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HYDRAULIC FOUR ROLLER

BENDING MACHINE

AHS

AKYAPAK Mak.San. ve Tic. Ltd.Şti. Akçalar Sanayi Bölgesi 16225 Akçalar / BURSA / TÜRKIYE Tel : 0090 224 280 75 00 Fax : 0090 224 280 75 02 www.akyapak.com.tr

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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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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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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. Şti Akçalar Sanayii Bölgesi 16225 Akçalar/ BURSA / TURKEY Tel: 0090 224 280 75 00 Fax: 0090 224 280 75 02 www.akyapak.com.tr

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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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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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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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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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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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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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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) ıt 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 : ıt should be fixed securely and it sholud be in a place that can be seen easily POWER CABLE : ıt should be fixed securly to the machine it should not be broken and or strıpped. It should have safety protection against mechanical damage CONTROL PANEL CONNECTION CABLE : It should be assembled and the flexıble outer cover should be checked for damage.

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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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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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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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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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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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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

PumpOil 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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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 SWITCHSTART 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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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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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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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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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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CONTROL PANEL

12

37

8

64

5

17

20

22

21

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CONTROL PANEL OPTIONAL

15

65

47

32

1

18

19

17

13

16

11

812

9 10

13

20

22

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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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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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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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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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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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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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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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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 DEFECTBARREL DEFECT

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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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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 = √ h2 + ( 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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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 - Tılt 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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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 roller’s 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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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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03.04-B1

TOP ROLL

Reductor Side

SIDE ROLL

A

Cover Side

BOTTOM ROLL

Cover Side

B

Reductor Side

TOP ROLL

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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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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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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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 workıng 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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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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MACHINE PART BODY AND FRAME

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BOTTOM ROLL

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TOP ROLL

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SIDE ROLL

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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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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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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