High-Performance Air Skid (HPA-75-ENC) — Filter & Preventive Maintenance – South-Tek Systems

Applies to: High-Performance Air Skid (HPA-75-ENC)

🛑 Before Any Maintenance: Isolate the system before performing any maintenance or service work. Press Stop, turn off the main disconnect, and blow down all pressure from filters, receivers, piping, and purifiers. If a bank system is in use, close the appropriate isolation valves. Confirm zero pressure before opening any connection, fitting, or plug.

ℹ Maintenance Priority: Run hours take priority over calendar intervals for all scheduled maintenance. If the specified run hours have not been reached but the calendar interval has elapsed — for example, six months have passed but only 300 hours have accumulated — perform the maintenance based on whichever threshold is reached first.

Maintenance Schedule

Daily Checks

Task	Instruction
Oil level check	Inspect oil level through the sight glass on the front of the crankcase — level must be below the red line. Top up with approved oil if needed before starting.
Leak check	Listen for unusual sounds during operation. Apply foam solution to fittings, connections, and piping joints to identify leaks. Tighten or address any leaks found before continuing operation.
Pressure and gauge check	Verify LP receiver, HP receiver, and stage pressure gauges are reading within expected ranges for current inlet pressure conditions.
Manual condensate drain	Open manual drains beneath water separators briefly every 10 minutes during the first operational period at a new site or after extended downtime to confirm condensate is being removed. Auto drain solenoids handle routine drainage during normal operation.
Auto drain cycle verification	Confirm drain valves are cycling — the system should drain for approximately 5 seconds every 10 minutes during operation. Audible discharge from the muffler assembly confirms correct drain valve operation.

Weekly Checks

Task	Instruction
Intake filter inspection	Remove and inspect the booster compressor intake filter element. Clean with low-pressure compressed air directed from inside the element outward. Replace immediately if damaged or heavily loaded. Replace at a maximum of every three months regardless of condition.
V-belt tension check	Apply a 1 kg (2 lb) load to the center of each belt. Correct tension allows 13 mm (½ inch) of deflection. Adjust if deflection is greater or less than this value.
Fastener tightness check	Inspect and re-tighten all accessible bolts, fittings, and cable connections using appropriate torque values. See the Torque Values section below.
Cooling surface cleaning	Blow dust from serpentines, intercoolers, aftercooler fins, and the flywheel using 85–100 PSI compressed air. Wipe residue with a clean cloth if needed. Blocked cooling surfaces cause excessive discharge temperatures and accelerate wear.
Current check	Use an ammeter to measure motor current under full load and confirm it matches the nameplate rating. Elevated current indicates mechanical resistance, incorrect voltage, or phase imbalance.

500 Hours / 1 Year — Whichever Comes First

Task	Details
Oil change	Replace with 4 liters of approved ALK-100 synthetic oil or equivalent. See Oil Change Procedure below.
Oil reservoir sponge replacement	Replace all 6 oil retainer sponge elements (part 3016-37) in the oil retainer assembly during each oil change service.
Carbolescer filter — ELM-C-50-40 (part 1032596)	Replace the Carbolescer filter element in the HP outlet filter assembly every 12 months regardless of run hours. This element removes oil aerosol and vapor — a saturated element will allow oil contamination to reach the laser cutting head.

1,000 Hours / 1 Year — Whichever Comes First

Task	Details
Safety valve inspection	Apply foam solution to all safety valves while the system is running. A properly functioning valve will show no bubbles at operating pressure. Replace any valve that shows leakage. See Safety Valve Check procedure below.
Stage valve inspection	Inspect stage valves for dirt and carbon deposits. Clean carefully if contamination is present. Do not attempt valve adjustment — consult South-Tek Systems if valves are damaged or worn.
Check valve inspection	With the HP receiver pressurized and compressor running, remove the check valve inlet pipe and apply foam solution. Any leakage indicates a failed check valve requiring replacement. See Check Valve procedure below.
V-belt inspection and replacement if needed	Inspect both V-belts for cracking, glazing, fraying, or uneven wear. Replace as a matched set if either belt shows damage. See V-Belt Replacement procedure below.

4,000 Hours / 4 Years — Whichever Comes First

Task	Details
Piston rings	Replace full ring set — contact South-Tek Systems for current part number
Stage valves	Replace complete valve assemblies at general overhaul — South-Tek service personnel or trained customer technician
Head gaskets	Replace full gasket set at general overhaul — contact South-Tek Systems for current part number
O-ring set	Replace full O-ring set at general overhaul — contact South-Tek Systems for current part number
Connecting rod bearings	Replace connecting rod bearing set — contact South-Tek Systems
V-belts	Replace both belts as a matched set regardless of visible condition — part 7953-06 (22 × 2200 mm @ 60Hz)

8,000 Hours — Filter Element Replacement

Filter	Part Number	Location
Oil Removal Filter — GON-US-130-MY	1038788	LP inlet triple filter assembly
Fine Particle Filter — GON-US-130-MX	Contact South-Tek	LP inlet triple filter assembly
Particle Filter — GON-US-130-MP	1038789	Post-dryer / pre-LP receiver
Particle Filter — HG-US-350-MX	1006371	HP outlet wall-mounted filter assembly
Oil Removal Filter — HG-US-350-MY	1006358	HP outlet wall-mounted filter assembly

⚠ Filter Element Change Indicator: Replace filter elements when differential pressure across the housing reaches 10 PSI regardless of hours elapsed. Elevated differential pressure indicates a loaded element that is restricting flow and increasing system backpressure. Do not wait for the scheduled interval if the pressure drop limit is reached earlier.

Maintenance Procedures

Oil Level Check and Top-Up

Check oil level before every start using the sight glass on the front face of the crankcase. Oil level must be below the red line. If level is low, remove the oil fill cap using a No. 17 wrench, add approved oil in small increments, and recheck the sight glass. Do not overfill.

Oil Change Procedure

Start the compressor and run for 5 minutes to warm the oil — warm oil drains more completely.
Stop the compressor and allow the system to fully depressurize.
Remove the oil fill cap using a No. 17 wrench.
Position a funnel and drain bowl beneath the oil drain plug.
Remove the oil drain plug using a No. 17 wrench and allow all oil to drain completely.
Reinstall the drain plug using a No. 17 wrench.
Refill with 4 liters of fresh ALK-100 synthetic oil or approved equivalent.
Reinstall the oil fill cap using a No. 17 wrench.
Start the compressor and check the sight glass — confirm oil level is below the red line.

Approved Oil Specifications

Oil	Type	Quantity
ALK-100	ISO 100 synthetic di-ester — primary recommendation	4 liters
Anderol 755	Synthetic equivalent	4 liters
Shell Corena S2 P100	Mineral equivalent	4 liters

🛑 Oil Mixing Prohibited: Do not mix different brands or types of oil. If switching from one approved oil to another, drain the crankcase completely before refilling with the new oil. Use of non-approved oils will void the warranty and can cause carbon accumulation on valves, accelerating component failure.

V-Belt Tension Check

With the compressor stopped and fully depressurized, apply a 1 kg (2 lb) load to the midpoint of each belt. Correct tension allows exactly 13 mm (½ inch) of deflection. If deflection is greater, the belt is too loose. If deflection is less, the belt is too tight. Both conditions accelerate belt and bearing wear. Adjust belt tension using the belt tightener on the drive assembly and recheck after adjustment.

V-Belt Replacement Procedure

Stop the compressor and confirm complete depressurization.
Remove the belt guard using appropriate tools.
Loosen the belt tightener to relieve tension on the belts.
Remove both old belts from the flywheel and motor pulley.
Install the new matched belt set — part 7953-06 (22 × 2200 mm @ 60Hz).
Adjust belt tightener until deflection is 13 mm (½ inch) under a 1 kg (2 lb) load at belt midpoint.
Rotate flywheel by hand several full revolutions and recheck tension.
Reinstall belt guard with appropriate tools.
Start the compressor and verify correct rotation and no abnormal vibration or noise.

⚠ Always Replace as a Matched Set: Never replace only one belt. Installing a new belt alongside a worn belt causes uneven load distribution, accelerated wear on the new belt, and increased vibration. Always replace both belts together.

Intake Filter Replacement Procedure

Stop the compressor and confirm complete depressurization.
Remove the retaining wires (1) securing the inlet filter head (2).
Remove the inlet filter head (2).
Replace the intake filter element (3) with a new element.
Reinstall the inlet filter head (2) and secure with retaining wires (1).
Start the compressor and confirm no air leaks at the filter housing.

Safety Valve Check Procedure

Start the compressor and allow it to reach normal operating pressure.
Apply foam solution to each safety valve body and discharge port while the system is running.
A properly functioning valve will show no bubbles at normal operating pressure.
If a valve shows leakage, plan for replacement at the next available shutdown — do not attempt to adjust the valve settings.

🛑 Safety Valve Warning: Never adjust, tamper with, or remove the seal on any safety valve. Safety valves are factory set and sealed. Do not replace a leaking safety valve with a plug under any circumstances — this is extremely dangerous and will void the warranty. Return failed safety valves to South-Tek Systems for reconditioning.

Check Valve Check and Replacement

With the compressor running and the HP receiver pressurized, disconnect the check valve inlet pipe and apply foam solution to the check valve inlet port. Bubbles indicate backflow through a failed check valve. If leakage is confirmed, stop and depressurize the system, remove the check valve using appropriate tools, clean the port thoroughly, and install a new check valve. Restart and recheck with foam solution.

Torque Values

Use the following torque values when reinstalling fasteners during maintenance. Always use a calibrated torque wrench. For pipe connections, hand-tighten plus one-half turn unless otherwise specified.

Bolt Size	Quality Class	Max Torque
M6 Allen Head	8.8	10.5 Nm
M8 Allen Head	8.8	25.3 Nm
M10 Allen Head	8.8	50.8 Nm
M12 Allen Head	8.8	86.9 Nm
M14 Allen Head	8.8	139 Nm
M16 Allen Head	8.8	213 Nm
Pipe connections (nuts)	—	Hand tight + ½ turn

Bolt Tightening Order (4-bolt and 6-bolt patterns)

Contact South-Tek Systems

Phone: (910) 415-1880

Email / Ticket: support@southteksystems911.zendesk.com