In heavy machinery and equipment, the air conditioning system has never been an optional comfort configuration, especially in high-temperature summer operations. Once the air conditioning compressor has a problem, the cab temperature will soar to 90°F or even above 100°F. Many people think that a broken compressor is nothing more than the air conditioning not working, but in fact, things are not that simple. A broken AC compressor not only cannot compress the refrigerant, but may also damage the entire air conditioning and refrigeration system, causing chain damage to parts such as the condenser, expansion valve, and evaporator. Repairing it is not just a matter of a few hundred dollars.
A stuck or depressurized compressor will cause the refrigerant to be unable to circulate, which will, in turn, affect the condenser, evaporator, and even the electronic control module. If you still want the air conditioner to run normally for a whole summer, don’t hesitate. If you find signs such as abnormal noise, no cooling, and frequent tripping and stopping of the compressor, you must act quickly. In this article, I will provide a detailed guide on AC compressor replacement so that you can solve this problem alone.
Air Conditioning Compressor Replacement Steps
If you want to replace the compressor well, it is not as simple as removing the old one and installing the new one. If you ignore the intermediate steps, not only will the new compressor not last long, but the entire system may be “hit” again.
1. Clean the System Thoroughly
If the compressor is scrapped due to internal burnout or mechanical jam, then you have to be careful – it is very likely that it has thrown black iron filings, colloidal residues, and dirty oil into the entire refrigerant system. At this time, the pipeline must be flushed clean with a special air-conditioning cleaning agent, and it cannot be dealt with by simply blowing or passing nitrogen.
- Pay special attention to the following points when cleaning:
- Remove the dryer or filter to avoid residue accumulation.
- If conditions permit, remove the condenser and evaporator and wash them separately.
- Repeatedly clean until the discharged cleaning fluid is clean and transparent.
Otherwise, once these impurities run into the new compressor, it is equivalent to stepping into a deep pit of secondary damage.
2. Vacuum Extraction
Many experienced maintenance technicians like to skip this step, but in fact, vacuuming is one of the most critical steps in the whole process. If there is residual air or moisture in the system, it will cause air blockage when the refrigerant is running, and it may also freeze on the evaporator and corrode internal components.
It is recommended to use a vacuum pump to continuously evacuate for at least 30-45 minutes until the pressure gauge pointer stabilizes below deep negative pressure (about 500 microns Hg). It’s really not okay to turn it off halfway through the pumping.
3. Add Oil to the New Compressor
Some newly purchased AC Compressors are “dry” and need you to add lubricating oil manually. Be sure to:
- Use special air conditioning oil (such as PAG or POE) that matches the refrigerant;
- The amount of filling should be in accordance with the instructions, not too much.
- Evenly distribute the lubricating oil at the inlet and outlet, and inside.
Excess oil will occupy the refrigerant space, resulting in abnormal system pressure; too little will cause the compressor to dry grind, and the life span will be directly halved.
4. Add Refrigerant
Next is to add refrigerant. Your experience might cheat you. The correct way is to use an electronic scale to accurately weigh and use a pressure gauge to monitor whether the high and low pressures of the system are normal. If you accidentally add too much or too little, not only will the cooling effect be poor, but the compressor will also easily explode due to overpressure. Here is something you should pay attention to:
- Follow the type of refrigerant marked on the equipment nameplate (commonly, such as R134a);
- In summer, when the temperature is high, the amount of filling can be slightly reduced to avoid overpressure in the system.
- Before starting the compressor, let it stand for a few minutes to allow the refrigerant and oil to be fully distributed.
Conclusion
You don’t have to replace the AC Compressor every year, but you have to know that the life of the compressor is limited, especially for equipment that runs on the construction site every day and is exposed to high temperatures. If you wait until it is completely broken before repairing it, you may even need to replace the air conditioning system.
I believe you can now judge whether your air conditioning compressor needs to be replaced, and you can also replace it yourself under the guidance of this article. I hope you have a smooth driving summer!
