KC-AA014A Common All Buss

KC-AA014A
Body Mounting Manual
COMMON to all Hino

Bus Models
No part of this manual may be reproduced or transmitted in any form without the express written permission of Hino Motors, Ltd.
2009,
All rights reserved. Printed in Japan.
PRODUCT PLANNING DIVISION

3-1-1, HINO-DAI, HINO-SHI, TOKYO, 191-8660 JAPAN
Telephone
042-586-5249
Facsimile
042-586-5868
2009 - 07
KC-AA014A
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 bus chassis for mounting of bodies and modification.
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 bus chassis (hereinafter collectively referred to as Hino Chassis), or
modify or alter a Hino Chassis.
Important
This manual contains the instructions commonly applicable to all Hino bus models.
Peculiar instructions such as chassis layout drawings, chassis mass, precautions, etc.
for each model, are given separately in the peculiar body mounting manuals for each
vehicle model (hereinafter collectively referred to as the "Manual for each model").
Therefore this manual should be used together with the Manual for each model series.
(Details of construction of Hino's Body Mounting Manual are mentioned at the last part
of this chapter.)
The Manuals for each model is available at authorized Hino distributor.

For more information on mounting bodies and equipment or on chassis modifications,
refer to the appropriate workshop manuals, parts catalog, 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.
KC-AA014A
ABOUT THIS MANUAL

Warning
It is the responsibility of the body and equipment manufacturer or the modification company, 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 which has been installed,
modified, or altered by Body and Equipment Manufacturers.
This manual does not affect that the ultimate responsibility for the manufacture and
mounting of the body, installation, modification, or alteration on a Hino Chassis
devolves upon the Body and Equipment Manufacture.
Each individual Body and Equipment Manufacture 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.
KC-AA014A
ABOUT THIS MANUAL
CONSTRUCTION OF HINO
BODY MOUNTING MANUALS
KC-AA014A
COMMON TO ALL HINO BUSES

BODY MOUNTING
Body Mounting Manual
COMMON to all Hino

Bus Models
This manual contains the basic common instructions to apply to all Hino
bus models for installation, mounting,
modification, or alteration.
MODEL SERIES
BODY MOUNTING MANUAL
KK-RM201
This manual contains the peculiar

chassis specifications and data for
each model.
BODY MOUNTING
MANUAL
BUS
CHASSIS
MODEL
RM1E SERIES
KC-AA014A
CONTENTS
1. GENERAL PRECAUTIONS
2. EQUIPMENT INSTALLATION PROCEDURES
3. PRECAUTION WHEN APPLYING THE FINAL
COAT OF PAINT
4. BUS BODY
KC-AA014A
Chapter 1
GENERAL PRECAUTIONS
1. BODY DESIGN AND CONSTRUCTION 2

2. NEVER MODIFY SAFETY PARTS 14
3. CLEARANCES 18
4. FITTING THE BODY 22
KC-AA014A
GENERAL PRECAUTIONS
This section describes general precautions that must be taken when
mounting a bus body or equipment or when making modifications to
the chassis.
Improper mounting of a bus body or equipment or improper modifications may cause unforeseen faults in the vehicle and lead to serious accidents.
If you intend to mount a bus body or equipment, or make modifications to the chassis of a HINO vehicle, be sure to observe the precautions described in this section.
KC-AA014A
GENERAL PRECAUTIONS
1. BODY DESIGN AND CONSTRUCTION

ENSURING TOTAL VEHICLE QUALITY
The final quality of a vehicle depends not only on the chassis manufacturer but also on
the body builder. Accordingly, body builders should pay attention to the following
aspects of body design and construction:
QUALITY
ITEMS TO BE CONSIDERED
GVM CAPACITY
SPECIFICATIONS
GAM CAPACITY
MOUNTED BODY
(CITY OR INTER CITY USE & ETC.)
BODY DIMENSIONS
OPERATION OF EACH SYSTEM
FUNCTIONS
AIR INTAKE
COOLING
MASS DISTRIBUTION
HEIGHT OF CENTER OF GRAVITY OF VEHICLE
STABILITY
BODY DIMENSIONS
BODY MOUNTING METHOD
DESIGN OF BODY
GVM CAPACITY
GAM CAPACITY
STIFFNESS
CHASSIS MODIFICATIONS
INTERIOR NOISE
COMFORT OF
RIDE
HEAT INSULATION
EASE OF
MAINTENANCE
SAFETY
ACCESSIBILITY
INSPECTION LIDS
FIRE PREVENTION
KC-AA014A
GENERAL PRECAUTIONS
Mass and Dimensions
When designing or constructing a body, make sure that:
the total mass of the vehicle is within the permissible axle or gross axle mass rating
capacity, tire capacity and gross vehicle mass capacity,
the front axle load satisfies the minimum ratio of gross vehicle mass,
the height of the center of gravity from the ground after body mounting is within the specified limit,
the vehicle mass is evenly distributed between left and right wheels,
the overall width of the vehicle is within the specified limit, and
the dimensions and mass of the vehicle comply with local regulations.
The specified values for the above items are given under 1. Vehicle summary
Chassis Specifications & 2. General Precautions Weight Distribution on Front Axle,
Body Max. Width & Height of Center of Gravity in the Hino body mounting manual for
the respective model series.
Example:
VEHICLE SUMMARY (CHASSIS SPECIFICATIONS)
Chassis Model
Item
Wheelbase
(mm)
Front
Tread
RM2KSKA
6,000
2,025
(mm)
Rear
Max. GVM. capacity

Allowable axle
capacity
(kg)
Chassis mass
(On std. spec. without
space tire)
(kg)
Engine
(According to JIS Gross)
1,820
(kg)
16,000 (15,100 Legal limit)
Front
6,000
Rear
11,000 (9,100 Legal limit)
Total
6,160
Front
935
Rear
5,225
Model
K13D
Max. output
kw (ps) at r/min
191 (260) / 2,150
Max. Torque N m
(kgf m) at r/min
883 (90) / 1,400
Height of gravity from ground
(m)
0.80
Tire
STD: 11.00-20-14PR
OPT: 10.00-20-14PR OR 16PR,
10.00R20-16PR
OPT: 11R22.5-16PR, 11.0-20-16PR
OPT: 11.00R20-14PR OR 16PR.
12R22.5-14PR
Disc
STD: 20 x 7.50V-offset 165mm

OPT: 22.5 x 8.25-offset 165mm
Tire and disc
Fuel tank
(L)
Battery
V-KC (A h)-No.
Generator
V-A
STD: 250 / OPT: 350

STD: 12-540 (150) -2
OPT: 12-720 (200) -2
STD: 24 - 140
OPT: 24 - 70
OPT: 24 - 210
NOTE
Allowable axle and GVM. capacity listed above table must not be exceeded.
Both front 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 lopsided mass distribution between left and right wheels should be avoided.
KC-AA014A
GENERAL PRECAUTIONS
GENERAL PRECAUTIONS
WEIGHT DISTRIBUTION ON FRONT AXLE, MAX. BODY WIDTH & HEIGHT
OF CENTER OF GRAVITY
When mounting the body, you must observe the following standards to prevent rollover
and spring failures.
EXAMPLE:
M a s s d i s t r i b u t i o n Height of
on front axle
gravitational
(Fr / VM or GVM) center (m)
Engine
location
Model
Rear
More than 28%

RM2KSKA (Unladen and
Laden)
Less than
1.29
(Unladen)
Recommended
body maximum
width (m)
Less than 2.5
NOTE
Hino cannot guarantee against field trouble or take countermeasures if
the specifications of the completed vehicle with body mounted exceed
the above standards.
If a wide body is needed for special purposes, it is essential that limits on
weight distribution and height of the center of gravity are strictly
observed.
The height of the center of gravity is calculated as follows.
EXAMPLE:
Mass
(kg)
Height of
gravitational
center (m)
Chassis
6,160
0.800
4,928
Body
3,800
1.970
7,846
495
1.700
Seats
Total
(Unladen)
10,455
Moment
(k m)
From HINO
Refer Chassis
specification
Page 1-3
841.5
13,255.5
The height of
Moments
13,255.5
= = = 1.26 < 1.29
gravitational center
Vehicle mass
10,455
KC-AA014A
GENERAL PRECAUTIONS
Formulae for Calculation
When calculating
gross vehicle mass, and
height of center of gravity from ground for chassis with body mounted,
use the formulae described in this section.
Gross Vehicle Mass (GVM)

The meaning of gross vehicle mass (GVM) is described below.
Chassis Mass
Body Mass
Vehicle Mass
Crew, Passengers and Other Load (baggage and cargo)
Gross Vehicle Mass (GVM)

01-001
KC-AA014A
1
Basic Formulae for Mass Distribution
The distribution of mass on front and rear axles is calculated as follows:
For one unit of load

W
Wr
Wf
L1
WB
01-002
Wf =
W x L1
WB
Wr = W Wf
Para mltiples unidades de carga

W3
W2
W1
W4
r
Wr
Wf
L1
L4
L2
L3
WB
01-003
(W1 x L1) + (W2 x L2) + (W3 x L3) (W4 x L4)

Wf =
WB
Wr = (W1 + W2 + W3 + W4) Wf
KC-AA014A
GENERAL PRECAUTIONS
Calculation of Gross Vehicle Mass
The details of each factor used in calculating GVM are as follows:
CHASSIS MASS
Wfc
.Wfc and Wrc are given under 1

Vehicle Summary
Chassis Specification in the body
mounting manual for the respective
model series.
Wrc
WB
01-004
BODY MASS
L1
L5
Construction
L2
W2
L6
L4
L3
W3
W6
W1
Wfb
WB
W4
W5
Wrb
01-005
Mass (W)
Front const.
W1
L1
Roof const.
W2
L2
Side const.
W3
L3
Floor const.
W4
L4
Rear const.
W5
L5
Seats
W6
L6
Calculate Wfb and Wrb using the basic

formulae for mass distribution.
PASSENGERS AND CREW MASS
Lc
Lp
Load
Mass (kg)
L (m)
Crew
Wc
Lc
Passengers
Wp
Lp
+ WB
Calculate Wfp and WRP using the basic

formulae for mass distribution.
Wp
Wc
Wfp
Wrp
WB
01-006
KC-AA014A
GENERAL PRECAUTIONS
Example:
2490
Calculating mass distribution for a Model AK3HMKA front engine bus (wheelbases 5,000
mm)
3180
80
1960
5000
2840
100
9980
01-007
Calculation of Gross Vehicle Mass and Gross Axle Mass
Wfc
Item
Total
Front
Rear
Chassis
4145
(Wfc)
2390
(Wrc)
1755
Body
3500
(Wfb)
1435
(Wrb)
2065
Vehicle Mass
7645
3825
3820
2640+65
=2705
(Wfp)
565+75
=640
(Wrp)
2075+-10
=2065
Gross Vehicle
Mass
(GVM)
10350
(Wf)
4465
(Wr)
5885
GVMR and axle

capacity
12500
5500
8500
5000
9200
Wrc
Passengers and
crew
Wfb
Wrb
Tire capacity
(9.00 - 20 - 14PR)
Wfp
Wrp
01-008
Mass distribution on front axle

Wf x 100 = 4465 x 100 = 43.1 > 28%
PBV
10350
*This value should be greater bigger than of the basic value.
KC-AA014A
GENERAL PRECAUTIONS
Height of Center of Gravity from Ground
A High Center of Gravity Causes Poor Steerability
The height from the ground of the vehicles center of gravity has a major impact on the
steering and handling of the vehicle. Therefore on safety during running, make sure
that the height of the center of gravity does not exceed the specified limit.
The specified limit on the height of center of gravity represents the maximum height of
center of gravity that will assure a turn-over angle of 35 when the vehicle is unloaded.
(For the maximum height of center of gravity from ground for each model when a body
is mounted, see the Body Mounting Manual for the respective model series.)
Height of center
of gravity
Height of center
of gravity
01-009
GOOD STEERABILITY
POOR STEERABILITY
Calculation
Calculate height of center of gravity as follows:
HC HB
HD
L : Body mass offset (m)

HB: Height of center of gravity of
body from upper surface of
chassis frame (m)
HC:Ground height of upper surface
of chassis frame at body mass
offset point (m)
HD:Height of center of gravity of
body from ground (m)
WB
01-010
NOTE
The vehicle which is adopted the leaf spring suspension, ground height
of upper surface of chassis frame, marked HC, must be considered the
deflection value of the leaf spring due to weight of the mounted body.
KC-AA014A
GENERAL PRECAUTIONS
Calculate body mass offset (L) in meters.
Wf x WB
Wr
= L (m)
Total mass of body
Wf
HR
HD
HC HB
HF
WB
01-011
Calculate height of center of gravity of body from upper surface of chassis frame (HB).
Calculate HB in meters according to the following example:
Roof const.
H2
W2
Side const.
Front const.
Rear const.
H6
Floor const.
Seat
W5
HB
W1
W4
H3
H4
H1
W3
H5
W6
Chassis frame
01-012
Construction
Mass (W)
(kg)
Height (H)
(m)
Moment (W x H)
(kg m)
Front const.
330
0.5
165.0
Roof const.
440
2.05
902.0
Side const.
1190
0.5
595.0
Rear const.
280
0.5
140.0
Floor const.
885
0.01
Seat
375
0.4
Total
(A) 3500
HB =
0.560
8.85
150.0
(B) 1960.85
(B)
1960.85
=
= 0.560 (m)
(A)
3500
KC-AA014A
10
GENERAL PRECAUTIONS
Calculate ground height of upper surface of chassis frame (HC) at body mass offset point
in meters.
HR {(HR HF) x
L
} = HC (m)
WC
HR
HD
HC HB
HF
WB
01-013
Calculate height of center of gravity of body from ground (HD) in meters.
HB + HC = HD (m)
WB
HR
HB
HC
HF
HD
01-014
Finally, make sure that the height of the center of gravity of the vehicle does not exceed
the specified limit height of center of gravity from ground at the vehicle mass that is
shown in the Body Mounting Manual.
HD (m) < limit specified in Body Mounting Manual
If the height exceeds the specified limit, you must take steps to reduce the height and
bring it within the limits specified in the Body Mounting Manual for the respective model
series by modifying body design or other means.
KC-AA014A
11
GENERAL PRECAUTIONS
Example:
Height of center of gravity on model AK3HMKA with body
2040 (L)
HC
HD
HB
1005*
(HR)
945*
(HF)
5000 (WB)
01-015
Dimensions marked * are indicated in the model series Body Mounting Manual.
HC
= HR {(HR HF) x L/WB}
HD
= HB + HC
HC
= 1005 {(1005 945) x 2040/5000}
HD
= 0.560 + 0.980
= 980 (mm) = 0.980 (m)
= 1.540
Height of center of gravity

from ground (H) (m)
Mass
(W) (kg)
Chassis
0.92
4145
3813.4
Body
(HD)
1.540
3500
5390
Total
H = 1.204
7645 (A)
H=
Moment
(H x W) (kg m)
9203.4 (B)
(B)
9203.4
= 1.204 < * 1.23 (m)
=
(A)
7645
Value marked * is indicated under 1. Vehicle Summary - Chassis Specifications in the

model series Body Mounting Manual.
KC-AA014A
12
GENERAL PRECAUTIONS
Body Dimensions
It is the responsibility of the body and equipment manufacturer to ensure that the dimensions of the completed vehicle conform to the regulations of the country in which the
vehicle is to be operated.
When designed a body, in addition to observing the maximum height for the center of
gravity of the completed vehicle, you should also observe the maximum body width specified under 1. Vehicle Summary - Chassis Specifications in the body mounting manual
for the model series.
Body Dimensions (Maximum width)
OVERALL WIDTH
OVERALL HEIGHT
100
ROH
9.00-20-14PR
WB
OVERALL LENGTH
9.00-20-14PR
1960
80
01-016
KC-AA014A
13
GENERAL PRECAUTIONS
2. NEVER MODIFY SAFETY PARTS

Never modify and never heat safety parts relating to the front axle, steering system or
brake booster device, etc. Modifying or heating these parts may affect their strength and
is highly dangerous.
The parts of the chassis relating to the body mounting which must not be modified are as
shown in the figures below.
Front Axle
STOPPER BOLT
AXLE BEAM
KNUCKLE
OUTER
TURN
INNER
TURN
01-017
TIE ROD ARM
TIE ROD
Under view of truck showing

front axle and suspension for
example.
KINGPIN
LOCK BOLT
KINGPIN BUSHING
THRUST WASHER
FRONT WHEEL HUB
KNUCKLE ARM
CASTER SHIM
HUB BOLT
TIE ROD SOCKET

THRUST BALL BEARING
01-018
Sectional views of front axle
KC-AA014A
14
GENERAL PRECAUTIONS
Steering system
A
STEERING
WHEEL
STEERING
SHAFT
UNIVERSAL
JOINT
SLIDING
YOKE
SLIDING
SHAFT
UNIVERSAL
JOINT
GEAR
BOX
C
PITMAN ARM
DRAG LINK
01-019
Brake booster
1.
2.
3.
4.
5.
6.
7.
8.
9.
Power cylinder
Power piston
Return spring
Push rod
Seal
Oil seal
End cover
Valve
Hydraulic piston assembly
10.
11.
12.
13.
14.
15.
16.
17.
Hydraulic cylinder
Air bleeder
Cylinder plug
Check valve
Pin
Plunger
Stroke warning switch
Return spring (if so
equipped)
A. From and To brake valve

B. From reservoir
C. To wheel cylinder
POWER BOOSTER ASSY

01-020
KC-AA014A
15
GENERAL PRECAUTIONS
Suspensions
MULTI-LEAF SPRING
SPRING
BRACKET
U-BOLT
SHACKLE
SHACKLE PIN
SPRING
BRACKET
SPRING ASSY
(NO. 1 & NO. 2)
SPRING PIN
01-021
AIR SPRING
STABILIZER BAR
AIR PIPE
AIR SPRING COVER

TORQUE ROD
TURNBUCKLE
SUPPORT BEAM
SHOCK ABSORBER
AIR SPRING
01-022
KC-AA014A
16
GENERAL PRECAUTIONS
Propeller Shaft
To alter the length of the wheel base it is necessary to modify the propeller shaft.
However, improper modification of the propeller shaft may lead to damage and unusual
noises during driving or even cause serious accidents, and is therefore highly dangerous.
FRONT AND INTER SHAFT
LOCK NUT
YOKE SHAFT
CENTER BEARING ASSY
UNIVERSAL JOINT ASSY
REAR SHAFT
YOKE SHAFT
SLIDING YOKE
KC-AA014A
17
GENERAL PRECAUTIONS
3. CLEARANCES
Clearances Between Chassis Parts and Body or Equipment
To prevent contact with chassis parts that vibrate or rotate during driving, be sure to
allow adequate clearances between chassis parts and the body or equipment. Also be
sure to allow sufficient space to allow easy filling, maintenance and repair work.
Engine, Clutch and transmission Clearance of peripheral parts with the body
Observe the following clearances between the peripheral parts of the engine, clutch and
transmission, and the body.
Minimum clearance
Engine periphery and body
Above and below: min. 40 mm

Right and left:
min. 30 mm
Front and back:
min. 25 mm
Transmission periphery and body
min. 25 mm
Allow minimum clearance.
Body parts
01-023
KC-AA014A
18
GENERAL PRECAUTIONS
Space for removal and refitting of transmission
When removing the clutch and transmission, to extract the clutch spline shaft, it is necessary to pull the transmission assembly backwards approximately 200 mm in the line of
the engine. Make sure you allow enough space for this work.
Allow space for

removal and refitting
of the transmission.
01-024
Propeller Shaft
The clearance between the propeller shaft (including joints) and the body (body equipment such as cooler unit and other body parts, etc.) must be at least 50 mm from the limit
of displacement of the propeller shaft (above, below, left, right, front or back of the axle).
Allow 50 mm clearance from limit of
displacement (above, below, left, right,
front, or back).
UPPER LIMIT
UNIVERSAL
JOINT
LOWER LIMIT
PROPELLER
SHAFT
01-025
KC-AA014A
19
GENERAL PRECAUTIONS
Rear Axle
Clearance when metal contacting
The clearance between the rear axle (including the brake hose which is located on the
rear axle) and the body must be at least 50 mm from the limit of displacement of the rear
axle (above, below, left, right, front or back), so that the axle does not touch the body nor
even contact the rubber bumper.
* For details of range of axle movement, see the Body Mounting Manual for the respective model series.
01-026
Springs
Clearance from end of spring
During driving, the spring end (shackle) moves rearward. When mounting the body, do
not position any part of the body inside the area marked A in the diagram.
* For details of measurements of area A, see the Body Mounting Manual for the respective model series.
Front axle
center line
Do not mount any part of the body inside this area.
KC-AA014A
01-027
20
GENERAL PRECAUTIONS
Brake & Air hose or Pipes
Strictly observe the minimum clearances between the brake & air hose or pipes and the
body or equipment. If the hoses or pipes are allowed to come into contact with the body
or equipment they will quickly become damaged and this may lead to serious accidents.
For details of minimum clearances, see 6. BRAKE/HYDRAULIC PIPING.
Electrical Wiring
Strictly observe the minimum clearance between electrical wiring and the body or equipment. If electrical wiring is allowed to come into contract with the body or equipment it
will quickly become damaged and this may lead to serious accidents such as fire.
For details of minimum clearances, see 7. ELECTRICAL SYSTEM.
Exhaust Muffler & Tail Pipe

Strictly observe the minimum clearance between the exhaust muffler or tail pipe and the
body or equipment. If the exhaust muffler or tail pipe are allowed to come into contact
with the body or equipment this may lead to serious accidents such as fire.
For details of minimum clearance, see 4. EXHAUST SYSTEM.
KC-AA014A
21
GENERAL PRECAUTIONS
4. FITTING THE BODY

Basic Point
The strength of the Hino bus chassis frame has been determined on the premise that a
normal bus type of body will be installed on it. Integrated construction of body and frame
has been made a basic principle. Body design should be carried out in full recognition of
the fact that, looking at the bus as a whole, the frame only bears part of the load received
by the vehicle. The rigidity of the frame has been designed to a level where it is possible
for it to be self-propelled with only the chassis.
However, take good care not to run the bus on bad roads such as unpaved roads so as
not to place excessive loads on it.
Approached and Departure Angles

When installing fittings in relatively low positions in the front or rear overhang. The
approach and departure angles should be at least equal to those of the chassis.
If you must mount body components or equipment that will project below the line of these
angles, be sure to allow for operating conditions when deciding the ground height of
these components.
[FRONT ENGINE VEHICLE]
Approach angle
Departure angle
[REAR ENGINE VEHICLE]
Approach angle
Departure angle
01-028
KC-AA014A
22
GENERAL PRECAUTIONS
Keeping the Chassis Frame Level
When fitting the bus body, avoid stress that may cause damage to the frame and other
structural chassis parts.
Always check that the chassis frame is level and ensure that it remains level during body
mounting.
Paved horizontal plane

01-029
JACK OR ADJUSTABLE STAND
Paved horizontal plane
JACK OR ADJUSTABLE STAND
KC-AA014A
01-030
23
GENERAL PRECAUTIONS
Points to Note on Electrical Welding
Electrical components such as the alternator and tachograph are directly connected to
the battery and one end is grounded to the chassis frame. Under these conditions, welding current will flow back along the ground circuit if electric welding is carried out and
damage may be caused to the alternator, tachograph, electrical components, etc.
Always take the following precautions during welding.
Disconnect the ground terminal of the battery from the frame fitment and ground the
welding equipment securely to the frame itself. (Do not ground the welding equipment to
such things as the tire rims, brake pipes or fuel pipes.)
Procedure before Welding
Turn the starter switch off.
Disconnect the batterys negative terminal.
Disconnect each of the electronic instruments.
Ground welding equipment securely, near to the area to be welded.
Computer
Alternator,
etc.
Computer for
Engine control
Transmission control
ABS & etc.
Battery
DISCONNECT THE BATTERY & COMPUTER
GROUND AT THE SIDE
FRAME SIDE.
DISCONNECT
THE ALTERNATOR
GROUND
Side frame
Welding rod
Arc welding
machine
CONNECT THE GROUND OF

THE ARC WELDING MACHINE
NEAR THE PLACE ON THE
FRAME TO BE WELDED.
BUT NOT CONNECT IT TO
PLATED PARTS SUCH AS FUEL
PIPES AND BRAKE PIPES.
01-031
Important: Broken line ( ) show the current flow if the ground

connector is connected. If the ground connector is
connected in this way, the alternator and other electrical equipment will be seriously damaged.
To protect ancillary equipment from sparks during welding, place fire-resistant covers
over the engine and transmission, instrument panel, steering wheel, hoses or pipes of
brake and fuel system, electrical wiring and tires, etc.
KC-AA014A
24
GENERAL PRECAUTIONS
Inspection Covers & Lids
When building the body structure, remember to position inspection covers & lids so that
no obstruction is caused to the following inspections and maintenance routines.
Checking engine oil, filling and removing oil.
Checking cooling water level, filling and removing water.
Checking transmission oil, filling and removing oil.
Checking differential oil, filling and removing oil.
Checking battery fluid, filling, removing the battery.
Checking fuel gauge sender, fuel feed and return hose of fuel tank.
Draining fuel filter.
Draining air tank.
Removing spare tire and checking that it is securely mounted.
Checking and removing of relay valves, check valves and other valves connected with
the brakes.
i
b
a
c
01-032
a
a
c
f
f
b
f
01-033
NOTE
Details of inspection covers & lids position, size, etc. are shown in
Manual for each model.
KC-AA014A
25
GENERAL PRECAUTIONS
Tire Wheel House & Splash Guards
To protect chassis components (air cleaner, engine, clutch and transmission, air tank,
brake parts, fuel tank, etc.) from water, mud and stones thrown up by the tires, tire wheel
house and splash guards of the appropriate size must be fitted as shown below.
Wheel house
(Front)
A
C
WHEEL HOUSE
Wheel house
(Rear)
SPLASH GUARD
A
COVER
PLATE
C
VIEW A
CHASSIS FRAME
SIDE RAIL
VIEW B
CHASSIS
CENTER
SECTION C-C
01-034
NOTE
Above dimensions are given in the Body Mounting Manual for the
respective model series.
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26
GENERAL PRECAUTIONS
Reducing Interior Noise Levels (The front engine vehicle)
In front engine buses, the noise tends to be greatest near the front seats in the passenger room.
Rubber sealing sheets should therefore be fitted to each part shown below to prevent the
noise of the engine from entering the passenger room.
AT THE OUT-SKIRTS OF
ENGINE HOOD
AROUND THE STEP & DOOR

(PAY ATTENTION TO THE UPPER &
LOWER CLEARANCE.)
AROUND BRAKE COMPONENT PARTS &

PIPING INSPECTION COVER OR LID
AROUND TRANSMISSION
INSPECTION COVER OR LID
01-035
Fire Prevention
Great care must be exercised with electrical components, the fuel system and the
exhaust system to prevent problems that may cause fires.
During body fitting, debris from steel plates may come into contact with electrical fittings
and cause short circuits.
This debris must be completely removed by the time of shipment.
Use a non-combustible or flame-retardant material for body parts that are close to the
exhaust pipe or engine room.
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27
GENERAL PRECAUTIONS
Avoiding Damage to Chassis
When installing the body, be careful not to damage the chassis or interfere with its functions.
For example, do not stand on brake valves, brake pipes and hoses, fuel pipes and
hoses, air or vacuum tanks, battery wiring harness, T/M control rods or cables, and etc.
Allowing for Maintenance of Chassis

When mounting the bus body, it is important to allow for easy removal, inspection and
maintenance of chassis parts (spring pins on leaf springs, radiator, propeller shaft, etc.)
Leaf Additions
Leaves should not be added to leaf springs beyond the number of leaves which have
been prepared as an option as this may lead to snags in the steering system at the front
and unusual propeller shaft noise.
Care of Injury of the Passengers

Take good care that no cut ends of plates or sharp angles project either inside or outside
the passenger room.
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28
GENERAL PRECAUTIONS
Installation of Ancillary Heavy Machinery and Equipment
The layout of ancillary heavy machinery and equipment above and below the floor of the
body must be carefully designed to ensure that the weight distribution respects the maximum capacity of front and rear axles and tires, as specified in the Body Mounting Manual
for the respective model series.
Example:
INSTALLATION OF COOLER UNIT
SPARE TIRE & FUEL TANK MUST ALSO BE

MOVED TO ADJUST WEIGHT DISTRIBUTION.
INSTALL COOLER UNIT

IN REAR OVERHANG.
01-036
INSTALL COOLER UNIT

BEHIND FRONT AXLE.
01-037
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29
GENERAL PRECAUTIONS
Shipment
After installing the body, make sure that there is no body vibration, noise or other abnormalities before shipping the vehicle. (Perform a thorough shipping inspection.)
Brake, steering and suspension systems are all important safety components. If any of
these components have had to be temporarily removed to allow for body installation,
make sure that they are refitted exactly as before and verify their operation before shipping the vehicle. (Be sure to perform a thorough shipping inspection.)
Towing Vehicles
If you must tow a vehicle, be sure to remove the propeller shaft before towing. (This is
not necessary when moving vehicles inside a factory during body mounting.)
Stocking Vehicles
If you must stock vehicles in chassis form, make sure that they are stocked indoors.
If you must stock chassis outdoors, make sure that you cover the instrument panels,
electrical equipment boxes and engine to protect them from rain and dust damage.
Complying with Laws and Regulations

The completed vehicle with body fitted must comply with the vehicle laws and regulations of the country in which it is used and tolerance limits for axle capacity, weight distribution on front axle and height of the center of gravity must not be exceeded.
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30
Chapter 2
EQUIPMENT INSTALLATION PROCEDURES
1. ENGINE 2
2. ENGINE COOLING SYSTEM
(RADIATOR & RELATED PARTS) 15
3. ENGINE AIR INTAKE SYSTEM 26
4. CHASSIS FRAME 39
5. FUEL TANK 55
6. STEERING 65
7. CLUTCH CONTROL SYSTEM 68
8. BRAKE SYSTEM 71
9. PROPELLER SHAFT 93
10. SUSPENSIONS 94
11. EXHAUST SYSTEM 99
12. TIRE 107
13. ELECTRICAL EQUIPMENT AND RELATED
PARTS 116
14. ATTACHMENT OF THE PACKAGED PARTS 147
KC-AA014A

In order to assure the performance of the vehicle once a bus body
has been mounted and the functions of each part of the chassis
equipment, in addition to the General Precautions described in the
Section 1 be sure to observe the procedures described in this section for installing each part of the chassis equipment.
The instructions in this section are confined to the general procedures which are common to all vehicle models.
For more detail, refer to the Body Mounting Manual for the respective
model series.
KC-AA014A
1. ENGINE
The engine is the most important component part of any vehicle.
To ensure that it remains in optimum condition requires regular inspection, maintenance
and repair work.
The engine can be the source of noise and heat which are the most important factor in
passenger comfort.
When mounting a bus body, you should therefore observe the precautions and procedures described in this section and be sure to allow for ease of regular inspection, maintenance and repair work, and prevent engine noise and heat from entering the passenger
room.
KC-AA014A

Important Points of Body Mounting
Installing inspection/maintenance covers and lids
Ensuring that body parts around engine are detachable (to ensure ease of maintenance, mounting and dismounting of engine)
Ensuring sufficient clearance between body parts and engine
Installing an engine hood (front engine vehicles)
Installing an engine bulkhead (rear engine vehicles)
Sealing off engine space from passenger room
Installing heat insulation and noise absorption material under engine hood or bulkhead
KC-AA014A

Details of Important Point of Body Mounting
This section describes in outline the most important points of body mounting.
For details of dimensions, shape and other items particular to each model, see the Body
Mounting Manual for the respective model series.
(Please note that shapes and dimensions in the diagrams of this section are intended
simply as examples.)
ENGINE HOOD
RADIATOR
02-001
ENGINE
Installing an Engine Hood

To prevent engine noise and heat as well as dust and other running noise from entering
the passenger room, fit an engine hood to isolate the engine from the passenger room.
Observe these precautions when fitting the engine hood:
Make sure that the hood is constructed to allow easy mounting and dismounting.
Fit an inspection lid to allow for checking of the engine oil level.
To prevent heat and noise from entering the passenger room, fit an appropriate insulation material on the inside surface of the engine hood.
KC-AA014A

Make sure that the hood is big enough to cover the cooling radiator assembly as well
as the engine.
During running, both the engine and cooling radiator have a natural vibration. Be sure
to allow the specified clearances.
To prevent dust and noise from entering the passenger room, make sure that the joints
and joints of the engine hood are properly sealed.
Make sure that the engine hood does not obstruct inspection and maintenance work in
any way.
FRONT
CONSTRUCTION
(FRONT DASH PANEL)
ENGINE HOOD
(SHOULD BE DETACHABLE CONSTRUCTION AND COVER
TOGETHER WITH COOLING RADIATOR)
FLOOR
CHASSIS CENTER
MAKE SURE TO SEAL BETWEEN

ENGINE HOOD AND FLOOR BY
MEANS OF FITTING THE SEAL RUBBER
02-002
KC-AA014A

Detail of Engine Hood Assembly
Example:
FRONT AXLE
DATUM LINE
CHASSIS
CENTER
UPPER SURFACE
OF CHASSIS
FRAME
02-003
Grab handle
(to facilitate removal)
Inspection cover for

engine oil level
Seal rubber
Seal rubber
Seal rubber
Insulator
(for heat & noise)
02-004
KC-AA014A

Allowing for Ease of Inspection/Maintenance and Repair
Before the engine is lowered into the chassis, remove crossmember No. 1 and place
the engine in the front part of the chassis.
The shaded area of the front part of the body in the drawing below should be of detachable construction.
Any beam or structure of the body under the engine and transmission should also be of
detachable construction.
CHASSIS FRAME
02-005
Parts of body in and under the shaded area must

be of detachable construction.
KC-AA014A

ENGINE
02-006
Installing an Engine Bulkhead

In rear engine vehicles, major components of the chassis such as the engine, transmission and rear axles are concentrated in the rear overhang.
Therefore, to prevent engine noise and heat as well as dust and other running noise from
entering the passenger room and affecting passenger comfort, you should fit an engine
bulkhead of appropriate construction between the engine room and the passenger room.
ENGINE BULKHEAD
TO FRONT
ENGINE ROOM
02-007
Observe the following precautions when installing the engine bulkhead:

Allow sufficient clearance from the engine, radiator and other chassis components.
Fit opening covers to ensure ease of inspection, maintenance and repair work.
To prevent heat and noise from entering the passenger room, fit an appropriate insulation material on the inside surface of the engine bulkhead.
To prevent dust and noise from entering the passenger room, make sure that every
part of the bulkhead (especially the floor inspection lid in the passenger room) is properly sealed.
KC-AA014A

Detail of Engine Bulkhead Structure
Example:
Dimensions of Engine Bulkhead
Dimensions of the engine bulkhead are given in the Body Mounting Manual for the
(Dimensions marked * are example figure.)
BODY
REAR
END
PANEL
(225)
MN. 40
ENGINE BULKHEAD
*
*
(310) (355)
02-008
Allow sufficient clearance from the engine, radiator and

other chassis components.
(The dimensions indicated in the diagram are the minimum dimensions that will ensure
sufficient clearance.
Make sure that the component parts of the engine bulkhead such as the framework and
insulation do not protrude further into the engine room than the dimensions shown.)
KC-AA014A

Insulation under the engine bulkhead
Insulation material such as glass wool should be installed under the engine bulkhead to
insulate against heat and to prevent direct airborne noise generated by engine from
entering the passenger room.
IDetails of the insulation under the engine bulkhead are described in the Body
ENGINE BULKHEAD
A
TO FRONT
REAR
INSPECTION LID
ENGINE ROOM
02-009
FLOORING t = 2.5
WATERPROOF PLAY WOOD t = 12
STEEL PLATE t = 1.2
GLASS WOOL t = 30 (32 kg/m3)
(COVERED WITH ALUMINIUM SEAT)
BULKHEAD
ENGINE
ROOM SIDE
STRUCTURE WITH
INSULATION MATERIAL
CLAMP (INTERVAL
APPOROX. 300 mm)
02-010
Construction of Section A-A (Under the Engine Bulkhead)
KC-AA014A
10

Installing Engine Inspection/Maintenance Covers
Install opening covers as indicated in the drawings to allow for ease of engine inspection,
maintenance and repair work.
When installing the opening covers, fit cushion rubbers and seal rubbers to prevent any
noise (both noise caused by shaking and banging of the covers themselves and engine
noise) from entering the passenger room and escaping from the vehicle.
IDetails of inspection/maintenance covers, such as installation position and dimensions are described in the body mounting manual for the respective model series.
ENGINE ROOM
SIDE OPENING COVER
ENGINE ROOM
FLOOR OPENING COVER
ENGINE ROOM
REAR OPENING
COVER
FRONT
DIFFERENTIAL
FLOOR OPENING
COVER
TRANSMISSION
FLOOR OPENING
COVER
ENGINE ROOM
SIDE PARTITION
OPENING COVER
02-011
KC-AA014A
11

Detail of Inspection/Maintenance Opening Cover Structure
Example:
IDetails are described in the Body Mounting Manual for the respective model series.
Installation of cushion rubbers and seal rubbers
CUSHION OR SEAL RUBBER SHOULD BE

INSTALLED TO THE COVER.
OPENING
COVER FOR
RADIATOR
HEADER TANK
ENGINE ROOM
SIDE OPENING
COVER
ENGINE ROOM
REAR OPENING COVER
02-012
Cushion Rubber
Seal Rubber
BODY OUTER
PANEL
SEAL RUBBER
(INSTALL CIRCUMFERENCE
OF THE OPENING COVER)
INSTALL
MIN. 4 PARTS
R 11
OPENING
COVER
(1.4
)
19
(11)
19 ++ 0.5
1.0
R 7.3
(1.4)
1.5
R 0.5
2
Section A-A
R 0.5
R1
R2
12
02-013
18.5
02-014
Detail of Seal Rubber (Example)

[Type of Seal Rubber]
TOYODA GOSEI T501C non-flammable EPDM or equivalent
KC-AA014A
12

Installation of Engine Noise Insulation Material
ENGINE BULKHEAD
A
TO FRONT
A
REAR
INSPECTION LID
B
ENGINE ROOM
B
Section A-A
02-015
OPENING COVER
FLOOR
WATERPROOF
PLAY WOOD t = 12
0.8
GLASS WOOL
(t = 30, 32 kg/m3)
FLOORING t = 2.5
PUNCHING METAL
SEAL RUBBER
Section B-B
02-016
OPENING
COVER
GLASS
WOOL
4
0.8
PUNCHING METAL
8
02-017
NOTE
Noise insulation material must be fitted to the opening covers of the
engine room as necessary to comply with legislation on external noise.
KC-AA014A
13

Allowing for Ease of Maintenance and Repair
The engine will need to be dismounted for heavy maintenance and major repair work.
The shaded area of the rear part of the body as shown in the drawing below should
therefore be of detachable construction.
Any beams or structures of the body that lie below the engine and transmission should
also be of detachable construction.
Engine Room
Rear Opening
Chassis frame
upper surface
End crossmember
have to be detachable
structure.
Structural elements of the body in and below

the shade area must be of detachable
construction.
KC-AA014A
02-018
14
2. ENGINE COOLING SYSTEM (RADIATOR & RELATED PARTS)

The radiator plays an extremely important role in cooling the engine.
The method of mounting of the bus body around the radiator is very important.
Improper mounting of the body may lead to the engine overheating or other serious
trouble.
Therefore, when mounting a bus body, be sure to observe the following precautions.
RADIATOR
02-019
RADIATOR
02-020
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15

Important Precautions for Body Mounting
Do not alter the mounting position or modify the components themselves of the cooling
system, radiator, header tank and other related parts.
Mounting of radiator relative to body side structure (rear engine buses)
Provide a partition plate or radiator room in front of the radiator to ensure a smooth air
flow to the radiator.
Provide air intake openings on the body front or side panels and ensure that the openings are of the minimum effective size to ensure a sufficient air flow to the radiator.
Completely seal the area between the radiator and
the engine hood or partition plate or radiator room, and
the body front or side panel
to ensure sufficient air flow and prevent any backflow of hot air from the engine room to
the radiator.
Mounting of header tank or reservoir tank relative to body structure
Adjustment of cooling fan idler pulley alignment (offset) with engine crank pulley (rear
engine buses)
Be sure to allow for ease of inspection, maintenance and repair by
allowing for the mounting and dismounting of the radiator,
providing detachable or hinged inspection covers on the body front or side panels and
the partition plate of the engine room,
providing a detachable or hinged inspection over to allow cooling water level inspection
and water filling on the body front or rear panels.
KC-AA014A
16

Details of Important Points of Body Mounting
For details of dimensions, shape and other items particular to each model, see the
Body Mounting Manual for the respective model series.
[GENERAL POINTS]
Do Not Modify or Alter the Engine Cooling System.
The engine cooling system (radiator, header tank, reservoir tank and other related
parts) play an important role in the cooling of the engine.
Modifying the structure of these components or changing their positions may have a
significant impact on engine performance and may lead to the engine overheating, the
engine lifetime shortening, or other serious trouble.
It is therefor essential that you should never modify or alter the engine cooling system
in any way.
Allow for Ease of Inspection, Maintenance and Repair Work.
Fit inspection covers to allow for ease of inspection, maintenance and repair of engine
cooling components and make sure that surrounding body elements are of detachable
construction (e.g. bolt mounted) to allow for removal. Specifically:
Allow for the mounting and dismounting of the radiator.
Provide detachable or hinged inspection covers on the body front or side panels and
the partition plate of the engine room.
Provide a detachable or hinged inspection cover to allow cooling water level inspection
and water filling on the body front or rear panels.
Make sure that body elements around and under the cooling system are of detachable
construction.
KC-AA014A
17

Provision of Air Intake Opening
Provide an air intake opening with a mesh cover on the front panel to assure sufficient
intake of air into the radiator while vehicle is running.
Make sure that the size of the opening conforms to the shown in the drawing below
minimum effective opening area.
The mesh cover of the air intake opening should be of detachable construction to allow
for ease of inspection and maintenance work on the radiator and engine.
Assure the minimum effective opening area.

The dimensions of the opening shown in the
diagram of Body Mounting Manual for the
respective model are a minimum and must
be strictly observed.
AIR INTAKE
OPENING
02-021
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18

Apply Sealing Rubber around the Partition Plate
Securely seal the partition plate with sealing rubber or a similar material around the circumference of the radiator and fit steel plates leading from the body front panel to the
radiator in order to
prevent any backward flow of hot air from the engine room, and
induct a sufficient volume of cooling air.
* BACKWARD FLOW OF
HOT AIR & AIR FLOW
MARKED
MUST
BE AVOIDED.
COOLING
AIR FLOW
BODY FRONT
PANEL
02-022
RADIATOR
ENGINE
HOOD
* SECURELY SEAL CIRCUMFERENCE HATCHED AREA

WITH SEALING RUBBER
OR SIMILAR MATERIAL.
RADIATOR
FLOOR
SURFACE
CHASSIS FRAME
SIDE MEMBER
02-023
ENGINE HOOD
* PROVIDE THE PARTITION

PLATE CIRCUMFERENCE
HATCHED AREA BETWEEN
BODY FRONT PANEL AND
RADIATOR.
BODY FRONT
PANEL
RADIATOR
02-024
KC-AA014A
19

Rear engine bus chassis are usually shipped with the radiator temporarily mounted.
When mounting the bus body, remove the temporary radiator mounting bracket (painted orange) and observe the precautions described in this section in addition to the
GENERAL POINTS of the previous section.
[LOCATION OF RADIATOR]
Location of radiator
Radiator and header tank are installed
temporary in this position with temporary
support beams.
02-025
[OUTLINE OF ENGINE COOLING SYSTEM OF REAR ENGINE VEHICLE]

Header Tank
(Temporarily
fixed in bare
chassis)
condition
Water Filling Port
Overflow Tube
Radiator
THERMOSTAT
CASE
A
ENGINE CENTER
CHASSIS CENTER
Temporarily fixed in bare

chassis condition
Chassis
Frame Side
Member
02-026
REAR VIEW
KC-AA014A
20

Fixing the Radiator and Overflow Tube to the Body Structure
To allow the vehicle to run as a bare chassis, one end of the radiator support is mounted on the chassis frame and the other end and the tension rod are fixed to a temporary
bracket.
When mounting the body, remove the temporary bracket and attach the radiator support securely to the side structure of the body and the tension rod to the body rear
structure.
The mounting of the radiator support and tension rod to the body structures must allow
for the dismounting of the radiator.
Also, securely attach the overflow tube to the body rear structure using clips.
THERMOSTAT
CASE
Attach the overflow tube to

the body rear structure using
clips.
ENGINE CENTER
CHASSIS CENTER
Rear view
A
Secure the radiator support to the body side
structure.
No. 8
Secure the tension rod to

the body rear structure
CORE CENTER
FRAME UPPER SURFACE
ENGINE
CENTER
KC-AA014A
MIN. POSITION OF
BODY REAR END
Side view
RADIATOR CASE CENTER
RADIATOR CENTER
02-027
CROSSMEMBER
02-028
21

Fixing the Radiator Header Tank to the Body Structure
Like the radiator, the header tank is temporarily mounted on a temporary bracket to
allow the chassis to run without a body.
When installing the body, remove the temporary bracket and securely fix the header
tank to the lower part of the engine bulkhead or to the body rear structure using a
header tank mounting bracket.
The method used to secure the header tank should allow for dismounting of the tank.
Provide an inspection cover in the rear body panel of the specified size to allow inspection of the water level in the header tank and water filling.
No. 8
CORE CENTER
FRAME UPPER SURFACE
ENGINE
CENTER
MIN. POSITION OF
BODY REAR END
Side view
Provide an inspection cover in the

rear body panel.
RADIATOR CASE CENTER
RADIATOR CENTER
Attach the header tank to the

bulkhead or body rear structure using a bracket.
CROSSMEMBER
02-029
KC-AA014A
22

Adjusting the Cooling Fan Idler Pulley Alignment
Once the radiator is mounted, make sure that you adjust the alignment of the cooling
fan idler pulley.
Adjust the alignment of the pulley by turning the turnbuckle of the tension rod that
secures the radiator.
After alignment, the difference between the datum lines of the engine crank pulley and
cooling fan idler pulley must be no greater than 5 mm.
DATUM
LINE
02-030
COOLING FAN
IDLER PULLEY
ENGINE CRANKSHAFT
PULLEY
If the alignment is poor, the fan drive belt will wear more quickly leading to engine overheating. It is therefore essential to adjust the alignment correctly and verify belt tension.
lkh
ea
Turnbuckle
Body rear end
Radiator
Bu
Tension rod
Cooling fan
idler pulley
5 mm
Within
Side rail
Cooling fan
KC-AA014A
Engine crankshaft
pulley
02-031
23

Providing and Sealing a Radiator Room
Once the radiator is securely mounted on the body structure, provide a radiator room
by mounting partition plates in front of the radiator (see diagram) to prevent any backflow of hot air from the engine room and protect the radiator against stones and dust
which will be thrown up by the rear tires during vehicle operation.
Securely seal the entire circumference between the radiator and the radiator room, and
between the radiator room and body side panels using sealing rubber or a similar
material.
Provide an inspection cover of the specified size in the partition plate on the engine
side of the radiator room to allow inspection and maintenance of the engine.
Rubber sheet
Hot air must not flow

back into the area in
front of the radiator.
Engine
inspection lid
Upper partition
Side partition
Front partition
(Between right and
left side wall)
Front of
the vehicle
Rubber sheet
No. 8 crossmember
Under cover
Under cover protects against
air blowback, heated air from
the muffler, and stones and
dust thrown up by the rear
wheels.
02-032
KC-AA014A
24

Provision of Air Intake Opening
Provide an air intake opening with a mesh structure cover in the body side panel to
allow the intake of cool air to the radiator.
Make sure that the size of the opening conforms to the minimum effective opening area
to assure a sufficient intake of air into the radiator.
The body side panel in which the air intake opening is provided should be fitted with a
detachable or hinged inspection cover of the specified size to allow inspection and
maintenance of the radiator and engine.
Mesh
Front of the vehicle
Air intake opening

The air intake opening must
assure the minimum effective
opening area.
Chassis frame
Inspection cover
02-033
Be sure to provide an
inspection cover to allow for
inspection, maintenance
and repair of the engine and
radiator.
KC-AA014A
25
3. ENGINE AIR INTAKE SYSTEM

The air intake system is of vital importance in ensuring that the engine receives a sufficient amount of combustion air that is free of water, dust and coarse foreign matter.
It is therefor important that the induction system should conform to the specified dimensions and structure.
Moreover, the induction system must not give rise to noise.
For these reasons, when mounting a bus body, be sure to observe the following precautions.
[OUTLINE OF ENGINE AIR INTAKE SYSTEM]
For Front Engine Vehicle
AIR INDUCTION PIPE

ENGINE AIR CLEANER
FRONT
AIR TANK
SPLASH GUARD OF AIR CLEANER
AIR INTAKE CHAMBER
02-034
For Rear Engine Vehicle
AIR INTAKE CHAMBER &

AIR INLET IN BODY WITH
PROTECTIVE NET
FRONT
AIR INDUCTION PIPE

ENGINE AIR
CLEANER
02-035
KC-AA014A
26

Main Points of Body Mounting
Do not modify the engine air cleaner and the induction pipe between the engine air
cleaner and the engine, nor change the positions in which they are mounted.
Remove engine air cleaner temporary mounting bracket and fix engine air cleaner to
body structure (only with chassis where the engine air cleaner is temporarily mounted.)
Take steps to prevent damage to engine air cleaner during vehicle operation (e.g. fit
under cover or splash guard).
Remove temporary cap of engine air cleaner and construct air intake system. The
structure of the air intake system must satisfy the following conditions:
It must extract moisture from the intake air.
It must be of a structure that will reduce the noise of air intake.
The air intake pipe must be of sufficient size and any bends in the intake pipe to minimize air resistance.
(e.g. fit an air intake chamber and intake pipe of appropriate strength which assure the
above functions.)
Ensure that the engine air intake provides a sufficient volume of air. (Ensure that the
air intake opening conforms to the minimum effective opening area.)
The air intake opening must be at a sufficient height from the ground to ensure that
clean air is taken into the engine. (i.e. the opening must be in the front, roof, or side of
the vehicle and have a ground height of at least 1.6 m.)
Be sure to allow for inspection, maintenance and repair work, by
making sure that it is easy to inspect and replace the filter element of the engine air
cleaner, and
providing detachable or hinged inspection covers.
KC-AA014A
27

Details of Important Points of Body Mounting
For details of dimensions, shape and other items particular to each model, see the
Body Mounting Manual for the respective model series.
[GENERAL POINTS]
Do not Modify or Alter the Engine Air Cleaner.
The design of the air cleaner takes account of engine performance. Never modify the
air cleaner itself nor change its mounting position.
The air cleaner is fitted with a filter element indicator to facilitate day-to-day inspection
and a dust outlet unloader valve.
Never make any modification to the air cleaner or change in its mounting position as
such modifications will affect the functions of these devices.
Allowing for Ease of Inspection, Maintenance and Repair Work
To allow for inspection, maintenance and repair of the component parts of the engine
air intake system, provide inspection covers and ensure that body components are of
detachable construction by basing body design on bolt mounting. Give particular attention to
the mounting and dismounting of the engine air cleaner filter element, and
the provision of detachable or hinged inspection covers.
KC-AA014A
28

Air Intake Position
We have already seen that it is extremely important to assure a good supply of combustion air to the engine.
To ensure that the engine combustion air is fresh, clean and supplied in sufficient volume, strictly observe the following precautions:
Never position the air inlet in the engine room.

Never position the air inlet in the passenger room.
The air inlet should take air from outside the vehicle.
Never position the air inlet within the broad band of speed-wind
with dirty air that flows along the sides of the vehicle during driving.
The size of the air inlet must be of at least the minimum effective
opening area.
Failure to observe these precautions will lead to a shortage of engine combustion air,
which will reduce the power of the engine and lead to black exhaust emissions. For
reference, the graphs below show the relationship between temperature of engine
combustion air at the inlet and engine performance (power and exhaust smoke levels).
The graphs read decrease of engine power and increase of exhaust smoke if the air
inlet take hot air from the engine room.
Power (PS)
Temperature of engine combustion air at inlet versus engine performance (power and
exhaust smoke levels)
Smoke
(Increase)
Low
Temperature
KC-AA014A
High
02-036
29

Air Induction Piping
If the configuration of the body means that you must alter the route of the air induction
piping and make changes in the position of the air intake chamber or the installation of
an air induction pipe to connect with the air intake chamber, use steel pipe with a diameter equal to or greater than that of the existing connecting pope between the air cleaner and engine. Secure the connection using a sealant such as Three Bond No. 1141 or
equivalent, and clamps.
To prevent suction resistance, the piping route should have no sharp curves or bends.
Minimum radius of curvature at center of pipe:

pipe diameter x 1.5
Precautions for Rubber Hose
Connection
CLAMP
TO ENGINE
FROM AIR INTAKE CHAMBER
AIR
CLEANER
RUBBER HOSE
02-037
EVENLY COAT THE PIPE SURFACE OF THIS AREA WITH

SEALANT (THREE BOND NO. 1141 OR EQUIVALENT).
TO PREVENT THE SEALANT FROM BUILDING
UP ON THE INNER FACE AS SHOWN, NEVER
COAT ON THE INSIDE OF THE RUBBER HOSE.
80~40
RUBBER HOSE
PIPE
15~20
PREVENT THE CLAMP FROM GETTING

ON THE RAISED PORTION.
CLAMP FIXING
PORTION
02-038
CLAMP IS GETTING ON THE RAISED PORTION.

BAND IS INCLUDING.
RIGHT
WRONG
02-039
KC-AA014A
30

Air Intake Chamber
In front engine vehicles, the air intake chamber is usually already mounted on the chassis.
If you must move the air intake chamber when mounting a body, be sure to secure it
firmly to the body structure using rubber mountings as in the original mounting position.
Never make any modifications to the original chamber itself. (Modifications may lead to
water being taken into the engine and to intake noise.) Also make sure that the chamber is positioned at the same height above the ground as in the original position or
higher if possible.
If no air intake chamber is fitted, provide a chamber of suitable strength and volume
with a water draining function.
Air Intake
Chamber
Upper View
CHASSIS CENTER LINE
Mount the chamber using

rubber mountings to prevent
intake noise (vibration) from
being transmitted to the body
and passenger room.
FRONT AXLE DATUM LINE
A
ENGINE
CHASSIS FRAME
UPPER SURFACE
CENTER
To prevent water from

being taken into the
engine, make sure
that the chamber is at
a sufficient height
above ground level.
Air Intake
Chamber
Side View
Air Cleaner
02-040
KC-AA014A
31

Clearance Between Air Intake Chamber Inlet and Body Parts
Ensure adequate clearance between the inlet of the air intake chamber and body parts.
Minimum clearance from body parts: 100 mm min.
If the clearance is insufficient, the engine will not have sufficient combustion air, leading
to a loss of power and black smoke emissions.
100
To ensure that hot air from the engine is not taken into the inlet of the air intake chamber, fit a partition plate between the engine and the chamber.
Fit a partition plate

between the engine
and the intake chamber, air cleaner.
AIR INTAKE
CHAMBER
100
AIR CLEANER
Upper View
FRONT AXLE DATUM LINE
CHASSIS CENTER LINE
To ensure sufficient air flow to the air

cleaner, do not mount any part of the body
within the hatched area around the air
intake chamber.
100
100
A
ENGINE
CHASSIS FRAME
UPPER SURFACE
CENTER
AIR INTAKE CHAMBER
AIR CLEANER
Side View
02-041
KC-AA014A
32

Fitting a Splash Guard
In front engine vehicles, the engine air cleaner is fitted in front of or behind the front
wheel.
In such vehicles, you should fit a splash guard to prevent stones, dust and water
thrown up by the wheels during driving from damaging the air cleaner and to prevent
dust from being taken into the engine.
FRONT
ENGINE AIR CLEANER
AIR TANK
SPLASH GUARD OF ENGINE AIR CLEANER
AIR INTAKE CHAMBER
02-042
KC-AA014A
33

Engine Air Cleaner
In rear engine vehicles, the chassis is shipped with the engine air cleaner temporarily
mounted. When mounting the body, remove the temporary mounting bracket (colored
orange) and fix the engine air cleaner securely to the body structure using the air
cleaner bracket according to the Body Mounting Manual for the respective model
series.
The air cleaner is also fitted with a temporary cap to allow the chassis to be driven without a body. When mounting the body, remove the temporary cap and fit an engine air
intake system according to the procedures described in this section.
Remove the temporary

cap. (Colored Orange)
Engine
Engine Air Cleaner must be

securely fixed to body structure.
to Engine
02-043
Engine Air Cleaner
NOTE
For convenience of easy body mounting, recent Hino rear engine bus
chassis has been adopted new type of engine air intake system which
already has functions of the water elimination from intake air and
sound absorbing of intake air noise.
Therefore, the detail procedure of the bus body mounting for air intake
system must be followed the instruction described in the body mounting manual for respective model series.
KC-AA014A
34

Engine Air Intake System
In buses, while the vehicle is being driven, a broad band of speed-wind carrying dirty
air will flow rearwards from the rear wheels along the sides of the body.
To ensure that the engine receives clean air, you must observe the following precautions when fitting the air intake system.
Make sure that the system takes in fresh and clean air.
Make sure that the system is able to eliminate water vapor from
the intake air.
The system must not give rise to any noise.
Ensure that the air intake opening and piping are of sufficient
size to ensure a proper supply of air to the engine and do not
create any intake resistance.
IN THIS DIRTY WIND ZONE MUST

BE AVOIDED TO SET THE ENGINE
AIR INLET.
02-044
Band of speed-wind carrying dirty

air from rear wheels during driving
KC-AA014A
35

Air Intake Position
The freshest and cleanest combustion air for the engine is obtained at roof height and
for this reason it is best for the air inlet to be positioned on the roof.
However, this position is relatively complicated from a design standpoint since it
requires the installation of a special air duct in the bodywork shell. This air duct must
also be insulated against noise.
A simpler alternative for the position of the air inlet is as high up as possible on the side
of the body under the rear window. In this position, a combined water separator and
sound baffle can be positioned directly adjoining the body side so that the air duct will
be much shorter and simpler in design.
AIR INLET TO ENGINE
MUST BE KEPT
MIN. GROUND HEIGHT 1.6 m.
02-045
KC-AA014A
36

Installation of Air Intake Chamber
The air intake system must also include a water separator. Hino recommends that this
water separator should incorporate a sound baffle. This will prevent the development
of noise-generating air currents in the water separator (air intake chamber).
The air intake system may also be a source of noise. To prevent the transmission of
noise to the body shell, the combined water separator and sound baffle (air intake
chamber) should be rubber-cushioned and connected to the side of the body via rubber
seals.
AIR INLET IN BODY SIDE WITH

PROTECTIVE NET
(COMBINED AIR INTAKE CHAMBER = WATER SEPARATOR &
SOUND BAFFLE)
AIR INDUCTION PIPE

ENGINE AIR CLEANER
02-046
SIDE WINDOW
RUBBER CUSHIONING
AIR INLET IN BODY SIDE WITH
PROTECTIVE NET
AIR INTAKE CHAMBER
RUBBER SEAL
SETTING BRACKET IN BODY
BODY SIDE
AIR INDUCTION PIPE

ENGINE AIR CLEANER
INSPECTION COVER
IN BODY SIDE FOR
MAINTENANCE
02-047
AIR INTAKE CHAMBER CONNECTED

TO ENGINE AIR CLEANER
KC-AA014A
37

Construction of Air Intake Chamber
The exterior shape of the air intake chamber and the combined water separator and
sound baffle may vary according to body design.
The choice of shape is left to the B&E manufacturer, but it is essential that volume of
chamber should be of sufficient size and provision of the buffle plate to assure the
extraction of water from the intake air and reduce intake noise.
Impurities and moisture tend to collect in the intake chamber. To allow the chamber to
be cleaned and moisture to be drained off, the chamber should be provided with a
removable bottom plate. This plate should have a number of draining holes fitted with
unloader valves.
The bottom plate must be easy to remove. Hino recommends that it be attached by
screws to the side plate of the intake chamber.
(For details of the recommended construction of the air intake chamber, see the Body
Mounting Manual for the respective model series.)
Baffle Plates
A noise-damping mat of foam plastic is
glued to the back of the baffle plates.
Air Inlet in Body Side
Bottom Plate with Drain Hole

(An unloader valve must be fitted to the
drain hole.)
Make sure that the effective cross-sectional

area of the air flow passage in the intake
chamber is such that air flow speed is 7
m/sec or less. (For precise values, see the
Body Mounting Manual for the respective
model series.)
Connection Socket for Air Pipe to
Engine Air Cleaner
02-048
Example Construction of Air Intake Chamber
KC-AA014A
38
4. CHASSIS FRAME
Chassis Frame
02-049
Among the component parts which constitute a vehicle, the chassis frame resembles a
human backbone and functions as the most essential solid member in a vehicle.
Because of this, a material with a high tensile strength harder than ordinary metals is
used as the frame material. The strength of this material as well as the shape are
designed to match the size of the vehicle (GVM) and the usage conditions.
Accordingly, careless alterations or modifications will cause stress concentration and
material deformation resulting in major problems such as bending or cracking in the
frame.
When mounting a bus body, be sure to observe the instructions given below when carrying out the mounting operations.
KC-AA014A
39

Frame Materials
HINO vehicles use the following frame materials.
Material
Type of metal
Tensile strength
Yield strength
Hot rolled
steel plate
440 N/mm2
{45 kgf/mm2}
304 N/mm2
{31 kgf/mm2}
Hot rolled
steel plate
540 N/mm2
{55 kgf/mm2}
392 N/mm2
{40 kgf/mm2}
Depending on the country in which the vehicle is to be used, some models may use
frame material with a tensile strength 55 kgf/mm2.
For details, see the Body Mounting Manual for the respective model series.
KC-AA014A
40

Drilling the Frame
Drilling the chassis frame greatly affects the strength of the frame.
If drilling is done incorrectly, it may seriously damage the frame and lead to cracks or
breakage.
When mounting a bus body, as much as possible, avoid drilling the chassis frame other
than when mounting to the chassis frame of a cross sill of a body floor construction.
When drilling the chassis frame, observe the instructions given below.
DRILLING POSITION
Never drill on the upper or lower flanges of the side member of the chassis frame.
Observe the maximum permissible diameters give in the table below.
Dimensions (mm)
Do not drill on the upper

& lower flanges.
min. 50
min. 70
min. 70
Original rivet or holes
B
A
Maximum permissible
diameter of drilling
hole: 15 mm
02-050
KC-AA014A
41

DRILLING PROCEDURE
Use the correct drill. Do not use gas torches.
Always chamfer the edges of the hole after drilling.
GAS TORCH
DRILL
02-051
WRONG
RIGHT
PREVENTING OF DAMAGE TO PIPES

AND HARNESS WIRES
Be careful not to damage the pipes and harness wires inside the side frame when
drilling.
Do not damage the

pipe & wire harness.
02-052
KC-AA014A
42

Welding the Chassis Frame
In like manner to drilling, welding the chassis frame greatly affects the strength of the
frame.
If welding is done incorrectly, it may seriously damage the frame and lead to cracks or
breakage.
Accordingly, without exception gas or electrical welding of the chassis frame during bus
body mounting are not allowed.
GAS & ELECTRICAL WELDING

ARE NOT ALLOWED.
02-053
Further, use electrical welding when it is necessary to mount a body bracket or similar
part that does not greatly affects the chassis frame excluding when mounting (joint) to
the chassis frame of a cross sill of a body floor construction but be sure to observe the
following precautions.
[Refer to the following section Body Mounting for details on mounting (joint) to the
chassis frame of a cross sill of a body floor construction that greatly affects the chassis
frame.]
PRECAUTIONS FOR ELECTRICAL WELDING

For electrical welding, observe the
No. 1. GENERAL PRECAUTIONS page 1-4-3

[4) Points to Note on Electrical Welding]
as procedure before welding work such as disconnected battery ground terminal and
etc., to avoid damage to electrical, computer and other ancillary equipment components of chassis.
KC-AA014A
43

WELDING POSITION
Welding the upper and lower flanges of the chassis frame side member is strictly prohibited.
When welding the web surface of the chassis frame side member, do not weld within
30 mm from the edge of the upper and lower flange, edge of holes.
Dimensions (mm)
Do not weld on the upper

and lower flanges.
min. 30
min. 30
02-054
Intermittent welding
A
B
Dimensions (mm)
A
min. 30
min. 30
B
A
02-055
Plug welding
KC-AA014A
44

PREVENTION OF DAMAGE TO ANCILLARY COMPONENTS
To prevent damage to ancillary components from sparks during welding, cover the
engine, meters, steering wheel, hoses, brake pipes, harness wires and tires, etc. with
fire-resistant covers.
(Example)
Heat insulator
WRONG
RIGHT
02-056
KC-AA014A
45

WELDING BEAD SHAPE
Make sure that the shape of the welding beads corresponds to the shape illustrated
below:
2
WRONG
RIGHT
1. Undercut
2. Concave welding
3. This area should be smooth and
free from undercuts.
02-057
Avoid the following defects in welding beads:

Deposited Metal Cracking
Toe Crack
Blow Hole
Slag Inclusion
Under Cut
Poor Penetration
02-058
WELDING RODS
Use special welding rods for high tensile steel in places where the weld must have the
same strength as the base metal.
BASE METAL (FRAME)
WELDING ROD
Hot rolled steel plate:

tensile strength 45 kgf/mm2
Same tensile strength as base

metal
(JIS D4301 or ISO E432)
Hot rolled steel plate:

tensile strength 55 kgf/mm2
Same tensile strength as base

metal
(JIS DA5001G or ISO E513)
NOTE:JIS and ISO standards are shown below.

JIS Z 3211-1993 and Z 3214-1993
ISO 2560-1972(E)
KC-AA014A
46
PO
SIT
ION
KC-AA014A
3.2 or 4.0
4.0 or 5.0
(A)
90
to
140
(A)
80
to
130
Flat
plate thinner than 5 mm

plate thicker than 6 mm
NOTE:Diameter of welding rod.
Welding Rod
Tensile strength; 50 kg/mm2
Illuminated type
Coated electrode
Weld Metal
(Hot roll plate)
Welding Rod
Illuminated type
Coated electrode
Weld Metal
Hot roll plate
MECHANICAL
PROPERTY OF WELD
METAL & ROD
WE
LD
ING
ROD
DIA.
WELDING CURRENT = AMP
3.2 mm
(A)
80
to
130
(A)
60
to
110
Vertical
overhead
141
to
1 90
(A)
(A)
1 20
to
180
Flat
4 mm
(A)
110
to
160
(A)
100
to
150
Vertical
overhead
WELDING CURRENT
(A)
(A)
180
to
250
170
to
250
Flat
5 mm
(A )
130
to
200
Vertical
overhead
2
WELDING CURRENT
47

Other Precautions for Drilling and Welding
DO NOT HEAT THE FRAME UNNECESSARILY.
Heating greatly affects the strength of the frame. Do not unnecessarily heat any part of
the frame unless performing welding work on the web surface of the side member.
NEVER MAKE CUTOUTS IN FLANGES.

Do not make cutouts in the flanges of the side members when mounting the body.
Cutouts may lead to cracks in the side members.
FRAME SIDE MEMBER
Do not make cutouts

in flanges.
02-059
WRONG
RIGHT
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.
FRAME SIDE MEMBER
Do not drill, weld,

or make cutouts.
02-060
Crossmember
WRONG
RIGHT
KC-AA014A
48

Frame Alteration or Modification
As stated in the beginning of this section, the chassis frame resembles a human backbone and functions as the most essential solid member in a vehicle. The chassis
frame is the connecting member of the front and rear axle and has brake components
which are necessary for safe operation of the vehicle mounted on it as well as the
steering system and other components.
Accordingly, without exception frame alterations and modifications during body mounting are not allowed.
Do not alter or modify the

chassis frame.
02-061
Because of the connecting between the front or rear construction of the body, the front
or rear overhang of the frame must be extended. Further, when shifting a towing hook,
be sure to observe the following points.
(When extending the rear overhang of the frame, the exhaust tail pipe should be
extended as well. For details, refer to the EXHAUST SYSTEM section.
KC-AA014A
49

EXTENSION OF FRONT OR REAR
OVERHANG OF THE FRAME
Maximum extension length:

must be within 300 mm.
Max. 300 mm.

Extension material:
must be the same as the chassis frame.
How to make an extension:
Use a welding rod designed for use with the frame base metal.
Use continuous butt welding for the extension material and intermittent welding for
stiffeners with a circumference of 35 mm.
Always fit stiffeners having the same length as the extension.
Max. 300 mm
B
Original frame
Min. 10 mm
Extension
R9
A
t 4.5
02-062
R12
L-shaped stiffener
(should be the same length
as the extension.)
Same thickness as
side member
02-063
A = 2/3 x side member height

At least 2 passes
Do not grind unless the bead interferes with
body mounting.
02-064
Detailed view of B
KC-AA014A
50

Precautions for butt welding
Before welding, the ends of both materials, the side member and the extension material,
must be cut to form a V-shape as shown in the diagram.
UNIT: mm
a
s
6
7
8
70
70
70
1.0
1.5
1.5
0
1
1
02-065
Precautions for intermittent

welding of stiffeners
Stiffeners must be welded using the intermittent method, as shown in the diagram:
30 mm
30 mm
35 mm
02-066
Never weld here.
KC-AA014A
51

Other precautions for frame extension
When extending the front or rear overhang, shifting or altering an end crossmember is
prohibited for any case.
After extending the frame, if it is necessary to shift an end crossmember due to the
body mounting state, create and mount a new crossmember.
02-067
ORIGINAL CROSSMEMBER
DO NOT MODIFY.
If necessary to fit the end crossmember

after extending the frame, has to be created
and fitted a new crossmember.
KC-AA014A
52

MOUNTING THE FRONT OR REAR HOOK
If you have removed the rear hook when extending the frame, follow the instructions
below to remount it.
Mounting the rear hook on the side of the frame

If the final crossmember is not at the end of the frame, weld a steel plate stiffener 4.5
mm thick, 150 mm long and 100 mm wide to the inside of the frame, using intermittent
welding 20 mm in circumference.
If the final crossmember is at the end of the frame, it is permissible to mount the hook
without the use of stiffeners.
Mounting the rear hook on the flange of the frame

If the final crossmember is at the end of the frame, mount the hook using bolts passing
through both the side member and the final crossmember.
If the end of the frame is open, use a stiffener 4.5 mm thick, 150 mm long and 55 mm
wide to bridge the gap between the upper and lower flanges.
[MOUNTING THE REAR HOOK ON AN OPEN END FRAME]
UNIT: mm
150
Strengthen the web surface by

mounting an inner stiffener.
Use intermittent welding to
mount the stiffener.
Mount the hook using bolts (M16
or M18).
100 t 4.5
20 mm
Mounting the hook on the web of a side member
02-068
t 4.5
50 10
150
02-069
Strengthen the flange of the side

member using an inner stiffener.
Bridge the gap between the
upper and lower flanges of the
side member using a stiffener.
Mount the hook using bolts (M16
or M18).
Mounting the hook on the flange of a side member
KC-AA014A
53

[MOUNTING THE REAR HOOK WHEN THE FINAL CROSSMEMBER IS AT THE END
OF THE FRAME]
Mounting the hook on the web of a side member
Use bolts (M16 or M18) to

mount the hook directly on the
web.
02-070
Mounting the hook on the flange of a side member
Mount the hook directly on the

flange using bolts (M16 or M18),
passing through the side member and the final crossmember.
02-071
General precautions for mounting rear hook

Strength and tightening torque of bolts for mounting rear hook
Bolt
Strength
Tightening torque N m (kgf cm)
M16
M18
CLASS 8
CLASS 8
170-226 (1,730-2,310)
233-311 (2,380-3,170)
The procedure for mounting the rear hook described above is suitable only for normal
conditions of use, e.g. towing broken-down vehicles directly behind. Heavier work may
lead to deform of the chassis frame.
KC-AA014A
54
5. FUEL TANK
Unsuitable location of the fuel system can lead to major accidents such as vehicle fires.
When mounting a body, make sure that you strictly observe the following precautions.
The fuel tank is normally mounted on the chassis frame. Do not make any
unnecessary modifications to the fuel tank.
With large-capacity fuel tanks (250 and 300 liters), simply securing the tank
to the chassis frame will not ensure sufficient strength of mounting. If the
mounting is not of sufficient strength, there is a danger that the fuel tank
itself may be dislodged and fall off during driving.
You should therefore follow the procedures described below and secure the tank firmly to
the body structure as well as the chassis frame.
MOUNTING ON BODY FLOOR AND CROSS BEAM

This method is suitable when the fuel tank is suspended on tension rods hanging from
a cross beam mounted on the frame upper surface.
UNIT: mm
Fix securely to body

side structure
Cross Beam or Battery

Mounting Beam
If the original cross beam has been

removed, install a cross beam of the
same type as the original beam and
suspend the tank using tension
rods, then fix a cross beam securely
to the body side structure.
Tension
Rod
Hole 11
02-072
40
Body Side Structure
t = 4.5
60
40
Section Detail of Cross Beam
02-073
KC-AA014A
55

MOUNTING ON BODY SKIRT RAIL
This method is suitable if the fuel tank is not suspended on tension rods hanging from a
cross beam mounted on the frame upper surface, or if the body specifications are for a
high floor.
UNIT: mm
FUEL TANK SUPPORT
SKIRT RAIL OF BODY

SIDE STRUCTURE
Securely fix to fuel tank support and body skirt rail using
bolts.
ADDED BRACKETS TO THE TANK
SUPPORT
02-074
(Fix with the tank support by welding as shown

detailed FIG. A.)
FIG. A. Details of added brackets to the fuel

tank support for connecting to body
structure and mounting method
FIG. B. Added brackets to the body side

skirt rail.
(Fix to the body side skirt rail by
welding.)
This bracket must be added to the fuel tank

support by the B&E manufacture.
2 - 11(B)
FUEL
TANK
CENTER
25
55
Fuel Tank Support
100
C8
25
140
40
Edge preparation must be

done when welding.
25
100
100
450
100
70
MATERIAL: Hot rolled steel plate for automobile structure use.
Tensile strength:
440 N/mm2 {45 kgf/mm2}
Bending Radius of Plate: (inside)
KC-AA014A
Bolt M10 (7T) - 4 Nos

Tightening torque 35 - 52Nm
{360-530 kgfcm}
02-075
56

Allowing for ease of Maintenance and Repair
The fuel tank may have to be dismounted in the future. Ensure that the construction of
the body allows for the dismounting of the fuel tank.
To allow ease of maintenance of the fuel tank components such as the fuel level
sender unit and pipe connections, provide an inspection cover of the specified size in
the floor.
To ensure ease of fueling, provide a feed tunnel in the body floor and a fuel feed lid of
the specified size in the outer panel. (In vehicles with a low-floor body, these facilities
will be essential.)
Chassis Center Line
Feed Tunnel
Body Floor
Fuel Feed Lid
02-076
To ensure that the engine is supplied with clean fuel, a pre-fuel filter & sedimenter has
been fitted to the fuel tank. To allow for ease of maintenance of this device, provide an
inspection cover of the specified size.
Floor Inspection Cover

Fuel Pre-fitter & Sedimenter
Fuel Tank
Chassis Center Line
Crossmember
02-077
Upper View
KC-AA014A
57

Modification & Alteration
You may have to move the fuel tank owing to considerations of the distribution of vehicle weight (distribution on forward and rearward axles or left/right balance), or the need
to fit an air-conditioning unit, or other body design problems.
If the vehicle is required to travel long distances and you may decide to fit an additional
fuel tank.
In any of these cases, please be sure to observe the following precautions and pay
special attention to the strength of the fuel tank mountings and to fire prevention.
GENERAL PRECAUTIONS
Follow the instructions in item 4. Frame, when welding or drilling on the frame.
Install the inspection covers and fuel feed lid accordingly.
A minimum distance of 10 mm should be kept between the fuel hose and parts listed
below.
Pipes and Harnesses
Frame Edges
Flange edges of fuel tank
The minimum bending radius of the fuel hose is 50 mm.
Check the entire fuel line. The line should not be twisted or pulled in tight or too loose.
Ensure a clearance of at least 30 mm between the fuel hose and moving parts to prevent
contact.
When joining the fuel pipe to the fuel hose, apply Three Bond No. 2 adhesive (or equivalent) over a space of 5-10 mm from the pipe edge, join the hoses, then securely clamp
the fuel hose to the fuel pipe over the center of the overlap, which should extend at least
30 mm from the fuel pipe end.
ABRAZADERA
TUBERA DE
COMBUSTIBLE
15
15
30
MANGUERA DE
COMBUSTIBLE
02-078
Secure the fuel hoses using clamps at 300 ~ 400 mm intervals. Fuel hoses must not run
next to electrical wiring and battery cables. Make sure that fuel hoses are positioned at
least 30 mm away from harness wires and battery cables.
For clearances between the exhaust system, fuel tank, and fuel hoses, see item 2-11.
EXHAUST SYSTEM.
KC-AA014A
58

Make sure that even in the event of a fuel leak, fuel will not drip onto any part of the
exhaust system. Joints must not be positioned above any part of the exhaust system.
Make sure that the filling port of the fuel tank is positioned at least 300 mm away from the
mouth of the exhaust tail pipe, and at least 200 mm away from any exposed electrical
terminals.
Make sure that the filling port of the fuel tank is positioned to allow easy filling and easy
removal and replacement of the filler cap.
When using the vehicles main fuel tank to supply fuel to the engine of an air-conditioner
or other equipment, be sure that the fuel for this engine is taken directly from the main
fuel tank. Never take a line from the main fuel feed system as this will interfere with the
main engine fuel supply.
Make sure that pipe and hose are clean before they are jointed, to prevent foreign matters from contaminating the system.
Take care not to damage pipe surfaces.
The tightening torque of clip bands is 9.81-11.77 Nm {100-120 kgfcm}.
NOTE
Refer to the list of precautions at the end of ITEM 2-8 brake piping for
details of precautions to take with the fuel lines.
KC-AA014A
59

PRECAUTIONS FOR FUEL PIPING AND ELECTRICAL WIRING
When moving or mounting an additional fuel tank, also be sure to observe the following
procedures:
If you intend to change the fuel lines, be sure to use the specified fuel hose or steel
pipe.
Polyvinyl chloride hose
Use polyvinyl chloride (PVC) hose for the fuel feed line (from the fuel tank to the
engine) of vehicles with in-line 4 and in-line 6 engines.
Rubber hose
Use rubber hose for the fuel return line (from the engine to the fuel tank) or in vehicles
with V-type engines.
WARNING
Never use polyvinyl chloride hose for the fuel return line (from the engine to the fuel
tank) or in vehicles with V-type engines.
Using defective polyvinyl chloride or rubber hoses can lead to vehicle fires. Always use
genuine HINO parts.
Vehicle category and pipe diameters
Hose type
Notes
Medium-duty vehicles
Internal: 8 mm External: 14 mm

Rubber hose
Use for fuel feed line

Use for fuel return line
Heavy-duty vehicles/
In-line 6 engine vehicles

Rubber hose
Use for fuel feed line

Use for fuel return line
Heavy-duty vehicles/
V-type engine vehicles
Rubber hose
Use for fuel feed line and

fuel return line
Note: Hose length is discretionary.

BLEEDER PLUG
FUEL FILTER
INJECTION
NOZZLE
DRAIN PLUG
TIMER
Fuel return line

THROUGH
FEED
VALVE
FEED PUMP
COUPLING
PUMP DERIVE SHAFT
INJECTION
PUMP
FUEL TANK
02-079
Fuel feed line
KC-AA014A
60

Steel pipe
Steel pipe must be rustproofed inside and outside, and the pipe ends must be spool
shaped as in the drawing below:
Rustproofing:
Internal: copper plating, min. 8
External: zinc plating, min. 8
Pipe dimensions:
Medium-duty vehicles
External diameter: 8 mm
Thickness: 0.7 mm
Heavy-duty vehicles
External diameter: 10 mm
Thickness: 0.7 mm
L1
L2
Internal diameter of
rubber or PVC hose to
be connected
(reference value)
D
Nominal
diameter
Standard
diameter
9.0 ~ 9.6
4.5
3.5
10
10
11.2 ~ 11.8
10
4.5
3.5
L1
R1
R
A
D
R
L2
02-080
STEEL PIPE
ASSEMBLY DRAWING
(FOR REFERENCE)
CLIP
RUBBER HOSE
02-081
KC-AA014A
61

Never extend fuel pipes or hoses.
As a rule, steel pipes should be used for fuel lines within the engine room.
As a rule, you should not change the clipping method or positions of clamps for fuel lines
subject to movement due to the relative movement of the engine and the frame. If you
must change either clipping method or clamp positions, be sure to allow sufficient slack
to absorb the movement of the engine.
FUEL INJECTION PUMP

KEEP
PROPER
SLACK.
FUEL
PIPING
CHASSIS FRAME
ENGINE
02-082
When extending the harness wires of the fuel gauge, use wires of the same color and
size as the existing ones. The connections must be secured by soldering or force-fitting.
Remove the burrs of soldered connections or joints and wrap them with adhesive vinyl
tape or the like to insulate and prevent short circuits.
INSULATE THE CONNECTIONS WITH ADHESIVE VINYL TAPE.
OVER
30 mm
OVER
50 mm
OVER
30 mm
02-083
THIS AREA MUST BE HALF-WRAPPED WITH ADHESIVE VINYL AREA TYPE.
KC-AA014A
62

If you shorten the harness wires, bundle up the excess length, half-wrap it with adhesive
vinyl tape and fasten it securely using clips fitted to the fuel tank mounting band.
THIS AREA MUST BE HALF-WRAPPED

WITH ADHESIVE VINYL TAPE.
02-084
02-085
FUEL GAUGE
CLIPS FOR FASTENING

HARNESS WIRES
KC-AA014A
63

PRECAUTIONS WHEN MOUNTING AN ADDITIONAL FUEL TANK
When mounting an additional fuel tank, observe the precautions described in GENERAL
PRECAUTIONS and PRECAUTIONS FOR FUEL PIPING AND ELECTRICAL WIRING
and follow the procedure described below, and be sure to secure the tank firmly to prevent loosening of the mounting bands or slipping of the tank due to vibrations during driving.
Fit a cut-off cock to the connecting pipe between the main tank and the additional subtank.
Bracket
Frame Side Member
Connecting Pipe
Main tank
Sub Tank
Connecting Pipe
Cut-Off Cock
Joint
02-086
The main tank and the sub-tank must be mounted at the same height.
When welding the joint of the connecting pipe to the head plate of the tank, empty all fuel
from the tank and fill the tank with water. Use the gas welding method.
KC-AA014A
64
6. STEERING
The steering system is extremely important in assuring the maneuverability of the vehicle.
In recent years, adjustable steering wheels (the position of the steering wheel can be
adjusted to front and rear and up and down) and power steering systems have been
introduced to make more comfortable, so that the steering system has become more
complex.
When mounting a body, be sure to strictly observe the following precautions.
Safety
To assure safety, never dismount the steering system from the chassis during body
mounting and never modify it in any way.
Fixing Securely to Body Structure and Mounting of Body Parts

The chassis is supplied with the steering column secured to the brake pedal and temporarily attached to the dashboard. Make sure that you remove the temporary delivery
bracket (colored orange) at the time the body is mounted on the chassis, and install
according to the following guidelines.
Remove temporary
bracket (colored
orange) & securely
mount on body
front structure.
METER
CLUSTER
The steering column casing should

be sufficiently rigid.
Up and down
Deflection X1 = max. 1.0 mm
against load P1 = 130 kg
Forward and backwards
Deflection X2 = max. 0.5 mm
against load P2 = 70 kg
02-087
Be careful to avoid damaging the dust cover of the tie rod ball joint and drag link with
tools or other objects while mounting the body on the chassis.
As stressed in item 1 GENERAL PRECAUTIONS, when any electric welding is carried
out nearby, you should ensure that these parts are protected by a fireproof covering.
When mounting body parts close to steering devices such as the drag link and pitman
arm, etc., make sure that these body parts do not come within the range of motion of
these steering devices.
Make sure that there is a clearance of at least 40 mm between the body parts and these
steering devices when they are at maximum displacement.
During body mounting, cover the steering column and the meter & gauge cluster to protect them from damage and to prevent dust and other foreign particles from penetrating
the system.
KC-AA014A
65

Power Steering
If the vehicle is equipped with power steering, observe the following precautions as well
as the previously described precautions for body mounting.
The hydraulic oil reservoir and piping for the power steering system have already been
installed in the correct position on the chassis at the time of shipment.
When mounting a body, never dismount the power steering devices or change the positions in which they are mounted.
When mounting a body, take care to avoid damaging the power steering components
with tools or other objects.

To allow for Ease of Maintenance and Repair, do not mount body parts close to the
steering system.
If you must mount body parts close to the steering system, observe the specified minimum clearances between the steering components and the body parts, and make sure
that the body parts are of detachable construction (e.g. mounted using bolts).
Provide inspection covers or lids of the specified sizes as follows:
Drag link inspection cover
Power steering oil reservoir inspection lid
The power steering oil level must be

checked every day. Be sure to allow for
ease of inspection work.
KC-AA014A
66

Storing the Chassis
If you must store the chassis without a body or while body mounting is in progress, cover
the steering column and the meter & gauge cluster with waterproof covers to protect
them against damage and to prevent water, dust and other foreign matter from penetrating the system.
KC-AA014A
67
7. CLUTCH CONTROL SYSTEM

In most Hino bus chassis, the fluid reservoir tank for the clutch control system is mounted to the right or left of the drivers seat.
When mounting a bus body, please observe the following precautions.
Securing to the Body Front Structure

When shipped, the fluid reservoir tank for the clutch control system is temporarily
mounted on the chassis in the correct position.
Refer to the Body Mounting Manual for the respective model series and securely fix the
reservoir tank to the body front structure.
Clutch fluid
reservoir
Securely fixed to body

front structure.
Clutch
pedal
STEERING CENTER
Clutch
control
cylinder
02-088
Do not Modify the Clutch Control System

Do not make any modifications to the clutch control system. Changing the position in
which the fluid reservoir tank is mounted, or otherwise modifying the clutch control system may introduce air into the control piping system.
If air gets into the clutch control piping, the clutch may fail and this may lead to serious
mechanical failures.
KC-AA014A
68

If for inevitable reasons you must change the mounting position of the fluid reservoir,
make sure that you mount the fluid reservoir higher up than the clutch control cylinder.
If air gets into the control piping during modifications, be sure to bleed the air out of the
piping. (See the SERVICE WORKSHOP MANUAL published by Hino for details of the
air bleeding procedure.)

Provide an inspection cover for the fluid reservoir to allow for daily inspection of the
clutch fluid level and filling of fluid oil.
No. 1
CROSSMEMBER
Inspection cover
Body dash panel
Clutch pedal
Body front construction
02-089
When mounting a body, allow for ease of mounting and dismounting of clutch control
system components. (Make sure that body parts are mounted using bolts and provide
inspection covers.)
KC-AA014A
69

To remove the clutch pedal from a Hino front engine bus chassis, you will first need to
pull out the shaft on which the pedal is mounted. When mounting a body, make sure that
you allow sufficient space to pull out this shaft. (For details, see the Body Mounting
Manual for the respective model series.)
Space to pull out shaft

(Do not mount body parts
within this space.)
02-092
KC-AA014A
70
8. BRAKE SYSTEM
The brake system is an extremely important safety component of the vehicle.
Incorrect body mounting may have a major impact on the functions and performance of
the brake system and may lead to serious mechanical failures or accidents.
When mounting a bus body, strictly observe the following precautions:
Brake System Specifications

Hino vehicles are equipped with an assisted brake system that is matched to the size
of the vehicle to allow the driver to operate the brakes in safety and comfort.
The table below shows, in outline, how brake systems are matched to chassis models.
CHASSIS MODEL
BRAKE SYSTEM
LIGHT MEDIUM CHASSIS
HYDRAULIC BRAKE WITH

VACUUM OR AIR SERVO
MEDIUM DUTY CHASSIS
AIR OVER HYDRAULIC BRAKE

OR FULL AIR BRAKE
HEAVY DUTY CHASSIS
FULL AIR BRAKE
If body equipment design means that you need to take power from the brake system,
be sure to make a thorough study of the basic brake system before implementing these
modifications.
For details of the brake system on each chassis, see the Body Mounting Manual for the
KC-AA014A
71

Do not Modify the Brake System
The brake system is the most important safety component of the vehicle and you must
never modify it when mounting a bus body.
If you must modify the piping of the brake system in order to make other modifications to
the chassis during body mounting (moving the fuel tank, etc.), please contact your nearest Hino distributor and follow the advice that the distributor provides.
If body equipment design means that you must take power from the brake system (piping
off air), take the air from the specified power point connection.
In this case, to protect the brake system, always fit a protection valve between the brake
system and the body equipment.
[EXAMPLE FOR DOOR ENGINE]
BRAKE
CIRCUIT
DOOR ENGINE CIRCUIT
BRAKE AIR
RESERVOIR
AIR RESERVOIR
23 (L)
DOOR ENGINE
PROTECTION VALVE
OPTIONAL EQUIPMENT (HINO) OR BODY

MANUFACTURER HAS TO PROVIDE.
BODY
MANUFACTURER
02-090
For details of the positioning of the power point connection, see the Body Mounting
Manual for the respective model series and the description of piping for powered
equipment in the following section.
KC-AA014A
72

To allow for day-to-day inspection and repair of the brake system, make sure that you
provide inspection covers or lids of the specified sizes in the body floor and outer panels.
In chassis that are equipped with a hydraulic brake system, the brake fluid reservoir tank
is sometimes mounted in the region of the No. 1 crossmember. In this case, provide an
inspection cover or lid in the body front panel to allow for day-to-day inspection of brake
fluid level and for fluid oil filling. (For details, see the Body Mounting Manual for the
respective model series.)
STEELING WHEEL
02-091
An inspection lid for the brake

fluid reservoir should be provided
on the front panel.
In chassis that are equipped with an air-over or full air brake system, the air reservoir is
mounted on the chassis frame.
In this case, provide a water drainage link to allow the draining of water from the air
reservoir to be performed easily from the side of the body.
(For details, see the Body Mounting Manual for the respective model series.)
ROD (5)
AIR
RESERVOIR
BRACKET
CHASSIS CENTER
CHASSIS FRAME
BODY SIDE PLATE
PLANE
WASHER
SPLIT PIN
DRAIN COCK
20
A
DRAINAGE LINK
KC-AA014A
02-093
Detailed at A
02-094
73

Brake Piping
Steel Piping Used in the Chassis
The table below shows the steel piping used in the chassis and the configuration of the
flare of each type of pipe.
UNIT: mm
Flare configuration
Nominal
diameter
D
Material
S
STEEL
STEEL
4.76
6.6 ~ 7.2
3.0 ~ 3.8
0.7
1.4
1.0
6.35
8.6 ~ 9.2
4.5 ~ 5.3
0.7
1.4
1.0
10.4
~ 11.0
6.0 ~ 6.8
0.7
1.4
1.6
10
12.8
~ 13.4
8.0 ~ 8.8
0.7
1.4
1.6
12
15.3
~ 19.0
9.5 ~ 13.5
0.9
1.8
1.6
15
18.0
~ 19.0
12.5
~ 13.5
HSTD 1
HSTD 2
or
HSTD 3
HSTKM 1
1.6
2.0
R1
1.0
452
9030
THIS SURFACE MUST BE SMOOTH.

02-095
KC-AA014A
74

[DETAILS OF MATERIALS]
Pipe dia. (mm)
Type
1) Pipe
4.76 ~ 12
Double-wound plated steel

pipe
12 ~ 22
Plated carbon steel pipe for

mechanical structures
2) Plating Code
Inside
Outside
HSTD 1
HSTD 2
HSTD 3
MFCuB
MFCuB
MFCuA
DFHaB
MFZnA-C
MFZnA-C
HSTKM 1
MFCuA
MFZnA-C
Chemical composition and mechanical properties

Mechanical properties
Chemical composition %
Tensile strength
Si
Cu
HSTD 2
HSTD 3
10
0.35
HSTD 1
HSTKM 1
Mn
0.12
0.50
0.04
0.25
0.30
~ 0.90
0.04
Beding test
Yield
Tensile
Elonga- Applicable
Inside dia.
Bending
point
Strength
pipe dia.
(D=pipe
tion
2
2
angle
N/mm
N/mm
mm
dia.)
(%)
{kg/mm2} {kg/mm2}
Pipe
0.045
0.04
294
{ 30}
373
{ 38}
216
{ 22}
25
25
12
360
1.5D
3D
90
6D
Plating code
Plating method
Base material
M Electric
plating
F Fe
D Dip plating
Tape of
plating
or coating
Plating
method
Cu Copper
A 8
B 4
Zn Zinc
Ha Solder
A 8
A 3
KC-AA014A
Treatment
after plating
C Colored
chromate
75

Precautions when Mounting a Bus Body
The joints of pipes and hoses must be accessible to allow tightening and so that pipes
and hoses can be removed. If you have fitted stiffeners to bridge the gap between the
flanges of side members, be sure to cut inspection holes in the stiffener.
The pitch between holes must be 100 mm or less, and the diameter of the holes must be
at least 60 mm. Make sure that the holes are in front of the clips used to secure the piping to the member. You must be able to insert or remove the clips using a box wrench.
Max. 100 mm
Min. 60 mm
02-097
Make sure that valves are easily accessible

Drains are fitted under the air tank and relay valve. When mounting a body, make sure
that the drains are easily accessible.
Make sure that the following parts are easily accessible for maintenance and replacement:
Air dryer
Pressure regulator
Brake valve
Protection valveRelay valve
Magnetic valve Quick release valve
Check valve
Safety valve
Brake booster, etc.

In vehicles with hydraulic brakes, make sure that the air bleeders of following part are
easily accessible for air bleeding:
Brake booster Brake master cylinder
Wheel cylinder
Allow sufficient clearance between the brake pipes, hoses, equipment and body. When
mounting the body, make sure that body and equipment do not interfere with the brake
system.
(For details of required clearances, see after PIPING CLEARANCE.)
The above precautions also apply to the valves and piping of optional equipment such as
ABS (anti-lock brake system).
KC-AA014A
76

Precautions for Modification
As far as possible avoid modifying any piping. If you modify piping, be sure to observe
the following precautions.
PIPING
When extending a pipe, do not join two pipes directly.

When joining pipes, use the flare joint method and avoid twisting the pipes too much.
Most pipes are made of steel but have anti-corrosive plating on the inside. Never braze
these pipes and never heat them to high temperatures.
Do not weld brake piping and do

not heat to high temperatures.
02-098
Do not use copper pipes for high-pressure hydraulic brake piping and for piping in areas
below unsprung parts as on axles.
Where pipes pass through the chassis frame material, fit a grommet in the hole and
secure the pipe with clips close to the hole so that the pipe does not touch the hole or the
grommet.
Use of Grommet
Grommet
Min. 5 mm
02-099
KC-AA014A
77

To remove the transmission, it is necessary to pull the transmission assembly backwards
in the line of the crankshaft. Do not install piping in areas around the transmission.
Where piping may be affected by the failure of other equipment, install the pipes inside
the side members or crossmembers, and do not allow them to protrude below the bottom
flange surface of the chassis frame.
To prevent fires caused by oil leaks, do not install joints in hydraulic piping near to or
over any part of the exhaust system.
Do not install piping between the spring brackets of the front and rear suspensions (outside the lower flange surface of the frame) or within the range of movement of the spring
shackle.
The piping located on the axle below the springs is carefully designed to prevent damage
from the complex vibrations which arise in this area. Do not modify this piping.
Do not install piping near to the moving parts of the chassis side propeller shaft.
Avoid making
ficult.
shape bends in hydraulic brake piping as this makes air bleeding dif-
Do not install piping in places where earth, sand, or water accumulate. Avoid covering
pipes with rubber or vinyl tubes as this tends to trap water.
45
02-100
Install pipes high enough so that they are

not covered by any earth or sand that may
accumulate on the lower flange.
When changing brake and clutch fluids, use only genuine HINO brake and clutch fluids.
(For details of brake and clutch fluids, see the appropriate workshop or maintenance
guides.)
Never reuse old brake or clutch fluids. Never use mineral oil or mix HINO products with
other brands of fluid.
KC-AA014A
78

To prevent air brake piping from freezing in cold weather, observe the following precautions:
Do not make
shape bends in piping as this allows water to accumulate (especially
between the compressor and the wet tank).
Where a pipe ends in a hose joint, raise the end of the pipe before the joint to prevent
water from running into the end of the pipe.
Use piping of the same diameter as the piping already installed.
When installing relay valves, etc., make sure that
they are easily accessible for maintenance and replacement,
they have sufficient clearance from other parts, and
they are protected from flying stones and rust.
When bending pipes, observe the following precautions:
Use a bender and do not heat the pipes in order to bend them.
Observe the standard bending radiuses shown in the table below.
UNIT: mm
Nominal
dia. of pipe
Standard
bending R
4.76
6.35
10
12
15
20
30
40
40
50
50
The minimum lengths of the straight section at the end of a pipe and of the straight section between two bends are shown in the drawings blow.
R
R
a 2d
b 2d
02-101
Flush the inside of the pipe and remove any foreign matter before use. Use compressed air to flush the pipe.
For details of pipe machining at the flare nut, see item 1 of this section, Piping Used in
the Chassis. After machining, remove any foreign matter by flushing the pipe with
compressed air.
KC-AA014A
79

PIPING FOR POWERED EQUIPMENT
When you install air piping to power a body or equipment, make sure it will not affect the
brake system during operation or in the event of a breakdown. When taking off an air
line, do not position them
on the main brake line (front brake line or rear brake line)
on the charge line (between the compressor and air drier, air drier and air tank or
between the vacuum pump and vacuum tank)
If you must take an air line from brake system, follow the rules given below:
Take the line from the plug of the wet tank or air reservoir for auxiliary equipment.
Provide the protection valve between air reservoir or wet tank and the body equipment.
[EXAMPLE] FOR DOOR ENGINE
BRAKE CIRCUIT
DOOR ENGINE CIRCUIT
BRAKE AIR RESERVOIR
TO DOOR ENGINE
23 (L)
PROTECTION VALVE
Must be provided.
AIR RESERVOIR FOR
DOOR ENGINE CIRCUIT
02-102
When installing the door engine to the body,

air reservoir for door engine circuit must be
provided.
If you must take an air line to power equipment form the brake system piping, take
account of the frequency of use of the equipment, the performance of the air supply and
safety considerations, and consult your HINO distributor beforehand.
KC-AA014A
80

PIPING CLEARANCES
To prevent rust and damage from contact with other parts. When modifying piping,
observe the following precautions.
Clearances between two pipes
No.
1
Position
Clearances
Between two pipes
A
Min. 10 mm (horizontal)
Pipe crossing points

(Vertical)
(Horizontal) 0
(Vertical)
Min. 10 mm
Min. 10 mm
Clip
02-105
Clip
02-104
Between a pipe and a joint
Between two joints
Use clips to secure pipes

near crossing pints.
Min. 10 mm
Min. 35 mm
Min. 10 mm
Min.
50 mm
02-106
Between two hoses
At maximum
displacement
min. 20 mm
02-107
KC-AA014A
81

Clearances between pipes and other parts
No.
1
Position
Clearances
Between pipes and chassis frame
Min. 5 mm
L1=L2
L2
02-108
L1
Do not install pipes in shaded area.
Between a pipe and a flat metal

surface
Min. 5 mm
02-109
Between a pipe and a metal corner or

edge
Min.
10 mm
Min. 10 mm
02-110
Between a grommet and a pipe
D d, 10 mm
02-111
Between pipes and metal structural Min. 10 mm

parts
*But min. 30 mm clearance
Between a pipe and a moving part
from limit of motion of moving part
30 mm
Limit of motion
02-112
KC-AA014A
82

No.
Position
Clearances
Between a hose and a structural part
Make sure that clearances of brake and air hoses

linked to wheels are at least 50 mm during driving.
Take account of vibrations (e.g. when steering is
at full lock). Clearances for other hoses at the
limit of motion must be:
at least 10 mm from flat surfaces
at least 30 mm from corners and edges
Clearance
02-113
Between hoses and heated parts

(exhaust system, etc.)
Air valve
Vacuum pipe
Hydraulic pipe
Air master
Brake hoses
Min. 100 mm
Min. 150 mm
Min. 200 mm at limit of motion. If this is not
possible, protect the hose with heat absorbing
plates.
Between hoses or pipes and

electrical parts
Between a pipe and a battery cable
Battery cable
Min. 20 mm
Min. 10 mm
(at limit of motion
of cable)
Between pipes and electric

terminals min. 30 mm
Between pipes and harness wires
KC-AA014A
02-114
Between parallel pipes/wires at limit of sag:

min. 10 mm
At crossing points
min. 20 mm
83

CLIPPING
Pipes must be secured with clips to prevent them from swinging due to the motion of the
vehicle. Use vinyl-coated or rubber-coated clips and follow the rules given in the table
below.
No.
1
Item
Notes
Clip spacing
Pipe diameter
Clip spacing
6 mm
max. 400 mm
10 mm
max. 500 mm
12 mm or more
max. 600 mm
However, at bends, crossig points,
joints, and where pipes and wires,
etc. are installed in parallel, and are
subject to movement, and where two
copper pipes are installed, reduce
the spacing of clips to prevent any
vibration.
Secure pipes with clips at

400 mm ~ 600 mm intervals.
02-115
Clipping two items with one clip

Never bind two pipes together with tape.
Never clip a pipe with a
harness wire or a fuel
pipe.
Never clip a pipe and a harness wire

together with one clip.
Fuel pipes may only be clipped
together with copper pipes. Never
clip fuel pipes together with vinyl
hoses or rubber hoses.
02-116
Maximum number of pipes clipped together
KC-AA014A
A maximum three pipes
84

FLARE NUT TIGHTENING
Retightening brake pipe flare nuts
When retightening flare nuts to prevent air or oil leaks, observe the specified tightening
torques in the table below.
Unit: N.m {kgf.cm}
4.76
Steel
6.35
10
12
15
155
255
365
527
677
888
{15050} {25050} {37050} {53070} {68070} {90080}
If the oil or air leak does not stop after a retightening, do not continue to tighten the
flare nut. Remove the nut completely, align the joint correctly and retighten the nut
carefully. Flare nut will be damaged if adjust the length of pipe by means of tightening
of the flare nut. Before tightening the nut, carefully check the cause of the leak.
Retightening when replacing pipes
When replacing pipes between two joints or between two units, first lightly tighten the
flare nuts at both ends of the pipe by hand before finally tightening with a spanner.
If you have difficulty in tightening the nut, do not use a spanner at first, but adjust the
alignment and configuration of the pipe until you can lightly tighten the nuts at both
ends by hand. Never attempt to join two pipes which are not perfectly aligned. This
will place an excessive load on the flare of the pipe and vibration due to the movement
of the vehicle may damage the pipes and lead to accidents.
KC-AA014A
85

Using sealing agents on taper thread
If possible, use a genuine HINO product or Loctite #575 sealing agent.
Clean tapers with cotton waste and thinners before coating with sealing agent. If you
intend to reuse joints which have been sealed with sealing agent or vulcanized tape,
make sure you remove all trace of the old sealing agent or tape before re-sealing.
Always apply sealing agent starting at one thread from the top of the taper thread, and
apply the agent across three thread over one quarter of the circumference of the
thread. Apply approximately 0.1 g of agent to each joint.
1/4 of circumference
Apply agent across

three thread.
Leave one thread.
02-117
When using vulcanized tape, make sure that the sealing agent does not penetrate any
valve, etc. (If the sealing agent penetrates a valve, it may choke the valve.) As a standard, leave two thread from the top of the taper thread and apply 1.5 ~ 2 turns of vulcanized tape.
Leave two thread.

Apply vulcanized tape lightly.
02-118
Inspection after fitting

After tightening the joint,
Make sure that there are no air or oil leaks.
Make sure that the fitting does not place any strain on the pipe or hose (bending, distortion, etc.).
KC-AA014A
86

Nyron Tube for Brake Piping
Precautions for handling the nylon tube
When using nylon tube for brake piping, take a special care so that the nylon tube might
not be heated while electrical welding. Also, be sure to conduct your work by putting a
protection cover on it so that welding spotters, etc. might not fall on the nylon tube. With
respect to other general precautions, observe the following instruction.
PRECAUTIONS FOR NYLON TUBE WHILE BODY MOUNTING

Precaution to take when
Countermeasures
Influence exerted on performance
handling
P r o t e c t i o n o f n y l o n t u b e Fit a protection cover on the nylon tube or Splashing of welding sparks, etc. on
when welding or grinding remove the nylon tube, if necessary.
the nylon tube causes sometimes air
with a sander
leakage as the result of melting of the
nylon tube.
Prevention of penetrating W h e n f i t t i n g a n d r e m o v i n g t h e n y l o n t u b e P e n e t r a t i n g a f o r e i g n m a t t e r s b i t
a foreign matters into the and its connector, it is necessary to prevent i n t o v a l v e c o n n e c t o r s m a y c a u s e
i n s i d e o f t h e n y l o n t u b e penetrating a foreign matters from sticking to sometimes air leakage or malfunction
and connector
or into them by covering them with a vinyl sac of the valves, etc.
(sac producing textile rags is not acceptable).
P r o t e c t i o n a g a i n s t t h e A l l o w a s p a c e a s d e s c r i b e d i n t h e t a b l e Perforated to the nylon tube by friction,
interference of nylon tube between the nylon tube and chassis or body wear, etc. can cause the air leakage.
parts.
Chassis or body parts
Min. clearance
(mm)
Fixed parts
Vibration parts
(Engine, Transmission, Cab &
etc.)
30
Rotating parts
(Tire, Propeller shaft & etc.)
50
Heat emitted parts

(Exhaust pipe & etc.)
20 0
Securing of space between Allow spaces of more than 200 mm between High temperature created by the heat
t h e n y l o n t u b e a n d t h e t h e n y l o n t u b e a n d t h e e x h a u s t s y s t e m from the exhaust system will melt the
exhaust system.
(exhaust pipe, muffler, etc.) or cover it with n y l o n t u b e a n d w i l l c a u s e a n a i r
insulators to protect the nylon tube. Also be leakage.
sure to protect the nylon tube by fitting
insulators to the flange portions of the
exhaust system.
Preventing swaying of nylon After installation of the nylon tube, securely If the cliping intervals are longer than
tube
fix it with clips as following procedure.
400 mm, tube will sway, the nylon
tube will contact with other
Interval: Max. 400 mm
Parts of clip band: Parts No. 47837-1230 components and will bring forth wear
Use the special tool (09620-1010) when of the nylon tube, this resulting in the
tighten the clip band and make sure the leakage of air.
tightening force described in tightening
tool.
Securing bending radius The minimum bending radius of the nylon If the piping of the nylon tube is executed
of nylon tube
t u b e s a r e s h o w n o n t h e f o l l o w i n g t a b l e . with the bending radius less than the
Never attempt to carry out piping by bending minimum bending radius, it will result
the nylon tube with the bending radius less in breakage of the tube or in the air
than what are indicated on the table.
leakage by the end portion of the
R (mm)
connector.
6
30
8
50
10
65
12
70
R
15
80
K98010-251
KC-AA014A
87

Precaution to take when
handling
Influence exerted on
performance
Countermeasures
Preventing sticking of acid As the nylon tube is weak against acid, protect it
solution
so that it may not be exposed to the splashing of
the battery liquid. Also, don't use those waste or
gloves on which are sticking the battery liquid.
If an acid solution such as battery

liquid sticks to the nylon tube, the
tube will melt and may result in an
air leakage.
Preventing penetration of W h e n w a s h i n g a t a h i g h p r e s s u r e , s e c u r e a
water when washing at a d i s t a n c e o f m u n i m u m 3 0 0 m m b e t w e e n t h e
high pressure
connector and the injection port.
Therefore, when using a fumace the temperature
of which exceeds this range, remove the nylon
tube.
P r o t e c t i o n o f t h e n y l o n Using range of temperature for the nylon tube is
t u b e w h e n p a i n t i n g a t a from -40 to 90 C.
high temperature.
If the distance between the

connector and the injection port is
not sufficient, water may
penetrate into the piping,
resulting in rusting, freezing
malfunction of valves, etc.
Air tightness of the nylon tube
lowers down if the temperature
exceeds the normal using range
and results in the air leakage.
Spare parts
Never fail to use HINO Genuine Spare Parts.

Connectors for intermediate connection of
the nylon tube
6
8
10
12
15
34801-2240
34801-3070
34801-2250
34801-2260
34801-2270
Tightening type connectors
6
8
10
12
Nut
Sleeve
Insert
23721-1070A
23721-1150A
23721-1120A
23721-1090A
47983-1250A
47983-1750A
47983-1550A
47983-1400A
47983-1260A
47983-1760A
47983-1560A
47983-1410A
Nylon tubes
20 m
6
8
10
12
15
Special tools
46769-2820
46769-3100
46769-2830
46769-2840
46769-2850
Use las herramientas especiales para retirary

cortar los tubos de nylon.
Herramienta especial para retirar el tubo de
nylon, HINO parte No. 09421-1560.
Herramienta especial para cortar el tubo de
nylon, HINO parte No. 09460-1020.
Herramienta especial para ajustar la banda
del clip, HINO parte No. 09620-1010.
NOTE
Parts No. will be changed without any notice.
Therefore, parts number must be re-checked together with spare parts catalog.
KC-AA014A
88

Installation procedure for nylon tube
Nylon tubes with the following 2 kinds of joint systems are adopted on HINO vehicles
depending upon the vehicle models.
Push-one joint (One touch type)
Sleeve nut joint
Please find below the outline of the fitting procedure of each joint system.
Carry out modification and installation strictly observing the Precautions to take when
handling nylon tubes indicated in paragraph i).
More detailed installation procedures are described to the Body Mounting Manual for
the respective model series as well as on the workshop manual. Kindly carry out sure
jobs in referring to them in parallel with this installation procedure.
FITTING PROCEDURE OF PUSHONE JOINT (ONE TOUCH TYPE)

Securely insert and fit the tube according to the following procedures
Inserting length of the nylon tube
Tube diameter
(Outside diameter x inside diameter)
Inserting length of the tube

(mm)
6 x 4 mm
23
8 x 6 mm
25
10 x 7.5 mm
25
12 x 9 mm
26
15 x 12 mm
27
Inserting length of the tube

Nylon tube
Presence of marking while

the part is new.
One touch joint
KC-AA014A
89

Fitting procedures
No. Combination of tube and joint
How to fit
Procedure
1
Inserting length (marking)
New tube &

new joint
Securely insert
Inserting length
(marking)
New tube &

reused joint
Securely
insert
Check the inside

contamination and
remove adhesion of
dust, etc. by airblow etc.
1
Cut off
Reused tube &

new joint
Inserting
length
(Marking)
Check to see that

there is no flaw.
Trace of joint
Securely
insert
Reused tube &

reused joint
2
Cut off
Check the inside contamination

and remove adhesion of dust, etc.
by air-blow, etc.
Check to see that
there is no flaw.
Trace of
joint
Inserting
length
(marking)
Securely
insert
Check to see that there is no inclusion of dust, etc. inside the joint.
If there is any inclusion, remove it by air-blow, etc.
Cut off the tip of tube according to the trace of joint left on the tube surface and check to
see that there is no flaw on the surface of the tube which is inserted into the joint. If there
is any flaw, cut off the tube. (Applicable only when there is sufficient margin of length)
Put a marking by a white pen, etc. at the position of inserting length on the tube upper
covering before inserting the tube and securely insert the tube up to the marked position.
(A marking exist on a new part)
KC-AA014A
90

FITTING PROCEDURES OF SLEEVE-NUT JOINT
Securely fit the nylon tube according to the following procedures.
Pass the sleeve-nut and the sleeve onto the tube and insert the insert into the tip of the
tube. (Pay attention to the fitting direction.)
Insert
Connector/Union
Sleeve
Tube
Sleeve-nut
Taking care so that the sleeve-nut, sleeve and insert do not fall off, insert the tube until
the tip of the insert touches the connector-union and, in this condition, fully tighten the
sleeve-nut by hand.
Holding the tube so that it will not move (come off), tighten the sleeve-nut until the following torques are obtained.
Unit: N.m (kgf.cm)
Naming of
thread
M6 x 1
M10 x 1.25
M12 x 1.5
M15 x 1.5
Tightening
torque
20 ~ 25
(200 ~ 260)
35 ~ 44
(350 ~ 450)
50 ~ 58
(500 ~ 600)
54 ~ 58
(550 ~ 600)
NOTE
Perform tightening of the nut to 2015C
Case where the tube is once removed from the joint and is reinstalled
to the same position.
Put marks on the connector and the union (using a magic pen, etc.) before slackening
the sleeve-nut so that the position can be identified.
Match mark
KC-AA014A
91

When reinstalling the tube, slacken the sleeve-nut up to the position before disassembling (position of match marks) and retighten it by 60.
After reinstalling never fail to check an air leakage (use or soap water is OK). If any leakage is found, retighten the sleeve-nut until the leakage is stopped.
If the leakage cannot be stopped, replace the tube, sleeve and insert with new parts.
If this countermeasure cannot stop the leakage, replace also sleeve-nut, connector and
union.
OTHER CAUTIONS
Use the nylon tube within the following temperature range.
Continuous use: -40 ~ 90C
NOTE
When mounting a body or performing repair work, never use the nylon tube at a
higher temperature beyond the limit of use.
Pay special attention when drying up the painting.
When performing drilling, welding, soldering, grinding with a sander, protect the nylon
tube against tools, chips, thermal source or sparks or remove the nylon tube.
Dont mount the clamps of welding equipment near the tube.
Be careful not to pour an acid solution such as battery fluid on the tube.
Pay attention to the following points when defining the bending radius of the nylon tube.
NOTE
. Do not bend with a radius lesser than what are indicated in the following table.
Never use the tube on which remains a folding frace due to excessive bending.
Nominal
diameter
Minimum bending radius at the time of handling:

R (mm)
30
60
10
65
12
70
15
80
The perpendicularity of the tube edge face at the time of cutting shall be 905 with
respect to shaft axis.
(Refer to the following illustration.)
Within 5
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9. PROPELLER SHAFT
The propeller shaft is an important component that transfers drive power generated by
the engine to the rear axle. The propeller shaft rotates at high speeds while operating
making it a very dangerous component.
Accordingly, when mounting a bus body, be sure to observe the instructions given
below.
Prohibited Modifications and Alterations

Careless modifications will result in vibrations and unusual noises while the vehicle is
driving and are very dangerous. These type of modifications must not be carried out.
Confirming Correct Clearance

The propeller shaft rotates at high speeds while simultaneously vibrating up and down
and right and left along the road surface.
Accordingly, the clearance between the propeller shaft (including joints) and the body
or body equipment parts must be at least 50 mm from the limit of displacement of the
propeller shaft (above, below, right, left, and front or back of the rear axle).
REAR AXLE
PROPELLER SHAFT
Allow 50 mm clearance from limit of
displacement (above, below, right, left,
front, or back).
UPPER LIMIT
UNIVERSAL JOINT
LOWER LIMIT
PROPELLER
SHAFT
02-119
KC-AA014A
93
10. SUSPENSIONS
Vehicles manufactured by HINO normally use a multi-leaf spring or air type suspension. (To confirm which type of suspension is being used, see the Body Mounting
In addition to cushioning shocks from the road surface received while driving, the suspension couples the front and rear axles to the chassis frame playing the role of an
important stabilizing component while the vehicle is accelerating and braking.
Accordingly, when mounting a bus body, be sure to observe the instructions given
below.
Description drawing
Multi-leaf suspension
Air suspension
Front
02-120
Front
02-122
Rear
02-121
Rear
02-123
KC-AA014A
94

Prohibited Modifications and Alterations
Careless modifications will greatly influence driving stability of the vehicle (in particular
driving in a straight forward direction) and riding comfort and may cause an accident.
These type of modifications must not be carried out.
Depending on the usage conditions, when using an additional leaf, it will be provided
as optional equipment. Be sure to use equipment manufactured by HINO. (Contact
the nearest HINO distributor for information on how to install an additional leaf.)
If the additional leaf is not manufactured by HINO or excessive number of additional
leafs are used, the mounting angle of the propeller shaft will change and result in vibrations and unusual noises while the vehicle is driving. This is very dangerous and
should never be carried out.
Front
This additional leaf of the multileaf suspension is an option.

Be sure to use equipment
manufactured by HINO.
02-124
Rear
KC-AA014A
95

Inspection, Maintenance & Repair
The suspension is a component which is always moving while the vehicle is driving and
as such requires periodic greasing and parts replacement in addition to daily maintenance and inspection.
Accordingly, to make these operations easier, consider a construction which allows
simple removal of the body parts of the peripheral assemblies as well as installing an
inspection cover.
Shock absorber
U-bolt
Spring pad
Shackle
Spring pin
Spring pin
Stabilizer
Leaf spring assy
02-125
Torque rod
Torque rod
Shock absorber
Air spring
02-126
NOTE
. To make it possible to carry out inspections, maintenance and repair or
replace the parts inside the , an inspection cover should be installed or
the construction should be such to allow the body parts to be removed.
The figure above shows a multi-leaf and air front suspension. The same
procedures should be followed for the rear suspension.
KC-AA014A
96

Other Precautions When Mounting
WELDING SUSPENSION PARTS

AND BRACKETS IS PROHIBITED.
02-127
Grounding
the
welding
machine is prohibited.
Protect using a cover when
welding peripheral parts.
02-128
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 a
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.
Using a welding or gas torch to
apply heat here is prohibited.
02-129
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.
NOTE
The figure above only shows a multi-leaf suspension. The same precautions also apply to air suspension as well.
KC-AA014A
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ADJUSTING THE SUSPENSION AFTER MOUNTING THE BODY
[AIR SUSPENSION VEHICLE]
For vehicles which are adapted an air suspension, after mounting the body confirm the
functions of the vehicle (PDI=Pre-Delivery Inspection) as well as whether the values of
the air spring height and the caster angle of the front wheel are within the standard.
If either of the values are outside the standard, the values must be adjusted following
the adjustment procedure to bring them within the standard. (For details on the adjustment procedure and standard values, see the Body Mounting Manual for the respective
model series.
If this adjustment is not carried out, the front and rear or right and left of the vehicle
may lean or abnormal tire wear may occur. Be sure to carry out the adjustment after
mounting the body.
Adjustment of air spring height
Spring Height
Front & Rear

02-130
Adjustment of caster angle
Torque rod
Upper view
Front
Spacer insertion position for adjusting the caster angle

02-131
KC-AA014A
98
11. EXHAUST SYSTEM

The exhaust system becomes very hot during driving.
When mounting a bus body, observe the following procedures to prevent vehicle fires.
Modifying or altering the exhaust system will have a major effect on vehicle performance and external noise.
As a rule, the exhaust system must not be modified.
In some countries, external noise control regulations prohibit any modification of the
exhaust system.
Clearances from the Exhaust System

When mounting a body or installing related equipment, maintain the following clearances from the exhaust system.
For wood, rubber, cloth and resin parts, maintain a clearance of at least 100 mm.
For brake hoses including nylon tube, fuel hoses and electrical harness, maintain a
clearance of at least 200 mm.
For any other equipment that may be affected by heat, maintain a clearance of at least
80 mm.
If it is impossible to observe the above clearances, fit heat insulators between the relevant parts.
Maintain the proper clearances from the

exhaust system to a body parts or equipment
and chassis parts.
Brake Hose, Brake Nylon Tube,

Fuel Hose or Electrical Harness
Min
.
200
mm
M
20 in.
0m
m
02-132
KC-AA014A
99

Rubber
M
10 in.
m 0
m
Muffler
Min. 100 mm
M
10 in.
m 0
m
Exhaust pipe
W
oo
d
02-133
Maintain clearance of at least 80 mm

from the exhaust system to the noninflammable parts, such as steel
parts or equipment.
Body and
relevant parts
Heat
insulator
Min. 80 mm
Fit heat insulators, if it is impossible
to observe the proper clearances
from the exhaust system.
02-134
WOODEN OR
RUBBER PARTS
MIN. 35 mm
CHASSIS FRAME
SIDE MEMBER
HEAT
INSULATOR
HARNESS, BRAKE PIPE OR
HOSE AND NYLON TUBE
MIN. 35 mm
EXHAUST PIPE
02-135
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100

Mounting a Body Parts or Equipment Near the Mouth of the Exhaust Tail
Pipe
When mounting or installing body parts or equipment to the rear of the mouth of the
exhaust tail pipe, do not mount or install any parts or equipment within the area indicate
by the hatching in the figure below:
Do not mount any parts or

equipment near the mouth
of the tail pipe.
Min. 15
Min. 15
Mouth of tail pipe
Min. 1000 mm
NOTE
Applies to area above, below, right and left
of tail pipe.
02-135
Make sure that no inflammable parts (brake

hoses, tubes, electrical wires) are in the flow
of the exhaust gas.
02-137
KC-AA014A
101

Modify or Altering the Exhaust System
Modifying or altering the exhaust system will have a major effect on vehicle performance (engine power and black exhaust smoke) and external noise.
Accordingly, modifying or altering the exhaust system is basically prohibited.
If modifications or alterations must be done because of mounting a body or installing
related equipment, be sure to observe the instructions given below.
PROCEDURE OF MODIFYING OR ALTERATION

Range of allowable modifications or alterations (position)
Modifications or alterations to only the tail pipe protruding from the muffler are allowed.
Modifications or alterations between the engine and muffler including the muffler itself
are prohibited.
Exhaust pipe between

engine and muffler
Front
Tail pipe
Muffler
Do not modify or alter any part

within this range.
02-138
(Above drawing shows the exhaust system of the rear

engine vehicle.)
KC-AA014A
102

Material and size of tail pipe
The material and inside diameter of the pipe must be identical to that of the vehicles
original pipe.
The material used differs according to the type of vehicle;
Machine structural carbon steel pipe
color: black
Zinc-plated steel pipe
color: silver
Aluminum-plated steel pipe
color: silver
The plating of a zinc or aluminum-plated pipe will peel if the pipe is welded and the
rust-resistance of the pipe will deteriorate.
Therefore, paint the pipe in a similar color after welding.
Extending or bending the tail pipe
Extending or bending the pipe raises the exhaust resistance and will result in a decline
in engine output, an increase in fuel consumption, and an increase in exhaust gas density (black smoke level).
Study the likely effects with care before making any modification or alteration of this
kind.
As a rule, the bending radius of the tail pipe should be at least 1.5 times the diameter of
the pipe.
R
R
02-139
Bending radius of exhaust tail pipe

should be min. R 1.5D.
KC-AA014A
103

When the exhaust tail pipe is extended or the rute is modified, securely retain the tail
pipe end to the chassis frame or body structure.
Like the engine, because the exhaust always vibrates, be sure to use a rubber cushion
to retain the tail pipe and absorb vibrations. (Use the same type as the ones used in a
base vehicle.)
CUSHION RUBBERS
WASHER
BOLT
02-140
KC-AA014A
104

Position or direction of the mouth of the tail pipe
The position or direction of the opening of the tail pipe should basically be as shown in
the figure below.
However, detail of the procedure must be followed the instruction described in the body
mounting manual for respective model series.
Further, if there are vehicle laws and regulations on the position or direction or the
height from the ground of the opening of the tail pipe, the standards of the regulations
should all be satisfied.
MIN. 1 m
To face the mouth of the

tail pipe to the pedestrian
side is strictly prohibited.
0 ~ 15
115
Pipe must not protrude beyond

overall width of vehicle.
MAX. 25
MAX. 25
02-141
The clearances between exhaust parts and other parts

As stated in the beginning of this section and 1)., when modifications or alterations to
the exhaust tail pipe are done, proper clearance between the chassis parts and body
parts or equipment should be ensured to prevent fires from occurring.
CLEARANCES FROM CHASSIS PARTS
Clearances from fuel system parts

Maintain a clearance of at least 200 mm between the fuel tank, fuel pipes, etc. and the
exhaust system.
If you cannot maintain a clearance of 200 mm, fit heat insulators to protect the fuel tank
and fuel pipes.
KC-AA014A
105

When arranging fuel piping, make sure no fuel will come into contact with the exhaust
system even if a fuel line ruptures and fuel leaks out.
Never make joints in the fuel pipes above the exhaust system, etc.
Precautions on fuel tank
When moving the fuel tank or mounting an additional tank, make sure that the filling
port is at least 300 mm away from the mouth of the tail pipe and at least 200 mm away
from exposed electrical terminals.
Clearances from other chassis parts
When the exhaust system approaches the periphery of the engine air cleaner, an insulator must be installed completely isolated from the exhaust system to prevent the
engine air cleaner from being subjected to heat.
Maintain the clearances shown in the table below if you cannot maintain these clearances, fit heat insulators.
Clearance (mm)
Chassis part
min. 100
Air pipes, vacuum pipes, oil pipes
min. 150
Air master, hydro master
min. 200
Electrical wires, battery, battery cables, rubber parts (hoses, etc.), resin
parts.
CLEARANCES FROM BODY PARTS OR EQUIPMENT

Observe the instructions given in this section Item 1, concerning clearances from body
parts or equipment with the exhaust system.
After Body Mounting

After body mounting, cut the tail pipe not to appear buck from a body end.
KC-AA014A
106
12. TIRE
A chassis on which genuine tires are mounted sent to the body mount manufacturer.
While mounting the body, there is a danger that scratches, paint adhesion, or other
damage may occur during welding and other operations. Be sure to observe the
instructions for the mounting operation given below.
Precautions Before Start Body Mounting Work

While mounting the body, attach covers to tires to prevent paint deposit and damages
to tires. Or begin body mounting after changing tires to dummy tires.
Body Mounting
MOUNTING A TIRE WHEEL HOUSE & SPLASH GUARD
As previously stated in 1. General Precautions 1-4 Tire Wheel House & Splash
Guards, install a tire wheel house & splash guard to protect the chassis parts from
dust, water, or mud thrown up by the tires while the vehicle is driving.
(For details on installing the wheel house & splash guard, see the Body Mounting
A
02-142
WHEEL HOUSE
CHASSIS CENTER
INSTALL A
COVER
PLATE
TIRE
SPLASH
GUARD
200 ~ 250 mm
Splash guard
(More detail, refer to next page.)
FRAME SIDE RAIL
02-143
Section A-A
KC-AA014A
107

Details of splash guard
UNIT: mm
[DETAIL OF FRONT SPLASH GUARD]
If there is space between floor and chassis frame, it should be
closed by steel plate.
Floor
Body
Chassis
frame
Splash guard
(Made by steel
plate)
200
Splash
rubber
150
Ground level
02-144
[DETAIL OF REAR SPLASH GUARD]

If there is space between floor and chassis frame, it should
be closed by steel plate.
Floor
Body
Chassis
frame
Splash guard
(Made by
steel plate)
200
Splash rubber
110
Ground level
Groove for the
propeller shaft
02-145
(The figure above shows a splash guard for a rear engine as a representative example.)
KC-AA014A
108

SPARE TIRE & TIRE CARRIER
The spare tire & tire carrier is mounted between the front or rear overhang or the
wheelbase under a chassis condition.
The spare tire is a very heavy part and if dropped while the vehicle is driving can cause
a severe accident. Be sure to observe the instructions for the body mounting operation
given below.
Installing the hole of the wind handle & caution plate for operation
Provide a hole on the body outer panel for the wind handle that operates the spare
tire carrier to pass through.
UNIT: mm
FRONT
HOLE OF WIND HANDLE
50
SPARE TIRE
15
R85
0
25
02-146
Install a caution plate for spare tire removal and installation operations close to the hole
of the wind handle so it can easily be verified from the outside area.
(The caution plate is packed the same time the chassis is shipped.)
How to Handle the Spare Tire
Make sure that claw of hanging plate and disk wheel are properly located.
Do not wind up spare tire when chain is twisted.
Remove mud from contact surfaces and wind handle until it stops, then tighten
with 30 ~ 40 kg force (max. strength of adult using one hand).
After tightening, make sure that the claw of hanging plate is not caught on the
contact surface, and remove handle without winding back.
Hanging plate claw
02-147
KC-AA014A
109

Modification or alteration of spare tire carrier
The spare tire carrier is designed to have sufficient strength, durability and ability to
hold a spare tire as well as ease of removal and installation.
Accordingly, careless alterations or modifications are prohibited.
If modifications or alterations must be done because of the body design, be sure to
observe the instructions given below.
Ensure that:
There is sufficient strength, durability and ability to hold a spare tire.
The spare ire should be easily removed or installed by one person.
There should be no obstructions interfering with winding up the spare tire.
During tightening, the tire should only contact the stopper.
If the tire is supported by the disc wheel contact face, the distance between the supports should allow proper contact with the disc wheel contact face.
Spare tire support

[Contact face should be
longer than disc wheel
contact face.]
TIRE CARRIER
DISTANCE BETWEEN SUPPORTS

CONTACT WIDTH
02-148
KC-AA014A
110

If the tire is supported by the tire rubber itself, the distance between the supports
should be close to the maximum width of the tire and the supports should be covered
by cushion rubber which are firmly fixed to the supports.
Further, the structure should provide adequate tightening resistance for the punctured
tire to be carried.
TIRE CARRIER
Spare tire support
CUSHION RUBBER
[Should have cushion rubbers

& distance between supports
should be close to the max.
width of the spare tire.]
02-149
Distance should be
close to tire width.
For the case that a spare tire carrier is supported by

the tire rubber itself, the construction should be such
that the attached stopper makes contact with both the
tire and disc wheel to allow carrying even for a punctured tire.
TIRE STOPPER
The carrier must have
a stopper that will give
adequate tightening
resistance even with a
punctured tire.
DISK STOPPER
PUNCTURED TIRE
DISK
02-150
Even when attaching a spare tire carrier not manufactured by HINO, carry out the
installation operation described above and be sure to install a caution plate that states
the operation procedure, such as the wind up torque, close to the wind handle hole.
KC-AA014A
111

Other precautions
Observe the instructions given below when carrying out modifications or alterations to
the spare tire carrier.
[MOUNTING POSITION]
Make sure that the spare tire carrier is mounted sufficiently high to prevent grounding
during driving on rough roads and in reverse. Make sure that the carrier does not protrude beyond the end of the rear overhang or beyond the overall width of the vehicle.
Maintain proper clearances from rotating, moving, or hot parts (propeller shaft, springs,
brake hoses, exhaust system, etc.).
Make sure the mounting position allows enough space to remove and install the spare
tire.
[MOUNTING THE CARRIER BRACKET]
The spare tire carrier may be mounted on the chassis frame side rail using bolts or rivets.
Whatever the method you use, make sure that it does not adversely affect the strength of
either the bracket or the chassis frame side rail, and observe the precautions listed in
Section 4, CHASSIS FRAME. When mounting the carrier bracket using bolts, make
sure the bolts are properly tightened but that they can be re-tightened further if the need
arises.
Mounting the carrier bracket by welding is strictly prohibited.
[CAUTION PLATE FOR OPERATION OF THE SPARE TIRE]
Fit caution plate showing the proper wind up tightening torque and operation for the carrier in a visible location as close as possible to the carrier.
The style of the caution plate should be similar to that of a genuine HINO caution plate
when installing a spare tire carrier not manufactured by HINO. (A sample of a HINO caution plate is as attached previously.)
KC-AA014A
112

[SPARE TIRE CARRIER]
When installing a carrier not manufactured by HINO
When the tire is secured in place, make sure that dimension h is within the makers recommended range. (Important with regard to chain strength.)
TIRE CARRIER ASSEMBLY

CARRIER BASE POSITION
HANGING PLATE
UPPER SURFACE
OF DISC
02-151
For details, refer to the instructions of the

carrier manufacturer.
[MOUNTING THE CARRIER AT AN ANGLE]

As a rule, the carrier should not be mounted at an angle, except when the slope is due to
the structure of the chassis frame.
[CARRIER MOUNTING BRACKET]
The carrier mounting bracket is important in maintaining the function of the carrier. Make
sure you observe the following precautions.
Bracket shape
Take proper care when designing the bracket shape. The shape of the racket must differ according to type of vehicle and mounting position. The two diagrams below show
typical bracket shapes for reference.
KC-AA014A
113

Bracket for mounting on side of chassis frame
Medium-duty vehicles: min. L40 x 40 x t5 (cross sectional coefficient min. 1.9 cm3)
Heavy-duty vehicles: min. L50 x 50 x t6 (cross sectional coefficient min. 3.5 cm3)
(Material: SS41P or stronger)
Pitch should be as large as possible.

If large pitch is not possible, use three
bolts (min. pitch 50 mm).
Min. 50 x t6
40
Frame
Min. Min.
200 80
To prevent catching, make sure disk

contact face is smooth and flat.
Min. bolt dia. 12 mm

(use at least 7t)
Allow the actual measure

of tire carrier.
150
Make sure there are no defects in welding.

Allow the actual measure of tire carrier.
Note:
Make sure mounting bolts are properly tightened, but allow

for further tightening.
02-152
Bracket for mounting between side members

Min. bolt dia. 12 mm
(use at least 7t)
To prevent catching, make sure disk contact face

is smooth and flat.
Heavy-duty vehicles: cross section min. L80 x 80 x 4.5t (Z=min. 4.1 cm3)
Medium-duty vehicles: cross section min. L80 x 50 x 4.5t (Z=min. 4.0 cm3)
(H) x (W)
(Material: SS41P or stronger)
Note:
Make sure mounting bolts are properly tightened, but allow

for further tightening.
02-153
KC-AA014A
114

[CRANK HANDLE (HANDLE FOR WIND UP THE TIRE)]
The size of the arm of the crank handle (L) must be the length that allows the carriers
manufacturers recommended tightening torque when installing a carrier not manufactured by HINO.
L
02-154
Make sure that the operation of the crank handle is not obstructed with other parts.
Shipping Inspection After Mounting the Body

After mounting the body, carry out the following inspections of the tires in addition to
inspecting each function when shipping the vehicle.
If the results of the inspection do not satisfy the standards, either adjust or correct so
the standards are met or, if necessary, replace with new parts. After these actions,
ship the vehicle.
(Contact the nearest HINO distributor for information on the inspection procedure and
standard values.)
[INSPECTION ITEMS]
Tire inflation pressure
Tightening torque of wheel nut
Scratches or contamination on tires (paint adhering, etc.)
Looseness of spare tire carrier installation bolt
Looseness of spare tire and clattering
KC-AA014A
115
13. ELECTRICAL EQUIPMENT AND RELATED PARTS

Because the electrical wire harness and equipment normally are temporarily attached
to the chassis under a chassis condition, be sure to observe the mounting instruction
and take correct actions.
Due to recent improvements in vehicle performance and to comply with laws and regulations, Hino chassis have electrical computers for engine or transmission control
installed and it a mistake is made in the mounting procedure, there is a chance these
computers will stop operating. Therefore, great care must be taken during the mounting procedure.
If the electrical equipment or wire harness are poorly prepared, fire may result causing
a major accident.
General Precautions for Electrical Equipment

During electrical welding, be sure to observe the instructions in the previously
described section 1. GENERAL PRECAUTIONS [Points To Note On Electrical
Welding] .
Do not install additional accessory lamps which use the lamp circuit of the chassis for
the power supply. Otherwise, the capacity of the detector relay incorporated into the
lamp circuit will be exceeded and the Open Circuit Detector System will stop functioning.
When removing the power supply of the electrical equipment on the body side from the
chassis, be sure to remove from the indicated terminal. The power consumption
should also be within the indicated capacity. Removing the power supply from a position other than the indicated one may result in burning or fires. Accordingly, do not
remove the supply incorrectly.
If the temperature of the computer that controls the engine or transmission becomes
high, the computer may suffer damage. Be sure to install the computer at a location
where the ambient temperature is maintained at 60C or less.
If necessary, inspect or replace each of the electrical equipment of the chassis.
Accordingly, add an inspection cover or lid at a position that allows easy inspection and
maintenance.
For more details than above and for additional instructions when mounting a body, follow the instructions after 2).
For the chassis wiring diagrams, see the Body Mounting Manual for the respective
model series.
KC-AA014A
116

Front and Rear Chassis Harness Wiring
The front and rear chassis harness wiring is installed temporarily under a chassis condition.
After installing the electrical component box, head lamp and rear combination lamp to
the body, confirm the wiring is correct and firmly secure them to the chassis and body
structure using a clip.
(For details on the method to secure the harness using a clip, refer to the section on
Harness Wiring. For details on the front and rear harness wiring, see the Body
Mounting Manual for the respective model series.)
FRONT HARNESS WIRING
Setting position during the

time of body mounting
Front electrical
component box
FLOOR SURFACE
Inter harness and front harness
should be connected above the
floor surface for protected against
water, dust, mud, etc.
TEMPORARY SETTING
POSITION UNDER THE
CHASSIS CONDITION
02-155
REAR HARNESS WIRING
Setting position during the

time of body mounting
02-156
Temporary setting position

under the chassis condition
KC-AA014A
117

Front and Rear Electrical Component Box
Various types of relays, fuses and other important electrical components are housed
inside the electrical component box.
When mounting a body, these components should not be subjected to water, dust, or
heat.
Further, an inspection cover or lid must be installed for inspection or maintenance.
Because the front electrical components are in a temporarily installed state during
chassis, they should be installed at correct locations in consideration of the points stated above.
(For details on the temporary installation position during chassis and the normal installation position during the body mounting, see the Body Mounting Manual for the
respective model series.)
FRONT COMPONENT BOX
HAZARD & PARK SWITCH

CIGARETTE LIGHTER (OPT)
FOG LAMP
SWITCH
WIPER SWITCH
HEAD LAMP RELAY

(MAIN)
BATTERY SWITCH
COMBINATION
SWITCH
STARTER SWITCH
HORN RELAY
HEAD LAMP RELAY (DIMMER)
TAIL LAMP RELAY
FLASHER UNIT
POWER RELAY
OVER HEAT RELAY
WARNING BUZZER
FUSE
BLOCK
RESERVOIR TANK
(BRAKE FLUID)
02-157
Above drawing shows the setting position

under the chassis condition.
02-158
Should be set in the front panel and has

suitable inspection cover or lid
KC-AA014A
118

REAR COMPONENT BOX
Setting position of rear electrical
component box
(For rear engine only)
Do not modify or alter the setting

position.
Fit the inspection cover or lid for
maintenance.
02-159
Electrical Computer Box

Due to recent improvements in vehicle performance and to comply with exhaust gas
emission regulations, electronic computers for controlling engines and transmissions
have come into use being installed in chassis.
If these computers are subjected to water, dust, or heat, they may be damaged and
stop functioning.
Further, because the installation position under a chassis condition is a temporary
installation condition, be sure to securely install the computer to the body side while
observing the following instructions when mounting the body.
(For detailed instructions on mounting, see the Body Mounting Manual for the respective model series.)
INSTALLATION PROCEDURE OF COMPUTER BOX

Install at a position where no water or dust enter and high temperatures are avoided.
(The peripheral temperature of the installation position should be 60C or less.)
Installation inside the passenger compartment is usually recommended but if the computer must be installed on the floor, be sure to provide an installation box that keeps water
or dust from entering and an inspection cover or lid for inspection and maintenance.
Also, be sure the computer is installed at a position not subjected to direct sunlight or that
a cover is provided to protect it from possibly being subjected to direct sunlight.
KC-AA014A
119

Sealing should be securely made so water or dust do not enter the floor surface of the
harness wire or the passageway of the partition plate of the box.
Further, the harness should not interfere with the edges to prevent short circuits.
Installation of computer box

Computer box
02-160
Temporary setting position

under the chassis condition
Passageway of the harness

Securely seal to prevent water or dust from
entering.
Should not interfere with the edges and the
harness should be protected by rubber.
Computer box
Floor surface
02-090
NOTE
The figure above shows a rear engine vehicle. The same specifications
apply to a front engine vehicle as well.
Do not set antennas of televisions, radios, or other electronic devices close to the computer box.
In principle, the connecting wire between the computer box and the harness wire should
not be removed. However, when the coupler must be removed during installation, be
sure to securely connect again. (Be careful not to make any wiring mistakes or to forget
to connect the wires.)
KC-AA014A
120

Any paint or contamination on the terminal installation surface of the computer box
ground should be removed and the ground connected between the computer case and
the bracket.
Ground connection of computer box
BRACKET
CPU (COMPUTER) BOX
CPU (COMPUTER) BOX
SUB-HARNESS
FOR GROUND
CPU (COMPUTER) BOX CASE
Remove any paint or contamination on

the terminal installation surface and
securely connect the ground.
02-162
KC-AA014A
121

Fuse block
The fuse block is installed inside the front electrical box.
If the fuse is blown due to operation mistakes while mounting the body, the fuse should
be replaced with a fuse of the rated capacity.
Do not use wire not for the fuse.
(Do not use a fuse with a rating other than the correct value because of the danger of
burns to the wire harness or damage to the electrical equipment due to the fuse not
operating properly if a circuit error occurs.)
HAZARD & PARK SWITCH
CIGARETTE LIGHTER (OPT)
FOG LAMP
SWITCH
WIPER SWITCH
BATTERY SWITCH
Front electrical
component box
COMBINATION
SWITCH
HEAD LAMP RELAY

(MAIN)
HORN RELAY
STARTER SWITCH
HEAD LAMP RELAY (DIMMER)
TAIL LAMP RELAY
FLASHER UNIT
FUSE BLOCK
POWER RELAY
OVER HEAT RELAY
WARNING BUZZER
RESERVOIR TANK
(BRAKE FLUID)
02-163
Fuse block
FUSE BLOCK TOP
ENG. STOP
REGULATOR
ABS
10A
ENG. STOP
5A
GAUGE
10A
5A
EXH. BREAK
10A
TAIL LAMP
RELAY
ZF-T/M
(F1)
ZF-T/M
(F2)
10A
10A
AIR DRIER
GAUGE
LAMP
ZF-T/M
(F3)
15A
STOP LAMP
TAIL LAMP
TICS
5A
5A
HORN
5A
10A
10A
5A
5A
SUB
STARTER
10A
10A
10A
10A
10A
10A
CIGARETTE
LIGHTER
BACK LAMP
10A
HEAD LAMP
DIM. RH
SPARE (TAIL)
5A
76588-3530
HEAD LAMP
DIM. LH
10A
WIPER
HEAD LAMP
MAIN RH
FOG LAMP
5A
STARTER
HEAD LAMP
MAIN LH
10A
20A
KEY SWITCH
10A
USE THE DESIGNATED FUSES ONLY
20A
TICS
DETAIL OF BLOCK ASSY. FUSE

(EXAMPLE)
KC-AA014A
122

Electrical Power Source Terminal
Because the power source of the electrical equipment of the body has a special
removal terminal provided on the chassis, be sure to remove it from the specified terminal.
[POSITION OF POWER SOURCE TERMINAL]

Front engine chassis Installed inside the junction block between the
wheelbase
Rear engine chassis Installed inside the rear electrical component box
The power consumption should be controlled at the indicated capacity or less.

Removing the electrical power from a terminal harness other than the specialized ones
will result in burns or fires and must not be done.
Fuses should be provided for each circuit inside the electrical equipment circuit on the
body side.
When taking electrical power directly from the battery of the chassis, a fuse must be
provided between the battery and the electrical equipment on the body side. Be sure
to observe the instruction given below.
POWER SOURCE TAKING OUT TERMINAL POSITION

FRONT ENGINE VEHICLE
OUTPUT POWER TERMINAL OF BODY &

COOLER
(MAX. OUTPUT CAPACITY: 35A)
FROM
BATTERY
RELAY
TO ALTERNATOR
TO STARTER MOTOR
Junction block
(Installed between wheelbase.)
KC-AA014A
02-164
123

REAR ENGINE VEHICLE
Power source taking out terminal
FOR BODY
ELECTRICAL
EQUIPMENT
MAX. OUTLET
CAPACITY 42A
ELECTRICAL
OUTPUT SOURCE
BOX
SAFETY RELAY
FOR COOLER
MAX. OUTLET
CAPACITY 70A
STOP LAMP RELAY
REGULATOR (OPT)
02-165
Rear electrical component box

(Installed on the No. 8 crossmember)
NOTE
For details of the maximum removal electrical capacity (A), see the Body
If indicated capacity is exceeded, a blow of the fuse on the chassis side
or harness burning may result causing a fire. Be sure not to exceed the
indicated capacity.
KC-AA014A
124

USING POWER DIRECTLY FROM THE BATTERY
If you intend to use power for the body electrical equipment directly from the battery,
secure the battery cable and the body power supply terminal together with the same
nut (see drawing).
In this case, a fuse must be installed at a suitable point in the circuit. Take precautions
to prevent short circuits as these may lead to vehicle fires.
When securing the cable and power terminal, make sure the nut is properly tightened.
Battery cable
To body
02-166
Battery + Terminal
Terminal
KC-AA014A
When taking out power source

directly from the battery terminal, a
fuse must be installed between battery terminal and body electrical
equipment.
125

Notes about the ground of additional circuit.
Don't connect the ground of additional circuit to the same position as the existing earth
wire of vehicle.
Be sure to connect the ground of additional circuit to the frame to which the negative
"" battery cable is connected.
Install the grounding terminal of additional circuit in a frame with the bolt with a "LOCK
WASHER, EXTERNAL TOOTH".
(For detailed informetion, contact to authorized HINO dealer.)
The grounding terminal should use a round shape terminal.
Weld a nut to the frame and take the measures which prevent the rust of the nut.
Remove the paint of the frame of the position in which a grounding terminal is installed.
Install the grounding terminal securely in a frame.
KC-AA014A
126

Wiper and Washer System Circuit
Only the wiper and washer switch are incorporated into the steering column under a
chassis condition.
Accordingly, the body manufacturer is responsible for designing the wiper and washer
system circuit with the necessary parts provided and installed to the body.
[PARTS PREPARED BY THE BODY MANUFACTURER]

Wiper motor assembly
Wiper blade and control linkage assembly
Wiper relay
Intermittent relay
Washer system assembly
Wire harness
Be sure to observe the following instructions in the design of the wiper and washer system circuit and installation to the body.
KC-AA014A
127

DESIGN OF WIPER CIRCUIT AND ASSEMBLY
The capacity of the contacts of the wiper and washer switches installed in the steering
column under a chassis state is small.
The main operating current to operate the wiper motor should not flow through these
switches.
Accordingly, the wiper circuit should have a circuit design that operates the relay of the
installed wiper motor.
(The design should be such to create a circuit in which only the signal current that controls the relay for the wiper and washer switches flows.)
The capacity of the contacts of the wiper and washer switches should be as follows.
[SWITCH CONNECTION DIAGRAM]

WIPER & WASHER
SWITCH
Terminal
WW EW WI WL WH
Position
WASHER
SWITCH
OFF
OFF
INT.
INT
LO
LO
HI
HI
WIPER SWITCH
WASHER ON
02-167
Electrical capacity of each
EW-WI : 0.5 A
EW-WL : 0.5 A * Relay operation
resistance only
EW-WH : 0.5 A
WW-EW : 2.0 A (motor load)
NOTE
The * mark indicates a motor load is
not included.
The power supply of the wiper circuit should be removed from the specified terminal
inside the front electrical component box.
If removed from another wire harness, an overload will result causing a short-circuit in
the fuse or harness of fire. Do not remove from the incorrect terminal.
Refer to the typical recommended wiper circuit for details.
However, detail of the wiper circuit and installation procedure must be followed the
instruction described in the body mounting manual for respective model series.
KC-AA014A
128
KC-AA014A
GROUND
WASHER
MOTOR
3WR
2
1
2BW
5
1
0.5LG
0.85B
0.85BY
3
2
2B
GROUND
WW FW WI WI WH
0.5GR
WIPER WASHER SWITCH
WASHER
HI
LO
INT.
OFF
1 2 3
4 5
0.5GB
0.85BY
FUSE
GR
GB
2
5 WIPER (POWER) 4
RELAY
6
3
1
7
2BW
2LY
2LB
2LR
2
3
4 INTERMITTENT
1
5
RELAY
6
2B
85910-1330
INTERMITTENT RELAY . . . . . . .
GROUND
WIPER MOTOR
(EXTERNAL GROUND TYPE)
85910-1360
LG
1 2 3
4 5 6
[NOTE] PARTS NO. OF RELAY

WIPER (POWER) RELAY . . . . . . .
WIPER MOTOR
(INTERNAL GROUND TYPE)
2BW
20A
2LB
BY
2LB
2BW
2LR
2L
2BW
2B
5
6 7
2BW
1 2
3 4
2LW
[TYPICAL EXAMPLE]
2LR
RECOMMENDED WIRING DIAGRAM FOR WIPER
2LW
2
02-169
129
3
2 5
1 4
S-1
S-2
S-3
S-4
S-5
TO A
TO RL
TO RW
TO I-4
TO I-2
DETAIL OF CONNECTOR OF
WIPER SWITCH
3
5 2
4 1
1
2
3
4
5
(FOR WIPER)
POWER
SOURCE
3 6
2 5
1 4
1
2
3
4
5
6
02-170
6
7
6
5
7
5
6
7
I-1
I-2
I-3
I-4
I-5
I-6
RY
R
G
RB
RW
RL
B
TO L
TO A
TO H
TO I-5
TO S-3
TO S-2
TO B
02-173
GROUND
WASHER
MOTOR
2
1
GROUND
WIPER MOTOR
(INTERNAL GROUND TYPE)
2BW
02-172
(WIPER MOTOR)
(WIPER SWITCH, CONNECTOR NO. 1)
(WIPER MOTOR)
(INTERMITTENT RELAY, CONNECTOR NO. 5)
(GROUND)
TO D (GROUND)
TO S-5 (WIPER SWITCH, CONNECTOR NO. 5)
TO A
TO S-4
TO RB (WIPER SWITCH, CONNECTOR NO. 4)
TO C (WIPER RELAY, CONNECTOR NO. 4)
(WIPER MOTOR)
WIPER RELAY
INTERMITTENT RELAY
INTERMITTENT RELAY
(PARTS NO. :
85910-1330)
6 3
5 2
4 1
WIPER (POWER) RELAY

(PARTS NO:
85910-1360)
(WIPER RELAY, CONNECTOR NO. 2)

(INTERMITTENT RELAY, CONNECTOR NO.3)
(WIPER MOTOR)
(WIPER RELAY, CONNECTOR NO.6)
(WIPER RELAY, CONNECTOR NO.5)
FRONT ELECTRICAL COMPONENT BOX
WIPER
SWITCH
OFF
INT
LO
HI
1
2
3
4
FROM S-5
WASHER
SWITCH
3 1
4 2
02-171
GROUND
WIPER MOTOR
(EXTERNAL GROUND TYPE)
2BW
1 3
2 4
2LB
2B
WIPER & WASHER

SWITCH
2BW
2LB
FROM A
2B
2LW
2LR
2LR
2LW
KC-AA014A
0.85BY
[TYPICAL EXAMPLE]
2LW
DETAIL OF CONNECTOR OF RECOMMENDED WIRING DIAGRAM FOR WIPER
2LR
2
130

PRECAUTIONS OF DESIGN OF WIPER CIRCUIT AND ASSEMBLE
Relays which is described in diagram are option parts.
If it is needed, contact authorized HINO distributor.
NOTE
Parts number of relay
Wiper (power) relay: 85910-1360
Intermittent (power) relay: 85910-1360
How to read the connector and color symbol marks marked on each wiring in the diagram.
CONNECTOR
Connector
See from this side.
Harness
3 4
2 5
1 6
02-174
COLOR SYMBOL MARK

0.85
BL
Color symbol of harness wiring
Cross section area of harness conductor
Color symbols
B
Black W
G
Green Y
Br
Brown Lg
White L
Yellow R
Light green
Blue
Red
Symbols-two letters
The first letter Ground color
The second letter
Marking color
[Ex.] BL
With blue marking on the red back ground
Select a wiper relay with sufficient capacity taking into consideration the performance
(capacity) of the wiper motor.
The wire harness size and power supply fuse for circuit should be selected depending on
the capacity (operation current) of the wiper motor.
For wiper motor capacity of 7A or less:
Harness size 0.85 Sq. mm
Fuse
10A
For wiper motor capacity of 7A but less than 14A:
Harness size 1.25 Sq. mm or bigger
Fuse
20A
KC-AA014A
131

NOTE
The wire harness size and power supply fuse are determined based on the capacity
of the operating current and are not related to the number of wiper motors installed.
If the capacity of the operating current will exceed 7A, modifications to the power
supply fuse as well as the power supply harness for wiper circuit incorporated on
the chassis side are necessary.
[Ex.] Modifications of power supply fuse and harness incorporated

on the chassis side.
Fuse
10A
20A
Harness size
0.85 OR
1.25 Sq. mm or bigger
1.25 Sq. mm
For details of power supply fuse and harness for wiper circuit incorporated on the
chassis side are described in 6 ATTACHED DATA, ELECTRICAL WIRING DIAGRAM.
For details on modifying the fuse and harness, contact the nearest HINO distributor.
The capacity of the operating current of the circuit should be controlled at 70% or
less of the capacity of power supply fuse in view of safety considerations.
KC-AA014A
132

Lamps
The lamps, head lamp, tail lamp and other lamps, are temporarily installed on the chassis or separately supplied at delivery of the chassis.
Therefore, when mounting the body, these lamps should normally installed to the body.
For details of installation holes for lamps, see the Body Mounting Manual for the
Open Circuit Detector System

In order to increase the level of safety, an Open Circuit Detector System that informs
the driver of an open circuit in the lamp circuit is incorporated into the circuit associated
with the lamp.
When installing additional accessory lamps which use the lamp circuit of the chassis for
the power supply, the Open Circuit Detector System will stop functioning if the capacity of the detector system relay is exceeded.
Accordingly, observe the following points when installing additional accessory lamps
which use the lamp circuit of the chassis for the power supply.
DIRECTIONAL INDICATOR AND HAZARD LAMPS

If one of the circuits of the directional indicator lamps opens, detector system will change
the flashing frequency and function to inform the driver of the open circuit.
Therefore, the flasher unit uses components equal to the total W number of directional
indicator lamps. If the number of lamps is increased when mounting the body, the total
W number will increase and the detector system will stop functioning.
Accordingly, when increasing the number of lamps which use the directional indicator
lamp circuit for the power supply, be sure to replace the flasher unit.
Capacity and parts umber of flasher unit

Standard
Increased lighting
Capacity (one side)
25W x 3 + 3W
25W x 3 + 10W x 2 + 3W
Parts number
81980-1480
81980-1121
(Parts number of flasher unit will be changed according to chassis model.)
Front
3W
25W
25W
10W x 2
(INCREASED LIGHTING)
02-175
KC-AA014A
133

Precautions of Electronic Machines
As described previously, due to recent improvements in vehicle performance and to
comply with laws and regulations, vehicles are also being equipped with electronic
computers.
If this electronic equipment is subject to heat, shocks, or other factors such as high
voltage electrical welding, internal damage will occur and the equipment will stop functioning.
Accordingly, be sure to carefully observe the following precautions when mounting a
bus body on a chassis in which electronic equipment is installed.
KINDS OF ELECTRONIC EQUIPMENT

The electronic equipment used in HINO bus chassis are shown below.
HINO TE-system
Electronic control governor
Electronic control timer
Pre-lift control fuel injection pump
A.B.S. (anti-lock brake system)
A.S.R. (anti-slip regulation system)
FSV controller
Vehicle speed control limiter
Auto-transmission control computer
HANDLING PRECAUTIONS
Circuits related to electronic control (control unit, actuator, sensor, etc.) use a special
multi-terminal connector because they use a very small current.
Therefore, take note of the following points when handling them while mounting the
body.
Unnecessary removal or insertion of connectors should not be done.
Deformation or damage to connectors will result in decreases in the insertion force and
poor connections.
KC-AA014A
134

When removing the connector, be sure to hold the male and female parts of the connector housing.
Removing the connector by holding the harness wire and pulling or twisting will cause
damage to the harness wire and deformation of the terminal. Do not remove the connector in this way.
Be sure water, oil, or dust do not adhere to the removed connector. Poor connections or
unstable continuity will result.
When connecting the connector, be sure to securely connect it until the lock engages.
Observe the following precautions for electronic equipment installed on the body side.
The electronic equipment may malfunction due to large amounts of noise generated by
the equipment itself.
Accordingly, a component with a noise eliminator such as a diode of bakusuta attached
should be used for the relay, solenoid, or motors installed to the body.
KC-AA014A
135

Harness Wiring
If a mistake is made in the harness wiring while mounting the body, the harness may
be damaged by vehicle vibration while the vehicle is driving, or water, dust, or mud
entering into the harness. If these occur, a short-circuit or fire may result causing a
severe accident.
Accordingly, be sure to observe the procedures given below for modifications or alterations of the harness wiring involved with the body mounting or other actions.
PRECAUTION WHEN MOUNTING BUS BODY

OR RELATED EQUIPMENT
When installing U-bolts or body mounting brackets, or when mounting bus body or related equipment, observe the following precautions.
Make sure that harness wires and battery cables are not squeezed or pinched, and do
not come into contact with sharp edges or corners.
Squeezed
Pinched
Sharp edge
02-176
Make sure that harness wires, battery cables and other electric equipment (switches,
magnetic valves, battery, etc.) are easily accessible for maintenance.
If you fit additional switches or lamps for a body or equipment, observe the following precautions.
To prevent accidental operation or confirmation, install a caution plate showing the purpose of each switch, etc.
Caution
plate
02-177
KC-AA014A
136

Common use of switches which are already installed on the chassis side for control of
lamps installed on the body side or other electrical equipment is prohibited.
An overload will occur resulting in burning of the switch contacts or harness.
The control of the electrical equipment on the body side should be done using a separately installed switch.
02-178
ADDITIONAL SWITCH
[RIGHT]
EXISTING SWITCH
[WRONG]
If you intended to fit a buzzer for a body or equipment, make sure that its sound is clearly
different from that of the existing buzzer around the drivers seat of chassis.
[SPECIFICATION OF EXISTING BUZZER AROUND DRIVERS SEAT]
Buzzer type
Specifications
Low brake pressure warning buzzer
Sound pressure: 90 to 105 dB (A)

(At a distance of 1 m)
Engine overrun buzzer
Frequency: 400 to 600 Hz
For details of any other buzzers, see the Body Mounting Manual for the respective
model series.
KC-AA014A
137

ADDITION OR MODIFICATION OF WIRING
If you intend to extend wiring, make sure that you use the same size and color of wire as
the original.
Make all connections secure by soldering or pressure joints. After connecting, remove
burrs and cover fully with insulation material.
When making connections in chassis side wiring, cover connections with waterproof
sealant, then cover fully with insulating material.
[WATERPROOFING]
Cover connections with butyl rubber solution.
Butyl rubber solution
Cover completely so that no metal part is exposed.

02-179
Wrap with butyl rubber sheet.
Butyl rubber sheet

02-180
Wrap with adhesive vinyl tape.
Adhesive vinyl tape

02-181
KC-AA014A
138

When soldering, do not use chlorine.
If you intend to move the battery or modify the battery cable layout, do not extend or
shorten the battery cable.
In areas where the battery cables are subject to movement due to relative motion of the
starter and the frame, do not modify the clamping method, positions of clamps, or the
amount of slack in the cables.
Clamp electric wiring firmly to prevent it from contacting the moving or vibrating parts of
the chassis or body, and any sharp edges or corners.
[CLEARANCES FOR WIRE]
Position
Clearances
B e t w e e n m o v i n g p a r t s a n d At the close point:

wiring Between sharp edges or Minimum clearance:
corners and wiring
min. 30 mm
min. 10 mm
Min. 30 mm
Range of motion
KC-AA014A
02-182
139

Where wiring passes through the frame or a panel, always use a grommet to prevent
damage to the wire and potential short circuits.
Protection of harness which

penetrates frame and panel
USING GROMMET
Grommet
Min. 5 mm
02-183
Do not install wiring where it may be damaged by accumulation of mud or snow, by

freezing, or by flying stones.
If you must install wiring in such positions, protect it with metal plates.
Harness wires should be installed where there is
no danger of damage from accumulation of mud,
sand, or snow.
Min. 5 mm
L1 = L2
L2
L1
Do not install wiring within

the shaded area.
02-184
When wiring of the harness wire is done inside the chassis frame, place the wiring along
already installed wiring and do not wire independently along empty spaces.
Also, when wiring under the floor of the body or inside the roof construction, be sure to
place the wiring along the structure frame, use a clip following the indicated interval,
carry out water proofing measures and observe the harness wiring rules.
Do not make connections by cutting open the coating of a wire and pulling out the bare
wire. This procedure is very dangerous and may damage other wires.
KC-AA014A
140

To prevent water from running along wires and penetrating electrical equipment, always
seal holes through which wires pass using grommets and make connections so that the
terminal is higher than the wire.
Electrical equipment or its cover
Grommet
02-185
Install wires where they are not exposed to dust or water.

Do not install the harness wire on the top or outer side of the chassis frame.
In such positions, they may be damaged by being stepped on during body mounting, or
by flying stones during vehicle operation.
If there is a harness for the chassis already installed close to the wiring area when wiring
is done inside the chassis frame, the wiring and taping should be done along this harness.
When installing wiring for parts of the engine, transmission, etc., install the wiring in parallel to existing wires, and be sure to allow sufficient slack to absorb any relative movement. Make sure that the wiring does not touch any other part.
When installing the harness wire to connect to the power unit, make sure that harness wire has sufficient slack to absorb relative movement.
Air compressor for cab
air conditioner
Sufficient slack
Chassis frame
Engine
02-186
KC-AA014A
141

Where electrical wiring runs parallel to pipes (including rubber hoses, vinyl hoses, and
steel pipes) or brake system pipes (including brake hoses and brake pipes) or grease
pipes, never clamp the wiring together with these pipes.
[CLEARANCES BETWEEN HARNESS WIRES AND PIPES]
Wiring method
Clearances
Pipe and parallel wire
min. 10 mm
Crossing point of wire and pipe
min. 20 mm
Never secure harness wires together

with pipes or link rods.
Harness wire
Pipe
02-187
WRONG
Harness wire (upper side)
Min. 10 mm
Fuel hose or pipe (lower side)
02-188
If you move the battery, you may have to temporarily remove the battery cables from the
terminals of the battery relay. When refitting the battery cables, observe the specified
torque to avoid damaging the battery relay terminal:
Tightening torque
13.73.9 Nm {14040 kgfcm}
(If a terminal is damaged, replace it with a new part.)
If you move the battery, make sure it is positioned at least 200 mm away from the
exhaust system (muffler, tail pipe, etc.). If you must install the battery within 200 mm of
the exhaust system, protect it wit insulating panels.
KC-AA014A
142

If you use a plug-type connecting terminal, fit the female terminal into the power supply
side.
This is due to the connecting terminal detaching which does not allow a short-circuit to
occur even if the chassis or body construction make contact.
Female terminal
Power supply side harness
02-189
To prevent sagging, contact with other parts or contact with sharp edges or corners,
secure all wiring with clips.
The clips should be spaced at a standard interval of 300 ~ 500 mm. This interval should
be shorter where conditions dictate.
Clipping interval
Max. 500 mm
02-190
KC-AA014A
143

All clips should use resin coating or attached grommets.
[RECOMMENDED CLIP TYPES]
Rubber grommet
R shaped flange
Section A-A
Vinyl coated
A
02-191
02-192
Clip with rubber grommet

(in case of relative movement)
Clip coated with more than

0.6 mm thick vinyl
Crocodile clips and adhesive clips should only be used for temporary installation.
Harness wires should be installed above fuel hoses or pipes to avoid fuel dripping onto
the harness wire in the event that a fuel leak occurs. Keep a clearance of at least 20 mm
between the harness wire and fuel hose.
Harness wire (upper side)
Min. 20 mm
Fuel hose or pipe
(lower side)
02-193
Bundle unused harness wires and their terminals should be bundled with other harness
wires and covered with vinyl tape to prevent water from penetrating the terminal.
Unused harness wire

02-194
KC-AA014A
144

ELECTRIC WIRE SIZE AND PERMISSIBLE CURRENTS
When wiring the harness wire together with the body mounting operations, select an
appropriate type of wire harness taking into consideration the power consumption
capacity (A) of the electrical equipment such will be mounted and the condition of the
installation location.
Select wires to suit local conditions (e.g. ambient temperature).
Permissible ambient
temperature
Wire type
AV wire
(low voltage wire for vehicles)
max. 60
AVX wire (cross-lined vinyl)

(heat-resistant low-voltage wire for
vehicles)
max. 70
AEX wire (cross-lined polyethylene)

(heat-resistant low-voltage wire for
vehicles)
max. 90
Notes
Use for nomal wiring
Use for wiring in engine

room and other areas with
high ambient temperature
NOTE
If you intend to use AEX wire, make sure that you also use heat-resistant
protective tubing, tape, and clips.
b)
Select wire size according to the permissible current.

Nominal crosssectional area
(mm2)
AV
AVX
AEX
0.5
0.85
11
10
1.25
14
13
12
20
17
17
27
24
23
36
33
32
47
43
42
Permissible current (A)
NOTE
Where the wire is subject to movement caused by relative motion, use wire
of 0.85 mm2 cross section or larger.
KC-AA014A
145

CODING FOR ELECTRICAL WIRES & CONNECTORS
The identification indications of the harness wire and connectors stated in the
Electrical Wiring Diagram of the chassis indicated in the Body Mounting Manual for
the respective model series should comply with the following standards.
Additions or modifications of the chassis harness wire involved with body mounting
must be done by referring to the identification indications and using a harness wire with
an identical size and color.
[HARNESS WIRE CODES REPRESENT SIZE AND COLOR]
Wire color (stripe color)

Wire color (base color)
Wire size (nominal cross-sectional area) (0.5 mm wires not listed)
Wire type (AV wires not listed)
Code
Wire color codes
Wire color
WHITE
BLACK
RED
YELLOW
GREEN
BLUE
Br
BROWN
Lg
LIGHT GREEN
ORANGE
0.85
W B
Stripe color: black
Base color: white
Wire size: 0.85 mm
Wire type: AV wire
KC-AA014A
146
14. ATTACHMENT OF THE PACKAGED PARTS

Because the handling precautions of each chassis component, caution plates including
maintenance instructions, and optional equipment such as windshield wiper parts are
parts installed on the body side, they are packed in the chassis under a chassis condition.
Accordingly, when mounting the body, be sure to attach or install these packaged parts
at their correct positions.
TYPES OF PACKAGED PARTS

The following types of parts are packaged in the chassis.
Rubber boot and parts related to boot installation for transmission control level
Each type of caution plate
Emblem or ornament showing HINO and model name
Spare fuse set
Towing hook and parts related to hook installation
Reflex reflector
Crank handle for spare tire
Others including optional parts for body mounting, etc.
[EXAMPLE OF INSTALLATION POSITION]
CAUTION PLATE
(ENGINE)
TRANSMISSION
CONTROL LEVER
Boots
Floor
02-220
02-221
CAUTION PLATE
(AIR CLEANER)
02-222
NOTE
For details of packaged parts and installation positions, see the Body
KC-AA014A
147
Chapter 3
PRECAUTION WHEN APPLYING THE FINAL COAT OF PAINT
1. COMPONENTS TO BE MASKED 1
2. UNPAINTED COMPONENTS 1
3. ELECTRICAL PARTS 1
4. FORCED DRYING 1
5. PAINTING THE WHEEL DISC 3
6. PRECAUTIIONS OF WHEEL INSTALLATION 4
KC-AA014A

When applying the final coat of the body, the following points should be noted as the
chassis involves components to be masked which are sensitive to heat when drying
and components which are not to be painted.
1. COMPONENTS TO BE MASKED
Components which are not coated, such as the top mark, ornaments, identification
plates (with model and chassis numbers) and warning plates (caution plates) should be
completely masked.
Never paint rubber hoses, pipes, and bulbs.
2. UNPAINTED COMPONENTS
Stains on unpainted components should be removed with gasoline.
Using thinner is not recommended.
3. ELECTRICAL PARTS
During painting, cover all electrical connections, wiring, batteries and other electric
components to protect them from paint.
4. FORCED DRYING
Natural drying takes a long time, but the low drying temperature ensures there will be
no problems with non-heat resistant parts.
But if forced drying is used, the upper temperature limit must be maintained lower then
80C.
If you plan to force dry at temperatures over 80C, first remove all plastic, rubber and
electric parts of the chassis from the vehicle or shield them to prevent their temperature
rising over 80C.
KC-AA014A

Adhesives (chloroprene rubber-based, product name semidyne 5100) are also used in
the engine hood weather strip for front engine chassis, joints of fuel lines end hoses,
and joints in the air intake system of the engine and rubber hoses.
At temperatures above 80C, this adhesive softens resulting in a danger of components coming apart.
Take care that the ambient temperature does not rise over 80C of these parts.
Drying booth
03-001
Recommended ambient
temperature in drying
booth max. 80C.
NOTE
Refer to the last section of the PARTS HEAT RESISTANCE TABLE
for information on the heat resistant temperature of each part installed
on the chassis.
KC-AA014A
5. PAINTING THE WHEEL DISC

Wheel manufacturers paint these wheels before shipment, but some customers may
request repainting in custom colors. The thickness of the paint may affect the tightness
of the wheel nut.
Therefore, use the following procedures to paint wheels.
MAIN POINTS TO NOTE WHEN PAINTING CUSTOM COLORS.

Mask the side of the wheel on which the disk is installed (including the parts that come
into contact with the wheel nut washer, as well as parts in contact with the other hub, the
drum and disk wheel).
A
This part should therefore be
masked on both the front and
rear of the vehicle.
After the wheel has been

installed on the vehicle, only
parts visible from outside
should be painted, and only
lightly.
03-002
CONTACT AREA OF WHEEL NUT
Section A-A
03-003
After installing the wheel on the vehicle, the parts which need to be painted on the front
and rear outer wheel should be lightly coated in the same color (after the wheel nut has
been installed).
When the coated part comes in contact at the tire rotation, a thick coating of additional
paint on the spherical washer after installation may cause loosening of the wheel nut.
KC-AA014A

PRECAUTION WHEN TIRE ROTATION (FOR REFERENCE)
Tire rotation may change the position of the disk wheel. This may cause the painted
parts to come into contact with other components.
If this happens, and the paint is thick, the wheel nuts may loosen. Therefore, the following procedure should be followed when tires have a rotation work.
The paint must be removed from the paint contact with the disk (including the spherical
washer). Clean, for example with a wire brush, and repaint the part lightly to prevent
rusting.
If a thick coat of paint is not removed, the wheel nuts will loosen, even if the part is
cleaned, for example with a wire brush.
6. PRECAUTIONS OF WHEEL INSTALLATION

It is strictly forbidden that the wheel and other than the wheel are tightened together
with a wheel nut.
If it tightens, the wheel nut will loosen and a serious problem will be caused.
Refer the owner's manual for the right procedure of the wheel installation.
KC-AA014A

PARTS HEAT RESISTANCE TABLE
No.
Parts name
Material
Permissible
temperature
(Centigrade)
Meter housing
Polypropylen
90C
Meter housing inspection lid
Polypropylen
90C
Meter housing side cover
Polypropylen
90C
Steering column cover
Polypropylen
80C
Steering column cover, upper
ABS
90C
Steering column cover, lower

and floor
Polypropylen
80C
Ornament (model name)
ABS
80C
Emblem (Top "HINO" Mark)
ABS
80C
Radiator seal
Rubber
10
Head lamp
11
Front directional indicator lamp
Lens; AS
80C
12
Tail lamp
Lens; AS
80C
13
Licence plate lamp
14
Combination meter
ABS+
Polypropylen+
Acryle
90C
15
Steering column adjustable knob
Polypropylen
80C
16
Steering wheel
Polypropylen
80C
17
Electrical equipment box
18
Pedal rubber
(Accelerator, brake, clutch)
19
Engine mounting rubber
Rubber
20
Electrical wire harness
Vinyl
100C
21
Air hose
Rubber
100C
22
Brake hose (oil)
Rubber
70C
23
Brake air booster
Rubber
70C
24
Brake valve
Rubber
70C
25
Horn pad
ABS
80C
Notes
100C
100C
100C
90C
100C
KC-AA014A
80C
Chapter 4
BUS BODY
1. BASIC POINTS OF BUS BODY MOUNTING 1
2. DESCRIPTION OF A BUS BODY 2
3. PRINCIPAL PRECAUTIONS WHEN MOUNTING
A BUS BODY 5
4. BASIC LAYOUT OF BODY STRUCTURE 9
5. LAYOUT OF STRUCTURAL ELEMENTS 15
6. RUST AND CORROSION PREVENTION 36
7. RIDE COMFORT IN RELATION TO VIBRATION
AND NOISE 51
8. DESIGN TO FACILITATE INSPECTIONS AND
MAINTENANCE 67
9. SAFETY CONSIDERATIONS 69
10. FIRE PREVENTION 70
11. APPEARANCE AND WORKMANSHIP OF
BUS BODY 73
12. ADVANTAGES AND DISADVANTAGES OF FRONT
AND REAR-ENGINED BUSES, AND AIR
CONDITIONING SYSTEMS 76
KC-AA014A
BUS BODY
1. BASIC POINTS OF BUS BODY MOUNTING

The design strength of the Hino bus chassis frame assumes that a conventional type
of bus body will be installed on it.
The chassis frame has been designed on the basic principle that the completed
body and chassis frame will form an integrated structure.
When designing a body, take account of the fact that the chassis frame bears only part
of the overall load received by the bus.
The chassis frame has been designed with sufficient rigidity to allow the vehicle to be
driven as a bare chassis without mounting a body.
However, do not run under the bare chassis on bad or unpaved roads so as not to subject it to excessive stress.
Body strength + chassis strength

= overall strength of vehicle
04-002
When designing and actually mounting a bus body, remember the above points and be
sure to observe the following precautions.
The instructions given in this section are based on a stressed skeleton structure bus
body (a type of body commonly adopted in recent years), in which the load received by
the vehicle is supported largely by the main structure of the body.
KC-AA014A
BUS BODY
2. DESCRIPTION OF A BUS BODY

Classification and characteristics of BUS bodies by structure
Bus bodies can normally be classified according to which part of the structure supports
the external force from the road surface while the vehicle is stopped or in operation.
The table below shows the major types of bus body structure in common use today and
outlines their principal characteristics.
Principal characteristics
Body structure
Stressed
outer-skin
structure
Rafter
Pillar
Rail
Stressed-skin structure
Stiffener
Crossmember
04-003
Stressed
outer panel
The outer panels are the main

strength elements of the body
structure.
The size of openings in the outer
panels must be restricted to
ensure sufficient rigidity (i.e. the
size of windows and doors are
limited).
The large number of rivets
required in this type of construction detracts from the appearance
of the vehicle.
The inner panels are the main

strength elements of the body
structure.
Because the strength elements
are on the inside of the body, the
outside can be covered with decorative outer panels, giving this
type of body an advantage in
terms of appearance.
The inner panels must be maintained to ensure sufficient rigidity,
so that this type of body tends to
be heavier than others.
Stressed
nner-skin
structurei
Stressed inner panel

04-004
Stressed
skeleton
structure
Stressed
skeleton
Strength and rigidity are provided

by an integrated chassis frame
and body structure.
This type of body offers considerable advantages in freedom of
design and appearance. (The
appearance is clean, with no rivets in outer panels, and windows
and doors can be made large.)
04-005
KC-AA014A
BUS BODY
Method of joining of body to chassis frame
In the body mounting process, the bus body may be joined to the chassis frame by a
number of methods.
The figure below shows a number of methods commonly used to join the body structure to the chassis frame.
Body
structure
Type of
chassis frame
Frameless or
sectional frame
Coupling system
Crossmember
Subframe
Frameless
system
04-006
Stress-skin
structure
Frameless system
Outrigger
Side frame
Ladder shaped
frame
Outrigger
system
04-007
Outrigger system
Sill cross
system
Sill cross
Side frame
04-008
Sill cross system
Stressed skeleton
structure
Ladder shaped
frame
Outrigger
system
Sill cross
system
Sill cross
Side frame
Sill cross +
Outrigger system
Truss cross
system
04-009
Sill cross + Outrigger system
Square tube
Side frame
04-010
Truss frame
Truss frame
system
Truss cross system

Square tube
04-011
Truss frame system
KC-AA014A
BUS BODY
In addition to these methods, there is also a rubber mounting system in which rubber is
used to minimize the vibration and noise transmitted from the chassis to the body when
the vehicle is in operation.
This method does not give the same degree of strength and rigidity as methods in
which the body and chassis frame form an integrated structure. It also has the disadvantage that if the rubber used is not of the correct hardness, it will not provide the
vibration- and sound-absorbing qualities required and will make the vehicle unstable in
operation.
Accordingly, this method is suitable only for small buses in which the chassis frame
already provides adequate strength and is not suitable for large buses.
Body
Sill cross
Rubber
Chassis frame
Bracket
Chassis
04-012
KC-AA014A
04-013
BUS BODY
3. PRINCIPAL PRECAUTIONS WHEN MOUNTING A BUS BODY

Relationship between bus body characteristics and vehicle performance
The dimensions and other specifications of the bus body and other equipment as a
whole or in part will affect the performance and functions of the vehicle in many ways.
The table below presents a summary of the factors involved.
Vehicle performance
Related body characterictics
DRIVING PERFORMANCE
Mobile performance
Handling stability
Driving performance on unpaved
roads
Peso, resistencia de la carrocera al aire.

Centro de gravedad, distribucin frontal y posterior del peso.
Holgura mnimo desde la tierra, ngulo de acercamiento,
ngulo de alejamiento.
DURABILITY
Strength, rigidity
Rust resistance, corrosion
resistance
Estructura del esqueleto de la carrocera, rigidez de las

uniones entre cada una de las partes de la estructura, rigidez de fijacin de los paneles exteriores, etc.
Resistencia al agua, drenaje de agua, especificaciones de
pintado y propiedades de los materiales de cada parte.
COMFORT
Passenger comfort
Vibration, ride
Passenger room noise
Espacio destinado al compartimiento de los pasajeros,

partes salientes en el espacio de los pasajeros, visibilidad, iluminacin natural, luces, color, circulacin de aire,
ventilacin, etc.
Frecuencia caracterstica y modo de vibracin de la carrocera, ruido y especificaciones de atenuacin de la vibracin de cada parte.
SAFETY
Safety of passengers and
pedestrians
Accident prevention, fire
prevention
Facilidad para la subida y bajada de los pasajeros, facilidad de movilizacin interna de los pasajeros, seguridad
del equipo interno y externo.
Proteccin de los mazos de cables, tuberas, etc.
This section (4. Bus Body) lists a number of essential precautions that you should
observe to assure the above aspects of vehicle performance when designing or mounting a body.
Items in boxes like this have the greatest impact on body mounting and are particularly
important.
KC-AA014A
BUS BODY
Strength and rigidity of the bus body
DISTRIBUTION OF FORCES AND
LOADS ACTING ON THE BUS BODY
Forces acting on the bus body

When the bus is stopped or in operation, the bus is subject to a variety of forces. The
most important forces, in terms of their magnitude and frequency are as follows:
Bending load:
Torsional load:
The forces which try to bend the body,

resulting from payload weight and reaction
forces from the road surface
The forces which try to twist the body,
resulting from alternative right and left
interactions to the body caused by reactions from road surface and the unbalance
of payload weight in the right and left
direction.
These loads lead to extreme deformation (stress concentration) in all parts of the body
structure. Especially in parts which have insufficient rigidity.
The action of such loads is described in the drawings shown on the following page
under FORCES ACTING ON THE BUS BODY and BENDING MOMENT AND
DEFORMATION OF STRUCTURE UNDER A STATIC LOAD.
As is clear from these drawings, significant bending forces act on the bus as a whole
even when it is stopped (deformation is especially great around the passenger door
and tire houses and progressing the overall bending deformation), and results in a
stress concentration in the joints at either end of the side window pillars tensioned by
bending forces.
Moreover, when the vehicle is in operation, torsional load (resulting from reaction
forces from road surface which act alternatively right and left to the bus body) and the
increase of the load due to vibration are added to the stress and acted on the bus
repeatedly. Thus stress concentration will become severe and cause frequent cracking
and breaking.
When designing and mounting a bus body, make sure that the shape of body parts
around the following openings provides sufficient strength, and/or take steps to reinforce them.
PASSENGER DOORS AND EMERGENCY EXITS

SIDE WINDOWS
WINDSHIELD AND REAR WINDOW
KC-AA014A
BUS BODY
Forces acting on the bus body
Four loads act on the bus when stop and in operation:
TORSIONAL LOAD
LATERAL LOAD
(DURING QUICK TURNING)
BENDING LOAD
TO AND FRO LOAD

(DURING QUICK BRAKING)
04-014
Bending moment and deformation

of structure under a static load
[Example: Rear engine bus]

Bending moment
(+)
Moment
kgm
()
Deformation
04-015
KC-AA014A
BUS BODY
Distribution of load on body components
The distribution of the forces acting on the body of the bus described in the preceding
paragraphs is shown in the two diagrams Bending rigidity and Torsional rigidity
below. These diagrams are based on the example of a skeleton-structure bus body.
Distribution of load on body components
[Example: Skeleton-structure bus body]

Fittings 6%
Front & rear structure outer panel
Fittings 7%
Front & rear structure

outer panel
Roof structure outer panels

Side structure
skeleton
Frame
13%
Outer panels 20%
Side structure
skeleton
Frame
17%
Side structure
outer panels
Roof structure outer

panels
Side structure
outer panels
Front &
rear structure skeleton
Outer panels 28%
Roof structure skeleton
Front &
rear structure skeleton
Body skeleton
61%
Body skeleton 48%

[Bending rigidity]
Roof structure skeleton

[Torsional rigidity]
04-016
From these diagrams it is clear that, in a skeleton-structure bus body,
THE GREATER PART OF THE BENDING AND TORSIONAL

LOADS IS BORNE BY THE INTEGRATED SKELETON STRUCTURE OF THE BODY (INCLUDING CHASSIS FRAME), AND
THE CHASSIS FRAME AND ROOF STRUCTURES (INCLUDING
BOTH SKELETON AND OUTER PANELS) BEAR THE GREATER
PART OF THE TORSIONAL LOAD.
When designing and mounting a bus body, make sure that you take account of the
forces acting on the bus body and their distribution as described in the above paragraphs.
Overseas, a lack of equipment often means that outer panels are not tensioned as they
are mounted or that aluminum panels are used (FRP being used for front and rear
outer panels), so that the outer panels cannot be expected to contribute to body rigidity.
In this case, make other structures (especially the skeleton) proportionately more rigid
and stronger.
KC-AA014A
BUS BODY
4. BASIC LAYOUT OF BODY STRUCTURE

Important points and measures
Given the forces and distribution of load acting on the bus body as described in Section
2, make sure that you observe the following points when deciding the basic layout of
the body structure.
IMPORTANT POINTS
Ensure that loads acting on the body are distributed as smoothly as possible
to all parts of the structure, so that the entire structure plays a part in the
load-bearing (= dispersion of loads).
Keep the rigidity of the whole structure as high as possible and try to make
the rigidity between the each part uniform (= distribution of deformation and
stress concentration).
Mount the outer panels on the skeleton in the proper methods as their tensioned rigidity to contribute the rigidity of the whole structure and not to
cause permanent deformation (buckling) due to any excessive deformation
of the skeleton (= efficient use of tension rigidity of outer panels).
For specific measures, see Section 4.

Layout of Each Part of the Body Structure.
Selection of materials for structure

As far as possible, use closed-section square tube (
) for the main strength elements of the body and make the joints at each end by butt welding the tubes together.
Strength elements of
body structure
Use square-section tube

(
)
Closed- (e.g. square-) section tube materials only have superior cross-sectional characteristics to open-section material (
).
The butt welding of closed-section materials also provides a stronger joint than that of
open-section materials.
A square tube can also be made lighter than an open-section material for the same
strength, helping to reduce vehicle weight.
KC-AA014A
BUS BODY
Disposition of materials for structure
The outer frame which forms the six faces of the body structure should be made of
thicker members to achieve a high rigidity of the frame itself.
The main longitudinal horizontal members of the body side structure (window top and
bottom rails, lower rail of trusses below windows, skirt rail, etc.) should be made of a
single length of square-section tube material.
Where horizontal members and vertical members cross, the horizontal members
should, asa rule, take priority (priority disposition of horizontal members).
A member composed of a single length of square-section tube is more rigid and more
stable than a member made up of a number of square-section tubes welded together.
This means that the priority disposition of horizontal members tends to transmit loads
along the length of the vehicle and makes a significant contribution to the even distribution or dispersion of deformation and stress.
Structure in which horizontal longitudinal members have priority over vertical members
Butt welding
Main horizontal
longitudinal members
04-017
[Crossing of vertical and

horizontal members]
KC-AA014A
10
BUS BODY
Position the principal vertical elements of the body structure in the same lateral plane
as sill crosses or outriggers of the floor and the roof rafters, so as to form a number of
hoops.
The role of these hoop structures is as follows:
Hoop structure
Roof rafter
Vertical structure
(Including window
pillar)
Sill cross
Gusset
Chassis frame
04-018
[The role of the hoops is]

to transmit the reaction force from the road surface and the
payload to the body skeleton via the crossmembers, and
to act literally as hoops, joining all the main horizontal longitudinal members of the skeleton and increasing the overall
bending and torsional rigidity of the body.
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11
BUS BODY
Strength of joints between structural elements
The body skeleton is a composite structure made up of many elements which collectively support the loads placed on the vehicle.
Even if the materials themselves are well chosen and appropriately disposed, problems
of strength and rigidity will arise if the joints between the structural elements are weak.
Choose the method of joining structural on the basis of a clear understanding of the
characteristics and role of each element.
Joints between two square-section tubes

Joints between two square-section tubes should be
butted joints with continuous fillet welding around their
full circumference.
When designing the structure, be sure that the layout does not make welding difficult,
leading to incomplete welding of joints, and that it allows anti-rust treatment after welding.
Min. 30
If angle is less than 30.
at least
30 mm
at least
15 mm
Weld a separate
piece onto the
truss before welding the joint.
04-019
[Examples of skeleton layout designed to facilitate welding work]
KC-AA014A
12
BUS BODY
With continuous fillet welding around its circumference, as far as possible ensure that
the two members are orientated so that their width or height is the same, and that the
centers of their respective cross-sections coincide.
Method of joining two square-section tubes by a butted joint

made with continuous fillet welding.
3 mm max.
04-020
RIGHT
WRONG: These joints will lead to local deformation

and concentration of stress.
If an outer panel will come into direct contact with a welded joint, grind the welding
bead flat so that it does not damage the outer panel.
Treat the welding and panel thoroughly to prevent rust developing from the back of the
outer panel. (For details of rust prevention treatment, see Section 5).
Method of welding joints that will come into

direct contact with outer panels
Grind the bead on the side that will touch
the outer panel and treat against rust.
Outer panel
04-021
KC-AA014A
13
BUS BODY
Gusset joints
When joining two square-section tubes using gussets, any joint where strength and
rigidity are particularly important should if possible have a gusset on each side of the
square tubes.
To ensure sufficient welding strength, join gussets to square-section tubes by intermittent welding around the gusset and plug welding, or by intermittent welding around the
gusset and continuous fillet welding around the inner circumference of welding holes.
Example of gusset joint

Intermittent weld
Gussets on either side
Fillet weld
Plug weld
04-022
Bolted joints
Bolted joints are weaker than welded joints. Use them only in the cases shown below
and always take measures to prevent the nut or bolt from looseness.
[Bolted joints are permissible only]
where maintenance work requires the dismounting of a component,
and
where joint rigidity is not essential to structural strength.
Bolt size and tightening pitch should conform to the principles shown in the diagram
below. (No more than two plates may be joined by bolts.)
Bolt size and tightening pitch in bolted joints
D
A
d
L
B
B
L>1.5 d
A>3D
B>4D
C>3D
04-023
NOTE
Difference between L and d is to be as small as possible.
KC-AA014A
14
BUS BODY
5. LAYOUT OF STRUCTURAL ELEMENTS

This section describes the main precautions and specific measures relating to the
structure, method of mounting and design of the six-sided framework of the bus body,
taking into account the forces acting on the body and the distribution of load over each
structural element, as described in Section 3, Basic Layout of Body Structure.
Floor structure
The floor structure not only directly bears the weight of the vehicles payload but also
plays an extremely important role in joining the chassis frame and the bus body and
assuring overall structural rigidity and strength.
As shown in Section 1-2) Method of joining of body to chassis frame, there are many
different possible types of floor structure design. This manual will describe the precautions and specific measures to be taken in building a floor structure based on sill cross
joints, a type of design commonly adopted by body makers around the world.
Position and cross-sectional dimensions of sill crosses

Position the sill cross members so as to provide a secure link between the chassis
frame and the main vertical structure elements of the body side structure (main vertical
pillars at front and rear of structure, vertical pillars frontward and rearward of passenger
entrance door opening, window pillars, etc).
Fit sill crosses between the vertical structure elements of the body side structure for
strengthening purposes and to provide a base for the mounting of other body structures
and equipment.
Determine the total number of sill crosses and the pitch at which they are mounted
according to the load on the floor structure as a whole and the conditions under which
the vehicle is to be used (e.g. road surface conditions). (The appropriate pitch for the
sill crosses depends on the size and strength of the materials used in the floor structure
and overall vehicle size, but HINO recommends a pitch of 300-400 mm.)
KC-AA014A
15
BUS BODY
Example of positioning of sill crosses
SILL CROSS
300-400 mm
04-024
Note:
mark in the diagram indicates a vertical

pillar or window pillar.
Select material for sill crosses with as large a cross section as possible, and position it
to provide the greatest possible vertical bending rigidity (i.e. the longer dimension of the
cross section should be perpendicular to the ground).
Sill crosses in front or behind the front or rear axles will be directly exposed to thrust
from the road surface and vibration. Make sure that these sill crosses have sufficient
rigidity. (They should be twice as rigid as other sill crosses.)
The diagrams below show examples of the cross-sectional dimensions of sill cross
material.
Examples of cross-sectional dimensions of sill cross material

Cross-sectional dimensions of sill cross material
Cross
General use
Example
Forward or behind axles
t=3.2
100
Vehicle A
(large bus)
100
Welded (top and bottom)
t=3.2
50
50
50
04-025
04-028
t=3.2
60
t=3.2
t=3.2
80
Vehicle B
(large bus)
80
60
60
250 ~ 300
04-026
04-029
Welded (top and bottom)
Vehicle C
(small bus)
50
t=3.2
KC-AA014A
70
70
04-027
50 50
04-030
16
BUS BODY
Mounting sill crosses
Joining sill crosses to chassis frame
Use angle brackets secured with bolts to join sill crosses to the chassis frame.
Welding will give a more rigid joint than bolts, but poor welding work can cause the
problems listed below and welding should therefore be avoided:
[Problems arising from welding of sill crosses to chassis frame]

Reduced strength of chassis frame and sill crosses (cracking of
members)
Damage to chassis equipment (burning of brake pipes and wire
harness)
Peeling of paint due to heat (leading to rust)
When making a bolted joint, take particular account of the structure, shape and dimensions of the joint and of bolt size to ensure that the joint is sufficiently rigid. Take measures to prevent the nut or bolt from looseness.
(See Section 2-4 Chassis Frame for details on preparing to drill holes in the chassis
frame and a description of drilling work.)
Examples of bolted joints between chassis frame and sill cross
Example: Joint where the sill cross is a square-section tube material.
Chassis frame
Angle bracket
Sill cross
Mounting bolts
Use intermittent welding to fix the sill cross to the angle bracket.
04-031
KC-AA014A
17
BUS BODY
[Example:
-shape open-section sill cross]

Vertical pillar
of side structure
Sill cross reinforcing plate
Sill cross
Chassis
frame
Gusset
Angle bracket
(Mounting bracket)
UNIT: mm
Sill cross
Plane washer
(33, t3.2)
Sill cross
Lock nut
Plate (t3.2)
300
80
Sill cross
reinforcing plate
80
15
Rib plate
40
Bracket (t3.2)
Bolt (M12)
(With spring washer)
t3.2
150
Angle bracket
(Mounting bracket)
Chassis frame
Bolted joint
90
C40
C40
t3.2
04-032
Reinforcing plate
[Examples of method of joining an outrigger cross to the chassis frame]
Chassis frame
Bolted joint
Chassis frame
Bolted joint
Outrigger
Outrigger
04-033
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18
BUS BODY
Strengthening joints between sill crosses and chassis frame
(particularly around rear axle)
The rigidity of joints between sill crosses and chassis frame plays an important role in
assuring the comfort of the passengers.
In the front and the back of the rear axle, the pitch of the crossmembers of the chassis
frame is wider, and it is important to assure the same rigidity and strength integrated
with the body.
To compensate for the wider pitch of the crossmembers of the chassis frame, make the
pitch of the sill crosses smaller than in other parts of the body (increase the number of
sill crosses) and take other appropriate measures to assure the rigidity of joints
between sill crosses and chassis frame.
The drawings below show examples of measures to strengthen and increase the rigidity of the floor structure in vehicles with high floor structures such as buses built to
tourist specifications.
REAR AXLE
CENTER
CHASSIS CENTER LINE
FRONT
CHASSIS FRAME
SIDE MEMBER
B. 6
LH & RH
FLOOR CROSS SILL

PARTS A
FLOOR SUPPORT
220
30
PARTS B
No. 6
CROSSMEMBER
30
Ex. 325
No. 7
CROSSMEMBER
Ex. 452.5
B6
LH & RH
CHASSIS FRAME
SIDE MEMBER
2
04-034
KC-AA014A
19
BUS BODY
Detail of strengthening of joints between
chassis frame and floor cross sills (B)
50
Tube
Lower surface of
floor cross sill
C10
100
50 30
20
100
UPPER &
LOWER
B.4
B.2
UNIT: mm
PARTS NAME
50 30
Welding hole
20
MATESPECIFIQTY
RIAL
CATION
t
STKR41 1
50x30x2.3
Gusset
SPHC
t=3.2
Gusset
SPHC
t=3.2
Gusset
SPHC
t=3.2
Rib
SPHC
t=3.2
Plate
SPHC
t=2.3
B.2
(Grind flat after welding.)
30
Welding hole
2-30
35
90
180
3
C5
B.2
B.2
(Do not weld closer

than 5 mm from edge.)
Notes:
1. Ratio of inside bending radius to plate
thickness should be
t = 3.2: r. 5 mm
t = 2.3: r. 4 mm
2. Painting: CHF-3
Color: Black
3. Welding should be without undercut.
(Do not weld closer

70
25
2-30
Welding hole
04-035
Detail of strengthening of joints between chassis

frame and floor cross sills (A) RH & LH
UNIT: mm
50 30
Welding hole
PARTS NAME
20
100
100
C10
UPPER &
LOWER
B.4
B.2
Tube
Lower surface of
floor cross sill
50 30
50
20
not weld closer

(Do
35
90
70
SPHC
t=3.2
Gusset
SPHC
t=3.2
Rib
SPHC
t=3.2
Plate
SPHC
t=2.3
B.2
(Do not weld closer

(Do not weld closer

B.2
Gusset
30
C5
MATESPECIFIQTY
RIAL
CATION
t
STKR41 1
50x30x2.3
(Grind flat after welding.)
Welding hole
2-30
180
3
25
Notes:
1. Ratio of inside bending radius to plate
thickness should be
t = 3.2: r. 5 mm
t = 2.3: r. 4 mm
2. Painting: CHF-3
Color: Black
3. Welding should be without undercut.
04-036
KC-AA014A
20
BUS BODY
Joints between sill crosses and vertical pillars of body side structure
The method of joining sill crosses to the vertical pillars of the body side structure depends on the
type of materials used for both members.
If the sill cross and vertical pillar are both made of square-section tube:
Join the two square-section tubes by a butted joint with continuous fillet welding. (See
Section 4-4-5 for details of welding procedure.)
If the sill cross is made of
-shape open-section material:
Use welded gussets to make the joint and ensure that the joint has sufficient welding rigidity. (For details, see diagrams below.)
145
Sill cross
30
30
50
40 x 10 oval hole
12.5
20
15
40
35
40
Gusset
(t = 3.2)
40
20
190
5
80
60
80
Continuous fillet weld
15
Vertical pillar
of side structure
45
2
04-037
In vehicles with air suspension, No. 3, 6, 7, and 8 crossmembers are already mounted
on the chassis.
In such a vehicle, observe the following procedure to ensure that the joints with the vertical pillars of the body side structure have sufficient strength and rigidity.
KC-AA014A
21
BUS BODY
Examples of joints between chassis crossmembers
and vertical pillars of body side structure
CROSSMEMBER
No.8
ENGINE
CENTER LINE
REAR AXLE
DATUM LINE
No.7
CROSSMEMBER
CROSSMEMBER
No.6
Shorten the crossmember to

adjust the width of the body
structure.
Body outer panel
Upper surface of chassis

side member
04-038
Connecting gusset for
vertical structure
Method of joining No. 3, 6, & 7 chassis crossmembers with vertical pillars

of body side structure at A and B.
dy
Bo
Method of joining No. 3, or 8 chassis

crossmembers with vertical pillars of
body side structure at C.
No
cro . 8
ssm
em
be
r
ail
lr
a
nt
izo
r
ho
After welding all around, apply

sealant to entire circumference of butt to prevent water
from entering the crossmember tube.
No
cro . 6
ssm
em
ber
Gusset (t = 3-2)
t = 4-5
B 6
04-039
KC-AA014A
22
BUS BODY
Right- and left-hand side structures
As indicated in the drawings of load distribution in Section 4-3-2 Strength and rigidity
of the bus body, most of the bending load acting on the bus is supported by the rigidity
of the skeleton of the right- and left-hand side structures.
The torsional load transmitted via the chassis frame also acts on the right- and lefthand side structures respectively in the form of upward and downward bending loads of
different phases.
It is therefore extremely important to increase the bending rigidity of the right- and lefthand side structures in order to assure both the bending and torsional rigidity of the
structure as a whole.
The torsional load a vertical bending load on

the right- and left-hand side structures
Torsional load
04-040
Of the side structure elements, the truss structures under the side windows provide an
extremely high rigidity against vertical bending forces.
Position members and choose the method of joining so as to transmit the forces (loads)
acting on the inside and outside of the body structures as smoothly as possible to
these truss structures.
Door openings (for middle, rear and emergency doors) interrupt the high bending rigidity of this truss structure and produce an extreme local distortion and concentration of
stress around the doors.
This local distortion leads to an increase in stress at the butted joints of the window pillars.
Take steps to strengthen the side structures, particularly around door openings.
Also strengthen the side structures around the tire houses, which cut into the truss
structure.
KC-AA014A
23
BUS BODY
The following paragraphs describe measures for strengthening the right- and left-hand
side structures of the bus body to compensate for local distortion and concentration of
stress.
Outline diagram of truss structures under side windows
Truss structure
under side windows
04-041
Transmission lines of force in truss structure

The main vertical pillars in the body side structures, including the vertical elements of
the truss structure, should ideally be arranged to form hoops in the same plane.
However, the space allocated to side windows design and the layout of equipment
mounted under the vehicle floor may in some cases make it impossible to form hoops
in the same plane.
In this case, position vertical pillars so that they overlap within the truss structure and
join these vertical pillars with diagonal reinforcing members following the transmission
lines of force within the truss structure.
This effectively completes a hoop in the same plane and allows the transmission of
force with equal efficiency, helping to prevent the concentration of stress in any one
member.
Example of lines of force within an truss

structure and position of reinforcing member
Window pillar
Horizontal rail
Arrows () indicate
lines of force
Truss structure
Diagonal reinforcing
member
Horizontal rail
Joint with sill cross
KC-AA014A
04-042
24
BUS BODY
Reinforcing method around door openings and tire houses
This section explains how to reinforce the side structures of the bus body around door
openings (passenger, emergency doors, etc.) and the points where tire houses cut into
the truss structure.
Use thick material for the vertical pillars on frontward and rearward of the door opening.
Fit strengthening members around the door opening (including double pillars, trussing).
Add stress plates around the doors.
Add corner gussets around the doors.
Add strengthening members around tire houses, etc.
Example of local reinforcement of side structures
Around forward door:

Double pillars
(rear pillar 70 mm member)
Stress plates at top, between double pillars.
Inside corner gussets (top)
Around middle door:

Thick pillars on frontward &
rearward side (70 mm member)
Make truss structure at top.
Inside corner gussets
(top)
Around rear door:

Thick pillars on frontward &
rearward side
(forward pillar 70 mm, rear
ward pillar 100 mm member)
Make truss structure at top.
Inside corner gussets (top)
04-043
Cross position
Gusset
Corner gusset
Diagonal reinforcing member
KC-AA014A
25
BUS BODY
Strengthening joints at ends of window pillars
As described in Section 2-2) on the forces acting on a bus body, when a bending force
acts on the overall body structure, the resulting distortion pulls on the window pillars,
which tend to lean backwards or forwards, leading to a concentration of stress at their
ends.
Owing to functional restrictions (appearance, visibility, etc.) and structural restrictions
(shape of window frames, dimensions, etc.) it is difficult to reduce the concentration of
stress at the ends of the window pillars. The design of the window pillars is therefore
one of the most important points in skeleton design.
To minimize the concentration of stress at window pillar ends, observe the following
precautions:
The basic aim is to increase the bending rigidity of the overall structure
and minimize the leaning of the window pillars.
Minimize bending distortion in the side structures.
(Ensure that the side structures have sufficient bending rigidity by strengthening them.)
Control local distortion around door openings, etc. near to window pillars to minimize
the effect on the window pillars by strengthening areas around door openings, etc.
Take care that the material and dimensions of the window pillars and
top and bottom rails (see description of main longitudinal horizontal
members of the body side structure in Section 3-3)) and the position of
joints between window pillars and rails does not result in additional
local stress. Make sure that the joints between window pillars and rails
are sufficiently rigid.
Use square-section tube material of the same size and quality for the window pillars
and top and bottom rails.
When making welded joints between window pillars and rails, observe the procedures
described in Section 3-4) and make sure that the joints are sufficiently rigid.
When fitting corner gussets to increase the rigidity of joints between

window pillars and rails, be sure to use the appropriate shape of gusset
and method of welding.
(Warning: Corner gussets of unsuitable shape and unsuitable welding methods may
lead to cracking of the welded parts or of the gussets themselves.)
KC-AA014A
26
BUS BODY
Example of cracking of corner gusset itself
Crack
Crack
04-044
Examples of strengthening of upper and

lower ends of window pillar with gussets
Gusset should be long and

curved at ends.
Window bottom horizontal rail
Grind the welding bead flat to avoid a

concentration of stress.
High stress
Ground flat
04-045
KC-AA014A
27
BUS BODY
Front structure
Most of forces caused by the load acting on the front structure is torsional load since
reactions from road surface act on the body right and left alternatively.
The windshield in its rubber mounting constitutes a very large opening in the front
structure and it is therefore difficult to assure sufficient torsional rigidity of the front
structure against this load.
Particularly on bad roads, this may lead to distortion of the outer panels of the front
structure and to detachment and cracking of the windshield.
For this reason, take steps to maximize the torsional rigidity of the front structure and
prevent any torsional load on the windshield.
Measures to increase the torsional rigidity of the front structure

The front structure, including the crossmembers at the front end of the chassis frame,
must form a hoop with high torsional rigidity.
In front engine vehicles, the need to assure ease of engine maintenance and engine
mounting and dismounting makes a cross structure running across the front of the vehicle impractical. The solution is to build a hoop structure by mounting a truss type structure spanning the ends of the chassis frame, having a lower beam secured by bolts.
This beam is mounted using bolts in order to assure ease of mounting and dismounting
of chassis components such as the engine and radiator.
The drawings below show an example of the front structure of a front engine vehicle.
Example of front structure of a front engine vehicle

Chassis center
Floor surface
Drivers seat side
Chassis
frame
Beam secured by bolts
KC-AA014A
04-048
28
BUS BODY
[Precautions for mounting of windshield]
Secure the windshield in its frame using a seal rubber mounting (see windshield mounting diagram below).
The seal rubber is usually made of ethylene-propylene rubber (EPDM), which offers outstanding strength and weathering characteristics, but you should select a relatively hard
rubber if the main consideration is to prevent movement of the windshield or a relatively
soft rubber if the main consideration is to prevent cracking.
As a rule, the hardness of the rubber should be within a range of 50-70
The grip of the rubber mounting on the windshield and windshield frame should be as
deep as possible and secured with adhesive.
However, the grip should not be so deep as to detract from the appearance of the vehicle
or restrict the visibility.
Make sure that the adhesive does not damage the material of the mounting rubber.
Structure of windshield mounting
Windshield
Seal rubber
Windshield frame
Horizontal rail at lower
edge of windshield
04-049
KC-AA014A
29
BUS BODY
Mounting the windshield
Operating the bus on bad roads may result in the windshield becoming detached from
its mounting or cracking.
This section explains the mechanism by which these problems arise and describes preventive measures.
Mechanism of detachment and cracking of windshield
Cracks
.
=. 1000
.
=. 1000
04-046
Windshield
poorly glued to
rubber mounting.
Windshield glass
insufficiently thick
Windshield
becomes
detached from
mounting.
Vibration
from
running on
bad roads
Body front
structure
insufficiently rigid
Bad roads
Sudden
braking
Stones
KC-AA014A
Windshield
cracks
30
BUS BODY
Rear structure
The rear structure is mounted on the end of the rear overhang of the chassis frame and
is subject to two main types of load.
A bending load from the payload carried in the rear overhang.
An torsional load, as the front structure, caused by reactions from road surface which
act on the bus right and left alternatively.
The bending and torsional rigidity of the rear structure is particularly difficult in rear
engine vehicles because the rear end of the chassis frame supports the weight of the
engine and the provision of an inspection lid to allow engine maintenance makes a very
large opening in the rear structure.
The resulting distortion of the skeleton of the rear structure may lead to problems such
as cracking of the outer panels of the rear structure and detachment of spot-welded
joints.
For this reason, position the elements of the rear structure so as to ensure that the
skeleton of the rear structure itself has a high bending rigidity and that the load from the
rear overhang is transferred as smoothly as possible to the truss structures under the
side windows.
The following paragraphs show the positioning of members in the rear structure of rear
engine vehicles.
Note that in many front engine vehicles, the load on the rear axle is the same as that in
rear engine vehicles, and the structure, strength and rigidity of the rear structure should
therefore be identical to those adopted in rear engine vehicles.
Examples of positioning of members in body rear structure

members and joining of body rear structure to chassis frame
a
Rear structure vertical and

horizontal members
Chassis frame
The vertical and horizontal members of rear

stracture are jointed to
the chassis frame and
body side structures.
Outriggers are mounted

on either side of the
chassis frame and
joined to the final pillars
of the side structures to
reduce the load ofside
structures.
The end of the chassis

frame is suspended
from truss crossed in
the plane of the final pillars of the side structures to reduce the load
of the rear structure.
04-050
Final pillar of side structure
Position of outriggers
Outriggers
04-051
Position of truss crosses

Truss crosses
04-052
KC-AA014A
31
BUS BODY
Roof structure
The skeleton of the roof structure, shown as the below diagram, forms lattice structure
with stiffeners extended in the front-to-rear direction of the body and rafters extended in
the right and left direction.
To increase the torsional rigidity of the roof structure and ensure dimensional accuracy,
the rafters are bent from a single piece of steel and are linked by the stiffeners between
each rafter with the rafters taking priority.
Lattice structure of roof

Shear plates
(stress plates)
Rafters
Shear plates (stress plates)
Recommended materials for rafters and stiffeners

Stiffeners
Rafters
Stiffeners
Note:
04-053
50 x 30 - 1.2 mm
Stiffeners in the area within the broken line in the diagram

can be made of Z-section material.
Joining rafters and stiffeners

The diagram below shows the method of joining rafters and stiffeners.
Z-section stiffener
5
mm
Square-section tube stiffeners
5.5
mm
Window top horizontal rail
5
mm
B
Grind upper and lower surfaces flat.
04-054
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BUS BODY
Strengthening the roof structure
If the bus is operated under hard conditions such as on bad roads or excessive loads,
the outer panels of the roof structure above the entrance door, emergency door and
other openings in the body structure may become permanently deformed (buckled) or
may crack.
Under such hard conditions, reinforce the area around door openings in the side structures as described earlier and increase the rigidity and strength of the roof structure
itself by fitting stress plates above the door openings.
When fitting stress plates, observe the following precautions.
The stress plates should amply cover the width of the door opening.
The stress plates should be cut to a triangular form at each end (to reduce the concentration of stress at the end of the plate) and should be made of single thickness of steel
strip.
Also, plate thickness must be 1.6 to 2.3 mm.
Weld reinforcing rafters and stiffeners to the roof structure following the outline of the
area to be covered by the stress plate, then weld the stress plate securely to these
reinforcing members. (See mounting drawing below for details of welding method.)
Mounting of reinforcing stress plate

[Welding of reinforcing stiffeners]
B
3
Grind flat the surface that

will touch outer panels.
30
B
3
30-100
30-100
Weld for 50 mm on either

side of each rafter.
B
04-055
[Welding of stress plate]
2
2
Weld for 50 mm on
either side of each rafter.
KC-AA014A
30-100
30-100
B
04-056
33
BUS BODY
Strengthening roof structure to bear heavy objects
If heavy objects (e.g. the evaporator unit of an air-conditioner or a roof rack), are to be
carried on the roof of the bus, or if rafters and stiffeners must be cut to allow the mounting of such an object, you must take steps to strengthen the roof structure.
If the roof structure is not strengthened, it may become distorted and may leak in rainy
weather.
The following paragraphs explain how to strengthen the roof structure.
Note that mounting a heavy object on the roof will affect the overall strength and safety
of the bus. HINO recommends that luggage rooms should be built under the floor of
the vehicle.
Example of strengthening of part of roof structure

to carry the evaporator unit of an air-conditioner
Intended position of evaporator unit
Intended position of roof ventilator
B
Grind upper and lower surfaces.
B
3
Grind inner and outer surfaces.

04-057
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BUS BODY
Example of strengthening of part of
roof structure to carry roof rack
Roof rack
Roof rack
Bracket
04-058
Bolted joint
Outer panel of roof

Bolted joints
(Cover with sealant.)
Gusset
(Weld to rafter.)
Window pillar
Rafter
04-059
[Important points]
Fit brackets to the top rails of right- and left-hand side windows to keep the load of the
roof rack off the outer panels of the roof. The supporting pillars of the roof rack should
as far as possible be positioned above the window pillars.
Draw on experience when deciding the loaded weight of the roof rack and take care
that it is not too heavy. (Carefully consider the overall weight of the bus and the distribution of weight on front and rear axles. The maximum weight should ideally be no
greater than 2 tons.)
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BUS BODY
6. RUST AND CORROSION PREVENTION

In buses, rust due to water, mud and dust and corrosion due to salt damage not only
affect the appearance of the vehicle but may reduce the strength of structural elements
and lead to failures of functional components, the electrical system, etc.
Rust and corrosion prevention technology and the use of this technology are therefore
extremely important in assuring the quality of the bus.
This section describes basic measures for rust and corrosion prevention. Please be
sure to implement these measures when building a bus body.
Basic points of rust and corrosion prevention

When designing and building a bus body, be sure to observe the following precautions
against rust and corrosion.
Structural design
Structure should make it easy to keep out and easy to eliminate
water, mud, etc.
Structure should be easy to paint.
Avoid contact between different types of metal, provide protection
against stones, etc.
Selection of rust- and corrosion resistance materials

Use rust resistance steel plate, etc.
Use resin components, etc.
Quality of paint work

Surfaces should be thoroughly degreased and treated with chemical agents prior to painting.
Improve painting methods.
Ensure that paint film is of the proper thickness, etc.
Thorough local rust and corrosion prevention measures

Treat edges, joints and folds of steel plates.
Treat welded points, etc.
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BUS BODY
Preventing rust of body skeleton
As described in Section 2-2) Strength and rigidity of the bus body, in buses with
skeleton structure bodies the greater part of the forces acting on the vehicle are supported by the skeleton.
For this reason, any reduction in the strength of the structural elements of the body
skeleton and the joints between these elements due to rust will have a significant
impact on the service life of the body as a whole.
The drawing below shows the parts of the skeleton structure that it most important to
protect against rust.
Parts of body skeleton structure most

important to protect against rust

No. 1 pillar
No. 2 Pillar

Rear pillar
Skirt rail
Tie rod
Horizontal rails
Horizontal rail of floor
Skirt pillar
04-060
: key members above floor level

Easily penetrated by rain water due to faulty sealing of screw mountings of
rain gutters and window frames.
Because these members are made of long sections of material, rust and
corrosion have a major impact.
: key members below floor level
Easily penetrated by mud and dust.
Difficult to treat against rust because they are behind the skirt panels.
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BUS BODY
Principles of rust-prevention and examples of specific measures
Selection of square-section tube material

All of the structural members in the diagram on the previous page use materials which
have been surface-treated against rust.
Square-section tube used in general structure

polished steel or acid-pickled steel
Important structural elements requiring special protection
against rust
internally and externally alloyed steel
(hot dip zinc-coated steel)
Preventing water from penetrating to the square-section tube

When building the body, wherever possible avoid drilling holes in square-section tubes.
Where you must make holes in a square-section tube (e.g. in order to mount window
frames), use rubber seals, liquid sealant, resin-coated screws, etc. to prevent water
from penetrating the tube. (See drawing Measures to prevent water penetration of
window frame mounting.)
If a bolt passes through an opening in a square-section tube, insert a round pipe into
the hole to prevent water from penetrating the square-section tube and take steps to
prevent distortion of the sealing surfaces. (See diagram Measures to prevent water
penetration where bolt passes through tube.)
Glass
Measures to prevent water penetration of window frame mounting
Butyl rubber
sheet
Resin coated
screw
Glass
Molding
(aluminum, resin, etc.)
Top of window
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04-061
Bottom of window
38
BUS BODY
Measures to prevent water penetration
where bolt passes through tube
Seal
Pipe
Welded around full circumference
Seal
04-062
Make sure that you weld around the entire circumference of the joints at either end of
the square-section tube and of any butted joints to prevent water from running in.
If the end of a square-section tube is left exposed, make sure that you seal it off by
welding a plate of the same material over the end.
Butted joint with continuous

fillet welding
Seal off the ends of
square-section tubes.
04-063
Every welded joint must be protected against rust.

After welding, remove the welding slag, then apply a coat of welding primer (zinc-rich
primer) taking care not to leave any gaps.
As described in section 3-4, it is important in the skeleton structure that skeleton members should be arranged in consideration of the workability when welding around the
entire circumference of joints and carrying out anti-rust treatment as the above.
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BUS BODY
Preventing water from remaining in square-section tubes and anti-rust
treatment of interior of tubes
To prevent rust inside square-section tubes, carry out the measures for preventing
water penetration described in paragraph above.
Also be sure to take steps to facilitate the drainage of water from any parts of the body
skeleton that water may penetrate in spite of these precautions, e.g. imperfectly welded
joints, putty cracks, and other areas where seals are cracked.
When designing the body skeleton, plan water drainage routes and provide drainage
holes to allow any water which may penetrate the square-section tubes to escape.
Also be sure to treat the interior of the square-section tubes against rust, especially
along these water drainage routes.
The drawing below shows one example of water drainage routes and drainage holes in
a skeleton made of square-section tube.
Example of water drainage routes and drainage holes
Water drainage routes

Water drainage holes
04-064
Providing water drainage holes

To allow water that has penetrated the square-section tubes of the skeleton to escape,
position drainage holes under vertical pillars and on the lower surface of the skirt rail.
Diameter of drainage holes: 10 ~12

(If the holes are too small, the drainage will be poor. If they are too big, they may allow
mud to penetrate the tubes.)
Provide drainage holes in horizontal members such as window top and bottom rails
and the joints of end pillars.
Warning: Never make drainage holes in the tire houses.
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BUS BODY
Anti-rust treatment of interior of square-section tubes
After painting the entire skeleton, spray a rust inhibitor oil (e.g. tectil) inside the squaresection tubes.
Spray the tubes via the drainage holes, or create new spraying holes. Insert a vinyl
tube into the holes and spray thoroughly so that the entire inner surface of the tube is
coated with rust inhibitor oil. (See diagram Spraying interior of square-section tube
with rust inhibitor oil.)
As a rule, you should make no more than one spraying hole of 10 ~ 12 mm in diameter
in each member.
However, if the member is 6 m or longer, you may make two holes.
Spraying interior of square-section tube with rust inhibitor

Vinyl tube (Gradually pull this tube out of the hole as you spray.)
Water drainage hole
Water drainage hole
Spraying hole
Air gun
(Seal with a grommet after spraying.)
Rust inhibitor oil
Compressed
air
04-065
Preventing water, mud and dust from remaining on outer surface of

square-section tubes
The lower part of the skeleton structure (below floor level) is continually exposed to rain
water, mud and dust. If you are mounting gussets and brackets on this part of the
skeleton in particular, make sure that these gussets and brackets themselves and the
area in which they are mounted are shaped so as to prevent water, mud and dust from
remaining.
Make sure that the position of these gussets and brackets allows easy anti-rust treatment of the gussets and brackets themselves, the surrounding parts of the skeleton
structure, and the outer panels.
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BUS BODY
Example of anti-rust treatment when gusset
or bracket is mounted on a square tube
Skirt pillar
Seal all around.
(only in locations below the vehicle floor and
other places where rain water may penetrate.)
Side lid lock bracket
Skirt rail
04-066
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BUS BODY
Preventing rusting of the outer panels of the body
The entire body of a car can be dipped at once to coat the inner and outer surfaces of
the steel panels against rust by a chemical treatment such as zinc phosphate coating
or by electroplating. Obviously, this is impractical in the case of a bus.
To protect the outer panels of the bus body against rust, observe the following precautions.
Selection of steel panel materials

As with the square-section tubes used in the body skeleton, you can increase the durability of the vehicle by using material that have been surface-treated against rust:
Fixed outer panels: internally and externally alloyed steel

(hot dip zinc-coated steel)
Detachable outer panels: electro-galvanized steel
(steel plates individually treated against rust)
Measures for most important parts to protect against rust

This section describes representative examples of how to treat the outer panels of the
body against rust.
Preventing rust on back of outer panels

Follow the procedure given below to prevent rust on the back of the outer panels of the
body.
Priming
Touch up welded joints with a rust-inhibiting primer (e.g. zinc-rich
primer), then
paint the entire surface of panels below floor level with chassis
primer, and
paint the entire surface of panels above floor level with a rust-inhibiting primer (e.g. zinc-rich primer).
1st anti-rust treatment

Apply an undercoat 2 ~ 3 mm thick to the entire surface. It is not necessary to use undercoat on roof panels and side panels below windows and above floor level except to prevent joints with anti-vibration
and tension materials from getting off.
2nd anti-rust treatment

Spray a coat of rust-inhibitor oil (e.g. tectil) over the undercoat. Make
sure that the rust-inhibitor oil fully penetrates any parts of the skeleton
not painted with undercoat, such as joints. (For method of spraying
rust-inhibitor oil, see the following drawing.)
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BUS BODY
Example of treatment of back of outer panels
with rust inhibitor oil (Tectil)
[Lapping of front and rear outer panels

with roof outer panel]
[Lapping of roof outer panel and

window top rail]
Make sure that rust inhibitor oil penetrates

lapping of outer panels.
Make sure that a good quantity of rust

inhibitor oil penetrates join with skeleton structure.
04-067
[Inside of right and left tire houses]

(below floor)
[Inside of outer panels below

windows]
Make sure that a good quantity of rust inhibitor oil penetrates join with skeleton structure.
Make sure that a good quantity of rust inhibitor oil penetrates join with skeleton structure.
Apply undercoat paint to entire

surface, then spray with rust
inhibitor oil.
04-068
04-069
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BUS BODY
Preventing rust at joints between outer panels
The joints between the outer panels of the body are protected against rust by treating
the joints themselves and assuring the quality of the surface of the outer panels, but
also by filling the joints with putty. However, incorrect filling may lead to cracking of the
putty.
To protect the joints between outer panels against rust, observe the following procedure.
[Where body panels are to be mounted on the skeleton]

Mounting body panels on skeleton
Putty
Spot weld the outer panels onto the skeleton, allowing a gap of approximately 5 mm
between the edges of adjacent panels (for
putty).
51
Important: If the gap is too small, it will be

difficult to insert the putty; if it is too big, the
putty may crack.
20
Arc brazing
20
Spot welding
Any vibration of the corners of the outer

panels may cause the putty to crack.
Secure the corners of the panels by spot
welding and arc brazing.
40
20
20
20
04-070
Remove any burr from the edges of the

panels and from welded parts, then polish
the areas to be filled with putty and remove
all oil, dust and water before applying the
putty.
[Where two outer panels are to be joined together]

Joining two outer panels together
Outer panels of body side
Chamfer 2/3 of thickness
205
If the outer panels of the body must be

made flush surface, make a chamfer in one
panel, then spot weld the panels together
allowing a gap for putty.
To improve the adhesion of the putty,
chamfer the edge of the outer panel
through 2/3 of its thickness.
Putty
04-071
Outer panels of roof
Joints between panels which do not require

flush surface, such as roof panels, can be
made as shown in the drawing at left.
45
10
Putty
Important: Make sure that the overlapping

of the panels does not run counter to the
flow of rain water.
1.5 ~ 2.5
04-072
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BUS BODY
Preventing rust of other body components
Joints between outer panels in the parts of the body shown below are constantly
exposed to particularly harsh conditions (water, mud, dust, salt).
Take particular care to protect these joints against rust.
This section outlines procedures for protecting such parts.
[Tire fenders]
Steel plate over-fenders
Rubber over-fenders
Weatherproof rubber
Outer panel of fender
Sealant
Over-fender
Protector (resin)
(Inject silicon into protector)
Sealant
Sealant
Undercoat + Rust inhibitor oil

(e.g. tectil)
04-073
Aluminum over-fender
04-074
Single sheet of pressed aluminum
04-075
[Entrance steps]
Protecting entrance steps against rust
Sealant
Riser
Undercoat + Rust inhibitor oil (e.g. tectil)
Tread
Sealant
Edge plate
Notes:
Apply undercoat and rust inhibitor oil after mounting
the step parts on the body.
Undercoating the step parts plays a significant role in
reducing passenger room noise.
Tie rod
04-076
[Edges of inspection covers or lids]

Protecting edges of inspection covers or lids against rust
Sealant
Reinforcing strip
Note:
Dimension L of reinforcing strip should be no more
than 15 mm. If it is longer than 15 mm, vibration may
cause cracking of the sealant.
04-077
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BUS BODY
Protecting wooden flooring against rot
The flooring in buses is usually made of wooden boards or plywood panels.
In hot and humid climates, this wooden flooring may rot.
If the vehicle is to be used in a hot and humid climate, make sure that you treat wooden
flooring materials to protect them against rot.
This section describes which parts of the flooring are most vulnerable to rot and
explains the mechanisms by which rotting occurs.
Parts of flooring most vulnerable to rot
Around drivers seat

Around tire houses
Upper surface of bulkheads
Around rivets securing

floorboards
trim
er
Inn
Tire house
Flooring
Floorboards
Eyeboard
Rotting
Seat leg
04-078
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BUS BODY
chanism by which rotting of wooden floorboards occurs
Rain water penetrates

passenger room
Water penetrates
under-floor space
during vehicle
washing.
Splashing
from tires
via windows, doors, ducts.

via ventilators.
brought in on passengers clothing.
Water
penetrates
the joint
between tire
house lid
and
floorboards.
e
hous
Water
penetrates
mounting
bolt holes
for seat
legs.
Tire
Water
penetrates
screw holes
in
eyeboards
of flooring.
Water
penetrates
from lower
surface of
flooring.
Water follows pores

in wood and
penetrates to center
of floorboards.
Water penetrates
upper surface of
flooring.
Adhesive
used on
flooring
is soluble
in water.
Inside and upper surface of wooden is

always wet
Hot and humid climatic

conditions
(optimum conditions
for spread of rot
bacteria)
Apitong
Plywood
Pores
Rot bacteria
spreads.
Availability of nutrients and air

Humidity: approx. 80 %
Temperature: 25 ~ 35C
Rotting occurs.
04-079
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BUS BODY
Measures to prevent rotting
To prevent rotting, observe the following precautions.
Use well-seasoned materials.
Apply a preservative (e.g. KOSHIMAX) to the edges of wooden floor, edges of holes
for inspection covers or lids and other parts where the pores of the wood are exposed
and make sure that it penetrates the pores. Then apply a sealant (e.g. SIKAFLEX
221).
Always inject preservative into the holes for all bolts, rivets and screws used to secure
the flooring material.
In climates which are particularly conducive to rot, you should also spray the entire surface of the wooden flooring with preservative.
The drawings below show in detail which parts of wooden flooring which require treating with preservative and sealant.
Parts of wooden flooring which require

treating with preservative and sealant.
Plywood flooring
B
Board flooring
A
B
B
B
A
A
A
04-080
A : Apply preservative + sealant.

B : Inject preservative.
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BUS BODY
Using resin components to avoid rust and rot
The use of resin parts instead of steel parts (especially for front and rear outer panels,
skirt panels, etc.) in bus bodies is becoming increasingly widespread.
Resin parts avoid rust and rot, help to reduce the weight of the vehicle, and improve
productivity. (Resin parts are easier to mold.)
When replacing steel parts with resin parts, it is common to use FRP (fiber-reinforced
plastic) resins.
FRP resins are heat-resistant unexpanded polyester resins, reinforced with glass
fibers.
FRP resins offer excellent strength, weather resistance and heat resistance.
However, because FRP resin parts are thermosetting resins, they also have the following general characteristics:
The thermosetting process causes the structure of the resin to grow denser and
become more brittle.
Once hardened, the resin will not soften again even if reheated.
Once hardened, the resin will not dissolve even if a solvent is added.
If thermosetting resin parts are to be painted, special paints will be required.
Before deciding to use resin parts instead of steel parts, you should therefore give
careful consideration not only to production needs and methods, but also to dealing
with problems that may arise after the vehicle enters service (e.g. repair methods, parts
serviceability, etc.) and the method of disposal of such parts when the vehicle is
scrapped.
The drawing below shows examples of body parts that can be replaced with resin
parts.
Examples of body parts that can be replaced with resin parts

Extractor grille
Exhaust grille
Rear bumper
Colored moldings
Lids (especially movable lids)
04-081
Front bumper
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BUS BODY
7. RIDE COMFORT IN RELATION TO VIBRATION AND NOISE

Ride comfort, in the widest sense, is defined as the comfort with which passengers are
able to ride in the bus while subject to the following factors.
Coloring, lighting, natural lighting, ventilation, natural airflow

Vibration and noise transmitted from the road surface
Noise and heat emitted by the engine
This section describes the effects of vibration due to the road surface, and noise and
heat from the engine, and the main points involved in improving ride comfort in the
presence of these factors.
Ensure that sufficient attention is paid to ride comfort in the design and manufacture of
the bus body.
Vibration and Improvements in Ride Comfort

Types of Ride Comfort and feeling in Relation to Vibration
The relationship between ride comfort and vibration is very subjective, and the factors
involved are extremely complex. The final evaluation of ride comfort must therefore
rely on the subjective evaluation of the passengers.
The following vibrations are normally felt by passengers when the bus is in operation
under normal conditions.
Type of ride comfort
Feeling
Frequency
Vibration mode
Vibration above springs,

(body vibrating as a rigid
unit)
Soft & floating
A soft, floating feeling of movement on

either the vertical or longitudinal axis
Rumbling & rough
A rumbling feeling, particularly while

engine is idling
ower plant vibrating a

8~10Hz P
rigid unit
Sharp & rough
Comparatively sharp, high frequency,

vibration transmitted from the road
surface, etc.
10~13Hz Vibration below springs
Rumbling & rough
Fine vibrations in all components of body

(sensation of rigid body vibrating as one
unit)
1~2Hz
10Hz~
Elastic vibration of body

including chassis
NOTE
Frequency of vibration differs slightly depending upon vehicle size, body type, etc.
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BUS BODY
Illustrations of the vibration modes and primary factors for each type of ride comfort are
given below.
Primary Factors in Vibration Modes

Vibration mode
Primary factors
Affected by the vibration

characteristics of the
suspension system
a) Vibration
above springs
Bouncing
Pitching
04-082
Determined by the
relationship between weight,
inertia moment, and
mounting characteristics of
engine
b) Rigid vibration
of engine
E/G pitching
E/G rolling
04-083
Determined by the
relationship between weight
and suspension
characteristics above and
below springs
c) Vibration
below springs
F/A, R/A vertical
04-084
d) Elastic vibration
of structure
(Including bending
of chassis frame)
Considerably affected by
twisting and bending
characteristics of chassis
frame and body
Twisting
Bending
04-085
Points of Body Design for Improvements to Ride Comfort

Points and practical measures for improvement of body vibration characteristics in the
vibration modes above are given below.
Separate the natural oscillation frequency of the structural framework (including chassis), which forms the basis of body vibration, from the frequency of
the external vibration in order to avoid resonance in the overall framework.
(related to a) and c) above)
In particular, improve the vibration transmission coefficient of the floor structure which transmit vibration below spring and power plant (B/G, T/M, etc.)
component.
Suppress the local resonance and vibration levels of body components.
(related to d) above)
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BUS BODY
[Practical Points for Improvement of Vibration Characteristics]
Point 1
Increase rigidity and reduce weight of overall body skeleton as much as possible to
increase the natural frequency of vibration of the body beyond that of the external
vibration.
[Ensure that the natural frequency of vibration of the

body skeleton is greater than 14 ~ 15 Hz.]
See the following for details of practical measures to increase the rigidity of the basic
body skeleton.
[2. Principal Precaution when Mounting a Bus Body]
[3. Basic Layout of Body Structure]
[4. Layout of Structural Elements]
Point 2
As vibration of the body floor is transmitted to the bodies of the passengers via the
seats (or directly via the feet), vibration characteristics in this area have a significant
effect on ride comfort.
Use the following measures to reduce vibration.
Increase the rigidity of the floor structure, that is the chassis, sill cross, and main floor
sill (framework in the longitudinal direction of the floor). See 4-1) Floor Structure.
Attach the floor board to the floor structure with screws.
Note that insufficient attachment of the floor board to the floor structure will cause the
floor to vibrate and amplifying internal noise.
Use vibration dampening materials in the floor board, and rubber-mount the body as a
means of reducing internal noise.
Punto 3
Improvements in elastic vibration of the body involve localized improvements in rigidity
to increase the uniformity of bending and twisting over the body as a whole.
Practical measures are similar to those used to ensure structural strength. See - [4.
Layout of Structural Components] for details.
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BUS BODY
Internal Noise
Reduction of internal noise (passenger room) has an important effect on ride comfort in
the same a manner as does vibration as described above.
Ensure that the following points are noted in body design and manufacture.
Causes of Internal Noise, and Points to Note When Mounting a Body

The causes of internal noise, and the relevant points to note when mounting the body,
are as follows.
Causes of internal noise
Points to note when mounting a body
Engine noise (including air intake

and exhaust, and fan noise)
Wind noise
Noise from air conditioning

equipment
Chatter in body components
Improve shape of external protrusions (ends of

water drains, mirrors, etc.).
Improve sealing of passenger doors and
windows.
Reduce air speed in ducts by optimizing duct

area.
Improve shape of objects within ducts offering

air resistance (e.g. divider plates).
Install vibration and sound dampening material
in ducts.
Transmission noise
Improve sound dampening characteristics of

bulkheads and floors.
Improve sealing of joins in body, inspection
doors, etc.
Suppress vibration in air intakes and water
separation chambers.
Improve sound insulating characteristics of

floors.
Improve sealing of power train inspection doors.
Increase rigidity of body components (as with

strengthening and anti-vibration measures).
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BUS BODY
Reducing Internal Noise
Engine Noise
The engine is the major source of noise.
It consists of the 500 Hz or higher frequency of combustion and mechanical noise from
the engine itself (felt as a continuous sound of comparatively high frequency), and the
150 ~ 160 Hz noise air intake noise (felt as a series of discrete sounds).
Noise within the bus is primarily of these two frequencies.
Frequency Analysis of Internal Noise

(measured in the rear seats of a rear-engined bus)
Air intake noise
Engine noise
Noise level
04-086
20
32
50
80
125 200 320 500 800 1.25K 2K 3.2K 5K
(at full throttle, 80 km/hr)
This engine noise is transmitted into the bus via bulkhead and floor.
The energy of vibration generated from intake of air to the engine is transmitted to the
body of the bus and results in a drumming sound.
When mounting the body therefore, it is important to improve the sound dampening
and sound absorbing characteristics of the bulkhead and floor around the engine compartment, and to suppress vibration in the engine air intake system.
Practical measures to reduce engine noise are given below.
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BUS BODY
Examples of Measures to Reduce Internal Noise
via Engine Bulkhead [Rear-engined Bus]
Bulkhead
Front
04-087
Engine compartment
t = 2 flooring
Improved sound-absorbent
material in bulkhead
t = 12 waterproof plywood
(floor board)
t = 1.4 steel plate
Engine compartment
bulkhead improvements
Fit insulation within

structural beam.
t = 30 glass wool
GW416 (density = 32 kg/m3)
Structural beam
04-088
Improve structure of inspection

covers in bulkhead.
General
Inspection cover
2t flooring
12t flooring waterproof plywood
1.4t steel plate

GW416 t = 30
Punched metal
Rubber seal
Glass wool
04-089
KC-AA014A
56
BUS BODY
Examples of Measures to Reduce Engine
Air Intake Noise [Rear-engined Bus]
(a)
Body external panel on rear end.
Cover board with

sound-absorption
material
Water separation chamber

(Air intake chamber)
Air intake
port
(b)
(b)
(c)
(a)
Rubber seal
Engine compartment bulkhead
Body rear panel

Engine air cleaner
04-090
NOTE
The air intake system between the engine air cleaner and the intake is completely isolated from the passenger compartment with sound-absorbent rubber.
The engine air cleaner and the water separation chamber are fitted to the
body via anti-vibration rubber mountings (see (a) in diagram above).
The external plating of the water separation chamber is strengthened by the
addition of reinforcing beams (see (b) in diagram above).
Rubber seals are added between the plating in the circumference of the air
intake and the body (see (c) in diagram above).
KC-AA014A
57
BUS BODY
Reducing Wind Noise
Wind noise is generated by airflow around the vehicle, and air entering and leaving the
vehicle through gaps around windows and doors, while the vehicle is in operation.
While wind noise increases with speed, the characteristics of the noise differ with the
size of the gaps.
A roaring sound (600 ~ 16,000 Hz) results with large gaps, and a high pitched sound
(1,600 ~ 30,000 Hz) with small gaps.
Effective measures to reduce wind noise include removal of projections from the body,
smoothing of turbulent airflow, and improving seals around windows, doors, etc. to prevent entry of air.
These measures are illustrated below.
Example of Fitting a Wind Deflecting Plate

to the Rear-view Mirror
Wind deflecting
Front window
Noise intrudes from here.
Right rear-view mirror
Passengers
compartment
Outside
Source of wind noise

04-091
Example of Strengthening Seals

Seal rubber of side
window
Seal rubber of
side window
Seal of slide rail
A
Seal of slide
rail
A
04-092
Standard section (A-A)

04-093
KC-AA014A
Strengthened section (A-A)
04-094
58
BUS BODY
Reducing Air Conditioner Noise
The sound of cooling air from the air conditioning system exhausting from the air duct
has a significant effect on ride comfort.
It is therefore important to ensure that this noise is reduced as much as possible when
mounting the body.
The following gives an example of noise distribution inside the bus when the air-conditioning system is in operation, and the degree to which the system contributes to this
noise.
As shown below, when the air-conditioning system is in operation, the most significant
noise is that emanating from the cooling air ducts inside the bus.
This noise has a frequency of 125 ~ 320 Hz.
Noise distribution inside the bus when the

air conditioning system is in operation
High
Noise level (db (A))
Vertical duct (internal)

Sub engine unit (below floor)
04-095
Analysis of air conditioning system noise
Overall air conditioning system noise

Noise of duct
Noise level (db(A))
Noise from subsidiary power

unit (below floor)
KC-AA014A
59
BUS BODY
As levels of noise from air ducts are generally proportional to the speed of the air in the
duct, the following practical measures are available for noise reduction.
Increase the duct cross-section to obtain the same volume of air at a reduced airflow
speed, and thus reduce noise level.
As objects which offer resistance to airflow within the duct (e.g. airflow partition
plates) have a significant effect on noise levels, improve the shape of these object
and fit the inside of the duct with anti-vibration and sound insulating materials to
reduce the level of sound passing through the duct walls.
Example of Effects of Improving Partition Plates with Duct
Partition plate
With original partition plate
Noise level (db (A))
No partition plate
With improved partition plate
Low speed airflow
Medium speed
airflow
KC-AA014A
High speed
airflow
04-097
60
BUS BODY
Reducing Drive Train Noise
As described previously in , in addition to the noise developed by the power plant
itself, noise also emitted by the drive train (in particular the differential noise).
This noise is one of the noises in the passenger compartment which also effects ride
comfort.
The following diagram gives an example of differential noise.
As shown below, differential noise reaches a peak at a particular vehicle speed, and
increases the total noise level in the passenger compartment, thus providing a source
of discomfort for the passengers.
Example of Differential Noise
Peaks
Overall noise level
Internal noise level (db (A))
Vehicle: Bus
Location of measurement:
At ear level above rear axle
Differential noise
40
50
60
70
80
Vehicle speed (km/h)
90
100
04-098
The primary source of this differential noise is vibration from the meshing of gears
which is transmitted to the body via the drive train, suspension, and chassis, and is
apparent as noise inside the bus.
Noise is further amplified due to the fact that the whole bus is covered in the same
manner as a drum.
KC-AA014A
61
BUS BODY
The mechanism by which differential noise is
generated is expressed simply as follows.
Amplification
Vibration
associated with
gear meshing
Drive train
Chassis
Body
Differential noise
perceived in
passenger
compartment
On this basis, reductions in differential noise may be effected by improvements in the

chassis (by improving meshing of gears and suppressing transmission of vibration in
the drive train and chassis), and suppressing the amplification in the body of the vehicle.
The following page explains noise reduction measures related to the body.
KC-AA014A
62
BUS BODY
Reducing Sound Pressure Sensation in the Bus with the Use of
Vibration-Dampening Floor Boards
One method involves the use of floor boards to suppress noise (various vibrations)
transmitted via the chassis.
A comparison of the sound pressure attenuation characteristics of test pieces of floor
panels of plywood and vibration-dampening material (consisting of layers of vibrationdampening material sandwiched between layers of plywood), revealed the following differences in characteristics.
In contrast to the lack of attenuation of sharp peaks apparent with the wood or veneer
product, the vibration-dampening material flattens these peaks to a curve, indicating
the excellent attenuation characteristics of the material.
Comparison of Sound Pressure Attenuation

Characteristics of Various Materials
Plywood
Vibration-dampening material
Acceleration mobility (db/kg)
04-099
Frequency (Hz)
The following graph represents a comparison of measurements of noise in separate

buses in which plywood and vibration-dampening material have been used.
Use of floor boards of the vibration-dampening material dramatically attenuated noise
levels within the bus.
A Comparison of Plywood and

Vibration-dampening Material Used in Buses
Plywood
Noise level (db(A))
Vibration-dampening material
Vehicle speed (km/hr)
Optimum transitory frequency (Hz)
KC-AA014A
04-100
63
BUS BODY
Example of Use of Vibration-dampening Material in Bus
Vibration-dampening floor
board
Dampening material
(Butyl rubber)
Plywood
04-101
Section A-A
Detail of vibration-dampening material
KC-AA014A
64
BUS BODY
Reducing Gear Noise With Anti-vibration Rubber
The use of anti-vibration rubber in spring pins on the chassis is effective in preventing
transmission of vibration caused by meshing of differential gears to the body of the
vehicle.
The use of this rubber at the joins between the chassis and body is also effective.
Reducing the hardness of the rubber (spring rate) reduces noise in direct proportion,
however this also reduces the durability of the rubber (see diagram below).
The use of rubber as described changes both the rigidity of the chassis-body join and
the vibration characteristics of the whole body, and affects the strength of the body and
ride comfort in the presence of vibration.
For the above reasons, care is required when using rubber in this manner.
In general, the use of rubber joins is suited to smaller buses which use standard truck
chassis of sufficient strength.
Spring Constant of Rubber, and Noise Levels
Noise level (dB (A))
200
400
600
04-102
Spring Constant of Rubber (kgf/cm)
KC-AA014A
65
BUS BODY
Example of Structure of Rubber Mounting
Sill cross
Rubber
Chassis frame
Bracket
04-103
KC-AA014A
04-104
66
BUS BODY
8. DESIGN TO FACILITATE INSPECTIONS AND MAINTENANCE

Inspections and maintenance are an important factor in bus reliability.
In most buses the majority of the equipment and functional items to be inspected and
maintained are located under the floor, and surrounded by the floor structure or lateral,
or longitudinal structural members, and inspection covers are therefore required.
If the location of these inspection covers and the surrounding structure is unsuitable,
inspections will be difficult, structural strength will be reduced, and noise and water will
leak from around the inspection covers.
The following points should be kept in mind when installing inspection covers for
inspections and maintenance.
Refer to [General Precautions], [Equipment Installation Procedures], points noted
under [Bus Bodies], and other separately published the body mounting manual for the
Location and Size of Inspection and Maintenance

Position and opening size should facilitate work opening on the equipment and functional
items to be inspected daily, and be suitable for the prevailing methods of inspection and
maintenance.
The designer or person responsible for manufacture should therefore carry out the
inspection and maintenance himself to confirm this.
The example on the following page illustrates the inspection covers used for inspection
on a rear-engined bus.
Always avoid fitting inspection covers in locations which require cutting of primary structural members and thus reducing the strength of the structure.
The layout of the inspection covers required for inspection and maintenance noted in the
documentation on separately published the body mounting manual for the respective
model series should therefore first be checked to ensure that they do not coincide with
the structural members in the body.
KC-AA014A
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BUS BODY
Example-Inspection Covers for Inspection and Maintenance,
and Inspected Items in Rear-engined Buses
Engine side cover, for inspection of starter,
etc.
Inspection and replacement of upper engine components

(air conditioner compressor hoses, injection pump, etc.)
For inspection of cooling system (Belt

replacement, Checks for water leaks, Fan
drive checks)
View B
Replacement of starter, inspection and replacement of air hoses

For transmission removal
For inspection of engine system (Checking oil level,

Checks and replacement of engine components,
Replacement of air cleaner)
For lifting differential
View A
For tightening and removing stabilizers
(only vehicles with pneumatic suspension)
Checks of upper engine components

(Tightening rocker cover, Tightening head bolts)
Checking and replacement of electrical and charging
system components (electrical box)
Inspection and tightening of engine air piping
Inspection of injection pump
Bulkhead
Rear of body
Upper surface of chassis frame
04-105
Strength, Noise Prevention, and Waterproofing Around Inspection Covers

Add reinforcement as required to ensure that the area around the inspection covers is
not subject to excessive deformation or stress.
Ensure that inspection covers in the floor in particular, are well sealed, and rust and corrosion-proofed to prevent intrude of noise and water into the passenger room. See Bus
Body [5. Rust and Corrosion-prevention] for details.
KC-AA014A
68
BUS BODY
9. SAFETY CONSIDERATIONS
The nature of the bus as a means of public transport requires caution and careful consideration of safety.
The following describes the major items requiring consideration. Ensure that these
items are implemented carefully when mounting a bus body.
Visibility
Visibility encompasses general visibility in the forward direction, the visibility of instruments to the driver, and the following.
Ability of the driver to monitor movement of passengers within the bus
Ability of the driver to monitor passenger getting on/getting off from the bus
(This is particularly important in the case of urban buses in which passengers getting
on/getting off from the rear entrance.)
Ensure that internal and rear view mirrors are placed appropriately to allow the driver
to monitor the above.
Safety of Pedestrians
Urban buses designed primarily for mass transport of passengers commonly operate in
narrow, crowded streets, and require the following considerations of pedestrian safety.
Ensure that nothing projects from the bus.
Particular importance should be given to avoiding objects projecting from the side of
the bus.
Ensure that the design of the bus is such that have a under run protection of the tire.
Passenger Safety
Design should be such that passengers do not fall down inside the bus.
Especially in the route bus, as passengers are likely to move in the bus, care should be
taken to the difference in the passageway, inclination of the floor, and the installation of
handrails and handstraps and their fitting positions.
The following body specifications and structural items should also be considered.
To guard against injuries from hot water leaks, avoid having joins in hot water heating
pipe which runs near passengers, and avoid running this piping above passengers.
When lower rails of windows are low in relation to the seat, either restrict dimensions
of side window openings, or fit protective pipes to prevent passengers falling over.
Ensure that passageways and emergency exits are of suitable width to allow rapid
exit in case of accidents.
In long-distance buses or tourist buses in which the floor is high above the road level,
the height of the emergency exit above the road will require provision for steps or ladder.
KC-AA014A
69
BUS BODY
10. FIRE PREVENTION

The nature of the bus as a means of public transport obviously requires that care be
taken with fire prevention when mounting a bus body.
The following points must be strictly followed during mounting a bus body.
In addition to the following, see [1-General Precautions] and [2-Equipment Installation
Procedures].
Protection of Wiring Harness and Pipes During Mounting a Bus Body

Cover other components, including chassis components, to prevent born out of wiring
insulation material, and damage to brake and fuel piping during welding work.
When welding in areas backed by wiring harness and piping, cover by insulator over
these components to prevent heat damage.
When drilling holes in areas of the chassis backed by wiring harness and piping, check
before drilling to ensure that these components will not be damaged.
Example-Preventing Damage to Wiring Harness and

Piping During Drilling Work
(Procedure 1)
Drill
Stop
Drill
(Procedure 2)
Procedure 1 is ineffective if
the operator loses the drill
or uses a different drill.
Floor board
Floor
Wiring harness or pipe
Damage here
Drill stopper protects components
from over-drilling.
04-106
KC-AA014A
70
BUS BODY
Wiring Harness
Wiring harness for head lamps and tail lamps and other electrical components should
be slightly longer than required to provide a degree of flexibility in placement during
mounting a bus body.
Wiring harness must be well fastened in place to ensure that they do not contact
against chassis and body components, resulting in short circuits and fires.
The following points should be followed in this respect.
Preventing Movement of Wiring Harness Connectors

Connectors are normally used to join wire harness.
After the wire harness has been installed, fix it to the body with clips near the connector
to prevent movement due to vibration of the vehicle.
If the connector sags under its own weight it may interfere with other components,
break, or allow penetrating of water thus causing troubles.
Example-Unsatisfactory Placing of Clips

Near the Wiring Harness Connector
Clip
Flow of water
Clip
Movement of harness
Connector
Clips should be located as close as

possible to the connector to prevent
movement.
04-107
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71
BUS BODY
Fixing Loose Wiring Harness
After fixing wiring harness for head and tail lamps and other electrical components to
the body, fix the loose part of the wire harness as follows.
Thick harness, or multiple

harness bound together
Looped and fixed to body

with clips.
Single wires
Bent double and fixed to

body with clips.
If wire harness are not bound together and fixed in place correctly, they will interfere
with surrounding components resulting in damage and breakage.
Binding Loose Wire Harness and Fixing to Body Components
Fix in place with clips to prevent movement.
Thick harness, or
multiple harness
bound together
approx. 300
approx. 300
04-108
Single wires
200~300
200~300
approx. 300
KC-AA014A
72
BUS BODY
11. APPEARANCE AND WORKMANSHIP OF BUS BODY

The appearance and workmanship of the bus body, that is finishing, is extremely
important in that it affects the value of the bus as a product.
The construction and assembly of body components are generally affected by the manufacturers internal situation, the conditions of the environment in each country, and the
size and type of body.
Therefore universal major improvements in method of manufacture and assembly cannot be mentioned, however improvements in the quality of finish, and the fundamental
requirements for a stable level of finish, are described below in reference to appearance and workmanship and examples of measures for improvement.
During manufacture and mounting a bus body, endeavor to incorporate the following
points in improving methods of manufacture to ensure bodies of high quality.
Fundamental Points to Ensure High Levels of Appearance and

Workmanship
Begin body manufacture after checking the following points in your system to ensure
satisfactory levels of appearance and workmanship.
Clarification of work methods and sequences (processes)
Planning and use of tools and jigs
Education and training of worker
Clarification of methods of testing and checks, and criteria for evaluation
Clarification of problems by layer, and repair methods
Other matters related to the work condition (e.g. dust collection measures)
Establish the most appropriate methods and system for the above, and implement a
program of continuous improvement.
KC-AA014A
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BUS BODY
Primary Management Points to Ensure High Levels of Appearance and
Workmanship, and Examples of Improvements
The primary management points to ensure high levels of appearance and workmanship, and examples of improvements for each major item, are shown in the following
table.
Internal
External
Site
Other
Item
Examples of improvements
Overall
external
appearance
Inclination or torsion of
the bus body,
paint uniformity and
shining, scratch, rust,
corrosion
Assembly on the jig, adjustment with spacers, paint

types, painting methods, undercoating, drying,
dust-proof clothing for workers, footwear, covers
External
panels
Dents, unevenness,
incomplete spot welding,
crack of putty and sealer
Rigidity of structural framework, rigidity of external

panels, plug welding, supplementary gas welding,
spot welding methods (pitch and electric current)
Doors and
windows
Smooth operation, fitting,

gaps, force required to
open/close, water and
dust-tight
Dimensions, adjustment of angles, increase rigidity

of frames, improve functioning of open/close
devices.
Steps
Jagged edger on step

plates, inappropriate step
heights
Smooth edge, fit edge strips (also help to prevent

slipping), fit handrails.
Passageways
Gradients, projections,
obstacles
Design with maximum of 5 for tourist buses and

3.5 for route buses, smooth edges, rounded
shapes, protectors.
Ceiling lining
Finishing measure of
exposed screws and
rivets, exposed ends or
parts
Fit caps to exposed screws and rivets, fit covers

(PVC etc.), beading, and corner plates, welded
joins adjacent ceiling material of same type.
Seats
Non-uniform location
(pitch and ease of
passage through bus),
loose mountings
Use templates to position seat mouting holes,

method of fitting seats, tighten mounting bolts.
Wiring and
piping
Clearance, deformation,
damage
Described above.
Indicators
and signs
Position, size, ease of

visibility
KC-AA014A
74
BUS BODY
Tension Rigidity of Body Outer Panels
Dents and unevenness in the external panels of the bus body have the greatest effect
on its quality of appearance.
The methods noted in the following table, either singly or in combination, are generally
employed to increase the tension rigidity of the panels to improve appearance, and
therefore quality.
Conditions such as tensile strength of the panels, and temperature
Method of giving tension to the outer panel, and temperature applied, etc. must be
determined after investigation of a variety of factors including panel size, structure, and
the manufacturing condition in a process of trial-and-error repeated until a stable result
is obtained.
Method
Details and characteristics
Mechanical
Hold the edge of the panel in a vice, apply tension with a turnbuckle
or hydraulic device, and weld it to the skeleton.
This method requires equipment, however it produces a
comparatively stable result.
Heating
Heat the panel electrically or with hot air to expand it, and weld it
while hot.
This method does not require large equipment, but it is effected from
outside temperatures.
Tensioning
Insert a tensioning material ( shaped a piece of steel or felt,

rubber) between the skeleton and the outer panel.
Work is much simplified, however as results are uncertain its use is
recommended in combination with mechanical or heating methods
described above.
KC-AA014A
75
BUS BODY
12. ADVANTAGES AND DISADVANTAGES OF FRONT AND REAR-ENGINED

BUSES, AND AIR CONDITIONING SYSTEMS
The advantages and disadvantages of front and rear-engined buses, and air conditioning systems, are described below for reference when mounting a bus body.
Select the engine configuration and air conditioning system only after you have a clear
understanding of their advantages and disadvantages.
Advantages and Disadvantages of Front and Rear-engined Buses

A comparison of the advantages and disadvantages of front and rear-engined buses is
given in the table on the following page.
Changes in conditions currently affecting each country (increased levels of comfort and
luxury required, improved conditions for vehicles such as better road) are generally
leading to adoption of the rear-engined configuration on the basis of the advantages
and disadvantages noted in the table.
KC-AA014A
76
Item
Serviceability
Front/rear weight
distribution, when
body mounted.
Passenger seat
arrangement
(In case of mid-door)
Ease of installation of
direct drive coolers
(compressors)
Approach and
departure angle
Baggage space
Passenger access to
bus (in case of
frontdoor)
Riding comfort
1 Inside room noise

(passenger room
noise)
No.
Front engine
bus
Rear engine
bus
Evaluation
04-110
1) Better anti-noise insulation at engine

room by bulkhead construction which
prevent noise transmission to inside room
Rear engine bus
KC-AA014A
FLOOR
E/G HOOD
E/G
04-112
Mounting the engine in the rear

prevents a large departure angle.
Ample space for cooler

compressor due to
spacious bulkhead construction
Longer and flat inside body length

is taken without front engine hood.
LID CAN BE OPEN
NO ENGINE HOOD
04-120
04-119
04-118
04-117
04-116
04-115
Due to the presence of the drive shaft, baggage space A large volume of baggage space is available between the
across the bus is not available between the front and rear front and rear wheels across the bus.
wheels.
COMPRESSOR 04-113
FLOOR IS LIFTED.
A greater departure angle is possible.
Difficult to find
out space for
cooler compressor
Body length is shortened

by engine hood.
Difficult weight distrubution due to heavy load at front Better weight distribution
tires by front engine
with proper rear weight on
four tires in rear
2) Easy of engine dismounting
2) Difficult of engine dismounting
04-111
Ample space at front
1) Easy inspection/serviceability
by wider opening rear lid
ENGINE HOOD
04-114
Comfort riding due to proper load distribution on front & rear

axle
1) Less inspection/serviceability, as engine is

surrounded by engine hood & floor.
Narrow passage at
front due to engine hood
Harsh riding at rear due to less load on rear axle
2) Longer propeller shaft consisted of many parts and 2) Shorter propeller shaft & less noise source
make noise.
1) Engine noise is easy to

transmit through floor to
inside room.
Front engine bus
Advantages and Disadvantages (merit & demerit)
Advantages and Disadvantages of Front and Rear-engined Buses
4
BUS BODY
77
BUS BODY
Air-conditioning Systems
With the increasing level of luxury required in recent years, air- conditioning units are
now installed in most buses to improve ride comfort.
The advantages of the various types of air-conditioning systems, and of the ducting
systems are listed on the following page.
Select the appropriate air-conditioning system after an investigation of the bus specifications, the equipment and capacity of the factory in which it is to be mounted, and the
chassis specifications.
KC-AA014A
78
BUS BODY
Air-conditioner Types and Advantages
Type
Merit
One unit type

Integrated unit is easy for mounting,
minimum body work, no piping of vehicle
side.
Widely used for the sightseeing bus
04-121
Separate type
(split type)
The power unit and cooling unit are

separated, easy for mounting on the bus
with chassis frame.
Sub engine type
04-121
Separate type
(power unit type)
(type I)
Combination of direct coupled two units

type of cooling unit and power unit
assures good flexibility for mounting
including rear mount.
04-122
(type II)
Combination of direct coupled three units
type of cooling unit and power unit
assures good flexibility for mounting
including rear mount.
04-123
(type III)
Combination of direct coupled dispersion
type of cooling unit and power unit make
it easy to mount on re-built or special
purpose vehicle.
04-124
Two unit type

(package type)
Integration of evaporator and condenser

decreases the piping in the vehicle and
assures free choice of unit mounting
position.
04-125
Direct coupled type
Three units type

Small divided units assures good
flexibility for mounting and enables builtin.
04-126
Dispersion type
Dispersed cooling units in the room
assures good flexibility for mounting.
Required body work is little and built-in is
possible.
04-127
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79
BUS BODY
Characteristics of Types of Air ducts
[Evaluation:
Good,
Type
Item
Roof duct
Side duct
Normal,
Bad]
Remarks
Duct
960
920
390
390
Concept sketch
Duct
2344
2254
04-128
Temperature
distribution
Cooling capacity
04-129
Equalization of
temperature is easy
(good distribution).
Dead zone may be

Roof duct type can
create (bad distribution). keep the head cool and
feet worm. Cool air
covers the upper half of
the body.
Small resistance in the

duct
L a r g e r e s i s t a n c e i n t h e Power consumption of
duct
side duct type is larger
if the same wind
volume is required.
Uniform wind touch
Side duct type may

Wind is strong for the
passengers on window require an agitator on
the ceiling.
side. Wind is not
available enough for the
passengers on the aisle
side.
Interior width: 2344 mm

Seat width:
960 mm
Aisle width:
390 mm
Where the duct

thickness is 45 mm:
Interior width: 2254 mm
Seat width:
920 mm
Aisle width:
390 mm
Duct noise is low.
Duct noise is high

because of the air outlet
position.
Power consumption of
the evaporator blower
motor can be minimized
(duct resistance 10mm
Aq).
Power consumption is
high because of large
resistance of duct (duct
resistance 25mm Aq).
Larger flexibility,
enabling the mounting
from driver seat to rear
seat
Difficult to mount at the

driver seat or around the
emergency exit
Wind volume
Wind volume
distribution
Comfortability
Noise
Economy
Mounting easiness
KC-AA014A
Seat width is one of the

most important points
for middle and long
distance bus.
Power consumption of
side duct type is 15 to
20A larger than the
roof duct type, which
results in fuel
consumption increase
by 2 to 3%.
80

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KC-AA014A

Body Mounting Manual

COMMON to all Hino

All rights reserved. Printed in Japan.

PRODUCT PLANNING DIVISION

ABOUT THIS MANUAL

The Manuals for each model is available at authorized Hino distributor.

ABOUT THIS MANUAL

ABOUT THIS MANUAL

COMMON TO ALL HINO BUSES

COMMON to all Hino

This manual contains the peculiar

1. BODY DESIGN AND CONSTRUCTION 2

1. BODY DESIGN AND CONSTRUCTION

Max. GVM. capacity

16,000 (15,100 Legal limit)

11,000 (9,100 Legal limit)

191 (260) / 2,150

883 (90) / 1,400

Height of gravity from ground

STD: 20 x 7.50V-offset 165mm

Tire and disc

STD: 250 / OPT: 350

More than 28%

Gross Vehicle Mass (GVM)

Crew, Passengers and Other Load (baggage and cargo)

Gross Vehicle Mass (GVM)

For one unit of load

Para mltiples unidades de carga

(W1 x L1) + (W2 x L2) + (W3 x L3) (W4 x L4)

.Wfc and Wrc are given under 1

Calculate Wfb and Wrb using the basic

PASSENGERS AND CREW MASS

Calculate Wfp and WRP using the basic

Calculation of Gross Vehicle Mass and Gross Axle Mass

GVMR and axle

Mass distribution on front axle

L : Body mass offset (m)

Total mass of body

Calculate height of center of gravity of body from ground (HD) in meters.

= HR {(HR HF) x L/WB}

= 1005 {(1005 945) x 2040/5000}

= 980 (mm) = 0.980 (m)

Height of center of gravity

Value marked * is indicated under 1. Vehicle Summary - Chassis Specifications in the

Body Dimensions (Maximum width)

2. NEVER MODIFY SAFETY PARTS

TIE ROD ARM

Under view of truck showing

TIE ROD SOCKET

Sectional views of front axle

A. From and To brake valve

POWER BOOSTER ASSY

AIR SPRING COVER

CENTER BEARING ASSY

UNIVERSAL JOINT ASSY

UNIVERSAL JOINT ASSY

UNIVERSAL JOINT ASSY

Engine periphery and body

Above and below: min. 40 mm

Transmission periphery and body

Allow minimum clearance.

Allow space for

Do not mount any part of the body inside this area.