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FK 50 M a intenance Manual Type s : FK 50/460 K FK 50/460 N

FK 50

FK 50 M a intenance Manual Type s : FK 50/460 K FK 50/460 N FK

Maintenance Manual

Types:

FK 50/460 K FK 50/460 N FK 50/460 TK

FK 50/555 K FK 50/555 N FK 50/555 TK

FK 50/660 K FK 50/660 N FK 50/660 TK

FK 50/775 K FK 50/775 N FK 50/775 TK

96003-02.06-Gb

Foreword

Dear Customer,

9600 3 -02.06- Gb F or e wor d Dear C ustom er, - 2 -

- 2 -

,

9600 3 -02.06- Gb F or e wor d Dear C ustom er, - 2 -

9600 3 -02.06- Gb F or e wor d Dear C ustom er, - 2 -

standard there your

team at

-Right for making modifications reserved.-

96003-02.06-Gb

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

0

Function checks, oil level check, oil change

Operations of the shut-off valves

12

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 clutch

17

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 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

4

5

6

7

Removal of the cylinder cover and of the valve plates

0

Removal of the shaft seal

Removal of the oil pump

2

Removal of the baseplate

Disassembly of connecting rods from the crankshaft

34

8

9

Removal of the front bearing flange

5

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

- -

96003-02.06-Gb

Page

Contents

39

Checking the components of the compressor for damage / wear

9

Limiting values for wear

9

Cylinder liners

9

Crankshaft

40

Pistons

40

Connecting rods

40

Valve plates

40

Oil pump

4

Oil filter / suction filter

4

Internal safety valve

42

Assembly of the compressor

42

Fitting the roller bearings

4

2

Fitting the sight glass, the plugs and the internal safety valve

44

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

5

0 Installation of the base plate

52

Installation of the oil filter

5

2 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

- 4 -

96003-02.06-Gb

Introduction

Vehicle compressors Series FK 50 of Bock are among the most wide-spread machines used for bus A/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 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 or 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 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 analogous fashion.checked carefully for their economic efficiency beforehand. Safety S afety instructions A ttention! Refrigeration

Safety

present manual should be used in analogous fashion. Safety S afety instructions A ttention! Refrigeration compressors

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 compressorsunder pressure and as such require special care in handling. The national safety regulations, accident prevention

The national safety regulations, accident prevention regulations, technical rules and specific regulations (EN 378 and others) must be taken into account absolutely.are allowed to perform any work on refrigeration compressors Do not exceed the maximum operating pressure

Do not exceed the maximum operating pressure - not even for pur poses of checking! rposes of checking!

Never put the safety switch out of action!operating pressure - not even for pu r poses of checking! Prior to commissioning, check whether

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.).of checking! Never put the safety switch out of action! Before commissioning, evcuate the cooling system

Before commissioning, evcuate the cooling system carefully including the compressor and afterwards charge refrigerant.(e.g. piping, plugs, union nuts, replaced components etc.). Prior to starting the compressor open discharge shut-off

Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.including the compressor and afterwards charge refrigerant. Do not start the compressor in vacuum. Operate the

Do not start the compressor in vacuum. Operate the compressor only when the system is charged.open discharge shut-off valve and suction shut-off valve. According to the conditions of use surface temperatures

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. 0°C on the suction side.

Never grab rotating parts during operation! Danger of injury!temperatures in excess of 100°C may occur on the discharge side and temperatures below 0°C on

- 5 -

Product description

Product description

96003-02.06-Gb

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.

Further Characteristics:

Compact 6-cylinder compressor in V design.operational safety and efficiency. Further Characteristics: Wear resistant and long-lasting engine. Four sizes as

Wear resistant and long-lasting engine.Characteristics: Compact 6-cylinder compressor in V design. Four sizes as regarding capacity. Aluminum light weight

Four sizes as regarding capacity.in V design. Wear resistant and long-lasting engine. Aluminum light weight construction. Crankshaft supported in

Aluminum light weight construction.and long-lasting engine. Four sizes as regarding capacity. Crankshaft supported in roller bearings on both sides.

Crankshaft supported in roller bearings on both sides.as regarding capacity. Aluminum light weight construction. Bidirectional lubricating oil pump with relief valve.

Bidirectional lubricating oil pump with relief valve.Crankshaft supported in roller bearings on both sides. Variable arrangement of shut-off valves. Ideally equipped

Variable arrangement of shut-off valves.sides. Bidirectional lubricating oil pump with relief valve. Ideally equipped with valve plates for each application.

Ideally equipped with valve plates for each application.with relief valve. Variable arrangement of shut-off valves. Integrated pulsation damper for especially quiet running.

Integrated pulsation damper for especially quiet running.Ideally equipped with valve plates for each application. Name plate ( Example ) AM12345A017 4

Name plate (Example)

AM12345A017 4  FKX50/775N 2 67,6  5
AM12345A017
4
FKX50/775N
2
67,6
5

. Type of compressor 2. Theoretic volume flow rate at 1450 rpm

. ND(LP): max. tol. Stand still pressure intake side HD(HP): max. tol. Derating pressure high pressure side }

4. Serial number 5. Oil type filled in compressor by manuf.

note limits of application diagrams!

Type code (Example)

- 6 -

Explanation of the type designation FK X 50 / 775 K
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

96003-02.06-Gb

2

7

4

7

5

6

2

and functional parts 9600 3 -02.06- Gb  2 7  4 7 5 6 2
and functional parts 9600 3 -02.06- Gb  2 7  4 7 5 6 2
and functional parts 9600 3 -02.06- Gb  2 7  4 7 5 6 2
and functional parts 9600 3 -02.06- Gb  2 7  4 7 5 6 2

9

6

8

0

4  5
4
5

8

.

Cylinder cover

2.

Valve plate

.

Compressor casing

4.

Integrated leak oil collector

5.

Locating hole for fitting magnetic clutch

6.

Shaft end

7.

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

- 7 -

96003-02.06-Gb

Dimension drawing

View X Shaft end
View X
Shaft end

Connections

A

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“ UNF

C

Oil pressure safety switch connection OIL

/8“ NPTF

D

Oil pressure safety switch connection LP

/8“ NPTF

E

Port for oil pressure gauge

1/8`` NPTF

F

Oil drain plug

1/4`` NPTF

G

Opt. connection facility f. oil sump heating )

--

H

Oil filling plug

1/4`` NPTF

K

Sight glass

1

/ 8 “-8 UNEF

L

Heat protection thermostat connection

1/8`` NPTF

M

Oil filter

M 22 x 1/5

SV1

Opt. Connection facilities f. Suction shut-off valve

--

) = Only possible from factory

Technical Data

96003-02.06-Gb

Connections Cyl. Disp. Flow Weight Oil Num. m rate vol. Discharge Suciton side filling Type
Connections
Cyl.
Disp.
Flow
Weight
Oil
Num.
m
rate vol.
Discharge
Suciton
side
filling
Type
side
(1450 1 /min)
DV
SV
cm
m /h
kg
mm / Zoll
mm / Zoll
Ltr.
FK50/460
460
40,
4,0
28
/ / 8
5 / / 8
2,6
FK50/555
555
48,
42,5
28
/ / 8
5 / / 8
2,6
6
FK50/660
660
57,6
4,0
5 / / 8
2x5 / / 8
2,6
FK50/775
775
67,6
40,0
5 / / 8
2x5 / / 8
2,6
Mass moment of inertia of the engine [kgm2]:
0,005
Lubrication:
Forced lubrication
Oil pump:
bidirectional

- 9 -

96003-02.06-Gb

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.

Function checks to be carried out once a year:

Leak test of the plantplant. Fun ction checks to be carried out once a year : Checking the running noise

Checking the running noise of compressorto be carried out once a year : Leak test of the plant Checking pressures and

Checking pressures and temperatures of the planttest of the plant Checking the running noise of compressor Checking the tensioner for orderly seating

Checking the tensioner for orderly seatingcompressor Checking pressures and temperatures of the plant Checking the V-belts for tension and condition Ch

Checking the V-belts for tension and conditionof the plant Checking the tensioner for orderly seating Ch e cking the oil level in

Che cking the oil level in the crankcase ecking the oil level in the crankcase

Checking the fixing screws for tighteningand condition Ch e cking the oil level in the crankcase Checking the function of the

Checking the function of the ancillary unitsin the crankcase Checking the fixing screws for tightening Checking the electrical connections for clean, firmly

Checking the electrical connections for clean, firmly fixed contacts and leads for chafing pointsfor tightening Checking the function of the ancillary units Oil level check After starting the compressor,

Oil level check

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).the compressor, the oil level has to be checked. For this: Compressor running time at least

Compressor running time at least 10 min.idle" operating condition (elevated idling speed). The plant should have reached the operating point. The oil

The plant should have reached the operating point.idling speed). Compressor running time at least 10 min. The oil level must be visible Changing

The oil level must be visible10 min. The plant should have reached the operating point. Changing oil : In case of

Changing oil:

In case of orderly manufactured and operated plants and 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 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.

Lubricants

Standard oil type used by Bock

Recommended alternatives

For H-FCKWs (e.g. R22)

FUCHS Reniso SP 46

MOBIL SHC 425 SHELL Clavus SD 22-2 SUNOIL Suniso GS

SUNOIL Suniso 4GS TEXACO Capella WF 46

For FKWs (e.g. R 4a, R404A, R407C)

 

FUCHS Reniso Triton SE 55

FUCHS SEZ 2 / 68 / 80 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.

- 0 -

96003-02.06-Gb

� � � � � �� � � � � � � � � �
��
��
��
Operation of the shut-off valves
� �
� �
2
Opening the shut-off valve
Spindle 1 turn to the left (ccw)
until the end stop.
1
Shut off valve fully open / Service
port 2 closed.
3
Opening the service port (2)
2
��
Spindle 1 Turn ½-1 turn to the right
Service port 2 open /
��
��
1
Shut off valve opened.
Port 3 is intended for safety devices and
� �
cannot be shut off.
3
� �
� � � � � � � � � � � � � � �

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).

- -

96003-02.06-Gb

Fault diagnosis

Fault diagnosis

In case of malfunctions during compressor operation we recommend to prepare a measurement record for aiding the fault search:

Pressure measurement: D ischarge side, suction side, oil pressure : Discharge side, suction side, oil pressure

Temperatur measurement : Compressor casing, discharge end temperature, suction gas overheating According to the expected cause measurement: Compressor casing, discharge end temperature, suction gas overheating According 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-Symptoms

Function faults arising most frequently and their symptoms are:

Compressor stoppage, compressor cutofffaults arising most frequently and their symptoms are: - Compressor does not start - Compressor starts

- Compressor does not start

- Compressor starts and then stops again

Cooling performance too lowdoes not start - Compressor starts and then stops again Too high compressor temperature Oil problems

Too high compressor temperaturestarts and then stops again Cooling performance too low Oil problems Abnormal compressor running noise Malfunction

Oil problemsCooling performance too low Too high compressor temperature Abnormal compressor running noise Malfunction of the

Abnormal compressor running noise compressor running noise

Malfunction of the elektromagnetic clutchtemperature Oil problems Abnormal compressor running noise Compressor stand still Compressor does not start Symptom

Compressor stand still

Compressor does not startof the elektromagnetic clutch Compressor stand still Symptom Possible cause Remedy Open circuit -

Symptom

Possible cause

Remedy

Open 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 elements

Malfunction of

- see also p.16 "Malfunction electromagnetic clutch"

- Checking

electromagnetic clutch

- 2 -

Compressor cutoff

96003-02.06-Gb

Compressor cutoff 9600 3 -02.06- Gb Compressor starts and stops again Symptom Possible cause Remedy Cutoff

Compressor starts and stops again

Symptom

Possible cause

Remedy

Cutoff though low- pressure switch

Suction pressure too low:

 

- Check the setting of the low pressure switch

- Adjust the switching points or replace 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 blocked

- Replace filter / dryer

- Expansion valve not functioning properly

- Check the setting of the valve

- Solenoid valve on the liquid line not opening

- Check the control / function

Cutoff through high- pressure 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 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- protection thermostat (accessory)

Discharge end temperatures is too high - Operating limits of compressor exceeded

- Adapt the operating conditions to the 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

high-pressure side

Cutoff through control thermostat

- Temperature over / below the desired range

- Check operating points

- -

96003-02.06-Gb

Cooling performance too low

   

Symptom

Possible cause

Remedy

Suction pressure too

- Expansion valve not functioning properly

- Check valve setting; replace valve, if necessary

 

high

- 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"

- Checking

High pressure too high

- See "Cutoff through high-pressure switch"

- Checking

High 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 Bypass between suction and discharge

- Replace valve plate Localize leak between the discharge and suction side and repair it

side

Cooling temperature too high

- 4 -

Symptom

Possible cause

Remedy

Suction gas temperature too high

- Suction gas overheating

- Adjust expansion valve Insulate the gas suction line

- Too little refrigerant filling

- Liquid filter blocked

- Clean / replace filter / dryer

Discharge pipe

- Suction gas temperature too high Condensing pressure too high

see point above

too high

see "Cutoff through high-pressure switch"

- Operating limits of compressor

see "Cutoff through heat-protection thermostat

exceeded

- 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)

 

- Establish the operating filling (see Operating Instruction for the refrigeration plant) Localize leak

Oil problems

96003-02.06-Gb

Symptom

Possible cause

Remedy

Oil 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 oil

Oil foams during up phase

- Liquid refrigerant has moved into the oil sump

-

Check the laying of pipes

-

Installation of check valve in the discharge line

   

-

Installation of the solenoid valve in the liquid line

-

Check the control

Oil foams during operation

- Expansion valve not functioning

-

Adjust / replace expansion valve

Oil level decreasese

- During start-up, a portion of the oil is carried to the refrigeration plant with the refrigerant

-

Refrigerant and oil get mixed. 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

plate leaking

-

Replace valve- plate

Abnormal running noise from compressor

Symptom

Possible cause

Remedy

Fixation of compressor is loose

- Screwed connections have become loose

-

Tighten the screwed connections and

- Securing elements for screwed connection missing

secure them anew

 

- Vibration metals defective

- Replace vibration metals

Liquid shock

- Liquid refrigerant reaching the compressor

- Adjust / check expansion valve Check refrigerant filling Check evaporator fan Icing-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 valve

Electromagnetic clucth

- see also p. 16 "Malfunction of electro- magnetic clutch"

- Checking

slipping

V belt drive, increased noise generation

- Belts vibrating excessively

- Check belt tension Use tensioning roller / guidance roller

- Incorrect alignment of compressor and motor

- Check alignment and adjust anew

- 5 -

96003-02.06-Gb

Malfunction of the electromagnetic clutch

Symptom

Possible cause

Remedy

Clutch not switching

- No voltage applied

- Apply voltage and check

Clutch slipping too long, getting hot smoking and squeaking

- Voltage too low

- Keep the voltage at 12 or 24

- Volts (check vehicle network)

- 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, Armature disc is deformed

- Install new rotor and armature disc

- 6 -

Installation of service kits

Disassembly-Assembly of service kits

96003-02.06-Gb

Safety 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:

Furthermore the following should be taken into account: Before starting any work on the compressor: Switch

Before starting any work on the compressor:

Switch of the machine and guard it against switching oninto account: Before starting any work on the compressor: Close the discharge and suction shut-off valves

Close the discharge and suction shut-off valvesSwitch of the machine and guard it against switching on Relieve the compressor from system pressure

Relieve the compressor from system pressureswitching on Close the discharge and suction shut-off valves Use only genuine Bock spare parts. After

Use only genuine Bock spare parts. After the work is finished: After the work is finished:

Connect the safety switch and check its functiononly genuine Bock spare parts. After the work is finished: Evacuate the compressor Before commisioning, check

Evacuate the compressorfinished: Connect the safety switch and check its function Before commisioning, check whether all the components

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.).safety switch and check its function Evacuate the compressor Open the pressure and suction shut-off valves

Open the pressure and suction shut-off valves (see page 11)(e.g. piping, plugs, union nuts, replaced components etc.). Set off the switching-on lock. F o r

Set off the switching-on lock.Open the pressure and suction shut-off valves (see page 11) F o r changing components in

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

- 7 -

Leak oil collection ring (Part No 8029)

Procedure:

Leak oil collection ring

( Par t N o 8029) Procedure: Leak oil collection ring Remove the leak oil collection

Remove the leak oil collection ring (see Fig. ) )

The repair kit contains two felt inlays (Pos. 2 and Pos. 3, see Fig. 2)ring Remove the leak oil collection ring (see Fig. ) If the bearing flange with one

If the bearing flange with one oil pocket is installed, Pos. 3 must be inserted (see Fig. 3).kit contains two felt inlays (Pos. 2 and Pos. 3, see Fig. 2) If the bearing

If the bearing flange with six oil pocket is installed, Pos. 2 must be inserted (see Fig. 4).pocket is installed, Pos. 3 must be inserted (see Fig. 3). If the wrong felt inlay

If the wrong felt inlay or both felt inlays is/are inserted, the functioning of the oil collection system cannot be ensured.pocket is installed, Pos. 2 must be inserted (see Fig. 4). Fig. 2 3  2

functioning of the oil collection system cannot be ensured. Fig. 2 3  2 Fig .
Fig. 2 3  2
Fig. 2
3
2

Fig.

Type code 001

Type code 007 - 013

Bearing flange with one oil pocket
Bearing flange with
one oil pocket
Type code 007 - 013 Bearing flange with one oil pocket  Open at bottom

Open at bottom

Bearing flange with six oil pockets Open at top
Bearing flange with
six oil pockets
Open at top
bottom  Bearing flange with six oil pockets Open at top  Fig. Fig. 4 2

bottom  Bearing flange with six oil pockets Open at top  Fig. Fig. 4 2
Fig. Fig. 4
Fig.
Fig. 4

2

from type code 015- (from 4. Quarter of 2005) Bleeding the oil reservoir: The emptying
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. Hereto
disconnect the oil hose from the holder, remove the connection
plug 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.
96003-02.06-Gb

- 8 -

96003-02.06-Gb

Shaft seal (Part No 8002)

Removal:

Dismount the drive/magnetic clutc h from the compressor . ch 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 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 may run out of the shaft seal chamber. Keep a suitable collection container ready!

8b 8a Fig. 5  2  4 5 6 9 ‘‘TOP‘‘ Installation: Work with
8b
8a
Fig. 5
2
4
5 6
9
‘‘TOP‘‘
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.
sliding and sealing surfaces for cleanliness and damages. 7 Apply a thin film of oil on

7

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).sliding and sealing surfaces for cleanliness and damages. 7 Assemble the sliding ring (4), O-ring (3)

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)O-ring (3) and the compressor shaft (use copmressor oil). During the assembly the compression spring (1)

During the assembly the compression spring (1) must engage audibly in the drive slot of the crankshaft and of the guide ring (2).(4) should show in the direction of the shaft seal cover (6) Install the shaft seal

Install the shaft seal cover gasket (5) dry, don't impregnate it with oil.the drive slot of the crankshaft and of the guide ring (2). Install the shaft seal

Install the shaft seal cover (6) with the inscription "TOP" upwards. Tighten the fixing screws (7) evenly, crosswise tightening torque = 37 Nm.seal cover gasket (5) dry, don't impregnate it with oil. After installing the shaft seal, turn

After installing the shaft seal, turn the compressor shaft a few turns by hand and then carry out the leak test.screws (7) evenly, crosswise tightening torque = 37 Nm. I f available i nstall the leak

If available i nstall the leak oil collection ring (see section on leak oil collection f 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.i nstall the leak oil collection ring (see section on leak oil collection ring, page 18).

Mount the drive/clutch.section on leak oil collection ring, page 18). Insert the Woodruff key into the seat at

- 9 -

96003-02.06-Gb

Capacity regulation

The 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 a thermostat 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.by the thermostat by a thermostat or pressostat. During regulated operation the solenoid is energized and

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 . The capacity of the compressor is still approx. % and 66 %. Further information together the description of the working principle of the solenoid valve is contained in 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) . (4) with the washer (5).

Unscrew the valve body (2).nut (3), pull out the solenoid (4) with the washer (5) . Check the valve body

Check the valve body (2) for damages and whether the piston moves feerly. If necessary, replace the complete valve body (2).(4) with the washer (5) . Unscrew the valve body (2). Installation : Screw on the

Installation:

Screw on the valve (2) with the enclosed new O-ring () and tighten it . () and tighten it.

Push on the washer ( 5 ) and the solenoid (4) and fasten . them with the fixing nut (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.on the washer ( 5 ) and the solenoid (4) and fasten . them with the

- 20 -

 4 5 2  Fig. 6
4
5
2
Fig. 6

0754

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

80244

FK 50/775 N

 

80244

FK 50/775 TK

80244

FK 50/460 K to FK 50/775 K

08926

   

K type Valve plate

N type and TK type Valve plates

  2 2   TOP 4 4 Safety valve 5 5 Fig. 7
2
2
TOP
4
4
Safety valve
5
5
Fig. 7
96003-02.06-Gb

- 2 -

Removal (see Fig. 7):

Unscrew the screws (1) from the cylinder cover (2) and dismount cylinder cover (2) with valve plate (4).Removal (see Fig . 7) : Remove the gasket residues from the body of the compressor.

Remove the gasket residues from the body of the compressor.(2) and dismount cylinder cover (2) with valve plate (4). Reminder: Don't let any gasket residues

Remove the gasket residues from the body of the compressor. Reminder: Don't let any gasket residues

Reminder: Don't let any gasket residues fall into the compressor.

Installation (see Fig. 7):

fall into the compressor . Installation (s ee Fig . 7): A ttention: The conversion of

Attention: The conversion of the compressor from one type of valve plate to another is 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). A ttention: Install the K type valve plate (Part no. 0 8 926 ) only 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)!the inscription "TOP" facing upwards (see Fig. 7 ). 1 4 5 11 9 8 7

observe the screw tightening torque (see Table on page 55)! 1 4 5 11 9 8
1 4 5 11 9 8 7 10 2 6 3 Fig. 8: Sequence for
1
4
5
11
9
8
7
10
2
6
3
Fig. 8: Sequence for
tightening the cylinder
cover screws
96003-02.06-Gb

- 22 -

Electromagnetic clutch

Assembly instruction for electromagnetic clutch

96003-02.06-Gb

For the drive of A/C compressors in buses, mainly electromagnetic clutches are used. The followings 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).Assembly instruction for electromagnetic Typ e LA 16 Fig. 9 Ø 48 h8 Front bearing flange

Fig. 9
Fig. 9
of the electro- magnetic clutch (see Fig. 9). Fig. 9 Ø 48 h8 Front bearing flange

Ø 48 h8

the electro- magnetic clutch (see Fig. 9). Fig. 9 Ø 48 h8 Front bearing flange Magnetic
the electro- magnetic clutch (see Fig. 9). Fig. 9 Ø 48 h8 Front bearing flange Magnetic
the electro- magnetic clutch (see Fig. 9). Fig. 9 Ø 48 h8 Front bearing flange Magnetic

Front bearing

flange

Magnetic field

Fo r fitting the solenoid (1) remove the four M8 x 25 cylinder screws (2) or fitting 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)! A ttention! Use only M8 x 25 screws! Otherwise, serious damage may occur on the Attention! Use only M8 x 25 screws! Otherwise, serious damage may occur on the electromagnetic clutch and the compressor.

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

- 2 -

96003-02.06-Gb

Reminder: Arrange the cable (8) so that it doesn't touch hot parts (e.g. protection pipe). t m a x = 105°C! ). t max = 105°C!

Remove the K-circlip (5) and the clamping screw (4) from the rotor assembly (3). Looking through 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. Screw tightening torque: 85 Nm. Install the K-circlip (5).hot parts (e.g. protection pipe ). t m a x = 105°C! Push the sheave (6)

Push the sheave (6) over the studs (9) and fasten it with zinc-coated M8 DIN 934-8 nuts (7).Screw tightening torque: 85 Nm. Install the K-circlip (5). Connect the cable (8). The connection is

Connect the cable (8). The connection is polarity-independent. Voltage ± 0% of nominal voltage . Reminder for dismounting: For dismounting the clutch apply grease ± 0% of nominal voltage. 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.

A ttention! With all other methods of removal (pressing, hammering) there is risk of damage to
A ttention! With all other methods of removal (pressing, hammering) there is risk of damage to
Fig.
Fig.

- 24 -

Compressor defects

Compressor defects

96003-02.06-Gb

Compressor 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 specific remedying of the cause of the breakdown is faciliated.

Compressor parts

Possible causes

 

Remedy

 

Symptom

Valve plates

- Liquid shocks because of liquid refrigerant or oil

Liquid shocks:

 

- Overheating of compressor

-

Check, adjust expansion valve,

Shaft seal

- Lack of oil

replace it, if necessary; check

leaking

- Standstill time too long

refrigerant charge.

- Dirt in the system

- Moisture in the system

- Too frequent starting of the compressor

- Overheating of compressor

- Check evaporator fan.

- In case the evaporator is iced-up:

Check the dimensioning of piping

(gas velocity).

- Belts vibrating excessively

Overheating of compressor (Heat

- Alignment of compressor and motor incorrect

protection thermostat switches off):

-

Check the operating conditions

Oil pump

- Lack of oil

Lack of oil:

 

- Dirt in the system

-

Dirt in the system: Changing oil,

- Moisture in the system

clean the system; install a suction

- Overheating of compressor

line filter, if necessary.

Bearings

- Lack of oil

Moisture in the system /

 

- Dirt in the system

Acid formation in the system:

- Moisture in the system

-

Dry the system through changing

- Overheating of compressor

refrigerant and oil, replace the drier;

- Overloading of compressor

install a suction line filter, if necessary.

Pistons/

- Lack of oil

 

Connecting rods

- Dirt in the system

- Overloading of compressor

- Moisture in the system

 

Compare the operating

- Overheating of compressor

conditions with the application limits.

Copper plating

- Moisture in the system

 

- Acid formation in the system

- Remove defects in belting.

 

Formation of

- Overheating of compressor

 

oil-carbon

Frequent starting and stopping of compressor:

- 25 -

Dissasembly of the compressor

Removal of the compresor from the cooling system

96003-02.06-Gb

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.

onto a container which may be used for this refrigerant. Evacuate the system including the compressor.
Evacuate the system including the compressor.

Evacuate the system including the compressor.

Evacuate the system including the compressor.
Evacuate the system including the compressor.
Evacuate the system including the compressor.
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.

discharge shut-off ports on the compressor with stoppers . D isassembly of compressor The disassembly of
discharge shut-off ports on the compressor with stoppers . D isassembly of compressor The disassembly of
discharge shut-off ports on the compressor with stoppers . D isassembly of compressor The disassembly of
discharge shut-off ports on the compressor with stoppers . D isassembly of compressor The disassembly of
discharge shut-off ports on the compressor with stoppers . D isassembly of compressor The disassembly of
discharge shut-off ports on the compressor with stoppers . D isassembly of compressor The disassembly of

Disassembly of compressor

The 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.

the exploded drawing at the end of the maintenance manual. Preparation: Necessary tools Reminder ! F

Preparation: Necessary tools

Reminder! For the removal and installation of the internal safety valve the BOCK special tool Part No. 09524 is necessary!

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

- 26 -

Step 1
Step
1

Removal of all shut-off valves and blind flanges

Part list position: 2060, 2070, 232

Tools: Spanner SW 17, Allen key 6 mm

Pos. in

parts List

220

0, 20

20, 20

2,

22, 2,

2,

Working course

Unscrew the fixing screws of shut-off valves0, 20 20, 20 2,  22, 2, 2,  Working course Remove the shut-off valves

Remove the shut-off valves and the gasketsWorking course Unscrew the fixing screws of shut-off valves Remove the suction filter and the gasket

Remove the suction filter and the gasketshut-off valves Remove the shut-off valves and the gaskets Remove the screws from the blind flange

Remove the screws from the blind flangeRemove the shut-off valves and the gaskets Remove the suction filter and the gasket Remove the

Remove the blind flange and the O-ringthe shut-off valves and the gaskets Remove the suction filter and the gasket Remove the screws

Remove the suction filter and the gasket Remove the screws from the blind flange Remove the

Fig. 2

96003-02.06-Gb
96003-02.06-Gb

- 27 -

Step 2
Step
2

Removal of the oil filter

Parts list position: 2130

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

Pos. in

parts list

Pos. in part s list 50 500 490 Working course Drain the oil from the compressor

50

500

490

Working course

Drain the oil from the compressor into a suitable containerPos. in part s list 50 500 490 Working course Unscrew the plug Remove the gasket

Unscrew the plug490 Working course Drain the oil from the compressor into a suitable container Remove the gasket

Remove the gasket500 490 Working course Drain the oil from the compressor into a suitable container Unscrew the

Unscrew the oil filter50 500 490 Working course Drain the oil from the compressor into a suitable container Unscrew

Fig. a

Unscrew the plug Remove the gasket Unscrew the oil filter Fig . a Fig . b

Fig. b

96003-02.06-Gb
96003-02.06-Gb

- 28 -

Step 3
Step
3

Removal of the cylinder cover and valve plates

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

Tools: Spanner SW 17

s ), 1940, 2900 (K-Version) Tools : S panner SW 17 In order to prevent any

In 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.

Pos. in parts list

Working course

N / TK

K

80

950

Unscrew the cylinder covers screws80 950

70, 70

940, 90

Remove the cylinder cover and the upper gasket of the valve plate70, 70 940, 90

60, 50

920, 90

Remove the valve plate and the lower gasket of the valve plate60, 50 920, 90

Fig. 4a

920, 90 Remove the valve plate and the lower gasket of the valve plate Fig .
Fig. 4b 96003-02.06-Gb
Fig. 4b
96003-02.06-Gb

- 29 -

Step 4
Step
4

Removal of the shaft seal

Parts list position: 2010

Tools: Oil collection container, Allen key 6 mm

: 2010 Tools : Oil collection container, Allen key 6 mm For detailed description, see also

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

Pos. in

parts list

Working course

20

750

200

Place the oil collection container under the shaft seal area

Place the oil collection container under the shaft seal area If available r emove the leak

If available remove the leak oil collection device from the bearing flange

Unscrew the cylinder screws

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

Remove the shaft seal cover, the guide ring, the O-ring and the spring.cover is under spring tension! It may jump out by itself. Fig . 5a - 0

Fig. 5a

seal cover, the guide ring, the O-ring and the spring. Fig . 5a - 0 -
seal cover, the guide ring, the O-ring and the spring. Fig . 5a - 0 -

- 0 -

Fig. 5b Only to model code 0 96003-02.06-Gb
Fig. 5b
Only to model
code 0
96003-02.06-Gb

96003-02.06-Gb

Step 5
Step
5

Removal of oil pump

Parts list position: 2020

Tools: Spanner 13

Pos. in

Working course

parts list

40

Unscrew the screws40

460, 470

Remove the oil pump and gasket460, 470

Fig. 6a

Fig. 6b

Fig . 6a Fig . 6b
Fig . 6a Fig . 6b

- -

Step Removal of the base plate 6 Parts list position: 20 Tools: Oil collection pan,
Step
Removal of the base plate
6
Parts list position: 20
Tools: Oil collection pan, spanner 13
Pos. in
Working course
parts list
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
the screws from the baseplate 20,0 Remove the baseplate and the gasket Fig . 7a Fig.

Fig. 7a

the screws from the baseplate 20,0 Remove the baseplate and the gasket Fig . 7a Fig.
Fig. 7b 96003-02.06-Gb
Fig. 7b
96003-02.06-Gb

- 2 -

Step 7
Step
7

Disassembly of the connecting rods from the crankshaft

Parts list position: 2100

Tools: Spanner 10

Part s list position : 2100 Tools : S panner 10 In order to prevent any

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

Pos. in

parts list

Working course

Unscrew the hexagon head screws from the connecting rod cap.wipe-resistant fashion. Pos. in part s list Working course Mark the connecting rod cap and remove

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.the piston and connecting rod upwards until the stop . Remove the piston rings . Fig.

Fig. 8a Fig. 8b 96003-02.06-Gb
Fig. 8a
Fig. 8b
96003-02.06-Gb

- -

Step Removal of the front bearing flange 8 Parts list position: 2140 Tools: Allen key
Step
Removal of the front bearing flange
8
Parts list position: 2140
Tools: Allen key 6 mm
Pos. in
Working course
parts list
750
Unscrew the screws
70, 740, 745
Remove the front bearing flange, gasket, and O-ring

Fig. 9a

the screws 70, 740, 745 Remove the front bearing flange, gasket, and O-ring Fig . 9a

- 4 -

Fig. 9b

96003-02.06-Gb
96003-02.06-Gb
Step Removal of the crankshaft 9 Parts list position: 2050 Tools: — Pos. in Working
Step
Removal of the crankshaft
9
Parts list position: 2050
Tools: —
Pos. in
Working course
parts list
Pull out the crankshaft carefully in direction of the front bearing flange

Fig. 20a

list Pull out the crankshaft carefully in direction of the front bearing flange Fig . 20a

Fig. 20b

96003-02.06-Gb
96003-02.06-Gb

- 5 -

Step
Step

Removal of the pistons and connecting rods

10 Parts list position: 2040

Tools: Seeger circlip plier Form C 8-13 mm

Pos. in

parts list

Working course

280

270

Mark the piston and the cylinder bore belonging togetherForm C 8-13 mm Pos. in part s list Working course 280 270 Remove the piston

Remove the piston / connecting rod in direction of baseplate270 Mark the piston and the cylinder bore belonging together Remove the seeger circlip of the

Remove the seeger circlip of the piston pinsRemove the piston / connecting rod in direction of baseplate Push the piston pins out of

Push the piston pins out of the pistons and remove pistonsof baseplate Remove the seeger circlip of the piston pins In order to prevent mix-ups, fasten

In order to prevent mix-ups, fasten and connecting rodPush the piston pins out of the pistons and remove pistons caps to the connecting rods

caps to the connecting rods again.

Fig. 2a Fig. 2b 96003-02.06-Gb
Fig. 2a
Fig. 2b
96003-02.06-Gb

- 6 -

Step 11
Step
11

Removal of the remaining parts

Parts list position: -

Tools: Spanner 13, 14, 30 o. 36

Pos. in

Working course

parts list

570

Dismount the sight glass (use SW 3 0 or 3 6 spanner according to the type) 30 or 36 spanner according to the type)

590

Remove the O-ring590

520

Remove the 1 /8‘‘ NPTF screws520

50, 500

Remove the M22 x 1,5 screws with gasket50, 500

Fig. 22

96003-02.06-Gb
96003-02.06-Gb

- 7 -

Step
Step

Removal of the roller bearings

12 Parts list position: 310

Tools: Pulling apparatus

Pos. in

parts list

Working course

0, 70

With the pulling apparatus, pull out the roller bearing from the front bearing flange

pull out the roller bearing from the front bearing flange Use oil, if necessary! If no

Use oil, if necessary!

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.

0

2

the roller bearing can be pressed out by hand. 0 2 CAUTION! Parts are hot! Use

CAUTION! Parts are hot! Use protective gloves!

Press out the roller bearing from the compressor body.

Take out the tolerance ring, if there is any. Use oil, if necessary!

- 8 -

body. Take out the tolerance ring, if there is any. Use oil, if necessary! - 8
body. Take out the tolerance ring, if there is any. Use oil, if necessary! - 8
96003-02.06-Gb
96003-02.06-Gb

Fig. 2a

Fig. 2b
Fig. 2b

Checking the compressor parts

Checking compressor parts for damages / wear

Before re-using removed compressor parts we recommend that they be checked for usibility.parts Checking compressor parts for damages / wear The wear limits listed below should be taken

The wear limits listed below should be taken into considerationparts we recommend that they be checked for usibility. Wear limits maxim um allowable bearing play

wear limits listed below should be taken into consideration Wear limits maxim um allowable bearing play
wear limits listed below should be taken into consideration Wear limits maxim um allowable bearing play
wear limits listed below should be taken into consideration Wear limits maxim um allowable bearing play
wear limits listed below should be taken into consideration Wear limits maxim um allowable bearing play

Wear limits

maximum allowable bearing play:

.) Piston-cylinder bore

0, mm

2.) Connecting rod-piston pins 0,03 mm

.) Crankshaft connecting rod bearing 0, 08 mm

0,03 mm  .) Crankshaft connecting rod bearing 0, 08 mm Fig . 24 Other components

Fig. 24

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

Cylinder liners D The cylinder liners should not have any visible damages into the piston movement area. 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 The bearing surfaces should not have any damages. The oil channels should be clean so that. an unhindered oil flow is ensured.

Fig. 25 Clean the oil channels with compressed air and check for passage. 96003-02.06-Gb
Fig. 25
Clean the oil channels with compressed
air and check for passage.
96003-02.06-Gb

- 9 -

Pistons There should be no visible damages on the piston crown and the piston walls. The 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 There should be no damages on bearing surfaces. The connecting rod shank must be straight.

correct faulty
correct
faulty

Fig. 26

Valve plates Suction and pressure lamella mut be undamaged and un-deformed. The sealing surfaces must alve 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 replaced completely. Single lamella are not available.

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

Fig. 27 96003-02.06-Gb
Fig. 27
96003-02.06-Gb

- 40 -

96003-02.06-Gb

Oil filter /Suction filter The filter screen must be in an undamaged condition . Dirt and residues have to 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 al safety valve (Use Bock special tool, Part No. 09524, use until A013 Spanner 22 from A015) The internal safety valve must be replaced after it has operated.

Fig. 28

valve must be replaced after it has operated . Fig . 28 S afety valve In

Safety valve

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

Valve plates alve plates

Piston ringsthe replacement of the following assemblies: V alve plates Shaft seal Roller bearings Thus, concealed defects

Shaft sealof the following assemblies: V alve plates Piston rings Roller bearings Thus, concealed defects of parts

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

- 4 -

96003-02.06-Gb

9600 3 -02.06- Gb 310

310

9600 3 -02.06- Gb 310

9600 3 -02.06- Gb 310

9600 3 -02.06- Gb 310

Step

Fitting the sight glass, connection screws, safety valve

2

Parts list position: -

Tools: Spanner 13, 14, 30 o. 36

list position : - Tools: Spanner 13, 14, 30 o. 36 Observe the screw tightening torques

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

Pos. in

Working course

parts list

570, 590

Screw on the sight glass with oiled O-ring to the compressor body.570, 590

520

Screw on the 1/8‘‘ NPTF screws.520

500, 50

Screw on the M22 x 1,5 screws with gasket.500, 50

500, 50 Screw on the M22 x 1,5 screws with gasket. F i g .

Fig. 0a

Fig. 0b

500, 50 Screw on the M22 x 1,5 screws with gasket. F i g .
Fig. 0c 96003-02.06-Gb
Fig. 0c
96003-02.06-Gb

- 4 -

Assembly the pistons with the connectiong rods (in the reverse sequence of dis- assembly of
Assembly the pistons with the connectiong rods (in the reverse sequence of dis-
assembly of compressor, Step 7)
.
.
96003-02.06-Gb
96003-02.06-Gb

96003-02.06-Gb

9600 3 -02.06- Gb

9600 3 -02.06- Gb

9600 3 -02.06- Gb

96003-02.06-Gb

9600 3 -02.06- Gb

9600 3 -02.06- Gb

96003