Compressed air is industry’s fourth utility and many facilities and workshops rely heavily on compressors to drive a wide range of mechanical equipment. Needless to say, when a compressor suddenly stops working, a company’s entire operation can be significantly impacted.

Knowing the costs associated with unplanned stoppage and disruptions can be prohibitive, therefore it's crucial to take immediate and appropriate action when a compressor goes offline.

Though there are several different types, air compressors share some common problems that are readily checked and repaired. Here is a list of typical problems that compressors face and the steps you can take to potentially rectify each issue.

Note: Due to the risk of damaged pressure tanks rupturing, more complex repairs should be carried out by professional technicians.

Electrical System Malfunctions

If a compressor does not immediately turn on:

1. Check if the compressor is correctly plugged or wired in.
2. Press the red or black reset button on the back of the motor housing.
3. Connect another electrical appliance to the outlet. If the other device works, the compressor has internal electrical issues that a professional should check.
4. Check if any breakers are switched to the “off” position. If so, switch them on.

If the compressor doesn’t start, or if the breakers repeatedly cut out, have a professional check the compressor in the first case or the power supply system in the second.

Excessive Air Pressure

Sometimes, when a compressor engine does not start immediately, it is because the pressure is not low enough for the engine to engage.

1. Find the stop valve (a round valve that usually has a metal ring or short chain through it)
2. Pull the stop valve out, releasing pressure.

If the engine begins after this, a slight upward adjustment on the pressure regulator should allow for consistent future starts.

Air leaks at Fittings

If tools are lacking power, it is possible the compressor has leaks.

1. Remove tools and hose.
2. Turn compressor on and give it time to charge.
3. Spray soapy water around fittings and looks for bubbles indicating an air leak.
4. Pull stop valve to release pressure.
5. Use a wrench to remove fitting/s where bubbles appeared.
6. Wrap the threads of the fittings with Teflon plumber’s tape, then refasten them in place and tighten them with the wrench.
7. Recharge the compressor again and spray again with soapy water.

If any fittings are still leaking, replace those fittings with new ones.

Air Leaks in the Tank

Tank welds can weaken over time and develop leaks. The same soapy water solution will indicate the location of any leaks along tank welds. If leaks are apparent the tank will need to be replaced. Attempts to weld the leaking seams can result in a dangerous rupture the next time the tank is used.

Oil Leaks

• If smoke or fire is visible, turn off the compressor and disconnect power immediately.
• After the engine cools, check the oil to see whether the correct oil for the motor, clean and at the correct level. It may be time to change the oil.
• Confirm the gaskets are tight.
• If gaskets are leaking oil, tighten or replace them.
• Confirm that only limited amounts of oil are being released from the air output hose. Too much leaking oil can damage attached tools.
• Make sure hoses are not damaged or blocked in any way.