Common Problems with Air Compressors

An air compressor problem could stem from i of many issues, such as an air leak, an oil leak or a broken office. In some cases, you lot might take bereft pressurization or air flow. In other cases, the compressor might fail to get-go up or stop running as prompted. Whatever the cause of the problem, the symptoms can be frustrating, costly and time-consuming.

Thankfully, nigh such problems can be corrected with proper air compressor troubleshooting. The Titus Visitor has developed this troubleshooting guide for reference when your air compressor won't work. Whether you lot're hearing excessive noise from your portable air compressor or your system won't build pressure level, y'all'll discover the cause here — and, hopefully, a solution. If not, call u.s.. We'll exist there quickly with our 24/7 emergency services.

In This Article

  • Air Leaks
    • Compressor Is Constantly Leaking
    • Air Leaks From the Oil Fill Tube
    • Air Leaks From the Hood
  • Electric Motor and Power Problems
    • Compressor Blows Fuses and Breakers
    • Dimmed Compressor Lights at Startup
    • Breaker Trips at Startup
  • Won't Start or Won't Cease
    • Compressor Fails to Starting time
    • Compressor Fails to Stop
    • Compressor Runs Merely Fails to Generate Air Pressure
  • Oil in Air Lines
  • Force per unit area and Flow Bug
    • Obstructed Intake Filter Media-Element
    • No Air From the Hose
    • Air Only Comes in Short Bursts
  • Parts and Repair Needed
    • Broken Intake Filter
    • Cleaved Air Compressor Manifold
    • Broken Compressor Fan
    • Broken On/Off Switch
  • Get Air Compressor Aid From The Titus Company

Air Leaks

Good air pressure is essential to a well-powered machine. When air is leaking from your tank or hoses, y'all'll notice depression pressure, which brings on extra fourth dimension and free energy costs that can get out your business organization behind. An air leak could exist down to one of several factors. Fortunately, leaks can exist sealed with the right kind of air compressor troubleshooting. The following symptoms are among the most common leak-related air compressor issues:

What to do if your industrial air compressor leaks

1. Compressor Is Constantly Leaking

If you shut off the air compressor on full charge, yet the gauge drops while the compressor is deactivated, y'all definitely take an air leak. The compressor might even automatically restart just to counter the situation. What y'all need to do in this situation is pinpoint the source of the leak.

  • Apply lather to the connections: With the compressor unplugged, cover the connections with liquid soap, including all the couplers and the force per unit area switch. If bubbles form at any point, that is where the leak is located. Tighten upward the coupler, if possible, where the bubbling occurs.
  • Inspect the tank check valve: Air leaks are sometimes caused by tank check valves that fail to close completely. If the pressure approximate continues to drop when the tank is off, access the tank valve and inspect its condition. The valve might need to be cleaned or replaced.

If the air leaks occur but when a hose is plugged into the compressor, disconnect the hose. If the pressure level gauge stops dropping, the hose is the source of your leak.

2. Air Leaks From the Oil Fill up Tube

If your compressor is losing pressure through the oil fill tube, bank check the piston seals. In virtually such cases, the piston seals will be desperately worn and in need of immediate replacement. This is a trouble that you should remedy immediately, as worn pistons can cause metal-on-metal friction that could swiftly lead to internal corrosion.

3. Air Leaks From the Hood

Air leaks from nether the hood are sometimes encountered on smaller air compressors. To diagnose the problem, remove the hood, run the compressor for a few minutes, then shut it off and unplug the compressor. Feel around the motor parts for any sort of air draft. Chances are, the leak volition originate from the tank valve, in which case you volition need to remove and make clean or possibly replace the valve.

Electrical Motor and Power Problems

If you notice an electric effect, you need to take a look at information technology or have a professional come out as shortly every bit possible. It could exist anything from your motor capacitors to misfiring piston rings. If the power cuts out on your air compressor — or the ability is bereft and unreliable — the trouble is most probable down to one of the post-obit factors:

one. Compressor Blows Fuses and Breakers

Bold that your compressor is plugged into a working outlet and powered on, the following bug could exist causing fuses to blow:

  • Extension cords: If your compressor is connected to an outlet via an extension string, the motor could be deprived of sufficient free energy, causing the motor to overheat. Compressors are non like home electronics, which can suffice on extension cords and power confined. An air compressor should only be powered through a direct connection to a power source.
  • An old motor: If your compressor has run on the same motor for many years, information technology could be time for a alter-out. An older motor is liable to accept worn windings, loose capacitor wires and other general wear that could easily result in diddled fuses and breakers.

If the tank seems to lug at times of loftier pressurization, in that location is probably an effect with the motor capacitor.

ii. Dimmed Compressor Lights at Startup

An air compressor consumes massive volumes of power at the time of startup. This is known every bit the inrush, which vastly exceeds the amount of power generally consumed throughout the residuum of a usage cycle. To forbid fuses from breaking during this inrush, compressor motors are equipped with starter capacitors, which manage the incoming power. A dimming light is one of the tell-tale signs that the starter capacitor is worn and due for a replacement.

3. Breaker Trips at Startup

If your air compressor trips off the moment information technology powers on, the issue is likely acquired past trapped air over the pistons. To examination for this problem, shut off the tank, unplug information technology from the power supply and drain the tank of all air. This should relieve the pistons of undue air pressure and allow the tank to start without farther issues. Trapped air over the pistons is ordinarily caused by a faulty unloader valve, which should be inspected, cleaned and perhaps replaced if the issue persists.

Won't Kickoff or Won't Stop

When an air compressor fails to start up, shut down or provide any degree of air pressure while active, the trouble could exist down to one of several issues. Each instance should exist taken on its own, every bit follows:

1. Compressor Fails to Offset

Aside from the obvious oversights such as a disconnected power cord or a deactivated ability switch, a compressor will typically neglect to start when it lacks sufficient air pressure. If the cut-in pressure is not proportional to the amount of air pressure stored in the tank, the compressor volition often fail to starting time. Check the cut-in setting on the pressure switch and accommodate the level accordingly.

two. Compressor Fails to Stop

The compressor should cease one time the tank pressure drops to the cutoff point. If this fails to occur, the trouble will generally be down to one of two issues:

  • Faulty force per unit area release valve: If the valve fails to release pressure, the tank will be too pressurized for the motor to stop running. In cases like these, you should cut the power and refrain from further use until the valve is replaced, as farther apply could seriously impairment the compressor.
  • Faulty pressure level switch: If the force per unit area switch fails to signal the internal controls, a new switch should solve the problem.

Pressurization components are at the heart of a compressor'south functions and when they fail, the compressor essentially fails.

3. Compressor Runs Just Fails to Generate Air Force per unit area

If the compressor runs and runs yet air pressure is not forthcoming, the trouble is probable due to one of 2 issues:

  • Faulty pump: If the motor is running and making noise yet no air comes out, you probably have a faulty air-intake pump that needs to be replaced. Every bit long as the compressor is non too hot, y'all can feel for lack of pump pressure manually with a pair of protective gloves.
  • Faulty gasket: If the compressor only generates modest amounts of pressure, in that location might be an issue with the gasket between the low-pressure and high-pressure compartments of the compressor, such as air flowing from i side to the other without sufficient pressurization.

Fortunately, pumps and gaskets can hands be changed out. With a simple parts replacement, you should be able to get many more years of performance from the compressor at manus.

Oil in Air Lines

If compressor oil works its fashion into the air lines, the effects could be detrimental elsewhere in the compressor because the pump uses a unlike kind of lubricant than other parts of the system. Once inside the air lines, that oil volition be dispersed to other areas, potentially causing seals to scissure or swell. Oily air lines are near troubling when the oil travels to plastic parts of the air valve.

The sick-effects of oil on plastic are due to the additives in the oil, which tin can cause plastic surfaces to become brittle and ultimately split. A plastic lubricator bowl, for example, could dissever under such circumstances if the air pressure crosses a sure threshold. Y'all can protect the bowl — or incorporate the plastic in the issue of a rupture — by affixing it with a metal shroud.

In a reciprocating air compressor, the oil must beginning travel past the piston seals to make its fashion to the tank. When this occurs, the seals should be replaced immediately. This would also be an opportune time to supersede the valve and gasket.

Every bit before long every bit y'all find that oil has entered the air lines, check the sump to brand certain that it still has a sufficient quantity of oil. If the problem persists, the sump could exist depleted of its oil supply.

When removing the oil, have a expect at information technology and ensure it appears clear and consistent. Sometimes, you may find your oil has a milky expect to it — this happens when your air compressor is exposed to excessive humidity and condensation has gotten into the oil reservoir. In this instance, yous should bleed and replace the oil and movement your air intake pipe to a less humid environment.

Force per unit area and Menses Problems

Some of the nigh common problems with air compressors involve issues with the pressure and menstruation, which oft manifest with the post-obit symptoms:

one. Obstructed Intake Filter Media-Element

The main reason to supplant an intake filter is when it becomes corroded or damaged. However, the filter could be the source of pressure and menstruum issues if the intake becomes plugged. Tell-tale signs of trouble include the following symptoms:

  • The compressor tank takes longer and longer to build air pressure.
  • The motor recurrently overheats and trips the thermal cutting.

If you experience these bug, remove the filter housing from the intake pump and run the compressor once again. If the problems finish and the compressor runs usually, the issue is rooted in the air intake media. From hither, yous have two options — cleaning or replacing. To make clean a compressor filter, run water through it until you don't come across any dirt particles.

You can supercede the media with various types of filter elements sold at supply stores and car parts shops. The best options are media that resemble the kinds used in air conditioners. Cut the media to the dimensions of the intake filter and switch out the one-time for the new.

two. No Air From the Hose

If an air hose is connected to your compressor yet the air is not forthcoming, the consequence could exist downward to one of several factors:

  • The tank lacks air. This would be indicated by a zip pressure reading on the tank estimate.
  • The regulator force per unit area is set to zero. If so, adjust the regulator to a level within 20 psi of the compressor's cutout pressure.
  • The discharge coupler is fitted with the incorrect hose connector, thus blocking the flow of air. This could be the instance if yous recently replaced ane of the parts without checking OEM specifications.

The problem could also be down to the unproblematic fact that the connector on the attached pneumatic tool is sick-suited for the coupler.

3. Air Just Comes in Short Bursts

If your tank has sufficient air quantity, yet generates very little air pressure, check the gauge readings. If the gauge is besides depression, you lot will not go sufficient air pressure from the tank. If your tank gauge is 100 psi, the approximate should be gear up to somewhere around 90 psi.

Parts and Repair Needed

If an air compressor seems to have stopped working due to a broken office, you beginning need to test the part to verify the root of the problem. A compressor will non work if the following parts are cleaved. Fortunately, all tin be replaced:

Common parts and repairs needed for industrial air compressors

i. Broken Intake Filter

The intake filter is a crucial office of the air compressor considering it strains impure particulates from the incoming air. Since it physically sticks out from the residue of the unit, an intake filter is one of the more easily broken parts to an air compressor. Fortunately, it is likewise one of the easier parts to replace. As long as you find a filter with the same thread size and roughly the same portal size and diameter, it should work for your machine.

two. Broken Air Compressor Manifold

If you interruption the pressure level switch on an air compressor, yous might exist surprised by the underlying complexities. Fact is, any old replacement switch will not solve the trouble due to all the connecting points of the manifold. To fix the problem, you lot will need to find a switch that accommodates each of the four or five connecting points, which will more often than not include sockets for the pressure relief valve, the air tank gauge, the compressor tank and the quick coupling.

Earlier y'all purchase a new force per unit area switch and manifold, have note of the post-obit details on the old switch, each of which must be matched on any new switch you attach to the compressor:

  • The number of ports on your pressure switch and manifold.
  • The voltage of the original pressure switch.
  • The cut-in and cut-out settings on the onetime pressure switch.
  • The hookup of the unloader valve.

Be careful to properly thread the ports of the new manifold onto their corresponding parts of your air compressor.

3. Broken Compressor Fan

Many newer air compressors — specially those on the lower-cost finish of the spectrum — blow air with fans fabricated of plastic, which is less expensive than metal but is also more easily decumbent to wear and tear. Fortunately, a replacement fan made of either material will work in almost any compressor. Therefore, if you have a fan with broken plastic blades, y'all could plow this into an opportunity to upgrade to metal.

Before you pick a replacement fan, bank check the compressor manual for a listing of the part number and corresponding dimensions. If non constitute, measure the dimensions and the hole diameter of the original fan. Take note of the number of blades and the direction of airflow, as both details are consequential to the performance and make of the compressor.

iv. Cleaved On/Off Switch

If the motor of your air compressor fails to power on when you flip the switch, it could be a affair of the switch itself, though you should run some tests before yous depict any conclusions. Check the power string to ensure that it is plugged into a functioning socket. If the power switch still fails to activate the compressor, plug a low-cal or electronic device into the outlet to see if that powers on.

If the outlet works for other devices but not your compressor, pull back the housing that confines the switch, remove it from the socket and cheque the compressor possessor's manual for specs on the switch. Brand sure that your replacement switch will match the specs and fit the socket.

Get Air Compressor Assistance From The Titus Company

Air compressors serve all kinds of purposes on a professional person equally well as personal scale. From pressing plants and factories to repair shops and studios, pressurized air is used to assemble everything from automobiles and aircraft to appliances and home furnishings. Today'southward compressors are designed to deliver optimal power with sleek designs through many usage cycles.

At The Titus Company, we offer maintenance on a variety ofair compressor types and brands.Contact us today to learn more about our products and services and how we can help you lot set an air compressor that won't piece of work as intended.

Contact The Titus Company for Industrial Air Compressor Repair and Service