AHS

4 ROLLS HYDRAULIC PLATE BENDING MACHINE

OPERATION AND MAINTENANCE MANUAL

AKYAPAK ULUSLARARASI DIŞ TİCARET MAKİNA SANAYİ TİCARET A.Ş.

Address: Akçalar Sanayi Bölgesi Sanayi Cad. No: 8
16225 Akçalar / Bursa / TÜRKİYE
Tel: 0090 224 280 75 00
Fax: 0090 224 280 75 02
Web: https://www.akyapak.com.tr
REV. 1
 TABLE OF CONTENTS

INTRODUCTION ............................................................................................................................. 5

WARRANTY PROCEDURE .......................................................................................................................... 5

OUT OF WARRANTY CONDITIONS ............................................................................................................ 6
LIFE CYCLE ................................................................................................................................................. 7

GENERAL INFORMATION ............................................................................................................. 8

MACHINE DATA PLATE ............................................................................................................................... 8

TECHNICAL SPECIFICATIONS ................................................................................................................... 9
TECHNICAL SPECIFICATIONS ................................................................................................................. 10
PRODUCT INTRODUCTION ...................................................................................................................... 11
DESCRIPTION, USAGE AREAS AND CONDITIONS OF THE MACHINE ................................................... 12

SAFETY WARNINGS .................................................................................................................... 13

SAFETY FACTORS .................................................................................................................................... 13

POSSIBLE RISKS ON THE MACHINE........................................................................................................ 14
RISK OF DAMAGE ..................................................................................................................................... 14
MACHINE FUNCTIONS .............................................................................................................................. 15
PROPER OPERATION OF THE MACHINE ................................................................................................ 15
IMPROPER OPERATION OF THE MACHINE ............................................................................................ 16
PROPER OPERATOR ................................................................................................................................ 16
PROTECTION OF OPERATOR .................................................................................................................. 17
SAFETY FACTORS IN THE MACHINE INSTALLATION ............................................................................. 17
SAFETY PRECAUTIONS ........................................................................................................................... 17
CHECK THESE SAFETY PRECAUTIONS .................................................................................................. 17
CHECKING OF MAINTENANCE POINTS ................................................................................................... 18
SAFETY FEATURES .................................................................................................................................. 18
SAFETY PRECAUTIONS CHECK LIST ...................................................................................................... 20

OPERATING CONDITIONS .......................................................................................................... 21

WARNINGS ................................................................................................................................................ 21
GENERAL INFORMATION ......................................................................................................................... 22
MANUFACTURER INFORMATION ............................................................................................................ 22

IMPORTANT SAFETY PRECAUTIONS ....................................................................................... 23

SAFETY ...................................................................................................................................................... 23
SAFETY INFORMATION ............................................................................................................................ 23
OPERATING AREA SAFETY ...................................................................................................................... 24
MACHINE SAFETY INFORMATION ........................................................................................................... 25
GENERAL PRECAUTIONS ........................................................................................................................ 26
SAFETY OF THE EMPLOYEES WORKING ON THE MACHINE................................................................. 26
PERSONAL PROTECTION EQUIPMENT .................................................................................................. 26
WARNINGS ON OPERATION .................................................................................................................... 27
STORAGE .................................................................................................................................................. 27

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TRANSPORTATION ..................................................................................................................... 28

CHECKS TO BE DONE IN THE DELIVERY OF THE MACHINE ................................................................. 28

SAFE TRANSPORTATION OF THE MACHINE .......................................................................................... 28
HORIZONTAL ADJUSTMENT .................................................................................................................... 28
APPLICATION ............................................................................................................................................ 28

MAINTENANCE AND INSPECTION ............................................................................................. 29

PROCEDURE FOR ISOLATION OF THE MACHINE .................................................................................. 29

SAFETY DURING MAINTENANCE ............................................................................................................ 29
PREVENTION OF ACCIDENTS.................................................................................................................. 30
POINTS TO BE CONSIDERED IN DAILY OPERATION .............................................................................. 32

SECTION II INSTALLATION OF THE MACHINE ....................................................................... 33

GENERAL INFORMATION ON THE INSTALLATION OF THE MACHINE .................................. 34

INSTALLATION INSTRUCTIONS TRANSPORTATION .............................................................................. 34

TRANSPORTATION AND PLACEMENT OF THE MACHINE ...................................................................... 34
CAUTION:................................................................................................................................................... 34
REMOVEL OF PACKAGE........................................................................................................................... 35
PLACEMENT PLAN OF THE MACHINE ..................................................................................................... 35
INSTALLATION INFORMATION ................................................................................................................. 37

PRE-INSPECTIONS ...................................................................................................................... 38

SAFETY ROPE ........................................................................................................................................... 38

ELECTRICAL CONNECTION ..................................................................................................................... 39
FILLING OF OIL RESERVOIR .................................................................................................................... 39
CHECKING OF LUBRICATION................................................................................................................... 40
INSPECTION OF ELECTRIC MOTOR ROTATION DIRECTION ................................................................. 40
FOR 380/400/415V (OTHER VOLTAGES) .................................................................................................. 40

RECOMMENDED GREASE CHART ............................................................................................ 42

MACHINE OPERATION ................................................................................................................ 43

1. UP AND DOWN MOVEMENTS OF SIDE BALLS .................................................................................... 43

2. UP AND DOWN MOVEMENTS OF LOWER BALL .................................................................................. 43
BUTTONS................................................................................................................................................... 44
USAGE AND FUNCTIONS OF THE BUTTONS .......................................................................................... 44
ADJUSTMENT OF INTERNAL PRESSURE................................................................................................ 45
MATERIAL QUALITY .................................................................................................................................. 46
PLACING THE MATERIAL.......................................................................................................................... 46
BENDING OPERATIONS ........................................................................................................................... 47
BARREL ERROR ........................................................................................................................................ 49
BARREL ..................................................................................................................................................... 49
REVERSE BARREL ERROR ...................................................................................................................... 50
CYLINDER ERROR .................................................................................................................................... 50
OVALNESS ERROR ................................................................................................................................... 51
BENDING ERROR ...................................................................................................................................... 51
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WRONG AXIS ERROR ............................................................................................................................... 52
LAYOUT OF CONICAL ANGLES ................................................................................................................ 52
YOU SHALL USE HALF OF THE CAPACITY OF THE MACHINE. .............................................................. 52
CALIBRATION............................................................................................................................................ 53
OPERATION PROCEDURE ....................................................................................................................... 53
PREPARING THE MACHINE TO CONICAL BENDING ............................................................................... 53
PLACING THE MATERIAL.......................................................................................................................... 54
OPERATION PROCESS............................................................................................................................. 55
1) ADJUSTMENT OF EVENNESS OF SIDE ROLLER BALLS..................................................................... 57
ADJUSTMENT OF EVENNESS OF LOWER ROLLER BALLS .................................................................... 58
MAINTENANCE .......................................................................................................................................... 58
PREVENTIVE MAINTENANCE................................................................................................................... 58
REGULAR LUBRICATION AND CHECKING OF OIL LEVEL ...................................................................... 59
REGULAR CLEANING ............................................................................................................................... 59
INSPECTION OF WEARABLE PARTS ....................................................................................................... 59
REPAIR ...................................................................................................................................................... 59
LUBRICATION OF THE REDUCER ............................................................................................................ 59
RETURN FILTER ........................................................................................................................................ 60

SECTION III III PART LISTS ....................................................................................................... 61

BODY ......................................................................................................................................................... 62
LOWER BALL ............................................................................................................................................. 63
UPPER BALL .............................................................................................................................................. 65
SIDE BALL .................................................................................................................................................. 67

SECTION VI AHS MAINTENANCE AND SERVICE MANUAL ................................................. 69

END OF WORKDAY MAINTENANCE ......................................................................................................... 70

NOISE EMISSION RATE ............................................................................................................................ 71
GENERAL SAFETY INFORMATION........................................................................................................... 71
RECOMMENDATIONS FOR A FAULT CONDITION ................................................................................... 73

REDUCER FAULTS AND MAINTENANCE THROUGHOUT THE MACHINE ............................. 79

INTERVENTION TO REDUCERS ............................................................................................................... 79

OPERATION............................................................................................................................................... 79
MAINTENANCE .......................................................................................................................................... 79
LUBRICATION ............................................................................................................................................ 79
WARRANTY CONDITIONS ........................................................................................................................ 79
OIL TYPES ................................................................................................................................................. 81
TROUBLESHOOTING GUIDE FOR REDUCERS ....................................................................................... 82

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 INTRODUCTION
PLEASE READ THE OPERATION MANUAL CAREFULLY AND KEEP IT FOR FUTURE
REFERENCE!

 Operators who would be using the machine, shall read the information in the
operation manual thoroughly beside the training they will take from AKYAPAK
Makine instructor, and shall have information on the operation, settings and
maintenance of the machine.
 Machine shall never be operated by staff who does not have a good grasp of the
information in the manual.
 It is forbidden to reproduce, transfer or use this document or its contents without written
permission. People acting otherwise shall be responsible for any damage that may occur.
 All rights, including the registration rights of a model or design submitted for patent approval
or presented for use, are reserved by AKYAPAK Makina San. Tic. Ltd. Şti.
 It is possible that functions that are not described in this manual are available.
 Safety equipment may be represented in improper positions on some cross-sectional views
used in the manual. These views are used to provide the required visual information, and
the machine shall never be operated outside the specified safety positions.
 The conformity of the subjects described in this manual are checked by ourselves.
However, there may be some differences and it is not possible to guarantee that all these
information are exactly similar.
 It is possible to make changes on the machine and the document without prior information.
 Subjects included in this document are regularly reviewed and changes required are added
to the next issue. Your offers intended to develop the system would be gladly accepted by
us.

WARRANTY PROCEDURE
 AKYAPAK 4 Rolls Hydraulic Plate Bending Machine is warranted against material defects
and labour and manufacturing errors for 1 (one) including all of its component, provided that
the machine is operated in the way specified in the operation manual and never intervened
for maintenance, repair or for other purposes by people other than the Service technicians
authorized by AKYAPAK.

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  Warranty period of the parts replaced due to material or manufacturing defects when the
machine is under warranty cover shall be expired with the expiration of machine warranty
cover.
 This warranty does not cover the transportation costs, travel and labour expenses for the
parts required for renewal or repair.
 This warranty does not apply for parts worn under normal operating conditions.
 If the customer delays the installation of the machine after receiving the machine, it is under
the initiative of AKYAPAK Makine to determine whether time passed within warranty period
shall be added to the actual warranty period.

OUT OF WARRANTY CONDITIONS

 Commissioning of the machine by unauthorized persons,
 Damages and faults occurred due to usage errors,
 This warranty is void for damages that occur due to negligent use of the machine or
changes performed on the machine without written consent.
 Machine shall be void of warranty and AKYAPAK shall not be held responsible for risks that
may occur when the machine is used for other purposes than its intended purpose.
 Machine shall be installed, commissioned and delivered to the customer by personnel
authorized by AKYAPAK only. Otherwise, AKYAPAK does not accept any responsibility and
machine shall be out of warranty cover.
 Faults that occur due to the use of machine against the points specified in the operation
manual.
 Modification or repair of the machine by unauthorized persons,
 Consumables subject to normal wear,
 Damages and faults that occur during loading, unloading and transportation operations after
the delivery of the machine to the customer,
 Damages and faults that occur because of undervoltage or overvoltage, faulty electrical
installation, using the machine with a voltage other than the voltage specified in its data
plate,
 Damages and faults that occur because of fire or lightning strike.
 non-genuine spare parts and consumables are used.
 When consumables used in the machine are expired before their specified operation
periods,

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  This warranty shall be void if inspections and maintenances specified in this manual are
neglected.

 In case of Out of Warranty Conditions, faults shall be repaired for a charge.

LIFE CYCLE
Life Cycle is: 10 years. (Parts retaining period to ensure functioning of the machine)

AKYAPAK offers technical assistance and/or help to its customers when a problem occurs on the
operation and repair procedures of its machines. You may contact technical service or support
department both in written and oral form as specified in the relevant section of the manual when
required.

Technical Service Contact Information

Service Name: AKYAPAK ULUSLARARASI DIŞ TİCARET MAKİNA SANAYİ TİCARET A.Ş.
Service Address: Akçalar Sanayi Bölgesi Sanayi Cad. No:8 16225Akçalar / Bursa-TÜRKİYE
Service Tel: 0090 224 280 75 00
Service Fax. No.: 0090 224 280 75 02
E-mail: info@akyapak.com.tr

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 GENERAL INFORMATION

MACHINE DATA PLATE

Company Name: AKYAPAK Mak. San. ve Tic. Ltd. Şti.

Address: Akçalar Sanayi Bölgesi Sanayi Cad. No:8 16225
Akçalar / Bursa-TURKEY
Tel : (+)90 224 280 75 00 Fax : (+)90 224 280 75 02
Web: https:// www.akyapak.com.tr

Model Name :
Type: Rated Current : A
Serial No: Rated Power : Kw
Prod. Date : Rated Frequency: Hz
Mass of Machine : Kg Voltage : VAC
Width: mm No of Phase : 3PH+1N+1PE
Length mm IP :
Height: mm Pneumatic Pressure: 6 ~ 8 Bar (
min~max )
Electrical Panel : Hydraulic Pressure: Bar

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 TECHNICAL SPECIFICATIONS

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 TECHNICAL SPECIFICATIONS

Model

Serial No
Average Dimensions
Height
Length
Width
Weight
Dimensions of Roll Balls
Center Roll Balls
Rear Side Roll Balls
Bending Speed
Initial Speed
Power source
Pre-bending Thickness
Bending Thickness

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PRODUCT INTRODUCTION
All operating movements of plate bending machine are performed
manually.
Plate material prepared for using in various fields in the industry is placed on the machine in order
to bend it in the specified way.
Then, desired form is obtained by bending it as specified in the operation manual.
Standard features of our machine:
 Conical bending mechanism
 Induction hardened rollers
 Digital indicator for side rollers
 Completely steel (ST-52) welded construction machine body
 Separate control panel
 Double speed control
 Rollers mounted in bearing
 Upper roller cover that opens and closes hydraulically from the control panel. Upper roller is
raised automatically when the cover is opened.
 Conical opening and closing via control panel.
 Hydraulic motor and planetary reducer driven central rollers (upper and lower rollers)
 Calibration
 Registered manufacturing quality with CE, ISO 9001-2008, TSEK and TURQUM
certificates.

Also, in order to facilitate the bending operation:

 Infinitely adjustable rotation speed
 Side and central supporters for big sheet metal diameters
 Material feed table
 CNC Graphical control system
 NC Playback control system
 Replaceable upper roller (for smaller diameters)
 Oil cooling system Motors with different voltages and frequencies

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DESCRIPTION, USAGE AREAS AND CONDITIONS OF THE MACHINE

 Plate bending machine is designed to bend materials as cylindrical full circles (tube), half
circles, arcs and cones.
 Plate bending machine bends sheets with the thickness and width as specified in its
specifications.
 Machine is protected with various sheet construction housings.
 It is intended for bending plates within the limits specified in technical specifications as per
the safety, operation and maintenance instructions given in the operation manual of the
machine.
 Bending operation shall be performed with utmost care.
 Operator shall have adequate training for the operation and maintenance of the machine,
and shall be at the proper age as per the legislation of the relevant country.
 Use the protection and safety equipment specified in operation manual. Also, use the
personal protective equipment and/or other protective equipment required as per the
operation conditions.
 Safety measures include the operation of the machine as specified above.
 Use the drilling machine rationally and carefully to ensure operator safety and to increase
life cycle of the machine.
 Read the manual carefully after receiving the machine, and then operate it.
 As the plate bending machine is manufactured with advanced technology, proper use and a
good maintenance plan would increase the efficient life cycle of the machine.
 Human errors and improper use may cause serious damage to the machine. This may
increase the wear of parts and even cause serious safety risks for the operator.

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 SAFETY WARNINGS

SAFETY FACTORS
Upper and lower balls of AKYAPAK 4 roll bending machine can be rotated. Operator's hand and
fingers can be caught by these balls. Ensure that parts of your clothing or your fingers are not
caught in these balls while the machine is being operated.

 Do not perform repairs while the machine is being operated.

 Ensure that you have turned off the machine before lifting the rear plate.
 Check the safety rope after closing the plate.

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PRESS EMERGENCY STOP BUTTON IN CASE OF AN EMERGENCY OR PRESS ON THE
ROPE AROUND THE MACHINE

 Press emergency stop button in case of an emergency or press on the rope around the
machine.
 Stop the machine before maintenance and cleaning.
 Never remove the safety plates.

POSSIBLE RISKS ON THE MACHINE

Precautions for risks are taken on AKYAPAK 4 ball cylinder.
For example:
 Electrical installation is protected with a metal cover.
 Another dangerous area is where the balls rotate. Risky conditions may occur in case of
wrong and erratic operation.
 Safety rope is placed around the machine against accident during operation.

RISK OF DAMAGE
 Operator's fingers and hands
 Operator's clothings and other belongings
 Deformed operating material
 Third persons in material bending
 Bending materials for the machine
Anyone who will be operating, installing and maintaining the machine shall read the operation
manual with an applied and active manner. Do not try to bend hard materials other than aluminium
and metal sheets; you may hurt yourself or cause damage to the machine. It is forbidden to make
any modification on the machine for safety and efficiency reasons. Operating and safety
instructions specified in operation manual shall be followed and applied.
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MACHINE FUNCTIONS
AKYAPAK 4 roll hydraulic cylinder is designed to form the material, and its other functions are
given in the table below. This machine can bend closed and semi-closed tubes and cones.
Machines are manufactured in different capacities and dimensions as per the thickness of the
material to be bent.
Check the thickness of plate before starting to bend the material. Do not attempt to bend material
with the thickness higher than specified.
Cylinder diameter of AKYAPAK asymmetrical bending machine, width and thickness of the
material to bend are shown below.
For example AHS 3100*10/14
AHS=machine type
3100=width of the material to be bent
10=thickness of the material that may be bent up to 3 three times of cylinder diameter
These values are required for material with St-37 grade.
Yield point=240 N/mm2
Shrinkage point=370 N/mm2

PROPER OPERATION OF THE MACHINE

All bending operations shall be performed by one person, from the front of the machine, where the
control panel is. Then, material shall be placed on the machine and another employee shall help
him, and other bending operations shall be performed by the operator. However, operator shall
take all safety precautions and check all bending operations.
A safety area shall be available around the machine and no one shall enter this area other than the
operator in order to achieve maximum rate of bending operations.

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IMPROPER OPERATION OF THE MACHINE
No one shall be inside the safety area during bending.
Power shall be cut off during repair.
No one shall get over the machine in any circumstances.

PROPER OPERATOR
Persons under the age of 16 are not allowed to operate 4 roll hydraulic cylinder. Operator who will
be operating the machine shall confirm that he has read the manual and received all equipment.
Contact AKYAPAK in case of any doubt.

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PROTECTION OF OPERATOR
Operator is not required to other precautions under normal operating conditions of the machine.
During operation:
Employees shall wear steel boots against the risk of dropping material and work gloves for the
handling of the machine. Qualified staff shall have proper equipment for machine maintenance.

 Screwdriver set
 Allen set
 Wrench set
 Lubrication gun
 Gloves
 Steel boots

SAFETY FACTORS IN THE MACHINE INSTALLATION

AKYAPAK machine shall be placed on a hard and level ground (check the placement plan).
Machine may cause serious damage and accident if it is tipped over.
Material that is not properly installed cannot be bent correctly. Moreover, wrong placement of the
material may cause damage.
If the machine is stored, it shall be covered with tent and protected against dust.

SAFETY PRECAUTIONS
Safety precautions of 4 roll cylinder machine is given below. A check list is added to ensure that
these precautions are checked by the operator.

CHECK THESE SAFETY PRECAUTIONS

 Always check these factors before any shift.
 Please check the safety points regularly every week.
 Check these safety precautions after any maintenance operation.

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CHECKING OF MAINTENANCE POINTS
 Check if the position of the machine is correct.
 Check for any noise from the machine.
 Check whether the machine functions correctly.
 Check the machine is placed correctly.
Removed any problems or errors before operating the machine. Stop the machine immediately
and contact the dealer or AKYAPAK if you observe any problem during the operation of the
machine.
Do not skip safety elements before operating the machine or during operation.

SAFETY FEATURES
 Protective cover
 Main switch and circuit switch on the power panel
 Power indicator on power panel that indicates the electrical power
 Temperature indicator on power panel (indicates overloading)
 Emergency stop button on the control panel
 Switch on the control panel
 Indicator on the control panel
 Other buttons on the control panel
 Warning labels
 Condition of power cord
 Connection cables of control panel
 Whether manual lubrication is performed
 Safety rope

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AHS – Rev1 25.03.2016 19 / 86
SAFETY PRECAUTIONS CHECK LIST
Take a copy of this check list and use it on every inspection and operation. Mark with X after
checking each feature and function and file it against a risk of fault.

CHECK LIST CHECKED BY

MACHINE NAME
DATE
AND NO

-PROTECTIVE COVERS = they shall be in place and screwed

-ELECTRICAL ISOLATION MAIN SWITCH = it shall be installed and checked for functioning.
-POWER LIGHT = it shall be installed and checked for illumination. Check for any burned
bulbs.
-HEAT LIGHT= it shall be installed and illuminated in case of overheating.

-EMERGENCY STOP BUTTON = it shall be installed on the control panel and checked if it
stops the main motor.

-ROCKER SWITCH BUTTON (0-1) = it shall be installed on the control panel. It shall be
functioning on indicator and control circuits.

-DISPLAY= it shall be installed and it shall open when the power is on.

-OTHER PANEL FUNCTION BUTTONS = they shall be installed and checked for functioning.

-WARNING PLATE = it shall be secured and placed so that it can be seen easily.

-POWER CORD = it shall be secured on the machine safely and it shall not be broken or
peeled. It shall have a safety protection against mechanical damage.

-CONTROL PANEL CONNECTION CABLE = it shall be installed and its flexible sheath shall be
checked.

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 OPERATING CONDITIONS

WARNINGS
 Do not modify components and systems of the machine without consent of AKYAPAK.
 AKYAPAK warranty shall be void if any modification is made on the machine.
 Do not modify the power and safety systems of the machine to ensure operator safety.
 Machine shall be installed, commissioned and delivered to the customer by AKYAPAK staff
only. Otherwise, AKYAPAK does not accept any responsibility and machine shall be out of
warranty cover.
 Loading wrong workpieces on the machine and operation may damage the machine and
cause a risk for the operator.
 Do not distribute this manual to other persons, companies and agencies.
 This manual includes instructions on the installation, safety applications, operation of the
machine etc.

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GENERAL INFORMATION
Operation manual provided by the manufacturer includes required information on the machine
components. Moreover, all operations in the manual are organized by considering normal
operation and periodical maintenance of the machine. Therefore, instructions shall be strictly
followed for correct and optimal operation of the machine. We advise you to keep the operation
manual in suitable conditions in a place that can be accessed easily. Machine shall be operated by
trained and qualified staff. Each part that shall be removed from the machine and replaced shall be
removed by authorized technicians. All operators of the machine shall read these information, and
the machine shall be operated then.

MANUFACTURER INFORMATION
Please contact us using the telephone, fax or e-mail information provided above for any help
requests when you have a problem related with the machine or for your spare parts orders. It is
important that you provide the following information on any correspondence on the machine with
the manufacturer or dealership you have purchased the machine for minimizing the procedures
required:
 Machine serial no.
 Machine model
 Date of purchase
 Dealership where the machine is purchased
 Description of the fault detected
 Average daily operation time
 Voltage and frequency information
Technical data plates that define the machine model are riveted on the machine. Machine serial
number and date of production are inscribed on the technical data plate.

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 IMPORTANT SAFETY PRECAUTIONS

SAFETY
Machine is designed as conforming with the normal safety rules. However, machine may cause
accidents with risk of personal injury or death. Moreover, unsuitable operating conditions may
cause damage on the machine. Machine shall be used as per its intended use. Injuries may occur
when the machine is not used as per its intended use. AKYAPAK is not responsible for such a
condition. Basic safety rules shall be followed in order to ensure machine operation without faults,
risks or without causing an injury. Safety operations shall be well-known by the authorized person
operating the machine. Additionally, general safety rules shall be followed.

SAFETY INFORMATION
In addition to the recommendations in this operation and maintenance manual, all local accident
protection and environment protection legislation shall be followed. All issues such as safety
information etc. related with the machine shall strictly be considered. Machine is covered with
protective parts for safety reasons in order to prevent ingress of any foreign material, hand or arm
to the moving or rotating parts of the machine while it is operated.
Following symbols are safety symbols that shall be read and followed with special attention.

STOP DANGER MANDATORY WARNING

User may cause damage on the equipment or injury to himself when these symbols are not read or
are neglected.

Stop symbol is used to indicate conditions where system/machine shall be stopped,

turned off, paused or released.

Danger symbol provides warning against specific risks and it shall always be read. If
this symbol is neglected, damage to equipment or injury to staff may occur.

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 Mandatory symbol indicates the obligation to perform or not to perform some
operations or actions in the operation areas or the obligation to make some material available or
not (For example, grounding line is mandatory, keeping flammable substances away is mandatory
etc. )

Warning symbol indicates that personnel shall act with caution and attention and keep
their movements in specified limits in order to prevent injuries.

Read the manual carefully before operating the machine and making maintenance on it.

OPERATING AREA SAFETY

Always keep the machine and your equipment clean so that they can be operated at any time and
follow the instruction on maintenance operations and replacement of accessories in order to work
safely.
Check the plugs and cables periodically. Have AKYAPAK or an authorized technician replace it
when it is damaged.
Prevent soiling of the handles and grips with oil and grease.
Ensure that the operation area is neat and well-illuminated.
Never put any material inside the specified limits around the machine. Remove the dust and
chippings on the floor, disorder increases the risk of accidents.
Machine checks and operation shall be performed by the same operator.
It is very dangerous using the machine by several persons, avoid such a condition.
Do not put your hand or body parts into operating parts when the machine is operated. These
behaviours are very risky.
Ensure that the machine is not being operated (at standby) while changing tools or program.
Do not enter the operation area of the machine when it is operated. This is very dangerous, do not
attempt it.

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MACHINE SAFETY INFORMATION
All power equipment are potentially dangerous.
Do not put your hands in the operation area. There are compression and bending equipment in
this area. Remove all your jewellery such as rings, watches etc. when you are operating the
machine.
Do not wear loose or baggy clothes such as unzipped or unbuttoned jackets, scarves, torn clothes
or ties etc.
We recommend you to wear protective equipment such as hard hats, ear protectors, protective
glasses and dust mask etc. Consult your employer on the protection rules and equipment.
Do not attempt to operate the machine when a fault condition occurs. Ensure that all potential risks
are removed before operating the machine.
Inform AKYAPAK/maintenance personnel if a fault is observed on the machine operations.
Provide adequate illumination for safe operating conditions.
All safety and protection equipments shall be used for perfect efficiency. Warning signs on the
machine and recommendation in the operation manual shall always be followed.
It is strictly forbidden to operate the machine when the protective covers, safety switches and any
similar safety equipment are removed.
Authorized personnel shall be used for lifting and moving the machine (displacement of the
machine), and maintenances on the electrical and hydraulic systems.
It is strictly forbidden to modify any component or change the position of a component on the
machine.
It is forbidden to make any adjustment, cleaning or maintenance while the machine is being
operated.
Always follow “Danger” and “Warning” signs on any machine equipment!
If it is operated incorrectly, conditions that may cause injury or death to the operator or damage to
materials or machine may occur.
Besides that, if the conditions specified under 'Warning' are not applied, this may cause significant
damages in some conditions.

As a result, you shall always pay attention to following.

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GENERAL PRECAUTIONS
The protective precautions specified in this manual may change according to the machine and its
specifications.
AKYAPAK is not responsible for any damage that may occur if the standard equipment on the
machine is modified without the approval of AKYAPAK or if non-standard products are used in the
replacement machine components.
Consult AKYAPAK if the safety equipment or warning labels on the machine are damaged or
missing.

SAFETY OF THE EMPLOYEES WORKING ON THE MACHINE

Personnel shall be trained on the following points before operating the machine:
Basic safety and accident prevention instructions,
Conformity to the safety rules and periodical inspections for conformity,
Illumination of the surroundings and required areas.
Personnel who would be working with the machine shall use work clothes that fits on their body.
As loss of concentration and any illness would cause loss of reflexes and distraction, operator shall
not operate the machine in such conditions.

PERSONAL PROTECTION EQUIPMENT

Following protective equipment are recommended to be used.
 Strong gloves to prevent cutting, puncturing or stinging conditions while handling the
material,
 Earplugs that provide protection against noise,
 Glasses against chipping that may be splattered,
 Protective boots during handling of materials with a certain weight and size.

WARNING
Area of danger may change as per the size of the material that is being bent by the operator
besides the operation area of the machine. In brief, do not enter operation area of the materials
during the operation of the machine. This is very dangerous. Never attempt this.

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Ensure that there is no unnecessary tools or equipment in the operation area before starting to
work with the machine as this may cause damage to the machine or the operator. Pay attention to
these recommendations.

WARNINGS ON OPERATION
Pay attention to the following points in order to prevent electric shocks and risky conditions.
Do not press the function buttons while the machine is being operated.
Follow the technical codes and local wiring regulations during the installation of electrical
equipment.
Do not place any other equipment that may cause noise beside the machine. If the noise interferes
with the signal waves, this may cause wrong movement and risks.
Prevent damage to the cable and do not apply pressure on the cable, otherwise electric shock or
risks may occur.
Do not touch any operating part when the machine is powered on. Do not enter the operation area.
These behaviours may cause injuries.
Ensure that no foreign tools, equipment or person (other than operator) is present in the operation
area during the operation of this machine. Then start the operation.
Following areas are dangerous during the operation of the machine.
Do not put your hand or body in the application area.
Death or serious injury such as breaking the arm or a leg may occur.

STORAGE
Machine shall be protected against external conditions (rain, extreme heat etc.) in its operation
area and shall be stored indoors. All metal equipment on the machine shall be lubricated with
protective grease if the machine will not be operated for a long time. Cover the machine to protect
it against factors such as dust.
Do not store or operate the machine in damp conditions with poisonous gas or liquid.

Ambient temperature shall be + 10° /+ 50° C during storage.

Ambient humidity shall be 10%-80%.

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 TRANSPORTATION

CHECKS TO BE DONE IN THE DELIVERY OF THE MACHINE

On the delivery of the machine, check if the delivered goods are conforming with your order and
for any damage occurred during transportation. If there is a missing or damaged part, please
prepare an oral and written report, taking pictures if possible, immediately. This report shall be
submitted to the transportation company within 48 hours.

SAFE TRANSPORTATION OF THE MACHINE

All our machines are packed in perfect packing conditions after careful internal inspection and
checks. In overseas and TIR shipping, machines are specially packed using special lubricants that
protect against oxidation. A report shall be issued to the transportation company in case of any
damage in the machines. Also, check if all standard and optional accessories supplied with the
machine are delivered.

WARNING
Protect the machine against damage during transportation!

STOP
Do not store in places where rain, or water drops, poisonous gas or liquid are available.

HORIZONTAL ADJUSTMENT
If the level adjustment of the machine is not performed, machine may tilt and be deformed, and
this would decrease the precision of the machine, affect all products and increase the vibration of
the machine.
Level the machine on X, Y and Z directions with a precision spirit level.

APPLICATION
Operate the machine according to the operation manual and the instructions given below.
Caution:
AKYAPAK does not accept any responsibility for any accident that occur due to any action of the
operator that is not specified in this manual.

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 MAINTENANCE AND INSPECTION
PROCEDURE FOR ISOLATION OF THE MACHINE
As always, turn off this machine's power system from the main switch for maintenance, repair and
similar operations. Disengage hydraulic circuit pumps.
Maintenance and repair operations shall be performed by the person taking the precautions
specified above. If this is a simple operation, this person can be the operator after taking the
precautions specified above.
Main switch and hydraulic system shall be turned off is the machine is not operated.
In case of an electric shock, you shall take the injured person away from the power leak first. But,
this is also a potential risk. That is, electric shock is transferred to the person touching when the
body of the injured person is touched. Therefore, you shall turn off the power from the main switch,
if possible, or move the body of the injured person with an insulating material (wood or PVC etc.)
Take the injured person to a medical facility immediately.
All operations including installation, operation, maintenance, repair etc. on power installation shall
be performed by authorized and qualified electric technicians.
Faults that may cause unsafe operation of the machine shall be corrected as soon as possible.

SAFETY DURING MAINTENANCE

Always turn off the power and hydraulic systems before starting any maintenance or replacement
operation. Lock the required parts and put warning plates where required. These precautions are
always required in order to prevent accidents.
Perform maintenance, observation and inspection tasks periodically.
Inform the operator first before any maintenance operation.
Check whether the safety systems are active after any maintenance operation.
Replace the improper parts of the machine immediately. Always use the genuine spare parts of the
manufacturer.
AKYAPAK does not provide warranty against damages in the machine caused by parts provided
by other parties.
Regular maintenance of the mechanic and electrical parts is very important as it would increase
the life cycle of the machine and improve the performance.
It is strictly forbidden to perform any mechanical or maintenance operation without applying the
machine isolation procedure. During the removal and installation of any part, check whether it fits
its place and do not forget any foreign materials during the operation.
Do not get on the machine. Use genuine parts while replacing any part.
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Electrical components shall conform with the values specified in wiring diagrams and shall have
equivalent safety properties. Contact AKYAPAK in case of doubt. Otherwise, AKYAPAK accepts
no responsibility.
Safety information are provided above. Please read the safety information carefully and always
bear in your mind to prevent physical damages and equipment damages.
Do not remove or replace any tool. This may cause fires, malfunctions or erratic operation.
Do not weld directly on the machine. This may cause malfunctions or erratic operation.
Do not change the parameters and internal settings of the machine, this may cause risks or erratic
operation.

PREVENTION OF ACCIDENTS

DANGER
Manufacturer has designed and manufactured this machine conforming with the relevant
standards with reference to DIN EN-292-1, DIN EN-292-2, DIN EN-60204-1 principles for safety
design harmonized standards and 98-37 EC safety directives, EC-Directives 2006/42/EC, EC-Low
Voltage Directives 73/23/EWG EC-, Electromagnetic Directives 89/336/EC i.d.F. 93/31/EC
covering international directives and methods.
Employer's duty here is to warn the staff against risks, to train against possible accidents, and to
provide required protective safety equipment and apparatus for the safety of the operator.
Operator shall be used to his/her position before starting to work, and characteristic features of the
machine shall be controlled by the operator.
Machine shall only be used by staff who read the operation manual and understood its contents.
Directives, recommendations and general safety rules included in this manual shall be strictly
followed by the user. Accident risk will be increased when one or more machine parts purchased
from AKYAPAK are replaced without authorization or using accessories in a different way than the
recommendations provided here. AKYAPAK has no legal responsibility or obligation in such
operations. Machine warranty shall be void if any condition specified are valid.
Switch the power off (including main power) while installing or removing the machine or while
replacing any part/tool
and wait for 5 minutes, then you can make the operations; otherwise, this may cause an electric
shock or malfunction.
Turn the power off (including main power) before daily inspection.
An electric shock may occur if you make inspection or maintenance with the power on.
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Operator company shall put warnings signs such as 'Do not turn on the power', 'Do not operate the
machine' etc. on control panel, its surroundings etc. to prevent machine operation, maintenance
and inspection by unauthorized persons.
Do not remove and install electrical connections of the machine when the power is on. This may
cause electric shock and accidents.
If any error alarm is indicated on the program, solve this condition. Run the program again after
resolving the error.
Ensure that all screws are tightened, no tools are left in the vicinity of machine, and all covers of
the control panel and machine are closed after completing the maintenance and inspection.
Otherwise, electric shock, fire and accidents may occur.
AKYAPAK shall not be responsible for damages, accidents and injuries that may occur if the user
changes the machine pattern on his own.

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POINTS TO BE CONSIDERED IN OPERATION
Points to be considered to prevent risks

If you observe any abnormal condition on the machine, press the “Emergency Stop” button to turn
off the power on the machine.

Correct the abnormal condition by operating manually, then activate automatic operation when all
moving parts are in place.
If one person is responsible for machine operation, other persons shall not operate the machine.
Do not remove and install tools and perform settings on any part before the machine stops.

POINTS TO BE CONSIDERED IN DAILY OPERATION

 Machine maintenance shall be performed by staff responsible for this task.
 Do not alter hydraulic pressure settings.
 Ensure that moving parts working with each other are centrally lubricated and specified
lubricant is always available in central lubrication reservoir.
 Protect operating lubricant against dust and dirt.

WARNING
 Wrong movements of electromagnetic valve are 70% caused by the mismanagement of
operating lubricant.
 As a result, operating lubricant shall always be clean.
 Ensure that all operations on the machine are completed before starting the machine.
 Check the following points individually during inspection.
 Is the pressure set correctly?
 Is the setting of any individual part performed correctly?

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 SECTION II

INSTALLATION OF THE MACHINE

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 GENERAL INFORMATION ON THE INSTALLATION OF THE
MACHINE

INSTALLATION INSTRUCTIONS TRANSPORTATION

We recommend you to transport the machine with a water-proof cover that would prevent affecting
of the machine by weather conditions.
Place the heavy part of the machine (reducer) to the front side of truck bed. Thus, normal driving
stability shall be provided. (Figure 1).
Ensure that machine is correctly placed after loading the machine. Place supporting legs to the
moving parts if required.
In order to secure the machine on the ground tap it to the ground from 4 corners with a wooden
part as shown in figure 2.

Şekil 2
Figure-2
Figure-1
Şekil 1

TRANSPORTATION AND PLACEMENT OF THE MACHINE

Always use a high capacity crane and synthetic ropes to lift the machine. Check the lifting capacity
of the ropes by comparing it with the machine weight.
Bring the lower ball to the upmost level and attach to the lower and upper ball as shown in the
figure with a synthetic rope to lift the machine.

CAUTION:
If the lower ball does not come to the upmost level, reducer will be damaged.
Tighten the ropes before carrying and then lift the machine evenly, because the fixed weight is on
the reducer side (not on the cylinders). Do not loosen the ropes, otherwise the rope slide and
machine jerks.

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REMOVEL OF PACKAGE
Hydraulic cylinder machine is covered water-proof foil and
greased to prevent it being affected from weather conditions during transport.
Use suitable tar paper for vehicles with open beds or protect from weather conditions with other
types of coverings during transport.
Contact the transporter or dealer immediately if you observe any transport damage during the
removal of the package.
Use work gloves during the removal of the package.
Especially, if the packing material is composed of material with high plastic or chemical content,
you should avoid contact of material with children, and adults shall remove the package with
protective gloves.
Cleaning of machines lubricated with protective oil is as follows:
 Clean the cylinders and bright surfaces with thinner.
 Clean the painted surfaces using a mixture of diesel oil and water.

PLACEMENT PLAN OF THE MACHINE

Placement area of the machine shall be adjusted as per the placement information and plan.
Check the position of the machine, and then fix it. Use micro balance device to place the machine
correctly, check for any cracks.

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AHS – Rev1 25.03.2016 36 / 86
INSTALLATION INFORMATION
Consider the following before installing the machine.

1. Adequate space around the machine shall be left to access any part of the machine for
maintenance.
2. There shall be a distance 1.5 times more of the sheet length on the front of the machine to
provide lifting of the material freely. (L*1.5)
3. Leave a space on both sides of the machine to provide easy bending of the material and leave
another 1 meter of space for walking space.
On the area where the machine shall be placed, leave specified distances from the side and rear
walls as shown in the figure below, and install it in the safe operation area. The surface where the
machine shall be placed shall be level, and have the qualities to bear the machine weight. Ensure
that the legs of the machine are placed on the ground.

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 PRE-INSPECTIONS

SAFETY ROPE
Safety rope placed around the machine is removed during transport (depending on the dimensions
of the machine and the area). This shall be done after the placement of the machine. Safety rope
is placed on three sides of the machine. Corner pieces are used to strengthen the rope. Place
these pieces on the machine and tighten their screws. Place the rope on roller wheels and tighten
it. Safety rope is placed for emergency conditions. Pressing on the rope straightly shall be enough
to stop the machine. You shall pull the button up to operate the machine again.
Instead of safety ropes are not used for big machines that are located in a pit, emergency stop
buttons are located on top of the machine for safety purposes ( 2 emg stop buttons on the top roll
between 390-510 mm and 4 emg stop buttons over 540 mm)

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ELECTRICAL CONNECTION
Electrical connection shall be performed by an experienced electrician. Before making the
connection, check the ratings from the label on the power box and make the electrical connection
according to these ratings.
Plug the power cord to the socket beside the machine. Connect the power by putting it through the
hole in the power box.

FILLING OF OIL RESERVOIR

... liters of oil with the specifications of ISO HV/46 (codes of various brands of oil are shown in this
page) … shall be added for this operation.
a) Open the side cover next to the reducer.
b) You can add hydraulic oil from the filler opening on the reservoir.
Use external filter to prevent mixing of foreign material to the oil as shown below in order to
transfer the oil to the reservoir from the container.
c) Check the oil level from the inspection window in reservoir.
-Close the cover when you are done.

Oil
Filter
Pump
Oil Tank

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CHECKING OF LUBRICATION
Add grease from 7 different points on the machine (codes of various brands of grease are shown
in the following page)
AKYAPAK fills the points marked with grease and delivers the machine as such. Machine
lubrication system is shown in the following pages.

INSPECTION OF ELECTRIC MOTOR ROTATION DIRECTION

Operator shall check the rotation direction after the filling of the hydraulic oil is completed. Follow
the instructions below for this purpose.

FOR 380/400/415V (OTHER VOLTAGES)

These machines are equipped with phase order relay. This relay is intended to prevent operation
of electric motor in the reverse direction.
After making the electric connection, light shall illuminate in green if the phase is correct. Replace
R-S phases if the light is not illuminated.
 Bring the main switch on power panel to position 1.
 Bring the selector switch on control panel to position 1.
 Ensure that 'Power on' is illuminated; if this light is not illuminated, check the electrical
connection, emergency stop button and safety rope.
 Press start button, then press stop button and check the rotating direction of the electric
motor.

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Motor rotating direction is indicated on the motor. Stop the motor immediately if it
is rotating in the wrong direction. (For 3 seconds) If the electrical connection is wrong, disconnect
power. Try again after replacing the phases of the sockets.
Machine is now ready for operation.
To replace hydraulic oil:
 Set the cylinder rotating speed to maximum.
 That is, move cylinders up and down for 30 minutes minimum.
 There is a warning light that indicates dirtiness rate on hydraulic return filter.
If the arrow indicates green zone, you can continue your operation, but if the arrow indicates red
zone, you may continue your operation after replacing hydraulic return filter.

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 RECOMMENDED GREASE CHART

Mark Hydraulic Power Grease Plant Planetry

Unit Gearboxes
MOBIL Mobil DTE 25 Kup Grease 2 Mobil Gear 629

BP Energol HLP 46 Energrease GP2 Energol GR-XP

150

SHELL Tellus Oil 46 Livona 2 Omala Oil 150

CASTROL Hyspin AWS 46 Helvium 2 Alpha SP 150

TEXACO Rando Oil HD 46 - Meropa 150

ELF Hydrelf DS 46 - Reductelf SP

150

TOTAL Equivis ZS 46 - Carter EP 150

ESSO NUTO H 46 - Spartan EP 0

AGIP OSO 46 - Blasia 150

Q8 Haendel 46 - Goya 150

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 MACHINE OPERATION

MOVEMENTS

1. UP AND DOWN MOVEMENTS OF SIDE BALLS

Up and down movements of side balls are performed with the help of circular path of the hydraulic
cylinder. Evenness of side balls are provided mechanically by the camshaft. Perfect evenness is
provided
by heavy steel camshaft and the moving yoked arms of side balls. With this feature, it is very easy
that side balls take the conical bending position and smoothed.

2. UP AND DOWN MOVEMENTS OF LOWER BALL

Up and down movements of lower balls are performed with the help of the hydraulic cylinder and
eccentric cam. Evenness of lower ball is provided by the stabilizing shaft. Perfect evenness is
provided by the connection of powerful camshaft and the eccentric cam of the lower ball.

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BENDING SPEED
Our standard machines have 2 bending speeds. These speeds vary gradually.
1. Normal speed
2. Low speed
Low speed pulls the material during pre-bending in its axis. Low and normal speed buttons are
placed on the control panel.
Rabbit symbol is used for normal speed, and tortoise symbol is used for low speed. Optionally, you
may change the bending speed without increasing it gradually. In this option, bending option may
be set as per the experience of the user and thickness of material from 0 to maximum sped.
Pumps used in this system are special and do not allow an increase in the oil temperature, but
controls the oil flow according to bending speed.

BUTTONS
There are several buttons used to protect the operator and the machine.

USAGE AND FUNCTIONS OF THE BUTTONS

After bending operation, lower ball is slowed until it touches its switch. If the lower ball does not
slow, cover shall not open.
Cover shall open when the user presses the cover opening button in order to remove the material.
Then the upper ball is raised and material can be removed easily. Also, system does not operate
and balls do not rotate in this position.
After removing the material, upper ball starts to move when you press the cover closing button,
and
this is continued until the cover touches the switch. Machine is ready for another casting operation.
If you cannot manage the machine
by the buttons:
ERROR TYPE CAUSE REMEDY
Cover does not open Lower ball is not in the lowest Check the lower ball switch
position
Balls do not rotate Cover is open Check the cover closing switch

Check the cover opening

Upper ball does not move up Cover is not open
switch
Upper ball does not move Check the cover opening
Cover is not open
down switch
Upper ball is not in the lowest Check the upper ball down
Cover does not close
position switch.

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ADJUSTMENT OF INTERNAL PRESSURE
There are three types of hydraulic pressure in the machine.
 Pressure adjustment to rotate the upper roller ball
 Pressure adjustment to provide up and down movement of side roller balls
 Pressure adjustment for lower roller balls
Pressure adjustment of upper, lower and side roller balls are fixed.
Changes in the following setting are strictly forbidden. Otherwise, machine shall be heavily
damaged because of this. You may observe the rotation pressure value of the upper roller ball.
Lower ball pressure is adjusted by the pressure safety value near the manometer (C). D may be
adjusted by manometer D.
Lower ball pressure value shall be determined by testing the quality, thickness and harshness of
the metal to be bent.

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 BENDING
This machine shall be used and maintained properly and cleaned regularly in order to achieve high
efficiency.
Material shall be prepared before bending; and for this:
 excess parts of the material are cut with oxygen.
 Rust and snow on the material are removed. Roller balls may be damaged even if they are
strengthened.
 Both sides of the plate are cleaned.
 Check the plate one more time before starting to bend the material. Clean again if there is
any problem.
Physical conditions of the plate affect the quality of the material to be bent.

MATERIAL QUALITY
Various materials may not provide the same results; most important factors that affect the bending
quality because of the differences in quality are as follows:
 Plate quality
 Flow limit
 Elasticity limit
 Material direction
 Differences in the thickness of the material.
These factors are very important. If any of these are neglected, you cannot bend the material in
the dimensions you desire, for example when you want to bend a material with high elasticity with
the same machine, the resulting diameter shall be different. Similarly, there would be differences
between first bending and seconding operations.
Moreover, these differences are valid for the same material groups. Therefore, you shall use high
quality materials.

PLACING THE MATERIAL

You can start the bending operation after taking all the safety precautions described.
The first step of bending operation is placing the material. In order to bend with high quality,
material shall be placed (compressed) between roller balls properly. The starting steps for this
procedure are as follows:
1) Place the material between roller balls.
2) Place the material in parallel to the axis of roller balls.

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Side roller balls may be used for facilitating this operation. Evenness can be achieved by lifting the
side roller balls and leaning the material to be bent to the roller balls.

BENDING OPERATIONS
First step is powering the machine. Steps are as follows.
1) Bring the switch on power panel to position 1.
2) Bring the switch on control panel to position 1.
3) Ensure that the power light is illuminated. If it is not illuminated, check the safety rope and the
emergency stop button.
4) Press the start button.
Your machine is ready for operation. You may bend the material according to the steps that will be
described below.
OPERATION STAGES
When you operate the machine in rapid mode, you will observe that upper and lower roller balls
rotate together. When you operate the machine in slow mode, lower roller ball rotates only. If you
compress lower ball, lower ball and upper ball contact each other and rotate together. Pressure
moves in the easiest direction as per the logic of hydraulics. Therefore, resistance shall be equal
so that the rotating speed of the upper and lower roller balls will be equal.
When the roller balls are detached, endurance control system operates according to the pumping
capacity. Due to the low efficiency of hydraulic pump, only the lower roller balls rotate. This would
not affect the bending capacity.

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OPERATION STAGES
 Following figure shows the normal cylinder operation. Experience of the operator and
bending time has great effect on the finishing of the product.
 Ensure that center roller ball is on the lowest position before placing the plate on the
machine. Bring it to the lowest position if it is not.
 Load the plate to the left side of the machine. It is possible to load it on the right side. All
operations are certainly dependent of reciprocal movements of side roller balls.
 Raise the right roller ball. This procedure causes a dumbness in the roller balls, but allows
that the plate is placed smoothly. Then, place the plate between two roller balls and push it,
thus the plate shall be compressed between roller balls. It is possible to change the
compression force on the machine.
 Then, lower the right roller ball and push the plate to the left. Thus, we put the edge of the
plate through the nearest point to the center roller ball.
 Lift the left roller ball until you achieve the desired diameter and lean the plate to the right
(you may read the movement of the roller ball from the digital indicator. Thickness of plate
and the type of the material used is a determining factor on the diameter you will obtain.)
 Stop the movement of the plate when you see that the plate will be leaned towards the right
roller ball.

 Here (in the figures) you can see the results of bending time.

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Sometimes, some errors may occur in the bending process. These are divided into two:
1) Barrel error
2) Reverse barrel error
In fact, machines are produced by avoiding these errors.
Taper of the roller balls are calculated, so they can provide a good performance even in the
highest thickness. However, materials with excessive thickness or thinness may cause these
errors.

BARREL ERROR
This is the condition where the clearance on the center of the final form is greater. This is caused
by the elasticity of the roller balls placed under pressure during bending process.
CAUSE 1 = the fact that plate is excessively thick for the performance of the machine
REMEDY 1 = you cannot solve this problem unless you use a machine with high performance.
CAUSE 2 = jamming of the plate because of the excessive pressure between roller balls.
REMEDY 2 = slightly reduce the compression force, this may be performed at the end of the
process. As you can see clearly, the length of the first straight part shall be longer when the
compression force is lower.

BARREL

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REVERSE BARREL ERROR
This is the condition where the center of the final form is closed and ends are open.
CAUSE 1 = the fact that plate used is very thin
REMEDY 1 = there is no other solution to this problem than using a machine with lower
performance.
CAUSE 2 = the fact that compression pressure is very weak
REMEDY 2 = slightly increase the pressure of roller ball.

CYLINDER ERROR
This error occurs when one side of the tube is more closed than the other side.
CAUSE 1 = the fact that roller balls are not perfectly in parallel to each other.
REMEDY 1 = release the plate and place it on the center. If there is no progress, slightly tilt the
side roller balls, thus you can minimize the error.

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OVALNESS ERROR
This is the condition where the ends of the final form run into each other on one side. This means
that material diameter is not fixed and excessively wide in relation to the axes.
CAUSE = it may be caused by the dimensions of the plate to be bent
REMEDY = lower roller ball is lowered down to the lowest position and some rotation settings are
performed for the tube.
Lower roller ball is kept in the lowest position during this operation. Otherwise, welding or other
factors may cause serious damage to the machine.

BENDING ERROR
This error is caused by the fact that the force of roller balls are very high. Plate comes out of the
machine and irreparably damaged.
Compression pressure of the roller balls are reduced using the roller ball compression pressure
setting device.

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WRONG AXIS ERROR
This condition occurs when evenness of roller balls is wrong and when plates with irregular
thickness are used; alignments and evenness shall be checked in this condition. There is no
solution as this is caused by the material itself.

LAYOUT OF CONICAL ANGLES

Conical bending operation is performed by the conical bending system inside the machine. Conical
bending operation is the hardest operation amongst bending operations. Therefore, operators who
would be performing this operation shall be very experienced.

YOU SHALL USE HALF OF THE CAPACITY OF THE MACHINE.

This means that machine can bend only half of its capacity.
And, this is 1000mm x3mm. In other words, if the capacity of the machine is 2000x 6mm, it can
bend 1000mm x3mm.
If you want to obtained shortened cones as shown in the figure below, you shall be prepared as
per the angle position, length and diameter of the material; angle positions shall be prepared
according to the formulae below.

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CALIBRATION
After the bending operation, diameter of the material that has been transformed to a cylinder may
not be fixed. Ovalness may be observed. Correcting the diameter and making the cylinder circular
as much as possible is performed by calibration.

OPERATION PROCEDURE
Bent material shall be removed from the machine and welded. Welding points shall be cleaned by
removing the burrs both from inside and outside. Welded cylinder is placed on the machine again.
The narrowest diameter of the oval cylinder is brought to the lowest position of the upper ball. Both
side balls are raised until they contact cylinder so that they will be at the same position. Then, side
balls are raised a little more, and pushed with a light force to provide a pear form to the cylinder.
Bring the lower ball to the lowest position. Bring the calibration switch to calibration position.
Therefore, rotation of the lower ball shall be cancelled and rotating power shall be transferred to
the upper shaft only.
Rotate the cylinder by pressing the rotation button. You shall always rotate it in the same direction.
Lower the side balls gradually at each rotation. Desired circularity shall be achieved when the
contact of the side balls with the cylinder is lost.
CAUTION
Max. calibration capacity is 75% of max. thickness.

PREPARING THE MACHINE TO CONICAL BENDING

Prepare the machine to operation with the following procedure before placing the plate on the
machine:
1) Ensure that the material is compressed with the support of cone by leaning the higher part of
the roller ball in the center.
2) You can bend the cone correctly by leaning the side roller balls. Then, a conical form may be
obtained with the maximum slant. A maximum slant of 1.5 is the same
for all machines.

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PLACING THE MATERIAL
The mouth part of the material, which is smaller, shall always be on the control unit side and shall
always be leaned on the cone support.

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OPERATION PROCESS
Material you want to bend is placed between the rollers on the center so that it shall be as near as
possible to the own axes of the roller balls. Try to achieve the best alignment at this time. All
following operations is the same as the normal bending procedure. You shall clean and prepare
the plate before the start of the operation as conical bending is a difficult procedure and machine
works under a specific pressure.
Side supports of the machine slightly opens as the cones are pushed during conical bending. If
this happens, check the dimensions of the cone again and ensure machine may perform this
operation.
POINTS TO BE CONSIDERED DURING CONICAL BENDING AND PLACEMENT OF CONE
MATERIAL
The small diameter of the material shall be leaned on the cone support roller. Bring the side of the
angled cone plate that you will start to bend in parallel with the axes of lower and upper shafts.
Cone is compressed by pressing the lower ball up button after bringing the lower ball cone button
on the control panel to the cone position when 5 to 8 mm is left to the compression of the plate
after raising the lower ball. Compression shall be visually inspected in this operation. Plate shall be
rotated from the bigger diameter side of the plate that shall be bent conically for bending operation.
Side shaft is slightly raised in parallel position. Then, side shaft cone button is brought to cone
position. Bending operation is started when the desired cone angle is achieved by pressing the
lifting button.
When the shaft comes over the other side shaft, the other side shaft also brought to conical form in
the same way. When the ends of the plate come together in conical bending operation, plate is
spot welded from the inside and outside. After the machining of weld surfaces, calibration is
performed. Lower cone is closed when this operation is completed. Lower ball is lowered. Cover is
opened using the cover opening/closing button. Upper shaft is raised and operation is completed.
If these operations are not followed:
 You compress it further instead of adequately compressing with the lower shaft from the
bigger cone side of the plate.
 You may inadvertently compress the cone plate as parallel instead of the cone.
 If you try to compress the cone plate by lifting the cone when lower shaft is in the lowest
position,
 Machine does not bend conically (you may damage the shaft, cone thrust of the machine or
the material you want to bend conically.)
If the surface that contact the cone thrust roller of the material is rolled up or down, if it is crushed
or deformed, operations described above shall be performed.
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NOTE = Ensure that you have only compressed to provide rotation of the plate at a distance of 5
to 10 cm from the bigger diameter side of the conical plate.

Material is removed from the machine as follows at the end of the bending operation.
 Lowers the level of lower roller ball.
 Press button no. 2, upper cover shall be opened, and then upper roller ball shall move
upwards.

1. Bent plate is removed from the upper roller ball.

2. Upper roller ball moves upwards and cover is closed by pressing button no. 1.

Each move is checked from the limit switch to ensure that these operations are performed
smoothly and safely.

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1) ADJUSTMENT OF EVENNESS OF SIDE ROLLER BALLS
Ensure that conical bending device is turned off before performing the pre-operation described
above. If x>y, adjustment screw (A) is rotated counter-clockwise.
If x<y, adjustment screw (A) is rotated clockwise.
If x=y, roller balls are parallel.

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ADJUSTMENT OF EVENNESS OF LOWER ROLLER BALLS
CAUTION Ensure that conical bending device is turned off before performing the operation
described above. If x<y, adjustment screw (B) is rotated counter-clockwise.
If x>y, adjustment screw (B) is rotated clockwise.
If x=y, roller balls are parallel.

MAINTENANCE
Maintenance and cleaning operations shall be performed correctly in order to achieve high
efficiency.
We can divide maintenance operations to two groups.
1. preventive maintenance
2. “maintenance and repair” due to errors

PREVENTIVE MAINTENANCE
Preventive maintenance is the maintenance performed as a precaution before an error occurs.
These precautions are:
 Regular lubrication, and checking of oil level (of the reducer and hydraulic reservoir)
 Regular cleaning
 Cleaning of the material to be bent
 Checking of wearable parts
 Checking of cracks

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REGULAR LUBRICATION AND CHECKING OF OIL LEVEL
Information on this subject are given in detail.

REGULAR CLEANING
Dusts stick on the roller ball during bending operation. Roller balls shall be cleaned and their
surfaces shall be checked after each bending operation. It may not be possible to bend very tough
materials even if the roller balls are strengthened. Machines shall be kept away from dusty air
conditions.

INSPECTION OF WEARABLE PARTS

List of the parts used in the machine is given below. Operator shall inspect the parts carefully, and
inform the maintenance personnel if any irregularities, such as unusual noises from the machine or
irregular operation, are observed.

REPAIR
Machine shall be turned off and power shall be cut off when the error occurs. Machine shall be
repaired by qualified staff.
CAUTION!
Cut the power off and turn off the machine during any maintenance and repair operations.

LUBRICATION OF THE REDUCER

Reducer used in our machines is delivered with the oil. Oil in the reducer shall be replaced
annually and at every 2000 to 2500 hours of operation. Mixing of oils with various grades and filling
the reducer with this mixture is not recommended. Check the oil level in the reducer at least every
month.

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 Filling plug

Oil level plug

Drain Plug.

RETURN FILTER
Hydraulic oil shall be filtered meticulously to ensure proper operation of hydraulic system and long
service life of the parts. Use a precision filter with high to perform this filtering procedure. Return
filter shall be replaced at the following conditions.
If the contamination is very high (over red zone)
After 1000 hours of operation
At least once per year.
When the oil would not be replaced

Also check if the oil is lacking at least every 6 months for a long service life of the hydraulic
cylinders.

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 SECTION III III

PART LISTS

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BODY

BODY PART LIST

1 AHS-0001 MAIN BODY

2 AHS-0002 SMALL BODY
3 AHS-0003 BODY
4 AHS-0005 SUPPORT ROD

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LOWER BALL

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LOWER BALL MATERIAL LIST

1 AHS-0010 BOLT
2 AHS-0011 STOPPER SECTION
3 AHS-0012 PLATE BUSHING
4 AHS-0013 LOWER
5 AHS-0014 BRONZE BUSHING
6 AHS-0015 BOLT
7 AHS-0016 ADJUSTABLE SECTION
8 AHS-0017 COVER
9 AHS-0018 RING NEEDLE
10 AHS-0019 CIRCULAR ROLLER BALL NEEDLE
11 AHS-0020 LOWER ROLLER BALL BEARINGS
12 AHS-0021 PLATE BUSHING
13 AHS-0022 LOWER ROLLER BALL
14 AHS-0023 LOWER ROLLER BALL BEARINGS
15 AHS-0024 CIRCULAR ROLLER BALL BEARINGS
16 AHS-0025 RING NEEDLE
17 AHS-0026 COVER
18 AHS-0027 BOLT
19 AHS-0028 BOLT
20 AHS-0029 CIRCULAR SECTION
21 AHS-0030 BODY ADJUSTMENT SECTION
22 AHS-0031 BUSHING
23 AHS-0032 SMALL NEEDLE
24 AHS-0033 SETTING SCREW
25 AHS-0034 ECCENTRIC BEARING
26 AHS-0035 BRONZE BUSHING
27 AHS-0036 BUSHING
28 AHS-0037 INTERMEDIATE SECTION
29 AHS-0038 COVER
30 AHS-0039 BOLT
31 AHS-0040 ECCENTRIC ROLLER SHAFT
32 AHS-0041 CONNECTION PLATE
33 AHS-0042 SETTING SCREW
34 AHS-0043 HYD. CYLINDER, IF THE LOWER
ROLLER BALL IS SELECTED AS CONE
35 AHS-0044 BUSHING
36 AHS-0045 PIN
37 AHS-0046 HYDRAULIC CYLINDER
38 AHS-0047 PIN
39 AHS-0048 BUSHING
40 AHS-0049 SMALL PIN
41 AHS-0050 CYLINDER PLATE

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UPPER BALL

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UPPER BALL MATERIAL LIST

1 AHS-0051 BOLT
2 AHS-0052 STOPPER PLATE
3 AHS-0053 UPPER ROLLER BALL RED.
CONNECTION PART
4 AHS-0054 BRONZE BUSHING
5 AHS-0055 COVER
6 AHS-0056 RING NEEDLE
7 AHS-0057 BALL BEARING
8 AHS-0058 INTERMEDIATE SECTION
9 AHS-0059 COVER
10 AHS-0060 BOLT
11 AHS-0061 UPPER ROLLER BALL
12 AHS-0062 CONE HEADER
13 AHS-0063 CIRCULAR ROLLER BALL BEARING
14 AHS-0064 RING NEEDLE
15 AHS-0065 COVER
16 AHS-0066 SNAP RING
17 AHS-0067 CONE THRUST HEADER
18 AHS-0068 OPENING/CLOSING COVER
19 AHS-0069 PIN
20 AHS-0070 SMALL PIN
21 AHS-0071 BRONZE BUSHING
22 AHS-0072 COVER PIN
23 AHS-0073 BOLT
24 AHS-0074 PLATE
25 AHS-0075 PIN
26 AHS-0076 COVER HYD. CYLINDER
27 AHS-0077 BUSHING
28 AHS-0078 BUSHING
29 AHS-0079 UPPER ROLLER BALL HYD. CYLINDER
30 AHS-0080 CONNECTOR
31 AHS-0081 PLATE
32 AHS-0082 PIN
33 AHS-0083 SNAP RING
34 AHS-0084 -
35 AHS-0085 -
36 AHS-0086 -
37 AHS-0087 PLATE BUSHING
38 AHS-0088 PLATE
39 AHS-0089 BEARING PLATE
40 AHS-0090 SCREW NUT
41 AHS-0091 BOLT

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SIDE BALL

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SIDE BALL MATERIAL LIST

1 AHS-0092 PIN
2 AHS-0093 BUSHING
3 AHS-0094 COVER
4 AHS-0095 SNAP RING
5 AHS-0096 BALL BEARING
6 AHS-0097 SIDE ROLLER BALLS
7 AHS-0098 BEARING
8 AHS-0099 SNAP RING
9 AHS-0100 COVER
10 AHS-0101 THROTTLE SYSTEM SECTION
11 AHS-0102 BUSHING
12 AHS-0103 PIN
13 AHS-0104 LAYER
14 AHS-0105 BOLT
15 AHS-0106 CONICAL BENDING HYD. CYLINDER
16 AHS-0107 BUSHING
17 AHS-0108 BRONZE
18 AHS-0109 INTERMEDIATE SECTION
19 AHS-0110 COVER
20 AHS-0111 BOLT
21 AHS-0112 PLATE
22 AHS-0113 BOLT
23 AHS-0114 BUSHING
24 AHS-0115 PIN
25 AHS-0116 PIN
26 AHS-0117 BUSHING
27 AHS-0118 ECCENTRIC ROLLER SHAFT FOR SIDE
BALLS
28 AHS-0119 PIN
29 AHS-0120 SETTING SCREW
30 AHS-0121 SETTING AREA BODY
31 AHS-0122 SETTING SCREW
32 AHS-0123 BUSHING
33 AHS-0124 PIN
34 AHS-0125 PLATE
35 AHS-0126 BOLT
36 AHS-0127 HYD. CYLINDER
37 AHS-0128 BUSHING
38 AHS-0129 PIN
39 AHS-0130 BOLT
40 AHS-0131 PLATE

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 SECTION VI

AHS

MAINTENANCE AND SERVICE MANUAL

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ROUTINE INSPECTIONS AND MAINTENANCE
 Always bring the main switch to 0 position and apply the machine isolation procedure before
any maintenance or cleaning operation.
 All repair and maintenance operations shall be started when the machine is stopped and
electrical connection connection is cut off.
 Always check if the emergency stop button operates.
 Ensure that plate surfaces to be bent are clean and dry. Clean and dry the frame and
surfaces used.
 If the machine is not being operated for maintenance or service reasons, put a warning sign
indicating this to a suitable position on the machine.
 Clean the surfaces of roller balls. Operation area shall be clean and dry. Clean the
chippings and dust collected around the machine at the end of each work day. Use mildly
damp cloth or pressurized dry air for cleaning. Do not clean the surface of the machine with
flammable, caustic or abrasive cleaning materials.
 Do not use pressurized air to clean inside the panel.
 Check the oil level in hydraulic system. If the oil level is low, add oil. Deactivate the power
connection before starting any of these operations.

END OF WORKDAY MAINTENANCE

 Deactivate electric and hydraulic power connections.
 Remove chippings, burrs and foreign materials on all surfaces of the machine. Use a goggle
to protect your eyes against harmful substances.
 If the machine will not be used for a long period of time, bring the main switch to off position.
Turn off hydraulic system completely.
 Clean the roller balls them dry if required.
 Use protective oil to protect roller balls against corrosion.

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NOISE EMISSION RATE
 When measured as per EN ISO 3746, Noise Emission Rate shall be: 102.4dB. Machined
workpiece material shall be steel and its derivatives when the machine is measured against
operating conditions. If the correctness of declared emission values are to be checked,
measurement shall be made by using the declared measurement method and providing the
same operating conditions.
 Noise declaration shall be provided with the following expression. Figures declared for noise
are emission rates and these does not indicate the safe operation levels.
 Although there is a correlation between emission and exposure rates, a reliable
measurement may have to be performed in order to determine if more advanced
precautions are required.
 Factors affecting the real exposure rates affecting the workforce are the properties of the
work place, including the exposure period; in other words, number of other noise sources,
nearby operations and machines. Moreover, permissible exposure level may vary according
to country. However, this declaration allows the user of the machine to assess dangers and
risks better.
 All worker who will be employed in workplaces with a noise level of 80 dB and higher shall
be trained on possible effects of noise on hearing, purposes, advantages, disadvantages of
ear protectors, determination of the suitable protector type, maintenance of cleaning of the
protector etc. before starting to work. We recommend repeating these trainings every year.

GENERAL SAFETY INFORMATION

 Power cord shall be routed to prevent stepping or putting something on it. Pay special
attention to the areas where the cord leaves the panel and enters the machine.
 If the mains cord gets damaged during operation, do not touch the cord and remove the
mains plug from the panel. Never use a damaged power cord.
 Do not load over the bending values specified in operation manual. Your machines and
devices operate more safely in the specified power capacities.
 Do not put your hands between moving parts to take foreign materials out.
 Use safety goggles and ear protectors. Do not wear loose clothes and jewellery. These may
be caught by moving parts.
 Always keep the work area clean, dry and neat, irregularities in work place cause risk of
accident.
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  Use proper illumination and lights for the safety and health of the operator. (ISO 8995-89
Standard the lighting of indoor work system)
 Do not place anything on the machine.
 Do not use any other material than the ones specified by the manufacturer while bending on
the machine.
 Always keep the machine and your equipment clean so that they can be operated at any
time in order to work safely.
 Do not put much strain on your working position, ensure that you have a safe posture,
always keep your balance.
 Follow the instructions on maintenance and replacement of accessories. Check the plugs
and cables periodically. Have an authorized technician replace it when it is damaged.
 Remove the power supply connections when the machine is not operated or before
maintenance operations.
 Ensure that wrenches or setting devices are removed before operating the machine.
 Use recommended extension cords specified for this purpose only if you have to operate it
outdoors.
 Repairs shall only be performed by technicians. Otherwise, this may cause a risk of
accident for the user.
 Check whether protective equipment or lightly damaged components work properly and
perfectly before starting a new work. All components shall be properly installed and all
conditions for perfect operation shall be met. Damaged protective equipment or
components shall be repaired or replaced by the manufacturer or authorized dealer
properly.
 Do not operate machines where switches and breakers do not perform the turn on/off
function.
 Do not keep flammable or explosive liquids or materials beside the electrical and power
connections of the machine.

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 FAULT

RECOMMENDATIONS FOR A FAULT CONDITION

Faults usually can be repaired by an expert technician without the need for special tools. We
recommend you to observe the system periodically to detect and prevent mechanical faults.
VISUAL INSPECTION
We recommend you to observe the hydraulic system periodically to prevent possible faults.
 Check for signs of leaks: Detect wet components and pipes. If there are oil stains, oil level in
the system may be low. Check the oil level in reservoir periodically.
 If the oil is not fluid, you shall ensure that pipes and elbows are not worn:
 In case of a pipe line supplied by a pump, elbows may be damaged by pumping. If the oil is
milky and not still as would be, this means it is saturated with water and air. In other words,
it can cause a fault soon.
AUDIAL INSPECTION
Listening to the noises and sounds produced by the system in an operation, and distinguish
between abnormal sounds and normal sounds is very important for troubleshooting. Abnormal
noises are dry and striking, whereas normal noises are smooth. You may remove possible fault
reasons by finding the source of abnormal noises.
INSPECTION OF OIL GRADE
Oil temperature does not exceed 50°C at normal conditions. This temperature is a proper
operating condition for all parts and components of the hydraulic system. Inspect the temperatures
on the system with a thermometer, if there is a part or component exceeding 60°C limit, do not
forget to consider the ambient temperature and other conditions.
CONCLUSION
If you detect or observe one or more of the fault conditions specified above, you may contact with
AKYAPAK service department.
You may use the following hints to continue your operations until service is
provided. These hints also consist of information that may be helpful in describing the fault to
service personnel.

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 FAULT DETECTION REMEDY
Rope switch may be stuck as
Check the rope switch.
pressed.
Machine does not start Thermal fuse may be blown. Check the thermal fuse.

Oil level may be low. Check oil level.

Electric motor may be Check electric motor

connected in reverse connections.
Pressure valve relay may be Is power supplied to pressure
faulty. valve?
Control circuit voltage 24V DC-
Machine starts, but balls do Check it.
AC.
not move
Motor-Pump coupling may be Check the coupling by removing
faulty. the motor.
Pumps may be faulty. Check it.
Pump pressure lines may be
Check it.
removed.
Is power supplied to pressure Check by removing the
valve? connectors.
Pressure valve relay may be Is power supplied to pressure
faulty valve?
Pressure valve fuse may be
Check the fuse.
Balls rotate, but no other blown.
movement is available. Side
balls do not move (conically Pipe of the pump pressure line Remove the pump and inspect
and up/down) may be removed. it.
Pressure safety valve may be
Check the pressure safety valve.
faulty.
Any of the valves in the system
Check the valves manually.
may be stuck.
Secondary pump may be faulty. Check it.
Check the lower ball valve relay
Lower ball valve is not powered.
Only the lower ball does not and fuse.
move up Lower ball pressure setting is Adjust the pressure to 30 bar
very low. minimum for movement.
Modular twin lock may leak. Check it.

Pressure safety valve may leak. Check it.

Lower ball leaks There may be an oil leak. Check it.

Cylinder seals may be leaking. Check it.
If the contamination indicator is
Check the return filter
red, replace the filter element.

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 FAULT DETECTION REMEDY
Is power supplied to return
Check it.
valve?
Return valve relay may be
Check it.
faulty.
Return valve fuse may be
Check it.
blown.
Button may be faulty Check it.
Pressure safety valve may
Check it.
be faulty.
Side balls move, but Pump pressure line may
balls do not rotate. Check it.
be removed.
Primary pump may be
Check it.
faulty.
If the idle rotation which
Check the breaking
shall be 60-70 bar increase
valves.
up to 130 bar
Hydraulic motor may be
Check it.
faulty
Reducer may be faulty Check it.
Slider may be broken. Check it.
Side ball valve is not
Check it.
powered.
One of the balls does Check the side ball valve
not move up and down Check it.
relay and fuse.
Conical movement is
available Button may be faulty Button shall be checked.
Displays may be set
Check it.
incorrectly.
Counterbalances may be
Check it.
faulty.
Side balls slip down If the contamination
Check the return filter indicator is red, replace the
filter element.
Pump may be faulty. Check it.
Side balls move more
slowly than normal. Pressure adjustment valve
Check it.
may be faulty.
Side balls are not moved
Check it.
upwards adequately.
Cone valve is not
Check it.
powered.
Side cones do not open. Check the cone valve
Check it.
relay and fuse.
Button may be faulty Check it.
Cylinder seals may be
Check it.
leaking.

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 FAULT DETECTION REMEDY
Lower ball is not in the
Check it.
lowest position.
Cover valve is not
Check it.
powered.
Cover does not open
Check the cover valve
Check it.
relay and fuse.
Button may be faulty Check it.
Cover may be stuck. Check it.
Cover may not have
Check it.
contacted its switch down.
Upper ball valve is not
Check it.
powered.
Check the upper ball valve
Upper ball does not Check it.
relay and fuse.
move up
Button may be faulty Check it.
Check speed setting
valves in the lifting Check it.
cylinder.
Hydraulic cylinder leaks. Check it.
Speed setting valve may
Check it.
be faulty.
Excessive pressure may
Check it.
have applied on lower ball.
Upper ball rotates, lower
Slider may be broken. Check it.
ball does not rotate.
Hydraulic motor may be
Check it.
faulty.
Reducer may be faulty. Check it.
Slider may be broken. Check it.
Hydraulic motor may be
Lower ball rotates, upper Check it.
faulty.
ball does not rotate.
Reducer may be faulty. Check it.
Low speed valve is not
Check it.
powered.
Balls do not operate Check the low speed valve
Check it.
slowly/rapidly. relay and fuse.
Button may be faulty. Check it.
Valve may be faulty. Check it.

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 FAULT DETECTION REMEDY
Upper ball valve is not
Check it.
powered.
Check the upper ball valve
Check it.
relay and fuse.
Upper ball does not
Button may be faulty. Check it.
move down
Hydraulic cylinder leaks. Check it.
Check speed setting
valves in the lifting Check it.
cylinder.
Check the upper ball down
Check it.
switch.
Check the cover valve
Check it.
relay and fuse.
Cover does not close
Button may be faulty Check it.
Hydraulic cylinder leaks. Check it.
Cover closing pressure
Check it.
may be low.
Reducer oil may be
Noise from reducers Check it.
lacking.
Very cold oil Heat the oil
Adding thick oil Replace the oil
Vapor in the reservoir Check it.
Ventilation is not provided
Replace the oil filler cover.
in the reservoir
Air ingress from the seal
Noise from pump. Check it.
on the pump shaft
Air ingress from the intake
Check it.
pipe
Offsets in motor-pump
Check it.
connection
Pump may be faulty. Check it.
Elevator valve is not
Check it.
powered.
Elevator does not move Check the elevator valve
Check it.
up and down relay and fuse.
Button may be faulty. Check it.
Hydraulic cylinder leaks. Check it.

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 FAULT DETECTION REMEDY
Side thrust valve is not
Check it.
powered.
Check the side thrust
Check it.
Side thrust does not valve relay and fuse.
move up and down Button may be faulty. Check it.
Hydraulic cylinder leaks. Check it.
Counterbalance valves
Check it.
may be faulty.
Pressure valve may be
Check it.
stuck.
Machine may be operated
Oil is excessively Check it.
in full load continuously.
heated. Over 55 degrees
Rotating pump returns to
the reservoir as Check it.
pressurized in idle.
Numbers are displayed on
Logo faults Check it.
and off.

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 REDUCER FAULTS AND MAINTENANCE THROUGHOUT THE
MACHINE
REDUCERS SAFETY INSTRUCTIONS

INTERVENTION TO REDUCERS
Improper and uncontrolled work may cause injuries. Installation and maintenance of reducers shall
be performed by trained technical staff.
Foreign material in the surroundings may cause serious injuries. Ensure that there are no foreign
material and tools around the reducer before operating it.

OPERATION
Hot surfaces may cause burns. If the operating temperature is high, do not touch reducer surfaces
or use suitable gloves.
Rotating elements may cause injuries. There is a risk of scattering parts or being rolled and pulled
in. Stay away from the rotating elements and ensure that housings of all elements are closed.

MAINTENANCE
Unintentional operation of the machine during maintenance may cause serious accidents. Ensure
that no one can start the machine while you are performing maintenance.
Even a short period of operation of the machine during maintenance may cause accidents if safety
devices are not working properly. Ensure that safety devices are installed and activated.

LUBRICATION
Intensive contact with oil may cause irritation of the skin. Avoid intensive contact with oil and clean
oil on your skin thoroughly.
Hot oil may cause burns. Do not contact oil during oil replacement.

WARRANTY CONDITIONS
Standard reducers are suitable for operation in ambient temperatures from +5º C to +40ºC.
Operating reducers out of this interval of ambient temperatures may damage the reducer and the
environment.
Reducers shall be protected against rain, snow and dust.

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MAINTENANCE AND INSPECTION
Reducer shall be inspected in the intervals specified below under normal ambient and operating
conditions.

Element to be Every 3000 Every 4000 Every 10000 Every 25000

checked or operating hours operating operating operating
replaced or every 6 hours hours or every hours
months 3 years
Oil leak inspection X
Oil level inspection X
Oil leak inspection from
the seal X
Bearing noise inspection X (if required)

Mineral oil replacement X (See below

for details)
Synthetic-PAO oil X (See below
replacement for details)

Seal replacement X (See below

for details)
Bearing grease X (See below
replacement for details)

Bearing replacement X (See below

for details)
Change in the noise X (See below
inspection for details)

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LUBRICATION

OIL TYPES
Oil types for standard reducers

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TROUBLESHOOTING GUIDE FOR REDUCERS
All specified operations shall be performed by experienced electric or machinery technicians.
Procedure
Problem Observation Remedy
No.
You do not hear a
Check the supply voltage and frequency.
noise and reducer
Ratings on the motor data plate and
output shaft does
Reducer supply voltage shall be matching. Refer
not operate. You
001 is not to operation manual provided by the
do not use a
working manufacturer of motor. Refer to
driver or
procedure no. 100 if it does operate
frequency
against all attempts.
inverter.
You do not hear a Refer to operation manual of the driver or
noise and reducer frequency inverter. Detach motor from
Reducer output shaft does frequency inverter/driver and supply it
002 is not not operate. You directly, determine if the error is caused
working are using a driver by frequency inverter/driver. Refer to
or frequency procedure no. 100 if it does operate
inverter. against all attempts.
Check the supply voltage and frequency.
Ratings on the motor data plate and
supply voltage shall be matching. Refer
to operation manual provided by the
You do not hear a
manufacturer of motor. Load may be
noise and reducer
excessive for the motor selected if it does
Reducer output shaft does
operate against all attempts. Detach
003 is not not operate. You
output shaft of the reducer from load. If it
working do not use a
operates in this condition, problem may
driver/inverter or
be caused by inadequate motor power.
magnetic brakes.
Check the operation and starting
condensers for single-phased motors.
Refer to procedure no. 100 if it does
operate against all attempts.
You do not hear a Refer to operation manual of the driver or
noise and reducer frequency inverter. Detach motor from
Reducer output shaft does frequency inverter/driver and supply it
004 is not not operate. You directly, determine if the error is caused
working are using a driver by frequency inverter/driver. Refer to
or frequency procedure no. 100 if it does operate
inverter. against all attempts.

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 Check the voltage and frequency of your
power supply. Ratings on the motor data
plate and supply voltage and frequency shall
be matching. Refer to operation manual
provided by the manufacturer of motor. If the
brake is installed by Yılmaz Redüktör, check
is the brake connection is correct according
to the connection diagram provided in this
You do not hear a
manual. If you cannot find the fault, supply
noise and reducer
Reducer the brake directly with the voltage given in
output shaft does
005 is not brake plate. For example, with 198 VDC. A
not operate. You
working clicking sound that indicates the opening of
are using a
the brake shall be heard. If the sound is not
magnetic brake.
heard, brake or inverter may be faulty. If the
sound is heard, brake is operating. When
the brake is supplied and you have heard
the clicking sound, supply the motor directly
according to its data plate. Load may be
excessive for the motor selected if the
problem is continued. Refer to the problem
in procedure no. 3.
Check the moving parts. Detach the reducer
Reducer A regular knocking from the machine and operate it without
013
is noisy noise load. Reducer may be faulty if you hear
similar noises. Refer to procedure no. 100.
Check the play of connection elements
A regular connected to the output shaft. Detach the
Reducer
014 decreasing and element connected to the output shaft and
is noisy
increasing noise operate it without load. Refer to procedure
no. 100 if you hear similar noises.
Random clicks with a low intensity may
Reducer has a
come from the brake and this is normal. If
Reducer motor with a brake
015 the noise level is disturbing, brake may be
is noisy and noise comes
damaged or its play setting may be
from outside.
incorrect. Refer to procedure no. 100.
You are using a Parameters of frequency inverter are not
frequency inverter suitable for the motor you are using Refer to
Reducer
016 and noise is operation manual of the frequency inverter.
is noisy
changing with the Refer to procedure no. 100 if the problem is
speed. continued.
If the ambient temperature is over +40 and
the machine is continuously operated for
more than 16 hours, remove the plug on the
Oil leak from the
017 Oil leak upper side according to the installation
seal
position and use the ventilation plug. If this
is not your condition, seal may be damaged.
Refer to procedure no. 100.

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 If you are using a ventilation plug, check if
it is in the correct position. Correct position
is the plug that is placed on the uppermost
level according to installation position of
Oil leak from the
018 Oil leak the reducer. Plug may not be tightened
plug
properly. Clean the surface where the plug
is seated and the plug. Tighten it again.
Refer to procedure no. 100 if the problem
is continued.
Observe the exact leaking position of the
oil. Oil may be leaking from the plug or
seal and dripping on the body. Refer to
Oil comes out of procedure no. 17 and 18 if this is the
019 Oil leak
the body condition. If you are sure that the oil
comes from the body, there may be micro
cracks or fractures on the body. Refer to
procedure no. 100.
Gasket under the cover is torn or not
functioning. Remove the cover, clean the
Oil comes out
020 Oil leak surface under it, apply new sealant and
from the cover
tighten the cover back. Refer to procedure
no. 100 if the problem is continued.
Reducer is
jerking
The reason for the jerking of reducer is the
regularly
play of the shaft that you have connected
when it is You are using a
021 the reducer. This is not harmful to the
operated in moment arm.
reducer and it is normal for the reducer if
its
you are using a moment arm.
installation
place.

Reducer is
The reason for the jerking of reducer is the
jerking
play of the shaft that you have connected
randomly
the reducer and the clearance between the
when it is You are using a
022 shaft and sleeve. Check your shaft
operated in moment arm.
clearance tolerance. This is not harmful to
its
the reducer and it is normal for the reducer
installation
if you are using a moment arm.
place.
Motor is being
operated with an
Motor is Motor power is inadequate or motor is
amperage of its
023 heated overloaded. Motor may be faulty. Refer to
nominal value.
excessively. procedure no. 100.
Surroundings are
clean.

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 Ensure that all fan housing is clean for
air passage and that motor cooling
Motor is heated Surroundings are
023 blades are not covered with dust. If you
excessively. dusty.
are using a forced fan, ensure that it
operates.

Motor shaft A rubbing sound

rotates, reducer is heard or there Reducer may be faulty. Refer to
024
shaft does not is the motor procedure no. 100.
rotate. sound only.

Damage may be caused by the polygon

effect caused by chain gear or by the
radial load. Leg connections of the
reducer may be loosened or the plate it
is connected may not be rigid enough.
Ensure that you are using correct chain
gear/pinion gear diameter. Check the
You are using a
maximum allowed radial load. Check
chain gear or
Reducer body the connection elements you have
025 pinion gear in the
is broken connected to the output shaft and
reducer output
calculate the radial load again
shaft.
according to this position. Check if the
chain driver used has the correct
diameter and check the maximum
radial load. Check the position of output
element and check by calculating the
radial load again. Refer to procedure
no. 100.
Damage may be caused by the polygon
effect caused by chain gear or by the
radial load. Check if the securing bolts
If you are using a are loosened or if the reducer plate is
Output shaft is
026 chain driver or rigid enough. Check whether chain gear
faulty
pinion gear has correct diameter. Check the
position of output element and check by
calculating the radial load again. Refer
to procedure no. 100.
Check brake connection diagram.
There are two types of brake
Reducer stops You are using a connections. Reducer is delivered with
027
late braked motor. delayed braking from the factory. Refer
to electrical wiring diagram for abrupt
braking.

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 Big brakes over 100 N/m require shock
Reducer
You are using a transformer supplied by YILMAZ
028 starts
braked motor. REDÜKTÖR in order to start the machine
very late
rapidly. Refer to procedure no. 100.
Please contact YILMAZ REDÜKTÖR service
points. These are provided on the rear of the
manual. Replacement of mechanical parts
This problem
and any modifications performed without
Service cannot be
100 informing YILMAZ REDÜKTÖR renders
required. resolved by
product warranty and CE manufacturer's
yourself.
declaration void and removes the
responsibilities of YILMAZ REDÜKTÖR on
the product.

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