Troubleshooting & Emergency Handling for Air Compressors: QuanWei’s Practical Guidelines
January 08, 2026
Air compressors, as core industrial equipment, are prone to occasional faults due to long-term high-load operation, harsh working environments, or improper operation. Sudden failures not only disrupt normal production but also increase maintenance costs if handled improperly. Mastering basic troubleshooting methods and emergency response skills is crucial for minimizing downtime. Based on years of on-site service experience and fault data accumulation, QuanWei Machinery summarizes practical guidelines for common air compressor faults, helping factory operators resolve issues efficiently.
1. Fault: Abnormal Noise During Operation
Abnormal noise (such as knocking, squealing, or rattling) is a typical early warning signal of air compressor faults. Common causes include loose internal components, worn bearings, or improper rotor meshing. QuanWei’s on-site fault statistics show that over 60% of noise faults are related to component wear or loosening.
Emergency handling: First, stop the machine immediately to avoid further damage. Check for loose fasteners (such as bolts and nuts) and tighten them if necessary. If the noise persists, it may indicate worn bearings or rotor issues—replace the damaged parts with QuanWei’s original matching components promptly. QuanWei’s original parts are designed to fit perfectly with its compressors, effectively eliminating noise caused by mismatched components and ensuring stable operation.
2. Fault: Insufficient Air Supply/Pressure Drop
Insufficient air supply or sudden pressure drop directly affects production progress. The main causes include clogged air filters, pipeline leaks, or inefficient frequency conversion control. According to QuanWei’s fault diagnosis data, clogged filters and pipeline leaks account for 70% of such faults in industrial scenarios.
Emergency handling: Clean or replace the air filter first—using QuanWei’s high-efficiency precision filter elements can reduce clogging frequency and maintain stable air intake. Then, check for pipeline leaks (apply soapy water to joints to identify bubble points). For minor leaks, repair them promptly; for severe leaks, use QuanWei’s dedicated pipeline repair accessories for quick fixes. For frequency conversion models, check if the frequency adjustment system is functioning normally—QuanWei’s intelligent frequency conversion control module has a self-diagnostic function, which can quickly locate control-related pressure drop faults.
3. Fault: Overheating During Operation
Long-term overheating of air compressors accelerates component aging and even causes shutdowns. Common causes include insufficient lubricating oil, clogged cooling systems, or abnormal ventilation. QuanWei’s on-site maintenance records show that insufficient lubricating oil and cooling system blockages are the top two causes of overheating, accounting for 80% of cases.
Emergency handling: Stop the machine and let it cool down first. Check the lubricating oil level and quality—replenish or replace it with QuanWei’s dedicated matching lubricating oil if necessary. Clean the cooling fins and radiators to remove dust and debris, ensuring smooth heat dissipation. For factories in high-temperature environments, QuanWei recommends equipping its dedicated cooling system accessories to enhance heat dissipation capacity and prevent overheating recurrence.
4. Fault: Oil Leakage (Oil-Injected Models)
Oil leakage in oil-injected air compressors not only wastes lubricating oil but also pollutes the workshop environment and affects product quality. The main causes include worn seals, loose oil pipe joints, or excessive oil levels. Based on QuanWei’s accumulated fault handling experience, worn seals account for 65% of oil leakage faults.
Emergency handling: First, reduce the oil level to the standard range if it is too high. Tighten loose oil pipe joints and replace worn seals with QuanWei’s original high-temperature resistant seals. QuanWei’s original seals are made of special materials, which have better wear resistance and high-temperature resistance than ordinary seals, effectively solving oil leakage problems and extending the service life of the compressor.
5. Fault: Automatic Shutdown Without Warning
Unexpected automatic shutdown often results from overpressure protection, overheating protection, or electrical system failures. It is critical to identify the cause before restarting to avoid secondary damage. QuanWei’s compressors are equipped with intelligent fault alarm systems, which can display fault codes to quickly locate the root cause.
Emergency handling: Check the fault code displayed on the control panel first—refer to QuanWei’s fault code interpretation guidelines (provided by the after-sales team) to identify whether it is a protection shutdown caused by overpressure/overheating or an electrical fault. For electrical faults (such as loose wiring or faulty sensors), contact QuanWei’s professional technical team for guidance; for protection shutdowns, eliminate the overpressure/overheating cause first before restarting the machine.
The Core of QuanWei’s Fault Handling Guidelines: Practicality & Matching
QuanWei’s fault handling guidelines are not theoretical speculations but are summarized from thousands of on-site fault cases. The core lies in two points: practical operability and component matching. Each troubleshooting step is designed for on-site operators, avoiding complex professional tools; all recommended replacement parts are QuanWei’s original components, ensuring perfect fit and reliable performance. In addition, QuanWei’s after-sales technical team provides targeted guidance for complex faults, helping factories resolve issues quickly and minimize production losses.
For factory operators, mastering these practical fault handling methods can effectively respond to sudden air compressor failures. With QuanWei’s professional guidelines and original matching components, most common faults can be resolved in a timely manner, ensuring continuous and stable production. If you encounter complex faults that are difficult to handle, you can consult QuanWei’s technical team to obtain customized solutions based on the specific fault situation.
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