---===SD-SM-305E1-0100_0001.djvu===--- FOREWORD To assist you in your service activities, this manual explains the main characteristics of the HINO 700 Series TRUCK and TRACTOR, in particular providing a technical explanation of the construction and operation of new mechanisms and new technology used. Applicable model: HINO ZS, ZY and SV Series CAUTION, NOTICE, REFERENCE and NOTE are used in the following ways: For detailed service specifications and repair procedures, refer to the following Workshop Manual. All information contained herein is the most up-to-date at the time of publication. We reserve the right to make changes without prior notice. This manual is for the exclusive use of the dealers. c 2012 Hino Motors, Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written per- mission of Hino Motors, Ltd. First printing: April. 2012 CAUTION A potentially hazardous situation which could result in injury to people occur if instructions on what to do or not to do are ignored. NOTICE Damage to the vehicle or components may occur if instructions on what to do or not to do are ignored. REFERENCE Explains the theory behind mechanisms and techniques. NOTE Notes or comments not included under the above 3 titles. '12.4.27.update ---===SD-SM-305E1-0100_0002.djvu===--- 1. INTRODUCTION PRODUCTION CODE .. ..... ..... ..... ..2 HINO VIN STRUCTURE . ..... .... .....3 HINO VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE ON CHASSIS STAMPING ............................ 3 MODEL LINE-UP ..... .... ..... ..... ..... ..4 2. ENGINE ENGINE .... ..... ..... ..... .... ........ .... .....8 OUTLINE ................................................ 8 ENGINE SPECIFICATIONS AND PERFORMANCE CURVES ................. 10 EMISSION CONTROL ......................... 13 COOL EGR SYSTEM (FOR CHILE)....... .... ....... .... ....... .... ... . 13 INTAKE SYSTEM................................. 16 PRE CLEANER (PRE CLEANER- EQUIPPED VEHICLE) . .... .... ... .... ...... 17 AIR CLEANER STACK DUCT (STACK DUCT-EQUIPPED VEHICLE) .... ....... .... ....... .... ....... .... ... . 17 AIR CLEANER .... .... ....... .... ....... .... ... . 18 INTAKE MANIFOLD AND PIPE.. ..... . 18 EXHAUST SYSTEM............................. 19 EXHAUST PIPE AND MUFFLER .... ....... .... ....... .... ....... .... ... . 19 EXHAUST MANIFOLD. .... .... ... .... ...... 20 COOLING SYSTEM ............................. 21 LUBRICATION SYSTEM ..................... 22 OIL PAN . .... .... ... .... .... ... .... .... ... .... ...... 22 TURBOCHARGER (FOR EURO2 AND EURO3 REGULATION ADAPTED VEHICLE)............................................. 23 MULTI STEP AIR CYLINDER. .... ...... 25 TURBOCHARGER (FOR EURO4 REGULATION ADAPTED VEHICLE)........................... 26 3. CHASSIS TRANSMISSION ... ..... ..... ..... ..... . 30 TRANSMISSION MECHANICAL.......... 30 TRANSMISSION CONTROL................ 31 PROPELLER SHAFT . ..... ..... ..... . 32 FRONT AXLE .... .... ..... ..... ..... ..... . 33 REAR AXLE . ..... .... ..... ..... ..... ..... . 34 DIFFERENTIAL CARRIER..... .... 35 MANUAL DIFFERENTIAL LOCK . ..... 39 HUB REDUCTION ... ... .... .... ... .... .... ... 42 SUSPENSION ............................ 44 FRONT SUSPENSION......................... 44 REAR SUSPENSION ........................... 47 STEERING. ..... ..... ..... ..... ....... ..... . 48 STEERING COLUMN........................... 48 POWER STEERING SYSTEM ............. 50 STEERING GEAR.. ....... .... ....... .... ..... 51 POWER STEERING BOOSTER (MODEL: ZY) ..... .... ....... .... ....... .... ..... 51 SERVICE BRAKE .... ..... .... ..... .... 52 APU (AIR PROCESSING UNIT) ...... .... ..... 59 WHEEL BRAKE (S-CAM TYPE) .. ..... 61 BRAKE CHAMBER ....... .... ....... .... ..... 64 PARKING BRAKE.... ..... .... ..... .... 65 WHEEL AND TIRE ... ..... .... ..... .... 66 DISC WHEEL ..... .... ....... .... ....... .... ..... 66 FRAME .. .... ..... ..... ..... ..... .... ..... .... 67 FRAME ASSEMBLY............................. 67 4. BODY ELECTRICAL BODY ELECTRICAL..... .... ..... .... 70 LIGHT ................................................... 70 TABLE OF CONTENTS ---===SD-SM-305E1-0100_0003.djvu===--- 1. INTRODUCTION 2. ENGINE 3. CHASSIS 4. BODY ELECTRICAL