Unicla UX330 User manual

UX330
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
UX330 ………………………………………………………….…………1
Magnetic clutch …………………………………………………………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
Disassembly and reassembly procedures ……………………………7
Magnetic clutch installation …………………………………………… 8
Removal of lip seal ………………………………………………………9
Installation of lip seal …………………………………………………9
Installation of lip seal continued ……………………………………10
Disassembly of the body……………………………………………10
Assembly of the body………………………………………………… 11
Assembly of the body continued …………………………………… 12
System oil quantity ……………………………………………………13
Oil type and grade ……………………………………………………13
®
UX330 Compressor Service Manual

1.
Compressor UX330
Compressor Model UX-330
Number of cylinders 10
Displacement 330 cc/rev
Refrigerant HFC-134a
Maximum continuous speed 4500 rpm
Initial oil charge 600 cc
Oil type PAG or POE
Voltage DC 12/24 volt
Weight without clutch 11.5 kg

Diameter ø168
2.
Magnetic clutches
Diameter ø168
Diameter ø178

Compressor parts
3.
No. Description Part number Qty
1 Body 21405-000740 1
2 Front cap 21510-000012 1
3 Working assembly 22010-000430 1
4 Suction valve 22602-000010 2
5 Valve plate assembly 22601-000010 2
6 Gasket 93204-000030 2
7 Rear cap 21505-000260 1
8 Sight glass 35801-000010 2
9 Nipple 42203-000161 1
10 Relief valve 38305-000030 1
11 Plug 13201-000010 2
12 Lip seal assembly 92503-000050 1
13 Felt 11950-11000 1
14 Charge valve (H) 38101-000030 1
15 Charge valve (L) 38101-000020 1
16 O-ring (S115) 92501-00190 2
17 O-ring (S11.2) 92501-000120 2
18 O-ring (P22) 92501-000070 3
19 Screw (M10 x 30) 91015-10030 5
20 Screw (M10 x 35) 91915-10035 5
21 O-ring (P18) 92501-000090 1

4.
Exploded view
21
18
UX330UX330
UX330UX330
1
3

5.
Service tool part numbers
Bolt torque specications
No. Description Part number
1 Working installer 03301- 000290
2 Stand 03301- 000310
3 Installer ring & seal 03301- 000320
4 Remover seal 03301- 001000
5 Shaft rotating handle 03301- 000340
6 Clutch wrench 03301- 000370
7 Torque wrench 03301- 000380
8 Installer pulley 03301- 000350
9 Guide sleeve 03301- 000330
10 Guide pin 03301- 000360
11 Armature Remover 03301 - 010010
12 Pulley remover pad 03301- 010050
13 Pulley remover 03301-000410
14 Thickness guage 03301-000400
15 M10 Hexagonal socket 03301- 000450
16 M8 Socket 03301- 000440
17 Plastic hammer 03301- 000390
18 Snap ring pliers (Shaft) 03301- 000430
19 Snap ring pliers (Hole) 03301- 000420
Description Bolt diameter (mm) Tightening torque (N•m)Housing cap bolts M10 x P1.5 34.3 ± 1
High/low service valve M12 x P1.0 11.7 ± 1
High/low pressure port M8 x P1.25 24.5 ± 1
Clutch coil bolts M6 x P1.0 5.9 ± 1
Clutch armature bolts M8 x P1.25 19.6 ± 1

6.
Service tools
03301- 000290
03301- 000340
03301-
000330
03301-
000410
03301- 000310
03301- 000370
03301-
000360
03301-
010010
03301-
000450
03301- 000390
03301-
010050
03301-
000320
03301- 000380
03301-
000440
03301-
000430
03301-
001000
03301-
000350
03301-
000400
03301-
000420
- Genuine Unicla tools - Optional generic tools
1
5
9
15 1716 18 19
10 11 1312 14
6 7 8
2 3 4
< optional

7.
Disassembly & reassembly procedure
I. Removal of magnetic clutch
Tools required: • Stand • Clutch wrench
• Torque wrench • M8 Socket
Procedure: Place the compressor on the stand.
Hold clutch wrench by inserting the claws of the clutch
wrench into the holes on the armature (3 points).
Remove the centre bolt by using the torque wrench.
Pull the armature upwards
II. Removal of snap ring
Tools required: • Snap ring pliers (shaft)
Procedure: Remove the snap ring by the snap ring pliers
as shown
III. Removal of pulley
Tools required: • Pulley remover • Standard wrench
• Pulley remover pad
IV. Removal of coil
Tools required: • Standard screwdriver
Procedure: Remove 3 M6 bolts with screwdriver
V. Inspection of magnetic clutch components
Armature - Contact surfaces must be clean, smooth and
unmarked, with no abnormal scoring
Pulley - As above. Ensure bearings run smoothly
Coil - Wiring harness must be in good condition
Clutch
wrench
Armature
Shim
Snap ring
(+) Driver
Armature Pulley Coil

8.
Magnetic clutch installation
I. Installation of coil
Tools required: • Stand • Standard screwdriver
Procedure: Tighten 3 bolts (wire must be visible at 3
o’clock position, when viewed from the front).
Tightening torque: 5.9 ±1 N•mII. 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 key and snap ring
Tools required: • Snap ring pliers (shaft)
Procedure: Install the snap ring into the 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
•M8 Socket
Procedure: Place washers and spring washers on M8 by
holding the clutch wrench on the holes (3 positions) on
the armature. Tightening torque: 19.6 ± 1 N•mVI. Air gap
Tools required:• Thickness guage
Procedure: Ensure clutch clearance is correct all around.
(0.3mm≤ gap ≤0.6mm)
(+) Driver
Wire
Installer
Snap ring
Clutch key
Shims
0.3≤ Gap ≤0.6

9.
Removal of lip seal
Installation of lip seal
I. Removal of the felt
Procedure: Removal of the felt on the shaft by hooking
with the slender bar.
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 lip seal into the recess as shown in
the gure, turn around lightly and pull out.
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.
I. Setting the guide sleeve
Tools required: • Stand •Guide sleeve
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 •Lipseal installer
Procedure: Slice the lipseal over the guide sleeve. Place the
remover on the lip seal correctly and press the lipseal with
the remover until it stops. Then remove the guide sleeve.
Bar
Remover
Felt Snap ring Lipseal
Guide sleeve
Lipseal

10.
Installation of lip seal - continued
Disassembly of the body
III. Assembly of the snap ring
Tools required: • Snap ring pliers (hole) •Installer ring
Procedure: Insert the snap ring into nose section (tapered
part of the snap ring must be facing downwards as shown in
photo). Push the snap ring downward with the remover, and
t into groove.
IV. Assembly of the felt seal
Tools required: • Installer ring
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 (hexagon) 10mm • Stand
Procedure: Remove the M10 securing bolts (5pcs) 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 end of front cap and body.
(-) Driver

11.
V. Removal of rear valve
Procedure: Remove gasket, valve plate and suction valve.
Remove the working assembly by pressing the end of the
shaft into the front of the body as shown.
VI. Removal of front valve and working assembly
Procedure: After removal of the cylinder, remove gasket,
valve plate and suction valve from the front side.
Assembly of the body
I. Installation of the O-ring for front and 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 the front cap
Tools required: • Torque wrench
Procedure: Place the body with front section facing upward.
Place the front cap on the body (be careful not to twist the
o-ring). Tighten M10 bolts (5pcs) with torque wrench.
Tightening torque: 34.3 ±1 N•mIII. Installation of the front valve plate and body
Tools required: • Working assembly bench
Procedure: Place the working assembly on locating pins.
Stack the suction plate, the valve plate and gasket on
locating pins in sequence as shown in the gure. Carefully
lower the body over the working assembly until it stops next
to the working bench guide.
Working assembly
Gasket
Valve plate
Suction plate
O-ring
5-M10
Bolt
Front
cap
Gasket
Valve
plate
Suction
plate

12.
Assembly of the body - continued
IV. Installation of the rear valve plate and rear cap
Tools required: • Stand
Procedure: Place the body in an inverted position on the
stand and stack the suction plate, valve plate and gasket in
the gure. Thoroughly lubricate and install the o-ring into
the rear cap groove. Ensure the o-ring is lying straight in the
groove without any twists.
V. Inspection, tightening and clearance of the rear cap
Tools required: • Torque wrench • Hexagon socket
• Thickness guage
Procedure: Tension the M10 Hexagonal ange bolts (5pcs)
diagonally, alternately and carefully. Check the rear cap
clearance as specied: 0.3≤ Gap ≤1.2mm
Tightening torque: 34.3 ±1 N•mVI. Installation of lipseal (Refer to page 9 for instructions)
VII. Test working assembly rotation
Tools required: • Shaft rotating handle
Procedure: Install the handle into the front section to check
the shaft rotates smoothly.
VIII. Filling compressor oil
Procedure: Fill the following amount of oil from the low
pressure charge port as shown in the photo.
Ensure drain correctly plugged.
Standard oil type: Unidap 7 (PAG) or Unidap 6 (POE)
Amount of oil = 600±10 cc
IX. Plug cap on oil port
Procedure: Tighten high/low pressure port caps with M8
bolts.
Tightening torque: 24.5 ±1 N•m
Bench
guide
Valve
plate
Rear cap
Gasket
Suction
plate
5-M10
bolt
0.3≤
Gap
≤0.6
Shaft rotating
handle
PAG or POE
4-M8 Bolts

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 Unicla UX330 compressors in standard applications where the suction and
discharge lines are less than 6 metres in length.
•30% for Unicla UX330 compressors in applications where suction and discharge lines
exceed 6m in length.
Example:
Calculate oil charge as 20% of refrigerant charge, 5 kg charge = 5000 g x 20% = 1000 ml (cc) of
oil. If tting a UX330 compressor, then deduct the compressor initial oil charge to determine
amount of oil to be added. Therefore 1000 – 600 = 400cc oil to be added to system.
Each Unicla UX330 is tted with either PAG oil (Unidap 7) or POE oil (Unidap 6). 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 UX330 compressor:
POE type PAG type
Compressor
Model
Refrigerant Oil Type
(Unicla)
Viscosity @
40˚C
Viscosity @
100˚C
Application Low side
Saturation
Oil Separator
UX330 R134a Unidap 7 48.01 10.51 Airconditioning > 0˚C Optional
UX330 R134a Unidap 6 65.5 9.3 Airconditioning >0˚C Optional

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. M1001