GMC PBR-0412 Guide

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Table of Contents
I. Main Specifications and Safety Instruction … page3
II.Safety Instruction & Preparation ……………... Page3-5
III. Operation Instruction for E-Models ………… page5-12
HOW TO USE CONE ATTACHMENT TO MAKE A CONE… page9-12
IV. Operation Instruction for Manual Models … page13
V. Lubrication ……………………………………... page14
VI. Troubleshooting ……………………………… page14
VII. Electrical Diagrams for E-Models ……….. page15-16
VIII. Electrical Diagrams for Manual Models … Page17
IX. Part Breakdown for E-Models ……………….. page18-20
X. Part Breakdown for Manual Models ………. Page21-23

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I. MAIN SPECIFICATIONS
II. SAFETY INSTRUCTION
WARNING: THIS IS A VERY DANGEROUS MACHINE! FAILURE TO FOLLOW THE
SAFETY RULES MAY RESULT IN SERIOUS PERSONAL INJURY
As with all machinery there are certain hazards involved with operation and use of the
machine. Using the machine with respect and caution will considerably lessen the
possibility of personal injury. However, if normal safety precautions are overlooked or
ignored, personal injury to the operator may result.
This machine was designed and constructed for roll forming metal plate and some
similar material. We strongly recommend that this machine SHOULD NOT be modified
and/or used for any application other than for which it was designed. If you have any
questions about its application, do not use the machine until you contact us.
Read all instructions before using this very dangerous machine!
1. MACHINERY GENERAL SAFETY WARNINGS
1) Misuse of this machine can cause serious injury. For safety, machine must be set up,
used and serviced properly. Read, understand and follow instructions in the operator’s
and parts manual which was shipped with your machine.
2) Wear proper apparel. No loose clothing or jewelry which can get caught in moving
MODEL PBR-0412E PBR-04316E PBR-0425E PBR-0510E PBR-0610E
Max rolling width 51” 51” 51” 61” 81”
Max rolling thickness 12GA 3/16” ¼” 10GA 10GA
Rolling diameter 3-1/2” 4-3/4” 5-7/8” 4-3/4” 5”
Rotate speed 22rpm 16.5rpm 15rpm 16.5rpm 16.5rpm
Bending roll up/down motor motor motor motor motor
Main motor 2HP 3HP 4HP 3HP 4HP

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parts. Gloves and rubber soled footwear is recommended for best footing.
3) Do not overreach. Failure to maintain proper working position can cause you to fall into
the machine or cause your clothing to get caught — pulling you into the machine.
4) Keep guards in place and in proper working order. Do not operate the machine with
guards removed.
5) Avoid dangerous working environments. Do not use stationary machine tools in wet
or damp locations. Keep work areas clean and well lighted.
6) Avoid accidental starting, Make sure switch is in “OFF” position before plugging in
power cord.
7) Never leave the machine running while unattended. Machine shall be shut off
whenever it is not in operation.
8) Disconnect electrical power before servicing. Whenever changing accessories or
general maintenance is done on the machine, electrical power to the machine must be
disconnected before work is done.
9) Machinery must be anchored to the floor.
10) Use the right tool. Know the tool you are using — its application, limitations, and
potential hazards. Don’t force a tool or attachment to do a job it was not designed for.
11) Stay alert, Watch what you are doing; use common sense. Do not operate any tool
when you are tried. Keep hands in sight and clear of all moving parts and rolling
surfaces.
12) Keep children away. Children must never be allowed in the work area. Do not let them
handle machines, tools, or extension cords.
13) All visitors should be kept at a safe distance from the work area. Make workshop
completely safe by using padlocks, master switches, or by removing starter keys.
14) Store idle equipment. When not in use, tools must be stored in a dry location to inhibit
rust. Always lock up tools and keep out of reach of children.
15) General Electrical Cautions: This machine should be grounded in accordance with the
National Electrical Code and local codes and ordinances. This work should be done by
a qualified electrician. The machine should be grounded to protect the user from
electrical shock.
2. TRANSPORTATION (CERTIFIED FORKLIFT DRIVER IS REQUIRED)
1. Each chain or strap belt should be capable of lifting weight over 5,000LBS
2. The strap belt must be arranged properly as per cavity center of wooden box.
3. The forklift driver should be a qualified & trained person.
4. Machine should be loaded at the cavity center of the truck to avoid any sliding.
5. After loading onto truck, use steel wire to fix the machine body on truck and ensure
to fasten it firmly before transportation.
3. POSITIONING & CLEANING
·Site : When select site, ensure there is free space for material handing around the
machine.

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·Foundation: The machine requires a plain & stable ground to have an excellent bending
performance. It is better to be fixed on 150mm reinforced concrete ground.
·Leveling: Four sheet shims are placed under the adjusting bolt of the foot plate, the
machine is leveled by level gauge.
·Cleaning: Use a liquid solvent such as kerosene or white spirit to remove the protective
coating and any dirt from the up-painted surface of the machine. Don’t disturb any
moving parts until the full surface has been cleaned.
4. ELECTRICAL CONNECTION
·Before connecting machine into local 3-phase ac source at your plant, please double
check same voltage and phase.
·Connect the ac source with machine cable which has 4 wires, correctly, the ground wire
must be connected with ground.
·After connecting ac source to shaft, check motor rotation is in the correct rotation
direction as per the arrow on the motor.
·If wrong direction, please immediately stop motor to avoid motor damage. Please
correct your connection at ac source until motor rotation direction is in the correct
direction.
III. OPERATION INSTRUCTION
For models#
PBR-0412E/ PBR-04316E / PBR-0425E / PBR-0510E / PBR-0610E/ PBR-0810E &
PBR-1010E:
1.Press the down push button to move the bending roll down
2. Put the sheet metal material into the rolls as picture shown and crank the big
hand-wheel to barely touch the material.
Width of the sheet metal – is necessary to form the designed size circles is the 1st

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consideration in circle forming. Decide approximate length of material need. Use the
formulary “C=πx ID”(C is Circumference;πis 3.1416; ID is Internal Diameter).
Sample:ID=12”, operator need to prepare material length approximate 37.7” or
approximate length of material which need.
3.Push the up/down buttons to move the bending roll up/down for right position,
and press foot pedal to roll the sheet metal material.

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4. Press the foot pedal to make the rolls turn forward and reverse to roll the
material back and forth completely to make the part.
5. Press the foot pedal When finished with that part, then turn the cone
attachment down 90 degrees.
Loose this cone attachment

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Press the foot pedal Loosen this locking bolt, get ready to swing out the top
roller.
6.Rotate this handle counter clockwise 90 degrees, and hold and pull the top
roller shaft to swing out the top roller, then remove the part out of the top
roller. Then push the top roller back into the housing, and turn this handle
clockwise 90 degrees, make sure the top roller sits correctly. Turn the
black knob of the locking bolt to lock the top roller in position.
This handle is to
swing out the
top roller

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HOW TO USE CONE ATTACHMENT TO MAKE A CONE:
1. Make the material like circular sector
2. Loosen the set screw on the right coupler and remove it away from the left
coupler to disconnect the two couplers.
3. Push the up button switch to move right side of the bending roll up to make it
tilt as shown in the picture below.

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4.After the bending roll titling degree is set up correctly, please put the coupler
back and connect properly, then tighten the set screw to lock the coupler.
5. Put the sector material into the rolls, and crank the big hand-wheel to move the
pinch roll up till barely touching the sector material, one side of the sector material
will keep touching against the cone attachment while rolling it.
Material against
cone attachment.
Make this cone
attachment vertical

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6. Push the up button switch or down button switch to adjust the bending roll
position. Press the foot pedal to make the rolls turn.
7. Press the foot pedal to make the rolls turn forward and reverse to roll the
sector material back and forth completely to make the cone.

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8. Loosen and turn the cone attachment down, and swing out the top roller to
remove the cone part out.
Cone attachment

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IV. OPERATION INSTRUCTION
For Models# PBR-0412 / PBR-04316 / PBR-0510
1. Turn main switch on, then press push button “ON”
2. Length of material – necessary to form the designed size circles is the 1st consideration
in circle forming. Decide approximate length of material needed, Use the formulary “C=πx
ID”(C is Circumference;πis 3.1416; ID is Internal Diameter).
Sample:ID=12”, operator needs to prepare material length approximate 37.7” or
approximate length of material which is needed.
3. Cut a few pieces of material to the measured length for testing by roll forming. The
material might need to be lengthened or shortened depending upon the testing result.
4. Rotate this left hand-wheel to move the pinch roll up/down to barely touch the sheet
metal material, and rotate the right hand-wheel to move the bending roll up/down to set
up the bending radius.
5.Press foot pedal forward and reverse
to roll the material into the radius

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V. LUBRICATION
In this machine we have three grease fittings, please use grease gun to lubricate all of
them, 3 times a day, using grease oil Mobil # Dorcia-150
VI. TROUBLESHOOTING
Any questions, please call our service # 1-909-947-7787
www.gmcmachinetools.com www.GMCMachineTools.com
PROBLEM SOLUTION
The motor does not run
make sure the power supply connected correctly
Check the power voltage, 220V or 440V, +- 10%
Voltage can not be lower than 208V, 3phase
The rolls do not turn
On the control foot pedal, make sure the E-stop is fully released
and pops up
check the safety wire and make sure the limit switch is fully
released
Top roller can not push back Need to jog the foot pedal to turn the rolls a little bit because the
driven gears are not engaged well
Push or pull the safety cable but do not
shut down the machine
Check the limit switch for the safety cable to make sure the
distance is correct
The digital display number does not
change when the bending roll moves up
or down
Display wires may be loose or display is bad
The encoder is bad
How to make cone Tilt the bending roll and use the cone attachment
How to limit the flat spot
Make sure the pinch roll can not touch the material, need a little
gap
Roll the material one pass, then slip over the material and roll
second pass, and repeat to make a round part
Material has cracking waves Make sure the pinch roll isn't touching the material, needs a little
gap

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VII. ELECTRICAL SYSTEM
1. Preparation: The main wall breaker needs 30A or 50A, and 10Ga. 3 phase cables
2. Operation of the machine
Turn on main power switch, and the indicator light is on, which means the machine
Is connected with power supply correctly. Press the right foot pedal, the rolls turn
forward-clockwise continuously, release the foot pedal then rolls stop until loosen the
pedal. Press the left foot pedal, the rolls turn reverse-counter clockwise continuously,
release the foot pedal then rolls stop. If there is something wrong with the machine, push
the emergency stop button, or hit the safety cable on the handle to stop the machine.
3. Electric diagrams
4. The list of electrical components
No. Symbol Name
1 LW Main power switch
2 QF Breaker
3 SQ Limit switch
4 TC Control Transformer
5 KM Main contractor
6 FR1/FR2 Overload relay
7 EL Indicator light
8 TA Lash-up switch
9 M Motor

ELECTRICAL DIAGRAM FOR PBR-0412E/04316E/0425E/0510E/0610E/0810E/1010E:
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VIII. Electrical Diagrams for Manual Models ELECTRICAL DIAGRAM FOR PBR-0412/ PBR-04316 / PBR-0510:
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IX. Part Breakdown for E-Models PARTS BREAK DOWN FOR PBR-0412E/04316E/0425E/0510E/0610E/0810E/1010E:
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PARTS LIST FOR PBR-0412E/04316E/0425E/0510E/0610E/0810E/1010E:
Part # Description Qty Part # Description Qty
1 Protecting Cover 1 39 Key 8x45 2
2 Hex Bolt M6X10 5 40 Worm Shaft 1
3 Bolt M12X30 5 41 Right frame 1
4 Washer 3 42 Bottom roller 1
5 Big gear 1 43 Sleeve 2
6 Small gear 2 44 Adjusting block 2
7 Bushing 1 45 Oil cup M8X1 1
8 Washer 1 46 Bolt 1
9 Shaft 1 47 Nut M20 1
10 Block plate 1 48 Left frame 1
11 Hex Bolt M6X25 40 49 Supporting plate 1
12 Block plate 1 50 Hex Bolt M8X25 4
13 Spring pin 2 51 Shaft 1
14 Spacer Bushing 8 52 Washer 1
15 Supporting bushing 3 53 Bushing 2
16 Worm wheel 3 54 Chain wheel 1
17 Bearing 2 55 Connecting plate 1
18 Screw rod 2 56 Bolt M6X12 9
19 Locking bolt M6X16 4 57 Bolt M8X16 8
20 Adjusting block 2 58 Block plate 1
21 Washer 8 59 Small screw rod 2
22 Worm 1 60 Worm shaft 1
23 Worm shaft 4 61 Block plate 2
24 Block Plate 2 62 Connecting bushing 2
25 Locking bolt M6X16 8 63 Bushing 1
26 Connecting shaft 2 64 Locking bolt M10X30 1
27 Rear roller 1 65 Hex bolt M16X30 1
28 Key 6X25 4 66 Handle 1
29 Connecting bushing 2 67 Connecting bushing 1
30 Connecting bushing 2 68 Bushing 2
31 Nut M6x16 8 69 Rotary handle 1
32 Spring washer 2 70 Pole of Handle 1
33 Connecting bushing 3 71 Locking Nut M8 1
34 Hex Bolt M8X20 9 72 Hex bolt M8X45 1
35 Sleeve 1 73 Shaft 1