Downtime and repairs on my AV 4500

Forums Air Tanks, Pumps, Compressors, & Filters Downtime and repairs on my AV 4500

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    jking
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    First off, overall I've been mostly pleased with the performance of my AV 4500 110vac compressor after getting it new December 12th (delivered on the 19th) of 2017, which has 12hrs of documented run time. I'd consider it fast for topping off my SCBA's. Usually from 3100-3200 to 4400-4500 about 20min.

    The first problem I had was about 6 months into it. The power supply that runs the cooling system went out. I called AirVenturi and talked to Jordan and he diagnosed it being that power supply. He promptly sent me another one and I installed it. Problem resolved.

    The second problem started in late November (2018), still under warranty when it started producing a LOT of black oily fluids into the filter housing and at the same time the compressor would change sounds just for a second. It was still compressing well but I knew something was wrong. I contacted Jordan again and we decided to send it back in for repairs. This is why you want to keep your box and take care of it. Jordan found a broke high pressure ring which he replaced and he said he also found a leak somewhere on the hose that I wasn't aware of.

    Turn around time was about two weeks when I received it back. Unboxed it found that the power supply cord and bleed screw were missing. The box had busted open on two corners so I was afraid the two parts had slipped out. I called Jordan and he had the parts. Stuff happens, no problem. About a week later I received the missing parts.

    Thursday January 3rd I'm good to go. I get hooked up to my first SCBA start the compressor, sounds great, let it purge for a couple of minutes, close the bleeder and start pressuring up the compressor, filter housing and hose. It seemed slow though but I finally got it to within a couple of hundred pounds of my SCBA. I then opened the SCBA valve very slowly and equalized the two sides and started filling it. I started at 3200# and after 45min it had only increased to 4100#, hmm something not right here. I then just tried a dead head test of just the compressor, it's filter housing and the fill hose. This took 3:40sec to build 4000#.

    I called Jordan and described how it was performing and he asked if I wouldn't mind pulling the second stage cylinder top off and looking at the high pressure piston. No problem, another learning opportunity I thought to myself. Not being sarcastic here I really wanted/needed to learn a little more about these machines. The top comes off very easily and here is what I found.

    The bottom ring was broke and the middle had significant damage. I also inspected the cylinder bore and it shows some scoring but I don't know if that's normal or not. I also inspected the valve area and noted some pitting and a gouge very close to the high pressure discharge port.

    I sent these same photos to AV and again visited with Jordan. He thinks the only thing needed will be the rings replaced and a cleaning and it should be good to go. AV sent the new rings and and a installation tool yesterday so I should have it in a few days. Hopefully I can get back to making some air soon.

    Has anyone else had this issue with theirs? Just curious.

    Jimmy

     

     

     

     

     

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    golfer70
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    Wow! Seems like quite a journey to put air in your equipment. You have a great attitude about the whole deal. I hope that the next fix is the last. I’ll be looking for a compressor soon so this info is valuable to me and I’m sure many others. We have to hope/ assume that these manufacturers are working out the bugs out of these systems. 

    Best wishes. 

    Tim.

     

     

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    Glem.Chally
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    That's pretty bad,  look at the scoring on the second stage piston.  That ring is partly metal I think and got torn and smeared up and down between the cylinder and piston.

    I would be surprised if it runs as it should for the hours that are on it with even minor damage to the (soft) brass piston (soft) aluminum cylinder,  but who knows rings might just do it.

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    jking
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    Tim, I'm trying to stay on the positive side. The 19th will be two months since I noted the problem and started working on getting it repaired. Fortunately I still have plenty of air to keep me shooting. If I was out the story might have a different tone to it, lol.

    jk

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    crittahitta
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    Jking keep us updated please. I have a bout the same amount of hours on mine. Thanks.

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    2manyAirGunz
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    I have that same compressor, purchased maybe one year ago. No problems to-date. However, I only use it to fill my air rifles — directly from the compressor to the guns' fill ports. At first, I did this because of the time required to top-off an SCBA tank with this compressor. As I used the this compressor more, just filling a rifle to 250 bar made me realize that attempting to fill an SCBA tank would be taxing for this machine, and would shortened it's lifespan significantly. 

    One great feature of my AV 4500, is the ability to preset the desired pressure. The machine shuts off when the set pressure is reached.

    Hope everything works out well for you. Good luck.

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    sonny
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    i don't see a lot of difference between the AV and the YH except price.

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    jking
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    Csonny

    i don't see a lot of difference between the AV and the YH except price.

    Completely different. The AV is a twin cylinder and has a self contained cooling system and probably more electrics, The crank case cover  looks very familiar though.😉

    jk

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    jking
    Participant
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    Learned something new yesterday. I figured that since I had a couple of more days till my high pressure rings come in that I'd pulled the main cylinder off and check the rings on it. I'd noticed these four holes on the top of the piston head and just assumed they were just shallow holes for what purpose I have no idea.

    I then removed the two hex screws and pull the cylinder off to expose the piston and rings. Everything looked great but then I realized the holes on top of the piston go all the way through the piston head.

    So basically the large piston is just a base for the smaller high pressure piston to set on. I assumed some how this piston was supplying compressed air to the HP piston but the low pressure from the other separate cylinder is the only source of feed air (LP air) to the small high pressure cylinder.

    I can also understand now how small amounts of lube oil, probably mist or vapors could pass through the four holes and If the high pressure rings have failed could produce that black oily now combusted oil gunk. Glem Chally suggested this BTW. Probably also explains the change in sound if the oil is indeed combusting (dieseling) under the high pressure strokes. At least this is what I'm thinking is taking place. I could be 100% wrong so don't hold me to it.

    Jking

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    jking
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    WooHoo! , I'm back to making air for my starving FX's. You can actually see their O-ring showing because they are so hungry for air. Well, maybe not that bad but I'm back in business. I received my new, 3 high pressure rings and a installation tool yesterday. Today I started the process of removing my old ones and putting the new ones on. Here are the new rings and the install tool.

    These rings are a lot smaller when you get them and you must use the cone tool to stretch them large enough to go over the end of the piston. CRAZY!

    This one has already been stretched a little. I couldn't believe they'd stretch that far without breaking but they did. There are also three SS rings that go under the sealing rings.

    There are two parts to the install kit. A cone piece that slips over the end of the piston rod and a "resizing tool" that you use to reduce the size of the piston rings after you've stretched them large enough to slide over the piston rod.

    After I got the rings in place and resized I installed the HP cylinder head and all the associated plumbing.

    I then double checked all the nuts and bolts and ran it on just the cooling system to check for any water leaks, all good so I kicked on the compressor and ran it unloaded for 5 minutes. I then pressured up the compressor and hose with a dead head stuck in the end of the hose. Found a small leak on the hose and tightened it up for a complete seal.

    I then connected the compressor to one of my 75cuft tanks that had roughly 3800# still in it, started the compressor and topped off the tank to 4600# in 17min!!. I'm calling this (knock on wood" a success and I'm back in business. Just like tearing into a air gun I learned a LOT about the compressor and would feel comfortable making any further repairs when they arise.

    I want to thank Jordan at AV/PA for the help in getting me the parts, instructions and the overall great service in getting my unit back to compressing again.

    Jimmy

     

     

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