NHTSA ID Number: 10118494
Manufacturer Communication Number: SP15-324E
TSB/Document Date: 2017-10-04
Summary
On the vehicles affected by this bulletin, vibration is causing damage to A/C compressor and compressor harness connectors. Addition of a reinforcement bracket to Bitzer A/C compressor is needed to increase the installation stiffness and reduce vibration amplitude.
9 & FIGURE 10 to identify bolts C & E).
E= 40 lbf-ft (54 N-m)
C= 74 lbf-ft (100 N-m)
Apply torque seal mark to all bolts
23. Reinstall tensioner, bolt and washer (B) and
bolt and nut (A). Do not tighten these bolts at
this moment as the belt tension adjustment will
be done later in this procedure.
FIGURE 14
24. Install the alternator washing warning plate
#069451 using two rivets #504339 as shown
on the image at right.
25. Install nylon tie mount #509815 where
indicated on the image. This tie mount will be
used to secure the electromagnetic clutch
cable.
FIGURE 15
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Special Bulletin
SP15-324E
Date
Expiration
Release
Page
10.2015
10.2017
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26. Install the new electromagnetic clutch coil.
Position cable lead near 5 o’clock position. Slip
the coil on the retainer on the compressor
flange. Fasten the coil with 4 cap screws
#5001775 to the compressor.
Coil mounting cap screws (F): 22 lbf-ft. Use
blue Loctite 243.
Apply torque seal
Caution: Pay attention to the precise seat of
the coil. All parts should be clean and free from
debris. Pay attention to the precise seat of coil.
The coil should sit flush with the face of the
compressor.
FIGURE 16
27. To provide a clear indication that the coil has
been replaced, using a steel punch set,
engrave a date code on the pulley as follows:
Pulley of 1st generation clutch – replacement date
code added
Engrave the current month and year on the
outside face of the pulley with a format similar
to the one found on 2nd generation clutch
assembly.
ex.: S11
S=2015
11= November
February 2016 would give date code T02.
FIGURE 17
nd
Pulley of 2 generation – replacement date
code added
FIGURE 18
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Special Bulletin
SP15-324E
Date
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Page
10.2015
10.2017
6
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28. Mount the clutch on the shaft end.
The flange and the shaft end of the compressor
must be clean and free from dirt.
29. Carefully mount the rotor on the shaft end by
hand.
Never use a hammer for pressing the rotor on.
Align the key on the compressor shaft with the
keyway on the pulley bore. To avoid damaging the
bore of the rotor, feel the engagement of the key in
the keyway and slip the rotor on the shaft end of
the compressor till reaching the stop.
The Woodruff key on the shaft end and the groove
in the location hole of the rotor must be flush.
FIGURE 19
30. Fasten the rotor to the shaft end by using the
M12 screw and by holding-up with a wrench on
the rotor.
Rotor mounting screw (G): 60 lbf-ft (81 N-m) Use
blue Loctite 243 on threads. Apply torque seal.
31. Turn rotor by hand and pay attention to the
free run and the generation of noises. In case
of grinding or similar noises, dismount the
clutch and check installation.
FIGURE 20
32. Reinstall the drive belts.
A belt strand tension gauge is needed. Belt
tension should be within this range:
90-100 lbs new belts (mean of 2 belt values)
75-85 lbs used belts (mean of 2 belt values)
33. Apply blue Loctite 243 on bolt (B) threads and
then hand-tighten bolt (B). Adjust belt tension
using bolt (A). Use the jam nut to prevent
rotation of bolt (A).
Note: Once thread locker is applied, do not
wait too long before applying final torque.
When proper tension is achieved, tighten bolt
(B) to 43 lbf-ft. (58 N-m). Apply torque seal
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FIGURE 21
Special Bulletin
SP15-324E
Date
Expiration
Release
Page
10.2015
10.2017
6
12(20)
34. Prepare the clutch coil cable for hooking up to
the compressor harness.
Crimp and solder the terminals to the clutch
coil cable using the following parts:
561568
TERMINAL, MALE 16-14
qty: 2
561690
PED CONNECTOR, WEATHERPACK qty: 1
561786
qty: 2
FIGURE 22
35. Open the Weatherpack connector secondary
lock. Insert terminals into connector cavities as
follows:
Circuit 77AC in cavity A (red wire)
Circuit 0RA2 in cavity B (green wire)
36. Snap the Weatherpack connector secondary
lock closed.
WEATHERPACK CONNECTOR WITH SECONDARY LOCK OPENED
FIGURE 23
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Special Bulletin
SP15-324E
Date
Expiration
Release
Page
10.2015
10.2017
6
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UNLOADER COIL REPLACEMENT
A new “clip-on” type unloader coil must be installed
in order to avoid unloader failure.
1. Loosen the screw securing the connector to
the coil and then unplug the connector (A).
Keep the screw and the connector rubber
gasket for reuse.
2. Unscrew the aluminum cap and discard.
3. Remove the plastic capture nut and discard.
4. Remove the coil, the O-ring and discard.
FIGURE 24
5. Install the new clip-on coil on the stem. To do
so, slide the coil over the stem assembly with
the O-ring #950577 at the base of the stem.
Ensure the coil snaps in place.
FIGURE 25
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Special Bulletin
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Date
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Release
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10.2015
10.2017
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HARNESS #069206 INSTALLATION
1. While proceeding with one connector at a time,
remove the existing A/C compressor harness
simultaneously as you install the new harness.
The new harness should be installed and
routed like the one being removed.
So9: A/C compressor electromagnetic clutch
Se29: A/C pressure switch
L199: R.H. side cylinder unloader coil
Se23: high side pressure transducer
Se24: low side pressure transducer
C228: other C228 connector half
Take special care to route the harness according to
the following figures.
HARNESS #069206
Refer to best practices at the end of this document.
Prefer larger, heat resistant cable ties over small
cable ties to limit the “pinch effect”.
FIGURE 26
Secure the cable on the cable tie mounts where
applicable.
2. Install new harness 069206. Connect L199 to
the unloader coil. Tighten the screw securing
connector L199 to the coil.
3. Secure the cable on the cable tie mounts as
shown on FIGURE 27.
FIGURE 27
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4. Route the electromagnetic clutch cable as shown on FIGURE 28 and connect to compressor harness
S09 connector. Secure connector SO9 as shown on FIGURE 29 using two nylon ties.
FIGURE 28
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UNLOADER CABLE – NYLON TIES LOCATION SHOWN BY GREEN ARROWS
ELECTROMAGNETIC CLUTCH CONNECTOR SECURED WITH TWO NYLON TIES
FIGURE 29
ATTACH THE EXCESS LENGTH OF CABLE ALONG MAIN STRAND OF HARNESS AS SHOWN– NYLON TIES LOCATION
SHOWN BY ARROWS
FIGURE 30
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ATTACH THE EXCESS LENGTH OF CABLE ALONG MAIN STRAND OF HARNESS AS SHOWN– NYLON TIES LOCATION
SHOWN BY ARROWS
FIGURE 31
SENSOR IDENTIFICATION
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FIGURE 32
Special Bulletin
SP15-324E
Date
Expiration
Release
Page
10.2015
10.2017
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ATTACH THE EXCESS LENGTH OF CABLE ALONG MAIN STRAND OF HARNESS AS SHOWN– NYLON TIES LOCATION
SHOWN BY ARROWS
FIGURE 33
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Special Bulletin
SP15-324E
Date
Expiration
Release
Page
10.2015
10.2017
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19(20)
BEST PRACTICES FOR CABLE SECUREMENT AND ROUTING
(Source: engineering Spec 20.0)
Prefer larger cable ties over smaller cable ties in
your assembly to limit local pinch effect.
Avoid sharp edges to prevent chaffing and
abrasion.
Always attach over harness loom or corrugated
tubes, not on the bare cables themselves.
No over-tightening of cable ties. (Must only prevent harness movement)
Perform
smart
harness
routing
to prevent water intrusion in the connectors.
(nearest low point: below connector)
Also avoid sharp edges of plastic corrugated
tubes.
No pulling or tension on connections.
Avoid sharp radius routing paths. (routing path
inside diameter = 2 X cable diameter)
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Special Bulletin
SP15-324E
Date
Expiration
Release
Page
10.2015
10.2017
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20(20)
PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)
ESTIMATED TIME
The time required to perform this special bulletin is approximately 1 ½ hour.
OTHER
VBC Bulletin
N/A
Fail Code
22.00
Defect Code
09
System Condition
B
Causal Part
950570
Prevost
engages in a continuous program of testing and evaluating to provide the best possible product. Prevost, however, is not
committed to, or liable for updating existing products.
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TSB/Document ID: SP15-324E
Replacement Service Bulletin Number:
MFR Communication Date: 2016-01-07
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
MFR Component Subsystem:
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