Campbell Hausfeld air compressors Troubleshooting Chart
Below you will find brief information for air compressors. This troubleshooting chart covers a wide range of potential issues that you may encounter with your air compressor, providing step-by-step guidance on how to identify and resolve them. Learn about common issues like low discharge pressure, excessive noise, and water in the discharge air, with detailed explanations and corrective actions.
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Troubleshooting Chart TM BUILT TO LAST Single Stage Air Compressors Troubleshooting Chart Symptom Low discharge pressure Possible Cause(s) Corrective Action 1. Air demand exceeds pump capacity 2. Air leaks 1. Reduce air demand or use a compressor with more capacity. 3. Restricted air intake 4. Blown gaskets 5. Leaking or damaged valves Pump overheating causes air filter to melt Excessive noise (knocking) 1. Insulating gasket between filter and head is missing 2. Broken valves/blown gasket 1. Install gasket. 1. Loose motor or compressor pulley 1. Loose motor or compressor pulleys are a very common cause of compressors knocking. Tighten pulley clamp bolts and setscrews. 2. Check for proper oil level; if low, check for possible damage to bearings. Dirty oil can cause excessive wear. 3. Replace connecting rod. Maintain oil level and change oil more frequently. 4. Remove piston assemblies from the compressor and inspect for excess wear. Replace excessively worn piston pin or pistons, as required. Maintain oil level and change oil more frequently. 5. Remove the compressor head and valve plate and inspect for carbon deposits or other foreign matter on top of piston. Replace head and valve plate using new gasket. See Lubrication section for recommended oil. 6. Replace. Do not disassemble check valve with ! DANGER air pressure in tank 2. Lack of oil in crankcase 3. Worn connecting rod 4. Worn piston pin bores 5. Piston hitting the valve plate 6. Noisy check valve in compressor system Large quantity of oil in the discharge air NOTE: In an oil lubricated compressor there will always be a small amount of oil in the air stream. 2. Listen for escaping air. Apply soap solution to all fittings and connections. Bubbles will appear at points of leakage. Tighten or replace leaking fittings or connections. 3. Clean the air filter element. 4. Replace any gaskets proven faulty on inspection. 5. Remove head and inspect for valve breakage, misaligned valves, damaged valve seats, etc. Replace defective parts and reassemble. Install a new head gasket each time the ! CAUTION head is removed 1. Worn piston rings 2. Compressor air intake restricted 3. Excessive oil in compressor 4. Wrong oil viscosity 2. Replace valves or install new gasket. 1. Replace with new rings. Maintain oil level and change oil more frequently. 2. Clean filter. Check for other restrictions in the intake system. 3. Drain down to full level. 4. Use Mobil 1® 10W-30 Water in discharge air/tank 1. Normal operation. The amount of water increases with humid weather 1. Drain tank more often. At least daily. 2. Add a filter to reduce the amount of water in the air line. Motor hums and runs slowly or not at all 1. Do not use an extension cord. Use longer air hose with larger diameter. 2. Replace check valve, unloader valve or pressure switch. Do not disassemble check valve with ! DANGER air pressure in tank 3. Check with voltmeter, check reset switch on motor. If reset switch trips repeatedly, find and correct the cause. See next item. 1. Use of extension cord 2. Malfunctioning check valve or unloader valve 3. Low voltage ® 2001 Campbell Hausfeld For parts, product & service information visit www.chpower.com IN603300AV 8/01 Single Stage Air Compressors Troubleshooting Chart Continued Symptom Possible Cause(s) Corrective Action Motor hums and runs slowly or not at all (Continued) 4. Malfunctioning pressure switch - contacts will not close 4. Repair or replace pressure switch. Reset mechanism cuts out repeatedly or fuses blow repeatedly 1. Too many devices on same circuit 2. Incorrect fuse size or circuit breaker 3. Malfunctioning check valve 1. Limit the circuit to the use of only the air compressor. 4. Pressure switch set too high 5. Loose wiring 6. Malfunctioning motor Tank does not hold pressure when compressors off and the shut off valve is closed 1. Worn check valve 2. Check all connections and fittings for leaks 3. Check tank for cracks or pin holes 2. Be sure that fuses or circuit breakers are rated properly. 3. Replace check valve. Do not disassemble check valve with ! DANGER air pressure in tank 4. Adjust or replace. 5. Check all electrical connections. 6. Replace motor. 1. Replace check valve. Do not disassemble check valve with ! DANGER air pressure in tank 2. Tighten. 3. Replace tank. Never repair a damaged tank. Pressure switch 1. Malfunctioning check valve continuously blows air out the unloader valve 1. Replace the check valve if the unloader valve bleeds off constantly. Do not disassemble check valve with ! DANGER air pressure in tank Pressure switch does not release air when the unit shuts off 1. Malfunctioning unloader valve on pressure switch 1. Replace the pressure switch if it does not release the pressure for a short period of time when the unit shuts off. Do not disassemble pressure switch ! DANGER with air pressure in tank Excessive vibration 1. Loose fasteners 2. Belt needs replaced 3. Belt alignment 1. Tighten. 2. Replace with correct size. 3. Align flywheel and pulley. 2
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Key Features
- Troubleshooting guide
- Comprehensive symptom list
- Detailed corrective action instructions
- Safety precautions
- Common problem resolution
Frequently Answers and Questions
What are the possible causes of low discharge pressure in my air compressor?
Low discharge pressure can be caused by several factors, including air demand exceeding pump capacity, air leaks, restricted air intake, blown gaskets, and leaking or damaged valves. The troubleshooting chart provides corrective actions for each of these potential issues.
How do I address excessive noise (knocking) coming from my air compressor?
Excessive noise can be caused by various factors, such as loose motor or compressor pulleys, lack of oil in the crankcase, worn connecting rod, worn piston pin bores, piston hitting the valve plate, or a noisy check valve in the compressor system. The chart details the corrective actions for each scenario, including tightening pulleys, checking oil levels, replacing worn parts, and inspecting for carbon deposits.
What should I do if I notice a large quantity of oil in the discharge air?
A small amount of oil in the discharge air is normal for oil-lubricated compressors. However, excessive oil can indicate worn piston rings, a restricted air intake, excessive oil in the compressor, or the wrong oil viscosity. The chart outlines the steps to take in each case, including replacing rings, cleaning the filter, adjusting oil levels, and using the recommended oil viscosity.
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