Compressor - North America Transport Air Conditioning
Contents
1. Discard valves and gaskets U se only new valves and gaskets when assembling cylinder head and valve plate assemblies b Reassembly Some 05K compressors for refrigeration use only may have canted valve plates The canted valve design allows a reduction in the distance between the discharge valve and the top of the piston When piston is at TDC the volume of the compression chamber is smaller contributing to increased compressor efficiency 1 Install only new valves and gaskets and do not interchange valves 4 5 6 7 9 Valve Plate Gasket 10 Suction Valve 11 Position Spring 12 Dowel Pin Figure 3 1 Cylinder Head amp Valve Plate 3 1 2 Install suction valve positioning spring on dowel pins Assemble positioning spring springs with spring ends bearing against cylinder deck The spring will bow outward in the middle See Figure 3 2 3 Place suction valve on dowel pins over the positioning spring 4 Place valve plate and new valve plate gasket on cylinder deck ensuring that the valve plate is properly positioned on the four dowel pins 5 Using a small screwdriver operate the suction valvesto ensure that the valve tips are not being held by the valve plate gasket See Figure 3 3 1 Positioning Spring 2 Suction Valve Figure 3 2 Installing Suction Valves Figure 3 3 Checking Suction Valve 6 Install discharge valve and discharge valve stop with c2. a Major Working Parts 1 Solenoid and valve system 2 Spring loaded piston type bypass control valve 3 Spring loaded discharge check valve b Unloaded Operation Pressure from the discharge manifold Figure 1 5 item 15 passesthrough the strainer 9 and bleed orifice 8 to the back of the piston bypass valve 7 U nless bled away this pressure would tend to close the piston 6 against the piston spring 5 pressure With the solenoid valve 1 energized the solenoid valve stem 2 will open the gas bypass port 3 Refrigerant pressure will be bled to the suction manifold 10 through the opened gas bypass port A reduction in pressure on the piston bypass valve will take place because the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice 8 When the pressure behind the piston has been reduced sufficiently the valve spring will force the piston bypass valve back opening the gas bypass from the discharge manifold to the suction manifold Discharge pressure in the discharge manifold will dose the discharge piston check valve assembly 14 isolating the compressor discharge manifold from the individual cylinder bank manifold The unloaded cylinder bank will continue to operate fully unloaded until the solenoid valve control device is de energized and the gas bypass port is closed 1 Solenoid Valve 11 Cylinder Discharge 2 Valve Stem Valve 3 Gas Bypass Port 1
3. 5 3 6 3 6 3 7 3 7 3 7 3 7 3 8 3 9 SECTION 1 DESCRIPTION 11 INTRODUCTION Thisoperation and service manual coversthe Carrier Transicold M odel 05K compressors T hese compressors are designed for refrigeration or air conditioning applications They are compact iron based machinesthat are particularly well suited for use with high pressure refrigerants The 05K compressors offers ball bearing support in the drive end See Figure 1 1 The following table list the special tools for the 05K compressors PART NO SPECIAL TOOLS 07 00219 Wrench Compressor Sight Glass 07 00223 Pliers Compressor Unloader Ring Wrench Spanner 07 00240 01 for Housing Mounted Clutch 07 00241 Rotor Installation Tool for Housing Mounted Clutch Bearing Retaining Nut Socket 3 5 Housing Mounted Clutch 07 00242 01 07 00260 00 Acid Test Kit 07 00265 01 Totaltest Kit Package of 1 07 00266 00 Replacement Tubes for Totaltest Kit Filter Felt Suction Sock for System Clean Up 58 04165 00 1 2 GENERAL DESCRIPTION The M odel 05K compressors are of the open drive reciprocating type A crankshaft connecting rods pistons and reed type valves accomplish vapor compression Compressor wear is minimized by splash lubrication and byforcefeed lubrication There arethree types of oil pumps Vane Gear and Low Profile G ear driven directly from the end of the compressor crankshaft See Figure 1 3 CAUTION The gear oil pump must b
4. Refrigerant Oi R 12 R 22 or R 502 Suniso 3GS Mobil Artic EAL 68 R 134a or R 404A Castrol Icematic SW 68C ICI Emkarate RL68H Revised 10 96 ELECTRIC UNLOADER PRESSURE UNLOADER 4 CYLINDER 3 2 CYLINDER 1 Suction Service Valve 5 Oil Fill Plug 2 Discharge Service Valve 6 Low Pressure Connection 3 Oil Level Sight Glass 7 High Pressure Connection 4 Oil Drain Plug 8 Oil Pump See Figure 1 3 Figure 1 1 Model 05K Compressor 1 2 14 DETAILED DESCRIPTION 1 4 3 LUBRICATION SYSTEM 1 4 1 SUCTION AND DISCHARGE VALVES Thecompressor usesreed type suction and discharge valves made of highest quality steel for long life The valves operate against hardened integral seats in the valve plate The downstroke of the piston admits refrigerant gas through the suction valve and then compresses this gas on the upstroke thereby raising it s temperature and pressure The compressed gas is prevented from re entering the cylinder on it s next downstroke by the compressor discharge valve See Figure 1 2 5 Eo LOR QN LOW PROFILE GEAR PUMP l Position Spring f 2 Suction Valve Figure 1 3 Oil Pumps 3 Valve Plate 4 Discharge Valve CAUTION 5 Discharge Valve Stop The Gear oil pump must be set to rotate in the same direction as the crankshaft Refer to Figure 1 2 Suction amp Discharge Valve section 3 4 There are three types of oil pumps Vane Gear and 1 4 2 SUCTION amp DISCHARGE SERVICE VALV
5. a stiff bristle brush to remove dirt from grooves and crevices b Inspect all parts for wear and overall condition Replace any defective or excessively worn parts c Inspect suction and discharge valve seats on valve plate d If unloaders are installed inspect operation of unloader 3 2 e After cleaning ensure all moving parts are coated with compressor oil before reassembly f U se only new gaskets during reassembly E nsure all gaskets includes cylinder head valve plate and unloader or bypass plug gaskets are installed dry 1 Capscrew 5 Lockwasher 2 Cylinder Head 6 Discharge Valve Stop 3 Cylinder Head Gasket 7 Discharge Valve 4 Capscrew 8 Valve Plate 33 CYLINDER HEAD AND VALVE PLATE a Disassembly WARNING Do not unscrew capscrews all the way before breaking seal E ntrapped pressure could result in injury 1 Loosen cylinder head capscrews If the head is stuck tap it lightly with a wooden or lead mallet to free it Be careful not to drop the head or damage the gasket sealing surface Remove cylinder head capscrews and gasket See Figure 3 1 2 Remove the discharge valve capscrews lock washers stops and valves 3 Free the valve plates from the cylinder deck by using the discharge valve capscrews without washers as jackscrews through the outermost tapped holes in the valve plate after the valve stops and valves have been removed Remove the valve plate gasket 4
6. to 18 1 38 to 2 49 1 4 20 Connecting Rod 6to 10 0 83 to 1 38 Low Profile Oil 1 4 28 Unloader Valve 12 to 16 1 66 to 2 21 Pump Cover 5 16 18 Cover Shaft Seal ae 15 to 21 2 08 to 2 91 Cover Cylinder Head 40 to 55 5 55 to 7 63 Oil Pump 3 8 16 Bearing Head 30 to 40 4 16 to 5 55 Seal End Cover 1 2 13 Mounting Feet 50 to 80 6 93 to 11 1 14 OilLevel Sight 35 10 50 4 84 to 6 91 Glass Table 3 2 Wear Limits MAXIMUM WEAR PART NAME FACTORY MAXIMUM FACTORY MINIMUM BEFORE REPAIR Main Bearing Diameter 1 3760 34 9504 Main Bearing J ournal Diameter 13735 CONNECTING ROD Connecting Rod Diameter 1 3768 349707 0020 0 051 Piston Pin Bearing 0 6883 17 4752 0 6878 17 4701 0 0254 CRANKSHAFT Crankpin Diameter 13735 348869 0025 I 9995 Throw Height 0955 276320 osere smi THRUST WASHER Thickness CYLINDERS and PISTONS Boe 25m 3099 om 99 Piston Dames Seerowers 002 005 Piston Pin Damete 9895 mana Xi 095 0 535 gt 1 988 to 1 994 a 1 9960 to 1 9968 Figure 3 18 Piston Dimension Wear Limits 3 9
7. unloader systems can be controlled with either a pressure actuated valve or an electrically actuated solenoid valve The pressure operated unloaders are controlled by suction pressure and actuated by discharge pressure T he unloader valve controls two cylinders On startup controlled cylinders do not load up until differential between suction and discharge pressure is 10 psi 1 7 kg cm During loaded operation when suction pressure is above the valve control point the poppet valve will close Discharge gas bleeds into the valve chamber the pressure closes the bypass piston and the cylinder bank loads up Discharge gas pressure forces the check valve open permitting gas to enter the discharge manifold See Figure 1 9 SUCTION PRESSURE DISCHARGE PRESSURE 1 Sealing Cap 2 Pressure Differential Adjustment Screw 3 Control Set Point Adjustment Nut 4 Poppet Valve Figure 1 9 Pressure O perated U nloader Loaded Operation During unloaded operation when suction pressure drops below the valve control point the poppet valve will open Discharge gas bleedsfrom behind the bypass piston to the suction manifold The bypass piston opens discharge gas is recirculated back to the suction manifold and the cylinder bank is unloaded Reduction in discharge pressure causes the check valve to close isolating the cylinder bank from the discharge manifold See Figure 1 10 SUCTION PRESSURE DISCHARGE PRESSURE Sealing
8. 2 Valve Plate 4 Spring Guide 13 Cylinder Suction 5 Spring Valve 6 Piston 14 Discharge Piston 7 Piston Bypass Valve Check Valve 8 Bleed Orifice Assembly 9 Strainer 15 Discharge Manifold 10 Suction Manifold Figure 1 5 Compressor Cylinder Head Unloaded Hot Gas Bypass c Loaded Operation Discharge pressure bleeds from the discharge manifold Figure 1 6 item 15 through the strainer 9 and 8 bleed orifice to the solenoid valve stem 2 chamber and the back of the piston bypass valve 7 With the solenoid valve 1 de energized the solenoid valve stem will closethe gas bypass port 3 Refrigerant pressure will overcome the bypass valve spring 5 tension and force the piston 6 forward closing the gas bypassfrom the discharge manifold to the suction manifold 10 Cylinder discharge pressure will force open the discharge piston check valve assembly 14 Refrigerant gas will pass into the compressor discharge manifold The loaded cylinder bank will continue to operate fully loaded until the solenoid valve control device is energized and the gas bypass port is opened 1 4 1 Solenoid Valve 11 Cylinder Discharge 2 Valve Stem Valve 3 Gas Bypass Port 12 Valve Plate 4 Spring Guide 13 Cylinder Suction 5 Spring Valve 6 Piston 14 Discharge Piston 7 Piston Bypass Valve Check Valve 8 Bleed Orifice Assembly 9 Strainer 15 Discharge Manifold 10 Suction Manifold Figure 1 6 Compressor
9. 2 Installing Compressor ccc eect eee eee Hn 2 2 3 COMPRESSOR MAINTENANCE sseennnnn nn 3 1 ZL Introduction zes e tuae dre re xe aes Reihe p dee 3 1 3 2 Inspection and Preparation for Reassembly 0 31 33 Cylinder Head and Valve Plate 0 1 anaana 3 1 34 OilPumpandBearingHead ct eee nn 3 2 341 Low Profile Gear Pump cece cece eee mmn 3 2 34 2 Gear PUMP sho vik ae eee edit cue t e tta ea ek 3 3 3 4 3 Mane Pump sei cones arans meat ae RNA ac tec EO ek 3 4 3 0 Shaft Seal shiners a tide hash Staak ena re Lathe Mera RD tanh tari s ge ae hake ta 3 5 3 6 Compressor Running Gear Removal sussa 3 6 37 Compressor Running Gear Reassembly 0 eee eee eens 3 7 3 8 lt SUCHON Stralnier c rennen e he i e c ace ea 3 8 3 9 Adding Oes beta ct dada ee de 3 8 3 10 Installing Compressor iiare nmasi mne uaran III nn 3 8 Figure 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 2 1 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 3 17 3 18 Table 3 1 3 2 LIST OF ILLUSTRATIONS Model 05K Compressor sssssssssss see Suction amp Discharge Valve usuau OME PUD era en ee ee he s Eee ax wees NI Compressor U nloader Hot Gas Bypass cee eee eee eee Compressor Cylinder Head Unloaded Hot Gas Bypass Compressor Cylinder Head Loaded Hot Gas Bypass Compressor Cylin
10. Cap Pressure Differential Adjustment Screw Control Set Point Adjustment Nut Poppet Valve 1 2 3 4 Figure 1 10 Pressure O perated Unloaded Unloaded Operation 1 6 HCFC 22 1750 RPM 20 DEG F Superheat 0 DEG F Subcooling SAT DISCHARGE TEMPERATURE DEG F SAT DISCHARGE TEMPERATURE DEG F 160 140 120 05K 24 4 Cylinders SAFE fig OPERATING RANGE 804 T I T T 60 40 20 0 20 40 SAT SUCTION TEMPERATURE DEG F 60 160 140 120 05K 12 2 Cylinders SAFE i OPERATING RANGE 804 T T T T 60 40 20 0 20 40 SAT SUCTION TEMPERATURE DEG F Note Actual operating envelope is determined by discharge Maximum gas temperature is 300 F measured in the cy 1 7 1 8 i 60 as temperature nder head SECTION 2 COMPRESSOR REPLACEMENT 2 1 COMPRESSOR REMOVAL Refer to the operation and service manual covering the equipment in which the compressor is installed for specific removal instructions A general removal procedure is given below a If compressor is completely inoperative frontseat the suction and discharge service valvesto trap therefrigerantinthe unit If the compressor will operate pump down the unit then frontseat the suction and discharge service valves b Ensure power source is removed from any controls installed on the compressor c Removerefrigerant usinga refrigerant recovery system d Disconnect refrigerant lin
11. Compressor MODEL 05K LLI OF eg UU du ne OZ O lt TRANSICOLD 0 OPERATION AND SERVICE MANUAL MODEL 05K COMPRESSOR NUM TECHNOLOGIES i icold Divisi i i ae CARRIER Carrier Transicold Division Carrier Corporation P O Box 4805 Syracuse N Y 13221 U S A TRANSICOLD Carrier Transicold E T O Boite Postale Nr 16 Franqueville Saint Pierre 76520 Boos FRANCE Carrier Corporation 1995 D Printed in U S A 0795 TABLE OF CONTENTS Section Page 1 DESCRIPTION is ne ee nee einen 1 1 1 1 Introduction aei edere dank Ree a as there eet nex ant uaa lang 1 1 1 2 General Description su er CREE C Be er CR Ua Sec CR 1 1 13 Compressor Reference Data 2 2 zzz szvsz eet nn 1 1 14 Detailed Description 0 ccc cece cece RII rr 1 3 1 4 1 Suction and Discharge Valves ccc cece eect een nennen 1 3 14 2 Suction amp Discharge Service Valves 0 cece eects 1 3 1 43 Lubrication System er en EROR ke ek 1 3 1 5 Compressor Unloader 2 2 Meier tee Er pn 1 3 15 1 HotGasBypassUnloader ssesssssseeeeeee en 1 4 15 2 Suction Cutoff Unloader cceeeeeeeeeeeeeeeeee nn 1 5 15 3 Pressure Operated Unloaders s sss 1 6 2 COMPRESSOR REPLACEMENT eeeenenennn n n nmn 2 1 21 CompressorRemoval ccc cece ccc hs 2 1 2 2 Compressor Replacement 0 ccc eee e nnn 2 1 2 2 1 Installing Compressor Unloaders 0 ccc cece eect e teen eens 2 1 2 2
12. Cylinder Head Loaded Hot Gas Bypass 15 2 SUCTION CUTOFF UNLOADER The compressor is equipped with unloaders for capacity control Thisconsists of a self contained suction cut off arrangement which iselectronically controlled by the temperature controller The capacity controlled cylinders are easily identified by the solenoid which extends from the side of the cylinder head When the solenoid energizes cylinders unload preventing suction gas from being drawn into the cylinder See Figure 1 7 The unloaded cylinders operate with little or no pressure differential consuming very little power A de energized solenoid reloads the cylinders as shown in Figure 1 8 a Major Working Parts 1 Solenoid and valve system 2 Unloader piston assembly 3 Spring and cover plate b Unloaded Operation When the unloader valve solenoid energizes the capacity control valve port opens item 3 Figure 1 7 Thisallowsthe discharge gas behind the unloader piston assembly item 4 to vent back to the suction side The unloader valve spring item 7 atthis point can movethe unloader valve body to the left blocking the unloader suction port The cylinder bank is now isolated from the compressor suction manifold to unload these two cylinders N o refrigerant isallowed into the cylindersand no compression takes place 1 5 SUCTION PRESSURE DISCHARGE PRESSURE 1 Solenoid Valve 9 Suction Manifold 2 Coil 10 Suction Valve 3 Capa
13. ES Low Profile Gear driven directly from the end of the The suction and discharge service valves used on the compressor crankshaft See Figure 1 3 Force feed compressor are equipped with mating flanges for lubrication of the compressor is accomplished by a oil connection to flanges on the compressor These valves pump driven directly from the compressor crankshaft are provided with a double seat and a gauge connection Refrigeration oil isdrawn fromthe compressor crankcase which allows servicing of the compressor and refrigerant through the oil filter screen and pick up tube to the oil lines See Figure 1 1 pump located in the bearing head assembly The crankshaft is drilled to enable the pump to supply oil to Turning the valve stem counterclockwise all the way the main bearings connecting rod bearings and the shaft out will backseat the valve to open the suction or seal discharge line to the compressor and close off the gauge 15 COMPRESSOR UNLOADER connection In normal operation the valve is backseated to allow full flow through the valve The valve should The 4 cylinder 05K compressor can be applied with 1 manifold gauge lines to the gauge ports available with unloading Turningthe valve stem clockwise all the wayforward will frontseatthe valveto close off the suction or discharge line to isolate the compressor and open the gauge connection To measure suction or discharge pressure midseat cover plate Suction cutoff There
14. a cylinder in the bearing head flat end in then insert the plunger spring and spring guide Insert retaining ring with ring pliers Force the spring guide down to compress the plunger spring and to allow the retaining ring to fit into itslocking groove Follow the same procedure to reassemble the other plunger spring guide and snap ring in its plunger cylinder 1 Oil Pump Cover 9 Retaining Ring 2 Cover Gasket 10 Spring Guide 3 Capscrews and 11 Bearing Head Lockwashers 12 Pump Rotor 4 Oil Pump Drive 13 Oil Feed Guide 5 Rotor Retaining Ring 14 Retainer Spring 6 Pump Vane Cylinder 15 Capscrews and 7 Pump Vane Washers 8 Vane Spring 16 Oil Inlet Passage Figure 3 7 Vane Oil Pump c Reassembly 1 Install the bearing head assembly with a new gasket on the compressor crankshaft Carefully push oil pump on by hand ensuring that the bearing head mounts flush to the crankcase body The top of the bearing head is marked on the mounting flange 2 Align the gasket and install the eight capscrews in the mounting flange R efer to Table 3 1 for applicable torque values 3 Install the drive segment with the two capscrews and lock washer 4 Insertthe oil feed guide with the large diameter in Insertthe guide retaining spring so that it fits over the smaller diameter of the feed guide The pump cover can now be installed 5 Place the pump cover with a new gasket over the guide retaining spring and compress th
15. apscrews and lock washers 7 Install cylinder head and new cylinder head gasket with capscrews ensuring that the gasket and cylinder head are properly positioned on the valve plate Torque the capscrews in a diagonal pattern to a value shown in Table 3 1 34 OIL PUMP AND BEARING HEAD There are three types of oil pumps Vane G ear and Low Profile Gear driven directly from the end of the compressor crankshaft 3 2 3 4 1 LOW PROFILE GEAR PUMP a Removal Remove eight capscrews and remove oil pump bearing head assembly gasket and thrust washer See Figure 3 4 Set screw must be removed for Low Profile Gear Pump 1 OilPump amp Bearing Head 2 Thrust Washer Not used on Vane Pump 3 OilPickup Tube 4 Oil Inlet Port Figure 3 4 Oil Pump and Bearing H ead Assembly b Disassembly amp Inspection If it was determined that the oil pump was not operating properly the entire oil pump and bearing head assembly must be replaced Replacement parts for the pump are not available H owever in the event the pump requires inspection or cleaning disassembly and reassembly by referring to Figure 3 5 Clean all parts coat all moving parts with compressor oil before proceeding with reassembly Capscrews 7 O Ring Cover 8 Oil Pump amp Bearing Reversing Assembly 9 Set Screw 1 2 3 4 5 6 Pinion 10 Relief Valve Gear 11 Pin Drive Figure 3 5 Low Profile Gear Oil Pump c Reassembly 1 Set s
16. aretwo types of compressor unloader systems the first one is the hot gas bypass and the second is the suction cutoff They are easily distinguished from each other by observing the bottom side of the compressor cylinder head itis either blank H ot gas bypass or hasa the valve by opening the valve clockwise about 2 turns The two types of compressor unloader systems can With the valve stem midway between frontseated and be controlled with either a pressure actuated valve or an backseated positions the suction or discharge line is electrically actuated solenoid valve open to both the compressor and the gauge connection 1 3 15 1 HOT GAS BYPASS UNLOADER The compressor is equipped with an unloader for capacity control This consists of a self contained cylinder head bypass arrangement See Figure 1 4 which is electronically controlled by the temperature controller The capacity controlled cylinder is easily identified by the solenoid which extends from the side of the cylinder head When the solenoid energizes the cylinder unloads allowing discharge gasto circulate asshown in Figure 1 5 The unloaded cylinder operates with little or no pressure differential consuming very little power A de energized solenoid reloads the cylinder as shown in Figure 1 6 Discharge Check Valve Discharge Manifold Solenoid Valve Piston Bypass Control Valve Cylinder Head Suction Manifold Figure 1 4 Compressor Unloader Hot Gas Bypass
17. c in direction indicated CW or CCW as so desired so oil pump rotates in the same direction asthe crankshaft T he stampingin the eccentric next to the pin showsthe direction the pump will rotate as viewed from the crankshaft end of the compressor 10 Install the pin in the shortest of the two grooves inside the bearing head 11 Install the O ring and pump cover 12 Install the relief valve assembly c Reassembly 1 Install the pump end thrust washer on the two dowel pinslocated on the bearing head See Figure 3 4 CAUTION Ensurethat thrust washer does not fall off dowel pins while installing oil pump 2 Install the bearing head assembly with a new gasket on the compressor crankshaft Carefully push oil pump on by hand ensuring that the thrust washer remains on the dowel pins the tang on the end of the drive segment engages the slot in the crankshaft and the oil inlet port on the pump is aligned with the oil pickup tube in the crankcase The pump should mount flush with the crankcase and should be oriented as shown in Figure 1 1 3 Align the gasket and install the eight capscrews inthe mounting flange R efer to Table 3 1 for applicable torque values 3 4 3 VANE PUMP a Removal 1 Remove four capscrews gaskets and remove oil pump cover this will free the oil feed guide retaining spring cover gasket and the oil feed guide See Figure 3 7 2 Remove the two drive segment capscrews and lock washer and re
18. city Control 11 Piston Valve Open 12 Discharge Valve 4 Unloader Piston 13 Discharge Manifold 5 Unloader Head 14 Valve Plate 6 Valve Body 15 Strainer 7 Valve Spring 16 Bleed Orifice 8 Cover Plate Figure 1 7 Compressor Cylinder Head Unloaded Suction C utoff c Loaded Operation When the unloader valve solenoid de energizes the capacity control valve port closes item 3 Figure 1 8 This allows discharge pressure to build up behind the unloader piston assembly The high pressure will compress the unloader valve spring opening the unloader suction port Suction gas can now be drawn into the cylinders running the bank fully loaded 1 16 15 14 13 12 11 10 9 SUCTION PRESSURE DISCHARGE PRESSURE 1 Solenoid Valve 9 Suction Manifold 2 Coil 10 Suction Valve 3 Capacity Control 11 Piston Valve Closed 12 Discharge Valve 4 Unloader Piston 13 Discharge Manifold 5 Unloader Head 14 Valve Plate 6 Valve Body 15 Strainer 7 Valve Spring 16 Bleed Orifice 8 Cover Plate Figure 1 8 Compressor Cylinder Head Loaded Suction Cutoff 1 5 3 Pressure O perated Unloaders There are two types of compressor unloader systems the first one is the hot gas bypass and the second is the suction cutoff They are easily distinguished from each other by observing the bottom side of the compressor cylinder head it is either blank H ot gas bypass or hasa cover plate Suction cutoff The two types of compressor
19. crew on crankshaft must be removed for Low Profile Gear Pump CAUTION Set screw on crankshaft must be removed for Low Profile Gear Pump See Figure 3 4 2 Install the pump end thrust washer on the two dowel pinslocated on the bearing head See Figure 3 4 CAUTION Ensurethat thrust washer does not fall off dowel pins while installing oil pump 3 Install the bearing head assembly with a new gasket on the compressor crankshaft Carefully push oil pump on byhand ensuring that the thrust washer remains on the dowel pins the tang on the end of the drive engagesthe slot in the crankshaft and the oil inlet porton the pump is aligned with the oil pickup tube in the crankcase The pump should mount flush with the crankcase and should be oriented as shown in Figure 1 1 4 Align the gasket and install the eight capscrews in the mounting flange R efer to Table 3 1 for applicable torque values 3 4 2 GEAR PUMP a Removal Remove eight capscrews and remove oil pump bearing head assembly gasket and thrust washer See Figure 3 4 b Disassembly amp Inspection If it was determined that the oil pump was not operating properly the entire oil pump and bearing head assembly must be replaced Replacement parts for the pump are not available H owever in the event the pump requires inspection or cleaning disassembly and reassembly instructions are provided below 1 Remove pump and O ring See Figure 3 6 2 Note di
20. der Head Unloaded Suction Cutoff Compressor Cylinder Head Loaded Suction Cutoff Pressure O perated U nloader Loaded Operation Pressure O perated U nloaded U nloaded Operation Removal of Piston PIUQ cece ccc eee Hmm Cylinder Head amp Valve Plate sssssssssse n Installing Suction Valves issssssssss Hn Checking Suction Valve 0 kc cc cece nn Oil Pump and Bearing Head Assembly 00 cece eee eee Low Profile Gear Oil Pump ssssssse mn Gear QI PUMP Ataia pex nhe Bebe ob IR AU eee s Varie Oil PUMPS 2 ee aed etel eee eet oe nk Clutch Bus amp Ratl 3 252 nen Ba aet dre a Shaft Seal 52 02 09 Be ai Dinar Bun Skea Aa ERIS Shaft Seal Removal tat inaa emel hat r t ee nnn Seal End Cover Removal 0 cece ete n Piston Rings Removed ccc e cece eect hn Connecting Rod Piston and Pin cece cece nn Contoured PIS N ze eh date re etree Lee debe REY Piston RUN GS ia i ee Ba ater balk ae hy haya UAR IN etel Wala adh Seki la Installing Pistons Er al Meta a us esto Qo Riedl e Installing Suction Strainer sss n Piston Dimension Wear Limits ssese RR LIST OF TABLES Compressor Torque Values 0 0 cece cece eee nnn Wear Limits anstehen eil E eh ale 1 2 1 3 1 3 1 4 1 4 1 5 1 5 1 6 1 6 1 6 2 1 3 1 3 2 3 2 3 2 3 2 3 3 3 4 3 5 3 5 3
21. e set to rotate in the same direction as the crankshaft Refer to section 3 4 The tapered end of the crankshaft which extends outside the crankcase is adaptable to a variety of direct drive or belt driven clutch mechanisms A mechanical seal preventsrefrigerant leakage wherethe rotating shaft passes through the crankcase The compressor is equipped with flanges for connecting suction and discharge service valves Connections are also provided for pressure gauges and safety cutout switches A sight glass in the crankcase provides a meansfor checking oil level in the compressor crankcase A drain plug facilitates draining of oil from the crankcase and an oil fill plug enables addition of oil when necessary 1 1 WARNING Do not operate compressor unless suction and discharge service valves are open Capacity of the Model O5K compressor is determined by piston displacement and clearance suction and discharge valve size compressor speed suction and discharge pressure type of refrigerant and unloader valves 13 COMPRESSOR REFERENCE DATA Model 05K1 1024 O5K 012 m NoCymdes 4 f 2 0 mm 1 937 in 1 937 in Weight 38 kg 84 Ibs Oil Charge 1 9 L 4 0 pts SPEED RPM FOR OIL PUMP Vane 50010 2200 Low Profile 500 to 2200 500 to 2200 Stroke NOTE The oils are suitable for use with compressors using R 12 R 22 R 500 or R 502 and with evaporator temperatures above 40 F 40 C Approved Oil
22. e spring to enable installation of the cover capscrews 3 5 SHAFT SEAL a Disassembly 1 ForBus amp Rail application remove clutch hub and adapter See Figure 3 8 3 1 2 u 8 E rame E at Adapter Capscrew Hex Head Hub Clutch Mounting Clutch Assembly Figure 3 8 Clutch Bus Rail 1 2 3 4 2 Remove capscrews and remove shaft seal cover and carbon washer See Figure 3 9 3 Tap seal end of crankshaft to loosen seal grip on shaft U singtwo long screwdrivers pry out the shaft seal See Figure 3 10 l ShaftSeal 4 SealPlate 2 Carbon Ring 5 HexHead Screw 3 Gasket Figure 3 9 Shaft Seal 3 5 Figure 3 10 Shaft Seal Removal b Reassembly 1 Install new shaft seal assembly cover gasket and cover plate only Never install a used seal assembly or gasket A new carbon washer should never be installed in a used cover plate W hen installing the seal assembly use care not to damage carbon washer or seal seat 2 Remove new carbon washer from new seal assembly Lubricate shaft and neoprene seal bellows where it contactsthe shaft Slide seal assembly onto shaft until neoprene bellows start to grip the shaft 3 Install the OLD carbon washer in the new seal seat Install two capscrews in opposite sides of the old cover plate Draw up capscrews evenly to properly position new seal assembly against shoulder on shaft Remove capscrews and old ca
23. es at service valve flange connections on the compressor retain hardware e Remove any components necessary to gain access to the compressor or to enable removal f Disconnect the drive mechanism at the compressor g Remove mounting hardware and remove compressor from unit h If compressor isto be repaired refer to section 3 for repair procedures if a replacement compressor isto be installed refer to section 2 2 for replacement procedures 2 2 COMPRESSOR REPLACEMENT Consult the unit service parts list for the correct replacement Service replacement compressors are furnished without suction and discharge service valves and unloader valves T he service valvesare normally retained on the unit to isolate the refrigerant lines during compressor replacement B lank off pads are installed on the service replacement compressor valve flanges T hese pads must be removed prior to installing the compressor If the defective compressor isto be returned for overhaul or repair install the pads on the compressor for sealing purposes during shipment Service replacement compressors are normally furnished with cylinder head bypasspiston plugsinstalled on the unloader flanges in lieu of the unloader valves The unloaders if used must be removed from the defective compressor and transferred to the replacement compressor prior to installation Refer to section 2 2 1 If the defective compressor is to be returned for overhaul or repai
24. ession ringischamfered on theinside circumference This ring is installed with the chamfer towardsthe top Stagger the ring end gaps so they are not aligned 4 Measure side clearance between ring and ring groove in piston M aximum dimensions are provided in Table 3 2 b Crankshaft l A brasspump end thrust washer is positioned on two dowel pins located on the bearing head and is installed with the oil pump and bearing head assembly The thrust washer should be inspected for wear and scoring before reassembly Refer to Table 3 2 2 Ensurepiston rodsare pushed out of the way and install the crankshaft CAUTION Do not allow crankshaft to drop on connecting rods inside the crankcase when installing the crankshaft c Seal End Cover Strainer and Connecting Rod Caps 1 Do not tap piston with hammer if rings are caught at entrance to the cylinder Using a ring compressor squeeze rings sufficiently to allow piston to be pushed down into the cylinder Ensure that ring ends are staggered so that the gaps are not aligned and lightly tap piston down into the cylinder See Figure 3 16 The ring compressor can be easily fabricated from a piece of sheet metal Figure 3 16 Installing Pistons 2 Install connecting rod caps on connecting rods using new capscrews special and flat washers R euse of the old capscrews is not recommended E nsure that the capsare installed on the dowel pins Torque capscrewsto torque value show
25. l and reassembly pistons pins and connectingrodsin matched sets 2 Qr 6 5 4 3 1 Connecting Rod 4 Piston Pin 2 Connecting Rod Cap 5 Lock Ring 3 Capscrew 6 Piston Figure 3 13 Connecting Rod Piston and Pin 37 COMPRESSOR RUNNING GEAR REASSEMBLY a Pistons Rods and Rings Prior to installing new piston rings it is necessary to break the hard glazed surface of the cylinder in order to reduce the wearing in period of the new rings Break the glaze by honinglightlyin an up and down rotating motion Clean thoroughly after breaking glaze Some 05K compressors for refrigeration use only may have contoured pistons See Figure 3 14 When installing contoured pistons into compressor check suction valve and contoured piston are in the same orientation Figure 3 14 Contoured Piston 1 Thegap between the endsof the piston ringscan be checked with a feeler gauge by insertingthe ring into the piston bore about one inch below the top of the bore Align the ring in the bore by pushing it slightly with a piston The maximum and minimum allowable ring gaps are shown in Table 3 2 2 Install the piston and rod assemblies up through the crankcase and into the cylinders Allow pistons to extend beyond the top of the cylinder to enable installation of piston rings Pistons must be installed so that the chamfer on the connecting rod faces toward the crankshaft journals 3 7 SI SI Figure 3 15 Piston Rings 3 Thecompr
26. move the drive segment 3 Remove eight capscrews and remove oil pump bearing head assembly and gasket See Figure 3 4 b Disassembly amp Inspection If it was determined that the oil pump was not operating properly it is recommended that the entire oil pump and bearing head assembly be replaced to ensure trouble free operation H owever if the cause of oil pump failure can be determined in the field and replacement parts for the pump are available the pump can be repaired The pump end bearing is integral with the bearing head and is not replaceable 1 Remove the plunger snap ring with snap ring pliers As each snap ring is removed the spring guide plunger spring and plunger may be removed from the cylinder in the bearing head Identify parts to ensure replacement in same cylinder 2 Pushthe pump rotor out of the bearing head by forcing against the rotor Apply force from the bearing side and remove rotor from the opposite side The pump rotor retaining ring will come out with the rotor 3 Clean all parts coat all moving parts with compressor oil before proceeding with reassembly 4 nsertthepump rotor into the bearing head from the side opposite the bearing with the rotor retaining ring in place on the rotor Install the rotor retaining ring with the chamfered edge in Compress the retaining ring close gap in order to fit the rotor and ring into their proper positions 3 4 5 Insert one of the plungers into
27. n in Table 3 1 Ensure freedom of movement of crankshaft after capscrews are torqued on each rod cap 3 Check operation and reinstall check valves and relief valve See Figure 3 11 The check valves are free floating devices and can easily be checked visually The relief valve is a spring loaded device which can be checked by using a small piece of stiff wireto ensure that the spring mechanism can be depressed 4 Clean and reinstall the oil strainer 5 Using a new gasket install the seal end cover Torque cover capscrews in a diagonal pattern to the torque value shown in Table 3 1 6 Reassembly the cylinder head oil pump and shaft seal Refer to sections 3 3 3 4 and 3 5 3 8 SUCTION STRAINER Remove and clean the suction strainer See Figure 3 17 Check it for damage If it is damaged replace suction strainer Install suction strainer and suction service valve using a new gasket Figure 3 17 Installing Suction Strainer 3 9 ADDING OIL Add the proper oil charge to the compressor through the oil fill plug Refer to section 1 3 for the required oil charge 3 10 INSTALLING COM PRESSOR Refer to section 2 2 2 and the unit service manual to install the compressor A Ilow compressor to run for 4to 5 hours before checking new shaft seal assembly for leaks 3 8 Table 3 1 Compressor Torque Values TORQUE RANGE BOLT abpLICATION DE RANGE EH O Ring Plugs 8t025 1 11 to 3 47 Oil Return Check Valve 10
28. r install the plugson the compressor for sealing purposes during shipment 2 2 1 INSTALLING COMPRESSOR UNLOADERS a Remove the three socket head capscrews holding piston plug to cylinder head of the replacement compressor See Figure 2 1 goce up RR c gt 3a el 4 S HOT GAS BYPASS SUCTION CUTOFF Capscrews Flange Cover Gasket Spring Bypass Piston Plug Seat Ring Strainer Sleeve Plug Figure 2 1 Removal of Piston Plug CO EJ OY UT whe b Remove flange cover gasket spring bypass piston plug and seat ring A tapped hole is provided in piston plug for use with a jackscrew to enable removal of the plug One of the socket head capscrews may be used as a jackscrew c Remove the three socket head capscrews holding unloader in the cylinder head of the defective compressor remove the unloader and retain the capscrews NOTE Capscrews removed from the bypass piston plug flange cover are not interchangeable with capacity control unloader valve capscrews When installingthe unloaders be sureto usethe unloader capscrews d Usinga new gasket install the unloaders in the cylinder heads of the replacement compressor R efer to Table 3 1 for required torque values e Ifthe defective compressor is to be returned for overhaul or repair install the bypass piston plug spring seat ring and flange cover onto the cylinder heads 2 1 2 2 2 INSTALLING COMPRESSOR WARNING M idseat service valves or b
29. rbon washer and cover plate 4 Lubricatenew carbon washer and carbon washer seal seat with refrigerant oil Install new carbon washer in Seal seat taking care not to damage the carbon washer or the seat Ensure that notches in carbon washer are aligned with two small knurls inside the seal seat Install the new cover plate and gasket Draw capscrews down evenly to prevent damage to carbon washer NOTE Do nottouch carbon washer sealing surface with your fingers 5 For Bus amp Rail application install clutch hub and adapter See Figure 3 8 3 6 COMPRESSOR RUNNING GEAR REMOVAL 2 CYLINDER SHOWN Capscrew Oil Pressure Relief Valve Check Valves Bearing TIN IE O Ring Connecting Rod and Cap Oil Strainer END Figure 3 11 Seal End Cover Removal In order to disassemble Piston Rod and R ings first the cylinder head oil pump and shaft seal must be disassembled Refer to sections 3 3 3 4 and 3 5 a Seal End Cover Strainer and Connecting Rod Caps 1 Remove the seal end cover See Figure 3 11 Scrape off gasket 2 Remove the oil strainer 3 Match mark each connecting rod cap and connecting rod for correct reassembly Remove the capscrews flat washers and connecting rod caps It is recommended that the capscrews and flat washers be discarded and new capscrews special and flat washers be installed during compressor reassembly See Figure 3 11 4 Push the pi
30. rection of pump by location of pin in eccentric The stamping in the eccentric next to the pin shows the direction the pump will rotate as viewed from the crankshaft end of the compressor 3 If direction of oil pump is not the same rotation as the crankshaft remove pin Pin can be removed by holding eccentric in tipping top of pin slightly outward and turning pump bottom side up pin should fall out or use magnet to remove pin 4 The remainder of the pump components can now be removed if so desired by pushing out the drive segment from the crankshaft end of the bearing head 5 Remove the relief valve assembly by removing the retainer pin 6 Clean all parts coat all moving parts with compressor oil before proceeding with reassembly M ark outside of pump at the short groove for ease of installing pin at a later time cover 3 3 ROTATION ARROW N 10 ROTATION ARROW wh Clockwise T Counterclockwise l OilPump amp Bearing 6 Eccentric Head 7 PIn 2 Relief Valve 8 O Ring 3 Drive Segment 9 Cover 4 Five Lobed Rotor 10 Vent Hole 5 Four Lobed Rotor Figure 3 6 Gear Oil Pump 7 Insert drive segment and five lobed rotor ensuring that the pins on the rotor are inserted into the appropriate holes in the drive segment drive wheel 8 Install the four lobed rotor inside the five lobed rotor ensuring that the end with the counter bore is installed toward the drive segment 9 Install the eccentri
31. ston rods down so that the piston rings extend below the cylinders Remove and discard piston rings U se only new rings when reassembling the compressor See Figure 3 12 Figure 3 12 Piston Rings Removed 3 6 b Crankshaft CAUTION Do not allow crankshaft to drop on connecting rods inside the crankcase when removing the crankshaft 1 Push piston rod assemblies out of the way and remove crankshaft 2 Removeand check operation of oil return check valves See Figure 3 11 The check valves are free floating devices and can easily be checked visually 3 Remove and check oil pressure relief valve See Figure 3 11 The oil pressure relief valve is a spring loaded device which can be checked by usinga small piece of stiff wire to ensure that the spring can be depressed 4 Remove piston rod assemblies c Pistons Rods and Rings 1 Piston and pin and connecting rod and rod cap are matched sets and must not be interchanged That is if either the piston or piston pin isto be replaced you must replace both of them Likewise if a connectingrod or rod cap must be replaced both must be replaced 2 Match mark and disassembly pistons pins connecting rods and caps See Figure 3 13 3 Check wear dimensions of disassembled partsto determine if they are worn beyond limits given in Table 3 2 4 If parts are worn beyond limits replace them in matched sets as specified above 5 Coat piston pins with compressor oi
32. y other means relieve pressure in replacement compressor before removing plugs CAUTION The gear oil pump must be set to rotate in the same direction as the crankshaft Refer to Section 3 4 a Install the compressor by reversing the procedure of section 2 1 Install new locknuts on compressor mounting bolts and new gaskets on suction and discharge service valves 2 2 b Check oil level sight glass Oil level should be between 1 8 and 1 2 of sight glass If necessary add or remove oil C Leak test evacuate and dehydrate the compressor d Fully backseat suction and discharge service valves e Run the compressor and check for leaks and noncondensibles in the refrigerant system f Check refrigerant level g Recheck compressor oil level h Check operation of compressor unloaders if installed SECTION 3 COMPRESSOR MAINTENANCE 3 1 INTRODUCTION Prior to disassembly ofthe compressor oil must first be drained from the crankcase Place the compressor in a position where it will be convenient to drain the oil Remove the oil fill plugto vent the crankcase L oosen the drain plug and allow the oil to drain out slowly If dismantled parts are to be left overnight or longer dip them in clean compressor oil to prevent rusting and store in protected area Refer to Table 3 1 for torque values for tightening bolts INSPECTION AND PREPARATION FOR REASSEM BLY a Clean all parts with an approved solvent Use
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