GEA FK-40 Maintenance manual
GEA Bock FK40
Maintenance manual
09665-08.2018-Gb
Translation of the original instructions
FK40/390 K
FK40/470 K FK40/560 K FK40/655 K FK40/755 K
FK40/390 N FK40/470 N FK40/560 N FK40/655 N
FK40/390 TK FK40/470 TK FK40/560 TK FK40/655 TK
FKX40/390 K FKX40/470 K FKX40/560 K FKX40/655 K FKX40/755 K
FKX40/390 N FKX40/470 N FKX40/560 N FKX40/655 N
FKX40/390 TK FKX40/470 TK FKX40/560 TK FKX40/655 TK
09665-08.2018-Gb
1
About these instructions
Read these instructions before assembly and before using the
compressor. This will avoid misunderstandings and prevent damage. Improper assembly and use of the compressor can result
in serious or fatal injury.
Observe the safety instructions contained in these instructions.
Contact
GEA Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Telephone +49 7022 9454 0
Fax +49 7022 9454 137
refrigeration@gea.com
www.gea.com
Liability and warranty
Manufacturer‘s liability and warranty are excluded if
• Alterations and functional modifications have been carried out
• No original replacement parts have been used
Contents Page
1 Introduction 3
2 Safety 3
3 Product description 5
4 Technical data 8
5 Maintenance 9
6 Fault diagnosis 11
7 Installation of service kits 15
8 Electromagnetic coupling 21
9 Compressor defects 23
10 Disassembly of the compressor 24
11 Checking the compressor parts 37
12 Assembly of compressor 40
13 Parts list 54
14 Exploded drawing 58
09665-08.2018-Gb
2
1 I Introduction
This maintenance manual is intended to make the repair and maintenance of the FK40 easier for the servicing personnel. The maintenance
manual contains a complete description of each work step for the disassembly and assembly of the compressor components. Each step must
be carefully adhered to in order to ensure a reliable repair.
Note:
For replacing components GEA Bock provides suitable spare part kits. Yet assembly jobs which go beyond the replacement of the shaft
seal, the valve plates and - if there is one - the capacity regulator (accessory) should be checked carefully for their economic efciency
beforehand.
The maintenance manual describes the standard type of the FK40 compressor which we deliver. Because of different system conceptions,
some passages in this service manual may differ from the unit which you have come across. In these cases the present manual should
be used in analogous fashion.
2 I Safety
Safety instructions
Target group of these instructions
• Work on the compressor may only be carried out by persons whose technical training, skills and expe rience along with their knowledge of pertinent regulations and documentation means that they are capa ble of assessing the work to be carried out and detecting any possible dangers
• Specialist can mean a refrigeration technician for example. Note that electrical work may only be carried
out by a qualified electrician. Alternatively, on a country-specific basis, persons who have undergone elec trotechnical instruction and who have proof of their qualification are also permitted to carry out the work.
Identication of safety instructions
DANGER Indicates a dangerous situation which, if not avoided,
will cause immediate fatal or serious injury.
DANGER Indicates a dangerous situation which by electrical current, if not avoided,
will cause immediate fatal or serious injury.
WARNING Indicates a dangerous situation which, if not avoided,
may cause fatal or serious injury.
CAUTION Indicates a dangerous situation which, if not avoided,
may cause fairly severe or minor injury.
ATTENTION Indicates a situation which, if not avoided,
may cause property damage.
INFO Important information / tips on simplifying work.
09665-08.2018-Gb
3
2 I Safety
General safety instructions
DANGER Risk of electric shock
• Before you carry out any repair work, disconnect the compressor from the electricity network
• Turn the main switch to "O" (OFF)
• Secure the main switch against an unauthorized restart
WARNING • Refrigerating compressors are pressurised machines and therefore require particular
caution and care in handling.
• Only qualied personnel are allowed to perform any work on refrigeration compressors.
• The national safety regulations, accident prevention regulations, technical rules and specic
regulations (EN 378 and others) must be taken into account absolutely.
• Never put the safety switch out of action!
• Prior to commissioning, check whether all the components installed by the user have been
fastened expertly and connected pressure-tight with the compressor (e.g. piping, plugs, union
nuts, replaced components etc.).
• Before commissioning, evacuate the refrigerant systems carefully including the compressor and
afterwards charge refrigerant.
• Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.
• Do not start the compressor in vacuum. Operate the compressor only when the system is charged.
• Risk of burns! Depending on the operating conditions, surface temperatures of over 60 °C
on the pressure side or below 0 °C on the suction side can be reached.
• The maximum permissible overpressure must not be exceeded, even for testing purposes.
• Danger of injury! Never grab rotating parts during operation!
09665-08.2018-Gb
4
3 I Product description
Product description
Series FK40 vehicle compressors are designed for mobile applications.
Short description
Three design variations are available for different areas of application:
> For air conditioning the K design
> For air conditioning or normal cooling the N design
> For deep freezing the TK design
The differences are mostly associated with the valve plate version which is adapted to each application range where operational safety and
efciency are concerned.
More features:
Compact 4-cylinder compressor in V design
Wear resistant and long-lasting engine
Five sizes as regards capacity
Aluminium light-weight construction
Crankshaft supported in roller bearings on both sides
Bidirectional lubricating oil pump with relief valve
Variable arrangement shut-off valves
Ideally equipped with valve plates for each application
Integrated pulsation damper for especially quiet running
Name plate (example)
GEA Bock GmbH
72636 Frickenhausen, Germany
1
2
3
1. Type designation 4. Machine number
2. Displacement at 1450 rpm 5. Factory-lled oil type
3. ND(LP): max. permissible operating pressure low pressure side
HD(HP): max. permissible operating pressure high pressure side
19/28bar
AR12345A020
Oil:
Type code (example)
Explanation of the type designation
FK 40 655NX /
Designs
Swept volume
Size
Ester oil charge (HFC refrigerant, e.g. R134a, R407C)
09665-08.2018-Gb
Series
Observe the limits of
}
application diagrams!
4
5
5
3 I Product description
Main and functional parts
1
2
3
15
10
4
5
6
8
9
18
11
7
12
13
14
16
17
1. Discharge shut-off valve
2. Cylinder cover
3. Valve plate
4. Compressor housing
5. Location hole for tting magnetic coupling
6. Integrated leak oil collector
7. Leak oil drain hose
8. Shaft seal
9. Shaft end
6
10. Baseplate
11. Connection thermal protection thermostat
12. Oil lling plug
13. Oil sight glasses (2x)
14. Oil drain plug
15. Suction line valve
16. Oil pump
17. Oil drain plug / Oil lter
18. Name plate
09665-08.2018-Gb
ca.170
h8
148
F
E
D
C
1
2
34
Dimensions in mm
Cotes en mm
Maße in mmÄnderungen vorbehalten
Massenschwerpunkt
Centre of gravity
Centre de gravité
253
Y
Lecköl-Ablass Schlauch
Leak oil drain hose
Tuyau d'évacuatio n d'huile de fuite
F
E
1
2
Dimensions in mm
Cotes en mm
Maße in mmÄnderungen vorbehalten
Massenschwerpunkt
Centre of gravity
Centre de gravité
Y
3 I Product description
8x M872130
6x M8
A5x9 DIN 6888
2
M12x28
F
E
D
1
2
34
5
Dimensions in mm
Cotes en mm
Maße in mmÄnderungen vorbehalten
Subject to change without notice
Sous réserve de toutes modifications
Massenschwerpunkt
Centre of gravity
Centre de gravité
Y
Lecköl-Ablass Schlauch
Leak oil drain hose
Tuyau d'évacuation d'huile de fuite
ca.50
168,5
ca.170
8x M872130
6x M8
A5x9 DIN 6888
1
2
34
5
6
7
( ) K Ausführung
( ) K version
Dimensions in mm
Cotes en mm
Maße in mmÄnderungen vorbehalten
Subject to change without notice
Sous réserve de toutes modifications
( ) Version K
Massenschwerpunkt
Centre of gravity
Centre de gravité
F
DV
B
B1
L
H
K
D
Y
130
108,5
253
4xM10x21 LK
170
344
Y
Lecköl-Ablass Schlauch
Leak oil drain hose
Tuyau d'évacuation d'huile de fuite
ca.370
ca.319 (325)
Dimension drawing
329
145
110
98
90
G
4x 13
210
232
8x M872130
6x M8
SV1
A5x9 DIN 6888
M12x28
2
40
SV
A
A1
C/E
M
170
4xM10x21 LK
Y
L
H
K
F
108,5
DV
168,5
B
344
B1
ca.385
Centre of gravity
ca.50
130
253
ca.170
D
09665-08.2018-Gb
50
1:5
54
66
Dimensions in mm
Connections
A Connection suction side, not lockable 1/8“ NPTF
74
100
Shaft end
Leak oil drain hose
A1 Connection suction side, lockable 7/16“ UNF
B Connection discharge side, not lockable 1/8“ NPTF
B1 Connection discharge side, lockable 7/16“ UNF
C Connection oil pressure safety switch OIL 1/8“ NPTF
D Connection oil pressure safety switch LP 1/8“ NPTF
E Connection oil pressure gauge 1/8“ NPTF
F Oil drain 1/4“ NPTF
G Opt. connection for oil sump heater
H Oil charge plug 1/4“ NPTF
K Sight glass 2 x 1 1/8“ NPTF
L Connection thermal protection thermostat 1/8“ NPTF
M Oil lter M22x1.5
SV1 Optional connection for suction line valve - -
1)
= No connection available as standard.
Available on request (Connection M22 x 1,5)
1)
- -
7
4 I Technical data
Lubrication Oil pump
]
2
unit
Inertia
of the
moment
[kgm
driving
Rotation-
independent
Forced
lubrication
Oil
charge
SV
line
Suction
Connections
DV
line
Discharge
Weight
Swept
volume
(1450 rpm)
ment
Displace-
3
1
8
/
/ 1
35
8
/
/ 1
3
1
2.0 0.0043
/
/ 1
35
/
/ 1
8
8
8
/
/
3
3
/ 1
/ 1
35
35
8
8
8
/
/
3
3
/ 1
/ 1
Ltr.
8
/
1
/ 1
mm/inch
28
8
/
7
/
mm / inch
kg
/h
3
m
3
385 33.5 34.0 22
cm
Cyl.
4
Type No. of
FK(X)40/470 466 40.5 33.0 28
FK(X)40/390
FK(X)40/560 554 48.3 33.0 28
FK(X)40/655 650 56.6 31.0 35
FK(X)40/755 755 65.6 31.0 35
The technical data for the different designs K, N and TK are identical.
The compressor type data therefore do not mention these additions.
09665-08.2018-Gb
8
5 I Maintenance
Maintenance
Service intervals
Practically no maintenance is required. However, for an optimal operating safety and service life of the compressor we recommend to
carry out the necessary maintenance work regularly according to the specications 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 crankcase
Checking the xing screws for tightening
Checking the function of the ancillary units
Checking the electrical connections for clean, rmly xed contacts and the leads for chang points
Oil level check
After starting the compressor, the oil level has to be checked. For this:
The driving engine should be in the „High idle“ operating condition (elevated idling speed)
Compressor running time at least 10 min.
The plant should have reached the operating point
The oil level must be visible in the sight glass
Changing oil
In case of orderly manufactured and operated plants an oil change is in principle not absolutely necessary.
Yet, based on decades-long experience we recommend to carry out the following oil change and servicing.
- First oil change at the rst maintenance of the vehicle.
- After that, changing the oil every 5000 operating hours, but at the latest after 3 years.
At the same time the oil lter and the suction lter should be cleaned and the oil collecting ring
from the shaft seal replaced.
Lubricants
The oil type charged as standard in the factory is marked on the name plate. This oil type should be used as a preference.
Alternatives are stated in the extract from our lubricants table below:
Standard oil type used by GEA Bock Recommended alternatives
For HCFC (e.g. R22)
Fuchs Reniso SP 46
For HFC (e.g. R134a, R404A, R407C)
Fuchs Reniso Triton SE 55
Information about other suitable oils should be taken from GEA Bock lubricant tables. Information may also be retrieved from vap.gea.com
(mobile applications -> documentation -> technical information -> vehicle compressor -> ... -> lubrication chart).
09665-08.2018-Gb
BP Energol LPT 46 SUNOCO Suniso 3.5GS
TEXACO Capella WF 46
FUCHS SEZ 32 / 68 / 80 ESSO / Mobil EAL Arctic 46
9
5 I Maintenance
Operating of the shut-off valves
Opening the shut-off valve:
a) Spindle 1: turn to the left (counter-clockwise) as far as it
will go.
—> Shut-off valve fully opened / service connection 2
closed (position A), Fig.
Opening the service connection (2)
b) Spindle 1: Turn 1/2 -1 rotation to the right.
—> Service connection 2 opened / shut-off valve opened
(position B), Fig.
Connection 3 is provided for safety devices and is not lockable.
Position A
1
Position B
1
2
2
3
Pipe connection
3
Pipe connection
INFO Before opening or closing the shut-off valve, loosen the valve spindle seal (Fig. left) by 1/4 turn.
After operating the shut-off valve, tighten the valve spindle seal carefully again (Fig. right).
10
09665-08.2018-Gb
6 I 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. Further information is
retrievable under vap.gea.com (mobile applications -> tools ->
online analysis). Additionally a failure analysis slide is obtainable
under info@gea.com.
Compressor stand still
Compressor does not start
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
Problem Possible cause Remedy
Control circuit is interrupted
Malfunction of electromagnetic
coupling
Main - or control fuse is switched off or tripped Replace fuse
Determine and remove the cause
Cut off through:
- Low pressure switch
- High pressure switch
- Heat protection thermostat
- Control thermostat
- Other safety elements
- see also page 14 "Malfunction of
electromagnetic coupling"
Locate the interruption in the circuit
and remove
Checking
Compressor cutoff
Compressor starts and stops again
Problem Possible cause Remedy
Cutoff through low pressure
switch
Suction pressure too low:
- Check the setting of the low pressure switch
- Suction valve of the compressor closed - Open suction valve
- Adjust the switching points or replace switch
- Capacity of compressor too large - Check operating conditions
- Refrigerant deciency - Leak test / add refrigerant
- Filter / dryer in the liquid line blocked - Replace lter / dryer
- Expansion valve not functioning properly - Check the setting of the expansion valve
- Solenoid valve on the liquid line not opening - Check the control / function
09665-08.2018-Gb
11
6 I Fault diagnosis
Problem Possible cause Remedy
Cutoff through high pressure
switch
Cutoff through heat protection
thermostat (accessory)
Condensing pressure too high:
- Check the setting of the high-pressure switch
- Pressure valve of the compressor closed - Open the pressure valve
- Condenser fan not functioning - Check the control / replace motor
- Condenser performance insufcient, con-
denser and fan motor contaminated
- Excessive refrigerant lling - Extract refrigerant to normal lling
- Non-condensible gases in refrigerant - Extract refrigerant and evacuate the
Discharge end temperatures is too high
- Operating limits of compressor exceeded
- Suction gas overheating - Check expansion valve / check
- Condenser cooling insufcient
- Valve plate damage - Replace valve plate
- Internal decompression valve has opened - Replace decompression valve
- Adjust the switching points or replace switch
- Cleaning of condenser ns and fan
refrigeration plant / rell refrigerant
- Adapt the operating conditions
to the operating range
insulation on the suction side
- Check fan motors / cleaning of condenser
-> Check compressor and refrigeration plant
Determine and remove the cause for the
inadmissible high pressure in the highpressure side
Cutoff through control
thermostat
Temperature over / below the desired range Check operating points
Refrigerant performance too low
Problem Possible cause Remedy
Suction pressure too high
Suction pressure too low
High-pressure too high
High-pressure too low
- Evaporator iced up - Remove the cause
- Expansion valve not functioning properly
- Lack of compressor capacity
- Shortage of refrigerant - Run leakage test / rell
- See „Cutoff through low-pressure switch“ - Checking
- See „Cutoff through high-pressure switch“ - Checking
- Condenser being cooled to much - Adjust the control of condenser cooling
- Check expansion valve setting;
replace valve, if necessary
- Check the function of the compressor by
evacuating to vacuum.
Check function of capacity regulator
(accessory)
refrigerant
12
- Lack of compressor capacity
- Pressure laminations of valve plate leaking - Replace valve plate
- By-pass between suction and discharge side
- Check compressor / Check the functioning
of capacity regulator
- Localize leak between the discharge and suction side and repair it
09665-08.2018-Gb
6 I Fault diagnosis
Refrigerant temperature too high
Problem Possible cause Remedy
Suction gas temperature
too high
Discharge pipe temperature
too high
- Suction gas overheating
- Too little refrigerant lling - Establish the operating lling (see Operating
- Liquid lter blocked - Clean / replace lter / dryer
- Shortage of refrigerant - Run leakage test / rell refrigerant
- Suction gas temperature too high
(Condensing pressure too high)
- Operating limits of compressor exceeded - see „Cutoff through heat-protection
- Cooling insufcient - Check refrigerant lling
- Short circuit between the discharge and the
suction side of the compressor
- Valve plate damage - Replace valve plate
- Internal decompression valve has opened - Replace decompression valve (see the section-
- Adjust expansion valve
Insulate the gas suction line
Instruction for the refrigeration plant),
localize leak
- Adjust expansion valve
Insulate the gas suction line
- see „Cutoff through high-pressure switch“
thermostat“
- Adjust expansion valve
- Check gaskets on valve plate /
change
on Disassembly / Assembly of Compressor)
Oil problems
Problem Possible cause Remedy
Oil pressure too low
Oil foams during start-up phase
Oil foams during operating
Oil level decreases
- Refrigerant in oil - see „Oil foams“
- Too little oil in compressor - Add oil and search for the cause of oil loss
- Oil lter dirty / blocked - Clean / replace oil lter
Change oil
- Liquid refrigerant has moved into the oil sump - Check the laying of pipes
- Installation of the check valve in the
discharge line
- Installation of the solenoid valve in the
liquid line
- Check the control
- Expansion valve not functioning - Adjust / replace expansion valve
- During start-up, a portion of the oil is carried
to the refrigeration plant with the refrigerant
- Refrigerant in oil - see „Oil foams during start-up phase“
- Piston rings worn - Replace piston rings
- Suction / discharge laminations of the valve
plate leaking
- Refrigerant and oil get mixed. After some time
the oil level should stabilize.
Add oil, if necessary.
- Replace valve plate
09665-08.2018-Gb
13
6 I Fault diagnosis
Abnormal running noise from compressor
Problem Possible cause Remedy
Fixation of compressor is loose
Liquid shock
Capacity regulator (accessory)
Electromagnetic coupling slipping
V belt drive,
increased noise generation
- Screwed connections have become loose
- Securing elements for screwed connections
missing
- Vibration metals defective - Replace vibrations metals
- Liquid refrigerant reaching the compressor
- Oil shocks because of too much oil - Check oil level
- Switching on and off constantly / oscillating - Check the control
- Defective - Replace capacity regulator valve
- see also p. 14 „Malfunction of electromag-
netic coupling“
- Belts vibrating excessively - Check belt tension
- Incorrect alignment of compressor and motor - Check alignment and adjust anew
- Tighten the screwed connections and secure
them anew
- Adjust / check expansion valve
Check refrigerant lling
Check evaporator fan
- Icing-up of the evaporator
Check the dimensioning of pipes (gas velocity)
Replace worn piston rings
- Checking
Use tensioning roller / guidance roller
Malfunction of the electromagnetic coupling
Problem Possible cause Remedy
Coupling not switching
Coupling slipping too long, getting hot, smoking and squeaking
Coupling not separating
- No voltage applied - Apply voltage and check
- Voltage too low - Keep the voltage at 12 or 24 Volts (check
vehicle network)
- Driving power too high - Check operating conditions
- Rotor rubbing at the magnetic eld - Check the seating of the magnet possibly
to high belt tension
- Voltage still being applied to the magnet - Check switch / relay
- Coupling is stuck - Disconnect the armature disc from the rotor
mechanically
- Coupling overloaded,
Armature disc is deformed
- Install new rotor ans armature disc
14
09665-08.2018-Gb
7 I Installation of service kits
Disassembly and assembly of the compressor
WARNING Before starting any work on the compressor:
• Switch of the compressor and guard it against switching on
• Close the discharge and suction shut-off valves
• Relieve the compressor from system pressure
• Prevent air from infiltrating the system
• Move and transport the compressor using an appropriate hoist
• Use only genuine GEA Bock spare parts
After the work is finished:
• Connect the safety switch and check its function
• Evacuate the compressor
• Before commissioning, check whether all the components installed by the user have been
mounted expertly and are connected pressure-tight to the compressor
• Open the pressure and suction shut-off valves
• Set off the switching-on lock
For changing components in the framework of customary service works we recommend the kits described on the following pages.
Important Notes
INFO Use only new gaskets for assembly
The following illustrations show a FK40 compressor in standard design.
Components of other designs can differ from these illustrations.
However, the procedure for disassembly and assembly of the compressor is identical.
09665-08.2018-Gb
15
7 I Installation of service kits
Shaft seal (Item No. 80023 (ester oil charge) resp. 80682 (mineral oil charge))
Removal:
Dismount the drive/magnetic coupling from the compressor.
Remove the woodruff key from seat at the shaft end.
Remove the clamping ring (10) and the oil felt (9) (for this see Fig. 3 on page 17).
Unscrew the screws (8) from the shaft seal cover (6) .
Remove the gasket residues and the shaft seal cover gasket (5) from the bearing ange.
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!
9
1
10
Fig. 1
Installation:
Work with utmost cleanliness.
Always replace the shaft seals complete, never individual parts thereof.
Do not use used parts.
Prior to installation, check the sliding and sealing surfaces for cleanliness and damages.
Apply silicone grease to O-ring (3) and its seat in guide ring (2). Moisten sealing surfaces of the sliding ring (4), shaft seal cover (6) and
compressor shaft using compressor oil.
Assemble the sliding ring (4), O-ring (3) and the guide ring (2) together as a unit. The large chamfer on the sliding ring (4) should show in the
direction of the shaft seal cover (6).
During the assembly the compression spring (1) must engage audibly in the drive slot of the crankshaft and of the guide ring (2).
Install the shaft seal cover gasket (5) with applied compressor oil.
Install the shaft seal cover (6) with the inscription „TOP“ upwards. Lubricate the pre-installed rotary shaft seal (7) with silicone grease. Use
the protective sleeve. Tighten the xing screws (8) evenly, crosswise tightening torque = 34 Nm.
Remove the protective sleeve. After installing the shaft seal, turn the compressor shaft a few turns by hand and then carry out the leak test.
Install the clamping ring, if available (see section on clamping ring with oil felt, page 17).
Insert the Woodruff key into the seat at the compressor shaft end.
Mount the drive/coupling.
2
3
4
5
6
7
8
“TOP“
16
09665-08.2018-Gb
7 I Installation of service kits
Clamping ring with oil felt (Item No. 80129)
Procedure:
Remove the clamping ring (1) and the oil felt (2) (see Fig. 3)
Insert the oil felt (2) included in the repair kit and mount
the clamping ring (1).
Clamping ring
Fig. 2
1
Type code 007 - 014
2
2
Open at top
Fig. 4
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 airconditioning maintenance and motor service. Proceed by removing
the oil hose from the bracket, remove the sealing plug and drain
the oil into a collecting vessel. After emptying, close the oil hose
with the sealing plug and x it to the bracket. Dispose of used oil
in accordance with the regulations applicable in the country of use.
09665-08.2018-Gb
17
7 I Installation of service kits
Capacity regulation
The capacity regulation takes place through the turning off of the suction gas ows by means of a solenoid valve on the cylinder cover. For
this, the valve is activated electrically by a thermostat or pressostat.
During normal operation the solenoid is de-energized and the suction gas channel in the valve plate and in the cylinder cover is open.
During regulated operation the solenoid is energized and the suction gas ow is closed through the shut-off piston of the solenoid valve.
The compressor pistons of the cylinder bank which is regulated down run idle. The capacity of the compressor is still approx. 50%.
Further information together the description of the working principle of the solenoid valve is contained in the publication „Capacity regulation“
(Item No. 09900).
Capacity regulation valve (Item No. 07541)
(Only for the capacity regulation which is an accessory)
Removal:
De-energize the solenoid (4).
Screw on the xing nut (3), pull out the solenoid (4) with the
washer (5).
Unscrew the valve body (2).
Check the valve body (2) for damages and whether the piston
moves freely. If necessary, replace the complete valve body (2).
70 Nm
3
4
5
2
07541
Installation:
Screw on the valve body (2) with the enclosed new O-ring (1) and
tighten it. Observe the screw tightening torque!
Push on the washer (5) and the solenoid (4) and fasten them with the
xing nut (3).
Put the compressor into operation and check the functioning of the
capacity regulation.
1
Fig. 5
18
09665-08.2018-Gb
7 I Installation of service kits
Valve plate
Compressor type Kit (Item No.) Compressor type Kit (Item No.)
FK(X)40/390 N 80240 FK(X)40/390 TK 80240
FK(X)40/470 N 80240 FK(X)40/470 TK 80240
FK(X)40/560 N 80241 FK(X)40/560 TK 80241
FK(X)40/655 N 80241 FK(X)40/655 TK 80241
FK(X)40/390 K to FK(X)40/655 K 80010
FK(X)40/755 K 81297
K type valve plate N type and TK type Valve plate
Fig. 6
09665-08.2018-Gb
19
Loading...