Preventative Maintenance Schedule Template (UK Workshops)
Every air compressor—whether an ABAC piston, Atlas Copco screw, FINI MK or HPS industrial unit—needs consistent maintenance to stay reliable. This preventative maintenance schedule helps UK workshop owners reduce downtime, avoid costly repairs, and stay compliant with PSSR 2000 and PUWER 1998.
1. Why a Preventative Maintenance Plan Matters
Unplanned breakdowns cost more than scheduled servicing. By performing simple checks and documenting each task, you extend equipment life, maintain air quality and avoid lost production time. A structured plan also supports warranty claims and health-and-safety audits.
2. How to Use This Schedule
Print the checklist below, laminate it, and mount it near your compressor. Operators can tick off daily items while engineers record weekly and monthly tasks. For multi-compressor sites, duplicate this sheet for each machine and keep digital copies in your maintenance log.
3. Daily Maintenance Checklist (Operator)
- Check oil level and top-up with approved compressor oil.
- Drain condensate from the receiver or confirm auto-drain operation.
- Inspect for air or oil leaks.
- Listen for abnormal noises or vibration.
- Verify pressure and temperature readings are normal.
4. Weekly Maintenance (Technician)
- Clean or replace the intake filter element.
- Check drive belt tension and alignment.
- Test safety valve and confirm proper reseating.
- Wipe down the machine and remove dust from vents.
- Inspect flexible hoses and fittings for wear.
5. Monthly Maintenance
- Record running hours; schedule next service interval.
- Check differential pressure across filters (> 0.5 bar = replace).
- Clean coolers with low-pressure air or vacuum.
- Inspect electrical connections and contactors for heat marks.
6. Quarterly / 2 000 Hour Service (Screw Compressors)
- Change oil and replace oil & air filters.
- Replace separator element if due.
- Check coupling alignment and bearing noise.
- Test safety valve, gauges and temperature switch.
7. Annual Maintenance / Statutory Inspection
- Internal inspection of receiver tank for corrosion.
- Calibrate gauges and safety devices.
- Replace worn hoses and rubber seals.
- Check control panel for dust and contactor wear.
- Update Written Scheme of Examination (if > 250 bar-litres).
8. Printable Maintenance Schedule Table
| Frequency | Task | Completed ✔ | Date | Initials |
|---|---|---|---|---|
| Daily | Check oil level and drain condensate | |||
| Daily | Inspect for leaks and abnormal noise | |||
| Weekly | Clean intake filter and test safety valve | |||
| Weekly | Check belt tension and cooler cleanliness | |||
| Monthly | Record hours and check filter pressure drop | |||
| Quarterly | Change oil, oil filter & air filter | |||
| Annual | Receiver inspection & gauge calibration |
Tip: Keep a digital backup of completed sheets for traceability and HSE audits.
9. Recommended Replacement Intervals
| Component | Typical Interval | Notes |
|---|---|---|
| Intake Filter | 1 000 h / 6 months | Replace sooner in dusty areas. |
| Oil Filter | 2 000 h / 6 months | Change with each oil service. |
| Separator Element | 4 000–8 000 h | Use OEM-equivalent only. |
| Drive Belts | 12 months | Retension after first 100 h. |
| Coolers | Clean monthly | Prevent heat build-up. |
| Safety Valve | Test monthly / Calibrate annually | Mandatory under PSSR. |
10. Parts & Supplies Checklist
- Compressor Service Kits (OEM & Aftermarket)
- Compressor Oil & Lubricants
- Intake & Coalescing Filters
- Automatic Drains & Oil-Water Separators
- Anti-Vibration Mounts & Feet
11. Storing Maintenance Records
For small workshops, a simple spreadsheet or Google Sheet works well. Larger sites may benefit from a maintenance management system that logs hours and sends email reminders. Whatever method you choose, records must be retained for at least 5 years under UK safety guidance.
12. Digital Download
You can download a ready-to-use printable version of this schedule as a PDF from our resources page:
Download Maintenance Checklist (PDF)
13. Service Kit Planning
Each make and model has specific filters and oils. Enter your compressor’s serial number or model code into our parts finder to view the correct kit. Buying complete kits saves money and ensures all seals, filters and gaskets are replaced together.
14. Example Service Kit Contents
- Air filter element
- Oil filter
- Separator cartridge (screw models)
- Gaskets and O-rings
- Replacement oil (ISO 46 or 100)
15. Environmental & Safety Reminders
- Dispose of used oil & filters via licensed recyclers.
- Install an oil-water separator on drain outlets.
- Never open pressurised components — isolate power & pressure first.
- Ensure all receivers carry valid CE/UKCA markings.
16. Key Benefits of Following This Schedule
- ✔ Improved reliability and fewer breakdowns
- ✔ Lower electricity costs through efficient operation
- ✔ Extended compressor and tool life
- ✔ Better air quality and compliance with ISO 8573-1
FAQs
How often should I change my compressor oil?
Piston compressors: every 250–500 hours. Screw compressors: every 2 000–4 000 hours depending on oil type and environment.
Can I use car engine oil in my compressor?
No. Engine oil contains detergents that foam under pressure. Use dedicated compressor oil only.
What happens if I miss a scheduled service?
Efficiency drops, wear accelerates, and warranty coverage may lapse. A single missed oil change can cause bearing failure or rotor seizure.