etGram Refrigeration: YORK INTERNATIONAL A/S - Service Directions Reciprocating Compressor HC/HCL/HCH 6100/8100 ® ‘Attn. 82 600 0049.00 Ordre nr 22 00%Contents 1, In general 1.1, Introduction .. Application. ‘Compressor type.. Avoid liquid slug-over.. Starting-up fie Further information.. Identification Ordering spare par Instructions in general. 2. Operating and Maintenance 2.1, Maintenance Programme... 2.2. Service and repair ... Dismanting the compressor. Oil charge - during standstil. 1) Vacuum 1) Oil charging pump. Checking the Oi charge 1) Oil charging pump with non-return valv Il) Throttling the suction valve. Leak test... Spare parts. Trouble shootin 2.3. Compressor inspector Coupling alignment... V-belt Inspection of V-beltflywheel... Checking main- and axial bearing Mounting the bearings in end covers. Mounting the bearing cover, crank and checking clearance ‘Checking the crankshaft. ‘Checking connecting rods and bearings . Checking piston pins, Checking suction and discharge valves... New suction and discharge valve plates New suction and discharge valve springs Checking valve seats and guides... Pistons, cylinders and connecting rods Mounting cylinders / noxious spack ~ eter retetes BONAR ARa EEE © OOOO OMOIVIIO00RChecking cylinders Checking pistons Checking the shaft seal Mounting the shaft seal and oil pressure valve. Mounting and checking the carrier and oil pump. ‘Checking the oil system E Mounting the oil fer. ‘Checking the capacity control. Mounting the connecting tube between flang Mounting tube for capacity control. Mounting capacity control Checking the bypass valves Checking the oil control valve Checking pressure switch function Checking thermostat function. Checking the oi return... ‘Checking the oil cooling .. Mounting the oil cooler . : ‘Checking water-cooled top covers 2.4, Relief of trouble-shooting 2.5. HC/HCT Tolerance and adjusting measurements Bearing clearance. Piston / cylind. Piston ring gap. End clearance. 2.6. Survey of Torque Values 2.7. Placement of Cylinders and Discharge Valves ... HC 6100/8100 R717 ~ Ammonia. HC 6100/8100 HCFC, HFC. HCL 6100/8100 R717 - Ammonié HCL 6100/8100 HCFC, HFC. HCH 6100/8100 R717 ~Ammoni HCH 6100/8100 HCFC, HFC. Reference List: . [1] Operating and Maintenance Directions for HC/HCLHCH 6100/8100. [2] Installation Directions for HC/HCL/HCH 6100/8 100. Further documentation: ~ Technical Data. ~ Operating and Maintenance Directions for HC/HCL/HCH 6100/8100. ~ Installation Directions for HC/HCL/HCH 6100/8100. ~ Spare Parts List for HC/HCL/HCH 6100/8100. ~ Design Data. 26092019001.1. Application ‘These service instructions apply to the mainte nance of compressors. If the operating range of the compressor is changed or a’refrigerant is replaced by a new ty- pe, the supplier must be contacted. Compressor type HC is designed for normal cold rooms. HCH is designed for higher pressure and tempo- rature, @.g. as in air conditioning plant. HCL is for use as a low-pressure compressor in two-stage plant, To ensure economic and problem-free running, it is important that the correct compressor be used within the various operating ranges. The primary difference between compressor ty- pes lies in the suction and discharge valves, the refore it is extremely important that these are of the appropriate type, correctly assembled. See details in the sections dealing with discharge and suction valves. Avoid liquid slug-over To avoid slug-over itis important that the suction gas be superheated at the compressor inlet. A ‘Superheat of at least 5°C is recommended. It is also important that the heating element be connected during the standstill period - and for at least two hours before starting up. zens 001000 Introduction Starting-up filter ‘When supplied, the compressor is equipped with a starting-up fiter (in the suction fiter). The star— ting-up fiter must-be-removed “after about 50 hours'-running time. The starting-up fiter should bbe used after major repair or modification, etc. of the refrigeration plant. Further information if questions arise regarding installation, servi- cing, operation, maintenance and ‘spare parts, please contact your supplier. Identification ‘When supplied, the compressor has a nameplate giving year of manufacture, serial. number, type, refrigerant, etc. Ordering spare parts When enquiring about or ordering spare parts, please give model, serial nimber, refrigerant and ‘order number if applicable. Instructions in general Before carrying out repairs on the compressor, please read both the Operating and Maintenance Directions [1], and the Installation Directions [2] for the type of compressor concerned.2.1. Maintenance Programme 5 = 1. Normal maintenance, not calling for technical qualifications ‘Operating hours 5 | 50 | 500 | 4000 | 8000 [12000] 16000] 24000 - 1_| Check of V-belts for wear x [xxx [x fx [x lw 2 | Check of belt tension x [x [x [x [x Px Tx Tw . 3 | Disassembling of start-up filter x 4 | Visual checking of coupling [x [x | x | x | x | x | x | 5 | Tightening up of bots x x 60) 6 | Oilchange x x |x [x Tx Tw 7 | Cleaning of crankcase x x | x [x [x Tw 8 | Oifiter change x x |x |x [x [| ® 9 | Cleaning of suction fiter x [x [xe [x [x [x fx Tw 10 | Check for leaks x |x |x |x |x fx fx | 11_| Check of oil return x |x [x fx |x. fx fx | 12 | Cleaning of fiterforoitretum [x [ x [| x | x | x | x | x | & - The maintenance programme does not re- - Oil filers can be ordered from your agent. A place the daily routines described under the set of spare parts consisting of gaskets, O- Operating and Maintenance Directions [1] rings, aluminium rings etc. can be ordered too. = (8) indicates that the maintenance should be done in co-operation with the refrigerating - An oil change can be replaced by a fine-fi- firm in charge of the rest of the maintenance. tration 3 ym beta <75, and an analysis certi- fying the continued use of the oil. - The maintenance programme is repeated ‘every 24000 operating hours.2. Compressor inspection, calling for technical qualifications Operating hours 4000 [8000 [76000 [24000 | 32000 | 40000 [48000 1 [Alignment of coupling x [xx Tx [x [x Tx 2 [Change of V-belts x x ‘3 [Check of pulleys /fiywheels x [x [x |x fx Tx [x 4 | Check of main and thrust bearings x x “| Check of connecting rods Tx x and bearings _| Check of piston pins x x 7_|Check*of suction and discharge valves | _x '8_[ New suction and discharge valve plates: x [x [x [x fx [x ‘9 | New suction and discharge valve xlxlxtlxlxlsx springs 10 [Check of valve seats and guides x |x |[x fx >xt[x lx 11 [Check of piston rings x x 12__| Check of cylinders x x 13_| Check of pistons x x 14 [Check of Crankshaft x x 15 | Check of shaft seal x [x [x Px [x Tx 16 [Check of oil pump x x 17_[Check of oil system x x 18 [Check of capacity control x x 19_ [Check of by-pass valves x x [20 [Check of oil requiating valve x x 21 | Check of pressure control function x [x [x [x Px [x [x '22_| Check of thermostat function x [x |x |x |x ][-x]-x 23 [Check of oil return x [x [x |x [x [x |x 24 [Check of oil cooling x |x [x [x |x {x fx [25 [Check of water cooled top covers x [x [x [Tx ]x«fx [x It is possible to order the following standard Spare parts sets: ~ Sets of gaskets ~ Sets of spare parts, mini = Sets of spare parts, maxi For particulars, apply to your agent. Further spare parts can be ordered according to the spare parts lst. In case of a total damage of the compressor some hand-picked agents have a complete set of spare parts for a total compressor renovation. The intervals indicated only apply to normal loaded compressors, seeo0n000 At high speed and/ or high pressure conditions it may be expedient to reduce the maintenance intervals. The opposite applies to compressors with a low speed, Service during the guarantee period has to be carried out by the refrigerating firm in charge of the installation. Besides, some countries demand statutory inspections by an authorized reftige- rating firm, The maintenance programme is repeated at the same intervals as in the above table. Inspections have to be carried out according to the compressor service manual.2.2. Dismantling the compressor ‘When performing inspection or repairs, do not loosen covers or dismantle parts before the compressor has been sucked empty. Close the suction’ stop valves and allow the ‘compressor to run until the suction pressure ‘gauge indicates maximum vacuum, then stop the ‘compressor and close the pressure stop valves quickly. Wait until pressure in the compressor is equali- zed, i.e. suction and manometers show the same pressure. The pressure must be as close as possible to atmospheric pressure, preferably with ‘no more than 0.2-0.3 bar deviation, Oil charge - during standstill 1) Vacuum. Connect a hose to the oil charging valve and le- ad the hose down into a vessel containing refti- geration machine oil. Then connect the vacuum Pump to atmospheric pressure. Carefully open the oil charging valve. Oil will flow into the com- pressor. Avoid sucking air into the system. The normal oil level is the middle og the sight glass, maximum level is the top, minimum level the bottom. Il) Oil charging pump Connect the hose from the oil charging pump to the oil charging valve. Lower the pump suction pipe into a vessel containing refrigeration ‘machine oil and pump oil into the compressor. The normal oil level is the middle of the sight glass, maximum level is the top, minimum level the bottom. Service and repairs Checking the oil level After the compressor has been charged with oil and started, check the oil level regularly. Ifthe oil level falls below the bottom of the sight glass, it must be replenished. Oil replenishment is possible while the compressor is running. Oil charge ~ while running 1) Oil charging pump with non-return valve Connect the pump to the oil charging valve. Lower the suction hose into a vessel containing refrigeration machine oil. Open the oil charging valve and pump oil into the compressor. The normal oil level is the middle of the sight glass, maximum level is the top, minimum level the bottom. I) Throttling the suction valve Connect a hose to the oil charging valve, fill the hose with refrigeration machine oil and lower into vessel containing refrigeration machine oil Throttle the suction stop valve on the ‘compressor so that pressure in the crankcase falls to slightly below atmospheric pressure. Now carefully open the oil charging valve. Oil will then flow into the compressor. Avoid sucking air into the compressor. The normal cil level is the middle of the sight glass, maximum level is the top, minimum level the bottom.Leak test After repair or inspection, check all joints for leaks before starting the compressor. R 717 (ammonia) units can be checked by brushing a concentrated soap solution on joints and welds. Another possibility is the use of sulphur sticks or litmus paper. When in contact with R717, a burning sulphur stick emits white smoke; red moist litmus Paper becomes blue. Electronic leak detection equipment must be used where HCFC and HFC are involved. . s2eo000000 Spare parts The spare parts list contains parts that can be ordered by stating spare part numbers, item No., and compressor size, When ordering spare parts, remember to give the compressor machine number. Trouble shooting The following pages describe the remedies for faults.that might occur. cH2.3. Coupling alignment ‘See Installation Directions, 2.2, [2]. V-belt For belt tension, alignment and number of belts, see Installation Directions, 2.3, [2]. Inspection of V-beltflywheel Operating wear will occur on belts, motor pulley and flywheel. At some point, wear on the motor pulley and/or flywheel will become such that belt replacement alone will not be the most economic remedy. A worn pulley and flywheel subject the belts to extraordinary wear and then the most appropriate step is to replace the whole transmission. Wear canbe checked using a DIN 2211 gauge for the SPB profile. Note that there is a difference in profile between pulleys < 190 mm or > 190 mm. If wear has occurred, the pulley profile wil appear concave, as in fig. 1. Compressor inspection ‘The gauge can be ordered. For belt tensions, see Installation Directions, 2.8 and 2.9, (2) Fig. 1 20000000Checking main- and axial bearings ‘After pressing in new main bearings, check that the bearing clearance is as stated in the appropriate table. Also check whether the the Mounting the bearings in end covers ‘Main bearing pressed in as shown 14 mm from rear edge The end clearance can be adjusted by the number of gaskets used on the rear bearing cover. Insert thrust bearing I Lubricate bearings with ite refrigeration machine oil al ZZ Press the main bearing SaaS 4 flush with the edge of the 8 bearing hole 3 The opening pressure of d q Z Eber ZTTEDEEEETEEEEEE Mounting the bearing cover, crank and checking clearance the pressure control valve is checked Opening pressure: 4 Bar Before insertion, lubricate the crank, main and thrust bearings with refrigeration machine oil HH Checking the crankshaft ‘See table of clearances for wear measurement. 776006907, 0.6-1.0 MM Clearance between crank- shaft and pressure bearingChecking connecting rods and bearings See table of clearances for wear measurement. Checking piston pins ‘See table of clearances for wear measurement. Checking suction and discharge valves Check suction and discharge valves for wear. Typically, wear manifests itself by concentric rings inthe valve plates. If such wear has ‘occurred, replace the valve plates. Wear can also occur on the springs. This appears in the form of notching (see fig. 2) typically from compressor liquid slug-over. Replace the spring and take steps to prevent liquid slug-over. When valves become damaged, ‘the repair of valve springs and plates isnot advised. When springs have been taken out for checking, they must be refitted so that an open gap is created inside the ring, see fig. 3. The correct assembly of these springs is of the utmost importance to compressor running and output. I 8 al : i i Fig. 2. ‘The open crack should be in the ring Open crack Fig. 3. New suction and discharge valve plates When fitting new valve plates, make sure that they havethe correct number, see spare parts list. To ensure optimum compressor output and operation it is essential that the correct plates be fitted, New suction and discharge valve springs When fitting new springs, make sure that they have the correct number, see parts list. It is important that the springs be fitted correctly, Le. that an open gap is created inside the ring. See fig. 3 above under "Checking suction and discharge valves". To ensure optimum ‘compressor output and operation it is essenti that springs be fitted correctly. Checking valve seats and guides Check valve seats and guides for wear. Impact marks or similar must not appear on the surfaces. If there are marks, replace the parts. Also check that the seat has not become too wide. Slightly damaged valve seats can be lapped using compound and a lapping block. tons, cylinders and connecting rods When fitting new pistons and cylinders, check to ensure that the clearance is as given in the table, The easiest way to fit pistons and cylinders is to assemble and fit them and the connecting rod at the same time. Because of the small tolerances, it can sometimes be necessary to heat pistons when inserting piston pins. When replacing piston rings, check that they move easily in the piston grooves and that the gap between the ends when the rings are fitted _ are as stated in the table. Insert standard piston rings and then a scraper ring. Fit an oil check ring in the bottom groove. A bearing is inserted in the connecting rod eye; a split bearing bush in the connecting rod end. When inserting new bearings, check that the clearance in the piston pin bearing and the clearance between crank pin and bearing are as given in the table,Mounting cylinders / noxious space Check to ensure that the numbers marked on top and bottom parts of the connecting rod are the same and that they face in the same direction Lubricate crankshaft and connecting rod bearing with refrigeration machine oil. ‘Cylinder installed with piston, piston rings, scraper ring and connecting rod is passed through the valve lifting ring and fastened to the frame. Assemble bearings with connecting rod bolts and nuts. Tightening torque: 50 Nm Pour 5 cm? refrigeration machine oil into each oylinder. Fit discharge valves and liquid slug- ‘over springs to the cylinders. Now mount top covers with gaskets. Tightening torque: 190 Nm 776006909 Checking cylinders Each cylinder must be checked for visible and perceptible rim where the piston is at top or bottom.in this case the cylinder is replaced. Also ensure that there are no fractures or cracks in the cylinder Checking pistons When assembling, check that the clearance between the piston in its top position and thedischarge valve seat is 1.1-1.5 mm, corresponding to a distance between discharge valve seat and bottom of piston top of 16.7-17.1 mm, See table of clearances for wear measurement. Check the noxious space i10 Checking the shaft seal The shaft seal consists of a special cast iron, spring-loaded, lapped ring that rotates against a stationary, lapped carbon ring. (O-rings provide the seal between cast iron ring and crankshaft, and between carbon ring and cover. Before fing, inspect the O-rings, clean all parts thoroughly and lubricate them with the oil used in the compressor. ‘Check the shaft sebl to ensure that all surfaces are clean and plane. It is possible to remove small scratches and eliminate minor leakage by lapping the wearing surfaces. If there ate tarry deposits around the shaft seal, remove them and check the oil system. Cap Guide Cone Mounting the shaft seal and oil pressure valve Lubricate all components. Insert spring holder, stop end against the crankshaft collar. Check that the holder meshes with the crank— case shatt pin, ~ Insert the wearless ring with inside o-ring and spring and rotate so the ring's locking track meshes with the crankshaft pin. ‘When the ring is released, check the dimensions specified, Lubricate o-ring and mount in cover. Mount ‘carbon ring in cover. Apply oil to wearing surface and mount the cover using four M16x30 cyl. screws. Tightening torque: 190 Nm Spring holder Spring O-ring Wearless ring Carbon ring O-ring Cover for shaft seal Gasket 77600631 1001004Mounting and checking the carrier and oll pump Make sure that the pump is correctly assembled, in accordance with the direction of rotation. ‘Check for wear on gearwheel and housing. Check bearings for wear and replace with new ones if necessary. 776006918 Press the carrier into the bu: ‘mount in crankshaft as shown, Pump housing — Reference surfacg c Gear whe@ | ‘Space between cover and rotor: B>A B-A=0.08- 0.13 mm ‘Space between cover and gear wheel: C>A C-A=0.03 - 0.08 mm Spacer 072/59 x 0.05 42-17-0455 72156 x 0.10 42-17-0458 Measures are checked by means of a dial. ‘Gauge. Spacers has to be mounted here. " O-ring 776006919 ‘Mount the o-ring in the track of the bearing cover. Insert the oil pump pin into the bearing covers bearing boring. ‘Check that the pump rotor canter pin meshes with the cranks carrier. Attach the oil pump by using the two inlaid M10x80 ‘screws, which can be tightened through holes in the outside cover of the pump. M10x120 screws are to be mounted and tightened. Tightening torque: 40 Nm ‘Check that the pin in the outer cover of the pump shows the correct direction of the crankshaft rotation. 776006912 Pin in this hole. (Crank turning anticlockwise seen from the pump side, Fin in this hole. Crank turning clockwise seen from the pump side,12 Checking the oll system Check the oil system for circulation and leakage. For oil change after a given number of hours, Mounting the oil filter see the Operating and Maintenance Directions, 22, [1]. Checking the capacity control ‘The compressor unloading device consists of a spring assembly in which two rods press a valve lifting ring with pins against the suction valve plate. The suction valve is thus forced open and the cylinder put out of action. A hydraulic piston ‘compress the spring assembly to release the suction valve plate and bring the cylinder back into normal operation. il from the pump is supplied to the unloading cylinders via the solenoid valves. {tthe control fails, check the oil pressure, O-ring, sealing ring and the contact face of the pins on the lifing ring. Check the capacity control devices to ensure that they are able to raise the lifting pins and thus unload the valves. Check also whether the pins retract so that they do not ‘striket the valve plates. If this is the case, adjust the capacity control,Mounting the connecting tube between flanges 3/8" RC elbow for G15 mm tube 776006916 Mounting tube for capacity control 1/8" RC elbow for 98 mm tube 776006915 Mounting capacity control14 ‘Screw in cylinder for capacity regulation from crankcase until the control figures shown are reached. Tighten cylinder using nut M24, 151 MAX . Insert the crossbar and lifting arm into the suction chamber and assemble using a locking nut and disc spring. Check to ensure that the spring is facing the right way. oN @ a After tightening, it should be possible to move the crossbar and lifting arm in relation to each other with noticeable friction, Insert the cylinder into the mounting guide. Place the spacers on the mounting guide. ‘Compress the spring, keeping itin position using mounting clamps. Place the compressed spring on the bottom of the suction chamber around nut M24, Place the spring guide on the mounting guide. Place the crossbar with lifting arm on the mounting guide, az Nut Litting arm, Locking nut Dis spring Crossbar Spring control Spacer Mounting clamp. ‘Spring Mounting guide e2eos00100015 Press the mounting guide outwards from above, using the piston rod with ra fitted o-ring. Zi Mount the piston plate with fitted ened u-sleave on the piston rod and tighten, using the locking nut. . ! O-ring , Zz Piston plate U-sleeve Locking nut Position the valve ling ring between the lifing arms Insert the valve lifting ring H 1 nearest to the pressure t 1 outlet end first. t i 1 L t Lifting ring H Release the spring by removing the mounting clamps. Zi f g16 Checking the bypass valves The compressor is fitted with differential. pressure-independent bypass valves. These ‘open at 25 bar and allow gas to flow from the compressor discharge side to the suction side. ‘Check the bypass valves to ensure that they ‘open at the pressure for which they are set. The check ‘must be performed on a suitable test stand ory alternatively, the valves can be returned to the manufacturer for checking. Checking the oil control valve ‘The oil pressure of the compressor is set at 3- 4.0 bar for normal operation. The oil pump is fitted with an internal bypass that opens at 5 bar to prevent-pump overload when starting with cold oil. Checking pressure switch function On compressors with pressure control, check whether the pressure switches cut in/out at the required pressure and whether they are correctly set ‘Checking thermostat function Check whether the thermostats cut in/out at the required temperatures and whether they are correctly set. Checking the oil return Remove and clean the filter. Inspect the solenoid valve. Checking the oil cooling Check that the oil temperature is satisfactory. If not, look for possible calcium deposits. Check the solenoid valve. Mounting the oil cooler Nut Sealing ring ~ g k13 Cf rA\ eck rv Tube coil ‘Checking water-cooled top covers Check that the discharge temperature is satisfactory. If not, look for calcium deposits in the hoses. Check the solenoid valve. s2e000000002.4. 7 Relief of trouble-shooting ‘Symptom or difficulty Possible reason Remedy High condenser pressure Insufficient water passage through condenser, condenser pipes clogged up. Spaces between fins of air- cooled condenser have been fouled up, Incorrect setting of high- pressure cut-out. Check whether water supply to ‘condenser has been turned off. Set cooling water control valves, Check and if necessary, clean condenser pipes and filter in water line, Clean spaces between fins and check fan. Check whether high-pressure ‘cut-out is switching off at cor rect pressure. ‘Compressor short cycling Evaporator coils frosted up. | Defrost evaporators. {at connection and disconnection of low pressure | Filters of liquid valves, suction | Clean filters. control). valves, or regulation valves clogged up. Phial of regulating valve has lost] Remove phial from suction line. its charge, or insufficient liquid | Hold itn one hand and feel on charge in plant. suction line with the other. If the suction line does not get colder, add more refrigerant. ‘The compressor starts and The system is overfilled with stops too often (at the high refrigeant, pressure switch). ‘The high pressure switch switches in and out bedause the| condenser is overfilled and partly inactive as a large number of the condenser pipes are ‘submerged in the refrigerant, Drain off refrigerant s2ec000480018 ‘Symptom or difficulty Possible reason Remedy Compressor running Lack of refrigerant Check charge. If insuificient, add continuously the necessary quantity. Check for leaks, Compressor discharge and /or | Check valves, if damaged or De suction valves damaged or worn] worn away, repair or replace. = away. High condenser pressure Air or non-condensable gases | Purge at condenser and/ or in system. receiver. Install air purger. s Too warm cooling water or | Check and clean water valve insufficient passage through | and water filer. Check whether condenser. water valve has been suficientiy 3 open, Pipes in water condenser fouled] Clean condenser pipes. ‘ or furred up. : ‘Spaces between fins of ai Clean spaces between fins, and cooled condenser fouled up. | check fan. Too much liquid in receiver and | Drain refrigerant and fil itinto condenser. empty drum, Low condenser pressure Condenser receiving too much | Regulate water supply. cooling water. Leaky discharge and/or suction valves Unloading system has put some| of the cylinders out of operation, Remove top covers, check valve} plates and valve springs, replace if required. ‘See service instructions. 20000480019 ‘Symptom or difficulty Possible reason Remedy High suction pressure Leaky suction valves. Remove top cover, check valve plates and valve springs, replace if required. Unloading system has put some| -See service instructions. of the cylinders out of operation. Low suction pressure ‘Clogging of liquid line, regulating] “Evacuate, check, and clean Y valve, or suction filters, filters. Insufficient refrigerant charge. | Add reftigerant. ‘Too much oil circulating in ‘Check whether excessive oil is system (HCFC/HCF). found in system, drain superfluous oil. Incorrect setting of regulating — | .Set regulating valves for correct valves. flow. Regulating valve frozen Unfreeze regulating valve by (HCFCIHCR). means of warm, soaked rags, and let freon from receiver pass through the drying filter. Never add antifreeze to freon. Noisy compressor Excessive oil circulation ‘Check oil level. resulting in liquid slug-over. Liquid slug-over as a result of | Regulating valves opening to not evaporated refrigerant being] much - close a litle. drawn back to compressor. Phial placed incorrectly or loose.) Move or fasten the phial of regulating valve. ES20 Possi le reason. Remedy ‘Symptom or difficulty il disappearing from crankcase Liquid refrigerant returning to compressor. Piston rings or cylinder liner worn, Possible oil return line from oil separator to crankcase clogged up. Set regulating valves correctly ‘so that the compressor will work| ata suitable superheating, Replace piston rings, and replace pistons, and cylinder liners, if necessary. Clean oil filter in return fine, joes not return to crankcase (HCFC/HCF) Regulating valve admitting insufficient liquid to evaporator. Filler for solenoid valve in oil return pipe clogged up. ‘Solenoid valve coil in oil return line burned, Set expansion valve to admit more liquid. Clean filter, Replace coil Compressor will not start Oil pressure cut out interrupted current, safety fuses have fused | Main switch not switched on. Adjust oil pressure cut out, fit new fuses, and locate cause of trouble. ‘Switch on current. ‘Compressor starts, but stops again at once Insufficient compressor (il differential pressure contro) Oil differential pressure control defective. Oil slug-over. ‘Add oi Repair or replace pressure control. Check whether liquid refrigerant is drawn into crankcase, Check oil level, and correct. 200000100924 . ‘Symptom or difficulty Possible reason Remedy V-belts are turning in groves | Pulleys not inline. Check alignment of pulleys. ‘Wrong belt/ pulley profile. ‘Check whether pulley and belt match. . Defective keyways. } Replace V-belt pulleys. Insufficient V-belt tension. Tighten up. 7 Abnormal wear on V-belt slopes| Incorrect groove angle. Replace or machine pulleys. Defective keyways. Replace pulleys. @ Pulleys out ofline. Check alignment. Insufficient V-belt tension. Tighten up. Bolts run agains¥/hit belt guard. | Align belt drive to prevent dragging. ‘Abnormal noise level Pulleys out of line. ~] Check alignment. Insufficient V-belt tension. Tighten up. Irregular V-belt elongation Defective pulley grooves. Replace pulleys. New and old V-belts in same | Replace all V-belts. belt drive. Different belt makes in same | Replace all belts by belts of belt drive. ‘same make, Cam 2000000 - Pat22 [Symptom or difficulty Possible reason Remedy V-belts breaking after few hours| of operation Incorrect installation of V-belts, Belt drive has been blocked. When fiting V-belts on pulleys, comply strictly with instructions for installation of V-belts. Find reason for blocking, Fractures in bottom part of V-belts Abnormal belt slip, Excessive heating stress, Excessive cold stress. Check belt tension, Protect V-belt drive against heating stress. Have V-belts warmed before fiting. Excessive vibrations in V-belts Insufficient V-belt tension. Pulleys not dynamically balanced. Tighten up. Balance pulleys at correct speed Further tensioning of V-belts not possible Incorrect length of V-belts in belt drive, Replace by shorter V-belts.23 2.5. HC/HCT Tolerance and adjusting measurements Bearing clearance [.~«Y TG2075-HCBO7S .| HOBTOOHCETOO HCBI25 HCT4075/HCT8075 | HCT6100/HCT8100 | HCT8125 Main bearing aes 0,14 0,20 ar a Connecting rod bearing eames ogeaet Seer Ses ee 1s a Replace bearing and /or shaff, if max. is exceeded. Piston / cylinder At right angle to piston pin Piston, top (Manufactured HIC2075-HC8075 HCT4075/HCT8075 HC8100/HCB100 HCT6100/HCT8100 C8125 HCTB125 Imax. [Manufactured Piston, bottom fae Replace cylinder, pistons and rings, if max. is exceeded. Piston ring gap HC2075-H807S HCT4075/HCT8075 THCB1OOHCBT00 HCT6100/HCT8100 ICBI25 HCT8125 ‘The gap is measured, while the ring is placed in the cylinder. End clearance HG2075-HO807S HCT4075/HCT8075 04-08 TICBTOOC8TO0 HCT6100/HCT8100 06-1,0 C8125 HCTB125 08-15. (Manufactured Imax. Replace bearing, check shaft and adjust, if exceeded 10 13 1924 2.6. Survey of Torque Values ‘Steel bpits Grade 8.8 M M M M M M 4 6 8 10 12 14 Fe ASSES oS Nm 25 8 18 40 70 120 = eS ny 8) 6) ww Thin = Tepe Tip = TON ‘Steel bolts M M M M M 16 18 20 22 24 EE oS Nm 199 250 350 480 600 = & (ety (137 (18) 53) AT) (484) Connecting rod ‘Central screw bolts : Cylinder bore 7 100 125 152 75/100 125 152 ‘Steel bolt M M M M M M M ext 10x1,25 | 12x1,25 | 14x1,5 | 12x1,75 14x1,5 16x1,5, Grade Nm 2 50 90 140 100 140 190 10.9 (tot) (18) (38) (65) (100) (72) (100) (137) ‘Where two nuts are used, both should be tightened to the torque given. seeoo0ne8 co25 2.7. Placement of Cylinders and Discharge Valves Hc 6100/8100 Notice the difference between HC-HCL-HCH and refrigerants. 6100 ' DISCHARG. VALVE 77-600-6630 CYLINDER, 77-600-6620 DISCHARG. VALVE 77-60-6630 CYLINDER. 77-800-6625 DISCHARG. VALVE 77-60-6630 CYLINDER: 77-60-6620 8100 DISCHARG. VALVE 77-600-6630 CYLINDER, 77-60-6620 DISCHARG. VALVE 77-60-6630 CYLINDER: 77-800-6620 DISCHARG. VALVE 77-600-6630 CYLINDER, 77-600-6625 DISCHARG. VALVE 77-60-6630 CYLINDER 77-60-6620 cé cS C3 cl C8: C7 cé R717 - Ammonia 6100 DISCHARG. VALVE 77-60-6630 CYLINDER: 77-60-6620 DISCHARG. VALVE 77-60-6630 CYLINDER: 77-60-6625 DISCHARG. VALVE 77-600-6630 CYLINDER: 77-60-6620 8100 DISCHARG. VALVE 77-60-6630 CYLINDER, 77-600-6620 DISCHARG. VALVE 77-60-6630 CYLINDER. 77-60-6620 DISCHARG, VALVE 77-60-6630 CYLINDER: 77-60-6625 DISCHARG. VALVE 77-60-6630 CYLINDER. 77-60-662026 He 6100/8100 HCFC, HFC Notice the difference between HC-HCL-HCH and refrigerants. 6100 6100 :DISCHARG. VALVE 77-60-6631 C6 (C5 DISCHARG. VALVE 77-600-6631 CYLINDER 77-800-6621 CYLINDER 77-00-6621 1g DISCHARG, VALVE 77-60-6631 cs S:CYLINDER = 77-600-6626 DISCHARG. VALVE 77-60-6631 CYLINDER 77600-6626 *DISCHARG. VALVE 77-60-6631 C1 viscHare. vaALvE 77-60-6631 *CYLINDER - 77-60-6621 CYLINDER, 77-60-6621 8100 7 8100 DISCHARG. VALVE 77-600-6631 cé c DISCHARG. VALVE 77-600-6631 CMUNDER — 77-800-0621 See YLINDER rrceno-oe2t DISCHARG. VALVE 77-60-6631 ©5 oscuana. vaLvE 77-600-6601 CYLINDER 77-800-6621 CYLINDER, 77-600-6621 cs DISCHARG. VALVE 77-60-6631 DISCHARG. VALVE 77-60-6631 CYLINDER 717-600-6828 (5 Cy CYLINDER 77-60-6626 DISCHARG. VALVE 77-60-6631 = + DISCHARG. VALVE 77-600-6631 CYLINDER 77-60-6621 CYLINDER ‘77-600-6621 seo 004800