chapter 4 body... · always use the fuel hose which is same diameter as original and the hino...

Chapter 4TRUCK BODY AND SPECIAL EQUIPMENT

INSTALLATION PROCEDURE AND PRECAUTIONS

GENERAL PRECAUTIONS ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1WEIGHT DISTRIBUTION AND CENTER OF GRAVITY ••••••••••••••• 6CAUTIONS NEEDED FOR THE TILT HOOD •••••••••••••••••••••••••••••• 6FUEL TANK •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7PRECAUTIONS FOR THE FUEL HOSE ••••••••••••••••••••••••••••••••••••• 10PRECAUTION FOR CAUTION LABEL OF FUEL TANK ••••••••••••• 11INSTALLATION OF FENDER AND MUDGUARD •••••••••••••••••••••••• 13CAUTIONS ON WELDING ••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 13MINIMUM CLEARANCE WITH REAR SPRING AND •••••••••••••••••• 16 REAR SPRING HANGERNOTES ON SYSTEM CONTROL COMPUTERS ••••••••••••••••••••••••• 19PRECAUTION OF THE ANTENNA POSITION •••••••••••••••••••••••••••• 21PROCESS FOR REMOVING THE INSTRUMENT PANEL ••••••••••• 22NOTES ON ADDITIONAL WIRING IN THE ENGINE •••••••••••••••••• 23 COMPARTMENTCAUTION ON VEHICLE STORAGE ••••••••••••••••••••••••••••••••••••••••••• 23RESETTING OF VEHICLE SPEED SENSORING ••••••••••••••••••••••• 23 PULSE CONVERTERMAXIMUM VERTICAL TRAVEL RANGE OF LATERAL ROD ••••• 24 (REAR AIR SUSPENSION MODEL)PRECAUTION FOR LEVELING VALVE ••••••••••••••••••••••••••••••••••••• 25 (REAR AIR SUSPENSION MODEL)PRECAUTIONS FOR EXHAUST SYSTEM ••••••••••••••••••••••••••••••••• 27DPR MUFFLER ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 30PRECAUTION FOR DEF - SCR SYSTEM •••••••••••••••••••••••••••••••••• 32ASSEMBLY PROCEDURE OF VERTICAL EXHAUST ••••••••••••••• 36 TAIL PIPE

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Chapter 4 TRUCK BODY AND SPECIAL EQUIPMENT INSTALLATION PRECAUTIONS

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The following installation procedures and specific precautionary instructions are recommend-ed for the proper installation of bodies and/or equipment on Hino chassis.Failure to follow these recommendations could result in serious damage to the Hino chassis.

General Precautions

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

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

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

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

When body or additional components are mounted on the front or rear overhang, it is desir-able 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 at least 50 mm (2.0 in.) clearance.

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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 or equipment.

no fitting should be installed to ensure a space of 150 mm (6.0 in.) long for the clutch and transmission assembly to be withdrawn for removal 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 body, sufficient considerations are needed so that there will no trouble in carrying out daily inspection and maintenance.• 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 and DEF• 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 the front wheel alignment and make adjustments if needed. (Tighten spring U-bolts and center bolts with the specified torques.)

After a vehicle has been properly fitted out, make sure that it is free from any defects such as the 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 the Hino Chassis or impair its proper functioning. (For instance do not step on piping, wiring, air tank, fuel tank, air drier and other chassis frame component.)

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

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

Be careful that the mounted body may not interfere with the front and rear field of vision.

When a concentrated load is applied locally or the body is long, the amount of deflection may pose problems in some cases. So, it is advisable to use or or shaped steel beams as the main sill, and joint them securely to the side members in order to obtain suffi-cient overall strength and rigidity.When a body with a great rigidity is mounted as in the case of tank lorries and bulk cement carriers, please make reference to the paragraph devoted to the main sill to prevent a weak point appearing at the rear of the cab.

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

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

lines and the parts of body.• Make the inspection and working holes if the side rail is stiffened as a closed section.

Cautions needed when mounting the body 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 the

like heat insulating means.

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Do not place flammable material near the exhaust system.

• Care must be taken that there is no rope or sheet hanging close to the exhaust system. Do not place the rope hook near the exhaust system.

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

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space for dismounting and mounting work of air DrYer

The air dryer contains a desiccant, which must be inspected and replaced at regular intervals.This work needs dismounting and mounting the air dryer.Make sure to make room for dismounting and mounting the air dryer.

HYDRAULIC BRAKE ( NE )

FULL AIR BRAKE ( NJ and NV )

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WeiGht Distribution anD center oF GraVitY

recommended Weight Distribution on Front axle

To ensure satisfactory steerability of the vehicle under all conditions, proper weight distribution on 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 of body mounting.The height of center of gravity from the ground to the completed vehicle with payload should not 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.

Model

NE, NJ, NV Less than 1778 (70)

Unit: mm (in.)Height of center ofgravity from ground

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 when perform to mount the body or equipment.

Model A B C D

NENJNV

Unit: mm (in.)

1,620(63.78)

610(24.02)

2,680(105.51)

1,635(64.37)

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

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Fuel tank

Fuel Filler for Fuel tank

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

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handling of Fuel tank lock nut

The lock nut has been provided with plastic locking element.Therefore the lock nut should be changed with new genuine one when the lock nut is loosen.

Part No. SZ177-12005

It is strictly prohibited that the loosen lock nut is re-used.Be sure to tighent the lock nut with secified torque when installing new one.

Tightening torque 224±20 (16±1) kgf·cm (lb·ft)

Detail of Lock Nut

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FUEL TANK CAP.MODEL

NE AND NJ

NV

50gal

LESS

WITH

50gal x 2

LESS

LESS

90gal

LESS

LESS

Fuel cooler

A fuel cooler is equipped to the following models.( See the table )If it alters fuel tank capacity, install or remove the fuel cooler according to the table. For more detailed information, please contact local HINO dealer.

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Precautions For the Fuel hose

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

Always use the fuel hose which is same diameter as original and 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.)

Unit : mm (in.)

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, or equivalent.

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

For more detailed information, please contact with HMS.

Ø14

(0.6

)Ø

7.6

(0.3

)2

INNER RUBBER(FLUORIDE COATED)

OUTER RUBBER

BRAID

INTERMEDIATE RUBBER

(0.0

8)

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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 of Federal 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 - E0220

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• Detail of location of the Cautiion Label

CAPACITY : 190L (50gal)

CAPACITY : +190L (50gal, ADDITIONAL TANK : OPT)

CAPACITY : 341L (90gal)

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• 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.

installation oF FenDer anD MuDGuarD

Referring to Chapter 6 “MOUNTING OF REAR FENDER AND MUDGUARD”, determine the dimensions of the fender 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 above-mentioned chapter.

cautions on WelDinG

When performing welding, turn the starter key to "LOCK" position, wait at least 10 minutes, and disconnect the negative terminal of battery.Electronic instrument (e.g. ABS and Engine control computer) and other electrical parts al-ways need electric power are connected directly to the battery and the ground.If the welding is performed in this condition, an electric current of welding may flow reversely into the electrical parts from their ground circuit resulting in damage to the electrical parts.

Since welded parts becomes extremely hot and sparks are present, dismount the fuel tank or batteries when welding near those units. Make sure that there are no items present such as harnesses, nylon tubes, pipes, resin clips for piping, suspension components (such as spring brackets, spring leaves) 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, steering, and also do not weld any body parts or mounting brackets on the chassis frame for mounting the 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 the frame.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 after work.

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Welding processings to avoid damaging of chassis electrical parts:• Turn the starter key to "LOCK" position.• Wait at least 10 minutes.• 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 steps such 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 parts caused by sparks of welding operation, take protective measures on the engine, me-ters, 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 running condition of the engine and of developing the power of the engine to the maximum extent. The type of the system used on this vehicle is named “Common-rail Type Fuel Injection Sys-tem”. As you will notice from this name, it uses a computer. Therefore, you are kindly re-quested to observe 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

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TE SYSTEM DIAGRAM

Accelerator pedalposition sensor 1, 2

PTO accelerator sensor

Starter cut relay

Neutral switch

PTO switch 1

Diagnostic switch

DPR regeneration switch

PTO switch 2

Vehicle speed sensor

Diagnostic lamp (Check engine lamp)

Engine stop switch

Water in fuel switch

Brake switch

Glow lamp (wait-to-start lamp)

DPR indicator lamp

Malfunction indicator lamp (MIL)Oil pressure switch

Vehicle ECU

Boost pressure sensor

G

Variable nozzle turbocharger (VNT)controller and actuator -> 6-3

Fuel ra

il pr

ess

ure

senso

r (m

ain)

Inta

ke a

ir t

em

pera

ture

senso

r (A

FS b

uilt

-in

)

Air f

low

senso

r (F

requ

ency-

type)

Fuel temperature sensor

Fuel injector drive signal

Key switchFUSE

Starter switch

FUSE

Main relay

Actuator relay

Power source

Suction control valve for fuel supply pump drive signal

ＯＵＴＰＵＴ

EGR gas temperature sensor

Exhaust gas temperature sensor (DOC outlet)

Exhaust gas temperature sensor (DOC inlet)

Supply pump

DC motor

Turbocharger

Fuel ra

il pr

ess

ure

senso

r (s

ub)

Crankshaft position sensor

Camshaft position　sensor

+-

Battery

INPUT

N

Intake air temperature sensor (intake manifold)

EGRvalve

CAN communication（Variable nozzle turbo charger, EGR valve, DEF dosing system, Burner system）

Engine coolant temperature sensor 1

TT

S/P

CAN communication（Diagnosis, Vehicle ECU）

T

Suction control valve for fuel supply pump drive power

FUSE

Diagnostic tool

PCdiagnosis

Barometricpressuresensor

(ECU built-in)

DC motor

Frequency-typeAFS

T

Fuel injector

OTHERS

Glow status signal

Glow plug drive signal

P

P

Fuel rail

Exhaust brake drive signal

Intake air temperature sensor (intercooler outlet)

T

T

EGRcooler

Engine

Differential pressure sensor

Exhaust brake magnetic valve

ＰＴＴ

DPRcleaner

UreaSCR

Burner

Exhaust aftertreatment system　　　　　　　　　-> 6-4, 6-5

Glowcontroller

Glow plug

: monitored for the OBD requirements : monitored for the system safety

Intake throttle valve position sensor 1

DC motor (for Intake throttle valve) drive signal

DCmotor

Ａ

ＡIntake throttle valve position sensor 2

Intakethrottlevalve

EGR valvecontroller

and actuator-> 6-2

T

Engine coolant temperature sensor 2

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MINIMUM CLEARANCE WITH REAR SPRING AND REAR SPRING HANGER

Model NE / NJ / NV

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

• OPT, NV REINFORCED AIR SUSPENSION

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notes on sYsteM control coMPuters

Vehicle control, brake ABS and other 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 up the inside of cab.

• 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 com-puter harness.

• Do not alter the computer, harness wire or sensors (ex. acceleration sensor).• As you will see on the following figure, 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 the vicinity of the computer.

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engine control computer

The engine control computer ( hereinafter termed ECU ), the connector and harness are in-stalled in the left side of the cylinder block.Never do the following work to the ECU, connector and harness.

• Alteration• Remove• Movement• Paint

Take care about the following point at the time of body mounting.Be careful not to give any shock to the ECU. Certainly cover so that a paint dose not adhere to the ECU and the connector, at the time that the engine is painted. Do not cover the surrounding of the ECU, in order to prevent the depression by heat.At the time that you wash the engine with water, be sure to cover the ECU and connector to protect the water penetration.

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Precaution oF the antenna Position

The antenna which is installed on left corner top of the cab roof use right angle position in nor-mal operation.

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

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

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Process For reMoVinG the instruMent Panel

When removing the instrument panel for installation of electrical parts such as relay fuse and etc. 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 con-

trol 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.

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notes on aDDitional WirinG in the enGine coMPartMent

Since the engines in HINO chassis 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 be wired along the original chassis harness.

caution on Vehicle storaGe

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

resettinG oF Vehicle sPeeD sensorinG Pulse conVerter

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

Never attempt to apply such modification as would be altered the vehicle speed conditions, as changing 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 to reset the PULSE CONVERTER for vehicle speed sensorring.

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

Measurement for maximum vertical travel range of the rear lateral rod is shown below.When mounting body or equipment, allow a clearance at least 30mm (1.2in.) between shim for lateral rod and body or equipment.

VERTICAL TRAVEL RANGE OF REAR LATERAL ROD

TOP OF FRAME

SHIM FOR LATERAL ROD

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precaution for leveling valve (rear air SuSpenSion MoDel)

The leveling valve is installed with rear air suspension model to keep vehicle height.When mounting body or equipment, allow a clearance at least 30mm (1.2in.) between lever and body or equipment.


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

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

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

• Do not change the length of link rod. (Markedasfollowingfigure)

Unit : mm (in.)


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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 stated

later.• Clearances from fuel system parts Maintain a clearance of at least 200mm (8.0 in.) between the fuel tank, fuel pipes and hot

components 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 fuel pip-ing, make sure that even if a fuel line ruptures and fuel leaks out, no fuel will come into con-tact with the hot components of the exhaust system.

Never install connectors of the fuel pipes at the hot components or above of the exhaust system.

• Clearances from chassis parts other than fuel system parts If 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 exhaust sys-tem have a significant influence to safety. Maintain adequate clearances between components such as the exhaust pipe, muffler and a body or equipment, measure the temperature of these 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

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Precautions for Mounting a body or equipment

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

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 safe operation.

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 tail pipe, avoid the shaded area shown below.

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

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

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.

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DPr MuFFler

DPr MuFFler(DPR = Diesel Particulate active Reduction system)

(1) Outline of DPR Muffler Structure 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 the instrument panel in the cab and on the fuel tank.

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

(3) Working condition while under operation Purification 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.

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(4) Precautions 1) An exhaust gas differential pressure sensor and an exhaust temperature sensor are installed on muffler and a harness is attached to the sensor. At the time of mounting the body, take extra care with these system. If these parts are damaged, purification of particulate matter may not be performed sufficiently. 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, 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 a problem.

However, if the vehicle is left with the flashing DPR indicator light on and engine runs long time, the check engine light will turn on and output power will be restricted in order to

prevent damage to the DPR. If vehicle is used in one spot for body operation for a long time, it is necessary to make sure the DPR indicator light does not turn on.

(5) Paint application Never paint the muffler (DPR) or pressure sensor.

P

1RDM

HOUR MIN RESET CLOCK

2RPT

3 CDVOLUME

DISP

SCAN

AUDIO4 5 6 FMAM

DPR SWITCH

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Precaution For DeF - scr sYsteM

At the time of body mounting, always follow precautions below.

This vehicle is equipped with DEF ( Diesel Exhast Fluid ) - SCR ( Selective Catalystic Reduc-tion) system for reduction of NOx (nitrogen oxide) emission.DEF - SCR system is installed under the assistant side chassis step.

1 Exhaust pipe 4 DEF - SCR system

2 Insulator 5 Tail pipe

3 Exhaust control cylinder 6 Bracket sub assembly

OUTLINE OF SYSTEM

FR

6

4

2

1

1

3

5

E

4

The state installed in vehicle

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Precautions when body mounting and welding

WARNINGRemoval, installing on different place, painting and modification of any parts of DEF - SCR system is prohibited.

• At the time of body mounting, cover the whole system not to damage system parts.• At the time of welding work, cover whole system with nonflammable material to avoid the

damage by welding spatter, and the influence by heat. Before welding, turn the starter key to "LOCK" position, wait at least 10 minutes, and discon-

nect the negative terminal of battery.• Do not impact each system parts. Be careful not to impact the DEF tank especially because

it is made of resin.• If you need to replace any parts related to DEF- SCR system, use of Hino genuine parts is

required for the proper function of DEF-SCR system.• Around the filling port of DEF tank, body mounting or installing parts should not be done in a

way to obstruct replenishing DEF. ( See the following figure )• Be sure to wait for at least ten minutes after the stater key is turned to "LOCK" position be-

fore you disconnect the battery terminals from the battery, as DCU starts working for "After Run" after the starter key is turned to "LOCK" position.

Otherwise, DCU will not complete working properly (the DEF still remains in the exhaust gas after treatment system), which may result in the malfunction of DEF-SCR system.

What is the meaning of After Run• After you turn the starter key to "LOCK" position.• To avoid crystallizing of the DEF that remaining in the DEF pump, injection and pipes, the

exhaust gas after treatment system automatically returns the DEF to the DEF tank.• You can hear the sound of the DEF pump after you turn the starter key to the "LOCK" po-

sition is proper actuation.• The time when the sound of the DEF pump can begin to be heard changes with situations.

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Precautions when painting

• In the case of natural drying, in order to prevent adhesion of a paint, cover the whole sys-tem.

• In the case of forced drying such as drying in dry oven, drying temperature must be under 80°C(176F) because allowable heat limit of the DEF tank is 80°C(176F).

Also, extract DEF completely from the DEF tank and cover whole system with heat-resistant material.

( See the following figure )• Extract DEF after finishing After Run.• Do not re-use the extracted DEF. At the time that it extracts, tiny substance may mix and it causes failure of system parts.• Always use API certified DEF for replenishment of the DEF tank.

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KK-US009B

indicator light on the meter panel

After finishing body mounting and when starting the engine, if following indicator light on the meter panel goes on do as the instruction of safety label which is attached on the cover of overhead console or contact Hino dealer.

Precautions for DeF

Always use API certified DEF for replenishment of the DEF tank.Don't replenish the tank with DEF diluted even if it was API certified DEF.Never replenish the tank with diesel fuel, kerosene, gasoline or other fluid than API certified DEF.Use of the abovementioned unsuitable fluid causes not only the fall of an exhaust gas purifica-tion function but failure of each parts of DEF-SCR system.If you replenish the tank with the fluid other than API certified DEF by mistake, extract the fluid completely and replenish the tank with API certified DEF before starting engine.Never heat, dilute and never mix other medicines.

Precautions when handling DeF

Observe the following precautions when handling DEF.• Put on the appropriate protective equipment (ex. safety goggles, rubber gloves and etc.).• If DEF goes into eyes or adheres to the skin, wash 15 minutes or more with a lot of effluent

immediately, and receive diagnosis of a doctor.• Although there may be a smell like ammonia in DEF, there is no inconvenience in use.• Wipe off DEF adhering to the floor, the body, a container, etc. with a rag securely. DEF is

dried and crystallized. Crystallized DEF corrodes the metal side where it is not painted if it adheres.

• If it scrapes, treat DEF as industrial waste.• Don't scrap to a lake, the sea, a river, etc.

Indicator light

Indicator light

Indicator light(Information display)

Information display

DEF gauge

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KK-US009B

asseMblY ProceDure oF Vertical eXhaust tail PiPe

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

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

No.1 tail pipe

Clamp

No.2 tail pipe

Muffler unit

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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) Temporary attachment of the clamp is carried out at No.2 tail pipe. Do not bind the clamp tight. The clamp cannot be re-used once it binds tight.

3) Insert No. 1 tail pipe inside No.2 tail pipe until it touches the shoulder on the inside of the No. 2 tail pipe. Since hot exhaust gas comes out of No.1 tail pipe, make mouth of No.1 tail pipe the direction which is not applied to body or equipment. (For direction of the mouth of No.1 tail pipe, refer to “ASSEMBLY DRAWING” in the next page.)

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

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

6) Install the clamp 10±2mm (0.40±0.08in.) above the bottom end of the slit of No.2 tail pipe. (See the detail of E-E, F-F) Tighten the clamp with the proper torque.

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

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

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

10) 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.

No.1 tail pipe

5) Hand tighten No. 1 tail pipe with the U-bolt. 7) Tighten both U-bolt completely. Two nuts are used to tighten each U-bolt.

clamp

No.2 tail pipe4) If fitting is tight, loosen the U-bolt and tighten it with specified torque (4 nuts).7) Tighten both U-bolt completely. Two nuts are used to tighten each U-bolt.

No.1 tail pipeAssembling positionof the clamp

clamp

No.2 tail pipe

Nut of clamp FR

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assembly Drawing of Vertical exhaust tail Pipe

Unit : mm (in.)

chapter 4 body... · always use the fuel hose which is same diameter as original and the hino...

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