KK–GH117

Body Mounting Manual

TRUCK CHASSIS
MODEL GH1J SERIES
 No part of this manual may be reproduced or transmitted in any form without the
express written permission of Hino Motors, Ltd.
© 2003, Hino Motors, Ltd. All rights reserved. Printed in Japan.

HINO MOTORS, LTD.

SPECIAL PURPOSE VEHICLE DIVISION

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

Telephone : 042-586-5249
Facsimile : 042-586-5868

2003 - 05

KK-GH117
 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 model
GH1J series in the Hino of medium duty trucks.

Important
This instruction manual must be used in combination with
the Common Manual, No. KC-AA001F or KC-AA201.

• The Common Manual is available at authorized Hino distributors.

• 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.

KK-GH117
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.

KK-GH117
 CONTENTS

1. VEHICLE SUMMARY

2. GENERAL PRECAUTIONS

3. CHASSIS MASS & FRAME SECTION MODULUS

4. SPRINGS & REAR AXLES

5. PTO AND CONTROL

6. ELECTRICAL SYSTEMS

7. PAINTING

8. CHASSIS DRAWINGS

9. MOUNTING OF CHASSIS EQUIPMENT

10. OTHER

KK-GH117
 1. VEHICLE SUMMARY

1. 1 MODEL CODE•••••••••••••••••••••••••••••••••••••••••••••••••• 1 - 1
1. 2 IDENTIFICATION NUMBER •••••••••••••••••••••••••••••••• 1 - 2
1. 3 CHASSIS SPECIFICATIONS•••••••••••••••••••••••••••••••• 1 - 3

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1. VEHICLE SUMMARY 1-1

1.1 MODEL CODE

G A
G H 1 J · U ·
M D

VEHICLE TYPE
G CAB-OVER TRUCK

GVMR & (DRIVE) CODE

H GVMR 17,000kg CLASS
DRIVE 4 X 2

ENGINE CODE
1J J08C

WHEELBASE CODE
CODE WHEELBASE (mm)
G 3,750 ~ 3,999 SHORT

M 5,000 ~ 5,249 LONG

MODIFICATION CODE
CODE STEERING POSITION MODIFY
K FIRST
~

RH
R
S FIRST
LH
~

APPLICABLE CODE
CODE BODY TYPE ETC.
A GENERAL CARGO
D DUMP

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 1-2

1.2 IDENTIFICATION NUMBER

1.2.1 CHASSIS NUMBER

Located at the left side

member of chassis frame.

1.2.2 ENGINE NUMBER

ENGINE MODEL : J08C
Located at the right upper
front end of the engine's side wall.

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 CHASSIS MODEL GH1JGUD GH1JMUA

1.3

KK-GH117
DUMP GENERAL CARGO
ITEM
WHEEL BASE (mm) 3,760 5,030
FRONT (mm) 1,915
TREAD
REAR (mm) 1,840
MAX. GVM CAPACITY (kg) 17,000
PERMISSIBLE FRONT (kg) 6,500
AXLE CAPACITY
(GAM. RATING) REAR (kg) 10,500
CHASSIS MASS ON STD SPECIFICATIONS
(kg) Refer to page 3-1
(INCLUDING WATER, OIL AND FULL FUEL)
MODEL J08C-TT
JIS GROSS 191kW {260PS} at 2,500r/min
MAX. OUTPUT
ENGINE ISO NET 180kW {245PS} at 2,500r/min
JIS GROSS 745N·m {76kgf·m} at 1,500r/min
MAX. TORQUE
730N·m {74.4kgf·m} at 1,500r/min
CHASSIS SPECIFICATIONS

ISO NET
HEIGHT OF CENTER OF GRAVITY (mm) Refer to page 3-1
STD 11.00-20-16PR
TIRE
OPT 11.00R20-16PR,12R22.5-16PR,275/70R22.5(148/145), 275/80R22.5(149/146)
TIRE AND DISK
STD 20 X 7.50V-165
DISK
OPT 22.5 X 8.25-165
STD (L) 200
FUEL TANK
OPT (L) ----- 200 x 2
STD 12V-234kC {65A·h} -2
BATTERY
OPT 12V-432kC {120A·h} -2
ALTERNATOR 24V-50A
RECOMMENDED MAXIMUM BODY WIDTH (mm) 2,400

[NOTE]
• Permissible axle capacity and GVM or GCM capacity listed above table must not be exceeded.
• The front axle load must exceed 30% of the gross vehicle mass under full loaded condition.
• The height of center of gravity from ground on the unloaded vehicle with body mounted should be 1.05m or less.
1-3

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

• Both front axle and rear axle loads must not exceed the permissible load based on the tire load capacity according to the tire standards in your country.
• The mass and dimension of tires to be mentioned in above chassis specification shows design figure according to JATMA or ETRTO standard.
 2. GENERAL PRECAUTIONS

2. 1 FIRE SHIELD •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2 - 1

2. 2 CLEARANCE BETWEEN CAB AND
REAR BODY OR EQUIPMENT •••••••••••••••••••••••••••• 2 - 2
2. 3 RECOMMENDED POSITIONS OF U - BOLTS •••••••••••• 2 - 3
2. 4 RECOMMENDED POSITIONS OF REAR
FENDERS AND MUDGUARDS •••••••••••••••••••••••••••• 2 - 4
2. 5 ELECTRIC WELDING WORK •••••••••••••••••••••••••••••••••••• 2 - 5
2. 6 NOTES ON ADDITIONAL WIRING
IN THE ENGINE COMPARTMENT •••••••••••••••••••••••• 2 - 6
2. 7 PRECAUTION OF THE ANTENNA POSITION •••••••••• 2 - 7
2. 8 NOTES ON SYSTEM CONTROL COMPUTERS •••••••• 2 - 8

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2. GENERAL PRECAUTIONS 2-1

2.1 FIRE SHIELD

2.1.1 GAP BETWEEN CAB REAR END AND BODY
If the vehicle has a flat bed or similar body, a fire shield should be fitted
across the gap between the rear arch cover and the front end of the rear
body (header board of rear body) on the chassis frame to prevent fires that
may be caused by flammable materials falling off from the load platform onto
the exhaust pipe. (See the illustration below.)
A fire shield is not necessary when the body is fitted with a sheet carrier
attached directly to the top of header board.
A fire shield is also not necessary for such bodies as dump trucks, concrete
mixer, tankers and aluminum vans, where there is no danger of falling - off-
of flammable materials.
[NOTE]
When you mount the fire shield, use bolts, etc., that can be taken out to allow for
replacement of the chassis parts which are located at the rear part of cab.
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
rear arch cover.
• You may also install the fire shield so that
it covers only the exhaust pipe.

CAB REAR ARCH

RUBBER
FIRE SHIELD
BOLT & NUT

BODY OR
EQUIPMENT

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2-2-1

2.2 CLEARANCE BETWEEN CAB AND REAR BODY OR

EQUIPMENT
The rear part of the cab contains the cab lock mechanism or stack exhaust
pipe as well as the engine cylinder block.
When mounting the body, allow at least the minimum clearance between the
rear end of the cab and the front end of the rear body, to avoid obstructing
the operation of these mechanisms.

MINIMUM CLEARANCE WITH CAB REAR END

Unit : mm

A B
STACK
EXHAUST PIPE OPT 935 MIN.80
HORIZONTAL STD 805 MIN.50
EXHAUST PIPE

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 2-2-2

MEASUREMENT OF THE CAB TILT MECHANISM

Unit : mm

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2-2-3

MEASUREMENT OF THE ENGINE AIR INTAKE PORT

Unit : mm

CAUTION : 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.

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 2-2-4

MEASUREMENT OF THE ENGINE AIR CLEANER

Unit : mm

POSITION OF THE STACK EXHAUST PIPE

Unit : mm

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 2-3

2.3 RECOMMENDED POSITIONS OF U- BOLTS

• The U-bolts to be fastened on the body sub-frame and the chassis frame must be
provided sufficient clearance to prevent contact with the brake pipes, hoses, and
harness wires etc.
• The recommended setting positions of U-bolts should be observed according to
the figure shown below.

APPLICABLE MODEL : GH1J SERIES

Unit : mm
U-BOLT POSITION
WHEEL BASE X L2 L3 L4
RH 885 – 150 –
G 3760
LH 315 – 150 –
RH 885 1560 150 2120
M 5030
LH 315 1560 150 2120

No.2 CROSSMEMBER REAR AXLE

DATUM LINE DATUM LINE

X L2 L4
L3

No.1 U-BOLT No.2 U-BOLT No.3 U-BOLT No.4 U-BOLT

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 2-4

2.4 RECOMMENDED POSITIONS OF REAR FENDERS AND

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

APPLICABLE MODEL : GH1J SERIES

[NOTE] The dimension of tire to be mentioned in above table shows design figure
according to JATMA or ETRTO standard.

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 2-5

2.5 ELECTRIC WELDING WORK

Internal clocks in the tachograph and the radio and all the electronic
instruments are directly connected to the battery, and are body-earthed at
one end. Under these conditions, electric welding will cause damage to these
electrical units as the welding current flow back along the earth circuit.
When welding, take following precautions.
1) Turn the starter switch off.
2) Disconnect the negative terminal of the battery.
3) Disconnect all electronic instruments.
4) Earth all welding equipment properly, near to the area to be welded.

In order to prevent ancillary equipped components from sparks during

welding, take steps such as putting fire-resistant covers over things like the
engine, meters, steering wheel, hoses, tires and springs (leaf spring or air
bag) etc.

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 2-6

2.6 NOTES ON ADDITIONAL WIRING IN THE ENGINE

COMPARTMENT
Since the engines in HINO trucks are covered with sound arrest plates, the
engine compartment tends to heat up.
Avoid wiring in the engine compartment if possible.
Additional wiring harness or cable should be kept away from heated
elements, and should be wired along the main harness.

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 2-7

2.7 PRECAUTION OF THE ANTENNA POSITION

1) The antenna which is installed on right corner top of the cab roof use right
angle position in normal operation.
2) Make sure that not to obstruct the moving range of the antenna in
described following figure when perform to mount body or equipment.
3) It may cause the noise or poor receiving of the radio if occur an
interference with the antenna and body part.

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 2-8

2.8 NOTES ON SYSTEM CONTROL COMPUTERS

Engine control and brake ABS computers are installed left 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.
1) Be sure to disconnect the harness connector of the computer before
performing any electric welding.
2) Be sure to cover the computer to protect the water penetration when
performing cleaning up the inside of cab.
3) When mounting such devices as a radiophone, a wireless communication
device, be sure to use the devices that conforms to the electric control act
and install the devices on the places which are as far as possible from the
computers and it’s harness.
Do not install any high output (over 50W) device.
Be sure to check that no abnormal electric wave or electromagnetic wave
is found, after having installed the device, which affects on the electronic
signals passing through in computer harness.
4) Do not alter the computer, harness wire or sensors.
5) 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.

KK-GH117
 3. CHASSIS MASS & FRAME
SECTION MODULUS

3. 1 CHASSIS MASS •••••••••••••••••••••••••••••••••••••••••••••••••••••• 3 - 1

3. 2 MASS DISTRIBUTION OF THE OPTION
EQUIPMENT •••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3 - 2
3. 3 FRAME SECTION MODULUS •••••••••••••••••••••••••••••••••• 3 - 3

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3. CHASSIS MASS & FRAME SECTION MODULUS 3-1-1

3.1 CHASSIS MASS

3.1.1 GH1JGUD
GH1JGUD W/B : 3.760m
MODEL
T/M : FS-6109A TIRE : 11.00-20-16PR
MASS GRAVITY MOMENT GRAVITY MOMENT
POSITION FROM HEIGHT FROM
FROM F.A.C FROM FRAME
F.A.C FRAME UPPER
UPPER SURFACE
SURFACE
(kg) (m) (kg·m) (m) (kg·m)
FRONT BUMPER 27 -1.200 -32.400 -0.200 -5.400
CAB FRONT 341 -1.045 -356.345 0.725 247.225
CAB FRONT MTG. 31 -1.045 -32.395 0.110 3.410
STEERING 61 -0.820 -50.020 0.010 0.610
STEP - - - - -
RADIATOR 41 -0.485 -19.885 0.070 2.870
STEERING CONTROL 7 0.650 4.550 -0.024 -0.168
ENGINE FRONT 330 0.030 9.900 -0.120 -39.600
CONTROL 7 0.080 0.560 0.045 0.315
ENGINE ROOM - - - - -
AIR CLEANER 15 0.595 8.925 0.255 3.825
CAB REAR 184 0.745 137.080 0.725 133.400
CAB REAR MTG. 26 0.745 19.370 0.185 4.810
ENGINE REAR 505 0.870 439.350 -0.120 -60.600
REAR SPLASH 15 0.580 8.700 0.070 1.050
BRAKE SYSTEM 75 2.320 174.000 -0.135 -10.125
ELECTRIC SYSTEM 15 1.670 25.050 -0.130 -1.950
EXHAUST SYSTEM 30 1.755 52.650 -0.370 -11.100
STACK TAIL - - - - -
BATTERY 36 1.250 45.000 -0.285 -10.260
FUEL TANK 213 2.315 493.095 -0.325 -69.225
TRANSFER - - - - -
PROPELLER SHAFT 59 2.580 152.220 -0.395 -23.305
FRAME ETC. 607 2.320 1408.240 -0.148 -89.836
PLATFORM - - - - -
COUPLER - - - - -
TIRE CARRIER - - - - -
REAR BUMPER - - - - -
TOOL BOX - - - - -
SUB TOTAL 2,625 - 2487.645 - 75.946
FRONT 755 0.000 0.000 -0.440 -332.200
UNSPRUNG MASS
REAR 1,371 3.760 5154.960 -0.510 -699.210
TOTAL 4,751 1.609 7642.605 -0.201 -955.464

FRONT REAR TOTAL

SPRUNG MASS (kg) 1,963 662 2,625
UNSPRUNG MASS (kg) 755 1,371 2,126
CHASSIS MASS (kg) 2,718 2,033 4,751
GRAVITY POSITION FROM F.A.C (m) 1.609
GRAVITY HEIGHT FROM FRAME UPPER SURFACE (m) -0.201 TGH3 CM GH1JGUD

[NOTE]
• The mass of tires to be mentioned in above table shows design figure according
to JATMA or ETRTO standard.

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3-1-2

3.1.2 GH1JMUA
GH1JMUA W/B : 5.030m
MODEL
T/M : EATON FS-6109A TIRE : 11.00-20-16PR
MASS GRAVITY MOMENT GRAVITY MOMENT
POSITION FROM HEIGHT FROM
FROM F.A.C FROM FRAME
F.A.C FRAME UPPER
UPPER SURFACE
SURFACE
(kg) (m) (kg·m) (m) (kg·m)
FRONT BUMPER 27 -1.200 -32.400 -0.200 -5.400
CAB FRONT 341 -1.045 -356.345 0.725 247.225
CAB FRONT MTG. 31 -1.045 -32.395 0.110 3.410
STEERING 61 -0.820 -50.020 0.010 0.610
STEP - - - - -
RADIATOR 41 -0.485 -19.885 0.070 2.870
STEERING CONTROL 7 0.650 4.550 -0.024 -0.168
ENGINE FRONT 330 0.030 9.900 -0.120 -39.600
CONTROL 7 0.080 0.560 0.045 0.315
ENGINE ROOM - - - - -
AIR CLEANER 15 0.595 8.925 0.255 3.825
CAB REAR 184 0.745 137.080 0.725 133.400
CAB REAR MTG. 26 0.745 19.370 0.185 4.810
ENGINE REAR 505 0.870 439.350 -0.120 -60.600
REAR SPLASH 15 0.580 8.700 0.070 1.050
BRAKE SYSTEM 75 2.320 174.000 -0.135 -10.125
ELECTRIC SYSTEM 15 1.670 25.050 -0.130 -1.950
EXHAUST SYSTEM 30 1.755 52.650 -0.370 -11.100
STACK TAIL - - - - -
BATTERY 36 1.250 45.000 -0.285 -10.260
FUEL TANK 213 2.315 493.095 -0.325 -69.225
TRANSFER - - - - -
PROPELLER SHAFT 71 3.280 232.880 -0.395 -28.045
FRAME ETC. 658 3.500 2303.000 -0.148 -97.384
PLATFORM - - - - -
COUPLER - - - - -
TIRE CARRIER - - - - -
REAR BUMPER - - - - -
TOOL BOX - - - - -
SUB TOTAL 2,688 - 3463.065 - 63.658
FRONT 755 0.000 0.000 -0.440 -332.200
UNSPRUNG MASS
REAR 1,364 5.030 6860.920 -0.510 -695.640
TOTAL 4,807 2.148 10323.985 -0.201 -964.182

FRONT REAR TOTAL

SPRUNG MASS (kg) 2,000 688 2,688
UNSPRUNG MASS (kg) 755 1,364 2,119
CHASSIS MASS (kg) 2,755 2,052 4,807
GRAVITY POSITION FROM F.A.C (m) 2.148
GRAVITY HEIGHT FROM FRAME UPPER SURFACE (m) -0.201

[NOTE]
• The mass of tires to be mentioned in above table shows design figure according
to JATMA or ETRTO standard.

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 3-2

3.2 MASS DISTRIBUTION OF THE OPTION EQUIPMENT

3.2.1 FOR ALL MODELS

MASS GRAVITY MOMENT

POSITION FROM
FROM F.A.C
CONTENT OF OPTION F.A.C W/B REMARKS

(kg) (m) (kg · m)

CENTER SEAT LESS -4 - 0.215 - 0.860 ALL
AIR DRYER 6 1.800 10.800 ALL
T / M PTO 17 1.350 22.950 ALL
TIRE CARRIER 6 6.420 38.520 M
HORIZONTAL EXHAUST
PIPE TO STACK TAIL 37 1.180 43.660 ALL
EXHAUST PIPE
FUEL TANK
213 3.535 752.955 M
(200L TO 400L )

FRONT AIR SPOILER 6 - 1.200 7.200 ALL

BED 3 0.430 1.290 ALL
AIR CONDITIONER 16 - 0.510 8.160 ALL
BATTERY 33 1.280 42.240 ALL

FRONT SUS.
15 0.000 15.000 ALL
(REINFORCED MULTI)

FRONT SUS.
- 22 0.000 - 22.000 ALL
(STANDARD TAPER)

FRONT SUS.
12 - 0.650 7.800 ALL
(STANDARD TAPER W/STB.) UNSPRUNG MASS

FRONT SUS.
32 - 0.650 20.800 ALL
(REINFORCED TAPER W/STB.)

REAR SUS. 3.760 139.120 G

37
(REINFORCED MULTI) 5.030 186.110 M
WHEEL STEP LESS -3 0.000 - 3.000 ALL
CHASSIS STEP 22 - 0.750 16.500 ALL

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3-3-1

3.3 FRAME SECTION MODULUS

3.3.1 FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE)

Unit : mm
MODEL : GH1JGUD

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 3-3-2

3.3.2 FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE)

Unit : mm
MODEL : GH1JMUA

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 4. SPRINGS & REAR AXLES

4. 1 SPRING CHARACTERISTICS •••••••••••••••••••••••••••••••••• 4 - 1

4. 2 MAXIMUM VERTICAL
DEFLECTION OF REAR WHEELS •••••••••••••••••••••• 4 - 2
4. 3 TRAVEL RANGE OF REAR SPRING •••••••••••••••••••••••• 4 - 3

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4. SPRINGS & REAR AXLES 4-1-1

4.1 SPRING CHARACTERISTICS

For All Models
4.1.1 SPRING COMBINATION
Refer to SPRING CHARACTERISTICS CHART based on following table.
1) SPRING COMBINATION TABLE
(1) COMBINATION OF REAR AIR SPRING

STD OPT 1 OPT 2 OPT 3

MODEL GH1JGUD
FRONT A B C D
REAR E F
TGH4 COMB LEAF SPG GC1

STD OPT 1 OPT 2 OPT 3

MODEL GH1JMUA
FRONT A B C D
REAR G H
TGH4 COMB LEAF SPG GC2

NOTE
SYMBOL SPECIFICATION
A TAPER LEAF SPRING
B MULTI LEAF SPRING
C REINFORCED TAPER LEAF SPRING
D REINFORCED MULTI LEAF SPRING
E MULTI LEAF SPRING
F REINFORCED MULTI LEAF SPRING
G MULTI LEAF SPRING
H REINFORCED MULTI LEAF SPRING
TGH4 SPG COMB TABLE

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4-1-2

4.1.2 FRONT LEAF SPRING

1) SPRING CHARACTERISTICS CHART "A"
kgf
x 103 (kN) FRONT
5 50 a 0.241kN/mm {24.6kgf/mm}
b 23.860kN {2433.7kgf}
c c 38.700kN {3947.4kgf}
4 40
SPRING LOAD ON ONE SIDE

3 30
b

CONTACTING POINT OF
2 20

BUFFER RUBBER
HORIZONTAL

a
1 10
POINT

99.0 160.6
0 0 50 100 150 200 (mm)
VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING FGH4 4J SPG CHARA "A"

LOAD VS. DEFLECTION

2) SPRING CHARACTERISTICS CHART "B"
kgf
x 103 (kN) FRONT a 0.257kN/mm {26.2kgf/mm}
5 50
b 25.960kN {2647.9kgf}
c 37.800kN {3855.6kgf}
c
4 40
SPRING LOAD ON ONE SIDE

3 30 b
CONTACTING POINT OF

2 20
BUFFER RUBBER
HORIZONTAL

a
1 10
POINT

101.0 147.1
0 0 50 100 150 200 (mm)
VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING FGH4 4J SPG CHARA "B"
LOAD VS. DEFLECTION

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 4-1-3

3) SPRING CHARACTERISTICS CHART "C"

kgf
FRONT
x 103 (kN)
50 a 0.322kN/mm {32.8kgf/mm}
5
b 33.170kN {3383.3kgf}
c
c 49.780kN {5077.6kgf}

40
SPRING LOAD ON ONE SIDE

4
b

3 30

CONTACTING POINT OF
2 20

BUFFER RUBBER
a
HORIZONTAL

1 10
POINT

103.0 154.6
0 0 50 100 150 200 (mm)
VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING FGH4 4J SPG CHARA "C"

LOAD VS. DEFLECTION

4) SPRING CHARACTERISTICS CHART "D"

kgf
x 103 (kN) FRONT
5 50 a 0.282kN/mm {28.8kgf/mm}
c b 28.480kN {2905.0kgf}
c 41.480kN {4231.0kgf}
4 40
SPRING LOAD ON ONE SIDE

b
3 30
CONTACTING POINT OF

2 20
BUFFER RUBBER
HORIZONTAL

1 10
POINT

101.0 147.1
0 0 50 100 150 200 (mm)
VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING FGH4 4J SPG CHARA "D"

LOAD VS. DEFLECTION

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4-1-4

4.1.3 REAR LEAF SPRING

1) SPRING CHARACTERISTICS CHART "E"
kgf
x 103 (kN)
a 0.457kN/mm {46.6kgf/mm}
e
10
100 b 0.457+0.861=1.318kN/mm
{46.6+87.8=134.4kgf/mm}
c 27.420kN {2796.8kgf}
SPRING LOAD ON ONE SIDE

d 77.500kN {7903.0kgf}
80 e 105.180kN {10725.4kgf}
8
d

CONTACTING POINT OF
6 60

BUFFER RUBBER
4 40 c
HORIZONTAL

2 20
POINT

60 98.0 119
0 0 50 100 150 (mm)
VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING FGH4 1J SPG CHARA "E"
LOAD VS. DEFLECTION

2) SPRING CHARACTERISTICS CHART "F"

kgf
x 103 (kN)
a 0.516kN/mm {52.6kgf/mm}

b 0.516+0.997=1.513kN/mm
15 150 {52.6+101.7=154.3kgf/mm}
c 25.280kN {2577.8kgf}
SPRING LOAD ON ONE SIDE

d 99.420kN {10138.0kgf}
e 134.220kN {13686.6kgf}
e

10 100
CONTACTING POINT OF

d
BUFFER RUBBER

b
HORIZONTAL

5 50
c
POINT

a
49.0 98.0 121
0 0 50 100 150 (mm)
VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING FGH4 1J SPG CHARA "F"
LOAD VS. DEFLECTION

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 4-1-5

3) SPRING CHARACTERISTICS CHART "G"

kgf
x 103 (kN)
a 0.457kN/mm {46.6kgf/mm}

b 0.457+0.861=1.318kN/mm
15 150 {46.6+87.8=134.4kgf/mm}
c 27.420kN {2796.1kgf}
SPRING LOAD ON ONE SIDE

d 77.500kN {7902.8kgf}
e e 131.540kN {13413.3kgf}

10 100

CONTACTING POINT OF
BUFFER RUBBER
d
b
HORIZONTAL

5 50
c
POINT

a
60.0 98.0 139

0 0 50 100 150 (mm)

VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING FGH4 1J SPG CHARA "G"
LOAD VS. DEFLECTION

4) SPRING CHARACTERISTICS CHART "H"

kgf
x 103 (kN)
a 0.516kN/mm {52.6kgf/mm}
200
20 b 0.516+0.997=1.513kN/mm
{52.6+101.7=154.3kgf/mm}
c 25.280kN {2577.8kgf}
SPRING LOAD ON ONE SIDE

d 99.420kN {10138.0kgf}
15 150 e e 164.480kN {16772.3kgf}
CONTACTING POINT OF

10 100
BUFFER RUBBER

d
b
HORIZONTAL

5 50
c
POINT

a
49.0 98.0 141

0 0 50 100 150 (mm)

VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING FGH4 1J SPG CHARA "H"
LOAD VS. DEFLECTION

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 4-2

4.2 MAXIMUM VERTICAL DEFLECTION OF REAR WHEELS

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

DEFLECTION OF REAR TIRES

B
C

A : MAXIMUM DEFLECTION FOR B,C : MAXIMUM SIMULTANEOUS DEFLECTION

ONE SIDE WHEELS RIGHT AND LEFT WHEELS
Unit : mm
MODEL TIRE SIZE A B C
275/70R22.5 (148/145) 180 100 115
275/80R22.5 (149/146) 210 105 115
GH1J SERIES 11.00R20-16PR 250 170 115
12R22.5-16PR 250 170 115
11.00-20-16PR 255 175 115
• With tire chain : Dimentions A and B are added 60 mm.

[NOTE]
The dimension of tire to be mentioned in above table shows design figure
according to JATMA or ETRTO standard.

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 4-3

4.3 TRAVEL RANGE OF REAR SPRING

(FOR MULTI SPRING SERIES ONLY)
During driving, the shackle of the main spring slides beyond the end of the
rear bracket.
Do not mount any parts of body inside of the hatching range.

Unit : mm
REAR AXLE CENTER

Min. 40
775.2

FGH4 SPG T RANGE GC

KK-GH117
 5. PTO AND CONTROL

5. 1 TRANSMISSION SIDE POWER TAKE OFF (OPT) •••• 5 - 1

5. 2 FUEL INJECTION PUMP GOVERNOR LEVER •••••••••• 5 - 2
5. 3 ENGINE CONTROL FOR BODY OR EQUIPMENT •••• 5 - 3
5. 4 REAR BODY CONTROL LEVER (OPT) •••••••••••••••••••• 5 - 4

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5. PTO AND CONTROL 5-1-1

5.1 TRANSMISSION SIDE POWER TAKE OFF

(OPTION EQUIPMENT)
5.1.1 When the body require transmission Power Take Off (PTO) , genuine
PTO equipment and related parts should be supplied as shown below.
1) EATON FS-6109A TRANSMISSION
(1) Transmission series by vehicle model
MODEL TRANSMISSION SERIES
GH1J SERIES EATON FS-6109A
TFG5 FSTM SERIES2 C

(2) Data of the PTO output shaft

TRANSMISSION PERMISSIBLE TORQUE PTO CONTROL DIRECTION OF
SERIES (N·m{kgf·m} at r/min) TYPE ROTATION
Pneumatic Same to
EATON FS-6109A 235{24}/1,000 control engine

TFG5 FSPTO DATA2 C

(3) Necessary parts

TRANSMISSION MODEL
EATON FS-6109A
TRANSMISSION GEAR RATIO
LOW 12.637
1ST 8.806
2ND 6.550
3RD 4.768
4TH 3.548
5TH 2.481
6TH 1.845
7ST 1.343
8ST 1.000
REV 13.210
PTO CONTROL TYPE Pneumatic
PARTS NAME Parts No. Q'ty /
unit
POWER TAKE OFF ASSY 36610-4840 01
ADAPTER, SUB ASSY 31906-1230 01
HARNESS SUB ASSY,
82065-1120 01
TRANSMISSION
BRACKET, ELEC. PARTS 55912-3920 01
ELBOW 9739-10193
CONNECTOR 9729-14104 01
TFG5 FSTM PARTS2 C

[NOTE]
• Parts mentioned above table shows transmission PTO unit only.
• Other related parts of transmission PTO control, please contact each Hino sales
dealer.

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5-1-2

5.1.2 DETAIL OF PTO TRANSMISSION MODEL EATON FS-6109A

1) PTO Installation procedure
(1) Remove the drain plug to the transmission oil.
(Do not remove the drain plug while the oil is hot, or you maybe
burned.)
Remove the PTO cover which is at the left forward of the transmission.
Do not reuse the bolts and gasket that you remove at this time.
Clean the PTO mounting surface on the transmission side.
(2) Prepare the necessary parts, referring to paragraph "5.1.1 - 1) - (3)".
(3) Tighten the elbow and connector to the PTO, after binding up a sealing
tape at 1.5 to 2 times on the taper thread and make sure air do not
leak from the taper thread. (When binding up a sealing tape on the
taper thread, two thread from top of screw should not be binded and
bind up counter direction of the taper thread. And also make sure a
foreign material do not came into joint and control cylinder.)
(4) Installation angle of the elbow should be adjusted the tightening
direction of the taper thread.
(5) Adjust the backlash of each gears, between transmission counter shaft
gear and adapter gear, adapter gear and PTO gear as described with
paragraph "5.1.2 - 3)".
(6) Apply liquid packing to all fitting surfaces, such as the PTO mounting
surface of the transmission case, adapter and PTO body. (Do not apply
liquid packing between contact surface of each other of the gasket.)
(7) Install the adapter with proper bolts (furnished with adapter) in the PTO
aperture of the transmission case and the PTO with proper studs and
nuts (furnished with PTO) in the adapter.
(8) Tightening torque of stud, bolt and nut : 40 - 47 N·m {414 - 484 kgf·cm}
(9) After attaching the PTO, turn the output shaft coupling a few
revolutions to be sure that it turns freely.
(10) When you refill the transmission with oil, increase the amount by 0.5
liters, to allow for the PTO. And check the oil level of the transmission
case with filler plug of main case.
(11) More detail information if needed, please contact with "DANA
CORPORATION".

KK-GH117
 5-1-3

2) Gear layout and gear ratio

Gear ratio : i =N2/N1 X N4/N3 X N6/N5XN8/N7

TRANSMISSION N1 N2 N3 N4 N5 N6 N7 N8 i

EATON FS-6109A 33 43 32 18 24 22 21 37 1.183

TGH5 LXG RATIO2 AU

[NOTES]
• Number of revolutions of PTO output shaft
= number of revolutions of engine X1/ i
• The PTO output shaft turns in the same direction to the engine.

KK-GH117
5-1-4

3) How to check the gear backlash

The gear backlash of the PTO is important factor to prolong the PTO gear
life. The bigger backlash causes the noise from gears, on the contrary the
smaller backlash causes the damage of gears. When installing the PTO
measure and check the backlash according to the following procedures.
(1) Remove the PTO shaft housing and/or inspection plate.
(2) Mount the dial indicator so that it registers movement of the input gear
(driven gear) of the PTO. (See Fig. 1)
[NOTE]
See Fig 2 for proper location of dial indicator contact point. (Two common type
dial indicators shown.)

(3) Hold the PTO driver gear in transmission with a screwdriver or bar and
rock the PTO input gear (driven gear) back and forth with your hand.
Note the total movement on the dial indicator.
(4) Establish backlash at 0.15mm - 0.30mm by adding or subtracting
gaskets.
General rule -- A chelsea 0.25m gasket will change backlash approx.
0.15mm, a 0.51mm gasket changes backlash approx. 0.30mm.
(5) Replace the shift housing and/or inspection plate and retorque (4) four
capscrews to 22 - 27 N·m {221 - 276 kgf·cm}.
(6) Use same procedure for mounting the adapter and chacking backlash
as was used when mounting the PTO to transmission as described
above.
4) Pouring gear oil
When pouring gear oil into the transmission, add more oil (0.5L) for the
lubrication of PTO gears.
5) Other notices
After finishing PTO installation, check whether the output shaft can be
smoothly rotated when PTO is in the neutral position.

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KK-GH117
6) P.T.O. mounting location on transmission case

[NOTE]
5-1-5

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

5-1-6

7) Transmission PTO mounting

KK-GH117
 5-1-7

8) Layout of power line

CRANKCASE
A

SIDE RAIL UPPER FACE

FRONT AXLE DATUM LINE

TRANSMISSION
B

CASE
C

DRIVE SHAFT C
FLYWHEEL
ENTER

HOUSING

HOUSING
CLUTCH
R
ENGINE CENTE

D E F G

Unit : mm
ENGINE TRANSMISSION
MODEL MODEL A B C D E F G
EATON
J08C FS-6109A 270 187.6 3.5… 394 173.5 176 567

FGH5 4JPLLAYOUT2 AU

KK-GH117
5-2-1

5.2 FUEL INJECTION PUMP GOVERNOR LEVER

5.2.1 ENGINE MODEL : J08C-TT
1) Governor model : All speed control type. (BOSCH RLD-J)

[NOTE]
Precautions for installation of engine control device of the body or equipment.
• Make sure that the devices (as control cable) do not interfere with engine parts
while control devices to be installed.
• If use the bolts or nuts of the engine parts for installing the devices, make sure
that the bolt or nut can be properly tightened and confirm the tightening torque.

KK-GH117
 5-2-2

2) Governor lever for body control

Governor : BOSCH RLD-J (STANDARD EQUIPMENT)

KK-GH117
5-2-3

3)Governor lever for body control

Governor : BOSCH RLD-J W/Altitude compensator
(OPTION EQUIPMENT)

KK-GH117
 5-3

5.3 ENGINE CONTROL FOR BODY OR EQUIPMENT

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

RELATIVE MOVEMENT OF ENGINE AND CHASSIS ABSORBED

RELATIVE MOVEMENT OF ENGINE AND CHASSIS NOT ABSORBED

KK-GH117
 5-4

5.4 REAR BODY CONTROL LEVER (OPT)

5.4.1 MOUNTING POSITION OF DUMP BODY CONTROL LEVER
MODEL : GH1JGUD ONLY
Unit : mm

KK-GH117
 6. ELECTRICAL SYSTEMS

6. 1 FUSE BLOCK, RELAY PANEL AND

FUSIBLE LINK BLOCK •••••••••••••••••••••••••••••••••••••••• 6 - 1
6. 2 SPARE POWER TERMINALS •••••••••••••••••••••••••••••••••• 6 - 2
6. 3 ELECTRIC WIRING OF SPARE OUTLET •••••••••••••••••• 6 - 3
6. 4 PRECAUTION FOR INSTALLING WIRES, etc.,
TO CAB •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6 - 4
6. 5 REAR COMBINATION LAMP •••••••••••••••••••••••••••••••••••• 6 - 5
6. 6 OTHER LAMPS •••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6 - 6
6. 7 BACK-UP BUZZER (OPT) •••••••••••••••••••••••••••••••••••••••• 6 - 7
6. 8 ELECTRICAL WIRING DIAGRAMS •••••••••••••••••••••••••• 6 - 8

KK-GH117
6. ELECTRICAL SYSTEMS 6-1-1

6.1 FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK

6.1.1 LOCATION OF THE CAB SIDE
The fuse block and the relay panel are located inside the instrument panel as
shown below.

KK-GH117
6-1-2

1) Fuse block

[NOTE]
Be sure to use each capacity fuse designated in the above table.
Never use the capacity fuse exceeding the designated one in the above, otherwise
over current may damage the harness wires, and fusible linkage wires are in the
same.

KK-GH117
 6-1-3

2) Relay panel

KK-GH117
6-1-4

6.1.2 LOCATION OF THE CHASSIS SIDE

The fusible link block is located on left side of the cab rear arch as shown
below.

KK-GH117
 MAX. TE RMINAL COU P LING CONNE CTOR
6.2

KK-GH117
TERMINAL P OLE CIRCUIT WIRE SIZE AP PLICABLE
CAPACITY (CONNECTOR) (S P ARE P ARTS ) RE MARKS
MARK CODE (MAIN APPLICATION) & COLOR MODEL
(A) P ARTS No. P ARTS N o.

0.85
A AGM POWER SUPPLY, ACC 7 97830 - 4050 97840 - 4050 ALL MODEL
W-R

1.25
I O P POWER SUPPLY 10 PERMISSIBLE CURRENT : 10 A
W

0.85
I O Q POWER SUPPLY, ACC 7 PERMISSIBLE CURRENT : 7 A
W-G

C AB S IDE
B 82580 - 6920 82580 - 8380 ALL MODEL
POWER SUPPLY, 0.85
IOK 7 PERMISSIBLE CURRENT : 7 A
LIGHTING W-L

2.0
I O S GROUND 20 PERMISSIBLE CURRENT : 20 A
B

POWER SUPPLY, DUMP 0.85

D UEO 7 82580 - 4240 82580 - 4230 DUMP
UP SWITCH W-B
take it from the spare power supply.
SPARE POWER TERMINALS

PERMISSIBLE CURRENT : 7 A

CHASSIS SIDE
POWER SUPPLY, 0.85 {TOTAL CURRENT=NSIDE CAB
C AGQ 7 82580 - 6570 82580 - 6580 ALL MODEL
LIGHTING W-L CONNECTOR B (I O K)
6.2.1 SPARE POWER SUPPLIES AND POSITIONS

CONNECTOR C(AGQ)}

TFG6 SPSUPPLY

[NOTE]
• The permissible current to be taken from spare power terminal is determined from the capacity of the fuse and
wire size.
Make sure that the maximum load (current) of the installed equipment must be kept lower current than the
permissible capacity to be able to take from spare power terminal.
• Be sure to keep the lower current value than the alternator generated capacity when switched on the original and
If you must take an electrical power supply for the body from the chassis,

additional equipment same time to avoid over discharging electricity of the battery.
6-2-1
6-2-2

6.2.2 OUTLET POSITION INSIDE CAB

1) Center of instrument panel

POWER SUPPLY, ACC

POWER SUPPLY, LIGHTNING
STARTER SWITCH ON POWER SUPPLY POWER SUPPLY

B A

KK-GH117
 6-2-3

6.2.3 OUTLET POSITION OF CHASSIS SIDE

FRONT
FRAME SIDE RAIL

SPARE OUTLET (DUMP - UP S/W)

D
No.2 CROSSMEMBER

LAMP SPARE OUTLET

FFC6 CSSPAREOLT

6.2.4 HOW TO TAKE ELECTRICITY FROM POWER SUPPLY CIRCUIT

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

KK-GH117
6-2-4

6.2.5 DETAIL OF CONNECTOR

1) Cab side

CONNECTOR

VEHICLE SIDE COMPANION SIDE

AGM
A

PARTS No. 97840 - 4050 PARTS No. 97830 - 4050

ACC ILL
IOQ IOK 2 1

B GND +B 4 3
IOS IOP

PARTS No. 82580 - 6920 PARTS No. 82580 - 8380

TFC6 CAB CONNECTOR

2) Chassis side

CONNECTOR

VEHICLE SIDE COMPANION SIDE

AGQ 1
C

PARTS No. 82580 - 6570 PARTS No. 82580 - 6580

ON 1
D UEO

PARTS No. 82580 - 4240 PARTS No. 82580 - 4230

TFG6 CSCONNECTOR

KK-GH117
 6-3-1

6.3 ELECTRIC WIRING OF SPARE OUTLET

6.3.1 STANDARD WIRING CONFIGURATION

6.3.2 WIRING CONFIGURATION FOR INCREASED LOAD

Maximum added load is 170W.

6.3.3 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.

KK-GH117
6-3-2

6.3.4 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.
1) Instrument panel

No. DESCRIPTION APPLICATION

1 FR FOG LAMP SWITCH OPT
2 T/M PTO SWITCH OPT
3 -- --
4 H/L LEVELING SWITCH INSTALLATION BY VEHICLE SPECIFICATION
5 RR FOG LAMP SWITCH INSTALLATION BY VEHICLE SPECIFICATION
6 PARK LAMP SWITCH INSTALLATION BY VEHICLE SPECIFICATION
7 -- --
8 -- --
9 HI/LO SWITCH INSTALLATION BY VEHICLE SPECIFICATION
10 2WD/4WD SWITCH OR DIFF. LOCK SWITCH INSTALLATION BY VEHICLE SPECIFICATION
11 IDLE VOLUME SWITCH OPT
12 CIGARETTE LIGHTER OPT
13 ES START SWITCH INSTALLATION BY VEHICLE SPECIFICATION
14 -- --
15 CONVENIENCE HOOK STD

KK-GH117
 6-3-3

2) Floor console

16 17

No. DESCRIPTION APPLICATION

16 POWER MIRROR STAY SWITCH INSTALLATION BY VEHICLE SPECIFICATION
17 FLUORESCENT LIGHT SWITCH INSTALLATION BY VEHICLE SPECIFICATION
-- --
-- --

KK-GH117
6-4-1

6.4 PRECAUTION FOR INSTALLING WIRES, etc.,TO CAB

6.4.1 USING THE THROUGH HOLES FOR PIPING AND HARNESS FOR
FITTING THE FLOOR
When using the through holes for piping and for harness for fitting the
floor.
At the front part of the floor panel through holes are provided for fitting
harnesses or cables.
When mounting the body, remove the plug holes and then carry out wiring
after removing the plug holes and using the harness grommets.

FLOOR

VEHICLE'S FRONT

THROUGH HOLES
2 – ø30
FFC6 FPHOLE

KK-GH117
 6-4-2

6.4.2 USING THROUGH HOLES FOR BACK PANEL WIRING

When using through holes for back panel wiring, to secure the rust
prevention and water proof before the said taken-in, carry out fitting and
wiring according to the following instructions.
1) 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.
2) 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.
3) It is prohibited to fix the wiring with a tapping screw etc., because this can
be a cause of penetration of rust.

KK-GH117
 6-5

6.5 REAR COMBINATION LAMP

When chassis with cab are shipped, the rear combination lamp assembly is
temporarily installed onto the end of the frame.
Therefore, when installing it regularly, attach the combination lamp assembly
directly such that the tail lamp (red) is inside and the direction indicator 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.

KK-GH117
 6-6

6.6 OTHER LAMPS

6.6.1 BACK-UP LAMP

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˚
• Above drawing shows right side lamp, left
side lamp is symmetry shape.

6.6.2 LICENSE PLATE LAMP

KK-GH117
 6-7

6.7 BACK-UP BUZZER (OPTION EQUIPMENT)

If you move or install the back-up buzzer, or modify the surrounding parts of
the chassis, observe the precautions as followings.
6.7.1 INSTALLATION ANGLE
1) Must be kept the permissible range of installing angles shown in the figure
below.
2) If the installing angle is not within range, water will accumulate inside the
buzzer and may lead to failure.

Unit : mm

6.7.2 POSITION
Install the back-up buzzer in a position where it is not exposed to splashing
with muddy water, stone or water.

6.7.3 PRECAUTION FOR PAINTING

Make sure that the buzzer should be covered during painting to protect the
paint coming into buzzer from sound emitting hole for avoiding failure of no
sound.

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 6-8

6.8 ELECTRICAL WIRING DIAGRAMS

This manual does not contain electrical wiring diagrams.
The electrical wiring diagrams are in the WORKSHOP MANUAL.
For more details, please consult your nearest HINO sales outlet.

KK-GH117
 7. PAINTING

7. 1 GENERAL PRECAUTIONS FOR PAINTING •••••••••••••• 7 - 1

7. 2 NOTE ON THE TOP COAT OF PAINT •••••••••••••••••••••••• 7 - 2
7. 3 HOW TO REMOVE THE PARTS OF CAB •••••••••••••••••• 7 - 3
7. 4 MOUNTING AND STICKING OF WEATHER STRIP•••• 7 - 4
7. 5 HANDLING OF COMPUTERS(ECU) •••••••••••••••••••••••••• 7 - 5
7. 6 PROCEDURE FOR ADHERING ORNAMENTS •••••••••• 7 - 6
7. 7 CAUTIONS FOR PAINTING TIRE DISC WHEELS •••••• 7 - 7
7. 8 PRECAUTIONS FOR FITTING AND STORING
THE CAUTION PLATE •••••••••••••••••••••••••••••••••••••••• 7 - 8

KK-GH117
7. PAINTING 7-1-1

7.1 GENERAL PRECAUTIONS FOR PAINTING

When you apply finish paint to the cab etc. observe the following precautions.
Some parts of the cab and chassis are sensitive to heat of the drying; some
parts must not be painted and so require masking, etc.
7.1.1 GENERAL PRECAUTIONS FOR PAINTING
1) Parts to be masked:
Parts that must not be painted-ornaments, name plates (model names,
chassis number), caution plate, etc. must all be masked. (It is possible to
take off the top mark.)
Never paint the rubber hoses or valves, the brake booster, or hoses or
valves of the brake fluid reservoir.
2) If you get paint on the cab compartment, wipe it clean with gasoline.
Never use thinner.
3) 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.
4) Cover the battery, wiring connections and hoses to protect them from
paint.
5) When clean inside of the cab,must be clean it with a neutral detergent.
Never use gasoline and paint thinner.
6) 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”.

7.1.2 GENERAL PRECAUTIONS FOR FORCED DRYING

1) 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.
2) 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.
3) When removing off a air-cleaner assy, seal completely the inlet port side
of engine to prevent any penetration of dirt, paint or etc.

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7-1-2

4) 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

[NOTE]
When drying with heated air more than 80°C these parts described above must be
removed.

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 7-2

7.2 NOTE ON THE TOP COAT OF PAINT

7.2.1 NOTE ON THE TOP COAT OF PAINT
1) 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.

SANDING (BAD SANDING) (GOOD SANDING)

Imperfectly sanded Evenly sanded

Coated film Coated film

FFC7 SANDING

2) 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.
3) How to install weather strips
If door weather strips have been removed when painting the cab, remount
them according to the following procedure, item 7.4.
Be very careful not to make mistake in deciding the mounting procedure to
avoid an eventual cause of rain drop leakage.

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7-3-1

7.3 HOW TO REMOVE THE PARTS OF CAB

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

2) Top mark
Loose the bolts (4 pieces) from back side of radiator grille.

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 7-3-2

3) Front panel

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7-3-3

7.3.2 HOW TO REMOVE THE VENTILATOR

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

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 7-3-4

7.3.3 REMOUNTING THE DISMOUNTED MIRROR STAY

1) When remounting the dismounted mirror stay, mount it after the paint has
completely hardened.
2) When tightening the mirror stay, be careful not to scratch the painted
surface.
3) 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.
4) When remounting the dismounted stay adjust the tightening torques
referring to the figure shown below.

FLAT MIRROR

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7-3-5

CONVEX MIRROR

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 7-3-6

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7-3-7

7.3.4 REMOUNTING THE WIPER

1) When dismounting and remounting the wiper, confirm before the
remounting, that the wiper stays at the automatic stop position.
(After turning ON the wiper motor switch to motor, turn OFF the wiper
switch and the motor stops at the automatic stop position.)

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

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

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 7-3-8

[NOTE]
The set positions of the blades show the gaps at the top ends of the blades.

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7-4-1

7.4 MOUNTING AND STICKING OF WEATHER STRIP

7.4.1 MOUNTING AND STICKING OF WEATHER STRIP
1) Match the marks A and B on body side and the marks on the weather strip
and start mounting from this point.
2) Mounting of weather strips on general positions
Mount the weather strips on general positions after having finished
mounting of parts A and B and stick them in such a way that the slack of
the weather strips concentrate on corners of the part A and of the part 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

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 7-4-2

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 7-5

7.5 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.

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 7-6-1

7.6 PROCEDURE FOR ADHERING ORNAMENTS

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

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7-6-2

[NOTE]
Example for FC series.

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 7-7

7.7 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 hub, the brake drum and hub nuts.
Refer to the illustration below concerning the covering portions.

2) After mounting the tire disc wheel onto the vehicle, paint the remained
portions with same color paint as thin as possible. Because these
surfaces are fitting surfaces with rotating tire.
If the painting layer is thick, it causes hub 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 membrane is excessively
thick, this may lead to the loosening of the hub 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
hub 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 membrane
may lead to the loosening of hub nuts.

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 7-8

7.8 PRECAUTIONS FOR FITTING AND STORING THE CAUTION

PLATE
1) 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.
2) 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.
3) Other precautions for the caution plate
a. As the caution plate is made from vinyl chloride, it is thin, soft and
easily extensible.
Therefore, take utmost care for handling it.
b. When removing the caution plate, etc., be careful not to damage the
painted surface with a sharp knife, etc.
On the other hand, removal of the caution plate can be done more
easily by pulling the caution plate in perpendicular direction to the
sticking surface while heating it with a hair dryer.
c. Do not throw the caution plates away but keep them together to
compare with new caution plates and to prevent mixing up with the
new ones.

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 8. CHASSIS DRAWINGS

8. 1 CAB DRAWINGS •••••••••••••••••••••••••••••••••••••••••••••••••••••• 8 - 1

8. 2 CAB BACK DRAWINGS •••••••••••••••••••••••••••••••••••••••••• 8 - 2
8. 3 CHASSIS DRAWINGS •••••••••••••••••••••••••••••••••••••••••••••• 8 - 3
8. 4 CHASSIS FRAME DRAWINGS •••••••••••••••••••••••••••••••••• 8 - 4

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8. CHASSIS DRAWINGS 8-1-1

8.1 CAB DRAWINGS

8.1.1 MODEL ( For all models )
1) Front

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8-1-2

2) Rear
Unit : mm

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 8-2-1

8.2 CAB BACK DRAWINGS

8.2.1 Model ( For all models )
1) Left view
Unit : mm

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8-2-2

2) Upper view
Unit : mm

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 8-3-1
8.3 CHASSIS DRAWINGS
8.3.1 GH1JGUD Scale : 1/40
Unit : mm

NOTE : 1.Figures marked " "dimensions are measured

in parallel with the surface of the ground.
2.The dimension of tire to be mentioned in above
table shows design figure according to JATMA
or ETRTO standard.

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 8-3-2

8.3.2 GH1JMUA Scale : 1/40

Unit : mm

NOTE : 1.Figures marked " "dimensions are measured

in parallel with the surface of the ground.
2.The dimension of tire to be mentioned in above
table shows design figure according to JATMA
or ETRTO standard.

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 8-4-1
8.4 CHASSIS FRAME DRAWINGS
8.4.1 GH1JGUD Scale : 1/40
1) Detail of the chassis frame Unit : mm

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 8-4-2

Scale : 1/20
2) Detail of the cross member Unit : mm

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 8-4-3

8.4.2 GH1JMUA Scale : 1/40

1) Detail of the chassis frame Unit : mm

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 8-4-4

Scale : 1/20
2) Detail of the cross member Unit : mm

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 9. MOUNTING OF
CHASSIS EQUIPMENT

9. 1 FUEL TANK •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 1

9. 2 BATTERY •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 2
9. 3 AIR TANK & AIR BOOSTER •••••••••••••••••••••••••••••••••••• 9 - 3
9. 4 EXHAUST SYSTEM •••••••••••••••••••••••••••••••••••••••••••••••• 9 - 4

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9. MOUNTING OF CHASSIS EQUIPMENT 9-1-1

9.1 FUEL TANK

9.1.1 MODEL
For all models
1) Capacity : 200L
Unit : mm

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9-1-2

9.1.2 MODEL
GH1JMUA
1) Capacity : 400L (OPTION EQUIPMENT)
Unit : mm

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 9-2-1

9.2 BATTERY
9.2.1 MODEL
For all models
1) Capacity : 234kC {65Ah}
Unit : mm

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9-2-2

9.2.2 MODEL
For all models
1) Capacity : 432kC {120Ah} (OPTION EQUIPMENT)
Unit : mm

DISASSEMBLY SPACE OF
BATTERY COVER
23
TO No.2 CROSSMENBER

50

60
DATUM LINE 695.5

50
430
394

321

70 140
562.5 295
380.5
4.5
21

VEHICLE'S
FRONT
281.5

537.5

DFG9 BT432kC1AU

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 9-3-1

9.3 AIR TANK & AIR BOOSTER

9.3.1 MODEL
For all models
1) Standard equipment
Unit : mm

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9-3-2

2) Option equipment
Unit : mm

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 9-4-1
9.4 EXHAUST SYSTEM
9.4.1 MODEL Scale : 1/20
For all models Unit : mm
1) Standard equipment

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 9-4-2

Scale : 1/20
Unit : mm
2) Option equipment

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 10. OTHER

10. 1 BRAKE PIPING DIAGRAM •••••••••••••••••••••••••••••••••••••• 10 - 1

10. 2 LICENSE PLATE BRACKET •••••••••••••••••••••••••••••••••••• 10 - 2

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10. OTHER 10 - 1

10.1 BRAKE PIPING DIAGRAM

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10 - 2

10.2 LICENSE PLATE BRACKET

Unit : mm

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