SD Compressor Service Manual

1 SD CompressorService ManualSD Compressor Service MANUALTABLE OF CONTENTS 1. Compressor Models Covered11. Field Replaceable Parts 2. Compressor Nomenclature Compressor Parts 3. Cautionary Information Clutch Parts 4. R134a Information12. Service Operations - General Information R134a / Pag Oil Handling13. Oil Charging Table of Saturation Temperatures and Pressures Repairing Compressors 5. Compressor Identification Replacing Same Type of Compressors Label Replacing Different Types of Compressors Date Codes Oil Charge Determination for Long Hose Application 6. Compressor Specifications Oil Retained in System Components Belt Tension14. Clutch Service Speed Rating Armature Assembly Removal Basic Specifications Rotor Assembly Removal Assembly Torques Field Coil Assembly Removal Mounting Angles Field Coil Assembly Installation 7.

2 Cylinder Head / Porting Guide Rotor Assembly Installation 8. Tools Armature Assembly Installation Special Service Tools15. Shaft Seal Service Standard Tools16. Cylinder Head / Valve Plate Service 9. Service Procedures Cylinder Head Removal10. Inspection Procedures Valve Plate Removal Leak Checking Valve Plate and Cylinder Head Installation Oil Level Measurement17. Thermal Protector Switch Service Shaft Turning Smoothness Inspection TPS Testing Clutch Inspection TPS Replacement Unusual Noise Not Due to Compressor18. High Pressure Relief Valve Service Unusual Noise Due to Compressor19. Converting R-12 Systems to R134a Valve Plate Test** Service Oil InformationThis Service Manual has been prepared by Sanden International (USA), Inc. It Includes information onapplication, troubleshooting, and repair of automotive air conditioning compressors manufactured bySanden Corporation and its subsidiaries, in accordance with the appropriate SAE standards for mobile airconditioning.

3 Service operations not described in this Manual are not authorized for Sanden further information contact your nearest Sanden Models1. Model ConversionsTYPER-12R134a5 CylinderSD-505SD-507SD-508SD-510SD7B10 / SD5H09SD5H11SD5H14SD7H15HD and SD5H14HD7 CylinderSDB-706SD-708SD-709 SDB-709SD7B10SD7H13SD7H15SD7B15 Compressor NOMENCLATURE2. IdentificationR-12 CompressorsSD--709 Sanden reciprocatingwobble platecompressorsNumber of CylindersApproximate displacement, incubic inchesSD7H15HD Sandenreciprocatingwobble platecompressorsNumber ofcylindersPort location( H if on head, B ifon body )Approximatedisplacement,in cubiccentimeters(divided by 10) heavy duty (HD)or SealedHeavy- duty (SHD)clutchCAUTIONARY Pressure ReleaseBefore disconnecting any lines, always make sure refrigerant has been removed from the A/C system byrecovering it with the appropriate recovery working on compressors, separate from the system, always be sure to relieve internal pressure Compressor pressure can be relieved by removing the oil plug ( if necessary)

4 Or by removingshipping caps / pads from both Recovery of RefrigerantNever discharge refrigerant to the atmosphere. Always use approved refrigerant recovery / recyclingequipment to capture refrigerant which is removed from the A/Csystem. Do not mix refrigerants in the same piece of equipment; one should be designated for R-12 andanother for Handling of RefrigerantAlways wear eye and hand protection when working on an A/C system or Compressor . Liquid refrigerantcan cause frostbite and / or VentilationKeep refrigerants and oils away from open flames. Refrigerants can produce poisonous gasses in thepresence of a flame. Work in a well-ventilated Avoid Use of Compressed AirDo not introduce compressed air into an A/C system due to the danger of Warranty for Recycled RefrigerantThe warranty offered by Sanden International ( ), Inc.

5 , on air conditioning compressors when usedwith recycled refrigerant will be the same as for new refrigerant provided that the following SAE standardsare met:R-12R134aRefrigerant PurityJ1990J2099 Recycling MachineJ1989J2210 Recycling machines must be validated to the appropriate SAE standard by Underwriters refrigerant from other sources must meet the appropriate ARI standards. Failure to comply withthese provisions may void any warranty on the R134a / PAG Oil Handling PrecautionsAs a conscientious member of the global community, Sanden Corporation with its subsidiaries iscommitted to the elimination of CFC-based refrigerants. This manualfocuses on Service information forSanden compressors intended for use with R134a and PAG (Cont.)1. Always follow safety precautions described in Section Do not discharge R134a into the atmosphere.

6 Even though its ozone depletion potential is zero, itdoes have global warming potential. Recovery and recycling are mandated by the Clean Air Act. Userecovery equipment designated only for R134a. Never introduce another refrigerant into the Never mix R134a with other refrigerants or A/C systems failure is likely to Use only Sanden specified PAG lubricants for R134a systems using Sanden compressors. If otherlubricants are used, A/C system failure is likely to Never introduce R134a or PAG oil into a system not designed for them except when following theappropriate retrofit procedure described in Section The Sanden specified PAG oils used in R134a systems absorb atmospheric moisture very 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 containerimmediately after each use.

7 During A/C system repair, cap all fittings as soon as opened and leave capped until just beforethey are reconnected. If a repair is performed on an R134a Compressor or system, evacuate the system for at least 45minutes before recharging to ensure the removal of moisture which may have been absorbed bythe PAG oil in the Compressor and Table of Saturation Temperatures and PressuresTemp.( F)Pressure (psig)Temp.( F)Pressure (psig)Temp.( F)Pressure (psig) in. in. in. Hg4035115159-1505045120172-1026057130200 -547071140231068085150264598595160301101 2901041803151595114200485201810012421054 9 Compressor Manufacturing Date Codes Stamped on Compressor - Manufactured in USA OnlyCOMPRESSOR Belt TensionGroovesTension, lb (kgf)A121 5 (55 2)B132 5 (60 2)C132 5 (60 2)M132 5 (60 2)PV4132 5 (60 2)PV6198 5 (90 2) (PolyVee tension based on 33 lb (15kgf) per groove).

8 Speed RatingMaximum RPMM odelClutch ,0007,000SD5H14HD4,0006,000SD7B10 All6,0007,000SD7H13 All6,0008, ,0008,000SD7H15HD4,0006,000SD7H15 SHD4,0004, Basic Compressor SpecificationsTypical Weight, lb. (kg.)Standard Oil (cc)CompressorClutchAssemblyOilTypeSyste mTypeAmountfl. oz.(cc) (210 15) (138) ( ) ( ) ( ) (100) ( ) ( ) ( )SP-10 TXVN ostandardCW(Clockwise only) (129) ( ) ( ) ( ) (135 15)CW(Clockwise only) (135 15)SD7H15 (155) ( ) ( ) ( ) (240 15)CW(Clockwise only) (135 15)SD7H15 (155) ( ) ( ) ( ) (240 15)CW(Clockwise only) Assembly TorquesItemft -lbN-mkgf-cmArmature retaining nut, 1/2" - 40 Armature retaining nut, 30 Cylinder head bolts, M610 30 Cylinder head bolts, 50 Oil filler 50 Hose fitting 1" - 14 407/8" 403/4" Tube - 35 Pad fitting bolt, 40 Pad fitting bolt 3/8" 40 Pad fitting bolt, 40 Clutch lead wire clamp screw11 3 in 3 High pressure relief 20 Thermal protector switch clamp - - 30 - 20 Clutch dust cover screws (6 - M5) 290 20 Clutch dust cover screws (3 - 1/4" - 20) Acceptable Mounting AnglesCYLINDER HEAD / PORTING GUIDE7.

9 SD R143a Compressor SERIESFor SD5H14, SD7H13, SD7H15 and SD7H15HD / SHD UnitsHose Port InformationSD Compressor SeriesSandenService KitPart onCylinderheadSuction PortDimension/TypeDischarge PortDimension/TypeTPS orSwitch?5H147H137H157H15HD/SHD9580-9630 CVerticalTube-O 1" - 14 rotolockTube-O 1" - 14 rotolockNoXTDBFLV erticalTube-O #10 (7/8")Tube-O #8 (3/4")NoX9034-9630 KHorizontalTube-O #10 (7/8")Tube-O #8 (3/4")NoX9699-9630*MHorizontalTube-O 1" - 14 rotolockTube-O 1" - 14 rotolockNoX9150-9630*QHorizontalGM Pad, 3/8" - 24 BoltGM Pad, 3/8" - 24 BoltNoX9695-9630*QHHorizontalGM Pad, 3/8" - 24 BoltGM Pad, 3/8" - 24 BoltYesX9298-9630*UVerticalPad-M10 x 1 BoltPad-M10 x 1 BoltNoX9517-9630*UBVerticalPad-M10 x BoltPad-M10 x BoltNoX9516-9630*UBHorizontalPad-M10 x BoltPad-M10 x BoltNoX7412-9630 CBVerticalTube-O 1" - 14 rotolockTube-O 1" - 14 rotolockNoXXX7832-9630 JDVerticalTube-O #10 (7/8")Tube-O #8 (3/4")NoXXX7863-9630 JEVerticalTube-O #10 (7/8")Tube-O #8 (3/4")NoXXX7862-9630 KGHorizontalTube-O #10 (7/8")Tube-O #8 (3/4")

10 NoXXX7406-9630*MDHorizontalTube-O 1" - 14 rotolockTube-O 1" - 14 rotolockNoXXX7433-9630 QCHorizontalGM Pad, 3/8" - 24 BoltGM Pad, 3/8" - 24 BoltNoXXX7484-9630 QDHorizontalPad-M10 x BoltPad-M10 x BoltNoXXX7200-9631 UKVerticalPad-M10 x BoltPad-M10 x BoltNoXXXA) 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 portat the Special Service ToolsThese tools can be obtained from your local tool Oil Dipstick5. Lip Seal / SD7 Seal Plate Tool9. Rotor Installation Driver2. Armature Plate Spanner6. Armature Driver10. O-Ring Hook3. Armature Plate Puller7. Rotor Puller Jaws4. Rotor Puller Set8. Shaft Seal Protective Standard Tools1. External Snap Ring Pliers4. Gasket Scraper2. Internal Snap Ring Pliers5.