Series 60 – Section 11.1 Air Compressor (Vehicle Applications Only)

Section 11.1
Air Compressor (Vehicle Applications Only)

The original Series 60 air compressor is mounted to the rear of the gear case on the left side of the engine. See Figure "Original Air Compressor Mounting" .‪

Figure 1. Original Air Compressor Mounting

The original air compressor drives the engine fuel pump which is bolted to the rear end of the compressor. The air compressor is designed to accept a drive coupling placed between the air compressor and fuel pump.‪

Certain applications, and all Series 60 engines built before 1990, do not use the air compressor to drive the engine fuel pump. The air compressor is mounted in the same place on these units, but the engine fuel pump is mounted to the fuel pump drive assembly. The fuel pump drive assembly is bolted to the gear case above the air compressor and is driven by the bull gear. See Figure "Original Air Compressor with Flange Mounted Fuel Pump" .‪

Figure 2. Original Air Compressor with Flange Mounted Fuel Pump

The original air compressor is driven by the bull gear and water cooled. Engine coolant is fed to the compressor through a flexible hose tapped into the engine block water jacket and connected to the front of the compressor. Coolant returns from the rear of the compressor through a flexible hose to the engine cylinder head. Lubricating oil is supplied to the compressor by a line from the cylinder block oil gallery that connects to the air compressor. Lubricating oil returns to the engine crankcase through the air compressor drive assembly.‪

Note: An air compressor oil test card (DD5524) is available to test engine-mounted air compressors for excessive oil leakage. Contact an authorized Detroit Diesel service outlet for details.

The current adaptorless air compressors have replaced the original air compressors and adaptors on the majority of Series 60 on-highway engines. This change took effect with unit serial number 6R210293, built November 30, 1994. The original compressor and adaptor are available on certain on-highway models due to customer preference.‪

An optional 28 cfm, twin-cylinder air compressor has replaced the former optional 31 cfm, four-cylinder air compressor, starting with model year 1999. The 28 cfm, high output air compressor is a naturally aspirated design that requires the intake air to be plumbed from the clean air side of the air filter.‪

Both high-output air compressors require the engine-driven fuel pump to be mounted to the gear case above the air compressor.‪

For Series 60 2002 Exhaust Gas Recirculation (EGR) engine a naturally aspirated single cylinder reciprocating compressor with a rated displacement of 13 cubic feet per minute at 1250 rpm is used. The engine provides a continuous supply of oil to the compressor. Oil is routed from the oil passage in the gear case to the compressor oil inlet.‪

Current adaptorless air compressors are similar to the original compressors, except that their mounting flanges have been redesigned to permit direct installation of the compressor onto the gear case. The drive gear stackup on this compressor has been modified to eliminate the need for a drive adaptor. See Figure "Original Adaptor, Current 28 CFM-mounted, and Current Adaptorless Air Compressor" .‪

Figure 3. Original Adaptor, Current 28 CFM-mounted, and Current Adaptorless Air Compressor

Note: If information is required to service an original air compressor, refer to "11.1.8 Installation of Former Air Compressor" .

1. Gear Case‪

2. Single Cylinder Air Compressor 13 CFM‪

Figure 4. Series 60 2002 Single Cylinder Air Compressor 13 CFM

The current Series 60 adaptorless air compressor is flange-mounted to the rear of the gear case, located on the left side of the engine. See Figure "Adaptorless Air Compressor Mounting" .‪

Figure 5. Adaptorless Air Compressor Mounting

Current adaptorless air compressors also drive the engine fuel pump which is bolted to the rear end of the compressor. The compressor crankshaft is designed to accept a drive coupling placed between the compressor and fuel pump.‪

Section 11.1.1
Replacement of Adaptorless Air Compressor

Detroit Diesel does not service the adaptorless air compressor. Service of an adaptorless air compressor should be referred to an authorized service center of the original equipment manufacturer. ‪

To replace the adaptorless air compressor, perform the following procedure. See Figure "Flowchart for Replacement of Adaptorless Air Compressor" .‪

Figure 6. Flowchart for Replacement of Adaptorless Air Compressor

Section 11.1.2
Cleaning and Removal of Adaptorless Air Compressor

Precleaning is not necessary. ‪

Remove the adaptorless air compressor as follows:‪

1. Disconnect the air lines to and from the compressor.
2. Disconnect the fuel pump lines.
3. Remove the fuel pump and drive coupling. Refer to "2.8.2 Removal of Fuel Pump (One-piece Drive Shaft)" .
4. Drain the cooling system. Refer to "14.6.4 Cooling System" .
5. Disconnect and drain the coolant supply and return lines at the air compressor.
6. Disconnect the lubricating oil supply line from the compressor.
7. Remove the bolts securing the air compressor support bracket to the cylinder block and air compressor.
8. Remove the support bracket.

   Note: Due to the cylinder block and compressor configuration, the upper inside air compressor-to-air compressor drive bolt is difficult to reach with standard tools. Compressor Wrench (J–35948) will facilitate removal and installation of this bolt.

9. Remove the five bolts and one nut that secure the air compressor to the gear case.
10. For Series 60 2002 EGR Single Cylinder Air Compressor remove the five bolts that secure the air compressor to the gear case.
11. Slide the air compressor rearward to disengage the hub from the coupling.

Section 11.1.2.1
Inspection of Adaptorless Air Compressor

Refer to OEM guidelines to determine if the air compressor needs to be repaired or replaced.‪

Section 11.1.3
Installation of Adaptorless Air Compressor

Install the adaptorless air compressor as follows:‪

1. Clean all gasket material from the mating surfaces of the air compressor and the gear case.
2. Align the reference mark on the fuel pump drive coupling to the nine o'clock position. This will set the air compressor piston at top dead center and will help to ease the process of checking gear lash.
3. Using a new gasket and bolts and nut previously removed, install the air compressor to its original location on the gear case.

   Note: The shorter bolt is installed in the two o'clock position and the nut is installed in the twelve o'clock position.

4. For torquing sequence, see Figure "Bolt Torque Sequence " . Use compressor wrench (J–35948) to torque the upper inside bolt. Using the bolt and nut torquing sequence, torque five bolts and one nut to 58–73 N·m (43–54 lb·ft).
   

   Figure 7. Bolt Torque Sequence

   

   Figure 8. Bolt Torque Sequence Series 60 2002 Single Cylinder Air Compressor

5. For torque sequence for Series 60 2002 EGR Single Cylinder Air Compressor see Figure "Bolt Torque Sequence Series 60 2002 Single Cylinder Air Compressor" . Torque five bolts to 58-73 N·m (43-54 lb·ft).
6. Refer to "1.24.2.1 Check Engine Timing" step 15 and check the bull gear-to-air compressor drive gear lash measurement.
7. Refer to "1.24.2.1 Check Engine Timing" step 15 and install the power steering pump drive coupling, power steering pump, and cover assembly to the gear case cover.
8. Install the improved air compressor support bracket to the compressor and cylinder block as follows:
   1. Tighten the support bracket-to-air compressor bolts. For 25 mm long bolts, use a torque of 41 - 52 N·m (30 - 38 lb·ft). For 20 mm long bolts, use a torque of 30–38 N·m (22–28 lb·ft).
   2. Torque the support bracket-to-cylinder block bolts to 58 - 73 N·m (43 - 54 lb·ft).

   EYE INJURY ‪
   To avoid injury from flying parts when working with components under spring tension, wear adequate eye protection (face shield or safety goggles).‪

9. Install the hose clamps onto the hoses. Install the coolant supply and return lines and connect them to the air compressor.
10. Install the lubricating oil supply line to the air compressor.
11. Install the air lines to and from the compressor.
12. Refer to "2.8.6 Installation of Air Compressor-Driven Fuel Pump (One-piece Drive Shaft)" and install the air compressor-driven fuel pump.
13. Refer to "14.6.4 Cooling System" and fill the cooling system.

    PERSONAL INJURY ‪
    Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.‪ Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.

14. Start the engine and check for leaks.

Section 11.1.4
Replacement of the Original-type Air Compressor

Detroit Diesel does not service the original-type air compressor. Service of the original-type air compressors should be referred to an authorized service center of the original equipment manufacturer.‪

To replace the original-type air compressor, perform the following procedure. See Figure "Flowchart for Replacement of the Original-type Air Compressor" .‪

Figure 9. Flowchart for Replacement of the Original-type Air Compressor

Section 11.1.5
Cleaning and Removal of the Original-type Air Compressor

Precleaning is not necessary. ‪

Remove the air compressor as follow:‪

1. Disconnect the air lines to and from the compressor.
2. Disconnect the fuel pump lines.
3. Remove the fuel pump and drive coupling. Refer to "2.8.2 Removal of Fuel Pump (One-piece Drive Shaft)" .
4. Drain the cooling system. Refer to "14.6.4 Cooling System" .
5. Disconnect and drain the coolant supply and return lines at the air compressor.
6. Disconnect the lubricating oil supply line from the compressor.
7. Remove the bolts securing the air compressor support bracket to the cylinder block and air compressor.
8. Remove the support bracket.

   Note: Due to the cylinder block and compressor configuration, the upper inside air compressor-to-air compressor drive bolt is difficult to reach with standard tools. Compressor Wrench (J–35948) will facilitate removal and installation of this bolt.

9. Remove the five bolts that secure the air compressor to the air compressor drive assembly.
10. Slide the air compressor rearward to disengage the hub from the coupling.

Section 11.1.6
Inspection of Former Air Compressor

Refer to OEM guidelines to determine if the air compressor needs to be repaired or replaced.‪

Section 11.1.7
Pressure Relief Installation

Use the following procedure to install the air compressor pressure relief valve:‪

PERSONAL INJURY ‪
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪

1. Disconnect the battery terminals to prevent accidental engine start-up.
2. Carefully relieve air compressor system pressure by slowly opening the air storage tank drain valve or by loosening an air line. Allow all pressure to drain from the system.
3. Remove an unused compressor discharge port plug on the top or side of the compressor head. See Figure "Location of Bendix Air Compressor Pressure Relief Valve" .
   

   Figure 10. Location of Bendix Air Compressor Pressure Relief Valve

   NOTICE:
   To prevent possible damage to the valve, do not install with a crescent wrench or locking pliers and do not exceed required torque.‪

4. Threads on the pressure relief valve are precoated with sealant; so no additional sealant is required. Install the valve into the compressor port and, using a 7/8 in. (No. 14 metric) deep socket, carefully torque the valve to 23-31 N·m (17-23 lb·ft).
5. Close the air tank drain valve or retighten the air supply line, if previously loosened.
6. Refer to "11.1.3 Installation of Adaptorless Air Compressor" for the exhaust caution before proceeding. Reconnect the battery terminals, start the engine, and check for leaks.

Section 11.1.8
Installation of Former Air Compressor

Install the air compressor as follows:‪

1. Clean all gasket material from the mating surfaces of the air compressor and air compressor drive.
2. Using a new gasket, install the air compressor to the air compressor drive.
3. Align the bolt holes of the two components and install the air compressor-to-air compressor drive bolts. Torque the bolts to 101-126 N·m (75-93 lb·ft). Use compressor wrench (J–35948) to tighten the upper-inside bolt.
4. Install the air compressor support bracket to the compressor and cylinder block. Torque the support bracket-to-air compressor bolts to 18-23 N·m (13-17 lb·ft).
5. Torque the support bracket-to-cylinder block bolts to 58-73 N·m (43-54 lb·ft).

   EYE INJURY ‪
   To avoid injury from flying parts when working with components under spring tension, wear adequate eye protection (face shield or safety goggles).‪

6. Install the coolant supply and return lines from the cylinder block and connect to the air compressor using four spring type hose clamps.
7. Install the lubricating oil supply line to the compressor.

   EXPLOSION ‪
   The air intake manifold contains combustible gas. To avoid injury from explosion, do not connect the air inlet manifold to any devices or lines external to the manifold.‪

8. Install the air lines to and from the compressor.
9. If the unit has a compressor-driven fuel pump, install the fuel pump. Refer to "2.8.6 Installation of Air Compressor-Driven Fuel Pump (One-piece Drive Shaft)" .
10. Refer to "14.6.4 Cooling System" to fill the cooling system.