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Carlyle 5F20 Service And Maintenance Manual

Open-drive compressors
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Service and Maintenance Manual
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . 2
Check Lubrication System . . . . . . . . . . . . . . . . . . . . . 2
Check Water-Cooled Heads . . . . . . . . . . . . . . . . . . . . 3
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pressure-Relief Valves . . . . . . . . . . . . . . . . . . . . . . . 11
Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cylinder Head and Valve Assemblies . . . . . . . . . . . 11
Connecting Rods and Pistons . . . . . . . . . . . . . . . . . 14
Crankshaft Inspection and Service . . . . . . . . . . . . . 16
Pump-End Main Bearing . . . . . . . . . . . . . . . . . . . . . . 16
Center Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 17
• REASSEMBLY
Seal-End Main Bearing . . . . . . . . . . . . . . . . . . . . . . . 17
• DISASSEMBLY AND INSPECTION
• REASSEMBLY
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 574-605
Page
Printed in U.S.A.
Open-Drive Compressors
APPENDIX A - TROUBLESHOOTING . . . . . . . . . . . 20

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be
hazardous due to system pressure and electrical components. Only
trained and qualified service personnel should install, repair, or
service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of
cleaning coils and filters and replacing filters. All other operations
should be performed by trained service personnel. When working
on air-conditioning equipment, observe precautions in the
literature, tags and labels attached to the unit, and other safety
precautions that may apply.
Follow all safety codes, including ANSI (American National
Standards Institute) Z223.1. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire
extinguisher available for all brazing operations.
It is important to recognize safety information. This is the safety-
alert symbol
. When you see this symbol on the unit and in
instructions or manuals, be alert to the potential for personal
injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices, which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
WARNING
RISK OF PERSONAL INJURY
Before performing service or maintenance operations on unit,
turn off main power switch to unit. Electrical shock could
cause personal injury.
WARNING
RISK OF PERSONAL INJURY
Do not provide power to unit or turn-on compressor unless
suction and discharge service valves are open.
WARNING
CONTENTS
UNDER
PERSONAL INJURY
Compressor contains oil and refrigerant under pressure. Pres-
sure must be relieved before installation, servicing or opening
any connections.
Pg 1
8-24
5F, H
PRESSURE,
RISK
OF
Replaces: NEW

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Questions and answers

ed.burtch
February 27, 2025

sorry the threaded screw hole on the 5f40 is on the crankshaft

0
1 comments:
Mr. Anderson
May 14, 2025

The threaded screw hole on the Carlyle 5F20 crankshaft is located around the dowel pin.

This answer is automatically generated

0
ed.burtch
February 27, 2025

on 5f60 compressor there is a threaded screw hole what is that for

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Summary of Contents for Carlyle 5F20

  • Page 1: Table Of Contents

    Use quenching cloth for unbrazing operations. Have fire (NON-ADJUSTABLE) extinguisher available for all brazing operations. • OIL RETURN CHECK VALVE (5F20-60, AND 5H40-86) • CENTRIFUGAL OIL SEPARATOR It is important to recognize safety information. This is the safety- alert symbol .

  • Page 2: Scheduled Maintenance

    Use of accessory oil separator requires additional oil. Oil level and separator float valve movement during initial compressor opera- WARNING tion should agree with instructions furnished with the oil separator. RISK OF PERSONAL INJURY OIL FILTER MAINTENANCE HOT and COLD surface temperatures can occur during opera- A bleed-type, high-pressure, disposable filter is available as an tion and can result in severe burns of frostbite.

  • Page 3: Oil Cooler Usage

    Absolute Suction Pressure 5H4Q-66 NOTE: Do not operate unloaders at saturated suction tempera- 5H80,86 11/2-3 tures at or below 0°F without prior approval from Carlyle 5H120,126 Engineering. The compressor operates fully unloaded for prolonged peri- NOTE(S): a. Flow rate based on 80°F entering water.

  • Page 4: Service

    For replacement items, use Carlyle specified parts. See from 12:00 to 6:00) when the bearing head is installed. Press new Carlyle 5F, H Specified Parts list for compressor part inter- bushing into the pump-end bearing head from the inner side of the changeability.
  • Page 5 Fig. 3 — Setting Oil Pump Bushing (Typical 5F20-60 and 5H40-86 Fig. 4 — Setting Oil Pump Bushing 5F40 Bearing Head Shown) (Typical 5H120, 126) Fig. 5 — 5H Compressor External Components...
  • Page 6 Fig. 6 — 5H Compressor Internal Components...
  • Page 7 Fig. 7 — 5F Oil Pump Assembly Fig. 8 — 5H40-86 Oil Pump Assembly...
  • Page 8 Table 4 — Torque Values 5F UNITS SIZE DIA (in.) THREADS (per in.) RANGE (lb-ft) USAGE 20-25 Pipe Plug - Pump End Bearing Head Pipe 20-25 Pipe Plug - Crankshaft 20-25 Pipe Plug - Suction and Discharge Manifold Cover 10-15 Unloader Power Element Assembly - Crankcase 10-15 Unloader Cylinder Cover Plate - Unloader Cylinder Bracket...
  • Page 9 Table 4 — Torque Values (cont) 5H UNITS SIZE DIA (in.) THREADS (per in.) RANGE (lb-ft) USAGE 1/16 Pipe 10-15 Pipe Plug - Auxiliary Control Valve Body Pipe 15-20 Pipe Plug - Pump End Bearing Head 20-25 Pipe Plug - Crankcase Pipe 20-25 Pipe Plug - Pump End Cover...

  • Page 10: Auto Reversing Oil Pump

    See Fig. 10. alent) on each of the 5/16-18 adapter mounting screws and on Two disc-type check valves on 5F20 and 30 compressors are lo- threads of each mounting hole in bearing head. Position one...

  • Page 11: Pressure-Relief Valves

    Suction Strainer When pressure differential between high and low-pressure sides To withdraw strainer on 5F20, 40 and 5H40, 46 compressors, exceeds 350 ± 35 psi (5F60: 400 ± 40 psi), pressure-relief valve remove suction and discharge manifold cover on seal end of bleeds refrigerant from high to low side.

  • Page 12: Disassembly

    Place valve guide assembly on valve plate. Tighten all bolts INSPECTION and bend tabs on lock washer and lock plates. Replace cylin- Examine bore of sleeve for wear. Check suction valve seats for der head. scratches and wear. Check unloader sleeves, pins and springs for wear and freedom of movement.
  • Page 13 5H40,46,60,66,80,86,120,126 COMPRESSOR PART FACTORY TOLERANCES (in.) MAXIMUM FACTORY TOLERANCES (in.) MAXIMUM ALLOWABLE ALLOWABLE WEAR (in.) WEAR (in.) SEAL END Main Bearing Diameter — 5F20, 30 1.6264 1.6250 0.002 2.6264 2.6250 0.001 — 5F40, 60 2.0636 2.0618 0.001 Journal Diameter — 5F20, 30 1.6240...

  • Page 14: Connecting Rods And Pistons

    Unloaded Operation Connecting Rods and Pistons A drop in suction pressure decreases pressure against control REMOVAL valve bellows. Range adjustment spring presses against the push Remove cylinder head, valve plate and hand-hole cover or bottom pins, compressing the valve spring. This moves the needle valve plate to gain access to rods and pistons.

  • Page 15: External Adjusting Stem Removal

    EXTERNAL ADJUSTING STEM REMOVAL Loosen hex nut at valve stem base and remove adjusting stem assembly. It does not require compressor to be pumped down. REMOVAL OF CAPACITY CONTROL VALVE AND HYDRAULIC RELAY Assembly is located in pump-end cover (see Fig. 20) of 5F40 and 5H40-86 units;...

  • Page 16: Crankshaft Inspection And Service

    INSPECTION Crankshaft Inspection and Service Check crankshaft journals for wear and tolerances (refer to DISASSEMBLY Table 5). Remove crankshaft plugs, check oil passages and clean Remove cylinder heads, valve plates, connecting rod and piston if clogged. assemblies, and pump-end main bearing head. Connecting-rod bearing inserts and main bearings are available for On 5H80-126 units, remove hollow-center main bearing lock crankshafts reground from 0.010 in., 0.020 in., or 0.030 in.

  • Page 17: Reassembly

    5H40, 46, 60, 66, 80, 86, 120,126 5H140 NOTE(S): REASSEMBLY a. Bearing pullers can be ordered through Carlyle or Totaline Parts. Remove any burrs and clean bearing housing before replacing Center Main Bearing bearing. Lubricate outside of bearing with heavy grease.

  • Page 18: Crankshaft Seal Inspection And Replacement

    BEFORE INSTALLING SEAL Crankshaft Seal Inspection and Replacement The crankshaft seal in all current 5F, H compressors is a rotating, Pump-end bearing head must be in place for proper position- bellows-type seal. This seal is the service replacement for all earli- ing of seal on crankshaft.
  • Page 19 Step 1 - Lubricate the shaft and the neoprene bellows where it comes in contact with the shaft. Slide the seal assembly, as it is shipped from the factory, onto the shaft until the neoprene just starts to grasp the shaft. Step 2 - Holding the sleeve and spring assembly, pull forward on the seal nose assembly at the same time, turning it so that the lugs on the driving band are out of the slots in the retainer shell and rest on the...

  • Page 20: Appendix A - Troubleshooting

    APPENDIX A — TROUBLESHOOTING TROUBLE/SYMPTOM PROBABLE CAUSE REMEDY Power off. Check main switch, fuse and wiring. Thermostat set too high. Reset thermostat. Thermal overload switch open. Reset switch. Oil safety switch open. Reset switch. Dirty contacts. Clean all control contacts. Loose electrical connections or faulty wiring.
  • Page 21 Use correct piping techniques and support piping Improper support or isolation of piping. with suitable hangers. Check expansion valve setting. Check thermal bulb looseness and correct location. See Carlyle Slugging from refrigerant feedback. System Design Manual, Part 3 for standard piping System noises techniques.
  • Page 24 © 2024 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 574-605 Printed in U.S.A. Pg 24 8-24 Replaces: NEW...

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