Air Compressor Troubleshooting Guide, PDF, Chart And Tips

This guide aims to help you navigate common issues that may arise with your air compressor. It provides easy-to-understand solutions and recommendations to ensure your compressor functions optimally.


Remember that safety should always be your top priority when troubleshooting your air compressor. If you are unsure about any step, it is recommended to seek help from a professional.


Follow this guide to get your air compressor back up and running without any unnecessary downtime.

Air Compressor Troubleshooting



Air Compressor Troubleshooting

Air Compressor Troubleshooting Chart

94 Air Compressor Problems And Solution

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Air Compressor Not Working

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Cat Air Compressor Troubleshooting

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Chicago Pneumatic Air Compressor Troubleshooting

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Cummins Air Compressor Troubleshooting

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– – Dewalt D55140 Troubleshooting

– – Dewalt D55141 Troubleshooting

– – Dewalt D55146 Troubleshooting

– – Dewalt Cordless Air Compressor Troubleshooting

Doosan Air Compressor Troubleshooting

Elgi Air Compressor Troubleshooting

Emglo Air Compressor Troubleshooting

Fini Air Compressor Troubleshooting

Gardner Denver Air Compressor Troubleshooting

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– – Ingersoll Rand 185 Air Compressor Troubleshooting

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Air Compressor Troubleshooting Tips:

air-compressor-problems

Experiencing issues with your air compressor can be frustrating and time-consuming. However, with a good understanding of common problems and how to solve them, you can quickly get your compressor back up and running.


This guide aims to provide you with valuable information on air compressor troubleshooting, outlining the most common issues, their causes, and effective solutions.


Please remember, safety comes first; always ensure the machine is turned off and disconnected from any power source before you begin any troubleshooting procedures.


Air Compressor Troubleshooting Chart:


IssuesPossible ReasonSolution
Compressor not startingPower supply issueCheck the power supply
Noisy operationLoose partsTighten loose parts
Compressor overheatingLack of ventilationImprove ventilation flow
Air leakageDamaged sealsReplace the seals
Low pressureBlocked filtersClean or replace filters
Unstable pressureFaulty regulatorReplace the regulator
Compressor vibrates excessivelyUnbalanced compressorEnsure the compressor is balanced
Oil in compressed airWorn piston ringsReplace the piston rings
Compressor doesn’t stopPressure switch issueReplace the pressure switch
Moisture in compressed airIncorrect drainageCheck the system’s drainage
Slow to build pressureLeaks in systemCheck for leaks and seal them
Compressor trips breakerElectrical issueCheck the electrical circuits
Unusual smell from compressorOverheatingCheck for overheating and ensure proper ventilation
Compressor not producing enough airWorn out partsReplace worn out parts
Excessive oil consumptionPiston ring wearReplace the piston rings
Air output is warmLack of coolingImprove cooling system
Compressor runs but doesn’t fill tankValve issueCheck and replace valves if needed
Continuous motor rotationSwitch issueReplace the switch
Compressor shuts downOverheatingCheck for overheating and ensure proper ventilation
Unloaded compressor doesn’t stopPressure switch issueReplace the pressure switch
Compressor runs out of oil quicklyLeak in the oil systemCheck for oil leaks and fix
Rust in compressorExposed to damp environmentKeep compressor in dry place
Compressor takes longer time to startElectrical issueCheck the electrical circuits
Sludge in oilPoor maintenanceImprove maintenance schedule
Compressor blows fuseElectrical issueCheck the electrical circuits
Low compressor oil levelOil leak in systemCheck for oil leaks and fix
Unusual sound from compressorLoose partsTighten loose parts
Pressure drops quickly after start upLeaks in systemCheck for leaks and seal them
Compressor turns off suddenlyPressure switch issueReplace the pressure switch
Unstable air flow rateBlockage in lineCheck for blockages and fix them
High temperature from compressor discharge portOverheating or clogged filtersImprove cooling system, clean or replace filters
Compressor runs but doesn’t build pressureFaulty valve or regulatorCheck and replace valves/regulators if needed
Continuous on/off cycleWorn out partsReplace worn out parts
System does not reach the design pressureUndersized compressorGet a larger size compressor
Moisture carrying over in systemIncomplete condensation removalUpgrade the air drying system
Compressor runs out of oil quicklyImproper oil level settingCheck and adjust oil level to accurate setting
Compressor runs for short period of timeFaulty pressure switchReplace the pressure switch
Motor does not turn onElectrical issueCheck the electrical circuits
Excessive oil in air tankOil seal leakRepair or replace the oil seals
Compressor fails to startRestricted air intakeCheck the intake filter for blockage and clean it
Low air delivery rateBlockage in lineCheck for blockages and fix them
High pressure drops after start upTemperature sensing issueReplace temperature sensor element
Compressor stops after few minutesOverheatingCheck for overheating and ensure proper ventilation
Pressure rises to maximum very quicklyFaulty regulator settingAdjust the regulator setting to desired pressure
Motor runs but no air is delivered from systemClogged filtersClean or replace filters
Unusual noise from air-endWorn out partsReplace worn out parts
Oil consumption is highPoor maintenanceImprove maintenance schedule
Compressor trips the circuit breaker frequentlyShort circuit in wiringCheck the wiring and replace it, if needed
Moisture carryover from after coolerLeakage in air systemRepair or replace the air seals
Compressor stalls when pressure risesFaulty motor capacitorReplace the motor capacitor


Air-Compressor-Troubleshooting-Chart-infographics


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Air Compressor Troubleshooting PDF:

This PDF will serve as a comprehensive troubleshooting guide to aid in diagnosing and resolving common problems with your air compressor.


To utilize this PDF effectively, first identify the symptoms your air compressor is displaying, then locate these symptoms within the chart. Each issue will be paired with a likely cause and a recommended solution.



Air Compressor Electric Motor Troubleshooting:


1. Check Power Supply:

Ensure your air compressor is connected to a power outlet that is functional. If there are any doubts, try using another electronic device to confirm the power supply.


2. Inspect the Power Cord:

Look for any signs of damage or wear in the power cord. A faulty cord can often be the cause of a non-functioning motor.


3. Examine the Motor Capacitor:

The capacitor helps the motor start and run efficiently. If your air compressor is struggling to start, it might be due to a failing capacitor.


4. Test the Motor Windings:

Use a multimeter to check the resistance of the motor windings. If the readings fall outside the recommended range, the motor windings could be the problem.


5. Look for Overheating Signs:

If your motor is unusually hot, it could be due to overloading or inadequate ventilation. Ensure the motor has enough space for air circulation.


6. Check the Pressure Switch:

The pressure switch controls the motor operations, turning it on and off as needed. If the switch is faulty, it may cause the motor to malfunction.


7. Inspect the Belts:

If your air compressor uses belts, check for wear and tear or improper tension. Loose or worn-out belts can affect the motor’s operation.


8. Listen for Unusual Noises:

Squealing, grinding, or rattling noises can indicate problems within the motor. These might require professional attention.


9. Ensure Proper Lubrication:

Regular lubrication is essential for the smooth operation of the motor. Insufficient lubrication can cause the motor to run inefficiently or overheat.


10. Seek Professional Help:

If all the above steps do not resolve the issue, it may be best to seek professional help. They can perform a comprehensive examination and repair any complex motor problems.


Remember, your safety should always be the priority. Always disconnect the power supply before inspecting any parts of the air compressor.



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Air Compressor Not Working:

When your air compressor is not operating as expected, there are a few common issues to consider. The first step is to check the power supply – ensure that the compressor is plugged in and the circuit breaker hasn’t tripped.


If the power supply is fine, check the pressure switches – a faulty switch can prevent the compressor from maintaining the correct pressure.


Lastly, the motor could be the problem. If it’s overheated, it may need to cool down before it can operate again.


Remember, always refer to your compressor’s owner’s manual and consult with a professional if necessary.


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3 Phase Air Compressor Troubleshooting:

When troubleshooting a 3 phase air compressor, several issues could be the cause of the problem.


1. Compressor Not Starting:

Check the power supply. Ensure that the compressor is properly connected to a power source and that the circuit breaker has not tripped. If everything seems fine, the issue could be with the motor starter or pressure switch, which may need replacement.


2. Compressor Runs But Does Not Generate Enough Pressure:

This could be due to an air leak or a problem with the intake valve. Check all your connections and seals for leaks. If the intake valve is faulty, it may need to be replaced.


3. Compressor Overheating:

Overheating could result from inadequate ventilation, high ambient temperature or a clogged air filter. Ensure the compressor is well-ventilated, operate in a suitable temperature and clean the air filter regularly.


Remember, always consult with a professional if you’re unsure about performing these tasks yourself. Safety should always be your first priority.


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Air Compressor Maintenance Tips:

There are a few key maintenance tips that you should follow in order to ensure your compressor runs effectively and efficiently.


1. Check the oil level regularly:

Just like a car, an air compressor requires oil to run smoothly. Ensure the oil level is adequate, and top up if necessary.


2. Clean the air filter:

A clogged air filter can lead to compressor inefficiency. Clean or replace the filter if it becomes dirty or damaged.


1. Inspect the hoses:

Regularly check your compressor hoses for any signs of wear or damage. Replace them immediately if you spot any issues.


4. Drain moisture from the tanks:

Compressed air can produce condensation. Make sure to drain the tanks regularly to prevent rusting.


5. Clean the fuel tank:

For oil-based compressors, clean the fuel tank at least once a year to prevent build up of sediment and sludge.


6. Tighten all fasteners:

The compressor’s operation can loosen screws over time. Always ensure all fasteners are tight.


7. Check for leaks:

Regularly inspect the compressor for any signs of leaks, as they can lead to energy waste.


8. Keep the compressor clean:

Dust and grime can affect the compressor’s performance. Regular cleaning is essential.


9. Check the safety shutdown system:

Most compressors have a safety feature that shuts down the operation when the engine’s temperature is too high. Regularly test this feature to ensure it works correctly.


10. Regular professional maintenance:

Despite personal care, professional maintenance is essential at least once a year to ensure optimal operation of your air compressor.


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Air Compressor Reed Valve Troubleshooting:

When troubleshooting the reed valve of an air compressor, it is important to first understand its function. The reed valve controls the flow of air into the compression cylinder, and a malfunctioning reed valve could lead to inefficient operation or even damage to the compressor.


To identify if the reed valve is causing issues, look for symptoms like low pressure, excessive noise or vibrations, or a compressor that won’t start.


It’s critical to disconnect the air compressor from its power source before inspecting the reed valve to ensure safety. If the reed valve appears damaged or worn out, it should be replaced.


Step 1: Gather Necessary Tools

To effectively troubleshoot and potentially replace the reed valve, you’ll need a set of wrenches, a screwdriver, and a new reed valve kit. Ensure to have these tools on hand to streamline the process.


Step 2: Access the Reed Valve

Remove the top of the compressor head using your wrench and screwdriver. This will expose the reed valve for inspection.


Step 3: Inspect the Reed Valve

Examine the reed valve carefully. Look for any signs of wear, tear, or damage. If the reed appears bent, cracked, or broken, it will need to be replaced.


Step 4: Remove the Damaged Reed Valve

Using your wrench, carefully remove the damaged reed valve from the compressor. Be sure to keep track of any small parts or screws.


Step 5: Clean the Valve Seat

Before installing the new reed valve, clean the valve seat thoroughly to ensure a good seal.


Step 6: Install the New Reed Valve

Align the new reed valve with the valve seat and secure it using your wrench. Make sure it’s tight but be careful not to overtighten it.


Step 7: Reassemble the Compressor Head

Once the new reed valve is installed, put the compressor head back together and secure it with screws.


Step 8: Reconnect the Power

Only after the compressor is fully reassembled, reconnect the power source.


Step 9: Test the Compressor

Turn on the compressor and allow it to build pressure. Check for any abnormal noises or vibrations.


Step 10: Monitor its Performance

Over the next couple of days, keep a close eye on the compressor’s performance. If the symptoms persist, further troubleshooting may be required.



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