Hino Dutro WU300, 340, 410, XZU404, 412, 422, 434 Series Engine Chassis & Electrical Complete Workshop Service Repair Manual

FOREWORD This manual contains repair procedures for the DUTRO. Applicable models: WU300, 340, 410 series XZU404, 412, 414, 422, 424, 434 series Manual Name Pub. No. S DUTRO Electrical Wiring Diagram S1 YXZE05A SL S S05C B, S05C TA, S05C TB Engine Workshop Manual S5 YS05E06A S W04D J Engine Workshop Manual S5 YW04E06A S H260 Manual Transmission Workshop Manual S1 YXZE07A S H350 Manual Transmission Workshop Manual S1 YXZE06A S M150, M153 Manual Transmission Workshop Manual S1 YXZE08A All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice.

CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non specialized or uncertified technicians perform repair or service only using this manual or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer’s vehicle. In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow the instruction shown below. S Must read this manual thoroughly. It is especially important to have a good understanding of all the contents written in the PRECAUTION of ”IN” section. S The service method written in this manual is very effective to perform repair and service. When performing the operations following the procedures using this manual, be sure to use tools specified and recommended. If using non specified or recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer’s vehicle before starting the operation. S If part replacement is necessary, must replace the part with the same part number or equivalent part. Do not replace it with inferior quality. S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is important to warn of all the possible hazardous consequences that might result from failure to follow these instructions.

SEAT BELT LIGHTING WIPER & WASHER AUDIO & VISUAL SYSTEM WIRING COMMUNICATION SYSTEM WINDSHIELD/WINDOWGLASS/MIRROR INSTRUMENT PANEL/METER SEAT THEFT DETERRENT & DOOR LOCK ENGINE HOOD/DOOR EXTERIOR/INTERIOR TRIM VEHICLE CONTROL SYSTEM POWER TAKE OFF ALPHABETICAL INDEX 61 65 66 67 68 69 70 71 72 73 75 76 80 87 61 65 66 67 68 69 70 71 72 73 75 76 80 87

INTRODUCTION HOW TO USE THIS MANUAL 01 1 ............. GENERAL INFORMATION 01 1 .................. IDENTIFICATION INFORMATION 01 4 .......... VEHICLE IDENTIFICATION AND SERIAL NUMBERS 01 4 ...................... REPAIR INSTRUCTION 01 5 ................... PRECAUTION 01 5 ............................ VEHICLE LIFT AND SUPPORT LOCATIONS 01 14 .................. HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01 16 ............... GENERAL INFORMATION 01 16 .................. HOW TO PROCEED WITH TROUBLESHOOTING 01 17 .................... ELECTRONIC CIRCUIT INSPECTION PROCEDURE 01 27 ........................... TERMS 01 32 ................................. ABBREVIATIONS USED IN THIS MANUAL 01 32 ... GLOSSARY OF SAE AND HINO TERMS 01 37 .....

0108R 05 N17080 Filler Cap Float Reservoir Tank z Grommet Clip Slotted Spring Pin : Specified torque z Non reusable part Cylinder Piston Push Rod Washer Snap Ring Boot z Gasket Lock Nut Clevis Pin Clevis N·m (kgf·cm, ft·lbf) 12 (120, 9) 15 (155, 11) INTRODUCTION HOW TO USE THIS MANUAL 01 1 HOW TO USE THIS MANUAL GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is made in accordance with SAE J2008. (b) Generally, repair operations can be separated in the following 3 main processes: 1. Diagnosis 2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting 3. Final Inspection (c) This manual explains the 1st process of ”Diagnosis” (found in the ”Diagnostics” section), the 2nd process of ”Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting”, but the 3rd process of ”Final Inspection” is omitted. (d) The following essential operations are not written in this manual. However, these operations must be performed in actual situations. (1) Operations with a jack or lift (2) Cleaning of a removed part when necessary (3) Visual check 2. INDEX (a) An alphabetical INDEX section is provided at the end of the book (4/4) to guide you to the item to be repaired. 3. PREPARATION (a) Use of special service tools (SST) and special service materials (SSM) may be required, depending on the repair situation. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the Preparation section of this manual. 4. REPAIR PROCEDURES (a) Component drawing is placed under the title where necessary. (b) Non reusable parts, grease application area, precoated parts and tightening torque are specified in the components drawing. Example:

Illustration: what to do and where Component part No. Detailed test: how to perform task Task heading: what to do Set part No Illustration: what to do and where D26745 01 2 INTRODUCTION HOW TO USE THIS MANUAL (c) Tightening torque, grease application area, and non reusable parts are described as important points in the procedures. NOTICE: There are cases where such information can only be indicated by an illustration. In those cases, all the information such as torque, oil, etc. are described in the illustration. (d) Installing procedures are performed in the reverse order of the removal, and only the important points are described. (e) Only items with points are described in the procedure, and the operational portion and content are placed using an illustration. In the explanations, details of the operational method, standard value and notice are placed. (f) There may be a case where the illustrations of similar models are used. In that case, specific details may be different from the actual vehicle. (g) The procedures are presented in a step by step format: () The illustration shows what to do and where to do it. (2) The task heading tells what to do. (3) The explanation text tells how to perform the task and gives other information such as specifications and warnings. Example: HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task heading can be read at a glance when necessary, and the text below provides detailed information. Impor- tant specifications and warnings always stand out in bold type. 5. SERVICE SPECIFICATIONS (a) Specifications are presented in bold type throughout the manual. You never have to leave the procedure to look up your specifications. The specifications are also found in the Service Specifications section for a quick reference. 6. TERMS DEFINITION CAUTION Indicates the possibility of injury to you or other people. NOTICE Indicates the possibility of damage to the components being repaired. HINT Provides additional information to help you to perform the repair efficiently.

INTRODUCTION HOW TO USE THIS MANUAL 01 3 7. SI UNIT (a) The units given in this manual are primarily expressed according to the SI UNIT (International System of Units), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N m (310 kgf cm, 22 ft lbf)

010CB 03 D30383 B A C D30384 B A C 01 4 INTRODUCTION IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND SERIAL NUMBERS 1. VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the right frame. as shown in the illustration. This number has also been stamped on the manufacturer’s plate. A: Vehicle Identification Number B: Manufacturer’s Plate C: Manufacturer’s Plate (Regular cab LHD) 2. ENGINE SERIAL NUMBER AND TRANSMISSION SE- RIAL NUMBER (a) The engine serial number is stamped on the cylinder block of the engine, and the transmission serial number is stamped on the housing, as shown in the illustration. A: S05C B, S05C TA, S05C TB B: H260, H350, H351, M150, M153 C: 14B, 15B FTE, W04D J

010KH 01 5 4 3 6 2 1 D20200 INTRODUCTION REPAIR INSTRUCTION 01 5 REPAIR INSTRUCTION PRECAUTION 1. BASIC REPAIR HINT (a) HINTS ON OPERATIONS 1 Looks S Always wear a clean uniform. S Hat and safety shoes must be worn. 2 Vehicle protection S Set a grill cover, fender cover, seat cover and floor mat before starting operation. 3 Safe operation S When working with 2 or more persons, be sure to check the safety of one another. S When working with the engine running, pay attention to the ventilation in the workshop. S When working on high temperature, rotating, moving and vibrating parts, be careful not to burn or injure yourself. S When jacking up the vehicle, be sure to support the specified location with a safety stand. S When lifting up the vehicle, use safety equipment. 4 Preparation of tools and measuring gauge S Before starting repairs, prepare the tool stand, SST, gauge, oil, shop rag and parts for replacement. 5 Removal and installation, disassembly and assembly operations S Diagnose with a thorough understanding of the trouble condition and perform effective operation. S Before removing the parts, check the general condition of the assembly, and for deformation and damage. S When the structure is complicated, take a note or make matchmarks as not to make mistakes that affect the function of the parts. S Clean and wash the removed parts if necessary, and assemble them after a thorough check. 6 Removed parts S Place the removed parts in the correct order to avoid mixing them up or making them dirty. S As for non reusable parts such as gaskets, O rings, and self locking nuts, replace them with new ones following the instructions in this manual. S Organize the parts that were replaced in a box and show them to the customer. (b) JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page 01 14).

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Hino Dutro WU300, 340, 410, XZU404, 412, 422, 434 Series Engine Chassis & Electrical Complete Workshop Service Repair Manual

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