Disassemble/assemble compressor

AR13.30-Y-5511B

Disassemble/assemble compressor

19.08.2020

Engine

400.925/926/927/928 in model 831.001/002/005

Air compressor dismantling and assembly procedure

1

Top cover

3

Unloading plunger unit

4

Sealing ring

2

Cylinder head cover gasket

5

Cylinder head

7

Cylinder head baffle

9

Helical spring

6

Cylinder head inlet gasket

8

Cylinder head cup

10

Spring guide

11

Delivery ring valve

12

Bearing flange

13

Bearing flange O-ring

16

Air compressor locking special tool 090 589 02 40 00

19

Crankcase bottom cap

14

Air compressor O-ring

17

Idler gear with bush and thrust washer

20

Connecting rod

15

Crank case guide plate

18

Driven gear with washer

20

Connecting rod

22

Internal circlip

23

Gudgeon pin

21

Connecting rod with piston

24

Compression ring and oil ring

25

Snap ring

26

Crank shaft

27

Radial ball bearing

28

Idler gear bush

Piston and connecting rod installation

29

Piston ring compressor

 

Disassemble/assemble

1

Remove air compressor.

AR13.10-Y-5810C

2

Remove the top cover (1) from cylinder head mounting bolt.

3

Remove the cylinder head cover gasket (2).

4

Remove the unloading plunger unit (3) and sealing ring (4) from top cover.

5

Remove the cylinder head (5) from crankcase.

 Remove the cylinder head inlet gasket (6) from crankcase.

6

Remove the baffle (7) from cylinder head mounting bolt.

7

Remove the cup (8) from cylinder head.

8

Remove the helical spring (9) from cylinder head.

9

Remove the spring guide (10) from cylinder head.

10

Remove the delivery ring valve (11) from cylinder head.

11

Remove the bearing flange (12) mounting bolt from crankcase.

 Installation: Gently tap on top of the bearing flange for correct seating using mallet.

12

Tap the bearing flange (12) using mallet hammer and remove the bearing flange.

 Remove the bearing flange O-ring (13).

13

Remove the O-ring (14) from air compressor.

14

Remove the guide plate (15) from crankcase.

15

Remove the idler gear with bush and thrust washer (17) and the driven gear with washer (18) from air compressor.

 Use air compressor locking special tool (16).

 Installation: W mark on the driven gear and crankshaft must match.

 Air compressor drive gear nut

*BA13.30-Y-1001-01A

 Blocking device

*090589024000

16

Remove the bottom cap (19) from crankcase.

 Installation: If the dummy cap is damaged, replace with new component.

17

Remove the connecting rod (20) mounting bolt from crankshaft.

18

Remove the connecting rod with piston (21) from crankcase using mallet.


Care must be taken during removal of piston.
To avoid damages to the pistons or cylinder bore.

 Installation: Compress the piston rings using piston ring compressor (29) and insert the piston in to the cylinder bore along with connecting rod.
Before installing, the piston must be checked for piston rings end gap away from gudgeon hole.
Tapping on the top of the piston must be done with a soft material. Use nylon rod.

19

Remove the internal circlip (22) on both side from gudgeon pin.

20

Remove the gudgeon pin (23) and connecting rod (20) from piston.

 Installation:
Care must be taken while installing the gudgeon pin.
To avoid damage of the piston and connecting rod.

21

Remove the compression ring and oil ring (24) from piston.

 Installation:
Care must be taken while using piston expander.
Over expansion of ring may lead to damage.

22

Remove the snap ring (25) from radial ball bearing.

 Gently tap the drive coupler side using mallet because of clearance between crankcase and snap ring.

23

Remove the crankshaft (26) from crankcase using mallet.



BB00.40-P-0228-01A

 Installation: Apply oil in crankcase and bearing.

24

Remove the radial ball bearing (27) from crankshaft using three jaw puller.

25

Remove the idler gear bush (28) using appropriate tool.

26

Assemble in the reverse order.

 Installation:
Avoid reuse any O-ring, gasket, snap ring and circlip during installation.
Cause damage.

 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

27

Start engine and perform an engine test run.

 Continue running the engine at idling speed until the temperature is reached and then switch off engine.

28

Check both compressor and all lines for leaks.

 Visual inspection.

 Air compressor

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA13.30-Y-1001-01A

Air compressor drive gear nut

Nm

105