When your compressed air system goes down, production stops. For Australian industrial sites, that unplanned downtime costs roughly $25,000 per hour. The good news? Proper air compressor maintenance can prevent most of these expensive failures.
Since 1994, Cleveland Compressors has been helping businesses across Perth, Sydney, Brisbane and Adelaide keep their compressed air systems running smoothly. We’ve seen firsthand how a solid maintenance routine transforms reliability and slashes operational costs.
Why Air Compressor Maintenance Matters
Think of air compressor maintenance like servicing your car. Skip it, and you’re asking for trouble. Companies with scheduled maintenance programmes experience 96% less downtime than those who only fix things when they break. That’s not a small difference.
The numbers tell the story. A Micromain study found that preventive maintenance delivers a 545% return on investment. The annual cost of planned maintenance averages around $720, whilst the average reactive repair bill hits $1,400 per incident. And that doesn’t include lost production time.
There’s also the energy angle. Compressed air systems can consume up to 30% of a site’s electricity, and poor maintenance wastes up to 90% of that through leaks and inefficiency. In 2026, with energy costs climbing, that’s money literally leaking away.
Australian regulations add another layer. Pressure vessels (air receivers) must be inspected to AS/NZS 3788 every two or three years depending on hazard level. Receivers over 150 litres or 1,000 kilopascals require plant registration with state WorkSafe bodies. Skip these inspections and you’re looking at serious compliance issues.
Daily, Weekly & Monthly Air Compressor Checks
Regular inspections don’t need to be complicated. A few minutes each day can prevent major headaches down the track.
Air Filters
Your air filters are the first line of defence against dust, dirt and contaminants entering the compression chamber. Check them daily for visible dirt or damage. A clogged filter restricts airflow, forcing your compressor to work harder and consume more power.
Most filters need replacing every three to six months, but harsh environments might require monthly changes. If you’re in mining or heavy industry, regularly check filter condition and swap them out at the first sign of degradation.
Checking the Safety Valve Ring
The safety valve ring prevents dangerous pressure build-up in your air compressor tank. Test it weekly by pulling the ring whilst the compressor is under pressure. You should hear a sharp release of air. If nothing happens, or if the valve leaks continuously, it needs immediate replacement.
This isn’t optional. A faulty safety valve creates a genuine risk to your team and your site.
Draining the Air Compressor Tank
Moisture collects in your receiver tank every time compressed air cools. Drain the tank daily to prevent corrosion and water contamination in your air lines. Most tanks have a manual drain valve at the bottom. Open it, let the water and condensate flow out, then close it firmly.
Automatic condensate drains handle this job for you, but they still need checking to confirm they’re operating correctly. For more detail on receiver maintenance, read our guide on how to maintain your air receiver tank.
Specialist Air Compressor Maintenance Service vs DIY
Some maintenance tasks are straightforward. Others require specialist knowledge and equipment.
Basic tasks like draining tanks, checking filters and testing safety valves can be handled in-house with minimal training. But when it comes to oil changes, bearing inspections, seal replacements or calibrating pressure levels, you’re better off calling in professional service technicians.
Cleveland Compressors offers comprehensive air compressor service programmes across Australia. Our technicians carry a comprehensive spare parts inventory and can diagnose issues before they cause failures. We work with Atlas Copco, BOGE, ALMiG and other leading brands, so we understand the specific requirements of each system.
The reality is that DIY maintenance saves money on simple tasks, but attempting complex repairs without proper training often leads to bigger problems. Know your limits and don’t hesitate to call for help when needed.
Oilless & Oil-Free Air Compressor Maintenance
Oil-free air compressor maintenance is a different beast. These units are increasingly popular in food and beverage, pharmaceuticals and healthcare where oil contamination simply can’t be tolerated.
The global oil-free air compressor market was worth USD 12.9 billion in 2024 and is forecast to reach USD 17.2 billion by 2030. That growth is driven by industries that require ISO 8573-1 Class 0 certification for air purity.
Without oil lubrication, oil-free compressors rely on specialised sealing materials and coatings in the compression chamber. This means you won’t need to monitor oil levels or change oil filters, but you must pay closer attention to other components.
Air filters are even more important in oil-free systems because there’s no oil mist to help trap particles. Replace them more frequently. Bearings and seals also experience higher wear rates without oil cushioning, so regular inspections and timely replacement are essential.
The life expectancy of an oilless air compressor typically ranges from 10,000 to 20,000 hours with proper care, compared to 40,000+ hours for oil-injected units. The trade-off is absolutely clean air, which is non-negotiable in certain industries.
Browse our range of oil-free air compressors to find models suited to your application.
Predictive Maintenance & Remote Monitoring
We’re seeing a shift from reactive and preventive maintenance to predictive maintenance powered by IoT sensors and cloud platforms. Atlas Copco’s SMARTLINK and similar systems monitor temperature, vibration, pressure and other parameters in real time.
These platforms can predict component failures days or weeks in advance, allowing you to schedule repairs during planned downtime rather than scrambling when something breaks. Early data shows predictive analytics deliver an additional 7-10% in energy savings on top of standard maintenance benefits.
For large compressed air systems or multi-site operations, remote monitoring makes tremendous sense. You get visibility across your entire fleet, can compare performance between locations and catch problems early.
Cleveland Compressors is increasingly integrating these technologies into our customised solutions for clients across manufacturing, mining and other industries. It’s not just about fixing compressors anymore. It’s about optimising entire compressed air systems for maximum efficiency and reliability.
Keep Your Compressed Air System Running Strong
Air compressor maintenance isn’t glamorous, but it’s one of the highest-return activities you can do for your operation. The difference between a well-maintained system and a neglected one shows up in your power bills, your production schedules and your repair invoices.
Start with the basics. Daily draining, weekly safety valve tests, monthly filter changes. Build from there with professional servicing at appropriate intervals. And if you’re managing multiple compressors or operating in demanding environments, consider remote monitoring to stay ahead of problems.
For more information on maintaining safe operations, check out our air compressor safety guide or learn more about why air compressor maintenance is important.
Whether you’re running a small workshop or managing a major industrial site, Cleveland Compressors has the expertise and support network to keep your compressed air system performing at its best. Get in touch with our team on (08) 9452 3669 or email info@ccair.net.au to discuss your maintenance requirements.
Frequently Asked Questions
It depends on your compressor type. Oil-injected models require regular oil changes, typically every 1,000 to 2,000 operating hours. Check your manufacturer's guidelines. Oil-free compressors don't need oil in the compression chamber but may still require oil for motor bearings.
Most industrial air compressors need professional servicing every 2,000 to 4,000 operating hours, or at least annually. High-use environments may require more frequent servicing. Always follow the manufacturer's recommended schedule and Australian Standards requirements for pressure vessel inspections.
For oil-injected compressors, check oil levels weekly and change oil every 1,000 to 2,000 hours of operation. Heavy-duty or high-temperature applications may need more frequent changes. Always use the oil grade specified by your manufacturer.
No, you cannot add oil to the compression chamber of an oilless air compressor. These units are specifically designed to operate without oil lubrication. However, some oilless models have sealed bearings that may require periodic lubrication. Check your manual.
With proper maintenance, oilless air compressors typically last 10,000 to 20,000 operating hours. This is shorter than oil-injected models but acceptable for applications requiring oil-free air. Regular filter changes and component inspections extend service life.
Annual professional servicing is the minimum for most systems. High-use industrial compressors should be serviced every six months or after 2,000 operating hours, whichever comes first. Pressure vessel inspections must follow AS/NZS 3788 requirements.
Service costs vary depending on compressor size, type and condition. Basic servicing for small workshop compressors starts around a few hundred dollars, whilst comprehensive maintenance for large industrial systems can cost several thousand. Preventive maintenance is always cheaper than emergency repairs.
Drain moisture daily, test safety valves weekly, clean or replace filters monthly, check for air leaks regularly, maintain proper oil levels (if applicable), keep the compressor clean and ensure adequate ventilation around the unit. Schedule professional servicing according to manufacturer recommendations and Australian Standards.
