CHINOOK PUMP SERVICE MANUAL
Contents
1. Intake side of head is positioned over single set of holes in valve plate 15 16 KY K12 K24 K 25 K 28 K 30 K50 K60 K100 Tighten head bolts First hand tight then torque in a criss cross sequence as shown SCREWS HEAD Tightening Torque Inches Ibs K35 847 Reinstall flywheel nut and washer ae REMEMBER Left hand thread turns K100 694 counterclockwise to tighten CLEAN THE OIL BREATHER Wash the breather oil fill cap at regular intervals with kerosene or similar solvents to ensure that oil will flow back through the recovery inlet CHANGING THE FILTER CARTRIDGE Change the filter cartridge after 200 hours of work in standard working conditions CHECKING THE OIL LEVEL The oil level must be 3 4 to the top of the oil sight gauge Too much oil may cause oil to flow out of the oil breather or past the rings Not enough oil will result in insufficient lubrication to the internal components Change oil every 100 200 working hours Straight Weight OIL CAPACITY Ounces om n uma m4 a ao MAINTENANCE Regular maintenance insures trouble free operation Your new compressor represents the finest engineering and construction available However even the finest machinery requires periodic maintenance A good maintenance program will add years of service to your air compressor The following is recommended as a minimum maintenance program For your protection2. warrantable PLEASE CALL ASSOCIATE ENGINEERING CORPORATION FOR A RETURN GOODS AUTHORIZATION RGA BEFORE RETURNING ANY GOODS PERFORMANCE DATA po KT KAT f KAZ Kag K24 K30 k50 K60 K100 Flywheel Weight Flywheel Torque Specs Cylinder Head Bolts ft Ibs Cylinder Bolts ft Ibs Bearing Carrier Bolts ft Ibs Connecting Rod Bolts ft Ibs tolerance 5 Rod Seat 0 015 0 015 0 015 0 015 0 015 0 020 0 0 0 03 28 28 28 28 28 30 40 28 55 Crankshaft Bearing mm 0 015 0 015 0 015 0 015 0 015 0 015 0 015 0 015 0 01 Housing 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 00 25 25 25 25 25 30 6 65 55 0 9 Cylinder Bore mm 0 025 0 025 0 025 0 030 0 035 0 035 0 040 035 0 04 0 020 0 020 0 020 0 025 0 030 0 030 0 035 0 030 0 03 64 53 64 70 105 0 025 0 025 0 025 0 025 0 02 0 020 0 020 0 020 0 020 0 02 52 Piston Pins mm 0 0 0 0 0 0 0 0 0 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 005 15 15 15 15 18 18 25 18 25 To change kg meters to foot pounds multiply by 7 233 To change kg meters to inch pounds multiply by 86 8 21
3. 2 10 CHINOOK PUMP SERVICE MANUAL Disassembly amp Assembly 2 17 Rod Orientation amp Torque 6 Bearing Carrier Torque 9 Cylinder Torque 13 Head Torque 16 Oil Capacity amp Weight 17 Maintenance 18 Troubleshooting amp Warranty 19 20 Performance Data 21 RO L l E 606 South Lake Street gt P O Box 346 gt Hustisford WI 53034 0346 gt 920 349 3281 gt fax 920 349 6391 gt www rolair com Sry ST E amp M is NOTE Threaded end of crankshaft has a left hand thread Remove nut by turning clockwise Use two or three prong wheel puller to remove flywheel Apply a small amount of oil between puller and crankshaft Entire crankshaft connecting rod piston assembly can be removed from crankcase after bearings with carriers are extracted from crankshaft Remove flywheel side carrier first Entire assembly can be removed or replaced as shown in the above drawing When reassembling flywheel side is always opposite breather oil fill plug When installing new bearing shells make sure notches in shell and connecting rod line up Make sure Shells are snug and flush Apply generous amount of oil on crankshaft journals and bearing Shells prior to reassembling Bottom and top half of connecting rod have distinct markings which have to be matched together Position connecting rod with squares on same side Before torquing connecting rod bolts refer to table A to determine which direction oil hole on rod Sho
4. disconnect power supply after each day s operation and drain air from the system before any maintenance DAILY MAINTENANCE 1 Check and maintain oil level Always use a single viscosity non detergent oil SEE CHART 2 Drain condensate water from receiver unless it is equipped with an automatic tank drain in which case the drain should be checked to ensure that it is operating 3 Check for unusual noise or vibration WEEKLY 1 Check oil in the compressor and add as necessary IMPORTANT Replace the oil after the first 100 hours of operation 2 Clean compressor especially the intercooler and aftercooler 3 Open drain cock located on bottom of receiver and drain condensate water 4 Clean air intake filter 5i Check drive belt and adjust if necessary MONTHLY 1 Repeat weekly procedures 2 Change compressor oil 3 Check for air and oil leaks and correct 4 Tighten all hardware 1 000 HOURS 1 Repeat weekly procedures 2 Replace the oil in the compressor 2 000 HOURS 1 Repeat weekly procedures 2 Replace the oil in the compressor 3 Check the valves in the compressor and replace if they are damaged or worn Always make sure crankcase vent breather is free and unobstructed when changing or checking oll 18 1 2 3 TROUBLESHOOTING GUIDE Reduced efficiency of compressor unit a Run pump up time and compare against factory specification If pump up time is within factory specs the unit is wo
5. ey bore and key Clean shaft and reinstall with a small amount of Loctite c Worn connecting rod bearing inserts Disassemble head remove cylinder inspect and replace necessary components according to service manual Crankshaft journals should be polished with fine emery cloth If crankshaft journal are excessively worn replace crankshaft 19 4 Determining warrantable failures a The warranty covers defects in material and or workmanship for a period of one year from 20 date of sale or eighteen 18 months from date of manufacture whichever comes first Most warrantable failures should manifest within the first 100 200 hours of operation Proof of purchase is required Defective parts must accompany warranty claims Failures due to operator error are not warrantable Operator is responsible for the following A Operating machine in a level position 1 Operation in an unlevel position can be positively identified by scoring or discoloration to one entire side of the pump Discoloration to the dipper end of one connecting rod occurs without sufficient lubrication while the other connecting rod looks like new Same side connecting rod insert and crankshaft journal will deteriorate Piston cylinder above burnt rod will exhibit scoring vertical scratches that can be felt with the fingernail Finally piston pin will discolor 2 Contact Associate Engineering Corporation s service department with any questions during the inspect
6. ion of failed components B Operation with correct type of oil 1 Multi grade engine oil will foam and pass rings leaving carbon residues on the valve plate seats 2 Cylinder walls will glaze when incorrect type of oil is used C Maintaining proper oil level 1 Low oil operation results in scoring and or discoloration to entire lower end Both Shells will deteriorate journals will begin to wear piston and cylinder wall will show scoring 2 Contact Associate Engineering Corporation s service department with any questions during the inspection of failed components D Keeping air intake elements clean 1 Dirt accumulated in valve plate seats will reduce pumping efficiency may score cylinder walls and allow excessive oil consumption 2 Blown head gaskets caused by overheating of pump due to foreign material should not be covered under warranty E Operating at proper RPMs F Operation in a dry environment and proper storage 1 Water damage rust can occur from operation during high humidity conditions after pump cools down and is idle for extended periods G If a second opinion is requested the customer should be billed for a replacement pump until Associate Engineering Corporation s service department examines the failure usually 1 2 weeks maximum The service center distributor will be give credit for the difference between the cost of a new pump and the cost of repair to original if failure is determined to be non
7. rking to its capacity b Failure of valve strips blown gaskets or foreign material in valve plate assembly Disassemble head group and replace broken or damaged parts Reassemble using factory guidelines Excessive oil consumption a 700 much oll in crankcase Drain to proper level Oil level should be 3 4 full to the top of the sight gauge b Obstructed air intake element Clean or replace element c Clogged or dirty crankcase breather Clean or replace breather d ncorrect type or weight of oil f machine is new monitor consumption until end of break in period approximately 50 hours Detergent oil engine oil will foam and pass rings See owner s manual for recommended type of oil e Scored cylinder wall deep vertical scratches Disassemble and clean piston valve plate components Lightly hone cylinder and install new rings For glazed cylinder wall follow the Same procedure Replace valves and necessary gaskets f Worn stuck or broken rings Remove pistons clean piston components and install new set of rings Blown head gaskets or obstructed valve seats Replace broken pieces Inspect cylinder for scoring or glazing h Always clean discharge tube and make sure check valve is seating when the pump is passing excessive oil Pump noisy or knocking a Loose or misaligned belts Tighten realign or replace belts Refer to pulley belt section of your owner s manual b Loose motor engine pulley inspect pull
8. ts to above torque specifications If pistons need to be replaced start with piston pin fitted partially into piston Use a generous amount of oil between piston and pin Use center punch to drive piston pin into place Make sure snap ring is installed on opposite side Replace cylinder gasket if necessary Fit rings by hand Also make sure end gaps are staggered to prevent oil from pumping past rings WARNING KTop mark on ring faces Upward 11 12 Oil the inner side of cylinders and rings before reassembling A special pliers with steel band may be used to fit the cylinder onto the pistons Install cylinder with 0101 stamping located on same side that it was disassembled from Tighten cylinder bolts and torque to specified settings CYLINDER TORQUE SPECS Inches Ibs K100 13 Guide pins may be used to fit gaskets and valve plates Use small amount of petroleum jelly to hold valve centered into half moon grooves in valve plates 14 Top plate is positioned opposite bottom plate Single set of holes line up above double set of holes NOTE The valve plates of two stage pumps can be assembled in one position only However the valve plates of single Stage pumps can be assembled to allow the intake or discharge side in the position desired Simply rotate the head and entire valve plate assembly 180 to achieve desired direction
9. uld be facing After making sure oil holes are in correct position tighten connecting rod bolts with torque wrench Light hammer blows may be necessary to correctly seat bearing shells Retorque nuts if Shells need to be seated NOTE Connecting rod must be able to rotate freely MODEL K8 K11 K12 K17 K18 K22 K28 K30 K35 K50 K60 K70 K100 TAB A TIGHTENING TORQUE CONROD ORIENTATION inches Ibs 1213 i E 121 5 6 oS gt Conrod cast in asingle piece ze e E 121 5 roie a gon SS 121 5 173 6 Tt ST 173 Telise el 217 0 L2 Jle ee 217 0 J g Hia shd 1997 H m 199 7 EIRE O ft O g 2 S 5 E D a D S d Fit the connecting rods onto the crankshaft after placing the latter into its crankcase Once you have completed the tightening process screw the oil dippers into connecting rods and secure with Loctite ASSEMBLING THE CRANKCASE AND PLACING THE CRANKSHAFT Prior to reinstalling the crankshaft assembly place bearing carrier with bearing onto crankcase Start with breather oil plug side Bearing carrier bolts are shorter than cylinder bolts Lightly tap crankshaft assembly into breather side bearing carrier Guide pins may be used to reassemble flywheel side bearing carrier with roller bearing Drive Pins TIGHTENING TORQUE Inches Ibs K18 130 Lightly tap flywheel side bearing carrier onto crankcase l B fa ii Tighten bol
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