Problem Cause Solution

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

operate. Push the reset button.

2. Low oil level. Check oil level. Replace your oil if necessary

3. Pressure switch not See pressure switch adjustment.

making contact.

4. Pressure in the tank is See pressure switch adjustment.

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

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

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

2. Lack of oil in crankcase. Check for possible damage to bearings

Replenish the oil level.

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

4. Compressor floor Tighten the bolts on the air compressor. It may

mounting loose. also be a good idea to replace 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.

Milky oil in oil reservoir. 1. Water entering oil a. Pipe air intake to less humid air source.
reservoir due to compressor
 Problem Cause Solution
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 hours for oil changes.

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.

4. Wrong oil viscosity. Drain oil, refill with oil of proper viscosity.

5. Compressor tilted too Level compressor. Vibration pads may help

much. with this

6. Scored cylinder. Replace cylinder.

Oil in discharge air. 1. Compressor air intake Clean or replace your air filters.
restricted.

2. Worn piston rings. Replace rings.

3. Excessive oil in Drain down to full mark on sight gauge.

compressor.

4. Wrong oil viscosity. Check viscosity.

5. Piston rings installed up- Replace crankshaft.

side down.

Compressor vibrates. 1. Mounting bolts loose. Tighten.

2. Compressor not properly Level compressor so that all feet touch the
mounted. floor before tightening down.

3. Pulley and flywheel Realign.

misaligned.

4. Belts loose. Tighten belts.

5. Bent crankshaft. Replace crankshaft.

 Problem Cause Solution
Air blowing out of inlet. 1. Broken first stage inlet Replace valve plate assembly.
valve.

Insufficient pressure at 1. Leaks or restriction. Check for leaks or restriction in hose or piping.
point of use. 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.

5. Excessive air requirement. Limit air usage to compressor capacity by

using fewer or smaller tools.

Receiver does not hold 1. Faulty check valve. Bleed tank! Disassemble check valve assembly,
pressure when clean or replace faulty parts.
compressor is unloaded.

Excessive belt wear. 1. Pulley out of alignment. Realign motor pulley with compressor flywheel.

2. Belts too tight. Adjust tension.

3. Belts too loose. Adjust tension.

4. Pulley or flywheel Check for worn crankshaft, keyway or pulley

wobbles. bore, resulting from running with loose pulleys.
Check for bent crankshaft.

5. Nick in belt groove of File smooth.

pulley or flywheel.

Excessive discharge air 1. Dirty cooling surfaces. Clean cooling surfaces of cylinder, intercooler
temperature. and discharge tube.

2. Poor ventilation. Improve ventilation or relocate 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 1. Safety relief valve not Remove and install new safety relief valve. If
stage safety relief valve functioning properly. new safety valve leaks remove cylinder head,
when compressor is inspect and clean reed valve assembly.
pumping.

2. Leaky gasket - High Replace gasket.

 Problem Cause Solution
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 Install new valve plate.

pressure intake or discharge
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/tank.

up quickly on compressor. receiver.

2. Speed too fast. Check speed.

Reset mechanism cuts out 1. Motor overload. Shut down immediately to avoid damage.
repeatedly; fuses of proper
size blow.

2. Malfunction or improperly Adjust or replace.

adjusted.

3. High ambient Provide ventilation.

temperature.

Fuses blow repeatedly. 1. Wrong fuse size. Check to make sure that fuses are of proper
ampere rating.

Compressor will not 1. No electrical power. Turn on power, check fuse, breaker, or motor
operate. overload.

2. Pressure switch not Replace or repair.

making contact.

3. Defective unloader or Replace or repair.

check valve.

Excessive noise in 1. Loose pulley, flywheel Tighten.

operation. belt, belt guard, clamps or
accessories.
 Problem Cause Solution
2. Lack of oil in crankcase. Check for possible damage to bearings,
replenish oil.

3. Piston hitting the valve Remove the compressor cylinder head and
plate. inspect for foreign matter on top 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 bolt. Tighten bolt.

4. Loose flywheel. Tighten setscrew.

Milky oil in crankcase. 1. Water entering oil Pipe air intake to less humid air source.
reservoir due to compressor
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.

4. Wrong oil viscosity. Drain oil, refill with oil of proper viscosity.

5. Compressor tilted too Level compressor.

much.

6. Scored cylinder. Replace cylinder.

 Problem Cause Solution
Oil in discharge air. 1. Compressor air intake Clean air filter element and check for other
restricted. restrictions in the intake system.

2. Worn piston rings. Replace rings.

3. Excessive oil in Drain down to bottom of threads.

compressor.

4. Wrong oil viscosity. Check viscosity and change oil if necessary

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. Consider installing vibration pads.

Receiver does not hold 1. Faulty check valve. Bleed tank! Disassemble check valve assembly,
pressure when clean or replace faulty parts.
compressor shuts off

Excessive belt wear. 1. Pulley out of alignment. Realign motor pulley with compressor flywheel.

2. Belts too tight. Adjust tension.

3. Belts too loose. Adjust tension.

4. Pulley or flywheel wobble. Check for worn crankshaft, keyway or pulley

bore, resulting from running with loose pulleys.
Check for bentcrankshaft - if bent then replace.

5. Nick in belt groove of File smooth.

pulley or flywheel.

Excessive discharge air 1. Dirty cooling surfaces. Clean cooling surfaces of cylinder, intercooler
temperature. and discharge tube.

2. Poor ventilation. Improve ventilation or relocate 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.
 Problem Cause Solution
3. Worn or broken low Install new flapper valves and gaskets.
pressure intake or discharge
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 1. Motor overload. Shut down immediately to avoid damage.
repeatedly.

2. Malfunction or improperly Adjust or replace.

adjusted.

3. High ambient Provide ventilation.

temperature.

Fuses blow repeatedly. 1. Wrong fuse size. Check to make sure that fuses are of proper
ampere rating.

2. Low voltage.

3. Defective unloader Replace or repair.

or check valve.

4. Belt to tight. Loosen belt.

Compressor suddenly 1. Bad unloader valve Replace the unloader valve.

stops working

2. Loss of power Plug compressor into a new power source