Small Reciprocating Compressors
You do not have to hire an outside service
company to work on your small reciprocating compressors. We are pleased to offer
a unique book, to help you repair these compressors.
The book is easy to understand with useful information, such as the following:
• Explanations for the various components, including illustrations with exploded
• Simple diagrams that describe how the controls work.
• Maintenance tips on the 4 most common reasons small reciprocating compressors
• An in-depth trouble shooting guide that includes specific actions to solve
Order today. The book will pay for itself – many times over the years – by
eliminating the need for outside vendors to help with repairs. Here is a small
sample of the material from the trouble shooting section.
An Excerpt From Chapter 6
In an endeavor to simplify the very important
task of trouble shooting, we will first list the "symptoms" and then the
probable causes in a concise, compact manner. Then, in the following text, we
will take up each probable cause and outline the cure for it, in the same order
and by the same numerical listing:
A. Slow pumping or low discharge pressure.
1) Leaky head valves (or valves not seating).
2) Leaks in air lines, fittings, etc.
3) Restricted air intake or clogged filter
4) Compressor too small for equipment being
5) Belts slipping.
6) Unloading mechanism not operating
7) Blown gaskets on intercooler lines.
8) Defective pressure gauge.
9) Worn compressor rings.
A. Slow pumping or low discharge pressure
1) Leaky head valves (or valves not seating).
Valves must be removed by removing head (or
plates), hold-down cages and bolts must be removed. Then the valve may be lifted
out. Clean all parts thoroughly, including head and top of pistons. Valve discs
and seats must be smooth and flat and sometimes can be resurfaced on crocus
cloth or fine emery cloth. Badly worn parts, including springs with loose
tension, must be replaced.
Reassemble valve parts in proper sequence. Valves must move freely in retainers
when assembled. Care must be taken to remove old seat gaskets and all carbon
must be scraped and removed. Valve assemblies must sit flush on their seats so
that cages and hold-downs can secure them with absolutely no "play" or motion.
Use a film of grease on gaskets when replacing head on plates. Do not use
shellac. Blow out intercoolers to remove any loose dirt or carbon before
connecting to head.
Note: One of the simplest (and very effective) checks to see if valves are
properly seating, is to remove the intake filter and hold your hand over the
intake. If a valve is not seating it will blow back (at least partially) against
your hand. If valves are properly seating, your hand will be constantly pulled
in tight against the intake pipe.
2) Leaks in air lines or fittings
This must be done visually and physically. It
may be necessary to inspect the entire piping system, checking every connection,
hose and valve. Replace or tighten leaky fittings.
3) Restricted air intake
Clean inlet filters and replace clogged or
4) Compressor too small for load
Check air requirements and add to compressor
5) Belts slipping
When belts slip it sometimes sounds as if the
compressor is "loading" excessively. A good way to tell if belts are slipping is
to stop off the unit and feel the motor pulley next to the belt groove. If it
was slipping the pulley will be hot. The heat being caused by friction of the
slipping belt. But the surest way is to use a good amp meter (amp-probe) and
when the compressor appears to "load" the amps will DROP significantly when the
belts slip. If the compressor did actually "load", the amps would RISE
6) Unloading mechanism not properly operating
This situation is very common in "constant
running" compressors. When the compressor reaches "cut-out" pressure it idles
back. Then when the pressure falls to the "cut-in" limit, the unloaded does not
This can be several things: Check the pneumatic pilot valve to see that it is
clean and working. Check all lines running from the pilot valve to cylinder
heads and repair any leak and tighten all threaded connections. If the pilot is
good and all lines are air-tight, then check unloaded plungers and o-rings for
possible leaks or worn parts.
7) Blown gaskets on intercoolers
Carefully listen and feel for any leaks here,
and repair as needed.
8) Defective pressure gauge
Many times you will have a complaint "not
enough pressure" because the gauge is faulty. Always carry a master pressure
gauge and check against the gauge on the compressor. Replace the worn gauge if
it is not accurate, and reset the compressor controls to match the reading on
the master gauge.
9) Worn compressor rings
This can cause slow pumping. But if rings are
bad enough to cause this the unit will also be using entirely too much oil.
Rings should be replaced.
This book is exclusively available on this website.
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Table of Contents
This book has a soft cover with 25 pages filled with material on every aspect of
the small reciprocating compressor. Here is a list of the topics.
Chapter 1, Introduction
a) Compressed Air Terms
Chapter 2, Types of Air Compressors
a) Reciprocating, single and multi stage
b) Rotary Vane
c) Rotary Screw
Chapter 3, Nomenclature
b) Receiver Tanks
d) Safety Devices
This includes details on the check valve,
centrifugal unloader and aftercooler.
Chapter 4, Controls
a) Starting Controls
b) Operating Controls
Chapter 5, Installation
b) Pipe Size
c) Wire Size
Chapter 6, Trouble Shooting
a) Common Failures
c) Correction Procedures
Chapter 7, Overhaul Procedures
a) Minor Overhaul
b) Major Overhaul
Chapter 8, Maintenance
a) Recommended Schedule
b) Reference Charts
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How to Order
can learn more about maintenance and trouble shooting for the small
reciprocating compressor with this 24 page, soft cover book.
The book is $47.00 US with Free Shipping. Order today and start benefiting from this resource.
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