Air Compressor Troubleshooting Guide
I have created this troubleshooting guide, to help YOU with your air compressor problems. Let me guide you through troubleshooting the problem, step by step.
And I will prove you that troubleshooting air compressors isn’t hard, or expensive! You can do it too!
What this guide helps you do
- Diagnose common rotary screw compressor failures
- Identify root causes instead of swapping parts blindly
- Understand how the air, oil, and control systems interact
- Reduce downtime without vendor dependency
What's inside
This is a 146 page information-packed troubleshooting guide for oil-injected rotary screw air compressors.
There are two versions available, and a bundle:
Digital PDF version - Access to the online version, which includew a downloadable PDF for off-line viewing and printing, lifetime access and unlimited updates.
Hardcopy version - A physical printed copy of the book is send to you by mail. The hardcopy is spiral-bound and printed on high quality, oil-resistant paper.
Bundle - Best of both worlds: instant access to the online version, while a hardcopy is send to you by mail.
Note: at the moment, only the digital PDF version is available.
Why I created The Troubleshooting Guide
Many people don’t realize how important compressed air is for their factory, until their compressor breaks down.
Compressor problems can quickly result in hours (if not days) of production downtime and a loss of thousands of dollars per hour.
Even ‘small’ problems like a water or oil in the air can have tremendous consequences when they contaminate your products or ruin your machines.
Getting Help with your Compressor Problems Can Be Difficult
Not everyone has access to reliable, quick, professional support from a compressor company.
They can take hours, or even days, before visiting you… while you are stressing out over lost production hours, deadlines, angry customers, and things like that.
In other parts of the world, a good service technician is simply not available within a few hundred miles.
That's why I created this troubleshooting guide!
My guide will show you how to troubleshoot the most common air compressor problems.
The complete workings of the whole air compressor is explained. The oil system, the air system, the control system, and all the parts are explained in depth, with pictures and diagrams.
But if you don’t care about that, and just want to fix your compressor ASAP, that’s possible too! Just follow the troubleshooting flowcharts.
What's covered (detailed outline)
Introduction to oil-injected rotary screw air compressors
The guide starts with an detailed explanation these machines works. I believe it's important to really understand this if you want to to find the root-cause of your compressor problems.
(don't worry - I explain everything in easy to understand language, but without leaving anything important out).
Basic compressor knowledge
The oil-injected rotary screw air compressor
Oil-, Air- and Control-systems
Detailed troubleshooting instructions for each problem
The guide then continues with a detailed explanation of each of the most common compressor problems.
For each problem, a flowchart is included to quickly find the root cause of the problem.
Compressor Won't Start
High compressor temperature
Low pressure at point of use
Low pressure in compressor room
Oil in the compressed air
Water in the compressed air
Oil comes out of inlet valve
Compressor won't load
Compressor trips on overload/over-current
Explanation of each part in the air compressor
In this section of the book, each internal part of the air compressor is explained in detail.
For each part, I explain the function and location inside the air compressor.I explain how the part works, and the most common problems, and how to check if the part is still ok or not.
Inlet valve (unloading valve)
Compressor element (air-end)
Oil stop valve
Check valve
Oil Separator vessel
Oil separator
Scavenge line & pipe
Minimum pressure valve
Thermostatic valve
Oil filter
Oil cooler
After cooler
Condensate trap
Electrical motor & coupling
Loading solenoid
Unloading / blow off solenoid valve
Cooling fan + motor
Safety valve
Pressure sensor / switch
Temperature switch /sensor
Overload relay (thermal block)
Is this guide right for you?
This guide is for
- Maintenance technicians
- Operators responsible for uptime
- On-site engineers
- Service companies
This guide is not for
- Oil-free compressors
- Reciprocating compressors
- Vendor-specific service manuals
- Beginners looking for theory-only
What buyers say
-
I am very happy with your manual. It's great for troubleshooting any type of machine. Your manual helped me figure out what was wrong with a machine that others had given up on.
Garry, USA -
Thank you for the in depth analysis of our issue and the easy to follow step. You have a great talent for explaining in easy to follow language...thanks
Abbie, United Kingdom -
I was desperate enough to try something that will help the factory from being down for long. As a result of buying the guide, we got access to you (Cas), which basically is what helped us troubleshoot the problem. We tried what you told us in an email and it worked. Thank you! For individuals, it may be a little expensive, for us it is worth it.
Abel, USA / Ethiopia -
Very well organized and complete. All materials are well presented and the technical language is very clear. The perfection of this guide is the result of passion, competence, perseverance and hard work of site’s author.
Constantin Sandu, United Kingdom -
I downloaded it and it's awesome. I have to maintain 103nos of air compressors which includes 73nos of screw compressors (atlascopco, compair & boge brands) in our hospital medical gas systems. So I think this guideline will help me to find and rectify problems easily. Thanks again for this.
Dineesha -
I purchased a copy of your air compressor trouble shooting book. It is excellent. You have put a lot of home work into this whole program and it is of great benefit. Many thanks
Jim Bulloch, Pneutech Australia -
I am the owner of a compressor company as well and I want to COMPLIMENT YOU ON YOUR PUBLICATIONS. It helped me out on many occasions as I can not always be with my NEW YOUNG Technicians all the time and hold their hands and when they have to "FLY SOLO" . Now they have the freedom of using your Guide as learning course and making mistakes and FIXING by yourself is the only way to build confidence and gain knowledge and it also ensures NO COME BACKS due to inexperienced technicians as they have the tools to do the JOB.
Johan, Air Solutions -
I just bought you book (Hard copy and download) on rotary compressors. It is fantastic!!! I did a fast cursory read of the download, and it was great. This is the way all Tech book should be written. It is straight forward, no nonsense with great insight. I have been doing industrial millwright work for over 45 years. Great Job – I signed up for your upcoming work.
Stan Hart, S&C Electric Sacramento, CA, USA -
I didn't have any issues with our compressor... I mainly bought it as a learning guide as I am inexperienced with compressors. I looked over the book and liked the troubleshooting flow charts. I believe I will be able to use them in the future. Overall I thought the guide was good and worth the money.
Thomas, USA
FAQ
I have a ... insert make and model here - Will this guide work for my compressor?
Yes! This guide works for all oil-injected rotary screw air compressors: Atlas Copco, Ingersoll Rand, Kaeser, Compair, Chicago Pneumatic, Sullair, Quincy and many more!
All oil-injected rotary screw compressors have the same working principle, same parts and same problems. Yes, some details will vary but in general – they are all alike.
For this reason, my guide works for ALL oil-injected rotary screw air compressor.
I have two left hands - I'm really not sure I can do this?
While some parctical engineering experience is always helpful – you don’t need any special knowledge or experience with air compressors to use this guide.
The guide explains all in details and includes troubleshooting flowcharts for every part and every problem. It’s almost like I’m there holding your hand.
Will this work for my diesel- / portable air compressor?
In short: yes.
The compressor system of a diesel- /portable air compressor is 95% the same as for a stationary electric compressor. You will be able to use most of the information in this guide to fix your problem.
I want to use your guide to learn about rotary screw air compressors in general. Is it suMy guide will show you how to troubleshoot the most common air compressor problems.
The complete workings of the whole air compressor is explained. The oil system, the air system, the control system, and all the parts are explained in depth, with pictures and diagrams.
But if you don’t care about that, and just want to fix your compressor ASAP, that’s possible too! Just follow the troubleshooting flowcharts.itable for that?
Yes, very much.
Although the guide is primarily setup for troubleshooting help, it will definitely give you a full understanding of how oil-injected rotary screw compressors work.
I know at least one company who use it as training guide for their new technicians. And a few companies (compressor sales/maintenance) ordered multiple copies for their technicians.
Still unsure? Explore the troubleshooting hub or ask a specific question.