Engel 800 Series Instruction manual

ENGEL 800 SERIES
ROLLFORMER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Manual-MN031407
March 2007

© Copyright by Engel Industries
All Rights Reserved
The information in this document has been reviewed and is believed to be completely accurate. However, no
responsibility is assumed for inaccuracies. Furthermore, ENGEL INDUSTRIES reserves the right to make
changes to any products herein, at any time, to improve reliability, function, or design. ENGEL INDUSTRIES
does not assume any liabilities arising out of the application or any use of any product described herein,
neither does it convey any license under its patent rights nor the rights of others.
TRADEMARK NOTICES
Engel Industries is a registered trademark. All other brand and product names are trademarks or registered
trademarks of their respective companies.

March 14, 2007 i
TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY SECTION
LOCKOUT GUIDE
ASSEMBLY DRAWINGS (Back of Manual)
ELECTRICAL SCHEMATICS (Back of Manual) Section/Page
1. INTRODUCTION........................................................................................................................1-1
A. INSTALLATION ................................................................................................................................. 1-2
(1) Unpacking The Machine ..............................................................................................1-2
B. SAFETY............................................................................................................................................. 1-2
(1) Safety Precautions (Before Starting The Machine)......................................................1-2
(2) Safety Precautions (While Operating The Machine)....................................................1-3
2. SYSTEM OVERVIEW................................................................................................................2-1
A. ROLLFORMER.................................................................................................................................. 2-1
(1) Entrance Guides..........................................................................................................2-1
(2) Triplex Outboard Feed Guide Option...........................................................................2-2
(3) Factory Roll Gap Settings............................................................................................2-3
(a) Resetting Roll Gap & Tension...................................................................... 2-3
(4) Roll Gap Chart.............................................................................................................2-4
(5) Slitter Attachment (Option)...........................................................................................2-5
3. SYSTEM CONTROLS...............................................................................................................3-1
(1) ROLLFORMER START/STOP SWITCH .....................................................................3-1
4. MAINTENANCE.........................................................................................................................4-1
A. TORQUE VALUES FOR GENERAL ASSEMBLY............................................................................. 4-1
B. SERVICING....................................................................................................................................... 4-4
(1) Lubricant Recommendations / Specifications..............................................................4-4
(2) Lubrication, General Requirements .............................................................................4-4
(3) Lubrication Schedule ...................................................................................................4-4
C. TOOLING REPLACEMENT............................................................................................................... 4-6
D. PREVENTIVE MAINTENANCE......................................................................................................... 4-7
(1) Daily Maintenance .......................................................................................................4-7
(2) Monthly Maintenance...................................................................................................4-7
E. ASSEMBLY DRAWINGS & ELECTRICAL SCHEMATICS............................................................... 4-9
F. ORDERING PARTS .......................................................................................................................... 4-9
G. RETURNS.......................................................................................................................................... 4-9
(1) Returning Parts For Repair..........................................................................................4-9
(2) Warranty Returns.........................................................................................................4-9
(a) Warranty Claim Approved.......................................................................... 4-10
(b) Warranty Claim Disapproved..................................................................... 4-11
(3) Returning Unused Parts For Credit............................................................................4-11

ii March 14, 2007
H. ASSEMBLY & ELECTRICAL DRAWINGS.......................................................................................4-21
LIST OF TABLES
Table 4-1. Metric Bolt And Cap Screw Torque Values..........................................................4-2
Table 4-2. Unified Inch Bolt And Cap Screw Torque Values.................................................4-3
Table 4-3. Recommended Lubrication Products...................................................................4-4
Table 4-4. Lubrication Schedule............................................................................................4-5
Table 4-5. System Lubrication Points....................................................................................4-5
Table 4-6. Inspection Schedules...........................................................................................4-7
LIST OF FIGURES
Figure 1-1 Engel 800 Series Rollformer................................................................................1-1
Figure 2-1 Rollformer Assembly............................................................................................2-1
Figure 2-2 Typical Entrance Guides (HB-825S Shown)........................................................2-2
Figure 2-3 Triplex Entrance Feed Guide...............................................................................2-2
Figure 2-4 Roll Gap Adjustment Components.......................................................................2-3
Figure 2-5 Roll Gap Locations...............................................................................................2-4
Figure 2-6 Slitter Attachment.................................................................................................2-5
Figure 3-1 Start/Stop Switch .................................................................................................3-1
Figure 4-1 Hydraulic Symbols Used On Assembly Drawings .............................................4-17
Figure 4-2 Electrical Symbols Used On Assembly Drawings (Sheet 1 of 2).......................4-18

SAFETY - 1
SAFETY SUMMARY
INTRODUCTION
Safety is everyone’s business. Whether you are an equipment operator, a maintenance
person, a supervisor, or business owner, you are directly responsible for the day-to-day safe
operation of your Engel equipment. It is your responsibility to maintain and operate this
equipment in strict compliance with all applicable laws, safety regulations, and the
manufacturer’s recommended procedures.
PROMOTING SAFETY
Institute a company safety program. The formation of an organized safety program is
strongly recommended. This safety program should include the formation of a safety
committee to review and update company safety policies on a regular basis. Establish a firm
policy on safety regulations in the work place. Publish these objectives, spelling out each
employee’s responsibilities. Make certain that each employee knows what is expected of
them.
SAFETY PROGRAM
The following steps are suggestions that a company developing, or expanding, a
comprehensive safety program should consider:
1. Engel Industries carefully design safeguards into their products in order to minimize
hazards. However, the manner in which equipment is incorporated into a manufacturing
process may inadvertently create a hazard or otherwise defeat built-in safeguards.
Closely examine the operation of your company’s processing equipment. Take notice of
potential hazards. Install guards or take other appropriate action to eliminate hazard
risks.
2. Make certain equipment operators and maintenance personnel are properly trained.
3. Setup a program of daily, weekly, and monthly machinery inspection. Make a check list.
Keep a historical record of all maintenance work, repairs, and adjustments.
4. Frequently evaluate safety guards and devices during actual production runs. Correct
any unsafe practice or situation immediately.
5. Establish safe, convenient material handling systems. If conveyor equipment is installed
in your facility, it should conform to recommendations published in the ‘American National
Standard, Conveyors and Related Equipment, Safety Standards for ANSI/ASME B20.1’
which are available from the American National Standards Institute (ANSI).
6. Provide personal protective equipment, such as safety glasses with side shields, safety
helmets, tongs, gloves, hand pads, spats, and protective sleeves, as required to suit the
operation.
7. Organize a company safety committee. Schedule periodic meetings on a regular basis to
review and update all safety policies.
8. Establish a firm policy on safety regulations in the work place. Publish these objectives,
spelling out each employees responsibilities. Make certain that each employee knows
what is expected of them.
9. Investigate all accidents and close calls. Take immediate action to prevent a recurrence
of the incident. Keep records of the investigation and the corrective measures taken.