The Most Common Compressor Problems And How to Prevent Them

portableGreg Aiken
The Most Common Compressor Problems And How to Prevent Them

The Most Common Compressor Issues (and How to Prevent Them)

Whether you’re running a portable unit on a jobsite or managing a rotary screw compressor in a plant, some problems show up again and again. The good news? Most of them are preventable with the right plan, the right parts, and a little bit of consistency.

Here’s a breakdown of the most common compressor issues we see and how you can stay ahead of each one.

1. Overheating

Running hot is one of the fastest ways to shorten a compressor’s life. It’s usually caused by dirty coolers, low oil levels, restricted airflow, or overdue maintenance.

Prevention: Stick to your service schedule, monitor oil levels, and make sure your cooling system is clean. 

2. Oil Carryover

Excess oil in your compressed air can damage tools, contaminate product lines, and increase downstream maintenance. It often means your separator element is worn or your oil return line isn’t functioning properly.

Prevention: Replace separators on time and check oil levels regularly. If you’re unsure, our oil analysis kits can tell you what’s going on inside.

3. Pressure Drop or Slow Build

If your compressor is struggling to hit its pressure target, it could be due to clogged filters, bad valves, leaks, or internal wear.

Prevention: Replace filters regularly and inspect for leaks. If your compressor is older, it may be time to plan for an airend rebuild or full overhaul.

4. Excessive Noise or Vibration

Unusual sounds or shaking often mean there’s a mechanical issue, like a failing bearing, loose belt, or rotor imbalance. Ignoring it can lead to catastrophic failure.

Prevention: Don’t wait for the noise to get worse. If something sounds off, shut it down and inspect immediately. Schedule service if needed.

5. Frequent Shutdowns or Alarms

Recurring shutdowns can be caused by thermal overload, low oil, clogged filters, or faulty sensors. It’s your compressor’s way of saying, “Please help.”

Prevention: Track your shutdown codes, don’t override alarms, and make sure your maintenance intervals aren’t being skipped. The ACS app (also on Google Play) can help you manage it all.

Get Ahead of the Usual Suspects

Most compressor problems don’t come out of nowhere. They build up slowly and then show up when it’s least convenient. If you’re ready to stop reacting and start preventing, we’ve got the tools to help: