2-1
SECTION 2
COMPRESSOR REPLACEMENT
2.1 COMPRESSOR REMOVAL
Refer to the operation and service manual covering
the equipment in which the compressor is installed for
specific removal instructions. A general removal
procedure is given below.
a.
If compressor is completely inoperative,
frontseat the suction and discharge service valves to trap
the refrigerant in the unit. If the compressor will operate,
pump down the unit; then, frontseat the suction and
discharge service valves.
b.
Ensure power source is removed from any
controls installed on the compressor.
c.
Remove refrigerant using a refrigerant recovery
system.
d.
Disconnect refrigerant lines at service valve
flange connections on the compressor; retain hardware.
e.
Remove any components necessary to gain
access to the compressor or to enable removal.
f.
Disconnect the drive mechanism at the
compressor.
g.
Remove mounting hardware and remove
compressor from unit.
h.
If compressor is to be repaired, refer to section 3
for repair procedures. if a replacement compressor is to
be installed, refer to section 2.2 for replacement
procedures.
2.2 COMPRESSOR REPLACEMENT
Consult the unit service parts list for the correct
replacement.
Service replacement compressors are furnished
without suction and discharge service valves and
unloader valves. The service valves are normally retained
on the unit to isolate the refrigerant lines during
compressor replacement. Blank-off pads are installed on
the service replacement compressor valve flanges. These
pads must be removed prior to installing the compressor.
If the defective compressor is to be returned for overhaul
or repair, install the pads on the compressor for sealing
purposes during shipment.
Service replacement compressors are furnished with
cylinder head bypass piston plugs installed on the
unloader flanges in lieu of the unloader valves. The
unloaders (if used) must be removed from the defective
compressor and transferred to the replacement
compressor prior to installation. Refer to section 2.2.1.
If the defective compressor is to be returned for
overhaul or repair, install the plugs on the compressor for
sealing purposes during shipment.
2.2.1 INSTALLING COMPRESSOR UNLOADERS
a.
Remove the three socket head capscrews
holding piston plug to cylinder head of the replacement
compressor. See Figure 2-1.
1
2
7
SUCTION CUTOFF
HOT GAS BYPASS
3
6
1
2
3
4
5
8
1. Capscrews
2. Flange Cover
3. Gasket
4. Spring
5. Bypass Piston Plug
6. Seat Ring
7. Strainer
8. Sleeve Plug
Figure 2-1. Removal of Piston Plug
b.
Remove flange cover, gasket, spring, bypass
piston plug, and seat ring. A tapped hole is provided in
piston plug for use with a jackscrew to enable removal of
the plug. One of the socket head capscrews may be used
as a jackscrew.
c.
Remove the three socket head capscrews
holding unloader in the cylinder head of the defective
compressor; remove the unloader and retain the
capscrews.
NOTE
Capscrews removed from the bypass piston plug
flange cover are not interchangeable with
capacity control unloader valve capscrews.
When installing the unloaders, be sure to use the
unloader capscrews.
d.
Using a new gasket and unloader ring pliers (P/N
07-00223), install the unloaders in the cylinder heads of
the replacement compressor. Refer to Table 3-1, for
required torque values.
e.
If the defective compressor is to be returned for
overhaul or repair, install the bypass piston plug, spring,
seat ring and flange cover onto the cylinder heads.
