01) Dismantling of valves:-
To avoid damage to the valve and inner dowel pins, it is suggested to use a simple fixture for dismantle and assemble valves. Never tightened the valve directly in a vice and do not hammer on spanner when loosening or tightening the nut.
02) Cleaning of valves:-
Examine all the parts thoroughly after dismantled the valve. Remove the carbon formation with the help of Trichloroethylene or diesel and light scraping paper or brush. Don’t scratch the valve plate or seat while cleaning. Completely dry out the valves before installing it on compressor.
03) Inspection and Reconditioning:-
When valve plate, damper plate, spring plate shows sign of wear, it is imperative to replace these parts, even if no breakage has occurred. A maximum wear of about 10 % of the total thickness of valve plate is allowed. For highest efficiency of the valve it is important that the seat face is flat and free from any traces of wear, thus preventing valve leakage. If any damage on the seat observed, it is recommended to replace the same. Dew to presence of dowel pins, re-machining or lapping can not be carried out. It is also suggested to use a new valve plate with new valve seat.
04) Reassembly and Installation:-
A) Do the valve assembly in required sequence. (Refer diagram from instruction manual) Use fixture for proper tightening of valve nut. Check valve plate for free movement.
B) Test valves for leakage and insure it made dry after testing.
C) Suction valve equipped with unloader, the clearance between the valve plate and unloader lifter as well as the clearance between unloading piston and lifter is checked.
D) Valve cover nuts have to be tightened with specific torque by torque wrench.
E) The hollow side of the thin part in the centre of the valve plate must be placed upward facing, valve keeper.
The above information will help you to increase life of suction and discharge valve and hence the discharge pressure of the air compressor.
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