Manual-de-carroceria-para-camiones-hino-linea-300-xzu-y-xku.pdf

KK-XZU337D

HINO 300 SERIES

Body Mounting Manual

TRUCK CHASSIS MODEL SERIES

XZ U & XKU

(Hybrid vehicle)

No part of this manual may be reproduced or transmitted in any form without the express written permission of Hino Motors, Ltd. © 2016, Hino Motors, Ltd. All rights reserved. Printed in Japan.

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

July 2016

KK-XZU337D

RECORD OF CHANGE We have published the revised edition of Body Mounting Manual with the following changes. Therefore, please discard the Body Mounting Manual CD-ROM No. KK-XZU337C, and use the CD-ROM No. KK-XZU337D from now on. CONTENTS OF CHANGE 1. Complying for safety regulations of Colombia.

KK-XZU337D

WARNING Request for alteration to make when reading MODEL NAME. • The MODEL NAME in this manual of BODY MOUNTING MANUAL is described according to the “MODEL CODE” name. • When making use of the BODY MOUNTING MANUAL, use the MODEL NAME after replacing it in accordance with the following table. ( MODEL )

( MODEL CODE )

HINO 3514

XZU640L - HKMLN3 XZU650L - HKMMP3

HINO 3616

XZU710L - QKFMP3 XZU710L - HKFMP3

HINO 3716

XZU710L - HKFQP3

HINO 3816

XZU720L - HKFRP3

HINO 3616

XKU710L - HKUMP3

HINO 3716

XKU710L - HKUQP3

HINO 3816

XKU710L - HKURP3

KK-XZU337D

ABOUT THIS MANUAL Purpose This manual is provided the Body and Equipment Manufacturers, including inter-mediate and/or final stage manufacturers (hereinafter collectively referred to as Body and Equipment Manufacturers), to provide : (1) Technical instructions for Hino truck chassis with cab for modification and mounting of bodies. (2) An aid to Body and Equipment Manufacturers for producing safe vehicles under their own discretion and responsibility. (3) Other general advice for installation, modification or alteration.

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

Content This manual contains chassis specifications and instructions particular to model 300 series (ex. XZU, WU and XKU) in the HINO of light duty trucks.

Important • Make use of this manual after confirmed vehicle specification with the section three "CHASSIS SPECIFICATION" in chapter one. • This instruction manual must be used in combination with the Common Manual, No. KC-AA102. • ‌The instructions of individual model manual precede over the common manual. • The Common Manual is available in this CD-R. • For more information on mounting of bodies and equipments or on chassis modifications, refer to the appropriate workshop manuals, parts catalogs and owner's or driver's manual. • The information in this manual is accurate to the best of Hino's Knowledge at the time of going to press. Hino reserves the right to modify any and all information without notice and without obligation. • Should more detailed data or information be needed, please contact Hino authorized dealer or distributor.

KK-XZU337D

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ABOUT THIS MANUAL Warning • The vehicle has installed electric equipments such as the vehicle's control system and a computer for comply with vehicle regulation for each country. In that case, do must not alter of chassis such as change of wheelbase and tire size. Deterioration of vehicle's capability and vehicle regulation violation may lead to serious traffic accident. • In normal operation, the chassis frame and body frame provide sufficient strength for the mounting of a standard cargo, van and dump body. However, if body or equipment such as a small crane at the back of the cab, concrete pump, areal platform, tank supported reg type or a mixer are fitted, the chassis frame will be subject to concentrated loads and the chassis frame alone will not give sufficient strength. To help spread the load, you must strengthen the body structure (especially strengthening members corresponding to the sub frame=longitudinal main floor member of body or equipment) or the chassis frame itself, using L-shaped stiffeners to achieve sufficient strength for the mounting of the rear body or equipment. More detailed information will be needed, please contact Hino authorized dealer or distributor. • It is the responsibility of Body and Equipment Manufacturers or modification companies to make sure that the completed vehicle with body and equipment, or after modification, conforms to all applicable laws and regulations of the country in which the vehicle is to be used (e. g. regulations on lighting, tilt, overall size, axle load, external noise control etc.) • This manual does not guarantee the safety of a Hino chassis once a body or equipment has been mounted or modification has been made by a Body and Equipment 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. • In case of the vehicle with SRS air bag, strictly follow the instructions of SRS air bag.

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ABOUT THIS MANUAL • About installation of T/M PTO (Vehicle with N04C series engine only) It can not control stable engine revolution because engine governor character is not switch to PTO mode if installed PTO unit whether Hino genuine or not by local market. Should not install the PTO unit at local market except mount body of unnecessary constant engine revolution such as dump truck but if oblige to install PTO unit, refer to chapter 5 for installing by own responsibility of Body and Equipment Manufacturers. • About chassis mass The chassis mass of chapter 3 shows standard specification of vehicle. (It is not included mass of option equipment.) When consider the mounting of body, should include mass of option equipment. • Each individual Body and Equipment Manufacturer has the sole responsibility for the design, functions, materials and work concerning the body and equipment. • Hino Motors, Ltd. does not assume any liability whatsoever for any injury to persons or damage to property caused as a result of the utilization of this manual.

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CONTENTS



1. VEHICLE 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 11. REGULATION

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Chapter 1 VEHICLE SUMMARY

1. MODEL CODE

2. IDENTIFICATION NUMBER

3. CHASSIS SPECIFICATIONS

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VEHICLE SUMMARY

1. MODEL CODE

XZ W XK

①

②

③

④

⑤

XZ

U

60

0

R

-

⑥

⑦

⑧

⑨

⑩

⑪

⑫

H

K

M

R

B

Q

3

①ENGINE TYPE CODE N04C-VM/US/UT, N04C-UV/VC N04C-UY/VA/VB W04D-TM/TN, W04D-J N04C-UR/UU/UW

⑥CAB TYPE H SINGLE Q DOUBLE ⑦BODY DECK HEIGHT CODE HIGH FLOOR K HIGH FLOOR DUMP M STEEL HIGH FLOOR B

②VEHICLE MODEL CODE 300 SERIES U CODE 60 63 64 65 66 70 71 72 73

CODE 0 5

L R

③MODEL SERIES CODE WHEEL BASE (mm) CAB DRIVE ～2525 2525 2800, 3075 NARROW 3400 3870 4X2 2810 3430 WIDE 3870 4200

M F T U

⑧TRANSMISSION CODE 5-SPEED (MECH.) 6-SPEED (MECH.) 6-SPEED (AUTO) 5-SPEED (MECH. AUTO)

⑨GVMR AND REAR TIRE TYPE CODE GVMR (ton) REAR TIRE TYPE CODE SINGLE ～　3.5 F DOUBLE ～　3.5 G 5.5 H SINGLE 4.3　～　5.1 L 5.5 M 6.5 Q DOUBLE 7.5 R 8 S 8.5 T

④ENGINE AND FRONT SUSPENSION CODE SUSPENSION SUSPENSION XK SUSPENSION W RIGID RIGID RIGID N04C W04D N04C INDEPENDENT INDEPENDENT INDEPENDENT XZ

⑤CHASSIS TYPE CODE LEFT HAND DRIVE RIGHT HAND DRIVE

J K L M N P Q R S T

NIL T R Q W D N V

3

KK-XZU337D

PS ～　110 ～　110 111　～　136

W

⑩ENGINE CODE EMISSION EURO-1 EURO-2 EURO-2

PS ～　110 111　～　136 137　～　150 ～　110 111　～　136 137　～　150 ～　110 111　～　136 137　～　150 151　～　199

XZ, XK

EMISSION EURO-3 EURO-3 EURO-3 EURO-4 EURO-4 EURO-4 EURO-5 EURO-5 EURO-5 EURO-5

⑪DESTINATTION CODE DESTINATION HANDLE POSITION EXPORT STANDARD LHD RHD THAILAND RHD TAIWAN LHD AUSTRALIA & NEW ZEALAND RHD EURO LHD RHD INDONESIA RHD SOUTH AFRICA RHD GCC LHD

⑫SHIPPING CODE CHASSIS WITH CAB

1

1

VEHICLE SUMMARY

2. IDENTIFICATION NUMBER CHASSIS

Located at the side member of chassis frame.

ENGINE • Model : N04C

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1

VEHICLE SUMMARY

3. CHASSIS SPECIFICATIONS NARROW CAB SERIES

Cab type Chassis model

XZU640L-HKMLN3

4X2 (4)

Drive system (number of wheels) Body application Wheel base Tread

( mm )

2800

( kg )

1350 4500

Front

( mm )

Rear

Max. GVM Rating Capacity (On std. Spec.)

Front

Axle

Rear

( kg )

Front

Tire

Rear

Chassis mass

( kg ) Model

Engine

-

2300

Double

XZU650L-HKMMP3

1400

2300

XZU710L-QKFMP3

3400 1435 2600 4400

5500

4360

N04-VC

ISO net

390{39.8}/1400

420{42.8}/1400

Disc

Front Rear Front Rear Std. Spec. Opt. Spec.

T/M P.T.O. NO. ( Refer to Chapter 5 )

Opt. Spec. Opt. Spec.

Alternator Recommended Max. body width

5100 2430 4480

Max. Torque ( N·m{kgf·m}/rpm )

Tire

(L) ( V - kC {Ah} - No. ) (V-A)

M550

205/75R16C-113/111 205/75R16C-113/111 16X5.5K-115mm 16X5.5K-115mm

-

NO.1 -

Std. Spec. Std. Spec. Opt. Spec. Std. Spec. Opt. Spec. ( mm )

100

-

Opt. Spec.

1900

24-60 24-80

1665

3870 1655

6500

110{150}/2500

( mm )

XZU720L-HKFRP3

2260 4300 Refer to Chapter 3-1. N04-UV

EURO-4 Refer to Chapter 3-1.

-

XZU710L-HKFQP3

General Cargo 3430 1660 1480

100{136}/2500

Transmission series

Battery

4X2(6)

ISO net

Height of gravity from ground

Fuel tank

XZU710L-HKFMP3

Max. Out put ( kW{PS}/rpm )

Exhaust emission control

Tire and disc (On std. Spec.)

WIDE CAB SERIES

215/85R16-E(10) 215/85R16-E(10) 16x5.5K-122mm 16x5.5K-122mm MYY6S

1520 3100

7500 5500 3200 6200

215/75R17.5-124/123 215/75R17.5-124/123 17.5x6.00-127mm 17.5x6.00-127mm

NO.2 NO.3 100+70

12-216{60}X2 12-288{80}X2 2200

24-80 24-60

[NOTE] • Permissible axle capacity and GVM or GCM capacity listed above table must not be exceeded. • The front axle load must exceed 30% of the gross vehicle mass under full loaded condition. • The height of center of gravity from ground on the unloaded vehicle with body mounted should be 0.82m or less. (Case of narrow cab, rear single tire) • The height of center of gravity from ground on the unloaded vehicle with body mounted should be 0.84m or less. (Case of narrow cab) • The height of center of gravity from ground on the unloaded vehicle with body mounted should be 0.95m or less. (Case of wide cab) • Weight distribution on the left and right wheels should be balanced. • Both front axle and rear axle loads must not exceed the permissible load based on the tire load capacity according to the tire standards in your country. • The dimension of tires to be mentioned in above chassis specification shows design figure according to JATMA or ETRTO standard.

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1

VEHICLE SUMMARY

Cab type

XKU710L-HKUMP3

Chassis model Drive system (number of wheels) Body application Wheel base Tread

( mm ) Front

( mm )

Rear

Max. GVM Rating Capacity (On std. Spec.)

( kg ) Front

Axle

Rear

( kg )

Front

Tire

Rear

Chassis mass

( kg )

1660 1480 5500 2600 4400 2300 4360

5100 2430 4480 Refer to Chapter 3-1. N04C-UU

Model Engine

Max. Out put ( kW{PS}/rpm )

ISO net

110{150}/2500

Max. Torque ( N·m{kgf·m}/rpm )

ISO net

420{42.8}/1400

Exhaust emission control Height of gravity from ground Tire and disc (On std. Spec.)

( mm ) Tire Disc

Front Rear Front Rear

Transmission series Std. Spec. Opt. Spec.

T/M P.T.O. NO. ( Refer to Chapter 5 )

Opt. Spec. Opt. Spec.

Fuel tank Battery Alternator Recommended Max. body width

WIDE CAB SERIES XKU710L-HKUQP3 4X2(6) General Cargo 3430 1665 1520 6500

(L) ( V - kC {Ah} - No. ) (V-A)

Std. Spec. Opt. Spec. Std. Spec. Opt. Spec. Std. Spec. Opt. Spec. ( mm )

205/75R16C-113/111 205/75R16C-113/111 16x5.5K-115mm 16x5.5K-115mm

EURO-4 Refer to Chapter 3-1. 215/85R16-E(10) 215/85R16-E(10) 16x5.5K-122mm 16x5.5K-122mm M550 AMT NO.1 100 12-216{60}X2 2200

KK-XZU337D

XKU710L-HKURP3

3100

1655 1590 7500 5500 3400 6200

215/75R17.5-124/123 215/75R17.5-124/123 17.5x6.00-127mm 17.5x6.00-127mm

4

Chapter 2 GENERAL PRECAUTIONS 1. FIRE SHIELD 2. CLEARANCE BETWEEN CAB AND REAR BODY OR EQUIPMENT 3. INSTALLATION OF WATER PROTECTION PLATE 4. RECOMMENDED POSITIONS OF U-BOLTS 5. RECOMMENDED POSITIONS OF REAR FENDERS AND MUDGUARDS 6. ELECTRIC WELDING WORK 7. NOTES ON ADDITIONAL WIRING IN THE ENGINE COMPARTMENT 8. NOTES ON ENGINE CONTROL, BRAKE ABS SYSTEM COMPUTERS AND DC-DC CONVERTER 9. PRECAUTION FOR ABS AND VSC 10. HANDLING OF PARTS FOR MEETING THE EXTERNAL NOISE CONTROL REGULATION 11. PRECAUTION FOR BODY MOUNTING WORK OF HYBRID VEHICLE 12. PRECAUTION FOR FUEL SYSTEM 13. PRECAUTION FOR EXHAUST SYSTEM 14. INSTALLATION PROCEDURE OF FREEZING COMPRESSOR (OPT) 15. INCLINATION DEFAULT ADJUSTMENT OF THE INCLINATION SENSOR 16. PRECAUTION FOR ADJUSTMENT OF THE TIRE AIR PRESSURE 17. PRECAUTION FOR INSTALLING TIRE DISC WHEEL ONTO THE VEHICLE 18. ADJUSTMENT OF HEADLAMP LIGHT AXIS 19. ADJUSTMENT OF FOG LAMP LIGHT AXIS 20. HOW TO REMOVE THE INSTRUMENT PANEL COVER (NARROW CAB) 21. HOW TO REMOVE THE INSTRUMENT PANEL COVER (WIDE CAB) 22. PRECAUTION FOR REINSTALLING WASHER TANK INLET 23. PRECAUTION FOR AUTO CLUTCH UNIT 24. PROVISION FOR AM RADIO NOISE KK-XZU337D

2

GENERAL PRECAUTIONS

1. FIRE SHIELD

1) Gap Between Cab Rear End and Body

When a flat bed or similar body has been mounted, a fire shield should be fitted across the gap between the cab rear end and the front end of the load platform frame to prevent fires that may be caused by flammable materials falling off from the load platform onto the exhaust pipe (see figure below). A fire shield is not necessary if the body is fitted with a sheet 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 parts of cab.

・For approximately 50mm from the front edge of fire 　shield (the cab side), use rubber to match the shape 　of the fire shield to that of the cab rear end such 　as cab back cover. ・You may also install the fire shield so that it covers only the exhaust system. CAB BACK COVER ( CASE OF WIDE S/CAB ) CAB REAR END （ CASE OF WIDE D/CAB ） RR ARCH COVER （ CASE OF NARROW S/CAB ） RUBBER FIRE SHIELD BOLT&NUT BODY OR EQUIPMENT

KK-XZU337D

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2

GENERAL PRECAUTIONS

2. CLEARANCE BETWEEN CAB AND REAR BODY OR EQUIPMENT

The rear parts of the cab contains the cab lock mechanism or stack exhaust pipe as well 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) NARROW CAB series



Unit : mm 590 (For Full stack) 580 (For Half stack)

(2) WIDE CAB series

560

KK-XZU337D

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2

GENERAL PRECAUTIONS (3) DOUBLE CAB (WIDE CAB series)



Unit : mm

KK-XZU337D

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2

GENERAL PRECAUTIONS 2) Measurement of the Engine Air Intake Port • CAB TYPE

: NARROW CAB

Unit : mm

• ENGINE MODEL : N04C • DUCT TYPE

: HALF STACK

CLAMP

CLAMP Do not install any parts of body and equipment around the clamps. Make sure that there is enough working space for the clamps.

KK-XZU337D

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2

GENERAL PRECAUTIONS • CAB TYPE

: NARROW CAB

Unit : mm

• ENGINE MODEL : N04C • DUCT TYPE

: FULL STACK

CLAMP

CLAMP Do not install any parts of body and equipment around the clamps. Make sure that there is enough working space for the clamps.

KK-XZU337D

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2

GENERAL PRECAUTIONS • CAB TYPE

: WIDE CAB

Unit : mm

• ENGINE MODEL : N04C • DUCT TYPE

: HALF STACK

CLAMP

CLAMP

Do not install any parts of body and equipment around the clamps. Make sure that there is enough working space for the clamps.

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2

GENERAL PRECAUTIONS • CAB TYPE

: WIDE CAB

Unit : mm

• ENGINE MODEL : N04C • DUCT TYPE

: FULL STACK

CLAMP

CLAMP

Do not install any parts of body and equipment around the clamps. Make sure that there is enough working space for the clamps.

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2

GENERAL PRECAUTIONS • CAB TYPE

: WIDE DOUBLE CAB

Unit : mm

• ENGINE MODEL : N04C

CLAMP

CLAMP Do not install any parts of body and equipment around the clamps. Make sure that there is enough working space for the clamps.

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2

GENERAL PRECAUTIONS 3) Minimum Clearance with Cab Outer Shell

• Even under normal driving conditions, when the cab is not tilted, it moves back and front, 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 the cab is tilted, allow at least 40 mm clearance the cab and rear body or equipment.

MIN. 40mm

TILT CENTER

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2

GENERAL PRECAUTIONS 4) Contained Equipment of Cab Rear End

The rear parts of the cab contains the cab lock mechanism and the tilt mechanism, as well as the 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. 4)Contained Equipment of Cab Rear End MIN. 50 mm

Minimum clearance from cab back to front end of body or equipment. Rear end of cab tilt mechanism or various equipment.

For details of cab dimensions, see chassis drawings. [ EXAMPLE ]

KK-XZU337D

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2

GENERAL PRECAUTIONS

3. INSTALLATION OF WATER PROTECTION PLATE (FOR HALF STACK AIR INTAKE DUCT) Install stainless steel plate to prevent water into air intake duct if the air intake duct is half stack type. Detail as follows.

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2

GENERAL PRECAUTIONS

4. RECOMMENDED POSITIONS OF U-BOLTS [NOTES]

(1) The details of setting positions of the U-bolt are shown in following figure.

Fasten the U-bolt as much as possible to the positions described in following figure when a body or equipment are going to be mounted to the chassis.

(2) If the U-bolt positions are to be altered according to the constructions or kinds of the body, determine the place where U-bolt to be fastened after carefully studies the condition of the chassis to prevent contact with the brake pipes, hoses and harness wires.

CHASSIS MODEL

W/B (mm)

1

XZU, WU

2525

2

XZU, WU

3

XKU

4

XZU, WU

3075

5

XZU, WU, XKU

3400

6

XZU, WU

2810

7

XZU, WU

8

XKU

9

XZU, WU, XKU

10

XZU, WU

11

XKU

12

XZU, WU

3430

13

XZU, WU

3870

14

XZU, WU

4200

NO.

2800

CAB TYPE

NARROW CAB

3430 3870

WIDE CAB

4200

WIDE DOUBLE-CAB

POSITION RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH RH LH

KK-XZU337D

L1

DIMENSION (mm) L2 L3 L4

L5

1560

-

85

-

1000

1830

-

255

-

1235

1830

900 950

-

-

1235

2105

-

255

-

1235

2435

845

-

-

1410

1780

-

172

-

950

2400

861

-

-

1360

2400

971

-

-

1360

2840 1120

-

-

1530

3150 1545 3165 1925

172

-

1380

3170 1745

172

-

1380

164

-

1360

-

-

1530

172

-

1380

1352 1302 1792 1070 1742 2122 2072

12

2

GENERAL PRECAUTIONS

5. RECOMMENDED POSITIONS OF REAR FENDERS AND MUDGUARDS When mounting rear fenders and mudguards, determine required clearances with reference to the following table and figures of "MAXIMUM VERTICAL DEFLECTION OF REAR WHEEL" in 4-2.

1) Rear Fender

[NOTE] The dimension of tire to be mentioned the next page's table shows design figure according to JATMA or ETRTO standard.

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2

GENERAL PRECAUTIONS Unit : mm

MODEL

REAR TIRE SIZE

A

B

C

XZU640L-HKMLN3

205/75R16C-113/111

1555

1575

1350

205

7.00R16-12

1546

1566

1350

209

205/75R16C-113/111

1869

1889

1435

132

7.00R16-10

1860

1880

1435

136

7.00R16-12

1860

1880

1435

136

7.00R16-10

1905

1925

1480

134

205/75R16C-113/111

1914

1934

1480

129

7.00R16-10

1905

1925

1480

134

205/75R16C-113/111

1914

1934

1480

129

215/85R16-E(10)

1982

2002

1520

136

7.50R16-10

1985

2005

1520

133

215/75R17.5-124/123

1988

2008

1520

133

7.50R16-12

1985

2005

1520

133

205/75R16C-113/111

1915

1935

1480

130

215/85R16-E(10)

1982

2002

1520

136

215/75R17.5-124/123

1988

2008

1520

133

215/75R17.5-124/123

2058

2078

1590

168

XZU650L-HKMMP3 XZU710L-QKFMP3 XZU710L-HKFMP3 XZU710L-HKFQP3 XZU720L-HKFRP3 XKU710L-HKUMP3 XKU710L-HKUQP3 XKU710L-HKURP3

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2

GENERAL PRECAUTIONS 2) Mudguards

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2

GENERAL PRECAUTIONS

6. ELECTRIC WELDING WORK Electric equipments such as ABS-ECU and Engine control computer and other electric parts which always need electric power are connected directly to the battery and the ground. If the welding is performed in this condition, an electric current of welding may flow reversely into the electric parts from their ground circuit resulting in damage to the electric parts. Since welded parts becomes extremely hot and sparks are present, remove the fuel tank or battery when welding near those units. Make sure that there are no items present such as harnesses, nylon tubes, pipes, resin clips for piping, suspension components such as spring brackets and spring leaves which may be damaged. Do not arc strike on the chassis frame flanges. Do not weld any components such as engine, transmission, axle, spring, propeller shaft or steering. Do not weld any body parts or mounting brackets on the chassis frame for mounting of the rear body. Avoid welding additional parts onto the chassis frame except for parts used for the purpose of reinforcement. The ground of the arc welding machine must be connected to a low resistance parts such as the side rail. Never connect the ground to plated parts such as fuel pipes, brake pipes or exhaust pipe. When ground to the side rail, be sure to peel off the paint and apply under coat paint after work.

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2

GENERAL PRECAUTIONS Be sure to observe the following precautions when operating electric welding. For hybrid vehicle, also follow the section “PRECAUTION FOR BODY MOUNTING WORK OF HYBRID VEHICLE” in Chapter 2. 1) Procedure before welding

sure to wear the electric insulation equipment such as insulation * • Be rubber gloves during working. • Turn the starter switch to "LOCK" position. • Wait more than 90 seconds if SRS air bag is equipped.

out a service plug of PCU and must wait more than 7 minutes for * • Pull discharging electricity of a high-voltage condenser in the motor and generator control inverter. (See the "DETAIL OF SERVICE PLUG".)

Strictly observe above working manner to avoid getting an electric shock. • Disconnect the negative terminal of the battery. • Disconnect the connector of DC-DC converter if it is equipped.

the connector of DC-DC converter for hybrid system. * • Disconnect • Disconnect fuse(s) of engine control ECU, SRS air bag and ECU of the each electric instrument if they are equipped.

• Disconnect the connector of ABS/VSC-ECU unit if it is equipped.

all the signal circuit connectors in PCU after disconnect the * • Disconnect connector cover of PCU. (See the "DETAIL OF SIGNAL CIRCUIT CONNECTOR".)

See the next page figure for the detail of position of fuse, ECU and DC-DC converter for reference. Refer to Section “PRECAUTION FOR ABS AND VSC” in Chapter 2 for connector's position of ABS/VSC-ECU unit. Marked

* for hybrid vehicle (XKU series) only.

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2

GENERAL PRECAUTIONS

IGN (12V) ECU-B (12V)

37

AIR BAG (12V)

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

38 39

ECU-IG NO.1

DC-DC CONVERTER (WIDE CAB)

DC-DC CONVERTER (NARROW CAB)

ECU-IG NO.2 ECU-B E/G CONTROL ECU

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GENERAL PRECAUTIONS DETAIL OF SERVICE PLUG PCU

Service Plug Cover

Bolt ×4 Service Plug

・Procedure of the SERVICE PLUG removal

①

②

①Slide the grip to the left. ②Raise the grip. ③Extract the SERVICE PLUG.

③

・Procedure of the SERVICE PLUG reinstallation

①

②

①Insert the SERVICE PLUG. ②Push down the grip, and Slide the grip to the right certainly till it is locked.

※

※Confirm that the projection fit in a hole, otherwise engine doesn't start.

Do not put back the service plug until the end of welding operation.

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GENERAL PRECAUTIONS DETAIL OF SIGNAL CIRCUIT CONNECTOR PCU

UP

CHASSIS CENTER FR

Connector Cover

Connector A

Wire Harness of Signal Circuit

Connector C Connector B

Connector C Connector B

Connector A

Lock

A

Lever

Unlock the lock and cancel it.

Push down the lever, and disconnect the connector.

The connector of chassis side.

DETAIL OF A

• When reinstall connectors, in reverse manner the following above instructions. KK-XZU337D

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GENERAL PRECAUTIONS 2) Ground of the Welding Equipment Connect the ground of the welding equipment near the location to be welded. Welding to the chassis frame • Connect the ground to the bolt (plating bolt) or chassis frame near the place where to be welded. • Remove component finish to be welded. • Do not connect the ground to the chassis spring to prevent damage of spring. Welding to the cab body • Connect the ground to the fixing bolt of cab hinge after remove the front radiator grille or the cab body.

3) Other Precautions • To protect ancillary equipment from sparks during welding, put fire-resistant covers over the rubber hoses, wire harness, pipes, spring and tires, etc. • Weld under proper conditions. Minimize the heat generation of the work area as much as possible to maintain the weld integrity.

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GENERAL PRECAUTIONS <Example current flow of electric welding when weld to cab body> Case of disconnecting the negative terminal of BATTERY Turn the STARTER SWITCH to LOCK position. Do not turn on the STARTER SWITCH when the earth wire is disconnected.

WELDING ROD

EARTH OF EQUIPMENTS

ELECTRIC EQUIPMENTS

ARC WELDING MACHINE

+ EARTH WIRE OF CAB

–

GOOD

CHASSIS FRAME

BATTERY

Do not disconnect at CHASSIS FRAME. Disconnect the negative terminal of BATTERY.

Case of connecting the negative terminal of BATTERY ELECTRIC EQUIPMENTS will be damaged. WELDING ROD EARTH OF EQUIPMENTS

ELECTRIC EQUIPMENTS

ARC WELDING MACHINE

STARTER SWITCH

+

–

NG

CHASSIS FRAME

EARTH WIRE OF CAB BATTERY

WELDING ROD

CAB

ELECTRIC EQUIPMENTS

BATTERY

EARTH of ARC WELDING MACHINE

EARTH WIRE OF CAB

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GENERAL PRECAUTIONS 4) After Welding

sure to connect all the signal connectors in PCU. * • Be • Reinstall fuse(s). • Be sure to connect the connector of ABS/VSC-ECU unit if disconnected.

sure to connect the DC-DC converter for hybrid system. * • Be • Be sure to connect the DC-DC converter if disconnected.

• Be sure to connect the negative terminal of the battery, and the terminal should be horizontal. BATTERY TERMINAL

NO GOOD

B

GOOD

A

2

BATTERY A : B = SAME LEVEL

• Replace finish carried out in previous step where welding work was carried out. Finish should be of equal or greater quality and remain the same color. 5) Final Inspection after Welding • Reinstall each electric equipment to original place.

back a service plug to PCU. * • Put (See the "DETAIL OF SERVICE PLUG".)

• Inspect the operation and function of all electric equipment. • For the detail of inspection’s procedure, please consult Hino authorized dealer or distributor. Marked

* for hybrid vehicle (XKU series) only.

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GENERAL PRECAUTIONS

7. NOTES ON ADDITIONAL WIRING IN THE ENGINE COMPARTMENT Since 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(s) should be kept away from heated elements, and should be routed along the main harness.

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GENERAL PRECAUTIONS

8. NOTES ON ENGINE CONTROL, BRAKE ABS SYSTEM COMPUTERS AND DC-DC CONVERTER (It depend on vehicle specifications) Engine control and brake ABS computers are installed on the inside of the instrument panel. See the figure below. Therefore, give great care to the computer and converter when performing any body mounting work or modification as following points. Strictly follow the instructions of SRS air bag before body mounting work or modification if the SRS air bag is equipped. 1) Be sure to follow the all instruction to be described to Section “ELECTRIC WELDING WORK” and “PRECAUTION FOR BODY MOUNTING WORK OF HYBRID VEHICLE” in Chapter 2 before peforming electric welding.

*

2) Be sure to cover the computer and converter to protect from water penetration when performing cleaning up the inside of cab. 3) When installing such device as radiophone and wireless communication device, must use the device that built-in noise-killer such as condenser or diode, and install it on the place where from the computers and its harness as far as possible. Do not install any high output (over 50w) device. Be sure to check that there is no abnormal electric wave or electromagnetic wave after installed the device which affects on the electrical signals passing through in computer harness. If found abnormality, please contact Hino authorized dealer or distributor. 4) Do not alter the computer, converter, harness wire and sensors. 5) Do not give any shock to the computer and converter.

‌ not remove or peel off the plastic sheet covering the 22A DC-DC * 6) Do converter. Marked

* for hybrid vehicle (XKU series) only.

DC-DC CONVERTER (NARROW CAB)

DC-DC CONVERTER (WIDE CAB)

E/G CONTROL ECU

• Refer to next page for installing position of DC-DC converter. KK-XZU337D

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GENERAL PRECAUTIONS NARROW CAB

• 10A DC-DC CONVERTER

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GENERAL PRECAUTIONS WIDE CAB

• 10A DC-DC CONVERTER (The installation position is inside of the instrument panel of passenger side.)

• 22A DC-DC CONVERTER ( XKU SERIES ONLY )

• The figure shows RHD vehicle, LHD vehicle is symmetry. KK-XZU337D

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GENERAL PRECAUTIONS

9. PRECAUTION FOR ABS AND VSC Be sure to observe the following precautions for proper operation of each equipment when mounting body if ABS or VSC is equipped.

1) Strictly prohibited item

(1) Alteration, modification and taking off the electric power Do not move, alter and modify ABS/VSC-ECU integrated hydro unit, brake piping and ABS/VSC harness. Do not use ABS/VSC harness as power supply for audio device and auxiliary light. (2) Change of tire size Do not change the tire size, because the information of tire size has been installed in ABS/VSC-ECU. The meter indicates different speed from actual speed if changed a tire which size is not specified standard specification. (3) Shock/impact ABS/VSC-ECU integrated hydro unit is installed between No.1 and No.2 cross member. Do not give any shock to ABS/VSC-ECU such as step on by foot, because it is a delicate device. When washing vehicle, avoid watering directly with high pressure to ABS/ VSC-ECU. (4) Change of installing position and direction Do not alter and change of installing direction of the yaw rate sensor which is provided under the assistant seat to avoid malfunction of VSC. (5) Change of wheelbase length Do not alter the wheelbase length to avoid malfunction of ABS/VSC. Because the information of wheelbase length has been install ABS/VSCECU.

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GENERAL PRECAUTIONS 2) Precaution

(1) For electric welding Be sure to follow the all instructions about electric welding work in chapter 2. (2) About noise If install the following parts near ABS/VSC-ECU integrated hydro unit, allow sufficient clearance more than 100mm from it. Radio transmitting and receiving apparatus such as two-way radio and related antenna or harness, motor, relay or other machinery which causes noise. (3) For wiring Do not wire antenna wiring of two-way radio along with vehicle harness which goes through inside of the frame, as it may affect the wiring of ABS/ VSC-ECU which is in the vehicle harness. (4) For replacement of parts When performing the following items the vehicle with VSC, should conduct default adjustment to G-sensor or yaw rate sensor. For the detail of default adjustment , please consult Hino authorized dealer or distributor. - Replacement of ABS/VSC unit - Removing and reinstalling of yaw rate sensor (5) After completion of body mounting Check carefully if there is any damage to the piping or harness after mounting body. ABS/VSC needs the inspection after mounting body. Please consult Hino authorized dealer or distributor for detailed information of inspection. If turn the starter switch on under disconnecting the harness of rear combination lamp circuit, ABS warning lamp in combination meter is on by ABS diagnosis system with detecting abnormal condition (diag-code C1425) of the harness of rear combination lamp circuit when mounting body. Reconnect the harness of the rear combination lamp circuit, and turn the starter switch on again, and then ABS warning lamp is off but the diagcode C1425 is still remained in ABS computer, therefore, do not forget to erase diag-code from ABS computer. Please consult Hino authorized dealer or distributor for detailed information of erasing diag-code. (6) Others to check If two-way radio or other electric device for use while moving is set, conduct ABS/VSC inspection with such device working. If electric device for use while parking is set, put it in action while starter switch on or engine is running and check if there is malfunction of ABS/ VSC or warning light is on. KK-XZU337D

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GENERAL PRECAUTIONS 3) Position of ABS ECU integrated hydro unit For NARROW CAB

For WIDE CAB

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GENERAL PRECAUTIONS

10. ‌HANDLING OF PARTS FOR MEETING THE EXTERNAL NOISE CONTROL REGULATION To comply with the external noise control regulation, parts for external noise reduction, such as sound-insulating materials (cover, rubber) soundabsorbing materials, muffler etc., are equipped on the cab, the engine and the chassis. Since the parts for external noise reduction and their fitting locations are depending on the vehicle model. To ensure external noise reductions, 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 mounting a superstructure, handle them carefully to prevent their deformation and/or damage, and be sure attach them on original position after completion of mounting the superstructure. If the parts for external noise reduction have been deformed and/or damaged, replace them with genuine parts and never use rectified parts.

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GENERAL PRECAUTIONS

11. PRECAUTION FOR BODY MOUNTING WORK OF HYBRID VEHICLE

Be sure to observe the following instructions when mounting body for hybrid vehicle. If there is the laws and regulations for handling high - voltage device, should follow them, and operate mounting work. The following figure is the installing position of hybrid system related equipment. Their position may be different based on vehicle model.

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GENERAL PRECAUTIONS 1) Do not modify and relocate PCU It may have an accident such as fall off PCU caused by installing strength, and get an electric shock by high - voltage.

2) Precaution for mounting body • ‌Be sure to wear the electric insulation equipment such as insulation rubber groves during working. • Turn the starter switch to “LOCK” position. • ‌Pull out a service plug of PCU and must wait 7 minutes for discharging electricity of a high - voltage condenser in the motor and generator control inverter, and then disconnect negative terminal of the battery. Strictly observe above working manner to avoid getting an electric shock. • Do not touch the orange color harness which is high - voltage wire. • Do not step and get on the PCU. • Must protect the PCU with heat - resistant sheet during operation. • ‌After mounted body, be sure to put back service plug of PCU, and connect the negative terminal of battery. • ‌Turn the starter switch on, and then check the function of the PCU. If there is problem of function, please contact Hino authorized dealer or distributor and receive proper advice. Refer to the section “WELDING WORK” in Chapter 2 for service plug of PCU.

3) Precaution for mounting body with welding work • ‌Follow the precaution above and see the section “ELECTRIC WELDING WORK” in Chapter 2.

4) Precaution for checking mounted of body function Do not check operating for the body function with engine racing on neutral position of transmission for a long time. Because the 24V battery may be discharged. If charge lamp is on, do not stop the engine and turn off unnecessary electric parts such as head lamp and leave this situation until the indicator level of hybrid battery shows 2 or more. Should follow the instructions below when check operating for the body function with more than idling revolutions. • Increase revolutions by idle volume switch. (Max. 1200rpm) • By driving condition with D position of transmission.

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GENERAL PRECAUTIONS 5) Precaution for mounting body around PCU The PCU has the vent for ventilating and the lid for service as followings. • BATTERY COOLING INLET • RADIATOR COOLING INLET • REAR COVER OF VENTILATION • SERVICE PLUG COVER • CONNECTOR COVER Do not cover them by body equipment to avoid deteriorating ventilation. If cooling capability is decreased, HV function such as assist and charge of HV battery may be affected. Therefore, be sure to observe the following instructions when mounting body or equipment.

(1) The cooling inlet Upper View

Line of outside FRONT OF VEHICLE

The flow area of intake air Do not mount body and equipment this area.

Battery Cooling Inlet

Opening area

Radiator Cooling Inlet

Side View

Opening demension (mm) Opening area (c㎡)

Battery Cooling Inlet

Radiator Cooling Inlet

240 x 85

255 x 85

205

215

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GENERAL PRECAUTIONS (2) The rear cover of ventilation Do not modify the rear cover. Rear cover of ventilation

(3) The service plug cover Upper View

Line of outside

FRONT OF VEHICLE

Working space Do not mount body and equipment this area.

Service Plug Cover Service plug cover

Side View

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GENERAL PRECAUTIONS 6) Vehicle storage If you store a hybrid vehicle for a long time, check the battery level in the meter once a month. If the indicator level shows 1 or less, start the engine and keep idle for approximately 30 min.. If the auxiliary battery terminal of the hybrid vehicle is disconnected, start the engine and keep idle for approximately 30min. even if the indicator level shows 2 or more. CAUTION If the hybrid vehicle is stored for a long time without the process as above, you may not be able to start the engine.

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GENERAL PRECAUTIONS

12. PRECAUTION FOR FUEL SYSTEM Do not alter and modify any parts of fuel system. If hose or pipes of fuel system are any damaged, be sure to observe the following precautions for safety drive and prevention of troubles. Should use Hino genuine parts or follow the instructions below for repairing. Do not use the following materials to fuel system including biodiesel fuel. Natural rubber, Butyl rubber, Nitrile rubber, Copper, Bronze, Brass, Tin, Lead and Zinc. Use material as the follows. • Fuel Hose ; Fluorine rubber (Inner side or All) • Fuel Piping ; Nickel Plating (Inner side) • Fuel Tank ; Aluminum Plating, Aluminum tank and Tin-Zinc Plating

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GENERAL PRECAUTIONS

13. PRECAUTION FOR EXHAUST SYSTEM Modifying the exhaust system has a major effect on vehicle performance, gaseous emission and external noise. As a rule, the exhaust system must not be modified. Do not modify any parts the area shown in the figure below.

Do not modify any parts such as Catalyst Muffler of exhaust system this area.

Exhaust tail pipe

Front pipe

Catalyst Muffler

The Catalyst Muffler is equipped to comply with exhaust gaseous emission control regulation. Be sure to observe the following precautions for the catalyst muffler. • ‌Do not water into the muffler when washing the vehicle, especially under parts of the chassis. • ‌Do not give any shock such as dropping and hitting to the muffler when handling. If modify the tail pipe such as installing a fire arrester, be sure to observe the following precautions.

1) ‌The diameter, material and thickness of the tail pipe should use the same as base's vehicle ones. Recommended material : Stainless steel pipe and silver color



2) If ‌ welding the Stainless steel pipe, deteriorate rust-resistance, therefore, should paint the heat-resistant painting of same color after welded.



3) ‌The exhaust resistance raises with extending and additional bending of tail pipe, and may be lead to decline in engine output and increase in the fuel consumption and exhaust gas density. If obliged to modify such as the case, should be following conditions. • The diameter of extending pipe should use same as base's vehicle. • Inside ‌ bending radius of the tail pipe should be at least 1.5 times the diameter of the pipe.

4) ‌The manner of the supporting tail pipe and another details should be follow the common manual KC-AA102.

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GENERAL PRECAUTIONS Clearances between exhaust parts and other parts The exhaust system become very hot during operation, therefore, be sure to observe the following procedures to prevent unexpected problems. 1) ‌Clearance from body parts • Should follow the precautions for mounting of exhaust system. 2) ‌Clearance from fuel system parts • ‌Maintain a clearance of at least 200 mm between the fuel tank, fuel hose or pipes and the hot parts of the exhaust system. If cannot maintain a clearance of 200 mm, should fit the heat insulators to protect the fuel tank and fuel hose or pipes. When arranging the fuel piping, make sure that even if a fuel line break and fuel leaks out, fuel should not contact with hot parts of the exhaust system. • ‌Do must not make a joints of the fuel piping above the hot parts of the exhaust system. • ‌When moving the fuel tank or installing an additional tank, make sure that the filling port is at least 300 mm away from mouth of the tail pipe and at least 200 mm away from exposed electrical terminals. 3) Clearance ‌ from other chassis parts • ‌Maintain the clearance shown the table below. If cannot maintain these clearance, should fit the heat insulators.

The heat influence and interference of the exhaust pipe and muffler for the exhaust system are very important items for safety, therefore, make sure that secure a sufficient clearance between the related parts of exhaust system such as exhaust pipe and muffler and body and equipments, and check the temperature if need, then make sure that it is no problem for safety.

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GENERAL PRECAUTIONS

14. INSTALLATION PROCEDURE OF FREEZING COMPRESSOR (OPT) 1) REGARDING BRACKET KIT FOR INSTALLATION OF FREEZING COMPRESSOR

Follow the instruction below for installation of freezing compressor bracket kit. Make sure to select the option of vehicle specification to include the kit in packing, otherwise the kit will not be included and installation of freezing compressor will not be possible. The compressor which can be recommended are the following.

CHART OF THE COMPRESSOR SETTING KIT COMPRESSOR TYPE MODEL SWASH PLATE DKS22 THERMO KING SWASH PLATE SD7H13 DKS22 TOSHIBA CARRIER SWASH PLATE IN-LINE, 2CYL TM125 SWASH PLATE SD7H15 TOPRE ( ) SWASH PLATE DKS18-X SWASH PLATE DKS22-X RYOJYU COLD CHAIN SCROLL CS55V SCROLL CS90V RYOJYU COLD CHAIN ( ) SCROLL CS150V

COMPRESSOR

MANUFACTURER

• Marked

ENGINE N04C

COMPRESSOR BRACKET

: Except narrow cab LHD models.

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GENERAL PRECAUTIONS 2) PRECAUTIONS AT MOUNTING FREEZING COMPRESSOR (1) Mounting of compressor

Select compressor installation bracket kit as option. For installation of compressor with the included bracket, processing (perforation) is necessary. Follow the instruction on the attached figures as positions of perforation are different for types of compressor.

(2) Change of vehicle weight

When considering mounting freezing compressor, note that the load on front axle will increase for about 20Kg.

(3) Engine Control

When installing freezing compressor, make connection so that the working signal of the compressor will be given to engine ECU.

3) REGARDING IDLE-UP CIRCUIT FOR FREEZER

(1) Electric circuit to increase idle revolution is set up in order to prevent battery discharge when freezer is working. ENGINE MODEL ENGINE REVOLUTION (r/min)

N04C IDLE-UP LESS WITH IDLE-UP

650±50 850±50

Note ; Link warning signal of freezer's electromagnetic clutch to idle-up circuit of engine ECU. (2) How to link idle-up circuit

Link to the spare wiring for freezer's idle up which is inside of instrument panel of cab. The connector position and specification is as below.

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GENERAL PRECAUTIONS • CONNECTOR POSITION [ NARROW CAB ]

DETAIL OF A

KK-XZU337D

42

2

GENERAL PRECAUTIONS [ WIDE CAB ]

DETAIL OF A

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GENERAL PRECAUTIONS • HOW TO TAKE ELECTRICITY FROM POWER SUPPLY CIRCUIT

NOTE

• We recommend sub-harness type. • If you must take power using direct connecting type, be sure to observe the precautions in described COMMON MANUAL, Chapter 7-11 “HARNESS WIRING”.

• DETAIL OF CONNECTOR (PART NO. & POLE ARRANGEMENT)

A1

PART NO. OF CONNECTOR : 82824-37420 (WHITE COLOR)

• SPARE POWER SUPPLY AND POSITION CONNECTOR POLE CODE MARK CAB SIDE

#89

A1

CIRCUIT (MAIN APPLICATION)

MAX CAPA. (A)

IDLE-UP SIGNAL FROM BODY & EQUIPMENTS

0.1~0.2 * (ONLY SIGNAL)

WIRE SIZE USING WIRE & COLOR LENGTH (m) 0.50 (B)

1.6

CONNECTOR PART NO.

COUPLING CONNECTOR PART NO. (SPARE PARTS)

82824-37420

Cautions ;

* : Use for idle-up signal of working relay of body & equipements.

Use relay of surge absorption diode or relay with resistance (Part No. 90987-02017). For wiring, observe the common manual Chapter 7-12 "ELECTRIC WIRE SIZE AND PERMISSIBLE CURRENTS" about the length from fuse to spare power supply, kind, and size of wire. KK-XZU337D

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GENERAL PRECAUTIONS • IDLE-UP CIRCUIT OF FREEZING COMPRESSOR

FL

POWER SUPPLY

SWITCH

SURGE SUPPRESSION DIODE

CIRCUIT OF BODY SIDE

FREEZING COMPRESSOR

2G 0.50 BLACK

#89 (CLT)

TO BE PREPARED BY BODY MANUFACTURER

2P 0.35 BLACK

+2A

+2A

WIRE TO WIRE

EBZ (IDUP)

CIRCUIT OF CHASSIS SIDE

2

ENGINE CONTROL ECU

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GENERAL PRECAUTIONS 4) MOUNTING OF FREEZING COMPRESSOR (1) DETAIL OF THE COMPRESSOR SETTING KIT

KK-XZU337D

46

2

GENERAL PRECAUTIONS

Unit : mm

KK-XZU337D

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GENERAL PRECAUTIONS

Unit : mm

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GENERAL PRECAUTIONS ※About tightening idler pulley assy. Tighten Idler pulley assy according to the following procedure. ・ Tighten Center Nut (b) by 44N・m torque, after belt V adjusted in tightening Adjust Nut (a). ・ Tighten Adjust Nut (a) by of 6N・m torque.

Adjust Nut (a) （Ｔ＝６Ｎ・ｍ）

Center Nut (b) （Ｔ＝４４Ｎ・ｍ）

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GENERAL PRECAUTIONS (2) POINTS OF PERFORATION AND IMPOSITION OF INSTALLATION PARTS

Unit : mm

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GENERAL PRECAUTIONS (3) DETAIL ABOUT DRIVING PULLEY OF FREEZING COMPRESSOR

Unit : mm Driving pulley of freezing compressor

Timing gear case side Rh Fr

Detail of tension pulley

Detail of crank pulley

Freezing compressor driving belt

＜The upper side view＞

Freezing compressor driving belt

Up

Tension pulley 　φ89.4

A

Fr

＜The left side view＞

Freezing compressor

Fr Rh

Crank pulley 　φ168

SECTION A-A KK-XZU337D

A 51

2

GENERAL PRECAUTIONS 5) PRECAUTIONS ABOUT CLEARANCE FOR MOUNTED FREEZING COMPRESSOR



Be sure to observe the following instructions when mounting freezing compressor.

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GENERAL PRECAUTIONS

15. INCLINATION DEFAULT ADJUSTMENT OF THE INCLINATION SENSOR (FOR A860E AT OR AMT TRANSMISSION ONLY)

The G sensor is installed on the vehicle's control ECU of AT or AMT (Automated Manual Transmission) vehicle which has HINO STOP & START SYSTEM function. The inclination information is generated based on the signals from the G sensor and used for controlling HINO STOP & START SYSTEM and other function, too. It need to conduct default adjustment for proper generation of the inclination information after mounted of body. (It is also possible to conduct the inclination default adjustment at Hino-DX beside the following instructions.) ※If the AT/AMT vehicle with HINO STOP & START SYSTEM were installed the VSC, it doesn't need this process because the G sensor is installed the VSC side. The relevant vehicles : VSC - LESS vehicle and AT or AMT with HINO STOP & START SYSTEM function Follow the below instructions when readjustment to conduct default for the inclination information.

1) Preparation (1) Make sure that the vehicle is the following conditions. • Parking the vehicle on the horizontal place. • The starter key is on but the engine is off. • The parking brake is pulled. (2) Grand short the TC terminal of inside DLC connector. (See Fig.1. Short-circuit between TC and CG) (3) In the above conditions, pushed the HINO STOP & START SYSTEM cancellation switch more than three second.

2) Inclination default adjustment Inclination default adjustment will be start after the above operation is conducted. Make sure that the buzzer and ES start indicator lamp shows such as the followings. [Judgment criteria] • The buzzer sounds intermittently. • The indicator lamp blinks. (During the buzzer and indicator lamp are in the above conditions, the vehicle's control ECU is conducting default adjustment.) 3) Completion of inclination default adjustment When the buzzer and indicator lamp into the above conditions, release HINO STOP & START SYSTEM cancellation switch then default adjustment process is completed in about one second. KK-XZU337D

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GENERAL PRECAUTIONS • THE TABLE OF DLC CONNECTOR POSITION

KK-XZU337D

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GENERAL PRECAUTIONS • DETAIL OF DLC CONNECTOR POSITION

THE FIGURE SHOWS FRONT SIDE OF BRAKE BOOSTER.

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GENERAL PRECAUTIONS

16. PRECAUTION FOR ADJUSTMENT OF THE TIRE AIR PRESSURE The air pressure of tire is low for easy to transport when shipped out chassis with cab condition. Therefore, it need to adjust the proper air pressure of tire after mounting body. (When adjusting the tire air pressure, see the owner's manual or the label which shows proper air pressure putted on door pillar.)

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GENERAL PRECAUTIONS

17. PRECAUTION FOR INSTALLING TIRE DISC WHEEL ONTO THE VEHICLE Remove foreign matter when sticking a dust and etc. onto the thread of bolt. Replace with new bolt when thread of bolt is damaged. Make sure that there is no foreign matter such as dust and paints drip on the contact surface of hub and tire disc wheel. Make sure that there is no foreign matter such as dust and paints drip on the contact seat of tire disc wheel where to be tightened by wheel nut. Make sure that there is no foreign matter such as dust on the contact surface of wheel nut where to be contacted with tire disc wheel.

CAUTION

!

Never use oil or grease on the stop bolts or wheel bolts. Doing so may lead to overtightening the stop bolts and damaging the wheel bolts. The stop bolts may loose and the wheels may fall off, which could cause a serious accident. If there is oil or grease on any stop bolt or wheel bolt, clean it.

• Tightening Torque of Wheel Nut NUMBER OF BOLT TIGHTENING DIRECTION TIGHTENING TORQUE

5 or 6

RH

CLOCKWISE

LH

COUNTER CLOCKWISE

N•m {kgf·cm}

440 – 590 {4,500 – 6,000}

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GENERAL PRECAUTIONS

18. ADJUSTMENT OF HEADLAMP LIGHT AXIS

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GENERAL PRECAUTIONS (2) Precautions for the auto leveling device The auto leveling device makes adjustment to headlamp light axis with sensing the vehicle posture. Therefore, be sure to observe the following precautions. ・Should even out the weight of body when mounting body. ・Be sure to do the initial set of actuator for auto leveling (0 point adjustment) after mounted of body. After the initial set of actuator for auto leveling (0 point adjustment), must make adjustment to headlamp light axis. It need the initial set of actuator for auto leveling (0 point adjustment), if repaired or replaced the sensor, ECU and headlamp. ・Should use the proper tires with the proper condition of air pressure. ・Do not change and alter the suspension. ・Do not alter with changed length of wheel base. ・Do not give strong shock to the sensor assembly. ・Do must not disassemble the sensor assembly. It need to replace a new sensor if disassembled.

For the detail, please contact Hino authorized dealer or distributor. NOTE : Should conform to your country laws and regulations when adjusting the headlamp light axis of completed vehicle.

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GENERAL PRECAUTIONS

19. ADJUSTMENT OF FOG LAMP LIGHT AXIS It need to make adjustment to the fog lamp light axis which installed on the front bumper for changed the vehicle posture by mounted of body. When make adjustment, should use a screwdriver. For the detail, please contact Hino authorized dealer or distributor. NOTE : Should conform to your country laws and regulations when adjusting the fog lamp light axis of completed vehicle.

The bulb center of fog lamp

The ground height of the bulb center of fog lamp

[ Example for the adjustment ]

The indication point of dimension ① use for the bulb center of fog lamp

Side view of vehicle

The ground height of the bulb center

Front bumper

Screwdriver

SECTION SECTIONAA- -AA INITIAL AIMING

FRONT FOG LAMP LESS THAN -1.5% V

REQUIRED RANGE

KK-XZU337D

H

① ② (0.86°)

CUT OFF LINE

1.5%

AIMING RANGE (Shaded portion of right side drawing)

60

2

GENERAL PRECAUTIONS

20. HOW TO REMOVE THE INSTRUMENT PANEL COVER (NARROW CAB) When remove the parts of the instrument panel, refer to figure below. The figure shows RHD vehicle, LHD vehicle is symmetry.

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GENERAL PRECAUTIONS Be sure to observe the following instructions when remove the instrument panel cover. 1) Removing the lower cover of driver side (out side) (1) Remove the two retainers of the side surface then hold the bottle holder and pull back it towards you and remove the lower cover (out side). (Remove the three clips.)

2) Removing the lower cover of driver side (in side) (1) Hold the lower parts of lower cover (in side) then pull back it towards you. (Remove the two clips of lower parts.) (2) Hold the side surface of center tray side then pull back the lower cover (in side) towards you and remove it. (Remove the two clips of upper parts and clip of center parts.) 3) Removing the lower cover of passenger side (1) Remove the two screws and remove the two convenience hooks. (2) Hold the both side of HVAC cover then pull back it towards you and remove it. (Remove the three clips and two retainers.) (3) Put your finger on the parts of lower parts of filter cover then pull back it towards you and unlocked the four locks then pull down and remove the filter cover. (4) Remove the retainer of side surface, bolt of filter cover and bolt of lower parts. (5) Hold the bottle holder and the upper of lower cover then pull back it towards you and remove the lower cover of passenger side. (Remove the six clips.)

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GENERAL PRECAUTIONS 4) Removing the lower cover of center (1) Put your finger on the parts of lower parts of fuse cover then pull back it towards you and unlocked the four locks then pull down and remove the fuse cover. (2) Remove the retainer of side surface of driver side, bolt of fuse cover and bolt of end of passenger side. (3) Hold the upper parts of lower cover then pull back it towards you and remove it. (Remove the five clips.) 5) Removing the center cluster (1) Hold the lower parts of center cluster then pull back it towards you. (Remove the four clips of lower parts and two clips of middle parts.) (2) Hold the side surface of center cluster pull back it towards you and remove it. (Remove the four clips of upper parts.) 6) Removing the meter cluster (1) Pull back the lower parts of meter cluster towards you. (Remove the three clips of lower parts.) (2) Hold the of upper parts of meter panel then pull back a meter cluster towards you and remove it. (Remove the three clips of upper parts.)

7) Removing the upper box of passenger side (1) Pull back the lower parts of upper box towards you. (Remove the three clips of lower parts.) (2) Hold the side of upper box of passenger side pull back it towards you and remove it. (Remove the three clips of upper parts.)

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GENERAL PRECAUTIONS 8) Removing the tray of passenger side (1) Remove the bolt of lower parts then pull back the tray of passenger side towards you and remove it. (Remove the four clips and unlock the lock.)

9) Removing the tray of center (1) Remove the bolt of lower parts then pull back the tray of center towards you and remove it. (Remove the three clips.)

10) Removing the speaker grille (1) Pull up the lower back side of the speaker grille. (Remove the two clips of back side and unlock the two locks.) (2) Pull back the speaker grille towards you and remove it.

※ When reassemble the instrument panel, in a reverse manner the following above instructions.

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GENERAL PRECAUTIONS

21. HOW TO REMOVE THE INSTRUMENT PANEL COVER (WIDE CAB) When remove the parts of the instrument panel, refer to figure below. The figure shows LHD vehicle, RHD vehicle is symmetry.

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GENERAL PRECAUTIONS Be sure to observe the following instructions when remove the instrument panel cover. 1) Removing the lower cover of driver side (out side) (1) Remove the two retainers of the side surface then hold the bottle holder and pull back it towards you and remove the lower cover (out side). (Remove the three clips.)

2) Removing the lower cover of driver side (in side) (1) Hold the lower parts of lower cover (in side) then pull back it towards you. (Remove the two clips of lower parts.) (2) Hold the side surface of center tray side then pull back the lower cover (in side) towards you and remove it. (Remove the three clips of upper parts.) 3) Removing the lower cover of passenger side (1) Remove the two screws and remove the two convenience hooks. (2) Hold the lower parts of filter cover then pull back it towards you and remove it. (Remove the four clips and unlock the five locks.)

(3) Remove the retainer of side surface, two bolts of filter cover and bolt of lower parts. (4) Hold the bottle holder and the upper of lower cover then pull back it towards you and remove the lower cover of passenger side. (Remove the eight clips.)

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GENERAL PRECAUTIONS 4) Removing the lower cover of center (1) Put your finger on the parts of lower parts of fuse cover then pull back it towards you and unlocked the four locks then pull down and remove the fuse cover. (2) Remove the retainer of side surface of driver side, bolt of fuse cover and bolt of end of passenger side. (3) Hold the upper parts of lower cover then pull back it towards you and remove it. (Remove the five clips.) 5) Removing the center cluster (1) Hold the lower parts of center cluster then pull back it towards you. (Remove the four clips of lower parts and three clips of middle parts.) (2) Hold the side surface of center cluster pull back it towards you and remove it. (Remove the six clips of upper parts.) 6) Removing the meter cluster (1) Pull back the lower parts of meter cluster towards you. (Remove the three clips of lower parts.) (2) Hold the of upper parts of meter panel then pull back a meter cluster towards you and remove it. (Remove the three clips of upper parts.)

7) Removing the upper box of passenger side (1) Pull back the lower parts of upper box towards you. (Remove the three clips of lower parts.) (2) Hold the side of upper box of passenger side pull back it towards you and remove it. (Remove the three clips of upper parts.)

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GENERAL PRECAUTIONS 8) Removing the tray of passenger side (1) Remove the bolt of lower parts then pull back the tray of passenger side towards you and remove it. (Remove the five clips and unlock the lock.)

9) Removing the tray of center (1) Remove the bolt of lower parts then pull back the tray of center towards you and remove it. (Remove the five clips.)

10) Removing the speaker grille (1) Pull up the lower back side of the speaker grille. (Remove the two clips of back side and unlock the two locks.) (2) Pull back the speaker grille towards you and remove it.

※ When reassemble the instrument panel, in a reverse manner the following above instructions.

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GENERAL PRECAUTIONS

22. PRECAUTION FOR REINSTALLING WASHER TANK INLET When remove the instrument panel, also should remove a washer tank bezel and inlet tube. Be sure to observe the following instructions when reinstall washer tank bezel and inlet tube after installed instrument panel. If reinstalling position of washer tank inlet is not completed, the washer liquid may leaking or the worst case is the engine doesn't start.

FOR NARROW CAB • Original condition

• Parts name

The manner of reinstallation 1) Pull ‌ out a inlet to position which the right picture is showed after installed instrument panel.

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GENERAL PRECAUTIONS

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2

GENERAL PRECAUTIONS

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GENERAL PRECAUTIONS

FOR WIDE CAB • Do not remove a bezel. • Remove the inlet hose from washer tank. • Should follow the instructions below when removing the inlet hose.

Pull out this parts horizontally to back side the vehicle when removing the inlet tube. Insert this parts horizontally to washer tank socket, and then push it until stop when reinstalling.

Washer tank inlet (Bezel)

Inlet hose

Insert it completely until stop to this surface. KK-XZU337D

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GENERAL PRECAUTIONS

[NOTE] Should separate at the position in figure below when removing inlet tube from washer tank. Do not separate the parts of A and parts of B.

The separating position. When reinstalling, check the O ring that there is no scratch, no dirt, no twisting and no sticking foreign matter. And check the parts of inserting to washer tank that there is no scratch, no dirt and no sticking foreign matter.

<Washer tank side> When reinstalling, check the parts of inserting to inlet that there is no scratch, no dirt and no sticking foreign matter.

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GENERAL PRECAUTIONS

23. PRECAUTION FOR AUTO CLUTCH UNIT (FOR HYBRID VEHICLE ONLY)

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2

GENERAL PRECAUTIONS

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GENERAL PRECAUTIONS 3) Maintenance working space of ACU. (1) Do not obstruct a maintenance working space of ACU by mounted body. DETAIL OF ACU

Removing direction of motor

Removing direction of motor

Removing direction of cover < FRONT VIEW >

< REAR VIEW >

ACU module

4) The painting. (1) Do not paint to ACU for preventing to obstruct visibility of the clutch oil level.

Do not paint this area

ACU module

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GENERAL PRECAUTIONS

24. PROVISION FOR AM RADIO NOISE (FOR HYBRID VEHICLE ONLY) Be sure to install two earth wires to connect between body and chassis frame and body and motor generator for preventing AM radio noise with hybrid vehicle. 1) Between body and chassis frame (1) Should install an earth wire which is packed in the cab between the center parts of front end of body and chassis frame. (2) Should peel the paint off the terminal fix area on chassis frame side and body for securing electric conductivity. (3) Should use an available hole on the chassis frame for fixing terminal. (4) Be sure to process for preventing rusted after fixed terminal with chassis frame and body.

・Should peel the paint off the chassis frame and body. ・It need to process for preventing rusted.

Body side

Earth wire

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GENERAL PRECAUTIONS

2) Between body and motor generator (1) Should use a hole as shown below figure for fixing terminal with motor generator. ・Shape of hole : M8 × 1.25 The depth of screw : 16 mm The depth of base hole : 22 mm ・Tightening torque : 16.8 ~ 31.2 N・m (2) Should install an earth wire which is packed in the cab between the center parts of front end of body and motor generator. (3) Should peel the paint off the terminal fix area which it depend on each Body and Equipment Manufacturers on body side. (4) Should fix the terminal to the position as shown figure at motor generator side. (5) Be sure to fix the earth wire to nearby a cable with tie-rap.

The installing position of earth wire.

3) Part number of the earth wire. (1) They are packed in the cab. (2) Assembly Part number : 82046 - 37192 Place of installation Between the body and chassis frame Between the body and motor generator

Part number 82284 - 37160

・Body and Equipment Manufacturers should prepare a bolt, nut and washer for installing the earth wire.

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Chapter 3 CHASSIS MASS & FRAME SECTION MODULUS

1. CHASSIS MASS

2. MASS OF THE OPTION EQUIPMENT 3. FRAME SECTION MODULUS

KK-XZU337D

3

CHASSIS MASS & FRAME SECTION MODULUS

1. CHASSIS MASS

• CAB TYPE : NARROW CAB MODEL

XZU640L-HKMLN3

ITEMS

GRAVITY POSITION FROM F.A.C

FRONT BUMPER CAB FRONT CAB FRONT MTG. STEERING GEAR BOX RADIATOR STEERING CONTROL ENGINE FRONT CONTROL ENGINE ROOM (COVER) AIR CLEANER CAB REAR CAB REAR MTG. ENGINE REAR REAR SPLASH BRAKE SYSTEM ELECTRIC SYSTEM EXHAUST SYSTEM BATTERY FUEL TANK FUEL TANK (SUB) A/C PROPELLER SHAFT (FRONT) PROPELLER SHAFT (REAR) FRAME ETC. SPARE TIRE CARRIER SPARE TIRE FRONT SUSPENSION REAR SUSPENSION TOOL BOX TORSION BAR & SUPPORT(4WD) REAR BUMPER P.T.O CAB TILT PCU AIR BAG STABILIZER (FRONT) STABILIZER (REAR) DISCHARGE HEAD LAMP TOOL FUPD AMT MODULE TOTAL WHEEL BASE[m]

SPRUNG MASS UNSPRUNG MASS CHASSIS MASS

GRAVITY POSITION FROM F.A.C(m) GRAVITY HEIGHT FROM GROUND(m)

MASS

(kg)

5 201 23 19 17 4 384 7 1 11 118 33 113 2 6 14 19 37 104

(m)

-0.900 -0.827 -0.827 -0.715 -0.242 -0.200 0.175 0.440 0.000 0.492 0.445 0.410 1.114 0.450 -0.600 0.400 1.457 0.852 1.335

XZU650L-HKMMP3 MOMENT FROM F.A.C

(kg-m)

-4.500 -166.227 -19.021 -13.585 -4.114 -0.800 67.200 3.080 0.000 5.412 52.510 13.530 125.882 0.900 -3.600 5.600 27.683 31.512 138.840

GRAVITY POSITION FROM F.A.C

MASS

(kg)

5 201 23 19 17 4 384 7 1 11 118 33 113 2 6 14 19 37 104

(m)

-0.900 -0.827 -0.827 -0.715 -0.242 -0.200 0.175 0.440 0.000 0.492 0.445 0.410 1.114 0.450 -0.600 0.400 1.457 0.852 2.140

MOMENT FROM F.A.C

(kg-m)

-4.500 -166.227 -19.021 -13.585 -4.114 -0.800 67.200 3.080 0.000 5.412 52.510 13.530 125.882 0.900 -3.600 5.600 27.683 31.512 222.560

13

-0.431

-5.603

13

-0.431

-5.603

15 200 7 32 77 107

2.080 1.590 3.420 3.420 0.000 2.800

31.200 318.000 23.940 109.440 0.000 299.600

28 258 7 32 73 132

2.240 1.870 4.295 4.295 0.000 3.400

62.720 482.460 30.065 137.440 0.000 448.800

10

0.500

5.000

10

0.500

5.000

1041.879

1671

TOTAL (kg) 1,579 449 2,028 0.869 0.560

FRONT (kg) 1,228 192 1,420

1579 FRONT (kg) 1,207 192 1,399

2.800 REAR (kg) 372 257 629

3.400 REAR (kg) 443 340 783

1504.904 TOTAL (kg) 1,671 532 2,203 1.208 0.560

NOTE • The mass of tire follows design figure according to JATMA or ETRTO standard. • The chassis mass shows standard specification of vehicle. (It is not included mass of option equipment.) When consider the mounting of body, should include mass of option equipment. KK-XZU337D

1

3

CHASSIS MASS & FRAME SECTION MODULUS • CAB TYPE : WIDE CAB MODEL

XZU710L-QKFMP3

ITEMS

GRAVITY POSITION FROM F.A.C

FRONT BUMPER CAB FRONT CAB FRONT MTG. STEERING GEAR BOX RADIATOR STEERING CONTROL ENGINE FRONT CONTROL ENGINE ROOM (COVER) AIR CLEANER CAB REAR CAB REAR MTG. ENGINE REAR REAR SPLASH BRAKE SYSTEM ELECTRIC SYSTEM EXHAUST SYSTEM BATTERY FUEL TANK FUEL TANK (SUB) A/C PROPELLER SHAFT (FRONT) PROPELLER SHAFT (REAR) FRAME ETC. SPARE TIRE CARRIER SPARE TIRE FRONT SUSPENSION REAR SUSPENSION TOOL BOX TORSION BAR & SUPPORT(4WD) REAR BUMPER P.T.O CAB TILT PCU AIR BAG STABILIZER (FRONT) STABILIZER (REAR) DISCHARGE HEAD LAMP TOOL FUPD AMT MODULE TOTAL WHEEL BASE[m]

SPRUNG MASS UNSPRUNG MASS CHASSIS MASS

GRAVITY POSITION FROM F.A.C(m) GRAVITY HEIGHT FROM GROUND(m)

MASS

(kg)

9 298 17 20 16 5 395 7 2 12 278 38 122 4 6 15 19 35 108

(m)

-0.970 -0.920 -0.920 -0.755 -0.357 -0.190 0.175 0.480 0.000 0.366 1.330 0.840 1.180 0.460 -0.600 0.500 1.467 1.227 1.950

XZU710L-HKFMP3 MOMENT FROM F.A.C

(kg-m)

-8.730 -274.160 -15.640 -15.100 -5.712 -0.950 69.125 3.360 0.000 4.392 369.740 31.920 143.960 1.840 -3.600 7.500 27.873 42.945 210.600

GRAVITY POSITION FROM F.A.C

MASS

(kg)

9 219 22 20 16 5 395 7 2 12 171 37 122 4 6 15 19 35 106

(m)

-0.970 -0.920 -0.920 -0.755 -0.357 -0.190 0.175 0.480 0.000 0.427 0.387 0.387 1.180 0.460 -0.600 0.500 1.467 1.227 1.330

XZU710L-HKFQP3 MOMENT FROM F.A.C

(kg-m)

-8.730 -201.480 -20.240 -15.100 -5.712 -0.950 69.125 3.360 0.000 5.124 66.177 14.319 143.960 1.840 -3.600 7.500 27.873 42.945 140.980

GRAVITY POSITION FROM F.A.C

MASS

(kg)

9 219 22 20 16 5 395 7 2 12 171 37 122 4 6 15 19 35 106

(m)

-0.970 -0.920 -0.920 -0.755 -0.357 -0.190 0.175 0.480 0.000 0.427 0.387 0.387 1.180 0.460 -0.600 0.500 1.467 1.227 1.330

XZU720L-HKFRP3 MOMENT FROM F.A.C

(kg-m)

-8.730 -201.480 -20.240 -15.100 -5.712 -0.950 69.125 3.360 0.000 5.124 66.177 14.319 143.960 1.840 -3.600 7.500 27.873 42.945 140.980

GRAVITY POSITION FROM F.A.C

MASS

(kg)

9 219 22 20 16 5 395 7 2 12 171 37 122 4 6 15 19 35 106

(m)

-0.970 -0.920 -0.920 -0.755 -0.357 -0.190 0.175 0.480 0.000 0.427 0.387 0.387 1.180 0.460 -0.600 0.500 1.467 1.227 1.330

MOMENT FROM F.A.C

(kg-m)

-8.730 -201.480 -20.240 -15.100 -5.712 -0.950 69.125 3.360 0.000 5.124 66.177 14.319 143.960 1.840 -3.600 7.500 27.873 42.945 140.980

12

-0.463

-5.556

12

-0.463

-5.556

12

-0.463

-5.556

12

-0.463

-5.556

29 244 7 36 72 141

2.400 1.599 4.400 4.400 0.000 3.430

69.600 390.156 30.800 158.400 0.000 483.630

29 244 7 36 72 141

2.400 1.599 4.400 4.400 0.000 3.430

69.600 390.156 30.800 158.400 0.000 483.630

29 272 7 33 72 141

2.400 1.658 4.400 4.400 0.000 3.430

69.600 450.976 30.800 145.200 0.000 483.630

31 285 7 47 81 155

2.620 1.927 4.815 4.815 0.000 3.870

81.220 549.195 33.705 226.305 0.000 599.850

10

0.500

5.000

10

0.500

5.000

10

0.500

5.000

10

0.500

5.000

1721.393

1773

1399.421

1798

1447.041

1850

TOTAL (kg) 1,957 568 2,525 1.163 0.694

FRONT (kg) 1,365 214 1,579

TOTAL (kg) 1,773 568 2,341 1.116 0.641

FRONT (kg) 1,376 231 1,607

TOTAL (kg) 1,798 623 2,421 1.153 0.643

FRONT (kg) 1,396 257 1,653

1957 FRONT (kg) 1,455 214 1,669

3.430 REAR (kg) 502 354 856

3.430 REAR (kg) 408 354 762

3.430 REAR (kg) 422 392 814

3.870 REAR (kg) 454 446 900

1757.110 TOTAL (kg) 1,850 703 2,553 1.364 0.634

NOTE • The mass of tire follows design figure according to JATMA or ETRTO standard. • The chassis mass shows standard specification of vehicle. (It is not included mass of option equipment.) When consider the mounting of body, should include mass of option equipment. KK-XZU337D

2

3

CHASSIS MASS & FRAME SECTION MODULUS HYBRID

• CAB TYPE : WIDE CAB MODEL ITEMS

FRONT BUMPER CAB FRONT CAB FRONT MTG. STEERING GEAR BOX RADIATOR STEERING CONTROL ENGINE FRONT CONTROL ENGINE ROOM (COVER) AIR CLEANER CAB REAR CAB REAR MTG. ENGINE REAR REAR SPLASH BRAKE SYSTEM ELECTRIC SYSTEM EXHAUST SYSTEM BATTERY FUEL TANK FUEL TANK (SUB) A/C PROPELLER SHAFT (FRONT) PROPELLER SHAFT (REAR) FRAME ETC. SPARE TIRE CARRIER SPARE TIRE FRONT SUSPENSION REAR SUSPENSION TOOL BOX TORSION BAR & SUPPORT(4WD) REAR BUMPER P.T.O CAB TILT PCU AIR BAG STABILIZER (FRONT) STABILIZER (REAR) DISCHARGE HEAD LAMP TOOL FUPD AMT MODULE TOTAL WHEEL BASE[m] SPRUNG MASS UNSPRUNG MASS CHASSIS MASS

GRAVITY POSITION FROM F.A.C(m) GRAVITY HEIGHT FROM GROUND(m)

XKU710L-HKUMP3 GRAVITY POSITION FROM F.A.C

MASS

(kg)

9 217 22 20 16 5 425 7 2 12 170 37 154 4 6 17 19 35 108

(m) -0.970 -0.920 -0.920 -0.755 -0.357 -0.190 0.175 0.480 0.000 0.427 0.387 0.387 1.293 0.460 -0.600 0.500 1.517 2.392 1.950

12

-0.463

28 244 7 32 72 141

MOMENT FROM F.A.C

GRAVITY POSITION FROM F.A.C

MASS

9 217 22 20 16 5 425 7 2 12 170 37 154 4 6 17 19 35 108

(m) -0.970 -0.920 -0.920 -0.755 -0.357 -0.190 0.175 0.480 0.000 0.427 0.387 0.387 1.293 0.460 -0.600 0.500 1.517 2.392 1.950

-5.556

12

-0.463

2.400 1.600 4.400 4.400 0.000 3.430

67.200 390.400 30.800 142.560 0.000 483.630

28 272 7 33 72 141

115

1.510

173.650

10 0 14

0.500

5.000

0.809

1960 FRONT (kg) 1,453 207 1,660

3.430 REAR (kg) 507 339 846

(kg-m) -8.730 -199.640 -20.240 -15.100 -5.712 -0.950 74.375 3.360 0.000 5.124 65.790 14.319 199.122 1.840 -3.600 8.500 28.823 83.720 210.600

XKU710L-HKUQP3

(kg)

MOMENT FROM F.A.C

GRAVITY POSITION FROM F.A.C

MASS

(kg)

MOMENT FROM F.A.C

9 217 22 20 16 5 425 7 2 12 170 37 154 4 6 17 19 35 108

(m) -0.970 -0.920 -0.920 -0.755 -0.357 -0.190 0.175 0.480 0.000 0.427 0.387 0.387 1.293 0.460 -0.600 0.500 1.517 2.392 1.950

-5.556

12

-0.463

-5.556

2.400 1.660 4.400 4.400 0.000 3.430

67.200 451.520 30.800 145.200 0.000 483.630

28 272 7 47 81 155

2.400 1.660 4.400 4.400 0.000 3.430

67.200 451.520 30.800 206.800 0.000 531.650

115

1.510

173.650

115

1.510

173.650

0.500

5.000

5.000

0.809

11.326

10 0 14

0.500

11.326

10 0 14

0.809

11.326

1740.611

1989

1804.371

2026

TOTAL (kg) 1,960 546 2,506 1.158 0.606

FRONT (kg) 1,463 230 1,693

TOTAL (kg) 1,989 608 2,597 1.194 0.639

FRONT (kg) 1,468 256 1,724

3.430 REAR (kg) 526 378 904

(kg-m) -8.730 -199.640 -20.240 -15.100 -5.712 -0.950 74.375 3.360 0.000 5.124 65.790 14.319 199.122 1.840 -3.600 8.500 28.823 83.720 210.600

XKU710L-HKURP3

3.430 REAR (kg) 558 462 1,020

(kg-m) -8.730 -199.640 -20.240 -15.100 -5.712 -0.950 74.375 3.360 0.000 5.124 65.790 14.319 199.122 1.840 -3.600 8.500 28.823 83.720 210.600

1913.991 TOTAL (kg) 2,026 718 2,744 1.275 0.625

NOTE • The mass of tire follows design figure according to JATMA or ETRTO standard. • ‌The chassis mass shows standard specification of vehicle. (It is not included mass of option equipment.) When consider the mounting of body, should include mass of option equipment. KK-XZU337D

3

3

CHASSIS MASS & FRAME SECTION MODULUS

2. MASS OF THE OPTION EQUIPMENT

The table of option mass shows the difference mass with standard specifications.

• CAB TYPE : NARROW CAB No. 1 2 3 4 5 6 7 8

Option Power Take Off Front Suspension Rear Suspension Front Stabilizer Air Conditioner Front Bumper Battery Tool Box

Contents With Reinforced leaf spring Reinforced leaf spring With Less Steel 12V - 288kc {80Ah} x 2

With

Left Side

• CAB TYPE : WIDE CAB No.

Option

Contents

1 Fuel Tank

70L Additional Tank

2 Power Take Off

With

Transmission : MYY6S Transmission : M550 AMT

3 Front Suspension

Reinforced leaf spring

4 Rear Suspension

Reinforced leaf spring

5 Front Stabilizer

With

6 Rear Stabilizer

With

7 8 9 10 11 12

With Less With With 12V - 288kc {80Ah} x 2

Seat Suspension Air Conditioner Rear Air Conditioner Rear Heater Battery Tool Box

With

Left Side

KK-XZU337D

Fr kg

Rr kg

Total kg

Remarks

Fr kg

Rr kg

Total kg

Remarks

10 10 0 20 -20 5 10 10

25 30 5 10 10 10 15 0 0 20 15 -5 0 10 -20 5 5 10 10

5 0 10 -5 0 0 5 0

50 45 5 0 5 0 0 15 10 -5 0 25 20 0 0 0 0 5 0

15 10 10 15 -20 5 15 10

75 75 10 10 15 10 15 15 10 15 15 20 20 10 -20 5 5 15 10

3430 Wheel Base 3870 Wheel Base 3430 Wheel Base 3870 Wheel Base GVW5.5t & 6.5t GVW7.5t GVW5.5t & 6.5t GVW7.5t 3430 Wheel Base 3870 Wheel Base 3430 Wheel Base 3870 Wheel Base

Double Cab Double Cab

4

3

CHASSIS MASS & FRAME SECTION MODULUS MASS OF TIRE & WHEEL SET TIRE

LOAD INDEX

WHEEL

ASSY MASS [kg]

195/75R16C

110/108

16×5.5K-113

32

205/75R16C

113/111

16×5.5K-115

33

185/85R16

111/109

16×5.5K-113

31

195/85R16

114/112

16×5.5K-113

34

205/85R16

117/115

16×5.5K-115

34

16×5.5K-122

34

16×5.5K-122

33

16×6K-127

36

120/118

16×5.5K-122

36

205/75R17.5

124/122

17.5×6.00-127

41

215/75R17.5

124/123

17.5×6.00-127

42

126/124

17.5×6.00-127

43

225/80R17.5

123/122

17.5×6.00-127

41

225/70R19.5

12PR

19.5×6.00-127

57

7.00R16-10PR

113/111

16×5.50F-115

36

16×5.50F-127

36

16×5.50F-115

36

16×5.50F-127

37

215/85R16

7.00R16-12PR

10PR

116/114

7.50R16-10PR

119/117

16×6.00GS-127

44

7.50R16-12PR

121/120

16×6.00GS-127

45

7.50R16-14PR

122/120 123/121

16×6.00GS-127

50

7.00-16-10PR

113/111

16×5.50F-115

34

7.00-16-12PR

116/114

16×5.50F-115

34

7.00-16-14PR

-

16×5.50F-115

38

7.50-16-10PR

119/117

16×6.00GS-127

35

7.50-16-12PR

121/120

16×6.00GS-127

36

7.50-16-14PR

123/121

16×6.00GS-127

40

[NOTE] • The data above are based on JATMA standard. • ‌The mass will be different by brand and pattern of tires, therefore, each mass is just reference. (If use studless tire or mix tire, should add 30 ~ 50 kg more per vehicle. ) KK-XZU337D

5

3

CHASSIS MASS & FRAME SECTION MODULUS

3. FRAME SECTION MODULUS

FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE)

Unit : mm

MODEL : X  ZU640L-HKMLN3

KK-XZU337D

6

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) MODEL : X  ZU650L-HKMMP3

KK-XZU337D

Unit : mm

7

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) MODEL : ‌XZU710L-HKFQP3 XKU710L-HKUQP3 XKU710L-HKURP3

KK-XZU337D

Unit : mm

8

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) MODEL : ‌XZU710L-QKFMP3 XZU710L-HKFMP3 XKU710L-HKUMP3

KK-XZU337D

Unit : mm

9

3

CHASSIS MASS & FRAME SECTION MODULUS FRAME SECTION MODULUS (MAIN FRAME ON BOTH SIDE) MODEL : X  ZU720L-HKFRP3

KK-XZU337D

Unit : mm

10

Chapter 4 SPRINGS & REAR AXLES

1. SPRING CHARACTERISTICS

2. MAXIMUM VERTICAL DEFLECTION OF REAR WHEELS 3. TRAVEL RANGE OF REAR SPRING

4. CALCULATION FOR HEIGHT OF FRAME UPPER SURFACE FROM GROUND

KK-XZU337D

4

SPRINGS & REAR AXLES

1. SPRING CHARACTERISTICS 1) SPRING COMBINATION

Refer to SPRING CHARACTERISTICS CHART based on following table.

MODEL

FRONT

REAR

STD

OPT

STD

OPT

XZU640L-HKMLN3

F01

F04

R01

-

XZU650L-HKMMP3

F02

F05

R03

R06

XZU710L-QKFMP3

F08

F16

R10

R12

XZU710L-HKFMP3

F08

F16

R10

R12

XZU710L-HKFQP3

F09

F11

R10

R12

XZU720L-HKFRP3

F11

F13

R12

R15

XKU710L-HKUMP3

F08

F16

R10

R12

XKU710L-HKUQP3

F09

F11

R10

R12

XKU710L-HKURP3

F11

F13

R12

R15

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1

4

SPRINGS & REAR AXLES 2) FRONT LEAF SPRING

(1) SPRING CHARACTERISTICS CHART "F01"

KK-XZU337D

2

4

SPRINGS & REAR AXLES (2) SPRING CHARACTERISTICS CHART "F02"

KK-XZU337D

3

4

SPRINGS & REAR AXLES (3) SPRING CHARACTERISTICS CHART "F04"

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4

4

SPRINGS & REAR AXLES (4) SPRING CHARACTERISTICS CHART "F05"

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5

4

SPRINGS & REAR AXLES (5) SPRING CHARACTERISTICS CHART "F08"

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6

4

SPRINGS & REAR AXLES (6) SPRING CHARACTERISTICS CHART "F09"

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7

4

SPRINGS & REAR AXLES (7) SPRING CHARACTERISTICS CHART "F11"

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4

SPRINGS & REAR AXLES (8) SPRING CHARACTERISTICS CHART "F13"

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9

4

SPRINGS & REAR AXLES (9) SPRING CHARACTERISTICS CHART "F16"

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10

4

SPRINGS & REAR AXLES 3) REAR LEAF SPRING

(1) SPRING CHARACTERISTICS CHART "R01"

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11

4

SPRINGS & REAR AXLES (2) SPRING CHARACTERISTICS CHART "R03"

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12

4

SPRINGS & REAR AXLES (3) SPRING CHARACTERISTICS CHART "R06"

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13

4

SPRINGS & REAR AXLES (4) SPRING CHARACTERISTICS CHART "R10"

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14

4

SPRINGS & REAR AXLES (5) SPRING CHARACTERISTICS CHART "R12"

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15

4

SPRINGS & REAR AXLES (6) SPRING CHARACTERISTICS CHART "R15"

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16

4

SPRINGS & REAR AXLES

2. MAXIMUM VERTICAL DEFLECTION OF REAR WHEELS

Measurements for the maximum deflection for on tire and for simultaneous left and right deflection are shown below. When you mount the body, allow a clearance of at least 30mm so as not to obstruct tire deflection.

Deflection of rear tires

A

C B

A

C B

D

D

F4 RTIRES2

Maximum deflection for one side wheels.

Maximum simultaneous deflection right and left wheels.

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4

SPRINGS & REAR AXLES

A

MODEL

REAR TIRE SIZE

XZU640L-HKMLN3

205/75R16C-113/111 7.00R16-12 205/75R16C-113/111 7.00R16-10 7.00R16-12 7.00R16-10 205/75R16C-113/111 7.00R16-10 205/75R16C-113/111 215/85R16-E(10) 7.50R16-10 215/75R17.5-124/123 7.50R16-12 205/75R16C-113/111 215/85R16-E(10) 215/75R17.5-124/123 215/75R17.5-124/123

XZU650L-HKMMP3 XZU710L-QKFMP3 XZU710L-HKFMP3 XZU710L-HKFQP3 XZU720L-HKFRP3 XKU710L-HKUMP3 XKU710L-HKUQP3 XKU710L-HKURP3

B

C

D

[mm]

[mm]

[mm]

[mm]

173 200 131 159 159 122 94 122 95 123 130 127 135 95 122 120 129

141 169 94 122 122 82 54 82 54 85 92 81 91 54 84 81 80

58 58 88 88 88 128 128 128 128 128 128 128 128 128 129 129 116

182 184 123 127 127 122 118 121 118 127 128 114 123 119 128 120 150

REAR TIRE SINGLE

DOUBLE

With tire chain : Dimensions A and B are added 50mm.

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4

SPRINGS & REAR AXLES

3. TRAVEL RANGE OF REAR SPRING

During driving, the shackle of the main spring slides beyond the end of the rear bracket. MODEL XZU650L-HKMMP3 XZU710L-QKFMP3

XZU710L-HKFMP3

XZU710L-HKFQP3

XZU720L-HKFRP3

XKU710L-HKUMP3

XKU710L-HKUQP3

A 110

Unit : mm

130

XKU710L-HKURP3

MODEL : XZU640L-HKMLN3

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4

SPRINGS & REAR AXLES

4. CALCULATION FOR HEIGHT OF FRAME UPPER SURFACE FROM GROUND

Before mounting rear body or equipment on chassis, must calculate height of frame upper surface from ground. In order to confirm the vehicle posture as frame end upper surface from ground slightly higher than front end to ensure vehicle stability. Following are as formula for how to calculate.

L1

Wf

Wf Wr Hf1 Hr1 Hfo L1 L2

Hro

Hr1

Hf1

L2

Wr

: Load on front axle (kg) : Load on rear axle (kg) : Height of frame upper surface from ground on front axle datum line (mm) : Height of frame upper surface from ground on rear axle datum line (mm) : Height of frame upper surface from ground on frame end (mm) : Distance from front axle datum line to rear axle loading center (mm) : Frame rear overhung (mm) · · · From rear loading center to frame end. Hro = Hr1 +

Hr1 - Hf1 L1

x L2

NOTE

• Refer to the next page for how to calculate Hf1 and Hr1. • The calculation formula is not considered the deflection of tire. • Hf1 and Hr1 must add the deflection of tire based on ETRTO or JATMA standard.

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4

SPRINGS & REAR AXLES

CALCULATION FORMULA OF Hf1 & Hr1

CHAPTER TO BE REFERED CHAPTER NAME OF CLAUSE SPRING CHARAC4 TERISTICS CHART

ITEM SPRING CONSTANT (kg/mm) HIGHT OF FRAME UPPER SURFACE FROM GROUND (mm)

8

ELEMENT FRONT REAR

CHASSIS DRAWING

Tf

Tr

Hf

Hr



ELEMENT FRONT REAR

ITEM MASS DISTRIBUTION OF BODY OR EQUIPMENT(kg) Mass of payload must calculate mass distribution, Front and Rear, if need.

Wf

Wr

CALCULATION FORMULA OF MASS DISTRIBUTION W L3

W : BODY (EQUIPMENT) MASS Wf : FRONT DISTRIBUTION MASS OF BODY (EQUIPMENT) Wr : REAR DISTRIBUTION MASS OF BODY (EQUIPMENT) L3 : GRAVITY CENTER OF BODY (EQUIPMENT) MASS L4 : WHEELBASE

L4

Wf Wr W x L3 Wr = W - Wf Wf = L4 For more details if needed, refer to the Chapter 1 of Common Manual.

Hf1 = Hf - ( Wf 2

Hr1 = Hr - ( Wr 2

÷ Tf )

÷ Tr )

AN EXAMPLE OF CALCULATION This is the calculation of "Hro" of the vehicle with mounted rear body or equipment. SPRING CONSTANT : HIGHT OF FRAME UPPER SURFACE FROM GROUND : BODY MASS :

FRONT : 34.7 kgf/mm, REAR : 255.8 kgf/mm FRONT : 1036 mm, REAR : 1098 mm • BODY MASS : 6000 kg • GRAVITY CENTER OF BODY MASS : 1500 mm • WHEELBASE : 5000 mm • REAR OVER HANG : 3000 mm

Wf = W x L3 = 6000x1500 = 1800 kg

L4

Hf1 = Hf - (

Wr = W - Wf = 6000 - 1800 = 4200

5000

Wf 2

÷ Tf )

Hr1 = Hr - (

1800 ÷ 34.7 ) 2 = 1010 mm

÷ Tr )

4200 ÷ 255.8 ) 2 = 1090 mm

= 1036 - (

Hro = Hr1 + (Hr1 - Hf1) x L2 L1

Wr 2

= 1098 - (

= 1090 +

(1090 - 1010) 5000

KK-XZU337D

x 3000 = 1138 mm

21

Chapter 5 PTO AND CONTROL

1. LAYOUT OF POWER LINE

2. TRANSMISSION SIDE POWER TAKE OFF

3. ENGINE CONTROL FOR BODY OR EQUIPMENT 4. GOVERNOR CHARACTERISTIC OF PTO MODE 5. REAR BODY CONTROL LEVER

6. THE INSTRUCTIONS FOR INSTALLING T/M PTO

KK-XZU337D

5

PTO AND CONTROL

1. LAYOUT OF POWER LINE

MODEL XZU640L-HKMLN3 XZU650L-HKMMP3 XZU710L-QKFMP3 XZU710L-HKFMP3 XZU710L-HKFQP3 XZU720L-HKFRP3 XKU710L-HKUMP3 XKU710L-HKUQP3 XKU710L-HKURP3

T/M MODEL M550

MYY6S

E/G MODEL N04-VC

A

B

C

D

E

F

247

180

3°

436

287

944

357

221

860

436

287

1090

N04-UV 251

M550 AMT

153

4°

N04C-UU

KK-XZU337D

G

H

REAR BODY CONTROL (OPT)

DUMP LEVER 0

0

-

1

5

PTO AND CONTROL

2. TRANSMISSION SIDE POWER TAKE OFF

When the body require transmission Power Take Off (PTO) , genuine PTO equipment and related parts should be supplied as shown below.

[T/M PTO No.1]

1) Transmission Series by Vehicle Model Transmission series M550 M550 AMT

2) Data of the PTO Output Shaft Transmission series

Permissible torque (N·m{kgf·m} at r/min)

M550

245 {25} / 1,000

PTO control type Electric control

Direction of rotation Reverse to engine

3) Necessary Parts Transmission model Transmission gear ratio 1st 2nd 3rd 4th 5th Rev. PTO control type

M550 4.981 2.911 1.556 1.000 0.738 4.625 Electric

Power take off assy

36610-37410

Q'ty / unit 01

Gasket, PTO case

33162-37030

01

Lockwasher

94512-01000

05

Bolt

90119-10372

01

Stud bolt

92132-81025

05

Nut

94130-61000

05

Part name

Part No.

[NOTE] 1. Parts mentioned above table shows transmission PTO unit only. 2. Other ‌ related parts of transmission PTO control, please contact Hino authorized dealer or distributor. KK-XZU337D

2

5

PTO AND CONTROL 4) PTO Installation Procedure

(1) Drain the transmission oil. (Do not remove the drain plug while the oil is hot, or you will scaled yourself.) (2) Remove the PTO cover which is at the left of the transmission. ( Do not reuse the gasket that you remove at this time.) (3) Clean the PTO mounting surface on the transmission side. (4) Prepare the necessary parts, referring to paragraph "3)". (5) Install the stud bolts to the PTO mounting of the transmission case. (6) Fit the gasket and PTO on the PTO mounting position and tighten the fitting bolt and nuts. Tightening torque for bolt and nuts : 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 ratio : i = N2/N1 x N3/N2 x N5/N4 Transmission

N1

N2

N3

N4

N5

i

M550

32

35

34

31

40

1.371

[NOTES] 1. Number ‌ of revolutions of PTO output shaft = number of revolutions of engine x1/ i 2. The PTO output shaft turns in the opposite direction to the engine.

KK-XZU337D

3

6) Detail of M550 Transmission

Unit : mm

101

+0.05 0

MAINSHAFT CENTER LINE

70

142

164



PTO AND CONTROL

16 ±0.1

5

1.5

54

124 ±0.1

108 TO T/M CASE FRONT SURFACE 149

DRIVE GEAR (3rd)

6-M10x1.25 DEPTH 24

130

AUSXZU201 05F001

DRIVE GEAR SPECIFICATION (T/M SIDE /3rd COUNTER GEAR) Tooth profile

Helical gear

Number of teeth

35

Normal module

2.650

Normal pressure angle Helix angle (and direction)

17˚

Normal circular thickness Tooth Over ball diameter thickness Used ball diameter Face width

29˚ (Right)

0.05

106.046

Addendum modification coefficient

Base circle diameter

100.106

Gear layout

Whole depth Semi-topping

0

5.000

Rotation backlash

112.750 -0.1 8.1 0.2

0

113.403 -0.1 20 ±0.2

Standard pitch circle diameter Outside diameter

3.9171

INPUT SHAFT

32

-0.1515

35 PTO AUSXZU201 05T005

KK-XZU337D

4

5

PTO AND CONTROL 7) Transmission PTO mounting (M550) Electric control type

Unit : mm

STUD BOLT - 5

BOLT

[NOTE] 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˚.

PTO HOLE CENTER

KK-XZU337D

5

5

PTO AND CONTROL • Detail of PTO Flange



Unit : mm

• Detail of PTO Output Shaft

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6

5

PTO AND CONTROL

[T/M PTO No.2]

1) Transmission Series by Vehicle Model Transmission series

MYY6S

2) Data of the PTO Output Shaft Transmission series

Permissible torque (N·m{kgf·m} at r/min)

MYY6S

196 {20} / 1,000

PTO control type Electric control

Direction of rotation Reverse to engine

3) Necessary Parts Transmission model Transmission gear ratio 1st 2nd 3rd 4th 5th 6th Rev.

MYY6S 5.979 3.434 1.862 1.297 1.000 0.759 5.701

PTO control type

Electric

Part name

Part No.

Power take off assy

36610-37291

Q'ty / unit 01

Lockwasher

94512-01000

06

Stud bolt

90031-16079

06

Nut

94130-61000

06

[NOTE] 1. Parts mentioned above table shows transmission PTO unit only. 2. Other ‌ related parts of transmission PTO control, please contact Hino authorized dealer or distributor.

KK-XZU337D

7

5

PTO AND CONTROL 4) PTO Installation Procedure

(1) Drain the transmission oil. (Do not remove the drain plug while the oil is hot, or you will scaled yourself.) (2) Remove the PTO cover which is at the left of the transmission. ( Do not reuse the bolts that you remove at this time.) (3) Clean the PTO mounting surface on the transmission side. (4) Prepare the necessary parts, referring to paragraph "3)". (5) Install the stud bolts to the PTO mounting of the transmission case. (6) Apply liquid gasket 'THREEBOND 1215' or 'LOCKTITE 5127 (FMD-127)' to PTO sealing surface of transmission case 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 refill the transmission oil, increase the amount by 0.3 liters to allow for the PTO.

5) Gear Layout and Gear Ratio

Gear ratio : i =N2/N1xN4/N3xN5/N4 Transmission

N1

N2

N3

N4

N5

i

MYY6S

26

47

33

31

27

1.479

[NOTES] 1. Number ‌ of revolutions of PTO output shaft = number of revolutions of engine x1/ i 2. The PTO output shaft turns in the opposite direction to the engine. KK-XZU337D

8

5

PTO AND CONTROL 6) Detail of MYY6S Transmission

KK-XZU337D

Unit : mm

9

5

PTO AND CONTROL 7) Transmission PTO mounting (MYY6S) Electric control type

Unit : mm

[NOTE] 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˚. KK-XZU337D

10

5

PTO AND CONTROL • Detail of PTO Flange

Unit : mm

• Detail of PTO Output Shaft

KK-XZU337D

11

5

PTO AND CONTROL

[T/M PTO No.3]

1) Transmission Series by Vehicle Model Transmission series

MYY6S

2) Data of the PTO Output Shaft Transmission series

Permissible torque (N·m{kgf·m} at r/min)

MYY6S

196 {20} / 1,000

PTO control type Mechanical control

Direction of rotation Reverse to engine

3) Necessary Parts Transmission model Transmission gear ratio 1st 2nd 3rd 4th 5th 6th Rev.

MYY6S 5.979 3.434 1.862 1.297 1.000 0.759 5.701

PTO control type

Mechanical

Part name

Part No.

Power take off assy

36610-37351

Q'ty / unit 01

Lockwasher

94512-01000

06

Stud bolt

90031-16079

06

Nut

94130-61000

06

[NOTE] 1. Parts mentioned above table shows transmission PTO unit only. 2. Other ‌ related parts of transmission PTO control, please contact Hino authorized dealer or distributor.

KK-XZU337D

12

5

PTO AND CONTROL 4) PTO Installation Procedure

(1) Drain the transmission oil. (Do not remove the drain plug while the oil is hot, or you will scaled yourself.) (2) Remove the PTO cover which is at the left of the transmission. ( Do not reuse the bolts that you remove at this time.) (3) Clean the PTO mounting surface on the transmission side. (4) Prepare the necessary parts, referring to paragraph "3)". (5) Install the stud bolts to the PTO mounting of the transmission case. (6) Apply liquid gasket 'THREEBOND 1215' or 'LOCKTITE 5127 (FMD-127)' to PTO sealing surface of transmission case 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 refill the transmission oil, increase the amount by 0.3 liters to allow for the PTO.

5) Gear Layout and Gear Ratio

Gear ratio : i =N2/N1xN4/N3xN5/N4 Transmission

N1

N2

N3

N4

N5

i

MYY6S

26

47

33

31

27

1.479

[NOTES] 1. Number ‌ of revolutions of PTO output shaft = number of revolutions of engine x1/ i 2. The PTO output shaft turns in the opposite direction to the engine. KK-XZU337D

13

5

PTO AND CONTROL 6) Detail of MYY6S Transmission

KK-XZU337D

Unit : mm

14

5

PTO AND CONTROL 7) Transmission PTO mounting (MYY6S) Mechanical control type

Unit : mm

KK-XZU337D

15

5

PTO AND CONTROL • Detail of Coupling



Unit : mm

• Detail of PTO Output Shaft

SERRATION SPECIFICATION Tooth profile Involute tooth ( module ) （ 0.591 ） Number of teeth 36 pressure angle 42.3145° Tip diameter φ21.775±0.1 Pitch diameter φ21.276 Base circle diameter φ15.733 Over pin diameter φ22.718±0.033 Pin diameter for measuring φ1.0227

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5

PTO AND CONTROL

3. ENGINE CONTROL FOR BODY OR EQUIPMENT (OPTION EQUIPMENT) 1) Fuel Injection Pump Governor

• The vehicle use the following fuel injection pump governor. E/G MODEL N04C

GOVERNOR TYPE PUMP

GOVERNOR

COMMON-RAIL TYPE

ELECTRIC CONTROL TYPE

MANUFACTURER

DENSO

2) Installation of Engine Accelerator • ELECTRIC CONTROL TYPE

• Engine accelerator and extension harness for body control are packed in 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. • Be sure to set the engine revolution more than 900rpm when running on PTO. • Should more detailed data or information with regard to engine accelerator for body control be needed, please consult Hino authorized dealer or distributor.

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5

PTO AND CONTROL



Unit : mm

KK-XZU337D

18

5

PTO AND CONTROL

[HOW TO INSTALL ENGINE ACCELERATOR FOR BODY OR EQUIPMENT] (1) Be sure to provide the body control lever with the full speed stopper for controlling the stroke of the sensor lever. In that case, adjust the body side stroke in such a way that the body side stopper comes in contact earlier than the sensor side stopper. The standard for adjustment is 1mm clearance between the sensor side lever and stopper under the condition than the body side lever touches the stopper. (See the following figure.) • Be sure to set the accelerator 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 sensor is just for reference. If the sensor side stopper comes into contact earlier, a forcible stress will be imposed on the sensor shaft and it may result in the damage of the parts in cause. Moreover if sensor lever do not came into contact with idling stopper may result in a bad condition of the engine while vehicle to be driving.

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5

PTO AND CONTROL (2) When fitting the cable on the accelerator sensor lever, define the direction by pulling the cable parallelly to the direction of lever stroke so that an imbalanced load may not be imposed on the sensor shaft. (See the following figure.)

(3) Cautions when installing the Engine accelerator sensor (hereinafter termed the sensor). • Never attempt to disassemble the sensor. Do not drop the sensor or do not give any shock it. Each above thing may lead malfunction and failure. • The sensor is not integral waterproof type. Therefore, when installing it, pay attention to avoid the direct projection of vehicle washing water, tire splash etc. • The temperature range for use is -30 ~ 80 ℃. • 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 product or vibration. If it is impossible to find such place, protect it with a cover. • Install the wire harness certainly so that it may not twist or not bend extremely. • For fitting and clipping the harness wires, refer to the COMMON manual. • If the length of the sub-harness wire is too short, try to obtain the same kind of the harness wire for extension.

KK-XZU337D

20

5

PTO AND CONTROL

4. GOVERNOR CHARACTERISTIC OF PTO MODE

Governor characteristic curve will be changed according to PTO load.

Engine type : N04C-UV, N04C-UU 500 ENGINE TORQUE　（Nm)

450 400 350 300 250 200 150 100 50 0 5

10

15

20

25

30

35

30

35

ENGINE RPM　（×１００ｒｐｍ）

Engine type : N04C-VC 500

ENGINE TORQUE　（Nm)

450 400 350 300 250 200 150 100 50 0 5

10

15

20

25

ENGINE RPM　（×１００ｒｐｍ）

KK-XZU337D

21

5

PTO AND CONTROL

5. REAR BODY CONTROL LEVER

1) Mounting position of dump body control lever • NARROW CAB



Unit : mm

KK-XZU337D

22

5

PTO AND CONTROL • WIDE CAB



Unit : mm

KK-XZU337D

23

5

PTO AND CONTROL

6. THE INSTRUCTIONS FOR INSTALLING T/M PTO Be sure to observe the following instructions if need to install PTO after chassis with cab to be completed. 1) WARNING ・Should use Hino genuine parts for T/M PTO. ・Body and Equipment Manufacturers should prepare parts and installing the PTO unit by their own responsibility. 2) Contents ・The followings are this section mentioned. ・Be sure to observe the instructions of section 2 when installing the PTO unit. (1) The instructions for routing of wire harness for control of T/M PTO (2) The instructions for control of engine revolution 3) The application of engine, T/M and vehicle ENGINE MODEL T/M　SERIES

TYPE OF CONTROL ELECTRIC TYPE VACUUM TYPE

M153 M550 N04C MYY5A or ＭYY6S MZZ6F 　※Marks　○　are applicable.

ー ○ ○ ○

ー ー ー ー

TYPE OF VEHICLE 4X2 4X4

ー ○ ○ ○

ー ー ー ー

4) Necessary parts NAME WIRE, CONNECTING REPAIR WIRE, CONNECTING REPAIR PTO ASSY, T/M RELATED PARTS, PTO INSTALLATION

NARROW CAB Single Rear Tire

PTO CONTROLLER NARROW CAB except Single Rear Tire

WIDE CAB All

BELLCRANK ASSY, ACCELERATOR WIRE ASSY, ENGINE CLUTCH SWITCH PTO SWITCH

PART No.

82989-37310 82989-37300 See the section 2 85900-37220 85900-37190 85900-37231 78130-37131 82050-37010 84640-37080 84690-37040

[NOTE] ・Body and Equipment Manufacturers should make a preparation of other small parts such as bolt and nut for installing necessary parts.

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PTO AND CONTROL

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PTO AND CONTROL

Unit : mm

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PTO AND CONTROL (c) The instructions for installing PTO actuator and position switch harness Should cover wire harness of the area crossing transmission with vinyl tape.

PTO ACTUATOR PTO POSITION SWITCH

Be sure to fix the wire harness to main wire harness of crossing transmission or bracket less than 200 mm intervals with tie-rap.

(d) The instructions for installing PTO controller harness

PTO CONTROLLER

Be sure to fix the wire harness to chassis frame harness or chassis frame less than 200 mm intervals with tie-rap.

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PTO AND CONTROL (3) The detail of routing of wire harness into inside cab and connecting a cab harness NARROW LHD

Be sure to fix a wire harness which came from E/G room to main wire harness with tie-rap for avoiding too much looseness and to touch around equipment.

Remove a holder from bracket and pull it towards, then insert a terminal and there again put the holder back in the bracket.

To W TO W CONNECTOR

To E/G_ECU See the another sheet for insert position of terminal.

FLOOR GROMMET FOR PENETRATED HOLE

Put through wire harness a penetrated hole.

The detail of W to W holder KK-XZU337D

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PTO AND CONTROL WIDE ＬHD

DASH PANEL PENETRATED GROMMET

TO TIGHTENI THE BODY EARTH TIGHTENING TORQUE : 6.9 ～ 9.8 N・m

Put through wire harness a penetrated hole.

To Inside cab

Be sure to fix a wire harness which came from E/G room to main wire harness with tie-rap for avoiding too much looseness and to touch around equipment.

Put through wire harness which came from penetrated hole W to W box and connect connector terminal.

W/H ASSY CLAMP

To W TO W CONNECTOR

Be sure to fix a wire harness which came from E/G room to main harness with tie-rap for avoiding too much looseness and to touch around equipment.

To E/G_ECU

WIRE, ENGINE ROOM

Wire harness put through a penetrated hole.

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PTO AND CONTROL ・The detail of W to W box WIDE LHD Should unlock lever of LIF connector before connect terminal.

See the another sheet for insert position of terminal.

Put through wire harness which came from penetrated hole W to W box and connect connector terminal.

Wire harness should through a grommet.

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PTO AND CONTROL

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PTO AND CONTROL

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PTO AND CONTROL

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PTO AND CONTROL 6) The detail of wire harness and connector (1) Wire harness part No. 82989-37310 (1/2) ENGINE ECU

PTO POSITION SWITCH

PTO ACTUATOR

PTO POSITION J/B PLASTIC BAG

PTO CONTROLLER

CAB

INSERTS INTO BACK SHELL

EARTH

J/B_2

TO PTO RELAY

PTO ACCELERATOR SENSOR

CONNECTO R W TO W TO_141

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PTO AND CONTROL (1) Wire harness part No. 82989-37310 (2/2)

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PTO AND CONTROL (2) Wire harness part No. 82989-37300

CONNECTOR W TO W

PTO CLUTCH SWITCH

PLASTIC BAG

90980 - 09915

90980 - 09915

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PTO AND CONTROL (3) The detail of connector for chassis side 【PEDAL_SUB】

702

TO_141

　GR

　Ｌ

Insert to connector

701

701

702

JOINT JOINT

PEDAL_SUB SET PATRS 0.5 0.64Ⅱ M

90980-12371

(※82998-24270　×２)

ENG_ECU

【CHASSIS_SUB】 Insert to connector

31

32

32

33

L-R

R-Y

31

33

B CHASSIS_SUB SET PATRS 0.5 0.64Ⅲ F

JOINT JOINT

(※82998-12870　×３)

JOINT JOINT

CHASSIS_SUB SET PATRS 0.5 0.64Ⅱ F

703

(※82998-24290　×３)

832

82824-26140 Insert to connector

833

TO_141

703

90980-12774 R GR

832

833

LG

J/B

90980-12779 ・※No. shows spare part number. KK-XZU337D

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Chapter 6 ELECTRICAL SYSTEM

1. FUSE BLOCK AND RELAY BLOCK

2. ALTERNATOR AND DC-DC CONVERTER OUTPUT CHARACTERISTIC

3. SPARE POWER CONNECTORS

4. ADDITIONAL LAMPS OR ELECTRIC DEVICES

5. THE INSTRUCTIONS FOR LEADING WIRE HARNESS INTO THE CAB

6. INSTALLATION OF ADDITIONAL EQUIPMENT AND SWITCHES 7. REAR COMBINATION LAMP

8. LICENSE PLATE BRACKET AND LICENSE PLATE LAMP 9. BACK-UP BUZZER

10. ELECTRICAL WIRING DIAGRAMS

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ELECTRICAL SYSTEM

1. FUSE BLOCK AND RELAY BLOCK 1) LOCATION OF THE CAB SIDE

The fuse block and relay block are located inside the instrument panel as shown below.

(1) NARROW CAB

(2) WIDE CAB

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ELECTRICAL SYSTEM • Detail of SUB RELAY BLOCK • NARROW CAB • WIDE CAB



Detail of Connector CONNECTOR COLOR : BLACK

H-LP LO RELAY

H-LP HI RELAY

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ELECTRICAL SYSTEM • Detail of AC SUB RELAY BLOCK • NARROW CAB • WIDE CAB



Detail of Connector IS COOL OFF RELAY

IS BLOWEA RELAY

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ELECTRICAL SYSTEM 2) LOCATION OF THE CHASSIS SIDE • NARROW CAB

• WIDE CAB

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ELECTRICAL SYSTEM 3) FUSE BLOCK OF THE CAB SIDE

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ELECTRICAL SYSTEM 4) FUSE BLOCK AND RELAY BLOCK OF THE CHASSIS SIDE

1

2

4

3

5

6

7

9

8

ENGINE MODEL : N04C

B

A

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

10

11

12

13

15 24

27

I

M

L

K

J

Q

P

O

N

FUSE NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

26

28

29

30

31

32

14

16 25

17

18

C 19

D

20

E

21

F

22

G

23

H

33

6

RELAY DESCRIPTION ALT-S A/C COMP P-ACC E-FAN FUEL HTR P-BATT EPKB P-TAIL HTR P-IGN PWR5 NOX SSR DCDC3 GLOW AMT2 DCDC2 ABS SOL ABS MTR PWR1 PWR4 PWR2 PWR3 ENG2 FOG DCDC1 HV ENG1 HEAD ALT AMT STA

CAPACITY 10A 10A 20A 20A 30A 20A 20A 20A 20A 20A 15A 10A 30A 50A 30A 50A 30A 30A 50A 40A 50A 40A 15A 15A 30A 10A 15A 30A 120A 80A 140A

NOTE DIESEL

HV

HV HV

A B C D E F G H I J K L M N O P Q

DESCRIPTION HTR RELAY GLOW RELAY P-TAIL RELAY E-FAN RELAY FUEL HTR RELAY A/C COMP RELAY P-ACC RELAY ISS2 RELAY ISS1 RELAY ENG ACT RELAY EDU RELAY STARTER CUT RELAY IG1-4 RELAY -

HV

HV DIESEL

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ELECTRICAL SYSTEM

2. ALTERNATOR AND DC-DC CONVERTER OUTPUT CHARACTERISTIC

• The maximum power available for the whole vehicle is defined by the capacity of the alternator. Therefore, the electric power that is not consumed by electric equipments such as head lamps 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 Hino authorized dealer or distributor.

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ELECTRICAL SYSTEM

(3) XKU series only DC-DC converter installed only in Hybrid vehicle drop the voltage of Ni-MH battery and supplies the electric power to electrical equipment. Therefore, Alternator is not installed. DC-DC converter output characteristic Output voltage Output Current

24[V] 80[A]

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ELECTRICAL SYSTEM

3. SPARE POWER CONNECTORS

If you must take an electrical power supply for the body from the chassis, take it from the spare power supply.

Spare power supplies and positions Connector Pole Mark Code

Circuit (Main Application)

#82 Power supply ACC CAB SIDE

A

B CHASSIS SIDE

C

#83 Power supply Lighting

Max. Wire Size Permissible & Current Color (A) 0.85 7 R 7

#84 Power supply starter switch on

10

#81 Power supply

7

#86 Power supply ACC

7

#87 Power supply Lighting

7

#88 Power supply starter switch on

10

#85 Power supply

7

J0Q Power supply

–

J0P Accel sensor

–

Z6T Ground

–

0.85 G

0.85 L

Connector Part No.

82824-37440

Coupling Connector (Spare Parts) Part No.

82824-37430

Applicable Model

Permissible current : 7A { Total current together with Connector Mark B ( #86 ) } All model

0.85 Y

1.25 L

Permissible current : 10A { Total current together with Connector Mark B ( #88 ) }

Permissible current : 7A { Total current together with Connector Mark A ( #82 ) } 82824-37580

82824-37570

All model

1.25 Y 0.5 L-R 0.5 B 0.5 R-Y

Permissible current : 7A { Total current together with Connector Mark B ( #87 ) }

Permissible current : 7A { Total current together with Connector Mark B ( #85 ) }

1.25 R

1.25 G

Description

Permissible current : 7A { Total current together with Connector Mark A ( #83 ) }

Permissible current : 10A { Total current together with Connector Mark A ( #84 ) }

Permissible current : 7A { Total current together with Connector Mark A ( #81 ) }

90980-11930

90980-11929

All model

Connect with HINO genuine parts only.

[NOTE] (1) ‌The permissible current to be taken from spare power terminal is determined from the capacity of the fuse and wire size. Make sure that the maximum load (current) of the installed equipment must be kept lower current than the permissible capacity to be able to take from spare power terminal.

(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.

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ELECTRICAL SYSTEM 1) Outlet Position Inside the Cab • NARROW CAB

DETAIL OF SPARE POWER CONNECTOR

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ELECTRICAL SYSTEM • WIDE CAB

DETAIL OF SPARE POWER CONNECTOR

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ELECTRICAL SYSTEM 2) Outlet Position on Chassis Side

HOW TO TAKE ELECTRICITY FROM POWER SUPPLY CIRCUIT a. USING SUB-HARNESS TYPE

b. DIRECT CONNECTING TYPE

[NOTE] •‌ We recommend sub-harness type. • ‌If you must take power using direct connecting type, be sure to observe the precautions in described item "ELECTRICAL EQUIPMENT AND WIRING".

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ELECTRICAL SYSTEM 3) Detail of Connector (Part No. & pole arrangement) • INSIDE THE CAB

* • CHASSIS SIDE

*

* *(

) shows spare part No. of coupling connector.

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ELECTRICAL SYSTEM 4) Taking Power Directly From The Battery If you intend to take electrical power for the body or equipment directly from 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.

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ELECTRICAL SYSTEM

4. ADDITIONAL LAMPS OR ELECTRIC DEVICES

The lamps installed to the chassis has already been complied with the laws or regulations. Alteration and modification are therefore strictly prohibited. If you must install additional lamps, be sure to observe the following precautions. • 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. • Must be added relay in diagram of adding wiring for electric device such as lamp. 1) The instructions for adding tail lamp. (1) ‌A spare power terminal for additional lamp is provided in the tail lamp circuit. If need to adding wiring, use this circuit. (2) ‌The spare power terminal (Pole code : #87) is in spare power connector where back left side of crossmember No.3. (3) ‌Do not add more than one and 10w per side of vehicle when adding tail lamp. (4) Must check the functions for operating after adding lamp. 2) The instructions for adding stop lamp. (1) Add relay for adding stop lamp. (2) ‌Add relay at lamp side circuit. Do not add relay at engine ECU side circuit. (3) Do ‌ not add more than one and 21w per side of vehicle when adding stop lamp. (4) Must check the functions for operating after adding stop lamp. (5) Should ‌ install the relay the area which is do not splash water, and installing angle is within 30°. (All around.)

Part Name

Part No.

QTY per vehicle

Stop lamp relay

28490-58010

1

The upper of vehicle (All around)

The additional relay installing angle KK-XZU337D

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ELECTRICAL SYSTEM RECOMMENDED CIRCUIT

To Stop lamp switch

Current circuit

Additional circuit

To Tail lamp realy

Fuse for additional stop lamp power supply

Fuse

Above line

Additional tail lamp RH

Additional stop lamp RH

Tail lamp RH

Stop lamp RH

Stop lamp LH

Tail lamp LH

Additional stop lamp LH

Realy for additional stop lamp

is additional circuit.

FOR EXAMPLE OF ADDED STOP LAMP NG CIRCUIT

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Stop lamp RH

Additional stop lamp RH

Additional stop lamp LH

Stop lamp switch (Chassis side)

Stop lamp LH

Additional tail lamp LH

6

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ELECTRICAL SYSTEM

5. THE INSTRUCTIONS FOR LEADING WIRE HARNESS INTO THE CAB 1) A Penetrated hole for wire harness ・A Penetrated hole for wire harness into cab is provided as shown below. Should change to proper grommet and lead wire harness into cab when routing wire. ・Be sure to process the edge of hole and wrap wire harness with material such as corrugated tube to prevent short circuit by wire harness touched around hole. ・Be sure to completely seal with sealer to prevent water and noise from outside if there is clearance between wire harness and penetrated hole. ・Holes A ~ D may not use by the specifications for a vehicle. It need to confirm the each vehicle for finding an available holes then use them. (Refer to CAB drawing for position of holes A ~ D as shown below.) ・Do must not share a grommet of chassis harness. Chassis harness may be scratched when process grommet.

Unit : mm

・This drawing shows RHD, and LHD is symmetry. (For accel cable) (For PTO cable)

Slotted hole 41 x 32 (For transfer cable)

(For antenna of radio)

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ELECTRICAL SYSTEM Unit : mm

<WIDE CAB>

・This drawing shows RHD, and LHD is symmetry. (For PTO cable)

Slotted hole 60 x 30 (For mounting) (For antenna of radio)

2) The detail of leading wire harness into the cab if use hole A and B 　・This instructions is for only NARROW CAB, just use this manner for WIDE CAB. [Routing of wire harness] ・See the figure below for routing of wire harness. ・Should fix the wire harness to chassis cab harness and front panel with tie-rap. (Should not fix wire harness to installation hole for radiator grille. It may be the cause of come off radiator grille.) ・Make sure that there is the enough slack for cab tilt.

Fix a wire harness to panel with tie-rap. (The fix place is should not effect for installing grille.)

Fix a wire harness to cab harness of chassis with tie-rap.

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ELECTRICAL SYSTEM ・When routing wire harness into inside of radiator grille, wire harness may touched a parts of the backside of radiator grille. Therefore, should alter backside of radiator grille as show the instructions below. [Example of routing for additional wire harness] ・The rib on the backside of radiator grille (Area ○) touched wire harness when installed radiator grille. (The right of vehicle.)

[The detail of alter for radiator grille] ・Snap two ribs from their root on the backside of radiator grille as show the picture below. (The right of vehicle.)

Snap these ribs from their root.

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ELECTRICAL SYSTEM

6. INSTALLATION OF ADDITIONAL EQUIPMENT AND SWITCHES Layout of Equipment and Switches

1) Installing space of additional equipment • Have been provided the installing space (H:150mm x W:180 mm ) at the center cluster which can be installed three kind of additional equipment as a wireless radio, electric equipment and etc. 2) Layout of switches and lamps • Layout of switches and lamps are as following figure. This switch layout shows all the specifications of switches. (Included option.) It is different installation switch by the specifics of the vehicles, therefore, it need to confirm the each vehicles. • 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 additional switches and lamps, fit a caution label showing the purpose of them to prevent accidental operation or confirmation.

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ELECTRICAL SYSTEM

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ELECTRICAL SYSTEM Additional Switch • If you need additional switches which install on the instrument panel, please purchase the following switches and connector (with extension) for the switches, then use them. Part No. 84270-37350 84270-37360



Description Specification SWITCH ASSY, GENERALLY USE PULL TYPE Rated load : 24V 1A, 12V 1A SWITCH ASSY, GENERALLY USE PULL TYPE Rated load : 24V 1A, 12V 1A

*‌Should order switch hole base and switch hole cover for installing additional switch (Part No. 84270-37350) with single cab. Part No. 55446-37010 55539-32010

QTY Description per vehicle 1 BASE, SWITCH HOLE 5 COVER, SPARE SWITCH HOLE

BASE

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COVER

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ELECTRICAL SYSTEM Unit : mm

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ELECTRICAL SYSTEM Unit : mm

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ELECTRICAL SYSTEM

7. REAR COMBINATION LAMP

When chassis with cab are shipped, the rear combination lamp assembly is temporarily installed onto the end of the frame. Therefore, they should be relocated by subsequent manufacturer to conform to your country laws and regulations. Install the rear combination lamp directly such that the direction indicator lamp (amber) 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 water drain holes. When installing the rear combination lamps onto the rear body, install reinforcing stays to prevent breakage, deflection and vibration of rear combination lamp body.

1) Detail of rear combination lamp

• Drawing shows right-hand lamp only. Positions reversed for left side.



Unit : mm

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ELECTRICAL SYSTEM 2) Detail of light emission area

Unit : mm

3) Precaution for vehicle with ABS

• Check carefully if there is any damage to the piping or harness after mounting body. • The ABS needs the inspection after mounting body. • If turn the ignition switch on under disconnecting the harness of rear combination lamp circuit, ABS warning lamp in combination meter is on by ABS diagnosis system with detecting abnormal condition (diag-codeC1425) of the harness of rear combination lamp circuit when mounting body. Reconnect the harness of rear combination lamp circuit, and turn the ignition switch on again, and then ABS warning lamp is off but the diag-codeC1425 is still remained in ABS computer, therefore, do not forget to erase diag-code from ABS computer.

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ELECTRICAL SYSTEM

8. LICENSE PLATE BRACKET AND LICENSE PLATE LAMP

1) Use the bracket supplied with the chassis to install the license plate and license plate lamp. 2) The license plate must be installed so as to be clearly visible from the rear of the vehicle.



Make sure that it is not hidden by the 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 at such a position where it is not exposed directly to the water splashed by the rear wheels.

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ELECTRICAL SYSTEM • EXTERNAL ASPECT OF LICENSE PLATE BRACKET



Unit : mm

• EXTERNAL ASPECT OF LICENSE PLATE LAMP

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ELECTRICAL SYSTEM

9. BACK-UP BUZZER

If move the back-up buzzer or modify the around parts of back-up buzzer on the chassis, be sure to observe the following precautions.

1) Installation angle

• Must be kept the permissible range of installing angles shown in the figure below. • If the installing angle is not within range, water will accumulate inside the buzzer and may lead to failure.



Unit : mm

2) Installation area

• Should install the buzzer the area which is the muddy water, rainwater and stone do not splash.

3) Precaution for painting

• Should put a cover on the buzzer during painting to prevent the paint into it for avoiding failure of no sound.

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ELECTRICAL SYSTEM

10. ELECTRICAL WIRING DIAGRAMS

This manual does not contain electrical wiring diagrams. The electrical wiring diagrams are in the WORKSHOP MANUAL. For more details, please consult Hino authorized dealer or distributor.

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Chapter 7 PAINTING

1. TOP COAT PAINTING

2. PRECAUTION OF TOP COAT PAINTING FOR CAB 3. HANDLING OF LAMINATED WINDSHIELD

4. HOW TO REMOVE THE RADIATOR GRILLE

5. THE KIND AND THE ATTACHING POSITION OF MARK AND ORNAMENT

6. PRECAUTIONS FOR FITTING AND STORING THE CAUTION LABEL

7. HANDLING OF COMPUTERS (ECU)

8. CAUTIONS FOR PAINTING THE TIRE DISC WHEELS

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PAINTING

1. TOP COAT PAINTING

Take a care to the following points, when required to repaint it by a customer.

1) Sanding

When repainting, perform to sand the original coat carefully not to be left any parts no-sanded, in order to improve the adhesion of top coat paint. And, never remove off sealant, adhesive agent at connecting parts of the metal sheet.

[Sanding surface]

2) How to Choose Top Coat Paint

(1) When painting on the metal parts Hino recommends urethane-type, 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-grille, front garnish, etc.) and also, can prevent to lowering the shock resistant force at low temperature.

• Then, Avoid to paint backside of the resin parts as its shock resistant force lowers further down with the both side to be painted, of the resin parts. • Cab step, made of polypropylene material, can not be painted.

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PAINTING

2. PRECAUTION OF TOP COAT PAINTING FOR CAB 1) Cautions for Cab Painting

When painting the cab, take a caution to the following points, other than above. (1) The place and parts to be omitted from painting for cab and mounting body as well as adhesion of all kinds of oil: • Various kinds of the ornaments, marks. • Various kinds of caution labels. • Relating equipments and parts to the brake as well as a brake hose. • Various types of rubber hoses. • Electrical wiring, connectors, electric lamps, electric switch, relating equipments and parts. • Back-up buzzer, noise emitting hole of electric horn. • Rubber and plastic parts of cab, engine, chassis suspension and steering system. • Rubber hose for cab-tilt, piston rod of the cylinder for cab-tilt. (The vehicle with a hydraulic cab-tilt, driven by an electric 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 parts of the cab, cleaning it with a neutral detergent, do not use gasoline or thinner. • The fuel filter & fuel pre-filter. • The Auto clutch unit (ACU) of XKU series.

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PAINTING (2) Precaution for preventing to paint the fuel filter & fuel pre-filter If the fuel filter & fuel pre-filter are painted, it may deteriorate the function of fuel filter & fuel pre-filter, and there will be a crack at resin parts. Therefore, be sure to observe the following manner. • Mask the fuel filter & fuel pre-filter completely when painting. • If the fuel filter & fuel pre-filter are painted, it need replace a new one.



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PAINTING 2) Caution when Drying

• When you use forced drying, a temperature on the surface of any parts to be painted must be 80°C as an upper limit. • If the temperature will be over 80℃, should remove any plastic parts and rubber parts from vehicle. For detail of plastic parts and rubber parts. Headlamp, Side turn lamp, End outline marker lamp Front bumper, Radiator grille, Fender and rubber Side reflector, Mirror stay cover

Refer to the figure below for installing position of above parts.

• If the temperature of the pipes and hoses of air conditioner are over 100℃, pressure safety valve may function, and may discharge refrigerant gas. • When removing off a air cleaner assy, seal completely the inlet port side of engine to prevent any penetration of dirt, paint or etc. Also, install hoses securely and clamp them firmly when reinstalling air cleaner.



[Note] • ‌The drawing shows NARROW CAB with all specifications of plastic parts and rubber parts. • ‌It is different installation of plastic parts and rubber parts by the specifics of the vehicles, therefore, it need to confirm the each vehicles. • ‌Please contact Hino authorized dealer or distributor about procedure for removing and reinstalling of these parts. KK-XZU337D

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PAINTING

3. HANDLING OF LAMINATED WINDSHIELD

A laminated glass is produced in such order that polyvinyl butyral film is inserted between 2 glasses and pressed with heat. Under driving general condition, there is no problem. But under a hot temperature and a high moisture when painting, intermediate film is fallen 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 cover over the glass with something so that the temperature on the glass surface should not go up more than 120°C.

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PAINTING

4. HOW TO REMOVE THE RADIATOR GRILLE FOR NARROW CAB

1) How to remove (1) Loosen the screw

in the center parts.

(2) Remove the clips and of lower parts. Put your finger on area A and the other your hand hold on the headlamp then pull back the clip towards you and remove it. The another side also remove clips in the same manner. Put your finger on area B and the other your hand hold on the headlamp then pull back the clip towards you and remove it. (3) Remove the clips and of upper parts. Put your finger on area C and hold the grille with both your hands then pull back the grille towards you and remove the clips and .

※ ‌The clips and are two pieces type, after removed the grille, they separated a drive pin and a seal cap as show figure below.

KK-XZU337D

6

7

PAINTING 2) How to Install (1) Install the eleven clips on the radiator grille. Make sure that there are the eleven clips on the radiator grille before install. Especially, two pieces type of clip need to check that there is the seal cap at the cab body side. (2) The clips and on the grille put a each holes of the cab body (do not push them yet) then push the clips and with the grille in order from center to the side as shows figure below to the cab body. After installed the clips and , push the clips and then the grille fit with the cab body completely. (3) Install the screw

in the center parts.

(4) Make sure to check that the grille is complete fit with the cab body. If not, push the grille again to fit with the cab body.

3) NOTE (1) When remove the radiator grille, should follow above the instructions. If not, it may be that the parts was damaged or injure. (2) Make sure that there are no damage at the lock parts of clips before install the radiator grille but if there are any damage of clips, it need to replace a new ones.

KK-XZU337D

7

7

PAINTING FOR WIDE CAB

1) How to remove (1) Loosen the screw

in the center parts.

(2) Remove the clips and of lower parts. Put your finger on area A and the other your hand hold on the headlamp then pull back the clip towards you and remove it. The another side also remove clips in the same manner. Put your finger on area B and the other your hand hold on the headlamp then pull back the clip towards you and remove it. (3) Remove the clips , and of upper parts. Hold the radiator grille at area A and C with both your hands then pull back the grille towards you and remove the clip . The another side also remove clips in the same manner. Hold the radiator grille at area B and D with both your hands then pull back the grille towards you and remove the clip . It may be comes off the clip , when removed the clips and which is OK but if not came out , hold area C and E or area D and E with both your hands then pull back the grille towards you and remove the clip . Should not remove it forcibly.

KK-XZU337D

8

7

PAINTING 2) How to Install (1) Install the nine clips on the radiator grille. Make sure that there are the nine clips on the radiator grille before install. (2) The clips and on the grille put a each holes of the cab body (do not push them yet), then push the clips , and with the grille in order from center to the side as shows figure below to the cab body. After installed the clips , and , push the clips and then the grille fit with the cab body completely. (3) Install the screw

in the center parts.

(4) Make sure to check that the grille is complete fit with the cab body. If not, push the grille again to fit with the cab body.

3) NOTE (1) When remove the radiator grille, should follow above the instructions. If not, it may be that the parts was damaged or injure. (2) Make sure that there are no damage at the lock parts of clips before install the radiator grille but if there are any damage of clips, it need to replace a new ones.

KK-XZU337D

9

7

PAINTING

5. THE KIND AND THE ATTACHING POSITION OF MARK AND ORNAMENT The kind and the position to be attached of marks, caution label (DPR) and ornaments on the cab as well as the chassis are specified in the chart below. Implement masking them completely when repainting the cab or the body. When the marks, the caution label (DPR) and 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. Each table shows all specification of Mark and Ornament. (Included option.) It is different Mark and Ornament by the specifics of the vehicles, therefore, it need to confirm the each vehicles. CAB FRONT ATTACHING PLACE

NAME OF MARK

No.

KIND OF MARK

PART No. 75315-37070 ( NARROW CAB )

SYMBOL MARK

1

MODEL MARK

2

75311-37250

HINO MARK

3

75311-37260

HYBRID MARK

4

75316-37010

75315-37100 ( WIDE CAB )

CAB FRONT

[Note] Part ‌ numbers are changeable always. Accordingly, for confirmation, please contact Hino authorized dealer or distributor when you place an order for necessary parts.

KK-XZU337D

10

7

PAINTING DOOR ATTACHING NAME OF MARK No. PLACE HYBRID MARK

5

KIND OF MARK

PART No. 75316-37010 75427-0W020 75427-0W030

DOOR

EMISSION CONTROL MARK

75427-0W040 6 75427-0W050 75427-0W060 75427-F1010

[Note] Part ‌ numbers are changeable always. Accordingly, for confirmation, please contact Hino authorized dealer or distributor when you place an order for necessary parts.

KK-XZU337D

11

7

PAINTING <MODEL SERIES MARK> • The following figure shows the Mark example.

ATTACHING NAME OF MARK No. KIND OF MARK PLACE

DOOR

MODEL SERIES MARK

7

411 412 416 511 512 513 514 611 612 613 614 615 616 617 711 713 714 715 716 717 811 813 814 815 816 817 913 915 916 917 820 821 920 921

PART No. 75429-37250 75429-37260 75429-37270 75429-37280 75429-37290 75429-37300 75429-37310 75429-37320 75429-37330 75429-37390 75429-37340 75429-37350 75429-37360 75429-37400 75429-37410 75429-37420 75429-37430 75429-37540 75429-37370 75429-37440 75429-37450 75429-37460 75429-37470 75429-37480 75429-37380 75429-37490 75429-37500 75429-37510 75429-37520 75429-37530 75429-37550 75429-37560 75429-37570 75429-37580

[Note] Part ‌ numbers are changeable always. Accordingly, for confirmation, please contact Hino authorized dealer or distributor when you place an order for necessary parts. KK-XZU337D

12

7

PAINTING FUEL TANK ATTACHING PLACE

FUEL TANK

NAME OF CAUTION LABEL

DPR MUFFLER

No.

8

DETAIL OF CAUTION LABEL

FOLLOWING BELOW

PART No.

DESCRIPTION

74562-37230

For HONG KONG

74562-37240

For GENERAL Except HONG KONG, TAIWAN, ARGENTINA, CHILE & RUSSIA

74562-37270

For ARGENTINA & CHILE

74562-37280

For RUSSIA

74562-F1010

For TAIWAN

Detail of Caution label

[Note] Part ‌ numbers are changeable always. Accordingly, for confirmation, please contact Hino authorized dealer or distributor when you place an order for necessary parts. KK-XZU337D

13

7

PAINTING 1) Attaching Place and Procedure for Each Mark, Ornament and Caution label (DPR) Refer to the detailed figure of the attaching position for 1 to 8 of the attachments on the cab or fuel tank.

(1) Mark and Ornament

• NARROW CAB



• WIDE CAB

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14

7

PAINTING (2) Caution label (DPR) Recommended fitting position 8. FUEL TANK SURFACE FRAME (RH)

UP

RIGHT

FRONT FUEL TANK

(RIGHT SIDE OF THE VIECLE)

KK-XZU337D

15

7

PAINTING 2) Detail of Each Mark and Ornament attaching position (1) NAME : SYMBOL MARK PLACE : Radiator grille

• NARROW CAB



• WIDE CAB

HOW TO REMOVE THE HINO MARK ‌ After removed the radiator grille from the cab body, unlock (the arrow direction as show figure above) the install pin of HINO MARK from back side of radiator grille. Pull back an emblem forwards you and remove it.

KK-XZU337D

16

7

PAINTING (2) NAME : MODEL and HINO MARK PLACE : Cab front panel

• NARROW CAB

Unit : mm

KK-XZU337D

17

7

PAINTING

• WIDE CAB

Unit : mm

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18

7

PAINTING (3) NAME : HYBRID MARK PLACE : Radiator grille

• NARROW CAB



• WIDE CAB

Unit : mm

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19

7

PAINTING (4) NAME : HYBRID, EMISSION CONTROL and MODEL SERIES MARK PLACE : Door

• NARROW CAB

Unit : mm

6

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20

7

PAINTING

• WIDE CAB

Unit : mm

6

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21

7

PAINTING

6. PRECAUTIONS FOR FITTING AND STORING THE CAUTION LABEL 1) How to Stick It

(1) Stick the caution label to a dry place which is free from dust and dirt after the paint has completely dried up. (2) Clean your hand and don't use cotton work gloves, etc.. (3) Completely remove water, oil, dust, etc. from the surface to stick (surface of cab) with ethyl alcohol if they are found remaining there. (4) When the temperature is less than 10°C, warm up the surface to stick as well as the caution label with warm wind of more than 20°C before sticking the caution label. (5) After sticking the caution label, press it with a roller, etc., with a force of approximately 49 N/cm2 {5 kgf/cm2 }. (6) Remove liner paper (backing paper) just before using it. (7) When air remains inside, 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

(1) When storing the caution label, select a dry place with an ambient temperature (of 20 to 25°C) and without dust, dirt and stain. (2) Also, store the caution label at a flat place such as a shelf and do not place anything on it.

3) Other Precautions for the Caution label

(1) As the caution label is made from vinyl chloride, it is thin, soft and easily extendible.

Therefore, take utmost care for handling it.

(2) When removing the caution label, be careful not to damage the painted surface with a sharp knife, etc.

On the other hand, removal of the caution label can be done more easily by pulling the caution label in perpendicular direction to the sticking surface while heating it with a hair dryer.

(3) Do not throw the caution label away but keep them together to compare with new caution label and to prevent mixing up with the new ones.

KK-XZU337D

22

7

PAINTING

7. HANDLING OF COMPUTERS (ECU) When drying paint by forced dry method, follow the instructions below to avoid damage to ECU.

CONDITION OF FORCED DRYING PAINT • INSIDE TEMPERATURE OF THE FORCED DRYING BOOTH

: 120˚C

1 • INSIDE TEMPERATURE OF THE CAB : LESS THAN (PLACE AT THE 50mm HEIGHT 80˚C FROM UPPER SURFACE OF CAB FLOOR.)

2

3

HANDLING OF COMPUTER

WHEN UNKNOWN THE TEMPERATURE OF THE FORCED DRYING BOOTH OR USE INFRARED LAMP

INSTALLED

INSIDE TEMPERATURE OF THE CAB : LESS THAN (PLACE AT THE 50mm HEIGHT 80˚C FROM UPPER SURFACE OF CAB FLOOR.)

WHEN EXPECT MORE HIGH TEMPERATURE THAN ABOVE MENTIONED CASES.

KK-XZU337D

REMOVE COMPUTER

23

7

PAINTING

8. CAUTIONS FOR PAINTING THE TIRE DISC WHEELS Before painting the tire disc wheel, mask surfaces that will contact the wheel, the hub, the brake drum and wheel nuts. Refer to the figure below concerning the covering portions.

After installing the tire disc wheel onto the vehicle, paint the remained portions with same color as thin as possible. It is because paint coated face may become contact face by rotating the tire. If the painting layer is thick, it causes wheel nuts loosen.

Consideration should be taken when rotating the tires and wheels Sometimes, the installing position of tire disc wheel may be changed and paint coated face may become contact face. At this moment, if the thickness of the painted layer is excessively thick, this may lead to the loosening of the wheel nuts. Therefore observe the following instructions when carrying out the tire rotation. • Take off the paint on the contact face (including the contact surface of wheel nut) of the tire disc wheel and after having completely cleaned the face with a wire brush etc., apply thin layer of paint for rust preventive purpose. • If you use the tire disc wheel without taking off the paint, even if the face is completely cleaned with wire brush, etc., the thick painted layer may lead to the loosening of wheel nuts. KK-XZU337D

24

Chapter 8 CHASSIS DRAWINGS

1. CAB DRAWINGS 2. CAB BACK DRAWINGS 3. CHASSIS DRAWINGS

KK-XZU337D

8

CHASSIS DRAWINGS Refer to detail of the cab, cab back and chassis drawing based on following table.

XZU640L-HKMLN3

CHASSIS DRAWINGS CAB CAB BACK CHASSIS C-1 CB-1 CH-1

XZU710L-QKFMP3

C-2

MODEL XZU650L-HKMMP3

C-1

CB-2

CH-2

C-3

CB-3

CH-4

XZU720L-HKFRP3

C-3

CB-3

CH-5

XKU710L-HKUQP3

C-3

CB-4

CH-6

XZU710L-HKFMP3 XZU710L-HKFQP3

XKU710L-HKUMP3 XKU710L-HKURP3

C-3

C-3 C-3

KK-XZU337D

--

CB-3

CB-4 CB-4

CH-3 CH-4

CH-6

CH-6

1

8

CHASSIS DRAWINGS

1. CAB DRAWINGS No. C-1

Unit : mm

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2

8

CHASSIS DRAWINGS No. C-2 

Unit : mm

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3

8

CHASSIS DRAWINGS No. C-3 

Unit : mm

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4

8

CHASSIS DRAWINGS

2. CAB BACK DRAWINGS No. CB-1

Unit : mm

• Left view

 efer to Chassis with cab drawing for the R layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

5

8

CHASSIS DRAWINGS No. CB-1

• Right view

Unit : mm

 efer to Chassis with cab drawing for the R layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

6

8

CHASSIS DRAWINGS No. CB-1

• Upper view

Unit : mm

BATTERY BATTERY

Refer to Chassis with cab drawing for the layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

7

8

CHASSIS DRAWINGS No. CB-2

• Left view

Unit : mm

Refer to Chassis with cab drawing for the layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

8

8

CHASSIS DRAWINGS No. CB-2

• Right view

Unit : mm

Refer to Chassis with cab drawing for the layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

9

8

CHASSIS DRAWINGS No. CB-2

• Upper view

Unit : mm

BATTERY BATTERY

Refer to Chassis with cab drawing for the layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

10

8

CHASSIS DRAWINGS No. CB-3

• Left view

Unit : mm

Refer to Chassis with cab drawing for the layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

11

8

CHASSIS DRAWINGS No. CB-3

• Right view

Unit : mm

Refer to Chassis with cab drawing for the layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

12

8

CHASSIS DRAWINGS No. CB-3

• Upper view

Unit : mm

BATTERY BATTERY

Refer to Chassis with cab drawing for the layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

13

8

CHASSIS DRAWINGS No. CB-4

• Left view

Unit : mm

Refer to Chassis with cab drawing for the layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

14

8

CHASSIS DRAWINGS No. CB-4

• Right view

Unit : mm

Refer to Chassis with cab drawing for the layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

15

8

CHASSIS DRAWINGS No. CB-4

• Upper view

Unit : mm

Refer to Chassis with cab drawing for the layout of Fuel tank, Tool box and Spare tire. KK-XZU337D

16

8

CHASSIS DRAWINGS

3. CHASSIS DRAWINGS No. CH-1

Unit : mm

MODEL

TIRE SIZE

A

B

C

D

Tr

XZU640L-HKMLN3

205/75R16C-113/111 F:7.00R16-10 R:7.00R16-12

-

1555 1546

1400 1400

960 960

1350 1350

FRAME 5156 5156

DETAIL OF ★L SPARE Rr. HOOK TIRE BUMPER 5184 5184 -

★L

★Hc

★Hf

★Hr

★Hro

5184 5184

2100 2130

623 653

690 722

724 756

[NOTE] • The 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. • Figures marked " " dimensions are measured in parallel with the surface of the ground.

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17

8

CHASSIS DRAWINGS No. CH-2 

Unit : mm

MODEL

TIRE SIZE

A

B

C

D

Tr

XZU650L-HKMMP3

205/75R16C-113/111 7.00R16-10 7.00R16-12

230 230 230

1869 1860 1860

1400 1400 1400

840 840 840

1435 1435 1435

FRAME 5936 5936 5936

DETAIL OF ★L SPARE Rr. HOOK TIRE BUMPER 5964 5964 5964 -

★L

★Hc

★Hf

★Hr

★Hro

5964 5964 5964

2108 2138 2140

632 662 665

703 733 734

735 766 766

[NOTE] • The 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. • Figures marked " " dimensions are measured in parallel with the surface of the ground.

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8

CHASSIS DRAWINGS No. CH-3 

Unit : mm

MODEL

TIRE SIZE

A

B

C

D

Tr

XZU710L-QKFMP3

7.00R16-10 205/75R16C-113/111

230 230

1905 1914

1660 1660

885 885

1480 1480

FRAME 6121 6121

DETAIL OF ★L SPARE Rr. HOOK TIRE BUMPER -

★L

★Hc

★Hf

★Hr

★Hro

6121 6121

2231 2201

687 657

786 755

831 800

[NOTE] • The 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. • ‌Figures marked " " dimensions are measured in parallel with the surface of the ground.

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8

CHASSIS DRAWINGS No. CH-4 

Unit : mm

MODEL XZU710L-HKFMP3 XZU710L-HKFQP3

TIRE SIZE

A

B

C

D

Tr

7.00R16-10 205/75R16C-113/111 215/85R16-E(10) 7.50R16-10

230 230 244 254

1905 1914 1982 1985

1660 1660 1665 1655

885 885 885 885

1480 1480 1520 1520

FRAME 6121 6121 6121 6121

DETAIL OF ★L SPARE Rr. HOOK TIRE BUMPER -

★L

★Hc

★Hf

★Hr

★Hro

6121 6121 6121 6121

2203 2173 2221 2237

691 661 709 726

789 758 786 803

834 803 822 839

[NOTE] • The 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. • ‌Figures marked " " dimensions are measured in parallel with the surface of the ground.

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8

CHASSIS DRAWINGS No. CH-5 

Unit : mm

MODEL

TIRE SIZE

A

B

C

D

Tr

XZU720L-HKFRP3

215/75R17.5-124/123 7.50R16-12

254 254

1988 1985

1655 1655

885 885

1520 1520

FRAME 6739 6739

DETAIL OF ★L SPARE Rr. HOOK TIRE BUMPER -

★L

★Hc

★Hf

★Hr

★Hro

6739 6739

2216 2238

705 727

796 815

837 856

[NOTE] • The 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. • Figures marked " " dimensions are measured in parallel with the surface of the ground.

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8

CHASSIS DRAWINGS No. CH-6 

Unit : mm

MODEL

TIRE SIZE

A

B

C

D

Tr

XKU710L-HKUMP3

205/75R16C-113/111 215/85R16-E(10) 215/75R17.5-124/123 215/75R17.5-124/123

230 244 254 254

1915 1982 1988 2058

1660 1655 1655 1655

885 885 885 885

1480 1520 1520 1590

XKU710L-HKUQP3 XKU710L-HKURP3

FRAME 6118 6119 6119 6118

DETAIL OF ★L SPARE Rr. HOOK TIRE BUMPER -

★L

★Hc

★Hf

★Hr

★Hro

6118 6119 6119 6118

2169 2216 2214 2214

657 705 702 702

755 783 781 792

800 819 817 834

[NOTE] • The 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. • ‌Figures marked " " dimensions are measured in parallel with the surface of the ground.

KK-XZU337D

22

Chapter 9 CHASSIS FRAME DRAWINGS

1. CHASSIS FRAME DRAWINGS

KK-XZU337D

9

CHASSIS FRAME DRAWINGS Refer to detail of the chassis frame drawing based on following table. MODEL

CHASSIS FRAME DRAWINGS

XZU640L-HKMLN3 XZU650L-HKMMP3 XZU710L-QKFMP3 XZU710L-HKFMP3 XZU710L-HKFQP3 XZU720L-HKFRP3 XKU710L-HKUMP3 XKU710L-HKUQP3 XKU710L-HKURP3

CF-1 CF-2 CF-3 CF-3 CF-4 CF-5 CF-6 CF-7 CF-7

KK-XZU337D

1

9

CHASSIS FRAME DRAWINGS

1. CHASSIS FRAME DRAWINGS No. CF-1

Unit : mm

• Detail of the chassis frame

KK-XZU337D

2

9

CHASSIS FRAME DRAWINGS No. CF-1

• Detail of the cross member

Unit : mm

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3

9

CHASSIS FRAME DRAWINGS No. CF-2

• Detail of the chassis frame

Unit : mm

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4

9

CHASSIS FRAME DRAWINGS No. CF-2

• Detail of the cross member

Unit : mm

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5

9

CHASSIS FRAME DRAWINGS No. CF-3

• Detail of the chassis frame

Unit : mm

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6

9

CHASSIS FRAME DRAWINGS No. CF-3

• Detail of the cross member

Unit : mm

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7

9

CHASSIS FRAME DRAWINGS No. CF-4

• Detail of the chassis frame

Unit : mm

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8

9

CHASSIS FRAME DRAWINGS No. CF-4

• Detail of the cross member

Unit : mm

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9

9

CHASSIS FRAME DRAWINGS No. CF-5

• Detail of the chassis frame

Unit : mm

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10

9

CHASSIS FRAME DRAWINGS No. CF-5

• Detail of the cross member

Unit : mm

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11

9

CHASSIS FRAME DRAWINGS No. CF-6

• Detail of the chassis frame

Unit : mm

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12

CHASSIS FRAME DRAWINGS No. CF-6

• Detail of the cross member

Unit : mm

79

120

9

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13

9

CHASSIS FRAME DRAWINGS No. CF-7

• Detail of the chassis frame

Unit : mm

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14

CHASSIS FRAME DRAWINGS No. CF-7

• Detail of the cross member

Unit : mm

79

120

9

KK-XZU337D

15

Chapter 10 MOUNTING OF CHASSIS EQUIPMENT

1. THE TABLE OF CHASSIS EQUIPMENT 2. FUEL TANK 3. BATTERY

4. EXHAUST SYSTEM

KK-XZU337D

10

MOUNTING OF CHASSIS EQUIPMENT

1. THE TABLE OF CHASSIS EQUIPMENT

Refer to FUEL TANK, BATTERY and EXHAUST SYSTEM based on following table. MODEL

FUEL TANK

STD

OPT -

BATTERY

EXHAUST SYSTEM

STD

OPT

STD

BAT-1

BAT-2

EX-1

BAT-1

BAT-2

EX-1

XZU640L-HKMLN3

FT-1

XZU650L-HKMMP3

FT-1

XZU710L-QKFMP3

FT-2

-

BAT-3

BAT-4

EX-2

XZU710L-HKFMP3

FT-3

FT-4

BAT-3

BAT-4

EX-2

XZU710L-HKFQP3

FT-3

FT-4

BAT-3

BAT-4

EX-2

XZU720L-HKFRP3

FT-3

BAT-3

FT-5

BAT-4 -

EX-2

XKU710L-HKUMP3

FT-4 -

XKU710L-HKUQP3

FT-5

-

EX-3

XKU710L-HKURP3

FT-5

-

-

BAT-5 BAT-5 BAT-5

KK-XZU337D

-

EX-3 EX-3

OPT -

1

10

MOUNTING OF CHASSIS EQUIPMENT

2. FUEL TANK FT-1

Unit : mm

KK-XZU337D

2

10

MOUNTING OF CHASSIS EQUIPMENT FT-2 

Unit : mm

KK-XZU337D

3

10

MOUNTING OF CHASSIS EQUIPMENT FT-3 

Unit : mm

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4

10

MOUNTING OF CHASSIS EQUIPMENT FT-4 

Unit : mm

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5

10

MOUNTING OF CHASSIS EQUIPMENT FT-5 

Unit : mm

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6

10

MOUNTING OF CHASSIS EQUIPMENT

3. BATTERY BAT-1

Unit : mm

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7

10

MOUNTING OF CHASSIS EQUIPMENT BAT-2 

Unit : mm

PRODUCTION CODE

• • • •

XZU60 ※※ • WU60 ※※ XZU64 ※※ • WU64 ※※ XZU65 ※※ • WU65 ※※ XZU63 ※※

KK-XZU337D

8

10

MOUNTING OF CHASSIS EQUIPMENT BAT-3 

Unit : mm

KK-XZU337D

9

10

MOUNTING OF CHASSIS EQUIPMENT BAT-4 

Unit : mm

KK-XZU337D

10

10

MOUNTING OF CHASSIS EQUIPMENT BAT-5 

Unit : mm

KK-XZU337D

11

10

MOUNTING OF CHASSIS EQUIPMENT

4. EXHAUST SYSTEM EX-1

Unit : mm

A

A :

KK-XZU337D

A :

12

10

MOUNTING OF CHASSIS EQUIPMENT EX-2 

Unit : mm

KK-XZU337D

13

10

MOUNTING OF CHASSIS EQUIPMENT EX-3 

Unit : mm

KK-XZU337D

14

Chapter 11 REGULATION

1. HANDLING PRECAUTIONS OF CATALYST MUFFLER

KK-XZU337D

11

REGULATION This section is described the informations in relation to vehicle’s lows and regulations that must be complied while body or equipment is mounted on the Hino truck chassis with cab as following contents. • Items which the body or equipment manufacturer must be provided the facilities. • Handling precautions of parts which has already been equipped on the chassis, the cab, and the engine. • Other precautions which must be taken during the work of the body or equipment mounting. The body or equipment manufacturer must make sure the contents to be described in this section.

KK-XZU337D

1

11

REGULATION

1. HANDLING PRECAUTIONS OF CATALYST MUFFLER

To comply with exhaust gaseous emission control regulation, the Catalyst Muffler is equipped to 300 series. The catalyst muffler is equipped to the vehicle with EURO-4. The figure below shows the example exhaust system layout with catalyst muffler. Make sure that water do not into the muffler, when washing the vehicle, especially under parts of the chassis. Do not give any shock such as dropped off and fit by a hammer. Be sure to take great care about the handling of muffler when mounting body.

• Exhaust system layout Unit : mm

KK-XZU337D

2