This document is a reconditioning manual for an "Airpower Shamal/Chinook pump." While the specific type of pump isn't explicitly stated, the manual's content strongly suggests it is an air compressor pump, likely a reciprocating piston type, given the detailed instructions on pistons, rings, valves, crankshaft, and cylinder barrels.
Function Description
The Airpower Shamal/Chinook pump is designed to compress air. The reconditioning manual outlines the steps required to dismantle, inspect, replace worn components, and reassemble the pump's core mechanical parts, ensuring its continued efficient operation. Key components involved in its function include:
- Crankshaft and Connecting Rods: These convert the rotational motion of a motor (implied by the flywheel and main bearings) into the reciprocating motion of the pistons.
- Pistons and Rings: The pistons move within the cylinder barrels to compress air. Piston rings seal the combustion chamber, preventing air leakage and controlling oil consumption.
- Cylinder Barrels: These house the pistons and are where the air compression takes place.
- Valves and Cylinder Head: The valve plates, gaskets, and leaf valves control the intake of air into the cylinder and the discharge of compressed air. The cylinder head encloses the top of the cylinder barrel and houses the valve assembly.
- Main and Big End Bearings: These support the crankshaft and connecting rods, reducing friction and allowing smooth rotation/oscillation.
- Flywheel: This component helps to smooth out the power delivery and maintain rotational inertia.
- Oil Sump: Contains the lubricating oil essential for the internal moving parts.
- Air Intake Filter: Cleans incoming air to protect internal components from dust and debris.
- Breather: Likely part of the crankcase ventilation system.
- Non-return Valve: Prevents compressed air from flowing back into the pump when it's off.
- Safety Valve: A critical safety device that releases excess pressure if the system over-pressurizes.
- Pressure Switch: Controls the compressor's operation based on system pressure.
Important Technical Specifications
The manual provides torque specifications for various components, which are crucial for proper assembly and reliable operation. These specifications are given in both inches/lbs and Newton-meters.
Torque Specifications:
- Big End Bearings:
- 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)
- Note: Specific models (K8, K11, K12, K17, K18, K22, K28, K30, K35, K50, K60, K70, K100) have different torque values, as detailed in "TAB. A" on page 11.
- End Caps (Main Bearings):
- K8 to K35 models: 130 inches/lbs (14.69 Newton meter)
- K50 to K100 models: 165 inches/lbs (18.64 Newton meter)
- Cylinder Barrel:
- K8 model: 130 inches/lbs (14.69 Newton-meters)
- K11, K12, K17, K18, K24 models: 182 inches/lbs (20.56 Newton-meters)
- K28, K30, K35, K60, K70 models: 330 inches/lbs (37.28 Newton-meters)
- K50, K100 models: 521 inches/lbs (58.9 Newton-meters)
- Cylinder Head:
- K8 model: 148 inches/lbs (16.72 Newton-meter)
- K11, K12, K17, K18, K24 models: 243 inches/lbs (27.46 Newton-meters)
- K28, K30, K35, K60, K70 models: 347 inches/lbs (39.20 Newton-meters)
- K50, K100 models: 694 inches/lbs (78.41 Newton-meters)
Oil Sump Capacities:
- K8: 0.355 litres
- K11, K12: 0.5 litres
- K17, K18: 1.0 litres
- K24, K25, K28: 1.8 litres
- K30, K35: 1.39 litres
- K50: 1.75 litres
- K60: 2.9 litres
- K100: 4.0 litres
Usage Features
The manual primarily focuses on reconditioning, but it also includes "Important compressor usage points" that highlight best practices for operating the compressor:
- Control: The compressor should only be switched on and off at the pressure switch.
- Power Supply: Avoid using extension leads or double adapters for single-phase units. For three-phase units, electrical wires should be screwed directly onto an isolator, avoiding welding plugs which can cause loose connections.
- Starting Issues: If the compressor struggles to start, it may indicate insufficient power supply or voltage drop.
- Generator Use: Do not operate from a generator without prior consultation with Airpower.
Maintenance Features
The manual provides comprehensive instructions for reconditioning and routine maintenance.
Reconditioning Procedures:
The manual details the step-by-step process for dismantling and assembling the pump block, including:
- Dismantling and Assembly of Block: General overview (pages 2-22).
- Flywheel Removal: Loosen left-hand thread nut clockwise, use a wheel puller, and apply heat to the hub if necessary.
- Main Bearing Replacement: Remove cylinder barrel, pull pistons, remove end caps, and knock out the drive side bearing.
- Crankshaft Removal: For two-cylinder blocks, remove the complete crankshaft with connecting rods assembly after main bearings are removed. For V blocks (K60, K100), remove cylinder barrels first, then loosen big end bearings.
- Small End Bearing and Gudgeon Pin Replacement: Remove big end bearings, pistons from connecting rod, press out the brass bush (small end bearing), press in a new one, and ream until the gudgeon pin has a slide fit. Fit with ample oil.
- Connecting Rod and Big End Bearing Assembly: Do not mix top and bottom connecting rod parts. Replace crankshaft if damaged. Use ample oil. Ensure oil holes are correct. Tighten big end bolts to specified torque. Connecting rod must turn freely. For two-cylinder blocks, assemble crankshaft with connecting rods and pistons before installing in the oil sump. For V blocks, install crankshaft first, then assemble connecting rods onto crank journals. Check connecting rod position relative to pistons. Use oil dipper pins, Lock-tite, and tighten well.
- Main Bearing Fitment: Fit non-drive end bearing housing, bearing, and gasket. Tighten bolts. Insert crankshaft drive end through the port, then bring the non-drive end into its main bearing. Fit drive end main bearing onto the crankshaft. Assemble housing with gasket and oil seal. Tighten holding bolts to torque chart specifications, tapping lightly to settle the bearing.
- Piston Fitment: Remove circlips and gudgeon pins. Check gudgeon pin and small end bush fit (must be a slide fit); replace or ream bush if necessary.
- Piston Ring Fitment: Fit rings by hand, twisting slightly. Start with the oil ring at the bottom, then the stepped ring, then the compression ring on top. Ensure writing on rings faces upwards. Space ring gaps 120 degrees apart.
- Piston Barrel Fitment: Place gasket on oil sump. Hone barrels to remove glazing. Use a ring squeezer to guide pistons and rings into the barrel. Slide the squeezer down and remove once the piston is inside. Bolt barrel down to specified torque.
- Valve and Cylinder Head Assembly: Use locating pins. Fit bottom gasket, then bottom valve plate (ensure correct suction/compression side orientation: flat surface for air outlets, hollow for air inlet). Use grease to stick leaf valves in position. Place center gasket, then top valve plate, top gasket, and top. Fit and tighten top bolts using torque chart and sequence.
Preventive Maintenance (Every 500 working hours):
- Oil: Replace oil (ensure correct type is used).
- V-Belts: Replace if worn. Check and adjust tension (10 kg thumb pressure should cause deflection equal to belt thickness).
- Air Filter: Check, clean, or replace the intake air filter element and clean its housing. Check for dust entering the system.
- Fasteners: Check and tighten all loose bolts.
- Belt Guard: Check and repair.
- Cooling Fins: Clean.
- Non-return Valve: Check. Replace if worn or damaged (indicated by continuous air leak from pressure switch bottom when compressor is off).
- Leaks: Check for oil and air leaks and repair.
- Safety Valve: Very important. Adjust pressure switch to run manually 0.25 bar over pressure. If the safety valve doesn't blow, replace or repair it. Do not exceed the normal working pressure. Adjust pressure switch back to normal after the test.
- Pressure Switch: Check.
- Starter/Overload: Check starter and overload setting. Overload must be set at motor full load amps at the correct Hz.
- Gauges: Check.
- Safety: Ensure the machine is safe.
- Pressure Test: Check when the last pressure test was done. In South Africa, factories require a test every 3 years, and mines every year. Notify the user if a test is due.
Daily Checks:
- Drain air receiver.
- Check oil level.
- Clean and check air intake filter (weekly).
This comprehensive manual ensures that the Airpower Shamal/Chinook pump can be effectively maintained and reconditioned to deliver reliable compressed air.
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