Common Problems and Maintenance of Air Compressor

Air compressor maintenance is not in place will appear a variety of faults, want to quickly solve the air compressor fault needs to find the cause of the fault. The following summarizes some common fault types and solutions of air compressor.

1. Insufficient air displacement of air compressor. The size of the exhaust directly affects the operating efficiency of the air compressor. If there is insufficient exhaust, you can first replace the damaged or cracked parts, and then check and clean the air muffler, replenish the lubricating oil in time, and keep the oil sufficient.

2. Air compressor cooling system failure. Air compressor cooling system failure is common scaling phenomenon or air into the cooling system. To solve this problem, you can install a shell on the water meter to prevent air from entering, and then replace the cooler core regularly to avoid scaling and ensure the normal operation of the cooling system.

3. Air tightness problem of air compressor. The problem of reducing the pressure tightness of the air compressor valve can be solved by cleaning the valve plate and the valve plate to remove carbon deposits, or choose to prevent and control the electrostatic plastic pipe generated by carbon deposits, so as to effectively improve the cleanliness of the air compressor and avoid the occurrence of faults.

4, air compressor lubricating oil should be replaced in time. The quality of the lubricating oil affects the operation effect of the air compressor. Therefore, after the air compressor is put into operation, the lubricating oil can be replaced every 6000-7000 hours, which can effectively improve the quality of the lubricating oil. On the whole, keeping the air compressor clean and complete is an effective maintenance measure to ensure the normal operation of the air compressor. In addition, to ensure sufficient oil inside the air compressor, improve the maintenance and inspection of the air compressor, can comprehensively ensure that the air compressor play a good role [!-- empirenews.page --]

standardized operation, scientific management and timely maintenance is an effective way to reduce the failure rate of air compressor. Secondly, strengthening the training of equipment management personnel is also the key to ensure the good operation of the air compressor.

Why is it difficult for air compressors to start in winter? not only depends on their own technical conditions, but also affected by the outside temperature. Starting at low temperatures in winter is more difficult, mainly due to the following reasons:

⑴ In winter, the climate is cold, the ambient temperature is low, the oil viscosity increases, and the frictional resistance of each moving part increases, which reduces the starting speed and makes it difficult to start.

(2) The battery capacity decreases with the decrease of temperature, which further reduces the starting speed.

⑶ Due to the decrease in starting speed, the increase in compressed air leakage, and the increase in the heat dissipation of the cylinder wall, the temperature and pressure of the air at the end of compression are greatly reduced, which increases the delay period of diesel ignition, and even cannot burn in severe cases.

⑷ The viscosity of diesel at low temperature increases, which reduces the injection speed. In addition, the swirl speed, temperature and pressure of the air at the end of compression are relatively low, which makes the atomization quality of the diesel injected into the cylinder poor, and it is difficult to quickly form a good relationship with the air. The combustible gas is ignited and burned in time, or even cannot catch fire, resulting in difficulty in starting.

2. What are the conditions for good starting performance of the air compressor?

(1) There must be sufficient starting speed. The starting speed is high, the gas leakage in the cylinder is small, the heat transfer time of compressed air to the cylinder wall is short, and the heat loss is small, so that the gas temperature and pressure at the end of compression can be increased. Generally, the speed is required to be above 1_0_0_r_/_m_ I _n.

⑵ The sealing of the cylinder is better. This can further reduce the amount of air leakage and ensure that the gas has sufficient combustion temperature and pressure at the end of compression, and the compression pressure of the cylinder shall not be lower than 8_0_%_of the standard value_.

⑶ It is required that the matching clearance between the engine and the running parts is appropriate and well lubricated.

The battery should have enough starting capacitance, and the technical condition of the starting circuit is normal.

(5) The starting oil quantity shall meet the requirements, the injection quality shall be good, and the injection advance angle shall meet the requirements.

(6) Use fuel that meets the requirements

3. Diagnosis and repair of mechanical faults that the crankshaft cannot rotate when the air compressor is started. When the engine is started, when the starting system is intact, press the start switch, the starter makes a noise and the crankshaft cannot rotate, which is a mechanical fault. The reason why the crankshaft of the engine cannot rotate is as follows.

① Poor meshing between starter and flywheel teeth. The ring gear and the starter gear will collide when starting the engine, causing damage to the teeth or single-sided wear of the teeth. If more than three consecutive teeth are damaged or severely worn, it is difficult for the starter gear to mesh with the ring gear teeth.

② Stick the cylinder. When the engine temperature is too high, the engine stops and stalls, and the heat is difficult to dissipate. The piston ring under high temperature adheres to the cylinder and cannot be started after cooling.

③ The crankshaft is locked. Due to the failure of the lubrication system or lack of oil, the sliding bearing is dry friction, so that the crankshaft is eventually locked and cannot be started.

The injection pump plunger stuck.

4. Diagnosis of the air compressor can rotate when starting, but cannot start (there is no smoke in the exhaust pipe). When the engine is started, the exhaust pipe is smokeless and there is no explosive sound. It is generally an oil circuit problem. The detailed analysis is as follows:

① There is no oil in the oil tank.

⑵ The fuel filter and oil-water separator are blocked.

③ Low pressure oil circuit does not supply oil.

The fuel injection pump does not pump oil.

⑤ There is air in the oil circuit.

⑥ Misalignment of gas distribution phase. The opening moment of the valve is not coordinated with the stroke of the piston in the cylinder. For example, when the piston is making a compression stroke in the cylinder, the intake and exhaust valves are opened, and fresh air is driven out of the cylinder, so that there is no combustion gas in the cylinder and it cannot be started.

⑦ type fuel injection pump solenoid valve is broken, in the closed state, diesel can not enter the high pressure chamber.

5, the air compressor starting difficult or can not start, exhaust pipe a large number of white smoke diagnosis. When the engine is started, the reason why the exhaust pipe emits a large amount of white smoke is analyzed as follows:

① There is water in diesel, and the water evaporates into water vapor in the cylinder and is discharged from the exhaust pipe.

② The cylinder head bolts are loose or the cylinder head gasket is damaged, causing cooling water to enter the cylinder.

③There are trachoma or cracks somewhere in the cylinder block or cylinder head, and water enters the cylinder and evaporates and discharges.

6, the air compressor start difficult or can not start, exhaust pipe a large number of gray smoke diagnosis. The engine is difficult to start, and a large amount of gray smoke from the exhaust pipe is diesel vapor.

① The engine temperature is too low, diesel is not easy to evaporate and burn.

② Poor atomization of fuel injector

the oil supply time is too late.

④ The fuel supply is too small and the mixture is too thin.

⑤ The air leakage of the cylinder is too much, and the ignition temperature cannot be reached at the end of compression.

7, air compressor start difficult or can not start, exhaust pipe a lot of black smoke diagnosis. The engine is difficult to start, and the exhaust pipe emits a large amount of black smoke, which is the result of incomplete diesel combustion

① Poor quality diesel

②The air intake is not smooth and the air filter is blocked.

③The fuel injection timing is adjusted too early.

The injector needle valve sealing is poor, there is a phenomenon of oil leakage.

⑤ The injection pressure is too low.

The fuel injection pump fuel supply is too large, combustion deterioration.

⑦ Low cylinder pressure and poor atomization.

If there are any problems with the high-temperature cylinder pulling of the air compressor and the maintenance, consultation, information, technical support, experience sharing, communication, after-sales service and technical support of the air compressor, thank you.

8. Diagnosis of hot start difficulties of air compressor The engine has a good cold start, but it stalls after running for a period of time when the temperature rises. The difficulty in restarting is mainly due to the serious wear of the plunger pair of the fuel injection pump and the needle valve pair of the fuel injector. When a hot car starts, due to the high temperature of the fuel injection pump and fuel filter, the fuel viscosity decreases, and the starting speed is low, most of the diesel oil leaks from the worn gap, resulting in insufficient starting fuel and unable to start.

9. Diagnosis and treatment of air compressor with normal low speed and short-term high speed and too little smoke exhaust. The engine idling speed is good, and the throttle speed can increase rapidly, but the continuous throttle speed is not easy to increase, the driving is weak, or the use of gears above the medium speed cannot be driven. This is caused by insufficient low-pressure fuel supply.

① The diesel filter or oil-water separator is blocked.

② The low-pressure oil circuit is not smooth.

③ The oil supply of the oil transfer pump is insufficient or the oil filter screen is blocked.

④ Intake valve of fuel tank cap fails. The above conditions can cause insufficient fuel pressure in the low-pressure oil cavity of the fuel injection pump, and can only maintain the fuel supply required for a small load. For large, medium load requires more oil supply, it can not meet, resulting in driving weakness.

10, air compressor low speed normal but no high speed, exhaust smoke too little diagnosis.

The engine speed is good at low speed, but the speed can never increase when accelerating, and the driving is weak. This is caused by insufficient circulating fuel supply

improper adjustment of the fuel injection pump reduces the fuel supply.

② governor spring due to fatigue and reduce the elastic force. When the throttle is stepped to the end, the fuel adjustment lever cannot be moved forward to the end, resulting in a decrease in the fuel supply of the fuel injection pump and the engine cannot reach the rated speed

③The plunger and sleeve of the fuel injection pump, the needle valve of the fuel injector and the needle valve body are seriously worn, which increases the leakage of diesel oil when pumping oil, and the oil supply is relatively reduced.

④Improper adjustment of the accelerator control lever, or the accelerator pedal pin is too wide, so that the accelerator pedal cannot be in place, resulting in too little fuel supply at full load.

⑤ There is air in the oil circuit.

11, the air compressor power is insufficient, the fault diagnosis analysis of ash and white smoke is as follows:

the engine power is insufficient, and the exhaust pipe discharges gray smoke, which is generally caused by the late injection time. At this time, not only the high-speed operation is poor, the acceleration is not sensitive, and the temperature is too high.

① The fuel injection advance angle is too small.

② Poor atomization of the fuel injector.

The engine temperature is too low.

④ There is water in the cylinder.

⑤ Water in diesel

12, air compressor power shortage, exhaust black smoke failure cause analysis:

the engine power is insufficient, the speed is uneven, and the exhaust pipe exhausts dark smoke. There are two phenomena: one is continuous exhaust of black smoke; the other is intermittent exhaust of black smoke, and the engine shakes. The engine power is insufficient and the black smoke is continuously exhausted. Most or all cylinders of the engine have excessive fuel supply, the fuel and air mixing ratio is out of balance, the combustion is severely lacking in oxygen, the diesel combustion is incomplete, and the suspended free carbon element follows The exhaust gas is discharged together. If the exhaust pipe is intermittent black smoke, and accompanied by a "sudden" sound, indicating that the individual cylinder combustion is not complete. The reasons are summarized as follows

improper debugging of the fuel injection pump will cause excessive fuel supply and incomplete combustion.

② The injection quality of most injectors is poor.

③ The fuel supply is not timely.

④ The opening height of the intake valve is reduced and the opening time is delayed, resulting in insufficient intake.

⑤ The air filter element is too dirty or the air filter is installed incorrectly, making the air not smooth.

⑥ The supercharging efficiency of the supercharger decreases.

⑦ The fuel quality is too poor.

13, the air compressor power is insufficient, the diagnosis and treatment of blue smoke.

The engine exhausts blue smoke at low temperature or light load, and turns into dark gray smoke when the temperature rises, and the power is insufficient.

①The air intake is not smooth, causing the oil in the supercharger to be sucked into the cylinder for combustion.

②There is too much oil in the oil pan, and the oil exceeds the maximum limit.

③ Engine oil is supplied to the valve guide.

④ Serious oil leakage of the cylinder.

⑤ The rotor shaft of the turbocharger is severely worn and the oil retaining ring is damaged, causing the turbocharger to fail to reach the rated speed and oil leakage

14. Why is the supercharger the most prone to failure on the engine?

Because the rated working speed of the supercharger is above 130000 revolutions per minute, and it is at the outlet of the exhaust manifold, the temperature is extremely high (above 800 ℃), and the intake and exhaust pressures are also high, that is, high temperature, high pressure, and high speed. Therefore, the requirements for lubrication, cooling and sealing of the supercharger are relatively high. In order to ensure the service life of the supercharger, the design must ensure the lubrication and cooling of the floating bearing of the supercharger. At the same time, it is required to do:

①The engine should be idling for 3-5 minutes after starting, and do not load immediately to ensure good lubrication of the turbocharger. The main reason is that the supercharger is located on the top of the engine. If the supercharger starts to run at high speed immediately after the engine is started, the oil pressure will not rise in time to supply oil to the supercharger, causing the supercharger to lack oil and damage, or even burn out The entire supercharger.

② The idling time should not be too long, generally not more than 10 minutes. Too long idling time can easily cause oil leakage at the compressor end.

③_ Do not turn off the engine immediately before stopping, and idle for 3-5 minutes to reduce the speed of the turbocharger and the temperature of the exhaust system to prevent failures such as heat recovery-oil coking-bearing burning. Frequent incorrect use will damage the supercharger.

④For engines that have not been used for a long time (generally more than 7 days), or engines with new superchargers, add oil to the oil inlet of the supercharger before use, otherwise it will reduce the life or damage the supercharger due to poor lubrication.

⑤ Regularly check whether each connection part has loose air leakage/oil leakage, whether the oil return pipe is unobstructed, if any, it should be removed in time.

Ensure that the air filter is clean and replace it regularly as required.

⑦ Replace the oil/_oil filter regularly.

⑧ Regularly check the radial axial clearance of the turbocharger shaft. The axial clearance should not be greater than 0.15mm. The radial clearance is: the clearance between the impeller and the pressure shell is not less than 0.10mm, otherwise professional personnel should be invited to repair it to avoid expanding the loss.

15. Why does the air compressor have a short life after the supercharger on some engines is damaged?

① The lubricating oil is not clean.

② There are impurities in the oil passage.

③ There are foreign bodies in the intake and exhaust pipes

16. Reason analysis and fault handling of the air compressor without idle speed: the engine has no idle speed, which is generally manifested as the throttle is turned off when the throttle is placed in the idle position. When the throttle is slightly increased, the speed rises quickly and cannot be stable at low speed.

① The idle speed spring of the governor is too soft or broken.

② The governor sensing element is excessively worn.

The fuel injection pump plunger wear serious.

④ The temperature is too low.

⑤ Cylinder pressure is too low

17. Cause analysis and fault treatment of the excessive idle speed of the air compressor: The engine idle speed is too high, which is manifested as the engine speed is still higher than the idle speed specified value when the throttle is raised.

① Improper adjustment of the throttle lever.

② The throttle return spring is too soft.

③ The idle speed limit block or adjusting screw is out of adjustment.

④ The idle spring is too hard or the preload adjustment is too large

18. Cause analysis and fault diagnosis of air compressor idling instability: The manifestation of engine idling instability is that when idling, it is fast and slow, or there is vibration, which causes the machine to stall when decelerating or shifting gears. Detailed reason analysis is as follows:

there is air in the oil circuit.

② Low pressure oil supply is not smooth.

③ Idle speed stabilization device is improperly adjusted.

④ Poor atomization of the fuel injector.

⑤ The fuel supply of the fuel injection pump is uneven.

⑥ The pin shaft and fork head of each connecting rod of the governor are worn too much.

19. Analysis of the reasons for the sudden flameout during the operation of the air compressor? The sudden flameout during the operation of the engine refers to the phenomenon that the engine stalls rapidly due to non-driver operation factors when the throttle is not released when the engine is working, and cannot be restarted after the flameout. This phenomenon is generally caused by mechanical failure for the following reasons:

the fuel injection pump drive gear broken, transmission gear failure.

② The injection pump shaft is broken.

③ The internal moving parts of the engine are stuck.

④ The control rod and connecting pin of fuel injection pump fall off

20. Analysis of the cause of the slow flameout during the operation of the air compressor: The engine flameout slowly without releasing the throttle, which is generally caused by untimely fuel supply or fuel supply interruption. It is manifested as the gradual weakness of the engine during operation, and finally the automatic flameout.

① The diesel oil in the fuel tank is exhausted.

② The vent valve of the fuel tank cap is blocked.

③ The fuel filter or oil-water separator is blocked.

④ The oil supply pipeline is broken or more air is infiltrated.

⑤ The oil delivery pump does not work.

⑥ There is water in the oil tank