Top 10 Signs Your Rotary Screw Air Compressor Needs Service
Your rotary screw air compressor is the backbone of your operation. It keeps your tools running, your lines moving, and your team productive. But like any piece of equipment, it needs routine care to keep delivering reliable performance. Ignoring maintenance can lead to energy loss, downtime, and costly repairs — or worse, total system failure.
At Industrial Air Services, we’ve serviced thousands of rotary screw air compressors across Nashville, Knoxville, and Chattanooga. In this post, we’ll cover the top 10 signs your compressor may need service now — and what to do about it.
1. Unusual Noises or Vibrations
A healthy rotary screw compressor should run smoothly and quietly. If you hear rattling, grinding, hissing, or knocking, something’s wrong.
Possible causes:
Loose or damaged motor mounts
Worn bearings or gears
Misaligned couplings
Internal component wear
If the sound is new or worsening, call a service technician immediately to prevent further damage.
2. Increased Operating Temperature
Overheating is one of the most common warning signs of a compressor issue. Most systems are designed to operate within a specific temperature range. If the unit gets too hot, it can lead to shutdowns or permanent component damage.
Potential issues include:
Dirty or clogged coolers
Low oil level or degraded oil
Blocked ventilation
Faulty thermostats
Routine oil changes and cooler cleanings are key to preventing overheating.
3. Frequent Cycling or Failure to Reach Pressure
If your compressor is cycling too often (short-cycling) or struggling to build pressure, it could be a sign of:
Leaks in the system
Faulty pressure switch or sensor
Air-end degradation
Inadequate CFM output due to internal wear
Frequent cycling wastes energy and increases wear. A full diagnostic can help pinpoint the issue.
4. Oil Carryover or Excess Moisture in Air Lines
Rotary screw compressors use oil to lubricate the air-end. But if that oil is making its way into your air lines, you have a problem.
Oil carryover causes:
Worn separator elements
Incorrect oil level
Damaged seals
Moisture or oil in your lines can damage tools, contaminate products, and cause corrosion. You may also need to check your air dryers and filters.
5. Increased Energy Costs
An inefficient compressor uses more power to do the same job. If your energy bills are climbing without a corresponding increase in production, your compressor might be the culprit.
What to check:
Dirty filters or restricted flow
Leaking lines or fittings
Improperly sized piping
Worn internal components
Tip: An energy audit from Industrial Air Services can help identify and correct efficiency killers.
6. Visible Oil Leaks or Pooled Fluids
If you notice oil around the base of your compressor or on nearby surfaces, don’t ignore it. Leaks can quickly escalate into serious problems.
Common leak points include:
Oil filters
Seals and gaskets
Sight glasses
Hoses and fittings
Loss of oil leads to overheating, increased wear, and ultimately equipment failure. This is an urgent sign you need service.
7. Odd Smells (Burning or Musty Odors)
If your compressor emits a burning smell, that could indicate:
Electrical issues
Overheating components
Oil oxidation
A musty or damp smell could point to moisture problems in your air system or dirty filters that need replacing. Either way, unusual odors should trigger a call to your technician.
8. Alarms or Fault Codes
Modern compressors come equipped with built-in diagnostic systems that flash warnings or fault codes. Don’t ignore them. Even if the compressor keeps running, those alerts signal something isn’t right.
Common fault codes involve:
Overload conditions
High temperature
Sensor malfunctions
Pressure issues
Check your manual for code definitions or contact us to diagnose and clear the error safely.
9. Reduced CFM Output
If tools are underperforming or pressure drops occur at the point of use, your compressor may not be delivering full CFM.
This could mean:
Air-end wear
Intake valve issues
Filter restrictions
Piping bottlenecks
If your production is slowing down due to poor airflow, it’s time to service your unit and possibly your piping layout too.
10. It’s Been Over 2,000 Hours Since the Last Service
Even if your unit seems to be running well, regular maintenance is non-negotiable. Most rotary screw compressors require:
Oil changes every 2,000–4,000 hours
Filter replacements
Cooler cleanings
Belt and seal inspections
If it’s been too long since your last service, you’re running on borrowed time.
Bonus: Why Preventive Maintenance Matters
Waiting for problems to appear can be costly. Preventive maintenance saves:
Energy costs by keeping your unit running efficiently
Downtime by catching problems early
Capital by extending the life of your equipment
Industrial Air Services offers custom preventive maintenance programs tailored to your operation’s needs — including multi-location contracts across Tennessee.
Need Rotary Screw Compressor Service in Tennessee?
Whether you’re in Nashville, Knoxville, or Chattanooga, we’ve got you covered.
We offer:
On-site compressor repair
Air-end rebuilds
Emergency troubleshooting
OEM and aftermarket parts
Full system diagnostics
📞 Call (615) 641-3100 today to schedule your service or set up a maintenance plan.
Don’t let a minor issue turn into a major breakdown. If you’re seeing any of these warning signs, it’s time to call in the experts.
