Carrier . Compressors and Condensing Units Open, Water-Cooled Fig. 1 — 5F,H Compressor Unit Fig. 2 — 5F,H Condensing Unit Table 1 ~ Physical Data Sr 60 | san | sis | suen | snes | swgo | sues | srz0 suas o..5 ‘COMPRESSOR UNIT AND NI TREFRIGERANT COMPRESSOR DATA ox Rem Mio Rpm Min. Rpm Cop. Control oT 5F20 | 5F30 | SF40 4 ptt 1750 400 froquited for proper lubrication) 600 | 709 | 900 | 900 | B00 | 800 | 900 _| 900 | 110 ~ OT Charset (on (PPIBA] 5° |-S3 Tt a we Te Pa a a -wuee-- 4 = ve ret High Pr ‘Switch? ~ 7 oo (Cutout — Cut-in) | 7 0 el (Cut-in — Cutout) ‘ oe ee eet toa BamHI) ORAL GH ceaaaieeeaa fel sai |ova [on A aH i) ee 404 OF BST 15a 3 a5 Pe 43 | 2 jms | iow Opst Prods t oe *Gilrcharge for duplex compressor anit - — "S00 Tabled for typical pressure switch settings unit ~ ie ss snd bia. 0 {[Shollondoilcondansrs All other BF con OWL CHARGE Gis) a7 | TP BE fm | ia ‘demsrs sr shell and ube Naval if esos shown fh Physi Oat tble so above ation presi; ia TUCOndenae stra capacity 80 parent led Dreeaure ditferontal betwenn suction presure and dscharge pressive ool BUTS ‘with liquid retrigerant at 90 F © carrer Corsoration 1960 m SFISREFRIGERANT CHARGING Evacuate, Dehydrate and Leak Test the entire refrigerant system by methods described in Carrier Standard Service Techniques Manual, Chapter I, Sections 1-6 and 1-7. Use sight glass method to charge system. See Section 1-8 of Service Tech- nigties Manual for details. LEAK TESTING 1. Charge system with dry nitrogen or carbon dioxide to 40 psig and use soap bubble test to find large leaks Charge system to 10 psig with R-12, then add dry nitrogen or carbon dioxide until system pressure is 150 psig. Check for leaks with a halide leak detector. holding saturated condensing pressure constant at 125 F (air-cooled systems) or 105 F (water-cooled systems). Add additional refrigerant to fill con- denser subcooler coils, if required SF,H Condensing Units — After clear sight glass is Spiained aT charge until liquid. refrigerant reaches condenser liquid level test coc SF.H Compressor Units — See condenser data for Eiitional charge required to fill subcooter INITIAL START-UP Crankease heater should be energized a mini- mum of 24 hours before starting unit Ensure that motor rotation direction is same a arrow direction on compressor oil pump cover SPH Installation Instructions for Motor Rotation. ‘Check to see that proper oil level appears in compressor sight glass. Oil level should be 1/3 to 2/3 up on sight glass. Open water supply valve and allow water to reach condenser. Open pressure line valve of water regulating valve (if used). (Turn condenser fan on when the compressor unit is applied with air- cooled condenser.) Backseat (open) the compressor suction and discharge shutoff valves; open liquid line valve at receiver. ‘Start evaporator fan or chilled water pump, To Start Compressor — Close main power switch supplying current to compressor motor. Recheck oil level, and check oil pressure (oil pressure should be 45-55 psig above suction CHECKING OPERATIONS. Refer to Carrier Standard Service Techniques Manual, Chapter 2, for complete instructions on checking electrical components, Dual Pressurestat (Fig. 3) — High-pressure safety switeh is checked by throttling condenser water or blocking air flow on air-cooled units, allowing head pressure to rise gradually. Check discharge pressure constantly throughout — procedure. Compressor should shut off within 7 psi of values shown in Table 2. Check low-pressure switch by slowly closing suction shutoff valve. A decrease of suction pressure will follow. Compressor should shut off within 4 psi of values shown in Table 2. gH PREssune Low prescune ren swine Sater swrrcH \ RANGE ADJUSTMENT® TURN Clockwise 79 RAlSE BOTH EGHSIN AND cUToUT oorrenenma., anusrver'—ruRN SERA to SEER ou CBven e SETTING WITHOUT CHANGING THE foie trie aguesipsi/ TURN "nga -22es1/ TURN USM P28 TURN, tow SeSi/ TURN, Fig. 3 — Dual Pressurestat Typical Pressure Switch Settings TT PRESSURESTAT Set e “TWaterCooled [| 175 | 12 AinCooled 5 Water Cooled | Air-Cocled REFRIG. ERANT | ile 1 for pressuretat adjutant Oil Pressure Safety Switch (Fig. 4) may be checked by moving contact arm, on left side of switch, forward. Compressor should stop in approximately 45 seconds. (If compressor continues to run, check wiring to safely switch. If wiring is correct, the switch is faulty and should be replaced.) After, completing test, press reset button on. front of safeiy switch and restart compressor. {Allow 3 miautes before attempting to reset switch.) Check oil level in compressor sight glass after 15-20 minutes of operation. If oil level is low, add oil according to methods described in Standard Service Techniques Manual, Chapter 1, Section Ill CAPACITY CONTROL ADJUSTMENT (5F40 thru 5H126) If the system is to use R-22 or R-502, replace 7b range adjusting spring in capacity control valve with the [T-lb spring supplied with compressor. (Refer to instzuction tag for spring replacement.)REsIgTANCE contact nw PSH comecr BT |Series wie Ge ZoNTmOL cincur ve REFER TO Un Laser Grate Bachan lot pressure. ESiNecriON TO ae Bi FUME, Tow, pRessune BiscHaRGE eotnestion Fig. 4 — Oil Pressure Safety Switch An external adjusting stem (Fig. 5) is provided to set control point (suction pressure at which first step of cylinder unloading occurs). Control point is, adjustable from 0 to 50 psig (R-12 and R-500), and from 0 to 85 psig (R-22 and R-S02). One full turn (clockwise) of adjusting stem will raise control point approximately 6 Ib with R-12 and R-SO0 or 10 Ib with R-22 and R-502. Control oil pressure is an indication of cylinder loading condition of compressor. (Install a gage in control oil pressure gage connection, See Table 3.) Adjusting Control Point I. Load compressor until suction pressure is above desired control set point. 2. Reduce compressor suction pressure to control point pressure by slowly closing suction valve. 3. At control point pressure, turn adjusting stem in clockwise direction until first step of unload- ing takes place (observe change in control oil pressure, current draw, and change in sound of compressor), tric Rance: Cournot AONE wens) SoNNECTION\ SPRING Sai exreRNat soyagrins L rene ‘when compressor is received the capucty contotadusting stern Wall be backend (Compresior wil be fully Toaded under all ‘conitions) Fig. 5 — Capacity Control Valve Table 3 — Control Oil Pressures for Cylinder Loading and Unloading [APPROX CowPRessoR |sTEP* | 340,60; 5140.46, 60,66,80, 0,126 S H120 and SH126 Canvey co 7 T 7 2 A After completing step 3, the control point is set. Thereafter the compressor will be fully loaded when suction pressure is 3 psig (4 psig with R-22 and R-S02) above control point, and be fully unloaded when suction pressure is 4 psig (7 psig with R-22 and R-502) below control point. F20 and 5F30 capacity control (Fig. 31) packages available as an accessory for use with R-12 and R-500 or R-22 and R-502. When accessory package is received, capacity control adjusting stem will be backseated, and compressor will be fully loaded under all conditions. Adjust control set point same as shown above for P40 thru SH126 compressors. 50,88, : Fig. 6 — Cylinder Unloading SequenceOIL FILTER SH40 thru SH86 compressors have bleed-type, high-pressure, throwaway filters (Fig. 7). A yearly check should be made for a clogged filter. To replace the filter: 1. Close oil line shutoff valves on both sides of the filter. 2. Remove and repla valves ou. euteR, fousine PEE onirice evv0w Fig. 7 — Oil Filter (5H40 thru 5H86) 6H120 and 5H126 — Replace full flow oil filter (cartridge) after first 200 hours of operation. After filter change, a yearly check should be made for a clogged filter. The difference in oil pressure before and after filter should not exceed 5 psi. See Fig. 15, for SH120,126 Oil Filter assembly. Pump down SH120 and SH126 before removing filter CONDENSER MAINTENANCE. Local water conditions can cause excessive fouling or pitting of condenser tubes. If such conditions are anticipated, a water treatment anal- ysis is recommended. Refer to Carrier System Design Manual, Part 5, for general water condi- tioning information, To inspect and clean condenser, drain water and remove condenser heads. (Condenser heads not removable on 5F20 and SF30 shell-and-coil con- densers.) To drain condenser, shut off water supply and disconnect inlet and outlet piping. Remove drain plugs and vent plug, With condenser heads removed, inspect tubes for refrigerant leaks with a halide leak detector. (Refer to Carrier Standard Service Techniques Manual, Chapter 1, Section 1-6, Leak Testing, for instructions.) If condenser heads are not removable (SF20 and 5F30), test water for traces of refrigerant. A Micro-Baffle pass partition gasket (Fig. 8) on shelland-tube condensers seals the water passes. When replacing a damaged gasket, be sure to plai new gasket in correct position. ee ang Ber Seater on Fig. 8 — Typical Location of Pass Par Clean Condenser Tubes (on shell-and-tube con- densers) with a nylon brush (available from Carrier Service Department). Flush water thru tubes while cleaning. Do not use brushes that will scrape or scratch tubes, If hard scale has formed, clean tubes chemically. All 5F20 and 5F30 shell-and-coil con- densers must be cleaned chemically. Chemical cleaning solution — use inhibited hydrochloric acid solution (OAKITE 32). Handle acid cautiously. Clean condenser by gravity or forced circulation (Fig. 9 and 10). For average scale deposits, allow acid solution to remain in condenser overnight; for heavy deposits, allow 24 hours. Drain condenser and flush with clean water. 9 Protect Condenser From Freezing where ambient is below 32F by draining water from system or adding antifreeze to water. If condenser water is drained, used compressed air (150 cfm at 1/2 to one psi) to remove any remaining water. Use same size air connection as condenser water supply connection. Blow air into coils thru condenser water supply for 15 minutes and thru return connections for 15 minutes. FILL, CONDENSER WITH CLEANING SOLUTION. 00 Nor #09 SOLUTION MORE RAPIDLY THAN VENT CaN EXHAJST Gases CAUSED BY Ghewical AcTion ae | [Pre q pire 8 APPROX sro« —concensen L- Fig. 9 — Gravity Circulationcenvayruca, uve cas vert—=f c1ose vent rime { I 2. For replacement items use Carrier specified SO'GPIE aT 38'HEAD cine fae nee parts, See Carrier SE,H Specified Parts list for PRIMING /VALVES. TY RUNKING. ‘compressor part interchangeability, [ — A) 3. Before compressor is opened, the refrigerant sucTion “ must be removed from it by the pumpdown | rue method. | seshial ‘CONDENSER a, Start compressor, close suction shutoff | valve, and reduce crankcase pressure to 2 Ld Ze, \ psig. (Jumper low pressurestat.) rast AJ) noe waren b. Stop compressor and isolate from system by J closing discharge shutoff valve. ya . Bleed any residual refrigerant. Drain oil if Fe Mesa \4 necessary, Screen 4. After disassembly, clean all parts with solvent. { : : Use mineral spirits, white gasoline or naptha } eee eee ee 5. Before assembly, coat all parts with compressor oil and clean and inspect all gasket surfaces. Benen CoNEONENTEE: Replace all gaskets with mew factory-made gaskets, and coat with oil. See Table 4 for Service Notes torque values. 1. Where compressor components are shown they 6. After reassembly, evacuate compressor and are in normal order of removal from open suction and discharge valves. Restart com- compressor. pressor and adjust refrigerant charge CHLINDER HEAD GnskeT 2 VALVE PLATE: ag Sa uw eno cover uw eo kD cowrnoe DiscHanse vaLvE. . BEARING HEAD TROVE asSeniavy Inver Sea _—-vauve pare casker — RSSEMLY \ une END COVER GaoKeT wat wove cover Bn ON Swarr seat a cover Pare PUMP ENO BEARING WASHER - ee \ a By, seat SPRING end S&S.E ow FiureR screen“ z 4 2 ano HOLE ? . COVER GASKET a a ~~ waNo HOLE covER~ . S Fig, 11 — 5H Compressor Components (External) 5Onsen RING (OIL) PISTON PIN CYLINDER SLEEVE a eal f= riston pin vocx ine piston Shae ane Yo Cm an con \ UNLOADER SPRINGS-=A CONNECTING ROD ve o ae : uncoaoer , t UNLoAGEM SLEEVE S00" Seanine uytooen enackeT —ae” 7 ehseer connecTiNG aia exe CONNECTING ROD BOLTS ASSEMBLED Piston AND — CONNECTING ROD SEAL END BEARING MASHER ‘CRANKSHAFT seat eno THRUST WASHER Fig. 12—5H Compressor Components (Internal) e 6Table 4 — Torque Values SF UNITS 3H UNITS (Con) rroRave Sze Woraue { Tare ans| wane USAGE Sri THREADS "ote UsAce | | tenth ind tab) Pip Flag — Pomp End OT Pop Cover = Pon En ; 20-28 | Beoring Head 16-20 Paecring Heed } va 20-25 |Pipe Plug ~ Cronkshat capecity Control Valve ~ Puma Pigs Plog ~ Scetonan | 16-20 |PRE BL ring ea 20-25 |" Schr Hasiel Ea - se] oe agniigy Corel Yoke ~ Pune 5 1015 [Ugloades Power Ele | 16-20 [AP S00 Mood : feseere ye ch ae 16-20 |aniols CoverPlote~Cronkcase tants |Ustovder Cylinder Cover Plate ~ 2 ¢ Usioader Cylinder Bracket lWxloader Power Element = 1 piscoige Valve Cop Screw ~ [encase Om ; ner pacity Cantral Valve = Pump vee Discharge Voive Guide Assembly End Cover Valve Plate se Discharge Valve Guide Assembly | Vales Plate JO: Pump Cover ~ Pump End Booring Hood JAuxiliary Control Valve Cover — Valve Bodh Pischorae Valve Guide ~ toner i Icylinder Bracket I ISAS” | Coonan Rod Balt = Usclaar . Se ae Paiy End Baane gen ral ve "feos rig Perea ——— eee Pg —Crato _ | - sa Silay fo ese | . eee as 3 2 mm Sie ee Bi Ivctcn and recharge Wars els in wea esom Pete ~ Crone Peerage Montes ying - ee aio Retold sce es m6 Cl eee sti iss eee oe ay Scena ead Pee Bae ond te Cer Corkcose Pw End Cover and Porp End _ B Mose Oaks Pe ea ese sf Beli Ml = Coe oi Pe | ee ee Ser, Casa vane i ieee | y Pees Peace Ps d= Ree EF eons wena Pease Toe ra v2 3 onkcose v2 [Pressure Relief Valve — Suction } Pischorge Service Valve ‘ond Discharge Manifold Cover — ee Pepente elit Valve = | 58 ‘Stay anf —4 i 4 [Magnetic Plug — Cronkcose a ‘on rge Manifol [Magnetic Plug — Pump End rankepse Bess ne va pian Com cn _| Pie 6078 OH ovr leod TSuction onifold Cover ond | ors Mesende lave Adopter ~ eee TS eee see tes ale aes Wiagrcne Pon Pune End sors (Cpe ceg = fone — nc matt Wale Adopter ~ 041 Relief Volve Assembly — 60-75 encase 60-75 [01 Bypore Plus ~ Cronkoooe - cap a mess Bla ieee wa LEtyehosl 6078 Oe Hod Oi ype Pg Pome End | 1.72] 18 N e land Hole Cover s/o | ve | 60-75 |Cowte ° Nod ae eal ee Conar= tno [Hl Lac Scww—Pamn Eat | oy Pegs Reo Valve | 45-55 | Crankcase SH UNITS Tocas {Pipe Plug > AustTiary Control Pipe Plog - Porip End Beoring Hood Tionkegae 7 Pipe Plog ~ Pump End Cover Oil Pomp Gover ~ Pump Ead Ayniliony Control Valve Cover — Vie) Rive | 10-18 aa V8 | Pipe | 15-20 TY 20225 TBipe Pics va 20-28 | Pipe 20225 | Pipe Pug = Crankshaft 12-16 | Bearing Head Va} 28) 8-12 | Yelve Body 8-12 Spocio! Cap Serew ~ Auxiliary ‘Control Valve Body 80-90 |Cap-Oil Pressure Relief Valve Seal Plug ~ Pump End Beoring Food? [Pino Plug ~ Crankeose Bipe Piug ~ Cronkcase — Sight Glass Clamping Gland —— Ayullony Conteal Walvis Caver= Valve Body NEF ~ National Exta Fine Mond Hole Cover | ITable 5 — Wear Limits — 5F,H Compressors ‘COMPRESSOR PART Compressor ~~ sti, 60, 7 Factory. Allowable | __ Tolerances (In Moat (ns) tox Min va 7 Max Alle we SEAL END Main Beating Diam Journal Diam ~~ PUMP END Moin Bearing Diom Journal Diom | ‘CENTER (3i180,86, 120,126) Main Bearing Diom Main Bearing Thickness Journal Diam CONNECTING ROD Bearing Diam Becring Thickne Crankpin Diam : CRANKSHAFT ~ Throw THRUST WASHERS (Thickness) Seol End Pump End CYLINDERS Bore Piston Diom Weist Pin Diam Wrist Pin Bushing Piston Ring End Gop (comprossion ond oil) 2501 7507 ov Drive Shaft Diom Drive Shalt Bushing Diem (10) Drive Shaft Diom (SH120 & 126) Drive Shaft Bushing Diam | (iD ~ 5H120 & 5H126) sicTION VALVE Suction Velve Dise {dopth of woor below face) Suction Valve Seat 13 for Dim. A*) DISCHARGE VALVE Discharge Valve Dise (depth of wear below face) Discharge Valve Soot i (e00 Fig. 13 for Dim. 8**) 7 50 ana 560 “Replace thrust waters when snd clearanea exceeds 035 ia {Return assomblies for factory exchange 2 2 626 02 20 03 er 03 0} oot x0 (003 g {PMinimum helght of dimension A before replacing cylinder leave fe OID inches “+ Minimum nelght of dimension B befor replacing valve plata and scharge value inne sat fe O10 facesSUCTION VALVE SEAT ovuinoer - a CYLINDER SLEEVE OUTER DISCHARGE SALE Sear INNER DISCHARGE ) VALVE PLATE 13 — Suction and Discharge Valve Seat Height LUBRICATION SYSTEM Oil Pump (All models except current SH120 and 5H126 units with gear rotor oil pump.) Drain oil below level of pump end bearing head. Remove bearing head — complete end bell assembly must be removed on SH40,46,60,66,80, and 86 Models. Check oil pump rotor for end ‘play. Maximum, allowable movement of rotor is 0025 in, (Table 5). If there is excessive end play, reposition oil pump bushing in bearing head. (See Oil Pump Bushing). Turn rotor; if there is more than a slight drag, remove pump cover and disassembly oil pump. Cheek all parts (Fig. 14) for wear and damage. BRONZE BEARING WASHER MW a 4 pee ¢ a \, - | (MAGNETIC? OIL PRESSURE CONNECTION CRANKCASE PRESSURE CONNECTION OIL PRESSURE CONNECTION fhewove Fon AGCESS TO CONTROL OIL STRAINER) Inspect oil pump bushing for scoring. Replace bushing if scored. \f bearing head is scored, replace complete bearing head and oil pump assembly. il Pump Bushing INSTALLATION ~ Press new bushing into pump end bearing head with small end toward pump. Locate bushing oil groove at top of bearing head. POSITIONING (Fig. 15) 1. Place .001-in, circular shim against bushing and install pump. (Shim between bushing and oil pump rotor.) Complete assembly of oil pump. WARNING: Be sure oil pump assembly is flush with cover plate surface but does not protrade beyond bearing head surface. 3. Seat bushing against shim by tapping it with a cylindrical positioning tool (field-fabricated, Fig. 15) 4, Disassemble oil pump and remove shim. 5. Reassemble oil pump and check for binding, 6. Install bearing head to compressor. Line up tang on oil pump rotor shaft with slot in end of crankshaft. Ensure that off pump has. proper rotation. 7. Refill compressor oil to proper level. Observe oil pressure when starting compressor If correct pressure (Table 1) is not reached in 8-12 seconds, siop compressor and recheck oil pump. PUMP END BEARING HEAD O1L PUMP ROTOR O1L PUMP (OLER lL PUMP COVER GASKET ROTATION ARROW L— PUMP, COVER 20 ° 4 w~ ~~ Fig. 14 — 5F Oil Pump Assembly7) ost ONIN Foe (rien. FRGREATEDY Vy A_g 1 Fig. 15 — Setting Oil Pump Bushing (5H40 Bearing Head Shown) Gear Rotor Oil Pump (Current SH120 and 511126 Models) — Remove bearing head and oil pump cover. Disassemble oil pump. Check all parts for wear and damage. Check position of oil pump bushing and inspect bushing for scoring. Replace bushing if scored. If bearing head is scored, replace complete bearing head and oil pump assembly. To reposition oil pump bushing: reinstall oil pump into bearing head with 1/64in. shim be- ‘tween port insert and oil pump cover. Install oil pump cover without gasket during this procedure. Press bushing into bearing head until port insert seats against shim. Remove shim and_ install assembled head to compressor. Ensure that oil pump cover gasket is replaced. Oil Pressure Regulating Valve (nonadjustable, Fig. 17) is located on the side of compressor adjacent to seal housing, Regulator is important in main- taining correct oil pressure (Table 1) and satis factory unloader operation. Unscrew regulator from crankcase; use 5/16-in. allen wrench on all compressors except SH120 which requires 1/2-in, allen wrench. Be sure regu- lator is not clogged or the plunger is not stuck, Check drillings to regulator for fouling. The nonadjustable oil pressure regulator is interchangeable on all current SF,H compressors except 5H120 and SH126 Models, (Models SH120, 126 are equipped with nonadjustable regulator of larger size.) Early SF.H compressors were equipped with an adjustable type oil pressure regulator. When necessary to replace an adjustable type regulating valve, replace it with nonadjustable type. Oil Return Check Valve (SF20 thru SH86) allows oil to return from suction manifold to crankease. It is a normally open valve and will close when crankcase pressure becomes higher than suction pressure. ‘Two disc type check valves (Fig. 18) on SF20 and SF30 compressors are located beneath parti- tion between suction manifold and crankcase, one on each side of compressor. They can be removed thru bottom cover or pump end of compressor. Leaf type check valve (Fig. 18) on SF40,60; 5H40,46,60,66,80,86 compressors is accessible thru, and located at top center of hand hole cover opening. Remove check valves and check to see that flutter valve or leaf is not sticking and that it seats tightly. PUMP END BEARING HEAD lt FILL PLUS OLL PRESS GAGE. CONN. (heTen FILTER) lL FILTER COVER on FuteR: ove Olt FILTER SPRING BUMP INTAKE PLUG (MAGNETIC) SPRING RETAINER CAPACITY CONTROL VALVE ADJUSTING STEM {CONTROL OIL PRESS. GAGE CONN DRIVE vise OUTER GEAR iP GEAR COVER GASKET [sg bag Se lL PRESS. GAGE CONN. (BEFORE FILTER) Si FILTER Fig. 16 — Oil Pump and Filter Assembly (5H120,126) 10[ / T 1, REGULATING casket ol, aesut arin Save B09" Shiver ea Fig. 17 — Oil Pressure Regulating Valve (Nonadjustable) Ye ANSON ise TYPE. ¥ 9 Fig. 18 — Oil Return Check Valves Centrifugal Oil Separator on SH120,126 is mounted on crankshaft (Fig. 35) and provides for oil return to compressor crankcase. For oil separa- tor removal and replacement instructions, see Crankshaft section. Oil Screen (Fig. 11) in compressor crankease is, accessible thru hand hole cover or bottom plate, Remove and inspect it for holes and dirt. Clean it with solvent and replace. PRESSURE RELIEF VALVES Pressure relief valves relieve refrigerant pressure from high to low side at a pressure differential of 400 psi. Check relief valves for evidence of leaking. Change if defective or if valve has been opened due to excessive pressure BFGO Compressor (starting with Serial No. 9452380) internal relief valve screws into erank- case and projects up thru left cylinder bank valve plate (Fig. 19), Use a standard socket type screw- Griver to remove and replace valve. 5H40, 46, 80, 86 Compressor pressure relief valves are located on suction and discharge manifold cover (Fig. 20). Fig. 19 — Pressure Relief Valve (5F60) DISCHARGE MANIFOLD. _ Aen PRESSURE RELIEF VALVE \ . suerioN ano oiscuaRce . Fig. 20 — Pressure Relief Valve and Suction Strainer (5H40,46,80,86) 5H6O and SH66 Compressor relief valves located in wall between suction and discharge manifolds. Remove discharge manifold for access to relief valve. Use elongated 1-9/16-in. socket (Fig. 21) to remove valves on compressors prior to Serial No. 510001. Use a standard 1-1/2-in. socket to remove and install relief valves on current models, \Astanoano socker chr iw Hace WRENCH ENO Hex socker ae 200 STEEL TUANG 2F Lone THESE suRraces 70 oe WELDED Fig. 21 — Elongation of 1-9/16-in. Socket 5H120 and 5H126 Compressors are equipped with external relief valve mounted on bypass line between suction shutoff valve and discharge mani- fold. To remove valve, remove bolts from flanges on either side of valve.CLEANING SUCTION STRAINER, To withdraw strainer: On SF20, 40, 46 Models — remove suction and discharge manifold cover on seal end of compressor; $F30 — remove suction service valve; 5F60 and SH60, 66 — remove suction manifold and withdraw 2 strainers; 5H80, 86 remove suction manifold cover. On SHI20 and SH126 Models, remove one suction manifold plate at a time so as not to disturb position of detachable suction manifold and suction line, Withdraw 2 suction strainers. Clean strainer with solvent or replace if broken, or corroded. Do not damage suction strainer when replacing. On SH120 and 5H126, ensure that strainer bail is, compressed by positioned manifold cover plate. If bail is too short, grasp on side and elongate it enough to be compressed by manifold cover Position bail between the 2 bosses on inside of manifold cover (prevents strainer from turning). CAUTION: If a felt sock filter is installed, semove and inspect it after 50 hours of oper ation. Clean filter if required and replace it for another 50 hours. Remove sock when system is clean. CYLINDER HEADS Remove cylinder heads. Check heads for warp- ing, cracks and damage to gasket surfaces. SUCTION AND DISCHARGE VALVE ASSEMBLY (Fig. 22) ' sales ace. | DISCHARGE vaLvE 7 gape | BEAR gage / ZL Bie gene a VALVE, SEATS \ Fig. 22 — Suction and Discharge Valve Assembly Disassembly-Inspoction — Remove ¢ylinder head Loosen cap screws holding discharge valve seat to discharge valve guide, and cup screws holding valve guide fo valve plate. Remove cap screws holding valve plate to cylinder block. Remove valve plate from cylinder block, and discharge valve guide from valve plate. Inspect suction and discharge valve dises and valve seats for cracks or excessive wear (refer to Wear Limits, Table 5). Check cylinder deck valve stops for uneven wear. Replace valves if cracked or worn. If valve seats are worn, replace complete valve plate assembly. If cylinder deck valve stops are worn, replace compressor. Reassembly — Pistons must be below tops of cylinder sleeves, (Turn crankshaft or force pistons down). 1, Place suction valve springs in valve plate re- cesses. (Large spring coil should be in full contact with bottom of recess.) 2. Place suction valve dise on valve springs; press dise into valve plate recess. Slide valve retainer clips" into place (Fig. 23). Locate clips so they. do not cover valve lifter springs or pins. 3. Bolt valve plate to cylinder block. Remove valve clips 4, Place discharge valve springs in discharge valve guide spring recesses. 5, Place discharge valve disc over springs, and fit inner seat i. place over valve disc. Hand tighten bolts holding inner seat to valve guide (valve guide assembly) 6. Place valve guide assembly on valve plate. ‘Tighten all bolts and bend tabs on lock washer and lock plates. Replace cylinder head. VALVE PLATE SUCTION VALVE DISC SUCTION VALVE CLIPS Fig. 23 — Valve Clips in Place “Vat retainer clips 520-2061 (SF compressors) or SH40.2061 (SH compressors) ar field sunpliedCYLINDER AND UNLOADER SLEEVES Disassembly-Inspection — Remove cylinder head, suction and discharge valve assembly, and pump end bearing head. Whenever cylinder sleeve or valve plate is replaced, use a new suction valve disc. 1. Turn crankshaft until piston is in midposition. 2. Insert a sleeve puller into cylinder and push it down on to top of piston 3. Tighten nut on top of sleeve puller to expand puller in sleeve. 4, Turn crankshaft, forcing sleeve upward until it can be removed. 5. Remove unloader snap rings (SH compressors only). Disassemble unloader sleeve, pins and springs. Examine bore of sleeve for wear. Check suction valve seats for scratches and wear. Check unloader sleeves, pins and springs for wear and freedom of movement. Reassembly — When new rings are being installed in a used cylinder sleeve, break the hard, glazed surface of cylinder sleeve to reduce wearing-in period of new rings. Use No. 80 emery cloth or rehone lightly. Clean sleeves thoroughly after breaking glaze. 1, Rotate crankshaft so piston is at top center. 2. Lubricate piston rings and beveled surface at lower edge of cylinder sleeve. 3. Stagger ring gaps around piston. 4, With turning motion, work sleeve over piston and rings. Compress and align cach ring with beveled edge of sleeve. 5. Seat sleeve in suction manifold partition and oylinder deck recess. 6, Rotate sleeve so any 2 valve lifter pin holes lie equal distances from longitudinal axis of com- pressors (Fig. 24), In this position lifter pins line up with suction valve springs. CAUTION: Never operate compressor with valve plate off unless cylinder sleeves are fastened in place with cap screws and washers (Pig. 24). cap sonews, SRD Naghets Fig. 24 — Position of Cylinder Sleeves CONNECTING RODS, BEARING INSERTS, PISTONS, PISTON PINS, RINGS Remove cylinder head, valve plate, and hand hole cover or bottom plate. Connecting Rod and Piston Assembly Removal (Fig. 12) — Remove connecting rod caps. (Label caps and rods s0 they may be reinstalled in same places on crankshaft.) Remove cylinder sleeve, connecting rod, and piston assembly together by pushing assembly up thru cylinder deck. Do not allow piston to come thru top of sleeve during removal process. Disassemble connecting rods from pistons by removing retaining rings and piston pins. Remove 2 compression rings (plain) and 2 oil rings (one vented and one plain, Fig. 25). Keep each connecting rod and piston assembly together for proper reassembly. Check all parts and crankpin journals for wear (Table 5) FE coupRession RINGS ‘OL RING (VENTED) PISTON PIN RETAINING RING GAP lL RING (PLAIN) _-MARKED SIDE UP COMPRESSION RING —HL no Taper EITHER SIDE UP OIL RING Fig, 25 — Position of Piston Rings and Piston Pin Retaining Clips Connecting Rod and Piston Assembly Replacement = Attach connecting rods to pistons with piston pins and Jock in place with retaining rings. Piston pins are selectively fitted for a push fit; reassemble in the piston from which they were removed. Place piston pin retaining rings, with gap on side, on piston (Fig. 25). They should be tight enough so they cannot be rotated by finger pressure,RINGS 1. Check ring gap by inserting each ring separately in cylinder approximately 3/8-in. from top. Ring gap should be between .007 in. and .017 inch, 2. Install compression rings on piston with side marked top toward piston head. Install oil rings with either side up. 3. Stagger ring gaps around piston. 4, Measure side clearance between ring and piston (approximately .001 inch). Check rings for free action, CONNECTING ROD BEARING INSERTS — If bearing inserts are damaged and crankshaft is not worn, itis only necessary to replace inserts. Do not file bearing caps. Place the inserts in connecting rod and connecting rod caps so knobs on inserts fit into notches on rod and cap. Lubricate bearing and crankpin freely before i Install cylinder sleeve, connecting rod and piston assembly at the same time. Turn connecting rod, and install cap so chamfered sides are against radius of crankpin. (Small knobs on rod and caps must be on same side of journal.) CAPACITY CONTROL SYSTEM Unloader Power Element Removal — Remove cylinder head, valve plate, connecting rod, piston and cylinder sleeve. Remove allen head cap screws (2) holding unloader power element in position. Remove power element (Fig. 27) and dis assemble, Check all parts for wear and damage. Unloader Power Element Replacement — Check unloader fork height (Fig. 26) of assembled or new power element, Attach power element to internal suction mani- fold. Replace cylinder sleeve piston, connecting rod, valve plate, cylinder head and hand hole cover. 3 7 4 6a tor SH Fig. 26 — Unloader Fork Height for SF and SH Power Elements External Adjusting Stem removal does not require pumping compressor down. Loosen hex nut at valve stem base and remove adjusting stem assembly. Capacity Control Valve and Hydraulic Relay Assembly is located in hand hole cover (Fig. 28) of 5F40 and S60 units, in pump end cover (Fig. 29) ‘of SH40,46,60,56,80 and 86 units, and in pump end bearing head (Fig. 30) of SH120, 126 units. Remove capacity control valve and hydraulic relay. Inspect parts for wear, damage and evidence of leaking or sticking. ‘A new hand hole cover, pump end cover or pump end bearing head’ with control valve assembly may be installed. However, capacity control valve (and hydraulic relay on SH120,126 units) is available as a separate parts item for installation on original hand hole cover, pump end cover or pump end bearing head. CONTROL OIL STRAINER — On SF compressors the control oil strainer is on side of pump end bearing head (Fig. 14). Strainer is located beneath capacity control manifold block (Fig. 33) on 5H120 and SHI26 units and on pump end cover (Fig, 29) of all other SH compressors. Remove strainer and inspect it for holes and dirt. Clean it with solvent and replace ~~ unwonoeR —vLinoeR ppg unLoanen eYLINDER gages” Skene GeiMen SAAR Giater er Fro) piston Wash abee) oe ceonron / UNLOABER FORK ome dl | | ; so > ° we a Oc y cme ens 0 CYLINDER —UNLOADER PISTON UNLOADER —_UNLOADER _erLINDER Sees” GRUNER RSo™ SERRE SAARIOE. SOME Hare inner) SOUTER) Fig. 27 — Unloader Power Element 4Ree eon capa rou Power ELEMENTS caPaciTy CONTROL ONTROL, e ure SOS Berar 7 BRR J ram couvnesson \ §BNFFOE 4 oe ee \ LonvEs To uNLoaoeR Power" ELEMENTS Fig. 28 — Compressor Hand Hole Cover and Control Assembly (5F40 and 5F60) NOTE: POTTED LINES wae pn BEHIND SURGE OrUN ‘SURGE f HYDRAULIC row Crete eer gas os ‘GKGE CONN capitany——£ a es seagpre eat BW 7 Oop ee \ a a Fou Eewrs CARicase Fig. 29 — 5H Pump End Cover and Control Assembly (Except 5H120 and 5H126) BoM comRessoR oi Pui i lL puMP PressuRE (BEFORE FICTERING) cxanccase press, — | SRNR SE es. | sss CAPACITY CONTROL. VALVE yuL Flow HOUSING Pye Ol PuN Pre scuRe caruiagy 78° Oy Re ERIN eatin 3 A(3)onvonoer seovence pecan PLUG, MAGNETIC (PUMP INTAKE) Fig. 30 — 5H120 and 5H126 Pump End Bearing Head ‘5F20,30 Capacity Control Operation (Fig. 31) LOADED OPERATION — A tise in suction pres- sure causes needle valve to close. Oil pressure in power element increases as oil enters capacity control circuit from oil pump. Power element piston is forced upwards, pivoting lifting fork downward. Lifter pins drop allowing suction valve to seat and load controlled cylinder UNLOADED OPERATION — A drop in suction pressure causes needle valve to open. Oil bleeds thru valve to crankease decreasing oil pressure in power clement. As oil pressure to power element drops, the piston moves downward. Lifting fork is pivoted upward, moving lifting pins upward; suction valve is raised from its seat and controlled cylinder is unloaded. sugTion vauve t PRESSURE. (Pee BEB LF oye /_BeLLows, fia Bins NS fag a see Sora ggger ‘ate a Hobe Eau EE a) 10 OTHER unLoapeR POWER ELEMENTS TSPECIAL ORDER ON SF30 ONLY) TY ceaecase CD eReSsoRe Fig. 31 — Capacity Control (5F20, 5F30) IsSF40 thru 5H126 Capacity Control Oper Fig. 32 and 33, LOADED OPERATION — A rise in suction pres- sure increases pressure against capacity control valve bellows, compressing range adjustment spring. Compression of range adjustment spring allows valve spring to move push pins and valve needle point toward valve seat. Flow of control oil to crankcase thru oil drain is throttled. Control oil pressure rises as oil enters capacity control circuit thru orifice from compressor oil pump circuit. Increased control oil pressure advances hydraulic relay piston (against spring) which feeds oil at full pressure to one or more controlled cylinder power elements depending on position of control valve. Pump oil pressure in unloader power elements forces piston upward, pivoting the lifting fork(s) downward, Lifter pins drop allowing suction valve(s) to seat and load cylinder(s). UNLOADED OPERATION — A drop in suction pressure decreases pressure against control valve bellows, Range adjustment spring decompresses against push pins forcing valve spring to compress, and valve needle point away from valve seat Control! oil bleeds from hydraulic relay and control valve to crankcase, relieving oil pressure on hydrau- lic piston, The piston retracts, preventing tra mission of pressurized oil to controlled cylinder power element(s), and the oil drains to crankcase. As oil pump pressure to power element drops, the piston moves downward. Lifting fork(s) is pivoted upward, moving lifting pins upward; suction valves are raised from their seats and controlled cylinder(s) is unloaded, ion, Honey Fig. 32 — Capacity Control CRANKSHAFT Disassembly — Remove cylinder heads, valve plates, connecting rod and piston assemblies, and pump end main bearing head. On SH80, SH86, SH120 and SH126 Models, remove hollow center main bearing lock screw located beneath plug (Fig. 34) and loosen cone point lock screw (Fig. 37) until center main bearing can be slid from its support, On SH120 and 5H126, disconnect oil line to center main bearing, Pull crankshaft out thru pump end opening. Remove centrifugal oil separator impeller from 5H120 and SH126 crankshaft. OIL SEPARATOR IMPELLER (SH120,126) — To remove oil separator (Fig, 35) from crankshaft, heat to 180 F or more by immersion in hot water or oil. If water is used, ensure that all traces have been removed before reassembly. Do not heat impeller with torch INSPECT crankshaft journals for wear and tol erances shown in Table 5. Remove crankshaft plugs, check oil passages and clean if clogged. Connecting rod bearing inserts and main bear- ings are available for crankshafts reground .010-in, to .020-in. undersize. A worn crankshaft suitable for regrinding to above tolerances can be ex- changed for a factory-reground crankshaft and bearings. Factory-reground crankshafts are stamped on both ends with an A (.010-in, under- sized), or B (.020-in, undersized). FROM, comPResson spurt] ) on. powe ao suction vaLve i] PRESSURE bie’ rine tyogautic (5F40,60, 5H40,46,60,66,80 and 86) 16Sars recat suction vawe aise € To OTHER > ~ Sy BEER gure _—-Frow coueresson || tnt ‘CONTROL POWER ELEMENT ae | Btu —— elise caayncase Fig. 33 — Capacity Control (5H120, 5H126) shown in Table 5. For example, the factory tolerance for 5H40 seal end journal is 2.6225 in. to 2.6235 inches. A crankshaft reground to .010-in, undersize is then held between 2.6125 in, and 2.6135 inches, Reassembly (Sce oil separator impeller instructions before installing SH120 and 5H126 crankshafts.) When crankshaft is reground, remove crank: shaft plugs and clean oil passages. Replace and tighten plugs before installing crankshaft. Insert crankshaft, and replace pump end bearing head, connecting rod and piston assemblies, valve plate ou. separator aiecttee Fig. 34 — 5H80,86,120,126 Center Main Bearing Housing Lockscrew Location Hold throw on crankshafts reground locally to 1.001 in. for SF compressors, and 1.376 in. on SH compressors. Stamp A or B on crankshaft and © pump end bearing head ext 10 oil pressure gage connection. Determine maximum and minimum journal diameters for undersized shafts by subtracting the amount (in.) shaft will be ground undersize from Fig. 35 — Cent 1gal Oil Separatorand cylinder heads. On SH80, SH86, SH120 and 5H126, replace center main bearing lockscrew. On 5H120 and SH126 Models, reconnect oil line to center main bearing. INSTALLING OIL SEPARATOR IMPELLER 1. Install dowel key (Fig. 35) with axis paralle! to axis of crankshaft. Position key so chamfered, edge is toward radius of crankshaft journal. 2. Install oil separator impeller on crankshaft. Ensure that dowel key lines up with impeller keyway, and that impeller fits key snugly. 3. Ensure that seal end thrust washer is in place on dowel key in crankcase. PUMP END MAIN BEARINGS Disassembly — Remove pump end bearing head (Remove pump end cover first on 5H140,46,60,66,80,86 Models.) Inspect bearing for tolerances shown in Table 5. If pump end main bearing is worn, remove bronze bearing washer, and chisel out bearing. Inspect bearing housing for wear (Table 5) and damage. Remove any burrs. Reassembly — Lubricate outside of new bearing ith heavy grease 1. Line up hole in bearing with oil port in housing. 2. Press bearing into place using a puller shoulder (Fable 6) and jackscrew or bearing press. 3. Place bearing washer on bearing with notch in washer properly positioned around dowel key (Fig. 36). Table 6 — Main Bearing Puller Sizes COMPRESSOR, PULLER SIZE '3F20, 5F30 _4 SEI —5F40, 5F60 eee ee SHA0, 46, 60, 66, sao 80, 86, 120, 126 Notes 1 allbearingpullrspart of 520-092 bearing puller sombly 2, Side of pull marked Bis for urdrsicod beatings CENTER MAIN BEARING (8- and 12-Cylinder Models Only) Disassembly — Disconnect oil line to center main bearing (SH120 and SH126 only). Remove hollow center main bearing lock screw beneath plug (Fig. 34). Loosen cone point lock screw until bearing assembly can be slid from its support. Remove crankshaft and bearing assembly. Disassemble bearing (Fig. 37). Inspect bearing for tolerances given in Table 5. Reassembly — Install new bearing inserts. Assem= ble, bearing housing to crankshaft. Install crank- shaft, bearing, and lock screw to compressor crankease Dow: " eee yy 3B 3 P_—tonze tani * o PUMP END MAIN BEARING PUNP END BEARING HOUSING “Stool washer on SH120 and SH126 Models Fig. 36 — Pump End Main Bearing Position "> eearine insenrs P.ue~"P” cone eon oF te EENEn Fig. 37 — Center Main Bearing (SH120 and SH126)SEAL END MAIN BEARING Disassembly — With crankshaft removed, use a puller shoulder (Table 6) to remove and install seal end main bearings (Pig. 38). Inspect bearing and bearing housing for toler~ ances shown in Table 5. CRANKCASE BEARING HOUSING DIRECTION OF PULL {PULLER sHouLDER fo Fig. 38 — Removing 5H Seal End Main Bearing Reassembly — Remove any burrs and clean bearing housing before replacing bearing. Lubricate outside of bearing with heavy grease. 1. Position bearing so chamfered edge enters bearing housing first, oil holes in bearing and housing are aligned, and bearing relief groove is at top. 2. Pull bearing into housing. Edge of bearing should be 1/32 in, below surface of bronze bearing washer (Fig. 40). 3. Look thru oil pressure regulator opening to see that oil passage to bearing is not blocked. 4, Blow out oil groove in bearing housing and oil lines Gi any) to it CRANKCASE BEARING HOUSING — oP PLarE~ mz “SEARING on ssa WHE SEAL HOUSING ; : Fig. 39 — Installing 5F40 or 5F6O Seal End Main Bearing SEAL END MAIN BEARING HOUSING. BRONZE BEARING WASHER ——ef SEAL END MAIN BEARING Stool washer an 5H 120 and SH126 Models Fig, 40 — Seal End Main Bearing Position CRANKSHAFT SEAL Oil seal in all current SF,H compressors is a sleeve type rotary bellows seal with integral seal seat (Fig. 41). This seal available as a replacement for all earlier seal assemblies. Do not attempt to repair or replace seal components; replace complete seal assembly with current sleeve type rotary seal When replacing a seal the pump end bearing head must be in place for proper positioning of seal on crankshaft. GVEGRAC SEA" ear SRB RVESEENGEY me 4 Ve eageow pine pean SERRE at eopheye stat ReTaNeR BECLOWe eer 41 — Sleeve Type Rotary Bellows Seal (Service Replacement Seal) BS Rotary Bellows Type Seals (Fig. 42 and 43) REMOVE cover plate and sea! assembly. Be sure to remove spring guide. Retain cover plate for use with new seal, Clean seal cavity and crankshaft. Remove all burrs from crankshaft. Inspect cover plate for scoring; if scored replace with new cover plate, REPLACE with current sleeve type rotary bellows seal; see Fig. 45 for replacement instructions, 0 Go000 seao sae sea BELLOWS Gehan SSF Safer Fig. 42 — Rotary Seal (Insert Seal Seat) nf Foal y yw & to sues sre / gage ye eae firckat Sea Sear Fig. 43 — Rotary Seal (Integral Seal Seat)Stationary Bellows Type Seal (Fig. 44) REMOVE cover plate and seal assembly. Tap bellows frame with a plastic hammer if seal spring pressure does not force bellows clear of housing, REPLACE stationary seal with current sleeve type rotary bellows seal (Fig. 45). Use a new cover plate on SF compressors when converting to sleeve type rotary seal SHOULGER Gasxer Fig, 44 — Stationary Bellows Seal STEP 1 — Lubricate shaft and neoprene bellows where it contacts shaft. Slide seal assembly onto shaft until neoprene starts to grasp the shaft. STEP 3 — Using seal cover plate, push seal assembly on crankshaft until spring guide is tight against shaft shoulder. (Do not use cover plate bolts to push seal into position.) Remove cover a plate being careful not to damage carbon washer. Lp Turn seal nose assembly until lugs on driving head drop back into slots in retainer shell ate = . eet c STEP 4 — Ensure that driving band lugs are STEP 2 ~ Holding sleeve and spring assembly, pull positioned in senter of seal retainer shell slots. forward on seal nose assembly and turn it so that Lubricate carbon washer and seal seat. Reinstall lugs on driving band are out of slots in retainer cover plate, drawing bolts down evenly to prevent shell and rest on retainer shell surface. damage to carbon washer Fig. 45 — Installation of Sleeve Type Rotary Seal 20TROUBLESHOOTING Compressor Will Not Start Power off — check main switch, fuses and wiring. ‘Thermostat set too high — reset ‘Thermal overload switch open — reset Oil safety switch — reset. Dirty contacts — clean all control contacts Loose electrical connections on faulty wiring tighten connections. Check wiring and rewire. Compressor motor burned out — check and replace if defective. Solenoid valve closed — Check for burned out holding coil Replace if defective. Evaporator fan off Restart check fuses, overload. Evaporator condenser or cooling tower fan or pump not operating — check fuses, overloads and controls Restart. Compressor Cycles Intermittently Low pressure switch erratic in operation — check tubing (0 switch for clogging Check switch setting. Low refrigerant charge — add refrigerant. Capacity control setting incorrect — reset Thermostat differential too narrow — reser. Suction valve closed or throttled — open, Compressor Cycles On Dual Pressurestat Tubing to pressurestat restricted — check and clean tubing. Faulty pressurestat — repair or replace Refrigerant overcharge — remove excess refrigerant. Insufficient water flow thru condenser or clogged condenser — adjust water regulating valve to condenser. Clean condenser. Discharge shutoff valve not fully open valve open Air in system ~ purge. Condenser water pump off — check and start High Discharge Pressure Condenser inlet water temperature too high increase quantity by adjusting water regulating valve, Use colder water Insufficient water flow thru condenser Readjust water regulating valve, Increase water supply main size to condenser. Plugged or scaled condenser tubes — clean tubes Discharge shutoff valve partially closed — open valve. Refrigerant overcharge — remove excess refrigerant, Air in system — purg Low Discharge Pressure Excessive water flow thru condenser — adjust water regulating valve Suction shutoff valve partially closed — open valve. Leaky compressor suction valves — examine valve dises and valve seats. Replace if necessary. Worn piston rings ~ replace if worn, Flooding Defective or improperly set expansion valve reset to 5° ~ 6° superheat. Low Suction Pressure Low reftigerant charge — add refrigerant. Excessive superheat — reset expansion valves ‘System Noises Loose or misaligned coupling — check align- ‘ment and tightness. Insufficient clearance between piston and valve plate ~ replace defective parts Motor or compressor bearings worn — replace bearings. Loose or misaligned belts ~ check alignment and tension, (Belt slack should be at top.) Loose hold down bolts ~ tighten bolts Unit foundation improperly isolated — isolate foundation.TROUBLESHOOTING (Cont) System Noises (cont) Improper support or isolation of piping — use correct piping techniques and support piping with suitable hangers. Slugging due to refrigerant floodback — check expansion valve setting. Check thermal bulb looseness and correct location. See Cartier System Design Manual, Part 3, for standard piping techniques. Hydraulic knock due to excess of oil in circulation — remove excess oil. Check ex- pansion valve for floodback. Defective valve lifter mechanism (noise level varies with unloading) — replace stuck lifter pins. Check unloader fork for alignment. Check power element for stuck piston. Leakage of oit at tube connection to power element. Check amount of valve pin lift above valve seat. (33 in, for SF and .125 in for SH.) Piping vibration — support pipes as required, check pipe connections No muffler in discharge line or improperly located — install or move muffler closer to compressor. Hissing (insufficient refrigerant flow thru ex- pansion valves or clogged liquid line strainer) — add refrigerant, Clean strainer. Compressor Will Not Unload Capacity control valve inoperative — repair. Unloader element stuck — repair Hydraulic relay stuck — replace control cover assembly. Plugged pressure line to power element ~ clean line. External adjusting stem damaged ~ replace. Compressor Will Not Load Low oil pressure (below 45 psi) —see Table I Capacity control valve stuck open — repair or replace Unloader element stuck — repair Plugged or broken pressure line to power element — clean or repair. External adjusting stem damaged — replace. Control oil strainer blocked — clean or replace. Control valve bellows leaking — remove thread protector and leak test. Replace valve body if bellows leaks. Compressor Will Not Load (cont) Pipe plug installed in pneumatic connection — remove. Foaming in crankcase due to refrigerant flooding — cheek expansion valve and piping. Hydraulic relay stuck — replace control cover assembly, Rapid Unloader Cycling Excessive fluctuation in suction pressure (over- sized expansion valve) ~ resize expansion valve, Partially plugged control oil strainer ~ clean or replace. Low oil pressure ~ see Table J. Low Oil Pressure Low oil charge ~ add oil Faulty oil gage ~ check and replace. Defective oil pressure regulator — repair or replace. Clogged oil suesion strainer — clean. Broken oil pump tang ~ replace pump assembly. Clogged oil line remove obstruction. Worn oil pump ~ replace pump assembly, ‘Worn compressor bearings — replace. Cold Compressor Liquid carry-over from evaporator — check refrigerant charge and expansion valves. Low Crankcase Oil Level Oil return check valve stuck closed ~ repair or replace. Cylinders and Crankcase Sweating Refrigerant floodback — check refrigerant charge and expansion valves. High Crankcase Temperature (should be 105 F — 180 F at Seal Housing) Liquid line strainer clogged — clean, Excessive superheat — reset expansion valves Compression ratio too high ~ recheck design. Discharge temperature over 275 F application. check unit Leaking suction or discharge valves — replace. TH[Manufacturor eserves the right to change any product spzifieations without notice, CARRIER AIR CONDITIONING COMPANY + SYRACUSE, NEW VORK Tab 4 FormSF.H-ASS Superndes SF H6IPDT Printed inUSA —66B——Codes Cand ME Catalog No 630518