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Hino 500 Series Workshop Manual download

Tools & PPE
- Truck wheel balancer rated for commercial wheels (static/dynamic + large spindle + adapters/cones for 22.5", 19.5" etc.)
- Road-force balancer (optional, recommended for heavy truck steer/drive tires)
- Cone adapters / lock nut / spacer kits sized for Hino wheels
- Dial indicator with magnetic base (wheel/hub runout)
- Torque wrench (suitable for wheel nut torque range), impact gun (for removal only)
- Wheel nut socket set, breaker bar
- Wheel chocks, axle stands or vehicle lift rated for truck
- Tyre changer or bead breaker (if removing tyre)
- Valve core/shaft tools, tyre pressure gauge, compressor
- Wheel weight pliers / hammer / adhesive weight applicator
- Wire brush, cleaning rag, anti-seize or recommended hub lubricant
- Safety PPE: gloves, eye protection, hearing protection, steel-toe boots

Safety precautions (non-negotiable)
- Park on level ground, chock opposite wheels, put transmission in neutral or park and engage parking brake.
- Use a rated lift or axle stands; never work under a vehicle supported only by jacks.
- Ensure balancer rated for the gross wheel/tire weight you’ll spin.
- Deflate tyre before breaking bead; keep hands and clothing away from spinning assembly.
- Use eye protection when applying/removing wheel weights and when spinning balancer.
- Follow manufacturer torque specs and tightening sequence. Re-torque after road test (50–100 km) and after first duty cycle.

Step-by-step: off-vehicle wheel balancing (recommended for Hino 500)
1. Preparation
- Chock vehicle, lift and support securely, remove wheel cover and hub caps.
- Mark wheel orientation (e.g., outside-in) so you can reference mounting position when checking wear patterns.
- Remove wheel nuts and wheel assembly. Lay wheel on a clean surface or wheel dolly.

2. Inspect wheel & tyre
- Check tyre for tread depth, lateral/center wear, sidewall bulges/cuts, embedded objects.
- Inspect rim for cracks, bends, corrosion at mounting surface. If wheel bead seat is corroded, clean or replace.
- Check valve stem for leaks—replace if worn or if rubber looks aged/cracked.
- If tyre is damaged (sidewall cord exposure, major tread separation), replace tyre; balancing is futile on a damaged tyre.

3. Clean mating surfaces & studs
- Wire-brush hub and wheel mounting surface; remove rust/burrs that prevent correct seating.
- Inspect wheel studs/threads—replace damaged studs or nuts.

4. Measure and correct runout (critical for heavy vehicles)
- Mount wheel on a hub or balancer spindle; use dial indicator to measure radial and lateral runout at the rim bead and tire tread.
- If runout exceeds factory limits (check Hino workshop manual), attempt to reduce by cleaning surfaces, flipping tyres, or reseating the tyre. Excessive rim or tyre runout usually requires replacement of wheel or tyre.
- For steer wheels, road-force measurement often reveals irregularities; use road-force balancer and follow its corrective recommendations (match-mounting, replacing tyre or wheel).

5. Mount wheel on balancer properly
- Select correct cone adapter or spacer; center wheel on spindle using the cone and locknut until snug—wheel must be perfectly centered.
- Input accurate rim dimensions into the balancer: rim diameter, width, and offset/backspacing as required. Wrong inputs produce incorrect weight placement.
- Use balancer mode appropriate for truck tyre (static, dynamic, or road-force).

6. Spin and readout
- Ensure no one is near the machine, then perform spin cycle at recommended speed.
- Read balancer instructions: it will show amount (grams/ounces) and position for inside/outside weights or single-plane weights for wide-base tyres.
- Note if balancer reports excessive runout or forced balance condition—follow road-force or runout correction procedures.

7. Apply weights
- Use correct type: clip-on weights for steel rims, adhesive (sticky) weights for alloy rims, or bonded weights for heavy-duty wheels per wheel manufacturer guidance.
- Clean the area where adhesive weights are applied with solvent; press weights firmly and tape in place until adhesive cures if required.
- For clip weights, use proper size and ensure they engage rim flange securely. Never overhang weights beyond flange limits.
- Re-spin to verify balance. Repeat until within acceptable limits.

8. Match-mounting (optional but recommended for heavy trucks)
- Measure tyre radial low spot and rim high spot. Mount tyre so tyre low spot aligns with rim high spot. This reduces the amount of balance weight required and improves ride.
- Use wheel masks or marks to align when reseating tyre.

9. Reinstall wheel on vehicle
- Clean hub contact surfaces again; fit wheel, hand-start nuts, then tighten in a star/cross pattern to the manufacturer torque.
- Use torque wrench to final torque (follow Hino workshop manual for exact figure). Typical heavy truck wheel nut torque is high—use correct spec.
- If using an impact gun, finish with torque wrench to exact spec. Never rely on impact gun alone.

10. Road test & re-check
- Test drive vehicle, observe for vibration under different speeds/loads.
- After 50–100 km, re-torque wheel nuts to ensure nothing has loosened. Re-check balance if vibration persists.

How the balancer/tool is used (practical details)
- Spindle & cones: Place hub/bore over spindle and use tapered cones to center the wheel. The cone must be the correct size and firmly seated—an off-center wheel gives wrong balance.
- Input rim data: Enter rim diameter and width exactly. Incorrect width shifts weight positions and will produce vibration later.
- Dynamic vs static: Dynamic mode measures imbalance on two planes (inside/outside), used for most truck dual rims and wide-base tyres. Static mode is single-plane for wheels where only one plane correction is possible.
- Road-force balancer: A roller presses against the tyre as wheel spins to measure force variations. It will indicate tight spots, high runout, and suggest match-mount or replacement. Use the machine’s compensation or follow its instructions to reduce road-force variation.
- Applying weights: For heavy truck wheels, large clip-weights or adhesive blocks are used; balance values can be large and must be seated correctly. Use adhesive primer if recommended.

Common pitfalls & how to avoid them
- Using a passenger car balancer or incorrect spindle/adapter: causes misreads. Always use a balancer set up for truck wheels.
- Dirty mounting surfaces: leads to false imbalance—clean both hub and wheel.
- Incorrect rim dimensions entered: wrong width or diameter yields wrong placements—measure physically if unsure.
- Damaged wheel or tyre left in service: no amount of balancing will fix a cracked rim or broken tyre cord.
- Over-reliance on single-plane balance for dual-wheel setups: mismatch between duals creates vibration; match-run or dynamic balance both wheels as assembly.
- Poorly seated adhesive weights: they fall off; use cleaner/primer and press/tape until cured.
- Not measuring runout or road force on steer/drive tyres: leaves residual vibration even after static balance.
- Incorrect torque sequence or not re-torquing: leads to loose nuts and unsafe conditions.
- Ignoring valve stem condition: leaking stem causes pressure loss and changing balance characteristics.

Replacement parts commonly required
- Wheel weights (clip-on or adhesive) and adhesive primer
- Valve stems (replace if aged or leaking)
- Wheel studs/nuts if threads damaged or corroded
- Wheels or rims if cracked, bent, or with excessive corrosion
- Tyres that show internal damage, tread separation, large bulges, or excessive runout
- Balancer cones/spacers if damaged or wrong size

Notes specific to Hino 500 Series
- Follow Hino 500 workshop manual for exact wheel nut torque values, bolt patterns, and any hub-specific procedures (hub centering rings, hub cap seals).
- Steer axle tyres typically require more stringent runout/road-force checks; drive and trailer wheels require correct match-mounting for duals.

Final checks
- Verify wheel nut torque, check tyre pressure to recommended spec, ensure valve caps in place, and confirm wheel weights secured.
- Recheck for vibration after initial road use and retorque after 50–100 km.

That’s the complete, practical procedure. Follow the Hino workshop manual for torque specs and limits; replace any tyres or wheels that fail inspection rather than attempting to mask defects with weights.
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