GOCMAKSAN B45X1 Installation and operation manual

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B45X1
GÖÇMAKSAN
GÖÇMAKSAN
Rev: 01/2013

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B45X1
GÖÇMAKSAN
1
CONTENTS
CONTENTS ................................................................................................................................................................1
LIST OF FIGURES .......................................................................................................................................................2
MAIN SAFETY INFORMATION ...................................................................................................................................3
TAGS USED ON THE MACHINE..................................................................................................................................3
INTRODUCTION ........................................................................................................................................................4
1. MAIN PARTS OF BENDING MACHINE ..................................................................................................................4
2. MACHINE ASSEMBLY ...........................................................................................................................................5
3. MACHINE RUNNING PROCEDURES ORDER .........................................................................................................6
4. TECHNICAL DATA.................................................................................................................................................7
5. EQUIPMENT SUPPLIED WITH MACHINE..............................................................................................................8
6. USING THE MACHINE............................................................................................................................................8
6.1. Correct Placement of the Rebar to be bent on the machine ........................................................................8
6.2. Incorrect placement of the rebars to bu bent on the machine.....................................................................8
6.3. Incorrect placement of the rebars to be bent on the machine.....................................................................9
7. PROHIBITED USAGE ON THE MACHINE............................................................................................................ 10
8. SCOPE OF WARRANTY ...................................................................................................................................... 11
9. PROTECTORS TO BE USED WHEN WORKING WITH THE MACHINE................................................................... 11
9.1. Protector apparel ....................................................................................................................................... 11
9.2. Work clothes............................................................................................................................................... 11
10.HANDLING THE MACHINE ................................................................................................................................ 11
11. CONTROLS AND SETTINGS ON THE MACHINE............................................................................... 12
11.1. Thermal flow setting range and motor protection switch ....................................................................... 13
11.2. Bent Bar Bending setting (45°): ................................................................................................................ 13
11.5. Stirrup Bending:..................................................................................................................................... 16
12. MAINTENANCE AND LUBRICATION INSTRUCTIONS ........................................................................................ 18
13. FAULTS AND SOLUTION OFFERS...................................................................................................................... 19
14. MACHINE EQUIPMENT LIST............................................................................................................................. 22
15. MACHINE ASSEMBLY DEMONSTRATION......................................................................................................... 24
16. MACHINE ELECTRICITY SCHEME...................................................................................................................... 25
17. ABOUT COMPANY ........................................................................................................................................... 28

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LIST OF FIGURES
Figure 1: Main parts of bending machine.................................................................................................................5
Figure 2: Leveling the machine on a solid ground...................................................................................................6
Figure 3: Control buttons..........................................................................................................................................7
Figure 4: Placing the rebars on the machine correctly .............................................................................................8
Figure 5: Incorrect placement of the rebars on the machine ....................................................................................9
Figure 6: Wrong placement of the rebars on the machine........................................................................................9
Figure 7: Wrong positioning of the person making bend...................................................................................... 10
Figure 8: Handling the machine............................................................................................................................ 12
Figure 9: Machine control panel and functions..................................................................................................... 13
Figure10: Bent bar bending indicator.................................................................................................................... 15
Figure11:Protractor bending demonstration.......................................................................................................... 15
Figure12: Hook Bending demo ............................................................................................................................. 16
Figure13: Stirrup bending demonstration.............................................................................................................. 18

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MAIN SAFETY INFORMATION
➢This symbol is put before the articles giving warning explanations in order to draw attention of the
trained operator to important functions.
€This symbol is put before the articles giving warning explanations in order to draw attention of the
trained operator to electrical issues.
This symbol is put before the sentences in order to draw attention of the trained operator to the
master instructions and directive regarding to handling or safety.
TAGS USED ON THE MACHINE
Trademark plate of manufacturer company
Logo plate of manufacturer company
B45X1
Model name tag of the machine
CE norm conformity tag
Plate on capacity and technical information of the machine
Machine user's and maintenance manual tag
Handling and carrying hook tag
Electricity panel warning tag
Grounding output tag

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INTRODUCTION
B45X1 Mechanic Rebar Bending Machine is made only with the purpose of steel material
bending. Using other than the indicated purposes are prohibited. It is possible to mount various
apparatuses on the machine optionally for bending in different shapes.
In order to obtain the best yield from the machine it should be in a situation so that it can be
worked easily and in a position that more productivity might be obtained from the operator. Because of
this the location where the machine is operated should be close to the rebar stocks. Besides, it shall be
more useful to cover top of the location where the machine is operated with a shelter. We suggest two
workbenches to be located on two sides of the machine. Length of these workbenches should be as long
as the longest rebar that will be bended. Since the operator will be able to work without turning, lifting
any kind of rebar, it will enable the operator to work more effectively.
Important Warning !!!
•User's and maintenance manuals must be read.
•Machine should be operated by instructed workers.
•When adjustments such as controlling, maintaining, lubing are being made electricity of the
machine must be cut off.
•All of the explanations given under user's and maintenance manual must be complied.
1. MAIN PARTS OF BENDING MACHINE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

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Figure 1: Main parts of bending machine
1
Machine Frame
5
Zero Adjustment
Pin
9
Bending Sleeve
13
Bending Plates
2
Electricity Board Cap
6
Stirrup Pin
10
Retainer
14
Machine Table
3
Sensor Pin
7
Straight Pin
11
Adjustment
spanner
15
Control Panel
4
Switch Adjustment
Pin
8
Bending Pin
12
Rebar Leading
Support Roller
16
Foot Pedal
17
Plate
2. MACHINE ASSEMBLY
•Machine should be leveled on a solid ground. Figure 2
•Electricity connection of the machine should be made by competent technicians.
Explanation:
Electricity Connection
•For main electricity connection plug should be connected to supply line with a 5x4 mm² isolated cable
and then plugged into power outlet.
•Grounding connection should be made for safety. Machine shouldn't be operated without making
grounding connection.
Connection of grounding line
The following procedures should be followed for this system.
Connect one end of the grounding to a copper wire (minimum 16 mm²) as it will enable
electrical conductivity.The other end should be either connected with a pipe that has a conductivity
capacity immerged into the ground (preferably into a humid ground) or the copper plate should be
burried into the ground as much as deep.

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Figure 2: Leveling the machine on a solid ground
3. MACHINE RUNNING PROCEDURES ORDER
•Be sure that the machine is assembled in conformance with the Machine Assembly procedures.
•If there is any object on the machine (including the bending apparatus) they must be removed.
•LEFT-RIGHT switch on the control panel of the machine is turned to LEFT or RIGHT position,
MAN AUTO switch is turned to MAN position and machine turning direction is confirmed by
pressing on the foot pedal.
Explanation: Rotation direction is approved by taking the front of the machine as reference (Control
pane side) the clockwise as right and counter-clockwise as left. If the machine is rotating reverse of the
switch it means phases of the electricity supply are feeding reversely. This situation doesn't effect the
running system of the machine. In such case LEFT-RIGHT switch might be turned to the other side or
competent electricians might change the directions of the phases.
After fixing the direction of rotation bending adjustments should start.
Control buttons
1
6
5
2
3
4

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Figure 3: Control buttons
1
P1 Button
6
Program On-Off Switch
2
P2 Button
7
On Button
3
P3 Button
8
Off Button
4
Left-Right Switch
9
Power Button
5
Man-Auto Switch
10
Foot Pedal
4. TECHNICAL DATA
Machine Bending Capacity:
Machine Model: B45X1
Machine Name: Mechanic Rebar Bending Machine
Machine Dimensions:
Width : 84 Cm
Length : 110 Cm
Height : 85 Cm
Weight : 450 Kg
Specifications of the Motor Used:
Motor power : 4 kW
RPM : 1450 rpm
Motor Voltage : 380 V
Frequency : 50 Hz
Steel Quality
Diameter/Bending Capacity
45 kg/mm²
Ø45x1
Ø30x2
Ø18x4
Ø14x6
Ø14x6
65 kg/mm²
Ø36x1
Ø26x2
Ø18x3
Ø12x7
Ø12x7
85 kg/mm²
Ø32x1
Ø20x2
Ø14x4
Ø10x8
Ø10x8

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5. EQUIPMENT SUPPLIED WITH MACHINE
•Pin: 5 Pieces
•Stirrup Pin : 1 Piece
•Straight Pin : 1 Piece
•Bending Sleeve 5 Pieces
•Adjustment spanner 1 Piece
•SWITCH pin 6 pieces
•Retainer : 1 Piece
6. USING THE MACHINE
6.1. Correct Placement of the Rebar to be bent on the machine
Fixing the rebor to be bent on the machine with
the help of a retainer (4a)
Fixing the rebars to be bent on the machine with
the help of bending sleeves (4b)
Fixing the rebars to be bent on the machine in
multi-rebar bending with the help of a retainer
(4c)
Fixing the rebars to be bent on the machine in
multi-rebar bending with the help of bending
sleeves. (4d)
Figure 4: Placing the rebars on the machine correctly
6.2. Incorrect placement of the rebars to bu bent on the machine
Incorrect connection of a single rebar to be
bent with bending sleeves on the machine
(5a)
Incorrect connection of a single rebar to
be bent with retainer on the machine (5b)
(4a)
(4b)
(4c)
(4d)

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Figure 5: Incorrect placement of the rebars on the machine
6.3. Incorrect placement of the rebars to be bent on the machine
Incorrect connection of multi-rebars to be bent on
the machine with bending sleeves
Incorrect connection of multi-rebars to
be bent on the machine with retainer
Figure 6: Wrong placement of the rebars on the machine
(5a)
(5b)
(6a)
(6b)
(6c)
(6d)

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Figure 7: Wrong positioning of the person making bend
7. PROHIBITED USAGE ON THE MACHINE
➢When bending no one must stand in front of the machine and any one standing must be taken away.
(Figure 7)
➢While the machine is running no any other construction material such as adze, hammer, meter,
caliper etc. should be put between the bending apparatus other than the material that will be bent.
➢Machine mustn't be run when it is wet.
➢No any bending must be made other than the measurements, dimensions and units stated on the
capacity plate (Figure 1-17).
➢During the multi bending number of rebars stated on the capacity plate should be aligned one on top
of the other and should be leaned to the retainer or bending rollers. No any other bending should be
made other than this. (Figure 6c-6d)
€Machine mustn't be run when the electricity Board Cap (Figure 1-2) is open.
€Electrical settings made in the factory shouldn't be changed.
€Machine shouldn't be operated without making grounding connection.
➢Machine shouldn't be operated when the housing covers are dismantled.
➢Machine should be operated by instructed workers.
➢Machine never should be run unlubricated.
➢Warning plates attached on the machine mustn't be removed.
➢No other parts should be mounted to the machine other than the ones manufactured by Göçmaksan
company.
➢No bending should be made on the machine with bending apparatus which are deformed, cracked or
have an increased hole diameter.
➢No wrong bending should be made on the machine. (Figure 5a-5b-6a-6b-6c-6d)
➢Machine should be cleaned by air.

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€ In cases when electricity board cap should be opened, the cap mustn't be opened without cutting the
power of the machine from the main network.
➢Rebars to be bent should be fixed on the machine correctly. Fixing with retainer bending sleeve and
pins (Figure : 4a-4b-4c-4d).
8. SCOPE OF WARRANTY
Manufacturer acknowledges warranty and liability provided that complying with the following
conditions.
➢Protectors found on the machine should be used.
➢Warning signs should be taken into account.
➢Machine shouldn't be operated without making grounding connection.
➢Parts manufactured by Göçmaksan company should be used in case it is required to replace a broken
part.
➢Conditions indicated under the safety measures should be taken into account.
➢Prohibited usage should be taken into account.
➢Machine should be assembled in conformance with the assembly conditions.
➢Machine should be handled in conformance with the handling conditions.
➢Machine should be used by informed and authorized person.
➢Measurements, dimensions and steel quality stated on the capacity plate should be taken into
account.
➢Machine should be used in conformance with its manufacturing purpose.
➢Electricity connection should be made by competent technicians.
➢Machine shouldn't be used with any of the parts on it disassembled.
➢Motor of the machine shouldn't be changed.
➢Maintenance of the machine should be made in conformance with the maintenance conditions.
➢No rebar higher than the indicated size should be bent with retainer (maximum 16 mm)
➢Correct bending should be made with the machine.
9. PROTECTORS TO BE USED WHEN WORKING WITH THE MACHINE
9.1. Protector apparel
➢Helmet must be worn.
➢Glasses must be worn.
➢Boots with steel toe must be put on.
➢Gloves must be worn.
The aforementioned protectors will be used. In case of not using these apparels there are risks of
injury, cutting and trapping hands.
9.2. Work clothes
Inappropriate clothes against snatch or grip while working with the machine are listed below and
in case of not conforming with this list might cause risk of injury.
Long hair, dress with long arms, bracelet, uniform with long skirt, any ornament leaning out.
10.HANDLING THE MACHINE
In order to carry the machine forklift, mobile crane or a hoist should be used. When lifting the
machine steel cable, chain or fiber sling should be used. When lifting out of the chest lifting lugs on the

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machine should be used. During the lifting operations experienced expert staff and subcontractors
should be assigned.
WARNING!!!
Machine should be moved without any vibration. Machine shouldn't be run in a wet environment.
If there are any lost or damaged parts during the handling, they should be reported to the manufacturer.
•When using the lifting and carrying equipments their maximum loading capacities should be taken
into consideration.
•During the lifting equipment's center of gravity should be taken into consideration.
WARNING!!!Warning signs on the carrier equipment should be taken into consideration.
Figure 8: Handling the machine
11. CONTROLS AND SETTINGS ON THE MACHINE
1
2
3

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Figure 9: Machine control panel and functions
NO
BUTTON
FUNCTION
1
P1
It ensures settings for bent bar bending
2
P2
It ensures settings for protector bending
3
P3
It ensures settings for hook bending
4
Left-Right
It changes machine's rotation direction to left or right.
5
Man-Auto
It provides machine to be controlled automatically and manually.
6
Program ON
Programming Mode of the Machine
6
ProgramOFF
MACHINE runs in normal dimension.The bending is made according
to the preferred angle.
7
ON
It provides machine system to engage.
8
OFF
It ensures switching the machine system off.
9
Power Lamp
It indicates that there is electricity on the system when electricity is
supplied to the system when ON button is pressed.
10
Foot Pedal
It ensures rotation of bending flange.
11.1. Thermal flow setting range and motor protection switch
For a motor 4 kW 1450 rpm it is set 14 A by machine manufacturer. It is not appropriate for user to
change settings. Motor protection switch is mounted to the machine in order to prevent damage on the
system by cutting the electricity current when excessive current is drawn by the system. If the switch is
tripped switch should be turned on by turning the button to position 1. Motor protection switch should
never be disassembled.
11.2. Bent Bar Bending setting (45°):
Prog. Off Normal Bending Setting Systems:
Before starting angle setting, it should be ensured that there is no any material on the machine
other then the bending equipments.
6
10
4
7
8
9
5

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The Switch button should be taken to OFF position and P1 button should be pressed. There are
3 Switch Pins with same heights on the bending disc. Rotation direction should be controlled by taking
the machine to MAN position.Appropriate bending angle for venting should be set by trying the switch
pin (P1) (Figure 1-3) throughout the holes on the bending disc (A and B directions). As long as the
switch pins (A and B) are taken closer to the measurement sensor (Figure 1-4) from both sides, the
bending angle decreases. Conversely as they are taken away from the measurement sensor the bending
angle increases.
NOTE: For P1 button Switch pin=1; For P2 button Switch pin=2; For P3 button Switch pin=3 are
used to set the angle.
After the setting procedure is completed the rebar for bending and bending equipments must be
put on the machine and it should be available for bending as it is shown in Figure 4a-4b-4c-4d . It
should be mounted according to the diameter (if it is smaller than 16 mm the retainer and if it is bigger
than 16 mm the appropriate bending sleeve) of the rebar to be bent (Figures 4a-4b-4c-4d). Lastly when
the bending disc returns after bending the rebar it should be mounted on the bending plate on the front
side of the rebar for safety to prevent any injury due to movement of the rebar. (Figure 10). Setting
process should be completed by ensuring the rebar to be bent (Figures 4a-4b-4c-4d) positioned parallel
by moving bending plates backward and forward with the help of the adjustment spanner. (Figures 4a-
4b-4c-4d)
For serial bending, machine should be taken to AUTO position and then bending should be
made.
NOTE: When the machine is at the MAN position the bending disk revolves, after bending is
completed and the machine is on the holding position it stops. When the machine is at the AUTO
position bending disk stops at holding position by completing the bending just pressing the Foot Pedal
only once.When the machine is at the AUTO position, the machine can be stopped by pressing the foot
pedal as the bending process is started. The stopped machine might be turned to the starting point back
manually by continuously pressing the Foot Pedal and it is ensured to be turned to the automatic mode
again. Furthermore when the machine is at the AUTO position, Bending Disc might be stopped by
holding the Foot Pedal pressed while returning, after the bending process is completed. When the foot
1
Switch pin =P1
2
Switch pin =P2
3
Switch pin =P3
4
Measurement Switch
5
Stop Switch
5
1
2
3
4
B
DIRECTIO
N
A
DIRECTIO
N

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pedal is released the machine restarts moving on the direction it stopped and stops at the zero point.
The specifications indicated for dangerous cases are used for Emergency stop and it is ensured to
protect the operator from the danger.
To change settings, bending process of the machine should be completed (zero point) in the
cases where the setting change is required by pressing P1-P2-P3 buttons and then the button required to
change the settings should be pressed. Otherwise settings aren't changed when the buttons are pressed.
WARNING!!!When bending the rebar the rebar should be bent on bending apparatus with 5
times larger than the diameter of the rebar to be bent.
Figure10: Bent bar bending indicator
11.3. Protractor Bending Setting (90°):
It is set with the same method carried out in bent bar bending by pressing the P2 button on the
control panel.
NOTE:The required angle is set for P2 BUTTON by moving the figure:10 switch pin 2 to left and
right.
Figure11:Protractor bending demonstration
11.4. Hook Bending Settings (180°):
Bending pin mounted
with safety purpose
Bending pin mounted
with safety purpose

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It is set with the same method carried out in bent bar bending by pressing the P3 button on the
control panel.
NOTE:The required angle is set for P3 BUTTON by moving the figure:10 switch pin 3 to left and
right.
Figure12: Hook Bending demo
11.5. Stirrup Bending:
Stirrup Bending Mode:
Prog. On Stirrup Bending Setting Systems:
PROGRAM OFF-ON SWITCH BUTTON should be at program ON position. 90° angle which is
used in stirrup bending should be set to P2 button before the program is taken to ON position, the
SWITCH BUTTON should be turned to program non position (clockwise) after the stirrup tip bending
with 135° are set to P3 button.After turning the SWITCH BUTTON, P1 button should be pressed once.
Afterwards P1-P2-P3 buttons will blink only once. This warning indicates that the machine is ready for
programming. After this process, programming starts according to the required bending angle. For
example: Programming for performing stirrup bending shape is described below.
(Figure 9-6)
(Figure 9-6)
Bending pin mounted
with safety purpose

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Programming the described shape:
a ) Press P3 button for once for the 1st angle,
b) Press P2 button three times successively for 90° bending in 2nd, 3rd and 4th angles.
c) The programming process for the 5th angle made after pressing P3 button is saved to the memory by
pressing the foot pedal and programming process is completed.After the setting procedure is completed
(Figures 13a-13b-13c-13d-13e-13f-13h-13h) bending order is followed and Stirrup Bending should be
completed.
NOTE: When the program ON-OFF SWITCH BUTTON is turned to ON position program is reset
and it must be re-programmed.The button should be switched to OFF position as long as it is not
needed.In case it is turned, the program should be redone as it is shown in the example.
NOTE: Rebar that will be stirred up should be bent on an appropriate Bending Sleeve, Pin, Stir-up
pin or straight pin with at least 5 times bigger than the bending rebar's diameter.
(13a)
(13b)
(13h)

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Figure13: Stirrup bending demonstration
WARNING!!!
In order to fix the faults and determine the electricity malfunction if it is required to open the
power panel, power connection of the machine must be turned off and competent technicians should
make the maintenance.
12. MAINTENANCE AND LUBRICATION INSTRUCTIONS
(13c)
(13d)
(13e)
(13f)
(13g)
(13g)
(13h)

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It is important to make maintenance correctly in order to extend service life of the machine and to
ensure safe bending. We suggest for each user to set up a secure system for control and maintenance of
the machine. The following descriptions are given for reference. Number 140 gear oil is used in
machine's reductor unit.
Daily maintenance of the machine
•Clean dust and scales on the machine with a brush.
•If the machine is running outdoors it must be protected from rain water when raining.
•Machine should be checked if there is extraordinary voice or not.
Weekly maintenance of the machine
•Parts driving machine bending plates should be cleaned and lubricated.
•Machine adjusting lever mechanism should be cleaned and lubricated.
Monthly maintenance of the machine:
•Bending pins and bending plates should be checked and any cracked or skewed parts mustn't be
used.
•Reductor should be checked if there is oil leakage or not.
•Machine's sensor display should be checked if it has dirt on it or not and also the lamp behind it
should be checked if it is working or not.
Semi-annual maintenance of the machine:
•All the bolt connections of the machine should be checked.
Annual maintenance of the machine:
•Oil of the machine should be changed.
•If it is out of order seals and bearings should be changed.
•Any skewed, cracked, worn parts should be checked and replaced.
13. FAULTS AND SOLUTION OFFERS
Any faults those might arise when running the machine, and their causes and solutions are given in
the table below.
WARNING!!!
In order to fix the faults and determine the electricity malfunction if it is required to open
the power panel power connection of the machine should be turned off by switching the main
switch to 0 positions and competent technicians should make the maintenance.