Professional Documents
Culture Documents
Section 9O
CONTENTS
OTHER MATERIALS
Name U9e
COMPRESSOR SPECIFICATIONS
Item Measuiement Specifacation
Aluminum or
Steel Tubingt* Copper Tubing'
Torque Torque
Nm (rb.f0 (rb-fi)
Bolt
Oiameter Plrln H€adr
lb.tt N.m tb-fr N.m tb.ft N.m
1/4 in. 6 8 9 12 12 16
5/ 16 in. 10 '18
24 25 34
3/8 in. 20 27 30 4'l AF 61
7/16 in. 30 41 50 68 70 95
1/2 in. 61 75 101 110 149
9/ 16 in. 70 95 1 '10 150 155 2'to
5/8 in. o6 128 155 210 215 290
3/4 in- 165 225 270 ;to3 385 520
7 /g in. 170 230 435 590 620 840
1 in. 255 345 660 895 930 1 260
Torque ligures indicated above and in the Specification Sections of this manual are valid for non-greased or non-oiled
threads and heads unless otherwise specified. Therefore, do not grease or oil bolts or cap s"reius unless
otherwise
specified in this manual.
- Torque value lor bolts
and cap screws are ldentitied by their head markings.
c.-:.--O
A-Tubing Adapter G-Union Nui and Body
B-O-Ring Assembly
C-Poppet Valve Assembly H-O-Ring
D-Body l-Valve and Sleeve Assembly
E-Gasket Seal
F-Lock Nut
J-O-Binq
K-Tubing Adaptei
m--"
t;,"'""**
discharge the system:
use the lollowing procedure to
REMOVE COMPRESSOR
1. Disconnect suction (A) and discharge (B) lines from
compressor. Cap all lines and fittings to keep dirt and
moisture lrom entering system.
2. Loosen tension bracket cap screw(D) and two mountino
cap screws. Rotate compressor toward engine and remove
he{t {rom comprcscor pulloy
/a^^.J;t;^^;^4
A;. eut qvcl.|/'.
tultut tt tg ere.v,,t
^t
10. lf pressure is less than 370 kPa (3.70 bar) (55 psi),
disassemble the compressor and check the lollowino:
**,
MAKE SHAFT SEAL LEAK TEST
NOTE: It is normal for the compressor shalt seat to seep
oil at the wick on lower front of compressor. lf
leakage exceeds one pound of refrigerant per year
and no other leak is found, replace the shaft seal.
.l\.0
Remove six dust cover cap screws (A) and remove cover.
NOTE.' lf clutch drive plate sfips on hub, drill a y'a in. hole "\i:$:i.., ,,
..*gt*.-
(C). ?
/ )
11. Carefully pry head from body using a screw driver. pry
only slightly around the circumference of the head. Repeat
this procedure until head is removed.
]
lr
12. Remove and discard shaft seal (A).
,,
{
14. lI valve plate remains with front head, caref ullv separate
inlet reed valve (A) from valve plate (C). Do not looie locatrnq
dowel pin (B).
*'.:
15. lnstall JDG-227 puller (A) and caref ulty pull valve plate
(B) from head (C).
&"
17. lf wear pattern has any voids in it, replace reed valve
-
20. Turn compressor over and remove rear head by prying
on the small tabs cast into the head. Pry lightly around
circumference of head.
21 . Separate reed valve (A) from valve plate (B). Inspect the
three valves (C) for complete circular wear pattern as
oreviouslv instructed.
3. Clean up as necessary.
]
REPLACE SHAFT SEAL SEAT
1. Support front head on press and use JDG-228 driver to
press seat from head.
K
2. Lubricate the new O-ring (A) on the seal seat (B) with a
small amount ol clean refrigerant oil.
ASSEMBLE COMPRESSOR
1. Remove gaskets from both front and rear heads. Be sure
all gasket material is removed. Wash all parts in clean
solvent be{ore assembly.
2. Place suclion reed valve against compressor side of rear
head. lnstall locating dowel pin to assure that reed valve and
valve plate are properly indexed. Set in place in compressor.
12. Set clutch pulley in place over coil. Slight tap may be
needed to properly position pulley on shaf't.
13. lnstall new snap ring (A) with rounded edge oI snap ring
facing upward. Install removed shims (B) on front head. p.':!id'
17. Rotate the pulley one-halJ turn (180') and again check
the clearance in three equally spaced locations.
INSTALL COMPRESSOR
1. Belore inslalling any compressor, be sure it conlains the
correct quantity of oil. Determine compressor oil charge as
instructed in Determining Refrigerant Oil Charge, Group 06.
A(i7;kW5945 U90,090c05
*-',t
3. Discharge air conditioning system as instructed in Dis- |
charging The Systern, this group. il$$
4. Slide cooler/condenser partially out left side. {
..!t*: *
.,,,_
ffi$t
REPLACE RECEIVEB-DRYER
NOTE. The receiver-dryer is not repairable. lf malfunction
ts sLtspected, tnstall new receiver-dryeL
2. Flerrova rwo a.ge cap screws (A, one each side) from
top of SOUND-GARD body roof.
2. Test core by applying at least 345 kpa (3.4 bar) (50 psi)
alr pressure.
L_
2. Install No. 2634 Adaprer (F) and No. 2632 Tee Jitting (c)
to the thermal expansion valve (E).
3. Install No. 2636 TEE with 0.51 mm (0.020 in.) orilice cap
(C) to low pressure side o{ gauge manifold.
&ryJ,&!!ll,!!t!U
',rrr rrr*lr-.. --"bJ X. *-*. &,
5. Remove two large cap screws (A, one each side) from
top ot SGB roof.
NOTE; Order tools from your SERVTCE-GARD Catalog untess otherwise indicated.
, 7r:l: - rt03
')
OTHER MATERIALS
Name Use
Evacuating System Fequired Vacuum at Sea Level .. ... ... 73 kPa (0.7 bar) (29 in. Hg)
Discharge Pressure (at 2000 rpm) .. .... 690-2070 kPa (7-20 bar)
(100-300 psi)
Compressor Felief Valve ...... Opening Pressure 3030 kPa (30 bat (440 psi)
Hi-Pressure Sensing Switch .... Opening Pressure 2480-2930 kPa (24.8-29.3 baO
(360-405 psi)
Lo-Pressure Sensing Switch ... Opening pressure 14-41 kPa (.14-.41 bar)
(2-6 psi)
FLUSHING
a) F-11 stays in liquid form up to 24'c (76'F). 2) syslem has been exposed to dirty environment
(such as field condilions).
b) Above 0'C (32'F), R-1 1 will not freeze moisture
that may be trapped in a component. (R-12 will 3) system has been open to atmosphere for extended
freeze moisture, making it difficult to remove.) period of time.
R-11 will not freeze your skin when in direct After flushing, components and lines MUST be purged
contact. 1R-12 will freeze skin on conlact.) to remove R-1 1 .
PURGING
WHAT lT lS Purging is performed to remove air and WHEN lT SHOULD BE DONE Purging should be
-
moasture f rom the system. F-12 or dry nitrogen is blown perlormed any time the system -has been discharged
through the syslem to collect and remove moisture or opened up for service. Purge with 30-140 kPa (5-20
(R-12 collects moisture in its gaseous state) and to psi) pressure at point of gas entry. Purging should
expell air. always precede evacuating.
EVACUATING
WHAT lT lS (85'F), the moisture will not boil and vacuuming lhe
- Evacuating removes air and moisture
trom the system. This is done using a vacuum pump. system will not elfectively remove moisture.
Subjecting the system to a vacuum lowers the boiling
point of any moisture that may be trapped in the WHEN lT SHOULD BE DONE The system shoutd
system. This allows the moisture to boil oJf to a vapor -
be evacuated any time the system has been dis-
where it can be drawn f rom the system. lt should be charged or opened up for service. Evacuating should
noted that this should be done at an ambient tempera- always follow purging.
ture above 29'C (85'F). lf temperature is less than 29"C
lf compressor removal is not leasable, use the lollowing COMPONENT OIL CHARGE
chart at right as a general guideline for adding refrigerant
Condenser 30 mL (1.0 oz.)
orl to components. Evaporator 45 mL (1.5 oz.)
Receiver-dryer 23 mL (0.75 oz.)
NOTE: Total system oil charge is 330 mL (11.0 oz.). Relrigerant line (per line) 7 mL (0.25 oz.)
Compressor 180 mL (6.0 oz.)
":' )
Litho in u.s.A. 90-06-08 Tl\,4-1258 (M ay-83)
FLUSHING THE SYSTEM
1. lsolate compressor, receiver-dryer and expansion valve
from system Do this by disconnecting inlet and ouflet
fitlings.
3. Open valve (E) on R-12 can, then open high side valve
to purge from compressor discharge fitling toward receiver
dryer. Purge with 30-140 kPa (5-20 psi) pressure at point of
gas entry. A-Charging Hose t>-Low Side Hose
B-Hlgh Side Valve E-8.12 Cam Valve
4. Air and moisture will be purged out compressor low side C-Low Side Valve
fitting through low side hose of gauge set.
y'g',
r.,l j
5i-'.,' I
p_r',^ __,r- - - _
SPECIAL TOOLS
NOTE. Order tools from your SERVICE-GARD Catalog unless othewse indicated.
rr lr , :\ tl ,.1
3. Remove pin (C) and disconnect ride height rod (B) from
suspension assembly.
4. Remove six cap screws (E, three front and rea0 and
remove vertical suspension assembly.
3. Remove two bolts (A) and nuts (B). Remove two retaining
plates (C).
11. Remove nuts and bolts (A) from both sides of support.
Also remove retaining plates (B).
14. Remove cap screw with washers (A) and bushing (B).
Inspect metal bushing for excessive wear and replace as
necessary.
TN.4-1258 (Sep-82)
'16. Reinstall cap screw and bushings.
19. Inspect plastic frame guides. Be sure they are not nicked
or cul and thal they slide freely in tracks.
2. Align guide with track (B) and slide assemblv forward until
guides are seated in tracks.
.:.
2. Install six cap screws (E, three front and three rear) and
tighten securely.
NOTE: 8e sure seat valve rod levers were not bent and
adequate contact is made to hold valve rod on lever.
Seat
__., 1
t 4. Repair seat
by replacing cushions as required.
A-Arm Assembly
8-Suspension Frame
C-Shock Absorber
D-Shock Absorber Mounting
E-Shock Absorber Shatt
F-Shock Absorber Links
G-Bushings
f-
9. lf necessary remove rubber bushings (A) on shock
absorber (B) by removing retaining r ngs and prying off.
4. Slide top plate rollers out of open slot, then lift plate
assembly f rom arm assembly.
NOTE: Lower pin is shorter than top pin. Keep pins separate
to avoid confusion durino reassemblv.
f-
7. Remove springs (A) to remove plate (B).
9. Inspect spring pin (B), washer (C), and retaining rlng (D)
for breakage. Fieplace adjuster knob assembly if required.
A-Threads . A,i
B-Spring Pin
C-Washer
D-Betaining Ring
i,i2 r\!ar24 !l
12. Inspect washers (B) for wear and washer (C) for
cracking or breaking.
@
\ tQ ,C]
vI 1
ffi
1 3. Remove spring and shock assembly (A) by prying up on
shock absorbers at base studs.
A72jN36C24 r1 f90j090015