Hino FC FD GD FG GH FL FM FT GT SG Series Chassis Workshop Manual Volume 2 of 3 – Brake Equipment (S1-YFCE18G)

Description

The Hino FC FD GD FG GH FL FM FT GT SG Series Chassis Workshop Manual Volume 2 of 3 is the brake equipment volume of the three-part chassis workshop manual set, published under document number S1-YFCE18G 2/3. This volume delivers the complete brake-side service information for the Hino medium and heavy truck range, covering both the air over hydraulic brake vehicles and the full air brake vehicles fitted with J05D-TI, J05E-TI, J08E-TI, A09C and P11C engines.

Where Volume 1 of 3 handles the driveline side of the chassis (clutch, transmission, transfer, propeller shaft and differential carrier) and Volume 3 of 3 handles steering through to the cab and electrical systems, this second volume concentrates exclusively on the braking hardware and its electronic control systems. That makes it the reference a workshop reaches for when a truck rolls in with a brake complaint, when a valve needs overhauling, or when an ABS fault has to be traced back to its source.

File Details

• Manual type: Chassis Workshop Manual, Volume 2 of 3
• Brand: Hino Motors, Ltd.
• Document number: S1-YFCE18G 2/3
• Publication date shown: 2008-05 (’08-5)
• Language: English
• Page count: 605 pages
• File format: PDF
• Section index: Brake Equipment, Service Brake, ABS & ASR, ES Start, Exhaust Brake, Retarder Brake, Parking Brake

Chapters Covered in This Volume

This volume is organised under the BR-series chapter numbers, each covering a distinct brake-related system:

• BR01 – Brake Equipment: Air over hydraulic brake description, system diagram, troubleshooting, air bleeding
• BR01 – Brake Equipment (Full Air Brake): Full air brake description, system diagram, troubleshooting
• BR02 – Service Brake (Air Over Hydraulic): Pressure regulator, air dryer, check valve, safety valve, brake valve, protection valve, quick release valve, double check valve, brake fluid reservoir, brake air booster (Airmaster), spring brake control valve, relay valve, spring brake chamber, trailer hand brake control valve, limiting valve, two-way valve, wheel brake assemblies
• BR02 – Service Brake (Full Air): Pressure regulator, air dryer, check valve, safety valve, brake valve, protection valve (air suspension, 4-way, with/without Ireland spec), quick release valve, spring brake control valve, relay valve variants (front brake, trailer brake, rear brake, rear spring brake chamber, Ireland spec, WABCO ABS, with check valve), spring brake chamber variants (wedge type, S-cam front, S-cam rear), brake chamber (wedge type and S-cam, front and rear), trailer hand brake control valve, wheel brake (wedge type and S-cam type), expander for wedge-type brakes, wheel brake slack adjuster (auto adjuster) for S-cam brakes
• BR03 – ABS & ASR: Three separate ABS sections – DENSO ABS, WABCO ABS for air over hydraulic brake, WABCO ABS for full air brake. Each covers overview, composition and operation, function, front wheel brake overhaul, rear wheel brake overhaul
• BR04 – ES Start (Easy & Smooth Start System): Three matching sections – ES Start for DENSO ABS models, ES Start for WABCO ABS air over brake models, and ES Start for WABCO ABS full air brake models. Includes description, system diagram, piping diagram, special tools, adjustment and initial setting procedures, plus ES Start control valve overhaul
• BR05 – Exhaust Brake: Exhaust brake system diagram, troubleshooting, accelerator switch and clutch pedal switch adjustment, brake cylinder for models except FM2P, brake cylinder for FM2P
• BR06 – Retarder Brake (Electromagnetic Retarder): Data and specifications, system diagram, description, component locator, overhaul of the retarder drum and retarder coil assembly
• BR07 – Parking Brake: Two separate sections – Parking Brake for FC, FD and GD models, and Parking Brake for FG, GH, FL, FM and SG models. Each includes data, description, troubleshooting, special tools, component locator, overhaul, inspection and repair, and adjustment

What This Chassis Workshop Manual Volume 2 of 3 Gives Your Workshop

The brake equipment side of a Hino truck is one of the most service-intensive areas on the vehicle, and this volume treats it that way. Rather than general advice, it hands over the actual procedures Hino published for their own dealer technicians – the same teardown sequences, the same measured service limits, the same torque and pressure values that a repair facility needs to return a truck to the road safely.

The brake valves, air boosters, relay valves, spring brake chambers and quick release valves are all broken down into their component parts with exploded views, lubrication points, assembly marks and inspection tables. Where a component is serviceable in the field, the manual walks through the disassembly, cleaning, measurement and reassembly in the correct order. Where a value or clearance matters – spring free length, piston-to-cylinder clearance, plunger stroke, valve opening and closing pressure – it is given in metric, kgf/cm2 and lbf/in.2 so both metric and imperial workshops can work from the same page.

The ABS & ASR chapter is split three ways because Hino shipped these trucks with three different ABS architectures. DENSO ABS and the two WABCO ABS variants (one for air over hydraulic, one for full air brake) each get their own coverage of wheel sensor and sensor ring service, front and rear wheel brake overhaul, ABS control valve operation and the fail-safe behaviour of the system. That section alone is worth the price of the volume for anyone who has to diagnose an intermittent ABS warning light on a working truck.

The ES Start (Easy & Smooth Start System) section is another stand-out inclusion. This is Hino’s hill-hold and smooth take-off system, and the manual covers the operation check, release timing adjustment, initial setting of the clutch stroke sensor, and the ES Start control valve overhaul. The diagnosis monitor hookup and the buzzer patterns for confirming correct setup are documented step by step.

The exhaust brake, electromagnetic retarder and parking brake chapters round the volume out. The exhaust brake section covers the butterfly valve adjustment, accelerator switch and clutch pedal switch calibration, and the brake cylinder overhaul for both the standard and FM2P variants. The retarder brake chapter documents the electromagnetic retarder main unit, drive unit and control unit, with procedures for drum and coil assembly removal and installation. The parking brake chapter splits its coverage by model family, giving the lever, cable, cam lever, shoe adjuster and drum service in the form each model group actually uses.

Who This Manual Is For

This volume is written for the working technician, the fleet maintenance shop and the owner-operator who does their own brake work on a Hino FC, FD, GD, FG, GH, FL, FM, FT, GT or SG series truck. It is also useful for service advisors and parts staff who need to look up a component breakdown or confirm a valve part number before ordering. Because it is the original chassis workshop manual volume rather than a generic aftermarket guide, the procedures and specifications match the trucks as Hino built them.

Because this is Volume 2 of 3, the driveline information (clutch, transmission, transfer, propeller shaft and differential carrier) is in Volume 1 of 3, and the steering, axle, suspension, chassis, cab and electrical information is in Volume 3 of 3. Buyers who need the full chassis manual set should consider picking up all three volumes, though this volume stands alone for any brake-related job.

Put This Brake Equipment Manual to Work in Your Shop

With this Hino Chassis Workshop Manual Volume 2 of 3 open on the bench, the jobs that were once a phone call to the dealer become straightforward shop work. Overhauling a brake air booster, resealing a relay valve, replacing a spring brake chamber, tracing an ABS wheel sensor fault, resetting the ES Start clutch stroke sensor, adjusting an exhaust brake butterfly valve, servicing the electromagnetic retarder or setting up a parking brake cable – all of these are documented with the correct sequence, the correct torque values and the correct inspection limits.

Getting those details right is what separates a brake job that lasts from a comeback. An air booster assembled with the wrong spring setting will drag or fail to release. An ABS sensor pushed in with a hammer will fail within a month. A parking brake adjusted to the wrong notch count will either not hold or will overheat the drum. This manual removes the guesswork and replaces it with the manufacturer’s own numbers.

IMAGES PREVIEW

The file is delivered as an instant PDF download after checkout, so there is no shipping and no waiting. It can be stored on a laptop, tablet or phone in the workshop, printed out page by page for the job at hand, or kept on a shared drive for the whole service team. Once downloaded, it is yours to use across every FC, FD, GD, FG, GH, FL, FM, FT, GT and SG series Hino truck that comes through the door.