SD Compressor Service Guide

Table of Contents
1. Compressor Models Covered
2. Compressor Nomenclature
3. Cautionary Information
3.1 Pressure Release
3.2 Recovery of Refrigerant
3.3 Handling of Refrigerant
3.4 Ventilation
3.5 Avoid use of
3.6 Warranty for Recycled Refrigerant
4. R134a Information
4.1 R134a/PAG Oil Handling
4.2 Table of Saturation Temperatures and Pressure
5. Compressor Identification
5.1 Label
5.2 Date Codes
6. Application Specifications
6.1 Belt Tension
6.2 Speed Rating
6.3 Basic Specifications
6.4 Assembly Torques
6.5 Mounting
6.5.1 Compressor Rotation
6.5.2 Ear Deflection Bending
6.6 Recommended Pressure and Temperature Conditions
6.6.1 Discharge Gas Condition
6.6.2 Suction Gas Condition
6.6.3 Ambient Temperature
6.7 Clutch
6.8 Oil Charge
6.8.1 Oil Flow Theory
6.8.2 Oil Charging
6.8.2.1 Passenger Car Light Duty Truck Single Evaporator
6.8.2.2 Dual Evaporator Long Hose Systems
6.8.2.3 System Refrigerant charges greater than 56 oz (1600g)
7. Diagnosis Confirmation Of Compressor Failure
7.1 Compressor Rotation
7.2 Clutch Inspection
7.2.1 Voltage Test
7.2.2 Air Gap Test
7.2.3 Coil Resistance Test
7.3 Pressure or Pumping Test
7.4 Leak Checking
7.4.1 Visual
7.4.2 Soap bubble
7.4.3 Electronic
7.4.4 Dyes
7.5 Noise
7.5.1 Non Compressor
7.5.2Compressor
8. Compressor Repair
8.1 Clutch Removal
8.2 Clutch Installation
8.3 Cylinder Head Replacement
9. Compressor Replacement
9.1 Contamination Inspection
9.2 Oil Amount (No Contamination)
9.3 Oil Amount (Flushed System)
10. Service Procedures
10.1 Flushing
10.1.1 Equipment types
10.1.2 Safety
10.1.3 Acceptable Flushing Fluids
10.1.3 Components to Flush
10.1.4 Flushing Tips
10.1.5 Removal of Residual Flushing Fluid
10.2 Evacuation
10.3 Refrigerant Charge
10.3.1 Charging Systems
10.3.2 High Side Charging
10.3.3 Low Side Charging
10.4 System Oil Balance
10.4.1 Oil flow
10.4.2 In Laboratory Oil Amount Determination
10.4.3 Oil Checking is Not Required Under Normal Conditions
10.4.4 Circumstances When Oil Addition or Balancing is Required
10.4.5 Oil Addition during Component Replacement
11. Warranty
11.1 Return Process
11.2 Warranty Duration
12. Compressor Failure Causes
11.1 Overheating
11.2 Contamination
12.3 Clutch Slippage
12.4 Handling or Impact Damage
13. Tools
13.1 Special Service Tools
13.2 Standard Tools
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