REPLACEMENT COMPONENTS DIVISION

SERVICE BULLETIN
SUBJECT: 23XL Slide Valve Rework Procedure NUMBER: C9803A
DATE: 5-18-98
SUPERSEDES: C9803
DATE: 2-20-98
PAGE: 1 of 11
MODELS AFFECTED: All 23XL Chillers
Installation, repair and service and equipment referenced in this Service Bulletin should be undertaken only by qualified persons. Carrier
Corporation: (1) makes no representations or warranties, expressed or implied, concerning the accuracy, completeness or right to use the
information contained herein. (2) Disclaims all liability for injuries, damages, infringements and other losses which may arise on account of, or
which may result from, the use or application of any information, method or apparatus disclosed herein.

PURPOSE:

To provide information on how to rebuild the slide valve assembly and a list of repair parts.

REFERENCE:
Bulletins C9602A - Slide Valve Locknuts
C9709 - 23XL Frame 4 Slide Rod Change (new locknut design).
C9715 - 23XL Slide Valve Spring Retainer.
C9719 - 23XL Slide Valve Operation and Troubleshooting.
C9804 - 23XL Slide Valve Support.
23XL Parts List Catalog

TOOLS:

See bulletin C9802 - Compressor Maintenance Tools.

Retaining Compound - Loctite 603 other acceptable Loctite 675 and 609

PARTS:

See parts list on last page of this bulletin.

BACKGROUND:

Frame 1 and 2 chillers have C series compressors: C20, C21, C40, C41, C60, C61.
Frame 4 chillers have D series compressors: D40, D41, D60, D61.
Variable VI (volumetric index) compressors: C21, C41, C61, D41, D61

FIXED V. I. COMPRESSORS

I. Removal of the slide valve assembly from compressor

1. Lock out and tag the starter.

2. Transfer charge to the storage tank or condenser and set up rigging.
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3. Identify and tag each of the capacity solenoids and lines before removing them.
4. Remove the capacity control solenoid coils and supply and return oil lines from the top of the slide
casing.

CAUTION: Make sure the control panel power is off to prevent damaging the solenoid coils.

5. Insert guide bolts or steel threaded rods at 9 and 3 o’clock.

NOTE: Be ready to catch oil spillage when assembly is moved.

6. Support the slide valve assembly with a nylon sling and pull the assembly forward.

CAUTION: The slide valve assembly will be heavier on the slide valve end. Be very careful that the
assembly does not drop and cause damage to the slide valve and slide stop.

WARNING: Before the slide valve (43) clears the housing check to make sure it is still attached to
the shaft.

II. Disassembly of Slide Valve Assembly

NOTE: To remove locknuts or bolts that have been sealed with Loctite:
a. Apply localized heat to locknut or bolt (450?F/232?C ) for no longer than 5 minutes.
b. Disassemble while hot.

1. Set the slide valve assembly on a sturdy, clean work surface.

CAUTION: Remove all the hollow hex plugs to relieve the oil pressure

2. Place a pan in position to catch oil (a quart or more) and remove the slide valve cover.
3. Reach into the compressor slide valve port and remove spring retainer (shaft) (42,50). Refer to
bulletin C9715.
4. Remove the piston (45) from capacity rod (44).
5. Bend the lockwasher (if present) and remove the locknut (52) and lockwasher (53) or locking collar
using the socket p/n T-144502D or T144504D. Inspect the piston for wear under the locknut/locking
collar area.
6. Remove the slide valve (43) from capacity rod (44).
Hint: To prevent the rod from turning, grip the capacity rod next to the slide valve. This area of the
rod does not make contact with the seal ring.
7. Remove the two button (Loctite-sealed) screws (76D) from the slide casing by applying localized
heat to screws (450?F/232?C ) for no longer than 5 minutes.
8. Remove the slide casing plug (76A) that holds the slide seal assembly. Examine the O-ring for
damage and note cause of damage.
9. Remove slide seal adapter (48) from slide casing plug. Inspect seal ring (49). If seal is worn,
replace the slide rod or have the rod polished to 22 micro-inches (.55 micro-meter) at a machine
shop.
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10. Remove the capacity control valve (58) and check the passageway for blockage. Inspect the slide
casing bore for wear.

III. Slide Valve Reassembly

A. General
NOTE: Parts must be clean and threaded parts must be free of oil grease, and residue before
Loctite retaining compound is applied.
NOTE: Do not use Locquic (Loctite primer) for cleaning parts. Application of this primer will
accelerate curing time of the sealants. Use a degreasing type cleaner.
NOTE: Do not install the two small O-rings on the slide rod. These O-rings are no longer
necessary.

B. Reassembly
Break sharp edge of the shaft shoulders on the slide rod.
1. Place thin mylar (transparency film) over slide rod threads at slide valve end. Use this method to
slide the seal ring (49) into place. Note: Open side of the seal faces towards the slide valve.
2. Install the two new O-rings (63, 76B) on the casing plug (76A).
3. Install slide casing plug / separator plate on the slide rod from slide valve end.
4. Place the slide valve in the vertical position on the bench and set the capacity slide rod into the
valve.
5. Install new O-ring (55) in the slide seal adapter. Raise the slide seal (49) near top of the slide rod).
6. Place the slide seal adapter over shaft and lower on to the seal. Carefully lower seal adapter into
the slide casing plug. Make sure the seal is properly seated. Apply Loctite, install the four M6
screws and torque the screws to 7 ft-lb (9.5 Nm).
7. Remove the slide rod/seal assembly from slide valve and place in the horizontal position.
8. Apply Loctite on slide rod threads both ends.
Note: After Loctite has been applied, the locknuts must be installed and torqued in less than 10
minutes.
9. Place the slide valve in the horizontal and insert the slide rod / seal assembly.
10. Install the piston.
11. Loctite, install and torque the two locknuts with lockwashers to 75 ft-lb (102 Nm) with proper
locknut sockets at each end.
12. For C series, bend up the tab on the lockwasher that will match the slot in the locknut after both
locknuts have been torqued to specifications in bulletin C9602A. For D series, install set screws
and torque to specification in bulletin C9709.
13. Install the guide seal assembly (piston 45). There are two seal rings (47); the thin one faces the
slide valve. Place the thin seal ring on the piston so the open end with spring is toward the slide
valve. Check the illustration for orientation.
14. Remove the sharp edges around the two sharp corners on the face of the slide casing to prevent
damage to the O-ring during insertion of the casing plug into slide casing
15. Oil the slide casing and carefully insert the slide rod assembly into casing (D series) or lower slide
casing over the slide valve piston (C series). Do not damage the O-ring / seals.
HINT: Use rubber band number 84 (1/2-in. wide by 7-in. circumference ) , or nylon or banding strap
with vise grip pliers. These suggested methods will compress seal rings into the slot and
aid in assembly of the valve piston into slide casing.
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16. Install the two oversize washers (76C) and button head screws (76D).
Note: It is not necessary to apply Loctite to button screws.

IV. Final Assembly

1. Install the capacity control valves with new O-ring.

2. Install the slide valve cover (46A) with new O-ring (64A) and tighten the bolts but do not torque them.
3. Install the hollow hex plugs.
4. Apply air pressure to open ports to cycle the slide valve and check for seal leaks.
5. Remove the slide valve cover. Install spring retainer shaft (42) with spring (50).
Hint: Use a 3/8-in. -16 steel threaded rod about 3 ft (1 meter) long to hold the spring retainer during
reassembly.
6. Install the slide valve assembly, remove the steel threaded rod and install the slide valve cover.
7. Torque all the bolts to specifications, reconnect the oil lines and install the solenoid coils.
8. Perform a leak check.

VARIABLE VI COMPRESSORS

I. Removal of the slide valve assembly from compressor

1. Lock out and tag the starter.
2. Transfer charge to the storage tank or condenser and set up rigging.
3. Identify and tag each of the capacity solenoids and lines before removing them. The variable VI
compressor has four solenoids.
4. Remove the capacity control solenoid coils and supply and return oil lines from the top of the slide
casing.

CAUTION: Make sure the control panel power is off to prevent damaging the solenoid coils.

5. Insert guide bolts or steel threaded rods at 9 and 3 o’clock.

NOTE: Be ready to catch oil spillage when assembly is moved.
6. Support the slide valve assembly with a nylon sling and pull the assembly forward.

CAUTION: The slide valve assembly will be heavier on the slide valve end. Be very careful that the
assembly does not drop and cause damage to the slide valve and slide stop.
WARNING: Before the slide valve clears the housing check to make sure it is still attached to the
shaft.
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II. Disassembly of the Slide Valve Assembly

NOTE: To remove locknuts or bolts that have been sealed with Loctite:
a. Apply localized heat to locknut or bolt (450?F/232?C ) for no longer than 5 minutes.
b. Disassemble while hot.
1. Set the slide valve assembly on sturdy clean work surface.

CAUTION: Remove all the hollow hex plugs to relieve the oil pressure

2. Place a pan in position to catch oil (a quart or more) and remove the slide valve cover.
3. Remove the piston (67) from VI slide rod (66).
4. Bend the lockwasher (73) tabs and remove the locknut (72) using the locknut socket p/n T-
144502D. Inspect the piston for wear under the locknut area.

CAUTION: The assembly contains a coil spring (50) which is compressed

to a preload pressure.

5. Remove valve stop from VI slide rod.

6. Remove the 3 cylinder stop locking plugs (76F) . Earlier models used snap rings and ratchet snap
ring pliers will be required to remove them.
7. Remove cylinder stop.
8. Reach into the compressor slide valve port and remove spring retainer (shaft) (42,50). Refer to
bulletin C9715.
9. Remove the piston (45) from capacity rod (44).
10. Bend the lockwasher (if present) and remove the locknut (52) and lockwasher (53) or locking collar
using the socket p/n T-144502D or T144504D. Inspect the piston for wear under the locknut/locking
collar area.
11. Remove the slide valve (43) from capacity rod (44).
HINT: To prevent the rod from turning. grip the capacity rod next to the slide valve. This area of the
rod does not make contact with the seal ring.
12. Remove the two button (Loctite-sealed) screws (76D) from the slide casing by applying localized
heat to screws (450?F/232?C ) no more than 5 minutes.
13. Remove the slide casing plug (76A) that holds the slide seal assembly. Examine the O-ring for
damage and note cause of damage.
14. Remove slide seal adapter (48) from slide casing plug. Inspect seal ring (49). If seal is worn,
replace the slide rod or have the rod polished to 22 micro-inches (.55 micro-meter) at a machine
shop.
15. Remove the capacity control valve and check the passageway for blockage. Inspect the slide
casing bore for wear.

III. Slide Valve Reassembly

A. General
NOTE: Parts must be clean and threaded parts must be free of oil, grease, and residue before
Loctite retaining compound is applied.
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NOTE: Do not use Locquic (Loctite primer) for cleaning parts. Application of this primer will
accelerate curing time of the sealants. Use a degreasing type cleaner.
NOTE: Do not install the two small O-rings on the slide rod.

B. Reassembly
Break sharp edge of the shaft shoulders on the slide rod.
1. Place thin mylar (transparency film) over slide rod threads at slide valve end. Use this method to
slide the seal ring (49) into place.
Note: Open side of the seal faces towards the slide valve.
2. Install the two new O-rings (63, 76B) on the casing plug (76A).
3. Install slide casing plug/separator plate on the slide rod from slide valve end.
4. Place the slide valve in the vertical position on the bench and set the capacity slide rod into the
valve.
5. Install new O-ring (55) in the slide seal adapter. Raise the slide seal (49) near top of the slide rod).
6. Place the slide seal adapter over shaft and lower on to the seal. Carefully lower seal adapter into
the slide casing plug. Make sure the seal is properly seated. Apply Loctite to the four M6 screws,
install the screws and torque to 7 ft-lb (9.5 Nm).
7. Remove the slide rod/seal assembly from slide valve and place in the horizontal position.
8. Apply Loctite on slide rod threads both ends.
NOTE: After Loctite has been applied, the locknuts must be installed and torqued in less than 10
minutes.
9. Place the slide valve in the horizontal position and insert the slide rod/ seal assembly.
10. Install the piston (45).
11. Apply Loctite to the two locknuts with lockwashers, install the locknuts and torque to 75 ft-lb (102
Nm) with proper locknut sockets at each end. Install the guide seal assembly (piston 45). There are
two seal rings (47);
12. For C series bend up a tab on lockwasher that matches with slot in the locknut after both locknuts
have been torqued to specifications in bulletin C9602A. For D series install set screws and torque
to specification in bulletin C9709.
13. Install the guide seal assembly (piston). There are two seal rings (47). The thin one faces the slide
valve. Place the thin seal ring on the piston so the open end with spring is toward the slide valve.
Check the illustration for orientation.
14. Remove the sharp edges around the two sharp corners on the face of the slide casing to prevent
damage to the O-ring during insertion of the casing plug into slide casing
15. Oil the slide casing and carefully insert the slide rod assembly into casing (D series) or lower slide
casing over the slide valve piston (C series). Do not damage the O-ring/seals.
HINT: Use rubber band number 84 (1/2-in. wide by 7-in. circumference ) or nylon or banding strap
with vise grip pliers. These suggested methods will compress seal rings into the slot and aid in
assembly of the valve piston into slide casing.
16. Install the two oversize washers (76C) and button head screws (76D).
NOTE: It is not necessary to apply Loctite to button screws.
17. Install the cylinder stop (68A) and O-ring (76G) without the slide seal retainer (71) assembly.
NOTE: Do not install the two small O-rings on the VI capacity slide rod.
18. Install VI capacity slide rod (66) into the valve stop (65) , apply 2 drops of Loctite. Install the
lockwasher and locknut. Note: Do not bend up the tab in the lockwasher until torquing the locknut at
the other end.
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19. Insert the spring (D series has two) on the VI slide rod and lower the slide valve assembly over the
VI slide rod to compress the springs.
20. Place thin mylar over VI slide rod threads. Use this method to slide the seal ring into place.
NOTE: Open side of the seal faces towards the slide cover.
21. Install the slide seal retainer (71) and tighten the four screws.
22. Install the VI valve piston (67). Loctite, install and torque the two locknuts with lockwashers to 75 ft-
lb (102 Nm) with proper locknut sockets at each end.
23. Bend up the tab on the lockwasher that will match the slot in the locknut after both locknuts have
been torqued to specifications.
24. Install the guide seal assembly (67). There are two seal rings (47); the thin one faces the slide
valve. Place the thin seal ring on the piston so the open end with spring is toward the slide valve.
Check the illustration for orientation.

HINT: Use rubber band number 84 (1/2-in. wide by 7-in. circumference) or nylon or banding
strap with vise grip pliers. These suggested methods will compress seal rings into the
slot and aid in assembly of the valve piston into slide casing.
25. Raise the slide valve assembly and carefully insert the VI piston into the slide casing.

IV. Final Assembly

1. Install the capacity control valves with new O-ring.

2. Install the slide valve cover (46A) with new O-ring (64A) and tighten the bolts.
3. Install the hollow hex plugs.
4. Apply air pressure to open ports to cycle the slide valve and check for seal leaks.
5. Install the slide valve assembly with new O-ring
6. Install the slide valve assembly, remove the steel threaded rod and install the slide valve cover.
7. Torque all the bolts to specifications, reconnect the oil lines and install the solenoid coils.
8. Perform a leak check.
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Parts required to perform a major stop routine on slide valve assembly.

Compressor D40, D60 C20,C40,C60 C20,C40,C60

Prior s/n 5193J Starting s/n 5193J
Item (Qt.) P/N P/N P/N Description

5 8TD0082C 8TC0117C 8TC0117C O-ring

47 8TD0075D 8TC0053C 8TC0053C Guide Seal, piston
49 8TC0057C 8TC0057C 8TC0057C Seal Ring, shaft
52 (2) * 8TC0048C 8TC0048C Locknut 35mm
53 (2) * 8TC0051C 8TC0051C Lockwasher 35mm
54 (2) not required not required not required O-ring, slide rod
55 KK71EW228 KK71EW228 KK71EW228 O-ring
56,76b 8TC0119C 8TC0119C 8TC0418C O-ring
59 (4) 8TC0154C 8TC0154C 8TC0154C O-ring, solenoid
63 8TD0089C KK71EW245 KK71EW245 O-ring
64,64a 8TD0087C 8TC0120C 8TC0420C O-ring, cover
76c (2) 8TD0206C ---------- 8TD0206C Washer
76d (2) 8TD0207C ---------- 8TD0207C Screw, button
78a (2) KK71EW904 KK71EW904 KK71EW904 O-ring, hex plug
79a (3) KK71EW906 KK71EW906 KK71EW906 O-ring, hex plug

For Variable V.I. compressors order above plus these additional parts.
.
Compressor D41, D61 C21,C41,C61 C21,C41,C61

47 8TD0075D 8TC0053C 8TC0053C Guide Seal, piston V.I.

59 (4) 8TC0154C 8TC0154C 8TC0154C O-ring, solenoid
64,76,76g 8TD0087C 8TC0237C KK71EW252 O-ring, cylinder stop
70 8TC0056C 8TC0056C 8TC0056C Seal Ring, slide rod V.I.
72 (2) 8TC0047C 8TC0047C 8TC0047C Locknut, 20mm
73 (2) 8TC0050C 8TC0050C 8TC0050C Lockwasher, 20mm
75 (2) not required not required not required O-ring, slide rod VI

Notes: * For fixed VI compressors built after November, 1996 order locking collar P/N
KT51HZ100. For fixed VI compressors built prior to November 1996 a new slide rod and locking
collars will be required. Refer to bulletin C9709 for part numbers.
For variable VI compressors order locknut p/n 8TC0048C and lockwasher 8TC0051C.

Frame 4 Slide Valve Clamping Kit 23XL660021 refer to bulletin C9804.