Repair and Maintenance of Diesel Air Compressor

Aug 9, 2024

The maintenance operations in this manual are suitable for general conditions. In high temperature, high humidity, high altitude, high pollution and other environments, maintenance must be more frequent for Diesel Machine Air Compressor.

1. Safety Warning

1.1 Unlike routine inspection, maintenance (including refueling) shall be performed after the compressor stops operating.

1.2 Removal and maintenance of the pressure element shall be performed only after shutdown and release of all pressure.

1.3 Never use an open fire light source to inspect the interior of the machine or pressure vessel.

1.4 During maintenance and repair, the general parts shall be covered with dust proof, and the exposed parts shall also be cleaned with clean rags, paper or insulating tape to keep them clean.

1.5 Check air conditioning components, air filters, etc. to protect them from moisture erosion, especially when steam cleaning.

1.6 Do not use flammable solvents when cleaning components, beware of toxic gases generated by cleaning fluid.

1.7 After the repair work is completed, ensure that no tools, loose parts and wiping cloth are left out on the inside or surface of the machine.

1.8 When repairing moving parts, they shall be supported securely and not relied on jacks.

1.9 Replace parts with original parts.

1.10 Maintenance and repair of all machinery and equipment shall be recorded by the operator, and the number of repairs and reasons shall help to determine whether there is any potential safety hazard.

2. Daily maintenance (every 10 hours of operation)

Check compressor oil level.

Check and clean compressor air filter.

Drain water from the bottom of the oil-gas separator.

3. First 50-hour maintenance.

Check and clean compressor air filter.

Replace compressor oil filter.

Check control system function.

4. Maintenance for every 100 hours of operation

Cleaning compressor air filter

5.Maintenance per 500 hours of operation

5.1 Notes for Changing Lubricating Oil of Compressor

1) run that air compressor for a little time to raise the oil temperature, reduce the viscosity of

the oil and discharge the oil profitably.

2) Press the stop button to shut down the machine.

3) Open the drain valve at the bottom of the barrel when the pressure in the barrel is less than 0.1 Mpa. Due to the pressure, the drain speed is fast and easy to be ejected, so it should be opened slowly to avoid splashing of lubricating oil. Close the drain valve after the lubricating oil is exhausted. Note: The lubricating oil in the system, including pipelines, coolers and the barrel, must be drained completely.

4) Open the filler plug and fill it with new oil.

Replacing air filter element

Replacing compressor oil filter

Check the safety valve;

Check all connection bolts of the smart control box. .

Check oil, gas and water seal

5.2 Precautions for Lubricating Oil Use

1) The scrapping and replacement of oil products depends on the new and old Diesel Air Compressors, the environment, humidity, dust and the presence or absence of acidity and alkalinity in the air.

Generally speaking, the new compressor replaces the oil after 500 hours of the first use, and then replaces the oil every 2000 hours. Discontinuous air compressors should change the oil at the right time.

2) Do not let the lubricating oil exceed the service life of the oil products. The oil products should be replaced on time. Otherwise, the quality of the oil products will be degraded, the lubricity will be poor, and the service life of the engine head bearing will be reduced. It is easy

to cause high-temperature shutdown. At the same time, the flashing point of the oil products will be lowered, and the oil products will spontaneously ignite, resulting in burning-up of the air compressor.

3) after that Diesel Air Compressor is used for two year, it is better to use the lubricating oil to do the oil “system cleaning” once, the method is to replace the new lubricating oil, let the air compressor run for 6-8 hours, immediately replace the lubricating oil again, thoroughly clean all kinds of residual organic components in the original system, so that the replaced lubricating oil has longer service life.

5.3 Check the pressure difference between the front and rear of the filter element of the oil- gas separator and replace it if it exceeds 0.1 Mpa:

1) After shutdown of the air compressor, confirm that the system has no pressure.

2) Remove the pipeline above the oil and gas barrel and remove the pipeline from the minimum pressure valve outlet to the aftercooler.

3) Remove the fixing screws of the upper cover of the oil and gas barrel.

4) remove that upper cov of the oil and gas barrel.

5) Take out the oil core and replace it with a new oil core.

6) The oil and gas barrels shall be packed according to the reverse order of disassembly.

7) Note: When replacing the oil core, prevent unclean articles from falling into the oil barrel.