Early Warning Signs Your Air Compressor Is About to Fail
Air compressors rarely fail without warning. Long before a system shuts down completely, there are usually signs that something isn’t right. The problem is that these warning signals are often ignored, misunderstood, or treated as minor inconveniences—until a failure forces an emergency repair.
At Gordon Air Compressor, we see the same warning signs appear again and again before major breakdowns. Recognizing them early can prevent downtime, reduce repair costs, and protect equipment life.
Increasing Run Time Without Added Demand
One of the first signs of trouble is a compressor that runs longer than it used to—even though production hasn’t changed.
This often points to:
Air leaks
Pressure drop
Restricted airflow
Declining efficiency
When compressors run longer to meet the same demand, something in the system is no longer operating as it should.
Rising Operating Temperatures
Heat is a major enemy of compressed air equipment. If operating temperatures begin to climb, it’s a sign the system is under stress.
Common causes include:
Dirty or blocked coolers
Restricted ventilation
High ambient temperatures
Excessive run time
Uncontrolled heat accelerates wear on oil, seals, bearings, and electrical components.
Pressure Instability
Fluctuating pressure is more than an inconvenience—it’s a warning sign.
Pressure instability may be caused by:
Leaks
Inadequate storage
Control issues
Undersized piping
Inconsistent pressure forces compressors to work harder and increases wear across the system.
Unusual Noise or Vibration
Changes in sound or vibration often indicate mechanical issues developing inside the compressor.
Watch for:
New knocking or rattling sounds
Increased vibration
Changes in normal operating noise
These symptoms may point to worn bearings, misalignment, or other internal problems that will worsen if ignored.
Frequent Alarms or Fault Codes
Modern compressors are equipped with monitoring systems for a reason. Alarms and fault codes aren’t suggestions—they’re warnings.
Repeated alarms may indicate:
Temperature issues
Pressure problems
Electrical faults
Lubrication issues
Resetting alarms without addressing the root cause allows problems to escalate.
Oil or Air Quality Changes
Changes in oil condition or air quality often signal internal wear or contamination.
Signs include:
Dark or degraded oil
Increased oil carryover
Moisture in air lines
Contaminants at points of use
These issues affect both the compressor and downstream equipment.
Declining Tool or Equipment Performance
When air tools or machines don’t perform as expected, the problem isn’t always the tool.
Performance issues may indicate:
Pressure loss
Airflow restrictions
System instability
Blaming tools alone can delay addressing the real problem.
Warning Signs Are Opportunities
Each of these signs is an opportunity to intervene before failure occurs. Addressing issues early almost always costs less and prevents unplanned downtime.
Ignoring them allows small problems to grow into major failures.
Pay Attention Before It’s Too Late
Air compressors communicate problems long before they fail—you just have to listen. Recognizing early warning signs helps keep systems running smoothly and avoids emergency repairs.
If your compressor is showing any of these symptoms, addressing them now can prevent costly downtime later.
We would love to help with your compressed air needs!
📞 901-327-1327
📧 parts@gordonaircompressor.com
📧 service@gordonaircompressor.com
📍 706 Scott Street, Memphis, Tennessee 38112
Emergency Service Available @ 901-482-5925
