Ingersoll Rand has complied a list of some of the more frequently encountered compressor problems, their causes and some suggested corrective actions.
Please note: this guide is posted to identify problems and offer corrective measures, and also to make you aware of situations that will result in a major breakdown if left unattended.
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Motor will not run
Possible Cause
- Improper line voltage – Check line voltage, change lines as required.
- Poor contact on motor terminals or starter connections – Ensure good contact on motor terminals and starter connections.
- Improper starter heaters – Install proper starter heaters.
Oil in discharge gas
Possible Cause
- Clogged or dirty inlet and/or discharge filter – replace filter element.
- Oil viscosity too low – Drain existing lubricant from frame. Refill with proper lubricant.
- Oil level too high – Drain lubricant from frame to proper level.
- Detergent type lubricant being used – Drain existing lubricant from frame. Refill with specified lubricant.
- Piston rings damaged or worn (broken, rough, scratched, excessive end gap or side (clearance) – Replace piston rings.
- Piston rings not seated, stuck in grooves, or end gaps not staggered. – Clean and adjust piston rings. Replace as required.
- Cylinder scratched, worn or scored. – Replace or repair as required.
- Piston scratched, worn or scored. – Repair or replace as required.
Knocks or rattles
Possible Cause
- Loose belt wheel or motor pulley. Excessive end play in motor shaft. – Check belt wheel, motor pulley and shaft. Repair or replace as required.
- Valves leaking, broken, carbonized or loose. – Check valves. Clean and replace as required.
- Carbon build-up on top of piston(s). – Clean piston(s). Repair or replace parts as required.
- Cylinder scratched, worn or scored. – Replace or repair as required.
- Piston scratched, worn or scored. – Repair or replace as required.
- Defective ball bearings on crankshaft or motor shaft. – Check ball bearings. Replace as required.
Gas delivery has dropped off
Possible Cause
- Clogged or dirty inlet and/or discharge filter – replace filter element.
- Gas leaks in piping (on compressor or external piping/system). – Check tubing and connections. Repair or replace as required.
- Valves leaking, broken, carbonized or loose. – Check valves. Clean and replace as required.
- Automatic condensate drain valve defective – Inspect drain valve. Repair or replace as required.
- Piston rings damaged or worn (broken, rough, scratched, excessive end gap or side clearance) – Replace piston rings.
- Piston rings not seated, stuck in grooves, or end gaps not staggered. – Clean and adjust piston rings. Replace as required.
- Cylinder scratched, worn or scored. – Replace or repair as required.
- Piston scratched, worn or scored. – Repair or replace as required.
Relief valve vents pressure
Possible Cause
- Clogged or dirty inlet and/or discharge filter – replace filter element.
- Valves leaking, broken, carbonized or loose. – Check valves. Clean and replace as required.
- Automatic condensate drain valve defective. – Repair or replace as required.
Motor overload trips or draws excessive current
Possible Cause
- Oil viscosity too high – Drain existing lubricant from frame. Refill with proper lubricant.
- Improper line voltage – Improper line voltage – Check line voltage, change lines as require
- Poor contact on motor terminals or starter connections – Ensure good contact on motor terminals and starter connections.
- Improper starter heaters – Install proper starter heaters.
- Poor power regulation (unbalanced line) – Consult local power company.
- V-belt is pulled too tight – Adjust belt tension.
- Valves leaking, broken, carbonized or loose. – Check valves. Clean and replace as required.
- Automatic condensate drain valve defective. – Repair or replace as required.
- Cylinder scratched, worn or scored. – Replace or repair as required.
- Piston scratched, worn or scored. – Repair or replace as required.
- Connecting rod, piston pin or crankpin bearings worn or scored. – Inspect all. Repair or replace as required.
- Defective ball bearings on crankshaft or motor shaft. – Check ball bearings. Replace as required.
Moisture in frame or rusting in cylinders
Possible Cause
- Detergent type lubricant being used – Drain existing lubricant from frame. Refill with specified lubricant.
- Extremely light duty cycles – Run compressor for longer duty cycles.
- Extremely wet gas – Install dryer.
Excessive starting and stopping
Possible Cause
- Gas leaks in piping (on compressor or external piping/system). – Check tubing and connections. Repair or replace as required.
- Pressure switch differential is too narrow Adjust pressure switch to increase differential.
- Automatic condensate drain valve defective. – Repair or replace as required.
Compressor runs excessively hot
Possible Cause
- Inadequate ventilation around belt wheel – Relocate compressor or add ventilation.
- V-belt pulled too tight – Adjust belt tension.
- Wrong belt wheel direction of rotation. – Check motor wiring for proper connections.
- Valves leaking, broken, carbonized or loose. – Check valves. Clean and replace as required.
Compressor does not come up to speed
Possible Cause
- Loose belt wheel or motor pulley. Excessive end play in motor shaft. – Check belt wheel, motor pulley and shaft. Repair or replace as required.
- Improper line voltage – Improper line voltage – Check line voltage, change lines as required.
- Poor contact on motor terminals or starter connections – Ensure good contact on motor terminals and starter connections.
- Improper starter heaters – Install proper starter heaters.
- Defective ball bearings on crankshaft or motor shaft. – Check ball bearings. Replace as required.
Lights flicker and dim when compressor is running
Possible Cause
- Improper line voltage – Improper line voltage – Check line voltage, change lines as required.
- Poor contact on motor terminals or starter connections – Ensure good contact on motor terminals and starter connections.
- Improper starter heaters – Install proper starter heaters.
- Poor power regulation (unbalanced line) – Consult local power company.
Abnormal piston, ring and cylinder wear
Possible Cause
- Clogged or dirty inlet and/or discharge filter – replace filter element.
- Oil viscosity too low – Drain existing lubricant from frame. Refill with proper lubricant
- Oil viscosity too high – Drain existing lubricant from frame. Refill with proper lubricant.
- Oil level too low – Add lubricant to frame to bring level up to an acceptable point.
- Detergent type lubricant being used – Drain existing lubricant from frame. Refill with specified lubricant.
- Extremely wet gas – Install dryer.
Gas and/or oil leaking from shaft seal
Possible Cause
- Shaft seal leaking, broken or improperly seated – Repair or replace as required.
Gas and/or condensate leaking through condensate drain system
Possible Cause
- Automatic Condensate drain valve defective.
Excessive noise when compressor is operated
Possible Cause
- Loose belt wheel or motor pulley. Excessive end play in motor shaft – Check belt wheel, motor pulley and shaft. Repair or replace as required.
- Gas leaks in piping (on compressor or external piping/system) – Check tubing and connections. Repair or replace as required.
- Valves leaking, broken, carbonized or loose – Check valves. Clean or replace as required.
- Automatic condensate drain valve defective – Inspect drain valve. Repair or replace as required.
- Connecting rod, piston pin or crankpin bearings worn or scored – Inspect all. Repair or replace as required.
- Defective ball bearings on crankshaft or motor shaft – Check ball bearings. Replace as required.
Excessive lubricant consumption
Possible Cause
- Piston rings damaged or worn (broken, rough, scratched, excessive end gap or side clearance).
- Piston rings not seated, stuck in grooves, or end gaps not staggered – Clean and adjust piston rings. Replace as required.
- Cylinder scratched, worn or scored – Repair or replace as required.
- Piston scratched, worn or scored – Repair or replace as required.
