C7.1 Industrial Engine Caterpillar


Air Compressor - Remove and Install - Twin Cylinder Compressor

Usage:

C7.1 770

Removal Procedure

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


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.



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.

    ------ WARNING! ------

    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.


  1. Release the pressure from the air system. Refer to the Original Equipment Manufactures (OEM) for the correct procedure.

  2. 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.

  3. 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.

  4. 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.



    Illustration 1g01966313
    Typical example

  5. Remove plug (2) from the cylinder block. Remove O-ring seal (1) from the plug.

  6. 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.



    Illustration 2g01969655
    Typical example


    Illustration 3g02022020


    Illustration 4g01969454
    Typical example

  7. Slide hose clamps along coolant hose (3) and coolant hose (4). Disconnect coolant hose (3) and coolant hose (4) from air compressor (6).

  8. Disconnect the air line from port (5) (not shown) and air line from port (7). Ref to OEM for the correct procedure.

  9. Remove banjo bolt (10) and remove sealing washers (11) (not shown).

  10. Remove bolt (13) and bolt (15) from support bracket (14). Remove support bracket (14) from compressor (6) and the cylinder block.

  11. Support air compressor (6). Remove nuts (18) and remove the air compressor from front housing (9).

    Note: Note the position of tube assembly (12) before removal.

  12. If necessary, disconnect nut (8) (not shown) and remove tube assembly (12) from the union on the cylinder block.

  13. If necessary, remove studs (17) from front housing (9).

  14. If necessary, remove bolts (20) and remove plate (19). Remove O-ring seal (16) from plate (19). Refer to Illustration 4.


    Illustration 5g01969515
    Typical example

  15. Remove O-ring seal (24) from air compressor (6).

  16. If necessary, follow Step 16.a through Step 16.b in order to remove gear (21) 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 (23) and remove spring washer (22) (not shown).

    2. Use Tooling (C) in order to remove gear (21) from the crankshaft of the air compressor.

Installation Procedure

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


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.



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.




    Illustration 6g01969515
    Typical example

  1. If necessary, follow Step 1.a through Step 1.d in order to install gear (21) to air compressor (6).

    1. Ensure that the shaft of air the compressor is clean, free from damage, and dry. Ensure that the gear is clean, free from damage, and dry.

    2. Install gear (21) and a new spring washer (22) (not shown) to the shaft of the air compressor.

    3. Apply Tooling (D) to the threads of the shaft of the air compressor. Install nut (23) to the shaft of the air compressor.

    4. Use a suitable tool in order to prevent the shaft of the air compressor from rotating. Tighten nut (23) to a torque of 190 N·m (140 lb ft).

  2. Use Tooling (E) in order to lubricate a new O-ring seal (24). Install the O-ring seal to air compressor (6).

  3. 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.



    Illustration 7g02021419


    Illustration 8g01970516
    Typical example

  4. 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.

  5. Rotate the crankshaft of the air compressor until timing Mark (Y) is within (+ / -) 6 degrees of Position (Z).


    Illustration 9g01969454
    Typical example


    Illustration 10g02087758
    Compressor oil feed tube assembly

  6. If necessary, install studs (17) to the front housing. Tighten the studs to a torque of 25 N·m (221 lb in).

  7. If necessary, loosely install tube assembly (12) to the connection on the cylinder block. Tighten nut (8) finger tight.

  8. Align air compressor (6) with studs (17). 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.

    Note: Ensure that timing Mark (Y) is aligned with timing Marks (Z). Refer to Illustration 8 for the correct position of timing marks.

  9. Install nuts (18). Tighten the nuts to a torque of 78 N·m (58 lb ft).

  10. If necessary, follow Step 10.a through Step 10.c in order to install cover (19).

    1. Use Tooling (E) in order to lubricate a new O-ring seal (16). Install the O-ring seal to cover (19).

    2. Install cover (19) to air compressor (6).

    3. Install bolts (20). Tighten the bolts to a torque of 16 N·m (142 lb in).


    Illustration 11g02022020


    Illustration 12g01969655
    Typical example

  11. Position support bracket (14) onto air compressor (6). Install bolts (13) finger tight.

  12. Install bolts (15) finger tight.

  13. Tighten bolts (15) to a torque of 44 N·m (32 lb ft).

  14. Tighten bolts (13) to a torque of 22 N·m (195 lb in).

    Note: Ensure that the air compressor is not stressed as the bolts are tightened.

  15. Connect the air line to port (5) (not shown) and the air line to port (7) in the air compressor. Ref to (OEM) for the correct procedure.

  16. Connect coolant hose (3) and coolant hose (4) to the air compressor. Slide hose clamps along coolant hose assemblies into the correct position.


    Illustration 13g01970813

  17. Install new sealing washer (11) (not shown) onto banjo bolt (10). Position the banjo bolt onto tube assembly (12) and install remaining sealing washer (11). Install tube assembly (12) and tighten banjo bolt (10) finger tight.

  18. Tighten banjo bolt (10) 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.

  19. Securely tighten nut (8) (not shown) for tube assembly (12).

    Note: Ensure that the tube assembly does not contact any other engine components.



    Illustration 14g01966313
    Typical example

  20. Remove Tooling (B) from Hole (X) in the cylinder block.

  21. Install a new O-ring seal (1) to plug (2). Install the plug to the cylinder block. Tighten the plug to a torque of 21 N·m (186 lb in).

  22. 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.

  23. 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 procedure.

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