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AHS

INSTRUCTION MANUAL
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03.04-B1


HYDRAULIC
FOUR ROLLER
BENDING MACHINE

AHS




AKYAPAK Mak.San. ve Tic. Ltd.ti.
Akalar Sanayi Blgesi 16225
Akalar / BURSA / TRKIYE
Tel : 0090 224 280 75 00 Fax : 0090 224 280 75 02

www.akyapak.com.tr

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INSTRUCTION MANUAL
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03.04-B1
INDEX

PAGE 2 INDEX

PAGE 3 INDEX

PAGE 4 INDEX

PAGE 5 CONFIRMITY DECLARATION

PAGE 6 GUARANTEE

PAGE 7 INTRODUCTION

PAGE 8 MACHINE DIMENSION

PAGE 9 TECHNICAL FEATURES

PAGE 10 MACHINE INFORMATION

PAGE 11 SAFETY FACTORS -Introduction

PAGE 12 SAFETY FACTORS -Possiblity of danger on the machine,
Damage
-Can happen, Fuctions of the
machine

PAGE 13 SAFETY FACTORS -Appropriate and Inappropriate usage
Of The machine,
suitable operator

PAGE 14 SAFETY FACTORS - Operator protection

PAGE 15 SAFETY FACTORS - Safety Features

PAGE 16 SAFETY FACTORS -Check list of safety precautions

PAGE 17 INSTALLATION INSTRUCTION -Check list of safety precautions

PAGE 18 INSTALLATION INSTRUCTION -Unpacking, Machine grouding
mounting plan

PAGE 19 INSTALLATION INSTRUCTION - Mounting Information

PAGE 20 INSTALLATION INSTRUCTION -Ground plan

PAGE 21 PRELIMINARY CHECKS -Safety Rope
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PAGE 22 PRELIMINARY CHECKS -Electric Connection


PAGE 23 PRELIMINARY CHECKS -Filling the Plant, Control the
Lubrication

PAGE 24 PRELIMINARY CHECKS -Electric Motor rotation direction
Control
-Clean the hydraulic oil

PAGE 25 PRELIMINARY CHECKS -Table recommended lubricants

PAGE 26 MACHINE USAGE -Movement

PAGE 27 MACHINE USAGE -Bending Speed

PAGE 28 MACHINE USAGE -Switch

PAGE 29 MACHINE USAGE -Control Panel

PAGE 30 MACHINE USAGE -Control Panel Opsional

PAGE 31 MACHINE USAGE -Equipments Control Panel

PAGE 32 MACHINE USAGE -Adjustment of internal pressure

PAGE 33 MACHINE USAGE -Central and side support

PAGE 34 BENDING -Introduction, Quality of material

PAGE 35 BENDING -Placing material, Bending proces

PAGE 36 BENDING -Work Phases

PAGE 37 BENDING -Work Phases

PAGE 38 BENDING -Barrel defect, Reel defect

PAGE 39 BENDING -Cone, Ovaling, Rolling, Incorrect
Defect
PAGE 40 BENDING -Conic angle of location

PAGE 41 BENDING -Preparing the machine for bending
Cones

-Inserting the plate, working phases

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03.04-B1
PAGE 42 BENDING -Ferrule Exctraction

PAGE 43 BENDING -Adjusting Digital Display

PAGE 45 MAINTENANCE -Protective Maintenance, Regular oiling
and oil
-level check, Regular cleaning, Control of
-frayable parts, Control of nuts, Repairing

PAGE 46 MAINTENANCE Bushing, bearing and gearbox oiling

PAGE 47 MAINTENANCE Lubrications

PAGE 48 MAINTENANCE Hydraulic Circuit maintenance

PAGE 49 MACHINE PART Body and Frame

PAGE 50 MACHINE PART Bottom Roll

PAGE 51 MACHINE PART Top Roll

PAGE 52 MACHINE PART Side Roll

PAGE 53 MACHINE PART Part List

PAGE 54 MACHINE PART Part List

PAGE 55 MACHINE PART Part List

ATTACHMENT HYDRAULIC CIRCUIT

ATTACHMENT ELECTRIC CIRCUIT















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03.04-B1

GUARANTEE

- The guarantee time is 12 months after the time it is delivered.

- To guarantee is valid for part changing or repairing that result from failures due to
material or manufacture.

- Transport travel and labor costs of the parts, that is required for replacement and
repairing, are not guaranteed.

- The guarantee is unvalid on condition that any modification is made on the machine
and any damage caused by wrong grounding, trying to bend hard materials and wrong
installation.

- The guarantee is unvalid for frayet parts under normal conditions.

- The guarantee is unvalid if the machine is used for different works other than it has
been produced for.

This manual includes general information to provide you get enough information to
provide you get correct information about our machine.So, you can understand the
functions of the machine.

Required, you can contact and get information form the address below. AKYAPAK
provides help in case any problem occurs with the machine.




AKYAPAK
Mak. San. Ve Tic. Ltd. ti
Akalar Sanayii Blgesi 16225
Akalar/ BURSA / TURKEY

Tel: 0090 224 280 75 00
Fax: 0090 224 280 75 02

www.akyapak.com.tr






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03.04-B1


INTRODUCTION
This manuel includes placement operation Safety rules Maintenance. techinal
specification. Spare parts list and electrical plan of AKYAPAK Hydraulic 4 Roller Bending
Machine.

There may be some difference between the machine because of renvals and
developments. Please contact the seller company or AKYAPAK during assembling
operating and maintenance this manuel will help you and it should always be handy.

ATTENTION!!!!!
This instruction manuel should be kept attached to the machine.

ATTENTION!!!!!
The machine should be operated by trained staff.

Any modification on the machine without written conformation from AKYAPAK is strictly
forbinden as such changes in the machine may cause damage or injuries.

Working area of the machine should be away from flammadle and explosive materials. It
should be closed and should not be effected from air conditions.

Each time operator leaves off the machine he should turn the main switch to position 0
and should take the selective key with him.

Do not take off the safety covers from the machine.

The operator that will use this machine ahould confirm that he read the instruction
manual and understood everything.





Operator name and
surname
Signature Date Employer





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03.04-B1
SAFETY FACTORS

AKYAPAK 4 Roller Bending Machine has upper and lower rolls rotating. Between those
rolls, operators hands or fingers may be trapped. Be careful no to allow any of your
clothing or hands between these rolls while they are rotating.

- Do not do any maintenance when the machine is working.
- Be sure that the machine is off when you take off the back cover
- After closing the covers, control safety rope carefully

AT ANY DANGEROUS INSTANT : PRESS THE EMERGENCY BUTTON OR STEP ON
THE ROPE SURROUNDING THE MACHINE

-In an emergency, the first thing to do is to press emergency stop button on the panel or
to step on the rope surrounding the machine
- Stop the machine before maintenance, repairing and cleaning
-Never take off the safety covers from the machine.


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03.04-B1

POSSIBILITY OF DANGER ON THE MACHINE

On AKYAPAK 4 Roller Bending Machines, safety measures towards danger are taken.
For example:
The electric installation has a metal closure.
Other dangerous part is the place where rolls rotate. By wrong and careless use,
dangerous situations may arise. During working, safety rope is mounted around the
machine towards accidents.

DAMAGE CAN HAPPEN

-User operator's fingers or hands
-User operator's clothes or other subjects
-Deformed working material
-The third person when material is bending
-Machine bending equipment.....
All staff who run, install and maintain the machine are responsible to read the warnings
and apply the instruction manual. Do not attempt to bend hard materials except form
metal or aluminium sheet. You may give harm to either the machine or yourself. To make
modificition on the machine is forbidden because of safety and productivity. Working
maintenance and safety factors in the instruction manual are supposed to be obeyed and
applied.

FUNCTIONS OF THE MACHINE

AKYAPAK Hydraulic Bending Machines are produced to shape material and their
functions are shown below
This machine has the ability to bend closed and semi-closed pipes and conics. Our
machines are produced in different capacity and dimensions depending on the thickness
of the material bent Check sheet thickness on page 5 before starting to bend material. Do
not attempt to bend material that is larger than indicated sheet thickness or quality.

To identify AKYAPAK Asymmetrical Bending Machines, roll diameter, width of the bending
material and thickness of it are indicated.
For exampkle AHS 3100 x 10/14

AHS =Machine Type
2100 =Bending material width
10 =Thickness of material (mm) that is 3 times larger than roll diameter

These values are valid for materials in St-37 quality.
Yield Pressure = 240 N/mm2
Straight Pressure = 370 N/mm2


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03.04-B1

APPROPRIATE USAGE OF THE MACHINE

All bending process should be done in front of the machine where control panel takes
place andonly one person should operate
Then placing material in to the machine, another personnel should help, other bending
processshould be done only by operator himself
Therefore, operator take all safety precautions and he should control in each step
throughly

Around the machine, there should be a security area where max.bending material can
take place. and no one should be allowed to enter this area except from the operator.

INAPPROPRIATE USAGE OF THE MACHINE

There should be no one in security area during bending process.
During maintenance electricity should be cut off.
No one should be allowed to step in the machine in any condition



SUITABLE OPERATOR
Young people who are under 16 is not permitted to run 4 Roller Bending Machine. The
operatorwho will run this machine should confirm that he read instruction manual and
understood eveything. If in doubt, contact with AKYAPAK

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03.04-B1

OPERATOR PROTECTION

In the situation that machine is working under normal conditions, operator should not
need anyother measures.
In working situation:
Because of the danger of dropping working material, workers should wear steel type
shoes andwhen handling hard and sharp working material, they should wear work
gloves. For machineattention and maintenance, expert staff should have the right
equipment.
-Allen key set
-Spanner Set
-Oiling gun
-Protective gloves
-Steel tip protective shoes
-Screwdriver set

SAFETY FACTORS WHEN SETTING UP THE MACHINE
AKYAPAK machine should be positioned on strong, hard and ground level.
(Check the groundplan)
The machine which have overturns can cause serious damage and accidents.

Material can not be bent properly in the machine that is not positioned correctly. Besides,
damagemay happen due to wrong positioning.

If the machine stands with stocks for a while before running, it should be covered with an
awningand should be protected from dust.

SAFETY PRECAUTIONS
On page 11, Hydraulic 4 Roller Bending machine safety precautions are shown. To check
thesefactors also acheck list is added for the user (operator)

CONTROL THESE SAFETY PRECAUTIONS
-Control those factors for each working shift
-Please, check the safety elements once a week periodically
-After every service intervention and maintenance, control those safety precautions.

THE CARE POINTS ON CONTROL
-Check if the machine is in the correct position
-Check if the machine sound
-Check if the machine functions correctly.
-Check if the machine is mounted safety.





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03.04-B1

Eliminate any problem or failure before running the machine. Stop the machine
immediately ifyou see any problem when the machine is running and contact with the
salesman or AKYAPAK

Do not take off the safety elements that instant of machine is running or before

Safety Features
1- Protection plates
2- Switch on electric panel
3- Energy indicator on electric panel that shows there is electric power
4- Thermal indicator on electric panel. (Indicates overload trip.)
5- Emergency-stop button on the control panel
6- Key switch on the control panel
7- Displays on the control panel
8- Other buttons on the control panel
9- Warning labels
10- Soundness of the energy cable.
11- Connection cables of the control panel
12- Manuel lubrication has been done or not
13- Safety rope
Control Panel
Safety rope
Protection plates


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03.04-B1

CHECK LIST OF SAFETY PRECAUTIONS

Fotocopy this check list and use in each control and usege prodecure. Confirm each point
whichfunctions correctly by putting a and save it in case a failure arise.

CHECK LIST CONTROL
MACHINE TYPE DATE


PROTECTION PLATES : They should be mounted and screwed.

ELECTRIC MAIN ISOLATING SWITCH : It should be assembled and it should be
checked if it is working or not

POWER LAMP : It should be assmbled and when there is power the lamp sholud be
checked if its on or off. Check it against bulb failure

THERMAL LAMP : It should be assembled and when the thermal overload is tripped it
should turn on.

EMERGENCY STOP BUTTON : It should be assembled on panel check if it does its
functions stops main motor.

SELECTIVE KEY SWITCH (0-1) t should be assembled on panel. It should function
to switch on the display and control circuits

DISPLAYS : Should be assambled and when there is power the display should be on.
Check function

ALL OTHER PANEL FUNCTION BUTTONS : Should be assembled in and function
correctly

WARNING LABEL : t should be fixed securely and it sholud be in a place that can be
seen easily

POWER CABLE : t should be fixed securly to the machine it should not be broken
and or strpped. It should have safety protection against mechanical damage

CONTROL PANEL CONNECTION CABLE : It should be assembled and the flexble
outer cover should be checked for damage.




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03.04-B1
INSTALLATION INSTRUCTION
TRANSPORT

It is suggested that the machine is transported
with a covered waterproof folio no to be
effected from air conditions.

Place the heavy part (reducer side) of the
machine to the front part of the truck.
So, normal driving balance is adjusted by
preventing to put the weight to the back
side of truck. Figure 1

After the machine is loaded, be sure that the
machine is positioned correctly. If needed
put supporting legs to moving parts.

As shown on figure 2, fix the machine to the
Ground from 4 edges with wooden pieces
nailed to the base.

HANDLING AND LEVELING THE MACHINE
Always use high capacity quay and synthetic rope to lift the machine. Check lift capacity
of ropes and compare them with the machine's weight on page 5

To carry the machine move the bottom roll up the maximum upper position, then tie with
the synthetic rope the bottom and top roll as per drawing.

ATTENTION:
Gear of the machine would have been damaged, if the bottom roll had not been moved
up to maximum upper position.

It is suggested that ropes are tightened first and then you lift the machine in balance,
because dominant weight is on the reducer side (not on the roll)

It is required that you do not loose the ropes. Otherwise the machine may slide and jolt.

Figure 2
Figure 1

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INSTRUCTION MANUAL
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03.04-B1
UNPACKING
Hydraulic Bending Machine are oiled and covered with waterproof folio to protect
machine from weather conditions during transport.

During transport (in open vehicles) use suitable tarpaulins or other covers additional to
above films to protect from weather

At unpacking, if you see any transport damage call the transporter or seller at once.
Dispose of the packaging safety and with regard to the environment use gloves when
unpacking.
Unpainted surfaces are protected with oil for transport. Clean this off with "Kerosene" use
gloves, dispose of waste wipers safely.
Cleaning of the machine, that is oiled with protective oil, is as follows,
- Rolls and bright wrought surfaces are cleaned with thinner
- Painted surfaces are cleaned with a mixture of diesel oil and water

MACHINE GROUNDING MOUNTING PLAN
Machine mounting area should be arranged in accordance with mounting information
shown on page 15 and mounting plan on page 16. After controlling the machine's
position if balanced or not, it should be fixed. Decimal balance device should be used to
position the machine correctly and nuts should be checked.

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03.04-B1

MOUNTING INFORMATION

Before mounting the machine, pay attention to demensions on page 5 and explanations
below

1- Enough space should be left around the machine to reach every side of the machine
for maintenance.

2- On the front side of the machine, there should be space (Lx1,5) that is, 5 times larger
than sheet lenght to take off the material easily.

3- There should be enough space on both sides of the machine to bend material easily
and after this space, 1 meter walking area should be left
1 meter
L
Lx1,5


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03.04-B1
SAFETY ROPE

Safety rope; which is mounted around the machine, is taken off during transport
(depending on machine dimensions and holding). This should be done after ground
mounting.

Safety rope is mounted on the three side of the machine. Angular devices are used to
strengthen the rope. Screw these devices around the machine. Mount the rope round
pulley wheels and tighten them.

Safety rope is mounted in case of emergency. It is enough, touching smoothly on the
rope to stop the machine. To make the machine go on running, you should pull the
button.


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03.04-B1

ELECTRIC CONNECTION
Electric connection should be done by an experienced electrician. Before making
connection, the values should be checked on the label in electric box and electric
connection should be done according to these values

Push the energy cable into the hole on the side of the machine. Connect energy cable to
the electric box through tube which is between electric box and hole
Electric box
Control Panel
Multiple plug


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03.04-B1

FILLING THE PLANT

Hydraulic tank ISO HV/46 Qualified (Different mark oil codes are signed on page)
liter oil should be put for this operation.
a) Please open the side cover beside of reducer.
b) From oil filling window which is on the tank the cover of the oil filling. By open the
cover fill the hydraulic oil

To transfer the oil from the container to the tank, use an external filter positioned as
Fig.5 in order to prevent the introduction of foreign bodies at the time of filling

Filter
Pump
Oil Tank

c) Control the filling oil level from the oil level window gage on the tank.
Oil Level

Please shut down the cover after completing prodecure.

CONTROL THE LUBRICATION
Put grease oil from 7 different places that machine has (for different mark the gerase
codes are given on page)
AKYAPAK fills by grease those signed places and delivers the machine
The machine oiling system is shown on page 42
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03.04-B1
ELECTRIC MOTOR ROTATION DIRECTION CONTROL

After hydraulic oil filling has been done, operator should control motor rotation direction
control. For this follow the instructions below

For 380/400/415 (Other Voltages)

There are phase line relay on these machines. The role of this relay is to prevent the
electricmotor rotating in wrong direction.

When the power connection is established to the machine, if the phase is correct, the
lamp will be gren.If the lamp is not green, change the places of R-S phases.

1- Take the main switch on the electric panel to the position 1
2- Take the selective key on control panel to the position 1
3- Be sure that "electric is on" lamp is lit. If not functioning, check electric connection,
emergency stop button and safety rope.
4- By pressing start button on after taht pressing stop button please check in the turning
side of main electric motor.
Turning side of the main electric motor is shown over the motor.
Turning of the motor to the wrong side prodecure have to be completed in the shortest
time (like 3 seconds)
If electric connection is wrong, pull off the plug from the socket and cut electricity.
Change the phases of plug and try the procedure once more.RE

STOP 0-1 SWITCH START POWER ON LAMP
Machine is ready to operate. To clean the hydraulic oil,

a) Adjust the turning speed of the roll to the max.
b) Please move up and down the side rolls for at least 30 minutes.
c) There is a caution lamb that shows the pollution level in hydraulic return filter. If the
arrow that shows the pollution level in green region, please go on to work.
If it is in the red area, you could go on to work by machine after chenging the filter
element.

After completing the procedure, please do not forget to close up the covers.


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03.04-B1


TABLE RECOMMENDED LUBRICANTS

Mark Hydraulic Power
Unit
Grease Plant Planetry
Gearboxes
MOBIL Mobil DTE 25 Kup Grease 2 Mobil Gear 629
BP Energol HLP 46 Energrease GP2 Energol GR-XP 150
SHELL Tellus Oil 46 Livona 2 Omala Oil 150
CASTROL Hyspin AWS 46 Helvium 2 Alpha SP 150
TEXACO Rando Oil HD 46 - Meropa 150
ELF Hydrelf DS 46 - Reductelf SP 150
TOTAL Equivis ZS 46 - Carter EP 150
ESSO NUTO H 46 - Spartan EP 0
AGIP OSO 46 - Blasia 150
Q8 Haendel 46 - Goya 150


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03.04-B1

MOVEMENTS

1- SIDE ROLLS MOVEMENT UP AND DOWN SIDE

Movement of the side rolls up and down side is made by the help of hydraulic cylinders in
circular orbit. Paralelism of the side rolls is get by torque bar. Perfect paralelism is get by
a heavy solid steel torque bar and connecting points of side rolls moveable fork arms. By
the help of this specification, it is very easy to get the side rolls in to cone position and
make them flat.

2- BOTTOM ROLL UP AND DOWN SIDE
Movement of the bottom roll up and down side is made by hydarulic cylinders and
eccentric cam. Parallelism of bottom roll is get by compensating shaft. Perfect paralleism
is get by strong torgue bar and conneting of the bottom roll by eccantric cam to this part


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03.04-B1
BENDING SPEED

In our standart machine, there are two bending speed that is changed by gradually.
1- Normal Speed
2- Slower speed
Slower speed is used in the process of prebending to pull the lower roll until its axis. For
the normal and also, slower speed, the switch has to be used that has been placed on
control panel.


For normal speed, rubbit graphic; for slower speed turtle graphics are used.

As on optional extra bending speed could be adapted as not gradually. In this option,
bending speed could be adjusted between zero and max. according to the user
experience, material thickness and etc.

In this system, using pumps are special pumps that is not allow to the increasing of the
heat in the oil by the way that these pumps control the oil flow in accordance with
bending speed
Variable speed

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03.04-B1
SWITCHES
To guard the machine and protect the operator, there are used some switches in he
machine against harms switches and tasks.
Usage of the switches and tasks of them.
After completion of bending, as a first job bottom roll is lessened until the roll touch its
switch. If the bottom roll is not being lessened completely, cover could no to be opened.
To take out the material when the user press the cover openning button, cover is opened
up until it touchs to open cover switch. After that, upper roll is lift up and bended
material could take out easily.
Also, in this position, the system is out of work and rolls could not be turned.
After the material is put into, machine cover shut down button is pressed and after a
while upper roll is move and when the upper roll touch to the switch, cover is closed
down and this is also goes an until the cover touches to the switch.
Machine is ready to bend.
If the machine is could not receive order from switches,it cloud not operated in an order.

DEFECT TYPE BROKEN PLACE CONTROL
Cover could not be opened Bottom roll is not at Control the bottom roll
switch.
Rolls could not be truned Cover is open Control the cover close
switch
Top roll could not be moved Cover is not open Control the switch that
direct the
Upword opening of cover
Top roll could not be moved Cover is not open Control the switch that
direct the
Downword opening of cover
Cover could not be closed Top roll is not at the Control the switch that
direct the
lowest level lowering the upper
roll level.


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03.04-B1
CONTROL PANEL
1
2
3
7
8
6
4
5
1
7
2
0
2
2
2
1



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03.04-B1
CONTROL PANEL OPTIONAL
1
5
6
5
4
7
3
2
1
1
8
1
9
1
7
1
3
1
6
1
1
8 1
2
91
0
1
3
2
0
2
2

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03.04-B1


EQUIPMENTS CONTROL PANEL

1 - Start up button
2 - Stop Button
3 - Exiciting lamb specifying low oil level
4 - Exiciting lamb for emergency stop button
5 - Energy on process button
6 - Open close key
7 - Emergency stop button
8 - Left side roll parallel or conic up and down
9 - Left roll up
10 - Left roll down
11- Fast - slow adjusting button
12 - Cover opening and top roll up
13 - Cover closed and top roll down
14- Bottom roll parallel or conic up and down
15 - Bottom roll up
16 - Bottom roll down
17- Right roll parallel or conic up and down
18 - Right roll up
19 - Right roll down
20- Right side turning button
21- Left side turning button
22- Display
23-
24- Left guide upside lifting button Optional
25- Left guide downside button Optional
26- Top guide upside lifting button Optional
27- Top guide downside button Optional
28- Right guide downside button Optional
29- Right guide upside lifting button Optional















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03.04-B1

ADJUSTMENT OF INTERNAL PRESSURE

There are 3 kinds of hydraulic pressure in the machine
1- Pressure adjustment for turning the top roll.
2- Pressure adjustment for movement of the side rolls up and down.
3- Pressure adjustment for bottom roll

Top roll turning, bottom roll turning and side rolls pressure adjustment are stabilized by
our firm. Changes in the adjustments are strictly forbiden. Otherwise, machine could be
damaged deeply. You can see the top roll turning pressure value from A monometer.


Bottom roll pressure could be adjusted by pressure security value (C) that is near the
manometer board. Adjusting pressure could be by (B) manometer.
The values for bottom roll pressures should be found by testing that belongs to the
quality, hardness and the thickness of the bending material.

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03.04-B1

CENTRAL AND SIDE SUPPORT SYSYTEM

Bending fault occurs while bending big diameter material. While bending this kind of
material, it is bent correctly at the beginning. In the middle, it is sagged due to its weight
and spoils the radius. To prevent this, central and side support should be used.
CENTRAL SUPPORT SYSYTEM
SIDE SUPPORT SYSYTEM



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03.04-B1
To get high productivity, correct usage, correct maintenance and regular cleaning should
be done

Material should be prepared before bending due to its structure. For this:
1- Clean burrs which is on the edges of material cut with oxygen.
2-Clean all the spurs, rust,cinder. These may give harm to rolls, even if rolls are
hardened.
3- Clean both sides of the sheet.
4- Before starting to bend, check the sheet again. If there is a problem, clean again.

Physical condition of the sheet effects quality of material bent. If the face of the material
is dirty, the sheet may be grained.

QUALITY OF MATERIAL

You know that semi-quality material, which is to bend, is delivered in different qualities.
Multiple bending materials can not give the same result because of the difference
between material quality. The most important factor that effects bending quality:
1- Sheet quality
2- Flow limit
3- Elasticitiy limit
4- Material direction
5- If thickness is same on all surfaces of sheet or not; thickness homogeniety

These factors are so important that if one of them is changed, you can not get the
dimensions you bent.
For example, when you want to bend a material whose elasticity factor is high with the
same machine adjustment, diameter obtained will be different.
You might obtain different results, id you want to bend material in one step rather than in
two steps. Because, in two step procedure, flow limit might have changed after the first
step

These factor differences are faced (met) often even in the same material groups.
Therefore, you should use high quality material.

Another bending fault occurs while bending big diameter material. While bending this
kind of material, it is bent correctly at the beginning. In the middle, it is sagged due
to its weight and spoils the radius. To prevent this, central and side guides
should be used.







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03.04-B1

PLACING MATERIAL

After doing all the safety factors shown on page 16, you can start to bend material
First step of bending process is to place material. To obtain a high quality material bent,
you should push and position correctly the material that is squeezed in to rolls
Initial steps of this process are:

1-Material should be placed into the rolls on any condition.
2- Material should be placed paralel to rolls axis.
To make easy the procedure you could use the side rolls. By lifting up the side roll, and
by basing the bending material to the roll, get the parallelism.

BENDING PROCESS

First step is to give power to the machine. Steps are as follows
1- Take the switch on the electric panel to position 1
2- Take the selective key on the control panel to position 1
3- Be sure that power lamp is on. If not, check safety rope and emergency stop button.
4- Push start button.
Machine is now ready to run. You can start to bend material in accordance with the steps
indicated on page 32-33

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INSTRUCTION MANUAL
PAGE : 36

03.04-B1

WORK PHASES


When you run the machine on fast speed, you will see that top and lower rolls turn
together. When you run the machine on slow speed, you will see the lower rolls turns
only. If you pinch the lower roll and when the top and lower rolls touch each other, these
rolls will turn together


According to hydraulic logic, pressure goes to easiest way. So the resistances have to be
equal for top and lower roll in order to be equal of turning speed. In case of fast speed or
on slow speed, the top and lower rolls turn equal, because of the resistances equality


Resistance control system (tooperating rolls to turn together) runs according to pump
capacity, when rolls are seperated. The lower roll turns only, because of the low output
of hydraulic pump.



This will no t effect bending qulity or type











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INSTRUCTION MANUAL
PAGE : 37

03.04-B1

WORK PHASES

The following drawing illustrate the normal work cycle with
a four roll machine. The workman's expertise will contribute
enormously to the finished product, as well as to the bending
time.

Before inserting the plate in to the machine, make sure that the
central roll is in the lowest position; if not lower it.

All the bending operations of a normal cycle are described here.
In this case the plate is loaded on the left side of the machine.
it also possible to load it on the right side. Obviously, in the
case all operations will be done in a specular way, i.e using the
side rolls opposite movement.

Lift the right roll unit it is about in the middle between the
central rolls. This operation forms a contrast with the roll itself,
which will be useful for the squaring of the plate.
Insert the plate between the two central rolls and the push it, so
taht it pinched between the two central rolls. On this machine it
is possible to change the pinching strenght. To do this, see the
page 34

Now lower the right roll and drag the plate towards the left side,
so that you bring its edge the closest possible to the central roll
axis.


Now lift the left roll until you obtain the desired radius and the
drag the plate towards the right side (you can see the shift of the
rolls on the digital readout and the bending radius you obtain
is determined by the plate thickness, but also by the type of the
material you use.)
Stop the advancement of the plate when you realize this may
lean on the right roll.


Lift the right roll until you lean the plate and then lower the
left roll to the end. Now it is possible to go on dragging the
plate until the bending is completed.

Here it is possible to see the result at the end of the bending phases
In some cases, however, it is possible to find bending defects and more precisely the
barrel defect and the reel defect time.


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INSTRUCTION MANUAL
PAGE : 38

03.04-B1

The machine rollers are manufactured with the aim of avoiding these defects. In fact,
their surface is not perfectly cylindrical, but bi-conical.
The roll conicity is calculated, so that it can offer a good performance on the highest
number of thickness. It is ovious, however, that the final result of the bending as
concerns the extreme sizes (minimum and maximum thickness) may have these defects.
Defects and advice for improvement

BARREL DEFECT
You have the barrel defect when the pipe is closed at this ends, but it is more or less
open in the middle. This defect is caused by the roll flexion under the bending strenght

CAUSE 1 : The plate is too thick in relation to the machine performance
SOLUTION 1 : You cannot solve this problem, unless you use a machine with a higher
performance

CAUSE 2 : The plate is pinched between the two middle rolls with too much pressure
SOLUTION 2 : Slightly reduce the pinching strenght (pressure of lower roll upward
movement). This operation can also be done only at the last passages. It is obvious that
if the is lower, the lenght of the first straight piece will be higher

REEL DEFECT
You have reel defect when the tube is closed in the middle but open at its end. This
defect can be caused by the roll bi-conicity.

CAUSE 1 : The plate you are using is too thin in relation to the machine performance
SOLUTION 1 : There is no other solution than bending the material with a lower
performance machine

CAUSE 2 : The plate pinching pressure is to weak
SALUTION 2 : Slightly increase the roll strength

REEL DEFECT
BARREL DEFECT

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INSTRUCTION MANUAL
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03.04-B1
CONE DEFECT
This defect consists of one side of the tube which is more closed than the other side. It
can be caused by two different situations.
CAUSE 1 : The rolls are not perfectly paralel to each other.

SOLUTION 1 : Check the roll parallelism and, if necessary, adjust it

CAUSE 2 : The plate you are using is short and was not laid in the middle in relation to
the rolls
SOLUTION 2 : Release the plate and lay it in the middle. If there is no improvement,
slightly tilt the side rolls, so that you compensate the bending defect.

OVALING DEFECT
It is the tube crushing on one side of the tube. This means that its diameter is not
constant and is wider in relation to an axis

CAUSE : This may be caused by the plate dimansions
SOLUTION : Do some calibration turns with the tube, lowering the inferior roll to the end
and using using the lever to prevent any rolling
This operation must be exclusively done keeping the inferior roll in the lowest position. If
not, the welding or other factors may seriously damage the machine.

ROLLING DEFECT
This defect is always caused by too high a roll strength. The plate coming out of the
machine, is rolled and irreparably damaged.
Use the roll pinching presuure adjustment gauge and reduce its strength

INCORRECT AXIS DEFECT
This defect can be caused by a bad plate alignment, by an incorrect roll parallelism or by
a plate with irregular thickness. Check the alignment and the parallelism. If the defect is
caused by the material, there are no solutions.
INCORRECT AXIS DEFECT ROLLING DEFECT

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INSTRUCTION MANUAL
PAGE : 40

03.04-B1
CONIC ANGLE OF LOCATION
Conic bending process is done by means of conic bending system in our machine. Conic bending is the
most difficult operation among bending types. Therefore, operator needs too much experience
Now that this operation is difficult;

HALF OF MACHINE'S CAPACITY SHOULD BE USED.
This means that, our machine can bend half of its capacity that's 1000mm x 3 mm, if its total capacity is
2000x6 mm.
If you want to get truncated cone as shown on figure, you should prepare angle location of material
depending on diameter and lenght
This angle location should be prepared in accordance with
formulas below.

L = ( D x I ) / ( D - d )

I = h
2
+ ( R - r )
a = S x 180 x L / 3,14
S = D x 3,14
D, d, R, r average diameters.









CALIBRATION

After rolling, the result might vary in different radius on different parts of
cylinder. Ovality might be observed on cylinder. In order to reach the best round
shape and correct the oval diameter, calibration is required.

HOW TO ?

The rolled material is taken off the machine and welded. The welding line
should be cleaned and smoothed from inside and outside. Then the welded
cylinder is placed on the machine again.
The tighest diameter of oval cylinder should be placed to the lowest point of
top roll. The side rolls are moved up at the same position till they touch the
cylinder. Later on, both side rolls are highered a bit more and with a soft thrust
of side rolls to cylinder, oval cylinder gets into pear shape.
Then the bottom roll is dropped down to lowest position. Turn the switch of
calibration to calibration mode. With this, the rotation of bottom roll is cancelled
and all rotation power is transfered to top roll.
Rotate the cylinder by pressing rotation button. The cylinder must be rotated
always in the same direction. At each turn, lower the side rolls slowly. The
required round shape will be achieved when the touch of side rolls to cylinder
ends.

IMPORTANT NOTE!!!
The maximum calibration capacity is 75% of maximum bending capacity.


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INSTRUCTION MANUAL
PAGE : 41

03.04-B1


PREPARING THE MACHINE FOR BENDING CONES

Before inserting the plate, prepare the machine as follows.
1 - Lift the rear part of the lower central roll,so that the plateis only pinched from the
opposite side to the cone support
2 - Tlt the side rolls so that you can obtain a correct cone. Most cones can be made with
themaximum inclination which is 1,5 . This limit is due to the inclination limit of the roll
bearings andit is the same for all machines.

INSERTING THE PLATE
The smaller mouth part must ALWAYS be on the control unit side and must firmly lean on
thecone support

WORK PHASES
Put the fisrt part of the plate you want to bend between the two central rolls and the
closest possibleto the axis of the rolls themselves, trying to obtain the best alignment
For all other operations follow the phases of the normal bending.
As conical bending work is very hard and the machine is under particular stress, you need
to cleanand prepare the plate carefully before starting.

It is normal that, during the conical bending phases, the machine reversible support,
under stresscaused by the push of the cone, slightly opens. If this happens, but in a very
evident way, checkthe cone sizes again and make sure that tha machine can make it.

If the answer is yes, the defect may then be caused by too high a plate yielding limit and
you need, therefore, to change the material.

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INSTRUCTION MANUAL
PAGE : 42

03.04-B1

THE IMPORTANT MATTERS THAT OUGHT TO BE PAYED ATTENTION
ABOUT CONICAL BENDING AND PLACEMENT OF THE CONICAL MATERIAL

The small diameter of the material has to be lean on the conical support pulley. The edge
of the angled conical sheet which is about to be bent, should be paralleled to the axles of
the top and the bottom shafts. While moving the bottom roll upwards, the bottom roll
conical button on the control panel should be turned on to conical position when there is
5-8 mm s left to pinch the material, and then the material can be pinched as conical by
pushing the bottom roll-up button. The important thing that ought to be stated about this
process is eye-controllable pinching. The edge of the sheet which is going to bent as big
diametered edge after conical bending, has to be rotated while the bending process is
going on. The side roller should be moved a little bit upwards in parallel position.
Afterwards, the side rollers conical bending button should be turned on to the conical
position. Via pushing to the levelling button, the roller moves till the required conical
angle is obtained. Then the process starts.

When the plate touchs the other side roller, the other side roller should be positioned as
conical. Conical bending process ends with the sheet s edge to edge position. The
material is welded from the outer and inner side after bending process. The material can
be calibreted after welded surfaces grinding. By the end of this process the lower
conical gets closed. The bottom roll should be moved downwards. Via the usage of cover
opening button, the cover becomes to open position. The top roll moves upwards and the
process is finished.

Unless these processes are obeyed ;

A) The bottom roll is going to pinch the material from the large conical edge, with
more power than required as to rotate from that edge.
B) You might pinch the conical material as parallel by mistake.
C) If you move the bottom roll as conical and try to pinch the conical plate when the
bottom roll is at the lowest position, the machine will not do the cone bending. (
There might be damages on the rollers, cone bending support, the material which
is going to be bent conically.

If the edge of the material, which reaches to the cone support pulley, curls upwards or
downwards, squeezeing occurs, deformation is visible, there might be something wrong
about the application of the process which are described above.

NOTE : Make sure that you ve pinched the material from a part like 5-10 cm s on the
larger diametered edge only to rotate the material. ( Not much. )





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INSTRUCTION MANUAL
PAGE : 43

03.04-B1


After ferrule bending to extract the piece from the machine, operate as follows
1- Decrease the level of bottom roll
2- Determinated at below on controlrolling panel after press 2 numbered button the cover
opensand the top rolls moves upward.



3- Bended sheet takes of from top roll.
4- To press 1 numbered button the top roll moves downward and the cover get close

All those operations to work in reliabiliy on their sequence each movement controls by
limit switch.

ADJUSTMENT OF PARALLELISM

Cover Side
Reductor Side

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INSTRUCTION MANUAL
PAGE : 44

03.04-B1

T
O
P

R
O
L
L
Reductor Side
S
I
D
E

R
O
L
L
A
Cover Side

B
O
T
T
O
M

R
O
L
L
Cover Side
B
Reductor Side
T
O
P

R
O
L
L

MAINTENANCE
To get a higher productivity, it is necessary that correct maintenance and regular
cleaning shouldbe done;We can divide maintenance process in two groups;
1- Protective maintenance
2- Repairing and maintenance as a result of a failure




ADJUSTMENT PARALLEL OF SIDE
ROLLS
ATTENTION
Before doing th eprocess above, make
sure that
conical bending device at sides are
completly closed

If, x > y
Adjusting screw (A) is revoled to the
reverse way
of clock

If, x < y
Adjusting screw (A) is revoled clock way

If, x = y
Rolls are paralel


ADJUSTMENT PARALLEL OF BOTTOM
ROLLS
ATTENTION
Before doing th eprocess above, make sure that
conical bending device at sides are completly
closed
If, x < y
Adjusting screw (B) is revoled to the reverse
way
of clock
If, x > y
Adjusting screw (B) is revoled clock way
If, x = y
Rolls are paralel

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INSTRUCTION MANUAL
PAGE : 45

03.04-B1

PROTECTIVE MAINTENANCE
Protective maintenance is a series of precautions that are taken before failures take
placeThese precautions are:
-Regular oiling and oil level check. (reductor and hydraulic tank)
-Regular cleaning
-Cleaning of bending material
-Control of frayable parts (bearing, bushing, etc.)
-Control of nuts etc. against loosening.

REGULAR OILING AND OIL LEVEL CHECK
Information was given widely about this item on page 41 and 42

REGULAR CLEANING
During bending, rust, dust and etc.... adhere on rolls. Roll's should be cleaned after each
bendingprocess and its surface should be checked. Even if roll's are hardened, too hard
materials should notbe bended. Machine's working area should be far from dust wheather
conditions.

CONTROL OF FRAYABLE PARTS
List of parts used in the machine were given on pages 44,45,46,47,48,49 Operator should
examine theparts carefully. If something goes out of normal, for example bad sound from
the machine orworking irregularity etc......, he should inform maintenance personell.

CONTROL OF NUTS ETC.
While machine is working, gearbox screws, strained on gearbox's start, stop motion.
AKYAPAKcompany has taken all the precautions against loosening these nuts by using
locking washer andpasting agent. Yet, these nuts should be checked at least once a
month in overloading and denseworking times.

REPAIRING
When a failure occours, machine should be off and electricity should be cut off. The
machine should be repaired by a specialist personell and should examine montage figures
onpage 44,45,46,47,48,49 carefully

ATTENTION !!!!
The machine should be off and electricity should be cut off in every maintenance or
repairingapplied.

OILING
One types of oil are used in our machines.
-Grease ( to oil bearing and bushing)

Brans name of grease are given on page 22




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INSTRUCTION MANUAL
PAGE : 46

03.04-B1

OILING BUSHING AND BEARING

Bearings and bushings are oiled by means of grease gun and brush as shown on page 42

Grease oiling should be controlled once a month and when grease level decreases and it
shouldbe filled. Every place where oiled with oil or grease should be checked before
working. And ifnecessary, should be filled.

OILING GEARBOX

Main reducer, used in our machine, is delivered with oil. Reducer's oil should be changed
aftereach 2000-2500 working hours and once a year. It is not advisable that different
types of oils aremixed and put in the gearbox. Gearbox oil level should be checked once a
month.

Open drain plug and empty old oil. Then close drain plug and open filling plug. Control oil
levelby means of oil level plug after you put oil. When oil is filled up to oil level plug level,
then theprocess is over.

Check whether all plugs are closed or not.

Oil level plug
Filling plug
Drain Plug.

In oiling up the oil again to the machine, please use the 10 micron filter element.







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INSTRUCTION MANUAL
PAGE : 47

03.04-B1




LUBRICATION SYSTEM
Lubrication has to be made for each of machine that mentionedin pafe 7 by grease gun
1
2
3
4
5
6
7


The point that shown over the machine has been filled up by oil. Before using the
machine user has to control whether there is gress oil or not. If its necessary, user has to
fill the points by gress oil.
Afterevery 500 workng hour ,the gress oling points have to be changed

Gress type that has to be used is down in page 22.












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INSTRUCTION MANUAL
PAGE : 48

03.04-B1

HYDRAULIC CIRCUIT

To have a long time using and best efficiency in hydraulic system, user has to choice the
best oil that is suitable for the circuit and user has to follow maintenance program of
machinery carefully. Oil type is decribled in page 22. The items that are neededd to
follow maintenance program are;
1- Oil level control
2- Return filter control

1- OIL LEVEL CONTROL
Over hydraulic tank, there is used on indicator that shows the level and heat of the oil. To
follow the oil level carefully, there is used a hall over machine body.

Please, do not add hydarulic oil to the used one. If it is really necessary to add the oil use
the same quality and type hydraulic oil with used one. Please obey the rules for filling the
oil that are described in page 22

2 - RETURN FILTER
For the healty operation for hydraulic system and long lasting life for hydraulic
compenents, hydraulic oil has to be filtered strictly. To obtain this filtering prodecure in
our hydraulic system. We used the filter with big capacity and the sensetive. Return filter
has to be changed under the conditions that have been specified below.

a- If the pollution level is in red area
b- After 1000 hour operation time.
c- At least one times per year
d- When the oil is renewed.

Also, for the long life for hydraulic cylinders, at least one times in 6 months, there has to
be control whether there is oil leak or not. The miles taht include chromium has to be
controlled and if there occured blow on it, miles has to be replaced by new one.

Everyday, before operating the machine, this
level has to be controlled.

Also, there is used a switch for the reason
that if the hydraulic oil level decreases to the
lower level that hormful for the hydraulic
components, machine could stop.

It self filing hydraulic oil, has to be changed
in one year, after 2500 working hour.

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INSTRUCTION MANUAL
PAGE : 49

03.04-B1
MACHINE PART
BODY AND FRAME


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INSTRUCTION MANUAL
PAGE : 50

03.04-B1
BOTTOM ROLL


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INSTRUCTION MANUAL
PAGE : 51

03.04-B1
TOP ROLL


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INSTRUCTION MANUAL
PAGE : 52

03.04-B1
SIDE ROLL

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INSTRUCTION MANUAL
PAGE : 53

03.04-B1
1- Main frame
2- Small frame
3- Frame
4- Main frame support
5- Support bar between main and small frame
6- Manomater Panel
7- Bolt
8- Bolt
9- Bolt
10- Bolt
11- Stopping part
12- Plate Bushing
13- Roll reducer part
14- Bushing
15- Bolt
16- Adjusting part
17- Cover
18- Circlips for pin
19- Spherical roller bearing
20- Bottom roll bearing
21- Plate bushing
22- Bottom roll
23- Bottom roll bearing
24- Spherical Roller bearings
25- Circlips for pin
26- Cover
27- Bolt
28- Bolt
29- Spherical part
30- Adjusting frame part.
31- Bushing
32- Small pin
33- Adjusting screw
34- Eccentric bearing
35- Bushing
36- Bushing
37- Intermediate part
38- Cover
39- Bolt
40- Eccentric shaft
41- Holding plate
42- Adjusting screw
43- Hydraulic Cylinder - If the bottom roll is wanted as cone
44- Bushing
45- Pin
46- Hydraulic Cylinder
47- Pin
48- Bushing
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INSTRUCTION MANUAL
PAGE : 54

03.04-B1
49- Small pin
50- Cylinder plate
51- Bolt
52- Stopping plate
53- Top roll reducer part
54- Bushing
55- Cover
56- Circlips for pin
57- Spherical Roller Bearing
58- Intermediate part
59- Cover
60- Bolt
61- Top Roller
62- Cone head
63- Spherical Roller Bearing
64- Circlips for pin
65- Cover
66- Circlips for bore
67- Antrum of cone head
68- Opening-closing cover
69- Pin
70- Small pin
71- Bushing
72- Cover pin
73- Bolt
74- Plate
75- Pin
76- Hydraulic cylinder of cover
77- Bushing
78- Bushing
79- Hydraulic cylinder of top roll
80- Bushing
81- Pin
82- Hydraulic cylinder point
83- Spherical part
84- Bushing
85- Holding plate
86- Bolt
87- Plate bushing 130- Bolt
88- Plate 131- Plate
89- Bearing plate
90- Nut
91- Bolt
92- Pin
93- Bushing
94- Cover
95- Circlips for pin
96- Spherical Roller Bearing
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INSTRUCTION MANUAL
PAGE : 55

03.04-B1
97- Side roll
98- Spherical roller bearing
99- Circlips for pin
100- Cover
101- Butterfly part
102- Bushing
103- Pin
104- Plate
105- Bolt
106- Hydraulic cylinder for cone bend
107- Bushing
108- Bushing
109- Intermedia part
110- Cover
111- Bolt
112- Plate
113- Bolt
114- Bushing
115- Pin
116- Pin
117- Bushing
118- Eccentric shaft for side roll
119- Pin
120- Adjusting screw
121- Frame of adjusting part
122- Adjusting screw
123- Bushing
124- Pin
125- Plate
126- Bolt
127- Hydraulic cylinder
128- Bushing
129- Pin

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