QUICK REFERENCE GUIDE A/C SYSTEM FLUSHING MAINTENANCE INFORMATION

Transcription

1 QUICK REFERENCE GUIDE A/C SYSTEM FLUSHING MAINTENANCE INFORMATION

2 MAINTENANCE INFORMATION A/C FLUSHING PROCEDURES QUICK REFERENCE GUIDE: VEHICLES CAUTION: A/C service should be completed with a service station that meets J2788 standards and has had all the current required maintenance procedures completed. 1. Empty oil recovery bottle and then use the A/C service station to identify and recover refrigerant. 2. Check recovery bottle for excessive oil. 3. Remove the drier, or orifice tube, from vehicle. Use drier cutter tool to cut drier open 101.6mm (4 inches) from the top. 4. Carefully remove the desiccant carrier from drier to prevent oil splash and then remove press in retainer to access the filter element. Inspect filter element or orifice tube screen for metal shavings that indicate a failed compressor. 5. Determine the repairs required based on the level in the oil recovery bottle and inspection of the drier or orifice tube. WARNING: The A/C service station filters must be replaced after recovering refrigerant from a system that was determined to have metal contamination. Failure to replace the filters will result in premature compressor failure due to metal contaminants re-entering the system during the refrigerant charging process. 6. Remove components that require replacement. 7. Inspect all required flush adapters for damage and replace any damaged adapter seals. Install required adapters on the vehicle. 8. Place small lines removed during the adapter installation process in a suitable container filled with solvent to assist in cleaning. 9. Check the discharge assembly for flush solvent left from the last job. Excessive VOCs could be released into the atmosphere if there is excess solvent in the barrel. 10. Remove pulse valve assembly from the flush tank. Fill flush tank with 1 gal of solvent for Day-Cabs and 2 gal of solvent for Sleeper-Cabs and then re-install pulse valve assembly. 11. Connect discharge hose to the flush fitting on the vehicle using the cam-lock coupling. 12. Connect trigger assembly to the flush fitting on the vehicle using the quick coupling on the short trigger hose. 13. Connect trigger assembly to flush tank assembly using the quick coupling on the long hose. 14. Connect discharge hose to discharge tank using the cam-lock coupling. 15. Connect nitrogen regulator to pressure regulator on flush tank assembly. 16. Open valve on top of the nitrogen tank all the way. 17. Use regulator knob to adjust outlet pressure to 120psi, providing a 100psi working pressure. 18. Squeeze trigger to introduce solvent into the system and watch the discharge hose sight glass. Solvent should run clear and be free of debris. Release trigger after the appropriate amount of solvent has been injected. 19. Flushing solvent must be purged from each component using nitrogen after the solvent injection is complete. 20. Start by disconnecting the trigger-to-tank quick coupler and then connect the trigger assembly to the quick coupling located on the nitrogen regulator assembly. 21. Squeeze the trigger to introduce nitrogen directly into the component being purged. While purging, adjust regulator to 200psi and then down to 100psi working pressure. Purging is complete when 100 psi is reached. 22. Once purging is complete, remove the flush adapters and cap off each end of the component. Repeat steps 11 through 22 until all other lines and components are flushed and purged. 23. Drain discharge barrel of flushing solvent. Leave the top of the barrel off. 24. Set nitrogen pressure at 120 psi to provide 100 psi working pressure. 25. Use supplied flexible brush to scrub the inside of the tube(s) that are soaking in solvent. WARNING: To avoid contact with flush solvent always direct the discharge end of component and open thermistor bosses into the discharge barrel while performing cleaning and purging operations. 26. Use the blow gun supplied to blow any loose particles out of the tubes and dry the solvent. Cap off each end of the component as soon as the purging is complete, and then move to the next component. Continue flush procedures until all the small components are flushed and purged. 27. If the system was oil overcharged, replace accumulator or filter-drier. 28. If the vehicle had a compressor failure, replace compressor, condenser, orifice tube or TXVs, thermistors, and the accumulator or filter-drier Navistar, Inc. Lisle, IL All rights reserved. 08/2012

3 MAINTENANCE INFORMATION A/C SYSTEM FLUSHING QUICK REFERENCE GUIDE: VEHICLES Flushing is a required service procedure for A/C systems that have a failed compressor or an oil overcharge. PURPOSE OF FLUSHING Ensures complete removal of contamination from A/C system components Guarantees Navistar warranty support for vehicles with a warrantable failure Increases vehicle up-time and customer satisfaction APPLICATIONS: The A/C Flush Tool set applies to all International trucks manufactured between model years VEHICLE APPLICATIONS TERRASTAR, DURASTAR, WORKSTAR, TRANSTAR, PROSTAR, LONESTAR PAYSTAR & 9900 ORIFICE TUBE PRE-2007 FRONT EVAPORATOR LIQUID FRONT EVAPORATOR SUCTION SUCTION LINE AT SUCTION LINE PLUG SUCTION LINE AT TXV LINE AT LINE PLUG LINE LOOP LINE AT RECEIVER/DRYER EVAPORATOR LINE AT RECEIVER/DRYER SLEEPER REAR SUCTION LINE SLEEPER REAR LIQUID LINE SLEEPER REAR LINES AT REAR TXV SLEEPER EVAPORATOR SLEEPER EVAPORATOR NO-IDLE

4 MAINTENANCE INFORMATION QUICK REFERENCE GUIDE: VEHICLES TC3Q DRIER CUTTER TOOL A/C FLUSH TOOL IDENTIFICATION FLUSH TANK ASSEMBLY NITROGEN REGULATOR ASSEMBLY DISCHARGE ASSEMBLY

5 QUICK REFERENCE GUIDE: VEHICLES FLUSH ADAPTER LOCATIONS PRE-2007 ORIFICE TUBE ORIFICE TUBE ACCUMULATOR EVAPORATOR 2010 PAYSTAR & 9900 EVAPORATOR TXV RECEIVER/DRIER

6 TERRASTAR DURASTAR WORKSTAR TRANSTAR PROSTAR LONESTAR 2007 EVAPORATOR TXV RECEIVER/DRIER 2010 EVAPORATOR TXV RECEIVER/DRIER

7 2007 PROSTAR/LONESTAR W/SLEEPER RECEIVER/ DRIER CAB TXV SLEEPER TXV SLEEPER EVAPORATOR CAB EVAPORATOR

8 FLUSH ADAPTER LOCATIONS QUICK REFERENCE GUIDE: VEHICLES 2010 PROSTAR/LONESTAR W/ SLEEPER RECEIVER/DRIER ASSEMBLY SLEEPER TXV * CAB TXV SLEEPER EVAPORATOR CAB EVAPORATOR WITH 12-VOLT NO-IDLE A/C*