Sanden SD-505 Manuale utente

SD Compressor

Service Manual

SD COMPRESSOR SERVICE MANUAL

TABLE OF CONTENTS

1. Compressor Models Covered 11. Field Replaceable Parts

2. Compressor Nomenclature 11.1 Compressor Parts

3. Cautionary Information 11.2 Clutch Parts

4. R134a Information 12. Service Operations - General Information

4.1 R134a / Pag Oil Handling 13. Oil Charging

4.2 Table of Saturation Temperatures and Pressures 13.1 Repairing Compressors

5. Compressor Identification 13.2 Replacing Same Type of Compressors

5.1 Label 13.3 Replacing Different Types of Compressors

5.2 Date Codes 13.4 Oil Charge Determination for Long Hose Application

6. Compressor Specifications 13.5 Oil Retained in System Components

6.1 Belt Tension 14. Clutch Service

6.2 Speed Rating 14.1 Armature Assembly Removal

6.3 Basic Specifications 14.2 Rotor Assembly Removal

6.4 Assembly Torques 14.3 Field Coil Assembly Removal

6.5 Mounting Angles 14.4 Field Coil Assembly Installation

7. Cylinder Head / Porting Guide 14.5 Rotor Assembly Installation

8. Tools 14.6 Armature Assembly Installation

8.1 Special Service Tools 15. Shaft Seal Service

8.2 Standard Tools 16. Cylinder Head / Valve Plate Service

9. Service Procedures 16.1 Cylinder Head Removal

10. Inspection Procedures 16.2 Valve Plate Removal

10.1 Leak Checking 16.3 Valve Plate and Cylinder Head Installation

10.2 Oil Level Measurement 17. Thermal Protector Switch Service

10.3 Shaft Turning Smoothness Inspection 17.1 TPS Testing

10.4 Clutch Inspection 17.2 TPS Replacement

10.5 Unusual Noise Not Due to Compressor 18. High Pressure Relief Valve Service

10.6 Unusual Noise Due to Compressor 19. Converting R-12 Systems to R134a

10.7 Valve Plate Test ** Service Oil Information

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

SD-507

SD-508

SD-510

SD7B10 / SD5H09

SD5H11

SD5H14

SD7H15HD and SD5H14HD

7 Cylinder SDB-706

SD-708

SD-709

SDB-709

SD7B10

SD7H13

SD7H15

SD7B15

COMPRESSOR NOMENCLATURE

2. Identification

R-12 Compressors

SD -- 7 09

  

Sanden reciprocating

wobble plate

compressors

Number of Cylinders Approximate displacement, in

cubic inches

SD 7H15 HD

    

Sanden

reciprocating

wobble plate

compressors

Number of

cylinders Port location

( H if on head, B if

on body )

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 into 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

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 manualfocuses on service information for

Sanden compressors intended for use with R134a and PAG oils.

4.1 (Cont.)

1. Always follow safety precautions described in Section 3.

2. Do not discharge R134a into the atmosphere. Even though its ozone depletion potential is zero, it

does have 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.

3. Never mix R134a with other refrigerants or A/C systems failure is likely to occur.

4. Use only Sanden specified PAG lubricants for R134a systems using Sanden compressors. If other

lubricants are used, A/C system failure is likely to occur.

5. Never introduce R134a or PAG oil into a system not designed for them except when following the

appropriate retrofit procedure described in Section 19.

6. 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.(°F) Pressure (psig) Temp.(°F) Pressure (psig) Temp.(°F) Pressure (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 3

15 15 95 114 200 485

20 18 100 124 210 549

COMPRESSOR IDENTIFICATION

5.1 Label

5.2 Manufacturing Date Codes Stamped on Compressor - Manufactured in USA Only

COMPRESSOR SPECIFICATIONS

6.1 Belt Tension

Grooves Tension, lb (kgf)

A121 ± 5 (55 ± 2)

B132 ± 5 (60 ± 2)

C132 ± 5 (60 ± 2)

M132 ± 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 Maximum RPM

Model Clutch 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

6.3 Basic Compressor Specifications

Typical Weight, lb. (kg.) Standard Oil Charge

Model Refrigerant Displacement

cu.in. (cc) Compressor Clutch Assembly Oil

Type System

Type Amount

fl. oz.

(cc)

Rotation

TXV 7.2±0.5

(210±15)

SD5H14 R134a 8.4 (138) 11.2 (5.1) 6.0 (2.7) 17.2 (7.8) SP-20 CCOT No

standard

Either

Way

SD7B10 R134a 6.1 (100) 5.9 (2.7) 3.3 (1.5) 9.2 (4.2) SP-10 TXV No

standard

(Clock

wise only)

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)

(Clock

wise only)

TXV 4.6±0.5

(135±15)

SD7H15 /HD R134a 9.5 (155) 9.9 (4.5) 5.3 (2.4) 15.2 (2.4) SP-20 CCOT 8.1±0.5

(240±15)

(Clock

wise only)

TXV 4.6±0.5

(135±15)

SD7H15 /SHD R134a 9.5 (155) 9.9 (4.5) 7.7 (3.5) 17.6 (8.0) SP-20 CCOT 8.1±0.5

(240±15)

(Clock

wise only)

6.4 Assembly Torques

Item ft -lb N-m kgf-cm

Armature retaining nut, 1/2" - 20 22.4 ± 2.9 30.4 ± 3.9 310 ± 40

Armature retaining nut, M8 13.0 ± 2.2 17.7 ± 2.9 180 ± 30

Cylinder head bolts, M6 10 ± 2.2 13.7 ± 2.9 140 ± 30

Cylinder head bolts, M8 25.3 ± 3.6 34.3 ± 4.9 350 ± 50

Oil filler plug 14.5 ± 13.6 19.6 ± 4.9 200 ± 50

Hose fitting 1" - 14 rotolock 26.7 ± 2.9 36.3 ± 3.9 370 ± 40

7/8" Tube-O 23.9 ± 2.9 32.4 ± 3.9 330 ± 40

3/4" Tube - O 17.3 ± 2.5 23.5 ± 3.4 240 ± 35

Pad fitting bolt, M10 28.9 ± 2.9 39.2 ± 3.9 440 ± 40

Pad fitting bolt 3/8" -24 28.9 ± 2.9 39.2 ± 3.9 440 ± 40

Pad fitting bolt, M8 26.3 ± 2.9 34.3 ± 3.9 350 ± 40

Clutch lead wire clamp screw 11 ± 3 in•lb 1.3 ± 0.3 13 ± 3

High pressure relief valve 7.2 ± 1.4 9.8 ± 2.0 100 ± 20

Thermal protector switch clamp bolt 7.2 ± 2.2 - 1.4 9.8 ± 2.9 - 2.0 100 ± 30 - 20

Clutch dust cover screws (6 - M5) 6.5 ± 1.4 9 ± 2 90 ± 20

Clutch dust cover screws (3 - 1/4" - 20) 2.7 ± 0.9 3.6 ± 1.2 37 ± 12

6.5 Acceptable Mounting Angles

CYLINDER HEAD / PORTING GUIDE

7. SD R143a COMPRESSOR SERIES

For SD5H14, SD7H13, SD7H15 and SD7H15HD / SHD Units

Hose Port Information SD Compressor Series

Sanden

Service Kit

Part No. Name Position on

Cylinder

head Suction Port

Dimension/Type Discharge Port

Dimension/Type TPS or

Switch? 5H14 7H13 7H15 7H15

HD/SHD

9580-9630 CVertical Tube-O 1" - 14 rotolock Tube-O 1" - 14 rotolock No X

TDB FL Vertical Tube-O #10 (7/8") Tube-O #8 (3/4") No X

9034-9630 KHorizontal Tube-O #10 (7/8") Tube-O #8 (3/4") No X

9699-9630* MHorizontal Tube-O 1" - 14 rotolock Tube-O 1" - 14 rotolock No X

9150-9630* QHorizontal GM Pad, 3/8" - 24 Bolt GM Pad, 3/8" - 24 Bolt No X

9695-9630* QH Horizontal GM Pad, 3/8" - 24 Bolt GM Pad, 3/8" - 24 Bolt Yes X

9298-9630* UVertical Pad-M10 x 1 Bolt Pad-M10 x 1 Bolt No X

9517-9630* UB Vertical Pad-M10 x 1.25 Bolt Pad-M10 x 1.25 Bolt No X

9516-9630* UB Horizontal Pad-M10 x 1.25 Bolt Pad-M10 x 1.25 Bolt No X

7412-9630 CB Vertical Tube-O 1" - 14 rotolock Tube-O 1" - 14 rotolock No X X X

7832-9630 JD Vertical Tube-O #10 (7/8") Tube-O #8 (3/4") No X X X

7863-9630 JE Vertical Tube-O #10 (7/8") Tube-O #8 (3/4") No X X X

7862-9630 KG Horizontal Tube-O #10 (7/8") Tube-O #8 (3/4") No X X X

7406-9630* MD Horizontal Tube-O 1" - 14 rotolock Tube-O 1" - 14 rotolock No X X X

7433-9630 QC Horizontal GM Pad, 3/8" - 24 Bolt GM Pad, 3/8" - 24 Bolt No X X X

7484-9630 QD Horizontal Pad-M10 x 1.25 Bolt Pad-M10 x 1.25 Bolt No X X X

7200-9631 UK Vertical Pad-M10 x 1.25 Bolt Pad-M10 x 1.25 Bolt No X X X

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.

SERVICE TOOLS

8.1 Special Service Tools

These tools can be obtained from your local tool supplier.

1. Oil Dipstick 5. Lip Seal / SD7 Seal Plate Tool 9. Rotor Installation Driver

2. Armature Plate Spanner 6. Armature Driver 10. O-Ring Hook

3. Armature Plate Puller 7. Rotor Puller Jaws

4. Rotor Puller Set 8. Shaft Seal Protective Sleeve

8.2 Standard Tools

1. External Snap Ring Pliers 4. Gasket Scraper

2. Internal Snap Ring Pliers 5. Graduated Cylinder

3. Feeler Gauges

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