SERVICE MANUAL - Aftermarket-sanden
Contents
1. as facing clutch Mounting Angle Left 4 115 in gt 30 118 in 8mm Typical for 20 Notches SANDEN OIL DIPSTICK oe 6 Remove dipstick and count number of notches covered by oil Mounting Angle Acceptable oil level in increments Degrees SD5H14 SD7H15 T Add or subtract oil to meet the 0 3 5 5 7 specifications shown in the table 1 Ga 6 8 20 5 7 7 9 30 6 8 8 10 8 Re install oil plug Seat and O ring 40 7 9 9 11 must be clean and not damaged 50 8 10 10 12 Torque to 11 15 ftelb 15 20 Nem 60 8 10 11 13 150 200 kgfecm 90 8 10 16 18 10 3 Shaft Turning Smoothness Inspection If on vehicle remove refrigerant from A C system and disconnect hoses If on bench uncap fittings Using a socket wrench on the armature retaining nut turn the shaft clockwise only If severe rough spots or catches are felt while turning shaft the compressor has been damaged internally and must be replaced mw Ne 10 4 Clutch Inspection l Measure voltage at clutch Low voltage at the clutch may be due to poor ground or power connection or problems with the vehicle electrical system Check for tight fit of field coil retaining snap ring 2 Measure current draw when clutch is engaged Normal current should be 3 6 4 2A at 12VDC e Overcurrent Short circuit within field coil or in compressor circuit e No current Open circuit If a short or open is found in the field coil it must be replaced INSPECTION2. SD COMPRESSOR SERVICE MANUAL TABLE OF CONTENTS 1 Compressor Models Covered 1 11 Field Replaceable Parts 11 1 Compressor Parts 12 2 Compressor Nomenclature 1 11 2 Clutch Parts 12 3 Cautionary Information 2 12 Service Operations General Information 12 4 R134a Information 4 1 R134a Pag Oil Handling 3 13 Oil Charging 4 2 Table of Saturation 13 1 Repairing Compressor 13 Temperatures and Pressures 3 13 2 Replacing Same Type of Compressors 14 5 Compressor Identification 13 3 Replacing Different Types 5 1 Label 4 of Compressors 14 5 2 Date Codes 4 13 4 Oil Charge Determination for Long Hose Applications 15 6 Compressor Specifications 13 5 Oil Retained in 6 1 Belt Tension 4 System Components 17 6 2 Speed Rating 4 6 3 Basic Specifications 5 14 Clutch Service 6 4 Assembly Torques 5 14 1 Armature Assembly Removal 17 6 5 Mounting Angles 5 14 2 Rotor Assembly Removal 18 14 3 Field Coil Assembly Removal 18 7 Cylinder Head Porting Guide 6 14 4 Field Coil Ass y Installation 18 14 5 Rotor Assembly Installation 18 8 Tools 14 6 Armature Ass y Installation 19 8 1 Special Service Tools 7 8 2 Standard Tools 7 15 Shaft Seal Service 20 9 Service Prodecures 8 16 Cylinder Head Valve Plate Service 16 1 Cylinder Head Removal 22 10 Inspection Procedures 16 2 Valve Pl
3. If this repair does not fully solve the problem proceed to the next inspection step Symptom Problem Diagnosis and Inspection Cause and Remedy Unusually high suction 1 Valve Plate Test Replace or Repair pressure with unusually Reed Valve or Gasket Unusually low suction and discharge pressure 2 Leak Check Compressor 9 3 Leak Check and Diagnose System Shaft Seal Leak See System Service Manual Cylinder Head Leak Gasket Leak Oil Filler Plug Leak 7 Cracked Cylinder Block 1 Check Belt Tension Front Housing O Ring Leak 2 Check Clutch Air Gap 3 Check Clutch Volts Replace or Repair Amps Coil Lead Wire on 2 z 5 low discharge pressure Broken Head or Block Gasket 22 mM Broken or Deformed Reed Valve to 5 1 Check for low Refrigerant Charge Foreign Substance Under 25 a AS Replace or Repair Intermittent or Inoperative LACK OF COOLING Broken Lead Wire Clutch Coil Defect Internal System Ground see System Manual Rough Running or Intermittent or Inoperative 4 Shaft Turning Smoothness Test 1 Check Compressor Mounting Components 11 2 Check Engine 3 Check for Intermittent or 10 Adjust Air Gap 20 Slipping Clutch Defective Coil 4 Check for Proper Refrigerant Charge Recharge and Recheck 5 Check Clutch Bearing Replace Rotor Armature Ass y 17 19 6 Oil Level Procedure 9 Restore to Proper Level 7 Shaft Turning 10 Compressor Failure Internal Smoothness Te
4. v 7862 9630 KG Horizontal 10 Tube O 7 8 thd 8 Tube O 3 4 thd No 7406 9630 _ MD Horizontal 1 14 Rotolock Tube O 1 14 Rotolock Tube O No J v v 7433 9630 QC Horizontal GM Pad 3 8 24 Bolt _ GM Pad 3 8 24 Bolt No 7484 9630 QD Horizontal Pad M10x125Bolt Pad M10x1 25Bolt No 7200 9631 UK Vertical Pad M10 x 1 25 Bolt Pad M10 x 1 25 Bolt No SISS qa lt BORE BORE lt lt A Sanden R134a compressors do not offer the option of charging valves on the compressor B Indicates that a compressor featuring this cylinder head should not be mounted with the suction port at the bottom J Ue Ons 5 SERVICE TOOLS 8 1 Special Service Tools These tools can be obtained from your local tool supplier 1 Oil Dipstick 3 Armature Plate Puller 2 Armature Plate Spanner 4 Rotor Puller Set 5 Lip Seal SD7 Seal Plate Tool 7 Rotor Puller Jaws 9 Rotor Installation Driver 6 Armature Driver 8 Shaft Seal Protective Sleeve 10 O Ring Hook 8 2 Standard Tools 1 External Snap Ring Pliers 3 Feeler Gauges 5 Graduated Cylinder 2 Internal Snap Ring Pliers 4 Gasket Scraper SERVICE PROCEDURES 9 TROUBLESHOOTING CHART This chart refers specifically to the Sanden compressor During diagnosis follow the inspection procedures in the sequence shown until a defect is found Then perform the repair in the Cause and Remedy Section
5. 20 Clutch dust cover screws 3 4 20 2 70 9 3 61 2 374 12 6 5 Acceptable Mounting Angles All SD R134a Compressors CYLINDER HEAD PORTING GUIDE Te SD R134a COMPRESSOR SERIES For SD5H14 SD7H13 SD7HI5 and SD7H15HD SHD Units Hose Port Information SD Compressor Series Sanden Service Position on Suction Port Discharge Port TPS or 7H15 Kit Part No N Cyl Head Dimension Type Dimension Type switch 9H14 7HIS 7HIS esa 9580 9630 C Vertical 1 14 Rotolock Tube O 1 14 Rotolock Tube O No v TBD FL Vertical 10 Tube O 7 8 thd 8 Tube O 3 4 thd No v 9034 9630 K Horizontal 10 Tube O 7 8 thd 8Tube O 3 4 thd No v 9699 9630 M _ Horizontal 1 14 Rotolock Tube O 1 14RotolockTube O No v J 9150 9630 Q Horizontal GM Pad 3 8 24 Bolt GM Pad 3 8 24 Bolt No v 9695 9630 QH Horizontal GM Pad 3 8 24 Bolt GM Pad 3 8 24 Bolt Yes v 9298 9630 U Vertical Pad MIOx1 Bolt Pad M10x1Bot_ No v J 9517 9630 _ UB Vertical Pad M10x1 25Bolt Pad MI0x1 25Bolt_ No v J 9516 9630 Horizontal Pad M10 x 1 25 Bolt Pad M10 x 1 25 Bolt 7412 9630 CB Vertical 1 14 Rotolock Tube O 1 14 Rotolock Tube O No v v 7832 9630 JD Vertical 10 Tube O 7 8 thd 8 Tube O 3 4 thd No v v 7863 9630 JE Vertical 10 Tube O 7 8 thd 8 Tube O 3 4 thd No v
6. PROCEDURES 3 Air Gap Clutch air gap should be 0 016 0 031 in 0 4 0 8 mm Measure with a feeler gauge Adjust as per Section 14 6 4 Suspected Clutch Rotor Bearing Noise e Remove drive belt e With clutch disengaged rotate pulley by hand If excessive roughness or wobble is found replace the clutch rotor assembly 10 5 Unusual Noise Not Due To Compressor Unusual noises may be caused by components other than the compressor l Compressor Mounting Check for e Loose belt see belt tension specifications Broken bracket or compressor mounting ear Replace broken component Missing broken or loose mounting bolts Replace reinstall or tighten Flush fit of compressor to bracket and to vehicle engine Replace any part not properly fitted Loose or wobbling crankshaft pulley Check for damage to pulley incorrect center bolt torque or center bolt bottoming Repair to vehicle manufacturer s specifications e Bad idler pulley bearing Replace if necessary 2 Other Engine Components Check for noise in Alternator bearing Air pump if present Water pump bearing Valves Timing belt or chain Power steering pump if present Loose engine mount bolts 10 6 Unusual Noises Due to Compressor 1 Suction pressure less than about 5 psig can cause unusual noise Charge refrigerant to proper amount and test by applying heat to evaporator to increase suction pressure 2 Clutch Bearing See Clutch Inspection in Section 10 4 3 O
7. a small pocket of refrigerant trapped in a recess Cleaning the suspect area with soap and water never a solvent or blowing off the area with compressed air can help confirm a suspected leak e Leak check procedure should be in accordance with SAE J1628 4 Leak Detection Dyes The use of leak detection dyes is not recommended by Sanden as their chemical compositions are proprietary and their effects on Sanden oils and elastomers are unknown at this time 10 2 Oil Level Measurement In Vehicle Oil level in the compressor should be checked when a system component has been replaced when an oil leak is suspected or when it is specified as a diagnostic procedure 1 Run the compressor for 10 minutes with the engine at idle 2 Recover all refrigerant from the system slowly so as not to lose any oil 3 Determine the mounting angle of the compressor from horizontal i e oil plug or adaptor on top This is most readily done by using a machinist s universal level if access to the compressor permits INSPECTION PROCEDURES 4 Remove the oil filler plug Using a socket p Diestick wrench on the armature retaining nut turn VE ae the shaft clockwise until the C of Met hole counterweight is positioned as shown ae Insert oil dipstick up to the stop as shown peda in the figure above with the angle pointing in the correct direction Position of Counter Weight Mount ting Angle Right
8. containing XH7 or XH9 desiccant If a CCOT system is being repaired due to compressor damage or foreign material is found in the oil drained from the system this foreign material must be removed from the system At this time an in line filter should be installed in the liquid line Allow as much oil as possible to drain from the A C lines when installing the filter Change any O rings disturbed in the installation of the filter to approved HNBR O rings Perform any necessary repairs to the compressor or A C system Using the original refrigerant oil quantity specification add SP 20 or SP 10 oil to the compressor SP 10 for TR SDV SDB and SD7H15 Type C SP 20 for all other SD compressors Replace the compressor oil plug O ring with an HNBR O ring Reinstall the compressor oil plug The plug seat and O ring must be clean and free of damage Torque the plug to 11 15 fteIb 15 20 Nem 150 200 kgf cm Change any seals at the compressor ports to approved HNBR seals Reinstall the compressor to the A C system Evacuate the A C system for at least forty five 45 minutes to a vacuum of 29 in Hg using R 12 equipment to remove as much R 12 as possible from the residual mineral oil Remove all R 12 service equipment and disable the R 12 service fittings to prevent any refrigerant other than R134a from being used Permanently install R134a quick connect service fittings to the A C system Connect R134a service hoses and other equipment R
9. hammer and gasket scraper to separate the cylinder head from the valve plate Be careful not to scratch the gasket surface of the cylinder head Carefully lift the cylinder head from the valve plate It is recommended that both the head gasket between the cylinder head and the valve plate and the block gasket between the valve plate and cylinder block be replaced any time the cylinder head is removed However if no service is required to the valve plate it may be left in place If the valve plate comes loose from the cylinder block the block gasket must be replaced SERVICE OPERATIONS CYLINDER HEAD VALVE PLATE 7 Carefully remove old head gasket from top of valve plate with gasket scraper Be careful not to disturb the valve plate to cylinder block joint if valve plate is to be left in place If valve plate comes loose from cylinder block proceed to Section 16 2 Valve Plate Removal and replace block gasket 16 2 Valve Plate Removal l Using a small hammer and gasket scraper carefully separate valve plate from cylinder block Be careful not to damage sealing surface of cylinder block 2 Inspect reed valves and retainer Replace valve plate assembly if any part is damaged 3 Carefully remove any gasket material remaining on valve plate cylinder block or cylinder head Do not damage sealing surfaces of components 16 3 Valve Plate and Cylinder Head Installation l Large gasket OD of block gas
10. models of Sanden compressors are fitted with a high pressure relief valve HPRV to protect against damage from abnormally high discharge pressures 1 Note When replacing a failed HPRV with a new one be sure to identify whether the A C system is for R 12 or R134a The HPRV and the small O ring at the threaded portion are both different for R134a Contact your supplier for additional information 2 Be sure all gas pressure has been released from inside the compressor 3 Remove HPRV 4 Coat O ring of new HPRV with clean 5GS refrigerant oil Seat and O ring must be clean and not damaged 5 Install new HPRV and torque to 6 9 ftelb 8 12 Nem 80 120 kgf cm CONVERTING R 12 SYSTEMS TO R134a 19 1 Recommended Procedures For Sanden R 12 Compressors Retrofitted With R134a The use of R134a in mobile A C systems designed for R 12 refrigerant use causes higher discharge pressures as much as 10 15 and necessitates changing the compressor lubricant from mineral oil SGS to PAG oil Sanden s SP 10 or SP 20 to ensure compatibility These changes result in greater wear to the internal components of the compressor Therefore to ensure consistent and expected reliability Sanden does not recommend using R134a in systems and compressors designed for R 12 However Sanden recognizes the realities of the automotive service markets and consumer preferences If a retrofit is required please follow the vehicle manufacturer s published
11. remove cover If auxiliary sheet metal pulley is present remove the screws holding it in place Then remove pulley 2 Insert pins of armature plate spanner into threaded holes of armature assembly 3 Hold armature assembly stationary while removing retaining nut with 3 4 19mm or 14mm socket wrench as appropriate 4 Remove armature assembly using puller Thread 3 puller bolts into the threaded holes in the armature assembly Turn center screw clockwise until armature assembly comes loose 5 If shims are above shaft key remove them now If shims are below shaft key the key and bearing dust cover if present must be removed before the shims can be removed 6 Remove bearing dust cover if present Use caution to prevent distorting cover when removing it 7 Remove shaft key by tapping loose with a flat blade screwdriver and hammer 8 Remove shims Use a pointed tool and a small screwdriver to prevent the shims from binding on the shaft SERVICE OPERATIONS CLUTCH 14 2 Rotor Assembly Removal 1 If bearing dust cover has not been removed remove it now See step 6 of Section 14 1 for Armature Assembly Removal 2 If internal snap ring for bearing is visible above the bearing remove it with internal snap ring pliers 3 Remove rotor snap ring 4 Remove shaft key Remove rotor pulley assembly e Insert the lip of the jaws into the snap ring groove e Place rotor puller shaft protector Puller set
12. 50 200 kgf cm Be careful not to cross thread oil plug It is recommended that the oil quantity be confirmed after re installation of the compressor to the vehicle as per Section 10 2 13 2 Sanden Compressor Replaced by a New Sanden Compressor of the Same Type 1 Drain oil from the old compressor measure and record the amount as per the procedure in Section 12 1 Drain oil from the new compressor as per Section 13 1 Add new oil of the correct type to the new compressor as shown in Section 6 3 Use the same quantity as was removed from the old compressor in step 1 Re install oil plug Seal and O ring must be clean and not damaged Torque to 11 15 ftelb 15 20 Nem 150 200 kgfecm It is recommended that the oil quantity be confirmed after installation of the new compressor to the vehicle per Section 10 2 13 3 Sanden Compressor Used to Replace a Compressor of a Different Type This section applies to replacement of another manufacturer s compressor or to the replacement of a Sanden compressor by a different model Sanden compressor In this case the procedure of Section 13 2 should be followed except that the oil quantity must be confirmed after installation of the new compressor to the vehicle as shown in Section 10 2 SERVICE OPERATIONS OIL CHARGING 13 4 Oil Charge Determination for Long Hose Applications 13 4 1 TXV Systems Less than 56 oz 1600g Refrigerant Charge 1 The desired oil charge for systems with unus
13. ate Removal 23 10 1 Leak Checking 9 16 3 Valve Plate and Cylinder 10 2 Oil Level Measurement 9 Head Installation 23 10 3 Shaft Turning Smoothness Inspection 10 17 Thermal Protector Switch Service 10 4 Clutch Inspection 10 17 1 TPS Testing 24 10 5 Unusual Noise Not 17 2 TPS Replacement 25 Due to Compressor 11 10 6 Unusual Noise 18 High Pressure Relief Valve Service 25 Due to Compressor 11 10 7 Valve Plate Test 12 19 Converting R 12 Systems to R134a 26 This service manual has been prepared by Sanden International USA Inc It includes information on application troubleshooting and repair of automotive air conditioning compressors manufactured by Sanden Corporation and its subsidiaries in accordance with the appropriate SAE standards for mobile air conditioning Service operations not described in this manual are not authorized for Sanden compressors For further information contact your nearest Sanden representative COMPRESSOR MODELS 1 Model Conversions TYPE R 12 R134a 5 Cylinder SD 505 SD7B10 SD5H09 SD 507 SD5H11 SD 508 SD5H14 SD 510 SD7HI15HD and SD5H14HD 7 Cylinder SDB 706 SD7B 10 SD 708 SD7H13 SD 709 SD7H15 COMPRESSOR NOMENCLATURE 2 Identification R 12 Compressors S D 7 0 9 Sanden reciprocating wobble plate compressors a Number of cylinders Approximate displace
14. ation code 00 06 Japan 70 79 USA SD7HI15 80 89 Singapore Serial No Serial Number 123456 Month of manufacture 1 12 Year of manufacture last digit 5 2 Manufacturing Date Codes Stamped on Compressor Manufactured in USA Only Sanden internal I D code Manufacturing date codes are stamped on the mounting ear or boss at the front left of the compressor as seen when facing the clutch with oil plug or adaptor up Year of manufacture first digit i e 3 indicates manufacture in 1993 Month of manufacture last digit Jan Sept 1 9 Oct X Nov Y Dec Z COMPRESSOR SPECIFICATIONS 6 1 Belt tension Grooves Tension lb kqf A 121 5 55 2 B 132 5 60 2 C 132 5 60 2 M 132 5 60 2 PV4 132 5 60 2 PV6 198 5 90 2 PolyVee tension based on 33 lb 15kgf per groove 6 2 Speed Rating Clutch Max RPM Model Type Constant Downshift SD5H14 Std 6 000 7 000 SD5H14 HD 4 000 6 000 SD7B10 All 6 000 7 000 SD7H13 All 6 000 8 000 SD7H15 Std 6 000 8 000 SD7H15 HD 4 000 6 000 SD7H15 SHD 4 000 4 000 COMPRESSOR SPECIFICATIONS 6 3 Basic Compressor Specifications i ight tandard Oil Charge Model Refrigerant Deap een a oh Oil oe Rotation cu in
15. cc Compressor Clutch Assembly T Type Amount fl oz cc ype yp SD5H14 R134a 8 4 138 11 2 5 1 6 0 2 7 17 2 7 8 SP 20 a i Te 15 pa SD7B10 R134a 6 1 100 59 7 3 3 15 9 2 42 SP 10 TXV No standard CW SD7H13 R134a 7 9 129 9 3 4 2 4 6 2 1 13 9 6 3 SP 20 TXV 4 6 0 5 135 15 CW re R134a 9 5 155 9 9 4 5 5 3 2 4 15 2 6 9 a os ag D CW po R134a 9 5 155 9 9 4 5 7 7 3 5 17 6 8 0 ay a H a D CW 6 4 Assembly Torque s ITEM ft Ib Nem kgf cm Armature retaining nut 1 2 20 22 4 29 30 4 3 9 310 40 Armature retaining nut M8 13 0 22 17 7 2 9 180 30 Cylinder head bolts M6 25 3436 34 3 4 9 350 50 Cylinder head bolts M8 10 1 2 2 13 7 2 9 140 30 Oil filler plug 14 5 3 6 19 6 4 9 200 50 Service valve 9 4 2 2 12 8 2 9 130 30 Service valve cap 1 7 to 4 3 in lb 0 20 to 0 49 2to5 Hose fitting 1 14 rotolock 26 7 2 9 36 3 3 9 370 40 7 8 Tube 0 23 9 2 9 32 4 3 9 330 40 7 8 Flare 54 9 2 9 74 6 3 4 760 35 3 4 Tube 0 17 3425 23 5 3 4 240 35 3 4 Flare 37 6 1 4 51 0 20 520 20 Pad fitting bolt M10 26 9 2 9 39 2 3 9 440 40 3 8 24 28 9 2 9 39 2 3 9 440 40 M8 26 3 2 9 34 3 3 9 350 40 Clutch lead wire clamp screw 11 3 in lb 1 3 0 3 133 High pressure relief valve 7 2 1 4 9 8 2 0 100 20 Thermal protector switch clamp bolt 1 2 2 2 9 8 2 9 100 30 1 4 2 0 20 Clutch dust cover screws 6 M5 6 5 1 4 8 8 2 0 90
16. d ounces cc Model a Expansion valve systems Orifice tube systems SD 505 3 4 0 5 100 15 No standard SD 507 5 5 05 165 15 No standard SD 508 7 2 0 5 210 15 9 5 0 5 280 15 SD 510 No standard 8 1 0 5 240 15 SDB 706 No standard No standard SD 708 4 6 0 5 135 15 No standard SD 709 4 6 0 5 135 15 8 1 0 5 240 15
17. e evacuate the system for thirty 30 minutes using the R134a equipment Charge the A C system with R134a Generally about 5 by weight less than the R 12 charge amount is required Leak check the system per SAE J1628 procedure If the A C system is a CCOT type which has been repaired due to damage or the discovery of foreign material in the oil drained from the system run the system for sixty 60 minutes to capture this material in the filter installed in step 9 Recover the refrigerant remove and dispose of the filter reconnect the lines evacuate for at least forty five 45 minutes and recharge the A C system This step should not be necessary for TXV systems since the drier is fitted with an internal filter CONVERTING R 12 SYSTEMS TO R134a 20 Check the A C system operating parameters The system should function correctly within acceptable limits of temperatures and pressures This will ensure that the correct amount of R134a has been charged 21 In extreme circumstances when expected cooling performance cannot be achieved and high discharge pressures are experienced it may be necessary to add more condensing capacity to the A C system An electric fan s and or a larger capacity condenser can be used 22 Replace all R 12 compressor labels with retrofit labels per SAE J1660 in order to provide information on the R134a retrofit which has been performed Retrofit PAG oil amount flui
18. e only Sanden specified PAG lubricants for R134a systems using Sanden compressors If other lubricants are used A C system failure is likely to occur Never introduce R134a or PAG oil into a system not designed for them except when following the appropriate retrofit procedure described in Section 19 The Sanden specified PAG oils used in R134a systems absorb atmospheric moisture very quickly Moisture in the A C system can cause major damage or failure Never leave PAG oil exposed to air for a prolonged time Tightly reseal the oil container immediately after each use During A C system repair cap all fittings as soon as opened and leave capped until just before they are reconnected If a repair is performed on an R134a compressor or system evacuate the system for at least 45 minutes before recharging to ensure the removal of moisture which may have been absorbed by the PAG oil in the compressor and system 4 2 Table of Saturation Temperatures and Pressures Temp Pressure Temp Pressure Temp Pressure CF psig CF psig CF psig 40 7 2 in Hg 25 22 105 135 30 4 8 in Hg 30 26 110 147 20 1 7 in Hg 40 35 115 159 15 0 50 45 120 172 10 2 60 57 130 200 5 4 70 71 140 231 0 6 80 85 150 264 5 9 85 95 160 301 10 12 90 104 180 386 15 15 95 114 200 485 20 18 100 124 210 549 COMPRESSOR IDENTIFICATION 5 1 Label Manufacturing loc
19. e sure there is no gap between the end of the sleeve and the seal surface of the shaft Engage the lips of the seal removal and installation tool with the slots in the new lip seal housing Make sure the lip seal assembly especially the O ring is clean Dip the entire lip seal assembly on the tool into clean 5GS refrigerant oil Make sure the seal assembly is completely covered with oil Install lip seal over shaft and press firmly to seat Twist the tool in the opposite direction to disengage it from the seal and withdraw the tool Reinstall shaft seal snap ring with internal snap ring pliers Beveled side should face up outward away from compressor body Ensure that snap ring is completely seated in groove It may be necessary to tap the snap ring lightly to seat it in the groove SHAFT SEAL 11 12 13 14 SERVICE OPERATIONS SHAFT SEAL Tap new felt ring assembly into place Reinstall clutch shims shaft key rotor bearing dust cover if used and armature assembly as described in Section 14 6 Check and adjust air gap as necessary as shown in Section 14 6 Reinstall armature dust cover if used as described in Section 14 6 SERVICE OPERATIONS CYLINDER HEAD VALVE PLATE 16 1 Cylinder Head Removal 1 Be sure all internal compressor pressure has been relieved Inspect cylinder head for fitting or thread damage Replace if damaged Remove cylinder head bolts Use a small
20. for a prolonged time without a sufficient refrigerant charge in the system Probable results are overheating internal damage and seizure 4 If an internal repair is performed on an R134a compressor evacuate the A C system for at least 45 minutes before recharging to remove moisture which may have been absorbed by the PAG oil in the compressor 5 Parts which require lubrication before assembly such as O rings should be lubricated with clean 5GS refrigerant oil SERVICE OPERATIONS OIL CHARGING 13 1 Compressor Repaired Internally and Reinstalled in the System l Before any internal repair is done drain the oil from the compressor e Remove the oil plug and drain as much oil as possible into a suitable container e Remove the caps if present from suction and discharge ports e Drain oil from the suction and discharge ports into a suitable container while turning the shaft clockwise only with a socket wrench on the armature retaining nut SERVICE OPERATIONS OIL CHARGING Measure and record the amount of oil drained from the compressor Inspect the oil for signs of contamination such as discoloration or foreign material Perform repairs to the compressor Add the same amount of new oil to the compressor as was measured in step 2 Be sure to use the correct oil for the compressor as shown in Section 6 3 Re install oil plug Seal and O ring must be clean and not damaged Torque to 11 15 ftelb 15 20 Nem 1
21. has been removed with internal snap ring pliers 6 Reinstall rotor retaining snap ring with external snap ring pliers If a bevel is present on the snap ring it should face up away from the body of the compressor Ta Reinstall rotor bearing dust cover if present by gently tapping it into place 14 6 Armature Assembly Installation l Install shaft key with pliers 2 Install clutch shims NOTE Clutch air gap is determined by shim thickness When installing a clutch on a used compressor try the original shims first When installing a clutch on a compressor that has not had a clutch installed before first try 0 04 0 02 and 0 004 1 0 0 5 0 1 mm shims 3 Align keyway in armature assembly to shaft key Using driver and a hammer or arbor press drive the armature assembly down over the shaft until it bottoms on the shims A distinct sound change will be noted if driving with a hammer 4 Replace retaining nut and torque to specification 1 2 20 20 25 ftelb 27 34 Nem 270 350 kgecm M8 11 15 ftelb 15 21Nem 150 210kgf cm SERVICE OPERATIONS CLUTCH 5 Check air gap with a feeler gauge Specification is 0 016 0 031 0 4 0 8mm If gap is not even around the clutch gently tap down at the high spots If the overall gap is out of spec remove the armature assembly and change shims as necessary 6 Replace armature dust cover if used and torque 3 or 6 bolts to specification below 3 1 4 20 bo
22. il Level Insufficient oil can cause unusual noise See Oil Level Check Procedure in Section 10 2 4 Valve Noise Test for valve plate assembly failure per Valve Plate Test Procedure in Section 10 7 20A 20B 21A 21B 22 INSPECTION PROCEDURES 10 7 Valve Plate Test Suction or discharge valve breakage will cause a clacking sound at idle If head gasket failure occurs discharge pressure will be low and suction pressure will be 1 2 3 high at idle Valve and gasket condition can be checked as follows e Connect gauge set to suction and discharge service valves e Run compressor for 5 minutes at idle and stop e Observe time for discharge pressure and suction pressure to equalize If less than 2 minutes in a TXV system a valve or gasket may be damaged CCOT systems will equalize more quickly FIELD REPLACEABLE PARTS 11 1 Compressor p Ww ng 1 Shaft Key 2 Felt Ring 3 Shaft Seal Snap Ring 9 4 Lip Seal w O Ring 10 5 6 Oil Plug 11 2 Clutch Armature Dust Cover Screw SD 5 Armature Dust Cover Screw SD 7 Armature Dust Armature Dust Shaft Nut 11 Block Gasket 12 oo Valve Plate Assembly Head Gasket Cylinder Head Cylinder Head Bolt Pressure Relief Valve Optional Thermal Protector Switch Optional I7 18 TPS Clip Optional TPS Screw Optional Shaft Seal Kit 2 3 amp 4 Valve Plate Kit 6 7 amp 8 Cylinder Head Kit 8 a
23. ineering for additional information 1 Check continuity at room temperature If switch is open at room temperature remove and replace Check actuating temperature Remove TPS and place in container of PAG oil Heat oil using an electric hot plate while monitoring oil temperature TPS should open at 116 5 C 241 9 F If it does not function properly replace it SERVICE OPERATIONS THERMAL PROTECTOR SWITCH 17 2 TPS Replacement 1 Disconnect all electrical connections 2 Remove TPS retaining clip bolt 3 Spray around TPS with commercial non petroleum based solvent volatile type such as 1 1 1 trichloroethane or approved substitute to loosen silicone 4 Remove TPS with pliers Use care to prevent deforming the TPS housing because this can change the temperature setting 5 Clean silicone residue out of TPS well with a flat bladed screwdriver Wipe out the TPS well with a cloth Make sure well area is clean and dry 6 Apply a dot of silicone RTV Dow Corning 8390 or 1340 recommended approximately 1 4 6mm in diameter and 1 8 3mm high at the bottom of the TPS well 7 Install TPS making sure lead wires are oriented to the clearance notch 8 Install TPS retaining clip and bolt Hold clip tight against stop while torquing bolt to 6 9 ftelb 8 13 Nem 80 130 kgf cm 9 Reconnect electrical connections and check function SERVICE OPERATIONS HIGH PRESSURE RELIEF VALVE 18 HPRV Replacement Some
24. ket is 4 3 4 120mm and sealing face of block does not have a 4 1 2 114 7mm diameter step 2 Small gasket OD of gasket is 4 1 2 114 7mm and sealing face of the cylinder block has a 4 1 2 114 7mm diameter step 3 Coat new block gasket with clean 5GS refrigerant oil 4 Install block gasket Align new gasket to location pin holes and orifice s Notch if present should face same direction as oil plug or adaptor SERVICE OPERATIONS CYLINDER HEAD VALVE PLATE Place valve plate on cylinder block with discharge valve retainer and nut facing up away from cylinder block and location pins properly located in holes Use vacuum pump and small tube to remove residual oil from each bolt hole If this step is not performed hydraulic pressure can be created when the cylinder head bolts are tightened This pressure can break the cylinder block Coat head gasket with clean 5GS refrigerant oil Install head gasket over location pins checking for correct orientation Install cylinder head Install cylinder head bolts and tighten in a star pattern Torque first to approximately 14 ftelb 19 6 Nem 200 kgfecm then finish by torquing to 24 27 ftelb 32 4 36 3 Nem 330 370 kgfecm SERVICE OPERATIONS THERMAL PROTECTOR SWITCH 17 1 TPS Testing Some models of SD compressors are equipped with a bi metal type thermal protector switch TPS to protect against abnormally high temperatures Contact Sanden Application Eng
25. le doors open was determined in step 10 If the amount of e Maximum blower speed oil actually in the compressor amount e Ambient temperature at least 24 C 75 F drained plus 0 5 fl oz 15cc is less than the desired amount of oil add oil as necessary to the container and pour back into the compressor If the amount of oil actually in the compressor is too much remove oil from the container until the correct amount is reached and pour back into the compressor The amount of oil poured back into the compressor should equal the desired amount from the table minus 0 5 fl oz 15cc Use the correct oil type as per Section 6 3 13 Re install oil plug Seal and O ring must be clean and not damaged Torque to 11 15 fte lb 15 20 Ne m 150 200 kgfecm SERVICE OPERATIONS OIL CHARGING 13 5 Oil Retained in System Components l l l Componse Typical oil amount For reference the amount of oil typically retained fl oz cc in other system components after running at 1000 Evaporator 2 0 60 rpm compressor speed is shown at right These Condenser 1 0 30 volumes will of course vary with different designs Receiver drier 0 5 15 of the components and compressor speeds prior to Accumulator 2 0 60 shut down Hoses normal length 0 3 10 SERVICE OPERATIONS OIL CHARGING 14 1 Armature Assembly Removal l If armature dust cover is present remove the 3 or 6 bolts holding it in place and
26. lts SD 5 2 4 ftelb 2 5 Nem 25 50 kgfecm 6 MS bolts SD 7 5 8 ftelb 7 11 Nem 70 110 kgf cm Note Over torque of SD508 5H14 dust cover bolts will cause air gap to become out of spec SERVICE OPERATIONS SHAFT SEAL 15 Replacement of Lip Type Shaft Seal SD5H14 SD7B10 SD7H13 SD7HIS5 NOTE Lip seal assembly and felt ring must never be reused Always replace these components l Be sure all gas pressure inside the compressor has been relieved 2 Remove armature dust cover if used armature assembly rotor bearing dust cover if used shaft key and clutch shims as per section 14 1 3 Insert the points of a pair of snap ring pliers into the two holes of the felt ring retainer and pry out the retainer and felt ring 4 Remove seal snap ring with internal snap ring pliers 10 SERVICE OPERATIONS Use lip seal removal and installation tool to remove lip seal assembly Twist the tool until the 2 lips on the tool engage the slots in the lip seal housing and pull the seal out with a twisting motion Clean out shaft seal cavity thoroughly Debris can be removed using a non petroleum based solvent and a lint free cloth The area should then be blown out with clean dry compressed air Make sure all foreign material is completely removed Place shaft seal protective sleeve over compressor shaft Inspect the sleeve to ensure that it has no scratches and is smooth so that the lip seal will not be damaged Mak
27. ment in cubic inches R134a Compressors Sanden reciprocating wobble plate compressors til Number of cylinders Port location H if on head B if on block Approximate displacement in cubic centimeters divided by 10 Heavy duty HD or Sealed Heavy duty SHD clutch CAUTIONARY INFORMATION 3 1 Pressure Release Before disconnecting any lines always make sure refrigerant has been removed from the A C system by recovering it with the appropriate recovery equipment When working on compressors separate from the system always be sure to relieve internal pressure first Internal compressor pressure can be relieved by removing the oil plug if necessary or by removing shipping caps pads from both ports 3 2 Recovery of Refrigerant Never discharge refrigerant to the atmosphere Always use approved refrigerant recovery recycling equipment to capture refrigerant which is removed from the A C system Do not mix refrigerants in the same piece of equipment one should be designated for R 12 and another for R134a 3 3 Handling of Refrigerant Always wear eye and hand protection when working on an A C system or compressor Liquid refrigerant can cause frostbite and or blindness 3 4 Ventilation Keep refrigerants and oils away from open flames Refrigerants can produce poisonous gasses in the presence of a flame Work in a well ventilated area 3 5 Avoid Use of Compressed Air Do not introduce compressed air int
28. mp 9 Gasket Kit 6 amp 8 Cover SD 5 Cover SD 7 Sold in kits only 23 Armature Plate 24 Clutch Shims 25 Rotor Snap Ring 26A Rotor Bearing Dust Cover SD 5 26B Rotor Bearing Dust Cover SD 7 27 Rotor Assembly 28 Field Coil Ass y Snap Ring 29 Field Coil Ass y 30 Accessory Kit 1 22 24 25 amp 28 31 Armature Rotor Ass y Kit 23 amp 27 SERVICE OPERATIONS GENERAL INFORMATION 12 General Service Information It is recommended that a new receiver drier or accumulator drier be installed if a compressor is replaced or an internal repair is made l Keep dirt and foreign material from getting on or into the compressor or the A C system The area around A C hose fittings should be carefully cleaned with a non petroleum based solvent before the connections are broken All parts to be re used or installed should be cleaned with a non petroleum based solvent and blown dry with clean compressed air or lint free cloths 2 Trouble free installation and operation of an SD compressor require e Correct pulley alignment e Correct fit of compressor mounting surfaces to the bracket and correct fit of the bracket to the engine Clearance between compressor and bracket should not exceed 0 2mm 0 008in per ear for ear mount compressors or 0 4mm 0 016 in total for 2 ears e Correct torque of all mounting bolts and nuts e Correct drive belt tension 3 Never operate the compressor at high speed or
29. o an A C system due to the danger of contamination 3 6 Warranty for Recycled Refrigerant The warranty offered by Sanden International U S A Inc on air conditioning compressors when used with recycled refrigerant will be the same as for new refrigerant provided that the following SAE standards are met R 12 R134a R 12 R134a Refrigerant Purity J1990 J2099 Recycling machine J1989 J2210 Recycling machines must be validated to the appropriate SAE standard by Underwriters Laboratories Recycled refrigerant from other sources must meet the appropriate ARI standards Failure to comply with these provisions may void any warranty on the compressor R134a INFORMATION 4 1 R134a PAG Oil Handling Precautions As a conscientious member of the global community Sanden Corporation with its subsidiaries is committed to the elimination of CFC based refrigerants This manual focuses on service information for Sanden compressors intended for use with R134a and PAG oils 1 2 Always follow the safety precautions described in Section 3 Do not discharge R134a into the atmosphere Even though its ozone depletion potential is zero it does have a global warming potential Recovery and recycling are mandated by the Clean Air Act Use recovery equipment designated only for R134a Never introduce another refrigerant into the R134a equipment Never mix R134a with other refrigerants or A C system failure is likely to occur Us
30. over the exposed shaft e Align thumb screws to puller jaws and finger tighten e Turn puller center bolt clockwise using a socket wrench until rotor pulley is free A 14 3 Field Coil Assembly Removal 1 Loosen lead wire clamp screw with 2 Phillips screwdriver until wire s can be slipped out from under clamp 2 Undo any wire connections on the compressor which would prevent removal of the field coil assembly 3 Remove snap ring 4 Remove the field coil assembly 14 4 Field Coil Assembly Installation Reverse the steps of Section 14 3 Protrusion on underside of coil ring must match hole in front housing to prevent movement and correctly locate lead wire s 14 5 Rotor Assembly Installation l Place compressor on support stand supported at rear end of compressor If the compressor must be clamped in a vice clamp only on the mounting ears never on the body of the compressor 2 Set rotor squarely over the front housing boss 3 Place the rotor installer ring into the bearing bore Ensure that the edge rests only on the inner race of the bearing not on the seal pulley or outer race of the bearing SERVICE OPERATIONS CLUTCH 4 Place the driver into the ring and drive the rotor down onto the front housing with a hammer or arbor press Drive the rotor against the front housing step A distinct change of sound can be heard when using a hammer to install the rotor 5 Reinstall rotor bearing snap ring if it
31. retrofit procedures Ensure all work done complies with SAE recommended practices as described in J1660 amp J1661 e Repair any problems or leaks before retrofitting e Affix labels to the vehicle showing conversion status e Observe all safety recommendations If an OEM retrofit procedure is not available Sanden recommends the following procedure 19 2 Sanden s Procedure for Conversion from R 12 to R134a 1 If the R 12 vehicle air conditioning system is operational run it at idle with the A C blower on high speed for five 5 minutes to maximize the amount of oil in the compressor 2 Recover all R 12 refrigerant from the vehicle s A C system 3 Remove the compressor from the vehicle 4 Remove the compressor oil plug and then drain as much mineral oil as possible from the compressor body 5 Drain mineral oil from the cylinder head suction and discharge ports while turning the shaft with a socket wrench on the clutch armature retaining nut 6 Remove the existing R 12 receiver drier or accumulator drier from the vehicle and discard Allow as much oil as possible to drain from the A C hoses CONVERTING R 12 SYSTEMS TO R134a 10 11 12 13 14 15 16 17 18 19 Change any O rings on the receiver drier or accumulator drier joints to approved HNBR O rings replace any other O rings that have been disturbed Replace the receiver drier or accumulator drier with a new R134a compatible one
32. st Rough Running Compressor Failure Internal Clutch Engaged UNUSUAL NOISE 8 Remove Valve Plate 23 Replace OF Repair and Inspect Broken Discharge Valve Reed or Retainer Broken Suction Valve Reed Broken Gasket 1 Check Clutch Air Gap Replace or Repair Adjust Air Gap Defective Clutch Pulley or Front Plate Clutch disengaged chattering INSPECTION PROCEDURES 10 1 Leak Checking 1 Visual Inspection Although oil seepage does not necessarily indicate leakage of refrigerant it should be considered a sign that a leak may exist Look for the following items e Oil seepage in shaft seal area between clutch and compressor repairable e Pinching or extrusion of front housing O ring non repairable e Oil around cylinder head gaskets service valves fittings repairable e Oil around oil plug repairable e Stripped threads non repairable e Oil around crack in compressor body non repairable 2 Soap Bubble Detection Any leak showing up as bubbles on the compressor will require repair 3 Workshop Type Electronic Detectors e Fnsure that the detector being used is sensitive to R134a refrigerant Many leak detectors intended for R 12 cannot detect R134a leaks e Use the leak detector in accordance with the manufacturer s instructions e The leak rate at any portion of the compressor should not exceed 1 0 oz yr Make sure that a suspected leak is an actual flow of refrigerant not
33. system and immediately turn off engine Recover refrigerant from the system Remove compressor from vehicle 7 Remove the oil plug and drain as much oil as possible into a suitable container AM SERVICE OPERATIONS OIL CHARGING 8 Drain oil from the suction and discharge ports into a suitable container while turning the shaft clockwise only with a socket wrench on the armature retaining nut 9 Measure and record the volume of oil drained from the compressor 10 Approximately 0 5 fl oz 15cc will remain in the compressor as a film coating the internal surfaces Add 0 5 fl oz 15cc to the recorded volume of oil This is the calculated amount of oil in the compressor 11 The amount of oil in the compressor after running for 10 15 minutes should be as per the table at right if the proper amount of oil was in the system Determine from the table what the correct amount of oil should be for the particular speed used in step 3 The table amp shown applies to SD5H14 compressors Other Comp Oil in compressor compressors will exhibit a lesser oil amount RPM a fl oz dependent upon type It is important that a ae oes 1 000 100 3 4 quantity of oil remains in the crankcase after the test 2 000 75 2 5 3 000 50 1 7 12 Compare the desired amount of oil as 4 000 40 1 3 determined in step 11 with the calculated 5 000 35 1 2 actual amount of oil in the compressor which Vehic
34. ually long hoses such as trucks tractors etc can be determined based on the total refrigerant charge when less than 56 oz 1600g refrigerant is used 2 Calculate the desired oil charge as below SD5H14 Oil amount fl oz Refrigerant charge in oz x 0 125 1 35 Oil amount cc Refrigerant charge in grams x 0 125 40 SD7H15 Oil amount fl oz Refrigerant charge in oz x 0 06 2 2 0 9 Oil amount cc Refrigerant charge in grams x 0 06 60 0 9 3 For a new compressor to be used in this type of system subtract the standard oil charge shown in Section 6 3 from the desired total oil charge to determine how much oil should be added to the compressor 4 Remove the oil filler plug and charge the compressor with the amount of additional oil determined in step 3 Use only new oil of the correct type as shown in Section 6 3 5 Re install oil plug Seat and O ring must be clean and not damaged Torque to 11 18 fteIb 15 25 Nem 150 250 kgf cm 13 4 2 TXV Systems More Than 56 oz 1600g of Refrigerant For systems with more than 560z 1600g refrigerant on vehicle testing is required to determine the oil charge 1 Charge system with refrigerant Set up the vehicle as follows e Doors open e Maximum blower speed e Ambient temp at least 75 F 24 C 3 Run the compressor at one of the speeds listed in the table below for 10 15 minutes 4 While maintaining engine speed turn off A C
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