PA и PB compressors
PA и PB compressors
HERMETIC COMPRESSORS
OPERATION, MAINTENANCE, REPAIR PARTS,
AND SPECIAL TOOLS LIST New Release Form 180.30-RPSTL (1101)
MODELS
P43, 63, 83
P44, 64, 84
29685A
FORM 180.30-RPSTL
TABLE OF CONTENTS
SECTION 1 – GENERAL
General ......................................................................................................................................... 14
Handling ........................................................................................................................................ 14
Disconnect Electrical Power ......................................................................................................... 14
Recovering Refrigerant From the Compressor Before Repairs ........................................................ 14
Evacuation After Repairs ............................................................................................................... 14
Replacing the Oil Pump ................................................................................................................ 15
Capacity Control Solenoids & Unloaders ....................................................................................... 15
Crankcase Oil Heater/Oil Temp Sensor ......................................................................................... 16
Oil Strainer .................................................................................................................................... 16
Suction Strainer ............................................................................................................................ 17
Oil Level Sight Glass ..................................................................................................................... 17
Discharge Manifold and Cylinder Head and Access Cover(s) ......................................................... 18
Discharge and Suction Valves and Cylinder Sleeves ...................................................................... 18
Cylinder Sleeves ........................................................................................................................... 18
Suction, Discharge Valve Subassemblies ............................................................................... 18 - 27
Wave Spring Assembly Instructions ....................................................................................... 21 - 27
High Pressure Relief Valve ............................................................................................................ 28
Pistons and Connecting Rods ................................................................................................ 28 - 29
Bearings and Crankshaft ........................................................................................................ 30 - 32
Pump End Bearing .............................................................................................................. 30 - 31
Motor End Bearing .............................................................................................................. 30 - 32
Crankshaft ................................................................................................................................ 32
Rotor ............................................................................................................................................. 33
Stator ............................................................................................................................................ 34
Maintenance Requirements ........................................................................................................... 35
Design History .............................................................................................................................. 36
2 YORK INTERNATIONAL
FORM 180.30-RPSTL
P COMPRESSOR FEATURES
BEADED GASKETS
COMPATIBLE
WITH POE AND MINERAL
OILS
LD06586
Model PA and Model PB compressors share the same YORK Model P Semi Hermetic Compressors are in-
compressor bodies and components with the following dustrial duty reciprocating type compressors designed
difference: Model PAs are supplied with a factory- to meet refrigerating and air conditioning requirements
mounted motor protection module and Model PBs are using either R-22, R-134a or R-407C. They are avail-
supplied LESS the factory-mounted motor protection able in 4, 6, and 8 cylinder models in “short stroke” or
module. “long stroke” versions, as designated by the fourth char-
acter in the compressor model number.
YORK INTERNATIONAL 3
General
FORM 180.30-RPSTL
Model P compressor unloading capabilities allow the When used with the ISN Recipak Control Center, oil
compressor flow capacity to modulate as refrigeration temperature controls include a ‘high oil temp’ cutout
load changes occur, improving part load operating effi- set at 160°F (71°C) and an ‘oil temp inhibit’ feature
ciency and decreasing operating costs. that requires oil temperature to be at least 15°F (8.3°C)
above ambient at start up. If this condition is not satis-
Model P compressors incorporate “wave-spring” type fied, the starting circuit will not engage. This start in-
suction and discharge valve components in lieu of tradi- hibit safety verifies heater operation and ensures that
tional wire wound coil type springs. This improved de- refrigerant migration during the off cycle will not accu-
sign significantly reduces the valve maintenance inter- mulate excessive refrigerant in the oil. This prevents oil
val as compared to coil spring designs. Reliability in- foaming and oil pressure loss.
creases significantly as well.
Normal commissioning procedures or start-up after
Molded thermoplastic insulators replace the traditional months of off-time should include prelubricating the oil
paper/fiber type insulator on the terminal studs. system with a hand pump and allowing the crankcase
heater to be energized at least 24 hours prior to start up.
Gaskets feature a raised bead for improved sealing with
mineral oils, POE lubricants, and new refrigerants. Normal oil pressure range is 50-70 PSID on 60 Hz op-
eration and 40-60 PSID on 50 Hz.
P compressors boast an oil management system for con-
trol of oil flow within the compressor, along with an oil PRE-LUBRICATION
temperature safety system. This oil management sys-
tem significantly decreases oil carry over which im- To ensure long compressor life, pre-lubrication at
proves system heat transfer, operating efficiency, and commissioning and after long idle periods of several
reliability. months is recommended. This manual pre-lube is es-
pecially important on R-134a and R-407C units that
The oil management system consists of a motor end employ POE type lubricants due to the polar nature
bearing head that incorporates an oil control bearing out- of these lubricants. This is accomplished by attaching a
board of the two main bearings, and oil return ports that hand pump to the core-type access valve (Schrader fit-
direct oil back into the crankcase. Oil passes through ting) on the oil pump.
an eductor prior to entering the crankcase. Oil that may
accumulate in the motor housing will be transported to See pages 35 and 53 for maintenance chart and oil charg-
the crankcase via the eductor pickup tube. ing/pre-lubing pump.
Crankcase ventilation incorporates an oil mist precipi- Renewal parts are listed in a separate SECTION 3.
tator built into the pump end bearing head. Venting from Parts and professional service are available through your
this bearing head to the suction plenum is through an local YORK Service Office. Contact your nearest of-
external pipe connection. fice using the list on page 55. Sales and Service offices
are also listed on the web at:
For R-22 applications, YORK Type C mineral oil is nor-
mally used. Under high ambient conditions, YORK Type http://www.york.com/
E mineral oil is recommended.
Compressor Styles A and B are iden-
For R-134a and R-407C, YORK Type H, POE syn-
thetic lubricant is recommended.
tical except for Motor Protector Mod-
ule; Style A includes Factory-
Cylinder o-rings are used on all permanently loaded cyl- mounted Module; Style B is shipped
inders as well as the cylinders that can unload. without Module. (U.L. regulation
compliance) See Fig. 12A, page 9.
Connecting rods have a drilled port to provide forced
lubrication to the wrist pin. This is essential for POE
lubricants.
4 YORK INTERNATIONAL
FORM 180.30-RPSTL
NOMENCLATURE
COMPRESSOR IDENTIFICATION
LD06938
00609VIP
P A 4 3 1 — M H 46/50 S
▲
YORK INTERNATIONAL 5
General
FORM 180.30-RPSTL
PHYSICAL DATA
COMPRESSOR MODEL P43 P44 P63 P64 P83 P84
No. of Cylinders 4 6 8
Nom. Displacement 60 Hz 143 (67.5) 170 (80.2) 201 (94.9) 242 (114.2) 278 (131.2) 331 (156.2)
CFM (I/s) 50 Hz 119 (56.2) 140 (66.1) 168 (79.3) 199 (93.9) 232 (109.5) 273 (128.9)
Bore (Inches) (mm) 3-3/4 (95.3) 3-3/4 (95.3) 3-3/4 (95.3)
Stroke (Inches) (mm) 3.2 (81.3) 3.8 (96.5) 3.0 (76.2) 3.6 (91.4) 3.1 (78.7) 3.7 (94.0)
Suction Conn. (ODF) 3-1/8 3-1/8 3-5/8
Discharge Conn. (ODF) 2-5/8 2-5/8 3-1/8
Oil* Charge (Gals.) (liters) 2.0 (7.6) 2.0 (7.6) 2.0 (7.6)
Weight (Lbs.) (kg.) 1500 (680) 1560 (708) 1820 (826) 1860 (844) 2040 (926) 2140 (971)
* YORK C for R-22 Air Conditioning Applications. 5 gallon can 011-00312-000 (Mineral)
* YORK H for R-134a and R-407C Air Conditioning Applications. 5 gallon can 011-00549-000 (POE)
* YORK E for R-22 in high ambient environment (115°F and above). 5 gallon can 011-00582-000 (Mineral)
LIMITATIONS
VOLTAGE LIMITATIONS COMPRESSOR OPERATING LIMITATIONS
Maximum Compression Ratio 9.5:1
The following voltage limitations are absolute and op- Maximum Operating Differential (PSI) (Bar) 325 (22.8)
eration beyond these limits may cause serious damage Maximum Discharge Temp. (°F) (°C) 275 (135)
to the compressor or motor. Superheat (Nominal) (At Compressor) (°F) (°C) 12 - 18 (6.7 - 10)
Min. Oil Pressure (Above Suction Pressure) 25 (1.7)
NAMEPLATE MINIMUM MAXIMUM
(PSIG) (Bar)
VOLTAGE VOLTAGE VOLTAGE
Maximum Oil Temperature1 (°F) (°C) 160 (71.1)
200-3-60 180 220
Min. Oil Temp (At Start Up) (°F) (°C)
230-3-60 207 253 15 (8.3)
(Above Ambient)
380-3-60 355 415 Maximum Sat. Discharge Temp.2 (°F) (°C) 155 (68.3)
460-3-60 414 506 Maximum Sat. Suction Temp.2 (°F) (°C) 70 (21.1)
575-3-60 517 633 Maximum Ambient (°F) (°C) 130 (54.5)
190-3-50 171 208 Minimum Ambient (°F) (°C) 0 (-17.8)
220-3-50 198 242
346-3-50 311 381 1
Measured externally on pump suction boss as shown in Fig. 11
380/415-3-50 342 440 or may be a control panel feature on newer units.
2
Motor selection and operating conditions may limit maximum satu-
440-3-50 396 484 rated discharge temperature to lower levels and saturated suc-
500-3-50 450 550 tion temperature to higher levels.
29687A
6 YORK INTERNATIONAL
FORM 180.30-RPSTL
ELECTRICAL DATA
MOTOR RATED LOCKED
SIZE VOLTAGE PHASE HERTZ AMPS2 ROTOR AMPS
CODE 1 A/L PW
200 3 60 205 913 731
230 3 60 178 794 636
380 3 60 108 480 385 1
460 3 60 89 397 318
575 3 60 71 318 254
M 190 3 50 181 757 560
220 3 50 156 731 540
346 3 50 100 470 347
380/415 3 50 86 402 297
440 3 50 78 366 270
500 3 50 69 322 238
200 3 60 236 1099 782
230 3 60 206 956 680
380 3 60 125 579 412
460 3 60 103 478 340
575 3 60 82 382 272
N 190 3 50 181 885 650
220 3 50 184 856 629
346 3 50 118 540 400
380/415 3 50 102 471 346
440 3 50 94 428 315
500 3 50 82 377 277
200 3 60 279 1203 888
230 3 60 242 1046 772
380 3 60 147 633 467
460 3 60 121 523 386
575 3 60 97 418 309
P 190 3 50 247 910 670
220 3 50 214 876 647
346 3 50 136 557 412
380/415 3 50 118 482 356
440 3 50 107 438 323
500 3 50 94 386 285
200 3 60 319 1495 1095
230 3 60 277 1332 976
380 3 60 168 806 591
460 3 60 139 634 474
575 3 60 111 533 390
Q 190 3 50 280 1225 905
220 3 50 246 1187 876
346 3 50 160 775 572
380/415 3 50 135 645 475
440 3 50 123 594 438
500 3 50 108 522 386
200 3 60 401 1746 1322
230 3 60 348 1518 1150
380 3 60 211 919 696
460 3 60 174 759 575
575 3 60 140 607 460
S 190 3 50 353 1470 1087
220 3 50 308 1420 1051
346 3 50 196 903 668
380/415 3 50 169 781 578
440 3 50 154 710 526
500 3 50 135 625 462
230 3 60 401 1888 1424
380 3 60 2425 1143 862
460 3 60 206 1032 733
575 3 60 161 755 570
T 346 3 50 230 1148 865
380/415 3 50 197 1006 767
440 3 50 178 856 645
500 3 50 156 754 568
230 3 60 467 2100 1648
380 3 60 283 1271 997
460 3 60 234 1050 824
V 575 3 60 187 840 659
346 3 50 274 1160 950
380/415 3 50 237 1045 820
440 3 50 215 950 550
500 3 50 190 836 656
NOTES: 1. Sixth character in compressor model designation (See NOMENCLATURE).
2. Rated amps = .87 x maximum load amps.
YORK INTERNATIONAL 7
General
FORM 180.30-RPSTL
THREADED FASTENER TORQUES AND SEQUENCE When tightening the screws on the access cover/cylinder
head, handhole cover, oil pump, bearing head, motor cover,
When assembling a compressor or compressor parts, it and terminal block, it is important that the screws be tight-
is essential to tighten all nuts and screws to their proper ened in the proper sequence. This will help to eliminate
torque, using an accurate torque wrench. Table 1 shows leaks and/or damage to the parts or gaskets. Fig. 12 shows
the recommended torques for this compressor. All nuts the recommended tightening sequence.
and screws should be lightly oiled unless they are in-
tended for use with a sealing compound. Insert all screws It is advisable to “double-check” the torque on all exter-
and tighten them lightly. Then, using the torque wrench, nal screws before starting the compressor.
tighten each to its proper torque.
BEARING HEAD
8 YORK INTERNATIONAL
FORM 180.30-RPSTL
18
3
9
9 5
1
16, 22
19
LD06980
15
6 7 11 17
18
NOTE 1 13
14
10
21
10
4 LD06262
NOTE:
12 1. Brass suction and discharge service
valve pipe adapter/gasket by valve
manufacturer Mueller.
NOM.
VALVE ADAPTER GASKET
SIZE
20 2 2-1/8 A6267 A6261
LD06938 2-5/8 A6268 A6261
3-1/8 A6269 A6262
YORK INTERNATIONAL 9
General
FORM 180.30-RPSTL
coated with oil, wrapped in clean, tough paper and stored FIG. 13 – RIGGING THE COMPRESSOR
in a safe place.
Before reassembling any compressor part, it should be LUBRICATION SYSTEM – See Fig. 14.
thoroughly cleaned by immersing or flushing it with an
approved safety solvent and allowing it to dry in air with- The compressor oil supply is contained in the crankcase
out touching any wearing or contact surfaces. After it which is provided with two oil sight glasses (located in
is cleaned, each part should be carefully examined to be the oil pump end of the compressor) to permit a visual
sure it is free from cracks, flaws, bump marks, burrs or check of the oil level.
distortion and the part should be oiled to prevent dam-
age due to rusting or oxidation. New clean oil should be During unit operation, the oil level should be adjusted
applied to the wearing surfaces of any part just before so that oil-splashing is visible between the middle of the
it is installed. lower sight glass and the middle of the upper sight glass.
10 YORK INTERNATIONAL
FORM 180.30-RPSTL
LUBRICATION, MAIN BEARINGS, OIL PUMP END & LUBRICATION, CYLINDER WALLS, CONNECTING ROD
MOTOR END – Oil under pressure leaves the oil pump AND PISTON PIN BEARINGS – Oil under pressure is
and flows internally through the pump end bearing head conducted through drilled oilways in the crankshaft to the
to lubricate the pump end bearing. crankpins. The crankpin is provided with one radially drilled
hole (which connects with the drilled oilway in the crank-
Oil is fed through internal oilways in the crankshaft to shaft) for each connecting rod bearing.
1
supply oil to the thrust bearing, motor end bearings and
eductor. An oil pressure relief valve, installed in the mo- Lubrication of the cylinder walls is accomplished by the
tor end bearing housing, relieves oil pressure back to spray from the spaces between the connecting rod bear-
the crankcase. A separate oilway supplies an oil flow to ings and the cheeks of the crankpin as some of the pres-
the eductor. The eductor pickup tube will draw oil from
surized oil leaves these bearings.
the motor housing. Normal oil pressure range is 50-70
PSID on 60 Hz operation and 40-60 PSID on 50 Hz.
Wrist pin lubrication has been enhanced by an oil pas-
sage in the connecting rod.
The thrust bearing positions the crankshaft longitudi-
nally in the compressor and takes the thrust forces im-
posed upon the shaft. Radial grooves for oil are pro-
vided on the inner or thrust surface which is in contact
with the crankshaft shoulder.
SEAL RINGS
ON ALL CYL.
LD06628
YORK INTERNATIONAL 11
General
FORM 180.30-RPSTL
SOLENOID
ENERGIZED
LD03152
SUMMARY OF OPERATION
LOADED UNLOADED
SOLENOID DE-ENERGIZED SOLENOID ENERGIZED
SUCTION GAS FLOWS DISCHARGE GAS PRESSURE APPLIED
INTO SUCTION PLENUM TO TOP OF UNLOADER PISTON
UNLOADER PISTON UNSEATED UNLOADER PISTON SEATED
(UP), FLOW PATH OPEN (DOWN), FLOW STOPPED
When wiring an 8 cylinder compressor, the capacity con- verse order. This will assure that the compressor cylin-
trol solenoid valves should be wired to energize in the ders unload and load in the proper sequence. Location 1
following order: 3 first, followed by 2 if present (See is permanently loaded and cannot be unloaded.
Fig. 16). The valves should be de-energized in the re-
1
LD06259
ANALYSIS OF FAULTY COMPRESSOR VALVE 5. The operator should measure the cylinder head and
OPERATION, PREVENTATIVE MAINTENANCE access covers temperatures periodically to check
for hot spots on one particular cylinder bank which
The operator soon becomes accustomed to the sound may be running hot. If this condition occurs, it is an
of the compressor when it is running under normal con- indication of broken or leaking valves within that
ditions. Any unusual noise within the compressor should bank of cylinders. A large temperature differ-
be investigated immediately. ence of 20°F or more between adjacent cylin-
ders may indicate damage, and the unit must
External indications of trouble within the compressor be shut down for inspection and servicing.
are as follows: If leaking or broken valves are suspected, the head or
1. When operating on suction pressure control, long “on” cover should be removed and the valves should be ex-
cycles with short “off” periods may indicate leaking amined for breakage.
or broken compressor valves, piston rings or both.
Permanently loaded cylinders are not
2. A definite rise in temperature of the discharge gas equipped with unloaders (See Fig. 16)
may indicate defective suction or discharge valves, This prevents the possibility of over-
or a leaking relief valve or both.
heating, since a minimum volume of
3. Failure to pull down is a possible indication of a bro- cool refrigerant gas flows through the
ken suction or discharge valve or both.
compressor at all times during opera-
4. Unusual pressure gauge readings. tion, regardless of load conditions.
YORK INTERNATIONAL 13
Disassembly and Reassembly
FORM 180.30-RPSTL
WARNING
Before disassembling any part of the P Compressor, be sure the following Safety
Precautions are read and observed.
HANDLING EVACUATION AFTER REPAIRS
When performing service on the compressor it may be During the compressor repair procedure, the crankcase
convenient to remove it from the unit base. If so, refer and oil should be examined for the presence of metal
to RIGGING THE COMPRESSOR, page 10. particles. This would indicate wearing of parts within
the compressor. New oil should be charged into the com-
DISCONNECT ELECTRICAL POWER pressor using the oil charging valve. (See PHYSICAL
DATA, page 6.)
Before performing any service of the compressor, all
disconnect switches must be locked out and tagged to The compressor should be given a thorough leak test as
prevent accidental starting of the compressor and/or explained in instruction Form 55.05-NM.
electrical shock.
If the compressor is open for only a few hours, it should
RECOVERING REFRIGERANT FROM
be evacuated to a pressure of 300 microns using a qual-
ity vacuum pump following procedures outlined in Form
THE COMPRESSOR BEFORE REPAIRS 55.05-NM.
Before opening the compressor for repairs, the refriger- If the compressor is open for more than 24 hours, the com-
ant in the compressor must be recovered. Close the suc- pressor should be completely dehydrated; then evacuated
tion and discharge stop valves, and remove the refriger- to a pressure of 300 microns following procedures outlined
ant in accordance with EPA guidelines. in Form 55.05-NM. Do not allow compressors to remain
open to the atmosphere for long periods of time.
14 YORK INTERNATIONAL
FORM 180.30-RPSTL
If it becomes necessary to replace the oil pump, a com- Normally, the coil is the only part of the solenoid valve
plete new pump assembly should be installed. To replace that requires replacement. To replace the coil, proceed
the oil pump, refer to Fig. 17 and proceed as follows: as follows: (See Fig. 18A & 18B)
1. Remove the oil pump cap screws and pull the pump 1. Remove the unloader conduit and the wires from
assembly out of the bearing head. the terminal box.
2. Install the new oil pump assembly using a new gasket. 2. Remove the screw from the top center of the valve
Be sure that the flat end of the pump drive shaft en- and remove the coil.
gages the slot in the end of the compressor crankshaft. 3. Install the new coil. Use caution when reconnect-
3. Tighten the pump cover cap screws evenly by draw- ing the conduit to avoid placing stress on the valve.
ing down opposite and alternate pairs. Stress on the valve may deform the stem and cause
the valve to malfunction. Reconnect the wires.
SLOT FOR
OIL PUMP If the solenoid valve must be replaced, the entire plate
DRIVE SHAFT and valve mechanism is replaced.
.3125 - 18 UNC
SOLENOID CAPACITY CONTROL THREADED HOLE FOR
CONDUIT SOLENOID VALVE SOLENOID COIL (UNLOADER) PISTON PISTON REMOVAL
27524A
27527A
YORK INTERNATIONAL 15
Disassembly and Reassembly
FORM 180.30-RPSTL
CRANKCASE OIL HEATER / OIL TEMP SENSOR 1. Remove the wire harness from the sensor and the
sensor from the well.
The crankcase heater is located on the oil pump end of 2. Loosen the cable clamp nut.
the compressor. The heater is located within a well in the 3. Apply a thin coating of heat conductive compound
compressor housing. It is not in direct contact with the (YORK Part No. 013-00898-000) to the sensing
refrigerant or oil. To replace the heater, remove the con- zone of the replacement sensor element.
duit and the heater wires from the terminal box. Pull the
heater from the compressor (See Fig. 20). It may be 4. Screw the plastic sensor body into the well hand
necessary to remove all or part of the defective heater tight, and then wrench lightly while pushing the sen-
with a Ø .626 - .637 inch (16 mm) drill bit. If so, use sor toward the bottom of the well. Ensure that the
extreme care to avoid damaging the well in the housing. sensing zone of the sensor element lightly contacts
the bottom of the well. Inadequate sensor to well
When installing the new heater, coat it with heat con- contact will give false readings.
ductive compound (YORK Part No. 013-00898). 5. Hand tighten the cable clamp nut. Connect sensor
plug to proper wire harness.
The oil temp sensor is in a well, on the side of the com-
pressor. DO NOT REMOVE THE WELL!
LD06921
OIL STRAINER
Apply retaining compound (YORK Part No. 013-01752,
Loctite 675) to clean surface of tube of replacement
The compressor oil strainer tube is rolled into a hole in
strainer that engages housing and insert tube into hous-
the compressor housing and therefore is not readily re-
ing. MAKE CERTAIN TUBE DOES NOT BLOCK
movable in the field. However, it can be replaced.
VERTICAL OIL HOLE IN HOUSING. Roll copper
tube into housing to tighten.
Refrigerant must be recovered, pressure relieved and
oil drained before removing and replacing the oil strainer.
Clean pipe plug with an approved safety solvent (YORK
Remove the .375-18 NPT pipe plug located to the left
Part No. 013-02899, Loctite 7070). Apply primer
of the heater well. Drive the oil strainer from the hous-
(YORK Part No. 013-01753, Loctite N7469) and allow
ing using a 1/2" drift pin. (Loctite retaining compound
to dry. Apply thread sealant (YORK Part No. 013-02023,
675 seals housing/tubing interface).
Loctite 565) to pipe plug and reinsert/tighten pipe plug
in housing.
Thoroughly clean and remove oil from hole and pipe
threads in housing.
16 YORK INTERNATIONAL
FORM 180.30-RPSTL
may be necessary to move the compressor away from FIG. 20 – CRANKCASE HEATER
the suction line/valve.
2. Pull the suction strainer out of the housing and clean
with an approved safety solvent or install a new
strainer if required. GASKETS
3. Replace the suction strainer using new gaskets. Note
that two gaskets are used; one between the suction
stop valve and the suction strainer, the other between
the suction strainer and the motor cover.
4. Fasten the suction valve in place, making sure that it
seats properly. SUCTION
STRAINER
SCREEN
YORK INTERNATIONAL 17
Disassembly and Reassembly
FORM 180.30-RPSTL
REMOVING THE DISCHARGE MANIFOLD, 6. Clean, dry and oil all parts. Inspect the valve and springs
CYLINDER HEAD AND ACCESS COVER(S) for damage or wear and replace, if necessary.
7. Assembly is the reverse of removal.
There are two different types of cylinder bank covers.
One is a flat access cover. This type of cover has a small NOTE: Be sure to properly torque the 4 cap screws
dimple on its underside to accept a roll pin mounted in the holding the discharge valve cage in place using the
compressor housing. The second type of head is thicker torque values in Table 1.
with no provision for accepting the roll pin. This type of
head connects to the discharge manifold. Access covers INSTALLING CYLINDER SLEEVES
are not connected to the discharge manifold.
To install the cylinder sleeves proceed as follows:
To remove the discharge manifold, cylinder head and 1. Install a new and generously oiled o-ring on bottom
access covers, proceed as follows: of cylinder. Do not attempt to reuse o-rings ex-
1. Disconnect the discharge manifold from the com- posed to lubricant and refrigerant.
pressor cylinder head and remove the cylinder head 2. Carefully lower the cylinder sleeve over the piston.
from the compressor.
2. Disconnect the manifold from the housing. Never rotate the crankshaft when one
or more piston and connecting rod as-
When reinstalling a cylinder head, secure it to the dis- semblies are in place unless the re-
charge manifold before fastening the head to the com-
lated cylinder sleeve or sleeves are in
pressor housing. Be sure to use proper tightening se-
quence as shown in Fig. 12.
their proper position in the compres-
sor housing. If this caution is not ob-
REMOVING THE DISCHARGE AND SUCTION VALVES
served, serious damage could occur.
AND CYLINDER SLEEVES
Push the cylinder sleeve down until it enters the hole in
Mark the cylinder sleeves and dis- the lower compressor deck. Do not force the cylinder
sleeve. The lower end of the cylinder sleeve is cham-
charge valve cage and suction valve
fered to facilitate compressing the piston rings and enter-
plate subassemblies with a marker so
ing the compressor deck. Guide the sleeve squarely into
that they can be reinstalled in their the housing and rotate it as it is being lowered. If the
original location. cylinder sleeve is properly seated in the housing, it should
not bind but should spring up slightly due to o-ring com-
To remove the valve assemblies and cylinder sleeves, re- pression. O-rings are required on all cylinders.
fer to Figs. 23, 24A, 24B and 25 and proceed as follows:
1. Remove the access cover or disconnect the discharge INSTALLING SUCTION AND DISCHARGE VALVES
manifold from the compressor cylinder head and re-
move the cylinder head from the compressor. When reinstalling valves, install as originally removed,
2. Remove the four cap screws which secure the dis- mating the seats; do not turn over. If wear groove is
charge valve cage assembly to the housing, then lift noticeable, valve ring should be replaced.
out this assembly. The inner discharge valve plate,
the discharge valve ring, and the discharge valve To install the suction and discharge valves, refer to Figs.
springs will come out with the cage as an assembly. 24A, 24B and 25 through 36 and proceed as follows:
3. Slip the fingers inside the suction valve plate and un- 1. With the wave spring, valve ring side of the suction
der the suction valve ring. Lift off the suction valve valve plate up, assemble the suction wave springs
plate, the suction valve ring and suction valve springs. in their pocket and set the suction valve ring in place.
(See pages 19-27)
4. Lift the cylinder sleeve out of the compressor hous-
ing. (Pulling device may be required due to o-ring 2. To hold suction valve ring and springs firmly in place
swelling and or piston ring friction.) during installation, two sheet metal clips should be
placed over the suction valve plate and suction valve
5. Disassemble the discharge valve cage assembly.
ring. These clips may be ordered from the Factory
Remove the locking nut and center screw. Then lift
(YORK Part No. 064-37274). (See pages 19-27)
off the inner discharge valve plate, discharge valve
ring and springs.
18 YORK INTERNATIONAL
FORM 180.30-RPSTL
3. Assemble the discharge valve cage assembly. Torquing of the center screw/nut is
a. Insert the discharge valve wave springs in critical. (45 - 48 ft. lbs.)
their recess in the valve cage and set the dis-
charge valve ring in place.
b. Place the inner discharge valve plate over the
ring and springs. DO NOT pinch the ring or
springs between the cage and plate.
d. Verify that neither the ring or springs is pinched
c. Insert the discharge valve screw through the and kept from operating freely over inner dis-
inner discharge valve plate and the discharge charge valve plate pilot diameter.
valve cage. Then bolt the assembly together
using the self locking nut.
8 & 6 CYL:
RELIEF VALVES (2)
FOUND ON
(1) PERMANENTLY
LOADED BANK ONLY
4 CYL:
RELIEF VALVE (1) 2
ON PERMANENTLY
LOADED BANK
DISCHARGE VALVE
CAGE ASSEMBLY
29686A
FIG. 23 – CYLINDER BANK WITH VALVE CAGE ASSEMBLIES AND RELIEF VALVES
YORK INTERNATIONAL 19
Disassembly and Reassembly
FORM 180.30-RPSTL
CYLINDER
O-RING SLEEVE
29692A
SUCTION
VALVE
PLATE
ASSEMBLY
28954A
DISCHARGE VALVE
CAGE ASSEMBLY
FIG. 24A – CYLINDER SLEEVE, DISCHARGE VALVE CAGE AND SUCTION VALVE PLATE SUBASSEMBLIES
29697A
FIG. 24B – DISCHARGE VALVE CAGE ASSEMBLY - (P/N 364- OR 664- FOR SERVICE-49722-000)
29693A
FIG. 25 – SUCTION VALVE PLATE ASSEMBLY - (P/N 364- OR 664- FOR SERVICE -49723-000)
20 YORK INTERNATIONAL
FORM 180.30-RPSTL
4. It is important that the suction valve ring not be c. Holding the suction valve plate in place on top of
pinched during reassembly. The following steps are the cylinder sleeve (do not allow the sleeve to slip
recommended. down against the compressor housing) place the
discharge valve cage assembly on top of the suc-
a. The piston in the cylinder being reassembled
tion valve plate. Insert two cap screws through
should be close to the bottom of its stroke.
holes in diagonally opposite corners of the discharge
b. Place the suction valve plate, with suction valve valve cage and tighten them “finger-tight.”
ring and springs clipped in place, on the cylinder d. Push the discharge valve cage, suction valve plate
sleeve. Using one hand, hold the suction valve plate and cylinder sleeve down firmly against the compres-
firmly against the cylinder sleeve, but do not push sor housing. Insert remaining cap screws and tighten
the cylinder sleeve down against the housing. With all caps screws to their proper torque. See Table 1.
your free hand remove the valve clips. A distinct
5. Use new gaskets when installing the compressor
click will be heard as the clips are removed, if the
access cover and cylinder head and reconnect the
valve plate is seated properly.
discharge manifold to them. Note: Secure head to
Proper Seat Check: While maintaining suffi- manifold before fastening head to compressor.
cient pressure, the suction valve plate should Gasket may be lightly oiled.
rotate smoothly on the cylinder.
SUCTION VALVE
PLATE (1) SUCTION VALVE RING (1)
YORK INTERNATIONAL 21
Disassembly and Reassembly
FORM 180.30-RPSTL
Shown in Figure 24B are the parts of the discharge valve To begin assembly, place the valve plate or cage with
cage subassembly. Shown in Figures 25 and 26 are the the machined “back stop” surface up and the wave
parts needed to install the suction valve plate assembly springs with the “printing” on the surface facing up.
on a single cylinder. The two clips shown in Figure 26
are not part of the assembly and must be reused for
each cylinder assembly. The clips must be removed once
the assembly is fitted to the cylinder.
With the printing on the wave springs facing up, grasp the springs as shown in Figure 27.
29694A 28644A
DISCHARGE SUCTION
Pick up the two springs, and place them lightly together. Make certain the printing on the springs faces the palm of your
hands. As you hold the springs lightly together, the edge of the springs facing you may be separated by a small gap.
29695A
28646A
DISCHARGE SUCTION
Rotate the springs in one hand until the springs nest together in their most compact manner. The gap between the two
rings facing you will minimize such that rotating a spring in either direction will cause the gap to increase.
29696A 28645A
DISCHARGE SUCTION
2
Once the springs are properly oriented and appear to be nested together, holding them loosely by the edges as shown
will reveal that the spacing between the two wave springs will be approximately 1/8" uniformly around the inner
edges of the two springs. They are now properly oriented and should held in this position without rotating them
further.
28643A
DISCHARGE SUCTION
YORK INTERNATIONAL 23
Disassembly and Reassembly
FORM 180.30-RPSTL
Place the “nested” wave springs over the valve cage The pair of wave springs should be carefully placed on
pilot diameter. Gently “snap” the two springs down over the valve plate against the “back stop” surface. The
the pilot with light pressure using your thumbs. valve ring should then be placed on top of the wave
springs. The photo below shows the wave springs in
the right hand and the valve ring in the left.
DISCHARGE SUCTION
29699A
24 YORK INTERNATIONAL
FORM 180.30-RPSTL
29700A
NO SUCTION PHOTO
29701A
OPTIONAL
NO DISCHARGE PHOTO
28641A
SUCTION
26 YORK INTERNATIONAL
FORM 180.30-RPSTL
28638A
28639A
SUCTION
YORK INTERNATIONAL 27
Disassembly and Reassembly
FORM 180.30-RPSTL
REPLACING THE HIGH PRESSURE RELIEF VALVE 2. Remove the crankcase access (handhole) cover
plate(s).
The high pressure relief valve is screwed into the upper 3. With the cylinder sleeves in place, rotate the crank-
machined surface of the cylinder bank under the cylinder shaft to a position that will permit ready access to
head to relieve any abnormally high discharge pressure the connecting rod screws of the assembly(ies) to
back to the suction side of the compressor (See Figures 16 be removed. Loosen the screws and remove the
and 23). It is set to open at 375 psi differential pressure. If lower part (cap) of the connecting rod. Note the
leakage of the valve is suspected, replace. Signs of leaking identification number stamped on the half-bearing
may include hissing noise at shutdown, or high cylinder just removed.
head temperatures during operation.
4. Using care to make certain that the upper part of
the connecting rod remains in place on its crankpin,
To replace the high pressure relief valve when the com-
rotate the crankshaft to the point where the piston
pressor is not open for repairs or inspection, proceed as
is very near the top of its stroke.
follows:
5. Remove the cylinder sleeve.
1. Disconnect the discharge manifold from the cylin-
der head and remove the head. 6. Lift out the piston and its connecting rod. Note that
the identification number stamped on the upper part
2. Unscrew the leaking relief valve and screw in the
of the rod, matches the number on the lower part of
new valve.
the rod. These numbers should ALWAYS match.
3. Reassemble the cylinder head and discharge mani-
fold. Never rotate the crankshaft when one
or more piston and connecting rod as-
DO NOT use any thread locking semblies are in place unless the re-
sealer on the high pressure relief valve. lated cylinder sleeve or sleeves are in
the proper position in the compressor
housing. If this caution is not ob-
served, serious damage could occur.
Make certain also that when the bot-
tom part of the rod bearing has been
REMOVING PISTONS AND CONNECTING RODS
removed, and it is necessary to rotate
To remove the pistons and connecting rods, refer to Fig. the crankshaft, that the upper part of
37 and proceed as follows: the rod bearing remains in contact
The width of the connecting rods at with the crankpin.
their large end is greater than the in-
side diameter of the cylinder sleeve. 7. Remove piston and connecting rod assemblies ONE
Before a piston and connecting rod as- AT A TIME, repeating the above steps 3 through 6
sembly can be removed from the com- for each piston assembly. Proceed to step 8.
pressor housing, the cylinder sleeve 8. Remove the piston pin retaining rings.
must first be removed. Then the piston
9. Push piston pin out of the piston and connecting rod.
and connecting rod assembly can be
pulled outward from the compressor. 10. Remove the piston rings.
1. Remove the suction and discharge valve assem- 11. Clean, dry and inspect all parts.
blies. Allow the cylinder sleeves to remain in place 12. Oil and wrap parts that will be reused.
in the housing.
28 YORK INTERNATIONAL
FORM 180.30-RPSTL
INSTALLING PISTONS AND CONNECTING RODS Remove the lower part of the connecting rod bear-
ing, allowing the connecting rod screws to remain
To install the piston and connecting rod assemblies, re- in position. Check to see that the numbers on the
fer to Fig. 37 and 38, and proceed as follows: two parts of the connecting rod match and that they
1. Each piston is equipped with two piston rings. When are on the same side of the connecting rod. Apply a
installing the rings, use copper or brass strips under few drops of oil to the crankpin. Insert the piston
the rings and spread the rings only enough to slide and connecting rod assembly through the cylinder
them down over the piston. sleeve bore in the housing and carefully position the
upper part of the connecting rod bearing on its crank-
pin. Install o-ring on each cylinder sleeve. (See Fig-
Piston rings are tapered and must be
ures 14 and 24A). Insert the cylinder sleeve.
installed correctly. The wider part of
4. Install the lower part of the connecting rod bearing
the ring must be down. The top sur-
as described in step 3 above. Tighten the screws
face of the ring is stamped with a dot
evenly to the proper torque. (See Table 1). Hand
(See Fig. 38). turn the crankshaft to be sure there is no binding.
Install all piston assemblies, turning the shaft after
2. Set the piston with its top surface down on a bench. each rod is installed, to be sure that no binding exists.
Insert the small end of the rod into the piston and 5. Make sure that the compressor crankcase is clean.
slide the piston pin into position. The pin is a sliding Install the crankcase access (handhole) cover plates.
fit into the piston and rod. Install the retaining rings Fill the crankcase to the proper level with new oil.
in each side of the piston. Bearing surface of the
6. Reinstall the suction and discharge valves and the
connecting rod, piston, and wrist pin must be well-
oiled prior to reassembly.
compressor cylinder head and access covers mak- 2
ing sure they are in their original locations and re-
3. Cylinder sleeves and piston assemblies, when re- connect the discharge manifold and cylinder head,
used, should be installed in their original locations in using new gaskets as required.
the compressor housing.
ROD
28951A
CAP
SCREWS
LD03154
Replacement rod must match the remaining rods in any one unit, i.e.
long stroke with long stroke, short stroke with short stroke.
YORK INTERNATIONAL 29
Disassembly and Reassembly
FORM 180.30-RPSTL
REMOVING BEARINGS AND CRANKSHAFT 2. Using suitable timber, support the crankshaft inside
the crankcase.
Pump End Bearing 3. Remove the cap screws that hold the bearing head
assembly to the compressor housing.
To remove the pump end bearing refer to Fig. 39 and 4. Screw the rotor mandrel (YORK Part No. 364-
proceed as follows: 37273) into the end of the crankshaft and pull the
1. “Match-mark” the bearing head and compressor bearing head onto it. Use of the mandrel aids in
housing. preventing damage to the stator windings.
2. Remove the oil pump. 5. The motor end thrust collar may come out with the
3. Remove the hex flange screws which hold the bear- bearing head. If it does not, pull it off the crank-
ing head to the housing and remove the bearing head. shaft. Examine the thrust collar and replace if nec-
essary. A roll pin in the bearing head prevents the
4. The YORK Bearing Removal Tool (Part Number
364-37260) is required to remove the bearing from thrust collar from turning with the crankshaft.
the bearing head (See Fig. 42).
5. Using the bearing removal tool as shown in Fig. 40,
Detail A, pull the old bearing from the bearing head.
Note that the backup plate and the split plates must
be installed from the inboard end of the bearing.
6. Apply clean oil to the outside surface of the new
bearing and to the inside portions of the bearing head
into which the bearing is to be pressed.
7. Using the bearing removal tool as shown in Fig. 40,
Detail B, pull the bearing into the bearing head, tak- OIL
ing care that the bearing enters the bearing head PASSAGE
squarely. The “seam” in the bearing should be at 3 (FROM SUMP)
or 9 o’clock. Continue to pull the bearing into the
bearing head until the bearing is 0.155" (5/32") be-
low the inboard end surface on the bearing head. BEARING
Bearing ID after insertion should be: 3.0030 - 3.0045.
8. Inspect both ends of the bearing for and, if present,
remove any burrs or metal shavings that result from
the insertion. GASKET
30 YORK INTERNATIONAL
FORM 180.30-RPSTL
LD03163
LD03158
DETAIL A – PUMP END BEARING (REMOVAL) DETAIL A – MOTOR END BEARING (REMOVAL)
NOTES: NOTES:
1. Axial force required to assemble bearing into housing is 1500 1. Align seam of bearing -C- within +/- 10° of the top.
min. to 3500 max. lbs.
2. Align seam of bearings -A- and -B- at 90° +/- 10° from the top,
2. Bearing dia. shall be 3.0030 / 3.0045 (ref.) after insertion into on either side of vertical centerline.
housing and accept a full depth (2.5 min.) plug gauge. Go dia.:
3. Axial force required to assemble bearing into housing is 1500
3.0022.
min. to 3500 max. lbs.
4. Bearing dia. shall be 3.0030 / 3.0045 (ref.) after insertion into
housing. Bearing -A- must accept a full depth (2.5 min) plug
gauge. Go dia.: 3.0022. Bearings -B- and -C- must accept a full
2
depth (3.5 min.). Plug gauge. Go dia.: 3.0022.
LD03163
LD03158
LD06923
LD06922
DETAIL C – PUMP END BEARING COMPLETE DETAIL C – MOTOR END BEARING COMPLETE
YORK INTERNATIONAL 31
Disassembly and Reassembly
FORM 180.30-RPSTL
6. Using the bearing removal tool as shown in Fig. 41, more accessible. To remove the crankshaft, proceed as
Detail A, remove the old bearings from the hous- follows:
ing. Bearings are removed one at a time in a similar 1. Drain the oil from the compressor. Remove the
manner from opposite ends of the bearing head. crankcase hand hole cover plates, discharge mani-
7. Apply clean oil to the outside surface of the new fold, cylinder head, access covers, suction and dis-
bearings and to the inside portions of the bearing charge valve assemblies, pistons and connecting
head into which the bearings are to be pressed. rods, motor cover, and rotor following procedures
8. Using the bearing removal tool as shown in Fig. 41, outlined previously.
Detail B, pull the bearings into the bearing head one 2. Using suitable timber, support the crankshaft inside
at a time from opposite ends, taking care that the the crankcase.
bearings enter the bearing head squarely. The “seam” 3. Determine from which end the crankshaft is to be
in bearing -C- should be at the top; the “seam” in removed and remove the bearing head from that
bearings -A- and -B- should be turned 90° to either end of the compressor following procedures out-
side. Continue to pull the bearings into the head until lined previously.
they are positioned as shown in Fig. 41, Detail C.
4. Using two people, carefully remove the crankshaft
9. Inspect both ends of the bearings for and, if present, from the compressor.
remove any burrs or metal shavings that result from
5. If the crankshaft is removed through the pump end,
the insertion.
the thrust collar will probably remain in place in the
10. Reinstall the bearing head. Be sure the bearing head compressor on the motor end. Be sure that this thrust
is properly aligned with the oil passages (oil pres- collar is properly positioned on the roll pin before
sure regulating valve is at 6 o’clock position). reinstalling the crankshaft. Check thrust clearance,
after reassembly for allowable range of .013 - .038".
Crankshaft
6. Reassemble the compressor by following the above
The compressor crankshaft can be removed from ei- procedure in reverse order.
ther end of the compressor depending on which end is
LD03156
32 YORK INTERNATIONAL
FORM 180.30-RPSTL
TAPPED CAP SCREW 5. Mark each protector terminal screw with the cor-
PULLER rect lead number. (Ex. C, S1, S2, S3)
FLAT STATOR
HOLES 6. Disconnect any other compressor or unit wiring that
WASHER
will interfere with or prevent removal of the termi-
ROTOR
LOCKWASHER nal box from the motor cover.
7. Remove the terminal box and loosen the terminal
block.
8. Remove the nuts from the terminal bolts and the
protector terminal screws. Lift the terminal block
off the motor cover and push the bolts and screws
down through the holes in the terminal block. DO
NOT allow the bolts and screws to come in direct
contact with the stator windings.
9. Support the compressor housing using a crane or
other suitable method. Loosen, but do not remove,
the cap screws and nuts that hold the motor cover
to the compressor housing. Remove two diagonally
opposite screws (preferably at the 3 and 9 o’clock
locations) and insert guide pins (1/2" - 16) into the
screw holes. Remove remaining screws and nuts.
Remove the motor cover sliding it over the guide
pins, taking care not to damage the stator wind-
ings. Keep in mind that any contact with stator can
damage it.
10. Remove the cap screw, lockwasher and flat washer
that hold the rotor to the crankshaft. 2
29689A
11. Insert 2 cap screws (.500 - 13) into the tapped holes
FIG. 43 – MOTOR END OF COMPRESSOR in the end of the rotor.
12. Screw the rotor mandrel (YORK Part Number 364-
37273) into the end of the crankshaft and slide the
rotor onto it. It is not advisable to attempt to re-
REMOVING ROTOR
move the rotor without using the rotor mandrel.
13. To reinstall the rotor or to install a new rotor follow
The motor rotor must be removed in order to remove steps 10 and 12 in reverse order.
the crankshaft and/or motor end bearing head. Also, if 14. Reinstall the motor cover and a new gasket using
it becomes necessary to replace the rotor or stator, both two diagonally opposite guide pins. TAKE CARE
rotor and stator must be replaced. To remove the rotor, in installing the motor cover to avoid damaging the
proceed as follows: motor stator windings. Keep in mind that any con-
tact with the stator can damage it. DO NOT reuse
the old gasket. Be sure motor cover is properly lo-
WARNING cated on the compressor housing.
Be sure electrical power to unit 15. Pull all terminal bolts and protective terminal screws
has been disconnected. up through the terminal box opening in the motor
cover.
16. Be sure to place a new terminal block gasket in
1. Remove the cap screws that hold the suction stop position before inserting the terminal bolts and pro-
valve to the motor cover. Remove the suction stop tector terminal screws into the terminal block.
valve, suction strainer screen and gaskets. 17. Reinstall the terminal bolts and terminal screws.
2. Disconnect the unit power wiring from the motor Be sure the terminal bolts are reinstalled in the
terminal bolts. correct location (1, 2, 3, 7, 8, or 9). Refer to Figs.
3. Disconnect the motor protector wiring from the pro- 45 & 57 to be certain all components are installed
tector terminal screws. properly.
4. Mark each terminal bolt with the correct lead num- 18. Reinstall the terminal block, terminal box, power
ber. (Ex. 1, 2, 3, 7, 8, 9) wiring and cover.
19. Replace the suction strainer screen, gaskets and
stop valve.
YORK INTERNATIONAL 33
Disassembly and Reassembly
FORM 180.30-RPSTL
19 - 22 FT. LBS.
CONNECT UNIT
WIRING HERE
MAINTAIN
SEPARATION
TERMINAL
BLOCK
LD07215
YORK INTERNATIONAL 35
Disassembly and Reassembly
FORM 180.30-RPSTL
LD07217
36 YORK INTERNATIONAL
FORM 180.30-RPSTL
HANDHOLE COVER, FOR CRANKCASE FLOAT HANDHOLE COVER FOR CRANKCASE FLOAT
SUBASSEMBLY THROUGH SPEPTEMBER 2001 SUBASSEMBLY, AFTER SEPTEMBER 2001
ITEM DESCRIPTION PART NO. ITEM DESCRIPTION PART NO.
1 HANDHOLE COVER 064-26808-000 1 HANDHOLE COVER 064-50344-000
SCREW, HEX FLANGE, SCREW, HEX FLANGE,
35 021-17692-000 27 021-17692-000
.4375-14 X 1.75 .4375-14 X 2.00
NOTE: NOTE:
Item number 1 corresponds to same item specified in SECTION 3 – Item number 1 corresponds to same item specified in SECTION 3 –
RENEWAL PARTS, Figure 58. Item number 35 corresponds to same RENEWAL PARTS, Figure 58. Item number 35 corresponds to same
item specified in SECTION 3 – RENEWAL PARTS, Figure 47 and item specified in SECTION 3 – RENEWAL PARTS, Figure 47 and
Table 2. Torque Item 35 to 78 – 90 lb.-ft. Table 2. Torque Item 27 to 78 – 90 lb.-ft.
LD07219
LD07218
2
YORK INTERNATIONAL 37
Renewal Parts
FORM 180.30-RPSTL
All compressor parts are designed and manufactured for genuine YORK Renewal Parts. This section lists re-
a specific application. They are selected to withstand the placement parts for these compressors. When ordering
pressures normally associated with compressor opera- parts, be sure to include the complete Nomenclature:
tion. The substitution of nonstandard parts is not autho- Model, Part Number and Serial Number. Be sure that
rized as these parts could cause serious damage to the these numbers are copied accurately and completely.
compressor or operator. Parts should be replaced with
38 YORK INTERNATIONAL
FORM 180.30-RPSTL
LD06935
236
236
LD06936
NOM.
NOTE A: VALVE ADAPTER GASKET
1. Brass suction and discharge service valve pipe adapter/ SIZE
gasket by valve manufacturer Mueller. Also See NOTE 1 2-1/8 A6267 A6261
callout on Fig. 12A, regarding critical torque. 2-5/8 A6268 A6261
3-1/8 A6269 A6262
CRANK CASE
3
YORK INTERNATIONAL 39
Renewal Parts
FORM 180.30-RPSTL
204
LD06941
LD06938
LD06940
LD06939
NOTES:
s
LD06942
= Recommended Stock Spare Part
1
= Same as ITEM NO. 42 (TABLE 2)
2
= Includes Compression Ring and O-Ring
FIG. 48 – UNLOADING DEVICE ASSEMBLY
40 YORK INTERNATIONAL
FORM 180.30-RPSTL
100 99 99
100 99 99
21 21 76 77 77
239 239 77 77 76 76
21
LD06970
TABLE 2 – COMPRESSOR COMPONENTS, GENERAL (SEE FIGURES 46, 47, 48 & 49)
COMPRESSOR
ITEM NO. DESCRIPTION
4 CYLINDER 6 CYLINDER 8 CYLINDER
1 Housing 064-49269-000 064-49270-000 064-49271-000
S
2 Screen, Oil Strainer 029-20032-000 029-20032-000 029-20032-000
S
Valve, Relief 022-03871-000 022-03871-000 022-03871-000
3
No. Required Per Compressor 1 2 2
S
4 Sight Glass, Oil (2 Required) 026-17581-000 026-17581-000 026-17581-000
Sleeve, Cylinder 064-49655-000 064-49655-000 064-49655-000
5
No. Required Per Compressor 4 6 8
S
6 Valve, Oil Charging 022-01582-000 022-01582-000 022-01582-000
7 Cap, Oil Charging Valve 023-00977-000 023-00977-000 023-00977-000
8 Lockwasher, 7/16 (4 Required) 021-05270-000 021-05270-000 021-05270-000
10 Well, Oil Temp. Sensor 068-09987-000 068-09987-000 068-09987-000
11 Sealant, Refrigerant Pipe1 013-02023-000 013-02023-000 013-02023-000
12 Bearing Head, Motor End See Figure 56
13 Screw, 7/16 Hex Cap (4 Required) 021-10387-000 021-10387-000 021-10387-000
14 Washer, Thrust 029-11098-000 029-11098-000 029-11098-000
Gasket, Disch. Manifold 064-49546-000 064-49546-000 064-49546-000
15
No. Required Per Compressor 2 3 4
16 Bearing Head, Oil Pump End See Figure 54
17 Gasket, Bearing Head, Oil Pump End 064-49543-000 064-49543-000 064-49543-000
19 Gasket, Oil Pump 064-49544-000 064-49544-000 064-49544-000
20 Screw, 5/16 Hex Flange (6 Required) 021-17689-000 021-17689-000 021-17689-000
21 Manifold, Discharge 064-48340-000 064-48320-000 064-48341-000
Valve Plate Assembly (Suction) See Figure 51
22
No. Required Per Compressor 4 6 8
Valve Cage Assembly (Discharge) See Figure 50
23
No. Required Per Compressor 4 6 8
Screw, 3/8 Hex Cap 021-16827-000 021-16827-000 021-16827-000
24
No. Required Per Compressor 16 24 32
Cover, Access3 064-48176-000 064-48176-000 064-48176-000
25
No. Required Per Compressor 1 or 3 2 or 4 3 or 5
Gasket, Access & Handhole Covers & Head 064-49542-000 064-49542-000 064-49542-000
26
No. Required Per Compressor 4 5 6
Screw, 7/16 Hex Flange3 021-17693-000 021-17693-000 021-17693-000
27
No. Required Per Compressor 16 or 48 32 or 64 48 or 80
28
Pin, Coiled Spring 029-21378-000 029-21378-000 029-21378-000 3
No. Required Per Compressor 1 2 3
29 Head, Cylinder 064-48321-000 064-48321-000 064-48321-000
30 Screw, 7/16 Hex Flange (16 Required) 021-17783-000 021-17783-000 021-17783-000
31 Cover, Motor 064-49951-000 064-49949-000 064-49950-000
S
NOTES: = Recommended Stock Spare Part
1
= Not shown. Used for threaded pipe joints unless otherwise specified.
2
= Used to Replace Solenoid Valves for Reduced Steps of Unloading.
3
= See DESIGN HISTORY
YORK INTERNATIONAL 41
Renewal Parts
FORM 180.30-RPSTL
TABLE 2 – COMPRESSOR COMPONENTS, GENERAL (SEE FIGURES 46, 47, 48 & 49)
COMPRESSOR
ITEM NO. DESCRIPTION
4 CYLINDER 6 CYLINDER 8 CYLINDER
32 Gasket, Motor Cover 064-49549-000 064-49548-000 064-49548-000
33 Terminal Box See Figures 46, 57A and 57B and Table 4
35 Screw, 7/16 Hex Flange (12 or 44 Required)3 021-17692-000 021-17692-000 021-17692-000
Pipe Plug, 1/4 Square Head 023-01972-000 023-01972-000 023-01972-000
36
No. Required Per Compressor 3 4 5
37 Pipe Plug, 1/4 Hex Socket 023-01973-000 023-01973-000 023-01973-000
Sealer, Loctite
42 (Use with Items 10, 12-8, 013-01671-000 013-01671-000 013-01671-000
16-3, 16-5, 88, 140-3 and 242)
Screw, 1/2 Hex Cap 021-18021-000 021-18021-000 021-18021-000
43
No. Required Per Compressor 24 23 22
44 Gasket (2 Required) 064-47079-000 064-47079-000 064-47204-000
45 Screen, Suction 026-28473-000 026-28473-000 026-28474-000
Valve, Suction Stop 022-02844-000 022-02844-000 022-02845-000
46
Valve Size 3-1/8" 3-1/8" 3-5/8"
47 Screw, 5/8 Hex Cap (4 Required) 021-16817-000 021-16817-000 021-16818-000
48 Gasket, Discharge Valve 064-47078-000 064-47078-000 064-47079-000
Valve, Discharge Stop 022-01394-000 022-01394-000 022-02844-000
49
Valve Size 2-5/8" 2-5/8" 3-1/8"
50 Screw, 5/8 Hex Cap (4 Required) 021-16821-000 021-16821-000 021-16817-000
51 Gasket, Terminal Block 064-49545-000 064-49545-000 064-49545-000
52 Terminal Block 025-30402-000 025-30402-000 025-30402-000
70 Key, Motor 064-26560-000 064-26560-000 064-26560-000
71 Washer, Shaft 064-21835-000 064-21835-000 064-21835-000
72 Lockwasher, 5/8, Shaft 021-05295-000 021-05295-000 021-05295-000
73 Screw, 5/8 Hex Cap 021-01630-000 021-01630-000 021-01630-000
Heat Conductive Compound
75 013-00898-000 013-00898-000 013-00898-000
(Use with Items 202 & 240)
Screw, 3/8 Hex Flange — 021-17782-000 021-17781-000
76
No. Required Per Compressor — 4 4
Screw, 3/8 Hex Flange — 021-17781-000 021-19637-000
77
No. Required Per Compressor — 4 8
80 Retaining Cmpd, Loctite (Use with Item 2) 013-01752-000 013-01752-000 013-01752-000
S
Gasket, Solenoid Valve 064-49541-000 064-49541-000 064-49541-000
87
No. Required Per Compressor 1 2 3
Stud, 1/2 021-30172-000 021-30172-000 021-30172-000
88
No. Required Per Compressor 1 1 2
Nut, 1/2 Hex 021-11154-000 021-11154-000 021-11154-000
89
No. Required Per Compressor 1 1 2
Screw, 3/8 Hex Cap 021-17690-000 021-17690-000 021-17690-000
90
No. Required Per Compressor 6 12 18
Pipe Plug, 1/8 Hex Socket 023-01970-000 023-01970-000 023-01970-000
92
No. Required Per Compressor 1 2 3
Washer, 1/2, Clipped Circular 021-17774-000 021-17774-000 021-17774-000
98
No. Required Per Compressor 1 1 2
Screw, 3/8 Hex Flange — 021-17784-000 021-17784-000
99
No. Required Per Compressor — 4 4
Screw, 3/8 Hex Flange 021-17784-000 — —
100
No. Required Per Compressor 4 — —
Cover Plate, Blank2 064-48187-000 064-48187-000 064-48187-000
101
No. Required Per Compressor See Table 3
Drain Orifice Plug, .022" 064-47349-000 064-47349-000 064-47349-000
134
No. Required Per Compressor 1 2 3
Conduit w/Connectors 064-49020-001 064-49020-001 064-49020-001
136
No. Required Per Compressor See Figure 57B and Table 3
Conduit w/Connectors — 064-49020-002 064-49020-002
137
No. Required Per Compressor See Figure 57B and Table 3
S
Unloader Piston 364-48190-000 364-48190-000 364-48190-000
140
No. Required Per Compressor See Figure 48 and Table 3
Seal, O-ring, Cylinder Sleeve 028-12259-000 028-12259-000 028-12259-000
141
No. Required Per Compressor 4 6 8
S
NOTES: = Recommended Stock Spare Part
1
= Not shown. Used for threaded pipe joints unless otherwise specified.
2
= Used to Replace Solenoid Valves for Reduced Steps of Unloading.
3
= See DESIGN HISTORY
42 YORK INTERNATIONAL
FORM 180.30-RPSTL
TABLE 2 – COMPRESSOR COMPONENTS, GENERAL (SEE FIGURES 46, 47, 48 & 49)
COMPRESSOR
ITEM NO. DESCRIPTION
4 CYLINDER 6 CYLINDER 8 CYLINDER
Crankcase Heater - 120V 025-32938-000 025-32938-000 025-32938-000
202
- 240V 025-32939-000 025-32939-000 025-32939-000
S
Valve, Solenoid 025-29999-000 025-29999-000 025-29999-000
204
No. Required Per Compressor See Table 3
205 Pump, Oil See Figure 55
207 Cover, Handhole (0 or 2 Required)3 064-21645-000 064-21645-000 064-21645-000
S
208 Motor See Table 5
Screw, 7/16 Hex Cap for
021-16819-000 021-16819-000 Not Required
Motor Size Codes M, N and P (4 Req’d)
209
Motor Size Codes Q, S, T and V
Not Required 021-16820-000 021-16820-000
(4 Required)
Crankshaft
S
210 Stroke 3 364-49221-000 364-49222-000 364-49223-000
Stroke 4 364-49224-000 364-49225-000 364-49226-000
S
Piston Assembly See Figure 52
211
Connecting Rod Assembly See Figure 53
214 Clamp, 7/8 023-18276-000 023-18276-000 023-18276-000
215 Screw, 1/4 Hex Cap 021-16174-000 021-16174-000 021-16174-000
Coil, Solenoid (Less Valve)
S
120 Volt 025-30976-000 025-30976-000 025-30976-000
216
240 Volt 025-30977-000 025-30977-000 025-30977-000
No. Required Per Compressor See Table 3
219 Nut, 3/8 Hex 021-00466-000 021-00466-000 021-00466-000
220 Washer, 3/8 Plain 021-01267-000 021-01267-000 021-01267-000
Sealer, Removable Thread
224 (Use with Items 4, 16-4, 205-2, 227, 013-01678-000 013-01678-000 013-01678-000
228, 230 and 235)
Seal, O-Ring, conduit seal 028-03292-000 028-03292-000 028-03292-000
226
No. Required per Compressor See Table 3
227 Eductor, Oil Return 022-09716-000 022-09716-000 022-09716-000
228 Valve, Check 022-09741-000 022-09741-000 022-09741-000
Connector, 5/8 Flare 023-18955-000 023-18955-000 023-18955-000
229
No. Required per Compressor 2 1 1
230 Elbow, 3/8 fla 023-00868-000 023-00868-000 023-00868-000
231 Elbow, 5/8 Flare Not Required 023-18956-000 023-18956-000
232 Seal, O-Ring 028-13896-000 028-13896-000 028-13896-000
233 Connection, Eductor to Check Valve 364-49345-000 364-49345-000 364-49345-000
234 Connection, Bearing Head to Housing 364-49283-000 364-49284-000 364-49285-000
235 Elbow, 1/4 x 1/4 Street 023-01685-000 023-01685-000 023-01685-000
236 Magnet (2 Required) 029-22748-000 029-22748-000 029-22748-000
238 Pipe Plug, 3/8 Hex Socket 023-04298-000 023-04298-000 023-04298-000
Screw, 3/8 Hex Flange 021-17781-000 — —
239
No. Required Per Compressor 4 — —
240 Sensor, Oil Temp. 025-34177-000 025-34177-000 025-34177-000
242 Stud, 3/8 021-30147-000 021-30147-000 021-30147-000
S
NOTES: = Recommended Stock Spare Part
1
= Not shown. Used for threaded pipe joints unless otherwise specified.
2
= Used to Replace Solenoid Valves for Reduced Steps of Unloading.
3
= See DESIGN HISTORY
1 0 1 2 11 1 1 1 0 0 1 1 1 1
2 0 0 1 13 0 1 0 1 2 2 2 2 2
YORK INTERNATIONAL 43
Renewal Parts
FORM 180.30-RPSTL
4 2 3 6 29697A 5
29693A
1 2 3
44 YORK INTERNATIONAL
FORM 180.30-RPSTL
2 3
LD03066
28951A
PART NUMBER
ITEM NO. DESCRIPTION
Short Stroke Long Stroke
Screw, 5/16 Hex Cap 021-13665-000 021-13665-000
1
No. Required Per Connecting Rod 2 2
Dowel Pin (Not Shown) 029-22432-000 029-22432-000
2
No. Required Per Connecting Rod 2 2
Washer, 5/16 Plain (Package of 10) 221-01262-800 221-01262-800
3
No. Required Per Connecting Rod 2 2 3
Connecting Rod Assembly
4 664-49011-000 664-49012-000
Includes Items 1, 2 and 3
S
= Recommended Stock Spare Part
YORK INTERNATIONAL 45
Renewal Parts
FORM 180.30-RPSTL
46 YORK INTERNATIONAL
FORM 180.30-RPSTL
2, 3
LD06964
3
FIG. 55 – OIL PUMP ASSEMBLY
YORK INTERNATIONAL 47
Renewal Parts
FORM 180.30-RPSTL
LD06944
48 YORK INTERNATIONAL
FORM 180.30-RPSTL
COMPRESSOR MOTOR TERMINAL BOX COMPONENTS (See Figs. 46, 57A and 57B)
TERMINAL BOX
ITEM NO. DESCRIPTION QTY. A B
PART NUMBER
18 Knockout Cover 2 064-47460-000 064-47460-000
33* Terminal Box 1 364-48175-000 364-48704-000
34 Cover, Terminal Box 1 064-47459-000 064-47459-000
41 Washer, 3/8 Plain 16 021-01267-000 021-01267-000
51 Gasket, Terminal Block 1 064-49545-000 064-49545-000
52 Terminal Block 1 025-30402-000 025-30402-000
53 Terminal, Push-On Protector 8 025-18650-000 025-18650-000
Washer, 3/16 Plain (Package of 5) — 221-18694-800 221-18694-800
54 Number of Washers Required Per Compressor 16 — —
55 Seal, O-Ring, 5/32 ID 4 028-09347-000 028-09347-000
Washer, Terminal (Package of 10) — 228-09525-800 228-09525-800
56 Number of Washers Required Per Compressor 4 — —
57 Lockwasher, Internal Tooth 2 021-01133-000 021-01133-000
Screw, Cap Hex Soc Hd (Package of 5) — 221-14817-800 221-14817-800
58 Number of Screws Required Per Compressor 4 — —
59 Nut, Flange, Serrated 4 021-18936-000 021-18936-000
60 Seal, O-Ring, 7/16 ID 12 028-12551-000 028-12551-000
61 Bolt, Terminal 6 021-18660-000 021-18473-000
62 Spacer, Insulating 1 025-30978-000 025-30978-000
Nut, 7/16 Hex (Package of 6) — 221-12724-800 221-12724-800
64 Number of Nuts Required Per Compressor 18 — —
65 Label, Caution 1 035-05548-000 035-05548-000
66 Screw, 3/8 Hex Flange 16 021-17691-000 021-17691-000
67 Lockwasher, 3/8 Internal Tooth 4 021-01155-000 021-01155-000
68 Terminal Block End 1 025-20946-000 025-20946-000
69 Screw, Tap 9 021-13784-000 021-13784-000
78 Label, Field Wiring 1 035-17153-000 035-17153-000
Screw, Tap (Style PA Only) 2 021-12068-000 021-12068-000
79 Cap, Sealing (Style PB Only) 2 028-13952-000 028-13952-000
83 Lockwasher, 7/16 Internal Tooth 6 021-16246-000 021-16246-000
84 Wiring, Protector Terminals (Style PA Only) 1 564-47602-001 564-47602-001
85 Strip, Marker 1 025-30960-000 025-30960-000
91 Washer, 7/16 Plain 6 021-14111-000 021-14111-000
135 Terminal Block, Flat Base Note 1 025-20944-000 025-20944-000
Conduit w/Connectors (2)
136* 1-Step Unloading, 4, 6 and 8 Cylinder and 1 064-49020-001 064-49020-001
2-Step Unloading, 6 Cylinder Only
Conduit w/Connectors (2)
137* 2-Step Unloading, 6 Cylinder 1 064-49020-002 064-49020-002
2-Step Unloading, 8 Cylinder 2
Wiring, Common Jumper
138 1-Step Unloading 1 565-25211-003 565-25211-003
2-Step Unloading
Module, Motor Protector (Style PA Only)
1 565-25211-004 565-25211-004 3
203 115V/230V 1 025-35149-000 025-35149-000
217 Connector, Conduit 1 025-31309-000 025-31309-000
221 Label, Warning 1 035-00929-000 035-00929-000
––– Bar, Jumper (See Note 2) 1 064-47424-000 064-47424-000
1
NOTES: = See Table 3
2
= Not Shown. Used in Across-the-Line Applications
*
= Also listed in Table 2
YORK INTERNATIONAL 49
Renewal Parts
FORM 180.30-RPSTL
NOTE:
Insulate terminal bolts to prevent
condensation and reduce arcing
potential. In low temp. applications
and high humidity environments. Use
3M Scotchfil Electrical Insulation
Putty UPN #15140 or equivalent.
LD06965
From Heater
For 2- Steps of Unloading:
6 Cylinder Sol. (#2)
8 Cylinder Sol. (#3) LD06945
50 YORK INTERNATIONAL
FORM 180.30-RPSTL
The “Valve Replacement” Kit listed in Table 7 contains the suction and discharge valve rings and springs and gaskets
required to service one deck (two cylinders).
The “Overhaul” Kit listed in Table 8 contains the suction valve rings and springs, suction valve plates, discharge
valve cage assemblies, gaskets and screws required to service one deck (two cylinders).
Mineral Oil, Type E, 5-gallon can – 011-00582-000, for R-22 high ambient applications above 115°F
POE Lubricant, Type H, 5-gallon can – 011-00549-000, for R-134a and R407C applications
52 YORK INTERNATIONAL
FORM 180.30-RPSTL
The sump and the line connecting the pump to the com-
pressor should be filled with oil and purged of air prior to
00054VIP pumping any oil into the compressor. Charge oil into the
housing sump through the oil charging/drain valve. (See
FIG. 59 – OIL CHARGING Figure 59). Pre-lube the compressor through the access
valve on the oil pump (Figs. 11 and 56).
SERVICE AIDS
Crankshaft pre-lube service at start-up and after long YORK OIL CHARGING PUMP
idle periods is recommended. PART NO. 470-10654
00055VIP
YORK INTERNATIONAL 53
Renewal Parts
FORM 180.30-RPSTL
00055VIP
54 YORK INTERNATIONAL
FORM 180.30-RPSTL
YORK INTERNATIONAL 55
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by York International Corporation 2001 www.york.com ALL RIGHTS RESERVED
Form 180.30-RPSTL (1101)
New Release