Gas Compressor Troubleshooting Guide for compressor problems.

Problem: Motor will not run.
Possible Cause: 

1. Improper line voltage - Check line voltage, change lines as required.

2. Poor contact on motor terminals or starter connections - Ensure good contact on motor 
terminals and starter connections.

3. Improper starter heaters - Install proper starter heaters.


Problem:  Oil in discharge gas
Possible Cause:

1. Clogged or dirty inlet and/or discharge filter - replace filter element

2. Oil viscosity too low - Drain existing lubricant from frame. Refill with proper 
lubricant.

3. Oil level too high - Drain lubricant from frame to proper level.

4. Detergent type lubricant being used - Drain existing lubricant from frame. Refill with 
specified lubricant.

5. Piston rings damaged or worn (broken, rough, scratched, excessive end gap or side 
{clearance) - Replace piston rings.

6. Piston rings not seated, stuck in grooves, or end gaps not staggered. - Clean and adjust 
piston rings. Replace as required.

7. Cylinder scratched, worn or scored. - Replace or repair as required.

8. Piston scratched, worn or scored. - Repair or replace as required.


Problem: Knocks or rattles
Possible Cause:

1. Loose belt wheel or motor pulley. Excessive end play in motor shaft. - Check 
belt wheel, motor pulley and shaft. Repair or replace as required.

2. Valves leaking, broken, carbonized or loose. - Check valves. Clean and replace as 
required.

3. Carbon build-up on top of piston(s). - Clean piston(s). Repair or replace parts as
required.

4. Cylinder scratched, worn or scored. - Replace or repair as required.

5. Piston scratched, worn or scored. - Repair or replace as required.

6. Defective ball bearings on crankshaft or motor shaft. - Check ball bearings. Replace as 
required.


Problem: Gas delivery has dropped off.
Possible Cause

1. Clogged or dirty inlet and/or discharge filter - replace filter element.

2. Gas leaks in piping (on compressor or external piping/system). - Check tubing and 
connections. Repair or replace as required.

3. Valves leaking, broken, carbonized or loose. - Check valves. Clean and replace as 
required.

4. Automatic condensate drain valve defective - Inspect drain valve. Repair or replace as 
required.

5. Piston rings damaged or worn (broken, rough, scratched, excessive end gap or side 
clearance) - Replace piston rings.

6. Piston rings not seated, stuck in grooves, or end gaps not staggered. - Clean and adjust 
piston rings. Replace as required.

7. Cylinder scratched, worn or scored. - Replace or repair as required.

8. Piston scratched, worn or scored. - Repair or replace as required.


Problem: Relief valve vents pressure.
Possible Cause

1. Clogged or dirty inlet and/or discharge filter - replace filter element.

2. Valves leaking, broken, carbonized or loose. - Check valves. Clean and replace as 
required.

3. Automatic condensate drain valve defective. - Repair or replace as required.


Problem: Motor overload trips or draws excessive current.
Possible Cause

1. Oil viscosity too high - Drain existing lubricant from frame. Refill with proper 
lubricant.

2. Improper line voltage - Improper line voltage - Check line voltage, change lines as required.

3. Poor contact on motor terminals or starter connections - Ensure good contact on motor 
terminals and starter connections.

4. Improper starter heaters - Install proper starter heaters.

5. Poor power regulation (unbalanced line) - Consult local power company.

6. V-belt is pulled too tight - Adjust belt tension.

7. Valves leaking, broken, carbonized or loose. - Check valves. Clean and replace as 
required.

8. Automatic condensate drain valve defective. - Repair or replace as required.

9. Cylinder scratched, worn or scored. - Replace or repair as required.

10. Piston scratched, worn or scored. - Repair or replace as required.

11. Connecting rod, piston pin or crankpin bearings worn or scored. - Inspect all. Repair 
or replace as required.

12. Defective ball bearings on crankshaft or motor shaft. - Check ball bearings. Replace 
as required.


Problem: Moisture in frame or rusting in cylinders.
Possible Cause

1. Detergent type lubricant being used - Drain existing lubricant from frame. Refill with 
specified lubricant.

2. Extremely light duty cycles - Run compressor for longer duty cycles.

3. Extremely wet gas - Install dryer.


Problem: Excessive starting and stopping
Possible Cause

1. Gas leaks in piping (on compressor or external piping/system). - Check tubing and 
connections. Repair or replace as required.

2. Pressure switch differential is too narrow Adjust pressure switch to increase differential.

3. Automatic condensate drain valve defective. - Repair or replace as required.


Problem: Compressor runs excessively hot
Possible Cause

1. Inadequate ventilation around belt wheel - Relocate compressor or add ventilation.

2. V-belt pulled too tight - Adjust belt tension.

3. Wrong belt wheel direction of rotation. - Check motor wiring for proper connections.

4. Valves leaking, broken, carbonized or loose. - Check valves. Clean and replace as 
required.


Problem: Compressor does not come up to speed
Possible Cause

1.Loose belt wheel or motor pulley. Excessive end play in motor shaft. - Check 
belt wheel, motor pulley and shaft. Repair or replace as required.

2. Improper line voltage - Improper line voltage - Check line voltage, change lines as required.

3. Poor contact on motor terminals or starter connections - Ensure good contact on motor 
terminals and starter connections.

4. Improper starter heaters - Install proper starter heaters.

5. Defective ball bearings on crankshaft or motor shaft. - Check ball bearings. Replace as 
required.


Problem: Lights flicker and dim when compressor is running
Possible Cause

1. Improper line voltage - Improper line voltage - Check line voltage, change lines as required.

2. Poor contact on motor terminals or starter connections - Ensure good contact on motor 
terminals and starter connections.

3. Improper starter heaters - Install proper starter heaters.

4. Poor power regulation (unbalanced line) - Consult local power company.


Problem: Abnormal piston, ring and cylinder wear.
Possible Cause

1. Clogged or dirty inlet and/or discharge filter - replace filter element.

2. Oil viscosity too low - Drain existing lubricant from frame. Refill with proper lubricant

3. Oil viscosity too high - Drain existing lubricant from frame. Refill with proper lubricant.

4. Oil level too low - Add lubricant to frame to bring level up to an acceptable point.

5. Detergent type lubricant being used - Drain existing lubricant from frame. Refill with specified lubricant.

6. Extremely wet gas - Install dryer.


Problem: Gas and/or oil leaking from shaft seal.
Possible Cause 

1. Shaft seal leaking, broken or improperly seated - Repair or replace as required.


Problem: Gas and/or condensate leaking through condensate drain system.
Possible Cause

1. Automatic Condensate drain valve defective.


Problem: Excessive noise when compressor is operated
Possible Cause

1. Loose belt wheel or motor pulley. Excessive end play in motor shaft - Check belt wheel, motor pulley and shaft. Repair or replace as required.

2. Gas leaks in piping (on compressor or external piping/system) - Check tubing and connections. Repair or replace as required.

3. Valves leaking, broken, carbonized or loose - Check valves. Clean or replace as required.

4. Automatic condensate drain valve defective - Inspect drain valve. Repair or replace as required.

5. Connecting rod, piston pin or crankpin bearings worn or scored - Inspect all. Repair or replace as required.

6. Defective ball bearings on crankshaft or motor shaft - Check ball bearings. Replace as required.


Problem: Excessive lubricant consumption
Possible Cause

1. Piston rings damaged or worn (broken, rough, scratched, excessive end gap or side clearance).

2. Piston rings not seated, stuck in grooves, or end gaps not staggered - Clean and adjust piston rings. Replace as required.

3. Cylinder scratched, worn or scored - Repair or replace as required.

4. Piston scratched, worn or scored - Repair or replace as required.

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MAILING:	PHONE:	SHIPPING:
P.C. McKenzie Company P.O. Box 112638 Pittsburgh, PA 15241	1-877-244-4883 Fax: 412-257-8890 Phone: 412-257-8866	P.C. McKenzie Company 1365 McLaughlin Run Road Pittsburgh, PA 15241