Compressor Troubleshooting

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
below the cut-in pressure.
has 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
  2. Lack of oil in crankcase. bearings
Replenish the oil level.
Remove the compressor cylinder head
3. Piston hitting the valve and inspect for foreign matter on top
 
plate. of the piston. Add a new gasket and
reassemble the head.
Tighten the bolts on the air
4. Compressor floor
  compressor. It may also be a good
mounting loose.
idea to replace your vibration pads
  5. Defective crankcase. Repair or replace.
6. Excessive crank end
  Adjust and shim properly.
play.
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
  Tighten.
nut.
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.
 Problem Cause Solution
  c. Drain tank daily.
 
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. Vibration pads
 
much. may help with this
  6. Scored cylinder. Replace cylinder.
1. Compressor air intake
Oil in discharge air. Clean or replace your air filters.
restricted.
  2. Worn piston rings. Replace rings.
3. Excessive oil in Drain down to full mark on sight
 
compressor. gauge.
  4. Wrong oil viscosity. Check viscosity.
5. Piston rings installed up-
  Replace crankshaft.
side down.
Compressor vibrates. 1. Mounting bolts loose. Tighten.
Level compressor so that all feet
2. Compressor not properly
  touch the floor before tightening
mounted.
down.
3. Pulley and flywheel
  Realign.
misaligned.
  4. Belts loose. Tighten belts.
  5. Bent crankshaft. Replace crankshaft.
1. Broken first stage inlet
Air blowing out of inlet. Replace valve plate assembly.
valve.
Insufficient pressure at Check for leaks or restriction in hose
1. Leaks or restriction.
point of use. or piping. Repair.
  2. Restricted air intake. Clean or replace air filter element.
  3. Slipping belts. Tighten belts.
  4. Service hose too small. Replace with larger hose.
Limit air usage to compressor
5. Excessive air
  capacity by using fewer or smaller
requirement.
tools.
Receiver does not hold Bleed tank! Disassemble check valve
pressure when 1. Faulty check valve. assembly, clean or replace faulty
compressor is unloaded. parts.
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.
  4. Pulley or flywheel Check for worn worn crankshaft,
wobble. 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
when compressor is functioning properly. remove cylinder head, inspect and
pumping. clean reed 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
up quickly on Drain receiver/tank.
receiver.
compressor.
  2. Speed too fast. Check speed.
Reset mechanism cuts out
Shut down immediately to avoid
repeatedly; fuses of 1. Motor overload.
damage.
proper size blow.
2. Malfunction or
  Adjust or replace.
improperly adjusted.
3. High ambient
  Provide ventilation.
temperature.
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,
1. No electrical power.
operate. or motor overload.
2. Pressure switch not
  Replace or repair.
making contact.
3. Defective unloader or
  Replace or repair.
check valve.
 Problem Cause Solution
1. Loose pulley, flywheel
Excessive noise in
belt, belt guard, clamps or Tighten.
operation.
accessories.
Check for possible damage to
  2. Lack of oil in crankcase.
bearings, replenish oil.
Remove the compressor cylinder head
3. Piston hitting the valve and inspect for foreign matter on top
 
plate. of 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
  Tighten bolt.
bolt.
  4. Loose flywheel. Tighten setscrew.
1. Water entering oil
reservoir due to compressor Pipe air intake to less humid air
Milky oil in crankcase.
operating in high humidity source.
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
5. Piston rings installed up-
  Install rings in proper position.
side down.
  6. Plugged crankcase Clean or replace.
 Problem Cause Solution
breather.
Tighten. Consider installing vibration
Compressor vibrates. 1. Mounting bolts loose.
pads.
Receiver does not hold Bleed tank! Disassemble check valve
pressure when 1. Faulty check valve. assembly, clean or replace faulty
compressor shuts off parts.
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/tank.
up rapidly. receiver.
Reset mechanism cuts out Shut down immediately to avoid
1. Motor overload.
repeatedly. damage.
2. Malfunction or
  Adjust or replace.
improperly adjusted.
3. High ambient
  Provide ventilation.
temperature.
Check to make sure that fuses are of
Fuses blow repeatedly. 1. Wrong fuse size.
proper ampere rating.
  2. Low voltage.
 
3. Defective unloader or
  Replace or repair.
check valve.
 Problem Cause Solution
  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

Reciprocating Pumps Trouble Shooting Guide

 Low Volumetric Efficiency
 NPSHA Too Low
 Liquid Not Delivered
 Cavitation
 Leak at Cylinder Head or Valve Cover
 Water in Crankcase/Oil
 Oil Leakage from Crankcase
 Excessive Heat in Power End
 Pump Overloads Driver
 Stuffing Box Leakage
 Stud Failure
 Excessive Valve Noise
 Inlet or Discharge Line Vibration
 Noisy Operation

Top Low Volumetric Efficiency (Failure To Deliver Rated Capacity And Pressure)

1. Air or vapor pocket in inlet line

2. Capacity of charge pump less than capacity of power pump
3. Air or vapor trapped in or above inlet manifold
4. Air leak in liquid supply piping system
5. Loose bolts in pump inlet manifold
6. Air or gases entrained in liquid
7. Foreign object holding pump inlet or discharge valve(s) open
8. Incorrect drive ratio
9. Loose belts
10. Incorrect motor or engine speed
11. Loose valve covers or cylinder head
12. Worn valves and seats
13. Safety relief valve partially open, or not holding pressure
14. Worn liners, piston rings or plungers
15. Bypass valve open, or not holding pressure
16. Blown liner gasket
17. NPSHA not sufficient
18. Liquid bypassing internally
19. Foreign object blocking liquid passage
20. Vortex in supply tank
21. Insufficient power delivered by motor
Top NPSHA Too Low

1. Inlet line partially clogged

2. Liquid vapor pressure too high
3. Liquid pumping temperature too high
4. Restricted inlet pipe fittings
5. Inlet line too long
6. Too many pipe fittings
7. Too small inlet line
8. Too low static inlet head
9. Too low atmospheric pressure

Top Liquid Not Delivered

1. Pump not primed

2. Air or vapor pocket in inlet line
3. Clogged inlet line
4. All inlet valves propped open
5. All discharge valves propped open
6. Loose bolts in pump inlet manifold
7. Too high valve velocities

Top Cavitation

1. NPSHA too low

2. Liquid NOT Delivered to Pump Inlet Connection
3. Excessive Stuffing Box Leakage
4. NPSHR too high

Top Leak at Cylinder Head or Valve Cover

1. Over Recommended Pressure

2. Loose Cylinder Head/Valve Cover
3. Damaged Gasket/O-ring

Top Water in Crankcase/Oil

1. Water Condensation
2. Worn seals
3. Clogged Air Breather(s)
4. Worn Crankcase Packing
5. Loose Covers

Top Oil Leakage from Crankcase

1. Oil Level/Temperature Too High

2. Worn seals
3. Worn Crankcase Packing
4. Loose Crankcase Cover
Top Excessive Heat in Power End

1. Pump Running Backward/RPM too low 2) Insufficient Oil in Power End

2. Excessive Oil in Power End
3. Incorrect Oil Viscosity
4. Operating Pump above Recommended Pressure 6) Main Bearings too Tight
5. Drive Misaligned
6. Belts too Tight
7. Discharge Valve, one or more, Stuck Open 10) Insufficient Cooling
8. Pump RPM too Low
9. Inadequate Ventilation
10. Liquid End Packing Adjusted too Tight (adjustable style packing only)

Top Pump Overloads Driver

1. Pump RPM too High

2. Low Voltage or other Electrical Trouble
3. Trouble with Engine, Turbine, Gear Reducer or other Related Equipment
4. Excessive Discharge Line Pressure
5. Clogged Discharge Line
6. Closed/Throttled Valve in Discharge Line
7. Incorrect Plunger/Piston Size for Application
8. Improper Bypass Conditions
9. Over-tightened Stuffing Box Glands on Adjustable Packing

Top Stuffing Box Leakage

1. Worn Packing
2. Worn rods or plunger
3. Worn stuffing boxes
4. Wrong size packing
5. Worn O-ring seal (replaceable boxes)

Top Stud Failure

1. Excessive discharge pressure

2. Improper torquing of nuts
3. Shock overload caused by pump cavitation

Top Excessive Valve Noise

1. Broken or weak valve spring

2. Pump cavitation
3. Air leak in inlet piping or loose bolts in pump inlet manifold
4. Air trapped above inlet valve

Top Inlet or Discharge Line Vibration

1. Piping inadequately supported

2. Inlet line too long or too small in diameter
 3. Too many bends in inlet line
4. Multiple pump installations operating in phase
5. Obstruction Under Valve(s)
6. Packing Worn
7. Operating Above Recommended Pressure or RPM 8) Low NPSHA

Top Noisy Operation (Be sure to differentiate between liquid knock and mechanical knock - very few
knocks are mechanical on new installations.)

1. Piston or plunger loose

2. Valve noise amplified through power end
3. Pump cavitation
4. Liquid knock
5. Air leak in inlet piping
6. Loose bolts in pump inlet manifold
7. Hydraulic noise in liquid end
8. Loose or worn crosshead pins and bushings
9. Loose connecting rod cap bolt
10. Worn connecting rod bearings
11. Worn crosshead
12. Main bearing end play excessive
13. Worn gears or chains
14. Gears or chains out of line
15. Pump running backward
16. Partial loss of prime
17. Shocks in piping system
18. Water in power end crankcase
19. Poorly supported piping, abrupt turns in piping, piping misaligned, pipe size too
small

Centrifugal Pump Troubleshooting Guide

This “TROUBLESHOOTING” information is intended to guide in the general determination
of pump problems and their solutions. Each manufacturer normally provides a description of
warranty conditions. Some pump warranties are immediately voided if the unit is
disassembled. Be sure to thoroughly read the owner's manual and warranty.

Installation and parts manuals are provided only as reference tools. Neither the manufacturer
nor the Seller makes any representation or warranty of any kind to the Buyer that he or she is
qualified to neither install nor make any repairs to the product. In fact, the manufacturer and
the Seller expressly state that installation, repairs and parts replacements should be
undertaken by qualified and competent technicians or contractors and not by the Buyer. The
Buyer assumes all risk and liability arising out of his or her installation or repair to the
original product.
Little or no discharge

 Casing not initially filled with water. (Fill pump casing---prime pump)
 Total head too high. (Shorten suction and/or head)
 Suction lift too high , or too long (Lower suction lift, install foot valve and prime, or shorten
length of suction line)
 Impeller plugged (Clean impeller)
 Hole or air leak in suction line (Repair or replace; do not use Teflon tape;use pipe sealing
compound)
 Foot valve too small (Match foot valve to piping or install one size larger foot valve)
 Foot valve or suction line not submerged deep enough in water (Submerge lower in water--
at least 3 feet)
 Impeller damaged (Replace impeller)
 Insufficient inlet pressure or suction head ( Increase inlet pressure by adding more water to
tank or increasing back pressure)
 Suction piping too small (Increase to pump inlet size or one size larger)
 Motor wired incorrectly (Check wiring diagram)
 Casing gasket or "O" ring leaking (Replace)
 Suction or discharge valve closed (Open)
 Pump flow is greater than well flow capacity (Match pump flow to well capacity)

Loss of suction

 Air leak in suction line (Repair & replace)

 Suction lift too high (Lower suction lift, install foot valve and prime)
 Insufficient inlet pressure or suction head (Increase inlet pressure by adding more water to
tank or increasing back pressure)
 Clogged foot valve check valve or strainer (Unclog)
 Defective foot valve or check valve (Replace)
 Defective priming hose bibb on suction pipe (Replace)
 Defective well (Repair or replace)

Motor Overheats and Shuts Off (Overload)

 Motor voltage does not match power supply voltage (Check motor connection against wiring
diagram on the motor nameplate and against the power supply voltage)
 Improper wire size (Consult with a licensed electrician or refer to the National Electrical
Code for definite guide to wire sizeand circuit protection devices)
 Impeller is rubbing against pump case or not turning freely (Dismantle pump, unclog or
replace the impeller)
 Low voltage at the motor (Make sure electrical connections are tight)

Pump leaks at shaft

 Worn mechanical seal (Replace mechanical seal)

Pump vibrates and/or makes excessive noise

 Mounting plate or foundation not rigid enough (Reinforce)

 Foreign material in pump (Dismantle pump and clean)
 Impeller damaged (Replace impeller)
 Worn motor bearings (Replace bearings)
 Suction lift too high ( Lower suction lift, install foot valve and prime)

Pump will not deliver water or develop pressure

 No priming water in casing (Fill pump casing)

 Mechanical seal leaking (Replace mechanical seal)
 Leak in suction line (Repair or replace)
 Discharge line is closed and priming air has nowhere to go (Open)
 Suction line or valve is closed (Open)
 Pump is down (Replace worn parts)
 Foot valve or check valve is leaking ( Replace valve)
 Suction screen clogged (Clean or replace)

Pump will not prime

 No priming water in casing (Fill pump casing)

 Mechanical seal leaking (Replace mechanical seal)
 Leak in suction line (Repair or replace)
 Discharge line is closed and priming air has nowhere to go (Open)
 Suction line or valve is closed (Open)
 Pump is down (Replace worn parts)
 Foot valve or check valve is leaking ( Replace valve)
 Suction screen clogged (Clean or replace)

Pump will not start or run

 Improperly wired (Check wiring against diagram on motor)

 Blown fuse or open circuit breaker (Replace fuse, reset circuit breaker)
 Loose or broken wiring (Tighten connections, replace broken wiring
 Stone or foreign object lodged in impeller (Dismantle pump and remove foreign object)
 Motor shorted out (Replace motor)
 Thermal overload has opened circuit (Allow unit to cool, restrart after reason for overload
has been determined