Air compressors play a crucial role in a wide range of commercial and DIY tasks, enabling workers to complete jobs quickly and effectively. However, air tool maintenance is often overlooked, despite being vital for the compressor's longevity and consistent performance. Below, we highlight why maintaining your air tools is essential to keep your air compressor running at its best.
For optimal operation, air compressors need a steady flow of air at the right pressure. Dirty, damaged, or poorly maintained air tools can strain your compressor, causing it to work harder while delivering less air for your tasks. This additional strain on the engine and other components can lead to breakdowns and inefficiencies.
Air tools don't typically fail overnight; they gradually deteriorate, becoming less efficient over time. Small air leaks and declining performance often go unnoticed, but they can result in higher air demand, forcing your compressor to work overtime.
Thankfully, routine preventative maintenance of air tools can help both the tools and your compressor remain in top working condition.
One of the primary threats to air tools is moisture caused by water vapor in the air. You likely recognize this moisture as humidity. When air is compressed, the moisture in the air becomes concentrated.
Compressed air is also very hot, allowing moisture to stay in vapor form—until the air cools. As the compressed air cools when it leaves the compressor, moisture condenses into liquid water.
Water is the leading cause of wear and failure in air tools and associated equipment. Some air compressor systems include equipment to minimize moisture, but even these systems can’t eliminate water completely. Since moisture is always present in compressed air, it's critical to control it regularly.
Operating air tools with higher air temperatures to avoid moisture buildup can damage the tools. Excessive heat dries out lubricants, leading to increased friction, damaged gaskets, and worn o-rings. This can also harm other components of your air system.
Air tools are built with an intricate system of gears, rotors, pistons, o-rings, and so forth. While these tools are built to withstand working conditions, they still need regular maintenance and care.
During the air compression process, moisture is produced. This moisture mixes with the oil already in the tool and becomes an emulsion, which is a very poor lubricant. The emulsion can cause metal-to-metal impacts inside the tool and binding of pistons, which generates additional heat and results in premature wear and tear and loss of performance.
Additionally, moisture left in the tool at the end of the day can lead to rust forming on metal components by the next morning.
Fortunately, proper maintenance can help prevent these issues.
It’s common for dust, debris, and oil to accumulate in air tools due to their demanding work environments. These contaminants can clog and reduce tool performance, making regular cleaning essential. Wipe down your tools after every job and schedule a thorough servicing at least once per year.
Air tools need lubrication to operate properly, just like air compressors. Lubrication is essential for smooth tool operation and to prevent rust. Make a habit of adding a couple of drops of pneumatic tool oil into the tools after every day of use to keep them in tip-top condition. Just be careful not to over-lubricate!
Regularly inspect your tools for signs of wear and tear, giving extra attention to hoses and seals. Replace worn parts immediately to prevent air leaks and ensure optimal air pressure and tool performance and to minimize damage to the air tool and compressor.
Finally, store your air tools in a clean, dry environment - like a waterproof compartment in your work truck – to prevent rust and corrosion, which can damage them quickly.
The recommended air pressure for most air tools is 90 to 100 psi. Running air tools higher than the recommended air pressure can cause deterioration of the internal components and, in some applications, lead to dangerous accidents to the operator. Ruptured air hoses or couplings can injure the operator or others nearby.
FRLs are very important for each tool. The filter prevents dirt and dust from getting into the tool. The regulator maintains the operating air pressure within the preset psi rating, and the lubricator keeps the tool lubricated, helping it last longer. Only use lubricants recommended by the manufacturer. Also, ensure the hose between the FRL and tool is not too long. Excessive hose lengths between the FRL and the tool will result in the lubricant, delivered in an aerosol form at the discharge of the FRL, entering the tool as a liquid, and this liquid oil can damage the air tool.
You supplier can recommend the best after-treatment equipment to manage moisture and improve overall performance.
Air tool maintenance is about more than just preserving tools—it also protects your compressor and ensures safe operation. By committing to regular upkeep, you'll enhance energy efficiency, extend the life of your tools and compressor, and maintain consistent performance. By investing time in regular tool maintenance, you are ensuring the quality of your work and protecting your investment in your tools and air system.