First, the air compressor troubleshooting

Common faults of air compressor

1. Fault phenomena: high exhaust temperature of the unit (over 100 ℃)

Unit coolant level is too low (should be seen through an oil speculum, but not more than half);

Oil cooler dirty;Oil filter core is blocked;Temperature control valve fault (component is broken);The solenoid valve has no power or coil damage;Broken oil electromagnetic valve diaphragm rupture or aging;Fan motor failure;Cooling fan is damaged;The exhaust pipe is not smooth or the exhaust resistance (back pressure) is large;The ambient temperature exceeds the prescribed range (38 ° c or 46 ° c);Temperature sensor failure (Intellisys control unit);Whether the pressure gauge is out of order (relay control unit).

2, fault phenomenon: the unit fuel consumption or compressed air oil content is large

Too much cooling dose, the correct position should be observed when the unit is loaded, at this time the oil level should not be more than half;Blockage of return pipe;The installation of the return pipe (the distance from the bottom of the oil separation core) does not meet the requirements;Low exhaust pressure when the unit is running;Oil separation core rupture;The separation cylinder internal partition is damaged;Oil leakage of the unit;Coolant deterioration or overdue use.

3, fault phenomenon: low pressure unit

The actual gas consumption is larger than the unit output gas;Vent valve failure (unable to close during loading);Inlet valve failure;Hydraulic cylinder failure;Load solenoid valve (1SV) fault minimum pressure valve stuck;Leakage in user network;Low pressure setting;Pressure sensor failure (Intellisys control unit);Failure of pressure gauge (relay control unit);Pressure switch failure (relay control unit);Pressure sensor or pressure gauge input hose leakage;

4, fault phenomenon: the unit exhaust pressure is too high

Inlet valve failure;Hydraulic cylinder failure;Fault of loaded solenoid valve (1SV);Too high pressure setting;Pressure sensor failure (Intellisys control unit);Failure of pressure gauge (relay control unit);Pressure switch failure (relay control unit)

Second, the air compressor oil leakage fault judgment and elimination methods

(1) oil leakage of air compressor, pay attention to observe the oil seal position, check whether the oil seal is cracked, whether the inner lip crack or flanging.Should be replaced in any of the above cases;Check whether there are scratches and defects on the joint surface of oil seal and spindle, and replace those with scratches and defects.Check whether the oil return is smooth, and if the oil return is not smooth, the crankcase pressure is too high, leading to oil leakage or falling off of the oil seal. The minimum diameter of the oil return pipe must be guaranteed, and it is not twisted or bent, and the oil return is smooth.Check the fitting size of oil seal and box, and replace if it does not meet the standard.

(2) forcibly move the spindle to check whether the neck clearance is too large. If the clearance is too large, the bearing bush and oil seal should be replaced at the same time.

(3) check the sealing condition of sealing gaskets in all joints, repair or replace the sealing gaskets;Check and tighten the feed and return connector bolts and housing threads.

(4) check oil leakage of air compressor and re-adjust the belt tightness. It is advisable to press the thumb down 10mm.

(5) oil leakage of the air compressor requires inspection of the defects existing in the casting or processing of the box body, repair or replace the defective parts.

Overheating fault analysis

In the daily operation of air compressor, the air compressor will overheat due to the long time overload operation.

Overheating fault of air compressor:

(1) air compressor exhaust temperature is too high.

(2) hot operation parts.

Three, air compressor parts crack cause analysis and inspection maintenance methods

The common causes of air compressor parts cracking are:

(1) the cooling water is in the cylinder head of the engine body, which is frozen due to failure to release water timely after stopping in winter;

(2) due to the internal stress generated during casting, it gradually expands significantly after vibration in use;

(3) as a result of mechanical accidents, such as piston rupture, connecting rod screw broken, resulting in connecting rod broken off, or the crankshaft of the balance iron flying out to damage the body or gas cutting parts fall off top cylinder head.

The inspection and maintenance methods for cracks are as follows:

(1) permeability kerosene method: inspection process is first used to soak the cotton waste of kerosene to wipe the body, cylinder head, again with dry cotton waste kerosene jiang wipe crack may occur, and immediately white powder on figure in these places, where there is crack, kerosene will infiltrate into white powder, the location and length of the crack is clearly displayed.

(2) hydraulic pressure method: hydraulic pressure method is to improve the cooling water pressure method to check the crack site.Water pressure inspection is carried out on a special equipment, a water pressure tester.In the equipment environment conditions are poor enterprises, some with ordinary hand pressure pump system simple equipment can also check.That is, the body or cylinder head of the water pipe joint to try to plug, only one of the water pipe joint with rubber pipe and water pump outlet connection, the plane on the body should choose the size of the special cover plate, so that the cooling water can not overflow.Then open the switch to press the water pump, and the chamber water enters the cooling water jacket.When the switch is out of water, turn off the switch and continue to press the water pump to stop the water supply when the pressure gauge pointer reaches 3-4 atmospheres.At this time, whether cracks exist or not can be judged by checking whether there is any leakage or water leakage in the body or under the cylinder head.