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Air Compressor Down? Quick Diagnosis in 5 Minutes! 10 Common Fault Causes + Emergency Solutions

2025-07-22

Air compressors (especially screw air compressors) play a crucial role in industrial production, but sudden failure to start can disrupt production schedules. As a professional brand of air compressor manufacturers, we have compiled common fault causes and quick solutions to help you efficiently troubleshoot problems and minimize downtime.  


I. Power Supply and Electrical System Issues  

1. Abnormal Power Supply (Unstable Voltage/Power Outage)  

- Possible causes: Power not connected, circuit breaker tripped, voltage too high or too low (exceeding ±10% of rated voltage).  

- Solutions:  

 ✅ Check if distribution box switches and fuses are functioning properly.  

 ✅ Use a multimeter to measure voltage and ensure it meets the compressor’s rated requirements (e.g., 380V three-phase power).  


2. Motor Failure (Burned Windings/Seized Bearings)  

- Possible causes: Long-term overload operation of the screw air compressor, phase loss, or insufficient lubrication leading to motor damage.  

- Solutions:  

 ✅ Check for seizing; if the motor cannot rotate, replace bearings or the motor.  

 ✅ Use a megohmmeter to test winding insulation resistance. If below 0.5MΩ, repair or replace the motor.  


3. Contactor/Relay Malfunction  

- Possible causes: Oxidized contacts or burned coils preventing circuit connection in the screw air compressor.  

- Solutions:  

 ✅ Test the contactor’s engagement status; clean or replace damaged components.  


II. Triggered Control System and Protection Devices  

1. Pressure Switch or Sensor Failure  

- Possible causes: Incorrect settings on the screw air compressor or poor contact of contacts.  

- Solutions:  

 ✅ Short-circuit the pressure switch for testing; if the compressor starts, replace the switch.  


2. PLC/Controller Alarm  

- Possible causes: Program errors, abnormal sensor signals (e.g., excessive temperature or pressure).  

- Solutions:  

 ✅ Check fault codes on the control panel, reset, and restart.  


3. Thermal Relay/Overload Protection  

- Possible causes: Motor overload operation of the screw air compressor, triggering thermal relay tripping.  

- Solutions:  

 ✅ Reset the thermal relay and check mechanical loads (e.g., whether belts are too tight).  


III. Mechanical Failures (Common in Screw Air Compressors)  

1. Host Seizure (Insufficient Lubrication/Foreign Object Ingress)  

- Possible causes: Insufficient lubricating oil, oil deterioration, or bearing damage.  

- Solutions:  

 ✅ Check oil level and quality; replace lubricating oil if necessary.  

 ✅ Manually rotate the pulley; if it cannot turn, disassemble and inspect the host.  


2. Belt Breakage or Slippage (Belt-Driven Models)  

- Possible causes: Belt aging or insufficient tension.  

- Solutions:  

 ✅ Replace with a new belt and adjust tension to an appropriate level.  


3. Intake Valve Failure (Inability to Close)  

- Possible causes: Stuck valve core or air leakage from the control cylinder.  

- Solutions:  

 ✅ Disassemble, clean, or replace the intake valve assembly.  


IV. Environmental and Maintenance Issues  

1. Overheating Protection (Poor Heat Dissipation)  

- Possible causes: Cooling fan failure, blocked radiator, or degraded lubricating oil.  

- Solutions:  

 ✅ Clean the radiator, check fan operation, and replace with qualified lubricating oil.  


2. Oil Path Blockage or Oil Filter Failure  

- Possible causes: Long-term failure to replace the oil filter, resulting in poor oil supply.  

- Solutions:  

 ✅ Regularly replace the oil filter element (recommended every 2000 hours).  


Quick Troubleshooting Steps (Locate Issues in 5 Minutes)  

1. Check power supply → 2. Check alarms → 3. Test motor → 4. Check lubrication → 5. Check mechanics  



Choose a reliable brand of air compressor manufacturers to reduce failure rates!  

High-quality screw air compressors should be equipped with intelligent protection systems to minimize downtime caused by voltage fluctuations, phase loss, high temperatures, etc. Regular maintenance (e.g., replacing filters and lubricating oil) can significantly extend equipment lifespan.  


For professional technical support, please contact regular air compressor manufacturers to obtain original parts and repair services!

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