IK0900135 - WorkStar Hybrid Mount to Pad Mount A/C Compressor Retrofit

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Countries:

CANADA, UNITED STATES

Availability:

ISIS, FleetISIS, Body Builder, IsSIR Revision:

Document ID: IK0900135

Major System:

COOLING

2

Created:

9/23/2019

Current Language: English

Last Modified: 3/12/2020

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:
11/12/2019 ‐ Changed AC suction line part Number
10/01/2019 ‐ Initial Article Release.

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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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Page 2 of 5

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

Robinair A/C Machine 34988

Instructions

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

3866104C1

1

A/C Compressor Direct Mount

4034409C4

1

AC suction Line

4049904C91 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

4049904C91 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.
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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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