FK 40 Maintenance Manual - 09665-12-2014-Gb

FK40
Maintenance manual
FK40/390 K FK40/470 K FK40/560 K FK40/655 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
09665-12.2014-Gb
engineering for a better world GEA Refrigeration Technologies

1
About these instructions
Read these instructions before assembly and before using the Liability and warranty
compressor. This will avoid misunderstandings and prevent dam-
age. Improper assembly and use of the compressor can result Manufacturer‘s liability and warranty are excluded if
inserious or fatal injury. • Alterations and functional modifications have been carried out
Observe the safety instructions contained in these instructions. • No original replacement parts have been used
Contact
GEA Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Telephone +49 7022 9454 0

Fax +49 7022 9454 137
refrigeration@gea.com
www.gea.com
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
09665-12.2014-Gb
2
1 I Introduction
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 tu 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 efficiency
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.
2 I Safety
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.
Identification of safety instructions
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.
09665-12.2014-Gb
INFO Important information / tips on simplifying work.
3
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 unauthorised restart
WARNING • Refrigerating compressors are pressurised machines and therefore require particular
caution and care in handling.
• Only qualified personnel are allowed to perform any work on refrigeration compressors.
• The national safety regulations, accident prevention regulations, technical rules and specific
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!
09665-12.2014-Gb
4
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
efficiency are concerned.
More features:
Compact 4-cylinder compressor in V design
Wear resistant and long-lasting engine
Four 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)

GEA Bock GmbH
72636 Frickenhausen, Germany AR12345A020 4
1
2
3 19/28bar Oil: 5
1. Type designation 4. Machine number

2. Displacement at 1450 rpm 5. Factory-filled oil type
3. ND(LP): max. permissible operating pressure low pressure side
HD(HP): max. permissible operating pressure high pressure side }
Observe the limits of
application diagrams!
Type code (example)

Explanation of the type designation
FK X 40 / 655 N
Designs
09665-12.2014-Gb
Swept volume
Size
Ester oil charge (HFC refrigerant, e.g. R134a, R407C)
Series
5
Main and functional parts
1
2
3
4
18
5
6
8 11
9 7
12
13
10
14
15
16
17
1. Discharge shut-off valve 10. Baseplate

2. Cylinder cover 11. Connection thermal protection thermostat
3. Valve plate 12. Oil filling plug
4. Compressor housing 13. Oil sight glasses (2x)
09665-12.2014-Gb
5. Location hole for fitting magnetic coupling 14. Oil drain plug
6. Integrated leak oil collector 15. Suction line valve
7. Leak oil drain hose 16. Oil pump
8. Shaft seal 17. Oil drain plug / Oil filter
9. Shaft end 18. Name plate
6
8 4 8 7 7 3 6 6 2 5 5 1 4 4 3 3
Dimension drawing
( ) K Ausführung
( ) K Ausführung
ca.319 (325)(325)
ca.319 Änderungen
Änderungen
vorbehalten
vorbehalten Maße in mm
Maße in mm
Änderungen vorbehalten Maße in mm
(
(
) K version
( ) K version
) Version
( )KVersion K DV B
DV B1
B B1 Centre of
Subject to
Sous réserve
gravity
Subject
change
Sousde
towithout
changenotice
réserve
toutesde
without notice Dimensions
modifications
toutes modifications
Dimensions
in mm in m
Cotes enCotes
mm en mm
B B1 Subject to change without notice SV1inSV1
Dimensions mm
F Sous réserve de toutes modifications Cotes en mm Massenschwerpunkt
Massenschwerp
Centre ofCentre
gravityof gravit
Massenschwerpunkt F Centre deCentre
gravitéde gravit
Centre of gravity Y Y
Centre de gravité Y Y
Y SV SV
ca.370
ca.370
A A L L
170
170
329
329
A1 A1
253
253
E
4xM10x21 LK
4xM10x21 LK
C/E C/E
ca.170
ca.170
H H
253145
145
K K
E Lecköl-Ablass
Lecköl-Ablass
SchlauchSchlauch
Leak oil drain
Leak hose
oil drain hose
M M F F
ca.170
Tuyau d'évacuation
Tuyau d'évacuation
d'huile ded'huile
fuite de fu
6 5 4 3 2
G4x 13
G 4x 13 108,5108,5 D D
ca.50ca.50 8x M8 8x130
M8 130
210 210
Lecköl-Ablass Schlauch 168,5168,5 130 130 6x M8 6x72M8 72
( ) K Ausführung
(325) Leak oil drain hose
232
Änderungen vorbehalten Maße in mm
D
( ) K version
( ) Version K
Tuyau B 232
DVd'évacuationB1 d'huile de fuite Subject to change without344
notice 344 Dimensions in mm A5x9 DIN
A5x9
6888
DIN 68
Sous réserve de toutes modifications
ca.385Cotes en mm M12x28M12
SV1 ca.385
2
ca.50 D
148 h8
98h8
Anschlüsse Anschlüsse Connections
8x M8 Connections
130 Raccords Raccords FK(X)40/390 FK(X)40/390
FK(X)40/470 FK(X)40/470
FK(X)40/560 FK(X)40/560
FK(X)40/655 FK(X)40/655
Massenschwerpunkt
110
110
SV Saugabsperrventil,
SV Saugabsperrventil,
Rohr (L)* Rohr (L)* Suction line valve,Suction
tube line
(L)*valve, tube (L)*Vanne d’arrêt d’aspiration,
Vanne d’arrêtded’aspiration,
tuyau (L)* de tuyau
mm-Zoll
(L)* 28 –mm-Zoll
1 1/8 “ 28
35––111/8
3/8“ “ 35
35––113/8
3/8“ “ 35
35––113/8
3/8“ “ 35 – 1 3/8 “
90
98
90
40
148
130 DV
A
A1
Druckabsperrventil,
DV Druckabsperrventil,
Anschluß Saugseite,
A
Rohr
Anschluß
Anschluß Saugseite,
A1
(L)* Rohr
nicht absperrbar
Anschluß
(L)*
Saugseite, nicht absperrbar
absperrbar
Saugseite, absperrbar
Discharge line valve,
Discharge
Connection suction
tube line
Connection
Connection suction
(L)*valve, tube
side, not lockable
6x M8
Connection
(L)*
Vanne d’arrêt de refoulement,
suction side, not lockable
side, lockable 72
Vanne d’arrêt dede
Raccord côté aspiration,
suction side, lockable
Raccordnon
côté
refoulement,
tuyau (L)*
obturable
de tuyau
mm-Zoll
aspiration, non obturable Zoll
Raccordobturable
côté aspiration, obturable Zoll
(L)* 22 mm-Zoll
– 7/8 “
Zoll
Zoll
22
28 –– 7/8
1 1/8
“ “ 28
28––111/8
1/8“ NPTF
7/16“ UNF
1/8“ “
1/8“ NPTF
7/16“ UNF
28
35––111/8
3/8“ “ 35 – 1 3/8 “
Centre of gravity
Centre de gravité
B Anschluß Druckseite,
B Anschluß
nicht absperrbar
Druckseite, nicht absperrbar Connection discharge
Connection
side, not
discharge
lockableside, notRaccord
lockablecôté refoulement,
Raccord côté
non refoulement,
obturable non obturable
Zoll Zoll 1/8“ NPTF 1/8“ NPTF
Y
B1 Anschluß Druckseite,
B1 Anschluß
absperrbar
Druckseite, absperrbar Connection discharge
Connection
side, lockable
discharge side, lockable
Raccord côté refoulement,
Raccord côté
obturable
refoulement, obturable Zoll Zoll 7/16“ UNF 7/16“ UNF
344 C Anschluß Öldrucksicherheitsschalter

C Anschluß Öldrucksicherheitsschalter
OIL OIL Connection oil pressure
Connection A5x9 DIN 6888
safetyoilswitch
pressure
OIL safetyRaccord
switch OIL
pressostat
Raccord
de sécurité
pressostat
d’huilede OIL
sécurité d’huile OIL
D
50 50
1:5 1:5
D
E
Anschluß Öldrucksicherheitsschalter
D Anschluß Öldrucksicherheitsschalter
Anschluß Öldruckmanometer
E
LP
Anschluß Öldruckmanometer
LP Connection oil pressure
Connection
Connection oil pressure
safetyoilswitch
Connection
gauge
pressure
LP safetyRaccord
switch LP
pressostat
Raccord
oil pressure gaugeRaccord du manomètre
M12x28
de sécurité
Raccord
pressostat
dedu
d’huiledeLPsécurité d’huile LP
pression
manomètre
d’huile
Zoll
de pression d’huile
Zoll
Zoll
Zoll
1/8“ NPTF
1/8“ NPTF
1/8“ NPTF
1/8“ NPTF Y 54 54
ca.385 F
G
Ölablaß F Ölablaß
Opt. Anschlußmöglichkeit
G Opt. Anschlußmöglichkeit
Ölsumpfheizung 1)
Oil drain
Ölsumpfheizung 1)
Oil drain
Opt. connection oil
Opt.
sump
connection
Vidange d’huile Vidange d’huile
heater 1)oil sump heater
Raccord
1) opt. chauffage
Raccorddeopt.
carter
chauffage
d'huile 1)
Zoll
de carter d'huile 1)
-
Zoll
-
1/4“ NPTF
-
1/4“ NPTF
-
2
H Stopfen Ölfüllung
H Stopfen Ölfüllung Oil charge plug Oil charge plug Bouchon de remplissage
Bouchond’huile
de remplissage d’huile Zoll Zoll 1/4“ NPTF 1/4“ NPTF 66 66
SV
K Schauglas K Schauglas Sight glass Sight glass Voyant Voyant Zoll Zoll 2 x 1 1/8 “ – 18 UNEF
2 x 1 1/8 “ – 18 UNEF
148 h8
560 FK(X)40/655 L Anschluß Wärmeschutzthermostat

L Anschluß Wärmeschutzthermostat Connection thermal
Connection
protectionthermal
thermostat
protection Raccord
thermostat
de thermostat
Raccord
de de
protection
thermostat
thermique
de protection thermique
74 74
110
8“ 35 – 1 3/8 “ M Ölsieb M Ölsieb Oil filter Oil filter Filtre à huile Filtre à huile mm mm M22x1,5 M22x1,5
98
90
40
SV1 Opt. Anschlußmöglichkeit

SV1 Opt. Anschlußmöglichkeit
SaugabsperrventilSaugabsperrventil
Opt. connection suction
Opt. connection
line valve suction line valve
Raccord opt. vanne
Raccord
d'arrêtopt. vanne d'arrêt d'aspiration -
d'aspiration - - -
8“ 35 – 1 3/8 “
(L)* = Lötanschluß(L)* = Lötanschluß (L)* = Brazing connection
(L)* = Brazing connection (L)* = Raccord à braser
(L)* = Raccord à braser 100 100
C 1) = Nur ab Werk 1)möglich
L
= Nur ab Werk möglich 1) = Only possible1)ex= factory
Only possible ex factory 1) = Ne possible qu 1) ='exNe
usine
possible qu 'ex usine
A
170
Fahrzeugverdichter
Fahrzeugverdichter/ Vehicle/ Vehicle
Compressor
Compressor
/ Compresseur
/ Compresseur pour automobiles
pour automobiles
50 Typ / 1:5 Zeichn.-Nr.
Zeichn.-Nr.
/ Drawing
/ Drawing
no. / no.
A1 Typ / type type
54 FK(X)40/390
FK(X)40/390
Teile Nr.Teile
/ part
N 13977N (13985)
Nr.no.
/ part
13977 (13985)
Typno.
/ type
Typ / type
FK(X)40/390
Teile Nr.Teile
FK(X)40/390
K 13978
/ part
K (13986)
Nr.no.
/ part
13978 (13986)
Typno.
/ type
Typ / typeTeile Nr.Teile
FK(X)40/390
FK(X)40/390
TK 14339
/ part
TK (14343)
Nr.no.
/ part no.
14339 (14343)
NuméroNuméro
de plan:de plan:
253
4xM10x21 LK
FK(X)40/470
66 FK(X)40/470
N 13979N (13987)
13979 (13987) FK(X)40/470
FK(X)40/470
K 13980 K (13988)
13980 (13988) FK(X)40/470
FK(X)40/470
TK 14340TK (14344)
14340 (14344)
C/E 1.0851-13983.0
1.0851-13983.0
0f
ca.170
FK(X)40/560
FK(X)40/560
N 13981N (13989)
13981 (13989) FK(X)40/560
FK(X)40/560
K 13982 K (13990)
13982 (13990) FK(X)40/560
FK(X)40/560
TK 14341TK (14345)
14341 (14345)
H 74 FK(X)40/655
FK(X)40/655 N 13983N (13991)
13983 (13991) FK(X)40/655
FK(X)40/655
K 13984 K (13992)
13984 (13992) FK(X)40/655
FK(X)40/655
TK 14342TK (14346)
14342 (14346)
K 100
C
Lecköl-Ablass
Gußtoleranzen Schlauch
Gußtoleranzen
/ General casting
/ General
tolerances:
casting tolerances:
Zeichnungs-Nr.
Zeichnungs-Nr.
/ /
Teile-Nr. / Teile-Nr. / Blatt /
Shaft end
- - Drawing-No.Drawing-No. Part-No. Part-No. Page:
Leak oil drain hoseexamination:
esseur MDimensions in mmF
B pour automobiles Leak oil drain
Baumustergeprüft hose
Baumustergeprüft
/ Type / Type examination:
rt no. Typ / type Teile Nr. / part no.

Zeichn.-Nr. / Drawing no. /
Tuyau d'évacuation
Nein / No Nein d'huile
/ No de fuite
Gewicht / Weight:
Gewicht(kg)
/ Weight:
31,2 (kg) 31,2
1. 0851 -13983
1. 0851 -13983
.0 1/3
.0
Numéro de plan: Allgemeintoleranzen
Allgemeintoleranzen
/ General tolerances
/ General tolerances
4x
6) 13
FK(X)40/390 TK 14339 (14343) 108,5 ca.50 D 8x M8
DIN ISO 2768-mK
130
DIN ISO 2768-mK Benennung
Benennung
/ Description:
/ Description:
8) FK(X)40/470 TK
Connections 14340 (14344) 168,5 130
über /0.5
über / above above
bis / up to bis / 6
6 0.530 120
6 30
up to 30
120
6 30
400120
400120 400
1000400 1000 K-F
K
00) FK(X)40/560 TK 14341 (14345) 1.0851-13983.0 0f 6x M8±0.1 72
±0.2±0.1 ±0.5±0.3
±0.3±0.2 ±0.8
±0.5 ±0.8 C
Oberflächenbehandlung,
Oberflächenbehandlu
Härte / T
22) FK(X)40/655 TK
A
14342 (14346) 344
Connection suction side, not lockable
UnbemaßteUnbemaßte
Radien / Undimensioned
A5x9 DIN 6888
1/8“ NPTF
radii: -
Radien / Undimensioned Oberflächenangaben
radii: - Oberflächenangaben
Indication ofIndication
DIN EN ISODIN
/
surface texture
1302
of surface
EN ISO 1302-
/
- texture -
-
Der Lieferant muss

Der Lieferant
sicherstellen,
mussdass
sicherstellen,
ca.385
die Waredass die Ware M12x28 Ra Rz Ra Rz
A1 Connection suction side, lockable 7/16“ UNF

in einwandfreiem
in einwandfreiem
Zustand angeliefert
Zustand wird
angeliefert wird 25 Rz 160 25 6,3 Rz 63 6,32 Rz
Rz 160 25 1,6
Rz63 2 Rz 16 1,6
Rz25 0,7 R
2
(Korrosionsschutz,
(Korrosionsschutz,
Verpackung für Verpackung
sicheren für sicheren
Transport).
Gußtoleranzen Transport).
/ General casting tolerances:Zeichnungs-Nr. / Teile-Nr. / Blatt / Maßstab / Werkstoff (Zeile 2+3 alternativ) / Extranet:
148 h8
Raccords FK(X)40/390 FK(X)40/470 FK(X)40/560 FK(X)40/655

- The supplier has
Thetosupplier
ensure has
the to
delivery
ensureofthe
parts
delivery of parts Drawing-No. Part-No. Page: Scale: Material (Line 2+3 alternative): s st tu uw w
110
in proper conditions
in proper(L)*
(corrosion
conditions prevention,
(corrosion prevention, B
ube (L)*
A Vanne d’arrêt d’aspiration, de tuyau mm-Zoll 28 – 1 1/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “ 35 – 1 3/8 “
98
90
40
, tube (L)* Vanne

B
packaging for safe
Baumustergeprüft
Connection discharge side, not lockable
packaging
d’arrêt de refoulement,/ Type
transportation).
for safe transportation).
examination:
de tuyau (L)* mm-Zoll 22 – 7/8 “ 28 – 1 1/8 “ 28 – 1 1/8 “ 35 – 1 3/8 “ -
1/8“ NPTF
B
side, not lockable
side, lockable
Nein /côté
Raccord
Weitergabe sowie
Noaspiration,
Verwertung
handlungen
Gewicht / Weight:
non
Weitergabe
obturable
Vervielfältigung
obturable
undVerwertung
sowie dieses
Mitteilung seines
boten, soweit nicht
boten, ausdrücklich
Vervielfältigung
Dokuments,
und Mitteilung
soweit nichtgestattet.
verpflichten
handlungenzuverpflichten
(kg) 31,2
ausdrücklich
Schadenersatz.
dieses Dokuments,
Zollver-Inhalts sind ver-
Inhalts sind
seines
Zuwider-
zu Zoll
gestattet. Zuwider-
Schadenersatz. 1. 0851 -13983 .0 1/3 %
Alle 0f | Gussänderungen,
1/8“ NPTF
7/16“ UNF
Alle 0f | Gussänderungen,
Betrifft BlattBetrifft
2 Blatt 2 8510,8640
-
- 26.02.13 26.02.13
8510,8640 Zuder Schaich
Zuder Schaich
Alt.bezug /
Alt.supply:
-
Werkstückkanten
Werkstückkant
Workpiece edges
DIN ISO 13715
/ K.-A
Workpiece edg
Proje
DIN ISO 13715
B1 Connection discharge side, lockable 7/16“ UNF
Dok-ID: 088314
ge side, not lockable Rechte für den

Raccord côté refoulement, nonRechte
Fall derfürPatent-,
obturable den FallGebrauchsmuster-
der Patent-,
Zoll Gebrauchsmuster- 1/8“ NPTF
oder Geschmacksmustereintragung
oder Geschmacksmustereintragung
vorbehalten. vorbehalten.
ge side, lockable Allgemeintoleranzen
Raccord / General
côté refoulement, obturable tolerances Zoll 0e | Extranet 0eB| hinzugefügt,
Extranet B 7/16“
hinzugefügt,
Ansicht
UNF Sickenrichtung
Ansicht Sickenrichtung
hinzugefügthinzugefügt
(Bl.2) (Bl.2) 8266 + 83518266 + 10.08.12
8351 10.08.12
Gneiting Gneiting
Schaich Schaich
The reproduction,
Thedistribution
reproduction, Benennung / Description:
and distribution
utilization of andthisutilization of this
sure safety switch OIL DIN ISO
Raccord 2768-mK
pressostat de sécurité
document
contents
d’huile
to others
as OIL
as document
well
contents
without
the
to
well as the Zoll
as communication
express
others without
authorization
communication
of its
express
of its
0d | Betrifft
is authorization is Blatt 3
0d | Betrifft
1/8“ NPTF
3 NPTF
Blatt1/8“ 8251 19.04.12
8251 19.04.12
Gneiting Layh
Gneiting Layh 50 1:5
K - FK40/655 N
sure safety switch LP Raccord pressostat de sécurité d’huile LPbe Zoll the
Cthe grant0.5 Connection

6 30 120 400
oil pressure safety switch OIL 1/8“ NPTF
prohibited. Offenders
prohibited.
will Offenders
held liable
will befor held liable for the
sure gauge über /duabove
Raccord payment de
manomètre of damages.
payment
pression Allofrights
d’huile damages.
reserved All in
rights
the event
reserved in the event
Zoll 1/8“ NPTF GEA Bock GmbH
GEA -Bock
Benzstraße
GmbH -7Benzstraße
- 72636 Frickenhausen
7 - 72636 Frickenhausen
- Germany - w
bisd’huile
Vidange
of
/ up to
of ofa the
6 patent, grantutility
30of amodel patent,orutility
120 design.
400
Zoll
Zust.
model or /design.
1000 Rev. Zust. / Rev.
1/4“ NPTF
Änd.-Nr. / Mod-No.
Änd.-Nr.Datum
/ Mod-No.
/ Date
Datum
Bearb.
/ Date
/ Edited
Bearb.
Geprüft
/ Edited
/ Appr. Maß/ /Appr.
Geprüft Dimension
54
Maß / Dimension
Passung / Clearance
Passung / Clearance
sump heater 1)
8Bouchon 8
Raccord opt. chauffage de carter d'huile 1)
d’huile ±0.2 ±0.3 ±0.5
de remplissage±0.1
-
7
±0.8 7 -
6 6 C - FK40/655 5N 5 664 4 3 3
D Connection oil pressure safety switch LP 1/8“ NPTF
Zoll 1/4“ NPTF
Voyant Zoll 2 x 1 1/8 “ – 18 UNEF
Oberflächenbehandlung, Härte / Treatment of surface, Hardness: Ausgangsteil, Rohteil /
Base part, Raw part: 74
protection thermostat Unbemaßte
Raccord Radien
de thermostat / Undimensioned
de protection thermique radii: -
Zoll Oberflächenangaben / 1/8“ NPTF
Filtre à huile mm Indication of M22x1,5
surface texture -
tion line valve
ection
E Connection oil pressure
Raccord opt. vanne d'arrêt d'aspiration
(L)* = Raccord à braser
gauge
DIN EN ISO 1302- - -
- 100 1/8“ NPTF
x factory 1) = Ne possible qu 'ex usine Ra Rz -
F Oil drain 25 Rz 160 6,3 Rz 63 2 0,05 Rz 1,6 Rz 25 1,6 Rz 16 0,7 Rz 12,5 0,3 Rz 6,3
Status: in Bearbeitung (CAD) 1/4“ NPTF
hrzeugverdichter / Vehicle Compressor / Compresseur
s t u
pour automobiles
w x y z Ersatz für / replacement for:
G / partOpt. connection forTeile
oil sump heater 1) Zeichn.-Nr. / Drawing -no.
-A/
p / type Teile Nr. no. Typ / type Nr. / part no. Typ / type Teile Nr. / part no.
Werkstückkanten / K.-Auftrag / C.-Task: -
Numéro de plan:
Kunde / Customer:
(X)40/390 N 13977 (13985) FK(X)40/390 K 13978 (13986) FK(X)40/390
Workpiece edges TK 14339 (14343)
Schaich
(X)40/470 N
H
13979 (13987)
Oil charge plug
FK(X)40/470 K 13980 (13988) DIN ISO 13715
FK(X)40/470
Projektleiter / Project leader: -
TK 14340 (14344)
- 1/4“ NPTF
Datum / Date Name
Schaich
(X)40/560 N
Layh
13981 K(13989)SightFK(X)40/560
glass K 13982 (13990) FK(X)40/560 TK 14341 (14345) Erstellt / Drawn 1.0851-13983.0
27.07.07 0fNPTF
1 1/8“ 2x
Schnizler
(X)40/655 N 13983 (13991) FK(X)40/655 K 13984 (13992) FK(X)40/655 TK 14342 (14346) Geprüft / Verified 27.02.08 Schaich
ted Geprüft / Appr. Maß / Dimension
L Connection thermal protection thermostat
GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
Passung / Clearance Freigabe / Approved 1/8“ NPTF
09665-12.2014-Gb
4 3 2 1
M Oil filter Gußtoleranzen / General casting tolerances:
-
Zeichnungs-Nr. /
Drawing-No.
Teile-Nr. /
Part-No. M22x1.5 Blatt /
Page:
Maßstab /
Scale:
Werkstoff (Zeile 2+3 alternativ) /
Material (Line 2+3 alternative):
Baumustergeprüft / Type examination: -
SV1 Optional connection for suction line valve Nein / No
1. 0851 -13983-.0
- 1/3 % -
Gewicht / Weight: (kg) 31,2 -
1) Allgemeintoleranzen / General tolerances

Benennung / Description:
= No connection available as standard. DIN ISO 2768-mK
Available on request (Connection M22 x 1,5)

über / above
bis / up to
0.5 6 30 120 400
6 30 120 400 1000 K - FK40/655 N
±0.1 ±0.2 ±0.3 ±0.5 ±0.8 C - FK40/655 N
Unbemaßte Radien / Undimensioned radii: - Oberflächenangaben / Oberflächenbehandlung, Härte / Treatment of surface, Hardness:
7 Ausgangsteil
Indication of surface texture - Base part, R
DIN EN ISO 1302 -
8
Type No. of Displace- Swept Weight Connections Oil Inertia Lubrication Oil pump
Cyl. ment volume Discharge Suction charge moment
(1450 rpm) line line of the
DV SV driving
unit
cm3 m3/h kg mm / inch mm/inch Ltr. [kgm2]
FK40/390 385 33.5 34.0 22 / 7/8 28 / 1 1/8
FK40/470 466 40.5 33.0 28 / 1 1/8 35 / 1 3/8

Forced Rotation-
4 I Technical data
4 2.0 0.0043
lubrication independent
FK40/560 554 48.3 33.0 28 / 1 1/8 35 / 1 3/8
FK40/655 650 56.6 31.0 35 / 1 3/8 35 / 1 3/8
The technical data for the different designs K, N and TK are identical.
The compressor type data therefore do not mention these additions.
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5 I Maintenance
Maintenance
Service intervals
Practically no maintenance is required. However, for an optimal operating safety and service life of the compressor we recommend to
carry out the necessary maintenance work regulary according to the specifications of the manufacturer of the refrigerating plant.
Function 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 cranckcase
Checking the fixing screws for tightening
Checking the function of the ancillary units
Checking the electrical connections for clean, firmly fixed contacts and the leads for chaing 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 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 connecting ring
from the shaft seal replaced.
Lubricants
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:
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
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For HFC (e.g. R134a, R404A, R407C)

Fuchs Reniso Triton SE 55 FUCHS SEZ 32 / 68 / 80 ESSO / Mobil EAL Arctic 46
Information about other suitable oils should be taken from GEA Bock lubricant tables.
Information may also be retrieved from www.gea.com.
9
5 I Maintenance
Operating of the shut-off valves

2 3
Opening the shut-off valve: Position A

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. 1
Pipe connection
2 3
Position B
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
Pipe connection
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).
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10
6 I Fault diagnosis
Fault diagnosis Function faults - Symptoms

In case of malfunctions during compressor operation we recommend Function faults arising most frequently and their symptoms are:
to prepare a measurement record for aiding the fault search:
Pressure measurement: Discharge side, suction side, Compressor stoppage, compressor cutoff
oil pressure - Compressor does not start
Temperature measurement: Compressor casing, - Compressor starts and then stops again
discharge end temperature, suction gas overheating Refrigerant performance too low
Too high compressor temperature
According to the expected cause of the fault it may be necessary Oil problems
to check the electrical systems for faults in the control. Abnormal compressor running noise
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
available on our failure analysis slide that can be downloaded on
www.gea.com.
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: Locate the interruption in the circuit
- Low pressure switch and remove
- High pressure switch
- Heat protection thermostat
- Control thermostat
- Other safety elements
Malfunction of electromagnetic - see also page 14 "Malfunction of Checking
coupling electromagnetic coupling"
Compressor cutoff
Compressor starts and stops again
Cutoff through lowpressure Suction pressure too low:
switch - 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 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 expansion valve
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- Solenoid valve on the liquid line not opening - Check the control / function
11
6 I Fault diagnosis

Cutoff through high pressure Condensing pressure too high:
switch - 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 fan is dirty - Cleaning of condenser
- Excessive refrigerant filling - Extract refrigerant to normal filling
- Non-condensible gases in refrigerant - E xtract refrigerant and evacuate the
refrigeration plant / refill refrigerant
Cutoff through heatprotection Discharge end temperatures is too high - Adapt the operating conditions
thermostat (accessory) - Operating limits of compressor exceeded to the operating range
- Suction gas overheating - Check expansion valve / check
insulation on the suction side
- Suction gas overheating - Check expansion valve / check
insulation on the suction side
- 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 Temperature over / below the desired range Check operating points
thermostat
Refrigerant performance too low

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 / refill
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
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- Pressure laminations of valve plate leaking - Replace valve plate

- By-pass between suction and discharge side - Localize leak between the discharge and
suction side and repair it
12
6 I Fault diagnosis
Refrigerant temperature too high

Suction gas temperature - Suction gas overheating - Adjust expansion valve
too high Insulate the gas suction line
- Too little refrigerant filling - Establish the operating filling (see Operating
Instruction for the refrigeration plant),
localize leak
- Liquid filter blocked - Clean / replace filter / dryer
- Shortage of refrigerant - Run leakage test / refill refrigerant
Discharge pipe temperature - Suction gas temperature too high - Adjust expansion valve
too high (Condensing pressure too high) Insulate the gas suction line
- see „Cutoff through high-pressure switch“
- Operating limits of compressor exceeded - see „Cutoff through heat-protection
thermostat“
- Cooling insufficient - Check refrigerant filling
- Adjust expansion valve
- Short circuit between the discharge and the - Check gaskets on valve plate /
suction side of the compressor 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
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 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 - Refrigerant and oil get mixed. After some time
to the refrigeration plant with the refrigerant 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 - Replace valve plate
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plate leaking
13
6 I Fault diagnosis
Abnormal running noise from compressor

Fixation of compressor is loose - Screwed connections have become loose - Tighten the screwed connections and secure
- Securing elements for screwed connections them anew
missing
- Vibration metals defective - Replace vibrations 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 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- - Checking
netic coupling“
V belt drive, - Belts vibrating excessively - Check belt tension
increased noise generation Use tensioning roller / guidance roller
- Incorrect alignment of compressor and motor - Check alignment and adjust anew
Malfunction of the electromagnetic coupling

Coupling not switching - No voltage applied - Apply voltage and check
Coupling slipping too long, get- - Voltage too low - Keep the voltage at 12 or 24 Volts (check
ting hot, smoking and squeaking 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
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, - Install new rotor ans armature disc
Armature disc is deformed
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14
7 I Installation of service kits
Disassembly and assembly of the compressor
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
For changing components in the framework of customary service works we recommend the kits described on the following pages.
Important Notes
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.
09665-12.2014-Gb
15
Shaft seal (Item No. 80023)

Removal:
Dismount the drive/magnetic coupling from the compressor.
Remove the woodruff key from seat at the shaft end.
Remove the leak oil collection ring (9) and the felt inlay (8a or 8b, according to the type) (for this see Fig. 2 on page 17).
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!
8a
8b
1
2
3
4
5
6
Fig. 1
“TOP“
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 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
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) dry, don‘t impregnate it with oil.
Install the shaft seal cover (6) with the inscription „TOP“ upwards. Tighten the fixing screws (7) evenly, crosswise tightening torque = 34 Nm.
After installing the shaft seal, turn the compressor shaft a few turns by hand and then carry out the leak test.
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Install the leak oil collection ring (see section on leak oil collection ring, page 17).
Insert the Woodruff key into the seat at the compressor shaft end.
Mount the drive/coupling.
16
Leak oil collection ring (Item No. 80129)

Procedure:
Remove the leak oil collection ring (see Fig. 2)
Leak oil
The repair kit contains two felt inlays (Pos. 2 and Pos. 3, collection ring
see Fig. 3).
If the bearing flange with one oil pocket is installed Pos. 3
must be inserted (see Fig. 4).
If the bearing flange with six oil pocket is installed Pos. 2
must be inserted (see Fig. 5).
If the wrong felt inlay, or both felt inlays, is inserted the
functioning of the oil collection system cannot be ensured. Fig. 2
Fig. 3
1 2 3
Type code 001 Type code 007 - 013
Bearing flange with Bearing flange with

one oil pocket six oil pockets
3 Open at top
Open at bottom 2
Fig.4 Fig. 5
1 1
Starting from type code 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, the bracket. Dispo-
09665-12.2014-Gb
se of used oil in accordance with the regulations applicable in the

country of use.
17
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 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 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. 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)

(Only for the capacity regulation which is an accessory) 3
Removal:
De-energize the solenoid (4). 4
Screw on the fixing nut (3), pull out the solenoid (4) with the
washer (5).
5
Unscrew the valve body (2).
Check the valve body (2) for damages and whether the piston
70 Nm
moves freely. If necessary, replace the complete valve body (2).
2 07541
1
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
fixing nut (3).
Put the compressor into operation and check the functioning of the
capacity regulation.
Fig. 6
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18
Valve plate
Compressor type Kit (Item No.) Compressor type Kit (Item No.)
FK40/390 N 80240 FK40/390 TK 80240

FK40/470 N 80240 FK40/470 TK 80240
FK40/560 N 80241 FK40/560 TK 80241
FK40/655 N 80241 FK40/655 TK 80241
FK40/390 K to FK40/655 K 80010
K type valve plate N type and TK type Valve plate
Fig. 7
09665-12.2014-Gb
19
Removal (see Fig. 7):

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.
INFO Don‘t let any gasket residues fall into the compressor
Installation (see Fig. 7):
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).
ATTENTION Install the K type valve plate (Item No. 80010) 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!
5 1 4
9
60 Nm
8 7
10
6 3 2 7
Fig. 8: Sequence for tightening the

cylinder cover screws
09665-12.2014-Gb
20
8 I Electromagnetic coupling
Assembly instruction for electromagnetic coupling

For the drive of A/C compressors in buses, mainly electromagnetic couplings are used. The followings assembly instructions for coupling type
LA 16 is representative for couplings which are mounted onto the front bearing flange of the compressor.
Assembly instruction for electromagnetic coupling type LA 16

The front bearing flange has a location face Ø 148 h8 for fitting the solenoid of the electromagnetic coupling (see Fig. 9).
Front bearing flange
85 Nm
Magnetic field
148 h8 Fig. 9 Fig. 10
For fitting the solenoid (1) remove the four M8x25 cylinder screws (2) on the bearing flange (indicated with circles and arrows, Fig. 9 page
21 and Fig. 11 page 22).
Fit the solenoid onto the location seat and fasten it again with the four M8x25 cylinder screws (Fig. 10).
ATTENTION Use only M8x25 screws! Otherwise, serious damages may occur on the electromagnetic coupling and the
compressor. Observe the screw tightening torque!
09665-12.2014-Gb
21
8 I Electromagnetic coupling
INFO Arrange the cable (8) so that it doesn‘t touch hot parts (e.g. protection pipe).
tmax = 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 cor-
rect 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).
Push the sheave (6) over the studs (9) and fasten it with zinc-coated M8 DIN 934-8 nuts (7).
Connect the cable (8). The connection is polarity-independent. Voltage ± 10% of nominal voltage.
INFO For dismounting the coupling apply grease to the K-circlip and turn the clamping screw (4) to the left
for unscrewing.
ATTENTION With all other methods of removal (pressing, hammering) there is risk of damage to the coupling.
2 34 Nm
Bearing flange
9
5
85 Nm 4 7
Fig. 11
6
09665-12.2014-Gb
22
9 I Compressor defects
Compressor defects
Compressor defects may have various causes. The table below is meant to aid you while analysing the cause of the breakdown by means of
the defective compressor parts found. Thus, the specific remedying of the cause of the breakdown is facilitated.
Compressor part Possible causes / Symptom Remedy

Valve plates - Liquid shocks because of liquid refrigerant
or oil
- Overheating of compressor - Check the operating conditions
Shaft seal leaking - Lack of oil - Change oil, clean the system; install a suction
- Dirt in the system line filter, if necessary
- Standstill time too long
- Moisture in the system - Dry the system trough changing refrigerant
and oil, replace the drier; install a suction line
filter, if necessary
- Too frequent starting of the compressor
(Heat protection thermostat switches off)
- Belt vibrating excessively
- Alignment of compressor and motor incorrect
Oil pump - Lack of oil - Change oil, clean the system; install a suction
Bearings - Lack of oil - Change oil, clean the system; install a suction
- Überlastung des Verdichters - Compare the operating conditions with the
application limits
Pistons / - Lack of oil - Change oil, clean the system; install a suction
Connecting rods - Dirt in the system line filter, if necessary
09665-12.2014-Gb
Copper plating - Moisture in the system - Dry the system trough changing refrigerant
- Acid formation in the system and oil, replace the drier; install a suction line
Formation of oil-carbon - Overheating of compressor - Check the operating conditions
23
10 I Disassembly of the compressor
Removal of the compressor from the refrigerant system

Removal of the compressor from the system, shut-off valves remaining on the compressor
- Extract the refrigerant from the system into a container which may be used for this refrigerant
- Evacuate the systems including the compressor
- Cut off the 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 connection points on the system with stoppers
- Relieve the pressure before dismounting the compressor
Removal of the compressor from the system, shut-off valves for compressor remaining at the system
- Close shut-off valves on the suction and discharge side

- Extract the refrigerant from the compressor into a container which may be used for this refrigerant
- Evacuate the compressor
- Cut off the vacuum
- Remove the compressor from the system
- Close the suction and discharge shut-off ports on the compressor with stoppers
Disassembly of compressor
The disassembly of the compressor is explained in separate steps on the following pages. The indicated parts list positions refer to the
spare parts lists, repair set lists, special accessories part lists and are available online at www.gea.com.
You can find the exploded drawing at the end of the maintenance manual.
Preparation: Necessary tools
INFO For the removal and installation of the internal decompression valve the GEA Bock special too
Item No. 09524 is necessary (up to type code 015)!
Pos. Tool Size

1 Oil collection container > 2 liter
2 Spanner SW 10, 13, 14, 17, 19, 22, 30, 36
3 Allen key 6 mm, 10 mm
4 Needle-nosed plier
5 Pulling apparatus
6 Pressing apparatus
7 Piston ring pliers
8 Dial gage
9 GEA Bock special tool, Item No. 09524
INFO With compressors starting from year of construction 2008/09 the oil pump, the shut-off valves, the
valve plate and the cylinder covers are bolted with washers.
In the individual work sections separately with these washers does not deal.
09665-12.2014-Gb
When assembling the washers must be used again on the installation!
24
1 Removal of all shut-off valves and blind flanges

Position in Parts list position: 2060, 2070, 232
parts list
Tools: Spanner SW 17, allen key 6 mm
Working course
- The compressor has to be depressurized
220 - Unscrew the fixing screws of shut-off valves
330, 210 - Remove the shut-off valves and the gaskets
230, 210 - Remove the suction filter and the gasket
233 - Remove the screws from the blind flange
232, 231 - Remove the blind flange and the O-ring
09665-12.2014-Gb
25
2 Removal of the oil filter

Position in Parts list position: 2130
parts list
Tools: Container > 2 liter for colection oil, spanner SW 19, allen key 10 mm
Working course
- Drain the oil from the compressor into a suitable container
510 - Unscrew the plug
500 - Remove the gasket
490 - Unscrew the oil filter
09665-12.2014-Gb
26
3 Removal of the cylinder cover and valve plates
Position in parts Parts list position: 170, 2000 (N / TK versions), 1940, 2900 (K version)
list
Tools: Spanner SW 17
Working course
ATTENTION 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!
N / TK K
180, 181 1950, 180 - Losen screws at the cylinder cover and unscrew, remove the washers
170, 70 1940, 1430 - Remove the cylinder cover and the upper gasket of the valve plate
60, 50 1920, 1910 - Remove the valve plate and the lower gasket of the valve plate
09665-12.2014-Gb
27
4 Removal of the shaft seal

parts list
Tools: Allen key 6 mm
Working course
INFO For a detailed description for the old version (until type code 013) see also the section on
the removal of the shaft seal on page 16!
- Place the oil collection container under the shaft seal area
2110 - Remove the leak oil collection device from the bearing flange (until type code 013)
750 - Unscrew the cylinder screws
CAUTION Danger of injury!
The shaft seal cover is under spring tension! It may jump out by itself.
2010 - Remove the shaft seal cover, the guide ring, the O-ring and the spring
Leak oil collection device
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28
5 Removal of the oil pump

parts list
Working course
40, 41 - Losen screws on the oil pump and unscrew
460, 470 - Remove the oil pump and gasket
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29
6 Removal of the baseplate

Position in Parts list position: 20, 30, 40, 41
parts list
Tools: Container for colection oil, spanner SW 13
Working course
- Place the compressor into the oil collection pan and turn it sideways
40, 41 - Unscrew the screws with the washer from the baseplate
20, 30 - Remove the baseplate and the gasket
09665-12.2014-Gb
30
7 Disassembly of the compressor rods from the crankshaft

parts list
Working course
INFO In order to prevent any mix-up during reassembly, mark the connecting rods and caps
belonging together clearly and in a wipe-resistant fashion!
2100 - Unscrew the hexagon head screws from the connecting rod cap
2100 - Mark the connecting rod cap and remove it
2040 - Push the piston and connecting rod upwards until the shop
300, 290 - Remove the piston rings
- The same procedure should be applied for the remaining connecting rods
1 2
3
09665-12.2014-Gb
31
8 Removal of the front bearing

parts list
Working course
750 - Losen the screws at the front bearing and unscrew
730, 740, - Remove the front bearing flange, gasket, and O-ring
745
09665-12.2014-Gb
32
9 Removal of the crankshaft

parts list
Tools: -
Working course
2050 - Pull out the crankshaft carefully in direction of the front bearing flange
09665-12.2014-Gb
33
10 Remove pistons and connecting rods

parts list
Tools: Needle-nosed pliers
Working course
- Mark corresponding pistons of cylinder bore
2100, 2030 - Remove the piston / connecting rod in direction of baseplate
280 - Remove circlips of the piston pins with needle-nosed plier
270 - Push the piston pins out of the pistons and remove pistons
2100 - In order to prevent mix-ups, fasten the connecting rod caps to the connecting rods again
09665-12.2014-Gb
34
11 Removal of the remaining parts

Position in Parts list position: -
parts list
Tools: Spanner SW 13, 14, 30 or 36.
For the decompression valve: GEA Bock special tool item No. 09524 (up to A015*), socket wrench SW 22 (from A017*)
Working course
570 - Dismount the sight glass
590 - Remove O-ring
520 - Remove the 1/8‘‘ NPTF plugs
521 - Remove the 1/4‘‘ NPTF plugs
100 - Unscrew the decompression valve
*) see the last four sites of the machine number
100
520
520
570 590 521
2080
09665-12.2014-Gb
521 590 570
2080
35
12 Removal of the roller bearings

parts list
Tools: Pulling apparatus
Working course
2150, 730 - With the pulling apparatus pull out the roller bearing from the front bearing flange
INFO Use oil, if necessary!
If a pulling apparatus is not available, the front bearing flange may be heated for approx. 15 minutes in a pre-heated
(220°C) baking oven. Afterwards the roller bearing can be pressed out by hand.
CAUTION Risk of burns!

Parts are hot! Use protective gloves!
2150 - Press out the roller bearing from the compressor body
312 - Take out the tolerance ring, if there is any
INFO Use oil, if necessary!
09665-12.2014-Gb
36
11 I Checking the compressor parts
Checking compressor parts for damages and wear
Before re-using removed compressor parts we recommend that they be checked for usability.
The wear limits listed below should be taken into consideration:
1 Piston - cylindre bore 0.13 mm

2 Connecting rod - piston pin 0.03 mm 1
3 Crankshaft - connecting rod 0.08 mm
Other components have to be examined according to the following criteria:

Cylinder liners
The cylinder liners should not have any visible damages in 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 that an
unhindered oil flow is ensured.
CAUTION Remaining oil can cause eye injury!

When compressed air is used, remaining oil can splash out of the oil channels.
Wear protective googles.
Clean the oil channels with compressed

air and check for passage
Compressed air
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37
Pistons
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 rings for wear, fractures
and other irregularities.
Connecting rods
There should be no damages on bearing surfaces.

The connecting rod shank must be straight.
correct faulty
Valve plates
Suction and pressure lamella must be undamaged and un-deformed. The sealing surfaces must be
clean and undamaged, between lamellas and valve plates there should not be any pollution (dirt,
swarfs etc.). 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 pump by hand (turning to the left and to the right).
In the removed conditioning the reversing device of the oil pump must switch over audibly.
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38
Oil filter / suction filter
The filter screen must be in an undamaged condition. Dirt and residues have to be removed.
If necessary, the filter have to be cleanded with compressed air or replaced with new ones.
Internal decompression valve (use GEA Bock special tool item No. 09524 up to A015, socket wrench SW 22 from A017).
The internal decompression valve must be replaced after it has operated.
Decompression valve
Oil filter
INFO In case of larger compressor damages which necessitate a complete disassembly of the compressor,
we recommend in principle the replacement of the following assemblies
Valve plates
Piston rings
Shaft seals
Roller bearings
Thus, concealed defects of parts which have been in operation may be prevented.
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39
12 I Assembly of compressor
1 Fitting the roller bearings

parts list
Tools: Pressing apparatus
Working course
730 - Heat the bearing flange / compressor casing for approx. 20 minutes in a pre-heated (120°C) baking oven
312 - Insert tolerance ring into the roller bearing, if available
2150 - Press the roller bearings onto the compressor casing and the front bearing flange
CAUTION Risk of burns!

Parts are hot! Use protective gloves!
INFO Use tolerance ring if the bearing seat has a groove!
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40
2 Fitting the sight glass, plugs and decompression valve

Position in Parts list position: -
parts list
Tools: Spanner SW 13, 14, 30 or 36. For the decompression valve: GEA Bock special tool item No. 09524 (up to A015),
socket wrench SW 22 (from A017)
Working course
INFO Observe the screw tightening torques!
570, 590 - Screw on the sight glass with oiled O-ring to the compressor body
520 - Screw in the 1/8“ NPTF screw plugs
521 - Screw in the 1/4“ NPTF screw plugs
100 - Screws on the decompression valve to screw into the suction channel
100
520 20 Nm
520 20 Nm
570 590 521 25 Nm
2080
09665-12.2014-Gb
521 590 570

25 Nm
2080
41
3 Assembly of the pistons / connecting rods

parts list
Tools: Needle-nosed pliers
Working course
270 - Assemble piston and connecting rod with piston pin, use some oil for easier assembly
280 - Mount circlips with pliers on both sides of the piston pins
09665-12.2014-Gb
42
4 Fitting the piston / connecting rods

parts list
Tools: Spanner SW 10, piston ring plier
Working course
We recommend, cleaning the housing from the inside before assembly
2100 - Remove the connecting rod cap from the preassembled connecting rod assembly and mark it
- Apply a little oil to the cylinder bore
2040 - Insert pistons/connecting rods from below into the cylinder liners
-> In the case of TK compressors pay attention to the correct assembly position of the pistons (suction fin
290, 300 grooves, see figure)
- Install oil scraper rings in the lower groove and compression rings in the upper groove
-> Fit with the marking “TOP“ facing upwards
- > The butt joints of the piston rings have to be installed min. 30° twisted to each other and may not be lying
upon each other
Oil scraper ring Compression ring

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43
5 Fitting the crankshaft

parts list
Tools: -
Working course
2050 - Fit the crankshaft so that the drive journal engeges into the gump gear
- Apply bearing position with oil
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44
6 Installation of the front bearing flange

parts list
Working course
INFO Observe the tightening torques!
745 - Apply oil to the O-ring and place it into the groove in the bearing flange
740 - The sealing surfaces have to be clean. Slightly oil seals
730, 740 - Install the front bearing flange with gasket to the body so that the hole for the leak oil collection ring
faces upwards
750 - Tighten the screws (M8x25) crosswise
34 Nm
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45
7 Assembly of the inserted connecting rods and pistons

parts list
Tools: Piston ring plier, spanner SW 10
Working course
INFO Pay attention to the correct pairing of connecting rods and connecting rod caps!
Replace connecting rod cap screws or in the case of reusing put on a sticker!
290, 300 - Compress the oil scraper ring and compression ring with the piston ring plier and insert the piston into the
cylinder liner
2100 - Place the marked connecting rod caps onto the related connecting rods
- Screw on the connecting rod caps and tighten
2050 - Turn the crankshaft by hand. In case the crankshaft does not rotate freely check the seating of the connecting
rods; if necessary, disassemble the connecting rods and carry out this step once more
2 3
15 Nm
09665-12.2014-Gb
46
8 Install of the oil pump

parts list
Working course

Pay attention to the tightening sequence of the screws!
- The sealing surfaces have to be clean. Slightly oil seals
40, 41
- Install the oil pump with gasket into the body with the inscription „TOP“ facing upwards!
460, 470
INFO Pay attention to the position of the holes in the gasket!
- Screw oil pump tightly. Tighten the screws (M8x30) crosswise
1
3
2
1 3
8 5
6 7
4 2
34 Nm
INFO Adjust axial clearance!

The axial clearance of the crankshaft must be at least 0.15 mm. When parts of the driving unit of the
compressor have been repaired or replaced, an accurate measurement of the axial clearance is neces-
sary. The measurement has to be at the disassembly shaft seal cover. If the axial clearance is less than
0.15 mm, the bearing flange must be disassembled and a second seal must inserted.
09665-12.2014-Gb
second seal
47
9 Fitting the shaft seal

parts list
Working course
INFO Caution! Avoid damages! Pay attention to the markings! ly a little oil to the parts!
Observe tightening torques!
- Push the compression spring onto the crankshaft. Rotate the spring until the driving catch is engaged in the
crankshaft
- Push the guide ring with O-ring and sliding ring onto the crankshaft. Rotate all parts until the spring is enga-
880 ged in the guide ring. Avoid scratches on the sliding ring!
750 - Install the shaft seal cover with the gasket. The inscription „TOP“ must be at the top
2050 - Press the shaft seal cover onto the bearing flange and tighten the screws
2110 - Turn the crankshaft by hand
- Install the leak oil collection device (only up to type code 013 and see also under service-kits:
Leak oil collection device)
Leak oil collection device
34 Nm
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48
10 Installation of the baseplate

Position in Parts list position: 20, 30, 40, 41
parts list
Working course

Pay attention to the tightening sequence of the screws!
20, 30 - Install the baseplate with gasket
40, 41 - Tighten the screws with the washers (M8x30) crosswise
7 3 1 5 9
11 13
15 17
34 Nm
18 16
14 12
09665-12.2014-Gb
10 6 2 4 8
49
11 Installation of the oil filter

parts list
Tools: Allen key 10 mm, spanner SW 19
Working course
490 - With the allen key, screw on the filter into the hole in the body and tighten it
500 - Install gasket
510 - Screw on the M22x1.5 mm plug and tighten it
100 Nm
09665-12.2014-Gb
50
12 Installation of the cylinder covers and valve plates

Position in parts Parts list position: 170, 2000 (N / TK versions), 1940, 2900 (K version)
list
Working course
ATTENTION Install only the cylinder covers and valve plates which belong together,
avoid mix-ups! Observe the tightening torques!
N / TK K
60, 50 1920, 1910 - Mount the valve plate with the lower valve plate gasket onto the body
170, 70 1940, 1930 - Mount the cylinder cover with the upper valve plate gasket on the valve plate
INFO Mount the K type plate with the marking „TOP“ facing upwards!
180, 181 1950, 181 - Tighten the screws and washers cross-wise in at least two steps
5 1 4
8 11
60 Nm
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10 9
6 3 2 7
51
13 Installation of all shut-off valves and blind flanges

Position in Parts list position: 2060, 2070, 232
parts list
Tools: Spanner SW 17, allen key 6 mm
Working course
INFO Observe tightening torques!

Use screws of correct length for the installation of the intermediate flanges!
230, 210 - Put in the suction filter with the gasket

2060 - Install the shut-off valves (on the discharge and suction side) with gaskets and screws
233, 232, - Install the blind flange with O-ring and screws
231
- Tighten all screws
60 Nm
60 Nm
60 Nm
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52
Checking the compressor
Working course
1. Evacuation / leak check of compressor

Connect the discharge and suction sides of the compressor to a vacuum pump
Evacuate the compressor from both sides; vacuum < 1.5 mbar. Check increase in pressure
In case there is an increase in pressure, check the compressor for leaks and evacuate again
Fill in the stipulated amount of oil (2.0 liters)
2. Carrying out the function test
Install the compressor in the system
Carry out a leak test with refrigerant
Make a test run. During this, check the oil level, the leak-tightness of the compressor, the running noise, pressure, temperatures and
the functioning of additional devices such as the capacity regulation
Remark: If the compressor is going to remain in the warehouse, charge it with nitrogen (at about 3 bar pressure) for protection.
ATTENTION Take the reminders for commissioning in the assembly instruction for FK40 into account!
Torques for screwed connections

General connections with flat seal in fibre or metal design
Screw size Tightening torque

Note: Tighten the screws cross-wise in at least two stages
M8 34 Nm (tightening torque 50 / 100%) .
M10 60 Nm
Special connections
Designation Screw size Tightening torque
Shaft seal cover M8 34 Nm
Connecting rod screws M6 15 Nm
Oil drain plug M22x1.5 1) 100 Nm
Oil intake plug 1/4“ NPTF 25 Nm
Sight glass 1 1/8“-18 NPTF 25 Nm
Flange connection
M10 60 Nm
Soldering gland-shut-off valves
Screw plugs
1/8“ NPTF 25 Nm
Plug
Electromagnetic coupling M12 85 Nm
Decompression valve M24 100 Nm
1)
= Screw with aluminium sealing ring
09665-12.2014-Gb
53
13 I Parts list
Spare parts list
FK(X)40/ ...
Pos. Designation Version Piece
390 470 560 655
20 Baseplate N, K, TK 1 03876 03876 03876 03876
30 Baseplate gasket N, K, TK 1 06721 06721 06721 06721
40 Hexagon head screw M8x30 N, K, TK 26 06244 06244 06244 06244
41 Disc B8.4 N, K, TK 26 05644 05644 05644 05644
50 Lower valve plate gasket Ø 55 N, TK 2 05695 05695 - -
50 Lower valve plate gasket Ø 60 N, TK 2 - - 05696 -
50 Lower valve plate gasket Ø 65 N, TK 2 - - - 05697
60 Valve plate, complete Ø 50 / 55 N, TK 2 07117 07117 - -
60 Valve plate, complete Ø 60 / 65 N, TK 2 - - 07118 07118
70 Upper valve plate gasket N, TK 2 06730 06730 06730 06730
100 Decompression valve for 28bar operation N, K, TK 1 07940 07940 07940 07940
170 Cylinder cover N, TK 2 03384 03384 03384 03384
180 Hexagon head screw M10x65 N, TK 22 06034 06034 06034 06034
181 Disc B10.5 N, K, TK 22 05646 05646 05646 05646
199 Transport angle N, K, TK 1 50435 50435 50435 50435
210 Valve flange gasket N, K, TK 3 50636 50636 50636 50636
221 Disc B10.5 N, K, TK 3 05646 05646 05646 05646
230 Filter suction side N, K, TK 1 03370 03370 03370 03370
231 O-Ring Ø 34.59x2.62 N, K, TK 1 05153 05153 05153 05153
232 Blind flange 9 mm N, K, TK 1 04715 04715 04715 04715
233 Countersunk screw M10x25 N, K, TK 2 05075 05075 05075 05075
270 Piston pin Ø 15x10x41 N, K, TK 4 07211 - - -
270 Piston pin Ø 15x10x46 N, K, TK 4 - 07212 - -
270 Piston pin Ø 15x10x50 N, K, TK 4 - - 07857 07857
280 Seeger circlip 15x1, DIN 472 N, K, TK 8 05551 05551 05551 05551
290 Oil scraper ring piston 50 N, K, TK 4 05389 - - -
290 Oil scraper ring piston 55 N, K, TK 4 - 05390 - -
290 Oil scraper ring piston 60 N, K, TK 4 - - 06562 -
290 Oil scraper ring piston 65 N, K, TK 4 - - - 06572
300 Tapered compression ring piston 50 N, K, TK 4 05379 - - -
300 Tapered compression ring piston 55 N, K, TK 4 - 05380 - -
300 Tapered compression ring piston 60 N, K, TK 4 - - 06563 -
300 Tapered compression ring piston 65 N, K, TK 4 - - - 06564
312 Tolerance ring for bearing Ø 90 N, K, TK 1 05280 05280 05280 05280
320 Cap nut M22x1.5 N, K, TK 2 05784 05784 05784 05784
321 Cap nut 7/16“ UNF N, K, TK 2 05789 05789 05789 05789
322 Screw plug 1/8“ NPTF N, K, TK 2 05514 05514 05514 05514
330 Shut-off valve (AL) N, K, TK 2 07128 07128 07128 07128
340 Gasket ring 42x34x1 N, K, TK 2 05067 05067 05067 05067
350 Soldered bush Ø 22 N, K, TK 1 04366 - - -
350 Soldered bush Ø 28 N, K, TK 1 - 04367 04367 -
09665-12.2014-Gb
350 Soldered bush Ø 35 N, K, TK 1 - - - 05313

355 Flange oval 16 mm N, K, TK 1 04329 04329 04329 04329
360 Flange oval 16 mm N, K, TK 1 04329 04329 04329 04329
370 Hexagon head screw M10x35 N, K, TK 2 05447 - - -
370 Cylinder screw M10x35 N, K, TK 2 - 05489 05489 05489
54
13 I Parts list
FK(X)40/ ...
390 470 560 655
380 Hexagon head screw M10x35 N, K, TK 2 05447 05447 05447 -
380 Cylinder screw M10x35 N, K, TK 2 - - - 05489
400 Soldered bush Ø 28 N, K, TK 1 04367 - - -
400 Soldered bush Ø 35 N, K, TK 1 - 05313 05313 05313
460 Oil pump complete N, K, TK 1 07990 07990 07990 07990
470 Gasket for oil pump + rear bearing flange N, K, TK 1 05094 05094 05094 05094
490 Oil filter N, K, TK 1 06723 06723 06723 06723
500 Seal ring 27x22x2 N, K, TK 1 05342 05342 05342 05342
510 Screw plug M22x1,5 N, K, TK 1 06400 06400 06400 06400
570 Sight glass - insert Ø 18 N, K, TK 2 06026 06026 06026 06026
up to type code 012
570 Sight glass - insert Ø 22 N, K, TK 2 05361 05361 05361 05361
from type code 013
590 O-Ring Ø 23.52x1.87 N, K, TK 2 05142 05142 05142 05142
up to type code 012
590 O-Ring Ø 28.30x1.87 N, K, TK 2 06352 06352 06352 06352
from type code 013
726 Cylinder screw M10x10 N, K, TK 1 06169 06169 06169 06169
727 Cable / hose holder N, K, TK 1 03860 03860 03860 03860
728 Cable / hose clamp N, K, TK 1 03861 03861 03861 03861
729 Haft plug Ø 5 (PHT, SCHW.) N, K, TK 1 50184 50184 50184 50184
730 Front bearing flange N, K, TK 1 06726 06726 06726 06726
740 Front bearing flange gasket N, K, TK 1 06165 06165 06165 06165
745 O-Ring Ø 101.19x3.53 N, K, TK 1 05169 05169 05169 05169
750 Cylinder screw M8x25 N, K, TK 14 06067 06067 06067 06067
790 Woodruff key A5x9 DIN 6888 N, K, TK 1 05673 05673 05673 05673
800 Disc Ø 50x12.5x8 N, K, TK 1 04425 04425 04425 04425
810 Spring washer B12 N, K, TK 1 05666 05666 05666 05666
880 Shaft seal cover gasket N, K, TK 1 05063 05063 05063 05063
1910 Lower valve plate gasket Ø 50 K 2 06178 - - -
1910 Lower valve plate gasket Ø 55 K 2 - 06161 - -
1910 Lower valve plate gasket Ø 60 K 2 - - 06641 -
1910 Lower valve plate gasket Ø 65 K 2 - - - 06642
1920 Valve plate complete K 2 07700 07700 07700 07700
1930 Upper valve plate gasket K 2 06162 06162 06162 06162
1940 Cylinder cover K 2 03381 03381 03381 03381
1950 Hexagon head screw M10x70 K 22 05457 05457 05457 05457
Only for FK compressors:
3999 Mach. oil SP46 / 1 ltr. can N, K, TK 1 02279 02279 02279 02279
09665-12.2014-Gb
Only for FKX compressors:
3999 Mach. oil SE55 / 1 ltr. can N, K, TK 1 02282 02282 02282 02282
55
13 I Parts list
Repair set parts list
FK(X)40/ ...
390 470 560 655
2000 Set valve plate N, TK 2 80240 80240 80241 80241
2010 Set shaft seal with mineral oil charge N, K, TK 1 80682 80682 80682 80682
2010 Set shaft seal with ester oil charge N, K, TK 1 80023 80023 80023 80023
2020 Set oil pump N, K, TK 1 80017 80017 80017 80017
2030 Set piston Ø 50 optimized N, K 4 80102 - - -
2030 Set piston Ø 55 optimized N, K 4 - 80103 - -
2030 Set piston Ø 60 optimized N, K 4 - - 80104 -
2030 Set piston Ø 65 optimized N, K 4 - - - 80105
2035 Set piston Ø 50 rilled, optimized TK 4 80220 - - -
2035 Set piston Ø 55 rilled, optimized TK 4 - 80107 - -
2035 Set piston Ø 60 rilled, optimized TK 4 - - 80210 -
2035 Set piston Ø 65 rilled, optimized TK 4 - - - 80225
2040 Set piston connecting rod with 2 rings Ø 50 N, K 4 80108 - - -
2040 Set piston connecting rod with 2 rings Ø 55 N, K 4 - 80109 - -
2040 Set piston connecting rod with 2 rings Ø 60 N, K 4 - - 80110 -
2040 Set piston connecting rod with 2 rings Ø 65 N, K 4 - - - 80111
2045 Set piston con. rod Ø 50 rilled, optimized TK 4 80249 - - -
2045 Set piston con. rod Ø 55 rilled, optimized TK 4 - 80250 - -
2045 Set piston con. rod Ø 60 rilled, optimized TK 4 - - 80251 -
2045 Set piston con. rod Ø 65 rilled, optimized TK 4 - - - 80226
2050 Set crankshaft 49 stroke, optimized N, K, TK 1 80154 80154 80154 80154
2060 Set shut-off valve NW25 (AL) N, K, TK 1 08084 - - -
2060 Set shut-off valve NW32 (AL) N, K, TK 1 - 08082 08082 08082
2070 Set shut-off valve NW20 (AL) N, K, TK 1 08100 - - -
2070 Set shut-off valve NW25 (AL) N, K, TK 1 - 08084 08084 -
2070 Set shut-off valve NW32 (AL) N, K, TK 1 - - - 08082
2080 Set sight glass Ø 18 N, K, TK 2 08698 08698 08698 08698
up to type code 012
2080 Set sight glass Ø 22 N, K, TK 2 08552 08552 08552 08552
from type code 013
2090 Set gaskets (not shown) N, TK 1 80230 80230 80230 80230
2090 Set gaskets (not shown) K 1 80001 80001 80001 80001
2100 Set connecting rod N, K, TK 4 08449 08449 08449 08449
2110 Set collection ring with felt insert N, K, TK 1 80129 80129 80129 80129
up to type code 013
2130 Set oil filter N, K, TK 1 80076 80076 80076 80076
2140 Set front bearing flange N, K, TK 1 80081 80081 80081 80081
09665-12.2014-Gb
2150 Set cylinder roller bearing N, K, TK 2 80118 80118 80118 80118

2900 Set valve plate K 2 80010 80010 80010 80010
56
13 I Parts list
Parts list, optional accessories
FK(X)40/ ...
390 470 560 655
3200 Set capacity regulator LR87, 24V DC N, TK 1 08704 08704 08704 08704
with cylinder cover
3220 Cylinder cover for CR, with bush N, TK 1 03383 03383 03383 03383
3240 Upper valve plate gasket N, TK 1 06730 06730 06730 06730
3250 Hexagonal head screw M10x70 N, TK 11 05457 05457 05457 05457
3300 Set capacity regulator LR87, 24V DC N, K, TK 1 08418 08418 08418 08418
3310 Valve body LR87 N, K, TK 1 07541 07541 07541 07541
3311 O-Ring Ø 48.0x2.5 green N, K, TK 1 05987 05987 05987 05987
3312 Disc Ø30x16x2.0 N, K, TK 1 05143 05143 05143 05143
3313 Milled nut M15x1 with O-Ring N, K, TK 1 05885 05885 05885 05885
3320 Solenoid coil 24V DC N, K, TK 1 07526 07526 07526 07526
3600 Set replacement adapter set the same N, K, TK 1 80022 80022 80022 80022
shut-off valve positioning similar to FK4/467
(not shown)
3800 Set capacity regulator LR87 24V DC K 1 08709 08709 08709 08709
with cylinder cover
3820 Cylinder cover for CR, with bush K 1 03323 03323 03323 03323
3840 Upper valve plate gasket K 1 06162 06162 06162 06162
3850 Hexagonal head screw M10x85 K 11 06338 06338 06338 06338
09665-12.2014-Gb
57
180
58
FK40/390-655 K FK40/390-655 N+TK Zubehör / Accessories / Accessoires
181 220
220 221
1950 FK40/390-655 N+TK FK40/390-655 K
2060 221
170 199 3313 3313
181 2070
370 355 400 340 330 210 3320
330 210 340 350 360 380 3320
322 321 320
1940 3300 3300
70 320 321 322 3310 3310
3312 3312
1930 3850
60 2000 3250
3311 3311
181 181
3200 3800
50
1920 2900
3220 3820
230
1910
14 I Exploded drawing
210 233 3240 3840

40
FK40/390-655 TK 41 232
460 231
300
280 2020 520
470
290 100
270 2035 Bis Ausführungsschlüssel 013
2150 until version code 013
312 520 jusque code version 013
510
280 500 2080
590
2045 490 570
2130
521 2110
2050 521
2100
790 727 729

728
300 590 726
2080 750
290 570 2150
2030
280 312
270 2040 740
745 2010
730 880
30 2140
280
750
2100
20
800
810
41 820
40
Fahrzeugverdichter / Vehicle Compressor / Compresseur pour automobiles Zeichn.-Nr. / Drawing no. /

Typ Teile Nr. Typ Teile Nr. Typ Teile Nr.
Numéro de plan:
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) 1. 0851 - 13983 .0 0f
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)
Stand / As of date / État: 05.13
Dok-ID: 088312
09665-12.2014-Gb
09665-12.2014-Gb
59
We live our values.
Excellence • Passion • Integrity • Responsibility • GEA-versity
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment
and process technology. GEA Group is listed in the STOXX® Europe 600 index.
09665-12.2014-Gb © GEA Group AG. All rights reserved.
GEA Refrigeration Technologies

09665-12.2014-Gb
GEA Bock GmbH

Benzstraße 7, 72636 Frickenhausen, Germany
Phone: +49 7022 9454-0, Fax: +49 7022 9454-137
refrigeration@gea.com, www.gea.com
60

FK 40 Maintenance Manual - 09665-12-2014-Gb

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FK40

FK40/390 K FK40/470 K FK40/560 K FK40/655 K

engineering for a better world GEA Refrigeration Technologies

Telephone +49 7022 9454 0

Target group of these instructions

Identification of safety instructions

DANGER Indicates a dangerous situation which, if not avoided,

DANGER Indicates a dangerous situation which by electrical current, if not avoided,

WARNING Indicates a dangerous situation which, if not avoided,

CAUTION Indicates a dangerous situation which, if not avoided,

ATTENTION Indicates a situation which, if not avoided,

INFO Important information / tips on simplifying work.

General safety instructions

DANGER Risk of electric shock

> For air conditioning the K design

Name plate (example)

1. Type designation 4. Machine number

Type code (example)

Main and functional parts

1. Discharge shut-off valve 10. Baseplate

344 C Anschluß Öldrucksicherheitsschalter

560 FK(X)40/655 L Anschluß Wärmeschutzthermostat

SV1 Opt. Anschlußmöglichkeit

rt no. Typ / type Teile Nr. / part no.

Der Lieferant muss

A1 Connection suction side, lockable 7/16“ UNF

Raccords FK(X)40/390 FK(X)40/470 FK(X)40/560 FK(X)40/655

, tube (L)* Vanne

ge side, not lockable Rechte für den

Cthe grant0.5 Connection

1) Allgemeintoleranzen / General tolerances

Available on request (Connection M22 x 1,5)

FK40/390 385 33.5 34.0 22 / 7/8 28 / 1 1/8

FK40/470 466 40.5 33.0 28 / 1 1/8 35 / 1 3/8

FK40/655 650 56.6 31.0 35 / 1 3/8 35 / 1 3/8

Function checks to be carried out once a year

Oil level check

- First oil change at the first maintenance of the vehicle.

For HFC (e.g. R134a, R404A, R407C)

Operating of the shut-off valves

Opening the shut-off valve: Position A

Fault diagnosis Function faults - Symptoms

Compressor stand still

Problem Possible cause Remedy

Refrigerant performance too low

- Pressure laminations of valve plate leaking - Replace valve plate

Refrigerant temperature too high

Abnormal running noise from compressor

Problem Possible cause Remedy

Malfunction of the electromagnetic coupling

Problem Possible cause Remedy

Disassembly and assembly of the compressor

WARNING Before starting any work on the compressor:

• Switch of the compressor and guard it against switching on

After the work is finished:

INFO Use only new gaskets for assembly

The following illustrations show a FK40 compressor in standard design.

Shaft seal (Item No. 80023)

DANGER Indicates a dangerous situation which, if not avoided,

DANGER Indicates a dangerous situation which by electrical current, if not avoided,

WARNING Indicates a dangerous situation which, if not avoided,

CAUTION Indicates a dangerous situation which, if not avoided,

ATTENTION Indicates a situation which, if not avoided,