Service bulletin – Compressor repairs

To: Reefer technicians and EMR managers

From: Star Cool Service Team

Date: 13th of January 2009

Regarding: Replacement of valve plates

A lack of performance of the compressor is often due to leaking/damaged valve plates.

Sometimes you can avoid replacing the complete compressor. It is now possible to replace the
valve plates only if the following conditions have been met.

What to check:

1. Check refrigerant level. Low level?

- If yes, check for leaks, repair and recharge unit.
- No, then proceed.

2. Check hot gas valve. Is it warm on both sides of the valve in normal operation?
-If yes, then the valve is leaking and must be fixed before proceeding
- No, then proceed.

3. Has the compressor got an abnormal loud noise?

(Please make sure to check it in a normal running condition, without slugging)
- Yes, replace the complete compressor.
- No, then proceed.

4. Run a „Function test/compressor step” (PTI menu)

: Testing valve leaks
: Alarm- 8xx, will be shown in the display
- If compressor fails the test, troubleshoot using the manual. If conclusion is a compressor
problem then check the valve plates. Valve plates for low pressure stage is located on the
front of the compressor and valve plates for high pressure stage is located on the back of
the compressor.

When replacing valve plates only:

1. Make sure to replace the valve plates according to the instruction on the next page.

2. Only use 818601B for the low pressure stage (marked LP) and 818602B for the high
pressure stage (marked HP).

3. Check pistons and cylinder liner for damages. If damaged, replace complete compressor.

Sight glass, oil filter, oil plug, cylinder heads, gaskets and various connectors can
also be replaced without replacing the complete compressor.

________________________________________________________________________________________________________________________

Bjerndrupvej 47 • 6360 Tinglev, Denmark • Phone: +45 7364 3400 • Fax: +45 7364 3569
CVR/SE no.: 13 82 37 74 • starcool@starcool.dk • www.starcool.dk
 Service bulletin

Replacement of compressor valve plate / cylinder head gasket

1. Depressurize the compressor

2. Dismount cylinder head and valve plate (using a rubber mallet, if necessary). Carefully clean
all sealing surfaces.

3. Check valve plate; Exchange entire valve plate if damaged. Determine the cause and
eliminate it.

4. Mount the cylinder head, valve plate and new gaskets correctly. If located in an
inconvenient mounting position, use mounting pins.

5. Tighten the bolts in the illustrated sequence in two steps. Starting with bolt no. 1 and no. 2
tightened firmly by hand, and then in sequence no. 3 to no. 10 by tightening torque: 70Nm
(see bolt numbers on fig. below).

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