34
Procedures
259
Documented steps
7
Categories
Disclaimer:Field reference for trained technicians only. Not a substitute for OEM service manuals or applicable codes. Always verify procedures, torque values, and pressures against current manufacturer documentation. Use at your own risk — AirCompDX disclaims all warranties and liability.
Reciprocating· 5
Single-stage recip pump rebuild
Top-end rebuild on a single-stage reciprocating pump: valves, rings, gaskets, and break-in.
Intermediate 3–4 hr10 steps
Two-stage recip pump rebuild
HP + LP cylinder rebuild on a two-stage pump including intercooler service and stage balance.
Advanced 5–6 hr11 steps
Valve plate / reed valve service
Diagnose and replace reed and disc valves — the #1 cause of lost CFM on recip pumps.
Basic 1.5 hr6 steps
Cylinder hone & re-ring
Deglaze a serviceable cylinder bore, measure taper and out-of-round, and install new rings with correct end gap.
Advanced 4–5 hr8 steps
Crankshaft & connecting rod bearing service
Inspect and replace crank main and rod bearings on a splash- or pressure-lubricated reciprocating pump, including clearance checks.
Advanced 6–8 hr9 steps
Rotary Screw· 7
Rotary screw airend major PM
Coupling, shaft seal, inlet valve service, and bearing inspection on a lubricated rotary screw airend.
Advanced 6–8 hr11 steps
Air/oil separator change
Replace the separator element and restore proper carryover and ΔP on a lubricated screw.
Intermediate 1.5 hr7 steps
Rotary screw airend replacement
Remove and replace a lubricated rotary screw airend, including coupling alignment, sump flush, and controlled break-in.
Advanced 8–10 hr13 steps
Minimum pressure / check valve service
Rebuild or replace the MPV on a rotary screw package — the valve that holds sump pressure up for oil circulation and blocks backflow.
Intermediate 2–3 hr7 steps
Thermal valve & oil cooler service
Diagnose a stuck thermostatic mixing valve and clean or flush air-cooled and water-cooled oil coolers to restore discharge temperature.
Intermediate 3–4 hr7 steps
Inlet valve & blowdown solenoid service
Rebuild the load/unload inlet valve and verify the blowdown circuit — the two parts behind most load-cycling and hot-restart complaints.
Intermediate 2–3 hr8 steps
Drive coupling replacement & alignment
Replace a worn elastomeric coupling element on a direct-drive package and align motor to airend within OEM tolerance.
Intermediate 3–4 hr9 steps
Scroll / Oil-less· 2
Vacuum· 2
Rotary vane vacuum: oil + vane service
Oil change and vane inspection on a lubricated rotary vane vacuum pump.
Basic 1.5 hr7 steps
Vacuum system leak testing & rate-of-rise
Isolate the difference between a leaking system and a tired pump using a rate-of-rise test, then locate leaks methodically.
Intermediate 2–3 hr7 steps
Controls & Electrical· 5
Unloader + pressure switch service
Diagnose and replace pressure switches and pilot unloaders on tank-mounted recips.
Basic 1 hr6 steps
Check valve + safety relief test
Replace the tank check valve and proof-test the ASME safety relief valve.
Basic 45 min6 steps
Magnetic starter + overload service
Inspect and set NEMA / IEC starters and thermal overload relays.
Intermediate 45 min6 steps
VFD startup & commissioning
Parameterize, tune, and verify a variable frequency drive on a screw compressor package, including min-speed and PID setup.
Advanced 4–5 hr10 steps
Pressure transducer & RTD verification
Verify and correct compressor package instrumentation — pressure transducers, RTDs, thermistors, and ΔP sensors.
Intermediate 1–2 hr7 steps
Air Treatment· 6
Refrigerated dryer PM
Condenser clean, drain test, and dewpoint verification on a refrigerated dryer.
Basic 1 hr5 steps
Desiccant dryer PM
Desiccant inspection, valve/muffler service, and purge tuning on a heatless twin-tower.
Intermediate 2 hr6 steps
Condensate drain service (timer, zero-loss, float)
Service and verify automatic condensate drains on receivers, dryers, and filters — the cheapest fix with the biggest air-quality payoff.
Basic 1–2 hr8 steps
Coalescing & particulate filter PM
Replace inline filter elements on schedule, measure ΔP correctly, and pick the right filtration grade for the application.
Basic 45–90 min7 steps
Aftercooler & moisture separator service
Clean the aftercooler core and service the moisture separator to knock out the majority of water before it ever reaches the dryer.
Intermediate 2–3 hr6 steps
Oil/water separator service & compliance
Service the condensate oil/water separator and keep discharge within local limits for lubricated compressor rooms.
Basic 1 hr5 steps
PM & Commissioning· 7
Belt and sheave alignment
Tension, align, and replace V-belts on belt-drive recip and screw compressors.
Basic 1 hr7 steps
Oil change + new-pump break-in
Crankcase oil change and break-in procedure for a new or rebuilt recip pump.
Basic 45 min5 steps
Intake filter PM
Inspect and replace intake elements and check intake restriction.
Basic 20 min4 steps
Compressed air leak survey
Run a structured leak survey with ultrasonic detection, quantify the loss in CFM and dollars, and prioritize the repairs.
Basic half day8 steps
Receiver tank inspection & drain program
Inspect an ASME air receiver, verify the relief valve and gauge, and set up a drain program that stops internal corrosion.
Intermediate 1–2 hr8 steps
Compressor room commissioning checklist
End-to-end commissioning for a new or relocated compressor installation: ventilation, piping, electrical, controls, and documented baseline.
Advanced 6–8 hr11 steps
Annual PM — rotary screw package
Complete annual preventive maintenance for a lubricated rotary screw: consumables, inspections, electrical, and a documented performance check.
Intermediate 4–6 hr11 steps