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Low Capacity |
- Restricted air suction line or filter.
- Loose valve assembly.
- Leaking valve assembly.
- Defective inlet valve unloaders.
- Defective or improperly set load controller.
- Worn Piston rings.
- Excessive leakage at piston rod packing.
- V-belts slipping (where applicable).
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Low or No Oil Pressure |
- Defective pressure gauge or sensor.
- Crankcase oil level too low.
- Oil viscosity too light.
- Plugged oil filter.
- Leak in oil pump suction line.
- Incorrect oil pump relief valve setting.
- Oil pressure relief valve not seating.
- Broken relief valve spring.
- Defective oil pump.
- Oil pump drive coupling broken.
- Incorrect rotation (certain models).
- Worn main, crankpin or wrist pin bearings.
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Erratic Oil Pressure |
- Defective gauge or sensor.
- Worn main, crankpin or wrist pin bearings.
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Piston Rod Packing Failure |
- Scored or worn piston rod.
- Normal packing wear.
- Incorrect packing ring side clearance.
- Excessive piston rod runout.
- Restricted water flow thru case (water cooled only).
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Motor Overheats |
- Discharge pressure too high.
- Worn or broken valves.
- Abnormal interstage pressures.
- Inadequate crankcase lubrication.
- Voltage incorrect.
- Excessive belt tension.
- Ambient air temperature over 104oF.
- Motor single phased or shorted.
- Motor cooling air intake screen dirty.
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Crosshead Pin Bushing Failure (Repeated) |
- Excessive operation at 50% load.
- Bent connecting rod.
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Compressor Knocks |
- Inadequate running clearances.
- Insufficient head clearance.
- Excessive crosshead clearance.
- Loose piston rod nut.
- Loose compressor pulley.
- Excessive bearing clearance.
- Discharge pressure too high.
- Loose valve.
- Excessive piston to cylinder clearance.
- Valve debris lodged in piston face.
- Bent connecting rod.
- Worn or broken piston rings.
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Low First Stage Discharge Pressure |
- Defective pressure gauge or sensor.
- Dirty or restricted air filter.
- Loose or leaking first stage suction valves.
- Defective or sticking first stage discharge valves.
- Loose or leaking first stage discharge valves.
- Worn first stage piston rings.
- First stage intercooler drain valve stuck open.
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Low Second Stage Discharge Pressure |
- Defective pressure gauge or sensor.
- Loose or leaking second stage suction valves.
- Defective or sticking second stage suction valve unloaders.
- Loose or sticking second stage discharge valves.
- Worn second stage piston rings.
- Second stage intercooler drain valve stuck open.
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Low Third Stage Discharge Pressure |
- Defective pressure gauge or sensor.
- Loose or leaking third stage suction valves.
- Defective or sticking third stage suction valve unloaders.
- Loose or leaking third stage discharge valves.
- Worn third stage piston rings.
- Aftercooler drain valve stuck open.
- Plant demand greater than compressor capacity.
- Load controller set too low or defective.
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High First Stage Discharge Pressure |
- Defective pressure gauge or sensor.
- Loose or leaking second stage suction valves.
- Defective or sticking second stage suction valve unloader.
- Worn second or third stage piston rings.
- Final discharge pressure too high.
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High Second Stage Discharge Pressure |
- Defective pressure gauge or sensor.
- Loose or leaking third stage suction valves.
- Defective or sticking third stage suction valve unloader.
- Worn third stage piston rings.
- Final discharge pressure too high.
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High Third Stage Discharge Pressure |
- Defective pressure gauge or sensor.
- Restriction in discharge air line.
- Incorrect setting or defective load controller.
- Control air not getting to suction valve unloaders.
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High First Stage Discharge Air Temperature |
- Defective temperature gauge or sensor.
- Loose or leaking first stage valves.
- Defective or sticking first stage suction valve unloader.
- Insufficient cooling water.
- Cooling water temperature too high.
- Cylinder water jackets plugged.
- Worn first stage piston rings.
- Fouled first stage intercooler.
- High inlet air temperature.
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High Second Stage Discharge Air Temperature |
- Defective temperature gauge or sensor.
- Loose or leaking second stage valves.
- Defective or sticking second stage suction valve unloader.
- Insufficient cooling water.
- Cooling water temperature too high.
- Cylinder water jackets plugged.
- Worn second stage piston rings.
- Fouled second stage intercooler.
- High second stage suction temperature.
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High Final Discharge Air Temperature |
- Defective temperature gauge or sensor.
- Loose or leaking third stage valves.
- Defective or sticking third stage suction valve unloader.
- Insufficient cooling water.
- Cooling water temperature too high.
- Cylinder water jackets plugged.
- Worn third stage piston rings.
- Fouled aftercooler.
- High third stage suction temperature.
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Low or No Condensate from Drain Traps |
- Defective trap.
- Drain pipe to and from trap plugged.
- Compressor running unloaded.
- Intercooler or aftercooler not properly cooling.
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Too Much Condensate from Drain Traps |
- Cooling water leak in first, second or third stage cylinder.
- Cooling water leak in first or second stage intercooler.
- Cooling water leak in aftercooler.
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First Stage Relief Valve Lifting |
- Defective relief valve.
- First stage intercooler plugged.
- Loose or leaking valves in second stage.
- Defective or sticking second stage suction valve unloaders.
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Second Stage Relief Valve Lifting |
- Defective relief valve.
- Second stage intercooler plugged.
- Loose or leaking valves in third stage.
- Defective or sticking third stage suction valve unloaders.
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Third Stage Relief Valve Lifting |
- Defective relief valve.
- Aftercooler plugged.
- Final discharge pressure too high.
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