35391B Reva
35391B Reva
Compressor Manual
Models: 440, 450, 450XL, and 460
VPN 35391B June 2003 Rev_00 Price$60.00
TABLE OF CONTENTS This manual consists of the following sections: EXTENDED STORAGE PROCEDURES INSTALLATION INSTRUCTION SECTION This section should be read thoroughly before attempting to install a VMC Compressor. IMPORTANT: Local codes and ordinances should be checked beforehand so that violations do not occur, especially concerning devices for control and safety. COMPRESSOR OPERATION SECTION COMPRESSOR SERVICE SECTION COMPRESSOR REPLACEMENT PARTS SECTION Section 100R Section 102R Section 105R Section 105X
AUTO
In the Auto Position, the stop valve is operating as a check valve, allowing flow in the directions of the arrows. To set the valve to the automatic position, fully close the valve, and turn the stem out as indicated by the chart below.
CLOSED
In the manually Closed Postion, the stop check is operating as a convientional stop valve, not allowing flow in either direction.
OPEN
In the manually Open Position, with the valve stem fully back seated, the valve disc is lifted slightly, allowing flow in either direction.
Verify the location of Spring and note the direction of the Vilter name
Installation:
The new design will apply only to the 2 thru 4 stop valves. Retrofitting a field installation will require replacing the bonnet assembly.
The bonnet must be installed with the spring towards the bottom (see illustrations above). The drill fixture is designed so that the hole for the spring will always be drilled on the opposite side from the cast in Vilter name on the bonnet. From the outside of the valve, the casting numbers must always be towards the top of the valve.
P28 and P128 Series Lube Oil Controls with Built-in Time Delay Relay
The P28 and P128 Series Lube Oil Controls provide dependable and economical oil pressure cut-out for pressure-lubricated refrigeration compressors. The field-adjustable pressure differential of these controls provides compressor operation according to the manufacturers specifications. The P28 and P128 controls operate by measuring the net lube oil pressure and de-energizing the compressor if the pressure falls below the differential setpoint. Manual or automatic reset models are available with factory set and sealed time delays of 30, 45, 60, 90, or 120 seconds (all time delays may not be available on all models). The P128 is the same control as the P28 but with 1/4 inch male flare pressure connections.
Figure 1: P128AA
1998 Johnson Controls, Inc. Part No. 24-7664-605, Rev. A Code No. LIT-125420
I ntroduction
!
Dimensions
WARNING: Personal injury hazard. All P28 and P128 controls are designed as lubrication protection controls. Failure of the P28 or P128 could allow the refrigeration compressor to be damaged in a way that may not be apparent upon visual inspection. Follow proper procedures and the compressor manufacturers instructions, as well as any warning signs on or around the equipment, when discharging and disassembling the compressor. Environmental damage hazard. If leakage of sensed media (such as refrigerant or oil) can be harmful to the environment, or hazardous in any way, user must provide for proper containment. The P28 and P128 controls measure the net oil pressure available to circulate oil throughout a pressure-lubricated refrigeration system. The net oil pressure is the difference between the oil pressure at the pump discharge and the refrigerant pressure in the compressor crankcase. Example: If the oil pressure pump discharge reading is 90 psi (621 kPa) and the crankcase pressure is 70 psi (483 kPa), the net oil pressure is 20 psi (138 kPa). The P28 and P128 have a built-in time delay relay. This relay allows the oil pressure to build up for the time delay period before the compressor trips. This also prevents nuisance lockouts due to intermittent loss of oil pressure. The time delay relay is a trip free device. The manual reset cannot be overridden by pressing and holding the reset button. Manual reset models are available with time delays of 30, 45, 60, 90, or 120 seconds. Automatic reset models are available with a 90-second time delay. The time delay relay is compensated to minimize the effect of ambient temperature variations. However, the time delay relay will be affected by voltage variations.
O peration
When the compressor starts, the timer is energized because the net oil pressure of the system is zero. During normal operation, the net oil pressure should build up to the pressure switchs cut-out setting (scale setting) plus the switch differential (3 to 5 psi [21 to 34 kPa]) within the required time delay, causing the time delay relay to de-energize. If the net oil pressure does not rise to the cut-out pressure setting plus the switch differential within the required time delay, the time delay relay trips and stops the compressor. If the net oil pressure drops below the cut-out pressure setting during the compressors run cycle, the time delay relay energizes. If the net oil pressure returns within the time delay, the time delay relay deenergizes and the compressor continues to operate normally. If the net oil pressure does not return within the time delay, the control shuts down and locks out the compressor.
2 PP28 and P128 Series Lube Oil Controls with Built-in Time Delay Relay Product/Technical Bulletin
Example: Net oil pressure (oil pump pressure minus crankcase pressure) required to the bearings is 9 psi (62 kPa). The control scale setting should be 9 psi (62 kPa). The switch differential is 5 psi (34 kPa). Upon initial start of the compressor, the time delay relay energizes. If the net oil pressure does not build up to 14 psi (97 kPa), or the scale setting (9 psi) plus the switch differential (5 psi), during the time delay, the control breaks the circuit to the compressor. If the pressure of 14 psi (97 kPa) is reached during the time delay, the time delay relay de-energizes and the compressor continues to operate normally.
Pressure Connections
Avoid sharp bends or kinks in the capillary or tubing to avoid damage to the capillary. Coil and secure excess capillary or tubing. Because harmonic vibration can break the capillary or tubing, some slack must be provided. Do not allow the capillary or tubing to rub against metal surfaces where friction can cause damage. When using a control with 1/4 in. / 6.4 mm tubing, a pulsation damper must be used. Pulsation can cause excessive wear and damage the control.
I nstallation
Mounting
A P28AN or P28DN control used for ammonia service must be mounted separately from the electrical cabinet. An ammonia leak could damage the electrical circuitry. Do not use Johnson Controls/Penn Ecosafe hose tubing in applications with ammonia or other corrosive refrigerants. Corrosion could cause tube breakage and refrigerant leakage. Use only the mounting screws supplied with the control. Damage to internal components may occur if other screws are used.
1. Purge all tubing and lines before connecting the pressure control. 2. Connect the oil pressure line pump discharge to the pressure connector labeled OIL. 3. Connect the crankcase pressure line to the pressure connector labeled LOW. 4. Coil and secure excess capillary or tubing to avoid vibration.
Wiring
The P28 and P128 controls are not position sensitive and can be mounted in any position. Use the two mounting screw holes located on the back of the control case to mount the control directly to a wall or panel board. Mount the control so that the pressure connections on the bellows are above the crankcase liquid level of the equipment being controlled. Note: When mounting the control to a compressor is required, a mounting bracket (Part No. 271-51) is available.
G
WARNING: Shock hazard. Disconnect all power supplies before making wiring connections to avoid electrical shock or damage to the equipment.
Make all wiring connections using copper conductors only. Wire in accordance with National Electric Code and local regulations. For maximum electrical rating of the control, see the label inside the control cover. Use the terminal screws furnished (8-32 x 1/4 in. binder head). Substitution of other screws may cause faulty connections.
PP28 and P128 Series Lube Oil Controls with Built-in Time Delay Relay Product/Technical Bulletin 3
See Figures 3 through 10 for typical wiring diagrams or refer to the compressor manufacturers specifications. When the P28 or P128 control is supplied with a Terminal 3, it may be wired to operate a runlight for indicating when there is sufficient net oil pressure. When the control is supplied with a Terminal A, it can be wired to operate a shutdown alarm or signal for indicating when the compressor has tripped. For applications using a 208V control circuit, it is suggested that one leg of the 208V circuit and a neutral or ground wire be used as a 120V source to power the time delay relay.
When a P28 or P128 is installed on a 440 or 550 VAC system, use an external step-down transformer to provide either 120 or 240V to the pilot and time delay relay circuits. The transformer must be of sufficient volt ampere capacity to operate the motor starter and the time delay relay. Table 1 presents the power requirements for the P28 or P128 time delay relay. Table 2 presents the electrical ratings.
240V
30 VA
Pilot Circuit
750 VA, 120/240 VAC 125 VA, 24 VAC 57.5 VA, 24 VDC
Alarm Circuit*
10W Tungsten, 120/240 VAC 125 VA, 24 VAC 57.5 VA, 24 VDC
Runlight** (Terminal 3)
10W Tungsten 10W Tungsten
* Must be the same voltage as the pilot circuit. ** Must be the same voltage as the time delay relay circuit.
L ow
1 20 /24 0 M od els 3 1 2 40 L TD 1 M A DR
L ow
L ow Volta ge M od els 3 1 PC 2 P C 1 TD 2 2 H 2 4*
PC2
P C 1 TD 2 2 H 1 20
L TD 1 M A
O il
O il
P C 1 - P re ssu re actu ated con ta cts. O pe n on increa se in pre ssu re differe nce be tw e en o il an d lo w p ressure con ntecto rs. M a ke s a nd brea ks tim e de la y he ate r circu it. P C 2 - C o nta cts clo se sim ulta ne ou sly w he n P C 1 co ntacts o pe n (run ligh t circu it). TD 1 - Tim e d elay re la y. C on ta cts op en a fte r tim e d elay interval if p ressure d ffere nce be tw e en o il an d lo w p ressure con ne ctors is n ot e sta b lish ed or m ainta in ed. TD 2 - C o nta cts clo se sim ulta ne ou sly whe n TD 1 co n tacts o pe n (alarm circu it). D R - Vo ltag e dro pp in g resisto r u se d in d ua l vo lta ge m od e ls. H - H e ate r for tim e de la y relay. C o nn ect Te rm in als L a nd M a s a sing le po le sw itch . C o nn ect Te rm in als 2 a nd 2 40 o r 1 20 to e ne rgize circu it on ly w h en m otor sta rte r is closed .
Figure 3: P28 or P128 Internal Wiring Circuit, Showing Alarm Circuit and Runlight Terminals
4 PP28 and P128 Series Lube Oil Controls with Built-in Time Delay Relay Product/Technical Bulletin
2 40 V 3 -ph ase L1 L2 L3
A n y Vo lta ge C2 L1 C4 C3 R u nlig ht if U sed 2 40 3 1 L M A 2 40 or 1 20 V O pe ra tin g C o ntrol T1 T2 M otor A d ditio na l co ntrols in th is lin e on ly. T3 2 * L2 L3
C ra nkcase H e ate r W h e n U se d* 2 40 1 2 L M A 1 20 P 2 8 or P 12 8
O pe ra tin g C o ntrol
T1
T2
T3 A larm if U sed
M otor
1 20 P 2 8 or P 12 8
Figure 4: P28 or P128 Used on a 240V System with 240V Magnetic Starter Coil
Figure 6: P28 or P128 Where Separate Supply is Provided for Control Circuit (Jumper between 2 and M [or L] must be field installed.)
4 40 V 3 -ph ase L1 L2 L3
C ra nkcase H e ate r W h e n U se d*
R u nligh t if U sed 2 40 3 1 L 2* M A 1 20 P 2 8 or P 12 8
O pe ra tin g C o ntrol
C3
T1
T2
T3
A larm if U sed
A larm if U sed
2*
Figure 5: P28 or P128 Wired for 3-wire Control (Jumper between 2 and M [or L] must be field installed.)
*W h en cra nkca se h ea te r is u sed , d iscon ne ct ju m p e r 2 to M a nd reco nn ect 2 to L . A lso, m ake su re th at co ntrol circuit tra nsfo rm er ha s su fficie nt ou tp ut for ad ditio n al lo ad .
Figure 7: P28 or P128 Wired for 440V Supply and 240V Magnetic Start Coil (Also for 550V Using Proper Transformer) (Jumper between 2 and M [or L] must be field installed.)
PP28 and P128 Series Lube Oil Controls with Built-in Time Delay Relay Product/Technical Bulletin 5
2 40 V 3 -ph ase S tart C2 C ra nkcase H e ate r W h e n U se d* 3 1 A larm if U sed L T1 T2 M otor A d ditio n al co ntrols in th is lin e on ly. T3 R u nlig ht if U sed 2 40 C3 S top
O il L ow
C o m p re ssor M otor
O pe ra tin g 2 40 V C o ntrol
L1 L2 L3
L1
L2
L3
P 7 4A A
L ow
P 2 8/P 12 8
1 2 M 240 L
T1
T2
T3
O il
Jun ctio n B ox A
2 * M
1 20 P 2 8 or P 12 8
N o te: Th is system w o uld p ro vide shu td ow n o n low lu be o il pressu re in e ith er of tw o com presso rs o pe rated by the com m on m otor.
Figure 10: P28 or P128 and P74AA Wired for an Oil Pressure Control System Where One Motor Operates Two Compressors
Figure 8: P28 or P128 Where Manual Start-Stop Pushbutton Station is Used (Jumper between 2 and M [or L] must be field installed.)
Adjustments
The P28 and P128 controls are shipped with a cut-out pressure differential of 9 psi (62 kPa). However, the controls can be adjusted according to the compressor manufacturers specifications. Note: When the controls are shipped as an accessory to the compressor unit, time delay and cut-out pressure are set to manufacturers specifications. Replacement controls should duplicate the manufacturers specifications.
Tra nsfo rm er L1
2 40 V 3 -ph ase L2 L3
A larm if U sed 3 1 2 L M
S ta rte r C o il
!
O pe ra tin g C o ntro l T1 T2 T3 M otor
CAUTION: Equipment damage hazard. To avoid damage to the compressor, obtain the compressor manufacturers net oil bearing pressure specifications as soon as possible. If necessary, reset the cut-out pressure difference to the manufacturers specifications.
Figure 9: P28 or P128 Where 24V Control Circuit Power is from a Step-down Transformer (Jumper between 2 and M must be field installed.)
When the manufacturers specifications are not known, proceed as follows to set the cut-out pressure differential: 1. With the compressor running, read the oil pressure and the crankcase pressure. 2. Subtract the crankcase pressure reading from the oil pressure pump discharge reading. This is the net oil pressure to the bearings.
6 PP28 and P128 Series Lube Oil Controls with Built-in Time Delay Relay Product/Technical Bulletin
3. Set the cut-out pointer 6 to 8 psi (41 to 55 kPa) below the established running net oil pressure with the Adjusting Disk using a standard screwdriver. To increase the cut-out pressure, turn the Adjusting Disk counterclockwise. To decrease, turn clockwise. To raise the pressure differential, turn the Adjusting Disk (see Figure 2) to the left when viewing the front of the control. Turn the adjusting disk to the right to lower the pressure differential.
3. Apply power to start the compressor. The time delay relay should trip after the time interval and stop the compressor. 4. Remove power from the control and remove the jumper between Terminals 1 and 2. 5. Replace the cover on the control and apply power. 6. Manually reset the time delay relay if required.
C heckout Procedure
Before leaving the installation, observe at least three complete operating cycles to be sure that all components are functioning correctly.
F ungus Proofing
WARNING: Shock hazard. Disconnect power from the control before testing for shutdown to avoid electrical shock or damage to the equipment. Fungus proofing can be supplied at extra cost when specified. Conforms to government specifications MIL-V-173A.
To test for shutdown: 1. Remove power from the control and remove the control cover. 2. Connect a jumper between Terminals 1 and 2. See Figure 3 for terminal locations. Note: If the control is mounted on a condensing unit where air from auxiliary equipment (blowers or fans) may strike the control, the control cover should be replaced before proceeding to Step 3.
Voltage
120/240 VAC 120/240 VAC 120/240 VAC 120/240 VAC 24 VAC/VDC 120/240 VAC 120/240 VAC 120/240 VAC
Reset Type
Manual Manual Manual Automatic Manual Manual Manual Manual
Timing in Seconds
60 90 90 90 120 30 120 45
Alarm Circuit
No No Yes No No No No No
PP28 and P128 Series Lube Oil Controls with Built-in Time Delay Relay Product/Technical Bulletin 7
O rdering Information
Table 4: Ordering Information
Series Part Number
P28AA P128AA P28AN P28DA P28DN P28GA P28NA P28PA
Pressure Connections*
Style 13, Style 5, or Style 15 Style 5 Style 15 Style 13 Style 15 Style 13 Style 13 or Style 5 Style 5
Reset Type
Manual Manual Manual Manual Manual Automatic Manual Manual
Refrigerant
Non-corrosive All-range Non-corrosive All-range Ammonia Non-corrosive All-range Ammonia Non-corrosive All-range Non-corrosive All-range Non-corrosive All-range
Alarm Terminal
No No No Yes Yes No No No
Runlight Terminal
No No No Yes Yes No No No
* Style 5 connections are 1/4 in. / 6.4 mm SAE male flare connectors (no capillary tubing). Style 13 connections are 36 in. / 914 mm capillary tubing and 1/4 in. / 6.4 mm flare nut. Style 15 connections are 1/4 in. / 6.4 mm female National Pipe Thread connectors.
S pecifications
Product Power Requirements Pressure Specifications P28 and P128 Series Lube Oil Controls with Built-in Time Delay Relay See Tables 1 and 2. Adjustable Cut-out Pressure Difference: 8 to 70 psi (55 to 483 kPa)* Maximum Differential: 70 psi (483 kPa) Maximum Working Pressure: 250 psig (1724 kPa) on the high side Maximum Overpressure: 325 psi (2240 kPa) oil and low side pressure *The time delay relay is de-energized 3 to 5 psi (21 to 34 kPa) above the cut-out scale setting. Enclosed Dust-protected Pennswitch 32 to 104F / 0 to 40C Case: 0.062 in. / 1.6 mm Galvanized Steel Cover: 0.028 in. / 0.7 mm Cold Rolled Steel (plated and painted) Flat Surface or with a Universal Mounting Bracket (Part No. 271-51) Large 8-32 x 1/4 in. Binder Head Screws UL Guide No. SDFY; File SA516** CSA Class No. 1222 01; File LR948** **Most models. Contact Johnson Controls for a complete listing. 5.66 x 5.32 x 2.09 in. / 144 x 135 x 53 mm 3.0 lb / 1.36 kg
Pressure Switch Units Ambient Operating Conditions Material Mounting Wiring Terminal Agency Listings
The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these specifications, consult the local Johnson Controls Refrigeration Application Engineering at (414) 274-5535. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products.
Controls Group 507 E. Michigan Street P.O. Box 423 Milwaukee, WI 53201
8 PP28 and P128 Series Lube Oil Controls with Built-in Time Delay Relay Product/Technical Bulletin
Features
Long life contact structure with high contact force right up to break -- no bounce on make. Make reset models are trip-free. Ranges available to cover most applications. Auxiliary contact can be used to actuate an alarm circuit when the main contact opens. Two-pole construction provides a number of application advantages (see General Description). Heavy gauge low profile stainless steel element cup to protect against mechanical damage. Fig. 1 -- Single function temperature control, Style 1.
General Description
The A70 controls provide dependability and quality at attractive prices. The A72 DPST controls provide a number of application advantages such as: Control of polyphase motors without use of magnetic starters where protection against overloading and single phasing is otherwise provided. Provides two separate control circuits necessary for the control of multiple systems. One set of contacts breaks the hot line when wired as a twopole switch in single-phase circuits. Permits control of two separate load circuits. Automatic control of heavy electrical loads. All A70, A72 controls have a single calibrated scale which shows directly both cut-in and cutout settings. Adjustments can be made readily without removing the cover.
Specifications
Optional Constructions
Adjusting Knobs May be supplied on differential or range adjusting screw for limited adjustment within specified limits. Adjustment Cutout Stops Cutout stops, factory set as specified. Bulb and Capillary Standard bulb and capillary are copper. Stainless steel, monel and steel bulbs are available, if required. Bulb and capillary with neoprene coating to military specifications MIL-R-3065, Grade SB-515-ABFF may be supplied at additional cost. Capillary length 6 ft (1.8 m) only. Bulb Wells Supplied at extra cost, when specified. Capillary Tubing Standard temperature elements supplied with 6 ft (1.8 m) capillary. Extra length tube available at additional cost. Longer capillary tube supplied up to 10 feet (3 m) in 2 foot (0.6 m) increments; over 10 feet (3 m) in 5 foot (1.5 m) increments. Contact Action Open on rise or close on rise as specified.
Covers Standard finish is gray enamel. Stainless steel covers available at slight additional cost for exposed installations. Fungus Proofing Supplied at extra cost, when specified. Conforms to government specifications MIL-V-173A. Manual Reset Provides lockout which requires manual reset before a restart is possible. Manual reset is tripfree and cannot be blocked or tied down. Button must be pressed and released before operation will resume.
Metric Scale Plates Temperature models are available with Celsius plates. Mounting Brackets Controls are supplied less bracket unless specified. Controls may be supplied with mounting brackets at additional cost. Part No. 271-350 is standard.
Temperature Elements Standard temperature element styles are shown on Page 5. For styles other than shown, please check with the nearest Johnson Controls district office or Customer Service.
Knob
Conduit Opening
Misc.
Single-Pole
A70AA A70AQ A70BA A70DA A70GA A70HA A70JA A70KA Open Low Open Low Open Low Open High Open Low Open Low Open High Open High 1 1 1 1 1 1 1 1 No Yes No No No No No No 1/2 in. 1/2 in. 1/2 in. 1/2 in. 1/2 in. 1/2 in. 1/2 in. 1/2 in. Reverse Acting Aux. Contact Reverse Acting Aux. Contact Reverse Acting Aux. Contact Reverse Acting Aux. Contact Manual Start
Two-Pole
A72AA A72AC A72AE A72AP A72CA A72CE Open Low Open Low Open Low Open Low Open High Open High 2 2 2 2 2 2 No No No No No No No No No No No No 3/4 in. 3/4 in. 3/4 in. 3/4 in. 3/4 in. 3/4 in. Outdoor Case No Cover Outdoor Case Manual Start
Specifications
Fig. 1: P74 Differential Pressure Control with Style 13 elements. On a proof of flow application in a water chiller system the control activates a light or signal to indicate a loss of water. The control may also be applied as a lube oil pressure sensing control on refrigeration compressors. They may be used in combination with P28 and/or P45 oil pressure cutout controls on two compressor, single motor units to reduce the oil system cost. (See Fig. 4.) Special low pressure models are available for variable speed and screw compressor oil pressure applications. All Series P74 differential pressure controls are designed for use only as operating controls. Where an operating control failure would result in personal injury and/or loss of property, it is the responsibility of the installer to add devices (safety, limit controls) or systems (alarm, supervisory systems) that protect against, or warn of, control failure.
2004 Johnson Controls, Inc. Part No. 997-545, Rev. C Code No. LIT-125490 1
Features
Heavy duty, low profile elements withstand unduly high overrun pressures that may be encountered in shipment or in some machine rooms. Lockout models have a trip-free manual reset. Long life contact structure with high contact force -- no contact bounce. Single unit mounting and wiring -- saves installation time and material.
Electrical Ratings
General Description
Single and double pole models are available with contacts that open on a pressure differential increase or close on a pressure differential increase. Also available are models with singlepole, double-throw enclosed contacts or with main and separate reverse-acting auxiliary contacts. Controls with lockout feature require manual reset to reclose circuit after lockout. The trip-free reset will not permit restart until reset button is pushed and released. The operation point of the control is readily adjusted by rotating the adjusting disk. The control set points are easily read on a calibrated scale.
Optional Constructions
Pressure Elements Regularly supplied for noncorrosive refrigerants (fluorinated hydrocarbons). Available for ammonia service with 1/4 in. 18 FNPT connector (See Style Chart, Fig. 2.) Pressure Connectors Standard controls supplied with 36 in. capillary tubing with 1/4 in. flare nut (Style 13). Controls with 1/4 in. SAE male flare connector (no capillary tubing, Style 5), 36 in. capillary tubing with 1/4 in. sweat section (Style 34), or 1/4 in. FNPT connector (Style 15) may be supplied on quantity orders (see Pressure Element Styles).
2. 3.
Complete Product Number, if available. If complete Product Number is not available, specify Type Number (see Specifications table) and the following. Type of refrigerant or fluid. a. b. Non-corrosive. Ammonia.
Ordering Information
To order, specify: 1. Quantity required.
5. 6. 7.
Style of pressure connector. Optional constructions. Setting -- contacts close at ____ and open at ____.
Fig. 2: Pressure element styles available on the P74. Style 13 is standard. Other styles shown above can be supplied on quantity orders.
Fig. 4: Typical wiring diagram showing the P74AA and a P28 on a motor operating two compressors.
Performance specifications appearing herein are nominal and are subject to accepted manufacturing tolerances and application variables.
Controls Group 507 E. Michigan Street P.O. Box 423 Milwaukee, WI 53202
Printed in U.S.A.
HANSEN TECHNOLOGIES
CORPORATION
Specifications, Applications, Service Instructions & Parts
HCK4 IN-LINE CHECK VALVES 5 / 8" thru 4" PORT (16 thru 100 mm) Flanged / 8" thru 4" FPT, SW, WN, ODS for refrigerants
3
KEY FEATURES
ADVANTAGES
These compact check valves offer reliable operation regardless of position. Corrosion resistant stainless steel seat disc. Metal-to-metal seats facilitate durable, tight closing of valves.
APPLICATIONS
These in-line check valves are designed to provide refrigerant flow control to hot gas lines, liquid lines, compressor discharge lines, suction lines, and hot gas heated drain pans. These valves are not recommended for use with pulsating loads such as low speed compressor discharge and screw compressor side port applications. For applications such as these, use Hansen HCK1 piston type check valves.
ADDITIONAL FEATURES
Mounts in any position Less than 1 PSID wide opening pressure Can be close-coupled Low bubble leakage tolerance For Ammonia, R22, R134a, and other approved refrigerants Dimensionally replaces R/S CK4A-2, -3, -4, -8, & -1 U.L. Listed
MATERIAL SPECIFICATIONS
Body: 5 / 8 " thru 1": Steel, ASTM A108, zinc chromate plated 1" thru 4": Ductile iron, ASTM A536, zinc chromate plated Seat Disc: Stainless steel Seat Cartridge: 5 / 8 " thru 1": Stainless steel, ASTM A582 1" thru 4": Steel, ASTM A108, zinc chromate plated Spring: Stainless steel Safe Working Pressure: 400 PSIG (27 bar) Operating Temperature: -60F to 240F (-50 to 115C)
INSTALLATION
Valve may be located in any position. Arrow on valve body should match direction of flow. Secure valve with gaskets between flanges and tighten bolts evenly. Do not use this valve or any component to align pipes or tighten gap between flanges. Do not install on inlet side of solenoid valves or control valves with electric shut-off or shut-off valves unless a relief valve is used from therein between piping. Do not install on inlet side of outlet pressure regulators where liquid may become trapped. Instead, check valves should be located on outlet side of these valves. Check valves can be closecoupled to other matching solenoid valves, pressure regulators, or strainers by using a Male Adapter Ring and longer bolts supplied when so specified on order.
INSTALLATION DIMENSIONS
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5 8
)$, 1035
6.39" (162 mm) 7.13" (181 mm) 8.00" (203 mm) 1.00" (25 mm) 3.50" (89 mm) 6.06" (154 mm) 7.13" (181 mm) 5.00" (127 mm) 9.89" (251 mm) 1.40" (36 mm) 210 (180) 4"
2.50" (64 mm) 3.19" (81 mm) 3.50" (89 mm) 0.38" (10 mm) 1.03" (26 mm) 1.50" (38 mm) 1.56" (40 mm) 2.19" (56 mm) 3.26" (83 mm) 0.33" (8 mm) 5.8 (5) ", "
3.25" (83 mm) 4.50" (114 mm) 4.50" (114 mm) 0.50" (13 mm) 1.22" (31 mm) 2.37" (60 mm) 2.50" (64 mm) 3.12" (79 mm) 4" (102 mm) 0.49" (12 mm) 8.2 (7) "
3.25" (83 mm) 4.50" (114 mm) 4.50" (114 mm) 0.50" (13 mm) 1.22" (31 mm) 2.37" (60 mm) 2.50" (64 mm) 3.12" (79 mm) 4" (102 mm) 0.59" (15 mm) 11.7 (10) 1"
3.25" (83 mm) 4.50" (114 mm) 4.50" (114 mm) 0.50" (13 mm) 1.22" (31 mm) 2.37" (60 mm) 2.50" (64 mm) 3.12" (79 mm) 4" (102 mm) 0.62" (16 mm) 14.0 (12) 1"
5.06" (129 mm) 4.56" (116 mm) 6.38" (162 mm) 0.75" (19 mm) 2.56" (65 mm) 3.62" (92 mm) 4.56" (116 mm) 3.06" (78 mm) 6.06" (154 mm) 0.71" (18 mm) 39 (33) 1"
5.06" (129 mm) 4.56" (116 mm) 6.38" (162 mm) 0.75" (19 mm) 2.56" (65 mm) 3.62" (92 mm) 4.56" (116 mm) 3.06" (78 mm) 6.06" (154 mm) 0.87" (22 mm) 50 (43) 2"
6.06" (154 mm) 6.00" (152 mm) 7.50" (191 mm) 1.00" (25 mm) 2.92" (74 mm) 4.84" (123 mm) 6.00" (152 mm) 4.00" (102 mm) 7.06" (179 mm) 0.96" (24 mm) 74 (63) 2"
6.06" (154 mm) 6.00" (152 mm) 7.50" (191 mm) 1.00" (25 mm) 2.92" (74 mm) 4.84" (123 mm) 6.00" (152 mm) 4.12" (105 mm) 7.06" (179 mm) 1.08" (27 mm) 93 (80) 3"
*Dimensionally replaces R/S check valve models CK4A-2, -3, -4, -8, and -1. = "E" dimension is check valve body outside
edge to outside edge. Flange groove depth: nominal 0.12" each of two; gasket thickness: nominal 0.06" each of two.
(2-BOLT)
%&4$3*15*0/ 25: 1"35/0
HCK4-2
(2-BOLT)
7BMWF"TTFNCMZ,JU
Above Kit Consists of: 1 2 3 4 5 6 7 8 9 Seat Disc Closing Spring Seat Cartridge Seat Cartridge O-ring Flange Gasket Body, HCK4-2 Bolt ( 7/ 16" - 14 x 3.25") Nut (7/ 16 " - 14) Flange (FPT, SW, WN, ODS) 1 1 1 1 2 1 2 2 2 72-0069 72-0070 72-0068 72-0071 70-0065 72-0067 70-0225 70-0055 FACTORY
HCK4-3, -4, -5
*5&.
(2-BOLT)
25: 1"35/0
%&4$3*15*0/ 7BMWF"TTFNCMZ,JU
Above Kit Consists of: 1 2 3 4 5 6a 6b 6c 7 8 9 Seat Disc Closing Spring Seat Cartridge Seat Cartridge O-ring Flange Gasket Body, HCK4-3 Body, HCK4-4 Body, HCK4-5 Bolt ( 5/ 8" -11 x 4") Nut ( 5/ 8" -11) Flange (FPT, SW, WN, ODS) 1 1 1 1 2 1 1 1 2 2 2 72-0006 70-0204 72-0002 72-0003 70-0132 72-0004 72-0008 72-0001 72-0005 70-0136 FACTORY
HCK4-3, -4, -5
(2-BOLT)
(4-BOLT)
25: 1"35/0
1a 1b 1c 2a 2b 2c 3a 3b 3c 3d 4a 4b 4c 5a 5b 5c 5d 6a 6b 6c 6d 6e 7a 7b 7c 8a 8b 8c 9
Seat Disc 1", 2" Seat Disc 2", 3" Seat Disc 4" Closing Spring 1", 2" Closing Spring 2", 3" Closing Spring 4" Seat Cartridge 1", 2" Seat Cartridge 2" Seat Cartridge 3" Seat Cartridge 4" Seat Cartridge O-ring 1", 2" Seat Cartridge O-ring 2", 3" Seat Cartridge O-ring 4" Flange Gasket 1", 2" Flange Gasket 2" Flange Gasket 3" Flange Gasket 4" Body, HCK4-7 Body, HCK4-8 Body, HCK4-9 Body, HCK4-0 Body, HCK4-1 Bolt, HCK4-7, -8 (5/8" - 11 x 6") Bolt, HCK4-9, -0 (" - 10 x 7") Bolt, HCK4-1 ( 7/ 8" - 9 x 7.5") Nut, HCK4-7, -8 ( 5/ 8" - 11) Nut, HCK4-9, -0 (" - 10) Nut, HCK4-1 (7/ 8" - 9) Flange (FPT, SW, WN, ODS)
1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 4 4 4 4 4 4 2
72-0016 72-0034 72-0053 72-0021 72-0032 72-0048 72-0020 72-0029 72-0028 72-0047 72-0017 72-0027 72-0049 75-0138 75-0125 75-0137 75-0253 72-0042 72-0019 72-0025 72-0026 72-0046 70-0268 72-0033 72-0051 70-0136 75-0210 75-0280 FACTORY
(4-BOLT)
OPERATION
HCK4 check valves are normally closed valves. As inlet pressure increases, it overcomes the closing spring force. As the seat disc is pushed back and away from the seat cartridge, flow through the valve occurs. The valve will remain open until the inlet pressure drops below the closing spring force or there is a flow reversal, at which time the seat disc will close against the seat cartridge, preventing reverse flow.
WARRANTY
Hansen valves are guaranteed against defective materials or workmanship for one year F.O.B. our plant. No consequential damages or field labor is included.
5:1&
SIZING
Check valves are normally selected on the basis of line size. However, for gas flow applications at low load conditions, a minimum of 1 psid across the valve is essential. This will maintain valve at full open position. Valve Cv (Kv) is listed in the installation dimension table on page 2. Factory valve sizing assistance is available.
HCK4-2* HCK4-3* HCK4-4* HCK4-5 HCK4-7 HCK4-8* HCK4-9 HCK4-0 HCK4-1*
1035 4*;& NN
5 8
/"
/ ", "
1", 1"
5 8
/ " / "
7 8
TYPICAL SPECIFICATIONS
"Refrigeration in-line check valves shall have steel or ductile iron bodies, stainless steel seat discs, stainless steel closing springs, and be suitable for a safe working pressure of 400 PSIG, as manufactured by Hansen Technologies Corporation type HCK4 or approved equal." Typical close-coupling to solenoid valve.
CAUTION
Hansen check valves are only for refrigeration systems. These instructions and related safety precautions must be completely read and understood before selecting, using, or servicing these valves. Only knowledgeable, trained refrigeration mechanics should install, operate, or service these valves. Stated temperature and pressure limits should not be exceeded. Valves should not be removed unless system has been evacuated to zero pressure. See also Safety Precautions in current List Price Bulletin and Safety Precautions Sheet supplied with product. Escaping refrigerant might cause personal injury, particularly to the eyes and lungs.
ISO 9002
Hansen Technologies Corp. Burr Ridge, IL Cert. # 000472 Orlando, FL Cert. # 001523
HANSEN TECHNOLOGIES
CORPORATION
6827 High Grove Boulevard Burr Ridge, Illinois 60527 U.S.A. Telephone: (708) 325-1565 FAX: (708) 325-1572 Toll-free: 1-800-426-7368
1995 Hansen Technologies Corporation Printed in U.S.A.
SECTION A1
Provide a True Clamp Fit Are Easy to Install and Remove Permit Four-Way Mounting
A11
Sure-Grip Quick Detachable bushings are easy to install and remove. They are split through flange and taper to provide a true clamp on the shaft that is the equivalent of a shrink fit. All sizes except JA and QT have a setscrew over the key to help
6-hole drilling (most sizes) makes installation and removal quick and easy. Precise taper (3/4 in. per ft. on diameter) provides proper wedging action. Saw cut through flange and taper (and sometimes cut down into keyway also) to provide a true clamp fit.
maintain the bushings position on the shaft until the cap screws are securely tightened. Sure-Grip bushings have a very gradual taper (3/4-inch taper per ft. on the diameter) which is about half the inclined angle of many other bushings. The result is the Sure-Grip securely clamps the shaft, with twice the force of those competitive bushings, to provide extreme holding power. Versatile Sure-Grip bushings permit the mounting of the same mating part on shafts of different diameters, and the mounting of different sheaves on the same shaft using the same bushing. Their interchangeability extends through sheaves, pulleys, timing pulleys, sprockets, flexible and rigid couplings, made-toorder items by Woods, and to product lines of several other mechanical power transmission manufacturers. Sure-Grip bushings are manufactured with the drilled and tapped holes located at a precise distance from the keyseat; thus, a wide mating part having a bushing in each end can be mounted on a common shaft with the two keyways in line. This feature not only facilitates installation but also permits both bushings to carry an equal share of the load.
Cap screws used to secure bushings to sheave and to remove bushing from sheave.
STANDARD MOUNTING
REVERSE MOUNTING
1.
Cap screws from outside through drilled holes in the mating part and into threaded holes in the bushing flange located on the inside of the assembly. Or the complete assembly reversed on the shaft and;
2.
Cap screws from inside through drilled holes in the mating part and into threaded holes in the bushing flange located on the outside of the assembly.
3.
Cap screws from inside through drilled holes in the bushing flange located on the inside of the assembly and into threaded holes in the mating part.
4.
Cap screws from outside through drilled holes in the bushing flange located on the outside of the assembly and into threaded holes in the mating part.
A12
Sure-Grip bushings are designed to transmit the rated torque capacity listed in the table below when the cap screws are tightened as indicated. The bushings are stocked in all popular bore sizes, including metric bores, within the bore range for a particular bushing.
Bushing QT
B 1.625 1.375 1.871 2.1875 2.1875 2.8125 3.125 3.834 4.4375 5.1484 6.500 7.000 8.250 10.437 12.125
D 21/2 2 2 11/16 3 3/16 3 3/16 3 7/8 4 5/8 6 6 5/8 7 1/4 9 1/8 10 11 3/4 15 17 3/4
L 11/4 1 11/4 1 5/16 113/16 1 7/8 2 2 5/8 3 5/8 4 1/2 6 3/4 8 1/8 9 3/8 11 3/8 15 3/4
Bolt Circle 2 1 21/32 21/4 2 11/16 2 11/16 3 5/16 3 7/8 5 5 5/8 6 1/4 7 7/8 8 1/2 10 12 3/4 15
Cap Screws Required 2-1/4 x 1 3 - #10 x 1 3 -1/4 x 13/8 3 -1/4 x 13/8 3 -1/4 x 1 7/8 3 - 5/16 x 2 3 - 3/8 x 2 3 - 1/2 x 2 3/4 3 - 9/16 x 3 5/8 3 - 5/8 x 4 1/2 4 - 3/4 x 6 3/4 4 - 7/8 x 8 4 - 1 x 9 1/2 4 - 1 1/8 x 111/2 5 - 11/4 x 151/2
/ / 3/4 13/16 1
1 2 1 2
1 3/8 11/2 1 7/8 2 13/16 3 1/2 5 1/2 6 5/8 7 5/8 9 3/8 12 1/2
* Mating hub length. 1. MAX INCH BORE WITH KEYSEAT. 2. MAX MM BORE WITH STANDARD KEYSEAT.
See pages A14 to A18 for Bore and Keyseat information and weights. A13
QT BUSHINGS
QTMPB QT12 QT9/16 QT58 QT11/16 QT34 QT13/16 QT78 QT15/16 QT1 QT1116 QT118 QT1316 QT114 QT1516 QT138 QT1716 QT112 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 1-1/16 1-1/8 1-3/16 1-1/4 1-5/16 1-3/8 1-7/16 1-1/2 No KS 1/8 x 1/16 1/8 x 1/16 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 5/16 x 1/16 5/16 x 1/16 3/8 x 1/16 3/8 x 1/16 .6 .6 .6 .6 .6 .6 .6 .6 .6 .6 .6 .6 .6 .6 .6 .6 .6 .6
SH BUSHINGS (continued)
SH1116 SH118 SH1316 SH114 SH1516 SH138 SH1716 SH112 SH1916 SH158 SH11116 1-1/16 1-1/8 1-3/16 1-1/4 1-5/16 1-3/8 1-7/16 1-1/2 1-9/16 1-5/8 1-11/16 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 5/16 x 5/32 5/16 x 5/32 3/8 x 1/16 3/8 x 1/16 3/8 x 1/16 3/8 x 1/16 No KS .9 .9 .8 .8 .7 .7 .7 .6 .6 .5 .5
SD BUSHINGS (continued)
SD34 SD13/16 SD78 SD15/16 SD1 SD1116 SD118 SD1316 SD114 SD1516 SD138 SD13838KS SD1716 SD112 SD1916 SD158 SD11116 SD134 SD11316 SD178 SD11516 SD2 3/4 13/16 7/8 15/16 1 1-1/16 1-1/8 1-3/16 1-1/4 1-5/16 1-3/8 1-3/8 1-7/16 1-1/2 1-9/16 1-5/8 1-11/16 1-3/4 1-13/16 1-7/8 1-15/16 2 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 5/16 x 5/32 5/16 x 5/32 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 1/8 1/2 x 1/8 1/2 x 1/16 1/2 x 1/16 No KS 2.0 2.0 1.9 1.9 1.8 1.8 1.7 1.7 1.6 1.6 1.5 1.5 1.4 1.4 1.3 1.2 1.2 1.1 1.1 1.0 .9 .8
SDS BUSHINGS
SDSMPB SDS12 SDS9/16 SDS58 SDS11/16 SDS34 SDS13/16 SDS78 SDS15/16 SDS1 SDS1116 SDS118 SDS1316 SDS114 SDS1516 SDS138 SDS13838KS SDS1716 SDS112 SDS1916 SDS158 SDS11116 SDS134 SDS11316 SDS178 SDS11516 SDS2 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 1-1/16 1-1/8 1-3/16 1-1/4 1-5/16 1-3/8 1-3/8 1-7/16 1-1/2 1-9/16 1-5/8 1-11/16 1-3/4 1-13/16 1-7/8 1-15/16 2 No KS 1/8 x 1/16 1/8 x 1/16 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 5/16 x 5/32 5/16 x 5/32 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 1/8 1/2 x 1/8 1/2 x 1/16 1/2 x 1/16 No KS 1.7 1.7 1.7 1.6 1.6 1.6 1.6 1.5 1.5 1.5 1.4 1.4 1.4 1.3 1.3 1.2 1.2 1.2 1.1 1.1 1.0 1.0 1.0 .9 .9 .8 .7
JA BUSHINGS
JAMPB JA12 JA9/16 JA58 JA11/16 JA34 JA13/16 JA78 JA15/16 JA1 JA1116 JA118 JA1316 JA114 1/2 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 1-1/16 1-1/8 1-3/16 1-1/4 No KS 1/8 x 1/16 1/8 x 1/16 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 1/4 x 1/8 1/4 x 1/8 1/4 x 1/16 1/4 x 1/16 1/4 x 1/16 1/4 x 1/32 .8 .8 .8 .8 .8 .8 .8 .8 .8 .8 .8 .8 .8 .8
SK BUSHINGS
SKMPB SK12 SK9/16 SK58 SK11/16 SK34 SK13/16 SK78 SK15/16 SK1 SK1116 SK118 SK1316 SK114 SK1516 SK151638KS SK138 SK13838KS SK1716 SK112 SK1916 SK158 SK11116 SK134 SK13412KS 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 1-1/16 1-1/8 1-3/16 1-1/4 1-5/16 1-5/16 1-3/8 1-3/8 1-7/16 1-1/2 1-9/16 1-5/8 1-11/16 1-3/4 1-3/4 No KS 1/8 x 1/16 1/8 x 1/16 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 5/16 x 5/32 3/8 x 3/16 5/16 x 5/32 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3.8 x 3/16 3/8 x 3/16 1/2 x 1/4 3.6 3.6 3.6 3.6 3.5 3.5 3.5 3.4 3.4 3.3 3.3 3.2 3.2 3.1 3.1 3.1 3.0 3.0 2.9 2.9 2.8 2.7 2.6 2.5 2.5
SH BUSHINGS
SHMPB SH12 SH9/16 SH58 SH11/16 SH34 SH13/16 SH78 SH15/16 SH1 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 No KS 1/8 x 1/16 1/8 x 1/16 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 1/4 x 1/8 1/4 x 1/8 1.1 1.1 1.1 1.1 1.0 1.0 1.0 1.0 1.0 .9
SD BUSHINGS
SDMPB SD12 SD9/16 SD58 SD11/16 7/16 1/2 9/16 5/8 11/16 No KS 1/8 x 1/16 1/8 x 1/16 3/16 x 3/32 3/16 x 3/32 2.1 2.1 2.1 2.1 2.0
(Continuednext page)
A14
SK BUSHINGS (continued)
SK11316 SK178 SK11516 SK2 SK2116 SK218 SK2316 SK214 SK21458KS SK2516 SK238 SK2716 SK212 SK2916 SK258 1-13/16 1-7/8 1-15/16 2 2-1/16 2-1/8 2-3/16 2-1/4 2-1/4 2-5/16 2-3/8 2-7/16 2-1/2 2-9/16 2-5/8 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/8 1/2 x 1/8 5/8 x 1/8 5/8 x 1/16 5/8 x 1/16 5/8 x 1/16 5/8 x 1/16 No KS No KS 2.4 2.4 2.3 2.2 2.1 2.0 2.0 1.9 1.9 1.8 1.7 1.6 1.5 1.3 1.1 EMPB E78 E15/16 E1 E118 E1316 E114 E1516 E138 E13838KS E1716 E112 E1916 E158 E11116 E134 E11316 E178 E11516 E2 E2116 E218 E2316 E214 E21458KS E2516 E238 E2716 E212 E2916 E258 E1116 E234 E21316 E278 E21516 E3 E318 E3316 E314 E3516 E338 E3716 E312
E BUSHINGS
7/8 7/8 15/16 1 1-1/8 1-3/16 1-1/4 1-5/16 1-3/8 1-3/8 1-7/16 1-1/2 1-9/16 1-5/8 1-11/16 1-3/4 1-13/16 1-7/8 1-15/16 2 2-1/16 2-1/8 2-3/16 2-1/4 2-1/4 2-5/16 2-3/8 2-7/16 2-1/2 2-9/16 2-5/8 2-11/16 2-3/4 2-13/16 2-7/8 2-15/16 3 3-1/8 3-3/16 3-1/4 3-5/16 3-3/8 3-7/16 3-1/2 No KS 3/16 x 3/32 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 5/16 x 5/32 5/16 x 5/32 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 3/4 x 3/8 3/4 x 3/8 3/4 x 1/8 3/4 x 1/8 3/4 x 1/8 3/4 x 1/8 3/4 x 1/8 7/8 x 1/16 7/8 x 1/16 7/8 x 1/16 7/8 x 1/16 10.8 10.8 10.8 10.7 10.6 10.5 10.4 10.3 10.2 10.2 10.1 10.0 9.9 9.8 9.7 9.6 9.4 9.3 9.2 9.0 8.9 8.8 8.6 8.5 8.5 8.3 8.1 8.0 7.8 7.6 7.5 7.3 7.1 7.2 7.1 6.9 6.7 6.3 6.0 5.8 5.7 5.5 5.2 4.7
F BUSHINGS (continued)
F134 F178 F11516 F2 F2116 F218 F2316 F214 F21458KS F2516 F238 F2716 F212 F2916 F258 F21116 F234 F21316 F278 F21516 F3 F318 F3316 F314 F3516 F338 F3716 F312 F358 F31116 F334 F378 F31516 F4 1-3/4 1-7/8 1-15/16 2 2-1/16 2-1/8 2-3/16 2-1/4 2-1/4 2-5/16 2-3/8 2-7/16 2-1/2 2-9/16 2-5/8 2-11/16 2-3/4 2-13/16 2-7/8 2-15/16 3 3-1/8 3-3/16 3-1/4 3-5/16 3-3/8 3-7/16 3-1/2 3-5/8 3-11/16 3-3/4 3-7/8 3-15/16 4 3/8 x 3/16 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 3/4 x 3/8 3/4 x 3/8 3/4 x 3/8 3/4 x 3/8 3/4 x 3/8 3/4 x 3/8 3/4 x 3/8 7/8 x 3/16 7/8 x 3/16 7/8 x 3/16 7/8 x 3/16 7/8 x 3/16 7/8 x 3/16 7/8 x 3/16 1 x 1/8 1 x 1/8 No KS 16.3 16.0 15.8 15.6 15.4 15.2 15.0 14.8 14.8 14.5 14.3 14.1 13.9 13.7 13.4 13.2 12.9 12.6 12.3 12.1 11.8 11.2 10.9 10.6 11.0 10.6 10.3 10.0 9.4 9.0 8.7 8.1 7.7 6.9
SF BUSHINGS
SFMPB SF12 SF58 SF34 SF78 SF15/16 SF1 SF1116 SF118 SF1316 SF114 SF1516 SF138 SF13838KS SF1716 SF112 SF1916 SF158 SF11116 SF134 SF11316 SF178 SF11516 SF2 SF2116 SF218 SF2316 SF214 SF21458KS SF2516 SF238 SF2716 SF212 SF2916 SF258 SF21116 SF234 SF278 SF21516 1/2 1/2 5/8 3/4 7/8 15/16 1 1-1/16 1-1/8 1-3/16 1-1/4 1-5/16 1-3/8 1-3/8 1-7/16 1-1/2 1-9/16 1-5/8 1-11/16 1-3/4 1-13/16 1-7/8 1-15/16 2 2-1/16 2-1/8 2-3/16 2-1/4 2-1/4 2-5/16 2-3/8 2-7/16 2-1/2 2-9/16 2-5/8 2-11/16 2-3/4 2-7/8 2-15/16 No KS 1/8 x 1/16 3/16 x 3/32 3/16 x 3/32 3/16 x 3/32 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 5/16 x 5/32 5/16 x 5/32 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 5/8 x 5/16 5/8 x 3/16 5/8 x 3/16 5/8 x 3/16 5/8 x 3/16 5/8 x 1/16 5/8 x 1/16 5/8 x 1/16 5/8 x 1/16 3/4 x 1/16 3/4 x 1/32 5.1 5.1 5.0 5.0 4.9 4.8 4.8 4.7 4.7 4.6 4.5 4.5 4.4 4.4 4.3 4.2 4.2 4.1 4.0 3.9 3.8 3.7 3.6 3.5 3.4 3.3 3.2 3.1 3.1 3.1 3.0 2.9 2.8 2.6 2.5 2.4 2.2 1.8 1.7
J BUSHINGS
JMPB J1716 J112 J1916 J11116 J134 J178 J11516 J2 J218 J2316 J214 J2516 J238 J2716 J212 J258 J21116 J234 J278 1-7/16 1-7/16 1-1/2 1-9/16 1-11/16 1-3/4 1-7/8 1-15/16 2 2-1/8 2-3/16 2-1/4 2-5/16 2-3/8 2-7/16 2-1/2 2-5/8 2-11/16 2-3/4 2-7/8 No KS 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 1/2 x 1/4 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 5/8 x 5/16 3/4 x 3/8 28.1 28.1 28.0 27.8 27.4 27.2 26.7 26.5 26.3 25.8 25.6 25.3 25.0 24.7 24.5 24.2 23.6 23.3 23.0 22.2
F BUSHINGS
FMPB F1 F118 F1316 F114 F138 F1716 F112 F1916 F158 1 1 1-1/8 1-3/16 1-1/4 1-3/8 1-7/16 1-1/2 1-9/16 1-5/8 No KS 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 1/4 x 1/8 5/16 x 5/32 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 3/8 x 3/16 17.9 17.9 17.7 17.6 17.5 17.2 17.1 16.9 16.8 16.7
(Continuednext page)
A15
SERVICE SECTION
TABLE OF CONTENTS (contd)
PAGE 16 16 16 17 17 17 17 17 17 17 18 18 18 18 18 18 19 19 19 19 20 20 20 20 20 23 23 23 23 23 23 23 24 24 24 24 25 25 25 25 26 26 24 31 SAFETY VALVE (INTERNAL RELIEF) Removal Replacement OIL PRESSURE ADJUSTMENT ASSEMBLY Disassembly Reassembly Adjustment TRI-MICRO OIL FILTER Removal Replacement OIL PUMP ASSEMBLY Removal Replacement PREPARATION FOR INTERNAL SERVICING Handhole Cover Removal Handhole Cover Replacement CRANKSHAFT SEAL Oil Seal Leakage Removal Installing A New Shaft Seal CONNECTING RODS AND PISTONS Disassembly 440 & 450 VMC Compressors Only 450XL VMC Compressor Only Reassembly CONNECTING RODS AND PISTONS Disassembly 440 & 450 VMC Compressors Only 450XL VMC Compressor Only Reassembly CYLINDER LINERS Removal Lift Rings For Unloading 440 Lift Ring Assembly 450/450XL Lift Ring Assembly Installation Of Liners CRANKSHAFT General Removal From Drive End Removal From The Pump End Servicing The Center Bearing (12 & 16 Cylinders) Reinstallation MODIFICATION TO FRONT BEARING RETAINER AND FRONT BEARING COVER (440 Compressor Only) CONNECTING ROD NUTS TIGHTENING INSTRUCTIONS VMC COMRPESSORS
VMC SERVICE
-B-
SERVICE SECTION
ILLUSTRATIONS AND TABLES
PAGE
3 5 6 8 9 11 13 15 16 20 21 22 23 24 24 27 36
FIGURE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Bearing And Cylinder Covers Assembly & Disassembly Stud Upper Cylinder Cross Section Discharge Diaphragm Valve Placement Flywheel Removal Tool Unit Belting Requirements Due To Horsepower Belt Tension Spring Scale Typical Capacity Control Mechanism Arrangement 440 Compressor (Old Style Mushroom Type) Typical Capacity Control Mechanism Arrangement 450 & 450XL Compressor (New Style Bulletin Type) Safety Valve Location Piston Ring Compressing Tool Front Cover Assembly And Disassembly Tool Crankshaft Seal Assembly Piston Ring Dimensions Cylinder Liner Assembly Tool Cylinder Liner Removal Tool Retainer Partial Vertical Cross Section Typical 400 Series Compressor Vertical Cross Section and Lubricating System
PAGE
23 28 29 30 32
TABLE
1 2 3 4 5 Piston Ring Dimensions And Tolerances Torque Specifications VMC Model 440 Torque Specifications VMC Model 450 Torque Specifications VMC Model 450XL Factory Running Dimensions Tolerances, Clearances & Allowable Wear Limits For 440, 450 & 450XL VMC Compressors
VMC SERVICE
-C-
A. General Comments When working on the compressor, care must be taken to ensure contaminants, such as water from melting ice or snow, dirt, and dust, DO NOT enter the compressor while it is being serviced. It is essential that all dust, oil or ice that has accumulated on the outside of the compressor be removed before servicing. All gaskets, o-rings, roll pins and lock washers must be replaced when servicing and reassembling the compressor. As an aid in servicing compressors, a tool kit is available and can be ordered as Vilter Part No. KT067. This kit includes necessary wrenches as well as all the servicing tools pictured in this section. B. Preparation Of Compressor For Servicing Remove all refrigerant from the compressor before servicing it. To properly evacuate the compressor, employ the following procedure: 1. Refrigerant 717 (Ammonia) Compressor Shut down the unit, open the electrical disconnect switch and pull the fuses for the compressor motor to prevent the unit from starting. Put a lock on the disconnect switch and tag the switch to indicate maintenance is being performed. Isolate the unit by manually closing the discharge stop/check valve. Close the liquid supply valves and open all solenoid valves to prevent liquid refrigerant from being trapped between the stop valves and solenoid valves. Allow the unit to equalize to suction pressure before closing the suction
-1-
NOTE: Before proceeding, refer to Paragraph I, General Service Instructions. A. Disassembly To remove the compressor cylinder covers, remove the capacity control lines and water lines (or liquid cooling lines, if any) from the covers that will be removed. Next, remove two screws that are opposite each other diagonally across the cover (i.e. two screws by water connections). Install two assembly studs into these holes and tighten them to thread bottom. Screw on nuts to within one thread of touching the cover. Remove the other screws. Slowly back the two nuts off and make sure the cover follows. If the cover doesnt follow, STOP. DO NOT back off nuts more than one turn. Break the gasket seal and then continue cover removal. The studs are long enough to relieve all the spring tension before the nuts are removed. Remember, the studs must not be turned out with the nuts. After all of the spring tension is removed, the nuts can be removed, covers lifted off and head springs removed. It is best to keep all parts in the correct cylinder assignment. Invert the cover and place on work surface, placing each spring in its corresponding location in the cover.
-2-
B. Assembly Before replacing the cover on the compressor, inspect the gasket surfaces of the cover and compressor frame. Remove any debris adhering to either of these surfaces. Remove any burrs or rough edges from the mating surfaces to ensure a tight seal. Replace studs, if removed. Lightly lubricate both sides of the head gasket. Position the gasket over the studs and against the compressor frame in the correct orientation. Place the springs on top of the safety head yokes (rotating the spring until it stays on the yoke). Place the cover down over the studs and slowly lower on top of springs. When all pieces are in alignment, place the nuts on the studs and start to tighten. When the cover is secure within 1 (31.75 mm) of the gasket, install the rest of the screws so they come in contact with the cover. This will ensure they will not cross thread in the holes. Do not tighten each screw separately, however. Alternate on opposing screws, until the cover is seated on the gasket. Remove the studs and replace with screws. Finish tightening the screws in an opposing pattern to the recommended torque values shown in Table 2, 3 or 4 (depending upon your compressor model). Reinstall the capacity control and head cooling lines, and check for leaks.
To service valve plates in the compressor, remove the cylinder covers (refer to paragraph II.A). In cylinders without unloaders, the valve assemblies may be removed as soon as the covers are removed. On compressor cylinders equipped with unloaders, the unloader needs to be forced down before the valves are serviced. If the unloader remains up, the suction valve is forced off its seat, and will not seat and locate properly during reassembly. To hold the unloader mechanism down, remove the plug from the hole B in the frame. Force the unloader piston down and insert a short 5/16 (7.93 mm) diameter metal rod through the hole to restrain the piston. Use a wooden block to force the piston down to avoid scratching or damaging the top of the unloader piston. Once the piston is held down, the valve assemblies can be serviced. 1. 440 Compressor (Mushroom Style) (See Figure 7) Lift out the safety head yoke, which holds the safety head assembly in place. When the yoke is out, lift out the safety head assembly and suction valve plate. To disassemble the safety head assembly, remove the locknut on the valve retaining screw.
1.
-3-
-4-
10 10
99
6 4 4 5 3 3 2
2 1
Compressor Frame
KEY
ITEM NO. 1 2 3 4 5 5A
ITEM NAME Cylinder Liner Suction Valve Plate Suction Valve Spring (4) Safety Head Yoke Safety Head Spring (4) Roll Pin (4)
ITEM NO. 6* 7* 8* 9* 10 * 11 *
ITEM NAME Valve Retaining Screw Hexagon Lock Nut Valve Washer Valve Spacer Diaphragm Discharge Valves (3) Safety Head
FIGURE 2.
400 Series VMC SERVICE
-5-
FIGURE 3.
-6-
-7-
2 Dia.
FIGURE 4.
3.
Sheave Removal Specific instructions for motor sheave maintenance are located after the Operation Section of this manual. These should be consulted for specific maintenance instructions.
4.
Drive Inspection Inspect the motor and compressor shafts, sheave bushing and flywheel for fretting corrosion or other wear. Fretting corrosion is the result of two metallic surfaces (a shaft 5 Dia. and flywheel or bushing bore) having movement relative to one another. This is usually due to the incorrect tightening of drive components, use of oil or other anti-seize compounds, worn components, burrs or other imperfections not allowing the flywheel and crankshaft to mate properly.
-8-
456XL Booster
FIGURE 5.
4.
Drive Inspection (contd) The groove bottom should also be checked for polishing, as this indicates the belt is not riding correctly in the groove. What has happened is the belt or groove has worn to the point the belt is actually rubbing on the bottom of the groove. This effectively changes the pitch diameter of the sheave or pulley for that groove, causing the belt to operate at a different speed than the rest. This will result in excessive heat and wear to the drive components. When drive components are replaced, it is necessary to replace them with identical components. Due to operating conditions and the horsepower requirements of the compressors, the number of belts on a compressor package can vary from 2 through 10 belts and not all flywheel grooves will be filled. Drive belts should be inspected for abrasion, tearing, separation or checking that would indicate possible damage to drive components or alignment problems. They should
400 Series VMC SERVICE
also be inspected for sharp bends and kinks while they are slack as this indicates internal damage due to incorrect installation techniques. The belts can be cleaned at this time. Only soap and water should be used to clean the belts and other components. Belt dressing should never be used on drive components, as it will attack the elastomer used in construction of the belts. Belts should always be changed in sets to minimize length variations between used and new belts. Note the match numbers on the belts. The same number must be on all belts in the set. 5. Drive Installation If installation is new and the belts are being installed for the first time, the following items must be taken care of before the belts can be installed.
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assembly. As the anti-seize is trapped when the parts are tightened, it will create a sliding layer between the parts. The parts are not free to move independent of each other while the unit is in operation, creating fretting corrosion. This results in excessive wear of the drive components and the possibility of the parts welding themselves together. The belts can now be installed. The motor should be moved towards the compressor to facilitate the installation of the belts. The belt closest to the compressor should be installed first. The belts should not be rolled or pried when installing them, as this will damage the cords in the belts and cause a failure in a short time. Drive Alignment There are 3 different types of misalignment that are possible, more than one of which may be present at any one time. These are: Horizontal angular Vertical angular Parallel Although V-belt drives are somewhat tolerant to misalignment, the maximum amount of misalignment permitted is 1/16 of an inch per 12 of shaft, center to center distance. If this is exceeded, excessive drive, belt and bearing wear will result. Horizontal angular misalignment results when the motor and compressor shafts are in the same horizontal plane, but not in the same vertical plane. A straight edge is held against the compressor pulley face. The distance from the straight edge to the motor sheave sides is compared. They should be the same. If they are not the same, adjust the motor to bring the sheave and pulley into alignment.
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amount of deflection should be 19/64 (7.54 mm) and the tension required to achieve it should be between 12 to 18 lbs.
FIGURE 6.
The belt tension spring scale is placed in the center of the belt span. The scale is then pushed down until the proper deflection is reached. The tension should then be read and recorded. The process is then repeated for the remaining belts. If the tension is too low, the belts should be tightened evenly and rechecked. The tension between belts should be within 1 lbs. of each other. Inconsistent measurements indicate problems with alignment, belt length and/or wear of the drive components. The problem should be corrected before the unit is returned to service. 9. Banded 5V, V-belts Due to their design, banded V-belts require special tensioning techniques in order to set the tension properly. There are two methods to check the tension of banded belts. They are as follows: The first method utilizes a tension tester to measure the deflection. The number of belt bands in the belt is multiplied by the deflection force of 12 to 18 lbs. A board or metal plate is then placed across the bands to equalize the force as the tension tester is depressed on the board or plate. 9. Banded 5V, V-belts (contd)
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Inspect the compressor coupling bore and crankshaft to make sure they are clean and free of burrs. Apply anti-seize to shaft and coupling bore. Place the key on the shaft and slip on the coupling. Install the bolt (and washer, if required), and tighten. Reassemble shim pack and center member in correct orientation. Tighten bolts and note distance between hubs per coupling manufacturers bulletin. This bulletin is located in the Installation Section. Recheck alignment, if necessary. V. CAPACITY CONTROL
B. Direct Drive Compressors 1. Coupling Removal Remove the guard. Remove the bolts that extend through the coupling and remove the center member. Remove the bolts that hold the shim packs to coupling, and make note of location of the washers. Using one or two of these bolts through the shim pack will keep the shims in alignment. To remove the coupling from the crankshaft, remove the screw (and washer, if present). Try to lightly tap the coupling off the shaft, or apply heat to coupling. A puller can be constructed out of a flat steel bar with holes that match two holes in the coupling in a straight line past the center of the crankshaft. Make a hole in the center of the bar for a 5/8 (15.88 mm) bolt, thread the hole or weld a 5 /8 (15.88 mm) nut inline with the hole. Bolt this bar loosely to holes in coupling. Place a solid washer or disc (a little smaller than end of the shaft) between the bar and in front of the tapped hole in the crankshaft. Using a 5 /8 (15.88 mm) bolt, apply force to center crankshaft and a pulling force on the coupling. 2. Coupling Replacement
400 Series VMC SERVICE
A. Old Style (Mushroom Type) 1. Lift Pins, Ring and Springs Removal The valve lifting mechanism consists of the lift pins, lift ring and lift springs all assembled to the cylinder liner. To remove these parts from the cylinder liner, place the liner on a flat surface in an upright position. Rotate the lift ring slightly until the four semi-circular notches line up with the lift pins, and slide the ring down off the liner. Lift the pins out of the top of the liner. In order to put the unloading mechanism onto the cylinder liner, set the lift ring on a flat surface with the guides for the lift springs facing up. Next place the cylinder liner inside the lift ring. Drop the four lift pins into their holes in the liner with the notched ends of the pins facing down and the flat side facing out. Lift the rings so the semicircular notches slide over the pins. Then, rotate the lift ring so the springs fit into their holes in the cylinder liner.
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Use this illustration for: Oil Actuated Unloading High Stage Booster Both Stages of 2-Stage Gas Actuated Unloading High Stage High Stage of 2-Stage
Yoke assembly is bolted down on one end as shown on the two cylinder and two-stage compressor capacity control mechanism. All other compressors do not use these bolts.
FIGURE 7.
TYPICAL CAPACITY CONTROL MECHANISM ARRANGEMENT 440 COMPRESSOR (OLD STYLE MUSHROOM TYPE)
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the rear of the lifting rod. This keeps the yoke depressed for easier handling. Place the yoke into the frame through the cylinder opening and position it so the slot on the yoke lifting arm registers with the flats on the long pivot pin. Depress the piston with a block of wood, and remove the rod or piece of wood used to hold the yoke assembly depressed. Then, center the assembly between the two cylinder liner holes. B. New Style (Bullet Type) 1. Lift Pins, Ring and Springs Removal In order to put the unloading mechanism back in the cylinder liner, place the lift pins with the springs around them in their holes. Place the lift ring on the pins with the smaller inside diameter facing top of the liner so it will slip over and cover the retainer when it is in place. Placing the liner on its side and holding the lift ring back against the pins and springs, slide the ring retainer over the liner into its groove. 2. Unloader Piston Removal It is not necessary to remove or disturb the actuator mechanism or the cylinder liners to remove the unloader piston. There are two holes in the top of the unloader piston. One is threaded, the other is not. Use -20NC eyebolt in the center hole. Use the other hole to keep the piston from turning in the hole in the frame while doing this. Using the eyebolt as a handle, pull the piston out of its hole in the frame.
** COMPRESSOR APPLICATION NOTE Gas Actuated Unloading is standard on: High Stage, except 100% internal CR Oil Actuated Unloading is standard on: High Stage with 100% internal CR Booster Both Stages of integral 2-Stage
**
Yoke assembly is bolted down on one end, as shown, on all compressor banks equipped with optional single cylinder unloading. All other compressors do not use these bolts.
FIGURE 8. TYPICAL CAPACITY CONTROL MECHANISM ARRANGEMENT 450 & 450XL COMPRESSORS (NEW STYLE BULLET TYPE)
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Note: Safety Valve is set at a differential pressure of 300 PSIG (2069 kPa). Maximum discharge temperature is 300F (150C).
FIGURE 9.
B. Replacement Lightly oil the threads of the valve and screw the valve into place. Lightly oil a new gasket and place it on the frame. Position the cover and tighten it down.
- 16 -
- 17 -
To work internally on the compressor, the handhole cover and crankcase oil will have to be removed to gain access. The heater will have to be electrically disconnected at this time. Remember to shut the power off and lock it out. After disconnecting the wiring, loosen all but two screws on the upper corners of the cover. This helps support the cover during removal and prevents damaging the heater. If the cover sticks to the frame, a slight tap with a lead or soft face hammer will free it. Holding the cover in place, remove the two remaining screws, and pull the cover straight back away from the frame. Remove any gasket material from the cover and frame face. Also inspect and remove any burrs or rough edges from the mating surfaces to ensure a tight seal at time of reassembly. B. Handhole Cover Replacement Lightly lubricate both sides of a new gasket with refrigerant oil or general purpose grease. Place the gasket on the cover, and guiding in the heater, place the cover against the frame opening. While holding the cover and making sure the gasket is still in place, insert two screws in the lower row to help support the cover and keep the gasket from slipping out. Start the rest of the screws in their holes and continue to check gasket placement. Tighten screws evenly to the torque requirements in Table 2, 3 or 4 (depending upon compressor model). Connect the
C. Installing A New Shaft Seal Remove the mirror seats from the inner retainer and outer cover. The mirror face can be removed by tapping on back side that is exposed in each part. Make sure these parts are then cleaned. Place either on a flat surface with the recess up. Oil the o-ring sealing area. Take the mirror face (do not touch the mirrored surface), oil outer o-ring and lay it in the cover or retainer with the mirror face upward. Using a very clean cloth or similar item, cover mirror face and, using palm of hand, set it in the recess. Repeat this assembly process for the other mirror face. Vilter recommends that if any part of a seal needs replacement, the entire shaft seal should be replaced with a new one. Make sure the oil passage in the shaft is unobstructed. Install the inner retainer with mirror face, flush in front housing, with the word TOP at the top. Tighten down evenly with the 3 screws. The shaft seal assembly is symmetrical. It can be installed in either direction. Spray oil on inner mirror face. Liberally coat oil on one of the bellows and carbon assemblies. Avoid coming in contact with carbon. Carefully slip the assembly on the shaft until the carbon touches the mirror face. Put the spring over the shaft and seal on the bellows assembly, and slide it onto the shaft to join up with the spring. With the new cover gasket in place, install the cover over the end of the shaft. Push the cover all the way on, lining up the bolt holes so the drain is to the bottom. Tighten down the 8 screws evenly to the torque requirements in Table 2, 3 or 4 (depending upon compressor model). XII. CONNECTING RODS AND PISTONS NOTE: Before proceeding, refer to Paragraph I, General Service Instructions.
FIGURE 10.
- 20 -
FIGURE 11.
CAUTION
400 Series VMC SERVICE 2/01 Replaces all Previous Issues
- 21 -
FIGURE 12.
- 22 -
XIII. CYLINDER LINERS NOTE: Before proceeding, refer to Paragraph I, General Service Instructions. A. Removal
FIGURE 13.
TABLE 1. PISTON RING DIMENSIONS AND TOLERANCES DIMENSION COMPRESSION OIL RING RING A 4.500 4.500 B 0.160 to 0.170 0.170 to 0.180 C 0.1230 to 0.1240 0.1860 to 0.1870 D 0.013 to 0.0225 0.013 to 0.023 E 0.002 to 0.004 0.0015 to 0.004
Once the piston and rod assemblies are removed, the liner can be extracted from the frame by means of a Vilter Liner Pulling Tool (KT 257). This tool, or similar, is required for all 440/450 compressors and 2-stage compressors. NOTE: If the cylinder bank has unloading, the unloader piston needs to be held down for ease in liner removal. The liners in the 450XL compressor have a looser fit into the frame. They can be removed by pulling from the bottom of the liner by hand. NOTE: 2-Stage liners have an extra groove without ring that seals the suction chamber from the crankcase.
After a plain nut has been placed on a rod bolt and torqued to the specified value, turn a Palnut to the rod bolt with the open end of the hexagon pointing away from the plain nut. The Palnut should be turned until mating parts are pulled together and actual tightening begins. Final tightening and locking is then achieved by giving the Palnut an additional 1/3 to 1/2 (maximum) turn. Although the plain steel nuts may be reused, new unused Palnuts must be used each time the connecting rods are reassembled to the crankshaft. If used Palnuts are installed, their
- 23 -
Before the liner is installed, make sure the outer surface of the liner is clean and the seat area in the frame is free of foreign matter. If a new oring is required, lubricate the o-ring and frame seating area with refrigeration oil. Slide the liner into the frame and align with the bore. Roll pin on the top of the liner can be orientated so if an imaginary line is drawn to opposite pins, it forms the letter X. Seat the liner in the frame recess firmly by use of Vilter Cylinder Liner Tool (Vilter Part No. 33464A). A similar tool can be constructed. Be sure to protect the liner lapped seats to prevent damage.
FIGURE 14.
XIV. CRANKSHAFT
400 Series VMC SERVICE - 24 2/01 Replaces all Previous Issues
side on the frame. Slip out the spring behind the tee with a piece of wire. Secure a -13NCx10 long rod. Screw this into the threads in the end of the oil feed connector tube. Remove the tube from the frame with a slight pull on the rod. After the tube is taken out, separate the nut from the taper pin in the center bearing and tap the pin out of its hole. This releases the center bearing and allows the crankshaft to be removed. Once the front housing is removed, the crankshaft should be blocked from inside the frame due to its weight. Adjust the blocking as the work proceeds so the crankshaft does not bump the front bore nor make any contact with the journals. To aid in removal, a simple step can be added. Before removing the shaft from the rear housing, remove the rear bearing retainer and tap the center hole to 1 (31.75 mm) NPT. Reinstall the retainer on the end of the crankshaft. A 1 (31.75 mm) pipe can be threaded into it and used as an extension bar for handling the crankshaft during removal. C. Removal From The Pump End To pull the crankshaft from the pump end of the compressor, remove the pump cover filter adapter, the complete oil pump assembly and the rear bearing housing. The crankshaft does need to be blocked to prevent damage and on 12 and 16 cylinder compressors, the center bearing needs to be freed. The shaft seal cover, shaft seal, and inner retainer will also have to be removed. All special notes apply to this method as well.
D. Servicing The Center Bearing (12 & 16 Cylinders) The center bearing on this compressor is a split sleeve type bearing much like connecting rod bearings. To disassemble the bearing, remove the four bolts holding the halves of the center
2/01 Replaces all Previous Issues
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Whichever method was used to remove the crankshaft, extreme care is needed when placing the shaft back into the frame. Avoid any damage to the journals, and block the crankshaft once in position. If the crankshaft was removed from the front end and the rear housing left in place with the oil pump, it is imperative the locating pin on the rear bearing align with the slot in the bottom of the rear housing bore. Also, the pump drive key must engage with the pump shaft. If the unit is 12 or 16 cylinder, the center bearing must be guided into place. Align the hole in the bearing housing (for the oil feed connector tube) with hole in the frame. Screw the oil feed connector loosely on the end of the (12.7 mm) threaded rod, and insert it into the hole. Push the tube into the bearing housing. Unscrew the rod from the tube. Place the spring in the hole and screw in the tee. Use thread sealant. Insert the taper pin it its hole. After placement, pin must be tightened. This expands the bearing housing so it fits tightly in the frame for quiet operation.
400 Series VMC SERVICE - 26 2/01 Replaces all Previous Issues
SEE SKETCH BELOW FOR LOCATION AND DESCRIPTION OF OIL HOLE IN CURRENT BEARING RETAINER.
45 OIL HOLE 3 /16 DIA. DEEP 0.041 DIA. THRU ON VERTICAL CENTERLINE
FIGURE 16.
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ITEM NO. 102 102 112 112 112 112 121 128 201 209 210 213 215 216 219 224 232 232 236 243
VPN 13152L 13152G 13152C 13152D 13153E 13153D 13152E 13153E 30651B 13264B 13264C 13159E 13153E 13153Q 13153F 31909 1736G 13160D 11396D 1726E
BOLT SIZE 5 /8 x 3 5 /8 x 2 5 /8 x 1 5 /8 x 1 x 1 x 1 5 /8 x 2 x 1 Plug, Hex. Pipe Plug Plug, 3/8 Hex. Pipe Plug 5 /8 x 4 5 /8 x 2 x4 x 1 2 dia. X 18 Td/in. 5 /16 x 1 5 /16 x 1 Nut
GRADE 2 2 2 2 5 5 2 5
APPLICATION Head Bolt with H2O Jacket Head Bolt without H2O Jacket Suction Screen Cover Suction Screen Cover Suction Screen Cover Suction Screen Cover Safety Valve Cover Handhole Cover Cap, Valve
5 2 5 5 2 2 2
244 247 302 323 326 327 341 342 419 509 510 513 510A 518 518
13253F 31956A 13163E 1689G 13153E 13153F 13153E 13153F 1352D 2027A 2028A 1776B 1472A 31964A 1527B
2 2 2 2 5
65 Ft. Lb. 250 Ft. Lb. 75 Ft. Lb. 30 Ft. Lb. 100 Ft. Lb. 75 Ft. Lb.
Front Bearing Cover Front Bearing Cover Front Bearing Retainer Shaft Seal Cover Bearing Locknut Rear Bearing Retainer Rear Bearing Retainer (See Item 243) Center Bearing SupportHalf Bolt (Used on Item 236 x 1 Bolt VPN 11396D) Center Bearing Tapered Pin Flywheel Hub Oil Filter Shell Rear Bearing Cover Oil Pump Cover Same as 326 Same as 327 Yoke Assembly Conn. Rod Cap Conn. Rod Cap w/Nut Lock Discharge Valve Retaining Discharge Valve Retaining Use with 510A Use with 513
8 5 3 3 3
20 Ft. Lb. * * 25 Ft. Lb. 15-18 Ft. Lb. 15-18 Ft. Lb. 20-25 Ft. Lb.
NOTE: * Refer to Connecting Rod Nuts Tightening Instructions VMC Compressors on page 31.
- 28 -
116 121 125 201 209 210 213 215 216 219 224 232 236 243 244 245 247 323 334 335 419 509 510
VPN 13152L 13152C 13152D 13153E 13164E 13264D 13152E 13153E 30641B 13264B 13264C 13159E 13152E 13153Q 13153F 1736G 11396D 1726E 13253F 1603A 31956A 1689G 13152E 13153F 1352D 2027A 2028A
GRADE 2 2 2 5
2 5
Hex. Pipe Plug /8 Hex. Pipe Plug 5 /8 x 4 5 /8 x 2 x4 x 1 /16 x 1 x 1 Nut (Item 236) 9 /16 Nut x 1 x 17/8 7 /16 x 2 5 /8 x 2 x 1 3 /8 x 1 3 /8 x 24 Nut 3 /8 Palnut
5
5 2 5 5 2 2 2 2 2 2 2 5 8
APPLICATION Cylinder Head Suction Screen Cover Suction Screen Cover Suction Screen Cover Plug Plug Safety Valve Cover Handhole Cover Valve Cap Front Bearing Cover Front Bearing Cover Front Bearing Cover Front Bearing Cover Front Bearing Retainer Shaft Seal Cover Bearing Locknut Rear Bearing Retainer Bearing Support Bearing Support Half
Flywheel Hub Oil Filter Shell Rear Bearing Cover Oil Pump Yoke Assembly Connection Rod Cap Connection Rod Cap
NOTE: * Refer to Connecting Rod Nuts Tightening Instructions VMC Compressors on page 31.
- 29 -
ITEM NO. 102 112 116 121 125 201 209 210 213 215 216 219 224 232 236 243 244 247 323 334 335 419 504 505
VPN 13152L 13152E 13153E 13264E 13264D 13152E 13153E 30651B 13264B 13264C 13159E 13153E 13153Q 13153F KT 367 1736G 13153F 1726E 13253F 31956A 1689G 13153E 13153F 1352D 2027A 2028A
GRADE 2 2 5
2 5
Hex Pipe Plug /8 Hex Pipe Plug 5 /8 x 4 5 /8 x 2 x4 x 1 /16 x 1 x 1 Nut 9 /16 Nut 1 x 17/8 7 /16 x 2 5 /8 x 2 x 1 3 /8 x 1 3 /8 x 24 Nut 3 /8 Palnut
5
5 2 5 5 2 2 2 2 2 2 5 8
APPLICATION Cylinder Head Suction Screen Cover Suction Screen Cover Plug Plug Safety Valve Cover Handhole Cover Valve Cap Front Bearing Cover Front Bearing Cover Front Bearing Cover Front Bearing Cover Front Bearing Retainer Shaft Seal Cover Bearing Locknut Rear Bearing Retainer Machine Bolt Bearing Support Half Flywheel Hub Oil Filter Shell Rear Bearing Cover Oil Pump Yoke Assembly Connection Rod Cap Connection Rod Cap
NOTE: * Refer to Connecting Rod Nuts Tightening Instructions VMC Compressors on page 31.
- 30 -
- 31 -
ITEM 1
DIMENSION
NONE
2.8140 Dia.
2.8125 3.1875
+.0005 -.0000
NONE
Pump End
2.8125
Mounted
.0068
ALL Except 450XL ALL Except 450XL ALL Except 450XL 450XL All Models 450XL (ALL) 450XL (ALL)
2.874 Dia. 2.859 2.844 +.000 -.001 3.124 3.109 3.094 .0015 to .0036 .002
- 32 -
ITEM 3
PART NAME Connecting Rod I.D. w/Large End Brgs. Installed Std. W/.015 U.S. Brgs. Installed W/.030 U.S. Brgs. Installed
COMPRESSOR SIZE
DIMENSION
TOLERANCE
CLEARANCE
ALL Except 450XL 450XL (ALL) ALL Except 450XL 450XL (ALL) ALL Except 450XL 450XL
+.0011 -.0000
.0015 to .0036
.001
Shell Bearing Thickness Std. .015 U.S. .030 U.S. Connecting Rod Width Side Clearance Crankshaft Center Brg. O.D. Shell Bearings I.D. Thickness Piston Cylinder Bore O.D.
+.0000 -.0003
.001 +.001
ALL ALL
+.000 -.001 +.0026 -.0000 +.0000 -.0003 +.000 -.001 +.001 -.000 .001 +.001 -.000
.002 .0005
5 6
Frame Bore
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TABLE 5.
FACTORY RUNNING DIMENSIONS, TOLERANCES, CLEARANCES & ALLOWABLE WEAR LIMITS FOR 440, 450 & 450XL VMC COMPRESSORS (contd)
MAXIMUM ALLOWABLE WEAR Drops thru
ITEM 5
TOLERANCE
CLEARANCE Finger Tight (Dry) Tight .0007 .0012 See Above Pin Bore .0004 to .0009 Meas. In 4.500 Bore
.0002
None .0005
Pin Dia. 3 Connecting Rod Pin Bushing (I.D.) Rings, Piston End Gap Compression Oil (Solid) Oil (Flex) Oil (Rails) Fit in Groove Compression Oil (Solid) Oil (Flex) With Rails Suction Valve Thickness Cylinder Valve Seat Height To Top of Liner
ALL
ALL
.001
.012 .010
.025 .025
.002 .0025
.002
9 6
ALL ALL
.003 .010
None None
.002
None
.023
.012
ALL
None None (Lapped Flat to Seat) None (Lapped Flat to Seat) Must be Measured. Minimum .010
Dimension does not apply to assembled 450XL piston on connecting rod (piston shrink fit to wrist pin).
- 34 -
TABLE 5.
FACTORY RUNNING DIMENSIONS, TOLERANCES, CLEARANCES & ALLOWABLE WEAR LIMITS FOR 440, 450 & 450XL VMC COMPRESSORS (contd)
MAXIMUM ALLOWABLE WEAR None None Measured From Head To Rail .005 Minimum Height .002
ITEM 10
DIMENSION
TOLERANCE
CLEARANCE
11
ALL
.003 .006
.003
.003 .006
- 35 -
FIGURE 17.
TYPICAL 400 SERIES COMPRESSOR VERTICAL CROSS SECTION AND LUBRICATION SYSTEM
- 36 -
PAGE 1 2 3 4 5 9 10 9 10 12 13 14 15 16 17 18
REPLACEMENT PARTS ORDERING INSTRUCTIONS BASIC FRAME REPLACEMENT PARTS Illustration, 2 Cylinder (Figure 1) Illustration, 4, 6 & 8 Cylinder (Figure 2) Illustration, 12 & 16 Cylinder (Figure 3) Parts List DISCHARGE/SUCTION GAUGE Illustration (Figure 4) Parts List CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS Illustration (Figure 5) Parts List REAR BEARING COVER REPLACEMENT PARTS Illustration (Figure 6) Parts List CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS Illustration (Figure 7) Parts List PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS Illustration (Figure 8) Parts List RECOMMENDED SPARE PARTS LIST REPLACEMENT PARTS ORDERING INSTRUCTIONS
1.
Give the size, voltage, original order number and serial number of the compressor. All of this information is stamped on the nameplate attached to the compressor frame. The serial number is also stamped on the compressor frame. The compressor frame serial number location is directly above the suction flange on the frame of the compressor or directly above the rear bearing cover. The rear bearing is located on the oil pump/filter end of the compressor. Always give the name of the part as well as the corresponding part number and/or item number. Also include the quantity of parts required. Should there be a doubt regarding the part number or name, send a sketch of the part required or return the old part as a sample, transportation charges prepaid. Orders on which part numbers and description do not agree will be filled according to our best interpretation. All prices are F.O.B. factory. Minimum domestic parts order is $75.00 net price. Please indicate on the order preferred method of shipment. We will follow your instructions unless it is to your best interest to change routing. If you purchased the compressor from a party other than Vilter Manufacturing Corporation, please state when you purchased the compressor and from whom.
Patents Pending
2.
3.
4. 5.
6.
* PATENTS PENDING
* PATENTS PENDING
* PATENTS PENDING
DESCRIPTION Frame 5 Screw, /8 x 3 Hex Head Cap (Used with Water Jacket) 5 Screw, /8 x 2 Hex Head Cap (Used when Water Jacket not used) Cover, Water Jacket (Ammonia and R22) Gasket, Water Jacket (Ammonia and R22) Cover, Cylinder Banks w/o Capacity Reduction Banks w/Capacity Reduction (Oil Act.) Banks w/Capacity Reduction (Gas Act.) Banks w/o Capacity Reduction Banks w/Capacity Reduction (Oil Act.) Banks w/Capacity Reduction (Gas Act.) Banks w/o Capacity Reduction (Two-Stage) Gasket, Cylinder Cover 5 Stud, /8 x 3 (shown only on 2 cylinder) Stud, x 3 (not shown) Nut, 5/8-11NC-2B Nut, -10NC-2B Tee, Suction (++) 2 x 2 3 x 3 Elbow, Discharge (++) 2 x 2 (Ammonia) 2 x 2 (Ammonia) 3 x 3 (Ammonia) 4 x 3 (Ammonia) Suction Screen Suction Screen Suction Screen Bag, Suction Screen (not shown) Bag, Suction Screen (not shown) Bag, Suction Screen (not shown) Gasket, Suction Screen Cover Gasket, Suction Screen Cover Gasket, Suction Cover Cover, Suction Screen Cover, Suction Screen Cover, Suction Screen 5 Screw, /8 x 2 Hex Head Cap Screw, x Hex Head Cap Valve, Oil Charge and Drain (Ammonia) Valve, Oil Charge and Drain (Halocarbon) Nipple, x 4 Sch. 80 Pipe Gasket, Crankcase Oil Screen Crankcase Oil Screen Assembly Plug, Hex Head Pipe (not shown on 12 & 16) Plug, Hex Head Pipe (not shown on 2 thru 8)
QUANTITY REQUIRED PER COMPRESSOR NUMBER OF CYLINDERS 2 4 6 8 12 16 1 1 1 1 1 1 20 20 1 1 ---1 1** 1** -1 8 --1 -1 -------1 -1 --1 ---6 1 1 1 1 1 1 1 40 40 2 2 1 1** 1 ----2 4 4 4 -1 -1 --1 --1 ----1 --1 5 -1 1 1 1 1 1 1 60 60 3 3 ---1 2** 2** 3 3 4 4 4 ----1 -----2 -2 --2 ---12 1 1 1 1 1 1 1 80 80 4 4 2 2** 2 ----4 4 4 4 -----1 -1 --3 -2 -1 2 -1 5 12 1 1 1 1 1 1 1 120 120 6 6 ---2 4** 4 6 6 8 ------2 ---2 --2 -2 --2 --16 1 1 1 1 1 1 1 160 160 8 8 4 4** 4 ----8 8 ------2 ---2 --2 -2 --2 --16 1 1 1 1 1 1 1
PART NUMBER + 13152L 13152G 30299A 33329A A30332A 30332B 30332G A30364A 30364B 30364G A30364A 33330A 13156D 13157D 1726G 1726H A30319A A32417B 12270E 12270F 12271E A32498A A32428A A32428D A32565A A33474A A33474B A33474G 31892A 33493A 11323J 31893A 33492A 13706A 13152E 2796E 1956B 1956A 13189G 31889A A31886A 13264E 13264D
109 109 109 109-A 109-A 109-A 110 110 110 111 111 111 112 112 113 113 113-A 114 115 116 ++ 116 ++ NOTES: A. Unless otherwise indicated, quantities shown are for compressors with standard capacity reduction, and may vary if compressor is equipped with other versions. See Page 13 for application notes. * Patents Pending. ** Items shown are for compressors with optional oil unloading or optional single cylinder unloading. See Page 15 for application notes. + Part Number on application. ++ May not be shown, or only shown typically on one illustration.
ITEM 117 118 119 120 121 122 122 123 & 124
DESCRIPTION Pin Assembly, Crankcase Oil Screen Retaining Safety Valve (Internal Relief) Gasket, 2 Flange Cover, Safety Valve 5 Screw, /8 x 2 Hex Head Cap Gasket, Handhole Cover (Chain) Gasket, Handhole Cover (Strip) Handhole Cover and 2 Sight Glass Assy With openings for: 560W NEMA 1 & 7 Htr., F.V. & Therm. 560W NEMA 1 & 7 Heater and Therm. Cover, Handhole (with openings) Cover, Handhole (without openings) (not shown) Glass, Oil Sight 2 Screw, x 1 Hex Head Cap Tube, Oil Feed Connector Spring Hex Head Plug Long Shank Unloader Hold Down Hex Head Plug Short Unloader Hold Down 2 1 1 1 1 2 1 1
16 1 2 2 2 4 2 2
123 123A 124 125 126 127 135 136 NOTES: * Patents Pending.
1 1 1 -1 16 ----
1 1 1 -1 16 ----
1 1 1 -1 16 --1
1 1 1 -1 16 ----
1 1 1 1 1 32 1 1 2
1 1 1 1 1 32 1 1 --
A33034G A33034L Order Assy 33034B 1484A 2796E 33494A 31789A 35166A
PATENTS PENDING
DESCRIPTION Heater, Electric Crankcase Oil, 115V (not shown) Heater, Electric Crankcase Oil, 230V (not shown) Gauge, Discharge, 300 PSI Gauge, Suction, 150 PSI Stedy-Mount Connector, MPT x O.D. Compression Nipple x 4 Sch. 80 Pipe Thermometer, Crankcase Oil (not shown) Patents Pending. 2 1 1 1 1 2 2 2 1
16 2 2 2 1 3 3 3 1
PART NUMBER 2069J 2069K 1204E 1204C A17311SS 13229D 13181G 1467F
PATENTS PENDING
ITEM 201 thru 211 201 202 thru 208 202 203 204 205 206 207 208 209 thru 211 209 210 211 211B 211C 212 213 214 215 216 217 & 218 217 218 219 220 & 220A 220A 224 Thru 233 224 thru 244 less + 224 227 228 229
DESCRIPTION Front Bearing Cover and Relief Valve Assy Cap, Valve Oil Relief Valve Kit Gasket, Valve Cap Nut, Packing Washer 7 39 3 Packing, /8 O.D. x /64 I.D. x /8 Stem, Valve Spring 5 Ball, /8 dia. Steel Front Bearing Cover Assembly Plug, Hex Head Pipe 3 Plug, /8 Hex Head Pipe Cover, Front Bearing Shield, Splash 3 Screw, Hexagon Hd. No. 10-32 x /8 long Gasket, Bearing Cover 5 Screw, /8 x 4 Hex Socket Head Cap Retainer, Front Bearing (with Oil Hole) 5 Screw, /8 x 2 Hex Head Cap Screw, x 4 Hex Head Cap Seal and Gasket Kit Seal, Rotary Shaft Assembly Gasket, Shaft Seal Cover Screw, x 1 Hex Head Cap Cover and Tube Assembly, Shaft Seal Drain Tube Crankshaft and Bearings Assembly * Crankshaft and Bearings Assembly * Crankshaft and Bearings Assembly * Crankshaft and Bearings Assembly * Crankshaft and Bearings Assembly Kit * Crankshaft and Bearings Assembly Kit * Locknut and Retaining Compound Kit Front Bearing and Retaining Compound Kit Ring, Front Bearing Retainer Crankshaft and Retaining Compound Kit *
QUANTITY REQUIRED PER COMPRESSOR NUMBER OF CYLINDERS 2 4 6 8 12 16 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 3 1 2 1 6 3 1 1 1 8 1 1 1 -----1 1 1 -1 1 1 1 2 1 1 1 1 1 1 1 1 1 3 1 2 1 6 3 1 1 1 8 1 1 -1 ----1 1 1 -1 1 1 1 2 1 1 1 1 1 1 1 1 1 3 1 2 1 6 3 1 1 1 8 1 1 --1 ---1 1 1 -1 1 1 1 2 1 1 1 1 1 1 1 1 1 3 1 2 1 6 3 1 1 1 8 1 1 ---1 --1 1 1 -1 1 1 1 2 1 1 1 1 1 1 1 1 1 3 1 2 1 6 3 1 1 1 8 1 1 ----1 -1 1 1 -1 1 1 1 2 1 1 1 1 1 1 1 1 1 3 1 2 1 6 3 1 1 1 8 1 1 -----1 1 1 1 --
PART NUMBER A32566A 17355A KT486 30651C 31048A 31048D 31048E 31048C 31048F 13155K A36241A 13264B 13264C Order Assy 35274A 2583A 31890A 13159E 33500A 13152E 2796EV KT509 A33489A 33496A 2796EL A32564A 35078A A34555HX A34555KX A34555LX A34555BX KT588 KT589 KT367 KT369 33145A See Assembly Above
DESCRIPTION 2 3 2 1 1 4 1 ----------1 1 1 1 1 1 1 1 1 1
229A Plug, /8 Pipe, Hex Socket Head (not shown) 229B Plug, Pipe, Hex Socket Head (not shown) 231 Retainer, Rear Bearing 231A&231B Rear Bearing and Lock Pin Kit 5 232 Screw, /16 x 1 Hex Head Cap 233 Crank, Oil Pump Drive 234 Cap, Bearing Support 235 Pin, x 1 Dowel 236 Bolt, x 1 Machine 237 Bearing, Upper Right Half or Lower Left Half 238 Bearing, Upper Left Half or Lower Right Half 240 Pin, Threaded Taper 241 Case, Bearing Support 242 Washer, Spring Lock 243 Nut, Hex 9 244 Nut, /16 Hex 246 Key, Crankshaft 247 Screw, Flywheel Hub 248 Washer, Flywheel Hub Screw 249 Gauge, Oil Pressure, 300 PSI 250 Stedy-Mount 251 Valve, Screw End Globe 252 Nipple, x 7 Sch. 80 Pipe 253 Connector, MPT x O.D. Compression 254 Tee, 255 Nipple, x 2 Sch. 80 Pipe NOTES: * Patents Pending. ** Matched set with pins, sold as assembly A32163A. Shown in fiveparts to illustrate disassembly.
QUANTITY REQUIRED PER COMPRESSOR NUMBER OF CYLINDERS 4 6 8 12 3 3 3 5 2 2 2 4 1 1 1 1 1 1 1 1 4 4 4 4 1 1 1 1 ---1 ---2 ---4 ---2 ---2 ---1 ---1 ---4 ---4 ---1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
16 5 4 1 1 4 1 1 2 4 2 2 1 1 4 4 1 1 1 1 1 1 1 1 1 1 1
PART NUMBER 13163A 2606A 31904A KT353 1736G 33403A ** 13162X ** 2796EL ** 33508A 33508B 33497A ** 13165F 1726E ** 13253F 33505B 31956A 33495A 1204E A17311SS A11392A 13181M 13229D 1098B 13181C
PATENTS PENDING
ITEM 301 thru 304 & 333 301 302 303 304 305 306 307 308 309 309 310 *** 310 ** 311 *** 311A,312, 313 & 314 311A, 312 Thru 314 & 315A thru 319 & 321 311A ** 312 313 314 315 *** 315A ** 316 317 318 319 320 321 322 322A 322B 323 324 *** 324 **
DESCRIPTION Rear Bearing Cover Assembly Kit Cover, Rear Bearing Plug, Hex Socket Head Pipe 3 Pin, /8 x 1 Dowel Orifice, Oil Metering (not shown) Gasket, Oil Pump Body Oil Pump Assembly Gasket, Oil Pump Cover Gasket, Oil Pump and Rear Bearing Cover Seal Cover, Oil Pump and Filter Head (R12 & R502) Cover, Oil Pump and Filter Head (R717 & R22) Filter Assy., Complete (without Bypass Relief) Filter Assy., Complete (with Bypass Relief) Spool Assembly (without Bypass Relief) Spool Strainer Tube Assembly
PART NUMBER KT092 Order Kit 13163E 2868H 33361A 31899A A33480A 31900A 33320A 34565A 34760AB A35241A A35240A 2046A 1448U
1448T
325 1 1 326 1 1 327 3ft 3ft 327A *** AR AR 328 *** 2 2 329 2 2 329A *** 2 2 330 1 1 331 1 1 332 *** 1 1 333 1 1 334 10 10 335 8 8 NOTES: * Patents Pending. ** Filter with bypass relief is standard. These items are used. *** Filter without bypass relief is optional. When supplied, these items are used. Replacement recharge also includes gasket 1448B (Item 321).
Spool Assembly (with Bypass Relief) Seal, Spool End Strainer Tube Ring, Retaining Recharge (for A35241A & 2046A) (w/o Bypass) Recharge (for A35240A & 1448J) (with Bypass) Pressure Plate Assembly Pressure Plate O Ring Seal, Pressure Plate Spring, Pressure Plate 1 Plug, Steel Hexagon Head /8 Pipe Gasket, Oil Filter Head Filter Shell with Flange and Plug Flange, Oil Filter Tank Tank, Oil Filter 7 Screw, Hexagon Head Cap /16 x 2 Instruction/Nameplate (for use with A35241A) (not shown) Instruction/Nameplate (for use with A35240A) (not shown) Gauge, 2, 0-300 PSI, Oil Filter Elbow, 90 Female Compression Tubing, O.D. Steel Tubing, O.D. Steel (AR As Required) Tee, Compression Connector, MPT x O.D. Compression Connector, MPT x O.D. Compression Valve, 3-Way, Oil Filter Bracket, Valve Control, Pressure Differential Gasket, Bearing Cover 5 Screw, /8 x 2 Hexagon Head Cap Screw, x 1 Hexagon Head Cap
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 3ft AR 2 2 2 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 3ft AR 2 2 2 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 3ft AR 2 2 2 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 3ft AR 2 2 2 1 1 1 1 10 8
1448J 1448H 1448K 1448L 2115C 1448C 1448M 1448N 1448P 1448Q 13264A 1448B A34623A 35125A 34623A 1689G 40680AJ 40680AT 2047A 1892B S1589AA S1589AA 13239C 13229D 13229D 2030A 35106A 1643V 31890A 13152E 2796EL
* PATENTS PENDING
ITEM 401, 402 & 403 401, 402 Thru 408 401A, 402, 403 & 408A 401A, 402 Thru 408A 401 401A 402 403 405 405A + 405B + 406 407 408 408A 409 410A/B & 411 410 & 411 410 410A 410B 411 413 thru 420 413 414 414 415 416 417 418
DESCRIPTION Cylinder Liner Assembly (for cylinder without unloading) Cylinder Liner Assembly (for cylinder with unloading) Cylinder Liner Assembly (Two-Stage only) (for cylinder without unloading) Cylinder Liner Assembly (Two-Stage only) (for cylinder with unloading) Liner, Cylinder Liner, Cylinder (Two-Stage only) Seal, O Ring (upper) Pin, Roll, 0.125 dia. x 1 lg. Ring, Lift Ring, Lift Pin, Roll Spring, Lift Pin, Lift Retainer, Lift Ring Seal, O Ring (lower Two-Stage only) Plate, Suction Valve Piston & Rings Assy., Cap Red (Oil ) Piston & Rings Assy., Cap Red (Gas ) Ring Set (PTFE & rubber) Seal, Unload Piston (Oil only) Ring, Retaining Unload Piston (Oil only) Piston, Unloader (Gas or Oil) Complete Capacity Control Mechanism Assembly * (Low Suction R717 and all Booster) Arm, Yoke Lifting Yoke Assembly (2 Cylinder and Two-Stage only) Yoke Assembly 3 11 Pin, /8 x /16 lg. Roll Pin, Short Pivot Spring, Unloader Yoke Yoke Guide Assembly
QUANTITY REQUIRED PER COMPRESSOR NUMBER OF CYLINDERS 2 4 6 8 12 16 2(1**) -(1**) --2 -2 8 -(1**) 1 4 -(8**) -(8**) -(1**) -2 -(1**) -(1**) -(1**) 1 1 -(1**) --(1**) -(1**) --(1**) -(1**) -(4**) -2 2 --4 -4 16 2 2 4 16 16` 2 -4 1 1 1 1 1 1 1 1 -1 1 1 4 1 2 4 6(3**) -(3**) 6 6 6 24 4(3**) 4 4 32(24**) 32(24**) 4(3**) 6 6 2(3**) 2(3**) 2(3**) 1 1 2(3**) 2 2(3**) -(3**) 2 2(3**) 2(3**) 8(12**) 2 4 4 --8 -8 32 4 4 4 32 32 4 -8 2 2 2 1 1 2 2 2 -2 2 2 8 2 4 8 12(6**) -(6**) 12 12 12 48 8(6**) 8 4 64(48**) 64(48**) 8(6***) 12 12 4(6**) 4(6**) 4(6**) 1 1 4(6**) 4 4(6**) -(6**) 4 4(6**) 4(6**) 16(24**) 4 8 8 --16 -16 64 8 8 4 64 64 8 -16 4 4 4 1 1 4 4 4 -4 4 4 16 4
PART NUMBER KT475 KT476 A35108D A35108C 34510A 34710A 2176BH 1193Q 35071A 35380A 1193SS 35069A 35070A 1971A 2176BL 31909A A35315BX A35315CX 2557A 2639A 2638A Order Assy A41788BX 41725A A33575A A33335A 1193X 33250B 33686A A33347A
NOTES: * Patents Pending. ** Two cylinder high stage and 6 & 12 cylinder Two-Stage Compressor only: Unloading is NOT standard. When supplied as an option, single cylinder unloading is provided on 50% of the cylinders. These items and quantities in ( ) are then used. Also, for single cylinder unloading, the yoke assembly (Part Number A33575A) and two pins on the Yoke Guide Assembly (Part Number A33576A) have drill and tapped holes to accommodate screw (Item 419) and spacers (Item 420). *** Parts quantities are listed for standard unloading only (except 2 cylinder and two-stage, see note **). Standard unloading on compressors with 2 cylinders is none; 4 cylinders is 50%; 6 cylinders is 33 & 66%; 8 cylinders is 25 & 50%; 12 cylinders is 33 & 66%; 16 cylinders is 25 & 50%; and two-stage is none. See Operation Section for other unloading options. Actuation type presently on your compressor can be determined by checking unloading solenoid valve oil uses three-way valves, gas uses two-way valves. Gas unloading was considered standard on all high-stage compressors, except those with 100% capacity reduction. Oil unloading is standard on high-stage compressors with 100% capacity reduction, all boosters and two-stage compressors with capacity reduction. + If a single cylinder unloader mechanism serviced uses pivot bolts to hold down one half them mechanism, it should be replaced by 405A and 405B.
PATENTS PENDING.
ITEM 501 thru 508 501 502 503 504, 507 & 508 504 505 506 507 508 509 510 520
DESCRIPTION Piston Rings and Connecting Rod Assy Kit Piston Ring, Compression Piston Ring, Oil Piston and Connecting Rod Assy Bearing Half and Lock Nut Kit Lock Nut, /8, Connecting Rod 3 Nut, Plain Hex /8-UNF Bolt, Connecting Rod Bearing Half, Connecting Rod (upper) Bearing Half, Connecting Rod (lower) Spring, Safety Head Safety Head Yoke Kit (includes 4 of item 513) BoosterSafety Head Yoke 2-Stage Low sideSafety Head Yoke Spring, Valve Plate, Discharge Valve Valve, Diaphragm Discharge (Booster) 2-Stage Low Side Safety Hd. & Pins Assy (Std. Ammonia) Safety Hd. & Pins Assy (2- Stage High Side Comp.) Safety Hd. & Pins Assy (#) (Halo) Safety Hd. & Pins Assy (2- Stage High Side Comp.) 11 Pin, Roll, 0.187 dia. x /16 lg. Safety Head-STD.XL Spring, Valve Booster- Safety Head- Ammonia Booster- Safety Head- Halo 2- Stage Low Side-Safety Head- Ammonia 2- Stage Low Side- Safety Head- Halo Spring, Valve (Booster) 2- Stage Low Side
3
PART NUMBER KT573 ** 31989M 31989N ** KT575 2028A 2027A 31955A Order KT575 Order KT575 35252A KT543 31941B 31941B 33803A 35080SS 31939B A35082A A35272A 1712F *** 33803A A32695C A32695D A32695C A32695D 33803A
511 512 515B 513 & 514 513 514 515 513 thru 518 519
NOTES: * ** *** #
Patents Pending. Piston, wrist pin and connecting rod sold only as a kit. Shown for disassembly purposes only, order assembly. Install with pins outside longitudinal seam facing outside diameter of safety head. This Safety Head and Pins Assembly is used on standard Halocarbon and High Suction Pressure Ammonia Compressors. High Suction Pressure Compressors are identified with an X in the serial number. Also used in 2- Stage High Side Halo Compressors.
ITEM 118 217 & 218 306 315 315 401 Thru 404 401 Thru 408 409 413 Thru 420 501 thru 508 501 502 504, 507 & 508 511, 515 & 519 512
DESCRIPTION Valve, Internal Relief Rotary Shaft Seal Assembly Oil Pump Assembly Recharge, Oil Filter (Gasket 1448B included) (for use with 2046A & A35241A) (w/o bypass) Recharge, Oil Filter (Gasket 1448B included) (for use with A35240A & 1448J) (with bypass) Cylinder Liner Assembly Kit (for cylinder without unloading) (for cylinder without unloading, Two-Stage) Cylinder Liner Assembly Kit (for cylinder with unloading) (for cylinder with unloading, Two-Stage) ** Plate, Suction Plate Capacity Control Assembly Two Cylinder and Two-Stage Compressor ** 4 thru 16 Cylinder Compressors Piston, Rings and Connecting Rod Assembly Kit Piston Ring, Compression Piston Ring, Oil Bearing Half and Lock Nut Kit Spring, Valve Plate, Discharge Valve Safety Hd. & Pins Assy (Std. Ammonia) Safety Hd. & Pins Assy (2- Stage High Side Comp.) Safety Hd. & Pins Assy (#) (Halo) Safety Hd. & Pins Assy (2- Stage High Side Comp.) Booster- Safety Head- Ammonia Booster- Safety Head- Halo 2- Stage Low Side-Safety Head- Ammonia 2- Stage Low Side- Safety Head- Halo Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete 2 1 1 1 1 1 1 -1 -2 1 -1 6 2 2 24 2 2 2 2 2 1 ------
QUANTITY REQUIRED PER COMPRESSOR NUMBER OF CYLINDERS 4 6 8 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 -1 -4 -1 1 12 4 4 48 4 4 4 4 4 -1 ----1 1 2 1 2 1 6 1 1 2 18 6 6 72 6 6 2 6 2 6 6 4 4 --1 ---1 1 2 -2 -8 -1 2 24 8 8 96 8 8 8 8 8 ---1 --1 1 2 1 2 1 12 1 1 2 36 12 12 144 12 12 4 12 4 12 12 8 8 ----1 --
PART NUMBER 1721C KT 509 A33480A 2115C 1448C KT475 A35108D KT476 A35108C 31909A A41787AX A41788BX KT573 31989M 31989N KT575 33803A 35080SS A35082A A35272A A32695C A32695D A32695C A32695D KT041 KT043 KT045 KT049 KT051 KT055
------------NOTES: A. The above listing includes the minimum selection and quantity of recommended spare parts. All items listed do not necessarily apply to every compressor, because of type, size or optional features. Items should be selected for each individual compressor as they apply. * Patents Pending. ** When capacity reduction is supplied. # This Safety Head and Pins Assembly is used on standard Halocarbon and High Suction Pressure Ammonia Compressors. High Suction Pressure Compressors are identified with an X in the serial number. Also used in 2- Stage High Side Halo Compressors.
TABLE OF CONTENTS
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REPLACEMENT PARTS ORDERING INSTRUCTIONS BASIC FRAME REPLACEMENT PARTS Illustration, 2 Cylinder (Figure 1) Illustration, 4, 6 & 8 Cylinder (Figure 2) Illustration, 12 & 16 Cylinder (Figure 3) Parts List DISCHARGE/SUCTION GAUGE Illustration (Figure 4) Parts List CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS Illustration (Figure 5) Parts List REAR BEARING COVER REPLACEMENT PARTS Illustration (Figure 6) Parts List CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS Illustration (Figure 7) Parts List PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS Illustration (Figure 8) Parts List CAPACITY CONTROL MECHANISM REPLACEMENT PARTS Illustration (Figure 9) Parts List RECOMMENDED SPARE PARTS REPLACEMENT PARTS ORDERING INSTRUCTIONS
1.
Give the size and speed of the compressor, as well as serial number and refrigerant used. The serial number is stamped on the nameplate and the compressor frame. The compressor frame serial number location is directly above the suction flange on the frame of the compressor or directly above the rear bearing cover. The rear bearing is located on the oil pump/filter end of the compressor. Always give the name of the part as well as the corresponding part number and/or item number. Also include the number of parts required. Should there be a doubt regarding the part number or name, send a sketch of the part required or return the old part as a sample, transportation charges prepaid. Orders on which part numbers and description do not agree will be filled according to our best interpretation. If parts that appear on the parts list do not appear on the price list, it is because they are sold only as an assembly. All prices shown on the list are F.O.B. factory. Minimum domestic parts order is $75.00 net price. Prices are for a single item unless otherwise specified in the price list. Please indicate, on the order, preferred method of shipment. We will follow your instructions unless it is to your best interest to change routing. If you purchased the compressor from a party other than Vilter Manufacturing Corporation, please state when you purchased the compressor and from whom.
2.
3.
4.
5.
6.
20 40 60 80 120 160 13152G 103 1 2 3 4 6 8 30299A 104 1 2 3 4 6 8 33329A 107 * 8 4 4 4 8 8 13156D 107 * -4 4 4 --13157D 107 * ----8 8 13157F 107-A * 8 4 4 4 8 8 1726G 107-A * -4 4 4 --1726H 108 * 1 -----A30319A 108 * -1 ----A32417B 108 * ---1 --36254C 108 * --1 ---A36254B 108 * --1 ---A36254A 108 * ---1 --A36254C 108 * --1 ---12273C 108-A * --2 2 --11323L 108-A * 1 2 ----11323H 108-A * -1 ----11323K 108-A * --3 ---11323J 108-A * ----1 1 11323M 108-B * --1 ---13151L 109 1 -2 2 --A32428D 109 -1 ----A32428A 109 ---1 --A32428C 109 ---1 --A32428D 109 --1 1 --A35215A 109 ----2 2 A32565A 109-A * -1 ----A33474A 109-A * 1 -2 3 --A33474B 109-A * ----2 2 A33474G 109-A * --1 1 --A35234A 110 1 -2 2 --31892A 110 ----2 2 33493A 110 -1 -1 --11323J 110 --1 1 --35217A 111 1 -2 2 --31893A 111 ----2 2 33492A 111 -1 -1 --13706A 111 --1 1 --35216A 112 -5 -5 --13152C 112 --6 6 --13152D 112 6 -12 12 16 16 2796E 113 1 1 1 1 1 1 A15375A 113-A 1 1 1 1 1 1 13189G 114 1 1 1 1 1 1 31889A 115 1 1 1 1 1 1 A31886A 116 1 1 1 1 1 1 13264E 116 1 1 1 1 1 1 13264D NOTES: * May not be shown, or only shown typically on one illustration. + Part Number on application 6 Cylinder Compressors with serial numbers below 45461 (oil unloading) and 60019 (gas unloading) are equipped with a suction elbow and two suction screens (VPN A32428B) located behind the suction screen covers on the frame. 6 Cylinder compressors with serial numbers 45461 (oil unloading) and 60019 (gas unloading) and above are equipped with a suction tee (VPN 36254) and a single suction screen (VPN A35215A) located in the suction tee. 8 Cylinder compressors with serial numbers below 45461 (oil unloading) and 60019 (gas unloading) are equipped with a suction tee (VPN 36254C) and three suction screens, one in the tee and two behind the suction screen covers on the frame. 8 Cylinder compressors with serial numbers 45461 (oil unloading) and 60019 (gas unloading) and above are equipped with suction tee (VPN 36254) and a single suction screen (VPN A35215A) located in the suction tee. Part Number on application.
Frame 5 Screw, /8 x 3 Hex Head Cap (Used with Water Jacket) 5 Screw, /8 x 2 Hex Head Cap (Used when Water Jacket not used) Cover, Water Jacket (Ammonia and R22) Gasket, Water Jacket (Ammonia and R22) 5 Stud, /8 x 3 (shown only on 2 Cylinder) Stud, x 3 (not shown) Stud, x 3 5 Nut, /8 Hexagon (see Figure 1) Nut, Hexagon (see Figure 1) Tee, Suction 2 x 2 (see Figure 1) Tee, Suction 3x3 (not shown) Tee, Suction 5x4 (not shown) Tee, Suction 4x4 (not shown) (High Stage) Tee, Suction 4x3 (not shown) (Booster) Tee, Suction 5x4 (not shown) Elbow, Suction 4 (not shown) Gasket, 4 Flange (Suction/Discharge Conn) Gasket, 2 Flange (Suction/Discharge Conn) Gasket, 3 Flange (Suction/Discharge Conn) Gasket, 3 Flange (Suction/Discharge Conn) Gasket, 5 Flange (Suction/Discharge Conn) Ring, Male Joint 4 (Suction) Suction Screen Suction Screen Suction Screen (Center) Suction Screen (RH Side, 75% Cap Red) Suction Screen Suction Screen Bag, Suction Screen (not shown) Bag, Suction Screen (not shown) Bag, Suction Screen (not shown) Bag, Suction Screen (not shown) Gasket, Suction Screen Cover Gasket, Suction Screen Cover Gasket, Suction Tee Cover Gasket, Suction Tee Cover Cover, Suction Screen Cover, Suction Screen Cover, Suction Tee (VPN 32417 & 36254C) Cover, Suction Tee (VPN 36254) 5 Screw, /8 x 1 Hex Head Cap 5 Screw, /8 x 1 Hex Head Cap Screw, x 1 Hex Head Cap Valve, Oil Charge and Drain Nipple, x4 Sch. 80 Pipe Gasket, Crankcase Oil Screen Crankcase Oil Screen Assembly Plug, Hex Head Pipe (not shown on 12) Plug, Hex Head Pipe (not shown on 2 thru 8)
ITEM 117 118 119 120 121 122 123 124 125 126 127
DESCRIPTION Pin Assembly, Crankcase Oil Screen Retaining Safety Valve (Internal Relief) Gasket, 2 Flange Cover, Safety Valve 5 Screw, /8 x 2 Hex Head Cap Gasket, Handhole Cover Handhole Cover and Sight Glass Assy (Std Conn) Glass, Oil Sight 2 Screw, x 1 Hex Head Cap Tube, Oil Feed Connector Spring 2 1 1 3 1 2 1 1 1 16 ---
16 1 2 2 2 4 2 2 2 32 1 1
PART NUMBER A31936A 1721B 11323G 31954A 13152E 31894A A33034L 1484A 2796E 33494A 31789A
DESCRIPTION Heater, Electric Crankcase Oil, 115V (not shown) Heater, Electric Crankcase Oil, 230V (not shown) Gauge, Discharge, 300 PSI Gauge, Suction, 150 PSI Stedy-Mount Connector, MPT x O.D. Compression Nipple x 4 Sch. 80 Pipe Thermometer, Crankcase Oil (not shown) 2 1 1 1 1 2 2 2 1
16 2 2 2 1 3 3 3 1
PART NUMBER 2069J 2069K 1204E 1204C A17311SS 13229D 13181G 1467F
Front Bearing Cover & Relief Valve Assy Front Bearing Cover & Relief Valve Assy Complete Crankshaft Sub-Assembly Kit Complete Crankshaft Sub-Assembly Kit Complete Crankshaft Sub-Assembly Kit Complete Crankshaft Sub-Assembly Kit Complete Crankshaft Sub-Assembly Kit (HD) Complete Crankshaft Sub-Assembly Kit 201 thru Complete Crankshaft Sub-Assy Kit (Hi-Stage HD) 244 less * Complete Crankshaft Sub-Assy Kit (Booster) 201 Cap, Valve 202 Gasket, Durabla 203 Nut, Packing 204 Washers 7 39 3 205 Packing, /8 O.D. x /64 I.D. x /8 206 Stem, Valve 207 Spring 5 208 Ball, /8 dia. Steel 209 thru Front Bearing Cover Assembly 211A Front Bearing Cover Assembly 209 Plug, Hex Head Pipe 3 210 Plug, /8 Hex Head Pipe 211 Cover, Front Bearing 211A + Orifice, Oil Metering 211B Shield, Splash 3 211C Screw, Round Head, No. 10-32 x /8 long 212 Gasket, Bearing Cover 5 213 Screw, /8 x 4 Hex Socket Head Cap 214+ Retainer, Front Bearing (with Oil Hole) 214+ Retainer, Front Bearing (with Oil Hole) 5 215 Screw, /8 x 2 Hex Head Cap 216 Screw, x 4 Hex Head Cap 217 Seal, Rotary Shaft Assembly 217 Seal, Rotary Shaft Assembly 218 Gasket, Shaft Seal Cover 218 Gasket, Shaft Seal Cover 219 Screw, x 1 Hex Head Cap 220 & 220A Cover, Shaft Seal, Small 220 & 220A Cover, Shaft Seal, Large 220A Drain Tube 224 Crankshaft and Bearings Assembly Thru Crankshaft and Bearings Assembly 233 Crankshaft and Bearings Assembly Crankshaft and Bearings Assembly Crankshaft and Bearings Assembly (HD) Crankshaft and Bearings Assembly Kit Crankshaft and Bearings Assy Kit (High Stage HD) Crankshaft and Bearings Assy Kit (Booster) 224 Locknut and Retaining Compound Kit 224 Locknut and Retaining Compound Kit 227 Front Bearing and Retaining Compound Kit 227 Front Bearing and Retaining Compound Kit 228 Ring, Front Bearing Retainer 228 Ring, Front Bearing Retainer 228 Ring, Front Bearing Retainer NOTES: * Less items 234, 235, 236, 239 and 241. + See note with same symbol on Page 9.
PART NUMBER A31121A A32566A KT445 KT446 KT447 KT448 KT553 KT449 KT554 KT555 17355A 30651C 31048A 31048D 31048E 31048C 31048F 13155K A36240A A36241A 13264B 13264C Order Assy. 33361A + 35274A 1332C 31890A 13159E 31885A + 33500A + 13152E 2796EV A33483A A33489A 31897A 33496A 2796EL 31044A A32564A 35078A A34554A A34554B A34555A A34555B A34555BX KT556 KT557 KT558 KT366 KT367 KT368 KT369 33144A 33145A 34564A
229 Crankshaft & Retaining Compound Kit 229 Crankshaft & Retaining Compound Kit 229 Crankshaft & Retaining Compound Kit 229 Crankshaft & Retaining Compound Kit 229 Crankshaft & Retaining Compound Kit (HD) 229 Crankshaft & Retaining Compound Kit 229 Crankshaft & Retaining Compound Kit (H/S HD) 229 Crankshaft & Retaining Compound Kit (Booster) 1 229-A Plug, Pipe, /8, Hex Socket Head (not shown) 231 Retainer, Rear Bearing 231A&231B Rear Bearing and Lock Pin Kit 231-A Pin, Bearing Lock 231-B Bearing, Rear 5 232 Screw, /16 x 1 Hex Head Cap 233 Crank, Oil Pump Drive 234 Cap, Bearing Support 235 Pin, x 1 Dowel 236 Bolt, x 1 Machine 237 Bearing, Upper Right Half or Lower Left Half 238 Bearing, Upper Left Half or Lower Right Half 239 Dam, Center Bearing Oil 240 Pin, Threaded Taper 241 Case, Bearing Support 242 Washer, Spring Lock 243 Nut, Hex 9 244 Nut, /16 Hex 245 Screw, x Hex Head Cap 246 Key, Crankshaft 246 Key, Crankshaft 247 Screw, Flywheel Hub 248 Washer, Flywheel Hub Screw 249 Gauge, Oil Pressure, 300 PSI 250 Stedy-Mount 251 Valve, Screw End Globe 252 Nipple, x 7 Sch. 80 Pipe 253 Connector, MPT x O.D. Compression 254 Tee, 255 Nipple, x 2 Sch. 80 Pipe NOTES: * Matched set with pins, sold as assembly A32163A. Shown in three parts to illustrate disassembly. + See Page 8 for symbol regarding this information. Compressors below serial number 45330 were furnished with the no longer available front bearing cover assemblies A30294A (2 and 4 cylinders) or A32162A (6,8 and 12 cylinders), and front bearing retainer 31885A (2 and 4 cylinders) or 33500A (6, 8 and 12 cylinders) without oil hole. Former front bearing retainers (31885A or 33500A) without oil holes cannot be used with current front bearing cover assemblies A36240A (2 and 4 cylinders) and A36241A (6, 8 and 12 cylinders), as there is no way for oil to get to the bearing. If front bearing cover is being replaced, a current front bearing retainer (31885A or 33500A with oil hole) must be ordered also, unless one of these current styles is already being used. If a current front bearing retainer, (31885A or 33500A, both with oil hole) is used with former style cover (A30294A or A32162A) having an oil hole, remove orifice in cover (A30294A or A32162A) and replace with solid 1/8 pipe plug. Dams (Item 239) and screws (Item 245) are not needed when using VILTERs patented joined crankshafts. In this design version (introduced in 1980), two 6 cylinder or two 8 cylinder crankshafts are joined by a sleeve to form an inseparable 12 cylinder or 16 cylinder crankshaft. This specially machined sleeve eliminates the dams. This design is completely interchangeable with the former design.
ITEM 301 thru 304 301 302 303 304 305 306 307 308 309 310 310 * 311 311A,312, 313 & 314 311A,312 Thru 314 & 315A thru 319 311A * 312 313 314 315 315A * 316 317 318 319 320 321 322 323 324 324 * 325 326 327 328 ** 329 ** 330 331 332 332A ** 333 334 335
DESCRIPTION Rear Bearing Cover Assembly Kit Cover, Rear Bearing Plug, Hex Socket Head Pipe 3 Pin, /8 x 1 Dowel (not shown) Orifice, Oil Metering (not shown) Gasket, Oil Pump Body Oil Pump Assembly Gasket, Oil Pump Cover Gasket, Oil Pump and Rear Bearing Cover Seal Cover, Oil Pump and Filter Head Filter Assy., Complete (without Bypass Relief) Filter Assy., Complete (with Bypass Relief) Spool Assembly (without Bypass Relief) Spool Strainer Tube Assembly 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1
16 1 1 1 1 1 1 1 1 1 1 1 1 1 1
PART NUMBER KT092 Order Kit 13163E 2868H 33361A 31899A A33480A 31900A 33320A 34565A A35241A A35240A 2046A 1448U
1448T
Spool Assembly (with Bypass Relief) (used on 1448C) Seal, Spool End Strainer Tube Ring, Retaining Recharge (for use with 2046A and A35241A) Recharge (for use with A35240A and 1448J) Pressure Plate Assembly Pressure Plate O Ring Seal, Pressure Plate Spring, Pressure Plate 1 Plug, Steel Square Head Pipe /8 Gasket, Oil Filter Head Filter Shell with Bolt Ring 7 Screw, Hex Head Cap /16 x 2 Instruction/Nameplate (for use with A35241A) Instruction/Nameplate (for use with A35240A) Gauge, 2, 0-300 PSI, Oil filter Elbow, 90 Female Compression Tubing, O.D. Steel (AR = As Required) Tee, Compression Connector, MPT x O.D. Compression Valve, 3-Way, Oil Filter Bracket, Valve Elbow, 90 Male Compression Control, Pressure Differential Gasket, Bearing Cover 5 Screw, /8 x 2 Hex Head Cap Screw, x 1 Hex Head Cap
1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 AR 2 2 1 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 AR 2 2 1 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 AR 2 2 1 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 AR 2 2 1 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 AR 2 2 1 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 AR 2 2 1 1 1 1 1 10 8
1448J 1448H 1448K 1448L 2115C 1448C 1448M 1448N 1448P 1448Q 1190A 1448B A34623A 1689G 40680AJ 40680AT 2047A 1892B S1589A 13239C ** 13229D ** 2030A 35106A 13375D 1643V ** 31890A 13152E 2796EL
NOTES: * Filter with bypass relief is standard beginning with S/N 45497 (oil unloaded) and 60080 (gas unloaded). ** Used when center tube (Spool Assembly, Item 311) without bypass relief is used. Replacement recharge also includes gasket 1448B (Item 321).
ITEM 401, 402 & 403 401, 402 Thru 408 401A, 402, 403 & 408A 401A, 402 Thru 408A 401 401A 402 403 405 406 407 408 408A + 409 410A 411A & 412 410 411 & 412 410 410A 410B 411/411A 412 413 Thru 420
DESCRIPTION Cylinder Liner Assembly (High-Stage) (for cylinder without unloading) Cylinder Liner Assembly (High-Stage) (for cylinder with unloading) Cylinder Liner Assembly (Two-Stage) (for cylinder without unloading) Cylinder Liner Assembly (Two-Stage) (for cylinder with unloading) Liner, Cylinder (High-Stage) Liner, Cylinder (Two-Stage) Seal, O Ring (upper High Stage & Two-Stage) Pin, Roll, 0.125 dia. X 1 lg. Ring, Lift Spring, Lift Pin, Lift Retainer, Lift Ring Seal, O Ring (lower Two-Stage only) Plate, Suction Valve Piston Kit, Cap Red (Oil Actuated ) Serial Number 45,000 thru 45,999++ Piston Kit, Cap Red (Gas Actuated) Serial Numbers 60,000 thru 61,199++ Piston Ring (Steel For Gas Actuated) O Ring (Rubber for 0.187 Groove) Ring Set (PTFE for 0.120 Groove) Piston, Unloader (Gas or Oil) Pin, Long Pivot Complete Capacity Control Mechanism Assembly Serial No. 45,000-45,999 & 60,000-61,199++ (2 Cylinder and Two-Stage) (High-Stage) Arm, Yoke Lifting Yoke Assembly (2 Cylinder and Two-Stage) Yoke Assembly (High-Stage) 3 11 Pin, /8 x /16 lg. Roll Pin, Short Pivot Spring, Unloader Yoke Yoke Guide Assy (2 Cylinder and Two-Stage) Yoke Guide Assy (High-Stage) 3 Screw, /8 x 1 Cap Lock Spacer, Sleeve
QUANTITY REQUIRED PER COMPRESSOR NUMBER OF CYLINDERS 2 4 6 8 12 16 2(1*) -(1*) --2 -2 8 -(1*) -(8*) -(8*) -(1*) -2 -(1*) -(1*) -(4*) -(1*) -(1*) -(1*) -(1*) 2 2 --4 -4 16 2 16 16 2 -4 1 1 4 1 1 1 1 2 4 2(3*) 4(3*) 6 6 6 24 4(3*) 32(24*) 32(24*) 4(3*) 6 6 2(3*) 2(3*) 8(12*) 2(3*) 2(3*) 2(3*) 2(3*) 4 4 --8 -8 32 4 32 32 4 -8 2 2 8 2 2 2 2 4 8 4(6*) 8(6*) 12 12 12 48 8(6*) 64(48*) 64(48*) 8(6*) 12 12 4(6*) 4(6*) 16(24*) 4(6*) 4(6*) 4(6*) 4(6*) 8 8 --16 -16 64 8 64 64 8 -16 4 4 16 4 4 4 4
PART NUMBER KT475 KT476 A35108D A35108C 34510A 34710A 2176BH 1193Q 35071A 35069A 35070A 1971A 2176BL 31909A KT364 KT034 31989L 2176AX 2557A Order Kit 33250C
413 414 414 415 416 417 418 418 419 420 NOTES: * Except for 2 cylinder and Two-Stage machines, parts quantities are listed for standard unloading only. The 2 cylinder and TwoStage quantities are listed in parentheses ( ) for the 50% option. Standard unloading on compressors with 2 cylinders is none; 4 cylinders is 50%; 6 cylinders is 33 and 66%; 8 cylinders is 25 and 50%; 12 cylinders is 33 and 66%; 16 cylinders is 25 and 50%; and Two-Stage is none. See Operation Section for unloading options. Also, for single cylinder unloading, the yoke assembly (Item 414) and two pins on the yoke guide assembly (Item 418) have drilled and tapped holes to accommodate screws (Item 419) and spacers (Item 420). Actuation type can be determined by checking the unloading solenoid valve gas uses two-way valves, oil uses three-way valves. For oil unloaded compressors: In serial number range 45,000 thru 45,858, the design version of unloader piston with one Rubber Ring in a 0.187 in. Groove was used. In serial number range 45,859 thru 45,999, a PTFE/Rubber Ring Set in a 0.120 in. Groove was used. Pistons are interchangeable, but the rings are not. + This lower O Ring Seal is for Two-Stage Compressors only. Some initial design High-Stage Compressors also had a similar seal. Its use on the High-Stage machine was discontinued because it is not really needed. It is no longer available. Do not order the Two-Stage Seal for use on these older High-Stage machines. It will not fit. ++ For serial numbers above these ranges, see Page 17.
-1 1 -1 1 1 4 -1 ---
-2 2 -2 2 2 8 -2 ---
-4 4 -4 4 4 16 -4 ---
A33577A A33354A 33338A A33575A A33335A 1193X 33250B 33686A A33576A A33347A 1352D 33618A
ITEM 501 Thru 506 501 Thru 512 501 502 504 505 and 506 507 Thru 512 507 508 509 510 511 +512
DESCRIPTION Piston, Rings and Pin Assembly Kit Piston, Rings and Connecting Rod Assy Kit (All Compressors except 16 Cyl. High-Stage) Piston, Rings and Connecting Rod Assy Kit (Heavy Duty High-Stage #) Piston Ring, Compression Piston Ring, Oil Retaining Ring, Wrist Pin Piston and Wrist Pin Assembly (matched) Connecting Rod Assembly with Bearings Kit (All Compressors except 16 Cyl. High-Stage) Connecting Rod Assembly with Bearings Kit (Heavy Duty High-Stage #) Bushing, Wrist Pin 3 Lock Nut, /8, Connecting Rod 3 Nut, Plain Hex /8-UNF Bolt, Connecting Rod Connecting Rod and Cap Bearing Half, Connecting Rod (All Compressors Except 16 Cylinder High-Stage) Standard Size 0.015 Undersize 0.030 Undersize Bearing Half, Connecting Rod (Heavy Duty High-Stage #) Spring, Safety Head Safety Head and Pins Assembly (Standard Comp) Safety Head and Pins Assembly (Hi Suction Comp #) 11 Pin, Roll, 0.187 dia. x /16 lg. Safety Head Yoke Kit (includes 4 of item 514) Spring, Valve Plate, Discharge Valve Safety Head Spring, Valve
2 -6 2 4 2
4 -12 4 8 4
6 -18 6 12 6
8 8 24 8 16 8
12 -36 12 24 12
16 16 48 16 32 16
2 -2 4 4 4 2
4 -4 8 8 8 4
6 -6 12 12 12 6
8 9 8 16 16 16 8
12 -12 24 24 24 12
16 16 16 32 32 32 16
2 2 2
4 4 4
6 6 6
8 8 8
12 12 12
16 16 16
512
---8 -32 35273ST 513 2 4 6 8 12 16 35252A 514 2 4 6 8 12 16 A35082A and 518 2 4 6 8 12 16 A35272A 514 8 16 24 32 48 64 1712F 515 2 4 6 8 12 16 KT543 516 16 32 48 64 96 128 33803A 517 2 4 6 8 12 16 35080SS 518 2 4 6 8 12 16 ** 519 8 16 24 32 48 64 33803A NOTES: A. Early 450 compressors were equipped with pistons having 2 compression rings and 2 oil control rings. * Replacement wrist pin bushing must be reamed after installation to properly accommodate wrist pin. See Service Instructions for additional details. ** Shown for disassembly purposes only. Order appropriate Kit or Assembly. *** Piston Assembly with three compression rings and one oil ring is standard beginning with serial number 45664 (oil unloading) and 60433 (gas unloading). It is a direct replacement for former piston assembly (two compression rings and two oil rings with expander). Piston ring part numbers are the same for either assembly. Current assembly is interchangeable with and can be mixed with former piston assemblies within a compressor. Do not use expanders in either assembly they are no longer needed. Install with pins outside longitudinal seam facing outside diameter of safety head. # High Suction Pressure Compressors are identified by an X in the serial number. Heavy Duty Compressors are identified by HD in the serial number. + Do not use undersize bearing halves on 6, 8 and 12 Cylinder Belt Driven High-Stage compressors. Bearing half sets with quantities enough for one connecting rod are also available. For sets without Lock Nuts, order 35086ST, 41726ST, 35214ST or 35273ST. For sets with Lock Nuts, order KT512, KT513 or KT513A.
ITEM 410 & 411 410 411 413 Thru 420 413 414 414 415 416 417 418 418 419 420 NOTES: *, , +, ++ +
DESCRIPTION Piston & Rings Assy, Cap Red (Gas or Oil) Ring Set (PTFE & rubber) Piston, Unloader (Gas or Oil) Complete Capacity Control Mechanism Assembly (2 Cylinder and Two-Stage only) Complete Capacity Control Mechanism Assembly Arm, Yoke Lifting Yoke Assembly (2 Cylinder and Two-Stage only) Yoke Assembly 3 11 Pin, /8 x /16 lg. Roll Pin, Short Pivot Spring, Unloader Yoke Yoke Guide Assy (2 Cylinder and Two-Stage only) Yoke Guide Assembly 3 Screw, /8 x 1 Cap Lock Spacer, Sleeve
QUANTITY REQUIRED PER COMPRESSOR ** NUMBER OF CYLINDERS 2 4 6 8 12 16 -(1*) 1 2(3*) 2 4(6*) 4 -(1*) 1 2(3*) 2 4(6*) 4 -(1*) 1 2(3*) 2 4(6*) 4 -(1*) --(1*) -(1*) --(1*) -(1*) -(4*) -(1*) --(2*) -(2*) -1 1 -1 1 1 4 -1 ---(3*) 2 2(3*) -(3*) 2 2(3*) 2(3*) 8(12*) -(3*) 2 -(6*) -(6*) -2 2 -2 2 2 8 -2 ---(6*) 4 4(6*) -(6*) 4 4(6*) 4(6*) 16(24*) -(6*) 4 -(12*) -(12*) -4 4 -4 4 4 16 -4 ---
PART NUMBER A35315CX 2557A Order Assy A41787AX A41788BX 41725A A33575A A33335A 1193X 33250B 33686A A33576A A33347A 1352D 33618A
See Pages 12 and 13 for notes and lower serial number applications.
ITEM ------------118 217 217 306 315 315 401 Thru 404 401 Thru 408 409 413 Thru 420 501 Thru 512 501 502 508 512
DESCRIPTION Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Safety Valve (Internal Relief) Rotary Shaft Seal Assembly Rotary Shaft Seal Assembly Oil Pump Assembly Recharge, Oil Filter (Gasket 1448B included) (For use with 2046A and A35241A) Recharge, Oil Filter (Gasket 14483 included) (For use with A35240A and 1448J) Cylinder Liner Assembly Kit (for cylinder without unloading, High-Stage) (for cylinder without unloading, Two-Stage) Cylinder Liner Assembly Kit (for cylinder with unloading, High-Stage) (for cylinder with unloading, Two-Stage) * Plate, Suction Valve Capacity Control Assembly Two Cylinder and Two-Stage Compressor * 4 thru 16 Cylinder Compressors Piston, Rings and Connecting Rod Assembly Kit (All Compressors except 16 Cyl. High-Stage) Piston, Rings and Connecting Rod Assembly Kit (Heavy Duty High-Stage #) Piston Ring, Compression Piston Ring, Oil 3 Lock Nut, /8, Connecting Rod Bearing Half, Connecting Rod (All Compressors except 16 Cyl. High-Stage) 2 1 -----1 1 -1 1 1 1 -1 -2 1 -1 -6 2 8 2
QUANTITY REQUIRED PER COMPRESSOR NUMBER OF CYLINDERS 4 6 8 12 ----1 ----1 ----1 ----1 ----1 1 1 1 1 ----1 1 1 1 1 1 1 1 1 1 -1 -4 -1 1 -12 4 16 4 1 1 2 1 2 1 6 1 1 2 -18 6 24 6 1 1 2 -2 -8 -1 2 2 24 8 32 8 1 1 2 1 2 1 12 1 1 2 -36 12 48 12
16 -----1 1 -1 1 1 1 2 -2 -16 -1 2 2 48 16 64 16
PART NUMBER KT041 KT043 KT045 KT049 KT051 KT055 1721B A33483A A33489A A33480A 2115C 1448C KT475 A35108D KT476 A35108C 31909A A33577A A33354A KT478 KT478A 31989M 31989N 2028A 35086ST or KT512 35273ST 33803A
512 Bearing Half, Conn. Rod (Heavy Duty High-Stage #) ---8 -16 516 & Spring, Valve 24 48 72 96 144 192 519 517 Plate, Discharge Valve 2 4 6 8 12 16 35080SS 514 & Safety Head and Pins Assembly (Standard Comp) 1 2 2 2 2 2 A35082A 518 Safety Head and Pins Assembly (Hi-Suct Comp #) 1 2 2 2 2 2 A35272A NOTES: A. The above listing includes the minimum selection and quantity of recommended spare parts. All items listed do not necessary apply to every compressor, because of type, size or optional features. Items should be selected for each individual compressor as they apply. * When supplied, capacity reduction is optional, # High Suction Pressure Compressors are identified by an X in the serial number. Heavy Duty Compressors are identified by HD in the serial number.
PAGE
1A 2 3 4 5 7 8 9 12 13 14 15 16 17 19 19 20 21 24 25 26 28 29 31 32 32 33 REPLACEMENT PARTS ORDERING INSTRUCTIONS BASIC FRAME REPLACEMENT PARTS Illustration, 2 Cylinder (Figure 1) Illustration, 4, 6 & 8 Cylinder (Figure 2) Illustration, 12 & 16 Cylinder (Figure 3) Parts List CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS Illustration, 2 thru 8 Cylinder (Figure 4) Illustration, 12 and 16 Cylinder (Figure 5) Parts List REAR BEARING COVER REPLACEMENT PARTS Illustration, with Standard Tri-Micro Filter Option (Figure 6) Parts List Illustration, with Tri-Micro Filter Option (Figure 7) Parts List CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS Illustration (Figure 8) Parts List CAPACITY CONTROL MECHANISM ASSEMBLY REPLACEMENT PARTS Illustration (Figure 9) Parts List PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS Illustration (Figure 10) Parts List MODERNIZING 1200 RPM COMPRESSORS CYLINDER LINER & CAPACITY CONTROL REPLACEMENT PARTS (SERIAL NUMBERS BELOW 3638) Illustration (Figure 11) Parts List PISTON AND CONNECTING ROD REPLACEMENT PARTS (SERIAL NUMBERS BELOW 3638) Illustration (Figure 12) Parts List CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS (SERIAL NUMBERS BELOW 9999) Parts List HEAVY DUTY V-BELT DRIVEN REPLACEMENT PARTS Parts List RECOMMENDED SPARE PARTS LIST
1.
Give the size and speed of the compressor, as well as serial number and refrigerant used. When recording serial number, be certain to include letters (i.e. A, AH, R22S, R12H, etc.) which precedes the actual serial number. This will establish whether the compressor is built for 1000 RPM or 1200 RPM. The serial number is stamped on the nameplate and the compressor frame. On 2 cylinder compressors, the frame serial number location is directly below the cylinder cover on the crankcase handhole side. On 4 thru 16 cylinder compressors, the frame serial number location is directly above the suction flange or directly above the rear bearing cover. The rear bearing is located on the oil pump/filter end of the compressor.
2.
Always give the name of the part as well as the corresponding part number and/or item number. Also include the number of parts required. Should there be a doubt regarding the part number or name, send a sketch of the part required, or return the old part as a sample, transportation charges prepaid. Orders on which part numbers and description do not agree will be filled according to our best interpretation. If parts that appear on the parts list do not appear on the price list, it is because they are sold only as an assembly. All prices shown on the list are F.O.B. factory. Minimum domestic parts order is $75.00 net price. Prices are for a single item unless otherwise specified in the price list. Please indicate on the order the preferred method of shipment. We will follow your instructions unless it is to your best interest to change routing. If you purchased the compressor from a party other than Vilter Manufacturing Corporation, please state when you purchased the compressor and from whom.
3.
4.
5.
6.
SINGLE STAGE 6 8 12
16
TWOSTAGE 6 12
FROM
THRU
PART NUMBER
Frame 1 1 1 1 1 1 1 1 ----* 5 Screw, /8 x 3Hex Head Cap (Used with Water Jacket) 20 40 60 80 120 160 20 40 0 Present 13152L 5 102 Screw, /8 x 2 Hex Head Cap (Used without Water Jacket) 20 40 60 80 120 160 40 80 0 Present 13152G 103 Cover, Water Jacket (Amm & R22) 1 2 3 4 6 8 1 2 0 Present 30299A 104 Gasket, Water Jacket (Amm & R22) 1 2 3 4 6 8 1 2 0 Present 33329A 105 Cover, Cylinder ** Without Capacity Reduction -1 -2 -4 --0 Present A30332A With Capacity Reduction, Oil Type 1 -2 -4 --0 Present 30332B With Capacity Reduction, Gas Type -1 -2 -4 --0 Present 30332G Without Capacity Reduction 1 -1 -2 -3 6 0 Present A30364A With Capacity Reduction, Oil Type 1 -2 -4 -2 6 0 Present 30364B With Capacity Reduction, Gas Type 1 -2 -4 ---0 Present 30364G With Capacity Reduction, Two-Stage ------1 -0 Present 30364F 106 Gasket, Cylinder Cover 1 2 3 4 6 8 3 6 0 Present 33330A 5 107 Stud, /8 x 3 (shown only on 2 cyl.) 8 4 4 4 8 8 4 8 0 Present 13156D 107 Stud, x 3 (not shown) -4 4 4 --4 -0 Present 13157D 108 Tee, Suction 2 x 2 (all) 1 -------0 Present 30319A 3 x 2 (Ammonia) -1 ------0 Present 32417C 3 x 3 (Halocarbon) -1 ------0 Present 32417B 3 x 4 (Amm & Boosters) --1 ---1 -*** *** 36254A 4 x 4 (Halocarbon) --1 -----*** *** 36254B 4 x 4 (Amm & Boosters) ---1 ----*** *** 36254B 5 x 4 (Halocarbon) ---1 ----*** *** 36254C Elbow, Suction 4 x 3 (Amm & Boosters) --1 ---1 -0 *** 32418A 4 x 4 (Halocarbon) --1 -----0 *** 12273C 109 Screen, Suction (Right & Left Side) 1 -2 2 --2 -0 *** A32428D Screen, Suction -1 ------0 Present A32428A Screen, Suction (Center) ---1 ----0 *** A32428C Screen, Suction ----2 2 -1 0 Present A32565A Screen, Suction 1 -2 3 --2 -0 ***` A32428D (R.H. Side, 8 cyl., 75% Cap. Red.) Screen, Suction --1 1 --1 -*** *** A35215A 109-A Bag, Suction Screen (not shown) -1 ------0 Present A33474A Bag, Suction Screen (not shown) 1 -2 3 --2 -0 *** A33474B Bag, Suction Screen (not shown) ----2 2 -1 0 Present A33474G Bag, Suction Screen (not shown) --1 1 --1 -*** *** A35234A 110 Gasket, Suction Screen Cover 1 -2 2 --2 -0 *** 31892A Gasket, Suction Screen Cover ----2 2 -1 0 Present 33493A Gasket, Suction Tee Cover -1 -1 --1 -0 *** 11323J Gasket, Suction Tee Cover --1 1 --1 -*** *** 35217A 111 Cover, Suction Screen 1 -2 2 --2 -0 Present 31893A Cover, Suction Screen ----2 2 -1 0 Present 33492A Cover, Suction Tee (for VPN 32010) -1 -1 ----0 *** 13706A Cover, Suction Tee (for VPN 36254) --1 1 --1 -*** *** 35216A NOTES: * Part Number on application. ** Quantities shown are for compressors with standard capacity reduction, and will vary if compressor is equipped with additional steps of capacity reduction. Items shown are for compressors with optional oil unloading or optional single cylinder unloading. *** 6 cylinder compressors with serial numbers below 21937 (oil unloading) and 30039 (gas unloading) are equipped with a suction elbow and two suction screens (VPN A32428D) located behind the suction screen covers on the frame. 6 cylinder compressors with serial numbers 21937 (oil unloading), and 30039 (gas unloading) and above are equipped with a suction tee (VPN 36254 series) and a single suction screen (VPN 35215A) located in the suction tee. 8 cylinder compressors with serial numbers below 21937 (oil unloading) and 30039 (gas unloading) are equipped with a suction tee (VPN 32010) and three suction screens, one in the tee and two behind the suction screen covers on the frame. 8 cylinder compressors with serial numbers 21937 (oil unloading), and 30039 (gas unloading) and above, are equipped with suction tee (VPN 36254 series) and a single suction screen (VPN A35215A) located in the suction tee.
101 102
2 --6 -1 1 1 1 1 1 1 1 -1 1 2 1
4 5 ---1 1 1 1 1 1 1 1 -1 1 2 1
16 ---16 1 1 1 1 1 1 1 2 -2 2 4 2
FROM 0 * 0 0 0 0 0 0 0 0 0 0 --0 0 0 0
THRU * * Present Present Present Present Present Present Present Present Present Present --Present Present Present Present
112 112 112 112 113 113 114 115 116 116 117 118 118A 119 120 121 122 123 & 124A
123 123A 124A 124 + 125 + 126 + 127 + 128 130 131
Screw, /8 x 1 Hex. Head Cap 5 Screw, /8 x 1 Hex. Head Cap * Screw, x 1 Hex. Head Cap Screw, x 1 Hex. Head Cap Valve, Oil Charge & Drain (Ammonia) Valve, Oil Charge & Drain (Halo.) Gasket, Crankcase Oil Screen Crankcase Oil Screen Assembly Plug, Hex. Head Pipe (not shown on 12 & 16) Plug, Hex. Head Pipe (not shown on 2 thru 8) Pin Retaining Assy, Crankcase Oil Screen Safety Valve (Internal Relief) Valve, Crankcase Check (not shown) Gasket, 2 Flange Cover, Safety Valve 5 Screw, /8 x 2 Hex. Head Cap Gasket, Handhole Cover Handhole Cover and 2 Sight Glass Assy With openings for: 560W NEMA 1&7 Htr, F.V. & Therm 300W NEMA 1&7 Htr, F.V. & Therm 560W NEMA 1&7 Heater & Therm 300W NEMA 1&7 Heater & therm 560W NEMA 1&7 Heater & Float Valve 560W NEMA 1&7 Heater Cover, Handhole (with openings) Cover, Handhole (without openings) Glass, Oil Sight 2 Glass, Oil Sight 3 Washer, Oil Sight Glass 3 Lock, Oil Sight Glass 3 Gasket, Oil Sight Glass 3 Screw, x 1 Hex. Head Cap Tube, Oil Feed Connector Spring
1 1 1 1 1 1 1 -1 1 1 1 2 16 ---
1 1 1 1 1 1 1 -1 1 1 1 2 16 ---
1 1 1 1 1 1 1 -1 1 1 1 2 16 ---
1 1 1 1 1 1 1 -1 1 1 1 2 16 ---
1 1 1 1 1 1 1 1 1 1 1 1 2 32 1 1
1 1 1 1 1 1 1 1 1 1 1 1 2 32 1 1
1 1 1 1 1 1 1 -1 1 1 1 2 16 ---
1 1 1 1 1 1 1 1 1 1 1 1 2 32 1 1
0 0 0 0 0 0 0 0 13050 0 0 0 0 0 0 0
Present Present Present Present Present Present Present Present Present 13049 13049 13049 13049 Present Present Present
A33034G A33034GA A33034L A33034LA A33034G A33034L Order Assy 33034B 1484A 31212A 31636A 31211A 31226A 2796E 33494A 31789A
NOTES: * See Note ***, Page 5. **. For use on compressors without external oil drain arrangement. + The crankcase cover for the 3 sight glass is not available, but these sight glass parts can still be supplied.
CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS 2 THRU 8 CYLINDER COMPRESSORS FIGURE 4
CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS 12 AND 16 CYLINDER COMPRESSORS FIGURE 5
ITEM
DESCRIPTION
NO. OF CYL.
SINGLE STAGE 6 8 12
16
FROM
THRU
PART NUMBER RPM KT077 KT078 KT079 KT080 KT081 KT082 A31121A A32566A 17355A 30651C 31048A 31048D 31048B 31048C 31048F 13155K A36240A A36241A 13264B 13264C ** ** 33361A 35274A 1332C 31890A 13159E 31885A 33500A 13152E 2796EV A33483A A33489A 31897A 33496A 13153F 31044A 32564A 35078A A32574A A32574B A32574C A32574D
The following complete crankshaft sub-assemblies are available for all 440 VMC Compressors with aluminum pistons for 1000 compressors from serial number 3068 thru present and for 1200 RPM compressors from serial number 1660 thru present. *** 201 Complete Crankshaft Sub-Assembly Kit 1 -------See Thru Complete Crankshaft Sub-Assembly Kit -1 ------Note 233 Complete Crankshaft Sub-Assembly Kit --1 ---1 -Above Complete Crankshaft Sub-Assembly Kit ---1 ----See 201 Complete Crankshaft Sub-Assembly Kit ----1 --1 Note Thru Complete Crankshaft Sub-Assembly Kit -----1 --Above 245 201 Front Brg. Cover & Relief Valve Assy. 1 1 1 1 --1 -0 Present Thru Front Brg. Cover & Relief Valve Assy. ----1 1 -1 0 Present 211A 201 Cap, Valve 1 1 1 1 1 1 1 1 0 Present 202 Gasket 1 1 1 1 1 1 1 1 0 Present 203 Nut, Packing 1 1 1 1 1 1 1 1 0 Present 204 Washers 2 2 2 2 2 2 2 2 0 Present 7 39 3 205 Packing, /8 O.D. x /64 I.D. x /8 1 1 1 1 1 1 1 1 0 Present 206 Stem, Valve 1 1 1 1 1 1 1 1 0 Present 207 Spring 1 1 1 1 1 1 1 1 0 Present 5 208 Ball, /8 Dia. Steel 1 1 1 1 1 1 1 1 0 Present See note Present 209 Front Bearing Cover Assembly 1 1 1 1 --1 -See note Present Thru Front Bearing Cover Assembly ----1 1 -1 211A 209 Plug, Hex. Head Pipe 1 1 1 1 1 1 1 1 0 Present 3 210 Plug, /8 Hex (not used after 12/81) 1 1 1 1 1 1 1 1 0 Present 211 Cover, Front Bearing 1 1 1 1 --1 -0 Present 211 Cover, Front Bearing ----1 1 -1 0 Present 211A Orifice, Oil Metering 1 1 1 1 1 1 1 1 0 21354 211B Shield, Splash (Oil Relief Outlet Hole) 1 1 1 1 1 1 1 1 0 Present 3 211C Screw, Rd Hd No. 10-32 x /8 Lg. 3 3 3 3 3 3 3 3 0 Present 212 Gasket, Bearing Cover 1 1 1 1 1 1 1 1 0 Present 5 213 Screw, /8 x 4 Hex, Socket Head Cap 2 2 2 2 2 2 2 2 0 Present See note Present 214 Retainer, Front Bearing (w/oil hole) 1 1 1 1 --1 -See note Present 214 Retainer, Front Bearing (w/oil hole) ----1 1 -1 5 215 Screw, /8 x 2 Hex Head Cap 6 6 6 6 6 6 6 6 0 Present 216 Screw, x 4 Hex Head Cap 3 3 3 3 3 3 3 3 0 Present 217 Seal, Rotary Shaft Assembly 1 1 1 1 --1 -0 Present 217 Seal, Rotary Shaft Assembly ----1 1 -1 0 Present 218 Gasket, Shaft Seal Cover 1 1 1 1 --1 -0 Present 218 Gasket, Shaft Seal Cover ----1 1 -1 0 Present 219 Screw, x 1 Hex Head Cap 8 8 8 8 8 8 8 8 0 Present 220 Cover, Shaft Seal 1 1 1 1 --1 -0 Present 220 Cover, Shaft Seal ----1 1 -1 0 Present 220A Tube, Oil Drain 1 1 1 1 1 1 1 1 0 Present 224 Complete Crankshaft Assy (1200 RPM) Thru For Aluminum Pistons * 1 -------1660 Present 233 For Aluminum Pistons * -1 ------1660 Present For Aluminum Pistons * --1 ---1 -1660 Present For Aluminum Pistons * ---1 ----1660 Present
NOTE: * See page 31 for serial numbers below 1660. ** Sold only in Front Bearing Cover Assembly. *** Crankshafts for Cast Iron Piston for these machines are no longer available. Use current crankshaft and convert the compressor to aluminum pistons. See note with same symbol on Page 11.
SERIAL NO. TWOSTAGE 6 12 --1 -------1 -PART NUMBER A32574A A32574B A32574C A32574D KT068 KT069
ITEM
DESCRIPTION
NO. OF CYL.
2 1 ------
4 -1 -----
16 -----1
224 Thru 245 (less items 225, 226, 230, 234, 235 & 241) 224 224 227 * 227 228 228 229
Complete Crankshaft Assy (1000 RPM) For Aluminum Pistons For Aluminum Pistons For Aluminum Pistons For Aluminum Pistons Complete Crankshaft Assembly Kit 1000 or 1200 RPM, for Aluminum Pistons 1000 or 1200 RPM for Aluminum Pistons
229
229A
Locknut and Retaining Compound Kit Locknut and Retaining Compound Kit Front Bearing and Retaining Compound Kit Front Bearing and Retaining Compound Kit Ring, Front Bearing Retainer Ring, Front Bearing Retainer Crankshaft (1200RPM) (with oilway plugs) For Aluminum Pistons () For Aluminum Pistons () For Aluminum Pistons () For Aluminum Pistons () For Aluminum Pistons () For Aluminum Pistons () Crankshaft (1000RPM) (w/oilway plug) For Aluminum Pistons () For Aluminum Pistons () For Aluminum Pistons () For Aluminum Pistons () For Aluminum Pistons () For Aluminum Pistons () 1 Plug, Pipe, /8, Hex Socket Head (N.S.)
1 -1 -1 -1 -----1 -----5
-1 -1 -1 ----1 -----1 -8
-1 -1 -1 -----1 -----1 8
-1 -1 -1 ----1 -----1 -8
Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present
KT366 ++ KT367 ++ KT368 KT369 33144A 33145A KT370 KT371 KT372 KT373 KT375 KT376 KT370 KT371 KT372 KT373 KT375 KT376 13163A
NOTE: * This bearing is interchangeable with the bearing (Part No. A31988A) originally used on the 2, 4, 6 and 8 cylinder compressors. A spacer is incorporated as an integral part of this bearing, eliminating the use of shims and a bearing lock. When installing this bearing, do not use the shims (Item No. 230) and bearing lock (Item No. 226). + All 1200 RPM VMC Compressors with Serial No. 1660 and above have aluminum pistons. All other 1200 RPM VMC Compressors with serial numbers 1659 and below have cast iron pistons. If it is desired to change from cast iron pistons to aluminum pistons, it is absolutely necessary to change the crankshaft. ++ When ordering a crankshaft bearing locknut (Item 224) for a compressor with Serial No. 9,999 and below, also order crankshaft bearing lockwasher (Item 225). See page 31. When ordering bare crankshaft for a compressor with Serial No. 9999 and below, also order Item 224, crankshaft bearing locknut and retaining compound kit. Supplied as a kit, includes retaining compound for bearing locknut. Retaining compound also available separately; order Part No. KT365. N.S. = Not Shown.
SERIAL NO. TWOSTAGE 6 12 1 1 1 1 4 4 1 ------------1 -1 -1 1 1 1 4 4 1 1 2 4 2 2 2 1 1 4 4 1 8 -1 1 1 PART NUMBER 31904A KT353 33678A A33509A 13160D 1736G 33403A * 13162X 11396D 33508A 33508B 33498A 33497A * 13165F 1726E 13253F 2796AC 31994B 33505B 31956A 33495A
ITEM
DESCRIPTION
NO. OF CYL.
2 1 1 1 1 4 4 1 ------------1 -1 --
4 1 1 1 1 4 4 1 ------------1 -1 --
16 1 1 1 1 4 4 1 1 2 4 2 2 2 1 1 4 4 1 8 -1 1 1
FROM 0 0 4233 0
231 231A 231B 231A 231B 232 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 246 247 248
Retainer, Rear Bearing Rear Bearing and Lock Pin Kit Pin, Bearing Lock + Bearing, Rear Crankshaft 5 Screw, /16 x 1 Hex. Socket Head Cap 5 Screw, /16 x 1 Hex. Head Cap. Crank, Oil Pump Drive Cap, Bearing Support * Pin, x 1 Dowel * Bolt, x 1 Machine Bearing Half, Upper Right or Lower Left Bearing Half, Upper Left or Lower Right Oil Dam, Center Bearing Pin, Threaded Taper Case, Bearing Support * Washer, Spring Lock Nut, Hex 9 Nut, /16 Hex Screw, x Hex. Head Cap Key, Crankshaft Key, Crankshaft Screw, Flywheel Hub Washer, Fllywheel Hub Screw
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Present Present See Note Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present
NOTES: * Matched set with pin, sold as assembly A32163A. Shown in three parts to illustrate disassembly. + A bearing lock pin (Item 231A) is used to keep outer face of bearing (Item 231B) from turning. If compressor does not have groove in bottom of rear bearing cover (Item 301), make a notch with a deep radius and 17/8 long to accommodate pin in cover. Mounting holes on retainer (Item 231) were changed from counterbored holes to plain, straight-thru holes. Use replacement screw, part number 13160D, on the former retainer with counterbored holes. Use replacement screw, part number 1736G, on current retainer with straight-thru holes. Dams (Item 239) and screws (Item 245) are not needed when using VILTERs patented joined crankshafts. In this design version (introduced in 1980) two 6 cylinder or two 8 cylinder crankshafts are joined by a sleeve to form an inseparable 12 cylinder or 16 cylinder crankshaft. This specially machined sleeve eliminates the dams. This design is completely interchangeable with the former design. See page 9 for symbol regarding this information. Compressors below serial number 21355 were furnished with the no longer available front bearing cover assemblies A30294A (2,4,6, and 8 cylinders) or A32162A (12 and 16 cylinders), and front bearing retainer 31885A (2,4,6, and 8 cylinders) or 33500A (12 and 16 cylinders) without the oil hole. Former front bearing retainers (31885A or 33500A) without oil holes cannot be used with current front bearing cover assemblies A36240A (2,4,6, and 8 cylinders) and A36241A (12 and 16 cylinders), as there is no way for oil to get to the bearing. If front bearing cover is being replaced, a current front bearing retainer (31885A or 33500A with oil hole) must be ordered also, unless one of these current styles is already being used. If a current front bearing retainer, (31885A or 33500A, both with oil hole) is used with former style cover (A30294A or A32162A) having an oil hole, remove orifice in cover (A30294A or A32162A) and replace with solid 1/8 pipe plug.
REAR BEARING COVER REPLACEMENT PARTS (Compressors With Standard Tri-Micro Filter)
SERIAL NO. TWOSTAGE 6 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PART NUMBER KT092 ** 13163E 2868H 33361A 31899A A33480A KT361A & B+ 31900A 33320A ITEM DESCRIPTION
NO. OF CYL.
2 1 1 1 1 1 1 1 1
4 1 1 1 1 1 1 1 1
SINGLE STAGE 6 8 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
16 1 1 1 1 1 1 1 1
FROM 0 0 0 0 0 0 0 0
301 Thru 304 301 302 303 304 305 306 307 Thru 324 307 308 309 309 310 311, 312, 313 & 314 311, 312 thru 314 & 315 thru 319 &321 311 312 313 314 315 316 317 318 319 320 321 322
Rear Bearing Cover Assembly Kit Cover, Rear Bearing Plug, Hex. Socket Head Pipe 3 Pin, /8 x 1 Dowel (not shown) Orifice, Oil Metering (not shown) Gasket, Oil Pump body Oil Pump Assembly Conversion Kit, Std. Tri-Micro
Gasket, Oil Pump Cover Gasket, Oil Pump and Rear Bearing Cover Seal Cover, Oil Pump and Filter Head (Used when Oil Cooler not used) Cover, Oil Pump and Filter Head (Used when Oil Cooler is used) Filter Assy, Complete (Tri-Micro) (Items 311 thru 322B) Spool Strainer Tube Assembly
1 1
1 1
1 1
1 1
1 1
1 1
1 1
1 1
0 13375
Present Present
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
13375
Present
1448U
13375
Present
1448T
322A 1 1 1 1 1 1 1 1 13375 Present 35125A 322B 1 1 1 1 1 1 1 1 13375 Present 34623A 323 4 4 4 4 4 4 4 4 13375 Present 1689G 324 1 1 1 1 1 1 1 1 13375 Present 40680AT 325 1 1 1 1 1 1 1 1 0 Present 31890A 326 10 10 10 10 10 10 10 10 0 Present 13152E 327 8 8 8 8 8 8 8 8 0 Present 2796EL NOTES: A. Tri-Micro is a registered trademark of Vilter Manufacturing Corporation. ** The rear bearing cover is sold only in Kit KT092. + When Kit KT256 is ordered, the overall length of the existing oil pump (Item 306) on the compressor should be checked. If the 7 length from the end of the pump shaft to the end of the pump boss measures 5 /32, a new oil pump must be ordered with Kit KT256.
Spool Assembly (with bypass relief) Seal, Spool End Strainer Tube Ring, Retaining Recharge (Gasket 1448B included) Pressure Plate Assembly (Items 317, 318 and 319) Pressure Plate O Ring Seal, Pressure Plate Spring, Pressure Plate Plug, Steel Square Head Pipe, 1/8 Gasket, Oil Filter Head Filter Shell with Flange and Plug (Items 320, 322A and 322B) Flange, Oil Filter Tank Tank, Oil Filter 7 Screw, Hex. Head Cap /16 x 2 Instruction/Name Plate (not shown) Gasket, Bearing Cover 5 Screw, /8 x 2 Hex. Head Cap Screw, x 1Hex Head Cap
1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
13375 13375 13375 13375 13375 13375 13375 13375 13375 13375 13375 13375
Present Present Present Present Present Present Present Present Present Present Present Present
1448J 1448H 1448K 1448L 1448C 1448M 1448N 1448P 1448Q 13264A 1448B A34623A
SERIAL NO. TWOSTAGE 6 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PART NUMBER KT092 ** 13163E 2868H 33361A 31899A A33480A KT361A + KT361B + 31900A 33320A
ITEM
DESCRIPTION
NO. OF CYL.
2 1 1 1 1 1 1 1 1 1 1 1
4 1 1 1 1 1 1 1 1 1 1 1
SINGLE STAGE 6 8 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
16 1 1 1 1 1 1 1 1 1 1 1
FROM 0 0 0 0 0 0 0 0 0 0 0
THRU Present Present Present Present Present Present Present Present Present Present Present
301 thru 304 301 302 303 304 305 306 307 Thru 339 307 308
Rear Bearing Cover Assembly Kit Cover, Rear Bearing Plug, Hex Socket Head Pipe 3 Pin, /8 x 1 Dowel (not shown) Orifice, Oil Metering (not shown) Gasket, Oil Pump Body Oil Pump Assembly Conversion Kit, Special (improved) Tri-Micro Oil Filter, 120 volts Conversion Kit, Special (improved) Tri-Micro Oil filter, 240 volts Gasket, Oil Pump Cover Gasket, Oil Pump and Rear Bearing Cover Seal Cover, Oil Pump and Filter Head Filter Assembly, Complete (Tri-Micro) Spool Assembly (without bypass relief) Seal, Spool End Strainer Tube Ring, Retaining Recharge (Gasket 1448B included) Pressure Plate Assembly Pressure Plate O Ring Seal, Pressure Plate Spring, Pressure Plate 1 Plug, Steel Square Head Pipe /8 Gasket, Oil Filter Head Filter Shell with Bolt Ring 7 Screw, Hex Head Cap /16 x 2 Instruction/Nameplate Gauge, 2, 0-300 PSI, Oil Filter Elbow, 90 Female Compression Tubing, O.D. x 5 ft. Steel Tee, Compression Connector, MPT X O.D. Compression Valve, 3-Way, Oil Filter Bracket, Valve Elbow, 90 Male Compression Control, Pressure Differential 3 Screw, 10-32 x /8 Long, Round Head 3 Washer, Lock, /16 3 Washer, Flat, /16 Cover, Crankcase Handhole Thermometer, Crankcase Oil Heater, 535W, 115V Electric Crankcase Heater, 535W, 230V Electric Crankcase Gasket, Bearing Cover 5 Screw, /8 x 2 Hex Head Cap Screw, x 1 Hex Head Cap
309 1 1 1 1 1 1 1 1 0 Present 34565A 310 1 1 1 1 1 1 1 1 0 Present A35241A 311 1 1 1 1 1 1 1 1 0 Present 2046A 312 1 1 1 1 1 1 1 1 0 Present 1448H 313 1 1 1 1 1 1 1 1 0 Present 1448K 314 1 1 1 1 1 1 1 1 0 Present 1448L 315 1 1 1 1 1 1 1 1 0 Present 2115C 316 1 1 1 1 1 1 1 1 0 Present 1448M 317 1 1 1 1 1 1 1 1 0 Present 1448N 318 1 1 1 1 1 1 1 1 0 Present 1448P 319 1 1 1 1 1 1 1 1 0 Present 1448Q 320 1 1 1 1 1 1 1 1 0 Present 1190A 321 1 1 1 1 1 1 1 1 0 Present 1448B 322 1 1 1 1 1 1 1 1 0 Present A34623A 323 4 4 4 4 4 4 4 4 0 Present 1689G 324 1 1 1 1 1 1 1 1 0 Present 40680AJ 325 1 1 1 1 1 1 1 1 0 Present 2047A 326 1 1 1 1 1 1 1 1 0 Present 1892B 327 AR AR AR AR AR AR AR AR 0 Present S1589A 328 2 2 2 2 2 2 2 2 0 Present 13239C 329 3 3 3 3 3 3 3 3 0 Present 13229D 330 1 1 1 1 1 1 1 1 0 Present 2030A 331 1 1 1 1 1 1 1 1 0 Present 35106A 332 1 1 1 1 1 1 1 1 0 Present 13375D 333 1 1 1 1 1 1 1 1 0 Present 1643V 334 2 2 2 2 2 2 2 2 0 Present 1332C 335 2 2 2 2 2 2 2 2 0 Present 13165A 336 4 4 4 4 4 4 4 4 0 Present 13265A 337 * 1 1 1 1 1 1 1 1 0 Present A33034L 338 * 1 1 1 1 1 1 1 1 0 Present 1467F 339 * 1 1 1 1 1 1 1 1 0 Present 2069J 339 * 1 1 1 1 1 1 1 1 0 Present 2069K 340 1 1 1 1 1 1 1 1 0 Present 31890A 341 10 10 10 10 10 10 10 10 0 Present 13152E 342 8 8 8 8 8 8 8 8 0 Present 2796EL NOTES: AR = As required. Cut to suit when assembling. Not shown here, cover replaces item 123. Thermometer and heater mount on crankcase handhole cover so oil temperature can be monitored and raised to 100F (thermostat setting) before starting compressor. If an attempt is made to start with cold oil, the filter pressure differential switch will stop compressor. ** The rear bearing cover is sold only in Kit KT092. + When Kit KT361A & B is ordered, the overall length of the existing oil pump (Item 306) on the compressor should be checked. 7 If the length from the end of the pump shaft to the end of the pump boss measures 5 /32, a new oil pump must be ordered with Kit KT361A & B.
SERIAL NO. TWOSTAGE 6 12 --3* 3* -6 3* -6 3* --6* 6* -12 6* -12 6* PART NUMBER KT072 A31194B KT072 A33179B KT071 KT071 KT071 KT071 A33179A A33179A
4 2 2 --2 ------
16 8 8 --8 ------
FROM 3638 3638 3638 14204 3638 3638 3638 3638 14204 14204
THRU Present Present 14203 Present Present 14203 14203 Present Present Present
401 Thru 402B 401 Liner, Cylinder 2 4 6 8 12 16 --3638 Present 32687A 401 Liner, Cylinder ------6 12 3638 14203 32687A 401 Liner, Cylinder ------6 12 14204 Present 33179A 402 Seal, O Ring (Upper) 2 4 6 8 12 16 6 12 3638 Present 2176BH 402A ++ Pin, Roll 8 16 24 32 48 64 24 48 7000 Present 1193Q 402B Seal, O Ring (Lower) ------6 12 14204 Present 2176BL 402 Lift Ring & Post Assy (Std) 1* 2 4 4 8 8 3* 6* 3638 Present A33351A 403 Lift Ring & Post Assy (Hi-Suct #) -2 4 4 8 8 --3638 Present A33351A 405 Spring, Lift 4* 8 16 16 32 32 12* 24* 3638 Present 33352A 406 Pin, Lift 4* 8 16 16 32 32 12* 24* 3638 Present 33350A 407 Plate, Suction Valve 2 4 6 8 12 16 6 12 3638 Present 31909A 410B 411A & Piston Kit, Cap. Red. (Oil Actuated+) 1* 1 2 2 4 4 3* 6* 19247 22799 KT364 412 410, 411 & Piston Kit, Cap. Red. (Gas Actuated+) 1* 1 2 2 4 4 3* 6* 3638 19246 KT034 412 30000 32499 410 Piston Ring (Steel-For Gas Actuated) 4* 4 8 8 16 16 12* 24* 30000 32499 31989L 410A O Ring (Rubber-For 0.187 Groove) 1* 1 2 2 4 4 3* 6* 19247 22673 2176AX 410B Ring Set (PTFE-For 0.120 Groove) 1* 1 2 2 4 4 3* 6* 22674 22799 2557A 411/411 Piston, Unloader (Gas or Oil) 1* 1 2 2 4 4 3* 6* ----Order Kit A 412 Pin, Long Pivot 1* 1 2 2 4 4 3* 6* 3638 22799 33250C 413 Cap Cont Mech Assy (Std-Single) + 1* -----3* 6* 150 22799 A33577A Thru Cap Cont Mech Assy (Std-Double) + -1 2 2 4 4 --150 22799 A33354A 420 Cap Cont Mech Assy (Hi-Suct #) + -1 2 2 4 4 --150 22799 A35253A 413 Arm, Yoke Lifting 1* 1 2 2 4 4 3* 6* 150 22799 33338A 414 Yoke Assembly (Std-Single) 1* -----3* 6* 150 22799 A33575A 414 Yoke Assembly (Std-Double & Hi Suct) -1 2 2 4 4 --150 22799 A33335A 3 11 415 Pin, /8 x /16 lg. Roll 1* 1 2 2 4 4 3* 6* 150 22799 1193X 416 Pin, Short Pivot 1* 1 2 2 4 4 3* 6* 30000 32499 33250B 417 *** Spring, Unloader Yoke (Std) 4* 4 8 8 16 16 12* 24* 30000 32499 33686A 417 Spring, Unloader Yoke (Hi-Suct #) 6 6 12 12 24 24 --30000 32499 33686A 418 Yoke Guide Assembly (std-single) 1* -----3* 6* 30000 32499 A33576A 418 Yoke Guide Assembly (std-double) -1 2 2 4 4 --30000 32499 A33347A 418 Yoke Guide Assembly (Hi Suct #) -1 2 2 4 4 --30000 32499 A35248A 3 419 Screw, /8 x 1 Cap Lock 2* -----6* 12* 30000 32499 1352D 420 Spacer, Sleeve 2* -----6* 12* 30000 32499 33618A NOTES: * These items are used on Two-Stage and 2 cylinder compressors only when equipped with unloading. For single cylinder unloading, the yoke assembly (Item 414) and the two pins on the yoke guide assembly (Item 418) have drilled and tapped holes to accommodate screws (Item 419) and spacers (Item 420). ** Replacement parts for 1200 RPM compressors with serial numbers below 3638 are on pages 25 and 26. *** Spring part number was 33353A and quantity was 6. Replace all springs in the assembly. + Actuation type can be determined by checking unloading solenoid valve oil uses three-way valves, gas uses two-way valves. For serial numbers above these, see page 19. ++ Four roll pin holes are drilled thru the safety head and safety head yoke into the cylinder liner. Drilled replacement parts are interchangeable with undrilled parts. Discard roll pins from kits if new liner is used with former style safety head, safety head yoke and frame with built-in guide lugs. # High suction compressors are identified by an X in the serial number.
Cylinder Liner Kit (w/Unload-Std.) Cylinder Liner Assy (w/Unload-Hi Suct #) Cylinder Liner Kit (w/Unloading) Cylinder Liner Assy (w/Unloading) Cylinder Liner Kit (w/o Unloading) Cylinder Liner Kit (w/o Unloading) Cylinder Liner Kit (w/o Unloading) Cylinder Liner Kit (w/o Unloading) Cylinder Liner Assy (w/o Unloading) Cylinder Liner Assy (w/o Unloading)
CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS 1000 RPM HIGH STAGE AND TWO-STAGE COMPRESSORS AND 1200 RPM BOOSTER COMPRESSORS
NO. REQ. PER COMPRESSOR ITEM DESCRIPTION
NO. OF CYL.
SERIAL NO. TWOSTAGE 6 12 PART NUMBER KT072 KT033 KT072 KT072 A33179B KT071 KT071 KT071 KT071 KT071 A33179A A33179A 32687A A32609A 32687A 32687A 33179A 2176BH 1193Q 2176BL A33351A A33351A 33352A 33428A 33352A 33350A 33350A 31909A 33422A 31909A 33803A KT364
SINGLE STAGE 6 8 12
16
FROM 0 0 2656 0 14204 0 2656 0 0 0 14204 14204 0 0 2656 0 14204 0 7000 14204 160 2656 160 0 2656 150 2656 0 0 2656 0 19247
THRU Present Present Present 14203 Present Present Present Present 14203 14203 Present Present Present 2655 Present 14203 Present Present Present Present Present Present Present 2655 Present Present Present Present 2655 Present 2655 22799
Cylinder Liner Kit (w/unloading) 1* 2 4 4 --Cylinder Liner Kit (w/unloading) ----8 8 Cylinder Liner Kit (w/unloading) ----8 8 Cylinder Liner Kit (w/unloading) ------Cylinder Liner Kit (w/unloading) ------401 Cylinder Liner Kit (w/o unloading) 2 2 2 4 --Thru Cylinder Liner Kit (w/o unloading) ----4 8 402A Cylinder Liner Kit (w/o unloading) 1* -----Cylinder Liner Kit (w/o unloading) ------Cylinder Liner Kit (w/o unloading) ------401 Cylinder Liner Assy (w/o unloading) ------Thru 402B Cylinder Liner Assy (w/o unloading) ------401 Liner, Cylinder 2 4 6 8 --401 Liner, Cylinder ----12 16 401 Liner, Cylinder ----12 16 401 Liner, Cylinder ------401 Liner, Cylinder ------402 Seal, O Ring (upper) 2 4 6 8 12 16 402A++ Pin, Roll 8 16 24 32 48 64 402B Seal, O Ring (Lower) ------403 Lift Ring & Spring Post Assembly 1* 2 4 4 --403 Lift Ring & Spring Post Assembly ----8 8 405 Spring, Lift 4* 8 16 16 --405 Spring, Lift ----16 16 405 Spring, Lift ----32 32 406 Pin, Lift 4* 8 16 16 --406 Pin, Lift ----32 32 407 Plate, Suction Valve 2 4 6 8 --407 Plate, Suction Valve ----12 16 407 Plate, Suction Valve ----12 16 408 Springs, Valve (Helical) (not shown) ----48 64 410B 411A Piston Kit, Cap Red (Oil Actuated+) 1* 1 2 2 4 4 412 410 411 Piston Kit, Cap Red (Gas Actuated+) 1* 1 2 2 4 4 412 410 Piston Ring (Steel-for gas actuated) 4* 4 8 8 16 16 410A O Ring (Rubber-for 0.187 Groove) 1* 1 2 2 4 4 410B Ring Set (PTFE-for 0.120 Groove) 1* 1 2 2 4 4 411/411A Piston, Unloader (gas or oil) 1* 1 2 2 4 4 412 Pin, Long Pivot 1* 1 2 2 4 4 413 thru Capacity Control Mechanism Assembly 1* -----420 Capacity Control Mechanism Assembly -1 2 2 4 4 413 Arm, Yoke Lifting 1* 1 2 2 4 4 414 Yoke Assembly 1* -----414 Yoke Assembly -1 2 2 4 4 3 11 415 Pin, /8 x /16 lg. Roll 1* 1 2 2 4 4 416 Pin, Short Pivot 1* 1 2 2 4 4 417 *** Spring, Unloader Yoke 4* 4 8 8 16 16 418 Yoke Guide Assembly 1* -----418 Yoke Guide Assembly -1 2 2 4 4 3 419 Screw, /8 x 1 Cap Lock 2* -----420 Spacer, Sleeve 2* -----NOTES: *, +, ++, or *** See note with same symbol on Page 17. ** See Pages 25 and 26 for illustration. Refer to Home Office for compressor with serial numbers below 150.
150 30000 30000 19247 22674 --150 150 150 150 150 150 150 30000 30000 30000 30000 30000 30000
19246 32499 32499 22673 22799 --22799 22799 22799 22799 22799 22799 22799 32499 32499 32499 32499 32499 32499
KT034 31989L 2176AX 2557A Order Kit 33250C A33577A A33354A 33338A A33575A A33335A 1193X 33250B 33686A A33576A A33347A 1352D 33618A
SECTION 105-R
PAGE 19
CAPACITY CONTROL MECHANISM ASSEMBLY () REPLACEMENT PARTS Version used beginning with Serial Number: 32,500 for Gas Unloading 22,800 for Oil Unloading (++) FIGURE 9
Patents Pending. QUANTITY REQUIRED PER COMPRESSOR NUMBER OF CYLINDERS 4 6 8 12 1 2(3*) 2 4(6*) 1 1 -1 -1 1 -1 -1 1 1 4 6 --1 --2(3*) 2(3*) -(3*) 2 -(3*) 2 2(3*) -(3*) 2 -(3*) 2 2(3*) 2(3*) 8(12*) 12(18*) -(3*) -(3*) 2 -(6*) -(6*) 2 2 -2 -2 2 -2 -2 2 2 8 12 --2 --4(6*) 4(6*) -(6*) 4 -(6*) 4 4(6*) -(6*) 4 -(6*) 4 4(6*) 4(6*) 16(24*) 24(36*) -(6*) -(6*) 4 -(12*) -(12*) PART NUMBER 16 4 4 4 -4 -4 4 -4 -4 4 4 16 24 --4 --A35315BX A35315CX 2557A Order Assy A41787AX A41788BX A35305AX A35304AX 41725A A33575A A33335A A35247A A33335A 1193X 33250B 33686A 33686A A33576A A35249A A35248A 1352D 33618A
DESCRIPTION Piston & Rings Assy., Cap Red (Gas or Oil +) Ring Set (PTFE and rubber) Piston, Unloader (Gas or Oil) Complete Cap Control Mech Assy (Standard Single Cylinder) (Standard Double Cylinder) (High Suction Single Cylinder) (High Suction Double Cylinder) Arm, Yoke Lifting Yoke Assy (Standard Single Cylinder) Yoke Assy (Standard Double Cylinder) Yoke Assy (High Suct-Single Cylinder) Yoke Assy (High Suct-Double Cylinder) 3 11 Pin, /8 x /16 lg. Roll Pin, Short Pivot Spring, Unloader Yoke (Standard) Spring, Unloader Yoke (High Suction) Yoke Guide Assy (Std-Single Cylinder) Yoke Guide Assy (Hi Suct-Single Cyl) Yoke Guide Assy (Hi Suct-Double Cyl) 3 Screw, /8 x 1 Cap Lock Spacer, Sleeve 2 -(1*) -(1*) -(1*) -(1*) --(1*) --(1*) -(1*) --(1*) --(1*) -(1*) -(4*) -(6*) -(1*) -(1*) --(2*) -(2*)
413 414 414 414 414 415 416 417 417 418 418 418 419 420 NOTES: *, +, ++ See pages 16, 17, 18, 25 and 26 for notes and lower serial number applications.
PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS FIGURE 10
PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 1200 RPM High Stage and Two-Stage Compressors Serial Number 3638 to Present
NO. REQ. PER COMPRESSOR ITEM DESCRIPTION
NO. OF CYL.
SERIAL NO. TWOSTAGE 6 12 6 6 18 6 12 6 6 6 6 6 6 12 12 12 12 36 12 24 12 12 12 12 12 12 24 24 PART NUMBER KT213 KT478 31989M 31989N ** 33244A Order Kit KT463 KT512 KT513 31896B # Order Kit 2027A 2028A
2 2 2 6 2 4 2 2 2 2 2 2 4 4
4 4 4 12 4 8 4 4 4 4 4 4 8 8
SINGLE STAGE 6 8 12 6 6 18 6 12 6 6 6 6 6 6 12 12 8 8 24 8 16 8 8 8 8 8 8 16 16 12 12 36 12 24 12 12 12 12 12 12 24 24
16 16 16 48 16 32 16 16 16 16 16 16 32 32
FROM 3638 3638 3638 3638 3638 3638 3638 3638 3638 3638 3638 3638 3638
THRU Present Present Present Present Present Present Present Present Present Present Present Present Present
501 thru 505 501 thru 512 501 502 503 504 & 505 506 thru 512 510 & 511 506 507 509 510 510 & 511
Piston (Flat, AL) Rings and Pin Kit Piston (Flat, AL) & Connecting Rod Assembly Kit Piston Ring, Compression Piston Ring, Oil Snap Ring, Piston Pin Piston and Pin Assembly Connecting Rod Assembly with Bearings Kit Bearing Half & Lock Nut Kit (std size) Bearing Half & Lock Nut Kit (undersize) Bushing, Piston Pin Connecting Rod and Cap 3 Nut, Plain, Hex /8-24UNF 3 Nut, Lock, /8-24NF Bearing Half, Conn Rod (w/o Groove) Standard Size ++ 0.015 Undersize 0.030 Undersize Bolt, Connecting Rod Safety Head Assembly, Ammonia (for Helical Springs) Safety Head Assembly, R12 and R22 (for Helical Springs) 3 Nut, Lock, /8 Valve Retaining Washer, Diaphragm Valve Valve, Diaphragm Discharge Spacer, Diaphragm Valve Safety Head, Ammonia (for Helical Springs) Safety Head, R12 and R22 (for Helical Springs) Screw, Valve Retaining (60) Screw, Valve Retaining (82) Springs, Valve (Helical) Yoke, Safety Head Spring, Safety Head
512 513 Thru 518 513 514 515 516 517 517 518 518 519 520 521 NOTES: * ** # ++
4 4 4 4 2 2 2 2 6 2 2 2 2 2 8 2 2
8 8 8 8 4 4 4 4 12 4 4 4 4 4 16 4 4
12 12 12 12 6 6 6 6 18 6 6 6 6 6 24 6 6
16 16 16 16 8 8 8 8 24 8 8 8 8 8 32 8 8
24 24 24 24 12 12 12 12 36 12 12 12 12 12 48 12 12
32 32 32 32 16 16 16 16 48 16 16 16 16 16 64 16 16
12 12 12 12 6 6 6 6 18 6 6 6 6 6 24 6 6
24 24 24 24 12 12 12 12 36 12 12 12 12 12 48 12 12
3638 3638 3638 3638 3638 3638 3638 3638 3638 3638 3638 3638 3638 13491 3638 3638 3638
Present Present Present Present Present Present Present Present Present Present Present Present 13,490 Present Present Present Present
KT512 KT513A KT513 31955A A32695C A32695D 1776B 31990B 31939B 31990A 33531B 33532B 31964A 1527B 33803A 31941B 31882A
For replacement parts for compressors having serial numbers below 3638, see page 29. These oil rings do not require expanders. Do not use expanders. They may cause excessive wear. Replacement bushing must be reamed after installation to properly accommodate piston pin. Replaces bearing half with groove. If compressor has standard size bearings with groove, order 31957B-Std. Size bearing half. If crankshaft is groove undersize, order KT513 or KT513A bearing half set with locknuts with no groove. When ordering safety head (Item 517) for machines with serial number below 13491 Item 518 (1527B) must also be ordered. Screw hole was changed from a 60 hole to an 82 hole. AL = Aluminum Pistons
February 2001 SECTION 105-R VILTER MANUFACTURING CORPORATION Replaces PAGE 22 February 1985 440 VMC COMPRESSORS PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 1000 RPM HIGH STAGE AND TWO-STAGE COMPRESSORS, AND 1200 RPM BOOSTER COMPRESSORS
NO. REQ. PER COMPRESSOR ITEM DESCRIPTION
NO. OF CYL.
SERIAL NO. TWOSTAGE 6 12 6 -6 -12 6 12 6 6 6 6 6 12 12 12 12 12 12 6 -6 -6 -6 -18 -6 -6 -6 -12 -12 -24 12 24 12 12 12 12 12 24 24 24 24 24 24 12 -12 -12 -12 -36 -12 -12 -12 -PART NUMBER KT213 KT213 KT478 KT478 31989M 31989N ** 33244A KT463 KT512 KT513 31896B # Order Kit 2027A 2028A KT512 ++ KT513A KT513 ++ 31955A A32695C A32695C A32695D A32695D 1776B 1776B 31990B 31990B 31939B 31939B 31990A 31990A 33531B 33531B 33532B 33532B
2 2 -2 -4 2 4 2 2 2 2 2 4 4 4 4 4 4 2 -2 -2 -2 -6 -2 -2 -2 --
4 4 -4 -8 4 8 4 4 4 4 4 8 8 8 8 8 8 4 -4 -4 -4 -12 -4 -4 -4 --
SINGLE STAGE 6 8 12 6 -6 -12 6 12 6 6 6 6 6 12 12 12 12 12 12 6 -6 -6 -6 -18 -6 -6 -6 -8 -8 -16 8 16 8 8 8 8 8 16 16 16 16 16 16 8 -8 -8 -8 -24 -8 -8 -8 --12 -12 24 12 24 12 12 12 12 12 24 24 24 24 24 24 -12 -12 -12 -12 -36 -12 -12 -12
16 -16 -16 32 16 32 16 16 16 16 16 32 32 32 32 32 32 -16 -16 -16 -16 -48 -16 -16 -16
FROM 3068 2656 3068 2656 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2199+ 2656 2199+ 2656 0 2656 0 2656 0 2656 0 2656 2199+ 2656 2199+ 2656
THRU Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present Present
501 Thru 505 501 Thru 512 501 502 503 506 Thru 512 510 & 511 506 507 509 510 511
Piston (Flat,AL) Rings & Pin Kit Piston (Flat,AL), Rings & Pin Kit Piston (Flat,AL) & Conn Rod Assy Kit Piston (Flat,AL) & Conn Rod Assy Kit Piston Ring, Compression Piston Ring, Oil Snap Ring, Piston Pin Connecting Rod Assy with Bearings Kit Bearing Half & Lock Nut Kit (Std. Size) Bearing Half & Lock Nut Kit (Undersize) Bushing, Piston Pin Connecting Rod and Cap 3 Nut, Plain, Hex /8-24UNF 3 Nut, Lock, /8 Connecting Rod Bearing Half, Conn. Rod (w/o Groove) Standard Size 0.015 Undersize 0.030 Undersize Bolt, Connecting Rod Safety Head Assembly, Ammonia (for Helical Springs) (for Helical Springs) Safety Head Assembly, R12 and R22 (for Helical Springs) (for Helical Springs) 3 Lock Nut, /8, Valve Retaining 3 Lock Nut, /8, Valve Retaining Washer, Diaphragm Valve Washer, Diaphragm Valve Valve, Diaphragm Discharge Valve, Diaphragm Discharge Spacer, Diaphragm Valve Spacer, Diaphragm Valve Safety Head (for Helical Springs) Ammonia Safety Head (for Helical Springs) Ammonia Safety Head (for Helical Springs) R12 & R22 Safety Head (for Helical Springs) R12 & R22 Screw, Valve Retaining (60) Screw, Valve Retaining (82) Screw, Valve Retaining (60) Screw, Valve Retaining (82)
512 513 Thru 518 513 Thru 518 513 513 514 514 515 515 516 516 517 517 517 517
518 2 4 6 8 --6 12 2656 13490 31964A 518 2 4 6 8 --6 12 1349 Present 1527B 518 ----12 16 --2656 13490 31964A 518 ----12 16 --13491 Present 1527B NOTES: * The latest design for cast iron flat top pistons utilizes a set of three compression rings (Part No. 31989M) and can be used in a compressor having cast iron pistons with two compression rings. #, **, ++, See note with same symbol on page 21. + See note with same symbol on page 23. A. Abbreviation C.I. = Cast Iron Pistons; Al = Aluminum Pistons.
PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 1000 RPM HIGH STAGE AND TWO-STAGE COMPRESSORS AND 1200 RPM BOOSTER COMPRESSORS
NO. REQ. PER COMPRESSOR ITEM DESCRIPTION
NO. OF CYL.
SERIAL NO. TWOSTAGE 6 12 -24 6 -6 -48 12 -12 PART NUMBER 31915A 33803A 31941B 31941B 31882A
2 8 8 2 -2
4 16 16 4 -4
16 -64 -16 16
Springs, Valve (Volute) Springs, Valve (Helical) Yoke, Safety Head Yoke, Safety Head Spring, Safety Head
NOTES: + 1000 RPM high stage and VMC booster compressors with Serial No.s 2198 and below have volute springs, with the exception of Serial Nos. 2160, 2163, 2168, 2169, 2182, 2183, 2184, 2185, and 2186, which have helical springs. All 1000 RPM high stage and VMC booster compressors with Serial Nos. 2199 and above have helical springs. The old type volute springs are available. However, the safety head for volute springs is not available. If a replacement safety head for volute springs is needed, it will be necessary to purchase the helical spring as well as the safety head for helical springs. When this conversion is made, it is not necessary to make the conversion on all cylinders of the compressors. It may be well to do so to eliminate confusion in the future.
February 2001
Replaces March 1975
Pages 24 through 31 pertain to replacement parts for high speed compressors having serial numbers below 9999. These redesigned replacement parts are incorporated on all high speed compressors having serial numbers 3638 and above. The remaining repair parts pages apply to all existing high speed 440 VMC compressors. If it is desired to convert an existing high speed 440 VMC compressor having a serial number below 3638 to the latest design arrangement, kits listed below are offered, depending upon the particular compressor involved. It is recommended, though not mandatory, that the old parts be replaced by these kits containing the latest design parts when making a major parts replacement or general overhaul of the compressor.
It is also recommended that all cylinders be converted at one time to avoid unnecessary complications when stocking and ordering future replacement parts. It will not impair the performance of the machine if a combination of converted and unconverted cylinders exist in one machine; however, care must be exercised thereafter in ordering the proper replacement parts for each cylinder. Purchasing these conversion parts in kit form will result in some savings, as opposed to the purchasing of former style, high speed replacement parts individually. Refer to the Home Office for prices on these conversion kits. Include all information (especially serial number) regarding the compressor to be converted. Also include correct part number for kit as listed below. KITS ARE AVAILABLE AS FOLLOWS:
COMPRESSOR DESCRIPTION 1200 RPM, High Stage with Aluminum Plug Type Pistons 1200 RPM High Stage with Cast Iron Plug Type Pistons 1200 RPM High Stage with Aluminum Plug Type Pistons 1200 RPM High Stage with Cast Iron Plug Type Pistons
R12, R22 AMMONIA R12, R22 Part Number Part Number Part Number Kits With Connecting Rod Assemblies KT127 KT123 KT131
*
KT073A
*
KT076A
*
1.
Kits with Cast Iron Pistons are no longer available. Please contact the home office.
Kits KT119, KT120 * (Ammonia), and Kits KT127, KT128 * (R12, R22), for cylinders without unloading, include the necessary piston rings, Piston and Pin Assembly, Piston Pin Snap Rings, Connecting Rod Assembly, Connecting Rod Bearing Halves, Cylinder Liner, O Ring Seal, Safety Head Assembly, Safety Yoke, Suction Valve Plate, and Helical Valve Springs required to convert one cylinder from a plug type to a flat top piston. Kits KT073A, KT073C * (Ammonia) and Kits KT075A, KT075C * (R12, R22), for cylinders without unloading include all the parts listed in paragraph (1) except the Connecting Rod Assembly and Connecting Rod Bearing Halves. 3. Kits KT123, KT124 * (Ammonia), and Kits KT131, KT132 * (R12, R22) for cylinders with unloading, include all the parts listed in paragraph (1) as well as the Lift Ring and Spring Post Assembly, Lift Springs and Lift Pins. Kits KT074A, KT074C * (Ammonia) and Kits KT076A, KT076C * (R12, R22) for cylinders with unloading include all the parts listed in paragraph (1) and (3) except the Connecting Rod Assembly and Connecting Rod Bearing Halves.
4.
2.
OLD STYLE CYLINDER LINER & CAPACITY CONTROL REPLACEMENT PARTS FOR 1200 RPM HIGH STAGE COMPRESSORS WITH SERIAL NUMBERS BELOW 3638 FIGURE 11
ITEM 401 thru 405 401 And 402 401 402 403 404 405 407 408 408 408 409 409 409 409
DESCRIPTION
NO. OF CYL
NO. REQUIRED PER COMPRESSOR 4 6 8 12 16 2 2 -4 4 2 4 4 4 16 16 16 4 4 4 4 4 2 -6 6 4 8 8 6 24 24 24 6 6 6 6 4 4 -8 8 4 8 8 8 32 32 32 8 8 8 8 8 4 -12 12 8 16 16 12 -48 48 -12 12 12 8 8 -16 16 8 16 16 16 -64 64 -16 16 16
SERIAL NO. FROM THRU 0 0 0 0 0 0 0 0 0 0+ 2050+ 3290+ 0+ 2050+ 3290+ 3290+ 3637 3637 3637 3637 3637 3637 3637 3637 3637 2049 3289 3637 2049 3289 3637 3637
PART NO. KT033 KT032 KT032 A32609A 2176BH A33434A 33436A 33428A 33422A 31915A 33803A 13556A Obsolete Obsolete 33587A 33586A
410 thru 1* 1 2 2 4 4 150 3637 KT034 412 410 Piston Ring, Unloader 4* 4 8 8 16 16 150 3637 35278A 411 Piston 1* 1 2 2 4 4 150 3637 31989L 412 Pin, Long Pivot 1* 1 2 2 4 4 150 3637 33250C 413 Complete Capacity Control Mechanism Assy 1* -----150 3637 A33577A Thru Complete Capacity Control Mechanism Assy -1 2 2 4 4 150 3637 A33354A 420 413 Arm, Yoke Lifting 1* 1 2 2 4 4 150 3637 33338A 414 Yoke Assembly 1* -----150 3637 A33575A 414 Yoke Assembly -1 2 2 4 4 150 3637 A33335A 3 11 415 Pin, /8 x /16 long Roll 1* 1 2 2 4 4 150 3637 1193X 416 Pin, Short Pivot 1* 1 2 2 4 4 150 3637 33250B 417 Spring, Unloader Yoke 6* 6 12 12 24 24 150 3637 33686A 418 Yoke Guide Assembly 1* -----150 3637 A33576A 418 Yoke Guide Assembly -1 2 2 4 4 150 3637 A33347A 3 419 Screw, /8 x 1 Nylok Cap 2* -----150 3637 1352D 420 Spacer Sleeve 2* -----150 3637 33618A NOTES: * These items used on 2 cylinder compressors only when equipped with unloading. For single cylinder unloading, the yoke assembly (Item 414) and two pins on the yoke guide assembly (Item 418) have drilled and tapped holes to accommodate screws (Item 419) and spacers (Item 420). + All 1200 RPM VMC Compressors equipped with old style 1200 RPM parts from Serial No. 2050 thru 3289 had helical valve springs. Below 2050 had volute springs except 829, 831, 1489, 1706, 1707, 1723, 1733 and 1735, which also had helical springs. Above 3289 and thru 3637 had damped helical springs. Individual springs of each type are available for replacement; however, discharge valve outer seats to accommodate only the damped helical springs are available obsoleting all other seats. Therefore, when ordering seats for replacement on models previous to 3290, four damped helical valve springs must also be ordered with each seat. Damped springs must then be specified for any subsequent spring replacement. It is not essential that this change be 7 made on all cylinders if made on one. As a means of identification, the regular helical springs are /16 long and are constructed 17 with two dead coils at the end of the spring that is inserted into the hole. The damped springs are /32 long and are constructed with a special coil at one end with a closer winding pitch (not completely closed). If desired, see page 24 for converting to new style 1200 RPM parts. Refer to Home Office for Compressors with Serial Numbers below 150. Also available in Kit KT035, KT036 or KT037. See page 29.
Cylinder Liner Kit (For Cylinders w/Unloading) Cylinder Liner Kit (For Cylinders w/o Unloading) (For Cylinders w/o Unloading) Liner, Cylinder Seal, O Ring Unloader Ring Assembly Washer, Unloader Spring Spring, Unloader Ring Plate, Suction Valve Spring, Valve (Volute) Spring, Valve (Helical) Spring, Valve (Damped Helical) Outer Seat, Ammonia or R12 & R22 Discharge Valve (for Volute Springs) Outer Seat, Ammonia or R12 & R22 Discharge Valve (for Helical Springs) Outer Seat, Ammonia Discharge Valve (for Damped Helical Springs) Outer Seat, R12 & R22 Discharge Valve (for Damped Helical Springs) Piston Kit, Capacity Reduction
1* 2 1* 2 2 1* 2* 2* 2 8 8 8 2 2 2 2
CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS 1000 RPM HIGH STAGE AND 1200 RPM BOOSTER COMPRESSORS Serial Numbers 2655 and below
ITEM 401 Thru 402A 403 404 409 409 DESCRIPTION
NO. OF CYL
Cylinder Liner Kit (w/o unloading) Unloader Ring Assembly Washers, Unloader Spring Outer Seat, Ammonia Discharge Valve Outer Seat, R12 & R22 Discharge Valve
------
NOTE: These parts are given for information purposes only parts are no longer available.
ITEM 501 thru 512 501 502 503 504 and 505 506,507, 510,511 & 512 506 507 509 510 511 511 512 519 Thru 525 Except 521 519 thru 525 Except 521 Plus 408 & 409 519 519 519 520
DESCRIPTION
NO. OF CYL
Piston (Cup, CI) and Conn. Rod Assy Kit Piston (Cup, AL) and Conn. Rod Assy Kit Piston Ring, Compression Piston Ring, Oil Snap Ring, Piston Pin Piston (Cup, CI) and Piston Pin Assy Piston (Cup, AL) and Piston Pin Assy Connecting Rod Assembly with Bearing Kit Bushing, Piston Pin Connecting Rod and Cap 3 Nut, Plain, Hex /8-24UNF 3 Nut Lock, /8-24NF Bearing Half, Connecting Rod Bearing Half, Connecting Rod .030 Undersize Bolt, Connecting Rod Safety Yoke and Discharge Valve Inner Seat Assembly (for Volute Springs) (for Helical Springs) (for Damped Helical Springs, Amm&R22) (for Damped Helical Springs, R12 Complete Safety Yoke Assy Kit (Amm) Complete Safety Yoke Assy Kit (R12) Complete Safety Yoke Assy Kit (R22)
2 2 2 4 2 4 2 2 2
SERIAL NO. FROM THRU 0* 1659 1660* 3637 0 3637 0 3637 0 3637 0* 1659 1660* 3637 0 3637
PART NO. KT116 KT117 31989M 31989N 33244A A32457A A32567A KT212
2 2 4 4 4 4 4
4 4 8 8 8 8 8
6 6 12 12 12 12 12
8 8 16 16 16 16 16
12 12 24 24 24 24 24
16 16 32 32 32 32 32
0 0 0 0 0 0 0
2 2 2 2 2 2 2
4 4 4 4 4 4 4
6 6 6 6 6 6 6
8 8 8 8 8 8 8
-12 12 12 12 12 12
-16 16 16 16 16 16
521 523 524 524 525 NOTES: Designation: C.I. = Cast Iron Pistons; Al. = Aluminum Pistons. * All 1200 RPM VMC Compressors with Serial No. 1660 and above have aluminum pistons except 1875, 1876 and 1880, which have cast iron pistons. All other 1200 RPM VMCs have cast iron pistons with the exception of Serial No. 1489, which has the aluminum pistons. See note on Page 10 for crankshaft requirements. + All 1200 RPM VMC Compressors equipped with old style 1200 RPM parts from Serial No. 2050 thru 3289 had helical valve springs. Below 2050 had volute springs except 829, 831, 1489, 1706, 1707, 1723, 1733 and 1735, which also had helical springs. Above 3289 and thru 3637 had damped helical springs. Individual springs of each type are available for replacement; however, safety yoke and pin assemblies and safety yoke and discharge valve inner seat assemblies to accommodate only the damped helical springs are available, obsoleting all previous comparable assemblies. Therefore, when ordering these assemblies for replacement on models previous to 3290, eight damped helical valve springs must also be ordered with each assembly. Damped springs must then be specified for any subsequent spring replacement. It is not essential that this change be made on all 7 cylinders if made on one. As a means of identification, the regular helical springs are /16" long and constructed with two dead 17 coils at the end of the spring that is inserted into the hole. The damped springs are /32 long and are constructed with a special coil at one end with a closer winding pitch (not completely closed). If desired, see page 24 for converting to new style 1200 RPM parts. #, ++ See note with same symbol on page 21.
Springs, Valve (Volute) Springs, Valve (Helical) Springs, Valve (Damped Helical) Safety Yoke and Pin Assembly (for Volute Springs) (for Helical Springs) (for Damped Helical Springs) Spring, Safety Head Nut, 1 Flexloc Plate, Discharge Valve Ammonia, R22 Plate, Discharge Valve R12 Inner Seat, Discharge Valve
16 16 16 2 2 2 2 2 4 2 2
32 32 32 4 4 4 4 4 8 4 4
48 48 48 6 6 6 6 6 12 6 6
64 64 64 8 8 8 8 8 16 8 8
-96 96 -12 12 12 12 24 12 12
2049 3289 3637 2049 3289 3637 3637 3637 3637 3637 3637
31915A 33803A 13556A Obsolete Obsolete A33585A 31882A 1330B 33423A 33423A 33421A
PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 1000 RPM HIGH STAGE AND 1200 RPM BOOSTER COMPRESSORS Serial Numbers 3067 and below
ITEM 501 Thru 505 501 Thru 512 504 & 505 519 Thru 525 Except 521 520 523 524 524 525 DESCRIPTION
NO. OF CYL
2 2
Piston (Flat, CI) Rings & Pin Kit Piston (Flat, CI) & Conn Rod Assy Kit Piston (Cup, AL) & Conn Rod Assy Kit Piston (Cup, AL) & Pin Assy Safety Yoke & Discharge Valve Inner Seat Assy Amm & R22 Safety Yoke & Discharge Valve Inner Seat Assy R12 Assembly, Safety Yoke & Pin Nut, 1 Flexloc Plate, Discharge Valve Amm & R22 Plate, Discharge Valve R12 Inner Seat, Discharge Valve
2 ---
--------
--------
--------
--------
12 12 12 12 24 12 12
16 16 16 16 32 16 16
0 0 0 0 0 0 0
CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS Serial Numbers 9999 and below
NO. REQ. PER COMPRESSOR ITEM DESCRIPTION
NO. OF CYL.
SERIAL NO. TWOSTAGE 6 12 1 ----1 -1 ----------1 -----PART NUMBER A31905A A32612C A32612D A32612C A32612D 33365A + 35502A + 31902A A30291A A30304A A30291A A30304A
2 1 ----1 -1 -----
4 1 ----1 -1 -----
16 ------1 ------
FROM 0 0 0 0 0 0 0 0 0 0 0 0
THRU 1659 1659 1659 3067 3067 9999 9999 1659 1659 1659 3067 3067
220 224 Thru 233 224 Thru 233 225 225 226 229
229
Shim, Rear Bearing Retainer Complete Crankshaft Assy (1200 RPM) For Cast Iron Pistons For Cast Iron Pistons Complete Crankshaft Assy (1000 RPM) For Cast Iron Pistons For Cast Iron Pistons Lockwasher, Crankshaft Bearing Lockwasher, Crankshaft Bearing Lock, Bearing Crankshaft (1200 RPM) (w/oilways plug) For Cast Iron Pistons (*) For Cast Iron Pistons (*) Crankshaft (1000 RPM) (w/oilways plug) For Cast Iron Pistons (*) For Cast Iron Pistons (*)
NOTES: * Some compressors using cast iron pistons were equipped with an obsolete oil pump drive. If the compressor is not equipped with Item 233, and an interchangeable replacement crankshaft is ordered, it is necessary to order Item 233 at extra cost. + When ordering a crankshaft bearing locknut (Item 224) for a compressor with Serial No. 9999 and below, also order crankshaft bearing lockwasher (Item 225). When ordering bare crankshaft for a compressor with Serial No. 9999 and below, also order Item 224, crankshaft bearing locknut and retaining compound kit. *** Crankshafts for Cast Iron Piston for these machines are no longer available. Use current crankshaft and convert the compressor to aluminum pistons.
Heavy-Duty 8-cylinder 440 VMC Compressors are also available for use with V-Belt drives up to a maximum of 125 BHP as compared to the maximum of 100 BHP for the standard, 8-cylinder 440 VMC Compressors. This compressor will supplement, not replace, the standard 8-cylinder 440 VMC Compressor. This higher BHP is possible due to modifications of design. Construction of the Heavy-Duty compressor will be the same as the standard 8-cylinder 440 VMC Compressor except that a 12 or 16-cylinder front bearing cover assembly and rotary shaft seal replace the standard 8-cylinder parts. The crankshaft () is of special stepped design with a 3 diameter on the drive end and a 2 diameter on the pump end. The standard 8-cylinder 440 VMC Compressor has a straight shaft of 2 diameter.
REPAIR PARTS FOR 8-CYLINDER 1000 AND 1200 RPM HEAVY-DUTY 440 VMC COMPRESSORS CAN BE SELECTED FROM THE PRECEDING REPAIR PARTS PAGES FOR THE LATEST DESIGN OF STANDARD 8-CYLINDER COMPRESSOR WITH THE EXCEPTION OF THE FOLLOWING:
ITEM NUMBER PART NUMBER DESCRIPTION REQUIRED NUMBER 201 thru 211A Front Bearing Cover and Relief Assembly 1 A32566A 209 thru 211A Front Bearing Cover Assembly 1 A36241A 211 Cover, Front Bearing 1 * 214 Retainer, Front Bearing 1 33500A 217 Rotary Shaft Seal Assembly 1 A33489A 218 Gasket, Shaft Seal Cover 1 33496A 220 Cover, Shaft Seal 1 32564A 224 thru 233 Complete Crankshaft Assembly (for Aluminum Pistons) 1 A32792B 224 ** Locknut and Retaining Compound Kit 1 KT367 227 ** Front Bearing and Retaining Compound Kit 1 KT369 228 Ring, Front Bearing Retaining 1 33145A 229 ** Crankshaft and Retaining Compound Kit (for Aluminum Pistons) 1 KT374 229 Crankshaft (for Cast Iron Pistons) 1 A32255A 501 thru 505 Piston (Flat, Cast Iron), Rings and Pin Assembly Kit 8 KT214 501 thru 505 Piston (Flat, Aluminum), Rings and Pin Assembly Kit 8 KT213 501 Piston Ring, Compression 24 31989M 502 Piston Ring, Oil 8 31989N 501 thru 512 Piston (Cast Iron) Assembly and Connecting Rod Kit 8 KT114 501 thru 512 Piston (Aluminum) Assembly and Connecting Rod Kit 8 KT478 NOTES: * Sold only in front bearing cover assembly. ** Includes retaining compound for bearing lock nut. Retaining compound also available separately, order part number KT365. Shot peening is not standard on Heavy-Duty crankshafts, but is available as an option. + Heavy-Duty compressors are identified by HD in the serial number.
ITEM --------118 217 217 306 315 315 321 401 Thru 402A 401 Thru 406
PART NAME Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Gasket Kit, Complete Safety Valve (Internal Relief) Rotary Shaft Seal Assembly Rotary Shaft Seal Assembly Oil Pump Assembly (for all 440 VMC Compressor) Recharge (Includes Gasket 1448B) (Standard Tri-Micro Filter) Recharge (Includes Gasket 1448B) (Special-Improved Tri-Micro Filter Option) Gasket, Oil Filter Head Cylinder Liner Kit (for Cylinder w/o Unloading) a. 1000 RPM Compressors b. 1200 RPM Compressors Serial No. 3638 to present Cylinder Liner Kit (for Cylinder w/Unloading) a. 1000 RPM Compressors b. 1200 RPM Compressors Serial No. 0 to 3637 c. 1200 RPM Compressors Serial No. 3638 to Present Spring, Lift 1000 RPM (1200 RPM, 3638 to Present) and All Boosters Spring, Lift 1200 RPM below Serial No. 3638 Suction Valve Plate 1000 RPM (1200 RPM, 3638 to Present) and All Boosters Suction Valve Plate 1200 RPM, below Serial No. 3638 Capacity Control Assembly a. Two Cylinder and Two-Stage Compressors b. All Other Compressors Piston and Connecting Rod Assembly Kit a. Cast Iron, Flat Top Piston (1000 RPM) b. Aluminum, Flat Top Piston (All Speeds) Piston Ring, Compression Piston Ring, Oil 3 Nut, Plain, Hex /8-24UNF 3 Nut, Lock, /8-NF Bearing Half, Connecting Rod Bolt, Connecting Rod Safety Head Assy, Ammonia (All Speeds) Safety Head Assy, Halocarbon (All Speeds) Diaphragm Discharge Valve Plate (all speeds) Valve Retaining Screw Valve Springs (Volute) Valve Springs (Helical) Valve Springs (Damped Helical 1200 RPM) Discharge Valve Plate, 1200 RPM Compressor Serial No. 0 to 3637
QUANTITY PER COMPRESSOR RECOMMENDED FOR STOCK SINGLE STAGE TWO STAGE 6 8 12 16 6 12 ------------1 ------1 ------1 ------1 ------1 ------1 1 1 2 2 --1 1 --1 ---1 1 -1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 2 1 1 1 2 2 1 1 1 2 2 1 1 1 2 2 1 1 1 2 2
1 1 1 4 2 1 1
1 1 1 4 2 1 1
2 2 2 8 4 2 2
2 2 2 8 4 2 2
2 2 2 8 4 2 2
2 2 2 8 4 2 2
2 -2 8 -2 --
2 -2 8 -2 --
405 405 407 407 413 Thru 420 501 Thru 512 501 502 509 510 511 512 513 Thru 518 515 518 519 519 519 524
A33577A A33354A KT114 KT478 31989M 31989N 2027A 2028A KT512 31955A A32695C A32695D 31939B 1527B 31915A 33803A 13556A
1 -1 1 6 1 4 4 2 4 1 1 6 2 8 8 8
-1 1 1 12 1 8 8 4 8 1 1 12 4 16 16 16
-1 2 2 12 2 12 12 6 12 2 2 18 6 24 24 24
-1 2 2 12 2 16 16 8 16 2 2 24 8 32 32 32
-2 2 2 18 2 24 24 12 24 3 3 36 12 -48 48
-2 2 2 24 2 32 32 16 32 3 3 48 16 -64 64
1 --2 12 2 12 12 6 12 2 2 18 6 -24 --
2 --2 18 2 24 24 12 24 3 3 36 12 -32 --
33423A 2 2 4 4 4 4 --NOTES: A. The above listing includes the minimum selection and quantity of recommended spare parts. It may vary considerably depending upon the circumstances. All items listed do not necessarily apply to every compressor, because of serial number application or optional features. Items that apply should be selected for each individual compressor. B. All of the above parts can be used with either ammonia, R12 or R22 compressors unless specified otherwise.
PAGE 1 2 3 4 6 7 8 9 10 11 12 13
REPLACEMENT PARTS ORDERING INSTRUCTIONS BASIC FRAME REPLACEMENT PARTS Illustration, 2 Cylinder (Figure 1) Illustration, 4, 6 & 8 Cylinder (Figure 2) Parts List CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS Illustration (Figure 3) Parts List REAR BEARING COVER REPLACEMENT PARTS Illustration (Figure 4) Parts List CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS Illustration (Figure 5) Parts List PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS Illustration (Figure 6) Parts List REPLACEMENT PARTS ORDERING INSTRUCTIONS
1.
Give the size, voltage, original order number and serial number of the compressor. All of this information is stamped on the nameplate attached to the compressor frame. The serial number is also stamped on the compressor frame. The compressor frame serial number location is directly above the suction flange on the frame of the compressor or directly above the rear bearing cover. The rear bearing is located on the oil pump/filter end of the compressor. Always give the name of the part as well as the corresponding part number and/or item number. Also include the quantity of parts required. Should there be a doubt regarding the part number or name, send a sketch of the part required or return the old part as a sample, transportation charges prepaid. Orders on which part numbers and description do not agree will be filled according to our best interpretation. All prices are F.O.B. factory. Minimum domestic parts order is $75.00 net price. Please indicate on the order preferred method of shipment. We will follow your instructions unless it is to your best interest to change routing. If you purchased the compressor from a party other than Vilter Manufacturing Corporation, please state when you purchased the compressor and from whom.
2.
3.
4. 5.
6.
DESCRIPTION Frame 5 Screw, /8 x 2 Hex. Head Cap (Used w/o Water Jacket) 5 Screw, /8 x 3 Hex. Head Cap (Used with Water Jacket) Cover, Water Jacket Gasket, Water Jacket Cover, Cylinder w/o Capacity Reduction w/Capacity Reduction w/Capacity Reduction Banks w/o Capacity Reduction w/Capacity Reduction Gasket, Cylinder Cover 5 Stud, /8 x 3 (shown only on 2 cylinder) Stud, x 3 (not shown) 5 Nut, /8-11NC-2B Nut, -10NC-2B Tee, Suction (++) 2 x 2 3 x 3 Elbow, Discharge (++) 2 x 2 (Ammonia) 2 x 2 (Ammonia) 3 x 3 (Ammonia) 4 x 3 (Ammonia) Suction Screen Suction Screen Suction Screen (Center) Suction Screen (R.H. Side, 8 cyl., 75% Cap. Red.) Bag, Suction Screen (not shown) Bag, Suction Screen (not shown) Bag, Suction Screen (not shown) Gasket, Suction Screen Cover Gasket, Suction Screen Cover Gasket, Suction Cover Cover, Suction Screen Cover, Suction Screen Cover, Suction Screen 5 Screw, /8 x 1 Hex. Head Cap 5 Screw, /8 x 1 Hex. Head Cap Valve, Oil Charge and Drain (Ammonia) Valve, Oil Charge and Drain (Halocarbon) Nipple, x 4 Sch. 80 Pipe Gasket, Crankcase Oil Screen Crankcase Oil Screen Assembly Plug, Hex. Head Pipe Plug, Hex. Head Pipe Pin Retaining Assembly for Compressor Oil Screen Safety Valve, Internal Relief Gasket, 2 Flange Cover, Safety Valve 5 Screw, /8 x 2 Hex. Head Cap Gasket, Handhole Cover
QUANTITY REQUIRED PER COMPRESSOR NUMBER OF CYLINDERS 2 4 6 8 1 1 1 1 20 40 60 80 20 40 60 80 1 2 3 4 1 2 3 4 --1 1 1 1 8 --1 -1 ---1 ----1 -1 --1 ---6 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 ---2 4 4 4 -1 -1 ---1 --1 ---1 --1 -5 -1 1 1 1 1 1 1 1 1 1 1 2 1 --1 1 1 3 4 4 4 ----1 -2 ----2 1 2 -1 2 -1 -12 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 ---4 4 4 4 -----1 2 -1 1 -3 1 2 -1 2 1 1 5 12 1 1 1 1 1 1 1 1 1 1 1 2 1
PART NUMBER * 13152G 13152L 30299A 33329A A30332A 30332B A30364A A30364A 30364B 33330A 13156D 13157D 1726G 1726H A30319A A32417B 12270E 12270F 12271E A32498A A32428B A32428A A32428C A32428D A33474A A33474B A35234A 31892A 11323J 35217A 31893A 13706A 35216A 13152E 13153E A15375A 1956A 13189G 31889A A31886A 13264D 13264E A31936A 1721B 11323G 31954A 13152E 31894A
109 109 109 109 109-A 109-A 109-A 110 110 110 111 111 111 112 112 113 113 113A 114 115 116 116 117 118 119 120 121 122 NOTES: * Part Number on application.
DESCRIPTION Handhole Cover and 2 Sight Glass Assy With openings for: 560W NEMA 1 & 7 Htr., F.V. & Therm. 300W NEMA 1 & 7 Heater and Therm. 560W NEMA 1 & 7 Htr. & Therm. 300W NEMA 1 & 7 Htr. & Therm. Cover, Handhole (without openings) (not shown) Glass, Oil Sight 2 Screw, x 1 Hex Head Cap
PART NUMBER
1 1 1 1 -1 16
1 1 1 1 -1 16
1 1 1 1 -1 16
1 1 1 1 -1 16
ITEM 201 thru 211 201 202 thru 208 202 203 204 205 206 207 208 209 thru 211 209 thru 211 209 210 211 211B 211C 212 213 214 215 216 217 & 218 217 218 219 220 & 220A 220A 224 Thru 233 224 227 228 229
DESCRIPTION Front Bearing Cover and Relief Valve Assy Cap, Valve Oil Relief Valve Kit Gasket, Valve Cap Nut, Packing Washer 7 39 3 Packing, /8 O.D. x /64 I.D. x /8 Stem, Valve Spring 5 Ball, /8 dia. Steel Front Bearing Cover Assembly for 2 Shaft (Requires Oil Orifice in Item 214) Front Bearing Cover Assembly for 3 Shaft (Requires Oil Orifice in Item 214) Plug, Hex Head Pipe 3 Plug, /8 Hex Head Pipe Cover, Front Bearing Shield, Splash 3 Screw, Hexagon Hd. No. 10-32 x /8 long Gasket, Bearing Cover 5 Screw, /8 x 4 Hex Socket Head Cap Retainer, Front Bearing (with Oil Hole) 5 Screw, /8 x 2 Hex Head Cap Screw, x 4 Hex Head Cap Seal and Gasket Kit Seal, Rotary Shaft Assembly Gasket, Shaft Seal Cover Screw, x 1 Hex Head Cap Cover and Tube Assembly, Shaft Seal Drain Tube Crankshaft and Bearings Assembly * Crankshaft and Bearings Assembly * Crankshaft and Bearings Assembly * Crankshaft and Bearings Assembly * Locknut and Retaining Compound Kit Front Bearing and Retaining Compound Kit Ring, Front Bearing Retainer Crankshaft and Retaining Compound Kit * for Aluminum Pistons for Aluminum Pistons for Aluminum Pistons for Aluminum Pistons Retainer, Rear Bearing Rear Bearing and Lock Pin 5 Screw /16 x 1 Hex. Head Crank, Oil Pump Drive Key, 2 Crankshaft Screw, Flywheel Hub Washer, Flywheel Hub Screw
QUANTITY REQUIRED PER COMPRESSOR NUMBER OF CYLINDERS 2 4 6 8 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 3 1 2 1 6 3 1 1 1 8 1 1 1 ---1 1 1 1 ---1 1 4 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 3 1 2 1 6 3 1 1 1 8 1 1 -1 --1 1 1 -1 --1 1 4 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 3 1 2 1 6 3 1 1 1 8 1 1 --1 -1 1 1 --1 -1 1 4 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 3 1 2 1 6 3 1 1 1 8 1 1 ---1 1 1 1 ---1 1 1 4 1 1 1 1
PART NUMBER A32566A 17355A KT486 30651C 31048A 31048D 31048E 31048C 31048F 13155K A36240A A36241A 13264B 13264C Order Assy 35274A 2583A 31890A 13159E 31885A 13152E 13153Q KT509 A33483A 31897A 13153F A32564A 35078A A34555HX A34555KX A34555LX A34555BX KT366 KT368 33144A KT370 KT371 KT372 KT373 31904A KT353 1736G 33403A 31994B 31956A 33495A
ITEM 301 thru 304 & 333 301 302 303 304 305 306 307 308 309 309 310 311 311A,312, 313 & 314 311A, 312 Thru 314 & 315A thru 319 & 321 312 313 314 315 316 317 318 319 320 321 322 322A 322B 323 324 *** 324 ** 325 326 327 327A 328 329 329A 330 331 332 333 334 335
DESCRIPTION Rear Bearing Cover Assembly Kit Cover, Rear Bearing Plug, Hex Socket Head Pipe 3 Pin, /8 x 1 Dowel Orifice, Oil Metering (not shown) Gasket, Oil Pump Body Oil Pump Assembly Gasket, Oil Pump Cover Gasket, Oil Pump and Rear Bearing Cover Seal Cover, Oil Pump and Filter Head (used when Oil Cooler not used) Cover, Oil Pump and Filter Head (used when Oil Cooler is used) Filter Assy., Complete (with Bypass Relief) Spool Assembly (with Bypass Relief) Spool Strainer Tube Assembly
PART NUMBER KT092 Order Kit 13163E 2868H 33361A 31899A A33480A 31900A 33320A 36190A 34760AB A35240A 1448J 1448U
1448T
Seal, Spool End Strainer Tube Ring, Retaining Recharge (with Bypass) Pressure Plate Assembly Pressure Plate O Ring Seal, Pressure Plate (not shown) Spring, Pressure Plate 1 Plug, Steel Hexagon Head /8 Pipe Gasket, Oil Filter Head Filter Shell with Flange and Plug Flange, Oil Filter Tank Tank, Oil Filter 7 Screw, Hexagon Head Cap /16 x 2 Instruction/Nameplate (for use with A35241A) (not shown) Instruction/Nameplate (for use with A35240A) (not shown) Gauge, 2, 0-300 PSI, Oil Filter Elbow, 90 Female Compression Tubing, O.D. Steel Tubing, O.D. Steel (AR As Required) Tee, Compression Connector, MPT x O.D. Compression Connector, MPT x O.D. Compression Valve, 3-Way, Oil Filter Bracket, Valve Control, Pressure Differential Gasket, Bearing Cover 5 Screw, /8 x 2 Hexagon Head Cap Screw, x 1 Hexagon Head Cap
1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 3ft AR 2 2 2 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 3ft AR 2 2 2 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 3ft AR 2 2 2 1 1 1 1 10 8
1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 3ft AR 2 2 2 1 1 1 1 10 8
1448H 1448K 1448L 1448C 1448M 1448N 1448P 1448Q 13264A 1448B A34623A 35125A 34623A 1689G 40680AJ 40680AT 31890A 1892B S1589AA S1589AA 13239C 13229D 13229D 2030A 35106A 1643V 31890A 13152E 2796EL
ITEM 401, 402 & 403 401, 402 Thru 408 401 402 403 405 405A 405B 406 407 408 409 410 & 411 410 & 411 410 410A 410B 411 413 thru 420 413 414 415 416 417 418
DESCRIPTION Cylinder Liner Assembly (for cylinder without unloading) Cylinder Liner Assembly (for cylinder with unloading) Liner, Cylinder Seal, O Ring (upper) Pin, Roll, 0.125 dia. X 1 lg. Ring, Lift Ring, Lift Pin, Roll Spring, Lift Pin, Lift Retainer, Lift Ring Plate, Suction Valve Piston & Rings Assy., Cap Red (Gas or Oil ) Piston & Rings Assy., Cap Red (Gas or Oil) Ring Set (PTFE & rubber) Seal, Unload Piston (Oil only) Ring, Retaining Unload Piston (Oil only) Piston, Unloader Complete Capacity Control Mechanism Assembly * (Low Suction R717 and all Booster) Arm, Yoke Lifting Yoke Assembly 3 11 Pin, /8 x /16 lg. Roll Pin, Short Pivot Spring, Unloader Yoke Yoke Guide Assembly
PART NUMBER KT475 KT476 34510A 2176BH 1193Q A33351A 35380A 1193SS 33352A 33350A 1971A 31909A A35315BX A35315CX 2557A 2639A 2638A 35315A A41788BX 41725A A33335A 1193X 33250B 33686A A33347A
ITEM
DESCRIPTION
501 thru Piston Rings and Connecting Rod Assy Kit 508 501 Piston Ring, Compression 6 12 18 24 31989M 502 Piston Ring, Oil 2 4 6 8 31989N 503 Piston and Connecting Rod Assy 2 4 6 8 * 504, 507 Bearing Half and Lock Nut Kit 2 4 6 8 KT575 & 508 3 504 Lock Nut, /8, Connecting Rod 4 8 12 16 2028A 3 505 Nut, Plain Hex /8-UNF 4 8 12 16 2027A 506 Bolt, Connecting Rod 4 8 12 16 31955A 507 Bearing Half, Connecting Rod (upper) 2 4 6 8 Order KT575 508 Bearing Half, Connecting Rod (lower) 2 4 6 8 Order KT575 509 Spring, Safety Head 2 4 6 8 35252A 510 Safety Head Yoke Kit (includes 4 of item 513) 2 4 6 8 KT543 511 Spring, Valve 16 32 48 64 33803A 512 Plate, Discharge Valve 2 4 6 8 35080SS 513 & Safety Hd. & Pins Assy (Standard Ammonia Compr) 2 4 6 8 A35082A 514 Safety Hd. & Pins Assy (#) 2 4 6 8 A35272A 11 513 Pin, Roll, 0.187 dia. x /16 lg. 8 16 24 32 1712F 514 Safety Head 2 4 6 8 ** 515 Spring, Valve 8 16 24 32 33803A NOTES: * Piston, wrist pin and connecting rod sold only as a kit. ** Shown for disassembly purposes only, order assembly. # This Safety Head and Pins Assembly is used on standard Halocarbon and High Suction Pressure Ammonia Compressors. High Suction Pressure Compressors are identified with an X in the serial number.
Vilter Manufacturing Corporation 5555 South Packard Ave. PO Box 8904 Cudahy, WI 53110-8904 Telephone: 414-744-0111 Fax: 414-744-1769 www.vilter.com