Date:TSI–12-16-04 January2013 TechnicalServiceInformation … · 2018-12-16 · PARTSINFORMATION...

Technical Service Information

TSI–12-16-04

Date: January 2013

Subject File: Tools

Subject: A/C System Flush Tool 19-000-01

Model: This tool set applies to all trucks manufactured by International Trucks®, and branded as International®,built during model year 2004 through 2012.

DESCRIPTIONThe A/C System Flush Tool cleans the A/C system from contaminants caused by compressor failure or useof incorrect refrigerant or oil.

Figure 1. A/C System Flush Tool 19–000–01

DISCLAIMER

Please refer to the A/C HVAC Service Resource Center or Tool Instruction 4328094R1 before using the A/CSystem Flush Tool 19-000-01. This is to make sure the proper components are cleaned or replaced.

© 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.1

PARTS INFORMATIONTable 1. Flushing Equipment

Image Tool Number Qty Description

19-352-01 1 Flush Tank Assembly

19-352-01-01 1 Tank Assembly

19-352-01-02 1 Flush Gun Assembly

19-352-01-07 1 Regulator and PulseValve Assembly

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PARTS INFORMATION (CONT.)

Table 1. Flushing Equipment (cont.)


19-352-02 1 Discharge Assembly

19-352-02-01 1 Discharge Barrel

19-352-02-04 1 Discharge Hose

19-352-02-02 1 Charcoal Filter Pack

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Table 1. Flushing Equipment (cont.)


19-352-02-05 3 Filter Pack

19-352-03 1 Nitrogen RegulatorAssembly

19-352-03-01 1 Nitrogen Regulator

19-352-03-02 1 Nitrogen Regulator Hose

19-352-03-04 1 Blow Gun

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PARTS INFORMATION (CONT.)Table 2. Flush Fittings


19-353-01 1 A/C Fill Tool Fitting ¾M

19-353-02 1 A/C Line Plug Tool ¾M

19-353-03 2 A/C Fill Tool Fitting ¾F

19-353-04 1 A/C Drain Tool Fitting ¾F

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Table 2. Flush Fittings (cont.)


19-353-05 1 A/C Fill Tool Fitting ½F

19-353-06 2 A/C Drain Tool Fitting ½F

19-353-07 2 A/C Drain Tool Fitting ½M

19-353-08 1 A/C Line Plug Tool ½M

19-353-09 1 A/C Fill Tool Fitting ½M

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19-353-10 1 A/C Fill Tool Fitting 7/16M

19-353-11 1 A/C Drain Tool Fitting ⅜F

19-043-01 1 Condenser Loop Tool

19-094-01 2 Evaporator Adaptor Tool

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19-094-02 1 Evaporator Adaptor Tool

19-632-01 1 Line Loop Tool

19-632-02 1 Line Loop Tool

19-310-01 1 Adapter Fitting O-Ring Kit

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TC3Q 1 Drier Cutting Tool

19-318-01 1 Micron Gauge Adapter

19-000-01-06 1 Roll Cart

19-000-01-01 1 Roll Cart Foam Cut-Outs(Top Drawer)

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19-000-01-02 1 Laminate Tool LayoutSheet (Top Drawer)

19-000-01-03 1 Roll Cart Foam Cut-Outs(Bottom Drawer)

19-000-01-04 1 Laminate Tool LayoutSheet (Bottom Drawer)

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4328094R1 1 Instruction Sheet

69086 1 Micron Gauge

Table 3. Additional Tools Required (Not Included in Kit)

Image Tool Number Qty DescriptionZTSE4660 1 Cap Plug

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INSTRUCTIONS

WARNING: Engine fluids (oil, fuel, and coolant) may be a hazard to human health and theenvironment. Handle all fluids and other contaminated materials (e.g., filters, rags) in accordancewith applicable regulations. Recycle or dispose of engine fluids, filters, and other contaminatedmaterials according to applicable regulations.

WARNING: Read all safety instructions in the “Safety Information” section of the EngineService Manual or Engine Diagnostic Manual to prevent personal injury or death.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, setparking brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, allow engine to cool before draining coolant.

CAUTION: To prevent damage to vehicle or engine, read all safety instructions in Safety Informationsection of Service and Diagnostics Manual for application being serviced.

1. Bring truck into shop and park on flat surface.

2. Shift transmission to Park or Neutral, set parking brake, and block wheels.

3. Unlatch and open hood.

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INSTRUCTIONS (CONT.)

Figure 2. A/C System Evacuation.

4. Evacuate A/C system using proper refrigerant recovery equipment that is J-2788 compliant (refer toFigure 2).

5. Disconnect all connections within A/C system.

6. Remove drier, or orifice tube, from vehicle.

NOTE: Removal and cutting open of filter/drier will aid in diagnosing a failed A/C compressor. Cuttingfilter/drier 4 in (101.6mm) from top will allow easier removal of desiccant canister.

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Figure 3. Receiver/Drier Marking.

7. Make a mark 4 in (101.6mm) from top of receiver/drier (refer to Figure 3).

Figure 4. Drier Cutting.

1. Drier Cutting Tool TC3Q

8. Cut open receiver/drier using Drier Cutting Tool TC3Q (Figure 4, Item 1).

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Figure 5. Filter Element Access.

9. Carefully remove the desiccant carrier from drier to prevent oil splash, then remove press-in retainer toaccess filter element (refer to Figure 5).

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Figure 6. Metal Shavings in Filter Element.

10. Inspect filter element and desiccant for metal shavings indicating failed compressor (refer to Figure 6).

11. Visually inspect orifice tube for metallic shavings indicating failed compressor.

• Some compressors will not circulate very much metal through system; any evidence requires entiresystem to be flushed.

• A magnet cannot be used to check as metal shavings are aluminum.

12. Inspect all flush fittings for damage and replace any deteriorated seals.

13. Using Application Table (Table 4), install all fittings to proper locations.

Table 4. Application Table

TerraStar®®®, DuraStar®®®, WorkStar®®®, TranStar®®®,ProStar®®®, LoneStar®®®

PayStar®®® and9900 Orifice Tube

2007 2008 2010 2010 Pre-2007

FrontEvaporatorLiquid

19-353-07 19-353-07

FrontEvaporatorSuction

19-353-01

19-094-01 19-094-01 19-094-02

19-353-01

Suction Line atCompressor 19-353-03 19-353-03 19-353-03 19-353-03 19-353-03

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Table 4. Application Table (cont.)

Suction LinePlug 19-353-02 19-353-02 19-353-02 N/A N/A

Suction Lineat TXV 19-353-04 19-353-04 19-353-04 N/A 19-353-04

CondenserLine at

Compressor19-353-06 19-353-06 19-353-06 19-353-06 19-353-06

CondenserLine Plug 19-353-08 19-353-08 N/A N/A N/A

CondenserLine Loop 19-043-01 19-043-01 19-043-01 19-043-01 19-043-01

CondenserLine at

Receiver/Drier19-353-05 19-353-05 19-353-05 19-353-10 19-353-05

EvaporatorLine at

Receiver/DrierN/A N/A N/A 19-353-11 N/A

Sleeper RearSuction Line 19-353-03 19-353-03 19-353-03 N/A N/A

Sleeper RearLiquid Line 19-353-06 19-353-06 19-353-06 N/A N/A

Sleeper RearLines at Rear

TXV19-632-01 19-632-01 19-632-01 19-632-02 N/A

SleeperEvaporator 19-094-01 19-094-01 19-094-01 N/A N/A

SleeperEvaporatorNo-Idle

N/A N/A 19-094-02 N/A N/A

CondenserInlet 19-353-07 19-353-07 19-353-07 19-353-07 19-353-07

CondenserOutlet 19-353-09 19-353-09 19-353-09 19-353-09 19-353-09

14. Follow Flushing and Purging procedure in this instruction.

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FLUSHING AND PURGING1. Using a suitable container filled with solvent, submerge any small lines removed during adaptor installation

process.

Figure 7. Regulator and Pulse Valve Removal.

1. Regulator and Pulse Valve Assembly 19-352-01-072. Flush Tank 19-352-01-01

2. Remove Regulator and Pulse Valve Assembly 19-352-01-07 from top of Flush Tank 19-352-01-01 (refer toFigure 7).

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FLUSHING AND PURGING (CONT.)

Figure 8. Flush Tank Fill.

1. Flush Tank 19-352-01-01

3. Fill Flush Tank 19-352-01-01 with one gallon of solvent for day cabs, or two gallons of solvent for sleepercabs (refer to Figure 8).

4. Reinstall Regulator and Pulse Valve Assembly 19-352-01-07 into Flush Tank 19-352-01-01.

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Figure 9. Discharge Hose.

1. Discharge Hose 19-352-02-042. Flush fitting

5. Connect Discharge Hose 19-352-02-04 (Figure 9, Item 1) to appropriate flush fitting (Figure 9, Item 2) usingcam-lock coupling.

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Figure 10. Discharge Barrel.

1. Discharge Hose 19-352-02-042. Discharge Barrel 19-352-02-01

6. Connect Discharge Hose 19-352-02-04 (Figure 10, Item 1) to Discharge Barrel 19-352-02-01(Figure 10, Item 2) using cam-lock coupling.

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WARNING: Follow procedural steps below in correct order. Failure to do so could result indamage to the tool or vehicle, and may harm technician.

Figure 11. Flush Gun Assembly Connection.

1. Flush Gun Assembly 19-352-01-022. Flush fitting

7. Connect Flush Gun Assembly 19-352-01-02 (Figure 11, Item 1) to appropriate flush fitting (Figure 11,Item 2) using quick coupling on short Flush Gun Assembly 19-352-01-02 hose.

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Figure 12. Flush Tank Assembly Connection.

1. Flush Gun Assembly 19-352-01-022. Flush Tank Assembly 19-352-01

8. Connect Flush Gun Assembly 19-352-01-02 (Figure 12, Item 1) to Flush Tank Assembly 19-352-01(Figure 12, Item 2) using quick coupling on long hose.

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Figure 13. Nitrogen Regulator Hose Connection.

1. Flush Tank 19-352-01-012. Nitrogen Regulator Hose 19-352-03-023. Regulator and Pulse Valve Assembly 19-352-01-07

9. Connect Nitrogen Regulator Hose 19-352-03-02 (Figure 13, Item 2) to Regulator and Pulse ValveAssembly 19-352-01-07 (Figure 13, Item 3) on Flush Tank Assembly 19-352-01 (Figure 13, Item 1).

10. Completely open valve on nitrogen tank and set Nitrogen Regulator Assembly 19-352-03 pressure to120 psi (827 kPa). This will provide 100 psi (689 kPa) working pressure.

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Figure 14. Solvent Introduction.

11. Squeeze trigger on Flush Gun Assembly 19-352-01-02 (refer to Figure 14) to introduce solvent intosystem. Introduce solvent until return sight glass appears to be free of debris and solvent is clear.

12. After appropriate amount of solvent is injected, disconnect Flush Gun Assembly 19-352-01-02 fromFlush Tank Assembly 19-352-01 quick coupling.

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Figure 15. Nitrogen Regulator Assembly.

1. Nitrogen Regulator Assembly 19-352-03

13. Connect Flush Gun Assembly 19-352-01-02 to quick coupling located on Nitrogen Regulator Assembly19-352-03 (Figure 15, Item 1).

14. With Nitrogen Regulator Assembly 19-352-03 set to 120 psi (827 kPa), purge components by squeezingtrigger on Flush Gun Assembly 19-352-01-02.

15. While holding Flush Gun Assembly 19-352-01-02 trigger, adjust regulator to 200 psi (1,379 kPa), thenback down to 100 psi (689 kPa) working pressure.

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Figure 16. Discharge Hose Sight Glass.

1. Discharge Hose 19-352-02-04 sight glass2. Discharge Barrel 19-352-02-01

16. Monitor Discharge Hose 19-352-02-04 sight glass (Figure 16, Item 2). Purge until solvent is not evidentand continue for an additional 5 seconds.

17. Reconnect Flush Gun Assembly 19-352-01-02 to Flush Tank Assembly 19-352-01.

NOTE: After flushing, cap open ends of each component using ZTSE4660 or equivalent.

18. Move connections to each appropriate connection pair and repeat Steps 5-17.

REFRIGERANT LINE FLUSHING

WARNING: Make sure discharge assembly is completely drained. Excessive amounts ofVolatile Organic Compounds (VOCs) could be released into local air if barrel is not drained. ReadMSDs thoroughly before performing any flushing work.

1. Drain entire Discharge Assembly 19-352-02 of used flushing solvent to prevent a high amount of VOCsfrom being released. Dispose of used solvent in accordance with local EPA regulations. Do not reinstalltop of Discharge Assembly 19-352-02.

2. Remove Charcoal Filter Pack 19-352-02-02.

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REFRIGERANT LINE FLUSHING (CONT.)

CAUTION: Set nitrogen regulator pressure to 120 psi (827 kPA) to provide a 100 psi (689 kPa)working pressure, or damage to equipment may occur.

Figure 17. Blow Gun.

3. Use Blow Gun 19-352-03-04 to blow any loose particles out of lines and dry solvent from lines (refer toFigure 17).

CAUTION: Direct opposing end of line into discharge assembly while performing this operation.Take care to notice locations where thermistor bosses are located, as high pressure air may exitthese locations.

RETURNING VEHICLE TO SERVICE

CAUTION: A/C service station filters must be replaced after recovering refrigerant from a systemdetermined to have metal contamination. Failure to replace filters will result in prematurecompressor failure due to metal contaminants re-entering system during refrigerant chargingprocess.

1. After flushing is complete, remove all adaptors and return vehicle to in-service condition, includingreplacing all appropriate parts. Refer to A/C HVAC Service Resource Center.

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RETURNING VEHICLE TO SERVICE (CONT.)

Figure 18. Micron Gauge Adapter.

2. Attach Micron Gauge Adapter 19-318-01 to high-side fitting using quick coupler (refer to Figure 18).

Figure 19. Digital Micron Gauge.

3. Using Digital Micron Gauge 64086, attach sensor lead to Micron Gauge Adapter 19-318-01 fitting (refer toFigure 19).

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RETURNING VEHICLE TO SERVICE (CONT.)

Figure 20. A/C Service Station Connected.

4. Attach high-side A/C line (red) from A/C service station to remaining Micron Gauge Adapter 19-318-01fitting (refer to Figure 20).

5. Place vehicle into a vacuum using A/C service station. At completion of evacuation cycle, vacuum shouldmeasure 1,000 microns or less. Refer to A/C HVAC Service Resource Center for further information.

CONTACT INFORMATIONFor questions, concerns or feedback related to Service Tools:

Navistar Service Tool Support Center

Submit a Service Tool iKNow Case File or call 1-800-365-0088

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APPENDIX I

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APPENDIX I (CONT.)

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APPENDIX I (CONT.)

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APPENDIX I (CONT.)

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Date:TSI–12-16-04 January2013 TechnicalServiceInformation … · 2018-12-16 · PARTSINFORMATION...

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