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TK430 Compressor

Компрессор Thermo King 430

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Юрий Андращук
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TK430 Compressor

Компрессор Thermo King 430

Uploaded by

Юрий Андращук
Copyright
© © All Rights Reserved
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® i] THERMO KING X214, X418, ett X426 &X430 0 Compressor (A KING, HERe a ai a a | Ls PT Overhaul Manual m X214, X418, X426 & X430 Compressor ‘TK 6875-8-OM (Rev. 7, 12/01) Y—copyign 1880 Thermo king Corp. Mineapots, MN, U.S.A Printed in U.S.A. This manual is published for informational purposes only and the information so provided should not be considered as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation should be consulted, Sale of product shown in this manual is subject to Thermo King's terms and conditions including, but not limited to, the Thermo King Limited Express Warranty. Such terms and conditions are available upon request, ‘Thermo King's warranty will not apply to any equipment which has been “so repaired or altered outside the manu- facturer's plants as, in the manufacturer's judgment, to effect its stability.” ‘No warranties, express or implied, including warranties of fitness for a particular purpose or merchantabil- ity, or warranties arising from course of dealing or usage of trade, are made regarding the information, rec- ommendations, and descriptions contained herein. Manufacturer is not responsible and will not be held liable in contract or in tort (including negligence) for any special, indirect or consequential damages, including injury or damage caused to vehicles, contents or persons, by reason of the installation of any Recover Refrigerant At Thermo King, we recognize the need to preserve the environ- ment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere. In addition, service personnel must be aware of Federal regula- tions concerning the use of refrigerants and the certification of technicians. For additional information on regulations and tech- nician certification programs, contact your local THERMO KING dealer. Table of Contents ‘Thermo King Compressors ..... Safety Precautions . . Specifications Torque Values General Compressor Repair Techniques . . Dirt and Moisture can Easily Ruin Compressors! Compressor Oil IndicaTIons Compressor Oil Color Code Disassembly and Reassembly .......6.66++ Disassembly Sequence Reassembly Sequence . . Fastener Torque procedure. rer ‘Cleaning Components. Drive Coupling. Removal . Installation... Cylinder Head . Discharge Valve Plates Two-Piece Compressor Seal Plate and Mounting Flange Assembly Seal Plate Assembly... . — sie Installation of Spring Loaded Neoprene Bellows Type Seal . a 3 wat Installation of Metal Bellows Seal with Set Screws 18 Installation of Metal Bellows Seal with Drive Tangs 21 il Sump and Oil Pickup Screen. 23 il Pump . 24 Connecting Rod, Piston and Sleeve . 29 Crankshaft 32 Crankshaft End Play . . 35 Compressor Crankshaft Precautions 36 Removal and Installing Crankshaft Counterweights 37 Compressor Body Repair. . 38 Unloader Head... Leak Testing, Storage, and Break In . svsaven sal Leak Testing 43 Storage... 43 Break In. 43 Thermo King Compressors The most significant part of the refrigeration system is the ‘compressor. Its function is to pump low pressure gas out of the evaporator so that a rapid and continuous boiling action ned in the evaporator coil. The low pressure gas is ‘compressed and forced into the condenser coil where it is cooled by air passing through the coil. The high pressure and reduced temperature causes it to liquefy (condense). ‘The compressors covered by this manual are reciprocating piston type pumps, constructed mainly of cast aluminum. ‘The aluminum alloy pistons and cast iron sleeves are machined to close tolerances to that no rings are needed (0 seal the piston to the cylinder wall. The compressor is, ‘equipped with a high nickel alloy ductile iron crankshaft, To prevent leakage around the crankshaft, the compressor is fit ted with a rotary type refrigeration seal Pressurized lubrication is provided to the connecting rods ‘and bearings by a gerotor oil pump in the compressor body The oil level in the compressor can be inspected through the cil level sight glass in the body. Since the refrigeration sys tem is sealed, it should be necessary to add oil only if there has been a large refrigeration leak in the system, or if a ‘major item in the reftigeration system, such as an evapora tor coil or a condenser coil has been replaced. A spring loaded discharge valve and spring loaded valve sage provide pressure relief if liquid refrigerant enters the compressor. The entire cage lifts and prevents breaking or deforming of the valves. When any repairs or replacements are to be made on the ‘compressor, itis very important that the parts used are clean, and not nicked or scratched. During disassembly, parts should be cleaned and inspected; and if they are to be used in reassembly, they should be wrapped in a clean cloth to prevent marring the surfaces, Oil all parts with compressor cil during assembly, and be sure they are installed in the same position they were in before disassembly. NOTE: When replacement parts are required, we recom- mend using only Factory Approved Thermo King Replace- ment Parts. Only Genuine Thermo King Replacement Parts deliver the reliability, productivity, quality, and per- formance you've come to expect from Thermo King. NOTE: Most of the overhaul procedures for the compres- ‘sors covered in this manual are the same. Photographs of ‘an X426 compressor are used in this manual as examples. Other illustrations are provided in cases where the photo- graph is not applicable, Figure L: Two Cylinder Compressor y 1. [Compressor Body 45. [Oil Pump Shaft Key 2. | Cylinder Head Gasket 46. | Oil Pump Housing 3.__[Cylinder Head 47. [Oil Pump Assembly a. 48. [Oil Pump Cover O-ring 5. gW 49. [O-ring — 6 (Bi8-16 x 2) 0. [Oil Pump Cover Plate 7.__[ Bolt (9/8-16 x 2-5/8) 1. [Bolt (6/16-18 x 1-1/8) 8._[Discharge Valve Assembly Bolt (@/8-16 x 2-1/4) 72. [Stud 52,_[Flatwasher 20. | Valve Plate O-ring 53. | Oil Pressure Regulator Assembly 21. [Cylinder Sleeve 54. [Regulator O-ring 22. [Adapter Gasket 55. [Plug 23. [Suction Port Screen 56. |Plug O-ring 25. [Piston Assembly 57. ine Fitting or Valve 26. [Piston Pin 58, [Oil Sump 27._|Piston Pin Retaining Ring 59. [Oil Sump Gasket '31._|Connecting Rod Assembly 60. | Bolt 32._ [Connecting Rod Bolt 61. | Bolt 33._[Connecting Rod Nut 62. |Copper Washer 34, [Bearing Set (Standard) 63._[Oil Sump Screen Bearing Set (0.005) —[e4. [Oi Pickup O-ring Bearing Set (0.010) 65. [Bolt Bearing Set (0.020) (66. [Lockwasher Bearing Set (0.030) 67._|Flatwasher 35._| Pump Shaft O-ring 7 68. [Check Valve Assembly 36. [Crankshaft Pump End Bearing 69. [Oil Fill Screw 37. [Plug 70. |i Fill O-ring 38,_|[Dowel Pi 71. [Crankshaft Seal 39._| Crankshaft 72. [Crankshaft Seal Plate 40. [Metering Plug 73. [Bolt at. [Key 74. [Lip Seal -42._| Crankshaft Drive End Bearing 75._|Seal Plate O-ring 43. [Housing Gasket 76._| Sight Glass 44. [Oil Pump Shaft 77._[Sight Glass O-ring Two Cylinder Compressor anco1a Figure 2: Early Style Four Cylinder Compressor NOTE: The early style compressor had a spring loaded shaft seal, and the seal plate and mounting flange were made in one piece. 1. [Compressor Body. '33._[ Check Valve Assembly 2. [Connecting Rod Nut 34. [Pump End Gasket '3._[ Connecting Rod Bolt 35._|Pump Housing 4._ [Connecting Rod Assembly 36._[O-ring 5, [Bearing Set (Standard) 37. [O-ring Bearing Set (0.005) '38._|Oil Pump Cover Plug and Copper Washer Bearing Set (0.010) ‘39. [Oil Pump Cover Bearing Set (0.020) 40._[Oil Pump Cover Bolt and Washer Bearing Set (0.030) '41._[Oil Pump Cover Bolt and Washer Bearing Set (0.005) '42._|Regulator O-ring 7._[Piston Pin 43. [Oil Pressure Regulator 8.__| Piston Assembly 44. | Regulator Spring _ 9.__| Retaining Ring 45. [Plunger 10. [Key [46._| Regulator Retaining Ring 111._| Crankshaft Drive End Bearing 47. [Oil Line Fitting or Valve 12. [Metering Plug 48. [Oil Pump Assembly 5 13. [Crankshaft 49._[O-ring 14. [Crankshaft Oil Pump End Bearing ‘50. | Oil Pump Shaft 15. [Dowel Pin 51. [Oil Pump Drive Key 16._| Suction O-ring and Screen '52._| Seal Plate/Mounting Flange 17. [Copper Washer and Bolt '53. [Screw and Washer [18. [Cylinder Sleeve 54. [O-ring 19. [O-ring 55. [Oil Sump Gask 20. [Discharge Valve Plate Assembly 56. [Ol Sump 21._|Sight Glass O-ring 57. [Oil Sump Bolt and Washer 22._| Sight Glass 58._|Check Valve Assembly 23. |Gylinder Head Gasket 59._| Check Valve Assembly 24. [Cylinder Head 60. O-ring 25, [Cylinder Head Bolt and Fial Washer 61. [Oil Suction Screen Assembly /26. |Gylinder Head Bolt and Flat Washer 62._|Mounting Screen Hardware 27. [Manifold Gasket 63._| Screen Bracket 28. [Manifold 64. [Mounting Bracket Bolt and Washer 29. [Pipe Plug 65. [Crankshaft Seal Assembly 30._| Manifold Mounting Bolt (66. |Seal Plate Gasket 31. | Flatwasher 67._ | Rotation Nameplate '32._[Magnetic Plug and Copper Washer Early § le Four Cylinder Compressor 1._ [Compressor Body I _ 2. [Connecting Rod Nut I = = 3.__[ Connecting Rod Bott '32._| Magnetic Plug and O-ring 4. [Connecting Rod Assembly '33._|[ Check Valve Assembly [5. [Bearing Set (Standard) ‘34. |Pump End Gasket Bearing Set (0.005) '35. [Oil Pump Housing Bearing Set (0.070) 36. [O-ring Bearing Set (0.020) 37. [O-ring - ‘Bearing Set (0.030) 38,_| Oil Pump Cover Plug and O-ring Bearing Set (0.005) 39. [Oil Pump Cover 7._ [Piston Pin -40._[ Oil Pump Cover Bolt and Washer '8,_[Piston Assembly 41. [Oil Pump Cover Bolt and Washer 9.__ [Retaining Ring 42. [Regulator O-ring 11. [Crankshaft Drive End Bearing 43, [Oil Pressure Regulator 12. [Metering Plug 44. [Seal Plate Gasket 13._| Crankshaft 45. [Oil Pickup Tube and Screen 14._[Crankshatt Oil Pump End Bearing 46. [Oil Pickup Tube Clamp and Hardware 15. [Dowel Pin 47._ [Oil Pickup Tube Mounting Bracket 16._| Suction O-ring and Sereen 48._[Bolt and Lockwasher 17. Oil Fill Plug and O-ring _ 49._[Oil Line Fitting or Valve 18. [Cylinder Sleeve 50. [Oi Pump Assembly 19. [O-ring 51. [O-ring 20. [Discharge Valve Plate Assembi 52. [Oil Pump Drive Shaft 21. [Sight Glass O-ring '53._[Oil Pump Drive Key _ 22. [SightGlass ‘54. |Seal Plate Mounting Bolt 23. [Head Gasket ‘55. [Oil Sump Gasket 24. [Cylinder Head 56. [Oil Sump 25. [Cylinder Head Bolt Assembly 57. [Oil Sump Bolt 26. | Cylinder Head Bolt Assembly ‘58. |Check Valve Assembly 27. [Manifold Gasket 59. [Check Valve Assembly a | 28. | Manifold (60._|O-ring (61._| Crankshaft Seal (62, [Bolt (63. |Seal Plate Late Style Four Cylinder Compressor Safety Precautions GENERAL PRACTICES 1, ALWAYS WEAR GOGGLES OR SAFETY ASSES, Refrigerant liquid and battery acid can per- smanently damage the eyes (see First Aid under Rettig eration Oil) Never operate the unit with the compressor discharge valve closed. 3. Keep your hands clear of the fans and belts when the unit is running. This should also be considered when ‘opening and closing the compressor service valves, 4. Make sure the gauge manifold hoses are in good condi~ + let them come in contact with a belt, fan -y, or any hot surface. tion. Ne ‘motor pull Never apply heat 0 ed refrigeration system or container, 6. Fluorocarbon refrigerants, in the presence of an open. flame or electrical short, produce toxic gases that are severe respiratory iritants capable of causing death, 7. Make sure all mounting bolts are tight and are the cor- rect length for their particular application. 8. Use extreme caution when drilling holes in the unit ‘The holes may weaken structural components. Holes drilled imto electrical wiring san cause fire or explosion. 9. Use caution when working around exposed coil Fins. ‘The fins can cause painful lacerations. 10. Use caution when working with a refrigerant or reftig~ eration system in any enclosed or confined area with a limited Refrigerant tends to displace air and can cause oxygen depletion, resulting in suffocation, i supply (for example, a bus or garage). 11, EPA refrigeration systems, sction 608 Certification is needed to work on REFRIGERANT Although fluorocarbon refrigerants are classified as safe refrigerants, certain precautions must be observed when ‘handling them or servicing a unit in which they are used, ‘When exposed to t he liquid state, fluoro- carbon refrigerants evaporate rapidly, freezing anything they contact, atmosphere i First Aid In the event of frost bite, the objectives of First Aid are to protect the frozen area from further injury, to warm the affected area rapidly, and to maintain respiration. + EYES: For contact with liquid, immediately flush eyes ‘with large amounts of water and get prompt medical attention. + SKIN: Flush area with large amounts of lukewarm water. Do not apply heat, Remove contaminated cloth- ing and shoes. Wrap burns with dry, sterile, bulky ‘essing to protect from infectionvinjury. Get medical attention, Wash contaminated clothing before reuse, + INHALATION: Move vietim to fresh air and use CPR (oF mouth-to-mouth ven Victim until arrival of emergency medical personnel. ion, if necessary. Stay with REFRIGERANT OIL ‘Avoid refrigeration oil contact with the eyes. Avoid pro- Ionged or repeated contact of refrigeration oil with skin or clothing. Wash thoroughly after handling refrigeration oil to prevent irritation, First Aid In case of eye contact, immediately flush with plenty of er for at least 15 minutes. CALL A PHYSICIAN. Wash skin with soap and water. Specifications X214 COMPRESSOR No. Cylinder Two Bore/Stroke 2.25 in, (57 mm)/1.75 in. (45 mm) Cubic Inch Displacement 43.92 ou. in. (228 om?) Weight 45 Ibs (20 kg) _ X418 COMPRESSOR No. Cylinder Four Bore/Stroke 2.25 in, (57 mm)/1.62 in. (41 mm) Cubic Inch Displacement” 18 cu. in, (295 cm®) Weight _ 78 Ibs (35 kg) 426 COMPRESSOR No. Cylinder Four Bore/Stroke 2.25 in. (57 mm)/1.62 in, (41 mm) Cubic Inch Displacement* 25.84 cu. in. (424 om) Weight 78 Ibs (35 kg) X430 COMPRESSOR No. Cylinder Four Bore/Stroke 2.25 in. (57 mm)/1.88 in, (48 mm) Cubic Inch Displacement 29.82 cu. in, (489 cm?) Weight 7B tbs (35 kg) OPERATING CLEARANCES Inches Mitlimeters Crankshaft End Play @ 70 F (21) Bearing locked in bore 10,0070 to 0.0125 0.1778 to 0.3175 Bearing unlocked in bore 0.0070 to 0.0470 0.1778 to 1.1938 Connecting Rod Bearing To ‘Crankshaft Rod Journal 0.0008 to 0.0024 0.0203 to 0.0610 Oil Pump Cover Clearance (distance below housing) 0.0010 to 0.0040 0.0254 to 0.1016 Piston to Sleeve 0.0018 to 0.0027 0.0457 to 0.0686 Piston Wrist Pin to Bushing 0.0001 to 0.0008 0.0025 to 0.0152 Unloader Check Valve to Bore 0.0020 to 0.0040 0.0508 to 0.1016 Unloader Piston to Bore 0.0020 to 0.0040 0.0508 to 0.1016 “The X418 and X426 compressors have the same bore/stroke but differ in cubic inch displacement. This is accomplished by using different port locations in the cylinder sleeve. The closer the ports are to the top of the cylinder sleeve, the smaller the total displacement. Specifications (Rev. 7, 12/01) PART DIMENSIONS Connecting Rod Bearing Insert—Standard Lo. Crankshaft Rod Journal—Standard oD. Compressor Body Main Bearing Bore 1.0, Crankshaft Main Journal—Drive End op. Crankshaft Main Journal—Oil Pump End OD. Cylinder Sleeve 10. Piston on. Connecting Rod Wrist Pin Bushing—Standard 1D. Piston Wrist Pin—Standard oo. Oil Pump Gerotor Assembly Thickness il Pump Inner Wear Plate Thickness Oil Pump Outer Wear Plate Thickness (Check Valve—Unloader Head OD. Piston—Unloader Head OD. Bore in Unloader Head—Check Valve LD, Bore in Unloader Head—Piston, Lo, Inches 1.3755 to 1.3766 1.3742 to 1.3747 3.9355 to 3.9370 1.7718 01,7719 1.8746 to 1.5750 2.2495 to 2.2500 2.2473 to 2.2477 0.6255 to 0.6258 0.6250 to 0.6252 0.3430 to 0.3440 0.1867 to 0.1873 0.1867 to 0.1873 1.1240 to 1.1250, 0.9970 to 0.9980 1.1270 to 1.1280 1.0000 to 1.0010 Millimeters 34.9377 to 34.9656 34.9047 to 34.9174 99.9617 to 99.9998 44,9961 to 45,0063 39.9948 to 40.0050 87.1373 to 57.1500 57.0814 to 57.0916 15.8877 to 15,8953 15.8750 to 15.8801 8.7122 to 8.7376 4.7422 to 4.7574 4.7422 to 4.7574 28.5496 to 28.5750 25.3238 to 25.3492 28.6258 to 28.6512 25.4000 to 25.4254 Specifications (Rev. 7, 12/01) TORQUE VALUES THREAD SIZE TORQUE ek Bia | pitch [LPS | inp | te | kgm | Nm | fet | Reg. ‘Cylinder Head 38 16 2-5/8 275 22.9 | 3.17 31.1 [55-6806 | 8 [Cylinder Head we [ie | 2 | 27 | me | si7 | 311 [55-0805 | 12 CyinderHead wiUrioaders | 88 | 16 | +V | 275 3a7_[ 341 [859108 | 7 Cylinder Head w/Unloaders we 16 48 275 37 31.1 [55-6823 | 3 Cylinder Head w/Unloaders | 5/16 18 +18 | 150 | 125 | 1.73 | 170 [55-087 3 GylinderHeadwiUnloaders | 14 | 20 | 144 | 120 | 100 | 138 | 196 [55544 | 4 Center Screw in Large Check Valve Assembly va | 2 | - | 25 | 21 | ozo | 20 |sswaer| 1 Check Valve 1 Assembly—Large NEF 18 - 336 | 28.0 | 3.87 | 38.0 |22-787 | 1 ‘Check Valve va Assembly—Upper NPT - “ 300 | 25.0 3.46 33.9 [22-653 2 [Check Valve Wa Assembly—Lower NPT : - 120 | 100 | 1.38 | 136 |225e8 | 2 Connecting Rod Nut Bm | 24 = 300 | 250 | 346 | 339 |55-1681| AR ‘One Piece Seal Plate and Mounting Flange—Eary ‘Style Four Cylinder 3/8 16 1-5/8 335 28.0 3.86 3.79 |55-2306 | 9 Mounting Flange—Late Sie Four Cylinder ae | 1 | 158 | 035 | 200 | sa6 | 379 |s5-2006| 6 ‘Seal Plate—Late Style Four Cylinder 38 16 1-18 | 335 | 28.0 | 386 | 3.79 |55-9106| 3 ‘Seal Plate—Four Cylinder without Mounting Flange | 98 | 16 | 1-1 | 395 | 279 | 36 | 3.70 |s5-9106| 9 ‘Seal Plate—Two Cylinder 516 18 1-1/4 150 12.5 1.73 17.0 [55-172 6 Sight Glass = [=f soo [sof eer | 678 [22350 [AR Manifold 38 | 16 1-3/4 335 | 28.0 3.86 37.9 [55-3641 | 4 Manifold wa_| ie | eae | sas | 280 | ae6 | o7o |sseaza) 4 ii Drain Plug we [18 | - | #80 | a75 | 516 | 509 [558751] AR (Oil Fill Plug 12 13 7 450 | 375 | 516 | 509 (55-6750) 1 | Specifications (Rev. 7, 12/01) TORQUE VALUES (CONTINUED) THREAD SIZE TORQUE beers Fi | pitch | Lenath | ina | fea | kgm | um fart | Req. il Pickup Tube Bracket 4 20 | Wz 120 | 100 | 138 | 136 [55-165 | 2 Oil Pickup Plug Be | 18 ~_ | 40 [375 | 518 | 509 [se67et | 1 Oi Pressure Relief Valve one | 18 = | 225 | 188 | 259 | 264 |227e4 | 7 Oil Pump Cover/Housing oe | 16 | 214 | 275 | 229 | ai7 | 311 |se183 | 8 ‘Oil Pump Cover S16 18 1-38 | 150 | 125 | 4.73 | 17.0 |55-681 2 1 Sump we | 16 3” [335 [279 | a86 | 379 [58-1417] 16 (Oi Sump se | 16 | +14 | 335 [279 | 386 | S79 55109 | 16 Piston Head Nut, FlexLoc - Type without Oi sie | 24 =| 160 | 133 | 1.85 | 1.80 ae Piston Head Nut, Flangenut Type with Oil sie | 24 | 130 | 108 | 150 | 147 |s5-318 | an Throttling Valve Body oe 16 | 1-18 | 275 | 229 | 317 | aia [55-0106] 4 [All Other Bolts sé | 18 = 150 | 126 | 1.73 | 170 * AR ‘All Other Bolts we | 16 =| 275 | 229 | ai7 | aia -__ [AR] NOTE: Torque (in-lo) x 0.08333 = torque (felb) Torque (in-lb) x 0.01152 = torque (kgm) Torque (in-tb) x 0.1130 = torque (Nm) General Compressor Repair Techniques Because of the various refrigeration unit models a given compressor may be used on, no attempt is being made in this manual to show a removal procedure, This manual assumes that the compressor has been removed properly in accordance to the maintenance manual for the appropi ‘model This manual does cover the drive coupling removal and re-installation, The illustrations used are typical, your installation may vary from what is shown, DIRT AND MOISTURE CAN EASILY RUIN COMPRESSORS! Compressors are assembled at the factory in special clean ith filtered, conditioned air. Field conditions will ‘not always allow factory clean repair areas but every effort rooms should be taken (o keep the compressor work area as ch as possibl dirt and moisture, Follow these nules to protect compressors from + Pump down the system and recover the refrige ‘compliance with Federal, State and local regulations. + Use dry nitrogen to. bre dirt and moisture from getting into the compressor. the vacuum. This prevents + Use cap plugs or tape inste sor openings as soon as vibrasorbers or service valves of rags to cover compres are removed, Poloyol ester oil draw: sponge and rags will not stop moisture from entering the compressor. cisture like a + Remove all dirt and debris from the compressor prior to disassembly open doors or windows that allow dirt to blow in parts clean- ing are . grinding areas and bead blasting machines, + Keep your tools and workbench spotless. Keep your hands as clean as possible. + Once the compressor is opened to the atmosphere, get the job done quickly. Plan ahead, Have your parts and tools ready. + Only use chemical solvents that leave no oily residue, such as naphtha, lacquer thinner, or brake cleaner to clean compressor components, Do Not Bead Blast compressor components clean, + Ifthe job must be interrupted, cover the compressor, A. fresh, clean piece of plastic sheeting wrapped tightly around the compressor is best. Cloth should not be used as it does not block moisture. + Be sure to use the correct oil to prevent contamination of the system, + Always ket your reftigeration oil capped. A few utes with the cap off can ruin it! ers of oil used for Parts sit open and collect moisture, dirt and + Do not dip seal pauts in oil. Cor dippi dust. Instead, use a small, clean oil can dedicated for use only with the correct oil for the compressor you are repairing + Discard all the old O-rings and gaskets that are exposed while working on the compressor. O-rings and gaskets should not be reused. Replace them with new ones. COMPRESSOR OIL INDICATIONS. Discoloration of the oil is an indication of a cor system and future problems. Refer to the following com- pressor Oil Color Code to diagnose the conditions and cor- inated COMPRESSOR OIL COLOR CODE COLORLESS or LIGHT YELLOW, Indicates good com- pressor ol General Compressor Repair Techniques (Rev. 7, 12/01) BLACK OIL. Indicates carbonization caused by air in the system or the presence of wear particles that contain iron. Change the compressor oil and oil filter, LIGHT BROWN OIL. Use an acid test kit to test the acidity of a sample of the compressor oil. For alkyl benzine oil use ‘acid test kit P/N 203-346. For polyol ester oil use acid test kit P/N 203-518, Change the compressor oil ifthe test indi cates the oil is acidic, BROWN OIL. Indicates copper plating caused by moisture in the system. Air in the system or high compressor temper- atures can cause oxidation which will tum the oil brown, Change the compressor oil if the test indicates the oil is acidie GRAY OR METALLIC OIL. Indicates the presence of wear particles that contain aluminum, This is usually caused by bearing wear o piston scoring. The compressor should be disassembled and inspected for worn or damaged compo- nents. The oil and oil filter should be changed. GREEN OIL. Green compressor oil indicates there is water in the system and copper plating may have occurred. The ‘compressor should be disassembled and the shaft seal, bear- ings, gears, and rotors should be inspected. Parts with sig- nificant copper plating should be replaced, the oil separator should be replaced, and the oil and oil filter should be changed. A contaminated system will cause a failure if left uncor rected, The contaminate in the system will break down the refrigerant oil, causing excessive bearing wear and scoring of parts within the compressor. Copper plating and moisture will affect the valve plate rings and break down the reftiger- of the unit, antand affects the eapaci Particles and bearing scale traveling with the refrigerant will plug the driers and expansion valves, causing erratic operation until the condition is corrected, Flushing with refrigerant or the use of suction filters and liquid line driers is recommended whenever a contaminated system is found, In some cases, the contaminated condition can be corrected by changing oil, refrigerant and drier: Use a recommended evacuation process before the unit is placed in service. See ‘TK 40229 “Clean-up of Refrigeration Systems with Thermo. King Compressors.” Disassembly and Reassembly ‘The follow bly and reassembly of the compressor are suggested sequences for a full disassem- woe: When servicing compressors, make sure all parts are reinstalled in their original loca- tions. Carefully mark similar components, and pay special attention to fastener length to ensure they are reinstalled correctly. DISASSEMBLY SEQUENCE 1. Remove drive coupling. 2. Drain residual oil 3. Remove manifold (four ey \der compressors only). 4, Remove head, or heads from compressor body. 5, Remove discharge valve plates from cylinders. ankshaft seal 6. Remove seal plate/mounting flange and ct Remove oil sump and oil pickup sereen. 8, Remove connecting rods, pistons and sleeves. 9, Remove oil pump. 10, Remove crankshaft. 11, Remove check valves. REASSEMBLY SEQUENCE 1, Install check valves. 2. Install crankshaft 3. Install oil pump, 4. Install connecting rods, pistons and sleeves. 5, Install oil pickup screen. 6. Install oil sun 7. Install discharge valve plates. 8, Install head, or heads and manifold. 9, Install crankshaft seal and seal plate/mounting flange. 10, Install drive coupling. FASTENER TORQUE PROCEDURE Use the following procedure when specific steps are not provided 1, Carefully remove any remaining gasket material and thoroughly ‘clean both gasket surfacy 2. Always use new gasket and coat the gasket with clean ‘compressor oll just prior to assembly. 3. Install all bolts (and washers) and pre-tighten to 70% of the recommended torque, following a criss-cross pal- 4. Use a hand torque wrench and the same criss-cross pat- tem to bring all bolts to final torque. Hold bolts “On Torque” for a few seconds. CLEANING COMPONENTS CAUTION: Do wot bead Sat compres cmp DM cee icn ‘The etre med cen become cmbedied nrg fe nef rig emprser sper, and damage the compres. On 3

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