C6.6 Industrial Engine Air Compressor - Remove and Install - Single Cylinder 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 all hose assemblies and tube assemblies helps to prevent fluid loss and also 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.

2. 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.

3. If the engine is equipped with a hydraulic pump on the rear of the air compressor, remove the hydraulic pump. Refer to the Original Equipment Manufacturer (OEM) for the correct 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, "Fuel Injection Timing - Check" for the correct procedure.

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

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   Illustration 1	g01966313
   Typical example

5. Remove plug (2) from the cylinder block. Remove O-ring seal (1) from the plug.

6. 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	g01964836
   Typical example

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   Illustration 3	g01965121
   Typical example

7. Slide the hose clamps along coolant hose (3) and coolant hose (4). Disconnect coolant hose (3) and coolant hose (4) from air compressor (6).

8. Disconnect the air lines from port (5) (not shown) and air lines from port (7).

9. Remove banjo bolt (9) and sealing washers from air compressor (6).

10. Remove bolt (10) and bolt (12) from support bracket (11) and remove the support bracket.

11. Support air compressor (6) and remove nuts (15). Remove the air compressor from front housing (8).

12. If necessary, remove studs (14) from front housing (8).

13. If necessary, remove bolts (17) and remove plate (16). Remove O-ring seal (13) from plate (16).
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    Illustration 4	g01964860
    Typical example

14. Remove O-ring seal (21) from air compressor (6).

15. If necessary, follow Step 15.a through Step 15.b in order to remove gear (18) from the crankshaft of the air compressor.

    1. Use a suitable tool in order to prevent the shaft of the compressor from rotating. Remove nut (20) and remove spring washer (19).

    2. Use Tooling (C) in order to remove gear (18) from the crankshaft of the air compressor.
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    Illustration 5	g02091596

16. If necessary, follow Step 16.a through Step 16.b in order to remove the hose assembly.

    1. Make a temporary mark in order to identify the position of hose assembly (23).

    2. Disconnect nut (22) and remove hose assembly (23).

Installation Procedure

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

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Illustration 6	g01964860
Typical example

1. If necessary, follow Step 1.a through Step 1.d in order to install gear (18) to the air compressor.

   1. Ensure that the shaft of air compressor (6) is clean and dry, and free from damage. Ensure that gear (18) is clean and dry, and free from damage.

   2. Install gear (18) and a new spring washer (19) to the shaft of the air compressor.

   3. Apply Tooling (D) to the threads of the shaft. Install nut (20) to the shaft of air compressor (6).

   4. Use a suitable tool in order to prevent the shaft of the compressor from rotating. Tighten nut (20) to a torque of 120 N·m (89 lb ft).
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   Illustration 7	g02091596

2. If necessary, install hose assembly (23) to the connection on the cylinder block. Align hose assembly with the temporary marks. Tighten nut (22) to a torque of 9 N·m (80 lb in).

3. Use Tooling (E) in order to lubricate the new O-ring seal (21). Install the O-ring seal to air compressor (6).

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, "Fuel Injection Timing - Check" for the correct procedure.

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

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   Illustration 8	g02021419

5. 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 9	g02488337
   Typical example

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   Illustration 10	g01965121
   Typical example

6. Rotate the crankshaft of the air compressor until timing Mark (Y) is aligned with timing Mark (Z) on the rear face of the air compressor.

7. If necessary, install studs (14) to the front housing. Tighten the studs to a torque of 25 N·m (221 lb in).

8. Align air compressor (6) with studs (14). Install the air compressor to the front housing. If necessary, rotate the crankshaft of the air compressor in order to allow the gears to align.

9. Install nuts (15). Tighten the nuts to a torque of 78 N·m (58 lb ft).

10. If necessary, follow Step 10.a through Step 10.c in order to install cover (16).

    1. Use Tooling (E) in order to lubricate a new O-ring seal (13). Install the O-ring seal to cover (16).

    2. Install plate (16) to the air compressor.

    3. Install bolts (17). Tighten the bolts to a torque of 16 N·m (142 lb in).
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    Illustration 11	g01964836

11. Position support bracket (11) onto air compressor (6). Install bolts (10) finger tight.

12. Install bolts (12) finger tight.

13. Tighten bolts (10) to a torque of 22 N·m (195 lb in).

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

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

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    Illustration 12	g02091646
    Typical example

15. Install a new sealing washer to banjo bolt (9). Position the banjo bolt onto hose assembly (23) and Install the remaining new sealing washer to the banjo bolt.

16. Connect hose assembly (23) onto the air compressor. Tighten the banjo bolt to a torque of 9 N·m (80 lb in).

    Note: Ensure that the hose assembly is not stressed during the tightening procedure of the banjo bolt.

17. Connect the air lines to port (5) (not shown) and port (7) in the air compressor. Refer to the OEM for the correct procedure.

18. Connect coolant hose (3) and coolant hose (4) to the air compressor. Slide the hose clamps for the coolant hose assembly into the correct position.
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    Illustration 13	g01966313
    Typical example

19. Remove Tooling (B) from Hole (X) in the cylinder block.

20. Install a new O-ring seal (1) to plug (2). Install the plug to the cylinder block. Refer to Illustration 13. Tighten the plug to a torque of 21 N·m (186 lb in).

21. 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.

22. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, "Refill Capacities" and Operation and Maintenance Manual, "Cooling System Coolant Level - Check" for the correct procedure.