Form S70-452 SM (JUL 2004)

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

Service Manual

s
ne
ROTARY SCREW COMPRESSOR

rli
XJF 151mm

Ai
an
ic
er
Am
of
ty
er
op
Pr
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 2 SERVICE MANUAL

Contents

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

s
SAFETY PRECAUTIONS .......................................................................................................................................4

ne
GENERAL SAFETY PRACTICES (CONTD) ...........................................................................................................5
COMPRESSOR TEARDOWN ...................................................................................................................................5
BASIC PRACTICES ................................................................................................................................................5

rli
TABLE 3 - RECOMMENDED SPARE PARTS KITS ................................................................................................5
SECTION 1 - SHAFT SEAL REPLACEMENT. ........................................................................................................6

Ai
1.1 SHAFT SEAL REMOVAL..................................................................................................................................6
1.2 SHAFT SEAL INSTALLATION ...........................................................................................................................6
2.1 SLIDE STOP REMOVAL..................................................................................................................................10

an
3.1 GEAR COVER / JACKSHAFT REMOVAL .......................................................................................................11
3.2 JACK SHAFT LOCK NUT REMOVAL..............................................................................................................11
3.3 GEAR COVER REMOVAL ...............................................................................................................................12
ic
3.4 JACKSHAFT THRUST BEARING REMOVAL .................................................................................................12
3.5 SLIDE VALVE AND SLIDE PISTON REMOVAL ..............................................................................................14
er
3.6 PINION GEAR REMOVAL ...............................................................................................................................15
4.1 DISCHARGE HOUSING BEARING REMOVAL .............................................................................................15
5.1 CLEANING COMPONENTS FOR REASSMEBLY ..........................................................................................17
Am

5.2 SLIDE VALVE TO SLIDE VALVE GUIDE INSPECTION ..................................................................................17

6.1 ROTOR AND ROLLER BEARING INSTALLATION .........................................................................................18
ROTOR CASE TO CASE CLEARANCE ..........................................................................................................19
6.2 THRUST BEARING INSTALLATION................................................................................................................19
of

6.3 ROTOR DISCHARGE END CLEARANCE ......................................................................................................20

7.1 SLIDE VALVE / SLIDE STOP INSTALLATION ................................................................................................21
7.2 JACKSHAFT GEAR INSTALLATION ...............................................................................................................22
ty

7.3 PINION GEAR INSTALLATION ......................................................................................................................22

7.6 JACKSHAFT AND GEAR COVER MOUNTING ..............................................................................................23
7.5 JACKSHAFT BEARING INSTALLATION .........................................................................................................24
er

7.6 INSTALLATION OF JACKSHAFT LOCKNUT .................................................................................................24

8.1 SLIDE STOP PISTON INSTALLATION ............................................................................................................25
op

8.2 SLIDE VALVE PISTON INSTALLATION...........................................................................................................25

8.3 LINEAR TRANSMITTER ASSEMBLY .............................................................................................................26
Pr
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 3

GENERAL • Avoid slugging compressor with liquid refrigerant. While

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
XJF 151 M 0123
MODEL NUMBER
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 flooding 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
M
setting for long periods without running,it is advisable to
evacuate to low pressure and charge with dry nitrogen or

s
oil, particularly on systems known to contain amounts of
ROTOR DIA. (MM) water vapor.

ne
2.13/1 GEAR RATIO – S • Preventive maintenance inspection is recommended any
1.31/1 GEAR RATIO – M
1.62/1 GEAR RATIO – L time a compressor exhibits a noticeable change in vibration

rli
1.93/1 GEAR RATIO – N level, noise level, and/or performance.

Ai
SERIAL NUMBER NOTES:
A - 151A 1. Some photographs or illustrations in this manual may be
M - 151M of prototype or special order units. Production models may

an
L - 151L vary in some detail from those shown.
N - 151N
2. Some photographs or illustrations in this manual may
ic
show units with optional equipment installed. These items
TABLE 1 are available through your authorized Frick Factor.
er
Number of teeth 3. Some of the photographs shown in this manual are of the
XJF/XJS 120mm compressor. The photographs are used as
Am

Bull Gear Pinion Gear

S gear set 51 46 reference and are simular to the XJF151mm compressor.
M gear set 55 42
PREVENTIVE MAINTENANCE
L gear set 60 37 INSPECTION AND SERVICE
N gear set 64 33
of

Frick® Model XJF 151 Rotary Screw Compressors are

designed and manufactured to the highest engineering and
quality standards to provide optimum performance and
ty

GENERAL MAINTENANCE
continued service in applications of intended use, with no
Proper maintenance is important in order to ensure contin- deviations from original design. A preventive maintenance
er

ued, trouble-free service from your compressor. Some areas program ensures maximum compressor life and minimizes
critical to optimum compressor operation are: costly unscheduled unit downtime. Immediate shutdown and
op

inspection should be made if increased sound or vibration,

• Keep refrigerant and oil clean and dry to avoid moisture increased shaft seal leakage, erratic slide valve operation, fluc-
contamination. After servicing any portion of the refrigera- tuating oil pressure, loss of compressor efficiency, increased
tion system, evacuate to remove moisture before returning
Pr

oil consumption, and/or oil contamination are observed.

to service. Water vapor condensing in the compressor while Major inspection should be made, per the schedule, listed
it is running, or more likely while it is shut down, can cause in the Frick Rotary Screw Compressor IOM manual.
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
find its way into the compressor suction. Excessive dirt in the
suction strainer could cause it to collapse, dumping debris
into the compressor.
Keep oil filters clean. If filters show increasing pressure
drop (indicating dirt or water), stop compressor and change
filters. Running a compressor for long periods with high filter
pressure drop can cause oil starvation and lead to premature
bearing failure.
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 4 SERVICE MANUAL

TORQUE DATA
Indicates an imminently hazardous
Torque requirements applicable to the procedures contained situation which, if not avoided, will
in this manual are listed below. result in death or serious injury.

Indicates a potentially hazardous

TABLE 2 - TORQUE SPECIFICATIONS situation which, if not avoided, could
result in death or serious injury.
TORQUE VALUE
CAPSCREW SIZE
ENGLISH METRIC SOCKET SIZE
Indicates a potentially hazardous
M4 2 ft-lb 2.7 Nm 3 mm situation or practice which, if not
M5 4 ft-lb 5.4 Nm 4 mm avoided,will result in damage to
M6 7 ft-lb 9.5 Nm 5 mm equipment and/or minor injury.
M8 18 ft-lb 24.4 Nm 6 mm
M12 58 ft-lb 78.7 Nm 10 mm

s
Indicates an operating procedure,
M16 144 ft-lb 195.3 Nm 14 mm
NOTE: practice, etc., or portion thereof

ne
M20 260 ft-lb 352.5 Nm 17 mm
M22* 368 ft-lb 499 Nm 32 mm which is essential to highlight.

* Hex Head GENERAL SAFETY PRACTICES

rli
NOTE: To convert foot-pounds of torque to metric Newton-meters, It would be impossible to compile a list of all Safety Prac-
multiply foot-pounds times 1.3558 (Example: 75 ft-lb x 1.3558 equals

Ai
101.7 Nm)
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
SPECIAL TOOLS AND TEST EQUIPMENT
varied applications and customer-specified configurations.

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
Am
an
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-
ic
tion, combined with standard industry safety practices, local,
state, and federal regulations, establish the overall safety
er
requirements for the workplace.

Compressor Size 151mm

Always shut down unit and dis-
Equipment Item No. connect power before making any
Wrench, Spanner 333Q0000948 adjustments or repairs.
Arm, Spanner Tool 534A0579H01
of

Operating a damaged unit is not

Key for Torque Applier 534A0662H02
only unsafe, but continued use will
T-Wrench 534B0530G01 cause additional damage and/or
Torque Applier Assy. 534B0534G01
ty

component failure.
Rod Extension 534B0535H01
Bar Extension 534B0536H01 DO NOT attempt any operation or
er

Spacer Bearing 534B0540H01 perform any maintenance before

Spacer Bearing 534B0540H02 you read and understand all Safety
op

Puller, Pinion Gear 534C1093G01 Practices in this manual.

Wrench, Spanner 534C1096G01
Ensure that work area is adequate-
Air Cyliner Test Fixture 534E0541G01
Pr

ly ventilated, and wear proper

Jackshaft thrust bearing tool
**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 files.
• Snap ring pliers, assorted sizes.
• Inpact wrench, air or electric.
534D0243G01** safety equipment when compres-
sor is open to atmosphere.
SAFETY PRECAUTIONS
DANGERS, WARNINGS, CAUTIONS, and NOTES are
strategically placed throughout this manual to further empha-
size the importance of personal safety, qualifications 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 affixed
to applicable areas of the equipment. Safety Precautions are
defined as follows:
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 5

GENERAL SAFETY PRACTICES (CONTD) COMPRESSOR TEARDOWN

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
fittings; 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,
The procedures presented in this manual assume that all
maintenance will be performed by qualified, 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

s
and local ordinances, prior to begining any disassembly. 1. Always use Frick replacemment Parts. Substitution of
parts may result in faulty assembly.

ne
4. DO NOT make adjustments while the unit is operating,
unless required for service or maintenance checks. 2. NEVER reuse O-rings, Glyd Ring, seal-rings, locknuts
with Nyloc inserts, or lock washers.

rli
5. DO NOT operate a damaged compressor. Always com-
plete all repairs before running unit. 3. Coat all internal parts with clean refrigeration oil prior

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

an
in the area. nents.

7. NEVER operate compressor if you are taking medication
that causes blurred vision, dizziness, drowsiness, or slowed
reflexes.
er
8. DO NOT operate compressor if excessive vibration oc-
curs. Immediately shut down unit and complete all necessary
Am
5. NEVER allow anything to contact the sealing surfaces
ic
of shaft seals.
6. Bearings are supplied with a light film of oil. It is NOT
necessary to clean prior to installation. NEVER add grease
to compressor bearings.

repairs and required checks before attempting to restart. 7. Replace all cap bolts to prevent elongation of the
9. DO NOT operate compressor exhibiting excessive pres- threads.
sure and/or temperature changes. Immediately shut down
unit and complete all necessary repairs and functional checks TABLE 3
of

before attempting to restart.

10. NEVER alter compressor from original design. Only Recommended Spare Parts Kits
ty

those alterations approved by Frick and/or performed by

authorized Frick service personnel are permitted. 534M0602G02 Shaft Seal Kit
er

11. KEEP COMPRESSOR CLEAN, free of debris, and

properly lubricated. A clean, properly lubricated unit will 534M0602G01 O-ring - Gasket Kit
op

perform more efficiently and operate trouble-free.

534M0602G03 Bearing Kit (1)
REMEMBER: Any piece of equipment is only as
Pr

safe as those who use and maintain it. 534M0602G04 Jackshaft Kit 151 A (2)
534M0602G05 Jackshaft Kit 151M
534M0602G06 Jackshaft Kit 151 L
534M0602G07 Jackshaft Kit 151 N

NOTES:
1. Contains, adjusting shims, Gas Seals, Inlet Bushings.
DOES NOT contain Jackshaft Bearing.
2. Contains Shaft Seal.
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 6 SERVICE MANUAL

Evacuate compressor and oil separator (refer to S70-101 5. Remove rotating steel seat (43). Typically, the seat can be
IOM). removed by hand. If unable to be removed by hand, construct
two “L” shape puller rods to position behind the seat.
Remove flexible 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-
fied personnel to replace the jackshaft carbon-faced seal,
including required compressor disassembly.

1.1 SHAFT SEAL REMOVAL

s
Shaft seal removal shall be accomplished as follows: Refer

ne
to Figure 3 for parts identification.
1. Evacuate compressor and separator. Refer to

rli
S70-400 IOM.

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

an
3. Using the seal housing puller tool, remove seal housing (20) Figure 2 - Rotating steel seat
from gear cover. NOTE: Place container under shaft to
catch oil. Stationary carbon seal (43) and lip seal (44) are 6. Place seal housing on work table. Remove and discard
ic
secured in seal housing. The seal housing puller tool consists OD O-rings.
of two 10" long 8 mm threaded rods, two 8 mm nuts and 7. Remove carbon seal assembly by tapping on metal por-
er
a cross bar with two 10 mm holes drilled on 3.64" centers. tion of seal with rubber hammer. Remove and discard ID
Remove spacer (24). If a seal puller is not available, thread O-ring (66) in seal housing (20).
Am

an 8 mm cap bolt into the seal housing and pry against the
cap bolt head. See Figure 1. 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-
of

quired RMA paperwork. If the seal is out of the warranty

period discard seal, O-rings and lip seal.
ty

1.2 SHAFT SEAL INSTALLATION

er

Avoid damaging carbon-faced seal

and rotating seal seat. Mishandling
op

will shorten seal life. Do not touch

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

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
Figure 1 - Seal Housing Removal thrust bearing (53). See Figure 4.
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 7

19. Seal housing cover.

20. Seal housing.
24. Seal housing spacer.
43a. Carbon assem, Shaft seal.
43b. Stationary seat, Shaft seal.
44. Lip seal.

s
66. O-ring, ID of seal housing.

ne
69. O-ring, OD of seal housing
97. Wave spring

rli
Ai
Figure 3 - Shaft Seal Identification
an
ic
er
Am
of
ty
er
op

Figure 5 - Pin on Jackshaft

Figure 4 - Seal housing spacer install
Pr

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

S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 8 SERVICE MANUAL

7. Install lip seal (44) into seal housing (20). The lip seal has
an orifice hole located in the Teflon lip. The orifice must be
aligned with spring pin located on the opposite end of hous-
ing (20); this will ensure the orifice is located at the 12:00
o’clock position. Place the seal housing cover (19) on a flat
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.

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

rli
installed.
8. Install I.D. O-ring (66) and OD O-rings (69) on seal

Ai
housing spacer. Lubricate O-ring with refrigerant oil prior
to installing.

an
ic
er
Am

Figure 7 - Lip Seal

of
ty

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

er
op
Pr

Figure 8 - Lip Seal Installation Tool

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

 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 9

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.

s
ne
Figure 14 - Seal Housing fully seated

rli
NOTE: Wash hands before handling shaft seal. Take care

Ai
Figure 12 - Seal Housing Installation not to to allow the sealing faces to contact foreign objects.
Inspect carbon seal with flashlight prior to installation.
10. Install seal housing cover (19) and wave spring (97) over Only remove seal from container immediately prior to

an
jackshaft. Insert two 5" x 12 mm threaded rods through seal installation.
housing cover approximately 180 degrees apart. Install and
tighten 12mm nuts until seal cover is flush with gear cover. 11. Lubricate the carbon seal assembly with new refrigera-
ic
Remove threaded rods and seal cover. 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
er
seal housing. By using the seal housing cover as described
in step 10, push the carbon seal into the seal housing. See
Figure 15.
Am
of
ty
er
op
Pr

Figure 13 - Installing Seal cover to push on Seal spacer

Figure 15 - Installing Carbon Seal Assembly

S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 10 SERVICE MANUAL
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 16 - Seal housing cover installation.
Am
of
ty
er
Figure 17 - Installing Seal Cover Housing
2.1 SLIDE STOP REMOVAL
op
1. Place a suitable drain pan under slide stop piston cover.
Pr
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.
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.
s
ne
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
rli
cover. Secure piston with other hand to release spring
tension. Oil will follow piston.
Ai
6. Remove and discard Glyd Ring (40) and O-ring (76).
7. Remove slide stop piston (16) using "T" handle tool.
an
Remove and discard Gyld Ring (41) and O-ring (75).
ic
er
Figure 18 - Slide stop piston removal.
8. Remove unloader spring (96)
9. Remove slide stop (6) with "T" handle tool.
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 11

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 Torque Applier
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.
Spanner Arm
1. Figure 19 shows how the spanner wrench 534C1096G01

s
engages with the locknut (93). Figure 21 - Mounted assembly tool

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

rli
clockwise. Discard locknut.

Ai
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

an
mounted.
ic
er
Am

Figure 19 - Spanner wrench engaged in locknut

1. Slide spanner wrench over the jackshaft and engage in
of

locknut. See Figure 20.

ty
er

Figure 22 - Spanner wrench assembly

op
Pr

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.
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 12 SERVICE MANUAL

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.

s
ne
Figure 23 - Attachment of spanner tool arms

rli
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.

Ai
3.3 GEAR COVER REMOVAL

an
Prior to removing gear cover, refer to section 3.1, GEAR
COVER/JACKSHAFT REMOVAL.
1. Remove both slide stop solenoid valves (104) from gear
ic
cover (2). Remove gaskets (106) and discharge. Note posi-
er
tion of gaskets for reassembly.
2. Attach lifting strap around gear cover or lifting eye
Am

bolt to cover and attach to overhead lifting devise. See

Figure 24a.
of

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

the top of cover.
ty

Do not use prying devise between

gear cover and rotor housing.
er

5. Once gear cover (2) is removed from rotor housing, secure

op

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.
Pr

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.
Figure 24a - Eye bolt attached to gear cover
2. Install 3/4" - 10 threaded rod into jackshaft, Figure 25.
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 13

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.

s
Figure 28 - Arms added to Pusher Tool Assembly

ne
NOTE: Photograph showing tool used on TDSH163mm.
Setup is same for XJF151 compressor.
Figure 25 - Jackshaft with 3/4" - 10 threaded rod

rli
6. Once pusher tool is in place (see Figure 28), insert three
retainer arms into slots on pusher tool and secure arms to

Ai
gear cover using 12 mm cap bolts, figure (28). By turning
the jackscrew clockwise, the jackscrew contacts the jack-
shaft pushing the jackshaft free from the thrust bearing (53).

an
Remove jackshaft from gear cover.
It is important to secure the jack-
shaft during the bearing removal
ic
process. Once thrust bearing is free,
er
the jackshaft could fall causing damage or injury.
7. Remove retainer ring (89) from gear cover and push out
Am

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 fittings from gear cover
of

Figure 26 - Pusher insert tool for preparation of cleaning.

9. If the original jackshaft is being reused, the bearing
inner races and large gear (45) must be removed. Because
ty

the inner races and gear are heat shrunk to the shaft, a bear-
ing puller tool, see Figure 39, and heat is recommended for
er

removal. If a new jackshaft is being used, disregard this step

and proceed to Section 7.2 for reassembly.
op
Pr

Figure 27 - Thrust bearing tool assembled

5. Figure 27 shows the asembled thrust bearing tool.

S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 14 SERVICE MANUAL

3.5 SLIDE VALVE AND SLIDE PISTON

REMOVAL
88
Failure to remove transmitter (106) 80
prior to removing slide valve piston
bore cover (8) will result in damage
to the rod. 65
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. 109

s
21

ne
Figure 30 - Check valve components

rli
Ai
an
ic
er
Am

Figure 31 - Cap bolt removal

of

Figure 29 - Check valve retainer assembly

3. Remove check valve retainer (21) from the slide valve
ty

piston. Retainer (21) has a hex size of 1¼". Because of an

O-ring located between the retainer and slide stop piston
er

that becomes swollen during operation; it is recommended

to use an impact wrench and socket to remove the check
op

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
Pr

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 Figure 32 - Slide valve piston removal
Glyd Ring. Discard all three items.
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.
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 15

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.

s
ne
rli
Figure 35 - Pinion gear removal
Figure 33 - Pinion gear puller

Ai
4.1 DISCHARGE HOUSING BEARING REMOVAL
A fixture ball is placed between the jacking screw and rotor
shaft. The pinion gear puller plate is secured to the pinion This procedure covers the removal of the discharge bear-

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
er
force applied to the jacking screw for removal is extreamly
high. See Figure 35.
Am
an
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
ic
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).
of
ty
er
op
Pr

Figure 34 - Pinion puller tool mounted on gear

Figure 36 - Female distance sleeve, cover, and compres-

sion springs.
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 16 SERVICE MANUAL
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.
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.
Am
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.
of
Continue until locknut (96) is removed.
NOTE: Do not discard locknuts. They are reused to set
bearing clearance during assembly. Once clearance is
ty
set, old locknuts are discarded.
er
NOTE: Use steps 4 – 7 in reverse to tighten locknuts (92).
8. Remove solenoid valve located on top of the discharge
op
housing.
9. Remove cap bolts (58) attaching the discharge housing
Pr
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.
s
ne
Figure 38 - Discharge housing removal
11. Once the discharge housing is free from dowel pins, it
rli
can be pulled straight outward until free of rotors. Place dis-
charge housing on work table. The rotors should stay in the
Ai
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 fit design, they will remain in
an
the dicharge housing.
12. The thrust bearings (54) can be pulled out from the rotor
ic
housing by hand.
NOTE. There are shims located between various thrust
er
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.
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 17

2. Thoroughly clean all components with a grease-cutting

solvent.
3. Remove all plugs and fittings 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 filing are completed, clean
components with solvent and apply a light film of refrigera-

s
tion oil.

ne
Figure 39 - Roller bearing inner race puller
5.2 SLIDE VALVE TO SLIDE VALVE GUIDE
20. If inlet bushings (14) are damaged, remove by striking INSPECTION

rli
with brass drift in the same direction as the roller bearings
(49). If not damaged, bushings do not need removed. NOTE: During reassembly of the compressor, it is neces-

Ai
sary to determine if the slide valve has excessive wear.
21. Remove retainer ring (73) in front of roller bearing Excessive wear is defined as the slide valve being able to
(46). move upward into the rotor bore above flush. The proce-
dure to determine excessive movement is as follows.

an
22. The jackshaft rear bearing (52) can be removed with a
bearing puller as shown in Figure 40. 1. Insert the slide valve into the slide valve bore of the rotor
housing. Without installing the rotors, install the discharge
ic
housing to the rotor housing. Secure the discharge housing
with four cap screws and insert dowel pins.
er
2. By inserting your hands through the suction ports, move
the slide valve into the discharge port so that the slide valve
Am

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
of

moves into the rotor bore. The slide valve should not rise
above the bore more than .003"
ty

4. If the slide valve does move into the rotor bore, it may
be necessary to replace either the slide valve, the discharge
er

housing, or both. Because the slide valve guides on the dis-

charge housing are machined oversized , the slide valve must
Figure 40 - Bearing removal tool be hand fitted to the discharge housing. Use the following
op

procedure when new parts are required.

5.1 CLEANING COMPONENTS FOR
REASSEMBLY 5. Install the slide valve in the rotor housing. Without
Pr

installing the rotors, install the discharge housing with four

In order to ensure a successful rebuild, it is essential to capscrews and dowel pins.
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.
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 18 SERVICE MANUAL

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 fit. If
excessive material is removed from the guides, the slide
valve will move into the rotor bore.
7. Install rotors into rotor housing. Either rotor can be
installed first.
8. Place discharge casing (with flange 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.
Gas Seal

7. The slide valve is correctly fitted when it is able to move

smoothly in and out of the discharge housing guides without
rocking into the rotor bore.
Spring Pin

s
6.1 ROTOR AND ROLLER BEARING

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

rli
2. Lube all components with a light coat of clean refrigera- O-ring

Ai
tion oil.
3. Install both male and female inlet bushings (14), if previ-
ously removed. Ensure that spring pin (87) located in rotor

an
housing is properly engaged in bushing. Figure 41 - O-ring and gas seal installation

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

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
of
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

to installing inner races of roller bearings. bearings are being aligned with the roller elements of the
outer ring. Ensure that dowel pins (84) and (84) engage in
NOTE: When installing bearings, ensure that each inner dowel pin holes in housing. Secure discharge casing with four
ty

ring is matched to the respective outer ring. capscrews (59), evenly spaced around casing flange. Tighten
Heat-resistant gloves must be capscrews to a torque value of 144 ft-lb (195.3 Nm).
er

worn when installing bearing in-

ner races.
op

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

(49).
Pr

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 difficulty installing the inner ring,
instantly remove and reheat.

Figure 42 - Discharge housing installation

 FRICK XJF 151MM ROTARY SCREW COMPRESSOR
SERVICE MANUAL
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.
er
Am
Figure 43 - Air Cylinder Tool
ROTOR CASE TO CASE CLEARANCE
12. Thread two 3/4"-10 threaded pins into discharge end of
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
ty
to the inside port of the cylinder and adjust dial indicator to
zero. Remove pressure to inside port and apply pressure to
er
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.
op
NOTE: The arrow on the indicator may move slightly
while changing directions of cylinder force. DO NOT
Pr
READJUST INDICATOR. Total axial movement is be-
ing measured.
The specified rotor to rotor clearance is between .020" to
.028" (0.508 mm to 0.711 mm). Remove air cylinder tool
after measurements are recorded.
S70-452 SM (JUL 04)
Page 19
s
ne
Figure 44 - Mounting of dial indicator
rli
6.2 THRUST BEARING INSTALLATION
Ai
Shims are used at various locations in the thrust bearing
arrangement. Shim information is shown in A, B,and C
below.
an
A. Position a .020" (0.508 mm) shim (112) between the in-
ner races of the two female rotor thrust bearings. This shim
ic
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
(identification marks on bearing should be facing inboard).
Install bearing spacer (534B0540H01) on female rotor shaft.
Only the first 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.
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 20 SERVICE MANUAL
3. Repeat step 2 on the male rotor. Ensure that closed face
of inner race is facing outboard – identification 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 fluctuate. Record each reading. If the readings increase
after each actuation, the bearing is not secured on shaft.
Am
Re-secure the bearings and continue. The specification 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.
of
NOTE: It is important NOT TO READJUST INDICA-
TOR between actuation strokes.
ty
If the actual measured clearance is greater than the maximum
specified value, shims must be installed between the roller
bearing and thrust bearing outer races. If the actual measured
er
clearance is below the specified value, shims must be placed
between the roller bearing and thrust bearing inner races.
op
NOTE: Shim thickness is determined by amount of rotor
movement beyond the .003" to .005" specifications. See
Pr
the following examples. Information on shim adjustment
is also shown on the COMPRESSOR BUILD SHEET (see
Table of Contents for page reference).
Example #1
Measured end clearance = .008"
Desired mean end clearance = .004"
Desired shim size (location) = .004" between outer races
Example #2
Measured end clearance = .001"
Desired mean end clearance = .004"
Desired shim size (location) = .003" between inner race
Example #3
If 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 specification
install remaining bearings as outlined in steps 9 through
13. If a change is to be made to the clearance, continue
with Step 5.
s
5. Remove the thrust bearings from the rotor needing ad-
ne
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.
rli
6. Make adjustment to the adjusting shims as outlined in
Step 3.
Ai
7. Reinstall the thrust bearings, bearing spacer, and locknuts.
Repeat rotor measurements.
an
8. Once the specified clearance is achieved, remove old
locknuts and bearing spacer. Discard locknuts.
ic
9. With the first thrust bearing in place on the female rotor,
install the .020" shim (112) and push back against inner ring
er
of thrust bearing. Install second thrust bearing (54) with the
wide portion of the inner race facing inboard. Identification
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 first thrust bearing in place on male rotor, install
the next two thrust bearings (54) in the same direction as the
first thrust bearing, wide portion of inner race facing outboard
and bearing identification 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 identification
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).
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 21

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.
7.1 SLIDE VALVE / SLIDE STOP INSTALLATION
1. Thoroughly clean all parts with OSHA approved, non-
flammable 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.

s
Spring Pin

ne
Distance sleeve

rli
Ai
Figure 47 - Slide stop on left, slide valve on right, unloader
spring at bottom.
4. Install unloader spring (96) into slide valve.

an
Alignment Hole
ic
Bore cover
er
Figure 45 - Distance sleeve and cover
Am

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
of

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 48 - Location to secure unloader spring
ty

5. Install "T" wrench into slide stop. Guide the slide stop
Drain port onto the unloader spring. Ensure that spring is inserted both
er

in the slide valve hole and slide stop hole. Push the slide stop
into the compressor against spring force while at the same
op

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
Pr

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.

Figure 46 - Distance sleeve, drain port location

S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 22 SERVICE MANUAL

Gear

Shoulder

Jackshaft

s
ne
Figure 49 - Installing and securing slide stop

7.2 JACKSHAFT GEAR INSTALLATION Figure 50 - Bull gear on jack shaft

rli
NOTE: Slide valve piston will be installed after gear If heating in oil bath, ensure that
cover is mounted. temperature does not exceed flash

Ai
point of oil.
NOTE: Count the number of teeth on both gears and
compare with Table 1. This will ensure the correct set Heat resistant gloves must be worn

an
is being used. when installing gears and inner
rings.
NOTE: To save time during the jackshaft assembly ic
process, it is recommended that the inner rings of roller
bearings (51) and (52) be installed as soon as possible after Inner Ring (52)
er
installing the bull gear (45). Once the bull gear is installed, Spacer (26)
heat is pulled from the gear and into the jackshaft. The
added expansion of the jackshaft will make it difficult
Am

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. Spacer (25)
Inner Ring (51)
1. In preparation for installing both jackshaft bull gear (45)
of

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
ty

can be heated in oven or oil bath. DO NOT USE OPEN

FLAME.
er

2. Secure the jackshaft (17) vertically with the keyway

section downward. If using a vise, cover jaws with wood to
op

protect jackshaft. The jackshaft must be secured below the

shoulder where the bull gear is seated. See Figure 50.
Pr

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
Figure 51 - Jackshaft identification
of bearing (52). Push down on inner ring to ensure spacer
cannot rotate. See Figure 51.
7.3 PINION GEAR INSTALLATION
4. Turn jackshaft in opposite direction and install outboard
1. Ensure that rotor shaft is free of burrs and scratches prior
bearing spacer (25) and inner ring of roller bearing (51). Let
to installing pinion gear.
assembly cool. See Figure 51.
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.
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 23

s
ne
Figure 52 - Pinion gear installation

7.6. JACKSHAFT AND GEAR COVER

rli
MOUNTING

Ai
1. Install bearing (52) in rotor housing. Freezing the bearing
is recommended to make installation easier. The bearing can
Figure 54 - Mounting gear cover
also be installed by tapping on the outer ring. Install retainer

an
ring (89) in front of bearing.
2. Install two 12 mm guide pins in rotor houisng. See
Figure 53.
ic
er
Am
of
ty
er
op

Figure 55 - Mounting gear cover

Pr

6. Install new O-ring (73) on rotor housing. O-ring should

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.
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.
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 24 SERVICE MANUAL
7.5 JACKSHAFT BEARING INSTALLATION
1. Slide the inboard inner ring of bearing (53) onto the
jackshaft until it becomes affixed to major diameter of shaft.
The inner rings are interference fit 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.
Am
of
ty
Figure 57 - Inserting pusher barrel on pusher insert
er
op
Pr
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.
s
ne
Figure 59 - Bearing installation toll assembly
rli
6. Remove the thrust bearing installtion tool.
Ai
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
an
will be pushed into position. Reinstall the bearing installation
tool and repeat steps 3 to 5.
ic
7.6 INSTALLATION OF JACKSHAFT LOCKNUT
er
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.
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 25

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

s
(16). Repeat step 1b.

ne
NOTE: Once Glyd Ring is installed, mount retainer over Figure 62 - Slide stop piston installation
Glyd Ring in order to press the ring into position.
8.2 SLIDE VALVE PISTON INSTALLATION

rli
NOTE: Only stretch the Glyd Ring enough to allow it to
fit snugly over piston. Overstretching the Glyd Ring will 1. Install O-ring (65) into I.D. of check valve retainer (21).
result in permanent damage. Insert check valve (109), chamfered portion inward, into

Ai
retainer. Install retainer ring (88) in check valve retainer.
NOTE: Installing check valve (109) backwards will

an
result in the slide valve instantly traveling to the loaded
position at start-up.
ic 65
er
88
80
Am
of
ty

109
er

21
op

Figure 63 - Check Valve Parts, Slide vlave piston

Figure 61 - Retainer mounted over Glyd Ring
2. Install O-ring (74) and Glyd Ring (42) on slide valve
3. Thread "T" wrench into slide stop piston (16) and install
piston (18) Refer to Section 8.1, steps 1 and 2 for Glyd
Pr

piston in bore. See Figure 62.

Ring installation.
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.
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 26 SERVICE MANUAL

4. Place new cap bolt (61) through slide stop piston. Insert 9. Install O-ring (67) on bore cover (8). Secure bore cover
slide valve piston into bore until cap bolt can be inserted to dishcharge housing with cap bolts (63). Torque to 58 ft-lb
into slide valve. (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.

s
ne
rli
Ai
Figure 64 - Slide valve pistion installation

an
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 ic
approximately 2 in. (50.8 mm) and finish tightening cap bolt.
Tighten to 50 ft-lb (68 Nm). Reduce spring tension.
er
Am
of
ty
er
op

Figure 66 - Identification of Slide Valve Indicator, Linear

Figure 65 - Tightening Slide valve piston Transmitter design
Pr

6. Push the piston inward to the fully loaded position and Item (106) 534C1552H01 – Linear Transmitter with Well
allow the spring force to push the piston back. Item (94) 534A0883H01 – Spring
7. If slide valve piston sticks while unloading, loosen cap Item (79) 980A0012K62 – O-ring
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.
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 27

s
ne
rli
Ai
an
ic
er
Am
of
ty

Figure 67 - Bearing orientation and shim location

er

1. When adjusting shims are required, install between the roller bearing and the first thrust bearing.
op

2. Depending upon clearance adjustment, shim placement could be between either the inner rings or outer rings.
3. The parts identified as item 112 are .020" (0.508 mm) shims.
Pr
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 28 SERVICE MANUAL

s
ne
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr

Figure 68 - Top view of compressor

See pages following Figure 69 for part number identification for Figures 68 and 69.
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 29

s
ne
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr

Figure 69 - Side view of compressor

S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 30 SERVICE MANUAL

PARTS LIST

Refer to Figures 68 and 69.

ITEM P/N NAME ITEM P/N NAME

1 534A0542G01 FINISHED ROTOR PAIR 52 534B0004H31 CYLINDRICAL ROLLER BEARING
2 534A0925G01 ROTOR CASING ASSEMBLY 53 534B0101H27 FOUR-POINT BALL BEARING
3 534D0914C01 DISCHARGE CASING 54 534C0478H12 CAP BOLT
5 534D0916C01 SLIDE VALVE 55 111Q0740737 ANGULAR CONTACT BALL BEARING
6 534D0917H01 SLIDE STOP 56 111Q0740749 HEX HEAD CAP SCREW
7 534C1057C01 SLIDE STOP COVER 57 111Q0740781 HEX HEAD CAP SCREW M24x3.O

s
8 534C1058C01 CYLINDER COVER 58 111Q0740807 CAP BOLT

ne
9 534C1059C01 OUTLET BORE COVER 59 111Q0740845 CAP BOLT
10 534C1060C01 FEMALE DISTANCE SLEEVE 60 333Q0001522 HEXAGON HEAD CAP SCREW
11 534C1061C01 MALE DISTANCE SLEEVE 62 534A0572H02 CAPBOLT

rli
12 534C1062C01 SUCTION FLANGE 63 901A0085H08 CAP BOLT

Ai
14 534C1072HO1 INLET BUSHING 64 901A0085H19 CAP BOLT
15 534D0918H01 STEPPER PISTON 65 980A0012A52 0-RING
16 534D0919H01 SLIDE STOP PISTON 66 980A0012B63 0-RING

an
17 534D0920H01 JACKSHAFT 67 980A0012B72 0-RING
16 534D0921H01 SLIDE VALVE PISTON 68 980A0012B73 0-RING
19 534D0929C01 SEAL HOUSING COVER 69 980A0012B76 0-RING
ic
20 534D0944H01 SEAL HOUSING 70 980A0012B78 0-RING
er
21 534A0555H01 CHECK VALVE RETAINER 71 980A0012B91 0-RING
22 534A0557H01 LOW VI LIQUID INJ. PLUG 72 980A0012H10 0-RING
Am

23 534A0568H01 HIGH VI LIQUID INJ. PLUG 73 98OA0012H12 0-RING

24 534A0559H01 SEAL HOUSING SPACER 74 980A0012H49 0-RING
25 534A0560H01 OUTBOARD BEARING SPACER 75 980AO012H51 0-RING
26 534A0561H01 INBOARD BEARING SPACER 76 980A0012H55 0-RING
of

27 534B1023H01 INDICATOR ROD 77 980A0012K58 0-RING

28 534B0523H01 ECONOMIZER PLUG 78 980A0012K60 0-RING
29 534C0194H27 ORIFICE PLUG 79 980A0012K62 0-RING
ty

30 535B0243H01 SUCTION FLANGE 80 980A0012K66 0-RING

31 944A0296H08 SOCKET WELD FLANGE 81 980A0012K72 0-RING
er

32 531A0117H10 SEALING DISK 83 534A0037H12 DOWEL PIN

33 531A0117H15 SEALING DISK 84 534B0149H01 DOWEL PIN
op

37 534B0527H01 SUCTION STRAINER 85 534B0151H01 DOWEL PIN

38 534A0662H02 SQUARE KEY 88 534A0038H02 SPRINGPIN 316x58
Pr

39 534B0079H08 SLYDRING 87 534A0038H06 SPRING PIN

40 534C0187H16 GLYD RING 88 534A0570H01 RETAINING RING
41 534C0187H17 GLYD RING 89 534B0014H09 RETAINING RING
42 534C0187H18 GLYD RING 90 534B0015H13 RETAIN1IG RING
43 534BO732H01 SHAFT SEAL ASSEMBLY 91 534B0174H17 RETAINING RING
44 333Q0000910 LIP SEAL 92 534B0909H02 LOCKNUT
45 534A0564G01 GEAR SET 51:46 93 534B0909H04 LOCKNUT
46 534A0564G02 GEAR SET 55:42 94 534AO883H01 COMPRESSION SPRING
47 534A0564G03 GEAR SET 60.37 95 534A0218H01 COMPRESSION SPRING
48 534A0564G04 GEAR SET 64:33 96 534A0569H01 UNLOADER SPRING
49 534B0004H28 CYLINDRICAL ROLLER BEARING 97 534A0591H01 WAVE SPRING
50 534B0004H29 CYLINDRICAL ROLLER BEARING 98 111Q0630050 CAPPLUG
51 534B0004H30 CYLINDRICAL ROLLER BEARING 99 111QO451948 CHARGING VALVE
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 31

ITEM P/N NAME

101 649A0890H02 DIN CONNECONNECTOR
102 649A0890H11 SILICONE GASKET
103 951A0095H01 COIL
104 111Q0993344 SOLENOID VALVE V.I.
106 534A0565HO1 SOLENOID VALVE GASKET V.I
107 959A0044H11 GASKET
108 959A0057H09 GASKET
109 534A0173H01 CHECK VALVE
110 534A0673H01 COVER PLATE
111 111Q0831809 REFRGIERATION OIL

s
112 534A0568H05 CIRCULAR SHIM

ne
113 534A0394H01 WARNING LABEL
116 944A0246H01 BUSHING
117 944A0228H03 STRAIGHT THREAD O-RING PLUG

rli
118 944A0228H05 STRAIGHT THREAD O-RING PLUG
119 944A0228H06 STRAIGHT THREAD O-RING PLUG

Ai
120 944A0228H08 STRAIGHT THREAD O-RING PLUG
121 991A0036H01 NAMEPLATE

an
122 903A0003H08 DRIVE PIN
123 534C1160H01 GAS SEAL
124 980A0012B02 0-RING 2—151
125 534C0194H81 ORIFICE
ic
126 534C1552H01 TRANSMITTER
er
Am
of
ty
er
op
Pr
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 32 SERVICE MANUAL

COMPRESSOR BUILD SHEET

XJF 151 CLEARANCE RECORD

Compressor Model _____________________ Outlet Case Number ___________________

Serial Number _________________________ Rotor Case Number ___________________
Assembled by _________________________ Gear Cover Number ___________________
Date Assembled ________________________ Rotor Number ________________________

Male Female

s
ne
Total rotor-to-casing clearance: ___________ ___________
Model 151 mm .020" – .028" (0.508 mm – 0.711 mm)

rli
Ai
DISCHARGE END CLEARANCE CALCULATION
Male Female

an
As measured discharge end clearance ic ___________ ___________
Desired discharge end clearance .003" – .005" (.076 mm – .127 mm) ___________ ___________
er
Calulated shim thickness and location ___________ ___________
Am

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

NOTE: When calculated discharge end clearance is less than .0015 inch, install shims on rotor between
of

roller bearing and ball bearing.

Actual shim thickness ___________ ___________

ty

Location of shims (rotor or case) ___________ ___________

er

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

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

Pr

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)
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 33

NOTES

s
ne
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr
S70-452 SM (JUL 04) FRICK XJF 151MM ROTARY SCREW COMPRESSOR
Page 34 SERVICE MANUAL

NOTES

s
ne
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr
 FRICK XJF 151MM ROTARY SCREW COMPRESSOR S70-452 SM (JUL 04)
SERVICE MANUAL Page 35

NOTES

s
ne
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr
 s
ne
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr

Form S70-452 SM (704) YORK Refrigeration Systems

Supersedes: Nothing 100 CV Avenue • P.O. Box 997
Subject to change without notice Waynesboro, PA USA 17268-0997
Printed in USA • GUI 100 905 3.60 Phone: 717-762-2121 • FAX: 717-762-8624
© 2005 YORK International - ALL RIGHTS RESERVED www.frickcold.com