Centrifugal Compressors: Service Manual

CENTRIFUGAL COMPRESSORS
SERVICE MANUAL Supersedes: 160.75-M1 (418) Form 160.75-M1 (718)
K COMPRESSOR
USED WITH YORK
CENTRIFUGAL LIQUID CHILLER
LD17141
Issue Date:
July 20, 2018
FORM 160.75-M1
ISSUE DATE: 7/20/2018
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or
During rigging, installation, operation, maintenance, death to themselves and people at the site.
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to: This document is intended for use by owner-authorized
heavy objects, refrigerants, materials under pressure, rigging, installation, and operating/service personnel. It
rotating components, and both high and low voltage. is expected that these individuals possess independent
Each of these items has the potential, if misused or training that will enable them to perform their assigned
handled improperly, to cause bodily injury or death. It tasks properly and safely. It is essential that, prior to
is the obligation and responsibility of rigging, instal- performing any task on this equipment, this individual
lation, and operating/service personnel to identify and shall have read and understood the on-product labels,
recognize these inherent hazards, protect themselves, this document and any referenced materials. This in-
and proceed safely in completing their tasks. Failure dividual shall also be familiar with and comply with
to comply with any of these requirements could result all applicable industry and governmental standards and
in serious damage to the equipment and the property in regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation Identifies a hazard which could lead to

which will result in death or serious injury damage to the machine, damage to other
if proper care is not taken. equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Indicates a potentially hazardous situa- Highlights additional information useful

tion which will result in possible injuries to the technician in completing the work
or damage to equipment if proper care is being performed properly.
not taken.
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor-
dance with Johnson Controls’ published specifications and must be performed only by a qualified
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.
2 JOHNSON CONTROLS
FORM 160.75-M1
CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con- regarding the applicability of these documents, rig-
tinuous product improvement, the information con- ging, lifting, and operating/service personnel should
tained in this document is subject to change without verify whether the equipment has been modified and
notice. Johnson Controls makes no commitment to if current literature is available from the owner of the
update or provide current information automatically equipment prior to performing any work on the chiller.
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest CHANGE BARS
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts. Revisions made to this document are indicated with a
johnsoncontrols.com. line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
It is the responsibility of rigging, lifting, and operating/ formation and any other changes in spelling, grammar
service personnel to verify the applicability of these or formatting are not included.
documents to the equipment. If there is any question
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
K Compressor Replacement Parts 160.75-RP2
All Products - Replacement Parts Electrical Connectors 50.20-RP1
All Products - Replacement Parts Fittings 50.20-RP2
JOHNSON CONTROLS 3
FORM 160.75-M1
NOMENCLATURE
YD H J 76
Impeller Size -
Design Level (K, L, J) 76, 84, 95, 106, 119
High Pressure Refrigerant Compressor
Close-Coupled D Flange Motor
4 JOHNSON CONTROLS
FORM 160.75-M1

MISCELLANEOUS & ACCESSORIES
COMPOUNDS AND ABRASIVES

Crocus Cloth 041-02729-000
Garnet Paper 180 grit 041-10057-000
Molykote (2 Oz. Can) 364-21508-000
Removable Thread Sealer 013-01678-000
Permanent Thread Locker 013-01671-000
Refrigerant Pipe Sealer 013-02894-000
Primer for Thread Sealers 013-01753-000
Magic Bond Epoxy Stick 044-03420-000
P.O.E. Grease 044-03199-000
Caribbean Blue Enamel 013-01835-000
Gasket Eliminator Sealer 013-02827-000
Valve Stem Lube (2 Oz. Can) 360-00125-000
Lubricant, Nolybdenum 011-00253-000
COMPRESSOR TOOL KITS

COMPRESSOR COMPRESSOR COMPRESSOR PART TOOL KIT
CODE MODEL NUMBER NUMBER
K1 YDHK-76VDD 364-53357-201 364-51844-000
K2 YDHK-84VDD 364-53362-201 364-51728-000
K3 YDHL-95VDD 364-53348-201 364-51835-000
K4 YDHL-106VDD 364-53349-201 364-51835-000
K7 YDHJ-119VDD 364-53350-201 364-51665-000
YORK "K" OIL

COMPRESSOR 5 GAL CAN 1 GAL CAN
TOTAL OIL REQUIRED
CODE 011-00533-000 011-01202-000
K1-K4 4 - 20 Gallons
K7 4 4 24 Gallons
JOHNSON CONTROLS 5
FORM 160.75-M1

TABLE OF CONTENTS
SECTION 1 - GENERAL.......................................................................................................................................... 11
General Description......................................................................................................................................... 11
Nomenclature.................................................................................................................................................. 11
SECTION 2 - COMPRESSOR SERVICE.................................................................................................................13

Vibration Analysis............................................................................................................................................ 13
Thrust Endplay................................................................................................................................................ 13
Compressor Oil............................................................................................................................................... 13
Refrigerant....................................................................................................................................................... 13
Service Guidelines.......................................................................................................................................... 14
Cleaning and Checking Wearing Parts........................................................................................................... 14
Rigging the Compressor or Motor................................................................................................................... 15
Two Piece Proximity Probe............................................................................................................................. 16
Installation....................................................................................................................................................... 16
Motor Removal and Replacement................................................................................................................... 17
Alignment........................................................................................................................................................ 19
Seal Removal (Bellows Type) ........................................................................................................................ 20
Disassembly of Rotor Support......................................................................................................................... 22
Removing the Impeller ................................................................................................................................... 23
Removing Balance Piston Seal and Diffuser Plate.........................................................................................25
Removing Front Low-Speed Bearings............................................................................................................ 26
Removing Front High-Speed Bearing ............................................................................................................ 26
Removing Bearing Housing and Gears........................................................................................................... 28
Installing bearing housing................................................................................................................................ 29
Rear Low-Speed Bearing Components........................................................................................................... 29
Rear High-Speed Bearing Components.......................................................................................................... 31
High Speed Thrust Bearings........................................................................................................................... 31
Identifying Compressors utilizing updated High Speed Thrust Bearings........................................................ 31
K3 and k4 Compressors.................................................................................................................................. 31
J7/K7 Compressors......................................................................................................................................... 32
Installing Bearing Housing............................................................................................................................... 36
Installing Front High-Speed Bearings.............................................................................................................. 37
Installing Front Low-Speed Bearings.............................................................................................................. 37
Installing Balance Piston and Diffuser Plate.................................................................................................... 38
Installing the Impeller...................................................................................................................................... 38
Disassembly of Rotor Scroll............................................................................................................................ 38
Removing the Nozzle Base Plate (VGD)......................................................................................................... 39
Nozzle Baseplate Disassembly (VGD)............................................................................................................ 39
Removing the Impeller Eye Seal..................................................................................................................... 40
Re-assembly of the Eye Seal.......................................................................................................................... 41
Re-Assembly of Nozzle Base Plate
VGD assemble procedures............................................................................................................................. 41
VGD Motor Linkage......................................................................................................................................... 45
Re-Assembly of Scroll Housing to Rotor Support...........................................................................................45
Removing the Pre-Rotation Vane Housing...................................................................................................... 46
Replacing Control Shaft Assembly.................................................................................................................. 53
6 JOHNSON CONTROLS
FORM 160.75-M1

TABLE OF CONTENTS (CONT'D)

SECTION 3 - OIL PUMP SERVICE.........................................................................................................................55
Oil Pump.......................................................................................................................................................... 55
Removing Oil Pump from the Oil Sump.......................................................................................................... 55
Reassembling Oil Pump Assembly into Oil Sump...........................................................................................56
Oil Pump Housing Parts.................................................................................................................................. 57
SECTION 4 - VGD THEORY....................................................................................................................................59

General Description......................................................................................................................................... 59
How the VGD is Controlled............................................................................................................................. 64
SECTION 5 - DISASSEMBLE AND REASSEMBLE CHECKLIST ........................................................................65

Disassemble the Compressor......................................................................................................................... 65
Assemble the compressor............................................................................................................................... 65
Temperature.................................................................................................................................................... 67
INDEX......................................................................................................................................................................68
JOHNSON CONTROLS 7
FORM 160.75-M1

LIST OF FIGURES
FIGURE 1 - Compressor Identification��11
FIGURE 2 - Compressor Components ��12
FIGURE 3 - Two Piece Proximity probe��16
FIGURE 4 - Din Connector Wiring��16
FIGURE 5 - Motor Adapter��17
FIGURE 6 - Compressor Coupling��17
FIGURE 7 - Motor Alignment��18
FIGURE 8 - Axial Misalignment��19
FIGURE 9 - Angular Misalignment��19
FIGURE 10 - Parallel Misalignment��19
FIGURE 11 - Retainer Running Position��20
FIGURE 12 - Bellows Type Shaft Seal ��21
FIGURE 13 - Disassembly of Rotor Support from the Rotor Scroll��22
FIGURE 14 - DETAIL A – Checking Rim Runout ��23
FIGURE 15 - DETAIL B – Checking Eye Runout ��23
FIGURE 16 - D
ETAIL C – Checking Axial Thrust��23
FIGURE 17 - Impeller and Balance Piston��24
FIGURE 18 - Removing Impeller��24
FIGURE 19 - Balance Piston Seal��25
FIGURE 20 - Removing Diffuser Plate��25
FIGURE 21 - Balance Piston Seal Assembly��25
FIGURE 22 - Front Bearing Components��26
FIGURE 23 - Low-Speed Thrust Bearing��26
FIGURE 24 - Low-Speed Thrust Bearing Removed��27
FIGURE 25 - Checking Low-Speed Thrust Runout��27
FIGURE 26 - Low-Speed Thrust Collar Removed��27
FIGURE 27 - Front Low-Speed Bearing Removal��27
FIGURE 28 - Low-Speed Bearing Removed with High-Speed Bearing in Place��27
FIGURE 29 - Front High-Speed Bearing Removal��27
FIGURE 30 - All Front End Bearings Removed��28
FIGURE 31 - Removing Bearing Housing��28
FIGURE 32 - Bearing Housing Removed��28
FIGURE 33 - B
earing Housing Torque Sequence��29
FIGURE 34 - Bearing Housing Dowel Pins��29
FIGURE 35 - Rear Low-Speed Bearing��30
FIGURE 36 - Low-Speed Rear Bearing Removal��30
FIGURE 37 - Reverse High Speed Thrust Cover Plate��33
FIGURE 38 - High-Speed Bearing Components ��34
FIGURE 39 - High-Speed Reverse Thrust Bearing��34
FIGURE 40 - Checking High-Speed Thrust Collar Run-Out��34
FIGURE 41 - Gear Locking��34
FIGURE 42 - High-Speed Thrust Collar Removed��34
FIGURE 43 - High-Speed Forward Thrust Bearing��35
FIGURE 44 - Rear High-Speed Journal Bearing��35
FIGURE 45 - High-Speed Rear Bearing Removal��35
FIGURE 46 - Proximity Sensor��36
FIGURE 47 - Front Bearing Components��37
FIGURE 48 - Bearing Housing��37
FIGURE 49 - Impeller Mounting Screws Tightening Sequence��38
FIGURE 51 - Rotor Scroll��39
FIGURE 50 - Hand Whole Cover��39
FIGURE 52 - Tension Block��40
FIGURE 54 - K7 Eye Seal��40
FIGURE 53 - Nozzle Base Plate��40
FIGURE 55 - Eye Seal Installed��41
8 JOHNSON CONTROLS
FORM 160.75-M1

LIST OF FIGURES (CONT'D)

FIGURE 56 - Eye Seal Components��41
FIGURE 57 - VSD Assembly��43
FIGURE 58 - VSD Assembly��44
FIGURE 59 - Scroll Housing Ready for Re-Assembly to Motor Support�� 45
FIGURE 60 - Internal Parts - Pre-Rotation Vane Assembly��46
FIGURE 61 - VGD and PRV linkage Assembly��48
FIGURE 62 - Pre-Rotation Vane Housing Assembly��49
FIGURE 63 - Pre-Rotation Vane Assembly ��49
FIGURE 64 - Pre-Rotation Device��51
FIGURE 65 - Control Shaft Assembly��52
FIGURE 66 - Oil Pump Housing Cover Plate��56
FIGURE 67 - Oil Pump & Cover Plate Removal��56
FIGURE 68 - Oil Pump Motor Leads ��56
FIGURE 69 - Oil Pump Housing Assembly (K1 - K4, AND K7 Compressors)�� 58
FIGURE 70 - Typical Centrifugal Compressor��59
FIGURE 71 - Typical VGD Section��60
FIGURE 72 - Rear View of Diffuser��61
FIGURE 73 - Variable Geometry Diffuser (VGD) Model K1��62
FIGURE 74 - Side View of Diffuser��63
LIST OF TABLES
TABLE 1 - Compressor Weights (lbs.) - Less Motor��15
TABLE 2 - Torque Values��15
TABLE 3 - Coupling Torque��18
TABLE 4 - Total Indicator Reading��19
TABLE 5 - Impeller Information��23
TABLE 6 - B
alance Piston Seal Ring Dimensions��25
TABLE 7 - Permissible Runout of Impeller��38
TABLE 8 - Eye Seal Dimensions��41
TABLE 9 - VGD and PRV linkage Assembly��47
TABLE 10 - Pre-Rotation Device��50
TABLE 11 - Oil Pump Housing (K1-K4 & K7)��57
TABLE 12 - Variable Geometry Diffuser (VGD) Model K1��62
TABLE 13 - Measurements��67
TABLE 14 - SI Metric Conversion��67
JOHNSON CONTROLS 9
FORM 160.75-M1

THIS PAGE INTENTIONALLY LEFT BLANK.
10 JOHNSON CONTROLS
FORM 160.75-M1
SECTION 1 - GENERAL 1
GENERAL DESCRIPTION
These compressors are applied to YORK Model YK, are integrally assembled in the compressor rotor sup-
YST, CYK and YD Centrifugal Liquid Chillers. port and are film lubricated. Each shaft is individually
mounted in its own journal and thrust bearings.
The compressor is a single-stage centrifugal powered
by an open-drive steam turbine, gas engine or electric The open-drive compressor shaft seal consists of a
driven. The casing is fully accessible with vertical cir- spring-loaded bellows seal, high-temperature elasto-
cular joints and fabricated of close-grain cast iron. The mer O-ring static seal, and a stress-relieved, precision
complete operating assembly is removable from the lapped collar. The seal features a small face area and
compressor scroll housing. Compressor casting are de- low rubbing speed. It provides an efficient seal under
signed for 300 PSIG working pressure and hydrostati- high pressure conditions. The seal is oil-flooded at all
cally pressure tested at 900 PSIG. times and is pressure-lubricated during compressor op-
eration.
The rotor assembly consists of a heat-treated alloy
steel drive shaft with a lightweight, high strength, cast Compressors are available in various impeller sizes
aluminum, fully shrouded impeller. The impeller is de- (see Figure 1 on page 11).
signed for balanced thrust and is dynamically balanced
and overspeed tested for smooth, vibration-free opera- NOMENCLATURE
tion.
Compressor Identification
The insert type journal bearings are fabricated of Each compressor is identified by nomenclature as
aluminum alloy and are precision bored and axially shown below. The nomenclature is printed on a data
grooved. Thrust bearings are of the deflection-pad type plate which is located on the side of the unit control
design. The specially engineered, single helical gears panel (see Figure 1 on page 11). When contacting
with crowned teeth are designed so that more than one the factory or ordering renewal parts, include the com-
tooth is in contact at all times to provide even distri- plete compressor model and serial number. Be sure
bution of compressor load and quiet operation. Gears these numbers are copied accurately.
LD19818
LD17141
Figure 1 - COMPRESSOR IDENTIFICATION
JOHNSON CONTROLS 11
FORM 160.75-M1
High Speed Impeller

Front Bearing
High Speed
Rear Bearing
VGD
Assembly
High Speed
Forward Thrust
Bearing
PRV
Assembly
High Speed
Reverse Thrust
Bearing
Shaft Seal
Low Speed Gear Set Low Speed

Low Speed
Rear Bearing Forward Thrust
Front Bearing
Bearing LD19816
Figure 2 - COMPRESSOR COMPONENTS
12 JOHNSON CONTROLS
FORM 160.75-M1
SECTION 2 - COMPRESSOR SERVICE
The compressor is the most expensive part of the When performing the low and high-speed thrust in-
chiller and every effort should be made to maintain spections, the corresponding rear low and high-speed 2
and keep it operating at peak efficiency. Being a pre- shaft bearings may be removed from the compressor
cision-built machine, it is important to check the lu- to check for unusual wear. Corrective action should be
brication system for cleanliness by changing the oil taken if inspection shows excessive wear of the thrust
filter as documented in the Preventative Maintenance or journal bearing surfaces.
section of the Operating Instructions. To perform these inspections the refriger-
The compressor should not be disassembled for in- ant charge must be removed.
spection purposes only. The high and low speed shaft
bearings on YORK single stage centrifugal compres-
sors are aluminum, hydrodynamic fluid film journal
bearings. This bearing journal design allows the ro-
tating shafts to ride on an oil film and bearing wear is COMPRESSOR OIL
therefore minimal. The impeller eye and balance pis-
ton seals rings are made of a bearing grade aluminum. The compressor oil filter and oil should be replaced on
The thrust bearings are of the hydrodynamic tilting pad a yearly basis. A yearly oil sample should be collected
design. Here again the thrust collar rides on a cushion and analyzed prior to changing. The key points of the
of oil and there is no metal to metal contact. On sys- oil analysis report are moisture content and acidity.
tems with ideal operating conditions there is no need Spectrographic data supplied on oil analysis reports are
to disassemble compressors for inspection purposes. not generally a true indicator of wear metals. Howev-
Analytical tools are available that will identify poten- er, a spectrographic analysis may help to indicate other
tial mechanical problems developing prior to a failure undesireable contaminants.
occurring, or identify or indicate less than ideal con- As noted, YORK uses aluminum bearings and laby-
ditions that may warrant an internal inspection. These rinth seals. If a bearing or seal starts to wear, this metal
tools should be used to ensure proper compressor op- is collected in the oil filter. Aluminum that appears in
eration and reliability. oil sample analysis is almost always an aluminum ox-
ide that is caused by moisture in the oil. The oil filter
VIBRATION ANALYSIS
should be inspected for actual aluminum particles. It
Vibration analysis is valuable in identifying abnormal is normal on new machines to see some aluminum col-
wear of rotating parts and is particularly helpful when lected in the filter. This alumimum comes from the eye
performed on a periodic basis. Having a baseline vi- and balance piston seals as they come into contact with
bration report to compare vibration signature changes the impeller. Over time only tiny amounts of metal
over time can pinpoint potential internal compressor should be seen in the oil filter. If there is a sudden in-
problems. Systematic data collection will identify crease in metal collection on the filter, then an inspec-
potential gear wear or excessive vibration that would tion of the internal impeller seals or shaft bearings may
indicate a need for internal compressor inspection. Vi- be warranted.
bration data is also helpful in identifying potential mo-
tor bearing wear so corrective action can be scheduled REFRIGERANT
to prevent failure. Refrigerant analysis should be performed on a yearly
basis, again looking for excessive moisture and acidity.
THRUST ENDPLAY
Excessive moisture content in the refrigerant (or oil)
To check for low speed thrust bearing wear, one must can cause corrosion of internal parts of the compressor
measure and record the low speed axial thrust endplay that could in turn lead to failure of the shaft bearings,
and compare the results to design tolerances. The com- shaft seal, impeller labyrinth seals or to binding of the
pressor shaft seal will have to be removed to perform pre-rotation vanes.
the low speed axial thrust reading. To inspect the high
speed thrust bearings and thrust collar, the high speed
thrust cover plate and thrust collar must be removed.
JOHNSON CONTROLS 13
FORM 160.75-M1
By following the above listed maintenance procedures Clean Thoroughly - No compressor is completely
compressor health can be determined and ensured. If overhauled if it is not cleaned internally to “new part”
the compressor is exposed to less than ideal operating condition. Dirty parts can not be inspected or fitted and
conditions (i.e. excessive surging, excessive refriger- will cause excessive wear when the compressor is in
ant moisture, poor oil quality, or other unusual condi- operation.
tions), then the end user may want to perform an inter-
nal compressor inspection for verification that internal CLEANING AND CHECKING WEARING
components are not damaged. PARTS
However, if the compressor fails to function as outlined Before reassembling the compressor, all parts should
in the operating manual, it may be necessary to do so. be thoroughly checked for wear. Best practice is to get
Individual parts are available for replacement as de- pictures of the worn parts, to be used in the final in-
scribed in the following compressor servicing section. spection report.
Worn parts should be replaced with new and each
SERVICE GUIDELINES
new part should be thoroughly examined for shipping
The overhaul and replacement of parts of these com- damage.
pressors, like any other mechanical operation on ma-
chinery, is best accomplished by experienced service While the rotor support is open, carefully clean the in-
personnel using tools and measuring instruments to ac- terior, using an approved safety solvent and a lint free
complish accuracy in their work. cloth.
There are a number of good practices that should be Clean and check all oil passageways and all tubing us-
followed in disassembly and reassembly of the com- ing pressurized dry air or nitrogen.
pressor, some of these are listed below. Before assembling parts, all friction surfaces should be
Do Not Mix Parts - Keep parts in some general order lightly coated with a molybdenum disulfide lubricant
when removing them from the compressor. It is sug- such as “Molykote” or “Molkolube” and oil. Be sure to
gested that parts be laid out to follow exploded views use new YORK refrigerant Oil.
as shown in the many illustrations outlining the disas- “Molycote” is available from: Dow Corn-
sembly and assembly of the various parts. ing Corporation Dept. A0021 P.O. Box 1767
Midland, Michigan
Do Not Mix Cap Screws and Washers - Cap screws
are suited to the location in which they are used. Too Westinghouse Electric Corporation (Sales
long or too short a cap screw can result in leakage and/ offices in all major cities). When ordering
or interference with some interior parts. Washers have “Molycote” No. 8565-3, available from
been selected for specific screws, etc. It is very impor- YORK Part No. 364-21508 in 2 oz. cans.
tant to use correct washers or lock washers. The Parts
List and Figures in this instruction guide show the cor- When reassembling parts, each part should be care-
rect length and size of screws and washers. Refer to the fully checked for signs of uneven wear, keeping in
Renewal Parts Manual 160.75-RP2 to order the correct mind that a nicely polished surface is not an indica-
part numbers. tion of excessive wear. Sudden, excessive wear on
any part of the compressor is not normal but is usu-
Inspect As Compressor is Disassembled - It is de-
ally caused by some other condition which must be
sirable to record shaft and impeller runouts and thrust
determined and corrected to assure long periods of
clearances before disassembly. Once compressor parts
trouble-free operation.
have been disassembled and cleaned, many valuable
indications of the compressor condition are lost. Mate- Bearings and seals may be reused if their rubbing sur-
rials found in oil or on burned surfaces can often give faces and matching surfaces of their corresponding ro-
an indication as to why a part or parts have failed. tating parts are nicely polished with no sign of uneven
wear or gouging.
Protect Parts and Surfaces - Do not pile or throw
parts indiscriminately. Oil surfaces are likely to rust.
Tape surfaces subject to scratching or nicking during
repair operations. Plug off any passages likely to ac-
cumulate dust or abrasives. Do not tape the seals.
14 JOHNSON CONTROLS
FORM 160.75-M1
The impeller should be checked around its outside cir- gineering drawing dimensions. If the compressor is
cumference for evidence of rubbing. If this condition is making oil pressure without an elevated variable speed
found, excessive bearing wear is indicated, and the im- drive output frequency and the oil filter is clean, it is
peller may be worn sufficiently to require replacement. not likely there is an issue with the compressor journal 2
There maybe some grinding at the back- bearing tolerances.
side or front side of the impeller. This is
RIGGING THE COMPRESSOR OR MOTOR
for balancing purposes. No marks should
appear on the nozzel or diffuser plates. When it becomes necessary to remove a compressor
or motor from a unit or base, proper rigging methods
must be used to avoid damage to the equipment and/
All gaskets and O-rings must be replaced or injury to service personnel. Portable cranes must
with new parts when reassembling the be of adequate capacity and properly positioned and
compressor to assure that all surfaces blocked to prevent tipping or slipping while lifting the
have a tight seal after reassembly. compressor or motor. Be sure chains are of adequate
strength. Compressor weights are shown in Table 1 on
page 15.
When checking the compressor tolerances there is not
a value of allowable lateral movement on a low or high
speed shaft on a YK compressor. The correct way to
determine if the journal bearings are worn is to remove
them and measure the dimensions compared to the en-
Table 1 - COMPRESSOR WEIGHTS (LBS.) - LESS MOTOR

ROTOR SUPORT
SCROLL ASSEMBLY
COMPRESSOR COMPLETE COMPLETE W/ ALL
W/ PRV AND
CODE COMPRESSOR RUNNING GEAR &
NOZZLE BASE
D-FLANGE
K1 4,060 lbs. 2,061 lbs. 2,399 lbs.
K2 4,195 lbs. 2,058 lbs. 2,537 lbs.
K3 6,056 lbs. 2,965 lbs. 3,500 lbs.
K4 6,328 lbs. 2,841 lbs 3,887 lbs.
K7 8,089 lbs. 2,730 lbs. 5,759 lbs.
NOTE: Motor weights (lbs.) (Located on Motor Data Plate)
Table 2 - TORQUE VALUES

TORQUE
BOLT SIZE POUND FOOT
INCHES SOCKET OR
HEX HD
12 PT HD
1/4” 10 14
5/16” 20 30
3/8” 35 50
1/2” 75 121
5/8” 155 200**
3/4” 260 395
Unless otherwise specified, all screws must be tightened to the following torque values with lightly oiled threads.
** Lubricated with oil and graphite on male and female threads and under bolt heads. Moly-kote not acceptable.
JOHNSON CONTROLS 15
FORM 160.75-M1
TWO PIECE PROXIMITY PROBE That part number includes the probe tip, electronic
module, a PVC bushing and the connection cable from
A two-piece proximity probe is available which pro-
the probe tip to electronic module.
vides separate parts for the probe and the electronics
module. The two-piece probe is backward compatible If retrofiting from a single piece probe, all items shown
on all YK chillers (-70 diameter and larger) and is fac- below are needed. Use part number 364-51806-000.
tory installed on new chillers.
INSTALLATION
The two-piece probe eliminates the need to recover the
chiller refrigerant charge when replacing the electron- 1. The electronic module to control panel cable
ics module portion of the proximity probe. The elec- should be replaced if an intermittent connection
tronic module for the proximity probe is mounted into issue is suspected.
the “D” flange or motor adapter, or onto a bracket for 2. Installation torque values:
units not utilizing a “D” flange or motor adapter. Probe to compressor: 20 in/lb - use 7/8” wrench
The part number for the new probe is 025 40496 000. Electronic Module: 20 in/lb - use 2” Wrench
Interconnecting Cable Ends: 2 in/lb - use no tools
3. When installling the interconnecting cable, plug
PROXIMITY PROBE TIP the cable connector into the mating connector on
(025 40496 001)
each component. Rotate the cable connector hex
nut only. Do not attempt to install the intercon-
necting cable by holding the cable and rotating the
probe or electronic module.
ELECTRONICS MODULE
W/PVC BUSHING
(025 40496 002)
PROXIMITY PROBE TIP
"O" RING
(028 12209 000)
DIN CONNECTOR
(025 37805 000)
CONNECTING CABLE
(025 40496 003)
CONNECTING CABLE
(TO CONTROL PANEL)
(025 28701 003)
(Replace If Defective) LD27104
Figure 3 - TWO PIECE PROXIMITY PROBE
NEW CABLE EXISTING CABLE

DIN +24 VDC POWER SOURCE RED
RED
CONNECTOR * OUTPUT SIGNAL BLUE
WHITE
BLACK BLACK
* NOTES:
1. OPTIVIEW PANEL PIN 2 AT DIN CONNECTOR DIN CONNECTOR WIRING -
SENDS SIGNAL TO J8-15 ON MICROBOARD NOTE PIN 3 IS NOT USED
2. ONE LINE PANEL PIN 2 AT DIN CONNECTOR
SENDS SIGNAL TO J17-15 ON MICROBOARD
LD27105
Figure 4 - DIN CONNECTOR WIRING
16 JOHNSON CONTROLS
FORM 160.75-M1
MOTOR REMOVAL AND REPLACEMENT

Be sure the main disconnect switch to the
compressor motor is open and tagged, then
disconnect the electrical leads at the motor 2
terminals and tape the end of each lead.
Make sure leads are marked correctly for
later identification.
LD04755
REMOVAL (MOTOR ONLY) Figure 6 - COMPRESSOR COUPLING

The following paragraphs outline the procedure for
replacing or servicing the motor. Always contact the 4. Taking care to see that the motor is properly sup-
nearest Johnson Controls Service Office when replac- ported, by rigging assembly remove the bolts that
ing or servicing the motor. hold the motor to the motor adapter.
Close-Coupled Models 5. Remove the bolts, nuts, and washers holding the
1. Support the weight of the motor from a hoist us- motor to the mounting rails. Note location of any
ing eyebolts at locations provided in the motor shims.
housing. 6. Lift the motor and pull it away from the compres-
2. Remove the hex head cap screws that hold the sor. Lower motor to floor for servicing. Remove
sheet metal covers to the compressor motor adapt- shims from motor mounting rails. Mark shims lo-
er. After all screws are removed, remove covers cation.
(see Figure 5 on page 17). INSTALLATION
3. Remove the bolts holding the coupling hubs to the Close-Coupled Models
coupling spool and the disc pack. Note arrange-
1. Place the number of shims originally required on
ment of these parts (see Figure 6 on page 17).
each motor mounting rail.
Remove the coupling spool and disc packs. If disc
packs are required to be replaced, they must be 2. Lift motor to the proper location and push motor
purchased from the manufacturer. All couplings carefully against the compressor motor adapter.
have the manufactures ID on the face.
3. Line up holes in the face of the motor with the
holes in the compressor motor adapter. Place the
Motor
Adapter hex head cap screws through the compressor mo-
tor adapter and screw into the tapped holes on the
Cover motor, (but do not fully tighten screws) (Refer to
Figure 5 on page 17).
4. Place the hex head cap screws and washers in
holes in motor feet. Make sure the motor is
shimmed correctly. Place hex nuts on screws and
tighten and torque.
5. Tighten and torque screws holding motor to motor
adapter.
6. Assemble the coupling. Refer to Coupling Assem-
Figure 5 - MOTOR ADAPTER
LD19819
bly (Form 160.49-N4).
Bolts head orientation is not a problem.
JOHNSON CONTROLS 17
FORM 160.75-M1
Motor alignment on YK. Adjust the motor to achieve back to the magnetic center marking in order to get the
a parallel alignment see Table 4 - Total Indicator Read- correct coupling space. This will center the rotor. With
ing on page 19 The gap between the shim pack and refrigerant in the machine and the rotor centered, the
hub should be 0.010" max. This is a D-flange motor gap between the coupling hub and the disk pack should
so there will not be much adjustment possible. The be 0.010".
rotor may need to be centered in the bearing races in Use a small dial indicator as much as
sleeve bearing motors by motor with sleeve bearings possible and consider the dial indicator
should be brought to full speed and the magnetic cen- sag.
ter marked. When the motor decelerates it may move
off of magnetic center. The motor must then be moved
Motor
Face
130 FT. LBS.

Hub Driven
York Hub Driver
Compressor Motor
Shaft Shaft
LD19860
Figure 7 - MOTOR ALIGNMENT
Table 3 - COUPLING TORQUE

YORK
COUPLING
MODEL DRAWING TIGHTENING TORQUE
ASSEMBLY
NUMBER
364-51837-000 029-24118-000
K1 & K2 Follow the torque value shown on the coupling.
364-51838-000 029-20921-001
364-52351-000 029-21381-000
K3 364-51816-002 029-20899-001 Follow the torque value shown on the coupling.
364-52351-000 029-21381-000
364-52351-000 029-21381-000
K4 364-51816-002 029-20899-001 Follow the torque value shown on the coupling.
364-52351-000 029-21381-000
364-51816-001 029-24887-000
K7 Follow the torque value shown on the coupling.
364-51817-000 029-25108-000
18 JOHNSON CONTROLS
FORM 160.75-M1
ALIGNMENT Parallel Alignment

Rigidly mount a dial indicator to one of the hubs (or
Axial Shaft to Shaft Spacing
shaft) and place the pointer on the flange diameter of
The equipment must sit flat on its base. Any soft foot the opposite hub, as shown in Figure 10 on page 19. 2
must be corrected immediately. Set the equipment into Compensate for indicator set-up sag. Rotate both shafts
the approximate position. Measure the length of the at the same time. Adjust the equipment by shimming
spacer and the thickness of the two unitized flex discs and/or moving so that the indicator reading is within
from washer face to washer face to determine the “D” the tolerances shown in Table 4 on page 19.
dimension shown in Figure 8 on page 19. Measure
the separation between the hub flanges and adjust the
Parallel Motor
equipment until the axial hub separation equals the Mis-Alignment Face
sum of the spacer length and the thickness of the two
flex discs.
Axial
Mis-Alignment Motor
Face
Motor
Compressor Shaft
Shaft
LD18037d
Compressor Motor
Shaft Shaft
Figure 10 - PARALLEL MISALIGNMENT
LD18037c
Table 4 - TOTAL INDICATOR READING

Figure 8 - AXIAL MISALIGNMENT
MAX.
TOLERANCE
ALIGNMENT COMBINATION
(INCHES)
TOLERANCE
Angular Alignment
Horizontal or
Rigidly mount a dial indicator to one of the hubs (or Vertical Parallel
+.014
shaft) and place the pointer on the flange face of the +.028
Horizontal or
opposite hub, as shown in Figure 9 on page 19. Ro- Verical Angular
+.014
tate both shafts at the same time making sure the axial
spacing remains constant. Adjust the equipment by De-Flange Models
shimming and/or moving so that the indicator reading
1. Place the number of shims originally required on
is within Table 4 on page 19.
each motor mounting channel.
Angular 2. Lift motor to its proper location on the mo-
Mis-Alignment Motor
Face tor mounting channels. Fasten with cap screws,
washers, and hex nuts.
3. Assemble the coupling. Refer to Coupling Assem-
bly (Form 160.49-N4).
4. Re-assemble the coupling guard.
Compressor Motor
Shaft Shaft
LD18037b
Figure 9 - ANGULAR MISALIGNMENT
JOHNSON CONTROLS 19
FORM 160.75-M1
Before opening any part of the compres- 2. Inspect all wearing surfaces and replace parts as
sor, the compressor must be pumped down necessary. See Cleaning and Checking Wearing
to atmospheric pressure. Parts on page 14. Discard all O-rings and re-
place with new.
3. Thoroughly lubricate shaft and sleeve O-ring and
or C-ring with clean YORK refrigerant oil prior to
SEAL REMOVAL (BELLOWS TYPE) installation.
To remove/replace the bellows type shaft seal, proceed 4. Install the sleeve spacer on the shaft and slide it all
as follows: the way onto the shaft. The beveled edge should
face away from C-ring.
1. Remove compressor coupling as described on
previous pages under MOTOR REMOVAL AND 5. Thoroughly lubricate C-ring with clean YORK re-
REPLACEMENT. Also remove the compressor frigerant oil. Install the C-ring with the open side
coupling hub from the compressor shaft. of the ring facing the compressor. As pressure in-
creases the C-ring spring will expand to assure an
2. Remove the oil drain line from the bottom of the
appropriate seal.
seal.
3. Loosen the two set screws (C) shown in Figure 12
on page 21.
4. Remove the flat head screws and re-attach the re-
taining clips in the installation position.
It is important that the shaft seal sleeve is
securely attatched to the compressor shaft
prior to removal of the retaining clips.
These clips protect the seal internals from
harm during the assembly process and
insure the positioning of the shaft seal for
proper seal face loading. Anytime a seal
cartridge is outside the compressor, the
retaining clips need to be in their instal-
lation position.
LD22342
Figure 11 - RETAINER RUNNING POSITION
5. Loosen the 4 set screws (B) shown in Figure 12
on page 21. Care needs to be taken when installing
6. Remove the 8 hex head screws holding the shaft the C-ring to prevent damage to the ring.
seal to the compressor housing. Any burrs on the shaft or on the snap ring
groove may damage the seal.
7. Using guide pins, carefully remove the seal as-
sembly from the rotor support.
8. Remove the C-ring and sleeve spacer from the 6. Install shaft seal cover O-ring in rotor support
compressor shaft. housing.
9. Remove the O-ring from the rotor support hous- 7. Using guide studs, install seal cartridge in ro-
ing. tor support housing and secure with 3/8” or 1/4”
mounting screws.
Installation (Bellows Type)
1. Be sure the shaft seal cavity is thouroughly clean 8. Before tightening the shaft seal sleeve set screw,
by cleaning it with an approved safety solvent and rotate the compressor shaft to insure that the set
blowing it dry with compressed air. screws straddle the shaft keyway.
20 JOHNSON CONTROLS
FORM 160.75-M1
9. Without removing the two shaft seal retaining 11. Re-connect the oil drain line (if required) and re-
clips, tighten the 4 accessible sleeve set screws install the compressor coupling if no further ser-
to the compressor shaft (see Figure 12 on page vice is planned.
21). After installation of clips to operation 2
10. Remove the retaining clips and tighten the re- position and after the oil pump has been
maining 2 set screws. Torque all 6 set screws (see energized the clip should line up with the
Figure 12 on page 21) to 144 inch pounds, un- collar groove.
less otherwise stamped on the seal face. Install the
retaining clips in the operating position on the seal
face.
Sleeve Spring Energized

PTFE C-Ring
Sleeve Spacer (Spacer is Integral
with Seal Sleeve)
Detail Q
Sleeve Set Screws (B) (Qty. 4)

Torque to 144 IN. - LBS.
Plug (A) Oil Supply Inlet
Retaining Clip (Qty. 2) (Included w/Seal)
(In Installation Position)
Retaining Clip (Qty. 2 )
(In Operating Position)
Flat Head Screws

(Qty. 4)
See
Detail Q
Sleeve Set Screws (C) (Qty. 2)

Torque to 144 IN. - LBS.
Rotor Support
Oil Drain Outlet Connection Point
Seal Drain
Section N - N
LD19861
Figure 12 - BELLOWS TYPE SHAFT SEAL
JOHNSON CONTROLS 21
FORM 160.75-M1
DISASSEMBLY OF ROTOR SUPPORT

The following paragraphs outline the procedure for 4. Remove (2) of the 12-pt. cap screws holding the
separating the rotor support from the rotor scroll if it rotor support to the rotor scroll. Insert guide pins
becomes necessary to service internal parts: in place of the (2) cap screws.
Removing the Rotor Support from Rotor Scroll 5. Loosen the remaining cap screws.
For steps 1 through 3 follow the pro- 6. Use (3) of the cap screws as jacking screws in
cedures listed on previous pages of this the tapped holes provided to loosen the rotor sup-
instruction. port from the rotor scroll (see Figure 13 on page
22). Carefully pull the rotor support out of the
rotor scroll. Rotate the shaft by hand when remov-
ing the rotor support to prevent damage to the im-
1. Remove all external piping from the rotor support. peller inlet seal ring.
2. Using proper rigging techniques, temporarily sup- 7. The rotor support can now be removed and rested
port the weight of the back end of the rotor sup- on the end of the motor adapter.
port. Keep the motor support (D-flange) for better
balance.
3. Insert the 7/8" eye bolt into the top of the rotor
support and using the proper rigging methods sup-
port the weight of the rotor support see Table 1 on
page 15.
Rotor Scroll
Rotor Support
26439BA
LD27090
Figure 13 - DISASSEMBLY OF ROTOR SUPPORT FROM THE ROTOR SCROLL
22 JOHNSON CONTROLS
FORM 160.75-M1
REMOVING THE IMPELLER Detail C - High Speed Axial Thrust & Low Speed
1. Before removing the impeller, measure and record Axial Thrust (Table 5 on page 23)
the following.
Detail A - Impeller Rim Runout (Design 0.003”
2
max.)
LD22343
Figure 16 - DETAIL C – CHECKING AXIAL

THRUST
26347A Table 5 - IMPELLER INFORMATION

Figure 14 - DETAIL A – CHECKING RIM RUNOUT LOW SPEED HIGH SPEED
COMPRESSOR
AXLE THRUST AXLE THRUST
Detail B - Impeller Eye Runout (Design 0.002” K1-K7 0.011-0.019" 0.009-0.020"
max.)
K2-K4 0.011-0.019" 0.008-0.021"
2. Install the gear locking tool on the low-speed shaft

(see Figure 41 on page 34).
3. Remove the 3 (or 6) screws that hold the impel-
ler to the high-speed shaft (see Figure 18 on page
24). Or remove the cap screw and O-ring from
the impeller clamping collar. Pull the impeller
from the high-speed shaft.
4. Pull the impeller from the high speed shaft. Use
care when removing the impeller so that the bal-
ance piston seal is not damaged.
26346A
Figure 15 - DETAIL B – CHECKING EYE RUNOUT
JOHNSON CONTROLS 23
FORM 160.75-M1
3
ITEM DESCRIPTION
1 Diffuser Plate
4 2 Balance Piston Retainer
3 Socket Head Cap Screws (3)
5
4 Impeller
6 5 Cap Screws (3 or 6)
6 Impeller Clamping Collar
7 High-Speed Shaft
7
8 Balance Piston Seal
8 9 Flat Springs (1)
9
26439A
Figure 17 - IMPELLER AND BALANCE PISTON
Pull the impeller from the high speed shaft. Use care
when removing the impeller so that the balance piston
seal is not damaged.
26345A
Cap Screws Impeller

Impeller Clamping
Collar
Figure 18 - REMOVING IMPELLER
24 JOHNSON CONTROLS
FORM 160.75-M1
REMOVING BALANCE PISTON SEAL AND Tapped Holes Diffuser Plate

DIFFUSER PLATE
1. Remove the (3) socket head cap screws (shoul-
der bolts) that fasten the balance piston retainer 2
and balance piston seal to the plate (see Figure
19 on page 25 and Figure 20 on page 25).
Remove the balance piston retainer and balance
piston seal.
2. Remove (2) of the (6) cap screws that secure the
diffuser plate to the bearing housing. Insert guide
pins where cap screws were removed. Loosen the
(4) remaining cap screws (see Figure 20 on page
25). Insert jacking screws into holes provided
to loosen diffuser plate from bearing housing.
3. Insert eyebolts from tool kit into jacking holes and 26665A
use proper rigging methods to lift diffuser plate Figure 20 - REMOVING DIFFUSER PLATE
from compressor. Also, remove the O-ring from
the back of the diffuser plate. Retainer Flat Spring Balance Piston
Diffuser Plate Washer Seal
Plate
Balance
Piston
Seal
Balance
Piston
Retainer
High-Speed
Shaft
Allen Cap
Screws
(Shoulder
Bolts)
LD27091
LD22344
Figure 19 - BALANCE PISTON SEAL Figure 21 - BALANCE PISTON SEAL ASSEMBLY
Table 6 - BALANCE PISTON SEAL RING

DIMENSIONS
IMPELLER B.P O.D B.P SEAL I.D
K1
7.097" / 7.095" 7.104" / 7.102"
K2
K3 8.152" / 8.150" 8.162" / 8.160"
K4
9.800" / 9.798" 9.810" / 9.808"
K7
JOHNSON CONTROLS 25
FORM 160.75-M1
REMOVING FRONT LOW-SPEED BEARINGS Bearing Housing

(see Figure 22 on page 26 ) Front
1. Remove the (6) hex head cap screws that hold the High-Speed
Bearing
low-speed thrust bearing to the bearing housing,
and using (2) guide pins, remove the thrust bear-
ing. Be sure not to damage the bearing pads (see
Figure 23 on page 26 and Figure 24 on page High-Speed Shaft
27 .
2. Before removing the low-speed thrust collar Bearing Retainer
mount an indicator, as shown in Figure 25 on page Clip with Cap Screw
27, and check the runout of the thrust collar.
Maximum runout should not exceed .001” T.I.R. Roll Pin
(It will be necessary to remove the shaft locking
tool in order to take this measurement.)
Low-Speed
3. Re-install the shaft locking tool. Remove the allen Thrust Collar
head screws that hold the low-speed thrust collar Low-Speed
to the low-speed shaft, and remove the thrust col- Thrust Bearing
lar (see Figure 26 on page 27). Use care when
handling so that the surfaces are not damaged. Low-Speed Shaft
4. To remove the low-speed bearing, use (2) hook Front Low-Speed

tools (shown in Figure 27 on page 27). Care- Bearing
26439A
fully pull the bearing out of the bearing housing.
Note position of roll pin (see Figure 28 on page Figure 22 - FRONT BEARING COMPONENTS
27).
REMOVING FRONT HIGH-SPEED BEARING

(See Figure 22 on page 26)
Low-Speed
1. Remove the cap screw and retainer clip (see Fig-
Thrust
ure 28 on page 27). Bearing
2. Using (2) 1/4” puller rods as shown in Figure 29
on page 27, pull the high-speed bearing out of
the bearing housing.
26335A
Figure 23 - LOW-SPEED THRUST BEARING
26 JOHNSON CONTROLS
FORM 160.75-M1
Low-Speed 2
Forward Thrust
Bearing
LD04837
26334A
Figure 24 - LOW-SPEED THRUST BEARING Figure 27 - FRONT LOW-SPEED BEARING

REMOVED REMOVAL
Front
High-Speed
Bearing
Retainer
Low-Speed Clip With
Thrust Cap Screw
Collar
Roll Pin
(Location
below the
Bearing)
Low-Speed
Shaft
26330A
LD22345 Figure 28 - LOW-SPEED BEARING REMOVED

WITH HIGH-SPEED BEARING IN PLACE
Figure 25 - CHECKING LOW-SPEED THRUST
RUNOUT
Low-Speed
Bearing and
Thrust
Low-Speed
Thrust Collar
(Inside Surface)
26332A
LD27093
Figure 26 - LOW-SPEED THRUST COLLAR Figure 29 - FRONT HIGH-SPEED BEARING

REMOVED REMOVAL
JOHNSON CONTROLS 27
FORM 160.75-M1
Eyebolts
26329A
Figure 30 - ALL FRONT END BEARINGS

REMOVED
Suggested
Guide Pins
REMOVING BEARING HOUSING AND GEARS
Location
Bearing Housing LD27100
1. Insert (2) 3/8” guide pins as shown in Figure Figure 31 - REMOVING BEARING HOUSING
31 on page 28. Also insert (3) 3/8” eyebolts
as shown. On the compressors, the (3) 1/2” cap
screws shown in Figure 34 on page 29 are used
to secure the dowel pins which align the bearing
housing with the rotor support.
2. Attach proper rigging, remove the remaining cap
screws.
Remove the bearing housing, using care
so that the compressor is not damaged and
that no injury occurs to service personnel
as the bearing housing is quite heavy.
Gears
1. Remove the high-speed reverse thrust bearing,
high-speed thrust collar, and high-speed forward
thrust bearing.
2. Remove the shaft locking tool.
3. Remove the compressor shaft seal. Do NOT re-
move the rear low-speed bearing.
4. To remove the low-speed and high speed gears,
use a 1/2” - 13 eyebolt in the end of the shaft and
pull the gear out of the rotor support.
Before re-assembly, be sure the compressor hous-
ing is absolutely clean by cleaning it with an ap-
proved safety solvent and blowing it dry with
compressed air. Inspect all wearing surfaces and
replace parts as necessary. See Cleaning and
LD27092
Checking Wearing Parts on page 14. Discard Figure 32 - BEARING HOUSING REMOVED
O-rings and replace with new.
28 JOHNSON CONTROLS
FORM 160.75-M1
INSTALLING BEARING HOUSING 2. Remove the compressor shaft seal as described in

Motor Removal and Replacement on page 17.
With dowel pins removed and using proper rigging in-
stall the bearing housing back into the compressor, be 3. Remove the screw holding the retainer clip to the
sure that the oil emergency reservoir O-ring is securely compressor. 2
installed, insert the 3 dowel pins and torque the 3/8” 4. Using the (2) 1/4” puller rods as shown in Figure
bolts to 35 ft/lb in the sequence show in Figure 33 on 36 on page 30 remove the bearing from the
page 29. compressor.
5. Inspect the bearing. See Cleaning and Checking
Wearing Parts on page 14. Replace with new
bearing if necessary.
LD27103
LD27101
Figure 33 - BEARING HOUSING TORQUE Dowel Pins
SEQUENCE (Located Under 1/2” Cap Screws)
Figure 34 - BEARING HOUSING DOWEL PINS

REAR LOW-SPEED BEARING COMPONENTS
(see Figure 35 on page 30)
Removal
To remove/replace the rear low-speed bearing, proceed
as follows:
1. Remove the compressor coupling spool as de-
scribed in Motor Removal and Replacement on
page 17. Also remove the compressor coupling
hub from the compressor shaft.
JOHNSON CONTROLS 29
FORM 160.75-M1
Installation
1. Inspect the bearing surface of the drive shaft, and 4. Install the retainer clip and cap screw.
be sure the drive shaft is absolutely clean. 5. Install the shaft seal and coupling in Motor Re-
2. Apply a light coating of oil and Molykote to the moval and Replacement on page 17.
driveshaft and to the inside and outside surfaces
of the bearing.
3. Carefully slide the bearing into position over the
drive shaft. Be sure it is turned so that the slot for
the retainer clip is at the top (see Figure 35 on
page 30).
Retainer 29370AE
Clip & Screw BELLOWS TYPE SEAL

Puller
Puller Holes
Hole
Bearing
Retainer Clip
Location 26323A
LD11201 Bearing
Retainer Clip
Figure 35 - REAR LOW-SPEED BEARING
LD04838
Figure 36 - LOW-SPEED REAR BEARING REMOVAL
30 JOHNSON CONTROLS
FORM 160.75-M1
REAR HIGH-SPEED BEARING COMPONENTS HIGH SPEED THRUST BEARINGS

To remove/replace any of the components shown in Starting December 2010 changes have been imple-
Figure 38 on page 34, proceed as follows: mented for the High Speed Thrust Bearing Assemblies
used on the following compressors. 2
1. Remove the Proximity Probe. See Figure 3 on
page 16 for replacement proximity probe infor- • K3 - YDHL-95
mation if needed.
• K4 - YDHL-106
2. Remove the cap screws holding the high-speed
• J7 / K7 - YDHJ-119
reverse thrust bearing and remove the high-speed
reverse thrust bearing (see Figure 39 on page IDENTIFYING COMPRESSORS UTILIZING
34). Note alignment of oil passages. UPDATED HIGH SPEED THRUST BEARINGS
3. Before removing the high-speed thrust collar Compressors manufactured with or updated to the new
measure the run-out on the collar face. Mount a Thrust Bearing Assembly can be identified by a par-
dial indicator as shown in Figure 40 on page 34 tially drilled 1/4" hole at 9 o'clock position on the out-
and rotate the compressor shafts. Maximum al- board face of the Reverse High Speed Thrust Cover
lowable run-out is .001”. plate (see FIGURE 87 for additional details).
4. To remove the high-speed thrust collar, it is neces-
K3 AND K4 COMPRESSORS
sary to lock the shafts to prevent isolation. Use the
gear locking tool from the tool kit as illustrated in The new Thrust Bearings for these models are not di-
Figure 41 on page 34. rect replacements for compressors manufactured using
the legacy design bearings. Updating a K3 or K4 com-
5. Remove the cap screws that hold the high-speed
pressor to utilize the new thrust bearing design requires
thrust collar to the high-speed shaft (see Figure 42
replacing both the forward and reverse thrust bearings,
on page 34), and remove the thrust collar (1/4”-
the thrust collar and installing a new rear high speed
20 puller holes are provided for convenience).
journal bearing.
6. Remove the high-speed forward thrust bear-
To facilitate this modification a field replacement kit
ing (see Figure 43 on page 35), #10-24 puller
has been created for retrofitting the K3 and K4 com-
holes are provided for convenience. When insert-
pressors. The part number for this kit is 364-53001-
ing puller bolts, use care that bearing pads are not
000. The kit is supplied with all hardware needed to
damaged. Note position of indexing roll pin and
complete this replacement along with installation in-
mating hole in casing.
structions and O-rings. Loctite 243 (part # 013-03375-
7. Remove the cap screw holding the high-speed 000) used for securing bearing fasteners is not included
bearing (rear) retainer clip to the casing (see Fig- with kit.
ure 44 on page 35). Using items from the tool
kit as shown in Figure 45 on page 35, remove
the bearing from the compressor.
8. Inspect all parts removed above. See Cleaning
and Checking Wearing Parts on page 14. Re-
place with new parts as necessary.
JOHNSON CONTROLS 31
FORM 160.75-M1
Individual Part Numbers for New Style K3 and

K4 High Speed Thrust Bearings
The updated high speed thrust bearings part numbers
used with the K3 and K4 compressors are listed in the
following tables.
ITEM ORIGINAL PART NUMBER NEW PART NUMBER

HS Forward Thrust Brg 029-25063-000 029-25837-001
HS Thrust Collar 064-51780-000 064-52718-000
HS Reverse Thrust Brg 029-25062-000 029-24758-002
Rear HS Journal Brg 064-51781-000 064-52719-000
Reverse Thrust Brg Cover O-ring 028-12258-000
Internal O-rings for Reverse Thrust Brg Cover (qty 3) 028-12513-000
Small Pipe Plugs used w/ Reverse Thrust Brg (qty 3) 023-24908 000
O-rings for Small Pipe Plugs used w/ Reverse Thrust Brg (qty 3) 028-15846-000
O-ring for Proximity Probe 028-12961-021
J7/K7 COMPRESSORS
The new high speed thrust bearing design for this mod-
el compressor is a direct replacement. When replacing
thrust bearings for this compressor order the part num-
bers listed below:
ITEM ORIGINAL PART NUMBER NEW PART NUMBER

HS Forward Thrust Brg 029-24759-000 029-24759-001
HS Thrust Collar 064-51493-000
HS Reverse Thrust Brg 029-24758-000 029-24758-002
Reverse Thrust Brg Cover O-ring 028-12258-000
Internal O-rings for Reverse Thrust Brg Cover (qty 3) 028-12513-000
Small Pipe Plugs used w/ Reverse Thrust Brg (qty 3) 023-24908 000
O-rings for Small Pipe Plugs used w/ Reverse Thrust Brg (qty 3) 028-15846-000
O-ring for Proximity Probe 028-12961-021
32 JOHNSON CONTROLS
FORM 160.75-M1
ORIGINAL For the J7/K7 compressor each item can be replaced

NEW PART individually (example: if replacing forward thrust
ITEM PART
NUMBER
NUMBER bearing the original design reverse thrust bearing can
O-rings for Small Pipe be reused if not damaged). 2
Plugs used w/ Reverse 028-15846-000
It is recommended that when replac-
Thrust Brg (qty 3)
ing a damaged original design bearing
O-ring for
028-12961-021 that both the forward and reverse thrust
Proximity Probe
bearings are replaced with the new part
numbers.
1/4” Dia.
PARTIALLY
DRILLED HOLE
TO IDENTIFY
ENHANCED
BEARING DESIGN
Figure 37 - REVERSE HIGH SPEED THRUST COVER PLATE
JOHNSON CONTROLS 33
FORM 160.75-M1
Retainer
O-Ring
High-Speed
Forward
Thrust
Bearing
High-Speed
Thrust
Collar High-Speed
Thrust Collar
High-Speed High-Speed
Reverse Bearing
Thrust
(Rear)
Bearing
29439a LD22362
Figure 38 - HIGH-SPEED BEARING Figure 40 - CHECKING HIGH-SPEED THRUST

COMPONENTS COLLAR RUN-OUT
High-Speed
Reverse
Thrust Bearing
Proximity
Probe Location
(Not Shown)
LD04839
26664A
Figure 41 - GEAR LOCKING
High-Speed
Reverse High-Speed
Thrust Bearing Forward Thrust
(Inside Surface) Bearing
High-Speed
26662A
Thrust
Figure 39 - HIGH-SPEED REVERSE THRUST Collar
BEARING
Inside
Surface
26339A
NOTE: Oil Piping configuration may vary according to vintage of unit.
Figure 42 - HIGH-SPEED THRUST COLLAR

REMOVED
34 JOHNSON CONTROLS
FORM 160.75-M1
To remove/replace any of the components shown in

Puller Figure 38 on page 34, proceed as follows:
Holes
1. Remove the Proximity Probe Assembly as men-
(#10-24)
tioned (See Two Piece Proximity Probe on page 2
16).
2. Remove the cap screws holding the high-speed
Forward reverse thrust bearing and remove the high-speed
Thrust reverse thrust bearing. Note alignment of oil pas-
Bearing sages. Use guide pin to support the thrust bearing
to avoid damaging the bearing ped.
3. Before removing the high-speed thrust collar,
measure the run-out on the collar face. Mount a
dial indicator as shown in Figure 44 on page 35
LD27099
and rotate the compressor shafts to record the run-
Figure 43 - HIGH-SPEED FORWARD THRUST out. Maximum allowable run-out is .001”.
BEARING 4. To remove the high-speed thrust collar, it is neces-
sary to lock the shafts using the gear locking tool
from the tool kit.
Puller Holes
(1/4”)
5. Remove the (4) hex socket head cap screws that
hold the washer and thrust collar to the high-speed
shaft. Remove the thrust collar (1/4”-20 puller
holes are provided for convenience).
6. Loosen but do NOT remove the (3) hex head cap
Bearing screws that hold the high-speed forward thrust
Retainer Clip bearing to the high-speed bearing.
with Screw
7. Use the #10-24 puller rods to pull the high-speed
forward thrust bearing and high-speed bearing
from the compressor.
26336A
NOTE: Oil Piping configuration may vary according to vintage of unit.
8. Inspect all parts removed above. See Cleaning
and Checking Wearing Parts on page 14. Re-
Figure 44 - REAR HIGH-SPEED JOURNAL place with new parts as necessary.
BEARING
Installing Rear High-Speed Bearings
1. Be sure the bearing surface of the high-speed shaft
is clean and is in good condition.
2. Apply a light coating of oil and Molykote to the
high-speed shaft and to the inside and outside
surfaces of the high-speed bearing. On K1 and
K2 style compressors install a new O-ring on the
high-speed bearing.K3 through K7 does not have
an O-ring.
LD04840
Figure 45 - HIGH-SPEED REAR BEARING
3. Apply a light coating of oil and Molykote to the
REMOVAL inside diameter and pads of the forward thrust
bearing.
4. Insert but do NOT tighten the (3) hex head socket
screws that hold the high-speed forward thrust
bearing to the high-speed bearing.
JOHNSON CONTROLS 35
FORM 160.75-M1
5. Carefully follow the Replacement Procedures be-

low:
1. Follow the procedures in the correct com-
pressor service manual to access the forward
high speed thrust bearing.
2. Remove the existing high speed forward
thrust bearing and rear journal bearing with
retainer (if the rear journal bearing is being
replaced), from the compressor and discard.
3. Clean and examine the bearing bore and
thrust bearing land for any damage, high
spots or nicks. If damage is spotted, it needs
to be repaired before installing the new bear- LD27102
ing arrangement. Figure 46 - PROXIMITY SENSOR
4. Using removable thread locker (Loctite 243-
P/N 013-03375-000) on the bolts, assemble Installing Gears into Rotor Support
the new forward thrust and journal bearings 1. Oil the bearing surface on the drive end of the
as shown in Figure 43 on page 35 and Fig- low-speed gear, and carefully insert the low-speed
ure 44 on page 35. Torque the 3-¼” socket gear into the rear bearing.
head bolts to 80 in-lbs.
2. Oil the rear bearing surface of the high-speed
5. Insert the thrust and journal bearings into the shaft, and insert it into the rear bearing. Mesh the
compressor. Note the location of the anti- high-speed and low-speed gear teeth and rotate
rotation hole in the compressor housing and the gears as the gear is installed.
orient the thrust/journal bearing assembly
to align the anti-rotation (dowel) pin on the 3. Check the clearance between the high-speed pin-
back side of the forward thrust bearing with ion and the spray header. Clearance should be
the hole in the compressor housing. The roll 0.12” min. / 0.18” max. Adjust if necessary.
pin will align itself with the retainer bolt hole INSTALLING BEARING HOUSING
formerly used to secure the original bearing.
1. Install a new O-ring in the groove around the oil
6. Apply a light coating of oil and Molykote to both reservoir cavity (see Figure 48 on page 37).
sides of the thrust collar. Install the thrust collar Coat the O-ring with a suitable O-ring lubricant to
and tighten the hex socket cap screws to the high- hold it in the groove.
speed shaft. Check the run-out of the shaft collar.
Maximum run-out is .001”. 2. Insert (2) guide pins 180° apart into the rotor sup-
port.
7. Apply a light coat of oil and Molykote to the pads
of the high-speed reverse thrust bearing. Install 3. Lift the bearing housing and carefully push in
reverse thrust bearing using a new O-ring. Be sure place over the guide pins. Note location of dowel
oil passages in the bearing line up with the oil pas- pins. Be careful not to damage any of the ma-
sages in the compressor casing. chined surfaces on either the high-speed or low-
speed shafts. Leave the guide pins in position to
8. Re-install the Proximity Probe. help support the bearing housing.
After reinstalling the Proximity Probe, 4. Install the cap screws and dowel pins. Tighten cap
a Calibration Procedure, as outlined in screws to proper torque as outlined in Table 2 on
Form 160.54-M1 or 160.76-M1, MUST page 15. Install the (3) 1/2” cap screws used to
be performed before restarting the com- secure the dowel pins as shown in Figure 28 on
pressor. page 27.
36 JOHNSON CONTROLS
FORM 160.75-M1
INSTALLING FRONT HIGH-SPEED BEARINGS Check Valve

1. Apply a coating of oil and Molykote to the bear- Oil
ing surface of the high-speed shaft. Reservoir
2
2. Apply a coating of oil and Molykote to the inside
and outside surfaces of the high-speed bearing. O-Ring
3. Carefully slide the high-speed bearing into place

over the shaft and into the cavity in the bearing
housing. Install the retainer clip and cap screw.
Bearing Housing
Front
High-Speed
Bearing
26328A
Figure 48 - BEARING HOUSING

High-Speed Shaft
3. Carefully slide the low-speed bearing into place

Bearing Retainer over the shaft and into the cavity in the bearing
Clip with Cap Screw housing. Be sure hole in bearing flange engages
roll-pin in bearing housing (see Figure 28 on
Roll Pin page 27).
4. Re-install the shaft locking tool.
Low-Speed
5. Apply a coating of oil and Molykote to the lapped
Thrust Collar
surfaces of the low-speed thrust collar, using care
Low-Speed
Thrust Bearing that no damage occurs. Place the thrust collar into
position on the end of the low-speed shaft, insert
Low-Speed Shaft cap screws, and tighten to the proper torque (see
Table 2 on page 15).
Front Low-Speed 6. Mount a dial indicator as shown in Figure 25 on
Bearing
26439A page 27 and check the run-out of the thrust
collar. (It will be necessary to remove the shaft
Figure 47 - FRONT BEARING COMPONENTS
locking tool in order to take this measurement).
Maximum run-out should not exceed .001” T.I.R..
INSTALLING FRONT LOW-SPEED BEARINGS If run-out exceeds .001” T.I.R. DO NOT proceed
with further assembly; contact the YORK Factory
1. Apply a coating of oil and Molykote to the bear- Service for assistance.
ing surface of the low-speed shaft.
7. Re-install the shaft locking tool.
2. Apply a coating of oil and Molykote to the inside
and outside surfaces of the low-speed bearing. 8. Apply a coating of oil and Molykote to the bear-
ing pads of the low-speed thrust bearing and to
the low-speed thrust collar. Install the low-speed
thrust bearing.
JOHNSON CONTROLS 37
FORM 160.75-M1
INSTALLING BALANCE PISTON AND 6. Remove the shaft locking tool and check rim and
DIFFUSER PLATE eye radial run out using a dial indicator see Figure
14 on page 23 and Figure 15 on page 23.
1. Install a new O-ring in the groove around the oil
Maximum run out on rim is.003” and the run out
reservoir cavity. Coat the O-ring with a suitable
on eye is .002”. If T.I.R. deviates from specifica-
O-ring lubricant to hold it in the groove.
tion, increase torque to 140 ft.lbs. max to the bolts
2. Insert (2) 1/4” dia. guide pins into the rotor sup- opposite to the high side. Repeat as necessary un-
port. til allowable T.I.R is achieved.
3. Using proper rigging methods, slide the diffuser 7. Check high-speed thrust clearance. Acceptable
plate over the guide pins and into position against thrust tolerance is between .008” to .021” for K2,
the rotor support see Figure 20 on page 25. K3 & K4, .009" to .020" for K1 and K7.
4. Insert (4) of the bolts before removing rigging 8. Check low-speed thrust clearance. Acceptable
and guide pins; then insert remaining bolts and thrust tolerance is between .011” to .019” See
tighten. TTable 5 on page 23. Note that this measure-
ment must be taken with the shaft seal installed.
5. Place the flat side of the balanced piston seal ring
facing the diffuser plate. Install the flat spring Table 7 - PERMISSIBLE RUNOUT OF IMPELLER
washer on top of the balanced piston seal ring, in-
RIM RADIAL EYE RADIAL
stall retainer plate on top of both flat spring wash-
.003 .002
er and balanced piston seal ring.
Make absolutely certain that O-rings are
6. Apply Loctite and insert the (3) cap screws and
in place prior to installing and torque
fasten the balance piston seal and balance piston
cap screw.
retainer to the diffuser plate.
7. After tightening the (3) cap screws, check that the
balance piston is free to “float”.
9. Torque cap screw to 120 ft.lbs.
INSTALLING THE IMPELLER
1. Re-install the shaft locking tool. 10. Remove that shaft locking tool and check the rim
and eye radial runout using a dial indicator (see
2. Apply a light coat of oil or Molykote to the inside Figure 22 on page 36). Maximum runout on rim is
diameter of the balance piston seal and impeller. .003” and for the eye maximum is .002”.
3. Slide impeller into position on the high speed shaft 11. Check the high-speed thrust clearance. See Table
using care not to damage the balance piston seal. 5 on page 23.
4. Install the impeller clamping collar and the (3) or 12. Check low-speed thrust clearance. Acceptable
(6) cap screws onto the high-speed shaft. thrust tolerance is between .011” to .019”. Note
that this measurement can be taken with the shaft
5. Torque cap screws to 120 ft.lbs in (2) equal steps.
seal installed.
See to Figure 49 on page 38 for the proper se-
quence of tightening screws. DISASSEMBLY OF ROTOR SCROLL
1. Support the weight of the rotor support and motor
using proper rigging methods.
6
2. Remove the cap screws, and then fasten the suc-
tion connection and the discharge connection to
4 the scroll housing.
3. Remove all other external piping from the rotor
K1-K2 scroll.
K3, K4, K7
LD05188a
Figure 49 - IMPELLER MOUNTING SCREWS
4. Support the rotor scroll by proper rigging meth-
TIGHTENING SEQUENCE ods; then remove the bolts holding the rotor scroll
to the unit.
38 JOHNSON CONTROLS
FORM 160.75-M1
5. Carefully remove the rotor scroll from the unit 8. Remove cap screws, radial bearings and spacers
base, making sure the rotor scroll is out and away (3 or 4).
from the seal, and rest it on the end of the suc-
9. Remove the shoulder bolt and tensioner block.
tion housing. Do not lose any parts of isolators 2
that were beneath the compressor feet. Be sure the 10. Remove nuts and remove bearings and washers
rotor scroll is resting solidly – block if necessary. from drive pins (3 or 4).
REMOVING THE NOZZLE BASE PLATE (VGD) 11. Working from the nozzle base plate face, remove
cap screws (3 or 4 pair) in diffuser ring and re-
1. Remove hand whole cover. Disconnect the VGD move ring.
Drive linkage at VGD Drive Ring. See Figure 50
on page 39. 12. Remove the drive pins.
2. Remove the cap screws that hold the nozzle 13. Remove the bushings from the nozzle base.
base plate to the rotor scroll housing. Note there
are 3 holes spaced at 120° apart, tapped for
the eye bolts.
3. Using eyebolts, lift the nozzle base plate from the
rotor scroll housing.
NOZZLE BASEPLATE DISASSEMBLY (VGD)

1. Remove brass tipped set screw from tensioner pin
in tensioner block.
2. Remove tensioner bolt and conical washer set.
3. Remove tensioner pin from tensioner block.
4. Remove two cap screws from each axial bearing
block and remove blocks (3 or 4).
5. Remove nuts and washers and remove bearings LD27098
from bearing block. Hand Whole Cover
Figure 50 - HAND WHOLE COVER

6. Remove stop bolt from drive ring.
7. Rotate drive ring clockwise and remove from
bearings on drive pins.
Impeller Eye Seal Nozzle Base Plate
Rotor
Scroll Housing
Pre-Rotation Vane
Figure 51 - ROTOR SCROLL
26439A3
(PRV) Housing
JOHNSON CONTROLS 39
FORM 160.75-M1
Set Screw VGD
O-Ring
Nozzle
LD11392
Baseplate
LD11202
Conical Tension Figure 53 - NOZZLE BASE PLATE

Washer Set Block
REMOVING THE IMPELLER EYE SEAL

1. Remove the eye seal retainer and the eye seal
ring from nozzle base plate see Figure 55 on page
41.
NOTE: Conical Washer Set Orientation Required as Illustrated above.
Figure 52 - TENSION BLOCK
K7 Eye Seal
064-51506-000 LD13195a
Figure 54 - K7 EYE SEAL
40 JOHNSON CONTROLS
FORM 160.75-M1
RE-ASSEMBLY OF NOZZLE BASE PLATE

Eye VGD ASSEMBLE PROCEDURES
Seal Ring
1. Install bushings (item 14) in nozzle base plate
(item 27). 2
2. Install drive pins (item 3) in nozzle base plate. Do
not lubricate inside diameter of Bushings (item
Eye Seal
14). Lubricate drive pins (item 3) as shown prior
Retainer
to insertion into bushings (item 14). Take special
precaution such that end face of pin, threaded
LD27097
holes in end of pin and .12 inch length at end of
Figure 55 - EYE SEAL INSTALLED pin remain dry and completely free of lubricant.
3. Assemble diffuser ring (item 1) to nozzle base
Table 8 - EYE SEAL DIMENSIONS plate, align holes with drive pins, Shim to center
IMPELLER EYE O.D. EYE SEAL I.D. ring in slot. Using alignment tool 064-51664-000,
K1 8.0100" / 8.0070" 8.0260" / 8.0230"
align drive pins and attach to diffuser ring using
screws (item 2).
K2 8.8420 / 8.8390" 8.8580" / 8.8550"
K3 10.0140" / 10.110" 10.0330" / 10.0300" 4. Remove shims and install fixture or block to hold
K4 11.1930" / 11.1900" 11.2130" / 11.2100" diffuser ring in retracted position.
K7 12.292" / 12.290" 12.3130" / 12.3100" 5. Install cam follower, washer and nut (items 4, 9
and 5) to drive pins, torque nuts.
RE-ASSEMBLY OF THE EYE SEAL
6. Install two radial bearing tensioner blocks (item
1. Inspect all parts before re-assembly. See Clean-
22) to nozzle base using screws (item 23). Verify
ing and Checking Wearing Parts on page 14.
blocks move freely.
Replace with new parts as necessary.
7. Install two tensioner pins (item 19) in tensioner
blocks. Position pins so that the tapped holes are
aligned with the hole in the tensioner block.
8. Make up two tensioner spring assemblies from
screws (item 24), washers (item 16) and conical
washers (item 15).
00592VIP 9. Insert tensioner spring assemblies through hole
Impeller Eye Flat Spring Impeller in nozzle base plate, into tensioner block and just
Seal Retainer Washer Eye Seal start to engage in the tapped hole in the tensioner
pin. Do not tighten at this time.
Figure 56 - EYE SEAL COMPONENTS
10. Assemble four radial bearings and spacers (items
7 and 6) to the nozzle base plate and tensioner
2. Place flat spring washer into retainer and position
blocks using screws (item 8).
eye seal over spring retainer.
11. Lower drive ring (item 25) over drive pin cam fol-
3. Take complete eye seal assembly and position on
lowers and rotate counter clockwise into to fully
nozzle base plate. Insert cap screws and tighten.
retracted position.
Check that the seal ring is free to “float”.
12. Install drive ring stop screw (item 17).
JOHNSON CONTROLS 41
FORM 160.75-M1
13. Tighten tensioner spring assemblies to a finger 24. Adjust radial bearing tensioners by tightening
tight condition. do not tighten with tools. This screws (item 24) 1-1/2 to 1-3/4 turns. Assemble
will provide just enough tension to keep drive ring set screw (item 18) into tensioner pin (item 19)
centered. being careful not to get sealer between pin and
block (item 22). Torque set screw.
14. Assemble axial support blocks (item 10), bearings
(item 11), washers (item 13), nuts (item 5) and 25. Remove any fixtures or blocking. Operate mecha-
mounting screws (item 12) to nozzle base plate, nism; it should operate smoothly through the full
do not tighten screws or nuts. range of travel, without binding.
15. Align the axial support blocks such that the face 26. Check for correct diffuser ring travel per section
of the block is parallel to the inside diameter of a-a.
drive ring. torque the one mounting screw that is
27. Lubricate all moving surfaces with 50/50 mix of
opposite the cut in each block.
molybdenum disulfide and grease (item 25).
16. Lightly snug the mounting screws on cut side of
28. Assemble four inserts (item 29) into stabilizing
blocks.
ring (item 30).
17. Snug the nuts on the axial bearings just enough to
29. Install stabilizing ring (item 30) at the end of drive
seat axial bearings against face of support blocks. pins.
18. Rotate drive ring counterclockwise until it stops. 30. Adjust each insert (item 29) such that face of in-
19. Working through the holes in the drive ring, rotate sert bears lightly against face of drive pin (item 3).
the axial bearings to move the drive ring to the 31. Install screws (item 28) and torque per specifica-
furthest most position away from the nozzle base tion on drawing.
plate. Work one bearing at a time.
32. Rotate drive ring (item 25) to fully retract diffuser
20. Using a dial indicator on the drive ring top face, ring (item 1).
readjust the axial bearings to obtain a .001" to
.002" axial backlash to the drive ring at all four 33. Install spring pin (item 31) in stabilizing ring
locations. (item 30).
21. Torque the axial support block mounting screws 34. Install stop screw (item 32) and nut (item 33).
on the cut side of each block.
22. Torque the axial bearing retaining nuts.
23. Verify backlash at axial bearings.
42 JOHNSON CONTROLS
FORM 160.75-M1
33
32
31
LD22381
Figure 57 - VSD ASSEMBLY
JOHNSON CONTROLS 43
FORM 160.75-M1
27 25
6 Torque 10 Ft Lb
17
C A
1
Torque 35 Ft Lb
A
C
See Detail D
B
Section C-C
22
19
18 Torque 30 In Lb
6
Torque 18 Ft Lb
23
7
12 8
Torque 30 Ft Lb Torque 35 Ft Lb
Section A-A Section B-B
Torque 50 Ft Lb
E 14 Torque 250 In Lb 28
3 5
9
4
29
E 26 11
30
Torque 30 Ft Lb
2 13
16 5
Torque 250 In Lb
10
Section E-E
15
24 Section A-A
Detail D
LD22380
Figure 58 - VSD ASSEMBLY
44 JOHNSON CONTROLS
FORM 160.75-M1
VGD MOTOR LINKAGE 10. Reassemble the link to the lever.

1. With the drive link disconnected from the exter- 11. Cycle the VGD mechanism through full travel.
nal lever (motor lever installed and drive link con- The link should never get tight or bind and should
nected to motor lever), manually operate the VGD always be loose when shaken. 2
control to the fully retracted position (the most
clockwise position of the actuater motor). RE-ASSEMBLY OF SCROLL HOUSING TO
ROTOR SUPPORT
2. Loosen the two set screws that hold the external
lever to the feed through shaft. Verify that these 1. Using proper rigging methods, lift scroll housing
are tight (torque to 120 ft.lbs.). This is just a assembly into place on unit base.
clamped joint, there is no key or spline. 2. Using new gaskets, re-connect suction and dis-
3. Rotate the external lever counter clockwise ap- charge piping.
proximatly 30° with respect to the feed through 3. Insert guide pins into the scroll housing and install
shaft. a new O-ring.
4. Snug the lever screws enough to work the VGD
mechanism, but not loosen enough to slip on the
shaft.
5. Slowly rotate the external lever clockwise (re-
tracting the VGD mechanism) until it reaches the
internal hard limit.
6. Check the alignment of the holes between the ex-
ternal lever and the link. The center of the hole
should be to the right of the center of the external
lever hole.
7. With the VGD mechanism against the internal
limit, loosen the external lever clamp bolts just
enough to allow rotation of the lever about the
shaft but not loose enough to be overly free.
Do NOT make bolts too loose as the shaft
LD27096
may want to rotate counter clockwise.
Figure 59 - SCROLL HOUSING READY FOR RE-
ASSEMBLY TO MOTOR SUPPORT
Coat the O-ring with Loctite 515 or 518 to

8. Continue holding the VGD mechanism against secure the O-ring into the groove during
the internal stop and rotate the external lever assembly.
clockwise (slipping on the shaft) to properly align
the holes in the link with the hole in the lever. this
assures that the VGD mechanism does not bind
against the internal limit when fully retracted. 4. Apply a light coating of oil and Molykote to the
Proper alignment is obtained when the impeller where it enters the eye seal ring.
center of the hole in the lever is approx. 5. Using proper rigging methods, raise the rotor sup-
1/8” to the right (over traveling) of the port with motor adapter into proper position, and
centerline of the hole in the link. slide it into place over the guide pins.
6. Carefully slide the rotor support into place against
the scroll housing. Use care that the impeller is
9. Tighten the actuating arm clamping bolts, torque not damaged as it enters the eye seal ring by rotat-
to 120 ft. lbs. ing the shaft.
JOHNSON CONTROLS 45
FORM 160.75-M1
7. Insert the cap screws and tighten to the proper 4. If any of the individual vanes were removed or re-
torque specified in Torque Values on page 15. placed, coat the vane shank with oil and Molykote.
8. Re-install the compressor coupling (see Coupling Tighten the vane cap screws when clamped in the
Assembly (Form 160.49-N4)). closed position to the torque as indicated in Table
2 on page 15.
9. Bolt the motor to the motor adapter.
5. Re-assemble the pre-rotation vane assembly and
10. Re-connect all external piping. the nozzle base plate together in reverse order.
REMOVING THE PRE-ROTATION VANE Torque all screws in accordance with Table 2 on
HOUSING page 15.
The Pre-Rotation Vane Assembly cannot be removed

from the suction side of the compressor. The rotor sup-
port must first be removed from the rotor scroll and the
rotor scroll must be dis-assembled as decribed previ-
ously.
1. Remove the 12 pt. head cap screw and fill piece
to disconnect the adjustable bearing rod from the
Pre-Rotation
vane driving ring See Figure 60 on page 46 .
Vane Drive Ring
2. Remove 2 hex head cap screws at approximately
180° apart. Replace these screws with two guide
pins from the tool kit. Then remove the remain- Internal Lever
26666A
ing screws from around the perimeter of the PRV
Figure 60 - INTERNAL PARTS - PRE-ROTATION
assembly. Carefully pull the PRV assembly about
VANE ASSEMBLY
halfway on the guide studs. Hook a lifting device
to the assembly. Pull it off the guide studs and
place on a bench to replace any parts.
3. The PRV vanes are actuated by a rotating vane
driving ring through individual vane arms to each
vane. Individual vanes may be removed by:
a. unscrewing the cap screw which secures the
vane arm to the vane
b. lifting off the vane arm
c. lifting off the two special washers and pull-
ing the vane out toward the inside of the vane
housing (see Pre-Rotation Vane Housing As-
sembly on page 49)
46 JOHNSON CONTROLS
FORM 160.75-M1
Table 9 - VGD AND PRV LINKAGE ASSEMBLY

ITEM DESCRIPTION CONSUMABLES TORQUE
25 Grease Poe - -
54 Primer Locquic Grande N, Loctite - - 2
63 Screw, Cap Hex Soc Hd #10 See Item 54 & 118 80 FT/LB
65 Screw, Cap Hex Soc Hd 1/4 10 FT/LB
72 Screw, Cap 12 Pt Hd 3/8 52-1 35 FT/LB
73 Screw, Cap 12 Pt Hd 3/8 50 FT/LB
76 Screw, Cap 12 Pt Hd 3/8-16 35 FT/LB
82 Screw, Cap 12 Pt Head 3/8 50 FT/LB
85 Screw, Cap 12 Pt Hd 1/2 See Item 54 & 118 50 FT/LB
87 Screw, Cap 12 Pt Hd 1/2 - 85 FT/LB
89 Hhcs, 0.250-20 X 1.500 Gr 5 Bl See Item 54 & 118 14 FT/LB
90 Screw, Cap Hex 1/4 -20unc See Item 54 & 118 14 FT/LB
116 Sealer Gasket Eliminator - -
117 Sealer Grade AVV Loctite 086 - -
118 Sealer Removable Thread - -
JOHNSON CONTROLS 47
FORM 160.75-M1
82
83
90 85
89
VGD
Linkage
PRV
Linkage
73 72
63
84 69
76 VGD Actuator
Motor
88 63
84 37
76
PRV Actuator
87
Motor
LD19817
69
65 70
Figure 61 - VGD AND PRV LINKAGE ASSEMBLY
48 JOHNSON CONTROLS
FORM 160.75-M1
LD05191
LD27095
Figure 62 - PRE-ROTATION VANE HOUSING ASSEMBLY
METHOD 1
3
2
10
5 4
6
10
8 (7, 12)* 11
METHOD 2
2
2
5 4
6
ITEM DESCRIPTION QTY. ITEM DESCRIPTION QTY.

1 Ring, Driving 1 7 Washer 10
2 Vane 9 8 Stud, Ball 9
8
3 Retainer 9 9 Screw – 12 pt. 9 (7, 12)* 11
21501
4 Arm, Vane 9 10 Screw – Hex HD 18
5 Spacer, Arm 9 11 Nut, Self-Locking 9
6 Washer 9 12 Housing 1
Figure 63 - PRE-ROTATION VANE ASSEMBLY
JOHNSON CONTROLS 49
FORM 160.75-M1
Table 10 - PRE-ROTATION DEVICE

ITEM DESCRIPTION PART NUMBER CONSUMABLES TORQUE
Vane, Pre-Rotation K1-2 (prior 7/2012) 064 51641 000
2 See Item 10 -
Vane, Pre-Rotation K1-2 (after 7/2012) 029 26311 000
4 Spacer, PRV Arm K1-2 064 51668 000 See Item 10 -
7 Stud, Ball 1/4-28 Unf 029 15924 000 See Item 10 10 FT/LB
8 Screw, Cap 12pt Hd 1/2 021-11515-000 - 85 FT/LB
9 Nut, Selflock 1/4-28 Unf 021-12943-000 See Item 10 9 FT/LB
10 Lubricant, Molybdenum* 011-00253-000 - 10 FT/LB
*Apply 50/50 mix of lubricant (Item 10) and compressor oil to can
shanks, spacers and stud balls.
Verify part numbers before ordering. These part numbers may
change.
50 JOHNSON CONTROLS
FORM 160.75-M1
2
8
LD19820
Figure 64 - PRE-ROTATION DEVICE
JOHNSON CONTROLS 51
FORM 160.75-M1
LD22371
LD27094
External Lever Vane Motor Linkage

DETAIL A DETAIL B (TAPER DRIVE)
PRV
Internal
Linkage
PRV
Control Shaft
Cover
Bracket Support
LD11204
PRV Control External PRV Lever
Shaft PRV Plug Assembly
DETAIL C (SQUARE DRIVE)
Figure 65 - CONTROL SHAFT ASSEMBLY
52 JOHNSON CONTROLS
FORM 160.75-M1
REPLACING CONTROL SHAFT ASSEMBLY 12. Install the cover plate, but do not tighten the cap
screws at this time.
The external and internal levers are secured to the con-
trol shaft by means of a single 12 point head cap screw 13. Tighten the nut on the outside end of the stud
threaded into the internal lever (see Figure 65 on page against the end of the control shaft to pull the in- 2
52). Adjustable stops are provided in the internal le- ternal lever hard up on the taper of the shaft.
ver arm. These stops are NOT to be used to stop the
14. With the cover plate loosely installed, close the
vanes in the extreme positions of normal travel, but are
vanes by turning the nut on the outside end of the
supplied as protection should some external force be
stud. Position the external lever on the control
applied to the linkage. The stops are set about 1/32”
shaft so that the indicator pin punch mark or split
away from the rotor scroll casting walls when the
on the lever aligns with the closed “C” mark on
vanes are in their extreme position, and will prevent
the housing. Push external lever arm slightly to
overtravel from damaging the internal vane mecha-
seat on taper for taper type or snug pinch bolts for
nism. Loctite 243 is used on the threads when the stops
the split lever.
are initially positioned to prevent any change in posi-
tion. The compound should be used again if the stops 15. Remove the nut and stud (taper type only).
are ever removed.
16. Install the 6” cap screw and washer. Draw the cap
To replace control shafts, refer to Figure 65 on page screw tight. Move the external lever to the “open”
52 and proceed as follows: and “closed” positions, to check the indicator
points on the cover plate. Readjust the external
1. Reduce the system pressure to slightly above at- lever position, if necessary.
mospheric pressure.
17. Using a torque wrench, tighten the cap screw to a
2. Disconnect the linkage from the external lever torque of 75 ft. lbs for taper type and 85 ft. lbs. for
(refer to Figure 65 on page 52, Detail A). square drive.
3. Loosen and remove the 12 pt. hd. cap screw and 18. Move the external lever to its midposition (vanes
washer (refer to Figure 65 on page 52, Detail half open) and tighten the cover plate cap screw to
B). For square drive design, the O-ring plug must a torque of 35 ft. lbs.
be removed from the end of the shaft to gain ac-
cess to the cap screw. This is important and assures that the
sleeve will twist equally when the vanes
4. Remove external lever ( loosen pinch bolts on are moved to either the wide open or the
split lever). fully closed position.
5. Insert the special stud through the hole in the con-
trol shaft, and screw the stud into the internal le-
ver. Be sure to put a nut on the outside end of the 19. Connect the linkage to the external lever.
special stud (see Figure 65 on page 52). 20. For square drive/split lever design only, torque the
6. Using a hammer and block of hard wood, tap the lever pinch bolts to 121 ft. lbs. and install the O-
outside end of the stud to loosen the internal lever. ring plug into the end of the shaft.
DO NOT REMOVE THE SPECIAL STUD. When connecting the vane linkage to the electric mo-
7. Remove the cover plate cap screws. tor, rotate the motor shaft to the closed position and
connect the vane linkage while holding the vanes in
8. Remove the external lever and the control shaft the closed position. Operate the vane motor open and
cover from the scroll. closed several times to be sure the motor does not jam
9. Replace the existing gasket with a new one. at either end of its travel. Adjust as necessary by ei-
ther lengthening or shortening the distance between
10. Valve Stem Lubricant is a 2 part mixture 50/50 by the motor linkage and the external lever to be sure the
weight of grease and a dry molydenum disulphide vanes are wide open and tightly closed as the motor
powder throughly blended. rotates from one end of its travel to the other.
11. Slide the new shaft with O-rings into position
over the special stud.
JOHNSON CONTROLS 53
FORM 160.75-M1
IT IS IMPORTANT that the arm length from motor

centerline to force point, the arm length from control
shaft centerline to force point and the length of con-
nection arm be the same as original factory settings.
Also, the angular position of the motor shaft must be as
original factory settings.
54 JOHNSON CONTROLS
FORM 160.75-M1
SECTION 3 - OIL PUMP SERVICE
OIL PUMP REMOVING OIL PUMP FROM THE OIL SUMP

It is quite normal for the compressor oil consumption 1. Remove the power supply to the oil pump and oil
to increase with rising shaft RPM. The High Speed sump heater. Remove electrical leads from fusite
and Low Speed thrust collars operate in an oil flooded connections and transducers. 3
chamber and behave similarly to a centrifugal pump.
2. Drain oil from oil sump through drain valve on oil
This is part of the design intended to assist oil flow
pump housing cover plate.
through the bearings during power outages/coastdown.
The Pressure Drop across the compressor will decrease 3. Remove oil eductor line and oil line at the pressure
as the machine ramps up in speed. The VSD oil pump regulator. (NOTE that on Rev. Level E chillers
maintains the appropriate supply pressure, by increas- and above that the oil regulating valve has been
ing the speed/flow. All YK compressors behave in a replaced by using a variable speed oil pump).
similar manner.
4. Remove the 5/8” hex head bolts from the oil pump
The oil pump supplies oil to the compressor’s rotating cover (see Figure 66 on page 56).
components prior to start-up, during compressor opera-
5. After all bolts are removed, pull the oil sump
tion and during coastdown (post lube). If it is necessary
cover loose and remove the cover and oil pump
to service the oil pump, use the following procedure:
assembly (see Figure 67 on page 56).
25717A
JOHNSON CONTROLS 55
FORM 160.75-M1
Oil Pressure 24
8 Liquid Transducer Valve Push-On Terminals
Level Gage Oil Supply
21 Electrical 2
Box Oil-Pump
LD11481
10 Figure 67 - OIL PUMP & COVER PLATE REMOVAL

9
Terminal
Temperature
HV Fused Glass
Sensor
Drain and Charge Cover Plate
Valve Bolts
LD11465
Figure 66 - OIL PUMP HOUSING COVER PLATE
REASSEMBLING OIL PUMP ASSEMBLY INTO

OIL SUMP
Before assembling oil pump into oil sump pump, clean
the oil sump with an approved solvent, using the ut-
most care to eliminate all dirt. LD11466
1. Replace oil sump cover gasket with a new one. P/N VOLTS-PHASE-HZ FIGURE
Lubricate gasket with YORK refrigerant oil and 200-3-60 1
graphite. 208-3-60 1
220-3-60 1
2. Assemble the gasket and the oil pump and sump -001 230-3-60 1
cover assembly to oil sump using the 3/8” hex 240-3-60 1
bolts, apply one drop of Loctite 243 or equivalent 220-3-50 1
to the threads. Tighten bolts using the alternating 346-3-50 1
tightening method. Torque to 155 ft. lbs. 415-3-60 2
380-3-60 2
3. Tighten Cover Plate bolts to a recommended
-002 380-3-50 2
torque value of 120 LB. FT. minimum.
400-3-50 2
4. Reconnect all electrical leads to fusite connection 415-3-50 2
on sump cover (see Figure 68 on page 56). Re- 440-3-60 2
connect oil lines. Reconnect transducers. 440-3-50 2
460-3-60 2
5. Charge oil into oil sump. Refer to Operating In-
-003 480-3-60 2
structions (Form 160.49-01). Be sure oil is com-
550-3-60 2
patible with refrigerant being used. 575-3-60 2
6. Make sure there are no leaks around the cover and 600-3-60 2
connections.
Figure 68 - OIL PUMP MOTOR LEADS
56 JOHNSON CONTROLS
FORM 160.75-M1
OIL PUMP HOUSING PARTS

Table 11 - OIL PUMP HOUSING (K1-K4 & K7)
ITEM DESCRIPTION PART NUMBER FIGURE
Body, Oil Pump Housing (K1-K4 and K7) 375-60694-000
1
Body, Oil Pump Housing (K1-K4 and K7) (Canada) 375-61444-000
80 3
1A O-ring, Cover 13.475ID .275THK (All) 028-11977-000
1B Cover Plate (K1-K7)(All) 075-46360-000
Pump, Oil 20 GPM YK (prior 6-2010) 026-37937-000
2 80
Pump, Oil 20 GPM YK (after 6-2010) 026-46326-002
Heater, Electric Immer (3,000 W) (200-346) 025-32909-000
5 8
6 Valve, Stop Angle Vertical 022-09578-000 80
9 Gage, Liquid Level Sight Front 026-37571-000 80
12 Sensor, Temp. 50,000 OHMS DIN 025-39993-000 80
13 Terminal, HV Fused Glass 025-32933-000 *
19 O-ring, Neoprene 2.33id .118 Thk 028-12961-010 80
24 O-ring, Neoprene 0.468id 0.78 Thk 028-12961-003 80
25 O-ring, Neoprene 0.351id 0.772 Thk (Terminal) 028-12961-001 80
29 Box, Elec 4 Octagon x 4 Deep 025-33238-000 80
30 Cover, Filter Outout Assy. 375-26580-000 80
31 Screw, Mach Pan Head Recd 021-03741-000 80
33 Terminal, Push-on Str 14-10 (200-346) 025-09455-000 *
34 Terminal, Push-on Str 18-14 (380-416, 440-600) 025-25920-000 *
35 Strap, Cable T and B L7-50-9-M 025-09607-000 80
36 Insr, Elec 025-10371-000 80
37 Ferr, Splice Cap 025-10372-000 80
38 Cap, Sealing Caplug 250 028-04574-000 80
39 O-Ring, Neoprene 1.171id .116 Thk 028-12961-008 80
42 Plate, Oil Pump Mtg Machining (Canada) 075-54038-000 80
43 Pin, Slot Spg 3/16 x 1/2 (Canada) 029-04138-000 80
NOTE: Items with an * are NOT represented.
JOHNSON CONTROLS 57
FORM 160.75-M1
K1 - K4 AND K7 COMPRESSORS
OIL PUMP HOUSING (K1 - K4 AND K7 COMPRESSORS)
21
20
LD13591
Figure 69 - OIL PUMP HOUSING ASSEMBLY (K1 - K4, AND K7 COMPRESSORS)
58 JOHNSON CONTROLS
FORM 160.75-M1
SECTION 4 - VGD THEORY
GENERAL DESCRIPTION
VGD = “Variable Geometry Diffuser” VGD accomplishes this by eliminating aerodynamic
turbulance within the diffuser by tuning the diffuser
VGD eliminates the rise in noise and vibration - as geometry (width) to match flow.
issues that can arise with all centrifugal compressors
when they encounter extreme conditions.
Fixed Geometry Diffuser

Scroll Volute
Optimized for a Limited Flow Range
Impeller
26493A
Figure 70 - TYPICAL CENTRIFUGAL COMPRESSOR
JOHNSON CONTROLS 59
FORM 160.75-M1
Diffuser Plate
Gas Flow Nozzle Base Plate
Diffuser Ring
Variable Geometry Diffuser Drive Pin

Varies Width to Match Flow Drive Pin Cam Follower
Drive Ring
Axial Cam
Follower
Pin and Diffuser

Ring Motion
Axial Support
Impeller
Gas Flow
Gas Flow
LD11489
DRIVE RING - Circular rotating Drive Ring is driven by an external actuating motor.
DRIVE PIN CAM FOLLOWER - Follows precision cam-groove machined into the Drive Ring OD.
DRIVE PIN - Multiple drive pins are pushed and pulled by the Drive Pin Cam-Follower.
DIFFUSER RING - This circular ring is pushed in and out of the diffuser gap, by the drive pins, continuously vary-
ing the diffuser width to match the changing flow.
Figure 71 - TYPICAL VGD SECTION
60 JOHNSON CONTROLS
FORM 160.75-M1
Drive Pins
and Connecting Link
Drive Pin Cam
Followers
Actuating Arm
Drive Ring 4
Nozzle Base Plate
Radial
Bearing
Drive Pins
and
Drive Pin Cam
Followers
Axial Bearing
Assembly
Drive Pins
and
Drive Pin Cam
Followers
LD11490
ACTUATING ARM - Driven by an external actuating-motor this arm rotates the Drive Ring.
DRIVE RING - Circular rotating Drive Ring is driven by an external actuating-motor.
DRIVE PIN CAM FOLLOWER - Follows precision cam-groove machined into the Drive Ring OD.
DRIVE PIN - Multiple Drive Pins are pushed and pulled by the Drive Pin Cam-Follower.
DIFFUSER RING - This circular ring is pushed in and out of the diffuser gap, by the Drive Pins,
continuously varying the diffuser width to match the changing flow. Cannot be seen from this view.
Figure 72 - REAR VIEW OF DIFFUSER
JOHNSON CONTROLS 61
FORM 160.75-M1
Table 12 - VARIABLE GEOMETRY DIFFUSER (VGD) MODEL K1

ITEM DESCRIPTION CONSUMABLES TORQUE
Screw, Cap Hex Soc Hd 5/16 (prior 5/2012)
2 See Items 20 & 21 -
Screw, Cap Hex Soc Hd 5/16 (after 5/2012)
5 Nut, Hex 3/8 - 24 Unf-2b See Items 20 & 21 95 in/lb
8 Screw, Cap Hex Soc Hd 3/8 See Items 20 & 21 -
12 Screw, Cap Hex Soc Hd See Items 20 & 21 -
13 Screw, Cap Hex Soc Hd 5/16 See Items 20 & 21 30 ft/lb
17 Screw, Cap Hex Soc Hd 1/4 See Items 20 & 21
18 Screw, Set Hex Socket 1/4 See Items 20 & 21 30 in/lb
20 Primer Locquic Grade N, Loctite - -
21 Sealer Removable Thread - -
23 Screw, Shoulder Soc Hd 5/16 - 18ft/lb
25 Lub Valve Stem 2 oz Tin - -
27 Screw, Cap 12pt hd 3/8 (after 4/2012) See Items 20 & 21 -
26
1 2
27
5
17
18
13
23
12
27
364 53356 000 LD19830
Figure 73 - VARIABLE GEOMETRY DIFFUSER (VGD) MODEL K1
62 JOHNSON CONTROLS
FORM 160.75-M1
Actuating Arm
Nozzle Base Plate
Drive Ring
Cam Groove
Drive Pin
LD11522
ACTUATING ARM - Driven by an external actuating-motor this arm rotates the Drive Ring.
DRIVE RING - Circular rotating Drive Ring is driven by an external actuating motor.
CAM GROOVES - Drive-Pin Cam-Followers (hidden behind the Drive Pins) ride in this groove.
DRIVE PIN - Multiple drive pins are pushed and pulled by the Drive Pin Cam-Follower.
DIFFUSER RING - This circular ring is pushed in and out of the diffuser gap, by the drive pins,
continuously varying the diffuser width to match the changing flow. Cannot be seen from this view.
Figure 74 - SIDE VIEW OF DIFFUSER
JOHNSON CONTROLS 63
FORM 160.75-M1
HOW THE VGD IS CONTROLLED

1. Compressor Discharge-mounted Pressure Trans-
ducer monitors discharge pressure.
LD11524
PRESSURE TRANSDUCER
2. Dynamic Pressure Signal sent to Solid State Sig-

nal Processor.
LD11526
YORK OptiView
Computerized Control Panel
6. Internal Soild-State Signal Processor output is

used by control logic to optimize chiller perfor-
mance by adjusting the VGD and Pre-Rotation
Vanes for lowest noise and vibration yielding best
operating efficiency.
VGD Actuator
LD22363
SOLID STATE SIGNAL PROCESSOR
3. Solid State Signal Processor filters and processes

signal monitors 10-300Hz range.
LD11527
Transducer PRV Actuator

LD11525
TYPICAL COMPRESSOR SPECTRUM VGD EQUIPPED COMPRESSOR
4. Output to OptiView Control Panel. 7. Adjust VGD and PRV Actuators for optimum per-
formance.
5. Signal in from Dynamic Pressure Transducer.
64 JOHNSON CONTROLS
FORM 160.75-M1
SECTION 5 - DISASSEMBLE AND REASSEMBLE CHECKLIST
Before disassembly and after reassembly of the com- 17. Remove the diffuser plate using 3 eye bolts.
pressor, take the measurements listed in Table 13 on
18. Remove the forward low-speed thrust bearing
page 67.
(cover).
DISASSEMBLE THE COMPRESSOR 19. Take tolerance measurements of runout for the
1. De-couple the motor, keep all coupling compo- low-speed thrust collar. Record the actual mea-
nents together. surement.
2. Rig safely the motor and remove as described 20. Remove the low-speed thrust bearing collar.
later in the manual. 21. Remove the forward low-speed journal bearing.
3. Remove all piping connected to the rotor support 22. Remove the forward high-speed journal bearing.
and remove the proximity sensor.
23. Remove the bearing housing dowel pins. 5
4. Remove the rotor support and set it up for dis-
assembly safely. Keep compressor motor adapter 24. Remove the bearing housing.
(D-flange) connected, you may need to add some 25. Remove the high-speed and low-speed gears.
weight inside to keep the rotor support balanced
vertical. 26. Remove the rear low-speed journal bearing.
5. Take tolerance measurements for impeller rim 27. Remove and discard all gaskets and O-rings.
runout. Record the actual measurement and note 28. Remove, clean, and inspect the impeller eye seal
any abnormal condition. ring. Check and record the eye seal ring clear-
6. Take tolerance measurements for impeller eye ances.
runout and compare to specifications. Record the 29. Remove, clean, and inspect the nozzle base plate
actual measurement. with the VGD Inspect the PRV assembly for free
7. Take tolerance measurements for high-speed axial movements and no broken parts. Check vans arms
thrust clearance. Record the actual measurement. for any bent and repair as required.
8. Take tolerance measurements for low-speed axial ASSEMBLE THE COMPRESSOR

thrust clearance. Record the actual measurement
1. Clean all gasket and sealing surfaces to new clean
Remove the shaft seal, including O-rings and C-
condition, remove old paint and sealant residue.
rings.
Install the new gaskets and O-rings, referring to
9. Remove and inspect the impeller for scratches and the graphic in the appropriate parts manual.
wear.
2. Before installing any bearings you must coat them
10. Remove the high-speed reverse thrust bearing with a mixture of oil and molybdenum disulfide
(Thrust cover). powder. This includes but is not limited to the low
speed journal bearing, high-speed journal bearing,
11. Take tolerance measurements of runout for the
low speed thrust and a high-speed thrust.
high-speed thrust collar. Record the actual mea-
surement. 3. Install the rear low-speed journal bearing.
12. Remove the high-speed thrust collar. 4. Install the low-speed gear.
13. Remove the high-speed forward thrust bearing. 5. Install the high-speed gear.
14. Remove the high-speed journal bearing. 6. Install the bearing housing.
15. Remove the balance piston seal. 7. Install the bearing housing dowel pins.
16. Clean and inspect the balance piston seal ring for 8. Install the front high-speed journal bearing.
any damage. Check and record the B.P seal ring
9. Install the front low-speed thrust collar.
clearances.
JOHNSON CONTROLS 65
FORM 160.75-M1
SECTION 5 - Disassemble And Reassemble Checklist
10. Take tolerance measurements of runout for the K1

low-speed thrust collar and compare to specifica- H. S. THRUST L.S. THRUST
tions. Record the actual measurement. L.S. H. S.
COLLAR COLLAR
THRUST THRUST
FACE T.I.R FACE T.I.R
11. Install the front low-speed thrust bearing/cover. (INCHES) (INCHES)
(INCHES) (INCHES)
12. Connect the oil drain line. .011-.019* .009-.020* .001 .001
13. Install the diffuser plate. K2

14. Install the rear high-speed journal bearing. H. S. THRUST L.S. THRUST
L.S. H. S.
COLLAR COLLAR
15. Install the high-speed forward thrust bearing. THRUST THRUST
(INCHES) (INCHES)
(INCHES) (INCHES)
16. Install the high-speed thrust collar.
.011-.019* .008-.021* .001 .001
17. Take tolerance measurements of runout for the
high-speed thrust collar and compare to specifica- K3
tions. Record the actual measurement. H. S. THRUST L.S. THRUST
L.S. H. S.
18. Install the high-speed reverse thrust bearing/cov- COLLAR COLLAR
THRUST THRUST
er. (INCHES) (INCHES)
(INCHES) (INCHES)
19. Install the pressure switch or proximity probe, .011-.019* .008-.021* .001 .001
whichever is applicable.
K4
20. Install new O-rings and C-rings (if applicable) on
H. S. THRUST L.S. THRUST
the shaft seal. L.S. H. S.
COLLAR COLLAR
THRUST THRUST
21. Install the shaft seal. FACE T.I.R FACE T.I.R
(INCHES) (INCHES)
(INCHES) (INCHES)
22. Install the impeller. .011-.019* .008-.021* .001 .001
23. Take tolerance measurements for high-speed axi-

K7
al thrust clearance and compare to specifications.
Record the actual measurement. L.S. H. S.
H. S. THRUST L.S. THRUST
COLLAR COLLAR
THRUST THRUST
24. Take tolerance measurements for impeller eye (INCHES) (INCHES)
runout and compare to specifications. Record the (INCHES) (INCHES)
actual measurement. .011-.019* .009-.020* .001 .001
25. Take tolerance measurements for impeller rim

runout and compare to specifications. Record the
actual measurement.
26. Take tolerance measurements for low-speed axial
thrust clearance and compare to specifications.
Record the actual measurement.
27. Install the PRV assembly if it was removed.
28. Replace the nozzle base plate O-ring and install
the nozzle base plate with the VGD.
29. Reassemble and install the eye seal. Center the
Eye seal to its most upper position (12oclock)
lubricate the impeller eye seal surface with Mo-
lybdenum disulfide powder and oil, carefully slide
the rotor support into the scroll assembly so as not
to damage the impeller or eye seal.
66 JOHNSON CONTROLS
FORM 160.75-M1
SECTION 5 - Disassemble And Reassemble Checklist
Table 13 - MEASUREMENTS
REFERENCE BEFORE AFTER
Compressor Measurements
Eye Runout 0.002”
Rim Runout 0.003”
H.S. shaft axial thrust
K1 & K7 0.009” – 0.020”
K2, K3 & K4 0.008”- 0.021”
L.S. shaft axial thrust 0.011” – 0.019”
H.S Thrust collar Runout 0.001”
L.S Thrust collar Runout 0.001”
Motor, Compressor Coupling Measurements
Angler measurement 0.014”Max
Parallel Measurement 0.014”Max
Total Misalignment 0.028”Max
No more than 0.010” of the disc
Hub to hub distance
packs and spool combined
The following factors can be used to convert from

English to the most common SI Metric values.
Table 14 - SI METRIC CONVERSION
MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT
Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW)
Power Horsepower 0.7457 Kilowatts (kW)
Flow Rate Gallons / Minute (gpm) 0.0631 Liters / Second (l/s)
Feet (ft) 0.3048 Meters (m)

Length
Inches (in) 25.4 Millimeters (mm)
Weight Pounds (lbs) 0.4538 Kilograms (kg)
Velocity Feet / Second (fps) 0.3048 Meters / Second (m/s)
Feet of Water (ft) 2.989 Kilopascals (kPa)

Pressure Drop
Pounds / Square Inch (psi) 6.895 Kilopascals (kPa)
TEMPERATURE
To convert degrees Fahrenheit (°F) to degrees Celsius
(°C), subtract 32° and multiply by 5/9 or 0.5556.
Example: (45.0°F - 32°) x 0.5556 = 7.22°C
To convert a temperature range (i.e., a range of 10°F)
from Fahrenheit to Celsius, multiply by 5/9 or 0.5556.
Example: 10.0°F range x 0.5556 = 5.6 °C range
JOHNSON CONTROLS 67
FORM 160.75-M1
INDEX
A J
Alignment 19 J7/K7 Compressors 32
Angular Alignment 19
Angular Misalignment 19 K
Axial Shaft to Shaft Spacing 19 K3 and K4 Compressors 31
Axial Misalignment 19 Individual Part Numbers for New Style K3 and K4 High
De-Flange Models 19 Speed Thrust Bearings 32
Parallel Alignment 19
Parallel Misalignment 19 M
Total Indicator Reading 19
Motor Removal and Replacement 17
B Coupling Torque 18
Installation 17
Balance Piston Seal Ring Dimensions 25 Close-Coupled Models 17
C Motor Alignment 18
REMOVAL (MOTOR ONLY) 17
Cleaning and Checking Wearing Parts 14 Close-Coupled Models 17
Compressor Oil 13
Compressor Weights (lbs.) - Less Motor 15 N
Control Shaft Assembly 52 Nomenclature 11
D Compressor Identification 11
Nozzle Baseplate Disassembly (VGD) 39
Disassemble And Reassemble Checklist 65 Hand Whole Cover 39
Assemble the compressor 65 Nozzle Base Plate 40
Disassemble the Compressor 65 Rotor Scroll 39
Disassembly of Rotor Scroll 38 Tension Block 40
Disassembly of Rotor Support 22
Disassembly of Rotor Support from the Rotor Scroll 22 O
Removing the Rotor Support from Rotor Scroll 22 Oil Pump 55
E P
Eye Seal Dimensions 41 Pre-Rotation Device 50
G R
General Description 11 Rear High-Speed Bearing Components 31
H Checking High-Speed Thrust Collar Run-Out 34
Gear Locking 34
How the VGD is Controlled 64 General 31
High-Speed Bearing Components 34
I High-Speed Forward Thrust Bearing 35
Identifying Compressors utilizing updated High Speed High-Speed Rear Bearing Removal 35
Thrust Bearings 31 High-Speed Reverse Thrust Bearing 34
Installing Balance Piston and Diffuser Plate 38 High-Speed Thrust Collar Removed 34
Installing Bearing Housing 29 , Installing Gears into Rotor Support 36
Rear High-Speed Bearings Installation 35
36 Rear High-Speed Journal Bearing 35
Bearing Housing Torque Sequence 29 Reverse High Speed Thrust Cover Plate 33
Installing Front High-Speed Bearings 37 Rear Low-Speed Bearing Components 29
Front Bearing Components 37 Bearing Housing Dowel Pins 29
Installing Front Low-Speed Bearings 37 Installation 30
Bearing Housing 37 Low-Speed Rear Bearing Removal 30
Installing the Impeller 38 Rear Low-Speed Bearing 30
Impeller Mounting Screws Tightening Sequence 38 Removal 29
68 JOHNSON CONTROLS
FORM 160.75-M1
Reassembling Oil Pump Assembly into Oil Sump 56 S

Oil Pump & Cover Plate Removal 56
Oil Pump Housing (K1-K4 & K7) 57 Seal Removal (Bellows Type) 20
Oil Pump Motor Leads 56 Bellows Type Shaft Seal 21
Re-Assembly of Nozzle Base Plate Installation (Bellows Type) 20
VGD assemble procedures 41 Retainer Running Position 20
VSD Assembly 43 Service Guidelines 14
Re-Assembly of Scroll Housing to Rotor Support 45
Scroll Housing Ready for Re-Assembly to Motor Support
T
45 Thrust Endplay 13
Re-assembly of the Eye Seal 41 Torque Values 15
Eye Seal Components 41 Two Piece Proximity Probe 16
Refrigerant 13 Din Connector Wiring 16
Removing Balance Piston Seal and Diffuser Plate 25 Installation 16
Balance Piston Seal 25
Balance Piston Seal Assembly 25 V
Removing Diffuser Plate 25
VGD and PRV linkage Assembly 47
Removing Bearing Housing and Gears 28
VGD Theory 59
Bearing Housing 28
General Description 59
Bearing Housing Removed 28
Rear View of Diffuser 61
Gears 28
Side View of Diffuser 63
Removing Bearing Housing 28
Typical Centrifugal Compressor 59
Removing Front High-Speed Bearing 26
Typical VGD Section 60
All Front End Bearings Removed 28
Variable Geometry Diffuser (VGD) Model K1 62
Front High-Speed Bearing Removal 27
Vibration Analysis 13
Low-Speed Bearing Removed with High-Speed Bearing in
Place 27
Removing Front Low-Speed Bearings 26
Checking Low-Speed Thrust Runout 27
Front Bearing Components 26
Front Low-Speed Bearing Removal 27
Low-Speed Thrust Bearing 26
Low-Speed Thrust Bearing Removed 27
Low-Speed Thrust Collar Removed 27
Removing Oil Pump from the Oil Sump 55
Oil Pump Housing Cover Plate 56
Removing the Impeller 23
DETAIL A – Checking Rim Runout 23
DETAIL B – Checking Eye Runout 23
DETAIL C – Checking Axial Thrust 23
Impeller and Balance Piston 24
Impeller Information 23
Removing Impeller 24
Removing the Impeller Eye Seal 40
Eye Seal Installed 41
K7 Eye Seal 40
Removing the Nozzle Base Plate (VGD) 39
Removing the Pre-Rotation Vane Housing 46
Internal Parts - Pre-Rotation Vane Assembly 46
Pre-Rotation Vane Assembly 49
Pre-Rotation Vane Housing Assembly 49
Replacing Control Shaft Assembly 53
Rigging the Compressor or Motor 15
JOHNSON CONTROLS 69
5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2018 www.johnsoncontrols.com ALL RIGHTS RESERVED
Form 160.75-M1 (718)
Issue Date: July 20, 2018
Supersedes: 160.75-M1 (418)

Centrifugal Compressors: Service Manual

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Centrifugal Compressors: Service Manual

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CENTRIFUGAL COMPRESSORS

SERVICE MANUAL Supersedes: 160.75-M1 (418) Form 160.75-M1 (718)

Indicates a possible hazardous situation Identifies a hazard which could lead to

Indicates a potentially hazardous situa- Highlights additional information useful

CHANGEABILITY OF THIS DOCUMENT

High Pressure Refrigerant Compressor

Close-Coupled D Flange Motor

MISCELLANEOUS & ACCESSORIES

COMPOUNDS AND ABRASIVES

COMPRESSOR TOOL KITS

YORK "K" OIL

SECTION 2 - COMPRESSOR SERVICE.................................................................................................................13

TABLE OF CONTENTS (CONT'D)

SECTION 4 - VGD THEORY....................................................................................................................................59

SECTION 5 - DISASSEMBLE AND REASSEMBLE CHECKLIST ........................................................................65

LIST OF FIGURES (CONT'D)

THIS PAGE INTENTIONALLY LEFT BLANK.

Figure 1 - COMPRESSOR IDENTIFICATION

High Speed Impeller

Low Speed Gear Set Low Speed

Figure 2 - COMPRESSOR COMPONENTS

SECTION 2 - COMPRESSOR SERVICE

Table 1 - COMPRESSOR WEIGHTS (LBS.) - LESS MOTOR

NOTE: Motor weights (lbs.) (Located on Motor Data Plate)

Table 2 - TORQUE VALUES

NEW CABLE EXISTING CABLE

MOTOR REMOVAL AND REPLACEMENT

REMOVAL (MOTOR ONLY) Figure 6 - COMPRESSOR COUPLING

130 FT. LBS.

Figure 7 - MOTOR ALIGNMENT

Table 3 - COUPLING TORQUE

ALIGNMENT Parallel Alignment

Table 4 - TOTAL INDICATOR READING

Figure 9 - ANGULAR MISALIGNMENT

Sleeve Spring Energized

Sleeve Set Screws (B) (Qty. 4)

Flat Head Screws

Sleeve Set Screws (C) (Qty. 2)

Figure 12 - BELLOWS TYPE SHAFT SEAL

DISASSEMBLY OF ROTOR SUPPORT

Figure 13 - DISASSEMBLY OF ROTOR SUPPORT FROM THE ROTOR SCROLL

Figure 16 - DETAIL C – CHECKING AXIAL

26347A Table 5 - IMPELLER INFORMATION

2. Install the gear locking tool on the low-speed shaft

Figure 15 - DETAIL B – CHECKING EYE RUNOUT

Figure 17 - IMPELLER AND BALANCE PISTON

Cap Screws Impeller

REMOVING BALANCE PISTON SEAL AND Tapped Holes Diffuser Plate

Figure 19 - BALANCE PISTON SEAL Figure 21 - BALANCE PISTON SEAL ASSEMBLY

Table 6 - BALANCE PISTON SEAL RING

REMOVING FRONT LOW-SPEED BEARINGS Bearing Housing

4. To remove the low-speed bearing, use (2) hook Front Low-Speed

REMOVING FRONT HIGH-SPEED BEARING

Figure 23 - LOW-SPEED THRUST BEARING

Figure 24 - LOW-SPEED THRUST BEARING Figure 27 - FRONT LOW-SPEED BEARING

LD22345 Figure 28 - LOW-SPEED BEARING REMOVED

Figure 26 - LOW-SPEED THRUST COLLAR Figure 29 - FRONT HIGH-SPEED BEARING

Figure 30 - ALL FRONT END BEARINGS

Figure 16 - DETAIL C – CHECKING AXIAL

Table 6 - BALANCE PISTON SEAL RING