Dppevy FOUR-HIGH COLD BREAKDOWN MILL PART 3 PAGE 26 Davy McKee 3.4 SPECIAL MAINTENANCE 3.4.1 Changin: a Filter Element (Servo-valve Manifold) am @ «3 (4) (5) Shut down the power unit pumps. Check that the system pressure is vented by observing system pressure gauges. It is recommended that hydraulic accumulators stop valves are shut to isolate the accumulators from the circuit. Remove filter bowl and element, replace with new element. Open accumulator stop valves. Start duty power unit pumps. 3.4.2 Changing a servo-valve a (2) a) @ 3) (6) m we «a (10) Shut down the power unit pumps. Check that system pressure is vented by observing the system pressure gauges. Tt is recommended that hydraulic accumulator stop valves are shut to isolate the accumulators from the circuit. Operate the valve controls to ensure that the circuit served by the valve is fully unloaded. as a further Precaution it is recommended that local vents or test connections are cracked open to release any residual pressure. Disconnect electrical leads from valve solenoids. Slacken the socket-head capscrews securing the valve to the manifold block and remove the screws. Remove the valve making sure that the ‘0’ ring seals are retained. If a new valve is not fitted immediately a protection plate should be bolted in position to prevent the entry of dirt. Reposition the ‘o' ring seals, fit the new valve and tighten the capscrews. Reconnect the electrical leads. Open the accumulator stop valves ad restart the duty power unit pump.Davy McKee FOUR-HIGH COLD BREAKDOWN MILL PART 3 PAGE 27 ay (2) operate the valve controls to pressurise the valve cixcuit and crack open local vents or test connections to bleed air from the system. Check valve and vaive conections for leaks. 3:4,3 Roll Load Cylinders 3.4.3.1 Removal of Roll Load cylinder from the Will m @ (3) @ ) 3) m (3) 9) withdraw the rolls from the mili. Refer to PART 2 ~ BACK-UP ROLL CHANGE. Vent roll load system pressuxe and shut down the power unit. Close the stop valves to accumulators to isolate them from the cireuit. Disconnect the hydraulic and electrical services from the cylinders. Disconnect the hold down cylinder transducers from the cylinder by removing the upper mounting bracket from the cylinder. Lower the hold down cylinder/transducer away from the cylinder and fit the ram/cylinder brackets in position to prevent separation. Move the roll load cylinder removal trolley into position below the cylinder. Operate the hand-pump on the trolley to raise the cylinder from its mounting. Withdraw the trolley, complete with cylinder, along the back-up roll change rails. Transfer the cylinder complete with trolley to a clean workshop environment for dismantling. Keep cylinder vertical at all times. Replace reconditioned cylinders in reverse order to that given above. 3.4.3.2 Dismantling Roll Load Cylinder note: am Dismantling must be carried out in a clean environment. Utmost cleanliness must be observed throughout. Components should be placed on a clean bench top and care must be exercised at each stage of dismantling. Remove the brackets which hold the ram and cylinder together.Bypav FOUR-HIGH COLD BREAKDOWN MILL PART 3 PAGE 28 Davy McKee (2) Release the lifting plates and anti-rotation key from the cylinder by removing the securing bolts. (3) Separate the cylinder ram. (4) Unscrew the chamfered retaining ring and remove the seal Packing, inspect the seal packing and ring facing for freedom from damage. Check that the cylinder bore is free from scoring or corrosion and rectify by honing as necessary. (5) Engure that the ‘0’ ring seal, under the chamfered retaining ring is free from damage or wear, renew as necessary. (6) Check the condition of the anti-rotation key and its associated recesses. 3-4.3-3 Cleaning the Roll Load Cylinders Remove the hydraulic seals from the ram, degrease the internal faces and items using ‘INHIBSOL' CAUTION NINHIBSOL" must not contact the seals (1) Wipe the cleaned surfaces, including the seals, with industrial tissue paper 'KIMWIPE". Ports and inaccessible faces to be blown out with compressed dry air before wiping. (2) Lightly of1 all items, excluding tapped holes, using the same fluid ag used in the hydraulic system. DO NOP apply oil to the threaded holes as this will adversely affect the application of LOCTITE to threads during the assembly procedure NOTE: After assembly the connections must be fitted with metal plugs to exclude foreign matter from entering the cylinders until the hydraulic connections are made. If the cylinders are to be stored, machined surfaces should be protected by a suitable rust preventive agent.(Dp FOUR-HIGH COLD BREAKDOWN MILL PART 3 PAGE 29 Davy McKee 3.4.3.4 Assembly and Replacement of Roll Load cylinders NOTE: During assembly, ‘'LOCTITE screwlock 242' must be applied to all screw threads, and screws tightly secured. Refer to Drawing No. 314929 for cylinder assembly details. os) After cleaning and oiling, the cylinder should be lowered carefully over the ram, complete with seal, taking care not to damage the seal. (2) Screw in the air bleed valve breather plug on to the side of the cylinder. (3) Refit the lifting clamps which hold the cylinder and ram together. (4) Place the cylinder back in position, using the reverse Procedure to that used for removal. (5) Remove the lifting clamps and refit the position transducer mounting brackets. Connect the transducers to the brackets. Remove the lifting eye bolts. (6) Connect hydraulic and electrical services to the cylinders. (7) Replace the rolls in the mill with the roll load cylinders in position. (8) Start roll load hydraulic system as detailed in PART 2 - OPERATION. Pressurise the roll balance rams, and carry cut the procedure for preparing mill for commencement of rolling in accordance with the MILL PLANT MANUAL. (9) Re-zero the position transducers, as detailed in the Systems Instruction Manual. (10) Carry out normal procedure for preparing the mill for commencement of rolling- (11) Set up roll gap, using pushbuttons on the operators control panel, as detailed in the Systems Instruction Manual. (12) Bleed air from the roll load cylinders, using the bleed valves provided (see 3.1.9 SAFETY REQUIREMENTS).Davy] FOUR-HIGH COLD BREAADOW Hau parr 3 PAGE 30 Davy McKee 3.4.4 Replacing an Accumulator Bag (1) Shut down all pumps. Isolate the accumulator from the system using the shut off valve. Slowly open the 3.4.5 accumulator safety valve manual bleed if automatic release feature is not incorporated in the system. @) weave venting for several minutes until fluid flow from the accumulator is heard to stop. Deflate bag by depressing the gas valve bore until all nitrogen is expelled. (3) Remove the accumulator for stripping down. @ Strip the accumulator, remove the bag and replace with a new one. (5) Re-fit the accumulator onto its mounting. (6) Pre-charge the accumulator tc the correct pressure with nitrogen. (7) Clese manual bleed valve cn the safety valve. Open accumulator shut-off valve. (8) Start all pumps to refill the accumulator. (9) Top-up the reservoir to correct level. Edge Trimmer Knife Change, Sharpening and Set-up Procedure General Before attempting any maintenance work on the trimmer, isolate the trimer and adjacent machines electrically, hydraulically and pneumatically. Electrical isolation should be done at the control room. Air supplies can be turned off at local stop valves. Hydraulic supplies may be turned off at valve stand stop valves. The quality of the cut edge can be improved, and life expectancy of the knives increased, if the following recommendations are followed: » Engure that the trimmer knives are handled with care and protected against corrosion by coating with oil or grease. 2) Engure that the knives are kept apart from each other during transport or in storage; preferably in a wooden rack. They should be kept in a dry area free from acidic fumes and excessive heat or cold. 2 Engure that the reground knives are within the tolerances specified in Re-grinding Tolerances (see Page 40).[Dpevy FOUR-HIGH COLD BREAXDOWN MILL PART 3 PAGE 31 Davy McKee 4) Ensure that the knife clearance is as specified. 5) Ensure that the knives and spacers are clean and dry. 6) Ensure that the knives and spaces are free from burrs or blemishes. Rectify as necessary. knife Removal (Drawing No. 319848) n Depressurise the hydraulic mut, securing the knife to the shaft, by slackening the socket head piston in the side of the nut. | Retraction of the piston removes the pressure in the nut. 2) Rotate the nut by hand and remove from the shaft. 3) Remove the spacer from the uppex shaft. 4) Remove the support ring from the lower shaft. 5) Remove the knives. Knife Replacement knife Installation (Drawing No. 319848) The shafts, knives, spacers, etc-, should be wiped clean with lint free cloth to avoid particles of dirt which may cause interference when making the horizontal clearance settings. v Fit a knife against the top arbor spacer on either the arive-side head or the operator side head. 2) Fit the outer spacer against the knife on the top arbor. 3) Fit the AMPEC nut to secure the top knife as follows: a) Ensure that the thrust ring is not projecting from the face of the nut. To push the thrust ring back into the nut it will be necessary to firet release the socket head piston in the side of the nut. b) Screw up nut by hand. ¢) ‘Tighten up tomay bar. a IMPORTANT - back off by 10° = 15° e) Screw in socket head piston to load nut.Da) FOUR-HIGH COLD BREAKDOWN MILL PART 3 PAGE 32 Davy McKee ene K-TYPES Actuated by socket key. Compact design, big range of sraded sizes. Sealed system — only a socket key to actuate. No bleed-off vent, Standard-Series K-6.1 and K-6.2 Standard-Series K-7 with transverse pistons ~ flat profite with axial pistons — slimmer profile “yom 46.3 har onty one om a) a) ep oe as Toe Roy ee i Hee : RE a 1 ot ane re ao tra a He Treteting (aval § of 2,4 oF 8 mm forthe fess sole aocheaton 3 Standard finish: — chemi-black, temperatures up to about 120° C, knurled, and 2 oF 4 tommy bar Roles for Dertar hand: ling. Large secenes, kevnays oF oroirusions in the counter-tace thould be soe ‘Special equipment and special sizes a cegular feature of our production programme. cM necessary isieet larger arntec-type fe rut canaot be found, cetals of special ey are {valaple on request. — For Fitvoes, GX:tyaes and Hotvaes see apprace ste Alley seelt or chemi-nickelling, Sogeil finuines tor higher sheet, Further ceugat san be seen in Our soecia c temperatures of apcut 180°C and 280°C, {Carge seas ane ngher clamp-torees upon request FI. 3-1Dp FOUR-HIGH COLD BREAKDOWN MILL PART 3 PRGE 33 Davy McKee 4) Fit a knife against the spacer of the bottom arbor NOTE: Engure that the top and bottom knives do not come into contact before securing the bottom knife. 5) Fit the support ring against the knife 6) Fit an AMTEC nut to secure the bottom knife as described in operation 3) n Repeat operations 1) to 6) for the other head Setting of Horizontal Clearance and Vertical Overlap Between Knives Use the hand-wheel operated screw-jack on the rear end face of each head to adjust the horizontal clearance to a value of 10% of the thickness of the material to be trimmed. Check the clearance at four points, minimum, round the periphery of the knives. Use the hand-wheel operated racks on the top face of each head to adjust the knife penetration (overlap). A spring-loaded plunger is provided to lock the hand-wheel. Tt is recommended that for the materials to be trimmed in the thickness range 0.2 to 2.0 mm the initial overlap is set at 50% of material thickness for the thin strip to zero for the thick strip. Tt may be found in practice that the performance of the trimmer can be improved by deviating from the suggested settings. The customer shuld endeavour to establish his own settings based on running practice for this particular machine. For maximum knife life, as little overlap as possible should be used.Davy) FOUR-HIGH COLD BREAKDOWN MILL PART 3 PAGE 34 Davy McKee knife Grinding procedure (Figure 3.2) NOTE: TRIMMER KNIVES ARE RE~SHARPENED BY GRINDING ON THE FACES AND DIAMETER REMEMBER Grinding wheel ‘burn’ is the greatest enemy of the high alloy steel knives. Once a knife is burned it cannot be reclaimed, aor will it ever again give a satisfactory service. v Knives may be re-ground to a MINIMUM thickness of 20 om and 171 mm diameter 2) Knives should be ground using the maximum possible wheel-traverse speed with a very light cut - 0,03 om MAXIMUM per pass. The griding wheel should be supplied with an ample flow of coolant, fed as near as possible to the wheel/job contact point. 3) Recommended grinding wheel, or equivalent: NORTON 32A6 OT avG 4) it is recommended that sufficient metal is removed to produce a clean edge, then a further amount removed equal to 508 of the amount already removed, i.e. total ground-off = 1.5 x amount to produce clean edge. 5) After grinding the burrs should be removed using an oil-stone yort 1, Take care not to damage the cutting edge when removing burrs 2. Inspect each knife to ensure that the tolerances shown under the heading Re-grinding Tolerances have been achievedFOUR-HIGH COLD BREAKDOWN MILL PART 3 PAGE 35 Davy McKee Re-grinding Tolerances J pS FIG. 3.2 - Re-grinding Tolerances A (Outside Diameter)... ..-. Fixed: dimension 261.5 om or 281.4 mm B (Parallelism) sees eres Within 0,005 mm ¢ (Flatness) tea ++ Within 0.02 mm NOTE: Refer also to the information detailed on Drawing No. 317146. 3.4.6 Scrap Cutter Blades, Sharpening and Set-up Procedure Refer to the information detailed on Drawing No. 319850 overleaf.(Dypevy) BOUR-HIGH COLD BREAKDOWN MILL PART 3 PAGE 36 Davy McKee 3.4.7 Coil Preparation Unit Shear Blades Removal, Sharpening and Set-up Procedures (Drawing Nos. 316264 and 316267) Machine Tsolation Isolate the shears and adjacent machine electrics and hydraulics. A manual hydraulic shut off valve is provided on the valve stand serving the shear for this purpo: Electrical isolation must be carried out at the control room. Refer to the electrical manual. UNDER NO CIRCUMSTANCES SHOULD ANY WORK BE CARRIED OUT ON THIS MACHINE WITHOUT FIRST ENSURING THAT THE MACHINE IS FULLY ISOLATED Knife Removal Refer to the slade change Procedure detailed on Drawing No. 316267. » Slacken and remove the screws which secure the top knife to its carrier 2) Remove the knife 2 Remove the bottom knife in a similar manner, taking care not to lose the shims from behind the knife Care of Knives, Re-grind and Setting The quality of knife cutting edges can be improved and the life expectancy extended if the following recommendations are followed: NOTE: Industrial gloves should be worn at all times when handling knives » Ensure that the knives are handled with care and protected from corrosion 2 Knives should be kept apart from one another, preferably in wooden racks 2 For optimum performance, the knife clearance should be approximately 108 of strip thickness. However, it is not considered practicable to adjust the shear knife gap at each change of thickness of strip passing through the line. The best setting for the full range of thicknesses will be found by experiment, but can be expected to be set to favour the thin strip.(Dow FOUR-HIGH COLD BREAKDOWN MILL PART 3 Davy McKee PAGE 37 4 Each knife has four cutting edges and has only to be turned over to present a new cutting edge. 5) If all cutting edges are dulled then the knife must be re-ground. only grind on the face of the knives, not on the edges. Knives should be ground to tolerance specified ‘on Drawing No. 316267. Replacement of Knives Refer to the procedures detailed on Drawing Nos. 316264 and 316267. Belt Wrapper Belt Tracking Adjustment ‘This unit is designed to operate with a nylon belt. ‘The eccentric bearing cartridge housings fitted to the two rollers adjacent to the tension roller, are set so that the 10 m eccentric adjustments are "the same way" for both bearings of each roller- ‘The two rollers are then parallel to each other. The following instruction should be followed for tracking adjustment :- IF BELT MOVES TO OPERATOR-SIDB: Standing at the drive side of the belt wrapper adjust the rear top roller at the drive side eccentric bearing by turning clockwise until the belt stabilises. If the extreme forward position is reached (i.e. the bearing cartridge is turned through 180°) before the belt tracks correctly, then leave the top eccentric fully forward and adjust the bottom drive-side bearing in an anti- clockwise direction. IF BELT MOVES TO DRIVE~SIDE Standing at the operator-side of the belt wrapper adjust the rear top roller at the operator-side eccentric bearing cartridge by turning anti-clockwise until the belt stabilises. If the extreme forward position is reached (i.e. bearing is turned through 180°) before the belt tracks correctly, then leave the top eccentric fully forward and adjust the bottom rear bearing of the operator-side in a clockwise direction. REMOVAL AND FITTING OF BELT The procedure for removal of a worn belt is as follows: v Retract belt wrapper to the parked position away from coiler drum.jo) FOUR-HIGH COLD BREAKDOWN MILL PART 3 PAGE 38 Davy McKee 2) Fully retract belt tensioning cylinder. 3) Isolate hydraulic supply to the belt wrapper unit to ensure safety of maintenance personnel. 4) Remove the four packing pieces which provide bridging between the inner and outer frames of the wrapper. These packing pieces are fitted on the drive-side of the wrapper frame and each is secured by three through bolts. 5) Remove the packing piece which bridges across between the front arm frame and the wrapper nose piace. 6) Unshackle the drive-side front arm lifting cylinder at its elevis connection with the arm. This is done by undoing two screws and removing the keep plate. Drive out the connecting pin and lower the cylinder to a safe position. n he belt can now be slid out sideways from the wrapper ‘The procedure for fitting a new belt is as follows: 1) 2) 2 4) 5) 6) ay frame. Adjust both eccentrically-mounted tracking rollers so that they are at the maximum eccentricity towards the rear of the wrapper frame (i.e. roller axes should be 10 mm to the rear of the boss centres). ‘These rollers are those fitted one above the tension roll and one below it. Slide the new belt into the. wrapper frame from the arive-side of the machine. Refit the five packing pieces. Reconnect the clevis on the drive-side front arm cylinder. Make the unit operational with regard to hydraulic power and electrical controls. Apply pre-set tension to the hydraulic belt tensioning cylinder. 3.4.9 Scrap conveyor Belt Adjustment A tension adjusting take-up assembly is provided at the exit table end of this conveyor. Although a tensioning device this also gives a measur e of tracking adjustment.(Daw FOUR-HIGH COLD BREAXDOWN MILL PART 3 Davy McKee PAGE 39 2.5 36541 Belt Removal and Replacement In order to remove the belt from this conveyor it is necessary to Lift the locking pin at the exit table end of the unit and, after disconnecting the drive coupling between gearbox and top roll, manvally traverse the unit out from under the exit table. ‘The belt must then be cut in order to remove it and the new belt manually passed around the rollers. The join in the belt must be properly vulcanised by the belt suppliers, or by someone equally able to do this work. It may be necessary to relax the tension on the new belt by the tensioning device, whilst fitting the belt, and then re-set up to the correct tension after fitting. REPLENISHMENT OF HYDRAULIC SYSTEMS Replenishment Procedure for Roll Load and Auxiliary Hydraulic Systems NOTE: The following procedures apply to the roll load and auxiliary hydraulic systems where separate filler/filter pumps are fitted. » shut down the main power unit and filler/filter pumps. 2) Connect. hyéraulic {1 supply to system £111 point, ensure that all oll containers, hoses etc. are clean. 3) Turn £i11 point three-way valve to system PILL position. 4) Start the filler/filter pump. 5) Allow the pump to run until the storage tank is filled to the normal operating level as shown by the tank level sight gauge, then stop the pump. IMPORTANT Do not overfill the tank or allow the filler/filter pump to run dry; extended dry running could seriously damage the ‘pump. 8 Turn fill point three-way valve to system RETURN position. n Disconnect hydraulic oi1 supply. a) Start the duty main power unit pumps and filler/filter pump.