Air compressor problems can bring your operations to a sudden halt, costing your business valuable time and money. From overheating and air leaks to moisture buildup and pressure inconsistencies, these common issues often escalate from minor annoyances to expensive emergencies when left unaddressed.
The good news is that most air compressors are entirely preventable with a strategic preventative maintenance program. Investing in regular maintenance not only keeps your equipment running efficiently but also protects your bottom line by reducing energy costs, minimizing unexpected downtime, and extending the lifespan of your compressed air system.
Key Takeaways
- Industrial air compressors require regular maintenance to avoid serious issues that may result in poor performance or breakdown.
- The most common problems air compressors include overheating, air leaks, moisture issues, air pressure problems, intake filter problems, and belt and coupling issues, to name a few.
- Routine maintenance will improve energy efficiency and prevent many of these common issues from occuring.
Industrial air compressors face several common problems that can impact their performance and reliability. These are a few of the most common.
Oil Problems
Oil-related problems include the oil expiring too quickly, or aerosolizing. When the oil expires too quickly, it could be intake obstruction, oil leaks, worn piston rings, or an improper oil viscosity.
Oil can also contaminate machine parts and cause further damage. When it aerosolizes, it can cause seals to crack or swell and plastic areas to become brittle. There may be restriction in the air intake, excessive oil in the tank, or the wrong viscosity. These problems can cause significant damage throughout the compressor system.
Overheating
Overheating is one of the most frequent issues, often caused by inadequate ventilation, dirty cooling fans, low oil levels, or ambient temperature being too high. This can lead to automatic shutdowns and component damage.
You can usually recognize overheating when the released air is too hot. An overheating compressor can damage any surfaces it may come into contact with. The internal components may also be at risk at this point. Without attention, they will require immediate repair.
Air Leaks
Air leaks throughout the system significantly reduce efficiency and increase operating costs. These typically occur at fittings, valves, hoses, and connections, and can waste substantial amounts of compressed air.
You can either listen for the hissing sound or run your fingers over components to try to pinpoint the escaping air. If you still cannot find the leak, you can lather components in liquid soap and look for the bubbles. You can tighten the coupler to seal the leak.
Moisture Issues
If you notice condensation spraying with your compressed air, it’s a sign that your compressor has moisture issues. Other signs may include rust or corrosion, drops in air pressure, or air quality problems.
Moisture issues plague many systems, especially in humid environments. Excess moisture can cause corrosion in air lines, damage pneumatic tools, and reduce system efficiency. This often stems from inadequate drainage or malfunctioning moisture separators. You’ll need to drain the tank regularly, and possibly use an air dryer.
Air Pressure Problems
Pressure problems include the compressor not reaching target pressure, pressure dropping during operation, or pressure relief valves malfunctioning. These issues often trace back to worn rings, valves, or control system problems.
The machine may continue to appear to be working properly, even when air pressure is inadequate. But components like the intake valve, pressure valve, gasket, piston seal, or tank check valve could be compromised when pressure is the problem. Obstructed filters or an ill-fitting coupler could also become a problem. It could also be that the pressure gauge is set too low.
Electrical And Control Issues
Electrical and control issues can cause erratic operation, including problems with pressure switches, motor starters, and control panels. These can lead to improper cycling or complete system failures. You might receive error codes or unresponsive switches, too. You’ll want to check for loose wiring, blown fuses, or a dirty control panel.
Resetting the system after tightening or replacing components often resolves minor issues. Persistent problems may require the help of an air compressor technician.
Intake Filter Problems
Intake filter problems from clogged or dirty filters restrict airflow and force the compressor to work harder, reducing efficiency and potentially causing damage. When this problem is ignored, it can allow dust and debris into the compressor and lead to more costly repairs. The best solution is to replace the intake filter regularly and clean it when needed. It also helps to keep the compressor in a clean, dust-free environment.
Belt And Coupling Problems
Belt and coupling issues include worn, loose, or broken belts that affect power transmission and can cause vibration problems. In severe cases they may snap or fail, leading to breakdowns. But there are ways to eliminate and minimize downtime. It’s important to check belt tension and alignment regularly, to look for cracks or fraying. Proper lubrication and routine inspection can keep belts working properly.
Routine Preventative Maintenance Is the Solution
Regular preventive maintenance addressing basic air compressor problems can improve energy efficiency, reduce downtime and extend the life of your system. Most of these problems are preventable with proper maintenance and following your manufacturer’s operating instructions. A trained technician will spot potential problems during maintenance before they become an emergency or complete failure.
For thorough preventative maintenance care by an experienced professional, call Compressor Services. Contact us today to get started.
