Minor Compressor Repair Procedures

Disassembly

1. Remove pressure plate nut.








2. Using a pressure plate remover, remove the pressure plate.





3. Remove the shims from the shaft.
4. Remove drive clutch.
Using snap ring pliers, remove the snap ring.





5. Using plastic hammer, tap the drive clutch off the shaft.

NOTICE: Care should be exercised not to damage pulley when tapping off.





6. Remove clutch coil.
Disconnect the coil lead wire from the compressor housing using snap ring pliers, remove the snap ring.





7. Inspect pressure plate, drive clutch and clutch coil. a Inspect the pressure plate and drive clutch surface for wear and scoring. Replace if necessary.
b. Check the drive clutch bearings for wear and leakage of grease. Replace if necessary.
c. Check the clutch coil for resistance using ohmmeter. Replace it necessary.
Standard Resistance: 3.2 ± 0.2 Ohms

Assembly

11. Install service valves.



a. Lubricate new O-rings with compressor oil. Install the O-rings in the service valves.
b. Install the service valve on the compressor.

Tightening torque: 26 N.m (19 lb.ft.)

NOTICE: Suction port has larger internal opening than discharge port.





12. Check shaft rotating torque.

Starting torque: 30 kg/cm (2.2 lb. ft.)

1. Install magnetic clutch coil.
Install the clutch coil on the compressor.
2. Install drive clutch.
a. Install the drive clutch on the compressor shaft.
b. Using snap ring pliers, install the snap ring.





3. Install pressure plate.
a. Adjust the clearance between the pressure plate and drive clutch by putting the shims on the compressor shaft.

Standard Clearance: 0.4 - 0.7 mm (0.016-0.028 in)

b. Tighten the pressure plate nut.
Tightening torque: 16 N.m (12 lb. ft.)