Compressor failure

[gtae07]

Went out in my shop today to find my compressor (60 gal Husky single stage) running hot and the whole shop filled with a light haze of smoke. Shut the compressor off and ventilated. Looks like the oil fill cap (?) leaked and blew oil all down the side of the pump and onto the floor. I haven’t had time to mess with it and don’t need the compressor for a bit, but I was wondering if anyone here might have experienced something similar and/or be able to give me an idea of what I’m looking at for possible fixes. Are we talking change the oil, fix a relief switch, or junk it because fixing will cost more than replacing?

 

[PoorOwner]

The fill cap should be on top of the crankcase? Sounds like it is a serious case of blow by if the oil can exit there.

 

[Plastikosmd]

After reading about many fires I have gotten into the habit of shutting off the compressor power switch instead of leaving it to run and re-pressurize/ cycle

I think I read it here somewhere where someone uses a light system (green means compressor off etc) to remind them upon exiting the shop

Good luck and let us know what u find

 

[kelpaso1]

Who leaves a compressor powered up when not in the garage? I certainly don't. Live and learn I guess.

 

[Citation]

Hard to say what is wrong. Is the motor good? Does the pump turn and build pressure? If the thing works you might be lucky. If the pump is bad I would look at one of the "3hp" Harbor Freight pumps. With coupon it's right around $110.

 

[matt_i]

The fact that its still turning over says to me that the rotating and reciprocating parts are OK.

But you could have broken a valve or could have a ring pack issue and it won't build pressure.

To find out all you really need is some more oil.

 

[gtae07]

Yes, it was still turning over when I got out there. It sounded like it was making pressure and there was some in the tank/lines but not full pressure. I just shut it off and ventilated the area and went out to work on what I was there to do, today.

Eventually I'll get around to messing with the compressor but I really need to get the wings back off the airplane first--I mounted them temporarily so I could fit some stuff, and I only have a couple inches to spare on each side. There's really no working room out there till they come back off.

I will definitely be shutting the compressor off from now on, though. Used to just leave it running to keep the system charged as you can't hear it from outside.

 

[wildbill23c]

If it was running when you went out there, chances are its ok, if its still building pressure its a good sign as well. Blowing the oil plug/cap off on the other hand sounds like an internal pump issue of some sort, stuck valve maybe, causing the pressure to flow into the crank case blowing the cap/plug out of the pump. I don't think its something that should really happen unless something happens internally in the pump to over pressurize it. The plug/cap may have been lose and just finally got lose enough to blow out.

 

[jayfrank5074]

I have the breaker right by the light switch on the way out the door.


Sent from my iPhone using Garage Journal

 

[sberry]

I have 2 comps, only 1 on, been on for 40 years. If figure if something goes wrong no point in burning up 2. I have a service valve ahead of a couple old hose reels, I turn them off but the stuff I use all the time is live, I try to make sure it's in decent shape.

 

[Falcon67]

Who leaves a compressor powered up when not in the garage? I certainly don't. Live and learn I guess.

Always unless leaving town

 

[driftpin]

Seems like the prudent thing to do is to not leave the pump capable of running unless you're out there. I have at one time or another left mine plugged-in and on/energized, and when it leaks-down, it starts. My wife is quick to remind me that it's on, and I get-up and shut it down. (2-car attached garage which is my workshop)

I had a different issue recently, the Campbell-Hausfeld 240V 11 CFM/135 psi 60 gal. upright charged the tank, but when it cut-on to refill the tank, after a bit, the belt started chattering badly. I had replaced the belt awhile ago, and I rarely use the compressor unless I want to sandblast; I use a Porter Cable pancake compressor for airing tires, and air tools like wrenches. Anyway, I asked my friend who owns a new compressor sales and repair shop (30+ years) about it, and he said that if the belt is good, make-sure the belt is tensioned to be taut, w/little free-play in the middle, and the pulleys aligned.

I checked the tension and it looks like it loosened up since I had replaced the belt and had run it a bit. I re-tensioned the belt after checking to see it wasn't worn or glazed, and that seems to have fixed the problem. That's good, as I was counting my pennies about the possibility of replacing it with something of more CFM so I can do longer duty cycles of sandblasting of motorcycle parts. I have a HFT benchtop and a floor model blasting cabinet, it's just me, so I only use 1 at a time.

 

[Spareparts]

Mine has been on since 1996, except for changing belts once.

 

[sberry]

Everyone but me must have heard about many fires?

 

[jask]

I have had the same happen, and have heard of lots of garage fires being traced back to compressors.... now you know S Berry.

I have worked on compressors that had the contact points of the pressure switch weld themselves together and run continuously for at least 5 hours.
I have had my own compressor pop its pressure release valve and run until the shop was getting smokey... not sure if the Pressure switch or the relief valve had gone out of spec. and replaced both to be safe and I now have my compressor circuit wired with a relay that opens and kills power when I turn off the lights.

 

[sberry]

It would be interesting to know how many it has happened to. I have heard a couple on this forum over the years. I have heard of a couple tank failures. I don't know of any outside the internet, none in my own experience, don't know anyone it has happened to.
I have had a half a dozen no starts from the starter on mine, twice 've had a breaker trip, once from a failed cap and once from something else, i think, can't remember exact.
I have seen hoses blown up, a couple from fire and some where they drive on them with forklift. Matbe end crack off and one pvc/vynal type in super cold. I keep an eye on mine, never had one come loose unattended.

 

[sberry]

I had a bowl on a regulator, The one holds the adjustment screw and spring crack right off. It was an hf job I think, seems I ordered it about 20 years ago. Just out of the blue, I happened to be standing there, only thing i heard was it discharged the air I tbe hose reel connected to it.
I have seen pvc busted on air.

 

[gtae07]

Small update; pressure was holding today. Took the oil fill/vent cap off and there's something rattling around in it, and I am pretty sure I can see daylight through the vent holes. The O ring at the bottom was also destroyed.

Once the wings are off and the shop is cleaned back up I'll change the oil and look at replacing that cap. We'll go from there. Will probably also use the opportunity to mount it to vibration dampers.

 

[kelpaso1]

I don't know of any shops or people that don't turn the power off for the compressor when out of the shop for more than an hour and especially overnight. And turn the air off at the compressor because most air systems have small leaks in the airlines/couplers, no need to fill the tank, just the lines in the morning.

 

[IBenDcars]

I had a very similar situation last week. Same compressor Husky 60 gallon from HD. Probably 8 or 9 years old. I have an oil heater so it needs air pressure to run. Compressor needs to be on.
I went out to my shop and heater was off due to no air pressure. So I check my compressor and the breaker on the motor was tripped and the oil sight glass was a dark grey color. I drain my tank at least once a week and look at oil level every time. After resetting the breaker it Icame on. The pressure switch had failed. New switch and its building pressure but seems a lot slower. I changed the oil for now.
I also backed the new switch down to max out at 95 until I can find a new pump.
My pump has the same oil fill/breather cap. It has like a check ball that rattles in it.
Someone posted about a Harbor Freight pump. Is it a direct replacement or are mods required? Anyone know?

 

[Citation]

Odds are the HF pump isn't a direct fit. To put one on a Powermate compressor we had to drill 4 new mounting holes and bend up a copper tube since the pump outlet is in a different location. Not hard but more that a simple bolt on.

 

[IBenDcars]

Odds are the HF pump isn't a direct fit. To put one on a Powermate compressor we had to drill 4 new mounting holes and bend up a copper tube since the pump outlet is in a different location. Not hard but more that a simple bolt on.

Yea, I was reading HF reviews and some are bolt on and some need new holes and new plumbing. The reviews also say to make sure to inspect for damage before leaving the store.
I just need to make a trip to HF to get one now. It should be easy enough to modify for mine.

 

[Jason280]

I have 2x large compressors, an 80 & 60 gal, and the 80 gal has been powered up for at least 3-5 years. The 60 gal is a little newer, its been powered up for around a year.

Both are on cut-offs, and I do try to kill power if I'm away from home for any extended period of time.

 

[Citation]

Yea, I was reading HF reviews and some are bolt on and some need new holes and new plumbing. The reviews also say to make sure to inspect for damage before leaving the store.
I just need to make a trip to HF to get one now. It should be easy enough to modify for mine.

Be sure to get one of those 10 or 20% off coupons. They apply to these compressors.

 

[PassnThru]

There are a few failure points on a compressor that will cause it to run continuously if they fail. There are multiple failure points on a compressor that actually has anything hooked up to it.
Given that - why leave a compressor powered up when no air is required? If you plug the leaks - it's always ready the next time you need it.
Disregarding the hyperbole of fires and other such things - a leak could run it into the ground or at least reduce the life span for those of us that don't own industrial compressors.

 

[Jeff May]

I've got two 60 gal. units. I placed them in an added on structure outside my shop.
Each one is wired separately with a lighted switch.
At the end of each day both have the power shut off and I shut the air off coming in to the shop and drain the shop lines.
No way I would leave them powered when I'm not around.
They both have auto drains, but they are on a separate circuit.

 

[Joe69]

I shut the breaker off, and close the tank valve after every use. Yes, I've heard about fires, plus I avoid pressure loss due to parasitic leaks in the plumbing. My compressor is always full when I come back. It's a habit I've always been in.

Joe

 

[firebirdparts]

I have had a "runaway" once where a hose blew out and the compressor ran all day or something like that. My compressor survived, but I think by definition you have to replace it if you can't get parts. Like most guys I use a $500 compressor, so the potential consequences are very limited.

If it were me (and it was) I would oil it up and see if it works. You might be able to gauge whether it's running about as well as it used to.

 

[gtae07]

Okay, so the wings are offf and I had a chance to fire the compressor up. Immediately I noticed puffs of air escaping around the pump head—so my guess is first the head gasket is blown.

Either way, it looks like I’ll be pulling and tearing down the pump. Maybe it’ll be salvageable?

 

[cadunkle]

I have one of those 60 gal Husky single stage units, it has served me well for over a decade and still going strong with one motor replacement several years ago. Lots of continuous use sand blasting for hours. I recently upgraded to a HF (BelAire 216V) 60 gal 5 HP 2 stage as the Husky was always right on the cusp of having enough air and had to run very hard and hot. Got a good deal on the new unit and it was more convenient for me at the time to not be without air while getting the new wired and plumbed in a new spot.

This is a good excuse to upgrade the pump on yours. Sure you can probably just go through the head for cheap and easy but you've still got a wee little pump that runs hard, is loud, and if it's anything like mine before I fit a massive aftercooler and several filter/separators it makes more water than air in the summer.

I would look at getting a larger pump and running it slower. Less noise, less heat, less water, at least as much air. Easy to upgrade the motor and spin it a bit faster whenever the motor dies. Have a look at Eaton pumps, they have a 5 HP and a 7.5 HP pump that can be run with as slow as 600 RPM with 2 HP. I'm sure there are plenty of other good options for pumps.

https://eatoncompressor.com/product/5-hp-air-compressor-pump-19-cfm/
https://eatoncompressor.com/product/7-5hp-air-compressor-pump-32-cfm/

 

[gtae07]

Just an update... finally got around to replacing the head gasket and changed the oil for good measure. The pistons and head had a lot of burned residue that I cleaned off. Closed evverything up and fired it up last night and it seemed to run well. I’ll check on it again tonight and probably give the bolts another round of tightening.

 

[sberry]

For example, say we blow a hose off on a reel and have 3 hp running on it. How much heat is it going to build in the comp as the pressure drops? At some point it's going to be pretty low, you can run it pretty low with a tool on it in a hurry, with nothing on it probably drop to 20#, only as much as the line resistance can provide.

 

[sberry]

I had a couple junk little comps I wouldn't leave on. I don't leave my backup on, I figure if something goes south only one runs. My good 2 stage champ had been on since the early 70's. I had a couple no starts from the contactor, a time or 2 from breaker trip by a start cap. The con ected equipment is in pretty good shape and have service valve ahead of a couple older reels.
There is occasion we have 8 hour stretches unattended but someone is using or passing by quite regular and we using it daily. It would be a very rare day, almost never someone didn't use air here, it's handy on demand, could be used at any time. Used it at midnight recently.

 

[Bretny]

My kobalt blew the headgasket last year also. It also had s good ammount of oil sludge on the pistons. Just got a $32 gasket kit, cleaned it and changed the oil. Still works great today.