IK0900135 Service Bulletin/Repair Instructions

IK0900135 - WorkStar Hybrid Mount to Pad Mount A/C Compressor Retrofit
Page 1 of 5
Countries:
CANADA, UNITED STATES
Availability:
ISIS, FleetISIS, Body Builder, IsSIR Revision:
Document ID: IK0900135
Major System:
COOLING
0
Created:
9/23/2019
Current Language: English
Last Modified: 10/1/2019
Other Languages: NONE
Author:
Viewed:
Bobby Christopher
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Title : WorkStar Hybrid Mount to Pad Mount A/C Compressor Retrofit

Applies To : WorkStar
CHANGE LOG

Please refer to the change log text box below for recent changes to this article:

10/01/2019 ‐ Initial Article Release.


DESCRIPTION

A/C compressor update from hybrid mount to direct mount to engine.

This will affect all WorkStar variations with Cummins ISB 6.7 engine only.

In order to obtain proper clearance to address engine roll and rub issues, A/C suction line is redesigned.

Fan drive belt will need to be changed on High-Vis/Slope Hood (09WBM) models (going from 2125 mm to 2108 mm).

With direct mount compressor, support brackets for the hybrid mounted A/C compressor are removed.

On low visibility / sloped hood units a 50 mm extended frame modification is required for compressor clearance during engine torque roll. Use included

template (Figure 2).

New Design High Visibility / Sloped Hood (09WBM)

Requires Shorter Belt (2108 mm)
Original Design
New Design Low Visibility / High Hood

Uses Original Belt (2125 mm)
SYMPTOMS

Diagnostic Trouble Codes & Dashboard Indicator Lights:

DTC/Light
Description
N/A
N/A
Customer Observations or Concerns:
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IK0900135 - WorkStar Hybrid Mount to Pad Mount A/C Compressor Retrofit
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Fan Belt shreds

Fan Belt comes off

A/C not cooling

Noise under hood / engine compartment

A/C Compressor loose
SPECIAL TOOLS / SOFTWARE

Tool Description
Tool Number
Comments
Instructions
Refrigerant Handling

System
RTI RHS980CNAV
Refrigerant recover and charging

Station
SERVICE PARTS INFORMATION

High Visibility / Low Hood Model

(09WBM Sloped Front)
Part

Number
Quantity

Required
Wiring bracket part number
6137791C1
1
Wiring bracket part number
4145863C1
1
4 compressor Bolts
1817962C1
4
Fan Drive Belt
3866104C
1
A/C Compressor Direct Mount
4034409C4
1
AC suction Line
4049904C92 1
Receiver Dryer
6102498C90 1
Template / Frame notch
Figure 2
1
Cut out attached

IKNOW
Low Visibility / High Hood Model
Part

Number
Quantity

Required
Notes
Wiring bracket part number
6137791C1
1
Wiring bracket part number
4145863C1
1
4 Compressor Bolts
1817962C1
4
A/C Compressor Direct Mount
4034409C4
1
AC Suction Line
4049904C92 1
Receiver Dryer
6102498C92 1
Notes
Replaces Hybrid Mount

Compressor
Replaces Hybrid Mount

Compressor
DIAGNOSTIC STEPS

Step Action

DIAGNOSTIC:

Inspect A/C compressor mounting and engine serpentine belt.

Is A/C compressor belt off, broken, or shredded?

Is the A/C compressor loose (broken mounts)?

Refer to Figure 1 for example of broken compressor mounts.

1
Decision

Yes: Refer to Service Parts

Information listed above:

• Order all needed parts listed for

application

• Refer to Figure 2 High

Visibility/Sloped Hood only

(09WBM)

• Cut out template per directions

• Follow removal procedure

• Follow installation procedure
No: Reference HVAC System

Diagnostics in service portal
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IK0900135 - WorkStar Hybrid Mount to Pad Mount A/C Compressor Retrofit
Page 3 of 5
Figure 1 - Broken Hybrid Compressor Mount
Figure 2 - Frame Template
Printing instructions:

1. Print the iKNow article

◦ Must be printed at 100% on 8 1/2" x 11" Paper

◦ Measure 3 inches on front of template to verify the template has printed at the correct size

2. Cut out and place on right side frame rail (Passenger side)

3. Align dotted line up with point on old bevel (Figure 3, Item 1)

◦ The white dashed line is showing alignment to the old bevel

4. Mark the frame. Then grind / cut area that is shown in light green (Figure 3, Item 1) (Do not use a torch)

◦ This is for compressor clearance during engine torque roll on vehicles with High Visibility / Sloped hood only (09WBM)

◦ It is critical to follow template, must have beveled edge, do not square cut or notch the frame - "Could cause frame to crack"

◦ You are only removing a small sliver of frame rail flange (Shown in light green)

◾ You are NOT removing material the size of the template

Figure 3 - Frame Modification - Passenger Side Only
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IK0900135 - WorkStar Hybrid Mount to Pad Mount A/C Compressor Retrofit
Page 4 of 5
If you have any questions with placing the template on the frame rail, open a tech service case file before

making any frame modifications
REPAIR STEPS

1.

2.

3.

4.

5.
Install Wheel Chocks

Obtain Service Information

Obtain Service Part(s)

Obtain Service Tool(s)

Use / Template To Mark Frame Where Cut Is Needed And Mark
Special Tools

• A/C Machine

REMOVAL PROCEDURE:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.
Open Hood

Remove Fender, Front / Right

NOTE: Use Appropriate SRT for AIR CONDITIONING SYSTEM RECOVER, EVACUATION AND RECHARGE

Evacuate Air Conditioning System /of Refrigerant

Remove Belt, Serpentine / A/C Compressor

Remove Air Conditioning System / Belt from Engine

Disconnect Hose, Compressor To A/C Dryer / Accumulator /Install Red Cap

Disconnect Hose, Compressor To Condenser / At Compressor Install Red Cap

Remove Bracket, A/C Compressor / Cutting Two Zip Ties and Removing One Nut

Remove Bracket, A/C Compressor / From A/C Compressor Mounting Bracket Four Bolts

◦ The upper bracket is not re-used and can be discarded (Identified in RED below)

◦ The alternator mounting bolts will be re-used with a new bracket during installation
11.

12.

13.

14.

15.

16.
Disconnect Clutch, A/C Compressor / From Harness

Remove Compressor, A/C / From Engine Two Bolts One Nut

NOTE: Block Off Wiring Harness with Thin Metal Plate. As Some Cutting Tools Will Throw Sparks At Harness.

(High Vis/Slope hood only) Cut Frame Following Mark Made with Template. Clean / Any Burrs Or Sharp Edges (Do not use a torch)

Clean Frame Area with Cleaner To Remove Oils

(High Vis/Slope hood only) Apply / Paint To Frame Area
INSTALLATION PROCEDURE:

1. Drain / Oil From Old Compressor Into Measuring Cup

2. Drain / Oil From New Compressor Into Measuring Cup
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IK0900135 - WorkStar Hybrid Mount to Pad Mount A/C Compressor Retrofit
3.

4.

5.

6.
7.

8.

9.

10.

11.

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13.

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16.

17.

18.

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Page 5 of 5
Fill Compressor, A/C / With The Correct Amount Of Oil

Turn Compressor, A/C /Clutch By Hand To Circulate Oil Install Red Cap

Install New Compressor, A/C / Installing Four New Bolts, Install Bracket

Smaller One Goes On Bottom Bolt Of A/C Compressor Bigger Bracket Goes To Top A/C
Compressor Bolt

Torque Bolts / Four

Install Tie Strap, Wiring / To Bracket On Wiring Harness Two Top And Bottom Bracket

Install New Seal / A/C Line Compressor To Condenser

Connect Hose, Compressor To Condenser /Lube O-ring Seal Remove Red Cap

Torque Nut

Connect Hose, Compressor To A/C Dryer / Accumulator /Install Red Cap

Torque Nut

Connect Compressor, A/C /Electrical connector

Install New Tie Strap, Wiring / A/C Clutch Connector To Bracket

Install Belt, Serpentine

Perform / A/C Vacuum And Fill

Install Fender, Front

Torque Fender, Front

Close Hood
FOLLOW-ON PROCEDURE:

1. Tag And Return Service Part(s)

2. Return Service Tool(s)

3. Remove Wheel Chocks
WARRANTY INFORMATION

Warranty Claim Coding:

Refer to the Warranty Coding Manual for Group and Noun Codes.

Standard Repair Time(s):

Refer to the SRT Manual for Repair Times
OTHER RESOURCES

Master Service Information Site

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Copyright © 2019 Navistar, Inc.
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11/1/2019

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