BOCK FK50 Manual de usuario
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Maintenance manual
96003-01.2022-Gb
Translation of the original instructions
BOCK FK50
colour the world
of tomorrow
BOCK®
FK50/460 N FK50/555 N FK50/660 N FK50/775 N FK50/830 N FK50/980 N
FK50/460 K FK50/555 K FK50/660 K FK50/775 K FK50/830 K FK50/980 K
FK50/460 TK FK50/555 TK FK50/660 TK FK50/775 TK
FKX50/460 N FKX50/555 N FKX50/660 N FKX50/775 N FKX50/830 N FKX50/980 N
FKX50/460 K FKX50/555 K FKX50/660 K FKX50/775 K FKX50/830 K FKX50/980 K
FKX50/460 TK FKX50/555 TK FKX50/660 TK FKX50/775 TK
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Foreword
Read these instructions before assembly and before using the compressor. This will avoid
misunderstandings and prevent damage. Improper assembly and use of the compressor
can result in serious or fatal injury.
Observe the safety instructions contained in these instructions.
Bock GmbH
Benzstrasse 7
72636 Frickenhausen
Germany
Telephone +49 7022 9454 0
Fax +49 7022 9454-137
www.bock.de
Introduction 4
Safety instructions 5
Product description 8
Short description, nameplate, type code 9
Main and functional parts 10
Dimension drawing, connections 11
Technical data 12
Maintenance 12
Regular checks (at least annually), Oil level check, Oil change 12
Preventive maintenance, emptying the Oil reservoir 13
Recommended spare parts / accessories, Lubricants / Oils 14
Operation of the shut-off valves 15
Fault diagnosis 16
Function faults-symptoms 16
Compressor stand still 16
Compressor cutoff 17
Refrigerant performance too low 18
Compressor temperature too high 19
Oil problems 20
Contents
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Abnormal running noise from compressor 21
Malfunction of the electromagnetic clutch 22
Installation of service kits 23
Shaft seal, Part no. 80023 24
Emptying the oil reseroir, Version ID 007 - 014, Clamping ring with oil felt 25
Capacity regulation, capacity regulation valve Part no. 07541 26
Valve plate 27
Electromagnetic clutch 29
Compressor defects 31
Disassembly of compressor 34
Removal of the compressor from the refrigerant system 34
Disassembly of compressor 34
1 Removalofallshut-offvalvesandblindanges 35
2 Removalofoillter 36
3 Removal of the cylinder cover and of the valve plates 37
4 Removal of the shaft seal 38
5 Removal of the oil pump 39
6 Removal of the baseplate 40
7 Disassembly of the connecting rods from the crankshaft 41
8 Removalofthebearingange 42
9 Removal of the crankshaft 43
10 Removal of the pistons and connecting rods 44
11 Removal of the remaining parts 45
12 Removal of the roller bearings 46
Checking the components of the cmpressor for damage / wear 47
Valve plates 48
Oil pump 48
Oillter/suctionlter 49
Internal decompression valve 49
Assembly of the compressor 50
1 Fitting the roller bearings 50
2 Fitting the sight glass, the plugs and the internal decompression valve 51
3 Assembly of the pistons / connecting rods 52
4 Fitting the piston / connecting rod sets 53
5 Fitting the crankshaft 54
6 Installationofthefrontbearingange 55
7 Assembly of the inserted connecting rods / pistons 56
8 Installation of the oil pump 57
9 Fitting the shaft seal 58
10 Installation of the baseplate 59
11Installationoftheoillter 60
12 Installation of the cylinder cover and valve plates 61
13Installationoftheshut-offvalvesandblindanges 62
Checking the compressor 63
Tightening torques for screws 63
Spare parts list 64
Exploded drawing 65
Contents
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Liability and warranty
Liability and warranty
Manufacturer‘s liability and warranty are excluded if
• Alterations and functional modifications have been carried out
• No original replacement parts have been used
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:
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)shouldbecheckedcarefullyfortheireconomicefciencybeforehand.
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 analogous fashion.
Introduction
Introduction
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Safety
Safety instructions
Target group of these instructions
• Work on the compressor may only be carried out by persons whose technical training, skills and
experience along with their knowledge of pertinent regulations and documentation means that
they are capable of assessing the work to be carried out and detecting any possible dangers
• Specialist can mean a refrigeration technician for example. Note that electrical work may only
be carried out by a qualified electrician. Alternatively, on a country-specific basis, persons who
have undergone electrotechnical instruction and who have proof of their qualification are also
permitted to carry out the work.
Identication of safety instructions
DANGER Indicates a dangerous situation which, if not avoided,
will cause immediate fatal or serious injury.
DANGER Indicates a dangerous situation which by electrical current, if
not avoided,
will cause immediate fatal or serious injury.
WARNING Indicates a dangerous situation which, if not avoided,
may cause fatal or serious injury
CAUTION Indicates a dangerous situation which, if not avoided,
may cause fairly severe or minor injury.
ATTENTION Indicates a situation which, if not avoided,
may cause property damage.
INFO Important information / tips on simplifying work.
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GEFAHR Danger from electric shock
Compressors contain live parts. Touching these parts can cause
electric shock and lead to serious or even fatal injuries.
• Disconnect the compressor from the power supply before
commencing work!
• Turn the main switch of the plant to "0" (OFF)!
• Secure the main switch to prevent restart!
• Observe the instructions of the plant/vehicle manufacturer!
General safety instructions
WARNUNG Danger due to unqualied personnel
Workwithoronthecompressorbyinadequatelyqualiedpersonnel
can cause serious, or even fatal, accidents and injuries.
• Only adequately qualified persons, such as refrigeration plant service
technicians or refrigeration mechatronic engineers, are allowed to
work on or with the compressor!
• Generally, such persons must be able to assess and judge work and
dangers with and on the compressor!
WARNUNG Danger from malfunctions
If a compressor continues to be operated during extreme running noise
and/or a sharp reduction in refrigerating capacity, there is the danger
of further events occurring, such as the fracture of the housing wall. If
people are standing in the immediate surroundings, there is the risk of
severeinjuryorevendeathfromyingparts.
• In the event of extreme running noise, switch off the compressor
immediately!
• If there is a sharp reduction in refrigerating capacity, switch off the
compressor immediately!
• Secure the compressor to prevent restart!
• In such cases do not continue to operate the compressor under any
circumstances!
Safety
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WARNUNG Danger from pressure
Compressors are pressurized machines containing very high pressures.
They must therefore be handled with extreme caution and care.
Serious and even fatal injuries can occur.
• The maximum permissible overpressure must not be exceeded, even
for testing purposes!
• Depressurize the compressor before carrying out any work on it!
• Wear protective equipment, such as safety goggles or gloves!
WARNUNG Danger from hot parts
Parts on the compressor can get hot. They present a burn hazard.
• Avoid contact with hot parts, such as discharge line valves!
• Wear protective gloves if possible!
• Allow hot parts to cool down sufficiently whenever the situation
requires (during disassembly/installation for example)!
WARNUNG Danger from refrigerant
Severe frostbite and skin damage can be caused if the skin comes into
contact with the refrigerant.
• The skin must never be allowed to come into contact with
refrigerants!
• Wear safety equipment!
• When handling refrigerants, observe their properties!
• Observe the precautionary measures and specifications of the
refrigerant manufacturer!
Safety
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Type code (Example)
FK
Explanation of the type designation
Application
Swept volume
Size
Ester-oillling(HFKWrefrigerante.g.R134a,R407C)
Code letter for series
50 775 NX /
Product description
Product description
Series FK50 vehicle compressors are designed for mobile applications.
Short description
Three design variations are available for different areas of application:
> For air conditioning the K Design
> For air conditioning or normal cooling the N Design
> for deep freezing the TK Design
The differences are mostly associated with the valve plate version which is adapted to each applica-
tionrangewhereoperationalsafetyandefciencyareconcerned.
More features:
Compact 6-cylinder compressor in W design.
Wear resistant and long-lasting engine.
Six sizes as regards capacity.
Aluminium light-weight construction.
Crankshaft supported in roller bearings on both sides.
Bidirectional lubricating oil pump with relief valve.
Variable arrangement shut-off valves.
Ideally equipped with valve plates for each application.
Integrated pulsation damper for especially quiet running.
1. Type of compressor 4. Serial number
2. Volume baláye bei 1450 1/min 5.Oiltypelledincompressorbythe
manufacturer
3. LP: max. tol. stand still pressure intake side
HP:
max. tol. Derating pressure high pressure side
}note limits of
aplication diagrams!
Nameplate (Example)
1
2
3
4
5
FKX50/775N
67,6
AR12345A020
19/28bar
Bock GmbH, Benzstr. 7
72636 Frickenhausen, Germany
BOCK
Öl: BOCKlub E55
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Product description
Main and functional parts
1. Cylinder cover
2. Valve plate
3. Compressor casing
4. Integrated leak oil collector
5. Locationholeforttingmagneticclutch
6. Shaft end
7. Shaft seal
8. Connection thermal protection thermostat
9. Discharge shut-off valve
10. Oilllingplug
11. Sight glasses for oil (2x)
12. Baseplate
13. Suction shut-off valve
(FK50/660, 775, 830 and 980
with 2 suction shut-off valves)
14. Oil pump
15.Oildrainplug/oillter
16. Optional connection type
for suction shut-off valve
17. Nameplate
18. Leak oi drain hose
8
13
14
15
9
10
11
16
1
2
4
6
7
3
5
12
17
18
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Dimension drawing
Product description
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 Optional connection oil sump heater1) --
H Oil charge plug M22 x 1.5
K Sight glass 2 x 1 1/8“-18 UNEF
L Connection thermal protection thermostat 1/8“ NPTF
M Oillter M22x1.5
SV1 Optional connection suction valve --
1) = Only possible from factory
- additional SV at FK50/660, 775, 830 and 980 standart
- () = K-Design
DV
Dimensions in mm
Centre of gravity
oil tube
Shaft end
Este manual sirve para los siguientes modelos
32
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