MERITOR WABCO 636 AIR COMPRESSOR RETROFIT KIT FOR CX, CV, CH AND CL MODELS WITH E-TECH™ ENGINES
The Meritor WABCO 636 Twin Cylinder air compressor is a 28 cfm compressor designed forgreater durability, higher efficiency and greater air output. These compressors feature manydesign improvements that offer a significant reduction in oil passing to minimize air dryerand air system contamination. A retrofit kit (part No. 146SB1) is available through the MACKParts System if it is desired to replace any existing air compressor with a Meritor WABCO636 compressor on a CX, CV, CH or CL model chassis equipped with an E-Tech™ engine.Parts included in the retrofit kit are as follows:
This retrofit kit cannot be used on any chassis having acompressor-mounted power steering pump.
Meritor WABCO 636 Compressor Retrofit Kit
Qty. Part No. Description
1 8235-9115150050K Air compressor, WABCO 636
1 253GC3191 Bracket, mounting
4 26AM12 Flanged hex head capscrew, M8 x 1.25 x 20 mm
2 66AM4 Flanged hex head capscrews with patch-lock, M10 x 1.5 x 25 mm
In addition to the components included in the 146SB1 retrofit kit, the following additionalparts will be required depending upon chassis model and the existing air compressor. Theseparts must be ordered separately.
For CH or CX model chassis originally equipped with a Bendix Tu-Flo 550, Tu-Flo 750 orWABCO 318 compressor, the following additional parts will be required:
For CH or CX model chassis originally equipped with a Bendix Tu-Flo 1400 compressor, thefollowing additional parts will be required:
For CL model chassis originally equipped with a Bendix Tu-Flo 550, Tu-Flo 750 or WABCO318 compressor, the following additional parts will be required:
For CL model chassis originally equipped with a Bendix Tu-Flo 1400 compressor, thefollowing additional parts will be required:
For CV model chassis originally equipped with a Bendix Tu-Flo 550, Tu-Flo 750 or WABCO318 compressor, the following additional parts will be required:
1 63AX83 Plug, 1/2-NPT
1 5166-59214 Pipe thread sealant
1 83AX884 Clamp
Qty. Part No. Description
1 17QE520M Tube, intake
1 45MD419M2 Elbow, intake
Qty. Part No. Description
1 17QE520M Tube, intake
1 45MD419M2 Elbow, intake
1 45MD422M Elbow, intake
Qty. Part No. Description
1 17QE524M Tube, intake
1 45MD432M2 Elbow, intake
Qty. Part No. Description
1 17QE524M Tube, intake
1 45MD432M2 Elbow, intake
1 45MD422M Elbow, intake
Qty. Part No. Description
1 17QE521M Tube, intake
1 45MD320M7 Elbow, intake
Meritor WABCO 636 Compressor Retrofit Kit
Qty. Part No. Description
SB-261-009 — Page 2 of 14
The Meritor WABCO 636 air compressor retrofit kit (part No.146SB1) is not to be used as the warranty replacement of anexisting air compressor.
Procedures for installing the Meritor WABCO 636 compressor are as follows:
1. Secure the chassis for service, block the wheels and apply the parking brakes toprevent the vehicle from moving.
2. Drain the coolant from the cooling system into a clean container so that the samecoolant can be used to refill the system.
3. Remove the cab floor board.4. Remove the right-side inner fender.
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Figure 1 — Remove Right-Side Inner Fender
5. Remove the exhaust pipe from the turbocharger outlet connection, and disconnect theflex pipe from the exhaust pipe under the cab.
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Figure 2 — Remove Exhaust Pipes
SB-261-009 — Page 3 of 14
6. Remove the air inlet ducts and elbows from the air cleaner to the turbocharger, thenremove the air cleaner assembly.
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Figure 3 — Remove Inlet Air Elbows, Ducts and Air Cleaner Assembly
7. Remove the existing air compressor, coolant hoses, oil return line and brackets.
SB-261-009 — Page 4 of 14
8. If the existing compressor being replaced is a Bendix Tu-Flo 1400, remove the oilreturn fitting from the oil pan, then install a 1/2″ NPT pipe plug (part No. 63AX83) in theoil return port in the oil pan.
9. Install a 3/8″ NPT pipe plug (part No. 63AX212) in the coolant supply port in thecylinder block.
Pipe sealant (MACK part No. 5166-59214) should be applied tothe threads of all pipe plugs and fittings.
4
Figure 4 — Install Pipe Plugs in Oil Return and Coolant Supply Ports
10. Remove the 1/8″-to-No. 4 T-fitting from the existing air compressor, and install into thegovernor port of the new compressor. Also install fitting (part No. 63AX3710) into thedischarge port of the new compressor.
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Figure 5 — Install Fittings into Governor and Discharge Ports of New Air Compressor
11. Thoroughly clean the air compressor mounting surface on the engine block.
12. Remove the oil feed tube from the air compressor drive coupling and install into theauxiliary shaft. If the tube is missing or damaged, use a new tube (part No. 670GC276).
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Figure 6 — Install Oil Feed Tube into Auxiliary Shaft
Key Qty. Part No. Description
1 1 63AX3710 Fitting, compressor discharge port
2 1 existing T-fitting, 1/8″-to-No. 4, compressor governor port
SB-261-009 — Page 6 of 14
13. Position a new gasket (part No. 590GB2159) onto the air compressor mounting flange,then install the compressor to the engine. Use three bolts (part No. 27AM16) and threewashers (part No. 37AX83). Tighten the mounting bolts to 70 lb-ft (95 N·m).
14. Install the air compressor rear support bracket (part No. 253GC3191) using mountingbracket-to-compressor capscrews (part No. 26AM12) and mounting bracket-to-cylinderblock capscrews (part No. 66AM4). Tighten the capscrews to the followingspecifications:� Mounting Bracket-to-cylinder block (66AM4) — 50 lb-ft (67.8 N·m)� Mounting Bracket-to-compressor (26AM12) — 20 lb-ft (27 N·m)
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Figure 7 — Air Compressor Installation
Key Qty. Part No. Description
1 1 8235-9115150050K Air compressor, WABCO System Saver 636
2 1 590GB2159 Gasket, compressor mounting
3 3 27AM16 Flanged hex head capscrews, M12 x 1.75 x 40 mm, compressormounting
6 2 26AM12 Flanged hex head capscrews, M8 x 1.25 x 20 mm, mountingbracket-to-compressor
7 2 66AM4 Flanged hex head capscews, M10 x 1.5 x 25 mm, mounting bracket-to-cylinder block
SB-261-009 — Page 7 of 14
15. Install the 90-degree fittings (part No. 63AX3673) into the coolant inlet and outlet portslocated in the top of the air compressor.
Optimum routing for the air compressor coolant lines is to havethe coolant supply line routed to the forward port in thecompressor, and the coolant return line routed to the rearwardport in the compressor. Orient the fittings as shown in thefollowing illustration.
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Figure 8 — Coolant Inlet and Outlet Fittings and Line Routing
More efficient coolant flow to the air compressor can be obtainedby supplying coolant to the compressor from the water manifoldrather than from the coolant inlet port located at the right rearcorner of the cylinder port.
SB-261-009 — Page 8 of 14
16. Remove the 1/2″ pipe plug from the top rear section of the water manifold.9
Figure 9 — Remove Pipe Plug from Water Manifold
17. Install a 1/2″ NPT 90-degree elbow fitting (part No. 63AX3672) into the port in thewater manifold from where the pipe plug was removed. Orient the fitting so that it facesdirectly toward the rear of the engine.
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Figure 10 — Fitting Installed in Water Manifold
18. Fabricate a coolant line using approximately 41″ (1041.4 mm) of No. 6 hose (part973AX420RF) and two hose end fittings (part No. 63AX1719R).
SB-261-009 — Page 9 of 14
Line length will vary depending upon chassis model and specialequipment. Always measure the amount of hose needed andfabricate the line accordingly.
19. Install one end of the hose to the elbow fitting installed in the water manifold, then routethe hose around the back of the cylinder block and down to the compressor. Connectthe hose to the elbow fitting installed in the forward port on the air compressor cylinderhead.
20. Using an M12 x 1.75 x 20 mm bolt (part No. 27AM61, not included in kit) and clamp(part No. 83AX884), clamp the coolant line to the back of the cylinder block. Secure theclamp to the bolt hole located on the left-hand side of the cylinder block.
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Figure 11 — Bolt Hole Location in Cylinder Block
21. Fabricate a coolant line using approximately 46″ (1168.4 mm) of No. 6 hose (part No.973AX420RF) and two hose end fittings (part No. 63AX1719R).
Line length will vary depending upon chassis model and specialequipment. Always measure the amount of hose needed andfabricate the line accordingly.
SB-261-009 — Page 10 of 14
22. Install the coolant line between the water pump fitting and the elbow fitting located inthe rear port on the air compressor cylinder head.
Use the existing clamps to secure the hose.
23. Using approximately 71″ (1803.4 mm) of No. 4 air line (part No. 973AX100RF), connectone end of the line to the air governor signal port. Connect the lines from the airgovernor and air dryer to the air compressor port.
Line length will vary depending upon chassis model and specialequipment. Always measure the amount of hose needed andfabricate the line accordingly.
SB-261-009 — Page 11 of 14
24. Install the steel air intake tube to the air compressor air inlet fitting, and secure to theback of the engine block. Intake tube part numbers vary by chassis model. Refer to thefollowing table for a list of part numbers.
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Figure 12 — Air Compressor Intake Tube Installation
25. Connect the main discharge line to the fitting installed in the air compressor dischargeport.
Key Qty. Part No. Description
1 1 17QE520M Steel intake tube between compressor and air cleaner, CX and CHmodels
1 17QE524M Steel intake tube between compressor and air cleaner, CL models
1 17QE521M Steel intake tube between compressor and air cleaner, CV models
2 1 ft. 160AX526F Coupling hose, intake tube to inlet air duct
3 4 83AX838 Clamp, hose
4 1 42QE2307P2 Coupling hose, intake tube to air compressor fitting
5 1 83AX823 Clamp
6 1 26AM12 Bolt
SB-261-009 — Page 12 of 14
26. A new inlet air elbow at the air cleaner must be used to provide a connection point forthe air compressor inlet tube. Part numbers for the inlet air elbow vary by chassismodel. Refer the following table for a listing of the inlet air elbow part numbers.
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Figure 13 — Inlet Air Elbow — Air Cleaner End
Install the bulkhead fitting (part No. 40QE2143M) into the hole provided in the new inletair elbow.
On CH, CX and CL model chassis originally equipped with aBendix Tu-Flo 1400 air compressor, inlet air to the aircompressor was provided through a fitting located in the inlet airelbow at the turbocharger. On these chassis, it will be necessaryto replace the existing inlet air elbow at the turbocharger withelbow part No. 45MD422M.
27. Install the air cleaner assembly, inlet air elbows and ducts. Tighten all inlet air elbowand duct clamps to 75 lb-in (8.5 N·m) on CX and CH models, and 50 lb-in (5.6 N·m) onall other models.
28. Connect the air compressor intake tube coupling hose to the bulkhead fitting in the inletair elbow at the air cleaner.
29. Reinstall the exhaust pipe, cab floor panel and inner fender.
Key Qty. Part No. Description
1 1 45MD419M2 Inlet air elbow, CX and CH models
1 45MD320M7 Inlet air elbow, CV models
1 45MD432M2 Inlet air elbow, CL models
2 1 40QE2143M Bulkhead fitting
SB-261-009 — Page 13 of 14
30. Refill the cooling system with the proper coolant, and check the level of anti-freezeprotection.
31. Start the engine and check for coolant leaks, and for air leaks at all the compressorconnections.
32. Check the governor for correct setting. Governor cut-in and cut-out should be asfollows:
