US Chap05

Chapter 5
CHASSIS MODIFICATION
GENERAL CAUTIONS •••••••••••••••••••••••••••••••••••••••••••••••••••••• 1

MATERIAL FOR CHASSIS FRAME MODIFICATIONS •••••••••••••• 1
CHASSIS FRAME DRILLING•••••••••••••••••••••••••••••••••••••••••••••• 3
FLANGE CUTTING •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4
CHASSIS FRAME WELDING•••••••••••••••••••••••••••••••••••••••••••••• 4
REAR OVERHANG EXTENSION ••••••••••••••••••••••••••••••••••••••••• 6
STIFFENING OF SIDE RAILS ••••••••••••••••••••••••••••••••••••••••••••• 8
WHEELBASE MODIFICATIONS •••••••••••••••••••••••••••••••••••••••••• 10
PROPELLER SHAFT MODIFICATION AND ALTERATION ••••••••• 14
SERVICE BRAKE MODIFICATIONS ••••••••••••••••••••••••••••••••••••• 22
ELECTRIC WIRING MODIFICATIONS •••••••••••••••••••••••••••••••••• 46
ALTERATION OF EXHAUST SYSTEM •••••••••••••••••••••••••••••••••• 48
CAUTIONS NEEDED IN ADDITIONAL MACHINING ••••••••••••••••• 51
AND ALTERATION OF THE CAB
KK-US003D
Chapter 5 CHASSIS MODIFICATIONS
GENERAL CAUTIONS
Before modifying the chassis frame, consideration should first be given to selecting a standard
vehicle from Hino’s standard vehicle series.
Chassis frame modifications (including changes to the wheelbase and rear overhang) should
be kept to the absolute minimum since there is a danger that they will reduce the frame strength
and service life of the vehicle and impair the vehicle’s safety and running performance.
If such modifications are unavoidable, cautions and standards should be strictly adhered to
and the modifications should be kept to the absolute minimum.
The original Gross Axle Weight Rating (GAWR) and Gross Vehicle Weight Rating (GVWR)
must not be exceeded when a chassis frame has been modified.
When cutting the side rails, the vehicle should be placed on a flat floor and the modification
should be performed while supporting the side rails on both sides of the modification.
When modifying chassis frame and tightening modified parts, metric sized bolts and nuts com-
plying with SAE J1199 class 10.9 should be used.
When tightening a parts to be used bolt and nut method to the chassis frame, you must tighten
the nut, not to bolt, in order to get proper regulation axial tension. So there is a no chance that
a bolt and nut will come loose.
After the chassis frame has been modified, checks should be made as to whether the modifi-
cations have been performed as required by the procedures and cautions referred to herein.
MATERIAL FOR CHASSIS FRAME MODIFICATIONS
When a chassis frame is to be modified, the material used for the modification must be the
same as that of the original frame.
Employment of non-specified material will impair the vehicle’s service life and safety and lead
to trouble.
The material of the original frame is specified in following table.
KK-US003D 1
FRAME SPECIFICATION
Wheelbase mm
3,734 (147) 4,293 (169) 4,648 (183) 5,105 (201)
designation (in.)
NA6J, NB6J
Model
NC6J –
Frame rail material High tensile. SAE J1392 (Grade 980X)
Minimum yield strengthl 56.2 kg/mm2 (80000 PSI)
Section modulus 1.352 x 105 mm3
(one side) (8.25 in.3)
Resisting bending moment 75.47 x 105 mm·kg
(one side) (655100 in·lbs)
Width of frame assembly 863.6 mm (34 in.)
Wheelbase mm
4,445 (175) 4,750 (187) 5,207 (205) 5,512 (217) 5,969 (235) 6,426 (253) 6,883 (271)
designation (in.)
ND8J, NE8J – (NE8J ONLY)
Model NJ8J – – –
NV8J – – –
(one side) (13.02 in.3)
Width of frame assembly 863.4 mm (34 in.)
Wheelbase mm
6,426 (253) 6,883 (271)
designation (in.)
Model NV8J
(one side) (16.11 in.3)
Width of frame assembly 866.8 mm (34.1 in.)
KK-US003D 2
CHASSIS FRAME DRILLING
Drilling of the frame greatly affects strength and if such operations are executed improperly,
the frame might be seriously damaged. When drilling the frame, follow the instructions given
below carefully.
Drilling holes through the upper and lower flanges, must be strictly avoided.
Drilling holes through the side rail changing the exterior shape, or changing the section modu-
lus such as the inner stiffener is fitted, must be strictly avoided.
Drilling holes through the cross members of the frame

must be strictly avoided.
Drilling holes near the spring brackets and the maximum

bending moment sections of the frame must be strictly
avoided.
When drilling holes, brake hoses or nylon tubes, brake

pipes, and electrical wiring should be protected against
damage.
Be sure to use a drill in making holes. Never use a gas

torch or the like.
To avoid increasing the temperature of a drill, use an appropriate drill having a tip angle to suit
the material drilled.
The diameter of the hole in a side rail must be less than 17 mm (0.67 in.). Hole diameters must
not exceed bolt diameters by more than 1 mm (0.039 in.).
When drilling holes through the web, they

should be more than 43.2 mm (1.7 in.) away
from the upper or lower edge of the web.
Distance between holes should be more
than 35 mm (1.38 in.).
Original holes in the chassis frame must not be drilled again.
Holes should be deburred after drilling.
KK-US003D 3
FLANGE CUTTING
Never cut off the frame flange and crossmember for the reasons of a body mounting.
CHASSIS FRAME WELDING
General Warning
Welding the frame greatly affects its strength, and if such operations are executed improperly,
the frame can be seriously damaged.
When welding the frame, carefully follow the instructions given bellow.
• An experienced professional should always perform the welding to assure the following welding
conditions since a poor welding job on the frame can cause damage.
• Before and during welding, make sure that there are no flammable materials such as oil,
rags, etc. around.
• When arc welding, ventilate and/or wear an antitoxic mask against noxious gas.
• To prevent burns, electric shock, and gas poisoning during arc welding, wear a hard hat,
apron, antitoxic mask, safety goggles, arm coverings, leg coverings, safety boots, and gloves.
• Other basic cautions on welding to perform it before and after, refer to chapter 4. Truck Body
and Special Equpment Installation Precautions.
KK-US003D 4
Welding Conditions
Consult the table below for welding conditions.
WELDING CONDITIONS
Electric current (Unit: A)
Rod dia. ø 3.2 mm {0.126 in.} 4 mm {0.157 in.} 5 mm {0.197 in.}
Vertical Vertical Vertical
Welding position Flat Flat Flat
overhead overhead overhead
Weld Metal (Hot roll plate)

Tensile strength, 621 MPa
{63 kgf/mm2, 89.605 lbf/in.2}
Welding Rod
Tensile strength: 539 MPa 100 - 150 90 - 140 140 - 200 130 - 180 190 - 270 —
{55 kgf/mm2, 78.228 lbf/in.2}
Illuminate type
(JIS D8016 AWS E8018)
Mechanical
Coated electrode
property of
weld metal Weld Metal (Hot roll plate)
& rod Tensile strength, 538 MPa
{55 kgf/mm2, 78.228 lbf/in.2}
Welding Rod
Tensile strength: 490 MPa 90 - 140 80 - 130 141 - 190 110 - 160 180 - 250 —
{50 kgf/mm2, 71.116 lbf/in.2}
Illuminate type
(JIS D4301 AWS E6019)
Coated electrode
NOTE : • Diameter of welding rod ø3.2 mm {0.126 in.} or ø4 mm {0.157 in} - plate thinner than 5 mm {0.197 in.}
• Diameter of welding rod ø4 mm {0.157 in.} or ø5 mm {0.197 in.} - plate thicker than 6 mm {0.236 in.}
Welding Bead Shape

Make sure that the shape of the welding beads corre-
sponds to the shape illustrated below.
1. Under-cut
2. Concave welding
3. This area should be smooth and free from under-cuts.
KK-US003D 5
Welding Positions
Frame web welding must be conducted at least 30 mm (1.2 in.) away from the edges of the
frame or any hole.
Never weld near the edge of a flange.
In welding, be sure that there is no undercut or the overlap of the bead and a pin hole.
REAR OVERHANG EXTENSION
Rear overhang extension should be minimized since extension can reduce the service life of
the vehicle and impair its safety.
The material and dimensions of the extension rail must be the same as those of the original
side rail.
The extension rail should be aligned with the original side rail.
KK-US003D 6
• Rear overhang extension

(less than 200 mm (7.9 in.))
• Rear overhang extension

(more than 200 mm (7.9 in.))
KK-US003D 7
STIFFENING OF SIDE RAILS

(WHEN STIFFENING OF SIDE RAILS EXCEPT ALTERATIONS OF THE WHEELBASE OR THE REAR OVERHANG)
Normally, it is not necessary to attach the additional outer stiffeners and making of such alter-
ations to the side members is not recommendable. The use of such stiffeners are, however,
inevitable due to some special fittings or operating conditions, pay full attentions to the follow-
ing points.
When side members are to be stiffened, be sure to use the high tensile strength steel which is
equal to or better than that of the main member.
As -shaped steel stiffener could not be strictly fitted to the main member due to difficulty of
machining accuracy, L-shaped stiffener is recommendable.
When installing an L-shaped stiffener, its flange side must be placed onto the tensioned side of
the side member's stress.
If the ends of outer stiffener are positioned onto the end of inner stiffener or the cross beam or
the spring brackets where the rigidity undergoes sudden changes or load is concentrated, it
may cause the concentration of stress resulting damages or cracks of frame.
Do not cut off a stiffener at a sharp angle.

It should be cut so that its end has an angle at least 45° or less.
KK-US003D 8
When outer stiffeners are installed, the parts which are not stiffened may become relatively
weak in rigidity.
If the rigidity become partly weak in particular area, it may cause the breakage or crack of the
side member. By this reason, great care is needed in deciding the area where the stiffener is
applied.
As side members of a truck are most vulnerable generally in the area between the cab and the
rear body, it is recommendable that the stiffener is extended as far as near the front axle if
heavy concentrated load is expected to be applied just behind the cab.
How to fix stiffener to side member

As a rule a stiffener should be fixed to the side member by means of riveting or bolting, when
it is inevitable to weld them together, do not weld the stiffener to the flange but to the web. As
a rule the plug welding method should be used in this case.
In plug welding, be sure that the plug welding hole is at least 25.4 mm (1 in.) removed away
from the edge of the stiffener and 71 mm (23.8 in.) or more away from a bolt and rivet hole.
The plug welding hole should be 14 mm (0.55 in.) to 20 mm (0.8 in.) in diameter as a rule.
Unit: mm (in.)
KK-US003D 9
WHEELBASE MODIFICATIONS
General cautions
Hino ’05 MY series vehicles are equipped with Anti-lock Brake System (hereinafter termed as
ABS), you should strictly obey the instructions given in paragraph “Electric Wiring Modifica-
tion”, in case of modifying the harness of ABS as a result of changing the wheelbase.
Never undertake any modification or transposition of any equipments connected with ABS,
other than the harness.
Wheelbase modifications are accompanied by corresponding modifications of side rails (in-

cluding the detachment and addition of cross-members), propeller shafts, service brake lines,
electrical lines, and so reference should be made to the respective sections paragraph in
Chapter 5 of this book concerned.
Wheel base modifcation by removing the rear axle and the rear suspension (without cutting
side rails) should not be acceptable in rear air suspension models.
Wheelbase Modification Without Cutting Side Rails

(When moving the rear axle and the rear suspension)
The crossmembers and their positions subsequent to the wheelbase change must correspond
to those of a standard Hino vehicle of the same wheelbase as the modified wheelbase.
For details, refer to "Drawing of Side Rail Exterior Configurations" and "Drawing of
Crossmember".
Remove the rear axle and the rear suspension.
Remove the crossmembers and spring brackets forward and rearward of the rear axle.
Drill the holes for mounting the crossmembers and spring brackets at the new wheelbase
position. When drilling holes, refer to "Drawing of Drilling Holes on the Side Rails".
The holes at the new wheelbase position should be drilled in the relative positions recom-
mended by Hino.
Drawing of the Rear Suspension and Surrounding Parts as following figure (This figure shows
an example of the ND, NE, NJ and NV series except rear air suspension model).
Move the parts while keeping to the position relationship across this range.
KK-US003D 10
• When using bolts and nuts, tighten nuts to the specified tightening torque.
Unit : kg·cm (ft·lb)

Bolt dia. Tightening torque
M12 910 - 1,490 (66 - 108)
M16 2,490 - 3,070 (180 - 222)
Wheelbase Modification by Cutting of Side Rails

(When cutting the side rails within the wheelbase with the rear axle and the rear suspension in
their original position)
The crossmembers and their positions subsequent to the wheelbase change must correspond
to those of a standard Hino vehicle with the same wheelbase as the new wheelbase.
For details, refer to "Drawings of Side Rail Exterior Configurations" and "Drawing of
Crossmember".
When lengthening the wheelbase, cut the side rails at a 45-degree angle away from the
crossmember in front of the rear axle. Insert the extension rail between the cut ends and weld
it after aligning all surfaces with the original side rail. (This figure shows an example of the ND,
NE, NJ and NV series except rear air suspension model)
KK-US003D 11
When shortening the wheelbase, cut the side rail at two places at 45-degree angle between
the No.3 crossmember and the crossmember in front of the rear axle. After cutting the side
rails, weld together the cut ends after aligning all surfaces.
After the side rails have been welded in accordance with steps described in forward, the welded
areas must be sufficiently reinforced by welding and cold riveting or bolting stiffeners.
The reinforcing material should be bent to an angle of 90 degrees and the thickness of material
is as following figure.
The bending radius should be 12 mm (0.47 in.) on the inside.
If this reinforcement is neglected, it will reduce the service life of the vehicle and impair its
safety.
Unit: mm (in.)
Configuration of Reinforcing Material
• Wheelbase extension: • Wheelbase extension:

more than 1000 mm (39.4 in.) less than 1000 mm (39.4 in.)
Unit : mm (in.)
H L
NA, NB, NC 85 (3.3) 52 (2.0)
ND, NE, NJ, NV 105 (4.1) 52 (2.0)
Detail of Groove
KK-US003D 12
Welding Procedures
• Wheelbase extension (more than 1000 mm (39.4 in.))
• Wheelbase extension (less than 1000 mm (39.4 in.))
KK-US003D 13
PROPELLER SHAFT MODIFICATION AND ALTERATION
Any alteration of propeller shaft not recommendable.

If such alteration is inevitable, follow the instruction strictly.
Driveline Design Criteria

Typical installation showing yokes "In phase". "In phase" means that the yokes at either end of
a given propeller shaft assembly are in the same plane.
Cautions for Modification and Alteration of Propeller Shafts

The length, the tube outside diameter, the tube thickness, and the material of propeller shafts
for each model are shown in "Detail of Propeller Shafts". When modifying or altering propeller
shafts, refer to the table in the above mentioned.
As the maximum length of propeller shafts is shown in "Maximum Length of Propeller Shafts",
adhere strictly to the maximum length. If a propeller shaft exceeds the upper limit (maximum
length), add more propeller shafts and also more center bearing supports. When installing a
center bearing, observe the allowable tolerance described in the "Allowable Tolerance Be-
tween the Center Line of a Center Bearing and of Center Bearing Holder" and also refer to the
"Installing of Center Bearing Bracket".
Before mounting the propeller shaft, be sure to balance it as following limit per one end and
this must be performed on both ends of the propeller shaft.
LIMIT OF UNBALANCE Unit : g·cm (in·oz)

SHAFT SPL140 SPL140
SPL70 SPL100
SERIES (FRONT) (REAR)
TEST RPM 3,000 2,500 3,000 2,500
MAX. LIMIT 36 (0.5) 144 (1.10) 205 (2.85) 200 (2.78)
Align the yoke phase at both ends of the shaft.
KK-US003D 14
U-joint setting angles shown as θ in the equation below should be less than 3° as shown in
below. In case of the center bearing is fitted to the vehicle, may set the center bearing to any
position which is free from the vibration of propeller shaft.
KK-US003D 15
Detail of Propeller Shafts

(The length of No.2 and No.3 propeller shafts is that when unloaded.)
Explanation of propeller shaft length

(This drawing shows when used 3-piece propeller shafts.)
Unit: mm (in.)
Propeller Tube Propeller shaft
shaft Tube
Model series outside thickness Material T/M
diameter No. 1 No. 2 No. 3 No. 4
(DANA)
NB6JFSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,071 (42.2) — 1,311 (51.6) —
NA6JFSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,071 (42.2) — 1,311 (51.6) —
NB6JJSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,071 (42.2) 561 (22.1) 1,307 (51.5) —
NA6JJSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,071 (42.2) 561 (22.1) 1,307 (51.5) —
NB6JKSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,071 (42.2) 919 (36.2) 1,304 (51.3) —
EATON
NA6JKSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,071 (42.2) 919 (36.2) 1,304 (51.3) —
FS-4205A
NB6JMSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,321 (52.0) 1,126 (44.3) 1,303 (51.3) —
NA6JMSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,321 (52.0) 1,126 (44.3) 1,303 (51.3) —
NC6JJSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,071 (42.2) 561 (22.1) 1,239 (48.8) —
NC6JKSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,071 (42.2) 919 (36.2) 1,236 (48.7) —
NC6JMSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,321 (52.0) 1,126 (44.3) 1,235 (48.6) —
NA6JFSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,016 (40.0) — 1,310 (51.6) —
NB6JFSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,016 (40.0) — 1,310 (51.6) —
NA6JJSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,016 (40.0) 561 (22.1) 1,306 (51.4) —
NB6JJSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,016 (40.0) 561 (22.1) 1,306 (51.4) —
NA6JKSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,016 (40.0) 919 (36.2) 1,303 (51.3) —
NB6JKSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,016 (40.0) 919 (36.2) 1,303 (51.3) — 450-43LE
NB6JMSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,266 (49.8) 1,126 (44.3) 1,302 (51.3) —
NA6JMSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,266 (49.8) 1,126 (44.3) 1,302 (51.3) —
NC6JJSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,016 (40.0) 561 (22.1) 1,239 (48.8) —
NC6JKSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,016 (40.0) 919 (36.2) 1,235 (48.6) —
NC6JMSA SPL70 88.9 (3.50) 2.41 (0.095) SAE1017 1,266 (49.8) 1,126 (44.3) 1,234 (48.6) —
ND8JLSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,449 (57.1) — 1,523 (60.0) —
NE8JLSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,449 (57.1) — 1,523 (60.0) —
ND8JMSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,146 (45.1) 764 (30.1) 1,519 (59.8) —
NE8JMSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,146 (45.1) 764 (30.1) 1,519 (59.8) —
ND8JPSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,146 (45.1) 1,069 (42.1) 1,518 (59.8) —
NE8JPSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,146 (45.1) 1,069 (42.1) 1,518 (59.8) —
NJ8JPSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,236 (48.7) 1,069 (42.1) 1,518 (59.8) —
EATON
ND8JRSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,146 (45.1) 1,527 (60.1) 1,517 (59.7) —
FS-5406A
NE8JRSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,146 (45.1) 1,527 (60.1) 1,517 (59.7) —
NJ8JRSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,236 (48.7) 1,527 (60.1) 1,516 (59.7) —
ND8JTSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,449 (57.1) 1,679 (66.1) 1,518 (59.8) —
NE8JTSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,449 (57.1) 1,679 (66.1) 1,518 (59.8) —
NE8JVSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,146 (45.1) 1,069 (42.1) 1,374 (54.1) 1,514 (59.6)
NJ8JTSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,539 (60.6) 1,679 (66.1) 1,517 (59.7) —
NJ8JVSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,236 (48.7) 1,069 (42.1) 1,374 (54.1) 1,513 (59.6)
KK-US003D 16
Unit: mm (in.)
shaft Tube
Model outside thickness Material T/M
series
(DANA) diameter No. 1 No. 2 No. 3 No. 4
ND8JLSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,499 (59.0) — 1,523 (60.0) —
NE8JLSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,499 (59.0) — 1,523 (60.0) —
ND8JMSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,194 (47.0) 764 (30.1) 1,519 (59.8) —
NE8JMSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,194 (47.0) 764 (30.1) 1,519 (59.8) —
ND8JPSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,194 (47.0) 1,069 (42.1) 1,519 (59.8) —
NE8JPSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,194 (47.0) 1,069 (42.1) 1,519 (59.8) —
NJ8JPSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,196 (47.1) 1,069 (42.1) 1,519 (59.8) — ALLISON
ND8JRSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,194 (47.0) 1,527 (60.1) 1,517 (59.7) — 2200RDS
NE8JRSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,194 (47.0) 1,527 (60.1) 1,517 (59.7) —
NJ8JRSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,196 (47.1) 1,527 (60.1) 1,517 (59.7) —
ND8JTSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,499 (59.0) 1,679 (66.1) 1,517 (59.7) —
NE8JTSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,499 (59.0) 1,679 (66.1) 1,517 (59.7) —
NE8JVSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,196 (47.1) 1,069 (42.1) 1,374 (54.1) 1,512 (59.5)
NJ8JTSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,499 (59.0) 1,679 (66.1) 1,519 (59.8) —
NJ8JVSA SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,196 (47.1) 1,069 (42.1) 1,374 (54.1) 1,515 (59.6)
NV8JLSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,561 (61.5) — 1,462 (57.6) —
NV8JMSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 766 (30.2) 1,455 (57.3) —
NV8JPSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 1,071 (42.2) 1,455 (57.3) — EATON
NV8JRSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 1,528 (60.2) 1,454 (57.2) — FS-6406A
NV8JTSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,561 (61.5) 1,680 (66.1) 1,453 (57.2) —
NV8JVSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 1,071 (42.2) 1,372 (54.0) 1,452 (57.2)
NV8JLSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,429 (56.3) — 1,462 (57.6) —
NV8JMSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 766 (30.2) 1,456 (57.3) —
NV8JPSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 1,071 (42.2) 1,455 (57.3) — ALLISON
NV8JRSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 1,528 (60.2) 1,454 (57.2) — 3000RDS
NV8JTSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,429 (56.3) 1,680 (66.1) 1,455 (57.3) —
NV8JVSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 1,071 (42.2) 1,372 (54.0) 1,453 (57.2)
· Rear Air Suspension Unit: mm (in.)

Propeller Propeller shaft
shaft Tube Tube
Model series
outside thickness Material T/M
diameter No. 1 No. 2 No. 3 No. 4
(DANA)
NJ8JPSG SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,236 (48.7) 1,069 (42.1) 1,520 (59.8) —
NJ8JRSG SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,236 (48.7) 1,527 (60.1) 1,519 (59.8) — EATON
NJ8JTSG SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,539 (60.6) 1,679 (66.1) 1,520 (59.8) — FS-4205A
NJ8JVSG SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,236 (48.7) 1,069 (42.1) 1,374 (54.1) 1,516 (59.7)
NJ8JPSG SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,196 (47.1) 1,069 (42.1) 1,522 (59.9) —
NJ8JRSG SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,196 (47.1) 1,527 (60.1) 1,520 (59.8) — ALLISON
NJ8JTSG SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,499 (59.0) 1,679 (66.1) 1,522 (59.9) — 2200RDS
NJ8JVSG SPL100 101.6 (4.00) 2.41 (0.095) SAE1017 1,196 (47.1) 1,069 (42.1) 1,374 (54.1) 1,517 (59.7)
NV8JPSG SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 1,071 (42.2) 1,456 (57.3) —
NV8JRSG SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 1,528 (60.2) 1,456 (57.3) — EATON
NV8JTSG SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,561 (61.5) 1,680 (66.1) 1,456 (57.3) — FS-6406A
NV8JVSG SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 1,071 (42.2) 1,372 (54.0) 1,454 (57.2)
NV8JPSG SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 1,071 (42.2) 1,457 (57.4) —
NV8JRSG SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 1,528 (60.2) 1,456 (57.3) — ALLISON
NV8JTSG SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,429 (56.3) 1,680 (66.1) 1,456 (57.3) — 3000RDS
NV8JVSG SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 1,071 (42.2) 1,372 (54.0) 1,455 (57.3)
KK-US003D 17
· With Option 23,000 lbs Rear Axle Unit: mm (in.)

shaft Tube
Model series outside thickness Material T/M
(DANA) diameter No. 1 No. 2 No. 3 No. 4
NV8JLSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,561 (61.5) — 1,405 (55.3) —
NV8JMSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 766 (30.2) 1,398 (55.0) —
NV8JPSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 1,071 (42.2) 1,398 (55.0) — EATON
NV8JRSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 1,528 (60.2) 1,397 (55.0) — FS-6406A
NV8JTSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,561 (61.5) 1,680 (66.1) 1,397 (55.0) —
NV8JVSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,257 (49.5) 1,071 (42.2) 1,372 (54.0) 1,395 (54.9)
NV8JLSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,429 (56.3) — 1,405 (55.3) —
NV8JMSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 766 (30.2) 1,398 (55.0) —
NV8JPSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 1,071 (42.2) 1,398 (55.0) — ALLISON
NV8JRSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 1,528 (60.2) 1,397 (55.0) — 3000RDS
NV8JTSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,429 (56.3) 1,680 (66.1) 1,397 (55.0) —
NV8JVSA SPL140 107.2 (4.22) 3.5 (0.138) SAE1026 1,125 (44.3) 1,071 (42.2) 1,372 (54.0) 1,395 (54.9)
Maximum Length of Propeller Shafts

Unit: mm (in.)
Maximum length
Connection by single shaft Connection by two or more
Model Engine
between transmission and shafts between transmission
rear axle and rear alxe (per shat)
FRONT REAR
NA6J
NB6J J05D 1,300 (51.18) 1,330 (52.36) 1,320 (51.97)
NC6J
ND8J
NE8J J08C 1,000 (39.37) 1,680 (66.14) 1,530 (60.24)
NJ8J
NV8J
KK-US003D 18
Allowable Tolerance Between the Center Line of a Center Bearing and a Center
Bearing Holder
When installing a center bearing and a center bearing holder, be sure to observe the following
allowable tolerance.
Front and rear direction
Up and down, and left and right direction
Allowable tolerance Allowable tolerance

Model (A) of front and rear (B) of up and down,
direction and left and right
direction
NA6J
NB6J
NC6J Max.
ND8J ±3 mm (±0.118 in.) Max.
NE8J ±0.5 degrees
NJ8J
Max.
NV8J
±1 mm (±0.039 in.)
KK-US003D 19
Installing of Center Bearing Bracket

When modifying propeller shaft according to wheelbase modifications described in forward
paragraph, additionally necessary brackets to attach center bearing holder are shown in the
following table.
Brackets are unnecessary except relevant models because center bearing holder can directly
attach on web surface of the crossmember.
Position No.4 No.5 No.6

Model Crossmember Crossmember Crossmember
F 51504-8370 — —
NA6J
NB6J J 51504-8370 51504-8390 —
NC6J K, M 51504-8370 51504-8400 —
L 51504-8380 — —
ND8J
NE8J M, P 51504-8380 51504-8410 —
NJ8J R, T 51504-8380 — 51504-8420
NV8J
V 51504-8380 51504-8410 51504-8690
Cautions when mounting bracket
When mounting brackets, use cold head rivets or bolts in compliance with SAE J1199 class
10.9 and nuts corresponding to them.
KK-US003D 20
Drawing of center bearing bracket

Unit: mm (in.)
KK-US003D 21
SERVICE BRAKE MODIFICATIONS
General Points of Brake System

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.
CHASSIS MODEL BRAKE SYSTEM
NA, NB, NC, ND, NE HYDRAULIC BRAKE
NJ, NV FULL AIR BRAKE
If body equipment design means that you need to take power from the brake system such as
air to control transmission PTO provided by body or equipment manufacturer, be sure to make
a thoroughly study of the basic brake system before performing these modifications.
Do not Modify the Brake System

The brake system is the most important safety component of the vehicle and you must never
modify it when mounting a body or equipment.
If you must modify the piping of the brake system in order to make other modifications to the
chassis during body or equipment mounting (moving the fuel tank, etc.), please contact HMS
(USA) or dealer and follow the advice that the distributor provides.
Taking the Power from the Brake System (For Full Air Brake only)
• As a general rule, the taking air to power a body or equipment from the brake system is
prohibited.
• If you must take air pressure to power a body or equipment from the brake system piping,
take account of the frequency of use of the equipment, the performance of the air supply and
safety considerations, and consult HMS (USA) or dealer beforehand.
• When you install air piping, make sure it will not affect brake system during operation or in
the event of a breakdown and follow the rules given below;
The air tank must not be modified.
When taking off an air line, or installing check valves, do not position them
• on the main brake line (front and rear brake line),
• and on the charge line (between the compressor and air tank).
Install the protection valve to the taking off circuit of an air to protect the main brake line. (parts
number of protection valve is 44570-1320 for reference.)
And adjust the control air pressure to min. 5 kg/cm2 (71.1 lb/in.2) in order to keep the air pres-
sure on main brake circuit when breakdown (occurred air leakage, e. g.) the taking off line of
an air.
KK-US003D 22
Position to be taken off an air given below;

(Taking an air line from another position is strictly prohibited.)
• Full Air Brake Vehicles only

Take the line from the plug of the wet tank.
Refilling Brake Fluid (For HYDRAULIC Brake only)

• When changing brake fluid, use only genuine Hino brake fluid. (For details of brake fluid, see
the appropriate workshop manual or owner’s manual.)
• Never reuse old brake fluid.

Never use mineral oil or mix Hino products with other brands.
KK-US003D 23
Avoiding Effect of Exhaust Heat

Locate the brake hoses, pipes and nylon tubes min. 200 mm (7.9 in.) away from the exhaust
system.
When the specified clearance can not be made available, protect against heat by such means
as a heat insulating plate.
Locate the parking brake outer cable min. 200 mm (7.9 in.) away from the exhaust system.
When the specified clearance can not be provided, protect them against heat by such means
as a heat insulating plate.
KK-US003D 24
Brake Piping Used in The Chassis

Steel Piping Used in the Chassis
The table below shows the material of the piping used in the chassis and the configuration of
the flare of each type of pipe.
Unit: mm (in.)
Nominal Flare configuration
diameter Remarks
D A B t C S
4.76 7.1 3.2 0.7 2.5 —
(0.19) (0.28) (0.13) (0.03) (0.10) ISO standard pipe
6.35 8.77 — 0.83 — 1.02
(0.25) (0.35) (0.03) (0.04) SAE standard pipe
12 15.3~16.3 9.5~10.5 0.9 1.8 1.6
(0.47) (0.60~0.64) (0.37~0.41) (0.04) (0.07) (0.06)
JASO standard pipe
15 18.0~19.0 12.5~13.5 1.0 2.0 1.6
(0.59) (0.71~0.75) (0.49~0.53) (0.04) (0.08) (0.06)
ISO STANDARD PIPE SAE STANDARD PIPE

Flare shape is as folows, ISO 4038. Flare shape is as follows, SAE J53.
JASO STANDARD PIPE

Flare shape is as follows.
KK-US003D 25
[DETAILS OF MATERIAL]
Unit : mm (in.)
2) Plating Code
Pipe dia. Type 1) Pipe
Inside Outside
4.76~10 (0.19~0.39) Double-wound plated HSTD2 MFCuB MFZnA-C++Plastic
10 (0.39) steel pipe HSTD3 MFCuA MFZnA-C++Plastic
6.35~15 (0.25~0.59) Plated carbon steel pipe HSTKM3 MFCuB MFZnA-C++Plastic
10~15 (0.39~0.59) for mechanical structures HSTKM1 MFCuA MFZnA-C++Plastic
Notes :
1.Chemical composition and mechanical properties
2.Plating code
KK-US003D 26
Precautions when Mounting a Body or Equipment

Avoiding Interference with Piping
Take care that the piping is not caught by other parts.
Be sure that the piping is not flattened.
See to it that the piping is not in contact with the

sharp-angle portion of other parts.
Pay attention to the displacement of the brake

hose connected to the front and rear wheels while
the vehicle is running.
KK-US003D 27
Secure a sufficient clearance between the brake

piping and installed parts.
The joints of pipes and hoses must be accessible to allow tightening and so that pipes and
hoses can be removed.
If you have fitted stiffeners to bridge the gap between the flanges of side members, be sure to
cut inspection holes in the stiffener.
The pitch between holes must be 100 mm (3.9 in.) or less, and the diameter of the holes must
be at least 60 mm (2.4 in.).
Make sure that the holes are in front of the clips used to secure the piping to the member.
You must be able to insert or remove the clips using a box wrench.
Make sure that brake component parts are easily accessible.
• Drains are fitted under the air tank and relay valve. When mounting a body or equipment,
make sure that the drains are easily accessible.
• Make sure that the following parts are easily accessible for maintenance and replacement:
Air dryer Pressure regulator Double check valve
Relay valve Safety valve Spring brake control valve
Hydro master ABS valve Brake booster
• In vehicles with hydraulic brake, make sure that the air bleeders of caliper are easily acces-
sible for air bleeding.
KK-US003D 28
Allow sufficient clearance between the brake pipes, hoses, nylon tubes and mounted body or
equipment.
When mounting the body or equipment, make sure that body and equipment do not interfere
with the brake system.
• Clearance with engine
• Clearance with brake component parts
(pipes, hoses, nylon tubes,devices of ABS, etc.)
• Clearance with hoses around axles
(must be consider the maximum movement of axles)
• Clearances with rubber parts
(For more details of required clearances, see “PIPING CLEARANCE” here in after.)
Antidewing and anticorrosion of piping

Corrosion of the brake piping for the special rear bodies of the liquid oxygen truck, the vacuum
tank truck or fresh fish truck is promoted by the dew or water at low-temperature portions (such
as the liquid oxygen inlet/outlet).
Keep the brake piping away from or cover it with a protective plate at portions where dew forms
or water drops easily.
KK-US003D 29
Precautions for Modification (Alteration)

As far as possible avoid modifying any piping.
If you modify piping, be sure to observe the following precautions.
PIPING
• 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.
[NOTE]
Tightening torque of flare nut
Unit: kgf·cm (lb·ft)
Pipe external diameter ø4.76 ø6.35 ø12 ø15
mm (in.) (ø0.19) (ø0.25) (ø0.97) (ø0.59)
Pipe material
150±25 250±50 680±70 900±80
Steel
(11±2) (18±4) (49±5) (65±6)
Most pipes are made of steel but have anti-corrosive plating on the inside and the outside.
Never braze these pipes and never heat them to high temperatures.
Do not weld or braze brake

piping and do not heat to
high temperatures.
Do not use copper pipes for high-pressure hydraulic brake piping and for piping in areas below
unsprung parts as on axles.
KK-US003D 30
Where pipes pass through the chassis frame material, fit a grommet in the hole and secure the
pipe with clips close to the hole so that the pipe dose not touch the hole or the grommet.
Use of Grommet.
To remove the transmission, it is necessary to pull the transmission assembly backwards in

the line of the crankshaft.
Do not install piping in areas around the transmission
(areas between transmission and No.3 crossmember).
Where piping may be affected by the failure of other equipment, install the pipes inside the side
members or crossmembers, and do not allow them to protrude below the bottom flange sur-
face of the chassis frame.
To prevent fires caused by oil leaks, do not install joints in hydraulic piping near to or over any
part of the exhaust system.
Do not install piping between the spring brackets of the front and rear suspensions (outside the
lower flange surface of the frame) or within the range of movement of the spring.
The piping located on the axle below the springs is carefully designed to prevent damage from
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 or PTO drive
shaft.
Avoid making shape bends in hydraulic brake piping as this makes air bleeding difficult.
Do not install piping in places where earth, sand, or water accumulate.

Avoid covering pipes with rubber or vinyl tubes as this tends to trap water.
Install pipes high enough so that

they are not covered by any earth
or sand that may accumulate on the
lower flange.
KK-US003D 31
To prevent from water, stone splashed by tire, locate the piping inside of frame or behind
crossmember.
(must be away the piping min. 5mm from frame and crossmember.)
Don’t locate the piping behind the end of the exhaust tail pipe.
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 (in.)
Nominal dia. 4.76 6.35 12 15

of pipe (0.19) (0.25) (0.47) (0.59)
Standard 20 20 30 40
bending R (0.79) (0.79) (1.18) (1.57)
• The minimum lengths of the straight section at the end of a pipe and of the straight section
between two bends are shown in the drawing below.
• Flush the inside of the pipe and remove any foreign matter before use. Use compressed air
to flush the pipe.
• For details of pipe machining at the flare nut, see described in forward paragraph "Brake
Piping Used in the Chassis".
After machining, remove any foreign matter by flushing the pipe with compressed air.
Make sure that there are not to much slack and giving tension to the piping.
KK-US003D 32
Using sealing agents on tapers

• If possible, use a strong anaerobic sealing agent(Genuine Hino product or locktight #575).
• Clean tapers with cotton waste and thinners before coating with sealing agent. If you intend
to reuse joints which have been sealed with anaerobic 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 flat from the tip of the male thread, and apply the
agent across three flats over one quarter of the circumference of the thread. Apply approxi-
mately 0.1 g of agent to each joint.
• When using vulcanized tape, make sure that the sealing agent does not penetrate any valve,
etc. (If the sealing agent penetrate a valve, it may block the valve.) As a standard, leave two
flats from the tip of the thread and apply 1.5 ~ 2 turns of vulcanized 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, distortion,
etc.).
KK-US003D 33
Piping Clearances
To prevent rust and damage from contact with other parts. When modifying piping, observe the
following precautions.
Clearances Between Two Pipes
KK-US003D 34
Clearances Between Pipes and Other Parts
KK-US003D 35
KK-US003D 36
Clipping of Piping
Pipes must be secured with clips to prevent them from swinging due to the motion of the
vehicle.
Use vinyl-coated or rubber-coated clips and follow the rules given in the table below.
KK-US003D 37
Precautions to Take when Handling Nylon Tubes for Brakes

Nylon tubes are used in the air piping system of brakes, be careful so that they might not be
heated particularly at the time of welding.
Also, make sure to perform the welding by putting protecting covers on the nylon tubes so that
welding sputter, etc. might not be splashed on the tubes.
For other general precautions, refer to the instructions shown on the following table.
When dismounting and remounting the piping for the reason of facilitating the maintenance,
inspection of the brake and air line as well as of body or equipment mounting, make sure to put
matching marks (using paint, tape, tag, etc.) on the equipment side as well as on the piping
side to prevent by all means from making wrong fitting when remounting them.
Wrong mounting of equipment and piping will cause a serious functional damage to the system
using brake line and air line.
KK-US003D 38
Precautions to take for handling nylon tubes when mounting the body
Point to pay attention Influence on

for handling Contents the performance
1 Protection of nylon tube Fit a protecting cover on the nylon If welding sparks, etc are
when welding or grinding tube or remove it according to the projected on the nylon tube,
with a sander. necessity. the tube may melt and cause
air leakage sometimes.
2 Protection of nylon tube Securely fix a body or equipment with If nylon tube keeps on
when a body or equipment a clamp to the nylon tube protected interfering with a body or
interfere with nylon tube. with corrugated tube existing around it. equipment, the tube may break
and cause air leaking sometimes.
3 Prevention of introduction When dismounting and remounting Biting of foreign matters by
of foreign matters into the the nylon tubes and the connectors, valves and connectors may
nylon tubes and cover them with vinyl sac, etc (sac sometimes cause air leakage
connectors. producing fiber dust is not suitable) to or malfunctioning of valves.
prevent sticking and / or introduction
of foreign matters.
4 Protection against Matching parts Gap Holes may sometimes appear
interference of nylon on the tubes and pipes due to
tubes. Chassis parts 5mm rubbing and wear and may
(fixing position) (0.2 in.) result in air leakage.
Engine,transmission, 30mm
cab, etc (relative (1.2 in.)
moving position)
Tires, propeller shaft, 50mm
etc (rotating position) (2.0 in.)
Components for Equivalent
upper structures to the above
5 Securing gaps with Secure gaps of more than 200mm High temperature due to the
exhaust system. (7.9 in.) between the nylon tubes and heat of the exhaust system
the exhaust system (exhaust pipe, may cause sometimes melting
muffler, etc) or protect the tubes by of the tubes and may result
covering them with insulators, etc. in air leakage.
Also, be sure to fit insulators on the
flange section of the exhaust system.
6 Prevention of swinging Provide appropriate clip bands to the If the clip gap is too big, tubes
of the nylon tubes. nylon tubes to avoid swinging of the may swing to rub against
tubes after mounting. : other parts and may cause
• Gaps of the clip bands should have contact wear, this leading
pitches less than 400mm (15.7 in.). sometime to occurrence of air
leakage.
• Clip band to use : 47837-1230
7 Securing of bending "R" The minimum bending "R" for the If a tube is bent with the
for nylon tubes. nylon tubes should be as indicated on bending "R" less than the
the following table. Avoid bending the minimum bending "R" ,,the air
tubes with the bending "R" smaller may be clogged by broken
than the one indicated in the table. tube and air leakage may
occur by the end position of
the connector.
R
Outside diameter R
of nylon tube mm (in.)
1/4" 30 (1.2)
3/8" 65 (2.6)
1/2" 70 (2.8)
5/8" 90 (3.5)
KK-US003D 39
Point to pay attention Influence on

for handling Contents the performance
8 Prevention of adherence As nylon tubes are weak against acid, Sticking of acidic liquid such
of acidic liquid. be careful so that they might not be as battery liquid melts the
caught by battery liquid. Don't use tube and risks to cause air
waste cloth or cotton work gloves leakage.
contaminated with battery liquid.
9 Prevention of water Secure the distance minimum of If the distance between the
penetration at the time of 300mm (11.8 in.)( and above between connector and the injection
high pressure washing. the connector and the injection port port is not sufficient, water
when performing high pressure may penetrate into the piping,
washing. thus causing rusting, freezing,
and malfunctioning of valves.
10 Protection of nylon tubes As the temperature service limit of If this service limit is
when performing forced the nylon tube is from-40 to 100˚C exceeded, air tightness of the
drying of paint. (104 to 212°F), remove the nylon tube tube will be reduced and may
when using a drying booth whose cause air leakage sometimes.
service temperature exceeds this
limit.
11 Spare parts. Never fail to use genuine Hino spare
parts. Otherwise, the nylon tube may
be damaged.
• Connectors for intermediate
connection of nylon tubes
Outside diameter
of tube Parts No.
1/4" 34801-4750
3/8" 34801-4760
1/2" 34801-4770
• Sleeve connectors
1/4" 1/2"
Nut 9209-11107 9209-17101
Sleeve 49384-1040 49384-1030
Insert 44854-1130 44854-1110
• Nylon tubes
Outside diameter Parts No.
of tube L = 6m (20 ft.)
1/4" 9753-07600
3/8" 9753-09600
1/2" 9753-13600
• Corrugates tubes
of tube L = 1.2m (4 ft.)
1/4" 9756-07120
3/8" 9756-10120
1/2" 9756-13120
• For one-touch type connectors,

kindly contact authorized Hino
distributor nearest to you.
KK-US003D 40
Dismounting and remounting procedures (in the case of one-touch type connectors)
Procedure for dismounting

• Before performed dismounting, drain the air from all air tank.
• Confirm that there is no dust nor dirt around the ends of the connector. If any dust or dirt is
found sticking there, eliminate it completely by air blowing. etc.
• Keeping the end portion of the connector pressed, pull out the nylon tube by hand without
break in the middle along the axial direction of the connector.
1
Press the ring at connector end.
Pull out the tube 2
Procedure for remounting

• Confirm that there is no flaw, crush, dirt, burr nor dust, etc around the inserting position of the
nylon tube. If a flaw or a crush is found out, follow the instruction for repair described here in
after.
• Match the axis of the nylon tube with that of connector and insert the tube all the way without
break until it stops. At this moment, be careful not to touch the inserting portion with fiber
cloth such as cotton work globes, etc.
• After mounting, pull the nylon tube by hand to check if the nylon tube has been securely
connected.
• After pulling, check if the end of the joint terminal is located between the 2 markings of the
nylon inserting margin and that the gap between the end of the connector and of the end of
the nylon tube inserting margin is less than 5mm (0.2 in.) (If the nylon tube has been re-
paired).
End of the joint should be Taping of inserting

located between 2 markings. margin
End of the joint

5 mm (0.2 in.)
• With the condition that the air is filled in the piping, check if there is any leakage of air by
applying soapy water to the connecting position.
If any air leakage is found out, follow the instruction for modification described here in after.
KK-US003D 41
Dismounting and remounting procedures for nylon tubes (in the case of sleeve type
connectors)
The sleeve type connector consists of a connector, nut, sleeve and an insert and the nut,
sleeve and the insert are supplied as assembled by the manufacturer.
The nut, sleeve and insert are not reusable once they are disassembled.
If repair is required, carry out the work according to the following procedure.
Procedure for dismounting

• Before loosening the nut, put the matching mark between the connector and the nut so that
the position can be visible. (marking by a magic ink is acceptable.)
Matching mark
• Loosen the nut and pull out the tube by hand in the axial direction while paying attention so
that the sleeve and the insert may not fall off.
Procedure for remounting

• Put the nut and the sleeve onto the tube and put the insert into the tip of the tube. (Pay
attention to the remounting direction.)
Nut Sleeve Fastening type connector
Nylon tube Insert
• Drive the insert until the tip of the insert hits the connector while paying attention so that the
nut, sleeve and the insert may not fall off and, under this condition, fully tighten the nut by
hand.
• Hold the tube so that it may not move (comes off), tighten the nut up to the position before
dismounting (matching mark) and retighten it by 60º. Further tighten the nut using the tool
until the prescribed torque is obtained.
• Check the air leakage with a soapy water, etc. If any air leakage has been found out, re-
tighten the nut until the air leakage stops.
• If the leakage does not stop, replace the tube, sleeve and the insert. If in spite of such
replacement, the leakage does not stop, replace the nut and the connector in addition.
1/4" 1/2"
Nut 9209-11107 9209-17101
Sleeve 49384-1040 49384-1030
Insert 44854-1130 44854-1110
KK-US003D 42
Procedure for repairing the nylon tube

When repair becomes necessary due to appearance of harmful defects such as breakage,
crush, perforation, etc., carry out the repair according to the following instruction. (applicable
only to the position which is not apparent such as the inside of the frame, etc.)
• Prepare a nylon tube having the same size as that of the nylon tube to repair and a connector
for intermediate connection (exclusively for repair).

of tube
1/4" 34801-4750
3/8" 34801-4760
1/2" 34801-4770
• Confirm the position of the defect on the nylon tube and decide the cutting position to such
place where the connector is mountable. Use a cutter for cutting.
• Check if the cutting face of the nylon tube is smooth without any burr and that the cutting face
is 90º±5º to the axis of the nylon tube.
Less than 5°
• Wind the inserting margin taping according to the following table. (In the same way as in the
case of one-touch type connector )
Inserting margin taping D S

(Outside diameter (Inserting margin)
of tube) mm (in.)
D
1/4" 18±1 (0.71±0.04)

3/8" 22±1 (0.87±0.04)
S 1/2" 25±1 (0.98±0.04)
• Remount the connector according to the dismounting and remounting procedures of the
nylon tube.
• Securely fix the repair connector with a clamp to the nylon tube protected with corrugated
tube existing around it (If this does not exist around it, add the corrugated tube ).
• In the event that such repair work is difficult to carry out for the reason of layout or for the
reason of influencing on the external appearance such as on the air tank or that the tube is
relatively short and its replacement can be done easily, replace the nylon tube with a new
one.
KK-US003D 43
In the event that an air leakage has occurred after remounting of the nylon tube, take the
following measure (applicable only when the nylon tube has enough surplus length).
• Remove the part of the nylon tube that suffers from the air leakage together with the connec-
tor according to the dismounting procedure.
After dismounting, keep the outside and the inside of the connector free from any adhesion
of dust or dirt.
• Cut the nylon tube over the range of 15 to 20 mm (0.6 to 0.8 in.) from its end. Also, if any flaw
is found out within this range, cut the tube at the position where the flaw is no more recog-
nized. In the event that it is impossible to define the cutting position, replace the nylon tube
with a new one.
• Eliminate those matters sticking to the inside of the dismounted connector by air-blowing. If
any damage or heavy sticking of foreign matters is found out, replace the connector with a
new one.
• Wind an insert margin tape around the nylon tube (in the case of one-touch connector),
Mount the tube according to the remounting procedure. In the case of a nylon tube of single
part or the case of the tube whose overall length is less than 500 mm (20 in.), piping be-
comes difficult. In such a case, replace it with a new part.
Tightening torques
Tightening torque for tapered joint
Unit: kgf·cm (lb·ft)
Thread dia. (in.)
1/8 1/4 3/8 1/2
Material
Steel 200±50 500±100 650±150
(15±4) (36±7) (47±11)
Aluminum copper 200±50 250±50 350±50 450±50

(15±4) (18±4) (25±4) (32±4)
Tightening torque for sleeve type connector
ø1/4 ø3/8 ø1/2

kgf·cm (lb·ft) 235±30 410±50 560±50
(17±2) (30±4) (41±4)
Tightening torque for flare nut of female flare joint and male flare joint
Dia. mm (in.) ø4.76 ø6.35 ø10 ø12 ø15

(ø0.19) (ø0.25) (ø0.39) (ø0.47) (ø0.59)
Torque for steel pipe 150±25 250±50 530±70 680±70 900±80
kgf·cm (lb·ft) (11±4) (18±4) (38±5) (49±5) (65±6)
Tightening torque for bolt and nut
M6 M8 M10 M12 M16 M20 M22

4T kgf·cm (lb·ft) 55±11 175±30 490±100 980±195 1230±370 1350±300
(4±1) (13±2) (35±7) (70±14) (90±27) (98±22)
7T kgf·cm (lb·ft) 90±18 225±40 525±100 930±185

(7±1) (16±3) (38±7) (67±13)
The conventional units in the parenthesis ( ) in the table as well as the figures connected
therewith are shown as reference.
Attention: Hino reserves the right to modify the parts connected with nylon tubes for brakes
without notice.
When placing your order for spare parts, kindly consult with your authorized Hino
distributor nearest to you.
KK-US003D 44
Precautions for handling one-touch type connector
Precaution to take
when handling Contents Description
1 Assurance of quality • Do not use the joint without • The cap is fitted in order to
for parts in stock. cap or with cap detached but avoid deformation, flaw,
burn it down. introduction of dust and dirt.
In such case, securely crash If the one-touch type connector is
the one-touch type connector used without cap, this may
with a hammer. sometimes cause air leakage or
detaching of the tube.
2 Assurance of quality • Do not attempt a rough handling • If the one-touch type connector
during the transport. which will cause detaching or receives a strong external force
deformation of the cap. through the cap by falling it down
or due to a rough handling, air
leakage or detaching of tube may
occur sometimes.
3 Assurance of quality • Be sure to mount the one-touch • Presence of deformation or flaw

when assembling a type connector with cap fitted. may cause sometimes air leakage
new one-touch type or detaching of the tube.
connector on the • Carry out removal of the cap at
vehicle. the time of insertion of the nylon
tube.
KK-US003D 45
ELECTRIC WIRING MODIFICATIONS
Precautions for modifying chassis harness

• When fitting the harness wires, refer to the cautions described in the Body Builder Book.
• Before starting the operation, turn "OFF" the main key switch for modifying chassis harness,
and remove the connectors of the computer main unit as well as the terminal connectors of
the batteries.
• When extending the harness, use a genuine Hino harness for the extension in order to avoid
occurrence of various troubles.
IN CASE OF LENGTHENED WHEELBASE
Front chassis harness Rear chassis harness
Use a genuine Hino optional extension

cable described in following table.
EXTENSION CABLE PART NUMBERS
Relevant model Parts No. Length: mm (in.)

NA, NB, NC, ND, NE 82071-1480 590 (23.2)
82071-1490 490 (19.3)
NJ, NV 82071-1510 1,830 (72.1)
82071-1520 3,050 (120.1)
• When shortening the harness, do not cut it but bundle the surplus portion of the harness and
securely fix it to the frame by means of a clip, etc.
• Never attempt to apply the following modifications to the harness:
Extension or of shortening by cutting off the harness.
Connection by soldering or caulking.
Other precautions for modifying chassis harness.

• Before proceeding with the electrical work, be sure to disconnect the battery negative termi-
nal.
• When the wheelbase is lengthened or shortened, the harness wire removal must be mini-
mized in the required range by the work.
The care must be taken not to damage the harness wires during the work.
• When the wheelbase is shortened, the excessive harness wires on the original vehicle must
be bundled as shown in the figure below, and then they must be clipped securely by using
original clip holes on the side rails.
KK-US003D 46
When the bundled harness wires are not fitted to the original clips, the original clips must be
changed to other clips corresponded with the thickness of the bundled harness wires.
Under no circumstances wires must be cut and connected at any place.
When the harness wires are bundled at one place.
When the harness wires are bundled at two places.
• The lengthened portion of the wires must be clipped at a 300 mm (11.8 in.) to 400 mm (16 in.)
pitch in the same way as for the original vehicle.
KK-US003D 47
ALTERATION OF EXHAUST SYSTEM
ALTERATION OF EXHAUST SYSTEM MAY REQUIRE NOISE TESTING TO DETERMINE

COMPLIANCE TO FEDERAL AND/OR LOCAL NOISE STANDARDS.
Since the exhaust pipe is a thermal part, when other parts of vehicle are mounted above it,
follow the instructions given below, for the prevention of fire hazard.
Any alteration to the exhaust pipe is undesirable, for it will affect the engine performance,
exhaust fume density, fire hazard prevention. When it is inevitable to make some alteration to
the exhaust pipe, follow the instructions given below.
Prohibition Range of Alteration (Modification)
Modifying the Tail Pipe

Modifying the tail pipe has a major effect on external noise, internal noise and strength of
exhaust parts. As a rule, the tail pipe must not be modified. If you must modify the tail pipe,
observe the following procedure:
• Do not modify any part within the range shown in the drawing above.
• In order not to raise the exhaust resistance, avoid extending or bending the tail pipe as much
as possible. When extending the tail pipe, minimize the extension. When bending, the bend-
ing radius of the tail pipe should be at least 1.5 times of the tail pipe outside diameter at
internal bending radius.
• When extending the tail pipe, it is possible to move the position of the tail pipe support about
5 inches. For further extension, add a new support.
Use a cushion rubber for the new support to make it an elastic suspension.
• For the position and direction of the outlet of the tail pipe, observe the following procedure:
Do not emit the exhaust gas toward the fuel tank or the fuel pipe.
Do not position the outlet of the exhaust pipe right under or ahead of the cab.
KK-US003D 48
Handling the Muffler

The muffler incorporates a catalyst that may be broken by major shock like falling.
Take extra care for handling the muffler when mounting a body or equipment.
Clearances between Exhaust System Parts and Other Parts

The exhaust system becomes very hot during driving.
Observe the following procedure to prevent vehicle fire when modifying.
• Clearances from a body or equipment
Observe the precautions for mounting a body or equipment described here in after.
• Clearances from fuel system parts
Maintain a clearance of at least 200mm (8.0 in.) between the fuel tank, fuel pipes and hot
parts of the exhaust system. If you cannot maintain the clearance of 200mm (8.0 in.), fit heat
insulators to protect the fuel tank and fuel pipes. When arranging fuel piping, make sure that
even if a fuel line ruptures and fuel leaks out, no fuel come into contact with the hot parts of
the exhaust system.
Never make joints of the fuel pipes at the hot parts or the top of the exhaust system.
• Clearances from chassis parts other than fuel system parts
If you cannot maintain the clearances described below, fit heat insulators.
CLEARANCE
mm (in.) CHASSIS PARTS
Min. 100 (4.0) Air pipes, oil pipes
Min. 200 (8.0) Electrical cables, rubber parts (rubber hoses, etc.),
nylon tubes, resin parts, cables
Exhaust Pipe and Muffler

The effect and interference by the heat of the exhaust pipe, muffler, etc. of the exhaust system
have a significant influence to safety. Maintain adequate clearances between the exhaust sys-
tem parts such as the exhaust pipe, muffler etc. and a body or equipment, or measure the
temperature of the exhaust system as necessary to check safety.
KK-US003D 49
Precautions for Mounting a Body or Equipment

• When mounting a body or equipment, maintain the following clearances from the exhaust
system.
For wood, rubber and cloth, maintain a clearance of at least 100mm (4.0 in.).
For cables, brake hoses, nylon tubes, electrical harness and resin parts, maintain a clear-
ance of at least 200mm (8.0 in.).
If it is impossible to maintain the above clearances, fit heat insulators between the relevant
parts, or measure the temperature of the exhaust system to check safety.
When the heat insulators are removed at mounting, be sure to fit the heat insulators to the
original position. Never paint the heat insulators.
• When mounting equipment (tool box, etc.) or inflammable objects behind the outlet of the
tail pipe, avoid the hatched area shown below.
KK-US003D 50
• When mounting a body or equipment above and ahead of the outlet (beside the muffler, pipe,
etc.)
When mounting a body and relevant parts beside the pipe, maintain a clearance of at least
80mm (3.0 in.) from the pipe as shown in the drawing below. If it is impossible to maintain the
clearance of at least 80mm (3.0 in.), fit a heat insulator between the relevant parts.
CAUTIONS NEEDED IN ADDITIONAL MACHINING AND ALTERATION OF THE

CAB
When the cab floor has been drilled or notched in order to install the PTO control lever and the
like, appropriately stiffen around the hole or notch, since the floor is reduced in strength by
making holes or notches. Where the lever and the like passes through the floor, use a rubber
boot and the like to seal off the gap to shut off a draft and noise.
In case of cab alteration, pay attention to rust prevention.
Considerations are needed not to hamper the accessibility to the heater cover and other parts
for servicing.
KK-US003D 51

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Chapter 5

GENERAL CAUTIONS •••••••••••••••••••••••••••••••••••••••••••••••••••••• 1

MATERIAL FOR CHASSIS FRAME MODIFICATIONS

ND8J, NE8J – (NE8J ONLY)

CHASSIS FRAME DRILLING

Drilling holes through the cross members of the frame

Drilling holes near the spring brackets and the maximum

When drilling holes, brake hoses or nylon tubes, brake

Be sure to use a drill in making holes. Never use a gas

When drilling holes through the web, they

Original holes in the chassis frame must not be drilled again.

Holes should be deburred after drilling.

CHASSIS FRAME WELDING

Weld Metal (Hot roll plate)

Welding Bead Shape

Never weld near the edge of a flange.

REAR OVERHANG EXTENSION

• Rear overhang extension

• Rear overhang extension

STIFFENING OF SIDE RAILS

Do not cut off a stiffener at a sharp angle.

How to fix stiffener to side member

Wheelbase modifications are accompanied by corresponding modifications of side rails (in-

Wheelbase Modification Without Cutting Side Rails

Remove the rear axle and the rear suspension.

Unit : kg·cm (ft·lb)

Wheelbase Modification by Cutting of Side Rails

• Wheelbase extension: • Wheelbase extension:

• Wheelbase extension (less than 1000 mm (39.4 in.))

PROPELLER SHAFT MODIFICATION AND ALTERATION

Any alteration of propeller shaft not recommendable.

Driveline Design Criteria

Cautions for Modification and Alteration of Propeller Shafts

LIMIT OF UNBALANCE Unit : g·cm (in·oz)

Align the yoke phase at both ends of the shaft.

Detail of Propeller Shafts

Explanation of propeller shaft length

· Rear Air Suspension Unit: mm (in.)

· With Option 23,000 lbs Rear Axle Unit: mm (in.)

Maximum Length of Propeller Shafts

Front and rear direction

Up and down, and left and right direction

Allowable tolerance Allowable tolerance

Installing of Center Bearing Bracket

Position No.4 No.5 No.6

Cautions when mounting bracket

Drawing of center bearing bracket

SERVICE BRAKE MODIFICATIONS

General Points of Brake System

CHASSIS MODEL BRAKE SYSTEM

NA, NB, NC, ND, NE HYDRAULIC BRAKE

NJ, NV FULL AIR BRAKE

Do not Modify the Brake System

The air tank must not be modified.

Position to be taken off an air given below;

• Full Air Brake Vehicles only

Refilling Brake Fluid (For HYDRAULIC Brake only)

• Never reuse old brake fluid.

Avoiding Effect of Exhaust Heat

Brake Piping Used in The Chassis