Performance under pressure

Treat air compressors as well as you treat your best workers to extend their useful life and increase their productivity.

You handle your tools with care; after all, your business depends on them. But do you always give the same consideration to the power behind your your pneumatic tools: your compressor?

Easy-to-do routine maintenance and care in transport can go a long way toward getting the longest life from your compressor.

“When properly maintained, an air compressor can prove to be the best value of all your powered equipment purchases,” says Brad Miller, product manager at Campbell Hausfeld.

A few simple steps
Air compressor maintenance is not extensive or time-consuming. “It only takes about two minutes a day,” says Matt Hoefer, Mi-T-M Corp., “and it will extend the compressor’s life.”

Compressor experts agree that a good air compressor maintenance plan includes:

• Draining the tanks daily using the ball valve or petcock on the unit. “Moisture can build up inside the tank. If it’s not drained, a fine mist can enter the air line and make your tool sluggish,” says Rick Brashears, DeWalt compressor product manager. The moisture can cause premature rusting and tank leaks.

•  Check and change the oil regularly. The pump (and the engine on gas-powered models) require oil. It’s a good idea to check oil levels daily and fill as necessary with the oil recommended by the manufacturer.

• Change the oil at least monthly. Some manufacturers suggest changing it after the first 50 hours of operation and every 200 hours after that. Check your operator manual.

• Inspect the air filter. Jobsites are often dusty and dirty and the air filter keeps debris out of your air supply. It’s a vital compressor component that deserves attention. Clean and replace the air filter regularly.

• Give the unit a once-over. “Make sure all air connections are tight. Air leaking into the atmosphere is not available for tools,” says John Worth of Thomas Industries.

Daniel Fox and David Razner, regional sales managers for Associate Engineering Corp., suggest checking for loose bolts and fittings during the daily check. They recommend keeping vibration to a minimum. That means it’s important to maintain or replace rubber isolators or feet as needed.

For reliable psi, use TLC
“Show a compressor a little love and it will perform well for you,” Brashears says. “For example, don’t allow workers to pull it off the truck and bounce it on the ground. That’s hard on units. When loading the truck at the end of the day, be careful when piling other equipment on top. You could break off the air filter or damage the regulator.”

It’s also a good idea to cover the unit when not in use, says Mark Wiseman of PrimeSource BP. “Don’t leave it in the truck over the weekend. Instead, protect it from rain and weather. Store it in a heated place, too, because cold starts are hard on units,” he says.

Applications lead to innovations
Despite diligent care and maintenance, you will eventually need to replace an air compressor. Or perhaps you need to add another unit because your work has changed. If you haven’t shopped for an air compressor in the last few years, you’ll find some very contractor-friendly innovations.

Durability leads the list in design changes. Manufacturers understand jobsite conditions are often less than ideal, so many units are now outfitted with gauge guards and roll cages. These features protect the units from everyday conditions and increase portability. “For example, larger compressors’ roll cages and lifting hooks enable contractors to lift them when working on roofs,” Hoefer says.

“We spend a lot of time with contractors to understand their problems with air compressors,” says Chris Dutra, global product manager for Stanley-Bostitch pneumatic tools and compressors. “We put well-ventilated shrouds around the motors, roll cages to protect units if they tip, mini-cages around gauges to shield them from falling debris, and even add hose storage hooks on the roll cages.”

But even with these new design features, Wiseman advises you look closely at these features on new units. “Be sure to check the placement of the regulator because those exposed to heat from the pump can cause the O-rings to become brittle.”

Portability is gaining attention. One example of what’s new is DeWalt’s 61-lb. easy-to-carry, suitcase-like portable unit. It’s fully protected so if something is loaded on top of it during transport, the regulator and air filter are protected.

Another is Campbell Hausfeld’s Model WL5094. Miller says it’s the first compressor in the industry to couple an oil-free compressor to a vertical-shaft gas engine.

Thomas Industries has also rolled out new electric- and gas-powered oil-free models which Worth says have dirt deflectors, start well in cold weather and operate in any position.

The pressure increases
Higher pressure and flow capabilities can be found on newer air compressors, says James Vintzel, Porter-Cable’s compressor product line manager.

“With more usable air in the tank, you get more stored work capability. This increases the likelihood that the compressor will recharge while the contractor is in the midst of a natural work stoppage,” he says. It results in less downtime, waiting for the compressor to catch up.

In addition, more usable pressure at the end of the hose is important so you have the 90-psi air pressure to operate tools properly.

“Compressors with higher pressure and flow can have a 10- to 25-psi higher delivery to the tool at the end of the hose,” he adds.

Published in the November/December, 2002 issue of Contractor Tools and Supplies magazine.

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