KK–GT106

Body Mounting Manual

TRUCK CHASSIS
MODEL GT1J SERIES
 No part of this manual may be reproduced or transmitted in any form without the
express written permission of Hino Motors, Ltd.
© 2003, Hino Motors, Ltd. All rights reserved. Printed in Japan.

HINO MOTORS, LTD.

SPECIAL PURPOSE VEHICLE DIVISION

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

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

2003 - 05

KK-GT106
 ABOUT THIS MANUAL
Purpose
This manual is provided to Body and Equipment Manufacturers, including inter-
mediate and/or final stage manufacturers (hereinafter collectively referred to as
Body and Equipment Manufacturers), to provide;

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

Content
This manual contains chassis specifications and instructions particular to model
GT1J series in the Hino of medium duty trucks.

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

• The Common Manual is available at authorized Hino distributors.

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

KK-GT106
Warning
• It is the responsibility of Body and Equipment Manufacturers or modification
companies to make sure that the completed vehicle with body and equipment, or
after modification, conforms to all applicable laws and regulations of the country
in which the vehicle is to be used (e. g. regulations on lighting, tilt, overall size,
axle load, external noise control etc).
• This manual does not guarantee the safety of a Hino chassis once a body or
equipment has been mounted or modification has been made by a Body and
Equipment Manufacturer or a modification company.
• This manual does not affect that ultimate responsibility for the manufacture and
mounting of the body, installation, modification or alteration on Hino Chassis
devolves upon the Body and Equipment Manufacturer.
• Each individual Body and Equipment Manufacturer has the sole responsibility for
the design, functions, materials and work concerning the body and equipment.
• Hino Motors, Ltd. does not assume any liability whatsoever for any injury to
persons or damage to property caused as a result of the utilization of this manual.

KK-GT106
 CONTENTS

1. VEHICLE SUMMARY

2. GENERAL PRECAUTIONS

3. CHASSIS MASS & FRAME SECTION MODULUS

4. SPRINGS & REAR AXLES

5. PTO AND CONTROL

6. ELECTRICAL SYSTEMS

7. PAINTING

8. CHASSIS DRAWINGS

9. MOUNTING OF CHASSIS EQUIPMENT

10. OTHER

KK-GT106
 1. VEHICLE SUMMARY

1. 1 MODEL CODE •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 - 1

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

KK-GT106
1. VEHICLE SUMMARY 1-1

1.1 MODEL CODE

F
G T 1 J · U A
H

VEHICLE TYPE
G CAB-OVER TRUCK

GVMR & (DRIVE) CODE

GVMR 13,000kg CLASS
T
DRIVE 4 X 4

ENGINE CODE
1J J08C

WHEELBASE CODE
CODE WHEELBASE (mm)
F 3,500 ~ 3,749 SHORT

H 4,000 ~ 4,249 LONG

MODIFICATION CODE
CODE STEERING POSITION MODIFY
S FIRST
~

LH
Z

APPLICABLE CODE
CODE BODY TYPE ETC.
A GENERAL CARGO &
LEAF SUSPENSION
FGT1 MODEL CODELA

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 1-2

1.2 IDENTIFICATION NUMBER

1.2.1 CHASSIS NUMBER

Located at the left side

member of chassis frame.

FGD1 C No

1.2.2 ENGINE NUMBER

ENGINE MODEL : J08C

Located at the right upper

front end of the engine’s side wall

FFC1 E No

KK-GT106
 CHASSIS MODEL GT1JFUA GT1JHUA

1.3
GENERAL CARGO GENERAL CARGO

KK-GT106
ITEM
WHEEL BASE (mm) 3,650 4,100
FRONT (mm) 1,950
TREAD
REAR (mm) 1,820
MAX. GVM/GCM CAPACITY (kg) 13,000
PERMISSIBLE FRONT (kg) 4,500
AXLE CAPACITY
(GAM. RATING) REAR (kg) 9,200
CHASSIS MASS ON STD SPECIFICATIONS
(kg) Refer to page 3-1
(INCLUDING WATER, OIL AND FULL FUEL)
MODEL J08C-UL
JIS GROSS 158kW {215PS} at 2,500r/min
MAX. OUTPUT
ENGINE ISO NET 152kW {207PS} at 2,500r/min
JIS GROSS 608N·m {62kgf·m} at 1,500r/min
MAX. TORQUE
ISO NET 603N·m {61.5kgf·m} at 1,500r/min
CHASSIS SPECIFICATIONS

HEIGHT OF CENTER OF GRAVITY (mm) Refer to page 3-1

STD 9.00-20-14PR
TIRE
OPT 9.00R20-14PR,10.00-20-14PR,10.00R20-14PR
TIRE AND DISK
STD 20 X 7.00T -offset 152mm
DISK
OPT 20 X 7.50V -offset 165mm
STD (L) 100
FUEL TANK
OPT (L) – 200
STD 12V-234kC {65A·h}
BATTERY
OPT 12V-432kC {120A·h}
STD 24V-50A
ALTERNATOR
OPT –
RECOMMENDED MAXIMUM BODY WIDTH (mm) 2,400
[NOTE]
• Permissible axle capacity and GVM or GCM capacity listed above table must not be exceeded. TGT1 C SPECLA

• The front axle load must exceed 30% of the gross vehicle mass under full loaded condition.
• The height of center of gravity from ground on the unloaded vehicle with body mounted should be 1.05m or less.
1-3

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

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

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

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

KK-GT106
2. GENERAL PRECAUTIONS 2-1

2.1 FIRE SHIELD

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

• For approximately 50mm from the front

edge of fire shield (the cab side), use
rubber to match the shape of the fire
shield to that of the cab rear end such as
rear arch cover.
• You may also install the fire shield so that
it covers only the exhaust pipe.

CAB REAR ARCH

RUBBER
FIRE SHIELD
BOLT & NUT

BODY OR
EQUIPMENT

KK-GT106
2-2-1

2.2 CLEARANCE BETWEEN CAB AND REAR BODY OR

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

MINIMUM CLEARANCE WITH CAB REAR END

Unit : mm

A B
HORIZONTAL
EXHAUST PIPE STD 875 MIN.50
STACK OPT 1055 MIN.80
EXHAUST PIPE

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 2-2-2

MEASUREMENT OF THE CAB TILT MECHANISM

(FOR SINGLE CAB ONLY)
Unit : mm

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2-2-3

MEASUREMENT OF THE ENGINE AIR INTAKE PORT

Unit : mm

CAUTION : The blocking of the smooth flow of air into the air intake pipe
caused by any materials such as ropes, pieces of cloth, etc. leads
to the increase of exhaust temperature if driven long intervals.
The increase in exhaust temperature is caused by the decreased
efficiency in the combustion process, as the proportion of air in
the combustion chamber is also decreased by the above
mentioned factor. This situation will lead to major malfunctions
such as the cracking of the exhaust manifold and the breaking
down of the turbocharger. To avoid such malfunctions, please
keep the air intake pipe free from any blocking materials at all
times.

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 2-2-4

MEASUREMENT OF THE ENGINE AIR CLEANER

Unit : mm

SIDE VIEW REAR VIEW

POSITION OF THE STACK EXHAUST PIPE

Unit : mm

KK-GT106
 2-3

2.3 RECOMMENDED POSITIONS OF U- BOLTS

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

APPLICABLE MODEL : GT1J SERIES

Unit : mm
U-BOLT POSITION
X L2 L3 L4
WHEEL BASE
RH 260 – 180 985
F 3650
LH 230 – 180 985
RH 260 980 180 1475
H 4100
LH 230 980 180 1475

No.2 CROSSMEMBER REAR AXLE

DATUM LINE DATUM LINE

X L2 L4
L3

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

TGT2 UBOLT

KK-GT106
 2-4

2.4 RECOMMENDED POSITIONS OF REAR FENDERS AND

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

APPLICABLE MODEL : GT1J SERIES

Unit : mm
TIRE SIZE A B C D
9.00-20-14PR 2380 2400 1820 185
9.00R20-14PR 2380 2400 1820 185
10.00-20-14PR 2420 2440 1820 165
10.00R20-14PR 2425 2445 1820 162.5

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

KK-GT106
 2-5

2.5 ELECTRIC WELDING WORK

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

In order to prevent ancillary equipped components from sparks during

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

KK-GT106
 2-6

2.6 NOTES ON ADDITIONAL WIRING IN THE ENGINE

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

KK-GT106
 2-7

2.7 PRECAUTION OF THE ANTENNA POSITION

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

KK-GT106
 2-8

2.8 NOTES ON SYSTEM CONTROL COMPUTERS

Engine control and brake ABS computers are installed left part, inside of the
instrument panel as described following figure.
Therefore, give great care to the computer when performing any body
mounting work or modification as following points.
1) Be sure to disconnect the harness connector of the computer before
performing any electric welding.
2) Be sure to cover the computer to protect the water penetration when
performing cleaning up the inside of cab.
3) When mounting such devices as a radiophone, a wireless communication
device, be sure to use the devices that conforms to the electric control act
and install the devices on the places which are as far as possible from the
computers and it’s harness.
Do not install any high output (over 50W) device.
Be sure to check that no abnormal electric wave or electromagnetic wave
is found, after having installed the device, which affects on the electronic
signals passing through in computer harness.
4) Do not alter the computer, harness wire or sensors.
5) As you will see on the following Fig. Various kind of computers are
installed inside the cab, when fitting and modifying the inside of the cab,
be careful not to give any shock to the vicinity of the computer.

KK-GT106
 3. CHASSIS MASS & FRAME
SECTION MODULUS

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

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

KK-GT106
3. CHASSIS MASS & FRAME SECTION MODULUS 3-1-1

3.1 CHASSIS MASS

3.1.1 GT1JFUA

MODEL GT1JFUA W/B : 3.650m

T/M : LX06S TIRE : 9.00-20-14PR
GRAVITY
MOMENT
GRAVITY HEIGHT
MOMENT FROM
POSITION FROM
MASS FROM FRAME
FROM FRAME
(kg) F.A.C. UPPER
F.A.C. UPPER
(kg·m) SURFACE
(m) SURFACE
(kg·m)
(m)
Front Bumper 27 -1.180 -31.860 -0.200 -5.400
Cab Front 340 -1.025 -348.500 0.725 246.500
Cab Front Mtg. 31 -1.025 -31.775 0.110 3.410
Steering 47 -0.800 -37.600 0.005 0.235
Step - - - - -
Radiator 41 -0.465 -19.065 -0.055 -2.255
Steering Control 6 0.670 4.020 -0.025 -0.150
Engine Front 350 0.050 17.500 -0.070 -24.500
Control 6 0.100 0.600 0.045 0.270
Engine Room - - - - -
Air Cleaner 15 0.615 9.225 0.200 3.000
Cab Rear 183 0.765 139.995 0.725 132.675
Cab Rear Mtg. 26 0.765 19.890 0.240 6.240
Engine Rear 413 0.890 367.570 -0.070 -28.910
Rear Splash 16 0.600 9.600 -0.070 -1.120
Brake System 80 1.965 157.200 -0.150 -12.000
Electoric System 17 1.690 28.730 -0.130 -2.210
Exhaust System 32 1.420 45.440 -0.450 -14.400
Stack Tail - - - - -
Battery 36 1.270 45.720 -0.185 -6.660
Fuel Tank 105 2.080 218.400 -0.285 -29.925
Transfer 183 2.210 404.430 -0.510 -93.330
Properller Shaft 64 1.890 120.960 -0.520 -33.280
Frame etc. 553 2.155 1191.715 -0.160 -88.480
Platform - - - - -
Coupler - - - - -
Tire Carrier - - - - -
Rear Bumper - - - - -
Tool Box - - - - -
Sub Total 2571 - 2312.195 - 49.710
Front 949 0.000 0.000 -0.590 -559.910
Unsprung Mass
Rear 1197 3.650 4369.050 -0.655 -784.035
Total 4717 1.416 6681.245 -0.274 -1294.235
Front Rear Total
Sprung Mass (kg) 1938 633 2571
Unsprung Mass (kg) 949 1197 2146
Chassis Mass (kg) 2887 1830 4717
Gravity position from F.A.C. (m) 1.416
Gravity height from frame upper surface (m) -0.274 TGT3 GT1JFUA LA

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

KK-GT106
3-1-2

3.1.2 GT1JHUA

MODEL GT1JHUA W/B : 4.100m

T/M : LX06S TIRE : 9.00-20-14PR
GRAVITY
MOMENT
GRAVITY HEIGHT
MOMENT FROM
POSITION FROM
MASS FROM FRAME
FROM FRAME
(kg) F.A.C. UPPER
F.A.C. UPPER
(kg·m) SURFACE
(m) SURFACE
(kg·m)
(m)
Front Bumper 27 -1.180 -31.860 -0.200 -5.400
Cab Front 340 -1.025 -348.500 0.725 246.500
Cab Front Mtg. 31 -1.025 -31.775 0.110 3.410
Steering 47 -0.800 -37.600 0.005 0.235
Step - - - - -
Radiator 41 -0.465 -19.065 -0.055 -2.255
Steering Control 6 0.670 4.020 -0.025 -0.150
Engine Front 350 0.050 17.500 -0.070 -24.500
Control 6 0.100 0.600 0.045 0.270
Engine Room - - - - -
Air Cleaner 15 0.615 9.225 0.200 3.000
Cab Rear 183 0.765 139.995 0.725 132.675
Cab Rear Mtg. 26 0.765 19.890 0.240 6.240
Engine Rear 413 0.890 367.570 -0.070 -28.910
Rear Splash 16 0.600 9.600 -0.070 -1.120
Brake System 80 1.965 157.200 -0.150 -12.000
Electoric System 17 1.690 28.730 -0.130 -2.210
Exhaust System 32 1.420 45.440 -0.450 -14.400
Stack Tail - - - - -
Battery 36 1.270 45.720 -0.185 -6.660
Fuel Tank 105 2.080 218.400 -0.285 -29.925
Transfer 183 2.210 404.430 -0.510 -93.330
Properller Shaft 68 2.015 137.020 -0.520 -35.360
Frame etc. 624 2.595 1619.280 -0.160 -99.840
Platform - - - - -
Coupler - - - - -
Tire Carrier - - - - -
Rear Bumper - - - - -
Tool Box - - - - -
Sub Total 2646 - 2755.82 - 36.270
Front 949 0.000 0.000 -0.590 -559.910
Unsprung Mass
Rear 1197 4.100 4907.700 -0.655 -784.035
Total 4792 1.599 7663.520 -0.273 -1307.675
Front Rear Total
Sprung Mass (kg) 1974 672 2646
Unsprung Mass (kg) 949 1197 2146
Chassis Mass (kg) 2923 1869 4792
Gravity position from F.A.C. (m) 1.599
Gravity height from frame upper surface (m) -0.273 TGT3 GT1JHUA LA

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

KK-GT106
 3-2

3.2 MASS DISTRIBUTION OF THE OPTION EQUIPMENT

3.2.1 FOR ALL MODELS

GRAVITY
MOMENT
POSITION
MASS FROM
CONTENT OF OPTION FROM W/B REMARKS
(kg) F.A.C.
F.A.C.
(kg·m)
(m)
CENTER SEAT LESS -4 -0.155 -0.620 ALL
AIR DRYER 7 1.935 13.545 ALL
T/F PTO 7 2.410 16.870 ALL
T/M PTO 14 1.220 17.080 ALL
T/M POWER SHIFT 3 0.550 1.650 ALL
TIRE CARRIER 14 5.385 75.390 H
HORIZONTAL TO STACK
38 1.005 38.190 ALL
TAIL PIPE
BED 3 0.400 1.200 ALL
AIR CONDITIONER 16 -0.490 -7.840 ALL
BATTERY 33 1.305 43.065 ALL
WHEEL STEP LESS -3 0.000 -3.000 ALL UNSPRUNG MASS
CHASSIS STEP 25 -0.830 -20.750 ALL
TGT3 OPT LA

KK-GT106
 3-3

3.3 FRAME SECTION MODULUS

3.3.1 FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE)

Unit : mm
4980
6030
D
1330
1930
C
3650
4100
B
6122
7172
A
W/B

H
F

KK-GT106
 4. SPRINGS & REAR AXLES

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

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

KK-GT106
4. SPRINGS & REAR AXLES 4-1-1

4.1 SPRING CHARATERISTICS

For all models
4.1.1 SPRING COMBINATION
Refer to SPRING CHARACTERISTICS CHART based on following table.
1) Spring combination table
(1) Combination of leaf spring

STD
MODEL FOR ALL MODELS
FRONT A
REAR B
TGT4 COMB. LEAF SPG

NOTE
SYMBOL SPECIFICATION
A LOW CAMBER MULTI LEAF SPRING
B LOW CAMBER MULTI LEAF SPRING
TGT4 SPG. COMB. TABLE

KK-GT106
4-1-2

4.1.2 FRONT LEAF SPRING

1) Spring characteristics chart "A"
kgf
x 103 (kN) FRONT
3 30
c a 0.253kN/mm {25.8kgf/mm}
b 21.760kN {2218.9kgf}
c 25.300kN {2579.9kgf}
SPRING LOAD ON ONE SIDE

2 20
b

CONTACTING POINT OF
a
BUFFER RUBBER
1 10
HORIZONTAL
POINT

86.0 100.0
0 50 0
100 150 (mm)
VERTICAL SPRING DEFLECTION ON FRONT LEAF SPRING FGT4 4J SPG CHARA ”A”

LOAD VS. DEFLECTION

4.1.3 REAR LEAF SPRING

1) Spring characteristics chart "B"
kgf
x 103 (kN) e REAR
a 0.277kN/mm {28.2kgf/mm}
8 80
b 0.277+0.742=1.019kN/mm
{28.2+75.7=103.9kgf/mm}
c 19.110kN {1948.7kgf}
SPRING LOAD ON ONE SIDE

d d 52.740kN {5378.0kgf}
6 60 e 81.880kN {8349.4kgf}
CONTACTING POINT OF

4 40
b
BUFFER RUBBER

HORIZONTAL

2 20
POINT

69.0 102.0 130.6

0 0 50 100 150 (mm)
VERTICAL SPRING DEFLECTION ON REAR LEAF SPRING FGT4 4J SPG CHARA ”B”

LOAD VS. DEFLECTION

KK-GT106
 4-2

4.2 MAXIMUM VERTICAL DEFLECTION OF REAR WHEELS

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

DEFLECTION OF REAR TIRES

B
C

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

ONE SIDE WHEELS RIGHT AND LEFT WHEELS

Unit : mm
MODEL TIRE SIZE A B C
9.00-20-14PR
9.00R20-14PR
GT1J SERIES 45 -55 327
10.00-20-14PR
10.00R20-14PR
• With tire chain : Dimentions A and B are added 60 mm.
FGT4 DEF R TIRES LA

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

KK-GT106
 4-3

4.3 TRAVEL RANGE OF REAR SPRING

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

Unit : mm
REAR AXLE CENTER

Min. 40
872.4

FGT4 SPG T RANGE

KK-GT106
 5. PTO AND CONTROL

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

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

KK-GT106
5. PTO AND CONTROL 5-1-1

5.1 TRANSMISSION SIDE POWER TAKE OFF

(OPTION EQUIPMENT)
5.1.1 When the body require transmission Power Take Off (PTO) , genuine
PTO equipment and related parts should be supplied as shown below.
1) Transmission series by vehicle model
MODEL TRANSMISSION SERIES
GT1J SERIES LX06S
TGT5 LXTM SERIES

2) Data of the PTO output shaft

TRANSMISSION PERMISSIBLE TORQUE PTO CONTROL DIRECTION OF
SERIES (N·m{kgf·m} at r/min) TYPE ROTATION
Pneumatic Reverse to
LXO6S 245{25}/1,000 control engine

TFC5 LXPTO DATA

KK-GT106
5-1-2

3) Necessary parts

TRANSMISSION MODEL
LX06S
TRANSMISSION GEAR RATIO
1ST 6.515
2ND 4.122
3RD 2.500
4TH 1.718
5TH 1.261
6TH 1.000
REV 6.060
PTO CONTROL TYPE Pneumatic
PARTS NAME Parts No. Q'ty /
unit
POWER TAKE OFF ASSY 36610-5391 01
POWER TAKE OFF SUB ASSY 36610-5201 01
SWITCH ASS'Y,T/M POSITION 84220-1560 01
BRACKET,ELEC. PARTS 55912-3970 01
CONNECTOR, SUB ASS'Y 34801-2010 01
ADAPTER, PTO CASE 36628-2890 01
or 36628-2900 01
or 36628-2910 01
GASKET, PTO CASE 36635-1560 02
LOCK WASHER 9290-10300 08
STUD 9349-10155 02
STUD 9349-10148 06
NUT 9229-10110 08
VALVE ASS'Y,SOLENOID 27610-4550 01
BOLT,FLANGE 9069-08114 02
BRACKET, MAGNETIC VALVE 44582-3270 01
BOLT,FLANGE 9069-10143 01
HOLDER,CLIP 79993-2610 01
[NOTE] TFT5 LXTM PARTS

• Parts mentioned above table shows transmission PTO unit only.

• Other related parts of transmission PTO control, please contact each Hino sales
dealer.

KK-GT106
 5-1-3

5.1.2 DETAIL OF PTO TRANSMISSION MODEL HINO LX06S

1) PTO Installation procedure
(1) Drain the transmission oil.
(Do not remove the drain plug while the oil is hot, or you will scaled
yourself.)
(2) Remove the PTO cover which is at the left of the transmission.
( Do not reuse the bolts and gasket that you remove at this time.)
(3) Clean the PTO mounting surface on the transmission side.
(4) Prepare the necessary parts, referring to paragraph "5.1.1 3)"
(5) Apply liquid packing to all fitting surfaces, such as the PTO mounting
surface of the transmission case and installation gasket, adapter and
PTO body.
(6) Fit the PTO on the PTO mounting and secure the mounting position by
means of the reamer bolts (See the part described with marked "R" in
the section "PTO mounting location on transmission case") and tighten
the other fitting bolts.Tightening torque for bolts: 49±4.9N·m
{500±50kgf·cm}
(7) After attaching the PTO, turn the output shaft coupling a few
revolutions to be sure that it turns freely.
(8) When you refill the transmission oil, increase the amount by 0.5 liters
to allow for the PTO.

2) Gear layout and gear ratio

Gear ratio : i =N2/N1 x N4/N3 x N5/N4

PTO CONTROL
TRANSMISSION TYPE N1 N2 N3 N4 N5 i

LX06S PNEUMATIC 24 40 26 31 20 1.282

TFT5 LXG RATIO

[NOTE]
• Number of revolutions of PTO output shaft
= number of revolutions of engine x 1/ i
• The PTO output shaft turns in the opposite direction to the engine.

KK-GT106
5-1-4

3) How to check the gear backlash

The gear backlash of the PTO is important factor to prolong the PTO gear
life. The bigger backlash causes the noise from gears on the contrary the
smaller backlash causes the damage of gears. When installing the PTO
measure and check the backlash according to the following procedures.
(1) Measurement of backlash
(a) (between gear A and
B)
Attach a fuse (ø1 x
10mm), with grease on
the tooth surface of the
PTO gear B (3 places of
gear tooth).
After rotating gear B,
measure the thickness of
crashed fuses with a
micro-meter.
(2) Adjustment of backlash
(a) (between gear A and
B) When the backlash is
not within the following
standard backlash adjust
the backlash by selecting
an appropriate adapter.

STANDARD
MODEL GEAR POSITION
BACKLASH

Between gear A 0.08 ~

LX
and gear B (a) 0.21mm

TFC5 LXGBLASH2

If specified gear backlash value cannot be obtained, check whether all the
parts have been installed correctly.
If the specified gear backlash value cannot be obtained despite correct
installation, use another PTO assembly.

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 5-1-5

4) PTO Mounting location on transmission case

KK-GT106
 14 16
14.5 7

3
13
5-1-6

7
12

ø25
ø21.5
TAPER1/8
28 M14x1.5 MAIN SHAFT
CENTER
DETAIL OF PTO SHAFT

7
COUNTER SHAFT
6 CENTER
70 5
7.
123

º
45

65
50 ±0.1
20

ø34H9
+0.2
3.0 0 25 ±0.1
4 - ø8 +0.2
0
OUTPUT FLANGE
45
12.25
PTOHOLE CENTER
END OF T/M CASE
0.14 0.14
A
5) Transmission PTO mounting for pneumatic control type

91.5 124 65 130

ADAPTOR
215.5 PARTS t (mm)
GASKET 36628-2890 8.15
[NOTE] 36628-2900 8.04
• The devises on the body or equipment side (e. g. oil pump) must be 36628-2910 7.94
mounted at the same angle as engine to the body. (Direct mounting FFT5 LXPTOMTG1
the devices to the PTO output flange is strictly prohibited.)
Unit : mm

• The three-dimensional angle of the universal joint of the drive shaft

must be a Min. 1° to Max. 6°.

KK-GT106
 5-1-7

6) Layout of power line

CRANKCASE
A

SIDE RAIL UPPER FACE

FRONT AXLE DATUM LINE

TRANSMISSION
B

CASE
C

DRIVE SHAFT C

FLYWHEEL
ENTER

HOUSING

HOUSING
CLUTCH
R
ENGINE CENTE

215.5
D E
F

Unit : mm
CHASSIS TRANSMISSION
MODEL MODEL A B C D E F
GT1J
SERIES LX06S 290 138 3.5º 394 173.5 577

FGT5 1JPLLAYOUT

KK-GT106
5-2-1

5.2 FUEL INJECTION PUMP GOVERNOR LEVER

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

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

KK-GT106
 5-2-2

2) Governor lever for body control (BOSCH RLD-J)

KK-GT106
 5-3

5.3 ENGINE CONTROL FOR BODY OR EQUIPMENT

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

RELATIVE MOVEMENT OF ENGINE AND CHASSIS ABSORBED

RELATIVE MOVEMENT OF ENGINE AND CHASSIS NOT ABSORBED

KK-GT106
 5-4

5.4 TRANSFER REAR POWER TAKE OFF

(OPTION EQUIPMENT)
5.4.1 When the body require transfer Power Take Off (PTO) , genuine
PTO equipment and related parts should be supplied as shown below.

1) Transfer series by vehicle model

2) Data of the standard PTO output shaft

3) Necessary parts

KK-GT106
5-5

4) Transfer PTO mounting

KK-GT106
 5-6

5) Transfer PTO particulars

KK-GT106
5-7

6) Cautions for PTO

KK-GT106
 5-8

5.4.2 Caution when installing the propeller shaft for T/F PTO
Be sure to observe the following indications.

1) Fitting a pulley or a sprocket directly to the output shaft of transfer PTO is

strictly prohibited.
2) An oil pump, a pulley or a sprocket wheel should be supported properly
with the support bracket which is fixed firmly to the rear mounting body.
3) Indications for power taking out should be followed as the indicated below.

Length of drive shaft

To reduce the vibration of running shaft to minimum, HINO recommend that
the drive shaft length should be less than the value shown in the table.
If body builder must make the shaft which is longer than the value shown in
the table, fit a center bearing for the reduction of excessive vibration.

[NOTE]
• The support bracket for bearings should be fixed on the rear body.

KK-GT106
 6. ELECTRICAL SYSTEMS

6. 1 FUSE BLOCK, RELAY PANEL AND

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

KK-GT106
6. ELECTRICAL SYSTEMS 6-1-1

6.1 FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK

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

KK-GT106
6-1-2

1) Fuse block

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

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 6-1-3

2) Relay panel

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6-1-4

6.1.2 LOCATION OF THE CHASSIS SIDE

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

KK-GT106
 MAX. TE RMINAL COUP LING CON NE CTOR
6.2

KK-GT106
TERMINAL POLE CIRCUIT WIRE SIZE APP LICABLE
CAPACITY (CONNECTOR) (S P ARE P ARTS) RE MARKS
MARK CODE (MAIN APP LICATION) & COLOR MODEL
(A) P ARTS No. P ARTS No.

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

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

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

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

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

POWER SUPPLY, DUMP 0.85

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

PERMISSIBLE CURRENT : 7 A

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

CONNECTOR C(AGQ)}

TFG6 SPSUPPLY

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

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

6.2.2 OUTLET POSITION INSIDE CAB

1) Center of instrument panel

POWER SUPPLY, ACC

POWER SUPPLY, LIGHTNING
STARTER SWITCH ON POWER SUPPLY POWER SUPPLY

B A

KK-GT106
 6-2-3

6.2.3 OUTLET POSITION OF CHASSIS SIDE

FRONT
FRAME SIDE RAIL

SPARE OUTLET (DUMP - UP S/W)

D
No.2 CROSSMEMBER

LAMP SPARE OUTLET

FFC6 CSSPAREOLT

6.2.4 HOW TO TAKE ELECTRICITY FROM POWER SUPPLY CIRCUIT

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

KK-GT106
6-2-4

6.2.5 DETAIL OF CONNECTOR

1) Cab side

CONNECTOR

VEHICLE SIDE COMPANION SIDE

AGM
A

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

ACC ILL
IOQ IOK 2 1

B GND +B 4 3
IOS IOP

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

TFC6 CAB CONNECTOR

2) Chassis side

CONNECTOR

VEHICLE SIDE COMPANION SIDE

AGQ 1
C

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

ON 1
D UEO

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

TFG6 CSCONNECTOR

KK-GT106
 6-3-1

6.3 ELECTRIC WIRING OF SPARE OUTLET

6.3.1 STANDARD WIRING CONFIGURATION

6.3.2 WIRING CONFIGURATION FOR INCREASED LOAD

Maximum added load is 170W.

6.3.3 TAKING POWER DIRECTLY FROM THE BATTERY

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

KK-GT106
6-3-2

6.3.4 INSTALLATION OF ADDITIONAL EQUIPMENT AND SWITCHES

Layout of switches
• Standard layout of switches include option equipment are as following
figure.
• If you intend to install additional switches at instrument panel for the
convenience of body mounting, be sure to install it at empty space after
confirmation of original condition on the actual vehicle.

Avoid using additional switches with existing switches

• If you install additional switches, fit a caution plate showing the purpose of
each switch, etc., to prevent accidental operation or confirmation.
1) Instrument panel

No. DESCRIPTION APPLICATION

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

KK-GT106
 6-3-3

2) Floor console

16 17

No. DESCRIPTION APPLICATION

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

KK-GT106
6-4-1

6.4 PRECAUTION FOR INSTALLING WIRES, etc.,TO CAB

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

FLOOR

VEHICLE'S FRONT

THROUGH HOLES
2 – ø30
FFC6 FPHOLE

KK-GT106
 6-4-2

6.4.2 USING THROUGH HOLES FOR BACK PANEL WIRING

When using through holes for back panel wiring, to secure the rust
prevention and water proof before the said taken-in, carry out fitting and
wiring according to the following instructions.
1) A through hole of ø 36 is provided on the back panel but it is closed with a
grommet.
Make a slit on this grommet and, after the wiring, sufficiently seal its
periphery with a sealing agent.
2) In order to secure the water proofness, lower the wiring once as shown on
“ Section A - A ” to drain the water and after that bring the wiring into the
cab.
3) It is prohibited to fix the wiring with a tapping screw etc., because this can
be a cause of penetration of rust.

KK-GT106
 6-5

6.5 REAR COMBINATION LAMP

When chassis with cab are shipped, the rear combination lamp assembly is
temporarily installed onto the end of the frame.
Therefore, when installing it regularly, attach the combination lamp assembly
directly such that the tail lamp (red) is inside and the direction indicator lamp
(umber) is outside of the vehicle.
Do not install the rear combination lamps vertically so as not to affect the
performance of reflectors and water drain holes.
When installing the rear combination lamps onto the rear body, install
reinforcing stays to prevent breakage, deflection and vibration of rear
combination lamp body.

Unit : mm

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

KK-GT106
 6-6

6.6 OTHER LAMPS

6.6.1 BACK-UP LAMP

Unit : mm

[NOTE]
• When install the back-up lamp, mark
“TOP” on the lens must always be up side.
• Installation angle must be kept 4˚
• Above drawing shows right side lamp, left
side lamp is symmetry shape.

6.6.2 LICENSE PLATE LAMP

KK-GT106
 6-7

6.7 BACK-UP BUZZER (OPTION EQUIPMENT)

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

Unit : mm

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

6.7.3 PRECAUTION FOR PAINTING

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

KK-GT106
 6-8

6.8 ELECTRICAL WIRING DIAGRAMS

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

KK-GT106
 7. PAINTING

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

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

KK-GT106
7. PAINTING 7-1-1

7.1 GENERAL PRECAUTIONS FOR PAINTING

When you apply finish paint to the cab etc. observe the following precautions.
Some parts of the cab and chassis are sensitive to heat of the drying; some
parts must not be painted and so require masking, etc.
7.1.1 GENERAL PRECAUTIONS FOR PAINTING
1) Parts to be masked:
Parts that must not be painted-ornaments, name plates (model names,
chassis number), caution plate, etc. must all be masked. (It is possible to
take off the top mark.)
Never paint the rubber hoses or valves, the brake booster, or hoses or
valves of the brake fluid reservoir.
2) If you get paint on the cab compartment, wipe it clean with gasoline.
Never use thinner.
3) If the body of the air cleaner has been taken out, seal off the engine intake
port completely so that paint and dirt do not get in.
When you replace the body of the air cleaner, make sure that the hose is
properly fitted and securely clamped.
4) Cover the battery, wiring connections and hoses to protect them from
paint.
5) When clean inside of the cab,must be clean it with a neutral detergent.
Never use gasoline and paint thinner.
6) Pay attention when dismounting and removing the cab exterior fittings.
The bolts that thread diameter exceeds 6mm to be tighten the exterior
parts of the cab body have been modified from “+ type screw bolt” to “star
type bolt (torx bolt)” in order to improve stabilization of tightening torque
and avoiding the damage of tool groove.
Use proper tools to fit with “torx bolt”.

7.1.2 GENERAL PRECAUTIONS FOR FORCED DRYING

1) When you use forced drying, a temperature on the surface of any parts to
be painted must be 80°C as an upper limit.
Removing off any plastic parts, rubber parts from the vehicle, paint them
when you use a forced drying at over 80°C.(Refer to the figure as shown
in after.)
Take care to those as plastic parts like fender, air cleaner,etc.are much
used.
2) When a vehicle with air -conditioning whose piping and hosing are heated
at abnormal temperature(more than 100°C), a pressure safety valve may
function and come out refrigerant gas.
3) When removing off a air-cleaner assy, seal completely the inlet port side
of engine to prevent any penetration of dirt, paint or etc.

KK-GT106
7-1-2

4) Remove off the parts shown below, when you use forced drying at over
80°C.

NON-HEAT RESISTING PARTS AT THE HEATED AIR OR MORE THAN

80°C

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

KK-GT106
 7-2

7.2 NOTE ON THE TOP COAT OF PAINT

7.2.1 NOTE ON THE TOP COAT OF PAINT
1) To make sure that the top coat of paint adheres well, you must sand the
middle coat carefully.
Make sure that the sanding is even and complete.
When you have finished sanding, carefully dust off the shavings.

SANDING (BAD SANDING) (GOOD SANDING)

Imperfectly sanded Evenly sanded

Coated film Coated film

FFC7 SANDING

2) How to choose top coat paint

HINO recommends urethane-type paints for the top coat,as they have
superior rust-prevention properties to lacquer-type paints.
The top coat should be at 30 µ thick and the total paint thickness including
undercoat and primers should be at least 80 µ thick.
3) How to install weather strips
If door weather strips have been removed when painting the cab, remount
them according to the following procedure, item 7.4.
Be very careful not to make mistake in deciding the mounting procedure to
avoid an eventual cause of rain drop leakage.

KK-GT106
7-3-1

7.3 HOW TO REMOVE THE PARTS OF CAB

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

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

KK-GT106
 7-3-2

3) Front panel

KK-GT106
7-3-3

7.3.2 HOW TO REMOVE THE VENTILATOR

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

KK-GT106
 7-3-4

7.3.3 REMOUNTING THE DISMOUNTED MIRROR STAY

1) When remounting the dismounted mirror stay, mount it after the paint has
completely hardened.
2) When tightening the mirror stay, be careful not to scratch the painted
surface.
3) Never fail to retouch with clear lacquer, etc., those tool scratches which
have been made by screws, bolts and nuts when dismounting and
remounting the mirror stay.
4) When remounting the dismounted stay adjust the tightening torques
referring to the figure shown below.

FLAT MIRROR

KK-GT106
7-3-5

CONVEX MIRROR

KK-GT106
 7-3-6

KK-GT106
7-3-7

7.3.4 REMOUNTING THE WIPER

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

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

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

KK-GT106
 7-3-8

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

KK-GT106
7-4-1

7.4 MOUNTING AND STICKING OF WEATHER STRIP

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

KK-GT106
 7-4-2

KK-GT106
 7-5

7.5 HANDLING OF COMPUTERS (ECU)

When paint by forced drying, must be care to handle the computers as
following points.

CONDITION OF FORCED DRYING PAINT HANDLING OF COMPUTER

• INSIDE TEMPERATURE OF THE : 120°C

FORCED DRYING BOOTH
1 • INSIDE TEMPERATURE OF THE CAB : LESS THAN 85°C
(PLACE AT THE 50mm HEIGHT FROM
UPPER SURFACE OF CAB FLOOR.)
INSTALLED
WHEN UNKNOWN THE TEMPERATURE OF THE
FORCED DRYING BOOTH OR USE
INFRARED LAMP
2
INSIDE TEMPERATURE OF THE CAB : LESS THAN 85°C
(PLACE AT THE 50mm HEIGHT FROM
UPPER SURFACE OF CAB FLOOR.)
WHEN EXPECT MORE HIGH TEMPERATURE
3 REMOVE COMPUTER
THAN ABOVE MENTIONED CASES.

KK-GT106
 7-6-1

7.6 PROCEDURE FOR ADHERING ORNAMENTS

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

KK-GT106
7-6-2

[NOTE]
Example for FC series.

KK-GT106
 7-7

7.7 CAUTIONS FOR PAINTING THE TIRE DISC WHEELS

1) Before painting the tire disc wheel, cover its inside and outside surface to
be contacted with the hub, the brake drum and hub nuts.
Refer to the illustration below concerning the covering portions.

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

3) Precaution for carrying out tire rotation

Sometimes, the mounting position of tire disc wheel may be changed and
paint coated face may become contact face.
At this moment, if the thickness of the painted membrane is excessively
thick, this may lead to the loosening of the hub nuts.
Therefore observe the following instructions when carrying out the tire
rotation.
(1) Take off the paint on the contact face (including the contact surface of
hub nut) of the tire disc wheel and after having completely cleaned the
face with a wire brush etc., apply thin layer of paint for rust preventive
purpose.
(2) If you use the tire disc wheel without taking off the paint, even if the
face is completely cleaned with wire brush, etc., the thick membrane
may lead to the loosening of hub nuts.

KK-GT106
 7-8

7.8 PRECAUTIONS FOR FITTING AND STORING THE CAUTION

PLATE
1) How to stick it
a. Stick the caution plate to a dry place which is free from dust and dirt
after the paint has completely dried up.
b. Clean your hand and don't use cotton work gloves, etc..
c. Completely remove water, oil, dust, etc. from the surface to stick
(surface of cab) with ethyl alcohol if they are found remaining there.
d. When the temperature is less than 10°C, warm up the surface to stick
as well as the caution plate with warm wind of more than 20°C before
sticking the caution plate.
e. After sticking the caution plate, press it with a roller, etc., with a force of
approximately 49 N/cm2 {5 kgf/cm2 }.
f. Remove liner paper (backing paper) just before using it.
g. When air remains inside, make a tiny hole with a needle or a cutter
knife and press it out with your fingers from the bubble area.
2) How to store it
a. When storing the caution plate, select a dry place with an ambient
temperature (of 20 to 25°C) and without dust, dirt and stain.
b. Also, store the caution plate at a flat place such as a shelf, etc., and do
not place anything on it.
3) Other precautions for the caution plate
a. As the caution plate is made from vinyl chloride, it is thin, soft and
easily extensible.
Therefore, take utmost care for handling it.
b. When removing the caution plate, etc., be careful not to damage the
painted surface with a sharp knife, etc.
On the other hand, removal of the caution plate can be done more
easily by pulling the caution plate in perpendicular direction to the
sticking surface while heating it with a hair dryer.
c. Do not throw the caution plates away but keep them together to
compare with new caution plates and to prevent mixing up with the
new ones.

KK-GT106
 8. CHASSIS DRAWINGS

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

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

KK-GT106
8. CHASSIS DRAWINGS 8-1-1

8.1 CAB DRAWINGS

8.1.1 MODEL
For all models
1) Front
Unit : mm

KK-GT106
8-1-2

2) Rear
Unit : mm

KK-GT106
 8-2-1

8.2 CAB BACK DRAWINGS

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

KK-GT106
8-2-2

2) Upper view
Unit : mm

KK-GT106
 8-3-1
8.3 CHASSIS DRAWINGS
8.3.1 GT1JFUA Scale : 1/40
Unit : mm

NOTE : 1.Figures marked " "dimensions are measured

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

KK-GT106
 8-3-2

8.3.2 GT1JHUA Scale : 1/40

Unit : mm

NOTE : 1.Figures marked " "dimensions are measured

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

KK-GT106
 8-4-1
8.4 CHASSIS FRAME DRAWINGS
8.4.1 GT1JFUA Scale : 1/40
1) Detail of the chassis frame Unit : mm

KK-GT106
 8-4-2

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

KK-GT106
 8-4-3

8.4.2 GT1JHUA Scale : 1/40

1) Detail of the chassis frame Unit : mm

KK-GT106
 8-4-4

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

KK-GT106
 9. MOUNTING OF
CHASSIS EQUIPMENT

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

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

KK-GT106
9. MOUNTING OF CHASSIS EQUIPMENT 9-1-1

9.1 FUEL TANK

9.1.1 MODEL
For all models
1) Standard equipment
Capacity : 100L
Unit : mm

KK-GT106
9-1-2

9.1.2 MODEL
GT1JHUA
2) Option equipment
Capacity : 200L
Unit : mm

KK-GT106
 9-2-1

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

KK-GT106
9-2-2

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

VEHICLE FRONT

DISASSEMBLY SPACE OF
BATTERY COVER
23
TO No.2 CROSSMENBER

50

60
DATUM LINE 425.5

50
430
394

321

41 140
562.5 295
380.5
4.5
21

281.5

537.5

DFD9 BT432kC1AU

KK-GT106
 9-3-1

9.3 AIR TANK & AIR BOOSTER

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

KK-GT106
9-3-2

(2) Air booster

Unit : mm

KK-GT106
 9-3-3

2) Option equipment
(1) Air tank
Unit : mm

KK-GT106
9-3-4

(2) Air booster

Unit : mm

KK-GT106
 9-4-1
9.4 EXHAUST SYSTEM
9.4.1 MODEL Scale : 1/20
For all models Unit : mm
1) Standard equipment

KK-GT106
 9-4-2

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

KK-GT106
 10. OTHER

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

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

KK-GT106
10. OTHER 10 - 1

10.1 BRAKE PIPING DIAGRAM

KK-GT106
10 - 2

10.2 LICENSE PLATE BRACKET

Unit : mm

KK-GT106