English Author: Site Editor Publish Time: 2026-09-09 Origin: Site
During long-term operation, air hammers are prone to various types of faults due to factors such as wear and tear, improper operation, and inadequate maintenance. The following are typical problems frequently encountered during use and their corresponding solutions:
Ⅰ. Insufficient power and weak hammering
Fault manifestation : The striking force of the hammer head significantly decreases, making it impossible to complete the normal forging process, and the movement is sluggish.
The core cause of is : the air source pressure is lower than the standard value 0.6 to 0.8MPa, the air pipe is blocked, the inner wall of the cylinder is worn by more than 0.1mm, or the piston ring is broken, or there is air leakage in the compression chamber.
solution : Check the output pressure of the air compressor, clean the oil and impurities in the air pipe, and directly replace the components of the cylinder with excessive wear. Broken piston rings need to be replaced immediately to prevent fragments from scratching the cylinder.
Ⅱ, the equipment frequently leaks air
Fault manifestations : Continuous air leakage occurs at all sealing points of the fuselage, with a rapid drop in air pressure, accompanied by obvious abnormal air flow noises.
The core cause of is : the aging and failure of the sealing ring, the loosening of the gas pipe joint, the wear of the valve core, and the scratches on the surface of the piston rod will accelerate the damage of the sealing parts, with a leakage rate of up to 0.5m³ per minute.
Solution : Regularly inspect and replace the O-ring seal every 500 hours. Tighten the air pipe joint with PTFE tape. When the valve core is severely worn, replace the control valve as a whole.
Ⅲ. Abnormal Vibration and Abnormal Noise
Fault manifestations : Abnormal sounds like drumming occur during operation, the machine body shakes violently, and even accompanied by metal friction sounds.
The core cause of is : the wear clearance of the connecting rod bearing exceeds 0.2mm, the hammer head is eccentric, the fixing bolts are loose, or the fragments of the piston ring are stuck in the cylinder.
Solution : recalibrate the concentricity of the hammer heads (deviation less than 0.05mm), replace the bearings of the corresponding model, and use a torque wrench to tighten the bolts to the standard value of 50 to 60N·m.
Ⅳ. Abnormal movement of the hammer head
Fault manifestations : Insufficient lifting height of the hammer head, no descent after rising, and even uncontrolled continuous striking.
The core cause of is : the valve distribution is stuck (oil contamination crystallization causes the action to be delayed by more than 0.3 seconds), the solenoid valve coil is burned out, or the guide sleeve of the working cylinder is skewed, or the lower part of the hammer rod is swollen and stuck.
solution : disassemble and clean the gas distribution valve to remove oil stains. Replace the burned solenoid valve directly. Correct the verticality of the guide sleeve and grind, repair or replace the upset hammer rod.
Ⅴ. Overheating, deformation and damage of components
Fault manifestation : The temperature of the cylinder/bearing exceeds 80℃, the contact surface of the hammerhead anvil seat is dented, and the impact force is dispersed by more than 30%.
The core cause of is : the single hammer lifting operation time exceeds 1 second, causing the equipment to overheat. Long-term eccentric striking and overloading forging lead to the piston directly hitting the guide sleeve after the anvil seat sinks.
Solution : Control the duration of each hammer lift to no more than 1 second. It is strictly prohibited to forge workpieces that exceed the rated capacity of the equipment. After the anvil seat sinks, promptly raise the sleepers to adjust the stroke to prevent the piston from hitting the cylinder head.
Ⅵ. The operation handle is jammed and heavy
Fault manifestation : After startup, there is a large resistance when operating the handle, and the impact energy is difficult to control precisely.
The core cause of is : excessive wear of the rotary valve, insufficient lubrication, or impurities entering the handle transmission part and causing jamming.
solution : Regularly add ISO VG32 hydraulic oil for lubrication, disassemble and clean the rotary valve. Replace the rotary valve that is worn out of tolerance directly to ensure the handle operates flexibly.
If regular maintenance work such as pre-shift oiling, weekly filter element cleaning, and lubricating oil replacement every three months is carried out in accordance with the norms, the failure rate can be reduced by more than 80%, and the service life of the equipment can be significantly extended.
