2 4 APR2083
/\PanUnited
-J Pan-UnltedShipyard Pte Ltd
sF,H
@ A _Fr_-! ^
Open-DriveCompressors
Installation,
Start-UpandServicenstructions
CONTENTS Page
S A F E T YC O N S I D E R A T I O N S
Page
....... 1
Pressure-ReliefValves
SuctionStrainer..... :: 32
C v l i n d e rH e a da n d V a l v eA s s e m b l i e s. . . . . . . . . 2 7
INSTALLATION. ... 1-13 C i r t i n O earn d U n l o a d e rS l e e v e s . . . .. ...27
S t e p 1 - P r e p a r ef o r I n s t a l l a t i o n . . ...... 1 C 6 n n e c t i n gR o d s a n d P i s t o n s . . .. . . ...28
. PREPAREEQUIPMENT ROOM CapacityControlOperation ......28
S t e p 2 - R e c e i v eM a c h i n e .. .... l0 Capacity Control Inspection and Service . . . . .31
. BEFOREUNLOADING C r a n k s h a fl tn s p e c t i o na n d S e r v i c e. . . . . . . . . . . 3 2
. zuG UNIT CAREFULLY P u m p - E n dM a i nB e a r i n g . . . . .....33
S t e p3 - I n s t a l U l nit . ..... 10 CenterMainBearing.... ........33
. TOMOUNTMOTORONBASE Seal-EndMainBearing.... ......34
. TO MOUNT CARRIER COMPRESSORUNITS Crankshaft Seal lnspection and
AND CONDENSERPACKAGES Replacement.... ........34
. TO MOUNT COMPRESSORBASE ON Accessories.... ....34
SUPPORTSTANDS TROUBLESHOOTING
Step 4 - Assemble Refrigerant Piping .. ..37.39
andComponents ........10
. COMPRESSORDISCHARGEPIPING SAFETY CONSIDERATIONS
. REFzuGERANTDRIER Installation, start-upandservicingof this equipment can
. FELI FITJIERS behazardous dueto systempressures, electricalcomponents
S t e p 5 - I n s t a l lM u l t i p l eC o m p r e s s o r s. . . . . . . 1 0 andequipment location.
. EQUALZING LINES
Only trained,qualifiedinstallationandservicepersonnel
S t e p 6 - M a k e E l e c t r i c aC l o n n e c t i o n s. . . . . . . 1 2 shouldinstall,start-upor servicethis equipment.
. GENERALNOTES
. ATTACH POWER WIRES TO Whenworkingon thisequipment, observeprecautionsin
COMPRESSORMOTOR the literature,tags,stickersand labelsattachedto theequip-
. CHECK MOTOR ROTIITION ment and any othersafetyprecautionsthat apply.
. INSTALL CRANKCASE HEATER . Follow all saferycodes.
Step 7 - Check Compressor/lVlotor . Wearsafefyglassesand work gloves.
Alignment .. ...... 13 . Use care in handling, rigging and setting bulky
. BELT DRIVE equipment.
. DIRECT DzuVE
. HOT CHECK AND DOWELING
Step 8 - AssembleWater Piping . ..... 13
Step 9 - PrepareLubriCationSystem ..... ".. 13 Before performing service or maintenanceoperationson
. INSTALL OPTIONAL EQUIPMENT unit, shut off and tag main power supply to unit. Elec-
. CHECK OIL LEVEL trical shock could cause personal injury.
. RECOMMENDEDOILS
PREPARE F O R I N I T I A LS T A R T . U P. . . . . . . . . . . 1 3 INSTALLATION
E v a c u a t eD , e h y d r a t ea n d L e a k T e s t . . . . . . . . . . 1 3
R e f r i g e r a nCt harging ...... 13 Step 1 - Preparefor lnstallation
START.UP .. 13-16 PREPARE EQLIIPMENT ROOM - Locate compressoror
P r e l i m i n a rSy t e p s ......... 13 condensingunit in a well ventilated area. If natural venti-
S t a r tC o m p r e s s o r ......... 14 lation is inadequate, provide forced ventilation through
C h e c k C o n t r oO l peration ........t4 ductwork. Check applicablecode requirements.
C h e c k H i g h - P r e s s u rS ewitch .....t4 Provide freeze-upprotection for water-cooledcondens-
Check Low-PressureSwitch .. ... t4 ers, water lines and accessoriesif freezing temperaturescan
Adjust Capacity Control (if required) .. . . . . . .14 occur during winter shutdown periods.
SCHEDULEDMAINTENANCE ,.I7-T9 Provide sufficientclearancefor removal of compressorcyl-
CheckLubricationSystem .......t7 inder headsand valve plates.Allow spaceon the oil pump
Check Water-CooledHeads .... .. 19 end for crankshaft removal as follows:
SERVICE .. .. 19-36 5F20, 30, 40, and 60 compressors . . . . . .20 in.
S e r v i c eN o t e s ....... 19 5 H 4 0 , 4 6 , 6 0 , a n d 6 6 c o m p r e s s o r s. . . ... 20 in.
L u b r i c a t i oSn ystem .......19 5H80, 86, 120, and 126 compressors. . .30 in.
(Continuedon page 10.)
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-11S1
Tab l2a
Providespaceequalto condenserlengthfor tuberemoval condenser and liquid shutoff valve connectionfacing com-
nd cleaning. pressorend of base.Check that condenseroverhangssup-
'dtep 2 - Receive Machine (Fig. I through port standsfor same distanceon each end.
8)
Removesolderedshippingcap from hot gas inlet. To pre-
BEFORE UNLOADING - Check unit nameolares asainsr ventsolderfrom drippinginto inlet pipe while unsoldering,
rodel and serial numbers recorded in job siecificaiions. rotatecondenser until pipe is below horizontalposition.Re-
_lheck all items againstshipping list, and examine irems turn inlet to upright vertical position.
carefully for any shipping damage. If damage is found or
any major component has torn loose from its anchorage, Tightenlower supportstrapsenoughto lift condenseroff
ave transportationinspectorsexamine it before unloading. stands.Placeupperstrapslooselyin positionwith a strip of
protectivematerial betweencondenserand strap (5F20 and
_ile. claim immediatelywith shipping companyfor any loss 5F30 units use lower strap only).
or oamage.
DIG UNIT CAREFULLY - Check that rigging equipment TO MOUNT COMPRESSORBASE ON SUPPORT
tn safely handle the approximateequipment weights for STANDS - Placecompressorbaseon support standswith
-Jmpressors and condensingunits. 2 extra strips of protective material between top of con-
denserand base. Bolt base into position with cap screws
' Rig and move unit carefully to preventdamageto mount- and lock washersprovided.
,g brackets,refrigerantpiping or connections.
Step 4 - Assemble RefrigerantPiping and Com-
-tep3-lnstall Unit -
ponents Refrigeranrconnectionsizes are given in
TO MOUNTMOTORON BASE- Themotorfastenins Table 1.
rt, available as an accessoryfor all 5F,H base-mounted
)mpressors,includes motor blocks and shims for motor COMPRESSOR DISCHARGE PIPING RefeT to
alignment; cap screws,plate washersand lock washersfor Condensing Unit Piping Installation Instructions for
fasteningmotor to base;taper dowel pins for securingmo- information.
r position after alignmenq and beveled washersfor fas-
REFzuGERANT DRIER - A replaceable-corefilter drier
ning the unit baseto accessoryvibration isolators.
- is recommendedfor most systems, and is essentialon all
If vibration isolatorsare used, attachto base(Fig. 9). To low-temperaturesystems.Mount the field-supplied filter drier
avoid damaging the isolators, lift unit from ends when at- in the liquid line. Includea shutoff valve ro permit isolation
:hing isolators. of drier for servicing (Fig. l0).
- With compressorand motor positionedon the base,check Install a moisture indicator on downstreamside of drier
the height of the vibration isolators.Shim betweenisolators to indicatewhen drier cartridsesneed reolacine.
"nd floor as requiredto level compressorbase.When level, FELT FILTERS - Install felt-filter suppfied with compres-
cure vibration isolators to floor. Check that bevel washer sor in suction strainer(Fig. 3 through 8). Remove filter af-
--ig. 9) is in place. ter 50 hours of operation.If clean, discard it; if dirty, clean
with kerosene or neutral spirits and insert for another
50 hours of operation. Tag unit to show date that filter was
{:zo mp cleaned and reinstalled. SeeTab\e 2 for information on re-
J'o
a"
placementfilter packages.
l-ora.
'
Hd-ES
[tr;F=ll*'i^.!?',i,
r-5t-..1
5F
L I Q U I DL I N E
FROMCOND.
:i
;i
::
i!
ij
Step 5 - lnstallMultipleCompressors
EQUALZING LINES - Compressorsoperaring in paral-
lel requireinterconnectinglines for oil and gas pressureequal-
Fig. 9 - Typical Vibration lsolator Mounting ,
ization. Special handholecover plates, equipped with tafped *l
l-r MOUNT CARRIERCOMPRESSOR UNITS AND CON- lqles for eqlalizing lines, are availableas oprions for iizes J1
DENSERPACKAGES- Bolt thecompressor's lowersup- 5F40 and 5F60, as well as for sizes 5H40 through 86 com- .:l
pressors(Fig. I l). An oil float sysrem is an acCeptableal- f'
5^4 strapslooselyto undersideof eachsupportstandand
F cestripsof protectivematerial(suchasFabrica)on straps.
ternative to equalizer lines. n
' i.i
[_;ition condenseron standswith hot gas inlet at top of
5e3
I
'I
I
-+ 5H120 and 126Compressorsinclude factory-supplied,
tapped 5F20 and 30 Compressots.have no special tapped cover
cover plate. On thesecompressors,use only lower connec- plate. Use openingfor oil sight glassto attachihe lth-in.
tion for oil equalization(Fig. 1l). Connectgas equalizine (Fig' l2). AccessoryPack-
iine for gas and oil_e_q^ualization
line to flange connection shown. Mating flange foi IVB-\;. age No. 06DA900072-provides two Zs-in. line adaptersto
Iineis CarrierPafiNo. DK24CA712(MuellerPartNo.A-5151); tliread into the sight glass opening. If additional edualiza-
gasketPart No. is DK29GA005LA (Mueller PartNo. A-5152). tion is desired, run q %-in. line to the oil-filter phig con-
nection (Fig. I and2).
O R I V EA ND
SEAL END
GAS EQUALIZER
CONNECTION
r*"oD FLANGE
(5Hr20-126oNLYI S C R E WF I T T I N GI N T O
OPENINGFOROIL LEVEL
S I G H TG L A S SF O RI - I l 8 . .
E O U A L I Z E RL I N E
OIL EQUALIZER
q9NNECTTON
I IPS
OIL LEVEL
MaxlmumRpm 1750
MinlmumRpm 400 (required propef
MinlmumRpm Capaclty 1r
Control 800 I 800 | 9oo
(ln o.D.)
Suctlon 41/e
41/8
Oll Charge'
Normal Oll psig above suction pressure
Oll Flow Rate(gpm)t 3.0
Oll $fety Swltch
Cut-ln (pslg) (Se€ Note 2) t5 - 19.5
Cutout (pslg) 1 1- ' t 5
150-395 (adjustable)nominal
60-150 (adiustable)
C u t o u t , 3 0 Oa 1 5 ;C u l - i n , 2 1 0+ 1 0
Low-Pressur€
CutoutRange 20 in. Hg vac to 60 psig (adiustable)
Offferentlal(psl) 60-90 (adiustable)
Fac{orySetting (pslg) Cutout, 50 + 4; Cul-in. 120 + 6
Prcssurc
697
Table 2 - Suction (Felt) Filter Packages 5H40 throushg6 Compressors- Drain oil below level of
pump-endcover (Fig. 5-7). Removepump-endcover to ex-
COMPRESSOR FILTER PACKAGE PART NO. poseorl pump cover in centerof main bearinghousing. Ro-
5F40 5F40- tateoil pumpcover 180degreesandreplaceit. Replacepump-
5F60 5F60-A352
5H40,46 end cover and reverseexternalarrow to match new direction
5H40-A382
5H60,66 5H60-A382 of rotation. Proper direction can later be checked without
5H80,86 SHBO-A382 removing pump-end cover.
5H120,126 5H120-4382
5H120 and 126 Compressors(Beginning S/N 1086J---)-
Suppliedwith automaticallyreversingoil pump, eliminating
needfor adjustment.For 5H 120 and 126models built before
- Make Electrical Connections
_itep 6 S/N 1086J---,follow sameadjustmentprocedureourlinedfor
GENERAL NOTES 5F compressors.
. Factory wiring complies with National Electrical Code
(NEC). Any field modificationsor additions musr com-
-- ply with all applicable If the specialgasketbetweenoil pump cover and oil pump
codes.
2. *For is damaged,replacewith correctgasketonly. Cheik oil
control circuit information, refer to Accessory Con-
trol Panel Installation lnstructions. pressureimmediately after starting compressor.
i.
1l
,1
t
:l
Step 7 - Check Compressor/Motor T e x a c oI ,n c . . . ..WF32-150
Alignment S h r i e v e C h e m i cCa lo . . . . . . . ( s y n t h e t i cZ
) erol150
Mineral oil and synthetic oil have different characteris-
BELT DRIVE - SeeAccessoryBelt Drive Packagemanual
f o r i n s t a l l a t i o an n d a l i g n m e n ti n s t r u c t i o n s . tics. One is not necessarilybetterthan the other.Somechar-
acteristicsof the mineral oils have been found to be more
DIRECT DRIVE - Install and align compressor,coupling favorablefor use in someair conditioning and medium tem-
and motor as describedin manualfor Flexible Couplingsfoi peratureaPPlications.
Direct-Drive Units. Approvedcompressoroils are availablefrom authorized
HOTCHECKAND DOWELING -To help maintainatign- factory parts outlets.The oils recommendedare fully com-
ment, and to ensureexact repositioningof the motor after patible with eachother and can be mixed in any proportion.
servicing,the motor and compressormust be doweledto the
base. Install doweling only after motor/compressor align- PREPAREFOR INITIALSTART.UP
ment has been hot checked (checked after the com-
pressor has warmed up to operating temperature after ini- Evacuate,Dehydrateand Leak Test theenrire
re-
tial alignment). frigerantsystemas describedin Carrier StandardServiceTech-
After hot check and while components are still at oper- niquesManual, Chapterl, Sectionsl-6 and l-7.
ating temperature,drill and ream 2 holes through diagonally- LEAK TESTING
opposite motor and compressor feet and the base. Use a
e/tz-in. dnll and a no. 6 taper reamer.Secure the motor and PreferredMethod- Charge the system to 10 psig with re-
frigerant. Add dry nitrogen or dry air (DO NOT USE
compressorto the basewith the no. 6 x 2Vz-in.taper dowel
OXYGEN) until systempressureis 150psig.Check for leaks
pins provided in the motor fastening set.
with a halide or electronic leak detector.
Coat the dowels with white lead or other lubricant to pre-
vent rusting, and tap the dowel lightly into position so that AlternateMethod- Chargethe systemwith dry nitrogenor
%e of taper is left above the motor foot. dry air (DO NOT USE OXYGEN) to 40 psig and use soap-
bubble test to find larse leaks.
Check that all dowels are tight and that they do not
bottom.
Step I - Assemble Water Piping - SeeWater- Do not usecompressorto build up pressure.Do not over-
Cooled Condensers Installation Instructions and Water- charge the system.
Cooled Heads Installation Instructions for information.
Refrigerant Charging - Use the sight gtassmethod
to charge the system.See Section l-8 of Canier Standard
Step 9 - PrepareLubricationSystem ServiceTechniquesManual, Chapter l, for details.
INSTALL OPTIONAL EQUIPMENT - Consult local Chargethe systemto a clearsight glasswhile holding satu-
Carrier representativefor information on these accessories. rated condensing pressureconstant at 125 F for air-cooled
Oil Filter - Oil filter for 5H40 through 86 compressorsis systems or 105 F for water-cooled systems. Add
available as separateaccessorypackage.Refer to Accessory additional refrigerant to fill condensersubcooler coils, if
Oil Filter Package Installation Instructions for installation required.
procedures. 5RH CONDENSING UNITS - After a clear sight glass is
If an accessoryoil cooler is also installed (seebelow), pipe obtained,add chargeuntil liquid refrigerantreachesthe con-
oil filter into system as shown on diagrams in Accessory Oil denserliquid level test cock.
Cooler InstallationInstructions.
5F.H COMPRESSORUNITS - Seecondenserdatafor ad-
Oil Cooler - Refer to Accessory Oil Cooler Installation In- ditional charge requirements.
structions included with this accessorypackage.Adjust wa-
ter flow rate through oil cooler to maintain_I00 to 120 F oil
temperaturereturning to compressor.See Scheduledlv{ain-
tenance,page 17. PreliminarySteps
Oil Separator- If oil separator is used in system piping, l. Energize crankcase heater for at least 24 hours before
pipe oil return line to compressor suction line. To minimize starting unit.
possibility of flooding compressor with oil, oil return line 2. Ifcontrol transformer is not used, operate electrical con-
diameter should not exceed % inch.In addition, line should trol circuit with main oower switch OFF to ensurethat
have manual shutoff valve to throttle oil flow as required field connectionshave'beenproperly made.
and to isolate separatorfor service.
3. Install felt sock filter for the first 50 hours of compressor
CHECK OIL LEVEL - Check that oil level is visible at operation.Remove and inspect the filter, clean it if re-
center of compressor sight glass. Compressorsthat use op- quired and replaceit for another50 hours. Removesock
tional equipment such as filter, cooleq and oil separatorde- when systemis clean.(Not applicablefor 5F20 and 5F30
scribed above will require a greater oil charge than listed in units.)
Table 4. Recheck oil level after operating compressor.
4. Check that motor rotates in direction that the arrow on
RECOMMENDED OILS - When additional oil or a com- the compressoroil pump cover indicates.Refer to Instal-
plete oil change is required, use only the Carlyle engineer- lation, Check Motor Rotation section on page 12.
ing departmentapproved,dehydrated,wax-free refrigeration 5. Check that oil fills tZ to Vzof the compressorsight glass.
grade oils noted below:
6. Open water supply valve to condenser.Open pressureline
IGI PetroleumSpecialties,Inc. . .. ...... Cryol 150 valve of water-regulating valve (if used). If compressor
IGI PetroleumSpecialties,Inc. ... Cryol 150 with additive unit is equipped with air-cooled condenser,turn on con-
(Akzo Chemicals, Inc. additive Syn-O-Ad (8478) denser fan.
witco. ..Suniso3GS
Witco - Hi ambient application,
300 viscosity . Suniso 4GS
13
discharge If an accessoryoil cooler is provided. a-djustthe water
'' Backseat (open) comPressorsuction and
7.
r"*i"" valves.Open liquid line valve at receiver' flow as required-to maintain a 100 F to 120 F crankcase
return oil temperature.
8. Start evaporatorfan or chilled water pump'
ROEERTSHAW
Start Compressot - Close main power switch sup-
A _ R A N G E A D J U S T M E NSTC R E W
-- plying current to the compressormotor.
Immediately recheckoil level and check oil pressure.Pres- TOP
sureshouldeiceed suctionpressureby 45-55 psi. If correct
pressure is not reached in l0-12 seconds, stop compressor @-=r- D T F F E R E N T TAADLJs c R E w
- immediately and check oil PumP.
RANCO-
A - R A N G EA D J U S T M E NSTC R E W
If any safety device shuts down th-ecompressor, do not
reset the coritrol more than once before determining cause TOP
of shutdown.
4 - " - o T F F E R E N T T A L A D JS C R E W
Check Control Operation - Referto CarrierStan-
PENN
dard ServiceTechniquesManual, Chapter2, for complete
instructionson checkingelectricalcomponents. A - R A N G EA D J U S T M E NS
TC R E W
SHOIVN.
ARRANGEMENT
5H MOUNTING
Tabte 5 - Typical Pressure Switch Settings !
ScrewA raisesor lowersbothcutoutandcut-inpointsby a likeamount. x
!
1094
CONTACTARM RESISTANCE
An exrernalad..;usting.stem1Fig.l5) sersrhecontrolpoinr
(suctionpressureat which.firsr.stepof cylinder unloiding
C O N N E C TI N occurs).The control point is adjustableai fo1o*r,
S E R I E SW I T H
C O N T R O LC I R C U I T R - 2 2 a n dR - 5 0 2 . ...0to85psig
R - 1 2a n d R - 1 3 4 a . . . 0 to S0irsi!
One full clockwiseturn of adjustingstem will raisethe
( R E F E RT O U N I T L A E E L
conrrol point.app^rqr-rmately6 p_sigwith R-12 and R_134a,
W I R I N GD I A G R A M
} or 10 psig with R-22 and R-502.
Control oil pressureis an indication of cylinder loadins
condition (Table6). Refer to Fig. 3-8 for location of contiof
oil-pressureconnection.SeeAccessoryUnloaderPackage - In-
stallationInstructionsflor additional information.
See Fig. l6 for CapacityControl Sysrem,and Fig. l7 lor
unloading sequence.
-+ Table6 - ControlOil Pressuresfor
CylinderLoadingand Unloading
HIGH.PRESSURE
CONNECTIONTO APPROXIMATE
CONTROLOIL PRESS.(psig)
LOW-PRESSURE
CONNECTION
TO CRANKCASE
IF PNEUMATICCONTROL
IS NOT USED,THIS PORT To Adiust Control Point
MUSTBE VENTED -
DO NOTPLUG l. [tnposean artificial load on the compressoruntil suction
pressureexceedscontrol point.
2. Slowly close suction valve to lower compressorsuction
pressureto control point pressure.
3. When at control point pressure,turn external adjusting
stem clockwise until firslstep_of unloading takes place-,
cne--\a\ as indicated by changesin control oil pressure,current
draw and sound of compressor.
Control point is now set. Reopen suction service valve.
EXTERNAL Compressorwill be fully loaded when suction pressureis
ADJUSTING -3 psig (4 psig with R-22 and R-502) above coitrol point,
STEM*
NEWER ard will !e fglly unloaded when suction pressure is 4 psig
DESIGN
USES Q OsiSwith R-22 and R-502) below conirol point.
"O'RING
5F20 AND 30 COMPRESSORS- Two capacity conrrol
packages are available as accessories. One is suitable
SPRINGDETAILS for R- 12.or R- l34a applications;rhe other for R-22 and R-502
apptlcatlons.
PARTNO. PABTNO. The adjusting stem (Fig. 15) is shipped in a backseared
sF88a)6
(7-LBSPRTNG)
-<< EB39CZ001 (fully counterclockwise)position.Compressorwill be fully
( 1 1 - L BS P R T N G ) loaded under all conditions.Adjust the capacity control ser
USE WITH: _<-< USE WITH:
R-l2, R134a, point by the same3:stepproceduredescribedabovefor 5F40
R-22, R-502, R-zt&tA,
R401A, R-409A, R-507, R402A, R-408A
and 60, and 5H40 through 126 compressors.
R-500,R4018
'When compressor
is received, the capacitv control adiustino
stem will be backseated.(Compressor wit[ be fullv loaded un'deraji
conditions.)Compressoris suppliedwith 11lb siring.
-+ Fig. 15 - CapacityControl Valve
l5 697
- FROM COMPRESSOR
PNEUMATIC CON'TROL
OIL PUMP
NOTUSEO,THIS
RT MIJST8E VEI
C O N T R O LO I L H O I L P U M P
:W NOT PLUG PRESSURE PRESSURE
RANGE
ADJUSTMEN
SPRING LIFTER
AND PINS
LIFTING
/,
1.1
FORK
PISTON
XT
T R A V E L IN G
NUT
C A P A C I T Y coNTROti
VALVE
-
-
!
t C Y L IN D E R
I
SLEEVE SLEEVE
I SURGE
a CHAMBER
I
t
(5H ONLY'
I
a
a
a
a
TO OTHER
-
I
I FRuIsS*'r""-
UNLOADER
a
CAPILLARY POWER
i
o
ELEMENTS
DRILLEO
HOLE CRANKCASE
PRESSURE
IM CRANKCASE
.SSURE
HYDRAULIC
RELAY
5F20 5F30
5H40, rt6 5H60.66
@ rn
--J1
fl- I|J
'll
@
5F60 5 H r 2 0 t, 2 6
t7 r094
When crankcaseoil temperaturefalls within the 120 to
135 F range, the shaft seal-housingtemperatureshould be
approximatelyt40 to 150 F. Shaft seal housing tempera-
tures above 170 F may causeshaft seal to age rapidly, and
harden and crack. Th6refore:
If shaftseal housing temperatureexceeds170 F, STOP
THE COMPRESS6n. DO NOT restartuntil the cause
of overheating has been identified, and the condition
corrected.
G^!'K€T
PUMPE}O
EEARI}IG H€AT)
(6IAOAPTER
SCR€US UASHERS
(t-ari'r tl-20rzl-l
A
(Auto..Reversing)
PUMP ENO SEARING HEAD
BTJSHING LOC
PUTTPIilTAK€
PLUG(MAGNETICI
%,dr_
FILTER
B
OIL FILTER SPRING (ManualReversing)
- Oil Pump and Filter Assembly (SHt20, 126)
-> Table 7 - Actual Suction Gas Carrier 5F,H Specified Parts list for compressorpart
Temperature Limits (F), R-l2, R-22, R-134a, R-502 interchangeabiliry.
SAT. SUCT -60 -50 -40 -30 -20 -10 0to50
J. Before servicing compressor, pump down the refriger-
TEMP (F) ant as follows:
ACTUAL R-l2, 35 45 55 65 a. Startcompressor,close suctionservicevalve, and re-
sucTtoN R-l34a duce crankcasepressureto 2 psig. (Bypasslow pres-
GAS R-s02 25 45 65 75 surestatwith jumper.)
TEMP (F) R-22 See Note 1 b. Stop compressor;closedischargeservicevalve to iso-
NOTES: late it from system.
1. For continuousoperationwith R-22: c. Recoveror reclaim any residualrefrigerant.Drain oil
if necessary.
SAT. SUCT TEMP (F) MAx. SUPERHEAT(F)
-40 to 4 . After disassembly,cleanall partswith solvent.Use min-
eral spirits, white gasolineor naphtha.
2. Do not operateunloadersat saturatedsuctiontemperatures 5. Before assembly,coat all parts with compressoroil and
at or belbw 0'F without prior approvalfrom CarrieriCadyle clean and inspect all gasket surfaces. Replaceall gas-
Engineering. kets with new, factory-madegaskets, and lightly coat
with oil. See Table l0 for torque values.
6. After reassembly,evacuatecompressorand open suc-
tion and dischargevalves. Restart compressorand ad-
4. The compressoroperatesfully unloadedfor prolonged just refrigerant charge.
periods. Under theseconditions, suctiongas levels may
not suffice to remove the heat of compression and fric-
tion. This condition can occur in any application,but is
Lubrication System
most likely in low-temperature systems or variable- OIL PUMPS
volume applications that use hot-gas bypassto maintain 5F compressors.SeeFig. 23 and25.
specifiedconditionsunder low evaporatorload. Refer to 5H,m-86compressors. SeeFig. 24 and25.
5F,H Application Data for additional information.
5H120,126compressors, with automaticallyreversingoil
Adjust water flow rate through oil cooler to maintain 100 pump.SeeFig. 20(A).
to 120 F oil temperaturereturning to compressor.Crank-
case temperaturemust remain below 140 F; shaft seal tem- 5H120,126 with manuallyreversing
compressors, oil pump.
peratureat the seal housing should not exceed I'70 F. SeeFig. 20(B) and26.
Tables 8 and 9 list maximum working pressuresfor oil
and water and estimated water flow rates for various oil 5H120and 126 CompressorOil Pump
cooler/compressorcombinations. For additional informa-
History Reference
tion, see A-cessory Oil Cooler InstallationInstructions.
L9 1094
,i
Oil Pump Bushing Position 3. a. 5F20-60and 5H40-86.See Fig. 25. Disassemble oit
l. a. 5F20-60and 5H40-86. See Fie. 25. Place0.001-in. pump and removeshim. Reassemble oit pump. Check
circular field fabricatedshim aEainstbushinsand in- for bindins.
stall pump.. Shim between bus6ing and oil i'u-p .o- b. 5H120,126. Remove oil pump cover and shim.
tor. Complete assemblyof oil pump with giskei and Reassemblepump cover with gasket. Check for
cover. bindine.
b. 5Hl20,l?5. SeeFig. 26. Placn0.0l5-in. (t/e+-in.)shim 4 . Install bearingheadon compressor.Line up tang on oil
between po_rtinsert and oil pump cover. Complete pump rotor shaft with slot in end of crankshaft.Check
assemblyof oil pump and pump cover without tising oil pump for proper direction of rotation.
pump cover gasket.
5 . Refill compressoroil to proper level. Observe oil pres-
-2. Tap bushing with suitablecylindrical positioningtool to surewhen startingcompressor.Correctoil pressureshould
-
seat it againstshim. See typical arrangementsf,own in be 45-55 psig abiovesuction pressure.
Fig.25.
! HEAD
€@---cyLrirDER
CYLINDERHEAD GASKET
fri-----
L--P/
1
t-'
DISCHARGEVALVE
INNER SEAT
@ VALVEPLATE GASKET
PUMP END
E E A R I N GH E A O
ASSEMELY
PUMP END COVER
AND CONTROL
VALVE ASSEMBLY
SUCTIONVALVE
Drsc.
otL RETURN
HANO-HOLE COVER VALVE
GASKET
SEAL
HAFT
OVER ?'.tr.
.\KEY
?SsfR'Ei'
t u b.,^.T*-:
P U M P E N D E E A R I N GW A S H E R
\\\-
O{- FILTER
(ACCESSORY}
PUMPEND BEARING
HEADGASKET
s;,i
OIL FILTER SCREEN
HAND-HOLE COVER
\
Fig.21 - 5H Compressor Enternal Components
20
AUTO. REVERSTNGOIL PUMP and on threads of each mounting hole in bearing head'
Oil Pump Inspection - See Fig. 20(A) for 5H120 and 126 Position one of the supplied gasketsover holes in adapter
for automatic reversingoil pumps. and assemblethe adap-terloosely to bearing head.
l. Drain oil below level of pump-end bearing head. J. Be sure there are no nicks or burrs on oil pump or bores
in adapterand bearing head. Slide oil pump through adapter
2. Remove bearing head from compressor. and into bearing head bore, allowing enough clearance
3. Remove oil pump and adapterfrom bearing head. to tighten adapter mounting screws with an Allen
4. Check all parts for wear and damage. wrench. The clearance between oil pump housing and
bores in adapter and bearing head is necessarily very
Pump Installation close. DO NOT USE FORCE and do not attentpt to change
l. Using a new gasket, mount bearing head on compres- the clearance.
sor. Tighten the Vz-13cap screws to 80 lb-ft.
2. Put a drop of thread sealing compound (toctite 601 or
equivalent)on eachof the %6-18adaptermounting screws
o
e\-'
(olL)
RING
O*'lsroN
C Y L I N D E RS L E E V E
,ar,#'"-n'^-r,..oN PrN R,NG
LocK
C Y L I N D E RS L E E V E
SNAP RING R I N G( o l L )
t O*PlsroN
I
+\
U N L O A D E RS P R I N G S I
ROD
CONNECTING
T,-r-l
'NL.ADER C O N N E C T I N GR O D E O L T S
It
U N L O A D E RF O R K
\./
q \ ats-ELAsrlc LocK NUr
\e
Y
HshPA'?1.,,.**'|f
U N L O A D E RS L E E V E
__.-,4.
U N L O A D E RBRACKET
GASKET
ASSEMBLED
PISTONAND
CONNECTINGROD
SEAL END
B E A R I N GW A S H E R
(BRONZE )
CRANKSHAFT
SEAL END
T H R U S T W A S H E R( S T E E L )
Fig. ?2 - 5H Compressor lnternal Components
2L
Table 10 - Torque Values
USAGE USAGE
,93 22
Table11- WearLimits;5F,HCompressors
COMPRESSOR
COMPRESSORPART
=#.t$3in.n - gl?g,1g
Diameter
- 5F40. 60
Joumal Diameter - 5F20. 30
- 5F40, 60
- 5F20,30 .001
Main Bearing Diameter
(Assembled) - 5F40,60
.N2
Joumal Diameter
ENTER(sH80,86,12O,1261t .001
Main BearingDiameter .001
litain Bearing Thickness .002
Joumal Diameter
ROOt .002
Bearing Diameter .00r
Eearing Thickness
Crankpln Diameter qj
Seal End Bearing Washer Thlckness
s€al End Thrust Washer Thickness
Pump End Bearing WasherThickness
Bore
.003
Piston Diameter - Steel, Standard Stroke
.003
- Aluminum, Long Stroke
Body 3.241 .003
Ring Groove (OD) 3.235 .003
Piston Pin Oiameter .001 .001
'r.t)00 .001
Piston Pin Bushing .001
Piston Ring End Gbp (compression and oil)tt .030tt .017 .030tt
Piston Ring Slde Clearance rvl?
Compression Side .000
Oil Side
Axlal Clearanc,e
Drlve Shaft Diameter
.0015
.4361
.0005
.4356 ry_u
Drive Shaft Bushing Diameter (10) .03r5 .4370
Drive Shaft Diameter (5H120 & 126) .6240
Drive Shaft Diameter .6260
(lD - 5H120 &
23 398
ARONZE EEARING WASHER
P U M P E N O B E A R I N GH E A D
ROTATIONARROW
'IL FILL
:ONNECTION O I L P U M P COVER
OIL PRESSURECONNECTION
o
0
C R A N K C A S EP R E S S U R E C O N N E C T I O N
00 \\
\ \
IL PRESSURE CONNECTION
-iEMOVE FOR ACCESS TO CONTROL OIL STRAINER )
Yv
Fig.23 - SF Oil pump Assembty
IN.HOUSE
PRocESS
FITTING
SLEEVE
LOCATION
WHEN TJSING
OIL COOLER
OIL PUMP
@VER
otL PUMP orl puMp /
ROToR IDLER 1
\IA =--
-G t
&NE T :XIA >ROTATION
: a ,/ ARROWS
Ets gI Iil
r./
UNLOADERPORTS
(3 ON 4 CYUNDER
xtw
UNftS: v
4 ON 6 ANQ8 CYLTNOER'UNITS)
$
$
$
o o l "s H l M 6. Turn pump shaftto align drive tang with slot in end of
(FIELDFABRICATED} crankihaft.Holding pump assemblywith thumbson the
EEARING 2 screws, slide assemblyinto bearing head until tang
ensasesslot. A slight rotation should align screwswith
tupiJa holes in adapter.Start screws to hold alignment
atrd'th"ninstall balanceo[screws and lock washen.Torque
all screws (V4-20)to 8-10 ft-lb.
lrjbraru 7. Start compressorand check oil pressure.This oil pump
operatesin either direction of rotation. The conect oil
j piessure for compressorsusing this pump is 45 to 55
fsig abovesuctionpressure.
CYLINDRICAL
POSITIONING OIL PRESSUREREGULATING VALVE (nonadjustable,
T O O L( F I E L D -
FAERICATED } Fis.. 27\ is located on the side of compressoradjacentto
seil housing. Regulator maintains colrect oil pressure
(Table 6) and ensuressatisfactory unloader operation.
25
VALVE PLATE
CHECKVALVE
D I S C H A R GM
E ANIFOLD
R E L I E FV A L V E
PRESSURE
SUCTION
STRAINER
0
Fig. 29 - Centrifugal Oil Separator lmpeller Ea
S U C T I O NA N D D I S C H A R G E
M A N I F O L DC O V E R
CENTRIFUGAL OIL SEPARATOR on 5H120 and 126,
mounted on crankshaft (Fig. 29), returns oil to compressor Fig. 31 - Pressure Relief Valve and
crankcase.To remove or replace oil separator, see Crank- Suction Strainer (5H40,46, 80 and 86)
-shaft Inspectionand Service.
26
Clean strainerwith solvent or. replace if broken or cor- DISCHARGEVALVE VALVE LIFT E R
SPRING.
roded. When replacingsucrion strainer, do not damageit. SPRING
"kl+}@
\ /
On 5H 120 and L26compressors,positionedmanifold cover \ o'scHARGE vaLVE
plate must compressstrainerbail. If bail is too short, grasp D|SCHARGE ; r ' o r r r up u a c E suctror'r/
\ VILVE
on sidesand elongateit enough to be compressedby man- /
ffi
ifold cover. Positionbail betweenthe 2 bosseson inside of
manifold cover to prevent strainer from turning.
VALVE P L A T E S U C T I O NV A L V ED I S C
27
To reassemblel
piston at top center'
l. Rotate crankshaftto position
surfaceat lower edge
2. Lubricatepiston rings and beveled
of cYlinder sleevc.
3. Staggerring gaps around piston'
piston and rings'
-+. With turning motion, work sleeve.over
each ring with beveled edgeof sleeve'
C;F;;-uiaurign
5.SeatsleeveinSuctionmanifoldpartitionandcylinder
deck recess.
holes lie equal
- Rotate sleeveso that any 2 valve lifter-pin
6. (Fig' 3a)'
aiii""""t ftom longitudinal axis of compressor
pins line up with suction valve
ff;;;;;i,;;;-fii"'
springs.
valve plate
Never operate compressor with heads or
removed. Fig. 34 - Position of Cylinder Sleeves
COMPRESSION
RINGS(SOLIO)
Connecting Rods and Pistons
valve plate and
REMOVAL - Remove cylinder head' OIL RING.
or bottom ilut" to gain access to rods and (VENTED)
ffi;-h"G;ver
pistons.
Label caps and
Remove connecting rod caps (Fig' 22)' BoDYr
.oit-to ,tt"v may be"reinstdGa in iamg ql1::t on crank-
.ylind"t sleeve, connecting rod and piston OIL RING
;il;h. h;6t; (VENTED)
;; a ufit uy pushing assemblv up through cylin-^ (STANDARD
;;;6k
Aru;?.;; topo{
;;;'1i";'-pi'ti" to co^i upthrough STROKEONLY)
ii*ii"t pio'ess' Removeretain-ing ringsand
;i;r;;";;;; pistons' M A R K E DS I D E U P
dit^t"*ble connecting rods from
;il;;;;-io
Remove rings.
pistonassem-
KeeDeachindividualconnectingrod .and
uia i.*t"*ulv' Chleckall partsand crank-
bl;';;Jh";io
piir jo[rnals for wear (Table I l)'
C O M P R E S S I O NR I N G
- connect-
INSPECTIONAND REPLACEMENT 4tlach placewith
--L- No rAPER E I T H E RS I D EU P
iil;"dt i;;istons *ittr piston pins and.lockin
lii"ilft;"H. a push
pit,"" pi'"iareietectivelt.filtfdTor
nti r"uit"tn6le in the piston from which th"l I:t"^'l:-
on side'
*iuJ. pfu"e pistonpin retainingrings'.with sap inhibit
il;t'il to
dfiIijl tiil;ffiiai",i'et" "noulh ' olL RING
rotition underfinger Pressure' 'See Table11 for pistondiameters'
CheckRings
in Fig. 35 - Piston and Rings
t. Ctect ring gapby insertingeachring separately gyl-
^'
i;;;;;ffifiti'ut6tv % in. Fromtop' Ring gapshouldbe - All 5F'H seriescom-
Caoacity ControlOperation
betweeii.007and .017inches' ca-
or!il;,'"-;"pt irzo ina go units,include.hydraulic
-' Install compression
2. rings on pistonwith-markedsideup 5;;il;"ilii,ittr""a"i tvtt"*t * Jtutia-aequipment'(Fie!d-
ir"" Fig. ib toward piiton head'Install oil rings either i"JrirJJ^I*l,ttoty unr,juo"rpackages areivailablefor the
sideup. ;i"O-;Ji0.ir[" unloadei system activatesanddeacti-
3. Staggerring gapsaroundpiston' G" cylindeibanks,by permittingsuc-
-' Measuresideclearance
4. betweenri-ng9d piston(approx- ""t"i
tion valves to seator prLventingthem fiom doing so' in
""*iprissor's
io tttunging lbad dema--nds' Capacitycontrol un-
;;;it .001 inch). Checkrings for free action' r;;;
operatin
actual g capacitv.bv steps
- inserts i;;'d;; r;JucEi ilnit' s
CheckRod BearingInserts (Fig' 22) If bearing down to as little as 25Voof its total c-qpagtfy'rlgure
r/
-oo is iot worn, it is only neces- ,showsthe sequenceand number of cyliirderi that unload
@
ft;;:pft" int"ttt. not file bearingcaps'Placethe with eachsteP.
ioo *oio"necting-r6d capsso knobs
insertsin connectrng
iiua"uteinsert bear- Capacitycontrol unloadersystemsconsist of 4 major
on insertsfit into nor"tiJti'itJ"up' components:
ili! ;d crankpin freely before installing caps'
assem- ^' A capacity control valve' which increasesor de-
1.
Install cvlindersleeve,connectingrod qrd piston ;;"ase;;;n&otoil pressureto.thehydraulicrelaypiston
br"':tit,""i"*;ii;;- il;-;;;;"i7"8 rol' rand instaucap-
o i ii t, aai i s of c ankp in' (s^! !t ;;6;tti;;;iiv *tt"i ttre suctionpreisurefrom the crank-
i:; ;h":;f,;;;' ; a, ; i caserisesor falls.
;;;;';,";;;;-d-';;;;;; ";'- b" in 'o*i side oiiournat')
28
FROMCOMPRESSOR
ADJUSTINGSCREW O I LP U M P
O I LP U M P
PRESSURE
STRAINER
A N DO R I F I C E LIFTINGSPRINGS
AND PINS
LIFTING
FOFIK
CONTROLOIL
PRESSURE
NEEDLE
XTERNALCAPACITY VALVE
CONTROL VALVE
UNLOADER
POWER
I Y
ELEMENT
CRANKCASECONNECTION
FOR OIL RETURNAND
OPERATINGPRESSURE orL
DRAIN
{
TOOTHER
UNLOADERPOWER
ON 5F3OONLY
ELEMENTS
TRAVELING
NUT
CAPACITY
VALVE
POWER
ELEMENT
C Y L IN D E R
SLEEVE
otL TO OTHER
f FRuIsg.'.o
DRAIN UNLOADER
POWER
o
ELEMENTS
CRANKCASE
PRESSURE
FROM CRANKCASE
PRESSURE
HYDRAULIC
RELAY
29
2. Ahydraulic relay, which (gxcepton the 5F20and
30) case,decreasing oil pressurein powerelement.As oil pres-
feedi oil to the unloaderpower elementsin sequence' sure to power elementdrops, the pl919nmoves downward'
Control oil pressurefrom the capacity control valve ac- Lifting fork pivots upward, moving lifting pins.upward;suc-
tivatesthis rglaY. tion ialve hses from its seat and controlled cylinder
unloads.
3. A hydraulic power element, which suppliesthe po-wer
necessaryto operatethe valve-lifting mechanism.It is
modulatedby the capacity control valve. 5F4O AND 60, AND 5H4O THROIJGH T26 CAPACITY
4. A valve.lifting mechanism, which consistsof a sleeve, CONTROL OPERATION (Fig. 37 and 38)
a lifting fork and a push-pina,ssemblyaroundeachcon-
trolled cylinder. The valve-lifting mechanismholds the Loaded Operation - A rise in suction pressureincreases
suction valve open, or permits the valve to remain in prasu." againstcapacitycontrol valve bellows, compress-
normal operatingposition dependingon its actuationby ing rung" ialustmeitt spring, Compressionof range ldjust-
the power element. *6nt sp?ngillows valve sp-ringq9 move push pins and valve
- These componentsoperatein the following manner: needle'poiit toward valve seat.Flow of control oil to crank-
case through oil drain is throttled.
5F2O AND 30 CAPACITY CONTROL OPERATION Control oil pressure rises as oil enters capacity control
(Fig. 36) (With Optional Unloadersand Control) circuit through orifice from compressoroil pump circuit.
- LoadedOperation - A rise in suctionpressurecausesnee- Increasedcoitrol oil pressureadvanceshydraulic relay pis-
dle valve to close. Oil pressurein power elementincreases ton (againstspring) which feeds oil at full pressureto one
as oil enterscapacity control circuit from oil pump- Power or moie contrblled cylinder power elementsdependingon
elementpiston is forced upward, pivoting lifting fork down- position of control valve.
'- ward. Lifter pins drop, allowing suction valve to seat and Pump oil pressurein unloader power elements forces
load controlled cYlinder. piston ipward, pivoting the lifting fork(s) downward. Lifter
and load
Unloaded Operation - A drop in suction pressurecauses iins dr6p, all6wing suction valve(s) to seat
through valve to crank- cylinder(s).
'- needle valve to open. Oil bleeds
C O N T R O LO I L
PRESSURE
ORIFICE
S U C T I O NV A L V E
D ls c
CONTROL TO OTHER
otL olL UNLOADER
STRAINER POWER
ELEMENTS LIFTER SPRINGS
AND PINS
IF PNEUMATIC LIFTING
CONTROLIS NOT FROM COMPRESSOR FORK
USEq THISPORT OIL PUMP
MUSTBEVENTED
@ PISTON
PNEUMATIC
CONTROL
CONNECTION
UNLOADER
RANGE SLEEVE
ADJUSTMENT
SPRING
TRAVELING CYLINDER
NUT SLEEVE
EXTERNAL
ADJUSTING SURGE
STEM CHAMBER
CAPILLARY
C O N T R O LO I L
PRESSURE
FROM
f :ncssss'
CRANKCASE
<- PRESSURE
( S U C T I O NO F
OIL PUMP)
C-
Unloaded Operation - A drop in suction pressurede- EXTERNAL ADJUSTING STEM REMOVAL does not re-
creasespressure against control valve bellows. Range ad- quire compressorto be pumped down. Loosen hex nut at
justment spring pressesagainstthe push pins, compressing valve stem baseand remove adjustingstem assembly.
the valve spring. This moves the needle valve off the seat. REMOVALOFCAPACT|Y CONTROL VALVE AND HY-
Control oil bleeds from hydraulic relay and control valve DRAULIC RELAY - Assemblyis locatedin hand-holecover
to crankcase, relieving oil pressure on hydraulic pistons. (Fig. a1) of 5F40 and 5F60 units; in pump-endcover (Fig.
The piston retracts, preventing transmission of pressurized 42) of 5H40 through 86 units; and in pump-end bearing
oil to controlled cylinder power element(s),and the oil drains head(Fig. 43) of 5H120 and 126 units.
to crankcase
Remove capacity control valve and hydraulic relay.
As oil pump pressureon power element drops, the piston
moves downward. Lifting forKs) pivot(s) upward, moving NOTE: It is not practical to remove hydraulic relay from
lifting pins upward; suction valves rise from their seatsand 5H40 through 5H86 compressors.
controlled cylinder(s) unload(s). It should be noted that a Inspect parts for wear, damageor evidence of leaking or
minimum of 33 to 35 pounds of oil pressureis required for sticking.
proper unloader operation.
A new hand-holecover, pump-endcover or pump-endbear-
Capacity Control Inspection and Service ing head with control valve assembly and hydraulic relay
UNLOADERPOWERELEMENTREMOVAL- Re- may be installed. However, capacity control valve (and hy-
move cylinder head, valve plate, connectingrod, piston and draulic relay on 5H120 and 126 units) is available as a sep-
cylinder sleeve. Remove Allen head cap screws (2) holding arate parts item for installation on original hand-hole cover,
unloader power element in position. pump-endcover, or pump-endbearing head.
Remove power element (Fig. 39) and disassemble.Check INSPECT CONTROL OIL STRAINER - On 5F compres-
all parts for wear or damage. sors, the control oil strainer is located on the side of the
pump-end bearing head (Fig. 23). Strainer is located be-
POWER ELEMENT REPLACEMENT - Check unloader hind the control oil pressuregage connection block on the
fork height (Fig. a0) of new or assembledpower element. 5H120 and 126 units (Fig. 20) and on pump-end cover (Fig.
Attach power element to internal suction manifold. Re- 42) of all other 5H compressors.
place cylinder sleeve piston, connecting rod, valve plate, Remove strainer and inspect it for holes and dirt. Clean it
cylinder head and hand-hole cover. with solvent and replace.
3l
Crankshaftlnspection and Service
DISASSEMBLY - Removecylinderheads,valve plates,
connectingrod and piston assemblies,and pump-end main
bearing head.
SURGE HYDRAULIC
DRUM. RELAY On 5H80 through 126 units, remove hollow-centermain
ILIARY
CONTROL bearinglock screw locatedbeneathplug (Fig. 44) and loosen
TO CONTROL
VALVE) hollow-cupsetscrew(Fig. a5) until centermain bearingcan
OIL PRESS. be slid frorn its support.-On5H86, 120 and 126 units, dis-
GAGE CONN
connectoil line to centermain bearing. Remove crankshaft
CAPILLARY throughpump-endopening.
TUBE Normally it is not necessaryto remove the oil separator
impeller (Fig. 29) from the 5HI2O or 126 shaft. If impeller
must be removed for any reason, however, immerse it in
TOUNLOADER hot water or oil until heatedto 180 F or more. Remove all
P O W E RE L E M E N T S traces of water before reassembly. Do not heat impellers
TO UNLOADER
/.\L|N|.OAOER P O W E RE L E M E N T S with torch.
\JSEAUENCE FROM
CRANKCASE
NOTE: Dotted lines indicate piping behind surge drum.
Fig.42 - 5H Pump-End Cover and Control
Assembly {5H40 through 86}
CRANKCASEPRESS.
SURGE CONN AND OIL FILL
CHAMBER FULL FLOW
FILTER FILTER
- BYPASS HOUSING
PUMPEND
MAIN
BEARING
* OIL PUMP B E A R I N GI N S E R T S
TANG
PUMPPRESSURE
(AFTER FILTERING)
CAPILLARY
TO OIL PUMP
- INTAKE
UNLOADER
SEOUENCE
HYDRAULIC
RELAY P L U G ,M A G N E T I C( P U M P I N T A K E )
3"$i35"
uor*ur--\ a1
PLUG-6rs fo'-iro*-Ei
V SETSCREW
Fig.4 - 5H80 through 126 Center Main Bearing Fig. 45 - Center Main Bearing
Housing Setscrew Location (5H120and 126)
32
INSPECTION - Check crankshaftjournals for wear and Pump-EndMain Bearing (Fig.a6)
tolerances(Table ll). Remove crankshaftplugs, check oil
passagesand clean if clogged. DISASSEMBLY AND INSPECTION - On 5H40 through
86 units, remove pump-endcover. Remove pump-endbear-
Connecting-rodbearing insertsand main bearingsare avail- ing headon all units. Inspectbearing for tolerancesshown
able for crankshaftsregroundfrom .01O-in.,.020-in.,or.030- in-taUte ll. If a pump-end main bearing is worn, remove
in. undersized.Factory-regroundcrankshaftsarestampedon bronzebearingwasher,and chisel out bearing.Inspectbear-
both ends with an A (.010-in. undersized),B (.020-in. un- ing housing for wear (Table I l) and damage.Remove any
dersized),or C (.030-in.undersized). burrs.
REASSEMBLY
IMPORTANT:Do NOTEregrindcrankshafufor 5H46,
in thefield.Replaceshafts
66,86,and 126compressors l. Lubricate outside of new bearing with heavy grease.
with scoredjournals. 2. Line up hole in bearing with oil port in housing.
3. Pressbearinginto placeusing a puller shoulder(Table 12
AII instructions for feld grinding apply only to standard- and Fig. 47 and 48) and jack screw or bearing press.
stroke crankshaf'ts. 4. PIacebearing washer on bearing with notch in washer
On crankshafts reground locally, hold throw to 1.001 in. properly positionedaround dowel pin (Fig. a6).
for 5F compressorsand to L.376in. on 5H compressors.Stamp
A or B on crankshaft and pump-end bearing head next to oil PUMP ENO MAIN EEARING
pressuregage connection.
To determine maximum and minimum journal diameters E R O N Z EB E A R I N G
for undersizedshafts, subtract the amount (in.) that the shaft (ORSTEELWASHER
will be ground undersize from factory from the tolerances oN 5Hr20ANDt26
specified in Table 11. For example, the factory tolerancefor MODELS )
5H40 seal-endjournal is 2.6225 in. to 2.6235 inches. Tol-
erancefor a crankshaft resround to .010 in. undersizeshould
therefore be held betweei 2.6125 in. and 2.6135 inches.
REASSEMBLY -If 5H120 or 5H126 oil separaorhas been Table 12 - Main Bearing Puller Sizes
removed, read impeller paragraph below before installing
crankshaf't.
When regrinding crankshaft, remove crankshaft plugs and
clean oil passagesas well. Before replacing crankshaft, in-
sert and tighten plugs, and reinstall the 5H120 and 126 oil
sepzuatorimpeller:
l. Insert dowel key (Fig. 29) with axis parallel to axis of -) NOTE:Bearingpullerscan be orderedthrough
crankshaft. Position key so chamfered edge is toward ra- Carrieror TotalineParts.
dius of crankshaft journal.
2. Immerse oil separatorimpeller in oil or hot water to heat Center Main Bearing - Size5H80through126com-
it to 180 F or more. [f water is used, remove all traces pressorshave a center main bearing and housing.
before reassembly.Install impeller on cranlshaft with dowel DISASSEMBLYAND INSPECTION-On 5H86, 120and
key tined up with impeller keyway. Impeller must fit key 126 compressors,disconnect oil line to center main bearing.
snugly. (5H80 center main bearings are fed through the shaft.)
3. Check that seal-end thrust washer is in place on dowel Remove plug on compressor crankcases(Fig. 44). Then
key in crankcase. remove hollow lock screw beneath the plug (Fig. 45). Next,
lnsert crankshaft and install pump-end bearing head, con- loosen hollow-cup setscrewuntil center main bearing as-
necting rod and piston assemblies,valve plate and cylinder sembly can be slid from its support. Remove crankshaftand
heads.On 5H80 through 126 units, insert center main bear- bearing assembly.
ing setscrew and lock screw as described under Servicing Disassemblebearing (Fig. a5) and inspect for proper tol-
Center Main Bearing. On 5H86, 120 and 126 units, recon- erances(Table ll).
nect oil line to center main bearing.
JJ 697
AL HOUSING 2 . Pull bearingintohousing(Fig.a9).Edgeofbearingshould
HOUSING
PILOT
be /:z-in. below surfaceof bronze bearing waslier.
THRUST
Look throughoil pressureregulatoropening to check oil
WASHER passagefor blockage.
4. Blow out oil groove in bearinghousing and oil lines (if
any) to it.
- DIRECTION
OF PULL- TOP PLATE
SEAL END MAIN BEARING
HOUSINGINSIDE
SEAL END
MAIN BEARING
DOWELPIN
'Steel
washeron 5H120and '126models.
Fig.49- Seal-End
MainBearingPositioning
COVERPLATE GASKET
C A R S O NR I N G
SEAL NOSE
CARBONRING
SEALNOSE \
\
L
IL
R T
KB*
I B
lr
U'
COVERPLATE WITH INTEGRALSEALSEAT
FELT WIPER B _ 5F40,60 AND5H40 THROUGH86' (Type l) - Typical
'F540 and 60 - 1.5"diameter;
5H40through86 - 2.0"diameter.
- 5F20,30frype l)
"k I Hrc
CARBON RING
SEAL NOSE
ffiffiItre
WUW
gFFv\
U. coVER PLATE WITH INTEGRALSEALSEAT
C - 5H120,126(rypell)
Fig. 50 - Service Replacement Seals
Table13 - AccessoryLiterature
AccessoryWater4ooled HeadsPackage
AccessorirOll Fllter Package
AccessorirOil Cooler
AccessoryOll SafetySwltch Package
CapacltyControl Vaive
Accessorypnl-o,ader Package ,
*SeeyourCarrierDistributor
for cunentformnumbers.
35
Step 1 - Lubricatethe shaftandthe neoprenebel-
lowswhereit comesin contactwiththe shaft.Slide
the sealassembly,as it is shippedfromthe factory
ontothe shaftuntilthe neoprenejust startsto grasp
the shaft.
LUG IN CENTER
NOTE: The seal may leak slightly immediatelyafter installation,but a short period of operation will correct the condition.
Looseor misaligned
belts. Checkalignmentand tension.(Belt
slack should be at
bolts.
(cont)
TROUBLESHOOTING
Cleanor
Controlvalvebellowsleaking. Removethread and leaktest.
valve if bellowsleaks.
Pioeoluqin oneumatic
connection. Remove
fromrefrigerant
Foamingin crankcase Checkexpansionvalveand piping.
ace controlcover
Rapidunloadercycling Excessive fluctuation
in suction Resizeexpansionvalve.
pressurefromoversizedexpansion
valve.
Cleanor replacestrainer.
SeeT - lowoil
Low oil pressure Add oil.
Checkand
Cleanstrainer.
38
TROUBLESHOOTING
(cont)
TROUBLE/SYMPTOM PROBABLECAUSE
Low oil pressure (cont) Removeobstruction.
39