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Airpower
Shamal/ Chinook pump recondition manual
1. Dismantle and assemble block
2. Take off the flywheel
3. Replace main bearings
4. Replace small end bearings
5. Assemble the connecting rod
6. Assemble the big end bearings
7. Assemble the main bearings
8. Assemble the pistons and rings
9. Assemble the valves and cylinder head
10.Oil sump capacities
11.Preventive Maintenance on blocks
Page
2-22
2
2 -4
4
5-7
8-11
11- 15
16-19
20-22
23
24
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Summary of Contents for AirPower Shamal K8
- Page 1 Airpower Shamal/ Chinook pump recondition manual Page 1. Dismantle and assemble block 2-22 2. Take off the flywheel 3. Replace main bearings 2 -4 4. Replace small end bearings 5. Assemble the connecting rod 6. Assemble the big end bearings 8-11 7.
- Page 2 To remove the fly wheel: Loosen nut on fly wheel centre. Please note, it is a left hand thread. Turn nut clock wise to loosen. Pull flywheel with a wheel puller. You may have to put some heat on the flywheel hub with a gas flame while under tension from the wheel puller.
- Page 3 Remove crankshaft with connecting rods: On the two cylinder blocks, the complete crankshaft with connecting rods assembly, can be removed in one piece, provided the main bearings were removed from the crankshaft. On the V blocks, K60 and K100, remove the cylinder barrels and then loosen the big end bearings.
- Page 4 Small end bearings and gudgeon pins: If small end bearings needs replacement, remove big end bearings, remove pistons from connecting rod, press brass bush (small end bearing) from...
- Page 5 connecting rod. Press new small end bearing into position. Ream small end bush, until the gudgeon pin has a slide fit. Fit with ample oil...
- Page 8 Connecting rods and big end bearings: Do not mix top and bottom connecting rod parts with one another. It is a set and machined together. Loosen the big end bolts and disassemble the big end bearings. If crankshaft is damaged as a result of oil starvation, replace the crankshaft. Use enough oil when assembling the big end bearings.
- Page 10 -10-...
- Page 12 -11- Torque for big end bearings: Note: 121.2 inches/lbs = 13.69 Newton meter 173.6 inches/lbs = 19.62 Newton meter 217 inches/lbs = 24.52 Newton meter 199.7 inches/lbs = 22.57 Newton meter Fit Main bearings: Fit non drive end bearing housing, bearing and gasket into position. Tighten the four holding bolts.
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- Page 16 -15- TIGHTENING TORQUE FOR END CAPS. (Inches/lbs.) Newton-meter K8 = 130 14.69 K11=130 14.69 K12=130 14.69 K17=130 14.69 K18=130 14.69 K24=130 14.69 K28=130 14.69 K30=130 14.69 K35=130 14.69 K50=165 18.64 K60=165 18.64 K70=165 18.64 K100=165 18.64 Fit pistons: Remove circlips on gudgeon pin ends. Slide the gudgeon pins out. Fit new pistons, but first check gudgeon pin and small end bush fit.
- Page 17 -16- Fit piston rings: The piston rings must be fitted by hand. Slightly twist ring and put one end into the correct groove. Work ring around the piston into position. Be very careful not to break the rings. Start with oil ring at bottom of piston. Then the Stepped ring and the compression ring on top.
- Page 18 -17- Fit piston barrel: Put gasket in position on top of oil sump. Hone the barrels to remove the glazing. Use a ring squeezer to squeeze the rings. You will need an additional pair of hands to help you to get the pistons and rings into the barrel. Slide the ring squeezer down and remove, after piston is inside the barrel.
- Page 19 -18-...
- Page 20 -19- CYLINDER BARREL TORQUE SPECS (Inches/lbs.) Newton-meters K8=130 14.69 K11=182 20.56 K12=182 20.56 K17=182 20.56 K18=182 20.56 K24=182 20.56 K28=330 37.28 K30=330 37.28 K35=330 37.28 K50=521 58.9 K60=330 37.28 K70=330 37.28 K100=521 58.9...
- Page 21 -20- Fit Valve plates, gaskets and valves: Use locating pins to assemble the valve plates and valves. Normally old bolts without heads make good location pins. Fit bottom gasket first. Then fit bottom valve plate. Make sure the suction and compression side is as required on single stage units.
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- Page 24 Tightening Torque for cylinder head. (Inches/lbs.) Newton-meter K8=148 16.72 K11=243 27.46 K12=243 27.46 K17=243 27.46 K18=243 27.46 K24=243 27.46 K28=347 39.20 K30=347 39.20 K35=347 39.20 K50=694 78.41 K60=347 39.20 K70=347 39.20 K100=694 78.41 -23-...
- Page 25 Disassemble filter to clean. Wash breather with oil solvent. Correct oil level is centre of oil sight glass or to top of sight glass. Do not fill higher than top of sight glass. Do not run lower than sight glass. Oil capacities: Model litres...
- Page 26 Welding plugs may cause a loose connection. 8. If compressor struggles to start, it is due to insufficient power supply/ Voltage drop. 9. Do not operate from a generator without checking with Airpower first. Piston compressor...
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