Remove/install compressor cylinder head

AR13.30-W-6010CA

Remove/install compressor cylinder head

21.6.10

11.5.10

Work procedure completely revised.

Note: If the compressor cylinder head was replaced, bolts (14) must be loosened before tightening since these are not tightened as specified in the delivery condition and leaks can occur; inserted.

Step 15



Removing

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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



Notes on coolant

AH20.00-N-2080-01A

 Danger!

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut.

AS60.80-Z-0001-01A

1

Tilt cab



Notes on tilting the cab

AH60.80-N-0003-01A

2

Remove soundproofing on frame at upper left

3

Drain partially coolant at radiator

AR20.00-W-1142B

4

Disconnect suction line (5) on resonance container (3)

5

Remove bolt (4) and resonance container (3)

6

Disconnect compressed air line (2) at connecting point for frame

7

Remove clamp for compressed air line (2) on timing case bracket

8

Remove compressed-air lines (2) on compressor cylinder head (1) and inspect for carbonization

 Counterhold fitting on compressor cylinder head (1).

In the event of carbonization, also check compressed air lines between the compressor, compressed air drier and the four-circuit protection valve, if necessary replace the carbonized parts.

9

Remove control line (6) on compressor (1) cylinder head

10

Detach coolant lines (8, 9) on compressor cylinder head (1)

 Counterhold fitting and catch escaping coolant.

11

Detach compressor cylinder head (1)

 The control valves (10) can fall down while being lifted.

12

Remove seal/intake valve disk (12)



Checking

13

Check piston and cylinder barrels of dual compressor for damage and wear

 If wear or damage present:



Replace dual compressor.

AR13.30-W-5510CA

14

Check removed compressor cylinder head (1) for leaks

 If leaks are recognizable on the compressor cylinder head (1):



Disassemble compressor cylinder head (1), insert new seals and assemble

AR13.30-W-5511-04CA



*BA13.30-N-1004-01L



*BA13.30-N-1005-01L



*BA13.30-N-1008-01L



Installation

15

Lay on new seal/intake valve disk (12)

 Observe installation position of the seal/suction valve disk (12). The pins (11) on the compressor cylinder head (1) must match with the cutouts (arrows). Clean sealing surface.

16

Attach compressor cylinder head (1) on compressor cylinder crankcase (13) with the new bolts

 Observe tightening sequence.

Ensure that the control valve (10) does not fall out.

AR13.30-W-6010-01CA

 If the compressor cylinder head was replaced, bolts (14) must be loosened before tightening since these are not tightened as specified in the delivery condition and leaks can occur.



*BA13.30-N-1007-01L



*BA13.30-N-1009-01L

17

Attach coolant line (8, 9) to compressor cylinder head (1)



*BA13.30-N-1010-01L

18

Attach control line (6)

 Install new sealing rings.



*BA13.30-N-1006-01L

19

Attach compressed air line (2) at connecting point for frame

 Align compressed air line (2) to compressor cylinder head (1).

20

Attach clamp for compressed air line (2) on timing case bracket

21

Tighten compressed air line (2) on compressor cylinder head (1)



*BA13.30-N-1011-01L

22

Attach resonance tank (3) and tighten bolt (4)

23

Attach suction line (5) on resonance container (3)

 Check sealing ring; replace suction line (5) if necessary.

24

Pour in coolant

AR20.00-W-1142B

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

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

AS00.00-Z-0005-01A

25

Start the engine and check the separation and line interfaces on the dual compressor for a running engine for leaktightness

 Visual inspection.

26

Turn off engine

27

Install soundproofing on frame above on the left

 Danger!

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut.

AS60.80-Z-0001-01A

28

Lower cab

Number

Designation

Engine
457.9 with code MZ8

BA13.30-N-1004-01L

Fitting, compressed air line to compressor

Nm

80

BA13.30-N-1005-01L

Fitting, suction line to compressor

Nm

80

BA13.30-N-1006-01L

Banjo bolt, control line to compressor

Nm

15

BA13.30-N-1007-01L

Bolt, cylinder head to compressor crankcase

Stage 1

Nm

25

Stage 2

°

90

BA13.30-N-1008-01L

Fitting, coolant line to compressor

Nm

30

BA13.30-N-1009-01L

Bolt, cylinder head cover to valve intermediate plate

Stage 1

Nm

7

Stage 2

°

90

BA13.30-N-1010-01L

Union nut, coolant line to compressor fitting

Nm

40

BA13.30-N-1011-01L

Union nut, air line to fitting

M221.5

Nm

65

M261.5

Nm

75