Daikin Si50-203

Head office: Zandvoordestraat 300, B-8400 Oostende, Belgium Si50-203
Umeda Center Bldg., 4-12, Nakazaki-Nishi 2-chome,

Kita-ku, Osaka, 530-8323 Japan
Tokyo office:
Shinjuku Sumitomo Bldg., 6-1 Nishi-Shinjuku
2-chome, Shinjuku-ku, Tokyo, 163-0235 Japan
For Overhaul and Inspection

Semi-Hermetic Single Screw
Compressor Version
[Applied Models]
ZH(C)3LSF ZH3LMF ZH(C)3LTG

ZH(C)5MLF ZH5SLF ZH(C)3WLG
ZH(C), (A)5LLF ZH5LMF ZH(C), (A)5LMG
ZH(C), (A)7SLF ZHA7MLF ZH(C), (A)5WLG
ZH(C)7LLF ZHA7MSG ZH(C)7LSG
ZH(C), (A)9SLF ZH(C), (A)7WSG
ZH(C), (A)9LLF ZH(C), (A)9LSG
ZH(C), (A)9WSG
The specifications, designs, and information in this manual are subject to change without notice.
Printed in Japan 02/2003 AK

Si50-203
Semi-Hermetic Single
Screw Compressor
Version III
1. Scope of Application ...............................................................................2
2. Overhaul..................................................................................................3
3. Periodic Inspection..................................................................................4
3.1 Periodic Inspection Items and Intervals....................................................4
3.2 Periodic Inspection Instructions................................................................5
4. Overhaul Instructions ............................................................................10
4.1 Disassembly and Inspection...................................................................11
4.2 Replacing The Bearing...........................................................................20
4.3 Final Assembly .......................................................................................24
5. Airtightness Test ...................................................................................29
6. Charging Oil ..........................................................................................30
7. Caution in Test Operation .....................................................................31
8. Required Tools......................................................................................32
[Applicable Models]
ZH3LSF ZH3LMF ZHC3LSF ZH3LTG ZHC3LTG

ZH5MLF ZH5SLF ZHC5MLF ZH3WLG ZHC3WLG
ZH5LLF ZH5LMF ZHC5LLF ZHA5LLF ZH5LMG ZHC5LMG ZHA5LMG
ZH7SLF ZHC7SLF ZHA7SLF ZH5WLG ZHC5WLG ZHA5WLG
ZH7LLF ZHC7LLF ZHA7MLF ZH7LSG ZHC7LSG ZHA7MSG
ZH9SLF ZHC9SLF ZHA9SLF ZH7WSG ZHC7WSG ZHA7WSG
ZH9LLF ZHC9LLF ZHA9LLF ZH9LSG ZHC9LSG ZHA9LSG
ZH9WSG ZHC9WSG ZHA9WSG
Semi-Hermetic Single Screw Compressor Version III 1

Scope of Application Si50-203
1. Scope of Application
This booklet applies to semi-hermetic single screw compressor for use in Model F type (ZH_F),
G type (ZH_G). Replacement intervals specified in the booklet are empirically worked out
based on the design service life expected of the compressors operated under the design
conditions, and are intended to provide a general guide by which to formulate a maintenance
plan.
2 Semi-Hermetic Single Screw Compressor Version III

Si50-203 Overhaul
2. Overhaul
Generally, maintenance and inspection of equipment are important in preventing their failure
and damage to them. Equipment, even without defective structure or components, gradually
age and wear over long years of operation. For example, screw compressors, despite their
apparent good operating condition, may face such problems as decreasing insulation resistance
of the motor, oil deterioration, and worn and fatigued bearings during long periods of operation.
Most of such changes with time are invisible from the outside in many cases, and it is only after
an accident that they are noticed. For this reason, in the case of equipment required to be
highly reliable, it is most important to grasp their wear condition precisely and take necessary
measures against accidents if they are to maintain proper operating conditions for expanding
service life.
Overhaul interval: 40,000 hours or 7 years, whichever comes first.

Periodic Inspection Si50-203
3. Periodic Inspection
Periodical Inspection means to inspect, adjust and clean various parts of devices and
equipment at the scheduled interval.
3.1 Periodic Inspection Items and Intervals

Table 3-1 shows periodic inspection items and intervals. Conduct inspections at the earliest
indicated inspection intervals.
Table 3-1 Periodic inspection items and intervals

No. Item Inspection
Measurement of motor insulation
1 resistance 1 year
2 Inspection of refrigeration oil 7,500 hr or 4 years

3 Inspection of gate rotor 20,000 hr or 4 years
4 Inspection of suction filter 20,000 hr or 4 years

Si50-203 Periodic Inspection
3.2 Periodic Inspection Instructions

1. Insulation Resistance of The Motor
! Insulation Resistance Testing
A megger is used to apply voltage directly to an insulated object, measure leakage current
through the insulated object, and find the insulation resistance values. Its scale is voltage /
leakage graduated with such insulation resistance values.
The following equation holds:

Insulation resistance = applied voltage / leakage current
Note: 1. A megger indicates an increasing resistance value with time, because absorption current
flows through the insulated object at an early stage, lowering the resistance value
correspondingly.
2. Prohibit anyone from measuring insulation resistance in a vacuum.
It must be measured at atmospheric pressure or after the filling of refrigerant. The reason
is that in a vacuum, the insulation ability of gas lowers, and thus electric discharge is apt to
occur.
(Measuring Procedure)
(1) Turn off the main power and operating power.
(2) Remove the terminal cover.
(3) Before measurement, disconnect the cables connected to the compressor or control panel.
(4) Disconnect the CTP protector lead wire.
(5) Conduct measurement.
Fig. 3-1 Motor insulation resistance measuring method
(Measurement Standard)
Using a 500-V megger. The measured value shall be 3 M or higher.

2. Changing Refrigerating Oil

Oil degrades after many hours of operation and due to aging. Replace oil regularly after
7,500 hours of operation or four years, whichever comes first.
(Changing Procedure)
(1) Perform a pump down operation to reduce pressure inside the compressor.
(2) Release the internal pressure of the compressor.
Loosen the flare nut at the service port (with check valve) of the compressor (see Fig. 3-2).
Remove the partition lid, then tighten the flare nut to discharge refrigerant from the
compressor. To loosen and tighten the flare nut, use two wrenches to turn the flare nut and
keep the other nut stationary.
Fig. 3-2 Service port and oil charge port locations
(3) After confirming that refrigerant is completely discharged, drain oil from the two drain ports
located on the lower section of the casing.
The compressor rotates in the reverse direction when it stops operating. This causes oil to
remain in the suction side. Therefore, be sure to drain oil from the two drain ports.
Fig. 3-3 Drain port locations

(4) Charging oil

Connect a vacuum pump to the suction service port (1/4" DCut) on the casing. While
evacuating the compressor, add oil from the discharge service port (3/8" DCut).
Use SUNISO 4GSD refrigeration oil (possible for use equal product) for refrigerant R22
and DAPHNE FVC68D refrigerant oil for refrigerant R407C and R134a.
Add the same amount of new oil as drained because some remains in the refrigerant and
on various parts inside. Drained oil contains refrigerant and appears to be more in
volume than actual oil amount. Stir the oil to evaporate the dissolved refrigerant before
measuring. Do not add more oil than necessary, since an excessive amount of oil
reduces oil separation efficiency and causes system problems. (Oil surface should be
visible on the level gauge during equipment operation.)
Take care not to let in air, or dust and other foreign particles remaining on the bottom of
the oil container.
When charging oil from a previously opened container, conduct vacuuming of the
compressor to remove moisture and air.
3. Inspecting The Gate Rotor

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..
Loosen the flare nut of the service port (with check valve) of the compressor (see Fig. 3-2).
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.
Fig. 3-4 Side cap locations

(4) Inspection of the gate rotor

Visually check the gate rotor surface for scar, chipping, cracking, etc. Check all gate rotor
teeth.
Table 3-1 Gate rotor inspection standards

Item Standard Remedy
Cracking No cracking
Chipping No chipping 3 mm or more long in long side
Replace
Scar No scar 1 mm or more deep
Surface yellowing* No yellowing
* When the yellowing is observed on the gate rotor blade, remove gate rotor and check the
damage on outside of the screw rotor.
If the damage on screw rotor is found, conduct one of the following counter measures.
- Repair (deburr, etc.) the damaged part of the screw rotor.
- Replace the screw rotor.
Fig. 3-5 Inspection of gate rotor chipping Fig. 3-6 Inspection of gate rotor surface
(5) Measuring the slit clearance

The slit clearance is a gap between the gate rotor and casing, and it affects the compressor
performance and reliability to a great extent. Therefore, the slit clearance must be set
properly (60 to 90 m).
While pressing the periphery of the gate rotor shaft with fingers, insert a thickness gauge into
the slit clearance to measure the gaps on both suction and discharge sides. Be careful not
to insert the thickness gauge too deep. If the thickness gauge is inserted to deep, it can be
caught between the screw rotor and gate rotor and break.
(See Fig. 3-7 and 3-8.)
Fig. 3-7 Slit clearance measuring location Fig. 3-8 Measuring slit clearance on suction side

4. Cleaning The Suction Filter
Loosen the flare nut of the service port (with check valve) of the compressor (see Fig. 3-2).
compressor. (Same as Section 3.2.2)
(3) Disconnect the suction pipe, and remove the suction filter.
(4) Remove dust and foreign particles from the inside of the filter by using compressed air and
cleaning solution. Check the filter thoroughly for tears and damage. (Replace the filter if
there is a tear.) Dry the filter thoroughly before installation to remove cleaning solution and
moisture.
Fig. 3-9 Suction filter location (Cross sectional diagram of casing)
Fig. 3-10 Cleaning suction filter

Overhaul Instructions Si50-203
4. Overhaul Instructions
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.

Si50-203 Overhaul Instructions
4.1 Disassembly and Inspection

1. Draining Oil
Drain oil by referring to Section 3.2.2 "Changing refrigerating oil."
2. Remove The Side Caps (One on Each Side) and The Discharge End Cover. (in case of
ZH9F, oil collector)
! Receive remaining oil with a drain pan.
! Be sure to mount guide bolts when removing the discharge end cover.
! Be careful not to damage the oil filter with the discharge end cover.
! Locate the first demister between the discharge end cover and cylinder cover, and remove it.
(Except ZH9F)
Fig. 4-1 Removing side cap Fig. 4-2 Removing discharge end cover
Fig. 4-3 Removing first demister

3. Inspection of The Gate Rotor and Surrounding Parts
(1) Checking the slit clearance

Measure the slit clearance by referring to Section 3.2.3) "Inspecting The Gate Rotor."
(2) Measuring the backlash
Measure the backlash of the gate rotor and screw rotor. If the measured value exceed the
standard value, replace the gate rotor.
[Standard value] 0.15 mm or less for all teeth (ZH3, 5) and 0.20mm or less for all teeth
(ZH7, 9)
Fig. 4-4 Measurement of gate rotor backlash
4. Disassembling The Gate Rotor and Surrounding Parts
(1) Positioning the screw rotor

Position the screw rotor so that the gate rotor can be removed
without damage.
(2) Removing the gate rotor partition lid
In the ZH3F, the gate rotor partition lid is mounted together
with the lower bearing holder.
Fig. 4-5 Screw rotor position
Fig. 4-6 Cross sectional diagram of gate rotor

(3) Removing the gate rotor bearing retainer plate

While holding the gate rotor with hand, loosen the bolts. Be careful not to lose gate rotor
adjusting shims (1) mounted between the gate rotor shaft and retainer plate.
Be sure to use the original combination of gate rotor, lower bearing holder, gate rotor
adjusting shims and gate rotor adjusting shims (2). (Do not exchange parts between the
upper and lower sets).
Fig. 4-7 Removing gate rotor bearing retainer plate
(4) Removing the lower bearing holder (upward and downward units)
In the guide bolt hole, thread the bolt that was used for the lower bearing holder mounting
and lift the lower bearing holder from the casing.
Remove the shims inserted between the lower bearing holder and casing. (Do not lose
the shims.)
The lower bearing holder and casing are sealed by an O-ring. Therefore, it may be
difficult to remove the lower bearing from the casing. To separate them, insert two
standard screwdrivers at the flange section at locations opposite from each other, and
slowly twist the screwdrivers, as shown in Fig. 4-8.
Fig. 4-8 Removing lower bearing holder
In the upward gate rotor, the lower bearing holder falls off when the O-ring is separated.
Therefore, mount long bolts in the casing bolt holes and place a hand below the gate
rotor to support it during removal operation.

(5) Turn the gate rotor shaft to remove it from the screw rotor. Be careful not to damage the
gate rotor.
5. Removing and Installation of Gate Rotor
(1) Remove C type retaining ring.

(2) Remove the gate rotor from the shaft.
(3) Apply red check to the gate rotor, and check that the rotor is free of cracks.
If the rotor is found cracked, replace it with a new one.
(4) Install the gate rotor on the shaft, and mount the C-type retaining ring.
The gate rotor has front and back sides. Position the gate rotor so that the manufacturing
number is visible.
6. Removing The Suction End Cover
(1) Remove all the mounting bolts.

(2) Mount guide bolts in two bolt holes on the upper section.
(Be sure to mount guide bolts, since the suction end cover is heavy.)
(3) In the guide bolt holes, thread the bolts that were removed previously, then remove the
suction cover from the casing.
Locate positioning pins at two locations, and screw them.
Fig. 4-9 Removing suction end cover

7. Removing The Motor Rotor
(1) Remove the rotor locking plate using a standard screwdriver.

(2) Loosen the lock nut. (Use the special tool or jig (1).)
(3) As shown in Fig. 4-11 grip rotor fins with pliers, and remove the rotor. Securely support the
rotor so as not to drop the rotor. At removal, be careful not to damage the stator coil end.
(4) Remove the motor rotor key from the screw shaft.
Fig. 4-10 Removing rotor locking plate
Fig. 4-11 Removing motor rotor

8. Disassembly of The Controller
Fig. 4-12 Cross sectional diagram of controller
(1) Remove the slide valve arm.

Loosen the two locking nuts of the slide valve shaft and the bolt at the center of the arm.
A thread lock compound was used for the hexagon head bolt at the center. Use an impact
wrench to loosen this bolt.
Fig. 4-13 Removing slide valve arm

(2) Remove the oil filter using the special tool, and clean. (ZH3F only)
After cleaning, dry thoroughly.
If the filter is damaged or torn, replace.
Fig. 4-14 Oil filter removing tool
(3) Remove the mounting bolts, and remove the cylinder cover.
(4) Pull out the piston.
(5) Remove the mounting bolts, and remove the main bearing holder fixing plate.
Use guide bolts when removing the fixing plate, since it is heavy.
Do not lose screw adjusting shims (1) located inside.
(6) Remove the oil filter from the fixing plate, and clean. (except for ZH3F)
After cleaning, dry thoroughly.
If the filter is damaged or torn, replace.
(7) Remove the slide valve from the casing.
Fig. 4-15 Removing main bearing holder fixing plate

9. Removing and Disassembling The Screw Assembly Pulley
(1) Place alignment marks on the casing and main bearing holder.
Fig. 4-16 Placing alignment marks on casing and main bearing holder
(2) Removing the screw shaft

Push the screw shaft from the suction side until the bearing holder completely extends from
the discharge side. Then pull out the shaft from the discharge side. Insert one hand through
the side cap hole and support the shaft to prevent the screw shaft from damaging the casing
when the screw rotor section comes out of the casing. Use leather gloves during removal to
prevent injuries by the screw and stator.
Fig. 4-17 Removing screw shaft (1)

Fig. 4-18 Removing screw shaft (2)
(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).
Fig. 4-19 Disassembling screw assembly

4.2 Replacing The Bearing

Unlike slide bearings, roller bearings have limited service life. They must be replaced regularly.
To prevent accidents caused by worn roller bearings, replace all roller bearings during an
overhaul.
4.2.1 Removing Bearings

1. Main Shaft Bearing
(1) Suction end cover (outer ring of cylindrical roller bearing)

Remove the C-type retaining ring.
Remove the outer ring of the bearing.
Use an ordinary bearing remover or special jig (2) to remove the outer ring.
(2) Screw shaft (inner ring of cylindrical roller bearing)
Remove the C-type retaining ring.
Remove the inner ring of the bearing by using a chisel.
Be careful not to scratch the screw shaft. If the screw shaft is accidentally scratched,
remove burrs by grinding the irregular surface.
Fig. 4-20 Removing inner ring of screw shaft bearing
(3) Main bearing holder (angular-contact ball bearing, deep groove ball bearing)
Removing the beveled C-type retainer ring
The beveled C-type retainer is securely installed in the groove to keep the bearing in
place. For easy removal, first pry the end section of the C-type retainer ring toward
inside using snap-ring pliers.
Fig. 4-21 Removing C-type retainer ring

Removing the bearing

From the opposite side of the end with the C-type retainer ring, remove the outer ring of
the bearing by placing a bronze rod and hammering it. Since the outer ring is not
pressed in deeply, it can be removed easily.
Fig. 4-22 Removing main bearing holder bearing
2. Gate Rotor Bearings (Angular-Contact Bearing, Deep Groove Ball Bearing)

Remove the angular-contact ball bearing and deep groove ball bearing from the lower
bearing holder by using a bronze rod and hammer.
Fig. 4-23 Removing lower bearing holder bearing

4.2.2 Installation of Bearings

Before installing the bearings, clean the bearing holder and suction end cover.
1. Main Shaft Bearing
(1) Suction end cover (outer ring of cylindrical roller bearing)

Hammer the periphery of the outer ring of the cylindrical roller bearing to insert the bearing
into the suction end cover bearing housing. Be careful not to damage the bearing when
installing. Hammering the roller section can damage the holding section. After the bearing
is installed securely in the housing, mount the C-type retainer ring to secure the bearing.
(2) Screw shaft (inner ring of cylindrical roller bearing)
Heat the inner ring of the bearing (120C max.), and insert the tip of the screw shaft.
After the shaft is inserted, place a plate and hammer the shaft all the way. Then, mount the
C-type retainer ring.
(3) Main bearing holder (angular-contact ball bearing, deep groove ball bearing)
Insert the bearings into the main bearing holder. Since fitting is tight, cool the bearings to a
temperature of -50C or lower using dry ice. After inserting the bearings, mount the beveled
C-type retainer ring.
! Be sure to install the bearings in the correct direction.
! The beveled C-type retainer is tapered. After installation, hammer it into the groove.
Fig. 4-24 Direction of bearings

2. Installing and Adjusting The Gate Rotor Bearings
(1) Installing the bearings

Install the angular-contact ball bearing and deep groove ball bearing. The bearings must be
press-fit, but they do not have to be pressed deeply. Hammer them evenly, and make sure
that the bearings rest on the seats. Also, be sure to install the angular-contact ball bearing in
the correct direction.
Fig. 4-25 Front and back sides of angular-contact ball bearing
Fig. 4-26 Direction of bearings
(2) Adjusting the preload (temporary assembly)

Install the gate rotor shaft in the lower bearing holders mounted with the bearings, and check
the preload of the bearings.
Insert the gate rotor shaft into the bearings.
Install gate rotor shims (2) and the gate rotor bearing retainer plate, and tighten the bolts
to the specified torque.
Turn the gate rotor with full force by hand. The gate rotor must rotate smoothly and
should not produce rolling sound.
a) When rolling sound is produced
Reduce the thickness of the gate rotor adjusting shims, and check again.
b) When gate rotor does not rotate smoothly
Increase the thickness of the gate rotor adjusting shims, and check again.
After adjustment, disassembly.
During disassembly, separate the shims, lower bearings and gate rotor shafts according
to their installation locations (upward and downward units) so that they can be reinstalled
in the original positions.

4.3 Final Assembly

Caution
! Clean the casing and all other parts, and dry them thoroughly.
! Use new packings and O-rings.
1. Assembling The Screw Shaft and Main Bearing Holder

Install screw adjusting shims (2) and the main bearing holder on the screw shaft, and install
the screw bearing retainer plate. Tighten the two bearing retainer plate mounting bolts
evenly.
Adjust clearance between 0.03 and 0.05 mm(except ZH9), 0.04~0.06mm(ZH9 only), as
shown below. (Minimum clearance on periphery)
Fig. 4-27 Adjusting clearance between screw rotor and main bearing holder

2. Inserting The Screw Shaft

Insert the screw shaft into the casing until the shaft contacts the tapered section of the
casing.
For this process, wear leather gloves to prevent hand injuries. (Do not use fabric work gloves.)
The screw shaft is heavy, and the main bearing holder rotates, making it difficult to hold it.
Be careful not to drop the screw shaft during installation.
Fig. 4-28 Inserting screw shaft
3. Installing The Motor Rotor

Insert the motor rotor key into the screw shaft from the suction side, and insert the motor
rotor.
Insert the motor rotor in the direction shown below.
Fig. 4-29 Motor rotor inserting direction
Tighten the lock nut, and bend the tab on the lock washer to prevent the lock nut from
loosening.

4. Installing The Suction End Cover

(1) Extend the screw shaft from the motor side.
(2) Install the suction end cover. In this step, use the two positioning pins to position the suction
end cover. (Use guide bolts.)
(3) Insert the screw shaft into the bearing of the suction end cover.
The holding section of the cylindrical roller bearing is made of plastic. It can break easily if
applied with impact. Lift the screw shaft slightly higher than the side cap, and gently insert
the screw shaft from the discharge side.
Fig. 4-30 Installing suction end cover
(4) Rotate the screw rotor to make sure it moves smoothly.
5. Positioning The Screw Rotor

Mount jig (3) to the main bearing holder and casing. In this step, insert screw adjusting
shims (1) between the jig and main bearing holder for the adjustment of the directional
position of the screw rotor shaft.

6. Installing The Gate Rotor and Adjusting The Slit Clearance

(1) Install the O-rings on the lower bearing holder. (ZH_F : two O-rings)
(ZH_G : three O-rings (two kinds)Confirm the installing position on spare parts list.)
(2) Set the screw rotor in the position indicated in Fig. 4-5, and engage the screw rotor with the
gate rotor.
(3) Apply oil on the O-rings of the lower bearing holder, and install the lower bearing holder in
the casing.
After the lower bearing holder is inserted to the O-ring section, use the mounting bolt
holes to press the lower bearing holder into the casing.
(Use bolts that are 5 to 10 mm longer than the mounting bolts. Using the mounting bolts
may damage the threads since they are too short for this process.)
Before the casing and the flange of the lower bearing holder contact, insert shims, and
tighten securely.
(4) Install the gate rotor bearing retainer plate.
(To prevent the gate rotor from rotating, hold the gate rotor by hand while tightening.)
(5) Measure the slit clearance (gap between the gate rotor and casing) with a clearance gauge.
With the clearance gauge hooked on the gate rotor, insert jig (4) into the screw bearing
retainer plate. Rotate the screw rotor, and insert the gauge in the slit.
1 Standard value: 0.06 to 0.09 mm
1 If the measured clearance deviates from the standard value, adjust the thickness of the
gate rotor adjusting shims.
(To increase the clearance, add shims.)
(6) Mount the O-ring on the bottom cover of the lower bearing holder, and install the bottom
cover of the lower bearing holder.
(7) Install the side cap.
Fig. 4-31 Adjusting slit clearance

7. Installing The Main Bearing Holder Fixing Plate, Assembling The Controller, and
Installing The Oil Filter
(1) Insert the slide valve into the casing.
1 In the right hole, insert the slide valve with "2" stamped on the end surface.
1 Make sure the slide valve operates smoothly.
(2) Mount the oil filter on the fixing plate. (except for ZH3F)
(3) Remove jig (2), then install the fixing plate. During this step, insert guide bolts in the main
bearing holder, and place the screw adjusting shims between the main bearing holder and
fixing plate.
(4) Insert the piston in the fixing plate
(In case of ZH_F)

(5) Place the cylinder cover. Extend the piston until it contacts the cylinder cover, then tighten
the four bolts around the cylinder. (After tightening bolts, make sure the piston moves
smoothly.)
Fig. 4-32 Adjusting piston and installing cylinder cover
(6) Tighten the other mounting bolts of the cylinder cover.
(In case of ZH_G)

(5), (6) place the cylinder cover. Extend the piston until it contacts the cylinder cover, then
tighten the bolts. (After tightening the bolts, make sure the piston moves smoothly.)
(7) Install the oil filter using jig (5). (for ZH3F only)
(8) Pull the slide valve forward, then hook the slide valve spring on the slide valve shaft.
(upward and downward units)
(9) Install the slide valve arm with the locking nut (slide valve) and bolt (piston).
Use a thread lock compound (Loctite etc.) on the bolt, and use a new locking nut.
8. Installing The Discharge End Cover (In case of ZH9F, Oil collector)
Insert the first demister (except ZH9F) in the cylinder cover, and install the discharge end
cover.
Since the discharge end cover is heavy, be sure to use guide bolts.

Si50-203 Airtightness Test
5. Airtightness Test
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.
refrigerant type
R22 2.8MPa(28bar)
R134a 2.0MPa(20bar)
R407c 2.98MPa(29.8bar)

Charging Oil Si50-203
6. Charging Oil
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.

Si50-203 Caution in Test Operation
7. Caution in Test Operation

1) Check to make sure all bolts are tightened.
2) Check the wiring for proper connection.
3) Conduct inching.
Check the rotating direction using high and low pressure gauges.
(If the rotating direction is correct, the low pressure gauge indicates decreasing and the
high pressure gauge shows rising pressure.)
Check that no abnormal noise is generated.

Required Tools Si50-203
8. Required Tools
1. General Tools and Measuring Instruments
Table 8-1 List of general tools and measuring instruments

Name Specification (size) Application
1 Hex-key wrenches
M5, M6, M8, M10, M12, M16
2 Torque wrench Refer table 8-2
C-type retainer ring
3 For holes (large, small) and shafts Gate rotor and bearing holders
Tools
removing tools
4 Guide bolts M6, M8, M10, M12, M16 Fixing plate and cover installation
Adjustable end wrench, spanners, pliers,
5 Other general tools screwdrivers, hammer, plastic hammer, T-shape
wrenches, chisel
6 Megger taster 500-V megger
instruments
Measuring
7 Depth gauge Dial type (minimum scale division: 0.01 mm) Screw shims (1)
8 Thickness gauges 0.03 to 0.10 mm Clearance between main bearing holder

and screw and slit clearance
9 Dial gauge Minimum scale division: 0.01 mm, stroke: 10 mm For measuring Backlash
Table 8-2. Tightening torque values for bolts (N - m)

Nominal screw size 5T Class 12.9
M5 3.0 11.6
M6 5.2 14.0
M8 12.3 34.0
M10 25.2 68.0
M12 42.7 118
M16 103 293
M20 202 570
M24 348
Notes: 1. Indicate metric coarse threads and standard bolts (5T, 12.9).
2. Tolerances on tightening torque are 15%.
3. When tightening hexagon socket head cap screws in the compressor, apply specifications
for class 12.9.
2. Special Tools
For an overhaul, be sure to prepare jigs listed in Table 8-3.
Table 8-3. List of special tools

Name used in manual Tool name Application Applicable model
Jig(1) Jig(1) Lock nut tightening jig Motor rotor mounting ZH3~9F, G
Jig(2)-1 ZH3, 5F
Jig(2) Bearing removing jig Removal of suction end cover
Jig(2)-2 ZH3~9F, G
Jig(3) Jig(3) Temporary bearing holder Centering of screw ZH3~9F, G

mounting plate
Jig(4)-1 ZH3, 5F
Jig(4) Handle Adjustment of slit
Jig(4)-2 ZH3~9F, G
Jig(5) Jig(5) Oil filter removing jig Required only for ZH3F ZH3F

Si50-203 Required Tools
Jig (1) [Lock Nut Tightening Jig]
(4 locations)
(through hole)
Applicable
Material
model
STPG370E
ZH3_ 76.3 66 150 5 7.0 10
65A, sch80
STPG370E
ZH5F, ZH7F 89.1 75 200 6 7.6 10
80A, sch80
STPG370E
ZH9F 101.6 92 250 7 8.1 12
90A, sch80
ZH5G 76.3 70 150 6 7.0 10 STPG370E
65A, sch80
STPG370E
ZH7G, ZH9G 101.6 86 200 7 8.1 11
90A, sch80
(Z0115)

Jig (2)-1 [Bearing Removing Jig Set]
Bearing outer ring
Suction end cover housing section
(Z0116)
Parts No. Name Quantity Material Remarks

Guide plate 1 SS400 or SM400A See next page.
Batten(1) 2 SS400 or SM400A See next page.
Batten(2) 1 SS400 or SM400A See next page.
Removing bolt 1 S45C JIS B1180 fully threaded hexagon head bolt
A M10x70-10.9, chamfered end
JIS B1180 hexagon head bolt with nominal diameter body
Hexagon bolt 2 S45C A M8x25-5.6

Jig (2)-1 [Bearing Removing Jig Parts]

Jig (2)-2 [Bearing Removing Jig Set]
Holding device
Cylindrical roller bearing
Bearing outer ring
Suction end cover holding section

(Z0118)
Parts No. Name Quantity Material Remarks

Guide plate 1 SS400 or SM400A See next page.
Batten 1 SS400 or SM400A See next page.
Removing bolt 1 S45C See next page.
Hexagon bolt 2 S45C JIS B1180 hexagon head bolt with nominal diameter body
A M6x30-5.6

Jig (2)-2 [Bearing Removing Jig Parts]
2-M6 (through hole)
M (through hole)
Applicable
Removing bolt
model
JIS B 1180 fully threaded hexagon head bolt
ZH3_ 54 30 25 9 8
A M8x70-10.9 chamfered end
ZH5F, ZH7_ 62 40 35 13 12
ZH5G 46 30 25 9 8
ZH9_ 67 50 35 13 12 JIS B 1180 fully threaded hexagon head bolt
(Z0119)

Jig (3) Temporary Bearing Holder Mounting Plate [jig]

[For ZH3_] Material: SS400







Jig (4)-1 [Handle Jig Set]
Parts No. Name Material Remarks

20A, sch40
Handle STPG370E
(t2. 9)
Stay (1) SS400 or
SM400A
SS400 or
Stay (2)
SM400A
Disc SS400 or
SM400A
Straight pin S45C JIS B1354

Class A or equivalent
ZH3_F ZH5_F
300 325
160 185
+0.012 +0.015
6 0
8 0
20 24
+0.012 +0.015
6 +0.004
8 +0.006
22 28
(Z0124)

Jig (4)-2 [Handle Jig Set]

20A, sch40
Handle STPG370E
(t2. 9)
Stay (1) SS400 or

SM400A
SS400 or
Stay (2)
SM400A
Disc SS400 or
Refer next page
SM400A
JIS B1354
Straight pin S45C Class A or equivalent
Refer next page
Applicable
model
ZH3_F 307 160
ZH3_G 287 140
ZH5_ 333 185
ZH7_ 321 170
ZH9_ 371 220
(Z0125)

Jig (4)-2 [Handle Jig Parts]
Applicable
model
+0.012 +0.012
ZH3_F 6 0
20 6 +0.004 22 50.5 7 60
+0.012 +0.012
ZH3_G 6 0
20 6 +0.004 26 50.5 7 60
+0.015 +0.015
ZH5_ 8 0
24 8 +0.006 28 60.5 8 70
+0.015 +0.015
ZH7_ 8 0
24 8 +0.006 32 75.5 11 85
+0.015 +0.015
ZH9_ 8 0
24 8 +0.006 36 80.5 11 90
(Z0126)

Jig (5) [Oil Filter Removing Jig]

[For ZH3_F]

20A, sch40
Handle STPG370E
(t2. 9)
Stay (1) SS400 or

SM400A
SS400 or
Stay (2)
SM400A
Spanner SS400 or
SM400A
(Z0127)

Si50-203
Index
A R
Airtightness Test ....................................................29 Remove The Side Caps (One on Each Side)
Assembling The Screw Shaft and Main Bearing and The Discharge End Cover.
Holder .............................................................24 (in case of ZH9F, oil collector) ....................... 11
Removing and Disassembling The Screw
C Assembly Pulley ............................................. 18
Caution in Test Operation ......................................31 Removing and Installation of Gate Rotor .............. 14
Changing Refrigerating Oil Removing Bearings
Changing Procedure ..........................................6 Gate Rotor Bearings (Angular-Contact Bearing,
Charging Oil ...........................................................30 Deep Groove Ball Bearing) ................ 21
Charging oil ..............................................................7 Main Shaft Bearing ......................................... 20
Cleaning The Suction Filter ......................................9 Removing The Motor Rotor ................................... 15
Removing The Suction End Cover ........................ 14
D Replacing The Bearing .......................................... 20
Disassembling The Gate Rotor and Surrounding Required Tools
Parts ................................................................12 List of general tools and measuring
Disassembly and Inspection ..................................11 instruments ........................................ 32
Disassembly of The Controller ...............................16 List of special tools ......................................... 32
Draining Oil ............................................................11
S
F Scope of Application ............................................... 2
Final Assembly .......................................................24
T
I Tightening torque values for bolts (N - m) ............. 32
Inserting The Screw Shaft ......................................25
Inspecting The Gate Rotor .......................................7
Inspection of The Gate Rotor and Surrounding
Parts ................................................................12
Installation of Bearings
Installing and Adjusting The Gate Rotor
Bearings ..............................................23
Main Shaft Bearing ..........................................22
Installing The Discharge End Cover
(In case of ZH9F, Oil collector) .......................28
Installing The Gate Rotor and Adjusting
The Slit Clearance ..........................................27
Installing The Main Bearing Holder Fixing Plate,
Assembling The Controller, and Installing
The Oil Filter ...................................................28
Installing The Motor Rotor ......................................25
Installing The Suction End Cover ...........................26
Insulation Resistance of The Motor ..........................5
Insulation Resistance Testing
Measurement Standard .....................................5
Measuring Procedure ........................................5
O
Overhaul ...................................................................3
Overhaul Instructions .............................................10
P
Periodic Inspection ...................................................4
Periodic Inspection Instructions ...............................5
Periodic Inspection Items and Intervals ...................4
Positioning The Screw Rotor ..................................26
Index i
Si50-203
ii Index
Si50-203
Drawings & Flow Charts

A P
Adjusting clearance between screw rotor and Placing alignment marks on casing and main
main bearing holder ........................................24 bearing holder ................................................ 18
Adjusting piston and installing cylinder cover .........28
Adjusting slit clearance ..........................................27 R
Removing C-type retainer ring .............................. 20
C Removing discharge end cover ............................. 11
Cleaning suction filter ...............................................9 Removing first demister ........................................ 11
Cross sectional diagram of controller .....................16 Removing gate rotor bearing retainer plate ........... 13
Cross sectional diagram of gate rotor ....................12 Removing inner ring of screw shaft bearing .......... 20
Removing lower bearing holder ............................ 13
D Removing lower bearing holder bearing ............... 21
Direction of bearings ....................................... 22, 23 Removing main bearing holder bearing ................ 21
Disassembling screw assembly .............................19 Removing main bearing holder fixing plate ........... 17
Drain port locations ..................................................6 Removing motor rotor ........................................... 15
Removing rotor locking plate ................................. 15
F Removing screw shaft (1) ..................................... 18
Front and back sides of angular-contact ball Removing screw shaft (2) ..................................... 19
bearing ............................................................23 Removing side cap ................................................ 11
Removing slide valve arm ..................................... 16
I Removing suction end cover ................................. 14
Inserting screw shaft ..............................................25
Inspection of gate rotor chipping ..............................8 S
Inspection of gate rotor surface ...............................8 Screw rotor position .............................................. 12
Installing suction end cover ....................................26 Service port and oil charge port locations ............... 6
Side cap locations ................................................... 7
J Slit clearance measuring location ........................... 8
Jig (1) [Lock Nut Tightening Jig] ............................33 Suction filter location (Cross sectional diagram of
Jig (2)-1 [Bearing Removing Jig Parts] ..................35 casing) ............................................................. 9
Jig (2)-1 [Bearing Removing Jig Set] .....................34
Jig (2)-2 [Bearing Removing Jig Parts] ..................37
Jig (2)-2 [Bearing Removing Jig Set] .....................36
Jig (3) Temporary Bearing Holder Mounting Plate
[jig] [For ZH3_] Material: SS400 ......................38
Jig (4)-1 [Handle Jig Set] .......................................42
Jig (4)-2 [Handle Jig Parts] ....................................44
Jig (4)-2 [Handle Jig Set] .......................................43
Jig (5) [Oil Filter Removing Jig] [For ZH3_F] ..........45
M
Measurement of gate rotor backlash .....................12
Measuring slit clearance on suction side .................8
Motor insulation resistance measuring method ........5
Motor rotor inserting direction ................................25
O
Oil filter removing tool ............................................17
Drawings & Flow Charts iii

Si50-203
iv Drawings & Flow Charts

Head office: Zandvoordestraat 300, B-8400 Oostende, Belgium Si50-203
Umeda Center Bldg., 4-12, Nakazaki-Nishi 2-chome,
Kita-ku, Osaka, 530-8323 Japan
Tokyo office:
Shinjuku Sumitomo Bldg., 6-1 Nishi-Shinjuku
2-chome, Shinjuku-ku, Tokyo, 163-0235 Japan
For Overhaul and Inspection

Semi-Hermetic Single Screw
Compressor Version
[Applied Models]
ZH(C)3LSF ZH3LMF ZH(C)3LTG

ZH(C)5MLF ZH5SLF ZH(C)3WLG
ZH(C), (A)5LLF ZH5LMF ZH(C), (A)5LMG
ZH(C), (A)7SLF ZHA7MLF ZH(C), (A)5WLG
ZH(C)7LLF ZHA7MSG ZH(C)7LSG
ZH(C), (A)9SLF ZH(C), (A)7WSG
ZH(C), (A)9LLF ZH(C), (A)9LSG
ZH(C), (A)9WSG
The specifications, designs, and information in this manual are subject to change without notice.
Printed in Japan 02/2003 AK

Daikin Si50-203

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Head office: Zandvoordestraat 300, B-8400 Oostende, Belgium Si50-203

Umeda Center Bldg., 4-12, Nakazaki-Nishi 2-chome,

For Overhaul and Inspection

ZH(C)3LSF ZH3LMF ZH(C)3LTG

Printed in Japan 02/2003 AK

ZH3LSF ZH3LMF ZHC3LSF ZH3LTG ZHC3LTG

Semi-Hermetic Single Screw Compressor Version III 1

2 Semi-Hermetic Single Screw Compressor Version III

Overhaul interval: 40,000 hours or 7 years, whichever comes first.

Semi-Hermetic Single Screw Compressor Version III 3

3.1 Periodic Inspection Items and Intervals

Table 3-1 Periodic inspection items and intervals

2 Inspection of refrigeration oil 7,500 hr or 4 years

4 Semi-Hermetic Single Screw Compressor Version III

3.2 Periodic Inspection Instructions

The following equation holds:

Fig. 3-1 Motor insulation resistance measuring method

Semi-Hermetic Single Screw Compressor Version III 5

2. Changing Refrigerating Oil

Fig. 3-2 Service port and oil charge port locations

Fig. 3-3 Drain port locations

6 Semi-Hermetic Single Screw Compressor Version III

(4) Charging oil

3. Inspecting The Gate Rotor

Fig. 3-4 Side cap locations

Semi-Hermetic Single Screw Compressor Version III 7

(4) Inspection of the gate rotor

Table 3-1 Gate rotor inspection standards

(5) Measuring the slit clearance

8 Semi-Hermetic Single Screw Compressor Version III

4. Cleaning The Suction Filter

Fig. 3-9 Suction filter location (Cross sectional diagram of casing)

Fig. 3-10 Cleaning suction filter

Semi-Hermetic Single Screw Compressor Version III 9

10 Semi-Hermetic Single Screw Compressor Version III

4.1 Disassembly and Inspection

Fig. 4-3 Removing first demister

Semi-Hermetic Single Screw Compressor Version III 11

3. Inspection of The Gate Rotor and Surrounding Parts

(1) Checking the slit clearance

Fig. 4-4 Measurement of gate rotor backlash

4. Disassembling The Gate Rotor and Surrounding Parts

(1) Positioning the screw rotor

Fig. 4-5 Screw rotor position

Fig. 4-6 Cross sectional diagram of gate rotor

12 Semi-Hermetic Single Screw Compressor Version III

(3) Removing the gate rotor bearing retainer plate

Fig. 4-7 Removing gate rotor bearing retainer plate

Fig. 4-8 Removing lower bearing holder

Semi-Hermetic Single Screw Compressor Version III 13

5. Removing and Installation of Gate Rotor

(1) Remove C type retaining ring.

6. Removing The Suction End Cover

(1) Remove all the mounting bolts.

Fig. 4-9 Removing suction end cover

14 Semi-Hermetic Single Screw Compressor Version III

7. Removing The Motor Rotor

(1) Remove the rotor locking plate using a standard screwdriver.