Annual / major service - portable diesel air compressor (all makes)
Estimated duration: 2 - 3 hours • Frequency: every 500 engine hours or annually
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine (additional to 250-hour) | ||||
| 1 | Replace fuel filter | REPLACE | ☐ | |
| 2 | Replace air filter element | REPLACE | ☐ | |
| Compressor System (additional to 250-hour) | ||||
| 3 | Replace compressor oil separator element (rotary screw) | REPLACE | ☐ | |
| 4 | Test safety relief valve (pop test to rated pressure) | TEST | ☐ | |
| 5 | Inspect receiver tank internally (corrosion, scale) | INSPECT | ☐ | |
| 6 | Check and adjust pressure regulator | ADJUST | ☐ | |
| 7 | Replace drive belts | REPLACE | ☐ | |
| 8 | Inspect minimum pressure valve | INSPECT | ☐ | |
| 9 | Service aftercooler (clean/blow out) | CLEAN | ☐ | |
| 10 | Inspect unloader valve | INSPECT | ☐ | |
| 11 | Replace compressor oil (full change - rotary screw) | DRAIN/FILL | ☐ | |
| Electrical (additional to 250-hour) | ||||
| 12 | Full electrical check (wiring, contactors, overloads) | CHECK | ☐ | |
| Structural (additional to 250-hour) | ||||
| 13 | Check vibration isolator mounts | CHECK | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 CI-4 / CK-4 | 6 - 12 L |
| Compressor oil (rotary screw) | PAO or mineral | 8 - 15 L (full change) |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical portable diesel air compressors. Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by compressor size.
Parts / Consumables Required
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 6-12 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Fuel filter | 1 | ☐ | |
| 4 | Air filter element | 1 | ☐ | |
| 5 | Fuel/water separator element | 1 | ☐ | |
| 6 | Compressor oil separator element | 1 | ☐ | |
| 7 | Drive belts | 1 set | ☐ | |
| 8 | Compressor oil (full change) | 8-15 L | ☐ | |
| 9 | EP2 grease cartridges | 1-2 | ☐ | |
| 10 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager