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CLIENT : LEWEK SHIPPING PTE LTD

PROJECT : 65m A/I{ SUPPLY VESSEL

SUBJECT : OPERATING INSTRUCTION MANUAL FOR :.. AIR.CONDITIONING SYSTEM. REFRIGERATING PROVISION SYSTEM

HULL NO. : 160

2 4 APR 2083

/\PanUnited-J Pan-Unlted Shipyard Pte Ltd

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Open-Drive Com pressors

Installation, Start-Up and Service

CONTENTSPage

S A F E T Y C O N S I D E R A T I O N S . . . . . . . 1INSTALLATION . . . . 1-13Step 1 - Prepare fo r Ins ta l la t ion . . . . . . . . 1. PREPARE EQUIPMENT ROOMStep 2 - Rece ive Mach ine . . . . . . l0. BEFORE UNLOADING. zuG UNIT CAREFULLYS t e p 3 - I n s t a l l U n i t . . . . . . 1 0. TOMOUNTMOTORONBASE. TO MOUNT CARRIER COMPRESSOR UNITS

AND CONDENSER PACKAGES. TO MOUNT COMPRESSOR BASE ON

SUPPORT STANDSStep 4 - Assemble Refrigerant Piping

a n d C o m p o n e n t s . . . . . . . . 1 0. COMPRESSOR DISCHARGE PIPING. REFzuGERANT DRIER. FELI FITJIERSStep 5 - Ins ta l l Mu l t ip le Compressors . . . . . . . 10. EQUALZING LINESStep 6 - Make E lec t r i ca l Connect ions . . . . . . . 12. GENERALNOTES. ATTACH POWER WIRES TO

COMPRESSOR MOTOR. CHECK MOTOR ROTIITION. INSTALL CRANKCASE HEATERStep 7 - Check Compressor/lVlotor

A l i g n m e n t . . . . . . . . 1 3. BELT DRIVE. DIRECT DzuVE. HOT CHECK AND DOWELINGStep 8 - Assemble Water Piping . . . . . . 13Step 9 - Prepare LubriCat ion System .. . . . " . . 13. INSTALL OPTIONAL EQUIPMENT. CHECK OIL LEVEL. RECOMMENDED OILSP R E P A R E F O R I N I T I A L S T A R T . U P . . . . . . . . . . . 1 3Evacuate , Dehydra te and Leak Tes t . . . . . . . . . . 13Ref r igeran t Charg ing . . . . . . 13START.UP .. 13-16P r e l i m i n a r y S t e p s . . . . . . . . . 1 3S t a r t C o m p r e s s o r . . . . . . . . . 1 4C h e c k C o n t r o l O p e r a t i o n . . . . . . . . t 4Check H igh-Pressure Swi tch . . . . . t4Check Low-Pressure Switch . . . . . t4Adjust Capacity Control (if required) .. . . . . . .14SCHEDULED MAINTENANCE ,. I7-T9C h e c k L u b r i c a t i o n S y s t e m . . . . . . . t 7Check Water-Cooled Heads . . . . . . 19SERVICE . . . . 19-36S e r v i c e N o t e s . . . . . . . 1 9L u b r i c a t i o n S y s t e m . . . . . . . 1 9

Pressure-Relief ValvesS u c t i o n S t r a i n e r . . . . .

Page

:: 32C v l i n d e r H e a d a n d V a l v e A s s e m b l i e s . . . . . . . . . 2 7Ci r t inOer and Un loader S leeves . . . . . . . .27C6nnect ing Rods and P is tons . . . . . . . . .28C a p a c i t y C o n t r o l O p e r a t i o n . . . . . . 2 8Capacity Control Inspection and Service . . . . .31C r a n k s h a f t l n s p e c t i o n a n d S e r v i c e . . . . . . . . . . . 3 2P u m p - E n d M a i n B e a r i n g . . . . . . . . . 3 3C e n t e r M a i n B e a r i n g . . . . . . . . . . . . 3 3S e a l - E n d M a i n B e a r i n g . . . . . . . . . . 3 4Crankshaft Seal lnspection and

R e p l a c e m e n t . . . . . . . . . . . . 3 4A c c e s s o r i e s . . . . . . . . 3 4TROUBLESHOOTING . . . .37 .39

SAFETY CONSIDERATIONSInstallation, start-up and servicing of this equipment can

be hazardous due to system pressures, electrical componentsand equipment location.

Only trained, qualified installation and service personnelshould install, start-up or service this equipment.

When working on this equipment, observe precautions inthe literature, tags, stickers and labels attached to the equip-ment and any other safety precautions that apply.. Follow all safery codes.. Wear safefy glasses and work gloves.. Use care in handling, rigging and setting bulky

equipment.

INSTALLATIONStep 1 - Prepare for lnstallationPREPARE EQLIIPMENT ROOM - Locate compressor orcondensing unit in a well ventilated area. If natural venti-lation is inadequate, provide forced ventilation throughductwork. Check applicable code requirements.

Provide freeze-up protection for water-cooled condens-ers, water lines and accessories if freezing temperatures canoccur during winter shutdown periods.

Provide sufficient clearance for removal of compressor cyl-inder heads and valve plates. Allow space on the oil pumpend for crankshaft removal as follows:

5F20, 30, 40, and 60 compressors . . . . . .20 in.5H40,46,60, and 66 compressors . . . . . . 20 in .5H80, 86, 120, and 126 compressors . . .30 in.

(Continued on page 10.)

nstructions

Before performing service or maintenance operations onunit, shut off and tag main power supply to unit. Elec-trical shock could cause personal injury.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notlce and without incurring obligations.Bookl2 PC 802 Catalog No. 530-505 Printed in U.S.A. Form 5F,H-23S1 Pg 1 12-90 Replaces: 5F,H-11S1Tab l2a

Provide space equal to condenser length for tube removalnd c leaning.

'dtep 2 - Receive Machine (Fig. I through 8)

BEFORE UNLOADING - Check unit nameolares asainsrrodel and serial numbers recorded in job siecificaiions.

_lheck all i tems against shipping l ist, and examine iremscarefully for any shipping damage. If damage is found orany major component has torn loose from its anchorage,ave transportation inspectors examine it before unloading.

_ile. claim immediately with shipping company for any lossor oamage.DIG UNIT CAREFULLY - Check that rigging equipment

tn safely handle the approximate equipment weights for-Jmpressors and condensing units.

Rig and move unit carefully to prevent damage to mount-' ,g brackets, refrigerant piping or connections.

- t ep3 - l ns ta l l Un i tTO MOUNT MOTOR ON BASE - The motor fastenins

rt, available as an accessory for all 5F,H base-mounted)mpressors, includes motor blocks and shims for motor

alignment; cap screws, plate washers and lock washers forfastening motor to base; taper dowel pins for securing mo-

r position after alignmenq and beveled washers for fas-ning the unit base to accessory vibration isolators.

- If vibration isolators are used, attach to base (Fig. 9). To

avoid damaging the isolators, lift unit from ends when at-:hing isolators.

- With compressor and motor positioned on the base, checkthe height of the vibration isolators. Shim between isolators"nd floor as required to level compressor base. When level,

cure vibration isolators to floor. Check that bevel washer--ig. 9) is in place.

J'oa "

l-ora.' Hd-ES

Fig. 9 - Typical Vibration lsolator Mounting

l-r MOUNT CARRIER COMPRESSOR UNITS AND CON-DENSER PACKAGES - Bolt the compressor's lower sup-5^4 straps loosely to underside of each support stand andF ce strips of protective material (such as Fabrica) on straps.[_;ition condenser on stands with hot gas inlet at top of

5e3

condenser and liquid shutoff valve connection facing com-pressor end of base. Check that condenser overhangs sup-port stands for same distance on each end.

Remove soldered shipping cap from hot gas inlet. To pre-vent solder from dripping into inlet pipe while unsoldering,rotate condenser unti l pipe is below horizontal position. Re-turn inlet to upright vertical position.

Tighten lower support straps enough to l ift condenser offstands. Place upper straps loosely in position with a strip ofprotective material between condenser and strap (5F20 and5F30 units use lower strap only).

TO MOUNT COMPRESSOR BASE ON SUPPORTSTANDS - Place compressor base on support stands with2 extra strips of protective material between top of con-denser and base. Bolt base into position with cap screwsand lock washers provided.

Step 4 - Assemble Refrigerant Piping and Com-ponents - Refrigeranr connection sizes are given inTable 1.

COMPRESSOR DISCHARGE PIPING RefeTCondensing Unit Piping Installation Instructionsinformation.

L IQUID L INEFROM COND.

tofor

REFzuGERANT DRIER - A replaceable-core filter drieris recommended for most systems, and is essential on alllow-temperature systems. Mount the field-supplied filter drierin the liquid line. Include a shutoff valve ro permit isolationof drier for servicing (Fig. l0).

Install a moisture indicator on downstream side of drierto indicate when drier cartridses need reolacine.FELT FILTERS - Install felt-filter suppfied with compres-sor in suction strainer (Fig. 3 through 8). Remove filter af-ter 50 hours of operation. If clean, discard it; if dirty, cleanwith kerosene or neutral spirits and insert for another50 hours of operation. Tag unit to show date that filter wascleaned and reinstalled. SeeTab\e 2 for information on re-placement filter packages.

Step 5 - lnstall Multiple CompressorsEQUALZING LINES - Compressors operaring in paral-lel require interconnecting lines for oil and gas pressure equal-ization. Special handhole cover plates, equipped with tafpedlqles for eqlalizing lines, are available as oprions for iizes5F40 and 5F60, as well as for sizes 5H40 through 86 com-pressors (Fig. I l). An oil float sysrem is an acCeptable al-ternative to equalizer lines.

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-+ 5H120 and 126 Compressorsinclude factory-supplied, tappedcover plate. On these compressors, use only lower connec-tion for oil equalization (Fig. 1l). Connect gas equalizineline to flange connection shown. Mating flange foi IVB-\;.Iine is Carrier Pafi No. DK24CA712 (MuellerPartNo. A-5151);gasket Part No. is DK29GA005LA (Mueller Part No. A-5152).

5F20 and 30 Compressots .have no special tapped coverplate. Use opening for oil sight glass to attachihe lth-in.iine for gas and oil_e_q^ualization (Fig' l2). Accessory Pack-age No. 06DA900072-provides two Zs-in. line adapters totliread into the sight glass opening. If additional edualiza-tion is desired, run q %-in. line to the oil-filter phig con-nection (Fig. I and2).

GAS EQUALIZERCONNECTIONr*"oD FLANGE(5Hr20- 126 oNLYI

OIL EQUALIZERq9NNECTTONI IPS

ORIVE AN DS E A L E N D

SCREW FITTING INTOOPENING FOR OIL LEVELSIGHT GLASS FOR I - I l8 . .EOUALIZER L INE

O I L L E V E L

Fig.12 - Equalizer Connections (5F20 and 30)

Fig. 11 - Special Hand-Hole Cover andEqualizer Connections (Typicall

Tablel - Physical Data

COMPRESSOR UNIT ANDCONDENSING UNfT

Maxlmum RpmMinlmum RpmMinlmum Rpm Capaclty

Control

Bore (ln.)Stroke (in.)

Oll Charge'Normal OllOll Flow Rate (gpm)t

Low-Pressur€

Oll $fety SwltchCut-ln (pslg) (Se€ Note 2)Cutout (pslg)

R-12, R-22, R-I34a, and R-502

400 (required

800 I 800

psig above suction pressure3.0

t5 - 19 .51 1 - ' t 5

17501r propef| 9oo

(ln o.D.)Suctlon

3t/c37Ae

41/e41/8

Cutout RangeOffferentlal (psl)Fac{ory Setting (pslg)

150-395 (adjustable) nominal60-150 (adiustable)

Cutout ,30O a 15; Cul- in,210 + 10

20 in. Hg vac to 60 psig (adiustable)60-90 (adiustable)

Cutout, 50 + 4; Cul-in. 120 + 6

ttShell-and-coil condensers. All other SF,H condensers are shell-and-tube.ll Cond€nser storage capacity 80o/o filled wilh liquid refrigerant at 90 F.

NOTES:1. Oil flow rat€ is the nominal oil pump capacity.2. Oil safety switch has manual reset and lime delay ol 45 seconds.

Prcssurc

'Nominal oil pressures shown in Physical Data table are above suction pres-sure, i.e., pressure differential between suction pressure and discharge pres-sure of oil pump.

tOil flo,rr rate (gpm) for 5H. 12-cyl: 4.5 gpm with manual reversing oil pump;6.0 gpm with aulo. reversing oil pump.

"See Table 5 for typical pressure switch settings.

CONDENSER DATA sF20tt sF30tt 5F40 5F60 OgRH-o27

ff,RH.043

G'RH.054

OgRH.070

09RH.084

MRH.097

OgRH.127

erant StorageCapacltyll (lb)

R-12R-22R-502

40.437.238.2

fi.748.447.9

79.472.875.C

89.682.084.6

't54

139145

212193199

zoJ239248

zJ6216223

z6z257265

J5U327337

432447

Mlnlmum Refrlg- R-12erant Operatlng R-22.Charge (lb) R-q)2

2.O1.81 . 9

3.02.72.9

14.012.713.1

16.014.515.0

37.033.034.4

4 1 . 037.038.2

t 1 . u46.047.3

51.046.047.3

t67173

IUU9194

1261 1 41 1 8

Water SideSide 385 psig

250 psig150 psig

697

Table 2 - Suction (Felt) Filter Packages

_itep 6 - Make Electrical Connections

GENERAL NOTES. Factory wiring complies with National Electrical Code

(NEC). Any field modifications or additions musr com--- ply with all applicable codes.2. *For control circuit information, refer to Accessory Con-

trol Panel Installation lnstructions.

-. If control circuit power is supplied from a separate source,rather than from a transformer, bring 115-v power througha_fi e_ld_-supplied, I 5-amp disconnecr, in compliance wiihNEC Section 440-14 (disconnect musr be in sight from

- and readily accessible from unit).4. Open control-power disconnect only when servicing unit.

Crankcase heaters must remain energized when rlnit isnot operating.

5 *Factory wiring is for single pumpout control. Do not usepumpout control on equipment used with DX coolers. Wir-ing label shows field connections used with DX cooler.

_ *Contactor C2 is used with 208-v motors, 25 throueh60 hp, and 460-v motors, 50 through 150 hp.

' *When field interlocks are used, remove jumpers be-tween terminals 3 and 4, and between terminals 7 and 8

- on TB2.*Refers to compressor units and condensing units only.

MACH POWER WIRES TO COMPRESSOR MOTOR -?<rtach power wires in accordance with motor manufactur-er's instructions and in compliance with NEC and appli-

ble local codes.{ECK MOTOR ROTATION - Before connecring motor

tb- compressor, check direction of motor rotation. F.otationmust be in samc direction as that indicated by arrow oncom-1 ?ssor pump cover (or o1 plate anached-near pump-end, ,aring hgusjng). If direction is not the same, reverse motorr6-tation by reversing any 2 power leads to motor.

If rotation of oil pump is reversed, reverse direction ofI mp rotation arrow as well. At that time make the follow-i_; adjustments:

All 5F Compressors- Remove 6 cap screws from oil pumpr ver (Fig. l-4). Do nor damage gasket. Rorare couei tgb( grees and replace. Arrow at top of oil cover will indicatervw direction of rotation.

5H40 throush g6 Compressors- Drain oil below level ofpump-end cover (Fig. 5-7). Remove pump-end cover to ex-pose orl pump cover in center of main bearing housing. Ro-tate oil pump cover 180 degrees and replace it. Replace pump-end cover and reverse external arrow to match new directionof rotation. Proper direction can later be checked withoutremoving pump-end cover.5H120 and 126 Compressors(Beginning S/N 1086J---) -Supplied with automatically reversing oil pump, eliminatingneed for adjustment. For 5H 120 and 126 models built beforeS/N 1086J---, follow same adjustment procedure ourlined for5F compressors.

INSTALL CRANKCASE HEATER - Wire hearer ro relayor set of normally closed auxiliary contacts on compressorstarter to de-energize it when compressor is operating.

Remove rubber plug from crankcase heater casing(Fig. 1-8), and insert heater element entirely into casing. El:ement should fit snugly, not loosely. Wire to comply-withapplicable electrical codes.

When crankcase heater is installed, system can be oper-ated on single pumpout cycle, unless used with a DX cooler.

Table 3 lists crankcase heater packages. Table 4 showscorresponding relays. Use of 2 heaters on a 5H80 throush126 compressor requires only one relay.

Control circuit voltage determines relay coil voltage. Thisvoltage must be specified when ordering relays.

See Accessory Compressor Crankcase Heater lnstallationlnstructions for additional information.

Table 3 - sF,H Gompressor Crankcase

COMPRESSOR FILTER PACKAGE PART NO.5F40-5F60-A3525H40-A3825H60-A382SHBO-A3825H120-4382

5F405F605H40,465H60,665H80,865H120,126

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If the special gasket between oil pump cover and oil pumpis damaged, replace with correct gasket only. Cheik oilpressure immediately after starting compressor.

Heater Package

-5,H-40--381-5-H-40--391

-+ 5H80,86,120,126

Table 4 - Crankcase Heater Relay (60 Hz)

Step 7 - Check Compressor/MotorAlignmentBELT DRIVE - See Accessory Belt Drive Package manualfor insta l la t ion and a l ignment inst ruct ions.

DIRECT DRIVE - Install and align compressor, couplingand motor as described in manual for Flexible Couplings foiDirect-Drive Units.

HOTCHECKAND DOWELING -To help maintain atign-ment, and to ensure exact repositioning of the motor afterservicing, the motor and compressor must be doweled to thebase. Install doweling only after motor/compressor align-ment has been hot checked (checked after the com-pressor has warmed up to operating temperature after ini-tial alignment).

After hot check and while components are still at oper-ating temperature, drill and ream 2 holes through diagonally-opposite motor and compressor feet and the base. Use ae/tz-in. dnll and a no. 6 taper reamer. Secure the motor andcompressor to the base with the no. 6 x 2Vz-in. taper dowelpins provided in the motor fastening set.

Coat the dowels with white lead or other lubricant to pre-vent rusting, and tap the dowel lightly into position so that%e of taper is left above the motor foot.

Check that all dowels are tight and that they do notbottom.

Step I - Assemble Water Piping - See Water-Cooled Condensers Installation Instructions and Water-Cooled Heads Installation Instructions for information.

Step 9 - Prepare Lubrication SystemINSTALL OPTIONAL EQUIPMENT - Consult localCarrier representative for information on these accessories.

Oil Filter - Oil filter for 5H40 through 86 compressors isavailable as separate accessory package. Refer to AccessoryOil Filter Package Installation Instructions for installationprocedures.

If an accessory oil cooler is also installed (see below), pipeoil filter into system as shown on diagrams in Accessory OilCooler Installation Instructions.

Oil Cooler - Refer to Accessory Oil Cooler Installation In-structions included with this accessory package. Adjust wa-ter flow rate through oil cooler to maintain_I00 to 120 F oiltemperature returning to compressor. See Scheduled lv{ain-tenance, page 17.

Oil Separator - If oil separator is used in system piping,pipe oil return line to compressor suction line. To minimizepossibility of flooding compressor with oil, oil return linediameter should not exceed % inch.In addition, line shouldhave manual shutoff valve to throttle oil flow as requiredand to isolate separator for service.

CHECK OIL LEVEL - Check that oil level is visible atcenter of compressor sight glass. Compressors that use op-tional equipment such as filter, cooleq and oil separator de-scribed above will require a greater oil charge than listed inTable 4. Recheck oil level after operating compressor.

RECOMMENDED OILS - When additional oil or a com-plete oil change is required, use only the Carlyle engineer-ing department approved, dehydrated, wax-free refrigerationgrade oils noted below:

IGI Petroleum Specialt ies, Inc. . .. ...... Cryol 150IGI Petroleum Specialties, Inc. ... Cryol 150 with additive

(Akzo Chemicals, Inc. additive Syn-O-Ad (8478)w i t co . . .Sun i so3GSWitco - Hi ambient application,

300 viscosity . Suniso 4GS

T e x a c o , I n c . . . . . W F 3 2 - 1 5 0Shr ieveChemica l Co . . . . . . . ( syn the t i c ) Ze ro l 150

Mineral oil and synthetic oil have different characteris-tics. One is not necessarily better than the other. Some char-acteristics of the mineral oils have been found to be morefavorable for use in some air conditioning and medium tem-perature aPPl ications.

Approved compressor oils are available from authorizedfactory parts outlets. The oils recommended are fully com-patible with each other and can be mixed in any proportion.

PREPARE FOR INITIAL START.UP

Evacuate, Dehydrate and Leak Test the enrire re-frigerant system as described in Carrier Standard Service Tech-niques Manual, Chapter l, Sections l-6 and l-7.

LEAK TESTING

Preferred Method- Charge the system to 10 psig with re-frigerant. Add dry nitrogen or dry air (DO NOT USEOXYGEN) until system pressure is 150 psig. Check for leakswith a halide or electronic leak detector.

Alternate Method- Charge the system with dry nitrogen ordry air (DO NOT USE OXYGEN) to 40 psig and use soap-bubble test to find larse leaks.

Refrigerant Charging - Use the sight gtass methodto charge the system. See Section l-8 of Canier StandardService Techniques Manual, Chapter l, for details.

Charge the system to a clear sight glass while holding satu-rated condensing pressure constant at 125 F for air-cooledsystems or 105 F for water-cooled systems. Addadditional refrigerant to fill condenser subcooler coils, ifrequired.

5RH CONDENSING UNITS - After a clear sight glass isobtained, add charge until liquid refrigerant reaches the con-denser liquid level test cock.

5F.H COMPRESSOR UNITS - See condenser data for ad-ditional charge requirements.

Preliminary Stepsl. Energize crankcase heater for at least 24 hours before

starting unit.2. Ifcontrol transformer is not used, operate electrical con-

trol circuit with main oower switch OFF to ensure thatfield connections have'been properly made.

3. Install felt sock filter for the first 50 hours of compressoroperation. Remove and inspect the filter, clean it if re-quired and replace it for another 50 hours. Remove sockwhen system is clean. (Not applicable for 5F20 and 5F30units.)

4. Check that motor rotates in direction that the arrow onthe compressor oil pump cover indicates. Refer to Instal-lation, Check Motor Rotation section on page 12.

5. Check that oil fills tZ to Vz of the compressor sight glass.

6. Open water supply valve to condenser. Open pressure linevalve of water-regulating valve (if used). If compressorunit is equipped with air-cooled condenser, turn on con-denser fan.

Do not use compressor to build up pressure. Do not over-charge the system.

13

7. Backseat (open) comPressor suction and discharge'' r"*i"" valves. Open liquid l ine valve at receiver'

8. Start evaporator fan or chilled water pump'

Start Compressot - Close main power switch sup--- plying current to the compressor motor.

Immediately recheck oil level and check oil pressure. Pres-sure should eiceed suction pressure by 45-55 psi. If correctpressure is not reached in l0-12 seconds, stop compressor

- immediately and check oil PumP.

Check Control Operation - Refer to Carrier Stan-dard Service Techniques Manual, Chapter 2, for completeinstructions on checking electrical components.

HIGH- AND LOW-PRESSURE SWITCHES - All 5F and5H units except 5F20 and 30 have factory-installed, auto-matic reset, triitr- ana low-pressure switches. (These switchesare available is accessorids for 5F20 and 30 units.) Figurel3 illustrates adjustment procedures for both switches.

Check High-Pressure Switch - Throttle the con-denser watei on water-cooled unit or block the airflow onair-cooled unit, allowing head pressure to rise gradually'Compressor should shuioff within-!J psi of cutout valuelisted in Table 4. Now reverse procedfre; compressor shouldstart within p psi of cut-in value given'

Check Low-Pressure Switch - Slowly close thesuction service valve; suction pressure will decrease' Com-pressor should shut off within{ psi of cutout value listed inTable 5. Reverse procedure; compressor should start within

! Osi of cut-in value given.

Tabte 5 - Typical Pressure Switch Settings

REFRIG-ERANT CONDENSER

PRESSURESTATHigh(psls)

Low

Cutout Cut-ln Cutout

1 2 water-cooleoAlr-Cooled

175225

O R

1451 61 6 76

22 Water-CooledAlr-Cooled

280325

2AO245

3636

9696

502 Water-CooledAlr-Cooled

280325

200245

4545

105r05

If an accessory oil cooler is provided. a-djust the waterflow as required-to maintain a 100 F to 120 F crankcasereturn oil temperature.

ROEERTSHAWA _ R A N G E A D J U S T M E N T S C R E W

TOP

@-=r- DTFFERENTTAL ADJ scREw

RANCO-

A - R A N G E A D J U S T M E N T S C R E W

4 - " - o T F F E R E N T T A L A D J

TOP

S C R E W

P E N N

A - R A N G E A D J U S T M E N T S C R E W

@--u-o,FFERENTTAL ADJ

TOP

S C R E W

Screw A raises or lowers both cutout and cut-in points by a like amount.

Range and Differential scales are on the front of the switch.

High Pressure: Set cufout point first, with screw A; then set cut-'n'ooint with screw B.

Low Pressure: Set cut'in point first, rvith screw A; then set cutoutpoint with screw B.

LOCATION AND ADJUSTMENTS

Fig. 13 - High'and Low-Pressure Switches

For additional information, see Oil Safety Switch Acces-sory Package Installation Instructions.

Adiust Capacity Control (if required)

5F20 AND 30 COMPRESSORS - Refer to CapacityControl Valve Installation Instructions for additionalinformation.

.5F40 AND 60, AND 5H4O THROUGH 126 COMPRES-

SORS - Determine the refrigerant usage:-+ If the system is to use R- I2nr R- I 34a, replace the I I -lb

raige adjustment spring (FiS. I5) with !y-7-lb spring sup.'ptiid wiih compreisor. A change in 1982 reversed whichiange-adjusting spring a customer received. ̂ Ihe R-221R-5b2 siring ii n6w standard with the compressor. See in-stmction tag for spring replacement procedure.

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OIL PRESSURE SAFETY SWITCH - To check, movecontact arm at left side of switch forward (Fig. l4). Com-pressor should stop in approximately 45 seconds.

If compressor continues to run, check the wiringto safetyswitch. It wiring is correct, switch is faulty and should bereplaced.

After completing test, wait 3 minutes: then press restartbutton on front of safety switch and restart compressor.

Check oil level in compressor sight glass after 15-20 min-utes of operation. If thd oil level is low, add-oil- by themethods iescribed in Carrier Standard Service TechniquesManual, Chapter 1, Section l-l l .

1094

If any safety device shuts down th-e compressor, do notreset the coritrol more than once before determining causeof shutdown.

H I G H -P R E S S U R EswrTcH

5H MOUNTING ARRANGEMENT SHOIVN.

CONNECT INSERIES WITHCONTROL CIRCUIT

(REFER TO UNIT LAEELWIR ING D IAGRAM }

HIGH.PRESSURECONNECTION TO

LOW-PRESSURECONNECTIONTO CRANKCASE

CONTACT ARM RESISTANCE

Fig. 14 - Oil Pressure Safety Switch

PNEUMATIC

IF PNEUMATIC CONTROLIS NOT USED, THIS PORTMUST BE VENTEDDO NOT PLUG

An exrernal ad..;usting.stem 1Fig. l5) sers rhe control poinr(suction pressure at which.firsr.step of cylinder unloidingoccurs). The control point is adjustable ai fo1o*r,

R - 2 2 a n d R - 5 0 2 . . . . 0 t o 8 5 p s i gR-12 and R-134a . . . 0 to S0 i rs i !One full clockwise turn of adjusting stem will raise the

conrrol point.app^rqr-rmately 6 p_sig with R-12 and R_134a,or 10 psig with R-22 and R-502.

Control oil pressure is an indication of cylinder loadinscondition (Table 6). Refer to Fig. 3-8 for location of contiofoil-pressure connection. See Accessory Unloader Package In-stallation Instructions flor additional information.

-

See Fig. l6 for Capacity Control Sysrem, and Fig. l7 lorunloading sequence.

-+ Table 6 - Control Oil Pressures forCylinder Loading and Unloading

cne--\a\

To Adiust Control Point-l. [tnpose an artificial load on the compressor until suction

pressure exceeds control point.2. Slowly close suction valve to lower compressor suction

pressure to control point pressure.3. When at control point pressure, turn external adjusting

stem clockwise until firslstep_ of unloading takes place-,as indicated by changes in control oil pressure, currentdraw and sound of compressor.

Control point is now set. Reopen suction service valve.Compressor will be fully loaded when suction pressure is-3 psig (4 psig with R-22 and R-502) above coitrol point,ard will !e fglly unloaded when suction pressure is 4 psigQ OsiS with R-22 and R-502) below conirol point.

5F20 AND 30 COMPRESSORS - Two capacity conrrolpackages are available as accessories. One is suitablefor R- 12. or R- l34a applications; rhe other for R-22 and R-502apptlcatlons.

The adjusting stem (Fig. 15) is shipped in a backseared(fully counterclockwise) position. Compressor will be fullyloaded under all conditions. Adjust the capacity control serpoint by the same 3:step procedure described above for 5F40and 60, and 5H40 through 126 compressors.

EXTERNALADJUSTINGSTEM * NEWER

DESIGNUSES"O'RING

SPRING DETAILS

PART NO.sF88a)6(7-LB SPRTNG)USE WITH:R-l2, R134a,R401A, R-409A,R-500, R4018

-<<_<-<

PABT NO.EB39CZ001(11-LB SPRTNG)USE WITH:R-22, R-502, R-zt&tA,R-507, R402A, R-408A

-+

'When compressor is received, the capacitv control adiustinostem will be backseated. (Compressor wit[ be fullv loaded un'der ajiconditions.) Compressor is supplied with 11lb siring.

Fig. 15 - Capacity Control Valve

APPROXIMATECONTROL OIL PRESS. (psig)

5F40.60:ffiffiot.--,oe',a0;

86,120,126'Capacity Control reduction steps.

l 5 697

- PNEUMATIC CON'TROLNOT USEO, THISRT MIJST 8E VEI

W NOT PLUG:

RANGE

F R O M C O M P R E S S O RO I L P U M P

CONTROL O IL H O IL PUMPPRESSURE PRESSURE

L IFTERADJUSTMENSPRING

/,1 . 1

XT

AND P INSL IFT INGFORK

PISTON

TRAVELI N GN U T

CAPACITYVALVE

coNTROti

SURGECHAMBER(5H ONLY '

SLEEVE

TO OTHERUNLOADERPOWERELEMENTS

CYLI NDERSLEEVE

IM CRANKCASE.SSURE

CAPILLARY

DRILLEOHOLE

HYDRAULICRELAY

Fig. 16 - 5F,H Capacity Control System (Except 5H120,1261

5H40, rt6

I FRuIsS*'r""-CRANKCASEPRESSURE

OIL PUMPPRESSURE

5H60.66

oo

5F20

@--J1 rn

fl- 'l lI | J

@

-!-tIIaItIaaaaI-ai

5F30

5Hr20, t265F60

Fig. 17 - Cylinder Unloading Sequence

LEFT SIDE1 - Connection to Oil Cooler (Sleeve Location)2 - Oil Pump Pressure (Both Locations). Use either for

High-Side Oil Pressure Switch Connection'3 - Opening to Crankcase (Low-Side Oil Pressure

Switch Connection)-+ 'When using external electric capacity control, oil pressure connec-

tion must be made at the 9 o'clock position on the bearing rim. Theblank-off plate installed for extemal unloading will block oil pressureto the I o'clock position on the pump cover.

Fig. 18 - Typical 5H40 through 5H86

SCHEDULED MAINTENANCE5F,H compressor and condensing units provide long life

and dependable service when properly operated and regu-larly maintained. Establish a maintenance schedule based onfactors such as operating hours, load conditions and waterquality. Maintenance schedules listed in this section are of-fered as guides. Modify them as needed to satisfy individualmachine requirements. See Fig. 18 for important compres-sor service locations, connections, oil cooler sleeve location.

Check Lubrication System - Always check com-pressor oil level before starting unit. If oil is required, recorddate and amount added. Refer to Fig. 1-8 for location of oilfilterplug. Table I and Step 9 show specifted types and quan-tities of oil.

Use of accessory oil separator requires additional oil. Oillevel and separator float valve movement during initial com-pressor operation should agree with instructions furnishedwith the oil separator.

RIGHT SIDE

1 - Pneumatic Control Conneclion2 - Capacity Control Valve3 - Oil Pump Rotation Anow4 - Capacity Control Oil Pressure5 - Oil Fill Plug

Compressor Pump-End Connections

OIL FILTER MAINTENANCE - A bleed-type, high-pressure, disposable filter is available as an accessory for 5H40through 5H86 compressors (Fig. l9). Replace oil filter afterthe first 50 hours ofoperation, or whenever the oil is changedor becomes dirty.

Check yearly for clogged filter, indicated by a greater thannormal difference between oil pressure ahead of filter andafter filter (before orifice elbow). When this difference ex-ceeds 5 psig, change filter as follows:

l. Close oil-line shutoff valves on each side of filter(Fig. 19).

2. Disconnect oil lines at filter connections.

3. Loosen filter bracket; remove and replace filter body.

Refer to Accessory Oil Filter Instructions for additionalinformation.

The full-flow oil filter, on 5H120 and 5HI26 compressorsonly, contains a replaceable cartridge. Replace the filter car-tridge after the first 100 hours of compressor operation. Af-ter the initial filter change, check yearly for filter clogging.If the pressure difference across the fi-lter exceeds 5 psig, pumpdown the compressor and then remove the cartridge.Figure 20 (B) illustrates complete filter assembly (not shownin Fig. 20 tAl).

t 7 r094

When crankcase oil temperature falls within the 120 to135 F range, the shaft seal-housing temperature should beapproximately t40 to 150 F. Shaft seal housing tempera-tures above 170 F may cause shaft seal to age rapidly, andharden and crack. Th6refore:

Fig. 19 - Oil Filter Accessory Package(5H40 through 5H86)

CI{ECK OIL AND SHAFT SEAL TEMPERATURE _ Thenormal operating temperature of the oil in the crankcase

nges from 100 F to 135 F when fully loaded. Do not per-it maximum oil temperature to exceed 150 F. Conditions

under which such excessive temperatures could occur in-clude situations where the compressor operates in a fully

rloaded condition for an extended period, because the com-essor would not be able to remove all of the heat gener-

a-red by compression and friction. In such situations, use anoil cooler to maintain safe operating temperatures. Refer to-r,H

Application, Data for more information.

If shaft seal housing temperature exceeds 170 F, STOPTHE COMPRESS6n. DO NOT restart until the causeof overheating has been identified, and the conditioncorrected.

OL COOLER USAGE - The accessory oil cooler main-tains safe operating oil temperatures when:l. Applying long stroke compressorS (5H46, 66, 86 and

126). For added reliabil i ty, an oil cooler is recom-mended on all long stroke models regardless of operat-ing range or type of refrigerant. Additional heat of fric-tion from extended piston travel on long stroke modelsincreases oil temperatures.

2. The suction gas becomes highly superheared (Table 7).3. a. The compression ratio exceeds 5:l on R-22 systems.

b. Application data indicates the need for an oil coolerfor R-12, R-134a, and R-502 systems. The compres-sion ratio can be determined from the followinsformula:

Compression Ratio _ Absolute Discharge Pressure

Absolute Suction Pressure

G^!'K€T

OIL PRESS. CAGE CONN(8EFOfi€ FILTER } \

OIL FILTER IIOUSING

PUMP E}OEEARI}IG H€AT)

O I L F I L L P L U G

OIL FILTER SPRING

OIL FILTERcovgR .

%,dr_

(6IAOAPTERSCR€US(t-ari'r

A(Auto..Reversing)

P U M P E N O S E A R I N G H E A D

IROL OIL PRESS. GIGE CONN

DRIVE DISC

OUTER GEAR

INNER GEAR

COVER GASKET

PUTTP IilTAK€PLUG (MAGNETICI

orL PREss- GAGE coNN ( aFT€R FTLTER) ia t

FILTER

CAPACITY CONTROL VALVE AD.,USTING STEM

BTJSHING LOC

B(Manual Reversing)

UASHERStl-20rzl- l

- Oil Pump and Filter Assembly (SHt20, 126)

-> Table 7 - Actual Suction GasTemperature Limits (F), R-l2, R-22, R-134a, R-502

SAT. SUCTTEMP (F)

-60 - 5 0 -40 - 3 0 -20 - 1 0 0 t o 5 0

ACTUALsucTtoNGASTEMP (F)

R-l2,R-l34a 35 45 55 65

R-s02 25 45 65 75

R-22 See Note 1

NOTES:1. For continuous operation with R-22:

Carrier 5F,H Specified Parts list for compressor partinterchangeabiliry.Before servicing compressor, pump down the refriger-ant as follows:a. Start compressor, close suction service valve, and re-

duce crankcase pressure to 2 psig. (Bypass low pres-surestat with jumper.)

b. Stop compressor; close discharge service valve to iso-late it from system.

c. Recover or reclaim any residual refrigerant. Drain oilif necessary.

After disassembly, clean all parts with solvent. Use min-eral spirits, white gasoline or naphtha.

5. Before assembly, coat all parts with compressor oil andclean and inspect all gasket surfaces. Replace all gas-kets with new, factory-made gaskets, and lightly coatwith oil. See Table l0 for torque values.

6. After reassembly, evacuate compressor and open suc-tion and discharge valves. Restart compressor and ad-just refrigerant charge.

Lubrication SystemOIL PUMPS5F compressors. See Fig. 23 and 25.5H,m-86 compressors. See Fig. 24 and25.5H120,126 compressors, with automatically reversing oilpump. See Fig. 20(A).5H120,126 compressors, with manually reversing oil pump.See Fig. 20(B) and 26.

5H120 and 126 Compressor Oi l Pump

NOTE: By itsetf, the automatic reversing oil pump cannot be installed in placeof the manually reversing oil pump or vice versa. The complete bearing headassembly with ths oil pump (auto. or manual) is interchangeable as a com-plete assembly.

MANUALLY.REVERSING OIL PUMP r.,.Oil Pump Inspection - See Fig. 20B, 23 and 24 for 5Fand 5H manually reversing oil pumps. Also refer to 5H120,126 auto.-reversing oil pump section.

Drain oil below level of pump-end bearing head. Re-move bearing head. Complete end-bell assembly must beremoved to access bearing head assembly with oil pump on5H,10 through 86 models. Check oil pump rotor for endplay. Maximum allowable movement of rotor is 0.0025. Ifiheie is excessive end play, reposition oil pump bushing inbearing head as described below.

Ttrn rotor. If there is more than a slight drag, removepump cover and disassemble oil pump checking all partsfor wear and damage. Inspect oil pump bushing for scor-ing. Replace bushing if scored. If bearing head is scored,replace complete bearing head and oil pump assembly.

Oil Pump Bushing Installation - See Fig.25 and 26. Po-sition the bushing oil groove at top (running from 12:00 to6:00) when the bearing head is installed. Press new bushinginto the pump-end bearing head from the inner side of thehead with the chamfered end entering first.

J .

4 .

2. Do not operate unloaders at saturated suction temperaturesat or belbw 0'F without prior approval from CarrieriCadyleEngineering.

4. The compressor operates fully unloaded for prolongedperiods. Under these conditions, suction gas levels maynot suffice to remove the heat of compression and fric-tion. This condition can occur in any application, but ismost likely in low-temperature systems or variable-volume applications that use hot-gas bypass to maintainspecified conditions under low evaporator load. Refer to5F,H Application Data for additional information.

Adjust water flow rate through oil cooler to maintain 100to 120 F oil temperature returning to compressor. Crank-case temperature must remain below 140 F; shaft seal tem-perature at the seal housing should not exceed I'70 F.

Tables 8 and 9 list maximum working pressures for oiland water and estimated water flow rates for various oilcooler/compressor combinations. For additional informa-tion, see A-cessory Oil Cooler Installation Instructions.

Table I - Oil Cooler Maximum

Table I - Oil Cooler EstimatedWater Flow Rates

COMPRESSOR%-11-2

11/r32-4

5H40-665H80,865H120,126

'Flow rate based on 80 F entering water.

Check Water-Cooled Heads - To prevent oil break-down and sludge formation, the discharge gas temperaturemust remain below 275 F. Water-cooled cylinder heads areavailable as an accessory for this purpose. See AccessoryWater-Cooled Head Package Installation Instructions for ad-ditional information.

SERVICEService and repair of Carrier reciprocating compressors

and other refrigeration components should be performed onlyby fully trained and qualified personnel.

Service Notes1. Compressor components are shown in normal order of

removal from compressor (Fig. 2l and22).2. For replacement items, use Carrier specified parts. See

,i

SAT. SUCT TEMP (F) MAx. SUPERHEAT (F)-40 to

Working Pressure

History Reference

4901765 and

L9 1094

Oil Pump Bushing Position

l. a. 5F20-60 and 5H40-86. See Fie. 25. Place 0.001-in.circular field fabricated shim aEainst bushins and in-stall pump.. Shim between bus6ing and oil i'u-p .o-tor. Complete assembly of oil pump with giskei andcover.

b. 5Hl20,l?5. See Fig. 26. Placn 0.0l5-in. (t/e+-in.) shimbetween po_rt insert and oil pump cover. Completeassembly of oil pump and pump cover without tisingpump cover gasket.

-2. Tap bushing with suitable cylindrical positioning tool to- seat it against shim. See typical arrangement sf,own inFig.25.

3. a. 5F20-60 and 5H40-86. See Fig. 25. Disassemble oitpump and remove shim. Reassemble oit pump. Checkfor bindins.

b. 5H120,126. Remove oil pump cover and shim.Reassemble pump cover with gasket. Check forbindine.

4.

5 .

Install bearing head on compressor. Line up tang on oilpump rotor shaft with slot in end of crankshaft. Checkoil pump for proper direction of rotation.Refill compressor oil to proper level. Observe oil pres-sure when starting compressor. Correct oil pressure shouldbe 45-55 psig abiove suction pressure.

!€@---cyLrirDER

HEAD

fri----- CYLINDER HEAD GASKET

L--P/1

t - '

@ PUMP ENDEEARING HEAOASSEMELY

PUMP END COVERAND CONTROLVALVE ASSEMBLYDISCHARGE VALVE

INNER SEAT

HANO-HOLE COVERGASKET

VALVE PLATE GASKET

SUCTION VALVEDrsc.

otL RETURNVALVE

HAFTOVER

SEAL

?'.tr. ?SsfR'Ei'PUMP END EEARING WASHER

Oil pump assembly musr besurface, but must not protrudesurface.

. \ K E Y

\ \ \ -t u b.,^.T*-:OIL FILTER SCREEN

O{- FILTER(ACCESSORY}PUMP END BEARING

HEAD GASKET

s;,i

HAND-HOLE COVER

Fig.21 - 5H Compressor Enternal20

\

Components

AUTO. REVERSTNG OIL PUMP

Oil Pump Inspection - See Fig. 20(A) for 5H120 and 126for automatic reversing oil pumps.

l. Drain oil below level of pump-end bearing head.

2. Remove bearing head from compressor.

3. Remove oil pump and adapter from bearing head.

4. Check all parts for wear and damage.

Pump Installationl. Using a new gasket, mount bearing head on compres-

sor. Tighten the Vz-13 cap screws to 80 lb-ft.

2. Put a drop of thread sealing compound (toctite 601 orequivalent) on each of the %6-18 adapter mounting screws

C Y L I N D E R S L E E V E

C Y L I N D E R S L E E V ES N A P R I N G

U N L O A D E R S P R I N G S + \ I

and on threads of each mounting hole in bearing head'

Position one of the supplied gaskets over holes in adapterand assemble the adap-ter loosely to bearing head.

Be sure there are no nicks or burrs on oil pump or boresin adapter and bearing head. Slide oil pump through adapterand into bearing head bore, allowing enough clearanceto tighten adapter mounting screws with an Allenwrench. The clearance between oil pump housing andbores in adapter and bearing head is necessarily veryclose. DO NOT USE FORCE and do not attentpt to changethe clearance.

J .

'NL.ADER T,-r-l ItUNLOADER FORK \./

q \ ats-ELAsrlc LocK NUr

\eHshPA'?1.,,.**'|f Y

BRACKET __.-,4.U N L O A D E RGASKET

S E A L E N DBEARING WASHER(BRONZE )

e\ - ' p rs roN RrNGs (coMpRESsroN - TA 'ERED )oO * ' l s r o N

R I N G ( o l L )

,ar,#'"-n'^-r,..oN PrN LocK R,NG

tI

O * P l s r o N R I N G ( o l L )

C O N N E C T I N G R O D

UNLOADER SLEEVE

A S S E M B L E DPISTON ANDC O N N E C T I N G R O D

CRANKSHAFT

S E A L E N DTHRUST WASHER (STEEL)

Fig. ?2 - 5H Compressor lnternal Components

CONNECTING ROD EOLTS

2L

Table 10 - Torque Values

5F UNITS

USAGE

Plug - Pump EndPlug - Crankshaft

'ibe Plug - Suction and DischargeManifold Cover

USAGE

Pump - PumPBearino Hed

Caoacitytontrol Valve - PumPEnd dearing Head

Auxiliarv Control Valve - PumPEnd Bearing Head

Manifold Cover Plate - CrankcaseOil Pump Adapter (12 cylinder)

Power Element Assembly -Crankcase

Unloader Cylinder Cover Plale -Unloader Cylinder Bracket

Discharge Valve Cap Screw -lnner Seat

Discharge Valve Guide Assembly -Valve Plale

Ol Pump Cover - PumP EndBearing Head

Auxiliary Control Valve Cover -Vatue Body

Rod Bolt - LocknutCapacity Control Valve -

HanGHole Cover

Plug - Pump

Cvlinder Head - crankcaseShaft Seal Cover Plate - CrankcasesBo$om Plate - CrankcaseSuclion and Discharge Manifold

Cover - CrankcasePump End Bearing Head Assembly -

CrankcaseHand-Hole Cover - CrankcaseSuclion Manifold - Crankcase

Elemenl -Crankcase

Capacity Control Valve -Pumo End Cover

Discharge Valve Guide Assembly -Valve Plate

Discharge Valve Guide - Inner SeatCvlinder Bracket

- Pump End Bearing HeadPib Plug - Crankshaft

Pump End Bearing HeadConnecling Rod Bolt (Aluminum Rod)

and Discharge ManiloldCrankcase

Rod Bolt - Locknul'

Discharge Manifold - Cylinder HeadsValve Plate - CrankcaseCvlinder Head - CrankcaseHind-Hole Cover - CrankcaseShaft Seal CoverPump End Cover and Pump End

Bearing Head - Crankcase- Crankshaft

Oil ReturnCrankcase

ouut lg l l Qcrv rw vdvE - v td l lRkw

Discharge Service Valve - Crankcas€Valve -

Srction Manilold

Vatue AssernblyFlywheel Locknut -

ClampingCover

Control ValveValve Body

Modulating Valve Adapter -Pump End Bearing Head

Lock Screw - Pump End Eearing Headoil Regulator Vatve Assembly - Crankcase

Pipe PIug - CrankcasePipe Plug - Pump End Bearing HeadPressurJRelief Vilve - Suclioh and

Discharge Manifold CoverPressure Reliel Valve - Crankcase

Manifold -Crankcase

Suciion Manifold Cover - CrankcasePump End Bearing Head -

CrankcaseOil Fitter Housing - Bearing Head

anoSuciion Manifold - Crankcase

.Seal'Flug -Oil Pressure Valve: Crankcase

Pipe Plug -

Pipe Plug - Crankcase

Valve Cover -Valve Body

Magnetic Plug - Pump tndBearino Head

Modulatifu Vatue Adipter - CrankcaseOl Bypass Plug - CrankcaseOil Bypass Plug - Pump Enc

Bearino HeadOil Bypais Plug - Pump End CoverHollow Lock Screw - Pump End Cover

and Center Main Bearing HousingOil Pressure Begulator Valve - CrankcaseCapOil Pressure Regulator Valve Assembly

End Bearing Head

Pipe Plug - Pump End CoverPipe Plug - Crankshaft

oil Pump Cover - PumpEnd Bearing Head

Auxiliary Control Valve Cover -Valve Body

Special Cap Screw - AuxiliaryControl Valve Bodv

Pipe Plug -

Oil Pump -

NC - National CoarseNEF - National Extra FineNF - National Fine'Steel Rod.

5H UNITS (cont)

2*n25-?92*m25-?s

2*29

25-232*n

Magnetic Plug - CrankcaseMagnetic Plug - Pump End

Bearino HeadOil BypaSs Plug - Pump End

Bearing Head

,93 22

Table 11 - Wear Limits; 5F,H Compressors

3.2413.235'r.t)00.017

.001

.001

.030tt

.000

.0005

.4356

.4370

.6240

.6260

.0015

.4361

.03r5

COMPRESSOR

COMPRESSOR PART

- 5F40. 60Joumal Diameter - 5F20. 30

- 5F40, 60

=#.t$3in.n Diameter - gl?g, 1g

Main Bearing Diameter(Assembled)

Joumal Diameter

- 5F20, 30- 5F40, 60

.001

.N2

.001

.001

.002

.002

.00rqjBearing DiameterEearing ThicknessCrankpln DiameterSeal End Bearing Washer Thlcknesss€al End Thrust Washer ThicknessPump End Bearing WasherThickness

ENTER (sH80,86,12O,1261tMain Bearing Diameterlitain Bearing ThicknessJoumal Diameter

ROOt

Drive Shaft Diameter(lD - 5H120 &

BorePiston Diameter - Steel, Standard Stroke

- Aluminum, Long StrokeBodyRing Groove (OD)

Piston Pin OiameterPiston Pin BushingPiston Ring End Gbp (compression and oil)ttPiston Ring Slde Clearance

Compression SideOil Side

Axlal Clearanc,eDrlve Shaft DiameterDrive Shaft Bushing Diameter (10)Drive Shaft Diameter (5H120 & 126)

.003

.003

.003

.003

.001

.001

.030tt

rvl?

Suctlon Valve (Disc(depth of urear below face)

Suction Valve Seat

Dischame Valve Disc(cteptliof w€ar bclow tace)

Discharge valve seat

ry_u

.005

.N2

.005

.002

'Same wear allowance applies to undersized shafts and bearingg- .tfiemanufaclured service |ompressors can be built with underdized main bearings and conne€tingFrod bearings.'Comoressors

with undersized-bearings are identified by the letter A, B, or C stamped on the compressor nameplateafter'the model number, and on botti ends of the gankshaft.

A=.01Gin., B =.02Gin., C=.030in. und€rsizedb€arings-

Repl@ment bearing heads for conpressors with undersized shafts must be field{odified with proper undersizedbearing.

"Repta& thrust and bearing washers rvhen end clearance exceeds maximum listed:

CRANKSHAFT END CLEARANCE1l tol0 to .036

.011 to .037

.014 to .042

.014 to .Ozl4

5H40,465H60,665H80,86

5H120,126

-+ ttcap dimension increases (by up to 10%) when cylinder bores have been honed (if necessary) on SF/l-l remanu-factured @mpressors.

23 398

A R O N Z E E E A R I N G W A S H E R

P U M P E N O B E A R I N G H E A D

OIL PUMP ROTOR

' I L F I L L:ONNECTION

OIL PRESSURE CONNECTION

CRANKCASE PRESSURE CONNECTION

IL PRESSURE CONNECTION-iEMOVE FOR ACCESS TO CONTROL OIL STRAINER )

Fig.23 - SF Oi l pump Assembty

IN.HOUSEPRocESSFITTING

SLEEVELOCATIONWHEN TJSINGOIL COOLER

PUMP COVER GASKET

ROTATIONARROW

O I L P U M P COVER

0

00

o

\\

\

Yv\

OIL PUMP@VER

UNLOADER PORTS(3 ON 4 CYUNDER UNftS:4 ON 6 ANQ 8 CYLTNOER'UNITS)

otL PUMP orl puMp /ROToR IDLER 1

\ I A- G t = - -&NE T :XIA >ROTATION: a Iil ,/ ARROWSEts gI r./xtw

v

Fig.24 - 5H40 through 86 Oil pump Assembty

$$$

oo l " sH lM(FIELD FABRICATED}

# Pi#,t'JfiB,

EEARING

6. Turn pump shaft to align drive tang with slot in end ofcrankihaft. Holding pump assembly with thumbs on the2 screws, slide assembly into bearing head until tangensases slot. A slight rotation should align screws withtupiJa holes in adapter. Start screws to hold alignmentatrd'th"n install balance o[screws and lock washen. Torqueall screws (V4-20) to 8-10 ft-lb.

7. Start compressor and check oil pressure. This oil pumpoperates in either direction of rotation. The conect oilpiessure for compressors using this pump is 45 to 55fsig above suction pressure.

OIL PRESSURE REGULATING VALVE (nonadjustable,Fis.. 27\ is located on the side of compressor adjacent toseil housing. Regulator maintains colrect oil pressure(Table 6) and ensures satisfactory unloader operation.

lrjbraruj

CYLINDRICALPOSITIONINGTOOL (F IELD-FAERICATED }

Fig.25 - Setting Oil Pump Bushing{Typical 5F20 through 60, and 5H40

through 86 - 5F40 Bearing Head Shown)

OIL REGULATING GAVALVE BODY

OIL REGULATINGVALVE CAP

CRANKCASE

IOENTIFICATIOIIIIOTCH ATTHIS ENO

DRIVE DISC

Fig.27 - Oil Pressure Regulating Valve(Nonadiustable)

Unscrew regulator from crankcase; use 5/ro-in. Allen wrenchon all compressors except 5H120, which requires Vz-in, Allenwrench. Regulator must not be clogged and plunger mustnot be stuck. Check drillings to regulator for fouling.

The nonadjustable oil pressure regulator is interchange-able on all current 5F,H compressors except 5H120 and 126models. 5H120 and 126 units have larger, nonadjustableregulators. Early 5F,H compressors were equipped with anadj us tab I e -type oil-pressure regulator. When an adj ustable-type regulating valve needs replacing, use a nonadjustableregulator.

OIL RETURN CHECK VALVE (5F20 through 60, and 5H40through 86) allows oil to return from suction manifoldto crankcase. This normally open valve closes whencrankcase pressure becomes higher than suction pressure(Fig. 28).

Two disc-type check valves on 5F20 and 30 compressorsare located beneath partition between suction manifold and''crankcase, one on eiich side ofcompressor. Rernove checkvalves through bonom cover or pump end of compressor.

I-eaf-type check valve on 5F40 and 60 and 5H40 through86 compressors is accessible through, and located at topcenter of, hand-hole cover opening.

Remove check valves and check to see that flutter valveor leaf does not stick, and that it seats tightly.

OIL PUMPCOVER

REI'OVE SHIM FORFINAL ASSY

4.

5

Fig. 26 - Setting Oil PumP Bushing(Typical 5H120,126l-

Hold pump with one hand and rotate it while equallytightening adapter mounting screws. Proper alignmentbiween pump and bearing head bore is extremely im-portant. THERE MUST BE NO BINDING.

When adapter is secure, remove pump assembly and placesecond gasket on pump housing. Insert two Vt-20 mount-ing screws and lock washers, one on either side of theword TOP on pump end cover, and position gasket onscrews. For renwining operatiotts, be sure the wordTOPis at the top.

pSKET

25

CHECK VALVE

wwreLEAF TYPE

FiS.28 - Oil Return Check Valves

CENTRIFUGAL OIL SEPARATOR on 5H120 and 126,mounted on crankshaft (Fig. 29), returns oil to compressorcrankcase. To remove or replace oil separator, see Crank-

-shaft Inspection and Service.

OIL FILTER SCREEN (Fig. 21) in compressor crankcaseis accessible through hand-hole cover or bottom plate. Re-

_move and inspect it for holes, then clean it with solvent andreplace.

Pressure-Relief Valves - When pressure differen-tial between high- and low-pressgre sides exceeds 350 -+

-35.psi'(5F60: 400 t 4O psi); pressure-relief valve bleedsrefrigerant from high to low side.

Check relief valves for evidence of leaking. Change if_defective or if valve has ever opened due to excessive

pressure.

5F60 COMPRESSORS - Internal relief valve screws intocrankcase and projects up through left cylinder-bank valve

-plate (Fig. 30). Use a standard socket{ype screwdriver toremove and replace valve.

5H40, 46, 80 AND 86 COMPRESSORS - Pressure-relief-valve is located on suction and discharge manifold cover

(Fig. 31)

5H60 AND 66 COMPRESSORS - Relief valve is locatedin wall between suction and discharge manifolds. Remove

-discharge manifold for access to relief valve. Use a stan-dard lVz-in. socket to remove and install the valve.

NOTE: The Dressure-relief valve is not pan of the valve plate as-sembly. The'valve mounts in the crankcase in the left side cylinderdeck (looking at pump end). The valve plate opening outlined, slipsover the pressure-relief valve when assembled.

Fig. 30 - Pressure Relief Valve (5F60)

VALVE PLATE

PRESSURE RELIEF VALVE

Ea

SUCTION AND DISCHARGEMANIFOLD COVER

Fig. 31 - Pressure Relief Valve andSuction Strainer (5H40,46, 80 and 86)

5H120 AND 126 COMPRESSORS are equipped with ex-ternal relief valve mounted on bypass line between suctionshutoff valve and discharge manifold. To remove valve, re-move bolts from flanges on either side of valve.

Suction Strainer - To withdraw strainer on 5F20 and40 and 5H40 and 46 compressors, remove suction and dis-charge manifold cover on seal end of compressor.

On 5F30 compressor, remove suction service valve. On5F60 and 5H60 and 66 compressors, remove suction man-ifold and withdraw 2 strainers. On 5H80 and 86 compres-sors, remove suction manifold cover.

On 5H120 and 126 compressors, remove one suction man-ifold plate at a time so as not to disturb position of detach-able suction manifold and suction line. Withdraw 2 suctionstrainers.

PRESSURE RELIEF VALVE(SEE I{OTE}

D ISCHARGE MANIFOLD

SUCTIONSTRAINER

0Fig. 29 - Centrifugal Oil Separator lmpeller

26

Clean strainer with solvent or. replace if broken or cor-roded. When replacing sucrion strainer, do not damage it.

On 5H 120 and L26 compressors, positioned manifold coverplate must compress strainer bail. If bail is too short, graspon sides and elongate it enough to be compressed by man-ifold cover. Position bail between the 2 bosses on inside ofmanifold cover to prevent strainer from turning.

Cylinder Head and Valve Assemblies

CYLINDER HEAD INSPECTION - Remove cylinder headsand check heads for warping, cracks and damage to gasketsurfaces.

VALVE INSPECTION (Fig. 32)

Disassembly - Remove cylinder head. Loosen cap screwsholding discharge valve seat to discharge valve guide, andcap screws holding valve guide to valve plate. Remove capscrews holding valve plate to cylinder block. Remove valveplate from cylinder block and discharge valve guide fromvalve plate.

Inspection - Inspect suction and discharge valve discs andvalve seats for cracks or excessive wear (lable I l). Checkcylinder-sleeve valve stops for uneven wear. Replace valvesif cracked or worn. If valve seats are worn, replace com-plete valve plate assembly. If cylinder-sleeve valve stopsare worn, replace sleeve.

Reassembly - Pistons must be below tops of cylinder sleeves.To position correctly, nrrn crankshaft or force pistons down.

1. Place suction valve springs in valve plate recesses. Largespring coil should be in full contact with bottom ofrecess.

2. Place suction valve disc on valve springs; press disc intovalve plate recess. Slide valve retainer clips into place(Fig. 33). Clips must not cover valve lifter springs orpins. Valve retainer clips 5F20-2061 (5F compressors)and 5H40-2061 (5H compressors) are field supplied.

3. Bolt valve plate to cylinder block. Remove valve clips.

4. PIace discharge valve springs in discharge valve guidespring recesses.

5. Place discharge valve disc over springs, agd fit innerspring in place over valve disc. Hand-tighten bolts hold-ing inner seat to valve guide (valve guide assembly).

6. Place valve guide assembly on valve plate. Tighten allbolts and bend tabs on lock washer and lock plates. Re-place cylinder head.

t',Rtlo.[.ul*t

Fig. 32 - Suction and DischargeValve Assembly

VALVEPLATE

DISCHARGE VALVESPRING

\\ o'scHARGE vaLVE

D|SCHARGE \

; r 'o r r ru puacE"kl+}@|NNER sEAr

/ yt'DISCHARGE VALVE

OUTER SEAT

VALVE L IFTS P R I N G .

/suctror'r /VILVE /

ffit t

SUcTtoN IVALVE ISEATS I

E R

VALVE SUCTION VALVE D ISC

SUCTION VALVE RETAINER CLIPS

Fig. 33 - Valve Clips in Place

Cyl inder and Unloader Sleeves

DISASSEMBLY (Fig. 34) - Remove cylinder head, suc-tion and discharge valve assembly, and pump-end bearinghead. Whenever cylinder sleeve or valve plate is replaced,use a new suction valve disc.

l. Turn crankshaft until piston is in midposition.

2. Insert a sleeve puller into cylinder and push it down ontotop of piston.

3. Tighten nut on top of sleeve puller to expand puller insleeve.

4. Turn crankshaft, forcing sleeve upward until it can beremoved.

5. Remove unloader snap rings (5H compressors only). Dis-assemble unloader sleeve, pins and springs.

INSPECTION - Examine bore of sleeve for wear. Checksuction valve seats for scratches and wear. Check unloadersleeves, pins and springs for wear and freedom of move-ment (Table l l).

REASSEMBLY - When new rings are being installed in aused cylinder sleeve, break the hard, glazed surface of cyl-inder sleeve to reduce wearing-in period of new rings. Cleansleeves thoroughly after breaking gIaze.

If a felt sock filter is installed, remove and inspect itafter 50 hours of operation. Clean filter if required andreplace it for another 50 hours. Clean the suction strainerwhenever the felt sock is removed. Remove sock whensystem is clean. (Not applicable for 5F20 and 30compressors.)

PLATE

27

To reassemblel

l. Rotate crankshaft to position piston at top center'

2. Lubricate piston rings and beveled surface at lower edge

of cYlinder sleevc.

3. Stagger ring gaps around piston'

+. With turning motion, work sleeve.over piston and rings'-

C;F;;-uiaurign each ring with beveled edge of sleeve'

5 .Sea ts leeve inSuc t i onman i fo ldpa r t i t i onandcy l i nde rdeck recess.

6. Rotate sleeve so that any 2 valve lifter-pin holes lie equal-

aiii""""t ftom longitudinal axis of compressor (Fig' 3a)'

ff;;;;;i,;;;-fii"' pins line up with suction valve

springs.

Connecting Rods and Pistons

REMOVAL - Remove cylinder head' valve plate and

ffi;-h"G;ver or bottom ilut" to gain access to rods and

pistons.

Remove connecting rod caps (Fig' 22)' Label caps and

.oit-to ,tt"v may be"reinstdGa in iamg ql1::t on crank-

;il;h. h;6t; .ylind"t sleeve, connecting rod and piston

;;;6k ;; a ufit uy pushing assemblv up through cylin-^

Aru;?.;; ;;;'1i";'-pi'ti" to co^i up through top o{;i;r;;";;;; ii*ii"t pio'ess' Remove retain-ing rings and

;il;;;;-io dit^t"*ble connecting rods from pistons'

Remove rings.KeeD each individual connecting rod .and piston assem-

bl;';;Jh";io uia i.*t"*ulv' Chleck all parts and crank-

piir jo[rnals for wear (Table I l)'

INSPECTION AND REPLACEMENT - 4tlach connect-

iil;"dt i;;istons *ittr piston pins and.lock in place with

lii"ilft;"H. pit,"" pi'"iare ietectivelt.filtfdTor a pushnti r"uit"tn6le in the piston from which th"l I:t"^'l:-*iuJ. pfu"e piston pin retaining rings'.with sap on side'

il;t'il dfiIijl tiil;ffiiai",i'et" "noulh to inhibit

rotition under finger Pressure'Check Ringst. Ctect ring gap by inserting each ring separately in gyl-^'

i;;;;;ffifiti'ut6tv % in. From top' Ring gap should be

betweeii.007 and .017 inches'

2. Install compression rings on piston with-marked side up-' ir"" Fig. ib toward piiton head' Install oil rings either

side up.3. Stagger ring gaps around piston'

4. Measure side clearance between ri-ng 9d piston (approx--' ;;;it .001 inch). Check rings for free action'

Check Rod Bearing Inserts (Fig' 22) - If bearing inserts

@ is iot worn, it is only neces-

ft;;:pft" int"ttt. -oo

not file bearing caps' Place the

inserts in connectrng ioo *oio"necting-r6d caps so knobs

on inserts fit into nor"tiJti'itJ"up' iiua"uteinsert bear-

ili! ;d crankpin freely before installing caps'

Install cvlinder sleeve, connecting rod qrd piston assem-

br"':tit,""i"*;ii;;- il;-;;;;"i7"8 rol' and instau cap-i:; ;h":; f,;;;' ; a, ; ";'-

o i i i i t, aa i i s of c r a nkp i n' ( s ̂ ! ! t;;;;';,";;;;-d-';;;;;; b" in 'o*i side oiiournat')

' o l L R ING'See Table 11 for piston diameters'

Fig. 35 - Piston and Rings

Caoacity ControlOperation - All 5F'H series com-

or!il;,'"-;"pt irzo ina go units, include.hydraulic ca-5;;il;"ilii,ittr""a"i tvtt"*t * Jtutia-a equipment' (Fie!d-i"JrirJJ^I*l,ttoty unr,juo"r packages are ivailable for the;i"O-;Ji0.ir[" unloadei system activates and deacti-

""t"i G"

""*iprissor's cylindei banks, by permitting suc-

tion valves to seat or prLventing them fiom doing so' in

r;;; io tttunging lbad dema--nds' Capacity control un-

i;;'d;; r;JucE i ilnit' s actual operatin g capacitv. bv steps

down to as little as 25Vo of its total c-qpagtfy' rlgure r /,shows the sequence and number of cyliirderi that unload

with each steP.Capacity control unloader systems consist of 4 major

components:1. A capacity control valve' which increases or de-^'

;;"ase;;;n&otoil pressure to.the hydraulic relay piston

;;6;tti;;;iiv *tt"i ttre suction preisure from the crank-case rises or falls.

COMPRESSIONRINGS (SOLIO)

O IL R ING.(VENTED)

BoDYr

OIL RING(VENTED)(STANDARDSTROKE ONLY)

MARKED SIDE UP

E I T H E R S I D E U P

Never operate compressor with heads or valve plate

removed. Fig. 34 - Position of Cylinder Sleeves

COMPRESSION RING

--L- No rAPER

28

FROM COMPRESSOROIL PUMPADJUSTING SCREW

XTERNALCAPACITYCONTROL VALVE

IF PNEUMATIC COIVTROLIS NOT USED, THISPORT MTJST BE VENDO NOT PLUG

FROM CRANKCASEPRESSURE

OIL PUMPPRESSURE

STRAINERAND ORIFICE

NEEDLEVALVE

LIFTING SPRINGSAND PINS

LIFTINGFOFIK

CONTROL OILPRESSURE

UNLOADERPOWERELEMENT

{TO OTHERUNLOADER POWERELEMENTS ON 5F3O ONLY

Fig. 36 - Capacity Control (5F20, 5F30)

FROM COMPRESSOROIL PUMP,

CONTROL OILPRESSURE

LIFTER SPRIAND P INS

L IFT INGFORK

PISTON

POWERELEMENT

IY

CRANKCASE CONNECTIONFOR OIL RETURN ANDOPERATING PRESSURE

TRAVELINGNUT

CAPACITYVALVE

orLDRAIN

OIL PUMPPRESSURE SUCTION VALVE

orsc

CYLI NDERSLEEVE

TO OTHERUNLOADERPOWERELEMENTS

HYDRAULICRELAY

Fig. 37 - Capacity Control Operation (5F40, 60; 5H40, 60, 66, 80 and 86)

o t LDRAIN f FRuIsg.'.o''

CRANKCASEPRESSURE

OIL PUMPPRESSURE

oo

ADJUSTMESPRING

29

2. Ahydraulic relay, which (gxcept on the 5F20 and 30)

feedi oil to the unloader power elements in sequence'Control oil pressure from the capacity control valve ac-

tivates this rglaY.

3. A hydraulic power element, which supplies the po-wernecessary to operate the valve-lifting mechanism. It ismodulated by the capacity control valve.

4. A valve.lifting mechanism, which consists of a sleeve,a lifting fork and a push-pin a,ssembly around each con-trolled cylinder. The valve-lifting mechanism holds thesuction valve open, or permits the valve to remain innormal operating position depending on its actuation bythe power element.

- These components operate in the following manner:

5F2O AND 30 CAPACITY CONTROL OPERATION(Fig. 36) (With Optional Unloaders and Control)

- Loaded Operation - A rise in suction pressure causes nee-

dle valve to close. Oil pressure in power element increasesas oil enters capacity control circuit from oil pump- Powerelement piston is forced upward, pivoting lifting fork down-

'- ward. Lifter pins drop, allowing suction valve to seat andload controlled cYlinder.

Unloaded Operation - A drop in suction pressure causes

'- needle valve to open. Oil bleeds through valve to crank-

case, decreasing oil pressure in power element. As oil pres-sure to power element drops, the pl919n moves downward'Lifting fork pivots upward, moving lifting pins.upward; suc-tion ialve hses from its seat and controlled cylinderunloads.

5F4O AND 60, AND 5H4O THROIJGH T26 CAPACITYCONTROL OPERATION (Fig. 37 and 38)

Loaded Operation - A rise in suction pressure increases

prasu." against capacity control valve bellows, compress-ing rung" ialustmeitt spring, Compression of range ldjust-*6nt sp?ng illows valve sp-ring q9 move push pins and valveneedle'poiit toward valve seat. Flow of control oil to crank-case through oil drain is throttled.

Control oil pressure rises as oil enters capacity controlcircuit through orifice from compressor oil pump circuit.Increased coitrol oil pressure advances hydraulic relay pis-ton (against spring) which feeds oil at full pressure to oneor moie contrblled cylinder power elements depending onposition of control valve.

Pump oil pressure in unloader power elements forcespiston ipward, pivoting the lifting fork(s) downward. Lifter

iins dr6p, all6wing suction valve(s) to seat and loadcylinder(s).

C O N T R O L O I LPRESSURE

ORIF ICE

CONTROLotLSTRAINER

@PNEUMATICCONTROLCONNECTION

RANGEADJUSTMENTSPRING

TRAVELINGN U T

o lLTO OTHERUNLOADERPOWERELEMENTS

FROM COMPRESSORO I L P U M P

SUCTION VALVEDl sc

L IFTER SPRINGSAND P INS

L IFT INGFORK

PISTON

IF PNEUMATICCONTROL IS NOTUSEq THIS PORTMUSTBE VENTED

EXTERNALADJUSTINGSTEM

SURGECHAMBER

CAPILLARY

FROMCRANKCASE

<- PRESSURE(SUCTION OFO I L P U M P )

UNLOADERSLEEVE

CYL INDERSLEEVE

CONTROL O ILPRESSURE

f :ncssss'

Fig. 38 - capacity control (5H120,5H126)

f]-

C-

Unloaded Operation - A drop in suction pressure de-creases pressure against control valve bellows. Range ad-justment spring presses against the push pins, compressingthe valve spring. This moves the needle valve off the seat.

Control oil bleeds from hydraulic relay and control valveto crankcase, relieving oil pressure on hydraulic pistons.The piston retracts, preventing transmission of pressurizedoil to controlled cylinder power element(s), and the oil drainsto crankcase

As oil pump pressure on power element drops, the pistonmoves downward. Lifting forKs) pivot(s) upward, movinglifting pins upward; suction valves rise from their seats andcontrolled cylinder(s) unload(s). It should be noted that aminimum of 33 to 35 pounds of oil pressure is required forproper unloader operation.

Capacity Control Inspection and Service

UNLOADER POWER ELEMENT REMOVAL - Re-move cylinder head, valve plate, connecting rod, piston andcylinder sleeve. Remove Allen head cap screws (2) holdingunloader power element in position.

Remove power element (Fig. 39) and disassemble. Checkall parts for wear or damage.

POWER ELEMENT REPLACEMENT - Check unloaderfork height (Fig. a0) of new or assembled power element.

Attach power element to internal suction manifold. Re-place cylinder sleeve piston, connecting rod, valve plate,cylinder head and hand-hole cover.

UNLOADER P ISTON UNLOADER UNLOADER CYL INDERCYLTNDER RoD ii^LllR, is,l+tP )

covER PLArE

Fig. 39 - Unloader Power Element (Typical)

EXTERNAL ADJUSTING STEM REMOVAL does not re-quire compressor to be pumped down. Loosen hex nut atvalve stem base and remove adjusting stem assembly.

REMOVALOFCAPACT|Y CONTROL VALVE AND HY-DRAULIC RELAY - Assembly is located in hand-hole cover(Fig. a1) of 5F40 and 5F60 units; in pump-end cover (Fig.42) of 5H40 through 86 units; and in pump-end bearinghead (Fig. 43) of 5H120 and 126 units.

Remove capacity control valve and hydraulic relay.

NOTE: It is not practical to remove hydraulic relay from5H40 through 5H86 compressors.

Inspect parts for wear, damage or evidence of leaking orsticking.

A new hand-hole cover, pump-end cover or pump-end bear-ing head with control valve assembly and hydraulic relaymay be installed. However, capacity control valve (and hy-draulic relay on 5H120 and 126 units) is available as a sep-arate parts item for installation on original hand-hole cover,pump-end cover, or pump-end bearing head.

INSPECT CONTROL OIL STRAINER - On 5F compres-sors, the control oil strainer is located on the side of thepump-end bearing head (Fig. 23). Strainer is located be-hind the control oil pressure gage connection block on the5H120 and 126 units (Fig. 20) and on pump-end cover (Fig.42) of all other 5H compressors.

Remove strainer and inspect it for holes and dirt. Clean itwith solvent and replace.

TO UNLOADER N ${3ADERPOWER ELEMENTS \-./S€CX.ET.ICE

TO UNLOADERPOWER ELEMENTS

I

1 5 f i32

{

Fig. 41 - Compressor Hand-Hole Cover andAssembly (5F40 and 5F60)

( 5 R H : 2

Fig. 40 - Unloader Fork Height (5F and 5H)

3 l

TO CONTROLOIL PRESS.GAGE CONN

CAPILLARYTUBE

TO UNLOADERPOWER ELEMENTS

/.\L|N|.OAOER\JSEAUENCE

CAPACITY CONTROL VALVE

SURGECHAMBER

- PUMP ENDMAINBEARING

FROMCRANKCASE

CRANKCASE PRESS.CONN AND OIL FILL

HYDRAULICRELAY

ILIARYCONTROLVALVE )

TO UNLOADERPOWER ELEMENTS

FULL FLOWFILTERHOUSING

PUMP PRESSURE(AFTER FILTERING)

SURGED R U M .

Crankshaft lnspection and ServiceDISASSEMBLY - Remove cylinder heads, valve plates,connecting rod and piston assemblies, and pump-end mainbearing head.

On 5H80 through 126 units, remove hollow-center mainbearing lock screw located beneath plug (Fig. 44) and loosenhollow-cup setscrew (Fig. a5) until center main bearing canbe slid frorn its support.-On 5H86, 120 and 126 units, dis-connect oil line to center main bearing. Remove crankshaftthrough pump-end opening.

Normally it is not necessary to remove the oil separatorimpeller (Fig. 29) from the 5HI2O or 126 shaft. If impellermust be removed for any reason, however, immerse it inhot water or oil until heated to 180 F or more. Remove alltraces of water before reassembly. Do not heat impellerswith torch.

B E A R I N G I N S E R T S

NOTE: Dotted lines indicate piping behind surge drum.

Fig.42 - 5H Pump-End Cover and ControlAssembly {5H40 through 86}

FILTERBYPASS

OIL PUMP* TANG

CAPILLARYTO OIL PUMP

- INTAKE UNLOADER SEOUENCE

HYDRAULICRELAY PLUG, MAGNETIC (PUMP INTAKE)

Fig. € - 5H120 and 126 Pump-EndBearing Head

3"$i35"

Fig.4 - 5H80 through 126 Center Main BearingHousing Setscrew Location

Fig. 45 - Center Main Bearing(5H120 and 126)

uor*ur--\ a1PLUG-6r s fo'-iro*-EiV SETSCREW

32

INSPECTION - Check crankshaft journals for wear andtolerances (Table ll). Remove crankshaft plugs, check oilpassages and clean if clogged.

Connecting-rod bearing inserts and main bearings are avail-able for crankshafts reground from .01O-in., .020-in., or.030-in. undersized. Factory-reground crankshafts are stamped onboth ends with an A (.010-in. undersized), B (.020-in. un-dersized), or C (.030-in. undersized).

IMPORTANT: Do NOTE regrind crankshafu for 5H46,66, 86, and 126 compressors in the field. Replace shaftswith scored journals.

AII instructions for feld grinding apply only to standard-stroke crankshaf'ts.

On crankshafts reground locally, hold throw to 1.001 in.for 5F compressors and to L.376in. on 5H compressors. StampA or B on crankshaft and pump-end bearing head next to oilpressure gage connection.

To determine maximum and minimum journal diametersfor undersized shafts, subtract the amount (in.) that the shaftwill be ground undersize from factory from the tolerancesspecified in Table 1 1. For example, the factory tolerance for5H40 seal-end journal is 2.6225 in. to 2.6235 inches. Tol-erance for a crankshaft resround to .010 in. undersize shouldtherefore be held betweei 2.6125 in. and 2.6135 inches.

IMPORTANT: When regrinding the seal-end journalon 5H120 crankshaft, do not grind in the area of theoil separator impeller. This is not journal area, and mustremain intact or the oil separator impeller will not fitproperly.

REASSEMBLY -If 5H120 or 5H126 oil separaorhas beenremoved, read impeller paragraph below before installingcrankshaf't.

When regrinding crankshaft, remove crankshaft plugs andclean oil passages as well. Before replacing crankshaft, in-sert and tighten plugs, and reinstall the 5H120 and 126 oilsepzuator impeller:

l. Insert dowel key (Fig. 29) with axis parallel to axis ofcrankshaft. Position key so chamfered edge is toward ra-dius of crankshaft journal.

2. Immerse oil separator impeller in oil or hot water to heatit to 180 F or more. [f water is used, remove all tracesbefore reassembly. Install impeller on cranlshaft with dowelkey tined up with impeller keyway. Impeller must fit keysnugly.

3. Check that seal-end thrust washer is in place on dowelkey in crankcase.

lnsert crankshaft and install pump-end bearing head, con-necting rod and piston assemblies, valve plate and cylinderheads. On 5H80 through 126 units, insert center main bear-ing setscrew and lock screw as described under ServicingCenter Main Bearing. On 5H86, 120 and 126 units, recon-nect oil line to center main bearing.

Pump-End Main Bearing (Fig. a6)DISASSEMBLY AND INSPECTION - On 5H40 through86 units, remove pump-end cover. Remove pump-end bear-ing head on all units. Inspect bearing for tolerances shownin-taUte ll. If a pump-end main bearing is worn, removebronze bearing washer, and chisel out bearing. Inspect bear-ing housing for wear (Table I l) and damage. Remove anyburrs.

REASSEMBLYl. Lubricate outside of new bearing with heavy grease.

2. Line up hole in bearing with oil port in housing.

3. Press bearing into place using a puller shoulder (Table 12and Fig. 47 and 48) and jack screw or bearing press.

4. PIace bearing washer on bearing with notch in washerproperly positioned around dowel pin (Fig. a6).

PUMP ENO MAIN EEARING

E R O N Z E B E A R I N G(OR STEEL WASHERoN 5Hr20 AND t26MODELS )

DOWEL PIN

PUMP END BEARING HOUSING

Fig. 46 - Pump-End Main Bearing Position

Table 12 - Main Bearing Puller Sizes

-) NOTE: Bearing pullers can be ordered throughCarrier or Totaline Parts.

Center Main Bearing - Size 5H80 through 126 com-pressors have a center main bearing and housing.

DISASSEMBLYAND INSPECTION-On 5H86, 120 and126 compressors, disconnect oil line to center main bearing.(5H80 center main bearings are fed through the shaft.)

Remove plug on compressor crankcases (Fig. 44). Thenremove hollow lock screw beneath the plug (Fig. 45). Next,loosen hollow-cup setscrew until center main bearing as-sembly can be slid from its support. Remove crankshaft andbearing assembly.

Disassemble bearing (Fig. a5) and inspect for proper tol-erances (Table ll).

J J 697

AL HOUSING

HOUSING PILOT

THRUSTWASHER

- DIRECTION OF PULL- TOP PLATE

Fig.47 - Seal-End Main Bearing (SF40, 60)

Pull bearing into housing (Fig. a9). Edge ofbearing shouldbe /:z-in. below surface of bronze bearing waslier.Look through oil pressure regulator opening to check oilpassage for blockage.Blow out oil groove in bearing housing and oil lines (ifany) to it.

SEAL END MAIN BEARINGHOUSING INSIDE

BROMEWASHER T

OIL GROOVE

SEAL ENDMAIN BEARING

DOWEL PIN

2.

4.

'Steel washer on 5H120 and '126 models.

Fig. 49 - Seal-End Main Bearing Positioning

Crankshaft Seal Inspection and Replacement- The crankshaft seal in all current 5F,H compressors is arotating, bellows-type seal. This seal is the service replace-ment for all earlier seal assemblies. Figure 50 shows Typest__"q4 Il of this design (5F20 through 60 and 5HzlO through5H126 compressors).

Fig. 48 - 5H Seal-End Main Bearing

--REASSEMBLY - Install rhe new bearing inserts. As-semble bearing housing on crankshaft, but do not tighten the\ollow-cup setscrews. Install crankshaft, center main bear-ng and holsing, and pump-end main bearing assembly. Tighten

--oolts holding the pump-end main bearing assembly. Rbtategranphaf;while tightening setscrew on center main bearing\ousing. |"F"t"-y should tighten fully without any bindingrf crankshaft- If binding occurs, shim the opposiie side oT

-,aearing housing, using .001-in. shim stock. - '

Seal-End Main Bearing)ISAS SEMB LY AND INSPECTION - Wirh crankshaft re-

-*noved, use a bearing puller wittr a shouldering.device toremove and install seal-end main bearings (Fig. 47 and 48).jearing pullers can be ordered through Canier or Totaline)arts.

- Inspect bearing and bearing housing for tolerances shownin Table I l.

GASSEMBLY - Remove any burrs and clean bearing hous-_ng- before replacing bearing. Lubricate outside of &aringwith heavy grease.'. Position bearing so chamfered edge enters bearing hous-

ing first, oil holes in bearing and housing are aligned (seenote below), and bearing relief groove is at top.NOTE: On size 5 120 and 126 compressors oil hole inbearing and housing will not be aligned.

IMPORTANT: Do not attempt to repair or replace sealcomponents. Replace complete seal assembly with cur-rent rotating-bellows-type assembly. Do not disas-semble bellows assembly of service replacement seal.

BEFORE INSTALLING SEALl. Pump--end F-ing head must be in place for proper po-

sitioning of seal on crankshaft.2. Be sure shaft extension and edges of keyway are free of

sharp edges and nickS. Also, shaft must be clean arrd freeof rust. Polish shaft with crocus cloth.

3. Check seal assembly for proper bellows placement andcleanliness.

4. Apply compressor oil to seal assembly and crankshaft,completely saturating bellows and carbon ring.

INSTALLATION - Refer to Fig. 5l for procedure.

Accessories - For accessory installation literature, re-fer to Thble 13.

COVER PLATE WITHINTEGRAL SEAL SEAT_*_._\

COVER PLATE GASKET

CARSON RINGSEAL NOSE

COVER PLATE GASKET

CARBON RINGSEAL NOSE \

\LI LR T

KB*I B

lrU'

FELT WIPER

- 5F20,30 frype l)

B _ 5F40, 60 AND'F540 and 60 - 1.5"

COVER PLATE WITH INTEGRALSEALSEAT

5H40 THROUGH 86' (Type l) - Typical

diameter; 5H40 through 86 - 2.0" diameter.

CARBON RINGSEAL NOSE"k I HrcffiffiItre

WUWg F F v \U. coVER PLATE WITH INTEGRAL SEAL SEAT

C - 5H120, 126 (rype ll)Fig. 50 - Service Replacement Seals

Table 13 - Accessory Literature

Accessory Water4ooled Heads PackageAccessorir Oll Fllter PackageAccessorir Oil CoolerAccessory Oll Safety Swltch PackageCapaclty Control VaiveAccessory pnl-o,ader Package ,

*See your Carrier Distributor for cunent form numbers.

35

Step 1 - Lubricate the shaft and the neoprene bel-lows where it comes in contact with the shaft. Slidethe seal assembly, as it is shipped from the factoryonto the shaft until the neoprene just starts to graspthe shaft.

Step 2 - Holding the sleeve and spring assembly,pullforward on the seal nose assembly at the sametime, turning it so that the lugs on the driving bandare out of the slots in the remainer shell and reston the surface of the retainer shell as shown by thepencil. ffhis does not apply to the 5H120 Type ll seal.Lugs are permanently fixed.)

Step 3 - Using the seal cover plate, push the sealassembly into its proper location on the shaft. DONOT use cover plate bolts to push seal into position.The spring'guide,should be' tight against.the,shaftshoulder as shown by the pencil. Remove the coverplate, being careful not to damage the carbon washer.GRASP THE SEAL NOSE ASSEMBLY AND TURNIT UNTILTHE LUGS ON THE DRIVING BAND DROPBACK INTOTHE SLOTS INTHE RETAINERSHELL.

NOTE: The seal may leak slightly immediately after installation,

Step 4 - Lubricate the carbon seal.washer.and seal.seai. Reinstallthe sealcover plate, drawing the boltsdown evenly to prevent damage to the carbon sealnose. This view shows the lugs of the driving bandproperly positioned in the center of the slots in theseal retainer shell. This is the correct position duringoperation. This prevents the sealfrom being used asa thrust washer under all operating conditi-ons.

but a short period of operation will correct the condition.

LUG IN CENTER

Fig. 51 - Installation of Sleeve-Type Rotary Seal

TROUBLESHOOTING

Loose electrical connections or

Liquid line solenoid valve closed.

Evaporative condenser or cooling tower

Low-pressure switch erratic in

Thermostat differential too narrow.Suction valve closed or throttled.Tubing to pressurestat restricted.

lnsufficient condenser water flow or

Condenser inlet water temperature toohigh.

Insufficient water flow through condenser.

Suction seruice valve padiallv closed.

Insufficient clearance between piston

Loose or misaligned belts.

TROUBLSSYMPTOMCompressor will not start

Compressor cyclesintermittently

Compressor cycles on highpressurestat

High discharge pressure

Low discharge pressure

Flooding

Low suction pressure

System noises

REMEDYCheck main switch, fuse and

Reset thermostat.Reset switch.Reset switch.Clean all control contacts.Tighten connections; check wiring andrewtre.Check and replace if defective.

Check fuses, overload. Restart.Check fuses, overloads and controls.Restart.Check for clogged tubing to switch.Check switchAdd

Reset.Reset.Open up valve.Check and cleanRepair orRemove excessAdjust water regulating valve tocondenser. Clean condenser.

valve.

Check and start.lncrease water quantity by adjustingwater regulating valve. Use colderwater.

Check for burned-out holdino coil.Reolace if defective.

Readjust water regulating valve. ln-crease size of water supply main tocondenser.Clean tubes.

valve.Remove excess ant.Puroe air.

water valve.Open valve.Examine valve discs and valve seats.Replace if worn.Replace.Reset to 5 F - 10 F superheat. Valve

ation must be stable (noAdd reReset expansion valves.Check andReplace defective parts.

Check alignment and tension. (Beltslack should be at

bolts.

TROUBLESHOOTING (cont)

PROBABLE CAUSE

Unit foundation improperly isolated.

lmproper support or isolation of piping.

Slugging from refrigerant feedback.

Defective valve lifter mechanism (noiselevel varies with unloading).

Piping vibration.

No muffler in discharge line or

Hissing (insufficient flow through expan-sion valves, or clogged liquid linestrainer).

Pluooed oressure line to oower element.

Plugged or broken pressure line to

Control valve bellows leaking.

Pioe oluq in oneumatic connection.Foaming in crankcase from refrigerant

Excessive fluctuation in suctionpressure from oversized expansionvalve.

TROUBLSSYMPTOMSystem noise (cont)

Compressor willnot unload

Compressor willnot load

Rapid unloader cycling

Low oil pressure

REMEDYlsolate foundation.Use correct piping techniques and supportoioinq with suitable hanoers.

Replace sticking filter pins. Check un-loader fork for alignment. Check powerelement for sticking piston. Check for oilleakage at tube connection to powerelement. Check amount of valve pin liftabove valve seat (0.33 in. for 5F; 0.125 in.

Check expansion valve setting. Checkthermal billb looseness and correctlocation. See Carrier System DesignManual, Part 3 for standard PiPing

Remove excess oil. Check expansionvalve for floodback.

for 5H).

Support pipes are required. Check pipeconnections.lnstall muffler. Move muffler closer to

Add refrigerant. Clean strainer.

control cover asseClean line.

Check oil , switch

Clean or repair.

Clean orRemove thread and leak test.

valve if bellows leaks.RemoveCheck expansion valve and piping.

ace control coverResize expansion valve.

Clean or replace strainer.See T - low oilAdd oil.Check and

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Clean strainer.

TROUBLESHOOTING (cont)

PROBABLE CAUSE

Liquid carryover from evaPorator.

Oil return check valve stuck closed.

ion ratio too hiqh.

TROUBLE/SYMPTOMLow oil pressure (cont)

Cold comPressor

Low crankcase oil levelCylinders and crankcaseswea

Remove obstruction.

Check refrigerant charge andsion valves.or replace check valve.

Check refrigerant charge and

Clean strainer.

Check unit

High crankcase temperature(should be 150 F to 160 Fmax. at seal housing)

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