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BOCK FK40 - User Manual

BOCK FK40
58 pages
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09665-07.2012-Gb
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
BOCK FK40
Maintenance manual
09665-07.2021-Gb
Translation of the original instructions
colour the world
of tomorrow
BOCK
®
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Summary

Introduction

Safety

Safety Instructions and Target Audience

General safety guidelines and the intended audience for these instructions.

Identification of Safety Instructions

Explains the meaning of different safety symbols used in the manual.

General Safety Instructions

Specific safety precautions for operating and handling the compressor.

Product Description

Short Description and Applications

Overview of FK40 compressor variations and their intended uses.

Key Features

Highlights the main characteristics and design aspects of the compressor.

Name Plate Explanation

Details the information provided on the compressor's identification plate.

Main and Functional Parts

Identifies and illustrates the primary components of the compressor.

Dimensional Drawings and Connections

Provides technical dimensions and a list of all available connections.

Technical Data

Maintenance

Service Intervals and Checks

Recommends routine maintenance schedules and annual function checks.

Oil Level and Oil Change Procedures

Instructions for checking the oil level and performing an oil change.

Lubricants

Information on recommended oils for the compressor.

Operating Shut-Off Valves

Step-by-step guide on how to operate the compressor's shut-off valves.

Fault Diagnosis

Symptoms and Common Faults

Lists frequent operational issues and their associated symptoms.

Compressor Standstill Troubleshooting

Addresses problems when the compressor fails to start, with causes and remedies.

Compressor Cutoff Troubleshooting

Details causes and solutions for the compressor stopping intermittently.

High Temperature and Oil Issues

Diagnoses and rectifies problems related to high refrigerant temperatures and oil.

Abnormal Noise and Coupling Malfunctions

Troubleshooting guide for unusual noises and issues with the electromagnetic coupling.

Installation of Service Kits

General Disassembly and Assembly Procedures

Provides essential safety warnings and general procedures for compressor disassembly and assembly.

Important Assembly Notes

Highlights crucial considerations and tips for a successful assembly process.

Shaft Seal Replacement

Detailed instructions for the removal and installation of the shaft seal.

Clamping Ring with Oil Felt Procedure

Steps for installing the clamping ring and oil felt, including version-specific details.

Capacity Regulation Valve Installation

Procedure for removing and installing the capacity regulation valve.

Valve Plate Installation Guide

Details on valve plate types and their corresponding service kit part numbers.

Cylinder Cover and Valve Plate Installation

Instructions for installing cylinder covers and valve plates, emphasizing correct orientation.

Electromagnetic Coupling

General Assembly Instructions

Overview of electromagnetic coupling usage in A/C compressors.

LA 16 Coupling Installation

Specific assembly instructions for the LA 16 electromagnetic coupling type.

Compressor Defects

Disassembly of the Compressor

Compressor Removal from System

Steps to safely disconnect and remove the compressor from the refrigeration system.

Disassembly Overview and Tools

Introduction to compressor disassembly and a list of necessary tools.

Removal of Shut-off Valves and Blind Flanges

Procedure for removing the shut-off valves and blind flanges from the compressor.

Removal of the Oil Filter

Steps involved in safely draining oil and removing the oil filter.

Removal of Cylinder Cover and Valve Plates

Detailed instructions for removing the cylinder cover and associated valve plates.

Removal of the Shaft Seal

Procedure for safely removing the shaft seal, including warnings.

Removal of the Oil Pump

Steps for detaching and removing the oil pump assembly.

Removal of the Baseplate

Instructions for removing the compressor baseplate and its gasket.

Disassembly of Connecting Rods from Crankshaft

Procedure for separating the connecting rods from the crankshaft.

Removal of the Front Bearing

Steps for safely removing the front bearing assembly.

Removal of the Crankshaft

Instructions for carefully extracting the crankshaft from the compressor.

Removal of Pistons and Connecting Rods

Detailed process for removing pistons and their connecting rods.

Removal of Remaining Parts

Steps to remove miscellaneous components like sight glasses and plugs.

Removal of Roller Bearings

Procedure for removing the roller bearings using appropriate tools.

Checking Compressor Parts

Checking Parts for Damage and Wear Limits

Guidelines for inspecting compressor components for usability and wear.

Piston, Connecting Rod, Valve Plate, and Oil Pump Checks

Specific criteria for examining pistons, connecting rods, valve plates, and the oil pump.

Filter and Decompression Valve Checks

Procedures for checking the oil filter, suction filter, and decompression valve.

Assembly of Compressor

Fitting Roller Bearings

Instructions for installing roller bearings, including heating procedures.

Fitting Sight Glass, Plugs, and Decompression Valve

Steps for installing sight glasses, various plugs, and the decompression valve.

Assembly of Pistons and Connecting Rods

Procedure for assembling pistons with connecting rods and piston pins.

Fitting Pistons and Connecting Rods into Liners

Instructions for inserting assembled pistons/rods into cylinder liners, noting TK specifics.

Fitting the Crankshaft

Steps for correctly installing the crankshaft, ensuring engagement with the pump gear.

Installation of the Front Bearing Flange

Procedure for attaching the front bearing flange with gasket and O-ring.

Assembly of Inserted Connecting Rods and Pistons

Final assembly steps for connecting rods and pistons, including tightening.

Installation of the Oil Pump

Steps for installing the oil pump with gasket, ensuring correct orientation and tightening.

Fitting the Shaft Seal

Detailed instructions for fitting the shaft seal onto the crankshaft.

Installation of the Baseplate

Procedure for installing the baseplate with gasket and tightening screws.

Installation of the Oil Filter

Steps for installing the oil filter and the M22x1.5 plug.

Installation of Cylinder Covers and Valve Plates

Instructions for installing cylinder covers and valve plates, ensuring correct pairing.

Installation of Shut-off Valves and Blind Flanges

Procedure for installing shut-off valves and blind flanges with correct screw length.

Compressor Checking and Tightening Torques

Final checks, leak tests, function tests, and a table of screw tightening torques.

Spare Parts List

Exploded Drawing

Summary

Introduction

Safety

Safety Instructions and Target Audience

General safety guidelines and the intended audience for these instructions.

Identification of Safety Instructions

Explains the meaning of different safety symbols used in the manual.

General Safety Instructions

Specific safety precautions for operating and handling the compressor.

Product Description

Short Description and Applications

Overview of FK40 compressor variations and their intended uses.

Key Features

Highlights the main characteristics and design aspects of the compressor.

Name Plate Explanation

Details the information provided on the compressor's identification plate.

Main and Functional Parts

Identifies and illustrates the primary components of the compressor.

Dimensional Drawings and Connections

Provides technical dimensions and a list of all available connections.

Technical Data

Maintenance

Service Intervals and Checks

Recommends routine maintenance schedules and annual function checks.

Oil Level and Oil Change Procedures

Instructions for checking the oil level and performing an oil change.

Lubricants

Information on recommended oils for the compressor.

Operating Shut-Off Valves

Step-by-step guide on how to operate the compressor's shut-off valves.

Fault Diagnosis

Symptoms and Common Faults

Lists frequent operational issues and their associated symptoms.

Compressor Standstill Troubleshooting

Addresses problems when the compressor fails to start, with causes and remedies.

Compressor Cutoff Troubleshooting

Details causes and solutions for the compressor stopping intermittently.

High Temperature and Oil Issues

Diagnoses and rectifies problems related to high refrigerant temperatures and oil.

Abnormal Noise and Coupling Malfunctions

Troubleshooting guide for unusual noises and issues with the electromagnetic coupling.

Installation of Service Kits

General Disassembly and Assembly Procedures

Provides essential safety warnings and general procedures for compressor disassembly and assembly.

Important Assembly Notes

Highlights crucial considerations and tips for a successful assembly process.

Shaft Seal Replacement

Detailed instructions for the removal and installation of the shaft seal.

Clamping Ring with Oil Felt Procedure

Steps for installing the clamping ring and oil felt, including version-specific details.

Capacity Regulation Valve Installation

Procedure for removing and installing the capacity regulation valve.

Valve Plate Installation Guide

Details on valve plate types and their corresponding service kit part numbers.

Cylinder Cover and Valve Plate Installation

Instructions for installing cylinder covers and valve plates, emphasizing correct orientation.

Electromagnetic Coupling

General Assembly Instructions

Overview of electromagnetic coupling usage in A/C compressors.

LA 16 Coupling Installation

Specific assembly instructions for the LA 16 electromagnetic coupling type.

Compressor Defects

Disassembly of the Compressor

Compressor Removal from System

Steps to safely disconnect and remove the compressor from the refrigeration system.

Disassembly Overview and Tools

Introduction to compressor disassembly and a list of necessary tools.

Removal of Shut-off Valves and Blind Flanges

Procedure for removing the shut-off valves and blind flanges from the compressor.

Removal of the Oil Filter

Steps involved in safely draining oil and removing the oil filter.

Removal of Cylinder Cover and Valve Plates

Detailed instructions for removing the cylinder cover and associated valve plates.

Removal of the Shaft Seal

Procedure for safely removing the shaft seal, including warnings.

Removal of the Oil Pump

Steps for detaching and removing the oil pump assembly.

Removal of the Baseplate

Instructions for removing the compressor baseplate and its gasket.

Disassembly of Connecting Rods from Crankshaft

Procedure for separating the connecting rods from the crankshaft.

Removal of the Front Bearing

Steps for safely removing the front bearing assembly.

Removal of the Crankshaft

Instructions for carefully extracting the crankshaft from the compressor.

Removal of Pistons and Connecting Rods

Detailed process for removing pistons and their connecting rods.

Removal of Remaining Parts

Steps to remove miscellaneous components like sight glasses and plugs.

Removal of Roller Bearings

Procedure for removing the roller bearings using appropriate tools.

Checking Compressor Parts

Checking Parts for Damage and Wear Limits

Guidelines for inspecting compressor components for usability and wear.

Piston, Connecting Rod, Valve Plate, and Oil Pump Checks

Specific criteria for examining pistons, connecting rods, valve plates, and the oil pump.

Filter and Decompression Valve Checks

Procedures for checking the oil filter, suction filter, and decompression valve.

Assembly of Compressor

Fitting Roller Bearings

Instructions for installing roller bearings, including heating procedures.

Fitting Sight Glass, Plugs, and Decompression Valve

Steps for installing sight glasses, various plugs, and the decompression valve.

Assembly of Pistons and Connecting Rods

Procedure for assembling pistons with connecting rods and piston pins.

Fitting Pistons and Connecting Rods into Liners

Instructions for inserting assembled pistons/rods into cylinder liners, noting TK specifics.

Fitting the Crankshaft

Steps for correctly installing the crankshaft, ensuring engagement with the pump gear.

Installation of the Front Bearing Flange

Procedure for attaching the front bearing flange with gasket and O-ring.

Assembly of Inserted Connecting Rods and Pistons

Final assembly steps for connecting rods and pistons, including tightening.

Installation of the Oil Pump

Steps for installing the oil pump with gasket, ensuring correct orientation and tightening.

Fitting the Shaft Seal

Detailed instructions for fitting the shaft seal onto the crankshaft.

Installation of the Baseplate

Procedure for installing the baseplate with gasket and tightening screws.

Installation of the Oil Filter

Steps for installing the oil filter and the M22x1.5 plug.

Installation of Cylinder Covers and Valve Plates

Instructions for installing cylinder covers and valve plates, ensuring correct pairing.

Installation of Shut-off Valves and Blind Flanges

Procedure for installing shut-off valves and blind flanges with correct screw length.

Compressor Checking and Tightening Torques

Final checks, leak tests, function tests, and a table of screw tightening torques.

Spare Parts List

Exploded Drawing

BOCK FK40 Specifications

General IconGeneral
BrandBOCK
ModelFK40
CategoryAir Compressor
LanguageEnglish

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