Authorized Field Change

Transcript

Authorized Field Change AFC 10911R Date: August, 2010 Subject File: ENGINE Subject: Bendix Air Compressor on Certain MaxxForce® 7 and VT 365 Engines Model: 4200 Start Date: 02/05/2010 End Date: 05/10/2010 Model: 4300 Start Date: 02/05/2010 End Date: 05/10/2010 Model: CE Bus Start Date: 02/05/2010 End Date: 05/10/2010 Model: HC Bus Start Date: 02/05/2010 End Date: 05/10/2010 Engine Family: MaxxForce 7 Engine Family: VT 365 DESCRIPTION REVISION DESCRIPTION The model start and end build dates were updated. Certain truck and bus models (listed above), built with VT365 and MaxxForce® 7 engines between 02/05/2010 and 05/10/2010, may experience engine belt squealing and/or decreased belt life due to the air compressor mounting holes being located incorrectly on some air compressors. Some vehicles equipped with dual air conditioning (a/c) compressors may also have an incorrect idler spacer. This campaign will require the inspection and possible adjustment or replacement of the air compressor. In addition, if the compressor is not replaced, a tag will be attached to it to provide instructions for alignment during future repairs. On vehicles equipped with dual a/c compressors, the idler spacer washer will also be inspected. If an incorrect spacer washer is found, Tech Services must be contacted to acquire the correct spacer washer. PARTS INFORMATION Table 1 Parts Information Part Number Description Quantity 2606120C1 Metal tag, for air compressor mounting bolt As Required 2606121C1 Flat Washer for use with metal tag As Required 83817HB Gasket, for air compressor 1 3663598C91 Air compressor As Required Copyright © 2010 Navistar, Inc. All rights reserved. 1 PROCEDURE WARNING – To prevent vehicle damage, personal injury, or death, park the vehicle on a flat, level surface. Make sure the engine ignition is in the off position, and the transmission is in neutral or in the park position, if the vehicle is equipped with an automatic transmission. Set the parking brake, chock the wheels, and disconnect the batteries at the negative terminal before doing any service procedures on the engine or vehicle. WARNING – To prevent personal injury or death, do not allow engine fluids to remain on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. WARNING – To prevent personal injury or death, make sure that the engine has cooled before removing components. WARNING – To prevent personal injury or death, always wear safe eye protection when performing vehicle maintenance. WARNING – To prevent personal injury or death, get help when removing or installing the air compressor. The mounting position of the air compressor must be inspected to determine if adjustment or replacement of the compressor is necessary. If the inspection determines that the current compressor position is not within the stated specifications, adjustment of the compressor mounting will be attempted. If the compressor mounting position cannot be adjusted to within the required specifications, the compressor must be replaced. Each air compressor being inspected or adjusted will have a metal tag installed under the front-left mounting bolt. The tag (Figure 1) will provide the necessary information to correctly align the air compressor if it is removed for another repair at some time in the future. If the current air compressor is replaced with a new one, the metal tag is not necessary and will not be installed. Vehicles equipped with dual a/c compressors also require an inspection of an idler pulley spacer washer to determine if the idler pulley is positioned correctly. If an incorrect washer is found, Tech Services must be contacted to supply the correct washer. AFC–10911R 2 PROCEDURE (CONT.) Figure 1 Service Tag 1. Determine whether the vehicle is equipped with dual a/c compressors. • If the vehicle is not equipped with dual a/c compressors, proceed to step 4. • If the vehicle is equipped with dual a/c compressors, proceed to the next step. 2. Remove the drive belt that is running on the grooved idler pulley (Figure 2, Item 3). Figure 2 Belt Diagram for Vehicles with Dual A/C Compressors 1. 2. 3. 4. A/C COMPRESSOR AIR COMPRESSOR GROOVED IDLER PULLEY A/C COMPRESSOR 3. Remove the grooved idler pulley and measure the thickness of the spacer washer that is mounted behind the pulley. • If the washer thickness measures 1.0 mm (0.040”), reinstall the same washer and pulley, then proceed to the next step. • If the washer thickness measures 2.0 mm (0.080”), contact Tech Services to acquire the correct spacer washer. Contact Tech Services by opening a case file and referencing AFC 10911. After installing the correct spacer washer, proceed to the next step. 3 AFC–10911R PROCEDURE (CONT.) 4. Using feeler gauges, check the mounting position of the air compressor currently on the vehicle. Measure the distance between the shoulder of the front-left mounting bolt and the front edge of the compressor base flange (Figures 3 and 4). The distance must be between 0.8 mm (0.031”) and 4.3 mm (0.169”). • If the air compressor is currently mounted within the stated specifications, install the metal tag and a flat washer under the front-left-compressor mounting bolt. Install as follows: tag, flat washer, then bolt; and tighten bolt to 72 N•m (53 lbf-ft). Proceed to step 20. • If the air compressor position is not within the stated specifications, proceed to the next step. Figure 3 Flange Measure From Shoulder of Front-Left Mounting Bolt to Front Edge of Compressor Base Figure 4 Correct Mounting Bolt Location 1. 2. 3. 4. AFC–10911R BOLT HEAD BOLT SHOULDER COMPRESSOR BASE FLANGE COMPRESSOR MOUNTING BRACKET 4 PROCEDURE (CONT.) 5. Remove the drive belt from the air compressor pulley. (NOTE: Belt may have been removed in a previous step.) 6. Remove the four air compressor mounting bolts (Figure 5). Figure 5 Air Compressor Mounting Bolts 1. M10 X 30 BOLT 2. M10 X 45 BOLT (REAR-LEFT) WARNING – To prevent personal injury or death, get help when removing or installing the air compressor. NOTE – The rear-left mounting bolt is longer than the other mounting bolts. Insure that the long bolt is installed in the rear-left location when reinstalling the bolts. 7. While one person lifts the compressor, a second person must remove the old gasket, clean the gasket mounting surface if necessary, and install a new gasket (Figure 6). After verifying that the gasket is correctly positioned, lower the compressor into position. 5 AFC–10911R PROCEDURE (CONT.) Figure 6 Air Compressor Component Diagram 1. 2. 3. 4. 5. 6. 7. 8. COOLANT SUPPLY HOSE COMPRESSOR MOUNTING BOLT M10 X 30 COMPRESSOR MOUNTING BOLT M10 X 45 COOLANT RETURN HOSE OIL SUPPLY HOSE AIR COMPRESSOR GASKET COMPRESSOR MOUNTING BRACKET 8. While installing the four mounting bolts, attempt to adjust the compressor to the correct mounting position: between 0.8 mm (0.031”) and 4.3 mm (0.169”) as measured with the feeler gauges (Figures 3 and 4). • If the compressor can be mounted within the required specifications: A. Install the metal tag under the front-left-bolt as follows: tag, flat washer, then bolt. B. Tighten all four mounting bolts to 72 N•m (53 lbf-ft). C. Proceed to step 20. • If the compressor cannot achieve the required mounting specifications, the compressor must be replaced. Proceed to the next step. 9. Remove the pulley from the front of the compressor and set aside. The pulley will be installed on the new compressor. 10. Loosen the oil supply hose fitting nut and disconnect hose from air compressor (Figure 6). Position hose to prevent dripping. 11. Using hose pinch pliers, clamp the two compressor coolant hoses (Figure 6). AFC–10911R 6 PROCEDURE (CONT.) 12. Loosen the hose clamps securing the two coolant hoses to the air compressor and disconnect the hoses (Figure 6). Leave the loose hose clamps on the hoses. They will be used during reassembly. WARNING – To prevent personal injury or death, get help when removing or installing the air compressor. 13. Remove the four compressor mounting bolts (Figure 6). 14. Remove the air compressor (Figure 6). 15. Verify that the new gasket, installed in step 7, is undamaged and correctly positioned. 16. Place the new compressor into position and install the four compressor mounting bolts, with the long mounting bolt in the rear-left position (Figure 6). Tighten all four mounting bolts to 72 N•m (53 lbf-ft). 17. Connect the two coolant hoses to the air compressor and secure with the two hose clamps removed earlier (Figure 6). Release the hose pinch pliers on both hoses. 18. Connect the oil supply hose to the air compressor (Figure 6) and tighten the fitting nut to 20 N•m (177 lbf-in). 19. Install the pulley on the front of the new compressor. Tighten pulley nut to 120 N•m (88 lbf-ft). 20. Reinstall the engine drive belt(s). 21. If the vehicle is not equipped with dual a/c compressors, return the vehicle to service. If the vehicle is equipped with dual a/c compressors, proceed to the next step. 22. Start the engine and allow it to warm up for a few minutes. 23. Turn on both a/c systems and set the engine speed to 1600 rpm. 24. After 3 to 5 minutes verify that no belt squeal is heard. • If no belt squeal is heard, turn the engine off and return the vehicle to service. • If belt squeal is still heard, turn the engine off, and contact Tech Services by opening a case file and referencing AFC 10911. 7 AFC–10911R Operation number must appear on all claims. Table 2 Labor Information Operation No. Description Time A40–10911–1 Inspect air compressor mounting position and install tag only. No adjustment or replacement required. 0.4 hrs A40–10911–2 Inspect and adjust air compressor mounting position. Install tag. No replacement required. 0.7 hrs A40–10911–3 Inspect and replace air compressor. 2.9 hrs A40–10911–4 Add-on labor – Inspect and/or replace idler spacer washer. (Only on vehicles equipped with dual a/c compressors.) 0.1 hrs ADMINISTRATIVE PROCEDURE Expense is to be charged to Warranty. Claims are to be submitted in the normal manner, making reference to Authorized Field Change Number G-10911. It is important that the coding be completed properly to assist in processing the warranty claim. Complete instructions will be found in the Warranty Manual, Section 7–1. Special attention should be given to Items 39 through 44. To assure this important improvement is made in a timely manner, all claims for G-10911 activity must be submitted by August 31, 2011 or within the normal warranty period for the vehicle, if after August 31, 2011. All trademarks are marks of their respective holders. AFC–10911R 8