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,
whenBodyandEquipmentManufacturersinstall any body orother 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
VEHICLE SUMMARY
1. PRODUCTION CODE
8J
GVMR & (DRIVE) CODE

VEHICLE TYPE
ENGINE CODE
GVMR
DRIVE
CODE
MODEL
CAB-OVER TRUCK
10,400kg
CLASS
4x2
1J
J08C
CAB-OVER TRUCK
10,000 12,000kg
CLASS
4x2
6J
J05D
SEMI-TRACTOR
12,000 14,000kg
CLASS
4x2
7J
J07E
14,000 15,500kg
CLASS
4x2
8J
J08E
17,000kg
CLASS
4x2
9J
J05E
26,000kg
CLASS
6x2
1A
A09C
26,000kg
CLASS
6x4
10,000 13,000kg
CLASS
4x4
OVER 30,000kg
CLASS
8x4
2P
P11C
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
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.
GENERAL CARGO with

LEAF SUSPENSION
GENERAL CARGO with

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

SUSPENSION
MIXER with REAR AIR

SUSPENSION
NOTE
Refer to chassis specification for GVMR (Gross vehicle mass rating).

BM1503A5ECA
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
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
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
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
500Nm {51kgfm} at 1,500r/min
739Nm {75.4kgfm} at 1,500rpm
739Nm {75.4kgfm} at 1,500rpm
739Nm {75.4kgfm} at 1,500rpm
1,275Nm {130kgfm} at 1,500rpm
SUSPENSION
CAB
M009 (9MT)
Fr & Rr LEAF SPRING
Fr & Rr LEAF SPRING
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
8.25R16-14PR
9.5R17.5(129/127)
235/75R17.5(130/128)
225/70R19.5(130/128)
8.25-20-14PR
8.25R20-14PR
10.00-20-16PR
10.00R20-16PR
11.00-20-14PR
11.00-20-16PR
11.00R20-14PR
11.00R20-16PR
11R22.5-16PR
12R22.5-16PR
255/70R22.5(143/140)
275/70R22.5(148/145)
275/80R22.5(149/146)
295/80R22.5(152/148)
16x6.00GS-offset135mm
17.5x6.75-offset135mm
20x6.50T-offset145mm
20x7.50V-offset165mm
100L
200L
200Lx2
65AH
120AH
24V-50A
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
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
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
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
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 80C 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.
BM1503A5ECA
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.
BM1503A5ECA
GENERAL PRECAUTIONS
1.7 Precautions for cab paint
When heating the cab (ex. painting jobs) and it's temperature exceeds 80C,
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 : 5.91.2 Nm {5812 kgfcm}
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.
BM1503A5ECA
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 80C).
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.
BM1503A5ECA
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 80C 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.
BM1503A5ECA
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
<The electric current of welding>

WELDING ROD
CAB
ELECTRIC EQUIPMENTS
BATTERY
EARTH of ARC WELDING

MACHINE
EARTH WIRE OF CAB
BM1503A5ECA
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 its 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
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
10
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
11
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
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.
BM1503A5ECA
12
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.
BM1503A5ECA
13
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.
BM1503A5ECA
14
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.
BM1503A5ECA
15
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.
BM1503A5ECA
16
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.
BM1503A5ECA
17
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
BM1503A5ECA
18
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.
BM1503A5ECA
19
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.
BM1503A5ECA
20
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
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
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
PRODUCTION
CODE
-
755
1,005
955
80
80
80
935
80
1,075
1,255
1,000
80
80
175
APPLICATION
Unit : mm
SG2P
180
6.5
FM1A, FM2P
175
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
21
GENERAL PRECAUTIONS
MEASUREMENT DETAIL OF CAB TILT MECHANISM
(FOR SINGLE CAB, RIGID CAB MOUNT TYPE)
PRODUCTION CODE
APPLICATION
FC9JJSA-NNB
FC
613
GD8JLSA-PAB
FD,GD,FE
863
PRODUCTION CODE
APPLICATION
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
GENERAL PRECAUTIONS
MEASUREMENT DETAIL OF POWER CAB TILT MECHANISM
(FOR SINGLE CAB, RIGID CAB MOUNT TYPE)
PRODUCTION CODE
813
Unit : mm
BM1503A5ECA
23
GENERAL PRECAUTIONS
(FOR SINGLE CAB, FLOATING CAB MOUNT TYPE)
PRODUCTION CODE
APPLICATION
FG
851
GH,FL8J,FM8J
831
BM1503A5ECA
Unit : mm
24
GENERAL PRECAUTIONS
(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
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
25
GENERAL PRECAUTIONS
MEASUREMENT DETAIL OF REAR ARCH COVER
[TYPE C]
[TYPE A]
PRODUCTION CODE
APPLICATION
FC
650
FD,FE
900
APPLICATION
FG
864
GH,FL,FM
844
PRODUCTION CODE
APPLICATION
FG
860
143
49
GH,FM
840
143
49
GT
860
172
78
[TYPE B]
PRODUCTION CODE
[TYPE D]
PRODUCTION CODE
CHASSIS CENTER LINE
TO FRONT AXLE DATUM LINE
29
198
147
128
192
167
387
REAR BODY
FRAME UPPER SURFACE

180
30
BM1503A5ECA
26
GENERAL PRECAUTIONS
MEASUREMENT DETAIL OF ENGINE AIR INTAKE PORT
(FOR SINGLE CAB)
Unit : mm
APPLICATION
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
DUAL ELEMENT
215
PRODUCTION CODE
GH8JGSD-TGB
GH8JMSA-TGB
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
GENERAL PRECAUTIONS
MEASUREMENT DETAIL OF VERTICAL EXHAUST PIPE
(OPT)
Unit : mm
PRODUCTION CODE
Unit : mm
APPLICATION
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
29
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
1,370
1,370
1,755
1,755
1,370
1,370
1,755
1,755
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.
BM1503A5ECA
30
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
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
(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)
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
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
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
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
Unit : mm
BM1503A5ECA
32
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
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
33
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.
BM1503A5ECA
34
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
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
ARM SUB-ASSY,
FR BUMPER, RH/LH
Parts Number : 52011-E0070 (RH)

: 52012-E0070 (LH)
BOLT
Tightening torque
:12516.3Nm
[EXAMPLE]
FUPD
NUT,
BOLT
Tightening torque
:6318.9Nm
ARM SUB-ASSY,
FR BUMPER, RH/LH
BOLT
Tightening torque
:12516.3Nm
FUPD
NUT,
BOLT
Tightening torque
:6318.9Nm

: 52012-E0080 (LH)
ARM SUB-ASSY,
FR BUMPER, RH/LH
With four steps front of the vehicle

BOLT
Tightening torque
:12516.3Nm
FUPD
NUT,
BOLT
Tightening torque
:6318.9Nm
ARM SUB-ASSY,
FR BUMPER, RH/LH
BOLT
Tightening torque
:12516.3Nm
FUPD
BM1503A5ECA
NUT,
BOLT
Tightening torque
:6318.9Nm
36
GENERAL PRECAUTIONS
[TYPE B] APPLICATION : FG,SG,GH,FL,FM
ARM SUB-ASSY, FUP

[EXAMPLE]

Shape of bracket

FUPD
FUPD
[EXAMPLE]

FUPD
FUPD
BM1503A5ECA
37
GENERAL PRECAUTIONS
[TYPE B] APPLICATION : FG,SG,GH,FL,FM
BRACKET SIDE STEP

Shape of bracket
BRACKET, SIDE
STEP, No.1 RH/LH
NUT
Tightening torque
:6318.9Nm

: 51794-E0061 (LH)
[EXAMPLE]
BRACKET, SIDE
STEP, No.1 RH/LH
NUT
Tightening torque
:6318.9Nm
BRACKET, SIDE
STEP, No.1 RH/LH
NUT
Tightening torque
:6318.9Nm
If changed installation height for

FUP, should change bracket for
installation step.

: 51794-E0071 (LH)
BRACKET, SIDE
STEP, No.1 RH/LH
NUT
Tightening torque
:6318.9Nm
BM1503A5ECA
38
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
39
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 (16 bolt, equivalent to 8.8T) : 20030 Nm
Stay and rear bumper (12 bolt, equivalent to 8.8T) : 6318.9 Nm
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
40
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
41
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
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
42
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
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. 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
-
( kgm )
-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
( kgm )
-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.
BM1503A5ECA

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
-
( kgm )
-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
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
( kgm )
-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
BM1503A5ECA

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
-
( kgm )
-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
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
( kgm )
-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
( kgm )
-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
( kgm )
-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
BM1503A5ECA

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
( kgm )
-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
Moment
from
F.A.C
REAR
1,506
2,500
4,006
(m)
(m)
Moment
from
frame
upper
surface
M6
FM8JRSA-TGX
( kgm )
-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
( kgm )
-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
( kgm )
-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
BM1503A5ECA

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
( kgm )
-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
Moment
from
F.A.C
REAR
1,547
2,436
3,983
(m)
(m)
Moment
from
frame
upper
surface
M8
FM2PRSA-ZGL
( kgm )
-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
( kgm )
-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
( kgm )
-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
BM1503A5ECA
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
BATTERY (120Ah)
33
2.170
71.610
108
1.985
214.380
26
0.220
5.720
0.600
1.800
T/M PTO
14
1.270
17.780
FRONT SUS. (REINFORCED MULTI)
26
0.000
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.
(kgm)
BM1503A5ECA
REMARKS
0.000 UNSPRUNG MASS

P : OPT. EQUIPMENT
- : NOT PROVIDED
PRODUCTION CODE : GD8J
No. EQ2
GD8JLSA-PAB
AIR CONDITIONER
16
-0.600
-9.600
BATTERY (120Ah)
33
2.130
70.290
BED LESS
-3
0.450
-1.350
-1.100
-6.600
40
1.370
54.800
0.830
2.490
T/M PTO
14
1.270
17.780
FRONT SUS. (REINFORCED MULTI)
24
0.000
0.000 UNSPRUNG MASS
FRONT SUS. (REINFORCED MULTI W/STB.)
49
-0.650
-31.850 UNSPRUNG MASS
CONTENT OF OPTION
FRONT AIR SPOILER

T/M POWER SHIFT
GRAVITY
POSITION
FROM
MASS
F.A.C.
(kg)
(m)
MOMENT
FROM
F.A.C.
(kgm)
BM1503A5ECA
REMARKS

P : OPT. EQUIPMENT
- : NOT PROVIDED
PRODUCTION CODE : GH8J
GH8JMSA-TGB
No. EQ3
GH8JGSD-TGB
AIR CONDITIONER
16
-0.510
-8.160
BATTERY (120Ah)
33
1.280
42.240
BED LESS
-3
0.430
-1.290
CENTER SEAT LESS
-4
-0.215
0.860
-37
1.135
-41.995
17
1.350
22.950
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.
(kgm)
BM1503A5ECA
REMARKS

P : OPT. EQUIPMENT
- : NOT PROVIDED
PRODUCTION CODE : FM8J, FM2P
FM2PLSD-ZGL
FM2PRSA-ZGL
FM8JRSA-TGX
No. EQ4
FM8JLSD-TGX
AIR CONDITIONER
16
-0.510
-8.160
AIR CONDITIONER
22
-0.510
-11.220
-0.170
-1.360
33
2.520
83.160
0.430
1.290
CENTER SEAT LESS
-4
-0.215
0.860
CHASSIS STEP
22
-0.750
-16.500
-1.200
-7.200
213
3.325
708.225
38
1.175
44.650
1.395
5.580
T/M PTO
17
1.350
22.950
T/M PTO
14
1.465
20.510
TIRE CARRIER
15
7.140
107.100
-20
0.000
0.000 UNSPRUNG MASS
-3
0.000
0.000 UNSPRUNG MASS
CONTENT OF OPTION
AIR SUSPENSION SEAT (DRIVER'S SEAT)

BATTERY (120Ah)
BED
FRONT AIR SPOILER

FUEL TANK (200L -> 200L x 2)
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.
(kgm)
BM1503A5ECA
REMARKS
10
3. FRAME SECTION MODULUS

FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE)
No. Z1
Unit : mm
PRODUCTION CODE : FC9JJSA-NNB
BM1503A5ECA
11

No. Z2
Unit : mm
PRODUCTION CODE : GD8JLSA-PAB
BM1503A5ECA
12

No. Z3
Unit : mm
PRODUCTION CODE : GH8JGSD-TGB
BM1503A5ECA
13

No. Z4
Unit : mm
PRODUCTION CODE : GH8JMSA-TGB
BM1503A5ECA
14

No. Z5
Unit : mm
PRODUCTION CODE : FM8JLSD-TGX
BM1503A5ECA
15

No. Z6
Unit : mm
PRODUCTION CODE : FM8JRSA-TGX
BM1503A5ECA
16

No. Z7
Unit : mm
PRODUCTION CODE : FM2PLSD-ZGL
BM1503A5ECA
17

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
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
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}
CONTACTING POINT OF
BUFFER RUBBER
10
129.8
50
FRONT
20
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
20
10
50
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
POINT
SPRING LOAD ON ONE SIDE
40
60
a
b
c
150 (mm)
100

kgf
x 103 (kN)
40
4
60
VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING

LOAD VS. DEFLECTION
HORIZONTAL
POINT
HORIZONTAL
POINT
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}
30
b
80
c
3
REAR
CONTACTING POINT OF
BUFFER RUBBER
84.5
136.8
100
150 (mm)

LOAD VS. DEFLECTION
FFC4 4J SPG CHARA "D"
BM1503A5ECA
kgf
x 103 (kN)
40
4
FRONT
a
b
c

kgf
x 103 (kN)
15 150
0.226kN/mm {23.0kgf/mm}
21.130kN {2154.7kgf}
30.670kN {3127.5kgf}
REAR
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
93.5
135.7
20
a
1
CONTACTING POINT OF
BUFFER RUBBER
10
50
FRONT
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
20
10
50
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
POINT

a
b
c
50

LOAD VS. DEFLECTION
FGD4 1J SPG CHARA "C"

kgf
x 103 (kN)
40
4

LOAD VS. DEFLECTION
100
60
150 (mm)
100
10
HORIZONTAL
POINT
HORIZONTAL
POINT
84.5
136.7
100
150 (mm)

LOAD VS. DEFLECTION
FGD4 1J SPG CHARA "D"
BM1503A5ECA
kgf
x 103 (kN)
40
30
15
101.0
147.1
20
a
CONTACTING POINT OF
BUFFER RUBBER
10
50
100
150
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
50
c
a
49.0
200 (mm)

LOAD VS. DEFLECTION
98.0
121
50
100
150 (mm)

LOAD VS. DEFLECTION
FGH4 4J SPG CHARA "D"
FGH4 1J SPG CHARA "F"
kgf
x 103 (kN)
20
200
15
150
10
100
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}
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
POINT
0.282kN/mm {28.8kgf/mm}
28.480kN {2905.0kgf}
41.480kN {4231.0kgf}
a
b
c
CONTACTING POINT OF
BUFFER RUBBER
FRONT
HORIZONTAL
POINT
kgf
x 103 (kN)
50
5
HORIZONTAL
POINT
49.0
98.0
141
50
c
a
50
100
150 (mm)

LOAD VS. DEFLECTION
BM1503A5ECA
FGH4 1J SPG CHARA "H"
PRODUCTION CODE : FM8J, FM2P
40
30
20
FRONT
a
b
c
0.282kN/mm {28.8kgf/mm}
28.480kN {2905.0kgf}
44.300kN {4518.6kgf}
10
50
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
POINT
kgf
x 103 (kN)
50
5
101.0
157.1
100
200 (mm)
150

LOAD VS. DEFLECTION

kgf
x 103 (kN)
50
5
40
30
20
FRONT
a
b
c
10
50
CONTACTING POINT OF
BUFFER RUBBER
a
1
0.322kN/mm {32.8kgf/mm}
33.170kN {2905.0kgf}
51.230kN {5225.5kgf}
HORIZONTAL
POINT
FFL4 4J SPG CHARA B
103.0
159.1
100
150
200 (mm)

LOAD VS. DEFLECTION
FFL4 4J SPG CHARA A
BM1503A5ECA
2. CALCULATION FOR HEIGHT OF FRAME UPPER SURFACE FROM

GROUND
CALCULATION FORMULA OF Hf1 & Hr1

<CALCULATION DATA TO BE REFERED>
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
<CALCULATION FORMULA OF Hr1>
<CALCULATION FORMULA OF Hf1>
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
ELEMENT
FRONT REAR
<CLCULATION DATA TO BE PROVIDED>
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
<CONDITION OF CALCULATION>
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
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.
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
195
195
190
170
175
-
FC9J
B
185
185
180
160
165
-
50
50
50
50
50
-
250
250
225
-
GD8J
B
235
235
210
-
34
34
34
-
255
250
250
180
210
-
GH8J
B
175
170
170
100
105
-
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
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
701
645
30
35
697
645
30
35
BM1503A5ECA
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
37
34
6x2, 6x4 DRIVE MODEL
PRODUCTION
CODE
FORWARD
BM1503A5ECA
Unit : mm
REARWARD
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
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
BM1503A5ECA
FD7J
610
FE7J
663.3
10
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.
FD7J
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
8. REAR SHOCK ABSORBER
PRODUCTION CODE : NOT PROVIDED
BM1503A5ECA
12
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
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.(RLD-JREAR)
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
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
(Nm {kgfm} 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
617 Nm
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
617 Nm
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
-
617 Nm
Q'ty/
unit
01
01
01
01
01
08
08
02
06
-
617 Nm
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
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

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
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
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 (1x10mm), 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
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)
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
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
R1
COUNTER SHAFT
CENTER
FILLER PRUG
OUTPUT FLANGE
P.T.O. HOLE CENTER

18 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.)
P.T.O. AND CONTROL

[T/M P.T.O. : TP-1b, 1c, 1d]
Unit : mm
R : REAMER BOLT
MAIN SHAFT
CENTER
COUNTER SHAFT
CENTER
FILLER PRUG
3.0
P.T.O. HOLE CENTER
20
50 0.1
66
+0.2
0
25 0.1
4 - 8
OUTPUT FLANGE
R
45
70
123
7
6
34H9
91.5
+0.2
0
18 COUNTER BORED
11
46
END OF T/M CASE
(124)
65
16
14.5
13
TAPER1/8
28
21.5
12

25
WARNING
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
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
P.T.O. AND CONTROL

[T/M P.T.O. : TP-1]
Layout of power line
CRANKCASE
SIDE RAIL UPPER FACE

TRANSMISSION
CLUTCH
HOUSING
FLYWHEEL
HOUSING
B
R
ENGINE CENTE
FRONT AXLE DATUM LINE
CASE
DRIVE SHAFT C
ENTER
124
F
215.5
Unit : mm
TRANSMISSION
MODEL
LX06S
APPLICATION
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
FT1J
340
83
3.5
394 173.5 577
GT1J
GT8J
290
138
3.5
394 173.5 577
BM1503A5ECA
P.T.O. AND CONTROL

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

TRANSMISSION
MODEL
PERMISSIBLE TORQUE
LJ06S
245 {25} / 1,000
Necessary parts
T/M P.T.O.
TRANSMISSION MODEL
1ST
2ND
3RD
4TH
5TH
6TH
REV
P.T.O. CONTROL TYPE

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
617 Nm
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
617 Nm
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
494.5 Nm
494.5 Nm
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
494.5 Nm
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
617 Nm
NOTE

BM1503A5ECA
P.T.O. AND CONTROL

[T/M P.T.O. : TP-2]
DETAIL OF P.T.O., TRANSMISSION MODEL HINO LJ06S

transmission case and installation gasket, adaptor and P.T.O. body.
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.
P.T.O..

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
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

BM1503A5ECA
10
P.T.O. AND CONTROL

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

Measurement of backlash (a) (between gear A and B)
Attach a fuse (1 X 10mm), with grease on the tooth surface of the P.T.O. gear B (3
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
been installed correctly.
If the specified gear backlash value cannot be obtained despite correct installation, use
another P.T.O. assembly.
BM1503A5ECA
11
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

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
+0.10787

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
22 30'
22 30'
22 30'
28 RH
28 RH
28 RH
BM1503A5ECA
0
-0.04
12
P.T.O. AND CONTROL

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

BM1503A5ECA
13
P.T.O. AND CONTROL

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

TRANSMISSION
CLUTCH
HOUSING
FLYWHEEL
HOUSING
B
R
ENGINE CENTE
CASE
DRIVE SHAFT C
ENTER
275
Unit : mm
TRANSMISSION
MODEL
LJ06S
APPLICATION
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
P.T.O. AND CONTROL

[T/M P.T.O. : TP-3]
WARNING
TRANSMISSION
MODEL
PERMISSIBLE TORQUE
MF06S
245 {25} / 1,000

TYPE
ROTATION
Pneumatic
Reverse to
control
engine
Necessary parts
T/M P.T.O.
TRANSMISSION MODEL
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

BM1503A5ECA
15
P.T.O. AND CONTROL

[T/M P.T.O. : TP-3]
DETAIL OF P.T.O., TRANSMISSION MODEL HINO MF06S

transmission case, installation gasket and P.T.O. body.
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 : 494.5 Nm {50045 kgfcm}
P.T.O..

TRANSMISSION
MODEL
N1
N2
N3
N4
N5
MF06S
22
47
21
29
12
1.220
NOTE

BM1503A5ECA
16
P.T.O. AND CONTROL

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

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 (1X10mm) 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.
been installed correctly. If the specified gear backlash value cannot be obtained despite
correct installation, use another P.T.O. assembly.
BM1503A5ECA
17
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
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

MODULE
37.457 - 00.032 / 3
- 0.4313
153.151 - 00.096 / 8.731

5.0
20
BM1503A5ECA
18
P.T.O. AND CONTROL

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

TRANSMISSION
CLUTCH
HOUSING
FLYWHEEL
HOUSING
B
R
ENGINE CENTE
CASE
DRIVE SHAFT C
ENTER
121
Unit : mm
TRANSMISSION
MODEL
MF06S
APPLICATION
FG1J
FG8J
GH1J
GH8J
290 187.6 3.5
394 173.5 136
490
270 187.6 3.5
394 173.5 136
490
BM1503A5ECA
20
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

TRANSMISSION
MODEL
HK06S
PERMISSIBLE TORQUE
TYPE
ROTATION
( 245 {25} / 1,000 )
( CAPACITY OF OUTPUT GEAR OF T/M. )
Necessary parts
TRANSMISSION MODEL
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
P.T.O. AND CONTROL

[T/M P.T.O. : TP-4]
Remove the drain plug to drain transmission oil.
(Do not remove the drain plug while the oil is hot, as you may be burned.)
Do not reuse bolts and gasket that you remove at this time.
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 )
transmission case and installation gasket, shim and P.T.O. body.
Tightening torque for bolts : 44.1 ~ 53.9 Nm {450 ~ 550 kgfcm}
When you refill the transmission with oil, increase the amount by 0.5 liters,to allow for
the P.T.O..

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
HK06S
24
43
20
30
NOTE

BM1503A5ECA
22
P.T.O. AND CONTROL

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

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
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 (1 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
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]
CRANKCASE

TRANSMISSION
FLYWHEEL
HOUSING
CLUTCH
HOUSING
B
R
ENGINE CENTE
CASE
DRIVE SHAFT C
ENTER
Unit : mm
TRANSMISSION
MODEL
HK06S
APPLICATION
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
P.T.O. AND CONTROL

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

TRANSMISSION
MODEL
PERMISSIBLE TORQUE
M009
345 {35} / 1,000

TYPE
ROTATION
Electric pneumatic
Reverse to
control
engine
Necessary parts
TRANSMISSION MODEL
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

BM1503A5ECA
26
P.T.O. AND CONTROL

[T/M P.T.O. : TP-5]
DETAIL OF P.T.O., TRANSMISSION MODEL HINO M009

PTO Installation Procedure
(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 Nm {432 ~ 530 kgfcm}
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
M009
29
30
16
31
16
1.034
NOTE

BM1503A5ECA
27
P.T.O. AND CONTROL

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

Measurement of backlash (between gear A and B)
Attach a fuse (1x10mm), with grease on the tooth surface of the P.T.O. gear B (3
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
P.T.O. AND CONTROL

[T/M P.T.O. : TP-5]
TRANSMISSION MODEL
T/M GEAR RATIO
Unit : mm
M009
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
P.T.O. AND CONTROL

[T/M P.T.O. : TP-5]
Unit : mm
WARNING

drive shaft must be Min. 1 to Max. 6.
BM1503A5ECA
30
P.T.O. AND CONTROL

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

TRANSMISSION
CLUTCH
HOUSING
FLYWHEEL
HOUSING
B
R
ENGINE CENTE
CASE
DRIVE SHAFT C
ENTER
Unit : mm
TRANSMISSION
APPLICATION
MODEL
M009
FM1A
FM2P
323
175
4.0
BM1503A5ECA
394 181.6
438.5 138
302.5 419.7
31
P.T.O. AND CONTROL

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


TRANSMISSION
MODEL
EATON RT-8908LL
RTO-11909ALL
PERMISSIBLE OUTPUT TORQUE

IN ACCORDANCE WITH SAE STD HEAVY DUTY P.T.O.
Necessary parts
TRANSMISSION MODEL
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
Q'ty /
unit
NIL
(IN ACCORDANCE
WITH SAE STD
HEAVY DUTY P.T.O.)
BM1503A5ECA
32
P.T.O. AND CONTROL

[T/M P.T.O. : TP-6]
DETAIL OF P.T.O., TRANSMISSION MODEL EATON RT-8908LL / RTO-11909ALL

NO. OF GEAR
TRANSMISSION MODEL
EATON RT-8908LL
RTO-11909ALL
BM1503A5ECA
N1
N2
N3
48
69
47
33
P.T.O. AND CONTROL

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

TRANSMISSION
FLYWHEEL
HOUSING
CLUTCH
HOUSING
B
R
ENGINE CENTE
CASE
DRIVE SHAFT C
ENTER
Unit : mm
TRANSMISSION
MODEL
EATON RT-8908LL
/ RTO-11909ALL
APPLICATION
FM1A
323
175
394
BM1503A5ECA
181.6 203.28 761.5
35
P.T.O. AND CONTROL

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

TRANSMISSION
MODEL
EATON ES11109
FS-8209BBE
FS-6109A
PERMISSIBLE TORQUE
Necessary parts
TRANSMISSION MODEL
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
ELBOW
CONNECTOR

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

BM1503A5ECA
36
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
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.
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".
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 Nm {418 - 484 kgfcm}
Tightening torque of stud and nut : 48 - 54 Nm {490 - 551 kgfcm}
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
P.T.O. AND CONTROL

[T/M P.T.O. : TP-7]
Gear ratio : i = N2/N1xN4/N3xN6/N5xN8/N7

TRANSMISSION
MODEL
EATON ES11109
FS-8209BBE
FS-6109A
N1
N2
N3
N4
N5
N6
N7
N8
33
43
32
18
24
22
21
37
1.183
NOTES

BM1503A5ECA
38
P.T.O. AND CONTROL

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

bigger backlash causes the noise from gears, on the contrary the smaller backlash
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 Nm {221 - 276 kgfcm}.
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
P.T.O. AND CONTROL

[T/M P.T.O. : TP-7]
Unit : mm
NOTE
Gear data and backlash are specified by gear box manufacturer.

BM1503A5ECA
40
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]
CRANKCASE

TRANSMISSION
FLYWHEEL
HOUSING
CLUTCH
HOUSING
B
R
ENGINE CENTE
CASE
DRIVE SHAFT C
ENTER
Unit : mm
TRANSMISSION
MODEL
EATON ES11109
FS-8209BBE
FS-6109A
APPLICATION
FG1J
FG8J
GH1J
GH8J
FL1J
FL8J
FM1J
FM8J
BM1503A5ECA
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
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..

TRANSMISSION
SERIES
PERMISSIBLE TORQUE
(Nm {kgfm})
ZF 9S1310
800 {81.5}

TYPE
ROTATION
Pneumatic
Reverse to
control
engine
Necessary parts
TRANSMISSION MODEL
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

BM1503A5ECA
43
P.T.O. AND CONTROL

[T/M P.T.O. : TP-8]
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 110C is not exceeded. Brief temperature peaks of up to
130C are permissible(lasting not more than 30 minutes).
Gera ratio : i = N2/N1xN4/N3xN5/N4

TRANSMISSION
N1
N2
N3
N4
N5
N6
ZF 9S1310
32
33
14
21
14
1.031
NOTES

BM1503A5ECA
44
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
P.T.O. AND CONTROL

[T/M P.T.O. : TP-8]
P.T.O. Mounting location of transmission case
BM1503A5ECA
46
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]
CRANKCASE

TRANSMISSION
FLYWHEEL
HOUSING
CLUTCH
HOUSING
B
R
ENGINE CENTE
CASE
DRIVE SHAFT C
ENTER
Unit : mm
TRANSMISSION
MODEL
APPLICATION
ZF 9S1310
SG2P
323
180
BM1503A5ECA
6.5 438.5 138
216
598
48
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..

TRANSMISSION
MODEL
ALLISON 2500
PERMISSIBLE TORQUE

TYPE
ROTATION
See ALLISON's specifications section of the tech data book.
Necessary parts
TRANSMISSION MODEL
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]
CRANKCASE

TRANSMISSION
303.3
CASE
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
B
R
ENGINE CENTE
Unit : mm
TRANSMISSION
MODEL
ALLISON 2500
APPLICATION
FE7J
GT8J
402.9 171.3 3.5

290
BM1503A5ECA
138
3.5
331 173.5
394 273.5
50
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)
Nm (pound-foot)
With a PTO on Both Pads Simultaneously Each, Continuous
271 (200)
Nm (pound-foot)
BM1503A5ECA
51
P.T.O. AND CONTROL

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


TRANSMISSION
MODEL
ALLISON 3000
ALLISON 3500
PERMISSIBLE TORQUE

TYPE
ROTATION
See ALLISON's specifications section of the tech data book.
Necessary parts
T/M P.T.O.
TRANSMISSION MODEL
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
BM1503A5ECA
Parts No.
Q'ty /
unit
NIL
52
P.T.O. AND CONTROL

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

182.8
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
SPACER
R
ENGINE CENTE
TRANSMISSION
CASE
Unit : mm
TRANSMISSION
MODEL
ALLISON 3000
ALLISON 3500
APPLICATION
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
394
181.6
20
BM1503A5ECA
53
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
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
CRANKSHAFT
CENTER LINE
CHASSIS CENTER LINE
FRAME
ASSEMBLED WIDTH
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
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
Nm {kgfm}
343{35}
343{35}
343{35}
441{45}
392{40}
441{45}
Refer to 8.2
235
457.6
14
637{65}
REV.
RATIO
REV. DIRECTION
(See from engine rear)
0.722
0.722
0.722
1.000
1.000
0.896
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
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
P.T.O. AND CONTROL
BM1503A5ECA
57
P.T.O. AND CONTROL

427.5
CRANKCASE
TRANSMISSION
321.8
FLYWHEEL
HOUSING
ENGINE CENTER
CASE
DRIVE SHAFT CE
NTER
F
J
Unit : mm
CHASSIS
MODEL
GT8J
290
138
3.5
BM1503A5ECA
394 273.5 752.3
58
P.T.O. AND CONTROL
4. TRANSFER POWER TAKE OFF

When the body require transfer Power Take Off (P.T.O.) , genuine
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
P.T.O. AND CONTROL

Transfer P.T.O. mounting
Unit : mm
BM1503A5ECA
60
P.T.O. AND CONTROL

Transfer P.T.O. particulars
Unit : mm
BM1503A5ECA
61
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
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.
BM1503A5ECA
63
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.)

optional equipment

Engine Control ECU
(CUSTOMIZE)
revo. Only)
BM1503A5ECA
Hino Diagnostic Explore
64
P.T.O. AND CONTROL

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
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.
BM1503A5ECA
65
P.T.O. AND CONTROL

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
66
P.T.O. AND CONTROL

[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 -30~80C.
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
67
P.T.O. AND CONTROL

5.2. ENGINE CONTROL TYPE : U-2b
ENGINE MODEL
ENGINE MODEL
J05E-TC
J08E-UC
J05E-TD
J08E-TE
J08E-UB
J08E-UD
J08E-UE
ENGINE CONTROL
installation.
KIND OF METHOD
Device
engine speed
Idle up switch
Idle to 980 rpm

revo. Only)
To be provided by
body manufacturer
Engine accelerator

revo.)

optional equipment
BM1503A5ECA
Provision of device
68
P.T.O. AND CONTROL

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

Recommended electric circuit is as follows.
U2 - ECU
(ENGINE CONTROL ECU)
K4F
U2 - 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.
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
69
P.T.O. AND CONTROL

Engine accelerator


Other precautions


above conditions.

BM1503A5ECA
70
P.T.O. AND CONTROL


termed the sensor).
not bend extremely.
COMMON manual.
reference.
BM1503A5ECA
71
P.T.O. AND CONTROL

5.3. ENGINE CONTROL TYPE : U-2c
ENGINE MODEL
P11C-UV
P11C-VR
ENGINE CONTROL
installation.
KIND OF METHOD
Device
Idle up switch
Engine accelerator
engine speed
Idle to 850 rpm

revo. Only)
revo.)
BM1503A5ECA
Provision of device
To be provided by
body manufacturer
optional equipment
72
P.T.O. AND CONTROL

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

Recommended electric circuit is as follows.
U2 - ECU
K4F
U2 - 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.
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
73
P.T.O. AND CONTROL

Engine accelerator


Other precautions


above conditions.

BM1503A5ECA
74
P.T.O. AND CONTROL


termed the sensor).
not bend extremely.
COMMON manual.
reference.
BM1503A5ECA
75
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
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
J05CTF
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
76
P.T.O. AND CONTROL

5.4. ENGINE CONTROL TYPE : MECHA.(R901)
Governor lever for body control
ENGINE
MODEL
Unit : mm
J05E-TE
BM1503A5ECA
77
P.T.O. AND CONTROL

SPEED CONTROL LEVER REACTION

LOW IDLE
FULL SPEED
ENGINE
MODEL
J08C-F
12.55
403
14.4N {1.47kgf}
23.5N {2.40kgf}
J08C-TS
12.55
39.53
15.7N {1.6kgf}
25.5N {2.6kgf}
J08E-UG
13.55
373
14.4N {1.47kgf}
23.5N {2.40kgf}
J08E-UF
12.55
393
14.4N {1.47kgf}
23.5N {2.40kgf}
BM1503A5ECA
Unit : mm
78
P.T.O. AND CONTROL

ENGINE
MODEL
Unit : mm
J08C-TG
FOR BODY CONTROL (6.3
)
LOW IDLE
165
113
+0.1
-0.2
40
3
FULL SPEED
R5
CONTROL DIRECTION
OF CABLE FOR BODY
OR EQUIPMENT
R4

58
159.7
BM1503A5ECA
LOW IDLE
14.4N {1.47kg}
FULL SPEED
23.5N {2.40kg}
79
P.T.O. AND CONTROL

5.4. ENGINE CONTROL TYPE : MECHA.(RLD-J,FRONT)

LOW IDLE
FULL SPEED
ENGINE
MODEL
J05C-TF
55
34.53
7.8N {0.8kgf}
15.7N {1.6kgf}
J08C-TT
8.55
40.53
12.7N {1.3kgf}
36.3N {3.7kgf}
J08C-UL
8.55
36.53
6.8N {0.7kgf}
14.2N {1.4kgf}
BM1503A5ECA
80
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.
BM1503A5ECA
81
P.T.O. AND CONTROL

5.5. ENGINE CONTROL TYPE : MECHA.(RLD-J, REAR)

Engine Model : P11C-UB
BM1503A5ECA
82
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


BM1503A5ECA
83
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.
BM1503A5ECA
84
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
BM1503A5ECA
85
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
BM1503A5ECA
86
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
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
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.
1FOR GT FIRE FIGHTING MODEL.

2FOR OTHER MODELS EXCEPT MODEL 1.
BM1503A5ECA
87
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
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.
BM1503A5ECA
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
4/5
2
3
4
4
5/5/4
8
9
10
11
12
4/5
4
4
5
13
14
15
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
HEATER RLY
2
3
4
4
A/C RLY
A/C CONDENSER RLY
HORN RLY
U2 PCV RLY
BACK-UP LAMP RLY
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
ABS WARNING LAMP RLY
14
ABS EXHAUST BRAKE CUT RLY
15
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
M009 SELECT RLY
M009 THROTTLE RLY

ABS MOTOR RLY
36
37
A
B
E
F
G
H
5
4
ONE-KEY RLY
STOP LAMP RLY
ABS SOLENOID RLY
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
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
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
PARTS No. 82824 - E0K70 PARTS No. 82824 - E0K60
AGM
ALL MODEL
PARTS No. SZ591 - 04002 PARTS No. SZ591 - 04001
&06
PTO CUT RLY
0.5
W
NOT PROVIDED
ARLI
&06
PARTS No. 82824 - E0U30 PARTS No. S8258 - 06160
&07
ENGINE STOP SW
0.5
L-W
NOT PROVIDED
EGST
&07
GROUND
PARTS No. 82824 - E0U30 PARTS No. S8258 - 06160
CAB SIDE
Center of instrument panel
*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
I0Q
POWER SUPPLY, ACC
I0K
I0S
*2
NOT PROVIDED
ENGINE STOP SW
ACC ILL
I0Q I0K
GND +B
I0S I0P
PTO SW1
NOT PROVIDED
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.
%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
0.5
Y-W
%E6
%E6 IDLE-UP SENSOR (INPUT)
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
PARTS No. S8256 - 02970 PARTS No. S8256 - 02960
&04
PTO SW2 or IDLE-UP SENSOR
POWER SUPPLY
POWER SUPPLY, IGNITION KEY ON
PARTS No. 82824 - E0U70

PARTS No. S8258 - 08380
or
S8258 - 06920
AQK
PTO CUT RLY
ALL MODEL
NOT PROVIDED

POWER SUPPLY, ACC
GROUND
ALL MODEL
PARTS No. 82824 - E0U30
or
PARTS No. S8258 - 06160
S8258 - 06170
BM1503A5ECA
ELECTRICAL SYSTEMS
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
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
No.2 CROSSMEMBER
*2
7A
*4
0.85 or 1.25
NOT PROVIDED
O-
PTL2
AGQ
I
PARTS No. 82824 - E0M10 PARTS No. 82824 - E0M00
FOR FIRE ENGINE

CHASSIS SIDE
FRONT
FRONT
FRAME SIDE RAIL
ACCEL SENSOR
AGQ
AGQ POWER SUPPLY, LIGHTING
7A
NOT PROVIDED
No.2 CROSSMEMBER
0.85
W-L
ALL MODEL
AGQ
HOW TO TAKE ELECTRICITY FROM POWER SUPPLY CIRCUIT

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
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.
BM1503A5ECA
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 Nm {108 ~ 137 kgfcm}
To body
Should be added an adequate fuse.
Terminal
Battery positive terminal
BM1503A5ECA
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
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 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.
BM1503A5ECA
ELECTRICAL SYSTEMS

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
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
10
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.
BM1503A5ECA
11
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.
BM1503A5ECA
12
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
BM1503A5ECA
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
EXAMPLE
RESIN COVER
DRAIN PLUG
FOR 500/700 SERIES
PAINTING
GENERAL PRECAUTIONS FOR FORCED DRYING
When you use forced drying, a temperature on the surface of any parts to be painted
must be 80C as an upper limit.
Removing off any plastic parts, rubber parts from the vehicle, paint them when you use
a forced drying at over 80C. (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 100C), 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 80C.
NON-HEAT RESISTING PARTS AT THE HEATED AIR OR MORE THAN 80C
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 80C these parts described
above must be removed.
Detail of outside mirror to be equipped is shown following page.
BM1503A5ECA
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)
BM1503A5ECA
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 thick and the total paint thickness including undercoat
and primers should be at least 80 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.
BM1503A5ECA
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.
BM1503A5ECA
PAINTING
Front panel
BM1503A5ECA
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.
BM1503A5ECA
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.
BM1503A5ECA
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
DETAIL A (LH/RH)
C
DETAIL B (LH/RH)
DETAIL C (LH/RH)
BM1503A5ECA
PAINTING
TYPE B
SPECIFICATION : FLAT MIRROR, ADJUSTABLE STAY TYPE, LHD
BM1503A5ECA
10
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
11
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 Nm {200 20 kgfcm}

Wiper pivot tightening torque

11.8 1 Nm {120 10 kgfcm}
BM1503A5ECA
12
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

APPLICATION : FG, GH, SG, FL, FM, FT & GT ONLY
BM1503A5ECA
13
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.

APPLICATION : FC, FD & GD ONLY

APPLICATION : FG, GH, FL, FM ONLY
BM1503A5ECA
14
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 40C).
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
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
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
PAINTING
ILLUSTRATION OF THE WEATHER STRIP MARK POSITION
BM1503A5ECA
18
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
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.
BM1503A5ECA
20
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.
BM1503A5ECA
21
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.
BM1503A5ECA
22
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 120C.
When drying at the temperature of more than 120C, 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 120C.
BM1503A5ECA
23
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
: 120C
1 INSIDE TEMPERATURE OF THE CAB : LESS THAN 85C

(PLACE AT THE 50mm HEIGHT FROM
UPPER SURFACE OF CAB FLOOR.)
HANDLING OF COMPUTER
WHEN UNKNOWN THE TEMPERATURE OF THE

FORCED DRYING BOOTH OR USE
INFRARED LAMP
INSTALLED
INSIDE TEMPERATURE OF THE CAB : LESS THAN 85C

(PLACE AT THE 50mm HEIGHT FROM
UPPER SURFACE OF CAB FLOOR.)
WHEN EXPECT MORE HIGH TEMPERATURE

THAN ABOVE MENTIONED CASES.
BM1503A5ECA
REMOVE COMPUTER
24
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 10C, warm up the surface to stick as well as the
caution plate with warm wind of more than 20C 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 25C) 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.
BM1503A5ECA
25
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
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
CHASSIS DRAWINGS
1. CAB DRAWINGS
No. C-1
Unit : mm

Rear
Front
BM1503A5ECA
CHASSIS DRAWINGS
No. C-2

Unit : mm
Rear
Front
BM1503A5ECA
CHASSIS DRAWINGS
No. C-3

Unit : mm
Rear
Front
BM1503A5ECA
CHASSIS DRAWINGS
No. C-4
PRODUCTION CODE : FM8J

Unit : mm
Rear
Front
BM1503A5ECA
CHASSIS DRAWINGS
No. C-5
PRODUCTION CODE : FM2P

Unit : mm
Rear
Front
BM1503A5ECA
CHASSIS DRAWINGS
2. CAB BACK DRAWINGS

No. CB-1
Upper view
Unit : mm
Left view
BM1503A5ECA
CHASSIS DRAWINGS
No. CB-2

Upper view
Left view
BM1503A5ECA
Unit : mm
CHASSIS DRAWINGS
No. CB-3

Upper view
Left view
BM1503A5ECA
Unit : mm
CHASSIS DRAWINGS
No. CB-4
PRODUCTION CODE : FM8J

Upper view
Left view
BM1503A5ECA
Unit : mm
10
CHASSIS DRAWINGS
No. CB-5
PRODUCTION CODE : FM2P

Upper view
Left view
BM1503A5ECA
Unit : mm
11
CHASSIS DRAWINGS
3. CHASSIS DRAWINGS
Unit : mm
No. CH-1
BM1503A5ECA
12
CHASSIS DRAWINGS
No. CH-2
Unit : mm
-PAB
BM1503A5ECA
13
CHASSIS DRAWINGS
No. CH-3
Unit : mm
BM1503A5ECA
14
CHASSIS DRAWINGS
No. CH-4
Unit : mm
BM1503A5ECA
15
CHASSIS DRAWINGS
No. CH-5
Unit : mm
-TGX
BM1503A5ECA
16
CHASSIS DRAWINGS
No. CH-6
Unit : mm
-TGX
BM1503A5ECA
17
CHASSIS DRAWINGS
No. CH-7
Unit : mm
BM1503A5ECA
18
CHASSIS DRAWINGS
No. CH-8
Unit : mm
BM1503A5ECA
19
CHASSIS DRAWINGS
4. CHASSIS FRAME DRAWINGS

Unit : mm
No. CF-1
Detail of the chassis frame
BM1503A5ECA
20
CHASSIS DRAWINGS
No. CF-1
Detail of the cross member
Unit : mm
BM1503A5ECA
21
CHASSIS DRAWINGS
No. CF-2
Unit : mm
BM1503A5ECA
22
CHASSIS DRAWINGS
No. CF-2
Unit : mm
BM1503A5ECA
23
CHASSIS DRAWINGS
No. CF-3
Unit : mm
BM1503A5ECA
24
CHASSIS DRAWINGS
No. CF-3
Unit : mm
BM1503A5ECA
25
CHASSIS DRAWINGS
No. CF-4
Unit : mm
BM1503A5ECA
26
CHASSIS DRAWINGS
No. CF-4
Unit : mm
BM1503A5ECA
27
CHASSIS DRAWINGS
No. CF-5
Unit : mm
BM1503A5ECA
28
CHASSIS DRAWINGS
No. CF-5
Unit : mm
BM1503A5ECA
29
CHASSIS DRAWINGS
No. CF-6
Unit : mm
BM1503A5ECA
30
CHASSIS DRAWINGS
No. CF-6
Unit : mm
BM1503A5ECA
31
CHASSIS DRAWINGS
No. CF-7
Unit : mm
BM1503A5ECA
32
CHASSIS DRAWINGS
No. CF-7
Unit : mm
BM1503A5ECA
33
CHASSIS DRAWINGS
No. CF-8
Unit : mm
BM1503A5ECA
34
CHASSIS DRAWINGS
No. CF-8
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
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. AIR TANK & AIR BOOSTER
Unit : mm
AT-1
SPECIFICATION : FC9J
BM1503A5ECA

AT-2
Unit : mm
SPECIFICATION : GD8J
BM1503A5ECA

AT-3
Unit : mm
SPECIFICATION : GH8J
BM1503A5ECA

AT-4
Unit : mm
SPECIFICATION : FM8J
BM1503A5ECA

AT-5
Unit : mm
SPECIFICATION : FM2P
BM1503A5ECA

AT-6
Unit : mm
SPECIFICATION : FM8J, FM2P
BM1503A5ECA
2. BRAKE PIPING DIAGRAM

PD-1
SPECIFICATION : FC9J
BM1503A5ECA

PD-2
SPECIFICATION : GD8J
BM1503A5ECA

PD-3
SPECIFICATION : GH8J
BM1503A5ECA
10

PD-4
SPECIFICATION : FM8J
BM1503A5ECA
11

PD-5
SPECIFICATION : FM2P
BM1503A5ECA
12
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
FC9JJSA-NNB
GD8JLSA-PAB
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

BAT-2
SPECIFICATION : 234kC {65Ah} w/ SPACER
Unit : mm
58.5
63.5
PRODUCTION CODE
BM1503A5ECA
14
DISASSEMBLY SPACE OF
BATTERY COVER
50
321
50
60
23
394
430
TO No.2 CROSSMENBER
DATUM LINE L
Unit : mm
PRODUCTION CODE
551.5
140
284
380.5
A
VEHCLE FRONT
(BATTERY POSITION : RH)
BAT-3
SPECIFICATION : 432kC {120Ah} w/o SPACER
VEHCLE FRONT
(BATTERY POSITION : LH)
253
APPRICATION
BATTERY
POSITION
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

BAT-4
SPECIFICATION : 432kC {120Ah} w/ SPACER
Unit : mm
282
534
392
APPROX. 611
7.5
12.5
PRODUCTION CODE
APPLICATION
BATTERY
POSITION
TO NO.2 CROSSMEMBER
L
FC7J
RH
411
FD7J, FE7J
RH
426
BM1503A5ECA
16

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

BAT-6
SPECIFICATION : 432kC {120Ah} LARGE, w/ SPACER
Unit : mm
PRODUCTION CODE
BM1503A5ECA
18
4. FUEL TANK
Unit : mm
FT-1
SPECIFICATION : 100L (FC)
BM1503A5ECA
19

FT-2
SPECIFICATION : 200L (FC)
Unit : mm
BM1503A5ECA
20

FT-3
SPECIFICATION : 200L (GD)
Unit : mm
BM1503A5ECA
21

FT-4
SPECIFICATION : 200L (GH8J)
Unit : mm
BM1503A5ECA
22

FT-5
SPECIFICATION : 200L (FM8J, FM2P)
Unit : mm
BM1503A5ECA
23

FT-6
SPECIFICATION : 200L x 2 (FM8J, FM2P)
Unit : mm
BM1503A5ECA
24
5. FUEL COOLER
Unit : mm
NOT PROVIDED
BM1503A5ECA
25
6. AUTO CLUTCH UNIT (ACU)
Unit : mm
NOT PROVIDED
BM1503A5ECA
26
7. EXHAUST SYSTEM (EXHAUST TAIL PIPE)
Unit : mm
EX-1
SPECIFICATION : HORIZONTAL EXHAUST PIPE (FC4J, FC9J)
BM1503A5ECA
27

EX-2
Unit : mm
SPECIFICATION : STACK EXHAUST PIPE (FC4J, FC9J)
BM1503A5ECA
28

EX-3
Unit : mm
SPECIFICATION : HORIZONTAL EXHAUST PIPE (GD8J)
BM1503A5ECA
29

EX-4
Unit : mm
SPECIFICATION : STACK EXHAUST PIPE (GD8J)
BM1503A5ECA
30

EX-5
Unit : mm
SPECIFICATION : HORIZONTAL EXHAUST PIPE (GH8J)
BM1503A5ECA
31

EX-6
Unit : mm
SPECIFICATION : STACK EXHAUST PIPE (GH8J)
BM1503A5ECA
32

EX-7
Unit : mm
SPECIFICATION : HORIZONTAL EXHAUST PIPE (FM8J)
BM1503A5ECA
33

EX-8
Unit : mm
SPECIFICATION : STACK EXHAUST PIPE (FM8J)
BM1503A5ECA
34

EX-9
Unit : mm
SPECIFICATION : HORIZONTAL EXHAUST PIPE (FM2P)
BM1503A5ECA
35
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
BM1503A5ECA
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
36
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

[ATTENTION]
THIS CHAPTER IS NOT APPLICABLE TO YOUR MODEL SERIES.
BM1503A5ECA
Chapter 11
REGULATION
[ATTENTION]
THIS CHAPTER IS NOT APPLICABLE TO YOUR MODEL SERIES.
BM1503A5ECA

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BM1503A5ECA

HINO 500 SERIES

Body Mounting Manual

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

ABOUT THIS MANUAL

ABOUT THIS MANUAL

To be continued next page.

ABOUT THIS MANUAL

3. CHASSIS MASS & FRAME SECTION MODULUS

4. SPRINGS & REAR AXLES

5. P.T.O. AND CONTROL

9. MOUNTING OF CHASSIS EQUIPMENT

10. TRACTOR EQUIPMENT

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

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

GVMR & (DRIVE) CODE

GENERAL CARGO with

GENERAL CARGO with

FIRE ENGINE with

OTHER SPECIFICATION CODE

CAB, T/M TYPE ETC.

DUMP with REAR AIR

MIXER with REAR AIR

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

Located at the side

VEHICLE MANUFACTURED STAMPING POSITION (

LOCAL or ORIGIN (JAPAN)

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

500Nm {51kgfm} at 1,500r/min

739Nm {75.4kgfm} at 1,500rpm

739Nm {75.4kgfm} at 1,500rpm

739Nm {75.4kgfm} at 1,500rpm

1,275Nm {130kgfm} at 1,500rpm

Fr & Rr LEAF SPRING

Fr & Rr LEAF SPRING

SINGLE CAB, WIDE TYPE

SINGLE CAB, WIDE TYPE

SINGLE CAB, WIDE TYPE

SRS AIR BAG

FRONT UNDERRUN PROTECTION DEVICE (FUPD)

REAR UNDERRUN PROTECTION DEVICE (RUPD)

S : STANDARD EQUIPMENT P : OPTION EQUIPMENT

CHASSIS MASS ON STD SPECIFICATIONS

EATON ES11109 (9MT)

Fr & Rr LEAF SPRING

PERMISSIBLE AXLE CAPACITY

EATON ES11109 (9MT)

MAX. GVM/GCM CAPACITY (REGAL LIMIT)

VEHICLE CONTROL ECU

HEIGHT OF CENTER OF GRAVITY (CHASSIS)

RECOMMENDED HEIGHT OF GRAVITY CENTER

RECOMMENDED BODY WIDTH

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

3.1. CHASSIS MASS

5.3. ENGINE REAR END POWER TAKE OFF

5.4. TRANSFER POWER TAKE OFF

5.5. ENGINE CONTROL FOR BODY OR EQUIPMENT

8.2. CAB BACK DRAWINGS

8.3. CHASSIS DRAWINGS

9.1. AIR TANK & AIR BOOSTER

1. PRECAUTION FOR SRS AIR BAG

2.1 Procedure before welding

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

4. PRECAUTION FOR ENGINE ECU

5. PRECAUTION FOR EXHAUST SYSTEM

(3) Working condition while under operation

(1) Outline of DPR Muffler

(5) Paint application

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