8X1600 Cut To Length

KINGJIME MACHINE LIMITED
METAL CUT TO LENGTH LINE

8x1600 MODEL
OPERATING
MANUAL
KINGJIME MACHINE MANUFACTURER 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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I. Introduction
Cut To Length Lines can do uncoiling levelering, measuring, cross-cutting to
length and stacking work. It mainly includes uncoiler, leveler, measuring, shearer,
conveyor, stacker, hydraulic system, pneumatic system and electrical system, etc.,
the line can make sure of accurate feeding and shearing. It can be widely used in
cold or hot rolling carbon steel and all the other kinds of metal materials
Cut to length line is controlled by PLC system. It has PLC controlled the length
measurement. The information of length, shearing numbers and speed can be
input to the PLC systems. When the cut length is reached, the machine can cut
automatically. The line speed can be adjusted, It has a gauge with high precision,
and whole line can work automatically and operate easily, smooth sheet can be
made.
II General warning and warning signal
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NOTE:
Do not approach it when the machine is working.
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Do not set the machine when the machine is working.
When the machine is working do not open the panel cover.
Protect the cable. Do not let something on the cable. Do not crush the
cable.
III Transport method
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IV.Command and electrical knowledge
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V. Technical proposal
. LIST OF EQUIPMENTS UNDER SCOPE OF SUPPLY:

1. Coil car
2. Double Cone Decoiler
3. Snubber Arm.
4. entry support peeler table
5. Pinch roll
6. roller table
7. Side Guide Roller
8. Leveler
9. Hydraulic Shearing Machine
10. measuring device.
11. Conveyor
12. stacking table
13. Hydraulic Systems
14. Electrical System PLC Control
4. DESCRIPTION OF EQUIPMENTS
1 ) Coil car :
Application:
The entry coil car will be hydraulically actuated. It will be used to Traverse and
load coil onto the mandrel of the decoiler.
To gain time while working, new coil is loaded to the coil car and lifted to the ma
ndrel position by hydraulic lift and the coil car start to move horizontally let the
mandrel go inside through the coil Then the loading car moves to the park positi
on.
Construction:
The coil car is a fabricated body of prime materials; mounted on hardened
wheels and axles with spherical roller Bearing. The lifting face must be of ‘V’
shaped design liners. The cradle (i.e. V – Shape frame) is raised and lowered by a
Guide rail and a hydraulic cylinder. The coil car traverse is accomplished by a
hydraulic motor with a gear. A drag chain is provided for routing the hydraulic
hoses for lift and traverse functions .
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2) Double Cone Decoiler

Application:
the decoiler can handle the coil and be capable of feeding the coil into the Cut to
Length Line, and also rewinding partially consumed coils, so they can be
re-strapped whilst still on the mandrel, before returning to Coil Storage Facility
for use at a later date.
Construction:
The coil is handling and collapsed by double head. Steel fabricated duly
machined, mounted on heavy duty shafts on anti-friction bearings. The
individual body of fabricated steel construction and the whole housing should
slide on sub base frames on guides with suitable lubrication arrangement.
Sliding face must be provided with liners bolted on the face.
pneaumatic controlled braking system is provided to minimize over running of
the coil with tension. A brake is provided to stop the line whenever the line stops
for any reason.
3). Snubber roll (Guiding Equipment)

Application:
Anti coil break roll and guiding the coil to the cut to length line.
A motor is driven Snubber, (pressure roller) to prevent the coil from clock
springing when the coil retention straps are removed. Grooves are required on
the snubber roll, to enable re-strapping of partially consumed coils when they are
rewound on the mandrel. The Snubber will be capable of driving in both feed
and retrieve directions.
Construction:
Snubber Roll is made out of Steel Pipe with suitable journals duly machined to
be mounted on anti-friction bearings. The Snubber Roll is coated with Poly
rubber. Snubber roll is driven by electrical motor with chain & sprocket system.
Snubber Roll and its Drive system is fitted on fabricated structure which in turn
is mounted on the adjacent structure of Pinch Roll body. Actuation of arm shall
be by hydraulic cylinder.
4). Entry support peeler table

Application
A hydraulically actuated peeling spade extending to the coil tongue on the
Un-Coiler to “peel off” the leading edge of the coil and then retract to the Entry
Pinch Rolls of the straightener. This enables the operator to remotely thread the
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leading edge of the coil without having to manually handle the coil.
The operator activates the positioning of the peeling spade at either end by
hydraulic cylinders, actuated by “push button” controls.
Construction.
Welded steel plate construction pivot mounted from entry pinch roll. Telescoping
and positioned by hydraulic cylinders
5) Pinch roll
Applicatation
The pinch roll will be used to feed-up the strip during threading and to press coil
tip from the leading of the strip.
Construction
The body of the Pinch Roll is fabricated out of prime plates and machined to
house the roll assemblies.
Pinch rolls are provided to pull the strip from the coil mounted on the decoiler.
Adequately sized pinch rolls are provided at entry of the rough leveler to ensure
that the sheet is not damaged by the pinching forces.
The pinch roll are capable of being lowered or raised during threading to accept
the leading edge of the coil. The top roll must deflect the strip from Uncoiler to
suit the pass line and actuate up and down by means of a pair of hydraulic
cylinders.
The pinching force developed by the hydraulic cylinders must present slippage
between pinch rolls and sheet.
Straightener Work Roll:
a) Quantity of Rolls – 4 Nos.
b) Roll Material – 42Cr Forged steel
c) Roller fabrication: Quenched and tempered
6) Roller table
Application :
It can transfer and support the coil steel to the final leveler.
7). Mechanical side guide

Application:
Width shall be adjustable manually with hand-wheel and movement shall be
accomplished by guiding shaft with Left Hand & Right Hand Thread on the
same shaft.
Construction:
A fabricated body with roller mounted vertically at two sides (2 Nos. rollers each
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side). Roller is mounted vertically.
8 ) leveler
Application:
the final leveler can flatten the coil steel and feeding to the cut to length line.
Construction:
Fabrication of main frame is done with prime plates & materials and Frame is
Stress Relieved. Good quality of welding system is used. Machining is done
accurate and precise. straightener is provided with hardened rolls. Material with
52 to 60HRC) Bearings provided for rotary function is Roller Bearings which is
grease lubricated. Upper and lower rollers have back up rolls to improve
straightening accuracy.
The lower machine bed and the upper machine frame holds working rolls,
supported by rows of short back-up rolls.
The back-up rolls rows are fixed to the upper frame and have a wedge
adjustment for set-up
The upper bridge and therefore the upper bank has an up and down parallel
movement to adjust the rolls penetration according to the material thickness by
electrical motorize and manual.
The upper frame is horizontally pivoted, i.e. it can rotate around a horizontal
axis perpendicular to the line axis to allow a deeper penetration of the entry rolls.
The upper frame position and therefore that of the rolls penetration are
controlled by pushing button.
The carrying structure of the machine is well dimensioned according to the
possible deformation and holds the upper frame movements controls.
The gear pinion-box with outlet universal couplings shafts and their double-joint
adaptors, drive the work rolls.
leveler rolls are driven via drives motor, gearbox, universal couplings.
and electrical cabinet.
9)Measuring Roller:
Application:
measuring the length cutting set from the PLC program.
Construction:
The measuring roller assembled will give the sense of length to be cut controlled
by encoder.
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10). End plate run out Pinch Roll

Application:
It can pinch out the last plate to the shearing machine without manual power.
Construction:
It includes of base, frame, pinch roll and motorize.
11).Hydraulic Shearing Machine

Application:
the shearing machine can cut the coil steel automatically giving the sense via the
PLC signal.
Construction
1. machine frame
The frame is entirely welded with steel plates, and treated to relive stress by
tempering, the two hydraulic cylinders are fixed between the housing. Rigid steel
frame of Shear are optimally designed to avoid weak section at load support and
is interlocked designed.Table of frame is welded together with support of plates.
Table top surface will fitted with Rollers .Rollers will rotate on antifriction
bearings .
The upper blades frame
The frame is entirely welded with steel plates, and treated to relive stress by
tempering. The upper blade is supported by eccentric sets and swing beam
cutting driven by hydraulic cylinder and nitrogen return cylinder. Hydraulic
drive, return of knife beam is smooth and prompt by accumulator or nitrogen.
Roller guide:-The upper beam is guided by four point rollers guide. A
replaceable hardened liner is provided for minimum wear. It eliminates
lubrication of guide .
12). Stacking table car

Application:
The stacker facilities shall be able to handle up to a maximum 10 Tons plate. The
stacker shall support the pile packs.
13). Hydraulic System

hydraulic Power Pack with pump is provided for the hydraulic functions in the
line and it will remain in our scope of supply which is as follows.
Hydraulic Power Pack is consist of:
• Standard accessories like temperature switch, filler and breather, etc.
Control valves:
• The control valves for each equipment or group of equipment is mounted on the
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respective equipment and piping.

• Each control valve / group of valves is provided with an isolating valve on
the ’P’ line and Check valve on the ‘T’ line for ease of maintenance.
14). Pneumatic systems:

Pneumatic controls is used at various equipments for actuations. Pneumatic
control valves is mounted on individual equipment and piped.
The pneumatic systems is consist of following.
• The piping on equipment shall consist of necessary flexible piping with push in
type of fittings for easy maintenance.
15). Electrical System and programming

The system has a complete control of the equipment by means of one
programmable PLC simenz company made in Germany.
The system is provided with a PLC in the main control desk like HMI (Human
Machine Interface). The parameters of work are incorporated in the HMI and
communicated with the PLC.
Operator Interface (HMI)
Since the major components of the Automation metal cut to length line solutions
are on Control Net™, all process and diagnostic information is available for
display and interaction with the operator. By pre-programming these displays
into proven user-friendly designs, we’ve made complex HMIs affordable.
Machine is supplied with the following screens:
Machine Overview –
Increases efficiency by providing the operator a visual display of drive and
machine parameters in both a bar graph and digital format.
Fault Summary – This screen identifies alarms and faults. When a fault occurs that
causes the line to shut down, all faults are identified and the first fault flashes.
Line Run Permissive – The line run permissive screen lists all drives, auxiliary
and other associated equipment required to start the cut to length line.
Automated Stop On Length or Diameter Set-up – The operator sets up the automated
stop on length or diameter counters via this screen.
Electrical System supply will remain in our scope and is provided with following
list.
The electrical system is consist of following
 • AC motors and its controls
 • PLC for interlocking and programming
 • All field elements like limit switches, proxies etc.
 • All control desks
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VI. Installation and Commissioning
1. Installation
（1） Installation of the frame: Level the frame with cushion plates
ensuring its tolerance under 0.1 per square meter before grouting.
Do not install until it’s fully dried and screw tight to the floor.
（2） During installing and dissembling, wrapped parts with felt when using a
crane or other tools which may damage the parts.
（3） Lubricate surface of seals and bolts during installation.
（4） Evenly tight all bolts.
2. Line Commissioning without material
（1） Start all moving parts in clockwise and anticlockwise, forward

or backward direction without load and check operation of
each part.
（2） Start main motor and run the machine without load in
forward and backward direction continuously for 1-2 hours and
check connection and operation of each part, also check the braking system of
the leveler. Do not start machine with load and check operation of each part until
it runs well without load, If anything abnormal occurs, stop the machine
immediately, fix the problem before you start again , machine running should be
smooth and consistent without vibration and noise. Do not apply the line in
production until it has successfully.
passed the commissioning. Load weight should not exceed 80 percent of its
maximum weight before its fully accommodation.
VII. Lubricating System

The line is lubricated by both pump and manual mode. Pump
mode is used in parts needed for concentrated lubrication like leveler, manual
mode is used on separate parts by using a lubricating gun, or concentrated parts
which is not likely flow if using a pump mode.
1. Grease oil
Calcium base grease for the back up bearing or the rollers’ bearing.
it should lubricate one time each day, please use the calcium base grease.
Please full the grease oil according to the gauge.
2. Gear oil
AZOLLA-ZS-68 for the gear box
The gear box should lubricate with gear grease one time a year. the oil will be full
to LS-3” it is enough.
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3. ISOVG32 or VG46 for hydraulic cylinder and power pack.

ISOVG32 or VG46 for hydraulic system. It work after 1500 hours, please renew.
the oil reach to full gauge from the oil watch.
4. You will prepare for the oil according to the gauge.
VIII. Line operation manual with matereial

The Line uses 3 phase 50HZ,380V, Contactor and electric magnetic winding uses
220V,
power is supplied by using Switch, Insulating converter is applied to ensure the
security.
Please refer to the drawings and follow operation procedure.
Operation sequence
1.Charging
Connect the power and start the hydraulic station, hydraulic coil car, driven by
oil cylinder, will support the coil plate up to the center of hydraulic charging
machine. Then lifting the plates, so the center will match with uncoiler’s. Oil
cylinder for pushing on 2 sets of uncoiler will centrally push.
2. Uncoiling, pressing and guiding, pinch
Oil cylinder for pressing and guiding pressed, thus would made the
roller(covered with PU) closed pressing plate’s bull nose, cut the package strap,
switch pressing and guiding motor, close the clutch of uncoiler, so to make the
plate head stretch out, adjusting up-and-down balanced device of shovel head
and stretching out of it to connect with the plate head, as the plate head reach to
a stated length(about 400mm—500mm) of shovel head device, power-off the
pressing and guiding motor, coil opener started to work to straighten the arc
head, reset the opener, then switch on the motor to making the heads slowly
extended about 400mm, stop it, then coil opener will work as before. Repeat
several times until the plate head into pinch device.

2. Pinch Roll
Close the clutch and switch on alternative-current motor for pinch roll,
hydraulic cylinder will press down the roller, pinch device starts to work. Lifting
the pressing and guiding arm and cutting the power, the plates will move
forward under the function of pinch device.
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2. Guiding
Guiding device makes plates axis centering to axis of shearing machine (the line
axis) which had been adjusted, in order to avoid the plates from shifting.
2. Leveling
Plates enter into leveling machine, then adjust the clearance of it for leveling.
Cut to length
When the flattened plates runs to cut to length machine, the machine will cut the
heads, encoder roller pressing down, inputting the related data, then switch
“auto-op.” button to make cutting automatically. Gauge length is controlled by
encoder information feedback. Electric system will automatically cut the power,
brake will lock power resource, shearing machine cut at this moment. The
machine will reset when finished the above movements. Power-off the machine
and check the gauge length. If there’s some error, please modify if. Press the
“auto-op.” button to conduce next shearing.
Falling
Through pendulum pinch machine, the cross cutted plates will be controlled by
pneumatic falling frame, so to falling the plates on surface of unloading dolly,
pushing device will stacking the falling plates under the function of air cylinder.
When the weights of falling plates reached to 15 T, it is for packing.
3. The adjustment for leveling machine

Material of roller axle on the machine is 40Cr, with the process of
forging—processing—quality adjusting—processing—quenching—processing.
With the difference of plate’s thickness, leveling speed could be directly
controlled by direct-current speed adjustable motor.
Pressing amount of top roller could gradually be adjusted base on different
thickness of plates. Watch leveling conditions for the best result.
Top roller device has two sets of pressing motor which could pressing and lifting
individually and synchronously. Manual rotary hand shank to micro-adjust
pressing and nip angle (front and back). In order to prevent the roller from
becoming arch, installed up-and-down supporting wheel will closely contact the
up-and-down leveling roller through adjusting incline lump. In normal operation,
gaps in all connections shall definitely be forbidden. Having some pre-tighten
power of stud when connect the machine and crossbar is highly recommended.
During debugging and running conditions, it need to check whether connections
of all parts if loosen.
4. Common faults and solutions:
Precision:
Gauge precision not as demanded.
Adjusting the electric control part: figure out data of encoder and input it.
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Diagonal precision not as demanded

Adjusting guiding device;
Adjusting pressing amount on both side of machine;
Checking whether the consistent of leveling machine and cut to length machine
are equilibrium and parallel or not.
Checking whether thickness of plates is thick or thin;
Checking whether brake is in normal or not;
Flatness of the plates

Adjustment: whether the pressing amount of roller on surroundings in
consistent.
Adjustment: plate entering style is up-and-down, this line is adopt upper
entering.
Cutting burr of the plates:

Adjusting the clearance between scissors.
Using double plane blade rather than concavo –concave blade.
Changing new blade after long time use if blade has some tearing and burr.
Plates gouge
Cold plate line and stainless line could not use hot plate.
If any scratch of transitional table and rollers, it need to repair on time.
Service instruction of hydraulic system

The recommended viscosity is 15—200cst;
Hydraulic oil shall be ISOVG32 or VG46;

Oil temperature shall be －5℃—＋70℃;
The rated working pressure shall be 16Mpa, sudden Max. pressure is 12Mpa,
other pressure is adjusted by overflow valve at range of 0—12Mpa;
In order to prevent oil becoming polluted which would affect working

performance and longer the system life. After first month application, hydraulic
station needed change or filtering, since then every 6 month for once;
Overflow valve usage and maintenance:
Oil amount of it is variable from different working amount which could adjust
and balance the flow rate, thus will remain the pressure stable. If no power at all
which would caused by oil pollution or blinding of valve core, it needed to wash
the valve.
Electric magnetic reversing valve is the main components used to reversing oil
route which controlled by electricity. There are two problems that would cause
the valve dead:
Because of oil polluted. In this case, manual reversing the valve first, then make
out of the problems exists. If so, it need to wash or change a new one.
No signal on electric system, check the circuit and connect power.
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Section VII. 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)
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 composed by

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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 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:
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
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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 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
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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.
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.
4. the lubrication system

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
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straightener box
slitter box
recoiler box
scrap winder box

Calcium
Bearing for By Gum 3 months
grease
slitter
Rail for inside the 50#mach oil 6 months
sliting head box
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
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7． Service instruction of hydraulic system

a. The recommended viscosity is 15—200cst;
b. Hydraulic oil shall be ISOVG32 or VG46;
c. Oil temperature shall be －5℃—＋70℃;
d. The rated working pressure shall be 16Mpa, sudden Max. pressure
is 12Mpa, other pressure is adjusted by overflow valve at range of
0—12Mpa;
e. In order to prevent oil becoming polluted which would affect
working performance and longer the system life. After first month
application, hydraulic station needed change or filtering, since then
every 6 month for once;
f. Overflow valve usage and maintenance:
Oil amount of it is variable from different working amount which
could adjust and balance the flow rate, thus will remain the pressure
stable. If no power at all which would caused by oil pollution or
blinding of valve core, it needed to wash the valve.
g. Electric magnetic reversing valve is the main components used to
reversing oil route which controlled by electricity. There are two
problems that would cause the valve dead:
i． Because of oil polluted. In this case, manual reversing the valve
first, then make out of the problems exists. If so, it need to
wash or change a new one.
ii． No signal on electric system, check the circuit and connect
power.
h. Common faults and solutions:
FAULTS REASONS SOLUTIONS

Oil pump suction air:
1.blinding of suction oil filter 1.wash or change a new filter
2.lower of the oil level, pump can not 2.fill in hydraulic oil
suction oil 3.lower the oil temp. to a
HEAVY 3.higher of oil temp, has vapour stated temp.
Some foam in oil:
NOISE 1. use incorrect oil 1. change to a proper oil
2. suction air 2. romoving sir
Oil pump wore out or damaged which Repair or change a new one
can not overworked)
Machine vibration (universal coupling Repair or change a new one
loosen)
Pressure exceed the rated voltage, thus Lower the operation pressure or
make the overflow valve unstable. change a new one
Motor wore out or damaged Repair or change a new one
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Too hot of oil pump:

1. pump worm out or damaged 1.Repair or change a new one
2. lack of cooling or interrupt cooling 2.improve cooling system
Lack of oil supply or no supply:
LACK OF 1.Pump damaged 1. Repair or change a new one
PRESSURE 2.pump suction air 2. filling oil
OR OUT OF 3.oil viscosity improper 3. change new oil
IT Oil impurity caused blinding the small Wash or change a new one
hole in overflow valve core
Outloading valve core jammed(wore Wash or change a new one
out or damaged)
OIL PUMP 1.valve core jammed, because of seal 1. wash or change a new one
STOPED rings wore out or damaged.
2.electromagnetic double ended or 2. connect power.
single end no electric signal.
OIL HAS 1. oil cylinder or seal rings word out or 1.repair oil cylinder or change
FOAM damaged. seal rings.
2. pipe leaking oil or valve connection 2.stop leaking or change seal
leaking rings.
i. Lubricate list:
NO. LUBRICATE PARTS LUBRICATE GREASE PERIOD

MODE BRABD
1 Uncoiler brake In tank 50 machine oil
#
6 month
2 Seam needle decelerator of In tank 50# machine oil 6 month
pressing and guiding
machine
3 Decelerator of leveling In tank 50# machine oil 6 month
machine
4 Power distributing case In tank 50# machine oil 6month
5 Lubricate part of leveling Oil gun 50# machine oil 3 times/turn
machine
6 Lifting worm gear and Open the Calcium base 3 month
worm rod of leveling cover grease
machine
7 Leveling roller bearing Manual Calcium base 4 times/turn
lubricate grease 50#
pump machine oil
8 Slide guide of cut to length Oil gun 50# machine oil 4 times/turn
machine
9 Guiding track of uncoiler Oil gun 50# machine oil 2-4times/turn
10 Guiding pole of guiding Oil gun 50# machine oil 2-4times/turn
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device
11 Both side of cross universal Oil gun 50# machine oil 2-4times/turn
joint
12 Bearing stand of pressing Open the Calcium base 3 month
and guiding rubber wheel cover grease
13 Bearing stand of pinch Open the Calcium base 2 month
device cover grease
14 Slide stand of pinch device Oil gun 50 machine oil
#
2-4times/turn
15 Bearing stand of rollaway Open the Calcium base 3 month
nest cover grease
CHAPTER VII PNEUMATIC UNIT MAINTENANCE
Cut to length line using pneumatic parts including: pneumatic cylinder, control
valve, shuttle valve, pressure reducing valves, solenoid valves, lubrication
controller, each unit describe as follows:
1.Pneumatic cylinder
2.The pneumatic cylinder is a masterpiece of power components, consisting of
cylinder tube, electroplating axis, front cover, piston and oil seals.The most easily
loss part is oil seals, U-, O-two type . When the pressure output is weak or not
action, please first test, then change oil seal. (Method: Unplug the pipe of one
side , the other cylinder pipe leak.)
General speaking ,lubricating oil shortage will cut the service lift, please note.
3.Speed control valve

Speed control valve's function is control gas flow of pipe , in order to control
cylinder walk speed. It is the structure by needle valve and the valve knobs, when
clockwise rotation will reduce the air inlet volume, counter-clockwise will
increase the air inlet volume , through turn the knob to adjust the needed
cylinder speed, the component is half permanent components, is not easy to
damage.
3.Shuttle valve
The shuttle valve function is sense two ports pressure to the third port. Partakers
26
the two the extended single bead beads shuttle , the system is a single bead
shuttle. When the the uncoiler brake can not adjust brake strength, please adjust
this valve.
4. the reducing valve

Reducing valve used to reduce the system pressure. When the knob clockwise
rotation to increase pressure, counterclockwise rotation to reduce the pressure.
See pressure in table . it is composed by the diaphragm and spring. After long
time usage,it leak air or sound, then inside diaphragm damaged ,can not increase
pressure ,need to replace an new one .
5.Solenoid valve
Used for control the access of air，it is same as the manual direction valve，only
it uses electric power excitation to produce magnetic force to drive sliding
column.
Please pay attention to the voltage is DC or AC, and the what is the voltages ,this
system should use AC-220V. When the air cylinder can notwork. Please check
whether the coil burn out (short out),then replace coil.
6.Lubrication control valve

7.The function is to supply clean oily and waterless air Therefore, it is composed
of three parts as follows:
A).Filter: there are screen and drain valve at the bottom ,when air out from
filter,the moisture and dust will be block by this valve . the water will drip and
accumulate to a certain height at bottom, then get off.
B).Regulator:regulator the system pressure,when clockwise rotation to increase

pressure, counterclockwise rotation to decrease pressure.
C).Oil atomizer: for air does not contain oil, so it is necessary to have oil atomizer
for lubricating parts , when the air out of oil atomizer with a mist pressure to
lubrication parts , when Defective oil mist lubrication, the impact is very large ,
will result in accelerated wear of each part. Before use or using, should always
pay attention if enough oil in Oil atomizer. when knob open ,there is air in use,
there will be oil drips from a steel pipe, about 1 to 2 seconds for one drop.
27
CHAPTER VIII HYDARAULIC UNIT MAINTENANCE
This hydraulic system is open circuit which include hydraulic pump,motor,

electromagnetic direction control valves,hydraulic motion cylinder、pressure
Gauge,oil tank,heat exchanger. In order to let this system normal movement,
must usually pay attention to the operation and maintenance of every parts.
As following
1.Hydraulic pump
The system uses the variable capacity plunger pump,,the highest voltage 140
kg/cm2,common pressure setting in 70-100 kgf/cm2, can all day pressure
running.output is 40L/min.there is pressure adjusting screw on the pump:
clockwise→increase;anticlockwise→decreasing. Flow volume adjust
ment :clockwise→decrease,anticlockwise→increasing. When the pump running，
noise is below the 80 decibel, if have unusual noises, may be inhaled air , bad seal,
should stop to check. If you used years or months, the noise occurs, the oil filter
mesh may block , should be clean. Normally about a year cleaning a mesh, if
surrounding environment dirty, should increase the cleaning times.
2.Hydraulic oil
This machine use mineral oil, it is recommended to use for VG46 or VG 68
grades, viscosity 25-100cst. The oil temperature in 35℃~ 55℃ is best .Change
with new oil every year . In order to make the machinery working properly and
extended service life. should avoid oil pollution and water mixing. When the
liquid tank descended, may have some parts oil leakage, should check
immediately.
3.Hydraulic cylinder
This system oil cylinder maximum pressure is 140 kfg/cm2, using U synthetic
rubber oil seal, long life, good sealing and specifications standardization, change
more easily, as long as the hydraulic oil to maintain good condition, which is not
easy to damage. When the hydraulic system pressure is normal, but the oil
cylinder weakness, namely should tear open next examines, replace the new one.
28
4. Electromagnetic direction valve

This hydraulic system use AC-220V Electromagnetic valve is half permanent
products, in addition to coil possible damage , the other parts are not easy to
damage. When oil cylinder cannot function, may have dirt gets stuck, should be
removed for cleaning, prevent coil burn out. Before using, should pay attention
to the voltage is correct.
5.Oil tank
Oil tank is the place for oil storage，should pay attention to join the oil viscosity is
correct, oil level whether standard,the oil temperature is normal 35℃~ 55℃,and
pay attention to regular cleaning, once a year.
29

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KINGJIME MACHINE LIMITED

METAL CUT TO LENGTH LINE

KINGJIME MACHINE MANUFACTURER LIMITED

II General warning and warning signal

When the machine is working do not open the panel cover.

III Transport method

IV.Command and electrical knowledge

. LIST OF EQUIPMENTS UNDER SCOPE OF SUPPLY:

2) Double Cone Decoiler

3). Snubber roll (Guiding Equipment)

4). Entry support peeler table

7). Mechanical side guide

side). Roller is mounted vertically.

10). End plate run out Pinch Roll

11).Hydraulic Shearing Machine

12). Stacking table car

13). Hydraulic System

respective equipment and piping.

14). Pneumatic systems:

15). Electrical System and programming

VI. Installation and Commissioning

2. Line Commissioning without material

（1） Start all moving parts in clockwise and anticlockwise, forward

VII. Lubricating System

3. ISOVG32 or VG46 for hydraulic cylinder and power pack.

4. You will prepare for the oil according to the gauge.

VIII. Line operation manual with matereial

2. Uncoiling, pressing and guiding, pinch

a stated length(about 400mm—500mm) of shovel head device, power-off the

several times until the plate head into pinch device.

3. The adjustment for leveling machine

Diagonal precision not as demanded

Flatness of the plates

Cutting burr of the plates:

Service instruction of hydraulic system

Hydraulic oil shall be ISOVG32 or VG46;

In order to prevent oil becoming polluted which would affect working

Section VII. Protection and maintenance

2. Pneumatic system outline and maintenance

1) Pneumatic cylinder: The dynamic action installment is composed by

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

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

3. Hydraulic system and maintenance

pressure gauge and each kind of function valve is composed

movement the corresponding function, then maybe this function valve

4. the lubrication system

NO. lubrication method oil model circle time

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

gear box for inside the 50#mach oil 6 months

gear box for inside the 50#mach oil 6 months

gear box for inside the 50#mach oil 6 months

scrap winder box

Rail for inside the 50#mach oil 6 months

sliting head box

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

Coil guide box times/work

Couplings By gum 50#mach oil 2-4

Sliding By gum 50#mach oil 2-4

7． Service instruction of hydraulic system