Hino J08EVB User manual
Version #1 –8/26/2020
Revision #1 –8/26/2020
HINO
J08EVB & J08EVC
REMOVE AND REPLACE PROCEDURES
AIR COMPRESSOR
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Component Locator
1. Head cover.
2. Gasket *
3. Cylinder head
4. Valve seat
5. Suction valve
6. Unloader valve
7. O-ring *
8. Cylinder liner
9. Piston ring
10. Piston
11. Connecting rod
12. Connecting rod bearing
13. Lock washer *
14. Piston pin
15. Retainer ring *
16. Bearing holder
17. Ball bearing
18. Crankcase
19. Crankshaft
20. Woodruff key
21. Coupling
22. Coupling bolt
23. Pin
24. Air compressor assembly
25. Screw
Tightening Torque Unit: Nm {kgfm, lbfft}.
A. 29-34 {296-347, 22-25}
B. 25-29 {255-295, 19-21}
C. 23-26 {235-265, 17-19}
D. 30-36 {305-367, 22-27}
E. 23-26 {235-265, 17-19}
F. 2.5-3.9 {26-39, 1.9-2.8}
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Dismounting
1. Remove the Supply Pump
2. Remove the Air Compressor.
−Remove the six air compressor mounting bolts and remove the air compressor
without applying excessive force.
NOTICE: Excessive force to the air compressor may damage the mounting spigot or may cause
oil leakage due to flaking of liquid gasket between the flywheel housing and plate.
Mounting
1. Installation Procedures
−Fit the No.1 cylinder to the Top Dead Center.
−Align the aligning mark "0" on the top of coupling flange with protrusion on the
compressor housing.
−Insert the O-ring into the O-ring groove of the air compressor of bearing holder side.
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−Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or more) in the flywheel
housing as shown in the figure and insert the compressor onto the stud bolt.
−Tighten the mounting bolts (other than the stud bolt) then remove the stud bolt. Insert
a bolt in the place of the stud bolt.
Tightening Torque: 28.5 Nm {290 kgfcm, 20 lbfft}
−Make sure that the aligning mark "0" on the top of coupling flange is aligned with
protrusion on the compressor housing.
2. Install the Supply Pump and Air Compressor.
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2. Remove the Cylinder Head, Assembly and O-Ring.
−Remove the cylinder head, assembly, and O-ring.
NOTICE:
−Put the marking through the head cover to the cylinder liner.
−Do not decompose the cylinder head.
3. Remove the Connecting Rod with the Piston.
−Rotate the crankshaft to the top dead center position.
−Spread the staking of the nut completely with a chisel, then loosen the nut.
−Remove the connecting rod with piston.
4. Remove the Piston Rings.
−Remove the piston rings.
NOTICE:
−Handle the piston rings carefully because they are made of a special casting which is
easily broken.
−When reusing the piston rings, first arrange them face up and in the correct installation
sequence in order to prevent installing them incorrectly.
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5. Remove the Piston.
−Remove the retainer rings installed on both ends of the piston, using retainer ring
pliers.
−Strike out the piston pin.
NOTICE: Warm up the piston first in hot water, 80-90C {176-194F}, for approximately 5
minutes before removing the piston pin.
6. Remove the Crankshaft.
−Remove the bearing holder fitting screw.
−Use the press to remove the crankshaft together with the bearing holder.
NOTICE: Be careful not to damage the bearing holder.
7. Remove the Bearing Holder.
−Use the press to remove the bearing holder.
NOTICE: Be careful not to damage the bearing holder.
8. Remove the Ball Bearing.
−Using the special tool, remove the ball bearing from the end of the crankshaft.
Assemble
1. Install the Ball Bearing.
−Install the ball bearing onto the both ends of the crankshaft.
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2. Install the Crankshaft.
−Using the press, install the crankshaft to the bearing holder.
−Install the crankshaft and bearing holder into the crankcase.
−Tighten the bearing holder fitting screw.
3. Install the Connecting Rod and Measure the End Play.
NOTICE:
−Be sure to align the aligning mark.
−Apply engine oil to the connecting rod and cap.
−Apply engine oil to the thread before installing the connecting rod bolt.
−Measure the connecting rod end play.
Assembly standard: 0.2-0.4 mm {0.008-0.015 in.}
Limit: 0.5 mm {0.02 in.}
−Lock the nut with a lock washer.
4. Measure the End Play of the Crankshaft.
Assembly standard: 0-0.6 mm {0-0.0236 in.}
Limit: 1.0 mm {0.0394 in.}
5. Assemble the Piston.
NOTICE: Assemble the various parts after applying engine oil to the sliding parts.
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−When installing the piston rings on the piston, ensure that the piston skirt is at the
bottom, and use the special tool.
NOTICE: Install the piston rings in order shown in the figure.
6. Assemble the Piston and Connecting Rod.
NOTICE: Warm up the piston first in hot water, to 80-90C {176-194F}, for approximately 5
minutes.
−Install the retainer ring at one end of the piston pin holes.
−Apply engine oil to the piston pin.
−Fix the piston and connecting rod by inserting the pin.
−Fit the new retainer ring at the other end.
7. Install the Cylinder Liner and Cylinder Head.
NOTICE: Do not twist the O-ring when installing it on the cylinder liner and cylinder head.
−Rotate the crankshaft to the top dead center position.
−Arrange the piston rings so that their gaps are equally spaced.
−Install the cylinder liner and cylinder head.
This manual suits for next models
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