Airunco Compressor Parts & Equipment Co.,Limited

Airunco Compressor Parts & Equipment Co.,Limited

Regular Maintenance and Replacement for Air Compressors

In order to ensure the reliable operation and longevity of air compressors, specific maintenance plans must be established and executed, including designated personnel for operation, regular maintenance, and periodic inspection to keep the compressor clean, oil-free, and free from dirt.
A. When repairing or replacing various components as listed in the table, it is necessary to ensure that: the pressure in the compressor system has been released, it has been isolated from other pressure sources, the main circuit switches have been disconnected, and safety signs for prohibiting closing have been put in place.
B. For newly purchased air compressors, the oil should be changed after the first 500 hours of operation, and then replaced every 2000 hours according to the normal oil change cycle. For machines operating less than 4000 hours per year, the oil should be changed once a year.
C. The oil filter must be replaced after the first 300-500 hours of operation, then every 2000 hours thereafter according to the normal schedule.

D. When repairing or replacing air filters or intake valves, care must be taken to avoid any debris falling into the compressor main cavity. Block the compressor inlet during operation. After completion of the operation, manually turn the compressor rotation direction several times by hand to ensure there are no obstructions before starting the compressor.

E. The tension of the belts must be checked every 2000 hours of operation. If the belts are loose, they should be adjusted until tight. To maintain the belts, avoid oil contamination throughout the process to prevent premature belt failure.
F. Every time the oil is changed, the oil filter must also be replaced.
Cleaning the Cooler: Every 2000 hours of operation, the cooler should be cleaned to remove dust and dirt from the surface for effective heat dissipation. The cover of the fan bracket should be opened, and the cooler should be cleaned with an air blower until the surface is clean. If the dirt is severe, the cooler can be removed, drained of oil, and sealed to prevent contamination. Then, compressed air should be used to blow off the dust or water should be used for washing, followed by drying the surface. Reinstall in the original position. Note: Do not use hard objects such as iron brushes to remove dirt to avoid damage to the cooler surface.
Condensate Drainage: Water vapor in the air may condense in the oil-gas separation tank, especially in humid conditions. When the exhaust temperature is lower than the dew point of the air or during machine cooling, more condensate may accumulate. Excessive water in the oil can cause emulsification, affecting machine operation safety. Therefore, a condensate drainage schedule should be established based on humidity conditions.
Condensate Drainage Method: The condensate should be drained when the compressor is stopped, the oil-gas separation tank has no pressure, is adequately cooled, and the condensate has settled, such as before starting the machine in the morning. ① Unscrew the ball valve at the bottom of the oil-gas separation tank. ② Slowly open the ball valve to drain the condensate until oil flows out, then close the ball valve. ③ Screw the ball valve back.
Safety Valve: The safety valve has been adjusted before the entire machine leaves the factory, and users are not encouraged to adjust the safety valve arbitrarily. If adjustment is necessary, it should be carried out under the guidance of the local labor safety department or maintenance personnel.
Maintenance Suggestions: For ordinary users, provide some maintenance suggestions for compressors, which users can refer to and implement.
Weekly: a. Check for any abnormal sounds or leaks in the unit; b. Check whether the instrument readings are accurate; c. Check whether the temperature display is functioning properly.
Monthly: a. Check for rust or looseness inside the machine. If rust is found, remove it, apply oil, or paint over it, and tighten any loose parts; b. Drain the condensate water.
Every Three Months: a. Clean the surface of the cooler and the fan cover, as well as the fan blades; b. Add lubricating oil to the motor bearings; c. Check for signs of aging or cracking in hoses; d. Inspect electrical components and clean the control box.
Oil Refilling for the Compressor: During operation, the oil level in the compressor should be maintained between the minimum and maximum levels. Excessive oil can affect separation results, while insufficient oil can affect smooth operation and cooling. During the oil change cycle, if the oil level is below the minimum level, lubricating oil should be added promptly. The method is as follows: ① Stop the machine and release the internal pressure (ensure the system is pressure-free) and turn off the power switch. ② Open the oil filling port on the oil-gas separation tank and add excess lubricating oil. ③ The time for oil change after normal operation of the compressed air compressor can be referred to the regular maintenance schedule.

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