Maintenance Manual Gea

Maintenance manual
FK50/460 K FK50/555 K FK50/660 K FK50/775 K FK50/830 K FK50/980 K

FK50/460 N FK50/555 N FK50/660 N FK50/775 N FK50/830 N FK50/980 N
FK50/460 TK FK50/555 TK FK50/660 TK FK50/775 TK
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engineering for a better world

-1-
Foreword
Dear Customer,
GEA Bock compressors are top-quality, reliable, service-friendly quality products. Please comply with
the following operating and maintenance instructions so that you can benefit from all advantages to the
full and use your refrigerating system throughout its entire service life. If you have any questions about
installation, operation and accessories, please contact our technical service department under phone:
+49 7022 9454-0, e-mail: [email protected], Internet: www.gea.com or your refrigerating system
wholesale dealer or our representative. The GEA Bock service team can be contacted by phone with a
toll-free hotline 00 800 / 800 000 88.
Please read the information summarised for you in this manual before starting work.
It contains important instructions for safety, installation, initial commisioning and handling.
In addition you will find information on maintenance, spare parts and accessories.
Some instructions are identified by special symbols with the following meaning:
WARNING! This symbol is used to indicate that inaccurate compliance or total
failure to comply with the instructions could cause injury to persons or damage
to the comperssor or refrigerating machine.
This symbol indicates important additional instructions which you should

observe during your work.
The high quality standart of GEA Bock compressors is guaranteed also by on-going furtherdevel-
opment of machine, features and accessories. This could possible results in non conformities
between this present manual and your compressor. Please understand tha it is not possible for
any claims to be derived from the details, illstrations and descriptions.
Your team at
GEA Bock GmbH - Subject to modification -

Benzstrasse 7
72636 Frickenhausen
Germany
Telephone +49 7022 9454 0

Fax +49 7022 9454-137
[email protected]
www.gea.com
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-2-
Contents Page
Introduction 5
Safety instructions 5
Product description 6
Short description, nameplate, type code 6
Main and functional parts 7
Dimension drawing, connections 8
Technical data 9
Maintenance 10
Function checks, oil level check, oil change 10
Operation of the shut-off valves 11
Fault diagnosis / Remedying the malfunction 12
General, function faults - symptoms 12
Compressor stand still 12
Compressor cutoff 13
Refrigerant performance too low 14
Compressor temperature too high 14
Oil problems 15
Abnormal running noise from compressor 15
Malfunction of the electromagnetic clutch 16
Installation of service kits 17
Safety 17
Clamping ring, Part no. 80129 18
Shaft seal, Part no. 80023 19
Capacity regulating valve, Part no. 07541 20
Valve plate 21
Electromagnetic clutch 23
Compressor defects 25
Disassembly of compressor 26
Removal of the compressor from the refrigerant system 26
Disassembly of compressor 26
1 Removal of all shut-off valves and blind flanges 27
2 Removal of oil filter 28
3 Removal of the cylinder cover and of the valve plates 29
4 Removal of the shaft seal 30
5 Removal of the oil pump 31
6 Removal of the baseplate 32
7 Disassembly of the connecting rods from the crankshaft 33
8 Removal of the bearing flange 34
9 Removal of the crankshaft 35
10 Removal of the pistons and connecting rods 36
11 Removal of the remaining parts 37
12 Removal of the roller bearings 38
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Contents Page
Checking the components of the cmpressor for damage / wear 39

Limiting values for wear 39
Cylinder liners 39
Crankshaft 39
Pistons 40
Connecting rods 40
Valve plates 40
Oil pump 40
Oil filter / suction filter 41
Internal decompression valve 41
Assembly of the compressor 42
1 Fitting the roller bearings 42
2 Fitting the sight glass, the plugs and the internal decompression valve 43
3 Assembly of the pistons / connecting rods 44
4 Fitting the piston / connecting rod sets 45
5 Fitting the crankshaft 46
6 Installation of the front bearing flange 47
7 Assembly of the inserted connecting rods / pistons 48
8 Installation of the oil pump 49
9 Fitting the shaft seal 50
10 Installation of the baseplate 51
11 Installation of the oil filter 52
12 Installation of the cylinder cover and valve plates 53
13 Installation of the shut-off valves and blind flanges 54
Checking the compressor 55
Tightening torques for screws 55
Spare parts list 56
Repair kits parts list 58
Parts list for optional accessories 59
Exploded drawing 60
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Introduction
Vehicle compressors Series FK50 of GEA Bock are among the most wide-spread machines used
for bus A/C applications. The criteria that speak for choosing a FK50 compressor are its compact
dimensions, its low weight, the wide capacity spectrum together with the high operating safety and
service-friendliness.
This maintenance manual is intended to make the repair and maintenance of the FK50 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.
Reminder:
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 FK 40 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.
Safety
Safety instructions
Attention! Refrigeration compressors are machines under pressure an as such
require special care in handling.
Only qualified personnel are allowed to perform any work on refrigeration com-
pressors.
The national safety regulations, accident prevention regulations, technical
rules and specific regulations (EN 378 and others) must be taken into account
absolutely.
Do not exceed the maximum operating pressure - not even for purpose of
checking!
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
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system is charged.
According to the conditions of use surface temperatures in excess of 100°C may
occur on the discharge side and temperatures below 0°C on the suction side.
Never grab rotating parts during operation! Danger of injury!
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Product description
Product description
Series FK50 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 applica-
tion range where operational safety and efficiency are concerned.
More features:
Compact 6-cylinder compressor in W design.
Wear resistant and long-lasting engine.
Six 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.
Nameplate (Example)
GEA Bock GmbH
72636 Frickenhausen, Germany AR12345A020 4
1 FKX50/775N
2 67,6
3 19/28bar 5
1. Type of compressor 4. Serial number
2. Volume baláye bei 1450 1/min 5. Oil type filled in compressor by the
manufacturer
3. LP: max. tol. stand still pressure intake side note limits of
HP: max. tol. Derating pressure high pressure side } aplication diagrams!
Type code (Example)
Explanation of the type designation
FK X 50 / 775 N
Application
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Swept volume
Size
Ester-oil filling (HFKW refrigerant e.g. R134a, R407C)
Code letter for series
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Product description
Main and functional parts
1 9
2
17
3
4 16
7 18
5
10
6 11
12
8
14
13
15
1. Cylinder cover 12. Baseplate

2. Valve plate 13. Suction shut-off valve
3. Compressor casing (FK50/660, 775, 830 and 980
4. Integrated leak oil collector with 2 suction shut-off valves)
5. Location hole for fitting magnetic clutch 14. Oil pump
6. Shaft end 15. Oil drain plug / oil filter
7. Shaft seal 16. Optional connection type
8. Connection thermal protection thermostat for suction shut-off valve
9. Discharge shut-off valve 17. Nameplate
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10. Oil filling plug 18. Leak oi drain hose

11. Sight glasses for oil (2x)
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Product description
Dimension drawing
- additional SV at FK50/660, 775, 830 and 980 standart Dimensions in mm

- () = K-Design Centre of gravity
DV
Shaft end
oil tube
Connections
A Suction side connection, not lockable 1/8“ NPTF
A1 Suction side connection, lockable 7/16“ UNF
B Discharge side connection, not lockable 1/8“ NPTF
B1 Discharge side connection, lockable 7/16“ UNF
C Oil pressure safety switch connection OIL 1/8“ NPTF
D Oil pressure safety switch connection LP 1/8“ NPTF
E Oil pressure gauge connection 1/8“ NPTF
F Oil drain M22 x 1.5
G Optional connection oil sump heater1) --
H Oil charge plug M22 x 1.5
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K Sight glass 2 x 1 1/8“-18 UNEF

L Connection thermal protection thermostat 1/8“ NPTF
M Oil filter M22 x 1.5
SV1 Optional connection suction valve --
1)
= Only possible from factory
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Connections
Type Number Swept Displ. volume Weight Oil filling Inertia Lubri Oil pump
Discharge
of cyl. volume (1450 1/min) Suction line moment cation
line
SV
DV
cm3 m3 /h kg mm / inch mm / inch Ltr. [kgm2]
FK50/460 459 40,1 44 28 / 1 1/8 35 / 1 3/8

Technical data
FK50/555 556 48,3 43 28 / 1 1/8 35 / 1 3/8

0,0047
of rotation
FK50/660 662 57,6 42 35 / 1 3/8 2 x 35 / 1 3/8

6 2,6
FK50/775 776 67,6 41 35 / 1 3/8 2 x 35 / 1 3/8
Forced feed lubrication
Independent of direction
FK50/830 831 72,3 43 35 / 1 3/8 2 x 35 / 1 3/8

0,0056
FK50/980 976 84,9 42 35 / 1 3/8 2 x 35 / 1 3/8
The technical data are the same for the various design variants K, N and TK.
In the data concerning the type of compressor, these additions are not taken into account.
-9-
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 chafing 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 collecting ring
from the shaft seal replaced.
Lubricants
Standard oil type used by GEA Bock Recommended alternatives
For H-FCKWs (e.g. R22)
FUCHS Reniso SP 46 MOBIL SHC 425 SUNOIL Suniso 4GS
SHELL Clavus SD 22-12 TEXAKO Capella WF 46
For FKWs (e.g. R 134a, R404A, R407C)
FUCHS Reniso Triton SE 55 FUCHS SEZ 32 / 68 / 80 MOBIL Arctic EAL 46
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ICI Emkarate RL 46 S SHELL Clavus R 46

Information about other suitable oils should be taken from GEA Bock lubricant tables.
Information may also be retrieved from www.gea.com.
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Maintenance

Operating of the shut-off valves

2
Opening the shut-off valve

Spindle
1: Turn to
the

left

(ccw) until the end stop.

-> Shut-off
⇒ valve fully open / Service port 2
⇒
1
closed

3

Opening

the service port (2)

2
1: Turn
Spindle 1/2 -1 turn to the right
⇒
⇒

-> Service port
2 open / Shut-off valve open
1

Port 3 is
intended for safety

devices

and

cannot

be shut-off.
3

Note:

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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Fault diagnosis
Fault diagnosis
In case of malfunctions during compressor operation we recommend to prepare a measurement record
for aiding the fault search:
Pressure measurement: Discharge side, suction side, oil pressure
Temperature measurement: Compressor casing, discharge end temperature, suction gas
overheating.
According to the expected cause of the fault it may be necessary to check the electrical systems for
faults in the control.
In order to localize the causes of operating malfunctions as easy as possible we have compiled the
following table with suggestion for remedying compressor malfunctions.
Function faults-Symptoms
Function faults arising most frequently and their symptoms are:
Compressor stoppage, compressor cutoff
- Compressor does not start
- Compressor starts and then stops again
Refrigerant performance too low
Too high compressor temperature
Oil problems
Abnormal compressor running noise
Malfunction of the electromagnetic clutch
Compressor stand still

Compressor does not start
Symptom Possible cause Remedy
Open circuit - Fuse blown - Replace fuse
Determine and remove the cause
- Localize the interruption in the
circuit and remove the cause of
Cutoff through: the interruption
- Low pressure switch
- High pressure switch
- Heat protection thermostat
- Control thermostat
- Other safety elements
Malfunction of electro- - see also p. 16 „Malfunction of - Checking
magnetic clutch electromagnetic clutch“
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Fault diagnosis
Compressor cutoff
Compressor starts and stops again
Cutoff through low- Suction pressure too low:
pressure switch - Check the setting of the low pressure - Adjust the switching points or replace
switch switch
- Suction valve of the compressor closed - Open shut-off valve
- Capacity of compressor too large - Check operating conditions
- Refrigerant deficiency - Leak test / Add refrigerant
- Filter / dryer in the liquid line blocked - Replace filter / dryer
- Expansion valve not functioning properly
- Solenoid valve on the liquid line not - Check the setting of the valve
opening - Check the control / function
Cutoff through high- Condensing pressure too high:

pressure switch - Check the setting of the high-pressure - Adjust the switching points or replace
switch switch
- Pressure valve of the compressor closed - Open shut-off valve
- Condenser fan not functioning - Check the control / replace motor
- Condenser dirty - Cleaning of condenser
- Excessive refrigerant filling - Extract refrigerant to normal filling
- Non-condensible gases in refrigerant - Extract refrigerant and evacuate the
refrigeration plant / refill refrigerant
Cutoff through heat- Discharge end temperatures is too high

protection thermostat - Operating limits of compressor exceeded - Adapt the operating conditions to the
(accessory) - Suction gas overheating operating range.
- Check expansion valve / Check insula-
- Refrigerant of the condenser insufficient tion on the suction side
- Valve plate damage - Check fan motors / Clean the condenser
- Internal decompression valve has opened - Replace valve plate
- Replace decompression valve
-C heck 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 - Check operating points
thermostat range
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Fault diagnosis
Refrigerant performance too low
Suction pressure too - Expansion valve not functioning properly - Check valve setting; replace valve, if
high necessary
- Lack of compressor capacity - Check the function of the compressor by
evacuating to vacuum.
Check function of capacity regulator
(accessory)
Suction pressure too low - See „Cutoff through low-pressure switch“ - Checking
High-pressure too high - See „Cutoff through high-pressure switch“ - Checking
High-pressure too low - Condenser being cooled to much - Adjust the control of condenser cooling
- Check compressor / Check the functio-
- Lack of compressor capacity ning of capacity regulator
- Replace valve plate
- Pressure laminations of valve plate leaking Localize leak between the discharge and
By-pass between suction and discharge side suction side and repair it
Refrigerant temperature too high

Suction gas tempera- - Suction gas overheating - Adjust expansion valve
ture 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
Discharge pipe tem- - Suction gas temperature too high - see point above
perature too high Condensing pressure too high - see „Cutoff through high-pressure switch“
- see „Cutoff through heat-protection
- Operating limits of compressor exceeded thermostat“
- Cooling insufficient
- Short circuit between the discharge and the
suction side of the compressor
- Valve plate damage - Replace defective valve plate
- Internal decompression valve has opened - Replace decompression valve
(see the section on Dismantling / Assembly
of Compressor)
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Fault diagnosis
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
- Clean / replace oil filter
- Oil filter dirty / blocked Change oil
Oil foams during start- - Liquid refrigerant has moved into the oil - Check the laying of pipes
up phase sump - Installation of the check valve in the
discharge line
- Installation of the solenoid valve in the
liquid line
- Check the control
Oil foams during - Expansion valve not functioning - Adjust / replace expansion valve
operating
Oil level decreases - During start-up, a portion of the oil is carried - Refrigerant and oil get mixed.
to the refrigeration plant with the refrigerant After some time the oil level should
stabilize.
- Refrigerant in oil Add oil, if necessary.
- see „Oil foams during operation“
- Piston rings worn - Replace piston rings
- Suction / discharge laminations of the valve - Replace valve plate
plate leaking
Abnormal running noise from compressor

Fixation of compressor - Screwed connections hava become loose - Tighten the screwed connections and
is loose - Securing elements for screwed connections secure 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 - switching on and off constantly / oscillating - Check the control
(accessory) - defective - Replace capacity regulator valve
Electromagnetic clutch - see also p. 16 „Malfunction of electromag- - Checking
slipping netic clutch“
V belt drive, increased - Belts vibrating excessively - Check belt tension
noise generation Use tensioning roller / guidance roller
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- Incorrect alignment of compressor and motor - Check alignment and adjust anew
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Fault diagnosis
Malfunction of the electromagnetic clutch
Clutch not switching - No voltage applied - Apply voltage and check
Clutch slipping too long, - Voltage too low - Keep the voltage at 12 or 24 Volts (check
getting hot, smoking vehicle network)
and squeaking - Driving power too high - Check operating conditions
- Rotor rubbing at the magnetic field - Check the seating of the magnet possibly
to high belt tension
Clutch not separating - Voltage still being applied to the magnet - Check switch / relay
- Clutch is stuck - Disconnect the armature disc from the
rotor mechanically
- Clutch overloaded, - Install new rotor and armature disc
Armature disc is deformed
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- 16 -
Installation of service kits
Disassembly-Assembly of service kits
In principle, the same safety remarks described on page 5 of this Service Manual are
valid.
Furthermore the following should be taken into account:
Before starting any work on the compressor:
Switch of the machine and guard it against switching on.
Close the discharge and suction shut-off valves.
Relieve the compressor from system pressure.
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 connected pressure-tight to the compressor (e.g.
piping, plugs, union nuts, replaced components etc.
Open the pressure and suction shut-off valves (see page 11).
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.
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Clamping ring with oil felt (Part No. 80129)
Procedure:
Remove the clamping ring (1) and the oil felt (2) (see Fig. 2)
Insert the oil felt (2) included in the repair kit and mount the
clamping ring.
Clamping ring
Fig. 1 1 2 Fig. 2
Type code 007 - 014
Open at top
Fig. 3 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.
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Proceed by removing the oil hose from the bracket, remove

the sealing plug and drain the oil into a collecting vessel. Af-
ter emptying, the bracket. Dispose of used oil in accordance
with the regulations applicable in the country of use.
- 18 -
Shaft seal (Part No. 80023)
Removal:
Dismount the drive/magnetic clutch from the compressor.
Remove the woodruff key from seat at the shaft end.
Remove the clamping ring (10) and the oil felt (9) (for this, see Fig. 2 on page 18).
Unscrew the screws (7) from the shaft seal cover (6).
Remove the gasket residues and the shaft seal cover gasket (5) from the bearing flange.
Attention: The shaft seal cover (6) is under spring tension. The remaining oil may
run out of the shaft seal chamber. Keep a suitable collection container ready!
1 2
3 4 5
6
7
10
8
Fig. 4 “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. Insert the sealing ring (7).
Tighten the fixing screws (8) evenly, crosswise tightening torque = 37 Nm.
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After installing the shaft seal, turn the compressor shaft a few turns by hand and then carry out
the leak test.
Install the clamping ring (see section on clamping ring with oil felt, page 18).
Insert the Woodruff key into the seat at the compressor shaft end.
Mount the drive/clutch.
- 19 -
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“ (Part no. 09900).
Capacity regulation valve (Part No. 07541)

(Only for the capacity regulation which is an accessory)
3
Removal:
De-energize the solenoid (4).
Screw on the fixing nut (3), pull out the solenoid 4
(4) with the washer (5). 5
Unscrew the valve body (2).
Check the valve body (2) for damages and
whether the piston moves freely. If necessary,
replace the complete valve body (2). 2 07541
1
Installation:
Screw on the valve body (2) with the enclosed
new O-ring (1) and tighten it.
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 if the capacity regulation.
Fig. 5
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- 20 -
Valve plate
Compressor type Parts kit (Part No.) Compressor type Parts kit (Part No.)
FK50/480 N 80243 FK50/460 TK 80243
FK50/555 N 80243 FK50/555 TK 80243
FK50/660 N to FK500/980 N 80244 FK50/660 TK 80244
FK50/460 N to FK50/980 K 08926 FK50/775 TK 80244
K type Valve plate N type and TK type Valve plate
1 1
2 2
3 3
TOP 4 4
Decompression valve
5 5
Fig. 6
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- 21 -
Removal (see Fig. 6):
Unscrew the screws (1) from the cylinder cover (2) and dismount cylinder cover.
Remove the gasket residues from the body of the compressor.
Reminder: Don‘t let any gasket residues fall into the compressor.
Installation (see Fig. 6):

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 (Part no. 80010) only with the inscription
„TOP“ facing upwards (see Fig. 6).
Tighten the cylinder cover screws (Pos. 1 in Fig. 6) according to the sequence shown in Fig.
7 observe the screw tightening torque (see Table on Page 55)!
1
4
5
11
8 9
7
10
2
6
3
Fig. 7: Sequence for

tightening the cylinder
cover screws
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- 22 -
Electromagnetic clutch
Assembly instruction for electromagnetic clutch
For the drive of A/C compressors in buses, mainly electromagnetic clutches are used. The followings
assembly instructions for clutch type LA 16 is representative for clutches which are mounted onto
the front bearing flange of the compressor.
Assembly instruction for electromagnetic clutch Type LA 16 (Type LA 26 at FK50/830 and
FK50/980)
The front bearing flange has a location face ø148 h8 for fitting the solenoid of the electro-
magnetic clutch (see Fig. 8).
Fig. 8 Fig. 9
Front bearing
flange
Magnetic
clutch
Ø 148 h8

For fitting the solenoid (1) remove the four M8x25 cylinder screws (2) on the bearing flange
(indicated with circles and arrows in Fig. 8 on page 23 and Fig. 10 on page 24).

Fit the solenoid onto the location seat and fasten it again with the four M8 x 25 cylinder screws
(Fig. 9). Observe the screw tightening torque (see Table on page 55)!
Attention! Use only M8x25 screws! Otherwise, serious damages may occur on the
electromagnetic clutch and the compressor.
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- 23 -
Electromagnetic clutch
Reminder: 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 correct seating of the Woodruff key in the rotor
slot. It should be possible to turn the rotor by hand without the rotor touching the solenoid.
Pay attention to the checking projection! Screw on the clamping screw (4) and tighten it.
Screw tightening torque: 85 Nm. Install the K-circlip (5).
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.
Reminder for dismounting: For dismounting the clutch 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 clutch.
Bearing flange
Fig. 11Fig. 10
96003-02.2016-Gb
- 24 -
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.
Possible causes
Compressor part Remedy
Symptom
Valve plate - Liquid shocks because of liquid
refrigerant or oil Liquid shocks:
- Overheating of compressor - Check, adjust expansion valve, replace
Shaft seal - Lack of oil it, if necessary; check refrigerant
leaking - Standstill time too long charge
- Dirt in the system - Check evaporator fan
- Moisture in the system - In case the evaporator is iced-up:
- Too frequent starting of the compres- Check the dimensioning of piping
sor (gas velocity).
- Overheating of compressor Overheating of compressor (Heat protec-
- Belt vibrating excessively tion thermostat switches off):
- Alignment of compressor and motor - Check the operating conditions
incorrect Lack of oil:
Oil pump - Lack of oil - Dirt in the system: Change oil, clean
- Dirt in the system the system; install a suction line filter, if
- Moisture in the system necessary.
- Overheating of compressor Moisture in the system /
Bearings - Lack of oil Acid formation in the system:
- Dirt in the system - Dry the system trough changing refrig-
- Moisture in the system erant and oil, replace the drier; install a
- Overheating of compressor suction line filter, if necessary.
- Overloading of compressor Frequent starting and stopping of compres-
Pistons / - Lack of oil sor:
Connecting rods - Dirt in the system - Overloading of compressor
- Moisture in the system Compare the operating conditions with
- Overloading of compressor the application limits
Copper plating - Moisture in the system
- Acid formation in the system - Remove defects in belting
Formation of oil-carbon - Overloading of compressor

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- 25 -
Disassembly of the compressor
Removal of the compressor from the refrigerant system
a) 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.
b) 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 the exploded drawing at the end of the maintenance manual.
Preparation: Necessary tools

Reminder! For the removal and installation of the internal decompression valve the
GEA Bock special tool Part No. 09524 is necessary (only up to design key 015)!
Pos. Tool Size
1 Oil collection container > 2,6 ltr.
2 Spanner SW 10, 13, 14, 17, 19, 30, 36
3 Allen key 6 mm, 10 mm
4 Seeger circlip plier, Form C 8 - 13 mm
5 Pulling apparatus
6 Pressing apparatus
7 Piston ring plier
8 Dial gage
9 GEA Bock special tool, Part No. 09524
Reminder:
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.
96003-02.2016-Gb
When assembling the washers must be used again on the installation!
- 26 -
Step Removal of all shut-off valves and blind flanges
1
Pos. in
Parts list position: 2060, 2070, 232
Tools: Spanner SW 17, allen key 6 mm
Working course
parts list
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, 333 Remove the screws from the blind flange
232, 231
232, 331
} Remove the blind flange and the seal
Fig. 11
96003-02.2016-Gb
- 27 -
Step Removal of the oil filter
2
Pos. in
Parts list position: 2130
Tools: Oil collection container, spanner SW 19, Allen key. 10 mm
Working course
parts list
Drain the oil from the compressor into a suitable container
510 Unscrew the plug
500 Remove the gasket
490 Unscrew the oil filter
Fig. 12a
Fig. 12b
96003-02.2016-Gb
- 28 -
Step Removal of the cylinder cover and valve plates
3 Parts list position: 170, 2000 (N / TK-versions), 1940, 2900 (K-version)

Tool: Spanner SW 17
In order to prevent any mix-up during reassembly, mark the cylinder cover and
the valve plates belonging together clearly and in a wipe-resistant fashion!
Pos. in parts list Working course
N / TK K
180 1950 Unscrew the cylinder cover screw
170, 70 1940, 1930 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
Fig. 13a
Fig. 13b
96003-02.2016-Gb
- 29 -
Step Removal of the shaft seal
4 Parts list position: 2010

Tools: Oil collection container, Allen key 6 mm
For a detailed description see also the section on the removal of the
shaft seal on page 19!
Pos. in Working course
parts list
Place the oil collection container under the shaft seal area
2110 Remove the leak oil collection device from the bearing flange
750 Unscrew the cylinder screws
Watch out! 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.
Fig. 14a
Fig. 14b
96003-02.2016-Gb
only up to design
key 014
- 30 -
Step Removal of the oil pump
5
Pos. in
Tools: Spanner SW 13
Working course
parts list
40 Unscrew the screws
460, 470 Remove the oil pump and gasket
Fig. 15a
Fig. 15b
96003-02.2016-Gb
- 31 -
Step Removal of the baseplate
6
P os. in
Tools: Oil collection pan, spanner SW 13
Working course
parts list
Place the compressor into the oil collection pan and turn it sideways
40 Unscrew the screws from the baseplate
20,30 Remove the baseplate and the gasket
Fig. 16a
Fig. 16b
96003-02.2016-Gb
- 32 -
Step Disassembly of the compressor rods from the crankshaft

In order to prevent any mix-up during reassembly, mark the connecting rods
and caps belonging together clearly and in a wipe-resistant fashion.
parts list
Unscrew the hexagon head screws from the connecting rod cap
Mark the connecting rod cap and remove it.
Push the piston and connecting rod upwards until the shop.
Remove the piston rings.
The same procedure should be applied for the remaining connecting rods
Fig. 17a
Fig. 17b
96003-02.2016-Gb
- 33 -
Step Removal of the front bearing
8
Pos. in
Tools: Allen key 6 mm
Working course
parts list
750 Unscrew the screws
730, 740, 745 Remove the front bearing flange, gasket, and O-ring
Fig. 18a
Fig. 18b
96003-02.2016-Gb
- 34 -
Step Removal of the crankshaft
9
Pos. in
Tools: —
Working course
parts list
Pull out the crankshaft carefully in direction of the front bearing flange.
Fig. 19a
Fig. 19b
96003-02.2016-Gb
- 35 -
Step Removal of the pistons and connecting rods
10
Pos. in
Tools: Seeger circlip plier from C 8-13 mm
Working course
parts list
Mark the piston and the cylinder bore belonging together.
Remove the piston / connecting rod in direction of baseplate.
280 Remove the seeger circlip of the piston pins.
270 Push the piston pins out of the pistons and remove pistons.
In order to prevent mix-ups, fasten the connecting rod caps to the connecting rods
again.
Fig. 20a
Fig. 20b
96003-02.2016-Gb
- 36 -
Step Removal of the remaining parts
11
Pos. in
Parts list position: —
Tools: Spanner SW 13, 14, 30 o. 36
Working course
parts list
570 Dismount the sight glass (use 30 mm or 36 mm spanner according to the type)
590 Remove O-ring
520 Remove the 1/8‘‘ NPTF plugs
510, 500 Remove the plug M22 x 1,5 with the seal
Fig. 21
96003-02.2016-Gb
- 37 -
Step Removal of the roller bearings
12
Pos. in
Tools: Pulling apparatus
Working course
parts list
2150, 730 With the pulling apparatus pull out the roller bearing from the front bearing flange.
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.
WATCH OUT! 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.
Use oil, if necessary!
Fig. 22a
Fig. 22b
96003-02.2016-Gb
- 38 -
Checking the compressor parts
Checking compressor parts for damages / 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
Maximum allowable bearing play

1 Piston-cylindre bore 0,13 mm
2 Connecting rod-piston pin 0,03 mm 1
3 Crankshaft-connection rod bearing 0,08 mm
2
Fig. 23
3
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.
Com Fig. 24
pre
sse
da
ir
Clean the oil channels with

96003-02.2016-Gb
compressed air ans check for

passage
- 39 -
Check the compressor parts
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.
Fig. 25
correct faulty
Valve plates
Suction and pressure lamella must be undamaged and un-deformed. The sealing surfaces
must be clean and undamaged. In case of a damage the valve plate must be replaced com-
pletely. 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.
Fig. 26
96003-02.2016-Gb
- 40 -
Check the compressor parts
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, Part No. 09524 up to A015*,
socket wrench SW 22 from A 017*)
The internal decompression valve must be replaced after it has operated.
*) see on the last four pages of the machine number
Fig. 27
Decompression valve
In case of larger compressor damages which necessitate a complete disassembly of

the compressor, we recommend in principle the replacement of the following assem-
blies:
Valve plates
Piston rings
Shaft seals
Roller bearings
Thus, concealed defects of parts which have been in operation may be prevented.
96003-02.2016-Gb
- 41 -
Assembly of compressor
Step Fitting the roller bearings
1
Pos. in
Tools: Pressing apparatus
Working course
parts list
Heat the bearing flange / compressor casing for approx. 20 minutes in a pre-heated
(120°C) baking oven.
Press the roller bearings onto the compressor casing and the front bearing flange.
WATCH OUT! Parts are hot! Use protective gloves!
Use tolerance ring if the bearing seat has a groove!
Pressing tool
Fig. 28a Fig. 28b

96003-02.2016-Gb
- 42 -
Step Fitting the sight glass, plugs, decompression valve
2 Parts list position: —

Tools: Spanner SW 13, 14, 30 o. 36
Observe the screw tightening torques (see table on page 55)!

parts list
570, 590 Screw on the sight glass with oiled O-ring to the compressor body.
520 Screw on the 1/8‘‘ NPTF plugs.
500, 510 Remove the plug M22 x 1,5 with the seal
Fig. 29a Fig. 29b
570
570
2080
2080
Fig. 29c 520 590
590
500 510
500 510
520
520
570
570
96003-02.2016-Gb
590
2080
2080
- 43 -
Step Assembly of the pistons / connection

Tools: Seeger circlip plier Form C 8-13 mm
P os. in Work course
parts list
Assembly the pistons with the connecting rods (in the reverse sequence of the
disassembly of compressor, step 7)
270 Insert the piston pins; use oil, if necessary. (see. Fig. 30a).
280 Install seeger circlips on both sides of the piston pins (see. Fig. 30b).
Fig. 30a
Fig. 30b
96003-02.2016-Gb
- 44 -
Step Fitting the piston / connecting rod set

Take the markings of each part into account (see disassembly, step 7 on page 33)

parts list
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 the piston / connecting rod assemblies from the opening in the baseplate into
the cylinder liners.
In the case of TK compressors pay attention to the correct assembly posi-
tion of the pistons (suction fin grooves, Fig. 31)!
290, 300 Install the oil scraper rings and the compression rings of the pistons, afterwards turn
them by 30°.
T he butt joints may not lying upon each other (Fig. 31)
Fit with the marking “TOP“ facing upwards!
Fig. 31
Oil scraper ring Compression ring

96003-02.2016-Gb
- 45 -
Step Fitting the crankshaft
5
Pos. in
Tools: —
Working course
parts list
Fit the crankshaft so that the drive journal engeges into the gump gear.
Fig. 32
96003-02.2016-Gb
- 46 -
Step Installation of the front bearing flange
6 Partsl ist position: 2140

Observe the tightening torques (see table on page 55)!

parts list
745 Apply oil to the O-ring and place it into the groove in the bearing flange.
730, 740 Install the front bearing flange with oiled gasket to the body so that the hole for the
clamping ring faces upwards.
750 Tighten the screws.
Fig. 33
96003-02.2016-Gb
- 47 -
Step Assembly of the inserted connecting rods / pistons

Tools: Piston ring plier, spanner 10 mm
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!
parts list
290, 300 Compress the oil scraper ring and compression ring with the piston ring plier and
insert the piston into he cylinder liner.
2100 Place the marked connecting rod caps onto the related connecting rods.
Screw on the connecting rod caps and tighten.
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.
Fig. 34a
Fig. 34b
96003-02.2016-Gb
- 48 -
Step Install of the oil pump

Tools: Spanner 13 mm

parts list
460, 470 Install the oil pump with oil gasket into the body with the inscription „TOP“ facing
upwards.
Pay attention to the position of the holes in the gasket (Fig. 35a)!
40 Tighten the oil pump screws crosswise
Pay attention to the tightening sequence of the oil pump screws (Fig. 35b)!
Fig. 35a Fig. 35b Tightening sequence

for oil pump screws
1 3
TOP
5
8
6 7
4
2
Adjust end play!

The end play of the crankshaft should be minimum 0,1 mm. When parts of the driving
unit of the compressor have been repaired or replaced, an accurate measurement of
the end play is necessary. The measurement has to be at the disassembly friction ring
cover. Will the play of the crankshaft be less than 0,15 mm, the bearing flange hast to
be disassembled and a second seal hast to be inserted (Fig. 35d).
Fig. 35c
96003-02.2016-Gb
Fig. 35d second seal

- 49 -
Step Fitting the shaft seal

Watch out! Avoid damages! Pay attention to the markings! Apply a little oil to
the parts! Observe tightening torques (see table on page 55)!
parts list
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 engaged in the guide ring. Avoid scratches on the sliding ring!
880 Install the shaft seal cover with the gasket. The inscription „TOP“ must be at the top.
750 Press the shaft seal cover onto the bearing flange and tighten the screws.
Turn the crankshaft by hand (it now moves with a little more difficulty).
2110 Install the clamping ring (only up to design key 014, Fig. 36 c and d) and see
also under service-kits: clamping ring with oil felt.
Fig. 36a Fig. 36b
Fig. 36d
96003-02.2016-Gb
Fig. 36c
- 50 -
Step Installation of the baseplate


parts list
20, 30, 40 Install the baseplate with gasket and tighten the M8x30 screws.
Pay attention to the tightening sequence of the baseplate screws!
Fig. 37a
Fig. 37b
96003-02.2016-Gb
Tightening sequence of base-

plate screws
- 51 -
Step Installation of the oil filter

Tools: Allen key 10 mm, Spanner SW 19

parts list
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 M22 x 1.5 mm plug and tighten it.
Fig. 38a
Fig. 38b
96003-02.2016-Gb
- 52 -
Step Installation of the cylinder covers and valve plates
12 Parts list position: 170, 2000 (N / TK versions), 1940, 2900 (K versions)

Install only the cylinder covers and valve plates which belong together, avoid
mix-ups! Observe the tightening torques (see table on page 55)!
Pos. in parts list Working course
N / TK K
See page 21-22
60, 50 1920, 1910 Mount the valve plate with the lower valve plate gasket onto the body.
70, 170 1930, 1940 Mount the cylinder cover with the upper valve plate gasket (see Fig. 39a)
Mount the K type plate with the marking „TOP“ facing upwards!
180 1950 Tighten the screw cross-wise in at least two steps.
Pay attention to the tightening sequence of the cylinder cover screws!
(see Fig. 39b)
Fig. 39a
Fig. 39b 1
4
5
11
8 9
7
96003-02.2016-Gb
10
2 Tightening sequence for
6 cylinder cover screws
3
- 53 -
Step Installation of the shut-off valves and blind flanges
13 Parts list position: 2060, 2070, 232

Apply oil gaskets; observe tightening torques (see table on page 55)!
Use screws of correct length for the installation of the intermediate flanges!
parts list
230, 210 Put in the suction filter with the gasket.
220, 210 Install the shut-off valves (on the discharge and suction side) with gaskets and screws.
If there is an intermediate flange: Use screws of correct length.
232, 231 Install the blind flange with seals and screws.
Tighten all screws; observe tightening torques!
Fig. 40a Fig. 40b
Fig. 40c Fig. 40d

96003-02.2016-Gb
- 54 -
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 (2,6 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 operating manual for
FK50 into account!
Tightening torques for screwed fastenings

General fastenings with fibrous or metallic flat gasket
Screw size Reminder: Cylinder cover / valve
Tightening torque
plate: Tighten the screws cross-wise
M8 34 Nm in at least two steps (50 / 100 % of
M10 60 Nm the tightening torque).
Special fastenings
Designation Thread size Tightening torque
Shaft seal cover M8 34 Nm
Connecting rod screw M6 15 Nm
Oil filling plug
M22 x 1,51) 60 Nm
Oil drain plug
Sight glass 11/8“-18 UNEF 25 Nm
Flanged connection M10 60 Nm
Soldering gland-shut-off valves
1/ “ NPTF
Plugs 8 25 Nm

Electromagnetic clutch M12 85 Nm
Decompression valve M24 100 Nm
1)
With aluminium gasket
96003-02.2016-Gb
- 55 -
Spare parts list
FK(X)50 / ...
Pos. Designation Version Piece
460 555 660 775 830 980
20 Baseplate N, K, TK 1 03876 03876 03876 03876 03867 03867
30 Baseplate gasket N, K, TK 1 06721 06721 06721 06721 03876 03876
40 M8x30 Hexagon head screw N, K, TK 26 06244 06244 06244 06244 06721 06721
41 Disc B8,4 N, K, TK 26 05644 05644 05644 05644 05644 05644
50 Lower valve plate gasket Ø 55 N, TK 3 05695 05695 — — — —
50 Lower valve plate gasket Ø 60 N, TK 3 — — 05696 — — —
50 Lower valve plate gasket Ø 65 N, TK 3 — — — 05697 — 05697
60 Valve plate, complete Ø 50 / 55 N, TK 3 07117 07117 — — — —
60 Valve plate, complete Ø 60 / 65 N, TK 3 — — 07118 07118 07118 07118
70 Upper valve plate gasket N, TK 3 06730 06730 06730 06730 06730 06730
80 Eye bolt M8 N,K, TK 2 06381 06381 06381 06381 06381 06381
100 Decom. valve for 28bar operation N,K, TK 3 07940 07940 07940 07940 07940 07940
110 Seal ring 27,8x24,2x2 N,K, TK 3 05791 05791 05791 05791 05791 05791
170 Cylinder cover N, TK 3 03384 03384 03384 03384 03384 03384
180 M10x65 Hexagon head screw N, TK 33 06034 06034 06034 06034 06034 06034
181 Disc B10,5 N,K, TK 33 05646 05646 05646 05646 05646 05646
210 Valve flange gasket N, K, TK 3 05083 05083 — — — —
210 Valve flange gasket N, K, TK 5 — — 05083 05083 05083 05083
220 M10x65 Hexagon head screw N, K, TK 4 06034 06034 — — — —
220 M10x65 Hexagon head screw N, K, TK 6 — — 06034 06034 — —
221 Disc B10,5 N, K, TK 4 05646 05646 05646 05646 05646 05646
230 Filter, suction side N, K, TK 1 03370 03370 — — — —
230 Filter, suction side N, K, TK 2 — — 03370 03370 03370 03370
231 Valve flange gasket N, K, TK 1 05083 05083 — — — —
232 Blind flange 15 mm N, K, TK 1 04269 04269 — — — —
233 Screw M10x25 N, K, TK 2 05447 05447 — — — —
270 Piston pin Ø 15x10x41 N, K, TK 6 07211 — — — — —
270 Piston pin Ø 15x10x46 N, K, TK 6 — 07212 — — 07212 —
270 Piston pin Ø 15x10x50 N, K, TK 6 — — 07857 07857 — 07857
280 Seeger circlip 15x1, DIN 472 N, K, TK 12 05551 05551 05551 05551 05551 05551
290 Oil control ring piston 50 N, K, TK 6 05389 — — — — —
290 Oil control ring piston 55 N, K, TK 6 — 05390 — — — —
290 Oil control ring piston 60 N, K, TK 6 — — 06562 — 50506 —
290 Oil control ring piston 65 N, K, TK 6 — — — 06572 — 50507
300 Compression ring piston 50 N, K, TK 6 05379 — — — — —
300 Compression ring piston 55 N, K, TK 6 — 05380 — — — —
300 Compression ring piston 60 N, K, TK 6 — — 06563 — 50508 —
300 Compression ring piston 65 N, K, TK 6 — — — 06564 — 50509
310 Cyl. roller bearing NJ210EX5TNG C3 N, K, TK 2 07755 07755 07755 07755 07755 07755
312 Clearance ring for bearing Ø 90 N, K, TK 1 05280 05280 05280 05280 05280 05280
320 Cap nut M22x1,5 N, K, TK 2 05784 05784 — — — —
320 Cap nut M22x1,5 N, K, TK 3 — — 05784 05784 05784 05784
321 Cap nut 7/16“ UNF N, K, TK 2 05789 05789 — — — —
96003-02.2016-Gb
321 Cap nut 7/16“ UNF N, K, TK 3 — — 05789 05789 05789 05789

322 Locking screw 1/8“ NPTF N, K, TK 2 05514 05514 — — — —
322 Locking screw 1/8“ NPTF N, K, TK 3 — — 05514 05514 05514 05514
330 Shut-off valve (AL) N, K, TK 2 07130 07130 — — — —
330 Shut-off valve (AL) N, K, TK 3 — — 07130 07130 07130 07130
331 Valve flange gasket N, K, TK 1 05083 05083 05083 05083 05083 05083
- 56 -
FK(X)50/...
460 555 660 775 830 980
332 Blind flange 15 mm N, K, TK 1 04269 04269 04269 04269 04269 04269
333 M10x35 Hexagon head screw N, K, TK 2 05447 05447 05447 05447 05447 05447
340 Gasket soldered connect. 42x34x1 N, K, TK 2 05067 05067 — — — —
340 Gasket soldered connect. 42x34x1 N, K, TK 3 — — 05067 05067 05067 05067
350 Brazed hexagon nipple Ø 28 N, K, TK 1 04367 04367 — — — —
350 Brazed hexagon nipple Ø 35 N, K, TK 1 — — 05313 05313 05313 05313
355 Flange oval 16 mm N, K, TK 2 04329 04329 — — — —
355 Flange oval 16 mm N, K, TK 3 — — 04329 04329 04329 04329
355 Flange oval 16 mm N, K, TK 3 — — 04329 04329 04329 04329
360 Brazed hexagon nipple Ø 35 N, K, TK 1 05313 05313 — — — —
360 Brazed hexagon nipple Ø 35 N, K, TK 2 — — 05313 05313 05313 05313
370 Cylinder screw M10x35 N, K, TK 2 05489 05489 — — — —
370 Hexagonal head screw M10x35 N, K, TK 4 — — 05489 05489 05489 05489
380 Cylinder screw M10x35 N, K, TK 2 — — 05489 05489 05489 05489
380 Hexagonal head screw M10x35 N, K, TK 2 05447 05447 — — — —
460 Oil pump, complete N, K, TK 1 07990 07990 07990 07990 07990 07990
470 Gasket f. oilp. + rear bear. flange N, K, TK 1 05094 05094 05094 05094 05094 05094
490 Oil filter N, K, TK 1 06723 06723 06723 06723 06723 06723
500 Seal ring 27x22x2 N, K, TK 2 05342 05342 05342 05342 05342 05342
510 Locking screw M22x1,5 N, K, TK 2 06400 06400 06400 06400 06400 06400
520 Locking screw 1/8“ NPTF N, K, TK 2 05514 05514 05514 05514 05514 05514
570 Sight glass - insert Ø18 N, K, TK 2 06026 06026 06026 06026 06026 06026
up to design key 012
570 Sight glass - insert Ø22 N, K, TK 2 05361 05361 05361 05361 05361 05361
as of design key 013
590 O-Ring Ø 23, 52x1, 78 N, K, TK 2 05142 05142 05142 05142 05142 05142
590 O-Ring Ø 28, 30x1, 78 N, K, TK 2 06352 06352 06352 06352 06352 06352
726 Cylinder screw M10x10 N, K, TK 1 06169 06169 06169 06169 06169 06169
727 Cable / hose holder N, K, TK 1 03860 03860 03860 03860 03860 03860
728 Cable / hose clamp N, K, TK 1 03861 03861 03861 03861 03861 03861
729 Haft plug Ø5 (PHT, BLACK.) N, K, TK 1 50184 06726 06726 06726 06726 06726
730 Front bearing flange N, K, TK 1 06726 06726 06726 06726 06726 06726
740 Front bearing flange gasket N, K, TK 1 06165 06165 06165 06165 06165 06165
745 O-Ring Ø 101, 19x3, 53 N, K, TK 1 05169 05169 05169 05169 05169 05169
750 Cylinder screw M8x25 N, K, TK 14 06067 06067 06067 06067 06067 06067
790 Woodruff key A5x9 DIN 6888 N, K, TK 1 05673 05673 05673 05673 05673 05673
800 Disc Ø 50x12, 5x8 N, K, TK 1 04425 04425 04425 04425 04425 04425
810 Spring washer B12 N, K, TK 1 05666 05666 05666 05666 05666 05666
820 Hexagonal head screw M12x40 N, K, TK 1 05462 05462 05462 05462 05462 05462
880 Shaft seal cover gasket N, K, TK 1 05063 05063 05063 05063 05063 05063
1910 Lower valve plate gasket Ø 50 K 3 06178 — — — — —
1910 Lower valve plate gasket Ø 55 K 3 — 06161 — — — —
1910 Lower valve plate gasket Ø 60 K 3 — — 06641 — 06641 —
96003-02.2016-Gb
1910 Lower valve plate gasket Ø 65 K 3 — — — 06642 — 06642

1920 Valve plate complete K 3 07700 07700 07700 07700 07700 07700
1930 upper valve plate gasket K 3 06162 06162 06162 06162 06162 06162
1940 Cylinder cover K 3 03381 03381 03381 03381 03381 03381
1950 Hexagonal head screw M10x70 K 33 05457 05457 05457 05457 05457 05457
- 57 -
FK(X)50/...
460 555 660 775 830 980
Only for FK - compressors !
3999 Mach. oil. SP46 / 1 Ltr. can N, K, TK 1 02279 02279 02279 02279 02279 02279
Only for FKX - compressors !
3999 Mach. oil. SE55 / 1 Ltr. can N, K, TK 1 02282 02282 02282 02282 02282 02282
Repair set parts list

FK(X)50/...
460 555 660 775 830 980
2000 Set valve plate N, TK 3 80243 80243 80244 80244 80244 80244
2010 Set shaft seal N, K, TK 1 80023 80023 80023 80023 80023 80023
2020 Set oil pump N, K, TK 1 80017 80017 80017 80017 80017 80017
2030 Set piston Ø 50 (optimized) N, K 6 80102 — — — — —
2030 Set piston Ø 55 (optimized) N, K 6 — 80103 — — — —
2030 Set piston Ø 60 (optimized) N, K 6 — — 80104 — 80616 —
2030 Set piston Ø 65 (optimized) N, K 6 — — — 80105 — 80617
2035 Set piston Ø 50 rilled, optimized TK 6 80220 — — — — —
2035 Set piston Ø 55 rilled, optimized TK 6 — 80107 — — — —
2035 Set piston Ø 60 rilled, optimized TK 6 — — 80210 — — —
2035 Set piston Ø 65 rilled, optimized TK 6 — — — 80225 — —
2040 Set piston - con. rod 2 rings Ø50 N, K 6 80083 — — — — —
2040 Set piston - con. rod 2 rings Ø55 N, K 6 — 80084 — — — —
2040 Set piston - con. rod 2 rings Ø60 N, K 6 — — 80085 — 80018 —
2040 Set piston - con. rod 2 rings Ø65 N, K 6 — — — 80086 — 80619
2045 Set piston - con. rod 2 rings Ø50 TK 6 80425 — — — — —
2045 Set piston - con. rod 2 rings Ø55 TK 6 — 80246 — — — —
2045 Set piston - con. rod 2 rings Ø60 TK 6 — — 80247 — — —
2045 Set piston - con. rod 2 rings Ø65 TK 6 — — — 80248 — —
2050 Set crankshaft 39 stroke, optimized N, K, TK 1 80087 80087 80087 80087 — —
2050 Set crankshaft 49 stroke, optimized N, K, TK 1 — — — — 80614 80614
2060 Set shut-off valve NW25(AL) N, K, TK 1 80100 80100 — — — —
2060 Set shut-off valve NW32(AL) N, K, TK 1 — — 80101 80101 80101 80101
2070 Set shut-off valve NW32(AL) N, K, TK 1 80101 80101 — — — —
2070 Set shut-off valve NW32(AL) N, K, TK 2 — — 80101 80101 80101 80101
2080 Set sight glass Ø18 N, K, TK 2 08698 08698 08698 08698 08698 08698
2080 Set sight glass Ø22 N, K, TK 2 08552 08552 08552 08552 08552 08552
96003-02.2016-Gb
2090 Set gaskets (not shown) N, TK 1 80231 80231 80231 80231 80231 80231
2090 Set gaskets (not shown) K 1 80089 80089 80089 80089 80089 80089
2100 Set connecting rod N, K, TK 6 80090 80090 80090 80090 80090 80090
2110 Set clamping ring with oil felt N, K, TK 1 80129 80129 80129 80129 80129 80129
- 58 -
FK(X)50/...
460 555 660 775 830 980
2130 Set oil filter N, K, TK 1 80076 80076 80076 80076 80076 80076
2140 Set front bearing flange N, K, TK 1 80081 02280 02280 02280 02280 02280
2900 Set valve plate K 3 80010 80010 80010 80010 80010 80010
Parts list, optional accessories

FK(X)50/...
460 555 660 775 830 980
3200 Set cap. reg. LR 87 24V with N, TK 1 08704 08704 08704 08704 08704 08704
cylinder cover
3220 Cylinder cover for LR N, TK 1 03383 03383 03383 03383 03383 03383
3240 Upper valve plate gasket N, TK 1 06730 06730 06730 06730 06730 06730
3250 Hexagonal head screw M10x70 N, TK 11 05457 05457 05457 05457 05457 05457
3300 Set cap. regulation LR 87, 24 V N, K, TK 1 08418 08418 08418 08418 08418 08418
3310 Valve body LR 87 N, K, TK 1 07541 07541 07541 07541 07541 07541
3311 O-Ring Ø 48, 0x2, 5 green N, K, TK 1 05987 05987 05987 05987 05987 05987
3312 Disc Ø 30x16x2, 0 N, K, TK 1 05143 05143 05143 05143 05143 05143
3313 Milled nut M15x1 with O-Ring N, K, TK 1 05885 05885 05885 05885 05885 05885
3320 Solenoid coil, 24 V CC N, K, TK 1 07526 07526 07526 07526 07526 07526
3800 Set cap. reg. LR 87 24V with K 1 80022 80022 80022 80022 80022 80022
cylinder cover
3820 Cylinder cover for LR K 1 03323 03323 03323 03323 03323 03323
3840 Upper valve plate gasket K 1 06162 06162 06162 06162 06162 06162
3850 Hexagonal head screw M10x85 K 11 06338 06338 06338 06338 06338 06338
96003-02.2016-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.
© GEA Group AG. All rights reserved.
GEA Bock GmbH

96003-02.2016-Gb
96003-02.2016-Gb
Benzstraße 7, 72636 Frickenhausen, Germany

Telephone: +49 7022 9454-0, Fax: +49 7022 9454-137
[email protected], www.gea.com
- 60 -

Maintenance Manual Gea

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Maintenance manual

FK50/460 K FK50/555 K FK50/660 K FK50/775 K FK50/830 K FK50/980 K

engineering for a better world

This symbol indicates important additional instructions which you should

GEA Bock GmbH - Subject to modification -

Telephone +49 7022 9454 0

Checking the components of the cmpressor for damage / wear 39

1. Cylinder cover 12. Baseplate

10. Oil filling plug 18. Leak oi drain hose

- additional SV at FK50/660, 775, 830 and 980 standart Dimensions in mm

K Sight glass 2 x 1 1/8“-18 UNEF

cm3 m3 /h kg mm / inch mm / inch Ltr. [kgm2]

FK50/460 459 40,1 44 28 / 1 1/8 35 / 1 3/8

FK50/555 556 48,3 43 28 / 1 1/8 35 / 1 3/8

FK50/660 662 57,6 42 35 / 1 3/8 2 x 35 / 1 3/8

FK50/830 831 72,3 43 35 / 1 3/8 2 x 35 / 1 3/8

Oil level check

ICI Emkarate RL 46 S SHELL Clavus R 46

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Compressor stand still

Cutoff through high- Condensing pressure too high:

Cutoff through heat- Discharge end temperatures is too high

Refrigerant temperature too high

Abnormal running noise from compressor

Type code 007 - 014

Proceed by removing the oil hose from the bracket, remove

Capacity regulation valve (Part No. 07541)

K type Valve plate N type and TK type Valve plate

Installation (see Fig. 6):

Fig. 7: Sequence for

Formation of oil-carbon - Overloading of compressor

Preparation: Necessary tools

When assembling the washers must be used again on the installation!

3 Parts list position: 170, 2000 (N / TK-versions), 1940, 2900 (K-version)

4 Parts list position: 2010

7 Parts list position: 2100

Maximum allowable bearing play

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

Clean the oil channels with

compressed air ans check for

*) see on the last four pages of the machine number

In case of larger compressor damages which necessitate a complete disassembly of

Fig. 28a Fig. 28b

2 Parts list position: —

Observe the screw tightening torques (see table on page 55)!

Pos. in Working course

Fig. 29a Fig. 29b

3 Parts list position: 2040

4 Parts list position: 2040

Pos. in Working course

Oil scraper ring Compression ring

6 Partsl ist position: 2140

Observe the tightening torques (see table on page 55)!

Pos. in Working course

7 Parts list position: 2040

8 Parts list position: 2020

Observe the tightening torques (see table on page 55)!

Pos. in Working course