Sauer Compressor Troubleshooting Guide

As someone who has worked with Sauer Air Compressors for several years, I understand how crucial it is to get your system back up and running when troubles arise.

Whether your compressor isn’t building up pressure, it’s overheating, or making unusual noises, each problem has its own set of potential causes and solutions.

In this guide, I will provide you with a step-by-step process for troubleshooting your Sauer Air Compressor, drawing from my first-hand experience and professional expertise to help you diagnose and resolve common air compressor issues effectively and efficiently.

Sauer Compressor Troubleshooting

Sauer Compressor Troubleshooting:

Table Of Contents
  1. Sauer Compressor Troubleshooting:

When encountering issues with your Sauer Air Compressor, first ensure the power supply is stable and the unit is securely connected.

Check for evident signs of wear or damage. If the compressor fails to start, the problem could be with the motor or pressure switch.

For overheating issues, inspect the air filters, and if clogged, replace them promptly. Always remember, routine maintenance is key to optimal performance.

20 Common Sauer Air Compressor Problems And Solutions:

1. Overheating:

This can result from insufficient ventilation, extreme ambient temperatures, or a blocked air filter. Regular maintenance can help prevent this issue.

2. Oil Leaks:

Loose pipework or seals can lead to oil leaks. Regular inspections can help identify leaks early.

3. Excessive Noise:

Worn bearings, loose parts, or an incorrectly adjusted pressure switch can cause excessive noise. Proper alignment and tightening can mitigate this problem.

4. Decreased Air Output:

A clogged air filter, worn out belts, or a faulty valve can lead to decreased air output. Routine checks and replacements can help maintain optimal performance.

5. Motor Failure:

This can be caused by electrical issues or overheating. Regular inspections can help detect potential problems before they lead to motor failure.

6. Pressure Issues:

A faulty pressure switch or valve can cause pressure problems. These components should be checked regularly and replaced as needed.

7. Unloader Valve Problems:

A sticky unloader valve can cause the compressor to run continuously. Cleaning the valve regularly can prevent this issue.

8. Worn Belts:

Belts can wear out over time. Regular inspections and replacements can help ensure proper operation.

9. Electrical Issues:

Faulty wiring can lead to electrical problems. Regular inspections by a qualified electrician can prevent potential hazards.

10. Vibration Issues:

Loose parts can cause excessive vibration. Periodic checks can help identify and rectify this issue.

11. Inefficient Operation:

Dirty condensers can reduce the efficiency of the air compressor. Regular cleaning can help maintain optimal performance.

12. Start-up Problems:

These can result from electrical issues or motor problems. Proper maintenance can help prevent start-up issues.

13. Excessive Power Consumption:

This can be caused by inefficient operation or faulty components. Regular checks can help identify potential problems early.

14. Compressor Surging:

This can be due to dirty filters or pipes. Regular maintenance can help prevent this issue.

15. Air Dryer Failure:

Air dryer failure can cause moisture in the system. Regular inspections and maintenance can prevent this issue.

16. Leaking Air Compressors:

Worn seals or loose connections can cause leaks. Routine checks can detect leaks early.

17. Compressor Siezing:

Dirty or insufficient oil can lead to compressor seizing. Regular oil changes can prevent this problem.

18. System Blockage:

A blocked filter or pipe can cause system blockage. Regular cleaning can help maintain system performance.

19. Undersized Equipment:

If the compressor is not the right size for the task, it can lead to problems. Choosing the right equipment for the job is essential.

20. Improper Installation:

If the compressor isn’t installed correctly, it can lead to a multitude of problems. Ensure the compressor is installed by a trained professional.

Benefits Of Troubleshooting Sauer Air Compressor:

Troubleshooting a Sauer air compressor has several benefits. Firstly, it helps maintain the operational efficiency of the compressor, ensuring that it performs at its optimum capacity.

Secondly, regular troubleshooting can identify minor issues before they escalate into major problems, saving on potential repair costs.

Thirdly, it extends the lifespan of the compressor, protecting your investment in the long run. Lastly, it ensures safety by preventing malfunctions that could lead to accidents.

Hence, troubleshooting is an essential practice for the proper and safe functioning of a Sauer air compressor.

Maintenance Tips For Your Sauer Air Compressor:

1. Regular Inspection:

Inspect your Sauer air compressor frequently for any visible signs of wear and tear. This includes checking for oil leaks, loose fittings, or abnormal noises that may indicate a problem.

2. Change the Oil Regularly:

Depending on the model of your compressor, you may need to change the oil after a certain period or usage. Always refer to your owner’s manual for specific guidelines.

3. Check Air Filters:

Dirty or clogged air filters can reduce the efficiency of your compressor. Make sure to clean or replace air filters as recommended by the manufacturer.

4. Drain Moisture from Tanks:

Water can accumulate in the compressor’s tanks over time. To prevent rust and corrosion, it’s important to drain this water regularly.

5. Inspect Belts:

Check the belts for any signs of wear and replace them as necessary to keep your compressor running smoothly.

Remember, regular maintenance not only improves the performance and longevity of your Sauer air compressor but also reduces the likelihood of unexpected breakdowns.

How Do I Reset My Sauer Compressor?

Resetting your Sauer air compressor is a straightforward process. However, the exact steps may vary depending on the model of your compressor. Generally, you will follow these steps:

1. Turn off your compressor:

Before resetting, ensure that your compressor is turned off and disconnected from the power supply to ensure your safety.

2. Locate the reset button:

The reset button is typically red and located on the motor housing or the pressure switch of the compressor. Refer to your compressor’s manual if you’re having trouble locating it.

3. Press the reset button:

Once you have located the reset button, press it. You should feel a click as the button resets.

4. Reconnect the power:

After resetting the compressor, reconnect it to the power supply.

5. Restart the compressor:

Turn on the compressor. It should now start and function normally.

If your compressor doesn’t start or continues to function abnormally after resetting, consider seeking professional help.

Remember, regularly maintaining your compressor can prevent the need for resets and ensure its optimal operation.

How Do I Know If My Sauer Air Compressor Is Bad?

Identifying issues with your Sauer air compressor is crucial for maintaining its functionality. Several signs may indicate a problem with your compressor:

1. Reduced Air Pressure:

If your compressor is not delivering the same amount of air pressure as before, it could signal a problem. This could be due to a variety of reasons, such as leaks in the system or a worn-out piston ring.

2. Excessive Noise:

While all compressors make noise, excessively loud or abnormal sounds can indicate an issue. These noises could be caused by loose parts, motor failure, or other internal problems.

3. Overheating:

If your compressor is running hotter than usual, it might be a sign of a malfunctioning cooling system, inadequate ventilation, or other operational concerns.

4. Oil Leaks:

Oil leakage is a clear indication of a problem. It may be due to worn seals or broken parts within the compressor.

5. Poor Performance:

If the compressor is unable to power your pneumatic tools as effectively as it once did, it could be a sign of a failing compressor.

6. Frequent Resets Needed:

If you find yourself constantly needing to reset your compressor, this could indicate an underlying issue with the motor or pressure switch.

Remember, any changes in your compressor’s normal operation should be investigated. If you notice any of these signs, consider seeking professional assistance to diagnose and repair the problem.

Regular maintenance and inspections can help catch issues early and keep your Sauer air compressor running efficiently.

What Would Cause An Sauer Air Compressor To Not Build Pressure?

Several factors can cause a Sauer air compressor to fail in building pressure effectively. Here are some of the common causes:

1. Leaky Pipes and Fittings: If there are leaks in the pipes or fittings, air can escape causing a reduction in pressure. Regular inspection can help identify and fix any leaks.

2. Faulty Pressure Switch: The pressure switch is responsible for controlling the motor’s operation and maintaining the tank’s pressure. If it’s faulty, the compressor may fail to generate the required pressure.

3. Worn-out Piston Rings: Over time, the piston rings can wear out and cause pressure issues. If the rings are worn, they will need replacing.

4. Clogged Air Filter: A dirty or clogged air filter can impede the flow of air, leading to a drop in pressure. Regular cleaning or replacement of the filter can ensure the compressor builds pressure effectively.

5. Valve Failure: If the intake or discharge valves are damaged or broken, the compressor will not build pressure. If this is the case, the faulty valves need to be replaced.

If your compressor is failing to build pressure, it’s recommended to have it checked by a professional to diagnose and fix the issue.

Regular maintenance and inspections can help prevent such problems and ensure the efficient operation of your Sauer air compressor.

Sauer Air Compressor Won’t Start:

If your Sauer air compressor won’t start, there are several potential causes:

Electrical Issues:

Electrical problems are a common reason for compressors not starting. Check if your compressor is properly connected to the power supply and that there are no issues with the power source itself. If your compressor uses a cord, ensure it’s not damaged or frayed.

Faulty Pressure Switch:

A pressure switch that is not working correctly can prevent the compressor from starting. If the pressure switch is set too high, the compressor might not kick on because it believes the tank is already filled with the desired pressure.

Motor Problems:

Issues with the motor can prevent your compressor from starting. If the motor is overheating or has a defective capacitor, it may refuse to start.

Dirty or Clogged Air Filters:

Dirty or clogged air filters can cause your compressor to struggle on startup. Regular cleaning or replacement of the air filter can resolve this issue.

Starting Capacitor:

The starting capacitor gives the motor the initial boost it needs to start. If it’s faulty, the compressor won’t start.

If you’ve checked all these potential issues and your compressor still won’t start, it’s recommended to seek professional help.

Regular preventative maintenance can help catch issues before they become serious, keeping your Sauer air compressor running smoothly.

Sauer Air Compressor Not Building Pressure:

If your Sauer air compressor isn’t building up enough pressure, a few potential issues could be at fault:

Damaged Seals:

The seals in the compressor unit ensure that air remains contained within the system. If these seals are damaged, they could be causing leaks which result in a loss of pressure.

Faulty Pressure Relief Valves:

The pressure relief valves are designed to release excess pressure from the system to prevent it from becoming overpressurised. If these valves are faulty, they may be releasing air prematurely and preventing the system from building up the necessary pressure.

Blocked Air Intake:

If the air intake is blocked or dirty, the compressor may struggle to pull in enough air to create pressure. Regularly cleaning or replacing the air intake filter can help to resolve this issue.

Worn Out Compressor Pump:

Over time, the compressor pump can wear out, leading to reduced efficiency and a loss of pressure. In this case, the compressor pump would need to be replaced to restore the compressor’s performance.

Remember, regular maintenance and troubleshooting can help to identify potential issues before they become significant problems.

Always consult with a professional if you’re unsure about how to solve an issue with your Sauer air compressor.

Sauer Air Compressor Reset Button:

The reset button on a Sauer air compressor is a crucial component that helps protect the compressor from potential damage.

It is designed to automatically trigger when the compressor motor undergoes undue strain or overheats, effectively shutting off the system to prevent further harm.

To restore the compressor’s operation, the reset button must be manually pressed. The location of this button can vary depending on the model of the compressor but is typically found near the pressure switch or motor housing.

Always ensure the cause of the motor’s strain or overheating is identified and resolved before pressing the reset button to prevent causing further damage.

If the reset button continues to trip frequently, it can be a sign of a more serious issue and professional assistance should be sought.

Sauer Air Compressor Won’t Turn On:

If your Sauer air compressor won’t turn on, it may be due to several reasons:

Faulty Power Supply:

Ensure that the compressor is properly connected to a functioning power source. Check to see if there are any blown fuses or tripped circuit breakers. It’s also advisable to confirm that any extension cords used are in good condition and capable of handling the power needs of the compressor.

Overloaded Motor:

If the motor in your Sauer compressor is overloaded, it may refuse to start. This can be caused by a dirty air filter, a faulty capacitor, or if the compressor has recently been in heavy use and hasn’t had sufficient time to cool down.

Faulty On/Off Switch:

If the compressor’s on/off switch is faulty or not working properly, it may prevent the compressor from starting. Ensure that the switch is in good working condition and replace it if necessary.

If all these aspects are in order and your compressor still won’t turn on, it is recommended to seek professional assistance.

Regular maintenance can help prevent such issues and ensure the smooth operation of your Sauer air compressor.

Sauer Air Compressor Check Valve Problem:

The check valve in a Sauer air compressor plays a crucial role in maintaining the desired pressure and ensuring the smooth direction of air flow. If the check valve is faulty, it can lead to several issues:

Backflow of Air:

A faulty check valve may allow air to flow back into the pump, which can cause a pressure drop in the tank and interfere with the compressor’s operation.

Difficulty in Starting:

The compressor might face difficulty in starting if the check valve allows air to flow back into the pump when the compressor is off. This can create a backpressure against the pump, impeding the startup.

Unusual Noises:

If the check valve is not functioning correctly, it can cause unusual noises, such as a hissing sound, indicating that air is leaking out. If you encounter these issues, it’s advisable to inspect the check valve and replace it if necessary.

Always remember to seek professional assistance if you are unsure about any aspect of the check valve’s operation or replacement.

Regular maintenance checks can help prevent such issues and keep your Sauer air compressor running efficiently.

Sauer Air Compressor Cleaning Tips:

Keeping your Sauer Air Compressor clean enhances its efficiency and longevity. Here are a few tips:

• Exterior Cleaning:

Wipe the exterior of the compressor regularly with a damp cloth to remove dust and dirt. Avoid using harsh chemicals that could potentially damage the compressor’s casing.

• Air Filter Cleaning:

Clean the air filter frequently to ensure optimal airflow. If it’s extremely dirty or worn out, consider replacing it.

• Ventilation Slots Cleaning:

Dust and dirt often accumulate in the ventilation slots of the compressor. Use a soft brush or compressed air to clean these areas.

• Condenser Coils Cleaning:

Dirty condenser coils can result in overheating. Regularly clean these coils with a coil cleaner and brush.

• Drain the Tank:

Moisture can accumulate in the compressor tank, leading to rust and other issues. Drain the tank regularly to remove this moisture.

Remember, regular cleaning is a part of preventative maintenance that can help catch potential issues before they turn into larger problems. Always consult with a professional if you’re unsure about the cleaning process.

Sauer Air Compressor Lubrication Tips:

Proper lubrication is essential for the smooth functioning and longevity of your Sauer air compressor. Here are some lubrication tips:

Choose the Right Oil:

Ensure that you use the appropriate oil for your Sauer compressor. Always refer to your compressor’s manual to know the specific type and viscosity of oil recommended by the manufacturer.

Regular Oil Changes:

Just like your car, your air compressor needs regular oil changes. The frequency of oil changes depends on the usage and model of your compressor, but a good rule of thumb is to change the oil every 500-1000 operating hours.

Check Oil Levels:

Regularly check the oil level in your compressor. An oil level that is too low can lead to increased wear and tear, while an oil level that is too high could result in oil being blown out of the compressor.

Use a Filter:

An oil filter can help increase the lifespan of your compressor by removing impurities from the oil that could potentially cause damage over time.

Avoid Over Lubrication:

While lubrication is important, overdoing it can lead to its own set of problems, such as increased operating temperatures and energy consumption.

Remember, regular maintenance and proper lubrication can significantly extend the life of your Sauer air compressor. If you’re unsure about any aspect of the lubrication process, always consult with a professional.

Storing Your Sauer Air Compressor:

Proper storage of your Sauer air compressor is key to its longevity and optimal performance. Follow these guidelines when you are not using your compressor for a while:


Choose a dry, clean, and well-ventilated area for storage. Extreme temperatures and humidity can cause damage to your compressor.

Drain the Tank:

Before storing, drain any remaining air and moisture from the tank to prevent rusting.

Clean the Compressor:

Ensure that the compressor is clean and free from dust and dirt before storage. Cover: Use a protective cover to keep the compressor free from dust accumulation and damage during storage.

Periodic Starts:

Periodically run the compressor for a few minutes to prevent mechanical parts from seizing due to inactivity.

By following these steps, you can prolong the lifespan and maintain the functionality of your Sauer air compressor during periods of non-use.

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