Sanden 508/510 Compressors

DISASSEMBLY
1. Drain system of refrigerant (if not already carried out). Remove compressor from car.


NOTE: Compressor must be drained of oil before starting to replace seals. Drain oil through filler opening and connection branches.




2. If compressor is to be replaced by new unit from factory, replacement unit must be vented as described below.
The compressor is pressurized with preservative nitrogen gas by the manufacturer. Before the seals are removed, this gas must be vented off by opening and reclosing either valve (A) or connection (s). If connection (B) is used, ensure that the black and white seals are still in position after venting.


NOTE: Although the gas is not toxic, oil may easily escape from the unit and splash the eyes when venting. Place a cloth over the connections to prevent this.





If compressor must be replaced:
The new spare compressor is filled with mineral oil. Drain off and replace with ester oil (200 ml/0.21 US qt.) supplied with conversion kit.

CAUTION: Oil must not be allowed to enter air receiver when replacing compressor. Fill compressor with oil only through filler opening, not through inlet or outlet connection branches.


NOTE: The O-rings in the compressor inlet and outlet connection fittings must be replaced in all instances. These components are not included in the kit, but must be ordered separately.





3. Mount compressor in vise. Use jaw pads to avoid damaging compressor.




4. Remove clutch plate retaining nut. Use counterhold 999 5596 in tool kit and 19 mm swivel-head wrench (or ratchet handle and 19 mm socket).


NOTE: When dismantling: Place components on bench in order of removal to facilitate reassembly.





5. Remove clutch plate.
Use puller 999 5597 in tool kit.




6. Remove shaft key.
Tap out gently with brass or copper drift. Although a screwdriver may be easier to use in some cases, great care must be exercised to avoid damaging shaft or key.




7. Remove shims (two). Use screwdriver and tool 999 5603 with the small hook.

Note: Keep track of the order in which the shims are installed. Shims must be replaced in the same order.




8. Remove retainer and felt ring. Use screwdriver.
Wipe surfaces with dry, lint free cloth and blow clean carefully with compressed air.




9. Remove inner snap ring. Use snap ring pliers.





10. Remove clutch plate. Use puller 999 5597 in tool kit.




11. Remove sealing washer. Use claw tool 999 5605 and socket.




12. Remove O-ring in body. Use tool 999 5603 with the small hook.


NOTE: Do not score O-ring groove.


Inspect O-ring groove for impurities. Wipe clean as required with lint-free cloth.


NOTE: Compressed air must net be used.





13. Remove carbon seal. Use tool 999 5606 with black handle. Press in tool, turn clockwise and lift out seal.

14. Inspect to ensure that carbon seal has left no particles or other contamination. Wipe surfaces with dry, lint-free cloth.


NOTE: Compressed air must not be used to blow clean.


ASSEMBLY


NOTE: Do not touch seal faces when opening package.





15. Place shaft guard 999 5808 in position. Purpose of guard is to ensure that carbon seal O-ring is not damaged during installation.
Lubricate outside of shaft guard with compressor oil (ester oil), P/N 1161442-7.



16. Install carbon seal.
Oil both inside and outside of face of seal with a few drops of oil.


NOTE: Do not touch seal faces with fingers.


NOTE: Metal face of seal should face downward towards compressor. Mount carbon seal on drift 999 5606 with black handle. Press seal carefully over shaft ensuring that metal retainer is full seated on shaft chamfer. Remove tool counterclockwise.


NOTE: It is extremely important that the retainer is located correctly.





17. Install O-ring in compressor housing.
Lubricate O-ring with compressor oil (ester oil), P/N 1161442-7.





18. Install sealing washer.


NOTE: Do not touch bottom face of seal (facing carbon seal) with fingers.

Press home sealing washer with claw tool 999 5605.





19. Install retainer and felt ring (with felt surface facing downward). Use socket (e.g. 20 mm) which fits in retainer to press ring home.

Upper edge of retainer should be located immediately below upper edge of compressor neck.




20. Reinstall shims. Shims must be installed in same order as before (see operation AAE7). Use hook 999 5603.





21. Install shaft key. Tap gently into position with a drift or screwdriver.




22. Install clutch plate.
Ensure that slot in plate is aligned with shaft key. Feel with hand to ensure that plate is correctly seated.
Press down plate as far as possible by hand.




23. Tap clutch plate gently into position. Use socket 999 5609 in tool kit. Check that shaft key is seated in slot and has not slipped down.




24. Install and tighten clutch plate retaining nut. Use counterhold 999 5596. Tighten to 38 Nm (28 psi).

25. Fill unit with 200 ml (0.21 US qt.) of ester oil PIN 1161442-7 (included in basic conversion kit.

26. Reinstall compressor in car.




27. Tighten couplings.

28. Fill system with refrigerant.