Fault name
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Fault reason
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Exclusion method
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1. Oil pressure drops |
(1) The spring of the oil pump safety valve is damaged, causing the oil pumped by the oil pump to flow back to the machine body, resulting in a drop in pressure. |
(2) The oil level in the machine body is low, and the oil pump cannot draw oil. |
(3) The oil suction pipe has an air leak. |
(4) The oil pump filter is clogged. |
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(1) Replace the spring. |
(2) Inject the specified lubricating oil and raise the oil level. |
(3) Check the joints. |
(4) The filter should be cleaned. |
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2. Significant reduction or sudden drop in exhaust volume |
(1) The piston ring has improper thermal clearance and is stuck in the ring groove, losing gas tightness. |
(2) The piston ring is broken or damaged. |
(3) The gas valve has an air leak. |
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(1) Disassemble and repair. |
(2) Replace parts. |
(3) Adjust or repair the gas valve. |
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3. Discharged gas is impure (contains oil) |
(1) The oil scraping ring has lost its oil scraping function. |
(1) Disassemble for inspection or replace parts. |
4. Piston contacts or collides with the cylinder |
(1) The support ring has worn excessively and lost its supporting function. |
(2) The piston rod is loose with the crosshead or the piston rod is loose with the piston. |
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(1) Replace or adjust. |
(2) Adjust or tighten the fixation. |
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5. Safety valve and unloading valve malfunction or jammed |
(1) Rust or dirt causes movement to be unresponsive. |
(2) Spring force is too strong. |
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(1) Eliminate rust and grind the sealing surface, and apply silicone oil on the sealing surface. |
(2) Adjust to meet requirements. |
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6. Exhaust temperature is too high |
(1) The gas valve has an air leak. |
(2) The piston ring is damaged and of poor quality, causing gas to communicate between the two ends of the cylinder. |
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(1) Grind the valve seat and valve sealing surface, or replace with a new valve. |
(2) Repair or replace the piston ring. |
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7. First stage exhaust pressure is abnormal |
(1) First stage exhaust pressure is high due to air leakage or damage of the second stage intake valve. |
(2) First stage exhaust valve pressure is low due to air leakage or damage of the first stage intake and exhaust valves. |
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(1) Grind or replace the second stage gas valve. |
(2) Grind or replace the first stage gas valve. |
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8. Second stage exhaust pressure does not reach the specified value |
(1) The second stage exhaust valve may have severe air leakage or damage. |
(1) Grind or replace with a new gas valve. |
9. Drain valve malfunction |
(1) Dirt enters the drain valve, blocking the vent hole. |
(2) Dirt has jammed the float of the drain valve. |
(3) The components of the drain valve are damaged. |
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(1) Clean the drain valve to remove dirt. |
(2) Clean the filter to improve cleanliness. |
(3) Replace the drain net. |
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10. Severe air leakage from packing |
(1) The packing is severely worn and deformed, losing gas tightness. |
(2) The spring clamping force is too small, and the fit with the piston rod is not tight. |
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(1) Replace with new sealing components. |
(2) Adjust the spring or replace it with a new one. |
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11. Bearing temperature is too high |
(1) The gap between the bearing and the shaft is too small. |
(2) The viscosity of the lubricating oil is incorrect, the oil is dirty, or has lost its lubricating function. |
(3) Poor assembly, bad contact surface. |
(4) The bearing is fixed too loosely or too tightly. |
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(1) Adjust to the appropriate gap. |
(2) Replace with new oil. |
(3) Check and recalibrate. |
(4) Tighten to the appropriate level. |
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12. Safety valve leaks |
(1) The spring is not tightened or has lost its elasticity. |
(2) There are impurities between the valve plug and the valve seat. |
(3) The valve seat and valve sealing surface are not tight. |
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(1) Adjust or replace the spring. |
(2) Blow clean. |
(3) Adjust or grind the sealing surface. |
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13. The compressor has abnormal noises. |
(1) Hard objects have fallen into the cylinder and piston. |
(2) The connection between the piston rod and the crosshead is loose. |
(3) The radial clearance between the connecting rod big end bearing and the shaft is too large. |
(4) The suction and exhaust valves are installed loosely, causing noise from gas impact. |
(5) The gas valve collides with the piston. |
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(1) Stop and remove hard objects. |
(2) Tighten the nuts. |
(3) Check the gap and replace the bearings. |
(4) Tighten the nuts on the gas valve cover. |
(5) Adjust the gap between the upper and lower stop points. |
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14. Bubbles in the cooling water discharge. |
(1) The cooling tube of the cooler core is leaking. |
(2) The cooling tube is not expanded tightly with the tube sheet. |
(3) The gasket between the cylinder head and the cylinder is damaged. |
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(1) Weld the leaks or replace the core components. |
(2) Re-expand the tubes. |
(3) Replace with new gaskets. |
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15. The oil seal and storage of the compressor: The compressor is sealed with grease before leaving the factory, and the general storage time is one year (from the date of storage). If it exceeds this time, it must be cleaned and re-greased for sealing. If stored outdoors, in humid, or corrosive environments, the storage time should be reduced based on specific conditions, and sealing should be updated in advance. If it is necessary to pause use during operation for more than half a month, the non-oil lubricated moving surfaces of the gas valve, cylinder, piston parts, and piston should be greased for sealing. If it exceeds one month, it should be cleaned according to the sealing method, wiped clean, and coated with anti-corrosion grease for storage. |