BOCK FK40 Seroes Manuale utente
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Page
Contents
5 Introduction
5 Safety instructions
6 Product description
6 Short description, nameplate, type code
7 Main and functional parts
8 Dimension drawing, connections
9 Technical data
10 Maintenance
1 Function checks, oil level check, oil change
11 Operation of the shut-off valves
12 Fault diagnosis / Remedying t e 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. 8 19
19 Shaft seal, Part no. 8 23
2 Capacity regulating valve, Part no. 7541
21 Valve plate
23 Electromagnetic clutc
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
3 4 Removal of the shaft seal
31 5 Removal of the oil pump
32 6 Removal of the baseplate
33 7 Disassembly of the connecting rods from the crankshaft
34 8 Removal of the front bearing flange
35 9 Removal of the crankshaft
36 1 Removal of the pistons and connecting rods
37 11 Removal of the remaining parts
38 12 Removal of the roller bearings
96 8- 9. 3-DGbFEI
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Page
Contents
39 C ecking t e components of t e compressor for damage / wear
39 Limiting values for wear
39 Cylinder liners
39 Crankshaft
4 Pistons
4 Connecting rods
4 Valve plates
4 Oil pump
41 Oil filter / suction filter
41 Internal safety valve
42 Assembly of t e 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 piston / 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
5 9 Fitting the shaft seal
51 1 Installation of the baseplate
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 Tig tening torques for screws
56 Spare parts list
58 Repair kits parts list
59 Parts list for optional accessories
60 Exploded drawing
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96 8- 9. 3-DGbFEI
Introduction
Vehicle compressors Series FK 4 of Bock are among the most wide-spread machines
used for bus A/C applications. The criteria that speak for choosing a FK 4 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 4
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 to 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) should be checked carefully for their
economic efficiency beforehand.
The maintenance manual describes the standard type of the FK 4 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
Safety
Safety instructions
Attention! Refrigeration compressors are mac ines under pressure and as suc
require special care in andling.
Only qualified personnel are allowed to perform any work on refigeration compressors
T e national safety regulations, accident prevention regulations, tec nical rules
and specific regulations (EN 378 and ot ers) must be taken into account
absolutely.
Do not exceed t e maximum operating pressure - not even for purposes of c ecking!
Never put t e safety switc out of action!
Prior to commissioning, c eck w et er all t e components installed by t e user
ave been fastened expertly and connected pressure-tig t wit t e compressor
(e.g. piping, plugs, union nuts, replaced components etc.)
Before commissioning, evacuate t e cooling system carefully including
t e compressor and afterwards c arge refrigerant.
Prior to starting t e compressor open disc arge s ut-off valve and suction s ut-off
valve.
Do not start t e compressor in vacuum. Operate t e compressor only w en t e
system is c arged.
According to t e conditions of use surface temperatures in excess of 100°C may
occur on t e disc arge side and temperatures below 0°C on t e suction side.
Never grab rotating parts during operation! Danger of injury!
96 8- 9. 3-DGbFEI
- 5 -
Product description
Series FK 4 vehicle compressors are designed for mobile applications.
FK 40 -
N
FK 40 -
K
FK 40 -
TK
A/C compressor
for R134a
nmax= 3 rpm
Peak value = 35 rpm
A/C compressor
for R134a
nmax= 35 rpm
Deep-freeze compressor
for R4 4A (R22)
nmax= 26 rpm
S ort description
Compact 4-cylinder compressor in V design
Four sizes as regards 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
Nameplate (Example)
1. Type of compressor 4. Serial number
2. Theoretic volume flow rate at 145 rpm 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!
}
FK
X
40 /
655
N
Type code (Example)
Explanation of the type designation
Code letter for area of application
Code number for displacement
Code number for size
Code letter for ester-oil filling
Code letter for series
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96 8- 9. 3-DGbFEI
Product description
Main and functional parts
Figure 1
Figure 2
1. Discharge shut-off
2. Valve plate
3. Cylinder cover
4. Compressor casing
5. Locating hole for fitting magnetic clutch
6. Integrated leak oil collector
7. Shaft seal
8. Shaft end
9. Nameplate
1 . Connection for heat protection thermostat
11. Oil filling plug
12. Sight glasses for oil (2x)
13. Oil drain plug
14. Suction shut-off valve
15. Oil pump
16. Oil drain plug / oil filter
17. Baseplate
96 8- 9. 3-DGbFEI
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FK 4 /39 FK 4 /47 FK 4 /56 FK 4 /655
Dimension drawing
Connections
SV Suction shut-off valve, pipe dia.(L)*
DV Discharge shut-off valve,
pipe dia. (L)*
[mm]
[Inches]
[mm]
[Inches]
28 35 35 35
1 1/8 1 3/8 1 3/8 1 3/8
22 28 28 28
7 / 8 1 1/8 1 1/8 1 3/8
ASuction side port, not lockable [Inches] 1/8" NPTF
A1 Suction side port, lockable [Inches] 7/16"UNF
BPressure side port, not lockable [Inches] 1/8" NPTF
B1 Pressure side port, lockable [Inches] 7/16"UNF
COil pressure safety switch connection OIL [Inches] 1/8" NPTF
DOil pressure safety switch connection LP [Inches] 1/8" NPTF
EPort for oil pressure gage [Inches] 1/8" NPTF
FOil drain plug [mm] M 22x1.5
HOil filling plug [mm] M 22x1.5
LHeat protection thermostat connection [Inches] 1/8" NPTF
MOilfilter [mm] M 22x1.5
*L = Soldering connection
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96 8- 9. 3-DGbFEI
Tec nical data
No. of cylinders 4
Mass moment of inertia of the driving unit [kgm2] , 43
Lubrication Forced lubrication
Oil pump Bidirectional
Type of oil for R134a, R4 4A FUCHS Reniso Triton SE 55
Type of oil for R22 FUCHS Reniso SP 46
Oil filling [liters] 2,
Rotational speed see limits of application
Max. allowable operating pressure [bar], high-pressure side HD 25
low-pressure side ND 19
FK 4 /39 FK 4 /47 FK 4 /56 FK 4 /655
Displacement [cm3] 385 465 555 65
Theoretical volume flow rate [m3/h] 33,5 4 ,5 48,2 56,6
Weight incl. oil filling [kg] 33 32 32 31
96 8- 9. 3-DGbFEI
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Maintenance
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 c ecks 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 cranckcase
Checking the fixing screws for tightening
Checking the function of the ancillary units
Checking the electrical connections for clean, firmly fixed contacts and the leads for chafing points
Oil level c eck
C anging oil:
After 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 1 min.
The plant should have reached the operating point.
T e oil level must be visible in t e sig t glass.
In case of orderly manufactured and operated plants an oil change is in principle not absolutely
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 5 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.
Lubricants
Standard oil type used by Bock Recommended alternatives
For H-FCKWs (e.g.R22)
FUCHS Reniso SP 46
For H-FKWs (e.g.R 134a, R4 4A, R4 7C)
FUCHS Reniso Triton SE 55
MOBIL SHC 425
SHELL Clavus SD 22-12
SUNOIL Suniso 3GS
SUNOILSuniso 4GS
TEXACO Capella WF 46
FUCHS SEZ 32 / 68 / 8
ICI Emkarate RL 46 S
MOBIL Arctic EAL 46
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.
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96 8- 9. 3-DGbFEI
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