Diesel air compressors in industrial applications often suffer from high oil temperatures leading to downtime and affecting production efficiency. As a ZAKF
Screw Air Compressor manufacturer with 20 years of experience and 60,000 square meters of production base, our diesel models have a monthly production capacity of up to 800 units, support CE/ASME and other global certifications, and rely on 7 overseas warehouses to achieve 15 days' fast shipping in Southeast Asia / Middle East. The following is an analysis from the root cause of the failure to the solution, combined with the advantages of ZAKF technology.
Cooling System Failure: The First Cause of High Oil Temperature and ZAKF Optimization Solution
1. Decrease in Radiator Efficiency
Failure Mechanism: Insufficient coolant, dust or fouling of radiator leads to decrease in cooling efficiency, and for every 10℃ increase in oil temperature, the viscosity of lubricating oil decreases 15%, which aggravates the wear of parts.
ZAKF solution:
adopts high-efficiency plate-fin radiator (heat exchange area is 25% larger than traditional tube type), together with the automatic brazing process on the base of 60,000 square meters, the heat dissipation efficiency is increased by 20%;
is customized for the Middle East high-temperature region with automatic back-blowing device as standard, which blows the radiator surface every 15 minutes, and the oil temperature is controlled at a reasonable range of 75-85℃ in one case of Saudi Arabia's oil field.
2. Cooling Fan Failure
Failure: The diesel-driven fan belt slips or the motor fails, resulting in insufficient airflow.
ZAKF Technology Upgrade:
develops hydraulic driven fan system (ZAKF patented technology), which automatically adjusts the speed according to the oil temperature (adjustment range 30%-100%), with a response time of ≤0.5 seconds, which saves 12% energy compared with the traditional mechanical fan.
Lubrication System Abnormalities: ZAKF Precision Control Solution
1. Lubricant quality degradation
Core reason: lubricant oxidization, pollution, or model mismatch. ZAKF testing data shows that for every 1mgKOH/g increase in acid value of lubricant that is not regularly replaced, the temperature of the oil rises by 5-8°C. ZAKF maintenance standards: Recommended for use in the oil system, the oil temperature should not rise.
ZAKF Maintenance Standard:
ZAKF customized synthetic oil (for CE certified models) is recommended to be used, with an antioxidant life of 8000 hours, 50% longer than mineral oil;
In the after-treatment equipment with a monthly production capacity of 2000 units, the lubricant filter adopts ISO 16889 certified filter element, with a filtration accuracy of ≤10μm.
2. Clogged or leaking oil line
Solution:
ZAKF diesel models are equipped with an oil line as standard. ZAKF diesel engine models are equipped with a visual diagnostic system, which monitors the oil line pressure in real time (normal 1.2-1.6MPa) through pressure sensors, and gives an automatic alarm when the pressure fluctuates more than 0.3MPa, which is used in a Russian mining project to increase the accuracy of oil line failure warning to 95%.
Impact of Load and Working Conditions: ZAKF Intelligent Control Solution
1. Continuous Overload Operation
ZAKF Intelligent Control:
Adopting PLC + Frequency Conversion Technology, the diesel engine speed is automatically adjusted when the load exceeds 85% (adjustment range 40%-100%), and together with ZAKF's self-developed energy-saving algorithms, the fault of high oil temperature in a construction project in Indonesia dropped by 70%. 2. High Ambient Temperature Customization
2. High ambient temperature
Customized adaptation solutions:
Tropical region models are equipped with enlarged water tanks (volume increased by 30%) and high-temperature coolant (boiling point ≥120℃);
Desert region models use IP55 dustproof radiators, and seven warehouse bases ensure that customers in the Middle East can obtain high-temperature adapted components within 15 days.
Mechanical Component Failure: ZAKF Precision Manufacturing Guarantee
1. Bearing Wear or Rotor Failure
Preventive Measures:
The bearings of ZAKF diesel models are made of German FAG brand (life expectancy ≥100,000 hours), and the rotors are processed by 5-axis machining center (precision ±0.003mm), and the dynamic balancing residual amount is ≤5g/mm/kg, so there is no bearing failure in one mining project in Australia for 3 years. 2. Seal Failure Causing Internal Leakage
2. Internal leakage due to sealing failure
ZAKF sealing technology:
Shaft end adopts the combination structure of “double lip seal + labyrinth seal”, with the leakage controlled below 0.5%, and ASME certified model passes the 1.5 times design pressure test, which ensures that there is no lubricant leakage resulting in abnormal oil temperature.
V. ZAKF Factory Advantage: Full-chain Support from Diagnosis to Delivery
Customized Diagnostic Tools
Provides oil temperature anomaly analysis software (ZAKF self-developed), which generates fault probability model by inputting equipment operation data. A Vietnamese customer shortened the troubleshooting time from 4 hours to 1 hour by using this tool.
Extremely fast spare parts supply
7 warehousing bases reserve core spare parts (radiator, oil pump, etc.) for diesel models, and 15-day extremely fast shipment in Southeast Asia / Middle East. When a Thai concrete plant urgently replaced the radiator, ZAKF realized 72 hours of spare parts in place.
The global after-sales network
provides 24-hour online diagnosis from 3 overseas operating companies. ZAKF intelligent monitoring system can remotely read oil temperature, oil pressure and other data, which has reduced unplanned downtime by 80% in a German construction machinery plant.
Industry Cases: Practical Value of ZAKF Solutions
Mining Scenario Application:
An African gold mine uses ZAKF diesel air compressors (flow rate of 100m³/min), and through the combination of plate-fin radiator + intelligent fan, the oil temperature is lowered from 95℃ to 82℃, and the annual maintenance cost is saved by 35,000 USD.
Construction case:
A Middle East infrastructure project adopts ZAKF high-temperature diesel model with automatic back-purge system, which operates continuously for 6 months without oil temperature abnormality under 50℃ environment, and improves the efficiency by 18% compared with the traditional model.
ZAKF screw air compressor manufacturer always takes “technical innovation + global service” to crack the pain point of industrial equipment. Whether it is the efficient design of cooling system or intelligent load regulation, we provide full-cycle services from troubleshooting to customized solutions for global users with the manufacturing strength of 60,000m2 production base and the quality assurance of CE/ASME certification. If you need to get the oil temperature control solution for your working condition, welcome to contact ZAKF team, let our 2500 units/month capacity and 7 warehouses logistic network be the solid support for the stable operation of your equipment.
