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air conditioning compressor/clutch service manual

1. REMOVAL amp INSTALLATION CLUTCH HUB REMOVAL 1 Remove clutch retaining ring or nut Use a spanner wrench to prevent the hub plate from turning 2 Attach the tool to the end plate by threading the outer nut of the tool into the center hole of the clutch end plate 3 Tighten the inner tool arbor against the end of the compressor shaft to lift the plate Tech Tip Proper air gap between the clutch pulley and hub armature is critical to compressor overall performance Failure to maintain the proper spacing as indicated in the mfgrs specifications can lead to problems such as clutch burning or slippage SPANNER NUT WRENCH CT499 CLUTCH HUB INSTALLATION 1 Position the shaft key in place 2 Slide the clutch hub onto the shaft of the compressor Be careful not to damage the components by using excess force 3 Thread the inner part of the tool onto the shaft Tighten the outer nut of the tool to push the shaft key in 4 Set the air gap Add or remove shims to obtain the mfg specifications Always set at the min number and measure at multiple points around the circumference 5 Reinstall the retaining ring or nut 6 Check oil level and rotate the hub with the nose of the compressor down to help lubricate You can check for ease of rotation TYPICAL KEYED SHAFT FIELD COIL SNAP RING PULLEY SNAP RING FIELD COIL PULLEY AND BEARING ASSEMBLY TROUBLESHOOTING TROUBLESHOOTI
2. 56A Kallang Pudding Road 02 00 Singapore Road 349329 Tel 65 68461056 Fax 65 68461054 e mail cosasia singnet com sg 73 006 Rev B Us AIR CONDITIONING COMPRESSOR CLUTCH SERVICE MANUAL CTK1300A CLUTCH HUB TOOL KIT INCLUDES CT499 SPANNER WRENCH ss CONTENTS _ COMPRESSOR CLUTCH TOOLS R 134a COMPRESSOR SPECIFICATIONS SHAFT NUT TORQUE AND HUB AIR GAPS i y S a Vehicle Mfgr Compressor Mfgr Model Adjust Shaft Nut Torque Hub Air Gap Tool P N This manual contains compressor and clutch service information to Ho Tan General Motors Delphi Harrsion A 6 amp R 4 SAE Press Fit 15 ft lb 020 040 use with your tool kit The information includes clutch air gaps shaft nut torque oil viscosity and common problems to assist you in the compressor clutch repair Also the MACS Mobile Air Conditioning Society publishes a comprehensive air conditioning service manual Press Fit Press Fit Shims Shims 8 16 ft lb 8 12 ft lb 12 ft lb 8 12 ft lb General Motors Delphi Harrsion R 4 DA6 HR6 HR6HE FS 6 FS 10 FX 15 6P148 10P15 6E177 17 General Motors Delphi Harrsion Ford CT861 Delphi Harrison A6 R4 SAE Ford Lincoln Ford Lincoln Nippondenso CHRYSLER NIPPONDENSO that will supply wiring diagrams component locations trouble codes Remover Installer NIPPONDENSO VARIABLE DISPLACEMENT Chrysler Dodge Nippondenso ABO 171 6017 Shims 7
3. 2 ib 016 032 serpentine belt specs and additional service information RV2 A590 C171 COMPRESSOR Chrysler Dodge Sanden TRS90 105 Shim Adjust 25 30 ft lb 016 031 20 25 ft Ib 8 12 ft lb 8 12 ft lb 16 ft lb 20 25 ft Ib 15 ft lb 8 12 ft lb 20 25 ft Ib 16 ft lb 20 25 ft Ib 8 10 ft Ib 15 ft lb 16 ft lb 20 25 ft Ib 016 028 020 040 CT861 010 020 CT305 206 016 032 CT305 Chrysler Dodge Sanden SDB708 SD709 7H15 6P127 10P13 15 SD508 510 709 Metric Remover HARRISON HARRISON HARRISON HARRISON AXIAL A 6 RADIAL R 4 DA 6 HR 6 HE 6 V 5 COMPRESSOR Honda oi Us Installer V 7 R 134a Hyundai Zexel Diesel Kit DKS 15 BH 7 Hyundai Sanden Shim Adjust Shims Shims Shims Shim Adjust Press Fit Shims Shim Adjust Shims Shim Adjust Shims Press Fit Shims Shim Adjust CT861 867 Bearing 41 631 Acura Honda Audi VW Audi Zexel Diesel Kit Audi VW Audi Nippondenso Order A C Reference Manual 44151A Nippondenso Sanden CT867 Delphi Harrison DA6 V5 HR6 R4 Delphi Harrsion Nippondenso Phone 215 631 7020 or Fax 215 631 7017 Website www macs org w Ford Delphi Harrsion Zexel Diesel Kit Sanden Hyundai Isuzu ChryslerC171 Ford FS6 Hitachi MJ Tecumseh HR980 First select the model of compressor clutch you are repairing and the required tools Then reference the specific clutch problem for corrective action Additi
4. NG COMPRESSORS Checking compressor ratios is an excellent way to check system performance and possible failures Run the vehicle at 1500 RPM and record both gauge readings then add 15PSI to your reading Example 35PSI plus 15 50 low 235PSI plus 15 250 high 250 50 7 to 1 ratio R 12 acceptable ratios are between 5 to 1and 6 to 1 R 134a acceptable ratios are between 6 to 1 and 7 to 1 If a systems exceeds these ratios the compressor may fail to high internal pressure on the pistons and swash plates Possible causes of high ratios are refrigerant overcharges and air in the system Recover recharge vacuum and identify source of excess air Use refrigerant identifier to check equipment tanks and system CLUTCH PROBLEM AREAS BURNED CLUTCH 1 Hub armature and rotor pulley drive faces have oil or grease on them a Look for shaft seal leak and replace clutch b Compressor leaking through the bolt Repair leak source 2 Check for missing or improperly installed snap ring Repair or replace the clutch 3 Field coil snap ring is wrong size Measure thickness and refer to parts manual for correct size Repair or replace clutch if damaged Always check anti rotation pin damage Retaining ring should be facing away from the compressor fully seated in groove lug of ring should not be over the anti rotation pin and field ring tight against the compressor 4 Check to ensure clutch components are mat
5. ched correctly The straight coil to straight rotor pulley and stepped coil to stepped rotor pulley Repair or replace if they don t match REPLACE IN PAIRS 5 Look for high pressures Remember too much oil will cause slugging and low oil causes binding Make sure you don t have an airflow restriction TROUBLESHOOTING CLUTCH SLIPPING 1 Low torque problem Cycle on off between 2500 3000 RPM for 50 cycles to burnish the hub and rotor 2 Low voltage at the field coil Check for wiring shorts poor connections and defective relays 3 Compressor is seized or tight Check torque specs Repair or replace 4 High system pressures Check compressor oil levels Excess oil can slug compressor Low oil will cause binding Condenser restrictions from blockage or improper fan operation will reduce air flow and raise discharge pressures 5 High heat coming from clutch bearing will produce loose grease and then bearing failure NOISY CLUTCH 1 Check belt size tension and alignment 2 Rotor dragging Air gap is too small Reset and shim if necessary 3 Wrong coil snap ring and installed wrong Repair or replace 4 Field assembly installed incorrect Make sure it is bottomed completely on shoulder Pilot diameter is worn undersized The field shell pilot is worn oversize Replace compressor and or assembly The bearing is damaged Replace clutch CLUTCH DOESN T ENGAGE 1 The air gap is excessiv
6. denso YI A e gt 2 AOA This manual is not designed to replace factory service CT305 Sanden SD5 amp 7 k uzuki publications and CPS assumes no liability for use of such A gt Clutch End Plate ARo FORD PXT NIPPONDENSO 10PA17 KIEHIN T information contained in it or any damage incurred through Remover er MB Porshe VW York 206 209 210 No Adjust 20 25 ft lb 010 020 its use by the service technicians or repair facilities Manufacturers have changed their part numbers indicating upgrades Volvo Zexel Diesel Kit DKS 15 Shims 16 ft lb N A z lt Suburu Nippondenso to R 134a They use HNBR neoprene materials larger bearings ees ee improved oil passages and modifications for piston swash plate designs Paiva gee Delphi Harrsion eee A few models will have to be replaced during retrofit ESTER FOR RETROFIT USE SAME VISCOSITY EXCEPT EX5 Copyright 1999 CPS Products Inc All Right Reserved 016 031 020 040 CT861 20 25 ft Ib 15 ft Ib Volvo Sanden Shim Adjust Press Fit w z Replacement storage case 50 271
7. e Reset and remove shims 2 Voltage at coil isn t 10 8 Poor connection shorts relays or charging system 3 Resistance problem at coil Shorted or open coil so replace and diagnose electrical problems CLUTCH FAILS TO DISENGAGE 1 Clearance between the hub and rotor is too close Shim to increase 2 Rotor snap ring missing or installed wrong Repair or replace 3 The air gap is too small Reset and add shims 4 Clutch engages without turning on a c Diagnose electrical problem and repair WARRANTY POLICY CPS guarantees that all tools are free of manufacturing and material defects for one year If a tool should fail during the guarantee period it will be replaced at no charge This does not apply to tools that have been altered or misused ADDITIONAL COMPRESSOR TOOLS LS3000 REFRIGERANT LEAK DETECTOR TLFG FLUSH GUN KIT TM250A THERMOMETER TLJ4 R 134a OIL INJECTOR TLJ2 R 12 OIL INJECTOR CPS Products Inc 1010 East 31st Street Hialeah Florida 33013 USA Tel 305 687 4121 1 800 277 3808 Fax 305 687 3743 e mail cossales cpsproducts com www cpsproducts com CPS Products N V Krijgsbaan 241 2070 Zwijndrecht Belgium Tel 323 281 30 40 Fax 323 281 65 83 www cpsproducts be e mail info cpsproducts be CPS Australia PTY LTD 109 Welland Avenue Welland South Australia 5007 Tel 61 8 8340 7055 Fax 61 8 8340 7033 e mail sales cpsaustralia com au CPS Asia
8. onal tools maybe needed such as a Isuzu Jaguar A l m Nippondenso 6P 10P Jeep Chrysler Sanden SD5 amp 7 series Shim Adjust Press Fit 15 ft lb 016 032 Hell gauge set refrigerant oil injector feeler gauge and torque ean cially ere TT TT EEE ETA a l Mazda Ford FS 10 Shims 12 ft lb 016 028 wooo e D a a a eae anes je Mazda Sanden SD5 amp SD7 Shim Adjust 20 25 ft lb 016 031 Suning nae S n in the de eipig and editing his HR980 Tecumseh Nut Mercedes Benz Delphi Harrsion A 6 amp R 4 Shims 20 25 ft Ib 020 040 ERT Remover Mercedes Benz Nippondenso 10P15 17 Shims 8 12 ft lb 016 032 manual Mitsubishi Mitsubishi FX105 Shims 10 ft lb 015 023 CPS Products Mitsubishi Nippondenso 10P15 Shims 8 12 ft lb 016 032 MACS Member CT206 Zexel Diesel Kiki Nissan Infinity Zexel Diesel Kit DKV 14C Shims 16 ft lb 010 020 SAE Affiliate Member Mitsubishi Clutch End CCI YORK amp TECUMSEH HITACHI Nissan Infinity Zexel Diesel Kit DKS 16H Shims 16 ft lb 010 020 Ford Hitachi Shims Shims Shims Shim Adjust SHIM Shim Adjust Shims Shims Shims Shims 12 ft lb 14 15 ft lb 8 12 ft lb 20 25 ft Ib 20 25 ft Ib 16 ft lb 25 30 ft Ib 8 12 ft lb 8 12 ft lb SD5 7 series SS170 Nissan Plate Remover Nissan Always wear safety glasses and protective gloves Porsche Nippondenso Porsche Sanden Saab Sanden Seiko Seiki Saturn Zexel Diesel Kit Zexel Diesel Kit Nippon

air conditioning compressor/clutch service manual

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