GEA Bock FK40/755, Maintenance Manual

Page 1: ...s FK40 390 K FK40 470 K FK40 560 K FK40 655 K FK40 755 K FK40 390 N FK40 470 N FK40 560 N FK40 655 N FK40 390 TK FK40 470 TK FK40 560 TK FK40 655 TK FKX40 390 K FKX40 470 K FKX40 560 K FKX40 655 K FKX...

Page 2: ...rations and functional modifications have been carried out No original replacement parts have been used Contents Page 1 Introduction 3 2 Safety 3 3 Product description 5 4 Technical data 8 5 Maintenan...

Page 3: ...t group of these instructions Work on the compressor may only be carried out by persons whose technical training skills and expe rience along with their knowledge of pertinent regulations and document...

Page 4: ...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 pl...

Page 5: ...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...

Page 6: ...3 Valve plate 4 Compressor housing 5 Location hole for fitting magnetic coupling 6 Integrated leak oil collector 7 Leak oil drain hose 8 Shaft seal 9 Shaft end 10 Baseplate 11 Connection thermal prot...

Page 7: ...in m Cotes en mm Ma e in mm nderungen vorbehalten Subject to change without notice Sous r serve de toutes modifications Sight glass Version K 1 0851 13983 0 Schauglas K 1 Ne possible qu ex usine L Ra...

Page 8: ...Oil pump FK X 40 390 4 385 33 5 34 0 22 7 8 28 1 1 8 2 0 0 0043 Forced lubrication Rotation independent FK X 40 470 466 40 5 33 0 28 1 1 8 35 1 3 8 FK X 40 560 554 48 3 33 0 28 1 1 8 35 1 3 8 FK X 40...

Page 9: ...erating point 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 absolutely necessary Yet based on deca...

Page 10: ...1 Turn 1 2 1 rotation to the right Service connection 2 opened shut off valve opened position B Fig Connection 3 is provided for safety devices and is not lockable 1 3 Pipe connection 2 5 I Maintenan...

Page 11: ...ve not functioning properly Check the setting of the expansion valve Solenoid valve on the liquid line not opening Check the control function Fault diagnosis In case of malfunctions during compressor...

Page 12: ...switch Condensing pressure too high Check the setting of the high pressure switch Adjust the switching points or replace switch Pressure valve of the compressor closed Open the pressure valve Condense...

Page 13: ...hange Valve plate damage Replace valve plate Internal decompression valve has opened Replace decompression valve see the section on Disassembly Assembly of Compressor Oil problems Problem Possible cau...

Page 14: ...magnetic coupling slipping see also p 14 Malfunction of electromag netic coupling Checking V belt drive increased noise generation Belts vibrating excessively Check belt tension Use tensioning roller...

Page 15: ...dentical WARNING Before starting any work on the compressor Switch of the compressor and guard it against switching on Close the discharge and suction shut off valves Relieve the compressor from syste...

Page 16: ...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 enga...

Page 17: ...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...

Page 18: ...r bank which is regulated down run idle The capacity of the compressor is still approx 50 Further information together the description of the working principle of the solenoid valve is contained in th...

Page 19: ...ssor type Kit Item No FK X 40 390 N 80240 FK X 40 390 TK 80240 FK X 40 470 N 80240 FK X 40 470 TK 80240 FK X 40 560 N 80241 FK X 40 560 TK 80241 FK X 40 655 N 80241 FK X 40 655 TK 80241 FK X 40 390 K...

Page 20: ...ay attention to the correct installation position of the gaskets 3 5 of the valve plate 4 and of the cylinder cover 2 Tighten the cylinder cover screws Pos 1 in Fig 6 according to the sequence shown i...

Page 21: ...A 16 The front bearing flange has a location face 148 h8 for fitting the solenoid of the electromagnetic coupling see Fig 8 Fig 8 Front bearing flange Magnetic field Fig 9 148 h8 For fitting the solen...

Page 22: ...it Screw tightening 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 independe...

Page 23: ...an the system install a suction line filter if necessary Moisture in the system Dry the system trough changing refrigerant and oil replace the drier install a suction line filter if necessary Overheat...

Page 24: ...stem 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 Th...

Page 25: ...7 allen key 6 mm Working course 220 330 210 230 210 233 232 231 The compressor has to be depressurized Unscrew the fixing screws of shut off valves Remove the shut off valves and the gaskets Remove th...

Page 26: ...l filter Position in parts list Parts list position 2130 Tools Container 2 liter for collection oil spanner SW 19 allen key 10 mm Working course 510 500 490 Drain the oil from the compressor into a su...

Page 27: ...Removal of the cylinder cover and valve plates Position in parts list N TK K Parts list position 170 2000 N TK versions 1940 2900 K version Tools Spanner SW 17 Working course 180 181 170 70 60 50 1950...

Page 28: ...Remove the leak oil collection device from the bearing flange until version ID 014 Unscrew the cylinder screws Remove the shaft seal cover the guide ring the O ring and the spring INFO For a detailed...

Page 29: ...oval of the oil pump Position in parts list Parts list position 2020 Tools Spanner SW 13 Working course 40 41 460 470 Loosen screws on the oil pump and unscrew Remove the oil pump and gasket 10 I Disa...

Page 30: ...eplate Position in parts list Parts list position 20 30 40 Tools Container for collection oil spanner SW 13 Working course 40 20 30 Place the compressor into the oil collection pan and turn it sideway...

Page 31: ...e 2100 2100 2040 2045 300 290 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...

Page 32: ...bearing Position in parts list Parts list position 2140 Tools Allen key 6 mm Working course 750 730 740 745 Loosen the screws at the front bearing and unscrew Remove the front bearing flange gasket an...

Page 33: ...Gb 9 Removal of the crankshaft Position in parts list Parts list position 2050 Tools Working course 2050 Pull out the crankshaft carefully in direction of the front bearing flange 10 I Disassembly of...

Page 34: ...2100 Tools Needle nosed pliers Working course 2100 2030 280 270 2100 Mark corresponding pistons of cylinder bore Remove the piston connecting rod in direction of baseplate Remove circlips of the pist...

Page 35: ...r 36 For the decompression valve GEA Bock special tool item No 09524 up to A015 socket wrench SW 22 from A017 Working course 570 590 520 521 100 Dismount the sight glass Remove O ring Remove the 1 8 N...

Page 36: ...r bearing from the front bearing flange 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 bea...

Page 37: ...that an unhindered oil flow is ensured Piston cylinder bore 0 13 mm Connecting rod piston pin 0 03 mm Crankshaft connecting rod 0 08 mm Checking compressor parts for damages and wear Before re using...

Page 38: ...The connecting rod shank must be straight Valve plates Suction and pressure lamella must be undamaged and undeformed The sealing surfaces must be clean and undamaged between lamellas and valve plates...

Page 39: ...use GEA Bock special tool item No 09524 up to A015 socket wrench SW 22 from A017 The internal decompression valve must be replaced after it has operated INFO In case of larger compressor damages whic...

Page 40: ...730 312 2150 Heat the bearing flange compressor casing for approx 20 minutes in a pre heated 120 C baking oven Insert tolerance ring into the roller bearing if available Press the roller bearings onto...

Page 41: ...Bock special tool item No 09524 up to A015 socket wrench SW 22 from A017 Working course 570 590 520 521 100 Screw on the sight glass with oiled O ring to the compressor body Screw in the 1 8 NPTF scre...

Page 42: ...s Position in parts list Parts list position 2040 opt 2045 or 2030 opt 2035 together with 2100 Tools Needle nosed pliers Working course 270 280 Assemble piston and connecting rod with piston pin use s...

Page 43: ...eassembled connecting rod assembly and mark it Apply a little oil to the cylinder bore Insert pistons connecting rods from below into the cylinder liners In the case of TK compressors pay attention to...

Page 44: ...Assembly of compressor 5 Fitting the crankshaft Position in parts list Parts list position 2050 Tools Working course 2050 Fit the crankshaft so that the drive journal engages into the pump gear Apply...

Page 45: ...730 740 750 Apply oil to the O ring and place it into the groove in the bearing flange The sealing surfaces have to be clean Slightly oil seals Install the front bearing flange with gasket to the bod...

Page 46: ...on into the cylinder liner Place the marked connecting rod caps onto the related connecting rods Screw on the connecting rod caps and tighten Turn the crankshaft by hand In case the crankshaft does no...

Page 47: ...st axial clearance The axial clearance of the crankshaft must be at least 0 15 mm When parts of the driving unit of the compressor have been repaired or replaced an accurate measurement of the axial c...

Page 48: ...gasket using the protective sleeve The inscription TOP must be at the top Press the shaft seal cover onto the bearing flange and tighten the screws Turn the crankshaft by hand Remove the protective sl...

Page 49: ...49 09665 01 2019 Gb POE TOP TOP TOP 2 3 4 5 6 mm 8 9 POE 1 2 3 4 5 6 TOP TOP 6 7 CLICK 2 4 6 5 3 7 9 Fitting the shaft seal...

Page 50: ...50 09665 01 2019 Gb 8 9 1 2 3 4 5 6 TOP 10 11 12 6 mm 37 Nm 8 10 9 9 Fitting the shaft seal...

Page 51: ...arts list Parts list position 20 30 40 Tools Spanner SW 13 Working course 20 30 40 Install the baseplate with gasket Tighten the screws M8x30 crosswise 11 14 18 15 12 13 17 16 10 4 2 6 3 9 5 1 7 8 34...

Page 52: ...position 2130 Tools Allen key 10 mm spanner SW 19 Working course 490 500 510 With the allen key screw on the filter into the hole in the body and tighten it Install gasket Screw on the M22x1 5 mm plu...

Page 53: ...nt the valve plate with the lower valve plate gasket onto the body Mount the cylinder cover with the upper valve plate gasket on the valve plate Tighten the screws and washers cross wise in at least t...

Page 54: ...rse 230 210 2060 233 232 231 Put in the suction filter with the gasket Install the shut off valves on the discharge and suction side with gaskets and screws Install the blind flange with O ring and sc...

Page 55: ...n Note Tighten the screws cross wise in at least two stages tightening torque 50 100 Working course 1 Evacuation leak check of compressor Connect the discharge and suction sides of the compressor to a...

Page 56: ...N K TK 2 05075 05075 05075 05075 05075 270 Piston pin 15x10x41 N K TK 4 07211 270 Piston pin 15x10x46 N K TK 4 07212 07212 270 Piston pin 15x10x50 N K TK 4 07857 07857 280 Seeger circlip 15x1 DIN 472...

Page 57: ...06726 06726 740 Front bearing flange gasket N K TK 1 06165 06165 06165 06165 06165 745 O Ring 101 19x3 53 N K TK 1 05169 05169 05169 05169 05169 750 Cylinder screw M8x25 N K TK 14 06067 06067 06067 0...

Page 58: ...piston con rod 55 rilled optimized TK 4 80250 2045 Set piston con rod 60 rilled optimized TK 4 80251 2045 Set piston con rod 65 rilled optimized TK 4 80226 2050 Set crankshaft 49 stroke optimized N K...

Page 59: ...en N K TK 1 05987 05987 05987 05987 05987 3312 Disc 30x16x2 0 N K TK 1 05143 05143 05143 05143 05143 3313 Milled nut M15x1 with O Ring N K TK 1 05885 05885 05885 05885 05885 3320 Solenoid coil 24V DC...

Page 60: ...0 2035 2100 2045 280 FK40 390 655 N TK 3313 3312 3311 3310 3320 3250 3220 3240 3200 3300 181 FK40 390 755 K 3313 3312 3311 3320 3300 3850 3820 3840 3800 3310 181 1930 1920 1910 2900 FK40 390 755 K 195...

Page 61: ...61 09665 01 2019 Gb...

Page 62: ...eration gea com www gea com GEA Group is a global engineering company with multi billion euro sales and operations in more than 50 countries Founded in 1881 the company is one of the largest providers...