CPS Products CTK1300A A/C Clutch Hub Pullers and Installers Tool Kit Owner's Manual

REMOVAL & INSTALLATION
TROUBLESHOOTING
CLUTCH HUB REMOVAL
CLUTCH HUB INSTALLATION
1. Remove clutch retaining ring
or nut. Use a spanner wrench
to prevent the hub plate from
turning.
1. Position the shaft key in place.
2. Attach the tool to the end plate
by threading the outer nut of the
tool into the center hole of the
clutch end plate.
3. Tighten the inner tool arbor
against the end of the compressor
shaft to lift the plate.
2. Slide the clutch hub onto the
shaft of the compressor. Be careful
not to damage the components by
using excess force.
3. Thread the inner part of the tool
onto the shaft. Tighten the outer
nut of the tool to push the shaft
key in.
4. Set the air gap. Add or
remove shims to obtain the mfg.
specifications. Always set at
the min. number and measure
at multiple points around the
circumference.
TROUBLESHOOTING
COMPRESSORS
CLUTCH PROBLEM AREAS
BURNED CLUTCH
Checking compressor ratios is an
excellent way to check system
performance and possible failures.
Run the vehicle at 1500 RPM and
record both gauge readings then
add 15PSI to your reading.
1. Hub/armature and rotor/pulley
drive faces have oil or grease on
them.
Example:
35PSI plus 15=50(low)
235PSI plus 15=250(high)
250:50= 5 to 1 ratio
5. Reinstall the retaining ring or
nut.
Tech Tip: Proper air gap between
the clutch pulley and hub armature
is critical to compressor overall
performance. Failure to maintain
the proper spacing, as indicated in
the mfgrs. specifications can lead
to problems such as clutch burning
or slippage.
6. Check oil level and rotate the hub
with the nose of the compressor
down to help lubricate. You can
check for ease of rotation.
R-134a acceptable ratios are
between 6 to 1 and 7 to 1
TYPICAL KEYED SHAFT
FIELD COIL SNAP RING
PULLEY SNAP
RING
SHAFT KEY
FIELD COIL
LOCK
WASHER
SPANNER
WRENCH
CT499
NUT
R-12 acceptable ratios are
between 5 to 1and 6 to 1
SHIMS
HUB
PULLEY AND
BEARING
ASSEMBLY
If a systems exceeds these ratios
the compressor may fail to high
internal pressure on the pistons
and swash plates.
Possible causes of high ratios are
refrigerant overcharges and air in
the system. Recover /recharge,
vacuum, and identify source
of excess air. (Use refrigerant
identifier to check equipment,
tanks, and system)
a. Look for shaft seal leak and
replace clutch
b. Compressor leaking through the
bolt. Repair leak source.
2. Check for missing or improperly
installed snap ring. Repair or
replace the clutch.
3. Field coil snap ring is wrong
size. Measure thickness and
refer to parts manual for correct
size. Repair or replace clutch if
damaged. Always check antirotation pin damage. Retaining ring
should be facing away from the
compressor, fully seated in groove,
lug of ring should not be over the
anti-rotation pin, and field ring tight
against the compressor.
4. C h e c k t o e n s u r e c l u t c h
components are matched correctly.
The straight coil to straight rotor/
pulley and stepped coil to stepped
rotor/pulley. Repair or replace if
they don’t match. REPLACE IN
PAIRS.
5. L o o k f o r h i g h p r e s s u r e s .
Remember too much oil will
cause slugging and low oil causes
binding. Make sure you don’t have
an airflow restriction.
TROUBLESHOOTING
CLUTCH SLIPPING
1. Low torque problem. Cycle
on/off between 2500- 3000 RPM
for 50 cycles to burnish the hub
and rotor.
2. Low voltage at the field coil.
Check for wiring shorts, poor
connections, and defective
relays.
3. Compressor is seized or tight.
Check torque specs. Repair or
replace.
4. High system pressures. Check
compressor oil levels. Excess
oil can slug compressor. Low oil
will cause binding. Condenser
restrictions from blockage or
improper fan operation will reduce
air flow and raise discharge
pressures.
5. High heat coming from clutch
bearing will produce loose grease
and then bearing failure.
NOISY CLUTCH
1. Check belt size, tension, and
alignment.
2. Rotor dragging. Air gap is
too small. Reset and shim if
necessary.
3. Wrong coil snap ring and installed
wrong. Repair or replace.
4. Field assembly installed
incorrect. Make sure it is bottomed
completely on shoulder. Pilot
diameter is worn undersized. The
field shell pilot is worn oversize.
Replace compressor and or/
assembly. The bearing is damaged.
Replace clutch.
WARRANTY POLICY
CPS guarantees that all tools are free of manufacturing and material
defects for one year. If a tool should fail during the guarantee period it
will be replaced at no charge. This does not apply to tools that have been
altered or misused.
CLUTCH DOESN’T ENGAGE
1. The air gap is excessive. Reset
and remove shims.
2. Voltage at coil isn’t 10.8. Poor
connection, shorts, relays, or
charging system.
3. Resistance problem at coil.
Shorted or open coil so replace and
diagnose electrical problems
ADDITIONAL COMPRESSOR TOOLS:
LS3000 –
TLFG –
TM250A –
TLJ4 –
TLJ2 –
REFRIGERANT LEAK DETECTOR
FLUSH GUN KIT
THERMOMETER
R-134a OIL INJECTOR
R-12 OIL INJECTOR
AIR CONDITIONING
COMPRESSOR/CLUTCH
SERVICE MANUAL
CLUTCH FAILS TO DISENGAGE
1. Clearance between the hub
and rotor is too close. Shim to
increase.
2. Rotor snap ring missing or
installed wrong. Repair or
replace.
3. The air gap is too small. Reset
and add shims.
4. Clutch engages without turning
on a/c. Diagnose electrical problem
and repair.
CPS Products, Inc.
1010 East 31st Street, Hialeah, Florida 33013, USA
Tel: 305-687-4121, 1-800-277-3808, Fax: 305-687-3743
e-mail: [email protected] www.cpsproducts.com
CPS Products N.V.
Krijgsbaan 241, 2070 Zwijndrecht, Belgium
Tel: (323) 281 30 40, Fax: (323) 281 65 83, www.cpsproducts.be,
e-mail: [email protected]
CPS Australia PTY. LTD.
109 Welland Avenue, Welland, South Australia 5007
Tel: +61 8 8340 7055, Fax: +61 8 8340 7033
e-mail: [email protected]
CPS Asia
56A Kallang Pudding Road #02-00 Singapore Road 349329
Tel: (65) 68461056, Fax: (65) 68461054
e-mail: [email protected]
#73-006 Rev. B
CTK1300A - CLUTCH HUB TOOL KIT
(INCLUDES CT499 SPANNER WRENCH)
CONTENTS
COMPRESSOR CLUTCH TOOLS
CT861 Delphi/Harrison
A6/R4 SAE
Remover/Installer
Use to remove clutch hub
Always wear safety glasses and protective gloves.
This manual is not designed to replace factory service
publications and CPS assumes no liability for use of such
information contained in it or any damage incurred through
its’use by the service technicians or repair facilities.
© Copyright 1999, CPS Products, Inc. All Right Reserved
CT861/867 Bearing – 41-631
CT867 Delphi/Harrison
DA6/V5 HR6/R4
Metric Remover/
Installer
Phone 215-631-7020 or Fax 215-631-7017
Website: www.macs.org
First select the model of compressor/clutch you are repairing and
the required tools. Then reference the specific clutch problem
for corrective action. Additional tools maybe needed such as a
manifold gauge set, refrigerant oil injector, feeler gauge, and torque
wrench.
CPS would like to thank MACS, FOUR SEASONS, Denso/
Nippondenso, Sanden, Zexel/Sel Tec, CCI, and Warner with
supplying technical support in the developing and editing this
manual.
CPS Products
MACS Member
SAE Affiliate Member
R-134a COMPRESSOR SPECIFICATIONS
CT884 ChryslerC171/
Ford FS6/Hitachi MJ/
Tecumseh HR980/
Nippondenso 6P/10P
Remover/Installer
HR980- Tecumseh Nut
Installer
Remover
CT206 Zexel (Diesel Kiki)
Mitsubishi Clutch End
Plate Remover
CT305 Sanden SD5 & 7
Clutch End Plate
Remover
Replacement storage case – 50-271
Manufacturers have changed their part numbers indicating upgrades
to R-134a. They use HNBR/neoprene materials, larger bearings,
improved oil passages, and modifications for piston/swash plate designs.
A few models will have to be replaced during retrofit.
SHAFT NUT TORQUE AND HUB AIR GAPS
Adjust
Shaft Nut Torque
Hub Air Gap
Tool P/N
General Motors
Delphi / Harrsion
A-6 & R-4 SAE
PISTON/ PAG 150
Press Fit
15 ft./lb.
.020 -.040
CT861
General Motors
Delphi / Harrsion
V-5 & V-7
PISTON/ PAG 150
Press Fit
8-16 ft./lb.
.015 -.025
CT867
General Motors
Delphi / Harrsion
R-4/DA6 HR6/HR6HE
PISTON/ PAG 150
Press Fit
8-12 ft./lb.
.020 -.030
CT867
Ford / Lincoln
Ford
FS-6/ FS-10/ FX-15
PISTON/ PAG 68
Shims
12 ft./lb.
.016 - .028
CT884
Ford / Lincoln
Nippondenso
6P148/ 10P15/6E177/17
PISTON/ PAG 46
Shims
8-12 ft./lb.
.016 - .032
*CT884
Chrysler / Dodge
Nippondenso
A590/ C171/ 6C17
PISTON/ PAG 46
Shims
12 ft./lb.
.016 - .032
CT884
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
Acura / Honda
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
Audi / VW
Sanden
SD508/ 510/ 709
WOBBLE PLATE/ PAG 100
Shim Adjust
20-25 ft./lb.
.016 - .031
CT305
Audi
Delphi / Harrsion
A-6
PISTON/ PAG 150
Press Fit
15 ft./lb.
.020 -.040
CT861
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
Hyundai
Zexel (Diesel Kit)
DKS 15-BH
SWASH PLATE/ PAG 46
Shims
16 ft./lb.
.010 - .020
CT305/206
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
Isuzu
Delphi / Harrsion
R-4
PISTON/ PAG 150
Press Fit
15 ft./lb.
.020 -.040
CT861
Isuzu
Zexel (Diesel Kit)
DKS 13/ 14/ 17
SWASH PLATE/ PAG 46
Shims
16 ft./lb.
.010 - .020
CT305/206
Jaguar
Sanden
SD5 & 7 series
WOBBLE PLATE/ PAG 100
Shim Adjust
20-25 ft./lb.
.016 - .032
CT305
Jeep / Chrysler
Sanden
SD5 & 7 series
WOBBLE PLATE/ PAG 100
Shim Adjust Press Fit
15 ft./lb.
.016 - .032
CT305
Mazda
Nippondenso
10P13
SCROLL/ PAG 46
Shims
8-12 ft./lb.
.016 - .032
CT884
Mazda
Ford
FS-10
PISTON/ PAG 68
Shims
12 ft./lb.
.016 - .028
CT305/206
Mazda
Sanden
SD5 & SD7
WOBBLE PLATE/ PAG 100
Shim Adjust
20-25 ft./lb.
.016 - .031
CT305
Mercedes Benz
Delphi / Harrsion
A-6 & R-4
PISTON/ PAG 150
Shims
20-25 ft./lb.
.020 -.040
CT861
Mercedes Benz
Nippondenso
10P15/ 17
PISTON/ PAG 46
Shims
8-12 ft./lb.
.016 - .032
CT884
Mitsubishi
Mitsubishi
FX105
SCROLL/ PAG 46
Shims
10 ft./lb.
.015 - .023
CT206
Mitsubishi
Nippondenso
10P15
SCROLL/ PAG 46
Shims
8-12 ft./lb.
.016 - .032
CT884
Nissan / Infinity
Zexel (Diesel Kit)
DKV-14C
ROTARY VANE/ PAG 46
Shims
16 ft./lb.
.010 - .020
CT305/206
Nissan / Infinity
Zexel (Diesel Kit)
DKS-16H
SWASH PLATE/ PAG 46
Shims
16 ft./lb.
.010 - .020
CT305/206
Nissan
Ford
FS-10
SWASH PLATE/ PAG 68
Shims
12 ft./lb.
.016 - .028
CT884
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
Suzuki
Nippondenso
10P8
PISTON/ PAG 46
Shims
8-12 ft./lb.
.016 - .032
CT884
Toyota / Lexus
Nippondenso
10P13 / 15 /17
PISTON/ PAG 46
Shims
8-12 ft./lb.
.016 - .032
CT884
MB / Porshe / VW
York
206.209.210
PISTON/ ESTER
No Adjust
20-25 ft./lb.
.010 - .020
N/A
Volvo
Zexel (Diesel Kit)
DKS-15
SWASH PLATE/ PAG 46
Shims
16 ft./lb.
N/A
CT305/206
Volvo
Sanden
SD508,510, R-4
WOBBLE PLATE/ PAG 100
Shim Adjust
20-25 ft./lb.
.016 - .031
CT305
Volvo / Jaguar
Delphi / Harrsion
A-6, A-4
PISTON/ PAG 150
Press Fit
15 ft./lb.
.020 -.040
CT861
Vehicle Mfgr.
This manual contains compressor and clutch service information to
use with your tool kit. The information includes clutch air gaps, shaft
nut torque, oil viscosity, and common problems to assist you in the
compressor/clutch repair. Also the (MACS) Mobile Air Conditioning
Society publishes a comprehensive air conditioning service manual
that will supply wiring diagrams,component locations, trouble codes,
serpentine belt specs, and additional service information.
Order A/C Reference Manual #44151A
MODEL IDENTIFICATION
Compressor Mfgr.
* ESTER FOR RETROFIT USE SAME VISCOSITY
Model
* EXCEPT FX-15
TYPE / R 134a Oil