Complete Operation Guide for Air hammer

Ⅰ. Scope of Application and Basic Requirements This guide is applicable to the operation of conventional air hammers in scenarios such as forging and material unblocking, covering common models like 150 kilograms, while also taking into account the general operation norms for ordinary forging air hammers and pipeline/silo vibration air hammers. All operators must undergo professional training and hold relevant certificates to work. They should be familiar with the structure, working principle and key points of operation of the equipment. Non-professionals are strictly prohibited from starting the equipment without authorization. When operating, a safety helmet, protective glasses and anti-vibration gloves must be worn throughout the process. It is strictly prohibited to work after drinking alcohol, when fatigued or in a poor mental state.

Ⅱ. Preparations before Startup

1. Environmental and site inspection: Clear away irrelevant debris within the operation area to ensure that the operation space is unobstructed. No irrelevant personnel are allowed to loiter and observe within a 1.5-meter radius. Make sure the ground is flat and anti-slip, and there are no flammable or explosive items around to avoid potential safety hazards during the operation.

2. Inspection of equipment components: Check each core component such as the hammer head, hammer rod, and cylinder one by one to ensure there are no cracks or deformations. Check that all the fastening bolts are not loose. Add lubricating oil to each lubrication point according to the equipment lubrication chart to ensure the oil passage is unobstructed. In a low-temperature winter environment, the hammer rod and anvil should be preheated to around 100℃ in advance to prevent the components from cracking due to impact during cold start-up.

3. For the power system, first open the main valve of the compressed air. Wait until the air pressure stabilizes within the rated working range of the equipment before preparing to start. For electric drive models, it is necessary to confirm that the motor wiring is correct. After power-on, the motor should rotate clockwise. If it rotates in the opposite direction, any two wires need to be swapped for adjustment. For older models with auxiliary power supplies, it is necessary to confirm that the battery model and specification match the equipment. Give priority to choosing qualified products from regular brands. Select the corresponding capacity based on the continuous operation time and avoid using aged or swollen batteries.

4. Preparation of auxiliary tools: Prepare the corresponding fixtures and measuring tools according to the operation requirements. For forging operations, it is necessary to confirm in advance that the temperature of the forged part is qualified. It is strictly prohibited to directly forge completely cooled metals.

Ⅲ. Startup and Debugging Process

1. Move the operating handle to the idle position, start the motor and let the equipment run idle for 3 to 5 minutes. Listen to the sound of the equipment's operation throughout the process to ensure there are no abnormal noises, no lag or vibration.

2. Under no-load conditions, test the functional gears such as "suspended, compressed, single strike, and continuous strike" in sequence to confirm that the valve train responds normally and the operation handle and foot pedal move flexibly without any jamming.

3. For forging operations, during the debugging process, a wooden board or a preheated test forging piece must be placed on the anvil seat. It is strictly prohibited to strike the anvil empty to avoid direct rigid impact of the hammer head causing component cracking.

4. Adjust the striking force and frequency according to the material of the workpiece and the operation requirements. The striking force increases when the handle is moved backward and decreases when it is pushed outward. After the parameter debugging is completed, the operation can be officially started.

Ⅳ. Formal Operation Norms

During the operation, it is essential to follow the signal instructions of the hand clamp personnel, maintain a stable operation rhythm, avoid forceful and rough strikes, and strictly prohibit keeping the equipment in a full-load continuous strike state for a long time to prevent overheating and excessive wear of components.

When performing a single strike operation, wait until the hammerhead is fully reset and its state is stable before carrying out the next action to reduce unnecessary impact loads that may damage the equipment.

3. Always keep an eye on the status of the workpiece and the operation of the equipment. If any deviation of the workpiece, abnormal vibration or unusual noise of the equipment is detected, immediately suspend the operation and resume work only after the troubleshooting and handling are completed.

When multiple people are working together, only one person is allowed to operate the equipment. The rest of the personnel should keep a safe distance. It is strictly prohibited for multiple people to operate the handle or foot pedal device simultaneously.

5. For the use of air hammers for vibration in silos and pipelines, the vibration intervals should be adjusted according to the blockage of materials to avoid deformation and damage to the silo walls and pipelines caused by high-frequency continuous vibration.

Ⅴ. Shutdown and Closing Procedures

1.After the operation is completed, first turn the operating handle back to the idle position to stop the equipment from striking. When the hammerhead slowly and gently drops to the low position, place a wooden block of appropriate thickness between the hammerhead and the anvil to prevent the hammerhead from directly touching the anvil seat and causing rigid contact.

2. First, turn off the power of the equipment, and then close the main valve of the compressed air to prevent residual pressure in the pipeline from causing incorrect operation of the equipment. For electric models, finally cut off the main power supply and lock the power switch.

3. Clean the iron filings and debris from the surface of the equipment and the working area, thoroughly clean all moving surfaces of the equipment, replenish grease to the lubrication points as required, and keep a record of the equipment's operating status for the day.

4. For any issues such as component wear and tear or functional abnormalities discovered during the day's operation, they should be promptly registered and reported, and subsequent maintenance and handling should be arranged. It is strictly prohibited for equipment to operate with damage.

Ⅵ. Daily Maintenance and Safety Taboos

1. Regularly inspect the wear and tear of vulnerable parts according to the equipment maintenance cycle, replace failed seals and buffer parts in a timely manner, and conduct a comprehensive re-tightening of equipment fasteners once every quarter.

2. The storage and usage environment of the equipment should avoid high-temperature and high-humidity areas. Regularly check the status of the auxiliary battery and replace the aged battery in time to prevent leakage and corrosion of the equipment circuit.

3. Strictly enforce safety prohibitions: It is strictly prohibited to strike with an empty hammer, to forge overburned or cooled metals, to insert hands into the stroke range of the hammer head while the equipment is in operation, and to place irrelevant tools and debris on the equipment.

4.For equipment that has been out of use for a long time, anti-rust treatment should be carried out on all components, residual water vapor in the cylinder should be drained, and dust-proof protection should be well done. Before restarting, a comprehensive inspection and no-load test run must be completed.