AS

USER’S MANUEL
Page: 1

ASYMMETRICAL
3 ROLLER
BENDING MACHINE

AS

AKYAPAK Mak.San. ve Tic. Ltd.Şti.

Akçalar Sanayi Bölgesi 16225
Akçalar / BURSA / TÜRKIYE
Tel : 0090 224 280 75 00 Fax : 0090 224 280 75 02

www.akyapak.com.tr

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CE CONFORMITY DECLARATION

98 / 37 / EWG STANDARDS AND II-A ADDITIONAL INSTRUCTION

Akçalar Sanayi Bölgesi 16225

Akçalar / BURSA / TÜRKİYE

Tel : 00 90 224 280 75 00

Fax : 00 90 224 280 75 01-02

The machine production in our factory is suitable to the standards below.

European standards and instructions are listing at the table below.

3 ROLLER ASYMMETRICAL BENDING MACHINE

Machine name
(WITH ARM/OR WITH MOTOR)

Machine Type AS ..........x........

Production Year
and 200.../..........
Serial Number

EC-Terms (98/37/EC)
EC-Low Voltage Terms (73/23/EC)
EC- Instruction EC-Eloctro Magnetic Terms (89/336/EC i.d.f. 93/31/EC)

DIN EN-292-1
EC-Standartds DIN EN-292-2
DIN EN-60204-1

International Standards

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13.INDEX
PAGE
COVER 01
CE AGREEABLENESS DECLARATION 02
13. INDEX 03
1. GUARANTEE 04
2. COMMENCE 05
3. TECHNICAL SPECIFICATIONS TABLE 06
4. MACHINE MEASURMENTS 07
4.1. THE MACHINE MEASURMENTS WITH MOTOR 07
4.2. THE MACHINE MEASURMENTS WITH ARM 08
4.3. GENERAL APPEARANCE THE MACHINE(WITH MOTOR AND WITH ARM) 09
5. THE MACHINE KNOWLEDGE 10
5.1. STANDART EQUIPMENTS AND SPECIAL ACCESORIES 10
5.1.1. STANDART EQUIPMENTS 10
5.1.2. SPECIAL ACCESORIES 10
6. PROTACTION FACTORS 11
6.1. THE DANGER PLACES IN THE MACHINE 11
6.2. THE DANGER SITUATION ON THE MACHINE 12
6.3. THE LOOSES FROM THE WRONG USING 12
6.4. THE WORKING PROCESS IN THE MACHINE 12
6.5. THE RIGHT USING OF THE MACHINE 12
6.6. INAPPROPRIATE USING OF THE MACHINE 13
6.7. USING THE MACHINE FROM THE OPERATOR 13
6.8. THE PROTACTION FROM THE SIDE OPERATOR 13
6.9. THE SAFETY MACHINE AT THE ASSEMBLE PHASE 14
6.10. PROTACTION COMPONENTS 14
6.11. THE PROTACTION COMPONENT CHECKING LIST 15
7. SWITCH OF THE MACHINE 16
7.1. CARRIAGE 16
7.2. TO LIFT AND LAND THE MACHINE 16
7.3. EXTRACTING THE PACKAGE(DISASSEMBLE) 17
7.4. THE MACHINE ASSEMBLY PLAN ON THE GROUND 17
7.5.. SETTING KNOWLEDGE 17
7.6. MAIN PLAN 18
7.7. THE ELECTRICAL CONNECTION FOR THE MACHINE WITH MOTOR 19
7.8. CONTROLING THE DIRECTION OF THE ELECTRICAL ENGINE ROTATION 20
7.9. CONTROL PANELS FOR THE MACHINE WITH MOTOR 21
7.9.1. ROTATION WITH MOTOR 21
7.9.2. THE MOTOR ROTATION + REAR SHAFT WITH MOTOR 21
7.9.3- THE MOTOR ROTATION +REAR SHAFT WITH MOTOR + DIGITAL DISPLAY 22
7.10. FOR THE MACHINE WITH MOTOR (THE SAFETY ROPE) 22
7.11. IF THE MACHINE WITH MOTOR DOES NOT STARTING 23
7.12. THE THERMIC MAGNETIC SWITCH FOR THE MACHINE WITH MOTORS 23
7.13. THE SAFETY SWITCH FOR THE MACHINE WITH MOTORS 23
8. THE MACHINE USING 24
8.1. GENERAL INFORMATION 24
8.2. THE QUALITY OF THE BENDING MACHINE 24
8.3. SETTING THE BENDING MATERIAL 25
8.4. BENDING OPERATION 25
8.5. THE MACHINE METODS FOR THE BENDING OF THE MATERIAL 26
8.6. BENDING OPERATION LINE OF THE MATERIAL 27
8.7. CONE BENDING 28
8.8. THE BOTTOM ROLL COMPRESSION OF THE MATERIAL(UPPER AND DOWN MOVING) 29
8.9. CONE BENDING POSITION LINE 30
8.10. TAKEN THE BENDING MATERIAL OUT OF THE MACHINE 31
8.11. ADJUSTMENT OF THE DIGITAL DISPLAY 32
9. MAINTENANCE 32
9.1. PROTACTION OF THE MAINTENANCE 32
9.2. REGULAR LUBRICATION AND LUBRICATION CONTROL 33
9.3. REGULAR CLEANLINEES 33
9.4. CHECKING THE ABRASION PARTS IN THE MACHINE 33
9.5. REPAIRING THE FAILURE 33
10. GREASE 34
10.1. GREASE POINTS 34
10.2. THE TABLE FOR GREASE COMPARION 35
11. SPARE PARTS PLAN 36
11.1. SPARE PARTS PLAN FOR THE TYPE OF THE MACHINE WITH MOTOR 36
11.2. SPARE PARTS PLAN FOR THE TYPE OF MACHINE WITH ARM 37
12. THE LABEL USING ON THE MACHINE 38
14. ELECTRICAL PLANE EK

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WARRANTY CONDITIONS

I-) Warranty period is valid for only 1 (One) year after the date of the invoice. Guarantee
conditions will not be available unless the machine would be used apart from unsuitable purposes
and 3rd parties which is not mentioned in the invoice.

II-) Warranty is only covered for the parts to be delivered at Akyapak factory which is the
subject of poor design or production faults. Phone assistance is only given for software faults. All
other demands are into subjects of extra charges according to usual market price conditions.

III-) Akyapak Company undertakes the guarantee for 10 years to supply service support and
spare parts after the date of manufacturing. Only the exception of this situation is the subject of
the other parts what is not manufactured by Akyapak.

IV-) Never run the machine before reading and understanding the instruction manual. Just
because the instruction manual will provide general information for your use. So that you can
understand the functions of the parts and some reactions of the machine.

V-) Rest of the other principal conditions which are not the subject of warranty cases are
listed below. Please notice that those conditions are not gradual, but also covers all similar
situations. Warranty does not provide extra time with decleration of disgrace or the claim for
asking a justice. Buyer can not claim any written or oral justice opposed to the Seller for the
purposes which contradicts with warranty conditions.

• Faulty usage of the user

• Processes over capasity
• Problems occured later on designs made by user and never accepted by manufacturer
• Damage due to transportation
• Problems which is occured by rarely or poor maintenance
• Wrong using processes in contradistinction to the instruction manual
• Faults which are not informed in 3 (Three) working days
• Keep on using the machine even with the fault
• Damages because of using the machine under the rain or in open area or unsuitable
enviroment

All the related expenses are belongs to buyer for out of warranty cases…

Akyapak Mak. San. Tic.Ltd.Şti.

Akçalar Sanayi Bölgesi
Sanayi Caddesi No:8
Nilüfer – Bursa – Türkiye

Tel: 0090 224 280 75 00

Faks: 0090 224 280 75 01

http://www.akyapak.com.tr

service@akyapak.com.tr

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2.COMMENCE
This USER MANUAL,contain the AKYAPAK asymetrical machine setting,using,safety careful
maintenance repair,technical characteristics,spare parts listing and electrical connection planes.

Keep this USER MANUEL in your hand,when machine is setting ,working,and

maintenance repair.

ATTENTION!!!!!!
Keep this USER MANUEL near the machine working area.

ATTENTION!!!
Only the autorized personal may use this machine.

All the modifications making on the machine without the autorized personal, AKYAPAK is not
responsible for the accidents.

When the operator is leaving the working place,the machine key will close ‘’O’’
Position,and the machine voltage will stoped.

Don’t stripp the safety elements on the machine.

The operator reading this USER MANUEL must sign your name and confirm his boss that he is
understand the writing.

NAME AND SURNAME

Signature Date Signature Responsible
OPERATOR

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 WITH MOTOR
WEIGHT
SEE PAGE :6

Lenght
Working
(C)
(D)

(B)

Prebending
WIDE
WITH

Motor
MOTOR

Max. Bending
HEIGHT

LENGHT

Min. Diameter
POWER

Rolls Diameter

Machine Type
mm mm mm mm mm kW mm mm mm kg

AS 70-10/1,5 1050 1,5 1,8 70 105 1,1 1300 700 1100 700

AS 70-15/1,0 1550 1,0 1,2 70 105 1,1 2100 700 1100 700

AS 75-12/1,5 1250 1,5 2,0 75 117 1,1 2300 800 1100 800

AS 80-10/2,0 1050 2,0 2,5 80 115 1,1 1670 690 1090 460
3. TECHNICAL SPESIFICATIONS TABLE

03.04-B1
AS 80-15/1,5 1550 1,5 2,0 80 155 1,1 2190 690 1090 540

PS: THE MACHINES SPEED CAPACITY 5 M/MIN.

AS 86-15/2,0 1550 2,0 2,3 86 125 1,1 2190 690 1125 570

AS 86-20/1,5 2050 1,5 2,0 86 125 1,1 2690 690 1125 610
USER’S MANUEL

AS 90-10/3,0 1050 3,0 3,3 90 130 1,1 2100 800 1130 800

AS 90-12/2,5 1250 2,5 3,0 90 130 1,1 2350 800 1130 800

AS 90-15/2,2 1550 2,2 2,5 90 130 1,1 2600 800 1130 800
AS

AS 95-20/1,5 2050 1,5 1,8 95 135 1,1 3030 800 1130 800
Page: 6
 Tel. : ( + 90 - 224 ) 482 38 60
Telefax. : ( + 90 - 224 ) 482 28 16- 17

Model :
TSEK
Prad.Year :

Serial No. :

Motor : kW

Voltage : v

Fruquency : Hz

MAKiNA'YI SADECE YETiSMiS - USTA PERSONEL

KULLANABiLiR.!

ONLY PROPERLY TRAINED AND AUTHORIZED

PERSONNEL SHOULD OPERATE THIS MACHICE.!

DIE BEDIENUNG DER MASCHINE DARF NUR DURCH

QUALIFIZIERTES FACH PERSONAL ERFOLGEN.!

SEUL LE PERSONNEL FORME ET AUTORISE PEUT

UTILLSER CETTE MASCHINE.!

DANGER
PINCH
POINT
4. MACHINE MEASUREMENTS

03.04-B1
USER’S MANUEL

4.1. THE MACHINE MEASUREMENTS WITH MOTOR (See Page :5)

AS
Page: 7
 Tel. : ( + 90 - 22 4 ) 482 38 60
Telefax. : ( + 90 - 224 ) 482 28 16- 17

Model :
TSEK
Prad.Year :

Serial No. :

Motor : kW

Voltage : v

Fruquency : Hz

DANGER
PINCH
POINT

MAKiNA'YI SADECE YETiSMiS - USTA PERSONEL

KULLANABiLiR.!

ONLY PROPERLY TRAINED AND AUTHORIZED

PERSO NNEL SHO ULD OPERATE THIS MACHICE.!

DIE BEDIE NUNG DER MASCHINE DARF NUR DURCH

QUALIFIZIERTES FACH P ERSONAL ERFOLGEN.!

SEUL LE PERSONNEL FORME ET AUTO RISE PEUT

UTILLSER CETTE MASCHINE.!
!

03.04-B1
USER’S MANUEL

4.2. THE MACHINE MEASURMENTS WITH ARM (See Page :5)

AS
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4.3. GENERAL APPEARANCE THE MACHINE(WITH MOTOR AND WITH ARM)

E D
RIZ
T O
M O

U AL
N
MA

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THE BENDING FORCE LIMITS

The machıne bending force are bound at the following modifications.

-Machine kind (Mechanical and Chemical Spesifications,hardnees ,yield point v.b.)

-The bending diameter.
-Lenght of the material.

5.THE MACHINE KNOWLEDGE.

5.1.STANDARD EQUIPMENT AND SPECIAL ACCESORIES

The machine standard and special accessories are determine below.In all our machines the
standard equipments are present, and near the special accessories √ this mark is place on the
parts.

5.1.1.STANDARD EQUIPMENTS

- The machine body is casting.

-To take easy out the bending material, the upper rolls must be open azimuth angle.

- Cone bending appliances are present.

- The rear roll with hand wheel are moveable Up and Down .

- Upper, Bottom and rear rolls are moveable.

- Main Breake Motor (With motor)

- Circuit Breaker (With motor)

- Control panel and foot pedal with the machine independent moving . (With motor)

-The electrical installation Siemens,Legrand,General. (With motor)

- CE standard conformity.

5.1.2.SPECIAL ACCESORIES.

- The rear shaft moveable up and down with motor.

(With motor)
-With induction the shafts are hardened.

- Digital Display for rear rolls. (With motor)

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6.PROTACTION FACTORS
6.1.THE DANGER PLACES IN THE MACHINE.

The upper and bottom rolls asymmetrical sylinder machine are returning. Between this shaft you
may compress your fingers.When the shafts are returning be carefull your overalls did not
compress.

Do not make the maintenence and repaire the machine at the working time.

The machine must be closed ,if whichever reason the side cover are disassemling.
Carefully control the rope switch ,after closing the covers.

AT THE DANGER SITUATION ,PRESS THE EMERGENCY SWITCH OR PULLING THE ROPE.

DO NOT GIVE THE PERMISSION THE OTHER PERSON COMING NEAR THE WORKING
PLACE OF THE MACHINE .

At the time of danger situation the first operation is stopping the circuit of the machine, as
pressing on the emergency switch or pulling the rope switch.
Close the machine before maintanance ,cleaning and repairing the machine .
Don’t take the safety components machine out(rope switch,emergency switch, and etc.)

RG
EME
P
STO

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6.2.THE DANGER SITUATION ON THE MACHINE.

The AKYAPAK asymmetrical bending machine is taking measures about the risks.
When the machine is not using accurate,this protaction appliances,may create the danger
situation.At the machine with motor type for the create danger situation in the working time is
winding around the machine the rope switch emergency stop button .

6.3.THE LOOSES FROM THE WRONG USING.

- The hand operator or his finger.
- The dresses and the other things.
- The deformation of the bending material.
-When the material is bending, the other worker are staying near the machine.
-The bending accesories of the machine.
For the machine assembly,working ,maintenance and reading the user manuel all the autorized
personal are responsible.
Don’t bend the hard parts on the machine ,outside the sheet metal,and aluminium. This situation
from the looses in the machine, the operator and surroundings may take the damage.
For the productive working the modifications making in the machine are forbidden.
To the working process determine in this using manuel,are appropriate the maintenance and
protaction factors.

6.4.THE WORKING PROCESS IN THE MACHINE.

The cylinder bending machine , is desing to form the material and the working process and
specification are writing below.

The machine may bend the half open and close circular pipe ,and cone bending parts. The
machine may produce the parts about the different thicknees and diameters the material .
Before begin the bending operation on the page 5 control the determine thickness. . Don’t try to
bend the more thick material ,on the machine,because the determine dimensions are fixed.

The codes for the AKYAPAK cylinder bending machine are given below:
The rolls shaft diametrs ,the wide and thicknees of the bending material,are;
For example AS 90 - 15 / 2,5
AS = Machine Type
90 = The rolls shaft diameter
15 = The wide of the bending material 15=1550 mm.
2,5 = Min. Rolls shaft diameter 1,5 rigid more large the bending material thicknees mm.
This values are valid for the St-37 quality of the material .If the material yield point (quality)is
different the values will be also different.

6.5.THE RIGHT USING OF THE MACHINE.

All the bending operations on the machine must be controled on the front of the machine and
only from the autoritative personal.
The material taken upon the machine in the first operation must be helping from the other
operators,and after this operation the operator must bend the material alone.
For this reason the operator must to read and understand the user manuel very well.
For all the bending operations,the operator must be take safety dispositions,and control step by
step completely all the operations.
Surround the machine,at the bending operation,the max parts of the material,must be take at the
reliable place,and the other personel must not enter there.
The right using of the machine is given below.
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6.6.INAPPROPRIATE USING OF THE MACHINE.

In the bending operation the other personal must not enter near the safety area .For any
maintenance of the machine,absolutely the machine energy must be cutting.
For any other matter the any personal must not over the machine,and the rear place of the
machine must be working.

ERG
EM
P
STO

6.7.USING THE MACHINE FROM THE OPERATOR.

The personal under 16 years can not use the cylinder machine. The operator which will use this
machine must read completly the user manuel and confirm his boss.For the incomprehensible
situations,comeback to your producer AKYAPAK.
6.8.THE PROTACTION FROM THE SIDE OPERATOR.

The operator can not take the special disposition,for the machine using at the normaly
conditions.Nevertheless;
At the working time of the machine,for the hard and sharp material, the operator must use
the steal nose shoes and gloves.According the maintainence and repairment the machine,the
personel which are autorized must have the needed equipments at the wardrobe.
9 Screwdriver set.
9 Tighting set.
9 Key set.
9 Lubrication gun.
9 Gloves, Steal nose shoes.
6.9.THE SAFETY MACHINE AT THE ASSEMBLE PHASE

THE CYLINDER BENDING MACHINE must be place on the strong and straight ground.
The machine which is not connected to the ground,may fall over.The machine absolutely must
fixed on the base plan suitable.
If the machine did not setting on the strong and stright ground ,the bending material will not be
straight and in the machine will come vibration and damage.If the machine before working is
staying in the store,must be cover with water proof nylon and protacted from dust and
atmospher conditions.

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6.10.PROTACTION COMPONENTS.
The protaction components are warning equipments for the operator working at the
machine.This components are the machine moving parts ,and the wrong using of the machine.
On the page 14 and page 15 this protaction components are separate attached for USER.

CONTROL THE PROTACTION COMPONENTS

9 Before every work in relays, control the protaction components.
9 Once in the week periodicaly ,control the safety elements.
9 After all the repairments, control the protaction components.

TO MAKE THE CONTROL,BE CAREFULE FOR THE FOLLOWING SUBJECTS

9 Are the fixed position is right or not.
9 Reliable or not .
9 The function are right or not.
9 The assembly are right reliable or not.

Before working if the machine have problem or mistake, satisfy the problem.
In the working time if you see the problem,try to satisfy them.Before and at the working time
don’t pull out the safety elements,and don’t leave the circuit.

The machine protaction components.

1- SHEET METAL COVER
2- ELECTRICAL PANEL CIRCUIT BREAKER
3- THE ENERGY SIGNAL LAMP
4- THERMIC LAMP
5- EMMERGENCY STOP BUTTON FOR FOOT PEDAL.
6- THE DISPLAYS (OPTIONEL)
7- THE WORKING BUTTONS (OPTIONEL)
8- ATTENTION LABELS
9- THE ENERGY CABLES
10- THE CONTROL PANEL CABLE
11- THE MANUE LUBRICATION CONTROL
12- ROPE SWITCH
EMERGENCY
STOP BUTTON

ERG
EM
P
STO

PLATE

MULTIPLE
SOCKETS
LABELS
PEDAL
SWCHT
SWCHT START POWER ON

POWER
SWCHT THERMIC
TIRE MAIN SWCHT
MOTOR
PEDAL

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6.11.THE PROTACTION COMPONENT CHECKING LIST.

This checking list for any control ,use as copy and reproduce ,without the problem all the
functions take in the places and check on the paragraph.And save for any other damage to again
using .
CHECKING LIST THE CHECKING NAME
MACHINE NAME AND
DATE
NO

SHEET METAL COVER:MUST BE ASSEMBLY AND THE SCREW IS STRONG SCREWING.

ELECTRICAL PANEL CIRCUIT BREAKER :The machine with motor,must be assembly and
cutting the energy system .Control the circuit breaker is close or not the energy system.

THE ENERGY SIGNAL LAMP:The machine with motor must be assembly .Control the lamp is
lighting or not.

THERMIC LAMP:The machine with motor must be assembly .Control the lamp is lighting or
not.

EMMERGENCY STOP BUTTON :The foot pedal in the machine with motor is assembly
(Control Panel)Control the foot pedal is close or not the system.

THE DISPLAYS : Assembly inside the control panel machine with motor and is working or not
must be control(OPTIONAL)

THE WORKING BUTTONS : : Assembly inside the control panel machine with motor ,and is
working or not must be control(OPTIONAL)

ATTENTION LABELS : Assembly on the machine.

If the label is not there and or is worn illegible ,absolutely request the AKYAPAK COMPANY.

THE ENERGY CABLES :In the machine with motors the connecting ends must be control, and
the cable has got a phisical damage or not must be control also.

THE CONTROL PANEL CABLE:In the machine with motor, the cable has got a phisical damage
or not must be control .

THE LUBRICATION CONTROL:In the user manuel the points wich must lubricating are
determine and must be control.The needed points must be lubricate .

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7.SWITCH OFF THE MACHINE.

7.1.CARRIAGE

To be ineffected from the transport and atmosphere conditions AKYAPAK ASYMETRICAL

BENDING MACHINE are coverd with nylon water infect material. For the following operations to
be ineffected from the weather,must be carrying with nylon and rubberized waterproof cloth.
The heavy parts of the machine(the side with reductor),place at the front the truck.In this way
the heavy side of the machine will be in front side the truck,and normaly driving balance will be
adjustment. (Form 1)
After the loading the machine, be sure the machine is completly sitting on the truck. If necessary
,stand by parts the place which is not sitting very well on the truck.
The machine from four side of the corner indicating in Form 2,stand by pins on the base.

Tel . : ( + 9 0- 224 ) 482 38 60

Tel ef ax . : ( + 90 - 224 ) 482 2816- 17

Mod el :
TSEK
Prad.Year :

Serial No. :

Mot or : kW

Voltage : v

Fruqu ency : Hz

DANGER
PINCH
POINT

MAKiNA'Y I SADECE YETiSMiS - USTA PERSONEL

KUL L ANABiL R
i .!

ONL Y PROPERL Y T RAINED ANDAUT HORIZ ED

PERSONNEL SHOUL D OPERAT E THIS MACHICE.!

DIE BEDIENUNG DER M ASCHINE DARF NUR DURCH

QUAL IFIZ IERT ES F ACHPERSONAL ERF OL GEN.!

SEUL L E PERSONNEL FORM E ET AUT ORIS E PEUT

UT IL L SERCETT E MASCHINE.!

FORM : 1 FORM : 2
7.2.TO LIFT AND LAND THE MACHINE.

When you lıft the machıne ,use the cloth rope.The cloth rope using at lifting, control the load
pulling capacity and writing on the page 5 compare with the machine weight.
To lift the machine; connect all the rolls shaft (see Form 3).
The weight machine at the side reductor is not in the middle top rolls shaft, before lifting tight
the cloth rope wery well and balance the machine.
Don’t widen the cloth rope of the machine.In the opposite situation,the machine may to slip and
to be surrounded.

Tel . : ( + 90 - 224 ) 482 38 60

Tel ef ax. : ( + 90 - 224 ) 482 28 16- 17

Model :
TSE K
Prad.Year :

Se ria l No. :

Motor : kW

Voltage : v

Fruquency : Hz

DANGER
PINCH
POINT

MAKiNA' YI SADECE YETiSMiS - USTA PERSO NEL

KULLANABiLiR.!

O NLY PRO PERLY TRAINED AND AUTHORIZED

PERSONN EL SHOULD OPERATE THIS MACHICE.!

DIE BEDIENU NG DER MASCHINE DARF NUR DURCH

Q UALIFIZIERTES FA CH PERSONAL ERFO LG EN.!

SEUL LE PERSO NNEL FORME ET AUTORISE PEUT

UTILLSER CETTE MASCHINE.!

FORM : 3

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7.3. EXTRACTING THE PACKAGE (DISASSEMBLE)

To be ineffected from the transport and atmosphere conditions AKYAPAK ASYMETRICAL

BENDING MACHINE are coverd with nylon water infect material. For the following operations to
be ineffected from the weather,must be carrying with nylon and rubberized waterproof cloth.
At the time of the pulling out the package ,if you run into the damage from the transportation
mistake,call the shipping agency and inform the manufacturer company for the damage.
The children must not contact with the package material (if the plastic and chemistry material are
higher). The package must pull out with the gloves.During the carriage,the varios parts of the
machine are lubricate with oil.The oil may cleaning with diesel or solvent.

7.4. THE MACHINE ASSEMBLY PLAN ON THE GROUND

The main screw machine must screwing on the ground,inside the ground place with the
screw socket.(SEE PAGE 18)
* To strengthen the machine,be careful at the following points;

See the basis plane.

* The strength screw socket must be controled one time a mounth.The producer is not
responsible for the damages come out,if this step does not follow.

7.5. SETTING KNOWLEDGE

1-All the sides machine must approximetly and easily approuch,and for the maintenance repair
must leave the cavity.

2-The sheet bending on the machine must easily take out,and the sheet lenght must be (L)1,5
rigid and (Lx1,5)cavity.

3-The machine side border must leave a margin cavity 1 meter to moving the bending sheet
material.

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7.6. MAIN PLAN

The machine must be connecting on the hard and strong ground for the security of the working
machine.

The cement quality using on the ground basis must be appropriate to the machine weight and the
ground.

The machine must place after 72 hour on the cement spilling ground.

M12
BOLT
min.200

M12
STICKING

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7.7.THE ELECTRICAL CONNECTION FOR THE MACHINE WITH MOTOR.

Working Voltage (3 Phase) 380-415 V

Frequency 50 HZ
Rotation Motor 1,1 kW
Rear Shaft Motor 0,37 kW
Max.Current 5A
Conductor Diameter 5x2,5 Min

The electrical connections must be assembly only from the outhorized personal. Before the
connection see the technical specifications on the table and control the electrical connections
again.Take the energy cable insde the control panel,and enter inside the sockets L1,L2,L3,N,PE.

CONNECT THE CONTROL PANEL TO THE MACHINE.

Take the control panel near the machine and set the plug inside the socket.

EMERGENCY
BUTTON

G
ER
EM
OP
ST

MULTIPLE
SOCKETS

PEDAL

ELECTRIK PANEL

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7.8. CONTROLING THE DIRECTION OF THE ELECTRICAL ENGINE

ROTATION
After the electrical connections the electrician must control the rotation of the motor. Follow-up
the description below.

1-Take the circuit breaker in the position 1.

2-Control the emergency stop button is setting or not.
3-Press the start button.
4-Control the rotation of the rolls.

To press on the foot pedal,control the rotation arrow( picture A),If the arrow of the rotation is
correct,countinue to work .

If the rotation of the rolls are not like on the picture arrow,press the emergency stop button to
stop the machine. In this position,the machine working is loser.To correct this situation,must be
cutting the energy of the machine and change the phase R and S inside the socket.

7.9 CONTROL PANELS FOR THE MACHINE WITH MOTOR

7.9.1. ROTATION WITH MOTOR.

G
ER
EM
OP
ST

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7.9.2.THE MOTOR ROTATION + REAR SHAFT WITH MOTOR

G E NC
R

Y
EM E

P
O
ST

7.9.3-THE MOTOR ROTATION +REAR SHAFT WITH MOTOR + DIGITAL

DISPLAY

EMMERGENCY STOP BUTTON
REAR ROLL DOWN
REAR ROLL UP
LEFT ROTATION OF THE PEDAL
RIGHT ROTATION OF THE PEDAL
: When are pressing stop all the system.
: Using to move the rear roll to down position.
: Using to move the rear roll to upper position.
: Using to move the rolls to the left position.
: Using to move the rolls to the right position.

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7.10.FOR THE MACHINE WITH MOTOR THE SAFETY ROPE.

At the time of the transportation the machine,the safety rope assembling to the surrounding the
machine should take out.May using after the assembling on the ground the safety rope.
The safety rope at 3 side of the machine must be assembling.
To strengthen the rope,must be use the angular arms.Screw this arms to the surround the
machine.
Place the rope inside the round of the pulley and tight them. To adjust the switch,the end of the
rope must stretch over showing below,and the button will pulling up and straight.For the security
machine is assembly the safety rope.
To stopping the machine,touch slowly the rope. To working the machine pull the button (Pull to
reset).

RESET
TO

PULL

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7.11. IF THE MACHINE WITH MOTOR DOES NOT STARTING.

A.) Control the emergency stop switch is pressing or not.

B.) Control the safety rope tightness adjustment and press the reset button.
C.) Control the thermics are cuttings or not.

7.12. THE THERMIC MAGNETIC SWITCH FOR THE MACHINE WITH MOTORS.

1.)Present inside the electrical control panel.

2.)If the motor pulling the extremely current,the electrical material may stop the burning
situation.
3.)In the normaly working on the circuit breaker the position switch is (I).If the motor
pulling the extremaly current, the thermic is drop position (=).To take again in the
position (I)the thermic must become cold.

7.13. THE SAFETY SWITCH FOR THE MACHINE WITH MOTORS.

1.) THE COVER OPEN SWITCH :When the cover machine is open the cover open switch
is using to stoping the rotation the top rolls .
2.) THE ROPE SWITCH :The rope safety switch at the immediate situation is using to
stoping working the machine.
3.)

SWICHT

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8.THE MACHINE USING

8.1. GENERAL INFORMATION

To get the high yield of the machine ,the right using,maintenance and regular cleaning are
necessary.
The physics situation of the bending material is very important,preparing before the bending
operation .Of this:

1-For the material cutting with Oxygen ,the edge shavings is cleaning with emery stone.
2-On the sheet metal all the protrusion,rust,cinder,must be clening.They can damage the top
rolls,if only the rolls are hardened.
3- The two sides of the bending material must be cleaning.
4-Before the bending operation,control the parts.If you see the problem clean again.

The physics situation of the bending material, effect the quality bending parts of the material.If
the surface material is very dirty,the surface material must sanding.

8.2. THE QUALITY OF THE BENDING MACHINE

If the quality for bending material is different the bending adjustment will be different.The
materials which will bending with more quantity may can not give the same results. The effects
on the quality material,which are very important as below:
1-The quality of the material.
2- Yield point
3- Elasticity module.
4- If the thicknees of the material at all the places is not the same,the material will be without
homogeneous.
5-The material fibre direction.

This factors are very important.The dimensions can not get again,if one of them is changing
before bending operation .
For example,with the same machine adjustments the diameters will get different,if the elasticity
factor is more at the bending operation.

Again for example,according the twice material bending before the bending operations, you
will get the different results for the next one bending operation. The yield point may changing , if
the mill operation is made after the first operation , and the bending operations are done twice.
Of this factor differences frequently the same material group is come across.This reason,you must
use only the material with good quality.
The other mistake of the bending material, is the bigger diameters of the material. The begining
of the bending operation must be correct,when this type of the material are bending. At the
middle of the bending operation , the self weight may at the front surrounding and the spoil
requiring diameters.

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8.3.SETTING THE BENDING MATERIAL

You can begin the bending operation,after all the control operations.
The first step of the bending operations,is the place of the bending material.
The stright position of the material tighten between the top rolls,is initial condition for the good
quality bending material.

The step for this operations.

1-The bending material,absolutely must place between the top rolls.
2-The bending material,absolutely must be paralel to the top rolls axis.

8.4. BENDING OPERATION

The first operation is: giving the machine power. The other operations are following.

1- Turn the power switch to position 1 rear the face electrical panel.

2- Check the power lamp is lighting or not. If the lamp is not lighting,check the
electrical connections..
3- Press the start button.

The machine is ready to working. The steps determine on the page 25,you may begin the
bending operation.

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8.5.THE MACHINE METODS FOR THE BENDING OF THE MATERIAL

FORM : 4

FORM : 8
FORM : 3

FORM : 7
FORM : 2

FORM : 6
SABLON
FORM : 1

FORM : 5

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8.6. BENDING OPERATION LINE OF THE MATERIAL

Form 1 :Bring down the top rolls low and rear shaft according to the bending material thicknees
.

Form 2 : Ride the material which will bending between the top rolls shaft.

Form 3 : Put into place the sheet according the top rolls on the page 24 determine at the figure.
The top rolls shaft bring up and tight the material.
Form 4 :Pull the material near the side top rolls axis.

Form 5 : To make the prebending, bring up the rear top rolls shaft at the required diameters.

Form 6 : Press the foot pedal(turn the button)turn slowly the material.
Turn the arm at the type of the machine with arm.
According the requiring diameter, control the prebending operation with the preparing stencil.If
the prebending operation is right,turn the sheet metal backword side,and the same operation
repeat at the edge of the other side.

Form 7 : To reaching the require diameter, rotate the rear shaft top rolls up.

Form 8 : Reaching to the requiring diameter, one or two time rotate the material and make the
calibre.

The important component for the right measured bending material, is the development sheet
metal.According the bending form the development of the sheet metal must correct accounting
and cutting.The development accounting are given at the page 27.

At the bending operation the other important component for the material ,is between the lower
and upper rolls is the pressing strength.The pressing of the lower and upper rolls with the
standard machine is done with hand arm,and the requiring special equipments with motor.

If the lower pressing strenght is possible bigger,the sides of the bending material will touching
and the middle will be separated. For this kind of defect,it is say the barrel mistake.If the lower
strenght is possible small ,the sides of the bending material will separated,and the middle will be
touching.For this kind of defect,it is say the opposite barrel mistake.

CONTRARY BARREL DAMAGE

BARREL DAMAGE

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8.7. . CONE BENDING

The cone bending operation,is prepare together with the cone bending system.Cone bending;the
most difficult operations within the bending shape.About this the operator must have too much
experience.

The operation is difficult because;

THE HALF USING FOR THE MACHINE NORMAL CAPACITY.

This mean;the machine , 2000 mm x 6 mm.the thickness sheet metal and the capacity of the
cone bending ,the half of the capacity can bend 1000 mm x 3 mm.
If you want make at the below illustration the end of the cone is cutting,you must prepare the
diameter and lenght the sheet metal development.

This development,is prepare at the following formula.

L=(DxI)/(D-d) a = S x 180 x L / 3,14 S = D x 3,14

I= h +(R-r)

D, d, R, r the average diameters.

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8.8. THE BOTTOM ROLL COMPRESSION OF THE MATERIAL (UPPER AND DOWN
MOVING)

IN THE MOTOR WITH MACHINE – To compression the material the bottom roll(Form- 1)

1- Loose the handle number 01.

2- Rotate the handle number 02 and pull the bottom top rolls up.
3- After the material tighten between bottom and upper roll,dence the handle number 01.
To take out the machine the bending material,reduce the bottom roll shaft down.About this
repeat the same operation again.
THE MACHINE WITH ARM- To compression the material the bottom roll(Form- 2)
4- Loose the handle number 01.
5- Rotate the handle number 02 and pull the bottom top rolls up.
6- After the material tighten between bottom and upper roll,dence the handle number 01.
To take out the machine the bending material,reduce the bottom roll shaft down.About this
repeat the same operation again.

01
02

01 02

FORM-1 FORM-2

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8.9. CONE BENDING POSITION LINE

At the cone bending operation the operation lines are determine below.

1-Loose the headless bolt(A)on the clutch shaft to obtain the require cone bending.(See form 1
below).
2-Pull the clutch (B)orientate the arrow direction.(See form 1 below).
3-Rotate the rear shaft arm(C ) and take up the rear shaft to the requiring dimension. The rear
shaft opposite end hold down according to the cone position.(Form 1).
4-According the requiring dimensions take the rear shaft up, put forward the clutch shaft and
tighten the headless bolt.(Form 1).
5-As development for the cutting and bending material ,on the body rest are present the cone
bending apparatus.(form 2)Tight the lower top roll and make the bending operation.

B
A

ENCODER

FORM-1

CONE BENDING DEVICE

FORM-2

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8.10. TAKEN THE BENDING MATERIAL OUT OF THE MACHINE

After the bending operation of the material ,bring the lower rolls down and;

1- Take out the upper roll eccentric . So the upper top rolls bearing will come off position.

2- Pull the upper top rolls shaft sttraight yourself.Take out the shaft from the housing.

3- Take out the bending material from the opening space

To bring again the upper rolls inside the old place, repeat the above operations again in opposite
file/3,2,1/.

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8.11. ADJUSTMENT OF THE DIGITAL DISPLAY

ATTENTION !!!!
Without reading the user manuer,for Digital display don’t enter any value inside the apparatus.

Available of the dijital display purpose

The rear position of the top rolls is very important when the material is bending with the sylinder
machine.Because,the dimension which is geting with the side top rolls,is related how many unit
are moving completely.The digital display show us how many rear top rolls shaft are
positioning,that is to say how many unit is moving.For many bending parts,when the first part is
finish to bending,the display take notes for the rear top rolls shaft position ,this value for the
next bending materials will bend at the same dimensions. This will win you series production,for
all the parts you will adjust only one value.

9. MAINTENANCE

To take the high performance from our machine,must be cleaning and doing the regular
maintenance.

The maintenance operation we can add in two groups.

1- Protaction of the maintenance.
2- Maintenance and repairing after the machine damage.

9.1. PROTECTION OF THE MAINTENANCE

The protaction of the maintenance;the losses determined in the machine,before the damage,the
dispositions taken in this situations are below.
- Regular control of the lubrication
-Regular cleaning
- The cleanness of the bending material.
- Controling the machine parts with amortization.
- The risk of the loosing the screw parts due to vibration working.
Protaction of the maintenence.
Protaction of the maintenence;the damage come into existence the machine,determine in the
begining of the machine working,in respekt of this the required disposition are below:
This dispositions are;
- Regular lubrication and lubrication control.
- Regular cleaning.
-The cleanliness of the bending material.
-Control the corrosion parts present in the machine.
- Risk of the loosen parts and the components at the vibration situation.
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9.2. REGULAR LUBRICATION AND LUBRICATION CONTROL.

This subject are wide explaining at the pages 32,33,34..

9.3. REGULAR CLEANLINEES

In the bending operation on the rolls can stick the dirty and rust parts.The rolls shaft after the
bending operation must clean and their surfaces are controling.Don’t bend the hard materials
on the machine,if only the rolls are hardened.The machine working atmosphere,must not
effective ,from the atmosphere conditions,and must be witout the dust.Especially must to pay
attention for the lift screw at the bottom and side rolls shaft.This lift screw must control every
day by run an eye over,lubricate and clean their surface from the strange parts.

THE CLEANLINEES OF THE BENDING MATERIAL.

This subject are wide explaining at the page 23.

9.4. CHECKING THE ABRASION PARTS IN THE MACHINE. If the operator and the
person responsible for the maintenence parts,at the working operation,hear the voice inside the
machine ,must stop the machine and control the looses parts.If you don’t want to abrasion the
parts inside the machine,do the right time control and lubricate the machine
The parts which are using in the machine are given at the page 35,36.

9.5. REPAIRING THE FAILURE.

At the damage situatıons and maintenence, the machine cover must be closed and the energy is
cutting.The machine repairment must be doing from autorized personal,and the assembly
drawing given at the page 35,36 carefully to investigate.After all the damages do the controls
given at the page 15.

ATTENTION !!!!!

For all the maintanence and repairments the machine cover will be closed
and the energy must be cutting.

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10 GREASE

In the machine are using two kinds of the grease.

- Grease
- Liguid grease

The name for this two kinds are given at the page 32.

10.1. GREASE POINTS

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10.2. THE TABLE FOR GRAESE COMPARION

TYPE GRAESE LIQUID

MOBIL Kup Grease 2 Mobil Gear 629

BP Energrease GP2 Energol GR-XP 150

SHELL Livona 2 Omala Oil 150

CASTROL Helvium 2 Alpha SP 150

TEXACO - Meropa 150

ELF - Reductelf SP 150

TOTAL - Carter EP 150

ESSO - Spartan EP 0

AGIP - Blasia 150

Q8 - Goya 150

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55
54
08 11
06 14
105 10
49 33 15
50
52 35 09
57 01
51
116
34
11.SPARE PARTS PLAN

46 53 27

47 125
48 124
30 44 116
17
28 117 123
07
29 118
122
31 119
108 58
32 120
05 45
04 64 121
36
95 59 19 104 105
91 81 94 83 37 60 103
84 41
107 93 38

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92 20 70
88
115 96 59
87 60
114 98 16
90 85 42
82
03 21 40 69
86 02
89 22 43
113 25
23 68
USER’S MANUEL

26 109 67
100

101
99
102
11.1.SPARE PARTS PLAN FOR THE TYPE OF MACHINE WITH MOTOR

18
24
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106
 64 81
60 62
04 61 80
08
30
07 31 01 09 79
06 32
53
55 63
56 78
05
94 77
52
47
54 95
57 13
51 23
96 11
29 68 97 10
45 67
66
58
59 24
07 14 15
08 25
04 26 48
46 18 39
17 33 65
05 34 41
98 72
35

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27 16
49
28 50
99 49 69 36
92 70
100 03 19
43
93
02 20 37
21 38
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85 40 71
78 22 42
79 87 84 44
86 91
77
11.2. SPARE PARTS PLAN FOR THE TYPE OF MACHINE WITH ARM

82 73
83 27
90 28
88 75
AS

80 89 74
76
Page: 37

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12. THE LABEL USING ON THE MACHINE

DİKKAT! MAKİNAYA YAĞ KOYMADAN ÇALIŞTIRMAYIN

ATTENTION! DON'T USE THE MACHINE WITHOUT OIL

ACHTUNG! BENUTZEN SIE DIE MASCHINE NICHT OHNE ÖL

CAUTION! N'UTİLİSEZ LA MACHİNE SANS HUİLE

ATTENZIONE! NON USARE LA MACCHINA SENZA OLIO

ATTENCION! NO USAR LA MAQUİNA SİN ACEİTE

OPERATOR
MUST USE THE CAUTION !
ABOVE SECURITY PLEASE DO NOT
STAY IN THE WORKING
ACCESSORIES
THE WORKING AREA OF THE MACHINE

PROTACTION
LABEL

CAUTION ! CAUTION !
DANGER FOR DANGER FOR
COMPRESSION COMPRESSION

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