Maintenance Tracker

Check lubricant level in crankcase sight glass — never below mid-gauge

~2 min · operator

Risk if skipped: Bearing seizure, con-rod failure, catastrophic compressor damage

Drain water from receiver tank (manual or auto-drain)

~3 min · operator

Risk if skipped: Tank corrosion, water hammer downstream, contaminated air supply

Check discharge pressure and safety valve pop-off setting

~2 min · operator

Risk if skipped: Over-pressure event, safety valve failure goes undetected

Listen for abnormal knocking, rattling, or valve chatter during run

~3 min · operator

Risk if skipped: Broken valve, loose connecting rod, worn piston ring — escalates to major failure

Check for visible leaks (air, oil, coolant) on fittings, hoses, crankcase

~3 min · operator

Risk if skipped: Energy waste, oil contamination of compressed air

Verify all safeguards and guards are in place

~1 min · operator

Risk if skipped: Safety non-compliance, personnel injury

Test pressure relief valve (lift test) — every 40 hours or weekly

~5 min · operator

Risk if skipped: Relief valve stuck closed — tank over-pressure, explosion risk

Clean air intake filter element or inspect pre-filter

~10 min · operator

Risk if skipped: Restricted airflow, elevated discharge temp, reduced capacity

Clean intercooler fins (if accessible) and compressor exterior surfaces

~10 min · operator

Risk if skipped: Heat build-up, elevated discharge temp, accelerated wear

Inspect all hoses and fittings for air leaks (soap solution or electronic detector)

~10 min · operator

Risk if skipped: Compressed air waste (1/8" leak = ~25 CFM loss at 100 psi)

Inspect and adjust V-belt tension and condition — every 160 hours or monthly

~15 min · technician

Risk if skipped: Belt slip, overheated pulleys, belt breakage causing downtime

Check and tighten all electrical connections and terminal screws

~20 min · electrician or technician

Risk if skipped: Arcing at loose terminals, motor overload trip, fire risk

Inspect pressure switch and unloader valve operation

~15 min · technician

Risk if skipped: Short cycling, motor burnout, compressor never unloads

Change crankcase oil and replace oil filter — every 500 hours or quarterly

~30 min · technician

Risk if skipped: Acid buildup, bearing corrosion, increased wear metals

Inspect pulley nuts and drive screws for proper torque

~10 min · technician

Risk if skipped: Pulley loosening, belt damage, vibration damage to bearings

Inspect discharge check valve and unloader valve — every 500 hours

~20 min · technician

Risk if skipped: Backflow on shutdown, motor starts under load, valve failure

Blow down crankcase breather/vent filter

~5 min · technician

Risk if skipped: Crankcase pressure buildup, oil leakage past seals

Inspect inlet and discharge reed valves for carbon deposits, cracks, warping — every 1,000 hours

~60 min · technician

Risk if skipped: Valve failure causes loss of compression, hot discharge, oil carryover

Clean crankcase and inspect for metal particles

~45 min · technician

Risk if skipped: Circulating debris causes bearing and cylinder wall wear

Examine motor contact points and pressure switch diaphragm

~20 min · electrician

Risk if skipped: Pitted contacts cause motor starting failures; cracked diaphragm causes pressure control drift

Check and clean intercooler/aftercooler tubes; verify tube pressure integrity

~30 min · technician

Risk if skipped: Fouled coolers raise interstage temperature, increase moisture carryover

Full piston ring and cylinder bore inspection — measure bore for wear/taper

~180 min · factory-trained technician

Risk if skipped: Ring blow-by, oil carryover into air stream, compression loss

Inspect connecting rod bearings and crankshaft for wear

~120 min · factory-trained technician

Risk if skipped: Bearing failure is catastrophic and unannounced

Replace all valve plate assemblies (inlet and discharge) — or rebuild if within spec

~120 min · factory-trained technician

Risk if skipped: Valve efficiency degrades gradually; failure causes loss of compression

Inspect safety relief valves — replace if > 5 years old per ASME code

~30 min · technician

Risk if skipped: Relief valve may not operate at set pressure — explosion risk

Megger test motor windings; lubricate motor bearings per nameplate

~30 min · electrician

Risk if skipped: Winding insulation degradation goes undetected until motor fails

Full performance test: measure actual CFM delivery vs. rated capacity

~30 min · technician

Risk if skipped: Capacity loss accumulates silently; discovered only when production suffers