In this second part, we will still be talking about what can go wrong with air compressors.
An 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.
Inadequate Pressure at the Tool Tip
If there’s not enough pressure at the point of use, the problem is likely due to air restrictions, leaks or problems with the hose or compressor belts. The following issues are common and easy to remedy:
• Pressure blocks/leaks — Air can either get cut off or leak out at certain points along the way between the compressor and the tool. Inspect the hose or pipes for crimps or holes, then repair these problem areas by straightening the kinks or plugging the holes as needed.
• Air intake restrictions — If air is getting blocked from the intake valve, the filter is likely due for a cleaning, if not an outright replacement.
• Loose belts — When belts come loose, a retightening will usually fix the problem unless they’re too old, in which case they probably need to be replaced altogether.
• Undersized hose — You might discover that the hose is too narrow to supply the right air pressure, which would mean it’s time to upsize.
There could also be a problem with pressure at the point of use if the requirements of a tool exceed the capacity of the compressor. Before buying a new tool, check to see whether its cfm and psi requirements are within the range that your compressor can handle. Likewise, when buying a new compressor, make sure it has the capacity for every tool in your arsenal.
Extreme Stress on the Belts
When worn down excessively, there’s either a problem with the pulley or with the belts. Therefore, the solutions are relatively simple:
• Misaligned pulley — Trouble with the belts is just as likely due to the pulley as the actual belts. In cases like these, the problem can easily be solved by readjusting the motor pulley.
• Excessively tight or lose belts — Then again, it’s often just a matter of poor belt tension, in which case the belt(s) could be due for readjustment.
If the pulley or flywheel is unstable, inspect the crankshaft for any bend or signs of wear. Sometimes the problem could even be down to a nick or bump in the pulley groove, in which case the groove needs to be filed smooth.
Sluggish Buildup of Receiver Pressure
When the receiver pressure takes too long to build, the issue is most likely due to dirt accumulation or wear in any given one of the following compressor parts:
• Filthy air filter — One of the most common culprits when it comes to lagging receiver pressure is dirt buildup on the air filter, which could either need to be cleaned or replaced.
• Loose joints — Low pressure caused by air leaks can stem from joints that aren’t tight enough. Check to see if the joints need tightening.
• Loosened belts — The belts might need to be tightened or replaced.
• Worn head gasket — The cylinder head gasket could possibly be expired, in which case replacement is crucial.
• Expired valves — If the intake or discharge valve plates are torn or worn, replace them with new ones.
Alternately, slow receiver buildup could be down to insufficient compressor speed for the applications in question. When starting a first-time application, check to see if your compressor is capable of meeting the challenges at hand.
If you’re dealing with a reverse problem where the receiver pressure grows too rapidly, it’s likely caused by excess amounts of water in the receiver, which should be drained on a regular basis.
Extreme Air Heat at Discharge
If the compressed air comes out too hot, it can damage the items and surfaces being treated, as well as the tools and various internal mechanisms of the compressor. Excessive air heat often stems from the following problems:
• Dirty internal surfaces — Check to see whether dirt has built upon the cylinder, discharge tube or intercooler and clean as needed.
• Meager ventilation — If the compressor is set up in a hot or poorly ventilated area, move it someplace else where ambient air is cooler and flows more freely.
• Expired head gasket — When the head gasket blows, heat is inevitable. Therefore, it could be time to replace the head gasket.
• Run down valves — Hot compressed air is also an indicator that it’s time to replace the valve plate.
• Limited air intake — Compressed air can overheat when dust and lint accumulate on the filter. If overheating reoccur despite the above replacements, the filter probably needs to be cleaned at more frequent intervals.
Overly hot compressed air can be damaging in applications where the air itself is being applied to a given surface, such as when compressed air is used for the purpose of drying, cleaning and dusting. Thankfully, the problem is easy to remedy with inspections and maintenance of the valves, gasket, filter and internal surfaces.
Fuses Fail to Last
When compressor fuses repeatedly fail to last through their expected lifespan, it’s generally a problem with fuse size or voltage. In some cases, there could also be an issue with the unloader, valve or belts. Check for the following problems if fuse failure has been your constant burden:
• Incorrect fuse size — If a fuse doesn’t have the right ampere rating for the compressor, you could end up with a short fuse on your hands. Always check the rating when purchasing subsequent fuses.
• Low voltage — If the voltage is improper, a fuse could receive the wrong amount of power. Check the voltage requirements and raise the level accordingly.
• Faulty unloader — Constant fuse failure could be down to an unloader that’s due for replacement.
• Defective check valve — Just as with an unloader, the check valve might be expired and therefore a problem for any given fuse if not replaced.
• Overly tight belt — With constantly blown fuses, it’s sometimes a matter of belts that are too tight. Check the belt tension and loosen if needed.
A fuse shouldn’t blow on any compressor in which the mechanisms are properly aligned. Even with a verifiably correct fuse size and voltage amount, you should still perform periodic checkups on the unloader, check valve and belts to ensure that problems don’t emerge that could impact the life of a given fuse.
Recurrent Cuts in the Reset Mechanism
If the reset mechanism cuts abruptly on a frequent basis, it’s most likely an issue with the motor or the surrounding temperature.
• Overloaded motor — When the motor gets overworked, it must be shut off promptly to avoid the risk of serious damage.
• Humid surroundings — If the ambient temperature soars too high, you could need a boost in ventilation in the area that surrounds your compressor.
As with just about any piece of machinery, an air compressor has its limits in terms of the heat levels that can be withstood while performing the function of providing compressed air at reasonable temperatures.
Compressor Gets Bogged Down
When your compressor shows a tendency to work well for short durations but quickly and prematurely run out of steam, it’s often due to problems with the motor. Look for the following issues if constant bog-downs apply to your machine:
• Divided power supply — The power supply to a compressor can also be diluted by the use of a power bar. Instead of splitting the resources of an A/C outlet between a compressor and other machines, give your compressor the full, undivided power of one outlet.
• Overdrawn power circuit — An air compressor needs the undivided power of a 15-20 amp breaker at minimum. If other machines are also being powered on this same circuit, turn them off so the compressor can receive the full power source.
• Unloader valve failure — Power lags also result from failed unloader valves. This problem can be diagnosed by manually enacting the valve function. Open the tank and drain out the air and water, then close and power back up. If the compressor bogs down once again, the valve needs to be replaced.
Compressed air applications rely on a steady supply of pressure at the point of use. If your compressor fails to deliver the needed power despite running from a sufficient and undivided power source, the problem could simply be that your compressor lacks the capacity to handle the tools and applications in question.
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
