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Troubleshooting
Rev 30000-20080208
11
Troubleshooting
Problem
Cause
Solution
Air Compressor will not start
Power cord
Plug into grounded outlet
Motor Switch is in OFF position
Move lever to auto/on position
Blown fuse, circuit breaker trip
Replace fuse, reset circuit breaker
Unplug other appliances from same
outlet
Wrong gauge extension cord
Check gauge on cord and verify that it
is the correct size
Tank pressure is greater than auto
motor “kick in”
Open tank drain valve to release tank
pressure
Defective motor, motor switch
Call Champion Hotline #
Overheating
Insufficient Ventilation
Place compressor in environment with
well circulated supply of cool, dry air.
Dirty or obstructed cooling fins
Clean surfaces of cooling fins on and
around pump/motor area
When in Auto/On position, motor
runs continuously
Motor switch malfunction- does not
respond when tank reaches max
pressure, safety relief valve engage
Move motor switch to OFF position.
If motor does not shut-off, unplug the
compressor. Evaluate motor switch
wiring. Replace if needed
Incorrect compressor size for tool
application
The Air tool might be too big for the
compressor you are using. Use a
smaller air tool, or a larger
compressor
Air leak after motor stops at switch
release valve
The check valve is stuck open
Remove, clean or replace check valve
Air leak while motor is running at
switch release valve
Defective motor switch
Replace
The check valve is stuck open
Replace- NOTE – do not remove
while tank is pressurized. Release
tank pressure by opening tank drain
valve
Air leak from safety relief valve
Malfunctioning safety relief valve
Pull manually on ring. If valve does
not make a clean seal when closed,
replace.
Excessive Tank Pressure
Defective motor switch. Replace
Air leaks at pump
Malfunctioning/blown gaskets
Replace poor gaskets
Air leaks in tank
Rusted, broken welds – Defective tank Replace – Note – Do not attempt to
repair air tank!
Air leaks at fittings
Fittings are not sufficiently tight
Tighten fittings – Note- Do not over
tighten
Air blowing from intake filter
Damage intake valve
Contact Champion Hotline #
Insufficient pressure for air tool or
accessory
Air leaks
Check for leaks on all fittings and
connections. Tighten or repair
connections as needed
Air compressor is not large enough for
particular air equipment
Note the equipment requirement – if
higher then pressure supply of
compressor, or causes the motor to
run continuously, you need a larger
air compressor
Pressure regulator is not set to
accurate pressure
Adjust pressure regulator knob to
correct setting
Restricted air intake
Clean or replace filter element
Defective motor/pressure switch
Replace
Hose or hose connection(s) are
inaccurate size
Assess and replace if necessary
Air compressor not making enough air
Low compression
Possible worn piston rings and/or
cylinder walls. Inspect and replace as
needed
Malfunctioning intake filter
Clean or replace filter element
Leaking inlet valve
Release all tank pressure, then
measure pump up time. Compare to