What’s Wrong With My Air Compressor? (1/2)

The air compressor is a powerful machine that, in today’s high-tech world, is used by everyone from auto mechanics to furniture makers, in addition to manufacturers large and small. While compressed air is relied upon for heavy-duty tasks that would otherwise require tremendous manpower, a compressor will sometimes require regular maintenance to ensure proper operation. However, any piece of equipment may fail from time to time. Whether there’s a problem with the motor, lubricant supply or pressure, the issue needs to be remedied before it spirals into a costly repair. The following air compressor troubleshooting tips can help solve some of the most common problems that are known to occur with air compressors.

Air Compressor Won’t Operate

If a compressor fails to operate, it’s usually caused by a basic problem or simple oversight. Fortunately, operational issues are among the easiest problems to diagnose and remedy on air compressors. The most common problems can be remedied as follows: • No power — If the compressor lacks electrical power, check the power button and activate the reset switch if needed. Breakers should also be checked. • Lack of oil — Users sometimes forget to check or change the fluids, and the consequences are often grievous. If your compressor is failing to work properly, it could simply be from a nearly empty oil tank. • Power switch failure — When the compressor fails to power on, it could be due to a lack of contact between the pressure switch and inner circuitry. This can possibly be remedied with adjustments to the pressure switch. • Pressure disparity — If the tank pressure is too low in relation to the cut-in pressure, replace the pressure switch for one with reduced cut-in. When you’re used to a machine working and one day it fails to power on, the experience can be quite shocking. In most cases, however, the failure could be simply caused by oversights like an unturned switch, a lack of fluid or an unplugged chord. With compressors, operation failure could stem from one of the other issues covered in this air compressor troubleshooting guide.

Excessive Noise From the Compressor

When a reciprocating type air compressor makes loud noises that seem obnoxious and out of character, it’s likely due to one of the following, easily corrected issues: • Loose parts — Noise is often the result of loose internal parts. Check for looseness in the pulleys, cooler, flywheel, clamps, belt, accessories, etc. and perform tightening as needed. • Troubled crankcase — Another common noise culprit is the defective or oil-deficient crankcase. Check to see whether the crankcase needs new oil or bearings, or if it needs to be replaced outright. • Problem pistons — Noise also occurs when the piston hits the valve plate. Take out the cylinder head and check for dirt on the piston, then replace the gasket and reattach the head. • Improper mounting — A further cause of the noise is when the compressor is mounted loosely. Refasten the bolts on the compressor and check to see whether the vibration pads need to be installed or replaced. If compressor noise gets out of hand, it can make the machine quite difficult to workaround. In most cases, obnoxious sounds are an indicator that something is indeed wrong with the unit internally. While the problem might not indicate an immediate need for major repairs, it could lead to such if action isn’t taken now to stem the problem with simpler adjustments.

Oil Doesn’t Last Long Enough

A compressor needs oil to run properly, pure and simple. That said, few aspects of compressor operation are more annoying than periods where the oil expires too quickly. If a compressor’s oil supply is in constant need of replacement, it’s likely down to one of the following four factors: • Intake obstructions — A sign of neglect is when blockage forms at the air intake. If this happens, the filter needs urgent cleaning, and in some cases a replacement. • Oil leaks — Leaks of oil can usually be stopped by tightening the bolts of relevant machine parts or by replacing the oil gasket. • Worn piston rings — When piston rings appear visibly worn, the time to replace them is now, not later. • Improper oil viscosity — If the oil viscosity is off, it’s time to drain and refill with different oil and with the right viscosity. Oil can also be lost if the compressor constantly tilts, but this can be fixed by placing the compressor on a different surface with the addition of vibration pads. Furthermore, if you find the cylinder is scored, it needs to be replaced.

Excessive Oil in Compressor Discharge Air

When excess amounts of oil become aerosolized by the compressor’s discharge, it can be damaging to pneumatic tools and accessories. Even worse, oily discharge poses ill effects on applications, sometimes to the point where projects must be scrapped and reworked entirely. Luckily, the problem is usually easy to identify and remedy, since oily discharge is typically down to one of the following issues: • Restricted intake — Oily discharge is often caused by restrictions on the compressor’s air intake. In cases such as these, the air filters either need to be cleaned or replaced altogether. • Expired piston rings — Just as with oil leaks, oily discharge can stem from worn piston rings, which need to be replaced on a periodic basis. • Overfilled oil tank — If the compressor has too much oil, some of that excess can seep into the discharge. The oil level needs to be lowered to the “full” mark displayed on the gauge. • Wrong oil viscosity — If the viscosity doesn’t match the requirements of your compressor, empty the oil tank and refill with a different oil of the proper viscosity. • Inverted piston rings — A further possible cause of the oily discharge is upside-down piston rings, which could mean that it’s time to replace the crankshaft. If you use compressed air for the purpose of spray painting, sanding or the application of finishes, you cannot allow aerosolized oil to enter the airstream. With preventative maintenance, you’ll greatly reduce the risk of having projects ruined by the interference of oil particulates in paint jobs and finishes.

Constant Vibration of the Compressor

Vibrations from any piece of machinery can be troublesome. In the case of an air compressor, the vibration could be the result of looseness in any number of areas. The following parts should be inspected for looseness or alignment problems and tightened or adjusted accordingly if tremors/vibrations persist. • Mounting bolts — If the bolts are loose, they need tightening. • Crankshaft — If bent, it’s time for a new crankshaft. • Belts — If loose, the bolts need tightening. Inspect for wear and tear. It could be time for a replacement. • Pulley and flywheel — If either is misaligned, this must be repaired immediately. Vibrations could also persist if the compressor isn’t mounted correctly, in which case you’d need to check the underside to make sure all four legs of the unit are firmly flat on the ground. Even with all the aforementioned parts tightened, tremors/vibrations could still be an issue unless all legs are sufficiently touching the floor.

Milky Oil in the Reservoir

When compressor oil takes on a milky colour, water has made its way into the reservoir via condensation. This would indicate that operating conditions have been too hot for the compressor. For an instant remedy, you have two options: • Colder air — Move the pipe air intake to an area where the ambient air is of a lower temperature. • Daily drainage — Regardless of whether condensation occurs slowly or rapidly inside the compressor, the tank should be drained after each day’s usage. Oil is the lifeblood of any piece of machinery. As such, instances of off-colour oil inside your compressor should be a major concern. After all, if the oil fails to do its job properly, internal moving parts could cause friction and corrode, which could ultimately lead to costly maintenance or a shorter life for the compressor. Therefore, if oil problems get out of hand, have your compressor serviced by trained professionals. In any case, the quality of oil can be better maintained with frequent oil changes. Be sure to consult your owner’s manual for the recommended frequency for oil changes.
When properly maintained, a high-quality air compressor can provide super performance on a vast range of applications for many years of use. If you need more information on air compressors, do not hesitate to contact All Air Compressors today!

source: quincycompressor