Hino Motors 300 Series, Mounting Manual

Page 1: ...HINO 300 SERIES Body Mounting Manual TRUCK CHASSIS TRUCK CHASSIS XZU XKU Hybrid vehicle MODEL SERIES KK XZU215C ...

Page 2: ... 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 042 586 5249 Facsimile 042 586 5868 2010 02 ...

Page 3: ... Manual with the following changes Consequently please discard the current Body Mounting Manual CD ROM NO KK XZU215B and use the new CD ROM NO KK XZU215C from now on CONTENTS OF CHANGES The information about XKU417L HKFQB3 Hybrid vehicle has been added RECORD OF CHANGES ...

Page 4: ...f the BODY MOUNTING MANUAL use the MODEL NAME after replacing it in accordance with the following table MODEL PRODUCTION CODE HINO 3414 XZU307L HKMLB3 XZU307L HKMMB3 XZU347L HKMMB3 XZU407L HKMMD3 XZU407L HKMQD3 XZU417L HKMMD3 XZU407L HKFQD3 XZU417L HKFQD3 XZU427L HKFQD3 XZU407L HKFRD3 XZU417L HKFRD3 XZU427L HKFRD3 HINO 3714 XKU417L HKFQB3 AUSXZU201 00T001 HINO 3716 HINO 3816 HINO 3616 HINO 3614 ...

Page 5: ...llectively referred to as Hino Chassis or modify or alter a Hino Chassis Content This manual contains chassis specifications and instructions particular to model 300 series with US 04 emission control in the Hino light duty trucks Important This instruction manual must be used in combination with the Common Manual No KC AA102 For more information on mounting of bodies and equipments or on chassis ...

Page 6: ...ipment has been mounted or modification has been made by a Body and Equipment Manufacturers or a modification company This manual does not affect that ultimate responsibility for the manufacture and mounting of the body installation modification or alteration on Hino Chassis devolves upon the Body and Equipment Manufacturer Each individual Body and Equipment Manufacturer has the sole responsibilit...

Page 7: ... SUMMARY 2 GENERAL PRECAUTIONS 3 CHASSIS MASS FRAME SECTION MODULUS 4 SPRING REAR AXLE 5 PTO AND CONTROL 6 ELECTRICAL SYSTEMS 7 PAINTING 8 CHASSIS DRAWINGS 9 CHASSIS FRAME DRAWINGS 10 MOUNTING OF CHASSIS EQUIPMENT CONTENTS ...

Page 8: ...KK XZU215C 1 VEHICLE SUMMARY PRODUCTION CODE 1 1 IDENTIFICATION NUMBER 1 2 CHASSIS SPECIFICATIONS 1 3 ...

Page 9: ... 5 5 4 495 FOR AUS GVMR ton GVMR AND REAR TIRE TYPE CODE 4 8 5 1 4 495 FOR AUS REAR TIRE TYPE SINGLE 4 495 FOR AUS 8 0 8 5 ENGINE CODE T NA W TURBO DESTINATION CODE NIL S A B D D N Q R T V W EXPORT STANDARD INDONESIA SOUTH AFRICA AUSTRALIA NEW ZEALAND TAIWAN THAI GCC EURO SHIPPING CODE CAB WITH CHASSIS 3 34 40 U VEHICLE MODEL CODE 2525 33 XZ XK N04C TR TS TT N04C TP TW N04C TU TV ENGINE TYPE CODE ...

Page 10: ...1 2 KK XZU215C IDENTIFICATION NUMBER Located at the side member of chassis frame FXZ1 C No CHASSIS ENGINE ...

Page 11: ...Refer to page 3 1 Refer to page 3 1 Refer to page 3 1 Refer to page 3 1 Refer to page 3 1 Refer to page 3 1 Refer to page 3 1 Refer to page 3 1 Front 205 75R16C 205 75R16C 205 75R16C 205 75R16C 215 85R16 215 85R16 215 75R17 5 205 75R16C 215 85R16 215 75R17 5 215 85R16 215 75R17 5 215 85R16 Rear 205 75R16C 205 75R16C 205 75R16C 205 75R16C 215 85R16 215 85R16 215 75R17 5 205 75R16C 215 85R16 215 75R...

Page 12: ... REAR FENDERS AND 2 4 MUDGUARDS ELECTRIC WELDING WORK 2 5 NOTES ON ADDITIONAL WIRING IN THE ENGINE 2 6 COMPARTMENT NOTES ON ENGINE CONTROL BRAKE ABS SYSTEM 2 7 COMPUTERS AND DC DC CONVERTER HANDLING OF PARTS FOR MEETING THE EXTERNAL 2 8 NOISE CONTROL REGULATION PRECAUTION ON BODY MOUNTING WORK 2 9 THE NOISE MEASURES OF THE AM RADIO 2 10 Peculiar to XKU417L HKFQB3 ...

Page 13: ...t carrier attached directly to the top of the front guard A fire shield is also not necessary for such bodies as dump trucks mixers tankers and aluminum vans where there is no danger of flammable materials falling off NOTE When you mount the fire shield use bolts etc that can be taken out to allow for replacement of the chassis parts which are located at the rear part of cab KK XZU215C For approxi...

Page 14: ...as the engine cylinder block When mounting the rear body or equipment allow at least the minimum clearance between the rear end of the cab or stack exhaust pipe and the front end of the rear body to avoid obstructing the operation of cab lock mechanism or avoiding fire 1 Minimum Clearance with Cab Rear End 1 STANDARD CAB series Unit mm 2 WIDE CAB series ...

Page 15: ...2 2 2 2 Measurement of the Engine Air Intake Port STANDARD CAB series Unit mm SIDE VIEW LEFT SIDE REAR VIEW LEFT SIDE KK XZU215C ...

Page 16: ... driven long intervals The increase in exhaust temperature is caused by the decreased efficiency in the combustion process as the proportion of air in the combustion chamber is also decreased by the above mentioned factor This situation will lead to major malfunctions such as the cracking of the exhaust manifold and the breaking down of the turbocharger To avoid such malfunctions please keep the a...

Page 17: ...ont right and left and up and down The body or equipment must not interfere with cab movement Allow at least 30 mm clearance between the cab and rear body or equipment When cab tilt allow at least 70 mm clearance the cab and rear body or equipment For details of cab tilt dimensions see the Body Mounting Manual for the respective model series ...

Page 18: ...engine cylinder block or other various equipment When mounting the body or equipment allow at least the minimum clearance between the rear end of the cab and the front end of the rear body or equipment to avoid obstructing the operation and maintenance of these mechanisms or various equipment For details of cab dimensions see chassis drawings EXAMPLE ...

Page 19: ...due to structure and layout of each component parts of the chassis W B CAB mm TYPE L1 L2 L3 L4 L5 RH 1595 264 1000 LH 1495 264 1035 RH 1595 264 1000 LH 1495 264 1035 RH 2470 935 1410 LH 2362 935 1410 RH 1780 236 950 LH 1780 236 950 RH 1780 236 950 LH 1780 236 950 RH 1780 236 950 LH 1780 236 950 RH 1780 236 950 LH 1780 236 950 RH 2400 233 1360 LH 2400 233 1360 RH 2400 233 1360 LH 2400 233 1360 RH 2...

Page 20: ...XZU307L HKMLB3 205 75R16C 1636 1656 1350 210 SINGLE XZU307L HKMMB3 205 75R16C 1876 1896 1435 137 XZU347L HKMMB3 205 75R16C 1876 1896 1435 137 XZU407L HKMMD3 205 75R16C 1921 1941 1480 135 XZU407L HKMQD3 215 85R16 1986 2006 1520 142 XZU407L HKFQD3 215 85R16 1986 2006 1520 142 XZU407L HKFRD3 215 75R17 5 1994 2014 1520 138 XZU417L HKMMD3 205 75R16C 1921 1941 1480 135 XZU417L HKFQD3 215 85R16 1986 2006...

Page 21: ...2 4 2 KK XZU215C 2 Mudguards ...

Page 22: ...hapter 2 2 9 PRECAUTION ON BODY MOUNTING WORK and following precautions at performing any electric welding 1 procedure before welding Make sure to always wear the electric insulation equipment insulation rubber gloves etc while working Turn the starter switch OFF Pull out the SERVICE PLUG of PCU and wait more than 7 minutes Disconnect the battery s negative terminal Disconnect the connector of DC ...

Page 23: ...2 5 2 KK XZU215C DETAILS RELAY FUSE BLOCK AUSXZU201 02D006 E G CONTROL ECU ABS ECU DC DC CONVERTER PASSENGER SEAT SIDE ...

Page 24: ...2 5 3 KK XZU215C FRONT UNDER COVER SIGNAL CIRCUIT CONNECTOR PCU WIRE HARNESS OF SIGNAL CIRCUIT UP FR CHASSIS CENTER ...

Page 25: ...trictly prohibited to prevent damage of the spring Welding to the cab body Connect the ground to the fixing bolt of cab hinge after dismounting the front grille or to the cab body 3 Other Precautions To protect ancillary equipment from sparks during welding place fire resistant covers over the rubber hoses wire harness pipes chassis spring and tires etc Perform to weld under most suitable conditio...

Page 26: ...led off the paint for grounding the welding equipment by same color 5 Final Inspection after Welding Restore each electronic instrument and equipment to its original site Install the SERVICE PLUG Refer the 2 9 PRECAUTION ON BODY MOUNTING WORK Inspect the operation and function of all electronic instruments and equipments Consult to each Hino sales dealer or distributor for the details of inspectio...

Page 27: ... the engines in HINO trucks are covered with sound arrest plates the engine compartment tends to heat up Avoid wiring in the engine compartment if possible Additional wiring harness or cable should be kept away from heated elements and should be wired along the main harness ...

Page 28: ...rming any electric welding 2 Be sure to cover the computer and converter to protect the water penetration when performing cleaning up the inside of cab 3 When mounting such devices as a radiophone a wireless communication device be sure to use the devices that conforms to the electric control act and install the devices on the places which are as far as possible from the computers and it s harness...

Page 29: ...ductions following items must be observed when mounting a superstructure 1 The parts for external noise reduction must not be modified or detached since their specifications are determined to comply with the limiting value of the external noise regulation The position and or direction of the tail pipe must also not be changed 2 If the parts for external noise reduction are temporarily detached for...

Page 30: ...allation position of hybrid related equipment BATTERY PCU MOTOR GENERATOR INVERTER ECU BOX HV ECU BATTERY ECU KINDS OF RELAIES RADIATOR FOR INVERTER NICKEL METAL HYDRIDE Ni MH BATTERY SERVICE PLUG COOLING DUCT COOLING FAN FOR BATTERY INNER STRUCTURE OF PCU ...

Page 31: ... to OFF pull out the SERVICE PLUG of PCU and wait more than 7 minutes see following figures Strictly observe abouve precautions to avoid receiving electric shock Do not attach the SERVICE PLUG which removed till the end of work It takes 7 minutes to discharge the electricity of high voltage condenser of the inverter SERVICE PLUG LID PCU SERVICE PLUG Procedure of the SERVICE PLUG removal Procedure ...

Page 32: ...aching the LID the air intake port of LID must be placed in the direction of vehicle front see following figures If the LID is placed in the wrong direction the intake port of Ni MH BATTERY COOLING DUCT will be coverd and the battery gets hot unusually It causes other faults The state which attached the service plug lid in the wrong direction The inner service plug can be seen from the intake port...

Page 33: ...t end of body and the other side to the chassis frame with the fitting nut of parking brake cable bracket Tightening torque of nut 18 5N m In order to secure an electric conductivity remove the paint of the fixing part Make sure to give anti rust treatment to the fixing part after installing the each wire The above figure is the example witch connected the earth wire to the center part of front en...

Page 34: ...wing figure Tightening torque of bolt 24 7 2N m Tie the additional earth wire to the nearby cable with tie rap Additional earth wires are contained in the package in the cab Part number of earth cable Assembly part number 82046 37160 Prepare bolts nuts and washers to needed for mounting body by body builder Grounding terminal Earth wire of motor generator FR Place ti be fitted Part number Between ...

Page 35: ...3 CHASSIS MASS FRAME SECTION MODULUS CHASSIS MASS 3 1 FRAME SECTION MODULUS 3 2 KK XZU215C ...

Page 36: ... 27 1 269 34 263 BATTERY 32 1 157 37 024 32 1 157 37 024 32 1 157 37 024 38 1 207 45 866 38 1 207 45 866 FUEL TANK 76 1 335 101 460 76 1 335 101 460 104 2 140 222 560 104 1 325 137 800 104 1 325 137 800 FUEL TANK SUB A C PROPELLER SHAFT FRONT PROPELLER SHAFT REAR 12 1 800 21 600 12 1 800 21 600 25 2 240 56 000 14 2 090 29 260 14 2 090 29 260 FRAME ETC 184 1 335 245 640 217 1 270 275 590 258 1 870 ...

Page 37: ... 500 7 500 EXHAUST SYSTEM 27 1 269 34 263 27 1 269 34 263 27 1 269 34 263 27 1 269 34 263 27 1 763 47 601 BATTERY 38 1 207 45 866 38 1 207 45 866 38 1 207 45 866 38 1 207 45 866 38 1 207 45 866 FUEL TANK 104 1 325 137 800 104 1 325 137 800 104 1 945 202 280 104 1 945 202 280 104 1 945 202 280 FUEL TANK SUB A C PROPELLER SHAFT FRONT PROPELLER SHAFT REAR 14 2 090 29 260 14 2 090 29 260 26 2 400 62 4...

Page 38: ...0 0 500 10 000 EXHAUST SYSTEM 27 1 903 51 381 27 1 903 51 381 33 1 500 49 500 BATTERY 38 1 207 45 866 38 1 207 45 866 51 2 461 125 511 FUEL TANK 104 2 385 248 040 104 2 385 248 040 104 1 945 202 280 FUEL TANK SUB A C PROPELLER SHAFT FRONT PROPELLER SHAFT REAR 28 2 620 73 360 28 2 620 73 360 25 2 400 60 000 FRAME ETC 280 2 030 568 400 280 2 030 568 400 241 1 780 428 980 SPARE TIRE CARRIER 7 4 815 3...

Page 39: ...FRAME SECTION MODULUS MAIN FRAME ON BOTH SIDE 3 2 1 KK XZU215C MODEL XZU307L HKMLB3 ...

Page 40: ...FRAME SECTION MODULUS MAIN FRAME ON BOTH SIDE 3 2 2 KK XZU215C MODEL XZU307L HKMMB3 ...

Page 41: ...FRAME SECTION MODULUS MAIN FRAME ON BOTH SIDE 3 2 3 KK XZU215C MODEL XZU347L HKMMB3 ...

Page 42: ...FRAME SECTION MODULUS MAIN FRAME ON BOTH SIDE 3 2 4 KK XZU215C MODEL XZU407L HKMMD3 XZU407L HKMQD3 XZU407L HKFQD3 XZU407L HKFRD3 ...

Page 43: ...FRAME SECTION MODULUS MAIN FRAME ON BOTH SIDE 3 2 5 KK XZU215C MODEL XZU417L HKMMD3 XKU417L HKFQB3 XZU417L HKFQD3 XZU417L HKFRD3 ...

Page 44: ...FRAME SECTION MODULUS MAIN FRAME ON BOTH SIDE 3 2 6 KK XZU215C MODEL XZU427L HKFQD3 XZU427L HKFRD3 ...

Page 45: ...4 SPRINGS REAR AXLES SPRING CHARACTERISTICS 4 1 MAXIMUM VERTICAL DEFLECTION OF REAR WHEELS 4 2 TRAVEL RANGE OF REAR SPRING 4 3 KK XZU215C ...

Page 46: ...1 XZU307L HKMMB3 F2 F6 R2 R5 XZU347L HKMMB3 F2 F6 R2 R5 XZU407L HKMMD3 F3 F7 R3 R4 XZU407L HKMQD3 F4 F5 R3 R4 XZU407L HKFQD3 F4 F5 R3 R4 XZU407L HKFRD3 F5 F8 R4 R6 XZU417L HKMMD3 F3 F7 R3 R4 XZU417L HKFQD3 F4 F5 R3 R4 XZU417L HKFRD3 F5 F8 R4 R6 XZU427L HKFQD3 F4 F5 R3 R4 XZU427L HKFRD3 F5 F8 R4 R6 XKU417L HKFQB3 F4 F5 R3 R4 AUSXZU201 04T001 MODEL SPRING CHARACTERISTICS FRONT REAR ...

Page 47: ...2 FRONT LEAF SPRING 1 SPRING CHARACTERISTICS CHART F1 2 SPRING CHARACTERISTICS CHART F2 4 1 2 KK XZU215C ...

Page 48: ... 3 SPRING CHARACTERISTICS CHART F3 4 SPRING CHARACTERISTICS CHART F4 4 1 3 KK XZU215C ...

Page 49: ... 5 SPRING CHARACTERISTICS CHART F5 6 SPRING CHARACTERISTICS CHART F6 4 1 4 KK XZU215C ...

Page 50: ... 7 SPRING CHARACTERISTICS CHART F7 8 SPRING CHARACTERISTICS CHART F8 4 1 5 KK XZU215C ...

Page 51: ...3 REAR LEAF SPRING 1 SPRING CHARACTERISTICS CHART R1 4 1 6 KK XZU215C ...

Page 52: ... 2 SPRING CHARACTERISTICS CHART R2 4 1 7 KK XZU215C ...

Page 53: ...4 1 8 KK XZU215C 3 SPRING CHARACTERISTICS CHART R3 ...

Page 54: ...4 1 9 KK XZU215C 4 SPRING CHARACTERISTICS CHART R4 ...

Page 55: ... 5 SPRING CHARACTERISTICS CHART R5 4 1 10 KK XZU215C ...

Page 56: ...4 1 11 KK XZU215C 6 SPRING CHARACTERISTICS CHART R6 ...

Page 57: ...ensions A and B are added 50mm 1 SINGLE TIRE 2 DOUBLE TIRE MODEL TIRE SIZE A B C D REAR TIRE XZU307L HKMLB3 205 75R16C 139 132 42 198 SINGLE XZU307L HKMMB3 205 75R16C 137 97 96 120 XZU347L HKMMB3 205 75R16C 137 97 96 120 XZU407L HKMMD3 205 75R16C 100 54 125 113 XZU407L HKMQD3 215 85R16 124 79 128 127 XZU407L HKFQD3 215 85R16 124 79 128 127 XZU407L HKFRD3 215 75R17 5 120 75 134 123 XZU417L HKMMD3 2...

Page 58: ...R SHACKLE REAR LEAF SPRING A Do not mount any parts of body inside of the this range FRONT Unit mm MODEL A min XZU307L HKMMB3 XZU347L HKMMB3 XZU407L HKMMD3 XZU407L HKMQD3 XZU407L HKFQD3 XZU407L HKFRD3 XZU417L HKMMD3 XZU417L HKFQD3 XZU417L HKFRD3 XZU427L HKFQD3 XZU427L HKFRD3 XKU417L HKFQB3 AUSXZU201 04T003 100 130 MODEL XZU307L HKMLB3 ...

Page 59: ...5 PTO AND CONTROL LAYOUT OF POWER LINE 5 1 TRANSMISSION SIDE POWER TAKE OFF OPT 5 2 ENGINE CONTROL FOR BODY OR EQUIPMENT 5 3 REAR BODY CONTROL LEVER OPT 5 4 KK XZU215C ...

Page 60: ...0 0 1 DUMP LEVER XZU407L HKMQD3 N04C TV M550 240 153 4 436 287 944 0 0 1 DUMP LEVER XZU407L HKFQD3 N04C TV MYY6 240 153 4 357 221 860 0 0 2 DUMP LEVER XZU407L HKFRD3 N04C TV MYY6 240 153 4 357 221 860 0 0 2 DUMP LEVER XZU417L HKMMD3 N04C TV M550 240 153 4 436 287 944 0 0 1 DUMP LEVER XZU417L HKFQD3 N04C TV MYY6 240 153 4 357 221 860 0 0 2 DUMP LEVER XZU417L HKFRD3 N04C TV MYY6 240 153 4 357 221 86...

Page 61: ...es dealer or distributor Model Transmission series XZU307L HKMMB3 XZU347L HKMMB3 XZU407L HKMMD3 XZU407L HKMQD3 XZU417L HKMMD3 M550 AUSXZU201 05T006 Transmission series Permissible torque N m kgf m at r min PTO control type Direction of rotation M550 245 25 1 000 Vacuum control Reverse to engine Nut Stud bolt Bolt Gasket PTO case Power take off assy Parts name Rev 5th 4th 3rd 2nd 1st Transmission g...

Page 62: ...the transmission case 6 Fit the gasket and PTO on the PTO mounting position and tighten the fitting bolts and nuts Tightening torque for stud bolts 36 3N m 370kgf cm 7 After attaching the PTO turn the output shaft coupling a few revolutions to be sure that it turns freely 8 When you refill the transmission oil increase the amount by 0 3 liters to allow for the PTO 5 Gear Layout and Gear Ratio Gear...

Page 63: ...er of teeth Normal module Normal pressure angle Helix angle and direction Standard pitch circle diameter Base circle diameter Normal circular thickness Over ball diameter Used ball diameter Face width Rotation backlash Addendum modification coefficient Gear layout Outside diameter Whole depth Semi topping Helical gear 35 2 650 17 29 Right 106 046 3 9171 113 403 5 000 20 0 2 0 05 0 1515 100 106 112...

Page 64: ... 1 The devices on the body or equipment side e g oil pump must be mounted at the same angle as engine to the body Direct mounting the devices to the PTO output flange is strictly prohibited 2 The three dimensional angle of the universal joint of the drive shaft should be less than 6 ...

Page 65: ...5 2 5 KK XZU215C Detail of PTO Flange Unit mm Detail of PTO Output Shaft ...

Page 66: ...U417L HKFQD3 XZU417L HKFRD3 XZU427L HKFQD3 XZU427L HKFRD3 MYY6S AUSXZU201 05T012 Transmission series Permissible torque N m kgf m at r min PTO control type Direction of rotation MYY6S 196 20 1 000 Electronic control Reverse to engine AUSXZU201 05T013 Nut Stud bolt Power take off assy Parts name Rev 6th 4th 3rd 2nd 1st Transmission gear ratio Transmission model 94130 61000 90031 16079 36610 37290 P...

Page 67: ...se as shown Appling methods 1 Remove moisture and oils from sealing surface before appling 2 Dia of liquid gasket is 2 min 3 Liquid gasket bead must be continued all round 7 Fit the PTO on the PTO mounting position and tighten nuts Tightening torque for nuts 36 3N m 370kgf cm 8 After attaching the PTO turn the output shaft coupling a few revolutions to be sure that it turns freely 9 When you refil...

Page 68: ...5 2 8 KK XZU215C 6 Detail of MYY6S Transmission ...

Page 69: ...OTE 1 The devices on the body or equipment side e g oil pump must be mounted at the same angle as engine to the body Direct mounting the devices to the PTO output flange is strictly prohibited 2 The three dimensional angle of the universal joint of the drive shaft should be less than 6 ...

Page 70: ...5 2 10 KK XZU215C Detail of PTO Flange Unit mm Detail of PTO Output Shaft Unit mm ...

Page 71: ...ENSO 5 XZU407L HKMQD3 N04C TV COMMON RAIL TYPE ELECTRONIC CONTROL TYPE DENSO 6 XZU407L HKFQD3 N04C TV COMMON RAIL TYPE ELECTRONIC CONTROL TYPE DENSO 7 XZU407L HKFRD3 N04C TV COMMON RAIL TYPE ELECTRONIC CONTROL TYPE DENSO 8 XZU417L HKMMD3 N04C TV COMMON RAIL TYPE ELECTRONIC CONTROL TYPE DENSO 9 XZU417L HKFQD3 N04C TV COMMON RAIL TYPE ELECTRONIC CONTROL TYPE DENSO 10 XZU417L HKFRD3 N04C TV COMMON RA...

Page 72: ...n cabin as optional equipment Connect the connector of Engine accelerator with spare connector which is provided behind the No 3 crossmember at chassis frame LH side member Should more detailed data or information with regard to engine accelerator for body control be needed consult authorized Hino distributor ...

Page 73: ...5 3 3 KK XZU215C ...

Page 74: ... side lever touches the stopper See the following illustration Be sure to set the sensor lever that sensor lever should be contacted with idling stopper by adjusting body control lever while body or equipment do not operate while vehicle is driving The clearance indicated for the stroke stopper of accelerator stopper is just for reference If the sensor side stopper comes into contact earlier a for...

Page 75: ...ention to avoid the direct projection of vehicle washing water tire splash etc The usable range of temperature is 30 80 C Use it in the said range Install the sensor in the position which can apply lubrication Avoid such places where there is risk of receiving falling matters or stones that give impact Install the sensor where there is no possibility of exposing dust oil mist humidity chemical pro...

Page 76: ...5 4 KK XZU215C REAR BODY CONTROL LEVER OPT 1 Mounting position of dump body control lever Unit mm ...

Page 77: ...E BLOCK AND RELAY PANEL 6 1 ALTERNATOR OUTPUT CHARACTERISTIC 6 2 SPARE POWER TERMINALS 6 3 ADDITIONAL LAMPS 6 4 REAR COMBINATION LAMP 6 5 LICENSE PLATE BRACKET AND LICENSE PLATE LAMP 6 6 BACK UP BUZZER 6 7 ELECTRICAL WIRING DIAGRAMS 6 8 ...

Page 78: ...6 1 1 6 ELECTRICAL SYSTEM KK XZU215C FUSE BLOCK AND RELAY PANEL 1 LOCATION The fuse block and relay panel are located inside the instrument panel as shown below ...

Page 79: ...6 1 2 KK XZU215C 2 FUSE BLOCK ...

Page 80: ...P 1 SJ 2 SK 3 SL HORN L X36 ECU XD0 S Z23 B X35 ENGINE N04C HEATER IGNITION POWER WINDOW FOG LAMP HEAD LAMP ENGINE N04C A C COMP TAIL LAMP ACCESSORY 15A 20A 10A 15A 10A 10A 10A 10A 10A 20A 20A 15A 10A 10A 10A L D02 10A 10A 15A 20A 30 A STOP ENGINE 12V WIPER AIR CONDITIONING UNIT L 4G 10A IGNITION FOG LAMP DOME L CA 10A P TAIL POWER WINDOW HAZ HORN P ACC AM2 HEAD LAMP L H R H GAUGE TAIL LAMP ACC FU...

Page 81: ... SN 3 SP 1 SJ 2 SK 3 SL HORN L 6F S 6G S 6H B 6E ENGINE 3 HEATER IGNITION1 2 POWER WINDOW FOG LAMP HEAD LAMP ENGINE 2 A C COMP TAIL LAMP ACCESSORY 15A 15A 20A 10A 15A 10A 10A 10A 10A 10A 20A 20A 15A 10A 10A 10A L D02 10A 10A 15A 20A 30 A STOP ENGINE 12V HV 12V WIPER AIR CONDITIONING UNIT L 4G 10A IGNITION1 FOG LAMP DOME L CA 10A TAIL POWER WINDOW HAZ HORN AM2 HEAD LAMP L H R H GAUGE TAIL LAMP ACC ...

Page 82: ...ectric power that is not consumed by electrical equipments such as head lamps etc can be available for the body side Pay attention not to exceed the capacity of the alternator equipped on the vehicle In the event that you are obliged to carry out the body mounting exceeding the capacity of the alternator select the one available as an option or consult your nearest Hino service dealer or distribut...

Page 83: ...urrent of the installed equipment must be kept lower current than the permissible capacity to be able to take from spare power terminal 2 Be sure to keep the lower current value than the alternator generated capacity when switched on the original and additional equipment same time to avoid over discharging electricity of the battery 3 Using length show the wire length from fuse to each terminal po...

Page 84: ...6 3 2 KK XZU215C 1 Outlet Position Inside the Cab ...

Page 85: ...TY FROM POWER SUPPLY CIRCUIT a USING SUB HARNESS TYPE b DIRECT CONNECTING TYPE NOTE As far as possible take power using sub harness type If you must take power using direct connecting type be sure to observe the precautions in described item ELECTRICAL EQUIPMENT AND WIRING ...

Page 86: ...TE FOR COUPLING CONNECTOR PROVIDED AS AN OPTIONAL PARTS Parts number of coupling connector is shown in parenthesis Details of coupling connector are as follows Each connector of the chassis side has individual color Make sure that do not connect wrong coupling with spare power terminal connector ...

Page 87: ...ration and modification are therefore strictly prohibited If you must install additional lamps be sure to observe the following precautions Moreover installation of the additional lamps must be complied with the laws or regulations and install the harness to be observed the precautions of wire harness described in Common Manual ...

Page 88: ...ated tube on the harness to prevent damage to the wire and potential short circuit 2 Make sure that the clearance between wire and penetration hole should be properly sealed by sealant to prevent water coming in and abnormal noise 3 The penetration holes of wire marked A B may be not able to use according to the vehicle s specification Be sure to confirm the actual vehicle before drawing the harne...

Page 89: ...c 2 Layout of switches and lamps Standard layout of switches and lamps are as following figure If you intend to install additional switches or lamps at instrument panel for the convenience of body mounting be sure to install it at empty space after confirmation of original condition of the actual vehicle Avoid using additional switches and lamps with existing switches and lamps If you install addi...

Page 90: ...PT OPT 1DIN SPACE B TRAY AUDIO OPT WHEN TACHOGRAPH IS OPT OPT 1DIN SPACE C TRAY 1DIN SPACE a FRONT FOG LAMP SWITCH OPT b c COIN HOLDER STD d e PTO SWITCH OPT f i WARM UP SWITCH STD j k PEN HOLDER HOOK STD l IDLE STOP SWITCH STD m HAZARD SWITCH STD n o p GEXZU208 06T001 Except XKU417L HKFQB3 ...

Page 91: ...6 4 5 KK XZU215C Additional Switches If you intend to install the switch to the instrument panel use the switch mentioned hereinafter which is provided as a spare parts ...

Page 92: ...m the battery secure the battery cable and the body power supply connector together with the same nut For details see the following figure In this case you must install a fuse at a suitable point in the circuit and take precautions to prevent short circuits as these may lead vehicle fires When securing the cable and power connector make sure you tighten the nut properly ...

Page 93: ...n installing it regularly attach the combination lamp assembly directly such that the direction indicator lamp umber is outside and the back up lamp white is inside of the vehicle Do not install the rear combination lamps vertically so as not to affect the performance of reflectors and drain holes Drawing shows right hand lamp only Positions reversed for left side Unit mm ...

Page 94: ...6 5 2 KK XZU215C LIGHT EMISSION PORTION OF REAR COMBINATION LAMP ...

Page 95: ... rear bumper lamps or by the rear body 3 The license plate bracket must be securely installed by rivets or bolts so as to be complied with vehicle laws and regulations 4 To prevent the license plate bracket from shaking always use a strengthening stay when it is installed 5 Make sure that light of the license lamp do not directly come through toward the rear of the vehicle 6 Mount the license lamp...

Page 96: ...6 6 2 KK XZU215C EXTERNAL ASPECT OF LICENSE PLATE BRACKET Unit mm EXTERNAL ASPECT OF LICENSE PLATE LAMP Unit mm ...

Page 97: ... below If the installing angle is not within range water will accumulate inside the buzzer and may lead to failure 2 Position If you move the buzzer to make room for mounting a body reinstall it in a position where it is not exposed to splashing with muddy water stone or water 3 Precaution for painting Make sure that the buzzer should be covered during painting to protect the paint coming into buz...

Page 98: ...LECTRICAL WIRING DIAGRAMS This manual does not contain electrical wiring diagrams The electrical wiring diagrams are in the WORKSHOP MANUAL For more details please consult your nearest Hino sales dealer or distributor ...

Page 99: ...7 1 PRECAUTION OF TOP COAT PAINTING FOR CAB 7 2 HANDLING OF LAMINATED WINDSHIELD 7 3 HOW TO REMOVE THE RADIATOR GRILLE 7 4 THE KIND AND THE ATTACHING POSITION 7 5 OF MARK AND ORNAMENT PRECAUTIONS FOR FITTING AND STORING 7 6 THE CAUTION PLATE ...

Page 100: ...natural air drying paint to be used which have superior characteristics as in painting finish quality color fade out comparing with lacquer type paint The top coat should be at least 30 µ thick 2 When painting on the resin parts Hino recommends paint for the resin parts to be used which is best matched to the characteristics of the resin parts step rubber front grill front garnish etc and also can...

Page 101: ...tilt The vehicle with a hydraulic cab tilt driven by an electrical motor Batteries Wiper blade washer nozzle Installing surface of disc to the disc wheel Including the hub to be contacted and contacting surface of drum disc wheel as well as contacting surface of hub nuts Then when stained paint to the inner part of the cab cleaning it with a neutral detergent do not use gasoline or thinner 2 Cauti...

Page 102: ...over 80 C Note Remove off the radiator grille in accordance with Article 4 Radiator grille Garnish Head lamp A Side turn and Clearance lamp Fender rubber Reflex reflector AUSXZU201 07D001 ID MARKER LAMP CLEARANCE LAMP WIDE CAB ONLY MODEL PARTS NAME XZU307L HKMLB3 Mirror stay cover XZU307L HKMMB3 XZU347L HKMMB3 XZU407L HKMMD3 XZU407L HKMQD3 XZU407L HKFQD3 XZU407L HKFRD3 XZU417L HKMMD3 XZU417L HKFQD...

Page 103: ...n off or such defective occur as foaming may be caused Therefore a special caution needs to be taken Caution when Painting There is no problem when you use a natural drying But when a forced drying is used with infrared ray lamp etc be sure that the drying should be implemented within 30 minutes at less than 120 C When drying at the temperature of more than 120 C remove off the windshield glass or...

Page 104: ...diator Grille Install the clips on the radiator grille Install the radiator grille on the cab body by matching the clips holes and pushing it in the order from the bottom to the upper side Install the tapping screw or bolt at the central part 3 Caution After confirming that there are no damages at nail part etc of the clips install them 7 4 KK XZU215C Upper side Right side Front side Clip X 13 pie...

Page 105: ...the ornaments to be attached on cab are packed separately and shipped out together with the vehicle or when attaching them after complete painting attach them at the specified places in accordance with the attaching position chart and the attaching procedure HYBRID MARK No 4 and 5 is peculiar to XKU417L HKFQB3 CAB FRONT Note Parts numbers are changeable always Accordingly for confirmation get in c...

Page 106: ...TACHING PLACE NAME OF MARK No KIND OF MARK 75429 37010 75429 37240 75429 37040 75429 37100 75429 37220 75429 37020 75429 37030 75429 37210 75429 37050 75429 37060 75429 37070 75429 37080 75429 37090 75429 37110 75429 37190 75429 37120 75429 37130 75429 37140 75429 37200 75429 37150 75429 37160 75429 37170 75429 37230 75429 37180 MODEL SERIES MARK DOOR 6 7 DOOR EMISSION CONTROL MARK 75427 37180 754...

Page 107: ...5 3 KK XZU215C 1 Attaching Place and Procedure for Each Mark and Ornament Refer to the detailed figure of the attaching position for 1 to 6 of the attachments on the cab FRONT VIEW OF CAB SIDE VIEW OF CAB ...

Page 108: ...il of Each Mark and Ornament attaching position 1 NAME SYMBOL MARK PLACE Radiator grille 2 NAME MODEL and HINO MARK PLACE Cab front panel CAB FRONT VIEW RIGHT SIDE CAB FRONT VIEW LEFT SIDE 5 1 5 SECTION AA Radiator grille A A ...

Page 109: ...7 5 5 KK XZU215C 3 NAME HYBRID EMISSION CONTROL and MODEL SERIES MARK PLACE Door DRAWING SHOWS CAB LEFT SIDE VIEW RIGHT SIDE IS SAME AS OPPOSITE ...

Page 110: ...make a tiny hole with a needle or a cutter knife and press it out with your fingers from the bubble area 2 How to Store It When storing the caution plate select a dry place with an ambient temperature of 20 to 25 C and without dust dirt and stain Also store the caution plate at a flat place such as a shelf etc and do not place anything on it 3 Other Precautions for the Caution Plate a As the cauti...

Page 111: ...8 CHASSIS DRAWINGS CAB DRAWING 8 1 DETAIL OF THE CAB BACK DIMENSIONS 8 2 CHASSIS DRAWING 8 3 KK XZU215C ...

Page 112: ...8 1 1 KK XZU215C SCALE 1 20 Unit mm 8 CHASSIS DRAWINGS CAB DRAWING 1 STANDARD CAB XZU307L HKMLB3 ONLY ...

Page 113: ...8 1 2 KK XZU215C SCALE 1 20 Unit mm 2 STANDARD CAB ...

Page 114: ...8 1 3 KK XZU215C SCALE 1 20 Unit mm 3 WIDE CAB ...

Page 115: ...DETAIL OF THE CAB BACK DIMENSIONS 1 STANDARD CAB T M MODEL M550 LEFT VIEW Unit mm 8 2 1 KK XZU215C 1 3 ...

Page 116: ...RIGHT VIEW Unit mm 8 2 2 KK XZU215C 2 3 ...

Page 117: ...UPPER VIEW Unit mm 8 2 3 KK XZU215C 3 3 ...

Page 118: ...8 2 4 KK XZU215C 2 WIDE CAB T M MODEL M550 LEFT VIEW Unit mm 1 3 ...

Page 119: ...8 2 5 KK XZU215C RIGHT VIEW Unit mm 2 3 ...

Page 120: ...8 2 6 KK XZU215C UPPER VIEW Unit mm 3 3 ...

Page 121: ...8 2 7 KK XZU215C 1 3 3 WIDE CAB T M MODEL MYY6S LEFT VIEW Unit mm ...

Page 122: ...8 2 8 KK XZU215C 2 3 RIGHT VIEW Unit mm ...

Page 123: ...8 2 9 KK XZU215C 3 3 UPPER VIEW Unit mm ...

Page 124: ...8 2 10 KK XZU215C 4 HYBRID T M MODEL MYY6S LEFT VIEW Unit mm 1 3 ...

Page 125: ...8 2 11 KK XZU215C RIGHT VIEW Unit mm 2 3 ...

Page 126: ...8 2 12 KK XZU215C UPPER VIEW Unit mm 3 3 ...

Page 127: ...ons 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 manufacturer CHASSIS DRAWING ...

Page 128: ... dimensions 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 manufacturer ...

Page 129: ... dimensions 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 manufacturer ...

Page 130: ... dimensions 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 manufacturer ...

Page 131: ... dimensions 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 manufacturer ...

Page 132: ... dimensions 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 manufacturer ...

Page 133: ... dimensions 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 manufacturer ...

Page 134: ...9 CHASSIS FRAME DRAWINGS CHASSIS FRAME DRAWINGS 9 1 KK XZU215C ...

Page 135: ...9 CHASSIS FRAME DRAWINGS 9 1 1 KK XZU215C SCALE 1 20 Unit mm CHASSIS FRAME DRAWINGS ...

Page 136: ...9 1 2 KK XZU215C SCALE 1 20 Unit mm ...

Page 137: ...9 1 3 KK XZU215C SCALE 1 20 Unit mm ...

Page 138: ...9 1 4 KK XZU215C SCALE 1 20 Unit mm ...

Page 139: ...9 1 5 KK XZU215C SCALE 1 20 Unit mm ...

Page 140: ...9 1 6 KK XZU215C SCALE 1 20 Unit mm ...

Page 141: ...9 1 7 KK XZU215C SCALE 1 20 Unit mm ...

Page 142: ...9 1 8 KK XZU215C SCALE 1 20 Unit mm ...

Page 143: ...9 1 9 KK XZU215C SCALE 1 20 Unit mm ...

Page 144: ...9 1 10 KK XZU215C SCALE 1 20 Unit mm ...

Page 145: ...9 1 11 KK XZU215C SCALE 1 20 Unit mm ...

Page 146: ...9 1 12 KK XZU215C SCALE 1 20 Unit mm ...

Page 147: ...9 1 13 KK XZU215C SCALE 1 20 Unit mm ...

Page 148: ...9 1 14 KK XZU215C SCALE 1 20 Unit mm ...

Page 149: ...10 MOUNTING OF CHASSIS EQUIPMENT FUEL TANK 10 1 BATTERY 10 2 EXHAUST SYSTEM 10 3 KK XZU215C ...

Page 150: ...KMLB3 FT1 XZU307L HKMMB3 FT1 XZU347L HKMMB3 FT2 XZU407L HKMMD3 FT3 FT5 XZU407L HKMQD3 FT3 FT5 XZU407L HKFQD3 FT3 FT5 XZU407L HKFRD3 FT3 FT5 XZU417L HKMMD3 FT4 FT6 FT7 FT9 XZU417L HKFQD3 FT4 FT6 FT7 FT9 XZU417L HKFRD3 FT4 FT6 FT7 FT9 XZU427L HKFQD3 FT4 FT6 FT8 FT10 XZU427L HKFRD3 FT4 FT6 FT8 FT10 XKU417L HKFQB3 FT11 AUSXZU201 10T001 MODEL STD OPT 100L 70L BIG STANDARD ...

Page 151: ...10 1 2 KK XZU215C 1 FUEL TANK CHART FT1 CAPACITY 70L Unit mm ...

Page 152: ...10 1 3 KK XZU215C 2 FUEL TANK CHART FT2 CAPACITY 100L Unit mm ...

Page 153: ...10 1 4 KK XZU215C 3 FUEL TANK CHART FT3 CAPACITY 100L Unit mm ...

Page 154: ...10 1 5 KK XZU215C 4 FUEL TANK CHART FT4 CAPACITY 100L Unit mm XZU417L 1945 XZU427L 2385 AUSXZU201 10T002 MODEL A ...

Page 155: ...10 1 6 KK XZU215C 5 FUEL TANK CHART FT5 CAPACITY 100L Unit mm ...

Page 156: ...10 1 7 KK XZU215C Unit mm 6 FUEL TANK CHART FT6 CAPACITY 100L XZU417L 1945 XZU427L 2385 AUSXZU201 10T002 MODEL A ...

Page 157: ...10 1 8 KK XZU215C Unit mm 7 FUEL TANK CHART FT7 CAPACITY 100L 70L ...

Page 158: ...10 1 9 KK XZU215C Unit mm 8 FUEL TANK CHART FT8 CAPACITY 100L 70L ...

Page 159: ...10 1 10 KK XZU215C 9 FUEL TANK CHART FT9 CAPACITY 100L 70L Unit mm ...

Page 160: ...10 1 11 KK XZU215C 10 FUEL TANK CHART FT10 CAPACITY 100L 70L Unit mm ...

Page 161: ...10 1 12 KK XZU215C 11 FUEL TANK CHART FT11 CAPACITY 100L Unit mm ...

Page 162: ...10 2 1 KK XZU215C BATTERY CAPACITY 216kC 60AH STD Except XKU417L HKFQB3 Unit mm A B 254 G 190 404 359 C R 1 6 0 E D 254 APPROX 22 F VEHICLE S FRONT A B C D E F G 60 90 68 28 38 42 30 ...

Page 163: ...10 2 2 KK XZU215C CAPACITY 288kC 80AH OPT Except XKU417L HKFQB3 STD XKU417L HKFQB3 only Unit mm 404 361 329 190 A B C D E 254 G F R 1 6 0 APPROX 25 VEHICLE S FRONT A B C D E F G 60 90 68 28 38 42 43 ...

Page 164: ...10 3 1 KK XZU215C Unit mm EXHAUST SYSTEM ...

Page 165: ...10 3 2 KK XZU215C Unit mm ...

Page 166: ...10 3 3 KK XZU215C Unit mm ...

Page 167: ...10 3 4 KK XZU215C Unit mm ...

Page 168: ...FRONT AXLE DATUM LINE XKU417L HKFQB3 STD MODEL 10 3 5 KK XZU215C Unit mm ...

Page 169: ......