WG12D-4

SMART STIRRUP BENDING ROBOT WG12D-4

You best choice.

Information for use
(
(Mechanical part)

 WG12D-4
TJK :

TJK wouldliketothankyouforchoosingoneofitsnumerousproducts.
Wehavewrittenthismanualtoallow youtofullyappreciateallitsqualities.Werecommend youto
read throughitattentively,sinceit containsimportantand indispensableinformation,adviceand warnings.
Wearecertainyouquicklybefamiliarwithyournewmachineandwillhavelonguseofit,andthat with
mutual satisfactionyouwilldiscovercharacteristicsandprecious detailsthatwillconvinceyoutohave
madetherightchoice.

THE TECHNICAL DEPARTMENT

+86-22-2699-3711
Tel+86-22-2699-3711

Contents

2
I. Handover Statement 2
5
II. Specification 5
7
III. Equipment Breatplate 7
7
IV. Guarantee 7
10
V. Equipment Handover Notes 10
11
VI. Equipment Description 11
31
VII. Warning and Danger Mark 31
37
VIII. Safety Notes 37
67
IX. Technical Parameter 67
69
X. Storage 69
70
XI. Movement and Placement 70
72
XII. Installation 72
76
XIII. Equipment Starting 76
- 76
-Tools Installation 76
- 77
-Pay-off Rack 77
80
XIV. Adjustment 80
- 80
-Adjustment of Straightening Structure 80
- 84
-Adjustment of Dragging Structure 84
- 85
-Adjustment of Shearing Structure 85
- 86
-Adjustment and Use of Bending Axis and 86
Elbow
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87
XV. Maintenance of Equipment 87
- 88
-Outdoor Use of the Equipment 88
- 89
-Maintenance of Equipment 89
- 93
-Cleaning 93
- 96
- Maintenance of Machine 96
100
XVI. Easy damaged List 100
101
XVII. Handling Method for Being Failure-prone 101
106
XVIII. Common Faults and Removal Methods of 106
MSEJ
110
XIX. Conclusive Table for Equipment Maintenance 110
113
XX.Remarks 113

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 WG12D-4

Handover Statement

Dear users:
a)

This declaration is to confirm that you can use the

machine correctly. Operation manual and equipment
will be handed over to users together.
b)

Your responsibility is to confirm that operators of the

equipment will work in strict accordance with operation
manual.

c)

If correct use of the machine is performed according to

requirement of operation manual attached to the
machine and all safety measures of the equipment are
maintained correctly and at the state of normal work,
the equipment will not have any danger.

d)

()


Direction for use, drawings, tables and other contents

2
 WG12D-4
are technical and confidential. Therefore, any content of
such materials should not be copied and spread. In
addition, without written permission of TJK Machinery
(Tianjin) Co., Ltd, no unit and individual is allowed to
transfer the data to any third party.
e)

Owner of the machine must ensure that the designated

operators read and fully understand content of the
operation manual and ensure that regular maintenance
must be conducted according to operation manual.

f)

The manual is one component part of the machine. This

means that when the machine is transferred or sold, it
should be attached to the machine. The manual must be
kept at wok site so that work staffs for operation,
installation, start and maintenance of the equipment can
use it at any time.

g)
()

If the equipment is not manipulated according to

operation manual or any change is made to the
equipment, TJK Machinery (Tianjin) Co., Ltd will not
take any responsibility for any subsequence occurred
therefrom. The incorrect use may bring damage to
operators, facilities and environment,

3
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4006-190-618

If you find any error in the manual or you have any

problems during the process of use, please contact us.
Contact telephone: 4006-190-618

TJK Machinery (Tianjin) Co., Ltd hopes that you can make full

use of maximum performance of the equipment.

TJK Machinery (Tianjin) Co., Ltd

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 WG12D-4

Specification

The following is several marks used in the manual.

They are intended to tell users different danger level
during equipment operation and maintenance.

Warning!
If information or program is not observed strictly,
it may cause death, serious personal injury or
equipment damage. It usually refers to residual
danger or danger under any circumstance.

Caution!
Information or program tells operators how to use
the equipment best, extend the service life of the
equipment, avoid damage or lose program data and
optimize work so as to make it conform to standard
requirement.

!

Note!
Important information and program

5
 WG12D-4
Warning!
Typical language often appears in commercial
products. Although these terminologies are universal
and widely accepted in the world, we paste
identification in both Chinese and English in nameplate.

STOP =
START =
UP =
DOWN =
RESET =
EMERGENCY=
ON =
OFF =

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Equipment Breatplate

Please provide the equipment serial number

when contacting supplies. It can be found on

equipment nameplate.

Warranty

Equipment purchased from TJK Machinery

(Tianjin) Co., Ltd enjoys the following service.
12
1800

30

A warranty period of 12 months from the delivery
date or a warranty period of 1800 work days at
most at any condition. Within the warranty period,
the replaced parts or those which are required to be
withdrawn by TJK Machinery (Tianjin) Co., Ltd
do not return within 30 days, the expense caused
by replacing of parts will be covered by users.

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 WG12D-4

During the period of equipment warranty, TJK
Machinery (Tianjin) Co., Ltd will provide support
to replacement of parts that are damaged due to
quality problems that are acknowledged.

Warranty scope does not include accessories, tools

and normal replacement caused by wearing and
replacement caused by improper use.

TJK Machinery (Tianjin) Co., Ltd guarantees to
provide spare parts and technical personnel may
provide service in shortest time on request.

As for technical service, TJK Machinery
(Tianjin) Co., Ltd will charge experience from
users according to lowest standard.

TJK Machinery (Tianjin) Co., Ltd will not take
responsibility for any direct or indirect civil or
criminal problems caused by improper operation.

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TJK Machinery (Tianjin) Co., Ltd will not take
responsibility for any error and damage caused by
raw materials or components without written
permission of the company;

TJK Machinery (Tianjin) Co., Ltd only takes

responsibility for equipment component provided
by the company.

Where both parties have other agreement, such

agreement should be implemented.

Warranty will become invalid if one of the following

items occurs.

Installation and technical service is not carried out

by engineers approved by TJK Machinery (Tianjin) Co.,
Ltd.

Incorrect use and maintenance, equipment change

and use without following the operation manual.

Use of non-original parts.

Fail to pay in time.

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()

The said warranty clause includes the standard of

warranty certificate. Warranty takes effect from
the date of installation (subject to installation report
filled in by technician of our company). The
warranty takes effect from the delivery date stated
on official shipping document if installation report is
not provided.

V. Equipment Handover Notes

Whenreceivinggoodsnotes,pleasecheck;
A- 1
A- Whetherthepackageiscompleteornot
B-
B-Whetherthegoodslistsatisfyyourorder
1- 1
1-Stirrupbender 1set
2- 2
2-Pay-off rack 2set
3- 1
2
3-Toolskit 1set
4-
4-Userinstruction

TJK
3
Please check whether there is damage or
components lost when receiving machine. If there is
somethingwrong,pleasecontactTJK.

4
.
Foryour interest,when the commodity isdamaged,
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 WG12D-4
to minimizetheextent of any lost,you had bettermake
it clear of your reservation clause on the delivery order,
and apply the compensation from insurance company at
once attachedwithsituationandpictureforevidence.

Please read the User Instruction to obtain the right

function and maintenance specification.As the equipment
is continue to be updated, the technical parameter and
equipmentpicturewillbechangedaswell.

VI. Equipment Description

Warning

User has to ensure all parts are in good

condition.

!
Warning

Equipment cant be used and stored

outdoor, which only can be used in the closed
industrious environment, and should be kept
away from weather. The environment should be
good to store the machine.
!
Warning

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Do be cautious when processing surpasses

the rebar shapes of equipment surface. If it has
to be produced, the collection rack should be
increased. The working speed should be lowed
when any work-piece size is increased.

The work of equipment controller will be

simpler if computer is used to control the
system without any calculation.

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Equipment System

DOOR
SYSTIM ON -OFF CLOSE OPEN STEP CONTINUE START

Graphic Illustration of Equipment
System
1 Pre-distortion of

straight panel

2 Straightening

mechanism for external horizontal

3 Pulling mechanism

4 Straightening

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mechanism for inner vertical

5 Control panel

6 Shearing mechanism

7 Bending mechanism

8 Front board

9 Electric pusher

Description for Main Engine Back Parts

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1 Septal
door for machine
2 Electric cabinet
3 Switch
power for electric cabinet
4 Power
interface for equipment
5 Tool kit
6 Door handle

Septal Room for Machine

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1. 10.

Pulling part Big bending belt wheel

2. 11.

Leaf spring Elbow

3. 12.

Electric pusher Fixed cutter

4. 13.

Wheel for upward pulling Fixed cutter head

5. 14.

Vertical straightening mechanism Shearing tube

6. 15.

Shearing brake motor Bending servo motor

7. 16.

Switch frame for bending test Pulling servo motor

8. 17.

Pulling belt

Dynamo reducer(controlling 18.

flexibility of principal axis and Big pulling belt wheel

cardiac axis) 19.

9. Downward pulling wheel

Adjusting rod for upward and

downward movement.

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Pulling Parts

1. 13. 2

Chain wheel Lower shaft sleeve2

2. 14. 3206

Chain Bearing 3206

3. 15.

Pulling upper box Round nut and gasket

4. 2 16.

Upward drive shaft2 Sliding sleeve(upward drive sleeve)

5. 1 17.

Upward drive shaft1 Pulling lower box

6. 22210 C/W33 18. 6213-2RS

Bearing 22210 C/W33 Bearing 6213-2RS

7. J 65X90X12 19. 1

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J type oil seal 65X90X12 Lower shaft sleeve1

8. 20.

Upward pulling wheel Seal ring

9. 1 21.

Drive shaft1 Transparent cover for chain wheel

10. 22.

Pulling belt wheel shaft Stifle cover for chain wheel

11. 23.

Downward pulling wheel Upper stifle cover

12. 22213CC/W33 24.

Bearing 22213CC/W33 Upper transparent cover

The main part installation order of pulling part:

1. 22213 40%-60%
2 18*11*45
.
1.Cleaning up the pulling belt wheel shaft and iron scrap of drive shaft head,
adding 40% to 60% grease (molybdic sulfide) to 22213, pressing the bearing from the
back axis, putting lower shaft sleeve2 on the axis, inputting 18*11*45 key into the
end of both sides by copper bar.
2.
1 6213
40%-60%
65 120 95*120*12

2. Pulling belt wheel shaft is to be installed at the left front-end, and chain wheel
is installed from the end of pulling belt wheel shaft, putting pipe, pressed by punching
machine, pushing lower shaft sleeve1 from the end by hand, then adding 40% to 60%
grease (molybdic sulfide) to 6213, using punching machine press it into pulling belt
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 WG12D-4
wheel shaft, and using axis to put the check ring 65 on the end of axis, using check
ring 120 to install at the front hole, at last, the opening of seal ring 95*120*12 is
installed from the outside of box front axis, input by plastic hammer.
3.
3. The installation of assembly technique is the same as the above, the drive shaft
and related parts are installed on the pulling lower box.
4. M8*208.8
25NM,
4.Putting paper on the chain wheel stifle cover, dabing sealant on the end of box,
and using M8*20 (grade 8.8) screw with spring washer to tighten, to make it up to
25NM, to fix it by tightening bolts in diagonal.
5. 65*90*12
M8*208.8
25NM,
5. Using plastic hammer to input seal ring 65*90*12 into chain wheel
transparent cover, putting paper on the chain wheel cover, daubing sealant pushed
from the end of box long axis. using M8*20 (grade 8.8) screw with spring washer to
tighten, to make it up to 25NM, to fix it by tightening bolts in diagonal.
6. 1/4

6. To strengthen one quarter of outer wire of inner and outer wire joint and ball
valve outer wire with unsintered tape. To put the joint on bottom right of the lower
box threaded hole, to tighten the ball valve on the joint, tighten up and close the ball
valve.
7. A16
150

7. To put double chains on the double chain wheels to be linked by chain pitch,
then to tighten up the oil pointer A16 with unsintered tape on the bottom left of lower
box. Then to add the machine oil(#150) to the box till the oil pointer center line
appears.
8.

8. The bottom inner slot of upper box with sealant, to press iron plate on it.
When it is dried, install it on the top of lower box.
9.
8 M12*4512.9
200NM
9. Daubing sealant on the processing part of lower box top, to put upper box on
the lower box, to make the through hole of upper box alignment to the threaded hole
of lower box. Using 8 pieces of M12*45grade 12.9hexagon head bolt to be put with

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 WG12D-4
plain washers and spring washers, daubing anaerobic glue to tighten up the upper and
lower box with torque wrench, to make the torsion up to 200NM.
10. 4
10. Putting 4 pieces of spring into the holes of upper box.
11. 2 1 2
22210 C/W33 40%-60%
22210 C/W33 1 2
J 65X90X12
11. Preparing for 2 pieces of sliding sleeves, upper shaft sleeve1 and upper shaft
sleeve2, and cleaning up the internal thread and scrap iron. To add the 40% to 60%
grease (molybdic sulfide) to the running pulley of axis 22210 c/w33. To straighten the
upper shaft sleeve, axis 22210 c/w33 to be put by punching machine with strength.
Upper axis1 and upper axis2 separately to be press from the front end of upper shaft
sleeve, and put with J grease seal 65X90X12 on the top.
12. 3206 40%-60%
3206 M30*1.5

12. To add the 40% to 60% grease (molybdic sulfide) to axis 3206, to reverse the
above semi-finished product, to press the axis 3206 with punching machine, adding
retaining washer, tightening M30*1.5 round nut and lock it.
13.

13. Putting the installed upper drive shaft sleeve product on the upper box top,
putting bar iron on the two pieces of springs from the end of upper drive shaft sleeve.
Putting the slot part of upper drive shaft sleeve from the top end, and draw out the bar
iron form the back end.
14. M10*2512.9
8
72NM Z25 2

14. To install the upper stifle cover on the left upper drive shaft sleeve , to make it
short drive sleeve, using M12*45grade 12.9inside hexagonal bolt to be put with
spring washers, daubing anaerobic glue to bolts, to tighten up to the upper drive
sleeve. There are 8 screws per upper drive shaft sleeve, to fix it by tightening bolts in
diagonal, to make it up to 72NM. To put grease seal Z25 into the center hole of upper
drive sleeve cover, the same as the above, to install the upper stifle cover on the left
upper drive shaft sleeve, to make it short drive sleeve.
15. 12*8*25 3
6 M12*2512.9
15. Using copper bar to put key 12*8*25 into pulling wheel, 3 pieces per wheel.
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 WG12D-4
The pulling wheel is put into principle axis by copper, using 6 pieces of M12*25
grade 12.9internal hexagonal bolt and spring washers to tighten up.
16. 12*8*16
6 M8*3512.9
16. Key 12*8*16 is put into the front end of upper drive sleeve slot by copper
bar, using copper bar to put upper pulling wheel into upper drive axis, using 6 pieces
of M8*35grade 12.9internal hexagonal bolt and spring washers to tighten up.
17. 2 1/2
17. To tighten up pipe plug with unsintered tape, using half a pipe plug to tighten
up the top pulling upper box.
18. 20*20*1.5 2
18. Using copper bar to input 2 pieces of copper sleeve on the two ears of upper box,
and fixed with pin.
19.
19. The installation of pulling box main assembly is finished.
Shearing Parts

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1.. 11.

Shearing engine Shearing arm

2. 12.

Shearing speed reducer Active cutter

3. 13.

Supproting arm Cover of shearing arm end

4. 14

Drive shaft(eccentric shaft) Fixed cutter body

5. 15.

Cover of eccentric shaft ends Switch testing

6. 16.

Supporting cover Shearing limited stop

7.

Shearing base

8.

Supporting shaft

9.JBD 2

JBD bearing2

10.

Fixed cutter

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The Installation Order of Shearing Main Parts
1. 22210C/W33 6209-2RZ
40%-60%
22210C/W33 50 6209-2RZ 45
1. To put drive shaft on the work table, adding the 40% to 60% grease (molybdic
sulfide) to bearing 22210C/W33 and bearing 6209-2RZ, using wood hammer
and spring plier to install big belt wheel press cover, bearing 22210C/W33, axle
bumper 50, bearing 6209-2RZ, axle bumper 45 on the drive shaft in sequence.
2.
90 4 M6x20
8.8
2. Putting shearing base on the working table, to install the drive shaft with
bearing to the top bearing hole of shearing base. Then install hole block 90. To put
eccentric shaft end cover on the shearing base, and using 4 pieces of external
hexagonal bolts M6x208.8with spring washer, flat washer to fix.
3. 22206C/W33
3. Putting bending arm on the working table, to put aligning running pulley
bearing 22206C/W33 into arms.
4. 30 40%-60%
4 M6x208.8

4. To install the arms with bearing on the drive shaft ends, installing axle
bumper30, adding the 40% to 60% grease (molybdic sulfide), and installing
supporting cover on the arms, to fix with 4 pieces of hexagonal bolts M6x208.8and
spring flat washer.
5. 2 62
5. To put 2 pieces of retaining hole 62 separately into the snap spring slot of
shearing base.
6. 2 RNA4908 1
22206E 40%-60%
6. Putting 2 pieces of roller pins bearing RNA4908 without inner track from the
right end of shearing base, while spherical roller bearing 22206E is put from the left
end, and adding the 40% to 60% grease (molybdic sulfide).
7. JBD 2

7. Putting JBD bearing2 into round hole of shearing arm end by wood hammer,
ensuring that both ends of copper sleeve and shearing sleeve are in the same level.
8. XR-63.09*3.53 FPM75A
C 5x5x12
M30*1.5
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 WG12D-4
8. To install the star type seal ring XR-63.09*3.53 FPM75A on the ends of
shearing base and roller pin, and then installed on the shearing arm, finally installing
keyC5x5x12, shearing arm end cover on the bearing end of shearing arm, and using
round nut M30*1.5 with round nut collar to make it tight.
9. 25
9. Using supporting shaft to connect shearing arm and arms end, and using axle
bumper to fix.
10. 2 M5x6(12.9)

10. Using fixed cutter and stop piece with 2 pieces of hexagonal nuts M5x6(12.9)
in flat-bed machine to fix. Using the installed fixed cutter to put into the fixed cutter
body.
11. A14*9*60 2
M5x6(12.9) 4 M10x30
12.9
11. To install key A14*9*60 in the key slot of shearing base, and using 2 pieces
of hexagonal nuts M5x6(12.9) in flat-bed machine to fix. Installing fixed cutter on the
shearing base, and adding 4 pieces of M10x30 with hexagonal nuts(12.9) with spring
washer to fix.
12. M10*2512.9

12. To install cutter(active cutter) in the shearing arm slot, and adding hexagonal
nut M10*2512.9with spring washer to fix.
13. 4 M12*60 8.8
12x8x160
2 M5x16
2 M10x25
13. To install reduction box on the shearing base, using M12*60 bolt 8.8with
flat washer to fix, and adding the big flat washer to the shearing base. Installing key
12x8x160 from the back end of reduction box, and installing testing switch and 2
pieces of internal hexagonal round head nuts M5x16 with spring washer and big flat
washer ti tighten up. To install shearing limited stop from the bottom of reduction
box, and adding 2 piece of external hexagonal nuts M10x25 with spring washer, big
flat washer to tighten up.
14. 4 M12*60 8.8

14. To install engine in the speed reducing machine, using 4 pieces of

M12*60(8.8) nut with flat washer, spring washer to fix. Shearing part installation is
finished.

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Bending Parts

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1. 16.

Bending dynamo reducer Sleeve

2. 17.

Bending limited stop Eccentric sleeve

3. 18. M36*1.5

Testing piece Round nut M36*1.5 and washer

4. 19.

Rotary disk Eccentric shaft

5. 20. 6004-2LS

Bending shaft Deep groove ball bearing 6004-2LS

6. 21.

Mould bending head Reducer flange

7. NA4917 22.

Roller spin bearing NA4917 without Testing rack

inner ring 23.

8. QY100*110*5 Testing ring

Seal ring QY100*110*5 24.

9. Big bending belt wheel

Bending flange 25.

10. Big belt wheel gland

Bending slot 26.

11. Bending main support

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Wearable block 27.

12. Bending belt wheel bearing

Bending main shaft 28. 6214-2LS

13 Deep groove ball bearing6214-2LS

Bending cardiac axis 29. 6013-2LS

14. 7208C Deep groove ball bearing6013-2LS

Angular contact ball bearing7208C

15.

Bearing sleeve

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The Installation of Bending Main Parts
1. NA4917
40%-60%
1. To fix the main bending supporting horizontal, putting roller pin without inner
circle bearing NA4917 into bending main supporting front end and adding the
40% to 60% grease (molybdic sulfide) to the bearing.
2. QY100*110*5
6 M6*25
2. Putting seal ring QY100*110*5 into bending flange(the external opening), then
installing bending flange with 6 pieces of M6*25 internal hexagonal bolts with
spring washer, flat washer on the bending support.
3. 6214-2LS
6013-2LS 40%-60%
6214-2LS 70 6013-2LS 65
3. Putting bending belt wheel shaft on the working table, adding the 40% to 60%
grease (molybdic sulfide) to the deep groove ball bearing6013-2LS and deep
groove ball bearing6214-2LS,then to install bearing 6214-2LS, axle bumper70,
bearing 6013-2LS and axle bumper 65 on the bending belt wheel shaft by wood
hammer and criclip plier.
4. 125
4. To put the well-installed bending belt wheel shaft into the backend of bending
main support with hole block125.
5. 2 M6*20
C161056
2 M8*25
5. To put testing ring on the end of bending belt wheel shaft, using 2 pieces of
M6*20 internal hexagonal nuts with spring washer to fix.
6. 2 M8*30

6. To install the big belt wheel gland at the backend of bending belt wheel shaft,
using 2 pieces of M8*30external hexagonal nuts with flat washer, spring washer to
tighten up.
7.
78
7. To install the bending main shaft from the main support front end(To keep
testing ring straight up, to ensure key slot clockwise rotating 78 degree in the
vertical direction.)
8. 2 16*10*32 8
M12*25
8. To put 2 keys 16*10*32 in the bending slot and bending main support, finally 8
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 WG12D-4
pieces of internal hexagonal nuts M12*25 with spring washer to tighten up.
9. 2 7208C 40%-60%
7208C 7208C
2 M36*1.5 O
58*3.55
9. Adding the 40% to 60% grease (molybdic sulfide) to 2 pieces of Angular
contact ball bearing7208C, to install bearing 7208C, bearing retaining sleeve,
bearing7208C, sleeve, on the bending cardiac axis in turn, to tighten up with 2
pieces of round nuts M36*1.5 with retaining washer, finally, to install O ring
58*3.55 to the bending cardiac axis.
10. 6
M8*25
10. To put the above installed bending cardiac axis into bending main shaft, then
put into rotary disk, and to tighten up with 6 pieces of internal hexagonal nuts
M8*25 and spring washer. At last, To install the bending shaft on the rotary disk to
tighten up.
11. 2 4 M8*25

11. To put 2 pieces of wearable blocks at one side of bending slot opening, to fix
with 4 pieces of M8*25 internal hexagonal nuts and spring washer to fix.
12. 8
2 M8*55
12. Putting the central hole of mould bending head into the pressed-on forced
filling oil cup 8, then to install mould bending head on the center shaft, and using
2 pieces of internal hexagonal nuts M8*55 and spring washer to fix.
13. 2 6004-2LS 40%-60%
42
20
15
13. To put reducer flange on the working table, to add 40% to 60% grease
(molybdic sulfide) to 2 pieces of bearing 6004-2LS, to install from both sides of
reducer flange and retaining hole 42, installing eccentric shaft from the side of
big flange and installed with axle bumper20. At last, to put the eccentric shaft
sleeve on the eccentric shaft with axle bumper15.
14. C5*5*40 4
M8*35
14. To install dynamo reducer on the reducer flange with key C5*5*40, using 4
pieces of internal hexagonal nuts M8*35 with flat washer, spring washer to fix.
15.
15. To put testing piece and bending limited stop on the reducer top, and installed
with bolts to fix.

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 WG12D-4
16.
4 M8*30
16. To install the above installed parts on the bending main support, to make the
eccentric sleeve located in the groove of bending main shaft. At last, using 4
pieces of external hexagonal nuts M8*30with flat washer, spring washer to fix.
17.
17. The installation of bending parts is finished.

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Warning and Danger Mark

Warning!
Warning and danger mark on the equipment
should not be removed. If damaged, please
replace with the same mark.

Caution!
Operators must read the operation manual
before use.

Electrostatic discharge is very dangerous

after power supply of the equipment is cut.
After the equipment is disconnected with
power, there are five minutes for electrostatic
discharge. The equipment should not operate
during the process. In addition, the equipment
is hot when it runs. Do not touch it to prevent
scald.
Rotary component will still rotate for a
while due to inertia after power supply is
disconnected. Before rotary components stop
rotating, operators should not touch them to
avoid personal injury.

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Prompt/prohibition signs of tools for

personnel protection:

Signs for safety prompt:

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 WG12D-4

Safety prompt signs for equipment

maintenance:

Description for other signs:

Danger to scald fingers or hands.

Danger to press

f ingers or hands.

Danger to cut fingers or hands. Danger

to heave

fingers or hands in rotating chain wheel.

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 WG12D-4

Danger to wound by switch parts

Danger to wound by moving steel bars

Danger to heave fingers or hands into
conveyor belt

Danger to collide by rail-based
transportation tools

Danger to heave in fingers or hands by

rotating parts

Danger of dangerous voltage

Danger of electrostatic discharge after

cutting power supply. The minimum time for
discharge is 5 minutes.

Shut down the machine and pull out the key

before repair and maintenance
34
 WG12D-4

Lifting point for transportation

Wait for all rotating parts to stop before

touch

Dont take off the safety device during

operation of the equipment.

Lubricating oil

Lubricating grease

No hammer. Cause damage to all protective

parts!

Attention to protection against rain and sun

35
 WG12D-4

Declaration: these signs are main universal

marks for all types of machines
manufactured by TJK Machinery (Tianjin)
Co., Ltd. The purpose to list them is to make
operator understand their application. It
does not represent that each set of
equipment of Jianke is provided with above
marks.

TJK

TJK warns solemnly: operation

should take precaution in advance
according to warning and danger sings
when operating the equipment to avoid
damage to equipment and injury to personal
body.

36
 WG12D-4

VIII. Safety Notes:

Safe Operation Rules Involving the
Following Staff:

Workers of Equipment
Installation

Workers of Operating
Equipment

Workers of Equipment
Management

Workers of Equipment
Maintenance

Irregular operation will lead to

serious result, which does harm to
related workers, and may lead to
equipment faults appearing and
normal production.

To ensure the personal safety of

related workers and right use of
equipment, do be strict to follow the
rules of safety notes and operational
rules in the instructions.

37
 WG12D-4

Do read the instructions for user

before installing, using and maintain the
equipment.

The special safety requirements in

local area are not noted about the
equipment using unit.

Although we try to point out the

notes that should be cautious, but
limited ability, there may be something
forgotten.

The operating workers who are

not familiar with the equipment will
be easy to cause accident, leading to
workers getting hurt and machines
broken. So the related workers need
to be trained before using the
equipment.

Except to following the operating

rules, every worker has duty to
supervise others obeying the operating
rules and prevent those are not familiar
with the equipment from operating it.

38
 WG12D-4

When the equipment is unloaded

and installed in the users workshop, the
irrelevant workers should be away from
it.

Warning
The users has to make the operator
know the potential risk when using the
equipment, including pasting
appropriate warning mark.

Warning

1-
1- Equipment description

The design of equipment TJK and

manufacturing aim is to cut rebar and
bent to be shape, professional to process
rebar steel, producing stirrup and similar
shapes.

The size and shapes of equipment

can be read in the technical parameter.

Warning

Applied Area
39
 WG12D-4
1-
1-Requirements for material
h)
a) Range:

GB1499.1-2007 GB1499.2-2007
GB13788-2008

The mechanical property and sectio

nal shape should meet the requirements

of GB1499.1-2007,GB1499.2-2007,GB

13788-2008. There can't be greasy dirt,

rust on the rebar surface. The welding

rebar usually can't be used, if it has to to

used, the joint has to be smooth and

round, and its sectional area can't be

over the rebar sectional area.

HRB335(
) HRB400(
)HRB400MPa

,
1995
( 1995-384) HRB400

40
 WG12D-4

Hot-roller reinforced bar includes

HRB335 (Grade two rebar) and
HRB400(grade three
rebar).HRB400MPahot-roller reinforced
barhas been commonly used as superior
building rebar in Europe and USA. In
order to adapt to the fast development of
building industry and meet the need of
improving building quality, The
Ministry of Construction and Original
Ministry of Metallurgical cooperated to
write(smelting and constructing
1995-384) to spread the
HRB400hot-roller reinforced bar. Later,
Ministry of Construction wrote and held
the meeting several times, to coordinate,
research and communicate the
application experience, aiming to
spreading and popularizing this efficient
steel with high strength, good ductility,
good welding, and to improve the
anti-seismic of building.

HRB400

6--12HRB335
HRB400

,
,

We designed and research by

adopting the advanced experience of
home and abroad, basing on the
advanced technology, and combining the
actual situation of HRB400 rebar. This
machine can be bent cutting
for6--12HRB335,HRB400, plain
round rebar and cold-rolled ribbed rebar.
41
 WG12D-4
The characteristics are regular shape,
accurate size, fast speed and stable
mechanical property, which can be
widely used in steel plant, rebar
processing plant and rebar welded mesh
plant.

b)
65kg/mm 2.
b) The maximum strength of
extension cant be over 65kg/mm2 in
any case.
c)

c) The maximum bending diameter

and angle can be seen in the first chapter
of technology regulations.
d)180.
d)The maximum bending angle
180.
2-

2-As the choice of bending pin

depends on the bending rebar, do obey
the forced related standard terms in the
country.
2-
2-Interval distance of bending pin

The minimum distance of bending

shaft and bending pin should be referred
to following rules.

The Replacement of Bending
Shaft

The different rebar diameters

42
 WG12D-4
should be used different bending heads,
or the bending heads will be broken,
bending picture is not right and so on.

Be cautious!

Breaking these working

requirements will make bending system
overloaded, especially the eccentric
shaft may be extremely damaged even
cant be repaired.

Warning!

If the used material does not meet

the requirements, which will reduce the
service life, decrease the equipment
property, and affect the personal safety.

Warning!

The product processing limitation,

from the angle of safety, please doesnt
process the products that are not in the
equipment processing range, or the
serious danger will appear.

Warning

43
 WG12D-4

The safety, reliability and operating

property can be ensured according the
following requirements: The users
completely conform to the instructions,
rebar material meets the above
requirements, no defectives.

Warning!

The raw material rebar has to be

dry and no rust. Or the machine will be
broken and affect the operating safety.

Warning!

Though the equipment is in the

automatic working condition, and the
machine has to be monitored by the
trained worker. When the equipment is
suspended, the duty worker should keep
the keys, in case others use the
equipment.

Warning!

Dont lock human or animals in the

44
 WG12D-4
equipment or the working dangerous
area.

Warning!

If there is tripping operation or fuse

burned out, the worker of equipment
maintenance has to check up the
machine and find out the reasons. When
the problems are solved out, the
equipment can be used again. If fuse is
switched on, which will do harm to the
operating workers and equipment.

All switches of the equipment and

other safe devices cant be moved and
refitted in the process of use.

Warning!

When the equipment is working,

dont touch the dynamo and cylinder,
and the rebar being processed.

When stirrup bender is working, in

order to avoid the hurting accident, rebar
45
 WG12D-4
should be chose to meet the
requirements.

In addition, the stirrup bender

operator should wear grooves, working
clothing, and eyes protector, which is
convenient to observe and operate.

Warning!

If there is no pay-off rack of

braking system for the machine or the
pay-off rack of braking system is
controlled by man, when there is car
emergently stops, it cant be close to
until the pay-off rack stops rotating.

Disconnecting power

Warning

Although there is no special

requirement, when the equipment is
maintained, changed the components,
repaired, cleaned, do remember to
disconnect the power.

Disconnecting power referring to:
-
46
 WG12D-4
-Switch off electric appliance
-
-Gas system cutting off
-
-Letting out the gas system air
- 5
-Waiting for 5 minutes
-
-Hanging the mark

Switching off electric appliance
1- ON-OFF OFF
1-Turning ON-OFF to OFF
2- O

2-Turning the main switch to O,

locking it with key, and keep the key.
3-
3-Switch off the distributor

5
Waiting for 5 minutes
5

When the power is switched off,

waiting for 5 minutes, to make resting
batteries to discharge.

Hanging mark
3-

3-when the equipment is

maintained, repaired, cleaned, or
adjusted; the warning mark should be
hung on the operating table.

Warning

.
47
 WG12D-4
The null line and ground electrode
should be confirmed to be connected
according to the circuit diagram before
using the equipment.

Warning!
The users have to pay for the
connection cable and accessories, the
electric conductivity should be kept
good when the cable is connected. When
the cable is finished connecting, the
electricians have to use professional
tools to measure.

Warning!

To ensure there is nobody to close

to the equipment when the equipment is
working or maintained, especially the
children and animal.

When the equipment is working,

the operating workers have to wear
appropriate protective grooves,
especially touching rebar and
maintaining the equipment, and being
careful to clean up the left lubricating
oil.

48
 WG12D-4

Warning!
To put on the toes protector made
of steel, avoiding being injured.

Warning!

Dont run surrounding the machine,

but normal walking is allowed.

Warning

You are suggested to wear earmuff
when you are working.

Warning

If you want to use the compressed

air for some reasons, you have to wear
special protective spectacles. It cant be
sprayed to human being or face.

Warning!

49
 WG12D-4

There is no lighting system in the

machine, the install factor need the

better lighting condition. If the light is

too dark, it will increase the difficulty in

unloading goods, installing, adjusting,

and operating. Therefore, the working

area needs enough light, to ensure there

are no shadow area and producing

strobe.

Warning!

This equipment can produce radio

frequency radiation, so users of heart
impulsator and hearing AIDS can not
approach it.

Warning!

50
 WG12D-4

Not allowed to wear loose clothes

or items (bracelet, earning, necklace),
which will cause the risk of being
involved into the machine.

Warning

The equipment is a mechanical and

electrical product, so in addition to the
control cabinet and manipulation
platform, there is a servo motor in the
host, and other electrical appliances,
electronic products, mechanical
electronics, electrical components.
When choosing the machine installation
site, the following situations should be
considered: how to protect the
machinery in electronics and electrical
components, avoiding damage and
insulation which are caused by damp,
and preventing a short circuit device and
metal corrosion, and the interference of

51
 WG12D-4
other external factors and so on.

Clean up the place that is ready to

install the equipment, and its ground

level is in considerable seismic capacity.
Other stuff which have nothing to do
with the equipment should be cleaned to
other places, and to be sure that the site
is dry. Untidy site will increase the
difficulty of the equipment installation.

General requirements for the

installation of the stirrup bender: there
should have enough operation space,
and keep the site dry, ventilated, clean,
and no dust, oil mist, and other dirt. No
radiation, no radio transmitter, no high
tension line, especially the control
cabinet of the hoop bending machine

52
 WG12D-4
should go far away from the radio heat
sources. Gases with acid, salt or other
corrosive and flammable materials are
not allowed. Equipment installation area
should conform to the requirements of
the equipment of power supply, water
supply, and gas source.

Attention: we strongly
recommend that you should use safety
fences or other safety isolation
measures around the place where is
one meter beyond the machine for
safety protection, otherwise when the
steel is reinforced to be irregular, then
it may cause damage to personnel.

In order to protect the safety of

the operator, the performance
platform should be placed beyond the
safe net.

Warning!

4
4
53
 WG12D-4
Use appropriate lifting equipment
when the equipment needs to be moved.
Certain balance for the rated lifting
weight is necessary, because when
hoisting the equipment, its heaviest part
is 4 tons, so rated lifting weight must
greater than 4 tons of the lifted
equipment.

Improper lifting tool may cause

serious accident.

Hoisting the equipment should be

performed by specialized personnel or
professional company. The process of
Installation site
lifting the equipment and lifting its
material during production is easy to
accident.

When training and dispatching
objects, no standing below the machine.

If there is tripping operation or

fuse burned out, the worker of
54
 WG12D-4
equipment maintenance has to check up
the machine and find out the reasons.
When the problems are solved out, the
equipment can be used again. If fuse is
switched on, which will do harm to the
operating workers and equipment.

All switches of the equipment and

other safe devices cant be moved and
refitted in the process of use.

Warning!

In order to prevent mechanical

bruising, the following must be
emphasized: when countenancing,
debugging or replacement parts of the
stirrup bender, electrical source must be
cut off.

Regularly check the operation

condition of every equipment part. If
any fault or there is something wrong
with the parts, the change actions should
be taken immediately. Each class should
check that whether there exists loose

55
 WG12D-4
phenomenon, and if it exists, then
remedying the trouble in time to make
sure that the equipment is in good
working condition.

Warning!

If inspect the internal equipment

before it cools down, then do not touch
the motor and the connected
components, so as to avoid burns.

Warning!

Not allowed to spray water or other
liquid on the equipment.

General inspection items :

After using for a long time, every

month it is necessary to check all wiring

56
 WG12D-4
screws and connecting bolts of the
stirrup bender in order to check that
whether it is loose and the grounding is
reliable or not.

The power cord must use copper

cable, and the cable diameter must meet
the requirements of drawings(equipment
external distribution chart).

Regular measurements are needed

in order to check whether all
components are in normal conditions.

Check the gas path of any air

leakage phenomenon time to time, and
make sure that pump gas supply can

meet the operation needs of the
Regular inspection
equipment.

Each class shall check the cutting

knife, curved crankshaft if theres any
loose.

Lubrication points per shift filling

grease with reducer gear oil on a regular
basis.
57
 WG12D-4

Attention: lubricating oil play a

crucial role in this device, otherwise it
will cause mechanical wear serious,
which may cause serious damage to
the duration of the equipment.

Warning!

Clicked on the stop button, when

there is a need to stop the equipment.
And press the emergency stop button
if there is an emergence. It is banned to
off the power supply when the
equipment is in work, because this can
damage the equipment parts and
computer programs easily.

In order to guarantee the normal

operation of the equipment and prolong
its duration, maintenance of the
equipment must be taken in each
quarter.

58
 WG12D-4

After the maintenance of the

equipment, it is necessary to write the
maintenance diary, and this is good for
the user to quickly have a good
command of equipment manage
knowledge

Maintenance
When the equipment is in
maintenance or in repair, the main
power switch must be off and there must
be a note in maintenance on the
distribution box. And after the
maintenance, all the safety devices
should be set back to the normal
position.

In order to make sure the normal

operation of the equipment, the best
cleaning of its internal structures and
components is necessary, and industrial
vacuum cleaners and air guns can be

59
 WG12D-4
used for its cleaning. Pay attention to the
parts and structures when cleaning.

When the work is done, put all the

tools back to the tool storage room, and
by doing this, it is helpful to manage the
tools and reduce the accidents. Clean the
extra lubricating oil and other oils in
time, in case of making the steel dirty
and fire accident. Clean the iron chips
and waste materials in time, and put
them together for reclamation in case of
hurting workers and affecting the
production.

After the cleaning, lubricating and

maintenance of the equipment, or before
rebooting, fixing all the parts correctly,
especially the door, the cover and safety
devices.

When the equipment does not use for a long ti

Pay attention to the following me

60
 WG12D-4
points when the equipment does not use
for a long time:
1)
1) Evacuate off all gases in the
air path
2)

2) Make all parts of the
equipment in unwork condition
3)
3) Off the general power
switch
4)

4) Lock the control cabinet and
manipulation platform, and the key
is kept by specially-assigned
person
5)

5) Have anti-rust oil for parts
which are tend to rust
6)
6) Cover the equipment with
cotton cloth
7)

7) Separate damaged parts with
good ones in case of mixing them
together.

61
 WG12D-4

Once the fuse of the circuit system is

damaged,it
must be immediately replaced by a new
one, and the new one must
meet the requirement of the circuit,
otherwise, it will damage more easily,
and even affects the equipments
normal working.

Some safety attentions

When the general power is off,
lock the control cabinet in case that
someone accidentally shocks. And the
key to the control cabinet and
manipulation platform is kept by
specially-assigned person.

When in danger or machinery

breakdown, the stop button should
be presses immediately to stop the
machine, and off the power of the
machine later.

Do not damage, change or move

the original security fence,
safety devices or security tag of the
equipment.

Before starting up, check each

safety device that they are in normal or

62
 WG12D-4
not.

In the process of production, all

personnel in the workshop should wear s
afety helmet.

Warning!

The following actions can be
performed only in
following action only in low runni
ng speed :
-
- Traction motor
-
- Shear machine
-
- Bend the machine

-
-Move the bend plate
-
-Open the front door

Warning!

For security's sake, safety

protective nets can be arranged

63
 WG12D-4
around the equipment.

3665mm4040mm

The fence net must be at least two

meters high and the distance between it

and the pay-off rack is more than one

meter. If the net is metal, then the max

size of the opening is not over

3665mm or 4040mm. In order to

make the brake system in its best

function and adjustment, it is

recommended that steel guide pipes

should be put in one angle of the pay-off

rack base where is furthest from the

equipment.

64
WG12D-4

65
WG12D-4

66
 WG12D-4

IX. Technical parameter

Operation parameter

Single-line
5-13mm
rebar processing capacity

Double-lines
5-10mm
rebar processing capacity

Maximum
180
angle of bending

Diameter of
25-30mm
center shaft of bending

Maximum
110m/min
dragging speed

Maximum
1200/sec
bending speed

Length precision 1mm

Angle precision 1

Average
5KW/h
electricity consumption

Quantity of
2
processing rebar

67
 WG12D-4

Equipment power 25KW

Shape of + Modulized

processing rebar drawing library+Characteristic editing

Weight of main
2590KG
engine

Work
-540
environment temperature

Size of main engine 3600-950-2150mm

/Color Equipment
Tangerine
color/Color

68
 WG12D-4

Storage
!

Caution!

Put the machine and all parts into a sealed

environment to protect it against influence of

weather.

If the equipment is not used for long time,

accumulative water in air storage tank should

be discharged completely. Lubricating oil

should be added to all lubricating points.

Moreover, all parts of the equipment should be

packaged well to prevent dust.

69
 WG12D-4

XIMovement and placement
!

Warning!
The machine should be moved slowly to avoid
falling off and collision. The carried parts should be
low to the ground as possible.

Warning!
Proper lifting equipment should be used when
transferring or placing the equipment. The lifting
capacity should not be less than 4 tons.

Transportation of the machine may use:

Containers with open cover and sealed containers

After taking out from the container, remove canvas

cover (if any) and open the door.

Take out the machine from the container.

70
 WG12D-4

1000mm

Warning!
The distance from the equipment to wall should
not be less than 1000mm to facilitate equipment
maintenance.

Warning!
The equipment must be placed on horizontal and
firm ground to ensure that equipment base and ground
contact well. At the same time, equipment base is
fixed with the ground to prevent movement of the
equipment that may affect performance and service
life of the equipment.

71
 WG12D-4

XII. Installation

Before equipment was installed, adequate

place should be prepared according to
equipment installation drawing. Preparation of
ground level finding and foundation grooving
of workshop shall be done.

Warning

Our company is neither responsible for

connecting equipment to main source of
electrical power nor for providing cables to
connect main source of electrical power. They
are both users responsibilities. Connection of
power wire must be operated by professional
electrician in accordance with local law.

Warning!

15KG/cm2
The equipment must be placed in a sealed factory
building with good ventilation for use. Before the
equipment is placed, the anti-pressure ability of the
factory floor should not be less than 15KG/cm2.
72
 WG12D-4

Warning

Before completing the following

operations, connecting equipment to main
source of electrical power is forbidden.

Warning

Check power source meets equipment
requirements or not.

Read foregoing safety attentions in detail

before installation.

See Foundation Drawing of Equipment

Installation for requirements of equipment
installation. Foundation bolt shall be drilled
and fixed on site.user pays

Before installation, user shall prepare

working condition on equipment
requirements like power source and air
source.
316mm
-5-40

Service cable part 316mmcopper wire
Working environment -5-40
closed workshop
73
 WG12D-4

Distance between operation platform and

main engine is better to be more than 2m, so
that workers can freely pass by and reduce
impact to control system.

Pedestrian path shall be preserved

surrounding equipment for maintenance of
operation and equipment.

Operator of operation platform must face

equipment directly or broadside so as to notice
operation of equipment and take actions when
accident occurs.

Ground lead shall possess enough

sectional area, and is fixed by screws firmly.
Bender shall pass fuse and special air switch
before being connected to power network. See
drawing for detail of connection method of
equipment's external power source .

Connection cable between power wire

and main engine shall be covered by insulation
tube respectively and buried underground to
avoid danger in production process. Control

74
 WG12D-4
lines between control cabinet and main engine
shall keep away as far as possible from power
lines of transformer to reduce interference.

After bender production line is installed
completely ,the following items shall be
checked:

1)

1) Turn off main switch of power source,

turn up key switch of control cabinet and
observe whether indicator light of
corresponding power source is working
which indicates the power source works.

2)

2) Switch control mode to manual

operation, push open buttons of motors, and
then stop immediately to check whether
motor rotates inversely. If it really happens,
stop and cut off power source, and then
change connection method of this motor's
power lines.

Warning: Motors cannot work in
inversion for long time, so they shall be shut
down once opened in test.

Attention
15
75
 WG12D-4

Unused time of equipment shall not be

over 15 days to avoid computer data loss.

XIII. Equipment Starting

Becautious!

For the sake of safety in transportation,

just a little oil shall be added onto the
equipment for installation and adjustment.
Check and ensure adequate lubrication oil in
lubrication oil box before using equipment.

Becautious!

150

After the equipment is used for 150

hours, check whether the gear motor and
lubricating oil tank has sufficient lubricating
oil.

Tools Installation

Change corresponding accessories before

processing rebar of different diameters.

76
 WG12D-4
1.
1.Install fixed blades suitable for
processing rebar

2.
2.Install suitable bend shaft and elbow

Distance between center shaft and bend

pin can refer to selection and adjustment of
bend shaft and elbow

Change fixed blades

Discharge four fixed bolts and fixed

blades, put on new blades, fix with bolt.

Change mobile blades

Change elbow and bend shaft.

Pay-off rack

Warning

Put pay-off shaft onto pedestal of pay-off

rack, and then cut down banding wire of wire
rod rebar.

77
 WG12D-4
Warning

Pull out end of wire rod rebar through

guide roll of pay-off rack, and then manually
straighten and insert it into level straightening
mechanism of bender.

Becautious!
10mm.
This equipment can process two rebars
with maximum diameter of 10mm at the same
time.

Single-linerebar

1.

1.Operate feedstock button and air valve

handset until rebar near dragging wheel.

At this time equipment can start to work.

Double-lines rebar

As feedstock operation of single rebar,

the first rebar use upper track of level
straightening mechanism.

1.

1.In the meantime operate feedstock

78
 WG12D-4
button until rebar near dragging wheel.
2.

2.Insert the second rebar into nether track

of the level straightening mechanism.

At this time equipment can start to work.

Warning

When processing double-lines rebars

check upper rebar in internal track of external
straightener, nether rebar in external track of
external straightener.

When use single-line rebar, thread rebar

into upper track according to foregoing
operation.

79
 WG12D-4

XIV. Adjustment

AdjustmentofStraighteningStructure

Before starting equipment, adjust

straightening mechanism, including external
level straightener and internal vertical
straightener

Correct adjustment of straightening

mechanism plays very important role in
processing rebar with precise dimension.

Attention

This equipment can process two types of
rebar.
1.-
2.-
1.-cold-finished rebar
2.-hot-rolled rebar

The first type of rebar has uniform

transverse rib and uniform mechanical
properties. Therefore, it is easy for it to be
straightened without too much pressure from
straightening wheel.
80
 WG12D-4

However the second type of rebar has

non-uniform transverse rib and non-uniform
mechanical properties even in one rebar.
Therefore, it is difficult for it to be
straightened. So it is recommended to exert
much pressure on straightening wheel when
straightening this rebar.

Check whether the processing tool is fit
for the diameter of rebar.

1)
1) Adjustment of wheel of
straightening part:

Straightening can be divided into the first

level straightening and the second vertical
straightening which share the same
mechanism. Adjusting reduction of pressing
wheel with short distance can reduce small
local bend of rebar, and adjusting reduction of
pressing wheel with long distance can reduce
large bend of rebar.

81
 WG12D-4

2)
2) Adjustment of rebar with up and
down bend:

()

Rebar with upward bend(warped)

downward adjust last pressing roll of vertical
straightening mechanism or upward adjust
penult pressing roll.

()

Rebar with downward bend(warped)

upward adjust last pressing roll of vertical
straightening mechanism or downward adjust
penult pressing roll.

3) ()
3)Adjustment of rebar with inside and
outside(side direction) bend:

()

82
 WG12D-4
Rebar with inside bend(warped)loose last
compressing roll of level straightening
mechanism or fasten middle compressing roll.

()

Rebar with outside bend(warped)

fasten last compressing roll of level
straightening mechanism or loose middle
compressing roll.

4)

,3-4
,3-4,
4) Rolling reduction adjustment of rebar: As
for rebar with uniform transverse rib and
uniform mechanical properties, it is easy to be
straightened, so no need to put on too much
pressure from straightening wheel. As for
rebar with non-uniform transverse rib and
non-uniform mechanical properties, it is
83
 WG12D-4
difficult to be straightened, so it is
recommended to exert much pressure on
straightening wheel. After exiting rebar owing
to installation and adjustment or malfunction,
slowly operate for 3m to 4m to observe and
adjust and then operate for 3m to 4m to see the
straightness of rebar.

Be cautious!

When processing double rebars, adjust

rear separate wheel of two straighteners if
straightening effect of them is different.

AttentionEvery straightening wheel

must be in operation to ensure continuous
working and life of machine as well as
product quality.

Attention Rolling reduction of

straightening mechanism shall be adequate,
or else there will be overload of electric
current if over the value.

AdjustmentofDraggingStructure:

84
 WG12D-4
Adjustment of dragging mechanism:
compressing strength between upper and
nether compressing wheel of dragging
mechanism can be adjusted by pressing
compressing leaf spring of connecting piece of
electric pusher. It is recommended to adjust to
a stage where rebar can just be hauled
effectively depending on rebar diameter and
texture and combining actual situation. In
general, rebar with large diameter owns more
compressing strength, and rebar with small
diameter has less compressing strength. Too
much compressing strength will impact
surface quality and usage life of stirrup of
dragging mechanism.

AttentionExit tailing from the rear when

rebars are nearly worn out.

:
Adjustment of Shearing Structure:

Use double-lines rebar fixed cutter when

processing double-lines rebar; use single-line
rebar fixed cutter when processing single-line
rebar. When gap between flexible cutter and
fixed cutter is too big, inspect wear pattern of
end cap(copper) of shearing arm, and replace
with spare part if seriously worn. Too large
gap will lead to cutting failure of rebar. If rebar
can touch flexible cutter, inspect whether the
85
 WG12D-4
switch of motor is loose.

AttentionPay attention to whether the

output shaft key of shearing reducer is loose
and comes out. Solve the problem in
exceptional situation, or else there will
produce much cutting power between shaft
and reducer, leading to great damage to
equipment.

Adjustment and Use of Bending Axis
and Elbow:

Depending on different rebar diameter,

choose corresponding elbow and bend shaft.
Please select according to the following
comparison table:

Rebar diameter Elbow label disc hole No.
Elbow distance Bend shafts
mandril diameter diameter

58 12 60 D1 1
10-13 16 60 D2 1
58 10 60 D3 1
58 25 60 D6 2
10-13 30 60 D5 2
8-13 70 60 D4 1

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 WG12D-4

XV. Maintenance of Equipment

Must cut off main power source before

equipment maintenance. If it refers to
adjusting machinery part, let go residual gas
in air circuit to avoid accident.

Do not use chemical dissolving agent to
clean up equipment.

Lubrication of equipment seriously plays a

role in usage life of machine. Improper
maintenance will largely reduce usage life of
machine.

Equipment maintainer must seriously read

this instruction. Only a set of keys will be
provided and duplicating another set of keys is
forbidden. Keys just can be kept by maintainer
in maintenance process.

In order to ensure normal operation of

equipment, users are responsible for
maintenance of equipment to ensure every
part of equipment in good condition.

87
 WG12D-4

Keep equipment maintenance diary after

maintenance, which is useful to help user to
master equipment management knowledge
quickly. Use suitable tools to maintain and
repair the equipment so as to reduce damage to
equipment and avoid danger. Clean up
redundant lubrication oil and other oil in time
to prevent from polluting rebar and fire. Clear
scrap iron and waste in workshop and collect
them to recycle as well as protect workers from
damage and impact production.

1
1.Outdoor Use of the Equipment

,,
,
,,

When using equipment outdoors, we shall

install it under ceiling and on dry ground. Do
not use it under strong sunshine, in rain and in
snow. Protect the equipment and its control
system against sand and dust, or else it will
break down.

2
2. Maintenance of Equipment

88
 WG12D-4

Dragging part of equipment shall be

regularly added or changed lubrication oil. Add
oil to grease lubricating nipple weekly and
lithium grease to straightening rolls monthly to
lubricate the shaft. If there exists oil filler hole
above shearing mechanism and bend
mechanism, oiling with lithium grease
regularly is also needed to lubricate the shaft
and prolong usage life of all parts. In addition
to that, draw off the water in air circuit filter.

1)
1)Regular maintenance per shift

8
Note8 working hours per shift
,

At the beginning or at the end of every

work shift, common cleaning is suggested to
clean up scale and sundries.

Check integrity of cutter and looseness

of fixed bolt of compressing wheel. Confirm
firmness of wire tube of dragging part and
fasten it if needed, or else nether dragging
wheel will break down and splash scrap iron.

Draw off the water at the end of every

89
 WG12D-4
shift when the temperature is below 3, or
else frozen water will lead to malfunction of
the whole pneumatic system.

3


Suck dry moisture on silencer mouth
with cotton yarn at the end of every shift when
the temperature is below 3, or else it will
lead to slowness or malfunction of air cylinder.

Lubrication:

Fastening of screws of all parts

Fastening of screws dragging two driver
wheels, fastening of screws dragging two
pressing wheels, fastening of screws on end cap
of upper shaft sleeve, fastening of screws of all
cutters, fastening of bend mandril screws,
fastening of bend shaft.

2)
2)Regular maintenance weekly

Cleaning of control electric cabinet
and operation platform.

,

Check fastening of connecting bolt , and
fasten with special tools if necessary. Clean up
dust on all control components.
90
 WG12D-4


When electric machine break down, check
fuse, heat contactor and proximity switch first.

Check whether insulation skin of cable is
damaged.

Check and protect ground lead.

Check whether there is air leakage on
gas-type fitting and air circuit.



Check wear pattern of motor braking
system: spring, spring tension nut,
electromagnet, mobile brake, brake disc, motor.
3)
3)Regular maintenance monthly
,

Check clearance change of shaft on drive
part, and adjust when loose.

Lubrication oil on each reducer casing
,,
, CKC105
Look over oil pointer and check
lubrication oil. Add CKC105 lubrication oil in
time if oil level is low.

Check oil level through transparent
observation well is just a reference method.
Because some little lubrication oil may stick on
the well, misleading us to regard it as enough
91
 WG12D-4
lubrication oil, while actually lubrication oil
may be lower than observed oil level.

,,
Because of much scale of hot-rolled rebar
in feeding process, cleaning up weekly can
reduce wear and adjust hindrance.

4)
4)Maintenance of purchasing standard
fittings

Reducer: check air permeability of gas

hole weekly, and clean gas hole to smooth
venting.

Check lubrication oil before using reducer,

and add lubrication oil in assigned
specification. Supply lubrication oil according
to oil pointer. Replace oil according to
replacement time standard:

2000
Oil special for reducer 2000hours

5000
Gear oil 5000 hours

Operate machine in lubrication standard,

or else it will not work and impact lubricating
property and even damage all mechanisms
seriously owing to solidification of lubrication
oil.
92
 WG12D-4

The above daily maintenance period is the

lowest requirements and concrete time will
depend on use quantity of equipment.

3
3.Cleaning

!
Warning!

Please cut off power source before

equipment is being maintained, replaced parts,
repaired lubrication and adjusted operation.

5
Daily Cleaning of external equipment
every 5 working days

In order to ensure equipment in operation,

internal parts of equipment shall be best
cleaned with industrial cleaner and air gun
provided with the equipment. Control box shall
also be cleaned carefully without damage to
electrical apparatus element.

Clean tools carefully (every working day

Clean straightenerOne working day and
every shift exchange

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 WG12D-4

Often clean straightener to avoid blocking.

Do not use lubricating grease to prevent from
creating solid scrap.

Clean cooling fan filter
30
(every 30 working days

!
Warning!

Do not use chemical dissolving agent to

clean up equipment. Diesel can be used but
only with rag to wipe.

Clean safety sign, indicator light, screen

and keyboardevery working month

Serial
Lubricating Oiling
numbe Lubricating part Remark
agent period
r
10g

1 Lithium Once a
Bend shaft Oiling with grease gun
grease(10g) week
10g

2 Lithium Once a
Center shaft bearing Oiling with grease gun
grease(10g) week
2 10g
3 Nether driving shaft of Lithium Once a
Oiling with grease gun
dragging part2pieces grease(10g) week
2 10g
4 Upper driving shaft of Lithium Once a
Oiling with grease gun
dragging part2pieces grease(10g) week
10g

5 Lithium Once a
Shearing support arm Oiling with grease gun
grease(10g) week
10g

6 Lithium Once a
Main shaft of bending Oiling with grease gun
grease(10g) week

94
 WG12D-4

NoteReference brand of lithium grease:

, GB/T7324-1994
AGIPGR33/LiRD 10/010/1

ESSOLexdex 0,1;
SHELL()Sunlight Grease 0,1;
MOBIL()Mobil Grease 76,77;
China: General lithium grease, meet GB/T7324-1994
InternationalAGIPGR33/LiRD 10/010/1

ESSOLexdex 0,1;
SHELLSunlight Grease 0,1;
MOBILMobil Grease 76,77;

Oiling periodRefuel every shift exchange

50
Oil numberEngine oil no.50

Environment NLGI

Model
temperature
0 50

Precision

CHINA
ESSO
MOBiL SHELL

with
NLGI
-25 +80 VG220 MOBIL Shell
Gly goy le Tivela 01
30 WB
0 +40 VG220 130-160 SPARTAN Shell
MOBIL
EP EP 220 Omala
gear 630
01220

-15 +25 VG150 SPARTAN Shell

Sheari MOBIL
VG100 EP 150 Omala 01
ng 130-160 gear 629
100
reduce EP
- +10 VG68-46 ESSOATF MOBIL Shell Teilus
r,
30 VG32 D-21661 D.T.E 15M 01 T 32
draggi
- +60 VG22 UNIVSJ13 MOBIL Shell Teilus
ng box
20 VG5 D.T.E 11M 01 680
- 0 MOBIL
130-160
45 VG680 Gly goyle
EP
HE 680

95
 WG12D-4

4
4.Maintenance of Machine
1.
1.Check mobile bladesevery working day

2.

2.Check wear degree of mobile blades.

Change if damaged.

Be Cautious

3.

3.Please replace blades when there is jagged

score or deformation.

Warning

4.

4.Check bolt taken off is intact or not, and

change new one if damaged.

5.5

5.Check fastening of fixed bolt of blades

every 5 working days.

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 WG12D-4

Attention

No matter there is problem or not,take off

bend shaft monthly, clean shaft hole, and use little
lubrication oil to slightly lubricate wall of hole, to
prevent shaft locking. Paste a layer of lubricating
grease around the shaft.

6 .

6 .Check bend shaft every working day

Check whether outer ring of bend pin rotates
freely, or else operate the following

1).
1)Take off bend shaft.

2)

2)Clean and install until it can rotate freely.

Take of rebar before changing the following
components.

7.
7.Replace dragging wheel

1)
1) Screw sic bolts fastening dragging wheel.

2
2Take off dragging wheel

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 WG12D-4

3Change new dragging wheel, pat attention

to use degree of locating straight end-face key. If
there is damage or unreliable locating, change is
needed to ensure fastening of relative wheel of
shaft.

8 .
7
8 .Check wear degree of straightening wheel,
and replace if necessary.Every 7 working days

9.

9.Check wear pattern of motor brake system

every working month

special for three-phase motor

Diagram

1 =
2 =
3 =
4 =
5 =
6 =
1 = spring
2 = spring tension nut
3 = electromagnet
4 = Mobile brake
5 = brake disc
6 = motor

98
 WG12D-4

Check wear pattern of brake disc

a.

a. Screw fixed bolt of braking motor

protective case.

b.
b. Take off protective case.

f.
1.5.
f. Check no over-wear on brake disc, which
means thickness of brake lining shall not be less
than 1.5.

13.30

13.Clean motor cooling fan filter. every 30

working days.

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 WG12D-4

XVI. Easy damaged List

1
One-wire fixed blade 13 14.5

2
Double-wire fixed blade Standard work state, 145,000 times if
cutting 13 Grade III steel, requiring
3
Movable blade sufficient maintenance


4 Standard work state, requiring sufficient
Straightening wheel
maintenance


5 Standard work state, requiring sufficient
Traction wheel
maintenance


6 Standard work state, requiring sufficient
Counting wheel
maintenance


7 Standard work state, requiring sufficient
Bend
maintenance


8 Standard work state, requiring sufficient
Bending shaft
maintenance


9 Standard work state, requiring sufficient
Cutting end cap
maintenance


10 Standard work state, requiring sufficient
Inlet pressing plate
maintenance
6006/6205
11 Straightening wheel Standard work state, requiring sufficient
bearing 6006/6205 maintenance

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 WG12D-4

XVII. Handling Method for Being Failure-prone

Malfunction
Reasons Maintenance Methods
contents

Offline of main
engines and control cabinets Checking the online
condition and whether
The system is in electric wires are firmly
alarming state connected.

Scram buttons are

pressed Checking the

Inoperation of
position of monitors
the System
and whether switches
Bending axes are in of monitors are
working position or not broken.

Recovering the stop
control state

One back reference

Non-working The poor contact or Checking broken
of individual break of control wiring circuits
operating
organizations The loosening of Checking
optoelectronic swithes optoelectronic
switches

101
 WG12D-4

The break of diffusion Changing the
knives diffusion knives

The overlarge of gaps
of diffusion knives

Rebars cannot Checking whether
be sheared the shearing arms are loose
and if so, the copper end
caps of them need to be
changed. Checking
whether lock nets are loose
and fastening them.

Straightening rebars Adjusting and
which are not be corrected by straightening
organizations. organizations.
.
The improper position Adjusting the
of bending axis position of bending axle.

.
Using proper

The distance between bending axle sleeves and

elbows and bending elbows

axle sleeves is correct
Bending angles or not. Adjusting
are incorrect parameters of positive
and shapes are
and negative bows.
irregular
Parameters of positive
bows and negative Adjusting original
bows are proper or not. locations of
back-reference.
The original location of
back-reference is biased.
Checking and
There are external perfecting ground
interferences electrodes to avoid
interferences.
102
 WG12D-4
Break rubbers are
broken.
Circuits controlling air
cylinders are broken. of air cylinders
Difficult stall of The pressure of air
vertical pay-off cylinders is low
racks
Checking whether gas
vents of solenoid valves are
blocked.
The connection of shaft
couplings of encoders and
driven shafts is loose or not.
The serious abrasion of
counter wheels
degree of tightness is
The sizing rules
are incorrect
103
Changing break
rubbers
Checking circuits
Adjusting pressure
locks of air cylinders
Cleaning gas vents
of solenoid valves.
Tightening lock
screws of shaft
coupling(take attention: the
proper and it could be done
as long as the rotation of
driven wheels can drive the
rotation of shaft couplings.
If the screws is too much
tightened, shaft couplings
and driven axle will be
broken.)
Changing counter
wheels
 WG12D-4

3
Adjusting displays 2

Whether ground lines
are firm or not.

Opening rear
covers of displays. There

are 3 rotary knobs on the

left and 2 on the right
which are used
Pictures of respectively to adjust
displays flutter luminance, shake,
or unclear. clearness, position and
width. Do not break
displays with force when
adjusting them.

Firmly connected
grounding lines

The slipping
Servo motors phenomena of connecting
alarm and shafts of encoders occurred can Tacking screws of
display their not make servos return to shaft couplings of encoders
serial numbers reference points. to fix two connecting axles
as messy codes
onto shaft couplings.

In producing process,
backing wires finally is not
allowed.

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 WG12D-4

XVIII. Common Faults and Removal Methods of MSEJ

Rebars are not
straightly adjusted. Adjusting straightly
rebars or making it slightly
There are silk warped outside.
hanging
phenomena

The shearing Band-type brakes of
machines of shearing machines are broken. Checking and
stirrup bending adjusting band-type brakes.
machines have Default of shearing
abnormal machines.
sounds.
Checking whether
there are defaults of
shearing machines.

Band-type brakes of Adjusting
shearing machines are broken. band-type brakes of

shearing machines.
Holes of

plugging knives
The detective
of shearing
arms switchers(blades) of shearing Adjusting positions
are loose. of detective
switchers(blades) of
shearing.

105
 WG12D-4

Num Default Checking Parts and Solutions
ber Phenomenon Methods
a) 5 1) 5.
a) Checking whether the 1) Fastening the
screw 5 is loose; screw 5.
b) 2)
0.5mm 0.2-0.3mm
1 b) Measuring whether the .
gap is longer than 0.05mm; 2) Readjusting
c) the gap to keep
Brakes do not it between
work and 0.2-0.3mm.
have violent c) Using the multimeter to 3)
vibration and measure the resistance of
screams. three-phase winding; 3) There are
d) broken wires to be
500V repaired and magnet
yokes are to be
d) Using the 500V AC changed;
voltage profile of the 4)
multimeter to check whether
inlet wires of AC three-phase 4) Ruling out
supply have defaults; problemes if there
e) 0.3 are any;
5) 4
e) If the length of the gap
is within 0.3, the 5) Loosening
retarding torque may be too the screw 4 by
long; half-round or a
f) round;
6)

f) Checking whether there 6)Cleaning
are foreign bodies on the foreign bodies and
surface of iron absorption or oil oil clingages;
sludge so that the surface is 7)
uneven;
G) 7) Making flat
with lathes or flat
grinders;

106
 WG12D-4
G) The uneven of the
surface of iron absorption after
being long-time used;

a) 1)
4
2 a) The fiction plates are
Brakes does broken, the working gap is 1) Readjusting
not work or increased and moments of force the gap and tighten
not work well decline; the screw 4 by
b) half-round or a
b) The friction brades are round;
broken; 2)
c)
2) Changing a
c) The load inertia is too new friction disk
much and it surpasses the 3)
retarding torque;
3) Chosing the
type of electronic
motors.
a) 1)

a) The load is too heavy
3 surpassing the electric current 1) Lowering the
Motor regulated by nameplates; load and controlling
heating b) it within the electric
current regulated by
b)In low-frequency phase, nameplates;
using frequency converters for 2)
too long time;
c) 2) Adding
draught fans to the
external packing;
c) Checking whether there 3)
are cotton fibres at the air intake
and fan blades and whether 3) Cleaning
there are yarns and paper scraps cotton fibres;
to block the cooling wind;
107
 WG12D-4

d)

d) Checking whether there 4)
are defaults of power supplies 4) Reparing it.
and electrical motors.
a) 1
4
The pivot can a) The fiction blades and
not be turned armatures are rusting because of 1) Separating
after the the fiction plates are not used and taking down the
manual for a long time. friction plates and
release. assembling them
after being erased the
rusts and cleaned.

The checking and adjusting of gaps of shearing motors

0.2-0.3mm 0.5mm.

The gap () is defined as the moving distance between iron plates and
electromagnets. The normal working gap should be controlled with in 0.2-0.3mm
and can not surpass 0.5mm. After leaving factories, the working gap electric motors is
adjusted within normal values. After being used for a period of time, the gap
surpassing the largest value becuase of the increase of gap by the errosion of friction
blades will influence the normal inhale and braking of brakes which must be adjusted.
0.25mm
5 0.25mm.
7 5

5 5 5
7 60(
0.15mm,

Ways of adjusting: Praparing a set of gap gauges. Selecting one piece of 0.25mm
and measuring the gap at the position of the gap showed in the figure . And if
it surpasses the normal value, loosening the screw 5 and putting the gap gauge of
0.25mm into the gap of loosened screw. Slowly tightening the check nut 7,
pressing the gap gauge and tightening the screw5 outside. Pulling out the gap gauge.
108
 WG12D-4
Adjusting the gap at the second and the thrid screw by the same way. After that,
tightening the screw 5. It must be made sure that the screw 5 is tightened and it should
be frequently checked to aviod the loosening.
If there are no standard gap gauge, the iron sheet of the similar thickness can be
at its place.Every turning of 60 of the check net is about 0.15mm advance(the six
even angles of hex net). The three adjustating points of the gap should be even or it
will influence the inhale and braking of the brakes and when things get worse, it will
break coils.

The adjustment of moments of forces

4
180
.
4 180

After leaving the factory, the moments of forces are adjusted to standard values.
After being used for a period of time, the spring of brakes are loosened and the
moments of forces are eliminated because of the errosion of fiction blades. If there is
not too much influences, it can be remained untouched. If there are declines of the
moments of forces which are needed to be increased, the three check nuts of 4 should
be tightened 180 forward(about half round), one round at least. Because the too large
of moments of forces will lead to the difficult of inhale or the magnet sound and will
even break the coils when it is serious. If the forces need to be declined, the check nuts
4 will be loosened 180 backwards(about half round), one round at most or the forces
is too small. The gap need to be readjusted whether the forces are large or small.

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 WG12D-4

XIX. Conclusive Table for Equipment Maintenance

Careful maintenance

Working hour day week month season Half year year
8 38 150 450 900 1800
Applying the hour system for extra
work
cleaning
X
The ordinary external cleaning

Carefully cleaning the eqipment X

X
Cleaning straightener
X
Cleaning filters of cooling fans
X
Cleaning bending coils and alarming
light

Lubrication

A,2 / X
The greasing mouth A of bending
sysetm, 2g/grease
4 / X
The greasing mouth of shearing system,
4g/twice grease
2 /1 X
The greasing mouth of moving unit, 2g/
one grease
X
Checking oils in reducer casing
X
Changing reducer casing
X
Filling the oil cap

110
 WG12D-4
Erasing the cooling things in air filters X
X
Lubrication lightening
X
Lubrication of bending axle and bending
axle

Equipment maintenance
X
Cheking moving blade
X
Changing moving blade

Checking fixed blade X
X
Changing fixed blade
X

Checking whether the fixed screw of

blade is firm or not(moving and fixed blade)
X
Checking central axle
X
Checking the bending
X
Checking or changing the draught
wheels if necessary
X
Checking or changing straightening
wheels if necessay
X
Checking or changing the direction tubes
if necessart
X
Checking the errosion conditon of
motive blade of electric motors
X
Cleaning the filters of cooling fans

111
 WG12D-4

The maintenance of equipment
X
Checking the connection of the draught
encoders
X
Checking safe switchers
X
Checking ground wires

The maintenance period in the table is made according the usual use and it is
made for reference.

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 WG12D-4

XXRemark
()

Thank you for your use of the steel bar processing equipment manufactured by TJK Machinery
(Tianjin) Co., Ltd. The operation manual mainly makes simple description for considerations of the
equipment during the process of use. Therefore, the operation manual is universal instructions.
Pictures and contents in the manual may differ from the actual equipment you buy. This depends on
actual product. But the use and form are the same basically.

()

Registration and content of the operation manual is under copyright protection. Without written
permission of TJK Machinery (Tianjin) Co., Ltd, any part of the operation manual shall not be copied,
duplicated, reprinted, quoted or spread in any form for any purpose. Otherwise, the responsibility
will be investigated according to intellectual property law of the country. Content of the operation
manual is subject to change without prior notice.

The instructions for use and maintenance will be helpful for safe use of the machine.

The operation manual is one component part of the machine. This means that when the machine
is transferred or sold, it should be attached to the machine.

The operation manual must be kept on work site so that work staff for operation, installation, starts
and maintenance of equipment can use it at any time.

TJK Machinery (Tianjin) Co., Ltd will not take any responsibility for accident that is caused by
failing to operate the machine according to the method described in the manual. As the equipment is
subject to transformation and update, TJK Machinery (Tianjin) Co., Ltd has the right to change the
operation manual without further notice.

Technical data listed in the manual is only for reference!

If you find any error in the operation manual or you have any doubt during the process of use,
please contact us.
113
 WG12D-4

Notion

To ensure the normal use of equipment, please
use the original accesories and other accessories are
not allowed to use

TJK Machinery (Tianjin) Co., Ltd
Telephone+86 022 26993711 4006-190-618
+86 022 26993766
Address
7
Land port wuwei road 7, the industrial park of logistics
equipment, land port, Beichen district, Tianjin, China
Postcode300402
Websitewww.tjkmachinery.com
Emailinfo@tjkmachinery.com

The copywright is inclusive and those who voilate it will be punished

114