Usage:
1. Remove (bleed) the air from the system.
2. Drain the coolant from the engine.
3. Disconnect tube assembly (1) and hose assembly (4) from the engine. Disconnect hose assemblies (2) and (3) from the air compressor.
4. Remove the three bolts (6), the nuts and lockwashers that hold air compressor (5) to the flywheel housing. Remove the air compressor and gasket from the flywheel housing.
Install Air Compressor
1. Put air compressor (1) and the gasket in position on the flywheel housing. Install the three bolts, lockwashers and nuts to hold it.
2. Connect hose assemblies (2) and (5) to the air compressor. Connect hose assembly (4) and tube assembly (3) to the engine.
3. Fill the cooling system with coolant to the correct level.
Disassemble Air Compressor
start by:
a) remove air compressor
b) remove accessory drive
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 for 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 wear and damage, also if the valve movement (travel) exceeds .057 in. (1.45 mm).
7. Remove bolts (3) from the adapter. Remove adapters (4) from the compressor housing.
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 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 |
|---|
Be careful not to cause damage to 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 to 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 1/8 in. (3.18 mm) pipe threaded tap. Then install a 1/8 in. (3.18 mm) 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 .001 in. (0.03 mm) or taper is more than .002 (0.05 mm), the cylinder bore must be made larger (rebored 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 |
|---|
Be careful not to cause damage to 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 bearing is in alignment with the oil hole in the cover. Install thrust washer (12) and O-ring seal (13).
10. Put clean SAE 30 engine 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 38 to 45 lb.ft. (51.5 to 61.0 N·m).
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 .002 to .010 in. (0.05 to 0.25 mm).
b) Install expander ring (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 .001 to .003 in. (0.03 to 0.08 mm) between the inside groove top surface.
c) Install compression rings (16) as shown. The clearance between the rings must be .002 to .004 in. (0.05 to 0.10 mm).
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 .5314 to .5317 in. (13.497 to 13.505 mm).
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 wire on the cap bearing. Install the bearing caps to the respective connecting rod. Tighten the bolts to a torque of 100 to 115 in. lb. (11.30 to 12.99 N·m).
20. Remove the bearing caps and measure the wire. The clearance must be between .0030 to .0021 in. (0.0076 to 0.0533 mm).
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 100 to 115 in. lb. (11.30 to 12.99 N.m). 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 25 to 30 lb.ft. (33.9 to 40.7) N·m).
29. Install the oil (drain) tube, the air line elbows and three water line elbows.
end by:
a) install accessory drive
b) install air compressor