Compressor - TransArctic
Contents
1. 1 Solenoid Valve 9 Suction Manifold 2 Coil 10 Suction Valve 3 Capacity Control 11 Piston Valve Open 12 Discharge Valve 4 Unloader Piston 13 Discharge Manifold 5 Cylinder 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 Cutoff 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 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 OPERATED 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 Hot gas bypass or hasa cover pl2. After cleaning ensure all moving parts are coated with compressor oil before reassembly f Use only new gaskets during reassembly Ensure all gaskets includes cylinder head valve plate and unloader or bypass plug gaskets are installed dry 3 3 CYLINDER HEAD AND VALVE PLATE a Disassembly WARNING Do not unscrew capscrews all the way before breaking seal Entrapped 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 Discard valves and gaskets Use only new valves and gaskets when assembling cylinder head and valve plate assemblies b Reassembly Some 05G 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 Ins
3. Manifold Figure 1 4 Compressor Unloader Hot Gas Bypass 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 passes through the strainer 9 and bleed orifice 8 to the back of the piston bypass valve 7 Unless 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 close 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 Va
4. fingers 3 6 COMPRESSOR RUNNING GEAR REMOVAL In order to disassemble Piston Rod and Rings first the cylinder head oil pump and shaft seal must be disassembled Refer to sections 3 3 3 4 and 3 5 a Bottom Plate Strainer and Connecting Rod Caps 1 Turn the compressor over bottom side up and remove the bottom plate See Figure 3 10 Scrape off gasket 2 Remove the oil strainer 1 Bottom Plate 2 Oil Strainer Figure 3 10 Bottom Plate Removal 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 piston rods down so that the piston rings extend below the cylinders Remove and discard piston rings Use only new rings when reassembling the compressor See Figure 3 12 1 Oil Pressure Relief Valve 2 Connecting Rod and Cap 3 Capscrew 4 Check Valves Figure 3 11 Bottom Plate and Oil Strainer Removed Figure 3 12 Piston Rings Removed b Crankshaft and Seal End Thrust Washer 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 and seal end thrust washer 2 Remove and check operation of oil return chec
5. release of excessive pressure that has built up in the crankcase to the suction manifold this ensures that the oil loss is kept to a minimum 1 5 COMPRESSOR UNLOADER The 6 cylinder 05G compressor can be applied with 2 bank of unloading 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 Hot gas bypass or hasa cover plate Suction cutoff The two types of compressor unloader systems can be controlled with either a pressure actuated valve or an electrically actuated solenoid valve 1 5 4 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 gas to circulate as shown 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
6. that the chamfer on the connecting rod faces toward the crankshaft journals Center rods on each crankshaft throw may be installed in either direction See Figure 3 16 CHAMFERED EDGE SEAL END THRUST WASHER CHAMFERED EDGE Figure 3 16 Installing Piston Rod Assemblies and Seal End Thrust Washer 3 Depending on date of manufacture the compressor may be fitted with double or single ring pistons Double ring and single ring pistons may be installed in the compressor as long as matched pistons are used on each bank 4 Old double ring pistons with wider lower ring groove the oil ring is installed in the groove nearest the bottom and the compression ring in the groove nearest the top The oil ring is notched on the outside circumference This notch must be installed towards the bottom See Figure 3 17 Compression Ring Compression Ring Compression Rin Cil Ring R q OLD NEW Figure 3 17 Piston Rings 5 The compression ring is chamfered on the inside circumference This ring is installed with the chamfer towards the top If using a double ring piston stagger the ring end gaps so they are not aligned 6 Measure side clearance between ring and ring groove in piston Maximum dimensions are provided in Table 3 2 c Crankshaft and Seal End Thrust Washer 1 Two brass thrust washers are used The pump end thrust washer is positioned on two dowel pins located on the bearing head and is installed with the oil pump a
7. 15 Discharge Manifold 10 Suction Cavity Figure 1 6 Compressor Cylinder Head Loaded Hot Gas Bypass 15 2 SUCTION CUTOFF UNLOADER The compressor is equipped with unloaders for capacity control This consists of a self contained suction cut off arrangement which is electronically 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 This allows the discharge gas behind the unloader piston assembly item 4 to vent back to the suction side The unloader valve spring item 7 at this point can move the 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 1 5 cylinders No refrigerant is allowed into the cylinders and no compression takes place SUCTION PRESSURE DISCHARGE PRESSURE
8. 83 17 4752 0 6878 17 4701 001 0 0254 CRANKSHAFT Crankpin Diameter 1 3735 34 8869 0025 0 0635 Throw Height 37 CFM 0 9698 24 6329 0 9678 24 5821 Throw Height 41 CFM 1 072 27 2288 1 070 27 1780 THRUST WASHER Thickness Pump End 0 145 3 6830 0 144 3 658 0250 0 6350 Seal End 0 157 3 987 0 155 3 937 0250 0 6350 CYLINDERS and PISTONS Bore 2 0010 50 8254 002 0 051 Piston Diameter See Figure 3 20 002 0 051 Piston Pin Diameter 0 6873 17 4574 001 0 025 Piston Ring Gap 0 013 0 3302 0 005 0 127 025 0 635 Piston Ring Side Clearance 0 002 0 051 0 001 0 0254 002 0 051 1 9960 1 9968 Figure 3 20 Piston Dimension Wear Limits A9IA popo dx q 10SS2 1d0102 JZ angi
9. Consult the unit service parts list for the correct replacement Service replacement compressors are furnished without suction and discharge service valves and unloader valves The service valves are normally retained on the unit to isolate the refrigerant lines during compressor replacement Blank off pads are installed on the service replacement compressor valve flanges These pads must be removed prior to installing the compressor If the defective compressor is to be returned for overhaul or repair install the pads on the compressor for sealing purposes during shipment Service replacement compressors are furnished with cylinder head bypass piston plugs installed 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 repair install the plugs on the compressor for sealing purposes during shipment 22 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 Ge 2 a C 53 HOT GAS BYPASS SUCTION CUTOFF Capscrews Flange Cover Gasket Spring Bypass Piston Plug Seat Ring Strainer Sleeve Plug NON BO Figure 2 1 Removal of Piston Plug b Remove flang
10. INCH 1 16 27 pipe 8 to 12 1 11 to 1 66 Pipe Plug Crankshaft 1 8 27 pipe 15 to 20 2 07 to 2 77 Oil Return Check Valve Crankcase 1 4 20 pipe 20 to 25 2 77 to 3 46 Pipe Plug Gauge Connection 1 4 20 10 to 12 1 38 to 1 66 Connecting Rod Capscrew 1 4 28 6 to 10 0 83 to 1 38 Oil Pump Drive Segment Vane Pump 12 to 16 1 66 to 2 21 Unloader Valve Cover Plate Plate End 5 16 18 Iren a Bearing Head Vane Pump 20 to 30 2 77 to 4 15 Discharge Service Valve Pump End Bearing Head Bottom Plate Crankcase 3 8 16 40 to 50 5 53 to 6 92 Cylinder Head End Flange Shaft Seal Cover 1 2 13 55 to 80 7 61 to 11 06 Suction Service Valve 10 32 4to6 0 55 to 0 83 Oil Pump Drive Segment Vane Pump 1 1 2 18 NEF 35 to 45 4 84 to 6 22 Oil Level Sight Glass NEF National Extra Fine 3 9 Table 3 2 Wear Limits FACTORY MAXIMUM FACTORY MINIMUM MAXIMUM WEAR BEFORE REPAIR PART NAME INCHES MM INCHES MM INCHES MM SEAL END End Play Seal Removed 0 035 0 8890 030 0 7620 Main Bearing Diameter 1 8760 47 6504 002 0 051 Main Bearing Journal Diameter 1 8725 47 5615 002 0 051 PUMP END Main Bearing Diameter 1 3760 34 9504 002 0 051 Main Bearing Journal Diameter 1 3735 34 8869 002 0 051 CONNECTING ROD Connecting Rod Diameter 1 3768 34 9707 0020 0 051 Piston Pin Bearing 0 68
11. L Discharge Service Valve 6 Oil Level Sight Glass High Pressure Connection 7 Bottom Plate Low Pressure Connection 8 Oil Drain Plug Suction Service Valve 9 Oil Pump See Figure 1 3 Oil Fill Plug 10 Unloader Figure 1 1 Model 05G Compressor 1 2 14 DETAILED DESCRIPTION 1 4 1 SUCTION AND DISCHARGE VALVES The compressor uses reed 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 1 Position Spring 2 Suction Valve 3 Valve Plate 4 Discharge Valve 5 Discharge Valve Stop Figure 1 2 Suction amp Discharge Valve 1 4 SUCTION amp DISCHARGE SERVICE VALVES The suction and discharge service valves used on the compressor are equipped with mating flanges for connection to flanges on the compressor These valves are provided with a double seat and a gauge connection which allows servicing of the compressor and refrigerant lines See Figure 1 1 Turning the valve stem counterclockwise all the way out will backseat the valve to open the suction or discharge line to the compressor and close off the gauge con
12. OMPRESSOR REPLACEMENT 2 1 21 Compressor Removals s o dipole ann E rr Ba E RU 2 1 22 Compressor Replacement cee ee tenes 2 1 2 2 1 Installing Compressor Unloaders 2 1 2 2 2 Installing Compressor 0 eect eee eens 2 2 3 COMPRESSOR MAINTENANCE ccc cece cece hh 3 1 3 1 introduction a a RN eee tes Od e c pda d eee ea 3 1 3 2 Inspection and Preparation for Reassembly 3 1 3 3 Cylinder Head and Valve Plate 2 eee eee cee eee 3 1 34 Oil Pump and Bearing Head 3 2 34 1 Low Profile Gear Pump 0 0 eee cence eee 3 2 242 Gear Pumpi ccce A eer RU RRUBR UU ELA ERR RARE UC ae 3 3 24 9 Vane PUMP ior rem het etie sieve eee I ie te tend be eel A 3 4 35 Shalt Seales io e eoe Cr e Lb seb tei rie mei ba ha dd 3 5 3 6 Compressor Running Gear Removal 3 5 3 7 Compressor Running Gear Reassembly 3 7 3 8 GSUCHON Strainer 2vssg cttsg eelLpBo n a vo C PERRO SUPE ENDE OPNS ta aes 3 8 3 9 Addins CH ae NC EE 3 8 3 10 Installing CompressoT Hh 3 8 LIST OF ILLUSTRATIONS Figure Page 11 Model 05G Compressor 0226 21 be e Rp e eh eere RU C Re Cep RT 425 1 2 1 2 Suction amp Discharge Valve cee eee tee
13. R REASSEMBLY a Seal End Main Bearings 1 When installing new seal end main bearings the oil groove is on top of the compressor with V grooves pointing to each other When installed there must be a 5 16 inch 7 93 mm gap between the two bearings See Figure 3 14 2 Line boring seal end main bearings 5 16 GAP TOP OF COMPRESSOR Figure 3 14 Seal End Main Bearings b 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 honing lightly in an up and down rotating motion Clean thoroughly after breaking glaze Some 05G compressors for refrigeration use only may have contoured pistons See Figure 3 15 When installing contoured pistons into compressor check suction valve and contoured piston are in the same orientation Figure 3 15 Contoured Piston 1 The gap between the ends of the piston rings can be checked with a feeler gauge by inserting the 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 bottom of 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
14. TRANSICOLD Compressor MODEL 05G and 05G BUS c O lt am n Q O IT Q 2 T TT T O c lt TRANSICOLD _ 8 HH c OPERATION AND SERVICE MANUAL MODEL 05G and 05G BUS COMPRESSOR UU UNITED pA He Carrier Transicold Division Carrier Corporation PO 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 Replaces 62 03432 01 and T 199 02 Carrier Corporation 1995 e Printed in U S A 0395 TABLE OF CONTENTS Section Page 1 DESCRIPTION enne nhe n hne pe L8 v 406 ach OX Wao 030118 n ace i 5031478 1 1 TeV Inttoduction vp ES ere epe Baek EE Soe E a eed egi tae S rn 1 1 1 2 General Description sates cae Wace ane rex Me DER eM E M sis NUIT MO ENS 1 1 13 Compressor Reference Data esses 1 1 1 4 Detailed Description cs seris cid eb cU e E R a ER ERR E a cae FA 1 3 1 4 1 Suction and Discharge ValVes 1 3 14 2 Suction amp Discharge Service Valves 1 3 T4 3 L brication System erens e iraa 504260600060 E 09324056 Eee ETE WERDE 1 3 15 Compressor Unloader na 1 4 15 1 Hot Gas Bypass Unloader 1 4 15 2 Suction Cutoff Unloader 1 5 15 3 Pressure Operated Unloaders 1 6 2 C
15. ane Gear and Low Profile Gear driven directly from the end of the compressor crankshaft 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 Oil Pump amp Bearing Head 2 Thrust Washer 3 Oil Pickup Tube 4 Oil Inlet Port Figure 3 4 Oil Pump and Bearing Head 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 However 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 Cover Reversing Assembly 9 Set Screw Pinion 10 Relief Valve Gear 11 Pin Drive 7 O Ring 8 Oil Pump amp Bearing Figure 3 5 Low Profile Gear Oil Pump c Reassembly CAUTION Set screw on crankshaft must be removed for Low Profile Gear Pump See Figure 3 4 1 Set screw on crankshaft must be removed for Low Profile Gear Pump 2 Install the pump end thrust washer on the two dowel pins located on the bearing head See Figure 3 4 CAUTION Ensure that thrust washer does not fall off dowel pins while installing oil pump 3 Install the bearing
16. ate Suction cutoff The two types of compressor 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 The 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 cm2 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 aa en ED mm xxx SN um JABS N ANa N sy ON uu Lv S Pin ZA 2A EZA 12 3 N N EWEH N 72722222277 2 7 Sealing Cap Pressure Differential Adjustment Screw Control Set Point Adjustment Nut Poppet Valve Bom Figure 1 9 Pressure Operated Unloader Loaded Operation During unloaded operation when suction pressure drops below the valve control point the poppet valve will open Discharge gas bleeds from 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 dischar
17. cover 12 Install the relief valve assembly c Reassembly 1 Install the pump end thrust washer on the two dowel pins located on the bearing head See Figure 3 4 CAUTION Ensure that 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 in the mounting flange Refer 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 remove 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 However if the caus
18. dd 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 1 4 Sight Glass OLD SIGHT GLASS LOCATION and PROPER LEVEL Maximum Minimum NEW SIGHT GLASS LOCATION and PROPER LEVEL Figure 2 2 Oil Level in Sight Glass 2 2 SECTION 3 COMPRESSOR MAINTENANCE 31 INTRODUCTION Prior to disassembly of the 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 plug to vent the crankcase Loosen 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 3 2 INSPECTION AND PREPARATION FOR REASSEMBLY a Clean all parts with an approved solvent Use 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 e
19. de 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 Mark outside of pump at the short groove for ease of installing pin at a later time Check wear between items 3 amp 4 Figure 3 6 ROTATION ARROW ROTATION ARROW Clockwise o Counterclockwise 1 Oil Pump 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 1 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 eccentric in direction indicated CW or CCW as so desired so oil pump rotates in the same direction as the crankshaft 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 10 Install the pin in the shortest of the two grooves inside the bearing head 11 Install the O ring and pump
20. e 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 installing the unloaders be sure to use the unloader capscrews d Using a new gasket and unloader ring pliers P N 07 00223 install the unloaders in the cylinder heads of the replacement compressor Refer to Table 3 1 for required torque values e If the 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 Midseat service valves or by other means relieve pressure in replacement compressor before removing plugs CAUTION The high capacity 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 b Check oil level in sight glass See Figure 2 2 If necessary a
21. e 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 Push the 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 Insert the pump 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 5 Insert one of the plungers into 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 its locking groove Follow the same procedure to reassemble the other plunger spring guide and snap ring in its plunger cylinde
22. er Removed_ 3 6 3 12 Piston Rings Removed erasan dronea ia aT n R n 3 6 3 13 Connecting Rod Piston and Pin 3 6 3 14 Seal End Main Bearings SS 3 7 3 19 Contoured Piston iuis d EY teen e A RAD 4404016604 e TR don 3 7 3 16 Installing Piston Rod Assemblies and Seal End Thrust Washer 3 7 3 14 Piston RINES 4 26 ehe eet e ogra bh eR o EIER aA d 35656 einn 3 7 3 18 Installing Pistons cce cece wine oi seek m oon A ee ate 61604 E we 3 8 3 19 Installing Suction Sfrainer na 3 8 3 20 Piston Dimension Wear Limits 3 10 3 21 Compressor Exploded View 0 20002 0000 3 11 LIST OF TABLES Table Page S L torgi Values cus des onte e edt Rd e ant aay s ide Aaa 3412063 8 3 9 3 2 Weak LIMIS ee Deep I eee e eoe cese eta HAE Rate A deri eR ras 3 10 SECTION 1 DESCRIPTION 11 INTRODUCTION WARNING This operation and service manual covers the Carrier Do not operate compressor unless suction and Transicold Model 05G compressors These compressors discharge service valves are open are designed for refrigeration trailer or air conditioning f bus amp rail applications See Figure 1 1 The following Capacity of the Model 05G compress
23. flows to the pump end main bearings connecting rod bearings and seal end main bearings where the oil path is divided into two directions The largest quantity flows to the oil relief valve which regulates oil pressure at 15 to 18 psi 2 09 to 2 30 kg cm2 above suction pressure When the oil pressure reaches 15 to 18 psi above suction pressure the relief valve spring is moved forward allowing oil to return to the crankcase The remaining oil flows through an orifice and into the shaft seal cavity to provide shaft seal lubrication and cooling This oil is then returned to the crankcase through an overflow passage An additional oil pressure relief valve built into the Gear and Low Profile Gear Oil Pump is open at speeds above 400 rpm to relieve a portion of the oil pressure to the crankcase in order to maintain oil pressure below an acceptable maximum At low speeds the valve is closed to ensure adequate oil pressure at 400 rpm At speeds above 1900 rpm the oil pressure will be 25 to 30 psi 2 8 to 3 1 kg cm2 above suction pressure The crankcase pressure equalization system consists of two oil return check valves and a 1 8 inch pressure equalization port between the suction manifold and crankcase Under normal conditions check valves are open and allow for oil return to the crankcase Under flooded start conditions pressure rises in the crankcase and closes the check valves preventing excess oil loss The equalization port allows for
24. ge pressure causes the check valve to close isolating the cylinder bank from the discharge manifold See Figure 1 10 Sealing Cap Pressure Differential Adjustment Screw Control Set Point Adjustment Nut Poppet Valve Bom Figure 1 10 Pressure Operated Unloaded Unloaded Operation 1 6 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 valves to trap the refrigerant in the 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 Remove refrigerant using a refrigerant recovery system d Disconnect refrigerant lines 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 is to be repaired refer to section 3 for repair procedures if a replacement compressor is to be installed refer to section 2 2 for replacement procedures 2 2 COMPRESSOR REPLACEMENT
25. 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 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 4 Align the gasket and install the eight capscrews in the mounting flange Refer to Table 3 1 for applicable torque values 3 4 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 However in the event the pump requires inspection or cleaning disassembly and reassembly instructions are provided below 1 Remove pump cover and O ring See Figure 3 6 2 Note direction 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 si
26. k 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 using a 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 is to be replaced you must replace both of them Likewise if a connecting rod 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 parts to 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 2 Coat piston pins with compressor oil and reassembly pistons pins and connecting rods in matched sets 1 o 5 Lock Ring Connecting Rod Connecting Rod and Cap Capscrew Piston Pin Piston Figure 3 13 Connecting Rod Piston and Pin d Seal End Main Bearings 1 Inspect seal end main bearings Check wear dimensions to determine if they are worn beyond limits given in Table 3 2 2 If worn beyond limits remove seal end main bearings 3 7 COMPRESSOR RUNNING GEA
27. l pes of oil pumps Vane Gear and Low Profile Gear f driven directly from the end of the compressor R 12 eye R 500 7 50 Synthetic crankshaft See Figure 1 3 or R 502 IN 07 00274 CAUTION Castrol Icematic SW 68C The gear oil pump must be set to rotate in the IN TUUYU CC same direction as the crankshaft Refer to ICI Emkarate RL68H section 3 4 The tapered end of the crankshaft which extends outside the crankcase is adaptable to a variety of direct Approved Oil for AIR CONDITIONING USE drive or belt driven clutch mechanisms A mechanical BUS AND RAIL seal prevents refrigerant leakage where the rotating shaft Refrigerant Oil passes through the crankcase Calumet Refining R030 The compressor is equipped with flanges for connecting suction and discharge service valves R 12 or R 22 Texaco WF68 Connections are also provided for pressure gauges and Witco 4GS Suniso safety cutout switches Sight glasses installed on both Castrol Icematic SW 68C sides of the crankcase provides a means for checking oil level in the compressor crankcase A drain plug facilitates draining of oil from the crankcase and an oil fill plug ICI Emkarate RL68H enables addition of oil when necessary A bottom plate provides access through the bottom of the crankcase for maintenance Revised 10 96 Mobil Arctic EAL 68 1 1 Qi Ree AIR CONDITIONING COMPRESSOR BUS amp RAI
28. lve 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 Cavity 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 close the gas bypass port 3 Refrigerant pressure will overcome the bypass valve spring 5 tension and force the piston 6 forward closing the gas bypass from 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 1 4 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 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
29. nd bearing head assembly The seal end thrust washer is positioned just ahead of the seal end main bearing on two dowel pins installed in the crankcase Both thrust washers should be inspected for wear and scoring before reassembly Refer to Table 3 2 25 Install the seal end thrust washer on the two dowel pins See Figure 3 16 Ensure piston rods are 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 d Bottom Plate 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 18 The ring compressor can be easily fabricated from a piece of sheet metal Figure 3 18 Installing Pistons 2 Install connecting rod caps on connecting rods using new capscrews special and flat washers Reuse of the old capscrews is not recommended Ensure that the caps are installed on the dowel pins Torque capscrews to torque value shown 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 floati
30. ndard Shaft Seal Used with Housing Mounted Clutch LN 1 Shaft Seal 6 Clutch Mounting Hub 2 Carbon Ring 7 Snap Ring or Nut 3 Gasket 8 O Ring 4 Seal Plate 9 Wear Ring 5 Hex Head Screw Figure 3 8 Shaft Seal Figure 3 9 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 When 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 contacts the 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 carbon washer and cover plate 4 Lubricate new 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 not touch carbon washer sealing surface with your
31. nection In normal operation the valve is backseated to allow full flow through the valve The valve should always be backseated when connecting the service manifold gauge lines to the gauge ports Turning the valve stem clockwise all the way forward will frontseat the valve to close off the suction or discharge line to isolate the compressor and open the gauge connection To measure suction or discharge pressure midseat the valve by opening the valve clockwise about 2 turns With the valve stem midway between frontseated and backseated positions the suction or discharge line is open to both the compressor and the gauge connection 1 4 5 LUBRICATION SYSTEM There are three types of oil pumps Vane Gear and Low Profile Gear driven directly from the end of the compressor crankshaft See Figure 1 3 Force feed lubrication of the compressor is accomplished by a oil pump driven directly from the compressor crankshaft Refrigeration oil is drawn from the compressor crankcase through the oil filter screen and pick up tube to the oil pump 1 3 located in the bearing head assembly The crankshaft is drilled to enable the pump to supply oil to the main bearings connecting rod bearings and the shaft seal Oil Pressure Tap VANE PUMP GEAR PUMP Oil Pressure LOW PROFILE GEAR PUMP Figure 1 3 Oil Pumps CAUTION The Gear oil pump must be set to rotate in the same direction as the crankshaft Refer to section 3 4 The oil
32. ng 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 wire to ensure that the spring mechanism can be depressed 4 Clean and reinstall the oil strainer 5 Using a new gasket install the bottom cover plate See figure 1 1 for relative location of compressor mounting flanges 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 NOTE Suction strainer has been preformed to fit into suction cavity Remove and clean the suction strainer See Figure 3 19 Check it for damage If it is damaged replace suction strainer Install suction strainer and suction service valve using a new gasket Figure 3 19 Installing Suction Strainer 3 9 ADDING OIL Add the proper oil charge to the compressor through the oil fill plug Refer to section 2 2 2 for the required oil charge Refer to unit operation manual for other methods of adding oil to compressor 3 10 INSTALLING COMPRESSOR Refer to section 2 2 2 and the unit service manual to install the compressor Allow compressor to run for 4 to 5 hours before checking new shaft seal assembly for leaks Table 3 1 Torque Values TORQUE RANGE SIZE DIAMETER THREADS Er MKG USAGE INCHES PER
33. ns 1 3 13 2000 PUMPS e aeaa a ER t 403036 ded ore S MR a eaaa s 1 3 1 4 Compressor Unloader Hot Gas Bypass_ 1 4 1 5 Compressor Cylinder Head Unloaded Hot Gas Bypass 1 4 1 6 Compressor Cylinder Head Loaded Hot Gas Bypass 1 5 1 7 Compressor Cylinder Head Unloaded Suction Cutoff 1 5 1 8 Compressor Cylinder Head Loaded Suction Cutof 1 6 1 9 Pressure Operated Unloader Loaded Operation 1 6 1 10 Pressure Operated Unloaded Unloaded Operation_ 1 6 2 1 Removal of Piston Plug 6 eee cee eect eee eee 2 1 2 2 Oil Level in Sight Glass lesse 2 2 3 1 Cylinder Head amp Valve Plate nosier aiena cee cee ee E 3 1 3 2 Installing Suction Valves 0 0000 3 2 3 39 Checking Suction Valve 42691210640 664 616 0 s61 Hh eta Ehe 41640064 3 2 3 4 Oil Pump and Bearing Head Assembly 3 2 3 5 Low Profile Gear Oil Pump 0 cece cee ee eee 3 2 36 GearOil Pumpe seek ewer eee ete Ee ee Eque UP IUe ee E wp ee 3 3 327 Mane OIL Pump ss Se te aeree Ted Cause a Wc NOR e 3 4 39 8 c ShaftSeal iiio dee Rhe sels hard a a e e r 3 5 3 0 Shaft Seal Removal oki DER RENE RES EM e NER ER eae 3 5 3 10 Bottom Plate Removal Q0 HH na 3 5 3 11 Bottom Plate and Oil Strain
34. or is table list the special tools for the 05G compressors determined by piston displacement and clearance suction and discharge valve size compressor speed PART NO SPECIAL TOOLS suction and discharge pressure type of refrigerant and 07 00219 Wrench Compressor Sight Glass unloader valves 07 00223 Pliers Compressor Unloader Ring 13 COMPRESSOR REFERENCE DATA Wrench Spanner 07 00240 01 t Housing Mounted Clutch Model 05G 37CFM 05G 41CFM Rotor Installation Tool Displacement 37CFM 41CFM Dres for Housing Mounted Clutch No Cylinders 6 07 00242 91 Bearing Retaining Nut Socket Bore 50 8 mm 2 00 in 3 5 Housing Mounted Clutch Stroke 49 2 mm 54 36 mm 07 00242 o2 Bearing Retaining Nut Socket 1 937 in 2 14 in 3 for Housing Mounted Clutch Weight 62 kg 137 Ibs 07 00260 00 Acid Test Kit SPEED RPM FOR OIL PUMP 07 00265 01 Totaltest Kit Package of 1 Vane 900 to 2200 07 00266 00 Replacement Tubes for Totaltest Kit Gear 500 to 2200 Filter Felt Suction Sock for Low Profile Gear 500 to 2200 pe 0080200 System Clean Up NOTE L2 GENERAL DESCRIPTION The oils below are suitable for use with evaporator temperatures above 40 E The Model 05G compressors are of the open drive 40 C reciprocating type A crankshaft connecting rods pistons and reed type valves accomplish vapor Approved Oil for REFRIGERATION USE compression Compressor wear is minimized by splash TRAILER SCIAS in by s T2 bpm d m as Refrigerant Oi
35. r 1 Oil Pump Cover 9 Retaining Ring 2 Cover Gasket 10 Spring Guide 3 Capscrews and 11 Bearing Head Lockwashers 12 Pump Rotor Oil Pump Drive 13 Oil Feed Guide Rotor Retaining Ring 14 Retainer Spring ONO Pump Vane Cylinder 15 Capscrews and Pump Vane Washers 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 Refer to Table 3 1 for applicable torque values 3 Install the drive segment with the two capscrews and lock washer 4 Insert the oil feed guide with the large diameter in Insert the guide retaining spring so that it fits over the smaller diameter of the feed guide The pump cover can now be installed D Place the pump cover with a new gasket over the guide retaining spring and compress the spring to enable installation of the cover capscrews 3 5 SHAFT SEAL a Disassembly 1 Remove 6 capscrews remove shaft seal cover or clutch mounting hub and carbon washer See Figure 3 8 2 Tap seal end of crankshaft to loosen seal grip on shaft Using two long screwdrivers pry out the shaft seal but do not damage gasket surface See Figure 3 9 Sta
36. tall only new valves and gaskets and do not interchange valves 1 Capscrew 5 Lockwasher 2 Cylinder Head 6 Discharge Valve Stop 3 Cylinder Head Gasket 7 Discharge Valve 4 Capscrew 8 Valve Plate 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 valves to ensure that the valve tips are not being held by the valve plate gasket See Figure 3 3 l 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 capscrews and lock washers 1 Install capscrews cylinder head and new cylinder head gasket with flat side to valve plate 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 3 4 OIL PUMP AND BEARING HEAD There are three types of oil pumps V
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