body mounting manual - hino.com.co · device on hino bus chassis (hereinafter collectively referred...

COMMON to all HinoBus Models

Body Mounting Manual

KC-AA014A

KC-AA014A

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

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

2009 - 07

KC-AA014A

Purpose

This manual is provided to Body and Equipment Manufacturers, including inter-mediate and/or final stage manufacturers, (hereinafter collectively referred to as Body and Equipment Manufacturers), to provide:

• Technical instructions for Hino bus chassis for mounting of bodies and modification.• An aid to Body and Equipment Manufacturers for producing safe vehicles under their

own discretion and responsibility.• Other general advice for installation, modification, or alteration.

When Body and Equipment Manufacturers install any body or other equipment or device on Hino bus chassis (hereinafter collectively referred to as Hino Chassis), or modify or alter a Hino Chassis.

Important

This manual contains the instructions commonly applicable to all Hino bus models.

Peculiar instructions such as chassis layout drawings, chassis mass, precautions, etc. for each model, are given separately in the peculiar body mounting manuals for each vehicle model (hereinafter collectively referred to as the "Manual for each model").

Therefore this manual should be used together with the Manual for each model series. (Details of construction of Hino's Body Mounting Manual are mentioned at the last part of this chapter.)

• The Manuals for each model is available at authorized Hino distributor.• For more information on mounting bodies and equipment or on chassis modifications,

refer to the appropriate workshop manuals, parts catalog, maintenance guides and owner's or driver's manual.

• The information in this manual is accurate to the best of Hino's Knowledge at the time of going to press. Hino reserves the right to modify any and all information without notice and without obligation.

• Should more detailed data or information be needed, please contact authorized Hino distributor.

ABOUT THIS MANUAL

KC-AA014A

Warning

• It is the responsibility of the body and equipment manufacturer or the modification company, to make sure that the completed vehicle, with body and equipment, or after modification, conforms to all applicable laws and regulations of the country in which the vehicle is to be used (e.g. regulations on lighting, tilt, overall size, axle load, external noise control, etc.)

• This manual does not guarantee the safety of a Hino Chassis which has been installed, modified, or altered by Body and Equipment Manufacturers.

• This manual does not affect that the ultimate responsibility for the manufacture and mounting of the body, installation, modification, or alteration on a Hino Chassis devolves upon the Body and Equipment Manufacture.

• Each individual Body and Equipment Manufacture has the sole responsibility for the design, functions, materials and work concerning the body and equipment.

• Hino Motors, Ltd. does not assume any liability whatsoever for any injury to persons or damage to property caused as a result of the utilization of this manual.

ABOUT THIS MANUAL

KC-AA014A

ABOUT THIS MANUAL

COMMON to all HinoBus Models

Body Mounting Manual

KC-AA014A

BODY MOUNTING MANUAL

KK-RM201

BUS CHASSIS

MODELRM1E SERIES

COMMON TO ALL HINO BUSESBODY MOUNTING

This manual contains the basic common instructions to apply to all Hino bus models for installation, mounting, modification, or alteration.

MODEL SERIESBODY MOUNTING MANUAL

This manual contains the peculiar chassis specifications and data for each model.

CONSTRUCTION OF HINO BODY MOUNTING MANUALS

KC-AA014A

1. GENERAL PRECAUTIONS

2. EQUIPMENT INSTALLATION PROCEDURES

3. PRECAUTION WHEN APPLYING THE FINAL COAT OF PAINT

4. BUS BODY

CONTENTS

GENERAL PRECAUTIONS

1. BODY DESIGN AND CONSTRUCTION ･･････････････ 2

2. NEVER MODIFY SAFETY PARTS ･･････････････････14

3. CLEARANCES ････････････････････････････････････18

4. FITTING THE BODY ･･････････････････････････････22

KC-AA014A

Chapter 1

This section describes general precautions that must be taken whenmounting a bus body or equipment or when making modifications tothe chassis.

Improper mounting of a bus body or equipment or improper modifi-cations may cause unforeseen faults in the vehicle and lead to seri-ous accidents.

If you intend to mount a bus body or equipment, or make modifica-tions to the chassis of a HINO vehicle, be sure to observe the pre-cautions described in this section.

GENERAL PRECAUTIONS1

KC-AA014A 1

1. BODY DESIGN AND CONSTRUCTION

The final quality of a vehicle depends not only on the chassis manufacturer but also onthe body builder. Accordingly, body builders should pay attention to the followingaspects of body design and construction:

SPECIFICATIONS

FUNCTIONS

STABILITY

STIFFNESS

COMFORT OFRIDE

EASE OFMAINTENANCE

SAFETY

GVM CAPACITY

GAM CAPACITY

MOUNTED BODY(CITY OR INTER CITY USE & ETC.)

BODY DIMENSIONS

OPERATION OF EACH SYSTEM

AIR INTAKE

COOLING

MASS DISTRIBUTION

HEIGHT OF CENTER OF GRAVITY OF VEHICLE

BODY DIMENSIONS

BODY MOUNTING METHOD

GVM CAPACITY

GAM CAPACITY


CHASSIS MODIFICATIONS

INTERIOR NOISE

HEAT INSULATION


ACCESSIBILITY

INSPECTION LIDS

FIRE PREVENTION

ITEMS TO BE CONSIDEREDQUALITY

DESIGN OF BODY

ENSURING TOTAL VEHICLE QUALITY


KC-AA014A 2

Mass and Dimensions

When designing or constructing a body, make sure that:

the total mass of the vehicle is within the permissible axle or gross axle mass ratingcapacity, tire capacity and gross vehicle mass capacity,the front axle load satisfies the minimum ratio of gross vehicle mass,the height of the center of gravity from the ground after body mounting is within the speci-fied limit,the vehicle mass is evenly distributed between left and right wheels,the overall width of the vehicle is within the specified limit, andthe dimensions and mass of the vehicle comply with local regulations.

The specified values for the above items are given under “1. Vehicle summaryChassis Specifications & 2. General Precautions Weight Distribution on Front Axle,Body Max. Width & Height of Center of Gravity” in the Hino body mounting manual forthe respective model series.

Example:VEHICLE SUMMARY (CHASSIS SPECIFICATIONS)

NOTEAllowable axle and GVM. capacity listed above table must not be exceeded.Both front and rear axle, loads must not exceed the permissible load based on thetire load capacity according to the tire standards in your country.The lopsided mass distribution between left and right wheels should be avoided.

metIledoMsissahC AKSK2MR

esableehW )mm( 000,6

daerT )mm(tnorF 520,2

raeR 028,1

yticapac.MVG.xaM )gk( )timillageL001,51(000,61

elxaelbawollAyticapac )gk(

tnorF 000,6

raeR )timillageL001,9(000,11

ssamsissahChtiw.ceps.dtsnO( tuo

)eritecaps)gk(

latoT 061,6

tnorF 539

raeR 522,5

enignE)ssorGSIJotgnidroccA(

ledoM D31K

tuptuo.xaMnim/rta)sp(wk 051,2/)062(191

NeuqroT.xaM ·mfgk( · nim/rta)m 004,1/)09(388

dnuorgmorfytivargfothgieH )m( 08.0

csiddnaeriTeriT

RP41-02-00.11:DTS,RP61RORP41-02-00.01:TPO

RP61-02R00.01RP61-02-0.11,RP61-5.22R11:TPO

.RP61RORP41-02R00.11:TPORP41-5.22R21

csiD mm561tesffo-V05.7x02:DTSmm561tesffo-52.8x5.22:TPO

knatleuF )L( 053:TPO/052:DTS

yrettaB A(CK-V · .oN-)h 2-)051(045-21:DTS2-)002(027-21:TPO

rotareneG A-V041-42:DTS

:TPO 2 07-4:TPO 2 -4 012


KC-AA014A 3

GENERAL PRECAUTIONS

WEIGHT DISTRIBUTION ON FRONT AXLE, MAX. BODY WIDTH & HEIGHTOF CENTER OF GRAVITY

When mounting the body, you must observe the following standards to prevent rolloverand spring failures.

EXAMPLE:

EXAMPLE:

The height of Moments 13,255.5= ——————— = ————— = < 1.29

gravitational center Vehicle mass 10,4551.26

From HINO Refer Chassis specification Page 1-3

ssaM)gk(

fothgieHlanoitativarg

)m(retnectnemoM

k( · )m

sissahC 061,6 008.0 829,4

ydoB 008,3 079.1 648,7

staeS 594 007.1 5.148

latoT)nedalnU( 554,01 5.552,31

NOTEHino cannot guarantee against field trouble or take countermeasures ifthe specifications of the completed vehicle with body mounted exceedthe above standards.

If a wide body is needed for special purposes, it is essential that limits onweight distribution and height of the center of gravity are strictlyobserved.

The height of the center of gravity is calculated as follows.

enignEnoitacol

ledoMnoitubirtsidssaM

elxatnorfno)MVGroMV/rF(

fothgieHlanoitativarg

)m(retnec

dednemmoceRmumixamydob

)m(htdiw

raeR AKSK2MR%82nahteroM

dnanedalnU()nedaL

nahtsseL92.1

)nedalnU(

5.2nahtsseL


KC-AA014A 4

Formulae for Calculation

When calculating

• gross vehicle mass, and

• height of center of gravity from ground for chassis with body mounted,

use the formulae described in this section.

Gross Vehicle Mass (GVM)

The meaning of gross vehicle mass (GVM) is described below.

Chassis Mass

Body Mass

Vehicle Mass

Crew, Passengers and Other Load (baggage and cargo)

Gross Vehicle Mass (GVM)01-001


KC-AA014A 5


KC-AA014A 6

Basic Formulae for Mass Distribution

The distribution of mass on front and rear axles is calculated as follows:

01-002

Wf = W x L1 WB

Wr = W – Wf

(W1 x L1) + (W2 x L2) + (W3 x L3) – (W4 x L4)Wf = ––––––––––––––––––––––––––––––––––––– WBWr = (W1 + W2 + W3 + W4) – Wf

01-003

W

Wf

f

L1

WB

Wr

r

W3 W2 W1 W4

rf

Wr

L1 L4

L2

L3

WB

Wf

For one unit of load

For multiple units of load

Calculation of Gross Vehicle Mass

The details of each factor used in calculating GVM are as follows:

CHASSIS MASS

BODY MASS

PASSENGERS AND CREW MASS


KC-AA014A 7

.Wfc and Wrc are given under “1Vehicle Summary ––––––––Chassis Specification” in the bodymounting manual for the respectivemodel series.

Calculate Wfb and Wrb using the basicformulae for mass distribution.

01-004

01-005

01-006

Wfc WB Wrc

L1

L5

L2

W2

L6

L4L

3

W3

WrbWfbW

4WB

W1

W6 W

5

noitcurtsnoC )W(ssaM L

.tsnoctnorF W1 L1

.tsnocfooR W2 L2

.tsnocediS W3 L3

.tsnocroolF W4 L4

.tsnocraeR W5 L5

staeS W6 L6

Calculate Wfp and WRP using the basicformulae for mass distribution.

daoL )gk(ssaM )m(L

werC cW Lc+ BW

sregnessaP pW pL

Lc Lp

WcWfp Wrp

Wp

WB

Example:

Calculating mass distribution for a Model AK3HMKA front engine bus (wheelbases 5,000mm)

Calculation of Gross Vehicle Mass and Gross Axle Mass

Mass distribution on front axle

*This value should be greater bigger than of the basic value.


KC-AA014A 8

01-007

2490

3180

10028405000196080

9980

metI latoT tnorF raeR

sissahC 5414)cfW(

0932)crW(

5571

ydoB 0053)bfW(

5341)brW(

5602

ssaMelciheV 5467 5283 0283

dnasregnessaPwerc

56+04625072=

)pfW(57+565

046=

)prW(01-+5702

5602=

elciheVssorGssaM

)MVG(05301

)fW(5644

)rW(5885

elxadnaRMVGyticapac

00521 0055 0058

yticapaceriT)RP41-02-00.9(

0005 0029

01-008

Wfc Wrc

Wfb Wrb

Wfp Wrp

Wf x 100 = 4465 x 100 = 43.1 > 28%PBV 10350

Height of Center of Gravity from Ground

A High Center of Gravity Causes Poor Steerability

• The height from the ground of the vehicle’s center of gravity has a major impact on thesteering and handling of the vehicle. Therefore on safety during running, make surethat the height of the center of gravity does not exceed the specified limit.

• The specified limit on the height of center of gravity represents the maximum height ofcenter of gravity that will assure a turn-over angle of 35° when the vehicle is unloaded.

(For the maximum height of center of gravity from ground for each model when a bodyis mounted, see the Body Mounting Manual for the respective model series.)

Calculation

• Calculate height of center of gravity as follows:

NOTEThe vehicle which is adopted the leaf spring suspension, ground heightof upper surface of chassis frame, marked “HC”, must be considered thedeflection value of the leaf spring due to weight of the mounted body.


KC-AA014A 9

• L :Body mass offset (m)• HB:Height of center of gravity of

body from upper surface ofchassis frame (m)

• HC:Ground height of upper surfaceof chassis frame at body massoffset point (m)

• HD:Height of center of gravity ofbody from ground (m)

Height of center

of gravity

Height of center

of gravity

GOOD STEERABILITY POOR STEERABILITY

01-009

01-010

WB

L

HD

HC

HB

Calculate body mass offset (L) in meters.

Calculate height of center of gravity of body from upper surface of chassis frame (HB).

Calculate HB in meters according to the following example:


KC-AA014A 10

= L (m)Wf x WB

Total mass of body

01-011

01-012

WB

HD

HR

HF

HC

HB

Wf

Wr

L

Roof const.

H2

W2

W1

W4

W5

Floor const.

W6

H5

H4

H1

W3

H6 H

3

HB

Chassis frame

Side const.

Front const.

Rear const.

Seat

noitcurtsnoC )W(ssaM)gk(

)H(thgieH)m(

)HxW(tnemoMk( g· )m

.tsnoctnorF 033 5.0 0.561

.tsnocfooR 044 50.2 0.209

.tsnocediS 0911 5.0 0.595

.tsnocraeR 082 5.0 0.041

.tsnocroolF 588 10.0 58.8

taeS 573 4.0 0.051

latoT 0053)A( 065.0 58.0691)B(

HB =(B)

(A)= = 0.560 (m)

1960.85

3500

Calculate ground height of upper surface of chassis frame (HC) at body mass offset pointin meters.

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

Finally, make sure that the height of the center of gravity of the vehicle does not exceedthe specified limit height of center of gravity from ground at the vehicle mass that isshown in the Body Mounting Manual.

If the height exceeds the specified limit, you must take steps to reduce the height andbring it within the limits specified in the Body Mounting Manual for the respective modelseries by modifying body design or other means.


KC-AA014A 11

HD (m) < limit specified in Body Mounting Manual

HDH

F

HR

HC

HB

01-013

HR – {(HR – HF) x = HC (m)L

WC

L

WBH

DHF HRH

B

01-014

HB + HC = HD (m)

L

WB

HC

}

Example:

Height of center of gravity on model AK3HMKA with body

Dimensions marked “*” are indicated in the model series Body Mounting Manual.

HC = HR – {(HR – HF) x L/WB} HD = HB + HC

HC = 1005 – {(1005 – 945) x 2040/5000} HD = 0.560 + 0.980

= 980 (mm) = 0.980 (m) = 1.540

Value marked “*” is indicated under “1. Vehicle Summary - Chassis Specifications” in themodel series Body Mounting Manual.


KC-AA014A 12

HC

HB

HD

5000 (WB)

945*

(HF

)

1005

*(H

R)

2040 (L)

01-015

ytivargforetnecfothgieH)m()H(dnuorgmorf

ssaM)gk()W(

tnemoMk()WxH( g· )m

sissahC 29.0 5414 4.3183

ydoB)DH(045.1

0053 0935

latoT 402.1=H )A(5467 )B(4.3029

H =(B)

(A)= = 1.204 < * 1.23 (m)

9203.4

7645

Body Dimensions

It is the responsibility of the body and equipment manufacturer to ensure that the dimen-sions of the completed vehicle conform to the regulations of the country in which thevehicle is to be operated.

When designed a body, in addition to observing the maximum height for the center ofgravity of the completed vehicle, you should also observe the maximum body width spec-ified under “1. Vehicle Summary - Chassis Specifications” in the body mounting manualfor the model series.

Body Dimensions (Maximum width)


KC-AA014A 13

OVERALL LENGTHWB 1960 809.00-20-14PR9.00-20-14PR100 ROH

OV

ER

ALL

HE

IGH

T

OVERALL WIDTH

01-016

2. NEVER MODIFY SAFETY PARTS

Never modify and never heat safety parts relating to the front axle, steering system orbrake booster device, etc. Modifying or heating these parts may affect their strength andis highly dangerous.

The parts of the chassis relating to the body mounting which must not be modified are asshown in the figures below.

Front Axle


KC-AA014A 14

01-017

01-018

Under view of truck showingfront axle and suspension forexample.

KNUCKLE

KNUCKLE ARM

CASTER SHIM

TIE ROD ARM

STOPPER BOLTAXLE BEAM

TIE ROD

KINGPIN

LOCK BOLT

TIE ROD SOCKET

Sectional views of front axle

THRUST BALL BEARING

HUB BOLT

FRONT WHEEL HUB

KINGPIN BUSHINGTHRUST WASHER

OUTER TURN

INNER TURN

Steering system

Brake booster


KC-AA014A 15

01-019

01-020

C

DRAG LINK

STEERING WHEEL

A

B

STEERING SHAFT

UNIVERSAL JOINT

SLIDING YOKE SLIDING

SHAFT

PITMAN ARM

UNIVERSAL JOINT

GEARBOX

1. Power cylinder

2. Power piston

3. Return spring

4. Push rod

5. Seal

6. Oil seal

7. End cover

8. Valve

9. Hydraulic piston assembly

10. Hydraulic cylinder

11. Air bleeder

12. Cylinder plug

13. Check valve

14. Pin

15. Plunger

16. Stroke warning switch

17. Return spring (if so

equipped)

A. From and To brake valve

B. From reservoir

C. To wheel cylinder

A

POWER BOOSTER ASS’Y

Suspensions


KC-AA014A 16

MULTI-LEAF SPRING

01-021

AIR SPRING

01-022

U-BOLT

SPRING BRACKET

SPRING PIN

SPRING ASSY (NO. 1 & NO. 2)

SHACKLE PIN

SHACKLE

SPRING BRACKET

AIR PIPE

TURNBUCKLE

SUPPORT BEAM

AIR SPRING

SHOCK ABSORBER

TORQUE ROD

STABILIZER BAR

AIR SPRING COVER

Propeller Shaft

To alter the length of the wheel base it is necessary to modify the propeller shaft.However, improper modification of the propeller shaft may lead to damage and unusualnoises during driving or even cause serious accidents, and is therefore highly dangerous.


KC-AA014A 17

FRONT AND INTER SHAFT

REAR SHAFT

LOCK NUT

YOKE SHAFT

UNIVERSAL JOINT ASS’Y

CENTER BEARING ASS’Y



SLIDING YOKE

YOKE SHAFT

3. CLEARANCES

Clearances Between Chassis Parts and Body or Equipment

To prevent contact with chassis parts that vibrate or rotate during driving, be sure toallow adequate clearances between chassis parts and the body or equipment. Also besure to allow sufficient space to allow easy filling, maintenance and repair work.

Engine, Clutch and transmission Clearance of peripheral parts with the body

Observe the following clearances between the peripheral parts of the engine, clutch andtransmission, and the body.


KC-AA014A 18

ecnaraelcmuminiM

ydobdnayrehpirepenignEmm04.nim:wolebdnaevobA

:tfeldnathgiR mm03.nim:kcabdnatnorF mm52.nim

ydobdnayrehpirepnoissimsnarT mm52.nim

Body partsAllow minimum clearance.

01-023

Space for removal and refitting of transmission

When removing the clutch and transmission, to extract the clutch spline shaft, it is neces-sary to pull the transmission assembly backwards approximately 200 mm in the line ofthe engine. Make sure you allow enough space for this work.

Propeller Shaft

The clearance between the propeller shaft (including joints) and the body (body equip-ment such as cooler unit and other body parts, etc.) must be at least 50 mm from the limitof displacement of the propeller shaft (above, below, left, right, front or back of the axle).


KC-AA014A 19

Allow space forremoval and refittingof the transmission.

Allow 50 mm clearance from limit ofdisplacement (above, below, left, right,front, or back).

01-024

01-025

UNIVERSAL JOINT

LOWER LIMITPROPELLER SHAFT

UPPER LIMIT

Rear AxleClearance when metal contacting

The clearance between the rear axle (including the brake hose which is located on therear axle) and the body must be at least 50 mm from the limit of displacement of the rearaxle (above, below, left, right, front or back), so that the axle does not touch the body noreven contact the rubber bumper.

* For details of range of axle movement, see the Body Mounting Manual for the respec-tive model series.

SpringsClearance from end of spring

During driving, the spring end (shackle) moves rearward. When mounting the body, donot position any part of the body inside the area marked A in the diagram.

* For details of measurements of area A, see the Body Mounting Manual for the respec-tive model series.


KC-AA014A 20

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

01-026

01-027

Fro

nt a

xle

cent

er li

ne

A

Brake & Air hose or Pipes

Strictly observe the minimum clearances between the brake & air hose or pipes and thebody or equipment. If the hoses or pipes are allowed to come into contact with the bodyor equipment they will quickly become damaged and this may lead to serious accidents.

For details of minimum clearances, see 6. BRAKE/HYDRAULIC PIPING.

Electrical Wiring

Strictly observe the minimum clearance between electrical wiring and the body or equip-ment. If electrical wiring is allowed to come into contract with the body or equipment itwill quickly become damaged and this may lead to serious accidents such as fire.

For details of minimum clearances, see 7. ELECTRICAL SYSTEM.

Exhaust Muffler & Tail Pipe

Strictly observe the minimum clearance between the exhaust muffler or tail pipe and thebody or equipment. If the exhaust muffler or tail pipe are allowed to come into contactwith the body or equipment this may lead to serious accidents such as fire.

For details of minimum clearance, see 4. EXHAUST SYSTEM.


KC-AA014A 21

4. FITTING THE BODY

Basic Point

The strength of the Hino bus chassis frame has been determined on the premise that anormal bus type of body will be installed on it. Integrated construction of body and framehas been made a basic principle. Body design should be carried out in full recognition ofthe fact that, looking at the bus as a whole, the frame only bears part of the load receivedby the vehicle. The rigidity of the frame has been designed to a level where it is possiblefor it to be self-propelled with only the chassis.

However, take good care not to run the bus on bad roads such as unpaved roads so asnot to place excessive loads on it.

Approached and Departure Angles

When installing fittings in relatively low positions in the front or rear overhang. Theapproach and departure angles should be at least equal to those of the chassis.

If you must mount body components or equipment that will project below the line of theseangles, be sure to allow for operating conditions when deciding the ground height ofthese components.

[FRONT ENGINE VEHICLE]

[REAR ENGINE VEHICLE]


KC-AA014A 22

Approach angle Departure angle

Approach angle Departure angle

01-028

Keeping the Chassis Frame Level

When fitting the bus body, avoid stress that may cause damage to the frame and otherstructural chassis parts.

Always check that the chassis frame is level and ensure that it remains level during bodymounting.




KC-AA014A 23

Paved horizontal plane

JACK OR ADJUSTABLE STAND01-029

Paved horizontal plane

JACK OR ADJUSTABLE STAND01-030

Points to Note on Electrical Welding

Electrical components such as the alternator and tachograph are directly connected tothe battery and one end is grounded to the chassis frame. Under these conditions, weld-ing current will flow back along the ground circuit if electric welding is carried out anddamage may be caused to the alternator, tachograph, electrical components, etc.

Always take the following precautions during welding.

Disconnect the ground terminal of the battery from the frame fitment and ground thewelding equipment securely to the frame itself. (Do not ground the welding equipment tosuch things as the tire rims, brake pipes or fuel pipes.)

Procedure before Welding

• Turn the starter switch off.

• Disconnect the battery’s negative terminal.

• Disconnect each of the electronic instruments.

• Ground welding equipment securely, near to the area to be welded.

Important: Broken line ( ) show the current flow if the groundconnector is connected. If the ground connector isconnected in this way, the alternator and other electri-cal equipment will be seriously damaged.

To protect ancillary equipment from sparks during welding, place fire-resistant coversover the engine and transmission, instrument panel, steering wheel, hoses or pipes ofbrake and fuel system, electrical wiring and tires, etc.


KC-AA014A 24

• CONNECT THE GROUND OFTHE ARC WELDING MACHINENEAR THE PLACE ON THEFRAME TO BE WELDED.

• BUT NOT CONNECT IT TOPLATED PARTS SUCH AS FUELPIPES AND BRAKE PIPES.

Computer for

• Engine control

• Transmission control

• ABS & etc.

DISCONNECT THE BAT-TERY & COMPUTERGROUND AT THE SIDEFRAME SIDE.

01-031

Computer

BatteryAlternator, etc.

DISCONNECT THE ALTERNATORGROUND

Welding rod

Arc welding machine

Side frame

Inspection Covers & Lids

When building the body structure, remember to position inspection covers & lids so thatno obstruction is caused to the following inspections and maintenance routines.

Checking engine oil, filling and removing oil.Checking cooling water level, filling and removing water.Checking transmission oil, filling and removing oil.Checking differential oil, filling and removing oil.Checking battery fluid, filling, removing the battery.Checking fuel gauge sender, fuel feed and return hose of fuel tank.Draining fuel filter.Draining air tank.Removing spare tire and checking that it is securely mounted.Checking and removing of relay valves, check valves and other valves connected withthe brakes.



NOTEDetails of inspection covers & lids position, size, etc. are shown inManual for each model.


KC-AA014A 25

b

ac

i

01-032

01-033

a

b

ac

d

ff

f

Tire Wheel House & Splash Guards

To protect chassis components (air cleaner, engine, clutch and transmission, air tank,brake parts, fuel tank, etc.) from water, mud and stones thrown up by the tires, tire wheelhouse and splash guards of the appropriate size must be fitted as shown below.

NOTEAbove dimensions are given in the Body Mounting Manual for therespective model series.


KC-AA014A 26

C Wheel house (Front)

C Wheel house (Rear)

CB

CA

WHEEL HOUSE SPLASH GUARD

E CD

CE D

VIEW BVIEW A

SECTION C-C

B

A

CHASSIS CENTER

CHASSIS FRAME SIDE RAIL

COVERPLATE

01-034

Reducing Interior Noise Levels (The front engine vehicle)

In front engine buses, the noise tends to be greatest near the front seats in the passen-ger room.

Rubber sealing sheets should therefore be fitted to each part shown below to prevent thenoise of the engine from entering the passenger room.

Fire Prevention

Great care must be exercised with electrical components, the fuel system and theexhaust system to prevent problems that may cause fires.

During body fitting, debris from steel plates may come into contact with electrical fittingsand cause short circuits.

This debris must be completely removed by the time of shipment.

Use a non-combustible or flame-retardant material for body parts that are close to theexhaust pipe or engine room.


KC-AA014A 27

01-035

AT THE OUT-SKIRTS OFENGINE HOOD

AROUND BRAKE COMPONENT PARTS &PIPING INSPECTION COVER OR LID

AROUND THE STEP & DOOR (PAY ATTENTION TO THE UPPER &LOWER CLEARANCE.)

AROUND TRANSMISSIONINSPECTION COVER OR LID

Avoiding Damage to Chassis

When installing the body, be careful not to damage the chassis or interfere with its func-tions.

For example, do not stand on brake valves, brake pipes and hoses, fuel pipes andhoses, air or vacuum tanks, battery wiring harness, T/M control rods or cables, and etc.

Allowing for Maintenance of Chassis

When mounting the bus body, it is important to allow for easy removal, inspection andmaintenance of chassis parts (spring pins on leaf springs, radiator, propeller shaft, etc.)

Leaf Additions

Leaves should not be added to leaf springs beyond the number of leaves which havebeen prepared as an option as this may lead to snags in the steering system at the frontand unusual propeller shaft noise.

Care of Injury of the Passengers

Take good care that no cut ends of plates or sharp angles project either inside or outsidethe passenger room.


KC-AA014A 28

Installation of Ancillary Heavy Machinery and Equipment

The layout of ancillary heavy machinery and equipment above and below the floor of thebody must be carefully designed to ensure that the weight distribution respects the maxi-mum capacity of front and rear axles and tires, as specified in the Body Mounting Manualfor the respective model series.

Example:INSTALLATION OF COOLER UNIT




KC-AA014A 29

01-036

01-037

INSTALL COOLER UNITIN REAR OVERHANG.

SPARE TIRE & FUEL TANK MUST ALSO BEMOVED TO ADJUST WEIGHT DISTRIBUTION.

INSTALL COOLER UNITBEHIND FRONT AXLE.

Shipment

After installing the body, make sure that there is no body vibration, noise or other abnor-malities before shipping the vehicle. (Perform a thorough shipping inspection.)

Brake, steering and suspension systems are all important safety components. If any ofthese components have had to be temporarily removed to allow for body installation,make sure that they are refitted exactly as before and verify their operation before ship-ping the vehicle. (Be sure to perform a thorough shipping inspection.)

Towing Vehicles

If you must tow a vehicle, be sure to remove the propeller shaft before towing. (This isnot necessary when moving vehicles inside a factory during body mounting.)

Stocking Vehicles• If you must stock vehicles in chassis form, make sure that they are stocked indoors.

• If you must stock chassis outdoors, make sure that you cover the instrument panels,electrical equipment boxes and engine to protect them from rain and dust damage.

Complying with Laws and Regulations• The completed vehicle with body fitted must comply with the vehicle laws and regula-

tions of the country in which it is used and tolerance limits for axle capacity, weight dis-tribution on front axle and height of the center of gravity must not be exceeded.


KC-AA014A 30

EQUIPMENT INSTALLATION PROCEDURES

1. ENGINE ･･････････････････････････････････････････ 2

2. ENGINE COOLING SYSTEM (RADIATOR & RELATED PARTS) ････････････････15

3. ENGINE AIR INTAKE SYSTEM ････････････････････26

4. CHASSIS FRAME ････････････････････････････････39

5. FUEL TANK ･･････････････････････････････････････55

6. STEERING ･･････････････････････････････････････65

7. CLUTCH CONTROL SYSTEM ･･････････････････････68

8. BRAKE SYSTEM ･･････････････････････････････････71

9. PROPELLER SHAFT ･･････････････････････････････93

10. SUSPENSIONS ･･････････････････････････････････94

11. EXHAUST SYSTEM ･･････････････････････････････99

12. TIRE ････････････････････････････････････････････107

13. ELECTRICAL EQUIPMENT AND RELATED PARTS ････････････････････････････････････････116

14. ATTACHMENT OF THE PACKAGED PARTS ････････147

KC-AA014A

Chapter 2

In order to assure the performance of the vehicle once a bus bodyhas been mounted and the functions of each part of the chassisequipment, in addition to the General Precautions described in theSection 1 be sure to observe the procedures described in this sec-tion for installing each part of the chassis equipment.

The instructions in this section are confined to the general proce-dures which are common to all vehicle models.

For more detail, refer to the Body Mounting Manual for the respectivemodel series.

EQUIPMENT INSTALLATION PROCEDURES2

KC-AA014A 1

1. ENGINE

The engine is the most important component part of any vehicle.

To ensure that it remains in optimum condition requires regular inspection, maintenanceand repair work.

The engine can be the source of noise and heat which are the most important factor inpassenger comfort.

When mounting a bus body, you should therefore observe the precautions and proce-dures described in this section and be sure to allow for ease of regular inspection, main-tenance and repair work, and prevent engine noise and heat from entering the passengerroom.


KC-AA014A 2

Important Points of Body Mounting• Installing inspection/maintenance covers and lids

• Ensuring that body parts around engine are detachable (to ensure ease of mainte-nance, mounting and dismounting of engine)

• Ensuring sufficient clearance between body parts and engine

• Installing an engine hood (front engine vehicles)

• Installing an engine bulkhead (rear engine vehicles)

• Sealing off engine space from passenger room

• Installing heat insulation and noise absorption material under engine hood or bulkhead


KC-AA014A 3

Details of Important Point of Body Mounting

This section describes in outline the most important points of body mounting.

For details of dimensions, shape and other items particular to each model, see the BodyMounting Manual for the respective model series.

(Please note that shapes and dimensions in the diagrams of this section are intendedsimply as examples.)


Installing an Engine Hood

To prevent engine noise and heat as well as dust and other running noise from enteringthe passenger room, fit an engine hood to isolate the engine from the passenger room.

Observe these precautions when fitting the engine hood:

• Make sure that the hood is constructed to allow easy mounting and dismounting.

• Fit an inspection lid to allow for checking of the engine oil level.

• To prevent heat and noise from entering the passenger room, fit an appropriate insula-tion material on the inside surface of the engine hood.


KC-AA014A 4

RADIATORENGINE

ENGINE HOOD

02-001

• Make sure that the hood is big enough to cover the cooling radiator assembly as wellas the engine.

• During running, both the engine and cooling radiator have a natural vibration. Be sureto allow the specified clearances.

• To prevent dust and noise from entering the passenger room, make sure that the jointsand joints of the engine hood are properly sealed.

• Make sure that the engine hood does not obstruct inspection and maintenance work inany way.


KC-AA014A 5

02-002

CONSTRUCTION (FRONT DASH PANEL)

FRONT

FLOOR

ENGINE HOOD(SHOULD BE DETACHABLE CON-STRUCTION AND COVERTOGETHER WITH COOLING RADI-ATOR)

MAKE SURE TO SEAL BETWEENENGINE HOOD AND FLOOR BYMEANS OF FITTING THE SEAL RUB-BER

CHASSIS CENTER

Detail of Engine Hood AssemblyExample:


KC-AA014A 6

02-003

CHASSIS CENTER

FR

ON

T A

XLE

DA

TU

M L

INE

UPPER SURFACE OF CHASSIS FRAME

02-004

Grab handle(to facilitate removal)

Inspection cover forengine oil level

Seal rubber

Seal rubber

Seal rubber

Insulator(for heat & noise)

Allowing for Ease of Inspection/Maintenance and Repair

• Before the engine is lowered into the chassis, remove crossmember No. 1 and placethe engine in the front part of the chassis.

The shaded area of the front part of the body in the drawing below should be of detach-able construction.

Any beam or structure of the body under the engine and transmission should also be ofdetachable construction.


KC-AA014A 7

02-005

Parts of body in and under the shaded area mustbe of detachable construction.

CHASSIS FRAME


Installing an Engine Bulkhead

In rear engine vehicles, major components of the chassis such as the engine, transmis-sion and rear axles are concentrated in the rear overhang.

Therefore, to prevent engine noise and heat as well as dust and other running noise fromentering the passenger room and affecting passenger comfort, you should fit an enginebulkhead of appropriate construction between the engine room and the passenger room.

Observe the following precautions when installing the engine bulkhead:

• Allow sufficient clearance from the engine, radiator and other chassis components.

• Fit opening covers to ensure ease of inspection, maintenance and repair work.

• To prevent heat and noise from entering the passenger room, fit an appropriate insula-tion material on the inside surface of the engine bulkhead.

• To prevent dust and noise from entering the passenger room, make sure that everypart of the bulkhead (especially the floor inspection lid in the passenger room) is prop-erly sealed.


KC-AA014A 8

ENGINE

02-006

02-007

ENGINE BULKHEAD

TO FRONT

ENGINE ROOM

Detail of Engine Bulkhead StructureExample:

• Dimensions of Engine Bulkhead

• Dimensions of the engine bulkhead are given in the Body Mounting Manual for therespective model series.(Dimensions marked * are example figure.)

(The dimensions indicated in the diagram are the minimum dimensions that will ensuresufficient clearance.

Make sure that the component parts of the engine bulkhead such as the framework andinsulation do not protrude further into the engine room than the dimensions shown.)


KC-AA014A 9

ENGINE BULKHEAD

BODY REAR END PANEL

Allow sufficient clearance from the engine, radiator andother chassis components.

02-008

*(3

10)

*(3

55)

MÍN

. 40

(225

)

• Insulation under the engine bulkhead

Insulation material such as glass wool should be installed under the engine bulkhead toinsulate against heat and to prevent direct airborne noise generated by engine fromentering the passenger room.

• IDetails of the insulation under the engine bulkhead are described in the BodyMounting Manual for the respective model series.


KC-AA014A 10

ENGINE BULKHEAD

TO FRONT

ENGINE ROOM

REAR INSPECTION LID

Construction of Section A-A (Under the Engine Bulkhead)

02-009

02-010

FLOORING t = 2.5

STEEL PLATE t = 1.2GLASS WOOL t = 30 (32 kg/m3)(COVERED WITH ALUMINIUM SEAT)

WATERPROOF PLAY WOOD t = 12

BULKHEADENGINE ROOM SIDE

STRUCTURE WITH INSULATION MATERIAL

CLAMP (INTERVAL APPOROX. 300 mm)

A

A

Installing Engine Inspection/Maintenance Covers

Install opening covers as indicated in the drawings to allow for ease of engine inspection,maintenance and repair work.

When installing the opening covers, fit cushion rubbers and seal rubbers to prevent anynoise (both noise caused by shaking and banging of the covers themselves and enginenoise) from entering the passenger room and escaping from the vehicle.

• IDetails of inspection/maintenance covers, such as installation position and dimen-sions are described in the body mounting manual for the respective model series.


KC-AA014A 11

02-011

FRONT

ENGINE ROOM FLOOR OPENING COVER

ENGINE ROOM SIDE OPENING COVER

ENGINE ROOM REAR OPENINGCOVER

ENGINE ROOM SIDE PARTITION OPENING COVER

DIFFERENTIAL FLOOR OPENING COVER

TRANSMISSION FLOOR OPENING COVER

Detail of Inspection/Maintenance Opening Cover StructureExample:

• IDetails are described in the Body Mounting Manual for the respective model series.


KC-AA014A 12

Installation of cushion rubbers and seal rubbers

CUSHION OR SEAL RUBBER SHOULD BE INSTALLED TO THE COVER.

ENGINE ROOM SIDE OPENING COVER

OPENING COVER FOR RADIATOR HEADER TANK

ENGINE ROOM REAR OPENING COVER

02-012

02-013 02-014

A

A

Cushion Rubber Seal Rubber

INSTALLMIN. 4 PARTS

BODY OUTER PANEL

OPENING COVER

SEAL RUBBER

(INSTALL CIRCUMFERENCE OF THE OPENING COVER)

Section A-A

[Type of Seal Rubber]

TOYODA GOSEI T501C non-flammable EPDM or equivalent

Detail of Seal Rubber (Example)

19

R 1

1

R 7.3

(1.4)

(11)

19+

0.5

+ 1

.0

R 0.5R 1

R 2

R 0.5

2

12

18.5

1.5(1.4)

NOTENoise insulation material must be fitted to the opening covers of theengine room as necessary to comply with legislation on external noise.

Installation of Engine Noise Insulation Material


KC-AA014A 13

02-015

02-016

02-017

TO FRONT

ENGINE BULKHEAD

ENGINE ROOM

REAR INSPECTION LID

Section A-A

Section B-B

FLOOR OPENING COVER

SEAL RUBBER

FLOORING t = 2.5

PUNCHING METAL

WATERPROOF PLAY WOOD t = 12

GLASS WOOL (t = 30, 32 kg/m3)

4

0.8

8

GLASSWOOL

OPENING COVER

PUNCHING METAL

4

0.8

8

A

A

B

B

Allowing for Ease of Maintenance and Repair

• The engine will need to be dismounted for heavy maintenance and major repair work.

• The shaded area of the rear part of the body as shown in the drawing below shouldtherefore be of detachable construction.

• Any beams or structures of the body that lie below the engine and transmission shouldalso be of detachable construction.


KC-AA014A 14

Engine Room Rear Opening

End crossmember have to be detachable structure.

Chassis frame upper surface

Structural elements of the body in and belowthe shade area must be of detachable construction.

02-018

2. ENGINE COOLING SYSTEM (RADIATOR & RELATED PARTS)

• The radiator plays an extremely important role in cooling the engine.

• The method of mounting of the bus body around the radiator is very important.Improper mounting of the body may lead to the engine overheating or other serioustrouble.

• Therefore, when mounting a bus body, be sure to observe the following precautions.




KC-AA014A 15

02-019

RADIATOR

02-020

RADIATOR

Important Precautions for Body Mounting• Do not alter the mounting position or modify the components themselves of the cooling

system, radiator, header tank and other related parts.

• Mounting of radiator relative to body side structure (rear engine buses)

• Provide a partition plate or radiator room in front of the radiator to ensure a smooth airflow to the radiator.

• Provide air intake openings on the body front or side panels and ensure that the open-ings are of the minimum effective size to ensure a sufficient air flow to the radiator.

• Completely seal the area between the radiator and

the engine hood or partition plate or radiator room, and

the body front or side panel

to ensure sufficient air flow and prevent any backflow of hot air from the engine room tothe radiator.

• Mounting of header tank or reservoir tank relative to body structure

• Adjustment of cooling fan idler pulley alignment (offset) with engine crank pulley (rearengine buses)

• Be sure to allow for ease of inspection, maintenance and repair by

allowing for the mounting and dismounting of the radiator,

providing detachable or hinged inspection covers on the body front or side panels andthe partition plate of the engine room,

providing a detachable or hinged inspection over to allow cooling water level inspectionand water filling on the body front or rear panels.


KC-AA014A 16

Details of Important Points of Body Mounting• This section describes in outline the most important points of body mounting.

• For details of dimensions, shape and other items particular to each model, see theBody Mounting Manual for the respective model series.


[GENERAL POINTS]

Do Not Modify or Alter the Engine Cooling System.

• The engine cooling system (radiator, header tank, reservoir tank and other relatedparts) play an important role in the cooling of the engine.

• Modifying the structure of these components or changing their positions may have asignificant impact on engine performance and may lead to the engine overheating, theengine lifetime shortening, or other serious trouble.

• It is therefor essential that you should never modify or alter the engine cooling systemin any way.

Allow for Ease of Inspection, Maintenance and Repair Work.

• Fit inspection covers to allow for ease of inspection, maintenance and repair of enginecooling components and make sure that surrounding body elements are of detachableconstruction (e.g. bolt mounted) to allow for removal. Specifically:

Allow for the mounting and dismounting of the radiator.

Provide detachable or hinged inspection covers on the body front or side panels andthe partition plate of the engine room.

Provide a detachable or hinged inspection cover to allow cooling water level inspectionand water filling on the body front or rear panels.

Make sure that body elements around and under the cooling system are of detachableconstruction.


KC-AA014A 17


Provision of Air Intake Opening

• Provide an air intake opening with a mesh cover on the front panel to assure sufficientintake of air into the radiator while vehicle is running.

• Make sure that the size of the opening conforms to the shown in the drawing belowminimum effective opening area.

• The mesh cover of the air intake opening should be of detachable construction to allowfor ease of inspection and maintenance work on the radiator and engine.


KC-AA014A 18

• Assure the minimum effective opening area.• The dimensions of the opening shown in the

diagram of Body Mounting Manual for therespective model are a minimum and mustbe strictly observed.

02-021

AIR INTAKE OPENING

Apply Sealing Rubber around the Partition Plate

• Securely seal the partition plate with sealing rubber or a similar material around the cir-cumference of the radiator and fit steel plates leading from the body front panel to theradiator in order to

prevent any backward flow of hot air from the engine room, and

induct a sufficient volume of cooling air.


KC-AA014A 19

02-022

02-023

02-024

RADIATORBODY FRONT PANEL

COOLING AIR FLOW

* BACKWARD FLOW OF

HOT AIR & AIR FLOW

MARKED MUST

BE AVOIDED.

* SECURELY SEAL CIRCUM-FERENCE HATCHED AREAWITH SEALING RUBBEROR SIMILAR MATERIAL.

* PROVIDE THE PARTITIONPLATE CIRCUMFERENCEHATCHED AREA BETWEENBODY FRONT PANEL ANDRADIATOR.

RADIATOR

RADIATORBODY FRONT PANEL

ENGINE HOOD

CHASSIS FRAME SIDE MEMBER

FLOOR SURFACEENGINE

HOOD


• Rear engine bus chassis are usually shipped with the radiator temporarily mounted.

• When mounting the bus body, remove the temporary radiator mounting bracket (paint-ed orange) and observe the precautions described in this section in addition to the“GENERAL POINTS” of the previous section.

[LOCATION OF RADIATOR]

[OUTLINE OF ENGINE COOLING SYSTEM OF REAR ENGINE VEHICLE]


KC-AA014A 20

02-025

02-026

Location of radiator

Radiator and header tank are installedtemporary in this position with temporarysupport beams.

Temporarily fixed in barechassis condition

Radiator

A

Overflow Tube

Header Tank(Temporarilyfixed in barechassis) condition

Chassis Frame SideMember

Water Filling Port

TH

ER

MO

ST

AT

C

AS

E

EN

GIN

E C

EN

TE

RC

HA

SS

IS C

EN

TE

R

REAR VIEW

Fixing the Radiator and Overflow Tube to the Body Structure

• To allow the vehicle to run as a bare chassis, one end of the radiator support is mount-ed on the chassis frame and the other end and the tension rod are fixed to a temporarybracket.

When mounting the body, remove the temporary bracket and attach the radiator sup-port securely to the side structure of the body and the tension rod to the body rearstructure.

• The mounting of the radiator support and tension rod to the body structures must allowfor the dismounting of the radiator.

• Also, securely attach the overflow tube to the body rear structure using clips.


KC-AA014A 21

Attach the overflow tube tothe body rear structure usingclips.

Secure the radiator sup-port to the body sidestructure. E

NG

INE

CE

NT

ER

CH

AS

SIS

CE

NT

ER

TH

ER

MO

ST

AT

C

AS

E

Rear view

A

02-027

02-028

Secure the tension rod tothe body rear structure

ENGINE

CENTER

CORE CEN-TER

FRAME UPPER SURFACE

CR

OS

SM

EM

BE

R

No. 8

Side view

RA

DIA

TO

R C

EN

TE

R

RA

DIA

TO

R C

AS

E C

EN

TE

R

MIN

. PO

SIT

ION

OF

BO

DY

RE

AR

EN

D

Fixing the Radiator Header Tank to the Body Structure

• Like the radiator, the header tank is temporarily mounted on a temporary bracket toallow the chassis to run without a body.

When installing the body, remove the temporary bracket and securely fix the headertank to the lower part of the engine bulkhead or to the body rear structure using aheader tank mounting bracket.

• The method used to secure the header tank should allow for dismounting of the tank.

• Provide an inspection cover in the rear body panel of the specified size to allow inspec-tion of the water level in the header tank and water filling.


KC-AA014A 22

Attach the header tank to thebulkhead or body rear struc-ture using a bracket.

Provide an inspec-tion cover in therear body panel.

MIN

. PO

SIT

ION

OF

BO

DY

RE

AR

EN

D

CORE CENTER

FRAME UPPER SURFACE

CR

OS

SM

EM

BE

R

No. 8

Side view

ENGINE

CENTER

RA

DIA

TO

R C

EN

TE

R

RA

DIA

TO

R C

AS

E C

EN

TE

R

02-029

Adjusting the Cooling Fan Idler Pulley Alignment

• Once the radiator is mounted, make sure that you adjust the alignment of the coolingfan idler pulley.

• Adjust the alignment of the pulley by turning the turnbuckle of the tension rod thatsecures the radiator.

• After alignment, the difference between the datum lines of the engine crank pulley andcooling fan idler pulley must be no greater than 5 mm.

• If the alignment is poor, the fan drive belt will wear more quickly leading to engine over-heating. It is therefore essential to adjust the alignment correctly and verify belt ten-sion.


KC-AA014A 23

02-030

02-031

DATUMLINE

COOLING FAN IDLER PULLEY

ENGINE CRANKSHAFT PULLEY

5

Radiator

Turnbuckle

Bulkh

ead

Bod

y re

ar e

nd

Tension rod

Cooling fan idler pulley

Engine crankshaftpulley

Within ± 5 mm

Side rail

Cooling fan

Providing and Sealing a Radiator Room

• Once the radiator is securely mounted on the body structure, provide a radiator roomby mounting partition plates in front of the radiator (see diagram) to prevent any back-flow of hot air from the engine room and protect the radiator against stones and dustwhich will be thrown up by the rear tires during vehicle operation.

• Securely seal the entire circumference between the radiator and the radiator room, andbetween the radiator room and body side panels using sealing rubber or a similarmaterial.

• Provide an inspection cover of the specified size in the partition plate on the engineside of the radiator room to allow inspection and maintenance of the engine.

Rubber sheet


KC-AA014A 24

Engine

Hot air must not flowback into the area infront of the radiator.

Upper partition

inspection lid

Side partition

No. 8 crossmember

Front of the vehicle

(Between right andleft side wall)

Front partition

Under cover

Under cover protects againstair blowback, heated air fromthe muffler, and stones anddust thrown up by the rearwheels.

Rubber sheet

02-032

Provision of Air Intake Opening

• Provide an air intake opening with a mesh structure cover in the body side panel toallow the intake of cool air to the radiator.

• Make sure that the size of the opening conforms to the minimum effective opening areato assure a sufficient intake of air into the radiator.

• The body side panel in which the air intake opening is provided should be fitted with adetachable or hinged inspection cover of the specified size to allow inspection andmaintenance of the radiator and engine.


KC-AA014A 25

02-033

Front of the vehicle

Chassis frame

Mesh

Air intake opening

The air intake opening mustassure the minimum effectiveopening area.

Inspection cover

Be sure to provide aninspection cover to allow forinspection, maintenanceand repair of the engine andradiator.

3. ENGINE AIR INTAKE SYSTEM

• The air intake system is of vital importance in ensuring that the engine receives a suffi-cient amount of combustion air that is free of water, dust and coarse foreign matter.

• It is therefor important that the induction system should conform to the specified dimen-sions and structure.

• Moreover, the induction system must not give rise to noise.

• For these reasons, when mounting a bus body, be sure to observe the following pre-cautions.

[OUTLINE OF ENGINE AIR INTAKE SYSTEM]


KC-AA014A 26

For Front Engine Vehicle

For Rear Engine Vehicle

FRONT

AIR INDUCTION PIPE

ENGINE AIR CLEANER

AIR TANK

SPLASH GUARD OF AIR CLEANER

AIR INTAKE CHAMBER

FRONT

AIR INTAKE CHAMBER &AIR INLET IN BODY WITHPROTECTIVE NET

AIR INDUCTION PIPE

ENGINE AIR CLEANER

02-034

02-035

Main Points of Body Mounting• Do not modify the engine air cleaner and the induction pipe between the engine air

cleaner and the engine, nor change the positions in which they are mounted.

• Remove engine air cleaner temporary mounting bracket and fix engine air cleaner tobody structure (only with chassis where the engine air cleaner is temporarily mounted.)

• Take steps to prevent damage to engine air cleaner during vehicle operation (e.g. fitunder cover or splash guard).

• Remove temporary cap of engine air cleaner and construct air intake system. Thestructure of the air intake system must satisfy the following conditions:

It must extract moisture from the intake air.

It must be of a structure that will reduce the noise of air intake.

The air intake pipe must be of sufficient size and any bends in the intake pipe to mini-mize air resistance.

(e.g. fit an air intake chamber and intake pipe of appropriate strength which assure theabove functions.)

• Ensure that the engine air intake provides a sufficient volume of air. (Ensure that theair intake opening conforms to the minimum effective opening area.)

• The air intake opening must be at a sufficient height from the ground to ensure thatclean air is taken into the engine. (i.e. the opening must be in the front, roof, or side ofthe vehicle and have a ground height of at least 1.6 m.)

• Be sure to allow for inspection, maintenance and repair work, by

making sure that it is easy to inspect and replace the filter element of the engine aircleaner, and

providing detachable or hinged inspection covers.


KC-AA014A 27

Details of Important Points of Body Mounting• This section describes in outline the most important points of body mounting.

• For details of dimensions, shape and other items particular to each model, see theBody Mounting Manual for the respective model series.


[GENERAL POINTS]

Do not Modify or Alter the Engine Air Cleaner.

• The design of the air cleaner takes account of engine performance. Never modify theair cleaner itself nor change its mounting position.

• The air cleaner is fitted with a filter element indicator to facilitate day-to-day inspectionand a dust outlet unloader valve.

Never make any modification to the air cleaner or change in its mounting position assuch modifications will affect the functions of these devices.

Allowing for Ease of Inspection, Maintenance and Repair Work

• To allow for inspection, maintenance and repair of the component parts of the engineair intake system, provide inspection covers and ensure that body components are ofdetachable construction by basing body design on bolt mounting. Give particular atten-tion to

the mounting and dismounting of the engine air cleaner filter element, and

the provision of detachable or hinged inspection covers.


KC-AA014A 28

Air Intake Position

• We have already seen that it is extremely important to assure a good supply of com-bustion air to the engine.

• To ensure that the engine combustion air is fresh, clean and supplied in sufficient vol-ume, strictly observe the following precautions:

• Failure to observe these precautions will lead to a shortage of engine combustion air,which will reduce the power of the engine and lead to black exhaust emissions. Forreference, the graphs below show the relationship between temperature of enginecombustion air at the inlet and engine performance (power and exhaust smoke levels).

The graphs read decrease of engine power and increase of exhaust smoke if the airinlet take hot air from the engine room.

Temperature of engine combustion air at inlet versus engine performance (power andexhaust smoke levels)

Never position the air inlet in the engine room.

Never position the air inlet in the passenger room.

The air inlet should take air from outside the vehicle.

Never position the air inlet within the broad band of speed-windwith dirty air that flows along the sides of the vehicle during dri-ving.

The size of the air inlet must be of at least the minimum effectiveopening area.


KC-AA014A 29

02-036

Pow

er (

PS

)S

mok

e(I

ncre

ase)

Low HighTemperature

Air Induction Piping

If the configuration of the body means that you must alter the route of the air inductionpiping and make changes in the position of the air intake chamber or the installation ofan air induction pipe to connect with the air intake chamber, use steel pipe with a diam-eter equal to or greater than that of the existing connecting pope between the air clean-er and engine. Secure the connection using a sealant such as Three Bond No. 1141 orequivalent, and clamps.

To prevent suction resistance, the piping route should have no sharp curves or bends.


KC-AA014A 30

Minimum radius of curvature at center of pipe:pipe diameter x 1.5

Precautions for Rubber HoseConnection

AIR CLEANER

TO ENGINECLAMP

FROM AIR INTAKE CHAMBER

RUBBER HOSE

EVENLY COAT THE PIPE SURFACE OF THIS AREA WITHSEALANT (THREE BOND NO. 1141 OR EQUIVALENT).

TO PREVENT THE SEALANT FROM BUILDINGUP ON THE INNER FACE AS SHOWN, NEVERCOAT ON THE INSIDE OF THE RUBBER HOSE.

RUBBER HOSE

PIPE

CLAMP FIXING PORTION

15~20

80~40

PREVENT THE CLAMP FROM GETTINGON THE RAISED PORTION.

CLAMP IS GETTING ON THE RAISED PORTION.

WRONGRIGHTBAND IS INCLUDING.

02-037

02-038

02-039


Air Intake Chamber

• In front engine vehicles, the air intake chamber is usually already mounted on the chas-sis.

• If you must move the air intake chamber when mounting a body, be sure to secure itfirmly to the body structure using rubber mountings as in the original mounting position.

• Never make any modifications to the original chamber itself. (Modifications may lead towater being taken into the engine and to intake noise.) Also make sure that the cham-ber is positioned at the same height above the ground as in the original position orhigher if possible.

• If no air intake chamber is fitted, provide a chamber of suitable strength and volumewith a water draining function.


KC-AA014A 31

Air Intake Chamber

Upper View

Side View

CHASSIS CENTER LINE

FR

ON

T A

XLE

DA

TU

M L

INE

CHASSIS FRAME UPPER SURFACE

Air Cleaner

Air Intake Chamber

ENGINE

CENTER

02-040

Mount the chamber usingrubber mountings to preventintake noise (vibration) frombeing transmitted to the bodyand passenger room.

To prevent water frombeing taken into theengine, make surethat the chamber is ata sufficient heightabove ground level.

A

B

Clearance Between Air Intake Chamber Inlet and Body Parts

• Ensure adequate clearance between the inlet of the air intake chamber and body parts.

• If the clearance is insufficient, the engine will not have sufficient combustion air, leadingto a loss of power and black smoke emissions.

• To ensure that hot air from the engine is not taken into the inlet of the air intake cham-ber, fit a partition plate between the engine and the chamber.

Minimum clearance from body parts: 100 mm min.


KC-AA014A 32

AIR INTAKE CHAMBER

AIR CLEANER

100

Fit a partit ion platebetween the engineand the intake cham-ber, air cleaner.

Upper View

Side View

CHASSIS CENTER LINE

FR

ON

T A

XLE

DA

TU

M L

INE

CHASSIS FRAME

UPPER SURFACE

AIR CLEANER

ENGINE CENTER

AIR INTAKE CHAMBER

To ensure sufficient air flow to the aircleaner, do not mount any part of the bodywithin the hatched area around the airintake chamber.

02-041

100

100

100

A

B

Fitting a Splash Guard

• In front engine vehicles, the engine air cleaner is fitted in front of or behind the frontwheel.

• In such vehicles, you should fit a splash guard to prevent stones, dust and waterthrown up by the wheels during driving from damaging the air cleaner and to preventdust from being taken into the engine.


KC-AA014A 33

FRONT

ENGINE AIR CLEANER

AIR TANK

SPLASH GUARD OF ENGINE AIR CLEANER

AIR INTAKE CHAMBER

02-042


Engine Air Cleaner

• In rear engine vehicles, the chassis is shipped with the engine air cleaner temporarilymounted. When mounting the body, remove the temporary mounting bracket (coloredorange) and fix the engine air cleaner securely to the body structure using the aircleaner bracket according to the Body Mounting Manual for the respective modelseries.

• The air cleaner is also fitted with a temporary cap to allow the chassis to be driven with-out a body. When mounting the body, remove the temporary cap and fit an engine airintake system according to the procedures described in this section.

NOTE• For convenience of easy body mounting, recent Hino rear engine bus

chassis has been adopted new type of engine air intake system whichalready has functions of the water elimination from intake air andsound absorbing of intake air noise.

• Therefore, the detail procedure of the bus body mounting for air intakesystem must be followed the instruction described in the body mount-ing manual for respective model series.


KC-AA014A 34

Remove the temporarycap. (Colored Orange)

Engine Air Cleaner must besecurely fixed to body struc-ture.

Engine Air Cleaner02-043

to Engine

Engine

Engine Air Intake System

• In buses, while the vehicle is being driven, a broad band of speed-wind carrying dirtyair will flow rearwards from the rear wheels along the sides of the body.

• To ensure that the engine receives clean air, you must observe the following precau-tions when fitting the air intake system.

• Make sure that the system takes in fresh and clean air.

• Make sure that the system is able to eliminate water vapor fromthe intake air.

• The system must not give rise to any noise.

• Ensure that the air intake opening and piping are of sufficientsize to ensure a proper supply of air to the engine and do notcreate any intake resistance.


KC-AA014A 35

IN THIS DIRTY WIND ZONE MUSTBE AVOIDED TO SET THE ENGINEAIR INLET.

Band of speed-wind carrying dirty air from rear wheels during driving

02-044

• The freshest and cleanest combustion air for the engine is obtained at roof height andfor this reason it is best for the air inlet to be positioned on the roof.

• However, this position is relatively complicated from a design standpoint since itrequires the installation of a special air duct in the bodywork shell. This air duct mustalso be insulated against noise.

• A simpler alternative for the position of the air inlet is as high up as possible on the sideof the body under the rear window. In this position, a combined water separator andsound baffle can be positioned directly adjoining the body side so that the air duct willbe much shorter and simpler in design.

Air Intake Position


KC-AA014A 36

AIR INLET TO ENGINE

MUST BE KEPT

MIN. GROUND HEIGHT 1.6 m.

02-045

• The air intake system must also include a water separator. Hino recommends that thiswater separator should incorporate a sound baffle. This will prevent the developmentof noise-generating air currents in the water separator (air intake chamber).

• The air intake system may also be a source of noise. To prevent the transmission ofnoise to the body shell, the combined water separator and sound baffle (air intakechamber) should be rubber-cushioned and connected to the side of the body via rubberseals.

Installation of Air Intake Chamber


KC-AA014A 37

02-046

AIR INLET IN BODY SIDE WITHPROTECTIVE NET

(COMBINED AIR INTAKE CHAM-BER = WATER SEPARATOR &SOUND BAFFLE)

AIR INDUCTION PIPE

ENGINE AIR CLEANER

02-047

INSPECTION COVERIN BODY SIDE FORMAINTENANCE

BODY SIDE

RUBBER SEAL

AIR INLET IN BODY SIDE WITHPROTECTIVE NET

SIDE WINDOW

RUBBER CUSHIONING

AIR INTAKE CHAMBER

SETTING BRACKET IN BODY

AIR INDUCTION PIPE

ENGINE AIR CLEANER

AIR INTAKE CHAMBER CONNECTEDTO ENGINE AIR CLEANER

• The exterior shape of the air intake chamber and the combined water separator andsound baffle may vary according to body design.

The choice of shape is left to the B&E manufacturer, but it is essential that volume ofchamber should be of sufficient size and provision of the buffle plate to assure theextraction of water from the intake air and reduce intake noise.

• Impurities and moisture tend to collect in the intake chamber. To allow the chamber tobe cleaned and moisture to be drained off, the chamber should be provided with aremovable bottom plate. This plate should have a number of draining holes fitted withunloader valves.

• The bottom plate must be easy to remove. Hino recommends that it be attached byscrews to the side plate of the intake chamber.

(For details of the recommended construction of the air intake chamber, see the BodyMounting Manual for the respective model series.)

Construction of Air Intake Chamber


KC-AA014A 38

Bottom Plate with Drain Hole(An unloader valve must be fitted to thedrain hole.)

Air Inlet in Body Side

Baffle PlatesA noise-damping mat of foam plastic isglued to the back of the baffle plates.

Make sure that the effective cross-sectionalarea of the air flow passage in the intakechamber is such that air flow speed is 7m/sec or less. (For precise values, see theBody Mounting Manual for the respectivemodel series.)

Connection Socket for Air Pipe toEngine Air Cleaner

Example Construction of Air Intake Chamber

02-048

4. CHASSIS FRAME

• Among the component parts which constitute a vehicle, the chassis frame resembles ahuman backbone and functions as the most essential solid member in a vehicle.

• Because of this, a material with a high tensile strength harder than ordinary metals isused as the frame material. The strength of this material as well as the shape aredesigned to match the size of the vehicle (GVM) and the usage conditions.

• Accordingly, careless alterations or modifications will cause stress concentration andmaterial deformation resulting in major problems such as bending or cracking in theframe.

• When mounting a bus body, be sure to observe the instructions given below when car-rying out the mounting operations.


KC-AA014A 39

02-049

Chassis Frame

Frame Materials

HINO vehicles use the following frame materials.

• Depending on the country in which the vehicle is to be used, some models may useframe material with a tensile strength 55 kgf/mm2.

For details, see the Body Mounting Manual for the respective model series.

lairetaM

latemfoepyT htgnertselisneT htgnertsdleiY

dellortoHetalpleets

mm/N044 2

mm/fgk54{ 2}mm/N403 2

mm/fgk13{ 2}

dellortoHetalpleets

mm/N045 2

mm/fgk55{ 2}mm/N293 2

mm/fgk04{ 2}


KC-AA014A 40

Drilling the Frame• Drilling the chassis frame greatly affects the strength of the frame.

If drilling is done incorrectly, it may seriously damage the frame and lead to cracks orbreakage.

• When mounting a bus body, as much as possible, avoid drilling the chassis frame otherthan when mounting to the chassis frame of a cross sill of a body floor construction.

• When drilling the chassis frame, observe the instructions given below.

• Never drill on the upper or lower flanges of the side member of the chassis frame.

• Observe the maximum permissible diameters give in the table below.


KC-AA014A 41

DRILLING POSITION

)mm(snoisnemiD

A 05.nim

B 07.nim

C 07.nim

02-050

Do not drill on the upper& lower flanges. Maximum permissible

diameter of drillinghole: 15 mm

Original rivet or holes

A

A

BC

C

• Use the correct drill. Do not use gas torches.

• Always chamfer the edges of the hole after drilling.

• Be careful not to damage the pipes and harness wires inside the side frame whendrilling.


KC-AA014A 42

DRILLING PROCEDURE

PREVENTING OF DAMAGE TO PIPES AND HARNESS WIRES

02-051

02-052

GAS TORCHDRILL

WRONG RIGHT

Do not damage thepipe & wire harness.

Welding the Chassis Frame• In like manner to drilling, welding the chassis frame greatly affects the strength of the

frame.

If welding is done incorrectly, it may seriously damage the frame and lead to cracks orbreakage.

• Accordingly, without exception gas or electrical welding of the chassis frame during busbody mounting are not allowed.

• Further, use electrical welding when it is necessary to mount a body bracket or similarpart that does not greatly affects the chassis frame excluding when mounting (joint) tothe chassis frame of a cross sill of a body floor construction but be sure to observe thefollowing precautions.

[Refer to the following section “Body Mounting” for details on mounting (joint) to thechassis frame of a cross sill of a body floor construction that greatly affects the chassisframe.]

• For electrical welding, observe the

as procedure before welding work such as disconnected battery ground terminal andetc., to avoid damage to electrical, computer and other ancillary equipment compo-nents of chassis.


KC-AA014A 43

GAS & ELECTRICAL WELDING

ARE NOT ALLOWED.

PRECAUTIONS FOR ELECTRICAL WELDING

02-053

No. 1. GENERAL PRECAUTIONS page 1-4-3

[4) Points to Note on Electrical Welding]

• Welding the upper and lower flanges of the chassis frame side member is strictly pro-hibited.

• When welding the web surface of the chassis frame side member, do not weld within30 mm from the edge of the upper and lower flange, edge of holes.


KC-AA014A 44

WELDING POSITION

Do not weld on the upperand lower flanges.

Intermittent welding

Plug welding

A

B

)mm(snoisnemiD

A 03.nim

B 03.nim

02-054

)mm(snoisnemiD

A 03.nim

B 03.nim

02-055

A

B

B

A

To prevent damage to ancillary components from sparks during welding, cover theengine, meters, steering wheel, hoses, brake pipes, harness wires and tires, etc. withfire-resistant covers.


KC-AA014A 45

PREVENTION OF DAMAGE TO ANCILLARY COMPONENTS

02-056

(Example) Heat insulator

WRONG RIGHT

Make sure that the shape of the welding beads corresponds to the shape illustratedbelow:

Avoid the following defects in welding beads:

Use special welding rods for high tensile steel in places where the weld must have thesame strength as the base metal.

NOTE:JIS and ISO standards are shown below.• JIS Z 3211-1993 and Z 3214-1993• ISO 2560-1972(E)


KC-AA014A 46

WELDING BEAD SHAPE

WELDING RODS

1 23

WRONG RIGHT

02-057

02-058

1. Undercut2. Concave welding3. This area should be smooth and

free from undercuts.

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KC-AA014A 47

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FO

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Vdaehrevo

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mm/gk

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epytdetani

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WELDING CURRENT

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Other Precautions for Drilling and Welding

Heating greatly affects the strength of the frame. Do not unnecessarily heat any part ofthe frame unless performing welding work on the web surface of the side member.

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

The crossmembers which link the right and left side members are important strengthen-ing parts. When mounting the body or making modifications, do not drill, weld, or makecutouts in the crossmembers.


KC-AA014A 48

FRAME SIDE MEMBER

Do not make cutoutsin flanges.

WRONG RIGHT

02-059

WRONG RIGHT

02-060

FRAME SIDE MEMBER Do not drill, weld,or make cutouts.

Crossmember

DO NOT HEAT THE FRAME UNNECESSARILY.

NEVER MAKE CUTOUTS IN FLANGES.

DO NOT DRILL, WELD, OR MAKE CUTOUTS IN CROSSMEMBERS.

Frame Alteration or Modification• As stated in the beginning of this section, the chassis frame resembles a human back-

bone and functions as the most essential solid member in a vehicle. The chassisframe is the connecting member of the front and rear axle and has brake componentswhich are necessary for safe operation of the vehicle mounted on it as well as thesteering system and other components.

• Accordingly, without exception frame alterations and modifications during body mount-ing are not allowed.

• Because of the connecting between the front or rear construction of the body, the frontor rear overhang of the frame must be extended. Further, when shifting a towing hook,be sure to observe the following points.

(When extending the rear overhang of the frame, the exhaust tail pipe should beextended as well. For details, refer to the “EXHAUST SYSTEM” section.


KC-AA014A 49

02-061

Do not alter or modify the chassis frame.

• Maximum extension length:

must be within 300 mm.

• Extension material:

must be the same as the chassis frame.

• How to make an extension:

Use a welding rod designed for use with the frame base metal.

Use continuous butt welding for the extension material and intermittent welding forstiffeners with a circumference of 35 mm.

Always fit stiffeners having the same length as the extension.


KC-AA014A 50

EXTENSION OF FRONT OR REAROVERHANG OF THE FRAME

Max. 300 mm.

02-063

02-062

Original frame Extension

L-shaped stiffener(should be the same lengthas the extension.)

Same thickness asside member

t 4.5

R12

R9A

Min. 10 mm

Max. 300 mmB

A = 2/3 x side member height

At least 2 passes

Do not grind unless the bead interferes withbody mounting.

02-064

Detailed view of B

Before welding, the ends of both materials, the side member and the extension material,must be cut to form a V-shape as shown in the diagram.

Stiffeners must be welded using the intermittent method, as shown in the diagram:

Precautions for intermittent welding of stiffeners

Precautions for butt welding


KC-AA014A 51

t α° s a

678

070707

0.15.15.1

011

UNIT: mm

02-065

α

a

s

02-066

30 mm

30 m

m35

mm

Never weld here.

When extending the front or rear overhang, shifting or altering an end crossmember isprohibited for any case.

After extending the frame, if it is necessary to shift an end crossmember due to thebody mounting state, create and mount a new crossmember.

Other precautions for frame extension


KC-AA014A 52

02-067

If necessary to fit the end crossmemberafter extending the frame, has to be createdand fitted a new crossmember.

ORIGINAL CROSSMEMBER DO NOT MODIFY.

If you have removed the rear hook when extending the frame, follow the instructionsbelow to remount it.

If the final crossmember is not at the end of the frame, weld a steel plate stiffener 4.5mm thick, 150 mm long and 100 mm wide to the inside of the frame, using intermittentwelding 20 mm in circumference.

If the final crossmember is at the end of the frame, it is permissible to mount the hookwithout the use of stiffeners.

If the final crossmember is at the end of the frame, mount the hook using bolts passingthrough both the side member and the final crossmember.

If the end of the frame is open, use a stiffener 4.5 mm thick, 150 mm long and 55 mmwide to bridge the gap between the upper and lower flanges.

[MOUNTING THE REAR HOOK ON AN OPEN END FRAME]

Mounting the rear hook on the flange of the frame

Mounting the rear hook on the side of the frame


KC-AA014A 53

02-06820 mm

150

100 t 4.5

UNIT: mm

• Strengthen the web surface bymounting an inner stiffener.

• Use intermittent welding tomount the stiffener.

• Mount the hook using bolts (M16or M18).

02-069

• Strengthen the flange of the sidemember using an inner stiffener.

• Bridge the gap between theupper and lower flanges of theside member using a stiffener.

• Mount the hook using bolts (M16or M18).

Mounting the hook on the web of a side member

Mounting the hook on the flange of a side member

t 4.550

10

150

MOUNTING THE FRONT OR REAR HOOK

[MOUNTING THE REAR HOOK WHEN THE FINAL CROSSMEMBER IS AT THE ENDOF THE FRAME]

Strength and tightening torque of bolts for mounting rear hook

The procedure for mounting the rear hook described above is suitable only for normalconditions of use, e.g. towing broken-down vehicles directly behind. Heavier work maylead to deform of the chassis frame.

General precautions for mounting rear hook


KC-AA014A 54

02-070

• Use bolts (M16 or M18) tomount the hook directly on theweb.

Mounting the hook on the web of a side member

02-071

• Mount the hook directly on theflange using bolts (M16 or M18),passing through the side mem-ber and the final crossmember.

Mounting the hook on the flange of a side member

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5. FUEL TANK

• Unsuitable location of the fuel system can lead to major accidents such as vehicle fires.

• When mounting a body, make sure that you strictly observe the following precautions.

The fuel tank is normally mounted on the chassis frame. Do not make anyunnecessary modifications to the fuel tank.

With large-capacity fuel tanks (250 and 300 liters), simply securing the tankto the chassis frame will not ensure sufficient strength of mounting. If themounting is not of sufficient strength, there is a danger that the fuel tankitself may be dislodged and fall off during driving.

You should therefore follow the procedures described below and secure the tank firmly tothe body structure as well as the chassis frame.

• This method is suitable when the fuel tank is suspended on tension rods hanging froma cross beam mounted on the frame upper surface.


KC-AA014A 55

MOUNTING ON BODY FLOOR AND CROSS BEAM

Fix securely to bodyside structure

If the original cross beam has beenremoved, install a cross beam of thesame type as the original beam andsuspend the tank using tensionrods, then fix a cross beam securelyto the body side structure.

02-072

02-073

Cross Beam or Battery

Mounting Beam

Tension Rod

Body Side Structure

Hole ø11

UNIT: mm

40

60

40

t = 4.5

Section Detail of Cross Beam

• This method is suitable if the fuel tank is not suspended on tension rods hanging from across beam mounted on the frame upper surface, or if the body specifications are for ahigh floor.


KC-AA014A 56

MOUNTING ON BODY SKIRT RAIL

02-074

02-075

UNIT: mm

FUEL TANK SUPPORT

SKIRT RAIL OF BODYSIDE STRUCTURE

Securely fix to fuel tank sup-port and body skirt rail usingbolts.

(Fix with the tank support by welding as showndetailed FIG. A.)

ADDED BRACKETS TO THE TANKSUPPORT

FIG. A. Details of added brackets to the fueltank support for connecting to bodystructure and mounting method

This bracket must be added to the fuel tank

support by the B&E manufacture.

FIG. B. Added brackets to the body sideskirt rail.(Fix to the body side skirt rail bywelding.)

Fuel Tank Support

Edge preparation must bedone when welding.

FUEL TANK CENTER

Bolt M10 (7T) - 4 NosTightening torque 35 - 52N·m{360-530 kgf·cm}

MATERIAL: • Hot rolled steel plate for auto-mobile structure use.

• Tensile strength:440 N/mm2 {45 kgf/mm2}

Bending Radius of Plate: (inside)

5B

C8

55

25

100

40 25

70

ø25

140

100

2 - ø11(B)

100 100450

Allowing for ease of Maintenance and Repair• The fuel tank may have to be dismounted in the future. Ensure that the construction of

the body allows for the dismounting of the fuel tank.

• To allow ease of maintenance of the fuel tank components such as the fuel levelsender unit and pipe connections, provide an inspection cover of the specified size inthe floor.

• To ensure ease of fueling, provide a feed tunnel in the body floor and a fuel feed lid ofthe specified size in the outer panel. (In vehicles with a low-floor body, these facilitieswill be essential.)

• To ensure that the engine is supplied with clean fuel, a pre-fuel filter & sedimenter hasbeen fitted to the fuel tank. To allow for ease of maintenance of this device, provide aninspection cover of the specified size.


KC-AA014A 57

02-076

Cha

ssis

Cen

ter

Line

Body Floor

Feed Tunnel

Fuel Feed Lid

02-077

Floor Inspection Cover

Fuel Pre-fitter & Sedimenter

Fuel Tank

Crossmember

Cha

ssis

Cen

ter

Line

Upper View

RF

Modification & Alteration• You may have to move the fuel tank owing to considerations of the distribution of vehi-

cle weight (distribution on forward and rearward axles or left/right balance), or the needto fit an air-conditioning unit, or other body design problems.

If the vehicle is required to travel long distances and you may decide to fit an additionalfuel tank.

In any of these cases, please be sure to observe the following precautions and payspecial attention to the strength of the fuel tank mountings and to fire prevention.

Follow the instructions in item 4. Frame, when welding or drilling on the frame.

Install the inspection covers and fuel feed lid accordingly.

A minimum distance of 10 mm should be kept between the fuel hose and parts listedbelow.

• Pipes and Harnesses

• Frame Edges

• Flange edges of fuel tank

The minimum bending radius of the fuel hose is 50 mm.

Check the entire fuel line. The line should not be twisted or pulled in tight or too loose.

Ensure a clearance of at least 30 mm between the fuel hose and moving parts to preventcontact.

When joining the fuel pipe to the fuel hose, apply Three Bond No. 2 adhesive (or equiva-lent) over a space of 5-10 mm from the pipe edge, join the hoses, then securely clampthe fuel hose to the fuel pipe over the center of the overlap, which should extend at least30 mm from the fuel pipe end.

Secure the fuel hoses using clamps at 300 ~ 400 mm intervals. Fuel hoses must not runnext to electrical wiring and battery cables. Make sure that fuel hoses are positioned atleast 30 mm away from harness wires and battery cables.

For clearances between the exhaust system, fuel tank, and fuel hoses, see item “2-11.EXHAUST SYSTEM”.


KC-AA014A 58

GENERAL PRECAUTIONS

02-078

TUBERÍA DECOMBUSTIBLE

ABRAZADERA

MANGUERA DECOMBUSTIBLE

15 15

30

Make sure that even in the event of a fuel leak, fuel will not drip onto any part of theexhaust system. Joints must not be positioned above any part of the exhaust system.

Make sure that the filling port of the fuel tank is positioned at least 300 mm away from themouth of the exhaust tail pipe, and at least 200 mm away from any exposed electricalterminals.

Make sure that the filling port of the fuel tank is positioned to allow easy filling and easyremoval and replacement of the filler cap.

When using the vehicle’s main fuel tank to supply fuel to the engine of an air-conditioneror other equipment, be sure that the fuel for this engine is taken directly from the mainfuel tank. Never take a line from the main fuel feed system as this will interfere with themain engine fuel supply.

Make sure that pipe and hose are clean before they are jointed, to prevent foreign mat-ters from contaminating the system.

Take care not to damage pipe surfaces.

The tightening torque of clip bands is 9.81-11.77 N·m {100-120 kgf·cm}.

NOTERefer to the list of precautions at the end of ITEM 2-8 brake piping fordetails of precautions to take with the fuel lines.


KC-AA014A 59

When moving or mounting an additional fuel tank, also be sure to observe the followingprocedures:

If you intend to change the fuel lines, be sure to use the specified fuel hose or steelpipe.

Polyvinyl chloride hose

Use polyvinyl chloride (PVC) hose for the fuel feed line (from the fuel tank to theengine) of vehicles with in-line 4 and in-line 6 engines.

Rubber hose

Use rubber hose for the fuel return line (from the engine to the fuel tank) or in vehicleswith V-type engines.

WARNING• Never use polyvinyl chloride hose for the fuel return line (from the engine to the fuel

tank) or in vehicles with V-type engines.

• Using defective polyvinyl chloride or rubber hoses can lead to vehicle fires. Always usegenuine HINO parts.


KC-AA014A 60

PRECAUTIONS FOR FUEL PIPING AND ELECTRICAL WIRING

sretemaidepipdnayrogetacelciheV epytesoH setoN

selcihevytud-muideMmm41:lanretxEmm8:lanretnI

esohedirolhclynivyloPesohrebbuR

enildeefleufrofesUenilnruterleufrofesU

/selcihevytud-yvaeHselcihevenigne6enil-nI

mm41:lanretxEmm8:lanretnI

esohedirolhclynivyloPesohrebbuR

enildeefleufrofesUenilnruterleufrofesU

/selcihevytud-yvaeHselcihevenigneepyt-V

mm61:lanretxEmm01:lanretnIesohrebbuR dnaenildeefleufrofesU

enilnruterleuf

02-079

Note: Hose length is discretionary.

BLEEDER PLUGFUEL FILTER

DRAIN PLUGTIMER

PUMP DERIVE SHAFTCOUPLING

FEED PUMPINJECTION PUMP

Fuel feed line

FUEL TANK

THROUGH FEED VALVE

INJECTION NOZZLE

Fuel return line

Steel pipe

Steel pipe must be rustproofed inside and outside, and the pipe ends must be spoolshaped as in the drawing below:

Rustproofing:

Internal: copper plating, min. 8µ

External: zinc plating, min. 8µ

Pipe dimensions:

Medium-duty vehicles

External diameter: 8 mm Thickness: 0.7 mm

Heavy-duty vehicles

External diameter: 10 mm Thickness: 0.7 mm


KC-AA014A 61

lanimoNretemaid

D

A B L1 L2

foretemaidlanretnIotesohCVProrebbur

detcennoceb)eulavecnerefer(

dradnatSretemaid

8 8 0.9 ~ 6.9 8 5.4 5.3 7

01 01 2.11 ~ 8.11 01 5.4 5.3 9

02-080

L1

L2

R R1

D

R

A B

STEEL PIPE

RUBBER HOSE

ASSEMBLY DRAWING(FOR REFERENCE)

02-081

CLIP

Never extend fuel pipes or hoses.

As a rule, steel pipes should be used for fuel lines within the engine room.

As a rule, you should not change the clipping method or positions of clamps for fuel linessubject to movement due to the relative movement of the engine and the frame. If youmust change either clipping method or clamp positions, be sure to allow sufficient slackto absorb the movement of the engine.

When extending the harness wires of the fuel gauge, use wires of the same color andsize as the existing ones. The connections must be secured by soldering or force-fitting.Remove the burrs of soldered connections or joints and wrap them with adhesive vinyltape or the like to insulate and prevent short circuits.


KC-AA014A 62

02-082CHASSIS FRAME

KEEP PROPER SLACK.

FUEL PIPING

FUEL INJECTION PUMP

ENGINE

02-083

INSULATE THE CONNECTIONS WITH ADHESIVE VINYL TAPE.

THIS AREA MUST BE HALF-WRAPPED WITH ADHE-

SIVE VINYL AREA TYPE.

OVER30 mm

OVER50 mm

OVER30 mm

If you shorten the harness wires, bundle up the excess length, half-wrap it with adhesivevinyl tape and fasten it securely using clips fitted to the fuel tank mounting band.


KC-AA014A 63

02-084THIS AREA MUST BE HALF-WRAPPED

WITH ADHESIVE VINYL TAPE.

02-085

CLIPS FOR FASTENINGHARNESS WIRES

FUEL GAUGE

A

When mounting an additional fuel tank, observe the precautions described in “GENERALPRECAUTIONS” and “PRECAUTIONS FOR FUEL PIPING AND ELECTRICAL WIRING”and follow the procedure described below, and be sure to secure the tank firmly to pre-vent loosening of the mounting bands or slipping of the tank due to vibrations during dri-ving.

Fit a cut-off cock to the connecting pipe between the main tank and the additional sub-tank.

The main tank and the sub-tank must be mounted at the same height.

When welding the joint of the connecting pipe to the head plate of the tank, empty all fuelfrom the tank and fill the tank with water. Use the gas welding method.


KC-AA014A 64

02-086

PRECAUTIONS WHEN MOUNTING AN ADDITIONAL FUEL TANK

Cut-Off Cock

Main tank

Frame Side MemberBracket

Connecting Pipe

Sub Tank

Connecting Pipe

Joint

6. STEERING

• The steering system is extremely important in assuring the maneuverability of the vehi-cle.

• In recent years, adjustable steering wheels (the position of the steering wheel can beadjusted to front and rear and up and down) and power steering systems have beenintroduced to make more comfortable, so that the steering system has become morecomplex.

• When mounting a body, be sure to strictly observe the following precautions.

Safety

To assure safety, never dismount the steering system from the chassis during bodymounting and never modify it in any way.

Fixing Securely to Body Structure and Mounting of Body Parts

The chassis is supplied with the steering column secured to the brake pedal and tem-porarily attached to the dashboard. Make sure that you remove the temporary deliverybracket (colored orange) at the time the body is mounted on the chassis, and installaccording to the following guidelines.

Be careful to avoid damaging the dust cover of the tie rod ball joint and drag link withtools or other objects while mounting the body on the chassis.

As stressed in item 1 GENERAL PRECAUTIONS, when any electric welding is carriedout nearby, you should ensure that these parts are protected by a fireproof covering.

When mounting body parts close to steering devices such as the drag link and pitmanarm, etc., make sure that these body parts do not come within the range of motion ofthese steering devices.

Make sure that there is a clearance of at least 40 mm between the body parts and thesesteering devices when they are at maximum displacement.

During body mounting, cover the steering column and the meter & gauge cluster to pro-tect them from damage and to prevent dust and other foreign particles from penetratingthe system.


KC-AA014A 65

Remove temporarybracket (coloredorange) & securelymount on bodyfront structure.

METER CLUSTER

02-087

The steering column casing shouldbe sufficiently rigid.• Up and down

Deflection X1 = max. 1.0 mmagainst load P1 = 130 kg

• Forward and backwardsDeflection X2 = max. 0.5 mmagainst load P2 = 70 kg

P1

P2

X1

X2

Power Steering• If the vehicle is equipped with power steering, observe the following precautions as well

as the previously described precautions for body mounting.

The hydraulic oil reservoir and piping for the power steering system have already beeninstalled in the correct position on the chassis at the time of shipment.

When mounting a body, never dismount the power steering devices or change the posi-tions in which they are mounted.

When mounting a body, take care to avoid damaging the power steering componentswith tools or other objects.


To allow for Ease of Maintenance and Repair, do not mount body parts close to thesteering system.

If you must mount body parts close to the steering system, observe the specified mini-mum clearances between the steering components and the body parts, and make surethat the body parts are of detachable construction (e.g. mounted using bolts).

Provide inspection covers or lids of the specified sizes as follows:

Drag link inspection cover

Power steering oil reservoir inspection lid

The power steering oil level must bechecked every day. Be sure to allow forease of inspection work.


KC-AA014A 66

Storing the Chassis

If you must store the chassis without a body or while body mounting is in progress, coverthe steering column and the meter & gauge cluster with waterproof covers to protectthem against damage and to prevent water, dust and other foreign matter from penetrat-ing the system.


KC-AA014A 67

7. CLUTCH CONTROL SYSTEM

• In most Hino bus chassis, the fluid reservoir tank for the clutch control system is mount-ed to the right or left of the driver’s seat.

When mounting a bus body, please observe the following precautions.

Securing to the Body Front StructureWhen shipped, the fluid reservoir tank for the clutch control system is temporarilymounted on the chassis in the correct position.

Refer to the Body Mounting Manual for the respective model series and securely fix thereservoir tank to the body front structure.

Do not Modify the Clutch Control System

Do not make any modifications to the clutch control system. Changing the position inwhich the fluid reservoir tank is mounted, or otherwise modifying the clutch control sys-tem may introduce air into the control piping system.

If air gets into the clutch control piping, the clutch may fail and this may lead to seriousmechanical failures.


KC-AA014A 68

Securely fixed to bodyfront structure.

02-088

Clutch pedal

Clutch control cylinder

Clutch fluid reservoir

ST

EE

RIN

G C

EN

TE

R

If for inevitable reasons you must change the mounting position of the fluid reservoir,make sure that you mount the fluid reservoir higher up than the clutch control cylinder.

If air gets into the control piping during modifications, be sure to bleed the air out of thepiping. (See the “SERVICE WORKSHOP MANUAL” published by Hino for details of theair bleeding procedure.)


Provide an inspection cover for the fluid reservoir to allow for daily inspection of theclutch fluid level and filling of fluid oil.

When mounting a body, allow for ease of mounting and dismounting of clutch controlsystem components. (Make sure that body parts are mounted using bolts and provideinspection covers.)


KC-AA014A 69

02-089

Body front construction

No.

1

CR

OS

SM

EM

BE

RInspection cover

Body dash panel

Clutch pedal

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


KC-AA014A 70

Space to pull out shaft(Do not mount body partswithin this space.)

02-092

8. BRAKE SYSTEM

• The brake system is an extremely important safety component of the vehicle.

• Incorrect body mounting may have a major impact on the functions and performance ofthe brake system and may lead to serious mechanical failures or accidents.

• When mounting a bus body, strictly observe the following precautions:

Brake System Specifications• Hino vehicles are equipped with an assisted brake system that is matched to the size

of the vehicle to allow the driver to operate the brakes in safety and comfort.

The table below shows, in outline, how brake systems are matched to chassis models.

• If body equipment design means that you need to take power from the brake system,be sure to make a thorough study of the basic brake system before implementing thesemodifications.

• For details of the brake system on each chassis, see the Body Mounting Manual for therespective model series.

LEDOMSISSAHC METSYSEKARB

SISSAHCMUIDEMTHGILHTIWEKARBCILUARDYH

OVRESRIAROMUUCAV

SISSAHCYTUDMUIDEMEKARBCILUARDYHREVORIA

EKARBRIALLUFRO

SISSAHCYTUDYVAEH EKARBRIALLUF


KC-AA014A 71

Do not Modify the Brake System

The brake system is the most important safety component of the vehicle and you mustnever modify it when mounting a bus body.

If you must modify the piping of the brake system in order to make other modifications tothe chassis during body mounting (moving the fuel tank, etc.), please contact your near-est Hino distributor and follow the advice that the distributor provides.

If body equipment design means that you must take power from the brake system (pipingoff air), take the air from the specified power point connection.

In this case, to protect the brake system, always fit a protection valve between the brakesystem and the body equipment.

[EXAMPLE FOR DOOR ENGINE]

For details of the positioning of the power point connection, see the Body MountingManual for the respective model series and the description of “piping for poweredequipment” in the following section.


KC-AA014A 72

BRAKE CIRCUIT

BRAKE AIR RESERVOIR

DOOR ENGINE CIRCUIT

AIR RESERVOIR

PROTECTION VALVE

DOOR ENGINE

OPTIONAL EQUIPMENT (HINO) OR BODYMANUFACTURER HAS TO PROVIDE.

BODY MANUFACTURER

02-090

23 (L)


To allow for day-to-day inspection and repair of the brake system, make sure that youprovide inspection covers or lids of the specified sizes in the body floor and outer panels.

In chassis that are equipped with a hydraulic brake system, the brake fluid reservoir tankis sometimes mounted in the region of the No. 1 crossmember. In this case, provide aninspection cover or lid in the body front panel to allow for day-to-day inspection of brakefluid level and for fluid oil filling. (For details, see the Body Mounting Manual for therespective model series.)

In chassis that are equipped with an air-over or full air brake system, the air reservoir ismounted on the chassis frame.

In this case, provide a water drainage link to allow the draining of water from the airreservoir to be performed easily from the side of the body.

(For details, see the Body Mounting Manual for the respective model series.)


KC-AA014A 73

02-091

STEELING WHEEL

An inspection lid for the brakefluid reservoir should be providedon the front panel.

BRACKET

DRAINAGE LINK

BO

DY

SID

E P

LAT

E

CHASSIS FRAME

20 02-093 02-094Detailed at A

AIR RESERVOIR

CH

AS

SIS

CE

NT

ER

DRAIN COCK

ROD (5ø)

PLANEWASHER

SPLIT PIN

A

Brake Piping

Steel Piping Used in the Chassis

The table below shows the steel piping used in the chassis and the configuration of theflare of each type of pipe.

UNIT: mm

lanimoNretemaid

D

noitarugifnoceralF lairetaM

A B t CS

LEETSLEETS

67.4 6.6 ~ 2.7 0.3 ~ 8.3 7.0 4.1 0.1 1DTSH

53.6 6.8 ~ 2.9 5.4 ~ 3.5 7.0 4.1 0.1

2DTSHro

3DTSH8

4.01~ 0.11

0.6 ~ 8.6 7.0 4.1 6.1

018.21

~ 4.310.8 ~ 8.8 7.0 4.1 6.1

213.51

~ 0.915.9 ~ 5.31 9.0 8.1 6.1

1MKTSH

510.81

~ 0.915.21

~ 5.310.1 0.2 6.1


KC-AA014A 74

02-095

THIS SURFACE MUST BE SMOOTH.

90°±

30°

45°±

2°

A B D

C

SR

1 t

[DETAILS OF MATERIALS]

Chemical composition and mechanical properties

Plating code


KC-AA014A 75

)mm(.aidepiP epyT )1 epiPedoCgnitalP)2

edisnI edistuO

67.4 ~ 21 leetsdetalpdnuow-elbuoDepip

1DTSH2DTSH3DTSH

BuCFMBuCFMAuCFM

BaHFDC-AnZFMC-AnZFM

21 ~ 22 rofepipleetsnobracdetalPserutcurtslacinahcem 1MKTSH AuCFM C-AnZFM

epiP

%noitisopmoclacimehCseitreporplacinahceM

htgnertselisneT tsetgnideB

C nM P S iS uC

elisneThtgnertS

mm/N 2

mm/gk{ 2}

dleiYtniop

mm/N 2

mm/gk{ 2}

-agnolEnoit)%(

elbacilppA.aidepip

mm

gnidneBelgna

.aidedisnIepip=D(

).aid

1DTSH 21.0 05.0 40.0 540.0 — — 492{ }03

— 52 8 °063 D5.1

2DTSH — — — 8

3DTSH — — — 01 D3

1MKTSH 52.003.0

~ 09.0 40.0 40.0 53.0 — 373{ }83

612{ }22

52 21 °09 D6

Plating method Base material Tape ofplating or coating

Platingmethod

Treatment after plating

M ➝ Electric plating

D ➝ Dip plating

Cu ➝ Copper

Zn ➝ ZincHa ➝ Solder

A 8µB 4µ

A 8µA 3µ

C Coloredchromate

F ➝ Fe

Precautions when Mounting a Bus Body

The joints of pipes and hoses must be accessible to allow tightening and so that pipesand hoses can be removed. If you have fitted stiffeners to bridge the gap between theflanges of side members, be sure to cut inspection holes in the stiffener.

The pitch between holes must be 100 mm or less, and the diameter of the holes must beat least 60 mm. Make sure that the holes are in front of the clips used to secure the pip-ing to the member. You must be able to insert or remove the clips using a box wrench.

Make sure that valves are easily accessible

Drains are fitted under the air tank and relay valve. When mounting a body, make surethat the drains are easily accessible.

Make sure that the following parts are easily accessible for maintenance and replace-ment:

Air dryer Pressure regulator Check valve

Brake valve Protection valveRelay valve

Magnetic valve Quick release valve Safety valve

Brake booster, etc.

In vehicles with hydraulic brakes, make sure that the air bleeders of following part areeasily accessible for air bleeding:

Brake booster Brake master cylinder

Wheel cylinder

Allow sufficient clearance between the brake pipes, hoses, equipment and body. Whenmounting the body, make sure that body and equipment do not interfere with the brakesystem.

(For details of required clearances, see after “PIPING CLEARANCE”.)

The above precautions also apply to the valves and piping of optional equipment such asABS (anti-lock brake system).


KC-AA014A 76

02-097

Max. 100 mm

Min. 60ø mm

Precautions for Modification

As far as possible avoid modifying any piping. If you modify piping, be sure to observethe following precautions.

When extending a pipe, do not join two pipes directly.

When joining pipes, use the flare joint method and avoid twisting the pipes too much.

Most pipes are made of steel but have anti-corrosive plating on the inside. Never brazethese pipes and never heat them to high temperatures.

Do not use copper pipes for high-pressure hydraulic brake piping and for piping in areasbelow unsprung parts as on axles.

Where pipes pass through the chassis frame material, fit a grommet in the hole andsecure the pipe with clips close to the hole so that the pipe does not touch the hole or thegrommet.

PIPING


KC-AA014A 77

02-098

Do not weld brake piping and donot heat to high temperatures.

02-099

Use of Grommet

Min. 5 mm

Grommet

To remove the transmission, it is necessary to pull the transmission assembly backwardsin the line of the crankshaft. Do not install piping in areas around the transmission.

Where piping may be affected by the failure of other equipment, install the pipes insidethe side members or crossmembers, and do not allow them to protrude below the bottomflange surface of the chassis frame.

To prevent fires caused by oil leaks, do not install joints in hydraulic piping near to orover any part of the exhaust system.

Do not install piping between the spring brackets of the front and rear suspensions (out-side the lower flange surface of the frame) or within the range of movement of the springshackle.

The piping located on the axle below the springs is carefully designed to prevent damagefrom the complex vibrations which arise in this area. Do not modify this piping.

Do not install piping near to the moving parts of the chassis side propeller shaft.

Avoid making ì shape bends in hydraulic brake piping as this makes air bleeding dif-ficult.

Do not install piping in places where earth, sand, or water accumulate. Avoid coveringpipes with rubber or vinyl tubes as this tends to trap water.

When changing brake and clutch fluids, use only genuine HINO brake and clutch fluids.(For details of brake and clutch fluids, see the appropriate workshop or maintenanceguides.)

Never reuse old brake or clutch fluids. Never use mineral oil or mix HINO products withother brands of fluid.


KC-AA014A 78

02-100

Install pipes high enough so that they arenot covered by any earth or sand that mayaccumulate on the lower flange.

45°

To prevent air brake piping from freezing in cold weather, observe the following precau-tions:

• Do not make shape bends in piping as this allows water to accumulate (especiallybetween the compressor and the wet tank).

• Where a pipe ends in a hose joint, raise the end of the pipe before the joint to preventwater from running into the end of the pipe.

• Use piping of the same diameter as the piping already installed.

When installing relay valves, etc., make sure that

• they are easily accessible for maintenance and replacement,

• they have sufficient clearance from other parts, and

• they are protected from flying stones and rust.

When bending pipes, observe the following precautions:

• Use a bender and do not heat the pipes in order to bend them.

• Observe the standard bending radiuses shown in the table below.

UNIT: mm

• The minimum lengths of the straight section at the end of a pipe and of the straight sec-tion between two bends are shown in the drawings blow.

• Flush the inside of the pipe and remove any foreign matter before use. Use com-pressed air to flush the pipe.

• For details of pipe machining at the flare nut, see item 1 of this section, “Piping Used inthe Chassis”. After machining, remove any foreign matter by flushing the pipe withcompressed air.

lanimoNepipfo.aid

67.4 53.6 8 01 21 51

dradnatSRgnidneb

02 03 04 04 05 05


KC-AA014A 79

02-101

a

R

d d

R

b

R R

b

R

d

a ≥ 2d b ≥ 2d

When you install air piping to power a body or equipment, make sure it will not affect thebrake system during operation or in the event of a breakdown. When taking off an airline, do not position them

• on the main brake line (front brake line or rear brake line)

• on the charge line (between the compressor and air drier, air drier and air tank orbetween the vacuum pump and vacuum tank)

If you must take an air line from brake system, follow the rules given below:

• Take the line from the plug of the wet tank or air reservoir for auxiliary equipment.

• Provide the protection valve between air reservoir or wet tank and the body equipment.

[EXAMPLE] FOR DOOR ENGINE

If you must take an air line to power equipment form the brake system piping, takeaccount of the frequency of use of the equipment, the performance of the air supply andsafety considerations, and consult your HINO distributor beforehand.


KC-AA014A 80

PIPING FOR POWERED EQUIPMENT

02-102

BRAKE CIRCUIT DOOR ENGINE CIRCUIT

BRAKE AIR RESERVOIR

PROTECTION VALVEMust be provided.

TO DOOR ENGINE

AIR RESERVOIR FORDOOR ENGINE CIRCUIT

When installing the door engine to the body,air reservoir for door engine circuit must beprovided.

23 (L)

To prevent rust and damage from contact with other parts. When modifying piping,observe the following precautions.

Clearances between two pipes


KC-AA014A 81

PIPING CLEARANCES

.oN noitisoP secnaraelC

1 sepipowtneewteB

2 stniopgnissorcepiP

3 tniojadnaepipaneewteB

4 stniojowtneewteB

5 sesohowtneewteB

02-104

Min. 10 mm

Clip

Clip

Use clips to secure pipesnear crossing pints.

AMin. 10 mm (horizontal)A

A

(Vertical) (Horizontal) 0 (Vertical)

Min. 10 mm

02-105

02-106

02-107

Min. 10 mm

Min. 35 mm

Min. 50 mm

Min. 10 mm

At maximumdisplacementmin. 20 mm

Clearances between pipes and other parts


KC-AA014A 82


1 emarfsissahcdnasepipneewteB

2 latemtalfadnaepipaneewteBecafrus

3 rorenroclatemadnaepipaneewteBegde

4 epipadnatemmorganeewteB

5 larutcurtslatemdnasepipneewteBstrap

trapgnivomadnaepipaneewteB•

mm01.niMecnaraelcmm03.nimtuB*

trapgnivomfonoitomfotimilmorf

02-112

Limit of motion

30 mm

02-108

02-109

02-110

Do not install pipes in shaded area.

L1

L2L1=L2

Min. 5 mm

Min. 5 mm

02-111

Min. 10 mm Min. 10 mm

Dø – dø, ≥ 10 mm

dø Dø


KC-AA014A 83


6 traplarutcurtsadnaesohaneewteB sesohriadnaekarbfosecnaraelctahterusekaM.gnivirdgnirudmm05tsaeltaerasleehwotdeknilsignireetsnehw.g.e(snoitarbivfotnuoccaekaTehttasesohrehtorofsecnaraelC.)kcolllufta

:ebtsumnoitomfotimilsecafrustalfmorfmm01tsaelta•

segdednasrenrocmorfmm03tsaelta•

7 strapdetaehdnasesohneewteB).cte,metsystsuahxe(

evlavriA•epipmuucaV•epipciluardyH•

retsamriA•sesohekarB•

mm001.niM

mm051.niMtonsisihtfI.noitomfotimiltamm002.niM

gnibrosbataehhtiwesohehttcetorp,elbissop.setalp

8 dnasepiprosesohneewteBstraplacirtcele

elbacyrettabadnaepipaneewteB•

cirtcelednasepipneewteB•mm03.nimslanimret

seriwssenrahdnasepipneewteB• :gasfotimiltaseriw/sepiplellarapneewteBmm01.nimmm02.nimstniopgnissorctA

Clearance

02-113

02-114

Battery cable

Min. 10 mmMin. 20 mm

(at limit of motionof cable)

Pipes must be secured with clips to prevent them from swinging due to the motion of thevehicle. Use vinyl-coated or rubber-coated clips and follow the rules given in the tablebelow.


KC-AA014A 84

CLIPPING

.oN metI setoN

1

3

gnicapspilC

rehtegotdeppilcsepipforebmunmumixaM

gnicapspilCretemaidepiPmm004.xammm6

mm01 mm005.xameromromm21 mm006.xam

,stniopgissorc,sdnebta,revewoH,seriwdnasepiperehwdna,stnioj

eradna,lellarapnidellatsniera.cteowterehwdna,tnemevomottcejbusecuder,dellatsnierasepipreppocynatneverpotspilcfognicapseht

.noitarbiv

sepipeerhtmumixamA

Secure pipes with clips at 400 mm ~ 600 mm intervals.

Never clip a pipe with aharness wire or a fuelpipe.

02-115

02-116

2 Clipping two items with one clip

Never bind two pipes together with tape.

Never clip a pipe and a harness wiretogether with one clip.Fuel pipes may only be clippedtogether with copper pipes. Neverclip fuel pipes together with vinylhoses or rubber hoses.

Retightening brake pipe flare nuts

• When retightening flare nuts to prevent air or oil leaks, observe the specified tighteningtorques in the table below.

Unit: N.m {kgf.cm}

• If the oil or air leak does not stop after a retightening, do not continue to tighten theflare nut. Remove the nut completely, align the joint correctly and retighten the nutcarefully. Flare nut will be damaged if adjust the length of pipe by means of tighteningof the flare nut. Before tightening the nut, carefully check the cause of the leak.

Retightening when replacing pipes

• When replacing pipes between two joints or between two units, first lightly tighten theflare nuts at both ends of the pipe by hand before finally tightening with a spanner.

• If you have difficulty in tightening the nut, do not use a spanner at first, but adjust thealignment and configuration of the pipe until you can lightly tighten the nuts at bothends by hand. Never attempt to join two pipes which are not perfectly aligned. Thiswill place an excessive load on the flare of the pipe and vibration due to the movementof the vehicle may damage the pipes and lead to accidents.


KC-AA014A 85

FLARE NUT TIGHTENING

ø67.4 ø53.6 ø8 ø01 ø21 ø51

leetS5±51

}05±051{5±52

}05±052{5±63

}05±073{7±25

}07±035{7±76

}07±086{8±88

}08±009{

Using sealing agents on taper thread

• If possible, use a genuine HINO product or Loctite #575 sealing agent.

• Clean tapers with cotton waste and thinners before coating with sealing agent. If youintend to reuse joints which have been sealed with sealing agent or vulcanized tape,make sure you remove all trace of the old sealing agent or tape before re-sealing.

• Always apply sealing agent starting at one thread from the top of the taper thread, andapply the agent across three thread over one quarter of the circumference of thethread. Apply approximately 0.1 g of agent to each joint.

• When using vulcanized tape, make sure that the sealing agent does not penetrate anyvalve, etc. (If the sealing agent penetrates a valve, it may choke the valve.) As a stan-dard, leave two thread from the top of the taper thread and apply 1.5 ~ 2 turns of vul-canized tape.

Inspection after fitting

After tightening the joint,

• Make sure that there are no air or oil leaks.

• Make sure that the fitting does not place any strain on the pipe or hose (bending, dis-tortion, etc.).


KC-AA014A 86

02-117

Leave one thread.

1/4 of circumference

Apply agent acrossthree thread.

02-118

Apply vulcanized tape lightly.Leave two thread.

Nyron Tube for Brake Piping

Precautions for handling the nylon tube

When using nylon tube for brake piping, take a special care so that the nylon tube mightnot be heated while electrical welding. Also, be sure to conduct your work by putting aprotection cover on it so that welding spotters, etc. might not fall on the nylon tube. Withrespect to other general precautions, observe the following instruction.


KC-AA014A 87

nehwekatotnoituacerPgnildnah

serusaemretnuoC ecnamrofrepnodetrexeecneulfnI

ebutnolynfonoitcetorPgnidnirgrognidlewnehw

rednasahtiw

roebutnolynehtnorevocnoitcetorpatiF.yrassecenfi,ebutnolynehtevomer

no.cte,skrapsgnidlewfognihsalpSriasemitemossesuacebutnolynehtehtfognitlemfotluserehtsaegakael

.ebutnolyn

gnitartenepfonoitneverPehtotnisrettamngierofaebutnolynehtfoedisni

rotcennocdna

ebutnolynehtgnivomerdnagnittifnehWtneverpotyrassecensiti,rotcennocstidna

otgnikcitsmorfsrettamngierofagnitartenepcaslynivahtiwmehtgnirevocybmehtotniro.)elbatpeccatonsisgarelitxetgnicudorpcas(

tibsrettamngierofagnitartenePesuacyamsrotcennocevlavotninoitcnuflamroegakaelriasemitemos

.cte,sevlavehtfo

ehttsniaganoitcetorPebutnolynfoecnerefretni

elbatehtnidebircsedsaecapsawollAydobrosissahcdnaebutnolynehtneewteb

.strap

,noitcirfybebutnolynehtotdetarofreP.egakaelriaehtesuacnac.cte,raew

neewtebecapsfogniruceSehtdnaebutnolyneht

.metsystsuahxe

neewtebmm002nahteromfosecapswollAmetsystsuahxeehtdnaebutnolynehthtiwtirevocro).cte,relffum,epiptsuahxe(eboslA.ebutnolynehttcetorpotsrotalusnignittifybebutnolynehttcetorpoterusehtfosnoitropegnalfehtotsrotalusni

.metsystsuahxe

taehehtybdetaercerutarepmethgiHehttlemlliwmetsystsuahxeehtmorfrianaesuaclliwdnaebutnolyn

.egakael

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.riafoegakael

•••

mm004.xaM:lavretnI0321-73874.oNstraP:dnabpilcfostraPnehw)0101-02690(lootlaicepsehtesUehterusekamdnadnabpilcehtnethgitgninethgitnidebircsedecrofgninethgit

.loot

suidargnidnebgniruceSebutnolynfo

nolynehtfosuidargnidnebmuminimehT.elbatgniwollofehtnonwohserasebut

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.elbatehtnodetacidnieratahwnaht

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.rotcennoc

PRECAUTIONS FOR NYLON TUBE WHILE BODY MOUNTING

strapydobrosissahC ecnaraelc.niM)mm(

strapdexiF 5

strapnoitarbiV&baC,noissimsnarT,enignE(

).cte03

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strapdettimetaeH).cte&epiptsuahxE( 002

0305560708

ø6ø8ø10ø12ø15

R (mm)

R

K98010-251


KC-AA014A 88

nehwekatotnoituacerPgnildnah serusaemretnuoC nodetrexeecneulfnI

ecnamrofrepdicafognikcitsgnitneverP

noitulostitcetorp,dicatsniagakaewsiebutnolynehtsAfognihsalpsehtotdesopxeebtonyamtitahtosroetsawesohtesut'nod,oslA.diuqilyrettabeht

.diuqilyrettabehtgnikcitserahcihwnosevolg

yrettabsahcusnoitulosdicanafIeht,ebutnolynehtotskcitsdiuqilnanitluseryamdnatlemlliwebut

.egakaelria

fonoitartenepgnitneverPatagnihsawnehwretaw

erusserphgih

aeruces,erusserphgihatagnihsawnehWehtneewtebmm003muminumfoecnatsid

.tropnoitcejniehtdnarotcennocerutarepmetehtecamufagnisunehw,eroferehTnolynehtevomer,egnarsihtsdeecxehcihwfo

.ebut

ehtneewtebecnatsidehtfIsitropnoitcejniehtdnarotcennocyamretaw,tneiciffuston,gnipipehtotnietartenepgnizeerf,gnitsurnignitluser

.cte,sevlavfonoitcnuflamnolynehtfonoitcetorPatagnitniapnehwebut

.erutarepmethgih

siebutnolynehtroferutarepmetfoegnargnisU.C0°9ot04-morf

ebutnolynehtfossenthgitriAerutarepmetehtfinwodsrewolegnargnisulamronehtsdeecxe

.egakaelriaehtnistluserdna

straperapS .straPerapSeniuneGONIHesuotliafreveNfonoitcennocetaidemretnirofsrotcennoC•

ebutnolyneht

srotcennocepytgninethgiT•

sebutnolyN•

slootlaicepS Use special tools for removal and cutting of thenylon tubes.

Special tool for removal of nylon tubeHINO part number 09421-1560

•

Special tool for cutting nylon tubeHINO part number 09460-1020

•

Special tool for tightening clip bandHINO part number 09620-1010

•

0422-108430703-108430522-108430622-108430722-10843

ø6ø8ø10ø12ø15

tuN eveelS tresnI

A0701-12732A0511-12732A0211-12732A0901-12732

A0521-38974A0571-38974A0551-38974A0041-38974

A0621-38974A0671-38974A0651-38974A0141-38974

ø6ø8

ø10ø12

m02

0282-967640013-967640382-967640482-967640582-96764

ø6ø8ø10ø12ø15

NOTEParts No. will be changed without any notice.Therefore, parts number must be re-checked together with spare parts catalog.

Installation procedure for nylon tube

• Nylon tubes with the following 2 kinds of joint systems are adopted on HINO vehiclesdepending upon the vehicle models.

Push-one joint (One touch type)

Sleeve nut joint

• Please find below the outline of the fitting procedure of each joint system.

Carry out modification and installation strictly observing the “Precautions to take whenhandling nylon tubes” indicated in paragraph i).

• More detailed installation procedures are described to the Body Mounting Manual forthe respective model series as well as on the workshop manual. Kindly carry out surejobs in referring to them in parallel with this installation procedure.

Securely insert and fit the tube according to the following procedures

Inserting length of the nylon tube


KC-AA014A 89

FITTING PROCEDURE OF PUSHONE JOINT (ONE TOUCH TYPE)

retemaidebuT)retemaidedisnixretemaidedistuO(

ebutehtfohtgnelgnitresnI)mm(

mm4x6 32

mm6x8 52

mm5.7x01 52

mm9x21 62

mm21x51 72

Inserting length of the tube

Nylon tube

Presence of marking whilethe part is new.

One touch joint

Fitting procedures

Check to see that there is no inclusion of dust, etc. inside the joint.

If there is any inclusion, remove it by air-blow, etc.

Cut off the tip of tube according to the trace of joint left on the tube surface and check tosee that there is no flaw on the surface of the tube which is inserted into the joint. If thereis any flaw, cut off the tube. (Applicable only when there is sufficient margin of length)

Put a marking by a white pen, etc. at the position of inserting length on the tube uppercovering before inserting the tube and securely insert the tube up to the marked position.(A marking exist on a new part)


KC-AA014A 90

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1

&ebutweNtniojwen

2

&ebutweNtniojdesuer

3

&ebutdesueRtniojwen

4

&ebutdesueRtniojdesuer

Inserting length (marking)

1

Securely insert

Inserting length(marking)1

2

Securely insert

1

2

1

2

3

Check the inside contamination and remove adhesion of dust, etc. by air-blow etc.

Cut off Check to see thatthere is no flaw.

Trace of joint

Insertinglength(Marking)

Securely insert

Check the inside contaminationand remove adhesion of dust, etc.by air-blow, etc.

Check to see thatthere is no flaw.

Trace ofjoint Securely

insert

Inserting length (marking)

Y

Y

Y

Y

Cut off

Securely fit the nylon tube according to the following procedures.

Pass the sleeve-nut and the sleeve onto the tube and insert the “insert” into the tip of thetube. (Pay attention to the fitting direction.)

Taking care so that the sleeve-nut, sleeve and insert do not fall off, insert the tube untilthe tip of the insert touches the connector-union and, in this condition, fully tighten thesleeve-nut by hand.

Holding the tube so that it will not move (come off), tighten the sleeve-nut until the follow-ing torques are obtained.

Unit: N.m (kgf.cm)

Put marks on the connector and the union (using a magic pen, etc.) before slackeningthe sleeve-nut so that the position can be identified.

NOTEPerform tightening of the nut to 20±15°C

• Case where the tube is once removed from the joint and is reinstalledto the same position.


KC-AA014A 91

FITTING PROCEDURES OF SLEEVE-NUT JOINT

Tube

Insert

Connector/Union

Sleeve

Sleeve-nut

fognimaNdaerht

1x6M 52.1x01M 5.1x21M 5.1x51M

gninethgiTeuqrot

02 ~ 52002( ~ )062

53 ~ 44053( ~ )054

05 ~ 85005( ~ )006

45 ~ 85055( ~ )006

Match mark

When reinstalling the tube, slacken the sleeve-nut up to the position before disassem-bling (position of match marks) and retighten it by 60°.

After reinstalling never fail to check an air leakage (use or soap water is OK). If any leak-age is found, retighten the sleeve-nut until the leakage is stopped.

If the leakage cannot be stopped, replace the tube, sleeve and insert with new parts.

If this countermeasure cannot stop the leakage, replace also sleeve-nut, connector andunion.

Use the nylon tube within the following temperature range.Continuous use: -40 ~ 90°C

When performing drilling, welding, soldering, grinding with a sander, protect the nylontube against tools, chips, thermal source or sparks or remove the nylon tube.

Don’t mount the clamps of welding equipment near the tube.

Be careful not to pour an acid solution such as battery fluid on the tube.

Pay attention to the following points when defining the bending radius of the nylon tube.

The perpendicularity of the tube edge face at the time of cutting shall be 90±5° withrespect to shaft axis.

(Refer to the following illustration.)

NOTE.• Do not bend with a radius lesser than what are indicated in the following table.

• Never use the tube on which remains a folding frace due to excessive bending.

NOTE• When mounting a body or performing repair work, never use the nylon tube at a

higher temperature beyond the limit of use.

• Pay special attention when drying up the painting.

OTHER CAUTIONS


KC-AA014A 92

lanimoNretemaid

:gnildnahfoemitehttasuidargnidnebmuminiM)mm(R

0ø6

ø8

ø10

ø12

ø15

3

06

56

07

08

Within 5°

9. PROPELLER SHAFT

• The propeller shaft is an important component that transfers drive power generated bythe engine to the rear axle. The propeller shaft rotates at high speeds while operatingmaking it a very dangerous component.

• Accordingly, when mounting a bus body, be sure to observe the instructions givenbelow.

Prohibited Modifications and Alterations• Careless modifications will result in vibrations and unusual noises while the vehicle is

driving and are very dangerous. These type of modifications must not be carried out.

Confirming Correct Clearance• The propeller shaft rotates at high speeds while simultaneously vibrating up and down

and right and left along the road surface.

• Accordingly, the clearance between the propeller shaft (including joints) and the bodyor body equipment parts must be at least 50 mm from the limit of displacement of thepropeller shaft (above, below, right, left, and front or back of the rear axle).


KC-AA014A 93

02-119

PROPELLER SHAFT

REAR AXLE

Allow 50 mm clearance from limit ofdisplacement (above, below, right, left,front, or back).

LOWER LIMIT

UNIVERSAL JOINT

UPPER LIMIT

PROPELLER SHAFT

10. SUSPENSIONS

• Vehicles manufactured by HINO normally use a multi-leaf spring or air type suspen-sion. (To confirm which type of suspension is being used, see the Body MountingManual for the respective model series.)

• In addition to cushioning shocks from the road surface received while driving, the sus-pension couples the front and rear axles to the chassis frame playing the role of animportant stabilizing component while the vehicle is accelerating and braking.

• Accordingly, when mounting a bus body, be sure to observe the instructions givenbelow.


KC-AA014A 94

Description drawing

noisnepsusfael-itluM noisnepsusriA

Front 02-120

Rear 02-121

Front 02-122

Rear 02-123

Prohibited Modifications and Alterations• Careless modifications will greatly influence driving stability of the vehicle (in particular

driving in a straight forward direction) and riding comfort and may cause an accident.These type of modifications must not be carried out.

• Depending on the usage conditions, when using an additional leaf, it will be providedas optional equipment. Be sure to use equipment manufactured by HINO. (Contactthe nearest HINO distributor for information on how to install an additional leaf.)

If the additional leaf is not manufactured by HINO or excessive number of additionalleafs are used, the mounting angle of the propeller shaft will change and result in vibra-tions and unusual noises while the vehicle is driving. This is very dangerous andshould never be carried out.


KC-AA014A 95

Front

Rear

02-124

This additional leaf of the multi-leaf suspension is an option.Be sure to use equipmentmanufactured by HINO.

Inspection, Maintenance & Repair• The suspension is a component which is always moving while the vehicle is driving and

as such requires periodic greasing and parts replacement in addition to daily mainte-nance and inspection.

• Accordingly, to make these operations easier, consider a construction which allowssimple removal of the body parts of the peripheral assemblies as well as installing aninspection cover.

NOTE.• To make it possible to carry out inspections, maintenance and repair or

replace the parts inside the , an inspection cover should be installed orthe construction should be such to allow the body parts to be removed.

• The figure above shows a multi-leaf and air front suspension. The sameprocedures should be followed for the rear suspension.


KC-AA014A 96

Stabilizer

Spring pin

Shock absorberSpring pad

U-bolt

Shackle

Spring pin

Leaf spring assy 02-125

02-126

Torque rod

Air springShock absorber

Torque rod

Other Precautions When Mounting

• Suspension parts absorb shocks from the road surface received while driving and arealways changing shape. Accordingly, the parts are manufactured from very specialmetal materials or other materials.

• Accordingly, if subjected to the effects of heat or other environmental factors, this is adanger that the material hardness may easily drop or suffer damage. Therefore, donot use electrical welding of the suspension parts or a gas torch to apply heat.

• The ground used during electrical welding must not make connect with the suspensionparts.

• During welding operations around the periphery of suspension parts, be sure to protectthe suspension parts using a cover or similar item so the parts are not subjected towelding sparks.

• Because in the peripheral portion of the bracket where the suspension parts areinstalled constantly a large amount of stress is generated while the vehicle is driving,heat must not be applied to this portion by electrical welding or a gas torch.

NOTE• The figure above only shows a multi-leaf suspension. The same precau-

tions also apply to air suspension as well.


KC-AA014A 97

WELDING SUSPENSION PARTS

AND BRACKETS IS PROHIBITED.

02-127

02-128

• Grounding the weldingmachine is prohibited.

• Protect using a cover whenwelding peripheral parts.

02-129

Using a welding or gas torch to

apply heat here is prohibited.

[AIR SUSPENSION VEHICLE]

• For vehicles which are adapted an air suspension, after mounting the body confirm thefunctions of the vehicle (PDI=Pre-Delivery Inspection) as well as whether the values ofthe air spring height and the caster angle of the front wheel are within the standard.

• If either of the values are outside the standard, the values must be adjusted followingthe adjustment procedure to bring them within the standard. (For details on the adjust-ment procedure and standard values, see the Body Mounting Manual for the respectivemodel series.

• If this adjustment is not carried out, the front and rear or right and left of the vehiclemay lean or abnormal tire wear may occur. Be sure to carry out the adjustment aftermounting the body.


KC-AA014A 98

ADJUSTING THE SUSPENSION AFTER MOUNTING THE BODY

Adjustment of air spring height

02-130

Front & Rear

Spr

ing

Hei

ght

Adjustment of caster angle

02-131

Front

Upper view

Spacer insertion position for adjusting the caster angle

Torque rod

11. EXHAUST SYSTEM

• The exhaust system becomes very hot during driving.

When mounting a bus body, observe the following procedures to prevent vehicle fires.

• Modifying or altering the exhaust system will have a major effect on vehicle perfor-mance and external noise.

As a rule, the exhaust system must not be modified.

• In some countries, external noise control regulations prohibit any modification of theexhaust system.

Clearances from the Exhaust System• When mounting a body or installing related equipment, maintain the following clear-

ances from the exhaust system.

For wood, rubber, cloth and resin parts, maintain a clearance of at least 100 mm.

For brake hoses including nylon tube, fuel hoses and electrical harness, maintain aclearance of at least 200 mm.

For any other equipment that may be affected by heat, maintain a clearance of at least80 mm.

If it is impossible to observe the above clearances, fit heat insulators between the rele-vant parts.


KC-AA014A 99

02-132

Maintain the proper clearances from the

exhaust system to a body parts or equipment

and chassis parts.

Min. 200 mm

Min. 200 mm

Brake Hose, Brake Nylon Tube,Fuel Hose or Electrical Harness


KC-AA014A 100

02-133

02-134

02-135

Rubber

Wood

Min. 100 mmMin. 100 mm

Muffler

Exhaust pipe

Min. 100 mm

Maintain clearance of at least 80 mmfrom the exhaust system to the non-inflammable parts, such as steelparts or equipment.

Fit heat insulators, if it is impossibleto observe the proper clearancesfrom the exhaust system.

Body and relevant parts

Heat insulator

Min. 80 mm

EXHAUST PIPE

HEAT INSULATOR

MIN. 35 mm

WOODEN OR RUBBER PARTS

CHASSIS FRAMESIDE MEMBER

HARNESS, BRAKE PIPE ORHOSE AND NYLON TUBE

MIN. 35 mm

Mounting a Body Parts or Equipment Near the Mouth of the Exhaust TailPipe

• When mounting or installing body parts or equipment to the rear of the mouth of theexhaust tail pipe, do not mount or install any parts or equipment within the area indicateby the hatching in the figure below:


KC-AA014A 101

02-135

02-137

Do not mount any parts orequipment near the mouthof the tail pipe.

Make sure that no inflammable parts (brakehoses, tubes, electrical wires) are in the flowof the exhaust gas.

Mouth of tail pipe

Min. 15°

Min. 15°

Min. 1000 mm

NOTEApplies to area above, below, right and leftof tail pipe.

Modify or Altering the Exhaust System• Modifying or altering the exhaust system will have a major effect on vehicle perfor-

mance (engine power and black exhaust smoke) and external noise.

Accordingly, modifying or altering the exhaust system is basically prohibited.

• If modifications or alterations must be done because of mounting a body or installingrelated equipment, be sure to observe the instructions given below.

Range of allowable modifications or alterations (position)

• Modifications or alterations to only the tail pipe protruding from the muffler are allowed.

• Modifications or alterations between the engine and muffler including the muffler itselfare prohibited.


KC-AA014A 102

PROCEDURE OF MODIFYING OR ALTERATION

02-138

Exhaust pipe betweenengine and muffler

Front

Muffler

Tail pipe

Do not modify or alter any partwithin this range.

(Above drawing shows the exhaust system of the rearengine vehicle.)

Material and size of tail pipe

• The material and inside diameter of the pipe must be identical to that of the vehicle’soriginal pipe.

• The material used differs according to the type of vehicle;

Machine structural carbon steel pipe color: black

Zinc-plated steel pipe color: silver

Aluminum-plated steel pipe color: silver

• The plating of a zinc or aluminum-plated pipe will peel if the pipe is welded and therust-resistance of the pipe will deteriorate.

Therefore, paint the pipe in a similar color after welding.

Extending or bending the tail pipe

• Extending or bending the pipe raises the exhaust resistance and will result in a declinein engine output, an increase in fuel consumption, and an increase in exhaust gas den-sity (black smoke level).

• Study the likely effects with care before making any modification or alteration of thiskind.

• As a rule, the bending radius of the tail pipe should be at least 1.5 times the diameter ofthe pipe.


KC-AA014A 103

02-139

R

R

d

R

R

d

Bending radius of exhaust tail pipe

should be min. R 1.5D.

• When the exhaust tail pipe is extended or the rute is modified, securely retain the tailpipe end to the chassis frame or body structure.

Like the engine, because the exhaust always vibrates, be sure to use a rubber cushionto retain the tail pipe and absorb vibrations. (Use the same type as the ones used in abase vehicle.)


KC-AA014A 104

02-140

BOLT

WASHER

CUSHION RUBBERS

Position or direction of the mouth of the tail pipe

• The position or direction of the opening of the tail pipe should basically be as shown inthe figure below.

However, detail of the procedure must be followed the instruction described in the bodymounting manual for respective model series.

• Further, if there are vehicle laws and regulations on the position or direction or theheight from the ground of the opening of the tail pipe, the standards of the regulationsshould all be satisfied.

The clearances between exhaust parts and other parts

• As stated in the beginning of this section and 1)., when modifications or alterations tothe exhaust tail pipe are done, proper clearance between the chassis parts and bodyparts or equipment should be ensured to prevent fires from occurring.

Clearances from fuel system parts

• Maintain a clearance of at least 200 mm between the fuel tank, fuel pipes, etc. and theexhaust system.

• If you cannot maintain a clearance of 200 mm, fit heat insulators to protect the fuel tankand fuel pipes.


KC-AA014A 105

To face the mouth of thetail pipe to the pedestrianside is strictly prohibited.

MAX. 25°MAX. 25°02-141

1±150 ~ 15°

MIN. 1 m

Pipe must not protrude beyond

overall width of vehicle.

CLEARANCES FROM CHASSIS PARTS

• When arranging fuel piping, make sure no fuel will come into contact with the exhaustsystem even if a fuel line ruptures and fuel leaks out.

Never make joints in the fuel pipes above the exhaust system, etc.

Precautions on fuel tank

• When moving the fuel tank or mounting an additional tank, make sure that the fillingport is at least 300 mm away from the mouth of the tail pipe and at least 200 mm awayfrom exposed electrical terminals.

Clearances from other chassis parts

• When the exhaust system approaches the periphery of the engine air cleaner, an insu-lator must be installed completely isolated from the exhaust system to prevent theengine air cleaner from being subjected to heat.

• Maintain the clearances shown in the table below if you cannot maintain these clear-ances, fit heat insulators.

Observe the instructions given in this section Item 1, concerning clearances from bodyparts or equipment with the exhaust system.

After Body Mounting• After body mounting, cut the tail pipe not to appear buck from a body end.


KC-AA014A 106

)mm(ecnaraelC trapsissahC

001.nim sepiplio,sepipmuucav,sepipriA

051.nim retsamordyh,retsamriA

002.nim niser,).cte,sesoh(straprebbur,selbacyrettab,yrettab,seriwlacirtcelE.strap

CLEARANCES FROM BODY PARTS OR EQUIPMENT

12. TIRE

• A chassis on which genuine tires are mounted sent to the body mount manufacturer.

• While mounting the body, there is a danger that scratches, paint adhesion, or otherdamage may occur during welding and other operations. Be sure to observe theinstructions for the mounting operation given below.

Precautions Before Start Body Mounting Work• While mounting the body, attach covers to tires to prevent paint deposit and damages

to tires. Or begin body mounting after changing tires to dummy tires.

Body Mounting

• As previously stated in 1. General Precautions “1-4 Tire Wheel House & SplashGuards”, install a tire wheel house & splash guard to protect the chassis parts fromdust, water, or mud thrown up by the tires while the vehicle is driving.

(For details on installing the wheel house & splash guard, see the Body MountingManual for the respective model series.)


KC-AA014A 107

MOUNTING A TIRE WHEEL HOUSE & SPLASH GUARD

02-142

02-143

WHEEL HOUSE

A

A

A

A

INSTALL A COVER PLATE

FRAME SIDE RAIL

Section A-A

TIRESPLASH GUARD

200 ~ 250 mm

Splash guard(More detail, refer to next page.)

A

B

CH

AS

SIS

CE

NT

ER

UNIT: mm

[DETAIL OF FRONT SPLASH GUARD]

[DETAIL OF REAR SPLASH GUARD]

(The figure above shows a splash guard for a rear engine as a representative example.)

Details of splash guard


KC-AA014A 108

02-144

Splash rubber

Splash guard(Made by steelplate)

Body

If there is space between floor and chassis frame, it should beclosed by steel plate.

Floor

Chassis frame

Ground level

200

150

02-145

Splash rubber

Splash guard(Made by steel plate)

Body

If there is space between floor and chassis frame, it shouldbe closed by steel plate.

Floor

Chassis frame

Ground level

200

110

Groove for the propeller shaft

• The spare tire & tire carrier is mounted between the front or rear overhang or thewheelbase under a chassis condition.

• The spare tire is a very heavy part and if dropped while the vehicle is driving can causea severe accident. Be sure to observe the instructions for the body mounting operationgiven below.

Installing the hole of the wind handle & caution plate for operation

• Provide a hole on the body outer panel for the wind handle that operates the sparetire carrier to pass through.

UNIT: mm

• Install a caution plate for spare tire removal and installation operations close to the holeof the wind handle so it can easily be verified from the outside area.

(The caution plate is packed the same time the chassis is shipped.)


KC-AA014A 109

SPARE TIRE & TIRE CARRIER

02-146

SPARE TIRE

FRONT HOLE OF WIND HANDLE

50

15

ø25

R

R85

0

02-147

How to Handle the Spare Tire

• Make sure that claw of hanging plate and disk wheel are properly located.

• Do not wind up spare tire when chain is twisted.

• Remove mud from contact surfaces and wind handle until it stops, then tighten

with 30 ~ 40 kg force (max. strength of adult using one hand).

• After tightening, make sure that the claw of hanging plate is not caught on the

contact surface, and remove handle without winding back.

Hanging plate claw

Modification or alteration of spare tire carrier

• The spare tire carrier is designed to have sufficient strength, durability and ability tohold a spare tire as well as ease of removal and installation.

• Accordingly, careless alterations or modifications are prohibited.

• If modifications or alterations must be done because of the body design, be sure toobserve the instructions given below.

Ensure that:

There is sufficient strength, durability and ability to hold a spare tire.

The spare ire should be easily removed or installed by one person.

There should be no obstructions interfering with winding up the spare tire.

During tightening, the tire should only contact the stopper.

If the tire is supported by the disc wheel contact face, the distance between the sup-ports should allow proper contact with the disc wheel contact face.


KC-AA014A 110

02-148

Spare tire supportTIRE CARRIER

DISTANCE BETWEEN SUPPORTSCONTACT WIDTH

[Contact face should belonger than disc wheelcontact face.]

• If the tire is supported by the tire rubber itself, the distance between the supportsshould be close to the maximum width of the tire and the supports should be coveredby cushion rubber which are firmly fixed to the supports.

Further, the structure should provide adequate tightening resistance for the puncturedtire to be carried.

• Even when attaching a spare tire carrier not manufactured by HINO, carry out theinstallation operation described above and be sure to install a caution plate that statesthe operation procedure, such as the wind up torque, close to the wind handle hole.


KC-AA014A 111

02-149

Spare tire support

TIRE CARRIER

[Should have cushion rubbers& distance between supportsshould be close to the max.width of the spare tire.]

CUSHION RUBBER

Distance should beclose to tire width.

• For the case that a spare tire carrier is supported by

the tire rubber itself, the construction should be such

that the attached stopper makes contact with both the

tire and disc wheel to allow carrying even for a punc-

tured tire.

02-150

The carrier must havea stopper that will giveadequate tighteningresistance even with apunctured tire.

DISK STOPPER

TIRE STOPPER PUNCTURED TIRE

DISK

Other precautions

• Observe the instructions given below when carrying out modifications or alterations tothe spare tire carrier.

[MOUNTING POSITION]

Make sure that the spare tire carrier is mounted sufficiently high to prevent groundingduring driving on rough roads and in reverse. Make sure that the carrier does not pro-trude beyond the end of the rear overhang or beyond the overall width of the vehicle.

Maintain proper clearances from rotating, moving, or hot parts (propeller shaft, springs,brake hoses, exhaust system, etc.).

Make sure the mounting position allows enough space to remove and install the sparetire.

[MOUNTING THE CARRIER BRACKET]

The spare tire carrier may be mounted on the chassis frame side rail using bolts or rivets.

Whatever the method you use, make sure that it does not adversely affect the strength ofeither the bracket or the chassis frame side rail, and observe the precautions listed inSection 4, “CHASSIS FRAME”. When mounting the carrier bracket using bolts, makesure the bolts are properly tightened but that they can be re-tightened further if the needarises.

Mounting the carrier bracket by welding is strictly prohibited.

[CAUTION PLATE FOR OPERATION OF THE SPARE TIRE]

Fit caution plate showing the proper wind up tightening torque and operation for the carri-er in a visible location as close as possible to the carrier.

The style of the caution plate should be similar to that of a genuine HINO caution platewhen installing a spare tire carrier not manufactured by HINO. (A sample of a HINO cau-tion plate is as attached previously.)


KC-AA014A 112

[SPARE TIRE CARRIER]

When installing a carrier not manufactured by HINO

When the tire is secured in place, make sure that dimension h is within the maker’s rec-ommended range. (Important with regard to chain strength.)

[MOUNTING THE CARRIER AT AN ANGLE]

As a rule, the carrier should not be mounted at an angle, except when the slope is due tothe structure of the chassis frame.

[CARRIER MOUNTING BRACKET]

The carrier mounting bracket is important in maintaining the function of the carrier. Makesure you observe the following precautions.

Bracket shape

Take proper care when designing the bracket shape. The shape of the racket must dif-fer according to type of vehicle and mounting position. The two diagrams below showtypical bracket shapes for reference.


KC-AA014A 113

02-151

HANGING PLATE

TIRE CARRIER ASSEMBLYCARRIER BASE POSITION

UPPER SURFACEOF DISC

• For details, refer to the instructions of thecarrier manufacturer.

h

Bracket for mounting on side of chassis frame

Bracket for mounting between side members


KC-AA014A 114

Min. bolt dia. ø12 mm

(use at least 7t)

Frame

Pitch should be as large as possible.If large pitch is not possible, use threebolts (min. pitch 50 mm).

Medium-duty vehicles: min. L40 x 40 x t5 (cross sectional coefficient min. 1.9 cm3)Heavy-duty vehicles: min. L50 x 50 x t6 (cross sectional coefficient min. 3.5 cm3)

To prevent catching, make sure diskcontact face is smooth and flat.

Min. 50 x t6

Allow the actual measureof tire carrier.

Make sure there are no defects in welding.Allow the actual measure of tire carrier.

Note: Make sure mounting bolts are properly tightened, but allowfor further tightening.

02-152

(Material: SS41P or stronger)

150

Min.200

Min. 80

40

Note: Make sure mounting bolts are properly tightened, but allowfor further tightening.

02-153

Min. bolt dia. ø12 mm

(use at least 7t)

To prevent catching, make sure disk contact faceis smooth and flat.

Heavy-duty vehicles: cross section min. L80 x 80 x 4.5t (Z=min. 4.1 cm3)Medium-duty vehicles: cross section min. L80 x 50 x 4.5t (Z=min. 4.0 cm3)

(H) x (W) (Material: SS41P or stronger)

[CRANK HANDLE (HANDLE FOR WIND UP THE TIRE)]

The size of the arm of the crank handle (L) must be the length that allows the carrier’smanufacturers recommended tightening torque when installing a carrier not manufac-tured by HINO.

Make sure that the operation of the crank handle is not obstructed with other parts.

Shipping Inspection After Mounting the Body• After mounting the body, carry out the following inspections of the tires in addition to

inspecting each function when shipping the vehicle.

• If the results of the inspection do not satisfy the standards, either adjust or correct sothe standards are met or, if necessary, replace with new parts. After these actions,ship the vehicle.

(Contact the nearest HINO distributor for information on the inspection procedure andstandard values.)

[INSPECTION ITEMS]

• Tire inflation pressure

• Tightening torque of wheel nut

• Scratches or contamination on tires (paint adhering, etc.)

• Looseness of spare tire carrier installation bolt

• Looseness of spare tire and clattering


KC-AA014A 115

02-154

L

13. ELECTRICAL EQUIPMENT AND RELATED PARTS

• Because the electrical wire harness and equipment normally are temporarily attachedto the chassis under a chassis condition, be sure to observe the mounting instructionand take correct actions.

• Due to recent improvements in vehicle performance and to comply with laws and regu-lations, Hino chassis have electrical computers for engine or transmission controlinstalled and it a mistake is made in the mounting procedure, there is a chance thesecomputers will stop operating. Therefore, great care must be taken during the mount-ing procedure.

• If the electrical equipment or wire harness are poorly prepared, fire may result causinga major accident.

General Precautions for Electrical Equipment• During electrical welding, be sure to observe the instructions in the previously

described section “1. GENERAL PRECAUTIONS [Points To Note On ElectricalWelding]” .

• Do not install additional accessory lamps which use the lamp circuit of the chassis forthe power supply. Otherwise, the capacity of the detector relay incorporated into thelamp circuit will be exceeded and the “Open Circuit Detector System” will stop function-ing.

• When removing the power supply of the electrical equipment on the body side from thechassis, be sure to remove from the indicated terminal. The power consumptionshould also be within the indicated capacity. Removing the power supply from a posi-tion other than the indicated one may result in burning or fires. Accordingly, do notremove the supply incorrectly.

• If the temperature of the computer that controls the engine or transmission becomeshigh, the computer may suffer damage. Be sure to install the computer at a locationwhere the ambient temperature is maintained at 60°C or less.

• If necessary, inspect or replace each of the electrical equipment of the chassis.Accordingly, add an inspection cover or lid at a position that allows easy inspection andmaintenance.

• For more details than above and for additional instructions when mounting a body, fol-low the instructions after 2).

• For the chassis wiring diagrams, see the Body Mounting Manual for the respectivemodel series.


KC-AA014A 116

Front and Rear Chassis Harness Wiring• The front and rear chassis harness wiring is installed temporarily under a chassis con-

dition.

• After installing the electrical component box, head lamp and rear combination lamp tothe body, confirm the wiring is correct and firmly secure them to the chassis and bodystructure using a clip.

(For details on the method to secure the harness using a clip, refer to the section on“Harness Wiring”. For details on the front and rear harness wiring, see the BodyMounting Manual for the respective model series.)


KC-AA014A 117

FRONT HARNESS WIRING

REAR HARNESS WIRING

Setting position during thetime of body mounting

Front electrical component box

FLOOR SURFACE

TEMPORARY SETTINGPOSITION UNDER THECHASSIS CONDITION

Inter harness and front harnessshould be connected above thefloor surface for protected againstwater, dust, mud, etc. 02-155

02-156

Setting position during thetime of body mounting

Temporary setting positionunder the chassis condition

Front and Rear Electrical Component Box• Various types of relays, fuses and other important electrical components are housed

inside the electrical component box.

• When mounting a body, these components should not be subjected to water, dust, orheat.

• Further, an inspection cover or lid must be installed for inspection or maintenance.

• Because the front electrical components are in a temporarily installed state duringchassis, they should be installed at correct locations in consideration of the points stat-ed above.

(For details on the temporary installation position during chassis and the normal instal-lation position during the body mounting, see the Body Mounting Manual for therespective model series.)


KC-AA014A 118

02-158

FRONT COMPONENT BOX

WARNING BUZZEROVER HEAT RELAY

POWER RELAY

TAIL LAMP RELAY

FUSEBLOCK

FLASHER UNIT

HEAD LAMP RELAY (DIMMER)HORN RELAY

HEAD LAMP RELAY (MAIN)

WIPER SWITCH

CIGARETTE LIGHTER (OPT)

HAZARD & PARK SWITCH

FOG LAMP SWITCH

BATTERY SWITCH

STARTER SWITCH

COMBINATION SWITCH

Above drawing shows the setting position

under the chassis condition.

Should be set in the front panel and hassuitable inspection cover or lid

RESERVOIR TANK(BRAKE FLUID)

02-157

Electrical Computer Box• Due to recent improvements in vehicle performance and to comply with exhaust gas

emission regulations, electronic computers for controlling engines and transmissionshave come into use being installed in chassis.

• If these computers are subjected to water, dust, or heat, they may be damaged andstop functioning.

Further, because the installation position under a chassis condition is a temporaryinstallation condition, be sure to securely install the computer to the body side whileobserving the following instructions when mounting the body.

(For detailed instructions on mounting, see the Body Mounting Manual for the respec-tive model series.)

Install at a position where no water or dust enter and high temperatures are avoided.(The peripheral temperature of the installation position should be 60°C or less.)

Installation inside the passenger compartment is usually recommended but if the comput-er must be installed on the floor, be sure to provide an installation box that keeps wateror dust from entering and an inspection cover or lid for inspection and maintenance.

Also, be sure the computer is installed at a position not subjected to direct sunlight or thata cover is provided to protect it from possibly being subjected to direct sunlight.


KC-AA014A 119

REAR COMPONENT BOX

INSTALLATION PROCEDURE OF COMPUTER BOX

02-159

Setting position of rear electricalcomponent box(For rear engine only)

• Do not modify or alter the settingposition.

• Fit the inspection cover or lid formaintenance.

Sealing should be securely made so water or dust do not enter the floor surface of theharness wire or the passageway of the partition plate of the box.

Further, the harness should not interfere with the edges to prevent short circuits.

Do not set antennas of televisions, radios, or other electronic devices close to the com-puter box.

In principle, the connecting wire between the computer box and the harness wire shouldnot be removed. However, when the coupler must be removed during installation, besure to securely connect again. (Be careful not to make any wiring mistakes or to forgetto connect the wires.)

NOTEThe figure above shows a rear engine vehicle. The same specificationsapply to a front engine vehicle as well.


KC-AA014A 120

02-090

Installation of computer box

02-160

Computer box

Temporary setting positionunder the chassis condition

Passageway of the harness

• Securely seal to prevent water or dust fromentering.

• Should not interfere with the edges and theharness should be protected by rubber.

Floor surface

Computer box

Any paint or contamination on the terminal installation surface of the computer boxground should be removed and the ground connected between the computer case andthe bracket.


KC-AA014A 121

Ground connection of computer box

CPU (COMPUTER) BOX CASE

CPU (COMPUTER) BOX

BRACKET

CPU (COMPUTER) BOX

SUB-HARNESS FOR GROUND

• Remove any paint or contamination onthe terminal installation surface andsecurely connect the ground.

02-162

Fuse block• The fuse block is installed inside the front electrical box.

• If the fuse is blown due to operation mistakes while mounting the body, the fuse shouldbe replaced with a fuse of the rated capacity.

Do not use wire not for the fuse.

(Do not use a fuse with a rating other than the correct value because of the danger ofburns to the wire harness or damage to the electrical equipment due to the fuse notoperating properly if a circuit error occurs.)


KC-AA014A 122

WARNING BUZZER

OVER HEAT RELAYPOWER RELAY

TAIL LAMP RELAY

Front electrical component box

Fuse block

FUSE BLOCKFLASHER UNIT

HEAD LAMP RELAY (DIMMER)

HORN RELAY

HEAD LAMP RELAY (MAIN)

WIPER SWITCH

CIGARETTE LIGHTER (OPT)HAZARD & PARK SWITCH

FOG LAMP SWITCH

COMBINATION SWITCH

STARTER SWITCH

BATTERY SWITCH

RESERVOIR TANK(BRAKE FLUID)

FUSE BLOCK TOPFUSE BLOCK TOP

USE THE DESIGNATED FUSES ONLY

KEY SWITCHHEAD LAMP MAIN LH

FOG LAMP TAIL LAMP

GAUGE LAMP

SPARE (TAIL)

BACK LAMP

SUB STARTER

HORNZF-T/M(F1)

ZF-T/M(F2)

ZF-T/M(F3)

AIR DRIER

EXH. BREAK

ENG. STOP

ABS TICS

TICS

HEAD LAMP MAIN RH

HEAD LAMP DIM. LH

HEAD LAMP DIM. RH

CIGARETTE LIGHTER

STOP LAMP

TAIL LAMP RELAY

GAUGE

ENG. STOP

REGULATOR

STARTER

WIPER

20A

10A

10A

10A

5A

10A

10A

10A

10A

5A10

A5A

10A

10A

5A10

A5A

5A10

A5A

10A

10A

10A

5A10

A

15A

5A

10A

20A

76588-3530

02-163

DETAIL OF BLOCK ASSY. FUSE(EXAMPLE)

Electrical Power Source Terminal• Because the power source of the electrical equipment of the body has a special

removal terminal provided on the chassis, be sure to remove it from the specified termi-nal.

The power consumption should be controlled at the indicated capacity or less.

• Removing the electrical power from a terminal harness other than the specialized oneswill result in burns or fires and must not be done.

• Fuses should be provided for each circuit inside the electrical equipment circuit on thebody side.

• When taking electrical power directly from the battery of the chassis, a fuse must beprovided between the battery and the electrical equipment on the body side. Be sureto observe the instruction given below.


KC-AA014A 123

[POSITION OF POWER SOURCE TERMINAL]

• Front engine chassis ➝ Installed inside the junction block between thewheelbase

• Rear engine chassis ➝ Installed inside the rear electrical component box

02-164

POWER SOURCE TAKING OUT TERMINAL POSITION

FRONT ENGINE VEHICLE

FROM

BATTERY

RELAY

★ OUTPUT POWER TERMINAL OF BODY &COOLER(MAX. OUTPUT CAPACITY: 35A)

TO ALTERNATOR

TO STARTER MOTOR

Junction block

(Installed between wheelbase.)

NOTE• For details of the maximum removal electrical capacity (A), see the Body

Mounting Manual for the respective model series.

• If indicated capacity is exceeded, a blow of the fuse on the chassis sideor harness burning may result causing a fire. Be sure not to exceed theindicated capacity.


KC-AA014A 124

REAR ENGINE VEHICLE

Power source taking out terminal

• FOR COOLER• MAX. OUTLETCAPACITY 70A

• FOR BODYELECTRICALEQUIPMENT

• MAX. OUTLETCAPACITY 42A

ELECTRICAL OUTPUT SOURCE BOX

SAFETY RELAY

STOP LAMP RELAY

REGULATOR (OPT)

Rear electrical component box

(Installed on the No. 8 crossmember)

02-165

• If you intend to use power for the body electrical equipment directly from the battery,secure the battery cable and the body power supply terminal together with the samenut (see drawing).

• In this case, a fuse must be installed at a suitable point in the circuit. Take precautionsto prevent short circuits as these may lead to vehicle fires.

• When securing the cable and power terminal, make sure the nut is properly tightened.


KC-AA014A 125

USING POWER DIRECTLY FROM THE BATTERY

02-166

Battery + Terminal

Battery cable

To body

Terminal When taking out power sourcedirectly from the battery terminal, afuse must be installed between bat-tery terminal and body electricalequipment.

Notes about the ground of additional circuit.

• Don't connect the ground of additional circuit to the same position as the existing earthwire of vehicle.

• Be sure to connect the ground of additional circuit to the frame to which the negative"–" battery cable is connected.

• Install the grounding terminal of additional circuit in a frame with the bolt with a "LOCKWASHER, EXTERNAL TOOTH".(For detailed informetion, contact to authorized HINO dealer.)

• The grounding terminal should use a round shape terminal.

• Weld a nut to the frame and take the measures which prevent the rust of the nut.

• Remove the paint of the frame of the position in which a grounding terminal is installed.

• Install the grounding terminal securely in a frame.


KC-AA014A 126

Wiper and Washer System Circuit• Only the wiper and washer switch are incorporated into the steering column under a

chassis condition.

• Accordingly, the body manufacturer is responsible for designing the wiper and washersystem circuit with the necessary parts provided and installed to the body.

[PARTS PREPARED BY THE BODY MANUFACTURER]

• Wiper motor assembly

• Wiper blade and control linkage assembly

• Wiper relay

• Intermittent relay

• Washer system assembly

• Wire harness

• Be sure to observe the following instructions in the design of the wiper and washer sys-tem circuit and installation to the body.


KC-AA014A 127

The capacity of the contacts of the wiper and washer switches installed in the steeringcolumn under a chassis state is small.

The main operating current to operate the wiper motor should not flow through theseswitches.

Accordingly, the wiper circuit should have a circuit design that operates the relay of theinstalled wiper motor.

(The design should be such to create a circuit in which only the signal current that con-trols the relay for the wiper and washer switches flows.)

The capacity of the contacts of the wiper and washer switches should be as follows.

The power supply of the wiper circuit should be removed from the specified terminalinside the front electrical component box.

If removed from another wire harness, an overload will result causing a short-circuit inthe fuse or harness of fire. Do not remove from the incorrect terminal.

Refer to the typical recommended wiper circuit for details.

However, detail of the wiper circuit and installation procedure must be followed theinstruction described in the body mounting manual for respective model series.


KC-AA014A 128

DESIGN OF WIPER CIRCUIT AND ASSEMBLY

WASHER

SWITCH

WIPER & WASHER SWITCH

WIPER SWITCH

OFF •

INT •

LO •

HI •

02-167

[SWITCH CONNECTION DIAGRAM]

lanimreT

noitisoPWW WE IW LW HW

FFO

.TNI

OL

IH

NOREHSAW

Electrical capacity of each

• EW-WI : 0.5 A• EW-WL : 0.5 A• EW-WH : 0.5 A• WW-EW : 2.0 A (motor load)

* Relay operationresistance only

NOTEThe * mark indicates a motor load isnot included.


KC-AA014A 129

1 32 4

56

71

23

45

6

3WR

0.85BY

0.85BY

0.85B

0.5LG

0.5GR

0.5GB

FU

SE

20A

12

34

5

51

43

2

2BW

➁➀

2 1 M

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ER

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H

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7

45 6

INT

ER

MIT

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1

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GR

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2LR

2L

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2LB

2BW

LG2B

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2BW

2

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2LR

2LW

2LB

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➄➄

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02-169

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KC-AA014A 130

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02-1

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➅➄

➂➁

➅➃

➄➂

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2LB

2LW2LR

2BW2LB

2BW

2B

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2LW

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2B

Relays which is described in diagram are option parts.

If it is needed, contact authorized HINO distributor.

How to read the connector and color symbol marks marked on each wiring in the dia-gram.

• Color symbolsB Black W White L BlueG Green Y Yellow R RedBr Brown Lg Light green

• Symbols-two lettersThe first letter Ground colorThe second letter Marking color[Ex.] BLWith blue marking on the red back ground

Select a wiper relay with sufficient capacity taking into consideration the performance(capacity) of the wiper motor.

The wire harness size and power supply fuse for circuit should be selected depending onthe capacity (operation current) of the wiper motor.

For wiper motor capacity of 7A or less:• Harness size → 0.85 Sq. mm• Fuse → 10A

For wiper motor capacity of 7A but less than 14A:• Harness size → 1.25 Sq. mm or bigger• Fuse → 20A

NOTEParts number of relay

Wiper (power) relay: 85910-1360Intermittent (power) relay: 85910-1360


KC-AA014A 131

PRECAUTIONS OF DESIGN OF WIPER CIRCUIT AND ASSEMBLE

02-174

CONNECTOR

COLOR SYMBOL MARK

See from this side.

Connector

Harness3

2

1

4

5

6

Color symbol of harness wiring

Cross section area of harness conductor

0.85 BL


KC-AA014A 132

NOTE• The wire harness size and power supply fuse are determined based on the capacity

of the operating current and are not related to the number of wiper motors installed.

• If the capacity of the operating current will exceed 7A, modifications to the powersupply fuse as well as the power supply harness for wiper circuit incorporated onthe chassis side are necessary.

• For details of power supply fuse and harness for wiper circuit incorporated on thechassis side are described in “6 ATTACHED DATA, ELECTRICAL WIRING DIA-GRAM”.

• For details on modifying the fuse and harness, contact the nearest HINO distribu-tor.

• The capacity of the operating current of the circuit should be controlled at 70% orless of the capacity of power supply fuse in view of safety considerations.

[Ex.] Modifications of power supply fuse and harness incorporatedon the chassis side.

Fuse 10A → 20AHarness size 0.85 OR → 1.25 Sq. mm or bigger

1.25 Sq. mm

Lamps• The lamps, head lamp, tail lamp and other lamps, are temporarily installed on the chas-

sis or separately supplied at delivery of the chassis.

Therefore, when mounting the body, these lamps should normally installed to the body.

• For details of installation holes for lamps, see the Body Mounting Manual for therespective model series.

Open Circuit Detector System• In order to increase the level of safety, an “Open Circuit Detector System” that informs

the driver of an open circuit in the lamp circuit is incorporated into the circuit associatedwith the lamp.

• When installing additional accessory lamps which use the lamp circuit of the chassis forthe power supply, the “Open Circuit Detector System” will stop functioning if the capaci-ty of the detector system relay is exceeded.

• Accordingly, observe the following points when installing additional accessory lampswhich use the lamp circuit of the chassis for the power supply.

If one of the circuits of the directional indicator lamps opens, detector system will changethe flashing frequency and function to inform the driver of the open circuit.

Therefore, the flasher unit uses components equal to the total W number of directionalindicator lamps. If the number of lamps is increased when mounting the body, the totalW number will increase and the detector system will stop functioning.

Accordingly, when increasing the number of lamps which use the directional indicatorlamp circuit for the power supply, be sure to replace the flasher unit.

Capacity and parts umber of flasher unit


KC-AA014A 133

DIRECTIONAL INDICATOR AND HAZARD LAMPS

02-175

dradnatS gnithgildesaercnI

)ediseno(yticapaC W52 x W3+3 xW52 xW01+3 W3+2

rebmunstraP 0841-08918 1211-08918

(Parts number of flasher unit will be changed according to chassis model.)

Front

3W

25W

10W x 2(INCREASED LIGHTING)

25W

Precautions of Electronic Machines• As described previously, due to recent improvements in vehicle performance and to

comply with laws and regulations, vehicles are also being equipped with electroniccomputers.

• If this electronic equipment is subject to heat, shocks, or other factors such as highvoltage electrical welding, internal damage will occur and the equipment will stop func-tioning.

• Accordingly, be sure to carefully observe the following precautions when mounting abus body on a chassis in which electronic equipment is installed.

• The electronic equipment used in HINO bus chassis are shown below.

HINO TE-systemElectronic control governorElectronic control timerPre-lift control fuel injection pump

A.B.S. (anti-lock brake system)

A.S.R. (anti-slip regulation system)

FSV controller

Vehicle speed control limiter

Auto-transmission control computer

• Circuits related to electronic control (control unit, actuator, sensor, etc.) use a specialmulti-terminal connector because they use a very small current.

Therefore, take note of the following points when handling them while mounting thebody.

Unnecessary removal or insertion of connectors should not be done.

Deformation or damage to connectors will result in decreases in the insertion force andpoor connections.


KC-AA014A 134

KINDS OF ELECTRONIC EQUIPMENT

HANDLING PRECAUTIONS

When removing the connector, be sure to hold the male and female parts of the connec-tor housing.

Removing the connector by holding the harness wire and pulling or twisting will causedamage to the harness wire and deformation of the terminal. Do not remove the connec-tor in this way.

Be sure water, oil, or dust do not adhere to the removed connector. Poor connections orunstable continuity will result.

When connecting the connector, be sure to securely connect it until the lock engages.

Observe the following precautions for electronic equipment installed on the body side.

• The electronic equipment may malfunction due to large amounts of noise generated bythe equipment itself.

Accordingly, a component with a noise eliminator such as a diode of bakusuta attachedshould be used for the relay, solenoid, or motors installed to the body.


KC-AA014A 135

Harness Wiring• If a mistake is made in the harness wiring while mounting the body, the harness may

be damaged by vehicle vibration while the vehicle is driving, or water, dust, or mudentering into the harness. If these occur, a short-circuit or fire may result causing asevere accident.

• Accordingly, be sure to observe the procedures given below for modifications or alter-ations of the harness wiring involved with the body mounting or other actions.

When installing U-bolts or body mounting brackets, or when mounting bus body or relat-ed equipment, observe the following precautions.

• Make sure that harness wires and battery cables are not squeezed or pinched, and donot come into contact with sharp edges or corners.

• Make sure that harness wires, battery cables and other electric equipment (switches,magnetic valves, battery, etc.) are easily accessible for maintenance.

If you fit additional switches or lamps for a body or equipment, observe the following pre-cautions.

• To prevent accidental operation or confirmation, install a caution plate showing the pur-pose of each switch, etc.


KC-AA014A 136

PRECAUTION WHEN MOUNTING BUS BODY

OR RELATED EQUIPMENT

Squeezed Pinched Sharp edge

02-176

02-177

Caution plate

• Common use of switches which are already installed on the chassis side for control oflamps installed on the body side or other electrical equipment is prohibited.

An overload will occur resulting in burning of the switch contacts or harness.

The control of the electrical equipment on the body side should be done using a sepa-rately installed switch.

If you intended to fit a buzzer for a body or equipment, make sure that its sound is clearlydifferent from that of the existing buzzer around the driver’s seat of chassis.

[SPECIFICATION OF EXISTING BUZZER AROUND DRIVER’S SEAT]

For details of any other buzzers, see the Body Mounting Manual for the respectivemodel series.


KC-AA014A 137

ADDITIONAL SWITCH[RIGHT]

EXISTING SWITCH[WRONG]

02-178

epytrezzuB snoitacificepS

• rezzubgninrawerusserpekarbwoL

rezzubnurrevoenignE•

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zH006ot004:ycneuqerF

If you intend to extend wiring, make sure that you use the same size and color of wire asthe original.

Make all connections secure by soldering or pressure joints. After connecting, removeburrs and cover fully with insulation material.

When making connections in chassis side wiring, cover connections with waterproofsealant, then cover fully with insulating material.

[WATERPROOFING]

• Cover connections with butyl rubber solution.

• Wrap with butyl rubber sheet.

• Wrap with adhesive vinyl tape.


KC-AA014A 138

02-179

Butyl rubber solution

Cover completely so that no metal part is exposed.

02-180Butyl rubber sheet

02-181

Adhesive vinyl tape

ADDITION OR MODIFICATION OF WIRING

When soldering, do not use chlorine.

If you intend to move the battery or modify the battery cable layout, do not extend orshorten the battery cable.

In areas where the battery cables are subject to movement due to relative motion of thestarter and the frame, do not modify the clamping method, positions of clamps, or theamount of slack in the cables.

Clamp electric wiring firmly to prevent it from contacting the moving or vibrating parts ofthe chassis or body, and any sharp edges or corners.

[CLEARANCES FOR WIRE]


KC-AA014A 139

noitisoP secnaraelC

dnastrapgnivomneewteBrosegdeprahsneewteBgniriw

gniriwdnasrenroc

:tniopesolcehttA:ecnaraelcmuminiM

mm03.nimmm01.nim

02-182Range of motion

Min. 30 mm

Where wiring passes through the frame or a panel, always use a grommet to preventdamage to the wire and potential short circuits.

Do not install wiring where it may be damaged by accumulation of mud or snow, byfreezing, or by flying stones.

If you must install wiring in such positions, protect it with metal plates.

When wiring of the harness wire is done inside the chassis frame, place the wiring alongalready installed wiring and do not wire independently along empty spaces.

Also, when wiring under the floor of the body or inside the roof construction, be sure toplace the wiring along the structure frame, use a clip following the indicated interval,carry out water proofing measures and observe the harness wiring rules.

Do not make connections by cutting open the coating of a wire and pulling out the barewire. This procedure is very dangerous and may damage other wires.


KC-AA014A 140

02-183

Protection of harness which

penetrates frame and panel

USING GROMMET

Min. 5 mm

Grommet

02-184

Harness wires should be installed where there isno danger of damage from accumulation of mud,sand, or snow.

Do not install wiring withinthe shaded area.

Min. 5 mm

L2

L1

L1 = L2

To prevent water from running along wires and penetrating electrical equipment, alwaysseal holes through which wires pass using grommets and make connections so that theterminal is higher than the wire.

Install wires where they are not exposed to dust or water.

Do not install the harness wire on the top or outer side of the chassis frame.

In such positions, they may be damaged by being stepped on during body mounting, orby flying stones during vehicle operation.

If there is a harness for the chassis already installed close to the wiring area when wiringis done inside the chassis frame, the wiring and taping should be done along this har-ness.

When installing wiring for parts of the engine, transmission, etc., install the wiring in par-allel to existing wires, and be sure to allow sufficient slack to absorb any relative move-ment. Make sure that the wiring does not touch any other part.


KC-AA014A 141

02-185

Electrical equipment or it’s cover

Grommet

02-186

When installing the harness wire to con-nect to the power unit, make sure that har-ness wire has sufficient slack to absorb rel-ative movement.

Chassis frame

Sufficient slack Air compressor for cabair conditioner

Engine

Where electrical wiring runs parallel to pipes (including rubber hoses, vinyl hoses, andsteel pipes) or brake system pipes (including brake hoses and brake pipes) or greasepipes, never clamp the wiring together with these pipes.

[CLEARANCES BETWEEN HARNESS WIRES AND PIPES]

If you move the battery, you may have to temporarily remove the battery cables from theterminals of the battery relay. When refitting the battery cables, observe the specifiedtorque to avoid damaging the battery relay terminal:

Tightening torque ➞ 13.7±3.9 N·m {140±40 kgf·cm}

(If a terminal is damaged, replace it with a new part.)

If you move the battery, make sure it is positioned at least 200 mm away from theexhaust system (muffler, tail pipe, etc.). If you must install the battery within 200 mm ofthe exhaust system, protect it wit insulating panels.


KC-AA014A 142

02-187

02-188

dohtemgniriW secnaraelC

eriwlellarapdnaepiP mm01.nim

epipdnaeriwfotniopgnissorC mm02.nim

Never secure harness wires togetherwith pipes or link rods.

Harness wire

Pipe

WRONG

Harness wire (upper side)

Min. 10 mm

Fuel hose or pipe (lower side)

If you use a plug-type connecting terminal, fit the female terminal into the power supplyside.

This is due to the connecting terminal detaching which does not allow a short-circuit tooccur even if the chassis or body construction make contact.

To prevent sagging, contact with other parts or contact with sharp edges or corners,secure all wiring with clips.

The clips should be spaced at a standard interval of 300 ~ 500 mm. This interval shouldbe shorter where conditions dictate.


KC-AA014A 143

02-189

02-190

Female terminal

Power supply side harness

Clipping interval

Max. 500 mm

All clips should use resin coating or attached grommets.

[RECOMMENDED CLIP TYPES]

Crocodile clips and adhesive clips should only be used for temporary installation.

Harness wires should be installed above fuel hoses or pipes to avoid fuel dripping ontothe harness wire in the event that a fuel leak occurs. Keep a clearance of at least 20 mmbetween the harness wire and fuel hose.

Bundle unused harness wires and their terminals should be bundled with other harnesswires and covered with vinyl tape to prevent water from penetrating the terminal.


KC-AA014A 144

02-19202-191

Vinyl coated

Rubber grommet

R shaped flangeSection A-A

Clip with rubber grommet(in case of relative movement)

Clip coated with more than0.6 mm thick vinyl

A A

02-193

Harness wire (upper side)

Min. 20 mm

Fuel hose or pipe(lower side)

02-194

Unused harness wire

• When wiring the harness wire together with the body mounting operations, select anappropriate type of wire harness taking into consideration the power consumptioncapacity (A) of the electrical equipment such will be mounted and the condition of theinstallation location.

Select wires to suit local conditions (e.g. ambient temperature).

b) Select wire size according to the permissible current.

NOTEWhere the wire is subject to movement caused by relative motion, use wireof 0.85 mm2 cross section or larger.

NOTEIf you intend to use AEX wire, make sure that you also use heat-resistantprotective tubing, tape, and clips.


KC-AA014A 145

epyteriWtneibmaelbissimreP

erutarepmetsetoN

eriwVA)selcihevroferiwegatlovwol(

06.xam gniriwlamonrofesU

)lynivdenil-ssorc(eriwXVAroferiwegatlov-woltnatsiser-taeh(

)selcihev07.xam

enignenigniriwrofesUhtiwsaerarehtodnamoorerutarepmettneibmahgih)enelyhteylopdenil-ssorc(eriwXEA

roferiwegatlov-woltnatsiser-taeh()selcihev

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5.0 9 8 7

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2 02 71 71

3 72 42 32

5 63 33 23

8 74 34 24

ELECTRIC WIRE SIZE AND PERMISSIBLE CURRENTS

• The identification indications of the harness wire and connectors stated in the“Electrical Wiring Diagram” of the chassis indicated in the Body Mounting Manual forthe respective model series should comply with the following standards.

• Additions or modifications of the chassis harness wire involved with body mountingmust be done by referring to the identification indications and using a harness wire withan identical size and color.

[HARNESS WIRE CODES REPRESENT SIZE AND COLOR]


KC-AA014A 146

CODING FOR ELECTRICAL WIRES & CONNECTORS

sedocroloceriW roloceriW

W ETIHW

B KCALB

R DER

Y WOLLEY

G NEERG

L EULB

rB NWORB

gL NEERGTHGIL

O EGNARO

Wire color (stripe color)

Wire color (base color)

Wire size (nominal cross-sectional area) (0.5 mm wires not listed)

Wire type (AV wires not listed)

Code

0.85 W BStripe color: black

Base color: white

Wire size: 0.85 mm

Wire type: AV wire

14. ATTACHMENT OF THE PACKAGED PARTS

• Because the handling precautions of each chassis component, caution plates includingmaintenance instructions, and optional equipment such as windshield wiper parts areparts installed on the body side, they are packed in the chassis under a chassis condi-tion.

• Accordingly, when mounting the body, be sure to attach or install these packaged partsat their correct positions.

• The following types of parts are packaged in the chassis.

Rubber boot and parts related to boot installation for transmission control level

Each type of caution plate

Emblem or ornament showing HINO and model name

Spare fuse set

Towing hook and parts related to hook installation

Reflex reflector

Crank handle for spare tire

Others including optional parts for body mounting, etc.

[EXAMPLE OF INSTALLATION POSITION]

NOTEFor details of packaged parts and installation positions, see the BodyMounting Manual for the respective model series.


KC-AA014A 147

TYPES OF PACKAGED PARTS

02-220

TRANSMISSION CONTROL LEVER

Boots

Floor

02-221

CAUTION PLATE(ENGINE)

02-222

CAUTION PLATE(AIR CLEANER)

PRECAUTION WHEN APPLYING THE FINAL COAT OF PAINT

1. COMPONENTS TO BE MASKED････････････････････ 1

2. UNPAINTED COMPONENTS ･･････････････････････ 1

3. ELECTRICAL PARTS ･･････････････････････････････ 1

4. FORCED DRYING ････････････････････････････････ 1

5. PAINTING THE WHEEL DISC ･･････････････････････ 3

6. PRECAUTIIONS OF WHEEL INSTALLATION ････････ 4

KC-AA014A

Chapter 3

• When applying the final coat of the body, the following points should be noted as thechassis involves components to be masked which are sensitive to heat when dryingand components which are not to be painted.

1. COMPONENTS TO BE MASKED

• Components which are not coated, such as the top mark, ornaments, identificationplates (with model and chassis numbers) and warning plates (caution plates) should becompletely masked.

• Never paint rubber hoses, pipes, and bulbs.

2. UNPAINTED COMPONENTS

• Stains on unpainted components should be removed with gasoline.

• Using thinner is not recommended.

3. ELECTRICAL PARTS

• During painting, cover all electrical connections, wiring, batteries and other electriccomponents to protect them from paint.

4. FORCED DRYING

• Natural drying takes a long time, but the low drying temperature ensures there will beno problems with non-heat resistant parts.

• But if forced drying is used, the upper temperature limit must be maintained lower then80°C.

• If you plan to force dry at temperatures over 80°C, first remove all plastic, rubber andelectric parts of the chassis from the vehicle or shield them to prevent their temperaturerising over 80°C.

PRECAUTION WHEN APPLYING THE FINAL COAT OF PAINT3

KC-AA014A 1

• Adhesives (chloroprene rubber-based, product name semidyne 5100) are also used inthe engine hood weather strip for front engine chassis, joints of fuel lines end hoses,and joints in the air intake system of the engine and rubber hoses.

At temperatures above 80°C, this adhesive softens resulting in a danger of compo-nents coming apart.

Take care that the ambient temperature does not rise over 80°C of these parts.

NOTE• Refer to the last section of the “PARTS HEAT RESISTANCE TABLE”

for information on the heat resistant temperature of each part installedon the chassis.


KC-AA014A 2

03-001

Recommended ambienttemperature in dryingbooth max. 80°C.

Drying booth

5. PAINTING THE WHEEL DISC

• Wheel manufacturers paint these wheels before shipment, but some customers mayrequest repainting in custom colors. The thickness of the paint may affect the tightnessof the wheel nut.

• Therefore, use the following procedures to paint wheels.

MAIN POINTS TO NOTE WHEN PAINTING CUSTOM COLORS.

Mask the side of the wheel on which the disk is installed (including the parts that comeinto contact with the wheel nut washer, as well as parts in contact with the other hub, thedrum and disk wheel).

After installing the wheel on the vehicle, the parts which need to be painted on the frontand rear outer wheel should be lightly coated in the same color (after the wheel nut hasbeen installed).

When the coated part comes in contact at the tire rotation, a thick coating of additionalpaint on the spherical washer after installation may cause loosening of the wheel nut.


KC-AA014A 3

03-002

03-003

A

This part should therefore bemasked on both the front andrear of the vehicle.

After the wheel has beeninstalled on the vehicle, onlyparts visible from outsideshould be painted, and onlylightly.

CONTACT AREA OF WHEEL NUT

Section A-A

A

Tire rotation may change the position of the disk wheel. This may cause the paintedparts to come into contact with other components.

If this happens, and the paint is thick, the wheel nuts may loosen. Therefore, the follow-ing procedure should be followed when tires have a rotation work.

The paint must be removed from the paint contact with the disk (including the sphericalwasher). Clean, for example with a wire brush, and repaint the part lightly to preventrusting.

If a thick coat of paint is not removed, the wheel nuts will loosen, even if the part iscleaned, for example with a wire brush.

6. PRECAUTIONS OF WHEEL INSTALLATION

• It is strictly forbidden that the wheel and other than the wheel are tightened togetherwith a wheel nut.

• If it tightens, the wheel nut will loosen and a serious problem will be caused.

• Refer the owner's manual for the right procedure of the wheel installation.


KC-AA014A 4

PRECAUTION WHEN TIRE ROTATION (FOR REFERENCE)


KC-AA014A 5

PARTS HEAT RESISTANCE TABLE

.oN emanstraP lairetaMelbissimrePerutarepmet)edargitneC(

setoN

1 gnisuohreteM nelyporpyloP 09 °C

2 dilnoitcepsnignisuohreteM nelyporpyloP 09 °C

3 revocedisgnisuohreteM nelyporpyloP 09 °C

4 revocnmulocgnireetS nelyporpyloP 08 °C

5 reppu,revocnmulocgnireetS SBA 09 °C

6 rewol,revocnmulocgnireetSroolfdna

nelyporpyloP 08 °C

7 )emanledom(tnemanrO SBA 08 °C

8 )kraM"ONIH"poT(melbmE SBA 08 °C

9 laesrotaidaR rebbuR 001 °C

01 pmaldaeH 001 °C

11 pmalrotacidnilanoitceridtnorF SA;sneL 08 °C

21 pmalliaT SA;sneL 08 °C

31 pmaletalpecneciL 001 °C

41 retemnoitanibmoC +SBA+nelyporpyloP

elyrcA

09 °C

51 bonkelbatsujdanmulocgnireetS nelyporpyloP 08 °C

61 leehwgnireetS nelyporpyloP 08 °C

71 xobtnempiuqelacirtcelE 09 °C

81 rebburladeP)hctulc,ekarb,rotareleccA(

001 °C

91 rebburgnitnuomenignE rebbuR 08 °C

02 ssenraheriwlacirtcelE lyniV 001 °C

12 esohriA rebbuR 001 °C

22 )lio(esohekarB rebbuR 07 °C

32 retsoobriaekarB rebbuR 07 °C

42 evlavekarB rebbuR 07 °C

52 dapnroH SBA 08 °C

BUS BODY

1. BASIC POINTS OF BUS BODY MOUNTING･･････････ 1

2. DESCRIPTION OF A BUS BODY････････････････････ 2

3. PRINCIPAL PRECAUTIONS WHEN MOUNTING A BUS BODY ･･････････････････････････････････ 5

4. BASIC LAYOUT OF BODY STRUCTURE ････････････ 9

5. LAYOUT OF STRUCTURAL ELEMENTS ････････････15

6. RUST AND CORROSION PREVENTION ････････････36

7. RIDE COMFORT IN RELATION TO VIBRATION AND NOISE ････････････････････････････････････51

8. DESIGN TO FACILITATE INSPECTIONS AND MAINTENANCE ････････････････････････････････67

9. SAFETY CONSIDERATIONS ･･････････････････････69

10. FIRE PREVENTION････････････････････････････････70

11. APPEARANCE AND WORKMANSHIP OF BUS BODY ････････････････････････････････････73

12. ADVANTAGES AND DISADVANTAGES OF FRONT AND REAR-ENGINED BUSES, AND AIR CONDITIONING SYSTEMS ･･････････････････････76

KC-AA014A

Chapter 4

1. BASIC POINTS OF BUS BODY MOUNTING

• The design strength of the Hino bus chassis frame assumes that a conventional typeof bus body will be installed on it.

• The chassis frame has been designed on the basic principle that the completedbody and chassis frame will form an integrated structure.

• When designing a body, take account of the fact that the chassis frame bears only partof the overall load received by the bus.

• The chassis frame has been designed with sufficient rigidity to allow the vehicle to bedriven as a bare chassis without mounting a body.

• However, do not run under the bare chassis on bad or unpaved roads so as not to sub-ject it to excessive stress.

• When designing and actually mounting a bus body, remember the above points and besure to observe the following precautions.

The instructions given in this section are based on a stressed skeleton structure busbody (a type of body commonly adopted in recent years), in which the load received bythe vehicle is supported largely by the main structure of the body.

BUS BODY4

KC-AA014A 1

Body strength + chassis strength= overall strength of vehicle

04-002

2. DESCRIPTION OF A BUS BODY

Classification and characteristics of BUS bodies by structure• Bus bodies can normally be classified according to which part of the structure supports

the external force from the road surface while the vehicle is stopped or in operation.

• The table below shows the major types of bus body structure in common use today andoutlines their principal characteristics.

BUS BODY4

KC-AA014A 2

Body structure Principal characteristics

Stressedouter-skinstructure

Stressednner-skinstructurei

Stressedskeletonstructure

Str

esse

d-s

kin

str

uct

ure

RafterRail Pillar

Stiffener

Stressedouter panel

• The outer panels are the mainstrength elements of the bodystructure.

• The size of openings in the outerpanels must be restricted toensure sufficient rigidity (i.e. thesize of windows and doors arelimited).

• The large number of r ivetsrequired in this type of construc-tion detracts from the appearanceof the vehicle.

• The inner panels are the mainstrength elements of the bodystructure.

• Because the strength elementsare on the inside of the body, theoutside can be covered with deco-rative outer panels, giving thistype of body an advantage interms of appearance.

• The inner panels must be main-tained to ensure sufficient rigidity,so that this type of body tends tobe heavier than others.

• Strength and rigidity are providedby an integrated chassis frameand body structure.

• This type of body offers consider-able advantages in freedom ofdesign and appearance. (Theappearance is clean, with no riv-ets in outer panels, and windowsand doors can be made large.)

Stressed inner panel

04-003

04-005

04-004

Stressed skeleton

Cross-member

Method of joining of body to chassis frame• In the body mounting process, the bus body may be joined to the chassis frame by a

number of methods.

• The figure below shows a number of methods commonly used to join the body struc-ture to the chassis frame.

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Frameless orsectional frame

Ladder shapedframe

Framelesssystem

Outriggersystem

Ladder shapedframe

Truss frameTruss framesystem

Outriggersystem

Sill crosssystem

Sill cross +Outrigger system

Truss crosssystem

Sill crosssystem

Body structure

Type of chassis frame

Str

ess-

skin

stru

ctur

eS

tres

sed

skel

eton

stru

ctur

e

Coupling system

Crossmember

Subframe

Frameless system

Outrigger system

Sill cross system

04-006

04-007

04-008

04-009

04-010

04-011

Side frameOutrigger

Sill crossSide frame

Sill crossSide frame

Sill cross + Outrigger system

Truss cross system

Truss frame system

Square tube

Side frame

Square tube

• In addition to these methods, there is also a rubber mounting system in which rubber isused to minimize the vibration and noise transmitted from the chassis to the body whenthe vehicle is in operation.

• This method does not give the same degree of strength and rigidity as methods inwhich the body and chassis frame form an integrated structure. It also has the disad-vantage that if the rubber used is not of the correct hardness, it will not provide thevibration- and sound-absorbing qualities required and will make the vehicle unstable inoperation.

Accordingly, this method is suitable only for small buses in which the chassis framealready provides adequate strength and is not suitable for large buses.

BUS BODY4

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Body

Chassis

Rubber

Sill cross

Chassis frameBracket

04-012 04-013

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3. PRINCIPAL PRECAUTIONS WHEN MOUNTING A BUS BODY

Relationship between bus body characteristics and vehicle performance• The dimensions and other specifications of the bus body and other equipment as a

whole or in part will affect the performance and functions of the vehicle in many ways.• The table below presents a summary of the factors involved.

• This section (4. Bus Body) lists a number of essential precautions that you should observe to assure the above aspects of vehicle performance when designing or mounting a body.

Items in boxes like this have the greatest impact on body mounting and are particularly important.

Vehicle performance Related body characterictics• DRIVING PERFORMANCE

• Mobile performance• Handling stability• Driving performance on

unpaved roads

• DURABILITY

• Strength, rigidity

• Rust resistance, corrosion resistance

• COMFORT

• Passenger comfort

• Vibration, ride• Passenger room noise

• SAFETY

• Safety of passengers and pedestrians

• Accident prevention, fire prevention

• Weight, body air resistance• Center of gravity, front and rear weight distribution• M in imum g round c l ea rance , depa r tu re ang le ,

approach angle

• Body skeleton structure, rigidity of joints between each parts of structure, fixing rigidity of outer panels, etc.

• W a t e r r e s i s t a n c e , w a t e r d r a i n a g e , p a i n t i n g specifications and material properties of each part

• Passenge r r oom space , pa r t s p ro j ec t i ng i n t o passenger space, vis ibi l i ty, natural i l luminat ion, lighting, color, air circulation, ventilation, etc.

• Characteristic frequency and vibration mode of body, noise- and vibration damping specifications of each part

• Eas iness o f get t ing on/get t ing o f f , eas iness o f movement in passenger room, safety of internal and external equipment

• Protection of harness, piping, etc.

Strength and rigidity of the bus body

Forces acting on the bus body• When the bus is stopped or in operation, the bus is subject to a variety of forces. The

most important forces, in terms of their magnitude and frequency are as follows:

• These loads lead to extreme deformation (stress concentration) in all parts of the bodystructure. Especially in parts which have insufficient rigidity.

• The action of such loads is described in the drawings shown on the following pageunder “FORCES ACTING ON THE BUS BODY” and “BENDING MOMENT ANDDEFORMATION OF STRUCTURE UNDER A STATIC LOAD”.

• As is clear from these drawings, significant bending forces act on the bus as a wholeeven when it is stopped (deformation is especially great around the passenger doorand tire houses and progressing the overall bending deformation), and results in astress concentration in the joints at either end of the side window pillars tensioned bybending forces.

• Moreover, when the vehicle is in operation, torsional load (resulting from reactionforces from road surface which act alternatively right and left to the bus body) and theincrease of the load due to vibration are added to the stress and acted on the busrepeatedly. Thus stress concentration will become severe and cause frequent crackingand breaking.

• When designing and mounting a bus body, make sure that the shape of body partsaround the following openings provides sufficient strength, and/or take steps to rein-force them.

• PASSENGER DOORS AND EMERGENCY EXITS

• SIDE WINDOWS

• WINDSHIELD AND REAR WINDOW

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DISTRIBUTION OF FORCES AND

LOADS ACTING ON THE BUS BODY

• Bending load: The forces which try to bend the body,resulting from payload weight and reactionforces from the road surface

• Torsional load: The forces which try to twist the body,resulting from alternative right and leftinteractions to the body caused by reac-tions from road surface and the unbalanceof payload weight in the right and leftdirection.

• Four loads act on the bus when stop and in operation:

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Forces acting on the bus body

TORSIONAL LOAD LATERAL LOAD(DURING QUICK TURNING)

TO AND FRO LOAD(DURING QUICK BRAKING)

BENDING LOAD

[Example: Rear engine bus]

04-014

04-015

Bending moment and deformation of structure under a static load

Bending moment

Mom

ent

Deformation

kg·m

0

(–)

(+)

Distribution of load on body components• The distribution of the forces acting on the body of the bus described in the preceding

paragraphs is shown in the two diagrams “Bending rigidity” and “Torsional rigidity”below. These diagrams are based on the example of a skeleton-structure bus body.

• From these diagrams it is clear that, in a skeleton-structure bus body,

• When designing and mounting a bus body, make sure that you take account of theforces acting on the bus body and their distribution as described in the above para-graphs.

• Overseas, a lack of equipment often means that outer panels are not tensioned as theyare mounted or that aluminum panels are used (FRP being used for front and rearouter panels), so that the outer panels cannot be expected to contribute to body rigidity.

In this case, make other structures (especially the skeleton) proportionately more rigidand stronger.

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Distribution of load on body components

[Example: Skeleton-structure bus body]

Fittings 6%

Frame 13% Frame

17%

Body skeleton 48%

Outer panels 20%

Outer panels 28%

Side structure skeleton

Front & rear structure outer panel

Roof structure outer panels

Front & rear structure skeleton

Side structure outer panels

Roof structure skeleton

[Bending rigidity] [Torsional rigidity]

Side structure skeleton

Fittings 7%

Front & rear structureouter panel

Roof structure outerpanels

Side structure outer panels

Front & rear structure skeleton

Roof structure skeleton

• THE GREATER PART OF THE BENDING AND TORSIONALLOADS IS BORNE BY THE INTEGRATED SKELETON STRUC-TURE OF THE BODY (INCLUDING CHASSIS FRAME), AND

• THE CHASSIS FRAME AND ROOF STRUCTURES (INCLUDINGBOTH SKELETON AND OUTER PANELS) BEAR THE GREATERPART OF THE TORSIONAL LOAD.

04-016

Body skeleton 61%

4. BASIC LAYOUT OF BODY STRUCTURE

Important points and measures• Given the forces and distribution of load acting on the bus body as described in Section

2, make sure that you observe the following points when deciding the basic layout ofthe body structure.

• For specific measures, see Section 4.

“Layout of Each Part of the Body Structure”.

Selection of materials for structure• As far as possible, use closed-section square tube ( ) for the main strength ele-

ments of the body and make the joints at each end by butt welding the tubes together.

• Closed- (e.g. square-) section tube materials only have superior cross-sectional char-acteristics to open-section material ( ).

The butt welding of closed-section materials also provides a stronger joint than that ofopen-section materials.

A square tube can also be made lighter than an open-section material for the samestrength, helping to reduce vehicle weight.

BUS BODY4

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Strength elements ofbody structure

Use square-section tube( )

→

IMPORTANT POINTS• Ensure that loads acting on the body are distributed as smoothly as possible

to all parts of the structure, so that the entire structure plays a part in theload-bearing (= dispersion of loads).

• Keep the rigidity of the whole structure as high as possible and try to makethe rigidity between the each part uniform (= distribution of deformation andstress concentration).

• Mount the outer panels on the skeleton in the proper methods as their ten-sioned rigidity to contribute the rigidity of the whole structure and not tocause permanent deformation (buckling) due to any excessive deformationof the skeleton (= efficient use of tension rigidity of outer panels).➧

Disposition of materials for structure• The outer frame which forms the six faces of the body structure should be made of

thicker members to achieve a high rigidity of the frame itself.

• The main longitudinal horizontal members of the body side structure (window top andbottom rails, lower rail of trusses below windows, skirt rail, etc.) should be made of asingle length of square-section tube material.

Where horizontal members and vertical members cross, the horizontal membersshould, asa rule, take priority (priority disposition of horizontal members).

A member composed of a single length of square-section tube is more rigid and morestable than a member made up of a number of square-section tubes welded together.This means that the priority disposition of horizontal members tends to transmit loadsalong the length of the vehicle and makes a significant contribution to the even distribu-tion or dispersion of deformation and stress.

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Structure in which horizontal longitudinal members have pri-ority over vertical members

04-017

Main horizontal longitudinal members

Butt welding

[Crossing of vertical andhorizontal members]

• Position the principal vertical elements of the body structure in the same lateral planeas sill crosses or outriggers of the floor and the roof rafters, so as to form a number of“hoops”.

The role of these hoop structures is as follows:

BUS BODY4

KC-AA014A 11

04-018

[The role of the hoops is]

• to transmit the reaction force from the road surface and thepayload to the body skeleton via the crossmembers, and

• to act literally as hoops, joining all the main horizontal longi-tudinal members of the skeleton and increasing the overallbending and torsional rigidity of the body.

Hoop structure

Roof rafter

Vertical structure(Including windowpillar)

Sill cross

Gusset

Chassis frame

Strength of joints between structural elements• The body skeleton is a composite structure made up of many elements which collec-

tively support the loads placed on the vehicle.

Even if the materials themselves are well chosen and appropriately disposed, problemsof strength and rigidity will arise if the joints between the structural elements are weak.

• Choose the method of joining structural on the basis of a clear understanding of thecharacteristics and role of each element.

Joints between two square-section tubes

• When designing the structure, be sure that the layout does not make welding difficult,leading to incomplete welding of joints, and that it allows anti-rust treatment after weld-ing.

[Examples of skeleton layout designed to facilitate welding work]

BUS BODY4

KC-AA014A 12

Joints between two square-section tubes should bebutted joints with continuous fillet welding around theirfull circumference.

04-019

Weld a separatepiece onto thetruss before weld-ing the joint.

at least 15 mm

at least30 mm

Min. 30° If angle is less than 30°.

• With continuous fillet welding around its circumference, as far as possible ensure thatthe two members are orientated so that their width or height is the same, and that thecenters of their respective cross-sections coincide.

• If an outer panel will come into direct contact with a welded joint, grind the weldingbead flat so that it does not damage the outer panel.

Treat the welding and panel thoroughly to prevent rust developing from the back of theouter panel. (For details of rust prevention treatment, see Section 5).

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Method of joining two square-section tubes by a butted jointmade with continuous fillet welding.

04-020

RIGHT WRONG: These joints will lead to local deformation

and concentration of stress.

3 mm max.

Method of welding joints that will come intodirect contact with outer panels

04-021

Outer panel

Grind the bead on the side that will touchthe outer panel and treat against rust.

Gusset joints• When joining two square-section tubes using gussets, any joint where strength and

rigidity are particularly important should if possible have a gusset on each side of thesquare tubes.

• To ensure sufficient welding strength, join gussets to square-section tubes by intermit-tent welding around the gusset and plug welding, or by intermittent welding around thegusset and continuous fillet welding around the inner circumference of welding holes.

Bolted joints• Bolted joints are weaker than welded joints. Use them only in the cases shown below

and always take measures to prevent the nut or bolt from looseness.

• Bolt size and tightening pitch should conform to the principles shown in the diagrambelow. (No more than two plates may be joined by bolts.)

NOTEDifference between L and d is to be as small as possible.

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Example of gusset joint

Gussets on either side

Fillet weld

Plug weld

Intermittent weld

04-022

[Bolted joints are permissible only]

• where maintenance work requires the dismounting of a component,and

• where joint rigidity is not essential to structural strength.

04-023

Bolt size and tightening pitch in bolted joints

d L

L>1.5 d

A

BB B

C

D

A>3D

B>4D

C>3D

5. LAYOUT OF STRUCTURAL ELEMENTS

• This section describes the main precautions and specific measures relating to thestructure, method of mounting and design of the six-sided framework of the bus body,taking into account the forces acting on the body and the distribution of load over eachstructural element, as described in Section 3, “ Basic Layout of Body Structure”.

Floor structure• The floor structure not only directly bears the weight of the vehicle’s payload but also

plays an extremely important role in joining the chassis frame and the bus body andassuring overall structural rigidity and strength.

• As shown in Section 1-2) “Method of joining of body to chassis frame”, there are manydifferent possible types of floor structure design. This manual will describe the precau-tions and specific measures to be taken in building a floor structure based on sill crossjoints, a type of design commonly adopted by body makers around the world.

Position and cross-sectional dimensions of sill crosses• Position the sill cross members so as to provide a secure link between the chassis

frame and the main vertical structure elements of the body side structure (main verticalpillars at front and rear of structure, vertical pillars frontward and rearward of passengerentrance door opening, window pillars, etc).

• Fit sill crosses between the vertical structure elements of the body side structure forstrengthening purposes and to provide a base for the mounting of other body structuresand equipment.

• Determine the total number of sill crosses and the pitch at which they are mountedaccording to the load on the floor structure as a whole and the conditions under whichthe vehicle is to be used (e.g. road surface conditions). (The appropriate pitch for thesill crosses depends on the size and strength of the materials used in the floor structureand overall vehicle size, but HINO recommends a pitch of 300-400 mm.)

BUS BODY4

KC-AA014A 15

• Select material for sill crosses with as large a cross section as possible, and position itto provide the greatest possible vertical bending rigidity (i.e. the longer dimension of thecross section should be perpendicular to the ground).

Sill crosses in front or behind the front or rear axles will be directly exposed to thrustfrom the road surface and vibration. Make sure that these sill crosses have sufficientrigidity. (They should be twice as rigid as other sill crosses.)

• The diagrams below show examples of the cross-sectional dimensions of sill crossmaterial.

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Example of positioning of sill crosses

04-024

SILL CROSS

300-400 mm

Note: mark in the diagram indicates a verticalpillar or window pillar.

Examples of cross-sectional dimensions of sill cross material

ExampleCross Cross-sectional dimensions of sill cross material

Vehicle A(large bus)

Vehicle B(large bus)

Vehicle C(small bus)

General use Forward or behind axles

04-025

04-026

04-028

04-029

04-03004-027

Welded (top and bottom)

Welded (top and bottom)

t=3.2

50

100

t=3.2

60

8070

t=3.250

t=3.2

50 50

100

60

50 50

60

t=3.2 t=3.2 80

250 ~ 300

70

Mounting sill crosses

Joining sill crosses to chassis frame• Use angle brackets secured with bolts to join sill crosses to the chassis frame.

• Welding will give a more rigid joint than bolts, but poor welding work can cause theproblems listed below and welding should therefore be avoided:

• When making a bolted joint, take particular account of the structure, shape and dimen-sions of the joint and of bolt size to ensure that the joint is sufficiently rigid. Take mea-sures to prevent the nut or bolt from looseness.

(See Section 2-4 “Chassis Frame” for details on preparing to drill holes in the chassisframe and a description of drilling work.)

Example: Joint where the sill cross is a square-section tube material.

BUS BODY4

KC-AA014A 17

[Problems arising from welding of sill crosses to chassis frame]

• Reduced strength of chassis frame and sill crosses (cracking ofmembers)

• Damage to chassis equipment (burning of brake pipes and wireharness)

• Peeling of paint due to heat (leading to rust)

Examples of bolted joints between chassis frame and sill cross

04-031

Chassis frame Angle bracket

Sill cross

Mounting bolts

Use intermittent welding to fix the sill cross to the angle bracket.

[Example: -shape open-section sill cross]

[Examples of method of joining an outrigger cross to the chassis frame]

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Vertical pillar of side structure Sill cross Sill cross reinforcing plate

Chassisframe Gusset

Angle bracket(Mounting bracket)

Sill cross reinforcing plate

Sill cross

Rib plate

Angle bracket(Mounting bracket)

Sill cross Plane washer Lock nut

Plate (t3.2)

Chassis frame

Bolted joint

Reinforcing plate

Bolt (M12)(With spring washer)

Bracket (t3.2)

04-032

150

80 80

300

(ø33, t3.2)

R

40

90

15

t3.2

t3.2

C40

C40

UNIT: mm

04-033

Outrigger

Bolted joint

Chassis frame

Outrigger

Bolted joint

Chassis frame

Strengthening joints between sill crosses and chassis frame (particularly around rear axle)

• The rigidity of joints between sill crosses and chassis frame plays an important role inassuring the comfort of the passengers.

• In the front and the back of the rear axle, the pitch of the crossmembers of the chassisframe is wider, and it is important to assure the same rigidity and strength integratedwith the body.

• To compensate for the wider pitch of the crossmembers of the chassis frame, make thepitch of the sill crosses smaller than in other parts of the body (increase the number ofsill crosses) and take other appropriate measures to assure the rigidity of jointsbetween sill crosses and chassis frame.

• The drawings below show examples of measures to strengthen and increase the rigidi-ty of the floor structure in vehicles with high floor structures such as buses built totourist specifications.

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FRONT REAR AXLECENTERCHASSIS CENTER LINE

CHASSIS FRAME SIDE MEMBER

FLOOR CROSS SILL

No. 7CROSSMEMBER

FLOOR SUPPORT

CHASSIS FRAMESIDE MEMBER

No. 6CROSSMEMBER

PARTS B PARTS A

04-034

LH & RHB62

Ex. 325 Ex. 452.5

3030

220

LH & RHB. 6

2

BUS BODY4

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Detail of strengthening of joints between chassis frame and floor cross sills (B)

Detail of strengthening of joints between chassis frame and floor cross sills (A) RH & LH

Welding hole

UPPER &LOWER

(Grind flat after welding.)

(Do not weld closer than 5 mm from edge.)

Notes: 1. Ratio of inside bending radius to plate

thickness should be t = 3.2: r. 5 mmt = 2.3: r. 4 mm

2. Painting: CHF-3Color: Black

3. Welding should be without undercut.

Notes:1. Ratio of inside bending radius to plate

thickness should bet = 3.2: r. 5 mmt = 2.3: r. 4 mm

2. Painting: CHF-3Color: Black

3. Welding should be without undercut.

(Do not weld closer than 5 mm from edge.)

Welding hole2-ø30

Welding hole

➀

➁

➂

➃

➄

➅

PARTS NAMEMATE-RIAL

QTYSPECIFI-CATION

Tube

Gusset

Gusset

Gusset

Rib

Plate

STKR41

SPHC

SPHC

SPHC

SPHC

SPHC

1

1

1

1

2

2

50x30x2.3

t=3.2

t=3.2

t=3.2

t=3.2

t=2.3

t

UNIT: mm

➀

➁

➂

➃

➄

PARTS NAMEMATE-RIAL

QTYSPECIFI-CATION

Tube

Gusset

Gusset

Rib

Plate

STKR41

SPHC

SPHC

SPHC

SPHC

1

1

1

2

2

50x30x2.3

t=3.2

t=3.2

t=3.2

t=2.3

t

UNIT: mmWelding hole

UPPER &

LOWER

(Grind flat after welding.)

(Do not weld closerthan 5 mm from edge.)(Do not weld closer

than 5 mm from edge.)

➁

➀ (Do not weld closer than 5 mm from edge.)

Lower surface of floor cross sill

Lower surface offloor cross sill

04-035

04-036

3

➅

B.2

3B.2

30

25

20

3B.2

C5➁

➀

B.43

➄

100

203050

C10

100➃

50 30

50

B.2

➂

70

180

9035

Welding hole2-ø30

3B.2

3 B

30

25

20

3B.2

C5

B.4

100

203050

C10

100

50 30

50

B.2

70

180

9035

2-ø30

3

➂

➃

➄

Joints between sill crosses and vertical pillars of body side structure• The method of joining sill crosses to the vertical pillars of the body side structure depends on the

type of materials used for both members.

• If the sill cross and vertical pillar are both made of square-section tube:

Join the two square-section tubes by a butted joint with continuous fillet welding. (SeeSection 4-4-5 for details of welding procedure.)

• If the sill cross is made of -shape open-section material:

Use welded gussets to make the joint and ensure that the joint has sufficient welding rigidi-ty. (For details, see diagrams below.)

• In vehicles with air suspension, No. 3, 6, 7, and 8 crossmembers are already mountedon the chassis.

In such a vehicle, observe the following procedure to ensure that the joints with the ver-tical pillars of the body side structure have sufficient strength and rigidity.

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Continuous fillet weld

Sill cross

Gusset(t = 3.2)

Vertical pillar of side structure

40 x 10 oval hole

04-037

80

5

605

452

4040 190

40

1520

2015

30ø30 50 12.5

145

8035

BUS BODY4

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Examples of joints between chassis crossmembers and vertical pillars of body side structure

Method of joining No. 3, 6, & 7 chas-sis crossmembers with vertical pillarsof body side structure at A and B.

Method of joining No. 3, or 8 chassiscrossmembers with vertical pillars ofbody side structure at C.

CR

OS

SM

EM

BE

R

CR

OS

SM

EM

BE

R

CR

OSS

MEM

BER

ENGINE CENTER LINE

RE

AR

AX

LE

DA

TU

M L

INE

Shorten the crossmember toadjust the width of the bodystructure.

Upper surface of chassisside member

Connecting gusset forvertical structure

04-038

04-039

Body outer panel

Body horiz

ontal rail

No. 6 crossmember

No. 8 crossmember

After welding all around, applysealant to entire circumfer-ence of butt to prevent waterfrom entering the crossmem-ber tube.

Gusset (t = 3-2)

No.

6

No.

7

No.

8

A B C

B 6

t = 4-5

Right- and left-hand side structures• As indicated in the drawings of load distribution in Section 4-3-2 “Strength and rigidity

of the bus body”, most of the bending load acting on the bus is supported by the rigidityof the skeleton of the right- and left-hand side structures.

The torsional load transmitted via the chassis frame also acts on the right- and left-hand side structures respectively in the form of upward and downward bending loads ofdifferent phases.

• It is therefore extremely important to increase the bending rigidity of the right- and left-hand side structures in order to assure both the bending and torsional rigidity of thestructure as a whole.

• Of the side structure elements, the truss structures under the side windows provide anextremely high rigidity against vertical bending forces.

• Position members and choose the method of joining so as to transmit the forces (loads)acting on the inside and outside of the body structures as smoothly as possible tothese truss structures.

• Door openings (for middle, rear and emergency doors) interrupt the high bending rigidi-ty of this truss structure and produce an extreme local distortion and concentration ofstress around the doors.

This local distortion leads to an increase in stress at the butted joints of the window pil-lars.

Take steps to strengthen the side structures, particularly around door openings.

• Also strengthen the side structures around the tire houses, which cut into the trussstructure.

BUS BODY4

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The torsional load ➝ a vertical bending load onthe right- and left-hand side structures

Torsional load 04-040

• The following paragraphs describe measures for strengthening the right- and left-handside structures of the bus body to compensate for local distortion and concentration ofstress.

Transmission lines of force in truss structure• The main vertical pillars in the body side structures, including the vertical elements of

the truss structure, should ideally be arranged to form “hoops” in the same plane.

• However, the space allocated to side windows design and the layout of equipmentmounted under the vehicle floor may in some cases make it impossible to form “hoops”in the same plane.

• In this case, position vertical pillars so that they overlap within the truss structure andjoin these vertical pillars with diagonal reinforcing members following the transmissionlines of force within the truss structure.

This effectively completes a hoop in the same plane and allows the transmission offorce with equal efficiency, helping to prevent the concentration of stress in any onemember.

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Outline diagram of truss structures under side windows

Truss structure under side windows

04-041

Example of lines of force within an truss structure and position of reinforcing member

Diagonal reinforcing member

Arrows (➝ ) indicatelines of force

Window pillar

Horizontal rail

Horizontal rail

Joint with sill cross

Truss structure

04-042

Reinforcing method around door openings and tire houses• This section explains how to reinforce the side structures of the bus body around door

openings (passenger, emergency doors, etc.) and the points where tire houses cut intothe truss structure.

Use thick material for the vertical pillars on frontward and rearward of the door opening.

Fit strengthening members around the door opening (including double pillars, trussing).

Add stress plates around the doors.

Add corner gussets around the doors.

Add strengthening members around tire houses, etc.

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Example of local reinforcement of side structures

Around forward door:• Double pillars

(rear pillar 70 mm member)• Stress plates at top, between dou-

ble pillars.• Inside corner gussets (top)

Around middle door:• Thick pillars on frontward &

rearward side (70 mm member)• Make truss structure at top.• Inside corner gussets

(top)

Around rear door:• Thick pillars on frontward &

rearward side (forward pillar 70 mm, rearward pillar 100 mm member)

• Make truss structure at top.• Inside corner gussets (top)

Gusset

Diagonal reinforcing memberDiagonal reinforcing member

Diagonal reinforcing member

Cross position

Corner gusset

04-043

Strengthening joints at ends of window pillars• As described in Section 2-2) on the forces acting on a bus body, when a bending force

acts on the overall body structure, the resulting distortion pulls on the window pillars,which tend to lean backwards or forwards, leading to a concentration of stress at theirends.

• Owing to functional restrictions (appearance, visibility, etc.) and structural restrictions(shape of window frames, dimensions, etc.) it is difficult to reduce the concentration ofstress at the ends of the window pillars. The design of the window pillars is thereforeone of the most important points in skeleton design.

• To minimize the concentration of stress at window pillar ends, observe the followingprecautions:

The basic aim is to increase the bending rigidity of the overall structureand minimize the leaning of the window pillars.

• Minimize bending distortion in the side structures.

(Ensure that the side structures have sufficient bending rigidity by strengthening them.)

• Control local distortion around door openings, etc. near to window pillars to minimizethe effect on the window pillars by strengthening areas around door openings, etc.

Take care that the material and dimensions of the window pillars andtop and bottom rails (see description of main longitudinal horizontalmembers of the body side structure in Section 3-3)) and the position ofjoints between window pillars and rails does not result in additionallocal stress. Make sure that the joints between window pillars and railsare sufficiently rigid.

• Use square-section tube material of the same size and quality for the window pillarsand top and bottom rails.

• When making welded joints between window pillars and rails, observe the proceduresdescribed in Section 3-4) and make sure that the joints are sufficiently rigid.

When fitting corner gussets to increase the rigidity of joints betweenwindow pillars and rails, be sure to use the appropriate shape of gussetand method of welding.

(Warning: Corner gussets of unsuitable shape and unsuitable welding methods maylead to cracking of the welded parts or of the gussets themselves.)

BUS BODY4

KC-AA014A 26

BUS BODY4

KC-AA014A 27

Example of cracking of corner gusset itself

Examples of strengthening of upper and lower ends of window pillar with gussets

Crack

Crack

04-044

04-045

Gusset should be long andcurved at ends.

Window bottom horizontal rail Window bottom horizontal rail

Grind the welding bead flat to avoid aconcentration of stress.

High stress Ground flat

Front structure• Most of forces caused by the load acting on the front structure is torsional load since

reactions from road surface act on the body right and left alternatively.

• The windshield in its rubber mounting constitutes a very large opening in the frontstructure and it is therefore difficult to assure sufficient torsional rigidity of the frontstructure against this load.

Particularly on bad roads, this may lead to distortion of the outer panels of the frontstructure and to detachment and cracking of the windshield.

• For this reason, take steps to maximize the torsional rigidity of the front structure andprevent any torsional load on the windshield.

Measures to increase the torsional rigidity of the front structure• The front structure, including the crossmembers at the front end of the chassis frame,

must form a “hoop” with high torsional rigidity.

• In front engine vehicles, the need to assure ease of engine maintenance and enginemounting and dismounting makes a cross structure running across the front of the vehi-cle impractical. The solution is to build a hoop structure by mounting a truss type struc-ture spanning the ends of the chassis frame, having a lower beam secured by bolts.This beam is mounted using bolts in order to assure ease of mounting and dismountingof chassis components such as the engine and radiator.

• The drawings below show an example of the front structure of a front engine vehicle.

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KC-AA014A 28

Example of front structure of a front engine vehicle

Driver’s seat side

Chassis center

Floor surface

Chassis frame

Beam secured by bolts 04-048

[Precautions for mounting of windshield]

Secure the windshield in its frame using a seal rubber mounting (see windshield mount-ing diagram below).

The seal rubber is usually made of ethylene-propylene rubber (EPDM), which offers out-standing strength and weathering characteristics, but you should select a relatively hardrubber if the main consideration is to prevent movement of the windshield or a relativelysoft rubber if the main consideration is to prevent cracking.

As a rule, the hardness of the rubber should be within a range of 50-70°

The grip of the rubber mounting on the windshield and windshield frame should be asdeep as possible and secured with adhesive.

However, the grip should not be so deep as to detract from the appearance of the vehicleor restrict the visibility.

Make sure that the adhesive does not damage the material of the mounting rubber.

BUS BODY4

KC-AA014A 29

Structure of windshield mounting

04-049

Windshield

Seal rubber

Windshield frame

Horizontal rail at loweredge of windshield

Mounting the windshield• Operating the bus on bad roads may result in the windshield becoming detached from

its mounting or cracking.

This section explains the mechanism by which these problems arise and describes pre-ventive measures.

BUS BODY4

KC-AA014A 30

Mechanism of detachment and cracking of windshield

04-046

Windshield poorly glued to

rubber mounting.

Windshield glass insufficiently thick

Vibration from

running on bad roads

•Bad roads•Sudden

braking

Windshield becomes

detached from mounting.

Windshield cracksStonesBody front

structure insufficiently rigid

Cracks

= 1000.. = 1000.

.

Rear structure• The rear structure is mounted on the end of the rear overhang of the chassis frame and

is subject to two main types of load.

A bending load from the payload carried in the rear overhang.

An torsional load, as the front structure, caused by reactions from road surface whichact on the bus right and left alternatively.

• The bending and torsional rigidity of the rear structure is particularly difficult in rearengine vehicles because the rear end of the chassis frame supports the weight of theengine and the provision of an inspection lid to allow engine maintenance makes a verylarge opening in the rear structure.

The resulting distortion of the skeleton of the rear structure may lead to problems suchas cracking of the outer panels of the rear structure and detachment of spot-weldedjoints.

• For this reason, position the elements of the rear structure so as to ensure that theskeleton of the rear structure itself has a high bending rigidity and that the load from therear overhang is transferred as smoothly as possible to the truss structures under theside windows.

• The following paragraphs show the positioning of members in the rear structure of rearengine vehicles.

Note that in many front engine vehicles, the load on the rear axle is the same as that inrear engine vehicles, and the structure, strength and rigidity of the rear structure shouldtherefore be identical to those adopted in rear engine vehicles.

BUS BODY4

KC-AA014A 31

Examples of positioning of members in body rear structure members and joining of body rear structure to chassis frame

a

b

c

Rear structure vertical and horizontal members

Chassis frame

Final pillar of side structure

Position of outriggers

Outriggers

04-050

04-051

04-052

Position of truss crosses

• The vertical and hori-zontal members of rearstracture are jointed tothe chassis frame andbody side structures.

• Outriggers are mountedon either side of thechassis frame andjoined to the final pillarsof the side structures toreduce the load ofsidestructures.

• The end of the chassisframe is suspendedfrom truss crossed inthe plane of the final pil-lars of the side struc-tures to reduce the loadof the rear structure.

Truss crosses

Roof structure• The skeleton of the roof structure, shown as the below diagram, forms lattice structure

with stiffeners extended in the front-to-rear direction of the body and rafters extended inthe right and left direction.

• To increase the torsional rigidity of the roof structure and ensure dimensional accuracy,the rafters are bent from a single piece of steel and are linked by the stiffeners betweeneach rafter with the rafters taking priority.

Joining rafters and stiffeners• The diagram below shows the method of joining rafters and stiffeners.

BUS BODY4

KC-AA014A 32

Lattice structure of roof

• Recommended materials for rafters and stiffeners

Shear plates(stress plates) Rafters

Stiffeners

Shear plates (stress plates)

• Rafters• Stiffeners 50 x 30 - 1.2 mm} 04-053

Note: Stiffeners in the area within the broken line in the diagramcan be made of Z-section material.

04-054

Square-section tube stiffeners

Window top horizontal rail

Z-section stiffener

Grind upper and lower surfaces flat.

5.5mm

3

B

5 mm

5 mm

Strengthening the roof structure• If the bus is operated under hard conditions such as on bad roads or excessive loads,

the outer panels of the roof structure above the entrance door, emergency door andother openings in the body structure may become permanently deformed (buckled) ormay crack.

• Under such hard conditions, reinforce the area around door openings in the side struc-tures as described earlier and increase the rigidity and strength of the roof structureitself by fitting stress plates above the door openings.

• When fitting stress plates, observe the following precautions.

The stress plates should amply cover the width of the door opening.

The stress plates should be cut to a triangular form at each end (to reduce the concen-tration of stress at the end of the plate) and should be made of single thickness of steelstrip.

Also, plate thickness must be 1.6 to 2.3 mm.

Weld reinforcing rafters and stiffeners to the roof structure following the outline of thearea to be covered by the stress plate, then weld the stress plate securely to thesereinforcing members. (See mounting drawing below for details of welding method.)

BUS BODY4

KC-AA014A 33

Mounting of reinforcing stress plate

[Welding of reinforcing stiffeners]

[Welding of stress plate]

Grind flat the surface that will touch outer panels.

Weld for 50 mm on either side of each rafter.

Weld for 50 mm on either side of each rafter.

04-055

04-056

3

3

B

30B

3

B3 30-100

30-100

2 B 22 B

30-100

30-100

Strengthening roof structure to bear heavy objects• If heavy objects (e.g. the evaporator unit of an air-conditioner or a roof rack), are to be

carried on the roof of the bus, or if rafters and stiffeners must be cut to allow the mount-ing of such an object, you must take steps to strengthen the roof structure.

• If the roof structure is not strengthened, it may become distorted and may leak in rainyweather.

• The following paragraphs explain how to strengthen the roof structure.

• Note that mounting a heavy object on the roof will affect the overall strength and safetyof the bus. HINO recommends that luggage rooms should be built under the floor ofthe vehicle.

BUS BODY4

KC-AA014A 34

Example of strengthening of part of roof structure to carry the evaporator unit of an air-conditioner

Intended position of evaporator unit

Intended position of roof ventilator

Grind upper and lower surfaces.

Grind inner and outer surfaces.04-057

B

3

3

B

[Important points]• Fit brackets to the top rails of right- and left-hand side windows to keep the load of the

roof rack off the outer panels of the roof. The supporting pillars of the roof rack shouldas far as possible be positioned above the window pillars.

• Draw on experience when deciding the loaded weight of the roof rack and take carethat it is not too heavy. (Carefully consider the overall weight of the bus and the distrib-ution of weight on front and rear axles. The maximum weight should ideally be nogreater than 2 tons.)

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KC-AA014A 35

Example of strengthening of part of roof structure to carry roof rack

04-058

Roof rack

04-059

Roof rack

Bolted joint

Gusset (Weld to rafter.)

Rafter


Bracket

Outer panel of roof

Bolted joints(Cover with sealant.)

Window pillar

6. RUST AND CORROSION PREVENTION

• In buses, rust due to water, mud and dust and corrosion due to salt damage not onlyaffect the appearance of the vehicle but may reduce the strength of structural elementsand lead to failures of functional components, the electrical system, etc.

• Rust and corrosion prevention technology and the use of this technology are thereforeextremely important in assuring the quality of the bus.

• This section describes basic measures for rust and corrosion prevention. Please besure to implement these measures when building a bus body.

Basic points of rust and corrosion prevention• When designing and building a bus body, be sure to observe the following precautions

against rust and corrosion.

BUS BODY4

KC-AA014A 36

• Structural design

• Structure should make it easy to keep out and easy to eliminatewater, mud, etc.

• Structure should be easy to paint.

• Avoid contact between different types of metal, provide protectionagainst stones, etc.

• Selection of rust- and corrosion resistance materials

• Use rust resistance steel plate, etc.

• Use resin components, etc.

• Quality of paint work

• Surfaces should be thoroughly degreased and treated with chemi-cal agents prior to painting.

• Improve painting methods.

• Ensure that paint film is of the proper thickness, etc.

• Thorough local rust and corrosion prevention measures

• Treat edges, joints and folds of steel plates.

• Treat welded points, etc.

Preventing rust of body skeleton• As described in Section 2-2) “Strength and rigidity of the bus body”, in buses with

skeleton structure bodies the greater part of the forces acting on the vehicle are sup-ported by the skeleton.

For this reason, any reduction in the strength of the structural elements of the bodyskeleton and the joints between these elements due to rust will have a significantimpact on the service life of the body as a whole.

• The drawing below shows the parts of the skeleton structure that it most important toprotect against rust.

BUS BODY4

KC-AA014A 37

Parts of body skeleton structure most important to protect against rust

04-060

Tie rodHorizontal rails

No. 1 pillarNo. 2 Pillar


Window bottom horizontal rail

Rear pillar

Horizontal rail of floor

: key members above floor level

Easily penetrated by rain water due to faulty sealing of screw mountings of

rain gutters and window frames.

Because these members are made of long sections of material, rust and

corrosion have a major impact.

: key members below floor level

Easily penetrated by mud and dust.

Difficult to treat against rust because they are behind the skirt panels.

Skirt rail

Skirt pillar

Selection of square-section tube material• All of the structural members in the diagram on the previous page use materials which

have been surface-treated against rust.

Preventing water from penetrating to the square-section tube• When building the body, wherever possible avoid drilling holes in square-section tubes.

• Where you must make holes in a square-section tube (e.g. in order to mount windowframes), use rubber seals, liquid sealant, resin-coated screws, etc. to prevent waterfrom penetrating the tube. (See drawing “Measures to prevent water penetration ofwindow frame mounting”.)

• If a bolt passes through an opening in a square-section tube, insert a round pipe intothe hole to prevent water from penetrating the square-section tube and take steps toprevent distortion of the sealing surfaces. (See diagram “Measures to prevent waterpenetration where bolt passes through tube”.)

BUS BODY4

KC-AA014A 38

Principles of rust-prevention and examples of specific measures

• Square-section tube used in general structure

➝ polished steel or acid-pickled steel

• Important structural elements requiring special protection

against rust

➝ internally and externally alloyed steel

(hot dip zinc-coated steel)

Measures to prevent water penetration of window frame mounting

04-061

Top of window Bottom of window

Butyl rubber sheet

Resin coated screw

Molding (aluminum, resin, etc.)G

lass

Gla

ss

• Make sure that you weld around the entire circumference of the joints at either end ofthe square-section tube and of any butted joints to prevent water from running in.

• If the end of a square-section tube is left exposed, make sure that you seal it off bywelding a plate of the same material over the end.

• Every welded joint must be protected against rust.

After welding, remove the welding slag, then apply a coat of welding primer (zinc-richprimer) taking care not to leave any gaps.

• As described in section 3-4, it is important in the skeleton structure that skeleton mem-bers should be arranged in consideration of the workability when welding around theentire circumference of joints and carrying out anti-rust treatment as the above.

BUS BODY4

KC-AA014A 39

Measures to prevent water penetration

where bolt passes through tube

04-062

Seal

Pipe

Seal

Welded around full circumference

04-063

Butted joint with continuousfillet welding

Seal off the ends of square-section tubes.

Preventing water from remaining in square-section tubes and anti-rusttreatment of interior of tubes

• To prevent rust inside square-section tubes, carry out the measures for preventingwater penetration described in paragraph ➁ above.

Also be sure to take steps to facilitate the drainage of water from any parts of the bodyskeleton that water may penetrate in spite of these precautions, e.g. imperfectly weldedjoints, putty cracks, and other areas where seals are cracked.

• When designing the body skeleton, plan water drainage routes and provide drainageholes to allow any water which may penetrate the square-section tubes to escape.

• Also be sure to treat the interior of the square-section tubes against rust, especiallyalong these water drainage routes.

• The drawing below shows one example of water drainage routes and drainage holes ina skeleton made of square-section tube.

Providing water drainage holes• To allow water that has penetrated the square-section tubes of the skeleton to escape,

position drainage holes under vertical pillars and on the lower surface of the skirt rail.

(If the holes are too small, the drainage will be poor. If they are too big, they may allowmud to penetrate the tubes.)

• Provide drainage holes in horizontal members such as window top and bottom railsand the joints of end pillars.

Warning: Never make drainage holes in the tire houses.

BUS BODY4

KC-AA014A 40

Example of water drainage routes and drainage holes

04-064

Water drainage routes

Water drainage holes

• Diameter of drainage holes: 10 ~12ø

Anti-rust treatment of interior of square-section tubes• After painting the entire skeleton, spray a rust inhibitor oil (e.g. tectil) inside the square-

section tubes.

• Spray the tubes via the drainage holes, or create new spraying holes. Insert a vinyltube into the holes and spray thoroughly so that the entire inner surface of the tube iscoated with rust inhibitor oil. (See diagram “Spraying interior of square-section tubewith rust inhibitor oil”.)

• As a rule, you should make no more than one spraying hole of 10 ~ 12 mm in diameterin each member.

However, if the member is 6 m or longer, you may make two holes.

Preventing water, mud and dust from remaining on outer surface ofsquare-section tubes

• The lower part of the skeleton structure (below floor level) is continually exposed to rainwater, mud and dust. If you are mounting gussets and brackets on this part of theskeleton in particular, make sure that these gussets and brackets themselves and thearea in which they are mounted are shaped so as to prevent water, mud and dust fromremaining.

Make sure that the position of these gussets and brackets allows easy anti-rust treat-ment of the gussets and brackets themselves, the surrounding parts of the skeletonstructure, and the outer panels.

BUS BODY4

KC-AA014A 41

Spraying interior of square-section tube with rust inhibitor

04-065

Water drainage hole

Vinyl tube (Gradually pull this tube out of the hole as you spray.)

Water drainage hole

(Seal with a grommet after spraying.)

Air gun

Rust inhibitor oil

Spraying hole

Compressedair

BUS BODY4

KC-AA014A 42

Example of anti-rust treatment when gusset or bracket is mounted on a square tube

Skirt pillar

Seal all around.

(only in locations below the vehicle floor and

other places where rain water may penetrate.)

Side lid lock bracket

Skirt rail

04-066

Preventing rusting of the outer panels of the body• The entire body of a car can be dipped at once to coat the inner and outer surfaces of

the steel panels against rust by a chemical treatment such as zinc phosphate coatingor by electroplating. Obviously, this is impractical in the case of a bus.

To protect the outer panels of the bus body against rust, observe the following precau-tions.

Selection of steel panel materials• As with the square-section tubes used in the body skeleton, you can increase the dura-

bility of the vehicle by using material that have been surface-treated against rust:

Measures for most important parts to protect against rust• This section describes representative examples of how to treat the outer panels of the

body against rust.

Preventing rust on back of outer panels• Follow the procedure given below to prevent rust on the back of the outer panels of the

body.

BUS BODY4

KC-AA014A 43

• Fixed outer panels: internally and externally alloyed steel (hot dip zinc-coated steel)

• Detachable outer panels: electro-galvanized steel (steel plates individually treated against rust)

PrimingTouch up welded joints with a rust-inhibiting primer (e.g. zinc-richprimer), then• paint the entire surface of panels below floor level with chassis

primer, and• paint the entire surface of panels above floor level with a rust-inhibit-

ing primer (e.g. zinc-rich primer).

1st anti-rust treatmentApply an undercoat 2 ~ 3 mm thick to the entire surface. It is not nec-essary to use undercoat on roof panels and side panels below win-dows and above floor level except to prevent joints with anti-vibrationand tension materials from getting off.

2nd anti-rust treatmentSpray a coat of rust-inhibitor oil (e.g. tectil) over the undercoat. Makesure that the rust-inhibitor oil fully penetrates any parts of the skeletonnot painted with undercoat, such as joints. (For method of sprayingrust-inhibitor oil, see the following drawing.)

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KC-AA014A 44

Example of treatment of back of outer panels with rust inhibitor oil (Tectil)

[Lapping of front and rear outer panelswith roof outer panel]

[Lapping of roof outer panel andwindow top rail]

[Inside of right and left tire houses](below floor)

[Inside of outer panels belowwindows]

Make sure that rust inhibitor oil penetrateslapping of outer panels.

Make sure that a good quantity of rustinhibitor oil penetrates join with skele-ton structure.

Make sure that a good quanti-ty of rust inhibitor oil pene-trates join with skeleton struc-ture.

Make sure that a good quanti-ty of rust inhibitor oil pene-trates join with skeleton struc-ture.

04-067

04-068 04-069

Apply undercoat paint to entiresurface, then spray with rustinhibitor oil.

Preventing rust at joints between outer panels• The joints between the outer panels of the body are protected against rust by treating

the joints themselves and assuring the quality of the surface of the outer panels, butalso by filling the joints with putty. However, incorrect filling may lead to cracking of theputty.

• To protect the joints between outer panels against rust, observe the following proce-dure.

BUS BODY4

KC-AA014A 45

[Where body panels are to be mounted on the skeleton]

[Where two outer panels are to be joined together]

Mounting body panels on skeleton

Joining two outer panels together

04-070

04-071

04-072

20

20

40

20 20 20

5±1Putty

Arc brazing

Spot welding

• Spot weld the outer panels onto the skele-ton, allowing a gap of approximately 5 mmbetween the edges of adjacent panels (forputty).

Important: If the gap is too small, it will bedifficult to insert the putty; if it is too big, theputty may crack.

• Any vibration of the corners of the outerpanels may cause the putty to crack.Secure the corners of the panels by spotwelding and arc brazing.

• Remove any burr from the edges of thepanels and from welded parts, then polishthe areas to be filled with putty and removeall oil, dust and water before applying theputty.

• If the outer panels of the body must bemade flush surface, make a chamfer in onepanel, then spot weld the panels togetherallowing a gap for putty.

• To improve the adhesion of the putty,chamfer the edge of the outer panelthrough 2/3 of its thickness.

• Joints between panels which do not requireflush surface, such as roof panels, can bemade as shown in the drawing at left.

Important: Make sure that the overlappingof the panels does not run counter to theflow of rain water.

Outer panels of body side

4510

1.5 ~ 2.5

Chamfer 2/3 of thickness

20±5 5 Putty

Outer panels of roof

Putty

Preventing rust of other body components• Joints between outer panels in the parts of the body shown below are constantly

exposed to particularly harsh conditions (water, mud, dust, salt).

Take particular care to protect these joints against rust.

• This section outlines procedures for protecting such parts.

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KC-AA014A 46

[Tire fenders]

[Entrance steps]

[Edges of inspection covers or lids]

Steel plate over-fenders

Protecting entrance steps against rust

Protecting edges of inspection covers or lids against rust

Rubber over-fenders

Sealant

Over-fender

Sealant

Outer panel of fender

Protector (resin)(Inject silicon into protector)

Undercoat + Rust inhibitor oil(e.g. tectil)

Weatherproof rubber

Sealant

04-073 04-074

04-075

04-076

04-077

Aluminum over-fender

Single sheet of pressed aluminum

Edge plate

Tread

Riser

Sealant

Undercoat + Rust inhibitor oil (e.g. tectil)

Sealant

Tie rod

Notes:• Apply undercoat and rust inhibitor oil after mounting

the step parts on the body.• Undercoating the step parts plays a significant role in

reducing passenger room noise.

Note: • Dimension “L” of reinforcing strip should be no more

than 15 mm. If it is longer than 15 mm, vibration maycause cracking of the sealant.

Sealant

Reinforcing strip

L

Protecting wooden flooring against rot• The flooring in buses is usually made of wooden boards or plywood panels.

In hot and humid climates, this wooden flooring may rot.

• If the vehicle is to be used in a hot and humid climate, make sure that you treat woodenflooring materials to protect them against rot.

• This section describes which parts of the flooring are most vulnerable to rot andexplains the mechanisms by which rotting occurs.

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KC-AA014A 47

Parts of flooring most vulnerable to rot

Around driver’s seat

Around tire houses Upper surface of bulkheads

Around rivets securingfloorboards

Inner trim Tire house

Flooring

Eyeboard

Floorboards

Seat leg

Rotting

04-078

BUS BODY4

KC-AA014A 48

chanism by which rotting of wooden floorboards occurs

Rain water penetrates passenger room

• via windows, doors, ducts.

• via ventilators.

• brought in on passengers’ clothing.

Water penetrates screw holes

in eyeboards of flooring.

Water penetrates mounting bolt holes for seat

legs.

Water penetrates

the joint between tire

house lid and

floorboards.

Water penetrates

upper surface of

flooring.

Adhesive used on flooring

is soluble in water.

Hot and humid climatic

conditions

(optimum conditions

for spread of rot

bacteria)

Splashing

from tires

Water penetrates

under-floor space

during vehicle

washing.

Tire house

Water follows pores

in wood and

penetrates to center

of floorboards.

Water penetrates from lower surface of flooring.

Inside and upper sur-

face of wooden is

always wet

Pores

ApitongPlywood

Rot bacteria

spreads.

Rotting occurs.

• Availability of nutrients and air• Humidity: approx. 80 %• Temperature: 25 ~ 35°C

04-079

Measures to prevent rotting• To prevent rotting, observe the following precautions.

Use well-seasoned materials.

Apply a preservative (e.g. KOSHIMAX) to the edges of wooden floor, edges of holesfor inspection covers or lids and other parts where the pores of the wood are exposedand make sure that it penetrates the pores. Then apply a sealant (e.g. SIKAFLEX221).

Always inject preservative into the holes for all bolts, rivets and screws used to securethe flooring material.

In climates which are particularly conducive to rot, you should also spray the entire sur-face of the wooden flooring with preservative.

• The drawings below show in detail which parts of wooden flooring which require treat-ing with preservative and sealant.

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KC-AA014A 49

Parts of wooden flooring which require treating with preservative and sealant.

04-080

Plywood flooring Board flooring

AB

A

A

A

B

BB

B

B

A

A

A

B

: Apply preservative + sealant.

: Inject preservative.

A

A

Using resin components to avoid rust and rot• The use of resin parts instead of steel parts (especially for front and rear outer panels,

skirt panels, etc.) in bus bodies is becoming increasingly widespread.

Resin parts avoid rust and rot, help to reduce the weight of the vehicle, and improveproductivity. (Resin parts are easier to mold.)

• When replacing steel parts with resin parts, it is common to use FRP (fiber-reinforcedplastic) resins.

FRP resins are heat-resistant unexpanded polyester resins, reinforced with glassfibers.

• FRP resins offer excellent strength, weather resistance and heat resistance.

However, because FRP resin parts are thermosetting resins, they also have the follow-ing general characteristics:

The thermosetting process causes the structure of the resin to grow denser andbecome more brittle.

Once hardened, the resin will not soften again even if reheated.

Once hardened, the resin will not dissolve even if a solvent is added.

If thermosetting resin parts are to be painted, special paints will be required.

• Before deciding to use resin parts instead of steel parts, you should therefore givecareful consideration not only to production needs and methods, but also to dealingwith problems that may arise after the vehicle enters service (e.g. repair methods, partsserviceability, etc.) and the method of disposal of such parts when the vehicle isscrapped.

• The drawing below shows examples of body parts that can be replaced with resinparts.

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KC-AA014A 50

Examples of body parts that can be replaced with resin parts

04-081Front bumper

Extractor grille

Exhaust grille

Rear bumper

Colored moldings

Lids (especially movable lids)

7. RIDE COMFORT IN RELATION TO VIBRATION AND NOISE

• Ride comfort, in the widest sense, is defined as the comfort with which passengers areable to ride in the bus while subject to the following factors.

• This section describes the effects of vibration due to the road surface, and noise andheat from the engine, and the main points involved in improving ride comfort in thepresence of these factors.

• Ensure that sufficient attention is paid to ride comfort in the design and manufacture ofthe bus body.

Vibration and Improvements in Ride Comfort

Types of Ride Comfort and feeling in Relation to Vibration• The relationship between ride comfort and vibration is very subjective, and the factors

involved are extremely complex. The final evaluation of ride comfort must thereforerely on the subjective evaluation of the passengers.

• The following vibrations are normally felt by passengers when the bus is in operationunder normal conditions.

NOTEFrequency of vibration differs slightly depending upon vehicle size, body type, etc.

BUS BODY4

KC-AA014A 51

• Coloring, lighting, natural lighting, ventilation, natural airflow

• Vibration and noise transmitted from the road surface

• Noise and heat emitted by the engine

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• Illustrations of the vibration modes and primary factors for each type of ride comfort aregiven below.

Points of Body Design for Improvements to Ride Comfort• Points and practical measures for improvement of body vibration characteristics in the

vibration modes above are given below.

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Primary Factors in Vibration Modes

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04-082

04-083

04-084

04-085

Bouncing Pitching

E/G pitching

F/A, R/A vertical

Twisting Bending

E/G rolling

Separate the natural oscillation frequency of the structural framework (includ-ing chassis), which forms the basis of body vibration, from the frequency ofthe external vibration in order to avoid resonance in the overall framework.(related to a) and c) above)

In particular, improve the vibration transmission coefficient of the floor struc-ture which transmit vibration below spring and power plant (B/G, T/M, etc.)component.

Suppress the local resonance and vibration levels of body components.(related to d) above)

[Practical Points for Improvement of Vibration Characteristics]

• Increase rigidity and reduce weight of overall body skeleton as much as possible toincrease the natural frequency of vibration of the body beyond that of the externalvibration.

• See the following for details of practical measures to increase the rigidity of the basicbody skeleton.

• As vibration of the body floor is transmitted to the bodies of the passengers via theseats (or directly via the feet), vibration characteristics in this area have a significanteffect on ride comfort.

• Use the following measures to reduce vibration.

• Increase the rigidity of the floor structure, that is the chassis, sill cross, and main floorsill (framework in the longitudinal direction of the floor). See 4-1) Floor Structure.

• Attach the floor board to the floor structure with screws.

Note that insufficient attachment of the floor board to the floor structure will cause thefloor to vibrate and amplifying internal noise.

• Use vibration dampening materials in the floor board, and rubber-mount the body as ameans of reducing internal noise.

• Improvements in elastic vibration of the body involve localized improvements in rigidityto increase the uniformity of bending and twisting over the body as a whole.

• Practical measures are similar to those used to ensure structural strength. See - [4.Layout of Structural Components] for details.

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KC-AA014A 53

Point 1

Point 2

Punto 3

[Ensure that the natural frequency of vibration of the body skeleton is greater than 14 ~ 15 Hz.]

• [2. Principal Precaution when Mounting a Bus Body]

• [3. Basic Layout of Body Structure]

• [4. Layout of Structural Elements]

Internal Noise• Reduction of internal noise (passenger room) has an important effect on ride comfort in

the same a manner as does vibration as described above.

• Ensure that the following points are noted in body design and manufacture.

Causes of Internal Noise, and Points to Note When Mounting a Body• The causes of internal noise, and the relevant points to note when mounting the body,

are as follows.

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Reducing Internal Noise

• The engine is the major source of noise.

It consists of the 500 Hz or higher frequency of combustion and mechanical noise fromthe engine itself (felt as a continuous sound of comparatively high frequency), and the150 ~ 160 Hz noise air intake noise (felt as a series of discrete sounds).

Noise within the bus is primarily of these two frequencies.

• This engine noise is transmitted into the bus via bulkhead and floor.

The energy of vibration generated from intake of air to the engine is transmitted to thebody of the bus and results in a drumming sound.

• When mounting the body therefore, it is important to improve the sound dampeningand sound absorbing characteristics of the bulkhead and floor around the engine com-partment, and to suppress vibration in the engine air intake system.

• Practical measures to reduce engine noise are given below.

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Engine Noise

Frequency Analysis of Internal Noise

(measured in the rear seats of a rear-engined bus)

04-086

20 32 50 80 125 200 320 500 800 1.25K 2K 3.2K 5K

Noi

se le

vel

Air intake noise Engine noise

(at full throttle, 80 km/hr)

BUS BODY4

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Examples of Measures to Reduce Internal Noisevia Engine Bulkhead [Rear-engined Bus]

Bulkhead

Front

Engine compartment

04-087

• Engine compartment bulkhead improvements

Improved sound-absorbentmaterial in bulkhead

Fit insulation withinstructural beam.

Improve structure of inspectioncovers in bulkhead.

Structural beam

t = 30 glass woolGW416 (density = 32 kg/m3)

t = 1.4 steel plate

t = 12 waterproof plywood(floor board)

t = 2 flooring

04-088

04-089

General Inspection cover

Rubber seal Glass wool

Punched metal

GW416 t = 30

1.4t steel plate

12t flooring waterproof plywood

2t flooring

NOTE• The air intake system between the engine air cleaner and the intake is com-

pletely isolated from the passenger compartment with sound-absorbent rub-ber.

• The engine air cleaner and the water separation chamber are fitted to thebody via anti-vibration rubber mountings (see (a) in diagram above).

• The external plating of the water separation chamber is strengthened by theaddition of reinforcing beams (see (b) in diagram above).

• Rubber seals are added between the plating in the circumference of the airintake and the body (see (c) in diagram above).

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Examples of Measures to Reduce Engine Air Intake Noise [Rear-engined Bus]

04-090Engine air cleaner

Body rear panel

Engine compartment bulkhead

Rubber seal

(b)

Water separation chamber(Air intake chamber)

(a)Body external panel on rear end.

Cover board with sound-absorption material

Air intakeport

(a)

(b)

(c)

• Wind noise is generated by airflow around the vehicle, and air entering and leaving thevehicle through gaps around windows and doors, while the vehicle is in operation.

While wind noise increases with speed, the characteristics of the noise differ with thesize of the gaps.

A roaring sound (600 ~ 16,000 Hz) results with large gaps, and a high pitched sound(1,600 ~ 30,000 Hz) with small gaps.

• Effective measures to reduce wind noise include removal of projections from the body,smoothing of turbulent airflow, and improving seals around windows, doors, etc. to pre-vent entry of air.

• These measures are illustrated below.

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04-091

Reducing Wind Noise

Example of Fitting a Wind Deflecting Plate to the Rear-view Mirror

Example of Strengthening Seals

Outside

Passenger’s

compartment

Noise intrudes from here.

Front windowWind deflecting

Right rear-view mirror

Source of wind noise

04-09204-093 04-094

A

A

Seal rubber ofside window

Seal of sliderail

Standard section (A-A) Strengthened section (A-A)

Seal rubber of sidewindow

Seal of slide rail

• The sound of cooling air from the air conditioning system exhausting from the air ducthas a significant effect on ride comfort.

It is therefore important to ensure that this noise is reduced as much as possible whenmounting the body.

• The following gives an example of noise distribution inside the bus when the air-condi-tioning system is in operation, and the degree to which the system contributes to thisnoise.

As shown below, when the air-conditioning system is in operation, the most significantnoise is that emanating from the cooling air ducts inside the bus.

This noise has a frequency of 125 ~ 320 Hz.

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Reducing Air Conditioner Noise

Noise distribution inside the bus when the air conditioning system is in operation

Analysis of air conditioning system noise

04-095

Noi

se le

vel (

db (

A))

High

Vertical duct (internal)Sub engine unit (below floor)

Noi

se le

vel (

db(A

))

Overall air conditioning system noise

Noise of duct

Noise from subsidiary powerunit (below floor)

• As levels of noise from air ducts are generally proportional to the speed of the air in theduct, the following practical measures are available for noise reduction.

• Increase the duct cross-section to obtain the same volume of air at a reduced airflowspeed, and thus reduce noise level.

• As objects which offer resistance to airflow within the duct (e.g. airflow partitionplates) have a significant effect on noise levels, improve the shape of these objectand fit the inside of the duct with anti-vibration and sound insulating materials toreduce the level of sound passing through the duct walls.

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KC-AA014A 60

04-097

Example of Effects of Improving Partition Plates with DuctN

oise

leve

l (db

(A

))

Partition plate

With original partition plate

No partition plate

With improved partition plate

Low speed airflow Medium speed

airflow

High speed

airflow

• As described previously in ➁ , in addition to the noise developed by the power plantitself, noise also emitted by the drive train (in particular the differential noise).

This noise is one of the noises in the passenger compartment which also effects ridecomfort.

• The following diagram gives an example of differential noise.

As shown below, differential noise reaches a peak at a particular vehicle speed, andincreases the total noise level in the passenger compartment, thus providing a sourceof discomfort for the passengers.

• The primary source of this differential noise is vibration from the meshing of gearswhich is transmitted to the body via the drive train, suspension, and chassis, and isapparent as noise inside the bus.

Noise is further amplified due to the fact that the whole bus is covered in the samemanner as a drum.

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Reducing Drive Train Noise

04-098

Example of Differential Noise

Inte

rnal

noi

se le

vel (

db (

A))

Differential noise

Overall noise level

Peaks

Vehicle: BusLocation of measurement:At ear level above rear axle

Vehicle speed (km/h)

40 50 60 70 80 90 100

• On this basis, reductions in differential noise may be effected by improvements in thechassis (by improving meshing of gears and suppressing transmission of vibration inthe drive train and chassis), and suppressing the amplification in the body of the vehi-cle.

The following page explains noise reduction measures related to the body.

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The mechanism by which differential noise is generated is expressed simply as follows.

Amplification

Vibration associated with gear meshing

Drive train Chassis Body

Differential noise perceived in passenger

compartment

Reducing Sound Pressure Sensation in the Bus with the Use ofVibration-Dampening Floor Boards

• One method involves the use of floor boards to suppress noise (various vibrations)transmitted via the chassis.

• A comparison of the sound pressure attenuation characteristics of test pieces of floorpanels of plywood and vibration-dampening material (consisting of layers of vibration-dampening material sandwiched between layers of plywood), revealed the following dif-ferences in characteristics.

In contrast to the lack of attenuation of sharp peaks apparent with the wood or veneerproduct, the vibration-dampening material flattens these peaks to a curve, indicatingthe excellent attenuation characteristics of the material.

• The following graph represents a comparison of measurements of noise in separatebuses in which plywood and vibration-dampening material have been used.

Use of floor boards of the vibration-dampening material dramatically attenuated noiselevels within the bus.

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Comparison of Sound Pressure Attenuation Characteristics of Various Materials

A Comparison of Plywood and Vibration-dampening Material Used in Buses

04-099

04-100

Acc

eler

atio

n m

obili

ty (

db/k

g)

Vibration-dampening material

Plywood

Frequency (Hz)

Noi

se le

vel (

db(A

))

Plywood

Vibration-dampening material

Vehicle speed (km/hr)

Optimum transitory frequency (Hz)

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KC-AA014A 64

Example of Use of Vibration-dampening Material in Bus

Vibration-dampening floorboard

Section A-A Detail of vibration-dampening material

Dampening material(Butyl rubber)

Plywood

04-101

Reducing Gear Noise With Anti-vibration Rubber• The use of anti-vibration rubber in spring pins on the chassis is effective in preventing

transmission of vibration caused by meshing of differential gears to the body of thevehicle.

The use of this rubber at the joins between the chassis and body is also effective.

• Reducing the hardness of the rubber (spring rate) reduces noise in direct proportion,however this also reduces the durability of the rubber (see diagram below).

• The use of rubber as described changes both the rigidity of the chassis-body join andthe vibration characteristics of the whole body, and affects the strength of the body andride comfort in the presence of vibration.

• For the above reasons, care is required when using rubber in this manner.

In general, the use of rubber joins is suited to smaller buses which use standard truckchassis of sufficient strength.

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Spring Constant of Rubber, and Noise Levels

04-102

Noi

se le

vel (

dB (

A))

Spring Constant of Rubber (kg·f/cm)

0 200 400 600

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KC-AA014A 66

Example of Structure of Rubber Mounting

Bracket

Rubber

Sill cross

Chassis frame

04-103 04-104

8. DESIGN TO FACILITATE INSPECTIONS AND MAINTENANCE

• Inspections and maintenance are an important factor in bus reliability.

• In most buses the majority of the equipment and functional items to be inspected andmaintained are located under the floor, and surrounded by the floor structure or lateral,or longitudinal structural members, and inspection covers are therefore required.

• If the location of these inspection covers and the surrounding structure is unsuitable,inspections will be difficult, structural strength will be reduced, and noise and water willleak from around the inspection covers.

• The following points should be kept in mind when installing inspection covers forinspections and maintenance.

Refer to [General Precautions], [Equipment Installation Procedures], points notedunder [Bus Bodies], and other separately published the body mounting manual for therespective model series.

Location and Size of Inspection and Maintenance

Position and opening size should facilitate work opening on the equipment and functionalitems to be inspected daily, and be suitable for the prevailing methods of inspection andmaintenance.

The designer or person responsible for manufacture should therefore carry out theinspection and maintenance himself to confirm this.

The example on the following page illustrates the inspection covers used for inspectionon a rear-engined bus.

Always avoid fitting inspection covers in locations which require cutting of primary struc-tural members and thus reducing the strength of the structure.

The layout of the inspection covers required for inspection and maintenance noted in thedocumentation on separately published the body mounting manual for the respectivemodel series should therefore first be checked to ensure that they do not coincide withthe structural members in the body.

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Strength, Noise Prevention, and Waterproofing Around Inspection Covers

Add reinforcement as required to ensure that the area around the inspection covers isnot subject to excessive deformation or stress.

Ensure that inspection covers in the floor in particular, are well sealed, and rust and cor-rosion-proofed to prevent intrude of noise and water into the passenger room. See BusBody [5. Rust and Corrosion-prevention] for details.

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KC-AA014A 68

Example-Inspection Covers for Inspection and Maintenance, and Inspected Items in Rear-engined Buses

Inspection and replacement of upper engine components

(air conditioner compressor hoses, injection pump, etc.)

Replacement of starter, inspection and replacement of air hoses

For transmission removal

For lifting differential

For tightening and removing stabilizers (only vehicles with pneumatic suspension)

View B

Engine side cover, for inspection of starter,

etc.

For inspection of cooling system (Beltreplacement, Checks for water leaks, Fandrive checks)

For inspection of engine system (Checking oil level,Checks and replacement of engine components,Replacement of air cleaner)

Checks of upper engine components(Tightening rocker cover, Tightening head bolts)Checking and replacement of electrical and chargingsystem components (electrical box)

Inspection and tightening of engine air piping

Inspection of injection pump

Bulkhead

Rear of body

Upper surface of chassis frame

04-105

A

B

View A

9. SAFETY CONSIDERATIONS

• The nature of the bus as a means of public transport requires caution and careful con-sideration of safety.

• The following describes the major items requiring consideration. Ensure that theseitems are implemented carefully when mounting a bus body.

Visibility• Visibility encompasses general visibility in the forward direction, the visibility of instru-

ments to the driver, and the following.

• Ability of the driver to monitor movement of passengers within the bus

• Ability of the driver to monitor passenger getting on/getting off from the bus

(This is particularly important in the case of urban buses in which passengers gettingon/getting off from the rear entrance.)

Ensure that internal and rear view mirrors are placed appropriately to allow the driverto monitor the above.

Safety of Pedestrians• Urban buses designed primarily for mass transport of passengers commonly operate in

narrow, crowded streets, and require the following considerations of pedestrian safety.

• Ensure that nothing projects from the bus.

Particular importance should be given to avoiding objects projecting from the side ofthe bus.

• Ensure that the design of the bus is such that have a under run protection of the tire.

Passenger Safety• Design should be such that passengers do not fall down inside the bus.

• Especially in the route bus, as passengers are likely to move in the bus, care should betaken to the difference in the passageway, inclination of the floor, and the installation ofhandrails and handstraps and their fitting positions.

• The following body specifications and structural items should also be considered.

• To guard against injuries from hot water leaks, avoid having joins in hot water heatingpipe which runs near passengers, and avoid running this piping above passengers.

• When lower rails of windows are low in relation to the seat, either restrict dimensionsof side window openings, or fit protective pipes to prevent passengers falling over.

• Ensure that passageways and emergency exits are of suitable width to allow rapidexit in case of accidents.

In long-distance buses or tourist buses in which the floor is high above the road level,the height of the emergency exit above the road will require provision for steps or lad-der.

BUS BODY4

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10. FIRE PREVENTION

• The nature of the bus as a means of public transport obviously requires that care betaken with fire prevention when mounting a bus body.

• The following points must be strictly followed during mounting a bus body.

In addition to the following, see [1-General Precautions] and [2-Equipment InstallationProcedures].

Protection of Wiring Harness and Pipes During Mounting a Bus Body• Cover other components, including chassis components, to prevent born out of wiring

insulation material, and damage to brake and fuel piping during welding work.

When welding in areas backed by wiring harness and piping, cover by insulator overthese components to prevent heat damage.

• When drilling holes in areas of the chassis backed by wiring harness and piping, checkbefore drilling to ensure that these components will not be damaged.

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KC-AA014A 70

Example-Preventing Damage to Wiring Harness and Piping During Drilling Work

Drill

Floor board

Floor

Wiring harness or pipeDamage here

Drill stopper protects componentsfrom over-drilling.

(Procedure 1)Drill

Stop

Procedure 1 is ineffective ifthe operator loses the drillor uses a different drill.

(Procedure 2)

04-106

Wiring Harness• Wiring harness for head lamps and tail lamps and other electrical components should

be slightly longer than required to provide a degree of flexibility in placement duringmounting a bus body.

• Wiring harness must be well fastened in place to ensure that they do not contactagainst chassis and body components, resulting in short circuits and fires.

The following points should be followed in this respect.

Preventing Movement of Wiring Harness Connectors• Connectors are normally used to join wire harness.

After the wire harness has been installed, fix it to the body with clips near the connectorto prevent movement due to vibration of the vehicle.

• If the connector sags under its own weight it may interfere with other components,break, or allow penetrating of water thus causing troubles.

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Example-Unsatisfactory Placing of Clips Near the Wiring Harness Connector

Flow of water

Connector

Movement of harness

04-107

Clips should be located as close aspossible to the connector to preventmovement.

Clip

Clip

Fixing Loose Wiring Harness• After fixing wiring harness for head and tail lamps and other electrical components to

the body, fix the loose part of the wire harness as follows.

• If wire harness are not bound together and fixed in place correctly, they will interferewith surrounding components resulting in damage and breakage.

BUS BODY4

KC-AA014A 72

• Thick harness, or multipleharness bound together

• Single wires

Looped and fixed to bodywith clips.

Bent double and fixed to

body with clips.

04-108

Binding Loose Wire Harness and Fixing to Body Components

approx. 300 approx. 300

Fix in place with clips to prevent movement.

Thick harness, or multiple harness bound together

Single wires

200~300 200~300

approx. 300

11. APPEARANCE AND WORKMANSHIP OF BUS BODY

• The appearance and workmanship of the bus body, that is finishing, is extremelyimportant in that it affects the value of the bus as a product.

• The construction and assembly of body components are generally affected by the man-ufacturer’s internal situation, the conditions of the environment in each country, and thesize and type of body.

• Therefore universal major improvements in method of manufacture and assembly can-not be mentioned, however improvements in the quality of finish, and the fundamentalrequirements for a stable level of finish, are described below in reference to appear-ance and workmanship and examples of measures for improvement.

• During manufacture and mounting a bus body, endeavor to incorporate the followingpoints in improving methods of manufacture to ensure bodies of high quality.

Fundamental Points to Ensure High Levels of Appearance andWorkmanship

• Begin body manufacture after checking the following points in your system to ensuresatisfactory levels of appearance and workmanship.

• Clarification of work methods and sequences (processes)

• Planning and use of tools and jigs

• Education and training of worker

• Clarification of methods of testing and checks, and criteria for evaluation

• Clarification of problems by layer, and repair methods

• Other matters related to the work condition (e.g. dust collection measures)

Establish the most appropriate methods and system for the above, and implement aprogram of continuous improvement.

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KC-AA014A 73

Primary Management Points to Ensure High Levels of Appearance andWorkmanship, and Examples of Improvements

• The primary management points to ensure high levels of appearance and workman-ship, and examples of improvements for each major item, are shown in the followingtable.

BUS BODY4

KC-AA014A 74

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Tension Rigidity of Body Outer Panels• Dents and unevenness in the external panels of the bus body have the greatest effect

on its quality of appearance.

• The methods noted in the following table, either singly or in combination, are generallyemployed to increase the tension rigidity of the panels to improve appearance, andtherefore quality.

• Conditions such as tensile strength of the panels, and temperature

Method of giving tension to the outer panel, and temperature applied, etc. must bedetermined after investigation of a variety of factors including panel size, structure, andthe manufacturing condition in a process of trial-and-error repeated until a stable resultis obtained.

BUS BODY4

KC-AA014A 75

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12. ADVANTAGES AND DISADVANTAGES OF FRONT AND REAR-ENGINEDBUSES, AND AIR CONDITIONING SYSTEMS

• The advantages and disadvantages of front and rear-engined buses, and air condition-ing systems, are described below for reference when mounting a bus body.

• Select the engine configuration and air conditioning system only after you have a clearunderstanding of their advantages and disadvantages.

Advantages and Disadvantages of Front and Rear-engined Buses• A comparison of the advantages and disadvantages of front and rear-engined buses is

given in the table on the following page.

• Changes in conditions currently affecting each country (increased levels of comfort andluxury required, improved conditions for vehicles such as better road) are generallyleading to adoption of the rear-engined configuration on the basis of the advantagesand disadvantages noted in the table.

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KC-AA014A 76

BUS BODY4

KC-AA014A 77

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Air-conditioning Systems• With the increasing level of luxury required in recent years, air- conditioning units are

now installed in most buses to improve ride comfort.

• The advantages of the various types of air-conditioning systems, and of the ductingsystems are listed on the following page.

• Select the appropriate air-conditioning system after an investigation of the bus specifi-cations, the equipment and capacity of the factory in which it is to be mounted, and thechassis specifications.

BUS BODY4

KC-AA014A 78

BUS BODY4

KC-AA014A 79

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04-121

04-121

04-122

04-123

04-124

04-125

04-126

04-127

Air-conditioner Types and Advantages

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KC-AA014A 80

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Characteristics of Types of Air ducts[Evaluation: Good, Normal, Bad]✕

Co

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Duct

960 390

2344

Duct

920 390

2254

04-128 04-129

✕

✕

✕

✕

✕

✕

body mounting manual - hino.com.co · device on hino bus chassis (hereinafter collectively referred...

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