Compressor Air End Rebuild Service

To get started, send us an RFQ today or call Toll Free: 866-650-1937.

What Happens to Your Airend?

• Your airend is loaded off and taken immediately to the disassembly area which contains mounting stand, overhead crane and oil pit for collecting waste oil. All shipping documents are then forward to the office to be assigned a work order number, and a folder is generated for disassembly, teardown and spec sheets. This folder follows the airend through the entire rebuilding process to ensure accurate documentation.
• Once the airend is disassembled, damage and measurements are recorded, and pictures are taken identifying the problem areas. A report is generated telling us the front and rear covers were damaged, the sealing strips are partially worn and the bearing journal on the rear is damaged. The seal area on the unit has groves and a small area of the male rotor bore is out of round.
• At this point a quote is written for the rebuild and submitted to the customer for approval.
• The disassembled airend is then placed in one of the self-contained cleaning systems.
• Once we receive the OK and Purchase Order number from the customer, all parts that require work are brought to different areas of the shop and the repairs begin. The front and rear covers will be metalized using the thermal ARC system, when finished depending on the size of the cover, its moved to either the 20" or 36" Blanchard grinder for finishing.
• The front male rotor bearing journal is mounted and turned on a lathe and will also be metalized and ground according to specs.
• The main bore area if damaged will be plated and bored on a vertical boring mill.
• Seal strips are built up and re-cut on a custom jig.
• Depending on the extent of the damage, the above work normally takes one to two days to complete.
• All components are then rewashed and taken to the assembly area, where all the bearings, seals, gaskets, and related materials needed to complete the assembly are pulled from inventory.
• Before assembly takes place all the bearing pockets, bores, and alignments are rechecked. The two rotors are then checked for proper balance and alignment.
• The bearings are removed from the boxes and re-measured for proper fit before installing.
• To insure that the manufacturer's specs are being met, the unit is continually measured and re-checked for accuracy
• Upon completion all open ports are plugged with plastic caps and the inlet taped. The airend is now ready to be skid mounted and painted.
• As units enter the shipping area all necessary shipping documents and start-up procedures are attached to the unit, and trucking details are arranged.
• This whole process will normally take on the average 3 to 5 working days, depending on the MM size and degree of damage. We have setup our shop so the work flows through on a orderly path to insure that all our inspection steps and quality controls are adhered too.

eCompressedair.com is proud to service all of the following Manufacturers:

To get started, send us an RFQ today or call Toll Free: 866-650-1937.

eCompressedair.com warrants all airend rebuilding for a period of 2 years ( 24 months ) against defects in materials replaced and workmanship performed.

Here is a detailed list of popular OEMs and models which are serviced regularly.

Airend Frequently Asked Questions (FAQ)

• How many hours of service can I expect to get from a rotary screw airend?
  A rotary screw airend is a precision piece of equipment that has running tolerances in the thousandths, most units will provide an average of 25,000 to 50,000 hours, some of the older units will run into the 100,000 hour range.
  
  
• What kind of maintenance schedule should I follow with my airend?
  eCompressedair.com reccommends that you setup your unit on a regular maintenance schedule. Change oil, oil filter, and air filter on a regular basis. Once a year is not enough. The compressor is constantly taking in contaminates with the air. The only way to get rid of harmful contaminates is to change the oil.
  
  
• What temperature should my compressor be running at?
  Most compressors are designed to run 100° degrees above ambient. That makes the average temperature between 175° to 200° maximum. Anything above 200° and you'll be shortening the life of the unit. If you find that your unit is running hot and you can't bring the temperature down, you'll need to add a cooler.
  
  
• What could cause my airend to fail?
  There are numerous causes, contaminated oil, high running temperatures, and one over looked area - motor bearings. A percentage of airends we receive for remanufacturing fail because the motor bearings lost their trueness, placing stress on the front airend bearings. These bearings are not made to handle this kind of movement. We recommend that the motor bearings be done every 2 to 3 years on 24hrs operating units and every 5 years for the standards. Again a little preventive maintenance can save you thousands in the long run.
  
  
• What kind of oil should I use?
  Use a good quality synthetic oil, today's rotary screws run between 175 to 200 degrees, synthetic oil is the only one that will take the heat and not varnish. Mineral base and turbine oils will varnish, which will lead to overheating problems.
  
  
• Maintenance
  We can't stress filter and oil changes enough. A well-maintained unit will provide reliability, energy savings and peace of mind.

• Warranty
  eCompressedair rebuilds adhere to strict tolerances, use the highest standards to ensure quality, and are backed by a warranty on equipment repaired and defects in materials replaced as well as workmanship for a period of 2 years (24 months).

To get started, send us an RFQ today or call Toll Free: 866-650-1937.

Proper Installation is critical to airend life.

1. Motor Bearings: install new motor bearings, and inspect covers for wear. If the bearings are loose in the pockets, vibration will be transmitted to the front airend bearings and this will lead to premature failure.
2. Drain oil from the system and remove all oil piping, filter housings, sumps, and whatever else holds oil. Clean thoroughly all the components to remove all the old oil and particles. It is important to remove all the metal particles in the system. Most reinstalled airends fail because metal particles left in the machine clog the orifices.
3. Steam clean oil coolers inside and out.
4. Replace all filters in system and pre charge the oil lines and oil filter with fresh oil. This can be done with supplying outside air pressure to the sump and flowing through the coolers, oil filters and stop valves. Units with a stop valve will have to be pressurized to keep the valve open. Use a five ( 5 ) gallon container to capture any overflow. At this time you can also check how clean the system is. If any questions, please call.
5. IMPORTANT: Coupling alignment and placement is critical to airend performance and longer life. Install the new coupling per the manufacturer's installation instructions. There should be a gap on insert type couplings and bolt-on couplings. Make sure that you are not forcing the coupling cushion in place. This will add additional load on the pilot and motor bearings which will cause premature failure. The coupling should be aligned to within .005 both ways.
6. When installing the airend, cover the inlet to prevent any foreign material from entering the chamber.
7. Before installing the inlet control, pour fresh oil down the inlet and turn by hand. This will prevent the airend from starting dry. On some units, they may seem stiff, this most likely is caused by the sealer getting on the rotors, it will clear once the unit starts. NOTE: it takes five to ten seconds for the unit to build pressure and force oil through the airend.
8. Start unit and check for oil leaks and vibration. Let the unit run for about 15 minutes, shutdown and recheck all the oil ports and orifices to make sure there is no blockage.
9. Restart and change oil filters after the first 50 HRS and then every 500 HRS there after.
10. Use a good quality synthetic oil for longer life and a cleaner system.
11. When the airend comes from the factory, they are designed to run within 100 degrees of ambient. If it is eighty degrees outside, the unit should be running at 180 degrees. If you are experiencing high temp., check the coolers, thermal bypass, and oil filter housing. Sometimes the bypass valve breaks apart and blocks the oil flow.
12. Follow the manufacturers recommendations for all other related services.

eCompressedair.com has the resources and facilities to provide the Industry with umatched workmanship and customer service. From initial inspection and estimate, to replacement parts, keyway, and casting repairs, metalizing, and all the way down to the final coat of paint, eCompressedaor.com will rebuild your equipment with a quality workmanship that can only be achieved through patience and experience.

View photos from airend rebuilds done through eCompressedair.com: