Component Maintenance Manual Z26-8900
Contents
1. a 209 27 _ p G9 AI i 1 9 E 2 PLCS H LA EB z o c 2 PLCS DDD D 12 25 5 2 4 PLCS FIG 3 20 of 21 CMM Z26 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 9 0 SUMMARY OF MODIFICATIONS 9 1 MOD A This modification applies to the Z26 8900 5 MC only The modification is noted when Z99 800 1 Motor used has MOD E Mark an X in the block of the Modification Status section of the I D Plate 21 of 21 CMM Z26 8900 REV IR 1 28 062. OIL LEAKS DRIVE BELT EVERY 250 HRS INSPECT AS PER 1 000 SECTION 3 1 2 MOTOR DRIVE EVERY 1000 HRS INSPECT AS PER 2 000 COMPRESSOR SECTION 3 3 2 AND SERVICE LETTER 58 001 or 99 800 COMPRESSOR NEW AFTER THE FIRST 100 HOURS INSPECT AS PER SECTION 3 2 2 1 EVERY 500 HRS INSPECT AS PER 2 000 SECTION 3 2 2 UNIT OPERATING TIME COMPONENT IS PART OF THE Z26 8900 MOTOR COMPRESSOR ASSEMBLY REFER TO SANDEN SANDEN SD COMPRESSOR SERVICE MANUAL FOR ADDITIONAL COMPRESSOR SERVICE INFORMATION 6 0 TOLERANCES 6 1 COMPRESSOR OIL NEW refer to Illustration 2 and Illustration 3 and Table 1 REPLACEMENT refer to Section 3 2 2 2 12 of 21 CMM Z26 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 6 2 CLUTCH When assembled an air gap of 016 031 0 4 0 8mm between the pulley and clutch plate 6 2 REFRIGERANT CHARGE Refer to aircraft maintenance manual or ZEE Systems Inc Service Letter 226 1 6 3 BRUSH LENGTH COMPRESSOR DRIVE MOTOR The minimum brush length on the drive motor is 0 750 19mm Refer to SIL 58 001 6 4 TORQUE VALUES If not specified use standard torque values for bolts 14 mm Pulley Nut 11 15 Ib ft 15 21 N m 17 mm 10 mm Compressor Bolt Nut 30 Ib ft 42 N m 7 0 TROUBLE SHOOTING TROUBLE POSSIBLE CAUSE REMEDY Compressor Motor Motor shorted Replace Motor trips circuit breaker or Motor brushes worn current limiter beyond limits Short in wi
3. compressor from horizontal as shown in 2 Remove the oil fill plug on top of the compressor take care not damage the seal Place the dipstick in the opening make 7 of 21 CMM Z26 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 7226 8900 sure the dip stick goes in past the crankshaft and pistons Refer to TABLE 1 for correct oil level and add oil as necessary Return and tighten oil fill plug 3 2 2 2 Check oil level of existing system If you are replacing a failed compressor from an existing installation drain the oil from the defective compressor and record the amount Drain the oil from the new replacement compressor Add back the same amount of oil to the new replacement compressor that was removed from the defective compressor Dip Stick ILLUSTRATION 2 DETERMINE ANGLE RELATIVE TO LEVEL X DETERMINE ANGLE RELATIVE TO LEVEL Determine the angle of the compressor relative to horizontal ILLUSTRATION 3 TABLE 1 8 of 21 CMM Z26 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 3 2 5 INSTALLATION With the compressor pulley removed align the compressor and spacers 2 9 10 with angles 3 11 12 and slide the 10 mm x 150 mm bolt 2 44 into position Do not forget the flat washer 2 42 under bolt head before inserting Make sure the bolt head is on the pulley side Tighten the 17 mm nut just enough to secure the compressor b
4. oil container exposed to air for prolonged time Tightly reseal the oil container and compressor immediately after exposing the oil to air Liquid Detergent water soluble Commercially available Cloth lint free Commercially available Tape Insulation Commercially available 5 of 21 226 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 3 0 REPAIR AND REPLACEMENT OF COMPONENTS It may be necessary to remove Z26 8900 Motor Compressor MC Assembly from the aircraft to perform the inspections or maintenance described in this manual Refer to appropriate aircraft maintenance manual for removal and installation instructions CAUTION AIR CONDITIONING SYSTEM UNDER PRESSURE APPROPRIATE SAFETY MEASURES SHOULD BE TAKEN WHEN SERVICING THIS EQUIPMENT ONLY TRAINED PERSONNEL WITH APPROVED SAFETY EQUIPMENT SHOULD PERFORM SERVICING DUTIES NOTE IT IS UNLAWFUL TO RELEASE ANY REFRIGERANTS TO THE ATMOSPHERE USE APPROVED RECOVERY RECYCLE EQUIPMENT TO CAPTURE REFRIGERANTS USE ONLY LAWFUL MEANS TO DISPOSE OF RECOVERED REFRIGERANTS CHECK WITH LOCAL AGENCIES FOR APPROVED DISPOSAL PROCEDURES NOTE CAP ALL OPEN LINES TO PREVENT CONTAMINANTS AND MOISTURE FROM ENTERING THE SYSTEM NOTE DUE TO THE TIGHT FIT OF THE MOTOR COMPRESSOR CONDENSER ASSY IT MAY BE NECESSARY TO REMOVE THE MOTOR COMPRESSOR CONDENSER ASSY AND THE EVAPORATOR TO PERFORM SOME OF THE MAINTENANCE DESCRIBED BELOW FRONT SEAT SEAL TURN VALVE S
5. A BOLT 1 27 AN5 12A BOLT 29 AN6 6A BOLT 29 AN6 12A BOLT 2 30 AN76A11 BOLT 4 ALT MS20074 06 11 31 520995 025 LOCK WIRE AR 32 MS21045 5 NUT LOCK 2 33 MS21045 6 NUT LOCK 2 34 MS21251B6S TURNBUCKLE BARREL 1 C D 35 MS35338 44 WASHER LOCK 6 ALT AN935 416 36 MS35338 46 WASHER LOCK 5 ALT AN935 616 37 NAS1149F0463P WASHER FLAT 6 ALT AN960 416 38 NAS1149F0563P WASHER FLAT 4 ALT AN960 516 39 NAS1149F0663P WASHER FLAT 9 ALT AN960 616 40 NAS509 5R NUT JAM 1 41 NAS509 5L NUT JAM 1 42 M10 WASHER FLAT METRIC 2 43 10M 1 50 NUT LOCK METRIC 1 44 10 1 5 150 BOLT METRIC 45 AN316 6R NUT 2 46 NAS1149F0632 WASHER FLAT 4 ALT AN960 616L 47 400649 1 I D PLATE NS Z26 200 8 ADAPTER B S V 528775 013 O RING 1 NS Z26 200 10 ADAPTER B S V 1 528775 015 O RING 1 17 of 21 226 8900 REV IR 1 28 06 E ZEE Systems Inc COMPONENT MAINTENANCE MANUAL Z26 8900 444342 2 COMPRESSOR MOUNT HARDWARE NOT SHOWN 2 PLCS THIS SIDE 2 PLCS OPPOSITE SIDE FIG 1 18 of 21 CMM Z26 8900 REV IR 1 28 06 E ZEE Systems Inc COMPONENT MAINTENANCE MANUAL Z26 8900 QOS c d H a n j dd d B E 1 E H L Wo J IF d d d d F 44 83 62 2 9 COMPRESSOR MOUNT HARDWARE FIG 2 19 of 21 726 8900 REV IR 1 28 06 E ZEE Systems Inc COMPONENT MAINTENANCE MANUAL Z26 8900
6. E ZEE Systems Inc COMPONENT MAINTENANCE MANUAL Z26 8900 Component Maintenance Manual with Illustrated Parts List for Z26 8900 Series Motor Compressor Assembly 1 of 21 CMM Z26 8900 REV IR 1 28 06 E ZEE Systems Inc COMPONENT MAINTENANCE MANUAL Z26 8900 Record of Revisions REVISION ISSUE POSTED NO DATE DATE INSERTED BY 2 of 21 CMM Z26 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 7226 8900 List of Effective Pages and Table of Contents PAGE TITLE EFFECTIVE DATE REV 1 COVER PAGE 2 RECORD OF REVISIONS 3 LIST OF EFFECTIVE PAGES 4 1 0 INTRODUCTION s 2 0 SPECIAL TOOLS AND EQUIPMENT continued 6 3 0 REPAIR AND REPLACEMENT OF COMPONENTS ILLUSTRATION 1 3 1 DRIVE BELT UA x 7 3 2 COMPRESSOR 8 ILLUSTRATION 2 ILLUSTRATION 3 TABLE 1 9 3 3 MOTOR COMPRESSOR DRIVE 10 3 4 WIRING a WIRING DIAGRAM 1 11 WIRING DIAGRAM 2 WIRING DIAGRAM 3 12 4 0 SERVICING REFRIGERANT CHARGE 5 0 SERVICE SCHEDULES 6 0 TOLERANCES 13 7 0 TROUBLE SHOOTING 14 continued 15 8 0 ILLISTRATED PARTS LIST 8 1 EXPLINATION OF SYMBOLS 16 8 2 IPL 726 8900 MOTOR COMPRESSOR ASSY 17 continued 18 FIGURE 1 x 19 FIGURE 2 20 FIGURE 3 21 9 0 SUMMARY OF MODIFICATIONS 2 9 1 MOD A INTITIAL RELEASE 1 28 06 3 of 21 CMM Z26 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 1 0 INTRODUCTION 1 1 This Componen
7. ER THERMAL SWITCH PRESSURE SWITCH TERMINAL BLOCK _ COMPRESSOR DRIVE MOTOR CLUTCH COIL COMPRESSOR WIRING DIAGRAM 2 __ COMPRESSOR DRIVE MOTOR CLUTCH COIL COMPRESSOR M d 226 18 2 BASIC MINIMUM REQUIREMENT WIRING DIAGRAM 3 CAUTION AIR CONDITIONING SYSTEM UNDER PRESSURE APPROPRIATE SAFETY MEASURES SHOULD BE TAKEN WHEN SERVICING THIS EQUIPMENT ONLY TRAINED PERSONNEL WITH APPROVED SAFETY EQUIPMENT SHOULD PERFORM SERVICING DUTIES NOTE IT IS UNLAWFUL TO RELEASE ANY REFRIGERANTS TO THE ATMOSPHERE USE APPROVED RECOVERY RECYCLE EQUIPMENT TO CAPTURE REFRIGERANTS USE ONLY LAWFUL MEANS TO DISPOSE OF RECOVERED REFRIGERANTS CHECK WITH LOCAL AGENCIES FOR APPROVED DISPOSAL PROCEDURES NOTE CAP ALL OPEN LINES TO PREVENT CONTAMINANTS AND MOISTURE FROM ENTERING THE SYSTEM 11 of 21 226 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 4 0 SERVICING REFRIGERANT CHARGE 4 1 Refer to Aircraft maintenance manual or ZEE Systems Inc Service Letter Z26 1 for recommended refrigerant charging service instructions 5 0 SERVICE SCHEDULES 5 1 MAINTENANCE SCHEDULE The maintenance and service schedules are ZEE Systems Inc recommended intervals Actual operating and environmental conditions may require more frequent service ITEM INSPECTION R amp R T B O DESCRIPTION INTERVAL HRS Z26 8900 EVERY 250 HRS INSPECT FOR LOOSE M C DAMAGED ITEMS CHECK FOR 2 000 SIGNS OF
8. LAT 15 of 21 726 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 8 2 ILLUSTRATED PARTS LIST 726 8900 MOTOR COMPRESSOR ASSEMBLY FIG ITEM 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NUMBER Z26 8900 1 Z26 8900 2 Z26 8900 3 Z26 8900 4 Z26 8900 5 Z26 8900 5 5741 019 5 5743 008 3 SZ58 003 1 ALT SZ58 003 2 799 800 1 799 800 1 MOD E SZ83 041 4 Z14 401 1 725 404 1 725 404 2 726 400 1 726 401 1 726 401 2 726 402 1 726 402 2 726 403 1 726 404 1 726 405 1 799 421 7 799 421 9 799 423 1 799 915 4 7226 8900 NOMENCLATURE MOTOR COMPRESSOR ASSEMBLY MOTOR COMPRESSOR ASSEMBLY MOTOR COMPRESSOR ASSEMBLY MOTOR COMPRESSOR ASSEMBLY MOTOR COMPRESSOR ASSEMBLY MOTOR COMPRESSOR ASSEMBLY SPACER PULLEY MOTOR MOTOR PULLEY SUPPORT CLEVIS ROD END SUPPORT SPACER SPACER ANGLE ANGLE BRACKET BRACKET TURNBUCKLE BARREL CLUTCH PLATE COIL ASSY PULLEY ASSY COMPRESSOR 16 of 21 OTY USAGE CODE A NOTES F MOD A A B E F A B C D MOD A A B E F REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 FIG ITEM PART NUMBER NOMENCLATURE QTY USAGE NOTES CODE 1 2 3 20 255L075 BELT 21 2701100 BELT 1 22 400649 1 I D PLATE 23 8M 1 25 NUT LOCK METRIC 24 ANAHSA BOLT 2 25 7 BOLT 4 26 ANS 11
9. TEM ALL THE WAY IN VALVE STEM CLOCKWISE TO SHUT OFF CONNECTING LINE THIS IS FRONT SEATING THIS ISOLATES THE REFRIGERANT FROM THE COMPRESSOR TURN VALVE STEM ALL THE WAY OUT COUNTER CLOCKWISE FOR NORMAL BACK SEAT SEAL OPERATION THIS IS BACK SEATING THIS ALLOWS FULL FLOW THROUGH THE VALVE WES A PT s j 4 E HOSE CONNECTION ILLUSTRATION 1 3 1 DRIVE BELT 3 20 21 It may be necessary to remove Z26 8900 Motor Compressor Assembly from the aircraft to change or adjust the belt 3 1 1 REMOVAL Extreme care should be taken during maintenance not to strike or use pullers directly against the hardened black or grey area of these pulleys as this may crack or chip the anodized surface To remove the belt break the lock wire on the turnbuckle 1 15 34 and back off the jam nuts 1 40 41 The groove on the turnbuckle indicates the end with the left hand thread Loosen the hardware 1 19 32 38 on the clevis 1 7 the attaches to the bracket on the motor and the rod end hardware 1 6 26 32 38 that 6 of 21 CMM Z26 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 attaches to the compressor Loosen the 17 mm nut 2 43 on the 10 mm bolt 2 44 that secures the compressor to the angles 3 11 12 You will need two 17 mm wrenching tools Loosen the belt tension by turning the turnbuckle to bring the pulleys closer together When the
10. belt is loose slide it off of the large compressor pulley 2 18 then the small motor pulley 1 4 4 3 1 2 INSPECTION Inspect the belt for deterioration damage and fraying Replace defective belt 3 1 4 INSTALLATION Always place the belt over the smaller diameter pulley first then carefully slide the belt over the larger diameter pulley Care should be taken to not tear the edges of the belts 3 1 5 BELT ADJUSTMENT With the belt in place turn the turnbuckle 1 15 34 until a tension with a 1 8 deflection of the belt midway between pulleys with 2 3 pound pull is achieved Tighten the 17 mm nut 2 43 that secures the compressor bolt 2 44 to torque of 30 foot pounds Secure the jam nuts 1 40 41 and secure with lock wire Tighten the hardware the attaches the clevis 1 29 32 38 to the motor and rod end 1 26 32 38 to the compressor bracket 3 1 6 Check the belt alignment before running the motor Turn the compressor pulley by hand to see that the belt is properly aligned Slight striking of the belt against the rim on the small pulleys is normal but not to the point where chafing occurs Readjust belt if necessary Next run the motor and check for smooth operation If a belt hops or flutters it is too loose If the belt is too tight against the pulley rim a discharge of fine dust like rubber particles will occur Check the condition of the smaller pulley rim and readjust belts as necessary Secure the turnbuckle jam nuts with 025 lock wi
11. e flats on the motor shaft Place the spacer and hardware 3 1 36 39 on the end of the pulley Using a spanner wrench hold the motor pulley and tighten the bolt 3 28 3 3 3 1 Attach the supports 3 5 8 and hardware 3 25 35 37 to the motor Make sure they are aligned properly or the motor pulley will not be aligned with the compressor pulley Tighten bolts and secure with lock wire 3 3 3 2 Attach the supports 3 5 8 and motor to the angles 3 11 12 tighten and secure with lock wire 3 3 3 3 Install and adjust the belt as described in section 3 1 3 3 3 4 Attach wiring to motor Refer to Wiring Diagram 1 3 4 WIRING The Z26 8900 is part of the air conditioning system The circuitry may include features to control the Condenser Power Fan clutch High Low Pressure Switch to disengage the clutch should an unsafe pressure condition exist and a motor over temp switch that will shut down the motor if the case temperature exceeds 450 F The circuits may be connected through a Terminal Block which allows for easy replacement of components Refer to the following diagrams for example circuit schematics POWER CONDENSER FAN PRESSURE SWITCH TERMINAL BLOCK COMPRESSOR DRIVE MOTOR CLUTCH COIL COMPRESSOR JUMPER WIRING DIAGRAM 1 10 of 21 CMM Z26 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 POWER CONDENSER FAN 226 20 24 1 O 726 18 JUMP
12. fer to Diagram 1 Repair as necessary Replace Power Condenser Fan Assembly REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 8 0 ILLUSTRATED PARTS LIST 8 1 EXPLANATION OF SYMBOLS ALT The Part Number shown is an approved alternate either part number may be used MOD X Refers to modification information of this part as applicable to this assembly NP Not Procurable individually see next higher assembly NS Not Shown OBS Obsolete USAGE QTY This identifies parts used on specific applications not common to all units If no code is stated the part is common to all dash numbers Part of higher assembly See explanation at end of parts list AN MS and NAS equivalent hardware is considered to be approved alternates for each other and may be used The most common are as follows PART NUMBER ALTERNATE DESCRIPTION AN345 516 MS35650 3312 NUT MACHINE AN364 624A MS21083N6 LOCK NUT AN365 428A MS21044N4 LOCK NUT AN365 832A MS21044N08 LOCK NUT AN501A10 6 MS35266 61 SCREW AN935 416 MS35338 44 WASHER LOCK AN935 516 MS35338 45 WASHER LOCK AN935 616 MS35338 46 WASHER LOCK AN935 8 MS35338 42 WASHER LOCK AN960 4 16 NAS1149F0463P WASHER FLAT AN960 416L NAS1149F0432P WASHER FLAT AN960 516 NAS1149F0563P WASHER FLAT 960 5 161 NAS1149F0532P WASHER FLAT AN960 616 NAS1149F0663P WASHER FLAT AN960 616L NAS1149F0632P WASHER FLAT AN960 8L NAS1149FN816P WASHER F
13. ire back to pin C on the terminal block Refer to Wiring Diagram 1 for schematic 3 3 MOTOR COMPRESSOR DRIVE 3 3 Prior to disassembly mark the support positions 3 5 8 for proper alignment during reassembly The mounting holes are not centered on the supports 3 8 5 and the motor is not centered between the angles NOTE USE ONLY THE SPECIFIED MOUNTING HARDWARE INCORRECT BOLT LENGTH CAN CAUSE A SHORT IN THE MOTOR WINDINGS 3 3 REMOVAL Disconnect the positive and negative leads to the motor Remove the clamp and all remaining attached wiring from the motor 3 3 1 1 Remove and set aside the belt in accordance with paragraph 3 1 3 3 1 2 Break the lock wire and remove the four bolts and hardware 1 30 36 39 that attach the supports to the angles 3 11 12 9 of 21 CMM Z26 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 3 3 1 3 To remove the supports 3 5 8 from the motor loosen and remove the four bolts and hardware 3 25 35 37 Mark their position for proper reassembly 3 3 1 4 Use a spanner wrench to hold the motor pulley 1 2 4 Loosen and remove the bolt 3 28 and hardware 3 36 39 spacer 3 1 and pulley Inspect the motor pulley for damaged or rounded teeth Replace if damaged 3 3 2 INSPECTION Refer to Service Letter 58 001 or 99 800 for brush inspection information 3 3 3 INSTALLATION Place the motor pulley on the shaft Make sure the flats of the pulley mate with th
14. re Once the belts are adjusted and all of the hardware is properly tightened no further adjustments should be necessary if the components are not disturbed 3 2 COMPRESSOR 2 19 It is necessary to remove the compressor pulley 2 18 to remove the compressor from the mounting angles Take care not to damage or loose the shims and key on the compressor shaft 3 2 1 REMOVAL If the system has back seat valves move the valve stem to the front seat position to isolate the refrigerant from the compressor then remove the back seat valves from the compressor 3 2 1 1 Disconnect the electrical connections to the terminal block or motor for the clutch 3 2 1 2 Remove the belt as described in 3 1 Remove the bolt that secures the rod end on the turnbuckle 3 2 1 3 Hold the compressor pulley stationary while removing the 14 mm 1 23 retaining nut Remove the internal snap ring not shown just under the nut Now you can slide the clutch plate 1 16 out Now slide the pulley 3 18 off the compressor Take care not to damage or loose the key or shims not shown 3 2 1 4 Loosen and remove the 17 mm 2 42 nut that secures the 10 mm bolt 2 44 Remove the 10 mm bolt and spacers 2 9 10 The compressor can now be removed from the angles 3 2 2 INSPECTION Check for signs oil leakage around the fittings 3 2 2 Check oil level of new system installation Fashion an oil dipstick from any soft metal bar as shown in Illustration Determine the angle of the
15. ring Check wiring to motor repair as required Compressor Motor Motor open Replace Motor inoperative Motor brushes worn beyond limits Short in wiring Check wiring to motor repair as required Excessive vibration at Improper belt Adjust belt to correct Motor Compressor tension tension Worn damaged or Adjust or replace loose or over mounts tightened mounts Quick refrigerant loss Open in system Check compressor head gasket Check Hoses or tubing for holes Check connections 13 of 21 CMM Z26 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 TROUBLE Slow refrigerant loss Low or no cooling Low Pressures Compressor clutch does not engage MC and Clutch start up normally Clutch disengages after a short time 226 8900 POSSIBLE CAUSE Defective O Ring Loose connections Loose connections Incorrect Back Seat Valve position Low refrigerant Low or high discharge pressures Defective Pressure Switch Defective Coil Defective wiring Power Condenser Fan defective 14 of 21 REMEDY Replace defective com ponent Service system Replace defective O Ring Service system Tighten connections Service system Tighten connections Service system Place Back Seat Valve In proper position for normal operation Service as necessary Check refrigerant charge Service as necessary Replace Pressure Switch Replace Coil Re
16. s Commercially Available External Snap Ring Pliers Commercially Available Spanner wrench Commercially Available Graduated Cylinder Commercially Available 4 of 21 226 8900 REV IR 1 28 06 ZEE Systems Inc COMPONENT MAINTENANCE MANUAL 726 8900 Leak Detector for HFC 134a Commercially Available Power Supply capable of 28VDC 50 Amps Commercially Available Refrigerant Recovery Recycle equipment Commercially Available meeting SAE J1990 or J2209 specifications Manifold Gauge Set R 134a with Commercially Available automotive service connections Refrigeration Vacuum Pump Commercially Available Scale with 0 1 Ib increments minimum Commercially Available 2 1 2 Refer to applicable ZEE SYSTEMS Service Letter s for any additional special tools which may be required to service the air conditioning system 2 2 MATERIALS The following material may be required to perform maintenance described in this manual ITEM SOURCE MS20995C25 Lock Wire Commercially Available Refrigerant HFC 134a Commercially Available NOTE When servicing the air conditioning system always use virgin refrigerant DO NOT use recovered refrigerant PAG Lubricant Refrigeration HFC 134a Commercially Available Sanden SP 20 PAG or equivalent Commercially Available MOPAR 82300349 PAG Commercially Available PAG 100 Commercially Available NOTE PAG oil absorbs atmospheric moisture very quickly Never leave the compressor or
17. t Maintenance Manual provides information on the maintenance maintenance schedules and repair and replacement of parts 1 2 Refer to the Illustrated Parts List IPL in Section 5 when using this manual or ordering replacement parts Parts are identified in parenthesis FIG ITEM NO 1 3 This Motor Compressor MC Assembly is part of a vapor cycle air conditioning system The refrigerant is R 134a HFC 134a 1 3 1 In some installations the compressor is equipped with back seating shut off valves If the compressor has back seating valves always check the position of the stem prior to operating the unit The unit should be run with the valve in the back seat position stem full counter clock wise out ONLY Refer to the Illustration 1 for back seat valve operation NOTE UNITS ARE SHIPPED WITH THE BACK SEAT VALVE IN THE FRONT SEAT POSITION TO PREVENT OIL LEAKAGE DURING TRANSIT ALWAYS PLACE THE VALVE IN THE BACK SEAT POSITION AND REPLACE THE SEAL CAP PRIOR TO OPERATION IMPROPER VALVE POSITION COULD CAUSE DAMAGE TO THE COMPRESSOR SEE ILLUSTRATION I 2 0 SPECIAL TOOLS AND EQUIPMENT 2 1 TOOLS The following special tools are required to perform the maintenance described in this manual ITEM SOURCE Dip Stick Compressor Oil Refer to Illustration 2 Belt deflection gauge Commercially available 14 mm socket Commercially Available 17 mm wrenches sockets Commercially Available Feeler Gauges Commercially Available External Snap Ring Plier
18. ut loose enough to adjust the belt 3 2 5 1 Slide the compressor pulley 2 18 assembly on the compressor 3 2 5 2 Align the key way and place the clutch plate 1 16 on the compressor shaft Install the internal snap ring Replace the 14 mm 1 23 retaining nut and torque to 11 15 Ib ft 15 21 N m 3 2 5 3 Check the air gap between the clutch plate and the pulley with the feeler gauge that a clearance of 016 0317 0 4 0 8mm If the gap 15 not even around the clutch gently tap down at the high spots If overall air gap is out of specification remove the clutch plate and add or subtract shims as necessary 3 2 5 4 Remove the bracket 1 14 from the defective compressor and attach the bracket to the replacement compressor and tighten 3 2 5 5 Attach the rod end 1 6 of the turnbuckle to the bracket 1 14 on the compressor Do not fully tighten at this time 3 2 5 6 Attach and adjust the belt as described in Section 3 1 through 3 1 6 3 2 5 7 Check the operation of the clutch plate 1 16 and coil 1 17 If the wires are connected to a terminal block or strip DO NOT apply power directly across pins C and D on the terminal block Remove the wire from the compressor coil at pin C on terminal block Apply 28 VDC across the compressor coil wire and pin D on the terminal block The clutch should pull in to the pulley Remove power and the clutch should release move away and the pulley will be free Connect the coil w
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