AirPower Shamal K8 Instructions for use

Airpower
Shamal/ Chinook pump recondition manual
Page
1. Dismantle and assemble block 2-22
2. Take off the flywheel 2
3. Replace main bearings 2 -4
4. Replace small end bearings 4
5. Assemble the connecting rod 5-7
6. Assemble the big end bearings 8-11
7. Assemble the main bearings 11- 15
8. Assemble the pistons and rings 16-19
9. Assemble the valves and cylinder head 20-22
10.Oil sump capacities 23
11.Preventive Maintenance on blocks 24

-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.
To replace the main bearings:
Remove the entire cylinder barrel and pull upwards. The pistons will slide out
on bottom of cylinder.
Take end caps off and knock the drive side bearing from inside the sump.

-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.

-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

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
-5-

-6-

-7-

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. First put bearing shells in the
connecting rod. Make sure the oil holes are as per chart. Tighten big end bolts.
See torque chart. Connecting rod must be able to turn freely on the crankshaft.
For the two cylinder blocks, assemble complete crankshaft with connecting
rods and pistons, before installing in the oil sump. For the V Blocks, first install
crankshaft and then assemble the connecting rods onto the crank journals.
Check the position of connecting rods, to suit the position of the pistons in the
barrel. The one barrel is off set to the other barrel. Remember to use ample oil
on bearing shells. Remember the oil dipper pins. Use lock-tite and tighten well
in position.

-8-

-9-
-10-

-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. Put crankshaft drive end through drive end side port. When
inside the crankcase, bring non drive end side into non drive end main bearing.
When in position, fit drive end main bearing on to crank shaft. Assemble
housing with gasket and oil seal, pre-assembled. Fit onto the drive end side of
crankshaft. Tighten the four holding down bolts. Guide pins may help with
alignment during assembly. Tighten as per torque chart. Tap lightly during the
tighten process, to allow the bearing to settle into position.

-12-

-13-

-14-

-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. It must be a slide
fit. Replace or ream small end bush, to fit gudgeon pin. See small end bearings
and gudgeon pins on page 4.

-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. The writing on the rings must face
upwards on top of rings. Space the ring gaps 120 ° to one another. No two gaps
must be close to one another.

-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. Bolt barrel
down onto oil sump. See torque chart.

-18-

-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