BM2110ABGENFIG1

BM2110ABGEN
BODY MOUNTING
MANUAL
BUS MODEL
CHASSIS FC9J SERIES
No part of this manual may be reproduced or transmitted in any form without the
express written permission of Hino Motors, Ltd.
© 2021, Hino Motors, Ltd. All rights reserved. Printed in Japan.
3-1-1, HINO-DAI, HINO-SHI, TOKYO, 191-8660 JAPAN
Apr. 2021
BM2110ABGEN
PUBLISHING INFORMATION
PUBLISHING INFORMATION
We have newly published Body Mounting Manual for new BUS series,
complying of EURO-3 and EURO-5 emission control regulation.
Consequently, please discard the current Body Mounting Manual

NO. BM1961ABGEN and use the new NO. BM2110ABGEN
from now on.
CONTENTS
1. Position of the engine number has been corrected. (Chapter 1-2)
BM2110ABGEN
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.
When Body and Equipment Manufacturers install any body or other
equipment or device on Hino bus chassis (hereinafter collectively
referred to as Hino Chassis), or modify or alter a Hino Chassis.
Content
This manual contains chassis specifications and instructions particular
to model FC9J BUS series with EURO-3 and EURO-5 emission control
in the medium duty bus chassis.
Important
When use this instruction manual, please use it with common
manual KC-AA014A.
The necessary concept information to be considered for the body
mounting is described in the common manual.
The respective instructions described in the individual model
manual are given priority over the descriptions in the common
manual.
• The Common Manual is available in this CD-R.

• For more information on mounting of bodies and equipments or on
chassis modifications, refer to the appropriate workshop manuals,
parts catalogs, and maintenance guides and owner's or driver's
manual.
• The information in this manual is accurate to the best of Hino's
knowledge at the time of going to press.
Hino reserves the right to modify any and all information without
notice and without obligation.
• Should more detailed data or information be needed, please contact
authorized Hino distributor.
BM2110ABGEN
Warning
• The vehicle has installed electronic 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.)
• About chassis mass
The chassis mass of chapter 3 shows standard specification of
vehicle.
(It is not included mass of option equipment.)
When consider the mounting of body, should include mass of option
equipment.
• This vehicle is controlled by VEHICLE CONTROL ECU.
Therefore, don't change the specification of vehicle. (Ex. Tire size,
Final gear ratio, 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 Manufacturers 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.
• AdBlue® is registered trademark of the Verband der
Automobilindustrie e.V (VDA), and only urea solution meeting the
standard is permitted to use this trademark.
BM2110ABGEN
MUST SEE THE COMMON VERSION MANUAL
When mounting of body, must see the both individual respective model series
and common manual.
The following is the detail of common manual.
Must understand the content of a manual before start processing.
CORRESPONDING
GRAND ITEM MEDIUM ITEM PAGE IN COMMON
MANUAL
GENERAL
1. 1) BODY DESIGN AND CONSTRUCTION 1-1

PRECAU-
2) NEVER MODIFY SAFETY PARTS 1-2

TIONS
3) CLEARANCE 1-3
4) FITTING THE BODY 1-4
2. 1) ENGINE 2-1
2) ENGINE COOLING SYSTEM (RADIATOR & RELATED PARTS) 2-2
EQUIPMENT INSTALLATION
3) ENGINE AIR INTAKE SYSTEM 2-3

4) CHASSIS FRAME 2-4
5) FUEL TANK 2-5
6) STEERING 2-6
7) CLUTCH CONTROL SYSTEM 2-7
PROCEDURES
8) BRAKE SYSTEM 2-8

9) PROPELLER SHAFT 2-9
10) SUSPENSIONS 2 - 10
11) EXHAUST SYSTEM 2 - 11
12) TIRE 2 - 12
13) ELECTRICAL EQUIPMENT AND RELATED PARTS 2 - 13
14) ATTACHMENT OF THE PACKAGED PARTS 2 - 14
1) COMPONENTS TO BE MASKED 3-1
PRECAUTION
3.
FINAL COAT
2) UNPAINTED COMPONENTS 3-2

APPLYING
OF PAINT
3) ELECTRICAL PARTS 3-3

WHEN
4) FORCED DRYING 3-4

THE
5) PAINTING THE WHEEL DISC 3-5

4. 1) BASIC POINTS OF BUS BODY MOUNTING 4-1
2) DESCRIPTION OF BUS BODY 4-2
3) PRINCIPAL PRECAUTIONS WHEN MOUNTING A BUS BODY 4-3
4) BASIC LAYOUT OF BODY STRUCTURE 4-4
BUS BODY
5) LAYOUT OF STRUCTURAL ELEMENTS 4-5

6) RUST AND CORROSION PREVENTION 4-6
7) RIDE COMFORT IN RELATION TO VIBRATION AND NOISE 4-7
8) DESIGN TO FACILITATE INSPECTIONS AND MAINTENANCE 4-8
9) SAFETY CONSIDERATIONS 4-9
10) FIRE PREVENTION 4 - 10
11) APPEARANCE AND WORKMANSHIP OF BUS BODY 4 - 11
12) ADVANTAGES AND DISADVANTAGES OF FRONT AND 4 - 12
REAR-ENGINED BUSES, AND AIR CONDITIONING SYSTEMS
BM2110ABGEN
CONTENTS
1. VEHICLE SUMMARY

2. GENERAL PRECAUTIONS

3. CHASSIS MASS & FRAME SECTION MODULUS

4. EQUIPMENT INSTALLATION PROCEDURE

5. ATTACHED DATA
BM2110ABGEN
1. VEHICLE SUMMARY
1. MODEL CODE
2. IDENTIFICATION NUMBER
3. CHASSIS SPECIFICATIONS
4. ‌DETAIL OF VEHICLE CAPACITY
BM2110ABGEN
1. VEHICLE SUMMARY 1-1
1. MODEL CODE
F C 9 J K 7 Z
VEHICLE CODE
F FRONT ENGINE
GVM & DRIVE CODE
GVM 9,000kg
C
DRIVE 4 x 2
ENGINE CODE
9J J05E
WHEELBASE CODE
CODE WHEELBASE (mm)
G 3,850
K 4,650
L 4,990
MODIFICATION CODE
CODE STEERING POSITION MODIFY
K
···
FIRST
R RIGHT HAND
,
1
S
···
FIRST
Z LEFT HAND
,
7
APPLICABLE CODE
CODE BODY TYPE
A GENERAL CARGO
D DUMP TRUCK
···
Z BUS
COLFC101B01T001
BM2110ABGEN
1-2
2. IDENTIFICATION NUMBER
CHASSIS NUMBER
209
75
160
ENGINE NUMBER
Located at the right under

rear end of the engine's side wall.
BM2110ABGEN
1-3
3. CHASSIS SPECIFICATIONS
CHASSIS MODEL
ITEM FC9JK7Z-BB9HFAA FC9JK7Z-BX9HFAA FC9JL7Z-BB9HFAA FC9JL7Z-BX9HFAA FC9JG7Z-CB9LFAA FC9JG7Z-CX9LFAA FC9JK7Z-CB9LFAA FC9JK7Z-CX9LFAA FC9JL7Z-CB9LFAA
EMISSION CONTROL EURO3 EURO5
WHEEL BASE (mm) 4,650 4,650 4,990 4,990 3,850 3,850 4,650 4,650 4,990
FRONT (mm) 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800
TREAD
REAR (mm) 1,660 1,660 1,660 1,660 1,660 1,660 1,660 1,660 1,660
MAX. GVM/GCM CAPACITY (kg) 10,100 10,100 10,400 10,400 10,000 10,000 10,100 10,100 10,400
GAM. FRONT (kg) 3,600 3,600 3,600 3,600 3,600 3,600 3,600 3,600 3,600
PERMISSIBLE RATING REAR (kg) 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000
AXLE CAPACITY
(On std. spec.) FRONT (kg/axle) 3,700 3,700 3,700 3,700 3,700 3,700 3,700 3,700 3,700
TIRE
REAR (kg/axle) 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000 7,000
TOTAL (kg) 3,140 3,165 3,165 3,185 3,145 3,175 3,235 3,270 3,255
CHASSIS MASS ON STD SPECIFICATIONS
FRONT (kg) 1,720 1,730 1,730 1,745 1,675 1,690 1,760 1,780 1,805
(INCLUDING WATER, OIL AND FULL FUEL)
REAR (kg) 1,420 1,435 1,435 1,440 1,470 1,485 1,475 1,490 1,450
MODEL J05E-VC (Euro3) J05E-VC (Euro3) J05E-VC (Euro3) J05E-VC (Euro3) J05E-VE (Euro5) J05E-VE (Euro5) J05E-VE (Euro5) J05E-VE (Euro5) J05E-VE (Euro5)
MAX
ENGINE ISO NET 129kW {175PS} at 2,500r/min 129kW {175PS} at 2,500r/min 129kW {175PS} at 2,500r/min 129kW {175PS} at 2,500r/min 154kW {210PS} at 2,500r/min 154kW {210PS} at 2,500r/min 154kW {210PS} at 2,500r/min 154kW {210PS} at 2,500r/min 154kW {210PS} at 2,500r/min
OUTPUT
MAX
ISO NET 500N·m {51.0kgf·m} at 1,500r/min 500N·m {51.0kgf·m} at 1,500r/min 500N·m {51.0kgf·m} at 1,500r/min 500N·m {51.0kgf·m} at 1,500r/min 637N·m {65.0kgf·m} at 1,800r/min 637N·m {65.0kgf·m} at 1,800r/min 637N·m {65.0kgf·m} at 1,800r/min 637N·m {65.0kgf·m} at 1,800r/min 637N·m {65.0kgf·m} at 1,800r/min
TORQUE
TRANSMISSION MODEL LX06 ALLISON T2200 LX06 ALLISON T2200 LX06 ALLISON T2200 LX06 ALLISON T2200 LX06
HEIGHT OF GRAVITY FROM GROUND (m) 0.62 0.63 0.62 0.62 0.61 0.61 0.61 0.61 0.61
TIRE STD 9.5R17.5-129/127 9.5R17.5-129/127
TIRE AND WHEEL DISC
DISK STD 17.5x6.75-offset135mm 17.5X6.75-offset135mm
FUEL TANK (L) STD 200 200 200 200 200 200 200 200 200
BATTERY (V-kC{A・h}-No.) STD 12-432 {120} -2 12-432 {120} -2 12-432 {120} -2 12-432 {120} -2 12-432 {120} -2 12-432 {120} -2 12-432 {120} -2 12-432 {120} -2 12-432 {120} -2
STD 24-60 24-60 24-60 24-60 24-60 24-60 24-60 24-60 24-60
ALTERNATOR (V-A)
OPT 24-90 24-90 24-90 24-90 24-90 24-90 24-90 24-90 24-90
[NOTE]
1) Allowable GAM 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.
BM2110ABGEN
1-4
4. DETAIL OF VEHICLE CAPACITY

Unit : kg
ITEM STD/OPT
FRONT 3,600 STD

SPRING
REAR 7,000 STD
FRONT 3,700
9.5R17.5-129/127 STD
TIRE REAR 7,000
(ETRTO
STANDARD) FRONT 4,000
235/75R17.5-132/130 OPT
REAR 7,600
TIRE FRONT 3,800

(JATMA 225/70R19.5-130/128 OPT
STANDARD) REAR 7,200
• ‌Could not increase the GVM capacity even though optional tire
is equipped.
[NOTE]
Should not exceed the spring and tire capacity.
BM2110ABGEN
2. GENERAL PRECAUTIONS
1. BASIC POINTS OF BUS BODY

2. WEIGHT DISTRIBUTION ON FRONT AXLE & HEIGHT OF CENTER OF
GRAVITY
3. BODY DESIGN
4. FITTING THE BODY
5. POINTS TO NOTE ON ELECTRIC WELDING
6. NOTES ON SYSTEM CONTROL COMPUTERS
7. PRECAUTION FOR "ECU" WHEN MOUNTING OF BODY (for EURO5)
8. PRECAUTION FOR THE FUEL HOSE
9. GENERAL PRECAUTIONS FOR PAINTING
10. SHIPMENT
11. PRECAUTION FOR EXHAUST SYSTEM
12. CAUTIONS FOR PAINTING THE TIRE DISC WHEELS
13. PRECAUTION FOR ELECTROMAGNETIC RETARDER
BM2110ABGEN
2. GENERAL PRECAUTIONS 2-1
1. BASIC POINTS OF BUS BODY
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.
BM2110ABGEN
2-2
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.
WEIGHT HEIGHT OF GRAVITA - RECOMMENDED

ENGINE DISTRIBUTION ON TIONAL CENTER BODY MAXIMUM
LOCATION MODEL FRONT AXLE FROM GROUND WIDTH
(FR/VM) (UNLADEN) (m)
(m)
MORE THAN 28% MAX. MAX.
FRONT FC9J (UNLADEN AND 1.09 2.3
LADEN)
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 MOMENT OF
MASS GRAVITATIONAL GRAVITATIONAL
CENTER CENTER
(kg) (m) (kgf·m)
From HINO
CHASSIS Refer chassis
(1) (2) (1)x(2)=(A) specification
Page 1 - 3
BODY (Including option
(3) (4) (3)x(4)=(B) equipment)
By body builder
PASSENGER'S
SEAT (5) (6) (5)x(6)=(C)
TOTAL
(1)+(3)+(5)=(D) (A)+(B)+(C)=(E)
The height of ∑ Moments

= = (E) = (F) < 1.09 (UNLADEN)
gravitational center Vehicle mass (D)
BM2110ABGEN
2 - 3 - 1
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
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.
BM2110ABGEN
2 - 3 - 2
2) INSTALLATION OF ANCILLARY HEAVY MACHINERY OR EQUIPMENT
When install the ancillary heavy machinery or equipment above and below 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]
INSTALLING 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.
BM2110ABGEN
2 - 3 - 3
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 differential oil, filling and removing oil.
(4) Checking battery fluid, removing the battery.
(5) Fuel filter, drain.
(6) Air tank drain.
(7) Adblue 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 piping and
related valves.
ENGINE OIL LEVEL GAUGE
(LH)
ADBLUE TANK (LH) ※IF EQUIPPED
BM2110ABGEN
2 - 3 - 4
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 5-4 for details.)
CLEANER (LH)
AIR DRYER (CNT) ADBLUE TANK (LH)

※IF EQUIPPED
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.
BM2110ABGEN
2-4
4. 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.
[EXAMPLE]
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.
BM2110ABGEN
2 - 5 - 1
5. POINTS TO NOTE ON ELECTRIC WELDING
Internal clocks in the tachograph and the radio and all the electronic
instruments are directly connected to the battery, and are cab body-
earthed at one end.
Under these conditions, electric welding will cause damage to these
electrical instrument as the welding current flow back along the
earth circuit.
When welding, take following step of manner.
1) ‌Procedure before welding

(1) Turn the starter switch to "LOCK" position.
CK
LO
(2) Must
‌ wait more than 10 minutes after turned the starter switch to
"LOCK" position.
*Do not start the followings procedure before finishing operation
which return AdBlue® of UREA-SCR system to AdBlue® tank
(After-Run).
(3) Disconnect the negative terminal of the battery.
negative terminal
negative
(4) Wait more than 90 seconds.
(5) Dismount fuse indicated in the label next page.
BM2110ABGEN
2 - 5 - 2
RELAY
FUSE BLOCK
DISMOUNT THESE FUSES
BM2110ABGEN
2 - 5 - 3
2) ‌Ground of the Welding Equipment

Connect the ground of the welding equipment near the place where to be
welded.
Welding
‌ 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 fire-
resistant 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.
BM2110ABGEN
2 - 5 - 4
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
A
B
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
inspection’s procedure.
BM2110ABGEN
2 - 5 - 5
REFERENCE FOR FLOW OF CURRENT WITH ELECTRIC WELDING
BM2110ABGEN
2-6
6. NOTES ON SYSTEM CONTROL COMPUTERS

Vehicle control and brake ABS computers or ENGINE ECU, are installed
left or right part, inside of the instrument panel as described following
figure.
Therefore, give great care to the computer when performing any body
mounting work or modification as following points.
• Be sure to cover the computer to protect the water penetration when

performing cleaning up the inside of cab.
• When mounting such devices as a radiophone, a wireless
communication
device, be sure to use the devices that conforms to the electric control
act
and install the devices on the places which are as far as possible from
the
computers and 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.
• Do not alter the computer, harness wire or sensors (ex. acceleration
sensor).
• As you will see on the following Fig. Various kind of computers are
installed inside the cab, when fitting and modifying the inside of the cab,
be careful not to give any shock to the vicinity of the computer.
[LAYOUT EXAMPLE]
Check the vehicle for details of specification.
G SENSOR
(EURO5)
(EURO3)
ECU LAYOUT
BM2110ABGEN
2-7
7. PRECAUTION FOR "ECU" WHEN MOUNTING OF BODY

(for EURO5)
Engine's computer is equipped on the engine. See the below figure for the detail.
Do not give any shocks to the computer and around it when mounting of body.
1) Precaution for engine's computer
(1) ‌Do not altering, welding and removing of the computer unit and component
parts of the computer.
(2) ‌Do not painting to the computer unit and component parts of the computer.
(3) ‌Do not place the parts which heat supply near the computer.
(4) ‌The computer has vent valve, therefore, do not alter such as closing valve
and water and oil splashing all the time on the valve.
(5) ‌When disconnect and connect of connector,
• do not touch terminal directly.
• do not break connector.
• do not misconnect.
BM2110ABGEN
2-8
8. PRECAUTION FOR THE FUEL HOSE
Be sure to observe the following notes, if it will be changed a fuel hose by a

movement or an addition of a fuel tank.
Always use the fuel hose of the HINO genuine parts.
The following figure is an example of genuine parts.

(The material and quality of each component are based on the standard of HINO.)
Unit : mm
INNER RUBBER
(FLUORIDE COATED)
2
Ø17
Ø9.5
OUTER RUBBER
BRAID
INTERMEDIATE RUBBER
If genuine parts cannot be obtained, please get the following rubber hoses as a
substitute.
• ‌The rubber hoses which dose not contain a metal element.

or
• ‌The rubber hoses which a metal element does not melt into fuel.
(For example : The rubber hose which give the fluoride coat to the inside.)
The quality of the rubber hoses of a substitute should be more than equivalent to
genuine, or equivalent.
Use of unsuitable rubber hose may cause serious faults of engine, such as the
decline of an exhaust gas purification function.
For more detailed information, please consult your nearest HINO sales outlet.
BM2110ABGEN
2-9
9. GENERAL PRECAUTIONS FOR PAINTING • 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
When you apply finish paint to the cab etc. observe the following precautions.
fitted and securely clamped.
Some parts of the cab and chassis are sensitive to the drying heat, some parts must not
be painted and so require masking, etc.
• Precaution for preventing to paint the fuel pre-filter
If the fuel pre-filter is painted, it may deteriorate the function of fuel prefilter, and there
GENERAL PRECAUTIONS FOR PAINTING will be a crack at resin parts.
Therefore, be sure to observe the following manner.
• Parts to be masked:
- Should put a musk completely on the fuel pre-filter when painting.
Parts that must not be painted-ornaments, name plates (model names, Hino logo mark
- If the fuel pre-filter is painted, it need replace a new one.
chassis number), caution plate, etc. must all be masked.
(It is possible to take off the top mark.)
Never paint the rubber hoses and nylon tubes or valves, the brake booster, or hoses or
valves of the brake fluid reservoir. ［EXAMPLE］
Never paint the cab tilt and lock mechanism.
Do not paint this range
• Cover the battery, wiring connections and hoses to protect them from paint.
• If you get paint on the cab shell, wipe it clean with gasoline.
Never use thinner.
RESIN CASE
• When cleaning inside of the cab, must use a neutral detergent.
Never use gasoline nor paint thinner. DRAIN PLUG
• 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 FOR 500 SERIES
body have been modified from “+ type screw bolt” to “hexalobular internal type bolt
(TORX® bolt)” in order to improve stabilization of tightening torque and avoiding the
damage of tool groove.
Use proper tools to fit with “TORX® bolt”.
• Precaution for preventing to paint the AdBlue®-SCR system.

The AdBlue® injector, AdBlue® pump, muffler, electric wiring connections should be
covered properly to prevent them from being covered with paint.
• 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.
BM2110ABGEN
2 - 10
10. 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.)
BM2110ABGEN
2 - 11 - 1
11. PRECAUTION FOR EXHAUST SYSTEM

Modifying the exhaust system has a major effect on vehicle performance,
gaseous emission and external noise. As a rule, the exhaust system must
not be modified.
Prohibition Area of Alteration and Modification
[EXAMPLE]
FOR EURO3
FOR EURO5
FOR EURO5
Modifying the tail pipe (including install spark arrester) has a major effect
on external noise, internal noise and strength of exhaust parts. As a rule,
the tail pipe must not be modified.
The EXHAUST SYSTEM is equipped to comply with exhaust gaseous

emission control regulation.
Be sure to observe the following precautions for the EXHAUST SYSTEM.
• ‌Do not water into the muffler when washing the vehicle, especially
under parts of the chassis.
• ‌Do not give any shock such as dropping and hitting to the muffler
when handling.
The tail pipe is high temperature, therefore, there is no flammable parts

such as cable, hose, nylon tube, wire and resin parts within the following
area.
Applies to area above, below, right and left of tail pipe.
Also, should maintain clearance to be described in this section.
BM2110ABGEN
2 - 11 - 2
1) UREA - SCR SYSTEM

Be sure to observe the following instructions when mounting body or
equipment.
The UREA (*AdBlue®) - SCR (Selective Catalytic Reduction) system is
installed for reducing NOx (nitrogen oxide) emission.
See figure below shows installing position of UREA - SCR.
* ‌AdBlue® is registered trademark of the Verband der Automobilindustrie
e.V (VDA), and only urea solution meeting the standard is permitted to
use this trademark.
OUTLINE
• The urea SCR system is a system which reduces the NOx discharged from the engine with ammonia absorbed by the
SCR catalyst, which decomposes it then into nitrogen (N2) and water (H2O).
• Since ammonia required for purification is deleterious, it is put to the AdBlue® tank in a form of non-deleterious AdBlue®. It
is then sucked up by the AdBlue® pump and injected to the muffler unit through the AdBlue® injector. When injected
AdBlue® is exposed to hot exhaust gas, it is hydrolyzed into ammonia and the NOx is reduced in the SCR catalyst.
• Injection amount of AdBlue® is calculated by the DCU, and optimal injection amount is determined based on the informa-
tion of each sensor (NOx amount calculated by the engine ECU, temperature input from the SCR front temperature sen-
sor, and NOx amount input from the SCR NOx sensor).
• The urea SCR system extensively reduces the NOx (nitrogen oxides) produced in the engine without sacrificing the fuel
efficiency performance.
• The catalyst of the urea SCR system is composed of a SCR catalyst.
• AdBlue® is used as the urea solution used by the urea SCR system.
• AdBlue® is a water solution (urea solution) with 32.5 % high-quality urea dissolved in pure water, and it is a dedicated
product for exhaust gas processing of diesel motors using the urea SCR system.
• AdBlue® is registered trademark of the Verband der Automobilindustrie e.V (VDA), and only urea solution meeting the
standard is permitted to use this trademark.
BM2110ABGEN
2 - 11 - 3
NOx sensor
SENSOR, AdBlue® TANK
SCR catalist
Tail pipe
Exhaust pipe
Front
AdBlue® injector
BM2110ABGEN
2 - 11 - 4
(1) Precautions when body mounting and welding.

WARNING
Removal, installing on different place, painting and modification of any
parts of UREA-SCR system is prohibited.
• When mounting body and equipment, cover the whole system not to
damage system parts, especially the sensor connectors of AdBlue® and
NOx.
• Do not impact each system parts. Be careful not to impact the AdBlue®
tank because it is made of resin.
Also, do not impact sensors and DCU (the computer which controls the
quantity of AdBlue® injected for the catalyst), and do not pour water.
• When welding work, cover whole system with nonflammable material
to avoid the damage by welding spatter, and the influence by heat.
Before welding, turn the starter switch to “LOCK” position, wait at least
10 minutes, and disconnect the negative terminal of battery.
• Be sure to wait for at least ten minutes after the stater switch is turned
to “LOCK” position before you disconnect the battery terminals from
the battery, as DCU starts working for “After Run” after the starter
switch is turned to “LOCK” position.
Otherwise, DCU will not complete working properly (the AdBlue® still
remains in the exhaust gas after treatment system), which may result
in the malfunction of UREA-SCR system.
What is the meaning of After Run

• After you turn the starter switch to “LOCK” position.
• To avoid crystallizing of the AdBlue® that remains in the AdBlue®
pump, injection and pipes, the exhaust gas after treatment system
automatically returns the AdBlue® to the AdBlue® tank.
• You can hear the sound of the AdBlue® pump after you turn the
starter switch to the “LOCK” position is proper actuation.
• The time when the sound of the AdBlue® pump can be heard may
vary.
• If remove the AdBlue® tank temporary when mounting body, should

protect AdBlue® sensor connector from water.
• Around the filling port of AdBlue® tank, body mounting or installing parts
should not be done in a way to obstruct replenishing AdBlue®.
See the figure below.
• If you need to replace any parts related to UREA-SCR system, use of
Hino genuine parts is required for the proper function of UREA-SCR
system.
• When adding a battery disconnect switch, install it on the downstream
side of the power supply of the DCU.
BM2110ABGEN
2 - 11 - 5
DCU
SENSOR, AdBlue® TANK
UP
FR RH
AdBlue® TANK
BM2110ABGEN
2 - 11 - 6
(2) Precautions when painting.

• In the case of natural drying, in order to prevent adhesion of a paint,
cover the whole system.
• In the case of forced drying such as drying in dry oven, drying tempera-
ture must be under 80°C because allowable heat limit of the AdBlue®
tank is 80°C.
Also, extract AdBlue® completely from the AdBlue® tank and cover whole
system with heat-resistant material.
(3) Precautions when extract AdBlue®.

• Extract AdBlue® after finishing After Run.
• Do not re-use the extracted AdBlue®.
Caution should be exercised during fluid extraction. If particulate matter
is dislodged from the tank during extraction, the particulate matter needs
to be removed from the tank. Failure to remove the particulate matter
could cause damage other components.
• Always use AdBlue® for replenishment of the AdBlue® tank.
See the figure below for detail of AdBlue® tank.
AdBlue® tank
Plug
BM2110ABGEN
2 - 11 - 7
(4) Precautions for AdBlue®.

Always use API certified AdBlue® for replenishment of the AdBlue® tank.
Don’t replenish the tank with AdBlue® diluted even if it was API certified
AdBlue®.
Never replenish the tank with diesel fuel, kerosene, gasoline or other fluid
than API certified AdBlue®.
Use of the abovementioned unsuitable fluid causes not only the fall of an
exhaust gas purification function but failure of each parts of UREA-SCR
system.
If you replenish the tank with the fluid other than API certified AdBlue® by
mistake, extract the fluid completely and replenish the tank with API
certified AdBlue® before starting engine.
Never heat, dilute and never mix with non-approved or other fluids.
(5) Precautions when handling AdBlue®.

Observe the following precautions when handling AdBlue®.
• Put on the appropriate protective equipment (ex. safety goggles, rubber
gloves and etc.).
• If AdBlue® goes into eyes or adheres to the skin, wash 15 minutes or
more with a lot of effluent immediately, and receive diagnosis of a doctor.
• Although there may be a smell like ammonia in AdBlue®, there is no
inconvenience in use.
• Wipe off AdBlue® adhering to the floor, the body, a container, etc. with a
rag securely. AdBlue® is dried and crystallized. Crystallized AdBlue®
corrodes the metal side where it is not painted if it adheres.
• Do not drain AdBlue® into the environment and it should be treated like
an industrial waste.
(6) Indicator light on the meter panel.

After finishing body mounting and when starting the engine, if following
indicator light on the meter panel goes on do as the instruction of safety
label which is attached on the cover of sunvisor or contact Hino authorized
dealer or distributor.
(Information display)
BM2110ABGEN
2 - 11 - 8
2) CLEARANCE BETWEEN EXHAUST PARTS AND OTHER PARTS

The exhaust system become very hot during operation, therefore, be sure
to observe the following instructions to prevent a unexpected problems.
(1) Clearance from body parts

• Should follow the precautions for mounting of exhaust system.
(2) Clearance from fuel system parts

• ‌Maintain a clearance of at least 200 mm between the fuel tank, fuel
hose or pipes and the hot parts of the exhaust system.
If cannot maintain a clearance of 200 mm, should fit the heat
insulators to protect the fuel tank and fuel hose or pipes.
When arranging the fuel piping, make sure that even if a fuel line
break and fuel leaks out, fuel should not contact with hot parts of the
exhaust system.
• ‌Do must not make a joints of the fuel piping above the hot parts of
the exhaust system.
• ‌When moving the fuel tank or installing an additional tank, make
sure that the filling port is at least 300 mm away from mouth of the
tail pipe and at least 200 mm away from exposed electrical
terminals.
(3) Clearance from other chassis parts

• ‌Maintain the clearance shown the table below.
If cannot maintain these clearance, should fit the heat insulators.
The heat influence and interference of the exhaust pipe and muffler for the
exhaust system are very important items for safety, therefore, make sure
that secure a sufficient clearance between the related parts of exhaust
system such as exhaust pipe and muffler and body and equipments, and
check the temperature if need then make sure that it is no problem for
safety.
BM2110ABGEN
2 - 11 - 9
PRECAUTION FOR CATALYTIC MUFFLER AND NOx SENSOR
The catalytic muffler with NOx sensor is installed with satisfied regulation in
vehicle.
Therefore, do not alter, move and detach of muffler, NOx sensor and wire
harness.
It need to replace a new one if NOx sensor is broken.
Start the engine, then check that the MIL (Malfunction Indicator Light) is on
or not after mounted of body.
If the MIL is on, please contact Hino authorized dealer or distributor.
Be sure to observe the following precautions during operation for mounting
body.
• Do not give a shock to the muffler and NOx sensor.
• Do not paint the muffler, NOx sensor and wire harness.
• To avoid water comes from tail pipe.
RH
FR
NOx sensor
BM2110ABGEN
2 - 11 - 10
NOx SENSOR
A sensor is precision instrument parts, therefore, do not shock and strong
vibration to the sensor when mounting body.
Removal of the sensor is prohibited to prevent failure due to water
invasion.
The following figure shows detail of sensor.
Outer cover
Sensor head
Element Inner cover
Overview of NOx sensor Detail of sensor head
BM2110ABGEN
2 - 12
12. CAUTIONS FOR PAINTING THE TIRE DISC WHEELS

Tire Disc Wheel type : JIS
• Before painting the tire disc wheel, cover its inside and outside surface to be
contacted with the wheel, the hub, the brake drum and wheel nuts.
Refer to the illustration below concerning the covering portions.
• After installing the tire disc wheel onto the vehicle, paint the remained portions
with same color paint as thin as possible.
It is because these surfaces are installation surface rotation tire.
If the painting layer is thick, it causes wheel nuts loosen.
• Precaution for carrying out tire rotation

Sometimes, the mounting position of tire disc wheel may be changed and paint
coated face may become contact face.
At this moment, if the thickness of the painted layer is excessively thick, this may
lead to the loosening of the wheel nuts.
Therefore observe the following instructions when carrying out the tire rotation.
• Take off the paint on the contact face (including the contact surface of wheel
nut) of the tire disc wheel and after having completely cleaned the face with
a wire brush etc., apply thin layer of paint for rust preventive purpose.
• If you use the tire disc wheel without taking off the paint, even if the face is
completely cleaned with wire brush, etc., the thick painted layer may lead to
the loosening of wheel nuts.
BM2110ABGEN
2 - 13
13. PRECAUTION FOR ELECTROMAGNETIC RETARDER

Be sure to observe the following precautions for retarder when mounting
body.
1) Do
‌ not install any body or equipment which gets damaged by heat within
50mm from the retarder because the electromagnetic retarder become
high temperatures during operation.
2) ‌The following parts should allow clearance 120mm or more from the
retarder.
• Wire harness
• Nylon tube
• ‌Any parts which heat resistance temperature is less than 100℃ except
PTO drive shaft that can secure clearance 20mm.
3) If
‌ the above clearance cannot be maintained, should use the heat
insulators to prevent from heat.
4) ‌The retarder may protrude from the upper surface of the frame
depending on the chassis but also need to prevent interference and
heat.
5) Do not apply or adhere paint, oil and fat (including adhesion) to the
retarder.
LX06 transmission model
Do not install any body or

equipment this hatching area.
BM2110ABGEN
3. CHASSIS MASS &
FRAME SECTION MODULUS
1. CHASSIS MASS
2. CHASSIS MASS FOR OPTION SPECIFICATION
3. FRAME SECTION MODULUS
BM2110ABGEN
3. CHASSIS MASS & FRAME SECTION MODULUS 3 - 1 - 1
1. CHASSIS MASS
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• The mass of tire follows design figure according to JATMA or ETRTO standard.
• The chassis mass shows standard specification of vehicle.
When consider the mounting of body, should include mass of option equipment.
BM2110ABGEN
3 - 1 - 2
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BM2110ABGEN
3 - 1 - 3
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BM2110ABGEN
3 - 1 - 4
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BM2110ABGEN
3 - 1 - 5
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BM2110ABGEN
3 - 1 - 6
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BM2110ABGEN
3 - 1 - 7
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3 - 1 - 8
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BM2110ABGEN
3 - 1 - 9
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BM2110ABGEN
3 - 2 - 1
2. CHASSIS MASS FOR OPTION SPECIFICATION

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BM2110ABGEN
3 - 2 - 8
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BM2110ABGEN
3 - 2 - 9
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BM2110ABGEN
3 - 2 - 10
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BM2110ABGEN
3 - 3 - 1
3. FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE)

Unit : mm
MODEL : FC9JG7Z
BM2110ABGEN
3 - 3 - 2
MODEL : FC9JK7Z
Unit : mm
BM2110ABGEN
3 - 3 - 3
MODEL : FC9JL7Z
Unit : mm
BM2110ABGEN
4. EQUIPMENT INSTALLATION
PROCEDURE
1. ENGINE
2. RADIATOR
3. FUEL TANK
4. AIR CLEANER
5. AIR INTAKE SYSTEM
6. BATTERY SETTING
7. CLUTCH CONTROL
8. STEERING
9. SERVICE BRAKE
10. TRANSMISSION CONTROL
11. TOE-BOARD
12. METER BOARD
13. SUSPENSIONS AND RELATED PARTS
14. FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK
15. SPARE POWER TERMINALS
16. DESIGN OF WIPER CIRCUIT AND ASSEMBLY
17. ELECTRIC WIRING OF SPARE OUTLET
18. ELECTRICAL WIRING DIAGRAMS
19. CAUTION FOR ELECTRICAL EQUIPMENT
20. FRAME
21. EXHAUST SYSTEM
22. PROCEDURE OF RUST PREVENTIVE TREATMENT
23. ATTACHMENT OF THE PACKED PARTS
BM2110ABGEN
4. EQUIPMENT INSTALLATION PROCEDURE 4-1
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 - 5 " for detail regarding the installation of the
engine hood.
BM2110ABGEN
4 - 2 - 1
2. 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.
BM2110ABGEN
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 reserve tank
On this vehicle, the cooling water reservoir is temporally installed at front end of
vehicle.
Therefore, install the cooling water reservoir permanently according to following
procedure.
(1) ‌Make sure to install up-right position.

(2) Avoid
‌ such area where it will expose reserve tank it to high temperature or
direct sunlight.
BM2110ABGEN
4 - 2 - 3
(3) Make sure to install following range of position.
UPPER LIMIT RADIATOR
0mm or
FULL
Lower LOW
ENGINE
RESERVE TANK
LOWER LIMIT
MAX.
500mm
FULL
LOW
(4) Provide a proper size of lid to the body outer panel to perform the inspection
of cooling water level and filling cooling water.
[NOTE]
See " ATTACHED DATA 5-6 " for detail of installation position of reservoir
tank.
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4 - 3 - 1
3. FUEL TANK
1) "ATTACHED DATA 5-7" show standard location of the fuel tank.
Provide a fuel feed lid and tunnel, inspection lid for fuel gauge sender and
pre-fuel filter at the body (outer panel and floor) according to
"ATTACHED DATA 5-2".
2) Observe the following precautions if fuel tank is moved.
(1) ‌Follow the instructions described in Common Manual No.KC-AA014A for

chassis frame when drilling on the frame.
(2) ‌Provide a fuel feed lid and tunnel, inspection lid for fuel gauge sender and
pre-fuel filter at the body (outer panel and floor) according to
"ATTACHED DATA 5-2".
(3) ‌The filling openings are located outside the vehicle passenger compartment
and cargo.
(4) ‌No part of the fuel system is located in or on the passenger compartment.
(5) ‌Filling holes, filling pipes and fuel tanks should not be located in the
passenger's nor driver's compartment.
<Note>
It is allowed to pass or the intrusion of a part of the feeding tube of diesel
when is protected and covered with the same flooring material and so as not
to interfere with the mobility of passengers.
3) Make sure following notes, if fuel hose is changed by moving or addition of the
fuel tank.
(1) ‌Always use the fuel hose of the Hino genuine parts.
(2) ‌Case of changing the steel pipe, refer to the Common Manual No.KC-
AA014A.
(3) ‌Use of unsuitable rubber hose may lead serious fault of the engine such as
the decline of an exhaust gas purification function.
DETAIL OF HINO GENUINE FUEL HOSE

TYPE OF HOSE NOTES
Rubber Hose Inner dia. 9.5mm
FUEL FEED LINE
(Fluoride coat to inside) External dia. 17mm
Rubber Hose Inner dia. 9.5mm
FUEL RETURN LINE
(Fluoride coat to inside) External dia. 17mm
For more detailed information of the fuel hose, please consult your nearest Hino
sales outlet.
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4 - 3 - 2
4) Precaution for addition of the fuel tank.
When install additional fuel tank, make sure to check if the fuel sender works
correctly as following.
(1) ‌The meter of this vehicle incorporates a computer that calculates the input
signals and displays on different meters and gauges.
In the case of a fuel gauge, in order to prevent it from moving of needle of the
fuel sender with vehicle posture, its movement is intentionally dull,
consequently if move float from [E] to [F] (or [F] to [E]) it will not follow.
(The indicator moves only 2 degrees per minute.)
(2) ‌How to check if the fuel sender works correctly.
‌
Disconnect battery negative connecter and wait for more than 30 seconds.
‌Move the float of the fuel sender to the position corresponding to [F].
(The highest position of raised float.)
‌Connect battery negative connecter and turn on starter switch to [ON]
position.
( The fuel gauge indicates [F] position.)
‌Disconnect battery negative connecter again and wait for more than 30
seconds.
‌Move the float of the fuel sender to the position corresponding to 1/2
position.
(Move float to mid position between the highest and the lowest position of
the float.)
‌Connect battery negative connecter and turn on starter switch to [ON]
position.
( The fuel gauge indicates 1/2 position.)
As the result if the fuel gauge indicates [F] position in step and further
indicate 1/2 position in step , there is no problem.
5) Precaution for fuel hose
(1) ‌Make sure that fuel hoses are positioned at least 10mm away from the
corners of other parts, and at least 10mm away from the maximum range of
movement of any parts subject to relative movement.
(2) ‌Secure the hoses with clamps.
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4-4
4. AIR CLEANER
As air cleaner setting already has been completed, never modify the intake pipes
except the temporary cap or change the setting position for the air cleaner body.

Make sure to construct the air intake system as following manner.
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4 - 5 - 1
The following items must be observed strictly for the setting of the engine air
intake system.
Do not change from the chassis shipping condition.

It is not possible to modify the intake system or change the installation position of
the air cleaner body.
(To affect the exhaust gas and performance)
1) Securing an adequate supply of air to the engine.
(1) Set the air inlet located on the outer plate of the body as follows.
• Effective opening area: 300 cm2 or more

• Opening shape recommended square.
• Should be installed mesh guard and louver.
<Specifications of mesh>
• Material: Anti rust metal (for example SUS304)
• Line diameter: φ1.2 mm or equivalent
• Grid size: 8 x 4 mm or equivalent
• No gap between the air cleaner room and body panel.
<Specifications of louver>
• Overlap margin of 0 mm or more is required between louvers.
• Louver angle is 45 degree in ( ) dimension.
(2) ‌The duct route from the air inlet of the body outer plate to the air filter should
be set as follows.
• Secure the cross section which the circle more than diameter 4inch enters.
• Bending radius: More than 1.5 times the diameter.
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4 - 5 - 2
2) The position of the external clean air inlet.
(1) ‌The best position for the external clean air inlet is on the roof.
This position is particularly recommended for vehicles driben on dusty
unseald roads.
(2) ‌On vehicles that are driven on sealed roads, where there is less dust, it is
acceptable to have the inlet high on the side of the vehicle.
Install the air inlet at a position where water and dust can not enter from the
rear tire.
(3) ‌The lowest point of the air intake should be at least 1.6 m above the ground.
(4) ‌Intake air from the ""shielded and independent space"" so that the intake air
does not inhale the heat from the engine room etc.
(Do not inhale from the engine room or passenger compartment)"
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4 - 5 - 3
3) Design of the air cleaner room
(1) ‌Make sure to construct air cleaner room so that air cleaner (Cannot be moved
from the time of shipment) enters.
Be sure to install a drain hole at the bottom of air cleaner room.
It is not possible to connect air cleaner hose directly to air cleaner.(In order to
release water intrusion from the air intake to the drain hole.)
(2) ‌It is recommended to cover the exposed part in the room with a decorative
board.
It is recommended to use a decorative board covered with a material that
prevents vibration and blocks noise inside.
It is to prevent noise and vibration into the room.
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4 - 6 - 1
6. BATTERY SETTING
1) When a chassis is delivered, the batteries are temporarily mounted on the

chassis as shown in " ATTACHED DATA 5 - 9 ".
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 install 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 ø10 - 2nos. of water drain to the bottom cover.
And also ventilation opening must provide upper part of the battery room such as
making ø70 or ø45-2nos. 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 install 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.]
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4 - 6 - 2
BM2110ABGEN
4-7
7. 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 inspection hole and cover at the position of the fluid reservoir 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 securely fix 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 setting & etc.
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4 - 8 - 1
8. STEERING
1) The steering wheel is adjustable up and down as well as to the front and rear.
(tilting wheel)
It is therefore important to pay careful attention to the steering column.

2) The chassis is supplied with the steering column secured to the clutch pedal
bracket and temporarily attached to the dashboard.
Make sure to remove the temporarily delivery bracket (colored orange) at the
time the body is mounted on the chassis, and install according to the following
guidelines. No shimmy should occur.
The steering column casing should
METER
CLUSTER P1
be sufficiently rigid.
Remove temporary
bracket (colored • ‌Up and down
orange) & securely X 1
Deflection X1 = max. 1.0 mm
X2
mount on body P
2
against load P1 = 130 kg

front structure.
• ‌Forward and backwards
Deflection X2 = max. 0.5 mm
against load P2 = 70 kg
02-087
3) Be careful to avoid damaging the dust cover of the tie rod ball joint and drag link
with tools or other objects while mounting the body on the chassis.

When any electric welding is carried out nearby, you should ensure that parts are
protected by a fireproof cover.
4) When storing the chassis and mounting the body on it, keep it covered to prevent
any water or dirt from entering to steering column.
5) When mounting body parts close to steering devices such as the drag link and
pitman arm, etc., make sure that these body parts do not come within the range
of motion of these steering devices.
Make sure that there is a clearance of at least 40mm between the body parts and
these steering devices when they are at maximum displacement.
6) Power steering
• ‌The hydraulic oil reservoir and piping of power steering are installed as shown
in "ATTACHED DATA 5-12".
And there parts are already installed correct position on the chassis as
supplied.
• ‌Provide the inspection lid at left behind front wheel as shown in "ATTACHED
DATA 5-2", so that the hydraulic oil can be filled in and its level checked.
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4 - 8 - 2
POWER STEERING OIL RESERVOIR
NOTES
1. ‌Do not alter the oil reservoir position.
2. ‌Put cover on the oil reservoir and hose during body mounting.
3. ‌Provide the lid on the body for inspection and maintenance
of the power steering oil reservoir.
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4 - 9 - 1
9. SERVICE BRAKE
1) The brake system is the most important safety component of the vehicle.
It is strictly prohibited to modify any service brake components as well as their
connected parts.
2) The brake system to be equipped as follows.

• Model FC9JKUZ : Full-air brake
3) With respect to the brake piping diagram,

refer to the " ATTACHED DATA 5 - 13 & 14 " when mounting the body.
4) In case of installing a parts around a front brake hose,

install parts out of the range which the hose moves.
For detailed information, refer " ATTACHED DATA 5-3 ".
5) Consideration for the maintenance of brake valve
Brake valve is installed on pedal bracket assy,

therefore, the mounting method should be able to remove pedal bracket assy.
For example,
• To provide exterior opening for maintenance to body front panel.
• Body structure will be detachable composition around the pedal bracket assy.
The instructions of removing brake valve on workshop manual.

Please contact Hino authorized dealer or distributor, if need it.
DETAIL OF PEDAL BRACKET ASSY

[EXAMPLE]
BRAKE VALVE
FRONT STRUCTURE
OF CHASSIS
PEDAL BRACKET ASSY
BM2110ABGEN
4 - 9 - 2
RECOMMENDED FRONT EXTERIOR OPENING
‌
* The
Dimensions show size of pedal bracket assy.
exterior opening size of body front panel should larger than pedal
bracket assy.
[EXAMPLE]
The size of front exterior

opening is easily removing
and reinstalling with pedal
bracket assy.
Should seal around front
exterior opening for
preventing dust or water
intrusion.
BM2110ABGEN
4 - 9 - 3
6) For other precautions, refer to the Common Manual.
7) Output air source of door engine
(1) For
‌ setting a door engine, make sure to take air from valve for door engine as
shown in “ATTACHED DATA 5-13”.
(2) When
‌ 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.
BM2110ABGEN
4 - 10
Do not alter the transmission control.

Refer to the "ATTACHED DATA 5-15" for detail of transmission control.
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4 - 11
11. TOE- BOARD
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.
* 6) ‌Make sure to drill the air release hole for parking brake control valve on the body
floor.
*
FOR FULL AIR BRAKE ONLY.
*
Refer to " ATTACHED DATA 5 - 16 " for detail regarding the toe-board setting.
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4 - 12
12. METER BOARD
1) At chassis delivery, the meter board is supported with 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 - 17, 18 ".
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4 - 13
13. 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 - 22 ".
4) The front and rear spring deflection charts are shown in

" ATTACHED DATA 5 - 21 " for body design.
5) The frame height from ground at front and rear axle are also shown in
" ATTACHED DATA 5 - 1, 23 " 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 - 19, 20 " for detail regarding the front and rear
suspensions.
BM2110ABGEN
4 - 14 - 1
14. FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK Fuse block
[ EXAMPLE ]
LOCATION OF THE CAB SIDE

The fuse block and the relay panel are located inside the instrument panel as shown
below.
(The figure shown below is for LHD vehicle. RHD vehicle is symmetrical to this figure.)
NOTE
• The figure mentioned above is example, consequently, for various particular items, check them
on the actual vehicle.
• Be sure to use each capacity fuse designated in the actual vehicle caution plate.
Never use the capacity fuse exceeding the designated one in the above, otherwise over current
may damage the harness wires, and fusible linkage wires are in the same.
BM2110ABGEN
4 - 14 - 2
Relay panel
POLE NUMBER
No. DESCRIPTION
OF CONNECTOR
1 4 UREA TUBE HTR RLY
2 - -
3 5 ABS EXH CUT RLY
4 4 RETARDER RLY4
5 4 U2 ACT PWR RLY
6 4 U2 ECU MAIN RLY
7 - -
8 4 ES MAIN RLY
9 5 STARTER CUT RLY
10 - -
11 4 AT N DMY RLY
12 4 AT N SIGN RLY
13 - -
14 4 ATM NEUTRAL RLY
15 - -
16 5 IG1-6
17 4 H-LP HI RLY
18 4 H-LP LO RLY
19 - -
20 - -
21 - -
22 - -
23 - -
24 - -
25 4 TAIL-2
26 4 ACC-2
27 - -
28 4 HEATER RLY
29 - -
30 4 HORN
31 - -
32 - -
NOTE
• The figure mentioned above is example, consequently, for various particular items, check
themon the actual vehicle.
BM2110ABGEN
4 - 14 - 3
2) LOCATION OF THE FUSIBLE LINK BLOCK

The fusible link block is located on left side of the rear bkt, driver’s floor as
shown below.
FUSIBLE LINK BLOCK
BM2110ABGEN
4 - 15 - 1
15. SPARE POWER TERMINALS

1) SPECIFICATION OF SPARE POWER SUPPLIES
If you must take an electrical power for the body from the chassis, take it from the spare power supply terminal.
(MAIN APPLICATION)
(MAIN APPLICATION)
APPLICABLE MODEL
APPLICABLE MODEL
WIRE SIZE & COLOR
WIRE SIZE & COLOR

MAX. CAPACITY (A)
MAX. CAPACITY (A)

TERMINAL MARK
TERMINAL MARK
(SPARE PARTS)
(SPARE PARTS)
(CONNECTOR)
(CONNECTOR)
CONNECTOR
CONNECTOR
POLE CODE
POLE CODE
COUPLING
COUPLING
TERMINAL
TERMINAL
PARTS No.
PARTS No.
PARTS No.
PARTS No.
REMARK
REMARK
CIRCUIT
CIRCUIT
H18 13 0.85 W- LOW C4T 0.7 0.50 B-
H17 15 0.85 R- HIGH CAH 0.12 0.50 R-
B-1 H21 WIPER MOTOR 15 0.85 LG- S8258-07270 S8258-07260 ALL MODEL RUN C35 2.9 0.50 Y-
H20 15 0.85 L- E C37 10 0.85 B-
H19 13 0.85 B- INT A-1 C38 HEAD LAMP RH 2.9 0.50 GR- S8256-04390 S8256-04380 ALL MODEL
H22 7 0.30 W- C4S 0.7 0.50 L-
B-2 WASHER PUMP MOTOR S8258-06820 - ALL MODEL
H23 7 0.30 GR- CC4 0.12 0.50 B-
%80 10 1.25 Y- C52 0.12 0.50 P-
%81 10 2.00 B- Z95 2.9 0.50 B-
B-3 %82 DOOR BRAKE 0.01~0.02 0.50 W- 282090-1 - ALL MODEL C4R 0.7 0.50 B-
%83 0.7 0.50 BR- C9Y 0.12 0.50 R-
%84 0.7 0.50 BR- C30 2.9 0.50 L-
V2A 7 2.00 BR- FROM CONNECTOR-(V2G) C32 10 0.85 B-
INSTRUMENT PANEL
V2C 7 1.25 G- FROM CONNECTOR-(V2J) A-2 C33 HEAD LAMP LH 2.9 0.50 W- S8256-04390 S8256-04380 ALL MODEL
V2D 7 2.00 B- FROM CONNECTOR-(V2K) C4Q 0.7 0.50 Y-
B-4 SPARE CABIN 82824-E0K90 82824-E0K80 ALL MODEL
V2E 7 1.25 Y- FROM CONNECTOR-(V2L) CC7 0.12 0.50 B-
V2F 7 1.25 R- FROM CONNECTOR-(V2M) C54 0.12 0.50 P-
V2B 7 1.25 W- FROM CONNECTOR-(V2H) Z94 2.9 0.50 B-
AGH 10 1.25 Y- MAX. CAPACITY ; (AGH)+(IOP) C28 0.7 0.85 L-
A-3 SIDE TURN RH S8258-07660 S8256-02930 ALL MODEL
AGK 7 0.85 R- MAX. CAPACITY ; (AGK)+(IOQ)+(AGL) C29 0.7 0.85 B-
CHASSIS SIDE
B-5 POWER CABIN 1 82824-E0K70 82824-E0K60 ALL MODEL
AGM 10 0.85 L- C26 0.7 0.85 Y-
A-4 SIDE TURN LH S8258-07660 S8256-02930 ALL MODEL
AGP 10 0.85 O- MAX. CAPACITY ; (AGP)+(IOK)+(AGQ) C27 0.7 0.85 B-
B-6 AQK POWER CABIN 2 30 3.00 B- S8256-02970 S8256-02960 ALL MODEL %C5 20 2.00 B-
I0P 10 0.50 Y- MAX. CAPACITY ; (AGH)+(IOP) %C8 7 0.85 G-
I0Q 7 0.50 R- MAX. CAPACITY ; (AGK)+(IOQ)+(AGL) %C4 10 1.25 Y-
B-7 ETC SUB POWER 1 82824-E1790 82824-E1760 ALL MODEL
I0S 10 0.50 B- A-5 %CB Rr COMB LAMP WH 7 0.85 R-B S8258-06030 S8258-06040 ALL MODEL
I0K 10 0.50 O- MAX. CAPACITY ; (AGP)+(IOK)+(AGQ) +KE 7 0.85 P-
B-8 I0T ETC SUB POWER 2 1 0.50 R- 82824-E0U30 S8258-06160 ALL MODEL %CD 7 0.85 R-
I0M 0.015~0.02 0.50 R-L 0.015A ; EURO5, 0.02A ; EURO3 %C9 10 1.25 L-
B-9 ETC SUB POWER 3 82824-E0U40 S8258-07320 ALL MODEL
I0J 7 0.50 R- A-6 U07 HORN Lo 10 0.50 G- S8258-07590 - ALL MODEL
A-7 U08 HORN Lo 10 0.50 B- S8258-07590 - ALL MODEL
A-8 U05 HORN Hi 10 0.50 G- S8258-07590 - ALL MODEL
A-9 U06 HORN Hi 10 0.50 B- S8258-07590 - ALL MODEL
AGL 7 0.85 R- MAX. CAPACITY ; (AGK)+(IOQ)+(AGL)
A-10 POWER CHASSIS 82824-E0M10 82824-E0M00 ALL MODEL
AGQ 7 0.85 O- MAX. CAPACITY ; (AGP)+(IOK)+(AGQ)
V2G 7 1.25 BR- FROM CONNECTOR-(V2A)
V2K 7 2.00 B- FROM CONNECTOR-(V2D)
V2H 7 1.25 W- FROM CONNECTOR-(V2B)
A-11 SPARE CHASSIS 82824-E0M30 82824-E0M20 ALL MODEL
V2L 7 1.25 Y- FROM CONNECTOR-(V2E)
V2J 7 1.25 G- FROM CONNECTOR-(V2C)
V2M 7 1.25 R- FROM CONNECTOR-(V2F)
%85 0.7 0.50 BR-
A-12 DOOR BRAKE 282080-1 282104-1 ALL MODEL
%86 0.7 0.50 BR-
[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.
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2) OUTLET POSITION AROUND INSTRUMENT PANEL

(1) Center of instrument panel
B-3
DOOR BRAKE B5
B7 power cabin1
ETC sub power1
B4
Spare cabin B6
power cabin2
UP
UP
RH FR
LH
B9
ETC sub power3
B8 UP
ETC sub power2
RH
UP
RH
Ｂ-2 Ｂ-１
WASHER PUMP MOTOR WIPER MOTOR
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3) OUTLET POSITION AROUND CHASSIS SIDE
A12 A11
VIEW 1 DOOR BRAKE M/V VIEW 3 Spare Chassis
A8,A9 A6,A7 HORN LO

HORN HI
VIEW 3 VIEW 4
↓ ↓
VIEW 1 →
VIEW 5 →
← VIEW 2
VIEW 2 A3,A4 VIEW 4 VIEW 5 A5

SIDE TURN LAMP TO RR COMB LAMP HARNESS
A1,A2 HEAD LAMP

A10 Power Chassis
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4) HOW TO TAKE ELECTRICITY FROM POWER SUPPLY CIRCUIT
[NOTE]
• We recommend 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.
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5) DETAIL OF CONNECTOR
(1) Outlet connector around instrument panel
CONNECTOR CONNECTOR
COUPLING COUPLING
TERMINAL TERMINAL
CONNECTOR CONNECTOR
B-1 B-6
S8258-07270 S8258-07260 S8256-02970 S8256-02960
-
B-2 B-7
S8258-06820 - 82824-E1790 82824-E1760
-
B-3 B-8
282090-1 - 82824-E0U30 S8258-06160
B-4 B-9
82824-E0K90 82824-E0K80 82824-E0U40 S8258-07330
B-5
82824-E0K70 82824-E0K60
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(2) Outlet connector around chassis side
CONNECTOR CONNECTOR
COUPLING COUPLING
TERMINAL TERMINAL
CONNECTOR CONNECTOR
-
A-1 A-7
S8256-04390 S8256-04380 S8258-07590 -
-
A-2 A-8
S8256-04390 S8256-04380 S8258-07590 -
-
A-3 A-9
S8258-07660 S8256-02930 S8258-07590 -
A-4 A-10
S8258-07660 S8256-02930 82824-E0M10 82824-E0M00
A-5 A-11
S8258-06030 S8258-06040 82824-E0M30 82824-E0M20
-
A-6 A-12
S8258-07590 - 282080-1 282104-1
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16. 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 flows to switches.)
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 INT.
MOTOR
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 short-
circuit in the fuse or burnut of harness. Do not take from the incorrect
terminal.
Refer to the recommended wiper and washer circuit for details.
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RECOMMENDED WIPER AND WASHER CIRCUIT
(PROVIDED BY BODY
MANUFACTURER)
WIPER MOTOR
(SUPPLIED BY OPTION)
WIPER RELAY
WIPER SUB HARNESS
(SUPPLIED BY OPTION)
EARTH JUNCTION RH
EARTH JUNCTION LH
WASHER MOTOR
WIPER SWITCH
FUSE
[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.
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17. ELECTRIC WIRING OF SPARE OUTLET

1) STANDARD WIRING CONFIGURATION
2) WIRING CONFIGURATION FOR INCREASED LOAD

Maximum added load is 170W.
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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.
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4) CONTROL CHART OF CONSUMED ELECTRIC POWER

CONTROL CHART OF CONSUMED ELECTRIC POWER
Reference
MODEL : Clarify if it is equipped or not.
Condition of running the vehicle at night when raining.
A B AxB
EQUIPPED ELECTRIC CONSUM- CONSUMED REMARK
No. ITEM CONDITION POWER PTION ELECTRIC
YES NO IN USE RATE POWER
(W) (%) (W)
1 HEAD LAMPS NIGHT 140 100 140
2 TAIL LAMPS NIGHT 90 100 90
3 FOG LAMPS NIGHT 140 100 140
4 CLEARANCE LAMPS NIGHT 60 100 60
5 LICENSE LAMP NIGHT 20 100 20
WHEN
6 STOP LAMPS OPERATING BRAKE. 16 10 1.6
WHEN CHANGING
7 TURN SIGNAL LAMPS RUNNING DIRECTION. 80 30 24
WHEN RUNNING
8 BACK-UP LAMP VEHICLE BACKWARD. 35 0 0
WHEN RUNNING
9 WIPER VEHICLE IN THE RAIN. 72 100 72
10 CURB LAMP NIGHT 100 40
11 STEP LAMP WHEN RIDING AND OFF.
12 READING LAMP NIGHT
13 AISLE LAMP NIGHT
14 LUGGAGE RACK LAMP NIGHT
15 RADIO WHEN
16 AUDIO THE MOST POWER
CONSUMING DEVICE
17 TV IS TURNED ON.
AIR CONDITIONING WHEN USED IN
18 (COOLER) SUMMER TIME.
WHEN USED IN
19 HEATER WINTER TIME.
20 TOILET WHEN USED.
21 REFRIGERATOR WHEN USED.
22 OTHER LAMPS NIGHT
23
24
25
TOTAL
TOTAL OF CONSUMED [ ] / 28V = A
AxB ELECTRIC POWER (W)
REQUIRING ADJUSTMENT OF
SELECTED ALTERNATOR : A OK 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
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CONTROL CHART OF CONSUMED ELECTRIC POWER

Example of use
for reference
MODEL : FC9J TZ
* Clarify if it is equipped or not.
Condition of running the vehicle at night when raining.
A B AxB
EQUIPPED ELECTRIC CONSUM- CONSUMED REMARK
No. ITEM CONDITION POWER PTION ELECTRIC
YES NO IN USE RATE POWER
(W) (%) (W)
1 HEAD LAMPS NIGHT 140 100 140
2 TAIL LAMPS NIGHT 90 100 90
3 FOG LAMPS NIGHT 140 100 140
4 CLEARANCE LAMPS NIGHT 60 100 60
5 LICENSE LAMP NIGHT 20 100 20
WHEN
6 STOP LAMPS OPERATING BRAKE. 16 10 1.6
WHEN CHANGING
7 TURN SIGNAL LAMPS RUNNING DIRECTION. 80 30 24
WHEN RUNNING
8 BACK-UP LAMP VEHICLE BACKWARD. 35 0 0
WHEN RUNNING
9 WIPER VEHICLE IN THE RAIN. 72 100 72
10 CURB LAMP NIGHT 40 100 40
11 STEP LAMP WHEN RIDING AND OFF. 20 0 0
12 READING LAMP NIGHT --- 100 ---
13 AISLE LAMP NIGHT 100 100 100
14 LUGGAGE RACK LAMP NIGHT --- 100 ---
15 RADIO WHEN
16 AUDIO THE MOST POWER 100
CONSUMING DEVICE
17 TV IS TURNED ON. 182 0
AIR CONDITIONING WHEN USED IN
18 (COOLER) SUMMER TIME. --- 100 ---
WHEN USED IN
19 HEATER WINTER TIME. --- 100 ---
20 TOILET WHEN USED. 50 30 15
21 REFRIGERATOR WHEN USED. 56 100 56
22 OTHER LAMPS NIGHT 80 100 80
23
24
25
TOTAL 838.6
TOTAL OF CONSUMED [838.6] / 28V = 29.95 A
AxB ELECTRIC POWER (W)
REQUIRING ADJUSTMENT OF
SELECTED ALTERNATOR : 60A or 90A OK 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
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18. ELECTRICAL WIRING DIAGRAMS

Refer to the workshop manual for electrical wiring diagrams.
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19. CAUTION FOR ELECTRICAL EQUIPMENT
Set up the electrical equipments on the body to keep the facilitation of

inspection and maintenance.
Be sure to observe the following instructions when installing electrical
equipments.
HEAD LAMP (OPTION)

• The head lamp and the nut are set as the option.
• Install it regularly to the body.
• Tightening torque
NUT (M6) = 7.0 ± 2.0 N·m (71 ± 20 kgf·cm)
• For more details, please consult your nearest HINO sales outlet.
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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.
1) Detail of rear combination lamp
Unit : mm
HOLE FOR STAY

INSTALLING PARTS NUMBER OF VALVE
TYPE COMBINATION LAMP
RIGHT LEFT
The inside of indicates the marking

position of the device number
DEVICE NO.
POSITION OF
STAY INSTALLING
SIDE REFLECTOR
TAPE
OUTSIDE OF (for water proof)
THE VEHICLE
BACK LAMP
TAIL & STOP LAMP
TURN & HAZARD

SIGNAL LAMP HOLE FOR STAY
REAR REFLECTOR
INSTALLING
TAPE 141.5
(for water proof)
NOTE
• Drawing shows rear combination lamp, RH side.
And, LH side is symmetrical this drawing.
• About installation, conforms to all applicable laws and regulation of the country in which the
vehicle is to be used.
• Shading shows tape. Make sure you remove this tape after mounting the lamp.
• Please assemble so that side reflector is on the outside.
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2) Detail of light emission area
124.6
STOP LAMP
BACK LAMP
TURN & HAZARD TAIL LAMP
REAR SIGNAL LAMP
REFLECTOR
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LICENSE PLATE LAMP (OPTION)
Unit : mm
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BACK-UP BUZZER (OPTION)
If you move or install the back-up buzzer, or modify the surrounding parts of
the chassis, observe the precautions as followings.
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.
POSITION
Install the back-up buzzer in a position where it is not exposed to splashing
with muddy water, stone or water.
PRECAUTION FOR PAINTING

Make sure that the buzzer should be covered during painting to protect the
paint coming into buzzer from sound emitting hole for avoiding failure of no
sound.
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HARNESS WIRING
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20. FRAME
Observe the instruction given in the Common Manual for chassis frame drilling
and welding.
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 FC9J BUS SERIES.
For the detail of the frame configuration, refer to the " ATTACHED DATA 5 - 24 ".
1) WHAT IS THE CHASSIS FRAME
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2) DRILLING THE FRAME
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3) WELDING THE CHASSIS FRAME
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4) OTHER PRECAUTIONS FOR DRILLING AND WELDING
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5) FRAME ALTERATION OR MODIFICATION
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21. EXHAUST SYSTEM
• ‌The vehicle has the Catalyst muffler only EURO5 model.

The exhaust system becomes very hot during driving.
When mounting a bus body, observe the following procedures to
prevent vehicle fires.
• ‌Modifying or altering the exhaust system will have a major effect
on vehicle performance and external noise.
As a rule, the exhaust system must not be modified.
• ‌In some countries, external noise control regulations prohibit any
modification of the exhaust system.
• ‌When alter tail pipe should see "ATTACHED 5-25" to prevent
entering water even washing a vehicle.
Also the direction of tail pipe end is provided for provision for
noise, therefore, when reinstall tail pipe should see
"ATTACHED 5-25".
1) CLEARANCES FROM THE EXHAUST SYSTEM

• ‌When mounting a body or installing related equipment, maintain
the following clearances from the exhaust system.
a) ‌For wood, rubber, cloth and resin parts, maintain a clearance
of at least 200 mm.
b) For
‌ brake hoses including nylon tube, fuel hoses and electrical
harness, maintain a clearance of at least 200 mm.
c) For
‌ any other equipment that may be affected by heat, maintain
a clearance of at least 80 mm.
d) If
‌ it is impossible to observe the above clearances, fit heat
insulators between the relevant parts.
The heat insulators structure must be preventing the hear and
occur a fire from leaking exhaust gas by rust and damaged.
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2) MOUNTING A BODY PARTS OR EQUIPMENT NEAR THE MOUTH OF THE

EXHAUST TAIL PIPE
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3) MODIFY OR ALTERING THE EXHAUST SYSTEM
FOR EURO3
FOR EURO5
FOR EURO5
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MODEL : FC9JK7Z-BB9HFAA, FC9JK7Z-BX9HFAA
MODEL : FC9JL7Z-BB9HFAA, FC9JL7Z-BX9HFAA
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MODEL : FC9JG7Z-CB9LFAA, FC9JG7Z-CX9LFAA, FC9JK7Z-CB9LFAA,

FC9JK7Z-CX9LFAA, FC9JL7Z-CB9LFAA
FOR COLOMBIA
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MODEL : FC9JK7Z-CB9LFAA, FC9JK7Z-CX9LFAA

FOR PERU
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22. PROCEDURE OF RUST PREVENTIVE TREATMENT
When shipping vehicle to customer, make sure to carry out chassis rust
preventive treatment to the following parts for anti-rust of chassis.
1) ‌Touch up scratch of paint.
Even if carries out final paint of chassis, may rust from scratch of paint.
When there is scratch of paint, carry out chassis anticorrosive processing after
touch up of paint by Eporakku 100R of Tokyo Paint or equivalent material.
2) ‌Carry out 2nd anti-rust treatment.
Parts to be painted and kind of paint for anti-rust treatment as follows;

THICKNESS OF
PARTS KIND OF PAINT CONDITION
THE PAINT
• Chassis frame
(cross member, side rail)
• Chassis parts
(except parts mentioned Tectil or
Wax 50μm or more Wet
following table 1.) equivalent
• The bottom of body ﬂoor
• Leaf spring
(paint between each leaves)
SB coat of
• Inside of front and rear
Tokyo
tire house Under
kagakutoryo 1000μm or more Dry
• The bottom of body ﬂoor coat
Co. or
at front and rear axle
equivalent
Caution for painting.
Mask at a functional component according to following table 1.

TABLE 1.
PARTS MANAGEMENT FOR PAINTING
Brake valve and exhaust port
Air tank water drain cock and drain linkage parts
Bellows of air spring
Vehicle height control valve and exhaust port of sensor
Exhaust port of leveling valve
Opening of drain hose
Caution plates
Tire and wheel
Brake drum
Radiator and cooling fun
Masking
Nylon tube and joints
Check valve
Harness and connecters
Exhaust muffler and tail pipe
Propeller shaft and sliding yoke
Engine unit and inside of engine room
Exhaust port of air drier
Fuel pre-filter and fuel hoses
Hub
Wheel bolt and nut
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23. ATTACHMENT OF THE PACKED PARTS
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

2.PACKAGE PARTS AS OPTION
NO. PART NO. PARTS NAME Q'TY REMARKS
1 81110-E0E80 HEADLAMP ASSY, RH 1
2 81150-E0E80 HEADLAMP ASSY, LH 1
For head lamp and setting parts.
3 SZ101-06069 BOLT 2
4 SZ178-06001 NUT 6
5 81550-E0450 LAMP ASSY, RR COMBINATION, RH 1
6 81560-E0450 LAMP ASSY, RR COMBINATION, LH 1
For rear combination lamp and setting parts.
7 91671-80830 BOLT, FLANGE W/WASHER 4
8 94151-80800 NUT, FLANGE 4
9 81270-37171 LAMP ASSY, LICENSE PLATE 1
For license lamp and setting parts.
10 90981-16029 BULB 1
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5. ATTACHED DATA
1. CHASSIS DRAWING
2. FLOOR INSPECTION HOLES AND BODY EXTERIOR OPENING
3. WHEEL HOUSE
4. SPLASH GUARDS
5. INSTALLATION PROCEDURE OF ENGINE HOOD & INSPECTION LID
6. RADIATOR SETTING
7. FUEL TANK SETTING
9. BATTERY SETTING
10. STEERING CONTROL LINKAGE SETTING
11. CLUTCH CONTROL & RESERVOIR TANK SETTING
12. POWER STEERING, OIL RESERVOIR SETTING
13. SERVICE BRAKE COMPONENT
14. BRAKE PIPING DIAGRAM
16. TOE-BOARD SETTING (TEMPORARY BRACKET)
17. OPERATING CONTROLS SETTING
18. INSTRUMENT CLUSTER & STEERING COLUMN SETTING
19. FRONT SUSPENSION'S PARTICULAR WITH STABILIZER
20. REAR SUSPENSION'S PARTICULAR WITH STABILIZER
21. CHARACTERISTIC OF SPRING
22. TRAVEL RANGE OF SPRING
23. FRAME HEIGHT FROM GROUND
24. CHASSIS FRAME ASSY
25. EXHAUST SYSTEM
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5. ATTACHED DATA 5 - 1 - 1
1. CHASSIS DRAWING
Unit : mm
MODEL : FC9JK7Z-BB9HFAA
GROUND HEIGHT,
FRAME UPPER SURFACE
[ NOTE ]
MODEL TIRE WHEEL OH FR Tr RR Tr OW,TW
Hf0 Hf Hr Hr0 • The dimension shows design figure under the chassis condition.
17.5×6.75-135 765 790 915 990 1900 1800 1660 2180
9.5R17.5 129/127
17.5×6.75-135 ALLOY 765 790 915 990 1900 1815 1680 2205 • When
‌ selected or fitted optional equipment or local parts such as tire, leaf
spring, fuel tank and etc., should be examined the frame height from ground by
FC9JK7Z-BB9HFAA 225/70R19.5 130/128 19.5×6.75-136 750 775 900 970 1890 1815 1665 2180
17.5×6.75-135 740 765 890 965 1880 1800 1660 2170
235/75R17.5 132/130
17.5×6.75-135 ALLOY 740 765 890 965 1880 1820 1680 2200
body builder.
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MODEL : FC9JK7Z-BX9HFAA
Unit : mm
GROUND HEIGHT,
FRAME UPPER SURFACE
[ NOTE ]
17.5×6.75-135 765 790 915 990 1905 1800 1660 2180
9.5R17.5 129/127
17.5×6.75-135 ALLOY 765 790 915 990 1900 1815 1680 2205 • When
FC9JK7Z-BX9HFAA 225/70R19.5 130/128 19.5×6.75-136 750 775 900 970 1890 1815 1665 2180
17.5×6.75-135 735 765 890 965 1880 1800 1660 2170
235/75R17.5 132/130
17.5×6.75-135 ALLOY 735 765 890 965 1880 1820 1680 2200
body builder.
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MODEL : FC9JL7Z-BB9HFAA
Unit : mm
GROUND HEIGHT,
FRAME UPPER SURFACE
[ NOTE ]
17.5×6.75-135 765 790 920 985 1900 1800 1660 2180
9.5R17.5 129/127
17.5×6.75-135 ALLOY 765 790 920 985 1900 1815 1680 2205 • When
FC9JL7Z-BB9HFAA 225/70R19.5 130/128 19.5×6.75-136 750 775 900 965 1885 1815 1665 2180
17.5×6.75-135 740 765 895 960 1875 1800 1660 2170
235/75R17.5 132/130
17.5×6.75-135 ALLOY 740 765 895 960 1875 1820 1680 2200
body builder.
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MODEL : FC9JL7Z-BX9HFAA
Unit : mm
GROUND HEIGHT,
FRAME UPPER SURFACE
[ NOTE ]
17.5×6.75-135 765 790 915 985 1900 1800 1660 2180
9.5R17.5 129/127
17.5×6.75-135 ALLOY 765 790 915 985 1900 1815 1680 2205 • When
FC9JL7Z-BX9HFAA 225/70R19.5 130/128 19.5×6.75-136 750 775 900 965 1885 1815 1665 2180
17.5×6.75-135 740 765 890 960 1875 1800 1660 2170
235/75R17.5 132/130
17.5×6.75-135 ALLOY 740 765 890 960 1875 1820 1680 2200
body builder.
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MODEL : FC9JG7Z-CB9LFAA
Unit : mm
GROUND HEIGHT,
FRAME UPPER SURFACE
[ NOTE ]
17.5×6.75-135 755 790 915 985 1905 1800 1660 2180
9.5R17.5 129/127
17.5×6.75-135 ALLOY 755 790 915 985 1905 1815 1680 2205 • When
FC9JG7Z-CB9LFAA 225/70R19.5 130/128 19.5×6.75-136 740 775 900 965 1890 1815 1665 2180
17.5×6.75-135 730 765 890 960 1880 1800 1660 2170
235/75R17.5 132/130
17.5×6.75-135 ALLOY 730 765 890 960 1880 1820 1680 2200
body builder.
BM2110ABGEN
5 - 1 - 6
MODEL : FC9JG7Z-CX9LFAA
Unit : mm
GROUND HEIGHT,
FRAME UPPER SURFACE
[ NOTE ]
17.5×6.75-135 755 790 915 985 1900 1800 1660 2180
9.5R17.5 129/127
17.5×6.75-135 ALLOY 755 790 915 985 1900 1815 1680 2205 • When
FC9JG7Z-CX9LFAA 225/70R19.5 130/128 19.5×6.75-136 740 775 900 965 1885 1815 1665 2180
17.5×6.75-135 730 765 890 960 1875 1800 1660 2170
235/75R17.5 132/130
17.5×6.75-135 ALLOY 730 765 890 960 1875 1820 1680 2200
body builder.
BM2110ABGEN
5 - 1 - 7
MODEL : FC9JK7Z-CB9LFAA
Unit : mm
GROUND HEIGHT,
FRAME UPPER SURFACE
[ NOTE ]
17.5×6.75-135 760 790 915 985 1900 1800 1660 2180
9.5R17.5 129/127
17.5×6.75-135 ALLOY 760 790 915 985 1900 1815 1680 2205 • When
FC9JK7Z-CB9LFAA 225/70R19.5 130/128 19.5×6.75-136 745 775 900 970 1885 1815 1665 2180
17.5×6.75-135 735 765 890 960 1875 1800 1660 2170
235/75R17.5 132/130
17.5×6.75-135 ALLOY 735 765 890 960 1875 1820 1680 2200
body builder.
BM2110ABGEN
5 - 1 - 8
MODEL : FC9JK7Z-CX9LFAA
Unit : mm
GROUND HEIGHT,
FRAME UPPER SURFACE
[ NOTE ]
17.5×6.75-135 760 790 915 985 1900 1800 1660 2180
9.5R17.5 129/127
17.5×6.75-135 ALLOY 760 790 915 985 1900 1815 1680 2205 • When
FC9JK7Z-CX9LFAA 225/70R19.5 130/128 19.5×6.75-136 745 775 900 970 1885 1815 1665 2180
17.5×6.75-135 735 765 890 960 1875 1800 1660 2170
235/75R17.5 132/130
17.5×6.75-135 ALLOY 735 765 890 960 1875 1820 1680 2200
body builder.
BM2110ABGEN
5 - 1 - 9
MODEL : FC9JL7Z-CB9LFAA
Unit : mm
GROUND HEIGHT,
FRAME UPPER SURFACE
[ NOTE ]
17.5×6.75-135 760 790 915 975 1900 1800 1660 2180
9.5R17.5 129/127
17.5×6.75-135 ALLOY 760 790 915 975 1900 1815 1680 2205 • When
FC9JL7Z-CB9LFAA 225/70R19.5 130/128 19.5×6.75-136 750 775 900 960 1885 1815 1665 2180
17.5×6.75-135 735 765 890 950 1875 1800 1660 2170
235/75R17.5 132/130
17.5×6.75-135 ALLOY 735 765 890 950 1875 1820 1680 2200
body builder.
BM2110ABGEN
5 - 2 - 1
2. FLOOR INSPECTION HOLES AND BODY

Unit : mm
EXTERIOR OPENING
MODEL : F C9JG7Z-CB9LFAA,
FC9JK7Z-CB9LFAA,
FC9JL7Z-CB9LFAA
[ 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.
BM2110ABGEN
5 - 2 - 2
MODEL : F
C9JG7Z-CX9LFAA,
Unit : mm
FC9JK7Z-CX9LFAA
[ NOTE ]
BM2110ABGEN
5 - 2 - 3
MODEL : F
C9JK7Z-BB9HFAA,
Unit : mm
FC9JL7Z-BB9HFAA
[ NOTE ]
BM2110ABGEN
5 - 2 - 4
MODEL : F
C9JK7Z-BX9HFAA,
Unit : mm
FC9JL7Z-BX9HFAA
[ NOTE ]
BM2110ABGEN
5-3
3. 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.)
DETAIL OF FRONT WHEEL HOUSE (IN CASE OF FULL AIR BRAKE)

Make sure to keep clearance min. 50mm with brake hose.
BM2110ABGEN
5-4
4. SPLASH GUARDS
Unit : mm
AIR DRYER (CNT)
For protecting air cleaner, engine, air tank and fuel tank from splashing
water or mud, must be installed splash prevention covers.
BM2110ABGEN
5-5
5. INSTALLATION PROCEDURE OF ENGINE HOOD & INSPECTION LID

Unit : mm
RECOMMENDED MANNER TO PROVIDE ENGINE HOOD & INSPECTION LID

1) ‌Keep min. 50mm clearance with each part of the engine.
2) ‌Keep min. 50mm clearance with max. movement position of the generator.
3) ‌Provide inspection lid for engine oil level gauge, pouring of engine oil and radiator cap.
4) ‌Structure of the engine hood ;
• Install 50mm thickness of glass wool under the engine hood.
• Steel plate should be 1.2mm thickness.
• Detail of recommended structure of the engine hood see above figure.
[NOTE] 5) ‌Engine hood and inspection lid should seal completely by sponge rubber etc to avoid
The shape which is mentioned in this drawing transfer noise, heat and dust to passenger room.
are example for your reference. 6) ‌When install engine hood, take great care for the ventilation (air flow) around engine.
Otherwise the temperature in the engine room become high, it will cause the
overheating of the engine.
BM2110ABGEN
5 - 6 - 1
6. RADIATOR SETTING
Unit : mm
(for EURO3)
BM2110ABGEN
5 - 6 - 2
(for EURO5)
Unit : mm
BM2110ABGEN
5 - 7 - 1
7. FUEL TANK SETTING

Unit : mm
BM2110ABGEN
5 - 7 - 2
FUEL TANK SETTING

Unit : mm
BM2110ABGEN
5 - 7 - 3
FUEL TANK SETTING

Unit : mm
BM2110ABGEN
5-8

Unit : mm
BM2110ABGEN
5 - 9 - 1
9. BATTERY SETTING
Capacity : 432kC {120Ah}
<with battery cover>
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 4-6 BATTERY SETTING.
BM2110ABGEN
5 - 9 - 2
Capacity : 432kC {120Ah}

<without battery cover>
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 4-6 BATTERY SETTING.
BM2110ABGEN
5 - 10
10. STEERING CONTROL LINKAGE SETTING

Unit : mm
PRECAUTION
WHEN MOUNTING THE BODY,
CONSIDER THE LINK MOTION
OF STEERING AND INSTALL
THE BODY MEMBER.
Make sure that there is a clearance of at
least 40 mm between the body parts and
these steering devices when they are at
maximum displacement.
BM2110ABGEN
5 - 11
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.
BM2110ABGEN
5 - 12
12. POWER STEERING, OIL RESERVOIR SETTING

Unit : mm
BM2110ABGEN
5 - 13 - 1
13. SERVICE BRAKE COMPONENT

Unit : mm
MODEL : F
C9JK7Z-BB9HFAA, FC9JK7Z-BX9HFAA
[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.
BM2110ABGEN
5 - 13 - 2
MODEL : F
C9JL7Z-BB9HFAA, FC9JL7Z-BX9HFAA
Unit : mm
[NOTE]
BM2110ABGEN
5 - 13 - 3
MODEL : F
C9JG7Z-CB9LFAA, FC9JG7Z-CX9LFAA
Unit : mm
[NOTE]
BM2110ABGEN
5 - 13 - 4
MODEL : F
C9JK7Z-CB9LFAA, FC9JK7Z-CX9LFAA
Unit : mm
[NOTE]
BM2110ABGEN
5 - 13 - 5
MODEL : F
C9JL7Z-CB9LFAA
Unit : mm
[NOTE]
BM2110ABGEN
5 - 14
14. BRAKE PIPING DIAGRAM (ABS LESS)

FULL AIR BRAKE
BM2110ABGEN
5 - 15 - 1
Refer to detail of the transmission control

drawing based on following table.
See the following pages for details.
5-16
PRODUCTION TRANSMISSION
CODE CONTROL
STD OPT
FC9JK7Z-BB9HFAA TC-1
FC9JK7Z-BX9HFAA TC-3
FC9JL7Z-BB9HFAA TC-1
FC9JL7Z-BX9HFAA TC-3
FC9JG7Z-CB9LFAA TC-1 TC-2
FC9JG7Z-CX9LFAA TC-3
FC9JK7Z-CB9LFAA TC-1 TC-2
FC9JK7Z-CX9LFAA TC-3
FC9JL7Z-CB9LFAA TC-1 TC-2
BM2110ABGEN
5 - 15 - 2
Unit : mm
BM2110ABGEN
5 - 15 - 3
BM2110ABGEN
5 - 15 - 4
Unit : mm
BM2110ABGEN
5 - 15 - 5
BM2110ABGEN
5 - 15 - 6
Unit : mm
BM2110ABGEN
5 - 15 - 7
BM2110ABGEN
5 - 16 - 1
16. TOE-BOARD SETTING (TEMPORARY BRACKET)

Unit : mm
[NOTE]
(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.
(6) ‌Make sure to drill the air release hole for
parking brake control valve on the body
floor.
BM2110ABGEN
5 - 16 - 2
TOE-BOARD SETTING (TEMPORARY BRACKET)

Unit : mm
BOARD SUB ASSY, FLOOR
BM2110ABGEN
5 - 17 - 1
17. OPERATING CONTROLS SETTING
<MT>
Unit : mm
<AT>
BM2110ABGEN
5 - 17 - 2
COMBINATION METER LAYOUT
<FOR EURO 3 VEHICLE> LOW FUEL TURN SIGNAL & HAZARD（R) FRONT FOG LIGHT

OVERHEAT
TURN SIGNAL & HAZARD（L)
SRS AIRBAG HIGH BEAM & PASSING REAR FOG LIGHT
EXHAUST BRAKE SEAT BELT
WARM UP
SPEEDOMETER
RETADER
TACHO METER
OVERDRIVE(O/D OFF)
AIR PRESSURE BATTERY CHAGE
PARKING BRAKE COOLANT LEVEL
CRUISE CONTROL
OIL PRESSURE
CRUISE CONTROL CHECK ENGINE OR MIL

(Malfunction Indicator Light)
PREHEAT FUNCTION
/PREHEAT FUNCTION ABNOTMALITY WARNING
BRAKE FLUID LEVEL
BRAKE PRIOLITY
PTO VEHICLE CONTROL
ES START
ABS(ANTI‐LOCK BRAKE SYSTEM) TURBO BOOST
FUEL GAGE
WATER TEMPERATURE GAGE DRAINING FUEL FILTER WATER
CHECK AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSION OIL TEMPERATURE
FOR EURO5 VEHICLE
OIL PRESSURE EXAUST BRAKE / WARM UP
CHECK ENGINE OR MIL (Malfunction Indicator Light )
AIR PRESSURE RETARDER
SRS AIRBAG
OVER HEAT FRONT FOG LIGHT
ABS (ANTI‐LOCK BRAKE SYSTEM)
HIGH BEAM & PASSING
SEAT BELT
BATTERY CHARGE REAR FOG LIGHT
TURN SIGNAL & HAZARD (L)
TURN SIGNAL & HAZARD (R)
AdBlue
BRAKE FLUID LEVEL
PARKING BRAKE
PREHEAT FUNCTION
/ PREHEAT FUNCTION ABNORMALITY WARNING
SPEEDOMETER
TACHO METER
FUEL GAGE ES START
CRUISE CONTROL
/ AUTOMATIC TRANSMISSION OIL TEMPERATURE (A/T VEHICLE)
CRUISE CONTROL
WATER TEMPERATURE GAGE OVERDRIVE (O/D) OFF (A/T VEHICLE)
SCR SYSTEM
BM2110ABGEN
5 - 18
18. INSTRUMENT CLUSTER & STEERING COLUMN SETTING

Unit : mm
BM2110ABGEN
5 - 19
19. FRONT SUSPENSION'S PARTICULAR WITH STABILIZER

Unit : mm
MODEL : ALL MODEL
[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.
BM2110ABGEN
5 - 20
20. REAR SUSPENSION'S PARTICULAR WITH STABILIZER

Unit : mm
MODEL : ALL MODEL
[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.
BM2110ABGEN
5 - 21 - 1
21. CHARACTERISTIC OF SPRING
1) SPRING CHARACTERISTICS
SPRING COMBINATION
Refer to SPRING CHARACTERISTICS CHART based on following table.
SPRING COMBINATION TABLE

FRONT REAR
MODEL
STD STD
FC9JKUZ F1(FTL) R1(RTL)
NOTE
SYMBOL SPECIFICATION
FTL TAPERLEAF SPRING
FML MULTI LEAF SPRING
FRT RAINFORCED TAPERLEAF SPRING
FRM RAINFORCED MULTILEAF SPRING
RML MULTI LEAF SPRING
RTL TAPERLEAF SPRING
RRM RAINFORCED MULTILEAF SPRING
AIR AIR SPRING
BM2110ABGEN
5 - 21 - 2
CHARACTERISTIC OF SPRING
FRONT LEAF SPRING
MODEL : ‌ALL MODEL
F1
BM2110ABGEN
5 - 21 - 3
CHARACTERISTIC OF SPRING
REAR LEAF SPRING
MODEL : ‌ALL MODEL
R1
BM2110ABGEN
5 - 22
22. TRAVEL RANGE OF SPRING
BM2110ABGEN
5 - 23 - 1
23. FRAME HEIGHT FROM GROUND

MODEL ： FC9JG7Z
　　　　　　 FC9JK7Z
　　　　　　 FC9JL7Z
[ AT FRONT AXLE ]
・TIRE ： ① 9.5R17.5-129/127
・TIRE ： ② 235/75R17.5
・TIRE ： ③ 225/70R19.5
・SUSPENSION:LONG TAPERED
LEAF SPRING [STD]
FRAME UPPER
H
　　　　Ｆ１
(mm)
900
[FRAME HEIGHT FROM GROUND]
③
800
① 787.0
③ 768.7
② 763.9
① 733.1
① ③ 714.8
② 710.2
700 ②
15.7 30.9
0 10 20 30 40 50 (kN)
[ SPRING MASS ]
BM2110ABGEN
5 - 23 - 2
FRAME HEIGHT FROM GROUND

MODEL ： FC9JG7Z
　　　　　　 FC9JK7Z
　　　　　　 FC9JL7Z
[ AT REAR AXLE ]
・TIRE ： ① 9.5R17.5-129/127
・TIRE ： ② 235/75R17.5
・TIRE ： ③ 225/70R19.5
・SUSPENSION:LONG TAPERED
LEAF SPRING [STD]
FRAME UPPER
H
　　　　R１
(mm)
900
③
① 852.5
[FRAME HEIGHT FROM GROUND]
③ 834.2
② 829.9
800
①
① 744.0
②
③ 725.7
② 720.5
700
12.5 57.4
0 10 20 30 40 50 60 (kN)
[ SPRING MASS ]
BM2110ABGEN
5 - 24 - 1
24. CHASSIS FRAME ASSY

Unit : mm
MODEL : FC9JG7Z
BM2110ABGEN
5 - 24 - 2
DETAIL OF CROSSMEMBER
Unit : mm
MODEL : FC9JG7Z
BM2110ABGEN
5 - 24 - 3
CHASSIS FRAME ASSY

Unit : mm
MODEL : FC9JK7Z
BM2110ABGEN
5 - 24 - 4
Unit : mm
MODEL : FC9JK7Z
BM2110ABGEN
5 - 24 - 5
CHASSIS FRAME ASSY

Unit : mm
MODEL : FC9JL7Z
BM2110ABGEN
5 - 24 - 6
Unit : mm
MODEL : FC9JL7Z
BM2110ABGEN
5 - 25 - 1
25. EXHAUST SYSTEM

Unit : mm
MODEL : FC9JK7Z-BB9HFAA, FC9JK7Z-BX9HFAA
MODEL : FC9JL7Z-BB9HFAA, FC9JL7Z-BX9HFAA
BM2110ABGEN
5 - 25 - 2
MODEL : FC9JG7Z-CB9LFAA, FC9JG7Z-CX9LFAA, FC9JK7Z-CB9LFAA, FC9JK7Z-CX9LFAA, FC9JL7Z-CB9LFAA

FOR COLOMBIA
BM2110ABGEN
5 - 25 - 3
MODEL : FC9JK7Z-CB9LFAA, FC9JK7Z-CX9LFAA

FOR PERU
BM2110ABGEN
5 - 25 - 4
EXHAUST SYSTEM
Unit : mm
MODEL : FC9JG7Z-CB9LFAA, FC9JG7Z-CX9LFAA, FC9JK7Z-CB9LFAA, FC9JK7Z-CX9LFAA, FC9JL7Z-CB9LFAA
Adblue tank
BM2110ABGEN

BM2110ABGENFIG1

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BM2110ABGEN

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

Consequently, please discard the current Body Mounting Manual

1. Position of the engine number has been corrected. (Chapter 1-2)

• Technical instructions for Hino bus chassis for modification and

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

• The vehicle has installed electronic equipments such as the vehicle's

1. 1) BODY DESIGN AND CONSTRUCTION 1-1

2) NEVER MODIFY SAFETY PARTS 1-2

3) ENGINE AIR INTAKE SYSTEM 2-3

8) BRAKE SYSTEM 2-8

2) UNPAINTED COMPONENTS 3-2

3) ELECTRICAL PARTS 3-3

4) FORCED DRYING 3-4

5) PAINTING THE WHEEL DISC 3-5

5) LAYOUT OF STRUCTURAL ELEMENTS 4-5

GVM & DRIVE CODE

Located at the right under

EMISSION CONTROL EURO3 EURO5

* : See next page 1 - 4 for detail of vehicle capacity.

4. DETAIL OF VEHICLE CAPACITY

FRONT 3,600 STD

TIRE FRONT 3,800

1. BASIC POINTS OF BUS BODY

1. BASIC POINTS OF BUS BODY

2. WEIGHT DISTRIBUTION ON FRONT AXLE & HEIGHT OF CENTER

WEIGHT HEIGHT OF GRAVITA - RECOMMENDED

CALCULATION CHART (UNLADEN)

The height of ∑ Moments

1) CONSIDERATION OF WEIGHT ADJUSTMENT

2) INSTALLATION OF ANCILLARY HEAVY MACHINERY OR EQUIPMENT

4) INSPECTION COVERS AND LIDS

When making the body structure, remember such things as positioning

(1) Checking engine oil, filling and removing oil.

ENGINE OIL LEVEL GAUGE

ADBLUE TANK (LH) ※IF EQUIPPED

5) INSTALLATION OF FRONT AND REAR SPLASH GUARD

AIR DRYER (CNT) ADBLUE TANK (LH)

6) REDUCTION OF INTERIOR NOISE LEVEL

4. FITTING THE BODY

5. POINTS TO NOTE ON ELECTRIC WELDING

1) ‌Procedure before welding

(3) Disconnect the negative terminal of the battery.

(4) Wait more than 90 seconds.

(5) Dismount fuse indicated in the label next page.

DISMOUNT THESE FUSES

2) ‌Ground of the Welding Equipment

5) Final Inspection after Welding

REFERENCE FOR FLOW OF CURRENT WITH ELECTRIC WELDING

6. NOTES ON SYSTEM CONTROL COMPUTERS

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

7. PRECAUTION FOR "ECU" WHEN MOUNTING OF BODY

1) Precaution for engine's computer

8. PRECAUTION FOR THE FUEL HOSE

Be sure to observe the following notes, if it will be changed a fuel hose by a

Always use the fuel hose of the HINO genuine parts.

The following figure is an example of genuine parts.

• ‌The rubber hoses which dose not contain a metal element.

• Precaution for preventing to paint the AdBlue®-SCR system.

• Handling of computers (ECU)

CONDITION OF FORCED DRYING PAINT HANDLING OF COMPUTER

• INSIDE TEMPERATURE OF THE : 120°C

1) ‌After completing the vehicle installation, shipment is to be made after checks

11. PRECAUTION FOR EXHAUST SYSTEM

2. WEIGHT DISTRIBUTION ON FRONT AXLE & HEIGHT OF CENTER

1) ‌Procedure before welding

2) ‌Ground of the Welding Equipment

7. PRECAUTION FOR "ECU" WHEN MOUNTING OF BODY

• ‌The rubber hoses which dose not contain a metal element.

1) ‌After completing the vehicle installation, shipment is to be made after checks

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