Torque Specifications, Oil Level Check, System Flushing, Clutch Removal Information

TORQUE SPECIFICATIONS ft.lbs.
Clutch retaining nut 25-30
Cylinder head cap screws 22-25
Service port O-ring 9-12
Oil filler plug 6-9
High pressure hose 18-22
Low pressure hose 22-25
Drive belt (new) 100
Drive belt (after break in) 80-90

in.lbs.
Clutch wire clamp screw 35 +/- 12
Field coil cap screws 17-23
Charge valve cap 58 +/- 12

FIGURE 1:

Key to Fig. 1

1 Service port
2 Cylinder head
3 Hose connection
4 Anti-rotation gear
5 Oil filler plug
6 Planet plate
7 Clutch bearing
8 Electromatic clutch
9 Valve plate assembly
10 Cylinder & valve plate gasket
11 Cylinder block
12 Piston
13 Cam rotor
14 Needle thrust bearing
15 Front housing & O-ring
16 Shaft seal
NEW COMPRESSOR OIL LEVEL CHECK

When replacing a Sanden compressor (containing uncontaminated oil) with a new compressor, use the following procedure:

1. Drain the oil from the new compressor.
2. Drain and measure the oil from the old compressor.
3. Measure the new oil equal to the amount drained form the old compressor and add one fluid ounce (30 cc) of additional oil to this amount. Use it to refill the compressor.

SYSTEM FLUSHING

The system must be flushed when it becomes contaminated. When flushing the system with R11, do not allow the R11 to enter the compressor.

FIGURE 2:

CLUTCH REMOVAL

Fit Service Tool JD 146 to the clutch front late. Hold the plate stationary. Remove the nut with a 3/4" socket (Fig. 2).

FIGURE 3:

Install the center bolt assembly, and position the holding shaft into the center bolt assembly locating hole (Fig. 3).

FIGURE 4:

FIGURE 5:

Align the puller center bolt to the compressor shaft. Turn the center bolt clockwise until the front plate is loosened (Fig. 4). Remove the front plate and shaft key. Remove the external bearing circlip using pinch type circlip pliers (Fig. 5).

FIGURE 6:

Remove the clutch shims using O-ring hook and small screwdriver.

Remove front housing circlip using spread type circlip pliers. (Fig. 6).

FIGURE 7:

Insert the lip of the puller jaws into the external circlip groove. Place the rotor shaft protector over the exposed shaft. (Fig. 7).

FIGURE 8:

Install the puller assembly and holding shaft. (Fig. 8).

FIGURE 8:

FIGURE 9:

Turn the puller center bolt using three quarter inch (19 mm) socket/wrench (Fig. 8) until the rotor puller is free (Fig. 9).

FIGURE 10:

FIGURE 11:

Loosen the field coil lead from its clip, (Fig. 10). Using spread type circlip pliers, remove the circlip and field coil (Fig. 11).