User Manuals: Hino S5-LJ05E04A Truck Repair Procedures

Manuals and User Guides for Hino S5-LJ05E04A Truck Repair Procedures. We have 1 Hino S5-LJ05E04A Truck Repair Procedures manual available for free PDF download: Workshop Manual

Hino S5-LJ05E04A Workshop Manual (647 pages)

Brand: Hino | Category: Trucks | Size: 62 MB

General Introduction

5
- Table of Contents
  5
- How to Identify Vehicle Type
  
  6
  - Vehicle Model
    6
  - Vehicle Identification Number (Vin) Structure
    7
- Appearance of Vehicle
  
  8
- Safety Instructions and Readiness to Work
  
  9
  - Warning
    9
  - Identification Information
    13
  - Safety Instructions for Work
    16
  - Introduction to Workshop Manual
    19
  - Tightening of Bolts and Nuts
    23
  - Handling of Liquid Gasket
    33
- Glossary
  
  34
  - Definition of Abbreviation in this Manual
    34
- Lubricants
  
  40
  - Recommended Lubricants
    40
Standard Value (J05E)

41
- Mounting and Dismounting the Engine
  
  43
  - Engine Assembly
    43
- Engine Control
  
  44
  - Engine Ecu
    44
  - Engine Speed Main Sensor
    44
  - Engine Speed Sub Sensor
    44
  - Idle Set Volume
    44
  - Accelerator Pedal
    45
  - Block Heater
    45
- Fuel System
  
  46
  - Fuel Tank
    46
  - Fuel Sender Gauge
    46
  - Engine-Side Fuel Filter & Case
    47
  - Water Level Warning Switch
    47
  - Supply Pump
    48
  - Injector
    48
  - Common Rail
    49
  - Vehicle-Side Fuel Filter
    49
  - Fuel Cooler
    49
- Emission Control
  
  50
  - Egr Valve & Cooler
    50
  - Closed Ventilator
    50
- Intake
  
  51
  - Intake Manifold
    51
  - Diesel Throttle
    51
  - Intake Pipe (Exhaust Side)
    51
  - Stack Duct
    51
  - Air Cleaner
    52
  - Intake Temperature Sensor
    52
  - Boost Pressure Sensor
    52
  - Air Flow Sensor
    52
- Engine Mechanical
  
  53
  - Head Cover
    53
  - Rocker Arm Assembly
    53
  - Camshaft Assembly
    54
  - Cylinder Head Assembly
    55
  - Valve System
    56
  - Crankshaft Pulley
    57
  - Front Oil Seal Retainer
    57
  - Flywheel Assembly
    57
  - Flywheel Housing
    57
  - Timing Gear & Cam Idle Gear
    58
  - Piston & Connecting Rod
    59
  - Crankshaft
    60
  - Cylinder Liner
    61
  - Cylinder Block
    61
  - Engine Mounting and Bracket
    61
  - Glow Plug
    61
- Exhaust
  
  63
  - Exhaust Manifold
    63
  - Exhaust Pipe
    63
  - Exhaust Pipe (Atc)
    63
  - Def-Scr
    64
  - Dpr Cleaner
    64
  - Fuel Addition Valve
    65
  - Fuel Cutoff Valve
    65
  - Def Pump
    65
  - Def Injector
    66
  - Def Tank
    66
  - Coolant Cutoff Valve
    66
  - Dcu
    66
  - Dpr Differential Pressure Sensor
    67
  - SCR UPSTREAM Nox SENSOR
    67
  - SCR DOWNSTREAM Nox SENSOR
    67
  - Atc Downstream Temperature Sensor
    67
  - Doc Upstream Temperature Sensor
    68
  - Dpr Upstream Temperature Sensor
    68
  - Dpr Downstream Temperature Sensor
    68
  - Scr Upstream Temperature Sensor
    69
  - Exhaust Brake
    69
  - Exhaust Brake Magnetic Valve
    69
- Cooling
  
  70
  - Radiator
    70
  - Radiator Cap
    70
  - Reserve Tank
    70
  - Intercooler
    71
  - Thermostat Case & Thermostat
    71
  - Coolant Pump
    71
  - Cooling Fan & Fan Clutch
    72
  - Coolant Temperature Sensor
    72
- Lubrication
  
  73
  - Oil Cooler
    73
  - Oil Pump
    73
  - Oil Pan
    74
  - Oil Strainer
    74
  - Oil Pressure Switch
    74
  - Standard Value (J05E)
    75
- Starting/Charging
  
  75
  - Starter
    75
  - V-Belt
    75
  - Alternator (130 A)
    76
- Turbocharger
  
  77
  - Turbocharger Assembly
    77
Required Items (J05E)

78
- Mounting and Dismounting the Engine
  
  79
  - Engine Assembly
    79
- Engine Control
  
  80
  - Engine Ecu
    80
  - Engine Main Revolution Sensor
    80
  - Engine Sub Revolution Sensor
    81
  - Accelerator Pedal
    82
  - Idle Set Volume
    82
- Fuel System
  
  83
  - Fuel Sender Gauge
    83
  - Water Level Warning Switch
    83
  - Supply Pump
    84
  - Injector
    85
  - Common Rail
    86
  - Fuel Filter and Case (Vehicle Side)
    87
- Emission Control
  
  88
  - Egr Valve and Cooler
    88
  - Closed Ventilator
    89
- Intake
  
  90
  - Diesel Throttle
    90
  - Boost Pressure Sensor
    91
  - Air Flow Sensor
    92
- Engine Mechanical
  
  93
  - Head Cover
    93
  - Rocker Arm Assembly
    93
  - Camshaft Assembly
    93
  - Cylinder Head Assembly
    94
  - Valve System
    95
  - Crankshaft Front Oil Seal
    96
  - Front Oil Seal Retainer
    96
  - Flywheel Assembly
    96
  - Crankshaft Rear Oil Seal
    97
  - Flywheel Housing
    97
  - Timing Gear and Cam Idle Gear
    98
  - Piston and Connecting Rod
    99
  - Crankshaft
    101
  - Cylinder Liner
    102
  - Cylinder Block
    103
  - Glow Plug
    103
- Exhaust
  
  104
  - Exhaust Manifold
    104
  - Dpr
    105
  - Fuel Addition Valve
    106
  - Def Pump
    106
  - Def Injector
    106
  - Def Tank
    107
  - Dpr Differential Pressure Sensor
    107
  - SCR UPSTREAM Nox SENSOR
    107
  - SCR DOWNSTREAM Nox SENSOR
    107
  - Atc Downstream Temperature Sensor
    108
  - Doc Upstream Temperature Sensor
    108
  - Dpr Upstream Temperature Sensor
    108
  - Dpr Downstream Temperature Sensor
    109
  - Scr Upstream Temperature Sensor
    109
  - Dpr Exhaust Gas Temperature Sensor
    109
  - Exhaust Brake
    110
  - Exhaust Brake Magnetic Valve
    110
- Cooling
  
  111
  - Radiator Cap
    111
  - Thermostat Case and Thermostat
    111
  - Coolant Pump
    112
  - Coolant Temperature Sensor
    112
- Lubrication
  
  113
  - Oil Filter
    113
  - Oil Cooler
    113
  - Oil Pump
    114
  - Oil Pan
    114
  - Oil Pressure Switch
    114
- Starting/Charging
  
  115
  - Starter
    115
  - V-Belt
    115
  - Alternator (130A)
    115
- Turbocharger
  
  116
  - Turbocharger Assembly
    116
Mounting and Dismounting the Engine (J05E)

118
- Engine Assembly
  119
  - Precautions in Tilting and Lowering the Cab
    119
  - Measurement of Compression Pressure
    119
  - Adjusting the Valve Clearance
    122
  - Replacement
    124
Engine Control (J05E)

133
- Control Parts
  
  134
  - System Block Diagram
    134
- Engine Ecu
  
  135
  - Component Locator
    135
  - Replacement
    136
- Vehicle Control Ecu
  
  142
  - Replacement
    142
- Engine Speed Main Sensor
  
  143
  - Component Locator
    143
  - Inspection
    144
  - Replacement
    144
- Engine Speed Sub Sensor
  
  145
  - Component Locator
    145
  - Inspection
    146
  - Replacement
    146
- Idle Set Volume
  
  147
  - Component Locator
    147
  - Replacement
    148
- Accelerator Pedal
  
  150
  - Component Locator
    150
  - Replacement
    151
- Block Heater
  
  152
  - Component Locator
    152
  - Replacement
    153
- Diesel Throttle
  
  154
- Intake Temperature Sensor
  
  154
- Fuel Sender Gauge
  
  154
  - Replacement
    154
- Air Flow Sensor
  
  155
- Boost Pressure Sensor
  
  155
  - Replacement
    155
- SCR UPSTREAM Nox SENSOR
  
  156
- Dpr Differential Pressure Sensor
  
  156
  - Replacement
    156
- SCR DOWNSTREAM Nox SENSOR
  
  156
- Atc Downstream Temperature Sensor
  
  157
  - Replacement
    157
- Doc Upstream Temperature Sensor
  
  157
- Dpr Downstream Temperature Sensor
  
  158
- Dpr Upstream Temperature Sensor
  
  158
  - Replacement
    158
- Outside Temperature Sensor
  
  159
- Scr Upstream Temperature Sensor
  
  159
  - Replacement
    159
- Oil Pressure Switch
  
  160
- Coolant Temperature Sensor
  
  160
  - Replacement
    160
Fuel System (J05E)

161
- Fuel System
  
  162
  - Fuel System Diagram
    162
- Fuel Tank
  
  163
  - Component Locator
    163
  - Replacement (30 Gallon)
    164
  - Replacement (33 Gallon)
    167
- Fuel Sender Gauge
  
  171
  - Component Locator
    171
  - Replacement
    172
- Fuel Filter and Case (Engine Side)
  
  174
  - Component Locator
    174
  - Replacement
    175
- Water Level Warning Switch
  
  184
  - Component Locator
    184
  - Replacement
    185
- Supply Pump
  
  187
  - Component Locator
    187
  - Replacement
    188
- Injector
  
  196
  - Component Locator
    196
  - Replacement
    197
- Common Rail
  
  206
  - Component Locator
    206
  - Inspection
    207
  - Replacement
    208
- Fuel Filter and Case (Vehicle Side)
  
  213
  - Component Locator
    213
  - Replacement
    214
- Fuel Cooler
  
  222
  - Component Locator
    222
  - Replacement
    223
Emission Control (J05E)

225
- Egr Valve & Cooler
  
  226
  - Component Locator
    226
  - Inspection
    227
  - Replacement
    227
- Closed Ventilator
  
  234
  - Component Locator
    234
  - Replacement
    236
Intake (J05E)

242
- Intake Manifold
  
  243
  - Component Locator
    243
  - Replacement
    244
- Diesel Throttle
  
  249
  - Component Locator
    249
  - Inspection
    250
  - Replacement
    250
- Intake Pipe (Exhaust Side)
  
  252
  - Component Locator
    252
  - Replacement
    253
- Intercooler
  
  255
  - Overhaul
    255
- Stack Duct
  
  256
  - Component Locator
    256
  - Cleaning the Precleaner Housing
    257
  - Replacement
    258
- Air Cleaner
  
  260
  - Component Locator
    260
  - Replacement
    262
  - Cleaning the Air Cleaner Element
    266
- Intake Temperature Sensor
  
  267
  - Component Locator
    267
  - Replacement
    269
- Boost Pressure Sensor
  
  270
  - Component Locator
    270
  - Inspection
    271
  - Replacement
    271
- Air Flow Sensor
  
  273
  - Component Locator
    273
  - Inspection
    274
  - Replacement
    276
Engine Mechanical (J05E)

277
- Head Cover
  
  278
  - Component Locator
    278
  - Replacement
    279
- Rocker Arm Assembly
  
  282
  - Component Locator
    282
  - Overhaul
    283
- Camshaft Assembly
  
  290
  - Component Locator
    290
  - Overhaul
    292
- Cylinder Head Assembly
  
  297
  - Component Locator
    297
  - Replacement
    298
  - Overhaul
    306
- Valve System
  
  312
  - Component Locator
    312
  - Overhaul
    313
- Crankshaft Pulley
  
  322
  - Component Locator
    322
  - Replacement
    323
- Crankshaft Front Oil Seal
  
  325
  - Component Locator
    325
  - Replacement
    326
- Front Oil Seal Retainer
  
  329
  - Component Locator
    329
  - Replacement
    330
- Flywheel Assembly
  
  332
  - Component Locator
    332
  - Overhaul
    333
- Crankshaft Rear Oil Seal
  
  337
  - Component Locator
    337
  - Replacement
    338
- Flywheel Housing
  
  341
  - Component Locator
    341
  - Replacement
    342
- Timing Gear & Cam Idle Gear
  
  346
  - Component Locator
    346
  - Configuration Diagram
    347
  - Overhaul
    347
- Piston and Connecting Rod
  
  360
  - Component Locator
    360
  - Overhaul
    361
- Crankshaft
  
  377
  - Component Locator
    377
  - Replacement
    379
- Cylinder Liner
  
  388
  - Component Locator
    388
  - Replacement
    389
- Cylinder Block
  
  392
  - Component Locator
    392
  - Overhaul
    393
- Engine Mounting and Bracket
  
  401
  - Component Locator
    401
  - Replacement
    402
- Glow Plug
  
  404
  - Component Locator
    404
  - Replacement
    405
- Gcu
  
  408
  - Component Locator
    408
  - Replacement
    408
Exhaust (J05E)

409
- Exhaust Manifold
  
  411
  - Component Locator
    411
  - Replacement
    412
- Exhaust Pipe
  
  416
  - Component Locator
    416
  - Replacement
    417
- Exhaust Pipe (Atc)
  
  424
  - Component Locator
    424
  - Replacement
    425
- Def-Scr & Dpr
  
  427
  - Configuration Diagram
    427
  - Cautions on Def/Coolant Piping Attaching and Detaching
    428
- Def-Scr
  
  429
  - Component Locator
    429
  - Replacement
    430
- Dpr Cleaner
  
  434
- Fuel Addition Valve
  
  457
  - Component Locator
    457
  - Replacement
    458
- Fuel Cutoff Valve
  
  466
  - Component Locator
    466
  - Replacement
    467
- Def Pump
  
  468
  - Component Locator
    468
  - Replacement
    469
- Def Injector
  
  474
  - Component Locator
    474
  - Replacement
    475
- Def Tank
  
  480
  - Component Locator
    480
  - Inspection
    481
  - Replacement
    482
- Def Sensor
  
  491
  - Component Locator
    491
  - Replacement
    492
- Coolant Cutoff Valve
  
  494
  - Component Locator
    494
  - Replacement
    495
- Dcu
  
  497
  - Component Locator
    497
  - Replacement
    498
- Dpr Differential Pressure Sensor
  
  503
  - Component Locator
    503
  - Replacement
    504
- SCR UPSTREAM Nox SENSOR
  
  506
  - Component Locator
    506
  - Replacement
    507
- SCR DOWNSTREAM Nox SENSOR
  
  509
  - Component Locator
    509
  - Replacement
    510
- Atc Upstream Temperature Sensor
  
  512
  - Component Locator
    512
  - Replacement
    513
- Doc Upstream Temperature Sensor
  
  515
  - Component Locator
    515
  - Replacement
    516
- Dpr Upstream Temperature Sensor
  
  518
  - Component Locator
    518
  - Replacement
    519
- Dpr Downstream Temperature Sensor
  
  520
  - Component Locator
    520
  - Replacement
    521
- Scr Upstream Temperature Sensor
  
  523
  - Component Locator
    523
  - Replacement
    524
- Outside Temperature Sensor
  
  527
  - Component Locator
    527
  - Replacement
    528
- Exhaust Brake
  
  529
  - Component Locator
    529
  - Replacement
    530
- Exhaust Brake Magnetic Valve
  
  533
  - Component Locator
    533
Cooling (J05E)

536
- Cooling System
  
  537
  - Cooling System Diagram
    537
- Radiator
  
  538
  - Component Locator
    538
  - Inspection
    539
  - Replacement
    540
- Radiator Cap
  
  550
  - Component Locator
    550
  - Replacement
    551
- Reserve Tank
  
  553
  - Component Locator
    553
  - Replacement
    554
- Intercooler
  
  555
  - Component Locator
    555
  - Overhaul
    556
- Thermostat Case and Thermostat
  
  558
  - Component Locator
    558
  - Overhaul
    559
- Coolant Pump
  
  565
  - Component Locator
    565
  - Replacement
    566
- Cooling Fan and Fan Clutch
  
  568
  - Component Locator
    568
  - Overhaul
    569
- Coolant Temperature Sensor
  
  572
  - Component Locator
    572
  - Replacement
    573
Lubrication (J05E)

575
- Lubrication System
  
  576
  - Lubrication System Diagram
    576
- Oil Filter
  
  577
  - Component Locator
    577
  - Replacement
    578
- Oil Cooler
  
  580
  - Component Locator
    580
  - Overhaul
    581
- Oil Pump
  
  588
  - Component Locator
    588
  - Overhaul
    589
- Oil Pan
  
  597
  - Component Locator
    597
  - Replacement
    598
- Oil Strainer
  
  602
  - Component Locator
    602
  - Replacement
    603
- Oil Pressure Switch
  
  604
  - Component Locator
    604
  - Replacement
    605
- Oil Level Gauge and Guide
  
  607
  - Component Locator
    607
  - Replacement
    608
  - Starter
    611
    
    Component Locator
    611
    
    Replacement
    612
  - V-Belt
    617
    
    Component Locator
    617
    
    Replacement
    618
  - Alternator (130A)
    621
    
    Overhaul
    622
  - Turbocharger Assembly
    636
    
    Component Locator
    636
    
    Inspection
    637
    
    Replacement
    639

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User Manuals: Hino S5-LJ05E04A Truck Repair Procedures

Hino S5-LJ05E04A Workshop Manual (647 pages)

Table of Contents

General Introduction

How to Identify Vehicle Type

Appearance of Vehicle

Safety Instructions and Readiness to Work

Glossary

Lubricants

Standard Value (J05E)

Mounting and Dismounting the Engine

Engine Control

Fuel System

Emission Control

Intake

Engine Mechanical

Exhaust

Cooling

Lubrication

Starting/Charging

Turbocharger

Required Items (J05E)

Mounting and Dismounting the Engine

Engine Control

Fuel System

Emission Control

Intake

Engine Mechanical

Exhaust

Cooling

Lubrication

Starting/Charging

Turbocharger

Mounting and Dismounting the Engine (J05E)

Engine Control (J05E)

Control Parts

Engine Ecu

Vehicle Control Ecu

Engine Speed Main Sensor

Engine Speed Sub Sensor

Idle Set Volume

Accelerator Pedal

Block Heater

Diesel Throttle

Intake Temperature Sensor

Fuel Sender Gauge

Air Flow Sensor

Boost Pressure Sensor

SCR UPSTREAM Nox SENSOR

Dpr Differential Pressure Sensor

SCR DOWNSTREAM Nox SENSOR

Atc Downstream Temperature Sensor

Doc Upstream Temperature Sensor

Dpr Downstream Temperature Sensor

Dpr Upstream Temperature Sensor

Outside Temperature Sensor

Scr Upstream Temperature Sensor

Oil Pressure Switch

Coolant Temperature Sensor

Fuel System (J05E)

Fuel System

Fuel Tank

Fuel Sender Gauge

Fuel Filter and Case (Engine Side)

Water Level Warning Switch

Supply Pump

Injector

Common Rail

Fuel Filter and Case (Vehicle Side)

Fuel Cooler

Emission Control (J05E)

Egr Valve & Cooler

Closed Ventilator

Intake (J05E)

Intake Manifold

Diesel Throttle

Intake Pipe (Exhaust Side)

Intercooler

Stack Duct

Air Cleaner