FK 50 WHB_low_GB

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Maintenance Manual

FK 50

Types:

FK 50/460 K FK 50/555 K FK 50/660 K FK 50/775 KFK 50/460 N FK 50/555 N FK 50/660 N FK 50/775 NFK 50/460 TK FK 50/555 TK FK 50/660 TK FK 50/775 TK

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Foreword

Dear Customer,

,

standard

there your

team at

-Right for making modifications reserved.-

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5 Introduction 5 Safety instructions 6 Product description 6 Short description, name plate, type code 7 Main and functional parts 8 Dimension drawings, connections 9 Technical data10 Maintenance�0 Function checks, oil level check, oil change�� Operations of the shut-off valves12 Fault diagnosis / Remedying the malfunction�2 General, function faults - symptoms�2 Compressor stand still�� Compressor cutoff�4 Cooling performance too low�4 Compressor temperature too high�5 Oil problems�5 Abnormal running noise from compressor�6 Malfunction of the electromagnetic clutch17 Installation of service kits�7 Safety�8 Leak oil collection ring, Part no. 80019 �9 Shaft seal, Part-no. 8002� 20 Capacity regulating valve, Part-no. 0754�2� Valve plate 23 Electromagnetic clutch 25 Compressor defects26 Disassembly of compressor26 Removal of the compressor from the cooling system26 Disassembly of compressor27 1 Removal of all shut-off valves and blind flanges28 2 Removal of oil filter29 � Removal of the cylinder cover and of the valve plates�0 4 Removal of the shaft seal�� 5 Removal of the oil pump�2 6 Removal of the baseplate�� 7 Disassembly of connecting rods from the crankshaft34 8 Removal of the front bearing flange�5 9 Removal of the crankshaft�6 �0 Removal of the pistons and connecting rods�7 �� Removal of remaining parts�8 �2 Removal of the roller bearings

Page Contents

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39 Checking the components of the compressor for damage / wear�9 Limiting values for wear�9 Cylinder liners�9 Crankshaft40 Pistons40 Connecting rods40 Valve plates40 Oil pump4� Oil filter / suction filter4� Internal safety valve42 Assembly of the compressor42 � Fitting the roller bearings4� 2 Fitting the sight glass, the plugs and the internal safety valve44 � Assembly of the pistons / connecting rods45 4 Fitting the pistons / connecting rod sets46 5 Fitting the crankshaft47 6 Installation of the front bearing flange48 7 Assembly of the inserted connecting rods / pistons49 8 Installation of the oil pump50 9 Fitting the shaft seal5� �0 Installation of the base plate52 �� Installation of the oil filter5� �2 Installation of the cylinder cover and valve plates54 13 Installation of the shut-off valves and blind flanges55 Checking the compressor55 Tightening torques for screws56 Spare part list58 Repair kits parts list59 Parts list for optional accessories60 Exploded drawing

Page Contents

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Vehicle compressors Series FK 50 of Bock are among the most wide-spread machines used for busA/C applications. The criteria that speak for choosing a FK 50 compressor are its compact dimensions,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 FK 50 easier for the servicing personnel. This maintenance manual contains an complete description of each work step for thedisassembly and assembly of the compressor components. Each step must be carefully adhered to in orderto ensure a reliable repair.Reminder:

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 capacityregulator (accessory) should be checked carefully for their economic efficiency beforehand. The maintenance manual describes the standart type of the FK 50 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 analogousfashion.

Introduction

Safety instructionsAttention! Refrigeration compressors are machines under pressure and 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 purposes 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, evcuate the cooling system 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!

Safety

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Product description Series FK 50 vehicle compressors are designed for mobile applications.

Name plate (Example)

�2�

4

5

FK

Product description

�. Type of compressor 4. Serial number 2. Theoretic volume flow rate at 1450 rpm 5. Oil type filled in compressor by manuf. �. ND(LP): max. tol. Stand still pressure intake side HD(HP): max. tol. Derating pressure high pressure side } note limits of application

diagrams!

FKX50/775N67,6

AM12345A017

Compact 6-cylinder compressor in V design. Wear resistant and long-lasting engine. Four sizes as regarding capacity. Aluminum light weight construction. Crankshaft supported in roller bearings on both sides. Bidirectional lubricating oil pump with relief valve. Variable arrangement of shut-off valves. Ideally equipped with valve plates for each application. Integrated pulsation damper for especially quiet running.

Field of application Displacement Size Ester oil filling (HFKW-Coolants, such as R 134a, R407C) Series

Short description Three options for different application fields are available: > for air conditioning the K-model > for the air conditioner or normal cooling the N-model > for deep freezing the TK-model The differences lie in form of the valve plate mounting, which is conforming the current field of application in terms of operational safety and efficiency. Further Characteristics:

Type code (Example) Explanation of the type designation

X 50 / 775 K

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Main and functional parts

8

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�4

�5

�. Cylinder cover 2. Valve plate �. Compressor casing 4. Integrated leak oil collector 5. Locating hole for fitting magnetic clutch 6. Shaft end7. Mechanical seal 8. Connection for heat protection thermostat 9. Discharge shut-off �0. Oil filling plug ��. Sight glasses for oil (2x)

�2. Base plate��. Suction shut-off valve (FK 50/660 and FK 50/775 with 2 suction shut-off valves) �4. Oil pump �5. Oil drain plug / oil filter �6. Optional connection facilities for suction shut-off valves �7. Nameplate�8. Leak oil drain hose

9

�0��

�6

�2

4

6

7

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5

�2

�7

�8

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Dimension drawing

Shaft end

View X

ConnectionsA Suction side port, not lockable 1/8“ NPTF A1 Suction side port, lockable 7/16“ UNF B Pressure side port, not lockable 1/8“ NPTF B1 Pressure side port, lockable 7/16“ UNFC Oil pressure safety switch connection OIL �/8“ NPTFD Oil pressure safety switch connection LP �/8“ NPTFE Port for oil pressure gauge F Oil drain plug G Opt. connection facility f. oil sump heating�) --H Oil filling plug K Sight glass �/ 8“-�8 UNEFL Heat protection thermostat connection M Oil filter M 22 x 1/5 SV1 Opt. Connection facilities f. Suction shut-off valve --

�) = Only possible from factory

1/8`` NPTF1/4`` NPTF

1/4`` NPTF

1/8`` NPTF1

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Technical Data

Type

Cyl.Num.

Disp.m

cm�

Flowrate vol.(1450 1/min)

m�/h

Weight

kg

Dischargeside

DVmm / Zoll

Sucitonside

SVmm / Zoll

Oil filling

Ltr.FK50/460

6

460 40,� 4�,0 28 / � �/8 �5 / � �/8 2,6FK50/555 555 48,� 42,5 28 / � �/8 �5 / � �/8 2,6FK50/660 660 57,6 4�,0 �5 / � �/8 2x�5 / � �/8 2,6FK50/775 775 67,6 40,0 �5 / � �/8 2x�5 / � �/8 2,6

Connections

Mass moment of inertia of the engine [kgm2]: 0 ,005�Lubrication: Forced lubricationOil pump: bidirectional

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MaintenanceService intervalsPraticcally no maintenance is required. However, for an optimal operating safety and service life of thecompressor we recommend to carry out the necessary maintenance work regularly according to the specifications of the manufacturer of the refrigerating plant.

Changing oil:

In case of orderly manufactured and operated plants and oil change is in principle notabsolutely necessary.Yet, based on decades-long experience we recommend to carry out the following oil changeand 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 collecting ring from the shaft seal replaced.

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 the V-belts for tension and condition Checking the oil level in the crankcase Checking the fixing screws for tightening Checking the function of the ancillary units Checking the electrical connections for clean, firmly fixed contacts and leads for chafing points

LubricantsStandard oil type used by Bock Recommended alternativesFor H-FCKWs (e.g. R22)FUCHS Reniso SP 46 MOBIL SHC 425 SUNOIL Suniso 4GS SHELL Clavus SD 22-�2 TEXACO Capella WF 46 SUNOIL Suniso �GSFor FKWs (e.g. R ��4a, R404A, R407C)FUCHS Reniso Triton SE 55 FUCHS SEZ �2 / 68 / 80 MOBIL Arctic EAL 46 ICI Emkarate RL 46 S SHELL Clavus R 46Information about other suitable oils should be taken from Bock lubricant tables. Information may also be retrieved from www.bock.de.

Oil level checkAfter 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. The plant should have reached the operating point. The oil level must be visible

Maintenance

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Operation of the shut-off valves

Note: Before opening or closing the shut-off valve, loose the valve spindle seal (Fig. left) by ¼ turn. After operating the shut-off valve, tighten the valve spindle seal carefully again(Fig. right).

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Opening the shut-off valveSpindle 1 turn to the left (ccw) until the end stop. → Shut off valve fully open / Serviceport 2 closed.

Opening the service port (2) Spindle 1 Turn ½-1 turn to the right → Service port 2 open / Shut off valve opened. Port 3 is intended for safety devices andcannot be shut off.

1

3

2

3

2

1

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Fault diagnosisIn case of malfunctions during compressor operation we recommend to prepare ameasurement record for aiding the fault search: Pressure measurement: Discharge side, suction side, oil pressure Temperatur measurement: Compressor casing, discharge end temperature, suction gas

overheatingAccording to the expected cause of the fault it may be necessary to check the electrical system 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 suggestions for remedying compressor malfunctions.

Function faults-SymptomsFunction faults arising most frequently and their symptoms are: Compressor stoppage, compressor cutoff

- Compressor does not start - Compressor starts and then stops again Cooling performance too low Too high compressor temperature Oil problems Abnormal compressor running noise Malfunction of the elektromagnetic clutch

Fault diagnosis

Compressor does not startSymptom Possible cause RemedyOpen circuit - Fuse blown - Replace fuse Determine and remove the cause Cutoff through: - Localize the interruption in the circuit - Low pressure switch and remove the cause of the - High pressure switch interruption - Heat protection thermostat - Control thermostat - Other safety elementsMalfunction of - see also p.16 "Malfunctio n - Checkingelectromagnetic clutch electromagnetic clutch"

Compressor stand still

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Compressor cutoff Compressor starts and stops again

Symptom Possible cause RemedyCutoff though 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 - Replace filter / dryer blocked - Expansion valve not functioning properly - Check the setting of the valve - Solenoid valve on the liquid line not - Check the control / function opening Cutoff through high- Condensing pressure too highpressure 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 refrigarant to normal filling - Non-condensible gases in refrigerant - Extract refrigerant and evacuate the refrigerant plant / refill refrigerant Cutoff through heat- Discharge end temperatures is too highprotection thermostat - Operating limits of compressor - Adapt the operating conditions to the(accessory) exceeded operating range - Suction gas overheating - Check expansion valve / Check insulation on the suction side -Cooling of the condenser insufficient - Check fan motors / Clean the condenser - Valve plate damage - Replace valve plate - Internal safety valve has opened - Replace safety valve - Check compressor and refrigeration plant Determine and remove the cause for the inadmissible high pressure in the Cutoff through control - Temperature over / below the desired - Check operating pointsthermostat range

high-pressure side

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Cooling performance too low Symptom Possible cause Remedy Suction pressure too - Expansion valve not functioning properly - Check valve setting; replace valve, if necessary - Lack of compressor capacity - Check the functioning of the compressor by evacuating to vacuum. Check function of capacity regulator (accessory)Suction pressure too low - See "Cutoff through low-pressure switch" - CheckingHigh pressure too high - See "Cutoff through high-pressure switch" - CheckingHigh pressure too low -Condenser being cooled to much - Adjust the control of condenser cooling - Lack of compressor capacity - Check compressor / Check the functioning of capacity regulator - Pressure laminations of valve plate leaking - Replace valve plate Bypass between suction and discharge Localize leak between the discharge and suction side and repair it

Cooling temperature too high Symptom Possible cause RemedySuction gas - Suction gas overheating - Adjust expansion valvetemperature 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 / dryerDischarge pipe → see point abovetoo high → see "Cutoff through high-pressure switch" → see "Cutoff through heat-protection exceeded thermostat - Cooling insufficient - Short circuit between the discharge and the suction side of compressor - Valve plate damage - Replace defective valve plate - Internal safety valve has opened - Replace safety valve (see the section on Dismantling / Assembly of Compressor)

side

high

- Suction gas temperature too highCondensing pressure too high

- Operating limits of compressor

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Oil problems Symptom Possible cause RemedyOil pressure too low - Refrigerant in oil - see "Oil foams" - Too little oil in compressor - Add oil and search for the cause of oil loss - Oil filter dirty / blocked - Clean / replace oil filter Change oilOil foams during - Liquid refrigerant has moved into the oil - Check the laying of pipesup phase sump - Installation of 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 valveoperation Oil level decreasese - 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. Add oil, if necessary. - Refrigerant in oil - see "Oil foams during operation" - Piston rings worn - Replace piston rings - Suction / discharge lamination of the valve - Replace valve plate -

Abnormal running noise from compressor Symptom Possible cause RemedyFixation of compressor - Screwed connections have become loose - Tighten the screwed connections andis loose - Securing elements for screwed connection missing secure them anew - Vibration metals defective - Replace vibration metalsLiquid shock - Liquid refrigerant reaching the compressor - Adjust / check expansion valve Check refrigerant filling Check evaporator fan I cing-up of the evaporator - Oil shocks because of too much oil - Check oil level Check 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 valveElectromagnetic clucth - see also p. 16 "Malfunction of electro- - Checking slipping magnetic clutch"V belt drive, increased - Belts vibrating excessively - Check belt tensionnoise generation Use tensioning roller / guidance roller - Incorrect alignment of compressor and - Check alignment and adjust anew motor

plate leaking

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Malfunction of the electromagnetic clutch Symptom Possible cause RemedyClutch not switchi ng - No voltage applied - Apply voltage and check Clutch slipping too - Voltage too low - Keep the voltage at 12 or 24long, getting hot - Volts (check vehicle network)smoking and squeaking - Driving power too high - Check operating conditions - Rotor rubbing at the magnetic field - Check the seating of the magnet, possibly to high belt tension.

Clutch not separating - Voltage still being applied to the magnet - Check switch / relay - Clutch is stuck - Disconnect the armature disc from the rotor mechanically - Clutch overloaded, - Install new rotor and armature Armature disc is deformed disc

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Disassembly-Assembly of service kitsSafety remarks

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: Switch of the machine and guard it against switching on Close the discharge and suction shut-off valves Relieve the compressor from system pressure Use only genuine Bock spare parts.

After the work is finished: Connect the safety switch and check its function Evacuate the compressor Before commisioning, 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.).

Open the pressure and suction shut-off valves (see page 11) Set off the switching-on lock.

For changing components in the framework of customary service works we recommend the kitsdescribed on the following pages.

Installation of service kits

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Type code 001 Type code 007 - 013

Leak oil collection ring

Fig. �

Leak oil collection ring (Part No 80�29)Procedure:

Remove the leak oil collection ring (see Fig. �) The repair kit contains two felt inlays (Pos. 2 and Pos. 3, see

Fig. 2) If the bearing flange with one oil pocket is installed, Pos. 3

must be inserted (see Fig. 3). If the bearing flange with six oil pocket is installed, Pos. 2

must be inserted (see Fig. 4). If the wrong felt inlay or both felt inlays is/are inserted, the

functioning of the oil collection system cannot be ensured.

� 2

Bearing flange withone oil pocket

�

Open at bottom�

Fig.�

Bearing flange withsix oil pockets

Open at top

2

�Fig. 4

from type code 015- (from 4. Quarter of 2005) Bleeding the oil reservoir: The emptying of the oil reservoir is possible in the simplest way without dismounting the coupling respectively the brake pulley and is recommended by both air condition maintenance and engine service. Heretodisconnect the oil hose from the holder, remove the connectionplug and bleed the oil into the collection container. After the emptying, close the oil hose and fasten the holder. Used oil should be disposed according to national regulations.

�3 Fig. 2

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Fig. 5

24

6

8a

�5

�

8b

‘‘TOP‘‘

79

Shaft seal (Part No 8002�)Removal:

Dismount the drive/magnetic clutch from the compressor. Remove the Woodruff key from seat at the shaft end. If available remember move 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) Unscrew the screws (7) from 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 mayrun out of the shaft seal chamber. Keep a suitable collection container ready!

Installation: Work with utmost cleanliness. Always replace the shafts seals complete, never individual parts thereof. Do not use used parts. Prior to installation, check the sliding and sealing surfaces for cleanliness and damages.. 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 copmressor oil). 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) 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. If available 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.

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Capacity regulationThe 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 the thermostat by athermostat or pressostat.

During normal operation the solenoid is de-energized and the suction gas channel in the valve plate and in the cylinder cover is open.

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. ��% and 66 %.

Further information together the description of the working principle of the solenoid valve is containedin the publication "Capacity regulation" (Part No 09900).

Capacity regulation valve (Part No 0754�)(Only for the capacity regulation which is an accessory)Removal:

De-energize the solenoid (4). Screw on the fixing nut (3), pull out the solenoid

(4) with the washer (5). Unscrew the valve body (2). Check the valve body (2) for damages and whether

the piston moves feerly. If necessary, replace the complete valve body (2).

Installation: Screw on the valve (2) with the enclosed new

O-ring (�) and tighten it. Push on the washer (5) and the solenoid (4) and

fasten them with the fixing nut (3).. Put the compressor into operation and check the

functioning of the capacity regulation.

�

45

Fig. 6

0754�2

�

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Valve plate

Compressor type Parts kit (Part.-No.) Compressor type Parts kit (Part.-No.)

FK 50/460 N 8024� FK 50/460 TK 8024�FK 50/555 N 8024� FK 50/555 TK 8024�FK 50/660 N 80244 FK 50/660 TK 80244FK 50/775 N 80244 FK 50/775 TK 80244FK 50/460 K to FK 50/775 K 08926

K type Valve plate N type and TK type Valve plates

TOP

Fig. 7

�

2

�

5

4

�

2

�

5

4

Safety valve

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1

5

8

10

63

2

7

9

11

4

Removal (see Fig. 7): Unscrew the screws (1) from the cylinder cover (2) and dismount cylinder cover (2) with valve

plate (4). 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):Attention: The conversion of the compressor from one type of valve plate to anotheris not possible!

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. 08926) only with the inscription"TOP" facing upwards (see Fig. 7).

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 fortightening the cylinder cover screws

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Assembly instruction for electromagnetic clutchFor the drive of A/C compressors in buses, mainly electromagnetic clutches are used. Thefollowings 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 Type LA 16

The front bearing flange has a locationg face ø 148 h8 for fitting the solenoid of the electro-magnetic clutch (see Fig. 9).

Forfitting the solenoid (1) remove the four M8 x 25 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 locating seat and fasten it again with the four M8 x 25 cylinder screws(Fig. 10). Observe the screw tightening torque (see Table on page 55)!

Attention! Use only M8 x 25 screws! Otherwise, serious damage may occur on the electromagnetic clutch and the compressor.

Fig. 9

Electromagnetic clutch

Ø �48 h8

Front bearingflange

Magnetic field

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Reminder: Arrange the cable (8) so that it doesn't touch hot parts (e.g. protectionpipe). tmax = 105°C!

Remove the K-circlip (5) and the clamping screw (4) from the rotor assembly (3). Lookingthrough 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. Screwtightening torque: 85 Nm. Install the K-circlip (5).

Push the sheave (6) over the studs (9) and fasten it with zinc-coated M8 DIN 934-8 nuts (7).

Connect the cable (8). The connection is polarity-independent. Voltage ± �0% of nominalvoltage.

Reminder for dismounting: For dismounting the clutch apply grease to the K-circlip and turn the clamping screw (4) to the left unscrewing.Attention! With all other methods of removal (pressing, hammering) there is risk of damage to the clutch.

Fig. ��

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Compressor defectsCompressor defects may have various causes. The table below is meant to aid you while analyzing the cause of the breakdown by means of the defective compressor parts found. Thus, the specificremedying of the cause of the breakdown is faciliated.

Compressor parts

Valve plates

Shaft sealleaking

Oil pump

Bearings

Pistons/

Copper plating

Formation of

Possible causesSymptom

-Liquid shocks because ofliquid refrigerant or oil

- Overheating of compressor- Lack of oil- Standstill time too long- Dirt in the system- Moisture in the system-Too frequent starting of the compressor- Overheating of compressor- Belts vibrating excessively- Alignment of compressor and

motor incorrect- Lack of oil- Dirt in the system- Moisture in the system- Overheating of compressor- Lack of oil- Dirt in the system- Moisture in the system- Overheating of compressor- Overloading of compressor- Lack of oil- Dirt in the system- Moisture in the system- Overheating of compressor- Moisture in the system- Acid formation in the system- Overheating of compressor

Remedy

Liquid shocks:- Check, adjust expansion valve,

replace it, if necessary; check refrigerant charge.

- Check evaporator fan.- In case the evaporator is iced-up:

Check the dimensioning of piping (gas velocity).

Overheating of compressor (Heatprotection thermostat switches off):- Check the operating conditionsLack of oil:- Dirt in the system: Changing oil,

clean the system; install a suction line filter, if necessary.

Moisture in the system / Acid formation in the system:- Dry the system through changing refrigerant and oil, replace the drier;install a suction line filter, if necessary.

Frequent starting and stopping of compressor:- Overloading of compressor Compare the operating

conditions with the application limits. - Remove defects in belting.

Compressor defects

Connecting rods

oil-carbon

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Removal of the compresor from the cooling system

a) Removal of the compressor from the system; shut-off valves remaining on the compressor Extract the refrigerant from the system onto a container which may be used for this refrigerant. Evacuate the system including the compressor. Cut off 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 collection 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 the shut-off valves on the suction and discharge side. Extract the refrigerant from the system onto a container which may be used for this refrigerant. Evacuate the compressor. Cut off vacuum. Remove the compressor from the system. Close the suction and discharge shut-off ports on the compressor with stoppers.

Disassembly of compressorThe disassembly of the compressor is explained in separate steps on the following pages. The indicated parts list positions refer to spare parts list, repair set lists, special accessories part lists and the exploded drawing at the end of the maintenance manual.

Pos. Tool Size � Oil collection container > 2,0 ltr. 2 Spanner SW �0, ��, �4, �7, �9, 22, �0, �6 � Allen key 6 mm, �0 mm 4 Seeger circlip plier, Form C 8 - �� mm 5 Pulling aperatus 6 Pressing aperatus 7 Piston ring plier 8 Dial gage 9 Bock special tool, Part No. 09524

Preparation: Necessary toolsReminder! For the removal and installation of the internal safety valve the BOCKspecial tool Part No. 09524 is necessary!

Dissasembly of the compressor

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220 Unscrew the fixing screws of shut-off valves ��0, 2�0 Remove the shut-off valves and the gaskets 2�0, 2�0 Remove the suction filter and the gasket 2��, �� Remove the screws from the blind flange 2�2, 2��, Remove the blind flange and the O-ring ��2, ��

Pos. in Working course parts List

Part list position: 2060, 2070, 232

Step

1Removal of all shut-off valves and blind flanges

Tools: Spanner SW 17, Allen key 6 mm

Fig. �2

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Drain the oil from the compressor into a suitable container 5�0 Unscrew the plug 500 Remove the gasket 490 Unscrew the oil filter

Pos. in Working course parts list

Parts list position: 2130

Step

2Removal of the oil filter

Tools: Oil collection container, spanner 19 mm, Allen key 10 mm

Fig. ��a

Fig. ��b

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�80 �950 Unscrew the cylinder covers screws �70, 70 �940, �9�0 Remove the cylinder cover and the upper gasket of the valve plate 60, 50 �920, �9�0 Remove the valve plate and the lower gasket of the valve plate

Pos. in parts list Working course N / TK K

Parts list position: 170, 2000 (N / TK-Versions), 1940, 2900 (K-Version)

Step

3Removal of the cylinder cover and valve plates

Tools: Spanner SW 17In 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.

Fig. �4a

Fig. �4b

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Place the oil collection container under the shaft seal area 2��0 If available remove the leak oil collection device from the bearing flange 750 Unscrew the cylinder screws

Caution! The shaft seal cover is under spring tension! It may jump out by itself.

20�0 Remove the shaft seal cover, the guide ring, the O-ring and the spring.



Step

4Removal of the shaft seal

Tools: Oil collection container, Allen key 6 mm

For detailed description, see also the section of the removal of the shaft seal on page 19!

Fig. �5a

Fig. �5b

Only to model code 0��

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40 Unscrew the screws 460, 470 Remove the oil pump and gasket



Step

5Removal of oil pump

Tools: Spanner 13

Fig. �6a

Fig. �6b

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Place the compressor into the oil collection pan and turn it sideways 40 Unscrew the screws from the baseplate 20,�0 Remove the baseplate and the gasket



Step

6Removal of the base plate

Tools: Oil collection pan, spanner 13

Fig. �7a

Fig. �7b

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Unscrew the hexagon head screws from the connecting rod cap. Mark the connecting rod cap and remove it. Push the piston and connecting rod upwards until the stop. Remove the piston rings. The same procedure should be applied for the remaining connecting rods.



Step

7Disassembly of the connecting rods from the crankshaft

Tools: Spanner 10In order to prevent any mix-up during reassembly, mark the connecting rods and caps belonging together clearly and in wipe-resistant fashion.

Fig. �8a

Fig. �8b

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750 Unscrew the screws 7�0, 740, 745 Remove the front bearing flange, gasket, and O-ring



Step

8Removal of the front bearing flange

Tools: Allen key 6 mm

Fig. �9a

Fig. �9b

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Pull out the crankshaft carefully in direction of the front bearing flange



Step

9Removal of the crankshaft

Tools: —

Fig. 20b

Fig. 20a

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Mark the piston and the cylinder bore belonging together Remove the piston / connecting rod in direction of baseplate 280 Remove the seeger circlip of the piston pins 270 Push the piston pins out of the pistons and remove pistons In order to prevent mix-ups, fasten and connecting rod caps to the connecting rods again.



Step

10Removal of the pistons and connecting rods

Tools: Seeger circlip plier Form C 8-13 mm

Fig. 2�a

Fig. 2�b

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570 Dismount the sight glass (use SW 30 or 36 spanner according to the type) 590 Remove the O-ring 520 Remove the 1 /8‘‘ NPTF screws 5�0, 500 Remove the M22 x 1,5 screws with gasket


Parts list position: -

Step

11Removal of the remaining parts

Tools: Spanner 13, 14, 30 o. 36

Fig. 22

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��0, 7�0 With the pulling apparatus, pull out the roller bearing from the front bearing flange If no pulling apparatus is available, the front bearing flange may be heated for circa 15 minutes in a preheated (220 °C) baking oven. Afterwards, the roller bearing can be pressed out by hand. CAUTION! Parts are hot! Use protective gloves! ��0 Press out the roller bearing from the compressor body. ��2 Take out the tolerance ring, if there is any. Use oil, if necessary!



Step

12Removal of the roller bearings

Tools: Pulling apparatus

Fig. 2�b

Fig. 2�a

Use oil, if necessary!

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- �9 -

Other components have to be examined according to the following criteria: Cylinder liners

DThe cylinder liners should not have any visible damages into the piston movement area. If there is fluting, the casing should be replaced.

Crankshaft The bearing surfaces should not have any damages. The oil channels should be

clean so that an unhindered oil flow is ensured..

Checking compressor parts for damages / wear Before re-using removed compressor parts we recommend that they be

checked for usibility. The wear limits listed below should be taken into consideration

Clean the oil channels with compressedair and check for passage.

Checking the compressor parts

maximum allowable bearing play:

�.) Piston-cylinder bore 0,�� mm 2.) Connecting rod-piston pins 0,03 mm�.) Crankshaft connecting rod bearing 0, 08 mm

Wear limits

Fig. 24

Fig. 25

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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 drings for wear, fractures and other irregularities.

Connecting rods There should be no damages on bearing surfaces. The connecting rod shank must be straight.

Valve plates Suction and pressure lamella mut be undamaged and un-deformed. The sealing surfaces

must be clean and undamaged. In case of a damage the valve plate must be replacedcompletely. Single lamella are not available.

Oil pump It must be possible to turn the oil level pump by hand (turning to the left and to the right).

In the removed condition the reserving device of the oil pump must switch over audibly.

correct faulty

Fig. 26

Fig. 27

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In case of larger compressor damages which necessitate a complete disassembly ofthe compressor, we recommend in principle the replacement of the following assemblies:

Valve plates Piston rings Shaft seal Roller bearings

Thus, concealed defects of parts which have been in operation may be prevented.

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 cleaned with compressed air or replaced with new ones. Internal safety valve (Use Bock special tool, Part No. 09524, use until A013

The internal safety valve must be replaced after it has operated.

Safety valve

Fig. 28

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570, 590 Screw on the sight glass with oiled O-ring to the compressor body. 520 Screw on the 1/8‘‘ NPTF screws. 500, 5�0 Screw on the M22 x 1,5 screws with gasket.


Parts list position: -

Step

2Fitting the sight glass, connection screws, safety valve

Tools: Spanner 13, 14, 30 o. 36

Observe the screw tightening torques (s. Table S. 55)!

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See also page 21 - 22 60, 50 �920, �9�0 Install the valve plate with the lower valve plate gasket onto the body. 70, �70 �9�0, �940 Mount the cylinder cover with the upper valve plate gasket (s. Fig.40a) Mount the K type plate with the marking „TOP“ facing upwards! �80 �950 Tighten the screws crosswise in at least two times Pay attention to tightening sequence of the cylinder cover screws! (s. Fig. 40b)

Pos. in part list Working course N / TK K

Parts list position: 170, 2000 (N / TK-versions), 1940, 2900 (K-version)

Step

12Installation of the cylinder covers and the valve plates

Tools: Spanner SW 17NInstall only the cylinder covers and valve plates which belong together, avoid mix-ups! Observe tightening torques (s. Table S. 55)!

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08552 08552 08552 08552

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SET Valve plate2900 K 2 80926 80926 80926 80926

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Bock Kältemaschinen GmbH

Benzstraße 7

D-72636 Frickenhausen

Telefon +49 7022 9454-0

Telefax +49 7022 9454-137

[email protected]

www.bock.de

Art. Nr. 96003-02.06-Gb

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