Chapter 6 Lubrication System Faults and Solutions-KIMAIR.-The source of power for air compressors

Language

Section 1 Lubricating Oil Selection and Replacement

Lubricating oil is one of the key factors in the normal operation of air compressors. Choosing the right lubricating oil can effectively extend the equipment’s lifespan and reduce failure rates. When selecting lubricating oil, the following factors need to be considered: 1.Viscosity grade: The viscosity grade of the lubricating oil is an important parameter in the selection process. Different models of air compressors require different viscosity levels, which are typically specified in the compressor’s user manual. Oil with too high a viscosity will have poor flowability, increasing energy consumption; oil with too low a viscosity cannot form an effective lubricating film, which may cause wear. 2.Oxidation resistance: Air compressors generate high temperatures during operation, causing lubricating oil to oxidize and degrade. Choosing oil with good oxidation resistance can extend its service life and reduce the frequency of oil changes. Oils with good oxidation resistance usually contain antioxidants to effectively prevent oil deterioration. 3.Wear resistance: Air compressor components work under high loads, so selecting lubricating oil with good wear resistance can reduce wear and extend the life of the equipment. Oils with good wear resistance usually contain anti-wear additives that form a protective film on metal surfaces, reducing friction. 4.Cleanliness: Lubricating oil gradually accumulates impurities during use. Choosing oil with good cleaning properties can effectively remove these impurities and keep the oil passages clear. Oils with good cleaning performance usually contain detergents that can effectively remove deposits and impurities from the oil. 5.Compatibility: When replacing lubricating oil, it is important to consider the compatibility of the new and old oils. Different brands of oils may have different chemical compositions and mixing them could cause oil degradation. Therefore, when replacing the oil, it is recommended to thoroughly clean the oil passages to ensure that new and old oils do not mix. Steps for Changing Lubricating Oil: 1.Shutdown and cooling: Before changing the oil, the compressor should be shut down and allowed to cool to room temperature to prevent high-temperature lubricating oil from causing burns to operators. Drain the old oil: Open the drain valve at the bottom of the oil tank and completely drain the old oil. If there is sediment in the oil passages, use a cleaning agent to clean it. 3.Check the oil circuit: After draining the old oil, check for blockages or leaks in the oil circuit. If there are any issues, they need to be repaired promptly. 4.Add new oil: Choose lubricating oil that meets the required specifications and add it through the oil filler port. Ensure that the oil level is within the normal range on the oil level gauge during refilling. 5.Start-up check: After adding new oil, start the compressor and check for any oil circuit leaks and whether the oil pressure is normal. If any abnormalities occur, they should be addressed promptly.

Section 2 Oil Circuit Blockage Cleaning

Oil circuit blockage is one of the common failures in air compressors. Blockages can prevent the lubricating oil from flowing properly, affecting the normal operation of the equipment. The main causes ofoil circuit blockages are as follows: 1.Accumulation of impurities: Over time, impurities in the lubricating oil, such as metal shavings, dust, and oil sludge, accumulate and block the oil circuit. 2.Oil deterioration: The lubricating oil can easily oxidize and deteriorate under high temperatures, generating resins and sediments that clog the oil circuit. Oil degradation also reduces the oil's performance, affecting the equipment's normal operation. 3.Clogged filter: The filter in the oil circuit is designed to remove impurities from the lubricating oil, but after long use, the filter can become clogged, restricting oil flow. 4.Improper oil circuit design: Issues like small oil pipe diameters or excessive elbows in the oil circuit design can also lead to blockages. The steps for cleaning the oil circuit are as follows: 1.Shutdown and cooling: Before cleaning the oil circuit, shut down the compressor and allow it to cool to room temperature to avoid burns from hot oil. 2.Drain the old oil: Open the drain valve at the bottom of the oil tank and completely drain the old oil. If there is sediment in the oil circuit, use a cleaning agent to flush it out. 3.Disassemble the oil circuit: Disassemble the pipes and filters in the oil circuit and check for blockages. If there are any, use special tools to clean them. 4.Clean the oil circuit: Use a cleaning agent to clean the oil circuit, removing impurities and sediments. The cleaning agent should be compatible with the lubricating oil to avoid damaging the oil circuit. 5.Check the filter: Inspect the filter for blockages. If it is clogged, replace it with a new one. 6.Reassemble: After cleaning, reassemble the oil circuit, ensuring all components are correctly installed with no leaks. 7.Add new oil: Choose lubricating oil that meets the required specifications and refill it through the oil filler port. Ensure the oil level is within the normal range on the oil level gauge during refilling. 8.Start-up check: After adding new oil, start the compressor and check for any oil circuit leaks and whether the oil pressure is normal. If any abnormalities are detected, address them promptly. By following these steps, the oil circuit blockage can be effectively cleared, restoring the air compressor to normal operation. Regular cleaning and maintenance of the oil circuit can significantly extend the equipment’s lifespan and reduce failure rates.