KK-FC102B-B

BODY MOUNTING
MANUAL

BUS
CHASSIS

MODEL

FC9J SERIES

No part of this manual may be reproduced or transmitted in any form without the
express written permission of Hino Motors, Ltd.
2015, Hino Motors, Ltd. All rights reserved. Printed in Japan.

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

May 2015

KK-FC102B-B

RECORD OF CHANGES
We have published the new revised edition of Body Mounting Manual with
the following changes.
Consequently, please discard the current Body Mounting Manual
CD-ROM NO.KK-FC102A-B, and use the new CD-ROM NO.KK-FC102B-B
from now on.
CONTENTS OF CHANGES
Vehicle specifications has been changed for complying of Ecuador safety
regulations.

KK-FC102B-B

ABOUT THIS MANUAL

Purpose

This manual is provided the Body and Equipment Manufacturers, including

intermediate and/or final stage manufacturers (hereinafter collectively referred to as
Body and Equipment Manufacturers), to provide ;
Technical instructions for Hino bus chassis for modification and mounting of
bodies.
An aid to Body and Equipment Manufacturers for producing safe vehicles under
their own discretion and responsibility.
Other general advice for installation, modification or alteration.
WhenBodyandEquipmentManufacturersinstall any body orother equipment or
device on Hino bus chassis (hereinafter collectively referred to as Hino Chassis),
or modify or alter a Hino Chassis.

Content

This manual contains chassis specifications and instructions particular to model

FC9J BUS series with EURO3 emission control in the Hino of medium duty bus
chassis.

Important

This instruction manual must be used in combination

with the Common Manual, No. KC-AA014A.

The Common Manual is available in this CD-R.

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

KK-FC102B-B

Warning
The vehicle has installed electric equipments such as the vehicle's control system
and a computer for comply with vehicle regulation for each country.
In that case, do must not alter of chassis such as change of wheelbase and tire
size.
Deterioration of vehicle's capability and vehicle regulation violation may lead to
serious traffic accident.
It is the responsibility of Body and Equipment Manufacturers or modification
companies to make sure that the completed vehicle with body and equipment, or
after modification, conforms to all applicable laws and regulations of the country
in which the vehicle is to be used (e. g. regulations on lighting, tilt, overall size,
axle load, external noise control etc.).
This manual does not guarantee the safety of a Hino chassis once a body or
equipment has been mounted or modification has been made by a Body and
Equipment Manufacturer or a modification company.
This manual does not affect that ultimate responsibility for the manufacture and
mounting of the body, installation, modification or alteration on Hino Chassis
devolves upon the Body and Equipment Manufacturer.
Each individual Body and Equipment Manufacturer has the sole responsibility for
the design, functions, materials and work concerning the body and equipment.
About chassis mass
The chassis mass of chapter 3 shows standard specification of vehicle.
(It is not included mass of option specification.)
When consider the mounting of body, should include mass of option specification.
Hino Motors, Ltd. Does not assume any liability whatsoever for any injury to
persons or damage to property caused as a result of the utilization of this manual.

KK-FC102B-B

STRICT OBSERVANCE OF PARALLEL USE WITH "COMMON"

VERSION OF THE BODY MOUNTING MANUAL
Common Version of Body Mounting Manual for bus "KC-AA014A" recapitulates the
following important items :
a) Necessary instructions as complete vehicles.
b) Precautions to take when handling devices and equipments.
c) Instructions concerning the method of bus body mounting.
When studying the body mounting, securely execute the mounting operation by
making use of both Individual Respective Model Series of Vehicle Data Collection
and the Common Manual of Know-How Collection for Body Mounting.
Both manual, "Manual for the Respective Model Series and Common Manual".
On the other hand, you will find bellow the descriptions of common manual.
Observe the instructions given therein without fail.

1.

GENERAL
PRECAUTIONS

GRAND ITEM

3.

PRECAUTION
WHEN
APPLYING
THE
FINAL COAT
OF PAINT

EQUIPMENT INSTALLATION
PROCEDURES

2.

BUS BODY

4.

KK-FC102B-B

MEDIUM ITEM
1)
2)
3)
4)
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)

BODY DESIGN AND CONSTRUCTION

NEVER MODIFY SAFETY PARTS
CLEARANCE
FITTING THE BODY
ENGINE
ENGINE COOLING SYSTEM (RADIATOR & RELATED PARTS)
ENGINE AIR INTAKE SYSTEM
CHASSIS FRAME
FUEL TANK
STEERING
CLUTCH CONTROL SYSTEM
BRAKE SYSTEM
PROPELLER SHAFT
SUSPENSIONS
EXHAUST SYSTEM
TIRE
ELECTRICAL EQUIPMENT AND RELATED PARTS
ATTACHMENT OF THE PACKAGED PARTS
COMPONENTS TO BE MASKED
UNPAINTED COMPONENTS
ELECTRICAL PARTS
FORCED DRYING
PAINTING THE WHEEL DISC
BASIC POINTS OF BUS BODY MOUNTING
DESCRIPTION OF BUS BODY
PRINCIPAL PRECAUTIONS WHEN MOUNTING A BUS BODY
BASIC LAYOUT OF BODY STRUCTURE
LAYOUT OF STRUCTURAL ELEMENTS
RUST AND CORROSION PREVENTION
RIDE COMFORT IN RELATION TO VIBRATION AND NOISE
DESIGN TO FACILITATE INSPECTIONS AND MAINTENANCE
SAFETY CONSIDERATIONS
FIRE PREVENTION
APPEARANCE AND WORKMANSHIP OF BUS BODY
ADVANTAGES AND DISADVANTAGES OF FRONT AND
REAR-ENGINED BUSES, AND AIR CONDITIONING SYSTEMS

CORRESPONDING
PAGE IN COMMON
MANUAL

1-1
1-2
1-3
1-4
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2 - 10
2 - 11
2 - 12
2 - 13
2 - 14
3-1
3-2
3-3
3-4
3-5
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4 - 10
4 - 11
4 - 12

CONTENTS

KK-FC102B-B

1. VEHICLE SUMMARY
2. GENERAL PRECAUTIONS
3. CHASSIS MASS & FRAME SECTION MODULUS
4. EQUIPMENT INSTALLATION PROCEDURE
5. ATTACHED DATA

1. VEHICLE SUMMARY

MODEL CODE 1 - 1

IDENTIFICATION NUMBER 1 - 2

CHASSIS SPECIFICATIONS 1 - 3

DETAIL OF VEHICLE CAPACITY 1 - 4

KK-FC102B-B

1. VEHICLE SUMMARY

1-1

MODEL CODE
F

VEHICLE CODE
FRONT ENGINE

GVM & DRIVE CODE

GVM

9,000kg

DRIVE 4 x 2
ENGINE CODE
9J J05E
WHEELBASE CODE
WHEELBASE (mm)
CODE
G
K

3,850
4,650

MODIFICATION CODE
CODE STEERING POSITION MODIFY
K
FIRST
RIGHT HAND
R
S
FIRST
LEFT HAND
Z
APPLICABLE CODE
BODY TYPE
GENERAL CARGO
DUMP TRUCK

CODE
A
D
Z

BUS
COLFC101B01T001

KK-FC102B-B

1-2
IDENTIFICATION NUMBER
CHASSIS NUMBER

ENGINE NUMBER

Located at the right upper

front end of the engine's side wall.

FFC1 E No

KK-FC102B-B

1-3
CHASSIS SPECIFICATIONS
Chassis model

Item

Wheel base

Front

Tread
Max.GVM. Rating

*
(On std. spec.)

Capacity

(mm)
(mm)

Rear
GAM.

Rating
Tire

Chassis mass on standard

specifications

Tire and Disk

Fuel tank
Battery

Alternator

3,850

4,650

9,000
3,150

(kg)

Rear

(kg)

5,850

Front

(kg)

Total

(kg)

2,813

(kg)

1,262

Rear

(kg)

Front

(kg)

1,770
1,660

(kg)

Front

Model

3,600
6,800

1,551

2,866

1,602

J05E-TC

1,264

Max.

ISO NET

129kW {175PS} at 2,500r/min

Max.

ISO NET

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

Outp

Height of gravity from ground

FC9JKSZ

(mm)

(including, water, oil and full fuel) Rear

Engine

FC9JGSZ

JIS GROSS

Torque JIS GROSS

Tire
Disk

STD

(mm)

OPT

510Nm {52kgfm} at 1,500r/min

0.604

8.25R16-14PR

0.605

8.25-16-14PR

STD

16x6.00GS-offset135mm

OPT

(17.5 x6.75-offset135mm for local tire)

STD

(V-kC {Ah} -No.) STD

132kW {180PS} at 2,500r/min

200L

(V-A)

12-432 {120} -2
24-50

COLFC101B01T002

[NOTE]
1) Allowable axle and GVM rating listed above table must not be exceeded.
2) The lopsided weight distribution between left and right wheels should be avoided.
3) Both front axle and rear axle loads must not exceed the permissible load based
on the tire load capacity according to the tire standards in your country.
: See next page 1 - 4 for detail of vehicle capacity.

KK-FC102B-B

1-4
DETAIL OF VEHICLE CAPACITY
Unit : kg
ITEM

CAPACITY

SPRING

TIRE
(ETRTO
STANDARD)

8.25R16-14PR

8.25-16-14PR

STD
or
OPT

FRONT

3,150

STD

REAR

5,850

STD

FRONT

3,600

REAR

6,800

FRONT

3,420

REAR

6,520

STD

OPT
COLFC101B01T003

STANDARD TIRE CAPACITY.

* : 12.. JATMA
Even though optional tires are to be equipped, GVM capacity can not be
increased.

[NOTE]
Spring capacity and tire capacity, listed above table must not be exceeded.

KK-FC102B-B

2. GENERALPRECAUTIONS

BASICPOINTSOFBUSBODY 2 - 1

WEIGHTDISTRIBUTIONONFRONTAXLE&

HEIGHTOFCENTEROFGRAVITY 2 - 2

BODYDESIGN 2 - 3

FITTINGTHEBODY 2-7

SHIPMENT 2-9

KK-FC102B-B

2. GENERALPRECAUTIONS

2-1

BASICPOINTSOFBUSBODY
Basic points of bus body construction are described in the Common Manual.
Be sure to strictly observe the indicated points when designing the bus body.

KK-FC102B-B

2-2
WEIGHT DISTRIBUTION ON FRONT AXLE & HEIGHT OF CENTER
OF GRAVITY
In body mounting, keep the following standard, for preventing over rolling and
spring failures.
ENGINE
LOCATION

FRONT

MODEL

WEIGHT
DISTRIBUTION ON
FRONT AXLE
(FR/VM)

HEIGHT OF GRAVITA - RECOMMENDED

TIONAL CENTER
BODY MAXIMUM
FROM GROUND
WIDTH
(UNLADEN)
(m)
(m)

FC9JGSZ MORE THAN 28%

FC9JKSZ (UNLADEN AND
LADEN)

MAX.
1.09

MAX.
2.3
COLFC101B02T001

Notes:
1) When vehicle's specifications are against above mentioned standards after
mounting the body, HINO can not guarantee against any field troubles and take a
countermeasure.
2) If wide body needs for special use, the weight distribution and the height of
gravitational center limits from ground must be kept surely.
3) The calculating method for the height of center of gravity is as follows.
CALCULATION CHART (UNLADEN)
HEIGHT OF
GRAVITATIONAL
CENTER
(m)

MASS
(kg)
CHASSIS
BODY
PASSENGER'S
SEAT
TOTAL

(1)

(2)

(1)x(2)=(A)

(3)

(4)

(3)x(4)=(B)

(5)

(6)

(5)x(6)=(C)

(1)+(3)+(5)=(D)

Moments
The height of

=
Vehicle mass
gravitational center

KK-FC102B-B

MOMENT OF
GRAVITATIONAL
CENTER
(kgfm)
From HINO
Refer chassis
specification
Page 1 - 3
(Including option
equipment)
By body builder

(A)+(B)+(C)=(E)

= (E)
(D)

= (F) < 1.09 (UNLADEN)

2-3
BODY DESIGN
1. CONSIDERATION OF WEIGHT ADJUSTMENT
With careful consideration to ensure rigidity of the bus body, endeavor to improve
performance as much as possible by making adjustments to reduce dead weight
of the body.
Also, with regard to the bus body, carry out layout design of the ancillary
machinery and equipment above and below the floor of the body so that there is
no difference in weight left and right wheels, also be no exceeding the permissible
the capacity of the front and rear tire or axle in order to prevent such things as
one side action of the brakes and uneven tire wear, tilting the vehicle, etc.
(Give consideration also to the fitting position of such things as the spare tire,
battery, fuel tank, etc.)
If there is a weight discrepancy between left and right in this chassis, so that the
following adjustment should be done to eliminate the difference in weight left and
right.

Adjust the weight difference between left and right by giving consideration

to the construction of the body.

And fit the items in described as following.

<Spare tire>
Which have been fitted at rear over hang under the chassis frame, fit
under the floor at right side between wheelbase of the body.

KK-FC102B-B

2-4
2. INSTALLATION OF ANCILLARY HEAVY MACHINERY OR EQUIPMENT
When install the ancillary heavy machinery or equipment above and below the
floor of the body, layout design should be carefully considered to keep the weight
distribution within permissible capacity of the axles and tires under the both
condition of V.M.(Vehicle Mass) or G.V.M.(Gross Vehicle Mass) as well as G.V.M.
permissible capacity.
(Permissible capacities are described page 1 - 3 chassis specification.)
[EXAMPLE]
INSTALL THE COOLER UNIT TO THE REAR OVERHANG.

3. CONSIDERATION OF SAFETY
Take good care that dangerous items such as projections or cut ends of plates do
not stick out either inside or outside the compartment.
Also, use non-combustible or flame-retardant material for body parts that are
close to the exhaust pipe or engine room.

KK-FC102B-B

2-5
4. INSPECTION COVERS AND LIDS
When making the body structure, remember such things as positioning
inspection cover so that no obstruction is caused to the following routine
inspections and maintenance.

1) Checking engine oil, filling and removing oil.

2) Checking cooling water level, filling and removing water.
3) Checking transmission oil, filling and removing oil.
4) Checking differential oil, filling and removing oil.
5) Checking battery fluid, removing the battery.
6) Fuel filter, drain.
7) Air tank drain.
8) Possible to remove the spare tire and to check whether or not it is securely
fitting.
9) Checking and removal of the brake component parts such as air booster, oil
and air piping and related valves.

KK-FC102B-B

2-6
5. INSTALLATION OF FRONT AND REAR SPLASH GUARD
Splash guard should be fitted to the forward and rearward of front and rear tires
to protect the air cleaner, engine and etc. from splashing water and mud.
(See attached data 5-5 for details.)

6. REDUCTION OF INTERIOR NOISE LEVEL

In the case of front engine buses, noise near the front seat in the passenger
room tend more than elsewhere.
Therefore, rubber sealing sheets should be fitted to each parts of mentioned
below to prevent noise of the engine entering to the passenger room.

7. The completed vehicle with body fitted is to comply with the vehicle laws and
regulations of the country in which the said vehicle is used and in addition the
previously mentioned tolerance limits for such things as axle capacity, weight
distribution on front axle and height of the center of gravity are not to be
exceeded.

KK-FC102B-B

2-7
FITTING THE BODY
1. In fitting the bus body, avoid stress that would cause damage to the frame and
other chassis structural parts. Also, always take the horizontal level of the
chassis frame and carry out the fitting keeping level with this.

2. When making the installation, be careful not to damage the chassis or interfere
with its functions. For example, do not stand on such things as the brake valves,
brake pipes, fuel tank, fuel pipes, air tank, battery, wiring harness, T/M control
rods, etc.
3. With regard to the electrical components, fuel system and exhaust system,take
great care to prevent trouble leading to fire. As there are occasions when debris
from steel plates resulting from fitting the body comes into contact with electrical
fittings and causes short circuits, this debris should be completely removed by
the time of shipment.

KK-FC102B-B

2 - 8-1
4. 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.
1) Procedure before Welding
Turn the starter switch off.
Disconnect the batterys negative terminal.
Disconnect fuse of engine ECU instrument.

KK-FC102B-B

2 - 8-2
2) Ground of the Welding Equipment
Connect the ground of the welding equipment near the place where to be
welded.

W
 elding to the chassis frame

Connect the ground to the bolt (plating bolt) or chassis frame near the place
where to be welded.

Peel off the paint where to be welded.

Connecting the ground to the chassis spring is strictly prohibited to prevent
damage of the spring.
3) Other Precautions

To protect ancillary equipment from sparks during welding, place fireresistant covers over the rubber hoses, wire harness, pipes, chassis spring
and tires, etc.

Perform to weld under most suitable conditions of the
welding, and minimize the heat influence to the circumference where to be
welded, and as far as possible to keep the welding quality.

KK-FC102B-B

2 - 8-3
4) After Welding

Put back fuses as original condition.

Make sure to connect the negative terminal of the battery.
And the terminal should be horizontally setting.

BATTERY TERMINAL

NO GOOD

GOOD

BATTERY
A : B = SAME HEIGHT
FXZ2 BATTERY

Re-paint the place where to be peeled off the paint for grounding the
welding equipment by same color.

5) Final Inspection after Welding

Inspect the operation and function of each electronic instrument and
equipment after restored to its original site.

Consult to each Hino sales dealer or distributor for the details of
inspections procedure.

KK-FC102B-B

2-9
SHIPMENT
1. After completing the vehicle installation, shipment is to be made after checks
have been made that there are no body vibration, noise or other
discrepancies. (Shipment inspection is to be carried out thoroughly.)
2. As such things as the brakes, steering and suspension are important safety
components, if any of them have had to be removed while carrying out the
installation, they are to be refitted perfectly and their operation is to be
checked before shipment is made.
(Be make sure to carry out shipment inspections.)

KK-FC102B-B

3. CHASSIS MASS &

FRAME SECTION MODULUS

CHASSIS MASS 3 - 1

CHASSIS MASS FOR OPTION SPECIFICATION 3 - 2

FRAME SECTION MODULUS 3 - 3

KK-FC102B-B

3. CHASSIS MASS & FRAME SECTION MODULUS

CHASSIS MASS
MODEL
No.

ITEMS

WB :
Mass
(kg)

FLOOR

3 - 1-1

FC9JGSZ-NZL
(m)
TIRE : 8.25R-16-14PR
GRAVITY
Gravity
Moment
Morment
HEIGHT
FROM
FROM
Position
from
FRAME
FRAME
UPPER
UPPER
from F.A.C
F.A.C
SURFACE
SURFACE
(m)
(kgm)
(m)
(kgm)
3.850

128.0

-0.440

-56.320

0.210

26.880

INSTRUMENT PANEL

23.0

-0.740

-17.020

0.730

16.790

STEERING

53.0

-0.750

-39.750

-0.020

-1.060

STEERING CONTROL

5.0

0.190

0.950

0.065

0.325

RADIATOR

ENGINE FRONT

CONTROL

31.0

-0.360

-11.160

-0.100

-3.100

139.0

0.115

15.985

-0.135

-18.765

15.0

-0.310

-4.650

0.225

3.375

ENGINE ROOM

2.0

0.250

0.500

0.115

0.230

AIR CLEANER

15.0

0.435

6.525

0.245

3.675

10 ENGINE REAR

479.0

0.590

282.610

-0.135

-64.665

11 BRAKE SYSTEM

57.0

1.665

94.905

-0.110

-6.270

12 ELECTRIC SYSTEM

27.0

2.960

79.920

0.200

5.400

13 EXHAUST SYSTEM

48.0

2.290

109.920

-0.375

-18.000

14 BATTERY

66.0

2.310

152.460

-0.160

-10.560

207.0

1.270

262.890

-0.210

-43.470

37.0

2.460

91.020

-0.345

-12.765

371.0

2.430

901.530

-0.130

-48.230

15 FUEL SYSTEM
16 PROPELLER SHAFT
17 FRAME ETC
18 SPARE TIRE CARRIER

3.0

5.300

15.900

-0.230

-0.690

53.0

5.280

279.840

-0.380

-20.140

6.0

-0.850

-5.100

0.485

2.910

1765.0

1.224

2160.955

-0.087

-188.130

347

0.000

0.000

-0.375

-130.125

REAR

701

3.850

2698.850

-0.440

-308.440

TOTAL

2813

1.728

4859.805

-0.223

-626.695

19 SPARE TIRE
20 HEATER

SPRUNG MASS TOTAL

UN SPRUNG MASS
FRONT

FRONT

REAR

SPRUNG MASS

(kg)

UN SPRUNG MASS

(kg)

347

701

1048

CHASSIS MASS

(kg)

1551

1262

2813

GRAVITY POSITION FROM F.A.C

GRAVITY HEIGHT FROM
GROUND

1204

561

TOTAL

1765

(m)

1.728

(m)

0.604

[NOTE]
The mass of tires to be mentioned in above table shows design figure according
to JATMA or ETRTO standard.
Mass to be mentioned above table shows on standard specification condition.
In the case to be provided option equipment, make sure mass distribution on
front, rear and total followed by chassis mass for option specification.
KK-FC102B-B

3 - 1-2
CHASSIS MASS
MODEL

WB :

4.650
Gravity

No.

ITEMS

Mass

Position
from F.A.C

(kg)
1

FLOOR

(m)

FC9JKSZ-NZL
(m)
TIRE : 8.25R-16-14PR
GRAVITY
Moment
Morment
HEIGHT
FROM
FROM
from
FRAME
FRAME
UPPER
UPPER
F.A.C
SURFACE
SURFACE
(kgm)
(m)
(kgm)

128.0

-0.440

-56.320

0.210

26.880

INSTRUMENT PANEL

23.0

-0.740

-17.020

0.730

16.790

STEERING

53.0

-0.750

-39.750

-0.020

-1.060

STEERING CONTROL

5.0

0.190

0.950

0.065

0.325

RADIATOR

ENGINE FRONT

CONTROL

31.0

-0.360

-11.160

-0.100

-3.100

139.0

0.115

15.985

-0.135

-18.765

15.0

-0.310

-4.650

0.225

3.375

ENGINE ROOM

2.0

0.250

0.500

0.115

0.230

AIR CLEANER

15.0

0.435

6.525

0.245

3.675

10 ENGINE REAR

479.0

0.590

282.610

-0.135

-64.665

11 BRAKE SYSTEM

57.0

1.675

95.475

-0.110

-6.270

12 ELECTRIC SYSTEM

27.0

3.580

96.660

0.200

5.400

13 EXHAUST SYSTEM

51.0

2.530

129.030

-0.375

-19.125

14 BATTERY

66.0

2.310

152.460

-0.160

-10.560

15 FUEL SYSTEM
16 PROPELLER SHAFT
17 FRAME ETC
18 SPARE TIRE CARRIER

207.0

1.270

262.890

-0.210

-43.470

43.0

2.855

122.765

-0.345

-14.835

415.0

3.000

1245.000

-0.130

-53.950

3.0

6.100

18.300

-0.230

-0.690

53.0

6.080

322.240

-0.380

-20.140

6.0

-0.850

-5.100

0.485

2.910

1818.0

1.440

2617.390

-0.075

-197.045

347

0.000

0.000

-0.375

-130.125

REAR

701

4.650

3259.650

-0.440

-308.440

TOTAL

2866

2.051

5877.040

-0.222

-635.610

19 SPARE TIRE
20 HEATER

SPRUNG MASS TOTAL

UN SPRUNG MASS
FRONT

FRONT

REAR

SPRUNG MASS

(kg)

UN SPRUNG MASS

(kg)

347

701

1048

CHASSIS MASS

(kg)

1602

1264

2866

GRAVITY POSITION FROM F.A.C

GRAVITY HEIGHT FROM
GROUND

1255

563

TOTAL

1818

(m)

2.051

(m)

0.605

[NOTE]
The mass of tires to be mentioned in above table shows design figure according
to JATMA or ETRTO standard.
Mass to be mentioned above table shows on standard specification condition.
In the case to be provided option equipment, make sure mass distribution on
front, rear and total followed by chassis mass for option specification.
KK-FC102B-B

3-2
CHASSIS MASS FOR OPTION SPECIFICATION
The table of option mass shows the difference mass with standard specifications.

CONTENT OF OPTION

AIR CLEANER

PAPER FIL. TYPE

PAPER FILT(DRY DUAL)

TIRE

8.25R16-14PR
8.25-16-14PR

SPARE TIRE

WITH ONE (8.25R16-14PR)

WITH ONE (8.25-16-14PR)

ANTI-LOCK BRAKE

LESS
ABS(WITH AUTO ADJ)

AIR GAGE & LIMIT VALVE

TACHOGRAPH

GRAVITY

MASS

POSITION

FR AXLE

(kg)

FROM F.A.C

MASS

MASS

(m)

(kg)

(kg)

0.5

STD

0.435

0.5

0.0 OPT

3.1

20

40 OPT

6.08

-2

8 OPT

1.87

3.5 OPT

-0.9

-1 OPT

-60

STD

-10

STD

8.5

1 AIR GAGE

2 AIR GAGE+VALVE

RR AXLE REMARKS

STD
STD

STD

7DAYS 140km/h

1.5

OPT

LESS
REVO TACHO 7DAYS 140km/h

1.7

OPT

PACKEAGE PARTS No.5

REMODELING PARTS

0.7

OPT

PACKEAGE PARTS No.25

H-MARK ORNAMENT(FR)

0.1

OPT

PACKEAGE PARTS No.24

H-MARK ORNAMENT(RR)

0.5

OPT

PACKEAGE PARTS No.8

FUEL SENDER GAGE

0.2

OPT

PACKEAGE PARTS No.41

EXTENDED FILLER PIPE

0.4

OPT

PACKEAGE PARTS No.28

WIPER RELAY

0.1

OPT

PACKEAGE PARTS No.42

WIPER PARTS

OPT

PACKEAGE PARTS No.14

HEAD LAMP

OPT

PACKEAGE PARTS No.17

FRONT TURN SIGNAL

OPT

PACKEAGE PARTS No.18

REAR COMB LAMP

OPT

PACKEAGE PARTS No.15

BACK UP LAMP

OPT

PACKEAGE PARTS No.20

LICENSE PLATE LAMP

KK-FC102B-B

0.1

OPT

3 - 3-1
FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE)
MODEL : FC9JGSZ

KK-FC102B-B

Unit : mm

3 - 3-2
FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE)
MODEL : FC9JKSZ

KK-FC102B-B

Unit : mm

4. EQUIPMENT INSTALLATION
PROCEDURE

ENGINE 4 - 1

RADIATOR 4 - 2

FUEL TANK 4 - 3

AIR CLEANER 4 - 4

BATTERY SETTING 4 - 5

CLUTCH CONTROL 4 - 6

SERVICE BRAKE 4 - 7

TOE-BOARD 4 - 8

METER BOARD 4 - 8

SUSPENSIONS AND RELATED PARTS 4 - 9

FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK 4 - 10

SPARE POWER TERMINALS 4 - 10

DESIGN OF WIPER CIRCUIT AND ASSEMBLY 4 - 10

RECOMMENDED WIPER AND WASHER CIRCUIT 4 - 10

ELECTRIC WIRING OF SPARE OUTLET 4 - 10

ELECTRICAL WIRING DIAGRAMS 4 - 10

CAUTION FOR ELECTRICAL EQUIPMENT 4 - 10

HEAD LAMP (OPTION) 4 - 10

FRONT TURN SIGNAL LAMP (OPTION) 4 - 10

SIDE TURN SIGNAL LAMP (OPTION) 4 - 10

REAR COMBINATION LAMP (OPTION) 4 - 10

BACK-UP LAMP (OPTION) 4 - 10

FRAME 4 - 11

EXHAUST SYSTEM 4 - 12

ATTACHMENT OF THE PACKED PARTS (OPTION) 4 - 13

KK-FC102B-B

4. EQUIPMENT INSTALLATION PROCEDURE

4-1

ENGINE
Observe the following instructions when mounting a bus body.
1. When mounting a body structure under the engine and the transmission, make it
detachable construction so that the inspection and maintenance service can be
done without any problem.
2. Install an engine hood that covered the engine together with the radiator so that
the engine noise and heat might not be transmitted to inside of the passenger
room.
Also, this engine hood should be detachable construction allowing to perform the
inspection and maintenance service of the engine, and it should be provided with
a heat insulator and ensure to seal with the body floor surface.
3. The engine hood must be installed the following lid to enable daily inspection and
maintenance.
1) Lid for replenishment of the engine oil.
4. The size of the engine hood should be so designed that it does not make any
hindrance to dismounting and remounting of the engine and radiator.
[NOTE]
Refer to " ATTACHED DATA 5 - 6 " for detail regarding the installation of the
engine hood.

KK-FC102B-B

4 - 2-1
RADIATOR
The radiator being installed in front of the engine, mount the bus body by
observing the following instruction.
1. Provide a mesh structure air intake opening on the front panel in order to take
sufficient air to the radiator while driving the vehicle.

2. Securely seal the circumference of the radiator with a sealing rubber or similar in
order to prevent the backward flow of the warm air that has passed through the
circumference of the engine.

KK-FC102B-B

4 - 2-2
3. Provide the radiator under cover and partition plate for getting enough volume of
cooling air to the radiator.
And make sure that do not fit any structure and parts of body in front of radiator
and opening of radiator under cover for getting enough air flow to the radiator to
avoid engine problem as over heating, etc.

4. Mounting position of reservoir tank

On this vehicle, the reservoir tank of the radiator is installed at front end of
vehicle.
Therefore, provide the lid as described " ATTACHED DATA 5 - 7 " so that the
inspection of water level and filling of cooling water can be done without
hindrance.

[NOTE]

See " ATTACHED DATA 5 - 7 " for detail of installation position of reservoir

tank and provision of lid.
KK-FC102B-B

4-3
FUEL TANK
1. " ATTACHED DATA 5 - 8 " Show standard location of the fuel tank.
Provide a fuel feed lid and tunnel, inspection lids for fuel gauge sender and
pre-fuel filter at the floor.
2. Observe the following safety precautions, if the fuel tank has to be moved.
1) Follow the instruction to be described in the Common Manual for chassis
frame when drilling on the frame.
2) Install the inspection lids according to the instruction in
" ATTACHED DATA 5 - 3 ".

KK-FC102B-B

4-4
AIR CLEANER
When chassis is supplied, already permanently installed air cleaner system.
And, body builder must constructing air cleaner room on the bus body
construction.
Therefore, mount the bus body by observing following instructions.
1. The position of the air cleaner assembly has not be altered.
2. Make sure to construct a tire house to protect the air cleaner and etc. against
water, dust, mud and etc. splashed by the front tire.
3. Make sure to take fresh air into air cleaner for the engine conservation.
And, has not be taken air from inside of the bus body to the engine problem
prevention.
4. Make sure to install to a lid for maintenance of the air cleaner.
5. In case of dusty place operation, make sure to take fresh air from top of the roof
or front of the radiator of the bus body for air cleaner and engine conservation.
If installed air cleaner primary pipe as above position, make sure to install to a
water separate chamber on the air cleaner primary pipe side.
Air cleaner primary pipe diameter : 125mm or more
Round position of the air cleaner primary pipe diameter :
125mm X 1.5 times or more at center of the round position.

KK-FC102B-B

4 - 5-1
BATTERY SETTING
1. When a chassis is delivered, the batteries are temporarily mounted on the
chassis as shown in " ATTACHED DATA 5 - 10 ".
Mount the batteries to the body under the floor with careful consideration of
weight distribution on left and right.
2. The ground terminal of the battery should be kept away from the battery mount
during electric welding.
3. Cover plate must be installed around batteries, by means of making complete
sealed room for batteries, to avoid entering and remaining any dust and grime,
and be sure to make hole 10 - 2nos. of water drain to the bottom cover.
And also ventilation opening must be provided upper part of the battery room
such as making 70 or 45-2nos. ventilation hole to avoid remaining the gas
from battery.
4. Install the adequate size of the battery inspection lid on outer panel of body for
having maintenance and exchange the battery.
5. When installing the batteries, remove any dust and grime from the battery mount,
and be sure to fix the ground terminal securely to the mount.
6. When you exchange batteries, set the starter key to the lock position.
[CHANGING BATTERIES WHILE THE ENGINE IS RUNNING IS STRICTLY
PROHIBITED.]

KK-FC102B-B

4 - 5-2

KK-FC102B-B

4-6
CLUTCH CONTROL
1. When a chassis is delivered, the fluid reservoir of clutch control are permanently
mounted on the clutch pedal assembly as shown " ATTACHED DATA 5 - 11 ".
At body construction, provide the lid for visible inspection of its fluid level and for
easy filling fluid.
2. Do not alter the fluid reservoir of the clutch control.
3. Installation of the fluid reservoir tank
Provide an inspection hole and cover at the position of the fluid reservoir tank
on the front panel so that the fluid level inspection of the reservoir tank as
well as refilling of the fluid can be done easily.
When body mounting must be securely fixed the clutch pedal assembly with
front dash board structure.

Refer to " ATTACHED DATA 5 - 11 " for detail regarding the clutch control such as
installation of the clutch control pedal, fluid reservoir tank setting & etc.

KK-FC102B-B

4 - 7-1
SERVICE BRAKE
1. Brake system being one of the most important units for ensuring traffic safety
of a vehicle.
It is strictly prohibited to modify any service brake components as well as their
connected parts.
2. This model FC9J BUS SERIES is equipped with a air-over system.
3. With respect to the brake piping diagram,
refer to the " ATTACHED DATA 5 - 13 " when mounting the body.
4. For other precautions, refer to the Common Manual.

KK-FC102B-B

4 - 7-2
5. OUTPUT AIR SOURCE OF DOOR ENGINE

1) F
 or setting a door engine, make sure to take air from valve for door engine
as shown in ATTACHED DATA 5-13.

2) W
 hen take the air source of a door engine, air piping circuit should be set as
mentioned below.

3) This air piping circuit has a protection valve.

And, air reservoir for door engine should be fixed between protection valve
and door engine.

4) This protection valve shuts air supply to the air reservoir for a door engine,
when air leakage happened in a door engine circuit and the air pressure in
the brake tank dropped at 5 kg/cm2 {490.3 kPa}.
As a result of this function, the brake system is protected safety.

KK-FC102B-B

4-8
TOE- BOARD
At chassis delivery, the toe-board is supported with temporary brackets.
The body builder should fix it regularly onto the front body frames under the body
constructions.
Refer to " ATTACHED DATA 5 - 16, 17 " for detail regarding the toe-board setting.

METER BOARD
1. At chassis delivery, the meter board is supported with temporary bracket.
They should be fixed regularly onto the front body frames under the body
construction.
2. Make sure to keep the clearance with chassis parts, such as transmission control
lever, switches of electrical equipment & etc., when body is mounted to avoid any
trouble.
3. The setting position of the instrument cluster, steering column and driver's seat
are described in " ATTACHED DATA 5 - 18, 19 ".

KK-FC102B-B

4-9
SUSPENSIONS AND RELATED PARTS
1. Design each side panel near the front and rear springs to enable to extract each
spring pin and maintenance work such as greasing-up.
2. Design each side panel and fender near shockabsorber to enable to facilitate the
exchanging work.
3. Spring shackle always move front and rearward during operation, Therefore,
make sure to keep the enough clearance with body part.
The details of movement of the spring shackles front and rear are shown in
" ATTACHED DATA 5 - 23 ".
4. The front and rear spring deflection charts are shown in
" ATTACHED DATA 5 - 22 " for body design.
5. The frame height from ground at front and rear axle are also shown in
" ATTACHED DATA 5 - 2, 26 " for body design.
6. When performing welding for body mounting, be sure to do this operation by
covering the leaf springs in order to prevent them from getting bad influences
such as welding sputter, etc.
7. Never attempt to increase the number of leaf spring except the case when it is
prescribed as an option.
Refer to " ATTACHED DATA 5 - 20, 21 " for detail regarding the front and rear
suspensions.

KK-FC102B-B

4 - 10-1
FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK
1. LOCATION OF THE INSTRUMENT PANEL
The fuse block and the relay panel are located inside the instrument panel as
shown below.

KK-FC102B-B

4 - 10-2

1) Fuse block

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

KK-FC102B-B

4 - 10-3

2) Relay panel

LHD VEHICLE
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
A

KK-FC102B-B

POLE NUMBER
OF CONNECTOR
4
4
4
4

4
4
4

4
4
4
4
4

4
4

4
4

DESCRIPTION
HEATER RELAY
A/C RELAY
A/C CONDENSER RELAY
HORN RELAY

HEAD LAMP RELAY (MAIN)

HEAD LAMP RELAY (DIMMER)
FOG LAMP RELAY

ECU MAIN RELAY

ABS EXH CUT RELAY

POWER RELAY No.1

POWER RELAY No.3
POWER RELAY No.2
TAIL LAMP RELAY 1
TAIL LAMP RELAY 2

POWER RELAY No.4

POWER RELAY ACC.

BACK-UP LAMP RELAY

ABS MOTOR RELAY

STOP LAMP RELAY

ABS SOLENOID RELAY

4 - 10-4
2. LOCATION OF THE CHASSIS SIDE
The fusible link block is located on left side of the rear bkt, drivers floor as
shown below.

KK-FC102B-B

KK-FC102B-B

INSTRUMENT PANEL

WIPER MOTOR (Lo)

WIPER MOTOR (INT)

WIPER MOTOR (RUN)

WASHER MOTOR

GROUND

H18

H19

H21

H22

H23

AGQ

WIPER MOTOR (HI)

H17

POWER SUPPLY,
LIGHTING

GROUND

IOS

LIGHTING

POWER SUPPLY,

POWER SUPPLY, ACC

IOQ

IOK

POWER SUPPLY

IOP

POWER SUPPLY,
STARTER SWITCH ON

AGM

CIRCUIT
(MAIN APPLICATION)

POLE
CODE

15

13

13

15

20

10

MAX.
CAPACITY
(A)

CAPACITY : 30,000

CONTACT POINT

PERMISSIBLE CURRENT : 20A

PERMISSIBLE CURRENT : 7A

PERMISSIBLE CURRENT : 7A

PERMISSIBLE CURRENT : 10A

REMARKS

0.85
W-L

L-B

0.5

82580 - 4240

52580 - 4230

ALL MODEL

COLFC101B04T001

CONNECTOR C (AGQ) }

CONNECTOR B (IOK)

{ TOTAL CURRENT = INSIDE CAB

PERMISSIBLE CURRENT : 7A

CAPACITY : 30,000

CONTACT POINT

CAPACITY : 30,000

CAPACITY : 30,000
CONTACT POINT
ALL MODEL

ALL MODEL

ALL MODEL

ALL MODEL

APPLICABLE
MODEL

0.5
82580 - 8340

82580 - 8340

82580 - 8380

97840 - 4050

COUPLING CONNECTOR
(SPARE PARTS)
PARTS No.

CONTACT POINT

82580 - 8350

82580 - 8350

82580 - 6920

97830 - 4050

TERMINAL
(CONNECTOR)
PARTS No.

1.25

GR

1.25

L-B

1.25

L-G

1.25

2.0

W-L

0.85

W-G

0.85

1.25

W-R

0.85

WIRE SIZE
& COLOR

[NOTE]
The permissible current to be taken from spare power terminal is determined from the capacity of the fuse and
wire size.
Make sure that the maximum load (current) of the installed equipment must be kept lower current than the
permissible capacity to be able to take from spare power terminal.
Be sure to keep the lower current value than the alternator generated capacity when switched on the original and
additional equipment same time to avoid over discharging electricity of the battery.

CHASSIS
SIDE

TERMINAL
MARK

4 - 10-5

SPARE POWER TERMINALS

1. SPARE POWER SUPPLIES AND POSITIONS

If you must take an electrical power for the body from the chassis, take it
from the spare power supply terminal.

4 - 10-6
2. OUTLET POSITION INSIDE CAB

1) Center of instrument panel

GROUND
POWER SUPPLY, ACC
POWER SUPPLY, LIGHTNING
POWER SUPPLY, DIRECT TO BATTERY
B
POWER SUPPLY,
STARTER SWITCH ON
A

KK-FC102B-B

WIPER
C
COLFC101B04F002

4 - 10-7
3. OUTLET POSITION OF CHASSIS SIDE
FRAME SIDE RAIL

FRONT

No.2 CROSSMEMBER

POWER SUPPLY, LIGHTING

COLFC101B04F001

4. HOW TO TAKE ELECTRICITY FROM POWER SUPPLY CIRCUIT

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

KK-FC102B-B

4 - 10-8
5. DETAIL OF CONNECTOR

1) Cab side
CONNECTOR
VEHICLE SIDE

COMPANION SIDE

AGM
A
PARTS No.

97840 - 4050

PARTS No.

97830 - 4050

ACC ILL
IOQ IOK
B

GND +B
IOS IOP

PARTS No.

82580 - 6920

HIGH
H17

LOW
H18

INT
H19

RUN
H21

PARTS No.

82580 - 8350

H22

PARTS No. 82580 - 8380

PARTS No. 82580 - 8340

H23

PARTS No.

82580 - 8350

PARTS No. 82580 - 8340

2) Chassis side
CONNECTOR
VEHICLE SIDE

COMPANION SIDE

AGQ

PARTS No.

82580 - 4240

PARTS No.

82580 - 4230
COLFC101B04T002

KK-FC102B-B

4 - 10-9
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 be so designed 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]
Terminal
WW EW WI WL WH
Position
OFF

WASHER
MOTOR

INT.
LO
HI
WASHER ON

WIPER SWITCH
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 taken from the specified
terminal inside the instrument panel. (Detail, refer to "SPARE POWER
TERMINALS".)
If taking from another wire harness, an overload will result causing a shortcircuit in the fuse or harness of fire. Do not take from the incorrect terminal.
Refer to the recommended wiper circuit for details.

KK-FC102B-B

4 - 10-10
RECOMMENDED WIPER AND WASHER CIRCUIT

[NOTE]
1. The wiper / washer switch is already installed on the steering column at the time
being supplied of the chassis.
2. Total capacity of the wiper & washer motor must be MAX. 7A.
3. The electrical wiring diagrams are in the WORKSHOP MANUAL.
4. For more details, please consult your nearest HINO sales outlet.
KK-FC102B-B

4 - 10-11
ELECTRIC WIRING OF SPARE OUTLET
1. STANDARD WIRING CONFIGURATION

2. WIRING CONFIGURATION FOR INCREASED LOAD

Maximum added load is 170W.

KK-FC102B-B

4 - 10-12
3. TAKING POWER DIRECTLY FROM THE BATTERY
If you intend to take power for the body directly from the battery, secure the
battery cable and the body power supply terminal together with the same nut
(see drawing).
In this case, you must install a fuse at a suitable point in the circuit and take
precautions to prevent short circuits as these may lead vehicle fires.
When securing the cable and power terminal, make sure you tighten the nut
properly.

The maximum power available for the whole vehicle is defined by the capacity
of the alternator.
Therefore, the electric power that is not consumed by electrical equipments
such as head lamps etc. can be available for the body side.
Decide the electric power available for the body side as well as the one for the
whole vehicle by using the control chart described in following pages
" (4) CONTROL CHART OF CONSUMED ELECTRIC POWER ".
Pay attention not to exceed the capacity of the alternator equipped on the
vehicle.
In the event that you are obliged to carry out the body mounting exceeding the
capacity of the alternator, select the one available as an option or consult your
nearest Hino sales outlet.

KK-FC102B-B

4 - 10-13
4. CONTROL CHART OF CONSUMED ELECTRIC POWER
CONTROL CHART OF CONSUMED ELECTRIC POWER
Reference

MODEL :

No.

ITEM

Clarify if it is equipped or not.

Condition of running the vehicle at night when raining.
EQUIPPED
YES

1
2
3
4
5

HEAD LAMPS
TAIL LAMPS
FOG LAMPS
CLEARANCE LAMPS
LICENSE LAMP

STOP LAMPS

TURN SIGNAL LAMPS

BACK-UP LAMP

WIPER

10
11
12
13
14
15
16
17

CURB LAMP
STEP LAMP
READING LAMP
AISLE LAMP
LUGGAGE RACK LAMP
RADIO
AUDIO
TV
AIR CONDITIONING
18 (COOLER)
19 HEATER
20 TOILET
21 REFRIGERATOR
22 OTHER LAMPS
23
24
25
TOTAL

CONDITION

NO
NIGHT
NIGHT
NIGHT
NIGHT
NIGHT
WHEN
OPERATING BRAKE.
WHEN CHANGING
RUNNING DIRECTION.
WHEN RUNNING
VEHICLE BACKWARD.
WHEN RUNNING
VEHICLE IN THE RAIN.

A
B
AxB
ELECTRIC CONSUM- CONSUMED REMARK
PTION
ELECTRIC
POWER
RATE
POWER
IN USE
(W)
(%)
(W)
140
100
140
90
90
100
140
140
100
60
60
100
20
20
100
16

10

1.6

80

30

24

35

72

100

72

100

40

NIGHT
WHEN RIDING AND OFF.

NIGHT
NIGHT
NIGHT
WHEN
THE MOST POWER
CONSUMING DEVICE
IS TURNED ON.
WHEN USED IN
SUMMER TIME.
WHEN USED IN
WINTER TIME.
WHEN USED.
WHEN USED.
NIGHT

TOTAL OF CONSUMED
AxB ELECTRIC POWER

(W)

SELECTED ALTERNATOR :

[
OK

] / 28V =

REQUIRING ADJUSTMENT OF
NUMBER OF LAMPS ETC.

For those equipments which consist of several lamps, enter the total of watt
numbers in the column of " electric power in use ".
For consumption rate of the item to add, select out of the following:
Always in use: 100%
Frequency of use is high: 30%
Frequency of use is low : 10%
Only ones or twice in use: 0%
during one operation.
Decide the number of the lamps, etc. in such a way that the total of amperage
provided for the vehicle might not exceed the maximum amperage prescribed for
the alternator. In the event that the said total amperage exceeds the maximum of
the alternator capacity, select the alternator available as an option or consult your
nearest Hino sales outlet.
KK-FC102B-B

4 - 10-14
CONTROL CHART OF CONSUMED ELECTRIC POWER
MODEL : FC9JKSZ

No.

ITEM

Clarify if it is equipped or not.

Condition of running the vehicle at night when raining.
EQUIPPED
YES

1
2
3
4
5

HEAD LAMPS
TAIL LAMPS
FOG LAMPS
CLEARANCE LAMPS
LICENSE LAMP

STOP LAMPS

TURN SIGNAL LAMPS

BACK-UP LAMP

WIPER

10
11
12
13
14
15
16
17

CURB LAMP
STEP LAMP
READING LAMP
AISLE LAMP
LUGGAGE RACK LAMP
RADIO
AUDIO
TV
AIR CONDITIONING
18 (COOLER)
19 HEATER
20 TOILET
21 REFRIGERATOR
22 OTHER LAMPS
23
24
25
TOTAL

Example of use
for reference

CONDITION

NO
NIGHT
NIGHT
NIGHT
NIGHT
NIGHT

A
B
AxB
ELECTRIC CONSUM- CONSUMED REMARK
PTION
ELECTRIC
POWER
RATE
POWER
IN USE
(W)
(%)
(W)
100
140
140
90
100
90
140
140
100
60
60
100
20
20
100

WHEN
OPERATING BRAKE.
WHEN CHANGING
RUNNING DIRECTION.
WHEN RUNNING
VEHICLE BACKWARD.
WHEN RUNNING
VEHICLE IN THE RAIN.

NIGHT
WHEN RIDING AND OFF.

NIGHT
NIGHT
NIGHT
WHEN
THE MOST POWER
CONSUMING DEVICE
IS TURNED ON.
WHEN USED IN
SUMMER TIME.
WHEN USED IN
WINTER TIME.
WHEN USED.
WHEN USED.

16

10

1.6

80

30

24

35

72

100

72

40
20
--100
---

100
0
100
100
100

40
0
--100
---

100
182

---

---

100

---

100

---

30
100
100

15
56
80

50
56
80

NIGHT

838.6
TOTAL OF CONSUMED
AxB ELECTRIC POWER
SELECTED ALTERNATOR :

(W)
65

[838.6] / 28V = 29.95 A

OK

REQUIRING ADJUSTMENT OF
NUMBER OF LAMPS ETC.

For those equipments which consist of several lamps, enter the total of watt
numbers in the column of " electric power in use ".
For consumption rate of the item to add, select out of the following:
Always in use: 100%
Frequency of use is high: 30%
Frequency of use is low : 10%
Only ones or twice in use: 0%
during one operation.
Decide the number of the lamps, etc. in such a way that the total of amperage
provided for the vehicle might not exceed the maximum amperage prescribed for
the alternator. In the event that the said total amperage exceeds the maximum of
the alternator capacity, select the alternator available as an option or consult your
nearest Hino sales outlet.
KK-FC102B-B

4 - 10-15
ELECTRICAL WIRING DIAGRAMS

This manual does not contain electrical wiring diagrams.

The electrical wiring diagrams are in the WORKSHOP MANUAL.
For more details, please consult your nearest HINO sales outlet.

CAUTION FOR ELECTRICAL EQUIPMENT

KK-FC102B-B

1) Set up the electrical equipments on the meter board to keep the facilitation
of inspection and maintenance.

4 - 10-16
HEAD LAMP (OPTION)
The head lamp and the nut are set as the option.
Install it regularly to the body.
Tightening torque

NUT (M6) = 6.7 1.0 Nm (68 10 kgfcm)
For more details, please consult your nearest HINO sales outlet.

FRONT TURN SIGNAL LAMP (OPTION)

The front turn signal lamp and the bolt are set as the option.
Install it regularly to the body.
Tightening torque

BOLT (M6) = 5.0 2.0 Nm (51 20 kgfcm)
For more details, please consult your nearest HINO sales outlet.

FRONT TURN SIGNAL LAMP

BOLT

KK-FC102B-B

4 - 10-17
SIDE TURN SIGNAL LAMP (OPTION)
The side turn signal lamp and the retainer are set as the option.
Install it regularly to the body.
When tightening a bolt, dont break the parts of a lamp and a retainer.
The bolt is set up in the assembly of lamp.
For installing the lamp, set the shape of the hole of figure-1 on the side of
body
For more details, please consult your nearest HINO sales outlet.

figure-1

SIDE TURN SIGNAL LAMP

BOLT

KK-FC102B-B

4 - 10-18
REAR COMBINATION LAMP (OPTION)
The rear combination lamp is set as the option.
When installing it regularly, attach the combination lamp assembly directly
such that the tail lamp (red) is inside and the direction indicator lamp
(umber) is outside of the vehicle.
Do not install the rear combination lamps vertically so as not to affect the
performance of reflectors and water drain holes.
When installing the rear combination lamps onto the bus body, install
reinforcing stays to prevent breakage, deflection and vibration of rear
combination lamp body.

[NOTE]
Drawing shows rear combination lamp, LH side.

KK-FC102B-B

Unit : mm

4 - 10-19
BACK-UP LAMP (OPTION)
The back-up lamp is set as the option.
When install, mark TOP on the lens must always be up side.
Installation angle must be kept 4.
For more details, please consult your nearest HINO sales outlet.

KK-FC102B-B

Unit : mm

4 - 11-1
FRAME
1. Observe the instruction given in the Common Manual for chassis frame drilling
and welding.
2. When examining the frame strength, use the diagram of Frame Section
Modulus.
Tensile strength: 540 N/mm2 {55 kgf/mm2} steel material is used for the frame
of this model.
For the detail of the frame configuration, refer to the " ATTACHED DATA 5-27 "
For the detail of the frame section modulus, refer to the chapter 3-3.
3. Procedure of rust preventive treatment of chassis frame.
When shipping chassis to customer, make sure to carry out chassis rust
preventive treatment to the following parts for chassis anti-rust.

1). Touch up scratch paint.

Even if carries out chassis paint, it rusts from scratch point.
When there is scratch point, carry out chassis anticorrosive processing
after touch up paint (equivalent of tokyo paint eporakku 100R)

2). Implementation of 2nd anti-rust treatment

Paint part and paint kind.

paint kind

Paint part
chassis frame
(each cross, side rail)
chassis parts
(table 1 is excluded)
the bottom of a floor at large
leaf spg whole
(paint of between boards)
Fr and Rr tire house
(out side)
the bottom of floor at large
of fr and rr axle

KK-FC102B-B

Wax

equivalent of
tectil

equivalent of
Tokyo
Under coat kagakutoryo
kabushikikaisya
: SB coat

Thickness of
condition
the paint

50 m
or more

dry

1000 m
or more

wet

4 - 11-2

Caution for parts painting.

Mask at a functional component (according to table 1)

(ex. high molecular compound, Caution lable, Control link and the flexible
region of shafts, etc.)
table 1

Part
Brake valve body and exhaust port
Air tank water drain cock and drain rod fingerplate part
The aperture edge of drain hose (without a clog)
Caution lable
Tire
Wheel disc
Brake drum
Radiator and cooling fan
Nylon tube joint part
Checking valve body
Wiring harness coupler part
Muffler main unit and exhaust pipes
Propeller shaft (slide yoke part)
Engine main unit and inside of engine room
Air dryer exhaust port

KK-FC102B-B

Management at the time of paint

Masking

4 - 11-3
The instructions for cutting of frame R.O.H. .
If cut the frame R. O. H. for body specification (e.g. adjustment of total length of the body),
should perform cutting operation by own responsibility of body manufacture.
The followings is recommendation of the instructions for cutting of frame R.O.H. .

The minimum cutting length of R.O.H.

Be sure to observe the minimum cutting length as below figure.

Unitmm

Detail of A
Make sure that secure a
sufficient clearance minimum
305mm from rear spring bracket.

Precaution for cutting of frame R.O.H.

If using a gas torch for cutting, do not too much heating around cutting area.
(It may lead to decrease in strength of frame.)
Should smooth cutting surface with a grinder, and make sure that there is no burr and
crack.
Should proceed to prevent rust on cutting surface and peeled off area, and then paint
with chassis's black completely.

Connecting with body and the others

Be sure to connect the end of frame which after cutting and the body main structure.
Should use the bolt when connecting.
Rigidity of R. O. H. of vehicle should bear all receiving stress during running by the body
structure.
Should decide the final layout and install the exhaust tail pipe with satisfied Ecuador's
regulations by own responsibility of body manufacture.

KK-FC102B-B

4 - 12
EXHAUST SYSTEM
1. For detailed construction of the exhaust system, refer to the
" ATTACHED DATA 5 - 28 ".
For fire prevention when operating the vehicle, observe the instructions given in
the Common Manual regarding the general pre-caution for bus body mounting.
2. Attach heat insulator under the floor around rear axle as described
" ATTACHED DATA 5 - 28 - 3 " for fire prevention.

KK-FC102B-B

4 - 13-1
ATTACHMENT OF THE PACKED PARTS ( OPTION )
Some chassis parts are attached temporarily or unattached ( as parts are sent
separately ) on the chassis.
Fit it regularly onto the chassis or a body.
Detail of the packed parts are described in
" ATTACHING THE PACKED PARTS " in the below.
ATTACHING THE PACKED PARTS
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

PARTS NO.
S8425-01091
S5882-E0120
SK561-05016
SZ950-39179
S5890-E0011
SZ950-39319
SZ950-46171
75311-E0010
SZ167-04003
SZ950-64007
S7653-01102
S7653-11360
S7651-45090
S7651-47560
SZ167-04003
SZ950-64007
S8594-01120
SZ119-06053
85070-E0130
S8516-01720
S8521-E0020
85210-E0010
85220-E0010
SL113-01008
SH656-20822
SZ105-06009
SH656-20822
85370-E0070
85310-E0030
SH656-20826
SZ178-08001
S8535-31020
SZ950-24057
85301-E0040
SZ105-06009
S8536-11120
SH656-20826
SZ950-39055
S8594-01120
SZ119-06053

KK-FC102B-B

PARTS NAME
SWITCH ASSY,PARKING LAMP
COVER, SHIFT LEVER, N0.1
SCREW, TAPPING
RETAINER
COVER ASSY, PARKING BRAKE
RETAINER
GROMMET
EMBLEM, RADIATOR GRILLE
BOLT
COLLAR
EMBLEM ASSY
EMBLEM
ORNAMENT
ORNAMENT
BOLT
COLLAR
RELAY ASSY,W/S WIPER
BOLT
MOTOR & BRACKET ASSY, FR WIPER
LINK ASSY,WIPER
LABEL, WIPER CAUTION
ARM & BLADE ASSY, FR WIPER, RH
ARM & BLADE ASSY, FR WIPER, LH
NUT
BOLT,W/WASHER
BOLT, FLANGE
BOLT,W/WASHER
HOSE ASSY, WASHER
JAR & PUMP ASSY, FR WASHER
BOLT,W/WASHER
NUT
JOINT, WASHER HOSE
CLIP
INLET SUB-ASSY, WASHER
BOLT, FLANGE
BRACKET,WASHER
BOLT,W/WASHER
RETAINER
RELAY ASSY,W/S WIPER
BOLT

QTY
1
1
2
2
1
1
1
1
4
4
2
2
4
2
8
8
1
1
1
1
1
1
1
2
3
6
4
1
1
1
1
2
5
1
1
1
3
1
1
1

REMARKS
For control parts of paking brake and
setting parts of transmission control.

For front mark and setting parts.

For rear mark and setting parts.

For wiper and setting parts.

4 - 13-2

NO.
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68

PARTS NO.
S8332-02200
S8336-11160
SZ119-05003
77201-E0030
81110-E0043
81150-E0043
SZ178-06001
S8208-23462
S8592-02660
S8416-01210
S8207-51522
SZ464-01005
SH562-10825
SL151-00809
SH562-10820
81680-E0040
S8271-11560
81510-E0091
81520-E0091
SH656-30625
81730-E0040
S8173-51010
SZ950-39051
81550-E0160
81560-E0140
SH691-30825
SL151-00809
S8271-11550

KK-FC102B-B

PARTS NAME
GAGE ASSY,FUEL SENDER
GASKET,FUEL SENDER GAGE
BOLT
PIPE SUB-ASSY, FUEL TANK FILLER
HEADLAMP ASSY, RH
HEADLAMP ASSY, LH
NUT
HARNESS SUB ASSY
RELAY ASSY
SWITCH ASSY,FOG LAMP
HARNESS SUB ASSY,RR
CLAMP
BOLT,FLANGE
NUT,FLANGE
BOLT,FLANGE
LAMP ASSY, BACK-UP, LH
CLAMP,WIRING HARNESS
LAMP ASSY, FR TURN SIGNAL, RH
LAMP ASSY, FR TURN SIGNAL, LH
BOLT,W/WASHER
LAMP ASSY, SIDE TURN SIGNAL, RH
CAP, SIDE TURN
RETAINER
LAMP ASSY, RR COMBINATION, RH
LAMP ASSY, RR COMBINATION, LH
BOLT
NUT,FLANGE
CLAMP,WIRING HARNESS

QTY
1
1
5
1
1
1
8
1
1
1
2
4
2
4
2
1
2
1
1
2
2
2
2
1
1
2
2
2

REMARKS
For fuel sender gage and setting
parts.
For extension pipe of fuel filler
For head lamp and setting parts.

For back up lamp and setting parts.

For turn signal lamp and setting parts.

For rear combination lamp and

setting parts.

5. ATTACHED DATA

WARNING 5 - 1

CHASSIS DRAWING 5 - 2

FLOOR INSPECTION HOLES AND BODY EXTERIOR OPENING 5 - 3

WHEEL HOUSE 5 - 4

SPLASH GUARDS 5 - 5

INSTALLATION PROCEDURE OF ENGINE INSPECTION LID 5 - 6

RADIATOR SETTING 5 - 7

FUEL TANK SETTING 5 - 8

AIR INTAKE SYSTEM 5 - 9

BATTERY SETTING 5 - 10

CLUTCH CONTROL & RESERVOIR TANK SETTING 5 - 11

POWER STEERING, OIL RESERVOIR SETTING 5 - 12

SERVICE BRAKE COMPONENT 5 - 13

BRAKE PIPING DIAGRAM 5 - 14

TRANSMISSION CONTROL 5 - 15

TOE-BOARD SETTING (TEMPORARY BRACKET) 5 - 16

BOARD SUB ASSY, FLOOR (TEMPORARY BRACKET) 5 - 17

OPERATING CONTROLS SETTING 5 - 18

INSTRUMENT CLUSTER & STEERING COLUMN SETTING 5 - 19

FRONT SUSPENSION'S PARTICULAR WITH STABILIZER 5 - 20

REAR SUSPENSION'S PARTICULAR WITH STABILIZER 5 - 21

CHARACTERISTIC OF SPRING 5 - 22

TRAVEL RANGE OF SPRING 5 - 23

FRAME HEIGHT FROM GROUND 5 - 26

CHASSIS FRAME ASSY 5 - 27

EXHAUST SYSTEM 5 - 28

KK-FC102B-B

5. ATTACHED DATA

5-1

[WARNING]

This list is the summary of body mounting instructions concerning the Important Items to be
related with the Body Mounting Manual for the respective model series and Common Manual.
Be sure to read it carefully to well understand the important instructions for bus body mounting
before you proceed with your mounting operation.

LIST OF IMPORTANT INSTRUCTIONS FOR BODY MOUNTING AND RELATED DRAWINGS

No. OF
COMPONENTS

OBJECTIVES OF IMPORTANT INSTRUCTIONS

FOR BUS BODY MOUNTING

1.

PROVIDED TO AVOID TROUBLES OF THE AIR CLEANER, ENGINE,

ETC. CAUSED BY SPLASHING OF RAIN WATER OR MUD.

2.

PROVIDED FOR INSPECTION AND MAINTENANCE OF ENGINE AS

WELL AS FOR INSULATING NOISES AND HEAT.

MANUAL FOR THE RESPECTIVE MODEL SERIES

PAGE IN
DESCRIPTION
CHAPTER 5
5-4
WHEEL HOUSE
5-5
SPLASH GUARDS
5-3
5-6

3.

PROVISION OF RADIATOR COOLANT LEVEL INSPECTION.

5-7

4.

CLARIFICATION OF SETTING POSITION OF THE FUEL TANK AND

FUEL SYSTEM RELATED PARTS AT THE TIME OF DELIVERY AND
PROVISION OF INSPECTION HOLE AS WELL AS IMPORTANT
PRECAUTIONS TO TAKE WHEN MOVING THE FUEL TANK.

5-3

5.

6.

7.
8.

9.

10.

11.

PROVISION OF AIR CLEANER INSPECTION AND MAINTENANCE

HOLE AND PRECAUTIONS TO TAKE WHEN HANDLING.

CLARIFICATION OF THE PROVISIONAL MOUNTING POSITION AND

PRECAUTIONS TO TAKE WHEN INSTALLING THE BATTERY
DEFINITELY.

SETTING OF CLUTCH RESERVOIR TANK AND PROVISION

INSPECTION AND MAINTENANCE HOLE.
PRECAUTIONS TO TAKE WHEN HANDLING BRAKE SYSTEM AND
PROVISION OF INSPECTION HOLES FOR BRAKE SYSTEM
RELATED PARTS.

CLARIFICATION OF SETTING CONDITION OF THE PROVISIONALLY

INSTALLED TOE-BOARD AND UP OF TOE-BOARD COMPLETE
BUILDING.
CLARIFICATION OF THE PROVISIONALLY INSTALLED INSTRUMENT
CLUSTER AND COMPLETE BUILDING-UP OF INSTRUMENT CLUSTER,
STEERING WHEEL AND DRIVER SEAT.
PRECAUTION TO TAKE WHEN HANDLING SUSPENSION AS WELL AS
CLARIFICATION OF DATA AND INSTRUCTIONS CONCERNING THE
SUSPENSION REQUIRED FOR DESIGNING THE BUS BODY.

5-5
5-8

5-3
5-5
5-9
5 - 10

CLARIFICATION OF PRECAUTION TO TAKE WHEN HANDLING THE

ELECTRICAL EQUIPMENT AS WELL AS OF HOW TO INSTALL THE
TAIL LAMPS, ETC. CONTAINED IN THE PACKAGE PARTS.

5 - 11
5-3
5-5
5 - 13
5 - 14
5 - 16 - 1
5 - 16 - 2
5 - 17
5 - 18
5 - 19
5-2
5-4
5 - 20

5 - 22
5 - 23
5 - 24

5 - 25
13.
14.

CLARIFICATION OF PRECAUTIONS TO TAKE WHEN HANDLING THE

FRAME AS WELL AS OF ITS ACTUAL FIGURE DRAWING.
CLARIFICATION OF PRECAUTIONS TO TAKE WHEN HANDLING THE
EXHAUST SYSTEM AS WELL AS OF ITS ACTUAL FIGURE DRAWING.

FLOOR INSPECTION HOLES AND

BODY EXTERIOR OPENNING
SPLASH GUARDS
FUEL TANK SETTING

FLOOR INSPECTION HOLES AND

BODY EXTERIOR OPENNING
SPLASH GUARDS
AIR INTAKE SYSTEM
BATTERY SETTING

2 - 1 - 3~5
2-2
1-4-5
2-4
2-5
2-8
2 - 11 - 1
2 - 12 - 1~2
1-4-5
2-3
2 - 12 - 1~2
1-4-3
2-4
2 - 13

5 - 21

12.

FLOOR INSPECTION AND BODY

EXTERIOR OPENNING
INSTALLATION PROCEDURE OF
ENGINE HOOD
RADIATOR SETTING

COMMON MANUAL
PAGE IN
CHAPTER
1-4-5
2-3-8
2 - 12 - 1~2
1-4-6

5 - 26
5 - 27
5 - 28

CLUTCH CONTROL AND RESERVOIR

TANK SETTING
FLOOR INSPECTION HOLES AND
BODY EXTERIOR OPENING
SPLASH GUARDS
SERVICE BRAKE COMPONENT
BRAKE PIPING DIAGRAM
TOE-BOARD SETTING
BOARD SUB ASSY FLOOR
FRAME SUB ASSY FLOOR
OPERATING CONTROLS SETTING
INSTRUMENT CLUSTER & STEERING
COLUMN SETTING
CHASSIS DRAWING
WHEEL HOUSES
FRONT SUSPENSION'S PARTICULAR
WITH STABILIZER
REAR SUSPENSION'S PARTICULAR
WITH STABILIZER
CHARACTERISTIC OF SPRING
TRAVEL RANGE OF SPRING
DETAIL OF REAR LAMPS
(TAIL LAMP ASSEMBLY)
DETAIL OF REAR LAMPS
(BACK-UP & LICENSE LAMP)
CHASSIS FRAME ASSY
FRAME HIGHT FROM GROUND
EXHAUST SYSTEM

4 - 10 - 1
2-7
1-2
1-4-5
1-4-6

DESCRIPTION
TIRE WHEEL HOUSE & SPLASH GUARDS
FITTING A SPLASH GUARD
BODY MOUNTING
REDUCING INTERIOR NOISE LEVELS
(THE FRONT ENGINE VEHICLE)
DETAILS OF IMPORTANT POINT OF
BODY MOUNTING
ENGINE COOLING SYSTEM
(RADIATOR & RELATED PARTS)
TIRE WHEEL HOUSE & SPLASH GUARDS
CHASSIS FRAME
FUEL TANK
BRAKE SYSTEM (FOR REFERENCE)
CLEARANCE FROM THE EXHAUST
SYSTEM
BODY MOUNTING
TIRE WHEEL HOUSE & SPLASH GUARDS
ENGINE AIR INTAKE SYSTEM
BODY MOUNTING
POINT TO NOTE ON ELECTRICAL
WELDING
CHASSIS FRAME
ELECTRICAL EQUIPMENT AND
RELATED PARTS
FIRE PREVENTION
CLUTCH CONTROL SYSTEM

2-8
2 - 12 - 1~2

NEVER MODIFY SAFETY PARTS

TIRE WHEEL HOUSE & SPLASH GUARDS
REDUCING INTERIOR NOISE LEVELS
(THE FRONT ENGINE VEHICLE)
BRAKE SYSTEM (FOR REFERENCE)
BODY MOUNTING

1-2
2-6-1

NEVER MODIFY SAFETY PARTS

STEERING

1-1
1-2
1-4-7
1-3-3
2 - 10
1 - 12 -1~2

BODY DESIGN AND CONSTRUCTION

NEVER MODIFY SAFETY PARTS
LEAF ADDITIONS
SPRINGS
SUSPENSION
BODY MOUNTING

2 - 13
4 - 10

ELECTRICAL EQUIPMENT AND RELATED

PARTS
FIRE PREVENTION

2-4

CHASSIS FRAME

2 - 11

EXHAUST SYSTEM

FOR THOSE ITEMS WHICH ARE NOT MENTIONED ON THIS LIST CONCERNING THE CLEARANCES BETWEEN DIFFERENT DEVICES, HOW TO FIX THE SPARE WHEEL,
HOW TO MANUFACTURE THE BODY, ETC., REFER TO THE MANUAL OF THIS RESPECTIVE MODEL SERIES AS WELL AS THAT OF COMMON MANUAL.

KK-FC102B-B

5 - 2-1
CHASSIS DRAWING
MODEL : FC9JGSZ

KK-FC102B-B

Unit : mm

5 - 2-2
CHASSIS DRAWING
MODEL : FC9JKSZ

KK-FC102B-B

Unit : mm

5-3
FLOOR INSPECTION HOLES AND BODY
EXTERIOR OPENING

Unit : mm

[ NOTE ]
All the dimension, size of holes and openings, which are mentioned in
this drawing show the minimum requirement.
Therefore, make sure to keep the all dimensions when body is mounted.
KK-FC102B-B

5-4
WHEEL HOUSE
The wheel houses, front and rear, must be kept the spaces to prevent the tire from
interference to the wheel house.
And mud-guards must be installed backward of the each tire.

Unit : mm

[NOTE]
Additional space should be considered with the market conditions
where the bus is operated.
(Ex. local make tire, recap tire, with chains and etc.)

KK-FC102B-B

5-5
SPLASH GUARDS

Unit : mm

For protecting air cleaner, engine, air tank and fuel tank from splashing
water or mud, must be installed splash prevention covers.

KK-FC102B-B

5-6
INSTALLATION PROCEDURE OF ENGINE INSPECTION LID

[NOTE]
The shape which is mentioned in this drawing
are example for your reference.

KK-FC102B-B

Unit : mm

SUGGESTIONS ON MAKING THE ENGINE INSPECTION LID

1) Keep the distance more than 50mm from each part of the engine.
2) Keep the distance 50mm more than the max. movement position from the generator.
3) Arrange the engine oil level gauge and the oil pouring to make it possible the
establishment of the inspection cover and opening or shutting of inspection lid near
these gauge and hole.
4) structure of the engine inspection lid :
Hold the glass wool with the thickness of 50mm between two steel plates,
steel plate having thickness of approx. 1.2mm is recommendable.
5) Seal the engine inspection lid and the floor, the parting parts of the engine inspection lid,
completely with the sponge rubber etc. (for the arrest of noise and dust.)
6) If worst comes, for the arrest of the exhaust fumes,
the temperature in the engine room rise, it will cause the overheating.
Therefor, take great care with the ventilation.

5-7
RADIATOR SETTING

Unit : mm

[NOTE]
1) Must be provided following facility on the body.
Cooling air intake opening, on the front panel.
Air guide in front of radiator to air intake opening.
Sealing around radiator.
Air guide under the radiator.
Water

filling and inspection lid on the front panel.
(See 4 2 "radiator" for more detail and installation
procedure of the facilities.)
Inspection lid of water reservoir on the body panel.
2) Do
 not alter and modify the radiator setting, position of
the cooling water reservoir.
KK-FC102B-B

5-8
FUEL TANK SETTING

KK-FC102B-B

Unit : mm

5-9
AIR INTAKE SYSTEM

Unit : mm

[NOTE]
1) Do not alter and modify the air cleaner assembly.
2) See 4-4 "AIR CLEANER" for installation
procedure of the facilities.

KK-FC102B-B

5 - 10
BATTERY SETTING

Capacity : 432kC {120Ah}

Unit : mm

[NOTE]
Batteries are mounted on the chassis mentioned in this drawing as supplied.
When the body is mounted on the chassis, battery room should be constructed
with inspection lid for changing and having maintenance.
For details, refer to 4-5 BATTERY SETTING.

KK-FC102B-B

5 - 11
CLUTCH CONTROL & RESERVOIR TANK SETTING

Unit : mm

[NOTE]
1) Provide a lid or cover of fluid reservoir for inspection and maintenance.
2) The shaft, marked , must be taken out to remove clutch pedal.
Therefore, the layout of structure or installing facility of the body should be
placed to make it possible to pull the shaft rightward out of the pedal bracket.

KK-FC102B-B

5 - 12
POWER STEERING, OIL RESERVOIR SETTING

KK-FC102B-B

Unit : mm

5 - 13-1
SERVICE BRAKE COMPONENT

[NOTE]
1) Alteration and modification of the brake component part or
changing the setting position are strictly prohibited.
2) Provide a lid or cover of the air dryer and air tank.
KK-FC102B-B

Unit : mm

5 - 13-2
PARKING BRAKE CONTROL

KK-FC102B-B

5 - 14-1
BRAKE PIPING DIAGRAM

KK-FC102B-B

5 - 14-2
BRAKE PIPING DIAGRAM

KK-FC102B-B

5 - 15-1
TRANSMISSION CONTROL (1/2)

KK-FC102B-B

Unit : mm

5 - 15-2
TRANSMISSION CONTROL (2/2)

KK-FC102B-B

5 - 16
TOE-BOARD SETTING (TEMPORARY BRACKET)

Unit : mm

1) At chassis delivery, the important accessory parts of the steering, T/M,
parking control and etc are installed to
temporary bracket (colored orange or black) for to be self-propelled with
only the chassis condition.
2) Therefore, make sure to remove the temporary bracket (colored
orange or black) at the time the body is mounted on the chassis, and
install the important accessory parts according to the instruction
described in "4. EQUIPMENT INSTALLATION PROCEDURE &
5. ATTACHED DATA".
3) Obtain at least 150mm as minimum bend radius when installing
speedometer cable.
4) Install the speedometer cable aligning white marking with the datum point.
5) Cable must be clamped to position with the specified clips to prevent
vibration and interference.
And vinyl coating on the clips must not be peeled off.

KK-FC102B-B

5 - 17
BOARD SUB ASSY, FLOOR (TEMPORARY BRACKET)

KK-FC102B-B

Unit : mm

5 - 18
OPERATING CONTROLS SETTING

EXHAUST BRAKE
CHECK ENGINE
BEAM
WATER LEVEL
ECU
FUEL FILTER
TURN (L)

Unit : mm

ABS
CHARGE
OIL PRES.

TURN (R)

LOW AIR
BRAKE OIL LEVEL
PARK BRAKE

SPEEDOMETER
FUEL GAUGE

TACHOMETER
WATER TEMPERATURE GAUGE

COMBINATION METER LAYOUT

KK-FC102B-B

5 - 19
INSTRUMENT CLUSTER & STEERING COLUMN SETTING

KK-FC102B-B

Unit : mm

5 - 20
FRONT SUSPENSION'S PARTICULAR WITH STABILIZER

Unit : mm

[NOTE]
1) This drawing shows the spring assembly
when the spring camber is zero.
2) Do not ground the welding machine to the
spring.
3) Put cover on the spring during welding work.
4) Provide a inspection and maintenance lid or
cover of the spring pin.
KK-FC102B-B

5 - 21
REAR SUSPENSION'S PARTICULAR WITH STABILIZER

Unit : mm

[NOTE]
1) This drawing shows the mainspring when the
spring camber is zero.
2) Do not ground the welding machine to the spring.
3) Put cover on the spring during welding work.
4) Provide a inspection and maintenance lid or cover
of the spring pin.

KK-FC102B-B

5 - 22
CHARACTERISTIC OF SPRING
FOR ALL MODELS

KK-FC102B-B

5 - 23
TRAVEL RANGE OF SPRING

KK-FC102B-B

5 - 26-1
FRAME HEIGHT FROM GROUND
[ AT FRONT AXLE ]
TIRE : 8.25R16-14PR
SUSPENSION : L
 ONG TAPERED
LEAF SPRING
FRAME UPPER SURFACE

[ FRAME HEIGHT FROM GROUND ]

(mm)
800

790.6

737.1
700
0
0

15

30

1500

3000

1602

3150

[ SPRING MASS ]

KK-FC102B-B

45

(kN)

4500 (kgf)

5 - 26-2

[ AT REAR AXLE ]
TIRE : 8.25R16-14PR
SUSPENSION : L
 ONG TAPERED
LEAF SPRING
FRAME UPPER SURFACE

(mm)

[ FRAME HEIGHT FROM GROUND ]

900

861.7

800

754.9

700
0

20

40

60

(kN)

2000

4000

6000

(kgf)

1264

5860

[ SPRING MASS ]

KK-FC102B-B

5 - 27-1
CHASSIS FRAME ASSY
MODEL : FC9JGSZ

KK-FC102B-B

Unit : mm

5 - 27-2
CHASSIS FRAME ASSY
MODEL : FC9JKSZ

KK-FC102B-B

Unit : mm

5 - 27-3
DETAIL OF CROSSMEMBER

KK-FC102B-B

Unit : mm

5 - 28-1
EXHAUST SYSTEM
MODEL : FC9JGSZ

KK-FC102B-B

Unit : mm

5 - 28-2
EXHAUST SYSTEM
MODEL : FC9JKSZ

KK-FC102B-B

Unit : mm

5 - 28-3
EXHAUST SYSTEM

KK-FC102B-B

Unit : mm