Maintenance manual - Compressors for Commercial Refrigeration
Contents
1. COMPRESSORS Maintenance manual Types FK50 460K FK50 555 K FK50 660 K FK50 775 K FK50 460N FK50 555 N FK50 660 N FK50 775 N FK50 460 TK FK50 555 TK FK50 660TK FK50 775 TK FK50 830K FK50 980 K FK50 830N FK50 980 N 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 sys tem 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 addition for German speaking countries we have set up a toll free hotline under 00 800 800 000 88 from Monday to Saturday between 8 a m and 9 p m Any suggestions you may have regarding the on going devel opment 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 han dling In addition you will find information on maintenance spare parts and accessories Some instructions are identified by special symbols with the following m2. 1 Cylinder cover 12 Baseplate 2 Valve plate 13 Suction shut off valve 3 Compressor casing FK50 660 775 830 and 980 4 Integrated leak oil collector with 2 suction shut off valves 5 Location hole for fitting magnetic clutch 14 Oil pump 6 Shaftend 15 Oil drain plug oil filter 7 Shaft seal 16 Optional connection type 8 Connection thermal protection thermostat for suction shut off valve 9 Discharge shut off valve 17 Nameplate 10 Oil filling plug 18 Leak oi drain hose 11 Sight glasses for oil 2x Dimension drawing ca 370 375 356 4 Centre of gravity Ee me 7 7 S17 3 hH EN A m a 5 Ww LL Ne 8 ommo SEN T O Can a D LA XM S Boi eL See EQ A i A MSS Oa nuill N a CL ND o A V 4x M10 LK9210 additional SV at FK50 660 775 830 and 980 standart K Design 8x M8 130 6x M8 9 72 A5x9 DIN 6888 M12x28 SAKRI oil tube Connections A Suction side connection not lockable 1 8 NPTF A1 Suction side connection lockable 7 16 UNF B Discharge side connection not lockable 1 8 NPTF B1 Discharge side connection lockable 7 16 UNF C Oil pressure safety switch connection OIL 1 8 NPTF D Oil pressure safety switch connection LP 1 8 NPTF E Oil pressure gauge connection 1 8 NPTF F Oil drain M22 x 1 5 G X Optional connection oil sump heater H Oil charge plug M22 x 1 5 K Sight glass 2x1 1 8 18 UNEF L Con
3. 05462 05063 06642 07700 06162 03381 05457 830 04269 05447 05067 05313 04329 04329 05313 05489 05489 07990 05094 06723 05342 06400 05514 06026 05361 05142 06352 06169 03860 03861 06726 06726 06165 05169 06067 05673 04425 05666 05462 05063 06641 07700 06162 03381 05457 980 04269 05447 05067 05313 04329 04329 05313 05489 05489 07990 05094 06723 05342 06400 05514 06026 05361 05142 06352 06169 03860 03861 06726 06726 06165 05169 06067 05673 04425 05666 05462 05063 06642 07700 06162 03381 05457 58 Pos Designation 3999 Mach oil SP46 1 Ltr can 3999 Mach oil SP46 5 Ltr can 3999 Mach oil SP46 20 Ltr can Only for R22 compressors Mach oil SE55 1 Ltr can Mach oil SE55 5 Ltr can Mach oil SE55 10 Ltr can 3999 3999 3999 Version N K TK N K TK N K TK N K TK N K TK N K TK Piece 460 02279 02280 02281 02282 02283 02284 555 02279 02280 02281 02282 02283 02284 660 02279 02280 02281 02282 02283 02284 119 02279 02280 02281 02282 02283 02284 830 02279 02280 02281 02282 02283 02284 FK X 50 980 02279 02280 02281 02282 02283 02284 Only for X compressors Repair set parts list Pos 2000 2010 2020 2030 2030 2030 2030 2035 2035 2035 2035 2040 2040 2040 2040 2045 2045 2045 2045 2050 2050
4. 80089 80090 80129 08552 80231 80089 80090 80129 FK X 50 660 80244 80023 80017 80104 08552 80231 80089 80090 80129 T15 80244 80023 80017 08552 80231 80089 80090 80129 80614 80101 80101 08698 08552 80231 80089 80090 80129 08552 80231 80089 80090 80129 Pos Designation Version Piece 460 555 660 775 830 980 2130 Set oil filter N K TK 1 80076 80076 80076 80076 80076 80076 2140 Set front bearing flange N K TK 1 80081 02280 02280 02280 02280 02280 2900 Set valve plate K 3 80010 180010 80010 80010 80010 80010 Parts list optional accessories vet FK X 50 Pos Designation Version Piece 460 555 660 775 830 980 3200 Set cap reg LR 87 24V with N TK 1 08704 08704 08704 08704 08704 08704 cylinder cover 3220 Cylinder cover for LR N TK 1 03383 03383 03383 03383 03383 03383 3240 Upper valve plate gasket N TK 1 06730 06730 06730 06730 06730 06730 3250 Hexagonal head screw M10x70 N TK 11 05457 05457 05457 05457 05457 05457 3300 Set cap regulation LR 87 24 V N K TK 1 08418 08418 08418 108418 08418 08418 3310 Valve body LR 87 N K TK 1 07541 07541 07541 07541 07541 07541 3311 O Ring 48 0x2 5 green N K TK 1 05987 05987 05987 105987 05987 05987 3312 Disc 30x16x2 0 N K TK 1 05143 05143 05143 05143 05143
5. 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 A K K K K K K K MPOMONMPrtrrIAHtNDBDONAFPNMNMPH WwWwWNRH tt UNN ee i i l ee d I Co C Co CO CO Coco A oo oO 460 04269 05447 05067 04367 04329 05313 05489 05447 07990 05094 06723 05342 06400 05514 06026 05361 05142 06352 06169 03860 03861 90184 06726 06165 05169 06067 05673 04425 05666 05462 05063 06178 07700 06162 03381 05457 555 04269 05447 05067 04367 04329 05313 05489 05447 07990 05094 06723 05342 06400 05514 06026 05361 05142 06352 06169 03860 03861 06726 06726 06165 05169 06067 05673 04425 05666 05462 05063 06161 07700 06162 03381 05457 FK X 50 660 04269 05447 05067 05313 04329 04329 05313 05489 05489 07990 05094 06723 05342 06400 05514 06026 05361 05142 06352 06169 03860 03861 06726 06726 06165 05169 06067 05673 04425 05666 05462 05063 06641 07700 06162 03381 05457 115 04269 05447 05067 05313 04329 04329 05313 05489 05489 07990 05094 06723 05342 06400 05514 06026 05361 05142 06352 06169 03860 03861 06726 06726 06165 05169 06067 05673 04425 05666
6. N TK N TK N TK N TK N TK NK TK NK 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 Piece WN WNWNWNANAAAMWAAAAHMAMAMANMNHA N ADATWHBHWwwnwonwnwnwwow PB Pa a 460 03876 06721 06244 05644 05695 07117 06730 06381 07940 05791 03384 06034 05646 05083 06034 05646 03370 05083 04269 05447 07211 05551 05389 555 03876 06721 06244 05644 05695 07117 06730 06381 07940 05791 03384 06034 05646 05083 06034 05646 03370 05083 04269 05447 07212 05551 05390 FK X 50 660 03876 06721 06244 05644 05696 07118 06730 06381 07940 05791 03384 06034 05646 05083 06034 05646 03370 15 03876 06721 06244 05644 05697 07118 06730 06381 07940 05791 03384 06034 05646 05083 06034 05646 03370 830 03867 03876 06721 05644 980 03867 03876 06721 05644 05697 07118 06730 06381 07940 05791 03384 06034 05646 05083 05646 Pos 332 333 340 340 350 350 355 355 355 360 360 370 370 380 380 460 470 490 900 510 520 570 570 590 590 726 727 728 729 730 740 745 750 790 800 810 8
7. Removal of the compressor from the system shut off valves for compressor remaining at the system e Close shut off valves on the suction and discharge side e Extract the refrigerant from the compressor into a container which may be used for this refriger ant 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 gt 2 6 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 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
8. Replace vibrations metals Liquid shock Liquid refrigerant reaching the compressor Adjust check expansion valve Check refrigerant filling Check evaporator fan Icing up of the evaporator Oil shocks because of too much oil Check oil level Check the dimensioning of pipes gas velocity Replace worn piston rings Capacity regulator switching on and off constantly oscillating Check the control accessory defective Replace capacity regulator valve Electromagnetic clutch see also p 16 Malfunction of electromag Checking slipping netic clutch V belt drive increased Belts vibrating excessively Check belt tension noise generation Use tensioning roller guidance roller Incorrect alignment of compressor and motor Check alignment and adjust anew i5 246 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 Voltage still being applied to the magnet Clutch is stuck Clutch overloaded Armature disc is deformed Remedy Apply voltage 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 t
9. 05143 3313 Milled nut M15x1 with O Ring N K TK 1 05885 05885 05885 05885 05885 05885 3320 Solenoid coil 24 V CC NK TK 1 07526 07526 07526 07526 07526 07526 3800 Set cap reg LR 87 24V with K 1 80022 80022 80022 80022 80022 80022 cylinder cover 3820 Cylinder cover for LR K 1033235035231 0992921099299 03323103323 3840 Upper valve plate gasket K 1 06162 06162 06162 06162 06162 06162 3850 Hexagonal head screw M10x85 K 11 06338 06338 06338 06338 06338 06338 COMPRESSORS TAA B 0101 od 4 Bock K ltemaschinen GmbH Benzstraf e 7 D 72636 Frickenhausen Telefon 49 7022 9454 0 Telefax 49 7022 9454 137 mail bock de QUALITY SYSTEM L amp P Art Nr 96022 07 09 DGbTrRc Subject to change without notice certified by DOS according to DIN EN ISO 9001 Reg No 2177
10. 20 30 40 41 50 50 50 60 60 70 80 100 110 170 180 181 210 210 220 220 221 230 230 231 232 233 270 270 270 280 290 290 290 290 300 300 300 300 310 312 320 320 321 321 322 322 330 330 331 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 Eye bolt M8 Safety valve for 28bar operation Seal ring 27 8x24 2x2 Cylinder cover M10x65 Hexagon head screw Disc B10 5 Valve flange gasket Valve flange gasket M10x65 Hexagon head screw M10x65 Hexagon head screw Disc B10 5 Filter suction side Filter suction side Valve flange gasket Blind flange 15 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 Cyl roller bearing NJ210EX5TNG C Clearance ring for bearing 90 Cap nut M22x1 5 Cap nut M22x1 5 Cap nut 7 16 UNF Cap nut 7 16 UNF Locking screw 1 8 NPTF Locking screw 1 8 NPTF Shut off valve AL Shut off valve AL Valve flange gasket Version N K TK N K TK N K TK N K TK N TK
11. TOP Installation e Work with utmost cleanliness e 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 Install the shaft seal cover gasket 5 dry don t impregnate it with oil Install the shaft seal cover 6 with the inscription TOP upwards Tighten the fixing screws 7 evenly crosswise tightening torque 37 Nm After installing the shaft seal turn the compressor shaft a few turns by hand and then carry out the leak test Install the leak oil collection ring see section on leak oil collection ring page 18 Insert the Woodruff key into the seat at the compressor shaft end Mount the drive clutch 10 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
12. 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 Cutoff 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 Compressor cutoff Compressor starts and stops again _ Symptom Possible cause Remedy Cutoff through low 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 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 Solenoid valve on the liquid line not Check the setting of the valve opening Check the control function 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
13. high 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 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 e see Cutoff through high pressure switch e see Cutoff through heat protection Operating limits of compressor exceeded Cooling insufficient Short circuit between the discharge and the suction side of the compressor Valve plate damage
14. 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 5096 Further information together the description of the working principle of the solenoid valve is con tained in the publication Capacity regulation Part no 09900 Capacity regulation valve Part No 07541 Only for the capacity regulation which is an accessory Removal e De energize the solenoid 4 e Screw on the fixing nut 3 pull out the solenoid 4 with the washer 5 e Unscrew the valve body 2 e Check the valve body 2 for damages and whether the piston moves freely If necessary replace the complete valve body 2 Installation e Screw on the valve body 2 with the enclosed new O ring 1 and tighten it e Push on the washer 5 and the solenoid 4 and fasten them with the fixing nut 3 e Put the compressor into operation and check the functioning if the capacity regulation Fig 6 07541 Installating of service kits Valve plate Compressor type Parts kit Part No Compressor type Parts kit Part No FK50 480 N 80243 FK50 460 TK 80243 FK50 555 N 80243 F
15. 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 Cutoff through high Condensing pressure too high through high Condensing pressure too high refrigeration plant refill refrigerant Cutoff through heat Discharge end temperatures is too high through heat 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 e 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 through control Temperature over below the desired Check operating points thermostat range 215 sT Refrigerant performance too low Symptom Possible cause Remedy Suction pressure too Expansion valve not functioning properly Check valve setting replace valve if
16. which are mounted onto the front bearing flange of the compressor Assembly instruction for electromagnetic clutch Type LA 16 Type LA 26 at FK50 830 and FK50 980 e The front bearing flange has a location face 148 h8 for fitting the solenoid of the electro magnetic clutch see Fig 9 Front bearing flange Magnetic clutch 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 e 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 Attention Use only M8x25 screws Otherwise serious damages may occur on the electromagnetic clutch and the compressor 00 Reminder Arrange the cable 8 so that it doesn t touch hot parts e g protection pipe tax 105 C e 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 seating 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
17. 20 880 1910 1910 1910 1910 1920 1930 1940 1950 Designation Blind flange 15 mm M10x35 Hexagon head screw Gasket soldered connect 42x34x1 Gasket soldered connect 42x34x1 Brazed hexagon nipple 28 Brazed hexagon nipple 35 Flange oval 16 mm Flange oval 16 mm Flange oval 16 mm Brazed hexagon nipple 35 Brazed hexagon nipple 35 Cylinder screw M10x35 Hexagonal head screw M10x35 Cylinder screw M10x35 Hexagonal head screw M10x35 Oil pump complete Gasket f oilp rear bear flange Oil filter Seal ring 27x22x2 Locking screw M22x1 5 Locking screw 1 8 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 Version 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
18. 2060 2060 2070 2070 2080 2080 2090 2090 2100 2110 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 M Set sight glass up to design key Set sight glass as of design key Set gaskets not Set gaskets not optimized optimized optimized optimized rilled optimized rilled optimized rilled optimized rilled optimized rod 2 rings 050 rod 2 rings 055 rod 2 rings 060 rod 2 rings 065 rod 050 r opt rod 055 r opt rod 060 r opt rod 065 r opt Set crankshaft 39 stroke optimized Set crankshaft 49 stroke optimized Set shut off valve NW25 Set shut off valve NW32 Set shut off valve NW32 Set shut off valve NW32 AL Am AL AL AL 18 012 22 013 shown shown Set connecting rod Set coll ring w felt insert up to design key 013 Version N TK N K TK N K TK lt e FFanosd oso nakd ee ee Ed Xe JJ AA 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 TK K N K TK N K TK Piece MMO H KH KH HH DAAADAAAAIAIAAI AADIAADWAAAAADH1AD O0 w N G 08552 80231
19. 8 The connection is polarity independent Voltage 10 of nominal volt age 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 294 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 Possible causes Compressor part P P Symptom Remedy Valve plate Lack of oil Standstill time too long Dirt in the system Moisture in the system Shaft seal leaking Too frequent starting of the compres sor Overheating of compressor Belt vibrating excessively Alignment of compressor and motor incorrect Lack of oil Dirt in the system 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 Moisture in the system Acid formation in the system Copper plating Formation of oil carbon Overloading of compressor
20. Internal safety valve has opened thermostat Replace defective valve plate Replace safety valve see the section on Dismantling Assembly of Compressor Oil problems Symptom Possible cause Remedy Oil pressure too low Refrigerant in oil see Oil foams Too little oil in compressor Add oil and search for the cause of oil loss Clean replace oil filter Oil filter dirty blocked Change oil Oil foams during start Liquid refrigerant has moved into the oil Check the laying of pipes up phase sump Installation of the check valve in the discharge line Installation of the solenoid valve in the liquid line Check the control Oil foams during Expansion valve not functioning Adjust replace expansion valve operating Oil level decreases During start up a portion of the oil is carried Refrigerant and oil get mixed to the refrigeration plant with the refrigerant After some time the oil level should stabilize Refrigerant in oil Add oil if necessary see Oil foams during operation Piston rings worn Replace piston rings Suction discharge laminations of the valve Replace valve plate plate leaking Abnormal running noise from compressor symptom Possible cause Remedy Fixation of compressor Screwed connections hava become loose Tighten the screwed connections and is loose Securing elements for screwed connections secure them anew missing Vibration metals defective
21. K50 555 TK 80243 FK50 660 N to FK500 980 N 80244 FK50 660 TK 80244 FK50 460 N to FK50 980 K 08926 FK50 775 TK 80244 K type Valve plate N type and TK type Valve plate 2 3 3 4 4 Safety valve 5 5 itm Say SA Fig 7 soje 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 G Reminder Don t let any gasket residues fall into the compressor Installation see Fig 7 Attention The conversion of the compressor from one type of valve plate to AN another is not possible e Apply a little oil to the lower valve plate gasket 5 install the upper valve plate gasket 3 metallic gasket dry e 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 tightening torque see Table on Page 55 Fig 8 Sequence for tightening the cylinder cover screws n 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
22. Liquid shocks because of liquid refrigerant or oil Overheating of compressor 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 Removal of the compressor from the refrigerant system a Removal of the compressor from the system shut off valves remaining on the compressor e Extract the refrigerant from the system into a container which may be used for this refriger ant 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
23. able on page 55 Pos in Work arts list orking course 460 470 Install the oil pump with oil 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 G 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 Q Parts list position 2010 Tools Allen key 6 mm i 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 Working course arts list 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 e Install the shaft seal co
24. alve must be replaced after it has operated see on the last four pages of the machine number Fig 28 In case of larger compressor damages which necessitate a complete disassembly of the compressor we recommend in principle the replacement of the following assem blies e Valve plates e Piston rings e Shaft seals e Roller bearings Thus concealed defects of parts which have been in operation may be prevented 41 Assembly of compressor Step Fitting the roller bearings Parts list position 310 Tools Pressing apparatus Pos in Work gem orking course 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 Use tolerance ring if the bearing seat has a groove Pressing tool Fig 29a Fig 29b 4j Step Fitting the sight glass plugs 2 Parts list position Tools Spanner SW 13 14 30 o 36 Observe the screw tightening torques see table on page 55 Pos in ZH Working course 570 590 520 500 510 e Screw on the sight glass with oiled O ring to the compressor body e Screw on the 1 8 NPTF plugs e Remove the plug M22 x 1 5 with the seal AD SP Assembly of the pistons connection 3 Parts list position 2040 Tools Seeger circlip plier Form C 8 13 mm Pos in Work cou
25. 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 compressors 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 chekc whether all the components installed by the user have been fastened expertly and connected pressure tight with the com pressor 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 FK50 vehicle compressors are designed for mobile applications Short description Three design variations are available for different areas of applic
26. ation 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 6 cylinder compressor in W design e Wear resistant and long lasting engine e Six 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 e deally equipped with valve plates for each application e Integrated pulsation damper for especially quiet running Nameplate Example Frickenhausen Nr AR12345A020 1 2 hp 67 6 mih bei n 1450min 3 Pa ND LPYHD HP 219 28bar Ol SE55 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 50 775 N mE Application Swept volume Size Ester oil filling HFKW refrigerant e g R134a R407C Code letter for series Product description Main and functional parts 9 2 17 3 4 16 7 18 5 10 6 11 i n5
27. eaning WARNING This symbol is used to indicate that inaccurate compliance or total failure to comply with the instructions could cause injury to persons or damage to the comperssor or refrigerating machine DANGER This symbol refers to instructions for avoiding direct serve dangers to A persons persons or plant by electrical current f DANGER This symbol refers to instrucion for avoiding direct serve dangers to 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 furtherdevelop ment 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 Bock Kaltemaschinen GmbH Subject to modification 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
28. esistant fashion ad Working 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 Se e Fig 18b LEE LILLI 209 Se Removal of the front bearing a Parts list position 2140 Tools Allen key 6 mm Pos in parts list Working course 750 e Unscrew the screws 730 740 745 e Remove the front bearing flange gasket and O ring Fig 19a Fig 19b se Step 9 Pos in parts list Removal of the crankshaft Parts list position 2050 Tools Working course e Pull out the crankshaft carefully in direction of the front bearing flange 295 Step Removal of the pistons and connecting rods 1 0 Parts list position 2040 Tools Seeger circlip plier from C 8 13 mm is Working course e Mark the piston and the cylinder bore belonging together e Remove the piston connecting rod in direction of baseplate 200 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 236 step Removal of the remaining parts 1 1 Parts list position Tools Spanner SW 13 14 30 o 36 Pos in Wo
29. f 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 arts list Working course 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 Step Removal of the oil pump D Parts list position 2020 Tools Spanner SW 13 Pos in parts list 40 460 470 Working course e Unscrew the screws e Remove the oil pump and gasket Fig 16a Fig 16b inje Step 6 Pos in parts list 40 20 30 BUM Removal of the baseplate Parts list position 20 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 0 i i l e r A F b dE ur i f Step Disassembly of the compressor rods from the crankshaft Parts list position 2100 Tools Spanner SW 10 In order to prevent any mix up during reassembly mark the connecting rods and caps belonging together clearly and in a wipe r
30. g of the shut off valves Opening the shut off valve a Spindle 1 Turn to the left ccw until the end stop e 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 e 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 Note Before opening or closing the shut off valve loosen the valve spindle spindle seal carefully again Fig right siie uon 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 compressor malfunctions Function faults Symptoms Function faults arising most frequently and their symptoms are e Compressor stoppage compressor cutoff Compressor does not start Compressor starts and then stops again Refrigerant performance too low Too
31. he rotor mechanically Install new rotor and armature disc Disassembly Assembly of service kits A In principle the same safety remarks described on page 5 of this Service Manual are 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 Edo 248 Installating of service kits Leak oil collection ring Part No 80129 Procedure Leak oil collection ring e Remove the leak oil collection ring 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 mus
32. he cylinder cover and valve plates 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 OD 01 4 W n2 Vehicle compressors Series FK50 of Bock are among the most wide spread machines used for bus A C applications The criteria that speak for choosing a FK50 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 FK50 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 FK 40 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 used in
33. lary 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 e The driving engine should be in the High idle operating condition elevated idling speed e 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 4GS SHELL Clavus SD 22 12 TEXAKO Capella WF 46 For FKWs e g R 134a R404A R407C FUCHS Reniso Triton SE55 FUCHS SEZ 32 68 80 MOBIL Arctic EAL 46 ICI Emkarate RL 46 S SHELL Clavus R 46 Information about other suitable oils should be taken from Bock lubricant tables Information may also be retrieved from www bock de Maintenance Operatin
34. must be used again on the installation 296 Step Pos in parts list 220 330 210 230 210 233 333 232 231 232 331 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 seal sd 28 Step Removal of the oil filter 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 Step Removal of the cylinder cover and valve plates 3 Parts list position 170 2000 N 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 i un d Working course 180 1950 e Unscrew the cylinder cover screw 170 70 1940 1930 Remove the cylinder cover and the upper gasket of the valve plate 60 50 11920 1910 e Remove the valve plate and the lower gasket of the valve plate Fig 14a Fig 14b 96 30 Step Removal o
35. nection thermal protection thermostat 1 8 NPTF M Oil filter M22 x 1 5 SV1 Optional connection suction valve D Only possible from factory uno29e ojul UY jou 31 suonippe asau 40ssaJduio9 zo ed y BuiuJeouoo gyep 3y ul YI pue N y SjueueA uDisap snoueA dU JO 9ures 3y 94e ejep e3Iuu99 9u 9 1 Ge X2 9 eL se a eve 99 096 06 Bel Gexz el se w su ee 0 8 09 4 TESTA el se BENE MEM c 1 063 9 z Bel Gexz el se ee aa 099 054 elise nirse ey cow oss kirse Sb 8 vein OUI WILL m NS uIW OSL Sul uonons Forced feed lubrication GGG 093 Neha eo 2 jad e ab Oo u e a cb cO ab e cb O rotation 097 0654 upy 3 uUdsWOW eouqn eem Bui 110 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 e 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 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 ancil
36. nt 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 compressed 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 bearing 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 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 v
37. ont bearing flange 6 Partsl ist position 2140 Tools Allen key 6 mm Observe the tightening torques see table on page 55 Pos in Working course arts list 745 e Apply oil to the O ring and place it into the groove in the bearing flange 730 740 Install the front bearing flange with oiled gasket to the body so that the hole for the leak oil collection ring faces upwards 750 e Tighten the screws Fig 34 47 SP Assembly 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 Working course arts list 290 300 e Compress the oil scraper ring and compression ring with the piston ring plier and insert the piston into he cylinder liner e 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 2100 Fig 35a Fig 35b 48 step Install of the oil pump 8 Parts list position 2020 Tools Spanner 13 mm G Observe the tightening torques see t
38. rking course arts list J 570 e Dismount the sight glass use 30 mm or 36 mm spanner according to the type 590 e Remove O ring 520 Remove the 1 8 NPTF plugs 510 500 e Remove the plug M22 x 1 5 with the seal Fig 22 287 2 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 be pressed out by hand A WATCH OUT Parts are hot Use protective gloves 2150 Press out the roller bearing from the compressor body Working course 312 e Take out the tolerance ring if there is any Use oil if necessary Fig 23b Checking compressor parts for damages wear e Before re using removed compressor parts we recommend that they be checked for usabil ity e The wear limits listed below should be taken into consideration Maximum allowable bearing play L Piston cylindre bore 0 13 mm 2 Connecting rod piston pin 0 03 mm 0 3 Crankshaft connection rod bearing 0 08 mm Fig 24 NZ H 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 moveme
39. rse 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 200 e Install seeger circlips on both sides of the piston pins see Fig 31b Fig 31a Fig 31b 44 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 afte list Working 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 SN BH 45 Step Fitting the crankshaft D Parts list position 2050 Tools Pos in ee Working course e Fit the crankshaft so that the drive journal engeges into the gump gear Fig 33 N ib TH m E 46 step Installation of the fr
40. serve the tightening torques see table on page 55 m a d Working course See page 21 22 60 50 1920 1910 Mount the valve plate with the lower valve plate gasket onto the body 70 170 1930 1940 D 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 oth Fig 40a E Fig 40b pu Tightening sequence for 4 cylinder cover screws E VT step Installation of the shut off valves and blind flanges 1 3 Parts list position 2060 2070 232 Tools Spanner 17 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 arts list 230 210 e Put in the suction filter with the gasket 220 210 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 e Install the blind flange with seals and screws e Tighten all screws observe tightening torques Working course Fig 41a Fig 41b 54 Checking the compressor Working course 1 Evacuation leak check of compressor e Connect the discharge and suction sides of the compressor to a vacuum pump e Evacuate
41. t 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 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 e Remove the leak oil collection ring 9 and the felt inlay 8a or 8b according to the type for this see Fig 1 on page 18 e Unscrew the screws 7 from the shaft seal cover 6 e 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 9 Fig 5
42. the compressor from both sides vacuum 1 5 mbar Check increase in pressure e n case there is an increase in pressure check the compressor for leaks and evacuate again e Fill in the stipulated amount of oil 2 6 liters 2 Carrying out the function test e nstall the compressor in the system e Carry out a leak test with refrigerant e 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 for A FK50 into account Tightening torques for screwed fastenings General fastenings with fibrous or metallic flat gasket Reminder Cylinder cover valve Segue AUS plate Tighten the screws cross wise M8 34 Nm 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 OI filling plug M22 x 1 5 60 Nm Oil drain plug 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 With aluminium gasket 55 56 Spare parts list Pos
43. the electromagnetic clutch Installation 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 OD 01 4 W 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 t
44. ver with the gasket The inscription TOP must be at the top 880 750 e Press the shaft seal cover onto the bearing flange and tighten the screws e Turn the crankshaft by hand it now moves with a little more difficulty 2110 Install the leak oil collection device only up to design key 013 Fig 37 and see also under service kits Leak oil collection device Fig 37b Fig 37a step Installation of the baseplate 1 0 Parts list position 20 Tools Spanner 13 mm 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 base plate screws EST 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 e Install gasket 510 e Screw on the M22x1 5 mm plug and tighten it Fig 39a Fig 39b zB 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 Ob
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