NHTSA ID Number: 10044330
Manufacturer Communication Number: SB-L3-FSV-097
TSB/Document Date: 2012-06-12
Summary
NORTH AMERICAN BUS INDUSTRIES (NABI): CERTAIN BUSES WILL HAVE NEW GATES BELT TENSIONER INSTALLED AND REPLACING THE OLD AUTOMATIC BELT TENSIONER DUE TO BEING UNRELIABILITY. *PE
SB-10044330-1302
NABI: Gates Belt Tensioner Installation
Prepared by:
Kalman Takacs
Field Service Engineer
Phone (256) 241-1243
Fax (256) 832-0930
Approved by:
Scott Geier
Field Service Manager
Phone (256) 241-1303
Property name and top bus number: NABI buses equipped with automatic belt tensioner
Issue:
Short lifetime of AC belt tensioner.
Reason / cause:
The current AC belt tensioner is not reliable.
Solution:
Install new Gates belt tensioner per this work instruction (SOI).
06-13-2012
Work instruction number: L3/FSV-097
L4/PRO-003
Revision: Initial
Date: 05/15/2012
Revision: Initial
NABI: Gates Belt Tensioner Installation
Number of affected buses: as required
Estimate repair hours/bus: 30 minutes
Necessary parts:
Kit (arm, pulley, bearing),
Bolt, 7/16-14 X 4.25, Hex, Gr8,
Washer, Flat 7/16 Zn Gr8,
Nut nylock 7/16-14, Zn, Gr8,
Bolt, 3/8 X 2-1/2, Hex Head Zn, Gr8,
Washer, flat, 3/8, Zn, Gr8, USS,
Nut Nylock 3/8 Gr8,
NABI Part #: 501-7447-120,
Fastenal Part #: 15170,
NABI Part #: 2607,
NABI Part #: 5015555,
NABI Part #: 220616208,
NABI Part #: 2606,
NABI Part #: 5015559,
1/bus,
1/bus,
2/bus,
1/bus,
1/bus
2/bus
1/bus
Replace AC belt if signs of excessive ware
Necessary tools: Standard sockets and wrenches, 3/8 size drill bit, drill, hammer, center punch
06-13-2012
Work instruction number: L3/FSV-097
L4/PRO-003
Revision: Initial
Date: 05/15/2012
Revision: Initial
NABI: Gates Belt Tensioner Installation
SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY STANDARDS
AND LOCAL/PROPERTY REQUIREMENTS.
1.
2.
3.
4.
5.
6.
7.
8.
Park the bus on a flat surface.
Apply the parking brake.
Place wheel chocks underneath the front wheels.
Turn the main electric battery disconnect switch off.
Open the rear engine compartment door.
Remove belt guard.
Remove AC belt.
Remove the old AC belt tensioner, tensioner lock paw and hardware.
06-13-2012
9. Installing the new belt tensioner:
Install the new 7/16x4-1/4 inch bolt from the back side of the bracket
Install the tensioner base plate on the 7/16x4-1/4 inch bolt
Point the 3/8 base plate locking hole approximately 5 o’clock and mark the AC bracket
through the hole
drill a 3/8 hole at the mark into the AC bracket
Install 3/8x2 inch bolt, nut and washers into the 3/8 hole of locking base plate and tighten.
Install the belt tensioner assembly on the base plate with 7/16 bolt, 7/16 nut and flat washer
(do not tighten).
Install AC belt and rotate belt tensioner until it makes contact with the AC belt
With a marker mark the position of the belt tensioner with the tensioner base plate
Work instruction number: L3/FSV-097
L4/PRO-003
Revision: Initial
Date: 05/15/2012
Revision: Initial
NABI: Gates Belt Tensioner Installation
Remove the belt and rotate the tensioner assemble 3 notches as a starting point
Tighten the 7/16 bolt of the belt tension assembly.
Install AC belt by inserting a ½ inch ratchet in the end of the assembly then push down.
Check crank, tensioner and AC pulley for alignment. Adjust as needed per maintenance
procedure.
06-13-2012
10. Check the belt tension by using a belt tension gauge. The belt tension should be 135-150 lb.
To achieve the correct belt tension loosens the belt assembly 7/16 bolt and rotates the
assembly clockwise (tighten belt) or counter clockwise (loosen belt) one notch at a time until
you achieve the 135-150lbs of belt tension.
Work instruction number: L3/FSV-097
L4/PRO-003
Revision: Initial
Date: 05/15/2012
Revision: Initial
NABI: Gates Belt Tensioner Installation
06-13-2012
11. Turn the battery switch on and start the bus. Make sure that the AC system is working
properly. Run the engine on fast idle for 10 minutes with the AC on.
12. Then stop the engine then turn off the battery switch. Recheck the belt tension and make
necessary adjustments as needed.
13. Reinstall the belt guard. Inspect work for completeness.
14. Make sure that all of the tools and unused parts are removed from the engine compartment.
15. Record bus number, mileage and date of completion.
16. Continue to inspect AC Belt drive line components per Maintenance Manual intervals.
Work instruction number: L3/FSV-097
L4/PRO-003
Revision: Initial
Date: 05/15/2012
Revision: Initial
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TSB/Document ID: SB-L3-FSV-097
Replacement Service Bulletin Number:
MFR Communication Date: 2012-05-15
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS
MFR Component System:
MFR Component Subsystem:
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