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. |
| 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 |
| Rhythmic and metallic strokes | Broken bearings | Piston bearings | Contact the Service Center |
| Rhythmic and metallic strokes | Defective connecting rod | Connecting rod bearings | |
| 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) |
| Air leaks | Leaks from fittings and/or ducts | Gaskets | Change the gaskets |
| Dirty filter | Dirty/clogged air filter | Air filter | Clean/replace the intake filter |
| Belt tension | The belt slips | Belt | Check the tension of the belt and replace it if the movement is more than 1 cm |
| 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 |
| 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 |
| Belt tension | The belt slips | Belt | Check the tension of the belt and replace it if the movement is more than 1 cm |
| 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 |
| 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 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 |
| Overheating | Clogged air ducts | Air filter | Check and, if necessary, clean the air filter |
| 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 |
| Overheating | Insufficient lubrication | Lubricant | Top up or change the oil |
| Category | Cause | Component/scope | Solution |
|---|---|---|---|
| Oil consumption | Dirty/clogged air inlet | Air filter | Clean/replace the air filter |
| Oil consumption | Oil leaks | Gaskets | Tighten the bolts or replace the gasket |
| 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 |
| Oil consumption | The compressor has tilted too much | Support feet | Make the compressor stable. Fix / replace the anti-vibration feet |
| 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 |
| 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 |
| Oil in the line | Dirty/clogged air inlet | Air filter | Clean/replace the air filter |
| 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 |
| Category | Cause | Component/scope | Solution |
|---|---|---|---|
| Water leaks | Presence of dirt/debris inside the faucet | Tank | Clean the drain tap |
