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HINO DUTRO XZU404 XZU412 XZU414 XZU422 Workshop Manual

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🏷️ Basic Information Identification Make: Hino Model: Dutro Codes Chassis Codes: XZU404, XZU412, XZU414, XZU422, XZU424, XZU434, WU300, WU340, WU410 Engine Codes: 14B (3.6L Diesel), 15B (4.1L Diesel) 👋 Introduction Market Position Vehicle Segment: Light-duty commercial vehicle (truck/cab-chassis). Competitive Analysis Competitors: Isuzu Elf, Mitsubishi Fuso Canter, Toyota Dyna (depending on market). Key Features Utility: Designed for a wide range of commercial applications, from light cargo transport to specialized upfitting. Reliability: Hino is known for robust engineering and durability in commercial applications. Durability: Built for demanding commercial use, emphasizing longevity and operational uptime. Manual Value Proposition Content Quality: Highly comprehensive factory manual providing detailed information for technicians and skilled DIY users. 📋 Manual Details Coverage Areas Systems: Engine Mechanical, Fuel System, Intake System, Exhaust System, Cooling System, Lubrication System, Starting & Charging System, Front Suspension, Rear Suspension, Tire & Wheel, Differential, Drive Shaft/Propeller Shaft, Brake System, Parking Brake, Exhaust Brake, Manual Transmission/Transaxle, Clutch, Steering Column, Power Steering, Manual Steering, Heater & Air Conditioner, Supplemental Restraint System (SRS), Engine Control System, Diagnostics Applicable Models: Directly covers chassis codes WU300, 340, 410 series and XZU404, 412, 414, 422, 424, 434 series. Page Count Total Pages: >1800 Manual Type Type: Factory Workshop Service Manual Language Language: English Format Digital Format: PDF Download (originally on CD) Searchability: Fully searchable text for efficient information retrieval. 📖 Manual Coverage Systems Covered Powertrains: Engine Mechanical, Fuel, Intake, Exhaust, Cooling, Lubrication, Starting & Charging, Transmission, Clutch, Differential, Drive Shaft, Exhaust Brake Chassis And Suspension: Front Suspension, Rear Suspension, Tire & Wheel, Brake System, Parking Brake Steering And Comfort: Steering Column, Power Steering, Manual Steering, Heater & Air Conditioner Electrical Diagrams: Comprehensive wiring diagrams for various vehicle systems, essential for electrical troubleshooting. Cooling And Lubrication: Detailed service procedures for radiator, water pump, thermostat, oil pump, oil pan, and oil filter replacement. HVAC Service: Procedures for servicing the heater core, A/C compressor, refrigerant system (with appropriate safety precautions), and blower motor. Diagnostics And Electronics Electrical Systems: Starting & Charging, Engine Control System, Diagnostics, Supplemental Restraint System (SRS) Procedures Included Repair Procedures: Comprehensive repair and overhaul procedures for all covered systems. Maintenance Procedures: Detailed maintenance guidelines and schedules. Diagnostic Procedures: Systematic diagnostic steps, troubleshooting guides, and fault code interpretation. Engine Rebuild: Complete engine mechanical procedures including cylinder head overhaul, piston/ring replacement, crankshaft and bearing service, camshaft timing. Transmission Overhaul: Detailed disassembly, inspection, repair, and reassembly procedures for the manual transmission and clutch assembly. Suspension And Steering Repair: Detailed procedures for front and rear suspension component replacement, alignment specifications, and steering system repairs. Brake System Repair: Complete instructions for brake caliper service, rotor replacement, brake line maintenance, and parking brake adjustment. Body And Chassis: While not explicitly detailed in the listed sections, typical workshop manuals of this scope include basic body repair, frame inspection, and cab component service. Technical Depth Depth Of Information: Factory-level technical data, including specifications, diagrams, and step-by-step instructions for both routine maintenance and complex repairs. Engine Diagnostics: In-depth coverage of engine control module (ECM) diagnostics, sensor testing, actuator testing, and common fault symptom analysis. Troubleshooting Guides: Systematic troubleshooting trees and diagnostic flowcharts for various vehicle issues. Service Specifications: All essential service specifications including clearances, runout, pressures, voltages, and torque values. 📊 Manual Specifications File Format Digital Format Details: Searchable PDF, suitable for printing key sections. Print Quality Scan Quality: Not a scanned version; original factory documentation. Binding Type Digital Delivery: Downloadable PDF. Paper Type Physical Format: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 3.6L Diesel: Hino 14B engine series. Secondary Engine 4.1L Diesel: Hino 15B engine series. Engine Type Diesel Configuration: Inline 4-cylinder, direct injection (typical for these series). Emission Control: Compliance with relevant emissions standards for the period of manufacture, often involving EGR or other systems detailed in the manual. Fuel System Injection Type: Common Rail Direct Injection (CRDI) or Indirect Injection (IDI) depending on specific engine variant and year. Performance Power And Torque 14B: Specific figures vary by application and tuning, but typically in the range of 90-110 HP and 190-250 Nm torque. Power And Torque 15B: Specific figures vary by application and tuning, but typically in the range of 100-130 HP and 220-300 Nm torque. Maintenance Timing Belt Or Chain: Likely timing chain for durability in commercial applications. 🔧 Transmission Standard Transmission Type: Manual Transmission (likely 5-speed or 6-speed depending on model and GVW). Optional Transmission Type: Automatic transmission may be available on some variants or markets. Features Gear Ratios: Detailed gear ratios for all forward and reverse gears provided in the manual. Maintenance Fluid Type: Specific manual transmission fluid (MTF) and differential fluid specifications provided. 📐 Dimensions Exterior Wheelbase Options: Multiple wheelbase options available across the WU and XZU series, catering to different cargo lengths. Weights Gross Vehicle Weight Rating Gvw: Varies by model and configuration, typically ranging from 3.5 to 7.5 tons (or...
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HINO DUTRO XZU404 XZU412 XZU414 XZU422 Workshop Manual
🏷️ Basic Information
Identification
Make:
Hino
Model:
Dutro
Codes
Chassis Codes:
XZU404, XZU412, XZU414, XZU422, XZU424, XZU434, WU300, WU340, WU410
Engine Codes:
14B (3.6L Diesel), 15B (4.1L Diesel)
👋 Introduction
Market Position
Vehicle Segment:
Light-duty commercial vehicle (truck/cab-chassis).
Competitive Analysis
Competitors:
Isuzu Elf, Mitsubishi Fuso Canter, Toyota Dyna (depending on market).
Key Features
Utility:
Designed for a wide range of commercial applications, from light cargo transport to specialized upfitting.
Reliability:
Hino is known for robust engineering and durability in commercial applications.
Durability:
Built for demanding commercial use, emphasizing longevity and operational uptime.
Manual Value Proposition
Content Quality:
Highly comprehensive factory manual providing detailed information for technicians and skilled DIY users.
📋 Manual Details
Coverage Areas
Systems:
Engine Mechanical, Fuel System, Intake System, Exhaust System, Cooling System, Lubrication System, Starting & Charging System, Front Suspension, Rear Suspension, Tire & Wheel, Differential, Drive Shaft/Propeller Shaft, Brake System, Parking Brake, Exhaust Brake, Manual Transmission/Transaxle, Clutch, Steering Column, Power Steering, Manual Steering, Heater & Air Conditioner, Supplemental Restraint System (SRS), Engine Control System, Diagnostics
Applicable Models:
Directly covers chassis codes WU300, 340, 410 series and XZU404, 412, 414, 422, 424, 434 series.
Page Count
Total Pages:
>1800
Manual Type
Type:
Factory Workshop Service Manual
Language
Language:
English
Format
Digital Format:
PDF Download (originally on CD)
Searchability:
Fully searchable text for efficient information retrieval.
📖 Manual Coverage
Systems Covered
Powertrains:
Engine Mechanical, Fuel, Intake, Exhaust, Cooling, Lubrication, Starting & Charging, Transmission, Clutch, Differential, Drive Shaft, Exhaust Brake
Chassis And Suspension:
Front Suspension, Rear Suspension, Tire & Wheel, Brake System, Parking Brake
Steering And Comfort:
Steering Column, Power Steering, Manual Steering, Heater & Air Conditioner
Electrical Diagrams:
Comprehensive wiring diagrams for various vehicle systems, essential for electrical troubleshooting.
Cooling And Lubrication:
Detailed service procedures for radiator, water pump, thermostat, oil pump, oil pan, and oil filter replacement.
HVAC Service:
Procedures for servicing the heater core, A/C compressor, refrigerant system (with appropriate safety precautions), and blower motor.
Diagnostics And Electronics
Electrical Systems:
Starting & Charging, Engine Control System, Diagnostics, Supplemental Restraint System (SRS)
Procedures Included
Repair Procedures:
Comprehensive repair and overhaul procedures for all covered systems.
Maintenance Procedures:
Detailed maintenance guidelines and schedules.
Diagnostic Procedures:
Systematic diagnostic steps, troubleshooting guides, and fault code interpretation.
Engine Rebuild:
Complete engine mechanical procedures including cylinder head overhaul, piston/ring replacement, crankshaft and bearing service, camshaft timing.
Transmission Overhaul:
Detailed disassembly, inspection, repair, and reassembly procedures for the manual transmission and clutch assembly.
Suspension And Steering Repair:
Detailed procedures for front and rear suspension component replacement, alignment specifications, and steering system repairs.
Brake System Repair:
Complete instructions for brake caliper service, rotor replacement, brake line maintenance, and parking brake adjustment.
Body And Chassis:
While not explicitly detailed in the listed sections, typical workshop manuals of this scope include basic body repair, frame inspection, and cab component service.
Technical Depth
Depth Of Information:
Factory-level technical data, including specifications, diagrams, and step-by-step instructions for both routine maintenance and complex repairs.
Engine Diagnostics:
In-depth coverage of engine control module (ECM) diagnostics, sensor testing, actuator testing, and common fault symptom analysis.
Troubleshooting Guides:
Systematic troubleshooting trees and diagnostic flowcharts for various vehicle issues.
Service Specifications:
All essential service specifications including clearances, runout, pressures, voltages, and torque values.
📊 Manual Specifications
File Format
Digital Format Details:
Searchable PDF, suitable for printing key sections.
Print Quality
Scan Quality:
Not a scanned version; original factory documentation.
Binding Type
Digital Delivery:
Downloadable PDF.
Paper Type
Physical Format:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
3.6L Diesel:
Hino 14B engine series.
Secondary Engine
4.1L Diesel:
Hino 15B engine series.
Engine Type
Diesel Configuration:
Inline 4-cylinder, direct injection (typical for these series).
Emission Control:
Compliance with relevant emissions standards for the period of manufacture, often involving EGR or other systems detailed in the manual.
Fuel System
Injection Type:
Common Rail Direct Injection (CRDI) or Indirect Injection (IDI) depending on specific engine variant and year.
Performance
Power And Torque 14B:
Specific figures vary by application and tuning, but typically in the range of 90-110 HP and 190-250 Nm torque.
Power And Torque 15B:
Specific figures vary by application and tuning, but typically in the range of 100-130 HP and 220-300 Nm torque.
Maintenance
Timing Belt Or Chain:
Likely timing chain for durability in commercial applications.
🔧 Transmission
Standard Transmission
Type:
Manual Transmission (likely 5-speed or 6-speed depending on model and GVW).
Optional Transmission
Type:
Automatic transmission may be available on some variants or markets.
Features
Gear Ratios:
Detailed gear ratios for all forward and reverse gears provided in the manual.
Maintenance
Fluid Type:
Specific manual transmission fluid (MTF) and differential fluid specifications provided.
📐 Dimensions
Exterior
Wheelbase Options:
Multiple wheelbase options available across the WU and XZU series, catering to different cargo lengths.
Weights
Gross Vehicle Weight Rating Gvw:
Varies by model and configuration, typically ranging from 3.5 to 7.5 tons (or more for heavier duty variants).
Curb Weight:
Dependent on chassis configuration, engine, and body type.
🛡️ Safety Features
Active Features
Brakes:
Hydraulic disc brakes (front), drum brakes (rear) are common, with ABS often available or standard on newer models.
Exhaust Brake:
Integrated exhaust brake system for improved braking on descents.
Passive Features
Airbags:
Driver airbag standard on many later models; passenger airbags may be optional or absent depending on year/market.
Srs:
Supplemental Restraint System (SRS) coverage includes airbags and related sensors/modules.
💡 Technology Features
Infotainment
Features:
Basic radio/audio systems; advanced infotainment not a primary focus in this class of vehicle but may include CD player, AUX input.
Driver Assistance
Features:
ABS, power steering, and the exhaust brake are key driver aids. More advanced systems like lane departure or adaptive cruise control are less common on older models of this class.
Connectivity
Features:
Limited to basic audio connectivity; no advanced smartphone integration typically expected.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 km to 10,000 km or 6-12 months, depending on operating conditions. Specific intervals found in manual.
Air Filter Replacement:
Intervals vary based on operating environment; detailed guidance in the manual.
Fluid Specifications
Engine Oil Type:
API CI-4 or CH-4 diesel engine oil, viscosity grade typically 10W-30 or 15W-40. Exact spec in manual.
Coolant Type:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Specific Hino coolant type recommended.
Brake Fluid Type:
DOT 3 or DOT 4 automotive brake fluid.
Known Issues
Common Wear Items:
Brake pads/shoes, suspension bushings, clutch wear, EGR system (if equipped), glow plugs (diesel cold start).
Technical Specifications
Torque Specifications:
Detailed torque specifications for all critical fasteners are a key component of the manual.
📚 Vehicle History
Brand Heritage
Manufacturer:
Hino Motors, Ltd., a subsidiary of Toyota Motor Corporation, specializing in commercial vehicles.
Model Evolution
Dutro Lineage:
The Dutro series (also known as Hino 200 Series in some markets) is a long-standing line of light-duty trucks, evolving from earlier Hino light commercial models.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with assembly potentially in other global locations.
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