Pneumatic tools are one of the most essential tools on the factory floor. Yet, some technicians mishandle or neglect their tools, thereby impacting tool performance and life. Whether you mistakenly use the same tank of compressed air for impact wrenches and paint guns, miss lubrication, or carelessly toss air tools around the factory floor – careless mistakes can hurt the life of your tools.
Here, in this post, we share with you some maintenance tips to keep your pneumatic tools running for years to come, without any troubles.
Yes, it’s true that pneumatic tools are made to work in harshest environments. Here, at Alok Tools, leading Industrial Pneumatic tools manufacturer in India, our range of air tools are made with high-quality hardened metals that are tough and resilient to keep working day-in and day-out.
With that said, even the sturdiest tools have a breaking point. It can fail because of wear and tear or due to improper handling. As pneumatic impact wrench manufacturers, we have observed that anvils are the most commonly damaged parts in impact wrenches and ratchets. This is because anvils are always under heavy torque and pressure, which in turn, causes steel fatigue.
When it comes to tools like ratchets, grinders and drills, gears are most likely to fail, when the user adds too much load to the tool.
To ensure your pneumatic tools last for long, here’s one basic thumb rule that you have to follow:
“Always use the Right Air Tool for the Right Job.”
For instance, using small impact wrenches for larger models causes breakage due to overstressing. Remember that each tool has its limits. Always refer to the manufacturer’s instructions regarding usage limits.
In an ideal world, air tools will be stored in the right storage boxes both before and after usage. However, the reality of the industry floor is different – air tools are carelessly tossed or dropped. And, sometimes air tools even get run over by forklifts.
When an air tool is dropped, it could cause the internal mechanisms to break or misaligned. For instance, dropped wrenches fail to turn and compressor lines may leak. You may be able to repair dropped tools or it may be impossible to repair it.
To avoid such situations, follow this basic rule,
“Always have a flat resting area for pneumatic tools.”
Make sure that you instruct all factory workers to place tools only on this place and not on the factory floor. You can even add some shock-absorbing soft padding to the resting place, to prevent tools from slipping off. And, ensure that all workers are trained not to throw tools around. It’s not just harmful to the tool, but could even lead to injuries to other workers.
Just like all other tools, pneumatic tools require regular lubrication and oiling. Without lubricants, the internal tool parts will start to grind against one another. This causes friction, erosion and wear and tear.
There are two main reasons for air tools to fail:
Make sure that you use the right lubricant specified by the manufacturer. To find out more about the different types of lubricants and help to choose the right lubricant, check this post. Also, use the right lubricating tool to prevent oil from seeping all over the delicate internal components. Make sure that the lubricant you use doesn’t get into the airline.
The rule of thumb to follow here,
“Always oil air tools at the end of the work day.”
The inner components of air tools are made of steel and are prone to rust. Oil tools at the end of the work day, and run it for a few seconds. By doing this, you ensure that the lubricant stays in the tool overnight, and protects it from moisture.
Just like oiling, you have to ensure that pneumatic tools are kept clean at all times. Dirt build-up, dust accumulation, water-caused corrosion is a big No-No. To clean tools, all you have to do is wipe grime and moisture off it using a clean cloth.
The rule of thumb here,
“Don’t let dirt, dust or water accumulate on your air tool.”
If water enters the tool, you have to ensure that it’s dried off quickly. After drying the interiors, you must relubricate it. Check the tool’s service manual for instructions. Make sure to store your pneumatic tools in water-proof and air-tight containers to prevent water and dust from getting into it.
#1: Tool runs at normal speed, but loses speed or power midway or under load.
Possible Cause – Motor parts or the cam clutch could be worn down. Lack of lubricant.
Remedy – Lubricate the internal clutch housing. Make sure that the clutch case is not completely full. Overfilling can cause slowing down of clutch parts.
#2: Tool gets Heated up Quickly during Operation.
Possible Cause – Indicates insufficient grease.
Remedy – Proper lubrication.
#3: Tool runs slowly.
Possible Causes – Air flow could be blocked due to dirt. Power regulator could be closed. Motor could be jammed with dirt.
Remedy – Pour lubricant into the air inlet as per manufacturer instructions. Operate the tool in short bursts to dislodge dirt and dust.
#4: Tool does not run.
Possible Causes – Stuck up motor vanes.
Remedy – Pour lubricant into the air inlet as per manufacturer instructions. Operate the tool in short bursts to dislodge dirt and dust. Disconnect power supply and tap the motor housing gently. Try to free the motor by driving shank manually.
#5: Tool does not turn off.
Possible Causes – The “O” rings could be dislodged from the inlet valve.
Remedy – Replace the “O” ring.
If you are not able to troubleshoot on your own, it’s highly recommended that you contact the tool manufacturer or an authorized service center.
Whether you are a floor technician, general manager or a foreman, make sure to follow all the maintenance tips here and keep your pneumatic tools functioning for years to come. And, for the best Pneumatic Machine Tools in India, look no further than Ozar-Toku air tools.
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