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Air Compressor Troubleshooting Guide

The compressor doesn't start? Is the compressor making a strange noise? Is the compressor leaking air or water? Here's how to solve the most frequent problems.

Air compressor troubleshooting guide

Troubleshooting Compressor Performance Issues

The Compressor's Handbook: Identifying and Solving Common Issues

When your compressor stops working, it can bring your operations to a halt. Understanding the root cause is crucial to getting back on track. This guide will walk you through the common issues that may arise with your compressor, from power supply problems to internal mechanical failures. We'll provide you with practical steps to diagnose the problem and actionable solutions to fix it, ensuring minimal downtime and restoring your compressor's functionality. Whether you're facing a minor hiccup or a major breakdown, this guide aims to equip you with the knowledge and tools to tackle compressor challenges head-on.

 Category  Cause Component/scope  Solution
Starting up issue Environmental ambient operating temperature temperature too low Installation (external factor) Improves environmental conditions
Starting up issue
No electricity supply Electrical network/assembly booth

Check the electrical panel. Turn on and off via the pressure switch.

▶▶Watch video◀◀

Starting up issue Insufficient voltage Voltage Check that the voltage corresponds to that shown on the rating plate. Delete any extensions.
Starting up issue Cables not connected correctly Cables Check that the cables are well connected
Starting up issue Faulty solenoid valve Solenoid valve Contact the Service Center to change the solenoid valve
Starting up issue Contact interruption of the pressure switch Pressure switch Contact the Service Center to check and, if necessary, replace the pressure switch
Starting up issue The pressure switch is defective Pressure switch

Contact the Service Center to change the pressure switch
Starting up issue Insufficient/poor quality lubrication Lubrication

Check the oil level. Top up/change it using original ABAC oil.

▶▶Watch video◀◀

 Category  Cause Component/scope  Solution
Abnormal interruption The motor thermal protection activates Thermal protection Check that there are no extension cords. Reset the engine and restart. Contact the Service Center
Abnormal interruption The power goes out Switch - electric motor

Check that the size of the electric motor is supported by your panel.

▶▶Watch video◀◀

Abnormal interruption Electrical fault Electrical parts Contact the Service Center

 Category  Cause Component/scope  Solution
Noise Loose pulley, flywheel, belt, belt guard, cooler, clamps or accessories Mechanical parts Tighten any loose terminations
Noise There is no lubricant in the crankcase Lubricant 

Check the bearings for damage and top up the lubricant

▶▶Watch video◀◀

Noise The piston hits the valve plate Piston Remove the cylinder head. Check the top of the piston. Replace the cylinder gasket and reassemble the head. Do you need help? Contact the Service Center
Vibration The support feet are not stable Support feet Make the compressor stable and tighten the bolts. Change the anti-vibration feet and/or wheels if necessary
Vibration Pulley and flywheel are not aligned Flywheel  Contact the Service Center
Vibration The belt has come loose Belt

Tighten/replace belt

▶▶Watch video◀◀

Rhythmic and metallic strokes Broken bearings Piston bearings Contact the Service Center
Rhythmic and metallic strokes Defective connecting rod Connecting rod bearings

Contact the Service Center

Rhythmic and metallic strokes Flywheel loose Flywheel  Contact the Service Center
Rhythmic and metallic strokes Defective piston pin Piston Contact the Service Center
Rhythmic and metallic strokes Loose connecting rod Connecting rod Contact the Service Center
Hum Condensatore/fusibili guasti Motor Contact the Service Center

 Category  Cause Component/scope  Solution
Air leaks Leaks/fault in valve plate Valve plate

Change the valve plate (and gaskets)

▶▶Watch video◀◀

Air leaks Leaks from fittings and/or ducts Gaskets

Change the gaskets

▶▶Watch video◀◀

Dirty filter Dirty/clogged air filter Air filter

Clean/replace the intake filter

▶▶Watch video◀◀

Belt tension The belt slips Belt

Check the tension of the belt and replace it if the movement is more than 1 cm

▶▶Watch video◀◀

Air leaks Air leaks in the fittings Fittings Tighten the fittings. If the problem persists, contact the Service Center
Water in the tank Too much water in the tank Tank

Empty the tank daily

▶▶Watch video◀◀

 Category  Cause Component/scope  Solution
Air leaks Rilsan tube damaged or not inserted correctly Rilsan tube Check the connections and/or replace the rilsan tube
Reduced air entry Dirty or clogged air filter Air filter

Clean/replace the intake filter

▶▶Watch video◀◀

Belt tension The belt slips Belt

Check the tension of the belt and replace it if the movement is more than 1 cm

▶▶Watch video◀◀

Dimensions Service hose too narrow Hose Replace it with a wider tube
Air demand The demand for air exceeds the capacity of the compressor Usage Connect fewer air tools to the compressor or use tools that require less air. Alternatively, upgrade to a more powerful compressor

 Category  Cause Component/scope  Solution
Air leaks Poor sealing of the check valve internals Check valve interior

Replace internal cap and spring

▶▶Watch video◀◀

 Category  Cause Component/scope  Solution
Air leaks The pressure switch valve is leaking air Pressure switch valve Replace the pressure switch
Air leaks Rilsan tube not inserted correctly into the pressure switch Pressure switch Insert the rilsan tube correctly into the pressure switch

 Category  Cause Component/scope  Solution
Air leaks Defective valve plate/ reeds/intake valve Valve plate/intake valve

Replace the valve plate

▶▶Watch video◀◀

or overhaul the intake valve

 Category  Cause Component/scope  Solution
Overheating Insufficient ventilation/wall too close Installation (external factor)

Improve environmental conditions / Place the compressor at least 50 cm away from the wall

▶▶Watch video◀◀

Overheating Clogged air ducts Air filter

Check and, if necessary, clean the air filter

▶▶Watch video◀◀

Overheating Dirty cooling surfaces Cooling down Clean the cylinder cooling surfaces, intercooler and exhaust pipe
Overheating Blown head gasket Blown head gasket Replace the head gasket. If you need help, contact the Service Center
Overheating Worn valves Valve plate

Replace the valve plate

▶▶Watch video◀◀

Overheating Insufficient lubrication Lubricant

Top up or change the oil

▶▶Watch video◀◀

 Category  Cause Component/scope  Solution
Oil consumption Dirty/clogged air inlet Air filter

Clean/replace the air filter

▶▶Watch video◀◀

Oil consumption Oil leaks Gaskets

Tighten the bolts or replace the gasket

Contact the Service Center if you need help.

Oil consumption Worn piston rings Piston rings Replace the rings. Contact the Service Center if you need help.
Oil consumption Unsuitable oil Oil

Change the oil, replacing it with the original one

▶▶Watch video◀◀

Oil consumption The compressor has tilted too much Support feet

Make the compressor stable. Fix / replace the anti-vibration feet

▶▶Watch video◀◀

Oil consumption Scratched cylinder Cylinder Contact the Service Center to replace the cylinder

 Category  Cause Component/scope  Solution
Oil in the line Too much oil in the pumping unit Oil

Check the oil level

▶▶Watch video◀◀

Oil in the line
Worn piston rings Piston Contact the Service Center
Oil in the line
Unsuitable oil Oil

Change the oil, replacing it with the original one

▶▶Watch video◀◀

Oil in the line Dirty/clogged air inlet Air filter

Clean/replace the air filter

▶▶Watch video◀◀

 Category  Cause Component/scope  Solution
Water leaks Water in the carter Carter

It improves environmental conditions, so that the air sucked in by the compressor is less filled with humidity

▶▶Watch video◀◀

 Category  Cause Component/scope  Solution
Water leaks Presence of dirt/debris inside the faucet Tank

Clean the drain tap

▶▶Watch video◀◀

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