Hino FR1E FS1E FY1E SH1E SS1E ZS1E Chassis Workshop Manual Volume 2 of 3 – S1-YFSE16A PDF

Description

Hino FR1E FS1E FY1E SH1E SS1E ZS1E Chassis Workshop Manual – Volume 2 of 3

This is the second volume of the three-part Hino Chassis Workshop Manual produced by Hino Motors, Ltd. for the FR1E, FS1E, FY1E, SH1E, SS1E, and ZS1E series trucks equipped with the E13C engine. Published under document number S1-YFSE16A 2/3 (dated ’04-4), this volume delivers the brake, steering, axle, wheel and tire, and suspension service content in one complete reference. Every procedure, specification, and illustration has been prepared for technicians working on these specific chassis, with the level of detail Hino workshops rely on.

The manual is structured around the Hino chassis group numbering system, and each section opens with its own data and specification table, component locator diagram, overhaul sequence, and inspection and repair limits. Instead of forcing the reader to piece together information from generic truck references, every fastener torque, bushing clearance, and spring specification inside is tied directly to the FR1E, FS1E, FY1E, SH1E, SS1E, and ZS1E chassis.

File Details

• Manual Type: Chassis Workshop Manual (Volume 2 of 3)
• Brand / Publisher: Hino Motors, Ltd.
• Models Covered: FR1E, FS1E, FY1E, SH1E, SS1E, ZS1E
• Engine: E13C
• Publication Number: S1-YFSE16A 2/3
• Edition / Date: ’04-4 (April 2004)
• Language: English
• File Format: PDF
• Page Count: Approximately 480 pages

Chapters Covered in This Volume

• Brake Equipment (BR01) – Service brake assembly, description, diagram, troubleshooting
• Service Brake (BR02) – Air dryer, check valve, double check valve, safety valve, brake valve, protection valves Type A/B and 4-way, quick release valve, load sensing valve, spring brake control valves Type A/B, relay valves, cut valve, reducing valves Type A/B, brake chambers, spring brake chambers (WABCO, NABCO), control valve, wheel brake S-cam and wedge types, expander, pressure regulator
• ABS Anti-Lock Brake System (BR03, WABCO make) – System overview, composition and operation, fail-safe function, sub brake control, pressure increase/reduction/maintenance modes, front and rear wheel brake component locators and overhaul
• ES Start Easy & Smooth Start System (BR04) – Description, diagram, special tools, initial setting, control valve overhaul
• Steering Equipment (SR01) – Steering system troubleshooting
• Steering Unit (SR02) – Steering linkage description, component locator, special tools, overhaul, inspection and repair
• Power Steering (SR03) – Troubleshooting, air bleeding, hydraulic test, power steering gear unit, booster unit, pump, oil reservoir
• Front Axle (AX02) – ISO 10-Studs type (MF78I, MFM08I) and Trilex type (MF88S)
• Rear Axle (AX03) – ISO type wheel and spoke type wheel
• Wheel & Tire (AX04) – SAE, JIS, DIN, and ISO type wheels; spoke wheel and adapter type wheel; tire and rim specifications
• Suspension (SU02) – Front leaf suspension, rear leaf suspension (FR, FS, FY, SS, ZS), rear suspension (SH), Hendrickson HAS 250 and HAS 460

Stepping back from the chapter list, what this volume gives a working technician is a complete chassis-side service reference. The brake section alone runs from the air compressor and air dryer downstream through every control valve, relay valve, and brake chamber to the wheel-end S-cam and wedge brakes, with adjustment sequences and torque values that keep a commercial vehicle braking system inside Hino’s tolerances. The steering content covers both the linkage side and the hydraulic side, including the gear unit, booster, pump, and reservoir, plus the hydraulic test procedures needed to confirm relief pressure and flow control valve operation. On the axle side, the manual separates ISO 10-stud and Trilex front axle types, and ISO and spoke rear axle types, so the bearing preload, king pin clearance, and thrust washer adjustment values match the hardware actually fitted to the truck. Suspension coverage spans the leaf spring designs used across the model range and the Hendrickson HAS 250 and HAS 460 air/leaf systems, with the vehicle height adjustment procedure spelled out.

ABS and ES Start – Electronically Controlled Braking and Starting

Two systems in this volume deserve specific attention. The WABCO ABS section explains not just component removal and installation but the control logic itself – the slip ratio relationship, the pressure increase, reduction and maintenance modes, and the fail-safe and sub brake cut functions. Knowing how the ABS ECU reacts to wheel sensor signals makes diagnosis far more direct than swapping parts and hoping. The wheel sensor inspection values, sensor ring press-fit procedure, and clamping bushing service points are all included for both front and rear axles.

The ES Start section covers the Easy & Smooth Start system fitted to these trucks, including the controller initial setting procedure, clutch stroke sensor installation check, release position setting, slope sensor zero point setting, and the control valve overhaul. These are the procedures that cannot be shortcut – the manual walks through each setup step with the expected buzzer and indicator behaviour so a technician knows the controller has accepted the setting.

Detailed Service Data Throughout

One of the practical strengths of this volume is the density of measured data. Examples that appear in the document include:

• Air dryer governor valve opening pressure 960-1,000 kPa (9.8-10.2 kgf/cm²) and closing pressure 860-900 kPa (8.8-9.2 kgf/cm²)
• Protection valve Type A opening at 637 kPa, closing at 510 kPa; Type B opening at 540 kPa, closing at 390 kPa
• Spring brake control valve cam assembly dimension of 33.8-34.2 mm
• Brake lining thickness 15.5 mm with a 5.5 mm wear limit
• Brake drum inside diameter 406.4 mm (16.0 in) for ISO wheels and 440.0 mm (17.3 in) for spoke wheels, with regrind and service limits
• Front axle toe-in 1-3 mm on diagonal tires and 0-2 mm on radial tires; camber 0°-2°; king pin angle 6°-8°; caster 1°30′
• King pin diameter 50 mm with a clearance limit of 0.35 mm
• Wheel hub bearing preload turning torque 3.14-5.10 N·m (new bearing) with a spring balancer reading of 18.7-30.4 N
• Power steering relief pressure 14.0-14.7 MPa (143-150 kgf/cm²) and pump flow rate 18.5-21.5 L/min on single front axle models
• Wheel sensor resistance 1.0-1.3 kΩ and output voltage 150-1,999 mV AC

This is the kind of information that turns a manual into a working tool. Rather than looking up generic truck specifications, a technician can go straight to the Hino-published value for the exact model and axle configuration in front of them.

Who This Manual Is For

This Hino chassis workshop manual suits:

• Diesel technicians servicing FR1E, FS1E, FY1E, SH1E, SS1E, or ZS1E trucks
• Fleet maintenance workshops that keep these Hino series vehicles on the road
• Independent repair shops that need Hino’s own procedures and limits rather than generic aftermarket data
• Body builders and chassis modifiers who need to understand the brake, suspension, and axle layout before adding equipment
• Owners who do their own brake, suspension, and steering maintenance and want the correct torque and clearance values
• Apprentices and trade students learning commercial vehicle chassis systems on Hino platforms

Because the volume is a direct reprint of Hino’s workshop documentation, the terminology, part names, and layout match what the dealer technician sees. There is no translation drift between the manual and the truck.

Get the Hino FR1E FS1E FY1E SH1E SS1E ZS1E Chassis Workshop Manual – Volume 2 of 3

This Hino chassis workshop manual gives you the procedures and specifications to overhaul brake valves, replace brake chambers, adjust S-cam and wedge brakes, rebuild steering gear units and power steering pumps, set front axle king pin clearance, adjust wheel hub bearing preload, service ABS wheel sensors and sensor rings, set up the ES Start system, and rebuild leaf and Hendrickson air suspension. Having Hino’s own torque values, wear limits, and adjustment sequences on hand is the difference between a repair that lasts and a comeback.

IMAGES PREVIEW

Delivery is instant – the manual is provided as a downloadable PDF, no physical shipping, no waiting. Read it on a laptop in the workshop, on a tablet beside the truck, or print the pages you need for the job in front of you. When you order, you get access to the file immediately after checkout, and it stays available for you to use on any device.