Service Manual Property of American Airlines€¦ · FRICK XJF 151MM ROTARY SCREW COMPRESSOR...

Service Manual ROTARY SCREW COMPRESSOR

XJF 151mm

Form S70-452 SM (JUL 2004) SERVICE MANUAL

File: SERVICE MANUAL - Section 70Replaces: Nothing (New Information)

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FRICK XJF 151MM ROTARY SCREW COMPRESSORSERVICE MANUAL

Contents

GENERAL .................................................................................................................................................................3MODEL AND SERIAL NUMBER EXPLANATION ...................................................................................................3TABLE 1 - GEAR SET .............................................................................................................................................3GENERAL MAINTENANCE ...................................................................................................................................3PREVENTIVE MAINTENANCE, INSPECTION AND SERVICE ............................................................................3TORQUE DATA ........................................................................................................................................................4TABLE 2 - TORQUE SPECIFICATIONS ..................................................................................................................4SPECIAL TOOLS AND TEST EQUIPMENT ............................................................................................................4ADDITIONAL TOOLS REQUIRED, NOT IN KIT. ......................................................................................................4GENERAL SAFETY PRACTICES ...........................................................................................................................4SAFETY PRECAUTIONS .......................................................................................................................................4GENERAL SAFETY PRACTICES (CONTD) ...........................................................................................................5

COMPRESSOR TEARDOWN ...................................................................................................................................5BASIC PRACTICES ................................................................................................................................................5TABLE 3 - RECOMMENDED SPARE PARTS KITS ................................................................................................5SECTION 1 - SHAFT SEAL REPLACEMENT. ........................................................................................................61.1 SHAFT SEAL REMOVAL ..................................................................................................................................61.2 SHAFT SEAL INSTALLATION ...........................................................................................................................62.1 SLIDE STOP REMOVAL ..................................................................................................................................103.1 GEAR COVER / JACKSHAFT REMOVAL .......................................................................................................113.2 JACK SHAFT LOCK NUT REMOVAL ..............................................................................................................113.3 GEAR COVER REMOVAL ...............................................................................................................................123.4 JACKSHAFT THRUST BEARING REMOVAL .................................................................................................123.5 SLIDE VALVE AND SLIDE PISTON REMOVAL ..............................................................................................143.6 PINION GEAR REMOVAL ...............................................................................................................................154.1 DISCHARGE HOUSING BEARING REMOVAL .............................................................................................155.1 CLEANING COMPONENTS FOR REASSMEBLY ..........................................................................................175.2 SLIDE VALVE TO SLIDE VALVE GUIDE INSPECTION ..................................................................................176.1 ROTOR AND ROLLER BEARING INSTALLATION .........................................................................................18 ROTOR CASE TO CASE CLEARANCE ..........................................................................................................196.2 THRUST BEARING INSTALLATION ................................................................................................................196.3 ROTOR DISCHARGE END CLEARANCE ......................................................................................................207.1 SLIDE VALVE / SLIDE STOP INSTALLATION ................................................................................................217.2 JACKSHAFT GEAR INSTALLATION ...............................................................................................................227.3 PINION GEAR INSTALLATION ......................................................................................................................227.6 JACKSHAFT AND GEAR COVER MOUNTING ..............................................................................................237.5 JACKSHAFT BEARING INSTALLATION .........................................................................................................247.6 INSTALLATION OF JACKSHAFT LOCKNUT .................................................................................................248.1 SLIDE STOP PISTON INSTALLATION ............................................................................................................258.2 SLIDE VALVE PISTON INSTALLATION ...........................................................................................................258.3 LINEAR TRANSMITTER ASSEMBLY .............................................................................................................26

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GENERAL

This manual provides approved procedures for teardown, parts replacement, and rebuild of Model XJF 151 compres-sors, manufactured by Frick and installed on RXB and RXF Rotary Screw Compressor Units.

To avoid errors when ordering parts, always provide complete Model Number and Serial Number.

MODEL AND SERIAL NUMBER EXPLANATION

MODEL NUMBER

ROTOR DIA. (MM)

2.13/1 GEAR RATIO – S1.31/1 GEAR RATIO – M1.62/1 GEAR RATIO – L1.93/1 GEAR RATIO – N

SERIAL NUMBER

A - 151AM - 151ML - 151LN - 151N

• Avoid slugging compressor with liquid refrigerant. While screw-type compressors are probably the most tolerant to ingestion of some refrigerant liquid, they are not liquid pumps. Be sure to maintain adequate superheat, and properly size suction accumulators to avoid dumping liquid refrigerant into compressor suction.

• Keep liquid injection valves properly adjusted and in good condition to avoid fl ooding compressor with liquid. Liquid can cause a reduction in compressor life, and in ex-treme cases, can cause complete failure.• Protect compressor during extended periods of shutdown. If compressor will be setting for long periods without running,it is advisable to evacuate to low pressure and charge with dry nitrogen or oil, particularly on systems known to contain amounts of water vapor.

• Preventive maintenance inspection is recommended any time a compressor exhibits a noticeable change in vibration level, noise level, and/or performance.

NOTES:

1. Some photographs or illustrations in this manual may be of prototype or special order units. Production models may vary in some detail from those shown.

2. Some photographs or illustrations in this manual may show units with optional equipment installed. These items are available through your authorized Frick Factor.

3. Some of the photographs shown in this manual are of the XJF/XJS 120mm compressor. The photographs are used as reference and are simular to the XJF151mm compressor.

PREVENTIVE MAINTENANCEINSPECTION AND SERVICE

Frick® Model XJF 151 Rotary Screw Compressors are designed and manufactured to the highest engineering and quality standards to provide optimum performance and continued service in applications of intended use, with no deviations from original design. A preventive maintenance program ensures maximum compressor life and minimizes costly unscheduled unit downtime. Immediate shutdown and inspection should be made if increased sound or vibration, increased shaft seal leakage, erratic slide valve operation, fl uc-tuating oil pressure, loss of compressor effi ciency, increased oil consumption, and/or oil contamination are observed. Major inspection should be made, per the schedule, listed in the Frick Rotary Screw Compressor IOM manual.

GENERAL MAINTENANCE

Proper maintenance is important in order to ensure contin-ued, trouble-free service from your compressor. Some areas critical to optimum compressor operation are:

• Keep refrigerant and oil clean and dry to avoid moisture contamination. After servicing any portion of the refrigera-tion system, evacuate to remove moisture before returning to service. Water vapor condensing in the compressor while it is running, or more likely while it is shut down, can cause rusting of critical components and reduce the service life of the unit.

• Keep suction strainer clean. Check periodically, particu-larly on new systems where welding slag or pipe scale could fi nd its way into the compressor suction. Excessive dirt in the suction strainer could cause it to collapse, dumping debris into the compressor.

Keep oil fi lters clean. If fi lters show increasing pressure drop (indicating dirt or water), stop compressor and change fi lters. Running a compressor for long periods with high fi lter pressure drop can cause oil starvation and lead to premature bearing failure.

XJF 151 M 0123 M

Number of teeth Bull Gear Pinion Gear S gear set 51 46 M gear set 55 42 L gear set 60 37 N gear set 64 33

TABLE 1

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TORQUE DATA

Torque requirements applicable to the procedures contained in this manual are listed below.

TABLE 2 - TORQUE SPECIFICATIONS

* Hex Head

NOTE: To convert foot-pounds of torque to metric Newton-meters, multiply foot-pounds times 1.3558 (Example: 75 ft-lb x 1.3558 equals 101.7 Nm)

SAFETY PRECAUTIONS

DANGERS, WARNINGS, CAUTIONS, and NOTES are strategically placed throughout this manual to further empha-size the importance of personal safety, qualifi cations of user personnel, and proper use or maintenance of the equipment. These precautions supplement and/or complement standard industry practices and the safety information decals affi xed to applicable areas of the equipment. Safety Precautions are defi ned as follows:

GENERAL SAFETY PRACTICES

It would be impossible to compile a list of all Safety Prac-tices applicable to the operation and maintenance of the equipment covered in this manual. This is brought about in part by the diverse operating environments, as well as the varied applications and customer-specifi ed confi gurations. The following Safety Practices are provided as a guide in promoting safety during routine operation, service, inspec-tion, and maintenance of Frick® compressors. This informa-tion, combined with standard industry safety practices, local, state, and federal regulations, establish the overall safety requirements for the workplace.

Always shut down unit and dis-connect power before making any adjustments or repairs.

Operating a damaged unit is not only unsafe, but continued use will cause additional damage and/or component failure.

DO NOT attempt any operation or perform any maintenance before you read and understand all Safety Practices in this manual.

Ensure that work area is adequate-ly ventilated, and wear proper safety equipment when compres-sor is open to atmosphere.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation or practice which, if not avoided,will result in damage to equipment and/or minor injury.

Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.

NOTE:

SPECIAL TOOLS AND TEST EQUIPMENT

Special tools and/or test equipment required to perform the maintenance procedures contained in this manual are listed below. Master kit number for 151 mm is 534M0483G01.

Frick Manufactured

Compressor Size 151mm

Wrench, SpannerArm, Spanner ToolKey for Torque ApplierT-WrenchTorque Applier Assy.Rod ExtensionBar ExtensionSpacer BearingSpacer BearingPuller, Pinion GearWrench, SpannerAir Cyliner Test Fixture

333Q0000948534A0579H01534A0662H02534B0530G01534B0534G01534B0535H01534B0536H01534B0540H01534B0540H02534C1093G01534C1096G01534E0541G01

Jackshaft thrust bearing tool 534D0243G01**

**Not part of 151 tool kit

ADDITIONAL TOOLS REQUIRED, NOT IN KIT.

• Set of Metric Allen wrenches.

• Standard set of mechanics tools.

• Torque wrench, 0 to 400 ft-lb.

• Magnetic base and dial indicator.

• Fine tooth hand fi les.

• Snap ring pliers, assorted sizes.

• Inpact wrench, air or electric.

CAPSCREW SIZETORQUE VALUE

ENGLISH METRIC SOCKET SIZE

M4M5M6M8M12M16M20M22*

2 ft-lb4 ft-lb7 ft-lb18 ft-lb58 ft-lb144 ft-lb260 ft-lb368 ft-lb

2.7 Nm 5.4 Nm9.5 Nm24.4 Nm78.7 Nm195.3 Nm352.5 Nm499 Nm

3 mm4 mm5 mm6 mm10 mm14 mm17 mm32 mm

Equipment Item No.

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GENERAL SAFETY PRACTICES (CONTD)

1. If you are not familiar with this particular Frick compres-sor, take time to read the operator’s manual (IOM) before attempting to run the unit for any purpose.

2. INSPECT COMPRESSOR VISUALLY before start-up. Tighten/replace any loose or missing bolts, nuts, etc. Repair any leaks; replace any damaged hoses, lines, and/or fi ttings; repair/replace any damaged electrical wiring and/or components.

3. USE CAUTION PRIOR TO DISASSEMBLY, as compressor may still be pressurized. Evacuate compressor in accordance with S70-400 IOM and applicable Federal, State, and local ordinances, prior to begining any disassembly.

4. DO NOT make adjustments while the unit is operating, unless required for service or maintenance checks.

5. DO NOT operate a damaged compressor. Always com-plete all repairs before running unit.

6. STAY ALERT at all times. Watch what you are doing at all times. Be aware of all persons in the immediate vicinity of operating equipment. Allow only authorized personnel in the area.

7. NEVER operate compressor if you are taking medication that causes blurred vision, dizziness, drowsiness, or slowed refl exes.

8. DO NOT operate compressor if excessive vibration oc-curs. Immediately shut down unit and complete all necessary repairs and required checks before attempting to restart.

9. DO NOT operate compressor exhibiting excessive pres-sure and/or temperature changes. Immediately shut down unit and complete all necessary repairs and functional checks before attempting to restart.

10. NEVER alter compressor from original design. Only those alterations approved by Frick and/or performed by authorized Frick service personnel are permitted.

11. KEEP COMPRESSOR CLEAN, free of debris, and properly lubricated. A clean, properly lubricated unit will perform more effi ciently and operate trouble-free.

REMEMBER: Any piece of equipment is only as safe as those who use and maintain it.

COMPRESSOR TEARDOWN

The procedures presented in this manual assume that all maintenance will be performed by qualifi ed, Frick-trained service personnel equipped with all special tools and test equipment necessary to properly tear down and rebuild XJF 151 mm compressors.

XJF 151 compressors weigh 1,100 lb (498 kg). Ensure that rigging is properly attached and secure before lifting compressor.

BASIC PRACTICES

1. Always use Frick replacemment Parts. Substitution of parts may result in faulty assembly.

2. NEVER reuse O-rings, Glyd Ring, seal-rings, locknuts with Nyloc inserts, or lock washers.

3. Coat all internal parts with clean refrigeration oil prior to installation.

4. All covers and housings are equiped with jackbolt holes for disassembly; NEVER use pry bars between compo-nents.

5. NEVER allow anything to contact the sealing surfaces of shaft seals.

6. Bearings are supplied with a light fi lm of oil. It is NOT necessary to clean prior to installation. NEVER add grease to compressor bearings.

7. Replace all cap bolts to prevent elongation of the threads.

TABLE 3

NOTES:

1. Contains, adjusting shims, Gas Seals, Inlet Bushings. DOES NOT contain Jackshaft Bearing.

2. Contains Shaft Seal.

Recommended Spare Parts Kits

534M0602G02 Shaft Seal Kit

534M0602G01 O-ring - Gasket Kit

534M0602G03 Bearing Kit (1)

534M0602G04 Jackshaft Kit 151 A (2)

534M0602G05 Jackshaft Kit 151M534M0602G06 Jackshaft Kit 151 L534M0602G07 Jackshaft Kit 151 N

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Evacuate compressor and oil separator (refer to S70-101 IOM).

Remove fl exible drive coupling (refer to S70-101 IOM).

NOTE: Provisions should be made to catch residual oil that will drain when seal houing is removed.

SECTION 1 - SHAFT SEAL REPLACEMENT.

This procedure provides the information necessary for quali-fi ed personnel to replace the jackshaft carbon-faced seal, including required compressor disassembly.

1.1 SHAFT SEAL REMOVAL

Shaft seal removal shall be accomplished as follows: Refer to Figure 3 for parts identifi cation.

1. Evacuate compressor and separator. Refer to S70-400 IOM.

2. Remove oil drain tubing and seal housing cover (19). Seal housing cap bolts require a 10mm allen wrench. Remove wave spring (97).

3. Using the seal housing puller tool, remove seal housing (20) from gear cover. NOTE: Place container under shaft to catch oil. Stationary carbon seal (43) and lip seal (44) are secured in seal housing. The seal housing puller tool consists of two 10" long 8 mm threaded rods, two 8 mm nuts and a cross bar with two 10 mm holes drilled on 3.64" centers. Remove spacer (24). If a seal puller is not available, thread an 8 mm cap bolt into the seal housing and pry against the cap bolt head. See Figure 1.

5. Remove rotating steel seat (43). Typically, the seat can be removed by hand. If unable to be removed by hand, construct two “L” shape puller rods to position behind the seat.

Figure 2 - Rotating steel seat

6. Place seal housing on work table. Remove and discard OD O-rings.

7. Remove carbon seal assembly by tapping on metal por-tion of seal with rubber hammer. Remove and discard ID O-ring (66) in seal housing (20).

8. Remove lib seal (44) by striking against the metal surface located inside the seal housing.

9. If the failed seal is under warranty, both seal components, O-rings and lip seal must be returned to Frick with the re-quired RMA paperwork. If the seal is out of the warranty period discard seal, O-rings and lip seal.

1.2 SHAFT SEAL INSTALLATION

Avoid damaging carbon-faced seal and rotating seal seat. Mishandling will shorten seal life. Do not touch

sealing surfaces. Surfaces can be blemished by perspira-tion. Ensure that carbon is not chipped or cracked.

1. Clean all parts and coat with refrigerant oil ONLY.

NOTE: DO NOT USE GREASE OR LIKE SUBSTANCE ON SEAL COMPONENTS.

2. Clean jackshaft; polish minor scratches with crocus cloth; wipe clean and coat shaft and housing bore with refrigerant oil.

3. Install seal spacer (24) against outer ring of thrust bearing (53). See Figure 4.Figure 1 - Seal Housing Removal

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19. Seal housing cover.20. Seal housing. 24. Seal housing spacer.43a. Carbon assem, Shaft seal.43b. Stationary seat, Shaft seal.44. Lip seal.66. O-ring, ID of seal housing. 69. O-ring, OD of seal housing97. Wave spring

Figure 3 - Shaft Seal Identifi cation

Figure 4 - Seal housing spacer install

4. Remove steel seal from protective wrapping. ONLY REMOVE SEAL FROM PACKAGING IMMEDIATELY PRIOR TO INSTALLATION. Inspect face to ensure it is free of damage. Apply oil by either dipping seal in oil or by spray bottle. DO NOT WIPE ON OIL.

5. Position Pin (83) on jackshaft at the 12:00 o'clock posi-tion. See Figure 5.

6. Install rotating steel seat by pushing against the chamfer portion of the seat. Ensure the seat is secured on drive pin (83). See Figure 6.

Figure 6 - Rotating seal seat installation

Figure 5 - Pin on Jackshaft

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Figure 7 - Lip Seal

Figure 8 - Lip Seal Installation Tool

Figure 9 - Lip Seal Installed. Also shows the carbon seal installed.

8. Install I.D. O-ring (66) and OD O-rings (69) on seal housing spacer. Lubricate O-ring with refrigerant oil prior to installing.

Figure 10 - I.D. O-ring installation.

Figure 11 - O.D. O-ring Installation.

7. Install lip seal (44) into seal housing (20). The lip seal has an orifi ce hole located in the Tefl on lip. The orifi ce must be aligned with spring pin located on the opposite end of hous-ing (20); this will ensure the orifi ce is located at the 12:00 o’clock position. Place the seal housing cover (19) on a fl at surface with the outboard portion facing down. Position the seal housing spacer (20) on top of the seal cover. This will prevent damage to the spring pin. With the wide portion of the lip seal facing downwards, use lip seal installation tool P/N 534B0665H01 to insert the lipseal into position. Due to the tightness of the lip seal, a mallet is required for striking force. See Figures 7, 8, and 9.

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9. Install seal housing (20) into gear cover housing as far as possible by hand. Ensure that spring pin is at the 12:00 o'clock position.

Figure 12 - Seal Housing Installation

10. Install seal housing cover (19) and wave spring (97) over jackshaft. Insert two 5" x 12 mm threaded rods through seal housing cover approximately 180 degrees apart. Install and tighten 12mm nuts until seal cover is fl ush with gear cover. Remove threaded rods and seal cover.

Figure 14 - Seal Housing fully seated

Figure 13 - Installing Seal cover to push on Seal spacer

Figure 15 - Installing Carbon Seal Assembly

NOTE: Wash hands before handling shaft seal. Take care not to to allow the sealing faces to contact foreign objects. Inspect carbon seal with fl ashlight prior to installation. Only remove seal from container immediately prior to installation.

11. Lubricate the carbon seal assembly with new refrigera-tion oil by dipping the seal in oil or by using a spray bottle. Carefully place the seal over the jackshaft and slide into the seal housing. By using the seal housing cover as described in step 10, push the carbon seal into the seal housing. See Figure 15.

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Figure 16 - Seal housing cover installation.

4. Loosen nuts several turns and observe if cover is being pushed from housing. If the cover does not move, back off nuts to approximately 3/4" (19 mm). Insert 12 mm cap bolts into jackbolt holes and begin to push off cover. If the slide stop stepper piston (16) follows the cover, continue to use the threaded rods. If stepper piston (16) remains in housing, remove threaded rods and continue to step 5.

5. Remove the stepper piston (16) by threading the 12mm "T" handle tool 534B0530G01 into one of the holes on the outboard face of the piston and pull outwards.

NOTE: Once Glyd Ring (40) is free of gear cover, un-loader spring tension is released. Piston (16) will be pushed forward.

NOTE: Eariler style stepper pistons did not have drilled and tapped holes for removal. Remove the piston by placing a strong magnet on the face and pull from gear cover. Secure piston with other hand to release spring tension. Oil will follow piston.

6. Remove and discard Glyd Ring (40) and O-ring (76).

7. Remove slide stop piston (16) using "T" handle tool. Remove and discard Gyld Ring (41) and O-ring (75).

Figure 18 - Slide stop piston removal.

8. Remove unloader spring (96)

9. Remove slide stop (6) with "T" handle tool.

12. Install seal housing cover (19) and wave spring (97). Ensure that spring pin on spacer engages slot in seal cover.Install cap bolts (63) and tighten to 60 ft-lb (81 Nm). See Figure 16.

Figure 17 - Installing Seal Cover Housing

2.1 SLIDE STOP REMOVAL

1. Place a suitable drain pan under slide stop piston cover.

2. Remove shaft seal as outline in Section 1.1, SHAFT SEAL REMOVAL. Also remove dowel pin (83) on jackshaft.

NOTE: The unloader spring (96) is pushing against the slide stop piston (6) which could cause the piston to be pushed out of the compressor rapitly.

3. Remove two opposite cap bolts from cover (7) and re-place with two 12 mm threaded rods and nuts. Tighten nuts against the cover. Remove remaining cap bolts.

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Figure 19 - Spanner wrench engaged in locknut

1. Slide spanner wrench over the jackshaft and engage in locknut. See Figure 20.

Figure 20 - Spanner wrench being installed

2. Install spanner arms (524A0579H01) from the spanner wrench to the gear cover. Secure arms to cover with gear cover cap bolts. See Figure 21.

Figure 21 - Mounted assembly tool

3. Install torque applier 534A0662H02 to end of jackshaft. See Figure 21. When removing locknut, turn the jackshaft clockwise. Discard locknut.

NOTE: Tighten the locknut to 330 ft./lb (447 Nm).

See Figure 22 which shows the spanner wrench assembly mounted and Figure 23 which shows the spanner arms mounted.

3.1 GEAR COVER / JACKSHAFT REMOVAL

1. Remove shaft seal (43) as outlined in Section 1.1, SHAFT SEAL REMOVAL.

2. Remove slide stop (6) as outlined in Section 2.1, SLIDE STOP REMOVAL.

3. Remove pin (83) from jackshaft (17)

3.2 JACK SHAFT LOCK NUT REMOVAL

In this section the Spanner Wrench Tool will be used to remove the locknut from the jackshaft.

1. Figure 19 shows how the spanner wrench 534C1096G01 engages with the locknut (93).

Spanner Arm

Torque Applier

Figure 22 - Spanner wrench assembly

Spanner Arm

Torque Applier

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Figure 23 - Attachment of spanner tool arms

NOTE: To tighten the locknut, position spanner arms as shown in the solid view. To loosen the locknut, position spanner arms as shown in the phantom view.

3.3 GEAR COVER REMOVAL

Prior to removing gear cover, refer to section 3.1, GEAR COVER/JACKSHAFT REMOVAL.

1. Remove both slide stop solenoid valves (104) from gear cover (2). Remove gaskets (106) and discharge. Note posi-tion of gaskets for reassembly.

2. Attach lifting strap around gear cover or lifting eye bolt to cover and attach to overhead lifting devise. See Figure 24a.

3. Remove all cap bolts (55) from gear cover (2). Install two 12 mm threaded rods at the 1:00 and 11:00 o'clock positions. See Figure 24b.

4. The gear cover is also attached and aligned to the rotor housing with two dowel pins. Two 12 mm jackbolt holes, located near the 12:00 and 6:00 o'clock positions, are used to push the gear cover away from rotor housing. Monitor distance between gear cover and rotor housing during re-moval.

NOTE: Care must be taken while conducting this step to ensure the cover is removed evenly to prevent damaging the dowel pins.

Figure 24a - Eye bolt attached to gear cover

Figure 24b - Gear cover removal. Guide pins located at the top of cover.

Do not use prying devise between gear cover and rotor housing.

5. Once gear cover (2) is removed from rotor housing, secure the cover in a vice in preperation to remove the jackshaft and bearings. If a vise is not availible a second person can secure the cover when removing the thrust bearing.

3.4 JACKSHAFT THRUST BEARING REMOVAL

Thrust bearing removal tool (534D0243G01) is needed to push off the jackshaft from thrust bearing (53).

1. Secure gear cover in vise or by second person.

2. Install 3/4" - 10 threaded rod into jackshaft, Figure 25.

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Figure 26 - Pusher insert tool

Figure 25 - Jackshaft with 3/4" - 10 threaded rod

5. Figure 27 shows the asembled thrust bearing tool.

Figure 28 - Arms added to Pusher Tool Assembly

NOTE: Photograph showing tool used on TDSH163mm. Setup is same for XJF151 compressor.

6. Once pusher tool is in place (see Figure 28), insert three retainer arms into slots on pusher tool and secure arms to gear cover using 12 mm cap bolts, fi gure (28). By turning the jackscrew clockwise, the jackscrew contacts the jack-shaft pushing the jackshaft free from the thrust bearing (53). Remove jackshaft from gear cover.

It is important to secure the jack-shaft during the bearing removal process. Once thrust bearing is free,

the jackshaft could fall causing damage or injury.

7. Remove retainer ring (89) from gear cover and push out outer races of the thrust bearing (53) and roller bearing (51). Discard all three parts. Inner races of roller bearings (51) and (52) will remain on jackshaft.

8. Remove and save all plugs and fi ttings from gear cover for preparation of cleaning.

9. If the original jackshaft is being reused, the bearing inner races and large gear (45) must be removed. Because the inner races and gear are heat shrunk to the shaft, a bear-ing puller tool, see Figure 39, and heat is recommended for removal. If a new jackshaft is being used, disregard this step and proceed to Section 7.2 for reassembly.

3. Place Pusher Insert tool, Figure 26 over jackshaft and into housing bore.

4. Install Removal Tool barrel and jackbolt assembly, Figure 27 over shaft and slide onto Pusher Insert tool.

Figure 27 - Thrust bearing tool assembled

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Figure 29 - Check valve retainer assembly

3. Remove check valve retainer (21) from the slide valve piston. Retainer (21) has a hex size of 1¼". Because of an O-ring located between the retainer and slide stop piston that becomes swollen during operation; it is recommended to use an impact wrench and socket to remove the check valve retainer. Discard O-ring (80).

4. Within the check valve retainer is check valve (109), O-ring (65) and retainer ring (88). Remove each item and discard. See Figure 30.

5. The slide valve piston (18) is secured to the slide valve (5) with a M12 x 170 mm capbolt (61). Use a 10 mm allen wrench to remove the M12 capbolt. See Figure 31.

6. Attach two 12 mm threaded rods into the outboard face of the slide valve piston and pull piston from discharge housing. Remove split Slyd Ring (39). Using a knife, cut off Glyd Ring (42) and remove O-ring (74) located beneath Glyd Ring. Discard all three items.

Figure 30 - Check valve components

Figure 31 - Cap bolt removal

Figure 32 - Slide valve piston removal

7. Push slide valve (5) out of suction side of compressor. Insert a rod through the discharge housing to push the slide valve out of the compressor.

21

80

109

65

88

3.5 SLIDE VALVE AND SLIDE PISTON REMOVAL

Failure to remove transmitter (106) prior to removing slide valve piston bore cover (8) will result in damage to the rod.

1. Remove slide valve linear transmitter (106) and spring (94) from the discharge housing. Remove O-rings (79) and discard. The hex size of the indicator rod guide is 3/4".

2. Remove cover (8) from discharge housing and discard O-ring (67). Slide stop piston (18) will be exposed.

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3.6 PINION GEAR REMOVAL

1. Attach pinion gear puller tool (P/N 534C1093G01) to pinion gear (42). The pinion gear is located on the male ro-tor. See Figure 35.

Figure 33 - Pinion gear puller

A fi xture ball is placed between the jacking screw and rotor shaft. The pinion gear puller plate is secured to the pinion gear by three 8 mm x 50 cap bolts. The cap bolts must be fully tightened. Ensure that the jacking screw is not touch-ing the rotor while tighting the capscrews. Keep the puller plate secured with a wrench while screwing in the jacking screw. Because the pinion is heat shrunk to the shaft, the force applied to the jacking screw for removal is extreamly high. See Figure 35.

Figure 34 - Pinion puller tool mounted on gear

Figure 35 - Pinion gear removal

4.1 DISCHARGE HOUSING BEARING REMOVAL

This procedure covers the removal of the discharge bear-ings, discharge housing and rotors.

1. Remove capscrews (63) securing male outlet bore cover (9) to discharge casing (3); remove outlet bore cover (9) and eight compression springs (95). Discard O-ring (68) located on cover (9).

2. Remove male distance sleeve (11) from discharge hous-ing.

3. Remove capscrews (63) securing female outlet bore cover (9) to discharge casing; remove outlet bore cover (9) and eight compression spring (95). Discard O-ring (68) located on cover (8).

Figure 36 - Female distance sleeve, cover, and compres-sion springs.

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Figure 37 - Rod extension tool

6. Install spanner wrench (333Q0000948) on locknut (92) on the male rotor (rotor with pinion gear). An impact wrench is recommended to remove the locknut due to the high torque (260 ft/lb - 353 Nm) required.

7. Move spanner wrench to female rotor and begin to remove locknut (92). The rod extension on the _____ rotor will break loose while attemping to remove locknut (96). Once the extension tool is free, reinstall on opposite rotor. Continue until locknut (96) is removed.

NOTE: Do not discard locknuts. They are reused to set bearing clearance during assembly. Once clearance is set, old locknuts are discarded.

NOTE: Use steps 4 – 7 in reverse to tighten locknuts (92).

8. Remove solenoid valve located on top of the discharge housing.

9. Remove cap bolts (58) attaching the discharge housing to the rotor housing. Install a 12 mm lifting eye into the top of the discharge housing.

10. The discharge housing is aligned to the rotor housing by two dowel pins (84) male side and (85) female side. By using the jackbolt holes on the discharge housing, push the housing from dowel pins.

Figure 38 - Discharge housing removal

11. Once the discharge housing is free from dowel pins, it can be pulled straight outward until free of rotors. Place dis-charge housing on work table. The rotors should stay in the rotor housing, if not, use an object such as a hammer handle and push the rotors back into the rotor housing. Becasue the thrust bearings are of the slip fi t design, they will remain in the dicharge housing.

12. The thrust bearings (54) can be pulled out from the rotor housing by hand.

NOTE. There are shims located between various thrust bearings. Record location of shims and tag for reas-smebly. Shim information will be discussed in detail in section 6.3.

13. Remove roller bearing (50) outer rings from the discharge housing by knocking out with a brass drift.

14. Remove male and female gas seals and O-rings. Discard O-rings. Figure 41 shows a gas seal.

15. Remove male rotor (1) from rotor housing by spinning the rotor out from the female. Place rotor on a surface such as wood or cardboard to protect tips.

16. Remove female rotor. Protect female rotor as described in step 15.

17. Remove roller bearing inner races from rotors. A bearing puller (not included in tool kit) show in Figure 39 is recom-mended. Along with the bearing puller, heat can be applied to the roller bearing inner rings to allow expansion to help in the removal process.

18. Remove retainer rings (91) in front of both roller bearings (49) located on the suction side of the compressor.

19. Roller bearings (49) can be removed by striking the bearing with a brass drift from the rotor cavity side of the bearing.

4. Remove female distance sleeve (10) from discharge houisng.

5. Install rod extension tool (P/N 534B0535H01) into the suction side (side nearest gear cover) of the female rotor. See Figure 37. Install bar extension tool (P/N 534B0536H01) into rod extension and secure as shown in Figure 37.

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Figure 39 - Roller bearing inner race puller

20. If inlet bushings (14) are damaged, remove by striking with brass drift in the same direction as the roller bearings (49). If not damaged, bushings do not need removed.

21. Remove retainer ring (73) in front of roller bearing (46).

22. The jackshaft rear bearing (52) can be removed with a bearing puller as shown in Figure 40.

Figure 40 - Bearing removal tool

5.1 CLEANING COMPONENTS FOR REASSEMBLY

In order to ensure a successful rebuild, it is essential to prepare the compressor for reassembly. The following are recommended steps to follow when rebuilding compressors. In the event of metal-to-metal contact, consult Frick service for recommendations. Digital photographs and measurements will be required.

1. Rebuilding should be conducted in a clean environment, free from airborne debris.

2. Thoroughly clean all components with a grease-cutting solvent.

3. Remove all plugs and fi ttings and clean connection ports and internal porting.

4. All rusted areas should be sanded and cleaned.

5. Sanding with emery paper can remove scratches and nicks on rotors. It is not necessary to completely remove the marks; only the high spots.

6. Debur sharp edges.

7. Once sanding, deburring, and fi ling are completed, clean components with solvent and apply a light fi lm of refrigera-tion oil.

5.2 SLIDE VALVE TO SLIDE VALVE GUIDE INSPECTION

NOTE: During reassembly of the compressor, it is neces-sary to determine if the slide valve has excessive wear. Excessive wear is defi ned as the slide valve being able to move upward into the rotor bore above fl ush. The proce-dure to determine excessive movement is as follows.

1. Insert the slide valve into the slide valve bore of the rotor housing. Without installing the rotors, install the discharge housing to the rotor housing. Secure the discharge housing with four cap screws and insert dowel pins.

2. By inserting your hands through the suction ports, move the slide valve into the discharge port so that the slide valve guides on the discharge housing are securing the slide valve in place.

3. Push against the side of the slide valve with one hand and by using thin feeler gauge, determine if the slide valve moves into the rotor bore. The slide valve should not rise above the bore more than .003"

4. If the slide valve does move into the rotor bore, it may be necessary to replace either the slide valve, the discharge housing, or both. Because the slide valve guides on the dis-charge housing are machined oversized , the slide valve must be hand fi tted to the discharge housing. Use the following procedure when new parts are required.

5. Install the slide valve in the rotor housing. Without installing the rotors, install the discharge housing with four capscrews and dowel pins.Pro

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7. Install rotors into rotor housing. Either rotor can be installed fi rst.

8. Place discharge casing (with fl ange down) on work surface and install two O-rings (124) and gas seals (123) in casing. Ensure that spring pin (87) in each gas seal engages oil hole in bore in discharge casing. See Figure 41.

Figure 41 - O-ring and gas seal installation

9. While discharge housing (3) is still positioned as shown in Figure 41, install roller bearings (50). It is recommended to freeze the roller bearing prior to installation. The bearing can also be pressed or tapped into position. See note after step 4 in this section.

10. Place new O-ring (72) in groove in discharge end of ro-tor casing; apply a light coating of grease to keep O-ring in place. Align discharge casing with rotor casing by viewing the alignment process through the discharge housing bore openings. This will help to ensure that the inner rings of the bearings are being aligned with the roller elements of the outer ring. Ensure that dowel pins (84) and (84) engage in dowel pin holes in housing. Secure discharge casing with four capscrews (59), evenly spaced around casing fl ange. Tighten capscrews to a torque value of 144 ft-lb (195.3 Nm).

Figure 42 - Discharge housing installation

Spring PinSpring Pin

O-ring

Gas Seal

6. After inserting your hands through the suction ports, move the slide valve into the discharge housing. The slide valve will get tight within the guides. Pull the slide valve completely out of the discharge port. Lightly sand the slide valve guides on the discharge housing. The process of sanding the guides must be done with care. Ensure that the sanding is conducted evenly across the guides and remove only a small amount of material before checking the fi t. If excessive material is removed from the guides, the slide valve will move into the rotor bore.

7. The slide valve is correctly fi tted when it is able to move smoothly in and out of the discharge housing guides without rocking into the rotor bore.

6.1 ROTOR AND ROLLER BEARING INSTALLATION

1. Thoroughly clean all parts as outlinded in Section 5.1.

2. Lube all components with a light coat of clean refrigera-tion oil.

3. Install both male and female inlet bushings (14), if previ-ously removed. Ensure that spring pin (87) located in rotor housing is properly engaged in bushing.

4. Install two new roller bearings (49) in rotor housing.

NOTE: It is recommended to freeze the outer ring of roller bearings prior to installation. Freezing the bearings can be conducted using a freezer or placing them in dry ice. The bearings can also be installed by tapping them in the casing with a rubber mallet. Care must be taken when tapping on the bearing. TAP ONLY ON THE SIDE OF THE OUTER RING.

NOTE: Any repair to rotors must be accomplished prior to installing inner races of roller bearings.

NOTE: When installing bearings, ensure that each inner ring is matched to the respective outer ring.

Heat-resistant gloves must be worn when installing bearing in-ner races.

5. Install two new retainer rings (91) in front of bearings (49).

6. Ensure that rotor pair (1) are clean and free of scratches. Heat inner rings of roller bearings (49) [suction side] and inner rings of roller bearing (50) [discharge side] to 225°F (107°C). Push inner rings against shaft shoulders and hold in place until inner ring cools and grips shaft.

NOTE: If there is diffi culty installing the inner ring, instantly remove and reheat.

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Figure 43 - Air Cylinder Tool

ROTOR CASE TO CASE CLEARANCE

12. Thread two 3/4"-10 threaded pins into discharge end of rotor shafts. Attach a magnetic base on the compressor and a dial indicator on the end of the pin to which the air cylinder is attached. See Figure 44. Apply and maintain air pressure to the inside port of the cylinder and adjust dial indicator to zero. Remove pressure to inside port and apply pressure to outside port. Record measurement on indicator. Measurments can be recorded on the Compressor Build Records. A blank example of the build record is shown in Figure 72.

NOTE: The arrow on the indicator may move slightly while changing directions of cylinder force. DO NOT READJUST INDICATOR. Total axial movement is be-ing measured.

The specifi ed rotor to rotor clearance is between .020" to .028" (0.508 mm to 0.711 mm). Remove air cylinder tool after measurements are recorded.

NOTE: If air tool is not available, a 3/4"- 10 “T” handle can be used to pull and push rotors.

11. Thread two 16 mm threaded rods into the rotor housing to aid the installation of the air cylinder tool. Connect Air Cylinder tool (534E0541G01) to the suction side of the compressor. Secure to housing with two cap bolts at the top and two cap bolts at the bottom. Thread in one air cylinder at a time while conducting measurements.

Figure 44 - Mounting of dial indicator

6.2 THRUST BEARING INSTALLATION

Shims are used at various locations in the thrust bearing arrangement. Shim information is shown in A, B,and C below.

A. Position a .020" (0.508 mm) shim (112) between the in-ner races of the two female rotor thrust bearings. This shim is used to preload the bearings.

B. Position a .020" (0.508 mm) shim (112) between the inner races of the last two thrust bearings installed on the male rotor. This shim is used to preload the bearings.

C. Shims are used to adjust the Rotor End Clearance. These shims are positioned between the roller bearing and thrust bearing and either between the inner races or outer races depending upon how the rotor is adjusted.

Figure 67 shows location of shims.

NOTE: It is recommendated to reinstall the original adjusting shims.

1. Reinstall original adjusting shims on both male and female rotors. Record shim thickness then slide over rotor shaft and push back against roller bearing.

2. Install one angular-contact ball bearing (54) on female rotor. Ensure that closed face of inner race is facing outboard (identifi cation marks on bearing should be facing inboard). Install bearing spacer (534B0540H01) on female rotor shaft. Only the fi rst thrust bearing is needed to measure Discharge End Clearance. If a bearing spacer is not available, all thrust bearings can be installed. See Figure 67 for an illustration of the thrust bearing arrangement.

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Example #2Measured end clearance = .001" Desired mean end clearance = .004"Desired shim size (location) = .003" between inner race

Example #3If end clearance is .000", begin by placing .001 inch shim between inner races to establish movement of the rotor.

4. Remove locknuts and bearing spacers from rotors. If rotor discharge end clearance is within specifi cation install remaining bearings as outlined in steps 9 through 13. If a change is to be made to the clearance, continue with Step 5.

5. Remove the thrust bearings from the rotor needing ad-justed. To remove the bearing, bend an "L" shape hook on a small diameter rod. Place the "L" shape end of the rod into the bearing and pull.

6. Make adjustment to the adjusting shims as outlined in Step 3.

7. Reinstall the thrust bearings, bearing spacer, and locknuts. Repeat rotor measurements.

8. Once the specifi ed clearance is achieved, remove old locknuts and bearing spacer. Discard locknuts.

9. With the fi rst thrust bearing in place on the female rotor, install the .020" shim (112) and push back against inner ring of thrust bearing. Install second thrust bearing (54) with the wide portion of the inner race facing inboard. Identifi cation markings on the bearing should be facing outboard. See bearing arrangemnt in Figure 67.

10. Install new locknut (92) and tighten as outlined in Section 4.1, Steps 4 – 7. Torque to 250 to 270 ft-lb (339 to 366 Nm).

11. With the fi rst thrust bearing in place on male rotor, install the next two thrust bearings (54) in the same direction as the fi rst thrust bearing, wide portion of inner race facing outboard and bearing identifi cation facing inboard. See Figure 67.

12. Install .020" shim (112) on male rotor against thrust bearing. Install fourth thrust bearing on rotor with the wide portion of the inner race facing inboard. Bearing identifi cation markings should be facing outboard. See bearing arrangment in Figure 67.

13. Install locknut (92) on male rotor and tighten as outlined in Section 4.1, Steps 4 – 7. Torque locknut to 250 to 270 ft-lb (339 to 366 Nm).

3. Repeat step 2 on the male rotor. Ensure that closed face of inner race is facing outboard – identifi cation marks on bearing should be facing inboard. Install bearing spacer (534B0540H02) on male rotor shaft. Again, if bearing spacer is not available, install remaining thrust bearing. See Figure 67.

4. Install rod extension tool (534B535H01) and Bar ex-tension tool (534B0536H01) on suction side of rotors. See Figure 37.

5. Install old (original) locknut (92) on rotors and tighten to 200 ft-lb (271 Nm). Move extension tools to opposite rotor and repeat process. Remove rotor extension tools after locknuts are tightened.

6.3 ROTOR DISCHARGE END CLEARANCE

The rotor discharge end clearance establishes the running clearance of the rotors to the discharge housing.

1. Install Air Cylinder Tool as shown in Section 6.1, step 13. Thread one cylinder into either the male or female ro-tor.

2. Thread the two pin extensions into the discharge side of the rotors.

3. Attach magnetic base and dial indicator to the rotor with air cylinder attached. Actuate cylinder as outlined in Section 6.1, step 12. Repeat three times to ensure measurements do not fl uctuate. Record each reading. If the readings increase after each actuation, the bearing is not secured on shaft. Re-secure the bearings and continue. The specifi cation for the rotor discharge end clearance is between .003" to .005" (0.076 mm to 0.127 mm). Record the measurements on the Compressor Build Sheet shown in Figure 72.

NOTE: It is important NOT TO READJUST INDICA-TOR between actuation strokes.

If the actual measured clearance is greater than the maximum specifi ed value, shims must be installed between the roller bearing and thrust bearing outer races. If the actual measured clearance is below the specifi ed value, shims must be placed between the roller bearing and thrust bearing inner races.

NOTE: Shim thickness is determined by amount of rotor movement beyond the .003" to .005" specifi cations. See the following examples. Information on shim adjustment is also shown on the COMPRESSOR BUILD SHEET (see Table of Contents for page reference).

Example #1Measured end clearance = .008"Desired mean end clearance = .004"Desired shim size (location) = .004" between outer races

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14. Install male distance sleeve (11) and female distance sleeve (10). To ensure distance sleeves are positioned cor-rectly in bore, spring pins (86) are installed on the inboard face of bore covers (9). To position sleeves, place sleeve approximately 1/2" out of bore. With coil springs (95) and O-ring (68) removed from covers, align covers with cap bolt holes on compressor. Position sleeve so that the alignment hole is adjacent to spring pin (86). With spring pin engaged in hole, push cover (9) into discharge housing ensuring that cap bolt holes in cover align with bolt holes in housing. Remove cover (9) and carefully continue to push the sleeve against the bearing. See Figure 45.

Figure 45 - Distance sleeve and cover

15. Install new O-ring (68) and coil spring (95) in covers (9). Carefully install male and female covers and torque cap bolts to 58 ft-lb (79 Nm).

NOTE: Misalignement of the female distance sleeve will cause the drain slot to be misaligned with the drain port of the solenid valve. If this occurs, the slide valve will not unload. See Figure 46.

Figure 46 - Distance sleeve, drain port location

Drain portDrain port

Alignment HoleAlignment Hole

Spring Pin

Distance sleeve

Bore cover

7.1 SLIDE VALVE / SLIDE STOP INSTALLATION

1. Thoroughly clean all parts with OSHA approved, non-fl ammable degreaser and clean, lint-free rags.

2. Lubricate all internal compressor parts with a coat of clean refrigerant oil.

3. With the discharge port of the slide valve facing the com-pressor, install slide valve (5) into drive end of compressor and push inward until slide valve stops.

Figure 47 - Slide stop on left, slide valve on right, unloader spring at bottom.

4. Install unloader spring (96) into slide valve.

Figure 48 - Location to secure unloader spring

5. Install "T" wrench into slide stop. Guide the slide stop onto the unloader spring. Ensure that spring is inserted both in the slide valve hole and slide stop hole. Push the slide stop into the compressor against spring force while at the same time inserting a 12 mm x (at least) 127 mm long threaded rod or cap bolt into the oil drill port located in the bottom of the compressor. Using the rod or cap bolt, feel along the bottom of the slide stop until the hole is located. Thread the rod / capbolt into the slide stop and reduce the force being applied to "T" handle. The bolt will stop against the side of the drain hole securing the slide stop and spring in place. Remove "T" handle. See Figures 48 and 49.

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Jackshaft

Gear

Shoulder

Figure 50 - Bull gear on jack shaft

If heating in oil bath, ensure that temperature does not exceed fl ash point of oil.

Heat resistant gloves must be worn when installing gears and inner rings.

Figure 49 - Installing and securing slide stop

7.2 JACKSHAFT GEAR INSTALLATION

NOTE: Slide valve piston will be installed after gear cover is mounted.

NOTE: Count the number of teeth on both gears and compare with Table 1. This will ensure the correct set is being used.

NOTE: To save time during the jackshaft assembly process, it is recommended that the inner rings of roller bearings (51) and (52) be installed as soon as possible after installing the bull gear (45). Once the bull gear is installed, heat is pulled from the gear and into the jackshaft. The added expansion of the jackshaft will make it diffi cult to install the roller bearing inner rings. If to much times expires after installing the gear, simply wait until the jackshaft cools to install bearing inner rings.

1. In preparation for installing both jackshaft bull gear (45) and the male rotor pinion gear (45), both gears must be heated to 300°F (148°C). Heating typicaly requires two hours to ensure that the entire mass of the gear is fully heated. Gears can be heated in oven or oil bath. DO NOT USE OPEN FLAME.

2. Secure the jackshaft (17) vertically with the keyway section downward. If using a vise, cover jaws with wood to protect jackshaft. The jackshaft must be secured below the shoulder where the bull gear is seated. See Figure 50.

3. Using heat resistant gloves, slide bull gear down jack-shaft until seated against shoulder. As soon as bull gear is seated, slide on inboard bearing spacer (26) and inner ring of bearing (52). Push down on inner ring to ensure spacer cannot rotate. See Figure 51.

4. Turn jackshaft in opposite direction and install outboard bearing spacer (25) and inner ring of roller bearing (51). Let assembly cool. See Figure 51.

Inner Ring (52)

Inner Ring (51)

Spacer (25)

Spacer (26)

Figure 51 - Jackshaft identifi cation

7.3 PINION GEAR INSTALLATION

1. Ensure that rotor shaft is free of burrs and scratches prior to installing pinion gear.

2. Install heated pinion gear on male rotor shaft (1). Push pinion gear against shoulder. Hold in place until gear cools and grips jackshaft. Gear must be installed with the threaded holes to the outside.

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Figure 52 - Pinion gear installation

7.6. JACKSHAFT AND GEAR COVER MOUNTING

1. Install bearing (52) in rotor housing. Freezing the bearing is recommended to make installation easier. The bearing can also be installed by tapping on the outer ring. Install retainer ring (89) in front of bearing.

2. Install two 12 mm guide pins in rotor houisng. See Figure 53.

Figure 53 - Jackshaft mounted in rotor houing

3. With the gear cover secured, install retaining ring (89) in jackshaft bore. Install retaining ring from the back side of gear cover (2).

4. Install outer ring of roller bearing (51) through front side of gear cover until positioned against retaining ring (89). The bearing can be installed as described in step 1 of this section.

5. Mount jackshaft into bearing (52) while ensuring that the bull gear meshes with the pinion gear.

Figure 55 - Mounting gear cover

6. Install new O-ring (73) on rotor housing. O-ring should be lubricated with new refrigeration oil. A light coat of grease can be used to secure the O-ring.

7. Attach lifting strap or eyebolt to gear cover and install the cover (2) over jackshaft and 12 mm guide pins. Care must be taken not to damage the jackshaft while mounting the housing. See Figure 55.

8. Push in on gear cover until dowel pins located on the cover align with the mating holes.

9. Install cap bolts (55) and tighten in a criss cross pat-tern to a 144 ft-lb (195 Nm). Ensure that cover is installed evenly.

Figure 54 - Mounting gear cover

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7.5 JACKSHAFT BEARING INSTALLATION

1. Slide the inboard inner ring of bearing (53) onto the jackshaft until it becomes affi xed to major diameter of shaft. The inner rings are interference fi t and must be pushed on.

2. Insert 3/4"-10 threaded rod into the end of the jack-shaft.

Figure 56 - Threaded rod, bearing tool

3. Insert pusher tool into pusher barrel and slide assembly over the jackshaft.

Figure 57 - Inserting pusher barrel on pusher insert

Figure 58 - Jackscrew, 3/4" nut, and washer

4. Ensure that jackscrew installed in pusher barrel does not contact jackshaft while installing thrust bearing.

5. Install washer and 3/4" nut on threaded rod. While hold-ing the jackscrew in place, tighten the 3/4" nut by turning it clockwise. Once the the 3/4" nut becomes tight, the inner ring is fully installed. See Figure 59.

Figure 59 - Bearing installation toll assembly

6. Remove the thrust bearing installtion tool.

7. Install the remaining components of bearing (53). The outer portion of the bearing will rest on the shaft. As the outboard inner ring is pressed on, the outer portion of bearing will be pushed into position. Reinstall the bearing installation tool and repeat steps 3 to 5.

7.6 INSTALLATION OF JACKSHAFT LOCKNUT

1. Install and hand tighten locknut (93) on the jackshaft.

Figure 60 - Locknut installation

2. Install spanner wrench (534C1096G01) over shaft and engage into locknut. See section 3.2.

3. Attach spanner tool arms (534A0579H01) as shown in section 3.2, Figure 23.

4 Install torque applier tool as described in section 3.2, Figure 21.

5. Turn the jackshaft in the counterclockwise to the required torque of 325 to 345 ft-lb (441 to 468 Nm). A torque multiplier is recommended to make the tightening process easier.

6. Install shaft seal as outlined in section 1.3.

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8.1 SLIDE STOP PISTON INSTALLATION

Install gear cover. See section 7.6.

Install Slide Stop. See section 7.1.

1. Install O-ring (75) into groove on slide stop piston (16). Heat Glyd Ring (41) to approximately 110°F (43°C). Care-fully stretch Glyd Ring over the piston and into groove over O-ring (75).

1b. Place a retainer ring over Glyd Ring. Let in place for 15 minutes.

2. Install O-ring (67) and Glyd Ring (40) on stepper piston (16). Repeat step 1b.

NOTE: Once Glyd Ring is installed, mount retainer over Glyd Ring in order to press the ring into position.

NOTE: Only stretch the Glyd Ring enough to allow it to fi t snugly over piston. Overstretching the Glyd Ring will result in permanent damage.

Figure 61 - Retainer mounted over Glyd Ring

3. Thread "T" wrench into slide stop piston (16) and install piston in bore. See Figure 62.

4. Install slide stop stepper piston (15) into gear cover and onto slide stop piston (16).

5. Install new O-ring (70) on slide stop cover (7). Mount cover to compressor.

6. Remove threaded rod from beneath the rotor housing that is securing the slide stop.

Figure 62 - Slide stop piston installation

8.2 SLIDE VALVE PISTON INSTALLATION

1. Install O-ring (65) into I.D. of check valve retainer (21). Insert check valve (109), chamfered portion inward, into retainer. Install retainer ring (88) in check valve retainer.

NOTE: Installing check valve (109) backwards will result in the slide valve instantly traveling to the loaded position at start-up.

6588

109

21

80

Figure 63 - Check Valve Parts, Slide vlave piston

2. Install O-ring (74) and Glyd Ring (42) on slide valve piston (18) Refer to Section 8.1, steps 1 and 2 for Glyd Ring installation.Pro

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9. Install O-ring (67) on bore cover (8). Secure bore cover to dishcharge housing with cap bolts (63). Torque to 58 ft-lb (79 Nm).

8.3 LINEAR TRANSMITTER ASSEMBLY

1. Install O-ring (79) on OD of Transmitter Well (126).

2. Insert compression spring (94) over indicator rod and install into well. Install Linear Transmitter assembly into compressor. Hex head on indicator rod guide is 3/4". Tighten until snug.

3. See Figure 66 for illustration of Linear Transmitter.

4. Place new cap bolt (61) through slide stop piston. Insert slide valve piston into bore until cap bolt can be inserted into slide valve.

Figure 64 - Slide valve pistion installation

5. Using a 10 mm Allen wrench, thread cap bolt into slide valve. DO NOT FULLY TIGHTEN. Using an object such as a hammer handle or the allen tool, push piston into bore approximately 2 in. (50.8 mm) and fi nish tightening cap bolt. Tighten to 50 ft-lb (68 Nm). Reduce spring tension.

Figure 65 - Tightening Slide valve piston

6. Push the piston inward to the fully loaded position and allow the spring force to push the piston back.

7. If slide valve piston sticks while unloading, loosen cap bolt (61), rotate piston 180 degrees, and repeat step 5.

8. Once piston moves freely, install check valve retainer. Hex size for retainer is 1¼". Tighten only until snug.

Figure 66 - Identifi cation of Slide Valve Indicator, Linear Transmitter design

Item (106) 534C1552H01 – Linear Transmitter with Well

Item (94) 534A0883H01 – Spring

Item (79) 980A0012K62 – O-ring

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Figure 67 - Bearing orientation and shim location

1. When adjusting shims are required, install between the roller bearing and the fi rst thrust bearing.

2. Depending upon clearance adjustment, shim placement could be between either the inner rings or outer rings.

3. The parts identifi ed as item 112 are .020" (0.508 mm) shims.

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Figure 68 - Top view of compressor

See pages following Figure 69 for part number identifi cation for Figures 68 and 69.

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Figure 69 - Side view of compressor

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ITEM P/N NAME

1 534A0542G01 FINISHED ROTOR PAIR2 534A0925G01 ROTOR CASING ASSEMBLY3 534D0914C01 DISCHARGE CASING 5 534D0916C01 SLIDE VALVE 6 534D0917H01 SLIDE STOP 7 534C1057C01 SLIDE STOP COVER8 534C1058C01 CYLINDER COVER9 534C1059C01 OUTLET BORE COVER10 534C1060C01 FEMALE DISTANCE SLEEVE11 534C1061C01 MALE DISTANCE SLEEVE12 534C1062C01 SUCTION FLANGE14 534C1072HO1 INLET BUSHING 15 534D0918H01 STEPPER PISTON16 534D0919H01 SLIDE STOP PISTON17 534D0920H01 JACKSHAFT16 534D0921H01 SLIDE VALVE PISTON19 534D0929C01 SEAL HOUSING COVER 20 534D0944H01 SEAL HOUSING 21 534A0555H01 CHECK VALVE RETAINER22 534A0557H01 LOW VI LIQUID INJ. PLUG23 534A0568H01 HIGH VI LIQUID INJ. PLUG24 534A0559H01 SEAL HOUSING SPACER25 534A0560H01 OUTBOARD BEARING SPACER26 534A0561H01 INBOARD BEARING SPACER27 534B1023H01 INDICATOR ROD28 534B0523H01 ECONOMIZER PLUG29 534C0194H27 ORIFICE PLUG 30 535B0243H01 SUCTION FLANGE 31 944A0296H08 SOCKET WELD FLANGE 32 531A0117H10 SEALING DISK 33 531A0117H15 SEALING DISK 37 534B0527H01 SUCTION STRAINER38 534A0662H02 SQUARE KEY39 534B0079H08 SLYDRING40 534C0187H16 GLYD RING 41 534C0187H17 GLYD RING42 534C0187H18 GLYD RING43 534BO732H01 SHAFT SEAL ASSEMBLY44 333Q0000910 LIP SEAL45 534A0564G01 GEAR SET 51:4646 534A0564G02 GEAR SET 55:4247 534A0564G03 GEAR SET 60.37 48 534A0564G04 GEAR SET 64:3349 534B0004H28 CYLINDRICAL ROLLER BEARING50 534B0004H29 CYLINDRICAL ROLLER BEARING51 534B0004H30 CYLINDRICAL ROLLER BEARING

ITEM P/N NAME

52 534B0004H31 CYLINDRICAL ROLLER BEARING53 534B0101H27 FOUR-POINT BALL BEARING54 534C0478H12 CAP BOLT55 111Q0740737 ANGULAR CONTACT BALL BEARING56 111Q0740749 HEX HEAD CAP SCREW57 111Q0740781 HEX HEAD CAP SCREW M24x3.O58 111Q0740807 CAP BOLT59 111Q0740845 CAP BOLT 60 333Q0001522 HEXAGON HEAD CAP SCREW62 534A0572H02 CAPBOLT63 901A0085H08 CAP BOLT 64 901A0085H19 CAP BOLT 65 980A0012A52 0-RING 66 980A0012B63 0-RING 67 980A0012B72 0-RING 68 980A0012B73 0-RING 69 980A0012B76 0-RING 70 980A0012B78 0-RING 71 980A0012B91 0-RING 72 980A0012H10 0-RING 73 98OA0012H12 0-RING 74 980A0012H49 0-RING 75 980AO012H51 0-RING 76 980A0012H55 0-RING 77 980A0012K58 0-RING 78 980A0012K60 0-RING 79 980A0012K62 0-RING 80 980A0012K66 0-RING 81 980A0012K72 0-RING83 534A0037H12 DOWEL PIN 84 534B0149H01 DOWEL PIN 85 534B0151H01 DOWEL PIN 88 534A0038H02 SPRINGPIN 316x5887 534A0038H06 SPRING PIN 88 534A0570H01 RETAINING RING89 534B0014H09 RETAINING RING90 534B0015H13 RETAIN1IG RING91 534B0174H17 RETAINING RING92 534B0909H02 LOCKNUT93 534B0909H04 LOCKNUT94 534AO883H01 COMPRESSION SPRING 95 534A0218H01 COMPRESSION SPRING 96 534A0569H01 UNLOADER SPRING 97 534A0591H01 WAVE SPRING98 111Q0630050 CAPPLUG99 111QO451948 CHARGING VALVE

Refer to Figures 68 and 69.

PARTS LIST

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S70-452 SM (JUL 04)


ITEM P/N NAME

101 649A0890H02 DIN CONNECONNECTOR102 649A0890H11 SILICONE GASKET103 951A0095H01 COIL104 111Q0993344 SOLENOID VALVE V.I. 106 534A0565HO1 SOLENOID VALVE GASKET V.I107 959A0044H11 GASKET108 959A0057H09 GASKET109 534A0173H01 CHECK VALVE110 534A0673H01 COVER PLATE 111 111Q0831809 REFRGIERATION OIL112 534A0568H05 CIRCULAR SHIM 113 534A0394H01 WARNING LABEL116 944A0246H01 BUSHING117 944A0228H03 STRAIGHT THREAD O-RING PLUG 118 944A0228H05 STRAIGHT THREAD O-RING PLUG 119 944A0228H06 STRAIGHT THREAD O-RING PLUG 120 944A0228H08 STRAIGHT THREAD O-RING PLUG 121 991A0036H01 NAMEPLATE122 903A0003H08 DRIVE PIN123 534C1160H01 GAS SEAL124 980A0012B02 0-RING 2—151125 534C0194H81 ORIFICE 126 534C1552H01 TRANSMITTER

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S70-452 SM (JUL 04)


XJF 151 CLEARANCE RECORD

Male Female

Total rotor-to-casing clearance: ___________ ___________

Model 151 mm .020" – .028" (0.508 mm – 0.711 mm)

Compressor Model _____________________Serial Number _________________________Assembled by _________________________Date Assembled ________________________

Outlet Case Number ___________________Rotor Case Number ___________________Gear Cover Number ___________________Rotor Number ________________________

DISCHARGE END CLEARANCE CALCULATION Male Female As measured discharge end clearance ___________ ___________

Desired discharge end clearance .003" – .005" (.076 mm – .127 mm) ___________ ___________

Calulated shim thickness and location ___________ ___________

NOTE: When calculated discharge end clearance is greater than .005 inch, install shims in casing borebetween roller bearing and ball bearing.

NOTE: When calculated discharge end clearance is less than .0015 inch, install shims on rotor between roller bearing and ball bearing.

Actual shim thickness ___________ ___________ Location of shims (rotor or case) ___________ ___________

Actural measured end clearance Spec. .003" – .005" (0.076 mm to 0.127 mm) __________ ___________

NOTE: Use maximum air pressure of 100 – 120 psi.

Number of teeth on drive gear ________ Number of teeth on pinion _________ See Table 1 for gear information

Jackshaft movement spec. .001" – .005" (0.0254 mm – 0.127 mm) _________

Slide valve indicator rod .044" – .084" (1.1176 mm to 2.1336 mm); measurement is taken from face of nut to tip of rod when compressor is unloaded _________

MAXIMUM TRAVEL _________ Spec. .390" +/- .040" - inch (travel measued at 2.2 V.I)

COMPRESSOR BUILD SHEET

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S70-452 SM (JUL 04)


NOTES

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Form S70-452 SM (704)Supersedes: Nothing

Subject to change without noticePrinted in USA • GUI 100 905 3.60

© 2005 YORK International - ALL RIGHTS RESERVED

YORK Refrigeration Systems 100 CV Avenue • P.O. Box 997Waynesboro, PA USA 17268-0997Phone: 717-762-2121 • FAX: 717-762-8624www.frickcold.com

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Service Manual Property of American Airlines€¦ · FRICK XJF 151MM ROTARY SCREW COMPRESSOR...

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