REMOVAL & INSTALLATION TROUBLESHOOTING TROUBLESHOOTING WARRANTY POLICY CLUTCH HUB REMOVAL CLUTCH HUB INSTALLATION TROUBLESHOOTING CLUTCH PROBLEM AREAS CLUTCH SLIPPING Replace compressor and or/ COMPRESSORS BURNED CLUTCH assembly. The bearing is damaged. CPS guarantees that all tools are free of manufacturing and material 1. Remove clutch retaining ring 1. Position the shaft key in place. 1. Low torque problem. Cycle Replace clutch. defects for one year. If a tool should fail during the guarantee period it or nut. Use a spanner wrench Checking compressor ratios is an 1. Hub/armature and rotor/pulley on/off between 2500- 3000 RPM be replaced at no charge. This does not apply to tools that have been to prevent the hub plate from 2. Slide the clutch hub onto the excellent way to check system drive faces have oil or grease on for 50 cycles to burnish the hub altered or misused. turning. shaft of the compressor. Be careful performance and possible failures. them. and rotor. not to damage the components by CLUTCH DOESN’T ENGAGE AIR CONDITIONING Run the vehicle at 1500 RPM and 2. Low voltage at the field coil. 2. Attach the tool to the end plate using excess force. record both gauge readings then a. Look for shaft seal leak and by threading the outer nut of the replace clutch Check for wiring shorts, poor 1. The air gap is excessive. Reset tool into the center hole of the 3. Thread the inner part of the tool add 15PSI to your reading. connections, and defective and remove shims. ADDITIONAL COMPRESSOR TOOLS: COMPRESSOR/CLUTCH onto the shaft. Tighten the outer b. Compressor leaking through the relays. LS3000 – REFRIGERANT LEAK DETECTOR clutch end plate. Example: 2. Voltage at coil isn’t 10.8. Poor nut of the tool to push the shaft bolt. Repair leak source. TLFG – FLUSH GUN KIT 3. Compressor is seized or tight. connection, shorts, relays, or 3. Tighten the inner tool arbor key in. 35PSI plus 15=50(low) TM250A – THERMOMETER SERVICE MANUAL against the end of the compressor 2. Check for missing or improperly Check torque specs. Repair or charging system. TLJ4 – R-134a OIL INJECTOR shaft to lift the plate. 4. Set the air gap. Add or 235PSI plus 15=250(high) installed snap ring. Repair or replace. remove shims to obtain the mfg. replace the clutch. 3. Resistance problem at coil. TLJ2 – R-12 OIL INJECTOR specifications. Always set at 250:50= 5 to 1 ratio 4. High system pressures. Check Shorted or open coil so replace and the min. number and measure 3. Field coil snap ring is wrong compressor oil levels. Excess diagnose electrical problems at multiple points around the size. Measure thickness and oil can slug compressor. Low oil circumference. refer to parts manual for correct will cause binding. Condenser size. Repair or replace clutch if restrictions from blockage or CLUTCH FAILS TO DISENGAGE 5. Reinstall the retaining ring or damaged. Always check anti- improper fan operation will reduce nut. rotation pin damage. Retaining ring air flow and raise discharge 1. Clearance between the hub should be facing away from the pressures. and rotor is too close. Shim to 6. Check oil level and rotate the hub compressor, fully seated in groove, increase. with the nose of the compressor lug of ring should not be over the 5. High heat coming from clutch down to help lubricate. You can anti-rotation pin, and field ring tight bearing will produce loose grease 2. Rotor snap ring missing or CPS Products, Inc. check for ease of rotation. R-12 acceptable ratios are against the compressor. and then bearing failure. installed wrong. Repair or 1010 East 31st Street, Hialeah, Florida 33013, USA Tech Tip: Proper air gap between between 5 to 1and 6 to 1 replace. Tel: 305-687-4121, 1-800-277-3808, Fax: 305-687-3743 the clutch pulley and hub armature 4. Check to ensure clutch e-mail: [email protected] www.cpsproducts.com is critical to compressor overall R-134a acceptable ratios are components are matched correctly. 3. The air gap is too small. Reset performance. Failure to maintain between 6 to 1 and 7 to 1 The straight coil to straight rotor/ NOISY CLUTCH and add shims. CPS Products N.V. the proper spacing, as indicated in TYPICAL KEYED SHAFT If a systems exceeds these ratios pulley and stepped coil to stepped 4. Clutch engages without turning Krijgsbaan 241, 2070 Zwijndrecht, Belgium 1. Check belt size, tension, and Tel: (323) 281 30 40, Fax: (323) 281 65 83, www.cpsproducts.be, the mfgrs. specifications can lead the compressor may fail to high rotor/pulley. Repair or replace if alignment. on a/c. Diagnose electrical problem to problems such as clutch burning FIELD COIL SNAP RING e-mail: [email protected] internal pressure on the pistons they don’t match. REPLACE IN and repair. or slippage. and swash plates. PAIRS. 2. Rotor dragging. Air gap is PULLEY SNAP too small. Reset and shim if CPS Australia PTY. LTD. RING Possible causes of high ratios are 5. Look for high pressures. necessary. 109 Welland Avenue, Welland, South Australia 5007 refrigerant overcharges and air in Remember too much oil will Tel: +61 8 8340 7055, Fax: +61 8 8340 7033 cause slugging and low oil causes 3. Wrong coil snap ring and installed SHAFT KEY the system. Recover /recharge, e-mail: [email protected] vacuum, and identify source binding. Make sure you don’t have wrong. Repair or replace. an airflow restriction. FIELD COIL of excess air. (Use refrigerant 4. Field assembly installed CPS Asia LOCK identifier to check equipment, 56A Kallang Pudding Road #02-00 Singapore Road 349329 WASHER incorrect. Make sure it is bottomed tanks, and system) completely on shoulder. Pilot Tel: (65) 68461056, Fax: (65) 68461054 CTK1300A - CLUTCH HUB TOOL KIT NUT SHIMS e-mail: [email protected] SPANNER PULLEY AND diameter is worn undersized. The (INCLUDES CT499 SPANNER WRENCH) WRENCH BEARING field shell pilot is worn oversize. CT499 HUB ASSEMBLY #73-006 Rev. B CONTENTS COMPRESSOR CLUTCH TOOLS MODEL IDENTIFICATION R-134a COMPRESSOR SPECIFICATIONS SHAFT NUT TORQUE AND HUB AIR GAPS

Vehicle Mfgr. Compressor Mfgr. Model TYPE / R 134a Oil Adjust Shaft Nut Torque Hub Air Gap Tool P/N This manual contains compressor and clutch service information to General Motors Delphi / Harrsion A-6 & R-4 SAE PISTON/ PAG 150 Press Fit 15 ft./lb. .020 -.040 CT861 use with your tool kit. The information includes clutch air gaps, shaft General Motors Delphi / Harrsion V-5 & V-7 PISTON/ PAG 150 Press Fit 8-16 ft./lb. .015 -.025 CT867 nut torque, oil viscosity, and common problems to assist you in the General Motors Delphi / Harrsion R-4/DA6 HR6/HR6HE PISTON/ PAG 150 CT861 Delphi/Harrison Press Fit 8-12 ft./lb. .020 -.030 CT867 compressor/clutch repair. Also the (MACS) Mobile Air Conditioning Ford / Lincoln Ford FS-6/ FS-10/ FX-15 PISTON/ PAG 68 Shims 12 ft./lb. .016 - .028 CT884 Society publishes a comprehensive air conditioning service manual A6/R4 SAE Ford / Lincoln Nippondenso 6P148/ 10P15/6E177/17 PISTON/ PAG 46 Shims 8-12 ft./lb. .016 - .032 *CT884 that will supply wiring diagrams,component locations, trouble codes, Remover/Installer Chrysler / Dodge Nippondenso A590/ C171/ 6C17 PISTON/ PAG 46 Shims 12 ft./lb. .016 - .032 CT884 serpentine belt specs, and additional service information. Chrysler / Dodge Sanden TRS90/ 105 SCROLL/ PAG 46 Shim Adjust 25-30 ft./lb. .016 - .031 CT305 Chrysler / Dodge Sanden SDB708/ SD709/ 7H15 WOBBLE PLATE/ PAG 100 Shim Adjust 20-25 ft./lb. .016 - .031 CT305 Order A/C Reference Manual #44151A Use to remove clutch hub CT861/867 Bearing – 41-631 / Nippondenso 6P127/ 10P13/ 15 PISTON/ PAG 46 Shims 8-12 ft./lb. .016 - .032 CT884 Audi / VW Nippondenso 10P17 PISTON/ PAG 46 Shims 8-12 ft./lb. .016 - .032 CT884 Audi Zexel (Diesel Kit) DCW WOBBLE PLATE/ PAG 46 Shims 16 ft./lb. .010 - .020 CT305/206 CT867 Delphi/Harrison Audi / VW Sanden SD508/ 510/ 709 WOBBLE PLATE/ PAG 100 Shim Adjust 20-25 ft./lb. .016 - .031 CT305 DA6/V5 HR6/R4 Audi Delphi / Harrsion A-6 PISTON/ PAG 150 Press Fit 15 ft./lb. .020 -.040 CT861 Metric Remover/ BMW Nippondenso 10P15 PISTON/ PAG 46 Shims 8-12 ft./lb. .014 - .026 CT884 Honda Sanden TR70 SCROLL/ PAG 46 Shim Adjust 20-25 ft./lb. .016 - .032 N/A Installer Phone 215-631-7020 or Fax 215-631-7017 Hyundai Zexel (Diesel Kit) DKS 15-BH SWASH PLATE/ PAG 46 Shims 16 ft./lb. .010 - .020 CT305/206 Website: www.macs.org Hyundai Sanden SD7 WOBBLE PLATE/ PAG 100 Shim Adjust 20-25 ft./lb. .016 - .031 CT305 Hyundai Ford FX15 PISTON/ PAG 68 Shims 8-10 ft./lb. .016 - .028 N/A First select the model of compressor/clutch you are repairing and CT884 ChryslerC171/ Delphi / Harrsion R-4 PISTON/ PAG 150 Press Fit 15 ft./lb. .020 -.040 CT861 the required tools. Then reference the specific clutch problem Ford FS6/ MJ/ Isuzu Zexel (Diesel Kit) DKS 13/ 14/ 17 SWASH PLATE/ PAG 46 Shims 16 ft./lb. .010 - .020 CT305/206 for corrective action. Additional tools maybe needed such as a Tecumseh HR980/ Jaguar Sanden SD5 & 7 series WOBBLE PLATE/ PAG 100 Shim Adjust 20-25 ft./lb. .016 - .032 CT305 Nippondenso 6P/10P Jeep / Chrysler Sanden SD5 & 7 series WOBBLE PLATE/ PAG 100 Shim Adjust Press Fit 15 ft./lb. .016 - .032 CT305 manifold gauge set, refrigerant oil injector, feeler gauge, and torque Nippondenso 10P13 SCROLL/ PAG 46 wrench. Remover/Installer Shims 8-12 ft./lb. .016 - .032 CT884 Mazda Ford FS-10 PISTON/ PAG 68 Shims 12 ft./lb. .016 - .028 CT305/206 CPS would like to thank MACS, FOUR SEASONS, / Mazda Sanden SD5 & SD7 WOBBLE PLATE/ PAG 100 Shim Adjust 20-25 ft./lb. .016 - .031 CT305 Nippondenso, Sanden, Zexel/Sel Tec, CCI, and Warner with Mercedes Benz Delphi / Harrsion A-6 & R-4 PISTON/ PAG 150 Shims 20-25 ft./lb. .020 -.040 CT861 supplying technical support in the developing and editing this HR980- Tecumseh Nut Installer Remover Mercedes Benz Nippondenso 10P15/ 17 PISTON/ PAG 46 Shims 8-12 ft./lb. .016 - .032 CT884 manual. Mitsubishi FX105 SCROLL/ PAG 46 Shims 10 ft./lb. .015 - .023 CT206 CPS Products Mitsubishi Nippondenso 10P15 SCROLL/ PAG 46 Shims 8-12 ft./lb. .016 - .032 CT884 MACS Member CT206 Zexel (Diesel Kiki) / Infinity Zexel (Diesel Kit) DKV-14C ROTARY VANE/ PAG 46 Shims 16 ft./lb. .010 - .020 CT305/206 SAE Affiliate Member Mitsubishi Clutch End Nissan / Infinity Zexel (Diesel Kit) DKS-16H SWASH PLATE/ PAG 46 Shims 16 ft./lb. .010 - .020 CT305/206 Plate Remover Nissan Ford FS-10 SWASH PLATE/ PAG 68 Shims 12 ft./lb. .016 - .028 CT884 Always wear safety glasses and protective gloves. Nissan Hitachi MJS170 ROTARY VANE/ PAG 46 Shims 14-15 ft./lb. .020 -.031 CT884 Porsche Nippondenso 10P PISTON/ PAG 46 Shims 8-12 ft./lb. .016 - .028 CT884 Porsche Sanden SD5 PISTON/ PAG 100 Shim Adjust 20-25 ft./lb. .016 - .031 CT305 Saab *Sanden,Seiko,Seiki SD5/ 7 series, SS170 WOBBLE PLATE/ PAG 100 SHIM, Shim Adjust 20-25 ft./lb. .016 - .031/ NA CT305 Saturn Zexel (Diesel Kit) DKV ROTARY VANE/ PAG 46 Shims 16 ft./lb. .010 - .020 CT305/206 Suburu Zexel (Diesel Kit) *92 Model/ 93 *PAG 46/ PAG 100 Shims 25-30 ft./lb. .010 - .020 CT305/206 This manual is not designed to replace factory service CT305 Sanden SD5 & 7 Nippondenso 10P8 PISTON/ PAG 46 Shims 8-12 ft./lb. .016 - .032 CT884 publications and CPS assumes no liability for use of such Clutch End Plate / Nippondenso 10P13 / 15 /17 PISTON/ PAG 46 Shims 8-12 ft./lb. .016 - .032 CT884 information contained in it or any damage incurred through Remover MB / Porshe / VW York 206.209.210 PISTON/ ESTER No Adjust 20-25 ft./lb. .010 - .020 N/A its’use by the service technicians or repair facilities. Manufacturers have changed their part numbers indicating upgrades Volvo Zexel (Diesel Kit) DKS-15 SWASH PLATE/ PAG 46 Shims 16 ft./lb. N/A CT305/206 © Copyright 1999, CPS Products, Inc. All Right Reserved to R-134a. They use HNBR/neoprene materials, larger bearings, Volvo Sanden SD508,510, R-4 WOBBLE PLATE/ PAG 100 Shim Adjust 20-25 ft./lb. .016 - .031 CT305 improved oil passages, and modifications for piston/swash plate designs. Volvo / Jaguar Delphi / Harrsion A-6, A-4 PISTON/ PAG 150 Press Fit 15 ft./lb. .020 -.040 CT861 Replacement storage case – 50-271 A few models will have to be replaced during retrofit. * ESTER FOR RETROFIT USE SAME VISCOSITY * EXCEPT FX-15