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Compressor Airend Rebuild Service

Compressor Airend Rebuild Service

$0.00
Turnaround time in as little as 5 to 7 days.

Air ends of screw compressors in industrial applications are exposed to heavy operation and thus underlie permanent wear. eCompressedair.com specializes in compressor airend rebuild service to make your compressor run reliable again, with a 2 year warranty.

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

Read Follow Our Blog Why replace when you can rebuild? to read more in detail about the common causes of air end failures.

  1. After you place your order, you'll skid your airend and ship it per our instructions
  2. Airend arrives at our repair center. The airend is inspected and enters our rebuild process
  3. Airend rebuild is completed in 3 to 5 business days
  4. Unit is skidded and packaged appropriately and shipped back to your location

 

Air End Repair Quote
Rotary_screw
Rebuilding Process

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. Rebuild Process
  • 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 manufacturers 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.
Manufacturers & Models

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.

  • Atlas Copco
  • Bauer
  • Broomwade
  • Champion
  • CompAir
  • Gardner Denver
  • GHH
  • Grimmer Schmidt
  • Howden Tamrotor
  • Ingersoll Rand
  • Joy
  • Kaeser
  • Kellogg-American
  • Leroi
  • Palatek
  • Quincy
  • Sullair
  • Sullivan
  • Worthington

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.

Sullair

  • Sullair 10 Airend Rebuild Service
  • Sullair 12 Airend Rebuild Service
  • Sullair 16 Airend Rebuild Service
  • Sullair 20 Airend Rebuild Service
  • Sullair 25 Airend Rebuild Service
  • Sullair 25S (200-350 HP) Airend Rebuild Service
  • Sullair 32 (200-700 HP) Airend Rebuild Service
  • Sullair ES-6 Airend Rebuild Service
  • Sullair ES-8 Airend Rebuild Service
  • Sullair ES-11 Airend Rebuild Service
  • Sullair LS 16/12 (163/127 mm) Airend Rebuild Service
  • Sullair LS-20/12 (204/127 mm) Airend Rebuild Service
  • Sullair LS-20/16 (204/163 mm) Airend Rebuild Service
  • Sullair TS-20/12 (204/127 mm) Airend Rebuild Service
  • Sullair TS-16/12 (163/127 mm) Airend Rebuild Service
  • Sullair TS-20/16 (100-200 HP and 204/163 mm) Airend Rebuild Service
  • Sullair TS-32/25 (200-600 HP and 321/255 mm) Airend Rebuild Service

Gardner Denver

  • BESD/BESE (15-40 HP and 121 mm)
  • BESF/BESG (15-40 HP and 121 mm)
  • BESH/EBE (15-40 HP and 121 mm)
  • ESG/ESH/ESI (30-50 HP and 153 mm)
  • ESK/ESL/ESM (60-100 HP and 175 mm)
  • ECH/HJ (40-50 HP and 177 mm)
  • ECM/KL (60-75 HP and 206 mm)
  • EAP-M (100 HP and 227 mm)
  • ESN/ESO/ESP (100-200 HP and 248 mm)
  • EAQN-O (100-200 HP and 248 mm)
  • EAU P-Q-R (200-300 HP and 296 mm)
  • ESQ ESR (200-300 HP and 321 mm)
  • ESS/EST/EAY (300-400 HP and 370 mm)

Ingersoll Rand

  • ESP-EP (3-15 HP)
  • ESP-EP (15-40 HP)
  • SP 15-50 (15-50 HP and 100 mm)
  • SSR EP 15-50 (15-50 HP and 100 mm)
  • SSR 100-150 (15-50 HP and 100 mm)
  • SSR 200-250H (50-75 HP HP and 127.5 mm)
  • SP 60 (50-75 HP and 127.5 mm)
  • SSR 60XF (50-75 HP and 127.5 mm)
  • SP 15-50 (15-50 HP and 127.5 mm)
  • PA 50-60 (50-75 HP and 127.5 mm)
  • PA 75-100 (75-100 HP and 163.2 mm)
  • SP 75-100 (75-100 HP and 178.5 mm)
  • SSR 75-100XF (75-100 HP and 178.5 mm)
  • SSR 300-500 (75-150 HP and 178.5 mm)
  • PA 75 (75-100 HP and 178.5 mm)
  • PA 100-150 (100-150 HP and 204 mm)
  • SSR 125-200XF (100-200 HP and 226 mm)
  • SSR 500-800 (100-200 HP and 226 mm)
  • PA 100-125 (100-200 HP and 226 mm)
  • SSR 350-450XF (350-450 HP and 304 mm)
  • SSR 1600-2850 (400-800 HP and 350 mm)
  • SSR 3000 (400-800 HP and 350 mm)

Joy

  • TA 007/TA 015 (7.5-15 HP and 72 mm)
  • TA 007/TA 015 (7.5-15 HP and 80 mm)
  • TA 007/TA 030 (20-30 HP and 100 mm)
  • TA 150 (40 HP and 108 mm)
  • TA 175/TA 290 (40-60 HP and 127.5 mm)
  • TA 300/TA 480 (75-100 HP and 163 mm)
  • TA 590/TA 750 (125-150 HP and 204 mm)
  • TA 975/TA 1000 (200 HP and 294 mm)
  • TA 1500/TA 1560 (250 HP and 307 mm)
  • TA 1550/TA 1560 (300-500 HP and 321 mm)
  • TA 2000/TA 2050 (450-500 HP and 356 mm)

Quincy

  • QMB (10-30 HP)
  • QSB (15-40 HP and 127 mm)
  • QMA (50-75 HP and 127 mm)
  • QMA (100-150 HP and 204 mm)
  • QSI 25-30-40 (25-40 HP and 171 mm)
  • QSI 235-350 (50-100 HP and 204 mm)
  • QSI 490-740 (100-200 HP and 255 mm)
  • QSI 1000-1250-1500 (200-350 HP and 312 mm)

Kellogg

  • KRS 15-30 (15-30 HP and 82 mm)
  • KRS 40-75 (40-75 HP and 127 mm)
  • KRS 100-200 (100-200 HP and 204 mm)
  • CRS 20EL-30EH (20-30 HP and 102 mm)
  • CRS 30/CRS 75 (40-75 HP and 127 mm)
  • CRS 100 (100 HP and 178 mm)
  • CRS 125 (125-200 HP)
  • 6060/6075 (60-75 HP and 204/150 mm)

Atlas Copco

  • GA 15-30 (15-30 HP and 134 mm)
  • GAU 407/409/507 (40-75 HP and 134 mm)
  • GAU 509/607/609 (40-75 HP and 134 mm)
  • GA 807/809/907 (100-200 HP and 220 mm)
  • GA 909/1107/1109 (100-200 HP and 220 mm)
  • GA 1407/1409 (100-200 HP and 220 mm)

Leroi

  • 20SS-30SS (15-30 HP and 100 mm)
  • 20-60SSE (20-60 HP and 127 mm)
  • A20-A30SS (20-60 HP and 127 mm)
  • 20-30-SST (20-60 HP and 127 mm)
  • 40SS-75SS (40-75 HP and 175 mm)
  • 100SS-150SS (100-150 HP and 245 mm)
  • 200SS-300SS (200-300 HP and 309 mm)
  • D330-D365SS (75-150 HP and 175 mm)
  • D450-D48SS (75-150 HP and 175 mm)
  • D750SS (150-200 HP and 245 mm)

Kaeser

  • SMB/SM11/SK18 (7.5-15 HP and 72 mm)
  • SK25/AS30/AS35 (20-40 HP and 105 mm)
  • BS44/BS50/BS60/
    CS75/CS90/CS120/DS140 (40-100 HP and 160 mm)
  • DS170/DS200/
    ES300/FS360 (100-200 HP and 250 mm)
  • FS440/FS560/FS620 (220-475 HP and 346 mm)
Airend FAQ

Airend Frequently Asked Questions (FAQ)

  • How many hours of service can I expect to get from a rotary screw airend? Airend FAQ Featured
    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 youll be shortening the life of the unit. If you find that your unit is running hot and you cant bring the temperature down, youll 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, todays 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 cant 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).
Airend Installation Procedure

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 manufacturers 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.
Gallery

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:

Airend Gallery