i

CLIENT : LEWEK SHIPPINGPTELTD

PROJECT : 65m A/I{ SUPPLYVESSEL

SUBJECT : OPERATINGINSTRUCTIONMANUAL FOR :.
. AIR.CONDITIONING SYSTEM
. REFRIGERATINGPROVISIONSYSTEM
HULL NO. : 160

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
nd cleaning.
'dtep 2 - Receive Machine (Fig. I through
8)
BEFORE UNLOADING - Check unit nameolares asainsr
rodel and serial numbers recorded in job siecificaiions.
_lheck all items againstshipping list, and examine irems
carefully for any shipping damage. If damage is found or
any major component has torn loose from its anchorage,
ave transportationinspectorsexamine it before unloading.
_ile. claim immediatelywith shipping companyfor any loss
or oamage.
DIG UNIT CAREFULLY - Check that rigging equipment
tn safely handle the approximateequipment weights for
-Jmpressors and condensingunits.
' Rig and move unit carefully to preventdamageto mount-
,g brackets,refrigerantpiping or connections.
-tep3-lnstall Unit
TO MOUNTMOTORON BASE- Themotorfastenins
rt, available as an accessoryfor all 5F,H base-mounted
)mpressors,includes motor blocks and shims for motor
alignment; cap screws,plate washersand lock washersfor
fasteningmotor to base;taper dowel pins for securingmo-
r position after alignmenq and beveled washersfor fas-
ning the unit baseto accessoryvibration isolators.
- is recommendedfor most systems, and is essentialon all
If vibration isolatorsare used, attachto base(Fig. 9). To
avoid damaging the isolators, lift unit from ends when at-
:hing isolators.
- With compressorand motor positionedon the base,check
the height of the vibration isolators.Shim betweenisolators
"nd floor as requiredto level compressorbase.When level,
cure vibration isolators to floor. Check that bevel washer
--ig. 9) is in place.
{:zo mp
J'o
a"
l-ora.
'
Hd-ES
[tr;F=ll*'i^.!?',i,
r-5t-..1
5F
Fig. 9 - Typical Vibration lsolator Mounting
l-r MOUNT CARRIERCOMPRESSOR UNITS AND CON-
DENSERPACKAGES- Bolt thecompressor's lowersup-
5^4 strapslooselyto undersideof eachsupportstandand
F cestripsof protectivematerial(suchasFabrica)on straps.
[_;ition condenseron standswith hot gas inlet at top of
5e3
condenser and liquid shutoff valve connectionfacing com-
pressorend of base.Check that condenseroverhangssup-
port standsfor same distanceon each end.
Removesolderedshippingcap from hot gas inlet. To pre-
ventsolderfrom drippinginto inlet pipe while unsoldering,
rotatecondenser until pipe is below horizontalposition.Re-
turn inlet to upright vertical position.
Tightenlower supportstrapsenoughto lift condenseroff
stands.Placeupperstrapslooselyin positionwith a strip of
protectivematerial betweencondenserand strap (5F20 and
5F30 units use lower strap only).
TO MOUNT COMPRESSORBASE ON SUPPORT
STANDS - Placecompressorbaseon support standswith
2 extra strips of protective material between top of con-
denserand base. Bolt base into position with cap screws
and lock washersprovided.
Step 4 - Assemble RefrigerantPiping and Com-
-
ponents Refrigeranrconnectionsizes are given in
Table 1.
COMPRESSOR DISCHARGE PIPING RefeT to
Condensing Unit Piping Installation Instructions for
information.
REFzuGERANT DRIER - A replaceable-corefilter drier
low-temperaturesystems.Mount the field-supplied filter drier
in the liquid line. Includea shutoff valve ro permit isolation
of drier for servicing (Fig. l0).
Install a moisture indicator on downstreamside of drier
to indicatewhen drier cartridsesneed 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, clean
with kerosene or neutral spirits and insert for another
50 hours of operation. Tag unit to show date that filter was
cleaned and reinstalled. SeeTab\e 2 for information on re-
placementfilter packages.
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-
,
ization. Special handholecover plates, equipped with tafped *l
lqles for eqlalizing lines, are availableas oprions for iizes J1
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'
ternative to equalizer lines. n
' i.i
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

Fig.12 - EqualizerConnections (5F20and 30)

Fig. 11 - Special Hand-HoleCover and

Equalizer Connections (Typicall
Tablel - PhysicalData
COMPRESSOR UNIT AND
CONDENSINGUNfT
R-12,R-22, R-I34a, and R-502

MaxlmumRpm 1750
MinlmumRpm 400 (required propef
MinlmumRpm Capaclty 1r
Control 800 I 800 | 9oo

Bore (ln.) 3t/c

Stroke(in.) 37Ae

(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

sF20tt sF30tt OgRH- ff,RH. G'RH. OgRH. 09RH. MRH. OgRH.

CONDENSER DATA 5F40 5F60 o27 043 054 070 084 097 127
R-12 40.4 79.4 't54
fi.7 89.6 212 zoJ zJ6 z6z J5U
erant Storage R-22 37.2 48.4 72.8 82.0 139 193 239 216 257 327 432
Capacltyll(lb) R-502 38.2 47.9 75.C 84.6 145 199 248 223 265 337 447
MlnlmumRefrlg- R-12 2.O 3.0 14.0 16.0 37.0 41.0 t1.u 51.0 t6 IUU 126
erant Operatlng R-22. 1.8 2.7 12.7 14.5 33.0 37.0 46.0 46.0 71 91 114
Charge(lb) R-q)2 1.9 2.9 13.1 15.0 34.4 38.2 47.3 47.3 73 94 118

Side 385 psig

Water Side 150psig 250 psig
'Nominal oil pressuresshown in Physical Data table are above suction pres-
ttShell-and-coil condensers.All other SF,H condensers are shell-and-tube.
sure, i.e., pressuredifferentialbetween suctionpressureand dischargepres- ll Cond€nser storage capacity 80o/ofilled wilh liquid refrigerantat 90 F.
sure of oil pump. NOTES:
tOil flo,rrrate (gpm) for 5H. 12-cyl: 4.5 gpm with manual reversingoil pump; 1. Oil flow rat€ is the nominal oil pump capacity.
6.0 gpm with aulo. reversing oil pump. 2. Oil safety switch has manual reset and lime delay ol 45 seconds.
"See Table 5 for typical pressure switch settings.

697
 Table 2 - Suction (Felt) Filter Packages
COMPRESSOR FILTER PACKAGE PART NO.
5F40 5F40-
5F60 5F60-A352
5H40,46
5H40-A382
5H60,66 5H60-A382
5H80,86 SHBO-A382
5H120,126 5H120-4382
- Make Electrical Connections
_itep 6
GENERAL NOTES
. Factory wiring complies with National Electrical Code
(NEC). Any field modificationsor 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 separatesource,
rather than from a transformer,bring 115-vpower through
a_fie_ld_-supplied,I 5-amp disconnecr, in compliance wiih
NEC Section 440-14 (disconnectmusr be in sight from
- and readily accessiblefrom unit).
4. Opencontrol-powerdisconnectonly when servicingunit.
Crankcase heaters must remain energized when rlnit is
not operating.
5 *Factory wiring is for singlepumpoutcontrol. Do not use
pumpoutcontrol on equipmentusedwith DX coolers.Wir-
ing label shows field connectionsused with DX cooler.
*Contactor C2 is used with 208-v motors,
_ 25 throueh
60 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.
*Refersto compressor
unitsandcondensing unitsonly.
MACH POWER WIRES TO COMPRESSOR MOTOR -
?<rtachpower wires in accordancewith 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.otation
must be in samc direction as that indicated by arrow oncom-
1 ?ssorpump cover (or o1 plate anached-near pump-end
, ,aring hgusjng). If direction is not the same,reversemotor
r6-tationby reversing any 2 power leads to motor.
If rotation of oil pump is reversed, reverse direction of
I mp rotation arrow as well. At that time make the follow-
i_; adjustments:
All 5F Compressors- Remove 6 cap screws from oil pump
r ver (Fig. l-4). Do nor damage gasket. Rorare couei tgb
( greesand replace. Arrow at top of oil cover will indicate
rvw direction of rotation.
5H40 throushg6 Compressors- Drain oil below level of
pump-endcover (Fig. 5-7). Removepump-endcover to ex-
poseorl pump cover in centerof main bearinghousing. Ro-
tateoil pumpcover 180degreesandreplaceit. Replacepump-
end cover and reverseexternalarrow to match new direction
of rotation. Proper direction can later be checked without
removing pump-end cover.
5H120 and 126 Compressors(Beginning S/N 1086J---)-
Suppliedwith automaticallyreversingoil pump, eliminating
needfor adjustment.For 5H 120 and 126models built before
S/N 1086J---,follow sameadjustmentprocedureourlinedfor
5F compressors.
If the specialgasketbetweenoil pump cover and oil pump
is damaged,replacewith correctgasketonly. Cheik oil
pressureimmediately after starting compressor.
INSTALL CRANKCASE HEATER - Wire hearer ro relay
or set of normally closed auxiliary contactson compressor
starter to de-energizeit when compressor is operating.
Remove rubber plug from crankcase heater casing
(Fig. 1-8),and insert heaterelemententirely into casing.El:
ement should fit snugly, not loosely. Wire to comply-with
applicable electrical codes.
When crankcaseheater is installed, system can be oper-
atedon singlepumpoutcycle, unlessusedwith a DX cooler.
Table 3 lists crankcase heater packages.Table 4 shows
correspondingrelays. Use of 2 heaterson a 5H80 throush
126 compressorrequires only one relay.
Control circuit voltage determinesrelay coil voltage. This
voltage must be specified when ordering relays.
SeeAccessory CompressorCrankcaseHeater lnstallation
lnstructions for additional information.
Table3 - sF,HGompressorCrankcase
Heater Package
-5,H-40--381
-5-H-40--391
-+ 5H80,86,120,126
f
Table4 - CrankcaseHeaterRelay(60 Hz) ig
I
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i.
1l
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 Step 7 - Check Compressor/Motor
Alignment
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 .
DIRECT DRIVE - Install and align compressor,coupling
and motor as describedin manualfor Flexible Couplingsfoi
Direct-Drive Units.
HOTCHECKAND DOWELING -To help maintainatign-
ment, and to ensureexact repositioningof the motor after
servicing,the motor and compressormust be doweledto the
base. 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 a
e/tz-in. dnll and a no. 6 taper reamer.Secure the motor and
compressorto the basewith the no. 6 x 2Vz-in.taper dowel
pins 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 not
bottom.
Step I - Assemble Water Piping - SeeWater-
Cooled Condensers Installation Instructions and Water-
Cooled Heads Installation Instructions for information.
Step 9 - PrepareLubricationSystem
INSTALL OPTIONAL EQUIPMENT - Consult local
Carrier representativefor information on these accessories.
Oil Filter - Oil filter for 5H40 through 86 compressorsis
available as separateaccessorypackage.Refer to Accessory
Oil Filter Package Installation Instructions for installation
procedures.
If an accessoryoil cooler is also installed (seebelow), pipe
oil filter into system as shown on diagrams in Accessory Oil
Cooler InstallationInstructions.
Oil Cooler - Refer to Accessory Oil Cooler Installation In-
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.
Oil Separator- If oil separator is used in system piping,
pipe oil return line to compressor suction line. To minimize
possibility of flooding compressor with oil, oil return line
diameter should not exceed % inch.In addition, line should
have manual shutoff valve to throttle oil flow as required
and to isolate separatorfor service.
CHECK OIL LEVEL - Check that oil level is visible at
center of compressor sight glass. Compressorsthat use op-
tional equipment such as filter, cooleq and oil separatorde-
scribed above will require a greater oil charge than listed in
Table 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 departmentapproved,dehydrated,wax-free refrigeration
grade oils noted below:
IGI PetroleumSpecialties,Inc. . .. ...... Cryol 150
IGI PetroleumSpecialties,Inc. ... Cryol 150 with additive
(Akzo Chemicals, Inc. additive Syn-O-Ad (8478)
witco. ..Suniso3GS
Witco - Hi ambient application,
300 viscosity . Suniso 4GS
13
T e x a c oI ,n c . . . ..WF32-150
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-
tics. One is not necessarilybetterthan the other.Somechar-
acteristicsof the mineral oils have been found to be more
favorablefor use in someair conditioning and medium tem-
peratureaPPlications.
Approvedcompressoroils are availablefrom authorized
factory parts outlets.The oils recommendedare fully com-
patible with eachother and can be mixed in any proportion.
PREPAREFOR INITIALSTART.UP
Evacuate,Dehydrateand Leak Test theenrire
re-
frigerantsystemas describedin Carrier StandardServiceTech-
niquesManual, Chapterl, Sectionsl-6 and l-7.
LEAK TESTING
PreferredMethod- Charge the system to 10 psig with re-
frigerant. Add dry nitrogen or dry air (DO NOT USE
OXYGEN) until systempressureis 150psig.Check for leaks
with a halide or electronic leak detector.
AlternateMethod- Chargethe systemwith dry nitrogenor
dry air (DO NOT USE OXYGEN) to 40 psig and use soap-
bubble test to find larse leaks.
Do not usecompressorto build up pressure.Do not over-
charge the system.
Refrigerant Charging - Use the sight gtassmethod
to charge the system.See Section l-8 of Canier Standard
ServiceTechniquesManual, Chapter l, for details.
Chargethe systemto a clearsight glasswhile holding satu-
rated condensing pressureconstant at 125 F for air-cooled
systems or 105 F for water-cooled systems. Add
additional refrigerant to fill condensersubcooler coils, if
required.
5RH CONDENSING UNITS - After a clear sight glass is
obtained,add chargeuntil liquid refrigerantreachesthe con-
denserliquid level test cock.
5F.H COMPRESSORUNITS - Seecondenserdatafor ad-
ditional charge requirements.
PreliminarySteps
l. 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 ensurethat
field connectionshave'beenproperly made.
3. Install felt sock filter for the first 50 hours of compressor
operation.Remove and inspect the filter, clean it if re-
quired and replaceit for another50 hours. Removesock
when systemis clean.(Not applicablefor 5F20 and 5F30
units.)
4. Check that motor rotates in direction that the arrow on
the compressoroil pump cover indicates.Refer to Instal-
lation, Check Motor Rotation section on page 12.
5. Check that oil fills tZ to Vzof the compressorsight glass.
6. Open water supply valve to condenser.Open pressureline
valve of water-regulating valve (if used). If compressor
unit is equipped with air-cooled condenser,turn on con-
denser fan.
 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

HIGH- AND LOW-PRESSURE SWITCHES- All 5F and

TOP
5H units except5F20 and 30 have factory-installed,auto-
maticreset,triitr- analow-pressureswitches.(Theseswitches
are availableis accessorids for 5F20and 30 units.) Figure @--u-o,FFERENTTAL ADJS C R E W
l3 illustratesadjustmentproceduresfor both switches.
Check High-Pressure Switch - Throttlethe con-
denserwatei on water-cooledunit or block the airflow on
air-cooledunit, allowingheadpressureto rise gradually'
Compressor shouldshuioff within-!J psi of cutoutvalue
listedin Table4. Now reverseprocedfre;compressor should
startwithin p psi of cut-invaluegiven'
Check Low-Pressure Switch - Slowly closethe HIGH-
PRESSURE
suctionservicevalve;suctionpressurewill decrease'Com- swrTcH
pressorshouldshutoff within{ psi of cutoutvaluelistedin
Table5. Reverseprocedure;compressor shouldstartwithin
cut-in valuegiven.
! Osiof

SHOIVN.
ARRANGEMENT
5H MOUNTING
Tabte 5 - Typical Pressure Switch Settings !
ScrewA raisesor lowersbothcutoutandcut-inpointsby a likeamount. x
!

PRESSURESTAT Rangeand Differentialscalesare on the frontof the switch. i?

.1
REFRIG- CONDENSER High Low HighPressure:Set cufoutpointfirst,with screwA; then set cut-'n' :. i
ERANT (psls) oointwithscrewB.
Cutout Cut-ln Cutout Low Pressure: Set cut'in pointfirst,rvithscrewA; then set cutout
OR 16
pointwithscrewB.
water-cooleo 175
12 Alr-Cooled 225 145 16 76 LOCATIONAND ADJUSTMENTS
Water-Cooled 280 2AO 36 96
22 Alr-Cooled 325 245 36 96 Fig. 13 - High'and Low-Pressure Switches
Water-Cooled 280 200 45 105
502 Alr-Cooled 325 245 45 r05
For additional information, seeOil Safety Switch Acces-
sory PackageInstallation Instructions.
OIL PRESSURE SAFETY SWITCH - To check, move Adiust Capacity Control (if required)
contact arm at left side of switch forward (Fig. l4). Com-
pressor should stop in approximately 45 seconds. 5F20 AND 30 COMPRESSORS- Refer to Capacity
Control Valve Installation Instructions for additional
If compressorcontinues to run, check the wiringto safety information.
switch. It wiring is correct, switch is faulty and should be .5F40
replaced. AND 60, AND 5H4OTHROUGH 126COMPRES-
SORS- Determinethe refrigerantusage:
After completing test, wait 3 minutes: then press restart -+ If the systemis to useR-I2nr R-I 34a, replacethe I I -lb
button on front of safety switch and restart compressor. raige adjustmentspring(FiS. I5) with !y-7-lb springsup.'
ptiid wiih compreisor.A changein 1982 reversed which
Check oil level in compressorsight glass after 15-20min- ^Ihe R-221
iange-adjustingspring a customer received.
utes of operation. If thd oil level is low, add-oil- by the R-5b2siring ii n6w standardwith the compressor.Seein-
methods iescribed in Carrier Standard Service Techniques stmctiontag for springreplacementprocedure.
Manual, Chapter1, Sectionl-ll.

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

Fig. 14 - Oil PressureSafety Switch

5F40.60:
ffiffi
ot.--,oe',a0;
86,120,126
PNEUMATIC 'Capacity
Control reduction steps.

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

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

o OIL PUMP
PRESSURE

5F20 5F30
5H40, rt6 5H60.66

@ rn
--J1
fl- I|J
'll
@
5F60 5 H r 2 0 t, 2 6

Fig. 17 - Cylinder Unloading Sequence

 LEFTSIDE
1 - 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. The
blank-offplate installedfor extemal unloading will block oil pressure
to the I o'clock position on the pump cover.
Fig. 18 - Typical5H40through5H86CompressorPump-EndConnections
SCHEDULEDMAINTENANCE
5F,H compressor and condensing units provide long life
and dependable service when properly operated and regu-
larly maintained. Establish a maintenanceschedulebasedon
factors such as operating hours, load conditions and water
quality. Maintenance scheduleslisted in this section are of-
fered as guides. Modify them as neededto satisfy individual
machine requirements.See Fig. 18 for important compres-
sor service locations, connections, oil cooler sleeve location.
Check Lubrication System - Alwayscheckcom-
pressoroil levelbeforestartingunit.If oil is required,record
date and amount added. Refer to Fig. 1-8 for location of oil
filterplug. Table I and Step 9 show speciftedtypes and quan-
tities of oil.
Use of accessoryoil separatorrequires additional oil. Oil
level and separatorfloat valve movement during initial com-
pressor operation should agree with instructions furnished
with the oil separator.
t7
RIGHT SIDE
1 - PneumaticControlConneclion
2 - Capacity Control Valve
3 - Oil Pump RotationAnow
4 - CapacityControlOil Pressure
5 - Oil Fill Plug
OIL FILTER MAINTENANCE - A bleed-type, high-
pressure,disposablefilter is availableas an accessoryfor 5H40
through5H86 compressors(Fig. l9). Replaceoil filter after
the first 50 hours ofoperation, or whenever the oil is changed
or becomesdirty.
Check yearly for clogged filter, indicated by a greaterthan
normal difference between oil pressure ahead of filter and
after 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 additional
information.
The full-flow oil filter, on 5H120 and 5HI26 compressors
only, contains a replaceablecartridge. 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 pressuredifference acrossthe fi-lterexceeds5 psig, pump
down the compressor and then remove the cartridge.
Figure 20 (B) illustrates complete filter assembly (not shown
in Fig. 20 tAl).
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.

OL COOLER USAGE - The accessoryoil cooler main-

Fig. 19 - Oil Filter Accessory Package
(5H40 through 5H86)
CI{ECK OIL AND SHAFT SEAL TEMPERATURE _ The
normal operating temperature of the oil in the crankcase
nges from 100 F to 135 F when fully loaded. Do not per-
it maximum oil temperatureto exceed 150 F. Conditions
under which such excessive temperatures could occur in-
clude situations where the compressor operates in a fully
rloadedcondition for an extendedperiod, becausethe com-
essor would not be able to remove all of the heat gener-
a-redby compression and friction. In such situations, use an
oil
-r,Hcooler to maintain safe operating temperatures.Refer to
Application, Data for more information.
tains safe operating oil temperatureswhen:
l. Applying long stroke compressorS(5H46, 66, 86 and
126). For added reliability, an oil cooler is recom-
mended on all long stroke models regardlessof operat-
ing range or type of refrigerant. Additional heat of fric-
tion from extended piston travel on long stroke models
increasesoil temperatures.
2. The suction gas becomeshighly superheared(Table 7).
3. a. The compressionratio exceeds5:l on R-22 systems.
b. Application data indicates the need for an oil cooler
for R-12, R-134a, and R-502 systems.The compres-
sion ratio can be determined from the followins
formula:
AbsoluteDischargePressure
Ratio _
Compression
AbsoluteSuctionPressure

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

OIL FILL PLUG

OIL PRESS. CAGE CONN
(8EFOfi€ FILTER } \ CAPACITY CONTROL VALVE AD.,USTING STEM

BTJSHING LOC

IROL OIL PRESS. GIGE CONN

OIL FILTER IIOUSING

DRIVE DISC
OUTER GEAR
INNER GEAR
OIL FILTER
covgR COVER GASKET
.

PUTTPIilTAK€
PLUG(MAGNETICI

orL PREss-GAGEcoNN ( aFT€R FTLTER) ia t

%,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.

Table I - Oil Cooler Maximum

Working Pressure
4901765and

NOTE: By itsetf,the automaticreversingoil pump cannot be installedin place

of the manually reversingoil pump or vice versa. The complete bearing head
Table I - Oil Cooler Estimated assembly with ths oil pump (auto. or manual) is interchangeableas a com-
plete assembly.
Water Flow Rates
COMPRESSOR MANUALLY.REVERSING OIL PUMP r.,.
%-1 Oil PumpInspection - SeeFig. 20B, 23 and24 for 5F
5H40-66 1-2 and5H manuallyreversing oil pumps.Also referto 5H120,
5H80,86 11/r3
5H120,126 2-4 126auto.-reversing oil pumpsection.
'Flow rate based on 80 F entering water. Drain oil below level of pump-endbearinghead. Re-
move bearinghead.Completeend-bellassemblymust be
removedto accessbearingheadassemblywith oil pumpon
Check Water-Cooled Heads - To preventoil break- 5H,10through 86 models.Check oil pump rotor for end
down and sludge formation, the discharge gas temperature play. Maximumallowablemovementof rotor is 0.0025.If
must remain below 275 F. Water-cooled cylinder headsare iheie is excessiveend play, repositionoil pumpbushingin
available as an accessory for this purpose. See Accessory bearingheadas describedbelow.
Water-Cooled Head PackageInstallation Instructions for ad-
ditional information. Ttrn rotor. If there is more than a slight drag, remove
pump cover and disassemble oil pump checkingall parts
for wear and damage.Inspectoil pump bushingfor scor-
SERVICE ing. Replacebushingif scored.If bearingheadis scored,
Service and repair of Carrier reciprocatingcompressors replacecompletebearingheadand oil pump assembly.
andotherrefrigerationcomponentsshouldbe performedonly Oil PumpBushingInstallation- SeeFig.25 and26. Po-
by fully trainedand qualifiedpersonnel. sition the bushingoil grooveat top (runningfrom 12:00to
ServiceNotes 6:00)whenthebearingheadis installed.Pressnewbushing
into the pump-endbearingheadfrom the inner side of the
1. Compressor components are shown in normal order of headwith the chamferedend entering first.
removal from compressor (Fig. 2l and22).
2. For replacement items, use Carrier specified parts. See

L9 1094

,i
 Oil Pump Bushing Position
l. a. 5F20-60and 5H40-86. See Fie. 25. Place0.001-in.
circular field fabricatedshim aEainstbushinsand in-
stall pump.. Shim between bus6ing and oil i'u-p .o-
tor. Complete assemblyof oil pump with giskei and
cover.
b. 5Hl20,l?5. SeeFig. 26. Placn0.0l5-in. (t/e+-in.)shim
between po_rtinsert and oil pump cover. Complete
assemblyof oil pump and pump cover without tising
pump cover gasket.
-2. Tap bushing with suitablecylindrical positioningtool to
-
seat it againstshim. See typical arrangementsf,own in
Fig.25.
3. a. 5F20-60and 5H40-86.See Fig. 25. Disassemble oit
pump and removeshim. Reassemble oit pump. Check
for bindins.
b. 5H120,126. Remove oil pump cover and shim.
Reassemblepump cover with gasket. Check for
bindine.
4 . Install bearingheadon compressor.Line up tang on oil
pump rotor shaft with slot in end of crankshaft.Check
oil pump for proper direction of rotation.
5 . Refill compressoroil to proper level. Observe oil pres-
surewhen startingcompressor.Correctoil pressureshould
be 45-55 psig abiovesuction pressure.

Oil pump assemblymusr be

surface, but must not protrude
surface.

! 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
Oil Pump Inspection - See Fig. 20(A) for 5H120 and 126
for automatic reversingoil pumps.
l. Drain oil below level of pump-end bearing head.
2. Remove bearing head from compressor.
3. Remove oil pump and adapterfrom bearing head.
4. Check all parts for wear and damage.
Pump Installation
l. Using a new gasket, mount bearing head on compres-
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
and on threads of each mounting hole in bearing head'
Position one of the supplied gasketsover holes in adapter
and assemblethe adap-terloosely to 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
and into bearing head bore, allowing enough clearance
to tighten adapter mounting screws with an Allen
wrench. The clearance between oil pump housing and
bores in adapter and bearing head is necessarily very
close. DO NOT USE FORCE and do not attentpt to change
the clearance.

p r s r o N R r N G s( c o M p R E S s r-oTNA ' E R E)D

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

5F UNITS 5H UNITS (cont)

USAGE USAGE

Plug - Pump End Pump - PumP

Plug - Crankshaft BearinoHed
'ibe Plug - Suction and Discharge Caoacitytontrol Valve - PumP
Manifold Cover End dearing Head
AuxiliarvControlValve- PumP
Power ElementAssembly- End BearingHead
Crankcase Manifold Cover Plate - Crankcase
Unloader Cylinder Cover Plale - Oil Pump Adapter (12 cylinder)
Unloader Cylinder Bracket
Discharge Valve Cap Screw - Elemenl-
lnner Seat Crankcase
Discharge Valve Guide Assembly- Capacity Control Valve -
Valve Plale Pumo End Cover
Ol Pump Cover - PumP End DischargeValve Guide Assembly -
Bearing Head Valve Plate
Auxiliary Control Valve Cover - DischargeValve Guide - Inner Seat
Vatue Body Cvlinder Bracket
Rod Bolt - Locknut - Pump End Bearing Head
Capacity Control Valve - Pib Plug - Crankshaft
HanGHole Cover
Plug - Pump Pump End Bearing Head
Connecling Rod Bolt (Aluminum Rod)
2*n Cvlinder Head - crankcase
25-?9 Shaft Seal Cover Plate - Crankcases and DischargeManilold
2*m Bo$om Plate - Crankcase Crankcase
25-?s Suclion and Discharge Manifold Discharge Manifold - Cylinder Heads
Cover - Crankcase Valve Plate - Crankcase
2*29 Pump End Bearing Head Assembly- Cvlinder Head - Crankcase
Crankcase Hind-Hole Cover - Crankcase
25-23 Hand-Hole Cover - Crankcase Shaft Seal Cover
2*n Suclion Manifold - Crankcase Pump End Cover and Pump End
- Crankshaft Bearing Head - Crankcase
Rod Bolt - Locknul'
Oil Return
Crankcase Pipe PIug - Crankcase
-
Pipe Plug - Pump End BearingHead
ouutlgll Qcrvrw vdvE vtdllRkw
PressurJRelief Vilve - Suclioh and
Discharge Service Valve - Crankcas€ DischargeManifoldCover
Valve - Pressure Reliel Valve - Crankcase
Srction Manilold Manifold-
Magnetic Plug - Crankcase Crankcase
Magnetic Plug - Pump End Suciion Manifold Cover - Crankcase
Bearino Head Pump End Bearing Head -
Oil BypaSsPlug - Pump End Crankcase
Bearing Head Oil Fitter Housing - Bearing Head
Modulating Valve Adapter - ano
Pump End Bearing Head Suciion Manifold - Crankcase
Lock Screw - Pump End Eearing Head
oil Regulator Vatve Assembly - Crankcase Magnetic Plug - Pump tnd
VatueAssernbly Bearino Head
Modulatifu VatueAdipter - Crankcase
Flywheel Locknut - Ol Bypass Plug - Crankcase
Clamping Oil Bypass Plug - Pump Enc
Cover Bearino Head
Control Valve Oil Bypais Plug - Pump End Cover
Valve Body Hollow Lock Screw - Pump End Cover
and Center Main Bearing Housing
Oil Pressure Begulator Valve - Crankcase
CapOil Pressure Regulator Valve Assembly
.Seal'Flug -
Oil Pressure Valve: Crankcase
Pipe Plug -
End Bearing Head
Pipe Plug - Pipe Plug - Crankcase
Pipe Plug - Pump End Cover
Pipe Plug - Crankshaft
oil Pump Cover - Pump Valve Cover -
End Bearing Head Valve Body
Auxiliary Control Valve Cover -
Valve Body NC - National Coarse
Special Cap Screw - Auxiliary NEF - National Extra Fine
Control Valve Bodv NF - National Fine
Oil Pump - 'Steel Rod.

,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 &

Suctlon Valve (Disc .005

(depth of urear below face)
Suction Valve Seat .002

Dischame Valve Disc .005

(cteptliof w€ar bclow tace)
Discharge valve seat .N2
'Same wear allowance applies to undersized shafts and bearingg-
.
tfiemanufaclured
'Comoressors service |ompressors can be built with underdizedmain bearings and conne€tingFrodbearings.
with undersized-bearings are identified by the letter A, B, or C stamped on the compressornameplate
after'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 undersized
bearing.
"Repta& thrust and bearing washers rvhen end clearance exceeds maximum listed:

CRANKSHAFT END CLEARANCE

1l to
5H40,46 l0 to .036
5H60,66 .011to .037
5H80,86 .014 to .042
5H120,126 .014to .Ozl4
-+ ttcap dimension increases (by up to 10%) when cylinder bores have been honed (if necessary)on SF/l-l remanu-
factured @mpressors.

23 398
 ARONZE EEARING WASHER

P U M P E N O B E A R I N GH E A D

OIL PUMP ROTOR

PUMP COVER GASKET

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)

Fig.24 - 5H40through 86 Oil pump Assembty

$
$
$
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.

Fig.25 - Setting Oil Pump Bushing

{Typical 5F20through 60, and 5H40
through 86 - 5F40 Bearing Head Shown)
OIL REGULATING
p
G AS K E T OIL REGULATING
VALVE CAP
VALVE BODY
CRANKCASE
# Pi#,t'JfiB, Fig.27 - Oil Pressure Regulating Valve
(Nonadiustable)

Unscrew regulator from crankcase;use 5/ro-in.Allen wrench

on all compressorsexcept5H120, which requiresVz-in,Allen
wrench. Regulator must not be clogged and plunger must
not be stuck. Check drillings to regulator for fouling.
IOENTIFICATIOII
IIOTCHAT The nonadjustable oil pressureregulator is interchange-
T H I SE N O ableon all current5F,H compressorsexcept5H120 and 126
models. 5H120 and 126 units have larger, nonadjustable
regulators. Early 5F,H compressorswere equipped with an
DRIVEDISC adj ustabIe -type oil-pressureregulator. When an adjustable-
type regulating valve needsreplacing, use a nonadjustable
OIL PUMP regulator.
COVER

OIL RETURN CHECK VALVE (5F20 through 60, and 5H40

REI'OVE SHIM FOR
FINAL ASSY
Fig. 26 - Setting Oil PumP Bushing
(Typical 5H120,126l-
4. Hold pump with one hand and rotate it while equally
tightening adapter mounting screws. Proper alignment
biween pump and bearing head bore is extremely im-
portant. THERE MUST BE NO BINDING.
5 When adapter is secure, remove pump assemblyand place
secondgasketon pump housing. Insert two Vt-20 mount-
ing screws and lock washers, one on either side of the
word TOP on pump end cover, and position gasket on
screws. For renwining operatiotts, be sure the wordTOP
is at the top.
through 86) allows oil to return from suction manifold
to crankcase. This normally open valve closes when
crankcase pressure becomes higher than suction pressure
(Fig. 28).
Two disc-type check valves on 5F20 and 30 compressors
are located beneathpartition between suction manifold and''
crankcase,one on eiich side ofcompressor. Rernove check
valves through bonom cover or pump end of compressor.
I-eaf-type check valve on 5F40 and 60 and 5H40 through
86 compressors is accessible through, and located at top
center of, hand-hole cover opening.
Remove check valves and check to see that flutter valve
or leaf does not stick, and that it seats tightly.

25

CHECKVALVE
wwre LEAF TYPE
FiS.28 - Oil Return Check Valves
Fig. 29 - Centrifugal Oil Separator lmpeller
CENTRIFUGAL OIL SEPARATOR on 5H120 and 126,
mounted on crankshaft (Fig. 29), returns oil to compressor
crankcase.To remove or replace oil separator, see Crank-
-shaft Inspectionand Service.
OIL FILTER SCREEN (Fig. 21) in compressor crankcase
is accessiblethrough hand-hole cover or bottom plate. Re-
_move and inspect it for holes, then clean it with solvent and
replace.
Pressure-Relief Valves - Whenpressure differen-
high-andlow-pressgre
tial between sidesexceeds 350 -+
-35.psi'(5F60:400 t 4Opsi); pressure-relief
valvebleeds
refrigerant 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 into
crankcaseand projects up through left cylinder-bank valve
-plate (Fig. 30). Use a standard socket{ype screwdriver to
remove 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 located
in 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.
26
VALVE PLATE
P R E S S U R ER E L I E F V A L V E
(SEEI{OTE}
NOTE: The Dressure-reliefvalve is not pan of the valve plate as-
sembly.The'valvemountsin the crankcasein the left side cylinder
deck (lookingat pump end). The valve plate opening outlined,slips
over the pressure-relief
valve when assembled.
Fig. 30 - PressureRelief Valve (5F60)
D I S C H A R GM
E ANIFOLD
R E L I E FV A L V E
PRESSURE
SUCTION
STRAINER
0
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
Fig. 31 - Pressure Relief Valve and
Suction Strainer (5H40,46, 80 and 86)
5H120 AND 126 COMPRESSORSare equipped with ex-
ternal relief valve mounted on bypass line between suction
shutoff valve and dischargemanifold. To remove valve, re-
move bolts from flanges on either side of valve.
Suction Strainer - To withdraw straineron 5F20 and
40 and 5H40 and 46 compressors,remove suction and dis-
charge manifold cover on seal end of compressor.
On 5F30 compressor,remove suction service valve. On
5F60 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 suction
strainers.
 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.

If a felt sock filter is installed, remove and inspect it

after 50 hours of operation. Clean filter if required and |NNER
sEAr VALVE
yt'
tt
replaceit for another50 hours. Clean the suction strainer / PLATE SUcTtoNI
VALVE I
whenever the felt sock is removed. Remove sock when DISCHARGEVALVE SEATS I
OUTER SEAT
system is clean. (Not applicable for 5F20 and 30
compressors.)
t',Rtlo.[.ul*t
Fig. 32 - Suction and Discharge
Valve Assembly

VALVE P L A T E S U C T I O NV A L V ED I S C

Cylinder Head and Valve Assemblies

CYLINDER HEAD INSPECTION - Remove cylinder heads
and check headsfor warping, cracks and damage to gasket
surfaces.

VALVE INSPECTION (Fig. 32)

Disassembly - Remove cylinder head. Loosen cap screws
holding discharge valve seat to discharge valve guide, and
cap screws holding valve guide to valve plate. Remove cap
screws holding valve plate to cylinder block. Remove valve
plate from cylinder block and discharge valve guide from SUCTIONVALVERETAINERCLIPS
valve plate.
Fig. 33 - Valve Clips in Place
Inspection - Inspect suction and dischargevalve discs and
valve seatsfor cracks or excessive wear (lable I l). Check
cylinder-sleevevalve stops for uneven wear. Replacevalves Cylinder and Unloader Sleeves
if cracked or worn. If valve seats are worn, replace com-
plete valve plate assembly. If cylinder-sleeve valve stops DISASSEMBLY (Fig. 34) - Remove cylinder head, suc-
are worn, replace sleeve. tion and discharge valve assembly, and pump-end bearing
head. Whenever cylinder sleeve or valve plate is replaced,
Reassembly - Pistonsmust be below tops of cylinder sleeves. use a new suction valve disc.
To position correctly, nrrn crankshaftor force pistons down.
l. Turn crankshaftuntil piston is in midposition.
1. Place suction valve springs in valve plate recesses.Large 2. Insert a sleevepuller into cylinder and push it down onto
spring coil should be in full contact with bottom of top of piston.
recess. 3. Tighten nut on top of sleevepuller to expand puller in
2. Place suction valve disc on valve springs; pressdisc into sleeve.
valve plate recess. Slide valve retainer clips into place 4. Turn crankshaft, forcing sleeve upward until it can be
(Fig. 33). Clips must not cover valve lifter springs or removed.
pins. Valve retainer clips 5F20-2061 (5F compressors)
5. Removeunloadersnaprings(5H compressorsonly). Dis-
and 5H40-2061 (5H compressors)are field supplied.
assembleunloadersleeve,pins and springs.
3. Bolt valve plate to cylinder block. Remove valve clips.
INSPECTION - Examine bore of sleeve for wear. Check
4. PIace discharge valve springs in discharge valve guide
suction valve seatsfor scratchesand wear. Check unloader
spring recesses.
sleeves, pins and springs for wear and freedom of move-
5. Place discharge valve disc over springs, agd fit inner ment (Table l l).
spring in place over valve disc. Hand-tighten bolts hold-
ing inner seat to valve guide (valve guide assembly). REASSEMBLY - When new rings are being installed in a
used cylinder sleeve, break the hard, glazed surface of cyl-
6. Place valve guide assembly on valve plate. Tighten all
inder sleeveto reducewearing-in period of new rings. Clean
bolts and bend tabs on lock washer and lock plates. Re-
sleevesthoroughly after breaking gIaze.
place cylinder head.

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

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

IF PNEUMATICCOIVTROL FROM COMPRESSOR

OIL PUMP,
IS NOTUSED,THIS
PORT MTJSTBE VEN
DO NOT PLUG CONTROLOIL OIL PUMP
PRESSURE PRESSURE S U C T I O NV A L V E
orsc

ADJUSTME LIFTER SPRI

SPRING AND PINS
LIFTING
FORK
PISTON

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

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

o OIL PUMP
PRESSURE

29
 2. Ahydraulic relay, which (gxcepton the 5F20and
30)
feedi oil to the unloaderpower elementsin sequence'
Control oil pressurefrom the capacity control valve ac-
tivatesthis rglaY.
3. A hydraulic power element, which suppliesthe po-wer
necessaryto operatethe valve-lifting mechanism.It is
modulatedby the capacity control valve.
4. A valve.lifting mechanism, which consistsof a sleeve,
a lifting fork and a push-pina,ssemblyaroundeachcon-
trolled cylinder. The valve-lifting mechanismholds the
suction valve open, or permits the valve to remain in
normal operatingposition dependingon its actuationby
the power element.
- These componentsoperatein the following manner:
5F2O AND 30 CAPACITY CONTROL OPERATION
(Fig. 36) (With Optional Unloadersand Control)
- LoadedOperation - A rise in suctionpressurecausesnee-
dle valve to close. Oil pressurein power elementincreases
as oil enterscapacity control circuit from oil pump- Power
elementpiston is forced upward, pivoting lifting fork down-
'- ward. Lifter pins drop, allowing suction valve to seat and
load controlled cYlinder.
Unloaded Operation - A drop in suction pressurecauses
through valve to crank-
'- needle valve to open. Oil bleeds
case,decreasing oil pressurein powerelement.As oil pres-
sure to power elementdrops, the pl919nmoves downward'
Lifting fork pivots upward, moving lifting pins.upward;suc-
tion ialve hses from its seat and controlled cylinder
unloads.
5F4O AND 60, AND 5H4O THROIJGH T26 CAPACITY
CONTROL OPERATION (Fig. 37 and 38)
Loaded Operation - A rise in suction pressureincreases
prasu." againstcapacitycontrol valve bellows, compress-
ing rung" ialustmeitt spring, Compressionof range ldjust-
*6nt sp?ngillows valve sp-ringq9 move push pins and valve
needle'poiit toward valve seat.Flow of control oil to crank-
case through oil drain is throttled.
Control oil pressure rises as oil enters capacity control
circuit through orifice from compressoroil pump circuit.
Increasedcoitrol oil pressureadvanceshydraulic relay pis-
ton (againstspring) which feeds oil at full pressureto one
or moie contrblled cylinder power elementsdependingon
position of control valve.
Pump oil pressurein unloader power elements forces
piston ipward, pivoting the lifting fork(s) downward. Lifter
and load
iins dr6p, all6wing suction valve(s) to seat
cylinder(s).

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)

Fig.38 - capacitycontrol (5H120,5H126)

f]-
C-
UNLOADER PISTON UNLOADER
CYLTNDER
RoD
ii^LllR,
Fig. 39 - Unloader Power Element (Typical)
Unloaded Operation - A drop in suction pressurede-
creasespressure against control valve bellows. Range ad-
justment spring pressesagainstthe push pins, compressing
the valve spring. This moves the needle valve off the seat.
Control oil bleeds from hydraulic relay and control valve
to crankcase, relieving oil pressure on hydraulic pistons.
The piston retracts, preventing transmission of pressurized
oil to controlled cylinder power element(s),and the oil drains
to crankcase
As oil pump pressureon power element drops, the piston
moves downward. Lifting forKs) pivot(s) upward, moving
lifting pins upward; suction valves rise from their seatsand
controlled cylinder(s) unload(s). It should be noted that a
minimum of 33 to 35 pounds of oil pressureis required for
proper unloader operation.
Capacity Control Inspection and Service
UNLOADERPOWERELEMENTREMOVAL- Re-
move cylinder head, valve plate, connectingrod, piston and
cylinder sleeve. Remove Allen head cap screws (2) holding
unloader power element in position.
Remove power element (Fig. 39) and disassemble.Check
all parts for wear or damage.
POWER ELEMENT REPLACEMENT - Check unloader
fork height (Fig. a0) of new or assembledpower element.
Attach power element to internal suction manifold. Re-
place cylinder sleeve piston, connecting rod, valve plate,
cylinder head and hand-hole cover.
15fi
I
(5RH:2
32
{
Fig. 40 - Unloader Fork Height (5F and 5H)
3l
UNLOADER CYLINDER
PLArE
covER
)
is,l+tP
EXTERNAL ADJUSTING STEM REMOVAL does not re-
quire compressorto be pumped down. Loosen hex nut at
valve stem baseand remove adjustingstem assembly.
REMOVALOFCAPACT|Y CONTROL VALVE AND HY-
DRAULIC RELAY - Assemblyis locatedin hand-holecover
(Fig. a1) of 5F40 and 5F60 units; in pump-endcover (Fig.
42) of 5H40 through 86 units; and in pump-end bearing
head(Fig. 43) of 5H120 and 126 units.
Remove capacity control valve and hydraulic relay.
NOTE: It is not practical to remove hydraulic relay from
5H40 through 5H86 compressors.
Inspect parts for wear, damageor evidence of leaking or
sticking.
A new hand-holecover, pump-endcover or pump-endbear-
ing head with control valve assembly and hydraulic relay
may 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-endcover, or pump-endbearing head.
INSPECT CONTROL OIL STRAINER - On 5F compres-
sors, the control oil strainer is located on the side of the
pump-end bearing head (Fig. 23). Strainer is located be-
hind the control oil pressuregage connection block on the
5H120 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 it
with solvent and replace.
TO UNLOADER N ${3ADER TO UNLOADER
POWER ELEMENTS \-./S€CX.ET.ICE POWER ELEMENTS
Fig. 41 - CompressorHand-HoleCover and
Assembly (5F40and 5F60)
 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}

CAPACITY CONTROL VALVE

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 )

Fig. € - 5H120 and 126 Pump-End

Bearing Head

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
tolerances(Table ll). Remove crankshaftplugs, check oil
passagesand clean if clogged.
Connecting-rodbearing insertsand main bearingsare avail-
able for crankshaftsregroundfrom .01O-in.,.020-in.,or.030-
in. undersized.Factory-regroundcrankshaftsarestampedon
both ends with an A (.010-in. undersized),B (.020-in. un-
dersized),or C (.030-in.undersized).
IMPORTANT:Do NOTEregrindcrankshafufor 5H46,
in thefield.Replaceshafts
66,86,and 126compressors
with scoredjournals.
AII instructions for feld grinding apply only to standard-
stroke crankshaf'ts.
On crankshafts reground locally, hold throw to 1.001 in.
for 5F compressorsand to L.376in. on 5H compressors.Stamp
A or B on crankshaft and pump-end bearing head next to oil
pressuregage connection.
To determine maximum and minimum journal diameters
for undersizedshafts, subtract the amount (in.) that the shaft
will be ground undersize from factory from the tolerances
specified in Table 11. For example, the factory tolerancefor
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.
IMPORTANT: When regrinding the seal-endjournal
on 5H120 crankshaft, do not grind in the area of the
oil separatorimpeller. This is not journal area,and must
remain intact or the oil separatorimpeller will not fit
properly.
REASSEMBLY -If 5H120 or 5H126 oil separaorhas been
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
crankshaft. Position key so chamfered edge is toward ra-
dius of crankshaft journal.
2. Immerse oil separatorimpeller in oil or hot water to heat
it to 180 F or more. [f water is used, remove all traces
before reassembly.Install impeller on cranlshaft with dowel
key tined up with impeller keyway. Impeller must fit key
snugly.
3. Check that seal-end thrust washer is in place on dowel
key in crankcase.
lnsert crankshaft and install pump-end bearing head, con-
necting rod and piston assemblies,valve plate and cylinder
heads.On 5H80 through 126 units, insert center main bear-
ing setscrew and lock screw as described under Servicing
Center Main Bearing. On 5H86, 120 and 126 units, recon-
nect oil line to center main bearing.
JJ
Pump-EndMain Bearing (Fig.a6)
DISASSEMBLY AND INSPECTION - On 5H40 through
86 units, remove pump-endcover. Remove pump-endbear-
ing headon all units. Inspectbearing for tolerancesshown
in-taUte ll. If a pump-end main bearing is worn, remove
bronzebearingwasher,and chisel out bearing.Inspectbear-
ing housing for wear (Table I l) and damage.Remove any
burrs.
REASSEMBLY
l. Lubricate outside of new bearing with heavy grease.
2. Line up hole in bearing with oil port in housing.
3. Pressbearinginto placeusing a puller shoulder(Table 12
and Fig. 47 and 48) and jack screw or bearing press.
4. PIacebearing washer on bearing with notch in washer
properly positionedaround dowel pin (Fig. a6).
PUMP ENO MAIN EEARING
E R O N Z EB E A R I N G
(ORSTEELWASHER
oN 5Hr20ANDt26
MODELS )
D O W E LP I N
P U M PE N D B E A R I N GH O U S I N G
Fig. 46 - Pump-End Main Bearing Position
Table 12 - Main Bearing Puller Sizes
-) NOTE:Bearingpullerscan be orderedthrough
Carrieror TotalineParts.
Center Main Bearing - Size5H80through126com-
pressorshave a center main bearing and housing.
DISASSEMBLYAND INSPECTION-On 5H86, 120and
126 compressors,disconnect oil line to center main bearing.
(5H80 center main bearings are fed through the shaft.)
Remove plug on compressor crankcases(Fig. 44). Then
remove hollow lock screw beneath the plug (Fig. 45). Next,
loosen hollow-cup setscrewuntil center main bearing as-
sembly can be slid from its support. Remove crankshaftand
bearing assembly.
Disassemblebearing (Fig. a5) and inspect for proper tol-
erances(Table ll).
697
 AL HOUSING
HOUSING
PILOT
THRUST
WASHER
- DIRECTION
OF PULL- TOP PLATE
Fig.47 - Seal-EndMain Bearing(SF40,60)
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.Rbtate
granphaf;while tightening setscrewon center main bearing
\ousing. |"F"t"-y should tighten fully without any binding
rf crankshaft- If binding occurs, shim the opposiie
-' side oT
-,aearinghousing,using .001-in.shim stock.
Seal-EndMain Bearing
)ISAS SEMB LY AND INSPECTION - Wirh crankshaftre-
-*noved, use a bearing puller wittr a shouldering.device to
remove and install seal-end main bearings (Fig. 47 and 48).
jearing pullers can be ordered through Canier or Totaline
)arts.
- cleanliness.
Inspect bearing and bearing housing for tolerancesshown
in Table I l.
GASSEMBLY - Remove any burrs and cleanbearinghous-
_ng- before replacing bearing. Lubricate outside of &aring
with heavy grease.
'. Position bearing so chamfered edge
enters bearing hous-
ing first, oil holes in bearing and housing are aligned (see
note below), and bearing relief groove is at top.
NOTE: On size 5 120 and 126 compressorsoil hole in
bearingand housing will not be aligned.
2 . Pull bearingintohousing(Fig.a9).Edgeofbearingshould
be /:z-in. below surfaceof bronze bearing waslier.
Look throughoil pressureregulatoropening to check oil
passagefor blockage.
4. Blow out oil groove in bearinghousing and oil lines (if
any) to it.
SEAL END MAIN BEARING
HOUSINGINSIDE
BROME
WASHERT
OIL GROOVE
SEAL END
MAIN BEARING
DOWELPIN
'Steel
washeron 5H120and '126models.
Fig.49- Seal-End
MainBearingPositioning
CrankshaftSeal Inspectionand Replacement
- Thecrankshaftsealin all current5F,Hcompressorsis a
rotating,bellows-type seal.This sealis the servicereplace-
mentfor all earliersealassemblies. Figure 50 showsTypes
t__"q4Il of this design(5F20through60 and 5HzlOthrough
5H126compressors).
IMPORTANT: Do not attempt to repair or replace seal
components.Replacecompleteseal assembly with cur-
rent rotating-bellows-type assembly. Do not disas-
semble bellows assemblyof service replacement seal.
BEFORE INSTALLING SEAL
l. Pump--endF-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 edgesand nickS.Also, shaft must be clean arrd free
of rust. Polish shaft with crocus cloth.
3. Check seal assembly for proper bellows placement and
4. Apply compressor oil to seal assembly and crankshaft,
completely saturatingbellows and carbon ring.
INSTALLATION - Refer to Fig. 5l for procedure.
Accessories - For accessoryinstallationliterature,re-
fer to Thble 13.
 COVER PLATE WITH COVERPLATEGASKET
INTEGRAL SEAL SEAT_*_._\

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.
Step 3 - Usingthe sealcoverplate,pushthe seal
assemblyinto its properlocationon the shaft.DO
NOTusecoverplateboltsto pushsealintoposition.
The spring'guide,should be'tightagainst.the,shaft
shoulderas shownby the pencil.Removethe cover
plate,beingcarefulnotto damagethecarbonwasher.
GRASPTHE SEALNOSEASSEMBLY ANDTURN
IT UNTILTHELUGSONTHEDRIVINGBANDDROP
BACKINTOTHESLOTSINTHERETAINERSHELL.
NOTE: The seal may leak slightly immediatelyafter installation,but a short period of operation will correct the condition.
Fig. 51 - Installationof Sleeve-Type
RotarySeal
Step2 - Holdingthe sleeveandspringassembly,
pullforward on thesealnoseassembly at the same
time,turningit so thatthe lugson the drivingband
are out of the slots in the remainershell and rest
on the surfaceof the retainershellas shownby the
pencil.ffhis doesnotapplyto the5H120Typell seal.
Lugsare permanently fixed.)
LUG IN CENTER
Step4 - Lubricate thecarbonseal.washer.and seal.
seai.Reinstallthesealcover plate,drawingthebolts
downevenlyto preventdamageto the carbonseal
nose.Thisviewshowsthe lugsof the drivingband
properlypositionedin the centerof the slotsin the
sealretainershell.Thisis thecorrectpositionduring
Thisprevents
operation. thesealfrombeingusedas
a thrustwasherunderall operating conditi-ons.
 TROUBLESHOOTING
TROUBLSSYMPTOM REMEDY
Compressorwill not start Check main switch, fuse and
Resetthermostat.
Resetswitch.
Reset switch.
Clean all control contacts.
Loose electricalconnectionsor Tightenconnections;check wiringand
rewtre.
Check and replace if defective.
Liquidline solenoidvalveclosed. Checkfor burned-outholdinocoil.
Reolaceif defective.
Checkfuses,overload.Restart.
or coolingtower
condenser
Evaporative Checkfuses,overloadsand controls.
Restart.
Compressorcycles switcherraticin
Low-pressure Check for clogged tubing to switch.
intermittently Check switch
Add
Reset.
Thermostatdifferential
too narrow. Reset.
Suctionvalveclosedor throttled. Openup valve.
Compressorcycles on high Tubingto pressurestat
restricted. Checkand clean
pressurestat Repairor
Removeexcess
lnsufficientcondenserwater flow or Adjustwaterregulatingvalveto
Cleancondenser.
condenser.
valve.

Check and start.

High dischargepressure Condenserinletwatertemperature too lncreasewaterquantityby adjusting
high. waterregulating
valve.Use colder
water.
waterflowthroughcondenser.Readjustwaterregulatingvalve.ln-
Insufficient
creasesizeof watersupplymainto
condenser.
Cleantubes.
valve.
Removeexcess ant.
Puroeair.
Low dischargepressure water valve.
Suction seruicevalve padiallvclosed. Openvalve.
Examinevalvediscsand valveseats.
Replaceif worn.
Replace.
Flooding Resetto 5 F - 10 F superheat.Valve
ationmustbe stable(no
Low suction pressure Add re
Resetexpansionvalves.
Systemnoises Check and
clearancebetweenpiston
Insufficient Replacedefectiveparts.

Looseor misaligned
belts. Checkalignmentand tension.(Belt
slack should be at
bolts.
 (cont)
TROUBLESHOOTING

TROUBLSSYMPTOM PROBABLECAUSE REMEDY

System noise (cont) Unit foundationimproperlyisolated.
lmpropersupportor isolationof piping.
Sluggingfrom refrigerantfeedback.
lsolatefoundation.
Usecorrectpipingtechniquesand support
oioinqwith suitablehanoers.
Check expansionvalve setting.Check
thermalbillb loosenessand correct
location.See Carrier System Design
Manual,Part 3 for standardPiPing

Removeexcess oil. Check expansion

Defectivevalve lifter mechanism(noise
levelvarieswith unloading).
Pipingvibration.
No mufflerin dischargeline or
valve for floodback.
Replacestickingfilter pins. Check un-
loaderfork for alignment.Check power
elementfor stickingpiston.Checkfor oil
leakageat tubeconnection to power
element.Checkamountof valvepin lift
abovevalveseat(0.33in. for 5F; 0.125in.
for 5H).
Supportpipesare required.Checkpipe
connections.
lnstallmuffler.Movemufflercloserto

Hissing (insufficientflow through expan- Cleanstrainer.

Add refrigerant.
sion valves,or cloggedliquidline
strainer).
Compressorwill
not unload
controlcoverasse
Pluooedoressurelineto oowerelement. Cleanline.

Compressorwill Checkoil , switch

not load

Pluggedor brokenpressurelineto Cleanor repair.

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.

Cold comPressor Liquid carryoverfrom evaPorator. Check refrigerantcharge and

sion valves.
Low crankcase oil level Oil returncheck valve stuck closed. or replacecheck valve.
Cylindersand crankcase Check refrigerantcharge and
swea
High crankcasetemperature Cleanstrainer.
(shouldbe 150F to 160 F
max.at seal housing)
ion ratio too hiqh.
Checkunit

39