HINO 300-Series / Dutro Owner’s Workshop Manuals PDF

By | 15/09/2022

HINO 300-Series / Dutro owner’s, service and maintenance manuals, error codes list, DTC, spare parts manuals & catalogues, wiring diagrams, schematics free download PDF

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HINO 300 Series

HINO 300 is a family of light and medium-duty commercial trucks made in Japan. HINO Motors has been part of Toyota Corporation since 1967, and HINO 300 vehicles are manufactured directly in Japan at a plant in Hamura. The same plant also produces Toyota Land Cruiser Prado and Toyota FJ Cruiser. HINO models of the 300th series with a gross weight of 3.5 tons (category B) and 7.5 tons (category C), chassis load capacity of 1.2 – 1.3 and 4.8 – 4.9 tons, respectively, are presented on the car market. The HINO 300 model was produced in the past under the names Toyota Dyna and HINO Dutro.

HINO 300 Modifications

The new HINO 300 trucks are sold in two versions: 3615 and 3815. The first of these modifications contains three wheelbase options, and the second four, which makes it possible to choose from seven vehicle options, with an overall chassis length from 4.7 to 7.285 meters. In this regard, there are many options for add-ons to equip the chassis, and this makes the cars of the 300 series truly universal. The digital indices of models 3615 and 3815 are deciphered as follows: the first digit indicates the series – 300, the second – the rounded value of the total mass (5.5 and 7.5 tons), and the last two digits – the number of tens of horsepower (the power of a standard diesel engine is 150 hp).

There are three versions of the 3615: XZU600L-HKMMPW3, XZU640L-HKMMPW3 and XZU650L-HKMMPW3. They differ:

  • wheelbase length: 2.525 m; 2.8 m or 3.4 m, respectively;
  • overall length dimensions: 4.7 m; 5.19 m; 5.965 m;
  • rear overhang: 1.135 m; 1.375 m; 1.555 m;
  • chassis load capacity: 1.361 t; 1.323 t; 1.278 t;
  • turning radius: on wheels – 5.2 m; 5.7 m; 6.8 m, from wall to wall – 5.8 m; 6.3 m; 7.4 m

The cab for all variants of this modification is installed narrow, single-row, or triple. Wheel formula for any of the options – 4×2.

The technically permissible load on the front axle is 1.9 tons, on the rear axle – 2.6 tons.

Vehicle width is 1.855 m; height – is 2.1 m.

The front chassis height is 625 mm; the chassis height at the rear is 695 mm.

Ground clearance on the rear axle – 160 mm.

The front wheel track is 1.4 m; the rear wheels – are 1.435 m.

The 3815 is available in four variants: XZU710L-HKFRPW3, XZU720L-HKFRPW3, XZU720L-QKFRPW3, and XZU730L-HKFRPW3.

They differ:

  • wheelbase length: 3.43 m; 3.87 m (in two medium versions) and 4.2 m;
  • overall length dimensions: 6.12 m; 6.735 m; 7.285 m;
  • rear overhang: 1.56 m; 1.76 m; 1.94 m;
  • chassis load capacity: 4.95 t; 4.935 t; 4.735 t; 4.9 t;
  • turning radius: on wheels – 5.8 m; 6.4 m; 6.9 m, from wall to wall – 6.5 m; 7.1 m; 7.6 m

The cab for all variants of this modification is installed wide, single-row, and triple. In addition to the XZU720L−QKFRPW3 variant: a double-wide cab is provided here, with an additional row of seats, a seven-seater. Wheel formula for any of the options – 4×2.

  • The technically permissible load on the front axle is, respectively: 2.492 tons; 2.566 t; 2.6 t; 2,034t. On the rear axle – 5.008 tons; 4.934 t; 4.9 t; 5.466 tons
  • The width of the 3815 is 1.995 m; the height – is 2.215 m (with a single cabin) and 2.240 m (with a double cabin).
  • The front chassis height is 705 mm; the chassis height at the rear is 795 mm.
  • Ground clearance on the rear axle – 190 mm.
  • The front wheel track is 1.655 m; the rear wheels – are 1.52 m.

HINO 300 engine

The engine on all modifications of the HINO 300 trucks is the same. This is a four-cylinder in-line diesel engine N04C−UV, HINO’s own production. It has a working volume of 4009 cm3 and is equipped with a turbocharger, an intercooler, an exhaust gas recirculation system, and a Common Rail electronic injection system. The piston stroke is 118 mm, and its diameter is 104 mm. The camshaft is in a cast iron block. The cylinder liners must be removed quite simply, without serious effort, special devices, and tools.

The N04C−UV diesel engine complies with the Euro-4 environmental standard. In addition, the EGR exhaust gas recirculation system helped reach a higher environmental safety level than the previous modification.

In cars of the latest years of production, the N04C−UV engine was also brought up to the Euro-5 environmental standard – using a DPR particulate filter. Moreover, with manual regeneration mode prolonging its service life.

The maximum power of the N04C−UV engine after the upgrade of the HINO 300 series in 2011 has increased to 150 horsepower (110 kW) at 2500 rpm. In the previous modification in 1999, it was 138 horsepower. The maximum torque is 420 N•m at 1400 rpm (previously 396 N•m). The increase in power was achieved thanks to an improved fuel system and updated compressor settings.

The turbine, manufactured by Garret, is equipped with an electronic adjustment mechanism. The fuel equipment on the updated HINO 300 is from the Japanese company Denso. A three-stage diesel fuel filtration system was used, with electric heating of the separator and the main filter.

A layer of polyamide applied to the piston skirt reduces friction, which improves piston performance when the engine is overheated. The fan drive device allows you to save fuel when driving in severe frosts and while warming up the diesel engine. The average diesel fuel consumption of trucks of the 3615th modification is, according to the manufacturer, 16.8 liters per 100 kilometers, and for the 3815th modification is 17.2 liters per 100 kilometers. A 70-liter fuel tank is installed – on the XZU600L−HKMMPW3 variant. For all others – 100 liters.

HINO 300 transmission

On trucks of modification 3615 (3.5 tons), a mechanical five-speed gearbox is installed. It’s fully synced. Model – M550 (Aisin). The gear ratios of this manual transmission are as follows: 1st gear: 4.981; 2nd: 2.911; 3rd: 1.556; 4th: 1,000; 5th: 0.738; reverse gear: 4.625. The final gear ratio is 4.875.

Modified 3815 (7.5 tons) cars are equipped with a mechanical six-speed gearbox MYY6S (Isuzu). The gear ratios of this manual transmission are: 1st gear: 5.979; 2nd: 3.434; 3rd: 1.862; 4th: 1.297; 5th: 1,000; 6th: 0.759; reverse gear: 5.701. The final gear ratio is 4.625.

A good range of gear ratios makes it easy to move off under load in first gear, and 2-5 gears provide smooth, dynamic acceleration and driving in optimal economy mode.

The aluminum crankcase contributes to the best possible running of the bearings and the durability of the parts. A distinctive feature of HINO 300 gearboxes is an efficient synchromesh. Gear shifting is carried out using cables. Relatively low fuel consumption is ensured by combining a modern and efficient gearbox, a fairly powerful engine, and a high-quality gearbox.

The clutch on any of these machines is installed single-disk, dry, diaphragm type, with a hydraulic drive and a vacuum booster. The aperture diameter is 325 mm.

Brake system HINO 300

The main brake system of HINO 300 trucks is hydraulic, dual-circuit, with a vacuum booster. Both the front and rear brakes of all cars of this model are discs ventilated. This way, HINO 300 machines compare favorably with many other Asian “classmates.” The brakes are quite informative and tenacious. Replacing the pads will not require serious effort.

The parking brake is installed drum type, with a mechanical drive. In addition, there is an auxiliary mountain brake. The braking system is equipped with safety systems: ABS (Antilock Brake System) – anti-lock braking system, EBD (Electronic Brake force Distribution) – electronic brake force distribution system, VSC (Vehicle Stability Control) – road stability system, ASR (Anti Slip Regulation) – traction control system.

The presence of an engine retarder allows the driver to save the resource of brake pads not only on long descents but in the process of intracity operation.

Suspension and running gear HINO 300

Obvious differences between the modifications of the HINO 300 series trucks can be seen with a cursory examination of the chassis. The number of wheel studs immediately catches the eye: 3615 has five, and 3815 has six. For the 7.5-ton model, a wider frame is also made. All Hino 300 series trucks are equipped with multi-leaf springs. The width of the front pack, consisting of six sheets, is 70 mm, and the thickness is 10 mm. The back sheets are the same width, but they will be thicker. Good handling and stability with the load provide the machine with anti-roll bars mounted on the front axle.

Suspension types: front-dependent, on semi-elliptical leaf springs, with hydraulic shock absorbers and anti-roll bar; rear-dependent, on semi-elliptical leaf springs, with hydraulic shock absorbers. The spring suspension has confirmed its reliability and durability through many years of experience.

Tire size and their load indexes:

  • R630 195/75R16C 110/108 (3615th variant) and
  • RY023215/75R17.5 126/124 (for 3815).

HINO 300 Cabin

Cabins for the HINO 300 family are designed using the EGIS (Emergency Guard Impact Safety) safety system. The driver’s airbag is standard. Also, the basic equipment includes central locking, heated two-piece electrically adjustable side-view mirrors, and a steering column for tilt and reach. The luxury package includes air conditioning and a radio with USB.

Compared to the previous family of the 1999 model, the cabin has become longer. This allows you to move the chair further back. Aerodynamic performance has been improved due to the greater inclination of the windshield. The headlights have grown in size, and the foglights have become round. Headlights – halogen, with a tilt angle corrector. Fog lights are LED. The doorway became wider and higher.

The opening is wide enough, and the footrest and handrail are comfortable. Due to this, landing in the driver’s seat is quick, easy, and comfortable. The ergonomics of the driver’s workplace are well thought out. All controls are at your fingertips. No need to reach anywhere. The instrument cluster on the front panel is straightforward. The cabin provides a large number of all kinds of glove compartments and drawers. A shelf stretches along the entire length of the front panel, plus two mezzanines in the upper part of the cabin. The place for the tool is arranged behind the back of the passenger seat.

HINO 300

HINO 300

An important point of equipping the cab: the gear lever can be folded. To do this, pull it up and bend to the right. As a result, it will not interfere with free movement around the cab and, on occasion, will let the driver sleep. The parking brake lever is also foldable. When the car is on the handbrake, the lever is raised as usual, but when you press the button, it freely falls, and the system remains engaged during this addition.

The cab is easily and quickly tilted manually for maintenance or repairs by releasing the locks using the handles.

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