Chapter 4 Body... · Always use the fuel hose of the HINO genuine parts. The following figure is an example of genuine parts. (The material and quality of each component are based

Chapter 4TRUCK BODY AND SPECIAL EQUIPMENT

INSTALLATION PROCEDURE AND PRECAUTIONS

GENERAL PRECAUTIONS •••••••••••••••••••••••••••••••••••••••••••••••• 1WEIGHT DISTRIBUTION AND CENTER OF GRAVITY•••••••••••••• 5CAUTIONS NEEDED FOR THE TILT HOOD••••••••••••••••••••••••••• 5FUEL FILLER FOR ADDITIONAL FUEL TANK•••••••••••••••••••••••• 6PRECAUTIONS FOR THE FUEL HOSE •••••••••••••••••••••••••••••••• 6PRECAUTION FOR CAUTION LABEL OF FUEL TANK •••••••••••• 7INSTALLATION OF FENDER AND MUDGUARD ••••••••••••••••••••• 9CAUTIONS ON WELDING ••••••••••••••••••••••••••••••••••••••••••••••••• 9PROTECTION OF INTERFERENCE WITH ••••••••••••••••••••••••••••• 13REAR SPRING AND REAR SPRING HANGENOTES ON SYSTEM CONTROL COMPUTERS •••••••••••••••••••••• 16PRECAUTION OF THE ANTENNA POSITION •••••••••••••••••••••••• 17PROCESS FOR REMOVING THE INSTRUMENT PANEL •••••••••• 18NOTES ON ADDITIONAL WIRING IN THE ENGINE ••••••••••••••••• 19COMPARTMENTCAUTION ON VEHICLE STORAGE ••••••••••••••••••••••••••••••••••••• 19RESETTING OF VEHICLE SPEED SENSORING ••••••••••••••••••••• 19PULSE CONVERTERMAXIMUM VERTICAL TRAVEL RANGE OF LATERAL ROD •••••• 20(REAR AIR SUSPENSION MODEL)PRECAUTION FOR LEVELING VALVE ••••••••••••••••••••••••••••••••• 21(REAR AIR SUSPENSION MODEL)PRECAUTIONS FOR EXHAUST SYSTEM ••••••••••••••••••••••••••••• 23DPR MUFFLER ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 27ASSEMBLY PROCEDURE OF VERTICAL EXHAUST ••••••••••••••• 29TAIL PIPE

KK-US005D

1

Chapter 4 TRUCK BODY AND SPECIAL EQUIPMENT INSTALLATION PRECAUTIONS

KK-US005D

The following installation procedures and specific precautionary instructions are recommendedfor the proper installation of special bodies and/or equipment on Hino truck chassis.Failure to follow these recommendations could result in serious damage to the Hino truckchassis.

GENERAL PRECAUTIONS

Any deviation from the original Hino truck chassis specification will become the responsibilityof the subsequent stage manufacturer or installer.

The final stage manufacturer has responsibility to certify that the completed vehicle conformsto all applicable Motor Vehicle Safety Standards.

The rear body installed on chassis must have adequate strength. In order to prevent insuffi-cient efficiency of brake or abnormal wear of tires, enough care is necessary to the weightdistribution to be loaded as evenly as possible onto right and left wheels.

When installing the rear body, be sure that all the wheels are on the same horizontal plane sothat the chassis is not inclined. (No difference in height from the ground on right and leftsides.)

When rear body or additional components are mounted on the front or rear overhang, it isdesirable that mounted position is not inside the approach and departure angle.

When installing a body or equipment parts near the engine, clutch and transmission, ensure atleast 50 mm (2.0 in.) clearance.

2


KK-US005D

When removing the transmission assembly from the engine, it is necessary to move the trans-mission assembly rearward about 150 mm (6.0 in.) in order to pull out the clutch spline.Therefore proper consideration should be given to the arrangement of the fittings of body orequipment.

No fitting should be installed to ensure a spaceof 150 mm (6.0 in.) long for the clutch andtransmission assembly to be withdrawn forremoval as illustrated below.

The fuel tank, battery and air tank supports should not be fitted with the side guard and any-thing like that which may give shock and external force to them.

When mounting the superstructure, sufficient considerations are needed so that there will notrouble in carrying out daily inspection and maintenance servicing.• Engine oil inspection, oil supply and discharge• Cooling water inspection, water supply and discharge• Air cleaner inspection• Transmission oil inspection, oil supply and discharge (Special care is needed when installing

P.T.O.)• Differential oil inspection, oil supply and discharge (Care is needed when spare tire is mounted

on the rear overhang.)• Grease up (Special care is needed when shifting the fuel tank on vehicles.)• Battery liquid inspection, water supply and discharge.• Supply of fuel• Air tank drain• Attaching and detaching the spare tire• Check valve and other valves relating to brake

When changing springs or installing additional spring leaves, check the wheelbase and thefront wheel alignment and make adjustments if needed. (Tighten spring U-bolts and centerbolts with the specified torques.)

After a vehicle has been properly fitted out, make sure that it is free from any defects such asthe vibration of the cab and noise before delivering it.

When mounting all the required component parts on a vehicle, be careful not to damage to thesides of chassis or impair its proper functioning.

Strictly avoid making any alterations to the component parts of the front axle and steering.

3


KK-US005D

When using additional spring leaves, do not use more than we have provided for option for theexcessively increased front spring leaves will cause interference with the locus of the steeringlink and the excessively increased rear spring leaves will may cause the propeller shaft to bedamaged by seizure or noises.

When mounting the superstructure, be careful not to damage the chassis side or impair itsfunctioning. (For instance do not step on piping and wiring and also air tank, fuel tank, air drier,other chassis component.)

Be careful that the mounted superstructure may not interfere with the front and rear field ofvision.

When a concentrated load is applied locally or the body is long, the amount of deflection maypose problems in some cases. So, it is advisable to use or or shaped steelbeams as the main sill, and joint them securely to the side members in order to obtain sufficientoverall strength and rigidity.When a body with a great rigidity is mounted as in the case of tank lorries and bulk cementcarriers, please make reference to the paragraph devoted to the main sill to prevent a weakpoint appearing at the rear of the cab.

Cautions when mounting the superstructure near brake units and brake pipe lines• The valves shall be made serviceable and detachable.• When a corrosive property is loaded on the rear body, use appropriate protective means to

protect the pipe lines.• Be careful to ensure sufficient clearance at least 30 mm (1.2 in.) between the brake pipe

lines and the parts for rear body.• Make the inspection and working holes if the side beam is stiffened as a closed section.

Cautions needed when mounting the superstructure above exhaust pipe• There must be the following clearances between exhaust pipe and others to be mounted on

the vehicle.Over 100 mm (4.0 in.) from wood, rubber, cloth, resins and the like.Over 200 mm (8.0 in.) from electric wire, brake hose or tube.When it is impossible to provide the above clearances, use the heat insulating plate or thelike heat insulating means.

4


KK-US005D

Do not place flammable material nearthe exhaust system.

• Care must be taken that there is no rope or sheet hanging close to the exhaust system. Donot place the rope hook near the exhaust system.

To prevent an interference of propeller shafts with the body parts due to the movement ofpropeller shafts, keep enough clearance at least 50 mm (2.0 in.) between propeller shaft (in-cluding joints) and body parts. (dump pump, brackets, etc.)

5


KK-US005D

WEIGHT DISTRIBUTION AND CENTER OF GRAVITY

Recommended Weight Distribution on Front Axle

To ensure satisfactory steerability of the vehicle under all conditions, proper weight distributionon front axle must be considered at the planning of body mounting.In the case of 2-axle vehicle, put more than 30% of the respective gross vehicle weight.The permissible front axle load must not be exceeded.

Permissible Height of Center of Gravity of the Completed Vehicle with Payload

The height of center of gravity of the completed vehicle must be considered at the planning ofbody mounting.The height of center of gravity from the ground to the completed vehicle with payload shouldnot exceed the guidelines as shown in the table.If the body is mounted in such a way that the height of center of gravity exceeds the guideline,the directional stability at braking and roll stability at cornering or rolling will be adversely af-fected.

GUIDELINE

NOTICE: These guidelines are applied to truck bodies only.

CAUTIONS NEEDED FOR THE TILT HOOD

Since the Hino truck has the tilt hood in front of the cab.Be sure that not to obstruct the tilting range of the hood in described following figure whenperform to mount rear body or equipment.

Model A B C D

1,400(55.12)

520 (20.47)

2,491 (98.07)

1,470(57.87)

NA NBNC

NDNENJNV

Unit: mm (in.)

1,530(60.24)

500(19.69)

2,745(108.07)

1,650(64.98)

NOTE: • Refer to chassis drawing for more detailed dimensions of engine hood tilting range.

Model

NA, NB, NC

ND, NE, NJ, NV

Less than 1600 (63)

Less than 1778 (70)

Unit: mm (in.)

Height of center ofgravity from ground

6


KK-US005D

FUEL FILLER FOR ADDITIONAL FUEL TANK

When mounting the rear body, care must be taken that the accessibility to the fuel filler and theoperation of the fuel gun are not hampered.

PRECAUTIONS FOR THE FUEL HOSE

Be sure to observe the following notes, if it will be changed a fuel hose by a movement or anaddition of a fuel tank.

Always use the fuel hose of the HINO genuine parts.

The following figure is an example of genuine parts.(The material and quality of each component are based on the standard of HINO.)

Ø14

(0.6

)

Ø7.

6(0

.3)

2

INNER RUBBER

Unit : mm (in.)

(FLUORIDE COATED)

OUTER RUBBER

BRAID

INTERMEDIATE RUBBER

(0.0

8)

7


KK-US005D

PRECAUTION FOR CAUTION LABEL OF FUEL TANK

1. See the Chapter 10 for layout of FUEL TANK.

2. Instruction to use ultra low sulfur diesel fuel is requirement of Part 86 of Title 40, Code ofFederal Regulations (40 CRF 86).The Caution Label (see the following figure) is stuck near the filling port of fuel tank.Make sure following cautiones when installing body or equipment.

• Detail of Caution Label

PART No. 74559 - E0072

If genuine parts cannot be obtained, please get the following rubber hoses as a substitute.

• The rubber hoses which dose not contain a metal element. or• The rubber hoses which a metal element does not melt into fuel. (For example : The rubber hose which give the fluoride coat to the inside.)

The quality of the rubber hoses of a substitute should be more than equivalent to genuine, orequivalent.

Use of unsuitable rubber hose may cause serious faults of engine, such as the decline of anexhaust gas purification function.

For more detailed information, please contact with HMS.

8


KK-US005D

• Detail of location of the Cautiion Label

MODEL : NA, NB AND NC

MODEL : ND, NE, NJ AND NV

MODEL : ND, NE, NJ AND NV (WITH VIRTICAL TAIL PIPE)

MODEL : ND, NE, NJ AND NV (WITH 90gal FUEL TANK)

9


KK-US005D

INSTALLATION OF FENDER AND MUDGUARD

Referring to the drawing showing the deflections of the tires, determine the dimensions of thefender and the underside of the floor so that the fender will not contact the tires.The use of tire chains also should be taken into consideration.The mudguards also should be installed by referring to the instructions for their installation.Detail dimensions of installation of fended and mudguard, refer to Chapter 6 “Instructions forBuidling Up of Rear Body”.

CAUTIONS ON WELDING

Disconnect the negative battery cable before using arc welding equipment. Electronic instru-ment (e.g. ABS and Engine control computer) and other electrical parts always need electricpower are connected directly to the battery and the ground.If the arc welding is performed in this condition, an electric current of arc welding may flowreversely into the electrical parts from their ground circuit resulting in damage to the electricalparts.

Since welded parts becomes extremely hot and sparks are present, dismount the fuel tank orbatteries when welding near those units. Make sure that there are no items present such asharnesses, nylon tubes, pipes, resin clips for piping, suspension components (such as springbrackets, spring leaves), etc., which may be damaged.

Do not arc strike on the frame flanges.

Do not weld any components such as engine, transmission, axle, spring, propeller shaft, steer-ing, and also do not weld any body parts or mounting brackets on the chassis frame for mount-ing the rear body.

Avoid welding additional parts onto the frame except for parts used for the purpose of rein-forcement.

The ground of the arc welding machine must be connected to a low resistance part such as theframe.Never connect the ground to plated parts such as fuel pipes, brake pipes or exhaust pipe.When ground to the frame, be sure to scrape off the paint and apply under coat paint afterwork.

• Cautiones when installing body or equipment.

1). Never come off the Caution Label.2). Do not install body or equipment, so that the Caution Label can not be seen.3). If the Caution Label becomes dirty or to be scratched, change the new one.

(Contact local HINO dealer to get the Caution Label.)4). To prevent paint from adhering to the Caution Label, it should be thoroughly masked

when painting.5). Do not use thinner or solvent containing thinner when wiping off paint should get onto

the Caution Plate, use gasoline to wipe it off, or change the new Caution Label.

10


KK-US005D

Welding processings to avoid damaging of chassis electrical parts:• Turn the starter switch to "LOCK" position.• Disconnect the negative terminal of the battery.• Earth all welding equipment properly, near to the area to be welded.• Put back battery negative ground as original condition.• Finally check the functioning of all instruments.

In order to prevent ancillary equipped components from sparks during welding, take stepssuch as putting fire-resistant covers over things like the engine, meters, steering wheel,hoses,tires and springs (leaf spring or air bag) etc.

In order to prevent the damage and the deterioration of the accessory component partscaused by sparks of welding operation, take protective measures on the engine, meters,steering handle, hoses, tires, etc. by means of fire resisting covers, etc.

Summary of the TE system for Engine ControlThe TE system (Total Electronic system) is applied to this vehicle.This is a total electric control system developed for the purpose of totally controlling runningcondition of the engine and of developing the power of the engine to the maximum extent. Thetype of the system used on this vehicle is named “Common-rail Type Fuel Injection System”.As you will notice from this name, it uses a computer. Therefore, you are kindly requested toobserve the above when welding.

Outline of the system (See the following illustration.)

WELDING ROD

BATTERY

BATTERY

CHASSIS FRAME

ARCWELDINGMACHINE

ARCWELDINGMACHINE

ELECTRONICINSTRUMENTS

ELECTRONICINSTRUMENTS

STARTERSWITCH

EARTH OF INSTRUMENTS

EARTH WIREOF CAB

EARTH WIREOF CAB

The electric current of welding.WELDING ROD CAB ELECTRONIC INSTRUMENTS BATTERY EARTH of ARC WELDING MACHINE

EARTH WIRE OF CAB

Case of connecting the – terminal of BATTERY.ELECTRONIC INSTRUMENTS will be damaged.

Case of disconnecting the – terminal of BATTERY.

Disconnect the – terminal of BATTERY.(Do not disconnect at CHASSIS FRAME.)

Turn the STARTER SWITCH to LOCK position.(Do not turn on the STARTER SWITCH when the earth wire is disconnected.)

CHASSIS FRAME

+ –

+ –

EARTH OF INSTRUMENTS

11


KK-US005D

TE SYSTEM DIAGRAM(FOR ALL MODEL)

12


KK-US005D

FEATURE COMBINATION TABLE

Precautions to be taken when performing the inspection services and repair works.When executing inspection services and repair works of your vehicle, be sure to observe thefollowing instructions in order to protect the computer, harness wires, sensors, etc. of the TEsystem.

• Disconnect the ground terminal of the battery at the securing position on the frame whenwelding.

• Be sure to turn the key switch to “LOCK” position before taking out or putting in a connectorwhen proceeding to the said operation.

• Do not apply any modification to the computer, harness wires and sensors.

• Do not equip your vehicle with any illegal appliances, such as a high-output wireless, etc.

MODEL ENGINE

NA, NB, NC

ND, NE, NJ, NV

J05D

J08E

COMMON-RAILFUEL INJECTION

TACHOMETERDRIVE PULSE

13


KK-US005D

PROTECTION OF INTERFERENCE WITH REAR SPRING AND REAR SPRINGHANGE

To prevent interference with rear spring, don’t install a rear body or equipment and shorteningof the frame in the following range.

Model NA / NB / NC

14


KK-US005D

Model ND / NE / NJ / NV

15


KK-US005D

Model ND (REAR AIR SUSPENSION) NE (REAR AIR SUSPENSION) NJ (REAR AIR SUSPENSION) NV (REAR AIR SUSPENSION)

16


KK-US005D

NOTES ON SYSTEM CONTROL COMPUTERS

Engine control, brake ABS and auto transmission control computers are installed right part,inside of the instrument panel as described following figure.Therefore, give great care to the computer when performing any body mounting work or modi-fication as following points.

• Be sure to cover the computer to protect the water penetration when performing cleaning upthe inside of cab.

• When mounting such devices as a radiophone, a wireless communication device, be sure touse the devices that conforms to the electric control act and install the devices on the placeswhich 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, afterhaving installed the device, which affects on the electronic signals passing through in com-puter harness.

• Do not alter the computer, harness wire or sensors (ex. acceleration sensor).• As you will see on the following Fig. Various kind of computers are installed inside the cab,

when fitting and modifying the inside of the cab, be careful not to give any shock to thevicinity of the computer.

17


KK-US005D

PRECAUTION OF THE ANTENNA POSITION

The antenna which is installed on left corner top of the cab roof use right angle position innormal operation.

Make sure that not to obstruct the moving range of the antenna in described following figurewhen perform to mount rear body or equipment.

It may cause the noise or poor receiving of the radio if occur an interference with the antennaand rear body or equipment parts.

18


KK-US005D

PROCESS FOR REMOVING THE INSTRUMENT PANEL

When removing the instrument panel for installation of electrical parts such as relay fuse andetc. which are related with a mounted body, refer to the instructions mentioned below.

• “A” “B” “D” are to be removed individually.• When removing “E” “F” “G”, be sure to remove all switches, cigarette lighter and throttle

control before proceeding.• When removing “H” “I”, can be done individually if “D” has been removed before proceeding.• When removing “D”, pull at lower both end of the panel.• For removing cluster housing (“J”) completely, be sure to remove “A” ~ “H” and following

parts before proceeding.* Heater control* Audio* DIN pocket and installed parts of body in DIN pocket.

19


KK-US005D

NOTES ON ADDITIONAL WIRING IN THE ENGINE COMPARTMENT

Since the engines in HINO trucks are covered with sound arrest plates, thus the engine com-partment tends to heat up.Avoid wiring in the engine compartment in the food if possible.Additional wiring harness or cable should be kept away from heated elements, and should bewired along the original chassis harness.

CAUTION ON VEHICLE STORAGE

We deliver only the vehicles which have passed our delivery inspection. However, it frequentlyhappens that when the vehicles (chassis with cab) are kept in a storage of the dealers or rearbody manufacturers for long periods of time, the vehicles are placed on the irregular-surfacedground in the manner in which their frames are twisted. If the frame is kept in a twisted state fora long time, it will be permanently deformed, thus becoming a cause of complaints to be lodgedlater. So, you are requested to make sure that the surface of the ground on which the vehiclesare stored be levelled to prevent the twisting the frame.

RESETTING OF VEHICLE SPEED SENSORING PULSE CONVERTER

In addition to the engine control etc., Hino vehicle are equipped with such device as ABS thatare obligatorily required by the FMVSS.

Never attempt to apply such modification as would be altered the vehicle speed conditions, aschanging of rear axle ratios or tire sizes.

In the event that, you are obliged to apply those modification, please consult with HMS (USA)or dealer the nearest to you for any appropriate advice and, at the same time, don’t forget toreset the PULSE CONVERTER for vehicle speed sensorring.

20


KK-US005D

MAXIMUM VERTICAL TRAVEL RANGE OF LATERAL ROD(REAR AIR SUSPENSION MODEL)

Measurement for maximum vertical travel range of the rear lateral rod is shown beiow.When you mount a body or equipment, allow a clearance of at least 30mm (1.2in) so as not tointerfere with shim for lateral rod.

VERTICAL TRAVEL RANGE OF REAR LATERAL ROD

21


KK-US005D

PRECAUTION FOR LEVELING VALVE(REAR AIR SUSPENSION MODEL)

Rear air suspension model installed leveling valve to keep vehicle height. When mountingbody or equipment on the vehicle, must be kept 10mm (0.4in) clearance between lever andbody or equipment.

MODEL A

N D 8 J

N E 8 J

N J 8 J

20 (0.8)

N V 8 J 22.3 (0.9)

Unit: mm (in.)

22


KK-US005D

• The adjustment of Leveling Valve has already been made under the chassis condition beforedeliver the chassis to body or equipment manufacturer.

Therefore, do not re-adjust and disassembly the Leveling Valve at the time or after rear bodymounted.

(Should more detailed data or information regarding adjust ment of Leveling Valve be needed,please contact HMS (USA) or dealer.)

• Do not change the length of link rod. (Marked as following figure)

23


KK-US005D

PRECAUTIONS FOR EXHAUST SYSTEM

Handling the Muffler

The muffler incorporates a catalyst and DPR filter that may be broken by mishandling or drop-ping.Take extra care when handling the muffler during mounting of a body or equipment.

Clearances between Exhaust System Parts and Other Parts

The exhaust system becomes very hot during driving.Ensure the following to prevent vehicle fire when modifying.• Clearances from a body or equipment

Observe the precautions for mounting a body or equipment described here and when statedlater.

• Clearances from fuel system partsMaintain a clearance of at least 200mm (8.0 in.) between the fuel tank, fuel pipes and hotcomponents of the exhaust system. If you cannot maintain the clearance of 200mm (8.0 in.),fit heat shields or insulators to protect the fuel tank and fuel pipes. When arranging fuelpiping, make sure that even if a fuel line ruptures and fuel leaks out, no fuel will come intocontact with the hot components of the exhaust system.Never install connectors of the fuel pipes at the hot components or above of the exhaustsystem.

• Clearances from chassis parts other than fuel system partsIf you cannot maintain the clearances described below, fit with heat insulators or heat shields.

Exhaust Pipe and Muffler

The effect and interference of the heat from the exhaust pipe, muffler, etc. of the exhaustsystem have a significant influence to safety. Maintain adequate clearances between compo-nents such as the exhaust pipe, muffler and a body or equipment, measure the temperature ofthese components as necessary to check for safe operation.

CLEARANCE mm (in.)

Min. 100 (4.0)

Min. 200 (8.0)

Air pipes, oil pipes

Electrical cables, rubber parts (rubber hoses, etc.),nylon tubes, resin parts, cables

CHASSIS PARTS

24


KK-US005D

Precautions for Mounting a Body or Equipment

• When mounting a body or equipment, maintain the following clearances from the exhaustsystem.

For wood, rubber, and cloth maintain a clearance of at least 100mm (4.0 in.).For cables, brake hoses, nylon tubes, electrical harness, and resin parts maintain a clear-ance of at least 200mm (8.0 in.).If it is impossible to maintain the above clearances, fit heat insulators or heat shields be-tween the relevant parts, or measure the temperature of the exhaust system to ensure safeoperation.When the heat insulators are removed during installation, be sure to return the heat insula-tors or heat shields to their original position. Never paint the heat insulators or heat shields.

• When mounting equipment (tool box, etc.) or flammable objects behind the outlet of the tailpipe, avoid the shaded area shown below.

25


KK-US005D

When mounting a body or equipment above and ahead of the outlet (beside themuffler, pipe, etc.)

When mounting a body and relevant parts near the pipe, maintain a clearance of at least80mm (3.0 in.) from the pipe as shown in the drawing below. If it is impossible to maintain theclearance of at least 80mm (3.0 in.), fit a heat insulator or heat shield between the relevantparts.

Minimum Clearance with Vertical Exhaust Tail Pipe

When mounting the rear body or equipment, allow at least the minimum clearance 80mm (3in)with vertical exhaust tail pipe.

26


KK-US005D

Installation of the Heat Insulator or Heat Shield(For Vertical Exhaust Tail Pipe)

If there are casies to access the operator around exhaust tail pipe to be marked dotted line asfollowing figure according to the kinds of body or equipment, fit heat insulators or heat shieldsaround exhaust tail pipe, or measure the temperature to ensure safe operation.

27


KK-US005D

DPR MUFFLER

DPR MUFFLER

(DPR = Diesel Particulate active Reduction system)

(1) Outline of DPR MufflerStructure of DPR muffler is shown following figure.

The DPR filter collects particulate matter found in exhaust gas and automatically burns them.

Be extra careful when refueling, refer to the “Fuel Caution Plate” attached on theinstrument panel in the cab and on the fuel tank.

(2) Working condition while runningThe DPR automatically purifies particulate matter during normal operation.This system does not negatively effect the vehicle operation.

(3) Working condition while under operationPurification of particulate matter

: When the vehicle stops for a traffic signal, the DPR may enter filter mode. At this time the engine idle speed may temporarily increase causing the exhaust brake to actuate.

When idling long time : To prevent emission of white smoke, when vehicle is left idling for certain time (approx. 1 hour), idling speed will increase causing exhaust brake to work.

28


KK-US005D

(4) Precautions1) An exhaust pressure outlet pipe and an exhaust temperature sensor are installed on

muffler and a harness is attached to the sensor. At the time of mounting the body, takeextra care with these system.If these parts are damaged, purification of particulate matter may not be performedsufficiently.

2) Muffler may be removed and remounted for maintenance.Place the parts of the body so that it is easy to remove and mount the muffler.

3) Depending on how vehicle is operated, DPR indicator light may be flashing.If the DPR indicator light is flashing, follow the instruction below within 150km.To prevent fire, make sure there is no flammable matter near the exhaust pipe.

1. Park vehicle in safe place.2. Do not stop the engine.3. Press the DPR switch shown below. Confirm that the flashing DPR indicator light turns on and idle speed increases, and turn on the exhaust brake. Wait for 15 to 20 minutes. When the DPR indicator light goes off and the idle speed returns to normal, you can drive normally.

This instruction is to reproduce the function of DPR filter and it does not mean there is aproblem.However, if the vehicle is left with the flashing DPR indicator light on and engine runs longtime, the check engine light will turn on and output power will be restricted in order toprevent damage to the DPR. If vehicle is used in one spot for body operation for a longtime, it is necessary to make sure the DPR indicator light does not turn on.

(5) Paint applicationNever paint the muffler (DPR) or pressure sensor.

P

1RDM

HOUR MIN RESET CLOCK

2RPT

3 CDVOLUME

DISP

SCAN

AUDIO4 5 6 FMAM

DPR SWITCH

DPR INDICATOR

29


KK-US005D

ASSEMBLY PROCEDURE OF VERTICAL EXHAUST TAIL PIPE

At vehicle (chassis with cab condition) delivery, vertical exhaust tail pipe No.1, will be packedon the vehicle.

Before deliver the vehicle to be mounted with rear body or equipment, assemble the verticalexhaust tail pipe as stated in the following procedure.

No.1

No.2

30


KK-US005D

Assembly Procedure

• Park the vehicle, apply the parking brake, and apply wheel chocks at the front or rear tires.• After stopping the engine, wait until the tail pipe cools adequately before starting the work.• Make sure to be careful, for the location of tail to install is in a high position.• If you drop foreign matter inside the tail pipe, contact a Hino dealer and have the foreign

matter removed by taking off the lower tail pipe.

1) Remove insulator (6 bolts).

2) Insert No. 1 tail pipe inside No.2 tail pipe until it touches the shoulder on the inside of the No. 2 tail pipe. Ensure the correct direction of the mouth of No. 1 tail pipe. (For direction of the mouth of N0.1 tail pipe, refer to “ASSEMBLY DRAWING” in the next page.)

3) If fitting is tight, loosen the U-bolt and tighten it with specified torque (4 nuts).

4) Hand tighten No. 1 tail pipe with the U-bolt.

5) Install the clamp hand tight 2±1mm (0.08±0.04in.) above the bottom end of the slit of No. 2 tail pipe. (Note blue mark) Final the clamp, tighten the end with collar first then tighten the other end with the specified torque.

6) Tighten both U-bolt completely. Two nuts are used to tighten each U-bolt.

7) Remove the protection sheet off of the insulator. Do not forget to remove the protection sheet from the connecting side also.

8) Install the insulator (6 bolts) with tighting torque 22±2N·m {195±18LB-IN/16±1LB-FT}.

9) If the insulator is deformed and there is not enough clearance between the insulator and U-bolt clamp, it may rub, causing noises. Make sure there is clearance after installation. If there is no clearance, adjust the insulator to ensure clearance.

NOTE : For details of tightening torques, see the ASSEMBLY DRAWING on the next page.

4) Hand tighten No.1 tail pipe with the U-bolt.

3) If fitting is tight, loosen the U-bolt and tighten it with specified torque.

No.1tail pipe

No.2tail pipe

Front of Vehicle

Up

Bracket

6) Tighten U-bolt completely.

6) Tighten U-bolt completely.

Blue mark

No.2tail pipe

Slit

Clamp

Install the clamp hand tight 2±1mm (0.08±0.04in.) above the bottom end of the slit of No. 2 tail pipe.

2±1

(0.0

8±0.

04)

31


KK-US005D

Assembly Drawing of Vertical Exhaust Tail Pipe

Unit : mm (in.)

Documents

Chapter 4 Body... · Always use the fuel hose of the HINO genuine parts. The following figure is an example of genuine parts. (The material and quality of each component are based