3. Air Intake and System Pressure Issues

• Clogged Air Filter: A dirty air filter restricts intake air. The compressor has to work much harder (higher load) to draw in air, generating more heat for the same amount of output.

• Solution: Clean or replace the air filter. In dusty environments, this needs to be done more frequently.

• Faulty Valves (Inlet/Discharge): Worn,      broken, or leaking valve plates/springs reduce compression efficiency. Air      can be trapped and re-compressed within the cylinder, creating massive      amounts of excess heat.

• Symptoms: Longer cycle times       to reach pressure, increased electricity consumption, and high       temperatures.

• Solution: This requires a professional technician to inspect and rebuild or replace the valve assembly.

• High Operating Pressure: The pressure switch might be set too high, forcing the compressor to operate beyond its design limits.

• Solution: Check and adjust  the cut-out pressure to the compressor's specified rating.

4. Mechanical Wear

• Worn Piston Rings or Cylinder: Over time, these components wear out, causing internal blow-by (air leaking past the piston). This drastically reduces compression efficiency and      increases heat generation.

• Solution: This is a major  overhaul requiring disassembly and replacement of parts by a qualified technician.

Summary and Action Plan

If your piston compressor is overheating in a 10-hour shift:

1. Stop Immediately: Allow it to cool down to prevent severe damage like piston seizure.

2. Perform External Checks First:

• Verify ventilation and clean cooling fins.

• Inspect and clean/replace the air filter.

• Ensure the cooling fan is operational.

• Check the oil level and condition.

3. Seek Professional Help: If the simple checks don't resolve the issue, the problem is likely internal (valves, piston rings). Contact a qualified technician for a thorough inspection.