A1 - DDCSN
Contents
1. Drive Seal Installer All information subject to change without notice 1 543a From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 17 Measure sleeve and seal run out using J 45877 part of toolset J 36024 D and a dial indicator Total indicator deflection should not exceed 0 0762 mm 0 003 in for the sleeve and 0 1778 mm 0 007 in for the seal If the run out is greater for either measurement install a new seal See Figure 1 435b J 45877 42561 1 Dial Indicator 2 Seal Sleeve Figure 1 435b J 45877 Seal Run Out Gauge Adaptor 18 Install the accessory drive pulley to the shaft NOTE If necessary use tool J 36024 1A part of toolset J 36024 D to seat the pulley on the shaft If pressing is necessary the opposite gear end of the shaft must be supported during the pressing operation 19 Attach J 36024 3 part of toolset J 36024 D to the drive gear See Figure 1 418 20 Place the accessory drive assembly holding fixture into a vise See Figure 1 436 All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 543b 1 28 ACCESSORY DRIVE 21 Install and torque the accessory drive pulley locknut to 360 400 N m 266 295 lb ft See Figure 1 436 TORQUE WRENCH Figure 1 436 Accessory Drive Pulley Locknut Tightening All information subject to change without n2. at 2 41 times engine speed The drive shaft is supported by a ball bearing at the drive end and a needle bearing at the pulley end NOTE A design change has been made to the accessory drive assembly The needle bearing inner race is now incorporated into the drive shaft See Figure 1 413 and see Figure 1 414 An O ring is used to seal the accessory drive housing to the gear case cover All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 521 1 28 ACCESSORY DRIVE 1 28 1 Repair and Replacement of the Accessory Drive To determine if repair is possible or replacement is necessary perform the following procedures See Figure 1 415 REMOVE ACCESSORY DRIVE DISASSEMBLE ACCESSORY DRIVE INSPECT ACCESORY DRIVE GALLED PITTED CRACKED OR DAMAGED REPLACE ASSEMBLE ACCESSORY DRIVE INSTALL Figure 1 415 Flowchart for Repair or Replacement of Accessory Drive All information subject to change without notice 1 522 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 1 28 2 Removal and Cleaning of the Accessory Drive Precleaning is not necessary Remove the accessory drive as follows 1 Loosen the alternator mounting bolts and the adjusting rod nuts to get slack in the alternator drive belts Remove
3. the alternator drive belts Refer to section 13 13 10 2 Remove the five bolts that secure the accessory drive assembly to the gear case cover 3 Remove the accessory drive assembly by pulling it straight out of the gear case cover to avoid damaging the rubber O ring See Figure 1 416 ACCESSORY DRIVE ASSEMBLY Figure 1 416 Accessory Drive Assembly Removal All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 523 1 28 ACCESSORY DRIVE 1 28 3 Disassembly of the Accessory Drive Disassemble the accessory drive as follows NOTE For disassembly and assembly of the accessory drive use toolset J 36024 D See Figure 1 417 NOTE Effective with engine serial number 6R631428 for accessory drive seal removal and installation use the following tools J 45533 seal remover J 45833 seal installer and J 45877 seal runout gauge adapter to verify proper installation of seal in accessory drive These tools are part of toolset J 36024 D See Figure 1 417 J 36024 3 J 36024 2 J 36024 1A J 36024 4 J 45833 J 45877 42610J Figure 1 417 Accessory Drive Service Tool Set J 36024 D All information subject to change without notice 1 524 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 1 Attach the accessory drive gear to the holding fixture J 36024 3 part of tools
4. AL 16 Remove the snap ring from the accessory drive shaft See Figure 1 424 SNAP RING FORMER SHAFT DESIGN CURRENT SHAFT DESIGN Figure 1 424 Snap Ring Removal All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 531 1 28 ACCESSORY DRIVE 17 Position two steel press plates under the ball bearing outer race See Figure 1 425 FORMER DESIGN SHAFT CURRENT DESIGN SHAFT STEEL PLATES Figure 1 425 Position of the Steel Press Plates NOTE Whenever the needle or ball bearing is removed from the shaft they MUST be replaced with new bearing assemblies 18 Use a press to apply pressure to the top of the shaft and remove the ball bearing from the shaft All information subject to change without notice 1 532 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 1 28 3 1 Inspection of the Accessory Drive Clean the accessory drive prior to inspection as follows 1 Clean all of the parts with clean fuel oil 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 parts with compressed air Inspect the accessory drive as follows 1 Visually examine the drive shaft for damage check the drive shaft for galling pitting cracks or other damage a If any damag
5. SERIES 60 SERVICE MANUAL 1 28 ACCESSORY DRIVE The accessory drive assembly is mounted to the front of the gear case cover and utilizes a two groove pulley to drive the alternator See Figure 1 413 and see Figure 1 414 1 Locknut 8 Drive Gear 2 Mounting Bolts 5 9 O ring 3 Drive Housing 10 Gear Case Cover 4 Snap Ring Small 11 Bearing Inner Race 5 Ball Bearing 12 Needle Bearing 6 Snap Ring Large 13 Oil Seal 7 Drive Shaft 14 Pulley Figure 1 413 Accessory Drive Assembly Related Parts Former Design All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 519 1 28 ACCESSORY DRIVE lt 4 S 1 Locknut 8 Drive Gear 2 Mounting Bolts 5 9 O Ring 3 Drive Housing 10 Gear Case Cover 4 Snap Ring Small 11 Needle Bearing 5 Ball Bearing 12 Oil Seal 6 Snap Ring Large 13 Pulley 7 Drive Shaft Figure 1 414 Accessory Drive Assembly Related Parts Current Design All information subject to change without notice 1 520 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL The accessory drive assembly is splash fed oil through two holes in the casting of the accessory drive housing The oil returns to the crankcase via the gear case The accessory drive is driven by a drive gear which is pressed onto the drive shaft The drive gear meshes with the bull gear and is driven
6. e is detected replace with a new part b If no damage is found reuse the part All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 533 1 28 ACCESSORY DRIVE 1 28 4 Assembly of the Accessory Drive Assemble the accessory drive as follows 1 Place a new ball bearing on the accessory drive shaft Use tool J 36024 1A part of toolset J 36024 D and a press to install the bearing onto the shaft until it bottoms out against the shoulder of the drive shaft See Figure 1 426 J 36024 1A BEARING Figure 1 426 Bearing Installation All information subject to change without notice 1 534 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 2 Install the snap ring to the accessory drive shaft making sure it is fully seated in the groove a full 360 degrees See Figure 1 427 SNAP RING FORMER SHAFT DESIGN CURRENT SHAFT DESIGN Figure 1 427 Snap Ring Installation All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 535 1 28 ACCESSORY DRIVE 3 Place the needle bearing inner race on the accessory drive shaft Use tool J 36024 1A part of toolset J 36024 D and a press to install the bearing inner race to the shaft until it is tight against the shoulder See Figure 1 428 NOTE On current design accessory dri
7. et J 36024 D using the three bolts provided See Figure 1 418 J 36024 3 HOLDING FIXTURE MOUNTING BOLTS Figure 1 418 Holding Fixture All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 525 1 28 ACCESSORY DRIVE 2 Place the accessory drive assembly holding fixture into a vise See Figure 1 419 ACCESSORY DRIVE a LOCKNUT 20291 Figure 1 419 Accessory Drive Pulley Locknut Removal 3 Remove the accessory drive pulley locknut See Figure 1 419 4 Remove the accessory drive pulley by tapping it with a rubber hammer or fiber mallet If the pulley does not come off easily use a puller to remove it All information subject to change without notice 1 526 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL J 45533 42559 1 Seal Sleeve Figure 1 419a J 45533 Accessory Drive Seal Remover NOTE Perform steps 5 6 and 7 unitized seal removal procedure for accessory drive assemblies effective with engine serial number 6R631428 5 Using J 45533 part of toolset J 36024 D remove seal sleeve a Ensure taper end of puller bolt is pointed toward inside jaws b Place inside jaws of tool over sleeve See Figure 1 419a c Finger tighten hex bolt on side of tool d Remove sleeve by tightening puller bolt All information subject to change with
8. f engine oil 8 Support the holding fixture J 36024 3 part of toolset J 36024 D on two steel plates and position the accessory drive housing into the hole in the fixture See Figure 1 421 All information subject to change without notice 1 538 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 9 Install the drive shaft to the housing See Figure 1 431 DRIVE SHAFT ASSEMBLY J 36024 3 Figure 1 431 Drive Shaft Installation 10 Press the drive shaft into the housing by placing tool J 36024 1A part of toolset J 36024 D on the bearing outer race All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 539 1 28 ACCESSORY DRIVE 11 Press the bearing into the housing until the bearing is seated against the shoulder of the housing See Figure 1 432 DRIVE SHAFT ASSEMBLY J 36024 3 Figure 1 432 Bearing Installation All information subject to change without notice 1 540 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 12 Install the snap ring to the accessory drive housing making sure the snap ring is fully seated in the groove a full 360 degrees See Figure 1 433 Figure 1 433 Snap Ring Installation 13 Lubricate the contact surfaces of the bearing with clean engine lubricating oil All information subject
9. otice 1 544 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 22 Support the accessory drive assembly See Figure 1 437 DIAL INDICATOR Figure 1 437 Accessory Drive Gear TIR Measurement 23 Assemble a dial indicator and magnetic base so that the indicator stem rests on the face of the accessory drive gear just inboard of the drive gear teeth See Figure 1 437 24 Zero the dial indicator 25 Rotate the drive gear two full rotations See Figure 1 437 As the gear is rotated the dial indicator needle may register both to the left and right of zero 26 The total amount the dial indicator needle moves to the left and right of zero added together gives the total indicated run out TIR The specified TIR is 0 04 mm 0 0015 in All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 545 1 28 ACCESSORY DRIVE 1 28 5 Installation of the Accessory Drive Install the accessory drive as follows 1 Install the O ring seal in the groove on the drive housing 2 Lubricate the O ring with petroleum jelly 3 Install the accessory drive housing to its original position in the gear case cover NOTE The word UP is cast into the drive housing 4 Install the bolts that secure the accessory drive housing to the gear case cover and torque to 30 38 N m 22 28 lb ft using the pattern sh
10. out notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 526a 1 28 ACCESSORY DRIVE 6 Removal of seal a Invert puller bolt See Figure 1 419b J 45533 42560 Figure 1 419b J 45533 Invert Puller Bolt b Loosen hex bolt on side of tool c Using a rubber mallet gently drive outside jaws between seal and shaft through the rubber membrane of seal until tool bottoms out d Finger tighten hex bolt on side of tool e Remove seal by tightening puller bolt 7 Clean accessory drive housing at seal location All information subject to change without notice 1 526b From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 8 Position the accessory drive assembly on a press bed with the holding fixture supported See Figure 1 420 J 36024 3 ACCESS HOLE SUPPORT PLATE Figure 1 420 Accessory Drive Gear Removal 9 Using a press apply pressure through the access hole in the holding fixture J 36024 3 part of toolset J 36024 D and press the drive shaft out of the gear See Figure 1 420 All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 527 1 28 ACCESSORY DRIVE 10 Remove the snap ring from the accessory drive housing See Figure 1 421 Figure 1 421 Snap Ring Removal 11 Turn the hou
11. own See Figure 1 438 Figure 1 438 Accessory Drive Housing Bolt Torque Sequence 5 Check the bull gear to accessory drive gear backlash Refer to section 1 21 2 1 6 Adjust the alternator belts Refer to section 13 13 10 7 Tighten the alternator mounting bolts 8 Install any other components removed for this procedure 9 Refer to section 11 3 for verification of proper accessory drive installation All information subject to change without notice 1 546 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION
12. sing over and support the accessory drive housing on the machined surface using V blocks 12 Using a press apply pressure to the pulley end of the shaft and remove the shaft and bearing assembly 13 Turn the accessory drive housing over and support it on the attaching bolt bosses using V blocks NOTE On current design the shaft serves as the inner race for the needle bearing All information subject to change without notice 1 528 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL NOTICE For assemblies with inner race for needle bearing place the accessory drive shaft in a vise with soft jaws taking care not to damage the shaft surface 14 Install J 36024 2 part of toolset J 36024 D and apply pressure to remove the needle bearing See Figure 1 422 J 36024 2 coe Figure 1 422 Needle Bearing Removal All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 529 1 28 ACCESSORY DRIVE 15 Remove the needle bearing inner race from the accessory drive shaft with a two jaw puller utilizing the slots provided in the shaft See Figure 1 423 TWO JAW PULLER Figure 1 423 Bearing Inner Race Removal All information subject to change without notice 1 530 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANU
13. to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 541 1 28 ACCESSORY DRIVE 14 A film of Lubriplate must be applied to the drive gear end of the accessory drive shaft See Figure 1 434 DRIVE GEAR Figure 1 434 Drive Gear Installation Preparation All information subject to change without notice 1 542 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 15 Use a press to install the drive gear on the accessory drive shaft until it is flush with the drive shaft end Make sure the three threaded holes are facing up See Figure 1 435 NOTE Support the opposite end of the drive shaft on the press bed when pressing the gear on the shaft A minimum press load of 17 8 kN 4000 Ib must be obtained when pressing the gear on the shaft ACCESSORY DRIVE GEAR Figure 1 435 Accessory Drive Gear Installation All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 543 1 28 ACCESSORY DRIVE NOTE For accessory drive assemblies effective with engine serial number 6R631428 perform the procedures in steps 16 and 17 16 Install seal using J 45833 part of toolset J 36024 D by tightening installer nut until a positive stop is obtained See Figure 1 435a J 45833 J 36024 3 42558 1 Vise Figure 1 435a J 45833 Accessory
14. ve shaft the needle bearing inner race is incorporated into the shaft J 36024 1A NEEDLE BEARING INNER RACE Figure 1 428 Needle Bearing Inner Race Installation All information subject to change without notice 1 536 From Bulletin 2 60 02 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 4 Install the needle bearing to the accessory drive housing using tool J 36024 2 part of toolset J 36024 D See Figure 1 429 e w lt D NEEDLE BEARING Pe Figure 1 429 Needle Bearing Installation NOTE The end of the bearing with the identification numbers must be against the installer NOTE The word INSTALL and an arrow are etched into the tool J 36024 2 part of toolset J 36024 D to facilitate correct bearing installation All information subject to change without notice 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 2 60 02 1 537 1 28 ACCESSORY DRIVE 5 Lubricate the oil seal contact area of the accessory drive housing with a thin film of engine oil 6 Install the accessory drive oil seal to the accessory drive housing using the seal installer J 36024 4 part of toolset J 36024 D and a plastic hammer or fiber mallet The oil seal must be installed flush to 0 25 mm 0 010 in below the face of the housing See Figure 1 430 g ene as OIL SEAL Figure 1 430 Accessory Drive Oil Seal Installation 7 Lubricate the oil seal with a thin film o
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