The assembly process of the air source processor is as follows:
1. Component Preparation and Inspection
Ensure that the air filter, pressure reducing valve, and oil mist generator (or choose a two-piece unit or oil mist separator as per requirements) are complete and undamaged. Confirm that the inlet and outlet ports match the toothed patterns of the pipe connections, and avoid incompatible installations.
2. Cleaning of Pipes and Connectors
Thoroughly clean the connecting pipes and joints to prevent impurities (such as fragments of sealing tape and rust) from entering the gas path, and to avoid malfunction of the pneumatic components.
3. Determine the installation sequence
Connect the components in the order of the airflow direction: air filter → pressure reducing valve → oil mist generator.
The air filter should be installed first to purify the air source.
The pressure reducing valve is located in the middle to stabilize the air pressure.
The oil mist generator is installed last. It atomizes the lubricating oil and mixes it with the compressed air to lubricate the downstream components.
If it is a two-piece assembly, the oil mist separator can be omitted; if oil-free lubrication is required, an oil mist separator can be used instead of the oil mist device.
4. Component Fixation and Alignment
Use a fixed bracket to securely install the three-piece assembly. Ensure that the protruding slot of the bracket matches the recessed slot of the body, and then tighten it with screws.
Check the arrow markings on the component housing to ensure they are aligned with the airflow direction. Do not install them in the reverse position.
5. Pressure adjustment of the relief valve
Before adjusting the pressure reducing valve, remove the oil mist器 (if installed) to avoid damage.
After pulling up the adjustment knob and rotating it: Clockwise rotation increases the outlet pressure, while counterclockwise rotation reduces the pressure.
Gradually adjust to the desired pressure value, avoiding a sudden change. After the adjustment is complete, press down the knob to lock it.
6. Oil mist lubrication settings
Use JIS K2213 grade engine oil (ISO Vg32 or equivalent grade oil), and the oil quantity should not exceed eight tenths of the oil cup.
Rotate the adjusting screw on the top of the oil mist generator to set the oil mist supply speed (for normal operation, it is recommended to be 1-3 drops per minute).
The number "0" represents the minimum fuel level, while "9" represents the maximum. When adjusting, it should be rotated clockwise. It is prohibited to rotate from "9" counterclockwise to "0".
7. Sealing inspection and testing
Make sure all connection ports are properly sealed. Use sealing gaskets or apply sealant to prevent leakage.
Slowly open the upstream gas source valve and observe the pressure gauge to confirm that the pressure is stable and not exceeding the limit.
Check the drainage function of the filter and the oil dripping condition of the oil mist device, and confirm that the system is operating normally.
8. Regular Maintenance and Record Keeping
Daily check the pressure of the pressure reducing valve, the drainage condition of the manual drainage type filter, and the oil level of the oil mist device.
Monthly inspections are conducted to check for leaks at all connections, tighten loose screws, and clean the impurities at the exhaust ports of the directional valves.
Replace the filter element regularly (for example, every 2000 hours or when the pressure difference reaches ≥ 0.1 MPa), clean the valve core and spring of the pressure reducing valve, and maintain the oil circuit of the oil mist generator.
Record maintenance information to facilitate fault diagnosis and handling.