How to Rebuild a Rolair/Chinook K30 pump / Snap-On BRA6180V Pump
Bottom and top half of connecting rod have distinct markings which have to be matched together.
Position connecting rod
with squares on same side.
After making sure oil holes are in correct position, tighten connecting rod bolts with torquewrench. 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.
*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.
Tighten, but do not over-torque.
Lightly tap flywheel side bearing carrier onto crankcase.
Tighten bolts 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.
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.
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 inone position only. However,the valve plates of singlestage 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.
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.
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 protection, disconnect power supply after each day’s operation and drain air from the system before any maintenance.
DAILY MAINTENANCE:
- Check and maintain oil level. Always use a single-viscosity, non-detergent oil (SEE CHART).
- 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. - Check for unusual noise or vibration.
WEEKLY:
- Check oil in the compressor and add as necessary.*
- Clean compressor – especially the intercooler and aftercooler.
- Open drain cock located on bottom of receiver and drain condensate water.
- Clean air intake filter.
- Check drive belt and adjust if necessary.
IMPORTANT: Replace the oil after the first 100 hours of operation.
MONTHLY:
- Repeat weekly procedures.
- Change compressor oil.*
- Check for air and oil leaks and correct.
- Tighten all hardware.
1,000 HOURS:
- Repeat weekly procedures.
- Replace the oil in the compressor.*
2,000 HOURS:
- Repeat weekly procedures.
- Replace the oil in the compressor.*
- 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 oil.
1. 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 working 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.
2.) Excessive oil consumption
a) Too much oil 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) Incorrect type or weight of oil. If 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.
g) 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.
3) 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 pulley 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.
4) Determining warrantable failures
a) The warranty covers defects in material and/or workmanship for a period of one year from 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.
b) 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 inspection 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 given 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-warrantable. PLEASE CALL ASSOCIATE ENGINEERING CORPORATION FOR A RETURN GOODS AUTHORIZATION (RGA) BEFORE RETURNING ANY GOODS.
