Air Compressor Problems, Causes And Solutions

In this article, I will share with you different air compressor problems, causes and solutions.

The article will cover common problems in all types of air compressors and how you can solve them.

It doesn’t matter whether you are using a reciprocating or rotary compressor.

Most of these problems are related.

Without wasting time, let me share with you what you need to know about air compressors and their problems.

Air compressor problems;

1. Compressor not starting.

In most air compressors, compressor failure is one of the main causes of air compressors to fail.

So, if your compressor is not starting, there are possible reasons why that is so.

There are several reasons why the compressor is not starting, once you identify the main problem with your compressor then you will be able to come up with a way to solve it.

The first thing you have to do is to relax and check your air compressor if it’s exactly the way it’s supposed to be.

It can be that it’s not starting simply because you have not plugged it into the power supply.

Check the following things from your air compressor before you decide to do anything else;

The electric connection of your air compressor to the mains.
Check the oil level in your compressor if it’s at the right level.
The pressure switch if it’s in contact with the controls.

Check if the pressure in the tank is below the cut-in pressure.
Check the operating condition of the air compressor.

Solution for an air compressor that is not starting.

If your air compressor is not starting then here are some of the solutions you need to make it start working.

The moment you notice that your compressor is not starting simply because it has faulty wiring then the only thing you will have to do is to ensure the wiring is in the correct shape.

But if it’s not starting because it’s not plugged in the electric mains then you will have to plug it in.

The Air compressor will not start if it’s not plugged into the electric socket or if it has faulty wiring.

The oil level in the compressor also plays a big part in the function of the compressor.

If you have checked the oil levels and you have found out that the compressor is not lubricated then you will have to ensure that it’s lubricated efficiently.

The smooth movement of the pistons within the air compressor largely depends on lubrication.

When the piston gets stuck then the air compressor will not start at all.

If you have found out that your pressure switch is not making contact then you should make some adjustments to the pressure switch for the air compressor to start.

On the other hand, if you have found the pressure in the tank is below the cut-in pressure then you should check the pressure switch adjustment and replace any pressure switch that has a lower cut in PSI.

When you overload an air compressor it will also fail to start.

So, if you are using large tools that your compressor can’t handle then you should use the required tools for that air compressor.

Not all tools will work with the same air compressor since some needs a large air requirement than your air compressor can supply.

When you find any broken component in the air compressor then you should find a way to repair or replace it if it’s beyond repair.

2. Excessive noise in operation.

Excessive noise in an air compressor is one of the common problems.

When you forget a single detail on the part of tightening the air compressor against where it’s needed to be you will experience this problem.

Though, it’s not the only problem that causes excessive noise when the air compressor is operating.

These noises will bring discomfort and if the problem is not identified and fixed then it will lead to a larger problem.

So, for you to fix this noise problem when the air compressor is operating you have to know the possible causes of this condition.

These are some of the main problems that cause excessive noise when the air compressor is operating;

Lack of lubrication on the moving parts of the air compressor causes excessive noise when the air compressor is operating.
When the pulley is loose it will also cause excessive noise when the belt is moving around it.
If the flywheel is loose also causes excessive noise when the air compressor is operating.

When the air compressor components are not tightly fastened, it will cause excessive noise during operation.
If the belt guard is not well fastened or it’s in contact with the moving belt this will cause excessive noise when the air compressor is operating.
The moment the clamps holding the air compressors are loose excessive noise will be experienced when it’s operating.

If the piston hits the valve as it operates this will cause excessive noise from the air compressor.

As you can see, there are several causes of the excessive noise when the air compressor is operating.

You have to find the main problem that causes the excessive noise before you think of dissembling the whole compressor.

Solution for excessive noise when the air compressor is operating.

Before you do anything the first thing you should do is to check if the air compressor is well fastened.

Check the bolts holding the air compressor and the accessories if they are well secured against where they are supposed to be.

If you find out that the bolts holding the compressor are loose then you should find a means of fastening them for the excessive noise to cease.

Also, check on the vibrating pads if they are well secured, if they are worn out then you should replace them and put in new vibrating pads.

These vibrating pads help in the control of vibration when the air compressor is working.

You might like this: Vibration Control In Mechanical Engineering (Methods)

Is the air compressor well lubricated? Check the lubrication on the moving parts of the compressor, if there is no lubrication or it’s little then that might be the cause of the excessive noise.

Lubricate the moving parts of the air compressor and start it again and listen to if the excessive noise will still be coming out of the compressor.

Check the pulley and flywheel if they are loose and tighten them. The moment the pulley or the flywheel is loose then there will be no smooth movement even if the air compressor is sufficiently lubricated.

Don’t forget to examine the belts, check them if they are loose and fasten them too.

If the belt guard is loose or comes in contact with the moving belt then make a point of fixing it.

Make sure that the belt doesn’t come into contact with the moving belt and this will stop the excessive noise when the air compressor is operating.

Also, ensure it’s fastened in the right place to prevent any complications of belt wear.

After trying to fix all the issues I have talked about and you still hear the excessive noise as the air compressor is operating then the problem may be within the cylinder.

Open the cylinder of the air compressor and check the piston if it’s clean.

If it’s not clean then know that this is one of the reasons why your air compressor is operating in such a noisy state.

Clean the piston and assembly the compressor and start it again. Listen if you will still experience the same problem of noise as its operating.

Sometimes this problem of excessive noise as the air compressor is operating is caused by a defective crankcase, the only solution for this you will have to repair or replace it.

3. Knocks- same cycle as the R.P.M

If there is a knock whenever the air compressor is operating in the same cycle as the revolution of the pulley or flywheel then know that there is a problem with your main bearing.

But, this is not the only problem, sometimes it can be caused by a loose flywheel.

In some cases, the connecting rod bearing also usually causes this problem of knocking in the same cycle as the R.P.M.

Solution of knocks same cycle as the R.P.M in air compressor

The first thing you should do if you are experiencing this problem with your air compressor is to check the main bearing of the air compressor.

It can be that your air compressor bearings are in bad shape or worn out.

If at any point the bearings are worn out then you will also experience the knocks as the air compressor is in operation.

The only solution to this problem is to replace the main bearings.

If this issue has anything to do with the connecting rod bearings then you should also replace them.

On the other hand, if the flywheel is loose then you should tighten it before it causes another big problem that will cost you more.

4. Knocks when the compressor is loading.

This is another common problem in an air compressor. For you to fix this issue the first thing you have to know is the causes of this problem.

The knocks that occur when the air compressor is loading are caused by;

The connecting rod bearings are worn out.
The wrist pins of the piston have a fault.
Loose connecting rod nut.

Solution for knocks while the compressor is loading.

To fix this problem, you will have to find the main cause of the knocks while the compressor is loading.

If you find out that the knocks are caused by the worn-out bearings of the connecting rod then you will have to replace them.

When you have replaced them and you still experience the same issue then it can be the piston has issues.

Check the piston and if it has a fault you will have to replace it.

If the connecting rod nut is loose the only solution for that will be for you to tighten it.

Hopefully, this will fix the knocks you are experiencing when the air compressor is loading.

5. Milky oil in the oil reservoir.

This is another problem with an air compressor.

The moment you find out that the oil in the oil reservoir is milky then know that it’s mainly caused by the high humidity of the environment you are operating the compressor.

If the humidity is too high then water will be entering the oil reservoir and this will cause the oil to be milky.

This is a problem since it will affect the lubrication of the compressor.

You have to fix this immediately before it messes up with your air compressor.

The bad thing is that you can’t change the humidity in the air, but there are some things you can do to ensure that this issue of humidity doesn’t affect you at all.

Solution for milky oil in the oil reservoir.

If you can change the pipe station so that it takes air with less humidity then you should do that.

The main issue here is the humidity.

When the air compressor takes in air with less humidity then your oil reservoir will be safe.

If this is something you can’t change then you will have to ensure that you do some frequent checks on the air compressor.

You will have to change the oil if it’s too milky and can’t be used in the air compressor.

Using the milky oil might affect the lubrication of the moving parts of the compressor.

Clean or replace the air cleaner element if it’s highly affected by the humidity.

The other thing you can do is drain the tank daily to reduce the amount of water entering the compressor.

Draining the tank daily will prevent water from accumulating and entering the oil reservoir.

Make sure there is a periodic check of the air compressor if you want to solve this problem.

6. Excessive oil consumption.

Excessive oil consumption in an air compressor is another common problem.

Without dealing with it you will be wasting so much money on oil and you will be drained financially because of an issue you can fix.

If your air compressor is using too much oil than it was first used when you purchased it then you have to find the main problem for you to be able to fix that.

Here are some of the main causes of excessive oil consumption in air compressors;

Oil leakage is one of the issues that result in excessive oil consumption in an air compressor.
Restricted air intake also leads to excessive oil consumption.
If the pistons are rings are worn out there will be much oil consumption when the air compressor operates.
Using the wrong oil with the wrong viscosity in the air compressor also results in excessive oil consumption.
When the air compressor is titled so much also there will be too much oil consumption in the air compressor.

The above are some of the causes of excessive oil consumption in air compressors find the main cause and find its specific solution.

Solution for excessive oil consumption in an air compressor.

If your air compressor is consuming too much oil than the volume you expect the first thing you have to check on is if it has leakages.

When you find that your air compressor has leakages, try your best to fix that.

You will have to fix the pipes that are broken and fix any faulty joints, if it’s the oil reservoir that has an issue then you will have to replace it.

Check the piston rings if they are still in good shape, if they are worn out replace them with new ones.

The oil that you feed in the cylinder keeps dripping from the pistons thus when lubricating it you realize that you use too much oil.

The type of oil you use also plays part in this issue of excessive consumption of oil.

If you are using oil with a lower viscosity then you will have to use too much for it to fit your needs.

You need to use oil that is viscous enough so that it won’t flow from the parts you keep lubricating.

Also, if you notice that your air compressor is titled too much then you should find a way to keep it on the correct level.

You can use vibration pads to keep them at the desired level so that it doesn’t consume too much oil.

7. Oil in discharge air.

If your air compressor has this problem then you should find out what causes it.

I will share with you some of the main causes of this problem so that you can troubleshoot your air compressor.

These are some of the common causes of oil in discharge air in air compressors;

Too much oil in the air compressor will cause the air discharged to have traces of oil.
Using oil of the wrong viscosity also causes the issue of oil in discharged air from the air compressor.
If there is an air intake restriction in the air compressor this also causes the oil in the air discharged from the compressor.
Dirty air filters or fault filters on the delivery side of the compressor cause oil in the air discharged from the air compressor.

Solution of oil in discharge air from an air compressor.

If the air compressor is consuming so much oil than the volume you expect then you should know that this is the main cause of this problem.

This means that there is so much oil in your compressor and that is why the air being discharged from the compressor has traces of oil.

The only thing you can do is to drain down to the full mark on the sight gauge.

Ensure that there is the correct level of oil in the air compressor.

If this is not an issue in your air compressor then know that it can be as a result of another issue.

Check your delivery filters if they are in good working conditions.

If they are too dirty or clogged, clean them and replace filters that are beyond the point of cleaning.

Also, clean your inlet valves since there might be a restriction on air intake within the compressor.

The other thing you can do is to check the piston too if they are in good working condition.

When you find out that the piston rings are worn out then you will have no choice but to replace them.

8. Air blowing out of the inlet instead of the delivery pipe.

The moment you experience this problem know that the main problem is with your valve.

Check out the inlet valve of the first stage.

Solution for air blowing out of the inlet.

The main solution for this problem is to replace the plate assembly that contains the first stage inlet valve.

This will fix the issue very easily.

9. Insufficient pressure at the point of use.

This is another common problem in an air compressor.

The main causes of insufficient pressure at the point of use of an air compressor are these;

The slipping of the belts causes insufficient air to be delivered at the point of use.
If the compressor has leakages then insufficient pressure will be a problem at the point of use.
When the air compressor is used to operate large tools that require excessive air demands that the compressor can meet.
The restricted air intake in the compressor is also one of the causes of insufficient pressure at the point of use.

Solution for insufficient pressure at the point of use in an air compressor.

The first thing you should do is to find out the main cause of this problem if you want to solve it.

If there is a slip of the belt whenever the air compressor is operating then you will have to change the belt if it’s worn out.

When you find out that the belt is loose then you will have to tighten it to allow a continuous run of the belt so that there is maximum energy transmission.

Also, if the belt is too long it should be reduced and put at the required length to allow maximum energy transmission.

The next thing you should do is to check if there is any leakage in the air compressor.

Find the fault that causes the leakage and fix it and this will fix this issue.

But if the main problem is brought by the tools you use then you should change them.

Sometimes when you require a large demand of compressed air that the air compressor can’t meet you will experience this issue of insufficient pressure at the point of use.

Check the rating of the tools you are using and confirm if they are fit to be used with the air compressor you are using currently.

When you are using a service hose that is too small then this is something you will experience.

If this is the cause then you will have to use the service of the required size.

10. Excessive belt wear.

Belt wear in an air compressor is another problem that causes inefficiencies when it’s operating.

These are some of the causes of excessive belt wear in air compressors;

Misalignment of the pulleys is one of the causes of excessive belt wear.
When the belts are too tight or loose this can cause excessive wear of the belt.
The pulley or the flywheel wobbling as the air compressor operates also cause excessive wear of the belt.

Solution for excessive belt wear in an air compressor.

These are some of the fixes for excessive belt wear in the air compressor.

If there is any misalignment in the pulley then make sure you correct it before you think of using another belt.

Ensure the belts are on the right tension when the air compressor is operating.

If they are too tightened, loosen them and if they are too loose then you should do some tensioning.

Check at the pulley and flywheel and ensure that they are rotating at the right angle.

The moment you notice any change in the way they rotate then you should fix that issue.

Check out for worn-out crankshaft, bents and pulley keyway if they are in the assembly that is intended.

Also, if the belt is too old or it’s disintegrating after coming in contact with oil from the air compressor then you should replace it.

11. Excessive discharge air temperature.

Air compressor discharging air that has a high temperature is another problem most people experience when using an air compressor.

These are some of the main causes of excessive discharge air temperature in air compressors;

The heat exchange surfaces are too dirty.
There is poor ventilation of air in the air compressor.
The head gasket is blown out.
Overworking of the air compressor also causes excessive discharge air temperature.

Solution for excessive discharge air temperature in an air compressor.

These are some of the things you can do to solve this issue in your air compressor.

When the air discharged from the air compressor has a higher temperature you should first clean the cooling surfaces of the air compressor.

Ensure the air compressor is placed in an area that receives good air circulation.

Replace the blown-out gasket if you find any in the air compressor.

Ensure that you are using the air compressor on the right load and give it breaks when using it.

Using the air compressor without a break while working on a heavy load will cause it to overheat and the air discharged from it will be under high temperatures.

Thanks for stopping reading, if you have any questions about the problems and solutions of air compressors, just leave your comment.