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Performance and durability count.

1. lt L ED lt L gt gt aa TT 7 PERFORMANCE AND DURABILITY COUNT All cast iron wear surfaces including permanent cast iron cylinder liners cast iron piston rings cast iron crankshaft and cast iron shaft seal plate High load ball bearings no needle bearings or sleeve bushings are utilized High strength aluminum alloy pistons and connecting rods permanently secured by steel wrist and dowel pins Swedish steel reed valve assemblies highly finished for maximum performance as well as maximized orifice porting to reduce the effects of liquid slugging Value added features like a generously lubri cated shaft seal area high quality steel head gaskets and the widest selection of compressor service valves available Large oil sump produces a unique splash lubrication system that allows the compressor to be self lubricating regardless of the amount of oil mixed with refrigerant 08 98 SUPERSEDES FORMS 180 72 NM 180 72 NM2 180 72 RP YA77 401 Table of Contents Compressor SDC CIN CANONS esas cnseceeeseecie 2 Heavy Duty and Standard Models 2 Super Compact Mini 5 3 Compressor ldentification NI mm 4 5 Jesi BT E 6 NAS POCORN P M 7 eEe 7 Leak Che
2. If the baseplate is stuck lightly tap the edges of the baseplate with a soft hammer 3 Remove any gasket material adhering to the baseplate or crank case This should be done ina manner such that the sealing sur faces are not scratched or nicked INSTALLATION 1 Apply a thin film of refrigeration oil to a new gasket and the sealing surface of the crankcase and base plate 2 Properly align the gasket on the crankcase 13 3 Install the baseplate and bolts Tighten baseplate bolts to 10 16 ft lbs 13 6 21 7 N m in sequence given on page 15 using a torque wrench GASKET TREATMENT Before assembly to the compressor all gaskets should be dipped in clean refrigeration oil of the type used in the crankcase Gaskets are made of a neoprene composition fiber and wicking action will result as oil follows the fiber Do not mistake this wicking action for leaking Wicking is a normal condition and is to be expected NOTES ON NOISE COMPLAINTS Many of the noise complaints can be traced to mount and drive and other related component problems Normally if the unit is noisy at one speed and this noise clears up at another it is not usually due to the compressor Each vehicle has its critical frequencies where all vibrations get into the correct harmony to generate sound or noise The speed at which these critical points are found will vary with each vehicle and each mount and drive arrangement By changing the mount
3. and drive components the noise level may be reduced Many times the noise generated can be eliminated or greatly reduced by chang ing the belt adjustment to a different tension A tension of 100 120 16 45 54 kg is considered normal Noises emanating from the clutch are difficult to recognize because of the close connecting feature with the compressor A loose bolt holding the clutch to the shaft will result in extremely noisy operation Extreme care must be exercised to prevent the removal of the wrong component Since a compressor has many moving parts it is normal for it to generate some noise just as a motor generates some noise as it is operated The refrigerant gases as they are moved by the compressor pistons also produce noises and vibrations as a normal situation CLASSIC 22 1272 CCI YORK ESSENTIAL SEAL TOOL KIT 99 431 and Tecumseh Oil Level Checker 99 474 Seal Installer and Plate Alignment Tool 99 499 Universal Clutch Holder Wrench 99 440 Clutch Remover 5 8 x 11 Thread and Tecumseh 99 441 Clutch Remover 5 8 x 18 Thread CCI and Tecumseh 99 473 Universal Seal Remover BASIC COMPRESSOR TOOLS AVAILABLE THROUGH CLASSIC TOOL DESIGN INC 31 WALNUT STREET NEW WINDSOR NY 12553 14 PH 914 562 8700 FAX 914 562 8596 Torque Sequence and Specifications Heavy Duty and Standard Models LOCATION Baseplate Rear Bearing Cover Plate Cylinder Head Seal Plate Oi
4. contamination from falling into it 5 Prior to installation check the seal assembly to make sure that the carbon seal ring is right side up narrow polished band up and confirm that the carbon rings notches are aligned with the drive tabs in the metal seal retainer Lightly place the seal assembly carbon ring side up onto the oiled crankshaft Te 2 Apply clean refrigerant oil to the seal plate O ring and place the ring into the seal plate O ring groove Invert the plate and observe that the ring remains in place 3 Place a few drops of clean refriger ant oil on the face of the seal plate between the O ring and the inside diameter and with a clean finger spread the oil into a thin film It is important that the surface not be over oiled and that there is no oil between the O ring groove and the outside diameter of the seal plate 4 Apply clean refrigerant oil around the entire exposed end of the crank shaft With a clean finger uniformly spread the oil completely over the surface Again take care that no dirt or contamination falls onto he main bearing 6 Insert the alignment tool into the seal plate and lightly place the plate s polished face into contact with the seal assembly With a uniform downward motion use the alignment tool to push the seal plate into contact with 17 the crankcase face Continue to hold pressure between t
5. Cap For Rotalock and Tube O Heads includes rubber seal 16mm High Side R 12 to R 134a adapter 13mm Low Side R 12 to R 134a adapter Suction Screen O Ring For Oil Plug and P R V Teflon Ring white 3 4 For Rotolock Heads Felt Ring oil wick and dust seal Oil Dip Stick Shaft Key Oil Wick Assembly standard amp heavy duty models Pressure Relief Valve P R V Rotolock Head Assembly W Gaskets Gasket Kit All Standard and Heavy Duty Models Valve Plate and Reed Assembly W Gaskets standard Flange Head Assembly W Gaskets Tube Head Assembly W Gaskets SC Mini Flange Head Assembly W Gaskets Valve Plate and Reed Assembly W Gaskets heavy duty Gasket Kit SC Mini Models SC Mini Blank Head Assembly W Gaskets Valve Plate and Reed Assembly W Gaskets SC Mini Shaft Seal Kit Neoprene All Refrigerants Including R 12 R 134a and Blends Deluxe Neoprene All Refrigerants Seal Kit W Felt Ring Centering Tool Special Clutch Coil Screws Classic Tool Kit Compressor Repair and Clutch Removal P O E ESTER Oil 14 Ounce Bottles 12 to a Case RETRO FIX II Brand GASKET OLD STYLE FLANGE HEAD ROUND RUBBER O RING INCLUDED WITH FITTING OR VALVE 1 3 16 30 2 mm TUBE O HEAD 20 MANUFACTURING amp SALES OFFICE WAREHOUSE VALIDATION SALES CONTACT 4763 WICKLOW DRIVE FRISCO TX 75035 972 731 9494 OFFICE 214 908 2560 MOBILE 972 731 9495 FAX
6. USA R amp D FACILITY amp WAREHOUSE 2120 NORTH 22ND STREET DECATUR IL 62526 217 422 0055 CHINA MANUFACTURING FACILITY NINGBO MANUFACTURING LTD 1226 JUXIAN ROAD NINGBO CHINA 315040 EUROPEAN HEADQUARTERS BWD AUTOMOTIVE GMBH A MEMBER OF GROUP SCHNACKENBURGALLEE 47 51 22525 HAMBURG GERMANY 49 0 40 89 05920 SALES TCCIMFG COM WWW TOCIMFG COM Member of MOBILE AIR CONDITIONING SOCIETY y EE t a 7 ORL D W D E lt LM N 08 242
7. either plug on a vertical mount installation the upper plug on horizontal mount installations LEFT HAND MOUNTING CHECK OIL WHEN NON ROK SHAFT KEY IS DOWN RIGHT HAND MOUNTING CHECK OIL WHEN NON ROK SHAFT KEY IS UP 4 3 4 R 121 mm 78 FIG 1 OIL DIP STICK The oil dip stick Fig 1 can be made locally or pur chased page 15 and is suitable for use on all compres sors in any mounting position If made locally it can be formed from 1 8 dia X 8 5 16 3 mm dia x 210 mm long stock preferably non ferrous material which is not subject to corrosion Notched ends are helpful in visibly detecting the oil depths OIL TYPE When adding or changing oil use only proper oil Keep the oil storage container tightly capped at all times Refrigerant Acceptable Lubricants R 12 R 22 1 Mineral Oil Zerol 150 R 502 Zerice S 68 P O E R 134a Polyol Ester P O E P A G Other Refrigerants Consult Factory The Table below shows the crankcase oil charge in fluid ounces and ml at various dip stick measurements for both horizontal and vertical mounts The oil charge after the system is stabilized should be maintained with 6 fluid ounces 177 ml minimum and 8 to 12 fluid ounces 237 to 355 ml for best results OIL CHARGE vs DIP STICK DEPTH HEAVY DUTY amp STANDARD MODELS Horizontal Vertical 45 Mount Mount Mount 6 fl oz 13 16 7 8 158 177 ml 21 mm 22 mm 41 mm 8 fl oz 1 1 1 13 16 237 ml 25
8. mm 25 mm 46 mm 10 fl oz 1 3 16 1 1 8 2 296 ml 30 mm 29 mm 51 mm 12 fl oz 1 5 8 1 7 16 2 1 4 355 ml 41 mm 37 57 14 fl oz 1 13 16 1 11 16 2 7 16 414 ml 46 mm 43 mm 62 mm 16 fl oz 1 15 16 1 7 8 2 5 8 473 ml 49 mm 48 mm 67 mm SUPER COMPACT MINI MODELS Horizontal Mount Vertical Mount 6 fl oz 3 4 1 177 ml 19 mm 25 mm 8 fl oz 1 1 1 4 237 ml 25 mm 32 mm 10 fl oz 1 3 16 1 1 2 296 ml 30 mm 38 mm 12 fl oz 1 7 16 1 13 16 355 ml 37 46 OIL LEVEL 45 Measurement up dip stick DIP STICK PART 029 25173 ROTATE KEY WAY TO THIS LOCATION The compressor oil level should never be permitted to go below the minimum oil level of 6 fluid ounces 177 ml If oil must be added the oil should be added until the level is 12 fluid ounces 355 ml An excessive amount of oil is detrimental to the proper functioning of the entire system If a compressor replacement is made a system which has been in operation the oil charge of the new com pressor should not exceed 12 fluid ounces 355 ml unless specified by the OEM manufacturer When inserting the oil fill plug the sealing O ring is slipped over the oil fill plug threads in such a manner that the O ring is not twisted Insert the oil plug in the oil fill opening and tighten the plug snug If the plug leaks do not attempt to stop th
9. tight sealing long lasting and when necessary easily and quickly replaced seals are machined to 3 helium light bands of flatness The carbon is lapped to the seal plate and the fit becomes even better as the seal assembly is run in during operation The tendency to condemn a seal assembly because of very slight leakage is an error that is often committed Few if any mechanical seal assemblies are 100 tight The rubbing surfaces of the seal are separated by a very fine film of oil Oil carries refrigerant and minute quantities which seep to the outside may be detected with ultra sensitive leak detectors which are capable of sensing leakage totalling one ounce of refrigerant over a twenty year period Such sensitivity serves a useful purpose in critical applications but for leak testing compressor joints or seal a leak detector will pick up any leak of sufficient magnitude to require correction Refer to comments on leak detector equipment page 8 Do not be too prone to condemn and replace a seal assembly until the seal has been given an opportunity to run in and until there is definite proof that replacement is really necessary If a refrigerant leak from the area behind the compressor clutch is verified with a refrigerant leak detec tor replacement of the compressor shaft seal is recommended Note Up to a few drops of compressor oil may normally be found in the area under the front seal Do not repl
10. 197 0 in 3 250 t82 6 6 0 156 4 02 E d CSS SM 0941235 L 57 16 24 UNF 2B THREAD L25 31 8 MIN DEEP L xxr I ji 20 63 jen 372 2 2 34 59 43 THIS DIMENSION MAY CHANGE DEPENDING UPON VALVE CONFIGURATION tia 6 84 173 0 681 117 3 0 116 12 91 6 NON ROK KEY 0 066 1 7 1020 20 5 3 874 98 41 1937 49 21 1 3 007 TAPER PER FOOT 1 4 3 05 77 31 2 PLACES 3 8 16 UNC 2B THREAD 0 62 15 71 DEEP IN CRANKCASE 40 469 11 9 CLEARANCE HOLE IN BASE PLATE 4 PLACES DIMENSIONS IN mm NOTE Super Compact models are designed to have the fittings on the top or from the rear low profile SPECIFICATIONS SC 209 No Cylinders 5 Bore in mm 1 875 47 63 Stroke in mm 1 573 39 95 Disp cu in rev cc rev 8 69 142 R P M Max 6000 6000 Refrigerant R 12 22 502 134a R 12 22 502 134a amp new blends amp new blends Initial Oil Charge fl oz ml 12 355 Weight 108 13 0 5 9 13 3 6 0 Lubrication Splash and Positive Pressure and Oil Return Through Suction Side Some OEM specifications are as high as 15 fl oz 444 ml Compressor Identification The metal nameplate located at the top front of the compressor serves as a means of identification The location permits viewing the nameplate with the clutch installed Data inscribed on the nameplate includes the serial number combination model part number date of m
11. ION 1 2 FLARE SIZE 8 5 8 FLARE SIZE 10 5 5 9022 05174 0202 03175 022 219253 1 2 O RING SIZE 8 R 134a VALVES amp FITTINGS ROTOLOCK O RING HOSE CONNECTION 1 2 O RING SIZE 8 5 8 O RING SIZE 10 GB OEE AL oJ 02 15 6022 21931 022 21929 0202 21930 FLANGE RING HOSE CONNECTION 1 2 O RING SIZE 8 5 8 O RING SIZE 10 ON _ dom j 022 219933 5 8 O RING SIZE 10 5 8 FLARE SIZE 10 r1 COLL 0622 21926 TUBE O O RING HOSE CONNECTION 1 2 RING SIZE 8 Ur 1j at 21935 22 21937 022 2134 022 2137 ADAPTER ADAPTER 2 5 8 O RING SIZE 10 Ue 97 022 21934 022 81936 25032 lt SCHRADER VALVE INSTALLED NOTE SIZE 8 O RING HOSE CONNECTION 3 4 16 UNC THREAD SIZE SIZE 10 O RING HOSE CONNECTION 7 8 14 UNC THREAD SIZE 88 21923 REV K 19 Service Parts Part Number 021 12373 022 25020 022 25103 022 25104 026 19841 028 21549 028 07146 028 25131 029 25173 029 09888 088 21831 388 20905 488 16314 488 16316 488 16319 488 16346 488 16999 488 20322 488 20610 488 20797 488 20798 488 20799 488 21802 488 25274 488 25080 ESTER 25065 R CAST IN HEAD ROTOLOCK HEAD ROUND OR SQUARE CUT O RING NEW STYLE FLAT TEFLON O RING O INSTALLED IN HEAD Description Oil Fill Plug all models Plastic
12. LISEZ 1 4 20 UNC 2B 37 21 0 515 1312 DEEP THIS DIMENSIDN MAY CHANGE ie 4 PLACES DEPENDING UPON VALVE 2 281 57 92 CONFIGURATION 3370 T 6 2 81 71 42 413 9 MED 173 71 02201 05 4 500 14 3 2 IPL 2 250 57 21 3 007 TAPER PER FOOT 1 41 3 8 16 UNC 2B X 0 62 15 72 DEEP TAP IN CRANKCASE 0 469 11 9 CLEARANCE HOLE IN BASE PLATE 4 PLACES DIMENSIONS IN mm SPECIFICATIONS 26 29 210 No Cylinder Bore in mm 1 875 47 63 Stroke in mm 1 866 47 40 Disp cu in rev cc rev 10 3 169 R P M Max 24 6000 Refrigerant 12 22 502 134a 12 22 502 134 12 22 502 134 amp new blends amp new blends amp new blends Initial Oil Charge fl ml 14 413 14 413 14 413 Weight 108 kg 14 6 6 6 14 6 6 6 14 6 6 6 Lubrication Splash and Positive Pressure and Oil Return Through Suction Side H 12 Heavy Duty models contain 12 fl oz 855 ml RH 134a Heavy Duty models contain 14 fl oz 413 ml Some OEM specifications are as high as 17 fl oz 503 ml Compressor Specifications Super Compact Mini Models 4 88 124 02 0020 ins 826 46 41 159 140 43 20 020 044 1121 Ee E PLACES pa 3 8 16 UNC 2B THREAD T e lll 0 56 14 21 MIN DEEP E ILI 6 PLACES EACH SIDE 1 4 20 UNC 2B THREAD 0 405 10 37 MIN DEEP 4 PLACES 0841 21 41 8 50 215 91 ny GAGE a 776
13. Run system to confirm normal operation Install label to identify that the system has been retrofit per SAE J1660 LN Shaft Detail Indicating Compressor Displacement MODEL 206 wa 030 X 45 CHAMFER MODEL 209 015 DEEP GROVE pe MODEL 210 SHARP CORNER 17 Compressor Service Valves and Fittings HEAVY DUTY amp STANDARD COMPRESSOR VALVES amp FITTINGS ROTOLOCK FLARE HOSE CONNECTION 1 2 FLARE SIZE 8 5 8 FLARE SIZE 10 1 2 O RING SIZE 8 5 8 O RING SIZE 10 _ _ TUBE O FLARE HOSE CONNECTION 1 2 O RING SIZE 8 5 8 O RING SIZE 10 jb Bi TUBE O O RING HOSE CONNECTION 1 2 O RING SIZE 8 5 8 O RING SIZE 10 1 2 O RING SIZE 8 22 04580 0282 21748 5 8 RING SIZE 10 0022 04581 02221749 5 SCHRADER VALVE INSTALLED BACK SEATING VALVE STEM CLM Turn valve stem all the way forward clockwise to shut off connect J ing line This is front seating Turn valve stem all the way backward counter clockwise to shut off gauge port and allow connection of 7 service line hose to gauge port This is back seating In normal GAUGE PORT operation valve stem is back seated to allow full flow through the valve HOSE CONNECTION 18 SUPER COMPACT MINI COMPRESSOR VALVES amp FITTINGS YOKE FLARE HOSE CONNECT
14. ace a seal based on the presence of small amounts of oil Verify a leak with a refrigerant leak detector before replacement then proceed as follows 10 REMOVAL 1 Remove the compressor and place on work bench s P Ls US 3 Use a clean lint free shop cloth to wipe clean the exposed end of the crankshaft 4 Use Climate Control Seal Kit 488 25274 5 Caution Prior to removing the seal late screws be certain that an compressor internal pressure has been relieved Remove the screws that hold the seal plate in place and lift plate from the compressor 6 Using a flat blade screw driver or similar tool pry up and remove the seal retainer assembly Use care not to scratch or mar the crankshaft or the machined face of the compressor ELS HT CUA e i e LI n gt c B 44 ct 4e E 5 o A 7 nearly every case the friction ring boot will not come off with the seal retainer assembly 8 With the tool used to remove the seal retainer assembly carefully pry up and remove the friction ring boot Again use care not to scratch or mar the crankshaft or machined face of the compressor INSTALLATION 1 Use a clean lint free shop cloth to wipe the crankshaft clean Note At this time the front main bearing is exposed therefore care must be taken to prevent dirt or any type of
15. age 15 An important factor in compressor servicing is cleanliness and care should be exercised to prevent dirt or foreign material from entering the compressor when it is opened All old gaskets should be removed and replaced All gasket surfaces should be clean and all parts to be reused should be washed in a suitable petroleum base solvent CLUTCH SERVICING REMOVAL 1 Remove the clutch center bolt and washer using the adjustable spanner wrench to hold the clutch pulley 2 Install clutch removal bolt into the clutch Using the adjustable spanner wrench to hold the clutch pulley in place tighten the clutch bolt until the clutch pulley is forced free 3 Remove the clutch mounting bolts INSTALLATION 1 Check that a key is properly inserted in the shaft of the compressor 2 Mount and center the coil bracket Tighten the four clutch mounting bolts using a torque wrench to 13 19 ft lbs 17 6 25 8 N m NOTE Only use bolts that have a loctite patch on the threads 3 Place clutch pulley over shaft making sure to align the key way over the shaft key 4 Install and tighten the clutch center bolt and washer using a torque wrench to 20 25 ft lbs 27 1 33 9 N m 5 Spin the clutch pulley to verify there is no interference Verify the clutch engages when the proper voltage is applied SHAFT SEAL SERVICING The shaft seal assembly of the compressor is of a simplified design yet
16. anufacture and type of refrigerant SERIAL NUMBER PART NUMBER A 01234567 MONTH OF MANUFACTURE P ER 2101 00000 YEAR OF MANUFACTURE MODEL NUMBER 00 00 Climate Control Inc O REFRIGERANT 134a O TYPE OF REFRIGERANT R RIGHT HAND SUCTION L LEFT HAND SUCTION 10 10 CUBIC INCH DISPLACEMENT 09 9 CUBIC INCH DISPLACEMENT 06 6 CUBIC INCH DISPLACEMENT 2 TWO CYLINDERS ROTALOCK CYLINDER HEAD TUBE O CYLINDER HEAD FLANGE CYLINDER HEAD HEAVY DUTY MODEL SC SUB COMPACT MINI Features TRUE UNIVERSAL MOUNT Can be installed and operated in any position from horizontal left to horizontal right as received No field adjustments are necessary If the compressor is mounted horizontally the suction side should be on top UNIVERSAL ROTATION Compressor rotation can be clockwise or counter clockwise No field adjustments are necessary LUBRICATION SYSTEM A splash lubrication system provides more than adequate lubrication to the front and rear crankshaft bearings connecting rods and cylinder walls Positive pressure differential between the crank case and the suction intake is utilized to provide lubrica tion to the front shaft seal TWO OIL PLUGS One on each side of the crankcase permits easy checking of crankcase oil level regardless of mounting position EXTERNAL CLUTCH MOUNT Four bosses on the seal end of the crankcase provide accomm
17. ck NNI TE nai en Ta EEEa 8 Evacuation Leak Testing Adjustment swa RC 8 FAO MUON PECI 8 lip a 9 9 gt gt 10 Head and Vave ON ra gee rei SETS DUE 12 Baseplate iiri 13 Gasket Treatment TT 14 Notes on Noise Complaints ae 14 Torque SEQUENCE and SDeCIIICallOliS uscuc sein sat iore tenera RES ho II Ra ES suse 13d Erbe 15 TOUS SOO TING 16 Retro Fix Il Retrofit Procedure R 17 SRAM RET 17 Compressor Service Valves and Fittings 18 SOIL VICE TOTIS 20 Compressor Specifications Heavy Duty Models uw 40 47 0 44 11 2 2 PLACES ia a ERBEN rv PEE na 3 8 16 UNC 2B X 0 56 14 21 DEEP s B PLACES 9 46 240 31 60 841 21 4 Gage 8 33 211 6 20 025 215 4 500 114 3 3396 86 37 L55 39 41 E 2 67 67 81 Xen d 5 16 24 UNF 28 125 31 82 MIN DEEP eee D ans
18. detection equipment is to be able to positively calibrate the equipment to the permissible leak rate and then to use the equipment as explained by its manufacturer The speed at which the probe is moved is very important in locating the larger than permissible leaks 8 EVACUATION LEAK TESTING ADJUSTMENT The instructions contained in the installation and service manual of the air conditioning system manufacturer should be followed in evacuating and charging the system and for adjustment of all controls After charging the entire system should be checked for leaks with a leak detector ROTATION SPEED The compressor may be operated in either a clockwise or counter clockwise direction of rotation No field adjustments are necessary The compressor is designed for operation between 500 and 6 000 rpm maximum 4000 rpm continuous rating Service The majority of compressor parts are made up of aluminum alloys and care must be taken in handling not to mar nick or scratch All machined surfaces must be free of nicks and burrs to insure proper fit and gasket seating When replacing parts and securing with bolts or cap screws the specified torque requirements on page 15 should never be exceeded Bolts should all be run in until the bolt heads make contact then tightened with a torque wrench in a sequence resulting in tightening of diagonally opposite bolts until all are drawn up to specified torques Refer to torque sequence p
19. e leak by over tightening the oil check plug A leak may be caused by dirt under the O ring or on the seat a fractured O ring or a damaged seat on the oil fill plug or oil fill opening To stop leaks at the oil fill plug correct the mechanical damages and insert a new O ring It must be remembered that the 206 209 and 210 models are high speed compressors and satisfactory operation depends on proper lubrication LEAK CHECK EQUIPMENT Most of the electronic leak checkers now on the market are capable of locating very small refrigerant leaks Since open type bolted and flanged compressors have a permissible leak rate of one ounce per year it then becomes quite important that the leak check equipment used be calibrated to pick up only those leaks which are in excess of the permissible one ounce per year limit Since shaft seals depend upon oil for lubrication and sealing it is quite natural to find oil in the shaft cavity This oil is heavily laden with refrigerant and electronic equipment would pick up this refrigerant and indicate it as a leak When checking the shaft seal for leakage the refrigerant laden oil must first be flushed from the seal cavity with a solvent which does not affect the operation of the electronic leak equipment Caution some of the more common solvents contain chemical compositions which affect the operation of the leak detector equipment The major point to consider in any electronic type leak
20. fter approximately 30 minutes of operation time the belt should stretch to a normal operation point and a further check for proper tension should be made Good align ment and belt tension are important to insure long belt life quiet operation and to maintain top system perfor mance The discharge and suction line connections must be made to the proper compressor service valves or fittings The word DISCH on the cylinder head designates the discharge service valve port The word SUCTION on the cylinder head designates the suction service valve port Because the compressor will move or float with the engine upon acceleration rigid connections to the compressor should be avoided and suitable flexible refrigerant lines which will permit compressor movement without causing excessive tubing strain should be used Clockwise or counterclockwise rotation NOTE CCI recommends that when positioning compressor at full 90 horizontal suction side should be on top Inspection OIL CHARGE the quantity of oil is unknown the compressor oil level must be checked at the time of installation and again after the system has been fully charged with refrigerant and the system has been operated and balanced out to the desired compartment interior temperature Make the initial oil level check after the compressor is mounted on the mounting bracket and before initial refrigerant charge Remove one oil fill plug with its O ring
21. g it not to damage the sealing surfaces REMOVAL 1 Remove the screws from flanged type service valves Note that these four screws are longer than the remaining head screws If the valves are of the Rotalock type or Tube O type remove by loosening the hex nuts which are a part of the valve assembly 2 Remove the remaining screws in the head and remove the valve plate and head from the cylinder by prying or tapping under the ears which extend from the valve plate If the head and valve plate adhere hold the head and tap the valve plate ears away from the head with a soft hammer Do not hit or tap the head to separate the head and valve plate because damage to the head may result 3 All gasket material adhering to the head valve plate or crankcase should be carefully removed in such a manner that the machined sealing surfaces are not scratched or nicked INSTALLATION Valves and valve plates are furnished only as acomplete assembly 1 Apply a thin film of clean refrigera tion oil on the area of the crankcase to be covered by the crankcase gasket Place the cylinder gasket in position on the cylinder so the dowel pins in the crankcase go through the dowel pin holes in the cylinder gasket 2 Apply a thin film of clean refrigeration oil to the top and bottom valve plate areas to be covered by gaskets Place the valve plate in position on the cylinder gasket so the discharge valve assemblies i e the s
22. ges 2 and 3 for compressor dimensions and physical data Very important factors in compressor installation are correct pulley alignment and proper belt tension The compressor flywheel or clutch must be in perfect alignment with the drive pulley on the engine and any auxiliary idler or belt adjustment pulley arrangements It is important to be sure that the shaft key is in place on the shaft and the flywheel bolt is drawn tight when installing a flywheel or clutch The pulley alignment may be checked by holding a 1 2 dia 12 13 mm rod 2 to 3 feet 0 6 to 0 9 m long firmly in the V groove of the flywheel or clutch making sure the rod falls squarely in the driver pulley grooves A further check may be made by seeing that the belt as it goes from pulley to pulley comes off the pulley grooves perfectly straight and that there are no side way bends in the belt as it approaches or leaves the pulleys Only high quality reinforced belts 180 degree left to right orientation should be used The belt tension adjustment should be made so the belt is taut but not too taut to create excessive bearing loads Due to the pulsating load created by the compressor the belt tension must be greater than for a normal steady load Belt tension can be accurately determined with the use of a belt tension gauge which gives a direct reading of belt load as determined by the deflection A belt tension of 100 120 Ibs 45 54 kg is considered normal A
23. he seal plate and the crankcase face while aligning and installing the six 6 hold down screws Use a nut driver or similar tool for initial tightening Failure to hold the seal plate against the crankcase face until all screws are firm against the seal plate may result in a chipped or broken carbon ring Remove the centering tool and use a star pattern sequence to tighten the six 6 screws to a finish torque of 5 8 ft Ib 7 11 N m 7 Install the metal dust cover tapping it firmly into place 8 Install felt ring dust shield placing it around the seal plate and tight against the compressor housing 12 ye cm 9 Reinstall the clutch using the four new screws supplied with the seal kit to attach the field coil assembly tighten these screws to 13 19 ft Ib 18 26 N m Install the clutch arma ture pulley assembly and tighten the center bolt to 20 25 ft lb 27 34 Insure that the pulley spins freely Remove the caps from the suction and discharge ports and using the tool that tightened the center bolt rotate the compressor six 6 to ten 10 revolutions to seat the carbon ring uniformly against the seal plate Heplace the suction and discharge port caps HEAD AND VALVE PLATE SERVICING Prior to servicing the head and valve plate both service valves should be opened to free any gas pressure which may be in the compressor The cylinder head is made of aluminum and care should be taken when removin
24. l Fill Plug Clutch Mounting Screw Clutch Center Bolt Rotalock Valve Tube Valve Flange Valve Pressure Relief Valve THREAD 1 4 20 UNC Hex 10 24 UNC FIELD TORQUE SPECS 10 16 ft Ib 13 6 21 7 N m 10 16 ft Ib 13 6 21 7 N m 17 25 ft Ib 23 0 33 9 N m 5 8 ft Ib 6 8 10 8 N m 5 10 ft Ib 6 8 13 6 N m 13 19 ft Ib 17 6 25 8 N m 20 25 ft Ib 27 1 33 9 N m 35 40 ft Ib 47 5 54 2 N m 35 40 ft Ib 47 5 54 2 N m 17 25 ft Ib 23 0 33 9 N m 5 10 ft Ib 6 8 13 6 N m Trouble Shooting PROBLEM DIAGNOSIS REPAIR Inspect Valve Plate Reed High Suction Pressure amp Gasket Areas Replace Valve Plate Low Discharge Pressure and Gaskets 2 Consult System Manual Low Suction and Discharge 1 Check for Low Refrigerant Charge Pressures 2 Leak Check Compressor Replace Shaftseal Gaskets Oil Fill Plug etc No unusual compressor noise 3 Consult System Manual 1 Check Belt Tension Intermittent or Non F unctioning 2 O 2 Check Clutch Volts amp Amps 3 Consult System Manual 1 Check Compressor Temperature Component Parts Run out Change out Compressor Rough Running 2 Consult System Manual 1 Check Compressor Mounting Components Torque to Specs Clutch Engaged 2 Check for Other Engine Noise 3 Check for Clutch Slippage Replace if Needed 4 Check for Pr
25. maller diameter assemblies with the restrainer over the valve reed are facing up and the locating dowel pins go through the dowel pin holes in the valve plate 3 Place the head gasket with the bead facing up in position on the valve plate so the dowel pins go through the dowel pin holes in the gasket 4 Apply a light film of clean refrigera tion oil on the machined surface of the cylinder head which matches the head gasket Place the head on the cylinder head gasket so the dowel pins go into the dowel pin holes in the head 5 For a flange head apply a thin film of clean refrigeration oil to the service valve flanges Place an oiled service valve O ring or gasket in position on the cylinder head service valve flanges Place the service valves in position on the proper service valve ports suction or discharge and insert the four longer screws through the service valve mounting pads the head the valve plate and into the crankcase For a Tube O or Rotalock head insert the longer torx screws on the inside of the service valve ports and the shorter torx screws on the outside Insert the remaining head screws and run in all the screws until the heads make contact Tighten the head and service valve screws using a torque wrench to 17 25 ft Ibs 23 0 33 9 N m in sequence as shown on torque sequence chart page 15 BASEPLATE SERVICING REMOVAL 1 Remove the baseplate bolts 2 Remove baseplate and gasket
26. odation for mounting the clutch Simplifies field replacement of compressor shaft seals SERVICEABILITY All components readily accessible and removable with standard tools Crankcase Light weight die cast noncorrosive aluminum Cylinder Liners Cast iron permanently cast into crankcase body Precision honed finish Head Die cast aluminum Base Die cast aluminum Piston Die cast aluminum fitted with cast iron piston rings for optimum wear Connecting Rods Die cast aluminum heavy cross section super finished surfaces assembly doweled for positive alignment Crankshaft Cast ductile iron Large connecting rod and main bearing areas Bearings High load capacity ball type bearings for longer life at heavy loads and high speed Valves Swedish steel suction and discharge valves mounted on ground valve plate Shaft Seal Carbon face seal specially designed for high speed operation Gaskets Neoprene composite fiber gaskets used to seal base plate and valve plate Rubber coated metal gaskets used to seal cylinder head Installation The compressor mounting bracket must be rigidly secured to the vehicle engine It is recommended to use at least six 3 8 16 UNC bolts of proper length to secure the compressor to the mounting brackets Mounting with the side mounting holes is preferred over the bottom mounting holes Lock washers must be used with all mounting bolts Refer to pa
27. oper Refrigerant Charge Charge as Necessary 5 Check Clutch Components Clearing etc Replace if Needed 6 Check Compressor Oil Level Fill to Recommended Level EXCESSIVE NOISE 7 Check Valve Plate Replace if Needed 8 Consult System Manual 1 Check for Slippage Replace if Needed Clutch Not Engaged 16 RETRO FIX Il Retrofit Procedure This P O E Ester lubricant is approved for use in R 134a Climate Control 2 cylinder compressor York systems It may not be suitable in other compressors Use for oil additions in R 134a systems or for retrofitting of R 12 systems RETRO FIT PER VEHICLE MANUFACTURER RECOMMENDATIONS and in accordance with SAE J1661 J1660 J1639 J1629 J2197 J1989 Barrier hoses are required for R 134a systems Heavy duty vehicles equipped with these hoses can normally be retrofit by following these guidelines Diagnose and repair all A C system malfunctions Flush system only if contamination exists Recover the R 12 refrigerant Remove compressor and drain oil from sump Replace receiver dryer with one containing XH 7 or XH 9 desiccant Change high and low side service ports to R 134a type by using adapters new service valves etc per SAE J1660 Add 14 fl ounces of RETRO FIX P O E Ester oil to compressor and install on vehicle Evacuate system 45 minutes minimum Charge system with R 134a Usually 15 20 less R 134a by weight will fully charge an R 12 system Leak test system

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