Daikin ZH7SLF [9/58] 1 perform a pump down operation to reduce pressure inside the compressor 2 release the internal pressure of the compressor loosen the flare nut of the service port with check valve of the compressor same as section 3 2 remove the partition lid then tighten the flare nut to discharge refrigerant from the compressor 3 remove the side caps from both sides of the compressor fig 3 4 since a small amount of oil is still in the compressor place drain pans under the side caps to receive oil before opening the side caps

Semi hermetic single semi hermetic single semi hermetic single semi hermetic single screw compressor screw compressor screw compressor screw compressor version iv version iv version iv version iv 2

Table of contents 2

Scope of application 3

Overhaul 4

Periodic inspection 5

Periodic inspection items and intervals 5

Periodical inspection means to inspect adjust and clean various parts of devices and equipment at the scheduled interval 5

Table 3 1 shows periodic inspection items and intervals conduct inspections at the earliest indicated inspection intervals 5

Periodic inspection instructions 6

1 perform a pump down operation to reduce pressure inside the compressor 2 release the internal pressure of the compressor loosen the flare nut of the service port with check valve of the compressor same as section 3 2 remove the partition lid then tighten the flare nut to discharge refrigerant from the compressor 3 remove the side caps from both sides of the compressor fig 3 4 since a small amount of oil is still in the compressor place drain pans under the side caps to receive oil before opening the side caps 9

4 inspection of the gate rotor visually check the gate rotor surface for scar chipping cracking etc check all gate rotor teeth 9

Inspecting the gate rotor 9

This inspection is done to check that no abnormal condition is present due to dust and other foreign particles inside or harsh operating conditions of liquid compression etc 9

Overhaul instructions 12

The driving and friction parts in the compressor wear for prolonged over time to prevent accidents caused by worn parts it is necessary to inspect those parts regularly and overhaul the compressor as needed 12

Disassembly and inspection 13

3 disassembling the screw assembly remove the bolts and remove the screw bearing retainer plate remove the main bearing holder from the screw shaft do not lose screw rotor adjusting shims 2 21

Check that the control motor is in its 100 position if this motor is not in the 100 position it cannot be disassembled the following section shows the checking method 22

Check the position of the control motor 22

Continuous capacity control unit disassembly of control motor 22

Should the control motor not be in its 100 position pass a rated voltage of the control motor through each pin as shown in table below reference it takes approximately two minutes for the motor to move from 0 to 100 the motor stops at 0 or 100 via a micro switch 22

The position of the control motor can be checked on the opening degree indication plate or according to the position of brass block provided on the side plate of the motor 22

Removing bearings 24

Replacing the bearing 24

Installation of bearings 26

Replacement of o ring of drive shaft bushing continuous capacity control unit 28

Final assembly 29

Airtightness test 36

Using dry air mixed with refrigerant pressurize to then use a gas detector or soap water to check for leaks apply soap water on the side caps and other cover mounting sections to make sure no air bubbles are formed if air bubbles are formed release the pressure then re tighten the bolts if the leak does not stop check the packing seating surfaces and replace the packing 36

Charging oil 37

Part of oil may remain in the refrigerating system therefore charge the same amount of oil removed from the compressor during disassembly when a new gate rotor is installed pour about a half of the total oil capacity to the suction side to prevent excessive heating during initial operation 37

Caution in test operation 38

General tools and measuring instruments 39

Notes 1 indicate metric coarse threads and standard bolts 5t 12 2 tolerances on tightening torque are 15 however the tolerance on tightening torque at terminal block is 5 3 when tightening hexagon socket head cap screws in the compressor apply specifications for class 12 39

Required tools 39

The tightening torque of hexagon socket head screw used for control motor is to be 3 n m 15 39

Special tools for an overhaul be sure to prepare jigs listed in table 8 3 40

Jig 1 lock nut tightening jig 41

Bearing outer ring 42

Jig 2 1 bearing removing jig set 42

Suction end cover housing section 42

Jig 2 1 bearing removing jig parts 43

Bearing outer ring 44

Cylindrical roller bearing 44

Holding device 44

Jig 2 2 bearing removing jig set 44

Suction end cover housing section 44

Jig 2 2 bearing removing jig parts 45

Jig 3 temporary bearing holder mounting plate jig for zh3_ material ss400 46

Jig 3 temporary bearing holder mounting plate jig for zh5_ material ss400 47

Jig 3 temporary bearing holder mounting plate jig for zh7_ material ss400 48

Jig 3 temporary bearing holder mounting plate jig for zh9_ material ss400 49

Jig 4 1 handle jig set 50

Jig 4 2 handle jig set 51

Jig 4 2 handle jig parts 52

Jig 5 oil filter removing jig for zh3_f 53

Jig 6 lever for continuous capacity control unit material ss400 54

Index index index index 56

Drawings flow charts 57

Drawings flow charts drawings flow charts drawings flow charts drawings flow charts 57

Printed in japan 03 2004 ak 58

The specifications designs and information in this manual are subject to change without notice 58

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