Hino Chassis Workshop Manual Vol 2 Euro 2 – FC9J FD8J GD8J FG8J GH8J FL8J FM8J FM2P SG8J Repair Manual PDF

Description

Hino Chassis Workshop Manual Volume 2 Euro 2 – FC9J FD8J GD8J FG8J GH8J FL8J FM8J FM2P SG8J

This Hino Chassis Workshop Manual Volume 2 is the second half of the chassis service set issued under publication number S1-YFCE18B (volume 2/2). It covers the chassis, brake, steering, axle, suspension, cab and electrical groups for the Hino Euro 2 truck and bus range, and it is written for the technician who is actually going to pull the components apart rather than for someone browsing specifications. Every procedure in the Hino Chassis Workshop Manual Vol 2 Euro 2 is presented with the dismounting, disassembly, inspection, assembly and mounting sequence laid out in order, together with the tightening torques, clearances and service limits you need at the bench.

The foreword states the manual applies to FC9J, FD8J, GD8J, FG8J, GH8J, FL8J, FM8J, FM2P and SG8J series vehicles equipped with J05E-TI, J08E-TI or P11C-TI engines. Content is organised into fifteen sections with a thumb index at the edge of the pages, and the chapter reference chart at the front maps each chassis system to its manual number so you can find the right group without hunting through the whole file.

File Details

• Manual type: Chassis Workshop Manual, Volume 2 of 2
• Publication number: S1-YFCE18B 2/2
• Date of issue: 6 November 2006
• Language: English
• File format: PDF
• Coverage: Hino FC9J, FD8J, GD8J, FG8J, GH8J, FL8J, FM8J, FM2P, SG8J
• Engines referenced: J05E-TI, J08E-TI, P11C-TI

Chapters Covered in This Chassis Volume

• Exhaust Brake — system diagram, troubleshooting, accelerator switch adjustment, clutch pedal switch adjustment
• Exhaust Brake Cylinder — overhaul, butterfly valve, seal ring and blind plate installation, close side and open side adjustment
• Brake Cylinder (FM2P) — slide valve, piston rod, poppet valve, match-marking and assembly
• Retarder Brake (Electromagnetic) — system diagram, component locator, retarder drum and coil assembly removal and installation
• Parking Brake — FC, FD, GD models
• Parking Brake — FG, GH, FL, FM, SG models, including MF06, EATON FS6109 / FS8209 and ZF9S109 transmission variants
• Steering Equipment — steering system troubleshooting
• Steering Unit — steering linkage, steering shaft and universal joint assembly, spiral cable, pitman arm, drag link, free play and turning force inspection
• Power Steering — air bleeding and hydraulic testing
• Power Steering Gear Unit — FC and FD models
• Power Steering Gear Unit — GD, FG, GH, FL, FM, SG models
• Power Steering Pump — FC and FD models
• Power Steering Pump — GD, FG, GH, FL, FM8J, SG models
• Power Steering Pump — FM2P model
• Oil Reservoir — FC and GD models, and FD, FG, GH, FL, FM, SG models
• Front Axle — LF366, LF451, LF578, LF571, MF678 and MF671 series
• Rear Axle — differential gear series SH13, SH14, SH16, SH17 and THD17
• Wheel and Tire — SAE, JIS, DIN and ISO type wheels, spoke wheel and adapter type wheel
• Suspension — FC, FD, GD, FG, GH models
• Suspension — FL, FM models
• Suspension — SG model
• Suspension — Hendrickson HAS 230
• Chassis Frame — rivet replacement, frame crack repair and welding conditions
• Cab — cab assembly, cab mounting parts, door, seat, instrument panel, heater and air conditioner, windshield
• Electrical Equipment — electrical parts, wiring code, connectors, fuse and fusible link, relay identification and inspection, lighting, starting, gauge and warning circuits
• Brake Control — ABS with ES Start (DENSO), ABS (WABCO), ES Start system, electromagnetic retarder
• Others — CAN communication and headlight auto leveling

Read together, these groups give a workshop the complete chassis-side service picture for the Hino Euro 2 range. The brake chapters cover the exhaust brake cylinder in both its standard butterfly-valve form and the FM2P slide-valve form, and the electromagnetic retarder chapter goes as far as drum and coil assembly removal with the torque figures for FD and for FG/GH variants. The parking brake material is split by model group and by transmission, so the adjustment figures you use depend on whether you are working on an MF06, an EATON FS6109 / FS8209 or a ZF9S109 unit.

Steering, Axle and Suspension Work

The steering section of this Hino Chassis Workshop Manual Vol 2 Euro 2 is unusually complete for a chassis volume. It carries the hydraulic test procedure for the power steering system with the relief valve and flow control valve pressures listed per model — FC and FD, GD, and the FG, GH, FL, FM, SG group each have their own figures — plus the system hydraulic pressure and discharge pressure measurements and the air bleeding sequence that has to be repeated after any of it. Gear unit overhaul is separated into an FC/FD version and a GD/FG/GH/FL/FM/SG version because the internals differ, and the pump overhaul is broken out three ways including the FM2P.

On the axle side the manual covers six front axle series and five rear axle differential series. Each front axle has its own data and specification set, special tools, component locator, overhaul sequence and inspection table, with king pin diameters, king pin clearances, thrust washer wear limits and wheel bearing preload figures given as assembly standards and service limits. The rear axle chapters follow the same pattern and add the greasing diagrams that show exactly how much wheel hub bearing grease goes where, plus the lock nut tightening torque and the lock plate installation note for when the plate holes will not line up.

Cab, Frame and Electrical

The cab chapter covers dismounting and mounting the cab assembly with the tilt system, torsion bar inspection and installation, cab tilt operating tension and its adjustment through shims, cab lock mechanism adjustment with the A to F dimension table, and door, seat, instrument panel, heater and windshield work. The chassis frame chapter deals with the repair side of frame service — replacing loosened rivets, reaming and riveting, reamer bolt torque values by bolt diameter, V-groove preparation for crack repair, patch plate rules, plug welding hole diameters and the welding current table for coated electrodes. The electrical equipment chapter explains the wiring colour code, connector terminal removal and installation, fuse and fusible link practice, and then walks through relay types with their part numbers and terminal test procedures, followed by circuit-by-circuit inspection for starting, gauges, headlights, turn signal, stop light, backup light, dome light, power window, wiper, engine stop, door lock, power mirror and heater circuits.

What This Manual Lets You Do

With this Hino Chassis Workshop Manual Vol 2 Euro 2 on the bench you can overhaul an exhaust brake cylinder and set the butterfly valve clearance, rebuild a power steering gear unit or pump and verify it against the hydraulic test pressures, service any of the six front axle variants or five rear axle variants covered, replace wheel hub bearings and set preload to the printed turning torque, rebuild leaf springs, repair a cracked chassis frame to the welding conditions given, and work through the ABS, ES Start and retarder diagnostics using the connector pin assignments and diagnosis code tables. Because the same document carries the tightening torques, service limits and inspection procedures alongside the disassembly steps, you are not guessing at a figure or borrowing a specification from a different model.

IMAGES PREVIEW

Delivery is instant — the PDF is available for download immediately after payment, there is no shipping and nothing to wait for. The file opens on any device, and every page including the exploded views, hydraulic schematics and connector pin diagrams can be printed and taken to the vehicle or into the workshop. Buy the Hino Chassis Workshop Manual Volume 2 Euro 2 and put the chassis service information for the FC9J, FD8J, GD8J, FG8J, GH8J, FL8J, FM8J, FM2P and SG8J range where you can actually reach it.