Top 7 Ways About How and Where To Service Air Compressor

TABLE OF CONTENTS

In this article Kotech will provide you with 7 comprehensive ways to service air compressors and a complete guide for air compressor maintenance to prevent these failures by analyzing the most common failures of air compressors from multiple perspectives.

As a key production equipment, air compressors need a well developed and strictly implemented  maintenance guide to ensure their long-term stable operation and extend their service life. This includes regular inspections, maintenance, and necessary repairs. A clean, oil-free, and dirt-free air compressor unit can not only improve energy and cost efficiency, but also promptly detect and eliminate potential hidden dangers.

Cris Li, Sales Manager

 

The 7 most common compressor faults and methods to service air compressor

Top 7 Ways About How and Where To Service Air Compressor

  1. Causes of compressor faults in startup

    ↘Methods to service air compressor faults in startup

  2. Causes of compressor faults in air leaks

    ↘Methods to service air compressor faults in air leaks

  3. Causes of compressor faults in air production reduction

    ↘Methods to service air compressor faults in production reduction

  4. Causes of and methods to service air compressor faults in abnormal noises

  5. Causes of and methods to service air compressor faults in stop

  6. Causes of compressor faults in high air oil content

    ↘Methods to service air compressor faults in high air oil content

  7. Causes of compressor faults in leaking or drippingwater

    ↘Methods to service air compressor faults in leaking or dripping water

Method to service air compressor in all faults—air compressors maintenance

  • Importance of air compressor maintenance
  • Air compressor maintenancemeasures

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The 7 most common compressor faults and methods to service air compressor

Causes of compressor faults in startup

  • Power line or power switch damage, incorrect air compressor power wiring, fuse burnt out;
  • The motorwinding may be burned out or short-circuited, causing the air compressor to fail to start;
  • Insufficient or excessive lubricating oil in the air compressor;
  • The temperature inside the air compressor is too high; the bearing inside the air compressor is damaged;
  • The oil pipe inside the air compressor is leaking or blocked;
  • And the pressure inside the air compressor is too low;

Methods to service air compressor faults in startup

  • If the power line and power switch are damaged, they should be replaced in time, and the power wiring of the air compressor should be correctly connected;
  • Replace the burnt fuse, check the motor winding, and repair it in time if there is a short circuit;
  • Check the screw and bearing inside the air compressor, and replace them in time if they are stuck or damaged;
  • Check the amount of lubricating oil, add enough lubricating oil if it is insufficient, and adjust it to an appropriate amount if it is too much;
  • Take cooling measures when the internal temperature of the air compressor is too high.
    If the oil temperature is too high, check the oil thermometer and radiator to see if the heat dissipation is normal. If the oil thermometer fails, it needs to be replaced with a new one, and the radiator should be cleaned to make it dissipate heat better;
  • The internal bearings of the air compressor should be replaced in time if they are damaged;
  • The oil pipe should be repaired in time if it leaks or is blocked;
  • The internal pressure of the air compressor should be adjusted to an appropriate pressure if it is too low;

Causes of compressor faults in air leaks

  • Damaged or aged seal of air compressor;
  • Loose or falling screw inside air compressor;
  • Wear or damage of bearing inside air compressor;
  • Improper installation or damage of seal assembly inside the air compressor

Methods to service air compressor faults in air leaks

  • Check seal of air compressor, if damaged, replace it in time;
  • Check screw and bearing inside air compressor, if loose or falling, repair it in time;
  • Check bearing inside air compressor, if worn or damaged, replace it in time;
  • Check seal assembly installation, if improper or damaged, correct it in time

Causes of compressor faults in air production reduction

During the operation of the air compressor, the exhaust volume sometimes decreases. This may be caused by a variety of reasons.

  • First, leakage of the air valve is the most common reason.
  • Secondly, excessive wear of the piston ring, scraper ring and cylinder may also lead to a reduction in exhaust volume.
  • In addition, blockage of the air filter or leakage of the gas pipeline may also lead to a reduction in exhaust volume.
  • In addition, excessive clearance at the top dead center of the piston will also affect the exhaust volume.
  • Finally, the operating speed of the air compressor will also affect its exhaust volume.

Methods to service air compressor faults in production reduction

  • Grind and repair the air valve or replace it with a new part.
  • Replace worn piston rings, scraper rings and cylinders.
  • Clean the dust in the filter and pipeline, or replace dirty filters and pipelines.
  • Reduce the gap volume by reducing the cylinder head gasket, thereby increasing the exhaust volume.
  • If the air compressor speed is lower than the rated speed, check whether the line voltage and frequency are normal, or consider replacing the motor to increase the operating speed.

Causes of and methods to service air compressor faults in abnormal noises

  • First, if the pressure indicated by the pressure gauge is insufficient, and the pressure still does not rise or rises slowly after the engine has been running for a few minutes, and there is a strong sound of deflation when the brake pedal is pressed, then the pressure gauge may be damaged. At this time, the pressure gauge should be repaired or replaced in time.Causes of air compressor failure
  • Secondly, if the air compressor does not charge the air tank, it may be that the oil-water separator, air filter or pipeline is blocked by too much dirt. At this time, it is necessary to remove the dirt on these parts to ensure the normal operation of the air compressor.
  • If the cause of the fault is still not found after the above inspection, it is necessary to further check whether the exhaust valve of the air compressor is leaking, whether the spring is too soft or broken and whether the cylinder head has damaged gaskets. Once these problems are found, the damaged parts should be replaced or repaired in time to avoid greater faults.
  • Sometimes, the noise is too loud during the operation of the compressorthan it should be. Then it is necessary to check whether the surface of the air compressor is loose, whether the screws are tightened, and whether the bearings are damaged and the drive belt is loose. These are common causes of noise.

In addition to the common situations mentioned above, it is also necessary to pay attention to whether the cylinder liner and piston ring of the air compressor are excessively worn and whether the installation direction of the unloading valve is correct. These may cause the air compressor to make abnormal sounds and affect its normal operation.

Causes of and methods to service air compressor faults in stop

  • The inability to stop the air compressor is a dangerous problem. You need to immediately check whether the electrical system is damaged and whether the pressure switch is normal. If the electrical system is damaged, you need to check whether the control cable and relay are damaged; if the pressure switch is abnormal, replace the new switch in time.
  • The inability to stop the air compressor may also be caused by the failure of the overload protector. If the overload protector is damaged, it will not be able to detect the overload current and cut off the circuit, causing the air compressor to be unable to stop. The solution is to replace the overload protector and restart the air compressor.
  • The pressure sensor is a key component in the air compressor. When the air compressor reaches the preset pressure, the pressure sensor gives the relay a signal to make the relay pop open, thereby disconnecting the line and stopping the compressor.
    If it fails, it will not correctly detect the poor working state of the air compressor and send an error signal, causing the air compressor to be unable to stop. In this case, you should check the pressure sensor and make sure it is operating normally. If it does not work properly, it is recommended to replace the pressure sensor.
  • There is an air leak that causes the air compressor to keep working. There may bea pipe leak in the part connected to the storage tank, causing the storage tank to be unable to store gas, so that the rated pressure cannot be reached, and the pressure sensor will not take effect to stop the air compressor.
  • Another situation is when the air usage is large. When our load gas usage is too large, and the pressure stored in the air compressor is not enough for us to use, the air compressor pressure storage tank is not full of air at this time, and it will keep working without stopping.

What’s more, there are also various causes make an air compressor suddenly stop working such as sudden overload tripping of air compressors. If interested in reasons of air compressor overload tripping and how to fix it, you can check our previous page about air compressor overload tripping.

Causes of compressor faults in high air oil content

  • The exhaust temperature is too low. When the exhaust temperature is too low, the moisture and oil in the air cannot be fully separated, and finally the exhaust compressed air is mixed with oil. This situation is usually caused by insufficient cooling water or poor water flow.
  • Failure of the oil-gas separator. The oil-gas separator is a key component used in the air compressor to separate moisture and oil in the air. When the oil-gas separator fails, a large amount of oil will be mixed in the exhaust gas.
  • Too much engine oil. When the air compressor is used normally, the engine oil will be continuously sprayed into the head lubricator to protect the turbine impeller. However, if the amount of engine oil is too large, the engine oil will not be completely separated from the exhaust gas and will eventually be mixed in the exhaust compressed air.

Methods to service air compressor faults in high air oil content

  • If the exhaust temperature is too low, the main solution is to strengthen the exhaust heat dissipation. You can use a variety of methods such as increasing the exhaust temperature of the air compressor, cleaning the radiator, strengthening the cooling water circulation, and adjusting the temperature of the cooling water.
  • If the oil-gas separator fails, you first need to find out the cause of the failure, and then perform corresponding repairs or replacements. Possible causes of failure include separator wear, oil-gas separator waste and shrinkage, etc.
  • Check whether the amount of oil used is normal. Generally, the amount of oil used in the lubrication system should be stable. If the amount of oil used is too much, you need to further check whether the head lubricator is blocked, etc.

Causes of compressor faults in leaking or dripping water

Causes of compressor faults in leaking or dripping water

  • The humidity of the air in the environment is too high. After the air is compressed, it will become supersaturated, and the water in the air will precipitate and become liquid. The moisture content in the compressed air is related to the humidity of the air. For example, if the environment in the machine room is too humid due to seasonal reasons, the water content in the air will exceed the standard.
  • The compression process produces liquid water. The internal temperature of the air compressor head is very high when it is working. The moisture in the natural air inhaled will form water vapor during the operation of the air compressor. If the cooling system of the air compressor itself fails, the automatic drainer is blocked or the automatic drainer of the air tank is blocked, these moisture will be discharged with the compressed air.
  • The air tank will help the water vapor condense. The air tank can not only provide a buffer and air storage space for the compressed air, but also play a role in cooling the compressed air. When the compressed air stays in the air tank, the heat will dissipate and the temperature will drop, causing the water vapor mixed in it to liquefy and form condensed water. If it is humid weather or winter, more condensed water will be formed.

Methods to service air compressor faults in leaking or dripping water

  • Check the ambient humidity, configure the air handling system when necessary, and ensure its normal operation.
  • Check the cooling system. If the cooling system fails, it needs to be repaired or replaced in time.
  • Check the drain valve, drain, etc. If it does not work properly, it needs to be adjusted or replaced in time.
  • Install an air dryer. The air dryer can reduce the moisture content in the air, thereby reducing the possibility of water in the air compressor exhaust. (Learn more about air dryers)
  • Regularly maintain and clean the air compressor. Regularly cleaning the filter and air exchange valve can effectively prevent the air compressor exhaust from carrying water.

Method to service air compressor in all faults—air compressors maintenance

Importance of air compressor maintenance

    • In daily use, we should also pay attention to the preventive air compressor maintenance.Developing and strictly following a preventive maintenance plan has proven to be the most effective way to service your air compressor. Preventive air compressor maintenance is a proactive maintenance strategy that aims to prevent equipment failures by regularly checking, cleaning, adjusting and replacing parts.
      This includes regularly checking the oil level, oil quality and filter status of the air compressor to ensure that the air compressor operates in the best condition. In addition, for air compressors that run continuously for a long time, additional inspection and maintenance of the cooling system should also be considered to prevent overheating and damage.
    • In addition to daily maintenance, we should also pay attention to the safety management of air compressors. As a high-pressure equipment, air compressors have certain safety risks during use. Therefore, operators must receive professional training and be familiar with the structure, performance and operating procedures of air compressors to ensure that they can use the equipment correctly and safely. At the same time, enterprises should also establish a sound safety management system, clarify the safety responsibilities of personnel at all levels, and ensure the safe operation of air compressors.
    • The stability of the air compressor directly affects the efficiency and stability of the entire production line. And preventive air compressor maintenance can effectively reduce frequency of service air compressor because regular air compressor maintenancecan timely discover and solve the faults and problems of the air compressor, improve the stability of the air compressor system, and reduce the impact of equipment downtime and scrapping on production due to failures. In addition, the air compressor will naturally wear out during use.

      If it is not maintained in time, it will affect the efficiency and work quality of the equipment. Regular air compressor maintenance can ensure the good condition of the equipment, improve the equipment operation efficiency, thereby achieving the purpose of energy saving and consumption reduction, extending the service life of the air compressor, and saving the company’s maintenance and replacement costs.

Air compressor maintenance measures

  • Regularly replace various filter elements, regularly replace air filter elements, oil-gas separators and oil filters, etc. to ensure air quality and oil-gas separation effect. The oil filter must be replaced after 300-500 hours of operation for the first time, and after 2000 hours of use for the second time, and then every 2000 hours at normal time;
  • Regularly replace lubricating oil and lubricating oil filter elements to ensure the normal operation of the air compressor and extend the life of the machine. The replacement time of the compressor cooling lubricating oil depends on the use environment, humidity, dust and whether there are acidic and alkaline gases in the air. The newly purchased air compressor must be replaced with new oil after the first 500 hours of operation, and then replaced every 4000 hours according to the normal oil change cycle. Machines that run less than 4000 hours a year should be replaced once a year.
  • Clean the cooler and check the pressure gauge, clean the radiator and cooler regularly to ensure the cooling effect of the machine and prevent overheating; regularly check the pressure gauge, safety valve and pressure switch, etc. to ensure the pressure and safety performance of the air compressor.
  • Check the transmission system. Regularly check the pulleys, belts and bearings of the transmission system to ensure the transmission effect and prevent failures. The tightness of the belt must be checked every 2,000 hours of operation. If the belt is loose, it must be adjusted until the belt is tightened. In order to protect the belt, the belt must be prevented from being scrapped due to oil contamination during the entire process.
  • Check the piping system and electrical system. Regularly check all piping systems of the air compressor system to promptly detect and repair air leaks, improve air compressor efficiency and prevent more serious problems; regularly check the wiring and circuits of the electrical system to ensure electrical safety and normal operation.
  • Check the oil level. The lubricating oil level of the air compressor should be kept at a reasonable level. Too much or too little lubricating oil will affect the normal operation of the equipment and the air quality. Therefore, daily checking the oil level through the oil level mirror is an important part of the maintenance process.
  • Keep air compressor The inside of the air compressor should be kept clean to prevent dust, impurities, etc. from entering. During the cleaning process, pay special attention to the cleaning of components such as radiators and coolers to ensure the normal operation of the equipment.
  • Replace worn parts. According to the use time and failure of the machine, replace the key parts of the air compressor to ensure the normal operation of the machine and extend its life.
  • The above are the main contents of air compressor maintenance projects. Different air compressor maintenanceprojects require different techniques and tools, so it is necessary to find professional air compressor maintenance personnel to perform maintenance. Regular air compressor maintenance and repair can effectively extend the service life of the air compressor, reduce maintenance costs, and ensure the normal operation and production and energy efficiency of the air compressor.

Regular KOTECH air compressor maintenance and repair can effectively extend the service life of the air compressor

Industrial air compressor services near me

From above we introduced the 7 most common air compressor failures as well as the causes of compressor faults and how to service air compressor direct at the specific causes, and a comprehensive air compressor maintenance guide. Air compressor services and maintenance are systematic works that require to start from multiple aspects to ensure the stable and efficient operation of air compressor system.

By formulating detailed maintenance plans, strengthening preventive maintenance, improving the professional quality of operators, and strengthening safety management, we can effectively extend the service life of air compressors and improve the production efficiency and economic benefits of enterprises.

But it’s also not rare that the air compressor operators cannot accurately judge and repair the various complex failures of the air compressor. At this time, it is recommended to contact professionals in time for inspection and maintenance to ensure the normal operation of the equipment. They generally have professional equipment and methods and rich experience to detect and find the root cause of air compressor failures, and have the ability to repair more complex failures and perform more difficult maintenance operations.

KOTECH group compressor services

Many air compressor suppliers will provide these maintenance services.

Don’t know where to find excellent air compressor maintenance services near me? Let Kotech help! Kotech is trust worthy and have been providing professional industrial air compressor services for 10 years, contact us for free from below:

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