Conversion of the 157-2812 Air Compressor Gp to the 113-8193 Air Compressor Gp for Certain Off-Highway Truck Applications{1803} Caterpillar

Off-Highway Truck/Tractor:

784C (S/N: 2PZ1-105)

784C (S/N: 8BR605-940)

785C (S/N: APX1-450; 8BR605-940)

789C (S/N: 2BW1-658; 7TR1-1435)

Introduction

Do not perform any procedure that is given in this instruction until you have read all of the information in this instruction.

This Special Instruction contains the necessary procedures in order to convert the engine and the chassis from a Tu-Flo 1000 air compressor to a Tu-Flo 750 air compressor. Only one air dryer is used on a Tu-Flo 750 air compressor.

Note: If a remanufactured engine arrangement is equipped with the 113-8193 Air Compressor Gp , only chassis modifications are necessary.

785C

Required Parts

Note:
The following table lists the parts that are removed from the vehicle and then installed onto the vehicle.

Table 1

Required Parts
Part	Part Name	Quantity
101-8352	Air Dryer Gp	1
188-0750	Hose As	1
8T-8917	Bolt	4
5P-1076	Hard Washer	1
4L-6454	Bolt	2
8T-4896	Hard Washer	2
5P-2566	Bolt	1
5P-1076	Hard Washer	1
6V-8188	Nut	1
5P-4431	Air Brake Elbow	1
3D-6931	Hose As	1
4S-7570	Hose As	1
4D-6311	Hose As	1

Note: The following table lists the new parts that are required.

Table 2

Required Parts
Part Number	Part Name	Quantity
244-1503	Plate As	1
7D-4903	Adapter	1
4D-3734	Elbow	2
9S-4181	O-Ring Plug	1
7M-8485	O-Ring Seal	1
113-8193	Air Compressor Gp	1
7N-4952	Cover	1
4D-2560	Pipe Connector	1
4M-8973	Elbow	1
4S-4606	Union	1
6K-6967	Pipe Adapter	1
1K-6937	Pipe Elbow	1
5F-6371	Connector	1
7N-4951	Cover	1
6V-3348	O-Ring Seal	1
5P-0840	O-Ring Seal	1
5M-2894	Hard Washer	8
259-4598	O-Ring Seal	1
235-3546	O-Ring Seal	1
1A-2029	Bolt	8

Disconnecting the Hoses and the Electrical Connectors From the Air Dryer Groups

Illustration 1	g01066815
(1) 189-5914 Hose As (2) 188-0750 Hose As (3) 188-0750 Hose As (4) 189-5914 Hose As

Illustration 2	g01066817
(5) Electrical connectors (6) Electrical connectors (7) 101-8352 Air Dryer Gp (8) 101-8352 Air Dryer Gp (9) 3D-6931 Hose As (10) 4D-6311 Hose As

1. Disconnect the following hoses from air dryers (7) and (8) :
   • 189-5914 Hose As (1) and (4)

   • 188-0750 Hose As (2) and (3)

   • 3D-6931 Hose As (9)

   • 4D-6311 Hose As (10)

2. Disconnect electrical connectors (5) and (6) .

Removing the 177-9305 Plate As and the Two Air Dryer Groups

Illustration 3	g01066970
(7) 101-8352 Air Dryer Gp (8) 101-8352 Air Dryer Gp (11) 177-9305 Plate As

1. Remove plate assembly (11) from the vehicle. Ensure that air dryers (7) and (8) are still attached.

2. Remove the air dryers from the plate assemblies. Also, remove the tube assemblies that are coiled around each of the air dryers.

Reassembling the Air Dryer Group

Illustration 4	g01067131
(12) 8T-8917 Bolt (13) 5P-1076 Hard Washer (14) 244-1503 Plate As (15) 101-8352 Air Dryer Gp

Illustration 5	g01109990
(16) 4L-6454 Bolt (17) 8T-4896 Hard Washer

Illustration 6	g01112222
(18) 5P-2566 Bolt (19) 5P-1076 Hard Washer (20) 6V-8188 Nut

1. Attach air dryer group (15) with the tube assembly to plate (14) by using bolts (12) and hard washers (13) .

2. Attach plate assembly (14) to the fore/aft beam and the left-hand support bracket for the accumulator. Use bolts (16), bolts (18), hard washers (17), hard washers (19), and nut (20) to attach plate assembly (14) .

Installing the Adapters and the Elbows

Illustration 7	g01067230
(21) 7D-4903 Adapter (22) 4D-3734 Elbow (23) 5P-4431 Air Brake Elbow

1. At the upper end of the tube assembly, install air brake elbow (23), adapter (21), and elbow (22) .

Removing the Hoses From the Air Compressor

Illustration 8	g01119346
(24) 2V-0146 Hose As (25) 189-5914 Hose As (26) Air compressor

1. Remove hoses (24) and (25) from the air compressor (26). The hoses will not be reused.

Rework for Installing the 113-8193 Air Compressor Gp

1. Remove the original crankshaft pulley.

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Illustration 9	g01119415
(27) 196-9131 Crankshaft Pulley Assembly

2. Install crankshaft pulley (27) .

3. Remove the original elbow from the auxiliary water pump outlet.

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Illustration 10	g01119797
(28) 230-1080 Elbow

4. Install elbow (28) onto the auxiliary water pump outlet.

5. Remove the 157-2812 Air Compressor Gp .

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Illustration 11	g01120007
(29) 113-8193 Air Compressor Gp (30) 119-6321 Air Compressor Lines Gp

6. Install air compressor (29) and air compressor lines (30) .

7. Remove the 157-2810 Refrigerant Compressor and Mounting Gp .

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Illustration 12	g01120019
(31) 129-9491 Refrigerant Compressor and Mounting Gp

8. Install refrigerant compressor and mounting gp (31) .

9. Remove the 152-1025 Accessory Drive Gp .

10. Remove the 152-1028 Auxiliary Drive Gp .

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Illustration 13	g01120023
(32) 115-0597 Auxiliary Drive Gp

11. Install auxiliary drive group (32) .

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Illustration 14	g01120026
(33) 119-6350 Front Housing Cover Gp

12. Convert the original front housing cover gp to the new front housing cover gp (33) by installing parts that are listed in Table 3.

Table 3

Part Number	Part Name	Quantity
7N-4952	Cover	1
7N-4951	Cover	1
6V-3348	O-Ring Seal	1
5P-0840	O-Ring Seal	1
5M-2894	Hard Washer	8
259-4598	O-Ring Seal	1
235-3546	O-Ring Seal	1
1A-2029	Bolt	8

Removing the Tube Assembly for the Air Intake

Illustration 15	g01120126
(34) 5M-3062 Bolt (35) 8T-4896 Hard Washer (36) 6V-8801 Nut (37) 4W-9923 Plate (38) 4L-6454 Bolt (39) 4D-7388 Clip (40) 2V-0146 Hose As (41) 184-7686 Elbow As

1. Remove the following parts that secure the hose as (40) :
   • Plate (37)

   • Hard Washer (35)

   • Bolt (34)

   • Nut (36)

   • Clip (39)

   • Bolt (38)

2. Remove hose as (40) that attaches to the tube assembly for the air intake.

   Note: When hose (40) is removed, elbow (41) for the air induction system must also be removed.

3. Install a 9S-4181 Plug and the 7M-8485 O-Ring Seal in place of the elbow (41) .

Installing the 4D-3734 Elbow and the 2G-6743 Hose As

Illustration 16	g01120200
(15) 101-8352 Air Dryer Gp (42) 2G-6743 Hose As

Illustration 17	g01120207
(42) 2G-6743 Hose As (43) 4D-3734 Elbow (44) Air compressor

1. Install elbow (43) to air compressor (44) .

2. Install hose as (42) between air compressor (44) and air dryer (15) .

Installing the 4S-7570 Hose As and Fittings

Illustration 18	g01120217
(45) 3D-8884 Elbow (46) 3D-6931 Hose As

Illustration 19	g01120286
(44) Air compressor (47) 3D-6931 Hose As (48) 4D-2560 Pipe Connector (49) 4M-8973 Elbow

1. Ensure that elbow (45) is still installed in the air dryer.

2. Install pipe connector (48) and elbow (49) to the new air compressor (44) .

3. Install hose (46) to the new air compressor (44) .

Installing the 4D-6311 Hose As

Illustration 20	g01120289
(15) 101-8352 Air Dryer Gp (50) 4D-6311 Hose As

1. Install hose (50) that was removed previously, to air dryer (15) .

Illustration 21	g01068245
(2) 188-0750 Hose As (15) 101-8352 Air Dryer Gp

1. Install hose as (2) to air dryer (15) .

Illustration 22	g01120296
(2) 188-0750 Hose As (51) 4I-8443 Check Valve (52) Air tank (53) 1K-6937 Pipe Elbow (54) 5F-6371 Connector

1. Disconnect hose as (2) from connector (54) that is on air tank (52) .

2. Remove 2H-3939 Elbow , 1L-8444 Tee , and connector (54) from the check valve (51). The elbow and the tee will not be reused.

   Note: Do not remove check valve (51) from air tank (52) .

3. Install pipe elbow (53) to check valve (51) .

4. Reconnect hose as (2) to connector (54) .

789C

Required Parts

Table 4

Part Number	Part Name	Quantity
217-6973	Crankshaft Pulley Assembly	1
230-1080	Elbow	1
129-9491	Refrigerant Compressor and Mounting Gp	1
115-0597	Auxiliary Drive Gp	1
7N-4952	Cover	1
7N-4951	Cover	1
6V-3348	O-Ring Seal	1
5P-0840	O-Ring Seal	1
5M-2894	Hard Washer	8
259-4598	O-Ring Seal	1
235-3546	O-Ring Seal	1
1A-2029	Bolt	8
4H-6147	Connector	1
247-2016	Hose As	1
7D-4903	Adapter	1
4D-3734	Elbow	1
246-6604	Hose As	1
113-8193	Air Compressor Gp	1
2H-3940	Elbow	1
4S-7606	Elbow	1
6K-6967	Pipe Adapter	1
247-2015	Hose As	1

Disconnecting the Hoses and the Electrical Connectors From the Air Dryer Groups

Illustration 23	g01098143
(1) 157-3244 Hose As

1. Disconnect hose as (1) from the forward air dryer. The other end of the hose as connects to the air tank. The hose will not be reused.

Removing and Installing the Fittings and the Hose on the Air Tank

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Illustration 24	g01110873
(2) 4I-8443 Check Valve (3) Air-tank (4) 5H-4778 Elbow (5) 5F-4778 Elbow (6) 156-9802 Hose As

1. Disconnect hose as (6) from elbow (5) that is connected to air tank (3) .

2. Remove 2H-3939 Elbow , 1L-8444 Tee , and 5F-6371 Connector (5) from check valve (2). The elbow and the tee will not be reused.

3. Install elbow (4) to check valve (2) .

4. Reconnect hose as (6) to elbow (5).

Removing the Hose As from the Air Dryers

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Illustration 25	g01098181
(7) Forward air dryer (8) 7D-3964 Hose As

1. Disconnect hose as (8) from the forward air dryer (7) .

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Illustration 26	g01098208
(9) Rear air dryer (10) 7D-3964 Hose As

2. Disconnect hose as (10) from the air dryer (9). The hose will not be reused.

Removing the Electrical Connector from the Air Dryer

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Illustration 27	g01098214
(7) Forward air dryer (11) Wiring harness (12) Electrical connector

1. Disconnect electrical connector (12) from forward air dryer (7). Secure wiring harness (11) with tie straps, as required. The wiring harness will not be reused.

Removing the 157-3245 Hose As

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Illustration 28	g01100562
(13) 157-2397 Tube (14) 157-3245 Hose As

1. Disconnect hose as (14) from tube (13) that is on the forward air dryer.

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Illustration 29	g01100550
(14) 157-3245 Hose As (16) Air compressor

2. Disconnect the hose as (14) from air compressor (16). Remove all of the clips that secure the hose.

   Note: The hose will not be reused.

Removing the Forward Air Dryer

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Illustration 30	g01100621
(7) Forward air dryer (17) Bolt

1. Remove the tube assembly that is coiled around the forward air dryer (7). Remove two bolts (17) that hold the air dryer. The air dryer will not be reused.

Removing the 7D-2984 Hose As

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Illustration 31	g01101459
(18) 7D-2984 Hose As (19) 4H-6147 Connector (20) 2D-7325 Pipe Tee

1. Disconnect hose as (18) from connector (19) .

2. Remove connector (19) and tee (20). The tee will not be reused.

Removing the 7D-2984 Hose As From the Air Compressor

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Illustration 32	g01101646
(16) Air compressor (18) 7D-2984 Hose As

1. Disconnect hose as (21) from air compressor (16). The hose will not be reused.

Removing the 157-3246 Hose As From the Air Dryer and the Air Compressor

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Illustration 33	g01101912
(16) Air compressor (22) 157-3246 Hose As

1. Disconnect hose as (22) from air compressor (16). The hose will not be reused.

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Illustration 34	g01101879
(7) Rear air dryer (23) 157-3246 Hose As (24) 2N-7308 Pipe Connector (25) 000-7246 Elbow (26) 007-0950 Pipe Adapter

2. Disconnect hose as (23) from connector (24) that is connected to air dryer (7) .

3. Remove connector (24), elbow (25), and pipe adapter (26) from air dryer (7) .

   Note: The connector, the elbow, and the adapter will not be reused.

Removing the 6J-7929 Hose As from the Air Compressor

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Illustration 35	g01102070
(16) Air compressor (27) 6J-7929 Hose As

1. Remove hose as (27) from air compressor (16) .

2. Remove the other side of the hose as from the outside connection on the right side of the cab. The hose will not be reused.

Rework for the Installation of the 113-8193 Air Compressor Gp

1. Remove the original crankshaft pulley.

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Illustration 36	g01117804
(28) 217-6973 Crankshaft Pulley

2. Install crankshaft pulley (28) .

3. Remove the elbow from the auxiliary water pump outlet.

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Illustration 37	g01117849
(29) 230-1080 Elbow

4. Install elbow (29) to the auxiliary water pump outlet.

5. Remove the 157-2812 Air Compressor Gp .

6. Install the 113-8193 Air Compressor Gp .

7. Remove the 157-2810 Refrigerant Compressor and Mounting Gp .

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Illustration 38	g01117854
(30) 129-9491 Refrigerant Compressor and Mounting Gp

8. Install refrigerant compressor and mounting gp (30) .

9. Remove the 152-1025 Accessory Drive Gp .

10. Remove the 152-1028 Auxiliary Drive Gp .

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Illustration 39	g01117859
(31) 115-0597 Auxiliary Drive Gp

11. Install auxiliary drive group (31) .

12. Remove the 153-7494 Front Housing Cover Gp .

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Illustration 40	g01117873
(32) 119-6350 Front Housing Cover Gp

13. Convert the original front housing gp to the new front housing cover gp (32) by installing parts that are listed in Table 5.

Table 5

Part Number	Part Name	Quantity
7N-4952	Cover	1
7N-4951	Cover	1
6V-3348	O-Ring Seal	1
5P-0840	O-Ring Seal	1
5M-2894	Hard Washer	8
259-4598	O-Ring Seal	1
235-3546	O-Ring Seal	1
1A-2029	Bolt	8

Installing the 247-2016 Hose As to the Air Dryer

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Illustration 41	g01101828
(33) 4H-6147 Connector (34) 7J-8611 Elbow

1. Install connector (33) to existing elbow (34) .

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Illustration 42	g01101837
(35) 247-2016 Hose As (36) 4H-6147 Connector

1. Install hose as (35) to connector (36) .

Installing the 246-6604 Hose As to the Air Dryer

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Illustration 43	g01101924
(37) 246-6604 Hose As (38) 4D-3734 Elbow (39) 7D-4903 Adapter

1. Attach adapter (39) and elbow (38) to the air dryer.

2. Connect hose as (37) to adapter (38) .

Installing the 247-2016 Hose As to the Air Compressor

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Illustration 44	g01101989
(16) Air compressor (40) 246-6604 Hose As (41) 2H-3940 Elbow

1. Install elbow (41) onto air compressor (16) .

2. Install hose as (40) onto elbow (41) .

3. Secure the hose by using the existing hose clamps.

Installing the 246-6604 Hose As to the Air Compressor

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Illustration 45	g01102245
(16) Air compressor (42) 6K-6967 Pipe Adapter (43) 4S-7606 Elbow (44) 247-2015 Hose As

1. Install elbow (43) and pipe adapter (42) to the new air compressor (16) .

2. Install hose as (44) to elbow (43) .

3. Install the other end of hose as (44) to the outside connection on the right side of the cab.

4. Secure the hose as by using the existing hose clamps.