Usage:
Remove And Install Air Compressor
1. Drain the cooling system. The capacity of the cooling system is 106 liter (28 gal.).
2. Remove air compressor coolant outlet tube (2).
3. Disconnect lubrication supply tube (3) at the governor.
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To prevent personal injury, release the pressure from the air reservoir before any air lines are disconnected. |
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4. Disconnect air compressor governor sensing hose (4) at the governor.
5. Disconnect pressure air hose (5) at the air compressor.
6. Disconnect air compressor air inlet tube (6) at the air compressor.
7. Disconnect air compressor coolant inlet tube (7) at the air compressor.
8. Fasten a nylon strap and hoist to the air compressor. The weight of the air compressor is 23 kg (51 lb.).
9. Remove three nuts (1) and the washers that hold the air compressor and adapter to the flywheel housing.
10. Disconnect the clip for tube (3) at the air compressor.
11. Move air compressor (8), adapter (9) and tube (10) away from the flywheel housing.
12. Cover the opening in the flywheel housing for the air compressor.
13. Install protective covers in the coolant, air and oil openings.
NOTE: The following steps are for installation of the air compressor.
14. Install a new O-ring seal on adapter (9), and put clean engine oil on it.
15. Install a new O-ring seal on tube (10), and put clean engine oil on it.
16. Remove the protective covers and place air compressor (8) and adapter (9) on the studs.
17. Install three nuts (1) and the washers to hold the air compressor.
18. Connect all hoses and tubes to the air compressor in their correct locations.
19. Fill the cooling system with coolant. See the Maintenance Guide.
Remove Accessory Drive (Air Compressor Drive Group)
START BY:
a. remove air compressor
1. Remove nut (4) from the compressor drive shaft with tool (A). Remove spacer (3).
2. Remove O-ring seal (2) from adapter (1).
3. Remove drive gear (5) from the compressor drive shaft with tool (B). Remove the key from the shaft.
4. Remove the adapter and gasket (6).
Install Accessory Drive (Air Compressor Drive Group)
1. Install the key on air compressor drive shaft (1).
2. Install gasket (5) and adapter (6) on the air compressor.
3. Put the groove in the drive gear in alignment with the key in the drive shaft. Install gear (2) on the shaft.
4. Install spacer (3) and nut (4) on the drive shaft. Tighten the nut with tool (A).
5. Install O-ring seal (7) on the adapter.
END BY:
a. install air compressor
Disassemble Air Compressor
START BY:
a. remove air compressor
b. remove accessory drive (air compressor drive group)
1. Remove the water line elbow, the air line elbows and oil (drain) tube from the air compressor.
2. Remove bolts (1) from the cylinder head. Remove cylinder head (2) and the gasket from the crankcase.
3. Remove inlet valve springs (7).
4. Remove (discharge) valve seats (6) from the cylinder head. Remove valves (8) and springs (5).
5. Inspect the valve seats from damage and wear. Make replacements if necessary.
6. Remove valve stops (9) as follows:
a. Put the machined surface of the cylinder head down on an arbor press.
b. Gradually push the stops from the top of the cylinder head and out of the bottom.
c. Be sure there is enough clearance for the stops between the press and the bottom of the cylinder head.
d. Inspect the stop bore in the cylinder head. Make a replacement of the head body if the bore is damaged.
NOTE: Remove the valve stops only if there is a wear and damage, also if the valve movement (travel) exceeds 1.45 mm (.057 in.).
7. Remove bolts (3) from the adapter. Remove adapters (4) from the compressor housing. See illustration A17939P1.
8. Remove O-ring seal (10), the thrust washer and the bearing from the adapter with tool (A).
9. Remove bolts (12) from the cover. Remove cover (11) and the gasket from the crankcase.
10. Bend down the lock on lock straps (13). Remove bolts (14) from the bearing caps.
11. Put identification marks on the bearing caps for correct installation with the connecting rod. Remove the bearing caps.
12. Remove pistons (15) from the crankcase through the top of the cylinders.
13. Remove crankshaft (16) from the crankcase. Remove the key from the crankshaft.
14. Remove end cover (17) from the crankcase. Remove the O-ring seal, the thrust washer and the bearing.
15. Remove cover (18), the gasket and the strainer from the air inlet opening.
16. Remove inlet valves (20) from their guides (21). Remove the inlet valve guides from around the inlet valve seats.
| NOTICE |
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Do not damage the inlet valve seats. |
17. Remove (unloader) spring (19), spring saddle (22) and the spring seat from the housing with needle nose pliers.
18. Remove (unloader) plunger (24) and guides (25) from the housing. Remove the guides from the plungers.
19. To remove (unloader) pistons (23) from the bore, put a cover over the inlet port, then blow air pressure in the governor mounting pad (unloader) port.
20. Remove lockpin (27) that holds rod pin (26) in the piston. Remove the pin from connecting rod (28).
21. Remove the piston rings from piston (30). Remove two compression rings (29), the oil ring and the expander ring with tool (B).
22. Remove the bearings from the connecting rod and the connecting rod cap.
23. Remove the piston pin bushing with tool (C).
24. Remove the small seal rings from both ends of the housing.
25. Clean all the oil passages through the housing, the crankshaft, the end cover and the adapter.
Assemble Air Compressor
1. Check (unloader) bore bushings (1) for damage and wear.
NOTE: If these bushings need replacement, remove the bushing by the use of a 3.18 mm (.125 in.) pipe threaded tap. Then install a 3.18 mm (.125 in.) pipe threaded rod, and pull the bushing straight up and out.
2. Check the cylinder bores in the crankcase housing for damages (scored or out of round). Measure the cylinder bore in several places. If the measurement difference is more than 0.03 mm (.001 in.) or taper is more than 0.05 mm (.002 in.) the cylinder bore must be made larger (rebores or honed oversize). See Specifications.
3. Install seal rings (3) in both ends of the crankcase housing.
4. Install the new (unloader) pistons in their bore.
| NOTICE |
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Be careful not to damage the O-ring seals or the spiral rings. |
5. Put the unloader plungers in their guides. Install the plunger and guide as a unit (6) to the crankcase housing and on top of the pistons. Install the unloader spring seat in the crankcase housing.
6. Put saddle (4) in position between the unloader piston guides. Install (unloader) spring (8). Make sure it makes a seat on the spring seats and on the saddle.
7. Install inlet valve guides (10) on (unloader) bore bushing (2) in the crankcase housing. Put inlet valves (9) in the guides.
8. Install strainer (7), the gasket and cover (5) over the air inlet port of the crankcase housing. Install the bolts that hold the cover.
9. Install bearing (11) in the cover with tooling (A). Make sure the groove in the bearings is in alignment with the oil hole in the cover. Install thrust washer (12) and O-ring seal (13).
10. Put clean SAE 30 oil on the bearing and the seal. Install the end cover and the bolts that hold it to the crankcase housing.
11. Install the crankshaft in the crankcase housing and the end cover bearing.
12. Install the bearing in adapter with tooling (B). Install thrust washer (14) and O-ring seal (15) in the adapter.
13. Put clean SAE 30 engine oil on the bearing and the O-ring seal. Install the adapter over the crankshaft and to the housing. Install the bolts that hold the adapter. Tighten the bolts to a torque of 49 to 60 N·m (36 to 44 lb.ft.).
14. Assemble the piston rings on the piston with tool (C) as follows:
a. Check piston ring (16) gaps. Check with the piston rings in the cylinder bore. The gap clearance must be 0.05 to 0.25 mm (.002 to .010 in.).
b. Install expander rin (17) on the bottom groove of the piston. Install oil ring (19) over the expander ring. Expander and oil ring (19) must have a clearance of 0.03 to 0.08 mm (.001 to .003 in.) between the inside groove top surface.
c. Install compression rings (16) as shown. The clearance between the rings must be 0.05 to 0.10 mm (.002 to .004 in.).
d. Turn the piston rings so the gaps are 120° apart.
15. Make alignment of the piston pin bushing oil hole with the oil hole in connecting rod (18). Install the bushing with tool (D). The bushing inside diameter must be 13.497 to 13.505 mm (.5314 to .5317 in.).
16. Install the connecting rods in the pistons. Make alignment of the connecting rod and the piston to install piston pin (20). Install lockpin (21) in the piston pin and the piston.
17. Install the bearing for the piston rod and for the rod cap with the tab of the bearing in the groove.
NOTE: The bearings must be installed only for the respective rods and caps.
18. Put clean SAE 30 engine oil on the piston rings and connecting rod bearings. Turn the crankshaft so that one of the connecting rod journals is in the "DOWN" position. Install tool (F) on the piston to put compression on the piston rings. Install the connecting rod in the crankcase housing and over the crankshaft journals.
19. Check the clearance between the connecting rod bearing and the crankshaft journals with tool (E). Put the Plastigage on the cap bearing. Install the bearing caps to the respective connecting rod. Tighten the bolts to a torque of 11.30 to 12.99 N·m (100 to 115 lb.in.).
20. Remove the bearing caps and measure the Plastigage. The clearance must be between 0.0533 to 0.0762 mm (.0021 to .0030 in.).
21. Put clean SAE 30 engine oil on the bearing cap and the bolts. Install the bearing caps and locks (22). Tighten the bolts to a torque of 11.30 to 12.99 N·m (100 to 115 in.lb.). Bend the locks up against the bolt.
22. Do Steps 17 through 21 for the other connecting rod assembly.
23. Install the gasket and the cover on the bottom of the housing. Install the bolts that hold the cover.
24. Install key (25) in the crankshaft groove (slot).
25. Install the (discharge) valve stop in the cylinder head. Put 7M7456 Sealant on the valve stop. Install the valve stop with tool (G) and an arbor press. Push the valve stop in the cylinder head from the inside machined surface.
26. Install the (discharge) valve springs and the valve in the cylinder head on the valve stops. Install (discharge) valve seats (23).
27. Put inlet valve springs (24) on the inlet valves that are in position in the crankcase housing.
28. Install a new head gasket on crankcase housing. Put the cylinder head in position on the crankcase housing. Install the bolts that hold the cylinder head to the crankcase housing. Tighten the bolts evenly to a torque of 35 to 40 N·m (26 to 30 lb.ft.).
29. Install the oil (drain) tube, the air line elbows and three water line elbows.
END BY:
a. install accessory drive (air compressor drive group)
b. install air compressor