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Operation Manual （Mechanical & Hydraulic part） Type：C92K-63 Name：63KJ CNC hydraulic close die forging hammer Anyang Forging Press Numerical Control Equipment Co., Ltd Contents 1.Copyright ………………………………………………………………1 2.Prologue………………………………………………… .……………2 3.Technical parameters ……………………………………… ……3 4.Safety rules…… ………………………………………… .…………4 4 .1 Safety instructions ………………………… ……….….…….5 4 .2 Main switch ……………………………………………… ……5 4 .3 Red－emergency stop button ………………………… … .……5 4 .4 Foot switch ……………… ………………… ………… .……5 4 .5 Mode switch …………………………………………… ….……6 4 .6 Tup mechanism safety device …………… … .……….… …6 4 .7“Tup top position” limit switch …………………… .…… … .6 4 .8 The lowest limit position of tup….……………… … …….7 4 .9 Hydraulic accumulator ………………………….… … .….…7 4 .10 Fireproofing …………………………… ….………….… …8 4 .11 Minimum dies height ……………………………… ………….8 4 .12 Change Oil……………………………………………… .….…9 4 .13 Shipment . ………………………………………… …… 9 4 .14 Guard rail ……………… ……………………….…… 9 4 .15 Inspection ………………………………………………….….9 4 .16 Production warning ……………………… .………… .….….9 5. Primary statement for safety………………… .…… …….…10 5 .1 Basic principle, Authorization operation …………… ….…10 5.2 Safety execution… …………………………… .……10 5.3 Staff ability and basic responsibility ………… …………………10 5 .4 The safety rules for the special operation safety… …… .…… 10 5 .4 .1 Operating the hammer ( forging) …………………….……10 5 .4 .2 Operating the hammer ( adjustment, maintenance) ………11 5 .5 Alarm……………………………………………………….……12 5 .5 .1 Electric power… ………………………………….…….…12 5 .5 .2 Gas, dust steam and soot……… ……………………….….13 5 .5 .3 Hydraulic system …………………………………………13 5 .5 .4 Noise ………………………………………………….….…13 5 .5 .5 Oil, lubricant, other chemistry material …………….…13 6. Installation & commissioning ……………………………………….13 7. Maintenance …………………………………………………………13 7 .1 Daily maintenance ………………………………………………13 7 .2 Weekly maintenance ………………………………………….…14 7 .3 Monthly maintenance ……………………………… ………… 14 7 .4 Quarterly maintenance ……………………………………… …14 7 .5 Oilness Inspection …………………………………………….…14 7 .6 Automatic lubrication system ……………… …………… ….15 7 .7 Motor .…………………………………………………….……15 7 .8 Hydraulic Pump……………………………………… ….…… .15 8. Hydraulic principle and function ……………… ……………………16 8 .1 Accumulator charge pressure/lifting tup（first step） …… …18 8 .2 Acceleration （Second step）…………………… ………….….18 8 .3 Oil replacement（Third step） …………………………… … 19 8 .4 Return（Fourth step）……………………………………….… 19 8 .5 Buffering（Fifth step）……………………………………….….19 8 .6 Slow down（Sixth step）………………………………….…….19 8 .7 Slow up（Seventh step）……………………….…………….…19 8 .8 Accumulator relieving pressure（Eighth step）….…… ………20 9.Structural overview……………………………………………… .…20 9 .1 General description ……………………………… .……….20 9 .2 Overview …………………………………………….……….20 10. Installation ………………………………………………….……21 11. Commissioning ……………………………………………… .……23 11 .1 Testing ………………………………………… .….…….23 11 .2 Oil relief ……………………………………………… ……23 12. Transportation ……………………………………………… …24 13. The faults & maintenance ………………………………… …….24 13.1 Overview ……………………………………………………24 13.2 Failure of hydraulic system ……………………………24 13.3 Automatic lubrication system …………… …………….27 13.4 Maintenance procedure ……………………………….……27 14. Wearing part list …………………………………………………32 ANYANG FORGING PRESS NUMERICAL CONTROL EQUIPMENT CO., LTD 1 1.Copyright The operating manual contains the technical requirements and drawings may not be copied, transmitted, or for the purpose of competition in the market for personal use or provide to third parties. If found, our company will pursue its legal responsibility according to law. If this operation manual has differences with the contents of our product brochure, the operating instructions in this manual shall prevail. This action changes the contents of the manual without notice. The operating manual of the final interpretation owned by our company. The operating manual of the copyright owned by our company. ANYANG FORGING PRESS NUMERICAL CONTROL EQUIPMENT CO., LTD 22. Prologue The operating manual must be looked though at any time at the place where hammer works You should read up the entire contents of the manual and familiar with the C92K-63 CNC hydraulic die forging hammer including control systems etc all contents. Notice: C92K-63 CNC hydraulic die forging hammer can play the useful effect under the proper operation, that is, the operator of the hammer should be accomplished in all the features. So the operator must have the operating manual Anyang Forging Press Numerical Control Equipment Co., ltd. has design and production ability for CNC hydraulic die forging hammer, electro hydraulic forging hammer, hydraulic forging press, pneumatic hammer, forging manipulator, loading and fetching manipulator. At present, they have been serialized, and we have obtained ISO9001 certification. So our company can provide reliable quality assurance, also give full consideration to their safety. Before the hammer start working, every operator must read, and abide with the operating instructions and safety rules! All the workers who do installation, operation, maintenance and repair, must read and understood the operating manual, especially the safety rules. ANYANG FORGING PRESS NUMERICAL CONTROL EQUIPMENT CO., LTD 3 3. Technical parameters Manufacturer: Anyang Forging Press Numerical Control Equipment Co., Ltd Hammer type……………………………………………C92K-63 Max blow energy ……………………………………… 63KJ Max striking frequency…………………………………. 80min-1 Min. striking frequency ………………………………… 40min-1 Max striking stroke ………………………….………… 800mm Dayliht between Guides ……………………… ………. 800mm Max. Height of dies without dovetails ………….…… 460mm Min. Height of dies without dovetails ……….……….220mm Working height of die seat ……………………………… 700mm Height above floor ……………………………………… 5200mm Total height …………………………… ……………… 6690mm Max loading hydraulic oil (prepared by buyer ) ……. about 2800L Hydraulic oil grade …………………. N46 anti-wear hydraulic oil Pre-filled gas pressure of accumulator ………………….13MPa Max work oil pressure …………………………………… 20Mpa Work voltage ………………………………… …………… 380V Main motor power ……………………… …….… …… 2×75KW Cooling motor ………………………….…….…………… 40KW ANYANG FORGING PRESS NUMERICAL CONTROL EQUIPMENT CO., LTD 44. Safety rules C92K-63 CNC hydraulic die forging hammer including technical parameters can meet the basic safety rules and health requirements, accord with the design and manufacture of forging hammer assembly, testing, inspection and other relevant national standards. C92K-63 CNC hydraulic die forging hammer is adopted the advanced technology in production , assembled an effective safety device. However, if the non-training personnel operate the hammer in incorrect or improper way, it may be dangerous. The Hammer should be authorized for operating! C92K-63 CNC hydraulic die forging hammer are used to hot forging metal material, can not be used for other purposes. Therefore, the security is the most important, safety first. The worker can operate C92K-63 CNC hydraulic die forging hammer after he is trained and authorized. In order to safety, the responsibility of worker must be clear. In addition, When you do any work related installation, operation, adjustment, die replacement, assembly, maintenance and repair, all the moving parts of the hammer must stop working for absolutely safe; the oil pressure in accumulator should be released There are many kinds of safety devices about C92K-63 CNC hydraulic die forging hammer to protect the personal safety and prevent accidents. please pay more attention to prevent dangerous in many different occasions,. Please notice particularly in the following circumstances: —Transportation and moving locations The dangerous caused by heavy goods fall down due to lifting hook or parts failure. —Installation Don’t collapse cable or damage flexible hoses when transportation and moving locations，. —When start working, set up and work when troubleshooting The risk of harm to the operator caused by the machine is used for other purpose, The risk to life and limb caused by mistake or illegal use. The risk due to touch on the forging hammer working zone. The risk of skin burns caused by handling high-temperature objects. The risk casued by hydraulic oil fire. The risk of explosion casued by error operate the hydraulic accumulator ——Maintenance, inspection and repair In the absence of the use of safety devices—safety pin body, the tup has the downside risks. Should pay particular attention to safety device of the tup. (Maintenance cycle = 1 week) Worried about the contents as follows: - Endanger the operator and third-party life and limb safety. - Machine and user’s other valuables damaged. - Affect the hammer work efficiently. ANYANG FORGING PRESS NUMERICAL CONTROL EQUIPMENT CO., LTD 5Hydraulic accumulators must be filled with nitrogen gas, or else in danger. The safety devices of the hammer must be regularly inspected, and the safety instructions should be enforced strictly. 4 .1 Safety instructions Any work endanger to safety must be stopped. Notic: Non-authorized worker forbid operating the hammer. The hammer must be checked periodically, any dangerous changes of the hammer must be reported immediately. The worker must ensure to operate the hammer in absolute good condition. The operator must wear the protective clothing (helmets, glasses, helmets, etc.). The workshop of the hammer must ensure cleaning and tidy according to the corresponding rules and inspections. The adequate lighting must be supply to the whole production line of the hammer. During the hammer working, the safety devices is not allowed to remove or invalid, unauthorized changes to the hammer and change are prohibited strictly. In the course of repair or maintenance, if the safety device is removed, the hammer must comply with the rules of the operating manual. such as: the hammer stop working (control switch in the "0" position); main motor must be switch off, accumulator must be pressure relief; and all moving parts must be locked. When finishing the maintenance and repair work, the safety device should be equipped immediately. Notice: When the safety device is removed, pay attention on the risk. 4.2 Main switch The main switch is installed in the electric control cabinet. It can separate the hammer and the power source. The switch input is working after the hammer stop power supply . the tup must be in the lower position during maintenance work normally, stop power supply , locking the main switch by padlock. Even if the main switch off , the switch input still power on. 4.3 Red—Emergency stop button The emergency stop button can stop all the working of the hammer in the control box. The button is installed in the front of control box, which place can be found and touch easily. The button is mushroom-type. Press down and don’t move until we can rotate along the direction of the arrow then loose. Press the stop button, if the tup falls down at the lowest position but not on the die, then the danger still exists, it will not be safe until by adjusting the tup down to the die. 4.4 Foot switch The foot switch has three control switches such as the left and right foot switches and ANYANG FORGING PRESS NUMERICAL CONTROL EQUIPMENT CO., LTD 6top-feed foot switch. The cable connection of foot switch must be accurate and strong, The screw nut must be fastened to prevent accidental hit occurrence. The connection cable between foot switch and control box must be placed on the safety position. And the connection cable between control box and electrical cabinet also must be placed on the safety position. During stop working, the front cover of foot switch should be folded, and turn off the operated hammer so as to avoid accident. 4.5 Mode switch The switch is set at the control panel to select work mode. The switch has two positions, namely the "Run" and "Adjustment." 4.6 Tup mechanic safety device The safety pin in the right arm of the hammer body must be extended before do any operation on the hammer at the dangerous zone. on the hammer body right arm should be extended, the step must be enforced strictly. It may also be placed vertically the auxiliary supports for the tup so as to be more safety. the auxiliary support must be strong, it should not be bigger inclined, and it should be ensured the enough contact area between the auxiliary support and die or die. When the safety pin for tup is extended out, although the control system of electric cabinet has stoped "hit function”, still the front cover of foot switch should be folded, in order to avoid damage resulting from misuse. In order to avoid accidents occurring at the dangerous zone, the following measures should be enforced strictly. 1). Before do work at the related machine, the maintenance staff must be accomplished in the relevant gules. Such as wear protective clothing, stop hammer, fix mobile parts, accumulator pressure relief and release gas pressure. The safety device can be removed only when you absolutely can not be avoided. 2). Don’t stay a long time under the tup at the dangerous area, and the time for safety pin extended out should be long enough. Any case, the auxiliary support for tup must be big part. 4.7 limit switch "Tup top position" If the limit switch (“Tup top position”) must be done an adjustment, installation or remove, the fixed seat of limit switch should be removed from outside completely together. The hammer must stop, running parts must be locked, main motor must be closed, the pressure of accumulator must be released. This means that the pressure of the hydraulic oil must be released thoroughly. The contents of the switch has detailed description in the electrical operation manual. [...]... pressure hose 1 piece high pressure hose 2 piece 1 piece 4-3 2-3 2 F2302φ32/A2301φ3 2-5 75(180°) 4-1 9-3 2 A2101Φ19/A2101Φ1 9-6 000 Remark 4WE6D60B/CG24NZ5LB12 electromagnetic valve Z1A-Hb40Z-4 cartridge inserted valve 1 piece F42C-H40F-4 restriction control cover 1 piece DBDS10K10B/315 relief valve 2 piece F01A-H32F-5 basic control cover 2 piece Z1A-Ha32Z-5 cartridge inserted valve 2 piece 4WE10E31B/CG24NZ5LB12... about hydraulic system of C92K-63 hammer, so as to help checking and repairing the fault 31 ANYANG FORGING PRESS NUMERICAL CONTROL EQUIPMENT CO., LTD 14 Wearing parts list Model and Specification Name (serial No.) Quantity 4-3 8-3 2 A2301φ38╱A2301φ3 8-8 30(90°) high pressure hose 1 piece 4-3 8-3 2 A2301φ38╱A2301φ3 8-8 30(270°) high pressure hose 1 piece 4-3 2-3 2 F2302φ32/A2301φ3 2-5 50(180°) high pressure hose... cover 2 piece Z1A-Ha32Z-5 cartridge inserted valve 2 piece 4WE10E31B/CG24NZ5LB12 electromagnetic valve 1 piece Beijing Huade Z1S10D 1-3 0B/ boltM6×90) stacking clappet valve 1 piece Beijing Huade DBW30B 2-5 X/31 5-6 EG24N9K4 electromagnetic relief valve 1 piece REXROTH Germany DB3 0-1 -3 0B/315 Relief valve 1 piece Bejing Huade 4WE6D6X/EG24N9K4/B12 electromagnetic valve reversal 1 piece REXROTH Germany electromagnetic... the end that the lights flash) See hydraulic schematic diagram Page 27 Please refer the full details to the operation manual of accumulator from manufacturer - Assembly and maintenance instructions - Assembly and repairing instructions - Liquid-filled and testing device If the accumulator to be removed or repaired, the gas pressure usually should be released completely 7 ANYANG FORGING PRESS NUMERICAL... vibration isolator, the whole U-Frame and “X” type guide rail are the important feature of the hammer The 60% blow energy comes from high pressure hydraulic oil, the remaining 40% energy comes from the potential energy of the tup, so we can achieve the blow number of short-stroke and high-frequency, which is favorable for the development the forging production 9.2 Overview 9.2.1 The U-Frame on the CNC hydraulic... hammer, the U-Frame provides a larger size of guide rail for tup, the vibration transmission of the hammer in the elastic cushion is buffered 9.2.2 The power head includes main oil tank and liquid-filled tank, the tank is welded with good weldability of steel plate, the all hydraulic components and hydraulic integrated installation pieces of oil-line are assembled between mail oil tank and liquid-filled... refer to chapter No.4 safety rules and chapter NO.5 Primary statement for safety Please loose oil discharging valve as upper 11.2 way, the oil will flow from fill-liquid tank to big oil tank, open the cover of fill-liquid tank, and remove fill-liquid valve and cover of oil cylinder, then screw in end of ram with special tools, the ram will be hanged out (Notice：Please keep the oil clean, it is not allowed... hydraulic close die hammer is adopted the oil pump-accumulator transmission The working oil pressure is connected with the lower chamber, and the upper chamber is controlled independently by hydraulic system The filling valve of upper chamber( blow valve) is opened, and three parts high-pressure oil flow into upper chamber from oil pump, accumulator and lower-cylinder, and make the tup to accelerate downwards... features of main blow valve is that, high sensibility, good sealability The system are roof placing structure, assembly integration, no-pipe connections, high reliability Please refer to the hydraulic schematic diagram about C92K-63 CNC hammer as follows, The functions of C92K-63 CNC hydraulic hammer have 8 steps as follows, accumulator charge pressure to lift tup, acceleration, oil replacement, return,... power head 10.5 The installation of vertical pipe-line: The vertical pipe-line is fixed on ground support structure, there is oil filter, lubrication system and cable connecting motor, it is convenient to test the hammer 10.6 The installation of ejector hydraulic station and electrical cabinet: Please install them according to the flat layout of C90K-63 CNC hydraulic close die forging hammer 10.7 Fill . type……………………………………………C92K-63 Max blow energy ……………………………………….. 63KJ Max striking frequency…………………………………. 80min-1 Min. striking frequency ………………………………… 40min-1 Max striking. contents as follows: - Endanger the operator and third-party life and limb safety. - Machine and user’s other valuables damaged. - Affect the hammer work