KINGJIME MACHINE LIMITED

MAINTENANCE DOCUMENT OF THE

EQUIPMENT OF CUT TO LEGNTH

LINE
3X1600 MODEL

KINGJIME MACHINE LIMITED

Add: SanZhong Industrial QingXi Town Dong Guan City Guan gDong Province
China Tel:0086-769-87307370 Fax:0086-769-87307456 E-MAIL :
kingjime@kingjime.com URL:www.kingjime.com

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_Recommended Routine Maintenance

Coil processors need to develop routine maintenance procedures for these

critical areas of a cut to length line.

Oil. Oil flows at approximately 16 to 32 gallons per minute (60 to 120

liters per minute) at a pressure of 1,600 pounds per square inch (120

kilograms per square centimeter). Over time small dirt particles turn oil

into a dangerous agent that can scratch pipes and cylinder inner walls and

block solenoid valves and joints. Dirty oil also can damage seals. Another

potential contaminant is a dirty filter. Filters, which can be mechanical,

electrostatic, or cloth, should be checked every 600 hours.

If oil level depletes too much, it's probable that dirt from the bottom is

mixing with flowing oil. A rule of thumb is to check oil levels every 600

hours. When it's time to add oil, make sure it's the same type of oil used

previously, because mixing different oils can ruin the working or

lubricating characteristics of the fluid.

Hydraulic oil must be prefiltered to eliminate the microparticles that

fluids always have and that can be deposited on the tube's walls. This

fluid should not damage other mechanisms or be harmful to the belts or

plastic rollers in the line.

Lines. Sooner or later all hydraulic circuits leak. To maintain a safe shop,

coil processors must never allow oil droplets from leaky lines to fall on

the floor, so all slitters should have a catch pan. Oil that flies off the coil

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strip under the pressure of the rolls should be collected by a reservoir.

These reservoirs should have a low point where a pump can be installed

to remove the collected oil

In some lines, reservoirs are joined together, and fluid is carried to the

lowest possible location, such as a central tank. This tank usually is

located at the bottom of a loop's pit and can be emptied with a pump or

drained.

Periodical checks—every 600 to 1,000 hours—should be made of the

cylinder seals and rotary joints of the uncoiler, and leveler shaft. All

tubing and flexible hoses should be inspected every 2,000 hours.

Pumps. Machine devices are powered by pressurized oil generated by a

dedicated hydraulic group . Pumps should be checked every 2,000 hours

to ensure that the right pressure and flow are achieved and bearings

lubricated and cleaned thoroughly. The hydraulic tank should be cleaned

every 1,500 hours. All sludge must be removed from the bottom of the

tank with a cleaning and washing agent. Line pressure in the hydraulic

circuit must be released before maintenance to prevent a sudden oil

shower.

Solenoid Valves. Solenoid valves, which act as the nerves of a system,

connecting power to all elements, control and distribute clean oil. It's

important to check all seals every 1,000 hours. If new seals are needed,

they should be coated with grease before installation to prevent them

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from being scratched because of friction. All pressure should be released,

including any buildup inside the solenoid valve chambers. If pressure is

not released, the remaining pressurized oil can produce an unexpected

shower, or cause erratic and sudden whiplike motions of the flexible

pipes.

Changing these seals is a precise task, so it should be performed by

skilled personnel. Every pipe in the solenoid valve manifold should be

labeled for easy recognition. Only authorized personnel should be near

the line during maintenance, because manipulating solenoid valves can

unexpectedly activate the line.

Cylinders. The hydraulic cylinders combine signals from solenoid valves

and oil pressure to activate the various components, including the

mandrels, straightener opening, coil cars, and pinch rolls. Cylinders must

be checked every 1,000 hours if they are activated frequently or 2,000

hours if they work intermittently.

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Other Hydraulic, Pneumatic

Components. Pressure monitors,

electrical components, flow sensors,

and lubricating units should be

checked every 1,800 to 2,000 hours. Figure 3

Neat, organized tubing ensures proper Neat, organized tubing ensures

accessibility for maintenance and proper accessibility for

inspection procedures maintenance and inspection
Tooling and knives must be checked procedures.

from time to time. During cutting,

some knife scratches can be produced that increase the burr on the cuts

and lowers the edge quality. At the least, a visual inspection should be

done every 1,000 hours. machine equipped with automatic hydraulic

clamping must be verified every 2,000 hours to guarantee the clamping

force. The eccentric gap-adjusting device also should be checked every

2,000 hours

Clutch and Brake. Manipulation of a clutch and brake can unexpectedly

activate some mechanisms, for instance, the shear, so extreme care must

be taken to prevent injury. The clutch and brake should be checked every

1,000 hours. Maintenance tasks include controlling the motions of the

friction pads, springs, and tie rods.

It's also important to check the rotary joint to be sure that air or oil flows

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properly into the clutch and brake—the performance of the entire unit

depends on this flow. At the least, this task should be done every 1,000

hours.

Ball Screws. In machines with a high degree of vibration, such as

screws must be checked every 1,000 hours and lubricated every 600

hours. They also should be secured with epoxy or wire.

Gearboxes. If an anomalous noise is heard, the whole device must be

inspected and tested. Additionally, temperature levels should be measured

every 1,000 hours, as well as oil levels, to lessen internal wear. An

infrared thermometer is ideal for checking temperature.

Guides. Many mechanisms are guided in one place or another. The

clearance between these guides must be checked every 1,000 hours. An

equipment supplier should provide a manual that includes all

recommended clearances. Components or guides that aren't automatically

lubricated require manual greasing.

Sensors. Magnetic sensors or switches should be calibrated every 2,000

hours. It's critical to maintain the correct distance between the sensor and

the element to be detected.

An Ounce of Prevention

If properly maintained, a slitting line can operate efficiently for 20 or

more years. Establishing and following these routine procedures can help

coil processors safely maintain their slitting lines without compromising

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ergonomics or operator safety.

1.Lubricating system

A).All online equipment has the corresponding lubrication

system,

manual pump and manual grease fitting and grease

fitting, etc.

B).Leveler and shearer adopt auto lubricating system,

other adopt

manual lubricating
C).This unit all moving parts have corresponding
lubrication
point. (see table below)
E).Lubricating oil system oil supply standard table
{reference}
Lubrication list

NO. lubrication method oil model circle time

Ietem

decoiler inside the 50#mach oil 6 months

gear box box

gear box for inside the 50#mach oil 6 months

snubber roll box

gear box for inside the 50#mach oil 6 months

leveler box

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The screw for inside the 50#mach oil 2-4

Coil guide box times/work

shift

Couplings By gum 50#mach oil 2-4

times/work

shift

Sliding By gum 50#mach oil 2-4

ponit times/work

shift

ELECTRICALUNIT MAINTENANCE

This production line adopts AC power supply. Electrical

system control part and the main circuit with control

transformer isolation. Ac contactor and electromagnetic

valve coil are AC220V, power supply by an independent

switching power.

This production line USES programmable controller (PLC)

to control, has the stable operation, reliable, easy to

maintain characteristics.

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This production line of leveling machine AC motor drive

with easy install and operate characteristics, it is an

advanced AC control system which can monitor the motor

speed, steering, torque and armature voltage and current .

Please refer to the production line circuit diagram, control

panel element layout diagram. Operating production line,

please be sure to refer to the production operation flow and

the matters needing attention.

II. The arlarm and troublesome for the hydrauic system ；

Problem 1 big nosice

Problem Reason Solution

Inhalation of oil filter pluggingOil Cleaning or replacement oil
Pump suction level is too low, the pump does not filter
air Oil To add a little hydraulic oil
Oil temperature is too high, to Work and reduced oil
generate steam temperature within the
specified temperature
Oil bubble Oil Error Change Suitable for
Health Inhalation hydraulic oil
Exclude air
Pump Wear and tear or damage (pump
not load operation) Repair or replacement of
fuel pumps
Mechanical Coupling (the original motivation Repair or replacement of
Vibration and pumps connected pieces)
Relief Valves Instability (adjusted pressure in To reduce the use of
excess of rated working pressure) pressure or replacement
valve
Mover Motor wear and tear or damage Repair or replacement of

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Problem 2: Pressure less than or completely stress-free

Problem Reason Solution

Pump Pump wear and tear or damage
overheating Inadequate cooling or cooling break Repair or replacement
Improving the cooling
water system
Pump less oil or Damage fuel pumps, fuel pumps suck air Refueling or
no oil Improper oil viscosity replacement oil
Relief Valves Plug holes due to oil pollution and Cleaning or
congestion (wear and tear or damage) replacement
Unloading Spool wear and tear or damage Clean or replace
valve

Problem 3 

Problem Reason Solution
Pump Non-working pressure Failure to exclude reference
non-opera Due to oil pollution or a long time to the phenomenon of two
ting does not work, Spool wear and tear or
ways cleaning or
damage Solenoid valve at both ends replacement
or an end-free signal Connected to the power
Fuel tank repair or
Oil Cylinder seals worn or damaged or a replacement of seals
bubble pipe junction leakage or valve Plugging or exchange seals
Health leakage

I. maintance

III. Protection and maintenance

1. Electric Equipment
The electric equipment in the machine should work in stable power

voltage. If the voltage is not stable, the E-equipment is easy to fail and

shorten their service life. The E-equipment should work in dry condition.

If they get damp, please dry them to go on working. Electric circuit

outside should be inspected and avoid electric leakage.

1) Regularly does the clean to the motor mesh (each week at least)
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2) The regular replenishment or the replacement motor lubricating oil

(each 3000h replaces)

3) Regularly does the cleaning up to in the electricity cabinet product

dust

4) Whether periodic inspection binding clamp does have to open

5) Abrasion series electricity part and so on of periodic inspection

motor carbon brush

2. Pneumatic system outline and maintenance

Useful pneumatic parts including: pneumatic cylinder, velocity modulation
valve, shuttle valve, solenoid valve, oil mist three associations and so on.

1) Pneumatic cylinder: The dynamic action installment is

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composed by pneumatic cylinder, the galvanization axis core,

around the lap, the piston and the gas seal. Easiest to lose is

the gas seal, the type has O, Y, V and so on. When using, if

perceived its working ability has the drop, maybe caused by

the gas seal or other component parts damage. Examination

method: Captures an air cylinder on the trachea, for

another end air feed, if has the gas to leak off from the

orifice, then determined is damaged for the seal or other

components.

2) Velocity modulation valve: Also is called the throttle valve.

Controls the air cylinder movement speed through the gas

current capacity the barometric pressure part. Usually it is

not easy to damage, if damages, possibly bursts for the valve

body or revolves the damage to be the result of.

3) Shuttle valve: The shuttle valve has two unidirectional with

an unidirectional division, the air current access has three,

in the feeling measured when relative more tremendous

pressure port, it does move the outlet pressure

demonstration for the more tremendous pressure

exportation, has the cone-way valve air current entrance to

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lock up. This valve usually uses in opening a book machine

to apply the brake and the tensity produces the different

pressure does uses in when the outlet uses, generally selects

the single entrance cone-way valve structure.

4) Solenoid valve: Is through the magnet coil when the

electricity has the electromagnetic force to impel the valve

core to complete the function valve. Our commonly used

valve has two Three Contacts, two five, three five and so on.

Here said the position refers to the valve body to have the

control air current channel the way, namely when some

"position" the air cylinder movement direction has

differently, "passes" refers is the gas in return route in and

out quantity.

5) Oil mist three associations: Means when the gas through,

the lubricating oil stored in oil cup was atomized then with

the gas enter the movement air cylinder to get up together

the lubrication, at the same time might the gas in moisture

separation, and the passable pressure-regulating valve has

controlled the exportation barometric pressure the

installment. Its structure composition is:

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Pressure-regulating valve, oil mist, mist separator.

3. Hydraulic system and maintenance

The hydraulic system divides into opens the return route and the

closed path, this one is the subordination open return route. The

hydraulic system by the oil station, the electromagnetism cross valve,

the hydraulic cylinder, the fuel pressure gauge and each kind of

function valve is composed

1) Oil station: Also is called the pressure to produce the station,

by the oil pump, the motor, the fuel tank, the chiller, filtrate

mesh and the direction control valve is composed, through

the motor impetus oil pump, squeezes out the oil in fuel tank

through the oil pump produces the system pressure, results

in the valve through the side the control to decide whether

sends in the pressure oil the closed path or to return the fuel

tank. When the solenoid valve opens, the pressure oil enters

the closed path to form the pressure, locks in when returns

to the fuel tank through the oil discharge mouth to be

unable to have the movement pressure. Through adjusts the

oil pump the pressure control bolt to the system pressure

which produces to carry on the fluctuation. When hydraulic

pressure station work, the mechanical noise should below 80

decibels, if has the unusual noise maybe the air entrainment

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or the seal is not good , should shut down and check

hydraulic pressure oil mass with mouth the mesh whether

stops up. Must regularly to clean filtrate mesh.

2) Electromagnetism cross valve: Through magnet coil circular

telegram when has the magnetic force to impel the valve

core about to control channel of the hydraulic oil function

valve, according to oil duct channel divides into : "O" "Y"

"H" "P" and so on. If the principle does not have the

movement when using, possibly has the following problem:

A. the magnet coil burns down

B. The valve core deactivation, this time the engine off for

examination, makes the corresponding maintenance service

3) Function valve: The function valve means through its

different internal structure completes the reduced pressure

in the system, the overflow, releases series function and so

on, after in use process like completes when cylinder some

movement cannot achieve this movement the corresponding

function, then maybe this function valve breakdown, must

promptly inspect and replace. The usual use function valve

includes: The cone-way valve, the overflow valve, the

pressure relief valve, and the sequence valve, contend with

the valve.

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4) Hydraulic cylinder: Is a function element in the hydraulic

system movement. It is composed by oil seal, the cylinder

body, the connecting rod, the piston and so on. The main

damage is the seal not good by oil seal damaged caused. If

eclipses, the thrust direction shake also has the possibility to

create the damage of the cylinder piston.

5) Hydraulic system pressure transmission medium for

hydraulic oil. The usual use viscosity in 25-100cst, according

to the temperature, the climate and the pressure needs to

make the appropriate choice. Usually uses VG46# to be

possible VG68# anti- to rub hydraulic oil.

NOTE IN USING:
1) The supply voltage is whether normal
2) Motor rotation side is whether normal
3) Whether the hydraulic oil is enough.
4) The oil temperature is whether normal, general control between 35 -55
5) Hydraulic pressure whether excessively high.

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