I have an '87 Emglo compressor and have had it 10-12 years 5HP 220V 80 gallon 2 stage 4 cylinder cast iron compressor head; it is a beast. IIRC it puts out something like 19 CFM of air at 175 PSI and 22 ish CFM at 100 PSI. I have never been able to out work it. Sandblasting, DA'ing, roofing, running multiple nailguns when I built my garage, run 150' of hose over to the neighbors' house to do "what ever", it has done all that I have ever asked. and still runs, does not consume oil, either.
During the last 4-6 months it has been discharging grey/white gooey oily sludge. I have seen this out of other compressors before but until recently never from mine. It still gets up to its 175 PSI "shutoff" setpoint without issue. but that gooey crap, (reminds me of a huge pile of fresh bird crap) cant be good for my tools; and I know that just draining the moisture out of the tank isnt carrying all of this crap with it;I run 2 water traps in series right at the compressor outlet so this was where I started seeing the gooey crap show up first.
I rarely paint with this unit but do occasionally. so;
1) what is causing this all of a sudden?
2) how can I flush the tank, once I solve the issue? (just wait for the air cycling thru to eventually carry it outta there? I'd like a little faster result.)
3) Do I need to rebuild my compressor head, to solve this? ( being commercial duty and all castiron, made in USA, I think it may be worth doing)
4) I know that Dewalt bought out Emglo, and that buyouts often leave a shell of a former good company: would parts be as available under DeWalt/jenny? (4b) where can I get parts?
5) do the engine aftermarket companies (like Sealed power, Hastings, Perfect Circle etc) make parts for these?
6) upon rebuild do these generally need a rebore or is a hone and new rings usually sufficient? I know I wont know for sure unless I tear into it; but for those that have done them what has been your experience?
6b) IF the cylinder needs overbored are oversize pistons and rings available? Or is the cylinder then scrap and need replacing? If this is the case i can see it "not being worth" rebuilding! the cylinder is a seperate casting from the crankcase.
7) is it generally worth rebuilding one of these or does parts cost come close to the price of a whole new compressor head?
I know this is basically a 4 stroke engine without an ignition system and no fuel added to the intake air... so i am guessing that without ignition that a compressor won't run as hot as an engine; does that equate to less wear on cylinders?