DIY Troubleshooting: Common Evaporative Cooler Issues & Fixes

Portacool evaporative coolers are built Texas Tough, designed for industrial cooling, residential spaces, and high-demand environments. These powerful coolers, also known as swamp coolers, are built to perform in extreme heat. However, like any cooling system, they require regular maintenance to keep running smoothly. 

This DIY evaporative cooler troubleshooting guide covers the most common issues—such as airflow problems, pump failures, and water flow issues—and how to safely repair your evap cooler without having to call a technician. 

Before you start – safety and prep tips 

Get familiar with these safety tips before starting any maintenance or repair on your evaporative cooler: 

• Perform occasional maintenance and inspections on your Portacool  
• Drain the water reservoir weekly 
• Clean the HydroTek™ evaporative media  
• Check for mold, mildew, and scale build-up 
• Turn off and unplug the unit before looking at internal components 
• Perform maintenance in a safe, and dry, area 
• Don’t run the pump without water in your Portacool 

Q: Why is my evaporative cooler not blowing air? 

A: If your cooler isn’t blowing air, or isn’t blowing enough air, there could be an issue with the fan or evaporative media.  

Common evap cooler airflow issues 

• Clogged evaporative media 
• Worn out motor or fan belt 
• Loose wiring or a faulty electrical outlet 

How to fix evap cooler airflow issues 

1. Fan and airflow issues can be caused by clogged evaporative media. Clean the HydroTek evaporative media, removing any dirt or debris. Replace evaporative media every few years to maintain the best performance, or as often as needed if you notice a loss of cooling, smells that won’t go away, or physical degradation of the media surfaces. If there’s hard water build-up, rinse the media with household white vinegar. Then, treat your water to reduce scale deposits.  
2. If your cooler still isn’t blowing air, then there could be a mechanical or electrical problem: 
3. Extension cord: If you’re using an extension cord with your evap cooler, make sure the cord meets the minimum requirements: it should be properly grounded and no longer than 50 feet. It should have 14AWG or greater for Portacool APEX™ 500 – APEX 4000 units, or 12AWG or greater for APEX 6500. Don’t use an extension cord when operating your cooler outside.  
4. Mechanical: Replace the fan and motor or fan capacitor if you notice any broken or pinched wires.  
5. Electrical: Ask an electrician to inspect your wall outlet.    

Q: How do I fix an evaporative cooler pump?  

A: Your evaporative cooler pump keeps the evaporative media wet and helps cool the air through evaporative cooling. A broken or faulty pump can make your cooler less effective and damage other components. Fix your broken pump by unclogging and cleaning the water line, troubleshooting any mechanical or electrical issues, or replacing the pump.  

Common evap cooler pump issues 

• Clogged water line 
• Low water level in the reservoir 
• Damaged or disconnected pump 

How to fix evap cooler pump issues 

1. Make sure that there’s enough water in the reservoir. Add more water if the water level indicator light is yellow or red. 
2. Check the spray bar and pump inlet for clogs. Clean or replace as necessary. 
3. Listen for water circulation and look for proper HydroTek media wetting.  
4. If the water isn’t circulating, turn off the cooler and unplug it. Check for broken, loose, or pinched wires and connectors. Clean out the pump connector terminals if necessary. Replace the pump if the problem persists.  
5. If your pump still isn’t working, then there could be a mechanical or electrical problem: 
6. Extension cord: If you’re using an extension cord with your evap cooler, make sure the cord meets the minimum requirements: it should be properly grounded, no longer than 50 feet, and have 14AWG or greater for APEX 500 – APEX 4000 units, or 12AWG or greater for APEX 6500. Don’t use an extension cord when operating your cooler outside.  
7. Mechanical: Replace the pump if you notice any broken or pinched wires.  
8. Electrical: Ask an electrician to inspect your wall outlet.  

Q: Why isn’t my evap cooler blowing cold air? 

A: If your cooler isn’t blowing cold air, it could be due to an issue with the settings, evaporative media, or internal components. 

Common cooling issues 

• Dry evaporative media 
• Fan or pump need to be replaced 
• “Max cooling” mode is off (only for APEX Series coolers) 

How to fix cooling issues 

1. Make sure that the evaporative media is wet and listen for water circulation. If water isn’t circulating, check the water level indicator and fill the reservoir. If the problem persists, clean any dirt and debris from the media, or replace the media if it’s older than 5 years.  
2. Ensure your fans and pumps are working properly and no wires are broken, pinched, or disconnected. Replace any broken parts.  
3. Check that the “max cooling” mode is on. In this mode, the cooler automatically adjusts the water flow rate and cooling based on the current air temperature. Press the cooling button with the snowflake graphic and use the arrows in the menu to change the mode. 

Q: Why does my evaporative cooler smell bad? 

A: Evaporative coolers, also known as swamp coolers,use water to cool the air, and they get this water from a water reservoir or connection to a water line. Unlike the name suggests, your swamp cooler shouldn’t smell like a swamp or anything at all. If your cooler has a musty odor, it could be due to algae or mildew buildup in the water tank or dirty evaporative media.  

Common evaporative cooler odor issues 

• Algae or mildew buildup in the tank 
• Dirty evaporative media 
• Minerals or impurities in the water supply 

How to fix evap cooler odor issues 

1. Drain the water tank and clean it with mild soap and water. 
2. Clean the evaporative media by removing any debris.  
3. Follow the Portacool maintenance routine to remove any algae or bacteria that may be causing the smell. 
4. Replace your media every few years to maintain the best performance, or as often as needed if you notice a loss of cooling, smells that won’t go away, or physical degradation of the media surfaces. 
5. Keep up with cooler maintenance by fully draining your water tank every week.  

Evaporative Cooler Troubleshooting Support 

At Portacool, we pride ourselves in delivering world-class customer care. From buying an evaporative cooler to maintenance, warranty claims, and beyond, we’re here for you every step of the way.  

How to troubleshoot evaporative cooler issues 

Check out these resources for help troubleshooting any evaporative cooler issues: 

• Portacool Maintenance and Care  
• Portacool Owner’s Manuals 
• Evaporative Cooler FAQs 
• Portacool Blog 

How to contact Portacool customer support 

We’re here to help you stay cool. Our USA-based care team is available Monday – Friday from 8am to 5pm CST. Call (800) 695-2942 to speak with a technical specialist or contact us via the form on our website.   

How to file a warranty claim with Portacool 

With Portacool Protect™, we stand by every product we make, providing customers with unmatched durability and peace of mind. To take full advantage of our program, register your Portacool for ongoing support, even after your warranty period ends.  

Our industry-leading warranty program offers: 

• Lifetime warranty on all molded housing 
• Up to 3 years protection for electrical parts 
• Live, US-based customer service 

If you’ve tried troubleshooting and still have an issue with your swamp cooler, fill out a warranty request form. 

Keep on cooling 

An evaporative cooler is a long-term investment in safety and comfort. With proper maintenance, cleaning, and seasonal care, you can keep your Portacool performing for years to come. 

For replacement parts, evaporative media, or professional support, contact your local Portacool dealer or visit our Support Center.