Chinook K Series Assembly, Operating, And Maintenance Instructions

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R01 21/09/2005

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Summary of Contents for Chinook K Series

Page 1 R01 21/09/2005...
Page 2 At CHINOOK we have two key words: specialisation and experience. Air compressors are own only product. All our engineering skills and nearly thirty years manufacturing experience specialization are dedicated exclusively toward the production of a complete line of single and...
Page 4 Insert the conrods with their piston pin onto the tool. Loosen the conrod nuts by means of a pneumatic screwdriver. Remove the nuts and washers (not to be used again)from the con- rod screws.
Page 5 Pull out the conrod and hold it as shown in the drawing; insert the half- shells. NOTE : The conrod stem and cap must be reassembled the way they were and not facing the other way. Fit and oil the half-shells; oil the conrod housing on the crankshaft.
Page 6 Position the conrod stem and cap on the conrod housing, on the flywheel side, making sure the lo- cator marks on one side of the stem and cap are properly matched. Locator marks The position of the conrod on the crank- shaft must be as shown in Table A, which lists the screw...
Page 7 If necessary, tighten the nuts with a calibrated dynamometric wrench, adjust conrod-crankshaft coupling with light hammer blows. After that, tighten the nuts again with the dynamometric wrench; the conrod must be able to rotate freely (see Table A). -K 9 Fit the conrods onto the crankshaft after placing the latter into its crankcase (see section 1 page 3);...
Page 9 Fit the support on vent side with a ball bearing previously placed into its support, with a support gasket in between. Fit the hexagonal Tighten the screws by means screw and the of a pneumatic screwdriver. aluminiumwasher.
Page 10 Put the crankshaft, with the conrods mounted, into the crankcase.
Page 11 Put the crankshaft into the ball bearing housing fitted to the vent support, by means of a special punch. Fit and tighten the guiding pins before fitting the support and the gasket. Fit the support on flywheel side with the ball bearing previously assembled onto the support, with the support gasket in between.
Page 12 Place the angular bearing on the support housing by Place support means of a special flywheel side punch. means of a Fix the hexagonal special screw punch. and aluminium washer; tighten the screws by means of a pneumatic screwdriver.
Page 14 Put the crankcase in a vice, oil the piston pin and the piston pin housing on the piston. Fit the piston pin half way onto the piston.
Page 15 Pull out the piston with the piston pin partially fit in it from the conrod. Put the piston on the conrod housing and drive the piston pin. Complete the driving of the piston pin by means of a special punch.
Page 16 Place the reating rings by means of special pliers. Level the pistons with theaid of a special faceplate. This is done by slightly Fitting the piston with the palm of your hand until the piston base is perfectly parallel to the faceplate.
Page 17 Fit the crankcase/cylinder gasket. Fit the piston rings. Warning: the rings must be placed with the “Top” mark facing up (towards the piston crown). The exacte position is shown in the figure. NOTE: In order to fit and change the piston rings you can use the special pliers shown on section 3 page 5.
Page 18 Special pliers...
Page 20 Oil the inner side of the cylinder in which the pistons will be placed. Tighten the rings onto the piston by means of a special pliers with a steel band; insert the cylinder onto the piston. Use the special tools shown in the figure.
Page 21 Repeat the foregoingstep and place the cylinder onto the second piston. Fix the hexagonal screw and the aluminium washer using a pneu- matic screwdriver.
Page 22 Place the guiding pins onto the cylinder and fit the cylinder/plate gasket. Spread a small amount of vaseline onto the end of the strip valves and fit them into the special housing built in the valve plates.
Page 23 Fit the two valve plates with a special gasket in- between. NOTE : The valve plates of twostage compressors can be assembled in one position only. In the case of single-stage compressors, instead, it is possible to invert the compression side with the intake side by rotating the plate Fit the head.
Page 24 All single-stage pumps in our range make it possible to position the intake on either side, as desired, by simply rotating the plates and head. The most important two-stage models are available with special plates affording the same possibilities. V type models are supplied with a special set of plates (called “contrary”...
Page 25 Place the hexagonal screws and steel shers; fit lightly the screws to the head and then drive them according to the sequence shown in the figure TIGHTENING TIGHTEN SCREWS/HEAD Kgm. TORQUE SCREW TIGHTENING TORQUE FLYWHEEL HEAD Kgm. Kgm. K 11 3÷3,5 K 12 2,6/2,8÷3...
Page 26 Test the assembly making sure that the intake and com- pression stages working properly. NOTE : To this end you can make use of a special tool, i.e. a geared motor which transmits the motion to the crank- shaft. If desired, the assembly can be tested by applying a suitable wrench to the nut and rotating it by...
Page 27 TIGHTENING COOLER BOLT Ø 10 mm (HEAD-COOLER BOLTS) Tightening GROUP K 11 K 12-K 9 K 17 K 18 K 24 K 30 K 35 K 50 Fit the aftercooler with a K 60 gasket in K 100 between; fit the filter elbow onto its housing.
Page 29 CLEANING THE OIL BREATHER Wash the cap tank at regular intervals with fuel oil, kero-sene or similar products so as to ensure that the oil will flow back through the recovery inlet. CHANGING THE FILTER CARTRIDGE After about hours work in standard environmental conditions.
Page 30 It consists in 3 stages for increasing complexity. For the first stage we supply the 1st maintenance kit necessary to replace the materials for the filter cartridge, the strip valves and the corresponding gaskets. The 2nd kit includes all the materials contained in the 1st, as well as piston rings, oil sight gauges and caps.
Page 31 Whenever it is necessary to disassemble the pump in its entirety, clean each individual piece and fit the new gaskets supplied with the kit. During the assembly operations, make sure that the valve pla- tes, the head and the cylinder are levelled and are correctly matched with one another.
Page 33 Defects Reduced efficiency of the compressor unit. • • Cause Failure of strips valves Broken gaskets Obstructing material in the valve plate air holes and/or in the strip valves themselves. • Remedy Take down the assembly and eliminate the cause of the defect During reassembly, make sure the lower piston plane is properly aligned with the upper plain of the crankcase (see section 3- page 3).
Page 34 Defect Exceedingly high temperature. Cause Incorrect flywheel rotation due to incorrect electrical connections. Poor ventilation of the room housing the unit. Remedy Check flywheel rotation. Position the compressor at no less than 30 cm. from the wall. Air the room. _______________________________________________________________________________ Defect Carbon residues on the plates.