Air Compressor Trouble Shooting Guide
Provided below is a general list of common air compressor problems, and a few quick
fixes that may help solve your dilemma. And may not necessarily fit your compressor.
Always remember to check your owner’s manual to ensure that the correct parts are
purchased.
Problem Cause
Compressor will not 1. No electrical power.
operate.
2. Low oil level.
3. Pressure switch not making
contact.
4. Pressure in the tank is
below the cut-in pressure.
Excessive noise in 1. Loose pulley, flywheel, belt,
operation. 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 1. Main bearings.
as R.P.M. 2. Connecting rod bearings.
3. Loose flywheel.
Knock occurs while 1. Connecting rod bearings.
compressor is 2. Wrist pins, wrist pin
loading. bearings.
3. Loose connecting rod nut.
Solution
Turn on power.
Push the reset button.
Check oil level. Replace your oil if
necessary
See pressure switch adjustment.
See pressure switch adjustment.
Replace pressure switch to one
that has a lower cut-in PSI
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.
Milky oil in oil 1. Water entering oil reservoir
reservoir. due to compressor operating
in high humidity environment.
Excessive oil 1. Restricted air intake.
consumption. 2. Oil leaks.
3. Worn piston rings.
4. Wrong oil viscosity.
5. Compressor tilted too
much.
6. Scored cylinder.
Oil in discharge air. 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.
Compressor vibrates. 1. Mounting bolts loose.
2. Compressor not properly
mounted.
3. Pulley and flywheel
misaligned.
4. Belts loose.
5. Bent crankshaft.
Air blowing out of 1. Broken first stage inlet
inlet. valve.
Insufficient pressure 1. Leaks or restriction.
at point of use.
2. Restricted air intake.
3. Slipping belts.
4. Service hose too small.
5. Excessive air requirement.
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.
Clean or replace air filter element.
Tighten belts.
Replace with larger hose.
Limit air usage to compressor
capacity by using fewer or smaller
tools.
Receiver does not 1. Faulty check valve.
hold pressure when
compressor is
unloaded.
Excessive belt wear. 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.
Excessive discharge 1. Dirty cooling surfaces.
air temperature.
2. Poor ventilation.
3. Blown head gasket.
4. Restricted air intake.
5. Worn valves.
Air leaking from 1. Safety relief valve not
inter stage safety functioning properly.
relief valve when
compressor is
pumping.
2. Leaky gasket - High
pressure inlet valve.
Receiver pressure 1. Dirty air filter.
builds up 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 1. Excessive water in receiver.
builds up quickly on 2. Speed too fast.
compressor.
Reset mechanism 1. Motor overload.
cuts out repeatedly;
fuses of proper size 2. Malfunction or improperly
blow. adjusted.
3. High ambient temperature.
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/tank.
Check speed.
Shut down immediately to avoid
damage.
Adjust or replace.
Provide ventilation.
Fuses blow 1. Wrong fuse size.
repeatedly.
Compressor will not 1. No electrical power.
operate.
2. Pressure switch not making
contact.
3. Defective unloader or check
valve.
Excessive noise in 1. Loose pulley, flywheel
operation. belt, belt guard, clamps or
accessories.
2. Lack of oil in crankcase.
3. Piston hitting the valve
plate.
4. Compressor floor mounting
loose.
5. Defective crankcase.
Knock-same cycle as 1. Main bearings.
RPM. 2. Connecting rod bearings.
3. Loose flywheel.
Knock occurs while 1. Connecting rod bearings.
compressor is 2. Wrist pins, wrist pin
loading. bearings.
3. Loose connecting rod bolt.
4. Loose flywheel.
Milky oil in 1. Water entering oil reservoir
crankcase. due to compressor operating
in high humidity environment.
Excessive oil 1. Restricted air intake.
consumption. 2. Oil leaks.
3. Worn piston rings.
4. Wrong oil viscosity.
5. Compressor tilted too
much.
6. Scored cylinder.
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.
Oil in discharge air. 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.
6. Plugged crankcase
breather.
Compressor vibrates. 1. Mounting bolts loose.
Receiver does not 1. Faulty check valve.
hold pressure when
compressor shuts off
Excessive belt wear. 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.
Excessive discharge 1. Dirty cooling surfaces.
air temperature.
2. Poor ventilation.
3. Blown head gasket.
4. Worn valve.
Receiver pressure 1. Dirty air filter.
builds up 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 1. Excessive water in receiver.
builds up rapidly.
Reset mechanism 1. Motor overload.
cuts out repeatedly.
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. Consider
installing vibration pads.
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/tank.
Shut down immediately to avoid
damage.
 2. Malfunction or improperly Adjust or replace.
adjusted.
3. High ambient temperature. Provide ventilation.
Fuses blow 1. Wrong fuse size. Check to make sure that fuses are
repeatedly. of proper ampere rating.
2. Low voltage.

3. Defective unloader or check Replace or repair.

valve.
4. Belt to tight. Loosen belt.
Compressor 1. Bad unloader valve Replace the unloader valve.
suddenly stops 2. Loss of power Plug compressor into a new
working power source