Air compressor Trouble shooting Problem Cause Compressor will not operate. 1. No electrical power. 2. Low oil level.

3. Pressure switch not making contact. Excessive noise in operation. 1. Loose pulley, flywheel, belt, belt guard, cooler, clamps or accessories. 2. Lack of oil in crankcase. 3. Piston hitting the valve plate.

4. Compressor floor mounting loose. 5. Defective crankcase. 6. Excessive crank end play. Knock - same cycle as R.P.M. 1. Main bearings. 2. Connecting rod bearings. Knock occurs while compressor is loading. 3. Loose flywheel. 1. Connecting rod bearings. 2. Wrist pins, wrist pin bearings. 3. Loose connecting rod nut. Milky oil in oil reservoir. 1. Water entering oil reservoir due to compressor operating in high humidity environment.

Excessive oil consumption.

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. 3. Pulley and flywheel misaligned.

Oil in discharge air.

Compressor vibrates.

Air blowing out of inlet.

4. Belts loose. 5. Bent crankshaft. 1. Broken first stage inlet valve.

Insufficient pressure at point 1. Leaks or restriction. 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 is unloaded. Excessive belt wear.

1. 1. 2. 3.

Faulty check valve. Pulley out of alignment. Belts too tight. Belts too loose.

4. Pulley or flywheel wobble.

Excessive discharge air temperature.

5. Nick in belt groove of pulley or flywheel. 1. Dirty cooling surfaces. 2. Poor ventilation. 3. Blown head gasket. 4. Restricted air intake. 5. Worn valves.

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

1. Safety relief valve not functioning properly.

2. Leaky gasket - High pressure inlet valve. Receiver pressure builds up 1. Dirty air filter. slowly. 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. Receiver pressure builds up 1. Excessive water in receiver. quickly on compressor. 2. Speed too fast. Reset mechanism cuts out repeatedly; fuses of proper size blow. 1. Motor overload.

2. Malfunction or improperly adjusted. 3. High ambient temperature. Fuses blow repeatedly. 1. Wrong fuse size.

Compressor will not operate. 1. No electrical power.

2. Pressure switch not making contact. 3. Defective unloader or check Excessive noise in operation. valve. 1. Loose pulley, flywheel belt, belt guard, clamps or accessories. 2. Lack of oil in crankcase. 3. Piston hitting the valve plate.

Knock-same cycle as RPM.

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.

Knock occurs while compressor is loading.

Milky oil in crankcase.

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. 5. 6. 1. Wrong oil viscosity. Compressor tilted too much. Scored cylinder. Compressor air intake restricted.

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 Excessive belt wear. 1. Mounting bolts loose. 1. Faulty check valve. 1. Pulley out of alignment. 2. Belts too tight. 3. Belts too loose. 4. Pulley or flywheel wobble. 5. Nick in belt groove of pulley or flywheel. 1. Dirty cooling surfaces. 2. Poor ventilation. 3. Blown head gasket. 4. Worn valve.

Excessive discharge air temperature.

Receiver pressure builds up 1. Dirty air filter. slowly. 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. Receiver pressure builds up 1. Excessive water in receiver. rapidly. Reset mechanism cuts out 1. Motor overload. repeatedly. 2. Malfunction or improperly adjusted. 3. High ambient temperature. Fuses blow repeatedly. 1. Wrong fuse size. 2. Low voltage. 3. Defective unloader or check valve. 4. Belt to tight.

shooting Solution Turn on power. Check oil level. Replace your oil if necessary See pressure switch adjustment. 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. 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. replace air filter element. Clean or 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 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. Check speed. Shut down immediately to avoid damage.

Adjust or replace. Provide ventilation. Check to make sure that fuses are of proper ampere rating. Turn on power, check fuse, breaker, or motor overload.

Replace or repair. 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. Tighten. 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. 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.

Liquid Rinq Vacuum Pumps - Troubleshooting Tips S.No Observed problem Problem source 1 Reduced capacity of pump 1a. Seal water temperature higher than design 1b. Low seal water flow rate 2 Excessive noise 1a.

1b.

2a. Excessive or 2a. insufficient seal liquid to pump 2b. Coupling misalignment 2b. 3 Excessive seal liquid 3a. 3b. Coupling misalignment 3b. 3c. Excessive discharge pressure 3d. Defective bearing 3e. Gland ring too tight 3f. Improperly mounted pump 3c. 3d. 3e. 3f.

3 High power consumption

4 Overheating

4a. Excessive seal liquid 4a. temperature 4b. Insufficient seal liquid 4b. flow rate 4c. Coupling misalignment 4c. 4d. Defective bearing 4e. Gland ring too tight 4f. Improperly mounted pump 5a. Coupling misalignment 5b. Pump or motor not properly anchored 5c. Rotor imbalance 5d. Improperly mounted pump 6 Insufficient lubrication 7a. Scale from hard water 7b. Foreign object in pump 7c. Improperly mounted pump 4d. 4e. 4f. 5a. 5b. 5c. 5d. 6 7a. 7b. 7c.

5 Vibration

6 Mechanical seals "squeak" 7 Pump shaft is seized and will not turn

s - Troubleshooting Tips Corrective measure Reduce temperature by increasing cooling water flow or check seal cooler for fouling Adjust seal water flow rate or check centrifugal recirculation pump Adjust seal flow rate Realign coupling Adjust seal flow rate Realign coupling Correct as necessary Replace bearing Loosen gland ring Make sure mounting surface is level Check coolant flow rate and seal cooler fouling Increase seal liquid flow rate Realign coupling Replace bearing Loosen gland ring Make sure mounting surface is level Realign coupling Anchor pump or motor Balance rotor Make sure mounting surface is level Check flow of coolant to seals Remove scale from pump Dismantle pump and remove object Make sure mounting surface is level