No part of this manual may be reproduced or transmitted in any form without the

express written permission of Hino Motors, Ltd.

2010,
All rights reserved. Printed in Japan.

PRODUCT PLANNING DIVISION

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

:
:

042-586-5249
042-586-5868

2010 - 12

KK-AK206

ABOUT THIS MANUAL

Purpose
This manual is provided the Body and Equipment Manufacturers, including
intermediate and/or final stage manufacturers (hereinafter collectively referred to as
Body and Equipment Manufacturers), to provide:
Technical instructions for Hino bus chassis for modification and mounting of
bodies.
An aid to Body and Equipment Manufacturers for producing safe vehicles under
their own discretion and responsibility.
Other general advice for installation, modification or alteration.
When Body and Equipment Manufacturers install any body or other equipment or
device on Hino bus chassis (hereinafter collectively referred to as Hino Chassis),
or modify or alter a Hino Chassis.

Content
This manual contains chassis specifications and instructions particular to model
AK8JRSA, medium duty bus chassis.

Important
This instruction manual must be used in combination
with the Common Manual, No. KC-AA014A.
For more information on mounting of bodies and equipments or on chassis
modifications, refer to the appropriate workshop manuals, parts catalogs, and
maintenance guides and owner's or driver's manual.
The information in this manual is accurate to the best of Hino's knowledge at the
time of going to press.
Hino reserves the right to modify any and all information without notice and
without obligation.
Should more detailed data or information be needed, please contact authorized
Hino distributor.

KK-AK206

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

KK-AK206

STRICT OBSERVANCE OF PARALLEL USE WITH THE BODY

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

GENERAL
PRECAUTIONS

GRAND ITEM
1.

3.

PRECAUTION
WHEN
APPLYING
THE
FINAL COAT
OF PAINT

EQUIPMENT INSTALLATION
PROCEDURES

2.

BUS BODY

4.

KK-AK206

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

BODY DESIGN AND CONSTRUCTION

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

CORRESPONDING
PAGE IN COMMON
MANUAL

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

CONTENTS

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

KK-AK206

1. VEHICLE SUMMARY
MODEL CODE 1 - 1
IDENTIFICATION NUMBER 1 - 2
CHASSIS SPECIFICATIONS 1 - 3
DETAIL OF VEHICLE CAPACITY 1 - 4

KK-AK206

1-1

1. VEHICLE SUMMARY
MODEL CODE
A

VEHICLE CODE
FRONT ENGINE BUS
REAR ENGINE BUS

A
R

DRIVE, CHASSIS & SUSPENSION

TYPE CODE

DRIVE
:4X2
CHASSIS
: WITH FRAME
TYPE OF
SUSPENSION
: LEAF SPRING
OVERALL LENGTH : OVER 9 m

ENGINE CODE
8J J08E
WHEELBASE CODE
WHEELBASE (mm)
CODE
M

R
S

5,000~5,249
5,750~5,999
6,000~6,249

MODIFICATION CODE
CODE
K
L

S
T

STEERING POSITION
RIGHT HAND DRIVE
LEFT HAND DRIVE

APPLICABLE CODE
CODE
A

KK-AK206

BODY TYPE
STD FLOOR

1-2
IDENTIFICATION NUMBER
CHASSIS NUMBER

ENGINE NUMBER

ENGINE NUMBER
At the right side of
the engine block.
(Located at the right
side of the vehicle.)

ENGINE MODEL : J08E

KK-AK206

1-3
CHASSIS SPECIFICATIONS
Chassis model
Item
(mm)

5,800

Front

(mm)

2,035

Rear

(mm)

1,840

(kg)

14,200

Front

(kg)

6,500

Rear

(kg)

9,200

Front

(kg)

6,000

Rear

(kg)

10,900

Total

(kg)

4,765

Front

(kg)

2,820

Rear

(kg)

1,945

Wheel base
Tread
Max.GVM. Rating

Capacity

*
(On std. spec.)

GAM.
Rating
Tire

Chassis mass on standard

specifications
(including, water, oil and full fuel)

Model

Engine

J08E-UD

Max.
Output

ISO NET

Max.
Torque

ISO NET

184kW {251PS} at 2,500r/min

JIS GROSS
739Nm {75.4kgfm} at 1,500r/min

JIS GROSS
(m)

Height of gravity from ground

STD
Tire
Tire and Disk
Disk

AK8JRSA

0.744
11R22.5-16PR

OPT
22.5 X 8.25-offset 165mm (t: 12mm)

STD
OPT

Fuel tank

Battery

Alternator

(L)

(V-kC {Ah} -No.)

STD

200

STD

12-360 {100}-2

OPT
(V-A)

24-50

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

KK-AK206

1-4
DETAIL OF VEHICLE CAPACITY

ITEM
SPRING
TIRE

STD
OPT
STD

addition of 1 leaf spring

addition of 2 leaf spring
11R22.5-16PR

Unit : kg
CAPACITY
FRONT
REAR
6,000
9,200
6,500
9,200
6,000
10,900

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

KK-AK206

2. GENERAL PRECAUTIONS
BASIC POINTS OF BUS BODY 2 - 1
WEIGHT DISTRIBUTION ON FRONT AXLE &
HEIGHT OF CENTER OF GRAVITY 2 - 2
BODY DESIGN 2 - 3
FITTING THE BODY 2 - 7
SHIPMENT 2 - 9

KK-AK206

2. GENERAL PRECAUTIONS

2-1

BASIC POINTS OF BUS BODY

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

KK-AK206

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

FRONT

MODEL

WEIGHT
DISTRIBUTION ON
FRONT AXLE
(FR/VM)

HEIGHT OF GRAVITA TIONAL CENTER

(UNLADEN)
(m)

RECOMMENDED
BODY MAXIMUM
WIDTH
(m)

AK8J
SERIES

MORE THAN 28%

(UNLADEN AND
LADEN)

MAX.
1.23

MAX.
2.5

Notes:
1) When vehicle's specifications are against above mentioned standards after
mounting the body, HINO can not guarantee against any field troubles and take a
countermeasure.
2) If wide body needs for special use, the weight distribution and the height of
gravitational center limits must be kept surely.
3) The calculating method for the height of center of gravity is as follows.
Example : AK8JRKA
HEIGHT OF
GRAVITATIONAL
CENTER
(m)

MASS
(kg)

MOMENT OF
GRAVITATIONAL
CENTER
(kgfm)

CHASSIS
(1)

(2)

(1)x(2)=(A)

(3)

(4)

(3)x(4)=(B)

(5)

(6)

(5)x(6)=(C)

BODY
PASSENGER'S
SEAT

From HINO
Refer chassis
specification
Page 1 - 3
(Including option
equipment)
By body builder

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

The height of
=
gravitational center

Moments
Vehicle mass

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

(E)
(D)

= (F) < 1.23 (UNLADEN)

KK-AK206

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

KK-AK206

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

COOLER UNIT
SPARE TIRE & FUEL TANK
WILL ALSO BE MOVED FOR THE
ADJUSTMENT OF WEIGHT DISTRIBUTION.

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

KK-AK206

2-5
4. INSPECTION COVERS AND LIDS
When making the body structure, remember such things as positioning of
inspection cover so that no obstruction is caused to the following routine
inspections and maintenance.
a) Checking engine oil, filling and drain.
b) Checking engine air-clener, exchange.
c) Checking cooling water level, filling and drain.
d) Checking power steering oil, filling and drain.
e) Checking battery fluid, filling, removing the battery.
f) Fuel filter, drain.
g) Fuel sender gauge removal.
h) Fuel feed.
i) Checking and removal of the brake component part such as air piping and
relay-valve.
j) Air tank drain.
k) Possible to remove the spare tire and to check whether or not it is
securely fitted.
[EXAMPLE]

(See attached data 5-3 for details.)

KK-AK206

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

6. REDUCTION OF INTERIOR NOISE LEVEL

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

The figure shows right hand drive vehicle, STEP & DOOR position of left hand
drive vehicle is symmetrical to this figure.
7. The completed vehicle with body fitted is to comply with the vehicle laws and
regulations of the country in which the said vehicle is used and in addition the
previously mentioned tolerance limits for such things as axle capacity, weight
distribution on front axle and height of the center of gravity are not to be
exceeded.
KK-AK206

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

ADJUSTING STAND

PAVED HORIZONTAL PLANE

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

KK-AK206

2-8-1
4. POINTS TO NOTE ON ELECTRICAL WELDING
Internal clocks in the tachograph and the radio and all the electronic instruments
are directly connected to the battery, and to be chassis frame-earthed at one
end.
Under these conditions, electric welding will cause damage to these electrical
instruments as the welding current flow back along the earth circuit.
(See the following figure.)

WRONG

1) Procedure before welding

Turn the starter switch to "LOCK" position.
Disconnect the negative terminal of the battery.
(or dismount the battery.)
Disconnect the all connectors of electrical equipments.
INSTRUMENT PANEL
FRONT ELECTRICAL COMPONENT PANEL
ENGINE CONTROL ECU
ABS ECU
RETARDER DRIVE UNIT, ETC
Put on a cover to all connecters to be disconnected for avoiding penetration
of dust, mud, water and grime.
2) Ground of the welding equipment
Ground the welding equipment securely, near the place where to be
welded.
(Ground to the plating parts is strictly prohibited.)
Peel off the paint where to be welded.
Connecting the ground to the chassis spring is strictly prohibited to prevent
damage of the spring.

KK-AK206

2-8-2
3) Other precautions of welding
To protect ancillary equipment from sparks during welding, take steps such
as putting fire-resistant covers over things like the engine, meter, steering
wheel, hoses, wire harness, pipes, chassis spring and tires, other chassis
components, etc..
Perform to weld under most suitable conditions of the welding, and
minimize the heat influence to the circumference where to be welded, and
as far as possible to keep the welding quality.
4) After welding
Make sure to connect all connecters which to be disconnected before
performing of the welding work.
Make sure to connect the ground terminal of the battery.
And the terminal should be horizontally setting.
Re-paint the place where to be peeled off the paint for grounding the
welding equipment by same color.
5) After restored
Inspect the operation and function of each electronic instrument and
equipment.
Consult to each Hino dealer or distributor for details of inspection's
procedure.

KK-AK206

2-9
SHIPMENT
1. After completing the vehicle installation, shipment is to be made after checks
have been made that there are no body vibration, noise or other
discrepancies. (Shipment inspection is to be carried out thoroughly.)
2. As such things as the brakes, steering and suspension are important safety
components, if any of them have had to be removed while carrying out the
installation, they are to be refitted perfectly and their operation is to be
checked before shipment is made.
(Be make sure to carry out shipment inspections.)
3. This chassis is setting the vin plate around a driver seat.
Attach a vin plate to the place where a check is easy in the
state of body built in the position specified as the regulation.

KK-AK206

3. CHASSIS MASS &

FRAME SECTION MODULUS
CHASSIS MASS 3 - 1
FRAME SECTION MODULUS 3 - 2

KK-AK206

3-1-1
CHASSIS MASS
1) MODEL : AK8JRSA

[NOTE]
Mass to be mentioned above table shows on standard specification condition.
In the case to be provided option equipment, make sure mass distribution on
front, rear and total followed by mass of option equipment.
KK-AK206

3-1-2
CHASSIS MASS FOR OPTION SPECIFICATION

Above table shows mass of optional equipment.

(When provide optional equipment, calculate vehicle mass to use the mass of above figure
instead of standard mass of each equipment.)

KK-AK206

3-2

MODEL : AK8JRSA

FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE)

KK-AK206

4. EQUIPMENT INSTALLATION
PROCEDURE
ENGINE 4 - 1
RADIATOR 4 - 2
FUEL TANK

4 - 3

AIR CLEANER 4 - 4
AIR INTAKE SYSTEM 4 - 5
BATTERY SETTING 4 - 6
ACCELERATOR CONTROL 4 - 7
CLUTCH CONTROL 4 - 8
STEERING CONTROL 4 - 8
SERVICE BRAKE 4 - 9
TOE-BOARD 4 - 10
METER BOARD 4 - 10
SUSPENSIONS AND RELATED PARTS 4 - 11
ELECTRICAL EQUIPMENT AND RELATED PARTS
FRAME

4 - 12

4 - 13

EXHAUST SYSTEM 4 - 14
RETARDER (OPT) 4 - 15
ENGINE CONTROL ECU 4 - 16
ATTACHMENT OF THE PACKED PARTS

KK-AK206

4 - 17

4. EQUIPMENT INSTALLATION PROCEDURE

4-1-1

ENGINE
Observe the following instructions when mounting a bus body.
1. Before the engine is lowered into the chassis, remove crossmember No. 1 and
place the engine in the front part of the chassis.
Thus the shaded area of the front part of the body in the drawing below should
be made detachable construction.

THE BODY FRONT CONSTRUCTION

IN THE SHADED AREA MUST BE
DETACHABLE CONSTRUCTION.

INSPECTION LID
CHASSIS FRAME

KK-AK206

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

INSTALL ENGINE LID

(MUST BE PROVIDED INSPECTION
AND MAINTENANCE LID.)

580

290

Unit : mm

KK-AK206

4-2-1
RADIATOR
The radiator being installed in front of the engine, mount the bus body by
observing the following instruction.
1. Provide a mesh structure air intake opening on the front panel in order to take
sufficient air into the radiator while driving the vehicle.
Also, make this air intake opening detachable construction so that inspection of
cooling water level and replenishment of water of the reservoir for the radiator
fitted at front end of chassis frame can be done without hindrance.

INSPECTION LID
MIN. EFFECTIVE OPENING
SHOULD BE 0.31m2.

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

ENGINE HOOD
OR FLOOR

THE HATCHING AREA MUST

BE SEALED BY RUBBER OR
SIMILAR MATERIAL.

INTER COOLER

RADIATOR

KK-AK206

CHASSIS FRAME
SIDE MEMBER

4-2-2
3. Provide the radiator partition plate for getting enough volume of cooling air to the
radiator.
And make sure that do not fit any structure and parts of body in front of radiator.

4. Providing the INSPECTION LID

The filler of the cooling water of radiator is located onto radiator in front of the
engine.
Make sure to provide inspection lid on the front construction of the body for
inspection and filling work of the cooling water of radiator as illustrated below.

[NOTE]
See ATTACHED DATA 5-6 for
detail of installation position of
reservoir tank and provision of lid.
KK-AK206

4-3
FUEL TANK
1. ATTACHED DATA 5-7 Show standard location of the fuel tank.
Provide a fuel feed lid and tunnel, inspection lids for fuel gauge sender and
pre-fuel filter at the floor.
2. Observe the following safety precautions, if the fuel tank has to be moved.
1) Follow the instruction given in the Common Manual for chassis frame when
welding or drilling on the frame.
2) Install the inspection lids according to the instruction in
ATTACHED DATA 5-3 .

KK-AK206

4-4
AIR CLEANER
When chassis is supplied, already installed air cleaner system (air cleaner
assembly and air intake chamber).
Therefore, mount the bus body by observing following instructions.
1. The position of the air cleaner assembly and air intake chamber has not be
altered.
2. Make sure to install a splash guard in front of the left front tire to protect the air
cleaner and air intake chamber against water, dust, mud & etc. splashed by the
front tire.
[REFERANCE]

Refer to ATTACHED DATA 5-5 for details regarding the installation of the
splash guard.

KK-AK206

4-5
AIR INTAKE SYSTEM
1. The modification or alteration of the air intake system is strictly prohibited.
As a careless modification or alteration of the air intake system will bring forth the
aspiration of water and dust or increase of suction resistance, which will lead to
shortening of the engine life, generation of a black smoke and the power down of
the engine.
2. The air intake chamber has to be painted with undercoat (SB COAT 323 or its
equivalent) to avoid suction noise by means of vibration of the chamber.
3. The clearance between air intake chamber and body parts should be kept
minimum 80mm to get enough air flow to the air cleaner.

[NOTE]
Do not mount any parts of body within hatching area around air intake chamber
to get enough air flow to the air cleaner.
Paint the air intake chamber with undercoat (SB COAT 323 or its equivalent),
2 to 3mm thickness, to avoid suction noise by means of vibration of the
chamber.
KK-AK206

4-6-1
BATTERY SETTING
1. When a chassis is delivered, the batteries are temporarily mounted on the
chassis as shown in ATTACHED DATA 5-9 .
Mount the batteries to the body under the floor with careful consideration of
weight distribution on left and right.
2. The earth terminal of the battery should be kept away from the battery mount
during electric welding.
3. Cover plate must be installed around batteries, by means of making complete
sealed room for batteries, to avoid entering and remaining any dust and grime,
and be sure to make hole 10-2nos. of water drain to the bottom cover.
And also ventilation opening must be provided upper part of the battery room
such as making 70 or 45-2nos. ventilation hole to avoid remaining the gas
from battery.
4. Install the adequate size of the battery inspection lid on floor or outer panel of
body for having maintenance and exchange the battery.
5. When installing the batteries, remove any dust and grime from the battery mount,
and be sure to fix the earth terminal securely to the mount.
6. When you exchange batteries, set the starter key to the lock position.
[CHANGING BATTERIES WHILE THE ENGINE IS RUNNING IS STRICTLY
PROHIBITED.]
[REFERENCE]

RECOMMENDED MOUNTING POSITION

(AT RIGHT SIDE UNDER THE FLOOR
OF BODY CONSTRUCTION.)

BATTERY

TEMPORARY SETTING POSITION

(AT CHASSIS CONDITION.)

KK-AK206

4-6-2

KK-AK206

4-7
ACCELERATOR CONTROL
1. Regarding the accelerator control system, dont alter the location of it.
At body construction, make sure to take the following cautions.

NOTE
1. Figure A must be maintained
more than 10mm.
2. Figure B must be maintained
the range of 30mm to 70mm.
3. It must not be a bad influence
on the accelerator operation
to separate upholstery (Exp. mats).

KK-AK206

4-8
CLUTCH CONTROL
1. Regarding the location of the fluid reservoir of clutch control, dont alter the
location of it.
At body construction, provide the lid for visible inspection of its fluid level and for
easy filling fluid.
2. Regarding the hose connecting with the fluid reservoir and the clutch main
cylinder, install the hose with a slight slope by setting the reservoir side upwards.
(See ATTACHED DATA 5-11 for details of clutch control such as installation of
clutch control pedal, fluid reservoir and etc.)

STEERING CONTROL
The vehicle has equipped the adjustable steering wheel system.
This system must be firmly installed in a body.
See ATTACHED DATA 5-17 for datailed information.

KK-AK206

4-9-1
SERVICE BRAKE
1. Brake system is one of the most important units for ensuring traffic safety
of a vehicle.
It is strictly prohibited to modify any service brake components as well as their
connected parts.
2. The vehicle is equipped with the dual circuit full air brake system.
3. With respect to the brake piping diagram, refer to the " ATTACHED DATA 5-12 "
when mounting the body.
4. In case of installing a parts around a front brake hose, install parts out of the
range which the hose moves.
For detailed information, refer ATTACHED DATA 5-4.
5. For other precautions, refer to the Common Manual.
6. Output air source of door engine
1) For setting a door engine, make sure to take air from EXHAUST BRAKE
MAGNETIC VALVE as following figure.
2) When take the air source of a door engine, air piping circuit should be set as
mentioned below.
3) This air piping circuit has a protection valve.
And air reservoir for door engine should be fixed between protection valve and
door engine.
4) This protection valve shuts air supply to the air reservoir for a door engine,
when air leakage happened in a door engine circuit and the air pressure in the
brake tank dropped at 490 kpa.
As a result of this function, the brake line is protected safely.

KK-AK206

4-9-2

KK-AK206

4 - 10
TOE- BOARD
At chassis delivery, the toe-board is supported with temporary brackets.
The body builder should fix it regularly onto the front body frames under the body
constructions.
Refer to " ATTACHED DATA 5-15 " for detail regarding the toe-board setting.

METER BOARD
1. Make sure to keep the clearance with chassis parts, such as transmission control
lever, switches of electrical equipment & etc., when body is mounted to avoid any
trouble.
2. The setting position of the instrument cluster, steering column and driver's seat
are described in " ATTACHED DATA 5-16, 17 ".

KK-AK206

4 - 11
SUSPENSIONS AND RELATED PARTS
1. Design each side panel near the front and rear springs to enable to extract each
spring pin and maintenance work such as greasing-up.
2. Design each side panel and fender near shockabsorber to enable to facilitate the
exchanging work.
3. Spring shackle always move front and rearward during operation, Therefore,
make sure to keep the enough clearance with body part.
The details of movement of the spring shackles front and rear are shown in
" ATTACHED DATA 5-20 ".
4. The front and rear spring deflection charts are shown in
" ATTACHED DATA 5-19 " for body design.
5. The frame height from ground at front and rear axle are also shown in
" ATTACHED DATA 5-2, 24 " for body design.
6. When performing welding for body mounting, be sure to do this operation by
covering the leaf springs in order to prevent them from getting bad influences
such as welding sputter, etc.
7. Never attempt to increase the number of leaf spring except the case when it is
prescribed as an option.

Refer to " ATTACHED DATA 5-18 " for detail regarding the front and rear
suspensions.

KK-AK206

4 - 12 -1
ELECTRICAL EQUIPMENT AND RELATED PARTS
1. FRONT ELECTRICAL COMPONENT PANEL
1) At chassis delivery, the front electrical component panel is temporarily installed
onto right side of chassis at front overhang as illustrated below.
Therefore, when the body is mounted, fix it regularly into body construction by
means of making sealed box to avoid entering water and dust and to keep it
accessible for inspection by means of provided inspection lid.

2) The detail of the equipment in the front electrical component panel are shown
in " ATTACHED DATA 5-22 "

KK-AK206

4 - 12 -2
2. FRONT AND REAR WIRING
The front and rear wiring of the chassis are temporarily wired at the chassis
delivery.
Therefore, at the time of body mounting, it's wiring must be redone properly in
accordance with page 2-13 of the COMMON MANUAL.
CAREFULLY TO PREVENT CONTACT WITH ANOTHER PARTS CAUSED BY
VIBRATION.

3. FUSE BOX
The fuse box is installed in the front electrical component panel.

4. ELECTRICAL POWER SOUCE

When electrical power must be taken from the chassis wiring for electrical
equipment installed on the body side such as inside room lamps, cooler
equipment and etc., take it from electrical spare power supply terminal in the
junction block which is installed onto left inside of chassis frame between
wheelbase as shown " ATTACHED DATA 5-22 "
[REFERENCE]

JUNCTION
BLOCK

UP

Fr

Inside of junction block

KK-AK206

4 - 12 -3
5. WIPER AND WASHER
1) At chassis deliverly, the switch of wiper & washer is installed on the steering
column. (See the following figure)
Hino does not provide the wiper motor and associated parts.
Body Builder needs to prepare the wiper motor etc.
Wiper circuit diagram which to be provided at the chassis condition shows
ATTACHED DATA 5-21-3.
Therefore, at the time of body mounting, the wiper and washer system must
be built up to the front body construction by body manufacture.
The harness for wiper and washer system is connected to the connector A of
the following figure and wiper motor etc.

FRONT ELCTRICAL
COMPONENT PANEL
(See 5-22-1)

10P : GRAY
TO WIPER SUB

KK-AK206

4 - 12 -4
6. WIPER MOTOR AND WASHER CIRCUIT
1) RECOMMENDED CIRCUIT
Body and equipment manufacturer must be made circuit diagram as follows.

2) DETAILS OF WIPER RELAY (TO BE SUPPLIED SEPARATELY)

Connection circuit diagram is as follows.

KK-AK206

4 - 12 -5

Details of connector of wiper relay

3) WIPER MOTOR CIRCUIT

Provide wiper motor with following condition.
Max. current : 23A (when 24V)
For reference
Constant load of wiper motor : Less than 0.8 Nm
Max. load when wiper motor is lock. : Less than 4.0 Nm
Operation circuit of wiper motor

GROUND TO BODY

SWITCHING CIRCUIT OF INSIDE OF

WIPER MOTOR WHEN OPERATED
CONNECT TERMINAL S AND
BODY GROUND TERMINAL
WHEN STOP THE MOTOR.
CONNECT TERMINAL S AND
TERMINAL + WHEN OTHER
CONDITION.

CONNECTION OF WIPER SWITCH AND OPERATION

SWITCH OFF : CONNECT S AND +1 TERMINAL
SWITCH LOW : CONNECT BATTERY + AND +1 TERMINAL
SWITCH HI
: CONNECT BATTERY + AND +2 TERMINAL
RELAY WHICH CAN BE ADJUSTED THE TIME, ADJUST THE LOAD OF CURRENT
TO THE CIRCUIT OF LOW SPEED OPERATION BY ADJUSTING TIME.

KK-AK206

4 - 12 -6
7. LAMPS
The lamps, head lamp tail lamp & other lamps, are temporarily installed on the
chassis for self propelled.
Therefore, at the time of body mounting, these lamps must be provided and
installed to the body by own responsibility of the body manufacturers.

8. HORN
The horn is mounted under the driver's floor at the chassis delively.
If this position should prove unsuitable due to body design, it can be relocated.

9. WIRING DIAGRAM
The wiring diagram of chassis is described in " ATTACHED DATA 5-21 " for
reference to the body mounting work.

KK-AK206

4 - 12 -7
10. OPEN CIRCUIT DETECTOR SYSTEM FOR DIRECTIONAL INDICATOR AND
HAZARD LAMP
The detector system, to alert the driver that a directional indicator lamp has
gone out and must be replaced, the frequency of the flashing singnal will
increase, is installed.
If more than the permissible wattage or number of lamps has been added, the
flashing signal will cease to work altogether in order to protect the unit.
However, if more than the required wattage or number of lamps will be going to
add, flasher unit must be changed as following manner.

KK-AK206

4 - 12 -8
11. BACK-UP BUZZER (OPT)
If you move or install the back-up buzzer, or modify the surrounding parts of the
chassis, observe the precautions as followings.
INSTALLATION ANGLE
Must be kept the permissible range of installing angles shown in the figure
below.
If the installing angle is not within range, water will accumulate inside the
buzzer and may lead to failure.

POSITION
Install the back-up buzzer in a position where it is not exposed to splashing with
muddy water, stone or water.
PRECAUTION FOR PAINTING
Make sure that the buzzer should be covered during painting to protect the paint
coming into buzzer from sound emitting hole for avoiding failure of no sound.

KK-AK206

4 - 12 -9
12. CONTROL CHART OF CONSUMED ELECTRIC POWER
CONTROL CHART OF CONSUMED ELECTRIC POWER
Reference

MODEL :

Clarify if it is equipped or not.

Condition of running the vehicle at night when raining.

EQUIPPED
No.

CONDITION

ITEM
YES

1
2
3
4
5

HEAD LAMPS
TAIL LAMPS
FOG LAMPS
CLEARANCE LAMPS
LICENSE LAMP

STOP LAMPS

TURN SIGNAL LAMPS

BACK-UP LAMP

WIPER

10
11
12
13
14
15
16
17

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

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

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

10

1.6

80

30

24

35

100

40

NIGHT
WHEN RIDING AND OFF.

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

TOTAL OF CONSUMED
AxB ELECTRIC POWER

(W)

SELECTED ALTERNATOR :

[
OK

] / 28V =

REQUIRING ADJUSTMENT OF
NUMBER OF LAMPS ETC.

For those equipments which consist of several lamps, enter the total of watt
numbers in the column of " electric power in use ".
For consumption rate of the item to add, select out of the following:
Always in use: 100%
Frequency of use is high: 30%
Frequency of use is low : 10%
Only ones or twice in use: 0%
during one operation.
Decide the number of the lamps, etc. in such a way that the total of amperage
provided for the vehicle might not exceed the maximum amperage prescribed for
the alternator. In the event that the said total amperage exceeds the maximum of
the alternator capacity, select the alternator available as an option or consult your
nearest Hino service dealer or distributor.
KK-AK206

4 - 12 -10
CONTROL CHART OF CONSUMED ELECTRIC POWER
Example of use
for reference

MODEL : AK8JRKA

Clarify if it is equipped or not.

Condition of running the vehicle at night when raining.

EQUIPPED
No.

CONDITION

ITEM
YES

1
2
3
4
5

HEAD LAMPS
TAIL LAMPS
FOG LAMPS
CLEARANCE LAMPS
LICENSE LAMP

STOP LAMPS

TURN SIGNAL LAMPS

BACK-UP LAMP

WIPER

10
11
12
13
14
15
16
17

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

NO
NIGHT
NIGHT
NIGHT
NIGHT
NIGHT

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

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

NIGHT
WHEN RIDING AND OFF.

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

16

10

1.6

80

30

24

35

72

100

72

40
20
--100
---

100
0
100
100
100

40
0
--100
---

100
182

NIGHT

---

100

---

---

100

---

50
56
80

30
100
100

15
56
80

838.6
TOTAL OF CONSUMED
AxB ELECTRIC POWER
SELECTED ALTERNATOR :

(W)
65

[838.6] / 28V = 29.95 A

OK

REQUIRING ADJUSTMENT OF
NUMBER OF LAMPS ETC.

For those equipments which consist of several lamps, enter the total of watt
numbers in the column of " electric power in use ".
For consumption rate of the item to add, select out of the following:
Always in use: 100%
Frequency of use is high: 30%
Frequency of use is low : 10%
Only ones or twice in use: 0%
during one operation.
Decide the number of the lamps, etc. in such a way that the total of amperage
provided for the vehicle might not exceed the maximum amperage prescribed for
the alternator. In the event that the said total amperage exceeds the maximum of
the alternator capacity, select the alternator available as an option or consult your
nearest Hino service dealer or distributor.
KK-AK206

4 - 13 -1
FRAME
Observe the instruction given in the Common Manual for chassis frame drilling
and welding.
When examining the frame strength, use the diagram of Frame Section Modulus.
Tensile strength: 440 N/mm2 {45 kgf/mm2} steel material is used for the frame of
this model.
For the detail of the frame configuration, refer to the " ATTACHED DATA 5-23 "
For the detail of the frame section modulus, refer to the chapter 3-2.
Procedure of rust preventive treatment of chassis frame.
When shipping chassis to customer, make sure to carry out chassis rust
preventive treatment to the following parts for chassis anti-rust.
1. Touch up scratch paint.
Even if carries out chassis paint, it rusts from scratch point.
When there is scratch point, carry out chassis anticorrosive processing
after touch up paint (equivalent of tokyo paint eporakku 100R)
2. Implementation of 2nd anti-rust treatment
Paint part and paint kind.
Paint part
chassis frame
(each cross, side rail)
chassis parts
(table 1 is excluded)
the bottom of a floor at large
leaf spg whole
(paint of between boards)
Fr and Rr tire house
(out side)
the bottom of floor at large
of fr and rr axle

paint kind

Wax

equivalent of
tectil

equivalent of
Tokyo
Under coat kagakutoryo
kabushikikaisya
: SB coat

Thickness of
condition
the paint

50 m
or more

dry

1000 m
or more

wet

KK-AK206

4 - 13 -2
Caution for parts painting.
Mask at a functional component (according to table 1)
(ex. high molecular compound, Caution plate, Control link and the flexible
region of shafts, etc.)
table 1
Part
Brake valve body and exhaust port
Air tank water drain cock and drain rod fingerplate part
The aperture edge of drain hose (without a clog)
Caution plates
Tire
Wheel disc
Brake drum
Radiator and cooling fan
Nylon tube joint part
Checking valve body
Wiring harness coupler part
Muffler main unit and exhaust pipes
Propeller shaft (slide yoke part)
Engine main unit and inside of engine room
Air dryer exhaust port

KK-AK206

Management at the time of paint

Masking

4 - 14
EXHAUST SYSTEM
For detailed construction of the exhaust system, refer to the
" ATTACHED DATA 5-25 ".
For fire prevention when operating the vehicle, observe the instructions given in
the Common Manual.

KK-AK206

4 - 15 -1
REATRDER (OPT)
Retarder drive unit is installed on front end right side of the chassis frame to be
described following figure

KK-AK206

4 - 15 -2
[NOTE]
Make sure to following points when altered the installation position of the retarder
drive unit.
Install retarder drive unit upward of the chassis frame.
Place to be installed retarder drive unit and harness connector where do not
get any water, mud, stone and grime while vehicle is running.
Alteration work must be done by owe responsibility of the body manufacturers.
Installation direction and place of the retarder drive unit must be kept following
condition.
1. Installation direction

2. Installation place where to be got cooling air more than 3m/sec. while
driving.

KK-AK206

4 - 16 -1
ENGINE CONTROL ECU
Engine control ecu is temporarily provided on left side behind driver's floor as
described followng figure.
Install engine control ecu to the body according to following procedure.
TEMPORARILY INSTALL POSITION

KK-AK206

4 - 16 -2
INSTALLATION PROCEDURE
1. Install the engine control ecu to the body over the floor with careful
consideration of water proof preparation.
2. Provide installation box of the engine control ecu to front dash panel of the
body to avoid penetration of water, dust and grime same with front electrical
component panel refer to ATTACHED DATA 5-22-2.
3. Provide adequate suze of inspection cover to the installation box of engine
control ecu.
4. Installation direction of engine control ecu must be kept following condition.
TIGHTENING TORQUE

DIRECTION OF CONNECTOR

UPWARD
NO GOOD
UPWARD FROM
HORIZONTAL LINE
HORIZONTAL
LINE

DOWNWARD FROM
HORIZONTAL LINE

GOOD

KK-AK206

4 - 17
ATTACHMENT OF THE PACKED PARTS
Some chassis parts are attached temporarily or unattached ( as parts are sent
separately ) on the chassis.
Fit it regularly onto the chassis or a body.
Detail of the packed parts are described in
" ATTACHING THE PACKED PARTS " in the below.

ATTACHING THE PACKED PARTS

KK-AK206

5. ATTACHED DATA
WARNING 5 - 1
5 - 2

CHASSIS DRAWING

FLOOR INSPECTION HOLES AND BODY EXTERIOR OPENING 5 - 3

WHEEL HOUSE 5 - 4
SPLASH GUARDS

5 - 5

RADIATOR SETTING 5 - 6
FUEL TANK SETTING 5 - 7
AIR INTAKE SYSTEM 5 - 8
BATTERY SETTING 5 - 9
5 - 10

STEERING CONTROL SYSTEM

CLUTCH CONTROL & RESERVOIR TANK SETTING 5 - 11

BRAKE PIPING DIAGRAM 5 - 12
TRANSMISSION CONTROL 5 - 13
CAUTIONS FOR HANDLING TRANSMISSION CABLE 5 - 14
TOE-BOARD SETTING

5 - 15

OPERATING CONTROLS SETTING 5 - 16

INSTRUMENT CLUSTER & STEERING COLUMN SETTING 5 - 17
FRONT AND REAR SUSPENSION 5 - 18
5 - 19

CHARACTERISTIC OF SPRING
TRAVEL RANGE OF SPRING

5 - 20

ELECTRICAL WIRING DIAGRAM 5 - 21

ELECTRICAL SYSTEM

5 - 22

CHASSIS FRAME ASSY 5 - 23

FRAME HEIGHT FROM GROUND

5 - 24

EXHAUST SYSTEM 5 - 25
RETARDER (OPT) 5 - 26

KK-AK206

5-1

5. ATTACHED DATA
[WARNING]
This list is the summary of body mounting instructions concerning the Important Items to be
related with the Body Mounting Manual for the respective model and Common Manual.
Be sure to read it carefully to well understand the important instructions for bus body mounting
before you proceed with your mounting operation.
[REFERENCE]
LIST OF IMPORTANT INSTRUCTIONS FOR BODY MOUNTING AND RELATED DRAWINGS
10. SETTING OF
INSTRUMENT
CLUSTER
7. CLUTCH CONTROL
SYSTEM

FRONT

3. RADIATOR
RESERVOIR TANK

2. INSTALLATION
ENGINE HOOD

9. SETTING OF
TOE-BOARD
5. AIR CLEANER

1. INSTALLATION OF
FRONT AND REAR
SPLASH GUARDS

COMMON MANUAL

OBJECTIVES OF IMPORTANT INSTRUCTIONS

FOR BUS BODY MOUNTING

1.

PROVIDED TO AVOID TROUBLES OF THE AIR CLEANER, ENGINE,

ETC. CAUSED BY SPLASHING OF RAIN WATER OR MUD.

2.

PROVIDED FOR INSPECTION AND MAINTENANCE OF ENGINE AS

WELL AS FOR INSULATING NOISES AND HEAT.

5-3

FLOOR INSPECTION AND BODY

EXTERIOR OPENNING

3.

PROVISION OF RADIATOR COOLANT LEVEL INSPECTION AND

FILLING PORT ON THE FRONT PANEL.
CLARIFICATION OF SETTING POSITION OF THE FUEL TANK AND
FUEL SYSTEM RELATED PARTS AT THE TIME OF DELIVERY AND
PROVISION OF INSPECTION HOLE AS WELL AS IMPORTANT
PRECAUTIONS TO TAKE WHEN MOVING THE FUEL TANK.

5-6

RADIATOR SETTING

2-2

5-3

FLOOR INSPECTION HOLES AND

BODY EXTERIOR OPENNING
SPLASH GUARDS
FUEL TANK SETTING

1-4
2-4
2-5
2-8
2 - 11

PROVISION OF AIR CLEANER INSPECTION AND MAINTENANCE

HOLE AND PRECAUTIONS TO TAKE WHEN HANDLING.

5-3

4.

5.

6. BATTERY
6.

4. FUEL TANK AND

FUEL SYSTEM
RELATED PARTS

MANUAL FOR THE RESPECTIVE MODEL SERIES

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

No. OF
COMPONENTS

7.
8.

8. SERVICE BRAKE

9.

CLARIFICATION OF THE PROVISIONAL MOUNTING POSITION AND

PRECAUTIONS TO TAKE WHEN INSTALLING THE BATTERY
DEFINITELY.

SETTING OF CLUTCH RESERVOIR TANK AND PROVISION

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

CLARIFICATION OF SETTING CONDITION OF THE PROVISIONALLY

INSTALLED TOE-BOARD AND UP OF TOE-BOARD COMPLETE
BUILDING.

5-5
5-7

5-5
5-8
5-9
5 - 21

FLOOR INSPECTION HOLES AND

BODY EXTERIOR OPENNING
SPLASH GUARDS
AIR INTAKE SYSTEM
BATTERY SETTING
ELECTRICAL WIRING DIAGRAM

PAGE IN
CHAPTER
1-4
2-3
2 - 12
1-4

2 - 12
1-4
2-3
2 - 12
1-4
2-4
2 - 13

5 - 11

5-5

CLUTCH CONTROL AND RESERVOIR

TANK SETTING
FLOOR INSPECTION HOLES AND
BODY EXTERIOR OPENING
SPLASH GUARDS

5 - 12
5 - 15

BRAKE PIPING DIAGRAM

TOE-BOARD SETTING

5-3

4 - 10
2-7
1-2
1-4
1-4

DESCRIPTION
TIRE WHEEL HOUSE & SPLASH GUARDS
FITTING A SPLASH GUARD
BODY MOUNTING
REDUCING INTERIOR NOISE LEVELS
(THE FRONT ENGINE VEHICLE)

ENGINE COOLING SYSTEM

(RADIATOR & RELATED PARTS)
TIRE WHEEL HOUSE & SPLASH GUARDS
CHASSIS FRAME
FUEL TANK
BRAKE SYSTEM (FOR REFERENCE)
CLEARANCE FROM THE EXHAUST
SYSTEM
BODY MOUNTING
TIRE WHEEL HOUSE & SPLASH GUARDS
ENGINE AIR INTAKE SYSTEM
BODY MOUNTING
POINT TO NOTE ON ELECTRICAL
WELDING
CHASSIS FRAME
ELECTRICAL EQUIPMENT AND
RELATED PARTS
FIRE PREVENTION
CLUTCH CONTROL SYSTEM

4-4
4-5
1-2
2-6

NEVER MODIFY SAFETY PARTS

TIRE WHEEL HOUSE & SPLASH GUARDS
REDUCING INTERIOR NOISE LEVELS
(THE FRONT ENGINE VEHICLE)
BRAKE SYSTEM (FOR REFERENCE)
DESCRIPTION OF A BUS BODY
PRINCIPAL PRECAUTIONS WHEN
MOUNTING A BUS BODY
BASIC LAYOUT OF BODY STRUCTURE
LAYOUT OF STRUCTURAL ELEMENTS
NEVER MODIFY SAFETY PARTS
STEERING

1-1
1-2
1-4
1-3
2 - 10

BODY DESIGN AND CONSTRUCTION

NEVER MODIFY SAFETY PARTS
LEAF ADDITIONS
SPRINGS
SUSPENSION

2 - 13
4 - 10

ELECTRICAL EQUIPMENT AND RELATED

PARTS
FIRE PREVENTION

2-8
4-2
4-3

10.

CLARIFICATION OF THE PROVISIONALLY INSTALLED INSTRUMENT

CLUSTER AND COMPLETE BUILDING-UP OF INSTRUMENT CLUSTER,
STEERING WHEEL AND DRIVER SEAT.

5 - 16
5 - 17

11.

PRECAUTION TO TAKE WHEN HANDLING SUSPENSION AS WELL AS

CLARIFICATION OF DATA AND INSTRUCTIONS CONCERNING THE
SUSPENSION REQUIRED FOR DESIGNING THE BUS BODY.

5-2
5-4
5 - 18

OPERATING CONTROLS SETTING

INSTRUMENT CLUSTER & STEERING
COLUMN SETTING
CHASSIS DRAWING
WHEEL HOUSES
FRONT AND REAR SUSPENSION

5 - 19
5 - 20

CHARACTERISTIC OF SPRING
TRAVEL RANGE OF SPRING

CLARIFICATION OF PRECAUTION TO TAKE WHEN HANDLING THE

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

5 - 21
5 - 22

ELECTRICAL WIRING DIAGRAM

ELECTRICAL SYSTEM

CLARIFICATION OF PRECAUTIONS TO TAKE WHEN HANDLING THE

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

5 - 23

CHASSIS FRAME ASSY

2-4

CHASSIS FRAME

5 - 25

EXHAUST SYSTEM

2 - 11

EXHAUST SYSTEM

11. SUSPENSION
12.

13. FRAME
13.

14. EXHAUST SYSTEM

12. ELECTRICAL
EQUIPMENT

KK-AK206

14.

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

5-2
CHASSIS DRAWING
MODEL : AK8JRSA

Unit : mm

[ NOTE ]
The dimension described above are designed figure under the chassis condition.
When selected or fitted optional equipment or local parts such as tire, leaf spring, fuel
tank and etc., should be examined the frame height from ground by body builder.
KK-AK206

5-3-1
[ NOTE ]
All the dimension, size of holes and openings, which are mentioned in
this drawing show the minimum requirement.
Therefore, make sure to keep the all dimensions when body is mounted.

FLOOR INSPECTION HOLES AND BODY

EXTERIOR OPENING

Unit : mm

ENGINE INSPECTION LID

420

814

(DETAILS, SEE NEXT PAGE 5-3-2)

1595

580

290

(OPT)

INSTALL LID ACCORDING TO

LAUOUT OF THE FUEL TANK.

KK-AK206

5-3-2
FLOOR INSPECTION HOLES AND BODY
EXTERIOR OPENING
[DETAILS OF INSTALLATION PROCEDURE OF THE ENGINE INSPECTION LID]

KK-AK206

Unit : mm

5-4
WHEEL HOUSE
The wheel houses, front and rear, must be kept the spaces to prevent the tire from
interference to the wheel house.
In the case of front wheel house, the range to which a brake hose moves should
also take into consideration. (See the following figure.)
And mud-guards must be installed backward of the each tire.
Unit : mm

[NOTE]
Additional space should be considered with the market conditions
where the bus is operated.
(Ex. Local make tire, recap tire, with chains and etc.)
Details, refer to the following figure.

THIS DRAWING SHOWS MIN. DIMENSIONS OF THE TIRE HOUSE.

THEREFORE, KEEP MORE BIGGER DIMENSIONS WHEN INSTALL TIRE HOUSE.
KK-AK206

5-5
SPLASH GUARDS

Unit : mm

For protecting air cleaner, engine and fuel tank from

splashing water or mud, must be installed splash prevention
covers.
1) Splash guard should be made by steel plate & thickness is around 1.6mm.
2) Splash rubber should also be provided underneath of the splash guard.
3) Clearance between splash guard and tire should be prepared a suitable crevice.
4) Keep greasing space for maintenance of suspension.
5) When install splash guards, see 5 - 20 "TRAVEL RANGE OF SPRING".
KK-AK206

5-6-1
RADIATOR SETTING

Unit : mm

[NOTE]
1) Must be provided following facility on the body.
Cooling air intake opening, on the front panel.
Air guide in front of radiator to air intake opening.
Sealing around radiator.
Water filling and inspection lid on the front panel.
(See 4 2 "RADIATOR" for more detail and installation procedure of the facilities.)
2) Do not alter and modify the radiator setting, position of the cooling water reservoir.
KK-AK206

5-6-2
RADIATOR SETTING
(INSTALLATION PROCEDURE OF INSPECTION LID)

Unit : mm

[NOTE]
Inspection lid must be provided at front construction
(front outer panel) for filling the cooling water and
checking the water level.

KK-AK206

5-7
FUEL TANK SETTING ( 200L, STD )
MODEL : AK8JRSA

Unit : mm

[NOTE]
Provide a lid for fuel filling on the left side and
inspection cover for fuel line, sender gauge on the
floor according to procedure described in 5-3 "FLOOR
INSPECTION HOLES AND BODY EXTERIOR OPENING".
KK-AK206

5-8
AIR INTAKE SYSTEM

Unit : mm

[NOTE]
Do not alter and modify the air cleaner assembly.
See 4-4 "AIR CLEANER" for installation procedure of the facilities.
When fitting dust indicator into secondary hose, insert pipe into hose
for the length of 40mm then securely clamp the hose.
Before fitting secondary hose, apply Three Bond TB-1104 or its
equivalent on the aircleaner joint then securely clamp the hose.
Air intake system is so designed as to prevent dust entry into engine,
therefore, strictly observe to avoid dust attachment on the component
parts or entry into the air intake system.
INSTALLATION PROCEDURE AROUND AIR INTAKE CHAMBER
1)DO NOT MOUNT ANY PARTS OF BODY WITHIN HATCHING AREA
AROUND AIR INTAKE CHAMBER TO KEEP ENOUGH AIR FLOW
TO THE AIR CLEANER.
2)PAINT THE AIR INTAKE CHAMBER WITH UNDERCOAT
(SB COAT 323 OR ITS EQUIVALENT),2 TO 3mm THICKNESS,
TO AVOID SUCTION NOISE BY MEANS OF VIBRATION OF THE
CHAMBER

KK-AK206

5-9
BATTERY SETTING
(TEMPORARY SETTING POSITION)

Unit : mm

[NOTE]
1. Batteries are mounted on the chassis mentioned in this drawing as supplied.
When the body is mounted on the chassis, battery room should be
constructed with inspection lid for changing and having maintenance.
2. Type of battery 95E41R.
3. Tighten bolts and nuts to correct torque as shown below.

Nm

KK-AK206

M8
224

M10
51.510

5 - 10 -1
STEERING CONTROL SYSTEM
STEERING LINKAGE PARTICULAR

KK-AK206

Unit : mm

5 - 10 -2
STEERING CONTROL SYSTEM
POWER STEERING OIL RESERVOIR TANK SETTING

KK-AK206

Unit : mm

5 - 11
CLUTCH CONTROL & RESERVOIR TANK SETTING

Unit : mm

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

KK-AK206

5 - 12
BRAKE PIPING DIAGRAM
STANDARD CIRCUIT

ABS CIRCUIT (OPTION)

KK-AK206

5 - 13
TRANSMISSION CONTROL

Unit : mm

Do not modify transmission control system.

Never attempt to move the installation position of following.
transmission control lever
position of clips to the chassis frame
position of cables to clips
position of cables to transmission

KK-AK206

5 - 14
CAUTIONS FOR HANDLING TRANSMISSION CABLE
When using CABLE TYPE TRANSMISSION CONTROL, strictly observe the following instructions so that you may make the most of its merit through
correct use of the system.

Unit : mm

1. WHEN TRANSPORTING (WHAT TO CHECK BEFORE MOUNTING)

1-1 When handling the cable, the bending R (Radius) must be more than R 450 mm.
1-2 Before mounting the cable, check if there is not any flaw on the outside of the
cable.
(Pay a special attention to the guide pipe (boot).)
2. WHEN ASSEMBLING
2-1 Never attempt to work holding the guide pipe (boot).
2-2 Define the mounting direction of the ball joint in accordance with the assembly
drawing .
2-3 Securely tighten the end metal parts (for casing cap or inner cable).
2-4 Mount the boot so that it may not be twisted.
2-5 Mount the parts so that they may not be difference from the designated positions
(markings).
2-6 When routing the cables, be careful not to damage the cables (boots).
(Before routing the cables, protect them with a think cloth, etc. See Fig. 1.)
2-7 Route the cables so that they may not be hit by the frame or the tools.
2-8 Observe the bending R for mounting. (See Fig. 2.)
2-9 Do not clip the cable in bent condition.(See Fig. 3.)
3.WHEN MOUNTING BODIES
3-1 Pay attention not to damage the boot with a spatter, etc.
When there is a risk of splash of the spatter, perform the welding by protecting the
parts with some high fire proof material (such as wet thick cloth, aluminum foil,
leather, etc.)
3-2 Cables are not interfered with body members.
Do not modify the track of the cables.

If the instructions mentioned above are not observed, the following

phenomena will appear :
-Need for heavier operating force is required.
-Immobilization of cable
-Breakdown of inner cable

KK-AK206

If something abnormal (hole or flaw in the boot) is found in the cable, replace
it with a new part at once.
(Hole or flaw in the boot, breakage or flaw on the outer casing {If the shielding wire
becomes visible, the cable is no more usable.}, etc.)
Premature breakage by sticking of rust will appear as a result of generation of rust in the
inner cable due to the penetration of water from the hole or the flaw of the boot.
(Also, sticking due to freezing will occur in cold region.)

5 - 15
TOE-BOARD SETTING
(DRIVER'S FLOOR)

KK-AK206

Unit : mm

5 - 16
OPERATING CONTROLS SETTING
Unit : mm

No.
29
4
11
14
15
17/22

KK-AK206

CONTENT
Cooler pilot lamp
Exhaust brake pilot lamp
Water level warning lamp
Charge warning lamp
Seat belt warning lamp
Turn signal indicator lamp

No.
24
19
20
21
23
25

CONTENT
Over heat warning lamp
High beam pilot lamp
ABS warning lamp
Oil pressure warning lamp
Parking brake pilot lamp
Air pressure warning lamp

5 - 17 -1
INSTRUMENT CLUSTER & STEERING COLUMN SETTING
Unit : mm

KK-AK206

5 - 17 -2
INSTRUMENT CLUSTER & STEERING COLUMN SETTING
1. The vehicle has equipped the adjustable steering control system.
Install this steering control system firmly with a body.
2. The steering colnmu is united with the clutch-pedal bracket,
and is installed in meter board installation bracket.
At the time of body mounting, remove brackets other than the above
mentioned two brackets, use referrence to following figure and
attach a body and meter board installation bracket firmly.
3. Refer the Common Manual for notes on work other than the above.

The steering column casing should

be sufficiently rigid.
Up and down
Deflection X1 = max. 1.0 mm
against load P1 = 130 kg
Forward and backwards
Deflection X2 = max. 0.5 mm
against load P2 = 70 kg

KK-AK206

5 - 18 -1
FRONT SUSPENSION WITH STABILIZER (STD)

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

KK-AK206

Unit : mm

5 - 18 -2
REAR SUSPENSION WITH STABILIZER (STD)

Unit : mm

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

KK-AK206

5 - 18 -3
FRONT SUSPENSION WITH STABILIZER (OPT)

Unit : mm

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

KK-AK206

5 - 22 -1
ELECTRICAL SYSTEM
FRONT ELECTRICAL COMPONENT PANEL, JUNCTION BLOCK, ABS PANEL & BATTERY RELAY SETTING
FRONT ELECTRICAL
COMPONENT PANEL
BATTERY
RELAY

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

JUNCTION
BLOCK

POWER RELAY (NO.1)

U2 ECU
MAIN RELAY
ELECTRIC
HORN RELAY

STOP LAMP RELAY

ABS SUB BRAKE
CUT RELAY (OPT)

POWER RELAY (NO.2)

HEAD LAMP RELAY (DIMMER)
HEAD LAMP RELAY (MAIN)

TAIL LAMP RELAY

FLASHER UNIT

OVER RUN RELAY

STARTER SAFETY
RELAY

FUSE BLOCK

WATER LEVEL
WARNING
CONTROLLER

10P : GRAY
TO WIPER SUB

KK-AK206

5 - 22 -2
ELECTRICAL SYSTEM
INSTALLATION PROCEDURE OF FRONT ELECTRICAL COMPONENT PANEL

At chassis the electrical component panel is temporally set on the side of the
right side frame. Therefore, when the body is mounted, install the electrical
component panel inside from the panel surface in the room to keep it accessible
for inspection and maintenance.

KK-AK206

5 - 22 -3
ELECTRICAL SYSTEM
INSTALLATION PROCEDURE OF FRONT AND REAR ELECTRICAL WIRE HARNESS

KK-AK206

Unit : mm

5 - 23 -1
CHASSIS FRAME ASSY (1/2)
MODEL : AK8JRSA

KK-AK206

Unit : mm

5 - 23 -2
CHASSIS FRAME ASSY (2/2)

KK-AK206

Unit : mm

5 - 24 -1
FRAME HEIGHT FROM GROUND
[AT FRONT AXLE]
TIRE : 11R22.5-16PR

KK-AK206

5 - 24 -2
FRAME HEIGHT FROM GROUND
[AT REAR AXLE]
TIRE : 11R22.5-16PR

KK-AK206

5 - 25 -1
EXHAUST SYSTEM
MODEL : AK8JRSA

KK-AK206

Unit : mm

5 - 25 -2
EXHAUST SYSTEM
MODEL : AK8JRSA

KK-AK206

Unit : mm

5 - 25 -3
EXHAUST SYSTEM
INSTALLATION PROCEDURE OF HEAT INSULATOR OF THE EXHAUST TAIL
PIPE (UNDER THE FLOOR AROUND REAR AXLE)

KK-AK206

5 - 26
RETARDER (OPT)

Unit : mm

[NOTE]
Make sure to following points when
altered the installation position of the
retarder drive unit.
Install retarder drive unit upward of
the chassis frame.
Place to be installed retarder drive
unit and harness connector where do
not get any water, mud, stone and
grime while vehicle is running.
Alteration work must be done by owe
responsibility of the body
manufacturers.

KK-AK206