Reconditioning Refrigerant Compressor

A. Delco refrigerant compressor engine 102

Data
Designation Delco radial 4-cylinder
Max. speed rpm (1/min) 7000
Power input at max. compressor approx. 6.3 (8.5)
speed kW (HP)
Cylinder capacity 164 cc

Oil filling capacity
Oil type cold-flowing oil

Oil capacity, fresh oil, 170 cc
in refrigerant compressor







Tightening torques












Special tools

Conventional tools
Socket 14 mm, 3/8" square e.g. Hazet, D-5630 Remscheid
Slip gauge (set) e.g. Hazet, D-5630 Remscheid
Order No. 2147
Langbeck pliers 72 J (internal lock) e.g. Hazet, D-5630 Remscheid
Order No. 1846a-1
Pliers for locking ring A 2 (outside lock) e.g. Hazet, D-5630 Remscheid
Order No. 1846 c-2

Double open-end wrench 1/2" x 9/16", 5/8" x 3/4',, 7/8" x 15/16", 1" x 11/8"

Self-made tool
Remover for O-ring

a) Renewing shaft seal of refrigerant compressor

Removal
1 Drain air conditioning system.
2 Remove refrigerant compressor.
3 Remove spring plate.







4 Remove locking ring (10) for shaft seal.







5 Remove slip ring (12) by means of remover and installer.







6 Remove shaft seal (13) by means of remover and installer. Keep pushing against tool, turn tool to the right to contact lug of shaft seal with detents on tool. Remove complete shaft seal from shaft by straight pulling.







1 Nut on drive shaft
2 Spring plate
3 Coupling member
5 Locking ring
6 Bearing for coupling member
7 Pulley
8 Screw with lock
9 Magnetic coil
10 Locking ring
11 O-ring
12 Slip ring
13 Shaft seal
14 Drive shaft
20 Housing cover

7 Remove O-ring (11) from inside bore in housing cover. A wire, bent to a hook, can be used for this purpose.

Installation
8 Check whether parts of the old shaft seal are still in bore of housing cover. Clean bore prior to inserting new seal.
9 Dip new sealing parts into clean cold-flowing oil. Insert O-ring (11) into groove of housing cover.
10 Insert shaft seal (13) into tool and slip on shaft. Keep turning tool to the right until shaft seal engages in shaft. Only then turn the tool to the left for disengagement on lugs of shaft seal and remove.
11 Introduce slip ring (12) into bore by means of tool until ring touches shaft seal. Make sure that the O-ring (11) is not pushed out of groove.

Attention!
Sealing surface of slip ring (12) must be protected against any kind of damage, e.g. scratches.

12 Introduce locking ring (10) with flat side facing downwards until the locking ring rests on slip ring. Then push against locking ring with lock pliers or a screwdriver until locking ring snaps into groove.
13 Install spring plate (83-526).

b) Checking refrigerant compressor for external leaks

NOTE: When working on shaft seal it will be of advantage to drain all the cold-flowing oil from refrigerant compressor. Determine drained quantity of cold-flowing oil and fill same quantity of fresh oil into refrigerant compressor. For details refer to Checking oil level in refrigerant compressor. Checking Compressor Oil Level







1 Refrigerant compressor
2 Sealing ring
3 Suction connection
4 Pressure Connection

14 Check installed sealing rings (2) on refrigerant compressor (1) for condition, renew if required and provide with cold-flowing oil.







15 Screw pressure-testing plate (3) with available hex. Screw to refrigerant compressor (1).
16 Connect inner connection of pressure-testing plate with hose line (4) of service unit.
17 Let refrigerant vapor flow into refrigerant compressor. A bottle or filling cylinder pressure of above 4 bar gauge pressure is required.
18 In installation position of refrigerant compressor, rotate compressor shaft in direction of rotation manually several times.
19 Check refrigerant compressor with leak tester for leaks.
20 Close valve on service unit or on filling cylinder again and remove hose line from pressure-testing plate.
21 Remove pressure-testing plate again, but only directly before attachment of pipe line.
22 For details concerning oil filling capacity of refrigerant compressor refer to "Checking oil level in refrigerant compressor".
23 Renew receiver-drier Service and Repair.
24 Install refrigerant compressor.
25 Evacuate air conditioning system and fill again, also check for function.

B. Nippondenso refrigerant compressor engine 601

Data, test values
Designation 10P 15 G, 5 double piston swash plate compressor
Displacement cc 153
Nominal output kcal/h 5200 at 14.7 bar
Power input kW 3.1
Max. rpm 1/min 8000
Nominal rpm 1/min 7000
Oil filling capacity (fresh oil) cc 120







Tightening torques







Special tools

Spare part
Closing plate for refrigerant compressor 601 131 00 21

Conventional tools
Pliers for locking ring J 3 (inner) e.g. Hazet, D-5630 Remscheid
Slip gauge (set) e.g. Hazet, D-5630 Remscheid
Socket 12 mm, 13 mm (3/8" square) e.g. Hazet, D-5630 Remscheid
Double opened wrench e.g. Hazet, D-5630 Remscheid
12 x 14, 17 x 19,24 x 26

NOTE:
Bores and screws with metric threads, hose connections as before with inch threads.

Renewing shaft seal of refrigerant compressor

Removal







1 Drain air conditioning system.
2 Remove refrigerant compressor.
3 Remove spring plate.
4 Push out dust seal (arrow) with a screwdriver.







5 Plug key puller on compressor shaft and rotate by half a turn.

Attention!
Pay attention to inclination of refrigerant compressor to prevent loss of oil.







6 Pull out key and remove.
7 Remove locking ring by means of circlip pliers (J 3).
8 Apply cold-flowing oil to inner bore of refrigerant compressor.







9 Insert sealing plate-assembly tool against shaft and push holding ring (arrow) down up to mark. Pull out sealing plate and remove from tool.












10 Introduce assembly tool for shaft seal against shaft, push in, turn to the right and remove shaft seal.







Installation

Attention!
The crankshaft seal on coupling side of refrigerant compressor is available as a complete unit only and must also be installed as such. Never install new and used parts together.

Newly installed shaft sealing sets need not be removed again immediately owing to a slight leak. The carbon ring is lapped together with the inside of the sealing plate. Its fit is getting better during running-in time of shaft seal.







1 Oust seal
2 Locking ring
3 Sealing plate
4 O-ring
5 Shaft seal
6 Head part,front

11 Fasten shaft seal on assembly tool and moisten with cold-flowing oil.
12 Insert shaft seal and loosen special tool by turning to the left.







13 Fasten sealing plate to assembly tool (Fig.) and lubricate with cold-flowing oil.
14 Insert sealing plate and mount locking ring.

Attention!
Tapered surface of lacking rings must be front end.







15 Mount key and push in (arrows).







16 Push in dust seal (arrows).
17 Install spring plate.







18 Let refrigerant vapor flow into refrigerant compressor at service valve (arrow). A bottle or filling cylinder pressure of above 4 bar gauge pressure is required.
19 In installation position of refrigerant compressor rotate compressor shaft several times manually in direction of rotation.
20 Test refrigerant compressor with leak tester for leaks.
21 Close valve on service unit or on filling cylinder again and remove hose line on service valve.
22 Install refrigerant compressor.
23 Renew receiver-drier. Service and Repair
24 Correct oil quantity, while adding an additional 10 cc of fresh oil into compressor.
25 Leak test and evacuate.
26 Evacuate air conditioning system and refill, also check for function.