Carrier 05G TWIN PORT Instruction manual

Compressor
62--11052 Rev C
WORKSHOP MANUAL
for
MODEL 05G TWIN PORT
COMPRESSOR
R

WORKSHOP MANUAL
COMPRESSOR
MODEL 05G TWIN PORT

Safety - 1 62--11052
SAFETY SUMMARY
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 appearing elsewhere in the manual follows the general safety notices.
FIRST AID
An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention
immediately.
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.
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.
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 injury or death.
CAUTION
CAUTION -- warns against potential hazard or unsafe practice which could result in minor
personal injury, or product or property damage.
NOTE
NOTE -- gives helpful information that may help and avoid equipment and property damage.

Safety - 2
62--11052
SPECIFIC WARNING AND CAUTION STATEMENTS
The statements listed below are specifically applicable to this unit and appear elsewhere in this manual.
These recommended precautions must be understood and applied during operation and maintenance of the
equipment covered 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 Section 3.5)
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.

i62--11052
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
SAFETY SUMMARY Safety--1....................................................................
GENERAL SAFETY NOTICES Safety--1............................................................
FIRST AID Safety--1.............................................................................
OPERATING PRECAUTIONS Safety--1............................................................
MAINTENANCE PRECAUTIONS Safety--1..........................................................
WARNINGS AND CAUTIONS Safety--1.............................................................
SPECIFIC WARNINGS AND CAUTIONS Safety--2...................................................
DESCRIPTION 1--1...............................................................................
1.1 INTRODUCTION 1--1.....................................................................
1.2 GENERAL DESCRIPTION 1--1.............................................................
1.3 COMPRESSOR REFERENCE DATA 1--1....................................................
1.4 DETAILED DESCRIPTION 1--3.............................................................
1.4.1 Service Valves 1--3....................................................................
1.4.2 Suction And Discharge Valves 1--3......................................................
1.4.3 Lubrication System 1--3................................................................
1.4.4 Shaft Seal Reservoir 1--3...............................................................
1.5 COMPRESSOR UNLOADERS 1--4.........................................................
1.5.1 Electric--Controlled Unloaders 1--4.......................................................
1.5.2 Pressure--Operated Unloaders 1--5......................................................
COMPRESSOR REPLACEMENT 2--1...............................................................
2.1 COMPRESSOR REMOVAL 2--1............................................................
2.2 COMPRESSOR REPLACEMENT 2--1......................................................
2.2.1 Installing Compressor Unloaders 2--1....................................................
2.2.2 INSTALLING COMPRESSOR 2--2..........................................................
COMPRESSOR MAINTENANCE 3--1...............................................................
3.1 SHAFT SEAL RESERVOIR 3--1............................................................
3.2 INTRODUCTION 3--1.....................................................................
3.3 INSPECTION AND PREPARATION FOR REASSEMBLY 3--1..................................
3.4 CYLINDER HEAD AND VALVE PLATE 3--1..................................................
3.4.1 Disassembly 3--1......................................................................
3.4.2 Reassembly 3--1......................................................................
3.5 OIL PUMP AND BEARING HEAD 3--2......................................................
3.5.1 Removal 3--3.........................................................................
3.5.2 Disassembly, & Inspection 3--3..........................................................
3.5.3 Reassembly 3--3......................................................................
3.6 SHAFT SEAL 3--3........................................................................
3.6.1 Disassembly 3--3......................................................................
3.6.2 Reassembly 3--4......................................................................
3.7 COMPRESSOR RUNNING GEAR REMOVAL 3--4............................................
3.7.1 Bottom Plate, Strainer, and Connecting Rod Caps 3--4.....................................
3.7.2 Crankshaft and Seal End Thrust Washer 3--5
.............................................
3.7.3 Pistons, Rods, and Rings 3--5...........................................................
3.7.4 Seal End Main Bearings 3--6............................................................

ii
62--11052
PARAGRAPH NUMBER Page
3.8 COMPRESSOR RUNNING GEAR REASSEMBLY 3--6........................................
3.8.1 Seal End Main Bearings 3--6............................................................
3.8.2 Pistons, Rods, and Rings 3--6...........................................................
3.8.3 Crankshaft and Seal End Thrust Washer 3--7.............................................
3.8.4 Bottom Plate, Strainer, and Connecting Rod Caps 3--7.....................................
3.9 SUCTION STRAINER 3--7.................................................................
3.10 ADDING OIL 3--7.........................................................................
3.11 INSTALLING COMPRESSOR 3--7..........................................................
LIST OF ILLUSTRATIONS
FIGURE NUMBER Page
Figure 1--1. Model 05G Compressor 1--2............................................................
Figure 1--2. Suction & Discharge Valve 1--3..........................................................
Figure 1--3. Oil Pump 1--3.........................................................................
Figure 1--4. Shaft Seal Reservoir 1--3...............................................................
Figure 1--5. Compressor Unloader 1--4.............................................................
Figure 1--6. Electric--Operated Unloader--Unloaded Operation 1--4......................................
Figure 1--7. Electric--Operated Unloader--Loaded Operation 1--5........................................
Figure 1--8. Pressure--Operated Unloader Loaded Operation 1--5.......................................
Figure 1--9. Pressure--Operated Unloader --Unloaded Operation 1--5....................................
Figure 2--1. Removal of Piston Plug 2--1.............................................................
Figure 2--2. Oil Level in Sight Glass 2--2.............................................................
Figure 3--1. Shaft Seal Reservoir 3--1...............................................................
Figure 3--2. Cylinder Head & Valve Plate 3--2........................................................
Figure 3--3. Installing Suction Valves 3--2............................................................
Figure 3--4. Checking Suction Valve 3--2.............................................................
Figure 3--5. Oil Pump and Bearing Head Assembly 3--3...............................................
Figure 3--6. Oil Pump 3--3.........................................................................
Figure 3--7. Shaft Seal 3--3........................................................................
Figure 3--8. Shaft Seal Removal 3--4................................................................
Figure 3--9. TOP Orientation 3--4...................................................................
Figure 3--10. Bottom Plate Removal 3--5............................................................
Figure 3--11. Bottom Plate and Oil Strainer Removed 3--5..............................................
Figure 3--12. Piston Rings Removed 3--5............................................................
Figure 3--13. Connecting Rod, Piston, and Pin 3--5....................................................
Figure 3--14. Seal End Main Bearings 3--6...........................................................
Figure 3--15. Piston 3--6...........................................................................
Figure 3--16. Correct Piston in CylinderOrientation 3--6................................................
Figure 3--17. Installing Piston Rod Assemblies and Seal End Thrust Washer 3--6.........................
Figure 3--18. Piston Rings 3--7.....................................................................
Figure 3--19. Installing Pistons 3--7.................................................................
Figure 3--20. Installing Suction Strainer 3--7..........................................................
Figure 3--21. Piston Dimension (Wear Limits) 3--9....................................................
LIST OF TABLES
TABLE NUMBER Page
Table 1--1. Compressor Reference Data 1--1..........................................................
Table 1--2. Oils 1--1................................................................................
Table 3--1. Torque Values 3--8.......................................................................
Table 3--2. Wear Limits 3--9.........................................................................

1--1 62--11052
SECTION 1
DESCRIPTION
1.1 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 1-1) 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--.
1.2 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 1-3)
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
crankcase, provides a means for checking oil level in the
compressor crankcase. A drain plug facilitates draining
of oil from the crankcase and an oil fill plug 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.
1.3 COMPRESSOR REFERENCE DATA
Table 1-1. 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
(1.937 in)
54.36 mm
(2.14 in)
Weight 62 kg (137 lbs)
SPEED (RPM) FOR OIL PUMP
Low Profile 500 to 2200
NOTE
The oils below are suitable for use with
evaporator temperatures above --40°F(--40°C).
Table 1-2. Oils
Approved Oil for REFRIGERATION USE
(TRAILER)
Refrigerant Oil
R--12, R--22, R--500
or R--502
Alkyl Benzene (Synthetic)
P/N 07--00274--00
R--404A Polyolester (POE)
P/N 07--00317--00PK6
Approved Oil for AIR CONDITIONING USE
(BUS AND RAIL)
Refrigerant Oil
R--12, R--22,
R--500 or R--502
Mineral (150 Viscosity)
P/N 07--00275--00
R--12, R--22,
R--502
Mineral (300 Viscosity)
P/N 07--00377--00
R--22 Alkyl Benzene (Synthetic)
P/N 07--00430--00
R--134a Polyolester (POE)
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 collect 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.

1--2
62--11052
12
34
67
10
8
11
9
COMPRESSOR WITH
MOUNTING FLANGE
(ULTRA TYPE SHOWN)
1 2 34
6
7
8
9
10
11
1. Discharge Service Valve
2. High Pressure Connection
3. Low Pressure Connection
4. Suction Service Valve
5. Guage Connection
6. Oil Fill Plug
7. Oil Level Sight Glass
8. Bottom Plate
9. Oil Drain Plug
10. Oil Pump (See Figure 1-3)
11. Unloader
12. Shaft Seal Reservoir
12
12
5
5
5
5
COMPRESSOR WITHOUT
MOUNTING FLANGE
Figure 1-1. Model 05G Compressor

1--3 62--11052
1.4 DETAILED DESCRIPTION
1.4.1 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 1-1).
Turning the valve stem counterclockwise (all the way
out) will backseat the valve to open the suction or
discharge line to the compressor and close off the
gauge 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.
1.4.2 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 1-2)
1. Valve Spring
2. Suction Valve
3. Valve Plate
4. Discharge Valve
5. Discharge Valve
Backer
512 3 4
Figure 1-2. Suction & Discharge Valve
1.4.3 Lubrication System
Force--feed lubrication of the compressor is accomplished
by an oil pump (See Figure 1-3) 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 1-3. Oil Pump
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
equalization port between the suction manifold and
crankcase. Under normal conditions, check valves are
open and allow for oil return to the crankcase. Under
flooded start conditions, pressure rises in the crankcase
and closes the check valves, preventing excess oil loss.
The equalization port allows for release of excessive
pressure, that has built up in the crankcase, to the suction
manifold; this ensures that the oil loss is kept to a
minimum.
1.4.4 Shaft Seal Reservoir
1. Shaft Seal Reservoir
2. Access Valve (Coreless)
1
2
Figure 1-4. Shaft Seal Reservoir
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.

1--4
62--11052
1.5 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 1-5)
The compressor unloader system can be controlled with
either a pressure actuated valve or an electrically
actuated (solenoid) valve.
1.5.1 Electric--Controlled Unloaders
The capacity controlled cylinder is easily identified by an
electric solenoid which extends from the side of the
cylinder head. When the solenoid energizes, the
cylinder unloads allowing discharge gas to circulate as
shown in Figure 1-6. 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 1-7.
1. Discharge Check
Valve
2. Discharge Manifold
3. Solenoid Valve
4. Piston Bypass
Control Valve
5. Cylinder Head
6. Suction Manifold
6
1
2
3
4
5
Figure 1-5. Compressor Unloader
a. Major Working Parts
1. Solenoid and valve system
2. Spring loaded piston type bypass control valve
3. Spring loaded discharge check valve
b. Unloaded Operation
Pressure from the discharge manifold (Figure 1-6, item
15) passes through the strainer (9) and bleed orifice (8)
to the back of the piston bypass valve (7). Unless bled
away, this pressure would tend to close the piston (6)
against the piston spring (5) pressure.
With the solenoid valve (1) energized the solenoid valve
stem (2) will open the gas bypass port (3).
Refrigerant pressure will be bled to the suction manifold
(10) through the opened gas bypass port . A reduction in
pressure on the piston bypass valve will take place
because the rate of bleed through the gas bypass port is
greater than the rate of bleed through the bleed orifice
(8).
When the pressure behind the piston has been reduced
sufficiently, the valve spring will force the piston bypass
valve back,opening the gas bypass from the discharge
manifold to the suction manifold.
Discharge pressure in the discharge manifold will close
the discharge piston check valve assembly (14)
isolating the compressor discharge manifold from the
individual cylinder bank manifold.
The unloaded cylinder bank will continue to operate fully
unloaded until the solenoid valve control device is
de--energized and the gas bypass port is closed.
1. Solenoid Valve
2. Valve Stem
3. Gas Bypass Port
4. Spring Guide
5. Spring
6. Piston
7. Piston Bypass Valve
8. Bleed Orifice
9. Strainer
10. Suction Cavity
11. Cylinder Discharge
Valve
12. Valve Plate
13. Cylinder Suction
Valve
14. Discharge Piston
Check Valve
Assembly
15. Discharge Manifold
11
1
23
4
5
67
8
9
10
15
12
13
14
Figure 1-6. Electric--Operated Unloader--
Unloaded Operation
c. Loaded Operation
Discharge pressure bleeds from the discharge manifold
(Figure 1-7, item 15) through the strainer (9) and bleed
orifice (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.

1--5 62--11052
The loaded cylinder bank will continue to operate fully
loaded until the solenoid valve control device is
energized and the gas bypass port is opened.
1. Solenoid Valve
2 Valve Stem
3. Gas Bypass Port
4. Spring Guide
5. Spring
6. Piston
7. Piston Bypass Valve
8. Bleed Orifice
9. Strainer
10. Suction Cavity
11. Cylinder Discharge
Valve
12. Valve Plate
13. Cylinder Suction
Valve
14. Discharge Piston
Check Valve
Assembly
15. Discharge Manifold
10
1
23
4
5
67
8
9
15
11
12
13
14
Figure 1-7. Electric--Operated Unloader--
Loaded Operation
1.5.2 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 suction and discharge pressure is 10 psi (0.68
bar).
During loaded operation, (Figure 1-8) 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 1-9) 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.
1. Sealing Cap
2. Pressure Differential Adjustment Screw
3. Control Set Point Adjustment Nut
4. Poppet Valve
5. Piston Bypass Valve
6. Discharge Piston Check Valve
4
1
2
3
5
6
Figure 1-8. Pressure--Operated Unloader
Loaded Operation
1. Sealing Cap
2. Pressure Differential Adjustment Screw
3. Control Set Point Adjustment Nut
4. Poppet Valve
5. Piston Bypass Valve
6. Discharge Piston Check Valve
4
1
2
3
5
6
Figure 1-9. Pressure--Operated Unloader --
Unloaded Operation

2--1 62--11052
SECTION 2
COMPRESSOR REPLACEMENT
2.1 COMPRESSOR REMOVAL
Refer to the operation and service manual covering the
equipment in which the compressor is installed for
specific removal instructions. A general removal
procedure is given below.
a. If compressor is completely inoperative, frontseat the
suction and discharge service valves to trap the
refrigerant in the unit. If the compressor will operate,
pump down the unit; then, frontseat the suction and
discharge service valves.
b. Ensure power source is removed from any controls
installed on the compressor.
c. Remove refrigerant 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 2.2 for replacement
procedures.
2.2 COMPRESSOR REPLACEMENT
Consult the unit service parts list for the correct
replacement.
Service replacement compressors are furnished
without suction and discharge service valves and
unloader valves. The service valves are normally
retained on the unit to isolate the refrigerant lines during
compressor replacement. Blank--off pads are installed
on the service replacement compressor valve flanges.
These pads must be removed prior to installing the
compressor. If the defective compressor is to be
returned for overhaul or repair, install the pads on the
compressor for sealing purposes during shipment.
Service replacement compressors are furnished with
cylinder head bypass piston plugs installed on the
unloader flanges in lieu of the unloader valves. The
unloaders (if used) must be removed from the defective
compressor and transferred to the replacement
compressor prior to installation. Refer to section 2.2.1.
If the defective compressor is to be returned for
overhaul or repair, install the plugs on the compressor
for sealing purposes during shipment.
2.2.1 Installing Compressor Unloaders
a. Remove the three socket head capscrews holding
piston plug to cylinder head of the replacement
compressor. See Figure 2-1.
1. Capscrews
2. Flange Cover
3. Gasket
4. Spring
5. Bypass Piston Plug
6. Seat Ring
7. Strainer
7
1
2
3
4
5
6
Figure 2-1. Removal of Piston Plug
b. Remove flange cover, gasket, spring, bypass piston
plug, and seat ring. A tapped hole is provided in piston
plug for use with a jackscrew to enable removal of the
plug. One of the socket head capscrews may be used
as a jackscrew.
c. Remove the three socket head capscrews holding
unloader in the cylinder head of the defective
compressor; remove the unloader and retain the
capscrews.
NOTE
Capscrews removed from the bypass piston
plug flange cover are not interchangeable with
capacity control unloader valve capscrews.
When installing the unloaders, be sure to use
the unloader capscrews.
d. Using a new gasket and unloader ring pliers (P/N
07--00223), install the unloaders in the cylinder heads
of the replacement compressor. Refer to Table 3-1,
for required torque values.
e. If the defective compressor is to be returned for
overhaul or repair, install the bypass piston plug,
spring, seat ring and flange cover onto the cylinder
heads.

2--262--11052
2.2.2 INSTALLING COMPRESSOR
WARNING
Midseat service valves or by other means
relieve pressure in replacement
compressor before removing plugs.
CAUTION
The high capacity oil pump must be set to
rotate in the same direction as the
crankshaft. (Refer to Section 3.5)
a. Install the compressor by reversing the procedure of
section 2.1. Install new locknuts on compressor
mounting bolts and new gaskets on suction and
discharge service valves.
b. Check oil level in sight glass (See Figure 2-2). If
necessary, add or remove oil.
c. Leak test, evacuate, and dehydrate the compressor.
d. Fully backseat suction and discharge service valves.
e. Run the compressor and check for leaks and
noncondensibles in the refrigerant system.
f. Check refrigerant level.
g. Recheck compressor oil level.
h. Check operation of compressor unloaders (if
installed).
PROPER LEVEL IN SIGHT GLASS
Figure 2-2. Oil Level in Sight Glass

3--1 62--11052
SECTION 3
COMPRESSOR MAINTENANCE
3.1 SHAFT SEAL RESERVOIR
The shaft seal reservoir 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.
1 Access Valve
2 Reservoir
3 Capscrew and
Washer
1
2
3
Figure 3-1. Shaft Seal Reservoir
NOTE
Do not return this oil to the compresser. 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-
cess valve.
d. Reinstall the capscrew and washer.
Refer to Table 3-1 for torque values for tightening the
capscrew.
3.2 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 3-1 for torque values for tightening bolts.
3.3 INSPECTION AND PREPARATION FOR
REASSEMBLY
a. Clean all parts with an approved solvent. Use a stiff
bristle brush to remove dirt from grooves and crev-
ices.
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 un-
loader or bypass plug gaskets) are installed dry.
3.4 CYLINDER HEAD AND VALVE PLATE
3.4.1 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 3-2)
b. Remove the discharge valve capscrews, lock wash-
ers, 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.
3.4.2 Reassembly
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 3-1.
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 3-3)

3--262--11052
1 Capscrew
2 Cylinder Head
3 Cylinder Head Gasket
4 Capscrew
5 Lockwasher
6 Discharge Valve Backer
7 Discharge Valve
8 Valve Plate
9 Valve Plate Gasket
10 Suction Valve
11 Suction Valve Spring
12 Dowel Pin
712 123891011
4,5
456
8
67
Figure 3-2. Cylinder Head & Valve Plate
1. Valve Spring
2. Dowel Pin
3. Suction Valve
4. Valve Plate
5. Discharge Valve
6. Discharge Valve
Backer
7. Lockwasher
8. Capscrew
6
1
34
5
7
8
2
1
2
3
4
56
78
Figure 3-3. Installing Suction Valves
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 3-4)
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 diago-
nal pattern, to a value shown in Table 3-1.
Figure 3-4. Checking Suction Valve
3.5 OIL PUMP AND BEARING HEAD
The oil pump is driven directly from the end of the
compressor crankshaft.

3--3 62--11052
3.5.1 Removal
Remove eight capscrews and remove the oil pump
bearing head assembly, gasket and thrust washer. (See
Figure 3-5.)
1. Oil Pump & Bearing Head
2. Thrust Washer
3. Oil Pickup Tube
4. Oil Inlet Port
4
1
2
3
Figure 3-5. Oil Pump and Bearing Head Assembly
3.5.2 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 3-6 for disassembly and
reassembly. Clean all parts; coat all moving parts with
compressor oil before proceeding with reassembly.
1 Capscrews
2 Cover
3 Eccentric Ring
4 Rotor
5 Idler
6 Shaft (Drive)
7 O--Ring
8 Oil Pump & Bearing
9 Dowel Pin
10 Relief Valve Assembly
11 Pins (2)
12 Thrust Washer
1
11
9
8
7
6
5
4
3
210
12
Figure 3-6. Oil Pump
3.5.3 Reassembly
a. Install the pump end thrust washer on the two dowel
pins located on the bearing head. (See Figure 3-5.)
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 3-12)
c. Align the gasket and install the eight capscrews in the
mounting flange. Refer to Table 3-1, for applicable
torque values.
3.6 SHAFT SEAL
3.6.1 Disassembly
a. Remove 6 capscrews, remove the shaft gland plate
or clutch mounting hub. Remove rotor from top of bel-
lows assembly. (See Figure 3-7)
Used with
Housing Mounted Clutch
Standard
Shaft Seal
1 Bellows Assembly
2 Rotor
3 Gasket
4 Stator
5 O--Ring
6 Lip Seal
7 Clutch Mounting Hub
8HubNut
9 Gland Plate
10 Hex Head Screw
9
4
4
6
6
1
1
2
2
3
3
5
5
10
10
7
8
Figure 3-7. Shaft Seal

3--462--11052
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 3-8)
Figure 3-8. Shaft Seal Removal
3.6.2 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
communication 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 com-
pressor, paying attention to the orientation of the cov-
er/hub (see Figure 3-9).
1 Seal Cover
2 Mounting Hub
12
“TOP”
Figure 3-9. TOP Orientation
k. Align the gasket and install the six capscrews in the
mounting flange. Refer to Table 3-1, for applicable
torque values.
3.7 COMPRESSOR RUNNING GEAR REMOVAL
In order to disassemble Piston, Rod and Rings, first the
cylinder heads and valve plate aseemblies, oil pump
and bearing head assemblies and shaft seal must be
removed. (Refer to sections 3.4, 3.5 and 3.6 ).
3.7.1 Bottom Plate, Strainer, and Connecting Rod
Caps
a. Turn the compressor over, bottom side up, and re-
move the bottom plate. (See Figure 3-10) Scrape off
gasket.
b. Remove the oil strainer.