question for anyone who knows the insides of an air compressor...

[fyton2v]

Just picked up a used Champion 5hp 60 gallon compressor. It runs quiet and smooth up until the point it gets over 100 PSI... and then it starts knocking. It's not a loud sound, but more of a tick-tick-tick-tick.

Is this a symptom that points to something specific, or could it be just about anything in and around the pump?

Thanks!

 

[Dirtsquirt]

hmm

You didnt offer enough info.
Is this a 2 stage machine? pump model R15 or something else
When lookin at the cylinder does it appear that there are 2 cylinders siamesed together, with one being smaller than the other.

If so, your problem is likely valves. more to the point your high pressure intake valve is leaking.

The noise you hear is the Intercooler safety valve popping off.
The intercooler saftey valve could be faulty also.

 

[fyton2v]

Hey... thanks! It's the R15A two stage pump. Since I posted I've tried to locate the approx area the noise is coming from by holding a screwdriver up to the pump and my ear. Through the metal I can hear a distinct knock on every stroke. It's not that audible on the outside though. Perhaps this is the normal sound of a running pump? No experience with compressors here. For whatever reason I wasn't expecting that noise ... i was expecting more of a tick tick like the sound from the valves on a nicely tuned 2F.

And since you're educated in these pumps... where do I find a socket that can take off those star bolts holding the head onto the cylinder?

Thanks much!

 

[fyton2v]

ummm. my last question was dumb. I didn't look at the bolt closely enough to realize it was a standard 3/8 12 point.

 

[zebrabeefj40]

My brother is rebuilding one of those pumps right now. We found a cracked rod on the low side. Was not broken yet. He was able to source a new rod along with all the other rebuild parts.

You also need to compare your pump to a drawing of how it is supposed to be assembled. I know that a PO in the past had installed pipe plugs in places they didn't belong on my brother's pump...like the unloader system. Made restarting the compressor with any pressure in the tank impossible.



Nick

 

[icesoft]

I'm Nick's brother,

The R-15 I bought was a real piece of work, good thing I got it for little more than a song.

Don't have a picture handy of the cracked rod, but I've got a good one of the the previous owner's unloader arrangement:

 

[icesoft]

Gonna have to get used to posting on this board....

Anyway, the check valve in the tank was bad and bleeding pressure back through the unloader valve, so the P.O. installed a pop-off valve to plug the leak....

Also found the compressor had been rolled at some point in it's life, as the intercooler tube was crushed at the low-pressure outlet:

And the thing was soaked in grease/oil from a leaking shaft seal:

I had a terrible time finding a shop that would return my e-mails, finally found Mckenzie Air out of Schertz, TX (830) 606-1240 that would return my messages and they got me some information, manuals, etc. I bought the new connecting rod assy-includes bearing and bolts ($88.60) and intercooler assy - includes compression ftgs ($115.74) from them.

I also bought a rebuild kit (valves, gaskets, rings, seals) from www.compressorpartsstore.com, for $115 and purchased a new set of Timken bearings (14138A/14276) from a local wholesaler.

After some time in the parts washer and a fresh coat of paint, this is about where I'm at, and still need to paint the tank and do a little more plumbing:

Mine is a little older, it's an R-15 with no suffix and the rod cap bolts are accessed from a cover on the bottom, whereas on the R-15A and B they are accessed from the top when you take the cylinders off the crankcase.

See link below for manuals:

http://stuff.stedman-machine.com/icesoft/compressor/RE10RE14.pdf
http://stuff.stedman-machine.com/icesoft/compressor/R15A.pdf
http://stuff.stedman-machine.com/icesoft/compressor/R15B.pdf

Good luck with it, mine's been a fun little project.

-Ben

 

[fyton2v]

Wow. That pump is looking great! I was able to call gardner denver and they emailed me a manual. Nice support. The person I spoke with thinks the reed valves need to be changed. I'll start there. Thanks for the link to the parts place!

George

 

[icesoft]

These pumps do not have reed valves in them, they are spring loaded disc valves, just remove the manifolds from the top of the cylinders, and pop the valve cartridge out, disassemble/clean/replace. They recommend using new valve gaskets when you reassemble the manifolds (big copper and aluminum crush washers).

-Ben

 

[Chloe Taylor]

Gonna have to get used to posting on this board....

Anyway, the check valve in the tank was bad and bleeding pressure back through the unloader valve, so the P.O. installed a pop-off valve to plug the leak....

Also found the compressor had been rolled at some point in it's life, as the intercooler tube was crushed at the low-pressure outlet:

And the thing was soaked in grease/oil from a leaking shaft seal:

I had a terrible time finding a shop that would return my e-mails, finally found Mckenzie Air out of Schertz, TX (830) 606-1240 that would return my messages and they got me some information, manuals, etc. I bought the new connecting rod assy-includes bearing and bolts ($88.60) and intercooler assy - includes compression ftgs ($115.74) from them.

I also bought a rebuild kit (valves, gaskets, rings, seals) from www.compressorpartsstore.com, for $115 and purchased a new set of Timken bearings (14138A/14276) from a local wholesaler.

After some time in the parts washer and a fresh coat of paint, this is about where I'm at, and still need to paint the tank and do a little more plumbing:

Mine is a little older, it's an R-15 with no suffix and the rod cap bolts are accessed from a cover on the bottom, whereas on the R-15A and B they are accessed from the top when you take the cylinders off the crankcase.

See link below for manuals:

http://stuff.stedman-machine.com/icesoft/compressor/RE10RE14.pdf
http://stuff.stedman-machine.com/icesoft/compressor/R15A.pdf
http://stuff.stedman-machine.com/icesoft/compressor/R15B.pdf

Good luck with it, mine's been a fun little project.

-Ben

Amazing and impressive pictures of Air Compressors.... Well done great posting.....