Section 11

Special Equipment

Section 11.1
Air Compressor

The Series 60 air compressor is mounted to the rear of the gear case on the left side of the engine.

The 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. 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.

Detroit Diesel Corporation offers two sizes of air compressors on Series 60 engines: the single cylinder
BA–921 rated at 16 cubic feet per minute (cfm), and the twin cylinder BA–922 rated at 32 cubic feet per
minute (cfm). Both compressors are adaptorless style installations.See Figure "Air Compressors BA-922
and BA-921" .

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 air compressor is designed to permit direct installation of the compressor onto the gear case. See
Figure "Air Compressors BA-922 and BA-921" .

 1. Twin Cylinder BA-922 (32 CFM)  2. BA-921 (16 CFM)

Figure 1. Air Compressors BA-922 and BA-921

The Series 60 air compressor is flange-mounted to the rear of the gear case, located on the left side of the
engine.
Figure 2. Air Compressor Mounting

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. See Figure "Air Compressor Mounting" .

Section 11.1.1
Replacement of Air Compressor

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

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

Figure 3. Flowchart for Replacement of Air Compressor

Section 11.1.2
Cleaning and Removal of Air Compressor

Precleaning is not necessary.

Remove the 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 "2.4.2 Removal of Fuel Pump" .
4. Drain the cooling system. Refer to "14.4.4 Cooling System" .
5. Disconnect and drain the coolant supply and return lines at the air compressor.
6. Remove the bolts securing the air compressor support bracket to the cylinder block and air
compressor.See Figure "Air Compressor and Related Parts" .

 1. Bolt M10 1.50 x 85  6. Hose

 2. Bolt M10 1.50 x 35  7. Tube

 3. Hose  8. Air Compressor Bracket

 4. Air Compressor  9. Bolt M10 1.5 x 20

 5. Elbow
 Figure 4. Air Compressor and Related Parts

7. 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.

8. Remove the five bolts that secure the air compressor to the gear case.
9. Slide the air compressor rearward to disengage the hub from the coupling.

Section 11.1.2.1
Inspection of Air Compressor

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

Section 11.1.3
Installation of Air Compressor

Install the 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 previously removed, install the air compressor to its original
location on the gear case.
4. For air compressor torque sequence see Figure "Bolt Torque Sequence for Air Compressor" .
Torque the five bolts to 58-73 N·m (43-54 lb·ft).
 Figure 5. Bolt Torque Sequence for Air Compressor

5. Refer to "1.21.2.1 Check Engine Timing"step 10 and check the bull gear-to-air compressor drive
gear lash measurement.
6. Refer to "1.21.2.1 Check Engine Timing"step 10 and install the power steering pump drive
coupling, power steering pump, and cover assembly to the gear case cover.
7. Install the 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 (cit25)

To avoid injury from flying parts when working with components under spring
tension, wear adequate eye protection (face shield or safety goggles).
8. Install the hose clamps onto the hoses. Install the coolant supply and return lines and connect them
to the air compressor.
9. Install the lubricating oil supply line to the air compressor.
10. Install the air lines to and from the compressor.
11. Refer to "2.4.5 Installation of Air Compressor-Driven Fuel Pump" and install the air compressor-
driven fuel pump.
12. Refer to "14.4.4 Cooling System" and fill the cooling system.
 PERSONAL INJURY (eng16)
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.

o Always start and operate an engine in a well ventilated area.

o If operating an engine in an enclosed area, vent the exhaust to the outside.
o Do not modify or tamper with the exhaust system or emission control system.
2. Start the engine and check for leaks.

Section 11.1.4
Pressure Relief Installation

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

PERSONAL INJURY (eov84)

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 6. 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. 22 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 Air Compressor" for the exhaust caution before proceeding.
Reconnect the battery terminals, start the engine, and check for leaks.

EPA07 Series 60 Workshop Manual (DDC-SVC-MAN-0005)

Copyright © 2012 by Detroit Diesel Corporation. All rights reserved.

Generated on 02-14-2012

Section 11.2
Air Compressor Unloader Valve

The air compressor is driven by the engine and functions continuously when the engine is in operation.
The function of the unloader valve allows the air compressor to operate in an “unloaded” state, where the
compressor piston continues to reciprocate, but does not build additional air pressure in the vehicle’s
compressed air system. Located within the cylinder head, the unloader valve assembly (in conjunction
with the governor) controls whether the air compressor operates in a loaded or unloaded state.

When the vehicle air pressure system is above the minimum threshold, air pressure from the governor acts
on the unloader piston, lifting it off its seat. With the unloader valve unseated, air from the cylinder flows
into a small chamber in the head instead of into the vehicle’s compressed air system. Air then cycles
between the cylinder and chamber in the head until the unloader valve is seated once again.

When the vehicle air pressure system is below the minimum threshold, no air pressure is sent to the
unloader valve. With the unloader valve seated, the air compressor will build air pressure in the vehicle
compressed air system.

Note: Two-cylinder compressor requires two Unloader Valve Service Kits, one for each cylinder.
 1. Unloader Cap  6. O-ring

 2. Gasket  7. Unloader Piston

 3. Balance Piston  8. O-ring

 4. Spring  9. O-ring

 5. Splash Shield

Note: Air in piston shuttles back and forth from the piston to the closed room during unloaded operation.
 1. Air fom Governor Unloader  2. Closed  3. Unloader Piston Up and
Port Room Unseated

When the vehicle air pressure system is below the minimum threshold, no air pressure is sent to the
unloader valve. With the unloader valve seated, the air compressor will build air pressure in the vehicle
compressed air system.

 1. Inlet Valve Closed  5. Air Inlet Port

 2. Valve Plate  6. Discharge Valve Open

 3. Cooling Plate  7. Unloader Port

 4. Air Discharge Port  8. Piston Down and Sealed

Section 11.2.1
Removal of the Air Compressor Unloader Valve

Remove as follows:

1. Clean the area surrounding the unloader valve assembly.

2. Hold the unloader cap (1) in place to restrain the spring pressure and remove the two unloader cap
screws. Remove and discard the unloader cap (1) and gasket (2).

Note: For LK-862 two cylinder compressors, retain the original caps for re-assembly. For BA-921
single cylinder compressors, discard cap, but retain the splash shield.

3. Remove and discard the balance piston (3) and spring (4) from the cylinder head. Then remove
and discard the unloader piston (7) along with its three O-rings (6, 8, 9).
 4. Inspect the cylinder head bore for any scoring or damage. If damage is found, replace the
compressor.

Section 11.2.2
Installation of the Air Compressor Unloader Valve

Install as follows:

1. Clean the unloader piston bore in the cylinder head and inspect for any scoring or damage.
2. Using the lubricant provided, thoroughly lubricate and install the O-rings on the unloader piston
and lubricate the unloader piston bore in the cylinder head. It is recommended to utilize the entire
grease cartridge for each unloader valve assembly being installed.

Note: Install the largest and smallest O-rings to the outside of the piston.

3. Insert the spring into the unloader piston.

4. Lubricate the balance piston and insert the piston (smaller diameter first) into the spring
previously installed in the unloader piston.

Note: For the LK-862 two cylinder compressor, install the original unloader caps and discard the
caps supplied with the service kit. For the BA-921 single cylinder compressor, install the cap
supplied in the kit, and re-use the splash shield.

5. Position the unloader cap gasket on the cylinder head. Position the unloader cap (and splash shield
for the BA-921 single cylinder compressor) on top of the balance piston, making certain the cap is
oriented properly.
6. Using manual pressure, gently push the balance piston into the unloader piston until the unloader
cap rests against the cylinder head.
7. Install and torque the unloader cap screws to 7-8 N·m (62-71 lb·in.).

EPA07 Series 60 Workshop Manual (DDC-SVC-MAN-0005)

Copyright © 2012 by Detroit Diesel Corporation. All rights reserved.

Generated on 02-14-2012