Remove/install 1-cylinder compressor

AR13.30-G-0001BC

Remove/install 1-cylinder compressor

19.08.2020

Engine

900.915/916, 902.923/924/935, 904.927/928, 906.935/955 in model 405

Engine

900.920/921, 904.952/953, 924.916/923/931 in model 437.42/43

Engine

924.916 in model 437.465 up to 3/31/17

Shown on the compressor (1) with 393 cm3 displacement

1

Compressor

2

Screw

3

Coolant line

4.1

Elbow fitting

4.2

Threaded fitting

5

Compressed-air line

6

Coolant line

B16

Cylinder 1 TDC sensor

Shown on the compressor (1) with 352 cm3 displacement

5

Compressed-air line

7

Control line

8.1

Ball

8.2

Union nut

1

Compressor

9

O-ring

10

Gear

11

Nut

12

Screw

13

Puller

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Charge the compressed air system up to shutoff pressure.

2

Switch off ignition.

3.1

Tilt cab to repair position.

Model 405, model 437.42/43

AR60.80-G-0005B

 Installation: Tilt back cab after oil level check and after bleeding of engine cooling system.

3.2

Open hood.

Model 437.465

 See information from body manufacturer.

 Installation: Close hood after oil level check and inspection work at engine cooling system.

4

Check return flow valve in the pressure regulator for the air drier for leaktightness.

Model 437.42/43 up to vehicle identification end number 262508, model 405, model 437.465

AR42.60-G-0025B

5

Remove the MR (PLN) control unit.

Only for engine 900, 904 in model 405, engine 900, 904, 924 in model 437

AR07.15-G-1628B

6

Remove power steering pump.

Model 405

AR46.30-G-0500B

Model 437

AR46.30-G-0500C

7

Unfasten all retaining clamps on coolant pipe above the compressor (1) and fix coolant pipe in place above.

Only for engine 900.915/916, 904.927/928 in model 405

8

Remove retaining clamp for control line (7) from compressed air line (5).

Only for engine 900.915/916, 902.923/924 in model 405 with compressor with 352 cm3 of displacement, engine 900.920/921, 924.923/931 in model 437.42/43 with compressor with 352 cm3 of displacement

 Installation: If, instead of compressor (1) with 352 cm3 of displacement, a compressor (1) with 393 cm3 of displacement is installed, the retaining clamp is no longer required.

9

Remove control line (7) up to the connecting point.

Only for engine 900.915/916, 902.923/924 in model 405 with compressor with 352 cm3 of displacement, engine 900.920/921, 924.923/931 in model 437.42/43 with compressor with 352 cm3 of displacement

 Installation: If, instead of compressor (1) with 352 cm3 of displacement, a compressor (1) with 393 cm3 of displacement is installed, the control line (7) is no longer required.
Close off the connection for the connecting point with a ball (8.1) and union nut (8.2).
Bind the line remaining in the vehicle with cable ties on the frame.

10

Slowly open cap on coolant expansion reservoir and then close it again.

 In order to reduce the overpressure in the engine cooling system.

11

Remove coolant line (3) from the compressor's cylinder head (1) and collect escaping coolant with suitable container.

 The cap on the coolant expansion reservoir must not be opened.

 Installation: Install new sealing rings.

 Banjo bolt, coolant line to compressor

*BA13.30-N-1004-01I

12

Close off coolant line (3), as shown, with screw/bolt, sealing rings and nut.

13

Remove coolant line (6) from the compressor's cylinder head (1) and collect escaping coolant with suitable container.

 Installation: Install new sealing rings.

 Banjo bolt, coolant line to compressor

*BA13.30-N-1004-01I

14

close off coolant line (6) with a screw/bolt, sealing rings and nuts.

15

Seal openings on the cylinder head of the compressor (1) with a suitable stop plug.

 Record plug

*129589009100

16

Remove retaining clamp of compressed-air line (5).

17

Remove the elbow fitting (4.1).

 Installation: When tightening elbow fitting (4.1), counterhold threaded fitting (4.2).

18

Seal openings on threaded fitting (4.2) and on the compressed air line (5) with suitable stop plugs.

 Plug

*963589019100

19

Remove the air intake line from the compressor (1) and seal openings with suitable stop plugs.

 Plug

*963589019100

20

Pull out TDC - sensor for cylinder 1 (B16) from timing case and seal openings with suitable stop plugs.

 Do not disconnect electrical connection.

 Installation: Press in the TDC sensor cylinder 1 (B16) up to the end stop.

 Plug

*963589019100

21

Remove the bracket and retaining clamp of the hydraulic lines from the frame in the area around the compressor (1) at the bottom.

Only for engine 900, 904 in model 405.10/12

22

Remove the compressor (1) from the crankcase and catch escaping engine oil in a suitable container.

 Suitable tool for removal/installation of compressor (1) with 393 cm3 of displacement can be ordered online at Snap-on (http://www.snapon.com).
Commercially available devices/tools
Adapter 3/8" to 1/4"
(Order no. GFAT1E)
1/4" extension 50 mm
(Order no. TMXWK2)
1/4" extension 100 mm
(Order no. TMXWK4)
1/4" extension 150 mm
(Order no. TMXWK60)
1/4" ball joint Torx socketE12
(Order no. TSE120)

 Installation: First tighten inner upper screw (2), then remaining screws (2).

 Screw/bolt, compressor to crankcase

*BA13.30-N-1006-01I

23

Remove compressor (1).

 Installation: Replace O-ring (9). Ensure that the O-ring (9) is correctly seated.

24

Remove the threaded fitting (4.2).

Only if replacing compressor (1).

 Installation: Replace sealing ring.

 Threaded fitting, compressed-air line to compressor

*BA13.30-N-1007-01I

25

Attach the blocking device to the compressor (1) and tighten the screws (12).

Only when replacing the gearwheel (10) or the compressor (1).

 Locking device

*904589036300

26

Loosen nut (11).

Only when replacing the gearwheel (10) or the compressor (1).

 Nut, gearwheel to compressor

*BA13.30-N-1005-01I

27

Loosen the gearwheel (10) with a puller (13).

Only when replacing the gearwheel (10) or the compressor (1).

 Commercially available devices/tools
Puller

28

Remove nut (11) and remove gearwheel (10).

Only when replacing the gearwheel (10) or the compressor (1).



Check

29

Check the elbow fitting (4.1), threaded fitting (4.2) and air line (5) for carbonization

If problems exist,



Replace carbonized components.

30

Check air intake duct on compressor (1) for damage.

If problems exist,



Replace air intake duct.

31

Check resonator box of compressor (1) for damage.

Only for engine 902, 906 in model 405

If problems exist,



replace the resonator.

32

Install in the reverse order



Check

33

Check engine oil level at electric display.

 See owner's manual.

If the engine oil level is not correct,



Correct engine oil level.

 Engine oil

*BF18.00-N-1001-01J

34

Check/correct coolant level.



Engine 900.915/916, 902.923/924/935, 904.927/928, 906.935/955 in model 405

AP20.00-G-2010B



Engine 900.920/921, 904.952/953, 924.916/923/931 in model 437.42/43/46

AP20.00-G-2010C

35

Purge engine cooling system.

Only for engine 900.915/916, 902.923/924/935, 904.927/928, 906.935/955 in model 405

AR20.00-G-1040B

36

Check engine cooling system for leak tightness.

 Visual check.

37

Check compressor (1), compressed air line (5) and power steering pump for leaktightness.

 Visual check.

38

Check control line (7) for leaktightness.

Only for compressor (1) with 352 cm3 of displacement.

 Visual check.

 Compressor (compressed air system)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA13.30-N-1004-01I

Banjo bolt, coolant line to compressor

Nm

40

 Compressor (compressed air system)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA13.30-N-1005-01I

Nut, gearwheel to compressor

Nm

270

 Compressor (compressed air system)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA13.30-N-1006-01I

Screw/bolt, compressor to crankcase

Nm

50

 Compressor (compressed air system)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA13.30-N-1007-01I

Threaded fitting, compressed-air line to compressor

Nm

100

 Engine lubrication

Number

Designation

ENGINE 900.91/92, 904.92/95, 924.91/92/93

Engine 902.92/93, 906.935/95, 926.96

BF18.00-N-1001-01J

Engine oil

Filling capacity with oil filter

l

15,8

29,3

Sheet

BB00.40-P-0228-05A

BB00.40-P-0228-05A

Sheet

BB00.40-P-0228-51A

BB00.40-P-0228-51A