ITS60814

INSTRUCTION TO SERVICE
ITS60814
September 15, 2023
SECTION:
549-Heating & Air Conditioning System
WRITTEN BY:
Aditya Gadepalli
SUBJECT:
Single Grove to Double Grove AC Belt Rework
AC belts on legacy D coaches equipped with ISX engine are failing
ISSUE:
prematurely.
Rework the coach to have double grove crank shaft and compressor clutch to
SUMMARY:
replace the single grove AC belt with double grove belt.
ITS60814
Ref. NHTSA Recall No.
Not Applicable
Ref. Transport Canada Recall No.
Not Applicable
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED TO FOR FUTURE MAINTENANCE UNTIL
THE PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A RESULT OF THIS
DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND MAINTENANCE STAFF
GOING FORWARD.
This document and the contents discussed herein are the confidential and proprietary information of New Flyer Industries Canada ULC and New Flyer of America Inc. and are disclosed by New Flyer in
confidence. This document and the contents herein are not to be disclosed by the intended recipient without the prior written authorization of New Flyer. Any unauthorized disclosure, reproduction or other
distribution of this document or information strictly prohibited and may result in action being taken against the party making the unauthorized disclosure. This document and all copies hereof must be returned
to New Flyer upon request.
INSTRUCTION TO SERVICE
ITS60814
PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Remove and discard the AC belt. Remove and save the alternator belt.
Remove and
discard the belt
4. Remove and discard the crank shaft pulley. Save the bolts.
Remove and discard the
crank pulley. Save hardware.
5. Remove and discard the compressor clutch. Save the hardware.
Remove and discard the
compressor clutch. Save hardware.
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INSTRUCTION TO SERVICE
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6. Install new clutch, MCI P/N: 08-04-1160, using existing hardware and torque to 63 Ft-Lbs.
Install new compressor clutch, 0804-1160 using existing hardware.
7. Install new crank shaft pulley, MCI P/N: 08-04-1186, using existing hardware. Torque the bolts to 72-78 Ft-Lbs.
Install new crank pulley, 08-0411686 using existing hardware.
8. Remove and save the hardware securing the spring tensioner to the compressor bed.
Remove and save the hardware
securing spring tensioner
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INSTRUCTION TO SERVICE
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9. Place the new adapter bracket, MCI P/N: 1047272, on the compressor base as shown ensuring the bottom
hole in the bracket matches the hole in compressor base.
Place new adapter bracket such that
the hole in the compressor base aligns
10. Mark the two holes on the bottom flange of the bracket and match drill on the compressor base using 37/32
drill bit.
Match drill two holes
using 37/32 drill bit
11. Install the adapter bracket, MCI P/N: 1047272, to the compressor base using bolts, MCI P/N: 19-01-2387, and
nuts, MCI P/N: 19-03-0497. Torque to 80-90 Ft-Lbs.
Install bracket using 1901-2387 and 19-03-0497
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INSTRUCTION TO SERVICE
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12. Install idler pulley plate, MCI P/N: 08-27-1442, to the adapter bracket using bolts, MCI P/N: 19-01-2387, and
nuts, MCI P/N: 19-03-0497. Torque to 80-90 Ft-Lbs.
Install idler pulley plate, 08-27-1442
using 19-01-2387 and 19-03-0497
13. Install idler pulley, MCI P/N: 08-27-1354, using bolt, MCI P/N: 19-01-1526, spacer, MCI P/N: 08-27-1543, and
nut, MCI P/N: 19-03-0497. Torque the bolt to 25-35 Ft-Lbs.
Install idler pulley, 08-27-1354
using 19-01-1526, 08-271543 and 19-03-0497
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INSTRUCTION TO SERVICE
ITS60814
14. Re-install the spring tensioner to the compressor base, using existing hardware. Torque the nut to 80-90 FtLbs.
Re-install spring tensioner
using existing hardware

NOTE: Ensure the belt is centered on top and bottom idlers. If not, move the bottom idler in the slots of
the bracket and install shims 08-27-1421 between the adapter bracket and idler plate and re-torque the
hardware.
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INSTRUCTION TO SERVICE
ITS60814
LABOUR ESTIMATE
Operation
1
Single Grove to Double Grove AC Belt Rework
Number of
Technician(s)
1
Hours
Labor Time
T X HR
1
1
PARTS REQUIRED
Qty.
per
Coach
1
Units
Item
Part Number
Description
1
08-04-1160
Clutch-A/C Compressor, Bitzer
3
08-04-1186
Pulley-Crank ISX Efan
1
EA
3
08-27-1442
Plate-Idler Pulley
1
EA
4
08-27-1354
Pulley-Idler/Tensioner
1
EA
5
08-27-1542
Belt-A/C CMPRSR,5VX,Matched Set
1
EA
6
19-01-2387
Screw-Hex Cap,1/2-13,FLG,2.0LNG
4
EA
7
19-03-0497
Nut-Lock Flanged,1/2-13,GR G, Yellow Zinc
4
EA
8
19-01-1526
Screw, Cap, 1/2-13 x 3 Inch
1
EA
9
1047272
Bracket-Idler Mount AC Belt
1
EA
Qty.
Units
Notes
EA
SPECIAL TOOLS REQUIRED
Item
Part Number
Description
1
08-27-1421
Shim
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Notes
4
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September 15, 2023