Problem Cause Solution
Compressor will not Turn on power.
1. No electrical power.
operate. Push the reset button.
Check oil level. Replace your oil if
  2. Low oil level.
necessary
3. Pressure switch not
  See pressure switch adjustment.
making contact.
See pressure switch adjustment.
4. Pressure in the tank is
  Replace pressure switch to one that has
below the cut-in pressure.
a lower cut-in PSI
1. Loose pulley, flywheel,
Excessive noise in
belt, belt guard, cooler, Tighten any loose ends.
operation.
clamps or accessories.
Check for possible damage to bearings
  2. Lack of oil in crankcase.
Replenish the oil level.
Remove the compressor cylinder head
3. Piston hitting the valve and inspect for foreign matter on top of
 
plate. the piston. Add a new gasket and
reassemble the head.
Tighten the bolts on the air compressor.
4. Compressor floor
  It may also be a good idea to replace
mounting loose.
your vibration pads
  5. Defective crankcase. Repair or replace.
  6. Excessive crank end play. Adjust and shim properly.
Knock - same cycle as
1. Main bearings. Replace bearings.
R.P.M.
  2. Connecting rod bearings. Replace rod.
  3. Loose flywheel. Tighten.
Knock occurs while
1. Connecting rod bearings. Replace rod.
compressor is loading.
2. Wrist pins, wrist pin
  Replace piston assembly.
bearings.
  3. Loose connecting rod nut. Tighten.
1. Water entering oil
reservoir due to compressor a. Pipe air intake to less humid air
Milky oil in oil reservoir.
operating in high humidity source.
environment.
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.
 
 Problem Cause
Excessive oil
1. Restricted air intake.
consumption.
  2. Oil leaks.
  3. Worn piston rings.
  4. Wrong oil viscosity.
5. Compressor tilted too
much.
  6. Scored cylinder.
1. Compressor air intake
Oil in discharge air.
restricted.
  2. Worn piston rings.
3. Excessive oil in
compressor.
  4. Wrong oil viscosity.
5. Piston rings installed up-
 
side down.
Compressor vibrates. 1. Mounting bolts loose.
2. Compressor not properly
mounted.
3. Pulley and flywheel
 
misaligned.
  4. Belts loose.
  5. Bent crankshaft.
1. Broken first stage inlet
Air blowing out of inlet.
valve.
Insufficient pressure at
1. Leaks or restriction.
point of use.
  2. Restricted air intake.
  3. Slipping belts.
  4. Service hose too small.
  5. Excessive air requirement.
Receiver does not hold
pressure when compressor 1. Faulty check valve.
is unloaded.
Excessive belt wear. 1. Pulley out of alignment.
  2. Belts too tight.
  3. Belts too loose.
  4. Pulley or flywheel
wobble.
Solution
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.
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
 Problem Cause Solution
running with loose pulleys. Check for
bent crankshaft.
5. Nick in belt groove of
  File smooth.
pulley or flywheel.
Excessive discharge air Clean cooling surfaces of cylinder,
1. Dirty cooling surfaces.
temperature. intercooler and discharge tube.
Improve ventilation or relocate
  2. Poor ventilation.
compressor.
  3. Blown head gasket. Replace head gasket.
  4. Restricted air intake. Clean or replace air filter element.
  5. Worn valves. Replace valve plate assembly.
Air leaking from inter Remove and install new safety relief
stage safety relief valve 1. Safety relief valve not valve. If new safety valve leaks remove
when compressor is functioning properly. cylinder head, inspect and clean reed
pumping. valve assembly.
2. Leaky gasket - High
  Replace gasket.
pressure inlet valve.
Receiver pressure builds
1. Dirty air filter. Clean or replace filter element.
up slowly.
2. Blown cylinder head
  Install new gasket.
gasket.
3. Worn or broken low
  pressure intake or discharge Install new valve plate.
valves.
  4. Air leaks. Tighten joints.
  5. Loose belts. Tighten or replace belts.
  6. Speed too slow. Check speed.
Receiver pressure builds 1. Excessive water in
Drain receiver.
up quickly on compressor. receiver.
  2. Speed too fast. Check speed.
Reset mechanism cuts out
Shut down immediately to avoid
repeatedly; fuses of proper 1. Motor overload.
damage.
size blow.
2. Malfunction or improperly
  Adjust or replace.
adjusted.
  3. High ambient temperature. Provide ventilation.
Check to make sure that fuses are of
Fuses blow repeatedly. 1. Wrong fuse size.
proper ampere rating.
Compressor will not Turn on power, check fuse, breaker, or
1. No electrical power.
operate. motor overload.
2. Pressure switch not
  Replace or repair.
making contact.
  3. Defective unloader or Replace or repair.
 Problem Cause Solution
check valve.
1. Loose pulley, flywheel
Excessive noise in
belt, belt guard, clamps or Tighten.
operation.
accessories.
Check for possible damage to bearings,
  2. Lack of oil in crankcase.
replenish oil.
Remove the compressor cylinder head
3. Piston hitting the valve and inspect for foreign matter on top of
 
plate. the piston, clean, add a new gasket, and
reassemble the head.
4. Compressor floor
  Tighten.
mounting loose.
  5. Defective crankcase. Repair
Knock-same cycle as
1. Main bearings. Replace bearings.
RPM.
  2. Connecting rod bearings. Replace rod.
  3. Loose flywheel. Tighten.
Knock occurs while
1. Connecting rod bearings. Replace rod.
compressor is loading.
2. Wrist pins, wrist pin
  Replace complete piston assembly.
bearings.
  3. Loose connecting rod bolt. Tighten bolt.
  4. Loose flywheel. Tighten setscrew.
1. Water entering oil
reservoir due to compressor
Milky oil in crankcase. Pipe air intake to less humid air source.
operating in high humidity
environment.
Excessive oil
1. Restricted air intake. Clean or replace air filter.
consumption.
  2. Oil leaks. Tighten bolts or replace gasket.
  3. Worn piston rings. Replace rings.
Drain oil, refill with oil of proper
  4. Wrong oil viscosity.
viscosity.
5. Compressor tilted too
  Level compressor.
much.
  6. Scored cylinder. Replace cylinder.
1. Compressor air intake Clean air filter element and check for
Oil in discharge air.
restricted. other restrictions in the intake system.
  2. Worn piston rings. Replace rings.
3. Excessive oil in
  Drain down to bottom of threads.
compressor.
Check viscosity and change oil if
  4. Wrong oil viscosity.
necessary
 Problem Cause Solution
5. Piston rings installed up-
  Install rings in proper position.
side down.
6. Plugged crankcase
  Clean or replace.
breather.
Compressor vibrates. 1. Mounting bolts loose. Tighten.
Receiver does not hold
Bleed tank! Disassemble check valve
pressure when compressor 1. Faulty check valve.
assembly, clean or replace faulty parts.
shuts off
Realign motor pulley with compressor
Excessive belt wear. 1. Pulley out of alignment.
flywheel.
  2. Belts too tight. Adjust tension.
  3. Belts too loose. Adjust tension.
Check for worn crankshaft, keyway or
4. Pulley or flywheel pulley bore, resulting from running
 
wobble. with loose pulleys. Check for bent
crankshaft - if bent then replace.
5. Nick in belt groove of
  File smooth.
pulley or flywheel.
Excessive discharge air Clean cooling surfaces of cylinder,
1. Dirty cooling surfaces.
temperature. intercooler and discharge tube.
Improve ventilation or relocate
  2. Poor ventilation.
compressor.
  3. Blown head gasket. Replace head gasket.
  4. Worn valve. Repair or replace valves.
Receiver pressure builds
1. Dirty air filter. Clean or replace filter element.
up slowly.
2. Blown cylinder head
  Install new gasket.
gasket.
3. Worn or broken low
  pressure intake or discharge Install new flapper valves and gaskets.
valves.
  4. Air leaks. Tighten joints.
  5. Loose belts. Tighten belt or replace belt.
  6. Speed too slow. Check pulley size and belt tension.
Receiver pressure builds 1. Excessive water in
Drain receiver.
up rapidly. receiver.
Reset mechanism cuts out Shut down immediately to avoid
1. Motor overload.
repeatedly. damage.
2. Malfunction or improperly
  Adjust or replace.
adjusted.
  3. High ambient temperature. Provide ventilation.
Check to make sure that fuses are of
Fuses blow repeatedly. 1. Wrong fuse size.
proper ampere rating.
 Problem Cause Solution
  2. Low voltage.
 
3. Defective unloader or
  Replace or repair.
check valve.
  4. Belt to tight. Loosen belt.
Compressor suddenly
1. Bad unloader valve Replace the unloader valve.
stops working
Plug compressor into a new power
  2. Loss of power
source