A Series UP90 UP120 UP150 UP170 Compressor Service Manual
Contents
1. 6mm Hex Clutch wrench Torque wrench Snap ring pliers Shaft Snap ring pliers Hole Remover pulley Plastic hammer Thickness guage Bolt torque specifications Description Bolt diameter mm Part number Tightening torque Nem Housing cap bolts 14 7 1 High low service valve 11 741 Blind plugs 117 1 Clutch armature bolts 13 7 El Service tools u Genuine Unicla tools Optional generic tools EF 03301 00084A PJ 03301 001170 EJ 03301 00914A 03301 B 03301 03301 03301 FJ 03301 000570 010050 001120 000600 000610 4 lt f q y 03301 203301 03301 P 03301 E 03301 03301 000360 000620 000630 000640 000650 000660 03301 5 03301 03301 E 03301 E 03301 FT 03301 000380 000430 000420 000410 000400 8 Removal of clutch assembly I Removal of fixing screw on armature Tools required Stand Clutch wrench e Wrench 10mm Socket Procedure Place the compressor on the stand Hold clutch by inserting the claws of the clutch wrench into the holes on the armature Remove the centre bolt by using the wrench II Removal of armature Tools required Hub remover Wrench Procedure Pull the armature upwards lll Removal of snap ring Tools required Snap ring pliers shaft Procedure Remove the snap ring with the snap ring pliers IV Removal of pulley assembly Tools required Remover pulley Wrench Pulley pad Pro2. A Series UP90 UP120 UP150 UP170 Compressor Service Manual A Group Compressor Service Manual Table of contents 1 Specifications UP90 UP120 UP150 UP170 Magnetic clutch Rear cap 2 Component part list Compressor part numbers 3 II Exploded view 3 Service Service tools part numbers 5 Bolt torque specifications 5 Service tools 6 Removal of clutch assembly 7 Magnetic clutch installation 8 Removal of lip seal 9 Installation of lip seal 9 Installation of lip seal continued 10 Disassembly of body 10 Disassembly of body continued 11 Assembly of body 11 Assembly of body continued 12 System oil quantity 13 Oil type and grade 13 Copyright 2007 All rights reserved No part of this document shall be reproduced in whole or in part without the permission of Unicla International Ltd This includes reproduction or copies in any form or by any means including photocopying printing or electronic media IMPORTANT DISCLAIMER This is a guideline document containing professional information using representative graphs charts and tables Manufacturers specifications must be consulted for specific guidelines and performance data Unicla published data specific to all models is available in promotional literature and from Unicla International Ltd on request or through your Unicla supplier Unicla International Ltd expressly disclaims all and any liability and responsibility to any person or business as a result of any actions
3. cedure Remove the pulley assembly with the remover V Removal of coil 3 bolt type Tools required Standard screwdriver Procedure Remove 3 M5 bolts with screwdriver Removal of coil snap ring type Tools required Snap ring pliers shaft Procedure Remove the snap ring with pliers as shown VI Inspection of clutch components 1 Armature Contact surface must be clean smooth and unmarked with no abnormal scoring 2 Pulley Contact surface must be clean smooth and unmarked with no abnormal scoring 3 Coil Wiring harness must be in good condition Armature wrench Clutch Magnetic clutch installation Driver I Installation of coil 3 bolt type Tools required Stand Standard screwdriver Wire Procedure Tighten 3 M5 bolts wire must be visible at 3 o clock position when viewed from the front Tightening torque 4 9 1 Nem Installation of coil snap ring type Tools required Stand Snap ring pliers shaft Procedure Install the snap ring into the groove II Installation of pulley Tools required Pulley installer Plastic hammer Procedure Place the pulley on the nose top and install it by tapping on the installer until it stops Do not tap if the pulley is not located correctly lll Installation of clutch snap ring Tools required Snap ring pliers shaft Procedure Install the snap ring into groove tapered side up IV Installation of s
4. ge lines are less than 6 metres in length 30 for all A group compressors 90 170cc in applications where suction and discharge lines exceed 6m in length Example Calculate oil charge as 20 of refrigerant charge 2 kg charge 2000 g x 20 400 ml cc of oil If fitting a UP UX170 compressor then deduct the compressor initial oil charge to determine amount of oil to be added Therefore 400 160 240cc oil to be added to system Oil type and grade Each Unicla A Group compressor is fitted with either PAG oil Unidap 7 or POE oil Unidap 3 is fitted to F series compressors When adding oil to the system Unicla oil must be used Warranty is void if these guidelines are not followed Application Low side Oil Saturation Separator Compressor Refrigerant Oil Type Viscosity Viscosity Model Unicla 40C UP UX R134a Unidap7 4801 10 51 Airconditioning gt 0 C Optional 90 120 150 170 UPF R404a Unidap 3 32 5 5 8 Airconditioning gt 15 C Required 90 120 150 170 The following labels will determine the type of oil in each A group or F series compressor XS Sa POEtype 170544 Y 7P PAG type mi j Pa POE fitted to F series Uni ae compressors Storage guidelines Evacuate compressor for 3 minutes and fill with nitrogen N at 0 1 0 2 MPa ll Place the compressor in a clean and dry area with low humidity and tag with details Ill Keep compressor away from direct su
5. hims and armature Tools required Guide pin Procedure Install the guide pin into the centre threaded hole of the shaft and select shims T 0 1 0 3 and 0 5mm to ensure the clutch clearance as in figure V Installation of armature Tools required Clutch wrench Torque wrench 10mm Socket Procedure Install the M6 bolt by holding the clutch wrench on the holes 3 positions on the armature Tightening torque 13 7 1 Nem VI Air gap Tools required Thickness guage Procedure Ensure clutch clearance is correct all around 0 3mm lt Gap lt 0 6mm Removal of lip seal I Removal of the felt ring F Lipseal remover Tools required Lipseal remover Procedure Insert the remover into the recess of the felt seal and turn around lightly and pull Remove the felt on the shaft by hooking with the needle tool II Removal of snap ring Tools required Snap ring pliers hole Procedure Remove the snap ring slowly with pliers as shown in the figure lll Removal of lip seal Tools required Lipseal remover Procedure Insert the remover into the recess of the seal and turn around lightly and pull IV Inspection of lip seal 1 Felt seal should be dry 2 Snap ring must be in one piece and not deformed 3 Lip seal contact surface must be clean smooth and unmarked with no abnomal scoring Installation of lip seal I Setting the guide sleeve Tools required Stand Guide sleeve Seal ins
6. nch Hexagon socket 6mm e Thickness guage Procedure Tension the M8 Hexagonal flange bolts 4pcs diagonally alternately and carefully Check the rear cap clearance as specified 0 2 lt Gap lt 0 6mm Tightening torque 14 7 1 Nem V Installation of lipseal Refer to page 9 for instructions VI Test working assembly rotation Tools required Shaft rotating handle Procedure Install the handle into the front section to check the shaft rotates smoothly VII Filling compressor oil Procedure Fill the following amount of oil into the drain hole as shown in the photo Ensure drain is correctly plugged Standard oil type Unidap 7 PAG or Unidap 3 POE Amount of oil UP150 170 160 10 cc UP90 120 140 10 cc Vill Drain plug Procedure Tighten drain plug Tightening torque 11 7 1 Nem plate Suction plate wrench Ma er F 0 2 lt Gap lt 0 6mm Thickness gauge Shaft rotating handle System oil quantity The correct amount of oil must be maintained in the compressor and system Long hose runs and dual evaporator systems must have additional oil added to the system Severe oil starvation problems may result from insufficient system oil being allowed To determine oil quantity required Unicla recommends a calculation as a percentage of refrigerant charge as follows e 20 for all A group compressors 90 170cc in standard applications where the suction and dischar
7. nlight IV Store the compressor horizontally on a flat even surface V Do not store the compressor in temperatures above 30 C V Place the compressor in a well ventilated area to avoid corrosion damage The contents of this manual are subject to change without prior notice 13 ny ____________ Unicla International Limited Unit 1209 1210 12F Manhattan Centre 8 Kwai Cheong Rd Kwai Chung N T Hong Kong Phone 852 2422 0180 Fax 852 2422 0680 Email salesaunicla hk Website www unicla hk Unicla Cat No M1003
8. taken on the basis of information in this publication Specifications Compressor Model UP 90 Nunberofofindes 10 Compressor Model UP 120 Numberofeyindes 110 ame Compressor Model UP 150 Nunberofofindes 10 Compressor Model UP 170 Nunberofofindes 10 Magnetic clutch Clutches available for Unicla A series compressors pulley diameter mm and voltage Type Rear cap for UP90 120 150 170 Rear caps and hose ports available for Unicla A series compressors Cap type Hose port No charging ports With charging ports hat 1 U Vertical Hose Ports With CC Vu C 2 D Horizontal Hose Ports charging E y 3 FN Flange Hose Ports ports ha agar 4 Relief valve is also available on the cap 5 5 Use the type no s shown in each box when selecting compressor model Compressor parts Item Description UP90 UP150 21404 Rearvalveplate A 93204 000060 _ A 93204 000060 7 Lip seal assy 93503 000040 92503 000040B 2 92503 000040A 00 11950 10400 11961 10400 Plug 13201 000010 E ju 21 91915 08035 1 1 1 1 NO 5 6 7 8 9 Exploded view Service tool part numbers No Description Working assembly bench Stand rear mount Stand front Hub remover clutch Pulley pad Remover lip seal Installer lip seal Shaft rotating handle Guide pin Guide sleeve Installer pulley Socket 10mm Socket
9. taller Procedure Place compressor on the stand Lubricate outside of the guide sleeve and insert into the shaft of the compressor Caution the sleeve must be clean and unmarked II Installation of lip seal Tools required Guide sleeve Seal installer Procedure Slide the lipseal over the guide sleeve Place the installer on the lip seal correctly and press the lipseal with the installer until it stops Then remove the guide sleeve Installation of lip seal continued III Assembly of the snap ring Tools required Snap ring pliers hole Seal installer Procedure Insert the snap ring into nose section tapered part of the snap ring must be facing downwards Push the snap ring downward with the installer and fit into the groove IV Assembly of the felt seal Tools required Installer seal Procedure Install the felt seal into the nose section Push the felt seal until it touches the snap ring Disassembly of the body Caution O ring should not be reused I Removal of oil Procedure Remove the drain plug and drain the oil Il Removal of lipseal Refer to page 9 for instructions lll Removal of the bolts on rear cap Tools required Socket wrench Socket 6mm hex Stand Procedure Remove the M8 securing bolts 4pcs from the rear Cap IV Removal of the rear cap Procedure Remove the rear cap by gently inserting a screw driver or lever into the recess Lever all around not just at one posi
10. tion Caution Do not damage the cap or body Disassembly of the body continued V Removal of rear valve Procedure Remove gasket valve plate and suction valve VI Removal of front valve and working assembly Procedure Remove the working assembly by pressing the end of the shaft into the front of the body as shown After removal of the cylinder remove gasket valve plate and suction valve from the front side Assembly of the body I Installation of the O ring for rear cap Procedure The o ring must be free from marks and dust Thoroughly lubricate new o ring properly and insert into the groove Ensure the o ring is lying straight in the groove without a twist II Installation of rear valve plate and working assembly Tools required Working assembly bench Procedure Stack suction plate valve plate and gasket on locating pins of rear cap in sequence as shown in the figure Place the working assembly on rear cap lll Installation of front valve plate and body Tools required Working assembly bench Procedure Stack suction plate valve plate and gasket on locating pins of working assembly Slide body over working assembly until it stops on the working bench guide 11 Suction _ Valve _ Gasket plate e Gasket plate Suction valve Valve Assembly of the body continued IV Inspection tightening and clearance of the rear cap Tools required Torque wre
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