C6.6 Engines for Caterpillar Built Machines Air Compressor - Remove and Install Caterpillar

Removal Procedure

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

Note: Put identification marks on all hoses, on all hose assemblies and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging hose assemblies and tube assemblies helps to prevent fluid loss and helps to keep contaminants from entering the system.

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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.

1. Release the pressure from the air system. Refer to the Original Equipment Manufacture (OEM) for the correct procedure.

2. If the engine is equipped with a hydraulic pump on the rear of the air compressor, remove the hydraulic pump. Refer to the OEM for the correct procedure.

3. 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 - Change" for the correct draining procedure.

4. Use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston".

   Note: The air compressor must be timed with the engine in order to minimize engine vibration.

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   Illustration 1	g01353468
   Typical example

5. Remove plug (1) from the cylinder block. Install Tooling (B) into Hole (X) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position.

   Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.

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   Illustration 2	g01353469
   Typical example

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   Illustration 3	g01353470
   Typical example

6. Disconnect coolant hose (2) and hose (3) from air compressor (5).

7. Disconnect the air lines from port (4) and port (6).

8. Remove tube assembly (8) from air compressor (5) and from the cylinder block.

9. Remove bolts (9) and bolts (11) from support bracket (10) and remove the support bracket.

10. Support air compressor (5). Remove nuts (14) and remove the air compressor from front housing (7).
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    Illustration 4	g01353471
    Typical example

11. Remove O-ring seal (19) from air compressor (5).

12. If necessary, remove bolts (16) and remove plate (15). Remove O-ring seal (12) from plate (15). Refer to Illustration 3.

13. If necessary, follow Step 13.a through Step 13.c in order to remove gear (17) from air compressor (5).

    1. Use a suitable tool in order to prevent gear (17) from rotating.

    2. Remove nut (18) and remove the spring washer.

    3. Use Tooling (C) in order to remove gear (17) from the crankshaft of air compressor (5).

Installation Procedure

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Illustration 5	g01353471
Typical example

1. If necessary, follow Step 1.a through Step 1.b in order to install gear (17) to air compressor (5).

   1. Ensure that the shaft of air compressor (5) is clean and dry. Ensure that gear (17) is clean and free from damage.

   2. Install gear (17) and a new spring washer to the shaft of air compressor (5).

   3. Apply Tooling (D) to the threads of the shaft. Install nut (18) to the shaft of air compressor (5).

   4. Use a suitable tool in order to prevent gear (17) from rotating as nut (18) is tightened. Tighten the nut to a torque of 120 N·m (89 lb ft).

2. Install a new O-ring seal (19) to the recess of air compressor (5). Use Tooling (E) in order to lubricate the O-ring seal.

3. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".

   Note: The air compressor must be timed with the engine in order to minimize engine vibration.

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   Illustration 6	g01353468
   Typical example

4. Ensure that Tooling (B) is installed in Hole (X) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position.

   Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.

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   Illustration 7	g01333452
   Typical air compressor with a SAE drive

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   Illustration 8	g01333453
   Typical air compressor with a DIN drive

5. Rotate the crankshaft of the air compressor until timing Mark (X) is aligned with timing mark A6 on the rear face of air compressor (5). Refer to Illustration 7 for air compressors with a SAE drive. Refer to Illustration 8 for air compressors with a DIN drive.
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   Illustration 9	g01353470
   Typical example

6. Align air compressor (5) with studs (13). Install the air compressor to the front housing. If necessary, rotate the crankshaft of the air compressor in a clockwise direction in order to align the gears.

   Note: Ensure that timing Mark (X) is aligned with the timing mark A6. Refer to Illustration 7 for air compressors with a SAE drive. Refer to Illustration 8 for air compressors with a DIN drive.

7. Install nuts (14). Tighten the nuts to a torque of 78 N·m (58 lb ft).

8. If necessary, follow Steps 8.a through 8.c in order to install cover (15).

   1. Install a new O-ring seal (12) to cover (15). Use Tooling (E) in order to lubricate the O-ring seal.

   2. Install cover (15) to air compressor (5).

   3. Install bolts (16). Tighten the bolts to a torque of 13 N·m (9.5 lb ft).
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   Illustration 10	g01353469
   Typical example

9. Position support bracket (10) onto air compressor (5). Install bolts (9) finger tight.

10. Install bolts (11) finger tight.

11. Tighten bolts (9) to a torque of 9 N·m (80 lb in).

12. Tighten bolts (11) to a torque 44 N·m (32 lb ft).

13. Loosen bolts (9) in order to allow air compressor (5) to return to the air compressor natural position.

14. Tighten bolts (9) to a torque of 22 N·m (195 lb in).

    Note: Ensure that the air compressor is not stressed as the bolts are tightened.

15. Install tube assembly (8) to air compressor (5) and to the cylinder block. Tighten the nuts to a torque of 9 N·m (80 lb in).

16. Remove Tooling (B) from Hole (X) in the cylinder block. Install plug (1) to the cylinder block. Refer to Illustration 6.

17. If the engine is equipped with a hydraulic pump on the rear of the air compressor, install the hydraulic pump. Refer to the OEM for the correct procedure.

18. Connect the air lines to ports (4) and (6) in the air compressor. Refer to the OEM for the correct procedure.

19. Connect coolant hoses (2) and (3) to air compressor (5).

20. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual.