C7.1 Industrial Engine Caterpillar

Air Compressor - Remove and Install - Single Cylinder

Usage:

C7.1 770

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A⁽¹⁾	9U-6198	Crankshaft Turning Tool	1
A⁽²⁾	5P-7306	Shaft Housing	1
A⁽²⁾	5P-7305	Engine Turning Tool	1
B	136-4632	Timing Pin	1
C	1P-2320	Combination Puller	1

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⁽¹⁾	The Crankshaft Turning Tool is used on the front pulley.
⁽²⁾	This Tool is used in the aperture for the electric starting motor.

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Put identification marks on all hoses, on all hose assemblies and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies helps to prevent fluid loss and also helps to keep contaminants from entering the system.

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Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.

Release the pressure from the air system. Refer to the Original Equipment Manufactures (OEM) for the correct procedure.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
If the engine is equipped with a hydraulic pump on the rear of the air compressor, remove the hydraulic pump. Refer to the OEM for the correct procedure.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Note: The air compressor must be timed with the engine in order to minimize engine vibration.
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Illustration 1 g01966313

Typical example
Remove plug (2) from the cylinder block. Remove O-ring seal (1) from the plug.
Install Tooling (B) into Hole (X) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position.
Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.
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Illustration 2 g01964836

Typical example

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Illustration 3 g01965121

Typical example
Slide hose clamps along coolant hose (3) and coolant hose (4). Disconnect coolant hose (3) and coolant hose (4) from air compressor (6).
Disconnect the air lines from port (5) (not shown) and air lines from port (7). Refer to the OEM for the correct procedure.
Remove banjo bolt (9) and sealing washers from air compressor (6).
Remove bolt (10) and bolt (12) from support bracket (11) and remove the support bracket.
Support air compressor (6) and remove nuts (15). Remove the air compressor from front housing (8).
If necessary, remove studs (14) from front housing (8).
If necessary, remove bolts (17) and remove plate (16). Remove O-ring seal (13) from plate (16).
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Illustration 4 g01964860

Typical example
Remove O-ring seal (21) from air compressor (6).
If necessary, follow Step 15.a through Step 15.b in order to remove gear (18) from the crankshaft of the air compressor.
1. Use a suitable tool in order to prevent the shaft of the compressor from rotating. Remove nut (20) and remove spring washer (19).
2. Use Tooling (C) in order to remove gear (18) from the crankshaft of the air compressor.
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Illustration 5 g02091596
If necessary, follow Step 16.a through Step 16.b in order to remove the hose assembly.
1. Make a temporary mark in order to identify the position of hose assembly (23).
2. Disconnect nut (22) and remove hose assembly (23).

Installation Procedure

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Table 2
Required Tools
Tool	Part Number	Part Description	Qty
A⁽¹⁾	9U-6198	Crankshaft Turning Tool	1
A⁽²⁾	5P-7306	Shaft Housing	1
A⁽²⁾	5P-7305	Engine Turning Tool	1
B	136-4632	Timing Pin	1
D	1E-2200M	Retaining Compound	1
E	1U-6396	O-Ring Assembly Compound	1

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⁽¹⁾	The Crankshaft Turning Tool is used on the front pulley.
⁽²⁾	This Tool is used in the aperture for the electric starting motor.

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

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Illustration 6	g02091596

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Illustration 7	g01964860
Typical example

If necessary, follow Step 1.a through Step 1.d in order to install gear (18) to the air compressor.
1. Ensure that the shaft of air compressor (6) is clean, free from damage, and dry. Ensure that gear (18) is clean and free from damage and dry.
2. Install gear (18) and a new spring washer (19) to the shaft of the air compressor.
3. Apply Tooling (D) to the threads of the shaft. Install nut (20) to the shaft of air compressor (6).
4. Use a suitable tool in order to prevent the shaft of the compressor from rotating. Tighten nut (20) to a torque of 9 N·m (80 lb in).
If necessary, install hose assembly (23) to the connection on the cylinder block. Align hose assembly with the temporary marks. Tighten nut (22) to a torque of 120 N·m (89 lb ft).
Use Tooling (E) in order to lubricate a new O-ring seal (21). Install the O-ring seal to air compressor (6).
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Note: The air compressor must be timed with the engine in order to minimize engine vibration.
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Illustration 8 g02021419
Ensure that Tooling (B) is installed in Hole (X) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position.
Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.
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Illustration 9 g02358916

Typical example

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Illustration 10 g01965121

Typical example
Rotate the crankshaft of the air compressor until timing Mark (Y) is aligned with timing Mark (Z) on the rear face of the air compressor.
If necessary, install studs (14) to the front housing. Tighten the studs to a torque of 25 N·m (221 lb in).
Align air compressor (6) with studs (14). Install the air compressor to the front housing. If necessary, rotate the crankshaft of the air compressor in order to allow the gears to align.
Install nuts (15). Tighten the nuts to a torque of 78 N·m (58 lb ft).
If necessary, follow Step 10.a through Step 10.c in order to install cover (16).
1. Use Tooling (E) in order to lubricate a new O-ring seal (13). Install the O-ring seal to cover (16).
2. Install plate (16) to the air compressor.
3. Install bolts (17). Tighten the bolts to a torque of 16 N·m (142 lb in).
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Illustration 11 g01964836
Position support bracket (11) onto air compressor (6). Install bolts (10) finger tight.
Install bolts (12) finger tight.
Tighten bolts (10) to a torque of 22 N·m (195 lb in).
Tighten bolts (12) to a torque 44 N·m (32 lb ft).
Note: Ensure that the air compressor is not stressed as the bolts are tightened.
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Illustration 12 g02091646

Typical example
Install a new sealing washer to banjo bolt (9). Position the banjo bolt onto hose assembly (23) and install the remaining new sealing washer to the banjo bolt.
Connect hose assembly (23) onto the air compressor. Tighten the banjo bolt to a torque of 9 N·m (80 lb in).
Note: Ensure that the hose assembly is not stressed during the tightening procedure of the banjo bolt.
Connect the air lines to port (5) (not shown) and port (7) in the air compressor. Refer to the OEM for the correct procedure.
Connect coolant hose (3) and coolant hose (4) to the air compressor. Slide hose clamps along coolant hose assemblies into the correct position.
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Illustration 13 g01966313

Typical example
Remove Tooling (B) from Hole (X) in the cylinder block.
Install a new O-ring seal (1) to plug (2). Install the plug to the cylinder block. Refer to Illustration 13. Tighten the plug to a torque of 21 N·m (186 lb in).
If the engine is equipped with a hydraulic pump on the rear of the air compressor, install the hydraulic pump. Refer to the OEM for the correct procedure.
Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, "Refill Capacities" and Operation and Maintenance Manual, "Cooling System Coolant Level - Check" for the correct fill procedure.