Bm1604a5egpfig1 PDF

BM1604A5EGP
HINO 500 SERIES

Body Mounting Manual
TRUCK CHASSIS
FG8J
MODEL
GH8J
FM2P
SG2P
COPYRIGHT
No part of this manual may be reproduced or transmitted in any form without the express
written permission of Hino Motors, Ltd.
© 2016, Hino Motors, Ltd. All rights reserved. Printed in Japan.
3-1-1, HINO-DAI, HINO-SHI, TOKYO, 191-8660 JAPAN
July 2016
BM1604A5EGP
PUBLISHING INFORMATION
PUBLISHING INFORMATION
We have published Body Mounting Manual for new 500 series.
BM1604A5EGP
ABOUT THIS MANUAL
Purpose
This manual is provided to Body and Equipment Manufacturers, including inter-mediate

and/or final stage manufacturers (hereinafter collectively referred to as Body and
Equipment Manufacturers), to provide;
• Technical instructions for Hino truck chassis with cab for modification and mounting of
bodies,
• An aid to Body and Equipment Manufacturers for producing safe vehicles under their
own discretion and responsibility,
• Other general advice for installation, modification or alteration,
when Body and Equipment Manufacturers install any body or other equipment or device

on Hino truck chassis with cab (hereinafter collectively referred to as Hino Chassis), or
modify or alter a Hino Chassis.
Content
This manual contains chassis specifications and instructions particular to

HINO 500 series medium duty trucks.
Important
• This instruction manual must be used in combination with
the Common Manual, No. KC-AA201A.
• The instructions of individual model manual precede over

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

• For more information on mounting of bodies and equipments or on chassis
modifications, refer to the appropriate workshop manuals, parts catalogs, and
maintenance guides and owner's or driver's manual.
• The information in this manual is accurate to the best of Hino's knowledge at the time
of going to press.
Hino reserves the right to modify any and all information without notice and without
obligation.
• Should more detailed data or information be needed, please contact authorized Hino
distributor.
BM1604A5EGP
ABOUT THIS MANUAL
Warning
• It is the responsibility of Body and Equipment Manufacturers or modification companies

to make sure that the completed vehicle with body and equipment, or after
modification, conforms to all applicable laws and regulations of the country in which the
vehicle is to be used (e. g. regulations on lighting, tilt, overall size, axle load, external
noise control etc).
• This manual does not guarantee the safety of a Hino chassis once a body or
equipment has been mounted or modification has been made by a Body and
Equipment Manufacturer or a modification company.
• This manual does not affect that ultimate responsibility for the manufacture and
mounting of the body, installation, modification or alteration on Hino Chassis devolves
upon the Body and Equipment Manufacturer.
• Each individual Body and Equipment Manufacturer has the sole responsibility for the
design, functions, materials and work concerning the body and equipment.
• Hino Motors, Ltd. does not assume any liability whatsoever for any injury to persons or
damage to property caused as a result of the utilization of this manual.
• About chassis mass

The chassis mass of chapter 1 and 3 shows standard specification of vehicle.
(It is not included mass of option equipment.)
When consider the mounting of body, should include mass of option equipment.
• About SRS air bag and ABS system

In the case of the vehicle which is installed the SRS air bag and ABS system, be sure
to comply with the remarks bellow.
The SRS air bag may inflate incorrectly according to wrong operations of body
mounting or unexpected cause.
The function of ABS system fall remarkably according to incorrect body mounting.
Therefore it is strictly prohibited that the following operations, modification or provision
of equipments install to the vehicle.
1. Removing the steering wheel, steering system and parts of cab.
2. Wheelbase modification
3. Front bumper modification
Stay extension
Bumper thickness change
Shape modification
4. Provide snow plough
(Snow removal)
5. Provide grille guard
6. Provide winch
7. Provide kangaroo bar, and so on.
Before starting work, be sure to refer to Chapter 2 PRECAUTION FOR SRS AIR BAG
or please consult Hino sales dealer or distributor.
• About VEHICLE CONTROL ECU

In the case of the vehicle which is installed VEHICLE CONTROL ECU, the vehicle is
controlled by.
Therefore, don't change the specification of vehicle. (Ex. Tire size, Final gear ratio, etc.)
BM1604A5EGP
ABOUT THIS MANUAL
• In normal operation, the chassis frame and body frame provide sufficient strength for
the mounting of a standard cargo, van and dump body.
However, if body or equipment such as a small crane at the back of the cab, concrete
pump, areal platform, tank supported reg type or a mixer are fitted, the chassis frame
will be subject to concentrated loads and the chassis frame alone will not give sufficient
strength. To help spread the load, you must strengthen the body structure (especially
strengthening members corresponding to the sub frame=longitudinal main floor
member of body or equipment) or the chassis frame itself, using L-shaped stiffeners to
achieve sufficient strength for the mounting of the rear body or equipment.
More detailed information will be needed, please contact to Hino authorized distributor
or sale outlet.
BM1604A5EGP
CONTENTS
1. VEHICLE SUMMARY
2. GENERAL PRECAUTIONS
3. CHASSIS MASS & FRAME SECTION MODULUS
4. SPRINGS & REAR AXLES
5. P.T.O. AND CONTROL
6. ELECTRICAL SYSTEMS
7. PAINTING
8. CHASSIS DRAWINGS
9. MOUNTING OF CHASSIS EQUIPMENT
10. 5TH WHEEL
11. REGULATION
BM1604A5EGP
Chapter 1
VEHICLE SUMMARY
1. PRODUCTION CODE
2. IDENTIFICATION NUMBER
3. CHASSIS SPECIFICATIONS
BM1604A5EGP
1 VEHICLE SUMMARY
1. PRODUCTION CODE
F G 8J K 1 A – BGJ
GVMR & (DRIVE) CODE ENGINE CODE WHEELBASE CODE MODIFICATION CODE APPLICABLE CODE
VEHICLE TYPE OTHER SPECIFICATION CODE
WHEELBASE STEERING BODY TYPE
GVMR DRIVE CODE MODEL CODE CODE MODIFY CODE
(mm) POSITION ETC.
10,400kg C 3000 GENERAL CARGO with

F CAB-OVER TRUCK C 4x2 1J J08C K A CAB, T/M TYPE ETC.
CLASS D 3000 3249 LEAF SUSPENSION
10,000 12,000kg E 3250 3499 R FIRST GENERAL CARGO with

G CAB-OVER TRUCK D 4x2 6J J05D , RH B
CLASS F 3500 3749 LEAF SUSPENSION
1
12,000 14,000kg G 3750 3999 DUMP with
S SEMI-TRACTOR E 4x2 7J J07E D
CLASS H 4000 4249 LEAF SUSPENSION
14,000 15,500kg J 4250 4499 DUMP with

G 4x2 8J J08E S E
CLASS K 4500 4749 LEAF SUSPENSION
17,000kg L 4750 4999 Z FIRST FIRE ENGINE with

H 4x2 9J J05E , LH F
CLASS M 5000 5249 LEAF SUSPENSION
7 GENERAL CARGO
26,000kg N 5250 5499
L 6x2 1A A09C G with REAR AIR
CLASS P 5500 5749 SUSPENSION
26,000kg R 5750 5999 GENERAL CARGO
M 6x4 2P P11C H with REAR AIR
CLASS S 6000 6249 SUSPENSION
10,000 13,000kg T 6250 6499 MIXER with
T 4x4 M
CLASS U 6500 6749 LEAF SUSPENSION
OVER 30,000kg W 7000 7249 DUMP with REAR AIR

Y 8x4 Q
CLASS SUSPENSION
MIXER with REAR AIR

U
SUSPENSION
NOTE
• Refer to chassis specification for GVMR (Gross vehicle mass rating).
BM1604A5EGP 1
1 VEHICLE SUMMARY
2. IDENTIFICATION NUMBER
CHASSIS NUMBER
Located at the right side

member of chassis frame.
FR.AXLE CENTER
ENGINE NUMBER
: ENGINE NUMBER
B
ENGINE MODEL STAMPING POSITION
J08E A
P11C B
BM1604A5EGP 2
1 VEHICLE SUMMARY
3. CHASSIS SPECIFICATIONS
Detail of specifications refer to following.
WARNING
• Permissible axle capacity and GVM or GCM capacity must not be exceeded.
• The front axle load must exceed 30% of the gross vehicle mass under full loaded
condition for 4x2, 8x4 and 4x4 drive vehicle.
• The front axle load must exceed 20% of the gross vehicle mass under full loaded
condition for 6x2 and 6x4 drive vehicle.
• The rear axle load must exceed 25% of the gross combination mass under full
loaded condition of semi-tractor vehicle.
• Mass distribution on the left and right wheels should be balanced.
• Both front axle and rear axle loads must not exceed the permissible load based on
the tire load capacity according to the tire standards in your country.
• The mass and dimension of tires mentioned in chassis specification shows design
figure according to ETRTO or JATMA standard.
BM1604A5EGP 3
1 VEHICLE SUMMARY
S : STANDARD EQUIPMENT P : OPTION EQUIPMENT
FG series
MODEL NAME HINO 51527
PRODUCTION CODE FG8JF7D-PG2 FG8JM7A-PG2
Ch1 BODY APPLICATION DUMP GENERAL CARGO
EMISSION CONTROL EURO2
ENGINE J08E-WL
191kW {260PS}
MAX. OUTPUT ISO NET
at 2,500r/min
794N·m {81.0kgf·m}
MAX. TORQUE ISO NET
at 1,500r/min
MAJOR TRANSMISSION MX06 (6MT)

SPECIFICATIONS SUSPENSION Fr & Rr LEAF SPRING
CAB SINGLE CAB, WIDE TYPE
VEHICLE CONTROL ECU LESS
SRS AIR BAG LESS
ABS STD:LESS / OPT:WITH
HEADLIGHT AUTOLEVERING LESS
FRONT UNDERRUN PROTECTION DEVICE (FUPD) LESS
WHEEL BASE (mm) 3,730 5,080
TREAD FRONT (mm) 2,050
REAR (mm) 1,835
MAX. GVM/GCM CAPACITY (kg) 15,100/-----
PERMISSIBLE AXLE CAPACITY FRONT (kg) 7,500
(GAM. RATING) REAR (kg) 11,500
DIMENSIONS TIRE CAPACITY SIZE F&R 10.00R20-16

& MASS ON STD SPECIFICATIONS FRONT (kg) 6,000
REAR (kg) 10,900
CHASSIS MASS ON STD SPECIFICATIONS
(kg) Refer to 3, 1
(INCLUDING WATER, OIL AND FULL FUEL)
HEIGHT OF CENTER OF GRAVITY (CHASSIS) (mm) Refer to 3, 1
RECOMMENDED HEIGHT OF GRAVITY CENTER
(mm) 1,250
OF VEHICLE (UNLOADED CONDITION)
RECOMMENDED MAXIMUM BODY WIDTH (mm) MAX. 2,500
FOR DETAILS OF DIMENSIONS & MASS, REFER TO EACH SECTIONS AS BELOW .

Ch3 3.1. CHASSIS MASS M1 M2
CHASSIS MASS &
FRAME SECTION 3.2. MASS OF THE OPTION EQUIPMENT EQ1 & EQ2 EQ1 & EQ2
MODULUS
3.3. FRAME SECTION MODULUS Z1 Z2
Ch4 4.1. SPRING CHARACTERISTICS FRONT STD F1(FML) F1(FML)
OPT1 F2(FTL) F2(FTL)
SPRINGS & OPT2 F3(FRT) F3(FRT)

REAR AXLES OPT3 F4(FRM) F4(FRM)
REAR STD R1(RML) R1(RML)
OPT R2(RRM) R2(RRM)
Ch5 5.2. TRANSMISSION SIDE POWER TAKE OFF TP-1 TP-1
P.T.O. AND
5.3. ENGINE CONTROL FOR BODY OR EQUIPMENT COMMON RAIL COMMON RAIL
CONTROL
5.4. REAR BODY CONTROL LEVER WITH(OPT) WITH(OPT)
Ch8 8.1. CAB DRAWINGS C-1 C-1
CHASSIS 8.2. CAB BACK DRAWINGS CB-1 CB-2

DRAWINGS 8.3. CHASSIS DRAWINGS CH-1 CH-2
8.4. CHASSIS FRAME DRAWINGS CF-1 CF-2
Ch9 9.1. AIR TANK & AIR BOOSTER STD AT-1 AT-1
OPT AT-2 AT-2
OPT - -
OPT - -
9.2. BRAKE PIPING DIAGRAM STD PD-1 PD-1
OPT PD-2 PD-2
OPT - -
9.3. BATTERY STD BAT-1 BAT-1
MOUNTING OF
CHASSIS OPT BAT-2 BAT-2
EQUIPMENT
9.4. FUEL TANK STD FT-1 FT-2
OPT - -
OPT - -
9.5. EXHAUST SYSTEM STD EX-1 EX-4
OPT EX-2 EX-2
OPT EX-3 EX-3
9.6. LICENSE PLATE BRACKET STD LPB-1 LPB-1
OPT LPB-2 LPB-2
10.00R20-16PR S S
11.00R20-16PR P P
11R22.5 148/145 P P
TIRE 12R22.5 152/148 P P
275/70R22.5 148/145 - -
275/80R22.5 - P
295/80R22.5 P P
20x7.50V-offset165mm S S
WHEEL DISC 22.5x7.50-offset162mm P P
22.5X8.25-offset165mm P P
200L S S
FUEL TANK 320L - -
390L - -
65AH S S
BATTERY
120AH P P
ALTERNATOR 24V-60A S S
BM1604A5EGP 4
1 VEHICLE SUMMARY
GH series
PRODUCTION CODE GH8JF7D-PG2 GH8JM7A-PG2
Ch1 BODY APPLICATION DUMP GENERAL CARGO
ENGINE J08E-WL
191kW {260PS}
MAX. OUTPUT ISO NET
at 2,500r/min
794N·m {81.0kgf·m}
MAX. TORQUE ISO NET
at 1,500r/min
MAJOR TRANSMISSION MX06 (6MT)

SRS AIR BAG LESS
WHEEL BASE (mm) 3,730 5,080
REAR (mm) 1,835

REAR (kg) 10,900
(kg) Refer to 3, 1
(mm) 1,250

Ch3 3.1. CHASSIS MASS M3 M4
CHASSIS MASS &
FRAME SECTION 3.2. MASS OF THE OPTION EQUIPMENT EQ1 & EQ2 EQ1 & EQ2
MODULUS
3.3. FRAME SECTION MODULUS Z3 Z4
Ch4 4.1. SPRING CHARACTERISTICS FRONT STD F1(FML) F1(FML)
OPT1 F5(FTL) F5(FTL)
SPRINGS & OPT2 F6(FRT) F6(FRT)

REAR AXLES OPT3 F4(FRM) F4(FRM)
REAR STD R3(RML) R3(RML)
OPT R4(RRM) R4(RRM)
Ch5 5.2. TRANSMISSION SIDE POWER TAKE OFF TP-1 TP-1
P.T.O. AND
5.3. ENGINE CONTROL FOR BODY OR EQUIPMENT COMMON RAIL COMMON RAIL
CONTROL
5.4. REAR BODY CONTROL LEVER WITH(OPT) WITH(OPT)
Ch8 8.1. CAB DRAWINGS C-1 C-1
CHASSIS 8.2. CAB BACK DRAWINGS CB-1 CB-2

DRAWINGS 8.3. CHASSIS DRAWINGS CH-3 CH-4
8.4. CHASSIS FRAME DRAWINGS CF-3 CF-4
Ch9 9.1. AIR TANK & AIR BOOSTER STD AT-1 AT-1
OPT AT-2 AT-2
OPT - -
OPT - -
9.2. BRAKE PIPING DIAGRAM STD PD-1 PD-1
OPT PD-2 PD-2
OPT - -
9.3. BATTERY STD BAT-1 BAT-1
MOUNTING OF
CHASSIS OPT BAT-2 BAT-2
EQUIPMENT
9.4. FUEL TANK STD FT-1 FT-2
OPT - -
OPT - -
9.5. EXHAUST SYSTEM STD EX-1 EX-4
OPT EX-2 EX-2
OPT EX-3 EX-3
9.6. LICENSE PLATE BRACKET STD LPB-1 LPB-1
OPT LPB-2 LPB-2
10.00R20-16PR S S
11.00R20-16PR P P
11R22.5 148/145 P P
TIRE 12R22.5 152/148 P P
275/70R22.5 148/145 - -
275/80R22.5 - P
295/80R22.5 P P
20x7.50V-offset165mm S S
WHEEL DISC 22.5x7.50-offset162mm P P
22.5X8.25-offset165mm P P
200L S S
FUEL TANK 320L P -
390L - -
65AH S S
BATTERY
120AH P P
ALTERNATOR 24V-60A S S
BM1604A5EGP 5
1 VEHICLE SUMMARY
FM series
PRODUCTION CODE FM2PR7A-MG2
Ch1 BODY APPLICATION GENERAL CARGO
ENGINE P11C-VP
250kW {340PS}
MAX. OUTPUT ISO NET
at 2,100r/min
1275N·m {130.0kgf·m}
MAX. TORQUE ISO NET
at 1,500r/min
MAJOR TRANSMISSION ZF9S1310

SRS AIR BAG LESS
WHEEL BASE (mm) 4530+1350
REAR (mm) 1,855

REAR (kg) 10,900
(kg) Refer to 3, 1
(mm) 1,250

Ch3 3.1. CHASSIS MASS M5
CHASSIS MASS &
FRAME SECTION 3.2. MASS OF THE OPTION EQUIPMENT EQ1 & EQ2
MODULUS
3.3. FRAME SECTION MODULUS Z5
Ch4 4.1. SPRING CHARACTERISTICS FRONT STD F7(FML)
OPT1 -
SPRINGS & OPT2 F8(FRT)

REAR AXLES OPT3 F9(FRM)
REAR STD R5(RML)
OPT R6(RRM)
Ch5 5.2. TRANSMISSION SIDE POWER TAKE OFF TP-3
P.T.O. AND
5.3. ENGINE CONTROL FOR BODY OR EQUIPMENT COMMON RAIL
CONTROL
5.4. REAR BODY CONTROL LEVER WITH(OPT)
Ch8 8.1. CAB DRAWINGS C-2
CHASSIS 8.2. CAB BACK DRAWINGS CB-3

DRAWINGS 8.3. CHASSIS DRAWINGS CH-5
8.4. CHASSIS FRAME DRAWINGS CF-5
Ch9 9.1. AIR TANK & AIR BOOSTER STD AT-3
OPT AT-4
OPT AT-5
OPT AT-6
9.2. BRAKE PIPING DIAGRAM STD PD-3
OPT PD-4
OPT PD-5
9.3. BATTERY STD BAT-1
MOUNTING OF
CHASSIS OPT BAT-2
EQUIPMENT
9.4. FUEL TANK STD FT-3
OPT FT-5
OPT -
9.5. EXHAUST SYSTEM STD EX-5
OPT EX-6
OPT EX-7
9.6. LICENSE PLATE BRACKET STD LPB-1
OPT LPB-2
10.00R20-16PR S
11.00R20-16PR P
11R22.5 148/145 -
TIRE 12R22.5 152/148 P
275/70R22.5 148/145 -
275/80R22.5 P
295/80R22.5 P
20x7.50V-offset165mm S
WHEEL DISC 22.5x7.50-offset162mm -
22.5X8.25-offset165mm P
200L S
FUEL TANK 320L P
390L -
65AH S
BATTERY
120AH P
ALTERNATOR 24V-60A S
BM1604A5EGP 6
1 VEHICLE SUMMARY
SG series
PRODUCTION CODE SG2PF7B-MG2
Ch1 BODY APPLICATION SEMI-TRACTOR
ENGINE P11C-VP
250kW {340PS}
MAX. OUTPUT ISO NET
at 2,100r/min
1275N·m {130.0kgf·m}
MAX. TORQUE ISO NET
at 1,500r/min
MAJOR TRANSMISSION M009OD

SRS AIR BAG LESS
ABS STD:WITH / OPT:LESS
WHEEL BASE (mm) 3,630
REAR (mm) 1,835
MAX. GVM/GCM CAPACITY (kg) 18,000/40,000

REAR (kg) 12,000
(kg) Refer to 3, 1
(mm) 1,250

Ch3 3.1. CHASSIS MASS M6
CHASSIS MASS &
FRAME SECTION 3.2. MASS OF THE OPTION EQUIPMENT EQ1 & EQ2
MODULUS
3.3. FRAME SECTION MODULUS Z6
Ch4 4.1. SPRING CHARACTERISTICS FRONT STD F10(FML)
OPT1 -
SPRINGS & OPT2 -

REAR AXLES OPT3 -
REAR STD R7(RML)
OPT -
Ch5 5.2. TRANSMISSION SIDE POWER TAKE OFF TP-2
P.T.O. AND
5.3. ENGINE CONTROL FOR BODY OR EQUIPMENT COMMON RAIL
CONTROL
5.4. REAR BODY CONTROL LEVER WITH(OPT)
Ch8 8.1. CAB DRAWINGS C-3
CHASSIS 8.2. CAB BACK DRAWINGS CB-4

DRAWINGS 8.3. CHASSIS DRAWINGS CH-6
8.4. CHASSIS FRAME DRAWINGS CF-6
Ch9 9.1. AIR TANK & AIR BOOSTER STD AT-7
OPT AT-8
OPT -
OPT -
9.2. BRAKE PIPING DIAGRAM STD PD-6
OPT PD-7
OPT PD-8
9.3. BATTERY STD BAT-1
MOUNTING OF
CHASSIS OPT BAT-2
EQUIPMENT
9.4. FUEL TANK STD FT-2
OPT FT-4
OPT FT-6
9.5. EXHAUST SYSTEM STD EX-8
OPT EX-9
OPT EX-7
9.6. LICENSE PLATE BRACKET STD LPB-1
OPT LPB-2
10.00R20-16PR -
11.00R20-16PR S
11R22.5 148/145 P
TIRE 12R22.5 152/148 P
275/70R22.5 148/145 P
275/80R22.5 P
295/80R22.5 -
20x7.50V-offset165mm S
WHEEL DISC 22.5x7.50-offset162mm P
22.5X8.25-offset165mm P
200L S
FUEL TANK 320L P
390L P
60AH S
BATTERY
120AH P
ALTERNATOR 24V-60A S
BM1604A5EGP 7
Chapter 2
GENERAL PRECAUTIONS
1. ELECTRIC WELDING WORK

2. NOTES ON SYSTEM CONTROL COMPUTERS
3. FIRE SHIELD
4. NOTES ON ADDITIONAL WIRING IN THE ENGINE
COMPARTMENT
5. CLEARANCE BETWEEN CAB AND REAR BODY OR
EQUIPMENT
6. CHASSIS FRAME
7. CHASSIS FRAME HOLE PATTERN
8. RECOMMENDED POSITIONS OF U-BOLTS
9. RECOMMENDED STRUCTURE OF BODY SUB-FRAME
10. RECOMMENDED DIMENSION OF SUB-FRAME
11. MOUNTING METHOD OF BODY OR EQUIPMENT
12. RECOMMENDED BODY ATTACHMENTS
13. TIGHTENING DETAIL AROUND REAR SUSPENSION
14. ASSEMBLY DETAIL OF ATTACHMENT PLATE
15. EXAMPLE OF BODY MOUNTING
16. RE-TIGHTEN INSTALLING BOLTS
17. BUILDING SIDE GATE OF SEPARATE TYPE
18. HOW TO EXTEND REAR OVER HANG (R.O.H.)
19. POWER TAKE OFF (P.T.O.)
20. RECOMMENDED POSITIONS OF FENDERS AND MUDGUARDS
21. PRECAUTION OF THE ANTENNA POSITION
22. PRECAUTION OF FUEL HOSE
23. INSTRUCTION AIR-BLEEDING
24. PRECAUTION OF HANDLING BRAKE NYLON TUBES
BM1604A5EGP
2 GENERAL PRECAUTIONS
1. 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
instrument as the welding current flow back along the earth circuit.
When welding, take following step of manner.
1) ‌Procedure before welding

(1) Turn the starter switch to "LOCK" position.
CK
LO

(2) Disconnect the negative terminal of the battery.
negative terminal
negative

(3) Dismount fuse indicated in the label below.
BM1604A5EGP 1
2) Ground of the welding equipment

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

• Connecting the ground to the chassis spring is strictly prohibited to prevent
damage of the spring.
• In case of welding the cab body, connect the ground to the fixing bolt of cab
hinge or to the cab body near the place where to be welded.
3) Other precautions of welding

• To protect ancillary equipment from sparks during welding, place fire-resistant
covers over the rubber hoses, wire harness, pipes, chassis spring and tires,
etc..
• Create the most suitable condition for welding, and minimize the heat influence
to the welding circumference and keep the welding quality as long as possible.
4) After welding
• Put back fuses of Engine ECU in original position.
• Make sure to connect the ground terminal of the battery.
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.
BM1604A5EGP 2
6) For reference
This is example current flow of electric welding when weld cab body.
Case of disconnecting the negative terminal of BATTERY
Turn the STARTER SWITCH to LOCK position.

Do not turn on the STARTER SWITCH when
the earth wire is disconnected.
EARTH OF
GOOD
EQUIPMENTS
ELECTRIC
EQUIPMENTS
ARC
WELDING
MACHINE
+ – CHASSIS FRAME
EARTH WIRE
OF CAB
BATTERY
Disconnect the negative terminal of BATTERY.

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

ELECTRIC EQUIPMENTS will be damaged.
WELDING ROD
EARTH OF
NG
EQUIPMENTS
ELECTRIC
EQUIPMENTS
ARC
WELDING
STARTER MACHINE
SWITCH
+ – CHASSIS FRAME
EARTH WIRE
OF CAB
BATTERY
<The electric current of welding>

WELDING ROD CAB ELECTRIC EQUIPMENTS BATTERY EARTH of ARC WELDING
MACHINE
EARTH WIRE OF CAB
BM1604A5EGP 3
2. NOTES ON SYSTEM CONTROL COMPUTERS
Engine ECU and brake ABS computers (option) are installed right part, inside of
the instrument panel as described following figure.
Therefore, give great care to the computer when performing any body
mounting work or modification as following points.
• Be sure to cover the computer to protect the water penetration when

performing cleaning up the inside of cab.
• When mounting such devices as a radiophone, a wireless communication
device, be sure to use the devices that conforms to the electric control act
and install the devices on the places which are as far as possible from the
computers and its harness.
Do not install any high output (over 50W) device.
Be sure to check that no abnormal electric wave or electromagnetic wave
is found, after having installed the device, which affects on the electronic
signals passing through in computer harness.
• Do not alter the computer, harness wire or sensors (ex. acceleration sensor).
• As you will see on the following Fig. Various kind of computers are
installed inside the cab, when fitting and modifying the inside of the cab,
be careful not to give any shock to the vicinity of the computer.
LAYOUT OF ECU
BM1604A5EGP 4
3. FIRE SHIELD
GAP BETWEEN CAB REAR END AND BODY

When a flat bed or similar body has been mounted, a fire shield should be fitted
across the gap between the cab rear end and the front end of the load platform
frame to prevent fires that may be caused by flammable materials falling off from
the load platform onto the exhaust pipe (see figure below).
A fire shield is not necessary if the body is fitted with a sheet carrier attached
directly to the top of the front guard.
A fire shield is also not necessary for such bodies as dump trucks, mixers,
tankers and van bodies, where there is no danger of flammable materials falling
off.
FITTING THE FIRE SHIELD
・For approximately 50mm from the front edge of fire

　shield (the cab side), use rubber to match the shape
　of the fire shield to that of the cab rear end such
　as cab back cover.
・You may also install the fire shield so that it

covers only the exhaust system.
CAB REAR ARCH

RUBBER
FIRE SHIELD
BOLT&NUT
BODY OR
EQUIPMENT
WARNING
• When you mount the fire shield, use bolts, etc., that can be taken out to
allow for replacement of the chassis parts which are located at the rear
part of cab.
BM1604A5EGP 5
4. NOTES ON ADDITIONAL WIRING IN THE ENGINE COMPARTMENT
Since the engines in HINO trucks are covered with sound arrest plates, the
engine compartment tends to heat up.
Avoid wiring in the engine compartment if possible.
Additional wiring harness or cable should be kept away from heated elements,
and should be wired along the main harness.
BM1604A5EGP 6
5. CLEARANCE BETWEEN CAB AND REAR BODY OR EQUIPMENT
MINIMUM CLEARANCE WITH CAB REAR END

The rear part of the cab contains the cab lock mechanism and the tilt
mechanism, as well as the engine cylinder block or other various equipment as
trailer brake connector stand and etc.
When mounting the body or equipment, allow at least the minimum clearance
between the rear end of the cab or some of the chassis component and the front
end of the rear body or swept radius of the trailer front end to avoid obstructing
the operation and maintenance of these mechanisms or various equipments, and
to avoid damage due to contact.
Unit : mm
HORAIZONTAL
CAB MOUNT REAR ARCH EXHAUST PIPE
MODEL
TYPE COVER
A B
FG8J
FLOATING LESS 830 50
GH8J
FM2P
SG2P
B : MINIMUM CLEARANCE
FROM THE FRONT END OF THE REAR BODY
TO THE CAB REAR END.
VERTICAL EXHAUST TAIL PIPE
Unit : mm
VERTICAL
CAB MOUNT REAR ARCH EXHAUST PIPE
MODEL
TYPE COVER
A B
FG8J
GH8J
FM2P
SG2P
B : MINIMUM CLEARANCE
FROM THE FRONT END OF THE REAR BODY
TO THE CAB REAR END OR THE EXHAUST PIPE
BM1604A5EGP 7
MEASUREMENT DETAIL OF CAB TILT MECHANISM
Unit : mm
MODEL A B
FG8J / GH8J 775 627
FM2P 675 759
SG2P 675 782
BM1604A5EGP 8
MEASUREMENT DETAIL OF ENGINE AIR INTAKE PORT

Unit : mm
MODEL A B C D
FG8J (W/B : F,M)

1,122.5 834.5 786.5 1,614.0
GH8J (W/B : F,M)
FM2P 1,122.5 966.5 686.5 1,746.0
SG2P 1,122.5 989.5 686.5 1,769.0
WARNING
• The blocking of the smooth flow of air into the air intake pipe caused by any
materials such as ropes, pieces of cloth, etc. leads to the increase of exhaust
temperature if driven long intervals.
• The increase in exhaust temperature is caused by the decreased efficiency in
the combustion process, as the proportion of air in the combustion chamber is
also decreased by the above mentioned factor. This situation will lead to major
malfunctions such as the cracking of the exhaust manifold and the breaking
down of the turbocharger. To avoid such malfunctions, please keep the air
intake pipe free from any blocking materials at all times.
BM1604A5EGP 9
MEASUREMENT DETAIL OF ENGINE AIR CLEANER

Unit : mm
DISASSEMBLY SPACE OF
AIR CLEANER COVER
DISASSEMBLY
SPACE OF ELEMENT
MODEL B C D
FG8J (W/B : F,M)

574.5 1077.6 294.5
GH8J (W/B : F,M)
WARNING
• Be sure to install HINO genuine element to avoid engine performance
and fuel-efficiency being affected.
• Use of non-genuine element may result of engine damage.
BM1604A5EGP 10
Unit : mm
DISASSEMBLY SPACE OF
AIR CLEANER COVER
DISASSEMBLY
SPACE OF ELEMENT
MODEL B C D
FM2P 459 1073.3 416.5
SG2P 459 1073.3 439.5
WARNING
• Be sure to install HINO genuine element to avoid engine performance
and fuel-efficiency being affected.
• Use of non-genuine element may result of engine damage.
BM1604A5EGP 11
6. CHASSIS FRAME
1) FRAME MATERIAL
HINO NEW 500 series use the following frame material;

MATERIAL
Metal type Tensile strength Yield strength
Hot rolled steel ≧620N/mm 2 ≧500N/mm 2
plate { 63kgf/mm 2 } { 51kgf/mm 2 }
2) HOW TO SUPPORT LOADED WEIGHT
The chassis frame is designed to distribute the weight of the cargo

rather than allowing it to be concentrated in one place.
Chassis frames are naturally quite hard and strong, but it is a mistake to
imagine that they do not change shape in any way under any external
force.
Chassis frames are actually quite flexible.
The chassis frame flexes and twists in response to forces that arise while
the vehicle is operation so as to support the vehicle's weight and allow it
to follow the bumps and follows of the road surface.
BM1604A5EGP 12
3) MUST INSTALL SUB-FRAME
When mounting a body or equipment, always fit

a sub-frame on the top surface of the chassis frame.
WARNING
• Sub-frame must be one-piece.
• Material of sub-frame must be steel.
(Section : or or )
• If using one-piece is difficult, follow the

instructions below when join sub-frame.
1) Do not join sub-frame around rear axle.

2) Must join sub-frame in between wheel base.
3) Reinforce
‌ a joint area sufficiently for considering
deterioration of welding strength.
BM1604A5EGP 13
When mounting the sub-frame on top of the chassis frame, be sure that
you position it so as to disperse the stress placed on the frame by loading.
Also be sure to secure all mechanisms of the body unit to the sub-frame,
except for the combination parts between the sub-frame and the chassis
frame.
In normal operation, the chassis frame and body sub-frame provide

sufficient strength for the mounting of a standard cargo or van body.
However, if equipment such as a small crane at the back of the cab or

a concrete mixer are fitted, the chassis frame will be subject to concentrated
loads and the chassis frame alone will not give sufficient strength.
To help spread the load, you must strengthen the body structure (especially
strengthening members corresponding to the sub-frame of body or
equipment) or the chassis frame itself, using L-shaped stiffeners to
achieve sufficient strength for the mounting of the body or equipment.
The chassis frame is the “backbone” of the vehicle.
4) DO NOT INSTALL SPACER
WARNING
• In order to increase total rigidity, do not install spacer between
chassis frame and sub-frame.
BM1604A5EGP 14
When installing spacer, the position of the front end of

spacer is as following figure.
Recommend spacer material is steel to prevent deformation
by load or deterioration.
Should match spacer shape with side kick of chassis frame.
BM1604A5EGP 15
5) DO NOT WELD CHASSIS FRAME
INCORRECT
INCORRECT
WARNING
• Frame is heat-treated.
• To avoid frame damage,
do not heat or weld,
do not drill, cut or notch
frame flange.
In case of new 500 series, high tensile strength steel

(tensile strength : 620 N/mm2 { 63 kgf/mm2 }) is used for chassis frame, and
sharp fall strength occurs due to welding.
Therefore, avoid welding on the frame.
Instead of that, we provide holes in new 500 series.
(For details, see the Body Mounting Manual for the respective model series.)
BM1604A5EGP 16
6) ‌OTHER PRECAUTIONS FOR DRILLING AND

ELECTRICAL WELDING
Do Not Heat the Frame Unnecessarily
Heating greatly affects the strength of the chassis frame. Do not

unnecessarily heat any part of the chassis frame unless performing
gas cutting work on the rear overhang.
Never Make Cutouts in Flanges
Do not make cutouts in the flanges of the side members when mounting
the body or making modifications.
Cutouts may lead to cracks in the side members.
Do Not Drill, Weld or Make Cutouts in Crossmembers
The crossmembers which link the right and left side members are important
strengthening parts. When mounting the body or making modifications,
do not drill, weld or make cutouts in the crossmembers.
BM1604A5EGP 17
Do Not Drill, Weld, or Make Cutouts in Stiffener of trunnion cross member
The cross member and trunnion stiffeners are important strengthening

parts which are fitted to avoid concentrated loads on the side members.
When mounting the body or making modifications, do not drill, weld, or make
cutouts in the stiffeners.
BM1604A5EGP 18
Do Not Modify the Crossmember
When accommodating devices of body or equipment within the chassis

frame, you should not modify crossmembers of the chassis frame.
If an equipment or a device comes across over the crossmember
section or if a sufficient clearance is not available, apply an appropriate
solution by moving the fitting position of the devices of body or equipment,
etc.
BM1604A5EGP 19
7. CHASSIS FRAME HOLE PATTERN
There are holes at intervals of 50 mm on the web surface of the side member.
Each equipment on chassis is installed with these holes.
Should use these holes when mounting of body. When install equipment of body
or parts to chassis frame, also use these holes.
The detail of holes are as follows.
1) Range of holes Unit : mm
2) Detail of holes
WARNING
• Must use these holes only when installing body and parts for body.
• There are not holes of No.2 and No.3 normally. If need holes for
installing body and parts for body, you can drill holes but must follow
the basic pattern of holes on frame.
The maximum hole's diameter is 15.5 mm.
• Never drill around pilot hole.
• Refer to chapter 3 for details of frame material and chapter 2 for
electric welding work, and then be sure to observe their instructions.
BM1604A5EGP 20
8. RECOMMENDED POSITIONS OF U-BOLTS
1) ‌MOUNTING FOR GENERAL BODIES
U-BOLT POSITION BEHIND THE CAB
IN CASE OF HORIZONTAL TAIL PIPE
The recommended setting positions of U-bolts behind the cab should be
observed according to the figure shown below.
Distance from No.2 cross member

Unit : mm
MODEL A B
FG8J
1080 ~ 1315 1165 ~ 1230
GH8J
FM2P 1080 ~ 1220 1110 ~ 1165
WARNING
• To use a proven method of attachment is acceptable, but it should be
longitudinally flexible.
• The shape of body sub-frame should follow the side kick of chassis frame
and extend the front end to the rear end of cab-arch.
BM1604A5EGP 21

IN CASE OF STACK TAIL PIPE
The recommended setting positions of U-bolts behind the cab should be
observed according to the figure shown below.

Unit : mm
MODEL A B
FG8J
GH8J 920 965
FM2P
WARNING
• To use a proven method of attachment is acceptable, but it should be
longitudinally flexible.
• The shape of body sub-frame should follow the side kick of chassis frame
and extend the front end to the rear end of cab-arch.
BM1604A5EGP 22
2) ‌MOUNTING FOR CAB BACK CRANE

U-BOLT POSITION BEHIND THE CAB
IN CASE OF HORIZONTAL TAIL PIPE
The recommended setting positions of U-bolts behind the cab are prepared
according to the figure shown below.

Unit : mm
MODEL A B C D
FG8J
1225 725 1225 725
GH8J
FM2P 1130 630 1130 630
WARNING
• Must calculate enough strength of chassis frame for crane, and reinforce
the chassis frame before mounting cab back crane.
• Please follow the crane maker's instructions for details.
• Refer to following for example reinforcement method of chassis frame.
BM1604A5EGP 23
EXAMPLE OF REINFORCEMENT METHOD OF CHASSIS FRAME
FOR MOUNTING CAB BACK CRANE
Must implement chassis reinforcement when mounting body such as occurring
stress concentration to chassis frame.
(ex. Mounting cab back crane)
Stress concentration value to chassis frame may be changed by capacity of mounting

crane (weight and capacity of crane etc.,), must follow the result of strength calculation
for mounting crane maker when implementing chassis reinforcement.
The following is example of reinforcement method when mounting cab back crane.
INSTALLING OF STIFFENER TYPE
BM1604A5EGP 24
INSTALLING OF SUB-FRAME TYPE
BM1604A5EGP 25
3) PROHIBITED AREA FOR INSTALLING U-BOLT
Drawing below shows prohibited area for installing U-bolt, bracket or plate at
“KICK POINT” .
Leave a space of 200mm from the both ends of each cross member.
(This technique does not apply to attachment plate or Bracket, described
later.)
Between the forward end stress release portion of body sub-frame is prohibited
to install U-Bolt.

Unit : mm
MODEL RIGHT LEFT
FG8J
1080 ~ 1315 1165 ~ 1230
GH8J
FM2P 1080 ~ 1220 1110 ~ 1165
WARNING
• The above is also applied on the other shape of forward end of body sub-
frame.
BM1604A5EGP 26
9. RECOMMENDED STRUCTURE OF BODY SUB-FRAME
1) FORWARD END SHAPE OF SUB-FRAME
Refer to the following shape and dimension for avoiding stress concentration.

Unit : mm
MODEL RIGHT LEFT
FG8J
1080 ~ 1315 1165 ~ 1230
GH8J
FM2P 1080 ~ 1220 1110 ~ 1165
WARNING
• Type A or B of Front edge should be formed in a round chamfer.
BM1604A5EGP 27
2) FRONT STRUCTURE OF SUB-FRAME
Front structure of sub-frame should be as following.
a. Sub-frame shape should follow the side kick of chassis frame.

b. Make the recommended shape type A~C for avoiding stress concentration.
c. Keep Stiffener out more than 600mm from the forward end of Sub-frame.
d. Do not install cross member at the forward end.
e. ‌Do not extend stiffener by the forward end.
Do not close the forward end with plate.
CORRECT INCORRECT
WARNING
• Do not install spacer between chassis frame and body sub-frame.
• If install spacer, can not have a sufficient strength.
BM1604A5EGP 28
3) CAUTION FOR SIDE KICK OF CHASSIS FRAME
The front end part of sub-frame must follow the side kick shape of chassis frame
as following figure.
And material of sub-frame must use shaped or pressed steel.
• FRONT SIDE KICK SHAPE OF SUB-FRAME
BM1604A5EGP 29
Must fit a sub frame with the following instructions,

if it is difficult to fit a sub frame on a side-kick of chassis frame.
BM1604A5EGP 30
4) FRONT END POSITION OF SUB-FRAME
The front end of sub-frame must extend upto rear end of cab-arch.
BM1604A5EGP 31
5) ‌POSITIONING FORWARD END OF SUB-FRAME

FOR HIGHT RIGID OF BODY OR EQUIPMENT
For trucks with highly rigid bodies such as tank lorries, LPG lorries, and van body
trucks (especially refrigerator trucks), etc., be sure to select the chassis model
and design the body so that the sub-frame extends as much as possible
toward the back of the cab.
If for unavoidable reasons, such as axle mass distribution, you must leave a
large gap between the body or equipment and the back of the cab, extend the
sub-frame as much as possible toward the back of the cab and secure it
firmly to the chassis frame.
DETAIL OF FORWARD END OF SUB-FRAME
BM1604A5EGP 32
10. RECOMMENDED DIMENSION OF SUB-FRAME
The section area of sub-frame of the mounted body or equipment

Must set a value greater than following steel material.
1) FOR GENERAL CARGO BODY
2) FOR LONG WHEELBASE VEHICLE
WARNING
• Vehicle condition of recommended sub-frame as follows;
GVM : Under standard GVM specified in chapter 1.
Payload : Even distributed load.
Operation road : On paved.
• If chassis frame may be occurred to concentrated load, must
strengthen the sub-frame.
• If vehicle is more heavy duty operation than standard which is
specified chapter 1, must consider greater section of sub-frame.
BM1604A5EGP 33
3) OTHER PRECAUTIONS
Sub-frame for long wheelbase vehicle
Must use a steel sub-frame.
The use of a wooden or aluminum sub-frame may deform the chassis frame,
and it may affect operating the rear body such as opening gate.
Must use the standard press-rolled structural steel material SS41 or more
greater one for heavy duty vehicle with a concentrated load with long wheelbase.
Provision of water drain hole for sub-frame
The water may deposit in the sub-frame such as a lip-formed steel

( channel-shaped) or close section steel, and It may be the cause
of rust.
Therefore, provide a drain hole on the sub-frame where avoiding to strength

problems.
BM1604A5EGP 34
11. MOUNTING METHOD OF BODY OR EQUIPMENT
HOW TO INSTALL THE SUB-FRAME
Install the sub-frame of the body or equipment on the chassis using

U-bolts or brackets.
The details of mounting methods are shown in the drawings below.
If the sub-frame even if made of steel to be secured to the chassis, should not be fixed
on the frame by welding or bolting on the frame upper flange.
BM1604A5EGP 35
If it is difficult to allow a clearance to the chassis parts, use U-bolts made from steel
sheet.
For the locations of the U-bolts used when mounting ordinary body or equipment, see the
U-bolt Mounting Position Drawing in the Body Mounting Manual for the respective model
series.
For the chassis frame with a -shaped cross section, install a appropriate props at the
U-bolt tightening section to prevent deformation of the flange on the frame side member.
Refer to Installation Method of U-bolts for more details of the props.
Install sub-frame tightening U-bolts and a appropriate props in such a manner that they
do not touch wires, brake pipes, and hoses and that these parts can be inspected,
serviced, removed, and reinstalled later.
Allow sufficient clearances around rubber hoses because they will move while the vehicle
in running.
The gap to the rubber hose must be 50 mm or more and the gaps to the brake pipe and
valve must be 15 mm or more.
When a prop is required around the exhaust pipe and muffler, use a steel prop.
BM1604A5EGP 36
12. RECOMMENDED BODY ATTACHMENTS
The detail of mounting methods are shown as followings.
1) THE DETAIL OF MOUNTING METHODS

(1) NO.1 U-BOLT AND PROP
Install PROP for avoiding deforming frame flange. Unit : mm
NOTE
• Must insert a shim if clearance
is more than 1mm between
frame side member and inner
reinforcement before installing
prop.
BM1604A5EGP 37
Unit : mm
WARNING
• Must tighten double nut to prevent loosening of tightening nut when installing
U-bolt.
• Follow the mounting methods for the instructions of installing No.1 U-bolt when
installing other area with U-bolt but must adjust each prop's height for avoiding
deformation of upper and lower flange of frame.
• Must perform to prevent dropping shim off, but welding or making hole to the
frame flange is prohibited.
• Must apply proper rust preventive treatment to frame after inserted a shim.
BM1604A5EGP 38
EXAMPLE STRUCTURE OF PROPS

For the frame side member which is fastened with a U-bolt, use appropriate
props to support the frame side member so that the lower and upper flange may
not be deformed.
Sufficient clearance should be allowed to prevent the props from contacting

brake nylon tubes, hoses, cables and harness wires etc.
In an area close to the muffler, use a steel prop to prevent burning.
BM1604A5EGP 39
BM1604A5EGP 40
2) ATTACHMENT BRACKET OR PLATE

This mounting method is used where U-bolts cannot be fitted owing to the shape
of the body to be mounted, e.g. with tanker bodies.
WARNING
• Installing of attachment bracket or plate should be tighten by bolts and nuts.
• Tightening holes should be used No.1 hole of chassis frame side member.
BM1604A5EGP 41
13. TIGHTENING DETAIL AROUND REAR SUSPENSION
Around rear suspension should be tighten by attachment plate depend on the
following reasons.
• To insure stability and stiffness of complete vehicle.

• To avoid interference with installing parts of chassis such as suspension.
The attachment plate must install four places at each side member.
Refer to installing position of attachment plate in the drawing below.

Unit : mm
WARNING
• Installing of attachment plate should be tighten by bolts and nuts.
• Tightening holes should be used No.1 hole of chassis frame side member.
• When installing attachment plate, must keep installing dimensions above
drawings.
BM1604A5EGP 42
Tandem rear axle
The following figures are HINO's recommend installing position for installing
attachment plates.
Using 4 pieces of Attachment Plate
WARNING
Be sure to observe the following precautions when installing attachment plate.
• Must install the attachment plate to chassis before installing body or equipment.
• Do not Installing the attachment plate to area.
• Should use No.1 hole of chassis frame side member when installing attachment plate.
• Should tighten attachment plate by bolts and nuts.
• Should prepare attachment plate by own responsibility of Body and Equipment
Manufactures.
See the following page for detail of attachment plate.
BM1604A5EGP 43
Attachment Plate
Making the attachment plate by own responsibility of Body and Equipment Manufactures.
The following figure is HINO's recommend attachment plate.
Detail of HINO's recommend attachment plate.
Plate : 3 holes type
When installing attachment plate, allow at least the minimum clearance.

The installing attachment plate and the installing bolts must not interfere with U-bolt for
leaf spring.
<Reference clearance between U-bolt and Side rail>
If difficult to follow the instructions above, please consult HINO authorized dealer or
distributor.
BM1604A5EGP 44
14. ASSEMBLY DETAIL OF ATTACHMENT PLATE
In case of FG, GH Model (Leaf sus)
BM1604A5EGP 45
In case of FM Model
NOTE
Bolt and nut of attachment plates indicated in the illustration above, should be an
adequate property class and size selected by body builder in accordance with shape of
the attachment plate.
BM1604A5EGP 46
15. EXAMPLE OF BODY MOUNTING
EXAMPLE OF MOUNTING FOR CARGO BODY. (FOR FG, GH MODEL)
• U-Bolt Method
• Attachment Plate Method
BM1604A5EGP 47
EXAMPLE OF MOUNTING FOR CARGO BODY. (FOR FM MODEL)
• U-Bolt Method
BM1604A5EGP 48
EXAMPLE OF MOUNTING FOR DUMP BODY. (FOR FG, GH MODEL)
• Attachment Bracket Method
BM1604A5EGP 49
16. RE-TIGHTEN INSTALLING BOLTS
Must check the installing bolts and nuts when maintaining a vehicle.
Should re-tighten the installing bolts and nuts if they are loosening.
The figures below are an example of installing bolts and nuts.
BM1604A5EGP 50
17. BUILDING SIDE GATE OF SEPARATE TYPE
For the side gate of the rear body which is open deck cargo body, recommend a
threeway open gate type (rigid piece side gate) keeping bending rigidity of rear
body to avoid deformation of the chassis frame rear overhang.
In change the side gate of rear body from rigid piece to separate type, provide
the center pole at forward position of rear axle between wheelbase.
And be sure to reinforce the center pole to keep the bending rigidity same with
rigid piece.
BM1604A5EGP 51
18. HOW TO EXTEND REAR OVER HANG (R.O.H.)
1) Extension length is 300mm or Less

(1) Extension material
Use the same material as the base metal for side member.
The shape of the cross section and thickness of the extension material must be
the same as the side member.
(2) Procedure of extension

Must use the continuous butt welding method for the extension material and
relocate the end cross member as shown in the drawing below to reinforce the
welding section.
(3) How to weld

Before butt welding, the end of both materials, the side-member and the
extension material, must be cut off as shown in the figure.
BM1604A5EGP 52
2) Extension length is more than 300mm

(1) Extension material
Use the same material as the base metal for side member. The shape of the
cross section and thickness of the extension material must be the same as the
side member.
(2) Procedure of extension

Must use the continuous butt welding method for the extension material and
tighten the stiffeners below indicated with adequate bolt and nut.
Following stiffeners show model FM.
NOTE
• In case of model FG, GH and SG, installing holes should be change to same position
of side member.
BM1604A5EGP 53
3) Crossmember pitch
‌ the distance is more than 2935mm between the final axle center and the rear
If
end of side member, add a cross member as shown below after extending the
side member and relocate the end cross member.
BM1604A5EGP 54
19. POWER TAKE OFF (P.T.O.)
After mounting a body or equipment, you may need to take a power

supply from the chassis and fit controls for the body or equipment.
When making these modifications, be sure to observe the following

precautions.
BM1604A5EGP 55
1). PROVISION OF POWER TAKE OFF (P.T.O.)

Following power take off (P.T.O.) may be provided as standard or
option equipment.
• TRANSMISSION SIDE P.T.O. : For all models

(Except mixer models)
• ENGINE REAR P.T.O. : For mixer models only
WARNING
• Never permit the P.T.O. unit to exceed the torque recommended by
Hino.
( For details of permissible torque, refer to Chapter 5. )
• When the P.T.O. is operated for a long time in the ordinary condition,
a heat protection fixture such as a heat insulator should be provided
in order to prevent fire and protect cables, hoses, tubes and wiring
harness from high heat emitted from exhaust manifold and exhaust
tail pipes.
BM1604A5EGP 56
WARNING
• The devices of the body or equipment ( eg. an oil pump) which will be
intended to drive by P.T.O., must be securely fixed at same installation
angle of engine to the body or equipment side via bracket, etc.
THE DIRECT FIXING THE DEVICES TO THE P.T.O.

OUTPUT FLANGE IS STRICTLY PROHIBITED.
BM1604A5EGP 57
2). P.T.O. (POWER TAKE OFF) DRIVE SHAFT

When fitting the drive shaft, be sure to observe followings.
If the installing angle of the drive shaft is too large, it will cause noise
and vibration, and may cause damage of P.T.O. or drive shaft.
Mounting Angle for Devices of Body or Equipment
The devices on the body or equipment (eg. oil pump) must be installed
at the same angle as the engine (θ), and the angle of the universal joint
of the drive shaft (D1 and D2) must be same.
Drive Shaft Angle
As a rule, the three-dimensional angle of the universal joint of the drive

shaft (D1, D2 and D3) should be a MIN.1°to MAX.6°.
BM1604A5EGP 58
Length of Drive Shaft
To keep a minimum vibration during driving, Hino recommended that

the drive shaft should be no longer than the values shown in the table.
If must make the shaft longer than the values shown in the table,
fit a center bearing to avoid excessive vibration.
BM1604A5EGP 59
20. RECOMMENDED POSITIONS OF FENDERS AND MUDGUARDS
1) 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 WHEELS” in 4 - 3.
(FOR REAR SINGLE AXLE) Unit : mm

PRODUCTION CODE STD/OPT REAR TIRE DISC SIZE A B C D
FG8J, GH8J STD 10.00R20 20X7.50V 2442 2500 1835 195
FG8J, GH8J OPT 11.00R20 20X7.50V 2448 2500 1835 192
FG8J, GH8J OPT 11R22.5 22.5X7.50 2432 2500 1835 200
FG8J, GH8J OPT 12R22.5 22.5X8.25 2459 2500 1835 186
FG8J (W/B : M)
OPT 275/80R22.5 22.5X8.25 2443 2500 1835 194
GH8J (W/B : M)
FG8J, GH8J OPT 295/80R22.5 22.5X8.25 2457 2500 1835 194
TIRE WHEEL
E F
SIZE (in)
150
16 or 17.5 or 19.5 200
~ 200
200
20 or 22.5 300
~ 250
NOTE
• The dimension mentioned above table shows design figure according to ETRTO or JATMA
standard.
BM1604A5EGP 60
(FOR TANDEM REAR AXLE) Unit : mm

PRODUCTION CODE STD/OPT REAR TIRE DISC SIZE A B C D
FM2P STD 10.00R20 20X7.50V 2462 2500 1855 201
FM2P OPT 11.00R20 20X7.50V 2468 2500 1855 210
FM2P OPT 12R22.5 22.5X8.25 2479 2500 1855 196
FM2P OPT 275/80R22.5 22.5X8.25 2463 2500 1855 204
FM2P OPT 295/80R22.5 22.5X8.25 2477 2500 1855 197
NOTE
• When mounting the fenders (shaded in the figure) make a drain hole at E to allow water
to escape.
• The dimension mentioned above table shows design figure according to ETRTO or JATMA
standard.
BM1604A5EGP 61
21. 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 an interference occurred
with the antenna and body part.
Unit : mm
MODEL A B
FG , GH 1933~2511 -220~1313
FM2P / SG2P 2096~2673 -250~1183
BM1604A5EGP 62
22. PRECAUTION OF 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.
Be sure to use the fuel hose of HINO genuine parts.
The following figure is an example of genuine parts.

(The material and quality of each component are based on the standard of
HINO.)
Unit : mm
INNER RUBBER
(FLUORIDE COATED)
ØA
ØB
OUTER RUBBER
BRAID
INTERMEDIATE RUBBER
DIAMETER
INNER OUTER
NOMINAL
A B
8 7.6 14
10 9.5 17
If genuine parts cannot be obtained, please get the following rubber hoses as a
substitute.
• The rubber hoses which dose not contain a metal element.

or
• The rubber hoses which a metal element does not melt into fuel.
(For example : The rubber hose which give the fluoride coat to the inside.)
The quality of the rubber hoses of a substitute should be more than equivalent to
genuine, or equivalent.
Use of unsuitable rubber hose may cause serious faults of engine, such as the
decline of an exhaust gas purification function.
For more detailed information, please consult your nearest HINO sales outlet.
BM1604A5EGP 63
23. INSTRUCTION OF AIR-BLEEDING
As a general rule, the air-bleeding from brake system is prohibited.
If take air-bleeding for mounting body, take account of the frequency of use of the
equipment, the performance of the air supply and safety considerations, and
consult Hino authorized dealer and distributor beforehand.
When install air piping, make sure it will not affect brake system during operation
or in the event of a breakdown and following rules;
a. Do not modify air tank.

b. Do not air-bleeding from
• main brake system (Front and Rear brake system)
• and on the charge line (between air compressor and wet tank).
Install the protection valve to air-bleeding circuit to protect the brake system.
And adjust the control air pressure to min. 49N/cm2 {5kgf/cm2} for keeping the air
pressure on brake system when breakdown (occurred air leakage, e.g.) the
air-bleeding line.
Detail of the taking place and manner for air-bleeding, refer to followings;
BM1604A5EGP 64
1) The place of air-bleeding

Air-bleeding from multi joint for accessory circuit in brake circuit.
Should install protection valve for protecting accessory circuit on the chassis
side.
(The installing position of multi joint is different by length of W/B, but

the multi joint is installed behind of No.2 cross member on inside of side member
of chassis frame RH.)
The basic circuit for air-bleeding
THE DETAIL OF PROTECTION VALVE

PART No. : S4457-01011
CONTROL PRESSURE : 49N/cm2 {5kgf/cm2}
PT : 1/4
BM1604A5EGP 65
2) Instructions of air-bleeding
(1) ‌Air-bleeding from multi joint, disconnect available the plug of port
and install push-in-connector of PT 1/4, then air-bleeding.
There are 2 type of push-in-connector by size of nylon tube for taking out the
air.
See the following table.
(2) Should
‌ install protection valve on circuit.
Fix the protection valve with M6 bolt ( x2) to body side.

Tightening torque : 9.0±1.8N·m
(3) ‌The port is not available for using all of it by vehicle specifications.
(The port using to T/M Control, T/M PTO Control & Exhaust Brake Control)
In that case, divide from using port, and taking out the air.
The push-in-connector for dividing should match the size of nylon tube, and
use the parts as following list.
(4) Should
‌ seal the installing push-in-connector with liquid packing or tape.
Refer to "Common Manual in Chapter 5" for sealing method of screw taper of
connector.
(5) Judging the presence of the air leak with bubble after installing.
BM1604A5EGP 66
24. PRECAUTION OF HANDLING BRAKE NYLON TUBES
When Nylon tubes are used for air piping system of brakes, be careful not to
heat particularly at the time of welding.
Also, make sure to perform the welding by putting protecting covers on the nylon
tubes so that welding sputter, etc. might not be splashed on the tubes.
For other general precautions, refer to the instructions shown on the following
table.
When dismounting and remounting the piping for the reason of facilitating the
maintenance, inspection of the brake and air line as well as of body or equipment
mounting, make sure to put matching marks (using paint, tape, tag, etc.) on the
equipment side as well as on the piping side to prevent by all means from
making wrong fitting when remounting them.
Wrong mounting of equipment and piping will cause a serious functional damage
to the system using brake line and air line.
BM1604A5EGP 67
Precautions to take for handling nylon tubes when mounting the body
1 Protection of nylon tube Fit a protecting cover on the nylon If welding sparks, etc are
when welding or grinding tube or remove it according to the projected on the nylon tube,
with a sander necessity the tube may melt and cause
air leakage sometimes.
2 Prevention of introduction When dismounting and remounting Biting of foreign matters by
of foreign matters into the the nylon tubes and the connectors, valves and connectors may
nylon tubes and cover them with vinyl sac, etc (sac sometimes cause air leakage
connectors. producing fiber dust is not suitable) to or malfunctioning of valves.
prevent sticking and / or introduction
of foreign matters.
3 Protection against Matching parts Gap (mm) Holes may sometimes appear
interference of nylon on the tubes and pipes due to
Chassis parts 5
tubes rubbing and wear and may
(fixing position) result in air leakage.
Engine,transmission, 30
cab, etc (relative
moving position)
Tires, propeller shaft, 50
etc (rotating position)
Components for Equivalent
upper structures to the above
4 Securing gaps with Secure gaps of more than 200mm High temperature due to the
exhaust system between the nylon tubes and the heat of the exhaust system
exhaust system (exhaust pipe, may cause sometimes melting
muffler, etc) or protect the tubes by of the tubes and may result
covering them with insulators, etc. in air leakage.
Also, be sure to fit insulators on the
flange section of the exhaust system.
5 Prevention of swinging Provide appropriate clip bands to the If the clip gap is too big, tubes
of the nylon tubes nylon tubes to avoid swinging of the may swing to rub against
tubes after mounting. : other parts and may cause
• Gaps of the clip bands should have contact wear, this leading
pitches less than 400mm. sometime to occurrence of air
leakage.
• Clip band to use : S4783-71230
• Use the special service tool for clip
band (S0962-01010) with a
fastening force of 3 indicated on
the tool (dial adjusting type)
6 Securing of bending "R" The minimum bending "R" for the If a tube is bent with the
for nylon tubes nylon tubes should be as indicated on bending "R" less than the
the following table. Avoid bending the minimum bending "R" ,,the air
tubes with the bending "R" smaller may be clogged by broken
than the one indicated in the table. tube and air leakage may
occur by the end position of
R(mm) the connector.
ø6 30
ø8 50
ø10 65
ø12 70
R ø15 80
BM1604A5EGP 68
7 Prevention of adherence As nylon tubes are weak against acid, Sticking of acidic liquid such
of acidic liquid be careful so that they might not be as battery liquid melts the
caught by battery liquid. Don't use tube and risks to cause air
waste cloth or cotton work gloves leakage.
contaminated with battery liquid.
8 Prevention of water Secure the distance minimum of If the distance between the
penetration at the time of 300mm and above between the connector and the injection
high pressure washing connector and the injection port when port is not sufficient, water
performing high pressure washing. may penetrate into the piping,
thus causing rusting, freezing,
and malfunctioning of valves.
9 Protection of nylon tubes As the temperature service limit of If this service limit is
when performing forced the nylon tube is from-40 to 100˚C, exceeded, air tightness of the
drying of paint remove the nylon tube when using a tube will be reduced and may
drying booth whose service cause air leakage sometimes.
temperature exceeds this limit.
10 Spare parts Never fail to use genuine HINO spare
parts. Otherwise, the nylon tube may
be damaged.
• Connectors for intermediate
connection of nylon tubes
ø6 34801-2240
ø8 34801-3070
ø10 34801-2250
ø12 34801-2260
ø15 34801-2270
• Sleeve connectors
ø6 ø8 ø10 ø12
Nut 23721-1070 23721-1150 23721-1120 23721-1090
Sleeve 47983-1250 47983-1750 47983-1550 47983-1400
Insert 47983-1260 47983-1760 47983-1560 47983-1410
• For Nylon tube and one-
touch type connectors, kindly
contact authorized HINO
distributor.
11 Special service tools Use special service tools for

dismounting and cutting nylon tubes.
• Tools for dismounting nylon tubes
HINO part number
09421-1560(release tool set)
ø6 09421-1510(release tool)
• Nylon tube cutting tool

HINO part number 09460-1020
• Clip band fastening tool

HINO part number 09620-1010
BM1604A5EGP 69
Dismounting and remounting procedures
(in the case of one-touch type connectors)
Procedure for dismounting

• Confirm that there is no dust nor dirt around the ends of the connector. If any dust or
dirt is found sticking there., eliminate it completely by air blowing. etc.
• Using the special service tool for dismounting the nylon tube and keeping the end
portion of the connector pressed, pull out the nylon tube by hand without break in the
middle along the axial direction of the connector.
Press the tool
Special service tool Pull out the tube

for dismounting
Procedure for remounting

• Confirm that there is no flaw, crush, dirt, burr nor dust, etc around the inserting position
of the nylon tube. If a flaw or a crush is found out, follow the instruction for repair 4).
• Match the axis of the nylon tube with that of connector and insert the tube all the way
without break until it stops. At this moment, be careful not to touch the inserting portion
with fiber cloth such as cotton work globes, etc.
• After mounting, pull the nylon tube by hand to check if the nylon tube has been
securely connected.
• After pulling, check if the end of the joint terminal is located between the 2 markings of
the nylon inserting margin and that the gap between the end of the connector and of
the end of the nylon tube inserting margin is less than 5mm (If the nylon tube has been
repaired).
End of the joint should be Taping of inserting

located between 2 markings. margin
End of the joint

5 mm
• With the condition that the air is filled in the piping, check if there is any leakage of air
by applying soapy water to the connecting position.
If any air leakage is found out, follow the instruction for modification 4).
BM1604A5EGP 70
Dismounting and remounting procedures for nylon tubes (in the case of
sleeve type connectors)
The sleeve type connector consists of a connector, nut, sleeve and an insert and the nut,
sleeve and the insert are supplied as assembled by the manufacturer.
The nut, sleeve and the insert are not reusable once they are disassembled.
If repair is required, carry out the work according to the following procedure.
procedure for dismounting

• Before loosening the nut, put the matching mark between the connector and the nut so
that the position can be visible. (marking by a magic ink is acceptable.)
Matching mark
• Loosen the nut and pull out the tube by hand in the axial direction while paying
attention so that the sleeve and the insert may not fall off.
procedure for remounting

• Put the nut and the sleeve onto the tube and put the insert into the tip of the tube. (Pay
attention to the remounting direction.)
Nut Sleeve Fastening type connector
Nylon tube Insert
• Drive the insert until the tip of the insert hits the connector while paying attention so
that the nut, sleeve and the insert may not fall off and, under this condition, fully tighten
the nut by hand.
• Hold the tube so that it may not move (comes off), tighten the nut up to the position
before dismounting (matching mark) and retighten it by 60º. Further tighten the nut
using the tool until the prescribed torque is obtained.
• Check the air leakage with a soapy water, etc. If any air leakage has been found out,
retighten the nut until the air leakage stops.
BM1604A5EGP 71
•If the leakage does not stop, replace the tube, sleeve and the insert. If in spite of such
replacement, the leakage does not stop, replace the nut and the connector in addition.
ø6 ø8 ø10 ø12
Nut 23721-1070 23721-1150 23721-1120 23721-1090
Sleeve 47983-1250 47983-1750 47983-1550 47983-1400
Insert 47983-1260 47983-1760 47983-1560 47983-1410
Procedure for repairing the nylon tube
When repair becomes necessary due to appearance of harmful defects such as

breakage, crush, perforation, etc., carry out the repair according to the following
instruction. (applicable only to the position which is not apparent such as the inside of
the frame, etc.)
• Prepare a nylon tube having the same size as that of the nylon tube to repair and a
connector for intermediate connection (exclusively for repair).
Connector for Outside Distance

intermediate Part number Diameter of at the end
connection applicable tube of the tube
34801-2240 ø6 16mm
34801-3070 ø8 14mm
34801-2250 ø10 10mm
L 34801-2260 ø12 10mm
34801-2270 ø15 6mm
• Confirm the position of the defect on the nylon tube and decide the cutting position to
such place where the connector is mountable. Use a cutter (special service tool) for
cutting.
• Check if the cutting face of the nylon tube is smooth without any burr and that the
cutting face is 90º±5º to the axis of the nylon tube.
Less than 5º
• Wind the inserting margin taping according to the following table. (In the same way as
in the case of one-touch type connector )
Inserting margin taping D S

(Outside diameter (Inserting margin)
of tube)
D
ø6 20.0±0.5
ø8 22.5±0.5
S ø10 22.5±0.5
ø12 23.0±0.5
ø15 24.5±0.5
BM1604A5EGP 72
• Remount the connector according to the dismounting and remounting procedures of
the nylon tube.
• Securely fix the repair connector with a clamp to the nylon tube protected with
corrugated tube existing around it (If this does not exist around it, add the corrugated
tube ).
• In the event that such repair work is difficult to carry out for the reason of layout or for
the reason of influencing on the external appearance such as on the air tank or that the
tube is relatively short and its replacement can be done easily, replace the nylon tube
with a new one.
Corrugated tube
Clamp 47837-1230C
In the event that an air leakage has occurred after remounting of the nylon tube, take the
following measure (applicable only when the nylon tube has enough surplus length).
• Remove the part of the nylon tube that suffers from the air leakage together with the
connector according to the dismounting procedure.
After dismounting, keep the outside and the inside of the connector free from any
adhesion of dust or dirt.
• Cut the nylon tube over the range of 15 to 20 mm from its end. Also, if any flaw is found
out within this range, cut the tube at the position where the flaw is no more recognized.
In the event that it is impossible to define the cutting position, replace the nylon tube
with a new one.
• Eliminate those matters sticking to the inside of the dismounted connector by air-
blowing. If any damage or heavy sticking of foreign matters is found out, replace the
connector with a new one.
• Wind an insert margin tape around the nylon tube (in the case of one-touch connector),
Mount the tube according to the remounting procedure. In the case of a nylon tube of
single part or the case of the tube whose overall length is less than 500 mm, piping
becomes difficult. In such a case, replace it with a new part.
BM1604A5EGP 73
VOSS type
Removal procedures
a. ‌When removing the whole coupling with the nylon tube press
fitted into the connector
Make sure that there are no adherents such as dirt and
stains around.
If adherents are recognized, remove all of them with air blow.
Fix the nylon tube near the press fit area so that it does not
turn together and is twisted, and turn only the coupling at the
base with a tool to remove.
b. ‌When removing the connector from the coupling
Tilt the tool with the special tool for removal fitted into the
groove of the fixing ring of the coupling as shown in the
illustration, and remove the resin ring. Or break the fixing
ring with nippers to remove.
Pull out two clips using the hook area of the special tool as
shown in the illustration, remove the clip holding ring, and
then remove the connector.
It is not permissible to reuse a coupling from which a fixing
ring is removed.
Special tool for disassembling coupling (VOSS made)
(S0911-E0030)
NOTICE
• ‌In the case of both a. and b. , store them so that no dirt, stain
and flaw adhere to either inner or outer surface of the
connector.
• ‌It is not permissible to remove the press fitted nylon tube from
the connector and to reuse the connector because it cannot
be guaranteed against air leak.
BM1604A5EGP 74
Tightening torques
Tightening torque for tapered joint
PT 1/4 PT 3/8 PT 1/2

N·m{kgf·cm} 25±5{250±50} 34±5{350±50} 44±5{450±50}
Tightening torque for sleeve type connector
ø6 ø8 ø10 ø12
N·m{kgf·cm} 23±5{230±50} 37±4{375±40} 40±5{410±50} 55±5{560±50}
Tightening torque for flare nut of female flare joint and male flare joint
M12 M16 M20

N·m{kgf·cm} 14.7±2{150±50} 29.4±5{300±50} 51.9±5{530±50}
Tightening torque for lock nut of brass joint
M12 M16 M20

N·m{kgf·cm} 15±2{150±15} 66±6{650±60} 97±9{950±90}
The conventional units in the parenthesis { } in the table as well as the figures
connected therewith are shown as reference.
NOTE
HINO reserves the right to modify the parts connected
with nylon tubes for brakes without notice.
When placing your order for spare parts, kindly consult
with your authorized HINO distributor nearest to you.
BM1604A5EGP 75
Precautions for handling one-touch type connector
Precaution to take
when handling Contents Description
1 Assurance of quality • Do not use the joint without • The cap is fitted in order to
for parts in stock. cap or with cap detached but avoid deformation, flaw,
burn it down. introduction of dust and dirt.
In such case, securely crash If the one-touch type connector is
the one-touch type connector used without cap, this may
with a hammer. sometimes cause air leakage or
detaching of the tube.
2 Assurance of quality • Do not attempt a rough handling • If the one-touch type connector
during the transport. which will cause detaching or receives a strong external force
deformation of the cap. through the cap by falling it down
or due to a rough handling, air
leakage or detaching of tube may
occur sometimes.
3 Assurance of quality • Be sure to mount the one-touch • Presence of deformation or flaw

when assembling a type connector with cap fitted. may cause sometimes air leakage
new one-touch type or detaching of the tube.
connector on the • Carry out removal of the cap at
vehicle. the time of insertion of the nylon
tube.
4 Assurance of quality • Never fail to use a special tool for • If you perform your job using
when dismounting removal of the nylon tube. something other than a special
and remounting the tool,deformation or flaw will occur
nylon tube for the • Never use a driver or spanner, and this may result in air leakage
purpose of body etc. or detaching of the tube.
mounting and/or
maintenance.
BM1604A5EGP 76
Chapter 3
CHASSIS MASS & FRAME SECTION MODULUS
1. CHASSIS MASS
2. MASS OF THE OPTION EQUIPMENT
3. FRAME SECTION MODULUS
BM1604A5EGP
3 CHASSIS MASS & FRAME SECTION MODULUS
Refer to CHASSIS MASS (STD & OPT) or FRAME SECTION MODULUS based on following.
PRODUCTION 3.2. MASS OF THE 3.3. FRAME SECTION

3.1. CHASSIS MASS
CODE OPTION EQUIPMENT MODULUS
FG8JF7D-PG2 M1 Z1
FG8JM7A-PG2 M2 Z2
GH8JF7D-PG2 M3 Z3
EQ1 & EQ2
GH8JM7A-PG2 M4 Z4
FM2PR7A-MG2 M5 Z5
SG2PF7B-MG2 M6 Z6
BM1604A5EGP 1
1. CHASSIS MASS
No. M1 M2 M3 M4
PRODUCTION CODE FG8JF7D-PG2 FG8JM7A-PG2 GH8JF7D-PG2 GH8JM7A-PG2
Gravity Moment Gravity Moment Gravity Moment Gravity Moment
Gravity Moment height from Gravity Moment height from Gravity Moment height from Gravity Moment height from
Mass position from from frame Mass position from from frame Mass position from from frame Mass position from from frame
ITEMS from F.A.C frame upper from F.A.C frame upper from F.A.C frame upper from F.A.C frame upper
F.A.C upper surface F.A.C upper surface F.A.C upper surface F.A.C upper surface
surface surface surface surface
( kg ) (m) ( kg·m ) (m) ( kg·m ) ( kg ) (m) ( kg·m ) (m) ( kg·m ) ( kg ) (m) ( kg·m ) (m) ( kg·m ) ( kg ) (m) ( kg·m ) (m) ( kg·m )
Front Bumper 42 -1.198 -50.316 -0.269 -11.298 42 -1.198 -50.316 -0.269 -11.298 42 -1.198 -50.316 -0.269 -11.298 42 -1.198 -50.316 -0.269 -11.298
Cab Front 347 -1.104 -383.088 0.746 258.862 347 -1.104 -383.088 0.746 258.862 347 -1.106 -383.782 0.746 258.862 345 -1.105 -381.225 0.746 257.370
Steering Control 76 -0.884 -67.184 -0.100 -7.600 76 -0.884 -67.184 -0.100 -7.600 76 -0.884 -67.184 -0.100 -7.600 76 -0.884 -67.184 -0.100 -7.600
Cab Mtg. 42 -0.678 -28.476 0.159 6.678 42 -0.678 -28.476 0.159 6.678 42 -0.678 -28.476 0.159 6.678 42 -0.678 -28.476 0.159 6.678
Radiator 40 -0.498 -19.920 0.008 0.320 40 -0.498 -19.920 0.008 0.320 40 -0.498 -19.920 0.008 0.320 40 -0.498 -19.920 0.008 0.320
Engine Room 15 -0.123 -1.845 0.085 1.275 15 -0.123 -1.845 0.085 1.275 15 -0.123 -1.845 0.085 1.275 15 -0.123 -1.845 0.085 1.275
Engine Front 262 0.009 2.358 -0.010 -2.620 262 0.009 2.358 -0.010 -2.620 262 0.009 2.358 -0.010 -2.620 262 0.009 2.358 -0.010 -2.620
Front Axle (Suspension) 174 0.000 0.000 -0.407 -70.818 199 0.000 0.000 -0.407 -80.993 198 0.000 0.000 -0.407 -80.586 198 0.000 0.000 -0.407 -80.586
Control 5 0.054 0.270 -0.008 -0.040 5 0.037 0.185 -0.008 -0.040 5 0.054 0.270 -0.008 -0.040 5 0.037 0.185 -0.008 -0.040
Air Cleaner 12 0.563 6.756 0.314 3.768 12 0.563 6.756 0.314 3.768 12 0.563 6.756 0.314 3.768 12 0.563 6.756 0.314 3.768
Cab Rear 176 0.686 120.736 0.746 131.296 176 0.686 120.736 0.746 131.296 177 0.683 120.891 0.746 132.042 175 0.686 120.050 0.746 130.550
Rear Arch 48 0.730 35.040 0.363 17.424 48 0.730 35.040 0.363 17.424 48 0.730 35.040 0.363 17.424 48 0.730 35.040 0.363 17.424
Engine Rear 586 0.751 440.086 -0.140 -82.040 586 0.751 440.086 -0.140 -82.040 586 0.751 440.086 -0.140 -82.040 586 0.751 440.086 -0.140 -82.040
Exhaust System 32 1.384 44.288 -0.344 -11.008 32 1.384 44.288 -0.344 -11.008 32 1.384 44.288 -0.344 -11.008 32 1.384 44.288 -0.344 -11.008
Frame etc. 602 1.809 1,089.018 -0.093 -55.986 721 2.689 1,938.769 -0.093 -67.053 602 1.812 1,090.824 -0.093 -55.986 721 2.691 1,940.211 -0.093 -67.053
Piping & Harness 61 1.746 106.506 0.041 2.501 61 2.107 128.527 0.041 2.501 61 1.708 104.188 0.041 2.501 61 2.107 128.527 0.041 2.501
Electoric System 2 2.025 4.050 0.109 0.218 2 2.025 4.050 0.109 0.218 2 2.025 4.050 0.109 0.218 2 2.025 4.050 0.109 0.218
Battery 43 1.215 52.245 -0.178 -7.654 43 1.215 52.245 -0.178 -7.654 43 1.215 52.245 -0.178 -7.654 43 1.215 52.245 -0.178 -7.654
Air tank unit/Dryer 64 1.392 89.088 -0.182 -11.648 64 1.392 89.088 -0.182 -11.648 64 1.392 89.088 -0.182 -11.648 64 1.392 89.088 -0.182 -11.648
Fuel Tank 216 2.099 453.384 -0.368 -79.488 225 2.023 455.175 -0.368 -82.800 216 2.099 453.384 -0.368 -79.488 225 2.023 455.175 -0.368 -82.800
Propeller Shaft 42 2.572 108.024 -0.379 -15.918 83 2.620 217.460 -0.379 -31.457 42 2.572 108.024 -0.379 -15.918 83 2.620 217.460 -0.379 -31.457
Cat walk 0 0.000 0.000 0.000 0 0.000 0.000 0.000 0 0.000 0.000 0.000 0 0.000 0.000 0.000
Side Guard 0 0.000 0.000 0.000 0 0.000 0.000 0.000 0 0.000 0.000 0.000 0 0.000 0.000 0.000
Coupler 0 0.000 0.000 0.000 0 0.000 0.000 0.000 0 0.000 0.000 0.000 0 0.000 0.000 0.000
Rear Axle(Suspension) 372 3.732 1,388.304 -0.198 -73.656 372 5.083 1,890.876 -0.198 -73.656 400 3.730 1,492.000 -0.198 -79.200 400 5.080 2,032.000 -0.198 -79.200
Slide rail 0 0.000 0.000 0.000 0 0.000 0.000 0.000 0 0.000 0.000 0.000 0 0.000 0.000 0.000
Tire Carrier 132 4.961 654.852 0.170 22.440 132 6.313 833.316 -0.400 -52.800 132 4.961 654.852 0.170 22.440 132 6.313 833.316 -0.400 -52.800
Rear Lamp 4 5.020 20.080 -0.019 -0.076 4 7.433 29.732 -0.019 -0.076 4 5.020 20.080 -0.019 -0.076 4 7.433 29.732 -0.019 -0.076
SUB TOTAL 3,395 4,064.256 14.932 3,589 5,737.858 -100.401 3,448 4,166.901 0.366 3,613 5,881.601 -107.776
UNSPRUNG FRONT 669 0.000 0.000 -0.481 -321.789 669 0.000 0.000 -0.478 -319.782 669 0.000 0.000 -0.480 -321.120 669 0.000 0.000 -0.478 -319.782
MASS REAR 1,118 3.730 4,170.140 -0.541 -604.838 1,071 5.080 5,440.680 -0.523 -560.133 1,118 3.730 4,170.140 -0.557 -622.726 1,118 5.080 5,679.440 -0.555 -620.490
TOTAL 5,182 1.589 8,234.396 -0.176 -911.695 5,329 2.098 11,178.538 -0.184 -980.316 5,235 1.593 8,337.041 -0.180 -943.480 5,400 2.141 11,561.041 -0.194 -1,048.048
FRONT REAR TOTAL FRONT REAR TOTAL FRONT REAR TOTAL FRONT REAR TOTAL
SPRUNG MASS ( kg ) 2,305 1,090 3,395 2,459 1,130 3,589 2,330 1,118 3,448 2,455 1,158 3,613
UNSPRUNG MASS ( kg ) 669 1,118 1,787 669 1,071 1,740 669 1,118 1,787 669 1,118 1,787
CHASSIS MASS ( kg ) 2,974 2,208 5,182 3,128 2,201 5,329 2,999 2,236 5,235 3,124 2,276 5,400
GRAVITY POSITION FROM F.A.C (m) 1.589 2.098 1.593 2.141
GRAVITY HEIGHT FROM FRAME UPPER SURFACE (m) -0.176 -0.184 -0.180 -0.194
NOTE
• The mass of tire follows design figure according to ETRTO or JATMA standard.
• The chassis mass shows standard specification of vehicle.
BM1604A5EGP 2
No. M5 M6
PRODUCTION CODE FM2PR7A-MG2 SG2PF7B-MG2
Gravity Moment Gravity Moment
Gravity Moment height from Gravity Moment height from
Mass position from from frame Mass position from from frame
ITEMS from F.A.C frame upper from F.A.C frame upper
F.A.C upper surface F.A.C upper surface
surface surface
( kg ) (m) ( kg·m ) (m) ( kg·m ) ( kg ) (m) ( kg·m ) (m) ( kg·m )
Front Bumper 63 -1.114 -70.182 -0.269 -16.947 63 -1.112 -70.056 -0.269 -16.947
Cab Front 355 -1.004 -356.420 0.746 264.830 353 -1.004 -354.412 0.746 263.338
Steering Control 81 -0.980 -79.380 -0.100 -8.100 81 -0.980 -79.380 -0.100 -8.100
Cab Mtg. 52 -0.850 -44.200 0.159 8.268 52 -0.850 -44.200 0.159 8.268
Radiator 49 -0.401 -19.649 0.008 0.392 49 -0.401 -19.649 0.008 0.392
Engine Room 28 -0.439 -12.292 0.085 2.380 15 -0.221 -3.315 0.085 1.275
Engine Front 474 -0.135 -63.990 -0.010 -4.740 474 -0.135 -63.990 -0.010 -4.740
Front Axle (Suspension) 194 0.000 0.000 -0.407 -78.958 174 0.000 0.000 -0.407 -70.818
Control 5 -0.048 -0.240 -0.008 -0.040 5 -0.048 -0.240 -0.008 -0.040
Air Cleaner 17 0.478 8.126 0.314 5.338 12 0.467 5.604 0.314 3.768
Cab Rear 180 0.586 105.480 0.746 134.280 179 0.586 104.894 0.746 133.534
Rear Arch 51 0.631 32.181 0.363 18.513 51 0.631 32.181 0.363 18.513
Engine Rear 892 0.722 644.024 -0.140 -124.880 989 0.722 714.058 -0.140 -138.460
Exhaust System 46 1.478 67.988 -0.344 -15.824 46 1.478 67.988 -0.344 -15.824
Frame etc. 954 3.229 3,080.466 -0.093 -88.722 500 1.471 735.500 -0.093 -46.500
Piping & Harness 72 2.435 175.320 0.041 2.952 92 1.430 131.560 0.041 3.772
Electoric System 2 1.929 3.858 0.109 0.218 2 1.929 3.858 0.109 0.218
Battery 43 1.114 47.902 -0.178 -7.654 43 1.105 47.515 -0.178 -7.654
Air tank unit/Dryer 73 1.564 114.172 -0.182 -13.286 73 1.594 116.362 -0.182 -13.286
Fuel Tank 225 1.923 432.675 -0.368 -82.800 225 1.923 432.675 -0.368 -82.800
Propeller Shaft 83 2.520 209.160 -0.379 -31.457 42 2.472 103.824 -0.379 -15.918
Cat walk 0 0.000 0.000 0.000 0 0.000 0.000 0.000
Side Guard 0 0.000 0.000 0.000 0 0.000 0.000 0.000
Coupler 0 0.000 0.000 0.000 44 3.738 164.472 0.000
Rear Axle(Suspension) 671 5.207 3,493.897 -0.198 -132.858 400 3.630 1,452.000 -0.198 -79.200
Slide rail 0 0.000 0.000 0.000 0 0.000 0.000 0.000
Tire Carrier 132 6.913 912.516 0.170 22.440 0 0.000 0.000 0.000
Rear Lamp 4 7.987 31.948 -0.019 -0.076 5 3.632 18.160 -0.019 -0.095
SUB TOTAL 4,746 8,713.360 -146.731 3,969 3,495.409 -67.304

UNSPRUNG FRONT 677 0.000 0.000 -0.487 -329.699 676 0.000 0.000 -0.446 -301.496
MASS REAR 2,377 5.205 12,372.285 -0.538 -1,278.826 1,144 3.630 4,152.720 -0.528 -604.032
TOTAL 7,800 2.703 21,085.645 -0.225 -1,755.256 5,789 1.321 7,648.129 -0.168 -972.832
FRONT REAR TOTAL FRONT REAR TOTAL

SPRUNG MASS ( kg ) 3,071 1,675 4,746 3,006 963 3,969
UNSPRUNG MASS ( kg ) 677 2,377 3,054 676 1,144 1,820
CHASSIS MASS ( kg ) 3,748 4,052 7,800 3,682 2,107 5,789
GRAVITY POSITION FROM F.A.C (m) 2.703 1.321
GRAVITY HEIGHT FROM FRAME UPPER SURFACE (m) -0.225 -0.168
NOTE
• The mass of tire follows design figure according to ETRTO or JATMA standard.
• The chassis mass shows standard specification of vehicle.
BM1604A5EGP 3
2. MASS OF THE OPTION EQUIPMENT
No. EQ1
The table of option mass shows the difference mass with standard specifications.
MODEL
FM2PR7A-MG2
SG2PF7B-MG2
GH8JM7A-PG2
FG8JM7A-PG2
DIFFERENCE
GH8JF7D-PG2
FG8JF7D-PG2
WEIGHT
OF GRAVITY
CONTENT OF OPTION DIFFERENCE REMARKS
POSITION
(kg)
FROM F.A.C
(m)
1-W AIR(VAC) 35KG 11 1.39 M009 DD(POWER LINE 5°) ●

1-W AIR(VAC) 35KG 11 1.35 M009 OD(POWER LINE 6.5°) ●
1-W AIR(VAC) 35KG 11 1.35 M009 OD(POWER LINE 4°) ● ●
T/M PTO
1-W AIR(VAC) 35KG 17 1.35 MX06 (POWER LINE 5.0°) ● ●
1-W AIR(VAC) 35KG 17 1.35 MX06 (POWER LINE 3.3°) ● ●
NH/1B 800N 1-W AIR(VAC) 11 1.35 M009 OD(POWER LINE 4°) ●
STD(MLS)+S.SHOCK→HARD(TLS)+D.SHOCK 10 0.00 ● ● ● ●
STD(MLS)+S.SHOCK→HARD(TLS)+D.SHOCK+STB 20 0.00 ● ● ● ● ●
FRONT SUSPENSION STD(MLS)+S.SHOCKHARD(MLS)+S.SHOCK 20 0.00 ● ● ● ● ●
STD(MLS)+S.SHOCKHARD(MLS)+S.SHOCK 20 0.00 ● ● ● ●
STD(MLS)+S.SHOCK→STD(MLS)+S.SHOCK+STB 20 0.00 ● ● ● ● ●
REAR SUSPENSION STD(MLS)→HARD(MLS) 40 0.00 ● ● ● ● ●
LESS(SUB BASE) 72 3.72 ●
COUPLER & OFFSET
2-INCH SIN-AXL 72 3.72 ●
SLIDE RAIL WITH 41 0.48 ●
WITH(ROH)→LESS -26 -1.23 ●
WITH(ROH)→LESS -26 -1.23 ●
TEMPORARY SETTING→LESS -10 1.00 ●
TIRE CARRIER
TEMPORARY SETTING→LESS -10 9.25 ●
LESS→WITH(ROH) -10 1.00 ●
LESS→TEMPORARY SETTING 10 -0.10 ●
W/ CHASSIS 18 -0.80 ● ● ● ●
W/ CHASSIS 22 -0.80 ● ●
CAB STEP
W/ CHASSIS+COVER 21 -0.80 ● ●
W/ CHASSIS+COVER 25 -0.80 ● ●
LO-CAB-OFF L/PAINT→LO-CAB-ON PAINT 32 -0.77 LOW CAB, ON ROAD TYPE ● ●
BUMPER F&R
HI-CAB ON PAINT→HI-CAB OFF L/PAINT -32 -0.82 HIGH CAB, OFF ROAD TYPE ● ●
LESS→WITH(AIR-SUS) DRIVER 9 0.12 ● ● ● ●
SEAT SUS.
LESS→WITH(AIR-SUS) DRIVER 9 0.02 ● ●
200L→370L 180 2.72 ●
200L→320L 123 2.51 ● ●
200L→390L 201 2.21 ●
FUEL TANK
320L→390L 78 1.73 ●
200L→320L(PREVENTION OF LEAK TYPE) 123 2.51 ● ●
390L→320L -78 2.32 ● ●
TRAILER CONNECTION LESS→W/H & PIPE ONLY 17 -0.21 ●
STACK TAIL PIPE (E2,3) 40 0.82 ● ● ● ● ● ●
EXHAUST SYSTEM STD TAIL PIPE (E2,3) 3 1.50 ● ● ● ● ● ●
STD TAIL PIPE, HIGH POSITION TYPE (E2,3) 4 1.50 ●
BATTERY 120A・h 30 0.00 ● ● ● ● ● ●
W/ AIR CONDITIONER 13 -0.64 FOR 8J ● ● ● ●
CAR COOLER
W/ AIR CONDITIONER 13 -0.74 FOR 2P ● ●
BM1604A5EGP 4
No. EQ2 (MASS OF THE TIRE AND WHEEL)
TIRE WHEEL Assy
MASS(kg/piece)
SIZE MAKER MASS(kg/piece) SIZE MAKER MASS(kg/piece)
Beolw decimal point rounding off
10.00R20-16PR - 67.3 20X7.50V - 45 112
11.00R20-16PR - 73.8 20X7.50V - 45 119
11R22.5 148/145 - 60.2 22.5X7.50V - 37 97
12R22.5 152/148 - 61.0 22.5X8.25 - 39 100
275/70R22.5 148/145 - 47.5 22.5X8.25 - 39 87
275/80R22.5 - 51.0 22.5X8.25 - 39 90
295/80R22.5 - 60.6 22.5X8.25 - 39 100
BM1604A5EGP 5
3. FRAME SECTION MODULUS
FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) Unit : mm
No. Z1 PRODUCTION CODE : FG8JF7D-PG2
BM1604A5EGP 6
No. Z2 PRODUCTION CODE : FG8JM7A-PG2
BM1604A5EGP 7
No. Z3 PRODUCTION CODE : GH8JF7D-PG2
BM1604A5EGP 8
No. Z4 PRODUCTION CODE : GH8JM7A-PG2
BM1604A5EGP 9
No. Z5 PRODUCTION CODE : FM2PR7A-MG2
BM1604A5EGP 10
No. Z6 PRODUCTION CODE : SG2PF7B-MG2
BM1604A5EGP 11
Chapter 4
SPRINGS & REAR AXLES
1. SPRING CHARACTERISTICS
2. CALCULATION FOR HEIGHT OF FRAME UPPER SURFACE
FROM GROUND
3. MAXIMUM VERTICAL DEFLECTION OF WHEELS
4. MAXIMUM VERTICAL TRAVEL RANGE OF REAR AXLE AND
SUSPENSION
5. PRECAUTION WHEN WELDING OPERATIONS AROUND THE
SUSPENSION PARTS
BM1604A5EGP
4 SPRINGS & REAR AXLES
1. SPRING CHARACTERISTICS
SPRING COMBINATION
Refer to SPRING CHARACTERISTICS CHART based on following table.
SPRING COMBINATION TABLE
PRODUCTION FRONT REAR

CODE
STD OPT1 OPT2 OPT3 STD OPT
FG8JF7D-PG2
F2(FTL) F3(FRT) R1(RML) R2(RRM)
FG8JM7A-PG2
F1(FML) F4(FRM)
GH8JF7D-PG2
F5(FTL) F6(FRT) R3(RML) R4(RRM)
GH8JM7A-PG2
FM2PR7A-MG2 F7(FML) - F8(FRT) F9(FRM) R5(RML) R6(RRM)
SG2PF7B-MG2 F10(FML) - - - R7(RML) -
NOTE
SYMBOL SPECIFICATION
FTL TAPER LEAF SPRING

FML MULTI LEAF SPRING
FRT REINFORCED TAPER LEAF SPRING
FRM REINFORCED MULTI LEAF SPRING
RML MULTI LEAF SPRING
RTL TAPER LEAF SPRING
RRM REINFORCED MULTI LEAF SPRING
AIR AIR SPRING
BM1604A5EGP 1
PRODUCTION CODE : FG8J
• SPRING CHARACTERISTICS CHART "F1" • SPRING CHARACTERISTICS CHART "R1"
　 kgf 　 kgf
×10 3 (kN) ×10 3 (kN)
a 0.277kN/mm {28.2kgf/mm}
SPRING LOAD ON ONE SIDE

b 30.470kN {3107.1kgf} 0.465+0.864=1.329kN/mm
c 44.350kN {4522.4kgf} b
{47.4+88.1=135.5kgf/mm}
c 26.505kN {2702.8kgf}
d 99.600kN {10156.4kgf}
e 112.757kN {11498.0kgf}
CONTACTING POINT OF
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
BUFFER RUBBER
HORIZONTAL
POINT
POINT
110.0 160.1
57.0 112.0 121.9
VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING
LOAD VS. DEFLECTION LOAD VS. DEFLECTION
　 kgf
×10 3 (kN)

0.526+0.982=1.508kN/mm
b
{53.6+100.1=153.7kgf/mm}
c 27.352kN {2789.1kgf}
b 26.600kN {2712.5kgf} d 117.832kN {12015.5kgf}
c 37.360kN {3809.7kgf} e 150.103kN {15306.2kgf}
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
POINT
52.0 112.0 133.4
VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING

LOAD VS. DEFLECTION
BM1604A5EGP 2
PRODUCTION CODE : FG8J
• SPRING CHARACTERISTICS CHART "F3"
b 32.590kN {3323.3kgf}
c 45.780kN {4668.3kgf}
　 kgf
×10 3 (kN)
b 32.970kN {3362.0kgf}
c 47.850kN {4879.3kgf}
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
POINT
111.0 161.1
VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING

LOAD VS. DEFLECTION
BM1604A5EGP 3
PRODUCTION CODE : GH8J
　 kgf 　 kgf
×10 3 (kN) ×10 3 (kN)

b 30.470kN {3107.1kgf} a 0.456kN/mm {46.5kgf/mm}

c 44.350kN {4522.4kgf} b
0.456+0.862=1.318kN/mm
{46.5+87.9=134.4kgf/mm}
c 27.360kN {2789.9kgf}
d 93.260kN {9509.9kgf}
CONTACTING POINT OF
e 154.811kN {15786.3kgf}
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
BUFFER RUBBER
HORIZONTAL
POINT
POINT
110.0 160.1
60.0 110.0 156.7
VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING
LOAD VS. DEFLECTION LOAD VS. DEFLECTION
　 kgf
×10 3 (kN)

0.529+1.001=1.530kN/mm
b
{53.9+102.1=156.0kgf/mm}
a 0.278kN/mm {28.3kgf/mm} c 25.394kN {2589.5kgf}
b 30.300kN {3089.8kgf} d 120.252kN {12262.3kgf}
e 191.703kN {19548.3kgf}
c 42.560kN {4339.9kgf}
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
POINT
48.0 110.0 156.7

LOAD VS. DEFLECTION
BM1604A5EGP 4
PRODUCTION CODE : GH8J
b 35.620kN {3632.3kgf}
c 49.640kN {5061.9kgf}
　 kgf
×10 3 (kN)
b 32.970kN {3362.0kgf}
c 47.850kN {4879.3kgf}
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
POINT
111.0 161.1

LOAD VS. DEFLECTION
BM1604A5EGP 5
PRODUCTION CODE : FM2P
b 30.470kN {3107.1kgf}
c 45.120kN {4601.0kgf}
b 35.620kN {3632.3kgf}
c 50.530kN {5152.7kgf}
BM1604A5EGP 6
PRODUCTION CODE : FM2P
　 kgf
×10 3 (kN)
b 32.970kN {3362.0kgf}
c 48.680kN {4964.0kgf}
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
POINT
111.0 163.9

LOAD VS. DEFLECTION
BM1604A5EGP 7
PRODUCTION CODE : SG8J
　 kgf
×10 3 (kN)

a 0.232kN/mm {23.6kgf/mm} 0.270+0.592=0.862kN/mm
b
{27.5+60.4=87.9kgf/mm}
b 21.810kN {2224.0kgf} c 16.065kN {1638.2kgf}
c 34.080kN {3475.2kgf} d 60.027kN {6121.1kgf}
e 84.853kN {8652.6kgf}
CONTACTING POINT OF
BUFFER RUBBER
HORIZONTAL
POINT
110.5 139.3
59.5

LOAD VS. DEFLECTION
BM1604A5EGP 8
2. CALCULATION
‌ FOR HEIGHT OF FRAME UPPER SURFACE FROM
GROUND
Before mounting rear body or equipment on chassis, must calculate 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.
Following are as formula for how to calculate.
[FOR 4x2 DRIVE MODEL ONLY]

L1 L2
Hf1
Hr1
Hro
Wf Wr
[FOR 6x2, 6x4 and 8x4 DRIVE MODEL ONLY]

L1 L2
Hf1
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 for how to calculate Hf1 and Hr1.
• The calculation formula is not considered the deflection of tire.
• Hf1 and Hr1 must add the deflection of tire based on ETRTO or JATMA standard.
BM1604A5EGP 9
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)
<CALCULATION DATA TO BE PROVIDED>

ELEMENT
ITEM
FRONT REAR
MASS DISTRIBUTION OF BODY OR
EQUIPMENT(kg)
Mass of payload must calculate mass Wf Wr
distribution, Front and Rear, if need.
CALCULATION FORMULA OF MASS DISTRIBUTION

W
L3
W : BODY (EQUIPMENT) MASS

Wf : FRONT DISTRIBUTION MASS OF BODY (EQUIPMENT)
Wr : REAR DISTRIBUTION MASS OF BODY (EQUIPMENT)
L3 : GRAVITY CENTER OF BODY (EQUIPMENT) MASS
L4 : WHEELBASE
L4
Wf Wr
Wf = W x L3 Wr = W - Wf
L4
For more details if needed, refer to the Chapter 1 of Common Manual, No.KC-AA201A.
<CALCULATION FORMULA OF Hf1> <CALCULATION FORMULA OF Hr1>
Hf1 = Hf - ( Wf ÷ Tf ) Hr1 = Hr - ( Wr ÷ Tr )
2 2
AN EXAMPLE OF CALCULATION
This is the calculation of "Hro" of the vehicle with mounted rear body or equipment.
<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
Wf = W x L3 = 6000x1500 = 1800 kg Wr = W - Wf = 6000 - 1800 = 4200

L4 5000
Wf Wr
Hf1 = Hf - ( ÷ Tf ) Hr1 = Hr - ( ÷ Tr )
2 2
1800 4200
= 1036 - ( ÷ 34.7 ) = 1098 - ( ÷ 255.8 )
2 2
= 1010 mm = 1090 mm
Hro = Hr1 + (Hr1 - Hf1) x L2 (1090 - 1010)

= 1090 + x 3000 = 1138 mm
L1 5000
BM1604A5EGP 10
3. MAXIMUM VERTICAL DEFLECTION OF WHEELS
Measurements for the maximum deflection for one side tire and for simultaneous left and
right deflection are shown below.
When you mount the body, allow a clearance of at least 30mm so as not to obstruct tire
deflection.
DEFLECTION OF REAR TIRES
A,D : MAXIMUM
‌ DEFLECTION FOR B,C : MAXIMUM
‌ SIMULTANEOUS DEFLECTION
ONE SIDE WHEELS RIGHT AND LEFT WHEELS
Unit : mm
MODEL FG GH FM SG
TIRE SIZE A B C D A B C D A B C D A B C D
10.00R20-16 219 133 125 165 209 123 133 161 161 75 32 162 - - - -
11.00R20-16 234 148 125 158 225 138 133 154 177 90 32 158 233 146 125 154
11R22.5 148/145 218 132 125 163 209 122 133 160 - - - - 217 130 125 160
12R22.5 152/148 236 149 125 151 227 139 133 147 179 91 32 148 235 147 125 147
275/70R22.5 148/145 - - - - - - - - - - - - 171 84 125 166
275/80R22.5 196 112 144 166 190 103 133 163 142 55 32 164 198 111 125 163
295/80R22.5 216 129 125 154 207 119 133 150 159 71 32 151 - - - -
NOTE
• When snow chains are fitted, add 50mm to measurements A and B.
• The dimension of tire mentioned in above table shows design figure
according to ETRTO or JATMA standard.
BM1604A5EGP 11
4. MAXIMUM
‌ VERTICAL TRAVEL RANGE OF REAR AXLE AND SUSPENSION
Measurement for maximum vertical travel range of the rear torque rod is shown below.
When you mount a body or equipment, allow a clearance of at least 30mm so as not to
interfere with rear torque rod.
VERTICAL TRAVEL RANGE OF REAR AXLE AND SUSPENSION

(FOR REAR TANDEM AXLE)
Unit : mm
MODEL A B C D
FM 656 668 34 34
BM1604A5EGP 12
5. PRECAUTION
‌ WHEN WELDING OPERATIONS AROUND THE
SUSPENSION PARTS
GENERAL PRECAUTION
• Suspension parts absorb shocks from the road surface received while driving and are
always changing shape.
• Accordingly, the parts are manufactured from very special metal materials or other
materials.
• Accordingly, if subjected to the effects of heat or other environmental factors, this is
danger that the material hardness may easily drop or suffer damage.
• Therefore, do not use electrical welding of the suspension parts or a gas torch to apply
heat.
• The ground used during electrical welding must not make connect with the suspension
parts.
• During welding operations around the periphery of suspension parts, be sure to protect
the suspension parts using a cover or similar item so the parts are not subjected to
welding sparks.
• Because in the peripheral portion of the bracket where the suspension parts are
installed constantly a large amount of stress is generated while the vehicle is driving,
heat must not be applied to this portion by electrical welding or a gas torch.
• The above sentences only describe a multi-leaf suspension. The same precautions
also apply to air bag type rear suspension as well.
Installation of suspension parts (For example)
BM1604A5EGP 13
Chapter 5
P.T.O. AND CONTROL
1. PROVISION OF P.T.O. AND CONTROL

2. TRANSMISSION SIDE POWER TAKE OFF
3. ENGINE CONTROL FOR BODY OR EQUIPMENT
4. REAR BODY CONTROL LEVER
BM1604A5EGP
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.
TRANSMISSION SIDE POWER TAKE OFF••••••••••••••••••••••••••••• refer to section 2.

PROVISION OF
T/M MODEL T/M P.T.O.
P.T.O. UNIT
MX06 TP-1 OPT
M009 TP-2 OPT
ZF9S1310 TP-3 OPT
BM1604A5EGP 1
ENGINE CONTROL FOR BODY OR EQUIPMENT•••••••••••••••••••• refer to section 3.

ENGINE CONTROL PROVISION OF
ENGINE MODEL
TYPE ENGINE ACCELERATOR
J08E
COMMON RAIL OPT
P11C
REAR BODY CONTROL LEVER•••••••••••••••••••••••••••••••••••••••••• refer to section 4.

PROVISION OF REAR
LEVER TYPE APPLICATION
BODY CONTROL LEVER
DUMP LEVER ALL MODEL OPT
BM1604A5EGP 2
2. TRANSMISSION SIDE POWER TAKE OFF
[T/M P.T.O. : TP-1]
When the body require transmission Power Take Off (P.T.O.) , genuine
P.T.O. equipment and related parts should be supplied as shown below.
NOTE
• Not install direct pump of transmission P.T.O..
• Data of the P.T.O. output shaft

TRANSMISSION PERMISSIBLE TORQUE P.T.O. CONTROL DIRECTION OF
MODEL (N·m {kgf·m} at r/min) TYPE ROTATION
Electric pneumatic Reverse to
MX06 343 {35} / 1,000 control engine
• Necessary parts
TRANSMISSION MODEL
MX06
TRANSMISSION GEAR RATIO
1ST 6.515
2ND 4.224
3RD 2.441
4TH 1.473
5TH 1.000
6TH 0.702
REV 6.991
PARTS NAME Parts No. Q'ty /
unit
POWER TAKE OFF ASSY 36610-E0F30 01
SWITCH ASSY, T/M POSITION 84220-E0200 01
PLUG SN480-01311 01
PLUG SZ341-24013 01
ELBOW SN352-10613 02
CLAMP, CONNECTOR S8258-61060 01
BOLT, STUD SZ116-10173 02
LOCKWASHER SL512-01030 04
BOLT SZ119-10172 04
STUD SZ116-10078 02
NUT SZ170-10064 04
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.
BM1604A5EGP 3
[T/M P.T.O. : TP-1]
DETAIL OF P.T.O., TRANSMISSION MODEL HINO MX06
• P.T.O. Installation procedure

• Drain the transmission oil.
(Do not remove the drain plug while the oil is hot, or you will scald yourself.)
• Remove the P.T.O. cover which is at the left of the transmission.
( Do not reuse the bolts and gasket that you remove at this time.)
• Clean the P.T.O. mounting surface on the transmission side.
• Prepare the necessary parts, referring to table of necessary parts.
• Apply liquid packing to all fitting surfaces, such as the P.T.O. mounting surface of the
transmission case, installation gasket and P.T.O. body.
• Fit the P.T.O. on the P.T.O. mounting and secure the mounting position by means of the
reamer bolts (See the part described with marked "R" in the section "P.T.O. mounting
location on transmission case") and tighten the other fitting bolts.Tightening torque for
bolts : 49±4.5 N·m {500±45 kgf·cm}
• After attaching the P.T.O., turn the output shaft coupling a few revolutions to be sure
that it turns freely.
• When you refill the transmission oil, increase the amount by 0.3 liters to allow for the
P.T.O..
• Gear layout and gear ratio
Gear ratio : i = N2/N1xN4/N3xN5/N4

TRANSMISSION
MODEL N1 N2 N3 N4 N5 i
MX06 30 43 11 31 10 1.303
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.
BM1604A5EGP 4
[T/M P.T.O. : TP-1]
• How to check the gear backlash
The gear backlash of the P.T.O. is important factor to prolong the P.T.O. gear life. The
bigger backlash causes the noise from gears on the contrary the smaller backlash
causes the damage of gears. When installing the P.T.O. measure and check the backlash
according to the following procedures.
• Measuring the backlash caused with a fuse
Use grease to paste a fuse (ø1X10mm) to the surface of a tooth of P.T.O. gear B. Make
the teeth interlock over the fuse, then measure the thickness of the crushed fuse with a
micrometer (at three points on the perimeter). This value is the backlash.
If specified gear backlash value cannot be obtained, check whether all the parts have
been installed correctly. If the specified gear backlash value cannot be obtained despite
correct installation, use another P.T.O. assembly.
BM1604A5EGP 5
[T/M P.T.O. : TP-1]
• P.T.O. Mounting location on transmission case
Unit : mm
(REAR VIEW)
TRANSMISSION CASE
(SIDE VIEW)
TRANSMISSION MODEL MX06

T/M GEAR RATIO 6.515 - 0.702
(A) GEAR SPECIFICATION
NUMBER OF TEETH 31
OUTSIDE DIAMETER (D) 149.43±0.1
FACE WIDTH (B) 45
OFFSET (C)
PITCH DIAMETER 139.5
CHORDAL THICKNESS / TEETH 61.950 - 00.04 / 5
COEFFICIENT OF PROFILE SHIFT 0.11693
OVER BALL DIAMETER / PIN DIAMETER 151.618 - 00.090 / 7.938
MODULE 4.5
PRESSURE ANGLE OF CUTTING TOOL 22.5°
HELIX ANGLE & DIRECTION
BM1604A5EGP 6
[T/M P.T.O. : TP-1]
• Transmission P.T.O. mounting for pneumatic control type
Unit : mm
WARNING
• The devises on the body or equipment side (e. g. oil pump)
must be mounted at the same angle as engine to the body.
(Direct mounting the devices to the P.T.O. output flange is
strictly prohibited.)
• The three-dimensional angle of the universal joint of the
drive shaft must be Min. 1° to Max. 6°.
BM1604A5EGP 7
[T/M P.T.O. : TP-1]
• Layout of power line
CRANKCASE
A
SIDE RAIL UPPER FACE

FRONT AXLE DATUM LINE
TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
110.5
D E F G
Unit : mm
TRANSMISSION
MODEL A B C D E F G
MODEL
FG8J (W/B : F)
250 193.6 5.0° 394 182 248 370.3
GH8J (W/B : F)
MX06
FG8J (W/B : M)
250 193.6 3.3° 394 182 248 370.3
GH8J (W/B : M)
BM1604A5EGP 8
[T/M P.T.O. : TP-2]
When the body require transmission Power Take Off (P.T.O.) , genuine
P.T.O. equipment and related parts should be supplied as shown below.

MODEL (N·m {kgf·m} at r/min) TYPE ROTATION
M009 OD Electric pneumatic Reverse to
M009 DD 345 {35} / 1,000 control engine
• Necessary parts
Transmission model
M009 OD M009 DD
Transmission gear ratio
1st 10.178 14.056
2nd 6.986 9.647
3rd 5.063 6.993
4th 3.636 5.021
5th 2.633 3.636
6th 1.921 2.653
7th 1.392 1.923
8th 1.000 1.380
9th 0.724 1.000
Rev. 9.874 13.636
Parts name Parts No. Q'ty / unit
GASKET, TRANS POWER TAKE-OFF COVER 33162-E0030 1
POWER TAKE-OFF ASSY 36610-E0300 1
SWITCH ASSY, TRANSMISSION POSITION IND 84220-E0150 1
BRACKET SUB-ASSY, TUBE CLIP S4701-EW150 1
BOLT SH782-01025 6
STUD SJ172-01022 1
NUT SL113-01008 1
NUT,FLANGE SL151-00809 1
LOCKWASHER SL511-01025 3
CLIP SN231-01001 1
CONNECTER SN351-10613 1
ELBOW SN352-10613 1
BOLT SZ101-10154 2
NOTE
BM1604A5EGP 9
[T/M P.T.O. : TP-2]
DETAIL OF P.T.O., TRANSMISSION MODEL HINO M009
• PTO Installation Procedure

• Drain the transmission oil.
(Do not remove the drain plug while the oil is hot, or you will scaled yourself.)
• Remove the PTO cover which is at the left of the transmission.
(Do not reuse the bolts and gasket that you remove at this time.)
• Clean the PTO mounting surface on the transmission side.
• Prepare the necessary parts, referring to table of Necessary parts.
• Install the stud bolts to the PTO mounting of the transmission case.
• Fit the gasket and PTO on the PTO mounting position and tighten the
fitting bolts and nuts.
Tightening torque for stud bolts : 44 ~ 54 N·m {432 ~ 530 kgf·cm}
• After attaching the PTO, turn the output shaft coupling a few revolutions to be sure that
it turns freely.
• Gear Layout and Gear Ratio
INPUT
SHAFT N1
N3
N2 N4
PTO
N5 OUTPUT
PTO unit
Gear ratio : i =N2/N1xN4/N3xN5/N4

TRANSMISSION N1 N2 N3 N4 N5 i
MODEL
M009 OD 29 30 16 31 16 1.034
M009 DD 28 40 16 31 16 1.428
NOTE
BM1604A5EGP 10
[T/M P.T.O. : TP-2]
• How to check the gear backlash
The gear backlash of the P.T.O. is important factor to prolong the P.T.O. gear life. The
bigger backlash causes the noise from gears on the contrary the smaller backlash
causes the damage of gears. When installing the P.T.O. measure and check the backlash
according to the following procedures.
• Measurement of backlash (between gear A and B)

Attach a fuse (Ø1x10mm), with grease on the tooth surface of the P.T.O. gear B (3
places of gear tooth).
After rotating gear B, measure the thickness of crashed fuses with a micro-meter.
• Adjustment of backlash (between gear A and B)
When the backlash is not within the following standard backlash, take following
measures.
1. ‌If specified gear backlash value cannot be obtained, check whether all the parts
have been installed correctly.
2. If
‌ the specified gear backlash value cannot be obtained in despite of correct
installation, use another P.T.O. assembly.
3. ‌Please consult with Hino sales dealer, if the backlash cannot be adjusted within
proper limit.
TRANSMISSION STANDARD
GEAR POSITION
MODEL BACKLASH
Between gear A 0.08 ~

M009
and gear B 0.300mm
BM1604A5EGP 11
[T/M P.T.O. : TP-2]
• P.T.O. mounting location on transmission case
Unit : mm
TRANSMISSION MODEL M009 OD M009 DD

T/M GEAR RATIO 10.178～0.724 14.056～1.000
(A) GEAR SPECIFICATION
NUMBER OF TEETH 31
STANDARD PITCH CIRCLE
139.500
OUTSIDE DIAMETER
DISPLACEMENT OVER A
62.073 -0.04 /5.000
0
GIVEN NUMBER OF TEETH

ADDENDUM MODIFICATION
0.1527
COEFFICICENT
OVER BALL / BALL DIAMETER 152.094 /8.000

0
-0.089
MODULE 4.50
NORMAL PRESSURE ANGLE 22°30'
HELIX ANGLE 0°
BM1604A5EGP 12
[T/M P.T.O. : TP-2]
• Transmission P.T.O. mounting for pneumatic control type
Unit : mm
WARNING
• The devises on the body or equipment side (e. g. oil pump) must be
mounted at the same angle as engine to the body. (Direct mounting the
devices to the P.T.O. output flange is strictly prohibited.)
• The three-dimensional angle of the universal joint of the drive shaft must
be Min. 1° to Max. 6°.
BM1604A5EGP 13
[T/M P.T.O. : TP-2]
CRANKCASE
A

TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
D E F G
Unit : mm
TRANSMISSION
MODEL A B C D E F G
MODEL
M009 SG2P 203 151 6.5° 438.5 138 302.5 419.7
BM1604A5EGP 14
[T/M P.T.O. : TP-3]
When the body require transmission Power Take Off (P.T.O.), genuine P.T.O.
equipment and related parts should be supplied as shown below.
This vehicle is mounted the ZF 9S1310 transmission.

Therefore, consult with the technical staff of ZF authorized dealer in your
country if need more detail information and data concerning ZF transmission
and P.T.O..

SERIES (N·m {kgf·m}) TYPE ROTATION
Pneumatic Reverse to
ZF 9S1310 800 {81.5} control engine
• Necessary parts
TRANSMISSION MODEL
ZF 9S1310
TRANSMISSION GEAR RATIO
CRAWLER GERA 9.479
1ST 6.576
2ND 4.678
3RD 3.478
4TH 2.617
5TH 1.890
6TH 1.345
7TH 1.000
8TH 0.752
REV. 8.967
P.T.O. CONTROL TYPE Pneumatic
PARTS NAME Parts No. Q'ty /
unit
POWER TAKE OFF ASSY 36610-E0370 01
SHAFT SET, POWER
S3601-E0050 01
TAKE OFF
NOTE
BM1604A5EGP 15
[T/M P.T.O. : TP-3]
• P.T.O. Installation procedure

• P.T.O. units is installed in place of the rear end plate of the layshaft.
The adapter shaft required for driving the P.T.O. is engaged with the reverse
intermediate gear of the main gearbox. The adapter shaft is included in the P.T.O.
delivery specification.
• When installing the P.T.O., it is important to ensure that the temperature of the gearbox
oil is not greatly affected by ambient conditions on the vehicle (e. g. exhaust pipe etc.).
Check the oil temperature and if necessary provide forced cooling(e.g.a fan) so that an
operating temperature of 110ºC is not exceeded. Brief temperature peaks of up to
130ºC are permissible(lasting not more than 30 minutes).
• Gear layout and gear ratio
Gera ratio : i = N2/N1xN4/N3xN5/N4

TRANSMISSION N1 N2 N3 N4 N5 N6 i
ZF 9S1310 32 33 14 21 14 — 1.031
NOTES
BM1604A5EGP 16
[T/M P.T.O. : TP-3]
• 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
9S1310 9.479-0.752 0.97
Direction of output rotation Reverse to engine
Required air pressure

for pneumatic engagement [bar] 6.2 to max. 10.0bar
Weight [kg] 3-5
Gravity torque [kg] 50
Output power
The permissible output power depends on permissible output torque and output speed.
It is calculated by the following formula :
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 = Efficiency
T= [Nm]
nX
or
9552 X Pperm.
T= n [Nm]
BM1604A5EGP 17
[T/M P.T.O. : TP-3]
• P.T.O. Mounting location of transmission case
BM1604A5EGP 18
[T/M P.T.O. : TP-3]
• P.T.O. Mounting on transmission case
BM1604A5EGP 19
[T/M P.T.O. : TP-3]
A CRANKCASE

TRANSMISSION
CASE
B
C
DRIVE SHAFT C
ENTER
FLYWHEEL
HOUSING
HOUSING
CLUTCH
R
ENGINE CENTE
D E F G
Unit : mm
TRANSMISSION
MODEL MODEL A B C D E F G
ZF 9S1310 FM2P 203 174 4.0° 438.5 138 216 598
BM1604A5EGP 20
3. ENGINE CONTROL FOR BODY OR EQUIPMENT
[ENGINE CONTROL TYPE : COMMON RAIL]
ENGINE MODEL
J08E-WL
P11C-VP
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
Range to be controlled
Device Provision of device
engine speed
Idle to 980 rpm
J08E (Can be controlled constant
revo. Only) To be provided by
Idle up switch
Idle to 850 rpm body manufacturer
P11C (Can be controlled constant
revo. Only)
Idle to Max. revolution
Related parts to be provided by
Engine accelerator (Can be controlled variable
optional equipment
revo.)
BM1604A5EGP 21
• ELECTRIC CIRCUIT OF ENGINE CONTROL FOR BODY OR EQUIPMENT
• Input the signal of P.T.O. switched on to E/G ECU
Whatever P.T.O. control system is mechanical or pneumatic or electric, the signal of

P.T.O. switched on should be always connected to E/G ECU.
Recommended electric circuit is as follows.
U2 - ECU
(ENGINE CONTROL ECU)
K4F
ECU CONNECTOR
A
SIGNAL CIRCUIT
OF P.T.O.
(GND )
K31
IDLE VOL
IDLE VOL
ACCEL SSR
IDLE UP1
(IUP1)
PTO SW
%E5
CAB SIDE
THE CIRCUIT OF P.T.O.

SWITCHED ON TO BE P.T.O.
CONNECTED.
[NOTE]
• THIS ALTERATION INCLUDING PROVISION OF P.T.O. UNIT ETC.
MUST BE PROVIDED OWN RESPONSIBILITY OF BODY OR EQUIPMENT MANUFACTURER.
• STANDARD FUNCTION OF ENGINE ACCELERATION CONTROL BY ACCELERATOR PEDAL
INSIDE OF CABIN IS CANCELLED DURING OPERATION OF BODY OR EQUIPMENT.
DETAIL OF A
WARNING
• No signal of P.T.O. switched on, engine speed will be fluctuated high and
low due to torque fluctuation of P.T.O..
• Consult to Hino sales dealer with regard to Electrical Wiring Diagram.
BM1604A5EGP 22
• Idle up switch
a. Install idle up switch and connect electric circuit as follows.
U2 - ECU
(ENGINE CONTROL ECU)
LINKED
STARTER
S/W ON
POWER
IDLE VOL
IDLE VOL
ACCEL SSR
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
IDLE UP S/W RESPONSIBILITY OF BODY OR EQUIPMENT
P.T.O. MANUFACTURER.
• STANDARD FUNCTION OF ENGINE ACCELERATION
CONTROL BY ACCELERATOR PEDAL INSIDE OF
CABIN IS CANCELLED DURING OPERATION OF
BODY OR EQUIPMENT.
b. Set engine speed by means of rewriting the program of E/G ECU by "Hino
Diagnostic Explore".
Consult to Hino sales dealer when set engine speed.
BM1604A5EGP 23
• Engine accelerator
a. Related parts, Engine accelerator unit and extension harness, are packed in cabin
as optional equipment.
b. Connect the connector of Engine accelerator unit with spare connector which is
provided forward No.2 crossmember at chassis frame LH side member.
Details of how to connect the connectors, see following figure.
OUTLET POSITION OF CHASSIS SIDE

For details, refer to chapter 6.2.
• Other precautions
a. Conditions of change of E/G ECU to body or equipment control mode as following.
• Vehicle speed is Max. 20km/h or less.

• Transmission shift position is neutral.
• Engine speed is idling revolution.
• Engine accelerator unit is idle position.
• P.T.O. switch on signal is connected.
E/G ECU will be changed as body or equipment control mode with fully completed
above conditions.
If a condition is loss, engine will run under normal vehicle operation to be controlled
by accelerate pedal.
b. Details of installation of Engine accelerator to be controlled for body and equipment,

refer to following page.
BM1604A5EGP 24
[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.
BM1604A5EGP 25
• 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.)
• Cautions when installing the Engine accelerator sensor (hereinafter

termed the sensor).
• Never attempt to disassemble the sensor.
Do not drop the sensor or do not impact it.
Each above thing may lead malfunction and failure.
• The sensor is not integral waterproof type.
Therefore, when installing it, pay attention to avoid the direct
projection of vehicle washing water, tire splash etc.
• The temperature range for use is -30~80°C.
• Avoid such places where there is risk of receiving falling
matters or stones that give impact.
• Install the sensor where there is no possibility of exposing
dust, oil mist, humidity, chemical product or vibration.
If it is impossible to find such place, protect it with a cover.
• Install the wire harness certainly so that it may not twist or
not bend extremely.
• For fitting and clipping the harness wires,refer to the
COMMON manual.
• If the length of the sub-harness wire is too short, try to abtain
the same kind of the harness wire for extension.
BM1604A5EGP 26
4. REAR BODY CONTROL LEVER
DUMP LEVER
NOTE
• LEVER RATIO 250/65=3.8
• Right hand drive is shown in this figure, left hand drive is symmetrical to this figure.
BM1604A5EGP 27
Chapter 6
ELECTRICAL SYSTEMS
1. FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK

2. SPARE POWER CONNECTORS
3. RECOMMENDED ELECTRIC WIRING OF SPARE CIRCUIT
4. PRECAUTION FOR INSTALLING WIRES, etc., TO CAB
5. REAR LAMPS
6. REAR COMBINATION LAMP
7. OTHER LAMPS
8. BACK-UP BUZZER
9. COUNTERMEASURE FOR LED STOP LAMP OF TRAILER
10. PRECAUTION FOR TURN SIGNAL LAMP
11. ELECTRICAL WIRING DIAGRAMS
12. SEMI-TRAILER ELECTRICAL CONNECTION
BM1604A5EGP
6 ELECTRICAL SYSTEMS
1. FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK
LOCATION OF THE CAB SIDE

The fuse block and the relay panel are located inside the instrument panel as shown
below.
RELAY PANEL FUSE BLOCK
BM1604A5EGP 1
Fuse block
[ EXAMPLE ]
WARNING
• The figure mentioned above is example, consequently, for various
particular items, check them on the actual vehicle.
• Be sure to use each capacity fuse designated in the actual vehicle
caution plate.
Never use the capacity fuse exceeding the designated one in the
above, otherwise over current may damage the harness wires, and
fusible linkage wires are in the same.
BM1604A5EGP 2
Relay panel
LHD VEHICLE
POLE NUMBER
No. DESCRIPTION
OF CONNECTOR
1 4 U2 PCV RLY
2 4 BACK LP RLY
3 4 RR FOG LP RLY
4 4 TAIL LP RLY 1
5 4 TAIL LP RLY 2
6 4 A/C RLY
7 5 ABS SUB BRK CUT RLY
8 4 FR FOG LP RLY
9 4 HORN RLY
10 4 HEATER RLY
11 4 A/C CDS RLY
12 4 TRAILER-M RLY
13 4 U2 ECU MAIN RLY
14 – –
15 5 HOUR METER RLY
16 4 HEAD LP MAIN RLY
17 4 HEAD LP DIM RLY
18 4 PWR ACC RLY
19 4 PWR RLY3
20 4 PWR RLY4
21 4 PWR RLY2
22 4 PWR RLY1
23 – –
24 – –
25 5 LO-HI IND RLY
26 4 ZF PTO RLY
27 – –
28 – –
29 – –
30 – –
31 4 DIFF LOCK RLY1
32 4 DIFF LOCK RLY2
33 – –
34 – –
35 – –
36 – –
A 4 STOP LP RLY
B – –
BM1604A5EGP 3
LOCATION OF THE FUSIBLE LINK BLOCK
The fusible link block is located on left side of the chassis frame as shown below.
WARNING
• The figure mentioned above is example, consequently, for various
particular items, check them on the actual vehicle.
• Be sure to use each capacity fusible link designated in the actual
vehicle caution plate.
Never use the capacity fusible link exceeding the designated one,
otherwise over current may damage the harness wires.
BM1604A5EGP 4
2. SPARE POWER CONNECTORS
SPARE POWER SUPPLIES AND POSITIONS
‌If you need to take an electrical power for the body or equipment from the Hino chassis, take it from the
electrical power supply connector.
CAB SIDE
Coupling
Permissible
Connector Pole Circuit Wire Size Connector Connector Applicable
Capacity Description
Mark Code (Main Application) & Color Parts No. (Spare Parts) Model
(A)
Parts No.
A AGM Power Supply, IG 7 0.75 W- 82824-E0U30 S8258-06160 ALL General use for electric equipment
I0P Power Supply, +B 10 0.5 P- General use (Required fuse & switch)
I0Q Power Supply, ACC 7 0.75 G- General use for electric equipment
B 82824-E0U70 S8258-08380 ALL
I0K Power Supply, LIGHTING 10 *1 0.5 V- For accessory lamps
I0S Ground 20 2.0 B For ground to chassis side
C #11 Idle-Up sensor (INPUT) - 0.5 W-L 82824-E0U30 S8258-06160 ALL E/G control for rear body (PTO signal)
D #13 E/G stop sensor (INPUT) - 0.5 SB-B 82824-E0U30 S8258-06160 ALL E/G control for rear body (E/G stop)
CONNECTOR
COUPLING
CHASSIS SIDE
CONNECTOR
A
PARTS NO. 82824-E0U30 PARTS NO. S8258-06160
C
D
WARNING
• The permissible current taken from spare power connector 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.
• 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.
• Marks *1 shows total current of Pole Code 10K & AGQ.
BM1604A5EGP 5
OUTLET POSITION INSIDE CAB
• Center of instrument panel
A ：POWER SUPPLY,IG
C ：IDLE-UP SENSOR
/ +B / LIGHTING / GROUND
：POWER SUPPLY+B
D ：E/G STOP SENSOR B
/ ACC / LIGHTING / GROUND
BM1604A5EGP 6
CHASSIS SIDE
Coupling
Permissible
Connector Pole Circuit Wire Size Connector Connector Applicable
Capacity Description
Mark Code (Main Application) & Color Parts No. (Spare Parts) Model
(A)
Parts No.
E AGQ Power supply, lighting 10 *2 1.25 V S8258-04240 S8258-04230 For Marker lamp
K95 Power Supply - 0.5 LG-B

ALL Accelerator device of E/G control
for rear body.
F K96 Accel sensor - 0.5 V-W S8256-01260 S8256-01250
Only for HINO genuine P.T.O accel
sensor.
K97 Ground - 0.5 L-W
CONNECTOR
COUPLING
CHASSIS SIDE
CONNECTOR
PARTS NO. S8258-04240 PARTS NO. S8258-04230
PARTS NO. S8256-01260 PARTS NO. S8256-01250
WARNING
• The permissible current taken from spare power connector 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.
• 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.
• Marks *2 shows total current of Pole Code 10K & AGQ.
BM1604A5EGP 7
OUTLET POSITION OF CHASSIS SIDE
Fr
F : POWER SUPPLY,
ACCEL SENSOR
E : POWER SUPPLY,
LIGHTING
HOW TO TAKE ELECTRICITY FROM POWER SUPPLY CIRCUIT
WARNING
• As far as possible take power using sub-harness type.
• If you must take power using direct connecting type, be sure to observe
the precautions in described item “ELECTRICAL EQUIPMENT AND
WIRING” of Common Manual.
BM1604A5EGP 8
3. RECOMMENDED ELECTRIC WIRING OF SPARE CIRCUIT
STANDARD WIRING CONFIGURATION
WIRING CONFIGURATION FOR INCREASED LOAD
TAKING POWER DIRECTLY FROM THE BATTERY

If you intend to take power for the body directly from the battery, secure the battery cable
and the body power supply terminal together with the same nut (see drawing).
In this case, you must install a fuse at a suitable point in the circuit and take precautions
to prevent short circuits as these may lead vehicle fires.
When securing the cable and power terminal, make sure you tighten the nut properly.
Battery cable
TIGHTENING TORQUE
11 ~ 14 N·m {108 ~ 137 kgf·cm}
To body
Should be added an adequate fuse.
Terminal
Battery positive terminal
BM1604A5EGP 9
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.
Avoid using additional switches with existing switches
• If you install additional switches, fit a caution plate showing the purpose of each switch,
etc., to prevent accidental operation or confirmation.
• Instrument panel
• Floor console
BM1604A5EGP 10
4. PRECAUTION FOR INSTALLING WIRES, etc.,TO CAB
USING THE THROUGH HOLE FOR HARNESS WIRE, etc. (CABLE) ON THE
FLOOR
When using the through hole for harness wire, etc. (cable) on the floor,
at the front part of the floor panel through hole is provided for mounting harnesses or
cables.
When installing, remove the plug hole and then carry out wiring with using the harness
grommets.
BM1604A5EGP 11
USING THROUGH HOLE OF BACK PANEL FOR WIRING
When using through hole of back panel for wiring, to secure the rust prevention and
water proof before carry out fitting and wiring according to the following instructions.
• 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.
BM1604A5EGP 12
5. REAR LAMPS
REAR LAMPS
The rear combination lamps, license plate lamp and reversing lamp are
temporarily mounted on the chassis for shipment.
At the time of mounting a body or equipment, use these parts as supplied
and fit them in the positions shown in the drawing below.
For details of fitting procedures for each lamp, see following pages.
MI
(R N. 1
R
FO 00m
G m
REAR ~S
& STOP LAMP TO BACK-UP LAMP
P
LA
REAR MP LICENSE PLATE LAMP
REFLECTOR )
DIRECTIONAL
INDICATOR
& HAZARD LAMP
LIGHTING REFLECTING
UPPER EDGE UPPER EDGE
LIGHTING REFLECTING
GROUND HEIGHT MIN.0.35m

LOWER EDGE
GROUND HEIGHT MAX.1.5m

LOWER
EDGE
MIN. 600mm
REAR & STOP LAMP'S MAX. 400mm
INNER EDGE SPACE
MIN. 600mm MAX. 400mm
DIRECTIONAL INDICATOR'S MAX. 400mm
GROUND HEIGHT
INNER EDGE SPACE

MIN.0.15m
MAXIMUM OVERALL WIDTH
RR FOG LAMP
[NOTE]
All distances from ground and protrusions beyond maximum width are the values
prescribed by Japanese laws and regulations.
When positioning lamps, make sure that you observe the laws and regulations
of the country in which the vehicle is to be used.
BM1604A5EGP 13
6. REAR COMBINATION LAMP
When chassis with cab are shipped, the rear combination lamp assembly is temporarily
installed onto the end of the frame.
Therefore, when installing it regularly, attach the combination lamp assembly directly
such that the tail lamp (red) is inside and the direction indicator lamp (turn signal lamp,
umber) is outside 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.
Unit : mm
NOTE
• Drawing shows rear combination lamp, LH side.
And, RH side is symmetrical this drawing.
• About installation, conforms to all applicable laws and regulation of the country in which the
vehicle is to be used.
BM1604A5EGP 14
1) PRECAUTION OF REAR COMBINATION LAMP
Install the lamps symmetry on right and left except license plate lamp.
Install the lamp that drainage hole is always to be bottom side.
CORRECT INCORRECT
The drainage hole in the bottom of the lamp is covered with tape for shipment. After
installing the lamps, be sure to remove the tape.
Don’t install any parts of body or equipment to rearward of the rear combination lamp to
insure the visibility of lamp.
Install the water guard plate in order to prevent direct exposure to water splashed up
from rear wheels.
Make sure that the lamp lenses and bodies do not come into contact with clear anti-rust
coating.
To prevent the lamp from shaking, always use a strengthening stay such as dump truck
in which lamps couldn’t be installed direct to the body (vessel).
BM1604A5EGP 15
2) MOUNTING OF REAR COMBINATION LAMP
The lamp body is made of resin. When fitting the lamp, always insert a flat washer to
prevent buckling.
To prevent the lamp from shaking, always use a strengthening stay.

To avoid placing an excessive load on the resin body, fit a stay F using the stay mounting
hole G.
With dump bodies and other bodies where the lamps cannot be mounted directly on the
load platform, use suitably strong brackets and stays to prevent the lamps from shaking.
The drainage hole in the bottom of the lamp is covered with tape for shipment.
After mounting the lamps, be sure to remove the tape.
(D drainage hole)
Make sure that the lamp lenses and bodies do not come into contact with clear anti-rust
coating.
BM1604A5EGP 16
3) DETAILS OF TEMPORARY MOUNTING FOR SHIPMENT
The lamps are temporarily mounted on the rear end of the chassis using mounting hole
C.
Notes on final mounting
Steel mounting bracket Wooden mounting bracket
Fitting a stay
BM1604A5EGP 17
7. OTHER LAMPS
BACK-UP LAMP
The back-up lamps are temporarily installed on the chassis frame, when shipped out the
chassis.
Therefore, should install the back-up lamp with satisfied your country laws and regulations
by own responsibility of Body and Equipment Manufactures.
Unit : mm
[NOTE]
• When install the back-up lamp, mark “TOP” on
the lens must always be up side.
• Installation angle must be kept 4°.
BM1604A5EGP 18
LICENSE PLATE LAMP
Unit : mm
BM1604A5EGP 19
REAR FOG LAMP
As the rear fog lamp is tempolly located on the chassis frame for shipment, it should be
relocated by subsequent manufacturer to conform to your country laws and regulations.
Unit : mm
BM1604A5EGP 20
REAREND MARKER LAMP
Unit : mm
SIDE MARKER LAMP & REFLECTOR
BM1604A5EGP 21
WORKING LAMP
Unit : mm
BM1604A5EGP 22
8. 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.
Installation area
• Should install the buzzer the area which is the muddy water, rainwater and stone do
not splash.
Precaution for painting

• Should put a cover on the buzzer during painting to prevent the paint into it for avoiding
failure of no sound.
BM1604A5EGP 23
9. COUNTERMEASURE FOR LED STOP LAMP OF TRAILER
RELEVANT MODEL : TRAILER WITH ABS

Be sure to observe the following procedure if stop lamps of trailer are LED stop lamp.
Comply with vehicle's laws and regulations of your country by own responsibility of Body
and Equipment Manufactures when proceeding below.
Failure to follow these procedure, it may be cause of the following problems.

• LED stop lamps of trailer are slightly lit at all time when the trailer is connected
with tractor.
• Warning system for trailer does not work properly even if trailer is connected.
• ABS trailer information system does not work properly.
1) PROCEDURE FOR LED LAMP

‌Electric power consumption demand value of stop lamp for trailer is 25w on each side.
‌Must confirm to electric power consumption value of one side of LED stop lamp for
installing to trailer.
‌Calculate the difference between and .
[ - = the difference of electric power consumption value. (w)]
‌Prepare dummy load what equivalent of the difference of electric power consumption
value ( ).
‌Install dummy load with parallel connection to LED stop lamp circuit on each side.
See the circuit diagram below for connection.
【Electric circuit diagram of stop lamp for trailer】

LED LAMP
When the total

electric power
consumption
value is below Install dummy load
25W on each side. for compensating electric power
consumption value in the stop
lamp circuit so that the ABS
trailer information system works
properly.
2) NOTES
• Dummy load is not need if electric power consumption value of stop lamp for trailer is
25w on each side.
• Check the operation and function of LED stop lamp after finishing countermeasure.
BM1604A5EGP 24
10. PRECAUTION FOR LED SIDE TURN LAMP
RELEVANT MODEL : VEHICLE WITH OPEN CIRCUIT DETECTIVE SYSTEM

Be sure to observe the following procedure if turn lamps of vehicle are LED side turn
lamps.
Comply with vehicle's laws and regulations of your country by own responsibility of Body
and Equipment Manufactures when proceeding below.
1) PROCEDURE FOR LED LAMP

‌Electric power consumption demand value of side turn lamp for vehicle is 21w on each
side.
‌Must confirm to electric power consumption value of one side of LED side turn lamp
for installing to vehicle.
‌Calculate the difference between and .
[ - = the difference of electric power consumption value. (w)]
‌Prepare dummy load what equivalent of the difference of electric power consumption
value ( ).
‌Install dummy load with parallel connection to LED side turn lamp circuit on each side.
See the circuit diagram below for connection.
【Electric circuit diagram of turn lamp】

LED LAMP
When the When the

electric power electric power
consumption consumption
value is below value is below
21W. 21W.
Install dummy load
for compensating electric power
consumption value in the side
turn lamp circuit.
2) NOTES
• Dummy load is not need if electric power consumption value of side turn lamp for
vehicle is 21w on each side.
• Check the operation and function of LED side turn lamp after finishing countermeasure.
BM1604A5EGP 25
10. PRECAUTION FOR TURN SIGNAL LAMP
Comply with vehicle's laws and regulations of your country by own responsibility.
Must not change the turn signal lamp from light bulb to LED lamp.
BM1604A5EGP 25
12. ‌SEMI-TRAILER ELECTRICAL CONNECTION
CONNECTOR TYPE : SAE TYPE, 7- CONDUCTOR ELECTRICAL CONNECTION
Detail of Connector's Plug Pin
• JUMPER CABLE
PRODUCTION CODE : SG2PF7B
Form for plug of Number of Wire Max.

Lamps and Signal circuits
jumper cable conductor color capacity
1 White Earth -
2 Black Spare outlet 7A

1
3 Yellow Turn signal lamp (LH) 1.8A
2 6 Hazard lamp (LH)
7 4 Red Stop lamp 1.8A

3 5
Turn signal lamp (RH)
4 5 Green Hazard lamp (RH) 1.8A
Tail lamp
6 Brown License plate lamp 10.5A
FRONT VIEW
7 Blue Back up lamp 1.8A
• ABS CABLE
PRODUCTION CODE : SG2PF7B
Form for plug of Number of Wire Max.

Signal circuits
ABS cable conductor color capacity
1 White Solenoid valve 14 A
2 Yellow Control device 2A

2 1
3 7 3 Green Control device –
4
5 6 4 Black Solenoid valve –
5 Red Warning device 10 mA
6 White/Green Communication 60 mA
FRONT VIEW
7 White/Brown Communication 60 mA
BM1604A5EGP 27
Chapter 7
PAINTING
1. GENERAL PRECAUTIONS FOR PAINTING

2. NOTE ON THE TOP COAT OF PAINT
3. HOW TO REMOVE THE PARTS OF CAB
4. PROCEDURE FOR ADHERING ORNAMENTS
5. MOUNTING AND STICKING OF DOOR WEATHER STRIP
6. HOW TO MOUNT THE MAIN AND SUB SEAL
7. HANDLING OF LAMINATED WINDSHIELD
8. HANDLING OF COMPUTERS (ECU)
9. PRECAUTIONS FOR FITTING AND STORING THE CAUTION
PLATE
10. CAUTIONS FOR PAINTING THE TIRE DISC WHEELS
BM1604A5EGP
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 the drying heat, some parts must not
be painted and so require masking, etc.
GENERAL PRECAUTIONS FOR PAINTING

• Parts to be masked:
Parts that must not be painted-ornaments, name plates (model names, Hino logo mark
chassis number), caution plate, etc. must all be masked.
(It is possible to take off the top mark.)
Never paint the rubber hoses and nylon tubes or valves, the brake booster, or hoses or
valves of the brake fluid reservoir.
• If 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.
• When cleaning inside of the cab, must use a neutral detergent.

Never use gasoline and paint thinner.
• 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 fuel pre filter.
• 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.)
BM1604A5EGP 1
7 PAINTING
GENERAL PRECAUTIONS FOR FORCED DRYING
• When you use forced drying, a temperature on the surface of any parts to be painted
must be 80°C as an upper limit.
Removing off any plastic parts, rubber parts from the vehicle, paint them when you use
a forced drying at over 80°C. (Refer to the figure as shown in after.)
Take care to those as plastic parts like fender, air cleaner, etc. are much used.
• When a vehicle with air-conditioning whose piping and hosing are heated at abnormal
temperature (more than 100°C), a pressure safety valve may function and come out
refrigerant gas.
• When removing off a air-cleaner assy, seal completely the inlet port side of engine to
prevent any penetration of dirt, paint or etc.
• Remove off the parts shown below, when you use forced drying at over 80°C.
NON-HEAT RESISTING PARTS AT THE HEATED AIR OR MORE THAN 80°C
WARNING
• When drying with heated air more than 80°C these parts described
above must be removed.
• Detail of outside mirror to be equipped is shown following page.
BM1604A5EGP 2
7 PAINTING
DETAIL OF OUTSIDE MIRROR TO BE EQUIPPED
CONVEX MIRROR TYPE
BM1604A5EGP 3
7 PAINTING
2. NOTE ON THE TOP COAT OF PAINT
• To make sure that the top coat of paint adheres well, you must sand the middle coat
carefully.
Make sure that the sanding is even and complete.
When you have finished sanding, carefully dust off the shavings.
(BAD SANDING) (GOOD SANDING)

Imperfectly sanded Evenly sanded
Coated film Coated film
• How to choose top coat paint

HINO recommends urethane-type paints for the top coat,as they have superior rust-
prevention properties to lacquer-type paints.
The top coat should be at 30 µ thick and the total paint thickness including undercoat
and primers should be at least 80 µ thick.
• How to install weather strips

If door weather strips have been removed when painting the cab, remount them
according to the following procedure, item 7.5.
Be very careful not to make mistake in deciding the mounting procedure to avoid an
eventual cause of rain drop leakage.
BM1604A5EGP 4
7 PAINTING
3. HOW TO REMOVE THE PARTS OF CAB
HOW TO REMOVE THE PARTS OF CAB FRONT
• Radiator grille
• Open the front panel. (front inspection lid)
• Loose the bolt from back side of the front panel.
• Remove the retainer. (15 pieces)
RETAINER
• Top mark
Loose the tapping screw (2 pieces) from back side of radiator grille.
TAPPING SCREW
BM1604A5EGP 5
7 PAINTING
• Front panel
BM1604A5EGP 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 cover.
BM1604A5EGP 7
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.
Refer to the following figure for details.
RH ASSISTANT SIDE LH DRIVER SIDE
a&b : RH MIRROR STAY c&d : LH MIRROR STAY
DETAIL OF b DETAIL OF d
BM1604A5EGP 8
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.)
WARNING
• Operate the wiper with the front panel shut down.
• With the front panel opened, you may risk to have your hand
pinched by the wiper links.
• Also after stop of the wiper motor, take out the starter key.
• When tightening the wiper arms, tighten them by adjusting the blade position (height)
with in the limit as shown as the following illustration.
• Adjust the wiper arms and the pivot positions to the following tightening torque values.
• Wiper arm tightening torque
19.6 ± 2 N·m {200 ± 20 kgf·cm}
• Wiper pivot tightening torque
11.8 ± 1 N·m {120 ± 10 kgf·cm}
BM1604A5EGP 9
7 PAINTING
WIPER BLADE SET POSITION
NOTE
• The set positions of the blades show the gaps at the top ends of the blades.
DETAIL OF WIPER ARM INSTALLATION
BM1604A5EGP 10
7 PAINTING
4. PROCEDURE FOR ADHERING ORNAMENTS
Ornaments adopt the inside adhesive system which is easy to fit.

Adhere them according to the following procedures.
• Preparation
Clean waste cloth
• Precaution
• Reuse of ornaments once adhered should be avoided because their adhering
power is reduced.
• Perform the adhering operation by adjusting the surface temperature (20 to 40°C).
If the ambient temperature is below the above, increase the temperature.
• Wipe off dust, dirt, stain, oil, water, etc., deposited on the adhering surface.
• Adhering procedure
• After having cleaned the surface to adhere, take off the backing paper of the
ornament.
• Adhere door boundary line and door character line with the outer form of the
ornament.
(Details are described in the following figure.)
BM1604A5EGP 11
7 PAINTING
ADHERING POSITION OF HINO LOGO MARK AND SERIES NAME ORNAMENT
NOTE
• Apply ornament, after remove moisture, oil and dust from attaching position.
BM1604A5EGP 12
7 PAINTING
5. MOUNTING AND STICKING OF DOOR WEATHER STRIP
In the case to disassemble the door weather strip when perform top coat paint,
reassemble it as following procedure.
Pay special attention when reassemble the door weather strip, otherwise it will cause
leakage of rain water.
MOUNTING AND STICKING OF WEATHER STRIP

• Match the marks A and B on body side notch and the marks on the weather strip then
start mounting from this point.
• Mounting of weather strips on general positions
Mount the weather strips on general positions after having finished mounting of point A
and B and stick them in such a way that the slack of the weather strips concentrate on
corners of the point A and of the point B. Execute this operation by squeezing them in
the direction of the arrow in the illustration of the weather strip position.
ILLUSTRATION OF THE WEATHER STRIP MOUNTING POSITION
BM1604A5EGP 13
7 PAINTING
ILLUSTRATION OF THE WEATHER STRIP MARK POSITION
BM1604A5EGP 14
7 PAINTING
6. HOW TO MOUNT THE MAIN AND SUB SEAL
HOW TO MOUNT THE MAIN SEAL AT THE POSITION OF THE FRONT COWL
When you apply the top coating, apply masking on the main seal of the front cowl.
If you are obliged to remove the door sub seal, replace it with a new part in the
following manner,
Part number of front cowl main seal : S7682-11270 (FG, SG, FL, FM) 1 piece/vehicle
• 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.
BM1604A5EGP 15
7 PAINTING
MOUNTING PROCEDURES OF MAIN SEAL AT THE POSITION OF THE
FRONT CORNER PANEL
To surely cure the main seal at the front corner panel by dismounting or masking the
concerned section when applying top cart.
Parts number of main seal at the front corner panel : S7681-11120 (2 pieces/vehicle)
• Mounting procedure
• Insert the front corner main seal into the hole provided on the front corner panel.
• Caution
• Securely fix the retainer on the front corner panel which is mounted onto main seal.
• In order to avoid the penetration of water, mount it in such a way that the section
shape of the seal might become as illustrated on the Section B-B.
BM1604A5EGP 16
7 PAINTING
7. HANDLING OF LAMINATED WINDSHIELD
A laminated glass is produced in such order that polyvinyl butyral film is inserted between
2 glasses and pressed with heat.
Under driving general condition, there is no problem. But under a hot temperature and a
high moisture when painting, intermediate film is fallen off or such defective occur as
foaming may be caused. Therefore, a special caution needs to be taken.
• Caution when Painting

There is no problem when you use a natural drying. But when a forced drying is used
with infrared ray lamp, etc., be sure that the drying should be implemented within 30
minutes at less than 120°C.
When drying at the temperature of more than 120°C, remove off the windshield glass or
cover over the glass with something so that the temperature on the glass surface should
not go up more than 120°C.
BM1604A5EGP 17
7 PAINTING
8. HANDLING OF COMPUTERS (ECU)
When paint by forced drying, must be care to handle the computers as following points.
CONDITION OF FORCED DRYING PAINT HANDLING OF COMPUTER
• INSIDE TEMPERATURE OF THE : 120°C

FORCED DRYING BOOTH
1 • INSIDE TEMPERATURE OF THE CAB : LESS THAN 85°C
(PLACE AT THE 50mm HEIGHT FROM
UPPER SURFACE OF CAB FLOOR.)
INSTALLED
WHEN UNKNOWN THE TEMPERATURE OF THE
FORCED DRYING BOOTH OR USE
INFRARED LAMP
2
INSIDE TEMPERATURE OF THE CAB : LESS THAN 85°C
(PLACE AT THE 50mm HEIGHT FROM
UPPER SURFACE OF CAB FLOOR.)
WHEN EXPECT MORE HIGH TEMPERATURE
3 REMOVE COMPUTER
THAN ABOVE MENTIONED CASES.
BM1604A5EGP 18
7 PAINTING
9. PRECAUTIONS FOR FITTING AND STORING THE CAUTION PLATE
• How to Stick It
a. Stick the caution plate to a dry place which is free from dust and dirt after the paint has
completely dried up.
b. Clean your hand and don't use cotton work gloves, etc..
c. Completely remove water, oil, dust, etc. from the surface to stick (surface of cab) with
ethyl alcohol if they are found remaining there.
d. When the temperature is less than 10°C, warm up the surface to stick as well as the
caution plate with warm wind of more than 20°C before sticking the caution plate.
e. After sticking the caution plate, press it with a roller, etc., with a force of
approximately 49 N/cm2 {5 kgf/cm2 }.
f. Remove liner paper (backing paper) just before using it.
g. When air remains inside, make a tiny hole with a needle or a cutter knife and press it
out with your fingers from the bubble area.
• How to Store It
a. When storing the caution plate, select a dry place with an ambient temperature
(of 20 to 25°C) and without dust, dirt and stain.
b. Also, store the caution plate at a flat place such as a shelf, etc., and do not place
anything on it.
• Other Precautions for the Caution Plate

a. As the caution plate is made from vinyl chloride, it is thin, soft and easily
extensible.
Therefore, take utmost care for handling it.
b. When removing the caution plate, etc., be careful not to damage the painted
surface with a sharp knife, etc.
On the other hand, removal of the caution plate can be done more easily by pulling the
caution plate in perpendicular direction to the sticking surface while heating it with a
hair dryer.
c. Do not throw the caution plates away but keep them together to compare with new
caution plates and to prevent mixing up with the new ones.
BM1604A5EGP 19
7 PAINTING
10. CAUTIONS FOR PAINTING THE TIRE DISC WHEELS
1) Before painting the tire disc wheel, cover its inside and outside surface to be contacted
with the wheel, the hub, the brake drum and wheel nuts.
Refer to the illustration below concerning the covering portions.
ISO type
SECTION A-A
2) After installing the tire disc wheel onto the vehicle, paint the remained portions with
same color paint as thin as possible.
It is because these surfaces are installation surface rotation tire.
If the painting layer is thick, it causes wheel nuts loosen.
3) Precaution for carrying out tire rotation

Sometimes, the mounting position of tire disc wheel may be changed and paint coated
face may become contact face.
At this moment, if the thickness of the painted layer is excessively thick, this may lead
to the loosening of the wheel nuts.
Therefore observe the following instructions when carrying out the tire rotation.
(1) Take off the paint on the contact face (including the contact surface of wheel nut)
of the tire disc wheel and after having completely cleaned the face with a wire brush
etc., apply thin layer of paint for rust preventive purpose.
(2) If you use the tire disc wheel without taking off the paint, even if the face is
completely cleaned with wire brush, etc., the thick painted layer may lead to the
loosening of wheel nuts.
BM1604A5EGP 20
Chapter 8
CHASSIS DRAWINGS
1. CAB DRAWINGS
2. CAB BACK DRAWINGS
3. CHASSIS DRAWINGS
4. CHASSIS FRAME DRAWINGS
BM1604A5EGP
8 CHASSIS DRAWINGS
Refer to detail of the cab, chassis and chassis frame drawing based on following table.
8.4. CHASSIS
PRODUCTION 8.1. CAB 8.2. CAB BACK 8.3. CHASSIS
FRAME
CODE DRAWINGS DRAWINGS DRAWINGS
DRAWINGS
FG8JF7D-PG2 C-1 CB-1 CH-1 CF-1
FG8JM7A-PG2 C-1 CB-2 CH-2 CF-2
GH8JF7D-PG2 C-1 CB-1 CH-3 CF-3
GH8JM7A-PG2 C-1 CB-2 CH-4 CF-4
FM2PR7A-MG2 C-2 CB-3 CH-5 CF-5
SG2PF7B-MG2 C-3 CB-4 CH-6 CF-6
BM1604A5EGP 1
8 CHASSIS DRAWINGS
1. CAB DRAWINGS
Unit : mm
No. C-1 PRODUCTION CODE : ‌FG8JF7D-PG2, FG8JM7A-PG2,
GH8JF7D-PG2, GH8JM7A-PG2
• Rear
• Front
BM1604A5EGP 2
8 CHASSIS DRAWINGS
No. C-2 PRODUCTION CODE : FM2PR7A-MG2
Unit : mm
• Front
• Rear
BM1604A5EGP 3
8 CHASSIS DRAWINGS
No. C-3 PRODUCTION CODE : SG2PF7B-MG2
Unit : mm
• Front
• Rear
BM1604A5EGP 4
8 CHASSIS DRAWINGS
OUT SIDE MIRROR : FOR EGYPT MODEL
BM1604A5EGP 5
8 CHASSIS DRAWINGS
BUMPER : FOR OFFLOAD MODEL (In case of J-ENGINE)
STEP LESS TYPE STEP (COVER LESS)
BM1604A5EGP 6
8 CHASSIS DRAWINGS
BUMPER : FOR OFFLOAD MODEL (In case of P-ENGINE)
STEP STEP (COVER LESS)
BM1604A5EGP 7
8 CHASSIS DRAWINGS
BUMPER : FOR ONLOAD MODEL (In case of J-ENGINE)
STEP LESS TYPE STEP (WITH COVER)
BM1604A5EGP 8
8 CHASSIS DRAWINGS
BUMPER : FOR ONLOAD MODEL (In case of P-ENGINE)
STEP STEP (WITH COVER)
BM1604A5EGP 9
8 CHASSIS DRAWINGS
2. CAB BACK DRAWINGS
Unit : mm
No. CB-1 PRODUCTION CODE : FG8JF7D-PG2, GH8JF7D-PG2
• Upper view
• Left view • Right view
BM1604A5EGP 10
8 CHASSIS DRAWINGS
No. CB-2 PRODUCTION CODE : FG8JM7A-PG2, GH8JM7A-PG2
Unit : mm
• Upper view
BM1604A5EGP 11
8 CHASSIS DRAWINGS
No. CB-3 PRODUCTION CODE : FM2PR7A-MG2
Unit : mm
• Upper view
BM1604A5EGP 12
8 CHASSIS DRAWINGS
No. CB-4 PRODUCTION CODE : SG2PF7B-MG2
Unit : mm
• Upper view
BM1604A5EGP 13
8 CHASSIS DRAWINGS
3. CHASSIS DRAWINGS
Unit : mm
No. CH-1 PRODUCTION CODE : FG8JF7D-PG2
BM1604A5EGP 14
8 CHASSIS DRAWINGS
No. CH-1 PRODUCTION CODE : FG8JF7D-PG2
Unit : mm
BM1604A5EGP 15
8 CHASSIS DRAWINGS
No. CH-2 PRODUCTION CODE : FG8JM7A-PG2
Unit : mm
BM1604A5EGP 16
8 CHASSIS DRAWINGS
No. CH-2 PRODUCTION CODE : FG8JM7A-PG2
Unit : mm
BM1604A5EGP 17
8 CHASSIS DRAWINGS
No. CH-3 PRODUCTION CODE : GH8JF7D-PG2
Unit : mm
BM1604A5EGP 18
8 CHASSIS DRAWINGS
No. CH-3 PRODUCTION CODE : GH8JF7D-PG2
Unit : mm
BM1604A5EGP 19
8 CHASSIS DRAWINGS
No. CH-4 PRODUCTION CODE : GH8JM7A-PG2
Unit : mm
2455
BM1604A5EGP 20
8 CHASSIS DRAWINGS
No. CH-4 PRODUCTION CODE : GH8JM7A-PG2
Unit : mm
BM1604A5EGP 21
8 CHASSIS DRAWINGS
No. CH-5 PRODUCTION CODE : FM2PR7A-MG2
Unit : mm
GROUND HEIGHT,
MODEL TIRE WHEEL FRAME UPPER SURFACE FR Tr RR Tr Tr Td
Hf0 Hf Hr Hr0
F&R 10.00R20-16 F&R 20X7.50V 1005 1015 1065 1090 2050 1855 2462 330
F&R 11.00R20-16 F&R 20X7.50V 1015 1030 1080 1105 2050 1855 2468 330
FM2PR7A-MG2 F&R 12R22.5 152/148 F&R 22.5X8.25 1015 1030 1080 1105 2050 1855 2479 330
F&R 275/80R22.5 F&R 22.5X8.25 985 995 1045 1070 2050 1855 2463 330
F&R 295/80R22.5 F&R 22.5X8.25 1000 1010 1060 1085 2050 1855 2477 330
BM1604A5EGP 22
8 CHASSIS DRAWINGS
No. CH-5 PRODUCTION CODE : FM2PR7A-MG2
Unit : mm
BM1604A5EGP 23
8 CHASSIS DRAWINGS
No. CH-6 PRODUCTION CODE : SG2PF7B-MG2
Unit : mm
GROUND HEIGHT,
MODEL TIRE WHEEL FRAME UPPER SURFACE FR Tr RR Tr Tr Td
Hf0 Hf Hr Hr0
11.00R20-16 20X7.50V 955 985 1070 1110 2050 1835 2448 330
11R22.5 148/145 22.5X7.50 945 970 1055 1095 2055 1835 2432 324
SG2PF7B-MG2 12R22.5 152/148 22.5X8.25 955 985 1070 1110 2050 1835 2459 330
275/70R22.5 148/145 22.5X8.25 900 930 1015 1055 2050 1835 2443 330
275/80R22.5 22.5X8.25 925 955 1040 1080 2050 1835 2443 330
BM1604A5EGP 24
8 CHASSIS DRAWINGS
No. CH-6 PRODUCTION CODE : SG2PF7B-MG2
Unit : mm
BM1604A5EGP 25
8 CHASSIS DRAWINGS
4. CHASSIS FRAME DRAWINGS
Unit : mm
No. CF-1 PRODUCTION CODE : FG8JF7D-PG2
• Detail of the chassis frame
BM1604A5EGP 26
8 CHASSIS DRAWINGS
No. CF-1 PRODUCTION CODE : FG8JF7D-PG2
• Detail of the cross member Unit : mm
BM1604A5EGP 27
8 CHASSIS DRAWINGS
No. CF-2 PRODUCTION CODE : FG8JM7A-PG2
• Detail of the chassis frame Unit : mm
BM1604A5EGP 28
8 CHASSIS DRAWINGS
No. CF-2 PRODUCTION CODE : FG8JM7A-PG2
BM1604A5EGP 29
8 CHASSIS DRAWINGS
No. CF-3 PRODUCTION CODE : GH8JF7D-PG2
BM1604A5EGP 30
8 CHASSIS DRAWINGS
No. CF-3 PRODUCTION CODE : GH8JF7D-PG2
BM1604A5EGP 31
8 CHASSIS DRAWINGS
No. CF-4 PRODUCTION CODE : GH8JM7A-PG2
BM1604A5EGP 32
8 CHASSIS DRAWINGS
No. CF-4 PRODUCTION CODE : GH8JM7A-PG2
BM1604A5EGP 33
8 CHASSIS DRAWINGS
No. CF-5 PRODUCTION CODE : FM2PR7A-MG2
BM1604A5EGP 34
8 CHASSIS DRAWINGS
No. CF-5 PRODUCTION CODE : FM2PR7A-MG2
BM1604A5EGP 35
8 CHASSIS DRAWINGS
No. CF-6 PRODUCTION CODE : SG2PF7B-MG2
BM1604A5EGP 36
8 CHASSIS DRAWINGS
No. CF-6 PRODUCTION CODE : SG2PF7B-MG2
BM1604A5EGP 37
Chapter 9
MOUNTING OF CHASSIS EQUIPMENT
1. AIR TANK & AIR BOOSTER

2. BRAKE PIPING DIAGRAM
3. BATTERY
4. FUEL TANK
5. EXHAUST SYSTEM
6. LICENSE PLATE BRACKET
BM1604A5EGP
9 MOUNTING OF CHASSIS EQUIPMENT
Refer to detail of the fuel tank, air tank & air booster, battery, exhaust system and fuel
cooler drawing based on following table.
9.6 LICENSE
9.1. AIR TANK & AIR 9.2. BRAKE PIPING 9.5. EXHAUST
PRODUCTION 9.3. BATTERY 9.4. FUEL TANK PLATE
BOOSTER DIAGRAM SYSTEM
CODE BRACKET
STD OPT OPT OPT STD OPT OPT STD OPT STD OPT OPT STD OPT OPT STD OPT
FG8JF7D-PG2 AT-1 AT-2 - - PD-1 PD-2 - BAT-1 BAT-2 FT-1 - - EX-1 EX-2 EX-3
FG8JM7A-PG2 AT-1 AT-2 - - PD-1 PD-2 - BAT-1 BAT-2 FT-2 - - EX-4 EX-2 EX-3
GH8JF7D-PG2 AT-1 AT-2 - - PD-1 PD-2 - BAT-1 BAT-2 FT-1 - - EX-1 EX-2 EX-3
LPB-1 LPB-2
GH8JM7A-PG2 AT-1 AT-2 - - PD-1 PD-2 - BAT-1 BAT-2 FT-2 - - EX-4 EX-2 EX-3
FM2PR7A-MG2 AT-3 AT-4 AT-5 AT-6 PD-3 PD-4 PD-5 BAT-1 BAT-2 FT-3 FT-5 - EX-5 EX-6 EX-7
SG2PF7B-MG2 AT-7 AT-8 - - PD-6 PD-7 PD-8 BAT-1 BAT-2 FT-2 FT-4 FT-6 EX-8 EX-9 EX-7
BM1604A5EGP 1
1. AIR TANK & AIR BOOSTER
AT-1 Unit : mm
BM1604A5EGP 2
AT-2 Unit : mm
BM1604A5EGP 3
AT-3 Unit : mm
BM1604A5EGP 4
AT-4 Unit : mm
BM1604A5EGP 5
AT-5 Unit : mm
BM1604A5EGP 6
AT-6 Unit : mm
BM1604A5EGP 7
AT-7 Unit : mm
BM1604A5EGP 8
AT-8 Unit : mm
BM1604A5EGP 9
2. BRAKE PIPING DIAGRAM
PD-1
BM1604A5EGP 10
PD-2
BM1604A5EGP 11
PD-3
BM1604A5EGP 12
PD-4
BM1604A5EGP 13
PD-5
BM1604A5EGP 14
PD-6
BM1604A5EGP 15
PD-7
BM1604A5EGP 16
PD-8
BM1604A5EGP 17
PD-9
BM1604A5EGP 18
3. BATTERY
BAT-1 Unit : mm
SPECIFICATION : 234kC {65Ah}
BM1604A5EGP 19
BAT-2 Unit : mm
SPECIFICATION : 432kC {120Ah}
BM1604A5EGP 20
4. FUEL TANK
FT-1
SPECIFICATION : 200L
BM1604A5EGP 21
FT-2 Unit : mm
BM1604A5EGP 22
FT-3 Unit : mm
BM1604A5EGP 23
FT-4 Unit : mm
BM1604A5EGP 24
FT-5 Unit : mm
BM1604A5EGP 25
FT-6 Unit : mm
BM1604A5EGP 26
5. EXHAUST SYSTEM (EXHAUST TAIL PIPE)
EX-1
SPECIFICATION : HORIZONTAL EXHAUST PIPE
Unit : mm
BM1604A5EGP 27
EX-2 Unit : mm
BM1604A5EGP 28
EX-3 Unit : mm
SPECIFICATION : VERTICAL EXHAUST PIPE
BM1604A5EGP 29
EX-4 Unit : mm
BM1604A5EGP 30
EX-5 Unit : mm
BM1604A5EGP 31
EX-6 Unit : mm
BM1604A5EGP 32
EX-7 Unit : mm
SPECIFICATION : VERTICAL EXHAUST PIPE
BM1604A5EGP 33
EX-8 Unit : mm
BM1604A5EGP 34
EX-9 Unit : mm
BM1604A5EGP 35
6. LICENSE PLATE BRACKET
LPB-1 Unit : mm
BM1604A5EGP 36
LPB-2
Unit : mm
BM1604A5EGP 37
Chapter 10
5TH WHEEL
1. MOUNTING OF 5TH WHEEL

2. OUTLINE OF 5TH WHEEL (COUPLER) MOUNTING METHOD
3. COUPLER BASE DIMENSION
4. RECOMMENDED 5TH WHEEL MOUNTING PLATE DIMENSION
5. SLIDE RAIL FOR 5TH WHEEL
6. SEMI-TRAILER BRAKE COUPLING
BM1604A5EGP
10 5TH WHEEL
1. MOUNTING OF 5TH WHEEL
5TH wheel is not mounted on this chassis.
Therefore, when mounting the 5TH wheel, it is necessary to mount it taking the
followings into consideration : smooth connection with a trailer, balance of weight
distribution on the front and rear axles as well as vibrations and riding comfort of the
vehicle.
OFFSET AND PERMISSIBLE LOAD ON THE 5TH WHEEL

For the reason of balance of weight distribution on the axles, vibration of vehicle and
riding comfort, HINO recommend the 5TH wheel offset as follows.
Unit : mm
MODEL 5TH wheel offset
SG 455
When mounting the 5TH wheel, it is necessary to satisfy the following conditions :
1) GCMR when a trailer under loaded condition is connected.

2) GVMR of tractor when a trailer under loaded condition is connected.
3) Axle capacity under the conditions 1) and 2) above.
4) Tire capacity under the conditions 1) and 2) above.
5) 5th wheel load when the trailer is connected under loaded condition. (less than the
value set by coupler manufacturer.)
Also, the following recommended values should be observed in order to ensure driving
stability and riding comfort of the vehicle.
6) Front axle load / GVM = 4 x 2 tractor : More than 30%
6 x 4 tractor : More than 20%
(when a tractor under loaded condition is connected.)
7) Rear axle load / GCM = More than 25%
(when a tractor under loaded condition is connected.)
BM1604A5EGP 1
10 5TH WHEEL
8) When the tractor is connected with the trailer, the clearances shown on the following
table should be secured for front fitting radius and rear fitting radius.
Minimum clearance between tractor and trailer
TRACTOR TRAILER CLEARANCE
FRONT FITTING RADIUS FR D FR – D ≥ 80 mm
REAR FITTING RADIUS RR G G – RR ≥ 100 mm
HOW TO DECIDE GROUND CLEARANCE OF 5TH WHEEL

1) Mount the 5TH wheel in such a way that the ground clearance (H) of the upper surface
of the 5TH wheel falls within the following range when articulated and loaded.
A + 50 mm ≤ H ≤ A + 150 mm

*A: King-pin base ground height of trailer when loaded.
2) Ground clearance (H) of the upper surface of the 5TH wheel should be decided so that
the floor plan of the trailer rises towards the front above the horizontal plan of the trailer
when the trailer is articulated and loaded.
BM1604A5EGP 2
10 5TH WHEEL
HOW TO MOUNT THE 5TH WHEEL
1) When mounting a 5TH wheel , never fail to place a mounting plate on the chassis and
then to mount the 5TH wheel.
The mounting plate recommended by HINO is shown at P.5.
2) When using a mounting plate supplied by the 5TH wheel manufacturer, fit it on the
chassis according to the recommendation given by the 5TH wheel manufacturer.
3) When making the mounting plate, make it by referring to the mounting plate
recommended by HINO shown at P.5 and by observing the following instructions.
(1) Fix the mounting plate at more than 6 positions on one side using fixing bolts whose
neck diameter is more than 16 mm.
(2) Use the material of bolt : JIS G 4052 steel material for structure equivalent to high
tensile strengthen steel : SMnC443H, SCr435H, SCM435.
4) Mount lower support bracket for 5TH wheel at the back of the 5TH wheel.
5) Mount slide rails on the upper faces of chassis frame at the back of the Lower support
bracket to secure the smooth connection with the trailer.
6) More detail as how to mount the 5th wheel, refer to “GENERAL PRECAUTIONS, 17
TRACTOR VEHICLE” of the Body Mounting Manual, common edition No. KC-AA201A.
BM1604A5EGP 3
10 5TH WHEEL
2. OUTLINE OF 5TH WHEEL (COUPLER) MOUNTING METHOD
Refer to detail of the COUPLER, COUPLER BASE, SUB BASE drawing
based on following table.
Unit : mm
COUPLER MODEL RECOMMENDED DIMENSION 'A'
MODEL COUPLER SUB BASE
BASE
SG 455
SG CP-1 CPB-1 SB-1
CP-1
A
COUPLER BASE
SUB BASE
BM1604A5EGP 4
10 5TH WHEEL
3. COUPLER BASE DIMENSION
CPB-1 Unit : mm
BM1604A5EGP 5
10 5TH WHEEL
4. RECOMMENDED 5TH WHEEL MOUNTING PLATE DIMENSION
SB-1 Unit : mm
BM1604A5EGP 6
10 5TH WHEEL
5. SLIDE RAIL FOR 5TH WHEEL
FOR 4X2 TRACTOR Unit : mm
DETAIL OF SLIDER RAIL, RH

(LEFT SIDE IS SYMMETRY CONSTRUCTION AS ABOVE DRAWING.)
BM1604A5EGP 7
10 5TH WHEEL
6. SEMI-TRAILER BRAKE COUPLING
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 ; Yellow being for Service purpose while
Red being for an Emergency purpose.
The actual form is as shown below.
Unit : mm
BM1604A5EGP 8
Chapter 11
REGULATION
1. REAR UNDER RUN PROTECTION DEVICE
BM1604A5EGP
11 REGULATION
This section is described the informations in relation to vehicle’s laws 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 be make sure the contents to

be described in this section.
BM1604A5EGP 1
11 REGULATION
1. REAR
‌ UNDER RUN PROTECTION DEVICE
(REAR BUMPER)
Refer to detail of the REAR UNDER RUN PROTECTION DEVICE drawing based on following table.
REAR UNDER RUN

PRODUCTION
PROTECTION DEVICE
CODE
STD OPT
FG8JF7D-PG2 RUP-1
FG8JM7A-PG2 RUP-2
GH8JF7D-PG2 RUP-1
LESS
GH8JM7A-PG2
RUP-2
FM2PR7A-MG2
SG2PF7B-MG2 -
BM1604A5EGP 2
11 REGULATION
RUP-1 Unit : mm
BM1604A5EGP 3
11 REGULATION
RUP-2 Unit : mm
BM1604A5EGP 4

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BM1604A5EGP

HINO 500 SERIES

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

This manual is provided to Body and Equipment Manufacturers, including inter-mediate

when Body and Equipment Manufacturers install any body or other equipment or device

This manual contains chassis specifications and instructions particular to

• The instructions of individual model manual precede over

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

• It is the responsibility of Body and Equipment Manufacturers or modification companies

• About chassis mass

• About SRS air bag and ABS system

• About VEHICLE CONTROL ECU

3. CHASSIS MASS & FRAME SECTION MODULUS

4. SPRINGS & REAR AXLES

5. P.T.O. AND CONTROL

9. MOUNTING OF CHASSIS EQUIPMENT

10. 5TH WHEEL

10,400kg C 3000 GENERAL CARGO with

10,000 12,000kg E 3250 3499 R FIRST GENERAL CARGO with

14,000 15,500kg J 4250 4499 DUMP with

17,000kg L 4750 4999 Z FIRST FIRE ENGINE with

OVER 30,000kg W 7000 7249 DUMP with REAR AIR

MIXER with REAR AIR

Located at the right side

Detail of specifications refer to following.

MAJOR TRANSMISSION MX06 (6MT)

DIMENSIONS TIRE CAPACITY SIZE F&R 10.00R20-16

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

SPRINGS & OPT2 F3(FRT) F3(FRT)

CHASSIS 8.2. CAB BACK DRAWINGS CB-1 CB-2

MAJOR TRANSMISSION MX06 (6MT)

DIMENSIONS TIRE CAPACITY SIZE F&R 10.00R20-16

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

SPRINGS & OPT2 F6(FRT) F6(FRT)

CHASSIS 8.2. CAB BACK DRAWINGS CB-1 CB-2

MAJOR TRANSMISSION ZF9S1310

DIMENSIONS TIRE CAPACITY SIZE F&R 10.00R20-16

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

SPRINGS & OPT2 F8(FRT)

CHASSIS 8.2. CAB BACK DRAWINGS CB-3

MAJOR TRANSMISSION M009OD

DIMENSIONS TIRE CAPACITY SIZE F&R 11.00R20-16

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

SPRINGS & OPT2 -

CHASSIS 8.2. CAB BACK DRAWINGS CB-4

1. ELECTRIC WELDING WORK

1) ‌Procedure before welding

2) Ground of the welding equipment

• Peel off the paint where to be welded.

3) Other precautions of welding

Case of disconnecting the negative terminal of BATTERY

Turn the STARTER SWITCH to LOCK position.

Disconnect the negative terminal of BATTERY.

Case of connecting the negative terminal of BATTERY

<The electric current of welding>

EARTH WIRE OF CAB

• Be sure to cover the computer to protect the water penetration when

GAP BETWEEN CAB REAR END AND BODY

FITTING THE FIRE SHIELD

・For approximately 50mm from the front edge of fire

・You may also install the fire shield so that it

CAB REAR ARCH

Avoid wiring in the engine compartment if possible.

1) ‌Procedure before welding

6) ‌OTHER PRECAUTIONS FOR DRILLING AND

2) ‌MOUNTING FOR CAB BACK CRANE

5) ‌POSITIONING FORWARD END OF SUB-FRAME