Hino KK-XZU215C Service Manual

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 3614

HINO 3616

HINO 3716

HINO 3816

- 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.)

M

DUMP

TRANSMISSION CODE

F

6 SPEEDS (MECH.)

BODY DECK HEIGHT CODE

B
K

Q

HIGH FLOOR

LOW FLOOR

300 SERIES

CAB DRIVEWHEEL BASE

2800
3400

L

R

LEFT 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

[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.

Cab type

Chassis model
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

Tread

Max. GVM Rating (kg) 4300 5500 5500 5500 5500 6500 7500 5500 6500 7500 6500 7500 6500

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

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

Tire and disc

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)

(mm)

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

Front 2600 2600 2600 2600 3100 3100 3100 2600 3100 3100 3100 3100 3100

Axle

Tire

Disc

V - kC {Ah} - No.

Rear 2300 4360 4360 4360 5280 5280 6200 4360 5280 6200 5280 6200 4480

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

Tire

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

XZU307L-HKMLB3 XZU307L-HKMMB3 XZU347L-HKMMB3 XZU407L-HKMMD3 XZU417L-HKMMD3 XZU427L-HKFRD3XZU407L-HKFQD3

STANDARD CAB SERIES

XZU407L-HKMQD3 XZU407L-HKFRD3

1896

WIDE CAB SERIES

2095

XZU427L-HKFQD3XZU417L-HKFQD3 XZU417L-HKFRD3

XKU417L-HKFQB3

AUSXZU201 01T002

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.

(mm)

(mm)

W/B CAB

1

XZU307L-HKMLB3

2

XZU307L-HKMMB3

3

XZU347L-HKMMB3

4

XZU407L-HKMMD3

5

XZU407L-HKMQD3
6 XZU407L-HKFQD3
7

XZU407L-HKFRD3

8

XZU417L-HKMMD3
9

XZU417L-HKFQD3

10

XZU417L-HKFRD3
11 XZU427L-HKFQD3
12 XZU427L-HKFRD3
13 XKU417L-HKFQB3 3430 WIDE

2525

3400

2810

3430

3870

TYPE L1 L2 L3 L4 L5

STD

WIDE

WIDE

WIDE

POSITIONNo. MODEL

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

DIMENSION

AUSXZU201 02T002

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

STD

WIDE

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

DOUBLE

AUSXZU201 02T003

2 - 4 - 2

KK-XZU215C

2) Mudguards

2 - 5 - 1

KK-XZU215C

ELECTRIC WELDING WORK

Electrical components such as the alternator and tachograph
are directly connected to the battery and one end is grounded
to the chassis frame. Under these conditions, welding current
will flow back along the ground circuit if electric welding is
carried out and damage may be caused to the alternator,
tachograph, electrical components, etc.

Be sure to follow all instructions to be described to chapter 2,
2-9 PRECAUTION ON BODY MOUNTING WORK and
following precautions at performing any electric welding.

(1) procedure before welding

• Make sure to always wear the electric insulation
equipment(insulation rubber gloves .etc)while working.

•Turn the starter switch OFF.

• Pull out the SERVICE PLUG of PCU and wait more than 7
minutes.

• Disconnect the battery's negative terminal.

• Disconnect the connector of DC-DC Converter.

• Disconnect fuse of ECU of the each electronic instrument
(except DC-DC Converter).

• Dinconnect all signal circuit connectors in PCU, after taking
off the front under cover of PCU.
(See the page 2-5-3)

Peculiar to XKU417L-HKFQB3

*

*

*
*

*

2 - 5 - 2

KK-XZU215C

DETAILS, RELAY & FUSE BLOCK

AUSXZU201 02D006

E/G CONTROL ECU

ABS ECU

DC-DC
CONVERTER

PASSENGER
SEAT SIDE

2 - 5 - 3

KK-XZU215C

FRONT UNDER COVER

SIGNAL CIRCUIT
CONNECTOR

PCU

WIRE HARNESS
OF SIGNAL
CIRCUIT

UP

FR

CHASSIS

CENTER

2 - 5 - 4

KK-XZU215C

(2) Ground of the Welding Equipment

Connect the ground of the welding equipment near the place
where 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.

• Peel off the paint where to be welded.

• Connecting the ground to the chassis spring is strictly
prohibited to prevent damage of the spring.

W

elding to the cab body

• Connect the ground to the fixing bolt of cab hinge after
dismounting the front grille or to the cab body.

(3) Other Precautions

•To protect ancillary equipment from sparks during welding,
place fire-resistant covers over the rubber hoses, wire
harness, pipes, chassis spring and tires, etc.

• Perform to weld under most suitable conditions of the
welding, and minimize the heat influence to the circumference
where to be welded, and as far as possible to keep the
welding quality.

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KK-XZU215C

(4) After Welding

• Make sure to connect all signal circuit connectors in PCU.

• Put back fuses as original condition.

• Make sure to connect the DC-DC Converter.

• Make sure to connect the negative terminal of the battery.
And the terminal should be horizontally setting.

• Re-paint the place where to be peeled off the paint for
grounding the welding equipment by same color.

(5) Final Inspection after Welding

• Restore each electronic instrument and equipment to its
original site.

• Install the SERVICE PLUG.
(Refer the 2-9 PRECAUTION ON BODY MOUNTING WORK)

• Inspect the operation and function of all electronic instruments
and equipments.

• Consult to each Hino sales dealer or distributor for the details
of inspection’s procedure.

Peculiar to XKU417L-HKFQB3

BATTERY

A : B = SAME HEIGHT

GOOD

NO GOOD

BA TTER Y TERMINAL

A

B

FXZ2 BATTERY

*

*

*

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KK-XZU215C

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 should be kept away from

heated elements, and should be wired along the main harness.

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KK-XZU215C

NOTES ON ENGINE CONTROL, BRAKE ABS SYSTEM
COMPUTERS AND DC-DC CONVERTER

Engine control and brake ABS computers are installed center
part, inside of the instrument panel, and DC-DC converter is
installed on right side of the cab back panel as described
following figure.

Therefore, give great care to the computer and converter when
performing any body mounting work or modification as
following points.

(1) Be sure to follow the all instruction to be described to

chapter 2, 2-5 ELECTRIC WELDING WORK and 2-9
PRECAUTION ON BODY MOUNTING WORK (XKU417L­HKFQB3 only) before peforming any electric welding.

(2) Be sure to cover the computer and converter to protect the

water penetration when performing cleaning up the inside
of cab.

(3) When mounting such devices as a radiophone, a wireless

communication device, be sure to use the devices that
conforms to the electric control act and install the devices
on the places which are as far as possible from the
computers and it's harness.
Do not install any high output (over 50w) device.
Be sure to check that no abnormal electric wave or
electromagnetic wave is found, after having installed the
device, which affects on the electronic signals passing
through in computer harness.

(4) Do not alter the computer and converter, harness wire or

sensors.

AUSXZU201 02D006

E/G CONTROL ECU

ABS ECU

DC-DC
CONVERTER

PASSENGER
SEAT SIDE

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KK-XZU215C

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) sound-absorbing 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, refer to the corresponding
explanatory example drawing shown in the following. 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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KK-XZU215C

PRECAUTION ON BODY MOUNTING WORK

Installation position of hybrid related equipment.

BATTERYPCU

MOTOR GENERATOR

INVERTER

ECU BOX
(HV-ECU, BATTERY ECU,
KINDS OF RELAIES)

RADIATOR
FOR INVERTER

NICKEL METAL HYDRIDE (Ni-MH)
BATTERY

SERVICE PLUG

COOLING DUCT

COOLING FAN
FOR BATTERY

INNER STRUCTURE OF PCU