140H and 160H Motor Graders Engine Supplement Caterpillar

Air Compressor - Assemble

Usage:

140H 126

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	5P-3520	Spanner Wrench	1
A	6V-2113	Pin	1
B	-	Loctite 11415	-

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Illustration 1	g02961438

Install bearing (71) into compressor housing (69).
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Illustration 2 g02961417
Install thrust washer (70) onto crankshaft (61).
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Illustration 3 g02961398
Install crankshaft (61) into compressor housing (69).
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Illustration 4 g02961381
Install bearing (68) into connecting rod (63). Repeat this step for the remaining connecting rod assembly
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Illustration 5 g02961378
Install caps (67) onto wrist pin (64).
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Illustration 6 g02961357
Install piston rings (65). Install piston (66) onto connecting rod (63). Install wrist pin (64). Repeat this step for the remaining piston and connecting rod assembly.
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Illustration 7 g02961340
Install bearing (62) onto connecting rod (63). Repeat this step for the remaining connecting rod.
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Illustration 8 g02961326

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Illustration 9 g02961337
Install piston and connecting rod assemblies (60). Push piston and connecting rod assemblies (60) into the block and onto crankshaft (61).
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Illustration 10 g02961321
Install bearings (59) onto bearing caps (58).
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Illustration 11 g02961316
Install bearing cap (58). Install bolts (57). Repeat this step for the remaining bearing cap.
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Illustration 12 g02961278
Install thrust washer (56).
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Illustration 13 g02961237
Install bearing (55) and O-ring seal (54) onto cover (53).
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Illustration 14 g02961216
Install cover (53). Install bolts (52).
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Illustration 15 g02961198
Install cover (51). Install bolts (50). Install fitting (49).
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Illustration 16 g02960987
Install fittings (48).
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Illustration 17 g02960980
Apply Tooling (B) onto plugs (47). Install plugs (47).
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Illustration 18 g02960958
Install valve seats (46). Install inlet valves (45).
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Illustration 19 g02960920
Install inlet valve springs (44).
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Illustration 20 g02960896

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Use Tooling (A) to install inlet valves (43). Install valves (42).
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Illustration 21 g02960818
Install springs (41).
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Illustration 22 g02960816
Install valves (40).
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Illustration 23 g02960800

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install valve seats (39).
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Illustration 24 g02960776
Install spring (38), backup ring (37), and O-ring seal (36) onto unloader valve (35). Repeat this step for the remaining unloader valve (35).
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Illustration 25 g02960759
Install unloader valves (35).
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Illustration 26 g02960756
Install gasket (34) onto unloader cover (33).
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Illustration 27 g02960736

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install unloader cover (33) and bolts (32). T
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Illustration 28 g02960722
Install gasket (31).
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Illustration 29 g02960696

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Illustration 30 g02962830
Install head (30) and bolts (29). Tighten bolts (29) to a torque of 23 N·m (200 lb in) in a crisscross pattern in the order indicated. Tighten bolts (29) again to a torque of 45 to 57 N·m (400 to 500 lb in) in a crisscross pattern in the order indicated.
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Illustration 31 g02960676
Install O-ring seals (28) onto valve assembly (26).
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Illustration 32 g02960636
Install check valve (27), valve assembly (26), and spacer (25).
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Illustration 33 g02959776
Install spring (24).
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Illustration 34 g02959759
Install O-ring seals (23) onto locking nut (22).
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Illustration 35 g02959698

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install locking nut (22). Apply Tooling (B) onto fitting (21). Install fitting (21).
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Illustration 36 g02959676

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Illustration 37 g02959683
Install gasket (20). Install manifold (19). Install bolts (18).
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Illustration 38 g02959656
Install O-ring seal (17).
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Illustration 39 g02959642
Install valve (16). Install spring (15).
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Illustration 40 g02959636

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install retainer (14).
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Illustration 41 g02959622
Install valve assembly (10). Install O-ring seals (13).
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Illustration 42 g02959577

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Illustration 43 g02959596

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install valve assembly (10), tappet (11), and spring (12). Install spring assembly (9) and retaining ring (8).
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Illustration 44 g02959528

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Illustration 45 g02959557
Install O-ring seal (7) onto cap (6). Install cap (6).
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Illustration 46 g02959525
Apply Tooling (B) onto fittings (5) and fitting (4). Install fittings (5) and fitting (4).
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Illustration 47 g02959522
Install gasket (3).
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Illustration 48 g02959516
Install governor (2). Install bolts (1).