Frick XJF 120, Service Manual

Page 1: ... 101 SM NOV 94 File SERVICE MANUAL Section 70 Replaces Nothing NewInformation Dist 3 3a 3b 3c Service Manual ROTARY SCREW COMPRESSORS XJS and XJF 95 120 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 2: ...n 15 SECTION5 ROTORSANDBEARINGS Removal 17 Installation 19 SECTION6 COMPRESSORSUCTIONSTRAINER Removal 24 Cleaning and Installation 24 APPENDIX Table 1 1 Compressor Clearance Record 27 FIGURES 1 1 Gear Cover End View 5 1 2 Shaftseal Jackshaft Gears Rotors and Bearings Sectional View 6 1 3 Clamp Collar Installation Tool 9 1 4 Slide Valve and Slide Stop Sectional View 10 1 5 Slide Valve Indicator 14 ...

Page 3: ...roperlyadjustedandingoodcondition toavoidfloodingcompressorwithliquid Liquidcancauseareduction incompressorlife andinextremecases cancausecompletefailure XJS 95 120 S 0123 D 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 know...

Page 4: ... damaged unit is not only unsafe but continued use will cause additional damage and or component failure DONOTattemptanyoperationor perform any maintenance before youreadandunderstandallSafety Practices in this manual Ensure that work area is ad equately ventilated and wear proper safety equipment when compressorisopentoatmosphere Indicates an imminently hazardous situation which if not avoided wi...

Page 5: ...9 DO NOT operate compressor exhibiting excessive pres sureand ortemperaturechanges Immediatelyshutdownunit and complete all necessary repairs and functional checks before attempting to restart 10 NEVERaltercompressorfromoriginaldesign Onlythose alterations approved by Frick Company and or performed by authorized Frick service personnel are permitted 11 KEEP COMPRESSOR CLEAN free of debris and prop...

Page 6: ...ring Pin 21 Male Inlet Bushing 22 Rotor Casing 23 O Ring 24 Gas Seal 25 Roller Bearing 26 Angular Contact Ball Bearing 27 O Ring 28 Pipe Plug 29 O Ring 30 Balance Piston Sleeve 31 Wave Spring 32 Bearing Spacer 33 Balance Piston 34 Four Point Contact Ball Bearing 35 Lockwasher 36 Locknut 37 Compression Spring 38 Male Distance Sleeve 39 Outlet Bore Cover 40 Spring Pin 41 Outlet Bore Cover 42 Wave Sp...

Page 7: ...ad screw in clamp collar 2 remove clamp collar and seal seat backup ring 3 from jackshaft 1 5 Remove capscrews 7 securing seal housing 4 to gear cover 52 Remove seal housing and seal housing o ring 8 A small amount of oil will drain from housing NOTE Provisions should be made to catch residual oil that will drain when seal housing is removed 6 Remove seal housing oil supply tubing 3 Figure 1 1 7 R...

Page 8: ...w port 4 Place seal housing on workbench with outboard side down Coat new o ring with clean refrigerant oil install o ring in groove in seal housing located in stationary carbon bore 5 Coat carbon faced seal with clean refrigerant oil 6 Carefully place carbon faced seal assembly with carbon end up in seal housing Using nonmetallic Seal Installation Toolandbeingcarefulnottotouchcarbon pushsealassem...

Page 9: ... ring 32 Figure 1 4 while holding stepper piston in by hand 8MM T WRENCH STEPPER PISTON 5 Remove stepper piston with glyd rings 10 and 28 Figure 1 4 and o rings 11 and 29 Figure 1 4 If glyd rings and o rings are to be replaced cut glyd rings off of stepper piston using knife and remove and discard o rings 4 Thread 8mm T wrench into stepper piston and push piston inagainstspringforce Withfinger thr...

Page 10: ...harge Casing 8 Socket Head Capscrew 9 Spring Pin 187 x 625 10 Glyd Ring 11 O Ring 12 O Ring 14 Cylinder Cover 15 Slyd Ring 16 Check Valve Retainer 17 Internal Check Valve 18 O Ring 19 Slide Valve Piston 20 Fastener for 19 21 Slide Valve 22 Unloader Spring 23 Spring Support 24 Pipe Plug 25 Slide Stop 26 Slide Stop Piston 27 Stepper Piston 28 Glyd Ring 29 O Ring 30 Slide Stop Cover 31 Key 32 O Ring ...

Page 11: ...tion of four point bearing from gear cover 12 Remove retaining ring 12 from gear cover using screw driver RETAINING RING 13 Remove outer race of roller bearing 11 from gear case using Bearing Puller Owattona Tool Co p n 943 BEARING PULLER NOTE If replacement Jackshaft Kit is used steps 14 through 16 do not apply SLIDE STOP PISTON 7 Remove two capscrews 1 from opposite sides of gear cover 2 Install...

Page 12: ...gainst bearing spacer 13 and hold in place until bearing cools and grips jackshaft Protective heat resistant gloves must be worn when installing bear ing inner race 3 Heat inner race of roller bearing 17 to 250 F 232 C for one hour andinstallraceonjackshaft Pushinnerraceagainstbearing spacer 16 and hold in place until race cools and grips jackshaft 4 Installouterraceofbearing 17 inrotorcasing 22 s...

Page 13: ... slide stop piston 26 Figure 1 4 To install glyd ring heat to 250 F 121 C for one hour and push into slot Use a 4 inch 10 cm hose clamp to hold glyd ring in place for 10 minutes Protective heat resistant gloves must be worn when installing bear ing inner race 18 Place slide stop piston inside stepper piston Thread 8mm T wrench into stepper piston install stepper piston and slide stop piston in com...

Page 14: ...op Figure 1 5 Slide Valve Indicator 1 9 2 3 4 5 6 7 8 1 Wiring Connection 2 O Ring 3 O Ring 4 Indicator Rod Spring 5 Rod Guide 6 Indicator Rod 7 Slide Valve Piston 8 Cylinder Cover 9 Discharge Casing 4 Placesuitabledrainpanunderslidestopcover 30 remove capscrews 7 Figure 1 2 securing slide stop cover to gear housing 2 Remove slide stop cover and o ring 32 5 Thread 8mm T wrench into stepper piston ...

Page 15: ... Without installing the rotors install the discharge hous ing to the rotor housing Secure the discharge housing with two cap screws and insert dowel pins 2 By inserting your hands through the suction ports move the s v into the discharge port so that the s v guides are securing the s v in place 3 Push against the side of the slide valve with one hand and by using either a thin feeler gauge or fing...

Page 16: ... slide stop 9 Ifpreviouslyremoved installo ring 11 andglyd rings 10 and 15 on slide valve piston To install glyd ring heat to 250 F 121 C and push into slot Use a 4 inch 10 cm hose clamp to hold glyd rings in place for 10 minutes 10 For old style piston Through drive end of compressor apply pressure to slide valve with handle of rubber mallet and install slide valve piston into discharge end of co...

Page 17: ...ssion springs 37 5 Remove capscrews 8 Figure 1 4 securing outlet bore cover 41 to discharge casing remove outlet bore cover with o ring remove spring washer 42 or wave spring on newer units 6 Remove male distance sleeve 38 and female distance sleeve 44 7 Atnondriveendofmaleandfemalerotorshafts 47 bend one tab back on each lockwasher 35 that was previously bent into recess of its respective locknut...

Page 18: ...drive end of female rotor shaft Turn jacking screw clockwise to remove angular contact ball bearings from shaft When jack ing screw bottoms remove tool NON DRIVE END FEMALE ROTOR SHAFT JACKING SCREW DISCHARGE BALL BEARING REMOVAL TOOL FEMALE DISCHARGE BEARING GROUP 15 Remove angle contact ball bearings and shim if used from female rotor bore in discharge casing Label any shims to permit reinstalla...

Page 19: ...n installing bear ing inner race ALWAYS tap against outer race NEVER on ball and cage 4 Install two new roller bearings 49 and 19 in rotor casing Bearings can be installed by freezing prior to installation or by tapping them into casing with a rubber mallet 5 Installtwonewretainingrings 50and18 securingroller bearings in place NOTE Any repair to rotors should be accomplished prior to installing in...

Page 20: ... discharge end of rotor casing apply a light coating of grease to keep o ring in place Align discharge casing with rotor casing ensuring that dowel pins 46 and 58 engage dowel pin holes secure discharge casing with four capscrews 1 and 5 Figure 1 4 evenly spaced around casing flange Tighten capscrews to a torque value of 58 foot pounds 79 Nm NOTE If air tool is not available a 12 mm T handle can b...

Page 21: ...ated in step 7 this section See Figure 1 6 for shim placement and correct orien tation of bearings NOTE Use 12mm T wrench threaded into opposite end of rotor to prevent rotor from turning while using D i s charge Ball Bearing Installation Tool 15 Using Discharge Ball Bearing Installation Tool install two angle contact ball bearings 26 one at a time on female rotor shaft Ensure that bearings are in...

Page 22: ...raph 1 3 2 38 Install jackshaft and gears Refer to paragraph 1 2 2 39 Install shaft seal Refer to paragraph 1 1 2 With bearing clamped record male rotor measured end play in Table 1 1 for future reference should be within 0015 003 31 RemovemodifiedMaleDistanceSleeveTool guidepin and modified Outlet Bore Cover Tool from male rotor 28 Install lockwasher 35 and locknut 36 on male rotor shaft tighten ...

Page 23: ... INSTALL BALL BEARINGS WITH IDENTIFICATION MARK ON THIS SIDE ONLY INSTALL BALL BEARING WITH IDENTIFICATION MARK ON THIS SIDE ONLY INSTALL BALL BEARING WITH IDENTIFICATION MARK ON THIS SIDE ONLY BEARING INSTALLATION MALE ROTOR BEARING INSTALLATION FEMALE ROTOR LOCATION OF 002 SHIM 1 Roller Bearing 2 Angular Contact Ball Bearing 3 Four Point Contact Ball Bearing Figure 1 6 Bearing Orientation P r o ...

Page 24: ... 2 COMPRESSOR SUCTION STRAINER CLEAN ING AND INSTALLATION Compressor suction strainer cleaning and installation shall be accomplished as follows SUCTION STRAINER ASSEMBLY ROTOR CASING Figure 1 7 Compressor Suction Strainer NOTE Index numbers refer to Figure 1 7 unless other wisenoted 1 Thoroughly clean suction strainer assembly with OSHA approved nonflammable degreaser and soft bristle brush 2 Ins...

Page 25: ...Figure 1 8 Orifice Hole Location for XJS and XJF 95 DISCHARGE BEARING ORIFICE MAIN OIL INJECTION ORIFICE The orifice holes shown require cleaning to ensure proper oil flow See Figure 1 9 for location of oil feed orifice hole P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 26: ...ATION OF MAIN OIL INJECTION ORIFICE PLUG C L MOUNTING HOLE HIGH VI LIQUID INJECTION ECONOMIZER 1 2 3 2 4 1 Seal Housing 2 Elbow 3 Oil Supply Line 4 Gear Cover Discharge bearing orifice on compressors which do not have control valve mounted on discharge housing Orifice hole to spray gear Oil feed orifice hole The orifice holes shown require cleaning to ensure proper oil flow Typ 95mm and 120mm P r ...

Page 27: ...ed discharge end clearance Total ________ ________ Estimated shim thickness ________ ________ Estimated discharge end clearance 0015 to 003 inch ________ ________ NOTE Whencalculateddischargeendclearanceisgreaterthan 003 inch installshimsincasingborebetween roller bearing and ball bearing NOTE When calculated discharge end clearance is less than 0015 inch install shims on rotor between roller bear...

Page 28: ...n U S A Subject to Change Without Notice 100 CV Avenue P O Box 997 Waynesboro Pennsylvania USA 17268 0997 Phone 717 762 2121 Fax 717 762 8624 www frickcold com P r o p e r t y o f A m e r i c a n A i r l i n e s ...