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Champion Operating Instructions & Parts Manual
Champion Single-Stage Air
Compressor Pump
Troubleshooting Chart
Compressor Trouble
NOTE: This is a general chart, some items may not apply to your specific compressor.
Pumping excessive amount of oil................................................................................................. 1, 7, 9, 11, 22, 23, 27
E
N
Knocks, rattles, excessive vibration ................................................................................... 2, 17, 18, 19, 20, 21, 23, 26
G
Air delivery has dropped off ................................................................................................................ 1, 5, 18, 22, 23
L
Low discharge pressure................................................................................................................. 1, 5, 6, 17, 18, 22, 23
I
Trips motor overload or draws excessive current ............................................................. 8, 13, 14, 15, 18, 20, 21, 23
S
H
Water in crankcase or rusting in cylinders.......................................................................................................... 11, 12
Machine won't unload (constant speed control) ............................................................................................... 1, 16
Excessive load/unload cycles ................................................................................................................................ 3, 5, 6
Compressor doesn't unload when stopped ............................................................................................................. 19
Compressor won't come up to speed.................................................................................................................. 13, 16
Pump running wrong direction................................................................................................................................ 24
Abnormal piston, ring or cylinder wear............................................................................................... 4, 7, 10, 11, 25
Compressor continues to unload......................................................................................................................... 19, 28
Discharge pressure relief valve releasing................................................................................................................. 29
Ref.
Possible Cause(s)
No.
1.
Clogged intake filter
2.
Loose flywheel or motor pulley
3.
Excess condensate in receiver
4.
Air to flywheel blocked off
5.
Air leaks in piping (on machine or in outside system)
6.
Receiver check valve leaking
7.
Oil viscosity too low
8.
Oil viscosity too high
9.
Oil level too high
10.
Oil level too low
11.
Detergent type oil being used
12.
Extremely light duty or located in a damp, humid spot
Poor contacts, wrong starter heaters, line voltage
13.
incorrect
14.
Poor power regulation (unbalanced line, 3 phase motors)
15.
V-Belts pulled excessively tight
16.
Defective unloading mechanism
17.
Carbon on top of piston
18.
Leaking, broken, carbonized or loose valves or restricted
air passage
19.
Defective centrifugal unloader
Worn or scored connecting rod piston pin or crankpin
20.
bushing
21.
Defective bearing on crankshaft or on motor shaft
22.
Piston rings broken or not seated in, end gaps not
staggered,
stuck in grooves, rough, scratched or excessive end gap
23.
Cylinders or pistons scratched, worn or scored
24.
Three phase motor connection incorrect
25.
Extremely dusty atmosphere
26.
Loose bolts, tank not level, compressor running too fast
27.
Running unloaded excessively
28.
Defective pilot valve
29
Blocked discharge
Possible Cause — Ref. Nos. (See Below)
Ref.
Corrective Action
No.
1.
Clean or replace
2.
Tighten
3.
Drain more often
4.
Clean unit or relocate in ventilated area
5.
Replace leaking components or tighten as necessary
6.
Replace or repair as necessary
7.
Use correct oil
8.
Use correct oil
9.
Drain excess
10.
Fill with proper amount
11.
Drain oil; fill with correct oil
12.
Run unit periodically even when not in use. Change
location to drier environment
13.
Check connections & starter heaters
14.
Consult power company
15.
Loosen to correct tightness
16.
Replace or repair as necessary
17.
Clean
18.
Clean or replace
19.
Replace or repair as necessary
20.
Repair or replace
21.
Replace
22.
Replace
23.
Replace or repair as necessary
24.
Interchange connections to starter
25.
Clean filter more often or use more effective filter
26.
Tighten bolts, shim tank to level position, slow unit
down by changing sheaves or slowing gas engine
27.
Change control to start-stop or turn unit off when
not in use for long periods
28.
Replace
29.
Check piping for blockage
6
3Z172
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