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1. 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 ROLAIR 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 deposits 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 bearing shells will deteriorate Journals will begin to wear and piston and cylinder wall will show scoring 20 2 Contact ROLAIR s service department with any questions during the inspection of failed components D Maintaining clean air intake elements 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 the intake of foreign material will not be covered under warranty E Supplying electric motors with proper voltage 1 Always suggest longer air hose rather than extension cords 2 Generators make poor power sources for ele2. Model 5715K17 5520K17 6820K17 3095K18 3230K24CS 4230K28CS 9230K30CS 4090HK17 4090HK17 20 6590HK18 6590HK18 20 1040HK18 7722HK28 7722HK28 20 8422HK30 8230HK30 P U T O PSI to top factory setting Factory Settings oss e Recovery Time time between factory setting 25 43 18 12 10 705 15 30 13 26 12 07 17 13 RPM Hi Low Engine 3000 2150 3000 2150 3000 2150 3000 2150 3000 1900 3200 1960 3200 1960 3122 1916 3122 1916 AMP Draw max before stopping or unloading 0 X NOTE Threaded end of crankshaft has a left hand thread Remove nut by turning clockwise Use two or three prong wheel puller to remove flywheel Apply a small amount of oil between puller and crankshaft Entire crankshaft connecting rod piston assembly can be removed from crankcase after bearings with carriers are extracted from crankshaft Remove flywheel side carrier first Entire assembly can be removed or replaced as shown in the above drawing When reassembling flywheel side is always opposite breather oil fill plug When installing new bearing shells make sure notches in shell and connecting rod line up Make sure Shells are snug and flush Apply generous amount of oil on crankshaft journals and bearing Shells prior to reassembling Bottom and top half of connecting rod have distinct markings which have to be matched together Position connecting rod with square
3. Worn connecting rod bearing inserts Disassemble head remove cylinder inspect and replace necessary components according to service manual Crankshaft journals should be 19 polished with fine emery cloth If crankshaft journals are excessively worn replace crankshaft 4 Motor engine problems a Inspect tank check valve to make sure tank pressure is not leaking back against head b Remove belt and rotate pump flywheel by hand If pump turns hard or is seized repair or replace pump c If problem is identified in motor or engine send to manufacturer s nearest authorized service center Include proper documentation if warranty is requested 5 w Determining warrantable failures a Warranty covers defects in material and or workmanship for a period of one year from date of sale or 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 for failures of compressors with serial numbers beyond one year of manufacture Serial Number 09020001 is read first unit produced 09020001 in February 09020001 2009 09020001 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
4. ctric compressors because most are not large enough to supply the 3 4 times running voltage needed to start motor F Operating gas powered unit at factory set RPMS 1 ROLAIR gas powered units are factory set well below the maximum speed of each engine Contact ROLAIR with model number to obtain specific settings 2 Running wide open will allow valves in pump to float and pump oil This can also cause vibration related failures to belt guard saddle and or tank welds G Operation with vibration pads feet intact 1 Operating without pads will cause vibration related failures to belt guard saddle and or tank welds 2 Feet should be examined and replaced if worn during every service call or job H 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 If a second opinion is requested the customer should be billed for a replacement pump until ROLAIR factory s service department examines failure usually 1 2 weeks maximum The service center distributor will be given credit for the difference between cost of new pump and cost of repair to original if failure is determined to be non warrantable PLEASE CALL ROLAIR FOR A RETURN GOODS AUTHORIZATION NUMBER BEFORE RETURNING ANY GOODS 21 PERFORMANCE DATA po KT KAT KAZ Kag K24 K30 k50 K60_ K100 Flywheel Weight Flywheel Torq
5. led 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 15 Intake side of head is positioned over single set of holes in valve plate K9 K12 K24 K 25 K 28 K 30 K50 K60 K100 SCREWS HEAD Tightening Torque Inches Ibs Reinstall flywheel nut and washer REMEMBER Left hand thread turns counterclockwise to tighten 16 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 A TEMPERATURE NON DETERGENT Straight Weight 30 32 55 20 32 or below 10 y N TAL W OIL CAPACITY Ounces 17 oe 1 2 3 TROUBLESHOOTING GUIDE Reduced efficiency of compressor pump a RUN pump up time and compare against factory specification If pump up time is within factory specifications unit is working to its capacity b Failure of valve strip
6. roller bearing Drive Pins TIGHTENING TORQUE Inches Ibs 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 Replace cylinder gasket If necessary Pee o oF 5 yoo 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 11 12 Oil the inner side of cylinders and rings before reassembling A special pliers with steel band may be used to fit the cylinder onto the pistons Install cylinder with 0101 stamping located on same side that it was disassembled from Tighten cylinder bolts and torque to specified settings CYLINDER TORQUE SPECS Inches Ibs 13 14 Guide pins may be used to fit gaskets and valve plates Use small amount of petroleum jelly to hold valve centered into half moon grooves in valve plates 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 in one position only However the valve plates of single Stage pumps can be assemb
7. s blown gaskets or foreign material in valve plate assembly Disassemble head group and replace broken or damaged parts Reassemble following factory Specifications 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 c Clogged or dirty crankcase breather Clean or replace d lncorrect 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 same procedure Replace valves and necessary gaskets f Worn stuck or broken rings Remove pistons clean piston components and install new set of rings 2 Blown head gaskets or obstructed valve seats Replace broken pieces Inspect cylinder for scoring glazing h Always clean discharge tube and make sure check valve is sealing properly when pump is passing excessive oil Pump noisy or knocking a Loose or misaligned belts Tighten realign or replace Refer to pulley belt section of owner s manual b Loose motor engine pulley Inspect pulley bore and key Clean shaft and reinstall with a small amount of Loctite c
8. s on same side Before torquing connecting rod bolts refer to table A to determine which direction oil hole on rod should be facing After making sure oil holes are in correct position tighten connecting rod bolts with torque wrench 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 MODEL K8 K11 K12 K17 K18 K22 K28 K30 K35 K50 K6 0 K70 K100 4 TAB A TIGHTENING TORQUE CONROD ORIENTATION inches Ibs _ 121 5 o ae 1215 Conrod cast in asingle piece nema 3 121 5 3e e E cae Ca Ffo ll G 1736 oe es E LEE si ee 6 el 217 0 e Hoe oe Te 217 0 J es 13 stEfa 1997 ic o mmc i z 5 a w 2 2 a S E K70 a H m ale es K40 f 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 7 Lightly tap crankshaft assembly into breather side bearing carrier Guide pins may be used to reassemble flywheel side bearing carrier with
9. ue Specs Cylinder Head Bolts ft Ibs Cylinder Bolts ft Ibs Bearing Carrier Bolts ft Ibs Connecting Rod Bolts ft Ibs tolerance 5 Crankshaft Connecting mm 0 020 0 020 0 020 0 020 0 020 0 025 0 005 0 005 0 05 Rod Seat 0 015 0 015 0 015 0 015 0 015 0 020 0 0 0 03 28 28 28 28 28 30 40 28 55 Crankshaft Bearing mm 0 015 0 015 0 015 0 015 0 015 0 015 0 015 0 01 Housing 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 00 25 25 25 25 25 30 65 65 55 0 015 Cylinder Bore mm 0 025 0 025 0 025 0 030 0 035 0 035 0 040 0 035 0 020 0 020 0 020 0 025 0 030 0 030 0 035 0 030 0 03 64 53 64 70 60 52 60 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 005 15 15 15 15 18 18 25 18 25 To change kg meters to foot pounds multiply by 7 233 To change kg meters to inch pounds multiply by 86 8 22
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