Máy búa thủy lực 63KJ - P1

Tài liệu hướng dẫn vận hành máy búa 63Kj

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

5.2 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 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

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

2 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

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

4 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

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

Hydraulic 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

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

top-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.

4.8 The lowest limit position of tup

When maintaining the hammer, (such as the replacement of guide plate), please dial the mode switch to the "adjustment", and then press "slow down button”, the limit position size of tup falling down should be strictly in accordance with drawing, otherwise, it will damage to main cylinder of power head, lead to the hammer don’t work

4.9 Hydraulic accumulator

The power head of the hammer is equipped with liner accumulator The accumulator is provided together with the filling pressure device and test device After one week, it should

be inspected whether to leak the nitrogen gas and avoid it promptly If no gas loss at the first

inspection, the second inspection should be done three months later, if no gas loss at the second time, the next inspection can be done six months later

Filled-gas pressure: 13MPa

When repairing the hammer, oil pressure must be vented out

Pressure Relief Methods: dial the mode switch to the "adjustment" position, then press the "stop" button

When shutdown the hammer, the residual pressure must be manually operated the 6DT on the

power head (when pressing "stop " button, the end that the lights flash) See hydraulic schematicdiagram 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

Notice: Accumulator can only be filled nitrogen gas.

4.10 Fireproofing

C92K series hammer is a hydraulic forging hammer, N46 antiwear hydraulic oil, this means that if the hydraulic oil splash onto the hot forging parts which the temperature above

1000 , it would be in the danger of fire.℃

Over the years, we improved the structure of the hammer and overcome the oil leakage defect The power unit is mounted inside the oil tank, it will be little affect to leak oil and there will not be the danger of fire In spite of this, it will be fire if leaking oil in the extreme situation

So , please take care of the oil hose pipe of power head especially Any leakage oil must be sealed immediately, the broken hose pipe must be replaced with new one immediately

: The fireproofing device from customer must fit with the hammer

4.11 The minimum height of the dies without dovetail

If the hammer is working under the condition of the dies height less than 220mm,the piston and its guide system will be broken severely

Notice

A=220mm

The user must equip the suitable crane to lift the goods

The user must be in charge of inspecting the execution of the site rules, The user obligation to take the necessary measure to protect the life and property at the working site, the operator must learn the safety rules carefully

Notice: before craning any parts of hammer，please check whether to have a crack on the crane wheel

4.14 Guard rail

The user must set up the suitable guard rail for the hammer at the dangerous zone of the

whole production line

The emergency stop button must be set up near to a place which the operator can reach easy at any time

4.15 Inspection

Notice: The safety system must be inspected regularly

If you find the irregularities working of hammer, please stop the hammer and report it to maintenance staff immediately The hammer can be only run again after troubleshooting

4.16 Production warning

1 The max blow energy of the hammer is 63KJ Please input the right height of dies carefully, don’t overload working

2 Don’t transfer the finished forging parts from front to rear through the hammer

3 The electrical components of the hammer must be complianced with national safety requirements to ensure the quality and performance

4 The hammer must be stopped working during maintenance or inspection of the hammer There is

no any other pressure for the hammer Motors and assistant device must be locked by the key which

on the suspending control panel, so as to avoid any unexpected connection

Forbid to stay under the crane lifting goods

5 Primary statement for safety

5.1 Primary principle for authorized to operating hammer

Manufacture of the hammer based on the latest safety principle, in spite of that, some irregularities operating may hurt the operator’s body or lift, even damage the hammer or other device

The hammer is only used for hot forging metal workpiece First of all, the operator must learn the safety precautions and danger prevention, and read the description of operation manual Troubleshooting immediately

This hammer is designed for the forming of hot metal Our company don’t undertake warranty for other purpose The customer must undertake all the risk for incorrect operating

The correct operating hammer includes executing all the requirements in the operation manual

5.2 safety execution

The operator must have the operation manual

Beside the operation manual, the operator should know Accident prevention and Environmental protection rules

The operator must learn the operation manual before working, special safety rules Don’t start reading it until the hammer running It is more important for the new operator

The operator don’t have long hair, don’t wear loose clothes or no earrings, in order to prevent the danger of hurt by the hammer

It must set up the protection facilities in the danger zone

The operator must learn and observe all the safety rules and warning about the hammer And please keep the operation manual intactness

Safety instruction and precaution on machine must be checked regularly to keep them integrity and clear!

If the safety device of the hammer was changed or illegitimate, the hammer must be stopped working immediately , and then report it to the maintenance staff Don’t change the safety device of the hammer without our permission

Don’t modify the software of PLC system The replace parts must be according to the technical requirements of our company

It is necessary for good tools and facility to maintain the hammer

Every body must be familiar with the extinguisher position and how to use it

5.3 Staff ability and basic responsibility

All operating of the hammer must be done by skilled worker

The worker must be comply with the statutory minimum age, And it must be trained and educated and know how to operate, adjust, maintenance of the hammer The operator should be trained for electrical operating, hydraulic operating, gas operating

The hammer must be only operated by the authorized staff

Forbid the untrained worker to operate the hammer

5.4 The safety rules for the special operation safety

Avoid any danger operating, and execute necessary inspection, take necessary safety precaution, and ensure the hammer working in the safety and reliable condition

The hammer can be operated when all the safety device is ok , such as moving safeguards, emergency stop device, noise safeguards and fire control device, etc

It must be checking the visible damage on the hammer in every shift time,

Any change or abnormal work to the machine must be report to director immediately, stop and lock

it if necessary

In case of hammer is abnormal, stop and lock the hammer, and check if there are any damage to the hammer

Always obey the procedure of turn on/off and other relative content described in this manual

Make sure the movement of hammer not to be danger to anyone before start it and set the procedure

5.4.2 Operating the hammer ( adjustment, maintenance )

It must be comply with the periodicity of adjustment and maintenance according the operation manual, includes replacing spare parts or device, it must be done by professional staff

The operators must be notified before adjustment and maintenance and an appointed worker inspect the process specially

Regarding any operation, adjustment and maintenance, it must strictly be comply with maintenance principle in the manual, normally it should be add fence around the working area

If stoping the hammer for maintenance, the hammer must be locked to avoid unexpected accident Lock the main order device, and take off the key and place a warning board on the switch

If a heavy part need be adjusted, it must be fixed carefully on the crane to avoid danger, it must adopt the suitable and strong lifting tools, Forbiding persons stay under the lifted part

The guidance person of the crane must be experienced And he must stay in the place where the operator of crane can see and hear him

When working on the high altitude operation, it usually adopt a special safe ladder and working platform Forbiding to make the hammer as the climbing tools A anti-fall down costumer is requirement during working on a high place from ground

Keep cleaning about handles, steps, handrails, workbenchs, baseboards and ladders of the hammer, especially the oil and other polluting substance on connectors, corrosive cleanser is strictly prohibited, only the non-fibre cloth can be use to wipe the hammer

Before cleaning the hammer with water/steam gun (high pressure) or cleanser, the slot or exposed parts should be covered or sealed, in order to prevent water/steam/cleanser invading, especially for the motor or electricity cabinet

Before cleaning the outside shell of hammer, make sure that the fire alarm temperature sensors and fire defence can’t touch with hot cleanser, otherwise, the fire defence will be started

Eradicating the defending covers and adhesive tape after cleaning

Check every hydraulic seal, hose tube connectors, if there are any damage, any trouble, it must be eliminated immediately

According to the following table, all of bolts should be tightened during maintenance

If the safety devices have to be disassembled out during maintenance, the safety devices must be assembled immediately after the maintenance

Dispose the replaced parts and assistant material carefully in case of damage the environment

The following table is suit for the spring washer

When using one self-locking NORDLOCK washer, the tightening torque must be increased 15%; when using two self-locking washers, the tightening torque must be increased 20%

The electric part of the hammer must be checked regularly, any problem such as loose connection or cable burned must be correct immediately

Operating the electric parts, includes put the emergency button and main switch with insulation tools in the emergency situation, and the second person should be at the locate

Operating the high voltage device, first power switch of , and then, the power cable must be grounded and short circuit of the part such as capacitance with a grounded stick

original stress(N) lock torque(N.m) spec tensile strength Tensile strength

8.8 10.9 12.9 8.8 10.9 12.9 M4 4000 5900 6900 2.8 4.1 4.8

5.5.2 Gas, dust, steam and soot

When it be permited definitely , the work can be operated, such as welding, flame cutting and polishing Otherwise, it may cause blast or fire Before the above work, it should be cleaning the dust and combustible material of hammer and keep the the good ventilation in workshop ( danger of blast )

If the work area is limited ,please comply with the national regulation

5.5.3 Hydraulic system

The hydraulic system should be operated by expert in hydraulic knowledge and skillful operators The hammer should be inspected periodically about the leakage or damage between hydraulic hose and connecting fittings, and the damaged parts must be repaired immediately

It should be relieved the pressure of hydraulic system before repairing

The hydraulic pipes must be fixed correctly and ensure the length and quality of hose requirements congruously

5.5.4 Noise: please keep a protective earplugs

5.5.5 Oil and Lubricant and other chemicals

When disposing the oil, lubricant and other chemicals, please comply with the relevant safety regulations Please be careful of disposing the hot combustible and accessories

6 Installation & Commissioning

For transportation, the hammer should be brushed the antirust paint and grease in order to preventing rustiness The antirust material should be removed during installation The smudge on surface in guides and removable surface should be cleaned completely by cleaning disc, don’t use the waste cotton

The hammer must be placed and installed vertically for normal use

Maximum deflection in verticality=1：500

The hammer can be used after inspection

Attention: please check the wheel of crane whether to have a crack before lifting the hammer

7 Maintenance

7.1 Daily maintenance

7.1.1 Cleaning the foot pedal the oxide skin should be taken out by air compressor

7.1.2 Checking the pressure of accumulator by screen panel

7.1.3 Cleaning the garbage around hammer , especially the oxide skin

7.1.4 Checking the guideway whether to be lubricated, otherwise, the guideway should be brushed the lubricating oil before working it is very important to start working

7.1.5 Checking the stop button switch

7.2 Weekly maintenance

7.2.1 Cleaning the oil filter and changing the damaged filter element

7.2.2 Checking the automatic lubrication and add the lubricanting oil

7.2.3 Checking the clearance of guide

The clearance is about 0.5-0.6mm in working or rest

7.2.4 Checking the gas filter

7.2.5 Checking the electronic function of tup safety device

7.3 Monthly maintenance

7.3.1 Checking the alarm logging

Checking the alarm logging within one month by screen panel, in order to maintain easily

7.3.2 Checking the contactor

Checking and changing the damaged contractor and cable conductor, tighten all the bolts in the end fixed sleeve and terminal set

7.3.3 Checking the die wedge

Checking the track on the wedge and confirming it whether to be moved

7.3.4 Checking the fixed system of power head

7.3.5 Checking the spring vibration damping of foundation

7.3.6 Checking the fixed bolts of accumulator whether to be loosed, preventing from prestressing force of bladder accumulator Checking the surface of bladder accumulator whether to be damaged

7.4 Quarterly maintenance

7.4.1 Checking the pollution level of oil

please check and change the dirty oil according to national standard

7.4.2 Checking the cooling system

7.4.3 Checking and cleaning the motor

The specialist only can clean the motor according to the national standard or the Operation manual from supplier If the surrounding environment is too dirty, please set up a evacuating equipment

7.4.4 Check the pressure of accumulator every quarter or half one year

Droping one oil from system on one filter paper, and waiting for 2-3 hours in room temperature If the oil is cleaning, it will make up a regular symmetrical oil spot If the oil is dirty, it will make up a clear core in the centre of drop oil The color will be changed from dark balck to bright grey, from inside to outside, so we can check the pollution degree of oil

The estimated method can be confirmed whether to change oil through the color comparison as follows

Bad oil and it must be changed

It can be used after cleaning

Good oil

7.6 Automatic lubrication system

The guide lubrication is supplied from lubrication pump driven by motor Please check whether the guides have a sufficient lubricating during forging If stop working for a long time, please supply sufficient lubrication oil for guideway by lubricating pump during preheat dies before forging, it can

be brushed oil on the guideway We suggest the best lubrication oil the viscosity is 200～240 ㎜2⁄s