R-124 MANUAL LOKRING W

Transcription

1 R-124 TECHNICAL SERVICE MANUAL TRAINING MANUAL LOKRING LOKRING Tube Tube Connection Connection System System W

2 FORWARD This Whirlpool Technical Training Manual, (Part No. W ), provides the In-Home Service Professional with training information for the LOKRING Tube Connection System. The Wiring Diagrams used in this Service Manual are typical and should be used for training purposes only. Always use the Manuals and Literature provided with the individual tools and equipment when performing repairs. Always use the Tech Sheet and Wiring Diagrams supplied with the product when servicing the refrigerator. For specific operating and installation information on the model being serviced, refer to the Use and Care Guide or Installation Instructions provided with the refrigerator. GOALS AND OBJECTIVES The goal of this Service Manual is to provide information that will enable the In-Home Service Professional to properly use the LOKRING Tube Connection System to repair refrigerator sealed sytems in the Whirlpool family of brands. The objectives of this Service Manual are to: Understand and follow proper safety precautions. Successfully perform necessary repairs. Successfully return the refrigerator to its proper operational status. WHIRLPOOL CORPORATION assumes no responsibility for any repairs made on our products by anyone other than authorized In-Home Service Professionals. LOKRING is a registered trademark of Lokring Technology, LLC, used with permission. ii LOKRING Tube Connection System Copyright 2017, Whirlpool Corporation, Benton Harbor, MI 49022

3 LOKRING Tube Connection System LOKRING REPAIR PROCEDURE TABLE OF CONTENTS REFRIGERATOR SAFETY OVERVIEW PRINCIPAL OF OPERATION TOOLS AND MATERIAL HAND ASSEMBLY TOOL ASSEMBLING A LOKRING FITTING ASSEMBLING A LOKRING FITTING ONTO A CAPILLARY TUBE ASSEMBLING A LOKRING FITTING ONE SIDE ASSEMBLING A LOKRING FITTING SHORT STUB QUALITY WORK PROCESSES LOKRING Tube Connection System iii

4 Refrigerator Safety LOKRING Repair Procedure Your safety and the safety of others are very important. We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word DANGER or WARNING. These words mean: DANGER You can be killed or seriously injured if you don't immediately follow instructions. WARNING You can be killed or seriously injured if you don't follow instructions. All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed. LOKRING Tube Connection System 1-1

5 Principle of Operation Overview Lokring is the only Whirlpool non brazing tool approved for sealed systems. The Lokring Tube Connection System hermetically joins sealed system tubing, without the need for a torch or solder. The system can make connections anywhere in the refrigerator. It is able to join tubes of any type, including dissimilar metals and thicknesses. The ability to join sealed system tubing without a flame is critical when working on sealed systems with flammable refrigerant (R600a). Lokring is also beneficial for use with traditional refrigerants, reducing repair time and repair defects. The system is capable of making connections anywhere in the refrigerator and is easy to learn, even for new technicians. Principle of Operation The Lokring system uses a fitting consisting of two Lokrings and one Tubular joint to join two tube ends (Figure 1). The hand tool (Figure 2) compresses the fittings over the joint, reducing the diameter of the connection creating a hermetic seal between the joint and the tube. Prior to compression, Lokprep, an anaerobic sealant (Figure 3), is applied to fill and seal microscopic imperfections in the tubing, ensuring hermetic integrity of the joint (Figure 4). FIGURE 3: Lokprep FIGURE 4: Lokprep Sealing Microscopic Imperfections FIGURE 1: Lokring Fitting Tools and Material The Lokring method requires limited tools and materials. Required tools: Tubing Cutter Tube Caliper Hand Assembly Tool FIGURE 2: Lokring Hand Tool Required materials: Sand Paper Lokprep Manual Lokprep Sealant Appropriately sized fitting 1-2 LOKRING Tube Connection System

6 Select the Correct Lokring Size and Material for Service About the Lokring Fittings The Lokring Fittings are composed of a Joint, and two Lokrings. They are shipped with the Lokrings fitted over the Joint. If necessary, the Lokrings can be removed from the Joint using pliers. LOKRING Repair Procedure Selecting the correct size This section covers the proper method to ensure the approriate sized fitting is selected. How to Select the Correct Fitting It is important to select the appropriate size and material to ensure a long lasting, leak free joint. Lokring fittings are sized and marked using the metric system. Sizes are available to cover all applications, and range from 1.6mm (1/16 ) to 35mm (1 3/8 ). Fittings are available as Union Connectors to join identical sized tubes, and as Reducing Connectors to join different sized tubing. Brass and aluminum Lokrings are available. Brass Lokrings may have steel or brass rings depending on the size. Aluminum joints always use aluminum rings. Selecting the Correct Material If either of the tubes being joined is aluminum, always use an aluminum (AL) Lokring. Due to corrosion only Aluminum Lokring should be used on the interior of the Refrigerator compartments. Use a brass (MS) connector to join any combination of steel or copper tubes (FIGURE 8). It is recommend to use a Heat Shrink covering on the Lokrings inside the Refrigeration compartments. Digital Micrometer-Caliper It is highly recommended that technicians use a digital caliper set in the millimeter mode to determine tubing size. Key steps are highlighted below. Always refer to the instructions provided with your digital calipers for specific instructions. Change the batteries regularly, or anytime the calipers indicate a low battery condition. Always measure in the millimeter mode. Ensure the measuring surfaces are clean and free of debris. Fully close the calipers, if calipers do not read zero when fully closed, zero the calipers. Measuring the Tube Use the center of the inside measuring blades to measure the tube outside diameter (OD). Tubing can often be oblong, or out of round. Taking two readings, 90 degrees apart helps ensure the appropriate size is selected. 1. It is critical to zero your calipers before taking any measurements. If you skip this step, your subsequent measurements may not be accurate. Measure the OD of the first tube, and record. 2. Rotate the digital calipers, 90 degrees. Measure and record this second reading of the OD. 3. Add these numbers and divide by 2 to get the average OD. 4. Repeat these steps on the second tube to get the average OD. 5. Use the conversion chart on the following pages to select the correct size fitting. 6. If the OD measurement is between two sizes, try the smaller size fitting first. Tubes should be measured using a digital caliper set to the millimeter mode. Example 7.8 to 8.2 O.D. Uses a 8mm Lokring connector 8.3 to 8.7 uses a 8.5. Lokring connector Figure 8: Joint Material Chart LOKRING Tube Connection System 1-3

7 Select the Correct Lokring Size and Material for Service Material Types MS = Brass Connector AL = Aluminum Connector Connector Type NK = Union Connector NR = Reducing Connector On each end of the couplings you will see numbers that Identify the Material and the size. You may need a Magnifying glass to see the numbers embossed on each end of the part. 1-4 LOKRING Tube Connection System

8 Select the Correct Lokring Size and Material for Service The tolerance fit generally built into Lokring connectors is as follows. Lokring capillary tube connectors have a tube O.D. tolerance of plus or minus 0.1 mm and come in sizes 1.8mm, 2mm, 2.2mm The most popular sizes for US appliances are 1.8 and 2mm. If the O.D. measurement falls between 2 sizes try the smaller size connector first; if it doesn t fit, use the Larger connector 2MM = No Grooves 2.2 MM = 2 Grooves It is suggested to use Heat shrink tubing on all dissimilar tubing inside the refrigerator compartments. Heat Shrink tubing, not only serves to bundle, protect components and other objects, but also provides an environmental seal that can prevent liquid, gaseous and solid contaminants from reaching sensitive components. The original inside diameter of the Heat Shrink tubing must be large enough to slip over the component to be covered, and the tubing can subsequently be shrunk onto the component by heating the tubing using a heat gun or other source of thermal energy. Step (1) is to choose the proper Shrink tubing to cover the Lokring and connecting tubing. Measure the Lokring and enough to cover the complete fitting. Step (2) Complete the full Lokring process to compress the Lokring. Step (3) move the Heat Shrink tubing over the Lokring and connecting tubing. Step (4) Use the heats source to properly shrink the tubing to seal the complete fitting. 1.8 MM = 3 Grooves Inches To Metric Conversion examples Capulary tubing 1/ / Connecting tubing 5/32 4 3/16 5 1/4 6 5/16 8 LOKRING Tube Connection System 1-5

9 1-6 LOKRING Tube Connection System Lokring Coupling Part Numbers Whirlpool single P/N Lokring Identifier Lokring Size Replacement Kit P/N-incl 2 pc per kit (Couplers Only) W Lokprep65G/15 Lokprep65G /15 ml Bottle W Sealant W /8NRMS00.413"-.313" or 5/16" Brass Reducer W Coupler W /8 NR MS " -.313" or 5/16" Brass Reducer W Coupler W /6 NR MS "-.250" or 1/4" Brass Reducer W Coupler W /5 NR MS "-.197" or 3/16" Brass Reducer W Coupler W /6 NR MS " or 5/16" -.250" or 1/4" Brass Reducer W Coupler W /5 NR MS " or 5/16" -.197" or 3/16" Brass Reducer W Coupler W /6 NR MS " -.250" or 1/4" Brass Reducer W Coupler W /6 NR MS " -.250" or 1/4" Brass Reducer W Coupler W /5 NR MS " -.197" or 3/16" Brass Reducer W Coupler W /5 NR MS " or 1/4" -.197" or 3/16" Brass Reducer W Coupler W /4 NR MS " or 1/4" -.156" or 5/32" Brass Reducer W Coupler W /2 NR MS " or 1/4" -.079" Brass Reducer W Coupler W /1.8 NR MS " or 1/4" -.071" Brass Reducer W Coupler W /4 NR MS " or 3/16" -.156" or 5/32" Brass Reducer W Coupler W NK MS " or 5/16" Brass Connector W Coupler W NK MS " or 1/4" Brass Connector W Coupler W NK MS " or 3/16" Brass Connector W Coupler W NK MS " or 5/32" Brass Connector W Coupler W NK MS " Brass Connector W Coupler W /2.2NRAL00.313" or 5/16"-.087" Alum Reducer W Coupler W /2NRAL00.313" or 3/8"-.079" Alum Reducer W Coupler W /1.8NRAL00.313" or 3/8"-.071" Alum Reducer W Coupler W NK AL " or 5/16" Alum Connector W Coupler W NK AL " or 1/4" Alum Connector W Coupler W VS MS " or 1/4" Brass Stopper W Coupler W NF MS SV.250" or 1/4" Charging Tube w/ Schrader Valve W Coupler W NAV.275" Ext For Compressor Stub W Coupler W NAV.295" Ext For Compressor Stub W Coupler W NAV 5/16" Ext For Compressor Stub W Coupler

10 Lokring tool kit and kit part numbers Lokring Identifier Number Lokring Size Whirlpool Part Number VME5 Pre-Assembly Tool 3/16" W Tool VME6 Pre-Assembly Tool 1/4" W Tool VME8 Pre-Assembly Tool 5/16" W Tool NAV11 NAV Assembly Tool W Tool NAV-E6 NAV Assembly Tool Insert W Tool NAV-E8/7 NAV Assembly Tool Insert W Tool Lokprep65G/15 Lokprep65G /15 ml Bottle W Sealant HMRK-V Manual Hand Tool Double Hinged Handles W MB8 Assembly Jaws for up to 5/16" W Need Qty 2 Tool MB10 Assembly Jaws for up to 3/8" W Need Qty 2 Tool CTP 1 Capillary Tube Cutters W Tool EMERY Emery Cloth 9x11 W Cloth LRSZ 120 Degree Tube Cutter W Tool Tool Tool Box-Metal only no tools or fittings Tool Box-Metal, Tools & Coupler Service Kit W W Tool Kit Complete LOKRING Tube Connection System 1-7

11 Single Lokring Coupling Part Numbers inside the kit 1-8 LOKRING Tube Connection System

12 About the Hand Assembly Tool LOKRING Repair Procedure The Hand Assembly Tool (Figure 5) is used to joint the two tube ends using the Lokring fittings. Push Pin Out to Remove Jaw The tool has removable jaws (Figure 6), allowing the appropriately sized jaws to be installed for the job. The majority of the Lokrings used for refrigeration will use the 8mm on both sides of the tool. However we do use the 10mm Jaw on one side of the tool for a few fittings. Recommend to use the jaw that fits the Lokring firmly. Each handle of the tool has a release lever (Figure 6). The release levers are used to open the jaws to receive the Lokring fitting (Figure 7). Each release lever allows the orientation of the handles to be modified, permitting access to hard to reach places. By releasing the Lever you are setting the Ratchet assembly. Setting the ratchet allows the ratchet device continuous linear or rotary motion in only one direction while preventing motion in the opposite direction. Reminder: after completing every Lokring fitting clean the Lokring and Jaws with a dry cloth. Swing Out Release Lever to Open Jaws to Position Handles Figure 6: Removable Jaws and Handle Release Levers Figure 5: Hand Assembly Tool Close-up of the release lever Figure 7: Jaws Open to Receive Lokring Fitting LOKRING Tube Connection System 1-9

13 Service Technician Use Only Left Handed Operation Right Handed Operation Hold tool with Release Levers facing towards you. Pull down the ratchet release lever using your left thumb. Hold the tool with the release levers facing away from you. Pull down the ratchet release lever with your right index finger. While holding the lever use a pushing motion in direction of arrow to open tool until jaws are fully open. While holding the lever use a pushing motion in direction of arrow to open tool until jaws are fully open LOKRING Tube Connection System

14 Service Technician Use Only Left Handed Operation Right Handed Operation After the tool is fully open, fold the ratchet handle back against the fixed handle as shown. Place your thumb against the handle to hold the tool open. Grab both handles with your other hand. After the tool is fully open, fold the ratchet handle back against the fixed handle as shown. Place your thumb against the handle to hold the tool open. Grab both handles with your other hand. This frees your other hand to hold the tubes and connector. LOKRING Tube Connection System 1-11

15 Assembling a Lokring Fitting 1. Prepare the Connection 1. Use the tubing cutter to separate the tubing if necessary. 2. Check for and remove any burs on the tube end. 3.Clean the tube end with sandpaper, rubbing around the circumference of the tube. 3. Apply Lokprep 1. Note; There is a 3 minute curing time of the Lokprep. Do not apply unless the Lokring Fitting will be completed within this time. 2. Then back the tubing out about 1/4 before adding Lokprep, Apply one drop of Lokprep. Then fully insert the tubing into the Lokring 2. Insert Fitting 1. Push Joint onto the tubing until it reaches the inner stop. At this time verify the Lokring you have chosen is a correct fit. 2. If applicable, insert other side of Joint onto the other side of the tubing. 4. Rotate fitting 1. Rotate the fitting 360* after fully inserting tubing. This is to evenly distrubute the Lokprep evenly around the complete tubing. 5. Compress Lokrings 1. Insert Lokring fitting into jaws of hand tool. Ensure the fitting remains up against the marked line on the tubing. 2. Ratchet the tool closed, compressing the Lokrings until they are flush to the assembly stop of the joint. 6. Important! Wait 3 minutes before applying vacuum, pressure or force. This allows the Lokprep to cure before proceeding. Reminder: after completing every Lokring fitting clean the Lokring and Jaws with a dry cloth LOKRING Tube Connection System

16 Installing Lokring Fittings onto Capillary Tubes LOKRING Repair Procedure Lokring reducers for capillary connections such as at the evaporator inlet, or drier outlet, do not have an internal stop at the capillary side of the connector. This section provides additional guidance for installing capillary tubes. Follow guidance on the previous page for the other, non-capillary side of the fitting. 1. Prepare the Connection 1. Use the tubing cutter to separate the tubing if necessary. 2. Clean the capillary tube end with sandpaper, rubbing around the circumference of the tube. 3. Bend the Capillary Tube 1. Place a slight bend into the capillary tube, as shown, creating a stop for the capillary tube. 2. Complete Steps 1-4 on the previous page, for the other piece of tubing. 2. Insert Capillary Tube 1. Pass the capillary tube all the way through the properly sized Lokring Connector as shown, so that it just emerges from the other end. 4. Apply Lokprep to Capillary Tube 1. Pull the Capillary tube back slightly (about 1/8 ) 2. Apply only a single drop of Lokprep where the tube meets the fitting. Too much Lokprep or too close to the end may block the cap tube. 3. Rotate the fitting 360 to disperse Lokprep evenly around the tubing. Note: Tubing smaller than (1/4 or 6mm) Apply Lokprep while tubing is partially inserted in the Lokring. LOKRING Tube Connection System 1-13

17 This is showing a completed/compressed Lokring. Notice the joint and Lokring placement. You now will see the joint extended outside the Lokrings. Reminder: after completing every Lokring fitting clean the Lokring and Jaws with a dry cloth. Pre-assemble one side of the fitting coupling at a time. It is possible to Pre-assemble one side of the fitting joint at a time. There are three sizes of drive blocks that will act as a bypass. Figure (1) there are three different sizes. Use the proper size for the fitting you are using. In figure (2) you can see how the block inserts into the Lokring to prevent the Ring from compressing the Joint. Figure (3) is the proper position for the joint to be inserted into the jaws. Figure (4) is a completed one sided joint to be uses as needed at a later date. Pre-Assembly Block 3/16 1/4 and 5/16 Figure (2) Figure (1) Figure (3) Figure (4) In figure (3) the jaws are secured on the end of the block on one side and the end of the fitting to be compressed on the other. This will cause the end with the block the ability to be compressed at a later time. Insert the block on the side of the joint you will not being crimping. The block prevents the coupling from compressing. This will allow the blocked joint to be available for use as needed LOKRING Tube Connection System

18 Included in the Whirlpool kit you will find a short stub kit. Figure (1) shows the tools and parts needed to extend a compressor stud that is too short to get the compression tool around the Lokring. Figure (2) shows the two sides of the Lokring. One side is tapered and one is larger. On Figure (3) 1. It is very important that after Lokprep is added the tapered side is be inserted first. 2. Then the Compressor Extension insert tool. 3. Last insert the Compressor Extension assembly tool. 4. To secure the joint you need to use a hammer to hit the end of the Compressor Extension assembly tool. When using this method too much force with the hammer can damage the stud. You can remove and reinstall the assembly tool to check the fitting progress. When you have completed the installation of the Lokring be sure to wipe off any excess Lokprep. LOKRING Tube Connection System 1-15

19 Quality work processes. Two things can cause this bent coupling. Not inserting the jaws fully or leaving a buildup of Lokprep on the jaws. Restricted tubing can be caused by adding too much Lokprep. If the Lokprep is added too close to the end it will seep into the opening of the tubing and restrict the tubing. Jaws not installed fully. Causing a bent coupling This Jaw has a build up of Lokprep due to not cleaning after every use. This will cause the Lokring to move while compressing. It is very important to fully insert the tool jaws onto the Lokring. This will provide even pressure to the Lokring for proper seal. This is a properly cleaned compression jaw This is too close to the opening of the tubing and will cause the Lokprep to seep into the opening. The best process is to insert the tubing about 50% of the way. Then add the Lokprep then fully insert the tubing. Final process is to turn the coupling 360* to evenly distribute the Lokprep. Note: Tubing smaller than (1/4 or 6mm) Apply Lokprep while tubing is partially inserted in the Lokring LOKRING Tube Connection System

20 NOTICE TO THE TECHNICIAN It is the responsibility of the Service Technician to comply with all EPA Regulations and Standards and posses all necessary State and Federal licenses when servicing refrigerators. Federal regulations and Standards can be found on the United States Government EPA Web Site. State Regulations and Standards and licensing requirements, in most cases, can be found on the State Government Web Site. Notes LOKRING Tube Connection System 1-17

21 PRODUCT SPECIFICATIONS & WARRANTY INFORMATION SOURCES IN THE UNITED STATES: FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL: FOR WHIRLPOOL PRODUCTS: FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER S HOME CALL: THE TECHNICAL ASSISTANCE LINE: HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED IN-HOME SERVICE PROFESSIONAL FOR LITERATURE ORDERS (CUSTOMER EXPERIENCE CENTER): PHONE: FOR TECHNICAL INFORMATION AND SERVICE POINTERS: IN CANADA: FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL PHONE: FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER S HOME CALL: THE TECHNICAL ASSISTANCE LINE: HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED IN-HOME SERVICE PROFESSIONAL

22 LOKRING TUBE CONNECTION SYSTEM W