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Ideas for rebuilding my Charger AirPro air compressor?

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Forum topic by SweetTea posted 10-17-2018 11:54 AM 589 views 0 times favorited 15 replies Add to Favorites Watch
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SweetTea

369 posts in 832 days


10-17-2018 11:54 AM

So a few months ago I picked up this Charger AirPro 60 gallon air compressor. It had a broken rod, and I got it for under $80. I thought that I could replace the broken rod and have a decent, second air compressor for powering my nail guns, wide belt sander and hinge machine, then keeping my other compressor for dedicated paint spraying. Anyway, I looked online and found the rod for around $80. I installed the rod and it sounds like crap with lots of vibration. I may have purchased the wrong rod as it was the inner rod that needed replaced and I think they sent me an outer rod. They won’t send me the correct one unless I pay another $80 or so. But that is fine and that brings me to my next question…

This air compressor has a direct drive motor with the pump built into the shaft on the motor. The motor works fine though. Would it be possible for me to purchase the 3HP rated pump from Harbor Freight (which is like $160) and rig up a platform on top of my compressor and add a pully and belt onto my existing motor to power this thing and make it functional? I was thinking that I could strip the pump side off and hope that the motor shaft has a key or some way of attaching a pully that I could hook up to the outboard Harbor Freight pump.

What would you guys suggest? Does anyone know if the motor shaft on these compressors has a way to install a pully on it? Or should I give up on that idea and just buy a new motor from Harbor Freight at the same time I buy their pump?


15 replies so far

View Fresch's profile

Fresch

342 posts in 2093 days


#1 posted 10-17-2018 12:50 PM

What broken rod?
You have the tank.
Compressor
Motor
Controls
You can hook it up anyway you like so long as it works

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SweetTea

369 posts in 832 days


#2 posted 10-17-2018 02:24 PM



What broken rod?
You have the tank.
Compressor
Motor
Controls
You can hook it up anyway you like so long as it works

- Fresch

The rod that is connected to the piston inside the pump. The motor and pump are joined together in a direct drive fashion. No pullys or belts. I am trying to figure out if I can strip the pump side off exposing just the motor and find a way to attach a pully onto the shaft of the motor so that way I can buy an external, traditional pump that has a belt.

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tomsteve

844 posts in 1391 days


#3 posted 10-17-2018 03:08 PM

i think you’d need to be able to mount a pulley onto the motor shaft somehow. i think you could get a pulley with a set screw in it. iirc, compressor pumps have specific rpm’s they have to run so youd have to match up the pulleys to achieve that rpm. you might need to buy a motor,too.if that motor is run on 110 its not 6 hp.

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SweetTea

369 posts in 832 days


#4 posted 10-17-2018 05:05 PM



i think you d need to be able to mount a pulley onto the motor shaft somehow. i think you could get a pulley with a set screw in it. iirc, compressor pumps have specific rpm s they have to run so youd have to match up the pulleys to achieve that rpm. you might need to buy a motor,too.if that motor is run on 110 its not 6 hp.

- tomsteve

No it’s definitely not 6HP. I don’t think that I ever said it was, but I believe that it is 3HP, maybe smaller.

Do you know how i could go about determining the correct pully size for the motor pully? If the shaft doesn’t have a spot for a key, would a simple pully with a set screw be enough to hold it down?

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ajshobby

101 posts in 2480 days


#5 posted 10-17-2018 05:11 PM

Sweet Tea,
The motor should still have a keyed shaft. If you will take some advice, i would cut the bottom off of the tank and make a nice fire pit out of this unit. Ingersoll Rand Discontinued this line and no longer supports it for a reason. It may even be subject to a recall. Would need to check that by the serial number and a google search of “Charge Air Recall”.

AJ in Mpls

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Fresch

342 posts in 2093 days


#6 posted 10-17-2018 05:28 PM

Your picture shows 6.5hp
If the motor and pump are directly hooked shaft to shaft then 1 to 1, pump rotates at motor rpm.
Grind a flat spot on the shaft or keyway.
Take off all the safety plastic and see what you have.
Wrong piston rod, too long means it’s over traveling thus hitting someplace; get the correct rod.
How did you replace the rod and not tear it down

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SweetTea

369 posts in 832 days


#7 posted 10-20-2018 06:36 PM

What would be involved if I were to remove the stock motor and pump assembly and go with a 3HP motor and equivalent 3HP pump from Harbor Freight? The 3HP motor retails for $169 and the pump is $139 both from Harbor Freight. I would assume that I would need a pully for the motor end, but I have no idea what size to get to both correctly mate up to the 3HP Harbor Freight motor and be the correct size for the optimal RPM’s for the Harbor Freight pump. Any advice?

View tomsteve's profile

tomsteve

844 posts in 1391 days


#8 posted 10-20-2018 07:40 PM

whats involved is building a platform to put both on ,then determining optimal rpm for the pump, which with that and motor rpm, an online pulley rpm calculator can determine pulley size to get the pump rpm correct.

https://www.blocklayer.com/pulley-belteng.aspx

View MrUnix's profile

MrUnix

7004 posts in 2371 days


#9 posted 10-20-2018 07:57 PM

I’d fix it right… that is a pretty nice compressor made by DeVilbiss, and it’s probably something trivial, like not having the counterweight in the proper location (or missing?). Also, according to the parts diagram, it appears that both connecting rods are identical (same part numbers), so I doubt that is the issue unless you are talking about something different.

Cheers,
Brad

PS: If you do put an external pump on there – the current one is running at the motors rated speed since it’s direct drive. To replicate with a pulley, you would just need 1:1 (ie: same size pulleys). If the pump you get needs a different speed, then there are plenty of calculators out there that will get you the correct sizes (such as this one over at the vintage machinery site).

-- Brad in FL - In Dog I trust... everything else is questionable

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SweetTea

369 posts in 832 days


#10 posted 10-21-2018 02:46 PM



I d fix it right… that is a pretty nice compressor made by DeVilbiss, and it s probably something trivial, like not having the counterweight in the proper location (or missing?). Also, according to the parts diagram, it appears that both connecting rods are identical (same part numbers), so I doubt that is the issue unless you are talking about something different.

Cheers,
Brad

PS: If you do put an external pump on there – the current one is running at the motors rated speed since it s direct drive. To replicate with a pulley, you would just need 1:1 (ie: same size pulleys). If the pump you get needs a different speed, then there are plenty of calculators out there that will get you the correct sizes (such as this one over at the vintage machinery site).

- MrUnix

Well if it were possible to fix the current pump, I would certainly be open to that. When I ordered the rod kit, the instructions that came with the rod kit specifically stated not to use it as the inner rod as that would be a different part. I went ahead and put it on as the inner rod. And now it viberates the entire compressor very badly, and makes a load noise. I would describe the noise as a knocking of sorts that kind of sounds like the rods and pistons are not properly lubed.

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splintergroup

2341 posts in 1394 days


#11 posted 10-21-2018 02:54 PM

A broken rod can damage lot sod other parts. Did you do a complete teardown and inspection?

View MrRon's profile

MrRon

5130 posts in 3415 days


#12 posted 10-22-2018 04:57 PM

Direct drive compressors are very noisy. The motors usually run very fast. Attaching a pulley to the motor may not be possible, as the compressor is usually close coupled to the motor. Your best bet is to buy a belt drive compressor and an induction motor and attach it to a built up platform on the tank. Harbor Freight has what you need, but I can’t attest to their quality or how long it would last.

View SweetTea's profile

SweetTea

369 posts in 832 days


#13 posted 10-23-2018 11:52 AM



Direct drive compressors are very noisy. The motors usually run very fast. Attaching a pulley to the motor may not be possible, as the compressor is usually close coupled to the motor. Your best bet is to buy a belt drive compressor and an induction motor and attach it to a built up platform on the tank. Harbor Freight has what you need, but I can t attest to their quality or how long it would last.

- MrRon

I think that is what I plan to do. I will buy a 3HP motor and equivalent 3HP rated pump from Harbor Freight. The motor retails for approx $170 and the pump for $140 at Harbor Freight. I will build a larger platform on top of the tank to support them. I hope that the Harbor Freight pump has some literature included that mentions the optimal rpm so that I can use a pully/rpm calculator to determine the optimal pully size. The total cost from HF should be about $280 with my coupons. Then I will have to source a pully and belt.

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tomsteve

844 posts in 1391 days


#14 posted 10-23-2018 12:40 PM

make sure to get the rotation on them right-the pumps only like to run in one direction.

View Fresch's profile

Fresch

342 posts in 2093 days


#15 posted 10-23-2018 01:43 PM

That puts you at about $500+ for the bargain you will need to design/ build.

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