Body Mounting Manual: KK-GH214
Body Mounting Manual: KK-GH214
Body Mounting Manual: KK-GH214
TRUCK CHASSIS
MODEL GH8 J
No part of this manual may be reproduced or transmitted in any form without the express
written permission of Hino Motors, Ltd.
© 2012, All rights reserved. Printed in Japan.
Telephone : 042-586-5887
Facsimile : 042-586-4172
2012 - 10
KK-GH214
WARNING
• When making use of the BODY MOUNTING MANUAL, use the MODEL NAME after
replacing it in accordance with the following table.
KK-GH214
ABOUT THIS MANUAL
Purpose
• 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,
Content
Important
This instruction manual must be used in combination with
the Common Manual, No. KC-AA201.
KK-GH214
ABOUT THIS MANUAL
Warning
• The vehicle has installed electronic equipments such as the vehicle's control system
and a computer for comply with vehicle regulation for each country.
In that case, do must not alter of chassis such as change of wheelbase and tire size.
Deterioration of vehicle's capability and vehicle regulation violation may lead to serious
traffic accident.
• 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 Manufacturers 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.
• About installation of T/M PTO (Engine for complied Euro-3,4 & 5 regulation.)
It can not control stable engine revolution because engine governor character is not
switch to PTO mode if installed PTO unit whether Hino original or not by local market.
Should not install the PTO unit at local market except mount body of unnecessary
constant engine revolution such as dump truck.
• About chassis mass
The chassis mass of chapter 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.
• 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.
KK-GH214
CONTENTS
1. VEHICLE SUMMARY
2. GENERAL PRECAUTIONS
6. ELECTRICAL SYSTEMS
7. PAINTING
8. CHASSIS DRAWINGS
10. OTHER
11. REGULATION
KK-GH214
Chapter 1
VEHICLE SUMMARY
1. MODEL CODE•••••••••••••••••••••••••••••••••••••••••••••••••••• 1
2. IDENTIFICATION NUMBER••••••••••••••••••••••••••••••••••• 2
3. CHASSIS SPECIFICATIONS•••••••••••••••••••••••••••••••••• 3
KK-GH214
1 VEHICLE SUMMARY
1. MODEL CODE
F D 7J J M A
GVMR & (DRIVE) CODE ENGINE CODE WHEELBASE CODE MODIFICATION CODE APPLICABLE CODE
VEHICLE TYPE
WHEELBASE STEERING BODY TYPE
GVMR DRIVE CODE MODEL CODE CODE MODIFY CODE
(mm) POSITION ETC.
10,400kg C 3000 GENERAL CARGO &
F CAB-OVER TRUCK C 4x2 6J J05D K A
CLASS D 3000 3249 FIRST LEAF SUSPENSION
RH
10,000 12,000kg E 3250 3499 R GENERAL CARGO &
G CAB-OVER TRUCK D 4x2 7J J07E B
CLASS G 3750 3999 LEAF SUSPENSION
NOTE
• Refer to chassis specification for GVMR (Gross vehicle mass rating).
KK-GH214 1
1 VEHICLE SUMMARY
2. IDENTIFICATION NUMBER
CHASSIS NUMBER
ENGINE NUMBER
: ENGINE NUMBER
Right side of
cylinder block A
ENGINE MODEL
A J05E
J05D
J08E
B
A09C
P11C
KK-GH214 2
1 VEHICLE SUMMARY
3. CHASSIS SPECIFICATIONS
NOTE
• Permissible axle capacity and GVM or GCM capacity listed above table must not be exceeded.
• The front axle load must exceed 30% of the gross vehicle mass under full loaded condition for 4x2 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 height of center of gravity from ground on the unloaded vehicle with body mounted should be m or less for 16inches disc wheel.
• The height of center of gravity from ground on the unloaded vehicle with body mounted should be 1.20 m or less for 20inches disc wheel.
• 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 to be mentioned in above chassis specification shows design figure according to JATMA or ETRTO standard.
KK-GH214 3
1 VEHICLE SUMMARY
ENGINE CLASSIFICATION
ITEMS TRANSMISSION CLASSIFICATION
STD/OPT ITEMS
RELEVANT MODEL NUMBER RELEVANT MODEL NUMBER
JIS GROSS LX06S
MAX. OUTPUT
ISO NET LJ06S
J05D-TG
JIS GROSS MF06S
MAX. TORQUE
ISO NET HK06S
JIS GROSS EATON RT-8908LL
MAX. OUTPUT
ISO NET
J05E-TC ZF 9S109
JIS GROSS
MAX. TORQUE GH-051,052,053 S EATON FS-6109A
ISO NET
EATON FS-8209BBE
JIS GROSS
MAX. OUTPUT ALLISON 3000
ISO NET
J05E-TD ALLISON 3500
JIS GROSS
MAX. TORQUE
ISO NET
JIS GROSS
MAX. OUTPUT
ISO NET
J05E-TE
JIS GROSS
MAX. TORQUE
ISO NET
JIS GROSS 191kW {260PS} at 2,500rpm REAR SUSPENSION CLASSIFICATION
STD/OPT ITEMS
MAX. OUTPUT
ISO NET 184kW {251PS} at 2,500rpm RELEVANT MODEL NUMBER
GH-051,052,053 J08E-UB AIR
JIS GROSS 745N·m {76kgf·m} at 1,500rpm
MAX. TORQUE GH-051,052,053 S LEAF
ISO NET 739N·m {75.4kgf·m} at 1,500rpm
JIS GROSS
MAX. OUTPUT
ISO NET
J08E-UC
JIS GROSS
MAX. TORQUE
ISO NET
JIS GROSS
MAX. OUTPUT
ISO NET
J08E-UD
JIS GROSS
MAX. TORQUE
ISO NET
JIS GROSS
MAX. OUTPUT
ISO NET
J08E-UE
JIS GROSS
MAX. TORQUE
ISO NET
JIS GROSS
MAX. OUTPUT
ISO NET
J08E-UF
JIS GROSS
MAX. TORQUE
ISO NET
JIS GROSS
MAX. OUTPUT
ISO NET
J08E-UG
JIS GROSS
MAX. TORQUE
ISO NET
JIS GROSS
MAX. OUTPUT
ISO NET
J08E-TB
JIS GROSS
MAX. TORQUE
ISO NET
JIS GROSS S : STANDARD EQUIPMENT
MAX. OUTPUT
P : OPTION EQUIPMENT
ISO NET
J08E-TE
JIS GROSS
MAX. TORQUE
ISO NET
JIS GROSS
MAX. OUTPUT
ISO NET
A09C-TE
JIS GROSS • Refer to chapter 1, 3 chassis specification for
MAX. TORQUE
ISO NET classification number.
JIS GROSS
MAX. OUTPUT
ISO NET
P11C-UB
JIS GROSS
MAX. TORQUE
ISO NET
KK-GH214 4
1 VEHICLE SUMMARY
TIRE CLASSIFICATION
STD/OPT ITEMS WHEEL DISC CLASSIFICATION
STD/OPT ITEMS
RELEVANT MODEL NUMBER RELEVANT MODEL NUMBER
8.25-16-14PR 16x6.00GS-offset135mm
9.5R17.5 (129/127) 17.5x6.75-offset135mm
235/75R17.5 20x6.50T-offset145mm
8.25-20-14PR 20x6.50T-offset152mm
9.00-20-12PR 20x7.00T-offset152mm
9.00-20-14PR 20x7.00T-offset162mm
9.00R20-14PR GH-051,052,053 P 20x7.50V-offset165mm
10.00-20-14PR 22.5x6.75-offset152mm
10.00-20-16PR 22.5x7.50-offset162mm
11.00-20-14PR GH-051,052,053 S 22.5x8.25-offset165mm
11.00-20-16PR 16x6.00GS-offset135mm
11.00R20-16PR 17.5x6.75-offset135mm
9R22.5 (133/131) 20x6.50T-offset152mm
10R22.5 (144/142) 20x7.50V-offset165mm
11R22.5-14PR 22.5X7.50-offset162mm
11R22.5-16PR 22.5x8.25-offset165mm
GH-051,052,053 S 11R22.5 (148/145)
235/70R22.5 (138/135)
255/70R22.5 (140/137)
275/70R22.5 (148/145)
275/80R22.5 (149/146)
295/80R22.5 FUEL TANK CLASSIFICATION
STD/OPT ITEMS
295/80R22.5 (152/148) RELEVANT MODEL NUMBER
8.25R16-14PR 100L
9.5R17.5 (129/127) GH-051,052,053 S 200L
235/75R17.5 (130/128) 300L
8.25R20-14PR 200L
9.00-20-14PR 200Lx2
9.00R20-12PR 400L
9.00R20-14PR
10.00-20-16PR
10.00R20-14PR
10.00R20-16PR
11.00-20-14PR
11.00-20-16PR BATTERY CLASSIFICATION
STD/OPT ITEMS
11.00R20-14PR RELEVANT MODEL NUMBER
GH-051,052,053 P 11.00R20-16PR GH-051,052,053 S 65AH
9R22.5 (133/131) GH-051,052,053 P 120AH
10R22.5-14PR
11R22.5-14PR
11R22.5-16PR
11R22.5 (148/145)
S : STANDARD EQUIPMENT
GH-051,052,053 P 12R22.5-16PR P : OPTION EQUIPMENT
235/70R22.5 (138/135) ALTERNATOR CLASSIFICATION
STD/OPT ITEMS
255/70R22.5 (143/140) RELEVANT MODEL NUMBER
24V-50A
GH-051,052,053 P 275/70R22.5 (148/145)
GH-051,052,053 S 24V-60A
GH-051,052,053 P 275/80R22.5 (151/148) • Refer to chapter 1, 3 chassis specification for
24V-90A
295/80R22.5 classification number.
KK-GH214 5
Chapter 2
GENERAL PRECAUTIONS
1. FIRE SHIELD•••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
2. CLEARANCE BETWEEN CAB AND
REAR BODY OR EQUIPMENT•••••••••••••••••••••••••••• 2
3. RECOMMENDED POSITIONS OF U-BOLTS•••••••••••••• 11
4. RECOMMENDED POSITIONS OF REAR
FENDERS AND MUDGUARDS•••••••••••••••••••••••••••• 13
5. ELECTRIC WELDING WORK••••••••••••••••••••••••••••••••• 15
6. NOTES ON ADDITIONAL WIRING
IN THE ENGINE COMPARTMENT•••••••••••••••••••••••• 17
7. PRECAUTION OF THE ANTENNA POSITION•••••••••••• 18
8. NOTES ON SYSTEM CONTROL COMPUTERS•••••••••• 19
9. PRECAUTION FOR ADDITIONAL FUEL TANK••••••••••• 20
10. PRECAUTIONS FOR THE FUEL HOSE•••••••••••••••••••• 21
11. ADJUSTMENT OF LIGHT AXIS OF HEADLIGHT•••••••• 22
KK-GH214
2 GENERAL PRECAUTIONS
1. FIRE SHIELD
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.
NOTE
• 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.
BODY OR
EQUIPMENT
KK-GH214 1
2 GENERAL PRECAUTIONS
2. CLEARANCE BETWEEN CAB AND REAR BODY OR EQUIPMENT
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
KK-GH214 2
2 GENERAL PRECAUTIONS
Unit : mm
MODEL A
FD, FT 1,600
FG 1,575
GT 1,550
KK-GH214 3
2 GENERAL PRECAUTIONS
RELEVANT MODEL
CLASSIFICATION NUMBER
Unit : mm
KK-GH214 4
2 GENERAL PRECAUTIONS
RELEVANT MODEL
CLASSIFICATION NUMBER A
RELEVANT MODEL
CLASSIFICATION NUMBER A B
GH-051, 052, 053 793 564
KK-GH214 5
2 GENERAL PRECAUTIONS
RELEVANT MODEL
CLASSIFICATION NUMBER A B C D E F G H
KK-GH214 6
2 GENERAL PRECAUTIONS
Unit : mm
RELEVANT MODEL
CLASSIFICATION NUMBER A B C D
GH-051, 052, 053 1122.5 772.5 805 1551.5
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.
KK-GH214 7
2 GENERAL PRECAUTIONS
B C D
614.5 1073.5 256.5
KK-GH214 8
2 GENERAL PRECAUTIONS
RELEVANT MODEL
CLASSIFICATION NUMBER : Unit : mm
KK-GH214 9
2 GENERAL PRECAUTIONS
RELEVANT MODEL
CLASSIFICATION NUMBER : Unit : mm
KK-GH214 10
2 GENERAL PRECAUTIONS
3. 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
RELEVANT MODEL Unit : mm
CLASSIFICATION
X L1 L2 L3 L4 A B
NUMBER
GH-051 RH 885 – 150 –
LH 435 – 150 –
GH-052 RH 885 1560 150 2120
LH 435 1560 150 2120
GH-053 RH 885 2110 150 2170
LH 435 2110 150 2170
RH
LH
RH
LH
RH
LH
RH
LH
L2 L3
A B
No.1 U-BOLT No.2 U-BOLT No.3 U-BOLT No.4 U-BOLT No.5 U-BOLT
NOTE
• 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.
KK-GH214 11
2 GENERAL PRECAUTIONS
RELEVANT MODEL
CLASSIFICATION NUMBER : 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-AA001F or KC-AA201 of Body Mounting Manual.
KK-GH214 12
2 GENERAL PRECAUTIONS
4. RECOMMENDED POSITIONS OF REAR FENDERS AND MUDGUARDS
When mounting rear fenders and mudguards, determine required clearances with
reference to the following table and figures of “MAXIMUM VERTICAL DEFLECTION OF
REAR WHEELS” in 4 - 2.
RELEVANT MODEL
(FOR REAR SINGLE AXLE) Unit : mm
CLASSIFICATION
STD/OPT REAR TIRE A B C D
NUMBER
8.25-16-14PR
8.25R16-14PR
9.5R17.5 (129/127)
235/75R17.5 (130/128)
8.25-20-14PR
8.25R20-14PR
9.00-20-12PR/14PR
9.00R20-12PR/14PR
10.00-20-14PR/16PR
10.00R20-14PR/16PR
11.00-20-14PR/16PR
GH-051, 052, 053 OPT 11.00R20-14PR/16PR 2455 2475 1840 167.5
9R22.5 (133/131)
10R22.5-14PR
10R22.5 (144/142)
11R22.5-14PR/16PR
GH-051, 052, 053 STD 11R22.5 (148/145) 2450 2470 1840 170
GH-051, 052, 053 OPT 12R22.5-16PR 2470 2480 1840 160
235/70R22.5 (138/135)
255/70R22.5 (140/137)
255/70R22.5 (143/140)
GH-051, 052, 053 OPT 275/70R22.5 (148/145) 2445 2465 1840 172.5
GH-051, 052, 053 OPT 275/80R22.5 (151/148) 2445 2465 1840 172.5
295/80R22.5
295/80R22.5 (152/148)
TIRE WHEEL
E F
SIZE (in)
150
16 or 17.5 200
~ 200
200
20 or 22.5 300
~ 250
NOTE
• The dimension of tire to be mentioned in above table shows design figure according
to JATMA or ETRTO standard.
KK-GH214 13
2 GENERAL PRECAUTIONS
RELEVANT MODEL
(FOR TANDEM REAR AXLE) Unit : mm
CLASSIFICATION
STD/OPT REAR TIRE A B C D
NUMBER
8.25-16-14PR
8.25R16-14PR
9.5R17.5 (129/127)
235/75R17.5 (130/128)
8.25-20-14PR
8.25R20-14PR
9.00-20-12PR/14PR
9.00R20-12PR/14PR
10.00-20-14PR/16PR
10.00R20-14PR/16PR
11.00-20-14PR/16PR
11.00R20-14PR/16PR
9R22.5 (133/131)
10R22.5-14PR
10R22.5 (144/142)
11R22.5-14PR/16PR
11R22.5 (148/145)
12R22.5-16PR
235/70R22.5 (138/135)
255/70R22.5 (140/137)
255/70R22.5 (143/140)
275/70R22.5 (148/145)
275/80R22.5 (151/148)
295/80R22.5
295/80R22.5 (152/148)
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 above table shows design figure according
to JATMA or ETRTO standard.
KK-GH214 14
2 GENERAL PRECAUTIONS
5. ELECTRIC WELDING WORK
Internal clocks in the tachograph and the radio and all the electronic instruments are
directly connected to the battery, and are cab body-earthed at one end.
Under these conditions, electric welding will cause damage to these electrical units as
the welding current flow back along the earth circuit.
When welding, take following step of manner.
4) After welding
• 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.
5) After restored
• Inspect the operation and function of each electronic instrument and equipment.
• Consult to each Hino dealer or distributor for details of inspection's procedure.
KK-GH214 15
2 GENERAL PRECAUTIONS
FOR REFERENCE
CURRENT FLOW OF ELECTRIC WELDING WHEN WELD CAB BODY
EARTH OF
INSTRUMENTS ELECTRONIC
INSTRUMENTS
ARC
STARTER WELDING
MACHINE
SWITCH
+ – CHASSIS FRAME
EARTH WIRE
OF CAB
BATTERY
The electric current of welding.
WELDING ROD CAB ELECTRONIC INSTRUMENTS BATTERY EARTH of ARC WELDING
MACHINE
EARTH OF
INSTRUMENTS ELECTRONIC
INSTRUMENTS
ARC
WELDING
MACHINE
+ – CHASSIS FRAME
EARTH WIRE
OF CAB
KK-GH214 16
2 GENERAL PRECAUTIONS
6. 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.
Additional wiring harness or cable should be kept away from heated elements, and
should be wired along the main harness.
KK-GH214 17
2 GENERAL PRECAUTIONS
7. 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
FOR RIGHT HAND DRIVE ONLY
RELEVANT MODEL
CLASSIFICATION NUMBER A B
• Refer to chapter 1, 3 chassis specification for
classification number.
RELEVANT MODEL
CLASSIFICATION NUMBER A B
GH-051, 052, 053 1,879~ -160~ • Refer to chapter 1, 3 chassis specification for
2,456 1,373 classification number.
KK-GH214 18
2 GENERAL PRECAUTIONS
8. NOTES ON SYSTEM CONTROL COMPUTERS
Engine control and brake ABS computers 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.
KK-GH214 19
2 GENERAL PRECAUTIONS
9. 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 needle of the fuel
sender with vehicle posture, 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.)
Disconnect battery negative connecter and wait for more than 30 seconds.
Move the float of the fuel sender to the position corresponding to [F].
(The highest position of raised float.)
Connect battery negative connecter and turn on starter switch to [ON] position.
( The fuel gauge indicates [F] position.)
Disconnect battery negative connecter again and wait for more than 30 seconds.
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.)
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 and further indicate 1/2
position in step , there is no problem.
KK-GH214 20
2 GENERAL PRECAUTIONS
10. PRECAUTIONS 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.
Unit : mm
INNER RUBBER
(FLUORIDE COATED)
2
Ø17
Ø9.5
OUTER RUBBER
BRAID
INTERMEDIATE RUBBER
If genuine parts cannot be obtained, please get the following rubber hoses as a
substitute.
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.
KK-GH214 21
2 GENERAL PRECAUTIONS
11. ADJUSTMENT OF LIGHT AXIS OF HEADLIGHT
Therefore, consult the adjustment of light axis after rear body or equipment to be
mounted to authorized Hino distributor or sales dealer.
NOTES
• 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.
KK-GH214 22
Chapter 3
CHASSIS MASS & FRAME SECTION MODULUS
1. CHASSIS MASS•••••••••••••••••••••••••••••••••••••••••••••••••• 2
2. MASS OF THE OPTION EQUIPMENT•••••••••••••••••••••• 11
3. FRAME SECTION MODULUS•••••••••••••••••••••••••••••••• 12
KK-GH214
3 CHASSIS MASS & FRAME SECTION MODULUS
CHASSIS MASS AND FRAME SECTION MODELS
RELEVANT MODEL
CLASSIFICATION CHASSIS MASS SECTION MODULUS
PAGE PAGE
NUMBER NUMBER DRAWING NUMBER
GH-051 W1 2 Z1 12
GH-052 W2 3 Z2 13
GH-053 W3 4 Z3 14
KK-GH214 1
3 CHASSIS MASS & FRAME SECTION MODULUS
1. CHASSIS MASS
No. W1
Gravity Moment
Gravity Moment height from
ITEMS Mass position from from frame
from F.A.C frame upper
F.A.C upper surface
surface
( kg ) (m) ( kg·m ) (m) ( kg·m )
Front Bumper 27 -1.200 -32.400 -0.200 -5.400
Cab Front 338 -1.045 -353.210 0.725 245.050
Cab Front Mtg. 31 -1.045 -32.395 0.110 3.410
Step - - - - -
Steering 61 -0.820 -50.020 0.010 0.610
Radiator 40 -0.485 -19.400 0.070 2.800
Steering Control 7 0.080 0.560 0.045 0.315
Engine Front 352 0.030 10.560 -0.120 -42.240
Control 7 0.080 0.560 0.045 0.315
Engine Room - - - - -
Air Cleaner 18 0.595 10.710 0.255 4.590
Cab Rear 185 0.745 137.825 0.725 134.125
Cab Rear Mtg. 26 0.745 19.370 0.185 4.810
Engine Rear 504 0.870 438.480 -0.120 -60.480
Rear Splash 15 0.580 8.700 0.070 1.050
Brake System 83 2.440 202.520 -0.185 -15.355
Electoric System 15 1.670 25.050 -0.130 -1.950
Exhaust System 38 1.410 53.580 -0.385 -14.630
Battery 36 1.250 45.000 -0.185 -6.660
Fuel Tank 215 2.315 497.725 -0.225 -48.375
Properller Shaft 59 2.560 151.040 -0.395 -23.305
Frame etc. 646 2.335 1508.410 -0.148 -95.608
TIRE CARRIER - - - - -
CAR COOLER - - - - -
TOOL BOX - - - - -
SUB TOTAL 2703 0.970 2622.665 0.031 83.072
UNSPRUNG FRONT 712 0.000 0.000 -0.455 -323.960
MASS REAR 1335 3.760 5019.600 -0.510 -680.850
TOTAL 4750 1.609 7642.265 -0.194 -921.738
NOTE
• The mass of tire follows design figure according to JATMA or ETRTO standard.
• The chassis mass shows standard specification of vehicle.
(It is not included mass of option equipment.)
When consider the mounting of body, should include mass of option equipment.
KK-GH214 2
3 CHASSIS MASS & FRAME SECTION MODULUS
No. W2
Gravity Moment
Gravity Moment height from
ITEMS Mass position from from frame
from F.A.C frame upper
F.A.C upper surface
surface
( kg ) (m) ( kg·m ) (m) ( kg·m )
Front Bumper 27 -1.200 -32.400 -0.200 -5.400
Cab Front 338 -1.045 -353.210 0.725 245.050
Cab Front Mtg. 31 -1.045 -32.395 0.110 3.410
Step - - - - -
Steering 61 -0.820 -50.020 0.010 0.610
Radiator 40 -0.485 -19.400 0.070 2.800
Steering Control 7 0.080 0.560 0.045 0.315
Engine Front 352 0.030 10.560 -0.120 -42.240
Control 7 0.080 0.560 0.045 0.315
Engine Room - - - - -
Air Cleaner 18 0.595 10.710 0.255 4.590
Cab Rear 185 0.745 137.825 0.725 134.125
Cab Rear Mtg. 26 0.745 19.370 0.185 4.810
Engine Rear 504 0.870 438.480 -0.120 -60.480
Rear Splash 15 0.580 8.700 0.070 1.050
Brake System 83 2.440 202.520 -0.185 -15.355
Electoric System 15 1.670 25.050 -0.130 -1.950
Exhaust System 38 1.410 53.580 -0.385 -14.630
Battery 36 1.250 45.000 -0.185 -6.660
Fuel Tank 215 2.315 497.725 -0.225 -48.375
Properller Shaft 71 3.260 231.460 -0.395 -28.045
Frame etc. 701 3.325 2330.825 -0.148 -103.748
TIRE CARRIER - - - - -
CAR COOLER - - - - -
TOOL BOX - - - - -
SUB TOTAL 2770 1.273 3525.500 0.025 70.192
UNSPRUNG FRONT 712 0.000 0.000 -0.455 -323.960
MASS REAR 1335 5.030 6715.050 -0.510 -680.850
TOTAL 4817 2.126 10240.550 -0.194 -934.618
NOTE
• The mass of tire follows design figure according to JATMA or ETRTO standard.
• The chassis mass shows standard specification of vehicle.
(It is not included mass of option equipment.)
When consider the mounting of body, should include mass of option equipment.
KK-GH214 3
3 CHASSIS MASS & FRAME SECTION MODULUS
No. W3
Gravity Moment
Gravity Moment height from
ITEMS Mass position from from frame
from F.A.C frame upper
F.A.C upper surface
surface
( kg ) (m) ( kg·m ) (m) ( kg·m )
Front Bumper 27 -1.200 -32.400 -0.200 -5.400
Cab Front 338 -1.045 -353.210 0.725 245.050
Cab Front Mtg. 31 -1.045 -32.395 0.110 3.410
Step - - - - -
Steering 61 -0.820 -50.020 0.010 0.610
Radiator 40 -0.485 -19.400 0.070 2.800
Steering Control 7 0.080 0.560 0.045 0.315
Engine Front 352 0.030 10.560 -0.120 -42.240
Control 7 0.080 0.560 0.045 0.315
Engine Room - - - - -
Air Cleaner 18 0.595 10.710 0.255 4.590
Cab Rear 185 0.745 137.825 0.725 134.125
Cab Rear Mtg. 26 0.745 19.370 0.185 4.810
Engine Rear 504 0.870 438.480 -0.120 -60.480
Rear Splash 15 0.580 8.700 0.070 1.050
Brake System 83 2.440 202.520 -0.185 -15.355
Electoric System 15 1.670 25.050 -0.130 -1.950
Exhaust System 38 1.410 53.580 -0.385 -14.630
Battery 36 1.250 45.000 -0.185 -6.660
Fuel Tank 215 2.315 497.725 -0.225 -48.375
Properller Shaft 97 3.530 342.410 -0.395 -38.315
Frame etc. 803 3.800 3051.400 -0.148 -118.844
TIRE CARRIER - - - - -
CAR COOLER - - - - -
TOOL BOX - - - - -
SUB TOTAL 2898 1.503 4357.025 0.015 44.826
UNSPRUNG FRONT 712 0.000 0.000 -0.455 -323.960
MASS REAR 1335 5.510 7355.850 -0.510 -680.850
TOTAL 4945 2.369 11712.875 -0.194 -959.984
NOTE
• The mass of tire follows design figure according to JATMA or ETRTO standard.
• The chassis mass shows standard specification of vehicle.
(It is not included mass of option equipment.)
When consider the mounting of body, should include mass of option equipment.
KK-GH214 4
3 CHASSIS MASS & FRAME SECTION MODULUS
No. W4
GRAVITY
MOMENT
GRAVITY HEIGHT
MOMENT FROM
POSITION FROM
MASS FROM FRAME
ITEMS FROM FRAME
(kg) F.A.C. UPPER
F.A.C. UPPER
(kg·m) SURFACE
(m) SURFACE
(kg·m)
(m)
Sub Total
Front
Unsprung Mass
Rear
Total
NOTE
• The mass of tires to be mentioned in above table shows design figure according to JATMA or
ETRTO standard.
KK-GH214 5
3 CHASSIS MASS & FRAME SECTION MODULUS
No. W5
GRAVITY
MOMENT
GRAVITY HEIGHT
MOMENT FROM
POSITION FROM
MASS FROM FRAME
ITEMS FROM FRAME
(kg) F.A.C. UPPER
F.A.C. UPPER
(kg·m) SURFACE
(m) SURFACE
(kg·m)
(m)
Sub Total
Front
Unsprung Mass
Rear
Total
NOTE
• The mass of tires to be mentioned in above table shows design figure according to JATMA or
ETRTO standard.
KK-GH214 6
3 CHASSIS MASS & FRAME SECTION MODULUS
No. W6
GRAVITY
MOMENT
GRAVITY HEIGHT
MOMENT FROM
POSITION FROM
MASS FROM FRAME
ITEMS FROM FRAME
(kg) F.A.C. UPPER
F.A.C. UPPER
(kg·m) SURFACE
(m) SURFACE
(kg·m)
(m)
Sub Total
Front
Unsprung Mass
Rear
Total
NOTE
• The mass of tires to be mentioned in above table shows design figure according to JATMA or
ETRTO standard.
KK-GH214 7
3 CHASSIS MASS & FRAME SECTION MODULUS
No. W7
GRAVITY
MOMENT
GRAVITY HEIGHT
MOMENT FROM
POSITION FROM
MASS FROM FRAME
ITEMS FROM FRAME
(kg) F.A.C. UPPER
F.A.C. UPPER
(kg·m) SURFACE
(m) SURFACE
(kg·m)
(m)
Sub Total
Front
Unsprung Mass
Rear
Total
NOTE
• The mass of tires to be mentioned in above table shows design figure according to JATMA or
ETRTO standard.
KK-GH214 8
3 CHASSIS MASS & FRAME SECTION MODULUS
No. W8
GRAVITY
MOMENT
GRAVITY HEIGHT
MOMENT FROM
POSITION FROM
MASS FROM FRAME
ITEMS FROM FRAME
(kg) F.A.C. UPPER
F.A.C. UPPER
(kg·m) SURFACE
(m) SURFACE
(kg·m)
(m)
Sub Total
Front
Unsprung Mass
Rear
Total
NOTE
• The mass of tires to be mentioned in above table shows design figure according to JATMA or
ETRTO standard.
KK-GH214 9
3 CHASSIS MASS & FRAME SECTION MODULUS
No. W9
GRAVITY
MOMENT
GRAVITY HEIGHT
MOMENT FROM
POSITION FROM
MASS FROM FRAME
ITEMS FROM FRAME
(kg) F.A.C. UPPER
F.A.C. UPPER
(kg·m) SURFACE
(m) SURFACE
(kg·m)
(m)
Sub Total
Front
Unsprung Mass
Rear
Total
NOTE
• The mass of tires to be mentioned in above table shows design figure according to JATMA or
ETRTO standard.
KK-GH214 10
3 CHASSIS MASS & FRAME SECTION MODULUS
2. MASS OF THE OPTION EQUIPMENT
RELEVANT MODEL
GRAVITY
MOMENT
POSITION
CLASSIFICATION MASS FROM
CONTENT OF OPTION FROM W/B REMARKS
NUMBER (kg) F.A.C.
F.A.C.
(kg·m)
(m)
RETERDER
PTO CONTROL IN CAB
PTO CONTROL LEVER
GH-051, 052, 053 UNSPRUNG
WHEEL STEP LESS -3 0.000 0.000
MASS
T/M POWER SHIFT
SPARE TIRE
HORIZONTAL TO STACK TAIL PIPE
FUEL TANK
(100L –> 200L)
FUEL TANK
(200L –> 400L)
FUEL TANK
(200L –> 200Lx2)
GH-051, 052, 053 FRONT AIR SPOILLER 6 -1.200 7.200
GH-051, 052, 053 BED 3 0.430 1.290
AIR SUSPENSION SEAT
(DRIVER)
GH-051, 052, 053 AIR CONDITIONER 16 -0.510 8.160
CAR HERTER
OVERHEAD CONSOLE
GH-051, 052, 053 ABS 8 2.440 19.520
GENERATOR
GH-051, 052, 053 CHASSIS STEP 22 -0.750 16.500
17 1.370 23.290
GH-051, 052, 053 T/M PTO
33 1.280 42.240
GH-051, 052, 053 BATTERY
FRONT SUS.
(STANDARD TAPER)
FRONT SUS.
(REINFORCED TAPER)
FRONT SUS.
(STANDARD TAPER WITH STB)
FRONT SUS.
(REINFORCED TAPER WITH STB)
FRONT SUS.
(TAPER –> MULTI)
UNSPRUNG
FRONT SUS. MASS
(REINFORCED MULTI)
FRONT SUS.
(MULTI WITH STB)
FRONT SUS.
(REINFORCED MULTI WITH STB)
REAR SUS.
(REINFORCED MULTI)
6 6.420 38.520
6 6.900 41.400
GH-052, 053 TIRE CARRIER
KK-GH214 11
3 CHASSIS MASS & FRAME SECTION MODULUS
3. FRAME SECTION MODULUS
FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) Unit : mm
No. Z1
KK-GH214 12
3 CHASSIS MASS & FRAME SECTION MODULUS
No. Z2
KK-GH214 13
3 CHASSIS MASS & FRAME SECTION MODULUS
No. Z3
KK-GH214 14
3 CHASSIS MASS & FRAME SECTION MODULUS
KK-GH214 15
3 CHASSIS MASS & FRAME SECTION MODULUS
KK-GH214 16
3 CHASSIS MASS & FRAME SECTION MODULUS
KK-GH214 17
3 CHASSIS MASS & FRAME SECTION MODULUS
KK-GH214 18
3 CHASSIS MASS & FRAME SECTION MODULUS
KK-GH214 19
3 CHASSIS MASS & FRAME SECTION MODULUS
KK-GH214 20
Chapter 4
SPRINGS & REAR AXLES
1. SPRING CHARACTERISTICS•••••••••••••••••••••••••••••••• 1
2. CALCULATION FOR HEIGHT OF FRAME
UPPER SURFACE FROM GROUND••••••••••••••••••••• 6
3. MAXIMUM VERTICAL
DEFLECTION OF REAR WHEELS•••••••••••••••••••••••• 8
4. MAXIMUM VERTICAL TRAVEL RANGE
OF REAR AXLE AND SUSPENSION••••••••••••••••••••• 9
5. MAXIMUM VERTICAL TRAVEL RANGE
OF REAR LATERAL ROD••••••••••••••••••••••••••••••••••• 10
6. PRECAUTION WHEN WELDING OPERATIONS
AROUND THE SUSPENSION PARTS•••••••••••••••••••• 11
7. TRAVEL RANGE OF REAR SPRING•••••••••••••••••••••••• 12
8. PRECAUTION FOR LEVELING VALVE LEVER•••••••••• 13
9. REAR SHOCK ABSORBER••••••••••••••••••••••••••••••••••• 14
KK-GH214
4 SPRINGS & REAR AXLES
1. SPRING CHARACTERISTICS
SPRING COMBINATION
Refer to SPRING CHARACTERISTICS CHART based on following table.
RELEVANT MODEL
STD OPT1 OPT2 OPT3
CLASSIFICATION GH-052,053
NUMBER
F1
FRONT
(FML)
R2
REAR
(RRM)
NOTE
SYMBOL SPECIFICATION
KK-GH214 1
4 SPRINGS & REAR AXLES
LEAF SPRING
• SPRING CHARACTERISTICS CHART "F1"
kgf
x 103 (kN) FRONT
5 50 a 0.282kN/mm {28.8kgf/mm}
c b 28.480kN {2905.0kgf}
c 41.480kN {4231.0kgf}
4 40
SPRING LOAD ON ONE SIDE
b
3 30
CONTACTING POINT OF
2 20
BUFFER RUBBER
HORIZONTAL
1 10
POINT
101.0 147.1
0 0 50 100 150 200 (mm)
VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING FGH4 4J SPG CHARA "D"
KK-GH214 2
4 SPRINGS & REAR AXLES
KK-GH214 3
4 SPRINGS & REAR AXLES
• SPRING CHARACTERISTICS CHART "R1"
kgf
x 103 (kN)
a 0.516kN/mm {52.6kgf/mm}
b 0.516+0.997=1.513kN/mm
15 150 {52.6+101.7=154.3kgf/mm}
c 25.280kN {2577.8kgf}
d 99.420kN {10138.0kgf}
SPRING LOAD ON ONE SIDE
e 134.220kN {13686.6kgf}
e
10 100
d
CONTACTING POINT OF
BUFFER RUBBER
b
HORIZONTAL
5 50
c
POINT
a
49.0 98.0 121
0 0 50 100 150 (mm)
VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING
LOAD VS. DEFLECTION
10 100
BUFFER RUBBER
d
b
HORIZONTAL
5 50
c
POINT
a
49.0 98.0 141
KK-GH214 4
4 SPRINGS & REAR AXLES
• SPRING CHARACTERISTICS CHART "R3"
KK-GH214 5
4 SPRINGS & REAR AXLES
2. CALCULATION FOR HEIGHT OF FRAME UPPER SURFACE FROM
GROUND
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 L2
Hf1
Hr1
Hro
Wf Wr
Hr1
Wf Hro
Wr
Wf : Load on front axle (kg)
Wr : Load on rear axle (kg)
Hf1 : Height of frame upper surface from ground on front axle datum line (mm)
Hr1 : Height of frame upper surface from ground on rear axle datum line (mm)
Hfo : Height of frame upper surface from ground on frame end (mm)
L1 : Distance from front axle datum line to rear axle loading center (mm)
L2 : Frame rear overhung (mm) · · · From rear loading center to frame end.
Hr1 - Hf1
Hro = Hr1 + x L2
L1
NOTE
• 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.
KK-GH214 6
4 SPRINGS & REAR AXLES
CALCULATION FORMULA OF Hf1 & Hr1
<CALCULATION DATA TO BE REFERED>
CHAPTER TO BE REFERED ELEMENT
ITEM
CHAPTER NAME OF CLAUSE FRONT REAR
SPRING CHARAC-
SPRING CONSTANT (kg/mm) 4 Tf Tr
TERISTICS CHART
HIGHT OF FRAME UPPER SURFACE
8 CHASSIS DRAWING Hf Hr
FROM GROUND (mm)
Hf1 = Hf - ( Wf ÷ Tf ) Hr1 = Hr - ( Wr ÷ Tr )
2 2
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.
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.
<CONDITION OF CALCULATION>
SPRING CONSTANT : FRONT : 34.7 kgf/mm, REAR : 255.8 kgf/mm
HIGHT OF FRAME UPPER SURFACE
FROM GROUND : FRONT : 1036 mm, REAR : 1098 mm
BODY MASS : • BODY MASS : 6000 kg
• GRAVITY CENTER OF BODY MASS : 1500 mm
• WHEELBASE : 5000 mm
• REAR OVER HANG : 3000 mm
KK-GH214 7
4 SPRINGS & REAR AXLES
3. MAXIMUM VERTICAL DEFLECTION OF REAR WHEELS
Measurements for the maximum deflection for one side tire and for simultaneous left and
right deflection are shown below.
When you mount the body, allow a clearance of at least 30mm so as not to obstruct tire
deflection.
B
C
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.
KK-GH214 8
4 SPRINGS & REAR AXLES
4. MAXIMUM VERTICAL TRAVEL RANGE OF REAR AXLE
AND SUSPENSION
Measurement for maximum vertical travel range of the rear torque rod is shown below.
When you mount a body or equipment, allow a clearance of at least 30mm so as not to
interfere with rear torque rod.
CLASSIFICATION
A B C D E F
NUMBER
KK-GH214 9
4 SPRINGS & REAR AXLES
5. MAXIMUM VERTICAL TRAVEL RANGE OF REAR LATERAL ROD
(For rear air spring series)
Measurement for maximum vertical travel range of the rear lateral rod is shown below.
When you mount a body or equipment, allow a clearance of at least 30mm so as not to
interfere with rear lateral rod.
Unit : mm
RELEVANT MODEL
CLASSIFICATION
A
NUMBER
Unit : mm
RELEVANT MODEL
CLASSIFICATION A
NUMBER FORWARD REARWARD
KK-GH214 10
4 SPRINGS & REAR AXLES
6. 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.
KK-GH214 11
4 SPRINGS & REAR AXLES
7. TRAVEL RANGE OF REAR SPRING
During driving, the shackle of the main spring moves beyond the end of the rear bracket.
Do not mount any parts of body inside of the hatching range.
Unit : mm
RELEVANT MODEL
CLASSIFICATION
A
NUMBER
GH-051,052,053 775.2
KK-GH214 12
4 SPRINGS & REAR AXLES
8. PRECAUTION FOR LEVELING VALVE LEVER
• Rear air suspension vehicle installed leveling valve to keep vehicle height. When
mounting body or equipment on the vehicle, must be keep 30mm clearance between
lever and body or equipment.
RELEVANT MODEL
CLASSIFICATION NUMBER :
• 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.
KK-GH214 13
4 SPRINGS & REAR AXLES
9. REAR SHOCK ABSORBER
Unit : mm
RELEVANT MODEL
CLASSIFICATION NUMBER :
KK-GH214 14
Chapter 5
P.T.O. AND CONTROL
NOTE
• Mark to be mentioned in each table of relevant model shows applicable
specification.
KK-GH214
5 P.T.O. AND CONTROL
1. PROVISION OF P.T.O. AND CONTROL
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.
NOTE
• Not install direct pump of transmission P.T.O..
KK-GH214 1
5 P.T.O. AND CONTROL
ENGINE CONTROL FOR BODY OR EQUIPMENT
RELEVANT MODEL
CLASSIFICATION ENGINE CONTROL PROVISION OF
ENGINE MODEL
NUMBER TYPE ENGINE ACCELERATOR
J05E-TE MECHANICAL –
J08E-UG MECHANICAL –
J08E-UF MECHANICAL –
P11C-UB MECHANICAL –
J05D-TG U-2 OPTION EQUIPMENT
J05E-TC U-2 OPTION EQUIPMENT
J05E-TD U-2 OPTION EQUIPMENT
GH-051,052,053 J08E-UB U-2 OPTION EQUIPMENT
J08E-UC U-2 OPTION EQUIPMENT
J08E-UD U-2 OPTION EQUIPMENT
J08E-UE U-2 OPTION EQUIPMENT
J08E-TB U-2 OPTION EQUIPMENT
J08E-TE U-2 OPTION EQUIPMENT
A09C-TE U-2 OPTION EQUIPMENT
KK-GH214 2
5 P.T.O. AND CONTROL
2. TRANSMISSION SIDE POWER TAKE OFF (OPT)
••Data•of•the•P.T.O.•output•shaft
TRANSMISSION PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF
SERIES (N·m {kgf·m} at r/min) TYPE ROTATION
Pneumatic Reverse to
LX06S 245 {25} / 1,000 control engine
••Necessary•parts
CLASSIFICATION NUMBER
TRANSMISSION MODEL
LX06S
TRANSMISSION GEAR RATIO
1ST 6.098 6.515 8.190
2ND 3.858 4.122 5.072
3RD 2.340 2.500 2.981
4TH 1.422 1.718 1.848
5TH 1.000 1.261 1.343
6TH 0.761 1.000 1.000
REV 5.672 6.060 7.619
P.T.O. CONTROL TYPE Pneumatic
PARTS NAME Parts No. Q'ty / Parts No. Q'ty / Parts No. Q'ty /
unit unit unit
POWER TAKE OFF ASSY S3661-05251 01 S3661-05391 01 S3661-05171 01
POWER TAKE OFF SUB ASSY S3661-05261 01 S3661-05201 01 S3661-05181 01
SWITCH ASSY, T/M POSITION S8422-01560 01 S8422-01560 01
BRACKET, ELEC. PART S5591-23970 01 S5591-23970 01
CONNECTOR, SUB ASSY SN352-10613 01 SN352-10613 01
ADAPTER, P.T.O. CASE S3662-82770 01 S3662-82890 01 S3662-82740 01
or S3662-82780 01 or S3662-82900 01 or S3662-82750 01
or S3662-82790 01 or S3662-82910 01 or S3662-82760 01
GASKET, P.T.O. CASE S3663-51560 02 S3663-51560 02 S3663-51560 02
LOCK WASHER SL512-01030 08 SL512-01030 08 SL512-01030 08
STUD, REAMER SZ116-10086 02 SZ116-10086 02 SZ116-10084 02
STUD SZ116-10079 06 SZ116-10079 06 SZ116-10085 06
NUT SZ170-10064 08 SZ170-10064 08 SZ170-10064 08
VALVE ASS'Y, SOLENOID S2761-04550 01 S2761-04550 01 S2761-04550 01
BOLT, FLANGE SH552-10825 02 SH552-10825 02 SH552-10825 02
BRACKET, MAGNETIC VALVE S4458-23270 01 S4458-23270 01 S4458-23270 01
BOLT, FLANGE SZ105-10041 02 SZ105-10041 02 SZ105-10041 02
HOLDER, CLIP S7999-32610 01 S7999-32610 01 S7999-32610 01
BOLT SH782-01020 01 SH782-01020 01 SH782-01020 01
NOTE
• Parts mentioned above table shows transmission P.T.O. unit only.
• Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.
KK-GH214 3
5 P.T.O. AND CONTROL
DETAIL OF P.T.O., TRANSMISSION MODEL HINO LX06S
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.
KK-GH214 4
5 P.T.O. AND CONTROL
• 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.
STANDARD
MODEL GEAR POSITION
BACKLASH
If specified gear backlash value cannot be obtained, check whether all the parts have
been installed correctly.
If the specified gear backlash value cannot be obtained despite correct installation, use
another P.T.O. assembly.
KK-GH214 5
5 P.T.O. AND CONTROL
• P.T.O. mounting location on transmission case
Unit : mm
KK-GH214 6
5 P.T.O. AND CONTROL
• Transmission P.T.O. mounting for pneumatic control type
Unit : mm
MAIN SHAFT
CENTER
7
COUNTER SHAFT
6 CENTER
5
7.
123
70
R
º
45
50 ±0.1
ø34H9
65
20
+0.2
3.0 0 25 ±0.1
4 - ø8 +0.2
0
OUTPUT FLANGE
45
12.25
P.T.O. HOLE CENTER
END OF T/M CASE
0.14 0.14
A
91.5 124 65 130
ADAPTOR A
215.5
GASKET
14 16
14.5 7 A (ADAPTOR)
T/M GEAR RATIO PARTS No. t (mm)
13
3
ø21.5
12
ø25
7
mounted at the same angle as engine to the body. (Direct mounting S3662-82890 8.15
6.515 ~ 1.000 S3662-82900 8.04
the devices to the P.T.O. output flange is strictly prohibited.) TAPER1/8 S3662-82910 7.94
• The three-dimensional angle of the universal joint of the drive shaft 28 M14x1.5 S3662-82740 1.98
must be a Min. 1° to Max. 6°. 8.190 ~ 1.000 S3662-82750 1.87
S3662-82760 1.77
DETAIL OF P.T.O. SHAFT
KK-GH214 7
5 P.T.O. AND CONTROL
• Layout of power line
CRANKCASE
A
TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
D 124
E
F
215.5
Unit : mm
CHASSIS
MODEL A B C D E F
KK-GH214 8
5 P.T.O. AND CONTROL
••Data•of•the•P.T.O.•output•shaft
TRANSMISSION PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF
SERIES (N·m {kgf·m} at r/min) TYPE ROTATION
Pneumatic Reverse to
LJ06S 245 {25} / 1,000 control engine
••Necessary•parts
CLASSIFICATION NUMBER
TRANSMISSION MODEL
LJ06S
TRANSMISSION GEAR RATIO
1ST 6.477 6.746 6.893
2ND 4.016 4.190 4.274
3RD 2.450 2.451 2.607
4TH 1.470 1.474 1.564
5TH 1.000 1.000 1.000
6TH 0.723 0.823 0.770
REV 6.064 6.453 6.453
P.T.O. CONTROL TYPE Pneumatic
PARTS NAME Parts No. Q'ty / Parts No. Q'ty / Parts No. Q'ty /
unit unit unit
POWER TAKE OFF ASSY S3661-05780 01 36610-E0080 01 S3661-05780 01
POWER TAKE OFF SUB ASSY S3661-05790 01 S3661-05790 01 S3661-05790 01
SWITCH ASSY, T/M POSITION S8422-01560 01 S8422-01560 01 S8422-01560 01
BRACKET, ELEC. PART S5591-23960 01 S5591-23960 01 S5591-23960 01
CONNECTOR, SUB ASSY SN352-10613 01 SN352-10613 01 SN352-10613 01
ADAPTER, P.T.O. CASE S3662-81490 01 S3662-82380 01 S3662-81490 01
or S3662-81670 01 or S3662-82390 01 or S3662-81670 01
or S3662-81680 01 or S3662-82400 01 or S3662-81680 01
GASKET, P.T.O. CASE S3663-51370 02 S3663-51370 02 S3663-51370 02
LOCK WASHER SL512-01030 02 SL511-01025 02 SL512-01030 02
BOLT SZ101-10165 02 SZ101-10152 02 SZ101-10165 02
BOLT SZ119-10105 06 SH782-01035 06 SZ119-10105 06
BRACKET, PIPE JOINT S4735-35590 01 S4735-35590 01 S4735-35590 01
HOLDER, CLIP S7999-53502 01 S7999-53502 01 S7999-53502 01
NOTE
• Parts mentioned above table shows transmission P.T.O. unit only.
• Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.
KK-GH214 9
5 P.T.O. AND CONTROL
DETAIL OF P.T.O., TRANSMISSION MODEL HINO LJ06S
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.
KK-GH214 10
5 P.T.O. AND CONTROL
• 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.
STANDARD
MODEL GEAR POSITION
BACKLASH
Between gear A 0.09 ~
and gear B (a) 0.25mm
LJ
Between gear B 0.09 ~
and gear C (b) 0.27mm
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.
KK-GH214 11
5 P.T.O. AND CONTROL
• P.T.O. Mounting location on transmission case
KK-GH214 12
5 P.T.O. AND CONTROL
• Transmission P.T.O. mounting for pneumatic control type
Unit : mm
A (ADAPTOR)
T/M GEAR RATIO PARTS No. t (mm)
S3662-81490 6.12
NOTE 6.477 ~ 0.723 S3662-81670 5.99
S3662-81680 5.86
• The devises on the body or equipment side (e. g. oil pump) must be S3662-82380 8.02
mounted at the same angle as engine to the body. (Direct mounting 6.746 ~ 0.823 S3662-82390 7.89
S3662-82400 7.76
the devices to the P.T.O. output flange is strictly prohibited.) S3662-81490 6.12
• The three-dimensional angle of the universal joint of the drive shaft 6.893 ~ 0.770 S3662-81670 5.99
S3662-81680 5.86
must be a Min. 1° to Max. 6°.
KK-GH214 13
5 P.T.O. AND CONTROL
• Layout of power line
CRANKCASE
A
TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
275
D E F G
Unit : mm
CHASSIS
MODEL A B C D E F G
KK-GH214 14
5 P.T.O. AND CONTROL
••Data•of•the•P.T.O.•output•shaft
TRANSMISSION PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF
SERIES (N·m {kgf·m} at r/min) TYPE ROTATION
Pneumatic Reverse to
MF06S 245 {25} / 1,000 control engine
••Necessary•parts
CLASSIFICATION NUMBER
TRANSMISSION MODEL
MF06S
TRANSMISSION GEAR RATIO
1ST 8.189 7.395
2ND 5.340 4.758
3RD 3.076 3.076
4TH 1.936 1.936
5TH 1.341 1.341
6TH 1.000 1.000
REV 7.142 7.142
P.T.O. CONTROL TYPE Pneumatic
PARTS NAME Parts No. Q'ty /
unit
POWER TAKE OFF ASSY S3661-05311 01
SWITCH ASSY, T/M POSITION S8422-01560 01
ELBOW SZ407-14002 01
CONNECTOR SZ404-14005 01
GASKET, P.T.O. CASE S3663-51030 01
BOLT SZ101-10151 02
LOCKWASHER SL511-01025 03
BOLT SH782-01030 05
STUD SJ182-01022 01
NUT SL110-01008 01
BRACKET, ELEC. PARTS S5591-24450 01
NOTE
• Parts mentioned above table shows transmission P.T.O. unit only.
• Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.
KK-GH214 15
5 P.T.O. AND CONTROL
DETAIL OF P.T.O., TRANSMISSION MODEL HINO MF06S
MF06S 22 47 21 29 12 — 1.220
NOTE
• Number of revolutions of P.T.O. output shaft
= number of revolutions of engine x1/ i
• The P.T.O. output shaft turns in the opposite direction to the engine.
KK-GH214 16
5 P.T.O. AND CONTROL
• 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.
• 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:
Use grease to paste a fuse (ø1X10mm) to the surface of a tooth of P.T.O. gear B. Make
the teeth interlock over the fuse, then measure the thickness of the crushed fuse with a
micrometer (at three points on the perimeter). This value is the backlash.
If specified gear backlash value cannot be obtained, check whether all the parts have
been installed correctly. If the specified gear backlash value cannot be obtained despite
correct installation, use another P.T.O. assembly.
KK-GH214 17
5 P.T.O. AND CONTROL
• P.T.O. Mounting location on transmission case
Unit : mm
KK-GH214 18
5 P.T.O. AND CONTROL
• Transmission P.T.O. mounting for pneumatic control type
Unit : mm
NOTE
• 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°.
KK-GH214 19
5 P.T.O. AND CONTROL
• Layout of power line
CRANKCASE
A
TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
121
D E F G
Unit : mm
CHASSIS
MODEL A B C D E F G
KK-GH214 20
5 P.T.O. AND CONTROL
••Data•of•the•P.T.O.•output•shaft
TRANSMISSION PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF
SERIES (N·m {kgf·m} at r/min) TYPE ROTATION
———
HK06S ( 245 {25} / 1,000 ) ——— ———
( CAPACITY OF OUTPUT GEAR OF T/M. )
••Necessary•parts
TRANSMISSION MODEL
HK06S
TRANSMISSION GEAR RATIO
1ST 7.028
2ND 4.389
3RD 2.495
4TH 1.592
5TH 1.000
6TH 0.743
REV 6.987
Q'ty /
PARTS NAME Parts No. 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
KK-GH214 21
5 P.T.O. AND CONTROL
INPUT N1
SHAFT
N2
N3
N4
N5 P.T.O.
OUT UNIT
P.T.O. UNIT
HK06S 24 43 20 30 — — —
NOTE
• Number of revolutions of P.T.O. output shaft
= number of revolutions of engine x1/ i
• The P.T.O. output shaft turns in the opposite direction to the engine.
KK-GH214 22
5 P.T.O. AND CONTROL
• How to check the gear backlash
The gear backlash of the P.T.O. is important factor to prolong the P.T.O. gear life.
The bigger backlash causes the noise from gear, on the contrary the smaller backlash
causes the damage of gear. When installing the P.T.O., measure and check the backlash
according to the following procedures.
• 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:
Use grease to paste a fuse (ø1 x 10 mm) to the surface of a tooth of P.T.O. gear B.
Make the teeth interlock over the fuse, then measure the thickness of the crushed fuse
with a micrometer (at three points on the perimeter). This value is the backlash
KK-GH214 23
5 P.T.O. AND CONTROL
• P.T.O. mounting location of transmission case
Unit : mm
NOTES
• 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".
KK-GH214 24
5 P.T.O. AND CONTROL
• Layout of power line
CRANKCASE
A
TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
D E F G
Unit : mm
CHASSIS
MODEL A B C D E F G
KK-GH214 25
5 P.T.O. AND CONTROL
••Data•of•the•P.T.O.•output•shaft
TRANSMISSION
SERIES PERMISSIBLE OUTPUT TORQUE
••Necessary•parts
TRANSMISSION MODEL
EATON RT-8908LL
TRANSMISSION GEAR RATIO
1ST 19.577
2ND 12.668
3RD 8.390
4TH 6.229
5TH 4.578
6TH 3.404
7TH 2.464
8TH 1.829
9TH 1.344
10TH 1.000
REV. L 20.467
M 13.243
H 3.889
KK-GH214 26
5 P.T.O. AND CONTROL
DETAIL OF P.T.O., TRANSMISSION MODEL EATON RT-8908LL
NO. OF GEAR
N1 N2 N3
TRANSMISSION
EATON RT-8908LL 48 69 47
KK-GH214 27
5 P.T.O. AND CONTROL
• P.T.O. mounting location on transmission case
Unit : mm
NOTE
• Gear data and backlash are specified by gear box manufacturer.
• More detail information if needed, please contact with "EATON CORPORATION
(TRANSMISSION DIVISION)".
KK-GH214 28
5 P.T.O. AND CONTROL
• Layout of power line
CRANKCASE
A
TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
D E F G
Unit : mm
CHASSIS
MODEL A B C D E F G
KK-GH214 29
5 P.T.O. AND CONTROL
••Data•of•the•P.T.O.•output•shaft
TRANSMISSION PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF
SERIES (N·m {kgf·m}) TYPE ROTATION
Pneumatic Reverse to
ZF 9S109 800 {81.5} control engine
••Necessary•parts
TRANSMISSION MODEL
ZF 9S109
TRANSMISSION GEAR RATIO
CRAWLER GERA 10.245
1ST 6.573
2ND 4.775
3RD 3.529
4TH 2.610
5TH 1.862
6TH 1.353
7TH 1.000
8TH 0.739
REV. 9.436
P.T.O. CONTROL TYPE Pneumatic
PARTS NAME Parts No. Q'ty /
unit
POWER TAKE OFF ASSY
S3307-03492 01
(T/M ASSY W/P.T.O.)
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.
KK-GH214 30
5 P.T.O. AND CONTROL
ZF 9S109 27 33 16 22 17 — 1.298
NOTES
• Number of revolutions of P.T.O. output shaft
= number of revolutions of engine x1/ i
• The P.T.O. output shaft turns in the opposite direction to the engine.
KK-GH214 31
5 P.T.O. AND CONTROL
• Technical data of P.T.O.
Model NH/1
Output-
torque Continuous operation [Nm] 800
Input Layshaft
Output speed
for transmission ratio Speed factor f
9S109 10.24-0.74 0.77
Output power
The permissible output power depends on permissible output torque and output speed.
It is calculated by the following formula :
P.T.O.•calculation
perm. output torque X noutput
Pperm. = [kw] P= Power [kw]
9552
T= Torque [Nm]
Speed n= Speed [rpm]
noutput = f X nengine [rpm] Q= Delivery volume [l]
p= Pressure [bar]
Output torque f = Speed factor
15.92 X Q X p M= Gravity torque [Nm]
T= [Nm]
nX s = Distance between the
or center of gravity of the
flange mounting face [m]
9552 X Pperm.
T= n [Nm] G = Pump weight [kg]
= Efficiency
Perm. pump gravity torque
Mperm. = s X G [Nm]
CENTER OF GRAVITY
KK-GH214 32
5 P.T.O. AND CONTROL
• P.T.O. Mounting location of transmission case
KK-GH214 33
5 P.T.O. AND CONTROL
• P.T.O. Mounting on transmission case
KK-GH214 34
5 P.T.O. AND CONTROL
• Layout of power line
CRANKCASE
A
TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
D E F G
Unit : mm
CHASSIS
MODEL A B C D E F G
KK-GH214 35
5 P.T.O. AND CONTROL
••Data•of•the•P.T.O.•output•shaft
TRANSMISSION PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF
SERIES (N·m {kgf·m} at r/min) TYPE ROTATION
Pneumatic Same to
EATON FS-6109A 235 {24} / 1,000 control engine
••Necessary•parts
TRANSMISSION MODEL
EATON FS-6109A
TRANSMISSION GEAR RATIO
LOW 12.637
1ST 8.806
2ND 6.550
3RD 4.768
4TH 3.548
5TH 2.481
6TH 1.845
7TH 1.343
8TH 1.000
REV 13.210
P.T.O. CONTROL TYPE Pneumatic
PARTS NAME Parts No. Q'ty /
unit
POWER TAKE OFF ASSY 36610-E0460 01
ADAPTER, SUB ASSY S3190-61230 01
HARNESS SUB ASSY,
S8206-51121 01
TRANSMISSION
BRACKET, ELEC. PARTS S5591-23920 01
ELBOW SZ407-10059 01
CONNECTOR SZ404-14004 01
NOTE
• Parts mentioned above table shows transmission P.T.O. unit only.
• Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.
KK-GH214 36
5 P.T.O. AND CONTROL
DETAIL OF P.T.O. TRANSMISSION MODEL EATON FS-6109A
KK-GH214 37
5 P.T.O. AND CONTROL
• Gear layout and gear ratio
NOTES
• Number of revolutions of P.T.O. output shaft
= number of revolutions of engine x1/ i
• The P.T.O. output shaft turns in the opposite direction to the engine.
KK-GH214 38
5 P.T.O. AND CONTROL
• 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.
NOTES
• See figure 2 for proper location of dial indicator contact point.
(Two common type dial indicators shown.)
• Hold the P.T.O. driver gear in transmission with a screwdriver or bar and rock the P.T.O.
input gear (driven gear) back and forth with your hand. Note the total movement on the
dial indicator.
• Establish backlash at 0.15mm - 0.30mm by adding or subtracting gaskets.
General rule -- A CHELSEA'S 0.25mm gasket will change backlash approx. 0.15mm, a
0.51mm gasket changes backlash approx. 0.30mm.
• Replace the shift housing and/or inspection plate and retorque four capscrews to 22 -
27 N·m {221 - 276 kgf·cm}.
• Use same procedure for mounting the adapter and checking backlash as was used
when mounting the P.T.O. to transmission as described above.
• 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.
KK-GH214 39
5 P.T.O. AND CONTROL
• P.T.O. mounting location on transmission case
Unit : mm
NOTE
• Gear data and backlash are specified by gear box manufacturer.
KK-GH214 40
5 P.T.O. AND CONTROL
• Transmission P.T.O. mounting
Unit : mm
KK-GH214 41
5 P.T.O. AND CONTROL
• Layout of power line
CRANKCASE
A
TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
D E F G
Unit : mm
CHASSIS
MODEL A B C D E F G
KK-GH214 42
5 P.T.O. AND CONTROL
••Data•of•the•P.T.O.•output•shaft
TRANSMISSION PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF
SERIES (N·m {kgf·m} at r/min) TYPE ROTATION
Pneumatic Same to
EATON FS-8209BBE 235 {24} / 1,000 control engine
••Necessary•parts
TRANSMISSION MODEL
EATON FS-8209BBE
TRANSMISSION GEAR RATIO
LOW 12.637
1ST 8.806
2ND 6.550
3RD 4.768
4TH 3.548
5TH 2.481
6TH 1.845
7TH 1.343
8TH 1.000
REV 13.210
P.T.O. CONTROL TYPE Pneumatic
PARTS NAME Parts No. Q'ty /
unit
POWER TAKE OFF ASSY 36610-E0460 01
ADAPTER, SUB ASSY S3190-61230 01
HARNESS SUB ASSY,
S8206-51121 01
TRANSMISSION
BRACKET, ELEC. PARTS S5591-23920 01
ELBOW SZ407-10059 01
CONNECTOR SZ404-14004 01
NOTE
• Parts mentioned above table shows transmission P.T.O. unit only.
• Other related parts of transmission P.T.O. control, please contact each Hino sales dealer.
KK-GH214 43
5 P.T.O. AND CONTROL
DETAIL OF P.T.O. TRANSMISSION MODEL EATON FS-8209BBE
KK-GH214 44
5 P.T.O. AND CONTROL
• Gear layout and gear ratio
NOTES
• Number of revolutions of P.T.O. output shaft
= number of revolutions of engine x1/ i
• The P.T.O. output shaft turns in the opposite direction to the engine.
KK-GH214 45
5 P.T.O. AND CONTROL
• 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.
NOTES
• See figure 2 for proper location of dial indicator contact point.
(Two common type dial indicators shown.)
• Hold the P.T.O. driver gear in transmission with a screwdriver or bar and rock the P.T.O.
input gear (driven gear) back and forth with your hand. Note the total movement on the
dial indicator.
• Establish backlash at 0.15mm - 0.30mm by adding or subtracting gaskets.
General rule -- A CHELSEA'S 0.25mm gasket will change backlash approx. 0.15mm, a
0.51mm gasket changes backlash approx. 0.30mm.
• Replace the shift housing and/or inspection plate and retorque four capscrews to 22 -
27 N·m {221 - 276 kgf·cm}.
• Use same procedure for mounting the adapter and checking backlash as was used
when mounting the P.T.O. to transmission as described above.
• 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.
KK-GH214 46
5 P.T.O. AND CONTROL
• P.T.O. mounting location on transmission case
Unit : mm
NOTE
• Gear data and backlash are specified by gear box manufacturer.
KK-GH214 47
5 P.T.O. AND CONTROL
• Transmission P.T.O. mounting
Unit : mm
KK-GH214 48
5 P.T.O. AND CONTROL
• Layout of power line
CRANKCASE
A
TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
D E F G
Unit : mm
CHASSIS
MODEL A B C D E F G
KK-GH214 49
5 P.T.O. AND CONTROL
••Data•of•the•P.T.O.•output•shaft
TRANSMISSION PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF
SERIES (N·m {kgf·m} at r/min) TYPE ROTATION
ALLISON 3000 See ALLISON's specifications section of the tech data book.
••Necessary•parts
TRANSMISSION MODEL
ALLISON 3000
TRANSMISSION GEAR RATIO
1ST 3.487
2ND 1.864
3RD 1.409
4TH 1.000
5TH 0.750
REV 5.027
KK-GH214 50
5 P.T.O. AND CONTROL
DETAIL OF P.T.O. TRANSMISSION MODEL ALLISON 3000
CRANKCASE
A
211.8 TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
R
ENGINE CENTE
D E
F
Unit : mm
CHASSIS
MODEL A B C D E F
KK-GH214 51
5 P.T.O. AND CONTROL
• Mounting position of transmission P.T.O. ass'y for ALLISON 3000
Unit : mm
KK-GH214 52
5 P.T.O. AND CONTROL
••Data•of•the•P.T.O.•output•shaft
TRANSMISSION PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF
SERIES (N·m {kgf·m} at r/min) TYPE ROTATION
ALLISON 3500 See ALLISON's specifications section of the tech data book.
••Necessary•parts
TRANSMISSION MODEL
ALLISON 3500
TRANSMISSION GEAR RATIO
1ST 4.593
2ND 2.257
3RD 1.535
4TH 1.000
5TH 0.749
6TH 0.651
REV 4.999
KK-GH214 53
5 P.T.O. AND CONTROL
DETAIL OF P.T.O. TRANSMISSION MODEL ALLISON 3500
CRANKCASE
A
211.8 TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
R
ENGINE CENTE
D E
F
Unit : mm
CHASSIS
MODEL A B C D E F
KK-GH214 54
5 P.T.O. AND CONTROL
• Mounting position of transmission P.T.O. ass'y for ALLISON 3500
Unit : mm
KK-GH214 55
5 P.T.O. AND CONTROL
3. ENGINE REAR END POWER TAKE OFF
RELEVANT MODEL
CLASSIFICATION NUMBER
• Refer to chapter 1, 3 chassis specification for
classification number.
MOUNTING PARTICULARS Unit : mm
FRONT AXLE
DATUM LINE
A
B
FRAME UPPER
FRAME
SURFACE ASSEMBLED WIDTH
C
DATUM LINE D
VIEW Y
ENGINE MODEL
A
B
C
D
E
TYPE OF COUPLING
PERMISSIBLE TORQUE
N·m {kgf·m}
REV. RATIO
REV. DIRECTION
COUPLING PARTICULARS
NOTE
• 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 a Min. 1° to
Max. 6°.
KK-GH214 56
5 P.T.O. AND CONTROL
4. TRANSFER POWER TAKE OFF (OPT)
When the body require transfer Power Take Off (P.T.O.) , genuine
P.T.O. equipment and related parts should be supplied as shown below.
RELEVANT MODEL
CLASSIFICATION NUMBER
• Refer to chapter 1, 3 chassis specification for
classification number.
• Transfer series
• Necessary parts
KK-GH214 57
5 P.T.O. AND CONTROL
• Transfer P.T.O. mounting
Unit : mm
KK-GH214 58
5 P.T.O. AND CONTROL
• Transfer P.T.O. particulars
Unit : mm
KK-GH214 59
5 P.T.O. AND CONTROL
• Cautions for P.T.O.
Unit : mm
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.
KK-GH214 60
5 P.T.O. AND CONTROL
Caution when installing the propeller shaft for T/F P.T.O.
Be sure to observe the following indications.
• Fitting a pulley or a sprocket directly to the output shaft of transfer P.T.O. is strictly
prohibited.
• An oil pump, a pulley or a sprocket wheel should be supported properly
with the support bracket which is fixed firmly to the mounted body.
• Indications for power taking out should be followed as the indicated below.
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.
KK-GH214 61
5 P.T.O. AND CONTROL
5. ENGINE CONTROL FOR BODY OR EQUIPMENT
J08E-UG 120.5
J08E-UF 105.5
Unit : mm
NOTE
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.
KK-GH214 62
5 P.T.O. AND CONTROL
• Governor lever for body control
Unit : mm
Engine Model : J05E-TE
KK-GH214 63
5 P.T.O. AND CONTROL
• Governor lever for body control
Unit : mm
Engine Model : J08E-UG & J08E-UF
KK-GH214 64
5 P.T.O. AND CONTROL
RELEVANT MODEL
CLASSIFICATION NUMBER
Unit : mm
NOTE
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.
KK-GH214 65
5 P.T.O. AND CONTROL
• Governor lever for body control
KK-GH214 66
5 P.T.O. AND CONTROL
• HOW TO INSTALL THE ENGINE CONTROL LINKAGES FROM
ENGINE INJECTION PUMP (ENGINE MODEL P11C-UB ONLY)
If body builder wants to install the engine control cable or linkage to engine,
prepare the following parts.
KK-GH214 67
5 P.T.O. AND CONTROL
• 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.
KK-GH214 68
5 P.T.O. AND CONTROL
U-2 FUEL INJECTION TYPE
RELEVANT MODEL
CLASSIFICATION NUMBER ENGINE MODEL
J05D-TG
J05E-TC
J05E-TD
GH-051,052,053 J08E-UB
J08E-UC
J08E-UD
J08E-UE
J08E-TB
J08E-TE
A09C-TE
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 Provision of device
engine speed
KK-GH214 69
5 P.T.O. AND CONTROL
• HOW TO TAKE MEASURE
• Input the signal of P.T.O. switched on to E/G ECU
U2 - ECU
(ENGINE CONTROL ECU)
KUG
KRS
L4G
K4S
K4F
ECU CONNECTOR
SIGNAL CIRCUIT
OF P.T.O.
(GND )
K8Y
K2Z
K90
K31
DETAIL OF A
IDLE VOL
IDLE VOL
ACCEL SSR
IDLE UP1
(IUP1)
PTO SW
%E5
CAB SIDE
[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.
NOTE
• 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.
KK-GH214 70
5 P.T.O. AND CONTROL
• Idle up switch
U2 - ECU
(ENGINE CONTROL ECU)
KUG
KRS
L4G
K4S
K4F
LINKED
STARTER
S/W ON
K8Y
K2Z
K90
POWER
ACCEL SSR
IDLE VOL
IDLE VOL
SUPPLY
CONNECTOR
IDLE UP1
(IUP1)
PTO SW
%E5
#PM
#PK
#PL
CAB SIDE
BODY SIDE
[NOTE]
• THIS ALTERATION INCLUDING PROVISION OF
P.T.O. UNIT ETC. MUST BE PROVIDED OWN
P.T.O. S/W P.T.O.
IDLE UP S/W 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".
KK-GH214 71
5 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.
• Other precautions
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.
KK-GH214 72
5 P.T.O. AND CONTROL
[HOW TO INSTALL ENGINE ACCELERATOR FOR BODY OR EQUIPMENT]
• 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).
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.
KK-GH214 73
5 P.T.O. AND CONTROL
• 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.)
KK-GH214 74
5 P.T.O. AND CONTROL
6. REAR BODY CONTROL LEVER
NOTE
• LEVER RATIO 250/65=3.8
KK-GH214 75
5 P.T.O. AND CONTROL
MIXER LEVER : ML-1, ML-2
NOTE
• LEVER RATIO 330/65=5.1
KK-GH214 76
Chapter 6
ELECTRICAL SYSTEMS
KK-GH214
6 ELECTRICAL SYSTEMS
1. FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK
KK-GH214 1
6 ELECTRICAL SYSTEMS
Fuse block
NOTE
• Be sure to use each capacity fuse designated in the above table.
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.
• The figure mentioned above is example, consequently, for various particular items, check them
on the actual vehicle.
KK-GH214 2
6 ELECTRICAL SYSTEMS
Relay panel
• RHD VEHICLE
KK-GH214 3
6 ELECTRICAL SYSTEMS
• LHD VEHICLE
KK-GH214 4
6 ELECTRICAL SYSTEMS
LOCATION OF THE FUSIBLE LINK BLOCK
The fusible link block is located on left side of the cab rear arch as shown below.
KK-GH214 5
6 ELECTRICAL SYSTEMS
2. SPARE POWER TERMINALS
COUPLING
MAX. TERMINAL
TERMINAL POLE CIRCUIT WIRE SIZE CONNECTOR APPLICABLE
CAPACITY (CONNECTOR) REMARKS
MARK CODE (MAIN APPLICATION) & COLOR (SPARE PARTS) MODEL
(A) PARTS No.
PARTS No.
0.85
A AGM POWER SUPPLY, ACC 7 97840 - 4050 97830 - 4050 ALL MODEL
W-R
1.25
IOP POWER SUPPLY 10 PERMISSIBLE CURRENT : 10A
W
0.85
IOQ POWER SUPPLY, ACC 7 PERMISSIBLE CURRENT : 7A
W-G
B 82580 - 6920 82580 - 8380 ALL MODEL
POWER SUPPLY, 0.85 or 1.25
IOK 7 PERMISSIBLE CURRENT : 7A
LIGHTING W-L
2.0
IOS GROUND 20 PERMISSIBLE CURRENT : 20A
CAB SIDE
B
ALL MODEL
IDLE-UP 0.5 TO BE ADOPTED
C %E5 — FOLLOWING ENGINE, E/G Control For Rear Body Prt.1
SENSOR (INPUT) G
• J05E-TC
• J05E-TD
82580 - 6170 82580 - 6160 • J08E-UB
• J08E-UC
• J08E-TE
IDLE-UP 0.5
D %E6 — • J08E-TB Do not applicable
SENSOR (INPUT) Y-W
• J08E-UD
• J08E-UE
POWER SUPPLY, DUMP- 0.5
E U39 7 82580 - 4240 82580 - 4230 DUMP
UP SWITCH W-B
PERMISSIBLE CURRENT : 7A
POWER SUPPLY, 0.85 or 1.25 {TOTAL CURRENT = INSIDE CAB
F AGQ 7 82580 - 4240 82580 - 4230 ALL MODEL
LIGHTING W-L CONNECTOR B (IOK)
CONNECTOR C (AGQ)
CHASSIS SIDE
NOTE
• 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.
• 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.
• 0.85 for all models except tractor, 1.25 for tractor only.
KK-GH214 6
6 ELECTRICAL SYSTEMS
OUTLET POSITION INSIDE CAB
IDLE UP
C (WIRE COLOR : GREEN)
POWER SUPPLY, ACC
POWER SUPPLY, LIGHTNING
GROUND POWER SUPPLY, DIRECT
POWER SUPPLY, ACC TO BATTERY
A B
This figure is for RHD vehicle. LHD vehicle is symmetrical this figure.
KK-GH214 7
6 ELECTRICAL SYSTEMS
OUTLET POSITION OF CHASSIS SIDE
FRONT
G
POWER SUPPLY, DUMP-UP S/W
E
No.2 CROSSMEMBER
NOTE
• 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.
KK-GH214 8
6 ELECTRICAL SYSTEMS
DETAIL OF CONNECTOR
• Cab side
CONNECTOR
AGM
A
ACC ILL
IOQ IOK 2 1
B GND +B 4 3
IOS IOP
%E5 1
C
%E6 1
D
KK-GH214 9
6 ELECTRICAL SYSTEMS
• Chassis side
CONNECTOR
ON 1
E U39
1
F AGQ
VCC SIG 2 1
K95 K96
G GND 4 3
K97
KK-GH214 10
6 ELECTRICAL SYSTEMS
3. ELECTRIC WIRING OF SPARE OUTLET
KK-GH214 11
6 ELECTRICAL SYSTEMS
INSTALLATION OF ADDITIONAL EQUIPMENT AND SWITCHES
Layout of switches
• 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.
RHD VEHICLE
• Instrument panel
KK-GH214 12
6 ELECTRICAL SYSTEMS
• Floor console
KK-GH214 13
6 ELECTRICAL SYSTEMS
LHD VEHICLE
• Instrument panel
• Floor console
KK-GH214 14
6 ELECTRICAL SYSTEMS
4. PRECAUTION FOR INSTALLING WIRES, etc.,TO CAB
USING THE THROUGH HOLE FOR PIPING AND HARNESS ON THE FLOOR
When using the through hole for piping and harness on the floor,
at the front part of the floor panel through hole is provided for mounting harnesses or
cables.
When mounting the body, remove the plug hole and then carry out wiring with using the
harness grommets.
FLOOR
VEHICLE'S FRONT
THROUGH HOLES
2 – ø30
KK-GH214 15
6 ELECTRICAL SYSTEMS
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 the said taken-in, carry out fitting and wiring according to the following
instructions.
• A through hole of ø 36 is provided on the back panel but it is closed with a grommet.
Make a slit on this grommet and, after the wiring, sufficiently seal its periphery with a
sealing agent.
• In order to secure the water proofness, lower the wiring once as shown on “ Section A -
A ” to drain the water and after that bring the wiring into the cab.
• It is prohibited to fix the wiring with a tapping screw etc., because this can be a cause
of penetration of rust.
KK-GH214 16
6 ELECTRICAL SYSTEMS
5. REAR COMBINATION LAMP
When chassis with cab are shipped, the rear combination lamp assembly is temporarily installed onto the end of the
frame.
Therefore, they should be relocated by subsequent manufacturer to conform to your country laws and regulations.
Install the rear combination lamp directly such that the direction indicator lamp (amber) is outside and the back-up
lamp (white) is inside of the vehicle.
Do not install the rear combination lamps vertically so as not to affect the performance of reflectors and water drain
holes.
When installing the rear combination lamps onto the rear body, install reinforcing stays to prevent breakage, deflection
and vibration of rear combination lamp body.
NOTE
• Drawing shows rear combination lamp, LH side.
And, RH side is symmetrical this drawing.
KK-GH214 17
6 ELECTRICAL SYSTEMS
6. LICENSE PLATE LAMP
KK-GH214 18
6 ELECTRICAL SYSTEMS
7. BACK-UP BUZZER
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.
Unit : mm
Installation area
• Should install the buzzer the area which is the muddy water, rainwater and stone do
not splash.
KK-GH214 19
6 ELECTRICAL SYSTEMS
8. ELECTRICAL WIRING DIAGRAMS
KK-GH214 20
6 ELECTRICAL SYSTEMS
9. SEMI-TRAILER ELECTRICAL CONNECTION
• JUMPER CABLE
RELEVANT MODEL
CLASSIFICATION NUMBER :
KK-GH214 21
Chapter 7
PAINTING
KK-GH214
7 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 heat of the drying, some parts must
not be painted and so require masking, etc.
• If you get paint on the cab compartment, wipe it clean with gasoline.
Never use thinner.
• 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.
• 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 “star 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 prevent painting the resin cover of fuel pre filter
If painted the resin cover of fuel pre filter, there will be a crack in the resin cover, then it
may occur serious problems such as leaking of fuel and the engine hasn't started by
suck the air.
Therefore, make sure the following manner.
NOTES
• When painting, should put a mask completely on the resin cover.
• When painting, if painted the resin cover, it need replace a new one.
(There is nothing changed shortly after painted the resin cover but it may be a crack
in resin cover proceed with time.)
KK-GH214 1
7 PAINTING
GENERAL PRECAUTIONS FOR FORCED DRYING
• When you use forced drying, a temperature on the surface of any parts to be painted
must be 80°C as an upper limit.
Removing off any plastic parts, rubber parts from the vehicle, paint them when you use
a forced drying at over 80°C. (Refer to the figure as shown in after.)
Take care to those as plastic parts like fender, air cleaner, etc. are much used.
• When a vehicle with air-conditioning whose piping and hosing are heated at abnormal
temperature (more than 100°C), a pressure safety valve may function and come out
refrigerant gas.
• When removing off a air-cleaner assy, seal completely the inlet port side of engine to
prevent any penetration of dirt, paint or etc.
• Remove off the parts shown below, when you use forced drying at over 80°C.
NOTE
• The figure shows RHD vehicle, LHD vehicle is the same with above figure, except
location of ANTENNA FITTING which is symmetrical.
• When drying with heated air more than 80°C these parts described above must be
removed.
• Detail of outside mirror to be equipped is shown following page.
KK-GH214 2
7 PAINTING
DETAIL OF OUTSIDE MIRROR TO BE EQUIPPED
RELEVANT MODEL
CLASSIFICATION MIRROR
NUMBER TYPE
GH-051, 052, 053 A
B
• Refer to chapter 1, 3 chassis specification for
C
classification number.
KK-GH214 3
7 PAINTING
2. NOTE ON THE TOP COAT OF PAINT
KK-GH214 4
7 PAINTING
3. HOW TO REMOVE THE PARTS OF CAB
• 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 bolts (4 pieces) from back side of radiator grille.
KK-GH214 5
7 PAINTING
• Front panel
KK-GH214 6
7 PAINTING
HOW TO REMOVE THE VENTILATOR
• Ventilator
• Hang your hand at under side of the ventilator.
• Push up ventilator to upper side. (Move to upper side about 1 or 2 mm only.)
• Pull under side of the ventilator toward you to remove ventilator.
KK-GH214 7
7 PAINTING
HOW TO REMOVE THE QUARTER GARNISH (OPTION)
RELEVANT MODEL
CLASSIFICATION NUMBER :
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.
KK-GH214 8
7 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.
RELEVANT MODEL
CLASSIFICATION NUMBER : GH-051, 052, 053
• Refer to chapter 1, 3 chassis specification for classification number.
KK-GH214 9
7 PAINTING
• CONVEX MIRROR TYPE [TYPE B]
RELEVANT MODEL
CLASSIFICATION NUMBER :
KK-GH214 10
7 PAINTING
• CONVEX MIRROR TYPE [TYPE C]
RELEVANT MODEL
CLASSIFICATION NUMBER :
KK-GH214 11
7 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.)
NOTE
• Operate the wiper with the front panel shut down.
• With the front panel opened, you may risk to have your hand pinched by the wiper
links.
• Also after stop of the wiper motor, take out the starter key.
• When tightening the wiper arms, tighten them by adjusting the blade position (height)
with in the limit as shown as the following illustration.
• Adjust the wiper arms and the pivot positions to the following tightening torque values.
• Wiper arm tightening torque
19.6 ± 2 N·m {200 ± 20 kgf·cm}
• Wiper pivot tightening torque
11.8 ± 1 N·m {120 ± 10 kgf·cm}
KK-GH214 12
7 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.
KK-GH214 13
7 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.
KK-GH214 14
7 PAINTING
4. PROCEDURE FOR ADHERING ORNAMENTS
• What to prepare
Clean waists
• 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.)
KK-GH214 15
7 PAINTING
ADHERING POSITION OF MODEL SERIES ORNAMENT (FOR DOOR)
RELEVANT MODEL
CLASSIFICATION HINO LOGO SERIES NAME MODEL NAME EXHAUST GAS MODEL NAME
NUMBER MARK (A) ORNAMENT (B) ORNAMENT (C) ORNAMENT (D) ORNAMENT (E)
GH-051, 052, 053 WITH WITH LESS LESS WITH
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.
KK-GH214 16
7 PAINTING
5. MOUNTING AND STICKING OF DOOR WEATHER STRIP
In the case to disassemble the door weather strip when perform top coat paint,
reassemble it as following procedure.
Pay special attention when reassemble the door weather strip, otherwise it will cause
leakage of rain water.
KK-GH214 17
7 PAINTING
ILLUSTRATION OF THE WEATHER STRIP MARK POSITION
KK-GH214 18
7 PAINTING
6. HOW TO MOUNT THE MAIN AND SUB SEAL
HOW TO MOUNT THE MAIN SEAL AT THE POSITION OF THE FRONT COWL
When you apply the top coating, apply masking on the main seal of the front cowl.
If you are obliged to remove the door sub seal, replace it with a new part in the
following manner,
Part number of front cowl main seal : 76821-1260 (FC, FD, GD) 1 piece/vehicle
76821-1270 (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.
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7 PAINTING
MOUNTING PROCEDURES OF MAIN SEAL AT THE POSITION OF THE
FRONT CORNER PANEL
When applying top coating do it either by dismounting the main seal at the front corner
panel or by masking the section concerned.
Parts number of main seal at the front corner panel : 76811-1120 (2 pieces/vehicle)
• Mounting procedure
• Insert the front corner main seal into the hole provided on the front corner panel.
• Caution
• Securely fix the retainer on the front corner panel which is mounted onto main seal.
• In order to avoid the penetration of water, mount it in such a way that the section
shape of the seal might become as illustrated on the Section B-B.
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7 PAINTING
MOUNTING PROCEDURE FOR DOOR SUB SEAL
• Wipe dirt, water, oil and wax etc. with clean waste on the double-sided tape's
fitting surface of door panel.
• Insert the clip of the door sub seal sufficiently well and fix it.
• Peel off the release coated paper of double-sided tape and press fit it on the door
panel.
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7 PAINTING
7. CAUTIONS FOR PAINTING TILT CYLINDER ROD
• 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.
NOTES
• Before painting, mask the rod completely
• Take great care not to dent or scratch the rod.
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7 PAINTING
8. HANDLING OF LAMINATED WINDSHIELD
A laminated glass is produced in such order that polyvinyl butyral film is inserted between
2 glasses and pressed with heat.
Under driving general condition, there is no problem. But under a hot temperature and a
high moisture when painting, intermediate film is fallen off or such defective occur as
foaming may be caused. Therefore, a special caution needs to be taken.
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7 PAINTING
9. HANDLING OF COMPUTERS (ECU)
When paint by forced drying, must be care to handle the computers as following points.
KK-GH214 24
7 PAINTING
10. PRECAUTIONS FOR FITTING AND STORING THE CAUTION PLATE
• How to Stick It
a. Stick the caution plate to a dry place which is free from dust and dirt after the paint has
completely dried up.
b. Clean your hand and don't use cotton work gloves, etc..
c. Completely remove water, oil, dust, etc. from the surface to stick (surface of cab) with
ethyl alcohol if they are found remaining there.
d. When the temperature is less than 10°C, warm up the surface to stick as well as the
caution plate with warm wind of more than 20°C before sticking the caution plate.
e. After sticking the caution plate, press it with a roller, etc., with a force of
approximately 49 N/cm2 {5 kgf/cm2 }.
f. Remove liner paper (backing paper) just before using it.
g. When air remains inside, make a tiny hole with a needle or a cutter knife and press it
out with your fingers from the bubble area.
• How to Store It
a. When storing the caution plate, select a dry place with an ambient temperature
(of 20 to 25°C) and without dust, dirt and stain.
b. Also, store the caution plate at a flat place such as a shelf, etc., and do not place
anything on it.
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7 PAINTING
11. CAUTIONS FOR PAINTING THE TIRE DISC WHEELS
• Before painting the tire wheel, cover its inside and outside surface to be contacted
with the hub, the wheel, the brake drum and wheel nuts.
Refer to the illustration below concerning the covering portions.
• After installing the tire 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.
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Chapter 8
CHASSIS DRAWINGS
1. CAB DRAWINGS••••••••••••••••••••••••••••••••••••••••••••••••• 2
2. CAB BACK DRAWINGS•••••••••••••••••••••••••••••••••••••••• 8
3. CHASSIS DRAWINGS•••••••••••••••••••••••••••••••••••••••••• 14
4. CHASSIS FRAME DRAWINGS••••••••••••••••••••••••••••••• 21
KK-GH214
8 CHASSIS DRAWINGS
Refer to detail of the cab, chassis and chassis frame drawing based on following table.
RELEVANT MODEL
CLASSIFICATION CHASSIS DRAWINGS
NUMBER CAB CAB BACK CHASSIS CHASSIS FRAME
GH-051 C-1 CB-1 CH-1 CF-1
GH-052 C-1 CB-1 CH-2 CF-2
GH-053 C-1 CB-1 CH-3 CF-3
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8 CHASSIS DRAWINGS
1. CAB DRAWINGS
• Front
KK-GH214 2
8 CHASSIS DRAWINGS
No. C-1 Unit : mm
• Rear
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8 CHASSIS DRAWINGS
No. C-2 Scale : 1/20
• Front Unit : mm
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8 CHASSIS DRAWINGS
No. C-2 Scale : 1/20
• Rear Unit : mm
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8 CHASSIS DRAWINGS
No. C-3 Scale : 1/20
• Front Unit : mm
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8 CHASSIS DRAWINGS
No. C-3 Scale : 1/20
• Rear Unit : mm
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8 CHASSIS DRAWINGS
2. CAB BACK DRAWINGS
No. CB-1
• Left view
Unit : mm
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8 CHASSIS DRAWINGS
No. CB-1
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8 CHASSIS DRAWINGS
No. CB-2
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8 CHASSIS DRAWINGS
No. CB-2
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8 CHASSIS DRAWINGS
No. CB-3
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8 CHASSIS DRAWINGS
No. CB-3
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8 CHASSIS DRAWINGS
3. CHASSIS DRAWINGS
No. CH-1
Unit : mm
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8 CHASSIS DRAWINGS
No. CH-2 Unit : mm
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8 CHASSIS DRAWINGS
No. CH-3 Unit : mm
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8 CHASSIS DRAWINGS
No. CH-4 Scale : 1/40
Unit : mm
NOTE
• Figures marked " " dimensions are measured
in parallel with the surface of the ground.
• The dimension of tire to be mentioned in above
table shows design figure according to JATMA
or ETRTO standard.
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8 CHASSIS DRAWINGS
No. CH-5 Scale : 1/40
Unit : mm
NOTE
• Figures marked " " dimensions are measured
in parallel with the surface of the ground.
• The dimension of tire to be mentioned in above
table shows design figure according to JATMA
or ETRTO standard.
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8 CHASSIS DRAWINGS
No. CH-6 Scale : 1/40
Unit : mm
NOTE
• Figures marked " " dimensions are measured
in parallel with the surface of the ground.
• The dimension of tire to be mentioned in above
table shows design figure according to JATMA
or ETRTO standard.
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8 CHASSIS DRAWINGS
No. CH-7 Scale : 1/40
Unit : mm
NOTE
• Figures marked " " dimensions are measured
in parallel with the surface of the ground.
• The dimension of tire to be mentioned in above
table shows design figure according to JATMA
or ETRTO standard.
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8 CHASSIS DRAWINGS
4. CHASSIS FRAME DRAWINGS
No. CF-1
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8 CHASSIS DRAWINGS
No. CF-1
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8 CHASSIS DRAWINGS
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8 CHASSIS DRAWINGS
No. CF-2 Unit : mm
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8 CHASSIS DRAWINGS
No. CF-3
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8 CHASSIS DRAWINGS
No. CF-3
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8 CHASSIS DRAWINGS
No. CF-4 Scale : 1/40
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8 CHASSIS DRAWINGS
No. CF-4 Scale : 1/20
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8 CHASSIS DRAWINGS
No. CF-5 Scale : 1/40
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8 CHASSIS DRAWINGS
No. CF-5 Scale : 1/20
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8 CHASSIS DRAWINGS
No. CF-6 Scale : 1/40
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8 CHASSIS DRAWINGS
No. CF-6 Scale : 1/20
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Chapter 9
MOUNTING OF CHASSIS EQUIPMENT
KK-GH214
9 MOUNTING OF CHASSIS EQUIPMENT
Refer to detail of the fuel tank, battery, air tank and exhaust system drawing based on
following table.
[STANDARD EQUIPMENT]
RELEVANT MODEL
CLASSIFICATION AIR TANK & EXHAUST
FUEL TANK BATTERY
NUMBER AIR BOOSTER SYSTEM
GH-051,052,053 FT-1 AT&A-1 BAT-1 EX-1
[OPTION EQUIPMENT]
RELEVANT MODEL
CLASSIFICATION AIR TANK & EXHAUST
FUEL TANK BATTERY
NUMBER AIR BOOSTER SYSTEM
GH-051,052,053 – AT & A-2 BAT-2 –
NOTE
SYMBOL SPECIFICATION
FT-1 200L
FT-2
FT-3
FT-4
FT-5
BAT-1 STD : 234kC {65AH}
BAT-2 OPT : 432kC {120AH}
EX-1 HORIZONTAL EXHAUST PIPE (STD)
VERTICAL EXHAUST PIPE (STD)
VERTICAL EXHAUST PIPE (OPT)
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9 MOUNTING OF CHASSIS EQUIPMENT
1. FUEL TANK
FT-1 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
FT-2 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
FT-3 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
FT-4 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
FT-5 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
2. AIR TANK & AIR BOOSTER
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9 MOUNTING OF CHASSIS EQUIPMENT
AT & A-2 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
AT & A-3 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
AT & A-4 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
AT & A-5 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
AT & A-6 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
AT & A-7 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
AT & A-8 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
AT & A-9 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
AT & A-10 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
3. BATTERY
Unit : mm
BAT-1
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9 MOUNTING OF CHASSIS EQUIPMENT
BAT-2
Unit : mm
DISASSEMBLY SPACE OF
BATTERY COVER
23
TO No.2 CROSSMENBER
50
60
DATUM LINE 696
50
430
394
321
70 140
551.5 323
380.5
VEHICLE’S FRONT
4.5
21
284.3
531.5
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9 MOUNTING OF CHASSIS EQUIPMENT
BAT-3
Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
4. EXHAUST SYSTEM (EXHAUST TAIL PIPE)
EX-1 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
EX-2 Unit : mm
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9 MOUNTING OF CHASSIS EQUIPMENT
EX-3 Scale : 1/20
Unit : mm
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Chapter 10
OTHER
KK-GH214
10 OTHER
1. BRAKE PIPING DIAGRAM (1/4)
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10 OTHER
BRAKE PIPING DIAGRAM (2/4)
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10 OTHER
BRAKE PIPING DIAGRAM (3/4)
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10 OTHER
BRAKE PIPING DIAGRAM (4/4)
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10 OTHER
2. LICENSE PLATE BRACKET Unit : mm
[TYPE A] [TYPE B]
[TYPE C] [TYPE D]
[TYPE E] [TYPE F]
RELEVANT MODEL
CLASSIFICATION
TYPE
NUMBER
A
B
GH-051,052,053 C
D
E
F
KK-GH214 5
10 OTHER
Unit : mm
[TYPE G] [TYPE H]
[TYPE I] [TYPE J]
RELEVANT MODEL
CLASSIFICATION
TYPE
NUMBER
G
H
I
J
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10 OTHER
3. SEMI-TRAILER BRAKE COUPLING (FOR TRACTOR ONLY)
The trailer brake system can be actuated by operating the foot brake and hand brake
valves that are provided at the inside of the tractor cab.
The trailer brake system is connected by a jumper hose and an air-coupling.
The air-coupling equipped on the HINO vehicle complies with SAE standard and color
distinction is made to clarify the purpose for use ; Blue being for Service purpose while
Red being for an Emergency purpose.
The actual form is as shown below.
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Chapter 11
REGULATION
1. HANDLING PRECAUTIONS OF
CATALYST MUFFLER••••••••••••••••••••••••••••••••••••••• 2
KK-GH214
11 REGULATION
This section is described the informations in relation to vehicle’s lows and regulations
that must be complied while body or equipment is mounted on the Hino truck chassis
with cab as following contents.
• Items which the body or equipment manufacturer must be provided the facilities.
• Handling precautions of parts which has already been equipped on the chassis, the
cab, and the engine.
• Other precautions which must be taken during the work of the body or equipment
mounting.
The body or equipment manufacturer must make sure the contents to be described in
this section.
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11 REGULATION
1. HANDLING PRECAUTIONS OF CATALYST MUFFLER
To comply with exhaust gaseous emission control regulation, the Catalyst Muffler is
equipped to the Model GH8J series.
Pay special attention that water do not intrude into the muffler, when washing the vehicle
especially under part of the chassis.
Do not give any shock as dropping a goods while rear body or equipment mounting to
the muffler.
KK-GH214 2