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FC 1022

Hino FC 1022 Service Manual

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Page 1
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FC 1022 ProShift 6 FC 1022 Manual
* Illustration may contain item not standard to the model
KEY FEATURES
ADR 80/03 Model
4 x 2 Cab Chassis
KEY SPECIFICATIONS
GVM . . . . . . . . . . . . . . . . . . . . . . . . . 10,400kg
. . . . . . . . . . . . . . . . . . . . Optional derate to 8,000kg
GCM . . . . . . . . . . . . . . . . . . . . . . . . . 16,000kg
Power . . . . . . . . . . . . . . . . . . .162kW @ 2400 RPM
Torque . . . . . . . . . . . . . . . . . . 647Nm @ 1500 RPM
Transmission . . . . . Six-speed Over Drive Automated Manual
. . . . . . . . . . . . . . . . . . . Six-speed Over Drive Manual
Wheelbase . 3420mm, 3850mm, 4350mm, 4650mm, 4990mm
Nominal Body
Length . . . . 4240mm, 5450mm, 6250mm, 6730mm, 7274mm
A Toyota Group Company
Page 2
FC 1022 ProShift 6 FC 1022 Manual
Engine & Driveline specifications
ENGINE
ProShift 6 Manual Model Hino J07E-TR Max. output (ISO NET) 162kW (220 HP) at 2400 RPM Max. output (JIS GROSS) 165kW (225 HP) at 2400 RPM Max. torque (ISO NET) 647Nm (66kgf/m) at 1500 RPM Max. torque (JIS GROSS) 667Nm (68kgf/m) at 1500 RPM Max. engine speed 2700 RPM 2400 RPM Engine compliance ADR 80/03 Type Diesel, turbocharged & intercooled, five-cylinder
in-line, overhead camshaft & water-cooled Combustion system Direct injection with EGR Bore & stroke 112 x 130mm Piston displacement 6.403L Compression ratio 17.0:1 Engine oil capacity 12.5L Coolant capacity 25L Fuel injection pump Electronic control common-rail type Intake system Stack-type air intake Air cleaner Dual paper elements Air compressor Single cylinder, water-cooled Bore & stroke 70 x 40mm Fan clutch Equipped Exhaust Horizontal outlet Emission Control System EGR & DPR meeting ADR 80/03 using EURO V Std
CLUTCH
ProShift 6 Manual Model CS-350 series Type Dry single plate with damper springs Facing material Moulded (non-asbestos) Facing outside diameter 350mm Control Controlled by transmisison Hydraulic with air booster
PERFORMANCE
ProShift 6 Manual
Calculations based on 10.4 ton GVM, 9.5R17.5 tyre
Engine RPM @ 100km/h 2240 2150
Max theoretical speed (km/h) 121 112
Gradeability tan
(%) @ GVM
43.2 39.9
BRAKES
Type . . . . . . . . . . . . . Hydraulic system with two leading shoes for
front and rear acting on all wheels
Control . . . . . . . . . . . . Air over hydraulic, dual circuits
Drum diameter x lining width . . . . Front: 320 x 110mm
. . . . . . . . . . . . . . . Rear: 320 x 145mm
Air dryer . . . . . . . . . . . Equipped with heater
ABS . . . . . . . . . . . . . Equipped
ASR (Anti Slip Regulator) . . . . . Equipped
Brake lock system . . . . . . . . Equipped
Parking brake . . . . . . . . . Mechanical, internal, expanding acting on
transmission output shaft
Exhaust brake . . . . . . . . . Electric-pneumatic with valve in exhaust pipe
Easy Start . . . . . . . . . . . Equipped
AXLE, SUSPENSION, TYRES & LOAD LIMITS
Front Axle Model & Type LF 366, Reverse Elliot I-Beam
Suspension
Spring Dimensions 1300 x 70mm Spring Rate 23kgf/mm
FRONT
Axle Limit (including suspension) (kg) Tyre Limit (kg) 3700
Rear Axle Model & Type
Suspension
REAR
Spring Dimensions
Spring Rates 25kgf/mm 73.9kgf/mm Axle Limit (including suspension) (kg) Tyre Limit (kg) 7000
Tapered leaf springs with shock absorbers
&stabiliser
3600
SH13, fully floating, single reduction,
single speed by Hypoid gears
Steel suspension
Tapered leaf springs with shockabsorbers
Main Auxiliary
1300 x 70mm 900 x 70mm
7000
TRANSMISSION & GEAR RATIOS
ProShift 6 Manual
Type Automated Manual
Transmission
Model LX06S Overdrive
Type Six forward and one reverse speeds,
synchromesh on 2nd to 6th
Control Electronic Cable with Power Shift
Rear axle gear ratio 4.625:1 4.33:1
1st . . . . . . . . 6.098 5th . . . . . . . . 1.000
2nd . . . . . . . . 3.858
3rd . . . . . . . . 2.340
4th . . . . . . . . 1.422 Rev. . . . . . . . . 5.672
6th (ProShift 6) . . . 0.744 (Manual) . . . 0.761
Manual
WHEELS & TYRES
Wheel type . . . . . . . . . . Six-stud disc wheel (JIS type) PCD 222.25
Rim size . . . . . . . . . . . 6.75 x 17.5 – offset 135mm
Tyre size . . . . . . . . . . . 9.5R17.5-129/127
Number of tyres . . . . . . . . . Seven (including one spare tyre)
Spare tyre carrier . . . . . . . . Equipped
FUEL TANK
Capacity . . . . . . . . . . . 200L
Type . . . . . . . . . . . All steel rectangle
Fuel pre-filter & sedimenter . . . . Equipped
Fuel tank cap key . . . . . . . . Equipped
Page 3
FC 1022 ProShift 6
J07E-TR
FC 1022 Manual
Cab, Instrumentation & Chassis
CAB DETAILS
Type . . . . . . . . . . . . . Forward control, all-steel construction with
torsion bar tilt mechanism
Drivers SRS Airbag . . . . . . . . Equipped
Seating capacity . . . . . . . . Three
Driver’s seat . . . . . . . . . . ISRI 6860/870 with urethane foam pads,
high-back, lumbar support, multi adjustable, air
suspended, with integrated safety belt
Side passenger’s seat . . . . . . Urethane foam pads, high-back & reclining seat
with fabric cover & under-tray
Centre passenger’s seat . . . . . Urethane foam pads & foldaway type with seat
back tray, fabric cover
Seat belt . . . . . . . . . . . 3-point type on driver’s & side passenger’s seat,
2-point type on centre passenger’s seat Sun visor and overhead console . . . For driver & passenger sides
Windshield wipers . . . . . . . . Electric, dual, intermittent & 2-speed
Ventilator . . . . . . . . . . . Forced type by electric blower
Rear view mirrors . . . . . . . . External: Electric & heated, two flat type,
two convex spotters
Cigarette lighter 24V . . . . . . . Equipped
Electrical converter . . . . . . . . 12V (harness type)
Floor mat . . . . . . . . . . . Vinyl type
Front air spoiler . . . . . . . . Equipped
Central locking & keyless entry . . . Equipped with immobiliser
Heater and defroster . . . . . . . Standard
Air conditioner . . . . . . . . . Standard
Trim . . . . . . . . . . . . . Full trim type (side, roof & back)
Cab pockets . . . . . . . . . . Equipped on both door sides
Power windows . . . . . . . . . Equipped
Audio . . . . . . . . . . . . DAB+ AM/FM radio with CD & DVD player
and Bluetooth
Speakers . . . . . . . . . . . Driver & passenger sides
Foot rest . . . . . . . . . . . Equipped
Easy Start . . . . . . . . . . . Equipped
Cup holder . . . . . . . . . . Equipped
Cruise Control . . . . . . . . . Equipped
POWER & TORqUE CHART (ISO Net) jO7E-TR
OUTPUT (kW)
250
(HP)
310
280
250
220
190
160
230
210
190
170
150
130
110
90
70
647Nm /1500rpm
647Nm /1500rpm (66kgm/1500rpm)
(66kgm/1500rpm)
162kW /2400rpm
162kW /2400rpm
(220hp/2400rpm)
(220hp/2400rpm)
1000 1400 1800
ENGINE SPEED (rpm)
2400
2200 2600
INSTRUMENTS
1. Meters & gauges
Speedometer Odometer with trip meter Tachometer Fuel gauge Coolant temperature gauge Air pressure gauges
2. Switches
One-key starting-stopping Lighting Directional indicator, dimmer & passing Wiper and washer Hazard lamp Exhaust brake Map lamp Fog lamp Easy Start Cruise Control DPR regeneration ASR off Mirror controls PTO (optional)
3. Warning, pilot lamps & buzzers
Oil pressure warning lamp & buzzer Air pressure warning lamp & buzzer Engine over-run warning buzzer Coolant level warning lamp & buzzer Brake fluid level warning lamp
& buzzer Brake adjustment warning lamp
& buzzer High beam indicator lamp Turn signal indicator lamp Parking brake indicator lamp Exhaust brake indicator lamp Engine control system warning lamp Hazard indicator lamp Back-up warning buzzer ABS & ASR warning lamp
4. Others
Idle up control knob Horn button 12V electric source
5. Multi information display
Fuel consumption Service reminders Warnings Faults
TORQUE (N-m)
800
700
600
500
400
300
200
100
0
3000
(kgf-m)
80
65
50
ProShift 6 models only
ELECTRICAL
Type . . . . . . . . . . . . . 24V, negative earth
Batteries . . . . . . . . . . . 2 x12V, series connection. Capacity 65Ah at
20-hour rate
Alternator type . . . . . . . . . Brushless with built-in rectifier and voltage
Starter type . . . . . . . . . . 24V, 4.5kW
Headlamps . . . . . . . . . . Halogen type includes fog lamps
High/low beam . . . . . . . . . Equipped
Fluorescent reading lamp . . . . . Equipped
Electric horn . . . . . . . . . . Equipped
regulator. Capacity 24V, 60A
STEERING
Type . . . . . . . . . . . . . Telescopic & tilt steering column with locking device.
Recirculating ball with Integral Power Steering
Gear ratio . . . . . . . . . . . 18.6:1
Steering angle . . . . . . . . . Inside: 50-53˚ Outside: 39˚
CHASSIS FRAME
Chassis Frame Dimensions Compact Short Medium Medium-long Long Type Ladder-shaped channel section side rails Chassis width (at rear) 820mm Main section in mm
(depth x flange x thickness) Tensile strength 540N/mm Front Underrun Protection Equipped Tow Hook (front and rear) Equipped
229.4 x
78 x 5.7
228.4 x 73 x 5.2
229.4 x
73 x 5.7
2
231.6 x
73 x 6.8
GENUINE ACCESSORY OPTIONS
Bull bar Chrome wheel covers GPS Navigation Rear vision camera (up to 3) LED driving lights
Please check with your dealer for price, availability & tment for these options
Stoneguard Sunvisor Engine driven PTO 1:0.72 step-down or 1:1.08 step-up
Page 4
FC 1022 ProShift 6 FC 1022 Manual
Dimensions
RC
FT
CA
DIMENSIONS – mm/capacities
Model Hino FC 1022 FC 1022 ProShift 6 FC 1022 Manual
Variants Short Medium
Product Code
Nominal Body length ((WBx.6)+CA-80)
Wheelbase (WB) 3,850 4,350 4,650 4,990 3,420 3,850 4,350 4,650 4,990 Overall Length (OL) 6,735 7,445 7,895 8,435 6,095 6,735 7,445 7,895 8,435 Overall width (OW) 2,175 2,175 2,175 2,175 2,175 2,175 2,175 2,175 2,175 Overall Height (OH) 2,450 2,450 2,450 2,450 2,450 2,450 2,450 2,450 2,450 Cab to Rear Axle centre (CA) 3,220 3,720 4,020 4,360 2,770 3,200 3,700 4,000 4,340 Front Overhang (FOH) 1,145 1,145 1,145 1,145 1,145 1,145 1,145 1,145 1,145 Rear Overhang (ROH) 1,700 1,910 2,060 2,260 1,490 1,700 1,910 2,060 2,260 Front Chassis Height (FCH) 775 775 775 775 775 775 775 775 775 Rear Chassis Height (RCH) 880 880 880 880 880 880 880 880 880 Road Clearance (RC) 215 215 215 215 220 220 220 220 220 Front Track (FT) 1,770 1,770 1,770 1,770 1,770 1,770 1,770 1,770 1,770 Rear Track (RT) 1,660 1,660 1,660 1,660 1,660 1,660 1,660 1,660 1,660 Turning Circle Kerb to Kerb 12,400 13,800 14,600 15,600 11,200 12,400 13,800 14,600 15,600
Wall to Wall 13,800 15,200 16,000 17,000 12,600 13,800 15,200 16,000 17,000 Indicative Chassis Mass – kg (standard tools, 10 litres of fuel and spare tyre and subject to a ± 3% tolerance) Total 3,230 3,260 3,320 3,375 3,200 3,210 3,240 3,295 3,360 Front 2,220 2,240 2,270 2,290 2,175 2,190 2,210 2,235 2,260 Rear 1,010 1,020 1,050 1,085 1,025 1,020 1,030 1,060 1,100 GVM STD 10,400 10,400 10,400 10,400 10,400 10,400 10,400 10,400 10,400 GVM Opt 8,000 8,000 8,000 8,000 8,000 8,000 8,000 8,000 8,000 GCM STD 16,000 16,000 16,000 16,000 16,000 16,000 16,000 16,000 16,000
FC7JGMA
-ENU
5,450 6,250 6,730 7,274 4,240 5,420 6,230 6,710 7,250
FC7JMA
-ENU
Medium-
Long
FC7JKMA
-ENU
Long Compact Short Medium
FC7JLMA
FC7JEMM
-ENU
-ANU
FC7JGMA
-ANU
FC7JJMA
-ANU
Medium-
Long
FC7JKMA
-ANU
Long
FC7JLMA
-ANU
OH
RCHFCH
ROHFOH WB
OL
OW
Drawings are for reference only to the table. For specifi c chassis layouts please refer to Body Mounting Manual drawings.
RT
WARRANTY
New vehicle warranty period
Light Duty Model Axle con guration
500 FC 1022 4 x 2 3 years or 150,000km 36 months
Battery warranty – 12 months from date of delivery Genuine parts or accessories warranty – 3 years unlimited kilometres when fi tted by an authorised Hino dealer *
* For conditions, refer to the Hino Parts & Service warranty brochure
roadside
assist
MAINTENANCE
AGREEMENT
Standard warranty
(whichever comes fi rst)
Cab corrosion perforation
DISCLAIMER
Important notice. Hino Trucks are distributed in Australia by Hino Motor Sales Australia Pty Ltd A.C.N. 064 989 724. All efforts have been made to ensure the information contained in this brochure was correct at time of printing or uploading. Hino Motor Sales Australia Pty Ltd reserves the right to alter any details of the specifi cations & equipment without notice. Hino in so far as it is permitted by law to do so, shall not be liable in any way as a result of any reliance placed by any person on anything contained in this brochure. You should therefore check with your authorised Hino dealer at the time of ordering your motor vehicle to ensure that colour, specifi cations, equipment, design features & options are available for the vehicle you are ordering. Please note that some options may only be available in combination with others. Authorised Hino dealers will on request provide up to date information on all accessories, design features, prices & availability.
HS500FC1022-03/15
A Toyota Group Company
Safer Greener Essential
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