Air compressor not building up full pressure

[BTDT]

Compressor is chinese 2 stage from traveling tool show/sale. Unit is about 5 years old. Only builds about 50#'s pressure. I have pulled heads, gaskets good, pistons appear good, valves (spring steel strips) appear good. I can hold finger over each intake to filter and 1 sucks harder than the other. I think it has a check valve where it discharges into tank, and that's something I haven't checked. Any ideas on what I need to check next (other than sales brochures for new unit )?

 

[SPYDERLK]

Are the 2 pistons the same size? Is it oiless or oil in crankcase?
larry

 

[Bird]

Is that really a two stage compressor, or just a two cylinder one? Do you hear air escaping anywhere? You say the valves are spring steel strips? Isn't that reed valves?

 

[BTDT]

I looked again, the pistons appear to be the same size, so I guess it is a 2 cylinder, not a 2 stage. It has oil in the crankcase, and is about midway up the sightglass. No air can be heard leaking anywhere. It has one air valve near top of tank with 1/4 turn handle for on/off, and then a small "header" with 2 slide air valves for on/off. Not blowing oil out air hose, so I'm guessing the rings are ok. Even though the "reed valves" appear to be ok, I may need to check into getting some replacements to see if that will fix problem. I'll try to take pics of unit this evening, and later in the week, if I tear it down I'll post pics of that also.

 

[SPYDERLK]

BTDT. Yes, you have a single stage 2cyl compressor - and from my standpoint a real mystery. If it was oiless, piston seals would be likely. Not so with oil. A leaking exhaust valve on either cyl would cause your type of problem. Check the reeds and the faces of the ports they seal against. It should be an obvious defect with the serious symptom you have. The reeds self seat during operation so you are just interested in smooth seating surface - not a tight static seal. Also, do you have an unloader valve that automatically releases head pressure when the compressor stops. This may be leaking during operation. With all the other noise you may not hear it. The line for this valve usually leads back to the pressure switch, and the valve is incorporated in the switch somehow. Youll have to take the cover off.
luck,
larry

 

[BTDT]

BTDT. Yes, you have a single stage 2cyl compressor - and from my standpoint a real mystery. If it was oiless, piston seals would be likely. Not so with oil. A leaking exhaust valve on either cyl would cause your type of problem. Check the reeds and the faces of the ports they seal against. It should be an obvious defect with the serious symptom you have. The reeds self seat during operation so you are just interested in smooth seating surface - not a tight static seal. Also, do you have an unloader valve that automatically releases head pressure when the compressor stops. This may be leaking during operation. With all the other noise you may not hear it. The line for this valve usually leads back to the pressure switch, and the valve is incorporated in the switch somehow. Youll have to take the cover off.
luck,
larry

Yes, it does have the unloader valve, I may have to check this. I still kind of think it is with the reed valves, due to one cyl. having more (it seems) suction when you cover intake with finger. Thanks for the reply's, keep them coming.

 

[Bird]

I still kind of think it is with the reed valves

We might be wrong, but that would sure be my best guess.

 

[George2615]

Does it continue running and just not build over 50 PSI or does it shut off at 50 PSI? If it shuts off at 50 maybe your pressure switch is bad. If it continues to run and not build its probably an exhaust valve problem like Larry said.

 

[BTDT]

Does it continue running and just not build over 50 PSI or does it shut off at 50 PSI? If it shuts off at 50 maybe your pressure switch is bad. If it continues to run and not build its probably an exhaust valve problem like Larry said.

It continues to run, but that's all the pressure it builds to. And it seems it did this all at once, not gradually over a period of time, so it's like one of the valves stuck, got weak, or something.

 

[Bird]

I once had one of the oilless single cylinder compressors that would continue to run, but never could get over 35 psi, but the broken reed valve was obvious on that one when I opened it up.

 

[DieselPower]

Sounds like a leaking reed valve to me to. What make is it?

 

[BTDT]

Sounds like a leaking reed valve to me to. What make is it?

I got it at one of the Homier traveling shows/sales. I think it is a Magnum brand. I looked on their site, the only one they show now is a little oil less model.

 

[BTDT]

Well, I got my compressor fixed this past week while I was off. I pulled the plug from the bottom, nothing unusual there, about a 1/2 cup of water, and a little rust. Pic 5 & 6. Brand of compressor is a Magnum Air-you can see the specs on sticker, pic 7. Pic 8 shows motor, 2 cyl. compressor, air header.

 

[BTDT]

Pic 9 & 10 shows filter on questionable cylinder. Filter clean, spiders not home. Pic 11 shows reed valves, aluminum gasket, cylinder head (2 ports is discharge, 1 port is intake). Pic 12 is reeds laying on table, pic 13 is the other half of reed valve holder, still on cylinder of compressor. Nothing out of the ordinary yet. (In my opinion).

 

[BTDT]

Top of piston (clean), pic 14, 15. Pic 16 shows piston down in cylinder, no side to side motion, no ring wear lip at top of cylinder. I put it back together and it still wouldn't pump up all the way. Tear it back down.

 

[BTDT]

Now I take the reed holder off of the top of head (didn't want to disturb gasket before, because I didn't have a replacement, and it was stuck on good). That's when I found the problem. The head is divided into 2 cavities by a "divider". When I look closely, the center is gone out of the gasket allowing blowby from discharge to intake. You can see this on the top side of reed holder. Pic 17, area of blowby between intake and discharge, pic 18, the "divider" with gasket gone in middle, 19, another pic of blowby area.

 

[BTDT]

Pic 21, I change from grinding wheel to wire brush, Pic 20, cleaned off top side of reed holder, traced cutouts onto new gasket material ($3.00 at Autozone). Pic 22, brushed off cylinder head, pic 23, new gasket and clean head. Put unit back together.

 

[BTDT]

Ah, sweet success. Pic 24 and 25, compressor from 0 to 120 lbs. pressure in about 8 minutes.

 

[Bird]

Congratulations! It's always a good feeling to find, indentify, and correct a problem successfully.

 

[kenmac]

Guess I'll have to send my compressor to TX. for repairs when it breaks


Glad to see you got it going & didn't have to invest in a new compressor