How To Replace Or Rebuild The Valves On A Ingersoll Rand Air Compressor Parts

Ingersoll Rand Air Compressor Parts

Today’s training is going to be rebuilding the vows on this air compressor behind me

this is a ingersoll-rand t30 model and the compressor model number is winged

out right here see if you can zoom in on that but I’m going to read it out loud

just in case you can’t see that that’s a model number 242 5D now

this is what has happened there’s two cylinder two cylinders right here

obviously this is the air filter so you know that the air is going into the air

filter and you’ll see that the diameter of this piston is much larger than

diameter Timnath to this piston so this is what is referred to as the first

stage cylinder piston okay what happens is is that the air gets drawn in and

then pushed out and then it goes there’s a tube here it’s a thin tube so

it can dissipate some of the heat then it comes over and it goes to the second

stage which is because it’s more compressed it set up less volume higher

so then it comes out of there goes into another heat exchanger when the what the

thing when the motor is running and then then it goes into the tank now this here

is safety valve this is actually set at 75 psi and safety valve is right on the

other side there can’t quite see it and care for beer so what was happening is

is that we’re running the compressor and we’re sitting there popping the safety

valve now you consume that oh you know what maybe the safety valve is about

safety god that’s that’s why the that’s why the thing is popping so what we did

was was we made out of the small adapter fitting set and I’ve got down here a

Schrader valve I got my 75 psi safety valve here and then this pressure gauge

here that goes from zero to 100 psi I put this on a tank of nitrogen and then

cranked up the regulator and this safety valve actually pops out approximately 75

it’s real tight and you can see that here on the gauge when I was with the

nitrogen so then the next question that you may ask yourself is okay what exactly is how

here why is this safety valve popping after the first stage now the answer I

believe is going to be the valves in the second stage are not seating properly

these particular valves are like finger valves so what happens is when the

piston draws in it allows the air from first stage to be drawn into the

cylinder when it’s on the pallet when it’s when the piston is rising those

valves are supposed to close off the port from the first stage it discharged the air out here

I believe those valves are leaking by so that way some of the air is going this

way and some of the higher pressure air is going back and that is why this

safety valve is is popping on me during normal operation this is a air

compressor number two I’ve got the disconnect shutoff over there for safety

so that this compressor cannot run there’s still some pressure to the tank

I’ll bleed that down right down to zero before we get started now I do have a

whole kit to rebuild both valves but what I’m going to do is I’m going to

start in over here high-pressure side and put the safety

valve back in and just do a little experiment here just to see if just that

one alone does it let me show you what the kit looks like all right so here’s

the the valve gasket kit and it’s got a part number here I distorted this online

through some internet site if I remember correctly this was very reasonable in

price it was only $20 all right so what you get for $20 and is that they have

different levels of rebuilt you can I mean you can change out the the rings of

the pistons and you can change out the Pistons the cranks and everything but

all I bought was stuff to do this section right here now

so it comes with these gaskets right here is different sized gaskets they’re

depending upon what it is it you got and these here are the actual valves we open

that up so you can see what it looks like all right so this here is what the

valves look like that’s why they call them finger valves because they

apparently they kind of look like a finger and there’s some type of a seat

in here that keeps it flat up against it it just lets it fold down and let’s a

fold down when it is on the intake stroke and when it goes on that on the

uptake stroke it comes up seats that off and it goes out through the discharge

port when I open this up I’ll show you what that looks like when I go to put

this back together I’m going to use a torque wrench and I’ll use a criss cross

pattern and that torque goes down appropriately and I’ll show you that

step when I get to it on my gaskets when I go to put my gaskets back down I’m

going to never seize up my gaskets so that way takes everything to do this

in the future taking off the gaskets will be quite easy

I don’t know how difficult it’s going to be for me to work with these gaskets

until I take it apart so that’s it we are I shut the tank bled down the

print web zero loosen up these with a half inch wrench socket wrench so now

I’m going to pull this off okay part of the gasket when I pull this off this is

the first time I’ve taken this off part of the gasket fell down on me when when

I took it apart so the gasket was failed that possibly was contributing to it as

I’m just looking here right here I can see part of the gasket material

underneath the finger which may have been causing some of my problem here now

you’ll notice that the finger is held on by two flat bladed screws and what else

okay then this comes off, okay now on the opposite side is another

finger okay one thing I’m going to do just to make sure I don’t get messed up

and turn something around that should not be turned around I’m going to take a

black sharpie and I’m going to put two lines side by side right here so that

way when I go to put this back together again because these are channels and

then if this is very specific you wouldn’t want to put this back in the

wrong way so by having all my marks here I know that what I’m going to do is I’m

going to line everything up the way that it comes off so it’s very important that

you pay attention to the orientation so that you don’t make a mistake like that

so anyways I got the end section off here this is the bow the plane with it

with the two finger valves and then this here is where you see the piston and

such and then there’s one more gasket right here that I’m going to have to

change out when I change out the gasket I’ll make sure that I stick a rag down

in here because I’m going to clean all this out and also I’m going to blow

everything out with compressed air before I put everything back together so

so that’s it for now so what we’ve done is we’ve just looked at the cylinder

head here the cylinder the cylinder and we got the gasket that goes here and I

was just to see what what about if someone installed it this way or this way or

this way if you is uh there’s only basically four combinations that you can

do and and it’s almost any approved that it has to go on this way there’s a hole

here in here this is the airflow coming in this the airflow going back out when

you line up on your gasket with these two holes here here then the four screw

holes line up perfectly if you tried to turn that around so that way he went in

this way and that way the screw holes do not line up so ingersoll-rand

made this idiot proof to force you to put it on and only one direction to make

sure that you have the appropriate situation down now once you do that

you’ll notice that this this is for the fingers here and here this has a cutout

telling you that that finger goes on the bottom what I mean by that is here’s the

finger here’s the finger valve plate, okay there’s one here and there’s one

here you could either put it on like this or you could put it on let’s see

here like this this would be wrong because the finger here is on the bottom and on

this gasket you’ll notice that there’s a cutout here and there’s no cutout right

there telling you that that is in the wrong position it has to go like this in

addition to that it lines up with the two marks that I did just in case you

were in the middle of this job and you did not put the two marks down there if

you were to just observe that you still could not make a mistake it would still

be correct but so that’s how that goes and then the top one whoops I’m dropping

a gasket on and on the top one here if you look at this section here there’s a

cutout section here it can only go on just that one way so you can’t really

mess up on your gaskets you can’t put it on this way you can’t put it on this way

or in any other combination and only works in one combination so I just

wanted to kind of show we show you that and right now we’re just going to start

removing these gaskets changing out these valve plates and putting this head

back together okay so what I did was as I put some rag material down the

discharge board and inside here in the suction port the piston port I left

alone because I have a I’m going to blow this out said I got a

brass bristled cup brush this entire plate up the the gasket came off pretty good

I was picking out it and it came off pretty easily and then I cleaned off all

the sections so it’s as soft as a baby’s behind right now now let me take you

over here to the Battle of plate okay so right here is the valve plate I’ve taken

off the fingers paying very special attention into exactly how we got the

screws were made up basically it goes like this it goes with the flat bladed

screw there’s a washer on here then put that on here and you’re going to put this on here and

then on the backside put on your lock washer and then you’re not but right now

we’re taking everything apart because what I want to do is I now want to clean

up this plate so I just have a workbench here just holding that down both sides

of this plate before I move on that’s it. okay what I’ve done is I’ve taken my brass

cup brush I have cleaned up the valve plate on both sides really nice we’ve

got a rag here so I can just wipe things down and I wipe down the surface that

I’m on before I got started with this particular Bal clay I drew a little

template here on my workbench this is just plastic so I could just draw

directly on the plastic and then I kind of align this up with my holes and exactly

where where where this goes so I know that the finger goes on top right here

these are the valve pore openings right here now this these here are the two old

valves you can tell from the discoloration and such and I don’t need

to reuse these because I’ve got brand new valves in my kit now the question

now becomes do I install that see if there’s a bend if you look at the actual

valve you’ll notice that there’s a bend to it it doesn’t sit flat it’s got it’s

got a band to it so would you want the bend to go up or would you want the bend

to go down the answer is we want the bend to go down because you’re trying to

force that when you put the screws in to be a very very flat seal so that way

when the pivot so what happens is when the piston is sucking down let’s say the

pistons on this side it’s coming down well then this is going to be here and

when it pulls down that vacuum that it draws is going to cause this finger to

bend down slightly allowing the air into the cylinder when the piston comes up on

the upstroke this is now going to be seated allowing air to flow through here

and out this finger valve which is like this this finger valve lifts up slightly

and then it goes out and into the discharge port so so basically that’s

how this works I know exactly which way and I’ve got my correct orientation I’m

going to go ahead and put on these finger valves right now with the

hardware that came off right there okay here we are we’ve got the valve plate

ready to go with our new valve fingers on there and they are tightened down

ready to rock this is already been dressed that’s a compressed air here I’m

going to blow this hour okay the next thing I need to do is put down a gasket

now I’ve got to pull out these and then I’ll blow out whatever’s in there as

well although there shouldn’t be anything in there but there’s anything

in there oh boy that’s super clean right now now next thing I want to do is I

want to put a gasket down here now the gasket that came off of here was this

one right here so obviously the gasket that’s going to go on is this one I’m

just going to wipe it down and I’m going to dress it up with some never seeds

right here anti-seize basically what I’m going to do it just takes them this step and I’m

just going to paint anything asking this way when you want to take off the gas

gets downstream it is an absolute breeze they don’t stick or anything like that

so that is the purpose of doing this all right so I’m just going to take a minute

off camera I’m just going to finish painting this at both sides okay I’ve

done dressing it up I’m just fusing that all right just to

kind of clean off any excess so there’s not of the an undue amount of anti-seize

on here and now I am actually going to put this down now I need to figure out

which way that it goes to make sure that I’m out case is they cannot even make a

mistake because if you tried it if you messed up on the holes and you had it

upside down the bolt holes don’t line up so it has to go in stay here it

absolutely has to go in this way right here so that is ready to rock next is my

mouth fleet I’ve got it nice and clean and we’re totally good here and now on

the valve plate I know that it has to go in this way also I’ve got my marks here

on the side to help guide me but I can tell just from looking at the fingers

that this was going in appropriately next is this gasket here now I got to

put the on the head on here and the gas the head and this can only go on one way

so here’s my head I know that it goes on this way because there’s my love my

lines all lined up so if I just take this and take it down like this this

little eyebrow must go like this so that this has to go in just like that so what

I’m going to do now is I’m going to just go ahead and dress this one up with some

anti-seize get this down it’s and then and get my bolts ready so I’ll go

off-camera to dress this up okay here we are the gasket is dressed I know that my

eyebrow has to go that way here’s my mouth plate I’ve already taken some

compressed air balloon that out so it’s nice and clean and dry there’s the

eyebrow there’s my two marks that has to go on like that – next is I going to get

my bulbs on so I’m just going to put a dab of never sees here on each bulb just

on one line like that and getting everything all kind of lined up put that

in all right so I’m going to do all four these then I’m going to Snug everything down

then I’m going to torque it down now see what the torque fitting range

what it feels like when I got my torque wrench on here we’ll see how many

foot-pounds we put on there I’m guessing right now I made you sixty but I’m going

to see how that feels before I commit myself to that so basically that is

rebuilding one head and this is the high pressure head discharged him you grab my

socket wrench okay everything’s in everything’s reasonably good now in a

crisscross pattern I am very gently going to tighten up all of these bolts

this is a 9/16 inch bolt head was about 18 threads per inch now I’ve got a chart

here for him to assume in right over here now this tells you what the torque

setting is depending upon whether you’ve got national course or national fine now

it doesn’t have 9/16 but the closest one has is 5 eggs at 18 threads per inch

they want me to go between 60 and 70 40 pounds that’s a minimum and a maximum

okay so I’ve got my handy dandy torque wrench here if you’ve never seen this

style this is what’s called the dial type of torque wrench so I’m just going

to come down here and I can see by the needle deflection where that’s going to

land into and I’m going to go with a crisscross pattern so I go even all the

way down that I want to just do one and then do another one you want to bring

your head down just kind of nice and slowly and evenly that’s your goal I

think I’m going to be fine 440 foot-pounds and all honesty I don’t

think we want to need to go to 60 because when I took these off they were

quite honestly I felt like only maybe 20 foot pounds it’s a matter of fact I

think I’m just going to go 30 there’s 30 on that line, there’s 30 on that one

in this 30 right there now what we’re going to do is we’re going to go online

here and see and do a test to see if that seats up by the way I pulled this

off of the Internet, this is for type of 30 compressor maintenance it tells you that the part

here the top part this is called the head the next one down is called the

valve plate because it has the valves and then back to the valve plate is

called the cylinder and it tells you which are the ports by the way tells you

which one is the intake port and the disc and the discharge valve so the

inlet valve and the discharge valve that tells you right here so the valve that

was on top when I was looking at it after I pulled the head off

that’s the discharge valve alright so anyways we’re going to go ahead and

start this up and we’re going to see if if that made a big difference because I

found a crack in one of the old city air here’s the old gaskets right here so

this is the head gasket this is the cylinder gasket this one here was broken

right there and got a feeling that that was the root cause of my cargo but we’re

going to turn this one online and do a test right now okay we just turn the

disconnect on this is the this pressure gauge here tells you the tank

pressure we cycle down at about 120 pounds okay we put the safety valve

never did release the pressure here you know as the compressor was on kind of

bounced around a little bit but it never got a load of 40 psi and the rebuilding

that the valves on the discharge valve definitely solved our problem

we were popping this safety valve and we could never get up to tank pressure and

it was because the valves were not operating properly they were blocked

blocked by that broken head gasket so even though that soft our problem since

we have all the tools and everything down here we’re going to plead the

pressure of the system up again and we’re going to go ahead and repeat the

process on the suction cylinder which is pretty much the same process it’s just a

larger diameter piston because it’s more volume of air but it’s getting close to

lunchtime so we got to head up to Margaritaville and then after that we’ll come back here.

Source : How to Replace or Rebuild the Valves on a Ingersoll Rand Air Compressor

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