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: +90 224 280 75 00
F: +90 224 280 75 01
E: info@akyapak.com.tr
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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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: 0090 224 280 75 00
E-mail: [email protected]
A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
T: +90 224 280 75 00
F: +90 224 280 75 01
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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: +90 224 280 75 00
F: +90 224 280 75 01
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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.
A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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SAFETY WARNINGS
SAFETY FACTORS
Upper and lower rolls of AKYAPAK 4 roll bending machine can be rotated. Operator's hand
and fingers can be caught by these rolls. Ensure that parts of your clothing or your fingers
are not caught in these rolls while the machine is being operated.
•Do not perform repairs while the machine is being operated.
•Ensure that you have turned off the machine before lifting the rear plate.
•Check the safety rope after closing the plate.
A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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PRESS EMERGENCY STOP BUTTON IN CASE OF AN EMERGENCY OR PRESS ON THE ROPE
AROUND THE MACHINE
•Press emergency stop button in case of an emergency or press on the rope around
the machine.
•Stop the machine before maintenance and cleaning.
•Never remove the safety plates.
POSSIBLE RISKS ON THE MACHINE
Precautions for risks are taken on AKYAPAK 4 roll cylinder.
For example:
•Electrical installation is protected with a metal cover.
•Another dangerous area is where the rolls rotate. Risky conditions may occur in case
of wrong and erratic operation.
•Safety rope is placed around the machine against accident during operation.
RISK OF DAMAGE
•Operator's fingers and hands
•Operator's clothing and other belongings
•Deformed operating material
•Third persons in material bending
•Bending materials for the machine
Anyone who will be operating, installing and maintaining the machine shall read the
operation manual with an applied and active manner. Do not try to bend hard materials
other than aluminium and metal sheets; you may hurt yourself or cause damage to the
A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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machine. It is forbidden to make any modification on the machine for safety and efficiency
reasons. Operating and safety instructions specified in operation manual shall be followed
and applied.
MACHINE FUNCTIONS
AKYAPAK 4 roll hydraulic cylinder is designed to form the material, and its other functions
are given in the table below. This machine can bend closed and semi-closed tubes and cones.
Machines are manufactured in different capacities and dimensions as per the thickness of
the material to be bent.
Check the thickness of plate before starting to bend the material. Do not attempt to bend
material with the thickness higher than specified.
Cylinder diameter of AKYAPAK asymmetrical bending machine, width and thickness of the
material to bend are shown below.
For example AHS 3100*10/14
AHS=machine type
3100=width of the material to be bent
10=thickness of the material that may be bent up to 3 three times of cylinder diameter
These values are required for material with St-37 grade.
Yield point=240 N/mm2
Shrinkage point=370 N/mm2
PROPER OPERATION OF THE MACHINE
All bending operations shall be performed by one person, from the front of the machine,
where the control panel is. Then, material shall be placed on the machine and another
employee shall help him, and other bending operations shall be performed by the operator.
However, operator shall take all safety precautions and check all bending operations.
A safety area shall be available around the machine and no one shall enter this area other
than the operator in order to achieve maximum rate of bending operations.
A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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IMPROPER OPERATION OF THE MACHINE
No one shall be inside the safety area during bending.
Power shall be cut off during repair.
No one shall get over the machine in any circumstances.
PROPER OPERATOR
Persons under the age of 16 are not allowed to operate 4 roll hydraulic cylinder. Operator
who will be operating the machine shall confirm that he has read the manual and received
all equipment.
Contact AKYAPAK in case of any doubt.
A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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PROTECTION OF OPERATOR
Operator is not required to other precautions under normal operating conditions of the
machine.
During operation:
Employees shall wear steel boots against the risk of dropping material and work gloves for
the handling of the machine. Qualified staff shall have proper equipment for machine
maintenance.
•Screwdriver set
•Allen set
•Wrench set
•Lubrication gun
•Gloves
•Steel boots
SAFETY FACTORS IN THE MACHINE INSTALLATION
AKYAPAK machine shall be placed on a hard and level ground (check the placement plan).
Machine may cause serious damage and accident if it is tipped over.
Material that is not properly installed cannot be bent correctly. Moreover, wrong placement
of the material may cause damage.
If the machine is stored, it shall be covered with tent and protected against dust.
SAFETY PRECAUTIONS
Safety precautions of 4 roll cylinder machine is given below. A check list is added to ensure
that these precautions are checked by the operator.
CHECK THESE SAFETY PRECAUTIONS
•Always check these factors before any shift.
•Please check the safety points regularly every week.
•Check these safety precautions after any maintenance operation.
A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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CHECKING OF MAINTENANCE POINTS
•Check if the position of the machine is correct.
•Check for any noise from the machine.
•Check whether the machine functions correctly.
•Check the machine is placed correctly.
Removed any problems or errors before operating the machine. Stop the machine
immediately and contact the dealer or AKYAPAK if you observe any problem during the
operation of the machine.
Do not skip safety elements before operating the machine or during operation.
SAFETY FEATURES
•Protective cover
•Main switch and circuit switch on the power panel
•Power indicator on power panel that indicates the electrical power
•Temperature indicator on power panel (indicates overloading)
•Emergency stop button on the control panel
•Switch on the control panel
•Indicator on the control panel
•Other buttons on the control panel
•Warning labels
•Condition of power cord
•Connection cables of control panel
•Whether manual lubrication is performed
•Safety rope
A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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SAFETY PRECAUTIONS CHECK LIST
Take a copy of this check list and use it on every inspection and operation. Mark with X after
checking each feature and function and file it against a risk of fault.
CHECK LIST
CHECKED BY
MACHINE NAME AND
NO
DATE
-PROTECTIVE COVERS = they shall be in place and screwed
-ELECTRICAL ISOLATION MAIN SWITCH = it shall be installed and checked for
functioning.
-POWER LIGHT = it shall be installed and checked for illumination. Check for any
burned bulbs.
-HEAT LIGHT= it shall be installed and illuminated in case of overheating.
-EMERGENCY STOP BUTTON = it shall be installed on the control panel and checked if
it stops the main motor.
-ROCKER SWITCH BUTTON (0-1) = it shall be installed on the control panel. It shall be
functioning on indicator and control circuits.
-DISPLAY= it shall be installed and it shall open when the power is on.
-OTHER PANEL FUNCTION BUTTONS = they shall be installed and checked for
functioning.
-WARNING PLATE = it shall be secured and placed so that it can be seen easily.
-POWER CORD = it shall be secured on the machine safely and it shall not be broken
or peeled. It shall have a safety protection against mechanical damage.
A: Akçalar Sanayi Bölgesi Sanayi Cad.
No: 8/A 16225 Akçalar BURSA / TURKEY
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-CONTROL PANEL CONNECTION CABLE = it shall be installed and its flexible sheath
shall be checked.
OPERATING CONDITIONS
WARNINGS
•Do not modify components and systems of the machine without consent of
AKYAPAK.
•AKYAPAK warranty shall be void if any modification is made on the machine.
•Do not modify the power and safety systems of the machine to ensure operator
safety.
•Machine shall be installed, commissioned and delivered to the customer by AKYAPAK
staff only. Otherwise, AKYAPAK does not accept any responsibility and machine shall
be out of warranty cover.
•Loading wrong workpieces on the machine and operation may damage the machine
and cause a risk for the operator.
•Do not distribute this manual to other persons, companies and agencies.
A: Akçalar Sanayi Bölgesi Sanayi Cad.
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•This manual includes instructions on the installation, safety applications, operation of
the machine etc.
Akyapak machines are produced with high-quality feature. However, if the machine is
exposed to rain, snow, high temperature and moisture, excessive cold weather, etc. in
external environment, it shall affect the machine adversely. The machine should be placed in
a closed area protected against environmental conditions. Working environment of the
machine should not be affected by the weather conditions. Moreover, machine should be
placed away from flammable-explosive materials.
If the machine is not placed in a proper, protected area, warranty shall be void in case of
failures.
GENERAL INFORMATION
Operation manual provided by the manufacturer includes required information on the
machine components. Moreover, all operations in the manual are organized by considering
normal operation and periodical maintenance of the machine. Therefore, instructions shall
be strictly followed for correct and optimal operation of the machine. We advise you to keep
the operation manual in suitable conditions in a place that can be accessed easily. Machine
shall be operated by trained and qualified staff. Each part that shall be removed from the
machine and replaced shall be removed by authorized technicians. All operators of the
machine shall read these information, and the machine shall be operated then.
MANUFACTURER INFORMATION
Please contact us using the telephone, fax or e-mail information provided above for any help
requests when you have a problem related with the machine or for your spare parts orders.
It is important that you provide the following information on any correspondence on the
machine with the manufacturer or dealership you have purchased the machine for
minimizing the procedures required:
•Machine serial no.
•Machine model
•Date of purchase
Table of contents
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