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Nissens’ Compressor Complaint

TROUBLE SHOOTING

Necessary documentation for having a compressor investigated

In order to have a possibly failed Nissens compressor covered by warranty,


a documentation list must follow the product in the process of complaint - Nissens’ original sticker:
including a copy of the original purchase receipt, and a copy of the original
repair order. Proven removal, lack or re-make of original Nissens sticker on the
product may be reason to reject any complaint/claim.

Any operator performing maintenance or repair must have the proper


authorization to handle the equipment in question, and must follow any
precautions or restrictions regarding air condition/climate systems.

A copy of the original repair order needs to prove that the following procedures have been followed/performed:

• The receiver dryer/accumulator has been replaced.


• The expansion device has been replaced (orifice tube, expansion valve or liquid line containing orifice tube).
• The system and parts not replaced have been flushed in order to remove any impurities or foreign particles. (NB: Never flush a compressor!).
Most damage to replacement compressors is caused by residues in the system from the previously installed compressor.

Visible symptom:
The oil is black and/or has aluminum particles in it.

Cause:
Insufficient refrigerant in the system, or the system has been blocked, leading to overheating
of the compressor which will cause a breakdown of the internal parts.

Result/customer feedback:
Claim is rejected.

Visible symptom:
The oil is discoloured green.

Cause:
The system was not flushed correctly before installation, or too much or wrong UV leak dye/
universal oil.

Too much or wrong UV leak dye/universal oil will cause an insuffient effect (lubrication) of the
contaminated oil, and in time that will cause a breakdown of the internal parts.

It is allowed to add UV-dye up to max. 5% of the total oil quantity.

Result/customer feedback:
Claim is rejected.

Nissens A/S Ormhøjgårdvej 9 1/3


DK-8700 Horsens +45 7626 2626
nissens@nissens.com www.nissens.com
Nissens’ Compressor Complaint
TROUBLE SHOOTING
3

Visible symptom:
Discharge side (small hole) is clean, but the suction side (bigger hole) has black residue.

Cause:
Due to insufficient refrigerant or compressor oil in the system, leading to overheating of the
compressor.

Result/customer feedback:
Claim is rejected.

Visible symptom:
The compressor is burned on the clutch/belt-wheel.

Cause:
The compressor has been exposed to too much heat due to insufficient refrigerant or compressor
oil in the system, leading to overheating of the compressor. The coating of the clutch/pulley
will be burned and be a brownish color.

Result/customer feedback:
Claim is rejected.

Visible symptom:
The epoxy in the coil has bubbles, cracks and looks “dried out”.

Cause:
The compressor has been exposed to too much heat due to insufficient refrigerant or compressor
oil in the system, leading to overheating of the compressor.

Result/customer feedback:
Claim is rejected.

Visible symptom:
The shaft on the compressor is stuck.

Cause:
The cause of the failure is due to missing oil. If the system is low on oil, the temperature will
rise inside the AC compressor, and due to higher friction that will, in time, cause a breakdown
of the internal parts.

To reject this type of claim, the oil drained from the compressor must be contaminated. If the
oil is clean, a thorough test must be done to identify the failure.

Result/customer feedback:
Claim is rejected.

Nissens A/S Ormhøjgårdvej 9 2/3


DK-8700 Horsens +45 7626 2626
nissens@nissens.com www.nissens.com
Nissens’ Compressor Complaint
TROUBLE SHOOTING
7

Visible symptom:
The compressor is working as it should, but is making too much noise.

Cause:
If the compressor is running like it should, but is exceeding the level of DB allowed, it indicates that the necessary run-in time of 2 to 3 minutes in
the idling position (1000-1500rpm) was either not respected, or carried out at a too high rotational speed.

To reject this type of claim, the oil drained from the compressor must be contaminated. If the oil is clean, a thorough test must be done to identify
the failure.

Result/customer feedback:
Claim is rejected.

Installation requirements and advise

• Remove the failed compressor, and try to determine the cause of the defect. When removing the hoses connected to the compressor, please make
sure to protect the connections. This is to avoid impurities sticking to the connection during installation of the compressor.

• The system must be properly flushed using R134a or a specially designed flushing solution. Nissens strongly recommends using a specially designed
flushing solution, due to its higher efficiency and chemical advances. After flushing, make sure that no refrigerant or flushing liquid is left in the system,
and dry the circuit using nitrogen if necessary. It is not advisable to reuse any refrigerant removed from the circuit, seeing that the used refrigerant is
most likely contaminated with impurities from the replaced compressor.

• Then complete the installation of replacement parts (dryer/accumulator, expansion valve or orifice tube).

• Check that the level of pre-filled oil is according to the vehicle manufacturer´s instructions. If extra filling is necessary, make sure to use oil of the same
viscosity as the vehicle manufacturer´s instruction.

• After checking or filling the oil, please turn the clutch on the compressor 10 times to distribute the oil inside.

• When mounting the compressor, do not remove the safety caps in the connection holes before the hoses are connected. This is to avoid impurities to
enter the system during the mounting of the compressor.

• Fill or re-charge the refrigerant cycle with the prescribed amount of refrigerant according to instructions. Only R134a can be used as refrigerant!

• Make sure the belt is aligned correctly when installed.

• Make sure the condition of the condenser is so that the performance is sufficient to maintain the proper temperature in the system. A non-conforming
condenser may cause overheating of the compressor.

• Before the vehicle can operate at usual working level, it must be started and left running at idling speed for a couple of minutes.

Nissens A/S Ormhøjgårdvej 9 3/3


DK-8700 Horsens +45 7626 2626
nissens@nissens.com www.nissens.com