Retrofitting a Cat 270 Air Compressor with a BA-921 CR Air Compressor on Certain C13 and C15 On-Highway Engines{1803} Caterpillar

Engine:

C13 (S/N: KCB1-UP; LEE1-UP)

C15 (S/N: SDP1-UP; NXS1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

New Cat 270 Air Compressors are no longer available from the supplier. The Cat 270 air compressor can be replaced with a Bendix BA-921 air compressor.

Important Safety Information

Show/hide table

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.

Parts Needed for C13 Engine

Step by Step Procedure for C13 Engines

Refer to the correct Disassembly and Assembly, "Air Compressor - Remove and Install" to remove the air compressor

1. Follow normal procedure of uninstalling the CAT 270 air compressor.

2. Install all connectors into the air compressor ports finger-tight. Some ports might not be accessible after the air compressor is installed on the engine. After the lines are installed, and all connector orientations are fixed, tighten all connectors that were initially finger-tightened to standard torque.

Show/hide table



Illustration 1	g02680398

3. To ease installation later, connect the air compressor end of the oil supply line hose (1) to the connector in the oil port. Then install the BA-921 CR air compressor on the engine.

4. Install the BA-921 CR air compressor on the engine.

5. Install the rear support bracket. Refer to ""Rear Support Bracket" " for a detailed explanation.

6. Install the coolant supply line. Refer to ""Coolant Supply Line" " for a detailed explanation.

7. Install the coolant return line. Refer to ""Coolant Return Line" " for a detailed explanation.

8. Install the oil supply line. Refer to ""Oil Supply Line" "for detailed explanation.

9. Install the air inlet line by using the bulk hose provided. Refer to ""Air Inlet Line" " for a detailed explanation.

10. Install the air discharge line. A new line is needed if the line is too short, or if the discharge line is a hard tube.

11. Install the governor line (for governor remote mount), or install the governor with the adapter kit (for governor direct mount) on the air compressor.

Rear Support Bracket

Illustration 2	g02680538
(2) 351-7088 Bracket (3) 6V-4248 Bolt (4) 6V-5839 Washer

Install the rear support bracket (2) with the hardware provided. Refer to Illustration 2. Finger-tighten all the fasteners initially, then tightened to standard torque to prevent the bracket from being pre-stressed at the time of installation.

Coolant Supply Line

There are two designs of the coolant supply line out in the field. In ""Design A" " the entire coolant line is a steel tube. In ""Design B" " the coolant line is a steel tube with a hose connection at the compressor end.

Design A

Illustration 3	g02681476

Illustration 4	g02681496
(5) Steel tube (6) 034-3679 Fitting (7) 9X-2488 Hose Clamp (8) 319-8815 Hose

Cut off to the length shown in Illustration 3 and remove the compressor end of the steel tube (5) . Bend the end portion of the remaining tube (5) slightly away from the engine block, for extra clearance. Insert the hose (8) onto the tube. A straight fitting (6) with a 6V-6609 O-Ring Seal would be installed in the compressor coolant supply port. The bulk hose (8) would then be installed as shown in Illustration 4. Use one clamp (7) to secure the hose on to the straight fitting. Since the tube does not have a hose barb, install two clamps (7) on the tube end of the connection to prevent any coolant leakage.

Design B

Illustration 5	g02681537
(9) 6V-1230 Elbow

Install the 45 deg connector (9) with a 6V-6609 O-Ring Seal in the air compressor coolant supply port. Install the bulk hose as shown in Illustration 5.

Coolant Return Line

Illustration 6	g02681559
(10) 379-8582 No Print

Uninstall the alternator bracket in order to remove the coolant return line. Replace the old coolant line with the new line (10) as shown in Illustration 6. Use the same P-clip and mounting hardware that was used to support the old coolant line.

Replace the alternator bracket.

Oil Supply Line

Illustration 7	g02680398

Install the other end of the oil line after the air compressor is installed on the engine, as shown in Illustration 7.

Air Inlet Line

Illustration 8	g02681566
(11) 8T-1117 Hose Clamp (Air compressor side of hose) (12) 302-7410 Hose (13) 8T-1117 Hose Clamp (Resonator side of hose)

Route the air inlet line by using the bulk hose (12) provided. When there is a resonator on the engine, route the air supply line from the air inlet connector of the air compressor to the resonator. Refer to Illustration 8.

Illustration 9	g02681576
(14) 8T-1117 Hose Clamp (Turbo side of hose)

Illustration 10	g02681678
(15) 3E-4041 Elbow

In all other cases, route the hose (12) to the elbow (15) on the turbo inlet elbow/CGI elbow. Refer to Illustration 9 and Illustration 10.

On 2006 engines where the air supply to the compressor is boosted air, the boosted air cannot be used with the BA-921 CR air compressor. This air compressor is designed to accept only naturally aspirated air, not boosted air. Use the 9S-8008 O-Ring Plug to seal the air supply port for the boosted air on the engine intake manifold. Install the elbow (15) with a 6V-5050 O-Ring Seal into the turbo air inlet elbow to connect the air supply hose (12) .

Parts Needed for C15 Engine

Step by Step Procedure for C15 Engines

Refer to the correct Disassembly and Assembly, "Air Compressor - Remove and Install" to remove the air compressor

1. Follow normal procedure of uninstalling the CAT 270 air compressor. Keep the existing oil supply line.

2. Since some ports might not be accessible after the air compressor is installed on the engine, install all connectors, finger-tight, into the air compressor ports. After the lines are installed, and all connector orientations are fixed, tighten all finger-tightenned connectors to standard torque.

3. Install the BA-921 CR air compressor on the engine.

4. Install the rear support bracket. Refer to ""Rear Support Bracket" ". The rear support bracket may be impossible to install on some engines, because other components on the engine would interfere with the rear support bracket. For example, the bracket cannot be installed on engines with a mid mount fuel filter, since the filter base uses the same mounting bosses as the rear support bracket. Engines with certain OCV groups may have the oil drain line and fumes disposal lines that interfere, and prevent installation of the rear support bracket.

5. Install the coolant supply line. Refer to ""Rear Support Bracket" ".

6. Install the coolant return line. Refer to ""Coolant Return Line" ".

7. Use the existing oil hose as. with the BA-921 CR air compressor. Refer to ""Oil Line " ".

8. Install the air inlet line with the bulk hose provided. Refer to""Air Inlet Line" ".

9. Install the air discharge line. Use a new line if the existing line is too short, or if the discharge line is a hard tube.

10. Install the governor line (for governor remote mount), or install the governor with the adapter kit, for governor direct mount, on the air compressor.

Rear Support Bracket

Illustration 11	g02686736
(1) 8M-0505 Connector (2) 321-7384 Hose As (3) 379-8581 NO PRINT (4) 6V-1820 Bolt (5) 3E-4353 Hard Washer (6) 0S-1588 Bolt (7) 9X-6458 Hard Washer

1. Install the rear support bracket (3) with the hardware provided. Refer to Illustration 11. Finger-tighten all fasteners initially, then tightened the fasteners to standard torque to prevent the bracket from being pre-stressed when installed.

2. Install the coolant supply line (2) .

Coolant Return Line

Illustration 12	g02688178
(8) Existing coolant return line

The existing coolant return line (8) can be used with the BA-921 CR air compressor, if the hose is in good condition. Refer to Illustration 12.

Illustration 13	g02688220
Use two 172-4702 Clamps and a 6V-1438 Connector to mount the hose (9) . (9) 6V-8843 Hose

If the previously used hose is not reusable, mount the new bulk hose (9) with the hardware listed above. Refer to Illustration 13.

Oil Line Installation

Illustration 14	g02688277

Install the existing oil line (10) on the new BA-921 CR Air Comp of the C15 Engine

Air Inlet Line

Illustration 15	g02688376
(11) 302-7410 Hose (12) 9S-8005 O-Ring Plug (13) 238-5080 O-Ring Seal (14) 8T-1117 Hose Clamp (15) 5P-1230 Connector (16) 6V-5050 O-Ring Seal

Illustration 16	g02688416
(17) 3E-4041 Elbow

Route the air inlet line by using the bulk hose (11) provided. When there is a resonator on the engine, route the air supply line from the air inlet connector of the air compressor to the resonator. In all other cases, route the hose to the elbow on the turbo inlet elbow/CGI elbow.

On some 2006 engines the air supply to the compressor is boosted air, and cannot be used with the BA-921 CR air compressor. The BA-921 CR air compressor can only use naturally aspirated air. Use the plug (12) and O-ring (13) to seal the boosted air supply port on the engine cylinder head for these applications. Refer to Illustration 15. Install the air supply hose (11) from the compressor into the elbow (16, 17) in the port of the turbo air inlet elbow. Refer to Illustration 16.