Recips are generally designed for ~50–75% duty cycle. Running continuously, recirculating hot air, or leaking valves make the head extremely hot, carbonise oil, and destroy valves and rings.
1
Excessive duty cycle (undersized compressor or leaks)
highReciprocating
CheckTime on vs off over an hour. Running more than ~75% of the time on a splash-lubricated recip is too much.
FixRepair leaks, reduce demand, or upsize to a larger recip or a rotary screw designed for 100% duty.
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2
Leaking discharge valve recompressing hot air
highReciprocating
CheckHead much hotter than normal; discharge line blue/discoloured; fills slowly.
FixReplace valve plate/reeds and gaskets.
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3
Wrong rotation on fan-blade pulley / blocked fins
medReciprocating
CheckThe pulley's fan blades should blow air across the pump. Fins clogged with dust/oil.
FixCorrect motor rotation (3-phase: swap two legs), clean fins and intercooler.
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4
Low or wrong oil
highReciprocating
CheckSight glass/dipstick low; oil dark and thin; automotive detergent oil used.
FixFill to correct level with compressor oil of the right viscosity.
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Safety
Lockout/tagout before opening enclosures. Verify zero energy. Bleed system pressure before opening any pneumatic connection.