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Hino 300 340 and 410 series truck Service Manual

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🏷️ Basic Information Identification Make: Hino Model: 300 Series (Dutro) Model Variants: 340 Series, 410 Series, Dutro Chassis Codes: WU300, WU340, WU410, XZU404, XZU412, XZU414, XZU422, XZU424, XZU434 Generation Applicable Generations: Specific to the generations covered by the listed chassis codes and engine variants (likely early to mid-2000s era Dutro/300 Series models). Codes Manual Reference Codes: S1VXZE05A, S1VXZE10A, S1VXZE11A, S1VXZE05A (repeat), S1VXZE07A, S1VXZE08A, S1VXZE09A, S5YS05E05A, S5VW04E05A, S5YN04E01A 👋 Introduction Market Position Segment: Light-duty commercial vehicle, often used for local delivery, trades, and municipal services. Competitive Analysis Competitors: Isuzu NPR/NQR, Mitsubishi Fuso Canter, Toyota Dyna/Hino Dutro (within other markets). Key Features Vehicle Strengths: Known for durability, reliability, fuel efficiency, and a compact footprint suitable for urban environments. Manual Value Proposition Benefit To Owner: Enables owners and technicians to perform accurate maintenance, diagnostics, and repairs, reducing downtime and repair costs. 📋 Manual Details Coverage Areas Primary Coverage Regions: General (S1VXZE05A), Oceania (S1VXZE10A) Page Count Total Pages: 3562 Manual Type Type: Workshop Service Manual Language Primary Language: English (assumed, common for international service manuals) Format Download Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (S05C Series, W04DJ, N04CTF), Differential (SH12), Manual Transmissions (H350/351, H260, M150/153, M550) Chassis: General chassis systems, specific chassis for Oceania region. Electrical: Electrical wiring diagrams for applicable series. Procedures Included Maintenance: Scheduled maintenance, fluid checks and changes, filter replacements. Repair: Detailed repair procedures for engine, transmission, differential, chassis components, and electrical systems. Troubleshooting: Diagnostic procedures and fault finding for various systems. Disassembly And Assembly: Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly. Engine Overhaul: Complete procedures for engine disassembly, inspection of internal components (pistons, rings, bearings, valves), cylinder head work, and reassembly. Transmission Rebuild: Detailed steps for the disassembly, inspection, repair, and reassembly of the specified manual transmissions, including gear sets, synchros, and bearings. Differentials Service: Procedures for differential disassembly, inspection of gears and bearings, backlash adjustment, and reassembly of the SH12 differential. Brakes Service: Inspection, repair, and replacement of brake components (pads, shoes, rotors, drums, calipers, wheel cylinders), brake system bleeding, and ABS system diagnostics. Suspension And Steering: Service procedures for steering gears, tie rods, ball joints, springs, shock absorbers, and alignment specifications. Technical Depth Depth: Comprehensive workshop level, covering routine maintenance to major component overhauls and diagnostics. Diagnostic Tools: Procedures may reference specific Hino diagnostic scan tools (e.g., Hino Diagnostic Explorer) and common OBD-II scan tools for engine and system diagnostics. Torque Specifications: Includes detailed torque specifications for all critical fasteners across engine, transmission, chassis, and suspension components. Schematics: Provides comprehensive electrical wiring diagrams, often color-coded, to aid in diagnosing electrical faults and component identification. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High-resolution, suitable for printing and digital viewing. Diagrams and illustrations are clear and legible. Binding Type Binding: N/A (PDF Download) Paper Type Type: N/A (PDF Download) ⚙️ Engine Specifications Primary Engine Engine Families Covered: Hino S05C Series, W04DJ, N04CTF Performance Power Output Range: Varies significantly by specific engine variant and chassis configuration. Typically in the range of 90-140 HP. Torque Output Range: Varies significantly by specific engine variant and chassis configuration. Typically in the range of 200-350 Nm. Fuel System Injection Type: Likely direct injection (common for these Hino engines), potentially common rail diesel (CRD) in later versions within this range. Cooling System Type: Water-cooled, pressurized system. Emission Control Systems: May include EGR (Exhaust Gas Recirculation), DOC (Diesel Oxidation Catalyst), DPF (Diesel Particulate Filter) depending on specific engine and model year. 🔧 Transmission Standard Transmission Types Covered: Manual Transmissions: H350, H351, H260, M150, M153, M550. Optional Optional Transmissions: While not explicitly detailed, automatic or automated manual transmissions might have been available on certain configurations, though the manual focuses on manual units. Features Gear Configurations: Typically 5-speed or 6-speed manual transmissions. Fluid Specifications Transmission Fluid Type: Specific GL-4 or GL-5 gear oil is typically required. Manual will specify exact viscosity and API rating (e.g., SAE 75W-90, SAE 80W-90). 📐 Dimensions Exterior Wheelbase Range: Varies significantly based on chassis code and body configuration. Typically ranges from approximately 2.4m to 3.5m. Overall Length Range: Varies, but generally compact for urban use, often under 6 meters. Weights Gvwr Range: Gross Vehicle Weight Rating (GVWR) varies widely depending on chassis and axle configurations, but typical for this class is in the 4,000 kg to 6,500 kg range. Curb Weight Range: Approximately 2,000 kg to 3,000 kg, depending on configuration. 🛡️ Safety Features Ratings Crash Test Results: Information not directly available from product description; specific safety ratings would be vehicle-model dependent and not a universal manual attribute. Active Features Brake System: Hydraulically operated, typically front disc and rear drum brakes. ABS (Anti-lock Braking System) may be optional or standard depending on market and year. Passive Features Occupant Protection: Driver and passenger airbags (optional or standard depending on market/year), seatbelts with pretensioners, reinforced cab structure....
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Hino 300 340 and 410 series truck Service ManualHino 300 340 and 410 series truck Service ManualHino 300 340 and 410 series truck Service ManualHino 300 340 and 410 series truck Service Manual
🏷️ Basic Information
Identification
Make:
Hino
Model:
300 Series (Dutro)
Model Variants:
340 Series, 410 Series, Dutro
Chassis Codes:
WU300, WU340, WU410, XZU404, XZU412, XZU414, XZU422, XZU424, XZU434
Generation
Applicable Generations:
Specific to the generations covered by the listed chassis codes and engine variants (likely early to mid-2000s era Dutro/300 Series models).
Codes
Manual Reference Codes:
S1VXZE05A, S1VXZE10A, S1VXZE11A, S1VXZE05A (repeat), S1VXZE07A, S1VXZE08A, S1VXZE09A, S5YS05E05A, S5VW04E05A, S5YN04E01A
👋 Introduction
Market Position
Segment:
Light-duty commercial vehicle, often used for local delivery, trades, and municipal services.
Competitive Analysis
Competitors:
Isuzu NPR/NQR, Mitsubishi Fuso Canter, Toyota Dyna/Hino Dutro (within other markets).
Key Features
Vehicle Strengths:
Known for durability, reliability, fuel efficiency, and a compact footprint suitable for urban environments.
Manual Value Proposition
Benefit To Owner:
Enables owners and technicians to perform accurate maintenance, diagnostics, and repairs, reducing downtime and repair costs.
📋 Manual Details
Coverage Areas
Primary Coverage Regions:
General (S1VXZE05A), Oceania (S1VXZE10A)
Page Count
Total Pages:
3562
Manual Type
Type:
Workshop Service Manual
Language
Primary Language:
English (assumed, common for international service manuals)
Format
Download Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (S05C Series, W04DJ, N04CTF), Differential (SH12), Manual Transmissions (H350/351, H260, M150/153, M550)
Chassis:
General chassis systems, specific chassis for Oceania region.
Electrical:
Electrical wiring diagrams for applicable series.
Procedures Included
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements.
Repair:
Detailed repair procedures for engine, transmission, differential, chassis components, and electrical systems.
Troubleshooting:
Diagnostic procedures and fault finding for various systems.
Disassembly And Assembly:
Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly.
Engine Overhaul:
Complete procedures for engine disassembly, inspection of internal components (pistons, rings, bearings, valves), cylinder head work, and reassembly.
Transmission Rebuild:
Detailed steps for the disassembly, inspection, repair, and reassembly of the specified manual transmissions, including gear sets, synchros, and bearings.
Differentials Service:
Procedures for differential disassembly, inspection of gears and bearings, backlash adjustment, and reassembly of the SH12 differential.
Brakes Service:
Inspection, repair, and replacement of brake components (pads, shoes, rotors, drums, calipers, wheel cylinders), brake system bleeding, and ABS system diagnostics.
Suspension And Steering:
Service procedures for steering gears, tie rods, ball joints, springs, shock absorbers, and alignment specifications.
Technical Depth
Depth:
Comprehensive workshop level, covering routine maintenance to major component overhauls and diagnostics.
Diagnostic Tools:
Procedures may reference specific Hino diagnostic scan tools (e.g., Hino Diagnostic Explorer) and common OBD-II scan tools for engine and system diagnostics.
Torque Specifications:
Includes detailed torque specifications for all critical fasteners across engine, transmission, chassis, and suspension components.
Schematics:
Provides comprehensive electrical wiring diagrams, often color-coded, to aid in diagnosing electrical faults and component identification.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
High-resolution, suitable for printing and digital viewing. Diagrams and illustrations are clear and legible.
Binding Type
Binding:
N/A (PDF Download)
Paper Type
Type:
N/A (PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Families Covered:
Hino S05C Series, W04DJ, N04CTF
Performance
Power Output Range:
Varies significantly by specific engine variant and chassis configuration. Typically in the range of 90-140 HP.
Torque Output Range:
Varies significantly by specific engine variant and chassis configuration. Typically in the range of 200-350 Nm.
Fuel System
Injection Type:
Likely direct injection (common for these Hino engines), potentially common rail diesel (CRD) in later versions within this range.
Cooling System
Type:
Water-cooled, pressurized system.
Emission Control
Systems:
May include EGR (Exhaust Gas Recirculation), DOC (Diesel Oxidation Catalyst), DPF (Diesel Particulate Filter) depending on specific engine and model year.
🔧 Transmission
Standard
Transmission Types Covered:
Manual Transmissions: H350, H351, H260, M150, M153, M550.
Optional
Optional Transmissions:
While not explicitly detailed, automatic or automated manual transmissions might have been available on certain configurations, though the manual focuses on manual units.
Features
Gear Configurations:
Typically 5-speed or 6-speed manual transmissions.
Fluid Specifications
Transmission Fluid Type:
Specific GL-4 or GL-5 gear oil is typically required. Manual will specify exact viscosity and API rating (e.g., SAE 75W-90, SAE 80W-90).
📐 Dimensions
Exterior
Wheelbase Range:
Varies significantly based on chassis code and body configuration. Typically ranges from approximately 2.4m to 3.5m.
Overall Length Range:
Varies, but generally compact for urban use, often under 6 meters.
Weights
Gvwr Range:
Gross Vehicle Weight Rating (GVWR) varies widely depending on chassis and axle configurations, but typical for this class is in the 4,000 kg to 6,500 kg range.
Curb Weight Range:
Approximately 2,000 kg to 3,000 kg, depending on configuration.
🛡️ Safety Features
Ratings
Crash Test Results:
Information not directly available from product description; specific safety ratings would be vehicle-model dependent and not a universal manual attribute.
Active Features
Brake System:
Hydraulically operated, typically front disc and rear drum brakes. ABS (Anti-lock Braking System) may be optional or standard depending on market and year.
Passive Features
Occupant Protection:
Driver and passenger airbags (optional or standard depending on market/year), seatbelts with pretensioners, reinforced cab structure.
💡 Technology Features
Infotainment
Features:
Basic radio/audio systems, possibly with CD player or MP3 compatibility on later models within this range. Focus is on utility, not luxury.
Driver Assistance
Features:
Limited by the era and class of vehicle. ABS, power steering are common. Advanced driver-assistance systems (ADAS) are unlikely to be standard.
Connectivity
Features:
Very basic, if any. Primarily focused on vehicle operation and diagnostics.
🔧 Maintenance
Service Intervals
Oil Change Interval Engine:
Typically 5,000 km to 10,000 km or 6 months, whichever comes first. Manual will provide precise intervals for each engine variant.
Transmission Fluid Change Interval:
Generally every 40,000 km to 80,000 km, depending on operating conditions. Manual will specify.
Brake Fluid Change Interval:
Recommended every 2-3 years due to moisture absorption. Manual will confirm.
Fluid Specifications
Engine Oil Type:
Depends on engine and ambient temperature. Commonly API CJ-4 or CK-4 rated diesel engine oils with viscosities like 10W-30 or 15W-40. Manual will specify exact API and viscosity.
Coolant Type:
Hino's proprietary long-life coolant (or equivalent ethylene glycol-based coolant with appropriate additives).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, depending on system requirements. Manual will specify.
Known Issues
Common Wear Items:
Clutch wear, brake pad/shoe wear, exhaust system components, suspension bushings, diesel particulate filter (if equipped) clogging.
Diagnostic Challenges:
Electronic control unit (ECU) diagnostics for emission control systems, fuel injector issues, EGR valve problems.
📚 Vehicle History
Brand Heritage
Manufacturer:
Hino Motors, Ltd. (a subsidiary of Toyota Motor Corporation), renowned for its commercial vehicle expertise.
Model Evolution
Lineage:
The Hino 300 Series (and its Dutro predecessor/variants) is a long-standing line of light-duty trucks known for its versatility and robust construction.
Production
Manufacturing Locations:
Primarily Japan, with potential assembly in other global locations for specific markets.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Information not directly available from product description. Hino vehicles generally receive recognition for reliability and commercial suitability.
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