Kellogg compressor pump rebuild.

[Jim Johnstone]

This isn't going to be an overnight build thread, it will probably drag out for quite a while getting it rebuilt, but I figured I may as well start documenting the rebuild.

So here is the deal, my boss had a kellogg 452 compressor at work running our machine shop. It started popping the over pressure relief valve and he decided it wasn't worth rebuilding the pump and was going to buy a new pump. I planned to grab the old pump and rebuild it, but then he changed his plans and decided to replace the entire unit and he wanted too much money to make it worth while for me to buy the whole machine.

So I started watching kijiji, and I spot an ad for a compressor tank with a pump on it. Emailed the guy and he said it was gone and asked what size tank I was looking for since he had several. I said I didn't need the tank but I wanted a good 2 stage compressor. He says he's got nothing for me. Couple hours later he texts me and says the guy that bought it from him doesn't need the pump so he would be in touch. I get a text from the other guy who says he'll sell me the pump. I ask what make/model and what price. He says it's a kellogg 452 and he wants 28 bottles of bud light. SOLD!

So here is the beast



I'm just getting started messing with the pump. I knew going in that it was seized. I popped the valve covers off each cylinder and I found this.



I'm pretty sure I can tell which cylinder is the main culprit. Anyway I was able to hold open the intake valves with a screw driver, and dribble in some ATF into each cylinder. Hopefully by tomorrow I'll have the pump free and ready to tear down.

 

[bsaint]

If the old pump was popping the interstage check valve, it probably only needed an intake valve on the high pressure side.

 

[Jim Johnstone]

If the old pump was popping the interstage check valve, it probably only needed an intake valve on the high pressure side.

Yeah that's exactly why I wanted to buy it lol. I do get why the boss didn't want to have it serviced, the tank was old and spitting out rusty water all the time, the shop had expanded a great deal and he wants more air, plus the air compressor service guy obviously is going to make his money on the service job. Didn't make much sense to have it repaired.

 

[Jim Johnstone]

Had a bit of time this afternoon to have another look at that pump. 5 out of 8 valves came out without any issues, the other 3 had to be tapped out from under neath after I pulled the heads.



All 8 valves are soaking in some simple green overnight, I'm about 99% sure I'm just going to order a full set of valves anyway.



Both heads looked like that, ironic that I could really use a good high volume compressor and a blast cabinet right now lol.



Oddly, the low pressure cylinder on one bank and the high pressure cylinder on the opposite bank were in good shape, and the opposite cylinders were in rough shape.



Finally, this is the ****** intake manifold that someone along the way cobbled together. I'm planning to toss this and use 2 separate intake filters, one for each first stage cylinder.

 

[Jim Johnstone]

After three rounds of long soaking in straight simple green concentrate, all three times the simple green was solid black with an oil slick each time. Finally starting to look like valves.



I need to pick up some mineral spirits and get a bit more stubborn goo off them, then they will go for an evaporust bath after that. I'm starting to think I may be able to actually get some use out of these valves.

 

[md21722]

The before pictures look really disgusting. If the valves are that bad with oil, you can only expect the rings and/or cylinder walls to be shot.

 

[Jim Johnstone]

The before pictures look really disgusting.

Oh yeah, I've got my work cut out for me on this rebuild.

 

[Jim Johnstone]

The before pictures look really disgusting. If the valves are that bad with oil, you can only expect the rings and/or cylinder walls to be shot.

Rings are shot for sure. 2 of the cylinders are really clean, surprisingly clean actually. The other 2 I won't know for sure until I get the cylinders off, hopefully another night this week. I'll try honing them, worst case I bore them out and put a cast iron liner in.

 

[Jim Johnstone]

Finally back at this pump again, I got sidetracked with another pump that is being sold, so this one being for me got kicked to the back burner. Not much to show, valves finally look like they may be useful, just need to disassemble them, lap the mating surfaces and probably replace the valve springs.