Bock FK40 Maintenance Instructions
Contents
1. With aluminium gasket 55 56 Spare parts list Pos 20 30 40 41 50 50 50 60 60 70 100 170 180 181 199 210 220 221 230 231 232 233 270 270 270 280 290 290 290 290 300 300 300 300 312 320 321 322 330 340 350 350 350 355 360 370 370 380 380 Designation Baseplate Baseplate gasket M8x30 Hexagon head screw Disc B8 4 Lower valve plate gasket 55 Lower valve plate gasket 60 Lower valve plate gasket 65 Valve plate complete 50 55 Valve plate complete 60 65 Upper valve plate gasket Safety valve for 28bar operation Cylinder cover M10x65 Hexagon head screw Disc B10 5 Transport angle Valve flange gasket M10x65 Hexagon head screw Disc B10 5 Filter suction side 0 Ring 34 59x2 62 Blind flange 9 mm Screw M10x25 Piston pin 15x10x41 Piston pin 15x10x46 Piston pin 15x10x50 Seeger circlip 15x1 DIN 472 Oil control ring piston 50 Oil control ring piston 55 Oil control ring piston 60 Oil control ring piston 65 Compression ring piston 50 Compression ring piston 55 Compression ring piston 60 Compression ring piston 65 Clearance ring for bearing 90 Cap nut M22x1 5 Cap nut 7 16 UNF Locking screw 1 8 NPTF Shut off valve AL Gasket soldered connect 42x34x1 Brazed hexagon nipple 22 Brazed hexagon nipple 28 Brazed hexagon nipple 35 Flange oval 16 mm Flange oval 16 mm Hexagonal head screw M10x35 Hexagonal head screw M2. Moisture in the system Overheating of compressor Oil pump Lack of oil Dirt in the system Moisture in the system Overheating of compressor Overloading of compressor Bearings Lack of oil Dirt in the system Moisture in the system Overloading of compressor Pistons Connecting rods Copper plating Moisture in the system Acid formation in the system Formation of oil carbon Overloading of compressor Liquid shocks because of liquid Liquid shocks Check adjust expansion valve replace it if necessary check refrigerant charge Check evaporator fan n case the evaporator is iced up Check the dimensioning of piping gas velocity Overheating of compressor Heat protec tion thermostat switches off Check the operating conditions Lack of oil Dirt in the system Change oil clean the system install a suction line filter if necessary Moisture in the system Acid formation in the system Dry the system trough changing refrig erant and oil replace the drier install a suction line filter if necessary Frequent starting and stopping of compres Sor Overloading of compressor Compare the operating conditions with the application limits Remove defects in belting ee 296 Removal of the compressor from the refrigerant system a Removal of the compressor from the system shut off valves remaining on the compressor Extract the refrig
3. Maintenance manual FK40 390 K FK40 470 K FK40 560 K FK40 655 K FK40 390 N FK40 470 N FK40 560 N FK40 655 N FK40 390 TK FK40 470 TK FK40 560 TK FK40 655 TK GEA Bock Dear Customer Bock compressors are top quality reliable service friendly quality products Please comply with the following operating and maintenance instructions so that you can benefit from all advantages to the full and use your refrigerating system throughout its entire service life If you have any questions about installation operation and accessories please contact our technical service or your refrigerating system wholesale dealer or our representative The Bock service team is available by phone under 49 7022 9454 0 by e mail under mail bock de or on the internet under www bock de In addi tion for German speaking countries we have set up a toll free hotline under 00 800 800 00 88 from Monday to Saturday between 8 a m and 9 p m Any suggestions you may have regarding the on going development of our compressor equipment and parts programme are welcome at any time Please read the information summarised for you in this manual before starting work It contains important instructions for safety installation initial commisioning and handling In addition you will find information on maintenance spare parts and accessories Some instructions are identified by special symbols with the following meaning WARNING This symbol is used to indicate that inaccurate
4. Solenoid valve on the liquid line not Check the setting of the valve opening Check the control function Cutoff through high 1 Condensing pressure too high pressure switch Check the setting of the high pressure Adjust the switching points or replace switch switch Pressure valve of the compressor closed Open shut off valve Condenser fan not functioning Check the control replace motor Condenser dirty Cleaning of condenser Excessive refrigerant filling Extract refrigerant to normal filling Non condensible gases in refrigerant Extract refrigerant and evacuate the refrigeration plant refill refrigerant Cutoff through heat 1 Discharge end temperatures is too high protection thermostat Operating limits of compressor exceeded Adapt the operating conditions to the accessory Suction gas overheating operating range Check expansion valve Check insula Refrigerant of the condenser insufficient tion on the suction side Valve plate damage Check fan motors Clean the condenser Internal safety valve has opened Replace valve plate Replace safety valve Check compressor and refrigeration plant Determine and remove the cause for the inadmissible high pressure in the high pressure side Cutoff through control Temperature over below the desired Check operating points thermostat range 215 Refrigerant performance too low Symptom Possible cause Remedy Suction pressure too
5. 13 Installation of the shut off valves and blind flanges Checking the compressor Tightening torques for screws Spare parts list Repair kits parts list Parts list for optional accessories Exploded drawing CON O O1 4 Co n2 09665 07 2011 Gb 09665 07 2011 Gb Vehicle compressors Series FK40 of Bock are among the most wide spread machines used for bus A C applications The criteria that speak for choosing a FK40 compressor are its compact dimen sions its low weight the wide capacity spectrum together with the high operating safety and service friendliness This maintenance manual is intended to make the repair and maintenance of the FK40 easier for the servicing personnel The maintenance manual contains a complete description of each work step for the disassembly and assembly of the compressor components Each step must be carefully adhered to in order tu ensure a reliable repair Reminder e For replacing components Bock provides suitable spare part kits Yet assembly jobs which go beyond the replacement of the shaft seal the valve plates and if there is one the capacity regulator accessory should be checked carefully for their economic efficiency beforehand e The maintenance manual describes the standard type of the FK40 compressor which we deliver Because of different system conceptions some passages in this service manual may differ from the unit which you have come across In these cases the present manual should be us
6. K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK ZA ZN UN UZ N K TK N K TK N K TK N K TK N K TK N K TK 6 5 Faas aaa a NO NS 390 04367 07990 05094 06723 05342 06400 05514 05801 06026 05361 05142 06352 06169 03860 03861 50184 06726 06165 05169 06067 05673 04425 05666 05462 05063 06178 07700 06162 03381 05457 02279 02280 02281 02282 02283 02284 FK X 40 470 05313 07990 05094 06723 05342 06400 05514 05801 06026 05361 05142 06352 06169 03860 03861 06726 06726 06165 05169 06067 05673 04425 05666 05462 05063 06161 07700 06162 03381 05457 02279 02280 02281 02282 02283 02284 560 05313 07990 05094 06723 05342 06400 05514 05801 06026 05361 05142 06352 06169 03860 03861 06726 06726 06165 05169 06067 05673 04425 05666 05462 05063 06641 07700 06162 03381 05457 02279 02280 02281 02282 02283 02284 655 05313 07990 05094 06723 05342 06400 05514 05801 06026 05361 05142 06352 06169 03860 03861 06726 06726 06165 05169 06067 05673 04425 05666 05462 05063 06642 07700 06162 03381 05457 02279 02280 02281 02282 02283 02284 Repair set parts list Pos 2
7. Oil foams Add oil and search for the cause of oil loss Clean replace oil filter Change oil Check the laying of pipes Installation of the check valve in the discharge line Installation of the solenoid valve in the liquid line Check the control Adjust replace expansion valve Refrigerant and oil get mixed After some time the oil level should stabilize Add oil if necessary see Oil foams during operation Replace piston rings Replace valve plate Remedy Tighten the screwed connections and secure them anew Replace vibrations metals Adjust check expansion valve Check refrigerant filling Check evaporator fan Icing up of the evaporator Check oil level Check the dimensioning of pipes gas velocity Replace worn piston rings Check the control Replace capacity regulator valve Checking Check belt tension Use tensioning roller guidance roller Incorrect alignment of compressor and motor Check alignment and adjust anew An 16 Malfunction of the electromagnetic clutch Symptom Possible cause Clutch not switching No voltage applied Clutch slipping too long Voltage too low getting hot smoking and squeaking Driving power too high Rotor rubbing at the magnetic field Clutch not separating 1 Voltage still being applied to the magnet Clutch is stuck Clutch overloaded Armature disc is deformed Remedy Apply voltage
8. and the solenoid 4 and fasten them with the fixing nut 3 Put the compressor into operation and check the functioning if the capacity regulation Fig 6 09665 07 2011 Gb 09665 07 2011 Gb Valve plate Compressor type Parts kit Part No Compressor type Parts kit Part No FK40 390 N 80240 FK40 390 TK 80240 FK40 470 N 80240 FK40 470 TK 80240 FK40 560 N 80241 FK40 560 TK 80241 FK40 655 N 80241 FK40 655 TK 80241 FK40 390 K to FK40 655 K 80010 K type Valve plate N type and TK type Valve plate 3 2 2 3 3 4 4 5 5 Fig 7 mo Removal see Fig 7 e Unscrew the screws 1 from the cylinder cover 2 and dismount cylinder cover e Remove the gasket residues from the body of the compressor Reminder Don t let any gasket residues fall into the compressor Installation see Fig 7 A Attention The conversion of the compressor from one type of valve plate to another is not possiblel Apply a little oil to the lower valve plate gasket 5 install the upper valve plate gasket 3 metallic gasket dry Pay attention to the correct installation position of the gaskets 3 5 of the valve plate 4 and of the cylinder cover 2 Attention Install the K type valve plate Part no 80010 only with the inscription TOP facing upwards see Fig 7 e Tighten the cylinder cover screws Pos 1 in Fig 7 according to the sequence shown in Fig 8 observe the screw tightenin
9. and check Keep the voltage at 12 or 24 Volts check vehicle network Check operating conditions Check the seating of the magnet possibly to high belt tension Check switch relay Disconnect the armature disc from the rotor mechanically Install new rotor ans armature disc 09665 07 2011 Gb 09665 07 2011 Gb Disassembly Assembly of service kits In principle the same safety remarks described on page 5 of this Service Manual are A valid Furthermore the following should be taken into account Before starting any work on the compressor e Switch of the machine and guard it against switching on e Close the discharge and suction shut off valves e Relieve the compressor from system pressure e Use only genuine Bock spare parts After the work is finished e Connect the safety switch and check its function e Evacuate the compressor e Before commissioning check whether all the components installed by the user have been mounted expertly and connected pressure tight to the compressor e g piping plugs union nuts replaced components etc e Open the pressure and suction shut off valves see page 11 e Set off the switching on lock For changing components in the framework of customary service works we recommend the kits described on the following pages 7 248 Installation of service kits Leak oil collection ring Part No 80129 Procedure Leak oil collection ring e Remove the leak oil collection rin
10. be pressed out by hand A WATCH OUT Parts are hot Use protective gloves Working course 2150 Press out the roller bearing from the compressor body 312 Take out the tolerance ring if there is any Oo Use oil if necessaryl 38 09665 07 2011 Gb 09665 07 2011 Gb Checking compressor parts for damages wear Before re using removed compressor parts we recommend that they be checked for usability The wear limits listed below should be taken into consideration Maximum allowable bearing play 1 Piston cylindre bore 0 13 mm 2 Connecting rod piston pin 0 03 mm 2 3 Crankshaft connection rod bearing 0 08 mm m gel Hl pr Fig 24 N T in Other components have to be examined according to the following criteria e Cylinder liners The cylinder liners should not have any visible damages in the piston movement area If there is fluting the casing should be replaced e Crankshaft The bearing surfaces should not have any damages The oil channels should be clean so that an unhindered oil flow is ensured Fig 25 Clean the oil channels with com pressed air ans check for passage 39 e Pistons There should be no visible damages on the piston crown and the piston walls The grooves for the piston rings must be clean and undamaged Check the condition of the piston rings for wear fractures and other irregularities e Connecting rods There should be no damages on bearin
11. compliance or total failure to comply with the instructions could cause injury to persons or damage to the comperssor or refrigerating machine This symbol indicates important additional instructions which you should observe during your work The high quality standart of Bock compressors is guaranteed also by on going furtherdevelopment of machine features and accessories This could possible results in non conformities between this present manual and your compressor Please understand tha it is not possible for any claims to be derived from the details illstrations and descriptions Your team at GEA Bock GmbH Subject to modification Benzstrasse 7 72636 Frickenhausen Germany Telephone 49 7022 9454 0 Fax 49 7022 9454 137 mail bock de www bock de QUALITY SYSTEM I Net 09665 07 2011 Gb certified by DOS according to DIN EN ISO 9001 Reg No 2177 09665 07 2011 Gb Introduction Safety instructions Product description Short description nameplate type code Main and functional parts Dimension drawing connections Technical data Maintenance Function checks oil level check oil change Operation of the shut off valves Fault diagnosis Remedying the malfunction General function faults symptoms Compressor stand still Compressor cutoff Refrigerant performance too low Compressor temperature too high Oil problems Abnormal running noise from compressor Malfunction of the electromagnetic clutch Installa
12. on both sides of the piston pins see Fig 31b Fig 31a Fig 31b 09665 07 2011 Gb 09665 07 2011 Gb step Fitting the piston connecting rod set 4 Parts list position 2040 Tools Spanner SW 10 Take the markings of each part into account see disassembly step 7 on page 33 Pos in i Work asas orking course 2100 Remove the connecting rod cap from the preassembled connecting rod assembly and mark it e Apply a little oil to the cylinder bore 2040 Insert the piston connecting rod assemblies from the opening in the baseplate into the cylinder liners In the case of TK compressors pay attention to the correct assembly position of the pistons suction fin grooves Fig 32 290 300 e Install the oil scraper rings and the compression rings of the pistons afterwards turn them by 30 The butt joints may not lying upon each other Fig 32 Fit with the marking TOP facing upwards Fig 32 Oil scraper ring Compression ring KL BH 45 46 step Fitting the crankshaft D Parts list position 2050 Tools Pos in z V orking course Fit the crankshaft so that the drive journal engeges into the gump gear Fig 33 N Ty r ni wei E 09665 07 2011 Gb 09665 07 2011 Gb Step 0 o Pos in arts list 745 730 740 750 Fig 34 Installation of the front bearing flange Partsl ist position 2140 Tools Allen key 6 mm Observe th
13. the shaft seal cover 6 Remove the gasket residues and the shaft seal cover gasket 5 from the bearing flange Attention The shaft seal cover 6 is under spring tension The remaining oil may run out of the shaft seal chamber Keep a suitable collection container ready Fig 5 TOP installation Work with utmost cleanliness Always replace the shaft seals complete never individual parts thereof e Do not use used parts e Prior to installation check the sliding and sealing surfaces for cleanliness and damages e Apply a thin film of oil on the sealing surfaces of the sliding ring 4 shaft seal cover 6 O ring 3 and the compressor shaft use compressor oil e Assemble the sliding ring 4 O ring 3 and the guide ring 2 together as a unit The large chamfer on the sliding ring 4 should show in the direction of the shaft seal cover 6 e During the assembly the compression spring 1 must engage audibly in the drive slot of the crankshaft and of the guide ring 2 e nstall the shaft seal cover gasket 5 dry don t impregnate it with oil e nstall the shaft seal cover 6 with the inscription TOP upwards Tighten the fixing screws 7 evenly crosswise tightening torque 37 Nm e After installing the shaft seal turn the compressor shaft a few turns by hand and then carry out the leak test e Install the leak oil collection ring see section on leak oil collection ring page 18 e Inse
14. 0 Tools Oil collection pan spanner SW 13 Working course e Place the compressor into the oil collection pan and turn it sideways e Unscrew the screws from the baseplate e Remove the baseplate and the gasket 09665 07 2011 Gb 09665 07 2011 Gb step Disassembiy of the compressor rods from the crankshaft Parts list position 2100 Tools Spanner SW 10 aD In order to prevent any mix up during reassembly mark the connecting rods and caps belonging together clearly and in a wipe resistant fashion Pos in Work are orking course e Unscrew the hexagon head screws from the connecting rod cap e Mark the connecting rod cap and remove it e Push the piston and connecting rod upwards until the shop e Remove the piston rings e The same procedure should be applied for the remaining connecting rods Fig 18a Fig 18b 527 24 Sep Removal of the front bearing 9 Parts list position 2140 Tools Allen key 6 mm Pos in Working course parts list J 750 e Unscrew the screws 730 740 745 Remove the front bearing flange gasket and O ring Fig 19a 09665 07 2011 Gb 09665 07 2011 Gb Step Removal of the crankshaft 9 Parts list position 2050 Tools Pos in parts list Working course e Pull out the crankshaft carefully in direction of the front bearing flange Fig 20a 35 step Removal of the pistons and connecting rods 1 Parts list position 2040 Tools Seeger c
15. 00 510 520 521 570 570 590 590 726 121 728 129 730 740 745 750 790 800 810 820 880 1910 1910 1910 1910 1920 1930 1940 1950 3999 3999 3999 3999 3999 3999 Designation Brazed hexagon nipple 28 Brazed hexagon nipple 35 Oil pump complete Gasket f oilp rear bear flange Oil filter Seal ring 27x22x2 Locking screw M22x1 5 Locking screw 1 8 NPTF Locking screw 1 4 NPTF Sight glass insert 018 up to design key 012 Sight glass insert 022 as of design key 013 O Ring 23 52x1 78 up to design key 012 O Ring 28 30x1 78 as of design key 013 Cylinder screw M10x10 Cable hose holder Cable hose clamp Haft plug 05 PHT BLACK Front bearing flange Front bearing flange gasket O Ring 101 19x3 53 Cylinder screw M8x25 Woodruff key A5x9 DIN 6888 Disc 50x12 5x8 Spring washer B12 Hexagonal head screw M12x40 Shaft seal cover gasket Lower valve plate gasket 50 Lower valve plate gasket 55 Lower valve plate gasket 60 Lower valve plate gasket 65 Valve plate complete upper valve plate gasket Cylinder cover Hexagonal head screw M10x70 Only for FK compressors Mach oil SP46 1 Lir can Mach oil SP46 5 Lir can Mach oil SP46 20 Lir can Only for FKX compressors Mach oil SE55 1 Ltr can Mach oil SE55 5 Ltr can Mach oil SE55 10 Ltr can Version N K TK N K TK N K TK N K TK N K TK N K TK N K TK N
16. 000 2010 2020 2030 2030 2030 2030 2035 2035 2035 2035 2040 2040 2040 2040 2045 2045 2045 2045 2050 2060 2060 2070 2070 2070 2080 2080 2090 2090 2100 2110 2130 2140 2150 2900 58 Designation Set valve plate Set shaft seal Set oil pump Set piston 50 Set piston 55 Set piston 60 Set piston 65 Set piston 50 Set piston 55 Set piston 60 Set piston 65 Set piston con Set piston con Set piston con Set piston con Set piston con Set piston con Set piston con Set piston con s nn optimized optimized optimized optimized rilled optimized rilled optimized rilled optimized rilled optimized rod 2 rings 050 rod 2 rings 555 rod 2 rings 060 rod 2 rings 065 r rod 050 r opt rod 055 r opt rod 060 r opt rod 065 r opt Version N TK N K TK N K TK Z zz m Jd Ea col co ca Es I Set crankshaft 49 stroke optimized N Set shut off valve NW25 L A Set shut off valve NW32 Set shut off valve NW20 Set shut off valve NW25 Set shut off valve NW32 Set sight glass 018 up to design key 012 Set sight glass 022 as of design key 013 Set gaskets not shown Set gaskets not shown Set connecting rod Set coll ring w felt insert up to design key 013 Set oil filter Set front bearing flange Set cylinder roller bearing Set valve plat
17. 10x35 Cylinder screw M10x35 Cylinder screw M10x35 Version N K TK N K TK N K TK N K TK N TK N TK N TK N TK N TK N TK N K TK N TK N TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK N K TK Piece 0 FK X 40 470 560 03876 03876 06721 06721 06244 06244 05644 05644 05695 05696 07118 06730 06730 07940 07940 03384 03384 06034 06034 05646 05646 50435 50435 05083 05083 06034 06034 05646 05646 03370 03370 05153 05153 04715 04715 05075 05075 r2ig 07857 05551 05551 05390 06562 053800 06563 05280 05280 05784 05784 05789 05789 05514 05514 07128 07128 05067 05067 04367 04367 04329 04329 04329 04329 05489 05489 05447 05447 06564 05280 05784 05789 05514 07128 05067 05313 04329 04329 05489 05489 09665 07 2011 Gb 09665 07 2011 Gb Pos 400 400 460 470 490 5
18. Evaporator iced up Remove the cause high Expansion valve not functioning properly Check valve setting replace valve if necessary Lack of compressor capacity Check the function of the compressor by evacuating to vacuum Check function of capacity regulator accessory Suction pressure too low See Cutoff through low pressure switch Checking High pressure too high See Cutoff through high pressure switch Checking High pressure too low 1 Condenser being cooled to much Adjust the control of condenser cooling Check compressor Check the functio Lack of compressor capacity ning of capacity regulator Replace valve plate Pressure laminations of valve plate leaking Localize leak between the discharge and By pass between suction and discharge side suction side and repair it Refrigerant temperature too high Symptom Possible cause Remedy Suction gas tempera Suction gas overheating Adjust expansion valve ture too high Insulate the gas suction line Too little refrigerant filling Establish the operating filling see Operating Instruction for the refrigeration plant Localize leak Liquid filter blocked Clean replace filter dryer Discharge pipe tem Suction gas temperature too high see point above perature too high Condensing pressure too high see Cutoff through high pressure switch see Cutoff through heat protection Operating limits of compressor exceeded thermost
19. TK N K TK N K TK N K TK N K TK Piece 390 08704 03383 06730 05457 08418 07541 05987 05143 05885 07526 80022 08709 03323 06162 06338 FK X 40 470 560 08704 08704 03383 03383 06730 06730 05457 05457 08418 08418 07541 07541 05987 05987 05143 05143 05885 05885 07526 07526 80022 80022 08709 08709 03323 03323 06162 06162 06338 06338 655 08704 03383 06730 05457 08418 07541 05987 05143 05885 07526 80022 08709 03323 06162 06338 59 GEA GEA Refrigeration Technologies www gearefrigeration com www bock de 09665 07 2011 Gb
20. TK versions 1940 2900 K version Tool Spanner SW 17 In order to prevent any mix up during reassembly mark the cylinder cover and the valve plates belonging together clearly and in a wipe resistant fashion Working course 1950 e Unscrew the cylinder cover screw 1940 19301 Remove the cylinder cover and the upper gasket of the valve plate 1920 19101 Remove the valve plate and the lower gasket of the valve plate 20 30 Step Removal of the shaft seal 4 Parts list position 2010 Tools Oil collection container Allen key 6 mm G For a detailed description see also the section on the removal of the shaft seal on page 19 Pos in Working course arts list e Place the oil collection container under the shaft seal area 2110 Remove the leak oil collection device from the bearing flange 750 e Unscrew the cylinder screws Watch out The shaft seal cover is under spring tension It may jump out by itself 2010 Remove the shaft seal cover the guide ring the O ring and the spring Fig 15a only up to design key 013 09665 07 2011 Gb 09665 07 2011 Gb Step Removal of the oil pump D Parts list position 2020 Tools Spanner SW 13 e Unscrew the screws e Remove the oil pump and gasket Pos in W parts list orking course 40 460 470 Fig 16a BUM Step 6 Pos in parts list 40 20 30 Removal of the baseplate Parts list position 2
21. ain and functional parts Sa S QU DI us 1 gt Discharge shut off Valve plate Cylinder cover Compressor casing Location hole for fitting magnetic clutch Integrated leak oil collector Oil tube Shaft seal Shaft end Baseplate Connection for heat protection thermostat Oil filling plug Sight glases for oil 2x Oil drain plug Suction shut off valve Oil pump Oil drain plug oil filter Nameplate Dimension drawing ca 320 325 370 SV1 i gt i SV A y T P gt A1 C E LO SS poro 4x O13 210 _ L 232 8x M8 2130 ex M8 272 A5x9 DIN 6888 i 12 28 Fr q 90 5148 h8 5110 Dimensions in mm Connections A A1 g x m x m Tim O c 02 00 Suction side connection not lockable Suction side connection lockable Discharge side connection not lockable Discharge side connection lockable Oil pressure safety switch connection OIL Oil pressure safety switch connection LP Oil pressure gauge connection Oil drain Optional connection oil sump heater Oil charge plug Sight glass Connection thermal protection thermostat Oil filter Optional connection suction valve Only pos
22. at Cooling insufficient Short circuit between the discharge and the suction side of the compressor Valve plate damage Replace defective valve plate Internal safety valve has opened Replace safety valve see the section on Dismantling Assembly of Compressor 09665 07 2011 Gb 09665 07 2011 Gb Oil problems Symptom Oil pressure too low Possible cause Refrigerant in oil Too little oil in compressor Oil filter dirty blocked Oil foams during start up phase Liquid refrigerant has moved into the oil sump Oil foams during Expansion valve not functioning operating Oil level decreases Refrigerant in oil Piston rings worn Suction discharge laminations of the valve plate leaking Abnormal running noise from compressor Symptom Possible cause Fixation of compressor Screwed connections hava become loose is loose missing Vibration metals defective Liquid shock Liquid refrigerant reaching the compressor Oil shocks because of too much oil Capacity regulator switching on and off constantly oscillating accessory defective Electromagnetic clutch see also p 16 Malfunction of electromag slipping netic clutch V belt drive increased noise generation Belts vibrating excessively During start up a portion of the oil is carried to the refrigeration plant with the refrigerant Securing elements for screwed connections Remedy see
23. cation gt For air conditioning the K Design gt For air conditioning or normal cooling the N Design gt For deep freezing the TK Design The differences are mostly associated with the valve plate version which is adapted to each applica tion range where operational safety and efficiency are concerned More features e Compact 4 cylinder compressor in V design e Wear resistant and long lasting engine e Four sizes as regards capacity e Aluminium light weight construction e Crankshaft supported in roller bearings on both sides e Bidirectional lubricating oil pump with relief valve e Variable arrangement shut off valves ideally equipped with valve plates for each application e Integrated pulsation damper for especially quiet running Nameplate Example G k GmbH ieee Germany Nr AR1 2345A01 7 4 1 Typ FKX40 655 N 2 Vin 96 6 m h bei n 1450min 3 Pac ND LP HD HP 19 28bar l SE55 5 1 Type of compressor 4 Serial number 2 Volume bal ye bei 1450 1 min 5 Oil type filled in compressor by the manufacturer 3 LP max tol stand still pressure intake side note limits of HP max tol Derating pressure high pressure side aplication diagrams Type code Example Explanation of the type designation FK X 40 655 N Application Swept volume Size Ester oil filling HFKW refrigerant e g R134a R407C Code letter for series 09665 07 2011 Gb 09665 07 2011 Gb Product description M
24. e AL AL AL AL N K TK N K TK N K TK N K TK N K TK N K TK N K TK N TK K N K TK N K TK N K TK N K TK N K TK K Piece Nanan ont aR RRR ER BR RRB ERR pRB n mom 390 80240 80023 80017 80102 08552 80230 80001 08449 80129 80076 80081 80118 80010 FK X 40 470 560 80240 80241 80023 80023 80017 80017 80103 80104 80107 80210 80109 80110 80250 80251 80154 80154 08082 08082 08084 08084 08698 08698 08552 08552 80230 80230 80001 80001 08449 08449 80129 80129 80076 80076 80081 80081 80118 80118 80010 80010 08552 80230 80001 08449 80129 80076 80081 80118 80010 09665 07 2011 Gb 09665 07 2011 Gb Parts list optional accessories Pos 3200 3220 3240 3250 3300 3310 3311 3312 3313 3320 3600 3800 3820 3840 3850 Designation Set cap reg LR 87 24V with cylinder cover Cylinder cover for LR Upper valve plate gasket Hexagonal head screw M10x70 Set cap regulation LR 87 24 V Valve body LR 87 O Ring 48 0x2 5 green Disc 30x16x2 0 Milled nut M15x1 with O Ring Solenoid coil 24 V CC Set replacement adapter set the same shut off valve positioning similar to FK4 467 not shown Set cap regulation LR 87 24V with cylinder cover Cylinder cover for LR Upper valve plate gasket Hexagonal head screw M10x85 Version N TK N TK N TK N TK N K TK N K
25. e tightening torques see table on page 55 Working course e Apply oil to the O ring and place it into the groove in the bearing flange e install the front bearing flange with oiled gasket to the body so that the hole for the leak oil collection ring faces upwards e Tighten the screws 47 Step o Assembiy of the inserted connecting rods pistons Parts list position 2040 Tools Piston ring plier spanner 10 mm Pay attention to the correct pairing of connecting rods and connecting rod caps Replace connecting rod cap screws or in the case of reusing put on a sticker Observe the tightening torques see table on page 55 Pos in arts lisi Working course 290 300 Compress the oil scraper ring and compression ring with the piston ring plier and insert the piston into the cylinder liner 2100 Place the marked connecting rod caps onto the related connecting rods e Screw on the connecting rod caps and tighten e Turn the crankshaft by hand In case the crankshaft does not rotate freely check the seating of the connecting rods if necessary disassemble the connecting rods and carry out this step once more Fig 35a Fig 35b 48 09665 07 2011 Gb 09665 07 2011 Gb step Install of the oil pump 9 Parts list position 2020 Tools Spanner 13 mm G Observe the tightening torques see table on page 55 Pos in Work arts list orking course 460 470 Install the oil pump with o
26. eating of the Woodruff key in the rotor Slot It should be possible to turn the rotor by hand without the rotor touching the solenoid Pay attention to the checking projection Screw on the clamping screw 4 and tighten it Screw tightening torque 85 Nm Install the K circlip 5 e Push the sheave 6 over the studs 9 and fasten it with zinc coated M8 DIN 934 8 nuts 7 e Connect the cable 8 The connection is polarity independent Voltage 10 of nominal voltage Reminder for dismounting For dismounting the clutch apply grease to the K circlip and turn the clamping screw 4 to the left for unscrewing Attention With all other methods of removal pressing hammering there is risk of damage to the clutch 09665 07 2011 Gb 09665 07 2011 Gb Compressor defects Compressor defects may have various causes The table below is meant to aid you while analysing the cause of the breakdown by means of the defective compressor parts found Thus the specific remedying of the cause of the breakdown is facilitated Compressor part Possible causes Symptom Remedy Valve plate refrigerant or oil Overheating of compressor Shaft seal Lack of oil leaking Standstill time too long Dirt in the system Moisture in the system Too frequent starting of the compressor Overheating of compressor Belt vibrating excessively Alignment of compressor and motor incorrect Lack of oil Dirt in the system
27. ed in analogous fashion A Safety instructions Attention Refrigeration compressors are machines under pressure an as such require special care in handling Only qualified personnel are allowed to perform any work on refrigeration com pressors The national safety regulations accident prevention regulations technical rules and specific regulations EN 378 and others must be taken into account absolutely Do not exceed the maximum operating pressure not even for purpose of checking Never put the safety switch out of action Prior to commissioning check whether all the components installed by the user have been fastened expertly and connected pressure tight with the compressor e g piping plugs union nuts replaced components etc Before commissioning evacuate the refrigerant systems carefully including the compressor and afterwards charge refrigerant Prior to starting the compressor open discharge shut off valve and suction shut off valve Do not start the compressor in vacuum Operate the compressor only when the system is charged According to the conditions of use surface temperatures in excess of 100 C may occur on the discharge side and temperatures below 0 C on the suction side Never grab rotating parts during operation Danger of injury Product description Series FK 40 vehicle compressors are designed for mobile applications Short description Three design variations are available for different areas of appli
28. erant from the system into a container which may be used for this refrigerant Evacuate the systems including the compressor Cut off the vacuum humid air should not get into the system Close the shut off valves on the suction and discharge side remove the compressor Close the suction and discharge line connection points on the system with stoppers Relieve the pressure before dismounting the compressor b Removal of the compressor from the system shut off valves for compressor remaining at the system Close shut off valves on the suction and discharge side Evacuate the compressor Cut off the vacuum Remove the compressor from the system Close the suction and discharge shut off ports on the compressor with stoppers Disassembly of compressor The disassembly of the compressor is explained in separate steps on the following pages The indicated parts list positions refer to the spare parts lists repair set lists special accessories part lists and the exploded drawing at the end of the maintenance manual Preparation Necessary tools Reminder For the removal and installation of the internal safety valve the BOCK special tool Part No 09524 is necessary only up to design key 015 Pos Tool Size 1 Oil collection container 2 0 ltr 2 Spanner SW 10 13 14 17 19 30 36 3 Allen key 6 mm 10 mm 4 Seeger circlip plier Form C 8 13 mm 5 Pulling apparatus 6 Pressing apparatus 7 Piston ring plier 8 Dial gage 9 Bock
29. evented 41 Assembly of compressor step Fitting the roller bearings Parts list position 2150 Tools Pressing apparatus Pos in i Working course arts list e Heat the bearing flange compressor casing for approx 20 minutes in a pre heated 120 C baking oven e Press the roller bearings onto the compressor casing and the front bearing flange A WATCH OUT Parts are hot Use protective gloves o Use tolerance ring if the bearing seat has a groovel Pressing tool Fig 29a Fig 29b 09665 07 2011 Gb 09665 07 2011 Gb step Fitting the sight glass plugs safety valve 2 Parts list position Tools Spanner SW 13 14 30 o 36 for the safety valve Bock special tool Part no 09524 up to A015 socket wrench SW 22 from A 017 G Observe the screw tightening torques see table on page 55 Pos in Working course arts list 570 590 Screw on the sight glass with oiled O ring to the compressor body 521 e Screw on the 1 4 NPTF plugs 520 Screw on the 1 5 NPTF plugs 100 Fig 30d 100 A3 44 SP Assembly of the pistons connection 3 Parts list position 2040 Tools Seeger circlip plier Form C 8 13 mm Pos in Work course arts list e Assembly the pistons with the connecting rods in the reverse sequence of the disassembly of compressor step 7 270 e Insert the piston pins use oil if necessary see Fig 31a 280 Install seeger circlips
30. g see Fig 1 e The repair kit contains two felt inlays Pos 2 and Pos 3 see Fig 2 e f the bearing flange with one oil pocket is installed Pos 2 must be inserted see Fig 4 e f the bearing flange with six oil pocket is installed Pos 2 must be inserted see Fig 4 e f the wrong felt inlay or both felt inlays is inserted the functioning of the oil collection system cannot be ensured Fig 1 Type code 007 013 Bearing flange with one oil pocket Bearing flange with six oil pockets Open at top Open at bottom 1 Starting from type code 015 starting from 4th quarter 2005 Emptying the oil reservoir The oil reservoir can be emptied very simply without having to dismantle the coupling and or belt drive It is recommended that this is done at the same time as the air conditioning maintenance and motor service Proceed by removing the oil hose from the bracket remove the sealing plug and drain the oil into a collecting vessel Af ter emptying the bracket Dispose of used oil in accordance with the regulations applicable in the country of use 09665 07 2011 Gb 09665 07 2011 Gb Shaft seal Part No 80023 Removal e Dismount the drive magnetic clutch from the compressor e Remove the Woodruff key from seat at the shaft end Remove the leak oil collection ring 9 and the felt inlay Sa or 8b according to the type for this see Fig 1 on page 18 Unscrew the screws 7 from
31. g surfaces The connecting rod shank must be straight Fig 26 e Valve plates correct faulty Suction and pressure lamella must be undamaged and un deformed The sealing surfaces must be clean and undamaged In case of a damage the valve plate must be replaced com pletely Single lamella are not available e Oil pump It must be possible to turn the oil pump by hand turning to the left and to the right In the removed conditioning the reversing device of the oil pump must switch over audibly Fig 27 40 09665 07 2011 Gb 09665 07 2011 Gb Check the compressor parts e Oil filter suction filter The filter screen must be in an undamaged condition Dirt and residues have to be removed If necessary the filter have to be cleanded with compressed air or replaced with new ones e Internal safety valve use Bock special tool Part No 09524 up to A015 socket wrench SW 22 from A 017 The internal safety valve must be replaced after it has operated Fig 28 Safety valve 24 x Agi a N Oil filter In case of larger compressor damages which necessitate a complete disassembly of the compressor we recommend in principle the replacement of the following assemblies e Valve plates e Piston rings e Shaft seals e holler bearings Thus concealed defects of parts which have been in operation may be pr
32. g torque see Table on Page 55 Fig 8 Sequence for tightening the cylinder cover screws 09665 07 2011 Gb 09665 07 2011 Gb Electromagnetic clutch Assembly instruction for electromagnetic clutch For the drive of A C compressors in buses mainly electromagnetic clutches are used The followings assembly instructions for clutch type LA 16 is representative for clutches which are mounted onto the front bearing flange of the compressor Assembly instruction for electromagnetic clutch Type LA 16 The front bearing flange has a location face 0148 h8 for fitting the solenoid of the electro magnetic clutch see Fig 9 Fig 9 Fig 10 Front bear ing flange Magnetic field 148 h8 e For fitting the solenoid 1 remove the four M8x25 cylinder screws 2 on the bearing flange indicated with circles and arrows in Fig 9 on page 23 and Fig 11 on page 24 Fit the solenoid onto the location seat and fasten it again with the four M8x25 cylinder screws Fig 10 Observe the screw tightening torque see Table on page 55 A Attention Use only M8x25 screws Otherwise serious damages may occur on the electromagnetic clutch and the compressor ca 294 Reminder Arrange the cable 8 so that it doesn t touch hot parts e g protection pipe tax 105 C Remove the K circlip 5 and the clamping screw 4 from the rotor assembly 3 Looking through the rotor hole pay attention to the correct s
33. il gasket into the body with the inscription TOP facing upwards Pay attention to the position of the holes in the gasket Fig 36a 40 e Tighten the oil pump screws crosswise Pay attention to the tightening sequence of the oil pump screws Fig 36b Fig 36b Tightening sequence for oil pump screws Adjust end play The end play of the crankshaft should be minimum 0 1 mm When parts of the driving unit of the compressor have been repaired or replaced an accurate measurement of the end play is necessary The measurement has to be at the disassembly friction ring cover Will the play of the crankshaft be less than 0 15 mm the bearing flange hast to be disassembled and a second seal hast to be inserted Fig 36d Fig 36c 49 step Fitting the shaft seal 9 Parts list position 2010 Tools Allen key 6 mm Watch out Avoid damages Pay attention to the markings Apply a little oil to the parts Observe tightening torques see table on page 55 Pos in l eli Working course e Push the compression spring onto the crankshaft Rotate the spring until the driving catch is engaged in the crankshaft e Push the guide ring with O ring and sliding ring onto the crankshaft Rotate all parts until the spring is engaged in the guide ring Avoid scratches on the sliding ring 880 install the shaft seal cover with the gasket The inscription TOP must be at the top 750 e Press the shaft seal cover onto the bearing fla
34. irclip plier from C 8 13 mm Pos in Working course arts list 9 Mark the piston and the cylinder bore belonging together e Remove the piston connecting rod in direction of baseplate 280 e Remove the seeger circlip of the piston pins 270 e Push the piston pins out of the pistons and remove pistons e n order to prevent mix ups fasten the connecting rod caps to the connecting rods again Fig 21a Fig 21b CE CC CO emma 236 09665 07 2011 Gb 09665 07 2011 Gb Step 11 Pos in arts list 570 590 520 521 100 100 Removal of the remaining parts Parts list position Tools Spanner SW 13 14 30 o 36 for the safety valve Bock special tool Part no 09524 up to A015 socket wrench SW 22 from A 017 Working course e Dismount the sight glass use 30 mm or 36 mm spanner according to the type e Remove O ring e Remove the 1 8 NPTF plugs e Remove the 1 NPTF plugs e Unscrew the safety valve see the last four sites of the machine number 2080 570 7 step Removal of the roller bearings 1 2 Parts list position 2150 Tools Pulling apparatus Pos in arts list 2150 730 e With the pulling apparatus pull out the roller bearing from the front bearing flange Use oil if necessary If a pulling apparatus is not available the front bearing flange may be heated for approx 15 minutes in a pre heated 220 C baking oven Afterwards the roller bearing can
35. nge and tighten the screws e Turn the crankshaft by hand it now moves with a little more difficulty 2110 e Install the leak oil collection device only up to design key 013 Fig 37 and see also under service kits Leak oil collection device m Fig 37a PEST 22 am Fig 37b o Fig 37d 09665 07 2011 Gb 09665 07 2011 Gb Step Installation of the baseplate 1 Parts list position 20 Tools Spanner 13 mm G Observe the tightening torques see table on page 55 Pos in arts list 20 30 40 Working course e Install the baseplate with gasket and tighten the M8x30 screws Pay attention to the tightening sequence of the baseplate screws Fig 38a Fig 38b 3 1 Tightening sequence of baseplate screws le 2B step Installation of the oil filter 1 1 Parts list position 2130 Tools Allen key 10 mm Spanner SW 19 Observe the tightening torques see table on page 55 Pos in arts list Working course 490 e With the allen key screw on the filter into the hole in the body and tighten it 500 Install gasket 510 e Screw on the M22x1 5 mm plug and tighten it Fig 39a Fig 39b 09665 07 2011 Gb 09665 07 2011 Gb step Installation of the cylinder covers and valve plates 1 2 Parts list position 170 2000 N TK versions 1940 2900 K versions Tools Spanner 17 mm Install only the cylinder covers and valve plates which belong together avoid mix ups Obse
36. rt the Woodruff key into the seat at the compressor shaft end e Mount the drive clutch 19 20 Capacity regulation The capacity regulation takes place through the turning off of the suction gas flows by means of a solenoid valve on the cylinder cover For this the valve is activated electrically by a thermostat or pressostat e During normal operation the solenoid is de energized and the suction gas channel in the valve plate and in the cylinder cover is open e During regulated operation the solenoid is energized and the suction gas flow is closed through the shut off piston of the solenoid valve The compressor pistons of the cylinder bank which is regulated down run idle The capacity of the compressor is still approx 50 Further information together the description of the working principle of the solenoid valve is contained in the publication Capacity regulation Part no 09900 Capacity regulation valve Part No 07541 Only for the capacity regulation which is an accessory d 3 Removal De energize the solenoid 4 e Screw on the fixing nut 3 pull out the solenoid 4 4 with the washer 5 5 e Unscrew the valve body 2 Check the valve body 2 for damages and whether the piston moves freely f necessary replace the complete valve body 2 07541 D i Installation e Screw on the valve body 2 with the enclosed new O ring 1 and tighten it Push on the washer 5
37. rve the tightening torques see table on page 55 Pos in paris list Worki orking course 60 50 1920 19101 Mount the valve plate with the lower valve plate gasket onto the body 70 170 1930 1940 Mount the cylinder cover with the upper valve plate gasket see Fig 40a Mount the K type plate with the marking TOP facing upwards 180 1950 e Tighten the screw cross wise in at least two steps Pay attention to the tightening sequence of the cylinder cover screws see Fig 40b Fig 40b Tightening sequence for cylinder cover screws 53 54 Fig 41a step Installation of the shut off valves and blind flanges 1 3 Parts list position 2060 2070 232 Tools Spanner 17 mm Allen key 6 mm Apply oil gaskets observe tightening torques see table on page 55 Use screws of correct length for the installation of the intermediate flanges Pos in Working course arts list 9 230 210 Put in the suction filter with the gasket 220 210 e Install the shut off valves on the discharge and suction side with gaskets and screws If there is an intermediate flange Use screws of correct length 232 231 Install the blind flange with O ring and screws e Tighten all screws observe tightening torques Fig 41b 09665 07 2011 Gb 09665 07 2011 Gb Checking the compressor Working course 1 Evacuation leak check of compressor e Connect the discharge and suction
38. sible from factory 4xM10 LK 0170 4p Centre of gravity oil tube 1 8 NPTF 7 16 UNF 1 8 NPTF 7 16 UNF 1 8 NPTF 1 8 NPTF 1 8 NPTF M22 x 1 5 1 4 NPTF 2 x 1 1 5 18 UNEF 1 8 NPTF M22 x 1 5 09665 07 2011 Gb juepuedepul UOIJEIOY duind io uomneouqn P99104 Hqn cr000 upy yun y JO USWOW erau 02 n ofueuo 10 Biol GE 9 e L 8 Bel SE 1 8 Bet SE SA L 82 er Ib cer 0 22 YOU WW YOU WW AS Ad eui oul uonong hbupuos q suon uuo2 SUOHIPpE BS9U UOIUSW 104 OP 31043194 ejep ddA 10ss94du109 9u e9nuopi ase 4 pue N 4 suDisap Jualay p 34 101 ejep 8014 291 IUL 116 16 16 6 yb am 9 96 8v GEE U W urd 0971 euinjoA ds q 069 759 997 982 UInIOA dams 959 093 0734 0 7 068 074 49 Jo IN odAL 09 1102 70 69960 10 Maintenance Service intervals Practically no maintenance is required However for an optimal operating safety and service life of the compressor we recommend to carry out the necessary maintenance work regulary according to the specifications of the manufacturer of the refrigerating plant Function checks to be carried out once a year Leak test of the plant Checking the running noise of compressor Checking pressures and temperatures of the plant Checking the tensioner for orderly seating Checking
39. sides of the compressor to a vacuum pump e Evacuate the compressor from both sides vacuum lt 1 5 mbar Check increase in pressure e n case there is an increase in pressure check the compressor for leaks and evacuate again Fill in the stipulated amount of oil 2 0 liters 2 Carrying out the function test e Install the compressor in the system e Carry out a leak test with refrigerant Make a test run During this check the oil level the leak tightness of the compressor the running noise pressure temperatures and the functioning of additional devices such as the capacity regulation Remark If the compressor is going to remain in the warehouse charge it with nitrogen at about 3 bar pressure for protection Attention Take the reminders for commissioning in the operating manual IN for FK 40 into account Tightening torques for screwed fastenings General fastenings with fibrous or metallic flat gasket Reminder Cylinder cover valve uu plate Tighten the screws cross wise Ms 34Nm in at least two steps 50 100 of M10 60 Nm the tightening torque Special fastenings Designation Thread size Tightening torque Shaft seal cover M8 34 Nm Connecting rod screw M6 15 Nm Oil filling plug M22 x 1 5 60 Nm Oil drain plug 1 4 NPTF 25 Nm Sight glass 11 8 18 UNEF 25 Nm Flanged connection 10 60 Nm Soldering gland shut off valves Plugs 1 8 NPTF 25 Nm Electromagnetic clutch M12 85 Nm Safety valve M24 100 Nm
40. sor malfunctions Function faults Symptoms Function faults arising most frequently and their symptoms are Compressor stoppage compressor cutoff Compressor does not start Compressor starts and then stops again Refrigerant performance too low Too high compressor temperature Oil problems Abnormal compressor running noise Malfunction of the electromagnetic clutch Compressor stand still e Compressor does not start Symptom Possible cause Remedy Open circuit Fuse blown Replace fuse Determine and remove the cause Localize the interruption in the circuit and remove the cause of Cut off through the interruption Low pressure switch High pressure switch Heat protection thermostat Control thermostat Other safety elements Malfunction of electro see also p 16 Malfunction of Checking magnetic clutch electromagnetic clutch 09665 07 2011 Gb 09665 07 2011 Gb Compressor cutoff e Compressor starts and stops again symptom Possible cause Remedy Cutoff through low 1 Suction pressure too low pressure switch Check the setting of the low pressure Adjust the switching points or replace switch switch Suction valve of the compressor closed 1 Open shut off valve Capacity of compressor too large Check operating conditions Refrigerant deficiency Leak test Add refrigerant Filter dryer in the liquid line blocked Replace filter dryer Expansion valve not functioning properly
41. special tool Part No 09524 Reminder With compressors starting from year of construction 2008 09 the oil pump the shut off valves the valve plate and the cylinder covers are bolted with washers In the individual work sections separately with these washers does not deal When assembling the washers must be used again on the installation e Extract the refrigerant from the compressor into a container which may be used for this refrigerant 09665 07 2011 Gb 09665 07 2011 Gb Step Pos in parts list 220 330 210 230 210 233 232 231 Fig 12 Removal of all shut off valves and blind flanges Parts list position 2060 2070 232 Tools Spanner SW 17 allen key 6 mm Working course e Unscrew the fixing screws of shut off valves e Remove the shut off valves and the gaskets e Remove the suction filter and the gasket e Remove the screws from the blind flange e Remove the blind flange and the O ring 97 28 Step Removal of the oil filter 2 Parts list position 2130 Tools Oil collection container spanner SW 19 Allen key 10 mm Pos in parts list Working course e Drain the oil from the compressor into a suitable container 510 e Unscrew the plug 500 e Remove the gasket 490 e Unscrew the oil filter Fig 13a 09665 07 2011 Gb 09665 07 2011 Gb Step Pos in N TK 180 170 70 60 50 Removal of the cylinder cover and valve plates Parts list position 170 2000 N
42. te RL 46 S Information about other suitable oils should be taken from Bock lubricant tables Information may also be retrieved from www bock de 09665 07 2011 Gb 09665 07 2011 Gb Maintenance Operating of the shut off valves Position A 3 Opening the shut off valve a Spindle 1 Tum to the left counter clockwise until the end stop gt Shut off valve fully open Service port 2 closed Position A Fig Opening the service port 2 b Spindle 1 Turn 1 2 1 turn to the right gt Service port 2 open Shut off valve open Position B Fig port 3 is intended for safety devices and cannot be shut off seal Fig left by 1 4 turn After operating the shut off valve tighten the valve spindle seal carefully again Fig right A O Note Before opening or closing the shut off valve loosen the valve spindle ie Fault diagnosis In case of malfunctions during compressor operation we recommend to prepare a measurement record for aiding the fault search e Pressure measurement Discharge side suction side oil pressure e Temperature measurement Compressor casing discharge end temperature suction gas overheating According to the expected cause of the fault it may be necessary to check the electrical systems for faults in the control In order to localize the causes of operating malfunctions as easy as possible we have compiled the following table with suggestion for remedying compres
43. the V belts for tension and condition Checking the oil level in the cranckcase Checking the fixing screws for tightening Checking the function of the ancillary units Checking the electrical connections for clean firmly fixed contacts and the leads for chaf ing points Oil level check After starting the compressor the oil level has to be checked For this The driving engine should be in the High idle operating condition elevated idling speed Compressor running time at least 10 min e The plant should have reached the operating point e The oil level must be visible in the sight glass Changing oil In case of orderly manufactured and operated plants an oil change is in principle not abso lutely necessary Yet based on decades long experience we recommend to carry out the following oil change and servicing First oil change at the first maintenance of the vehicle After that changing the oil every 5000 operating hours but at the latest after 3 years At the same time the oil filter and the suction filter should be cleaned and the oil connecting ring from the shaft seal replaced Lubricants Standard oil type used by Bock Recommended alternatives For H FCKWs e g R22 FUCHS Reniso SP 46 MOBIL SHC 425 SUNOIL Suniso 465 SHELL Clavus SD 22 12 TEXAKO Capella WF 46 For FKWs e g R 134a R404A R407C FUCHS Reniso Triton SE 55 FUCHS SEZ 32 68 80 MOBIL Arctic EAL 46 SHELL Clavus R 46 ICI Emkara
44. tion of service kits Safety Leak oil collection ring Part no 80019 Shaft seal Part no 80023 Capacity regulating valve Part no 07541 Valve plate Electromagnetic clutch Compressor defects Disassembly of compressor Removal of the compressor from the refrigerant system Disassembly of compressor 1 Removal of all shut off valves and blind flanges Removal of oil filter Removal of the cylinder cover and of the valve plates Removal of the shaft seal Removal of the oil pump Removal of the baseplate Disassembly of the connecting rods from the crankshaft Removal of the bearing flange 9 Removal of the crankshaft 10 Removal of the pistons and connecting rods 11 Removal of the remaining parts 12 Removal of the roller bearings CON CO 01 4 Co n2 Checking the components of the cmpressor for damage wear Limiting values for wear Cylinder liners Crankshaft Pistons Connecting rods Valve plates Oil pump Oil filter suction filter Internal safety valve Assembly of the compressor 1 Fitting the roller bearings Fitting the sight glass the plugs and the internal safety valve Assembly of the pistons connecting rods Fitting the piston connecting rod sets Fitting the crankshaft Installation of the front bearing flange Assembly of the inserted connecting rods pistons Installation of the oil pump 9 Fitting the shaft seal 10 Installation of the baseplate 11 Installation of the oil filter 12 Installation of the cylinder cover and valve plates
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