Air compressor stalling

60 gallon CH compressor is stalling out around 75-80psi. Runs like a top up to that point, though it does seem to take longer than it used to. Tank does hold pressure.

Any ideas?

 

I had to replace the pressure switch on mine at about 1.5 years old. It wasn't turning on at all, though.

When you say, "stalling out", do you meant the compressor runs but doesn't build anymore air?

 

Motor is trying to run, but pump stops pumping.

 

Mine was more on the electrical side, yours sounds like something mechanical.

Did you open the air cleaner to make sure nothing built a nest in there? I am assuming this is a two stage? Other than that, I'm sure some one who deals with these things on the regular will drop in shortly.

 

1 stage. Checked air filter, same problem with filter removed. Looks to be check valve or pressure switch based on internet research.

 

If it’s not building pressure but the pop off valve isn’t blowing off, I’d say your problem is in your compressor head/cylinder.

How old is it? Service history? Oil level correct and clean?

 

I have an 80 gallon IR, its had all the problems. Im not exactly sure what you mean by stalling out, but.. I had a problem where the copper tube going from the compressor to the tank developed a crack at the fitting, and was blowing air out there instead of into the tank. It didn’t leak if the compressor wasn’t running. I had a head gasket go bad, and leaked air out there. I also had the valves in the head come loose, and make it so the pump didn’t work right. First thing I would do, is check around the pump for air leaks while it is running. If that doesn’t show any problems, order some new gaskets, and pull the pump apart, and check all the valves. Compressors are pretty simple, and should be no problem if you have any mechanical knowledge.

 

Pump is newish, maybe a year. Crank sheared on the last one.

Prolly need to change oil. Last time I put was when I replaced the pump.

Serivce history: an ape has thrown wrenches at it for about 10 years.

 

All of my problems with mine, happened when it was pretty new, must have been a Friday compressor. After I rebuilt everything, I haven’t had a problem, and that’s probably been over 15 years. And this compressor gets used for automotive painting which is constant duty for a significant amount of time.

 

So maybe stalling isn't the right word? I start with tank empty and swtich it on. Motor spins, pulls flywheel, pump pumps, pressure builds to about 75 psi at which point the motor can no longer pull the flywheel, pump stops pumping, motor hums, then I shut it off.

Edit: if it were a bad gasket, would it build any pressure at all?

 

I feel like that was similar to what happened when I had a bad head gasket. The pump got tight, but the motor had the power to spin, then it shredded the belt.

 

I called IR telling them what happened. They told me it needed a head gasket. They shipped me new parts, I put em in, and everything worked fine after that, until the valves came loose.

 

Aaaaaahhhhhhhh…

That sounds like a weak motor or too high of friction in the compressor.

Considering the compressor rolls well enough to get that 75psi into the tank I’d suspect the motor is on its way out. If you’re able to, bump up a fraction of a HP on a replacement motor so it doesn’t have to work as hard, so long as your wiring and frame supports the larger motor.

 

Is there a way to trouble shoot if it is the motor or just a capacitor? There are two. I'm assuming one is start and the other a run?

If it's the motor, I might just bite the bullet on a better compressor.

 

My compressor had a similar issue when the regulator went bad..

 

Most likely if the run cap was bad the motor would overheat and thermal would kick out before it could even build 25psi. Motors do not like low voltages.

How long does it run before the motor binds up? If it’s more than a minute or two, I doubt it’s the run cap.

 

I've got two compressors in the shop , the older one runs my lift table. Probably 5 years ago the head gasket went out of it, old enough I couldn't get a new one so I made one out of the cover of a Parts Unlimited catalog. Still holding and going strong, if it blows out again I'll just make another.

 

If the motor is running and it’s not building pressure it could be the unloaders, usually they may have rubber diaphragm’s that have worn (cracked, dry rotted)

 

A few min to get to 75 psi.

 

Put a new motor on it.