Problem Cause Solution

Compressor will not 1. No electrical Turn on power.

operate. power. Push the reset button.

  2. Low oil level. Check oil level. Replace

your oil if necessary

  3. Pressure See pressure switch

switch not adjustment.
making contact.

  4. Pressure in the See pressure switch

tank is below the adjustment.
cut-in pressure. Replace pressure switch
to one that has a lower
cut-in PSI

Excessive noise in 1. Loose pulley, Tighten any loose ends.

operation. flywheel, belt,
belt guard,
cooler, clamps or
accessories.

  2. Lack of oil in Check for possible

crankcase. damage to bearings
Replenish the oil level.

  3. Piston hitting Remove the compressor

the valve plate. cylinder head and inspect
for foreign matter on top
of the piston. Add a new
gasket and reassemble
the head.

  4. Compressor Tighten the bolts on the

floor mounting air compressor. It may
loose. also be a good idea to
replace your vibration
pads
Problem Cause Solution

  5. Defective Repair or replace.

crankcase.

  6. Excessive Adjust and shim properly.

crank end play.

Knock - same cycle 1. Main bearings. Replace bearings.

as R.P.M.

  2. Connecting rod Replace rod.

bearings.

  3. Loose Tighten.
flywheel.

Knock occurs while 1. Connecting rod Replace rod.

compressor is bearings.
loading.

  2. Wrist pins, Replace piston assembly.

wrist pin
bearings.

  3. Loose Tighten.
connecting rod
nut.

Milky oil in oil 1. Water entering a. Pipe air intake to less

reservoir. oil reservoir due humid air source.
to compressor
operating in high
humidity
environment.

  b. Service unit (change oil,

  clean or replace air
cleaner element, more
often, at least every 45
days or 500 operating
Problem Cause Solution

hours for oil changes.

  c. Drain tank daily.

 

Excessive oil 1. Restricted air Clean or replace air filter.

consumption. intake.

  2. Oil leaks. Tighten bolts or replace

gasket.

  3. Worn piston Replace rings.

rings.

  4. Wrong oil Drain oil, refill with oil of

viscosity. proper viscosity.

  5. Compressor Level
tilted too much. compressor. Vibration
pads may help with this

  6. Scored Replace cylinder.

cylinder.

Oil in discharge air. 1. Compressor air Clean or replace your air

intake restricted. filters.

  2. Worn piston Replace rings.

rings.

  3. Excessive oil Drain down to full mark on

in compressor. sight gauge.

  4. Wrong oil Check viscosity.

viscosity.

  5. Piston rings Replace crankshaft.

installed up-side
down.
Problem Cause Solution

Compressor 1. Mounting bolts Tighten.

vibrates. loose.

  2. Compressor Level compressor so that

not properly all feet touch the floor
mounted. before tightening down.

  3. Pulley and Realign.

flywheel
misaligned.

  4. Belts loose. Tighten belts.

  5. Bent Replace crankshaft.

crankshaft.

Air blowing out of 1. Broken first Replace valve plate

inlet. stage inlet valve. assembly.

Insufficient 1. Leaks or Check for leaks or

pressure at point of restriction. restriction in hose or
use. piping. Repair.

  2. Restricted air Clean or replace air filter

intake. element.

  3. Slipping belts. Tighten belts.

  4. Service hose Replace with larger hose.

too small.

  5. Excessive air Limit air usage to

requirement. compressor capacity by
using fewer or smaller
tools.

Receiver does not 1. Faulty check Bleed tank! Disassemble

hold pressure when valve. check valve assembly,
compressor is clean or replace faulty
Problem Cause Solution

unloaded. parts.

Excessive belt 1. Pulley out of Realign motor pulley with

wear. alignment. compressor flywheel.

  2. Belts too tight. Adjust tension.

  3. Belts too Adjust tension.

loose.

  4. Pulley or Check for worn worn

flywheel wobble. crankshaft, keyway or
pulley bore, resulting from
running with loose pulleys.
Check for bent crankshaft.

  5. Nick in belt File smooth.

groove of pulley
or flywheel.

Excessive 1. Dirty cooling Clean cooling surfaces of

discharge air surfaces. cylinder, intercooler and
temperature. discharge tube.

  2. Poor Improve ventilation or

ventilation. relocate compressor.

  3. Blown head Replace head gasket.

gasket.

  4. Restricted air Clean or replace air filter

intake. element.

  5. Worn valves. Replace valve plate

assembly.

Air leaking from 1. Safety relief Remove and install

inter stage safety valve not new safety relief valve. If
relief valve when functioning new safety valve leaks
Problem Cause Solution

compressor is properly. remove cylinder head,

pumping. inspect and clean reed
valve assembly.

  2. Leaky gasket - Replace gasket.

High pressure
inlet valve.

Receiver pressure 1. Dirty air filter. Clean or replace filter

builds up slowly. element.

  2. Blown cylinder Install new gasket.

head gasket.

  3. Worn or broken Install new valve plate.

low pressure
intake or
discharge valves.

  4. Air leaks. Tighten joints.

  5. Loose belts. Tighten or replace belts.

  6. Speed too Check speed.

slow.

Receiver pressure 1. Excessive Drain receiver/tank.

builds up quickly on water in receiver.
compressor.

  2. Speed too fast. Check speed.

Reset mechanism 1. Motor Shut down immediately to

cuts out overload. avoid damage.
repeatedly; fuses of
proper size blow.

  2. Malfunction or Adjust or replace.

improperly
Problem Cause Solution

adjusted.

  3. High ambient Provide ventilation.

temperature.

Fuses blow 1. Wrong fuse Check to make sure that

repeatedly. size. fuses are of proper
ampere rating.

Compressor will not 1. No electrical Turn on power, check

operate. power. fuse, breaker, or motor
overload.

  2. Pressure Replace or repair.

switch not
making contact.

  3. Defective Replace or repair.

unloader or
check valve.

Excessive noise in 1. Loose pulley, Tighten.

operation. flywheel belt,belt
guard, clamps or
accessories.

  2. Lack of oil in Check for possible

crankcase. damage to bearings,
replenish oil.

  3. Piston hitting Remove the compressor

the valve plate. cylinder head and inspect
for foreign matter on top
of the piston, clean, add a
new gasket, and
reassemble the head.

  4. Compressor Tighten.
floor mounting
Problem Cause Solution

loose.

  5. Defective Repair
crankcase.

Knock-same cycle 1. Main bearings. Replace bearings.

as RPM.

  2. Connecting rod Replace rod.

bearings.

  3. Loose Tighten.
flywheel.

Knock occurs while 1. Connecting rod Replace rod.

compressor is bearings.
loading.

  2. Wrist pins, Replace complete piston

wrist pin assembly.
bearings.

  3. Loose Tighten bolt.

connecting rod
bolt.

  4. Loose Tighten setscrew.

flywheel.

Milky oil in 1. Water entering Pipe air intake to less

crankcase. oil reservoir due humid air source.
to compressor
operating in high
humidity
environment.

Excessive oil 1. Restricted air Clean or replace air filter.

consumption. intake.
Problem Cause Solution

  2. Oil leaks. Tighten bolts or replace

gasket.

  3. Worn piston Replace rings.

rings.

  4. Wrong oil Drain oil, refill with oil of

viscosity. proper viscosity.

  5. Compressor Level compressor.

tilted too much.

  6. Scored Replace cylinder.

cylinder.

Oil in discharge air. 1. Compressor air Clean air filter

intake restricted. element and check for
other restrictions in the
intake system.

  2. Worn piston Replace rings.

rings.

  3. Excessive oil Drain down to bottom of

in compressor. threads.

  4. Wrong oil Check viscosity

viscosity. and change oil if
necessary

  5. Piston rings Install rings in proper

installed up-side position.
down.

  6. Plugged Clean or replace.

crankcase
breather.

Compressor 1. Mounting bolts Tighten. Consider

Problem Cause Solution

vibrates. loose. installing vibration pads.

Receiver does not 1. Faulty check Bleed tank! Disassemble

hold pressure when valve. check valve assembly,
compressor shuts clean or replace faulty
off parts.

Excessive belt 1. Pulley out of Realign motor pulley with

wear. alignment. compressor flywheel.

  2. Belts too tight. Adjust tension.

  3. Belts too Adjust tension.

loose.

  4. Pulley or Check for worn

flywheel wobble. crankshaft, keyway or
pulley bore, resulting from
running with loose pulleys.
Check for
bent crankshaft - if bent
then replace.

  5. Nick in belt File smooth.

groove of pulley
or flywheel.

Excessive 1. Dirty cooling Clean cooling surfaces of

discharge air surfaces. cylinder, intercooler and
temperature. discharge tube.

  2. Poor Improve ventilation or

ventilation. relocate compressor.

  3. Blown head Replace head gasket.

gasket.

  4. Worn valve. Repair or replace valves.

Problem Cause Solution

Receiver pressure 1. Dirty air filter. Clean or replace filter

builds up slowly. element.

  2. Blown cylinder Install new gasket.

head gasket.

  3. Worn or broken Install new flapper valves

low pressure and gaskets.
intake or
discharge valves.

  4. Air leaks. Tighten joints.

  5. Loose belts. Tighten belt or replace

belt.

  6. Speed too Check pulley size and belt

slow. tension.

Receiver pressure 1. Excessive Drain receiver/tank.

builds up rapidly. water in receiver.

Reset mechanism 1. Motor Shut down immediately to

cuts out overload. avoid damage.
repeatedly.

  2. Malfunction or Adjust or replace.

improperly
adjusted.

  3. High ambient Provide ventilation.

temperature.

Fuses blow 1. Wrong fuse Check to make sure that

repeatedly. size. fuses are of proper
ampere rating.

  2. Low voltage.
 
Problem Cause Solution

  3. Defective Replace or repair.

unloader
or check valve.

  4. Belt to tight. Loosen belt.

Compressor 1. Bad unloader Replace the unloader

suddenly stops valve valve.
working

  2. Loss of power Plug compressor into a

new power source