Compressor Trouble Shooting Guide

Here are some Compressor Trouble Shooting Tips to help you or anyone providing the regular maintenance for your compressor system. Below are listed several very common problems, their probable cause and some usual remedies for the trouble. Of course, there can be multiple problems and unique circumstances to every compressor issue. but these tend to solve the most common situations Provided below is a general list of common compressor problems, and a few quick fixes that may help solve your dilemma. this solution can be done alone. but if you have trouble, is expected to be fixed to the experience people. There are many problems and solution for troubleshooting compressor. Problem Cause 1. No electrical power. 2. Low oil level. 3. Pressure switch not making contact. 4. Pressure in the tank is below the cut-in pressure. Solution Turn on power. Push the reset button. Check oil level. Replace your oil if necessary See pressure switch adjustment. See pressure switch adjustment. Replace pressure switch to one that has a lower cut-in PSI Tighten any loose ends. Check for possible damage to bearings Replenish the oil level. Remove the compressor cylinder head and inspect for foreign matter on top of the piston. Add a new gasket and reassemble the head. Tighten the bolts on the air compressor. It may also be a good idea to replace your vibration pads. Repair or replace. Adjust and shim properly. Replace bearings. Replace rod.

Compressor will not operate.

1. Loose pulley, flywheel, belt, belt guard, cooler, clamps or accessories 2. Lack of oil in crankcase. 3. Piston hitting the valve plate. Excessive noise in operation. 4. Compressor floor mounting loose 5. Defective crankcase. 6. Excessive crank end play. 1. Main bearings. 2. Connecting rod bearings.

Knock - same cycle as R.P.M.

Knock occurs while compressor is loading.

3. Loose flywheel. 1. Connecting rod bearings. 2. Wrist pins, wrist pin bearings. 3. Loose connecting rod nut. 1. Water entering oil reservoir due to compressor operating in high humidity environment.

Tighten. Replace rod. Replace piston assembly. Tighten. a. Pipe air intake to less humid air source. b. Service unit (change oil, clean or replace air cleaner element, more often, at least every 45 days or 500 operating hours for oil changes. c. Drain tank daily. Clean or replace air filter. Tighten bolts or replace gasket. Replace rings. Drain oil, refill with oil of proper viscosity Level compressor. Vibration pads may help with this. Replace cylinder. Clean or replace your air filters. Replace rings. Drain down to full mark on sight gauge. Check viscosity. Replace crankshaft. Tighten. Level compressor so that all feet touch the floor before tightening down. Realign. Tighten belts. Replace crankshaft. Replace valve plate assembly. Check for leaks or restriction in hose or piping. Repair. Clean or replace air filter element. Tighten belts. Replace with larger hose. Limit air usage to compressor capacity by using fewer or smaller tools.

Milky oil in oil reservoir.

Excessive oil consumption.

Oil in discharge air.

1. Restricted air intake. 2. Oil leaks. 3. Worn piston rings. 4. Wrong oil viscosity. 5. Compressor tilted too much 6. Scored cylinder. 1. Compressor air intake restricted 2. Worn piston rings. 3. Excessive oil in compressor. 4. Wrong oil viscosity. 5. Piston rings installed up-side down 1. Mounting bolts loose. 2. Compressor not properly mounted

Compressor vibrates.

Air blowing out of inlet.

Insufficient pressure at point of use.

3. Pulley and flywheel misaligned. 4. Belts loose. 5. Bent crankshaft. 1. Broken first stage inlet valve. 1. Leaks or restriction. 2. Restricted air intake. 3. Slipping belts. 4. Service hose too small. 5. Excessive air requirement.

Receiver does not hold pressure when compressor is unloaded.

1. Faulty check valve. 1. Pulley out of alignment. 2. Belts too tight. 3. Belts too loose. 4. Pulley or flywheel wobble.

Excessive belt wear.

5. Nick in belt groove of pulley or flywheel. 1. Dirty cooling surfaces. Excessive discharge air temperature. 2. Poor ventilation. 3. Blown head gasket. 4. Restricted air intake. 5. Worn valves. 1. Safety relief valve not functioning properly. 2. Leaky gasket - High pressure inlet valve. 1. Dirty air filter. 2. Blown cylinder head gasket. 3. Worn or broken low pressure intake or discharge valves. 4. Air leaks. 5. Loose belts. 6. Speed too slow. 1. Excessive water in receiver. 2. Speed too fast. 1. Motor overload. 2. Malfunction or improperly adjusted 3. High ambient temperature. 1. Wrong fuse size.

Air leaking from inter stage safety relief valve when compressor is pumping.

Bleed tank! Disassemble check valve assembly, clean or replace faulty parts. Realign motor pulley with compressor flywheel. Adjust tension. Adjust tension. Check for worn worn crankshaft, keyway or pulley bore, resulting from running with loose pulleys. Check for bent crankshaft File smooth. Clean cooling surfaces of cylinder, intercooler and discharge tube. Improve ventilation or relocate compressor. Replace head gasket. Clean or replace air filter element. Replace valve plate assembly. Remove and install new safety relief valve. If new safety valve leaks remove cylinder head, inspect and clean reed valve assembly. Replace gasket. Clean or replace filter element. Install new gasket. Install new valve plate. Tighten joints. Tighten or replace belts. Check speed. Drain receiver/tank. Check speed. Shut down immediately to avoid damage. Adjust or replace. Provide ventilation. Check to make sure that fuses are of proper ampere rating.

Receiver pressure builds up slowly.

Receiver pressure builds up quickly on compressor. Reset mechanism cuts out repeatedly; fuses of proper size blow.

Fuses blow repeatedly.

Compressor will not operate.

1. No electrical power. 2. Pressure switch not making contact. 1. Loose pulley, flywheel belt, belt guard, clamps or accessories. 2. Lack of oil in crankcase. 3. Piston hitting the valve plate. 4. Compressor floor mounting loose. 5. Defective crankcase. 1. Main bearings. 2. Connecting rod bearings. 3. Loose flywheel. 1. Connecting rod bearings. 2. Wrist pins, wrist pin bearings. 3. Loose connecting rod bolt. 4. Loose flywheel. 1. Water entering oil reservoir due to compressor operating in high humidity environment. 1. Restricted air intake. 2. Oil leaks. 3. Worn piston rings. 4. Wrong oil viscosity. 5. Compressor tilted too much. 6. Scored cylinder. 1. Compressor air intake restricted.

Turn on power, check fuse, breaker, or motor overload Replace or repair. Tighten. Check for possible damage to bearings, replenish oil Remove the compressor cylinder head and inspect for foreign matter on top of the piston, clean, add a new gasket, and reassemble the head. Tighten. Repair Replace bearings. Replace rod. Tighten. Replace rod. Replace complete piston assembly. Tighten bolt. Tighten setscrew. Pipe air intake to less humid air source. Clean or replace air filter. Tighten bolts or replace gasket. Replace rings. Drain oil, refill with oil of proper viscosity. Level compressor. Replace cylinder. Clean air filter element and check for other restrictions in the intake system. Replace rings. Drain down to bottom of threads. Check viscosity and change oil if necessary Install rings in proper position. Clean or replace.

Excessive noise in operation.

Knock-same cycle as RPM.

Knock occurs while compressor is loading.

Milky oil in crankcase.

Excessive oil consumption.

Oil in discharge air.

2. Worn piston rings. 3. Excessive oil in compressor. 4. Wrong oil viscosity. 5. Piston rings installed up-side down. 6. Plugged crankcase breather

Compressor vibrates. Receiver does not hold pressure when compressor shuts off

1. Mounting bolts loose. 1. Faulty check valve. 1. Pulley out of alignment. 2. Belts too tight 3. Belts too loose.

Excessive belt wear.

4. Pulley or flywheel wobble.

5. Nick in belt groove of pulley or flywheel. 1. Dirty cooling surfaces. Excessive discharge air temperature. 2. Poor ventilation. 3. Blown head gasket. 4. Worn valve. 1. Dirty air filter. 2. Blown cylinder head gasket. 3. Worn or broken low pressure intake or discharge valves. 4. Air leaks. 5. Loose belts. 6. Speed too slow. 1. Excessive water in receiver. 1. Motor overload. 2. Malfunction or improperly adjusted. 3. High ambient temperature. 1. Wrong fuse size. 2. Low voltage. 3. Defective unloader or check valve. 4. Belt to tight. 1. Bad unloader valve 2. Loss of power

Tighten. Consider installing vibration pads. Bleed tank! Disassemble check valve assembly, clean or replace faulty parts. Realign motor pulley with compressor flywheel. Adjust tension. Adjust tension. Check for worn crankshaft, keyway or pulley bore, resulting from running with loose pulleys. Check for bent crankshaft - if bent then replace. File smooth. Clean cooling surfaces of cylinder, intercooler and discharge tube. Improve ventilation or relocate compressor. Replace head gasket. Repair or replace valves. Clean or replace filter element. Install new gasket. Install new flapper valves and gaskets. Tighten joints. Tighten belt or replace belt. Check pulley size and belt tension. Drain receiver/tank. Shut down immediately to avoid damage. Adjust or replace. Provide ventilation. Check to make sure that fuses are of proper ampere rating. Replace or repair. Loosen belt. Replace the unloader valve. Plug compressor into a new power source

Receiver pressure builds up slowly.

Receiver pressure builds up rapidly. Reset mechanism cuts out repeatedly.

Fuses blow repeatedly.

Compressor suddenly stops working