Compressor

WORKSHOP MANUAL
For

MODEL 05G
TWIN PORT COMPRESSOR

62-11052 Rev D
 WORKSHOP MANUAL
For

MODEL 05G
TWIN PORT COMPRESSOR

© Carrier Corporation, 2017 Printed in U. S. A. December 2017

 TABLE OF CONTENTS
PARAGRAPH NUMBER PAGE

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1 GENERAL SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.2 FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.3 OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.4 MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.5 SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.2 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.3 COMPRESSOR REFERENCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.4 DETAILED DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.4.1 Service Valves ........................................................... 2–4
2.4.2 Suction And Discharge Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.4.3 Lubrication System ....................................................... 2–4
2.4.4 Shaft Seal Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.5 COMPRESSOR UNLOADERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.5.1 Electric-Controlled Unloaders ............................................... 2–5
2.5.2 Pressure-Operated Unloaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
COMPRESSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1 COMPRESSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.2 COMPRESSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.2.1 Installing Compressor Unloaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.2.2 Installing Compressor ..................................................... 3–2
COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1 SHAFT SEAL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.3 INSPECTION AND PREPARATION FOR REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.4 CYLINDER HEAD AND VALVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.4.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.4.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.5 OIL PUMP AND BEARING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.5.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.5.2 Disassembly, & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.5.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
4.6 SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
4.6.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
4.6.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.7 COMPRESSOR RUNNING GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
4.7.1 Bottom Plate, Strainer, and Connecting Rod Caps ............................... 4–7
4.7.2 Crankshaft and Seal End Thrust Washer ...................................... 4–8
4.7.3 Pistons, Rods, and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
4.7.4 Seal End Main Bearings ................................................... 4–9

i 62-11052
 4.8 COMPRESSOR RUNNING GEAR REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9
4.8.1 Seal End Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9
4.8.2 Pistons, Rods, and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
4.8.3 Crankshaft and Seal End Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
4.8.4 Bottom Plate, Strainer, and Connecting Rod Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
4.9 SUCTION STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
4.10 ADDING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
4.11 INSTALLING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
INDEX .......................................................................... INDEX–1

62-11052 ii
 LIST OF ILLUSTRATIONS
FIGURE NUMBER Page

Figure 2.1 Model 05G Compressor ........................................................ 2–3

Figure 2.2 Suction & Discharge Valve ...................................................... 2–4
Figure 2.3 Oil Pump .................................................................... 2–4
Figure 2.4 Shaft Seal Reservoir ........................................................... 2–5
Figure 2.5 Compressor Unloader .......................................................... 2–6
Figure 2.6 Electric-Operated Unloader – Unloaded Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Figure 2.7 Electric-Operated Unloader – Loaded Operation ..................................... 2–7
Figure 2.8 Pressure-Operated Unloader – Loaded Operation .................................... 2–8
Figure 2.9 Pressure-Operated Unloader – Unloaded Operation .................................. 2–8
Figure 3.1 Removal of Piston Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Figure 3.2 Oil Level in Sight Glass ......................................................... 3–2
Figure 4.1 Shaft Seal Reservoir ........................................................... 4–1
Figure 4.2 Cylinder Head & Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Figure 4.3 Installing Suction Valves ........................................................ 4–3
Figure 4.4 Checking Suction Valve ........................................................ 4–3
Figure 4.5 Oil Pump and Bearing Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Figure 4.6 Oil Pump Exploded ............................................................ 4–4
Figure 4.7 Shaft Seal ................................................................... 4–5
Figure 4.8 Shaft Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Figure 4.9 TOP Orientation .............................................................. 4–7
Figure 4.10 Bottom Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
Figure 4.11 Bottom Plate and Oil Strainer Removed ........................................... 4–7
Figure 4.12 Piston Rings Removed ........................................................ 4–8
Figure 4.13 Connecting Rod, Piston, and Pin ................................................ 4–9
Figure 4.14 Seal End Main Bearings ....................................................... 4–9
Figure 4.15 Piston .................................................................... 4–10
Figure 4.16 Correct Piston in Cylinder Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
Figure 4.17 Installing Piston Rod Assemblies and Seal End Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . 4–10
Figure 4.18 Piston Rings ............................................................... 4–11
Figure 4.19 Installing Pistons ............................................................ 4–11
Figure 4.20 Installing Suction Strainer ..................................................... 4–12
Figure 4.21 Piston Dimension (Wear Limits) ................................................ 4–14

iii 62-11052
 LIST OF TABLES
TABLE NUMBER Page

Table 2–1 Compressor Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

Table 2–2 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Table 4–1 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
Table 4–2 Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–14

62-11052 iv
 SECTION 1
SAFETY SUMMARY
1.1 GENERAL SAFETY NOTICES
The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this
manual. They are recommended precautions that must be understood and applied during maintenance of the
equipment covered herein. The general safety notices are presented in the following three sections labeled: First
Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions appear-
ing elsewhere in the manual follows the general safety notices.

1.2 FIRST AID

The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the
engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do
not remove the cap from a hot radiator. If the cap must be removed, do so very slowly in order to release the pres-
sure without spray.

1.3 OPERATING PRECAUTIONS

• Always wear safety glasses.
• No work should be performed on the unit until all circuit breakers and start- stop switches are turned off, and
power supply is disconnected.
• Always work in pairs. Never work on the equipment alone.

1.4 MAINTENANCE PRECAUTIONS

Be sure power is turned off before working on motors, controllers, solenoid valves and electrical control switches.
Tag circuit breaker and power supply to prevent accidental energizing of circuit.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems
with the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.

1.5 SPECIFIC WARNING AND CAUTION STATEMENTS

To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation
is given with the appropriate consequences:

! DANGER
DANGER – warns against an immediate hazard which WILL result in severe personal injury or
death.

! WARNING
WARNING – warns against hazards or unsafe conditions which COULD result in severe per-
sonal in-jury or death.

! CAUTION
CAUTION – warns against potential hazard or unsafe practice which could result in minor per-
sonal injury, or product or property damage.

NOTE
NOTE – gives helpful information that may help and avoid equipment and property damage.

1–1 62-11052
The statements listed below are specifically applicable to this unit and appear elsewhere in this manual. These rec-
ommended precautions must be understood and applied during operation and maintenance of the equipment cov-
ered herein.

! WARNING
Do not operate compressor unless suction and discharge service valves are open.

! WARNING
Midseat service valves or by other means relieve pressure in replacement compressor before
removing plugs.

! WARNING
Do not unscrew capscrews all the way before breaking seal. Entrapped pressure could result
in injury.

! CAUTION
The high capacity oil pump must be set to rotate in the same direction as the crankshaft. (Refer
to Figure 4.5)

! CAUTION
Ensure that thrust washer does not fall off dowel pins while installing oil pump.

! CAUTION
Do not allow crankshaft to drop on connecting rods inside the crankcase when removing the
crankshaft.

! CAUTION
Do not allow crankshaft to drop on connecting rods inside the crankcase when installing the
crankshaft.

62-11052 1–2
 SECTION 2
DESCRIPTION
2.1 INTRODUCTION
This workshop manual covers the Carrier Transicold Model 05G Twin Port compressors. These compressors are
designed for refrigeration (trailer) or air conditioning (bus & rail) applications. (See Figure 2.1) A detailed list of
tools needed to service the 05G Twin Port compressor may be found in the Service Tool catalog 62-03213.
Replacement parts may be found in the Service Parts List for Model 05G Twin Port Compressor 62-11053.

2.2 GENERAL DESCRIPTION

The 05G Twin Port 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 by
force feed lubrication. The oil pump is driven directly from the end of the compressor crankshaft. (See Figure 2.3).
The 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 prevents refrigerant leakage where the rotating shaft passes through
the crankcase. A shaft seal reservoir is provided to collect any oil seepage that might escape the seal.
The compressor is equipped with flanges for connecting suction and discharge service valves. Connections are
also provided for pressure gauges and safety cutout switches. Sight glasses installed on both sides of the crank-
case, 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 enables addition of oil when necessary. A bottom plate provides access
through the bottom of the crankcase for maintenance.

! WARNING
Do not operate compressor unless suction and discharge service valves are open.

Capacity of the Model 05G Twin Port 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.

2.3 COMPRESSOR REFERENCE DATA

Table 2–1 Compressor Reference Data

Model 05G- 37CFM 05G- 41CFM
Displacement 37CFM 41CFM
No. Cylinders 6
Bore 50.8 mm (2.00 in)
Stroke 49.2 mm 54.36 mm
(1.937 in) (2.14 in)
Weight 62 kg (137 lbs)
SPEED (RPM) FOR OIL PUMP
Low Profile 500 to 2200

2–1 62-11052
 NOTE
The oils below are suitable for use with evaporator temperatures above - 40°F (- 40°C).

Table 2–2 Oils

Approved Oil for REFRIGERATION USE (TRAILER)
Refrigerant Oil
Alkyl Benzene (Synthetic)
R- 12, R- 22, R- 500 or R- 502
P/N 07- 00274- 00
Polyolester (POE)
R- 404A
P/N 07- 00317- 00PK6
Approved Oil for AIR CONDITIONING USE (BUS AND RAIL)
Refrigerant Oil
Mineral (150 Viscosity)
R- 12, R- 22, R- 500 or R- 502
P/N 07- 00275- 00
Mineral (300 Viscosity)
R- 12, R- 22, R- 502
P/N 07- 00377- 00
Alkyl Benzene (Synthetic)
R-22
P/N 07- 00430- 00
Polyolester (POE)
R- 134a
P/N 07- 00317- 00PK6

NOTE
Proper use and storage of Polyester (POE) type oil used with HFC refrigerants is critical. This type of
oil is extremely hygroscopic, meaning that if allowed to become exposed to the atmosphere, it can col-
lect moisture that leads to the formation of acids that will damage refrigeration components. Some
refrigeration assemblies such as O-ring assemblies, compressor shaft seals and most solenoid valves
require that refrigerant oil be applied to some of the parts during the assembly process. When this is
needed, always use alkylated benzene oil CTD P/N 07- 00274 (Zerol 150) even for R134a or R404A
systems. All refrigerant oils must be stored in a sealed, airtight container.

62-11052 2–2
 Figure 2.1 Model 05G Compressor

2
1
3
4
5

5
11

10

COMPRESSOR WITH
MOUNTING FLANGE
(ULTRA TYPE SHOWN)

12
8
7 6

1 2
3
4
5

11
5
10

COMPRESSOR WITHOUT
MOUNTING FLANGE

9
12
8 7 6

1. Discharge Service Valve 7. Oil Level Sight Glass

2. High Pressure Connection 8. Bottom Plate
3. Low Pressure Connection 9. Oil Drain Plug
4. Suction Service Valve 10. Oil Pump (See Figure 1-3)
5. Guage Connection 11. Unloader
6. Oil Fill Plug 12. Shaft Seal Reservoir

2–3 62-11052
2.4 DETAILED DESCRIPTION

2.4.1 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 2.1).
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 connection. 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.

2.4.2 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 2.2)

Figure 2.2 Suction & Discharge Valve

1 2 3 4 5

1. Valve Spring 4. Discharge Valve

2. Suction Valve 5. Discharge Valve Backer
3. Valve Plate

2.4.3 Lubrication System

Force-feed lubrication of the compressor is accomplished by an oil pump (See Figure 2.3) 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 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.

Figure 2.3 Oil Pump

62-11052 2–4
The oil 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 (1.02 to 1.22 bar) above suction pressure. When the oil pressure reaches 15 to 18 psi (1.02 to 1.22
bar) 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 oil pump. It opens 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 (1.70 to 2.04 bar) above suction pressure.
The crankcase pressure equalization system consists of two oil return check valves and a 1/8- inch pressure equal-
ization 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 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.

2.4.4 Shaft Seal Reservoir

Figure 2.4 Shaft Seal Reservoir

2
1

1. Shaft Seal Reservoir

2. Access Valve (Coreless)

The shaft seal oil reservoir has been fitted to the crankcase. The coreless access valve taps into the crankshaft
seal cavity where any oil that escapes the crankshaft seal will form. The coreless access valve then drains that
compressor oil that escapes the crankshaft seal into the shaft seal reservoir.

2.5 COMPRESSOR UNLOADERS

The compressor is equipped with unloaders for capacity control. This consists of a self- contained, cylinder head
hot gas bypass arrangement. (See Figure 2.5)
The compressor unloader system can be controlled with either a pressure actuated valve or an electrically actu-
ated (solenoid) valve.

2.5.1 Electric-Controlled Unloaders

The capacity controlled cylinder is easily identified by an electric solenoid which extends from the side of the cylin-
der head. When the solenoid energizes, the cylinder unloads allowing discharge gas to circulate as shown in Fig-
ure 2.6. 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 2.7.

2–5 62-11052
 Figure 2.5 Compressor Unloader

3
4
2 5

1. Discharge Check Valve 4. Piston Bypass Control Valve

2. Discharge Manifold 5. Cylinder Head
3. Solenoid Valve 6. Suction Manifold

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 2.6, item15) 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.

62-11052 2–6
 Figure 2.6 Electric-Operated Unloader – Unloaded Operation

4
5 7
2 3 6 11

1 10

8 12
9 13
14

15

1. Solenoid Valve 9. Strainer

2. Valve Stem 10. Suction Cavity
3. Gas Bypass Port 11. Cylinder Discharge Valve
4. Spring Guide 12. Valve Plate
5. Spring 13. Cylinder Suction Valve
6. Piston 14. Discharge Piston Check Valve Assembly
7. Piston Bypass Valve 15. Discharge Manifold
8. Bleed Orifice

c. Loaded Operation
Discharge pressure bleeds from the discharge manifold (Figure 2.7, item 15) through the strainer (9) and bleed ori-
fice (8) 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 (2) 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.
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.
Figure 2.7 Electric-Operated Unloader – Loaded Operation

4
5 7 11
2 3 6

1 10

8 12
9 13

14
15

1. Solenoid Valve 9. Strainer

2. Valve Stem 10. Suction Cavity
3. Gas Bypass Port 11. Cylinder Discharge Valve
4. Spring Guide 12. Valve Plate
5. Spring 13. Cylinder Suction Valve
6. Piston 14. Discharge Piston Check Valve Assembly
7. Piston Bypass Valve 15. Discharge Manifold
8. Bleed Orifice

2–7 62-11052
2.5.2 Pressure-Operated Unloaders
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 suc-
tion and discharge pressure is 10 psi (0.68 bar).
During loaded operation, (Figure 2.8) when suction pressure is above the valve control point, the poppet valve (4)
will close. Discharge gas bleeds into the valve chamber; the pressure closes the piston bypass valve (5) and the
cylinder bank loads up. Discharge gas pressure forces the discharge piston check valve (6) open, permitting gas to
enter the discharge manifold.
During unloaded operation, (Figure 2.9) when suction pressure drops below the valve control point, the poppet
valve (4) will open. Discharge gas bleeds from behind the bypass piston to the suction manifold. The bypass piston
valve (5) opens, discharge gas is recirculated back to the suction manifold and the cylinder bank is unloaded.
Reduction in discharge pressure causes the discharge piston check valve (6) to close, isolating the cylinder bank
from the discharge manifold.

Figure 2.8 Pressure-Operated Unloader – Figure 2.9 Pressure-Operated Unloader –

Loaded Operation Unloaded Operation

1 5 1 5
2 2

3 4 3 4

6
6

1. Sealing Cap 1. Sealing Cap

2. Pressure Differential Adjustment Screw 2. Pressure Differential Adjustment Screw
3. Control Set Point Adjustment Nut 3. Control Set Point Adjustment Nut
4. Poppet Valve 4. Poppet Valve
5. Piston Bypass Valve 5. Piston Bypass Valve
6. Discharge Piston Check Valve 6. Discharge Piston Check Valve

62-11052 2–8
 SECTION 3
COMPRESSOR REPLACEMENT
3.1 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 refrig-
erant in the unit. If the compressor will operate, pump down the unit; then, frontseat the suction and dis-
charge service valves.
b. Ensure power source is removed from any controls installed on the compressor.
c. Remove refrigerant from the compressor 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 3.1 for replacement procedures.

3.2 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.
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 3.2.1.
If the defective compressor is to be returned for overhaul or repair, install the plugs on the compressor for sealing
purposes during shipment.

3.2.1 Installing Compressor Unloaders

a. Remove the three socket head capscrews holding piston plug to cylinder head of the replacement compres-
sor. See Figure 3.1.

Figure 3.1 Removal of Piston Plug

Capscrews

Flange Cover
Gasket

Spring

Strainer Bypass Piston Plug

Seat Ring

3–1 62-11052
 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 compres-
sor; 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 cap-
screws.
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 4–1, 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.

3.2.2 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 3.5)
f. Install the compressor by reversing the procedure of Section 3.1. Install new lock nuts on compressor
mounting bolts and new gaskets on suction and discharge service valves.
g. Check oil level in sight glass (See Figure 3.2). If necessary, add or remove oil.
h. Leak test, evacuate, and dehydrate the compressor.
i. Fully backseat suction and discharge service valves.
j. Run the compressor and check for leaks and noncondensibles in the refrigerant system.
k. Check refrigerant level.
l. Recheck compressor oil level.
m. Check operation of compressor unloaders (if installed).

Figure 3.2 Oil Level in Sight Glass

PROPER LEVEL IN SIGHT GLASS

62-11052 3–2
 SECTION 4
COMPRESSOR MAINTENANCE
4.1 SHAFT SEAL RESERVOIR
The shaft seal reservoir (Figure 4.1) will accumulate up to 3.5 ounces of oil. It should be serviced (checked and
drained) at least once a year. To service the reservoir:

a. Remove the capscrew and washer that secures the reservoir to the crankcase.

b. Remove the reservoir and properly dispense of the contents.

Figure 4.1 Shaft Seal Reservoir

Access Valve

Reservoir

Capscrew and Washer

NOTE
Do not return this oil to the compressor. This oil is contaminated.Dispose this oil in an environmentally
correct manner.

c. Return the reservoir to its mounting location insuring that the neck of the reservoir is seated over the ac-
secs valve.

d. Reinstall the capscrew and washer. Refer to Table 4–1 for torque values for tightening the capscrew.

4.2 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 4–1 for torque values for tightening bolts.

4.3 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. 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.

4–1 62-11052
4.4 CYLINDER HEAD AND VALVE PLATE

4.4.1 Disassembly

! WARNING
Do not unscrew capscrews all the way before breaking seal. Entrapped pressure could result
in injury.

a. 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 4.2)

b. Remove the discharge valve capscrews, lock washers, stops, and valves.

c. 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.

d. Discard valves and gaskets.Use only new valves and gaskets when assembling cylinder head and valve
plate assemblies.

4.4.2 Reassembly

NOTE
Install only new valves and gaskets, do not interchange valves.

a. Install the discharge valves and discharge valve stops with capscrews and lock washers onto the valve
plates. Torque the capscrews to a value shown in Table 4–1.

b. Turn the valve plate over.

c. Place suction valve on dowel pins.

d. Install the suction valve spring on the dowel pins with the spring ends bearing away from the cylinder head.
(See Figure 4.3)

Figure 4.2 Cylinder Head & Valve Plate

6 4,5
7
8

12 11 10 9 8 7 6 5 4 3 2 1

1 Capscrew 5 Lockwasher 9 Valve Plate Gasket

2 Cylinder Head 6 Discharge Valve Backer 10 Suction Valve
3 Cylinder Head Gasket 7 Discharge Valve 11 Suction Valve Spring
4 Capscrew 8 Valve Plate 12 Dowel Pin

62-11052 4–2
 Figure 4.3 Installing Suction Valves

8
7
6
5

3 4
1 2

1. Valve Spring 5. Discharge Valve

2. Dowel Pin 6. Discharge Valve Backer
3. Suction Valve 7. Lockwasher
4. Valve Plate 8. Capscrew
1
3
2
4

5
6

7
8

e. Place the valve plate and new valve plate gasket on cylinder deck, ensuring that the valve plate is properly
positioned on the four dowel pins.

f. 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 4.4)

g. 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 4–1.

Figure 4.4 Checking Suction Valve

4–3 62-11052
4.5 OIL PUMP AND BEARING HEAD
The oil pump is driven directly from the end of the compressor crankshaft.

4.5.1 Removal
Remove eight capscrews and remove the oil pump bearing head assembly, gasket and thrust washer.
(See Figure 4.5)

Figure 4.5 Oil Pump and Bearing Head Assembly

Oil Pump & Bearing Head

Thrust Washer

Oil Inlet Port Oil Pickup Tube

4.5.2 Disassembly, & Inspection

If it is determined that the oil pump is not operating properly, the entire oil pump and bearing head assembly must
be replaced. Replacement parts for the pump are not available except for the cover plate O-ring. However, in the
event the pump requires inspection or cleaning, refer to Figure 4.6 for disassembly and reassembly. Clean all
parts; coat all moving parts with compressor oil before proceeding with reassembly.

Figure 4.6 Oil Pump Exploded

11 12

6
5
4
3
1 2 10

9
8
7

1 Capscrews 7 O--Ring
2 Cover 8 Oil Pump & Bearing
3 Eccentric Ring 9 Dowel Pin
4 Rotor 10 Relief Valve Assembly
5 Idler 11 Pins (2)
6 Shaft (Drive) 12 Thrust Washer

62-11052 4–4
4.5.3 Reassembly

a. Install the pump end thrust washer on the two dowel pins located on the bearing head. (See Figure 4.5.)

! CAUTION
Ensure that thrust washer does not fall off dowel pins while installing oil pump.

b. 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 re- mains 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 oil pump should mount flush with the crankcase with the “TOP” stamp on the pump oriented
straight up. (See Figure 4.12)

c. Align the gasket and install the eight capscrews in the mounting flange. Refer to Table 4–1, for applicable
torque values.

4.6 SHAFT SEAL

4.6.1 Disassembly

a. Remove 6 capscrews, remove the shaft gland plate or clutch mounting hub. Remove rotor from top of bel-
lows assembly. (See Figure 4.7)

Figure 4.7 Shaft Seal

Standard 9
Shaft Seal 6
5 10
4
3
2
1 10

6
5
4
3
2 Used with
1 Housing Mounted Clutch

1 Bellows Assembly 6 Lip Seal

2 Rotor 7 Clutch Mounting Hub
3 Gasket 8 Hub Nut
4 Stator 9 Gland Plate
5 O--Ring 10 Hex Head Screw

b. Lubricate the end of the crankshaft with clean oil.

c. Using two long screwdrivers, pry out the shaft seal but do not damage the gasket surface or the crankshaft.
(See Figure 4.8)

4–5 62-11052
 Figure 4.8 Shaft Seal Removal

4.6.2 Reassembly

NOTE
Install a new shaft seal assembly and cover gasket, with the shaft seal cover/clutch mounting hub.
Never install a used seal assembly or gasket. A new rotor should never be installed with a used stator.
When installing the seal assembly, use care not to damage the rotor or stator.

a. Remove the NEW rotor (carbon ring) from the new seal assembly. Lubricate the shaft and the neoprene
seal bellows where it contacts the shaft with clean/ fresh compressor oil.

b. Insert the NEW seal into the 05G Shaft Seal Tool (P/N 07-00460-00).

c. Slide the seal assembly/ 05G Shaft Seal Tool onto shaft until the tool bottoms out on the crankshaft.

d. Install the NEW rotor. Ensure that notches in rotor are aligned with two small knurls inside the seal seat.
Install the new cover plate and gasket.

e. Remove the old stator and O-ring from the shaft seal cover/clutch mounting hub.

f. Inspect the lip seal that is still in the cover/clutch mounting hub. If it shows any signs of damage or wear
replace it.

g. Install the lip seal into the cover/clutch mounting hub. Insure that the back side of the lipseal seats on the
shoulder machined in the cover/clutch mounting hub.

h. Using clean refrigerant oil, lubricate the new O-ring and install it into the outside groove of the new stator
being careful not to touch the sealing surfaces of the stator with your fingers.

NOTE
Do not touch the sealing surfaces with your fingers. If the sealing surfaces become contaminated,
clean with isopropyl alcohol and a clean dry lint-free cloth.

i. Install the stator into the cover/clutch mounting hub. Insure that the back side of the stator seats to the lip seal.

NOTE
The shaft seal cover or clutch mounting hub on this compressor must be oriented so that the oil com-
munication hole in the cover/hub lines up correctly with the port in the crankcase. The cover/hub
should mount flush with the crankcase with the “TOP” stamp on the pump oriented straight up.

j. Assemble the seal cover/clutch mounting hub, the gasket and the six hex head screws on to the compres-
sor, paying attention to the orientation of the cover/ hub (see Figure 4.9).

62-11052 4–6
 Figure 4.9 TOP Orientation

“TOP”

Mounting
Seal Hub
Cover

k. Align the gasket and install the six capscrews in the mounting flange. Refer to Table 4–1, for applicable
torque values.

4.7 COMPRESSOR RUNNING GEAR REMOVAL

In order to disassemble Piston, Rod and Rings, first the cylinder heads and valve plate assemblies, oil pump and
bearing head assemblies and shaft seal must be removed. (Refer to Section 4.4, 4.5 and 4.6).

4.7.1 Bottom Plate, Strainer, and Connecting Rod Caps

a. Turn the compressor over, bottom side up, and remove the bottom plate. (See Figure 4.10) Scrape off gasket.
b. Remove the oil strainer.

Figure 4.10 Bottom Plate Removal

Bottom Plate

Oil Strainer

Reservoir

Figure 4.11 Bottom Plate and Oil Strainer Removed

Oil Pressure Relief Valve
Connecting Rod and Cap

Check Valves Capscrew

4–7 62-11052
 Figure 4.12 Piston Rings Removed

TOP

c. 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 4.11)

d. 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 4.12.)

4.7.2 Crankshaft and Seal End Thrust Washer

! CAUTION
Do not allow crankshaft to drop on connecting rods inside the crankcase when removing the
crankshaft.

a. Push piston rod assemblies out of the way and remove crankshaft and seal end thrust washer.

b. Remove and check operation of oil return check valves (See Figure 4.11). The check valves are free float-
ing devices and can easily be checked visually.

c. Remove and check oil pressure relief valve (See Figure 4.11). 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.

d. Remove piston rod assemblies.

4.7.3 Pistons, Rods, and Rings

a. 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.

b. Match mark and disassemble pistons, pins, connecting rods, and caps. (See Figure 4.13)

62-11052 4–8
 Figure 4.13 Connecting Rod, Piston, and Pin

Lock Ring
Connecting Rod

Connecting Rod Cap

Piston Piston Pin Cap Screw

c. Check wear dimensions of disassembled parts to determine if they are worn beyond limits given in Table 4–2.

d. Measure side clearance between ring and ring groove in piston. Maximum dimensions are provided in Table
4–2.

e. If parts are worn beyond limits, replace them in matched sets as specified above.

f. Coat piston pins with compressor oil and reassemble pistons, pins, and connecting rods in matched sets.

NOTE
Pay particular attention to the orientation of the piston in relation to the connecting rod, and the cylin-
der they are intended for. See Figure 4.15 and Figure 4.16.

4.7.4 Seal End Main Bearings

a. Inspect seal end main bearings. Check wear dimensions to determine if they are worn beyond limits given in
Table 4–2.

b. If worn beyond limits remove seal end main bearings.

4.8 COMPRESSOR RUNNING GEAR REASSEMBLY

4.8.1 Seal End Main Bearings

a. When installing new seal end main bearings the oil V grooves are oriented towards the top of the compres-
sor with oil 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 4.14)

b. Line boring seal end main bearings.

Figure 4.14 Seal End Main Bearings

BOTTOM OF
COMPRESSOR

OIL V GROOVE

5/16 TOP OF
GAP COMPRESSOR

4–9 62-11052
4.8.2 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 4.15. When installing
contoured pistons into compressor, check suction valve and contoured piston are in the same orientation.

Figure 4.15 Piston

a. 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 4–2.

Figure 4.16 Correct Piston in Cylinder Orientation

b. 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 en- able installation of piston rings. Pistons must be
installed so 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 4.17)

Figure 4.17 Installing Piston Rod Assemblies and Seal End Thrust Washer
CHAMFERED EDGE

CHAMFERED EDGE SEAL END

THRUST WASHER

62-11052 4–10
 c. The compressor will be fitted with double ring pistons.

Figure 4.18 Piston Rings

Compression Ring

Compression Ring
d. The compression ring is chamfered on the inside circumference. This ring is installed with the chamfer to-
wards the top. Stagger the ring end gaps so they are on opposite sides of the piston.

4.8.3 Crankshaft and Seal End Thrust Washer

a. 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 and bearing head assembly. The seal end thrust washer
is positioned just ahead of the seal end main bearing on one dowel pin installed in the crankcase. Both
thrust washers should be inspected for wear and scoring before reassembly. (Refer to Table 4–2)
b. Install the seal end thrust washer on the dowel pin. (See Figure 4.17) 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.

4.8.4 Bottom Plate, Strainer, and Connecting Rod Caps

a. 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 4.19)
The ring compressor can be easily fabricated from a piece of sheet metal.
b. 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 locating pins. Torque cap-
screws to torque value shown in Table 4–1. Ensure freedom of movement of crankshaft after capscrews are
torqued on each rod cap.
c. Check operation and reinstall check valves and relief valve. (See Figure 4.11) 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 wire to ensure that the spring mechanism can be depressed.

Figure 4.19 Installing Pistons

4–11 62-11052
 d. Clean and reinstall the oil strainer.

e. Using a new gasket, install the bottom cover plate. See Figure 2.1 for relative location of compressor
mounting flanges. Torque cover capscrews, in a diagonal pattern, to the torque value shown in Table 4–1.

f. Reassemble the cylinder head, oil pump and shaft seal (Refer to Figure 4.4, 4.5 and 4.6).

4.9 SUCTION STRAINER

NOTE
The suction strainer has been preformed to fit into the suction cavity.

Remove and clean the suction strainer (See Figure 4.20) Check it for damage. If it is damaged, replace suction
strainer. Install suction strainer and suction service valve using a new gasket.

Figure 4.20 Installing Suction Strainer

4.10 ADDING OIL

Add the proper oil charge to the compressor through the oil fill plug. Refer to Section 3.2.2 for the required oil
charge. Refer to unit operation manual for other methods of adding oil to compressor.

4.11 INSTALLING COMPRESSOR

Refer to Section 3.2.2 and the unit service manual to install the compressor.

62-11052 4–12
 Table 4–1 Torque Values

DIAMETER THREADS TORQUE RANGE

USAGE
(INCHES) PER INCH FT –LB MKG
1/16 27 (pipe) 5.5 to 7 0.8 to 1.0 Crankshaft Center Web Plug
1/8 27 (pipe) 8 to 16 1.1 to 2.2 Oil Return Check Valve - Crankcase
7/16 20 8 to 14 1.1 to 1.9 Oil Fill/Drain Plug
1/4 20 (pipe) 20 to 25 2.8 to 3.5 Pipe Plug - Gauge Connection
8 to 12 1.1 to 1.7 Connecting Rod Capscrew
1/4 20
10 to 13 1.4 to 1.8 Connecting Rod Counter Weight
5.5 to 7 0.8 to 1.0 Crankshaft Setscrew
1/4 28 8 to 18 1.1 to 2.5 Unloader Valve
12 to 16 1.7 to 2.2 Discharge Valve Backer
16 to 20 2.2 to 2.8 Cover - Oil Pump
5/16 18
20 to 30 2.8 to 4.1 Discharge Service Valve
8 to 15 1.1 to 2.1 Oil Reservoir
Bottom Plate - Crankcase
End Flange - Crankcase
3/8 16 30 to 50 4.1 to 6.9
Shaft Seal Cover
Pump End Bearing Head
42 to 55 5.8 to 7.6 Cylinder Head
1/2 13 55 to 80 7.6 to 11.1 Suction Service Valve
1-1/2 18 NEF 35 to 50 4.8 to 6.9 Oil Level Sight Glass

4–13 62-11052
 Table 4–2 Wear Limits
MAXIMUM WEAR
FACTORY MAXIMUM FACTORY MINIMUM
PART NAME BEFORE REPAIR
INCHES MM INCHES MM INCHES MM
SEAL END
End Play (Seal Removed) 0.034 0.8636 .013 0.3302 -- --
Main Bearing Diameter 1.8760 47.6504 1.8754 47.6352 .002 0.051
Main Bearing Journal Diameter 1.8732 47.5793 1.8725 47.5615 .002 0.051
PUMP END
Main Bearing Diameter 1.3761 34.9529 1.3754 34.9352 .002 0.051
Main Bearing Journal Diameter 1.3740 34.8996 1.3735 34.8869 .002 0.051
CONNECTING ROD
Connecting Rod Diameter 1.3768 34.9707 1.3760 34.9504 .0020 0.051
Piston Pin Bearing 0.6883 17.4752 0.6878 17.4701 .001 0.0254
CRANKSHAFT
Crankpin Diameter 1.3740 34.8996 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 2.001 50.8254 2.000 50.800 .002 0.051
Piston (Diameter) -- -- Figure 4.21 .002 0.051
Piston Pin (Diameter) 0.6882 17.4803 0.6877 17.4676 .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

Figure 4.21 Piston Dimension (Wear Limits)

1.988
1.994

1.9960
1.9968

62-11052 4–14
 INDEX

A P
Adding Oil 4-12 Pistons, Rods, and Rings 4-10
Pressure- Operated Unloaders 2-8
B Proper use and storage of Polyester 2-2

Bottom Plate 4-7, 4-11

R
C Running Gear Reassembly 4-9
Running Gear Removal 4-7
Compressor Reference Data 2-1
Compressor Removal 3-1
Compressor Replacemene 3-1
S
Compressor Unloaders 2-5 Seal End Main Bearings 4-9
Connecting Rod Caps 4-7, 4-11 Seal End Thrust Washer 4-8, 4-11
Crankshaft 4-8, 4-11 Service Valves 2-4
Cylinder Head and Valve Plate 4-2 Shaft Seal 4-5
SHAFT SEAL RESERVOIR 4-1
D Shaft Seal Reservoir 2-5
Specific Warning and Caution Statements 1-1
Detailed Description 2-4
Strainer 4-7, 4-11
Suction And Discharge Valves 2-4
E
Suction Strainer 4-12
Electric-Controlled Unloaders 2-5 Suction Valves 4-3

F T
First Aid 1-1 Torque Values 4-13

G W
General Description 2-1 Wear Limits 4-14
General Safety Notices 1-1

I
Inspection and Preparation for Reassembly 4-1
Installing Compressor 4-12
Introduction 2-1
Introduction to Compressor Maintenance 4-1

L
Lubrication System 2-4

M
Maintenance Precautions 1-1
Model 05G Compressor 2-3

O
Oils 2-2
Operating Precautions 1-1

Index–1 62-11052
North America Central America and Mexico
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Athens, GA 30601 USA 11320 Mexico, D.F.
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Carrier Transicold
P.O. Box 4805
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A part of UTC Building & Industrial Systems, a business unit of
United Technologies Corporation. Stock Symbol UTX. www.carrier.transicold.com