FK 50 - Bock

1 fk 50 . Maintenance Manual Types: fk 50 /460 K fk 50 /555 K fk 50 /660 K fk 50 /775 K. fk 50 /460 N fk 50 /555 N fk 50 /660 N fk 50 /775 N. fk 50 /460 TK fk 50 /555 TK fk 50 /660 TK fk 50 /775 TK. - - Foreword Dear Customer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3 WKURXJK WKH FRQWLQLRXV GHYHORSPHQW RI WKH GHVLJQ . HTXLSPHQW DQG DQG DFFHVVRULHV %HFDXVH RI WKLV there PD\ EH GLIIHUHQFHV EHWZHHQ WKH GHVFULSWLRQV DQG your QR GHPDQGV PD\ EH GHULYHG IURP WKH LQIRUPDWLRQ ILJXUHV . DQG GHVFULSWLRQV FRQWDLQHG KHUHLQ . %RFN .lOWHPDVFKLQHQ *PE+. <RXU team at 3 2 %R[ %RFN .lOWHPDVFKLQHQ *PE+. ' )ULFNHQKDXVHQ. %HQ]VWU . ' )ULFNHQKDXVHQ. 3 KRQH . )D[ . PDLO#ERFN GH. ZZZ ERFN GH -Right for making modifications - - Page Contents 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 data 10 Maintenance 10 Function checks, oil level check, oil change 11 Operations of the shut-off valves 12 Fault diagnosis / Remedying the malfunction 12 General, function faults - symptoms 12 Compressor stand still 13 Compressor cutoff 14 Cooling performance too low 14 Compressor temperature too high 15 Oil problems 15 Abnormal running noise from compressor 16 Malfunction of the electromagnetic clutch 17 Installation of service kits 17 Safety 18 Leak oil collection ring, Part no.]

4 80019. 19 Shaft seal, Part-no. 8002 . 20 Capacity regulating valve, Part-no. 0754 . 21 Valve plate 23 Electromagnetic clutch 25 Compressor defects 26 Disassembly of compressor 26 Removal of the compressor from the cooling system 26 Disassembly of compressor 27 1 Removal of all shut-off valves and blind flanges 28 2 Removal of oil filter 29 3 Removal of the cylinder cover and of the valve plates 30 4 Removal of the shaft seal 31 5 Removal of the oil pump 32 6 Removal of the baseplate 33 7 Disassembly of connecting rods from the crankshaft 34 8 Removal of the front bearing flange 35 9 Removal of the crankshaft 36 10 Removal of the pistons and connecting rods 37 11 Removal of remaining parts 38 12 Removal of the roller bearings - - Page Contents 39 Checking the components of the compressor for damage / wear 39 Limiting values for wear 39 Cylinder liners 39 Crankshaft 40 Pistons 40 Connecting rods 40 Valve plates

5 40 Oil pump 41 Oil filter / suction filter 41 Internal safety valve 42 Assembly of the compressor 42 1 Fitting the roller bearings 43 2 Fitting the sight glass, the plugs and the internal safety valve 44 3 Assembly of the pistons / connecting rods 45 4 Fitting the pistons / connecting rod sets 46 5 Fitting the crankshaft 47 6 Installation of the front bearing flange 48 7 Assembly of the inserted connecting rods / pistons 49 8 Installation of the oil pump 50 9 Fitting the shaft seal 51 10 Installation of the base plate 52 11 Installation of the oil filter 53 12 Installation of the cylinder cover and valve plates 54 13 Installation of the shut-off valves and blind flanges 55 Checking the compressor 55 Tightening torques for screws 56 Spare part list 58 Repair kits parts list 59 Parts list for optional accessories 60 Exploded drawing - - Introduction Vehicle compressors Series fk 50 of Bock are among the most wide-spread machines used for bus A/C applications.

6 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 the disassembly and assembly of the compressor components. Each step must be carefully adhered to in order to ensure a reliable repair. Reminder: For replacing components Bock provides suitable spare part 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. The maintenance manual describes the standart type of the fk 50 compressor which we deliver.

7 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 analogous fashion. Safety Safety instructions Attention! 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 ( piping, plugs, union nuts, replaced components etc.)

8 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. - - Product description Product description Series fk 50 vehicle compressors are designed for mobile applications. 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.

9 Further Characteristics: Name plate (Example). AM12345A017 4. 1 FKX50/775N. 2 67,6. 3 5. 1. Type 2. Theoretic volume flow rate at 1450 rpm 5. Oil type filled in compressor by manuf. 3. ND(LP): max. tol. Stand still pressure intake side HD(HP): max. tol. Derating pressure high pressure side }. note limits of application diagrams! Type code (Example). Explanation of the type designation FK X 50 / 775 K. Field of application Displacement Size Ester oil filling (HFKW-Coolants, such as R 134a, R407C). Series - - Main and functional parts 9. 1. 2. 17. 3. 4 16. 7 18. 5. 10. 6. 11. 12. 8. 14. 13. 15. 1. 12. 2. 13. 3. 4. 5. 14. 6. 15. Oil drain plug / oil filter 7. 16. 8. 9. 17. 10. 18. 11. - - Dimension drawing View X. Shaft end Connections A 1. A1 B B1 C 1/8 NPTF. D 1/8 NPTF. E 1 1/8`` NPTF. F 1 1/4`` NPTF. G 1) -- H 1 1/4`` NPTF. K 11 1/8 -18 UNEF.

10 L 1 1/8`` NPTF. M M 22 x 1/5. SV1 Opt. Connection facilities f. Suction shut-off valve -- 1). = Only possible from factory - - Technical Data Cyl. Disp. Flow Weight Connections Oil Num. m rate vol. Discharge Suciton filling Type (1450 1 /min) side side DV SV. cm3 m3 /h kg mm / Zoll mm / Zoll Ltr. FK50/460 460 40,1 43,0 28 / 1 1/8 35 / 1 3/8 2,6. FK50/555 555 48,3 42,5 28 / 1 1/8 35 / 1 3/8 2,6. 6. FK50/660 660 57,6 41,0 35 / 1 3/8 2x35 / 1 3/8 2,6. FK50/775 775 67,6 40,0 35 / 1 3/8 2x35 / 1 3/8 2,6. Mass moment of inertia of the engine [kgm2]: 0,0053. - - Maintenance Maintenance Service intervals Praticcally 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 regularly according to the specifications of the manufacturer of the refrigerating plant.