Appendix E—Troubleshooting
E . Troubleshooting
General
In most cases problems with a CORKEN gas compressor
can be solved quite simply. The table below lists some of
the more frequent problems that occur with reciprocating
compressors along with a list of possible causes. If a
problem is not listed, consult the factory.
Two-Stage Compressor Trouble Shooting
Two-stage compressors can have problems that never
occur with single-stage machines. Interstage pressure
is an important indicator of the condition of a two-
stage compressor.
If interstage pressure is too high:
• Second stage valves may be broken or leaking.
• Second stage piston rings may be worn.
If interstage pressure is too low:
• First stage valves may be broken or leaking.
• First stage piston rings may be worn.
• If suction and/or discharge pressures change, the
interstage pressure will also change.
Problem
Possible Cause
Low capacity
1, 2, 3, 4
Overheating
1, 2, 3, 5, 6, 11, 15
Knocks, rattles, and noise
1, 7, 9, 10, 11, 14
Oil in cylinder
8, 14
Abnormal piston-ring wear
1, 3, 5, 6, 11, 14, 15
Product leaking through crankcase breather
8, 14
Product leakage
4, 8, 14
Oil leakage around compressor base
16, 17
No oil pressure
18, 19
Excessive vibration
1, 7, 9, 10, 11, 12, 13, 25, 27
Motor overheating or starter tripping out
20, 21, 22, 23, 24, 25, 26, 27
Ref .
No .
Possible Causes
What To Do
1.
Valves broken, stuck or leaking
Inspect and clean or repair
2.
Piston ring worn
Inspect and replace as necessary
3.
Inlet strainer clogged
Clean or replace screen as necessary
4.
Leaks in piping
Inspect and repair
5.
Inlet or ambient temperature too high
Consult factory
6.
Compression ratio too high
Check application and consult factory
7.
Loose flywheel or belt
Tighten
8.
Worn piston-rod packing
Replace
9.
Worn wrist pin or wrist-pin bushing
Replace
10.
Worn connecting-rod bearing
Replace
11.
Unbalanced load
Inspect valve or consult factory
12.
Inadequate compressor base
Strengthen, replace or grout
13.
Improper foundation or mounting
Tighten mounting or rebuild foundation
14.
Loose valve, piston or packing
Tighten or replace as necessary
15.
Dirty cooling fins
Clean weekly
16.
Leaking gas blowing oil from crankcase
Tighten packing
17.
Bad oil seal
Replace
18.
No oil in crankcase
Add oil
19.
Oil-pump malfunction
See oil-pressure adjustment
20.
Low voltage
Check line voltage with motor nameplate. Consult power company
21.
Motor wired wrong
Check wiring diagram
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