GEA Bock FK40/755 User manual

1
09665-01.2019-Gb
GEA Bock FK40
Maintenance manual
09665-01.2019-Gb
Translation of the original instructions
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 FKX40/755 K
FKX40/390 N FKX40/470 N FKX40/560 N FKX40/655 N
FKX40/390 TK FKX40/470 TK FKX40/560 TK FKX40/655 TK

2
09665-01.2019-Gb
About these instructions
Read these instructions before assembly and before using the
compressor. This will avoid misunderstandings and prevent dam-
age. Improper assembly and use of the compressor can result
in serious or fatal injury.
Observe the safety instructions contained in these instructions.
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
Contents Page
1 Introduction 3
2 Safety 3
3 Product description 5
4 Technical data 8
5 Maintenance 9
6 Fault diagnosis 11
7 Installation of service kits 15
8 Electromagnetic coupling 21
9 Compressor defects 23
10 Disassembly of the compressor 24
11 Checking the compressor parts 37
12 Assembly of compressor 40
13 Parts list 54
14 Exploded drawing 58
Contact
GEA Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Telephone [phone]
Fax [phone]
[email protected]
www.gea.com

3
09665-01.2019-Gb
This maintenance manual is intended to make the repair and maintenance of the FK40 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.
Note:
For replacing components GEA 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 efciency
beforehand.
The maintenance manual describes the standard type of the FK40 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.
1 I Introduction
Identication of safety instructions
Safety instructions
Target 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 documentation means that they are capa-
ble 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 elec-
trotechnical instruction and who have proof of their qualification are also permitted to carry out the work.
2 I Safety
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.

4
09665-01.2019-Gb
2 I Safety
General safety instructions
DANGER Risk of electric shock
• Before you carry out any repair work, disconnect the compressor from the electricity network
• Turn the main switch to "O" (OFF)
• Secure the main switch against an unauthorized restart
WARNING • Refrigerating compressors are pressurised machines and therefore require particular
caution and care in handling.
• Only qualied personnel are allowed to perform any work on refrigeration compressors.
• The national safety regulations, accident prevention regulations, technical rules and specic
regulations (EN 378 and others) must be taken into account absolutely.
• Never put the safety switch out of action!
• Prior to commissioning, check whether all the components installed by the user have been
fastened expertly and connected pressure-tight with the compressor (e.g. piping, plugs, union
nuts, replaced components etc.).
• Before commissioning, evacuate the refrigerant systems carefully including the compressor and
afterwards charge refrigerant.
• Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.
• Do not start the compressor in vacuum. Operate the compressor only when the system is charged.
• Risk of burns! Depending on the operating conditions, surface temperatures of over 60 °C
on the pressure side or below 0 °C on the suction side can be reached.
• The maximum permissible overpressure must not be exceeded, even for testing purposes.
• Danger of injury! Never grab rotating parts during operation!

5
09665-01.2019-Gb
3 I Product description
Product description
Series FK40 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 application range where operational safety and
efciency are concerned.
More features:
Compact 4-cylinder compressor in V design
Wear resistant and long-lasting engine
Five 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
Name plate (example)
1. Type designation 4. Machine number
2. Displacement at 1450 rpm 5. Factory-lled oil type
3. ND(LP): max. permissible operating pressure low pressure side
HD(HP): max. permissible operating pressure high pressure side
1
2
3
4
5
AR12345A020
19/28bar
GEA Bock GmbH
72636 Frickenhausen, Germany
Observe the limits of
application diagrams!
}
Type key (example)
Explanation of the type designation
FK 40 655NX /
Designs
Swept volume
Size
Ester oil charge (HFC refrigerant, e.g. R134a, R407C)
Series
Oil:

6
09665-01.2019-Gb
15
16
17
1
2
3
5
6
8
9
10
4
11
12
13
14
18
7
3 I Product description
Main and functional parts
1. Discharge shut-off valve
2. Cylinder cover
3. Valve plate
4. Compressor housing
5. Location hole for tting magnetic coupling
6. Integrated leak oil collector
7. Leak oil drain hose
8. Shaft seal
9. Shaft end
10. Baseplate
11. Connection thermal protection thermostat
12. Oil lling plug
13. Oil sight glasses (2x)
14. Oil drain plug
15. Suction line valve
16. Oil pump
17. Oil drain plug / Oil lter
18. Name plate

7
09665-01.2019-Gb
Shaft end Leak oil drain hose
Dimensions in mm
ca.50
168,5
ca.170
8x M8 72 130
6x M8
A5x9 DIN 6888
1:5
110
98
h8
50
90
100
148
54
2
40
74
M12x28
66
z
Alt.bezug /
F
E
D
C
A
F
E
D
C
41
A
B
5
6
7
8
1
2
34
5
6
7
über / above
bis / up to
Numéro de plan:
B
32
088314
8
Freigabe / Approved
Extranet:
B
-
Alt.supply:
Maßstab /
Der Lieferant muss sicherstellen, dass die Ware
in einwandfreiem Zustand angeliefert wird
(Korrosionsschutz, Verpackung für sicheren
Ra Rz
Allgemeintoleranzen / General tolerances
Drawing-No.
Zeichn.-Nr. / Drawing no. /
Dok-ID:
±0.1
yxw uts
packaging for safe transportation).
model or design.
in proper conditions (corrosion prevention,
DIN ISO 2768-mK
Ersatz für / replacement for:
The supplier has to ensure the delivery of parts
Transport).
prohibited. Offenders will be held liable for the Dimension Passung / Clearance
Baumustergeprüft / Type examination:
--
K.-Auftrag / C.-Task:
Projektleiter / Project leader:
120
400
±0.5
0.5
6
GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
-
-
-
Unbemaßte Radien / Undimensioned radii:
-
Bearb. / EditedDatum / Date
payment of damages. All rights reserved in the event Änd.-Nr. / Mod-No.
Werkstoff (Zeile 2+3 alternativ) /
Base part, Raw part:
-
-
Geprüft / Appr.
NameDatum / Date
27.07.07
Material (Line 2+3 alternative):
Ausgangsteil, Rohteil /
Workpiece edges
DIN ISO 13715
Erstellt / Drawn
Geprüft / Verified Schaich
Schnizler
1/3
Oberflächenbehandlung, Härte / Treatment of surface, Hardness:
27.02.08
Werkstückkanten /
Page:
400 Benennung / Description:
±0.8
1000
306
31,2
±0.3
12030
-
Blatt /
±0.2
of the grant of a patent, utility /
DIN EN ISO 1302
Zust. / Rev.
Gußtoleranzen / General casting tolerances:
Gewicht / Weight: (kg)
Zeichnungs-Nr. /
Indication of surface texture
Scale:
%
C - FK40/655 N
Rz 25
Rz 160
25 0,05 Rz 1,6 0,3
0,7
1,6
2Rz 16
6,3 Rz 63 Rz 6,3
Rz 12,5 Status:
-
-
in Bearbeitung (CAD)
Nein / No 13983 .0
19.04.12
10.08.12
26.02.13
Gneiting
Gneiting
Zuder
0d | Betrifft Blatt 3
0e | Extranet B hinzugefügt, Ansicht Sickenrichtung hinzugefügt (Bl.2)
0f | Gussänderungen, Betrifft Blatt 2
8251
8266 + 8351
8510,8640
Layh
Schaich
Schaich
K - FK40/655 N
-
08511.
Kunde / Customer:
-
Weitergabe sowie Vervielfältigung dieses Dokuments,
Verwertung und Mitteilung seines Inhalts sind ver-
boten, soweit nicht ausdrücklich gestattet. Zuwider-
handlungen verpflichten zu Schadenersatz. Alle
Rechte für den Fall der Patent-, Gebrauchsmuster-
oder Geschmacksmustereintragung vorbehalten.
The reproduction, distribution and utilization of this
document as well as the communication of its
contents to others without express authorization is
Maß
Oberflächenangaben /
Teile-Nr. /
Part-No.
( ) K Ausführung
Fahrzeugverdichter / Vehicle Compressor / Compresseur pour automobiles
( ) K version Dimensions in mm
Cotes en mm
Maße in mmÄnderungen vorbehalten
Subject to change without notice
Sous réserve de toutes modifications
Sight glass
( ) Version K
1.0851-13983.0 0f
SchauglasK
1) = Ne possible qu 'ex usine
(L)* = Raccord à braser
1) = Only possible ex factory
(L)* = Brazing connection
L
1) = Nur ab Werk möglich
Raccord opt. vanne d'arrêt d'aspiration
Anschluß Wärmeschutzthermostat Connection thermal protection thermostat 2 x 1 1/8 “ – 18 UNEF Raccord de thermostat de protection thermique
Voyant Zoll
(L)* = Lötanschluß
Zoll
Massenschwerpunkt
-
1/8“ NPTF
M
Centre of gravity
Ölsieb Oil filter Filtre à huile mm M22x1,5
SV1 Opt. Anschlußmöglichkeit Saugabsperrventil
Centre de gravité
-Opt. connection suction line valve
Anschlüsse Connections Raccords FK(X)40/390 FK(X)40/470 FK(X)40/560 FK(X)40/655
SV Saugabsperrventil, Rohr (L)* Suction line valve, tube (L)* Vanne d’arrêt d’aspiration, de tuyau (L)* mm-Zoll 28 – 1 1/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “
DV Druckabsperrventil, Rohr (L)* Discharge line valve, tube (L)* Vanne d’arrêt de refoulement, de tuyau (L)* mm-Zoll 22 – 7/8 “ 28 – 1 1/8 “ 28 – 1 1/8 “ 35 – 1 3/8 “
A Anschluß Saugseite, nicht absperrbar Connection suction side, not lockable Raccord côté aspiration, non obturable Zoll 1/8“ NPTF
A1 Anschluß Saugseite, absperrbar Connection suction side, lockable Raccord côté aspiration, obturable Zoll 7/16“ UNF
B Anschluß Druckseite, nicht absperrbar Connection discharge side, not lockable Raccord côté refoulement, non obturable Zoll 1/8“ NPTF
B1 Anschluß Druckseite, absperrbar Connection discharge side, lockable Raccord côté refoulement, obturable Zoll 7/16“ UNF
C Anschluß Öldrucksicherheitsschalter OIL Connection oil pressure safety switch OIL Raccord pressostat de sécurité d’huile OIL Zoll 1/8“ NPTF
D Anschluß Öldrucksicherheitsschalter LP Connection oil pressure safety switch LP Raccord pressostat de sécurité d’huile LP Zoll 1/8“ NPTF
E Anschluß Öldruckmanometer Connection oil pressure gauge Raccord du manomètre de pression d’huile Zoll 1/8“ NPTF
F Ölablaß Oil drain Vidange d’huile Zoll 1/4“ NPTF
G Opt. Anschlußmöglichkeit Ölsumpfheizung 1) Opt. connection oil sump heater 1) Raccord opt. chauffage de carter d'huile 1) - -
H Stopfen Ölfüllung Oil charge plug Bouchon de remplissage d’huile Zoll 1/4“ NPTF
Typ / type Teile Nr. / part no. Typ / type Teile Nr. / part no. Typ / type Teile Nr. / part no.
FK(X)40/390 N 13977 (13985) FK(X)40/390 K 13978 (13986) FK(X)40/390 TK 14339 (14343)
FK(X)40/470 N 13979 (13987) FK(X)40/470 K 13980 (13988) FK(X)40/470 TK 14340 (14344)
FK(X)40/560 N 13981 (13989) FK(X)40/560 K 13982 (13990) FK(X)40/560 TK 14341 (14345)
FK(X)40/655 N 13983 (13991) FK(X)40/655 K 13984 (13992) FK(X)40/655 TK 14342 (14346)
F
DV BB1
L
H
K
D
Y
130
108,5
253
4xM10x21 LK 170
344
ca.385
Y
Lecköl-Ablass Schlauch
Leak oil drain hose
Tuyau d'évacuation d'huile de fuite
A1
C/E
SV
M
A
SV1
G210
ca.370
145
4x 13
329
232
ca.319 (325)
ca.50
168,5
ca.170
8x M8 72 130
6x M8
A5x9 DIN 6888
1:5
110
98
h8
50
90
100
148
54
2
40
74
M12x28
66
z
Alt.bezug /
F
E
D
C
A
F
E
D
C
41
A
B
5
6
7
8
1
2
34
5
6
7
über / above
bis / up to
Numéro de plan:
B
32
088314
8
Freigabe / Approved
Extranet:
B
-
Alt.supply:
Maßstab /
Der Lieferant muss sicherstellen, dass die Ware
in einwandfreiem Zustand angeliefert wird
(Korrosionsschutz, Verpackung für sicheren
Ra Rz
Allgemeintoleranzen / General tolerances
Drawing-No.
Zeichn.-Nr. / Drawing no. /
Dok-ID:
±0.1
yxwuts
packaging for safe transportation).
model or design.
in proper conditions (corrosion prevention,
DIN ISO 2768-mK
Ersatz für / replacement for:
The supplier has to ensure the delivery of parts
Transport).
prohibited. Offenders will be held liable for the Dimension Passung / Clearance
Baumustergeprüft / Type examination:
--
K.-Auftrag / C.-Task:
Projektleiter / Project leader:
120
400
±0.5
0.5
6
GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
-
-
-
Unbemaßte Radien / Undimensioned radii:
-
Bearb. / EditedDatum / Date
payment of damages. All rights reserved in the event Änd.-Nr. / Mod-No.
Werkstoff (Zeile 2+3 alternativ) /
Base part, Raw part:
-
-
Geprüft / Appr.
NameDatum / Date
27.07.07
Material (Line 2+3 alternative):
Ausgangsteil, Rohteil /
Workpiece edges
DIN ISO 13715
Erstellt / Drawn
Geprüft / Verified Schaich
Schnizler
1/3
Oberflächenbehandlung, Härte / Treatment of surface, Hardness:
27.02.08
Werkstückkanten /
Page:
400 Benennung / Description:
±0.8
1000
306
31,2
±0.3
12030
-
Blatt /
±0.2
of the grant of a patent, utility /
DIN EN ISO 1302
Zust. / Rev.
Gußtoleranzen / General casting tolerances:
Gewicht / Weight: (kg)
Zeichnungs-Nr. /
Indication of surface texture
Scale:
%
C - FK40/655 N
Rz 25
Rz 160
25 0,05 Rz 1,6 0,3
0,7
1,6
2Rz 16
6,3 Rz 63 Rz 6,3
Rz 12,5 Status:
-
-
in Bearbeitung (CAD)
Nein / No 13983 .0
19.04.12
10.08.12
26.02.13
Gneiting
Gneiting
Zuder
0d | Betrifft Blatt 3
0e | Extranet B hinzugefügt, Ansicht Sickenrichtung hinzugefügt (Bl.2)
0f | Gussänderungen, Betrifft Blatt 2
8251
8266 + 8351
8510,8640
Layh
Schaich
Schaich
K - FK40/655 N
-
08511.
Kunde / Customer:
-
Weitergabe sowie Vervielfältigung dieses Dokuments,
Verwertung und Mitteilung seines Inhalts sind ver-
boten, soweit nicht ausdrücklich gestattet. Zuwider-
handlungen verpflichten zu Schadenersatz. Alle
Rechte für den Fall der Patent-, Gebrauchsmuster-
oder Geschmacksmustereintragung vorbehalten.
The reproduction, distribution and utilization of this
document as well as the communication of its
contents to others without express authorization is
Maß
Oberflächenangaben /
Teile-Nr. /
Part-No.
( ) K Ausführung
Fahrzeugverdichter / Vehicle Compressor / Compresseur pour automobiles
( ) K version Dimensions in mm
Cotes en mm
Maße in mmÄnderungen vorbehalten
Subject to change without notice
Sous réserve de toutes modifications
Sight glass
( ) Version K
1.0851-13983.0 0f
SchauglasK
1) = Ne possible qu 'ex usine
(L)* = Raccord à braser
1) = Only possible ex factory
(L)* = Brazing connection
L
1) = Nur ab Werk möglich
Raccord opt. vanne d'arrêt d'aspiration
Anschluß Wärmeschutzthermostat Connection thermal protection thermostat 2 x 1 1/8 “ – 18 UNEF Raccord de thermostat de protection thermique
Voyant Zoll
(L)* = Lötanschluß
Zoll
Massenschwerpunkt
-
1/8“ NPTF
M
Centre of gravity
Ölsieb Oil filter Filtre à huile mm M22x1,5
SV1 Opt. Anschlußmöglichkeit Saugabsperrventil
Centre de gravité
-Opt. connection suction line valve
Anschlüsse Connections Raccords FK(X)40/390 FK(X)40/470 FK(X)40/560 FK(X)40/655
SV Saugabsperrventil, Rohr (L)* Suction line valve, tube (L)* Vanne d’arrêt d’aspiration, de tuyau (L)* mm-Zoll 28 – 1 1/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “
DV Druckabsperrventil, Rohr (L)* Discharge line valve, tube (L)* Vanne d’arrêt de refoulement, de tuyau (L)* mm-Zoll 22 – 7/8 “ 28 – 1 1/8 “ 28 – 1 1/8 “ 35 – 1 3/8 “
A Anschluß Saugseite, nicht absperrbar Connection suction side, not lockable Raccord côté aspiration, non obturable Zoll 1/8“ NPTF
A1 Anschluß Saugseite, absperrbar Connection suction side, lockable Raccord côté aspiration, obturable Zoll 7/16“ UNF
B Anschluß Druckseite, nicht absperrbar Connection discharge side, not lockable Raccord côté refoulement, non obturable Zoll 1/8“ NPTF
B1 Anschluß Druckseite, absperrbar Connection discharge side, lockable Raccord côté refoulement, obturable Zoll 7/16“ UNF
C Anschluß Öldrucksicherheitsschalter OIL Connection oil pressure safety switch OIL Raccord pressostat de sécurité d’huile OIL Zoll 1/8“ NPTF
D Anschluß Öldrucksicherheitsschalter LP Connection oil pressure safety switch LP Raccord pressostat de sécurité d’huile LP Zoll 1/8“ NPTF
E Anschluß Öldruckmanometer Connection oil pressure gauge Raccord du manomètre de pression d’huile Zoll 1/8“ NPTF
F Ölablaß Oil drain Vidange d’huile Zoll 1/4“ NPTF
G Opt. Anschlußmöglichkeit Ölsumpfheizung 1) Opt. connection oil sump heater 1) Raccord opt. chauffage de carter d'huile 1) - -
H Stopfen Ölfüllung Oil charge plug Bouchon de remplissage d’huile Zoll 1/4“ NPTF
Typ / type Teile Nr. / part no. Typ / type Teile Nr. / part no. Typ / type Teile Nr. / part no.
FK(X)40/390 N 13977 (13985) FK(X)40/390 K 13978 (13986) FK(X)40/390 TK 14339 (14343)
FK(X)40/470 N 13979 (13987) FK(X)40/470 K 13980 (13988) FK(X)40/470 TK 14340 (14344)
FK(X)40/560 N 13981 (13989) FK(X)40/560 K 13982 (13990) FK(X)40/560 TK 14341 (14345)
FK(X)40/655 N 13983 (13991) FK(X)40/655 K 13984 (13992) FK(X)40/655 TK 14342 (14346)
F
DV BB1
L
H
K
D
Y
130
108,5
253
4xM10x21 LK 170
344
ca.385
Y
Lecköl-Ablass Schlauch
Leak oil drain hose
Tuyau d'évacuation d'huile de fuite
A1
C/E
SV
M
A
SV1
G210
ca.370
145
4x 13
329
232
ca.319 (325)
3 I Product description
Dimension drawing
Connections
A Connection suction side, not lockable 1/8“ NPTF
A1 Connection suction side, lockable 7/16“ UNF
B Connection discharge side, not lockable 1/8“ NPTF
B1 Connection discharge side, lockable 7/16“ UNF
C Connection oil pressure safety switch OIL 1/8“ NPTF
D Connection oil pressure safety switch LP 1/8“ NPTF
E Connection oil pressure gauge 1/8“ NPTF
F Oil drain 1/4“ NPTF
G Opt. connection for oil sump heater 1) - -
H Oil charge plug 1/4“ NPTF
K Sight glass 2 x 1 1/8“ NPTF
L Connection thermal protection thermostat 1/8“ NPTF
MOil lter M22x1.5
SV1 Optional connection for suction line valve - -
1) = No connection available as standard.
Available on request (Connection M22 x 1,5)
ca.50
168,5
ca.170
8x M8 72 130
6x M8
A5x9 DIN 6888
1:5
110
98
h8
50
90
100
148
54
2
40
74
M12x28
66
z
Alt.bezug /
F
E
D
C
A
F
E
D
C
41
A
B
5
6
7
8
1
2
34
5
6
7
über / above
bis / up to
Numéro de plan:
B
32
088314
8
Freigabe / Approved
Extranet:
B
-
Alt.supply:
Maßstab /
Der Lieferant muss sicherstellen, dass die Ware
in einwandfreiem Zustand angeliefert wird
(Korrosionsschutz, Verpackung für sicheren
Ra Rz
Allgemeintoleranzen / General tolerances
Drawing-No.
Zeichn.-Nr. / Drawing no. /
Dok-ID:
±0.1
yxw uts
packaging for safe transportation).
model or design.
in proper conditions (corrosion prevention,
DIN ISO 2768-mK
Ersatz für / replacement for:
The supplier has to ensure the delivery of parts
Transport).
prohibited. Offenders will be held liable for the Dimension Passung / Clearance
Baumustergeprüft / Type examination:
--
K.-Auftrag / C.-Task:
Projektleiter / Project leader:
120
400
±0.5
0.5
6
GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
-
-
-
Unbemaßte Radien / Undimensioned radii:
-
Bearb. / EditedDatum / Date
payment of damages. All rights reserved in the event Änd.-Nr. / Mod-No.
Werkstoff (Zeile 2+3 alternativ) /
Base part, Raw part:
-
-
Geprüft / Appr.
NameDatum / Date
27.07.07
Material (Line 2+3 alternative):
Ausgangsteil, Rohteil /
Workpiece edges
DIN ISO 13715
Erstellt / Drawn
Geprüft / Verified Schaich
Schnizler
1/3
Oberflächenbehandlung, Härte / Treatment of surface, Hardness:
27.02.08
Werkstückkanten /
Page:
400 Benennung / Description:
±0.8
1000
306
31,2
±0.3
12030
-
Blatt /
±0.2
of the grant of a patent, utility /
DIN EN ISO 1302
Zust. / Rev.
Gußtoleranzen / General casting tolerances:
Gewicht / Weight: (kg)
Zeichnungs-Nr. /
Indication of surface texture
Scale:
%
C - FK40/655 N
Rz 25
Rz 160
25 0,05 Rz 1,6 0,3
0,7
1,6
2Rz 16
6,3 Rz 63 Rz 6,3
Rz 12,5 Status:
-
-
in Bearbeitung (CAD)
Nein / No 13983 .0
19.04.12
10.08.12
26.02.13
Gneiting
Gneiting
Zuder
0d | Betrifft Blatt 3
0e | Extranet B hinzugefügt, Ansicht Sickenrichtung hinzugefügt (Bl.2)
0f | Gussänderungen, Betrifft Blatt 2
8251
8266 + 8351
8510,8640
Layh
Schaich
Schaich
K - FK40/655 N
-
08511.
Kunde / Customer:
-
Weitergabe sowie Vervielfältigung dieses Dokuments,
Verwertung und Mitteilung seines Inhalts sind ver-
boten, soweit nicht ausdrücklich gestattet. Zuwider-
handlungen verpflichten zu Schadenersatz. Alle
Rechte für den Fall der Patent-, Gebrauchsmuster-
oder Geschmacksmustereintragung vorbehalten.
The reproduction, distribution and utilization of this
document as well as the communication of its
contents to others without express authorization is
Maß
Oberflächenangaben /
Teile-Nr. /
Part-No.
( ) K Ausführung
Fahrzeugverdichter / Vehicle Compressor / Compresseur pour automobiles
( ) K version Dimensions in mm
Cotes en mm
Maße in mmÄnderungen vorbehalten
Subject to change without notice
Sous réserve de toutes modifications
Sight glass
( ) Version K
1.0851-13983.0 0f
SchauglasK
1) = Ne possible qu 'ex usine
(L)* = Raccord à braser
1) = Only possible ex factory
(L)* = Brazing connection
L
1) = Nur ab Werk möglich
Raccord opt. vanne d'arrêt d'aspiration
Anschluß Wärmeschutzthermostat Connection thermal protection thermostat 2 x 1 1/8 “ – 18 UNEF Raccord de thermostat de protection thermique
Voyant Zoll
(L)* = Lötanschluß
Zoll
Massenschwerpunkt
-
1/8“ NPTF
M
Centre of gravity
Ölsieb Oil filter Filtre à huile mm M22x1,5
SV1 Opt. Anschlußmöglichkeit Saugabsperrventil
Centre de gravité
-Opt. connection suction line valve
Anschlüsse Connections Raccords FK(X)40/390 FK(X)40/470 FK(X)40/560 FK(X)40/655
SV Saugabsperrventil, Rohr (L)* Suction line valve, tube (L)* Vanne d’arrêt d’aspiration, de tuyau (L)* mm-Zoll 28 – 1 1/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “
DV Druckabsperrventil, Rohr (L)* Discharge line valve, tube (L)* Vanne d’arrêt de refoulement, de tuyau (L)* mm-Zoll 22 – 7/8 “ 28 – 1 1/8 “ 28 – 1 1/8 “ 35 – 1 3/8 “
A Anschluß Saugseite, nicht absperrbar Connection suction side, not lockable Raccord côté aspiration, non obturable Zoll 1/8“ NPTF
A1 Anschluß Saugseite, absperrbar Connection suction side, lockable Raccord côté aspiration, obturable Zoll 7/16“ UNF
B Anschluß Druckseite, nicht absperrbar Connection discharge side, not lockable Raccord côté refoulement, non obturable Zoll 1/8“ NPTF
B1 Anschluß Druckseite, absperrbar Connection discharge side, lockable Raccord côté refoulement, obturable Zoll 7/16“ UNF
C Anschluß Öldrucksicherheitsschalter OIL Connection oil pressure safety switch OIL Raccord pressostat de sécurité d’huile OIL Zoll 1/8“ NPTF
D Anschluß Öldrucksicherheitsschalter LP Connection oil pressure safety switch LP Raccord pressostat de sécurité d’huile LP Zoll 1/8“ NPTF
E Anschluß Öldruckmanometer Connection oil pressure gauge Raccord du manomètre de pression d’huile Zoll 1/8“ NPTF
F Ölablaß Oil drain Vidange d’huile Zoll 1/4“ NPTF
G Opt. Anschlußmöglichkeit Ölsumpfheizung 1) Opt. connection oil sump heater 1) Raccord opt. chauffage de carter d'huile 1) - -
H Stopfen Ölfüllung Oil charge plug Bouchon de remplissage d’huile Zoll 1/4“ NPTF
Typ / type Teile Nr. / part no. Typ / type Teile Nr. / part no. Typ / type Teile Nr. / part no.
FK(X)40/390 N 13977 (13985) FK(X)40/390 K 13978 (13986) FK(X)40/390 TK 14339 (14343)
FK(X)40/470 N 13979 (13987) FK(X)40/470 K 13980 (13988) FK(X)40/470 TK 14340 (14344)
FK(X)40/560 N 13981 (13989) FK(X)40/560 K 13982 (13990) FK(X)40/560 TK 14341 (14345)
FK(X)40/655 N 13983 (13991) FK(X)40/655 K 13984 (13992) FK(X)40/655 TK 14342 (14346)
F
DV BB1
L
H
K
D
Y
130
108,5
253
4xM10x21 LK 170
344
ca.385
Y
Lecköl-Ablass Schlauch
Leak oil drain hose
Tuyau d'évacuation d'huile de fuite
A1
C/E
SV
M
A
SV1
G210
ca.370
145
4x 13
329
232
ca.319 (325)
Centre of gravity
ca.50
168,5
ca.170
8x M8 72 130
6x M8
A5x9 DIN 6888
1:5
110
98
h8
50
90
100
148
54
2
40
74
M12x28
66
z
Alt.bezug /
F
E
D
C
A
F
E
D
C
41
A
B
5
6
7
8
1
2
34
5
6
7
über / above
bis / up to
Numéro de plan:
B
32
088314
8
Freigabe / Approved
Extranet:
B
-
Alt.supply:
Maßstab /
Der Lieferant muss sicherstellen, dass die Ware
in einwandfreiem Zustand angeliefert wird
(Korrosionsschutz, Verpackung für sicheren
Ra Rz
Allgemeintoleranzen / General tolerances
Drawing-No.
Zeichn.-Nr. / Drawing no. /
Dok-ID:
±0.1
yxw uts
packaging for safe transportation).
model or design.
in proper conditions (corrosion prevention,
DIN ISO 2768-mK
Ersatz für / replacement for:
The supplier has to ensure the delivery of parts
Transport).
prohibited. Offenders will be held liable for the Dimension Passung / Clearance
Baumustergeprüft / Type examination:
--
K.-Auftrag / C.-Task:
Projektleiter / Project leader:
120
400
±0.5
0.5
6
GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
-
-
-
Unbemaßte Radien / Undimensioned radii:
-
Bearb. / EditedDatum / Date
payment of damages. All rights reserved in the event Änd.-Nr. / Mod-No.
Werkstoff (Zeile 2+3 alternativ) /
Base part, Raw part:
-
-
Geprüft / Appr.
NameDatum / Date
27.07.07
Material (Line 2+3 alternative):
Ausgangsteil, Rohteil /
Workpiece edges
DIN ISO 13715
Erstellt / Drawn
Geprüft / Verified Schaich
Schnizler
1/3
Oberflächenbehandlung, Härte / Treatment of surface, Hardness:
27.02.08
Werkstückkanten /
Page:
400 Benennung / Description:
±0.8
1000
306
31,2
±0.3
12030
-
Blatt /
±0.2
of the grant of a patent, utility /
DIN EN ISO 1302
Zust. / Rev.
Gußtoleranzen / General casting tolerances:
Gewicht / Weight: (kg)
Zeichnungs-Nr. /
Indication of surface texture
Scale:
%
C - FK40/655 N
Rz 25
Rz 160
25 0,05 Rz 1,6 0,3
0,7
1,6
2Rz 16
6,3 Rz 63 Rz 6,3
Rz 12,5 Status:
-
-
in Bearbeitung (CAD)
Nein / No 13983 .0
19.04.12
10.08.12
26.02.13
Gneiting
Gneiting
Zuder
0d | Betrifft Blatt 3
0e | Extranet B hinzugefügt, Ansicht Sickenrichtung hinzugefügt (Bl.2)
0f | Gussänderungen, Betrifft Blatt 2
8251
8266 + 8351
8510,8640
Layh
Schaich
Schaich
K - FK40/655 N
-
08511.
Kunde / Customer:
-
Weitergabe sowie Vervielfältigung dieses Dokuments,
Verwertung und Mitteilung seines Inhalts sind ver-
boten, soweit nicht ausdrücklich gestattet. Zuwider-
handlungen verpflichten zu Schadenersatz. Alle
Rechte für den Fall der Patent-, Gebrauchsmuster-
oder Geschmacksmustereintragung vorbehalten.
The reproduction, distribution and utilization of this
document as well as the communication of its
contents to others without express authorization is
Maß
Oberflächenangaben /
Teile-Nr. /
Part-No.
( ) K Ausführung
Fahrzeugverdichter / Vehicle Compressor / Compresseur pour automobiles
( ) K version Dimensions in mm
Cotes en mm
Maße in mmÄnderungen vorbehalten
Subject to change without notice
Sous réserve de toutes modifications
Sight glass
( ) Version K
1.0851-13983.0 0f
SchauglasK
1) = Ne possible qu 'ex usine
(L)* = Raccord à braser
1) = Only possible ex factory
(L)* = Brazing connection
L
1) = Nur ab Werk möglich
Raccord opt. vanne d'arrêt d'aspiration
Anschluß Wärmeschutzthermostat Connection thermal protection thermostat 2 x 1 1/8 “ – 18 UNEF Raccord de thermostat de protection thermique
Voyant Zoll
(L)* = Lötanschluß
Zoll
Massenschwerpunkt
-
1/8“ NPTF
M
Centre of gravity
Ölsieb Oil filter Filtre à huile mm M22x1,5
SV1 Opt. Anschlußmöglichkeit Saugabsperrventil
Centre de gravité
-Opt. connection suction line valve
Anschlüsse Connections Raccords FK(X)40/390 FK(X)40/470 FK(X)40/560 FK(X)40/655
SV Saugabsperrventil, Rohr (L)* Suction line valve, tube (L)* Vanne d’arrêt d’aspiration, de tuyau (L)* mm-Zoll 28 – 1 1/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “
DV Druckabsperrventil, Rohr (L)* Discharge line valve, tube (L)* Vanne d’arrêt de refoulement, de tuyau (L)* mm-Zoll 22 – 7/8 “ 28 – 1 1/8 “ 28 – 1 1/8 “ 35 – 1 3/8 “
A Anschluß Saugseite, nicht absperrbar Connection suction side, not lockable Raccord côté aspiration, non obturable Zoll 1/8“ NPTF
A1 Anschluß Saugseite, absperrbar Connection suction side, lockable Raccord côté aspiration, obturable Zoll 7/16“ UNF
B Anschluß Druckseite, nicht absperrbar Connection discharge side, not lockable Raccord côté refoulement, non obturable Zoll 1/8“ NPTF
B1 Anschluß Druckseite, absperrbar Connection discharge side, lockable Raccord côté refoulement, obturable Zoll 7/16“ UNF
C Anschluß Öldrucksicherheitsschalter OIL Connection oil pressure safety switch OIL Raccord pressostat de sécurité d’huile OIL Zoll 1/8“ NPTF
D Anschluß Öldrucksicherheitsschalter LP Connection oil pressure safety switch LP Raccord pressostat de sécurité d’huile LP Zoll 1/8“ NPTF
E Anschluß Öldruckmanometer Connection oil pressure gauge Raccord du manomètre de pression d’huile Zoll 1/8“ NPTF
F Ölablaß Oil drain Vidange d’huile Zoll 1/4“ NPTF
G Opt. Anschlußmöglichkeit Ölsumpfheizung 1) Opt. connection oil sump heater 1) Raccord opt. chauffage de carter d'huile 1) - -
H Stopfen Ölfüllung Oil charge plug Bouchon de remplissage d’huile Zoll 1/4“ NPTF
Typ / type Teile Nr. / part no. Typ / type Teile Nr. / part no. Typ / type Teile Nr. / part no.
FK(X)40/390 N 13977 (13985) FK(X)40/390 K 13978 (13986) FK(X)40/390 TK 14339 (14343)
FK(X)40/470 N 13979 (13987) FK(X)40/470 K 13980 (13988) FK(X)40/470 TK 14340 (14344)
FK(X)40/560 N 13981 (13989) FK(X)40/560 K 13982 (13990) FK(X)40/560 TK 14341 (14345)
FK(X)40/655 N 13983 (13991) FK(X)40/655 K 13984 (13992) FK(X)40/655 TK 14342 (14346)
F
DV BB1
L
H
K
D
Y
130
108,5
253
4xM10x21 LK 170
344
ca.385
Y
Lecköl-Ablass Schlauch
Leak oil drain hose
Tuyau d'évacuation d'huile de fuite
A1
C/E
SV
M
A
SV1
G210
ca.370
145
4x 13
329
232
ca.319 (325)

8
09665-01.2019-Gb
4 I Technical data
Type No. of
Cyl.
Displace-
ment
cm3
Swept
volume
(1450 rpm)
m3/h
Weight
kg
Discharge
line
DV
mm / inch
Suction
line
SV
mm/inch
Oil
charge
Ltr.
Inertia
moment
of the
driving
unit
[kgm2]
Lubrication Oil pump
FK(X)40/390
4
385 33.5 34.0 22 / 7/828 / 1 1/8
2.0 0.0043 Forced
lubrication
Rotation-
independent
FK(X)40/470 466 40.5 33.0 28 / 1 1/835 / 1 3/8
FK(X)40/560 554 48.3 33.0 28 / 1 1/835 / 1 3/8
FK(X)40/655 650 56.6 31.0 35 / 1 3/835 / 1 3/8
FK(X)40/755 755 65.6 31.0 35 / 1 3/835 / 1 3/8
Connections
The technical data for the different designs K, N and TK are identical. The compressor type data therefore do not mention these additions.

9
09665-01.2019-Gb
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 regularly according to the specications of the manufacturer of the refrigerating plant.
5 I Maintenance
Function checks 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 crankcase
Checking the xing screws for tightening
Checking the function of the ancillary units
Checking the electrical connections for clean, rmly xed contacts and the leads for chang points
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)
Compressor running time at least 10 min.
The plant should have reached the operating 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 decades-long experience we recommend to carry out the following oil change and servicing.
- First oil change at the rst 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 lter and the suction lter should be cleaned and the clamping ring with oil felt
from the shaft seal replaced.
Standard oil type used by GEA Bock Recommended alternatives
For HCFC (e.g. R22)
Fuchs Reniso SP 46 BP Energol LPT 46 SUNOCO Suniso 3.5GS
TEXACO Capella WF 46
For HFC (e.g. R134a, R404A, R407C)
Fuchs Reniso Triton SE 55 FUCHS SEZ 32 / 68 / 80 ESSO / Mobil EAL Arctic 46
Lubricants
Information about other suitable oils should be taken from GEA Bock lubricant tables. Information may also be retrieved from vap.gea.com
(mobile applications -> documentation -> technical information -> vehicle compressor -> ... -> lubrication chart).
The oil type charged as standard in the factory is marked on the name plate. This oil type should be used as a preference.
Alternatives are stated in the extract from our lubricants table below:

10
09665-01.2019-Gb
1
3
Pipe connection
2
Opening the shut-off valve:
a) Spindle 1: turn to the left (counter-clockwise) as far as it
will go.
—> Shut-off valve fully opened / service connection 2
closed (position A), Fig.
Opening the service connection (2)
b) Spindle 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 Maintenance
Operating of the shut-off valves
Position A
Position B
INFO Before opening or closing the shut-off valve, loosen the valve spindle seal (Fig. left) by 1/4 turn.
After operating the shut-off valve, tighten the valve spindle seal carefully again (Fig. right).

11
09665-01.2019-Gb
6 I Fault diagnosis
Compressor stand still
Compressor does not start
Problem Possible cause Remedy
Control circuit is interrupted Main - or control fuse is switched off or tripped Replace fuse
Determine and remove the cause
Cut off through:
- Low pressure switch
- High pressure switch
- Heat protection thermostat
- Control thermostat
- Other safety elements
Locate the interruption in the circuit
and remove
Malfunction of electromagnetic
coupling
- see also page 14 "Malfunction of
electromagnetic coupling"
Checking
Compressor cutoff
Compressor starts and stops again
Problem Possible cause Remedy
Cutoff through 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 suction valve
- Capacity of compressor too large - Check operating conditions
- Refrigerant deciency - Leak test / add refrigerant
- Filter / dryer in the liquid line blocked - Replace lter / dryer
- Expansion valve 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 operation we recom-
mend to prepare a measurement record for aiding the fault search:
Pressure measurement: Discharge side, suction side,
oil pressure
Temperature 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 systems 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 suggestion
for remedying compressor malfunctions. Further information is
retrievable under vap.gea.com (mobile applications -> tools ->
online analysis). Additionally a failure analysis slide is obtainable
under [email protected].
Function faults - Symptoms
Function faults arising most frequently and their symptoms are:
Compressor stoppage, compressor cutoff
- Compressor does not start
- Compressor starts and then stops again
Refrigerant performance too low
Too high compressor temperature
Oil problems
Abnormal compressor running noise

12
09665-01.2019-Gb
6I Fault diagnosis
Refrigerant performance too low
Problem Possible cause Remedy
Suction pressure too high - Evaporator iced up - Remove the cause
- Expansion valve not functioning properly - Check expansion valve setting;
replace valve, if necessary
- Lack of compressor capacity - Check the function of the compressor by
evacuating to vacuum.
Check function of capacity regulator
(accessory)
- Shortage of refrigerant - Run leakage test / rell
refrigerant
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 - Replace valve plate
- By-pass between suction and discharge side - Localize leak between the discharge and suc-
tion side and repair it
Problem Possible cause Remedy
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 the pressure valve
- Condenser fan not functioning - Check the control / replace motor
- Condenser performance insufcient, con-
denser and fan motor contaminated
- Cleaning of condenser ns and fan
- Excessive refrigerant lling - Extract refrigerant to normal lling
- Non-condensible gases in refrigerant - Extract refrigerant and evacuate the
refrigeration plant / rell 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
- Condenser cooling insufcient - Check fan motors / cleaning of condenser
- Valve plate damage - Replace valve plate
- Internal decompression valve has opened - Replace decompression 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

13
09665-01.2019-Gb
6I Fault diagnosis
Refrigerant temperature too high
Problem Possible cause Remedy
Suction gas temperature
too high
- Suction gas overheating - Adjust expansion valve
Insulate the gas suction line
- Too little refrigerant lling - Establish the operating lling (see Operating
Instruction for the refrigeration plant),
localize leak
- Liquid lter blocked - Clean / replace lter / dryer
- Shortage of refrigerant - Run leakage test / rell refrigerant
Discharge pipe temperature
too high
- Suction gas temperature too high
(Condensing pressure too high)
- Adjust expansion valve
Insulate the gas suction line
- see „Cutoff through high-pressure switch“
- Operating limits of compressor exceeded - see „Cutoff through heat-protection
thermostat“
- Cooling insufcient - Check refrigerant lling
- Adjust expansion valve
- Short circuit between the discharge and the
suction side of the compressor
- Check gaskets on valve plate /
change
- 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 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 lter dirty / blocked - Clean / replace oil lter
Change oil
Oil foams during start-up phase - Liquid refrigerant has moved into the oil sump - Check the laying of pipes
- Installation of the check valve in the
discharge line
- Installation of the solenoid valve in the
liquid line
- Check the control
Oil foams during operating - Expansion valve not functioning - Adjust / replace expansion valve
Oil level decreases - 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 start-up phase“
- Piston rings worn - Replace piston rings
- Suction / discharge laminations of the valve
plate leaking
- Replace valve plate

14
09665-01.2019-Gb
6I Fault diagnosis
Abnormal running noise from compressor
Problem Possible cause Remedy
Fixation of compressor is loose - Screwed connections have become loose
- Securing elements for screwed connections
missing
- Tighten the screwed connections and secure
them anew
- Vibration metals defective - Replace vibrations metals
Liquid shock - Liquid refrigerant reaching the compressor - Adjust / check expansion valve
Check refrigerant lling
Check evaporator fan
- Icing-up of the evaporator
- Oil shocks because of too much oil - Check oil level
Check the dimensioning of pipes (gas velocity)
Replace worn piston rings
Capacity regulator (accessory) - Switching on and off constantly / oscillating - Check the control
- Defective - Replace capacity regulator valve
Electromagnetic 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 / guidance roller
- Incorrect alignment of compressor and motor - Check alignment and adjust anew
Malfunction of the electromagnetic coupling
Problem Possible cause Remedy
Coupling not switching - No voltage applied - Apply voltage and check
Coupling slipping too long, get-
ting 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 eld - Check the seating of the magnet possibly
to high belt tension
Coupling not separating - Voltage still being applied to the magnet - Check switch / relay
- Coupling is stuck - Disconnect the armature disc from the rotor
mechanically
- Coupling overloaded,
Armature disc is deformed
- Install new rotor ans armature disc

15
09665-01.2019-Gb
7 I Installation of service kits
Disassembly and assembly of the compressor
Important Notes
For changing components in the framework of customary service works we recommend the kits described on the following pages.
INFO Use only new gaskets for assembly
The following illustrations show a FK40 compressor in standard design.
Components of other designs can differ from these illustrations.
However, the procedure for disassembly and assembly of the compressor is identical.
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 system pressure
• Prevent air from infiltrating the system
• Move and transport the compressor using an appropriate hoist
• Use only genuine GEA Bock spare parts
After the work is finished:
• Connect the safety switch and check its function
• Evacuate the compressor
• Before commissioning, check whether all the components installed by the user have been
mounted expertly and are connected pressure-tight to the compressor
• Open the pressure and suction shut-off valves
• Set off the switching-on lock

16
09665-01.2019-Gb
7 I Installation of service kits
Shaft seal (Item No. 80023 (ester oil charge) resp. 80682 (mineral oil charge))
Removal:
Dismount the drive/magnetic coupling from the compressor.
Remove the woodruff key from seat at the shaft end.
Remove the clamping ring (10) and the oil felt (9) (for this see Fig. 3 on page 17).
Unscrew the screws (8) from the shaft seal cover (6) .
Remove the gasket residues and the shaft seal cover gasket (5) from the bearing ange.
Installation:
Work with utmost cleanliness.
Always replace the shaft seals complete, never individual parts thereof.
Do not use used parts.
Prior to installation, check the sliding and sealing surfaces for cleanliness and damages.
Apply silicone grease to O-ring (3) and its seat in guide ring (2). Moisten sealing surfaces of the sliding ring (4), shaft seal cover (6) and
compressor shaft using compressor oil.
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).
During the assembly the compression spring (1) must engage audibly in the drive slot of the crankshaft and of the guide ring (2).
Install the shaft seal cover gasket (5) with applied compressor oil.
Install the shaft seal cover (6) with the inscription „TOP“ upwards. Lubricate the pre-installed rotary shaft seal (7) with silicone grease. Use
the protective sleeve. Tighten the xing screws (8) evenly, crosswise tightening torque = 34 Nm.
Remove the protective sleeve. After installing the shaft seal, turn the compressor shaft a few turns by hand and then carry out the leak test.
Install the clamping ring, if available (see section on clamping ring with oil felt, page 17).
Insert the Woodruff key into the seat at the compressor shaft end.
Mount the drive/coupling.
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!
Fig. 1
6
5
4
3
2
1
7
8
9
10
“TOP“

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7 I Installation of service kits
Clamping ring with oil felt (Item No. 80129)
Procedure:
Remove the clamping ring (1) and the oil felt (2) (see Fig. 3)
Insert the oil felt (2) included in the repair kit and mount
the clamping ring (1).
Starting from version ID 015- (starting from 4th quarter 2005)
Emptying the oil reservoir: The oil reservoir can 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 removing
the oil hose from the bracket, remove the sealing plug and drain
the oil into a collecting vessel. After emptying, close the oil hose
with the sealing plug and x it to the bracket. Dispose of used oil
in accordance with the regulations applicable in the country of use.
Clamping ring
Fig. 3
Fig. 2 1 2
Version ID 007 - 014
Open at top
2
1
Fig. 4

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(Only for the capacity regulation which is an accessory)
7 I Installation of service kits
Capacity regulation
The capacity regulation takes place through the turning off of the suction gas ows by means of a solenoid valve on the cylinder cover. For
this, the valve is activated electrically 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.
During regulated operation the solenoid is energized and the suction gas ow 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. 50%.
Further information together the description of the working principle of the solenoid valve is contained in the publication „Capacity regulation“
(Item No. 09900).
Capacity regulation valve (Item No. 07541)
Removal:
De-energize the solenoid (4).
Screw on the xing nut (3), pull out the solenoid (4) with the
washer (5).
Unscrew the valve body (2).
Check the valve body (2) for damages and whether the piston
moves freely. If necessary, replace the complete valve body (2).
Installation:
Screw on the valve body (2) with the enclosed new O-ring (1) and
tighten it. Observe the screw tightening torque!
Push on the washer (5) and the solenoid (4) and fasten them with the
xing nut (3).
Put the compressor into operation and check the functioning of the
capacity regulation. Fig. 5
3
4
5
1
207541
70 Nm

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7 I Installation of service kits
Valve plate
Compressor type Kit (Item No.) Compressor 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 to FK(X)40/655 K 80010
FK(X)40/755 K 81297
K type valve plate N type and TK type Valve plate
Fig. 6

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7 I Installation of service kits
Removal (see Fig. 6):
Unscrew the screws (1) from the cylinder cover (2) and dismount cylinder cover (2) with valve plate (4).
Remove the gasket residues from the body of the compressor.
Installation (see Fig. 6):
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).
Tighten the cylinder cover screws (Pos. 1 in Fig. 6) according to the sequence shown in Fig. 7!
Fig. 7: Sequence for tightening the
cylinder cover screws
9
11
10
8
5 1 4
6 3 2 7
ATTENTION The conversion of the compressor from one type of valve plate to another is not possible!
INFO Don‘t let any gasket residues fall into the compressor
ATTENTION Install the K type valve plate (Item No. 80010) only with the inscription „TOP“ facing upwards (see Fig. 6).
60 Nm