Compressor Maintenance Guide

Daily Checks

• Check oil level: Verify oil is at the correct level on the sight glass. Top up if needed.
• Check operating pressure: Verify discharge pressure is within the normal range.
• Check operating temperature: Discharge temperature should be 70 to 95 degrees C. Above 100 degrees C requires investigation.
• Listen for unusual noises: Knocking, rattling, or whining indicates mechanical problems.
• Check for leaks: Visually inspect around fittings, hoses, and valves.
• Drain receiver tank: Open the drain valve to remove condensate. Automatic drains should be checked for flow.

Weekly Checks

• Inspect air intake filter: Check for dirt and blockage. Clean or replace if dirty.
• Check oil separator pressure drop: If above 0.5 bar, schedule separator replacement.
• Inspect drive belts (if belt-driven): Check tension and condition. Replace if cracked or worn.
• Check cooler cleanliness: Clean the air-cooled heat exchanger fins. Clogged fins cause overheating.
• Test safety valve: Gently lift the try lever to verify the safety valve moves freely.

Monthly Checks

• Check for leaks in the system: Use ultrasonic leak detector. Tag and repair all leaks.
• Inspect electrical connections: Check for loose terminals, overheating, and insulation damage.
• Check motor current: Compare to nameplate and baseline. High current indicates overloading or mechanical drag.
• Inspect hoses and fittings: Look for cracks, chafing, and oil seepage.
• Check condensate drain: Verify automatic drain is functioning. Manual drain should be done daily.

Annual Service

1. Change oil and oil filter. Use manufacturer's specified synthetic oil.
2. Replace oil separator element.
3. Replace air intake filter element.
4. Clean or replace all coalescing and particulate filters downstream.
5. Inspect and clean coolers (air-to-air and air-to-oil).
6. Check motor bearings. Regrease or replace as needed.
7. Test all safety devices: safety valve, high-temperature switch, low-oil pressure switch.
8. Calibrate pressure switches and sensors.
9. Inspect coupling (if belt-driven: check belts; if direct-coupled: check coupling).
10. Check and adjust unloader valve and inlet valve.
11. Perform a leak survey of the entire compressed air system.
12. Record all service data in the maintenance log. PlantLogica's scheduled maintenance reminders make this easy.