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Maintenance Manual
FK 50
Types:
FK 50/460 K FK 50/555 K FK 50/660 K FK 50/775 K
FK 50/460 N FK 50/555 N FK 50/660 N FK 50/775 N
FK 50/460 TK FK 50/555 TK FK 50/660 TK FK 50/775 TK
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Foreword
3ook oompressors are rop qua||ry proouors un|on are re||ao|e ano serv|oe-lr|eno|y. ln oroer ro oe ao|e ro
rake lu|| aovanrage ol your ooo||ng sysrem over |rs uno|e uselu| ||le p|ease rake rne lo||ou|ng operar|ng
ano ma|nrenanoe |nlormar|on |nro aooounr. ln oase ol quesr|ons aoour |nsra||ar|on, operar|on ano
aooessor|es p|ease rurn ro our oeparrmenr lor app||oar|on reonno|ogy or uno|esa|ers ol ooo||ng
equ|pmenr or our represenrar|ve. You oan reaon rne 3ook $erv|oe-Team o|reor|y oy pnone ar
+49 7022 6454-0, oy e-ma||. meilQbock.de or on |nrerner ar. www.bock.de. Voreover rnere |s
rne lree 3ook-lor||ne un|on |s ava||ao|e |n Serman-speak|ng oounrr|es lrom Vonoay unr|| $aruroay
lrom 8 a.m. unr|| 9 p.m. unoer {ro||-lree nor||nej. we sna|| oe a|uays rnanklu| lor your
suggesr|ons lor rne lurrner oeve|opmenr ol our oompressor, equ|pmenr ano spare parrs program.
ock K|temasch|nen Cmbh
P.0. ox 11 1
0-7232 Fr|ckenhausen
enzstr. 7
0-723 Fr|ckenhausen
Phone: +49 7022 9454-0
Fax: +49 7022 9454-137
ma||Qbock.de
www.bock.de
Dear Customer,
efore start|ng work p|ease read the |nformat|ons |n the
ma|ntenance manua| wh|ch have been summar|zed for you!
lrporlarl rer|rders reard|r salely, |rsla||al|or,
corr|ss|or|r ard operal|or are lurr|s|ed.
Voreover you W||| l|rd |rlorral|ors reard|r
ra|rlerarce, spare parls ard accessor|es.
3ore rer|rders are rar|ed d|llererl|y:
Th|s symbo| |nd|cates that
the non-observance or |ncomp|ete
observance of |nstruct|ons may |ead
to damages to peop|e, to the compressors
or the coo||ng system.
Th|s symbo| refers to |mportant add|t|ona|
rem|nders wh|ch have to be taken |nto
account dur|ng work.
T|e ||| qua||ly standard ol 8oc| corpressors |s ersured
l|rou| l|e corl|r|ous deve|oprerl ol l|e des|r,
equ|prerl ard ard accessor|es. 8ecause ol l||s, there
ray oe d|llererces oelWeer l|e descr|pl|ors ard your
ro derards ray oe der|ved lror l|e |rlorral|or, l|ures
ard descr|pl|ors corla|red |ere|r.
Your team at
8oc| Ka|lerasc||rer 0rol
-Right for making modifications reserved.-
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5 Introduction
5 Safety instructions
6 Product description
6 Short description, name plate, type code
7 Main and functional parts
8 Dimension drawings, connections
9 Technical data
10 Maintenance
10 Function checks, oil level check, oil change
11 Operations of the shut-off valves
12 Fault diagnosis / Remedying the malfunction
12 General, function faults - symptoms
12 Compressor stand still
13 Compressor cutoff
14 Cooling performance too low
14 Compressor temperature too high
15 Oil problems
15 Abnormal running noise from compressor
16 Malfunction of the electromagnetic clutch
17 Installation of service kits
17 Safety
18 Leak oil collection ring, Part no. 80019
19 Shaft seal, Part-no. 80023
20 Capacity regulating valve, Part-no. 07541
21 Valve plate
23 Electromagnetic clutch
25 Compressor defects
26 Disassembly of compressor
26 Removal of the compressor from the cooling system
26 Disassembly of compressor
27 1 Removal of all shut-off valves and blind flanges
28 2 Removal of oil filter
29 3 Removal of the cylinder cover and of the valve plates
30 4 Removal of the shaft seal
31 5 Removal of the oil pump
32 6 Removal of the baseplate
33 7 Disassembly of connecting rods from the crankshaft
34 8 Removal of the front bearing flange
35 9 Removal of the crankshaft
36 10 Removal of the pistons and connecting rods
37 11 Removal of remaining parts
38 12 Removal of the roller bearings
Page Contents
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39 Checking the components of the compressor for damage / wear
39 Limiting values for wear
39 Cylinder liners
39 Crankshaft
40 Pistons
40 Connecting rods
40 Valve plates
40 Oil pump
41 Oil filter / suction filter
41 Internal safety valve
42 Assembly of the compressor
42 1 Fitting the roller bearings
43 2 Fitting the sight glass, the plugs
and the internal safety valve
44 3 Assembly of the pistons / connecting rods
45 4 Fitting the pistons / connecting rod sets
46 5 Fitting the crankshaft
47 6 Installation of the front bearing flange
48 7 Assembly of the inserted connecting rods / pistons
49 8 Installation of the oil pump
50 9 Fitting the shaft seal
51 10 Installation of the base plate
52 11 Installation of the oil filter
53 12 Installation of the cylinder cover and valve plates
54 13 Installation of the shut-off valves and blind flanges
55 Checking the compressor
55 Tightening torques for screws
56 Spare part list
58 Repair kits parts list
59 Parts list for optional accessories
60 Exploded drawing
Page Contents
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Vehicle compressors Series FK 50 of Bock are among the most wide-spread machines used for bus
A/C applications. The criteria that speak for choosing a FK 50 compressor are its compact dimensions,
its low weight, the wide capacity spectrum together with the high operating safety and service-friendliness.
This maintenance manual is intended to make the repair and maintenance of the FK 50 easier for the
servicing personnel. This maintenance manual contains an complete description of each work step for the
disassembly and assembly of the compressor components. Each step must be carefully adhered to in order
to ensure a reliable repair.
Reminder:

For replacing components Bock provides suitable spare part kits.Yet assembly jobs which go
beyond the replacement of the shaft seal, the valve plates and - if there is one - the capacity
regulator (accessory) should be checked carefully for their economic efficiency beforehand.

The maintenance manual describes the standart type of the FK 50 compressor which we deliver.
Because of different system conceptions, some passages in this service manual may differ from the
unit which you have come across. In these cases the present manual should be used in analogous
fashion.
Introduction
Safety instructions
Attention! Refrigeration compressors are machines under pressure and as such
require special care in handling.
Only qualified personnel are allowed to perform any work on refrigeration compressors
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 purposes 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, evcuate the cooling system 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.
According to the conditions of use surface temperatures in excess of 100C may
occur on the discharge side and temperatures below 0C on the suction side.
Never grab rotating parts during operation! Danger of injury!
Safety
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Product description
Series FK 50 vehicle compressors are designed for mobile applications.
Name plate (Example)
1
2
3
4
5
FK
Product description
1. Type of compressor 4. Serial number
2. Theoretic volume flow rate at 1450 rpm 5. Oil type filled in compressor by manuf.
3. ND(LP): max. tol. Stand still pressure intake side
HD(HP): max. tol. Derating pressure high pressure side
}
note limits of application
diagrams!
FKX50/775N
67,6
AM12345A017



Compact 6-cylinder compressor in V design.
Wear resistant and long-lasting engine.
Four sizes as regarding capacity.
Aluminum light weight construction.
Crankshaft supported in roller bearings on both sides.
Bidirectional lubricating oil pump with relief valve.
Variable arrangement of shut-off valves.
Ideally equipped with valve plates for each application.
Integrated pulsation damper for especially quiet running.
Field of application
Displacement
Size
Ester oil filling (HFKW-Coolants, such as R 134a, R407C)
Series
Short description
Three options for different application fields are available:
> for air conditioning the K-model
> for the air conditioner or normal cooling the N-model
> for deep freezing the TK-model
The differences lie in form of the valve plate mounting, which is conforming the current field of
application in terms of operational safety and efficiency.
Further Characteristics:


Type code (Example)
Explanation of the type designation
X 50 / 775 K
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Main and functional parts
8
13
14
15
1. Cylinder cover
2. Valve plate
3. Compressor casing
4. Integrated leak oil collector
5. Locating hole for fitting magnetic clutch
6. Shaft end
7. Mechanical seal
8. Connection for heat protection thermostat
9. Discharge shut-off
10. Oil filling plug
11. Sight glasses for oil (2x)
12. Base plate
13. Suction shut-off valve
(FK 50/660 and FK 50/775
with 2 suction shut-off valves)
14. Oil pump
15. Oil drain plug / oil filter
16. Optional connection facilities for
suction shut-off valves
17. Nameplate
18. Leak oil drain hose
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16
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17
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Dimension drawing
Shaft end
View X
Connections
A Suction side port, not lockable 1/8 NPTF
A1 Suction side port, lockable 7/16 UNF
B Pressure side port, not lockable 1/8 NPTF
B1 Pressure side port, lockable 7/16 UNF
C Oil pressure safety switch connection OIL 1/8 NPTF
D Oil pressure safety switch connection LP 1/8 NPTF
E Port for oil pressure gauge
F Oil drain plug
G Opt. connection facility f. oil sump heating
1)
--
H Oil filling plug
K Sight glass
1
/
8
-18 UNEF
L Heat protection thermostat connection
M Oil filter M 22 x 1/5
SV1 Opt. Connection facilities f. Suction shut-off valve --
1)
= Only possible from factory
1/8`` NPTF
1/4`` NPTF
1/4`` NPTF
1/8`` NPTF
1
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Technical Data
Type
Cyl.
Num.
Disp.
m
cm
3
Flow
rate vol.
(1450
1
/min)
m
3
/h
Weight
kg
Discharge
side
DV
mm / Zoll
Suciton
side
SV
mm / Zoll
Oil
filling
Ltr.
FK50/460
6
460 40,1 43,0 28

/ 1
1
/
8
35

/ 1
3
/
8
2,6
FK50/555 555 48,3 42,5 28

/ 1
1
/
8
35

/ 1
3
/
8
2,6
FK50/660 660 57,6 41,0 35

/ 1
3
/
8
2x35

/ 1
3
/
8
2,6
FK50/775 775 67,6 40,0 35

/ 1
3
/
8
2x35

/ 1
3
/
8
2,6
Connections
Mass moment of inertia of the engine [kgm2]: 0 ,0053
Lubrication: Forced lubrication
Oil pump: bidirectional
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Maintenance
Service intervals
Praticcally no maintenance is required. However, for an optimal operating safety and service life of the
compressor we recommend to carry out the necessary maintenance work regularly according to the
specifications of the manufacturer of the refrigerating plant.
Changing oil:
In case of orderly manufactured and operated plants and oil change is in principle not
absolutely necessary.
Yet, based on decades-long experience we recommend to carry out the following oil change
and servicing.
- First oil change at the first maintenance of the vehicle.
- After that, changing the oil every 5000 operating hours, but at the latest after 3 years. At the
same time the oil filter and the suction filter should be cleaned and the oil collecting ring from
the shaft seal replaced.
Function checks to be carried out once a year:
Leak test of the plant
Checking the running noise of compressor
Checking pressures and temperatures of the plant
Checking the tensioner for orderly seating
Checking the V-belts for tension and condition
Checking the oil level in the crankcase
Checking the fixing screws for tightening
Checking the function of the ancillary units
Checking the electrical connections for clean, firmly fixed contacts and leads for chafing points
Lubricants
Standard oil type used by Bock Recommended alternatives
For H-FCKWs (e.g. R22)
FUCHS Reniso SP 46 MOBIL SHC 425 SUNOIL Suniso 4GS
SHELL Clavus SD 22-12 TEXACO Capella WF 46
SUNOIL Suniso 3GS
For FKWs (e.g. R 134a, R404A, R407C)
FUCHS Reniso Triton SE 55 FUCHS SEZ 32 / 68 / 80 MOBIL Arctic EAL 46
ICI Emkarate RL 46 S SHELL Clavus R 46
Information about other suitable oils should be taken from Bock lubricant tables.
Information may also be retrieved from www.bock.de.
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
Maintenance
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Operation of the shut-off valves
Note: Before opening or closing the shut-off valve, loose the valve spindle seal (Fig. left) by
turn. After operating the shut-off valve, tighten the valve spindle seal carefully again
(Fig. right).

Opening the shut-off valve
Spindle 1 turn to the left (ccw)
until the end stop.
Shut off valve fully open / Service
port 2 closed.
Opening the service port (2)
Spindle 1 Turn -1 turn to the right
Service port 2 open /
Shut off valve opened.
Port 3 is intended for safety devices and
cannot be shut off.
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2
1
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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
Temperatur measurement: Compressor casing, discharge end temperature, suction gas
overheating
According to the expected cause of the fault it may be necessary to check the electrical
system for faults in the control.
In order to localize the causes of operating malfunctions as easy as possible we have compiled
the following table with suggestions for remedying compressor malfunctions.
Function faults-Symptoms
Function faults arising most frequently and their symptoms are:
Compressor stoppage, compressor cutoff
- Compressor does not start
- Compressor starts and then stops again
Cooling performance too low
Too high compressor temperature
Oil problems
Abnormal compressor running noise
Malfunction of the elektromagnetic clutch
Fault diagnosis
Compressor does not start
Symptom Possible cause Remedy
Open circuit - Fuse blown - Replace fuse
Determine and remove the cause
Cutoff through: - Localize the interruption in the circuit
- Low pressure switch and remove the cause of the
- High pressure switch interruption
- Heat protection thermostat
- Control thermostat
- Other safety elements
Malfunction of - see also p.16 "Malfunctio n - Checking
electromagnetic clutch electromagnetic clutch"
Compressor stand still
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Compressor cutoff
Compressor starts and stops again
Symptom Possible cause Remedy
Cutoff though 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 - Replace filter / dryer
blocked
- Expansion valve not functioning properly - Check the setting of the valve
- Solenoid valve on the liquid line not - Check the control / function
opening
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 refrigarant to normal
filling
- Non-condensible gases in refrigerant - Extract refrigerant and evacuate the
refrigerant plant / refill refrigerant

Cutoff through heat- Discharge end temperatures is too high
protection thermostat - Operating limits of compressor - Adapt the operating conditions to the
(accessory) exceeded operating range
- Suction gas overheating - Check expansion valve / Check
insulation on the suction side
- Cooling of the condenser insufficient - Check fan motors / Clean the condenser
- Valve plate damage - Replace valve plate
- Internal safety valve has opened - Replace safety valve
- Check compressor and refrigeration
plant Determine and remove the cause
for the inadmissible high pressure in the

Cutoff through control - Temperature over / below the desired - Check operating points
thermostat range
high-pressure side
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Cooling performance too low
Symptom Possible cause Remedy
Suction pressure too - Expansion valve not functioning properly - Check valve setting; replace valve,
if necessary
- Lack of compressor capacity - Check the functioning of the compressor
by evacuating to vacuum.
Check function of capacity regulator
(accessory)
Suction pressure too low - See "Cutoff through low-pressure switch" - Checking
High pressure too high - See "Cutoff through high-pressure switch" - Checking
High pressure too low - Condenser being cooled to much - Adjust the control of condenser
cooling
- Lack of compressor capacity - Check compressor / Check the functioning
of capacity regulator
- Pressure laminations of valve plate leaking - Replace valve plate
Bypass between suction and discharge Localize leak between the discharge and
suction side and repair it
Cooling temperature too high
Symptom Possible cause Remedy
Suction gas - Suction gas overheating - Adjust expansion valve
temperature 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 see point above
too high see "Cutoff through high-pressure
switch"
see "Cutoff through heat-protection
exceeded thermostat
- Cooling insufficient
- Short circuit between the discharge and
the suction side of compressor
- Valve plate damage - Replace defective valve plate
- Internal safety valve has opened - Replace safety valve
(see the section on Dismantling /
Assembly of Compressor)
side
high
- Suction gas temperature too high
Condensing pressure too high
- Operating limits of compressor
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Oil problems
Symptom Possible cause Remedy
Oil pressure too low - Refrigerant in oil - see "Oil foams"
- Too little oil in compressor - Add oil and search for the cause of
oil loss
- Oil filter dirty / blocked - Clean / replace oil filter
Change oil
Oil foams during - Liquid refrigerant has moved into the oil - Check the laying of pipes
up phase sump - Installation of 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
operation
Oil level decreasese - 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.
Add oil, if necessary.
- Refrigerant in oil - see "Oil foams during
operation"
- Piston rings worn - Replace piston rings
- Suction / discharge lamination of the valve - Replace valve plate -
Abnormal running noise from compressor
Symptom Possible cause Remedy
Fixation of compressor - Screwed connections have become loose - Tighten the screwed connections and
is loose - Securing elements for screwed connection missing secure them anew
- Vibration metals defective - Replace vibration metals
Liquid shock - Liquid refrigerant reaching the compressor - Adjust / check expansion valve
Check refrigerant filling
Check evaporator fan
I cing-up of the evaporator
- Oil shocks because of too much oil - Check oil level
Check dimensioning of pipes (gas
velocity)
Replace worn piston rings

Capacity regulator - switching on and off constantly / oscillating - Check the control
(accessory) - defective - Replace capacity regulator valve
Electromagnetic clucth - see also p. 16 "Malfunction of electro- - Checking
slipping magnetic clutch"
V belt drive, increased - Belts vibrating excessively - Check belt tension
noise generation Use tensioning roller / guidance roller
- Incorrect alignment of compressor and - Check alignment and adjust anew
motor
plate leaking
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Malfunction of the electromagnetic clutch
Symptom Possible cause Remedy
Clutch not switchi ng - No voltage applied - Apply voltage and check

Clutch slipping too - Voltage too low - Keep the voltage at 12 or 24
long, getting hot - Volts (check vehicle network)
smoking 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
Armature disc is deformed disc
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Disassembly-Assembly of service kits
Safety remarks
In principle, the same safety remarks described on page 5 of this Service Manual are valid.
Furthermore the following should be taken into account:
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 Bock spare parts.
After the work is finished:
Connect the safety switch and check its function
Evacuate the compressor
Before commisioning, check whether all the components installed by the user have
been mounted expertly and connected pressure-tight to the compressor (e.g. piping,
plugs, union nuts, replaced components etc.).
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.
Installation of service kits
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Type code 001 Type code 007 - 013
Leak oil collection ring
Fig. 1
Leak oil collection ring (Part No 80129)
Procedure:
Remove the leak oil collection ring (see Fig. 1)
The repair kit contains two felt inlays (Pos. 2 and Pos. 3, see
Fig. 2)
If the bearing flange with one oil pocket is installed, Pos. 3
must be inserted (see Fig. 3).
If the bearing flange with six oil pocket is installed, Pos. 2
must be inserted (see Fig. 4).
If the wrong felt inlay or both felt inlays is/are inserted, the
functioning of the oil collection system cannot be ensured.

1 2
Bearing flange with
one oil pocket
3
Open at bottom
1
Fig.3
Bearing flange with
six oil pockets
Open at top
2
1
Fig. 4
from type code 015- (from 4. Quarter of 2005)
Bleeding the oil reservoir: The emptying of the oil reservoir
is possible in the simplest way without dismounting the
coupling respectively the brake pulley and is recommended by
both air condition maintenance and engine service. Hereto
disconnect the oil hose from the holder, remove the connection
plug and bleed the oil into the collection container. After the
emptying, close the oil hose and fasten the holder. Used oil
should be disposed according to national regulations.
3
Fig. 2
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Fig. 5
2
4
6
8a
3
5
1
8b
TOP
7
9
Shaft seal (Part No 80023)
Removal:
Dismount the drive/magnetic clutch from the compressor.
Remove the Woodruff key from seat at the shaft end.
If available remember move the leak oil collection ring (9) and the felt inlay (8a or 8b, according to the type)
(for this, see Fig. 1 on page 18)
Unscrew the screws (7) from the shaft seal cover (6).
Remove the gasket residues and the shaft seal cover gasket (5) from the bearing flange.
Attention: The shaft seal cover (6) is under spring tension. The remaining oil may
run out of the shaft seal chamber. Keep a suitable collection container ready!
Installation:
Work with utmost cleanliness.
Always replace the shafts seals complete, never individual parts thereof.
Do not use used parts.
Prior to installation, check the sliding and sealing surfaces for cleanliness and damages. .
Apply a thin film of oil on the sealing surfaces of the sliding ring (4), shaft seal cover (6),
O-ring (3) and the compressor shaft (use copmressor oil).
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 = 37 Nm.
After installing the shaft seal, turn the compressor shaft a few turns by hand and then carry out
the leak test.
If available install the leak oil collection ring (see section on leak oil collection ring, page 18).
Insert the Woodruff key into the seat at the compressor shaft end.
Mount the drive/clutch.
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-
G
b
- 20 -
Capacity regulation
The capacity regulation takes place through the turning off of the suction gas flows by means of a
solenoid valve on the cylinder cover. For this, the valve is activated electrically by the thermostat by a
thermostat or pressostat.
During normal operation the solenoid is de-energized and the suction gas channel in the valve
plate and in the cylinder cover is open.
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. 33% and 66 %.
Further information together the description of the working principle of the solenoid valve is contained
in the publication "Capacity regulation" (Part No 09900).
Capacity regulation valve (Part No 07541)
(Only for the capacity regulation which is an accessory)
Removal:
De-energize the solenoid (4).
Screw on the fixing nut (3), pull out the solenoid
(4) with the washer (5).
Unscrew the valve body (2).
Check the valve body (2) for damages and whether
the piston moves feerly. If necessary, replace the
complete valve body (2).
Installation:
Screw on the valve (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 of the capacity regulation.
3
4
5
Fig. 6
07541
2
1
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 21 -
Valve plate
Compressor type Parts kit (Part.-No.) Compressor type Parts kit (Part.-No.)
FK 50/460 N 80243 FK 50/460 TK 80243
FK 50/555 N 80243 FK 50/555 TK 80243
FK 50/660 N 80244 FK 50/660 TK 80244
FK 50/775 N 80244 FK 50/775 TK 80244
FK 50/460 K to FK 50/775 K 08926
K type Valve plate N type and TK type Valve plates
TOP
Fig. 7
1
2
3
5
4
1
2
3
5
4
Safety valve
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 22 -
1
5
8
10
6
3
2
7
9
11
4
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.
Reminder: 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 (Part no. 08926) only with the inscription
"TOP" facing upwards (see Fig. 7).
Tighten the cylinder cover screws (Pos. 1 in Fig.7) according to the sequence shown in Fig. 8,
observe the screw tightening torque (see Table on page 55)!
Fig. 8: Sequence for
tightening the cylinder
cover screws
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 23 -
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 Type LA 16
The front bearing flange has a locationg face 148 h8 for fitting the solenoid of the electro-
magnetic clutch (see Fig. 9).
For fitting the solenoid (1) remove the four M8 x 25 cylinder screws (2) on the bearing flange
(indicated with circles and arrows in Fig. 9 on page 23 and Fig. 11 on page 24).
Fit the solenoid onto the locating seat and fasten it again with the four M8 x 25 cylinder screws
(Fig. 10). Observe the screw tightening torque (see Table on page 55)!
Attention! Use only M8 x 25 screws! Otherwise, serious damage may occur on the
electromagnetic clutch and the compressor.
Fig. 9
Electromagnetic clutch
148 h8
Front bearing
flange
Magnetic field
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 24 -
Reminder: Arrange the cable (8) so that it doesn't touch hot parts (e.g. protection
pipe). t
max
= 105C!
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 unscrewing.
Attention! With all other methods of removal (pressing, hammering) there is risk of
damage to the clutch.
Fig. 11
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 25 -
Compressor defects
Compressor defects may have various causes. The table below is meant to aid you while analyzing
the cause of the breakdown by means of the defective compressor parts found. Thus, the specific
remedying of the cause of the breakdown is faciliated.
Compressor parts
Valve plates
Shaft seal
leaking
Oil pump
Bearings
Pistons/
Copper plating
Formation of
Possible causes
Symptom
- Liquid shocks because of
liquid refrigerant or oil
- Overheating of compressor
- Lack of oil
- Standstill time too long
- Dirt in the system
- Moisture in the system
- Too frequent starting of the compressor
- Overheating of compressor
- Belts vibrating excessively
- Alignment of compressor and
motor incorrect
- Lack of oil
- Dirt in the system
- Moisture in the system
- Overheating of compressor
- Lack of oil
- Dirt in the system
- Moisture in the system
- Overheating of compressor
- Overloading of compressor
- Lack of oil
- Dirt in the system
- Moisture in the system
- Overheating of compressor
- Moisture in the system
- Acid formation in the system
- Overheating of compressor
Remedy
Liquid shocks:
- Check, adjust expansion valve,
replace it, if necessary; check
refrigerant charge.
- Check evaporator fan.
- In case the evaporator is iced-up:
Check the dimensioning of piping
(gas velocity).
Overheating of compressor (Heat
protection thermostat switches off):
- Check the operating conditions
Lack of oil:
- Dirt in the system: Changing oil,
clean the system; install a suction
line filter, if necessary.
Moisture in the system /
Acid formation in the system:
- Dry the system through changing
refrigerant and oil, replace the drier;
install a suction line filter, if necessary.
Frequent starting and stopping of compressor:
- Overloading of compressor
Compare the operating
conditions with the application limits.

- Remove defects in belting.
Compressor defects
Connecting rods
oil-carbon
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 26 -
Removal of the compresor from the cooling system
a) Removal of the compressor from the system; shut-off valves remaining on the compressor
Extract the refrigerant from the system onto a container which may be used for this refrigerant.
Evacuate the system including the compressor.
Cut off vacuum, humid air should not get into the system.
Close the shut-off valves on the suction and discharge side; remove the compressor.
Close the suction and discharge line collection points on the system with stoppers.
Relieve the pressure before dismounting the compressor.
b) Removal of the compressor from the system; shut-off valves for compressor remaining at the system
Close the shut-off valves on the suction and discharge side.
Extract the refrigerant from the system onto a container which may be used for this refrigerant.
Evacuate the compressor.
Cut off vacuum.
Remove the compressor from the system.
Close the suction and discharge shut-off ports on the compressor with stoppers.
Disassembly of compressor
The disassembly of the compressor is explained in separate steps on the following pages. The
indicated parts list positions refer to spare parts list, repair set lists, special accessories part lists and
the exploded drawing at the end of the maintenance manual.
Pos. Tool Size
1 Oil collection container > 2,0 ltr.
2 Spanner SW 10, 13, 14, 17, 19, 22, 30,
36
3 Allen key 6 mm, 10 mm
4 Seeger circlip plier, Form C 8 - 13 mm
5 Pulling aperatus
6 Pressing aperatus
7 Piston ring plier
8 Dial gage
9 Bock special tool, Part No. 09524
Preparation: Necessary tools
Reminder! For the removal and installation of the internal safety valve the BOCK
special tool Part No. 09524 is necessary!
Dissasembly of the compressor
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 27 -
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, Remove the blind flange and the O-ring
332, 331
Pos. in
Working course
parts List
Part list position: 2060, 2070, 232
Step
1
Removal of all shut-off valves and blind flanges
Tools: Spanner SW 17, Allen key 6 mm
Fig. 12
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 28 -
Drain the oil from the compressor into a suitable container
510 Unscrew the plug
500 Remove the gasket
490 Unscrew the oil filter
Pos. in
Working course
parts list
Parts list position: 2130
Step
2
Removal of the oil filter
Tools: Oil collection container, spanner 19 mm, Allen key 10 mm
Fig. 13a
Fig. 13b
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 29 -
180 1950 Unscrew the cylinder covers screws
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
Pos. in parts list
Working course
N / TK K
Parts list position: 170, 2000 (N / TK-Versions), 1940, 2900 (K-Version)
Step
3
Removal of the cylinder cover and valve plates
Tools: 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.
Fig. 14a
Fig. 14b
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 30 -
Place the oil collection container under the shaft seal area
2110 If available remove the leak oil collection device from the bearing flange
750 Unscrew the cylinder screws

Caution! 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.
Pos. in
Working course
parts list
Parts list position: 2010
Step
4
Removal of the shaft seal
Tools: Oil collection container, Allen key 6 mm
For detailed description, see also the section of the removal of the shaft seal on page 19!
Fig. 15a
Fig. 15b
Only to model
code 013
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 31 -
40 Unscrew the screws
460, 470 Remove the oil pump and gasket
Pos. in
Working course
parts list
Parts list position: 2020
Step
5
Removal of oil pump
Tools: Spanner 13
Fig. 16a
Fig. 16b
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 32 -
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
Pos. in
Working course
parts list
Parts list position: 20
Step
6
Removal of the base plate
Tools: Oil collection pan, spanner 13
Fig. 17a
Fig. 17b
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 33 -
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 stop.
Remove the piston rings.
The same procedure should be applied for the remaining connecting rods.
Pos. in
Working course
parts list
Parts list position: 2100
Step
7
Disassembly of the connecting rods from the crankshaft
Tools: Spanner 10
In order to prevent any mix-up during reassembly, mark the connecting rods and
caps belonging together clearly and in wipe-resistant fashion.
Fig. 18a
Fig. 18b
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 34 -
750 Unscrew the screws
730, 740, 745 Remove the front bearing flange, gasket, and O-ring
Pos. in
Working course
parts list
Parts list position: 2140
Step
8
Removal of the front bearing flange
Tools: Allen key 6 mm
Fig. 19a
Fig. 19b
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 35 -
Pull out the crankshaft carefully in direction of the front bearing flange
Pos. in
Working course
parts list
Parts list position: 2050
Step
9
Removal of the crankshaft
Tools:
Fig. 20b
Fig. 20a
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 36 -
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 and connecting rod
caps to the connecting rods again.
Pos. in
Working course
parts list
Parts list position: 2040
Step
10
Removal of the pistons and connecting rods
Tools: Seeger circlip plier Form C 8-13 mm
Fig. 21a
Fig. 21b
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 37 -
570 Dismount the sight glass (use SW 30 or 36 spanner according to the type)
590 Remove the O-ring
520 Remove the 1 /8 NPTF screws
510, 500 Remove the M22 x 1,5 screws with gasket
Pos. in
Working course
parts list
Parts list position: -
Step
11
Removal of the remaining parts
Tools: Spanner 13, 14, 30 o. 36
Fig. 22
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 38 -
310, 730 With the pulling apparatus, pull out the roller bearing from the front bearing flange

If no pulling apparatus is available, the front bearing flange may be heated for circa
15 minutes in a preheated (220 C) baking oven. Afterwards, the roller bearing can
be pressed out by hand.
CAUTION! Parts are hot! Use protective gloves!
310 Press out the roller bearing from the compressor body.
312 Take out the tolerance ring, if there is any.
Use oil, if necessary!
Pos. in
Working course
parts list
Parts list position: 310
Step
12
Removal of the roller bearings
Tools: Pulling apparatus
Fig. 23b
Fig. 23a
Use oil, if necessary!
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 39 -
Other components have to be examined according to the following criteria:
Cylinder liners
DThe cylinder liners should not have any visible damages into the piston movement area.
If there is fluting, the casing should be replaced.
Crankshaft
The bearing surfaces should not have any damages. The oil channels should be
clean so that an unhindered oil flow is ensured. .
Checking compressor parts for damages / wear
Before re-using removed compressor parts we recommend that they be
checked for usibility.
The wear limits listed below should be taken into consideration
Clean the oil channels with compressed
air and check for passage.
Checking the compressor parts
maximum allowable bearing play:
1.) Piston-cylinder bore 0,13 mm
2.) Connecting rod-piston pins 0,03 mm
3.) Crankshaft connecting rod bearing 0, 08 mm
Wear limits
Fig. 24
Fig. 25
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 40 -
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
drings for wear, fractures and other irregularities.
Connecting rods
There should be no damages on bearing surfaces.
The connecting rod shank must be straight.
Valve plates
Suction and pressure lamella mut be undamaged and un-deformed. The sealing surfaces
must be clean and undamaged. In case of a damage the valve plate must be replaced
completely. Single lamella are not available.
Oil pump
It must be possible to turn the oil level pump by hand (turning to the left and to the right).
In the removed condition the reserving device of the oil pump must switch over audibly.
correct faulty
Fig. 26
Fig. 27
9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 41 -
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 seal
Roller bearings
Thus, concealed defects of parts which have been in operation may be prevented.
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 cleaned with compressed air or replaced with new ones.

Internal safety valve (Use Bock special tool, Part No. 09524, use until A013
The internal safety valve must be replaced after it has operated.
Safety valve
Fig. 28
Spanner 22 from A015)
Step
1
Asembly of compressor
Pos. in
parts list
Fitting the roller bearings
Parts list position: 310
Tools: Pressing apparatus
Working course
Heat the bearing flange / compressor casing for approx. 20 minutes in a pre-heated
(120C) 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. 29a Fig. 29b
-42-
9
6
0
0
3
-
0
2
.
0
6
-
G
b

















9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 43 -
570, 590 Screw on the sight glass with oiled O-ring to the compressor body.
520 Screw on the 1/8 NPTF screws.
500, 510 Screw on the M22 x 1,5 screws with gasket.
Pos. in
Working course
parts list
Parts list position: -
Step
2
Fitting the sight glass, connection screws, safety valve
Tools: Spanner 13, 14, 30 o. 36
Observe the screw tightening torques (s. Table S. 55)!
Fig. 30a
Fig. 30b
Fig. 30c
Pos. in
parts list
Working course
Assembly of the pistons / connecting rods
Parts list position: 2040
Tools: Seeger circlip plier Form C 8-13 mm
Assembly the pistons with the connectiong rods (in the reverse sequence of dis-
assembly of compressor, Step 7)
Insert the piston pins; use oil, if necessary (see. Fig. 31a).
Install seeger circlips on both sides of the piston pins (see. Fig. 31b).
270
280
Fig. 31a
Fig. 31b
-44-
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















Step
3
Pos. in
parts list
Working course
Fitting the piston / connecting rod set
Parts list position: 2040
Tools: Spanner 10 mm
Take the markings of each part into account (see Disassembly, Step 7 on page 33)
Remove the connecting rod cap from the preassembled connecting rod assembly and
mark it.
Apply a little oil to the cylinder bore.
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 position
of the pistons!
Install the oil scraper rings and the compression rings of the pistons, afterwards turn
them by 30.
Fit with the marking TOP facing upwards
2100
2040
290, 300
Fig. 32
Oil scraper ring Compression ring
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















-45-
Step
4
Pos. in
parts list
Fitting the crankshaft
Parts list position: 2050
Tools: -
Working course
Fit the crankshaft so that the drive journal engages into the pump gear.
Fig. 33
-46-
9
6
0
0
3
-
0
2
.
0
6
-
G
b

















Step
5
Pos. in
parts list
Working course
Installation of the front bearing flange
Parts list position: 2140
Tools: Allen key 6 mm
Observe the tightening torques (see Table on page 55)!
Apply oil to the O-ring and place it into the groove in the bearing flange
Install the front bearing flange with oiled gasket to the body so that the hole for the leak
oil collection ring faces upwards.
Tighten the screws.
Fig. 34
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















-47-
745
730, 740
750
Step
6
Pos. in
parts list
Working course
Assembly of the inserted connecting rods / pistons
Parts list position: 2040
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!
Observe the tightening torques (see Table on page 55)!
Compress the oil scraper ring and compression ring with the piston ring plier and
insert the piston into the cylinder liner.
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.
290, 300
2100
Fig. 35a
Fig. 35b
-48-
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















Step
7
Pos. in
parts list
Working course
Installation of the oil pump
Parts list position: 2020
Tools: Spanner 13 mm
Observe the tightening torques (see Table on page 55)!
Install the oil pump with oiled gasket into the body with the inscription "TOP" facing upwards!
Pay attention to the position of the holes in the gasket (Fig. 36a)!
Tighten the oil pump screws crosswise
Pay attention to the tightening sequence of the oil pump screws (Fig. 36b)!
460, 470
40
Tightening sequence
for oil pump screws
Fig. 36a Fig. 36b
Fig. 36c
Adjust end play!
The end play of the crankshaft should be 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. By means of shims an eventually necessary correction is possible.
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















-49-
Step
8
Pos. in
parts list
Working course
Fitting the shaft seal
Parts list position: 2010
Tools: Allen key 6 mm
Watch out! Avoid damages! Pay attention to the markings! Apply a little oil to the parts!
Observe tightening torques (see Table on page 55)!
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!
Install the shaft seal cover with the gasket. The inscription TOP must be at the top.
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).
Install the leak oil collection device (only to model code 013, Fig. 37 c and d, see also
under Service-kits: Leak oil collection device)
880
750
2110
Fig. 37a
Fig. 37c
Fig. 37d
Fig. 37b
-50-
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















Step
9
- 51 -
Installation of the baseplate
Parts list position: 20
Tools: Spanner 13 mm
Observe the tightening torque (see Table on page 55) !
20, 30, 40
Working course
Fig. 38a
Fig. 38b
Tightening sequence of
baseplate screws
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















Install the baseplate with gasket and tighten the M8x30 screws.
Pay attention to the tightening sequence of the baseplate screws!
Pos. in
parts list
10
Step
Pos. in
parts list
11
Step
490
500
510
Installation of the oil filter
Parts list position: 2130
Tools: Allen key 10 mm, Spanner 19 mm
Observe the tightening torque (see Table on page 55)!
Working course
With the Allen key, screw on the oil filter into the hole in the body and tighten it.
Install gasket.
Screw on the M22x1.5 mm plug and tighten it.
Fig. 39a
Fig. 39b
-52-
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















9
6
0
0
3
-
0
2
.
0
6
-
G
b
- 53 -
See also page 21 - 22
60, 50 1920, 1910 Install 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 (s. Fig.40a)
Mount the K type plate with the marking TOP facing upwards!
180 1950 Tighten the screws crosswise in at least two times
Pay attention to tightening sequence of the cylinder cover screws! (s. Fig. 40b)
Pos. in part list
Working course
N / TK K
Parts list position: 170, 2000 (N / TK-versions), 1940, 2900 (K-version)
Step
12
Installation of the cylinder covers and the valve plates
Tools: Spanner SW 17
NInstall only the cylinder covers and valve plates which belong together, avoid
mix-ups! Observe tightening torques (s. Table S. 55)!
Fig. 40b
Fig. 40a
1
5
8
10
6
3
2
7
9
11
4
Tightening sequence for
cylinder cover screws
-54-
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















Fig. 41d
230, 210
220, 210
Installation of the shut-off valves and blind flanges
Parts list position: 2060, 2070, 232
Tools: Spanner 17 mm, Allen key 6 mm
Apply oil to gaskets; observe tightening torques (see Table on page 55)!
Use screws of correct length for the installation of the intermediate flanges!
Working course
Install the blind flange with O-ring and screws.
Tighten all screws; observe tightening torques!
Pos. in
parts list
232, 231
Put in the suction filter with the gasket
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.
13
Step
Fig. 41a Fig. 41b
Fig. 41c
332, 331
- 55 -
9
6
0
0
3
-
0
2
.
0
6
-
G
b

















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
capacity regulation.
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 und evacuate again.
Fill in the stipulated amount of oil (2,6 l)
2. Carrying out the function test
General fastenings with fibrous or metallic flat gaskets
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 FK
50 into account!
Tightening torques for screwed fastenings
M8 37 Nm
M10 60 Nm
Reminder: Cylinder cover/valve plate:
Tighten the screws cross-wise in at
least two steps (50/100 % of the
tightening torque)
Screw size Tightening torque
Special fastenings
Designation Thread size Tightening torque
1)
With aluminum gasket
Safety valve
Shaft seal cover
Connecting rod screw
Oil filling plug
Oil drain plug
Sight glass
Flanged connection
Soldering gland-shut-off valves
Plugs
Electromagnetic clutch
M24
M8
M6
M22X1,5
1)
M24
NPTF
1
/ 8
M12
M10
37 Nm
15 Nm
60 Nm
25 Nm
60 Nm
25 Nm
85 Nm
60 Nm
1
/ 8 "
Pos.
Spare parts list
Designation Version Piece
FK (X) 50 /...
Baseplate
Baseplate gasket
M8x30 Hexagon head screw
Lower gasket Valve plate, 55
Lower gasket Valve plate, 60
Lower gasket Valve plate, 65
Valve plate, complete, 50 / 55
Valve plate, complete, 60
Upper gasket Valve plate
Safety valve for 25 bar operation
N, K, TK
N, K, TK
N, K, TK
N, TK
N, TK
N, TK
N, TK
N, TK
N, TK
N, K, TK
1
1
26
2
2
2
2
2
2
1
03876
06721
06244
05695
--
--
07117
--
06730
07940
03876
06721
06244
05695
--
--
07117
--
06730
07940
03876
06721
06244
--
05696
--
--
07118
06730
07940
03876
06721
06244
--
--
05697
--
07118
06730
07940
20
30
40
50
50
50
60
60
70
100
Cap nut M22x1,5
Cap nut 7/16 UNF
Plug, 1/8 NPTF
Shut-off valve
Cylinder cover
M10x65 Hexagon head screw
Valve flange gasket
M10x65 Hexagon head screw
Filter, suction side
O-Ring 34,59x2, 62
Blind flange 9 mm
Screw M10x25
Piston pin 15x10x41
Piston pin 15x10x46
Piston pin 15x10x50
Seeger circlip 15x1, DIN 472
Oil scraper ring for 50 mm piston
Oil scraper ring for 55 mm piston
Oil scraper ring for 60 mm piston
Oil scraper ring for 65 mm piston
Compression ring for 50 mm piston
Compression ring for 55 mm piston
Compression ring for 60 mm piston
Compression ring for 65 mm piston
Tolerance ring for bearing 9
N, TK
N, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
2
22
3
4
1
1
1
2
4
4
4
8
4
4
4
4
4
4
4
4
1
2
2
2
2
03384
06034
05083
06034
03370
05083
04269
07211
--
--
05551
05389
--
--
--
05379
--
--
--
05280
05784
05789
05514
07130
03384
06034
05083
06034
03370
05083
04269

--
07212
--
05551
--
05390
--
--
--
05380
--
--
05280
05784
05789
05514
07130
03384
06034
05083
06034
03370
05083
04269
05075
--
--
07857
05551
--
--
06562
--
--
--
06563
--
05280
05784
05789
05514
07130
03384
06034
05083
06034
03370
05083
04269
05075
--
--
07857
05551
--
--
--
06572
--
--
--
06564
05280
05784
05789
05514
07130
170
180
210
220
230
231
232
233
270
270
270
280
290
290
290
290
300
300
300
300
312
320
321
322
330
110 Gasket 27, 8x24, 2x2 N, K, TK
1
05791 05791 05791 05791
331
332
333
Gasket - Valve flange
Blind flange 15 mm
Allen screw M10x35
Ring gasket 42x34x1
Soldering gland 22
Soldering gland 28
Soldering gland 35
Oval flange 16 mm
Oval flange 16 mm
M10x35 Hexagon head screw
M10x35 Cylinder screw
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
2
1
1
1
1
1
2
2
05067
04366
--
--
04329
05447
05067
--
04367
--
04329
--
05067
--
04367

04329
--
05067
--
--
05313
04329
--
340
350
350
350
355
355
370
370
--
05489 05489 05489
N, K, TK 1
N, K, TK 1
05083 05083 05083 05083
04269 04269 04269 04269
05447 05447 05447 05447
460 555 660 775
05313
-56-
9
6
0
0
3
-
0
2
.
0
6
-
G
b

















N, K, TK
Designation Pos. Piece Version
FK (X) 50 /...
460 555 660 775
460
470
490
500
510
520
521
570
Oil filter
Seal ring 27x22x2
Plug, M22x1,5
Plug, 1/8 NPTF
Plug, 1/4" NPTF
Sight glass element 18
g g
Gasket, oil pump + bearing flange, rear
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
1
1
1
2
1
2
2
2
07990
05094
06723
05342
06400
05514
05801
06026
07990
05094
06723
05342
06400
05514
05801
06026
07990
05094
06723
05342
06400
05514
05801
06026
07990
05094
06723
05342
06400
05514
05801
06026
Oil pump, complete
to model code 012
570
from model code 013
Sight glass element 22
590

t t o mo d e l c o d e
590
726
727
728
O-Ring 23, 52x1, 78
to model code 012
O-Ring 28, 30x1, 78
from model code 013
730
740
745
750
790
800
810
820
880
1910
1910
1910
1910
1920
1930
1940
1950
Front bearing flange
Front bearing flange gasket
O-Ring 101, 19x3,53
Cylinder screw M8x25
Woodruff key A5x9 DIN 6888
Washer 50x12,5x8
Spring washer B12
M12x40 Hexagon head screw
Gasket for shaft seal cover
Lower gasket Valve plate 50
Lower gasket Valve plate 55
Lower gasket Valve plate 60
Lower gasket Valve plate 65
Valve plate, complete
Upper gasket Valve plate
Cylinder cover
M10x70 Hexagon head screw
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
K
K
K
K
K
K
K
K
1
1
1
14
1
1
1
1
1
2
2
2
2
2
2
2
22
06726
06165
05169
06067
05673
04425
05666
05462
05063
06178
--
--
--
07700
06162
03381
05457
06726
06165
05169
06067
05673
04425
05666
05462
05063
--
06161
--
--
07700
06162
03381
05457
06726
06165
05169
06067
05673
04425
05666
05462
05063
--
--
06641
--
07700
06162
03381
05457
06726
06165
05169
06067
05673
04425
05666
05462
05063
--
--
--
06642
07700
06162
03381
05457
Cable / hose clips
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
2
2
2
1
1
1
05361 05361 05361 05361
05142 05142 05142 05142
06169 06169 06169 06169
03860 03860 03860 03860
03861 03861 03861 03861
05142 05142 05142 05142
Cylinder screws
Cable / hose holder
-57-
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















2000
2010
2020
2030
2030
2030
2030
2035
2035
2035
2035
2040
2040
2040
2040
2045
2045
2045
2045
2050
2060
2060
2070
2070
2070
Repair set parts list
Pos.
SET Shut-off valve NW25(MS)
SET Shut-off valve NW32(MS)
SET Shut-off valve NW20(MS)
SET Shut-off valve NW25(MS)
SET Shut-off valve NW32(MS)
Designation
N, TK
N, K, TK
N, K, TK
N, K
N, K
N, K
N, K
TK
TK
TK
TK
N, K
N, K
N, K
N, K
TK
TK
TK
TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
SET Valve plate
SET Shaft seal
SET Oil pump
SET 50 piston, optimized
SET 55 piston, optimized
SET 60 piston, optimized
SET 65 piston, optimized
SET 50 piston, grooved, optimized
SET 55 piston, grooved, optimized
SET 60 piston, grooved, optimized
SET 65 piston, grooved, optimized
SET 50 piston -con-rod assy.
SET 55 piston -con-rod assy.
SET 60 piston -con-rod assy.
SET 65 piston -con-rod assy.
SET 50 piston -con-rod assy.
SET 55 piston -con-rod assy.
SET 60 piston -con-rod assy.
SET 65 piston -con-rod assy.
SET Crankshaft for 49 mm stroke, optim.
2
1
1
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
1
1
1
1
1
1
Piece Version
FK (X)
80243
80023
80017
80102
--
--
--
80220
--
--
--
80083
--
--
--
80245
--
--
--
80087
80100
--
08698
--
--
80243
80023
80017
--
80103
--
--
--
80107
--
--
--
80084
--
--
--
80246
--
--
80087
--
08084
--
80244
80023
80017
--
--
80104
--
--
--
80210
--
--
--
80085
--
--
--
80247
--
80087
--
80101
08084
--
80244
80023
80017
--
--
--
80105
--
--
--
80225
--
--
--
80086
--
--
--
80248
80087
--
80101
--
08082
FK (X) FK (X) 50/ ...
460 555 660 775
2090
2090
2100
SET Gaskets (not shown)
SET Gaskets (not shown)
SET Connecting rod
N, TK
K
N, K, TK
1
1
4
80231
80089
80090
80231
80089
80090
80231
80089
80090
80231
80089
80090
2080
2080
2080 SET collecter ring with felt insert
2130
2140
g
SET Oil filter
SET Front bearing flange
N, K, TK
N, K, TK
1
1
80076
80081
80076
80081
80076
80081
80076
80081

Sight glass 18
to model code 012
Sight glass 22
from model code 013
N, K, TK
N, K, TK
2
2
N, K, TK
to model code 013
08698 08698 08698 08698
08552 08552 08552 08552
1 08129 08129 08129 08129
80100
80698 80698 80698
SET Valve plate 2900 K 2
80926 80926 80926 80926
-58-
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















3820
3840
3850
Parts list, optional accessories
Pos.
3200
3220
3240
3250
3300
3310
3311
3312
3313
3320
3600
Upper gasket valve plate
M10x85 Hexagon head screw
Designation
SET Capacity regulator LR 87, 24V
with cylinder cover
Cylinder cover for capacity regulator, with bushing
Upper gasket valve plate
M10x70 Hexagon head screw
SET Capacity regulator LR 87, 24V
Valve body LR 87
O-ring 48,0x2,5 green
Flat washer 30x16x2,0
M15x1 mirror nut with O-ring
Solenoid, 24 V (DC)
3800
SET Replacement adapter set for
the same stop valve positioning
as FK4/467 (not shown)
SET Capacity regulator LR 87, 24V
with cylinder cover
Cylinder cover for capacity regulator, with bushing
N, K, TK
K
K
K
K
Version
N, TK
N, TK
N, TK
N, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
N, K, TK
1
1
1
1
11
Piece
1
1
1
11
1
1
1
1
1
1
08704
03383
06730
05457
08418
07541
05987
05143
05885
07526
08709
03323
06162
06338
80022
460
FK (X) 50 / ...
08704
03383
06730
05457
08418
07541
05987
05143
05885
07526
555
80022
08709
03323
06162
06338
08704
03383
06730
05457
08418
07541
05987
05143
05885
07526
80022
08709
03323
06162
06338
08704
03383
06730
05457
08418
07541
05987
05143
05885
07526
80022
08709
03323
06162
06338
- 59 -
9
6
0
0
3
-
0
2
.
0
6
-
G
b


















660 775
Explosionsbild, Stckliste / Exploded view, part list Vue eclatee, liste de pieces
9
6
0
0
2
-
0
2
.
0
6
-
D
- 60 -
Bock Kltemaschinen GmbH
Benzstrae 7
D-72636 Frickenhausen
Telefon +49 7022 9454-0
Telefax +49 7022 9454-137
mail@bock.de
www.bock.de
Art. Nr. 96003-02.06-Gb
nderungen vorbehalten