COMPRESSOR TROUBLESHOOTING:

Problem:
Air leaks out of the compressor’s intake port (port where the air filter is installed)
Possible Cause:
Faulty check valve, and/or intake or exhaust valve.
Solution:
Replace check valve or leader hose, replace intake or exhaust valve as needed.

Problem:
Air escapes from compressor intake (where the air filter goes)
Possible Cause:

1. Check valve may be faulty.
2. Intake & exhaust valves may be faulty.
3. Compressor may be taking in more air than it can compress through its valves.

Solution:

1. Replace check valve.
2. Replace intake and/or exhaust valve.
3. Check pressure in air tank. As long as air tank reaches cutoff pressure of pressure switch installed on air tank in the amount of time acceptable for the specific compressor you are running. (Fill times can be seen under each compressor heading on this website).

Problem:
Compressor shuts off after running the unit for an extended period of time, to higher pressures or in very hot weather.
Possible Cause:
The thermal overload protector has become engaged. This shuts down the unit to protect it from damage that can be sustained by high temperature operation.
Solution:
Allow the compressor to cool for approximately 30-45 minutes. Keep an eye on how long you operate the unit and at what approximate temperature in the future to keep from using the thermal overload protector as an “off” switch.

Problem:
New compressor installation – doesn’t build to rated pressure in tank.
Possible Cause:

1. Check valve faulty or leader hose may be installed backwards. (Do not disassembly a new unit; this will void your warranty).
2. Wrong pressure switch installed.

Solution:

1. Check flow direction of check valve and make sure that flow goes towards your tank, and away from the compressor. Extended operation in this manner will damage your compressor.
2. Check rating of pressure switch to determine ON & OFF pressures.

Problem:
Compressor starts, and then stops intermittently.
Possible Cause:
Possible incorrect wiring problem.
Solution:
Check all electrical connections, including grounds. If you don’t have a good chassis ground, your system may not function properly, or may have intermittent operation.

Problem:
Compressor blows fuses
Possible Cause:
Multiple causes (see below)
Solution:

1. Always operate your compressor(s) while your vehicle’s engine is running. This keeps them from operating in a low amperage situation, which can also blow fuses.
2. Check valve may be malfunctioning, causing an increased load on the compressor – which also creates a high amperage restart. –This often blows fuses since the amp draw if greater than the value of the fuse. –Never fuse a connection higher than 5-10 amps over maximum amp draw of system.

Problem:
Compressor sounds slower than normal, as if the RPM of the motor has decreased.
Possible Cause:

1. Motor may have been damaged due to low voltage operation.
2. Dirty or clogged air filter element.

Solution:

1. Replace compressor if motor has been damaged.
2. Replace air filter element more often due to environmental conditions.

Problem:
Compressor runs constantly, and will not shut off. – Safety valve may become engaged.
Possible Cause:
Multiple reasons:

1. Faulty pressure switch.
2. Possible faulty relay or wiring for relay.
3. Damaged intake or exhaust valve.
4. Damaged check valve.
5. Improper Safety Valve installed.

Solution:
Narrow down the cause using the above mentioned items and replace as needed.

Problem:
Compressor makes a loud, clanking noise during operation.
Possible Cause:
Worn main bearing on motor shaft, or worn piston seal on piston assembly.
Solution:
Replace piston and cylinder wall assembly. New piston assemblies come with a new bearing. Check old cylinder wall for scoring or scratches – replace if a finger nail catches in any score mark left by the old piston assembly.

Problem:
Compressor seems to take longer than usual to fill air tank.
Possible Cause:
Decreased performance due to wear or internal malfunction.
Solution:
Internal inspection of compressor should be done to evaluate the condition of internal parts. Decreased performance may be due to worn or damaged piston seal, or an intake or exhaust valve that is no longer sealing properly. If the compressor has been used for several months or years, it may be time to replace the carbon brushes in the unit. A thorough inspection, with the right parts can return a compressor to near-new operation.

Problem:
Compressor rattles internally.
Possible Cause:
Removal and repositioning of front mounting assembly on compressor to the back side of the front cover. This can destroy a compressor since the assembly is not properly assembled in this fashion.
Solution:
Move mounting assembly back to its original position immediately to avoid piston assembly failure.

Problem:
Compressor has rust inside intake cover (front cover).
Possible Cause:
Compressor was run without an air filter.
Compressor was run without replacing air filter.
Compressor was run in wet conditions, without remote mounted air filter option.
Solution:
Depending on the condition of the compressor, repair might be possible. In some cases, the compressor must be replaced. Moisture damage is not covered by any warranty from VIAR Corp.

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