Hino Motors 300 Series Guide

HINO 300 SERIES
Body Mounting Manual
TRUCK CHASSIS
TRUCK CHASSIS
XZU
XKU
(Hybrid vehicle)
&
MODEL
SERIES
KK-XZU215C

KK-XZU215C
No part of this manual may be reproduced or transmitted in any form without the
express written permission of Hino Motors, Ltd.
©2010, All rights reserved. Printed in Japan.
PRODUCT PLANNING DIVISION
3-1-1, HINO-DAI, HINO-SHI, TOKYO, 191-8660 JAPAN
Telephone : [phone]
Facsimile : 042-586-5868
2010 - 02

KK-XZU215C
We have published the new revised edition of Body Mounting Manual with
the following changes.
Consequently, please discard the current Body Mounting Manual
CD-ROM NO.KK-XZU215B, and use the new CD-ROM NO.KK-XZU215C
from now on.
CONTENTS OF CHANGES
The information about XKU417L-HKFQB3 (Hybrid vehicle) has been added.
RECORD OF CHANGES

KK-XZU215C
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 “PRODUCTION CODE” name.
•When making use of the BODY MOUNTING MANUAL, use the MODEL
NAME after replacing it in accordance with the following table.
(MODEL) (PRODUCTION CODE)
HINO 3414 XZU307L-HKMLB3
XZU307L-HKMMB3
XZU347L-HKMMB3
XZU407L-HKMMD3
XZU407L-HKMQD3
XZU417L-HKMMD3
XZU407L-HKFQD3
XZU417L-HKFQD3
XZU427L-HKFQD3
XZU407L-HKFRD3
XZU417L-HKFRD3
XZU427L-HKFRD3
HINO 3714 XKU417L-HKFQB3
AUSXZU201 00T001
HINO 3716
HINO 3816
HINO 3616
HINO 3614

- 1 - KK-XZU215C
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 with US-04 emission control in
the Hino light duty trucks.
Important
This instruction manual must be used in combination
with the Common Manual, No. KC-AA102.
•For more information on mounting of bodies and equipments
or on chassis modifications, refer to the appropriate workshop
manuals, parts catalogs, and maintenance guides and
owner's or driver's manual.
•The information in this manual is accurate to the best of
Hino's Knowledge at the time of going to press.
Hino reserves the right to modify any and all information
without notice and without obligation.
•Should more detailed data or information be needed, please
contact authorized Hino distributor.
ABOUT THIS MANUAL

- 2 -
KK-XZU215C
Warning
•It is the responsibility of Body and Equipment Manufacturers
or modification companies to make sure that the completed
vehicle with body and equipment, or after modification,
conforms to all applicable laws and regulations of the country
in which the vehicle is to be used (e. g. regulations on
lighting, tilt, overall size, axle load, external noise control etc.)
•This manual does not guarantee the safety of a Hino chassis
once a body or equipment has been mounted or modification
has been made by a Body and Equipment Manufacturers or a
modification company.
•This manual does not affect that ultimate responsibility for the
manufacture and mounting of the body, installation,
modification or alteration on Hino Chassis devolves upon the
Body and Equipment Manufacturer.
•Each individual Body and Equipment Manufacturer has the
sole responsibility for the design, functions, materials and
work concerning the body and equipment.
•Hino Motors, Ltd. does not assume any liability whatsoever
for any injury to persons or damage to property caused as a
result of the utilization of this manual.
ABOUT THIS MANUAL

KK-XZU215C
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
CONTENTS

KK-XZU215C
1. VEHICLE SUMMARY
PRODUCTION CODE･･････････････････････････････････････････ 1 - 1
IDENTIFICATION NUMBER ････････････････････････････････････ 1 - 2
CHASSIS SPECIFICATIONS････････････････････････････････････ 1 - 3

PRODUCTION CODE
1. VEHICLE SUMMARY 1 - 1
KK-XZU215C
XZ U 41 4 L - H K F R D W 3
AUSXZU201 01T001
DOUBLE
CODE
L
M
Q
R
S
7.5
6.5
4.495(FOR AUS.)
3870
4200
M
P
T
5 SPEEDS (MECH.)
4 SPEEDS (AUTO.)
6 SPEEDS (AUTO.)
MDUMP
TRANSMISSION CODE
F6 SPEEDS (MECH.)
BODY DECK HEIGHT CODE
B
K
Q
HIGH FLOOR
LOW FLOOR
300 SERIES
CAB DRIVEWHEEL BASE
2800
3400
L
RLEFT HAND DRIVE
RIGHT HAND DRIVE
CHASSIS TYPE CODE
41
MODEL SERIES CODE
CODE
30
32
4 X 2
NARROW
WIDE
2810
3430
CAB TYPE CODE
HSINGLE
DOUBLEQ
42
43
5.5
4.495(FOR AUS.)
GVMR (ton)
GVMR AND REAR TIRE TYPE CODE
4.8-5.1
4.495(FOR AUS.)
REAR TIRE TYPE
SINGLE
4.495(FOR AUS.)
8.0
8.5
ENGINE CODE
T
NA
W/TURBO
DESTINATION CODE
NIL
S
A
B
D
D
N
Q
R
T
V
W
EXPORT STANDARD
INDONESIA
SOUTH AFRICA
AUSTRALIA & NEW ZEALAND
TAIWAN
THAI
GCC
EURO
SHIPPING CODE
CAB WITH CHASSIS3
34
40
U
VEHICLE MODEL CODE
2525
33
XZ
XK
N04C-TR/TS/TT, N04C-TP/TW, N04C-TU/TV
ENGINE TYPE CODE
N04C-TN/TU (N04C-H1)
W W04D, W04D-TM, W04D-TN
6
EMISSION CONTROL
EURO-1/2
-
EURO-1/2
EURO-3
-
-
EURO-4
3
4
5
ENGINE AND SUSPENSION CODE
CODE
0
1
2
RIGID
INDEPENDENT
8
ENGINE
W04D
-
W04D-TM/TN
N04C-TR/TS/TT
-
N04C-TP/TW
FRONT SUSPENSION
RIGID
-
-
RIGID
RIGID
D
US04
N04C-TU
N04C-TN
7 RIGIN04C-TU/TV

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

CHASSIS SPECIFICATIONS
1 - 3
KK-XZU215C
Cab type
Item
Drive system (number of wheels) 4x2 (4) 4x2 (6) 4x2 (6) 4x2 (6) 4x2 (6) 4x2 (6) 4x2 (6) 4x2 (6) 4x2 (6) 4x2 (6) 4x2 (6) 4x2 (6) 4x2 (6)
Wheel base (mm) 2525 2525 3400 2810 2810 2810 2810 3430 3430 3430 3870 3870 3430
Front 1400 1400 1400 1660 1665 1665 1655 1660 1665 1655 1655 1655 1655
Rear 1350 1435 1435 1480 1520 1520 1520 1480 1520 1520 1520 1520 1520
Max. GVM Rating (kg) 4300 5500 5500 5500 5500 6500 7500 5500 6500 7500 6500 7500 6500
Front 2600 2600 2600 2600 3100 3100 3100 2600 3100 3100 3100 3100 3100
Capacity (kg) Rear 4400 4400 4400 4400 5100 5100 5500 4400 5100 5500 5100 5500 5100
(On std. Spec.) Front 2300 2300 2300 2300 2800 2800 3200 2300 2800 3200 2800 3200 2430
Rear 2300 4360 4360 4360 5280 5280 6200 4360 5280 6200 5280 6200 4480
Chassis mass (kg) Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1
Model N04C-TU N04C-TU N04C-TU N04C-TV N04C-TV N04C-TV N04C-TV N04C-TV N04C-TV N04C-TV N04C-TV N04C-TV N04C-UK
Max. Out put JIS gross 103{140}/2700 103{140}/2700 103{140}/2700 114{155}/2700 114{155}/2700 114{155}/2700 114{155}/2700 114{155}/2700 114{155}/2700 114{155}/2700 114{155}/2700 114{155}/2700 103{140}/3000
Engine (kW{PS}/rpm) ISO net 100{136}/2700 100{136}/2700 100{136}/2700 110{150}/2700 110{150}/2700 110{150}/2700 110{150}/2700 110{150}/2700 110{150}/2700 110{150}/2700 110{150}/2700 110{150}/2700 100{136}/3000
Max. Torque JIS gross 364{37.1}/1800 364{37.1}/1800 364{37.1}/1800 404{41.2}/1800 404{41.2}/1800 404{41.2}/1800 404{41.2}/1800 404{41.2}/1800 404{41.2}/1800 404{41.2}/1800 404{41.2}/1800 404{41.2}/1800 359{36.6}/1600
(N·m{kgf·m}/rpm) ISO net 358{36.5}/1800 358{36.5}/1800 358{36.5}/1800 397{40.5}/1800 397{40.5}/1800 397{40.5}/1800 397{40.5}/1800 397{40.5}/1800 397{40.5}/1800 397{40.5}/1800 397{40.5}/1800 397{40.5}/1800 353{36.05}/1600
Emission US04 US04 US04 US04 US04 US04 US04 US04 US04 US04 US04 US04 US04
Height of gravity from ground (m) Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1 Refer to page 3-1
Front 205/75R16C 205/75R16C 205/75R16C 205/75R16C 215/85R16 215/85R16 215/75R17.5 205/75R16C 215/85R16 215/75R17.5 215/85R16 215/75R17.5 215/85R16
Rear 205/75R16C 205/75R16C 205/75R16C 205/75R16C 215/85R16 215/85R16 215/75R17.5 205/75R16C 215/85R16 215/75R17.5 215/85R16 215/75R17.5 215/85R16
Front 16x5.5K-115mm 16x5.5K-115mm 16x5.5K-115mm 16x5.5K-115mm 16x5.5K-122mm 16x5.5K-122mm 17.5x6.00-127mm 16x5.5K-115mm 16x5.5K-122mm 17.5x6.00-127mm 16x5.5K-122mm 17.5x6.00-127mm 16x5.5K-122mm
Rear 16x5.5K-115mm 16x5.5K-115mm 16x5.5K-115mm 16x5.5K-115mm 16x5.5K-122mm 16x5.5K-122mm 17.5x6.00-127mm 16x5.5K-115mm 16x5.5K-122mm 17.5x6.00-127mm 16x5.5K-122mm 17.5x6.00-127mm 16x5.5K-122mm
Fuel tank (L) 70 70 100 100 100 100 100 100 100 100 100 100 100
Battery 12-216{60}x2 12-216{60}x2 12-216{60}x2 12-216{60}x2 12-216{60}x2 12-216{60}x2 12-216{60}x2 12-216{60}x2 12-216{60}x2 12-216{60}x2 12-216{60}x2 12-216{60}x2 12-288{80}x2
Alternator V - A 24-60 24-60 24-60 24-60 24-60 24-60 24-60 24-60 24-60 24-60 24-60 24-60 24-80
Body width (See notes.) (mm)
AUSXZU201 01T002
XKU417L-HKFQB3
WIDE CAB SERIES
2095
V - kC {Ah} - No.
Chassis model XZU427L-HKFQD3XZU417L-HKFQD3 XZU417L-HKFRD3
(mm)
XZU407L-HKMQD3 XZU407L-HKFRD3
STANDARD CAB SERIES
Tire and disc
Tire
Disc
Axle
Tire
Tread
1896
XZU307L-HKMLB3 XZU307L-HKMMB3 XZU347L-HKMMB3 XZU407L-HKMMD3 XZU417L-HKMMD3 XZU427L-HKFRD3XZU407L-HKFQD3
[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 (XZU307L-HKMLB3 only) or less.
•The height of center of gravity from ground on the unloaded vehicle with body mounted should be 0.88m (STANDARD CAB SERIES), 1.00m (WIDE CAB SERIES) or less.
•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.

KK-XZU215C
2. GENERAL PRECAUTIONS
FIRE SHIELD ････････････････････････････････････････････････ 2 - 1
CLEARANCE BETWEEN CAB AND REAR BODY OR ････････････ 2 - 2
EQUIPMENT
RECOMMENDED POSITIONS OF U-BOLTS ････････････････････ 2 - 3
RECOMMENDED POSITIONS OF REAR FENDERS AND･･････････ 2 - 4
MUDGUARDS
ELECTRIC WELDING WORK ･･････････････････････････････････ 2 - 5
NOTES ON ADDITIONAL WIRING IN THE ENGINE ･･････････････ 2 - 6
COMPARTMENT
NOTES ON ENGINE CONTROL, BRAKE ABS SYSTEM ･･････････ 2 - 7
COMPUTERS AND DC-DC CONVERTER
HANDLING OF PARTS FOR MEETING THE EXTERNAL ･･････････ 2 - 8
NOISE CONTROL REGULATION
PRECAUTION ON BODY MOUNTING WORK ････････････････････ 2 - 9
THE NOISE MEASURES OF THE AM RADIO ････････････････････ 2 - 10
Peculiar to XKU417L-HKFQB3
**
*

2 - 1
2. GENERAL PRECAUTIONS
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 part of cab.
KK-XZU215C
• For approximately 50 mm 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 rear arch cover.
• You may also install the fire shield so
that it covers only the exhaust pipe.

2 - 2 - 1
KK-XZU215C
CLEARANCE BETWEEN CAB AND REAR BODY OR EQUIPMENT
The rear part 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) STANDARD CAB series
Unit : mm
(2) WIDE CAB series

2 - 2 - 2
2) Measurement of the Engine Air Intake Port
• STANDARD CAB series Unit : mm
SIDE VIEW ( LEFT SIDE ) REAR VIEW ( LEFT SIDE )
KK-XZU215C

2 - 2 - 3
KK-XZU215C
• WIDE CAB series Unit : mm
SIDE VIEW ( LEFT SIDE ) REAR VIEW ( LEFT SIDE )
Caution
The blocking of the smooth flow of air into the air intake pipe caused by
any materials such as ropes, pieces of cloth, etc. leads to the increase
of exhaust temperature if driven long intervals. The increase in exhaust
temperature is caused by the decreased efficiency in the combustion
process, as the proportion of air in the combustion chamber is also
decreased by the above mentioned factor. This situation will lead to
major malfunctions such as the cracking of the exhaust manifold and
the breaking down of the turbocharger. To avoid such malfunctions,
please keep the air intake pipe free from any blocking materials at all
times.

2 - 2 - 4
KK-XZU215C
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 cab tilt, allow at least 70 mm clearance the cab and
rear body or equipment. For details of cab tilt dimensions, see
the Body Mounting Manual for the respective model series.

2 - 2 - 5
KK-XZU215C
4) Contained Equipment of Cab Rear End
The rear part 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.
For details of cab dimensions, see chassis drawings.
[ EXAMPLE ]

2 - 3
KK-XZU215C
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.
(3) The position of U-bolts at forward of No.3 crossmember
should be observed according to the figure shown next page
due to structure and layout of each component parts of the
chassis.
W/B CAB
(
mm
)
TYPE L1 L2 L3 L4 L5
RH 1595 – 264 – 1000
LH 1495 – 264 – 1035
RH 1595 – 264 – 1000
LH 1495 – 264 – 1035
RH 2470 935 – – 1410
LH 2362 935 – – 1410
RH 1780 – 236 – 950
LH 1780 – 236 – 950
RH 1780 – 236 – 950
LH 1780 – 236 – 950
RH 1780 – 236 – 950
LH 1780 – 236 – 950
RH 1780 – 236 – 950
LH 1780 – 236 – 950
RH 2400 – 233 – 1360
LH 2400 – 233 – 1360
RH 2400 – 233 – 1360
LH 2400 – 233 – 1360
RH 2400 – 233 – 1360
LH 2400 – 233 – 1360
RH 2820 1120 – – 1560
LH 2820 900 – – 1560
RH 2820 1120 – – 1560
LH 2820 900 – – 1560
RH 2400 – 233 – 1360
LH 2400 – 233 – 1360
AUSXZU201 02T002
3870
3430
2810
WIDE
WIDE
XZU417L-HKFQD3
XZU417L-HKFRD3
XZU407L-HKMQD3
12 XZU427L-HKFRD3
11 XZU427L-HKFQD3
6 XZU407L-HKFQD3
7
9
10
5
8
DIMENSION
(
mm
)
POSITIONNo. MODEL
1
2
3
4
3400
2525 STD
XZU417L-HKMMD3
XZU307L-HKMLB3
XZU307L-HKMMB3
XZU347L-HKMMB3
XZU407L-HKMMD3
XZU407L-HKFRD3
WIDE
13 XKU417L-HKFQB3 3430 WIDE

2 - 4 - 1
KK-XZU215C
RECOMMEND 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 Unit : mm
[NOTE]
The dimension of tire to be mentioned in above table shows design figure according
to JATMA or ETRTO standard.
CAB TYPE MODEL TIRE SIZE A B C D REAR TIRE
XZU307L-HKMLB3 205/75R16C 1636 1656 1350 210 SINGLE
XZU307L-HKMMB3 205/75R16C 1876 1896 1435 137
XZU347L-HKMMB3 205/75R16C 1876 1896 1435 137
XZU407L-HKMMD3 205/75R16C 1921 1941 1480 135
XZU407L-HKMQD3 215/85R16 1986 2006 1520 142
XZU407L-HKFQD3 215/85R16 1986 2006 1520 142
XZU407L-HKFRD3 215/75R17.5 1994 2014 1520 138
XZU417L-HKMMD3 205/75R16C 1921 1941 1480 135
XZU417L-HKFQD3 215/85R16 1986 2006 1520 142
XZU417L-HKFRD3 215/75R17.5 1994 2014 1520 138
XZU427L-HKFQD3 215/85R16 1986 2006 1520 142
XZU427L-HKFRD3 215/75R17.5 1994 2014 1520 138
XKU417L-HKFQB3 215/85R16 1989 2009 1520 141
AUSXZU201 02T003
STD
WIDE DOUBLE