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. P
rimary 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


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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.





















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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.
ANYANG FORGING PRESS NUMERICAL CONTROL EQUIPMENT CO., LTD


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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


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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.
(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.
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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
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


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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.

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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 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.

Notice: Accumulator can only be filled nitrogen gas.
ANYANG FORGING PRESS NUMERICAL CONTROL EQUIPMENT CO., LTD


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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
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4.12 change oil
when change the hydraulic oil，the pressure of accumulator must be released, the hammer
must be stopped power supply thoroughly，and the heat exchanger must be stopped
working, and then turn the main switch onto the “0”position and lock it ！
4.13 Shipment
Don’t permit persons stay or go through at the the area of crane during lift the goods with
crane.



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
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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
5.4.1 Operating the hammer ( forging )
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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.