1
System leaks
CheckUltrasonic leak detector or soap on fittings. >10% loss = major.
FixRepair fittings, hoses, drains, FRLs, tools.
ToolsUltrasonic leak detector · Soap solution
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2
Worn intake filter
CheckVisual / differential pressure gauge across filter.
FixReplace element.
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3
Unloader valve stuck open
CheckAir bleeding from unloader during run cycle.
FixRebuild/replace unloader.
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4
Worn rings / valves (reciprocating)
Reciprocating
CheckPump-up time test vs new specs. Hot head + low output = valve plate.
FixRebuild head / replace valve plates and gaskets.
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5
Inlet modulating valve not fully opening
Rotary screw
CheckVisual; check pilot air signal to inlet valve.
FixService inlet valve, check control air solenoid and pilot regulator.
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6
Belt slipping
CheckVisual smoke/squeal; deflection test (1/64" per inch of span).
FixTension or replace belts and sheaves if worn.
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7
Wrong rotation (3Φ)
criticalCheckLook at rotation arrow on airend/flywheel.
FixSwap any two line phases at disconnect. Verify before extended run.
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8
Min pressure valve stuck closed
Rotary screw
CheckSump pressure rises but line pressure stays low.
FixRebuild MPV with kit; verify spring and seat.
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9
Aftercooler restriction
Rotary screw
CheckΔP across aftercooler unusually high.
FixClean cooler internals; check condensate accumulation.
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Safety
Lockout/tagout before opening enclosures. Verify zero energy. Bleed system pressure before opening any pneumatic connection.