8
Operating Instructions
Troubleshooting Chart
Symptom Possible Cause(s) Corrective Action
Low discharge pressure 1. Air demand exceeds pump capacity 1. Reduce air demand or use a compressor with more capacity.
2. Restricted air intake 2. Clean or replace the air filter element.
3. Air leaks (fittings, tubing on
compressor, or plumbing outside of
system)
3. Listen for escaping air. Apply soap solution to all fittings and
connections. Bubbles will appear at points of leakage. Tighten or
replace leaking fittings or connections. Use pipe thread sealant.
4. Blown gaskets 4. Replace any gaskets proven faulty on inspection.
5. Leaking or damaged valves 5. Remove head and inspect for valve breakage, misaligned valves,
damaged valve seats, etc. Replace defective parts and reassemble.
Install a new head gasket
each time the head is removed
Pump overheating causes
air filter to melt
1. Insulating gasket between filter and
head is missing
1. Install gasket.
2. Broken valves/blown gasket 2. Replace valves or install new gasket.
Excessive noise (knocking) 1. Loose motor pulley or flywheel 1. Tighten pulley / flywheel clamp bolts and set-screws.
2. Loose fasteners on pump or motor 2. Tighten fasteners
3. Lack of oil in crankcase 3. Check for proper oil level; if low, check for possible damage to
bearings. Dirty oil can cause excessive wear.
4. Worn connecting rod 4. Replace connecting rod. Maintain oil level and change oil more
frequently.
5. Worn piston pin bores 5. Remove piston assemblies from the compressor and inspect for
excess wear. Replace excessively worn piston pin or pistons, as
required. Maintain oil level and change oil more frequently.
6. Piston hitting the valve plate 6. Remove the compressor head and valve plate and inspect for
carbon deposits or other foreign matter on top of piston. Replace
head and valve plate using new gasket. See Lubrication section for
recommended oil.
7. Noisy check valve in compressor
system
7. Replace check valve.
Do not disassemble check
valve with air pressure in tank
Large quantity of oil in
the discharge air
NOTE: In an oil lubricated
compressor there will
always be a small amount
of oil in the air stream.
1. Worn piston rings 1. Replace with new rings. Maintain oil level and change oil more
frequently.
2. Compressor air intake restricted 2. Clean or replace filter. Check for other restrictions in the intake
system.
3. Excessive oil in compressor 3. Drain down to full level.
4. Wrong oil viscosity 4. Use Mobil 1
®
10W-30.
Water in discharge air /
tank
Normal operation. The amount of
water increases with humid weather
1. Drain tank more often. At least daily.
2. Add a filter to reduce the amount of water in the air line.
Motor hums and runs
slowly or not at all
1. Low voltage 1. Check incoming voltage. It should be approximately 230 volts.
Motor will not run properly on 208 volts. Low voltage could be
due to wires (from electrical source to compressor) being too small
in diameter and / or too long. Have a qualified electrician check
these conditions and make repairs as needed.
2. Too many devices on same circuit 2. Limit the circuit to the use of compressor only
3. Loose electrical connections 3. Check all electrical connections
4. Malfunctioning pressure switch -
contacts will not close
4. Replace pressure switch.
5. Malfunctioning check valve 5. Replace check valve.
Do not disassemble check
valve with air pressure in tank
6. Defective unloader valve on
pressure switch
6. Replace unloader valve
7. Defective motor capacitor(s) 7. Replace capacitor(s)
8. Defective motor 8. Replace motor
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