- On-Highway Engine:
- C7 (S/N: C7S1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.
Timing Procedure for the Air Compressor
Follow the instructions below in order to properly time the air compressor on a C7 Engine. The air compressor must first be removed and then installed in order to properly time the air compressor.
Removal Procedure for the Air Compressor
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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. |
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| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| NOTICE |
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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. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
- Remove the air pressure from the air tank.
- 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 (ELC) - Change".
- Disconnect tube assembly (1), tube assembly (2), tube assembly (3), and hose assembly (4) .
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| Illustration 1 | g01261253 |
- Attach a suitable lifting device onto air compressor (5). The weight of air compressor (5) is approximately 32 kg (70 lb).
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| Illustration 2 | g01261257 |
- Remove bolts (8) and cover (9). Ensure that the timing mark on the crankshaft of the compressor is positioned between the timing marks on the housing for the compressor. Reinstall cover (9) and bolts (8). Remove bolts (6). Remove bracket (7) .
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| Illustration 3 | g01261254 |
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| Illustration 4 | g01271799 |
- Remove bolts (10). Remove the air compressor and the O-ring seal from the engine.
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| Illustration 5 | g01261261 |
Installation Procedure for the Air Compressor
- Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
- Attach a suitable lifting device onto air compressor (5). The weight of air compressor (5) is approximately 32 kg (70 lb). Position the O-ring seal and air compressor (5) onto the engine.
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| Illustration 6 | g01261257 |
Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.
- Install bolts (10) .
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| Illustration 7 | g01261261 |
- Remove bolts (8) and cover (9). Ensure that the timing mark on the crankshaft of the compressor is positioned between the timing marks on the housing for the compressor. Install cover (9) and bolts (8). Install bracket (7). Install bolts (6) .
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| Illustration 8 | g01271799 |
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| Illustration 9 | g01261254 |
- Connect hose assembly (4), tube assembly (3), tube assembly (2), and tube assembly (1) .
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| Illustration 10 | g01261253 |
Note: Removal of the timing pin is necessary prior to connecting hose assembly (4) .
- Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change.".
Timing Procedure for the Fuel Injection Pump
Follow the instructions below in order to properly time the fuel injection pump on a C7 Engine. The fuel injection pump must first be removed and then installed in order to properly time the fuel pump.
Removal Procedure for the Fuel Injection Pump
| Required Tools | ||
| Tool | Part Number and Part Description | Qty |
| A | 267-2647 Stop Plug | 1 |
| B | 9S-4180 Plug | 1 |
- Remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".
Note: Cleanliness is a critical factor. Before you begin the removal procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
- Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
| NOTICE |
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Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines. |
| 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. |
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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
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- Remove tube assembly (1), tube assembly (3), and tube assembly (4) .
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| Illustration 11 | g01352511 |
- Disconnect tube assembly (5) and tube assembly (6). Remove bolts (2) .
- Remove Tooling (B) and install Tooling (A) .
- Disconnect harness assemblies (8). Remove nuts (9) and the support assembly.
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| Illustration 12 | g01352571 |
- Remove bolts (10). Slide fuel injection pump (11) out of the front housing and disconnect hose assembly (7). Remove fuel injection pump (11) by pulling straight out of the front housing.
Installation Procedure for the Fuel Injection Pump
| Required Tools | ||
| Tool | Part Number and Part Description | Qty |
| A | 267-2647 Stop Plug | 1 |
| B | 9S-4180 Plug | 1 |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
- Align fuel injection pump (11) in the correct orientation relative to the front housing. Connect hose assembly (7) .
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| Illustration 13 | g01352571 |
Note: Ensure that Tooling (A) is installed prior to installation of the fuel injection pump.
- Install fuel injection pump (11). Move fuel injection pump (11) straight into the front housing in order to properly engage the gear. Install bolts (10) .
- Install the support assembly and nuts (9). Connect harness assemblies (8) .
- Remove Tooling (A) and install Tooling (B). Tighten Tooling (B) to a torque of 4.5 ± 0.5 N·m (40.0 ± 4.0 lb in).
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| Illustration 14 | g01352511 |
- Install bolts (2). Connect tube assembly (6) and tube assembly (5) .
- Install tube assembly (4), tube assembly (3), and tube assembly (1) .
- Install the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".