air conditioning compressor/clutch service manual
Contents
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 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 SHAFT KEY ny ea fh n DAN e Sake i a3 eth Fein ee 3H af P x i tg A e rii RY Wes e i bares srs DA Teef Siw os aCe 3 7 i LGR yea it he A NA ere it 7 al z shaft to lift the plate 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 TYPICAL KEYED2. WOBBLE PLATE PAG 100 Shim Adjust Sanden SD5 amp 7 Series 20 25 ft Ib 016 032 CT305 Nippondenso 10P13 15 ft lb 016 032 AC10861MA Shim Adjust Press Fit Shims Ford FS 10 8 12 ft Ib 016 032 AC884 Shims Sanden SD5 amp SD7 12 ft lb 016 028 CT305 206 Shim Adi Delphi Harrsion A 6 amp R 4 20 25 ft lb 016 03 1 CT305 PISTON PAG 150 Shims 10P15 17 20 25 ft Ib 020 040 CT305 PISTON PAG 46 Shims Nippondenso FX105 8 12 ft lb 016 032 AC884 SCROLL PAG 56 Shims Mitsubishi 10P15 10 ft lb 015 023 CT206 PISTON PAG 46 Shims DKV 14C 8 12 ft lb 016 032 AC884 ROTARY VANE PAG 46 Shims Zexel Diesel Kiki DKS 16H 16 ft Ib 010 020 CT305 206 SWASH PLATE PAG 46 Shims Ford FS 10 16 ft lb 010 020 CT30 O6 SWASH PLATE PAG 68 Shims Hitachi MJS170 12 ft lb 016 028 AC884 ROTARY VANE PAG 46 Shims Nippondenso 10P 14 15 ft lb 020 031 AC884 PISTON PAG 46 Shims Sanden SD5 8 12 ft lb 016 028 AC884 PISTON PAG 100 Shim Adjust Sanden Seiko Seiki SD5 7Series SS170 20 25 ft Ib 016 031 CT305 WOBBLE PLATE PAG 100 SHIM Shim Adjust Zexel Diesel Kiki DKV 20 25 ft Ib 016 031 N
3. A6 R4 SAE Remover Installer CS41 631 Bearing CT867 Re Order AC41067MA Delphi Harrison DA6 V5 HR6 R4 Metric Remover Installer CS41 631 Bearing CT884 Re Order AC884 ChryslerC171 Ford FS6 1 Hitachi MJ Tecumseh H Chena HR980 Nippondenso 6P 10P Remover Installer Tecumseh Nut CSCT206 Zexel Diesel Kiki Mitsubishi Clutch End Plate Remover Use with CT305 CSCT305 Sanden SD5 amp 7 Clutch End Plate Remover MODEL IDENTIFICATION DAA A WE CCPH Wel Fie lI aar i E r FEHU FR tit ese TUNES EAT meat Manufacturers have changed their part numbers indicating upgrades to R 134a They use HNBR neoprene materials larger bearings improved oil passages and modifications for piston swash plate designs A few models will have to be replaced during retrofit R 134a COMPRESSOR SPECIFICATION 4a Oll e Hub Air SHAFT NUT TORQUE AND HUB AIR GAPS PISTON PAG 150 V 5 amp V 7 ait Nut lorque 15 ft lb itd nein PISTON PAG 150 Press Fit 8 16 ft Ib 015 025 AC41067MA PISTON PAG 150 Press Fit FS 6 FS 10 FX 15 8 12 ft lb 020 030 AC41067MA PISTON PAG 68 Shims 6P148 10P15 6E171 17 12 ft lb 016 028 AC884 PISTON PAG 46 Shims A590 C171 6C17 8 12 ft lb 016 032 AC884 PISTON PAG 46 Shims Chrysler Dodge Sanden TRS90 105 12 ft lb 016 032 AC884 SCROLL P
4. C TOOLS AIR CONDITIONING COMPRESSOR CLUTCH SERVICE MANUAL AC10868A CLUTCH HUB TOOL KIT ee a Wel gt gt aan Sapa ANNE BaB EAC O P T This manual contains compressor and clutch service information to 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 that will supply wiring diagrams component locations trouble codes serpentine belt specs and additional service information Order A C Reference Manual 44151A Phone 215 631 7020 or Fax 215 631 7017 Website www macs org First select the model of compressor clutch you are repairing and the required tools Then reference the specific clutch problem for corrective action Additional tools maybe needed such as a manifold gauge set refrigerant oil injector feeler gauge and torque wrench Always wear safety glasses and protective gloves TOA This manual is not designed to replace factory service publications and MAC assumes no liability for use of such information contained in it or any damage incurred through its use by the service technicians or repair facilities Copyright 2003 MAC TOOLS INC All Right Reserved HR980 Removel Install COMPRESSOR CLUTCH TOOLS CT861 Re Order AC10861MA Delphi Harrison
5. 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 excessive 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 WARRANTY amp REPAIR POLICY MAC 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 repaired or replaced at our option at no charge This guarantee does not apply to tools that have been altered misused or returned solely in need of field service maintenance This repair policy does not include tools that are determined to be beyond economical repair A tool being returned for warranty repair must be accompanied by an original bill of sale and customer contact information WE ENCOURAGE PROFESSIONALISM E CERTIFIED THROUGH IDENTIFICATION TOOLS 1 800 MAC TOOLS WWW MACTOOLS COM 73 007 Rev
6. A CT305 ROTARY VANE PAG 46 Shims Zexel Diesel Kiki 92 Model 93 16 ft lb 010 020 CT30 OG PAG 46 PAG 100 Shims 10P8 25 30 ft Ib 010 020 CT305 206 PISTON PAG 46 Shims Nippondenso Nippondenso 10P13 15 17 8 12 ft lb 016 032 AC884 PISTON PAG 46 Shims York 206 209 210 8 12 ft lb 016 032 AC884 PISTON PAG ESTER No Adjust Zexel Diesel Kiki DKS 15 20 25 ft Ib N A N A Shims Sanden SD508 510 709 16 ft Ib 010 020 CT305 206 Shim Adi 20 25 ft lb 016 03 1 CT305 PISTON PAG 150 Press Fit Delphi Harrsion A 6 R 4 ESTER FOR RETROFIT USE SAME VISCOSITY EXCEPT FX 15 020 040 AC10861MA 15 ft lb
7. AG 46 Shim Adjust Chrysler Dodge Sanden SDB708 SD709 7H15 25 30 ft lb 016 03 1 CT305 WOBBLE PLATE PAG 100 Shim Adjust Acura Honda Nippondenso 6P127 10P13 15 20 25 ft Ib 016 031 CT305 PISTON PAG 46 Shims Nippondenso 10P17 8 12 ft lb 016 032 AC884 PISTON PAG 46 Shims Audi VW Zexel Diesel Kiki DCW 8 12 ft lb 016 032 AC884 WOBBLE PLATE PAG 46 Shims Sanden SD508 510 709 16 ft Ib 010 020 CT305 206 WOBBLE PLATE PAG 100 Shim Adjust Delphi Harrsion A 6 20 25 ft Ib 016 031 CT305 PISTON PAG 150 Press Fit Nippondenso 10P15 15 ft lb 020 040 AC10861MA PISTON PAG 46 Shims Sanden TRZ0O 8 12 ft lb 016 032 AC884 SCROLL PAG 46 Shim Adjust Handa Zexel Diesel Kiki DKS15 BH 20 25 ft Ib 014 026 N A SWASH PLATE PAG 46 Shims Sanden SD7 16 ft lb 010 020 CT30 O6 Hyundai Hyundai Ford FX15 20 25 ft Ib 016 031 CT305 WOBBLE PLATE PAG 100 Shim Adjust PISTON PAG 68 Shims Delphi Harrsion R 4 8 10 ft lb 016 028 N A PISTON PAG 150 Press Fit Zexel Diesel Kiki DKS 13 14 17 15 ft lb 020 040 AC10861MA SWASH PLATE PAG 46 Shims Sanden SD5 amp 7 Series 16 ft Ib 010 020 CT305 206
8. SHAFT FIELD COIL SNAP RING fy gt i A PULLEY SNAP i F RING ARN A i a EP ret AN oy 3 AtA e ORNS S AAA ON F y HA r D TN o R Sy ah f he ae C taal SHIMS SPANNER pas PULLEY AND WRENCH sh ae BEARING AC499 HUB ASSEMBLY TROUBLESHOOTING check for ease of rotation TROUBLESHOOTING 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 R 12 acceptable ratios are between 5 to land 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 siz
9. e 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 matched 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 TROUBLESHOOTING an airflow restriction 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
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