nosstec 4135 User manual

Bending Roll Machine 4135
Operating instructiOns

4135 English, rev 3 3
Table of conTenTs
Main components ............................................................4
Operation .....................................................................5
Safety..........................................................................6
Service and maintenance .................................................. 11
Lubrication / Grease chart ................................................. 12
Technical data .............................................................. 13
Machine plates and stickers ............................................... 14
Dismantling of bending roll machine ..................................... 15
Spare parts.................................................................. 16
Declaration of conformity.................................................. 18
Contact information.................................................See back
Note: We reserve the right to alter specifications without prior notice.
For copyright reasons all reproduction and copying of the texts, tables and illustrations within this manual is
prohibited without written permission from Nosstec AB.

Operating instructiOns 4135
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Stand, power
operated side
Motor with
gear box
Emergency
stop
Safety equipment
Top roll Lower roll
Stand, slip
collar side
Pull-out sleeve
Hand wheel for
lower roll
Lever for
bending roll
Main coMponenTs
Front side
Foot switch
Disclaimer: The machine pictured on this page is not necessarily representative of the actual product
as delivered. Differences in sizes, options and/or accessories may or may not be pictured here.

4135 English, rev 3 5
operaTion
Prebending
In order to give the workpiece a
symmetrically round shape, it is
necessary to prebend the part of the
workpiece, which should be bent first.
This must be made from the back
of the machine and with the rolls
rotating in the opposite direction (see
picture 1 in the figure on the right).
Bending
Place the bending roll in the required position.
Introduce the prebent workpiece between the upper and lower rolls and use the bending roll as a back
gauge.
Turn the hand wheel of the lower roll so that the workpiece is clamped between the rolls. Bend the sheet
(check that the sheet runs above the bending roll as per figure above).
Adjust the bending roll and repeat the operation until the workpiece has got the desired shape. Swing
out the top roll and remove the workpiece. Swing back the top roll into its initial position.
At the maximum operating length and sheet thickness tubes down to 1.5x the diameter of the top roll
can be bent and for thinner material down to 1.2x the diameter of the roll.
When bending steel sheet or stainless steel the capacity of the machine will be reduced to about ⁄
compared to mild carbon steel sheet.
Cone (taper) bending
In order to facilitate cone bending the bending roll can be set diagonally as follows:
The bending roll can be set diagonally in both ends by loosening the screw of the cam disk and adjust
the handle upwards or downwards. When the desired inclination of the roll has been obtained, retighten
the screw of the cam disk
Note: Do not forget to reset the parallelism of the rolls after completed cone bending.

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safeTy
General
This bending roll machine is designed with a view to eliminating personal injuries provided that the in-
structions in this manual are being followed.
Only authorized and trained staff is allowed to use the machine. Read the whole instruction manual and
make sure that you understand the contents before the machine is taken into use. It is important that
you read the safety instructions below.
Safety instructions in connection with the installation
The machine must be bolted to the floor with 4 pcs expansion shell bolts diameter 16 mm.
Electrical installation of the machine must be carried out by authorized staff.
Lifting instructions
This machine must be lifted by truck as long as it is
packed in a crate or a wooden case. When lifting it
from the packing to the permanent working site an ap-
proved lifting device type travelling crane must be used.
Instructions for lifting be means of travelling crane:
1. Check that the top roll is in the locked position.
2. Set lower and bending roll in upper position.
3. Put a lifting sling around the rolls as per figure.
4. Lift carefully at the same time as you check that the
rolls are pressed together.
Regarding weights: see technical data
Dangerous area
The dangerous area of the machine is
described in the figure.
This area shall in an appropriate way be
marked in the floor.
A person staying in the dangerous area
will henceforth be called “exposed per-
son” and the user of the machine the
“operator”.
Operator,
prebending
Operator
1,5 m
1,5 m 1,5 m
1,5 m

4135 English, rev 3 7
safeTy
Application
Never use the machine for material which is outside the capacity range of the machine. Check
the machine plate and the section “Technical data”.
Before the machine is operated the following steps must be taken:
Check that all safety devices function and that they are not damaged. Also check that moveable parts
are not exposed to obstacles e.g. owing to incorrectly mounted guards or parts. Broken parts or safety
components must be changed by authorized staff. Contact Nosstec in case spare parts are needed. The
machine has a 24 month applicable warranty from date of delivery.
Check that the environment around the machine is suitable.
• Do not expose the machine to rain.
• Do not use the machine in wet or damp premises.
• Check that the lighting of the premises is satisfactory.
• The floor must be clean, dry and free from oil and grease spots.
• Never use easily inflammable material close to the machine.
• Dirty working sites increase the risk of accidents.
Position of top roll
The top roll must never be in the swung-out position when the machine is in operation.
Avoid unstable working positions
Check that the operator always has a secure and stable working position. When prebending the opera-
tor must stand on the reverse side of the machine.
Do not keep tools on the machine
Remove all tools from the machine before it is operated.
All repairs must be carried out by authorized staff
The machine and its electrical equipment has been made according to valid safety rules. All
repairs must be carried out by trained and qualified staff. Only original spares must be used.
Note: If the repairs also involve dismantling of the machine, this must be carried out
according to the enclosed dismantling instruction. This instruction must not be kept
together with the machine.

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safeTy
Cut the power
Cut the current before touching live parts. This is done either by disconnecting the main
switch of the machine or by disconnecting the voltage of the electrical cabinet.
Note: Do not put the main switch or the safety switch of the machine out of operation.
Danger zone
In connection with production work check that no part
of the body comes too close to the infeed side of the
clamping rolls of the machine (see figure).
Note: The infeed side may vary owing to the direction
of rotation of the rolls.
Keep the instruction manual of the machine in a safe place.
The instruction manual contains important information that besides the safety information also give
important information regarding operation, service, maintenance etc.
Modification of the machine
All conversion, modification or change of this machine is strictly forbidden with the exception of
• Original spare parts
• Optional equipment supplied by the manufacturer.
Airborne noise
The following noise level has been measured at the operator’s place:
Equivalent noise level Leq, idle running 66 dB(A)
Equivalent noise level Leq, operation 68 dB(A)
Falling workpieces
Be careful when working with heavy workpieces so
that they do not fall down by mistake when the grip
loosens between the upper and lower rolls (see figu-
re). If necessary use a support table, travelling crane
or some other lifting device.

4135 English, rev 3 9
safeTy
Pinching risk of the workpiece
Note that there is a pinching risk between the ends
of the workpiece, see figure.
Emergency stop
This machine is equipped with two emergency stop functions, i.e. one emergency stop on the electrical
cabinet and one emergency wire running around the machine at foot height. This together with the fact
that the machine is equipped with brake motor enables the machine to stop instantaneously in case of
injury or risk of injury no matter where you are around the machine.
Service and maintenance
Before service and maintenance are carried out on the machine you must have had instructions from
your foreman. You must also read and understand this instruction manual. Disconnect the main switch
before the service job begins. If the machine must be dismantled, completely or partly, contact your
foreman.
Protective clothing
Important! Never use gloves when bending, as this consider-
ably increases the risk of getting pinched between the rolls.
For other handling of the workpieces use gloves. The operator
must not carry belts, rings or necklaces.
Working shoes with steel inserts must be used.
Loose hanging clothes must not be used.
If the operator has long hair, this must not hang loose.
Deburring of the workpiece
Burrs and sharp edges must be removed from the workpiece before bending.
Jamming
If for some reason the machine stops while
bending a workpiece, proceed as follows:
• Crank down the bottom roll and possibly also the bending roll.
• Remove the workpiece. Identify the trouble reason. If the motor protection is released,
wait for some minutes before it is reset. The machine is then ready for use again.
• If the trouble is mechanical or electrical: Cut the current and contact the supervisor.
Pinching risk

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safeTy
Regular checking
Daily check the function of the foot switch as well as the condition of the electric cable of the foot switch.
Also check that the emergency stop works. Carry also out the regular service, which is described in the
chapter Service and Maintenance in the instruction manual.
Safety in general
The chapters describing the safety devices are based on the assumption that the machine is used in the
manner described in this instruction manual, that the operator has got the necessary information regard-
ing the safety of the machine as well as the special risks involved with this type of machine.
If the machine is not used in the proper way, the manufacturer cannot be held responsible for personal
injuries or material damages, which may be the result. Also check the following:
• Take all necessary safety precautions when loading, setting, changing spare parts, cleaning, repairing
and servicing so that the exposed person cannot start the machine.
• Do not disconnect the safety devices of the machine.
• Do not remove any part of the machine belonging to the safety devices.
• Always check that all safety devices have been remounted after repair work etc.

4135 English, rev 3 11
service and MainTenance
Installation
The machine must be placed on firm ground e.g. cemented floor. The ground must be level in order to
avoid tensions in the machine when fixing it to the floor.
Check that the motor is branched to the right voltage. Also check the direction of rotation. Plates with
“Forward” and “Reverse” are mounted on the protection cover of the foot switch.
If the machine is equipped with motor powered setting of the bending roll and/or the lower roll also
check the voltage and oil level here.
Maintenance
The machine is delivered with greased bearings for about 200 hours’ continuous duty. After this period it
should be lubricated with ball bearing grease of good quality, e.g. Esso Multi purpose grease H or equiv-
alent. All rolls and worm gears are mounted on needle and ball bearings and therefore recommended
grease should be used. Guides for the roll bearing box as well as sleeves for the upper roll and cone
bending device to be lubricated when required. Grease lubs, see grease chart.
The gearbox is lifetime lubricated and doesn’t need any regular inspection. Should there be any leakage,
please check oil level and refill if necessary.
Daily check
• Brake function of the motor
• All emergency stop functions
Parallelism of the rolls
Check that all rolls are parallel. If adjustment is necessary proceed as follows:
Between upper and lower rolls:
• Crank up the lower roll to its highest position.
• Loosen the two nuts blocking the wedge on the transmission side.
• Adjust by means of the wedge until the distance between the upper and lower rolls are the same in
both ends
• Lock the wedge by means of the nuts.
Between upper and bending rolls:
• Press the bending roll by means of the lever up to its highest position.
• Loosen the screw of the cam disk.
• Adjust until the distance between the upper and bending rolls is the same at both ends.
• Retighten the screw against the cam disk .

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lubricaTion / Grease charT
Lubrication points
There are in total 8 lubrication points:
1. 1 grease nipple in each bearing
housing.
2. 1 grease nipple in the gear housing.
3. 1 grease nipple on the back side of each
stand, level with the axle.
4. 1 grease nipple in the guide of the
sleeve.
See images for locations of
the lubrication points.
1
1
1
4
3
1
3
2

4135 English, rev 3 13
Technical daTa
Serial No ...............................................................................
Type .....................................................................................
Rolling speed ......................................................................... m/min
Max. sheet thickness (at 400 N/mm2).......................................... mm
Operating length .................................................................... mm
Total net weight ..................................................................... kg
Weight of rolls
Top and lower rolls.............................................................. kg/m
Bending roll ....................................................................... kg/m
Total dimensions: length × width × height .................................. mm
Working height ...................................................................... mm
Motor rating .......................................................................... kW
Voltage ................................................................................. V
Feeding motor:
Brand .............................................................................
Type..............................................................................
..................................................................................... V
..................................................................................... kW
Diameter of rolls, top and lower rolls .......................................... mm
Diameter of roll, bending roll .................................................... mm
Optional equipment:
Hardened and ground rolls
Frequency inverter
Digital readout
Deviation from the normal execution:

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Machine plaTes and sTickers
Nosstec AB
Järnvägsgatan 19
465 30 Nossebro
SWEDEN
Productionyear:
Type:
Capacity:
Weight:
Serial No:
kg
mm
Current:
Voltage:
Phase:
Frequency:
Aluminium plate, blue anodized.
REVERSE FORWARD
Blue background, white text Blue background, white text
MAIN SWITCH MUST BE
DISCONNECTED FOR ALL
TYPES OF SERVICE AND
MAINTENANCE
O N LY T R A I N E D
STAFF MAY HANDLE
THIS MACHINE
NEVER RUN THE MACHINE
WITH THE TOP ROLL IN
SWINg-OUT POSITION
White and yellow background,
black text
White and yellow background,
black text
White and yellow background,
black text
Yellow background,
black text
Yellow background,
black text
Yellow background,
black text
Yellow background,
black text

4135 English, rev 3 15
disManTlinG of bendinG roll Machine
This instruction is made in order to support trained staff when repairing
with a view to minimizing the risk of personal injuries and damage to
the machine.
To enable dismantling of the machine in a safe way, the job must be car-
ried out by at least two trained mechanics.
This dismantling instruction must not be kept together with the machi-
ne. The proper holder is the supervisor and/or service staff.
Procedure:
1. Loosen the 3 bolts attaching the gear housing.
2. Pull the worm gear motor out of the worm gear box.
3. Loosen the four bolts and remove the cover.
4. Dismount the two gears.
5. Swing out the top roll and pull it out of the worm gear box.
6. Dismount the tube bar at the front bottom stand and place a suita-
ble support under the front of the tube bar.
7. Loosen the two nuts on the stand.
8. Loosen the nuts and dismount the wedge.
9. Dismount the shaft.
10. Secure the bending roll and the lower roll by means of lifting straps
and travelling crane.
11. Pull out the stand and remove the shaft.
12. Release the bending roll from the lifting strap and remove it from
the stand.
13. Repeat the same procedure with the lower roll.
Note: Handle the loose parts carefully and check that all pieces
removed also are mounted in their right places, but in the re-
verse order.
1
3
3
4
7
8
810
11
2

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spare parTs

4135 English, rev 3 17
spare parTs
Svenska English Deutsch Francais
1 1 Snäckväxel Worm gear Schneckengetriebe Engrenage à vis sans n
2 4 Skruv Screw Schraube Vis
3 1 Lock för växelhus Cover for gearbox Abdeckung für Getriebe Couvercle de boîte de vitesses
4:01 1 Kugghjul Gear Zahnrad Roue dentée
4:02 1 Kugghjul Gear Zahnrad Roue dentée
5 1 Växelhus Gearbox Getriebegehäuse Boîte de vitesse
6 1 Kil Wedge Keil Coin
7 1 Övervals Top roll Oberwalze Rouleau supérieur
8 1 Hylsa med styrning Sleeve with guide Buchse mit Führung Douille avec guide
9 1 Ändbricka End washer Endplatte Disque
10 1 Spännstift Roll pin Spannstift Goupille de serrage
11 1 Skruv Screw Schraube Vis
12 4 Skruv Screw Schraube Vis
13 1 Lagerhus Bearing housing Lagergehäuse Boîte de palier
14 1 Kil Wedge Keil Coin
15 8 Smörjnippel Grease nipple Schmiernippel Graisseur
16 1 Böjvals Bending roll Biegewalze Rouleau arriére
17 1 Undervals Lower roll Unterwalze Rouleau inférieur
18 1 Styrning Guide Führungen Guide
19 1 Smörjnippel Grease nipple Schmiernippel Graisseur
20 1 Lagerhus Bearing housing Lagergehäuse Boîte de palier
21 1 Lagerhus Bearing housing Lagergehäuse Boîte de palier
22 1 Kil Wedge Keil Coin
23 6 Mutter Nut Mutter Ecrou
24 1 Axel Axle Achse Axe
25 1 Ok Support Stütze Support
26 1 Lagerhus Bearing housing Lagergehäuse Boîte de palier
27 1 Kil Wedge Keil Coin
28 1 Mutter Nut Mutter Ecrou
29 1 Stoppskruv Stop screw Stellschraube Vis d’arrêt
30 1 Excenter Eccentric Exzenter Excentrique
31 1 Axel Axle Achse Axe
32 1 Spännstift Roll pin Spannstift Goupille de serrage
33 1 Skruv Screw Schraube Vis
34 1 Bricka Washer Scheibe Rondelle
35 1 Kamskiva Cam Kamscheibe Disque à came
36 1 Handtag Handle Gri Poignée
37 1 Fjäder Spring Feder Ressort
38 1 Bricka Washer Scheibe Rondelle
39 1 Skruv Screw Schraube Vis
40 1 Spärr Lock Verriegelungsgri Poignée de verrouillage
41 1 Kuggsegment Cog segment Zahnsegment Segment denté
42 1 Skruv Screw Schraube Vis
43 2 Flänsmutter Flange nut Flanschmutter Écrou à embase
44 1 Skruv Screw Schraube Vis
45 2 Skruv Screw Schraube Vis
46 1 Spännstift Roll pin Spannstift Goupille de serrage
47 1 Ratt Wheel Handrad Volant
48 2 Gavel underdel Side, lower Giebel, unten Bâti partie inférieure
49 8 Bricka Washer Scheibe Rondelle
50 8 Skruv Screw Schraube Vis
51 1 Rörstag Pipe strut Rohrstrebe Support tubulaire
52 1 Gavel utsvängbar sida Side, openable side Giebel, Nebentüren Bâti côté pivotant
53 1 Motor Motor Motor Moteur
54 2 Stag Strut Strebe Support
55 1 Skruv Screw Schraube Vis
56 1 Mutter Nut Mutter Ecrou
57 1 Gavel transmissionssida Side, transmission side Giebel, Transmissionseite Bâti côté de transmission
58 1 Axelsäkring Axle lock Achssperre Arrêt d’axe
59 4 Mutter Nut Mutter Ecrou
60 2 Skruv Screw Schraube Vis
61 4 Skruv Screw Schraube Vis
62 1 Fläns Flange Flansch Bride
63 1 Fläns Flange Flansch Bride
64 2 Klammer Clip Klammer Crampon
65 2 Skruv Screw Schraube Vis

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declaraTion of conforMiTy
Declaration of conformity
as per the EC Machinery Directive 98/37 EG, Annex II A.
Manufacturer: Nossebro Mekaniska Verkstad AB
SE 465 30 NOSSEBRO [phone]
Distributor: Nosstec AB
SE 465 30 NOSSEBRO [phone]
herewith declare that:
Machine: ..............................................................
Type
..............................................................
Serial No
is manufactured in conformity with:
– The Council Directive of 2006/42/EG
– EMC Directive 2004/108/EG
– Low voltage directive 2009/96/EG
............................... ..........................................
Place and date Signature, Managing Director

www.nosstec.se
Nosstec AB • Kristineholmsvägen 12, 441 39 Alingsås, SWEDEN
Tel: [phone] • Fax: [phone] • E-mail: [e-mail]
For copyright reasons all reproduction and copying of the texts, tables and illustrations
within this manual is prohibited without written permission from Nosstec AB.