Top 8 Common Air Compressor Problems

Air compressors are essential in many industries—from manufacturing and automotive to medical and food processing. However, when they malfunction, it can disrupt productivity and increase costs. This guide outlines eight of the most common air compressor issues, how to troubleshoot them, and tips to get your system back online quickly.

 1. Air Compressor Fails to Start

Possible Causes:

• No control voltage

• Blown fuse

• Malfunctioning control or time relay

Troubleshooting Steps:

• Verify if control voltage is present

• Inspect fuses and replace if necessary

• Test control relays and timer relays for proper operation

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2. Compressor Starts but Shuts Off Immediately

Symptoms:
Compressor turns on but stops within a few seconds.

Checkpoints:

• Ensure automatic circuit breaker hasn’t tripped

• Confirm proper input voltage

• Inspect air intake butterfly valve (starting under load may cause failure)

• Check Y-Δ starter (wye-delta) for contactor issues or phase imbalance

 3. No Air Output from the Compressor

Possible Causes:

• Control cylinder not actuating

• Butterfly valve failure

• Solenoid valve coil (ISV) not energizing

Action Steps:

• Check mechanical integrity of valves

• Verify electrical signal to ISV solenoid

• Test control circuit step by step

 4. Low Discharge Pressure

Root Causes:

• Pressure loss before/after separator

• Leaking manual or solenoid valve (2SV)

• Leaks in piping or air connections

• Intake regulator malfunction

• Misadjusted pressure switch (IPS)

Troubleshooting:

• Check for leaks in valves and piping

• Confirm that intake butterfly valve is fully open

• Test pressure sensor settings and recalibrate if needed

5. Oil Carryover or Oil Spitting from Compressor

Most likely in screw compressors.

Main Causes:

• Faulty oil stop valve (5SV)

• Check valve damage

• Improper assembly or internal wear

Solution:

• Verify voltage to 5SV

• Inspect the check valve for wear or debris

• Replace damaged parts

 6. Excessively High Discharge Temperature

Normal Range: 80–95°C
Common Causes:

• Low or degraded lubricant

• Dirty oil cooler or aftercooler

• Faulty temperature control valve

• Fan motor failure

• High ambient temperature

Fixes:

• Check and refill lubricating oil

• Clean or replace the cooler

• Replace malfunctioning thermostatic valve or damaged diaphragm

• Test the oil filter and replace if clogged

7. High Oil Consumption

Possible Problems:

• Overfilled oil tank

• Blocked oil return line

• Oil separator core deterioration

• Steam trap releasing oil-laden condensate

• Incorrect pressure valve settings

Prevention:

• Maintain correct oil levels

• Inspect and clean return lines

• Replace separator and filters as needed

• Use OEM parts for consistency and durability

8. Unexpected Auto Shutdown During Operation

Triggers Include:

• Overheat protection

• Overpressure shutdown

• Cooling fan failure

• Electrical issues (thermal relay, breaker)

How to Diagnose:

• Monitor exhaust temperature and system pressure

• Check fan motor and protective relays

• Use diagnostic tools or controller display for fault codes

 Bonus Tips: Preventive Maintenance Best Practices

• ✅ Schedule regular inspections for filters, separators, and valves

• ✅ Maintain proper ventilation in compressor rooms

• ✅ Monitor operating temperatures and pressures in real-time

• ✅ Always use manufacturer-recommended lubricants and parts

• ✅ Train personnel on proper startup/shutdown procedures

 

The Unsung Heroes Behind Reliable Air Compression – Our Operators!