Refrigerant Oil Calculation during Compressor Replacement

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1 Refrigerant Oil Calculation during Compressor Replacement Study Guide TMT: Dealer Education

2 2008 Navistar, Inc Winfield Road, Warrenville, IL All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of Navistar, Inc. 2

3 Refrigerant Oil Calculation During Compressor Replacement 1 Welcome to this Navistar training program on Refrigerant Oil Calculation During Compressor Replacement. To receive credit for completing this program, you are required to take a post-test on ISIS/Education/Service/Online Testing.

4 Objectives Identify background information on refrigerant oil level and its effect on system operation when it is not properly maintained. Perform the procedure for adding oil into the AC system during compressor replacement * There is no audio for this slide. 2 Upon completion of this training you will be able to: Identify background information on refrigerant oil level and its effect on system operation when it is not properly maintained. Perform the procedure for adding oil into the AC system during compressor replacement

5 Shop Safety Procedures 3 Before we begin inspection, diagnostics, and repair, keep in mind that proper service techniques, environmental concerns and safety are the most important parts of this process. Be sure to follow each warning, caution and note as they are presented throughout this training program. Warnings indicate procedures and safety measures that must be followed precisely, and to avoid damage to the vehicle, equipment or components. Cautions indicate procedure that you must follow exactly to avoid equipment or component damage. Notes indicate operations, procedures or instructions that are important for proper service.

Shop Safety Procedures Protect interior of

always protect the interior of the vehicle

6 Shop Safety Procedures Protect interior of vehicle by using A paper floor mat Steering wheel cover And seat covers. 4 When performing service work of any kind, always protect the interior of the vehicle by using: a paper floor mat steering wheel cover and a seat cover.

Set the parking brake and block the wheels.

7 Shop Safety Procedures To prevent personal injury or death Make sure the vehicle is parked on a flat surface. Set the parking brake and block the wheels. 5 Warning: Before beginning diagnostic or service procedures, always shift the transmission to park or neutral, set the parking brake and block the wheels.

8 Shop Safety Procedures To prevent personal injury or death perform service in a well ventilated, dry area. 6 Warning: Always provide proper ventilation when operating an engine in an enclosed area.

7 When working on the vehicle, keep the work area and tools as clean as

9 Shop Safety Procedures Keep tools and work area as clean as possible. Clean connections and fittings before removing components. 7 When working on the vehicle, keep the work area and tools as clean as possible. Also, clean all connections or fittings before disconnecting or removing components.

Shop Safety Procedures Use a suitable pan to catch fluids.

Know the location of properly rated and charged fire extinguishers.

All component and line openings should be immediately plugged during removal and

10 Shop Safety Procedures Use a suitable pan to catch fluids. Plug all line and component openings. Know the location of properly rated and charged fire extinguishers. 8 Use a suitable pan to catch any fluid when disconnecting components. All component and line openings should be immediately plugged during removal and remain so until re-installation to prevent contamination by dirt, moisture or other foreign material. Be sure that you know the location of properly rated and charged fire extinguishers.

Shop Safety Procedures Safety glasses Hearing

safety glasses with side shields, hearing protection,

11 Shop Safety Procedures Safety glasses Hearing protection Chemical-blocking nitrile gloves Know the location of eye wash station. 9 Warning: When working on the vehicle, always wear safety glasses with side shields, hearing protection, and chemical-blocking nitrile gloves. Be sure you know the location of an emergency eye wash station.

12 Introduction The correct volume of refrigerant oil in the A/C system is critical for proper system operation for the following reasons. Insufficient oil will result in compressor failure. Too much oil decreases cooling efficiency, resulting in poor system cooling performance. 10 The correct volume of refrigerant oil in the A/C system is critical for proper system operation for the following reasons: Insufficient oil will result in compressor failure. Excessive oil decreases cooling efficiency, resulting in poor system cooling performance.

13 Introduction During normal A/C operation oil circulates through the system with the refrigerant. Small amounts of oil are retained in each component. To maintain the proper oil level in a system that requires compressor replacement, the following steps should be performed. 11 During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. In order to maintain the proper oil level in an air conditioning system that requires compressor replacement, the following steps should be performed.

14 Compressor Failures There are two different failures that would cause compressor failure: Clutch failure Catastrophic failure * There is no audio for this slide. 12 There are two different failures that would cause compressor failure: Clutch failure Catastrophic failure

15 Replacement due to Clutch Failure 1. Recover the refrigerant. Measure and record the amount of oil removed during this process. 13 NOTE: The following procedure involves compressor replacement due to clutch failure (non-serviceable clutch compressors only). Recover the refrigerant from the air conditioning system. Measure and record the amount of oil removed during this process.

16 Replacement due to Clutch Failure 2. Remove the compressor. Drain, measure, and record the amount of oil. 14 Remove the compressor, Drain, measure and record the amount of refrigerant oil.

17 Replacement due to Clutch Failure 3. Drain and discard the shipping oil from the NEW compressor. 15 Drain and discard the shipping oil from the NEW compressor to be installed. Refer to ISIS to confirm the proper type of refrigerant oil for the vehicle.

18 Replacement due to Clutch Failure Reference the Air Conditioning System Specifications table in ISIS (manual s16019) for the vehicle being serviced to confirm the proper type of refrigerant oil. Oil calculation for clutch failure Amount of oil drained from the old compressor + Amount of oil removed during recovery process = Total NEW oil added to new compressor 16

19 Replacement due to Clutch Failure 4. Add NEW oil to the new compressor equal to the amount drained from the old compressor plus the amount removed during the recovery process. 5. Install the compressor. 17 Add NEW oil to the new compressor, equal to the amount drained from the old compressor plus the amount removed during the recovery process. Install the compressor.

20 Replacement due to Clutch Failure 6. Evacuate the system. 7. Charge the system. 8. Conduct a system performance test to verify proper operation of the air conditioning system. 18 Evacuate the system. NOTE: Vacuum should measure between 750 and 1000 microns. Refer to ISIS for the proper type and quantity of refrigerant for the vehicle and then charge the system. Finally, refer to ISIS to confirm the steps involved in the system performance test for the vehicle and conduct a test to verify proper system operation.

21 Replacement due to Catastrophic Failure Catastrophic compressor failure requires the replacement of the following components: The compressor The orifice tube or expansion valve The receiver drier, filter drier, or accumulator * If the remaining components are to be reused, they must be flushed and purged. 19 The following information involves refrigerant oil calculation when the compressor is being replaced due to catastrophic failure. When faced with catastrophic compressor failure, the following components must be replaced in addition to the compressor: the orifice tube or expansion valve the receiver drier, filter drier, or accumulator NOTE: If the remaining components are to be reused, they must be flushed and purged.

22 Replacement due to Catastrophic Failure Procedural Steps 1. Recover the refrigerant from the system. 2. Discard the oil captured during this process. 3. Disassemble the system. 4. If reused, flush and purge the condenser, evaporator, and hoses. 20 Follow this procedure when replacing a compressor due to catastrophic failure: Recover the refrigerant from the system and discard the oil captured during this process. Disassemble the system. Referencing the procedures found in ISIS, flush and purge: - the condenser - the evaporator - the hoses NOTE: This is necessary only if the components are reused.

Replacement due to Catastrophic Failure 5.

23 Replacement due to Catastrophic Failure 5. Replace either the receiver drier, filter drier, or accumulator with a new one. 21 Depending on how the vehicle is equipped, replace the appropriate component (receiver drier / filter drier / accumulator).

24 Replacement due to Catastrophic Failure 6. Replace the orifice tube or expansion valve with a new one. 22 Depending on how the vehicle is equipped, replace the appropriate component (orifice tube / expansion valve).

25 Replacement due to Catastrophic Failure 7. Drain and discard the shipping oil from the NEW compressor. 23 Drain and discard the shipping oil from the NEW compressor. Refer to ISIS to confirm the proper type of refrigerant oil for the vehicle as well as the full system quantity.

26 Replacement due to Catastrophic Failure Reference the Air Conditioning System Specifications table in ISIS (manual s16019) for the vehicle being serviced to confirm the proper type of refrigerant oil. Oil calculation for catastrophic failure Total System Refrigerant oil capacity fl. oz. (oil film left in compressor) = Total NEW oil added to new compressor 24

27 Replacement due to Catastrophic Failure 8. Add NEW oil to new compressor (equal to the total system capacity minus half an ounce to compensate for the oil film left in the compressor.) 25 Add NEW oil to the new compressor (equal to the total system capacity minus half an ounce to compensate for the oil film left in the compressor.)

28 Replacement due to Catastrophic Failure 9. Install the compressor. 10. Evacuate the system. 11. Charge the system. 12.Conduct a system performance test to verify proper operation of the air conditioning system. 26 Install the compressor. Evacuate the system. NOTE: Vacuum should measure between 750 and 1000 microns. Refer to ISIS for the proper type and quantity of refrigerant for the vehicle and then charge the system. Finally, refer to ISIS to confirm the steps involved in the system performance test for the vehicle and conduct a test to verify proper system operation.

29 Summary The correct volume of refrigerant oil is critical for proper system operation Incorrect volume can cause compressor failure and/or poor system performance There are two distinct procedures for refrigerant oil calculation depending upon the reason for compressor replacement 27 In summary, the key points discussed in this training program are as follows: The correct volume of refrigerant oil in the A/C system is critical for proper system operation. An incorrect volume can cause compressor failure and/or poor system cooling performance. There are two distinct procedures for refrigerant oil calculation depending on the reason for compressor replacement clutch failure and catastrophic failure

30 Conclusion 28 This concludes the Refrigerant Oil Calculation During Compressor Replacement training program. You are now required to take a post test via ISIS / Education / Service / Online Testing.

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