MODELS JG43, JG63, JG83 JG44, JG64, JG84

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1 MODEL J STYLE G HERMETIC COMPRESSORS RENEWAL PARTS Supersedes: RP4 (695) Form RP4 (1298) MODELS JG43, JG63, JG83 JG44, JG64, JG84 (See Page 2 for Complete Model Nomenclature) 27531A

2 UNIT NOMENCLATURE COMPRESSOR IDENTIFICATION Each compressor is identified by nomenclature as shown below. The nomenclature is printed on a data plate which is located near the oil pump as shown in Fig. 1. When contacting the factory or ordering renewal parts, include the complete Nomenclature, Serial Number, and Date Code. Be sure that these numbers are copied accurately. LD03309 LD03063 FIG. 1 COMPRESSOR DATA PLATE J G M 46/50 S Compressor Series Style G Motor Vendor L = Leroy Somer S = A.O. Smith Number of Cylinders Motor Voltage Code 4, 6, or 8 17 = /59 = / = Displacement Code 46/50 = /380/ = Short Stroke 58/70 = / = Long Stroke 63 = = = Number of Unloaders 36 = = (8 Cyl. Compr.) - % Loading: 100,75,50,25 2 = (8 Cyl. Compr.) - % Loading: 100,75,50 2 = (6 Cyl. Compr.) - % Loading: 100,66,33 1 = (8 Cyl. Compr.) - % Loading: 100,75 Motor Size Code 1 = (6 Cyl. Compr.) - % Loading: 100,66 M, N, P, Q, S, T or V 1 = (4 Cyl. Compr.) - % Loading: 100,50 0 = (All Comprs.) - % Loading: YORK INTERNATIONAL

3 FORM RP4 LD03720 FIG. 2 COMPRESSOR LD03721 YORK INTERNATIONAL 3

4 FIG. 3 MANIFOLD ARRANGEMENTS LD03064 ITEM COMPRESSOR DESCRIPTION NO. 4 CYLINDER 6 CYLINDER 8 CYLINDER 1 Housing, Compressor Head Compressor Gasket, Head No. Required Per Compressor Screw, Head No. Required Per Compressor Cover, Motor Gasket, Motor Cover Screw, 1/2 Hex Cap No. Required Per Compressor Lockwasher, Helic. Spring No. Required Per Compressor Stud, 1/ No. Required Per Compressor Nut, 1/2 Hex No. Required Per Compressor Washer Clipped Circular No. Required Per Compressor Screen, Suction (See Item 57 for Gasket) 13 Manifold, Discharge Gasket, Discharge Manifold No. Required Per Compressor Screw, 3/8 Hex Cap No. Required Per Compressor Washer No. Required Per Compressor Screw, 3/8 Hex Flange No. Required Per Compressor 4 18 Screw, 3/8 Hex Flange No. Required Per Compressor 4 19 Screw, 3/8 Hex Flange No. Required Per Compressor Bearing Head Oil Pump End See Figure 9 21 Gasket, Bearing Head Oil Pump End Screw, Hex Flange No. Required Per Compressor YORK INTERNATIONAL

5 FORM RP4 ITEM COMPRESSOR DESCRIPTION NO. 4 CYLINDER 6 CYLINDER 8 CYLINDER 23 Head, Bearing Assembly Motor End See Figure 9 24 Screw, 7/16 Hex No. Required Per Compressor Pump, Oil Gasket, Oil Pump Screw, Hex Flange No. Required Per Compressor Crankshaft Stroke Stroke Washer, Thrust* Motor See Table 2 31 Key, Motor Washer, Shaft Screw, 5/8 Hex Cap Lockwasher, Shaft Screen, Oil Strainer Retaining Compound, Loctite (Use with Item 35) 37 Valve, Relief (Not Shown) No. Required Per Compressor Device, Unloader See Figure 4 No. Required Per Compressor See Table 1 39 Valve, Solenoid No. Required Per Compressor See Table 1 40 Coil, Solenoid Less Valve 120 Volt Volt No. Required Per Compressor See Table 1 41 Gasket, Solenoid Valve No. Required Per Compressor Screw, 3/8 Hex Cap No. Required Per Compressor Cover, Access No. Required Per Compressor Pin, Coiled Spring No. Required Per Compressor Screw, 7/16 Hex Flange No. Required Per Compressor Cover, Handhole No. Required Per Compressor Valve Cage Assembly (Discharge) See Figure 5 48 Screw, Discharge Valve Cage No. Required Per Compressor Plate, Valve Suction See Figure 6 50 Sleeve, Cylinder No. Required Per Compressor Seal, O-Ring No. Required Per Compressor Cylinders Used On 1 & 2 1, 2, 5 & 6 3, 4, 5, 6, 7 & 8 *Not shown in Cut-away. Located at motor end bearings only. YORK INTERNATIONAL 5

6 LEGEND (Cont d.) ITEM COMPRESSOR DESCRIPTION NO. 4 CYLINDER 6 CYLINDER 8 CYLINDER 52 Piston Assembly See Figure 7 53 Connecting Rod Assembly See Figure 8 54 Terminal Box See Figure Valve, Suction Stop Screw, 5/8 Hex Cap No. Required Per Compressor Gasket (2 Required) Valve, Discharge Stop Screw, 5/8 Hex Cap No. Required Per Valve Gasket Sight Glass, Oil (2 Required) Sealer, Refrigerant Pipe Valve, Oil Charging Cap, Oil Charging Valve Valve, Oil Check, 1/ Crankcase Heater 120V V Heat Conductive Compound Drain Orifice Plug (Not Shown) No. Required Per Compressor Pipe Plug, 1/4 Square Hd (Not Shown) No. Required Per Compressor Pipe Plug, 3/ A Oil Temp Sensor Pipe Plug, Magnetic Sq Hd * Cover Plate, Blank * Used to replace Solenoid Valves for reduced steps of unloading. See Table 1. 6 YORK INTERNATIONAL

7 FORM RP4 LD02968 ITEM DESCRIPTION PART NO. NO. 38 Unloader, Blocked Suction 38A Piston B Washer, Seal C Screw, Cap Hex Socket Head D Sealer, Loctite Grade AVV E Washer, Plain Special F Ring, Compression FIG. 4 UNLOADING DEVICE TABLE 1 PART QUANTITIES FOR REDUCED STEPS OF UNLOADING QUANTITY (Part Quantities Vary, as Shown, with Steps of Unloading) ITEM NO. NUMBER OF UNLOADERS W (4 Cylinder) 1 0 N/A N/A 72 (6 Cylinder) N/A 72 (8 Cylinder) N/A = Not Available YORK INTERNATIONAL 7

8 PRE 1996 DISCHARGE ASSY. LD03722 ITEM NO. DESCRIPTION PART NUMBER 47 Cage, Discharge Valve Assembly Includes A, B, C, D, E, & F 47A Cage, Discharge Valve B Plate, Inner Valve C Valve, Discharge D Screw, 3/8 Button Head Cap E Nut, 3/8 Hex Self Locking F Spring, Helical No. Req d. Per Valve Ass y 6 *Not Shown CURRENT DISCHARGE ASSY. 47B 47C 47A 47D 47E 47F 28953A ITEM NO. DESCRIPTION PART NUMBER s 47 Cage, Discharge Valve Assembly Includes A, B, C, D, E, & F 47A Cage, Discharge Valve B Plate, Inner Valve C Ring, Discharge Valve D Screw, 3/8 Button Head Cap E Nut, 3/8 Hex Self Locking F Spring, Helical No. Req d. Per Valve Ass y 6 S = Recommended Stock Spare Part FIG. 5 DISCHARGE VALVE CAGE ASSEMBLY 8 YORK INTERNATIONAL

9 FORM RP4 49A SUCTION VALVE PLATE (1) 49B SUCTION VALVE (1) (VALVE RING) CLIPS (2) (OPTIONAL) USER SUPPLIED C WAVE SPRINGS (2) (WAVE RING) (Packs of 2) 28636A(R) WAVE SPRING SUCTION VALVE ASSEMBLY ITEM NO. DESCRIPTION PART NUMBER WAVE ASS Y S 49 Plate, Suction Valve Assembly Includes Items A, B, & C 49A Plate, Valve B Ring, Suction Valve C Spring (Package of 2 Waves) No. Req d. Per Valve Ass y 2 (Wave) S = Recommended Stock Spare Part FIG. 6 SUCTION VALVE PLATE ASSEMBLY YORK INTERNATIONAL 9

10 52A 52C 52B 52D LD03066 ITEM NO. DESCRIPTION PART NUMBER 52 Piston Assembly Includes A, B, C, & D 52A Piston, Bare B Ring, Piston (2 Req d. Per Piston) C Pin, Piston D Retainer (2 Req d. Per Piston) FIG. 7 PISTON ASSEMBLY 53C 53 53A 53B NOTE: NEW DRILLED RODS (Wrist Pin Lube) may be mixed w/ undrilled on R-22 applications only a ITEM PART NUMBER DESCRIPTION NO. SHORT STROKE LONG STROKE 53 Connecting Rod Assembly (with Wrist Pin Lube Circuit required for POE Lubricants) Includes Items A, B, & C (Replaces Rod Assembly) (Undrilled) A Screw, 5/16 Hex Cap No. Req d. Per Connecting Rod B Washer (Package of 10) No. Req d. Per Connecting Rod C Dowel Pin No. Req d. Per Connecting Rod 2 2 FIG. 8 CONNECTING ROD ASSEMBLY 10 YORK INTERNATIONAL

11 FORM RP4 LD03723 PUMP END ITEM NO. DESCRIPTION PART NUMBER BEARING HEAD OIL PUMP END 20 Head, Bearing Assembly (Oil Pump End) Includes A, B, C, D, E, & F 20A Bearing, Crankshaft B Pipe Plug, 3/8 Hex Socket C Pipe Plug, 1/8 Hex Socket D Sealer, Loctite Grade AVV (Use with Items 20B and 20C) 20E Pipe Plug, 1/4 Square Head F Sealer, Removable Thread (Use with Item 20E) Head, Bearing (Oil Pump End) (Does Not Include Items A, B, C, D, E & F) LD03724 MOTOR END FIG. 9 BEARING HEADS ITEM NO. DESCRIPTION PART NUMBER BEARING HEAD MOTOR END 23 Head, Bearing Assembly (Motor End) Includes A, B, C, D, E, F & G) 23A Bearing, Crankshaft (2 Required) B Cap, Seal, Oil Relief Valve (See Insert A) C Plunger, Oil Relief Valve (See Insert A) D Spring, Helical (See Insert A) E Plug, Pipe Flush Type Hex Socket F Sealer, Loctite Grade AVV (Use with Item 23E) G Pin, Slot 1/8 Spring Head, Bearing (Motor End) (Does Not Include Items A, B, C, D, E, F & G) YORK INTERNATIONAL 11

12 LD03725 FIG. 10 TERMINAL BOX LD YORK INTERNATIONAL

13 FORM RP4 ITEM NO. DESCRIPTION QUANTITY PART NO. 54 Terminal Box A Cover, Terminal Box B Screw, Tap C Lockwasher, Internal Tooth D Screw, Pan Head E Screw, 3/8 Hex Flange F Lockwasher, 3/8 Internal Tooth G Washer, Plain, 7/16 ID x 1 OD H Bolt, Terminal I Gasket, Terminal Bolt, 13/16 OD J Washer, Terminal Bolt (Package of 10) No. of Washers Req d Per Compressor 12 54K Washer, Plain L Nut, 7/16 Hex (Package of 6) No. of Nuts Req d Per Compressor 18 54M Lockwasher, 7/16 Internal Tooth N Screw, Cap Hex Soc Hd (Package of 5) No. of Screws Req d. Per Compressor 4 54O Terminal, Overload P Washer, Plain, 3/16 ID (Package of 5) No. of Washers Req d. Per Compressor 4 54Q Seal, O-Ring, 5/32 ID R Washer, Terminal (Package of 10) No. of Washers Req d. Per Compressor 8 54S Nut, Hex, Machine Screw T Terminal Block U Gasket, Terminal Block V Spacer, Insulating W Terminal Block, Flat Base See Table X Terminal Block End Y Bar, Jumper* Z Module, Motor Protector; Control Voltage: 1 24V V Dual Voltage, Auto Reset V Dual Voltage, Auto Reset * (Not Shown) Used in Across-the-Line Applications. FIG. 10 TERMINAL BOX (Cont d.) YORK INTERNATIONAL 13

14 FIG. 11 CRANKCASE FLOAT LD03067 ITEM NO. DESCRIPTION PART NO. CRANKCASE FLOAT Includes: Float Assembly Cover, Handhole Adaptor Valve Body Lever, Float Valve, Float Pin, Valve Pin, Lever Ball, Float Nut-Hex Self-Locking (Pkg. of 5) Lockwasher Nut, Hex Jam (Package of 10) Pin, Roll (Package of 5) Gasket, Copper TABLE 2 REPLACEMENT MOTORS (ROTORS & STATOR) 1 VOLTAGE VOLT MOTOR SIZE CODE 2 CODE M N P Q S T V / / /380/ / / / NOTES: 1. As Indicated by sixth digit of model. Replacement motor must be the same size code and voltage code as the original motor. Rotors and stators are not available separately. Replacement motors include Item 54H, Fig. 10, Page 13.) 2. The unused protector leads should be cut off in the area where they exit the bundle. They should be cut off at different lengths (approximately 1/4" difference) to prevent the bare ends from touching one another. The remaining portion of the unused protector leads must then be ty-rapped rigidly to the stator coils to prevent the exposed ends from touching any other component. YORK REMANUFACTURED COMPRESSORS ARE AVAILABLE FROM THE YORK REMANUFACTURING FACILITY IN WHEELING, ILLINOIS. FOR PRICES AND/OR AVAILABILITY, CALL OR FAX FOR AFTER HOURS EMERGENCY SERVICE, CALL YORK INTERNATIONAL

15 FORM RP4 TABLE 3 SERVICE AIDS GASKET KIT** VALVE BEARING STATOR ROTOR COMPRESSOR MODEL RETAINING REMOVAL REMOVAL MANDREL* 4 CYLINDER 6 CYLINDER 8 CYLINDER CLIP TOOL TOOL * Screws Into End of Crankshaft to Aid in Removing / Installing Rotor ** Depending on application, not all gaskets may be required. TOP HEAD VALVE REPLACEMENT KITS & TOP HEAD OVERHAUL KITS The price of the kits shown below is less than the total price of the individual parts. These kits provide a convenient, economical method of ordering replacement parts. Each Top Head Valve Replacement Kit listed in Table 4 contains the suction and discharge valves, springs, gaskets, screws and nuts that are recommended to be replaced when a valve replacement is required. Each Top Head Overhaul Kit listed in Table 5 contains the suction valves, suction springs, suction valve plates, discharge valve cage assemblies, gaskets, bolts and lockwashers that are recommended to be replaced when a top head overhaul in necessary. Each kit has all of the recommended parts to service the valves located under one head (2 cylinders per head) for each compressor listed. A threaded torque value table is included with each kit. If servicing a complete compressor, order the quantities as listed in the table. Valve replacement should be done annually or every 5,000 hours of running time. Depending on application, all gaskets may not be required that come in the kits. TABLE 4 TOP HEAD VALVE REPLACEMENT KIT KIT PART NO , COIL* EACH KIT NO. OF KITS REQUIRED CONTAINS PER COMPRESSOR (Parts for 2 cylinders) 4 CYL 6 CYL 8 CYL Suction Valve Discharge Valve Suction Valve Springs Discharge Valve Springs Top Head Gasket Discharge Manifold Gasket TABLE 5 TOP HEAD OVERHAUL KIT KIT PART NO , WAVE EACH KIT NO. OF KITS REQUIRED CONTAINS PER COMPRESSOR (Parts for 2 cylinders) 4 CYL 6 CYL 8 CYL Suction Valve, Plate & Spgs Dschg. Valve Cage Assmbly Top Head Gasket Discharge Manifold Gasket * Order parts separately for Wave Spring Replacements. See page 8. YORK INTERNATIONAL 15

16 Proud Sponsor of the 2000 U.S. Olympic Team 36USC380 P.O. Box 1592, York, Pennsylvania USA Copyright by York International Corporation 1999 Form RP4 (1298) Supersedes: RP4 (695) Subject to change without notice. Printed in USA ALL RIGHTS RESERVED

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