Engel TDF HB-1640 Instruction manual

ENGEL TDF®HB-1640
ROLLFORMER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Manual-MN061305
June 2005

© 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.

June 13, 2005 i
TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY SECTION
LOCKOUT GUIDE
MATERIAL PROCESSING
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 Guide............................................................................................................2-1
(a) Male Button Lock Adjustment...................................................................... 2-2
(2) Factory Roll Gap Settings............................................................................................2-3
(a) Resetting Roll Gap & Tension...................................................................... 2-3
(3) Side Roll Adjustment....................................................................................................2-5
(4) Short Part Assist Platform............................................................................................2-6
(5) Straightener Roll..........................................................................................................2-7
(6) Rubber Support Rollers ...............................................................................................2-7
3. SYSTEM CONTROLS...............................................................................................................3-1
(1) ROLLFORMER START/STOP PENDENT ..................................................................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. PREVENTIVE MAINTENANCE......................................................................................................... 4-7
(1) Daily Maintenance .......................................................................................................4-7
(2) Monthly Maintenance...................................................................................................4-7
D. ASSEMBLY DRAWINGS & ELECTRICAL SCHEMATICS............................................................... 4-9
E. ORDERING PARTS .......................................................................................................................... 4-9
F. RETURNS.......................................................................................................................................... 4-9
(1) Returning Parts For Repair..........................................................................................4-9
(2) Warranty Returns.........................................................................................................4-9
(a) Warranty Claim Approved.......................................................................... 4-10

ii June 13, 2005
(b) Warranty Claim Disapproved. ....................................................................4-11
(3) Returning Unused Parts For Credit............................................................................4-11
G. 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....................................................................................4-6
Table 4-6. Inspection Schedules...........................................................................................4-7
LIST OF FIGURES
Figure 1-1 Engel HB-1640 TDF® Rollformer ........................................................................1-1
Figure 2-1 Rollformer Assembly............................................................................................2-1
Figure 2 TDF Profile..............................................................................................................2-1
Figure 2-3 Entrance Guide Setup..........................................................................................2-2
Figure 4 Male Button Lock Locations....................................................................................2-2
Figure 5 Roll Gap Adjustment Components..........................................................................2-3
Figure 6 Roll Gap Locations..................................................................................................2-4
Figure 7 Side Roll Adjusting Components.............................................................................2-5
Figure 8 Side Roll Clearances...............................................................................................2-5
Figure 9 Short Part Assist Platform.......................................................................................2-6
Figure 10 Straightening Roll..................................................................................................2-7
Figure 11 Rubber Support Rollers.........................................................................................2-7
Figure 3-1 Start/Stop Pendent...............................................................................................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

June 13, 2005 Page 1-1
HB-1640 TDF®Rollformer
1. INTRODUCTION
The HB-1640®TDF Rollformer is equipped with Engel’s patented TDF flange and clip rolls,
which produces integral flange on straight ductwork and fittings. The HB-1640 is equipped
with sixteen forming stations, which produces the most consistent flange in the industry.
The patented flange design requires no adjustment when switching from 18 to 26 gauge
material. The TDF corners “Snap” into the flange without crimping. A small parts feeder is
included for minimum parts of 6 inch lengths.
A 7.5 HP motor is used to power the HB-1640, which in turn produces a production rate of
approximately 75 feet per minute. This machine was engineered and designed to provide
years of dependable service.
Figure 1-1 Engel HB-1640 TDF® Rollformer

Page 1-2 June 13, 2005
A. INSTALLATION
In selecting a location for the line, consider these factors:
•Working weight (including oil tank filled to capacity) in relation to the building structure for
proper support.
•Access to the selected location where the machine will be installed.
•An adequate area to allow sufficient working space around the machine (a clearance of
at least 3 feet or 914 mm) for proper ventilation and maintenance.
Some thought should also be given to availability of the required power source (refer to the
electrical drawing shipped with the machine or in the back of the manual). The machine
should also be located away from grinding machines, sanding machines, spray painting areas
and other sources of contamination if practical.
Answers to questions regarding site preparation and other technical assistance is available
free of charge via telephone between the hours of 8 AM and 4:30 PM CST Monday through
Friday by calling the Engel Customer Service Department at 314-638-0100.
(1) Unpacking The Machine
When the machine arrives, inspect it carefully before accepting the shipment. It is
important to note any damage on the Bill of Lading or other shipping documents so that a
claim can be filed with the carrier.
Pay special attention to the control console, because it contains delicate electronic
devices. Check for physical damage to the switches and the components inside. If
anything looks damaged, notify both the carrier (to file a claim) and our Customer Service
Department (to order replacement parts). It is important to notify the factory promptly so
the new parts arrive before the machine is installed, as it may not be possible to start up
and run the machine without them.
Normal procedures should be used to unpack the machine. Remove any covering, steel
strapping or skids that may be present. Remove all wooden blocks (used as spacers to
prevent movement of the machine parts during shipment). After inspection and
unpacking, prepare to move the machine into position, using the floor layout drawing in
the back of this manual. This can be done with a fork truck or overhead crane. Once the
equipment is in position, fill the hydraulic tank with Mobile Dte 25 hydraulic oil (or
equivalent) if applicable and make the necessary electrical connections. Then bring in the
required power source to the main control console. When doing the electrical hookups,
refer to the electrical drawings supplied with the equipment if necessary.
To safely operate this machinery, all personal must read and understand the safety
section of this manual. Study and follow the safety precautions in this section, which are
intended to prevent injury to you and your fellow workers. However, they cannot cover all
possible situations. Therefore, consider the consequences of your actions before
executing any procedure or operation.
B. SAFETY
(1) Safety Precautions (Before Starting The Machine)
¾Protect yourself. Wear safety glasses and leather gloves while handling the material.
Do not wear loose clothing, neckties, or jewelry. If long sleeves must be worn, avoid
cuffs and buttons.

June 13, 2005 Page 1-3
¾Keep your work area clean. Remove all scrap, oil spills, rags, tools, and any other
loose items that could cause you to slip, trip, or fall.
¾Make sure that hydraulic pressures are at specified levels before operating the
machine.
¾Be alert for loose, worn, or broken parts. Do not attempt to operate the machine with
such parts present, or if the machine is making unusual noises or actions.
¾Be sure that this manual is kept near the machine so the operator can refer to it when
necessary. If you have not already done so, study the manual before operating the
machine.
¾Be aware of the location of the POWER OFF push-button as well as the Emergency
Stop push-button and use them to stop the machine in emergencies.
(2) Safety Precautions (While Operating The Machine)
¾Be alert when operating the machine.
¾Only one person should control the machine. Never allow anyone to operate the
controls while you are working on the machine.
¾Remove all Power and tag and lock it out any time someone is working on or repairing
the machine.
¾Keep your arms and hands away from the internal workings of the machine when
starting, running, or stopping the machine.
¾Never leave the work area while the machine is running.
¾Use good quality metal coils free of damaged or mashed ends.
¾Continually observe the punching, shearing, and rollforming of the metal and monitor
the machine. If any unusual condition develops, immediately stop the machine and
investigate.
¾Do not work on any moving device without first powering down the machine and taking
every safety precaution.
¾When cleaning the machine, or any components, do not use toxic or flammable
substances. Do not perform any cleaning while the machine is running. Never
override or disable any safety switch or safety interlock.
¾Use proper size wrenches and tools. Do not use adjustable crescent wrenches or
worn wrenches. A slipping wrench can cause a serious injury. Replace worn nuts,
bolts, screws, etc., being sure they are of equivalent quality of those being replaced.
¾Use caution when using an air hose to clean in and around the machine. Air pressure
may drive dirt and small chips into bearing surfaces or cause bodily injury.

June 13, 2005 Page 2-1
2. SYSTEM OVERVIEW
A. ROLLFORMER
The Engel TDF Rollformer utilizes 16 forming stations to produce an integral TDF flange on
straight ductwork and fittings. It is powered by a 7.5 HP motor, with a production rate of
approximately 75 feet per minute.
The forming rolls were factory pre-gapped and should require little or no adjustment. The pre-
gap settings allow the production of various gauges, without resetting any roll gap.
Figure 2-1 Rollformer Assembly
(1) Entrance Guide
Located at the entrance end of the rollformer is a single guide which is used to support the
material as it enters the first set of forming rolls, which sets the location of the roll knives,
used to create the male button lock. The entrance guide also determines the position of
the profile on the short leg of the TDF pocket. The inside of the short leg should end at
the bottom of the pocket (see photo).
Figure 2 TDF Profile

Page 2-2 June 13, 2005
The face of the Entrance Guide just before the material enters the first forming roll is set
approximately 2 5/8” from the outside face of the first forming roll and is tailed out (see
illustration) approximately .030 on the entrance end, which allows the material to be pulled
straight as it enters the forming rolls.
DANGER:
NEVER perform maintenance or make any adjustments without removing power from
any power source and locking out that source. SAFETY IS ALWAYS FIRST!!!!!!
Figure 2-3 Entrance Guide Setup
(a) Male Button Lock Adjustment
The male button lock location, 3/16” from the side of the sheet to the knives, was set
at the factory and should require little or no adjustment. This location is determined
by the location of the entrance guide. If the male button lock dimension is incorrect,
the male lock may be flattened as the part is formed, resulting in NO button lock on
the inside of the TDF pocket.
To check the location of the male button lock, run a short piece of 20 gauge material
to check for knife location. Adjust entrance guide as needed to ensure the desired
distance is achieved.
Figure 4 Male Button Lock Locations

June 13, 2005 Page 2-3
(2) Factory Roll Gap Settings
The forming rolls were factory pre-gapped and should require little or no adjustment. The
pre-gap settings allow the production of various gauges, without resetting roll gap.
All 16 stations are factory gapped at .015 with the exception of the side rollers on stations
9, 15 and 16, which require special pre-gaps. Each set of four forming stations is
equipped with four Tensioning Assemblies (Items A-D) and four Roll Gapping Assemblies
(Items Eand F). All four of each type of assembly must be adjusted during this
procedure.
A Tension Bolt
B Locking Jam Nut
C Adjusting Jam Nut
D Tension Spring
Washers
E Roll Gap
Adjustment Bolt
F Jam Nut
Figure 5 Roll Gap Adjustment Components
(a) Resetting Roll Gap & Tension
The following is the recommended procedure for resetting the forming rolls to factory
specifications.
1. Ensure ALL power sources are shutoff and locked out.
DANGER:
NEVER perform maintenance or make any adjustments without removing power from
any power source and locking out that source. SAFETY IS ALWAYS FIRST!!!!!!
2. Remove the top cover.
3. Loosen Locking Jam Nut (B) on each Tensioning Assembly.
4. Turn Adjusting Jam Nut (C) clockwise until snug on each Tensioning Assembly.
5. Now, turn Adjusting Jam Nut (C) counter clockwise three flats on the nut on each
Tensioning Assembly, which sets the proper tension on the forming rolls.
6. Retighten all Locking Jam Nuts (B).
7. Loosen the Jam Nut (F) on each Roll Gapping Assemblies.
8. Turn each Roll Gap Adjustment Bolt (E) counter clockwise on each Tensioning
Assembly until the forming rolls are seated on top of each other.

Page 2-4 June 13, 2005
9. With a feeler gauge, raise the forming rolls slowly with the Roll Gap Adjustment Bolts
(Item E), until the desired gap (.015) is obtained.
NOTE:
Each set of four forming rolls are contained by a single side plate, so adjusting the first roll
and the last roll in each set of side plate is all that is required. The second and third roll
gaps will be set once the first and fourth are set.
Figure 6 Roll Gap Locations
10. This may take several adjustments to achieve the desired results.
11. Once the adjustment has been made retighten all Jam Nuts (F) on each Tensioning
Assembly and then confirm proper gap.

June 13, 2005 Page 2-5
(3) Side Roll Adjustment
Located at stations 9, 15 and 16 are Side Rolls used in conjunction with the stacked
forming rolls. The Side Rolls assist in completing two separate 90°bends. They are
equipped with and eccentric cam used to adjust the rolls latterly and one or two sets of
push/pull bolts used to set the vertical clearance.
A Eccentric Cam Set Screw
B Vertical Clearance Adjustment Bolt
C Lock Nut
D Lock Bolt
Figure 7 Side Roll Adjusting Components E Eccentric Cam
Figure 8 Side Roll Clearances
1. Vertical Adjustment
1. Ensure ALL power sources are shutoff and locked out.
DANGER:
NEVER perform maintenance or make any adjustments without removing power from
any power source and locking out that source. SAFETY IS ALWAYS FIRST!!!!!!
2. Remove the top cover.
3. Loosen both Lock Bolts (D).

Page 2-6 June 13, 2005
4. Loosen all Lock Nuts (C).
5. Using a feeler gauge, raise or lower the Side Roll assembly until the
desired clearance is obtained. Ensure the Side Roll assembly maintains a
90° angle to the bottom of the side plate.
6. Once the desired clearance is set, tighten the Lock Nuts (C) and Lock
Bolts (D).
7. Recheck clearance.
2. Lateral (Horizontal) Adjustment
1. Ensure ALL power sources are shutoff and locked out.
DANGER:
NEVER perform maintenance or make any adjustments without removing power from
any power source and locking out that source. SAFETY IS ALWAYS FIRST!!!!!!
2. Remove the top cover.
3. With an Allen wrench, loosen both Eccentric Cam Set Screws (A).
4. With the same wrench, insert the wrench into the positioning hole exposed
at the bottom of the Eccentric Shaft.
5. Using a feeler gauge, rotate the Eccentric Shaft (E) until the desired
clearance is obtained.
6. Secure both Eccentric Cam Set Screws (A).
7. Verify clearance.
(4) Short Part Assist Platform
For parts shorter than twelve inches, a Short Part Assist Platform is used to support the
material as it’s formed. Before using, ensure the guide rail is straight for proper tracking
and has a light coat of grease so the platform slides without binding.
To use the platform, position the platform over the guide rail at the entrance end of the
rollformer. Slide the part to be formed against the entry guide and secure it with two sets
of Vice Grips™ or similar clamps. Apply power to the unit and slide the platform into the
first set of forming rolls.
Figure 9 Short Part Assist Platform

June 13, 2005 Page 2-7
(5) Straightener Roll
Located on the exit end of the Rollformer is an adjustable roller (A) that can be raised or
lowered to remove down or up bow in the parts. If up bow is present, loosen the lock
screw (B) and lower the roll with the adjustment knob (C) or raise the roll if down bow is
present and retighten the lock screw.
This roll is typically only required when running 26 gauge material.
Figure 10 Straightening Roll
(6) Rubber Support Rollers
Located at stations 13 through 16 are four rubber support rollers that are used to hold the
material down as it passes through the last four stations of the rollformer. These rolls
enable the flange to be formed at a 90° angle.
If the flange is less than 90°, lower the rolls until they ride firmly on the material as it
passes underneath. If the flange is greater than 90°, raise the rolls slightly.
Figure 11 Rubber Support Rollers

June 13, 2005 Page 3-1
3. SYSTEM CONTROLS
This section describes the operational controls for the rollformer. The only control of the Engel
HB-1640 is a single hand held control pendent. This pendent is used to start and stop the
forming rolls.
(1) ROLLFORMER START/STOP PENDENT
A handheld controller used to start and stop the forming rolls. To utilize this switch, the
Rollformer must have power applied to the unit.
Figure 3-1 Start/Stop Pendent

June 13, 2005 Page 4-1
4. MAINTENANCE
A. TORQUE VALUES FOR GENERAL ASSEMBLY
The torque chart value (Table 1 and 2) is provided for reference when performing general
assembly of various components. These values should be used only if torque values are not
otherwise specified for a particular assembly. Refer to the associated assembly drawings for
assemblies or other component assemblies that may require special torque specifications.
The following conditions must be observed when using the general assembly torque values:
•Joints are assumed to be metal and rigid. Do use these values where gaskets or compressed
material may be damaged by over-torquing.
•During disassembly, note bolt head markings and always reassemble the same hardware or
equivalent new hardware in the correct locations.
•As a general rule, when reusing previously removed hardware, apply the minimum values from the
table.
•Reduce the table values by 20% when assembling plated hardware or phosphate coated
hardware.
•Reduce table values by 30% when molykote, white lead, or similar mixtures are used to lubricate
threads.
•Reduce the table values by 35% when torquing jam nut (thin nuts).
•Special use column values in the table are for capscrews in gray iron castings when
thread length engagement is at least 1.5 times the capscrew diameter.

Page 4-2 June 13, 2005
Table 4-1. Metric Bolt And Cap Screw Torque Values
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Lubricated* Dry* Lubricated* Dry* Lubricated* Dry* Lubricated* Dry*
size
N-m Lb-ft N-m Lb-ft N-m Lb-ft N-m Lb-ft N-m Lb-ft N-m Lb-ft N-m Lb-ft N-m Lb-ft
M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5
M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190
M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 220 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
DO NOT use these values if a different torque value or tightening
procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.
Make sure fasteners threads are clean and that
you properly start thread engagement. This will
prevent them from failing when tightening.
Shear bolts are designed to fail under predetermined loads. Always
replace shear bolts with identical property class.
Fasteners should be replaced with the same or higher property class.
If higher property class fasteners are used, these should only be
tightened to the strength of the original.
* "Lubricated" means coated with a lubricant such as engine oil, or
fasteners with phosphate and oil coatings. "Dry" means plain or zinc
plated without any lubrication.
Tighten plastic insert or crimped steel-type lock
nuts to approximately 50 percent of the dry
torque shown in the chart, applied to the nut, not
to the bolt head. Tighten toothed or serrated-
type lock nuts to the full torque value.

June 13, 2005 Page 4-3
Table 4-2. Unified Inch Bolt And Cap Screw Torque Values
Grade 1 Grade 2bGrade 5, 5.1, or 5.2 Grade 8 or 8.2
Lubricated* Dry* Lubricated* Dry* Lubricated* Dry* Lubricated* Dry*
size
N-m Lb-ft N-m Lb-ft N-m Lb-ft N-m Lb-ft N-m Lb-ft N-m Lb-ft N-m Lb-ft N-m Lb-ft
1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46
7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115
9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160
5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
DO NOT use these values if a different torque value or tightening
procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.
Make sure fasteners threads are clean and that
you properly start thread engagement. This will
prevent them from failing when tightening.
Shear bolts are designed to fail under predetermined loads.
Always replace shear bolts with identical property class.
Fasteners should be replaced with the same or higher property
class. If higher property class fasteners are used, these should
only be tightened to the strength of the original.
Tighten plastic insert or crimped steel-type lock nuts to
approximately 50 percent of the dry torque shown in the
chart, applied to the nut, not to the bolt head. Tighten
toothed or serrated-type lock nuts to the full torque
value.
* "Lubricated" means coated with a lubricant such as engine oil,
or fasteners with phosphate and oil coatings. "Dry" means plain
or zinc plated without any lubrication.
bGrade 2 applies for hex cap screws (not hex bolts) up
to 152mm (6 in.) long. Grade 1 applies to hex hex cap
screws over 152 mm (6 in.) long, and for all other types
of bolts and screws of any length.

Page 4-4 June 13, 2005
B. SERVICING
(1) Lubricant Recommendations / Specifications
To ensure that the system is kept in a correct operating condition, it must be inspected
and maintained on a regular basis. Proper cleaning and/or replacement of filters, the
periodic lubrication of bearings, bushings, chains and other moving friction and wear
generating points will prevent damage to or failure of the unit, and provide optimum
performance.
Table 4-3 lists the types of lubricants used to maintain the equipment. The LUBE TYPE
code on the left side of the table is utilized to identify the lubricant used in the text of this
manual.
Table 4-3. Recommended Lubrication Products
Lube Type Description Recommended Products
A CHAIN OIL WAY LUBRICANT 220
B MULTI-PURPOSE LUBE LUBRIKO M6
MARFAX MULTI-PURPOSE #2 (TEXACO)
MULTI-PURPOSE #2 GREASE (AMACO)
MOBILITH AW #2 (MOBIL)
C GEARBOX OIL SYNTHETIC OIL 634 (MOBILE)
VAN GUARD CYLINDER OIL 680 (TEXACO)
CYLINDER OIL 680 (AMACO)
D HYDRAULIC OIL DTE #25 MOBILE (NON-HYPOID)
RANDO HYD AW46 HYDRAULIC OIL (TEXACO)
AW-68 HYDRAULIC OIL (AMACO)
E GEAR GREASE ENLUBE S-CHEM 10M-2
(2) Lubrication, General Requirements
Table 4-5 shows some of the lubrication points on the system. The maintenance
technician must become familiar with all the lubrication points located throughout the line.
Chain drives, rack and pinion locations, dies, rollers, hand wheels, and those points where
metal-to-metal contact of movable surfaces are located must be adequately lubricated.
The lubrication schedule shown in Table 4 was developed as a "general" application. The
actual lubrication requirements for the line and for individual points will be determined by
usage requirements. These requirements will be based on line setup, usage, and
equipment environment.
During lubrication procedures, a preventative maintenance inspection should also be
conducted. Check the machine visually for loose nuts, bolts, parts out of adjustment, etc.
Correct all deficiencies while they are small, and before they become operational
problems.
Certain parts of the machine are left unpainted to aid in the movement of the slide
assembly when changing dies, etc. Keep these areas clean and coated with light grease.
(3) Lubrication Schedule
The lubrication schedule shown in Table 4-4 was developed as a "general" application.
The actual lubrication requirements for the line and for individual points will be determined
by usage requirements. These requirements will be based on line setup, usage, and
equipment environment.
1. Do not over-lubricate.

June 13, 2005 Page 4-5
2. When using a low pressure grease gun, lubricate only to the point of grease
starting to come out of the edges of the seals, etc., of the item being lubricated.
3. Do not over lubricate chains. Chain drives should not be lubricated to the point that
oil is "flung" off during operation.
4. Ensure that proximity sensor heads are kept clean and free of lubricant. Dirty
sensor heads will affect system operation.
5. NOT ALL lubrication points are shown in “System Lubrication Points” photos,
ensure ALL points are identified and properly lubricated.
Table 4-4. Lubrication Schedule
Procedure Lube
Type Weekly Monthly 6 Months 12 Months
ROLLFORMER
Shaft Support Bearings B X
Ball Screws C X
Gears E X
Roll Bearings B X