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Common Faults and Maintenance Methods of Air Compressors

2025-07-24

Latest company news about Common Faults and Maintenance Methods of Air Compressors

In modern industrial development, air compressors play an essential role by compressing gas and providing power for various equipment. Their performance directly impacts productivity and operating costs. Therefore, understanding the basic functions of air compressors, along with common faults and proper maintenance methods, is key to improving work efficiency and reducing downtime. Let’s explore the most frequent issues and how to fix them effectively.

 

Common Faults of Air Compressors


Due to varying operating conditions such as temperature, humidity, altitude, and workload, air compressors often encounter the following problems during use:

  • The machine fails to start or starts with difficulty

  • The air compressor doesn’t deliver air

  • The exhaust pressure is too low

  • The compressor shuts down unexpectedly during operation

  • The exhaust temperature is excessively high

  • The compressor sprays oil and shuts down

  • Excessive oil consumption

 

latest company news about Common Faults and Maintenance Methods of Air Compressors  0

 

Practical Maintenance Methods for Efficient Troubleshooting
 

Below are targeted maintenance methods for each of the issues mentioned above:

  • Startup failure or difficulty:
    First, shut down the machine and inspect the automatic circuit breaker, power supply voltage, and whether the air intake butterfly valve is functioning properly.
    If the compressor doesn’t start, check for control voltage. If present, inspect the control relay and time relay. If no voltage is detected, check the fuses for damage.

  • No air output:
    Inspect whether the control cylinder is actuating. If it is, check the butterfly valve for mechanical failure. Then check if the ISV solenoid coil is energized. Continue troubleshooting each related circuit component if needed.

  • Low exhaust pressure:
    Inspect for leakage in the manual valve or 2SV regulating solenoid valve, air piping leaks, incomplete butterfly valve opening, intake regulator malfunction, or leaks in solenoid valves 3SV and 8SV. Also check if the IPS pressure switch requires recalibration.

  • Unexpected shutdown during operation:
    Determine whether the shutdown was due to an automatic stop. Then check the main circuit breaker, thermal relay, cooling fan operation, exhaust temperature, pressure levels, and motor voltage.

  • High exhaust temperature:
    Normal exhaust temperature should range between 80–95°C. If temperatures rise excessively, verify the ambient temperature, oil level and quality, cooling fan functionality, temperature control valve, and oil cut-off solenoid valve.
    Replace any damaged components such as the valve diaphragm or temperature control core, and check whether the oil filter is clogged and needs replacement.

  • Shutdown due to oil spray:
    Examine whether the 5SV oil cut-off solenoid valve is receiving voltage and operating correctly. If all appears normal, check the non-return valve and either reassemble or replace as needed.

  • Excessive oil consumption:
    Check whether discharged condensate from the drain contains too much oil, whether the oil level is too high, if the minimum pressure valve is functioning properly, whether the oil return pipe is blocked, or if the oil separator is clogged. These factors can all lead to increased oil consumption and should be addressed promptly.

 

These are seven of the most common air compressor faults and their corresponding maintenance solutions. However, in real-world applications, not all operators are trained to perform repairs themselves. In such cases, it’s best to seek assistance from the brand’s after-sales service team to ensure proper handling.

 

We recommend choosing Rancheng air compressors, known for their dependable quality and responsive after-sales support.

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