Medium and high pressure air compressors are widely used in various industries, such as plastic blow molding machines (15-40 kg), fiber laser cutting machines (13-20 kg), and gas cylinder inspection (20-30 kg). Due to problems in recent years, the manufacturing industry is facing an unpredictable future, and many business owners are struggling. However, many leading companies in the manufacturing industry are still profitable, leading to full-load operation of air compressors and frequent malfunctions.
Some problems we have encountered:
1. The air output of the high pressure air compressor (only reciprocating compressors with crankcases are provided as an example) drops sharply, and the pressurization time is longer than before.
Analysis of the cause: The air compressor has not been regularly maintained.
Solution: Regularly maintain the air compressor. Generally, replace the air filter every 2000 hours, backflush the air filter monthly, and check it promptly. In harsh environments, shorten the maintenance interval. Replace piston rings and valve assemblies approximately every 4000-8000 hours to improve sealing and valve exhaust efficiency. Finally, and importantly, replace the air compressor lubricating oil. The first oil change is at 500 hours; after that, promptly drain the lubricating oil from the crankcase to remove debris and then add new oil. Because high-pressure air compressors operate at high temperatures, piston rings, valve plates, and other components require high-temperature operation. Therefore, the lubricating oil must be heat- and corrosion-resistant, and its replacement cycle is approximately 4000-8000 hours. Regular replacement ensures smooth operation of all components.
2. Safety valve automatically detonates.
Analysis: The check valve or drain valve is blocked, or dirt is stuck inside the valve.
Solution: Replace the check valve or disassemble it and clean out any impurities to achieve optimal condition. The same applies to the drain valve. If the valve is blocked, it needs to be disassembled and analyzed to see if it has caused a broken spring washer or if there is dirt inside. Replace or clean it promptly.
3. One of the cylinder head cylinders makes a loud noise during compressor operation.
Possible cause: The valve assembly inside may be faulty.
Solution: Disassemble and clean it promptly, or replace it with a new valve assembly.
2026
