRROR (LH)

SIDE UNDER MIRROR (LH)

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PAINTING

2. NOTE ON THE TOP COAT OF PAINT NOTE ON THE TOP COAT OF PAINT • To make sure that the top coat of paint adheres well, you must sand the middle coat carefully. Make sure that the sanding is even and complete. When you have finished sanding, carefully dust off the shavings.

(GOOD SANDING)

(BAD SANDING) Imperfectly sanded

Coated film

Evenly sanded

Coated film

• How to choose top coat paint HINO recommends urethane-type paints for the top coat,as they have superior rustprevention properties to lacquer-type paints. The top coat should be at 30 µ thick and the total paint thickness including undercoat and primers should be at least 80 µ thick. • How to install weather strips If door weather strips have been removed when painting the cab, remount them according to the following procedure, item 7.5. Be very careful not to make mistake in deciding the mounting procedure to avoid an eventual cause of rain drop leakage.

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PAINTING

3. HOW TO REMOVE THE PARTS OF CAB HOW TO REMOVE THE PARTS OF CAB FRONT • Radiator grille • Open the front panel. (front inspection lid) • Loose the bolt from back side of the front panel. • Remove the retainer. (16 pieces)

• Top mark Loose the tapping screw (4 pieces) from back side of radiator grille.

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7

PAINTING • Front panel

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7

PAINTING HOW TO REMOVE THE VENTILATOR • Ventilator • Hang your hand at under side of the ventilator. • Push up ventilator to upper side. (Move to upper side about 1 or 2 mm only.) • Pull under side of the ventilator toward you to remove ventilator.

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7

PAINTING HOW TO REMOVE THE QUARTER GARNISH (If equipped)

Quarter garnish is installed by clips (Right side : 5 numbers / Left side : 6 numbers). It can be uninstalled with to remove one or two clips by screw driver. • Be sure to protect the cab body (outer panel) where to be insert the screw driver from scratch or damage by clean waste. • Insert the screw driver between the quarter garnish and the cab body near the position where the clips are fitted. (See the following illustration) • Introduce the tip of the screw driver into the end and move it toward the outside of the vehicle and the clips can be removed. • Remove one or two clips. • For the rest of clips, hold the quarter garnish directly by hand, apply force toward the outside of the vehicle and the remaining clips can be removed.

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PAINTING REMOUNTING THE DISMOUNTED MIRROR STAY • When remounting the dismounted mirror stay, mount it after the paint has been completely hardened. • When tightening the mirror stay, be careful not to scratch the painted surface. • Never fail to retouch with clear lacquer, etc., those tool scratches which have been made by screws, bolts and nuts when dismounting and remounting the mirror stay. • When remounting the mirror stay adjust the tightening torques. Refer to the following figure for details. Refer to chapter 7, 1 for mirror variation TYPE A, B, C, and D, or production code.

TYPE A SPECIFICATION : FLAT MIRROR, FIXED STAY TYPE, RHD

A

D

B

DETAIL A (LH/RH) C

DETAIL B (LH/RH) DETAIL C (LH/RH)

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PAINTING TYPE B SPECIFICATION : FLAT MIRROR, ADJUSTABLE STAY TYPE, LHD

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PAINTING TYPE C SPECIFICATION : CONVEX MIRROR TYPE, RHD TYPE D SPECIFICATION : CONVEX MIRROR TYPE, LHD

The figure shown above is for LHD vehicle. RHD vehicle is symmetrical to this figure. BM1503A5ECA

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PAINTING REMOUNTING THE WIPER • When dismounting and remounting the wiper, confirm before remounting that the wiper stays are at the automatic stop position. (After turning ON the wiper switch and then turn OFF the wiper switch, so that the wiper motor stops at the automatic stop position.)

WARNING

• Operate the wiper with the front panel shut down. • With the front panel opened, you may risk to have your hand pinched by the wiper links. • Also after stop of the wiper motor, take out the starter key.

• When tightening the wiper arms, tighten them by adjusting the blade position (height) with in the limit as shown as the following illustration. • Adjust the wiper arms and the pivot positions to the following tightening torque values. • Wiper arm tightening torque 19.6 ± 2 N·m {200 ± 20 kgf·cm} • Wiper pivot tightening torque 11.8 ± 1 N·m {120 ± 10 kgf·cm}

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PAINTING WIPER BLADE SET POSITION (FOR RHD ONLY)

NOTE

• The set positions of the blades show the gaps at the top ends of the blades.

DETAIL OF WIPER ARM INSTALLATION APPLICATION : FC, FD, GD & FE ONLY

DETAIL OF WIPER ARM INSTALLATION APPLICATION : FG, GH, SG, FL, FM, FT & GT ONLY

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PAINTING WIPER BLADE SET POSITION (FOR LHD ONLY)

NOTE

• The set positions of the blades show the gaps at the top ends of the blades.

DETAIL OF WIPER ARM INSTALLATION APPLICATION : FC, FD & GD ONLY

DETAIL OF WIPER ARM INSTALLATION APPLICATION : FG, GH, FL, FM ONLY

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7

PAINTING

4. PROCEDURE FOR ADHERING ORNAMENTS Ornaments adopt the inside adhesive system which is easy to fit. Adhere them according to the following procedures. • What to prepare Clean waists • Points to pay attention • Reuse of ornaments once adhered should be avoided because their adhering power is reduced. • Perform the adhering operation by adjusting the surface temperature (20 to 40°C). If the ambient temperature is below the above, raise the temperature. • Wipe off dust, dirt, stain, oil, water, etc., deposited on the adhering surface. • Adhering procedure • After having cleaned the surface to adhere, take off the backing paper of the ornament. • Adhere door boundary line and door character line with the outer form of the ornament. (Details are described in the following figure.)

BM1503A5ECA

15

7

PAINTING ADHERING POSITION OF MODEL SERIES ORNAMENT (FOR DOOR)

DIMENSION (C) (13) (22) (36)

APPLICABLE MODEL

FM, FT, GT

FC, GH, FG, SG FD, GD, FL

ADHERING POSITION OF HINO LOGO MARK AND SERIES NAME ORNAMENT

PRODUCTION CODE

HINO LOGO MARK (A)

SERIES NAME ORNAMENT (B)

–

WITH

WITH

LESS

WITH (OPTION)

WITH

ALL

WITH

WITH

LESS

LESS

WITH

–

WITH

WITH

WITH

WITH

LESS

MODEL SERIES EXHAUST GAS ORNAMENT (C) ORNAMENT (D)

MODEL NAME ORNAMENT (E)

NOTE

• Figures are shown to be representative of the FC model,exact mark and ornament should be adhered by each model. • Apply ornament, after remove moisture, oil and dust from attaching position.

BM1503A5ECA

16

7

PAINTING

5. MOUNTING AND STICKING OF DOOR WEATHER STRIP In the case to disassemble the door weather strip when perform top coat paint, reassemble it as following procedure. Pay special attention when reassemble the door weather strip, otherwise it will cause leakage of rain water.

MOUNTING AND STICKING OF WEATHER STRIP • Match the marks A and B on body side notch and the marks on the weather strip then start mounting from this point. • Mounting of weather strips on general positions Mount the weather strips on general positions after having finished mounting of point A and B and stick them in such a way that the slack of the weather strips concentrate on corners of the point A and of the point B. Execute this operation by squeezing them in the direction of the arrow in the illustration of the weather strip position.

ILLUSTRATION OF THE WEATHER STRIP MOUNTING POSITION

BM1503A5ECA

17

7

PAINTING ILLUSTRATION OF THE WEATHER STRIP MARK POSITION

BM1503A5ECA

18

7

PAINTING

6. HOW TO MOUNT THE MAIN AND SUB SEAL HOW TO MOUNT THE MAIN SEAL AT THE POSITION OF THE FRONT COWL When you apply the top coating, apply masking on the main seal of the front cowl. If you are obliged to remove the door sub seal, replace it with a new part in the following manner, Part number of front cowl main seal : S7682-11260 (FC, FD, GD, FE) 1 piece/vehicle S7682-11270 (FG, GH, SG FL, FM, FT, GT) • Mounting procedures • Define both edges of the main seal in relation to the lange section of the front cowl and insert it along the positioning ribs. • Insert the main seal slowly from the both edges to center of the vehicle. • Caution • In order to avoid the penetration of water into the front panel have the both end of the front panels matched with the positioning ribs and tighten them together. • Mount the main seal in such a way that the section shape might become as illustrated by Section A-A.

BM1503A5ECA

19

7

PAINTING MOUNTING PROCEDURES OF MAIN SEAL AT THE POSITION OF THE FRONT CORNER PANEL When applying top coating do it either by dismounting the main seal at the front corner panel or by masking the section concerned. Parts number of main seal at the front corner panel : S7681-11120 (2 pieces/vehicle) • Mounting procedure • Insert the front corner main seal into the hole provided on the front corner panel. • Caution • Securely fix the retainer on the front corner panel which is mounted onto main seal. • In order to avoid the penetration of water, mount it in such a way that the section shape of the seal might become as illustrated on the Section B-B.

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20

7

PAINTING MOUNTING PROCEDURE FOR DOOR SUB SEAL • Wipe dirt, water, oil and wax etc. with clean waste on the double-sided tape's fitting surface of door panel. • Insert the clip of the door sub seal sufficiently well and fix it. • Peel off the release coated paper of double-sided tape and press fit it on the door panel.

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21

7

PAINTING

7. ‌CAUTIONS FOR PAINTING TILT CYLINDER ROD (If equipped) • Make sure you do not get paint on the tilt cylinder rod. • If there is paint on the tilt cylinder rod or the seal inside of the cylinder, or if the seal is damaged due to the paint, this may lead to cylinder oil leaks. To prevent paint from adhering to the rod,make the rod carefully. If paint adheres to the rod,make sure to remove it completely. Take care not to dent or scratch the rod.

NOTES

• Before painting, mask the rod completely • Take great care not to dent or scratch the rod.

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22

7

PAINTING

8. HANDLING OF LAMINATED WINDSHIELD A laminated glass is produced in such order that polyvinyl butyral film is inserted between 2 glasses and pressed with heat. Under driving general condition, there is no problem. But under a hot temperature and a high moisture when painting, intermediate film is fallen off or such defective occur as foaming may be caused. Therefore, a special caution needs to be taken.

• Caution when Painting There is no problem when you use a natural drying. But when a forced drying is used with infrared ray lamp, etc., be sure that the drying should be implemented within 30 minutes at less than 120°C. When drying at the temperature of more than 120°C, remove off the windshield glass or cover over the glass with something so that the temperature on the glass surface should not go up more than 120°C.

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23

7

PAINTING

9. HANDLING OF COMPUTERS (ECU) When paint by forced drying, must be care to handle the computers as following points.

CONDITION OF FORCED DRYING PAINT • INSIDE TEMPERATURE OF THE FORCED DRYING BOOTH

: 120°C

1 • INSIDE TEMPERATURE OF THE CAB : LESS THAN 85°C (PLACE AT THE 50mm HEIGHT FROM UPPER SURFACE OF CAB FLOOR.)

2

3

HANDLING OF COMPUTER

WHEN UNKNOWN THE TEMPERATURE OF THE FORCED DRYING BOOTH OR USE INFRARED LAMP

INSTALLED

INSIDE TEMPERATURE OF THE CAB : LESS THAN 85°C (PLACE AT THE 50mm HEIGHT FROM UPPER SURFACE OF CAB FLOOR.)

WHEN EXPECT MORE HIGH TEMPERATURE THAN ABOVE MENTIONED CASES.

BM1503A5ECA

REMOVE COMPUTER

24

7

PAINTING

10. PRECAUTIONS FOR FITTING AND STORING THE CAUTION PLATE • How to Stick It a. Stick the caution plate to a dry place which is free from dust and dirt after the paint has completely dried up. b. Clean your hand and don't use cotton work gloves, etc.. c. Completely remove water, oil, dust, etc. from the surface to stick (surface of cab) with ethyl alcohol if they are found remaining there. d. When the temperature is less than 10°C, warm up the surface to stick as well as the caution plate with warm wind of more than 20°C before sticking the caution plate. e. After sticking the caution plate, press it with a roller, etc., with a force of approximately 49 N/cm2 {5 kgf/cm2 }. f. Remove liner paper (backing paper) just before using it. g. When air remains inside, make a tiny hole with a needle or a cutter knife and press it out with your fingers from the bubble area.

• How to Store It a. When storing the caution plate, select a dry place with an ambient temperature (of 20 to 25°C) and without dust, dirt and stain. b. Also, store the caution plate at a flat place such as a shelf, etc., and do not place anything on it.

• Other Precautions for the Caution Plate a. As the caution plate is made from vinyl chloride, it is thin, soft and easily extensible. Therefore, take utmost care for handling it. b. When removing the caution plate, etc., be careful not to damage the painted surface with a sharp knife, etc. On the other hand, removal of the caution plate can be done more easily by pulling the caution plate in perpendicular direction to the sticking surface while heating it with a hair dryer. c. Do not throw the caution plates away but keep them together to compare with new caution plates and to prevent mixing up with the new ones.

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25

7

PAINTING

11. CAUTIONS FOR PAINTING THE TIRE DISC WHEELS 1) Before painting the tire disc wheel, cover its inside and outside surface to be contacted with the wheel, the hub, the brake drum and wheel nuts. Refer to the illustration below concerning the covering portions.

JIS type

ISO type SECTION A-A

2) After installing the tire disc wheel onto the vehicle, paint the remained portions with same color paint as thin as possible. It is because these surfaces are installation surface rotation tire. If the painting layer is thick, it causes wheel nuts loosen.

3) Precaution for carrying out tire rotation Sometimes, the mounting position of tire disc wheel may be changed and paint coated face may become contact face. At this moment, if the thickness of the painted layer is excessively thick, this may lead to the loosening of the wheel nuts. Therefore observe the following instructions when carrying out the tire rotation. (1) Take off the paint on the contact face (including the contact surface of wheel nut) of the tire disc wheel and after having completely cleaned the face with a wire brush etc., apply thin layer of paint for rust preventive purpose. (2) If you use the tire disc wheel without taking off the paint, even if the face is completely cleaned with wire brush, etc., the thick painted layer may lead to the loosening of wheel nuts.

BM1503A5ECA

26

Chapter 8 CHASSIS DRAWINGS

1. CAB DRAWINGS

2. CAB BACK DRAWINGS 3. CHASSIS DRAWINGS

4. CHASSIS FRAME DRAWINGS

BM1503A5ECA

8

CHASSIS DRAWINGS

Refer to detail of the cab, chassis and chassis frame drawing based on following table.

MODEL NAME

PRODUCTION CODE

8.1. CAB DRAWINGS

8.2. CAB BACK DRAWINGS

8.3. CHASSIS DRAWINGS

8.4. CHASSIS FRAME DRAWINGS

HINO 51018 HINO 51226 HINO 51726 HINO 51726 HINO 52626 HINO 52626 HINO 52635 HINO 52635

FC9JJSA-NNB GD8JLSA-PAB GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX FM2PLSD-ZGL FM2PRSA-ZGL

C-1 C-2 C-3 C-3 C-4 C-4 C-5 C-5

CB-1 CB-2 CB-3 CB-3 CB-4 CB-4 CB-5 CB-5

CH-1 CH-2 CH-3 CH-4 CH-5 CH-6 CH-7 CH-8

CF-1 CF-2 CF-3 CF-4 CF-5 CF-6 CF-7 CF-8

BM1503A5ECA

1

8

CHASSIS DRAWINGS

1. CAB DRAWINGS No. C-1

Unit : mm

PRODUCTION CODE : FC9J • Rear

• Front

BM1503A5ECA

2

8

CHASSIS DRAWINGS No. C-2

PRODUCTION CODE : GD8J Unit : mm

• Rear

• Front

BM1503A5ECA

3

8

CHASSIS DRAWINGS No. C-3

PRODUCTION CODE : GH8J Unit : mm

• Rear

• Front

BM1503A5ECA

4

8

CHASSIS DRAWINGS No. C-4

PRODUCTION CODE : FM8J Unit : mm

• Rear

• Front

BM1503A5ECA

5

8

CHASSIS DRAWINGS No. C-5

PRODUCTION CODE : FM2P Unit : mm

• Rear

• Front

BM1503A5ECA

6

8

CHASSIS DRAWINGS

2. CAB BACK DRAWINGS No. CB-1

PRODUCTION CODE : FC9J

• Upper view

Unit : mm

• Left view

BM1503A5ECA

7

8

CHASSIS DRAWINGS No. CB-2

PRODUCTION CODE : GD8J • Upper view

• Left view

BM1503A5ECA

Unit : mm

8

8

CHASSIS DRAWINGS No. CB-3

PRODUCTION CODE : GH8J • Upper view

• Left view

BM1503A5ECA

Unit : mm

9

8

CHASSIS DRAWINGS No. CB-4

PRODUCTION CODE : FM8J • Upper view

• Left view

BM1503A5ECA

Unit : mm

10

8

CHASSIS DRAWINGS No. CB-5

PRODUCTION CODE : FM2P • Upper view

• Left view

BM1503A5ECA

Unit : mm

11

8

CHASSIS DRAWINGS

3. CHASSIS DRAWINGS Unit : mm

No. CH-1

BM1503A5ECA

12

8

CHASSIS DRAWINGS No. CH-2 Unit : mm

-PAB

BM1503A5ECA

13

8

CHASSIS DRAWINGS No. CH-3 Unit : mm

BM1503A5ECA

14

8

CHASSIS DRAWINGS No. CH-4 Unit : mm

BM1503A5ECA

15

8

CHASSIS DRAWINGS No. CH-5 Unit : mm

-TGX

BM1503A5ECA

16

8

CHASSIS DRAWINGS No. CH-6 Unit : mm

-TGX

BM1503A5ECA

17

8

CHASSIS DRAWINGS No. CH-7 Unit : mm

BM1503A5ECA

18

8

CHASSIS DRAWINGS No. CH-8 Unit : mm

BM1503A5ECA

19

8

CHASSIS DRAWINGS

4. CHASSIS FRAME DRAWINGS Unit : mm

No. CF-1

PRODUCTION CODE : FC9JJSA-NNB

• Detail of the chassis frame

BM1503A5ECA

20

8

CHASSIS DRAWINGS No. CF-1

PRODUCTION CODE : FC9JJSA-NNB

• Detail of the cross member

Unit : mm

BM1503A5ECA

21

8

CHASSIS DRAWINGS No. CF-2

PRODUCTION CODE : GD8JLSA-PAB

• Detail of the chassis frame

Unit : mm

BM1503A5ECA

22

8

CHASSIS DRAWINGS No. CF-2

PRODUCTION CODE : GD8JLSA-PAB

• Detail of the cross member

Unit : mm

BM1503A5ECA

23

8

CHASSIS DRAWINGS No. CF-3

PRODUCTION CODE : GH8JGSD-TGB

• Detail of the chassis frame

Unit : mm

BM1503A5ECA

24

8

CHASSIS DRAWINGS No. CF-3

PRODUCTION CODE : GH8JGSD-TGB

• Detail of the cross member

Unit : mm

BM1503A5ECA

25

8

CHASSIS DRAWINGS No. CF-4

PRODUCTION CODE : GH8JMSA-TGB

• Detail of the chassis frame

Unit : mm

BM1503A5ECA

26

8

CHASSIS DRAWINGS No. CF-4

PRODUCTION CODE : GH8JMSA-TGB

• Detail of the cross member

Unit : mm

BM1503A5ECA

27

8

CHASSIS DRAWINGS No. CF-5

PRODUCTION CODE : FM8JLSD-TGX

• Detail of the chassis frame

Unit : mm

BM1503A5ECA

28

8

CHASSIS DRAWINGS No. CF-5

PRODUCTION CODE : FM8JLSD-TGX

• Detail of the cross member

Unit : mm

BM1503A5ECA

29

8

CHASSIS DRAWINGS No. CF-6

PRODUCTION CODE : FM8JRSA-TGX

• Detail of the chassis frame

Unit : mm

BM1503A5ECA

30

8

CHASSIS DRAWINGS No. CF-6

PRODUCTION CODE : FM8JRSA-TGX

• Detail of the cross member

Unit : mm

BM1503A5ECA

31

8

CHASSIS DRAWINGS No. CF-7

PRODUCTION CODE : FM2PLSD-ZGL

• Detail of the chassis frame

Unit : mm

BM1503A5ECA

32

8

CHASSIS DRAWINGS No. CF-7

PRODUCTION CODE : FM2PLSD-ZGL

• Detail of the cross member

Unit : mm

BM1503A5ECA

33

8

CHASSIS DRAWINGS No. CF-8

PRODUCTION CODE : FM2PRSA-ZGL

• Detail of the chassis frame

Unit : mm

BM1503A5ECA

34

8

CHASSIS DRAWINGS No. CF-8

PRODUCTION CODE : FM2PRSA-ZGL

• Detail of the cross member

Unit : mm

BM1503A5ECA

35

Chapter 9 MOUNTING OF CHASSIS EQUIPMENT

1. AIR TANK & AIR BOOSTER 2. BRAKE PIPING DIAGRAM 3. BATTERY

4. FUEL TANK

5. FUEL COOLER

6. AUTO CLUTCH UNIT 7. EXHAUST SYSTEM

8. LICENSE PLATE BRACKET

BM1503A5ECA

9

MOUNTING OF CHASSIS EQUIPMENT

Refer to detail of the fuel tank, air tank & air booster, battery, exhaust system and fuel cooler drawing based on following table. MODEL NAME

PRODUCTION CODE

HINO 51018 HINO 51226 HINO 51726 HINO 51726 HINO 52626 HINO 52626 HINO 52635 HINO 52635

FC9JJSA-NNB GD8JLSA-PAB GH8JGSD-TGB GH8JMSA-TGB FM8JLSD-TGX FM8JRSA-TGX FM2PLSD-ZGL FM2PRSA-ZGL

NOTE

SYMBOL AT-1 AT-2 AT-3 AT-4 AT-5 AT-6 PD-1 PD-2 PD-3 PD-4 PD-5 BAT-1 BAT-3 FT-1 FT-2 FT-3 FT-4 FT-5 FT-6

9.1. AIR TANK & AIR BOOSTER

9.2. BRAKE PIPING DIAGRAM

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

STD PD-1 PD-2 PD-3 PD-3 PD-4 PD-4 PD-5 PD-5

SPECIFICATION FC9J GD8J GH8J FM8J FM2P FM8J,FM2P AIR DRIER FC9J GD8J GH8J FM8J FM2P 234kC {65Ah} w/o SPACER 432kC {120Ah} w/o SPACER 100L (FC) 200L (FC) 200L (GD) 200L (GH8J) 200L (FM8J, FM2P) 200L x 2 (FM8J, FM2P)

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

SYMBOL EX-1 EX-2 EX-3 EX-4 EX-5 EX-6 EX-7 EX-8 EX-9 LPB-C

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

9.6. AUTO CLUTCH UNIT

STD – – – – – – – –

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

SPECIFICATION HORIZONTAL EXHAUST PIPE (FC4J, FC9J) STACK EXHAUST PIPE (FC4J, FC9J) HORIZONTAL EXHAUST PIPE (GD8J) STACK EXHAUST PIPE (GD8J) HORIZONTAL EXHAUST PIPE (GH8J) STACK EXHAUST PIPE (GH8J) HORIZONTAL EXHAUST PIPE (FM8J) STACK EXHAUST PIPE (FM8J) HORIZONTAL EXHAUST PIPE (FM2P) GENERAL USE, FOR CARGO

BM1503A5ECA

1

9

MOUNTING OF CHASSIS EQUIPMENT

1. AIR TANK & AIR BOOSTER

Unit : mm

AT-1 SPECIFICATION : FC9J

BM1503A5ECA

2

9

MOUNTING OF CHASSIS EQUIPMENT AT-2

Unit : mm

SPECIFICATION : GD8J

BM1503A5ECA

3

9

MOUNTING OF CHASSIS EQUIPMENT AT-3

Unit : mm

SPECIFICATION : GH8J

BM1503A5ECA

4

9

MOUNTING OF CHASSIS EQUIPMENT AT-4

Unit : mm

SPECIFICATION : FM8J

BM1503A5ECA

5

9

MOUNTING OF CHASSIS EQUIPMENT AT-5

Unit : mm

SPECIFICATION : FM2P

BM1503A5ECA

6

9

MOUNTING OF CHASSIS EQUIPMENT AT-6

Unit : mm

SPECIFICATION : FM8J, FM2P

BM1503A5ECA

7

9

MOUNTING OF CHASSIS EQUIPMENT

2. BRAKE PIPING DIAGRAM PD-1 SPECIFICATION : FC9J

BM1503A5ECA

8

9

MOUNTING OF CHASSIS EQUIPMENT PD-2 SPECIFICATION : GD8J

BM1503A5ECA

9

9

MOUNTING OF CHASSIS EQUIPMENT PD-3 SPECIFICATION : GH8J

BM1503A5ECA

10

9

MOUNTING OF CHASSIS EQUIPMENT PD-4 SPECIFICATION : FM8J

BM1503A5ECA

11

9

MOUNTING OF CHASSIS EQUIPMENT PD-5 SPECIFICATION : FM2P

BM1503A5ECA

12

9

MOUNTING OF CHASSIS EQUIPMENT

3. BATTERY

Unit : mm

BAT-1 SPECIFICATION : 234kC {65Ah} w/o SPACER

VEHCLE FRONT (BATTERY POSITION : RH)

APPROX. 325 (65D23L) APPROX. 351 (65D26L)

DISASSEMBLY SPACE OF BATTERY COVER

VEHCLE FRONT (BATTERY POSITION : LH)

TO NO.2 CROSSMEMBER DISASSEMBLY SPACE OF BATTERY COVER

PRODUCTION CODE

APPRICATION

– – –

GD1J, GD8J (W/B=E) GD1J, GD8J (W/B=J) FC7J

B

A

FC9JJSA-NNB GD8JLSA-PAB –

L

A

B

RH RH RH

470 499 519

35 35 35

50 50 50

FC4J, FC9J FD7J GD1J, GD8J (W/B=L) FE7J

RH

534

35

50

FG8J, GH8J

RH

750

62

77

LH

730

35

50

GH8JGSD-TGB GH8JMSA-TGB

FG1J, GH1J, GH8J

FM8JLSD-TGX FM8JRSA-TGX FM2PLSD-ZGL FM2PRSA-ZGL

FL1J FM1J, FM8J, FM2P

RH

367

29

44

SG2P FT1J GT1J

RH LH LH

-34 653 520

26 35 35

41 50 50

– – –

BM1503A5ECA

BATTERY POSITION

13

MOUNTING OF CHASSIS EQUIPMENT BAT-2 SPECIFICATION : 234kC {65Ah} w/ SPACER

Unit : mm

58.5

63.5

9

PRODUCTION CODE –

BM1503A5ECA

14

MOUNTING OF CHASSIS EQUIPMENT

DISASSEMBLY SPACE OF BATTERY COVER 50

321

50

60

23

394 430

TO No.2 CROSSMENBER DATUM LINE L

Unit : mm

PRODUCTION CODE

B

551.5

140

284

3

380.5 A

VEHCLE FRONT (BATTERY POSITION : RH)

BAT-3 SPECIFICATION : 432kC {120Ah} w/o SPACER

VEHCLE FRONT (BATTERY POSITION : LH)

9

253

APPRICATION

BATTERY POSITION

L

A

B

FC9JJSA-NNB GD8JLSA-PAB

FC4J, FC9J GD1J, GD8J

RH

426

21

41

GH8JGSD-TGB GH8JMSA-TGB

FG1J, GH1J, GH8J

LH

696

-8

70

FM8JLSD-TGX FM8JRSA-TGX FM2PLSD-ZGL FM2PRSA-ZGL

FL1J FM1J, FM8J, FM2P

RH

402

-2

64

–

SG2P

RH

-30

61

61

–

FT1J

LH

567

21

41

–

GT1J

LH

486

21

41

531.5

BM1503A5ECA

15

MOUNTING OF CHASSIS EQUIPMENT BAT-4 SPECIFICATION : 432kC {120Ah} w/ SPACER

Unit : mm

282

534

392

APPROX. 611

9

7.5

12.5

PRODUCTION CODE

APPLICATION

BATTERY POSITION

TO NO.2 CROSSMEMBER L

–

FC7J

RH

411

–

FD7J, FE7J

RH

426

BM1503A5ECA

16

9

MOUNTING OF CHASSIS EQUIPMENT BAT-5 SPECIFICATION : 432kC {120Ah} LARGE, w/o SPACER

Unit : mm

DISASSEMBLY SPACE OF BATTERY COVER

FRONT

TO NO.2 CROSSMEMBER

PRODUCTION CODE

APPLICATION

BATTERY POSITION

TO NO.2 CROSSMEMBER L

–

FG8J, GH8J

RH

750

–

FG8J, GH8J (SHORT W/B)

RH

200

BM1503A5ECA

17

9

MOUNTING OF CHASSIS EQUIPMENT BAT-6 SPECIFICATION : 432kC {120Ah} LARGE, w/ SPACER

Unit : mm

PRODUCTION CODE –

BM1503A5ECA

18

9

MOUNTING OF CHASSIS EQUIPMENT

4. FUEL TANK

Unit : mm

FT-1 SPECIFICATION : 100L (FC)

BM1503A5ECA

19

9

MOUNTING OF CHASSIS EQUIPMENT FT-2 SPECIFICATION : 200L (FC)

Unit : mm

BM1503A5ECA

20

9

MOUNTING OF CHASSIS EQUIPMENT FT-3 SPECIFICATION : 200L (GD)

Unit : mm

BM1503A5ECA

21

9

MOUNTING OF CHASSIS EQUIPMENT FT-4 SPECIFICATION : 200L (GH8J)

Unit : mm

BM1503A5ECA

22

9

MOUNTING OF CHASSIS EQUIPMENT FT-5 SPECIFICATION : 200L (FM8J, FM2P)

Unit : mm

BM1503A5ECA

23

9

MOUNTING OF CHASSIS EQUIPMENT FT-6 SPECIFICATION : 200L x 2 (FM8J, FM2P)

Unit : mm

BM1503A5ECA

24

9

MOUNTING OF CHASSIS EQUIPMENT

5. FUEL COOLER

Unit : mm

NOT PROVIDED

BM1503A5ECA

25

9

MOUNTING OF CHASSIS EQUIPMENT

6. AUTO CLUTCH UNIT (ACU)

Unit : mm

NOT PROVIDED

BM1503A5ECA

26

9

MOUNTING OF CHASSIS EQUIPMENT

7. EXHAUST SYSTEM (EXHAUST TAIL PIPE)

Unit : mm

EX-1 SPECIFICATION : HORIZONTAL EXHAUST PIPE (FC4J, FC9J)

BM1503A5ECA

27

9

MOUNTING OF CHASSIS EQUIPMENT EX-2

Unit : mm

SPECIFICATION : STACK EXHAUST PIPE (FC4J, FC9J)

BM1503A5ECA

28

9

MOUNTING OF CHASSIS EQUIPMENT EX-3

Unit : mm

SPECIFICATION : HORIZONTAL EXHAUST PIPE (GD8J)

BM1503A5ECA

29

9

MOUNTING OF CHASSIS EQUIPMENT EX-4

Unit : mm

SPECIFICATION : STACK EXHAUST PIPE (GD8J)

BM1503A5ECA

30

9

MOUNTING OF CHASSIS EQUIPMENT EX-5

Unit : mm

SPECIFICATION : HORIZONTAL EXHAUST PIPE (GH8J)

BM1503A5ECA

31

9

MOUNTING OF CHASSIS EQUIPMENT EX-6

Unit : mm

SPECIFICATION : STACK EXHAUST PIPE (GH8J)

BM1503A5ECA

32

9

MOUNTING OF CHASSIS EQUIPMENT EX-7

Unit : mm

SPECIFICATION : HORIZONTAL EXHAUST PIPE (FM8J)

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9

MOUNTING OF CHASSIS EQUIPMENT EX-8

Unit : mm

SPECIFICATION : STACK EXHAUST PIPE (FM8J)

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9

MOUNTING OF CHASSIS EQUIPMENT EX-9

Unit : mm

SPECIFICATION : HORIZONTAL EXHAUST PIPE (FM2P)

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9

MOUNTING OF CHASSIS EQUIPMENT

8. LICENSE PLATE BRACKET

Unit : mm

LPB-A

LPB-B

LPB-C

LPB-D

LPB-E

LPB-F

LPB-G

LPB-H

LPB-I

LPB-J

PRODUCTION CODE – – ALL – – – – – – –

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SYMBOL LPB-A LPB-B LPB-C LPB-D LPB-E LPB-F LPB-G LPB-H LPB-I LPB-J

SPECIFICATION FOR AUSTRALIA – GENERAL USE, FOR CARGO – – – – – – GENERAL USE, FOR TRACTOR

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Chapter 10 TRACTOR EQUIPMENT

1. MOUNTING OF 5TH WHEEL

2. OUTLINE OF 5TH WHEEL MOUNTING METHOD (EXAMPLE) 3. COUPLER BASE (NOT PROVIDED)

4. COUPLER BASE DIMENSION (NOT PROVIDED)

5. RECOMMENDED 5TH WHEEL MOUNTING PLATE DIMENSION (EXAMPLE)

6. LOWER SUPPORT BRACKET FOR 5TH WHEEL (EXAMPLE) 7. SLIDE RAIL FOR 5TH WHEEL (EXAMPLE) 8. SEMI-TRAILER BRAKE COUPLING

9. SEMI-TRAILER ELECTRICAL CONNECTION 10. REAR COMBINATION LAMP

[ATTENTION]

THIS CHAPTER IS NOT APPLICABLE TO YOUR MODEL SERIES.

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Chapter 11 REGULATION



[ATTENTION]

THIS CHAPTER IS NOT APPLICABLE TO YOUR MODEL SERIES.

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