AKYAPAK AHS User manual

A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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AKYAPAK-AHS-UserManual-2019.03.11
AHS
4 ROLLS HYDRAULIC PLATE BENDING MACHINE
OPERATION AND MAINTENANCE MANUAL
AKYAPAK ULUSLARARASI DIŞ TİCARET MAKİNA SANAYİ TİCARET A.Ş.

A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
T: [phone]
F: [phone]
E: [e-mail]
W: akyapak.com.tr
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TABLE OF CONTENTS
INTRODUCTION........................................................................................................ 5
LIFE CYCLE........................................................................................................................................ 5
GENERAL INFORMATION........................................................................................ 7
TECHNICAL SPECIFICATIONS.......................................................................................................... 7
TECHNICAL SPECIFICATIONS.......................................................................................................... 8
PRODUCT INTRODUCTION............................................................................................................... 9
DESCRIPTION, USAGE AREAS AND CONDITIONS OF THE MACHINE......................................... 10
SAFETY WARNINGS............................................................................................... 11
SAFETY FACTORS .......................................................................................................................... 11
POSSIBLE RISKS ON THE MACHINE.............................................................................................. 12
RISK OF DAMAGE............................................................................................................................ 12
MACHINE FUNCTIONS.................................................................................................................... 13
PROPER OPERATION OF THE MACHINE....................................................................................... 13
IMPROPER OPERATION OF THE MACHINE................................................................................... 14
PROPER OPERATOR ...................................................................................................................... 14
PROTECTION OFOPERATOR ........................................................................................................ 15
SAFETY FACTORS IN THE MACHINE INSTALLATION ................................................................... 15
SAFETY PRECAUTIONS.................................................................................................................. 15
CHECK THESE SAFETY PRECAUTIONS........................................................................................ 15
CHECKING OF MAINTENANCE POINTS......................................................................................... 16
SAFETY FEATURES......................................................................................................................... 16
SAFETY PRECAUTIONS CHECK LIST ............................................................................................ 18
WARNINGS ...................................................................................................................................... 19
GENERAL INFORMATION ............................................................................................................... 20
MANUFACTURER INFORMATION................................................................................................... 20
IMPORTANT SAFETY PRECAUTIONS.................................................................. 22
SAFETY............................................................................................................................................ 22
SAFETY INFORMATION................................................................................................................... 22
OPERATING AREA SAFETY............................................................................................................ 23
MACHINE SAFETY INFORMATION.................................................................................................. 25
GENERAL PRECAUTIONS............................................................................................................... 26
SAFETY OF THE EMPLOYEES WORKING ON THE MACHINE....................................................... 26
PERSONAL PROTECTION EQUIPMENT......................................................................................... 26
WARNINGS ON OPERATION........................................................................................................... 27
STORAGE......................................................................................................................................... 27
TRANSPORTATION................................................................................................ 28
CHECKS TO BE DONE IN THE DELIVERY OF THE MACHINE........................................................ 28
SAFE TRANSPORTATION OFTHE MACHINE................................................................................. 28

A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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HORIZONTAL ADJUSTMENT........................................................................................................... 28
APPLICATION................................................................................................................................... 29
MAINTENANCE AND INSPECTION........................................................................ 30
PROCEDURE FOR ISOLATION OF THE MACHINE......................................................................... 30
SAFETY DURING MAINTENANCE................................................................................................... 30
PREVENTION OF ACCIDENTS........................................................................................................ 31
POINTS TO BE CONSIDERED IN DAILY OPERATION.................................................................... 33
SECTION II INSTALLATION OF THE MACHINE.................................................. 34
GENERAL INFORMATION ON THE INSTALLATION OF THE MACHINE ............ 35
INSTALLATION INSTRUCTIONS TRANSPORTATION.................................................................... 35
TRANSPORTATION AND PLACEMENT OF THE MACHINE............................................................ 35
CAUTION:......................................................................................................................................... 35
REMOVEL OF PACKAGE................................................................................................................. 36
PLACEMENT PLAN OF THEMACHINE............................................................................................ 36
INSTALLATION INFORMATION....................................................................................................... 38
PRE-INSPECTIONS................................................................................................. 39
SAFETY ROPE ................................................................................................................................. 39
ELECTRICAL CONNECTION............................................................................................................ 40
FILLING OFOIL RESERVOIR........................................................................................................... 41
CHECKING OF LUBRICATION......................................................HATA!YER İŞARETİ TANIMLANMAMIŞ.
INSPECTION OF ELECTRIC MOTOR ROTATION DIRECTION....................................................... 42
FOR 380/400/415V (OTHER VOLTAGES) ........................................................................................ 42
RECOMMENDED GREASE CHART....................................................................... 44
MACHINE OPERATION........................................................................................... 45
1. UP AND DOWN MOVEMENTS OF SIDE ROLLS .......................................................................... 45
2. UP AND DOWN MOVEMENTS OF LOWER ROLL........................................................................ 45
BUTTONS......................................................................................................................................... 47
USAGE AND FUNCTIONS OF THE BUTTONS................................................................................. 47
ADJUSTMENT OF INTERNAL PRESSURE...................................................................................... 48
MATERIAL QUALITY ........................................................................................................................ 49
PLACING THE MATERIAL................................................................................................................ 49
BENDING OPERATIONS.................................................................................................................. 50
BARREL ERROR.............................................................................................................................. 53
BARREL............................................................................................................................................ 53
REVERSE BARREL ERROR............................................................................................................. 54
CYLINDER ERROR .......................................................................................................................... 54
OVALNESS ERROR ......................................................................................................................... 55
BENDING ERROR............................................................................................................................ 55
WRONG AXIS ERROR...................................................................................................................... 55

A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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LAYOUT OF CONICAL ANGLES ...................................................................................................... 56
YOU SHALL USE HALF OF THE CAPACITY OF THE MACHINE...................................................... 56
CALIBRATION .................................................................................................................................. 56
OPERATION PROCEDURE.............................................................................................................. 56
PREPARING THE MACHINE TO CONICAL BENDING..................................................................... 57
PLACING THE MATERIAL................................................................................................................ 57
1) ADJUSTMENT OF EVENNESS OF SIDE ROLLS ......................................................................... 63
ADJUSTMENT OF EVENNESS OF LOWER ROLL........................................................................... 65
MAINTENANCE................................................................................................................................ 65
PREVENTIVE MAINTENANCE......................................................................................................... 65
REGULAR LUBRICATION AND CHECKING OFOIL LEVEL............................................................. 66
REGULAR CLEANING...................................................................................................................... 66
INSPECTION OF WEARABLE PARTS.............................................................................................. 66
REPAIR............................................................................................................................................. 66
LUBRICATION OF THE REDUCER .................................................................................................. 66
RETURN FILTER.............................................................................................................................. 67
SECTION III PART LISTS..................................................................................... 68
BODY................................................................................................................................................ 69
LOWER ROLL................................................................................................................................... 69
UPPER ROLL.................................................................................................................................... 72
SIDE ROLL........................................................................................................................................ 74
SECTION VI AHS MAINTENANCE AND SERVICE MANUAL ........................... 76
END OF WORKDAY MAINTENANCE............................................................................................... 77
NOISE EMISSION RATE................................................................................................................... 78
GENERAL SAFETY INFORMATION................................................................................................. 78
RECOMMENDATIONS FOR AFAULT CONDITION......................................................................... 81
REDUCER FAULTS AND MAINTENANCE THROUGHOUT THE MACHINE ........ 87
INTERVENTION TO REDUCERS ..................................................................................................... 87
OPERATION..................................................................................................................................... 87
MAINTENANCE................................................................................................................................ 87
LUBRICATION.................................................................................................................................. 87
WARRANTY CONDITIONS............................................................................................................... 87
OIL TYPES........................................................................................................................................ 90
TROUBLESHOOTING GUIDE FOR REDUCERS.............................................................................. 91

A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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AKYAPAK-AHS-UserManual-2019.03.11
INTRODUCTION
PLEASE READ THE OPERATION MANUAL CAREFULLY AND KEEP IT FOR FUTURE REFERENCE!
•Operators who would be using the machine, shall read the information in the
operation manual thoroughly besides the training they will take from AKYAPAK
Makine instructor, and shall have information on the operation, settings and
maintenance of the machine.
•Machine shall never be operated by staff who does not have a good grasp of the
information in the manual.
•It is forbidden to reproduce, transfer or use this document or its contents without
written permission. People acting otherwise shall be responsible for any damage that
may occur.
•All rights, including the registration rights of a model or design submitted for patent
approval or presented for use, are reserved by AKYAPAK Makina San. Tic. Ltd. Şti.
•It is possible that functions that are not described in this manual are available.
•Safety equipment may be represented in improper positions on some cross-sectional
views used in the manual. These views are used to provide the required visual
information, and the machine shall never be operated outside the specified safety
positions.
•The conformity of the subjects described in this manual are checked by ourselves.
However, there may be some differences and it is not possible to guarantee that all
these information are exactly similar.
•It is possible to make changes on the machine and the document without prior
information.
•Subjects included in this document are regularly reviewed and changes required are
added to the next issue. Your offers intended to develop the system would be gladly
accepted by us.
LIFE CYCLE
Life Cycle is: 10 years. (Parts retaining period to ensure functioning of the machine)

A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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AKYAPAK offers technical assistance and/or help to its customers when a problem occurs on
the operation and repair procedures of its machines. You may contact technical service or
support department both in written and oral form as specified in the relevant section of the
manual when required.
Technical Service Contact Information
Service Name: AKYAPAK ULUSLARARASI DIŞ TİCARET MAKİNA SANAYİ TİCARET A.Ş.
Service Address: Akçalar Sanayi Bölgesi Sanayi Cad. No:8 16225Akçalar / Bursa-TÜRKİYE
Service Tel: [phone]
E-mail: [email protected]

A: Akçalar Sanayi Bölgesi Sanayi Cad.
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GENERAL INFORMATION
TECHNICAL SPECIFICATIONS

A: Akçalar Sanayi Bölgesi Sanayi Cad.
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TECHNICAL SPECIFICATIONS
Model
Serial No
Average Dimensions
Height
Length
Width
Weight
Dimensions of ROLLS
Center ROLLS
Rear Side ROLLS
Bending Speed
Initial Speed
Power source
Pre-bending Thickness
Bending Thickness

A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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PRODUCT INTRODUCTION
All operating movements of plate bending machine are performed manually.
Plate material prepared for using in various fields in the industry is placed on the machine in
order to bend it in the specified way.
Then, desired form is obtained by bending it as specified in the operation manual.
Standard features of our machine:
•Conical bending mechanism
•Induction hardened rolls
•Digital indicator for side rolls
•Completely steel (ST-52) welded construction machine body
•Separate control panel
•Double speed control
•Rolls mounted in bearing
•Upper roll cover that opens and closes hydraulically from the control panel. Upper
roll is raised automatically when the cover is opened.
•Conical opening and closing via control panel.
•Hydraulic motor and planetary reducer driven central rolls (upper and lower rolls)
•Calibration
•Registered manufacturing quality with CE, ISO 9001-2008, TSEK and TURQUM
certificates.
Also, in order to facilitate the bending operation:
•Infinitely adjustable rotation speed
•Side and central supporters for big sheet metal diameters
•Material feed table
•CNC Graphical control system
•NC Playback control system
•Replaceable upper roll (for smaller diameters)
•Oil cooling system Motors with different voltages and frequencies

A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
T: [phone]
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DESCRIPTION, USAGE AREAS AND CONDITIONS OF THE MACHINE
•Plate bending machine is designed to bend materials as cylindrical full circles (tube),
half circles, arcs and cones.
•Plate bending machine bends sheets with the thickness and width as specified in its
specifications.
•Machine is protected with various sheet construction housings.
•It is intended for bending plates within the limits specified in technical specifications
as per the safety, operation and maintenance instructions given in the operation
manual of the machine.
•Bending operation shall be performed with utmost care.
•Operator shall have adequate training for the operation and maintenance of the
machine, and shall be at the proper age as per the legislation of the relevant country.
•Use the protection and safety equipment specified in operation manual. Also, use the
personal protective equipment and/or other protective equipment required as per
the operation conditions.
•Safety measures include the operation of the machine as specified above.
•Use the drilling machine rationally and carefully to ensure operator safety and to
increase life cycle of the machine.
•Read the manual carefully after receiving the machine, and then operate it.
•As the plate bending machine is manufactured with advanced technology, proper use
and a good maintenance plan would increase the efficient life cycle of the machine.
•Human errors and improper use may cause serious damage to the machine. This may
increase the wear of parts and even cause serious safety risks for the operator.