Cleaning and maintenance methods for screw air compressors
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4. Cleaning of intake valve (load reducing valve)
The intake valve is composed of components such as valve body, valve core (piston), air circuit manifold block, solenoid valve, and proportional valve (volume control valve). The intake valve mainly controls the loading (screw air compressor heavy-duty), unloading (empty), and proportional (capacity adjustment) control of the air compressor. In addition, it can prevent lubricating oil from spraying out from the main engine head when the air compressor is stopped.
Disassembly of intake valve:
(1) Remove the hose connecting the intake valve to the air filter;
(2) Remove all other components connected to the intake valve's air pipe;
(3) Remove the solenoid valve coil;
(4) Remove the nut that connects the intake valve to the main engine assembly and remove it;
(5) Move the intake valve to a floor covered with clean cardboard or related clean materials.
Cleaning the intake valve: (The cleaning agent for screw air compressors should be soap water, diesel, clean gasoline, Tianna water, etc. The above cleaning agents should be selected according to the degree of dirt, and it is generally recommended to use soap water or diesel for cleaning).
Disassemble the solenoid valve: Disassemble the solenoid valve and check if the O-ring and sealing plate inside the solenoid valve need to be replaced (reminder: if you are not familiar with the intake valve, please note the position of the disassembled component to avoid errors when reinstalling). If replacement is not necessary, place the disassembled screws, O-rings, seals, electromagnetic rods, cores, and other components into a pre prepared container and soak them in a suitable cleaning agent (note: when using gasoline and thinner as cleaning agents, please do not soak rubber products such as O-rings for too long to prevent corrosion).
Dismantling the proportional valve: Remove the proportional valve from the valve body, then unscrew the adjusting nut (it is best to make a mark on the nut before tightening to avoid excessive deviation of the proportional value when reinstalling), take out the valve core, O-ring, U-shaped ring, and spring, and check whether the O-ring and U-shaped ring need to be replaced (all sealing rings and springs removed from the screw compressor must undergo this inspection, which will not be repeated in the following description). Soak the removed components in cleaning agent.
Dismantling the air circuit integrated block: Remove the integrated block from the valve body. There are air holes on the four sides of the integrated block (this hole of the screw air compressor plays a role in clearing the blockage of the integrated air circuit). Unscrew the sealing nut on the air hole and soak the integrated block together in cleaning agent.
Dismantling the intake valve core: Use clamp pliers to remove the clamp spring located at the connection between the valve core and the valve body, and then use pipe pliers to unscrew the valve core. Take out the cylinder, valve plate, O-ring, U-shaped ring, and spring inside and soak them in cleaning agent. Then remove the intake port on the valve body and immerse the entire valve body. At this point, the dismantling process of the intake valve is completed.
Cleaning: If the dirt on the intake valve is severe, replace it with a new cleaning agent during cleaning. During the cleaning process, clean the relatively clean parts first and then the parts with more dirt. The cleaned parts should be rinsed again with clean water to prevent corrosion and shorten the service life of the parts. The parts cleaned with clean water should be placed in a clean place to dry to prevent rusting of iron containing parts.
When cleaning the valve plate and the contact area between the valve body and the valve plate, attention should be paid to the flatness of the surface, and it should be cleaned thoroughly. If necessary, it should be replaced, otherwise it will cause the air compressor to start under load (the screw air compressor unit may not start under load).
Installation of components: The installation of components should be carried out in the reverse order of disassembly. It should be noted that when installing components, the position of the sealing ring and the movable components should be coated with an appropriate amount of engine oil to make the sealing ring easier to install and the movable components more flexible.
Due to the large number of components in the intake valve, if you are not sure how to remember the position of each component, you can clean each component before installing it again. However, do not install the components on the valve body first, and assemble them together after all components have been cleaned. After the entire cleaning process of the intake valve is completed, place it aside for installation into the air compressor.
5. Minimum pressure valve (pressure maintenance valve) cleaning
Although the minimum pressure valve in a screw air compressor may appear small in size, it controls the entire machine despite its small size. In order to ensure its normal operation under normal working conditions, the following is the maintenance method for the minimum pressure valve of the screw air compressor.
The minimum pressure valve consists of a valve body, valve core, adjusting nut, spring, sealing element, etc. The minimum pressure valve mainly serves to establish the internal pressure of the unit, promote the circulation of lubricating oil, and meet the working pressure of the load reducing valve. In addition, the minimum pressure valve also functions as a one-way valve to prevent the compressed air in the air storage tank from flowing back to the air compressor during unloading operation of the unit.
The structure of the minimum pressure valve is very simple. Simply unscrew the nut of the screw air compressor between the valve core and the valve body to remove the components inside. The minimum pressure valve core of the small unit is built into the valve body, and all internal components can be removed by removing the valve body cover.
The minimum pressure valve can be cleaned using the same method as cleaning the load reducing valve.
Due to the simple structure of the minimum pressure valve, the assembly process will not be described one by one. However, it should be noted that if there is a U-shaped ring inside, the direction of the U-shaped ring should be taken into account. After the entire cleaning process of the minimum pressure valve of the screw air compressor is completed, place it aside for installation into the air compressor.
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