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SERIES 60 AIR COMPRESSOR/RAW WATER PUMP DRIVE ASSEMBLY

The air compressor/marine engine raw water pump drive assembly mounts to the rear of the gear case on the intake side of the engine. See Figure 20153 . ‪

1. Plain Washers (Shims) ‪

8. Flange Nut, Drive Hub ‪

2. Short Bolt (1) ‪

9. Long Bolt, Drive Housing ‪

3. Housing, Drive ‪

10. Shaft, Drive ‪

4. Ball Bearing, Air Compressor Drive ‪

11. Gear, Drive ‪

5. Snap Ring ‪

12. Bolt, Drive Gear ‪

6. Spacer ‪

13. Gasket ‪

7. Hub, Drive ‪

14. Gear Case ‪

Air Compressor/Raw Water Pump Drive Detail and Location of Parts

A drive gear meshes with the bull gear and is driven at a ratio of 1.19:1. ‪

The drive gear is bolted to the air compressor /raw water pump drive shaft. A drive hub is installed onto the opposite end of the air compressor drive shaft, and is used to drive the air compressor or raw water pump. On vehicles with power steering, a short splined coupling connects the drive gear to the power steering pump. The coupling is inserted in the splined center of the air compressor drive gear. ‪

Two composition gaskets are used, one to seal the air compressor drive housing to the gear case, and one to seal the air compressor or raw water pump to the drive housing. ‪

Two air compressor drives have been used on Series 60 engines. The current drive assembly, see Figure 20153 , differs from the former, see Figure 20550 , in that it does not have an external oil supply, and only one bearing assembly is used to support the drive shaft. ‪

1. Bolt, Air Compressor Drive Gear ‪

11. Short Bolt (1) ‪

2. Gear, Air Compressor Drive ‪

12. Long Bolt, Air Compressor Drive Housing ‪

3. Shaft, Air Compressor Drive ‪

13. Plug, Air Compressor Housing ‪

4. Inner Race Bearing ‪

14. Plain Washers (Shims) ‪

5. Small Snap Ring ‪

15. Rear Roller Bearing ‪

6. Large Snap Ring ‪

16. Large Snap Ring ‪

7. Front Roller Bearing ‪

17. Hub, Air Compressor Drive ‪

8. Gear Case ‪

18. Flange Nut, Air Compressor Drive Hub ‪

9. Gasket ‪

19. "T" Fitting ‪

10. Housing, Air Compressor Drive ‪

Former Air Compressor Drive Detail and Location of Parts

Disassembly and assembly of the two drives are similar. Differences in the disassembly and assembly procedures are detailed in this section. ‪

Replacement of Air Compressor/Raw Water Pump Drive Assembly

To replace the air compressor/raw water pump drive assembly, perform the following procedure. See Figure 36029 . ‪

Flowchart for Replacement of Air Compressor/Raw Water Pump Drive Assembly

Removal of Air Compressor/Raw Water Pump Drive Assembly

Remove the drive assembly as follows: ‪

  1. If equipped, remove the air compressor or raw water pump. Refer to section and refer to section .
  2. If equipped with power steering, loosen and remove the five bolts securing the power steering pump and cover assembly to the gear case cover.
  3. Remove the pump and cover assembly.
  4. Remove the power steering drive coupling from the air compressor /raw water pump drive gear.
  5. Disconnect the oil supply lines from the "T" fitting, if applicable, at the top of the air compressor /raw water pump drive housing. See Figure 20550 .
  6. Remove the six bolts that secure the drive assembly to the gear case.
  7. Remove the assembly by pulling it straight out of the gear case.

Disassembly of Air Compressor/Raw Water Pump Drive Assembly

Disassemble the drive assembly as follows: ‪

  1. Secure the holding fixture, see Figure 20546 , in a suitable vise with the drive coupling facing up. See Figure 35448 .

    Air Compressor/Raw Water Pump Drive Hub Disassembly

  2. Position the drive assembly onto the holding fixture, engaging the internal teeth of the drive gear with the coupling on the holding fixture.
  3. Loosen and remove the flanged nut retaining the drive hub to the drive shaft.
  4. Remove the drive hub from the drive assembly.
  5. Remove the spacer from the drive shaft (current air compressor/raw water pump drive only).
  6. Remove the drive assembly from the holding fixture and place on bench.
  7. Remove the four bolts that secure the drive gear to the drive shaft flange and remove gear.
  8. Use the air compressor and fan drive service tool set, J 36310-A , for disassembly. See Figure 20598 .

    Air Compressor and Fan Drive Service Tool Set

  9. Support the air compressor/raw water pump drive housing on press plates with the drive hub side facing up.
  10. Press the drive shaft out of the drive housing.

    Note: Whenever the drive shaft is removed from the housing, the ball bearing assembly must be replaced.

  11. Remove the large snap ring retaining the ball bearing in the drive hub housing using snap ring pliers. See Figure 20552 .

    Roller Bearing Snap Ring Removal

  12. On current design drive only, turn the drive housing over and support it on the press bed.
  13. Using the narrow end of J 36310-6 part of J 36310A , against the bearing, press the bearing from the housing.
  14. Discard the bearing.

    Note: The next seven steps apply only to the former design air compressor drive.

  15. Using the snap ring pliers, turn the drive assembly over, and remove the large snap ring retaining the roller bearing in the air compressor drive housing. See Figure 36044 .

    Ball Bearing Snap Ring Removal

    Note: Whenever the bearings are removed from the housing, the bearing assemblies must be replaced.

  16. Install J 26941 , under the bearing. See Figure 20554 .

    Bearing Remover

  17. Tighten the thumb screw on the bearing remover until it is snug against the bearing.
  18. Install a suitable slide hammer to the top of the bearing remover. Remove the bearing.
  19. Repeat this procedure to remove the other bearing from the housing.
  20. Using snap ring pliers, remove the small snap ring retaining the roller bearing inner race on the air compressor drive shaft. See Figure 36044 .

    Roller Bearing Inner Race Snap Ring Removal

  21. Using a punch and hammer, work through the two access holes to drive the roller bearing inner race from the air compressor drive shaft. See Figure 20556 .

    Note: Whenever the roller bearing inner race is removed from the shaft, the roller bearing assembly must be replaced.

    Bearing Inner Race Removal

Cleaning of Air Compressor/Raw Water Pump Drive Assembly

Clean the air compressor/raw water pump drive assembly prior to inspection as follows: ‪

  1. Clean all of the parts with clean fuel oil.

    EYE INJURY

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  2. Dry with compressed air.
Inspection of the Air Compressor Drive Assembly

Inspect the air compressor drive assembly as follows: ‪

  1. Visually inspect the drive shaft for galling, pitting, cracks, or other damage.
    1. If drive shaft has galling, pitting, cracks, or other damage, replace with new part.
    2. If drive shaft has no damage, reuse part.

Assembly of Air Compressor/Raw Water Pump Drive Assembly

Assemble the air compressor/raw water pump drive assembly as follows: ‪

Note: The first four steps apply to the former air compressor drive assembly only. If rebuilding a current design air compressor/raw water pump drive assembly, begin with step .

  1. Install the roller bearing inner race to the air compressor drive shaft using a press and J 36310-4, part of J 36310A . See Figure 36043 .

    Note: The identification numbers on the race must face the installer. Be sure the race is firmly seated against the shoulder on the drive shaft.

    Bearing Inner Race Installer

  2. Install the small snap ring to the drive shaft using snap ring pliers.

    Note: Ensure the snap ring is fully seated in its groove on the drive shaft. See Figure 36042 .

    Bearing Inner Race Snap Ring Installation

  3. Install the roller bearing in the air compressor drive housing using J 36310-2, part of J 36310A . Ensure that the bearing is fully seated in the housing far enough for the snap ring to be installed. See Figure 36041 .

    Note: The bearing identification numbers must face the installer.

    Roller Bearing Installation

  4. Install the snap ring retaining the roller bearing in the drive housing using snap ring pliers. See Figure 35449 .

    Note: Ensure the snap ring is fully seated in its groove in the housing.

    Snap Ring Installation

    Note: The first four steps apply to the former air compressor drive assembly only. If rebuilding a current design air compressor/raw water pump drive assembly, begin with the following step.

  5. Turn the housing over.
  6. Install the ball bearing in the drive housing using a press and the large end of the ball bearing installer, pressing only on the outer race of the bearing. See Figure 35450 .

    Note: There is a plastic sleeve in the current design ball bearing which must not be removed when installing the bearing. The sleeve will be pushed out when the drive shaft is installed.

  7. Be sure the bearing is fully seated against the shoulder in the housing for the snap ring to be installed. See Figure 35450 .

    Note: The bearing identification numbers must face the installer when installing the bearing.

    Ball Bearing Installation

  8. Install the snap ring retaining the ball bearing in the housing using snap ring pliers. See Figure 35449 .

    Note: Ensure the snap ring is fully seated in its groove in the housing.

    Snap Ring Installation

  9. Lubricate the roller bearing inner race with clean engine oil. See Figure 35451 .

    Bearing Inner Race Lubrication

  10. Place the drive shaft, flange side down, on a press bed.
  11. Carefully position the drive housing over the shaft, and lower the housing down as far as it will go without forcing it.
  12. Place the small end of the ball bearing installer, J 36310-1 part of J 36310A , against the ball bearing inner race. Press the ball bearing and housing down onto the drive shaft until the ball bearing inner race is firmly seated against the shoulder of the drive shaft. See Figure 36040 .

    Air Compressor Drive Shaft Installation (Former Design)

    Note: The previous four steps apply to the former design air compressor drive only. If assembling a current design air compressor/raw water pump drive, go to the next step.

  13. Place wide end of ball bearing installer, J 36310-6, part of J 36310A , on press bed. See Figure 36039 .

    Air Compressor/Raw Water Pump Drive Shaft Installation (Current Design)

  14. Place the drive housing on the bearing installer, ensuring that the installer is centered on the bearing inner race.
  15. Position the drive shaft in the bearing inner race.
  16. Press the drive shaft into the bearing and housing assembly until the shaft shoulder is seated against the bearing inner race.
  17. Remove the drive assembly from the tool, and remove the plastic sleeve from inside the tool.
  18. Discard the plastic sleeve.
  19. Install the drive gear to the shaft. See Figure 35452 .

    Air Compressor Drive Shaft Installation (Former Design)

  20. Install the four drive gear-to-drive shaft bolts and torque to 58-73 Nm (43-54 lbft).
  21. Secure the holding fixture, see Figure 20546 , in a suitable vise with the drive coupling positioned up. See Figure 35448 .

    Air Compressor Drive Shaft Installation (Former Design)

  22. Position the drive assembly on the holding fixture, engaging the internal teeth of the drive gear with the coupling on the fixture.
  23. Lubricate the ball bearing with clean engine oil.
  24. Place the spacer on the drive shaft (current design only), seating it against bearing inner race. Install the drive hub on the drive shaft. See Figure 35453 .
  25. Torque flanged nut to 298-346 Nm (220-255 lbft).

    Air Compressor/Raw Water Pump Drive Hub Installation

  26. Remove the drive assembly from the holding fixture and position it on a suitable flat surface with the drive gear facing up.
  27. Assemble a dial indicator and magnetic base so that the indicator stem rests on the face of the drive gear just inboard of the drive gear teeth. See Figure 20566 .

    Air Compressor Drive Shaft Installation (Former Design)

  28. Zero the dial indicator.
  29. Rotate the drive gear two full revolutions. As the gear is rotated, the dial indicator may register both to the left and right of zero. The total amount the indicator needle moves to the left and right of zero, added together, gives the total indicated run-out (TIR).
  30. If maximum TIR exceeds 0.08 mm (0.003 in.), it may be necessary to repeat the assembly procedure until the cause can be detected and eliminated.

Installation of Air Compressor/Raw Water Pump Drive Assembly

Install the air compressor/raw water pump drive assembly as follows: ‪

  1. On engines manufactured through unit serial no. 06R175824, install two 1.5 mm x 10.0 mm (0.375 in. x 0.060 in.) flat washers under each of the six air compressor drive mounting bolts. Engines built after serial no. 06R175825 do not require the addition of washers to mounting bolts.
  2. Install the drive assembly to its original position in the gear case, using a new gasket between the housing and gear case. Install the bolts (and washers, if required) that secure the drive assembly to the gear case.

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

  3. Torque the five bolts and one nut to 58 - 73 Nm (43 - 54 lbft), using the required torque pattern. See Figure 39784 .

    Bolt Torque Sequence

  4. Measure the bull gear-to-drive gear lash. Refer to section
  5. Install the access cover. Use a new gasket between the access cover and the gear case cover, and torque the five bolts to 30-38 Nm (22-28 lbft) in a star-shaped tightening pattern.
  6. If the engine is equipped with a power steering pump, install the proper steering drive coupling and power steering pump and cover assembly to the gear case cover. Install a new gasket between the cover and the gear case cover, and torque the 5 bolts to 30-38 Nm (22-28 lbft) in a star-shaped tightening pattern.
  7. Connect the oil supply line at the Tee fitting, if applicable, at the top of the air compressor/raw water pump drive housing.
  8. Install the air compressor. Refer to section .

    Note: For engines used in coach applications, a high strength air compressor supply hose must be installed between the intake manifold and the air compressor inlet. This hose can be identified by the light blue color on the inside of the hose. Flat band spring type hose clamps must be used.

    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 any other components that were removed for this procedure.