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continued

Sr No Problems Probable Causes 1 2 3 4 5 6 7 8 9 10 11


1 Bearings Worn / Need  Foundation Bolts Loose N N N N N N L N N N H
Adjustment  Foundation Uneven /Unit
Rocks
 Excessive Vibrations

2 LP Discharge Valve Open  Valve damaged L N L N N L N L L N H


 Gasket blown on valve cage
assembly
 Foreign Materials
 Inadequate set-screw
tightening

3 HP Discharge Valve  Valve damaged N N L N N L N N L N N


Open  Gasket blown on valve cage
assembly
 Foreign Materials
 Inadequate set-screw
tightening

4 LP Discharge Valve  Valve improperly seated H H H H N H N H H H N


Stuck Closed  Damaged seat gasket
 Excessive carbon
 Channels sticking in guides

5 HP Discharge Valve  Valve improperly seated N N H H N H N N H H N


Stuck Closed  Damaged seat gasket
 Excessive carbon
 Channels sticking in guides

6 Intercooler Passages  Intercooler dirty H H L L N H N L L H N


Clogged  Fouled piping
 Defective capacity control

L- Low, H- High, N- Normal ; For parameters (1 to 11) refer table 4.1 47


continued

Sr No Problems Probable Causes 1 2 3 4 5 6 7 8 9 10 11


7 Intercooler Passages Leak  Tubes broken N L L L N L N L L L N
 Loose valve/Leaky gasket
 Defective capacity control
8 LP Clearance Decreased  Initial clearance too low H H H N N H N L H H H
 Carbonaceous deposits
abnormal
 Bent Crankshaft

9 HP Clearance Decreased  Initial clearance too low N N H H N H N N N H H


 Carbonaceous deposits
abnormal
 Bent Crankshaft

10 HP Clearance Increased  Piston Rod N N L N N L N N N L L


Bent/Twisted/Out of
alignment
 Piston rod wear excessive

11 Intercooler Relief Valve  Valve spring malfunctioning L N N N N L N L N N L


Open  Air passage blocked
 HP Suction valve stuck
 Water inside compressor
chamber

12 Intercooler Relief Valve  Unloader defective H H H N N H N H N N H


Stuck Close  Valve spring malfunctioning

13 Aftercooler Safety Valve  Valve spring malfunctioning N N L L N L N N L N L


Open  Air passage blocked
 Water inside compressor
chamber

L- Low, H- High, N- Normal ; For parameters (1 to 11) refer table 4.1 48


continued

Sr No Problems Probable Causes 1 2 3 4 5 6 7 8 9 10 11


14 Aftercooler Safety Valve  Unloader defective N N H H N H N N H N H
Stuck Close  Valve spring malfunctioning

15 LP Jacket CW Low Flow  Leakage in pipes H N N N N H N N N N N


 Clogging in pipes
 Water supply inadequate

16 HP Jacket CW Low Flow  Leakage in pipes N N H N N H N N N N N


 Clogging in pipes
 Water supply inadequate

17 Intercooler Water  Leakage in pipes N H H N N H N N N N H


Quantity Insufficient  Water supply inadequate

18 Aftercooler Water  Leakage in pipes N N N H N H N N N N N


Quantity Insufficient  Water supply inadequate

19 Lubrication Inadequate  Low level of oil N N N N H N L N N N H


 Oil filter/strainer Clogged
 Oil piping leaks
 Air leak into pump suction
 Oil feed excessive

20 Aftercooler Passage  Scale formation N N N H N H N N N N N


clogged/leak (water side)  Water jacket dirty
 Cooler dirty
 Dirty water used

21 LP Water Jacket Dirty  Scale formation H N N N N N N N N N H


 Water jacket dirty
 Cooler dirty
 Dirty water used

L- Low, H- High, N- Normal ; For parameters (1 to 11) refer table 4.1 49


continued

Sr No Problems Probable Causes 1 2 3 4 5 6 7 8 9 10 11


22 HP Water Jacket Dirty  Scale formation N N H N N N N N N N H
 Water jacket dirty
 Cooler dirty
 Dirty water used

23 Motor Speed High  Inappropriate Electric H N H N H N H N N N H


Supply
 Under loading of
Compressor
 Discharge Valves Open/Not
working
 Leakage in air pipes
 Belts loose

24 Motor Speed Low  Bearings Defective L N L N L N L N N N L


 Piston rings damaged
 Motor needs cleaning
 Low voltage
 Belts too tight

25 Discharge Pipe Restricted  Clogging in discharge pipe N N H H N N N N H N H


 Internal surface of pipe
weared out
 Dirt particles in air
 Scale formation

26 Discharge Pipe Leak  Valves stuck close N N L L N N N N L N L


 Motor speed high
 High voltage
 Gaskets damaged

L- Low, H- High, N- Normal ; For parameters (1 to 11) refer table 4.1 50


continued

Sr No Problems Probable Causes 1 2 3 4 5 6 7 8 9 10 11


27 Oil Relief Valve  High oil pressure N N N N H N H N N N N
Defective Clogged  Valve springs worn out
 Sealing damaged

28 Oil Relief Valve  High oil pressure N N N N H N L N N N N


Defective Leak  Valve springs worn out
 Sealing damaged

29 Aftercooler Passage  Scale formation N N H H N N N N H N H


Clogged (air side)  Relief valve stuck close
 Accumulation of foreign
particles
 Air filter needs cleaning

30 Air Suction Filter  Dirt,rust,scale or oil entering L N L N N L N L L N L


Clogged along with air

31 Intake Pipe  Dirt,rust,scale or oil entering L N L N N L N L L N L


Restricted/Leak along with air

32 LP Side Unloader  Solenoid Valve not working H H N N N H N H L N H


Defective/Stuck  Pressure line clogged
 Unloader dirty, jammed

33 LP Side Unloader  Dirt,rust,scale or oil entering L N L N N L N L L N L


/Suction Valve Open along with air
 Valve seat worn or broken
 Leaking gasket
 Springs broken
 Liquid Carryover
 Carbon or sludge formation

L- Low, H- High, N- Normal ; For parameters (1 to 11) refer table 4.1 51


continued

Sr No Problems Probable Causes 1 2 3 4 5 6 7 8 9 10 11


34 HP Side Unloader  Solenoid Valve not working L N H N N H N L L N H
Defective/Stuck  Pressure line clogged
 Unloader dirty, jammed

35 HP Side Unloader  Dirt,rust,scale or oil entering H H N N N H N H L N L


/Suction Valve Open along with air
 Valve seat worn or broken
 Leaking gasket
 Springs broken
 Liquid Carryover
 Carbon or sludge formation

36 LP Suction Valve  Dirt,rust,scale or oil entering L N L N N L N L L N L


Chocked along with air
 Valve Plate worn or broken
 Liquid Carryover
 Carbon or sludge formation

37 HP Suction Valve  Dirt,rust,scale or oil entering H N L N N H N H L N L


Chocked along with air
 Valve Plate worn or broken
 Liquid Carryover
 Carbon or sludge formation

38 LP Side Piston Ring  Dirt,rust,scale or oil entering H N N N N H N L L N L


Worn along with air
 Loose rider bands
 Speed too high

39 LP Cylinder Scored  Dirt,rust,scale or oil entering H N N N N H N L L N L


along with air
 Piston Ring broken
 Speed too high

L- Low, H- High, N- Normal ; For parameters (1 to 11) refer table 4.1 52


continued

Sr No Problems Probable Causes 1 2 3 4 5 6 7 8 9 10 11


40 HP Side Piston Ring  Dirt,rust,scale or oil entering N N H N L H N H L N L
Worn along with air
 Loose rider bands
 Speed too high

41 HP Cylinder Scored  Dirt,rust,scale or oil entering N N H N L H N H L N L


along with air
 Piston Ring broken
 Speed too high

42 LP Clearance Increased  Piston Rod L N N N N L L N N N L


Bent/Twisted/Out of
alignment
 Piston rod wear excessive

43 Packing Rings Tight  Assembly incorrect H N N N N H N H N N H

44 Packing Ring Leak  Improper Bolt Tightening L N N N N L N L N N N

45 Belts Loose  Pulley or Flywheel Loose N N N N N N N N N N L

46 Belts Misaligned  Excessive Vibrations N N N N N N N N N N H

L- Low, H- High, N- Normal ; For parameters (1 to 11) refer table 4.1 53