Unicla A Series User manual

TM
A Series
UP90 UP120 UP150 UP170
Compressor
Service Manual

Copyright ©2007 All rights reserved
No part of this document shall be reproduced in whole or in part without the permission of Unicla International Ltd. This
includes reproduction or copies in any form or by any means including photocopying, printing or electronic media.
IMPORTANT DISCLAIMER
This is a guideline document containing professional information using representative graphs, charts and tables.
Manufacturers’ specications must be consulted for specic guidelines and performance data. Unicla published data, specic to
all models, is available in promotional literature and from Unicla International Ltd on request or through your Unicla supplier.
Unicla International Ltd expressly disclaims all and any liability and responsibility to any person or business as a result of any
actions taken on the basis of information in this publication.
Table of contents:
1. Specications
UP90/UP120/UP150/UP170………………………………….…………1
Magnetic clutch …………………………………………………………2
Rear cap ………………………………………………………………….2
2. Component part list
I. Compressor part numbers ……………………………………………3
II. Exploded view …………………………………………………………4
3. Service
Service tools part numbers ……………………………………………5
Bolt torque specications ………………………………………………5
Service tools ………………………………………………………………6
Removal of clutch assembly ……………………………………………7
Magnetic clutch installation ……………………………………………8
Removal of lip seal ………………………………………………………9
Installation of lip seal ……………………………………………………9
Installation of lip seal continued ………………………………………10
Disassembly of body……………………………………………………10
Disassembly of body continued ………………………………………11
Assembly of body ………………………………………………………11
Assembly of body continued……………………………………………12
System oil quantity ……………………………………………………13
Oil type and grade ……………………………………………………13
®
A Group Compressor Service Manual

1.
Specications
Compressor Model UP-90
Number of cylinders 10
Displacement 92 cc/rev
Refrigerant HFC-134a
Initial oil charge 140 cc
Oil type Unidap 7 (PAG oil)
Weight without clutch 3.7 kg
Compressor Model UP-120
Number of cylinders 10
Displacement 119 cc/rev
Refrigerant HFC-134a
Initial oil charge 140 cc
Oil type Unidap 7 (PAG oil)
Weight without clutch 4.3 kg
Compressor Model UP-150
Number of cylinders 10
Displacement 145 cc/rev
Refrigerant HFC-134a
Initial oil charge 160 cc
Oil type Unidap 7 (PAG oil)
Weight without clutch 4.8 kg
Compressor Model UP-170
Number of cylinders 10
Displacement 172 cc/rev
Refrigerant HFC-134a
Initial oil charge 160 cc
Oil type Unidap 7 (PAG oil)
Weight without clutch 4.9 kg

2.
Magnetic clutch
Rear cap for UP90, 120, 150, 170
Rear caps and hose ports available for Unicla A series compressors
Clutches available for Unicla A series compressors - pulley diameter (mm) and voltage
Type 119 120 125 130 132 133 135 137 140 141 145 150 152 12V 24V
A Groove • • • • • •
AA Groove • • • • • •
B Groove • • • •
BB Groove • • • • •
4 Groove • • • • • •
5 Groove • • • • • •
6 Groove • • • • • • •
8 Groove • • •
10 Groove • • •
1. U = Vertical Hose Ports
2. D = Horizontal Hose Ports
3. FN = Flange Hose Ports
4. Relief valve is also available on the cap
5. Use the type no’s shown in each box when selecting compressor model
FN8FN1DO1
DO2
UO1
UO2
UO3
FN2 FN6
Cap type U DD FN
Hose port O ring O ring Flange
No
charging
ports
With
charging
ports
With
charging
ports

Compressor parts
3.
Item Description UP90 UP120 UP150 UP170 Qty
1 Body 21404-000690 21404-000700 21404-000102 21404-000092 1
2 Working assy 22010-000250 22010-000240 22010-000220 22010-000230 1
3 Suction valve plate 22602-000120 2
4 Front valve plate 22601-000052 1
5 Rear valve plate 1
6 Front gasket 93204-000060 1
7 Rear gasket 1
8 Lip seal assy 93503-000040 1
8-1 Snap ring 92503-000040B
8-2 Lip seal 92503-000040A
9 Felt seal 11950-10400 1
10 Felt ring 11961-10400 1
11 Plug 13201-000010 1
12 O ring 92501-000120 3
13 O ring 92501-000330 1
14 Rear cap see page 2 1
15 Charge Valve assy (H) 38101-000030 1
16 Charge Valve assy (L) 38101-000020 1
17 H Cap 12901-000030 1
18 L Cap 12901-000020 1
19 Relief valve 38305-000030 1
20 O ring 92501-000060 1
21 Bolt 91915-08035 4

4.
Exploded view
A SERIESA SERIES
A SERIESA SERIES

5.
Service tool part numbers
Bolt torque specications
No. Description Part number
1 Working assembly bench 03301- 00084A
2 Stand, rear mount 03301- 001170
3 Stand, front 03301- 00914A
4 Hub remover, clutch 03301- 000570
5 Pulley pad 03301- 010050
6 Remover, lip seal 03301- 001120
7 Installer, lip seal 03301- 000600
8 Shaft rotating handle 03301- 000610
9 Guide pin 03301- 000360
10 Guide sleeve 03301- 000620
11 Installer, pulley 03301- 000630
12 Socket, 10mm 03301- 000640
13 Socket, 6mm Hex 03301- 000650
14 Clutch wrench 03301- 000660
15 Torque wrench 03301- 000380
16 Snap ring pliers (Shaft) 03301- 000430
17 Snap ring pliers (Hole) 03301- 000420
18 Remover, pulley 03301- 000410
19 Plastic hammer 03301- 000390
20 Thickness guage 03301- 000400
Description Bolt diameter (mm) Tightening torque (N•m)
Housing cap bolts M8 14.7 ± 1
High/low service valve M12 11.7 ± 1
Blind plugs M12 11.7 ± 1
Clutch armature bolts M6 13.7 ± 1

6.
Service tools
03301- 00084A
03301-
000570
03301- 001170 03301- 00914A
- Genuine Unicla tools - Optional generic tools
1
403301-
000610
8
03301-
000620
10 03301-
000650
13 03301-
000660
14
03301-
000390
19
03301-
000640
12
03301-
000430
03301-
000380
1615 03301-
000420
17
03301-
000360
9
03301-
000410
03301-
010050
18
03301-
000630
11
2 3
03301-
000600
7
03301-
001120
6
03301-
000400
20
5

7.
Removal of clutch assembly
I. Removal of xing screw on armature
Tools required: • Stand • Clutch wrench
• Wrench • 10mm Socket
Procedure: Place the compressor on the stand. Hold clutch by
inserting the claws of the clutch wrench into the holes on the
armature. Remove the centre bolt by using the wrench.
II. Removal of armature
Tools required: • Hub remover • Wrench
Procedure: Pull the armature upwards.
III. Removal of snap ring
Tools required: • Snap ring pliers (shaft)
Procedure: Remove the snap ring with the snap ring pliers.
IV. Removal of pulley assembly
Tools required: •Remover, pulley •Wrench •Pulley pad
Procedure: Remove the pulley assembly with the remover.
V. Removal of coil (3 bolt type)
Tools required: • Standard screwdriver
Procedure: Remove 3 M5 bolts with screwdriver.
Removal of coil (snap ring type)
Tools required: • Snap ring pliers (shaft)
Procedure: Remove the snap ring with pliers as shown.
VI. Inspection of clutch components
1. Armature - Contact surface must be clean, smooth and
unmarked, with no abnormal scoring.
2. Pulley - Contact surface must be clean, smooth and
unmarked, with no abnormal scoring.
3. Coil - Wiring harness must be in good condition.
Armature
Pulley
Coil
Hub remover
Wrench
Clutch
wrench
Snap ring
Pulley
pad
Snap ring pliers
(+) Driver

8.
Magnetic clutch installation
I. Installation of coil (3 bolt type)
Tools required: • Stand • Standard screwdriver
Procedure: Tighten 3 M5 bolts (wire must be visible at 3 o’clock
position, when viewed from the front).
Tightening torque: 4.9 ±1 N•m
Installation of coil (snap ring type)
Tools required: • Stand • Snap ring pliers (shaft)
Procedure: Install the snap ring into the groove.
II. Installation of pulley
Tools required:• Pulley installer •Plastic hammer
Procedure: Place the pulley on the nose top and install it by
tapping on the installer until it stops. Do not tap if the pulley is
not located correctly.
III. Installation of clutch snap ring
Tools required: • Snap ring pliers (shaft)
Procedure: Install the snap ring into groove (tapered side up).
IV. Installation of shims and armature
Tools required: • Guide pin
Procedure: Install the guide pin into the centre threaded hole
of the shaft and select shims (T=0.1, 0.3 and 0.5mm) to ensure
the clutch clearance as in gure.
V. Installation of armature
Tools required: • Clutch wrench •Torque wrench
•10mm Socket
Procedure: Install the M6 bolt by holding the clutch wrench on
the holes (3 positions) on the armature.
Tightening torque: 13.7 ± 1 N•m
VI. Air gap
Tools required:• Thickness guage
Procedure: Ensure clutch clearance is correct all around.
(0.3mm≤ Gap ≤0.6mm)
(+) Driver
Wire
0.3≤ Gap ≤0.6
Snap ring pliers
Hammer
Pulley installer
Snap ring
Shims
Torque
wrench
Clutch
wrench
Thickness
gauge
Guide pin

9.
Removal of lip seal
Installation of lip seal
I. Removal of the felt ring
Tools required: • Lipseal remover
Procedure: Insert the remover into the recess of the felt seal
and turn around lightly and pull. Remove the felt on the shaft
by hooking with the needle tool.
II. Removal of snap ring
Tools required: • Snap ring pliers (hole)
Procedure: Remove the snap ring slowly with pliers as shown
in the gure.
III. Removal of lip seal
Tools required: • Lipseal remover
Procedure: Insert the remover into the recess of the seal and
turn around lightly and pull.
IV. Inspection of lip seal
1. Felt seal - should be dry.
2. Snap ring - must be in one piece and not deformed.
3. Lip seal - contact surface must be clean, smooth and
unmarked with no abnomal scoring.
I. Setting the guide sleeve
Tools required: • Stand •Guide sleeve •Seal installer
Procedure: Place compressor on the stand. Lubricate outside
of the guide sleeve and insert into the shaft of the compressor.
Caution - the sleeve must be clean and unmarked.
II. Installation of lip seal
Tools required: • Guide sleeve •Seal installer
Procedure: Slide the lipseal over the guide sleeve. Place the
installer on the lip seal correctly and press the lipseal with the
installer until it stops. Then remove the guide sleeve.
Lipseal
remover
Felt ring
1.
2. 3.
Lip seal
remover
Lip seal
1.
2. 3.

10.
Installation of lip seal - continued
Disassembly of the body
III. Assembly of the snap ring
Tools required: • Snap ring pliers (hole) •Seal installer
Procedure: Insert the snap ring into nose section (tapered
part of the snap ring must be facing downwards).
Push the snap ring downward with the installer, and t into
the groove.
IV. Assembly of the felt seal
Tools required: • Installer seal
Procedure: Install the felt seal into the nose section.
Push the felt seal until it touches the snap ring.
Caution - O-ring should not be reused.
I. Removal of oil
Procedure: Remove the drain plug and drain the oil.
II. Removal of lipseal (Refer to page 9 for instructions)
III. Removal of the bolts on rear cap
Tools required: • Socket wrench • Socket 6mm hex • Stand
Procedure: Remove the M8 securing bolts (4pcs) from the
rear cap.
IV. Removal of the rear cap
Procedure: Remove the rear cap by gently inserting a screw
driver or lever into the recess. Lever all around, not just at one
position.
Caution - Do not damage the cap or body.
Guide sleeve
Guide sleeve
Lipseal Seal
installer

11.
V. Removal of rear valve
Procedure: Remove gasket, valve plate and suction valve.
VI. Removal of front valve and working assembly
Procedure: Remove the working assembly by pressing the
end of the shaft into the front of the body as shown. After
removal of the cylinder, remove gasket, valve plate and
suction valve from the front side.
Assembly of the body
Disassembly of the body - continued
I. Installation of the O-ring for rear cap
Procedure: The o-ring must be free from marks and dust.
Thoroughly lubricate new o-ring properly and insert into
the groove. Ensure the o-ring is lying straight in the groove
without a twist.
II. Installation of rear valve plate and working assembly
Tools required: • Working assembly bench
Procedure: Stack suction plate, valve plate and gasket on
locating pins of rear cap in sequence as shown in the gure.
Place the working assembly on rear cap.
III. Installation of front valve plate and body
Tools required: • Working assembly bench
Procedure: Stack suction plate, valve plate and gasket on
locating pins of working assembly. Slide body over working
assembly until it stops on the working bench guide.
Gasket
Gasket
Gasket
Valve
plate
Valve
plate
Valve
plate
Suction
valve
Suction
valve
Suction
valve

12.
Assembly of the body - continued
IV. Inspection, tightening and clearance of the rear cap
Tools required: • Torque wrench • Hexagon socket 6mm
• Thickness guage
Procedure: Tension the M8 Hexagonal ange bolts (4pcs)
diagonally, alternately and carefully. Check the rear cap
clearance as specied: 0.2≤ Gap ≤0.6mm
Tightening torque: 14.7 ±1 N•m
V. Installation of lipseal (Refer to page 9 for instructions)
VI. Test working assembly rotation
Tools required: • Shaft rotating handle
Procedure: Install the handle into the front section to check
the shaft rotates smoothly.
VII. Filling compressor oil
Procedure: Fill the following amount of oil into the drain
hole as shown in the photo.
Ensure drain is correctly plugged.
Standard oil type: Unidap 7 (PAG) or Unidap 3 (POE)
Amount of oil:
UP150/170 = 160±10 cc
UP90/120 = 140±10 cc
VIII. Drain plug
Procedure: Tighten drain plug.
Tightening torque: 11.7 ±1 N•m
Gasket
Valve
plate
Suction
plate
Torque
wrench
Socket
Thickness gauge
Shaft
rotating
handle
0.2≤ Gap≤0.6mm

13.
System oil quantity
Oil type and grade
Storage guidelines
I. Evacuate compressor for 3 minutes and ll with nitrogen (N2) at 0.1 ~ 0.2 MPa.
II. Place the compressor in a clean and dry area with low humidity and tag with details.
III. Keep compressor away from direct sunlight.
IV. Store the compressor horizontally on a at, even surface.
V. Do not store the compressor in temperatures above 30˚C.
VI. Place the compressor in a well ventilated area to avoid corrosion damage.
*The contents of this manual are subject to change without prior notice.
The correct amount of oil must be maintained in the compressor and system. Long hose runs
and dual evaporator systems must have additional oil added to the system. Severe oil starvation
problems may result from insucient system oil being allowed. To determine oil quantity
required, Unicla recommends a calculation as a percentage of refrigerant charge as follows:
•20% for all A-group compressors (90-170cc) in standard applications where the
suction and discharge lines are less than 6 metres in length.
•30% for all A-group compressors (90-170cc) in applications where suction and
discharge lines exceed 6m in length.
Example: Calculate oil charge as 20% of refrigerant charge, 2 kg charge = 2000 g x 20% = 400
ml (cc) of oil. If tting a UP/UX170 compressor, then deduct the compressor initial oil charge to
determine amount of oil to be added. Therefore 400 – 160 = 240cc oil to be added to system.
Each Unicla A-Group compressor is tted with either PAG oil (Unidap 7) or POE oil (Unidap 3 is
tted to F-series compressors). When adding oil to the system, Unicla oil must be used.
Warranty is void if these guidelines are not followed.
The following labels will determine the type of oil in each A-group or F-series compressor:
POE type
(fitted to F-series
compressors)
PAG type
Compressor
Model
Refrigerant Oil Type
(Unicla)
Viscosity
@ 40˚C
Viscosity
@ 100˚C
Application Low side
Saturation
Oil
Separator
UP/UX
90/120/150/170
R134a Unidap 7 48.01 10.51 Airconditioning > 0˚C Optional
UPF
90/120/150/170
R404a Unidap 3 32.5 5.8 Airconditioning >15˚C Required

Notes:

Notes:

Unicla International Limited
Unit 1209-1210, 12F Manhattan Centre,
8 Kwai Cheong Rd, Kwai Chung, N.T.,
Hong Kong
Phone [phone]
Fax [phone]
Email: [email protected]
Website: www.unicla.hk
®
Unicla Cat. No. M1003