A – DELIVERY INFORMATION

A – 1.1 TECHNICAL CHARACTERISTICS

L W

H
E

C
B
Distance Between Columns

Approach Speed

Oiltank Capacity
Bending Length

Bending Speed
Bending Force

Return Speed

Throat Depth

Motor Power

Weight
Length

Height
Stroke

Width
TYPE

ton mm mm mm/sec mm/sec mm/sec mm mm kw lt mm mm mm ~ kg

A B C E L W H
HAP 1235 35 1250 1050 120 9 86 125 350 4 60 2100 1650 2100 2120
HAP 2035 35 2050 1650 120 9 86 125 350 4 60 2950 1595 2060 2600
HAP 2560 60 2550 2150 100 9 63 135 350 5.5 100 3500 1780 2200 3900
HAP 3080 80 3050 2550 100 8 68 135 350 7.5 100 4000 2040 2450 5980
HAP 3090 90 3050 2550 100 8 68 135 350 7.5 100 4000 2040 2450 5980
HAP 30120 120 3050 2550 100 9 77 155 350 11 150 4150 2150 2600 7260
HAP 30160 160 3050 2550 100 9 86 175 350 15 150 4250 2170 2800 9120
HAP 30200 200 3050 2550 100 7 73 185 350 15 150 4270 2400 2850 11300
HAP 30300 300 3050 2550 90 5 61 225 365 18.5 150 4330 2450 2850 15660
HAP 35160 160 3550 3100 100 9 86 175 350 15 150 4780 2170 2800 10600
HAP 35200 200 3550 3100 100 7 73 185 350 15 150 4800 2400 2850 13220
HAP 37120 120 3700 3100 100 9 77 155 350 11 150 4700 2150 2600 9800
HAP 37160 160 3700 3100 100 9 86 175 350 15 150 4780 2170 2800 10600
HAP 37200 200 3700 3100 100 7 73 185 350 15 150 4800 2400 2850 13700
HAP 37300 300 3700 3100 90 5 61 225 365 18.5 150 4950 2450 2850 18150
HAP 40160 160 4050 3100 100 9 86 175 350 15 150 5000 2170 2800 11620
HAP 40200 200 4050 3100 100 7 73 185 350 15 150 5050 2400 2850 13480

DURMAZLAR HAP Page 1 / 45

HAP 40300 300 4050 3100 90 5 61 225 365 18.5 150 5100 2450 2850 18600
HAP 40400 400 4050 3100 75 6 47 275 500 30 300 5100 2750 3100 26250
HAP 60200 200 6050 4100 100 7 73 185 350 15 150 6800 3200 3100 20000
HAP 60300 300 6050 4100 80 5 61 225 365 18.5 150 6650 2740 3340 30000
HAP 60400 400 6050 4100 75 6 47 275 500 30 450 6950 2850 3680 37500

A – 2.1 INTRODUCTION OF THE MACHINE

- The machines steel welded construction is made from Eregli Demir Celik St 44-A1 quality material
and it is frame is produced as monoblock. All the tension points are designed with large radius to
prevent welding cracks.

- Top table has a special top tool deflection. It is highly designed to prevent deflection on the top table.
The beds are placed vertically on the top table.

- Top and bottom tools are made from Asil Celik 42CrMo4 material and is designed on request. On the
T Slot a working axis has been placed so that single or multi bottom tool can be connected.

- The machine has a 3 different working positions and distance adjustment and double speed
hydraulic system arrangement. Also emergency buttons are supplied as a support security system.

- The hydraulic system products are imported from Germany marked Rexroth or Bosch.

- The hydraulic cylinders are made from MKE 1040 grinded material and the inside has been planed.

- The hydraulic pistons are made from SAE 1050 material , they are grinded and chromium plated with
ø 100 micron and again grinded. The purpose for this is to have a low resistance for wearing and
friction of the piston seals.

- The hydraulic leakage parts are imported from Germany marked Merkel or Busak Shamban.

- 25 micron sensitivity return filter is used for double filter hydraulic system of suction and return.

- The hydraulic pipes are made from St 35.4 quality steel pipes accordly to DIN 2391 / CY.

- The hydraulic connection parts are suitable for DIN 2353.

- To gain equal bending there is a single command control inner stopper system. As prefered by the
World this system is placed inside the cylinder and is worked synchronous and is able to change the
mesurement adjustments under strength. When the sheet bending degree is being adjusted the top
table wieght or the hydraulic pressure system is not effected. There fore it is not possible for the
system to be deformed or for any gap to occur. For this reason it is prefered to have a longer lasting
period.

- Adjustment of 600 mm can be made and 3 axis movement is possible on the motorised back gauge.
The back gauge and stopper system measurement values can be seen on the digital readout and both
system have a 0.1 mm accuracy.

- It is possible to adjust the bending sheet length and thickness from the hydraulic pressure system.

- Electrical circuit parts are from Siemens , Telemecanique or Merlin Gerin marked products. The
command circuit is supllied at 24 Volt DC.

DURMAZLAR HAP Page 2 / 45

- The machine functions has 3 main motors :
- Hydraulic system motor
- Stopper system motor
- Back gauge motor

- The machines surface is painted min. 60 micron thickness with main paint , which saves against
weather and working conditions.

- Besides from the operation use of the machine there is a 1 year garranty against production defects.

A – 3.0 STANDARD AND REQUESTED EQUIPMENT

A – 3.1 STANDARD EQUIPMENT

- 2 pieces of digital readout command panel

- 2 pieces of double axis adjustment sheet holder handle
- 1 piece of command panel
- 1 piece of bottom tool , 1 piece of top tool ( these toolings can be design upon requests )
- 2 pieces of chains to turn the tooling
- Illumination light
- 1 set of mobile pressure gauge
- Machines working and maintenance manual

A – 3.2 REQUESTED EQUIPMENT

- NC control unit ( ELGO , EMKO or NOUVA )

- it has a double axis position control
- during bending the back gauge fingers can be withdrawn
- Special security system and control is contained accordly to the CE certificate
- Amada Promecam top tool deflection system
- Ballscrew movement transmission system
- Sick Guarding light curtain security system
- Special design spare top and bottom tooling
- Grinding process of standard of spare tooling
- Command circuit is PLC control
- Manuel or motorized Wila bottom deflection system

DURMAZLAR HAP Page 3 / 45

 B – MACHINE AND PERSON SECURITY

B – 1.1 INFORMATION FOR HYDRAULIC OIL

The required hydraulic oil must be filled in the machine as stated on the number 1 points and this must
be done before installing the machine.
( Look at A – 1.1 for the required oil proportion )

PLACES WHERE PLACES WHERE

HYDRAULIC OIL TEMPERATURE IS TEMPERATURE IS
BELOW 20°C ABOVE 20°C
STANDARD NORM ISO VG 32 ISO VG 46
ARAL VITAN GF 32 VITAN GF 46
B.P. HLP 32 HLP 46
CALTEX-TEXACO RANDO OIL 32 RANDO OIL 46
ESSO NUTO H 32 NUTO H 46
PURFINA FRANCE HYDRAN 32 HYDRAN 46
HUILE RENAULT-ELF OLNA 32 OLNA 46
SHELL TELLUS 32 TELLUS 46
VALVOLINE ULTRAMAX 32 ULTRAMAX 46
VEEDOL ANDRAIN 32 ANDRAIN 46
YACCO TRANSHYD 32 TRANSHYD 46
GULF HARMONY 32 AW HARMONY 46 AW
CASTROL AWS 32 AWS 46

GREASE
SHEEL ALVANIA R 2
B.P. ENERGREASE HY 2

B – 1.2 FIRE DATA

Flash point ( °C ) and method : 193 closed cup.

Auto ignition temperature ( °C ) > 200

Flammability limits : 1.5 – 6

Products of combustion : Mainly oxides of carbon , water vapour with unidentified organic compounds.

Special fire / explosion hazards : Large surface areas exposed to air / oxygen ( e.g. , oil-soaked rags ,
paper or absorbed soillages ) may be easily ignited and these should be cleared up at once.

DURMAZLAR HAP Page 4 / 45

Special fire-fighting procedures : Firefighters should enter area wearing self-contained breathing
apparatus. Do not spray water directly into stroge containers due to boil over danger.

Extinguishers : Foam , dry chemical powder , carben dioxide , halon.

B – 1.3 STORAGE and REACTIVITY DATA

Suitable materials / coatings : Most common metals.

Unsuitable materials / coatings : May soften some rubbers.

Stability : Stable.

Reaction with water : None.

Dangerous reactions : None known.

Hazardous polymerisation : Will not occur.

Materials to avoid : Strong oxidising agents.

Conditions to avoid : Extreme temperatures.

Decomposition temperature ( °C ) : > 100

Dangerous decomposition products : Significant concentrations of hazardous decomposition

products are not expected.

Storage temperature ( °C ) : 0 - 40

Storage precautions : No special requirements. Avoid elevated temperatures.

B – 1.4 RECOMMENDED FIRST AID

Eye contact : Flush with plenty of water for at least 15 minutes. If irritation persists , obtain medical
attention.

Skin contact : Wash with soap , or approved skin cleanser , and water. Remove heavily contaminated
clothing. Where skin rashes or other abnormalities occur as a result of excessive contact , medical
advice should be obtained.

Inhalation : In the event of discomforting effects produced by overexposure , remove to fresh air. If
effects persist , obtained medical attention.

Ingestion : Milk or water to drink may be beneficial. DO NOT INDUCE VOMITING. Main hazard is
aspiration into the lungs during of following ingestion , childen being more susceptible than adults. If
this occurs ( e.g. , during vomiting ) , send to hospital immediately.

DURMAZLAR HAP Page 5 / 45

Notes for doctors : Treat symptomatically. Aspiration may cause sever pneumonitis , requiring
antibiotics and corticosteroid therapy.

B – 2.1 SIDE PROTECTION SHEETS MONTAGE MEASURE

100
C
D

Gmin A
F

MACHINE NAME A(mm) B(mm) C(mm) D(mm) E(mm) F(mm) Gmin(mm)

35 TON HAP 210 390 540 1100 1410 310 180

60 TON HAP 310 540 765 1300 1600 300 230

80 TON HAP 330 560 710 1300 1600 300 230

120 TON HAP 330 560 880 1540 1840 300 230

160 TON HAP 370 600 1000 1670 1970 300 230

200 TON HAP 390 620 985 1670 1970 300 230

300 TON HAP 430 660 1000 1670 1970 300 230
DURMAZLAR HAP Page 6 / 45
400 TON HAP 520 750 1175 2100 2400 300 230
 B – 3.1 PROTECTION OF HAND AND BODY

Always keep your hands away from the bending axis during bending. Once the bending has started
don’t forget that the material will go up to the required angle of the bend and protect yourself from the
material hitting you. After the bend the material will fall anytime. During the bend the machines tool
adjustment shouldn’t be changed and the protection covers should be closed. The protection covers
security switches on the main electrical panel shouldn’t be out of circuit at any time.

Don’t go close to the machine during the machines moving point. Stay at the given measurement for
the security distance.

Never go inside the machine during the bending process.

B – 4.1 INFORMATION FOR HYDRAULIC MACHINES

MANNESMAN REXROTH ROBERT BOSCH

Jahnstrasse 3-5 D – 97816 Robert Bosch GmbH
Lohr am Main Postlach 30 02 40
Mannesmann Rexroth AG D – 70422 Stuttgart – DEUTSCHLAND
http : //www.rexroth.com.tr/html/linker.html
ATOS SPA
VICKERS SYSTEMS DIVISION LIMITED Capitale lire 10.200 milioni
P.O Box 4 New Lane C.C.I.A.A. Milano – 510576 REA
Havant Tribunale Milano 101068 – R.I.
Hnats P09 2 NB Sede legale Milano
ENGLAND Banca : Caripla , Sesto Calende
N.Meccanografico Mi019303
HOERBIGER HYDRAULIC GMBH Cod. CEE IT00778630152
Martina – Hörbiger – STR.5 CF/P. IVA 00778630152
D – 86956 SCHONGAU GERMANY 21018 Sesto Calende / Italia
Tel : 00 49 8861210 – 344 via alia Piana 57
Fax : 00 49 8861210 – 350 Tel : 0 331 922078
Fax : 0 331 920005

B – 5.1 NOISE

This range of machines has been designed to keep noise levels down to a minimum. During design ,
the following factors were taken into account.

– The internal gear pump , gear pump and vone pumps are used which we believe to be one of the
quietest on the market.

DURMAZLAR HAP Page 7 / 45

– Flexible hoses are used to isolate the pump and manifold assembly from the main structure of the
machine.
– The side frames have been kept high to reduce transmitted airborne noise at ear level.
– Special considerations were taken in the design of the control circuit to reduce hydraulic knock due
to valves switching under pressure.
– On machines a vibration absorbing coupling is used between the pump and motor.

B – 5.2 NOISE LEVEL MEASUREMENT

MACHINE NAME UNLOADED WORK ( dBA ) LOADED WORK ( dBA )

HAP 1235 68 75

HAP 2035 68 75

HAP 2560 61 62

HAP 3080 68 70

HAP 3090 68 70

HAP 30120 64 67

HAP 37120 64 67

HAP 30160 61 67

HAP 35160 61 67

HAP 37160 61 67

HAP 40160 61 67

HAP 30200 61 68

HAP 35200 61 68

HAP 37200 61 68

HAP 40200 61 68

HAP 60200 61 68

HAP 30300 63 68

HAP 37300 63 68

HAP 40300 63 68

DURMAZLAR HAP Page 8 / 45

 HAP 60300 63 68

HAP 40400 62 68

HAP 60400 62 68

B – 6.1 SECURITY PROCEDURE

- When supplying the machine read all electrical description on the machine and apply to the given
value.

- Never bring any part of your body next to the working point.

- Never work and service the machine , maintenance or change any parts without reading the
instruction manual and consult the manager when you have any doubts.

- Never do any service when the motor is working.

- Specialized person should give service and maintenance to the machine.

- Do not change the hydraulic valve adjustment.

- Never change the top table limit switches ( fast fall switch and limit switch ).

- Don’t go over the given maximum pressure which is mentioned on the machines and pressure
description labels.

- For security reasons , security covers located on the moveble parts of the machine.

- Back gauge covers should only be opened during maintenance and some adjustments.

- For security reasons , there are emergenc stops on reachable places of the machine.

- All required security information exists on labels of the machines.

- On our machines don’t use tooling outside our production otherwise the machine can be damaged.

- Keep away unauthorised persons from the machine.

- Keep the working place in order other wise , there can be danger and stricts your working area.

- Before operating the machine , check security appliances and parts which are damaged.

- Please switch off the machine or hydraulic motor when the upper tool is totally down position.

DURMAZLAR HAP Page 9 / 45

 B - 7.1 SECURITY COVERS AND SWITCHES
C Y L IN D E R P R O T E C T IO N S H E E T

S ID E P R O T E C T IO N S H E E T

C Y L IN D E R P R O T E C T IO N S H E E T

S ID E P R O T E C T IO N
S H E E T S W IT C H
X C S -P L 7 7 1

S E C U R IT Y C O V E R
S ID E P R O T E C T IO N
S H E E T S W IT C H
X C S -P L 7 9 1
S ID E P R O T E C T IO N S H E E T

C Y L IN D E R P R O T E C T IO N S H E E T

C Y L IN D E R P R O T E C T IO N S H E E T

BACK GAUGE
P R O T E C T IO N S H E E T

S ID E P R O T E C T IO N S H E E T

S ID E P R O T E C T IO N
DURMAZLAR B A C K G A U G E P R O T E C T IO N HAP S H E E T S W IT C H Page 10 / 45
S H E E T S W IT C H X C S -P L 7 9 1
X C S -P L 7 9 1
 CYLINDER PROTECTION SHEET Y AXIS MIN.
LIMIT SWITCH
XCK-P 718
LOWER LIMIT SECURITY SWITCH
XCK-P102
Y AXIS MAX.
TEST O.K. SWITCH LIMIT SWITCH
XCK-P102 XCK-P 718
UPPER LIMIT SECURITY SWITCH
XCK-P102

CYLINDER PROTECTION SHEET

FAST FALL SWITCH

X AXIS MIN.
LIMIT SWITCH XCK-M102
XCK-P 718 UPPER LIMIT SWITCH
XCK-M102

SIDE PROTECTION SHEET

SIDE PROTECTION
SHEET SWITCH
X AXIS MAX. XCS-PL791
LIMIT SWITCH
XCK-P 718

SIDE PROTECTION SHEET SWITCH ( XCS-PL791 ) : During the running the machine , when the
side protection sheet is opened and the switch is on the circuit , then the machine automatically stops.
SIDE PROTECTION SHEET SWITCH ( XCS-PL771 ) : During the running the machine , when the
side protection sheet is opened and the switch is on the circuit , then the machine automatically stops.
BACK PROTECTION SHEET SWITCH ( XCS-PL791 ) : During the running the machine , when the
back protection sheet is opened and the switch is on the circuit , then the machine automatically stops.
X AXIS MIN / MAX LIMIT SWITCH ( MJ2-1703 ) : The back gauge axis X movements in min. and
max. points are limited with ( - , + ) limit switches.
Y AXIS MIN / MAX LIMIT SWITCH ( XCK-P718 ) : Limits the stopper shaft adjustment in min. and
max. points.
FAST APPROACH SWITCH ( XCK-M102 ) : Obtains the top table switching to pressing speed.
TOP LİMİT SWITCH ( XCK-M102 ) : Limits the top table movement at top point.
TOP LIMIT SECURITY SWITCH ( XCK-P102 ) : When top limit switch does not work in any reason ,
top limit security switch limits the top table movement at top point.

DURMAZLAR HAP Page 11 / 45

FAST APPROACH SECURITY SWITCH ( XCK-P102 ) : When fast approach switch does not work in
any reason , works as a second security ans stops the movement of top table. In this case , fast
approach switch has to be checked.
TEST O.K. SWITCH (XCK-A102 ) : When machine is in Automatically first operations , in first
movement of the top table , this switch stops the movement of top table. Obtains checking of hydraulic
system and command system.

B – 7.2 REST HAZARD

You have to leave a safety

distance between upper and
lower tool.

EA
AR
NG
KI
OR
W Please be carefull in working area. Use the
gloves. Don't forget that , sheet will be
moving to up side when you are pressing
time and save your body for probably
accident.

When you want to pull out , take at and

cleaning etc. for hydraulic aquipment , you
have to fix the upper beam. You have to
put support material between the top and
bottom tool.

Please do not enter the machine back side. You can enter
DURMAZLAR HAPjust Page 12 / 45
for maintenance. Don't forget that , back side is moving.
 B – 8.1 INTRODUCTION AND SAFETY LABELS PUT ONTO THE MACHINE

Motor
Motorleistung
durm azlar Moteur
Phase
TYPE Stromart ~
Phase
MANUFACTURING YEAR
BAUJAHR Frequency
ANNEE FABRICATION Frequenz Hz
Frequence
MACHINE NO
MASCH-NR Working voltage
N'DE SERIE Betriebsspannung V
Tension d'àlimentation
CAPACITY
KAPAZITÄT Command voltage
CAPACITE Steuerspannung V
Tension tèlècommande
STROKE
HUB Current
mm Nennstrom A
COURSE
Intensitè
STROKE IN A MINUTE
HUBZAHL PRO MIN. Intermediate fuse current
COURSE PAR MINUTE A
Puissance totale
LUBRICANT CAPACITY
ÖLTANK KAPAZITÄT lt E. circuit scheme no
CAPACITE RESERVOIR E. schaltplan nr.
TOP TOOL WEIGHT
Kg
POIDS OUTIL SUP.
BOTTOM TOOL WEIGHT
Kg Tel : (0 224) 219 18 00 pbx.
POIDS OUTIL INF.
Fax : (0 224) 242 75 80
WIDTH
BREITE mm
LARGEUR
LENGTH LABEL-2
LÄNGE mm
LONGUEUR
HEIGHT
HÖHE mm
HAUTEUR ATTENTION !
WEIGHT ACHTUNG !
GEWICHT Kg
POIDS

MADE IN TÜRKİYE LABEL-3

LABEL-1

Label - 1 : Machine introduction label

Label – 2 : Electrical introduction label of the machine.
Label – 3 : Label showing maximum operation of the machine.

LABEL-5
LABEL-4
DURMAZLAR HAP Page 13 / 45
 Label – 4 : Grounding warning label.
Label – 5 : The label which shows the turning direction of the motor.

TURN THE MACHINE OFF BEFORE

OPENING THE COVER.

AND REPAIRS.

LABEL-7

DO NOT OPEN MACHINE

IS TURNED OFF.
LABEL-6
LABEL-8

Label – 6 : The label for electrical warning.

Label – 7 : Label indicating that back protection covers must not be opened during operation.
Label – 8 : Please do not open protection sheets unless machine is turned off.

Safety Instruction
Read the instruction manual and the warning plates on the machine
Falling Time After Stopping ms
before operating the machine and take them into consideration. Nachlaufzeit
For the machine's safety and your safety :
- Do not wear loose clothes or ornaments , these cause accidents. Traversing Distance After Stopping mm
Nachlaufweg
- Wear safety-shoes while working for your safety.
- Never adjust or repair when the machine is running. If not in use,
Safety Distance
disconnect the machine from the network. mm
Sicherheitabstand
- Work only with the tools appropriate to the machine.
- Use only the tools that are not damaged to the machine.
- Never use the parts that are not fitting to the machine. LABEL-10
- Never remove this warning plate from the machine -

LABEL-9

Label – 9:This is the label which indicates to obey to the safety instruction for person who uses the machine
Label – 10 : Label showing valves obtained at test position of the machine.

Lütfen makinanın üst tablasını komple alt konuma almadan makinanın hidrolik
motorunu veya ana şalteri kapatmayınız.
Please switch off the machine or hydraulic motor when the upper tool is totally
down position.

Bitte, bevor sie den Oberbalken auf untere position genommen haben, schalten
Sie hydraulik Motor oder Hauptschalter nicht ab.

DURMAZLAR HAP Page 14 / 45

 WARNING !
VALVES. BEFORE STARTING THE MACHINE ,
BITTE VERSTELLEN SIE NICHT
PLEASE CONTROL THE OIL LEVEL

PRIERE DE NE PAS TOUCHER MOTOR.

AUX REGLAGES DES VALVES. USE OIL : ISO VG 32 - VG 46
LABEL-11
LABEL-12

Label – 11 : Pressure adjustment of the hydraulic valves are carried out in our fabrication. Label
indicating that subsequently valve adjustments must not be changed.
Label – 12 : Please control the oil level and check the rotation of the main motor , before starting the
machine.

DANGER

PINCH
POINT FOR BEST PERFORMANCE ,
CENTER MATERIAL WHEN BENDING

LABEL-13 LABEL-14

Label – 13 : The warning label which indicates the pinch point.

Label – 14 : To make good bending , bend the material at the centre ofthe machine.

LABEL-15 LABEL-16

DURMAZLAR HAP Page 15 / 45

Label – 15 : Do not forget that the material rises up during bending operation and protect your body
not to strike.
Label – 16 : Do not put your hand between top and bottom tool during bending process.

C – GUIDANCE NOTES FOR PLANT INSTALLATION

C – 1.1 INTRODUCTION

It is the policy of the company that the interests and satisfaction of our customers will be of paramount
importance and that , with in the practical constraints of manufacturing cost , the goods offered for sale
to them will be of a consistently high quality and reliability.

ABOVE ABBREVIATIONS ARE TAKEN FROM DURMAZLAR QUALITY CONTROL LEAFLET.

These guidance notes are provided to help ensure that the unloading , handling and siting of your
machine is carried out safety and efficiently.
Please note that the Manufacturer cannot be held responsible for damage due to improper machine
handling , disregard of the instructions or disregard of Health and Safety Regulations.

Your machine has to be installed by a specialist person. For installation , please contact with
DURMAZLAR company or the dealer that you bought the machine from.

C – 2.1 MACHINE RECEPTION

On receipt of the machine please ensure to the best of your ability that there is:
a – No damage has happened during transport.
b – No parts are missing.
c – Neither the machine nor the parts are deficient in any way.

C – 3.1 MACHINE TRANSPORT

Moving the machine to its points of use-the ideal situation is to be able to offload and internally
transport the machine to its point of use using the lifting beam with crane or overhead crane.
However , this is not always an appropriate or viable proposal.

The usual operation for the movement of the machine is as follows :

a – If on caterpillars or skates , use in four positions – two at the front , and two at the rear under the
sideframe legs of the machine.
b – Always move the machine in a longitudinal direction , never forward or backwards.
c – Secure the two front caterpillars with a piece of hard-grained wood , or a block of steel placed
beside each plate. This will support the machine in case one of the skates slip.
d – Check the floor on which the machine is to be transported for cracks , uneven surface or slopes. It
is recommended that the machine is transported over smooth and parallel floors.
POSITIONING : Ensure anchor bolts are in place while the machine is still suspended , before
lowering the machine into its final position. The levelling screws should be lubricated with grease and
screwed downwards to their maximum length. This facilitates the installation , as adjustment is only
required downwards. ( Refer the foundation plan. )

DURMAZLAR HAP Page 16 / 45

There are lifting points at the upper right and left hand side of the sideframes , towards the front of the
machine. ( refer to lifting illustrations )

These lifting points are located at the centre of gravity as seen along the length of the machine. The
machine this hangs fairly straight (depending on the position of the backgauge).

Points to remember , and recommendations :

a – The centre of gravity is high and there is a danger that it may tip over.
b – NEVER lift the machine using the oil tank , carrier , backgauge or cylinder. ALWAYS use the lifting
points ( Refer to lifting illustrations )
c – When lifting the machine from its transport to its point of use , it is strongly recommended that a
lifting beam of the appropriate lifting capacity is used.
d – If an appropriate liftng beam is not available , chains and shackles of the appropriate liftng capacity
must be used.
e – NEVER use slings of any sort for lifting.
f – ALWAYS use the correct methods for lifting the machine when using chains. ( Refer to lifting
illustrations. )
g – ALWAYS use shackles and lifting accessories of the correct specifications and loading capacities.
O.K.

> 45°

y x

POOR

<45°

y x

DURMAZLAR HAP Page 17 / 45

 B – 4.1 OPERATION AREA OF THE MACHINE

1500
Necessary distance for maintenance

X + 1000 Hydraulic Press Brake 1500

Y
Y + 4500 ~ 6500

A distance as big as the length of the Necessary distance for maintenance

pait and area must exist if the pait
which has to be bended exist from the X
side.
Operation Surface
3000 ~ 5000

A distance as big as the sheet

bending length must exist

2X + 2500

C – 5.1 PRE-START UP DETAILS

The machined surfaces of the shear have been treated against rust with cleaner. It can be removed
easily with appropriate cleaning fluid.

Cleaning operation : Cover the tools with wet cloth , wait 10 minutes and than clean it with a cloth.
Benzine or oil Solvent have to be used.

Machine jacking bolts should be supported on metal plates. Recommended plate sizes are available.
The machine should be bolted down using cast in anchor bolts , having positioned the machine allow
concrete to set before final tightening , or wedge bolts of sufficient dimension and quality , to be fixed
according to the type used.
The machine should be checked using a precision levelling instrument. The recommended positions
for checking the level are , centre of the table with the levelling device resting on the infill support
pads, to check the longitudinal level and at each end of the table , again resting on the infill support
pads to check front to back level. The machine level is adjusted using the jacking screws in each foot.

DURMAZLAR HAP Page 18 / 45

 THE FRAME MUST NOT BE TWISTED. A mean value should be obtained from end across the infill
support pads. The frame should not be twisted to achieve exact parallelism.

C – 6.1 ELECTRICAL CONNECTIONS

Connect the machine to the mains supply in accordance with local standard electrical codes and
practies. The machine is wired to suit the incoming 3 phase mains voltage.
CAUTION : Mains feed cable sizes and junctin box fuse ratings must be as noted in the
following table. These are minimum and may need to be larger dependent on the length of
cable run. ( Refer the table C – 7.2 )
Cable entry is in the panel bottom and connections are made to terminals as per the circuit diagram
supplied. Neutral is not used. Electrical connections should be made by qualified personnel.
NOTE : Check the local voltage with the transformer voltage and main motor voltage.

C – 7.1 DIRECTION OF MOTOR

Before starting the main motor , the manual blade gap adjustment level is set to maximum , to avoid
any possible clash of the cutting blades due to movement in transit.
Direction of the motor is indicated by an arrow on the flange of the pump. Check direction of the motor
looking at the ventilator. The motor must be run only for the minimum time necessary to establish the
direction of rotation.
If direction is wrong , stop immediately.
To change the direction of the motor , COMPLETELY ISOLATE the machine and cross over two
incoming phases. ( This work should be carried out by a qualified person. )
Please take in to account the label for the turning direction of the motor.

C – 7.2 MOTOR CURRENT INFORMATION

kW

q q q q q
HP
A A mm² A A mm² A A mm² A A mm² A A mm²

DURMAZLAR HAP Page 19 / 45

 D – STORING CONDITIONS

Transport the machine by taking all the necessary precautions not to have any damage on the
machine.
If machine is to be stored more then a period of 1 month , the below indicated clauses must be met
carefully.

1 – During consignment the machine is top tool is seated into the V chanel of the bottom die. The
machine has to preserve this position.

2 – If the machine is to be stored in a damp enviroment , damp removing materials ought to be placed
on the electric panel and hydraulic block , by means electrical parts shall be protected from moist.

3 – In order to prevent the top and tools from rusting , protective oil must be used.

4 – Machine must be protected carefully against sunlight.

5 – Stroge must never be carried out in open air ( wet inviroment ). Defect may occure in the valve
sockets or electrical parts.

DURMAZLAR HAP Page 20 / 45

 E – BENDING THEORY

E – 1.1 AIR and TOOL BENDING

Durmazlar Pressbrakes are developed to give shape to sheet plates. Our Pressbrake has the function
to do sensitive air bending and to bend the sheet plates with the tooling.

AIR BENDING : After choosing the suitable “ V “ canal , place the material on both edges of the “ V “
canal. After the stroke adjustment the top tool will start to move and the bending process will continue
unit the required value ( eg ; 30° , 60° , 75° , … ) is completed.
Take into consideration the material will have tension when doing this process.

Important values when selecting the “ V “ canal :

- Sheets up to 3 mm is 6-8 x s
- Sheets above 3 mm is 8-12 x s
- s : Thickness of bending sheet

NOTE : These values are also valid when bending short length material.
Refer to the manual for the bending table of the required strength , inner radius value and other
required information can be found.

Sample : 3 mm sheet thickness and required canal width is 25 mm and bending sheet is 18 mm. Inner
radius is 4.2 mm and required strength is 21 ton.

Important points to be careful when bending sheet :

A – 3 points which are effective for air bending. Is that both edges of the bottom tool and the bending
adge of the top tool.
B – Bending Sheet ( 90° ) with tooling ,

The top tool should be pressured on both sides until the bottom tool canal is reached. The advantage
of this is :
1 – There is no need to use all the tonnage strength of the Press ,
2 – Possibility of bending the suitable sheet thickness ,
3 – The same tool can be used on different degree bendings.

The below tolerance should be taken into consideration when air bending of the materials old form is
leaned back :
a – Bending with pointy end tool ± 2°
b – Bending with standart tool ± 3°
c – Bending with wide opening tool ±5°

Difference degree of the total length materail thickness value of air bending :

DURMAZLAR HAP Page 21 / 45

Sample : 2 mm sheet thickness with 140° bend ; Selected “ V “ canal opening is V :8 x s :
8 x 2 : 16 mm

As seen on the next table that 16 mm canal opening values is 0.081 and when compared to the
thickness sheet it is 0.08 mm which is a difference of 1° .

If we accept that the material total length thickness difference is 10% then the degree difference is
2.5° .
The values given on the side is pratically or theorical
calculated in the way which was explained before.



B/2
B/2

E – 2.1 ACCORDINGLY TO THE DEHLER TABLE

DURMAZLAR HAP Page 22 / 45

 PLATE RADIUS
MATERIAL THICKNESS B°
s ( mm ) r ( mm )

Soft steel 1s 4
Soft brass 0.8 1s . . . . 5s 5
B : 22 kg/mm² 5s 6
Aluminium 1s 2
Zinc 0.8 . . . . 2 1s . . . . 5s 3
5s 4
1s 0
2 1s . . . . 5s 1
5s 2
Steel middle - hard 1s 5
B : 40 kg/mm² 0.8 1s . . . . 5s 6
5s 8
1s 2
Hard brass
B : 35 kg/mm² 0.8 . . . . 2 1s . . . . 5s 3
5s 5
Bronze 1s 0
2 1s . . . . 5s 1
5s 3
Hard steel 1s 7
B : 60 kg/mm² 0.8 1s . . . . 5s 9
5s 12
1s 4
0.8 . . . . 2 1s . . . . 5s 5
5s 7
1s 2
2 1s . . . . 5s 3
5s 5

E – 3.1 PRESSING WITH THE TOOLING

Our toolings needs to be very good in order achieve a good result on sensitive profiles. In this suitation
high tonage is required. Pressing degree is given on our toolings and because of this there is no need
to make any adjustments for the degree.

Our advantages ; as we minimize the tendency of the material to have the previous form , degree
differences will be minimum.

DURMAZLAR HAP Page 23 / 45

The disadvantage is that when high tonnage and high bending is required it’s the toolings cost.

V : 4 ve 5 s

The bending sheets is connected to the “ V “ canal radius opening and it’s not connected to the sheet
thickness and length.
Under this condition the radius is smaller than the “ V “ canal radius.
r

R : 0.16 V

E – 4.1 SPECIFICATION TO THE TURNING OF THE SHEETS OLD FORM WHEN

AIR BENDING

As it is known that the sheet will go to it’s old form because of a elastic in the material.
They are related to the below :

a – r/s proportion
b – Materials capacity
c – Materials surface

DURMAZLAR HAP Page 24 / 45

d – Contents

A C B

1.42 x L x R x s²
P: (A)

s
1000 x V
V

P : Pressing strength ( ton )

L : Sheet length ( mm )
R : Strength ( kg/mm² )
s : Sheet thickness ( mm )
V : Opening of canal

SAMPLE :
Sheet length is 1000 mm.
Strength is 42 kg/mm²
If width of “ V “ canal V : 8 x s is chosen then the below value is made.

P : 1.42 x 1000 x 42 x s²
1000 x 8s

P : 1.42 x 42 x s²
8

P : 8s

With this formula there is no need other calculations to be done to find the pressing strength
( tonnage ).

Length : 2500 mm
Sheet thickness : 2 mm
Strength : 45 kg/mm²
Suitable pressing strength is 2.5 x 8 x 2 : 40 ton

as mentioned at the last sample that a hardness of 40-45 kg/mm² materials required pressing strength
is 2.5 mm.
If the Pressbrake is being used outside its capacity then there will be damage done to the tool and
material.
When the sheet is bended above the strength of 40 kg/mm² then in pratice you will need to 10% to the
value calculated.

DURMAZLAR HAP Page 25 / 45

In harder materials this value is 10 – 12 x s and due to the material hardness the possibility of damage
is prevented.

1° 1.5° 2° 2.5° 3° 3.5° 4° 4.5° 5°

V
mm
6 0.031 0.046 0.061 0.076 0.09 0.106 0.121 0.136 0.151

8 0.041 0.061 0.081 0.101 0.121 0.141 0.161 0.181 0.201

9.5 0.048 0.072 0.096 0.12 0.144 0.168 0.192 0.215 0.239

10 0.051 0.076 0.101 0.127 0.152 0.177 0.202 0.226 0.251

12 0.061 0.091 0.122 0.152 0.182 0.212 0.242 0.272 0.301

13 0.066 0.1 0.132 0.165 0.197 0.230 0.262 0.294 0.327

15 0.076 0.114 0.152 0.19 0.228 0.265 0.302 0.34 0.377

16 0.081 0.122 0.162 0.203 0.243 0.283 0.323 0.362 0.402

: 135°
19 0.097 0.145 0.193 0.241 0.288 0.336 0.383 0.43 0.477
The angle difference
which can occur to the 20 0.11 0.152 0.203 0.253 0.304 0.354 0.403 0.453 0.502
tooling due to the shown 24 0.122 0.183 0.244 0.304 0.364 0.424 0.484 0.544 0.603
V canel opening
25 0.127 0.19 0.254 0.317 0.379 0.442 0.504 0.566 0.628
V
30 0.153 0.23 0.305 0.380 0.455 0.53 0.605 0.679 0.754

32 0.163 0.244 0.325 0.405 0.486 0.566 0.645 0.725 0.804

35 0.178 0.267 0.355 0.443 0.53 0.619 0.706 0.793 0.849

38 0.194 0.299 0.386 0.481 0.577 0.672 0.766 0.861 0.955

40 0.204 0.305 0.406 0.507 0.607 0.707 0.807 0.906 1.005

50 0.255 0.381 0.508 0.633 0.759 0.884 1.01 1.132 1.256

52 0.265 0.4 0.53 0.66 0.789 0.919 1.05 1.178 1.306

55 0.28 0.42 0.56 0.7 0.835 0.972 1.109 1.246 1.382

60 0.306 0.46 0.61 0.76 0.911 1.06 1.21 1.36 1.51

63 0.321 0.48 0.64 0.8 0.96 1.11 1.27 1.43 1.58

70 0.357 0.54 0.71 0.89 1.06 1.24 1.41 1.59 1.76

76 0.387 0.58 0.77 0.96 1.15 1.34 1.53 1.72 1.91

80 0.41 0.61 0.81 1.01 1.21 1.42 1.61 1.81 2.01

100 0.509 0.76 1.0 1.27 1.52 1.77 2.02 2.26 2.51

125 0.637 0.95 1.27 1.58 1.9 2.21 2.52 2.83 3.14

160 0.815 1.22 1.62 2.03 2.43 2.83 3.23 3.62 4.02

200 1.02 1.52 2.03 2.53 3.03 3.53 4.03 4.53 5.02

250 1.27 1.9 2.53 3.17 3.8 4.42 5.04 5.66 6.28

320 1.63 2.4 3.25 4.1 4.9 5.7 6.45 7.25 8.04

400 2.03 3 4.01 5.1 6.1 7.1 8.1 9.1 10

500 2.55 3.8 5.01 6.4 7.6 8.8 10.1 11.3 12.6

630 3.2 4.8 6.4 8 9.6 11 12.7 14.3 15.8

E – 5.1 BENDING DIAGRAM

DURMAZLAR HAP Page 26 / 45

 V H R
0.5 0.8 1 1.2 1.5 1.8 2 2.5 3 3.5 4 4.5 5 6 7 8 9 10 12 15 18 20
6 5 1 2.5 6.5 10
8 6 1.3 2 5 8 11
10 7 1.7 1.5 4 6 9 13
12 9 2 3 5 7 11 16
15 12 2.7 4 6 9 13 16
20 15 3.3 4 7 10 12 19
26 18 4.2 5 7.5 9 14 21
30 22 5 6.5 8 12 19 24
32 23 5.4 7.5 11.6 17 23 30
37 25 5.8 10 14.5 20 26 33

42 29 6.7 13 17 23 29 35.5
45 32 7.5 16 21 27 33 48
50 36 8.3 P 19 24 30 43 58
60 43 10 20 25 36 49 64

70 50 11.5 21 31 42 55 69

80 57 13.5 27 37 48 60 75
90 64 15 32 42 54 66 95
100 71 17 38 48 60 86 134
R
130 93 22 37 46 66 103 149

180 130 30 V 33 48 75 107 133

200 145 33 43 67 97 119
250 180 42 54 77 95

Capacity ( ton )

L: Sheet length (mm) (L = 1000 mm)

R: Internal radius ( mm )

Tensile strength ( kg/mm² )

V: Mould opening ( mm )

P: Needed tonage ( Ton )

H: Min. sheet bending length ( mm )

S: Sheet thickness ( mm )

DURMAZLAR HAP Page 27 / 45

F – ADJUSTMENT OF PARALLELISM ПРИЛАГОЂАВАЊЕ паралелизма

F – 1.1 ADJUSTMENT OF PARALLELIMS AND SHEET BENDING

ПРИЛАГОЂАВАЊЕ паралелизам и савијање лимова ПРИЛАГОЂАВАЊЕ паралелизам и
савијање лима

The machine parallelism system is maintained with a balance pin. The balance pin may not be
sufficient to maintain the parallelism of the machine because of the friction forces which may appear in
front of the hydraulic cylinders , even if they are very little. There fore hydraulic cylinders are designed
with the internal stopper system for the most precise bendings in air dendings.

Машина паралелизам систем одржава равнотежу са ПИН-ом. ПИН стање не може бити довољно
да се одржи паралелизам машине због трења сила које могу да се појаве пред хидрауличних
цилиндара, чак и ако су врло мало. Постоји стога хидраулични цилиндри дизајнирани су са
унутрашње чеп система за најпрецизније бендингс у ваздуху дендингс.

The internal stopper system has in general four great advantages :

DURMAZLAR HAP Page 28 / 45

- easy usage
- precise bending
- easy service
- 0.1 mm precise adjustment
интерни чеп систем је у целини четири велике предности:
- једноставно коришћење
- прецизно савијање
- једноставан сервис
- 0,1 мм прецизно подешавање

The internal stopper system shown in picture 4 consist of the screwnut dual and unites which give
motion to them.

In air bendings , the bending in wanted angle can be made in limiting the cylinder stroke.

интерних чеп систем приказан на слици 4 се састоје од сцревнут дуал и уједињује који дају
предлог за њих.

У ваздуху бендингс, савијања у жељеном угао може бити извршена у ограничавању Ход клипа.

For e.g. we will make a 60° air bending : За пример ћемо направити 60 ° савијања ваздуха:

- First position switch to posiiton “ 2 “ ( machine is on manuel operation )

- The “ V “ mould at the bottom die must be adjust due to the sheet thickness
- After adjustment , start moving top tabler and the sheet pressing begins. Having reached the
wanted bending angle , take position switch to position 2 , press two hand button and the top
tabler goes upwards. Measure the bended sheet’s angle with a degreed set-square. Lets say the
angle is 65°. This means you made 5° closer than the wanted angle. In that case the hydraulic
cylinder stroke must be raised. A stroke adjustment of 0.0 – 0.1 mm can be made by touching the
( - ) 5S5 button on the front operation panel and by looking on the digital. After this process bend
the same sheet again and measure the angle with a degreed set-square. Then we made a closed
bending the angle is 58°. This means the hydraulic cylinder stroke is to much. It can be adjust by
touching the ( - ) 5S5 button on the front operation panel and by looking at the digital. So the
wanted precise bending degree will be reached.

- Прво место бисте се пребацили на посиитон "2" (машина је Мануел рад)

- "В" калуп при дну мора да се прилагоди умре због Дебљина лима
- После прилагођавања, крене врх таблер и лист притиском почиње. Пошто је достигла жељени
угао савијања, да бисте се пребацили положаја у положај 2, притисните дугме и две ручне врху
таблер иде нагоре. Мера савијени лист угао са дегреед скуп-квадрат. Рецимо угао је 65 °. То
значи да је 5 ° ближе него желео угао. У том случају хидраулични цилиндар ударац мора да буде
подигнута. хода од 0,0 - 0,1 мм се може обавити притиском (-) 5С5 дугме на предњем панелу и
рад гледајући на дигитални. Након овог процеса савијања истом листу поново и мери угао са
дегреед скуп-квадрат. Онда смо направили затворена савијања угао је 58 °. То значи да
хидраулични цилиндар удар је много. То може бити прилагодити додиром (-) 5С5 дугме на
предњем панелу и операцију тако што ћете погледати дигитални. Дакле, желео прецизно
савијање степен ће бити постигнут

DURMAZLAR HAP Page 29 / 45

The same measure can be used later for the same bendings. There fore , there is use to write down
the measure on the digital indicator.

- истој мери може касније користити за исту бендингс. Ту Стога, постоји употреба да напишу
мера на дигиталном индикатор.

IMPORTANT NOTE :

The measure of the sheet which will be bend depends on the :

- “ V “ mould wideness
- sheet thickness
- quality of sheet ( St 37 , St 42 etc )

Because of this the measure explained above is suitable for a very sheets same parameter.

- ВАЖНА НАПОМЕНА:

мера лист који ће се савити зависи од:

- "В" калуп ширина
- дебљина лима
- квалитет лима (37 Светог, Св 42 итд)

Због ове мере је горе објашњено је погодан за веома листова исти параметар.

F – 1.2 THE ADJUSTMENT OF DIFFERENT BENDING DEGRESS

Подешавање РАЗЛИЧИТИХ САВИЈАЊЕ ДЕГРЕСС

If you couldn’t have precise bending on left and right sides , you have to make stopper adjustment.
Ако није могао да прецизно савијање са леве и десне стране, морате да направите прилагођавања
чеп.

C VIEW
MIN.LIMIT MAX.LIMIT
SWITCH SWITCH
STOPPER
COUPLING
TOP TABLE
LEFT
CYLINDER

TOP TABLE
C VIEW

DURMAZLAR HAP Page 30 / 45

Firstly , disassembly the stopper coupling by taking off the two bolts. Than regarding to left sides
degree difference , make the adjustment from left cylinder. To do this ;

Прво, растављање чеп спојнице скидајући два вијка. Него у вези са леве стране степена разлике,
направити прилагођавања са леве стране цилиндра. Да бисте то урадили;

- If left side is more open according to right side , make the adjustment by pressing ( + ) plus button
for stopper adjustment on control panel. ( Regarding to degree difference , the adjustment will be too
short or longer. )
Ако се леве стране је више отворен према десној страни, да подешавање притиском (+) плус
дугме за подешавање чеп на контролној табли. (Што се тиче разлике у степену, прилагођавање
ће бити сувише кратка или дуже.)

- If left side is more closed according to right side , make the adjustment by pressing ( - ) minus
button for stopper adjustment on control panel.
Ако је са леве стране је затворен у складу са десне стране, чине подешавање притиском (-)
минус тастер за подешавање чеп на контролној табли.
-

After the adjustment , make test bending on narrow canel of the bottom tool ( 12 ~ 20 mm ) and check
the both sides. Until having the right result , repeat the above instructions when you have the right
result , assembly the stopper coupling with two bolts.
- Након усклађивања, чине теста савијање на уске цанел од дна алат (12 ~ 20 мм) и проверите
обе стране. До имају прави резултат, поновите горње упутства када сте прави резултат,
окупљања чеп спојница са два вијка.

Stopper adjustment is normally for 35 ton hap from 0 to 70 mm , for other tonnages itis between 0 to
120 mm . When limit bar is on minimum switch , digital shows 0 , when it is on maximum switch ,
digital shows 70 mm for 35 ton hap , 120 mm for the other tonnages.

- Чеп подешавање је нормално за 35 тона ХАП од 0 до 70 мм, за друге тоннагес ИТИС од 0 до

120 мм. Када је ограничење Бар је на минимум прекидач, дигитални показује 0, када је на
максимално прекидач, дигитални показује 70 мм за 35 тона ХАП, 120 мм за остале тоннагес.

DURMAZLAR HAP Page 31 / 45

If in any way the parallelism of the machine should be totally changed. Than both cylinder stopper
must be taken upwards to the top position. While the nuts are at the top position take out the coupling,
turn each stoppers motion pin with the help of a tool till the nut in the stopper reach the top point in the
cylinder. Take in the coupling , move the stopper downwards , control all adjustments.

- Ако на било који начин паралелизам машине требало би да буде потпуно промењен. Од оба
цилиндра чеп мора бити горе предузети да највишој позицији. Док ораси су на највишој
позицији извадити спојницу, наизменично сваки заустављачи ПИН кретање уз помоћ алата до
ораха у граничник до врха тачку у цилиндру. Узмите у спојнице, померите надоле чеп, контролу
свих подешавања.

ATTENTION :

1 – The stopper parallelism adjustment is made in the factory. The above noticed , should only be
made incases like ; pin compression , wedge cutting.
2 – All the things explained above should only be made when the hydraulic cylinders are total at the
close posiiton.

On Z axis , there has to be nı movement when top table and top tool are completing their stroke.
There has to be never sliding on Z axis. If there is a sliding , this problem can be solved with eccentric
adjustment.]
ПАЖЊА:

1 - чеп паралелизам подешавање је направљена у фабрици. горе приметио, треба само да буду
инцасес слично; ПИН компресије, клин за сечење.
2 - Све што је горе објашњено да само када хидраулични цилиндри су укупно на крају посиитон.

На З оси, мора да постоји ни кретање када врху табеле и врхунски алат се заврше своје
можданог удара. Мора да постоји никада клизање на З оси. Ако постоји клизне, овај проблем
може бити решен са ексцентричним прилагођавања.

TOP
TABLE
A
BACK VIEW X
TOP
TABLE
TOP
TOOL

Z
BOTTOM
TOOL

BOTTOM
TABLE

DURMAZLAR HAP Page 32 / 45

Firstly , loosen 1 numbered setscrew. Maintain the ‘’ X ‘’ axis easy movement on top table by turning
eccentric pin by auxiliary bolts.
- Прво, отпустите 1 нумерисана сетсцрев. Одржавати''к''оса лако кретање на врху табеле тако
што ћете ексцентрични ПИН помоћних завртњева.

B VIEW

TORSION BAR
TORSION BAR
TOP
TABLE

1
B VIEW

ECCENTRIC PIN

A VIEW

DURMAZLAR HAP Page 33 / 45

 F – 2.1 IMPORTANT NOTE FOR BENDING
ВАЖНА НАПОМЕНА за савијање

DO NOT
TS BEND
X

3/4 TS DO NOT
BEND
X

5/8 TS
RIGHT
BENDING
X X

3/8 TS DRAWING-2

DRAWING-1

Drawing – 1 : Drawing which shows max. tonnage permitted to determine the bending length.

TS : Total sheet length

Drawing – 2 : When you have to make short bendings , as you see on drawing 2 , bend the materials
with equal lengths on each ends of the machine.

- Цртеж - 1: Цртање који приказује мак. тонажа дозвољено да се утврди Дужина савијања.

ТС: Укупна дужина лист

Цртеж - 2: Када сте да се кратко бендингс, као што видите на цртежу 2, савијте материјала
са једнаким дужинама на свакој крајевима машине.

DURMAZLAR HAP Page 34 / 45

 G – MECHANICAL MAINTENANCE and ADJUSTMENT

G – 1.1 THE ADJUSTMENT OF THE TOP AND BOTTOM DIE

TOP TOOL

BOTTOM TOOL

BOTTOM TOOL ADJUSTMENT LAMA BOTTOM TOOL ADJUSTMENT LAMA

X
X

BOTTOM TOOL ADJUSTMENT BOLT

BOTTOM TABLE
BOTTOM TABLE TOP PART

The most important adjustment for precise bending is that both dies are adjust on the exact axis.
- Firstly loosen totally bottom tool adjustment bolt.
- Take bottom die upwards by attaching the bottom adjust chains to the top tool turn bolts.
- The bottom surface of the bottom die and the surface of the bottom die top part must be cleaned
very well.
- Set the bottom die on it’s place.
- The “ V “ mould of the bottom die and the press tip of the top tool must be cleaned very well.
- Place the top tool in a ballanced way in to the bottom die “ V “ mould and make it’s centering
( while position switch is on position 2 ).
- Slightly tighten bottom tool adjustment bolts.
- Take the top tool 5 – 6 mm. upwards.
- The X distance showen on the drawing must be measured with callipers on every point and adjust
by turning the tightening bolts.
- The adjust process must be done on the both side of the machine.

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 G – 2.1 ADJUSTMENT OF BACK GAUGE

max. A
min. B

The front and back movement switch has been limit because of the security for the back gauge
fingers. Especially the front side B minimum value shouldn’t be changed in anyway.

Back gauge finger precise adjustment ; turn 1 numbered special bolt to clock wise direction or
viceversa.

MACHINE NAME A ( mm ) B ( mm )
35 TON HAP 430 10
60 – 120 TON HAP 620 15
160 – 200 TON HAP 620 20
300 – 400 TON HAP 620 25
60 – 300 TON HAP
620 10
( AMADA PROMECAM )

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 G – 3.1 DISTANCE OF STOPPER ADJUSTMENT

A mm

When the top table is at the top dead point the stopper distance is downward to A ( mm ) . In this
suitation the stopper nut bar will not be jammed in the limit of the max. and min. stroke and the pistons
nut will not hit during the fall of the top table.

MACHINE NAME A ( mm )
35 TON HAP 70
60 – 400 TON HAP 120

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 G – 4.1 IMPORTANT NOTE FOR TOP TABLE

It’s possible that the connecting bolt which connects the top tool to hydraulic cylinder may loosen in
time by the effect of high pressure. At that moment , in the connection occurs blanks. So , depending
on working time , this connection have to be checked. At long working period , it’s possible to occur
loose in cover bolts which connects top tool to the top table ( 2 ). So , these bolts have to be checked.
( When the top posiiton power switch is in position 1 and top table is in “ V “ channel , please tighten
the bolts completely. )

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 G – 5.1 MAINTENANCE

1 – As shown on figure F – 4.3 the required lubrication should be done to the metioned parts.
2 – If the machine is being used for a long period of time then the possible rust surfaces needs to be
oiled with protection oil.
3 – The oxide piecs and other part which come form the material during the bending process can stick
on the surface of the top and bottom tool and as a result deform the tooling. For this reason the pieces
should be cleaned.
4 – The coolant fan of the electrical motor can be blocked due to the enviroment dust. This dust must
be cleaned.
5 – As shown on page F – 4.2 the oil for the back gauge and reducer of the stopper system needs to
be changed after 2000 working hours.
6 – The oil of the hydraulic needs to be changed the first 500 working hours and then 2000 working
hours. ( Refer to page B – 1.1 )
7 – The return filter has a sensitivity of 25 micron and in time it can be filled up with particals from the
system. For this reason the filters component needs to be changed every 3000 working hours.
8 – The suction filter inside the hydraulic tank in time can be blocked with particals from the system.
Alot of noise and cavitation can be because of this. Also the pump can be deformed due to the
particals going inside the pump. For this reason when changing the oil the suction filter should be
taken out from its place and cleaned with air and chemical component.
9 – The main valve and secondary security valve on the hydraulic unit is adjusted to the maximum
working conditons at ou factory. Never change these adjustments.

G – 5.2 OIL TYPES USED FOR THE REDUCERS

Reducer Temperature of
Oil Type BP Esso Mobil Shell
Type Environment
- 5 ..... + 40 Energol Spartan Mobilgear Omala Oel
( normal ) GR-XP 220 EP 220 630 220
- 15 ..... + 25 Energol Spartan Mobilgear Omala Oel
Mineral Oil
Helix Gear GR-XP 100 EP 150 629 100
Reducer - 50 ...... - 15 Energol Univis D.T.E. 11 Tellus Oel
SHF 15 J 13 T 15
Synthetic - 25 ...... + 80 Energol Umlauföl Glygoyle Tivela
Oil SG-XP 220 S 220 30 Oel WB
- 5 ..... + 40 Energol Spartan Mobilgear Omala Oel
( normal ) GR-XP 680 EP 680 636 680
- 15 ..... + 25 Energol Spartan Mobilgear Omala Oel
Endless Mineral Oil
GR-XP 220 EP 220 630 220
Screw
Reducer - 50 ...... - 15 Energol Univis D.T.E. 11 Tellus Oel
SHF 15 J 13 T 15
Synthetic - 25 ...... + 80 Energol Umlauföl Glygoyle Tivela
Oil SG-XP 220 S 220 30 Oel WB

NOTE : Special seals should be used with the temperatures of –30 and +60°

G – 5.3 LUBRICATION DIAGRAM

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 3

NR AMOUNT PART NAME PERIOD OIL

1 8 Bearing of the table Every Week Grease
2 2 Torsion bar bearing Every Week Grease
3 1 Hydraulic tank Reduce to oil ISO VG 32 - ISO VG 46
4 2 Back gauge propel shaft Every Week Grease

G – 5.4 OIL LEVEL DISPLAY OF THE HYDRAULIC TANK

At the same time the oil level display of the hydraulic

tank is used as a thermometer. °C °F
The oil must be filled up until it reaches 100°C line. 100
210
Oil must be added in the hydraulic tank when the
90
oil level is below 40°C line. 190
80
170
70
150
60
130
50
110
40
90
30

F – 5.1 PROBABLE DEFECTS TO OCCUR

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If ,
1 – Machine is not working :
- Check the main motor direction.
- Check the emergency stop buttons.
- Check guard security switches.
- Check the hydraulic oil level.
- Check energy supply.
- Check additional functions ( security photocell , hydraulic tool clamping , etc. )
- Check the valve security.
- Check the fuses and contactors inside the electrical panel.

2 – Machine is working , top table has no movement :

- Check the command panel.
- Check the valve sockets.
- Check the working switch locations.
- Check on NC machine , the locations of axis on digital.
- Check the location key is on 2 or 3 positions.

3 – Top table is only fast approaching , no pressing :

- In this condition , if we can take the table up , check the filling valves. ( Check , if oil comes from
thick pipes inside the main tank during pressing. If yes , when machine is off , diassembly the pilot
lines of filling valve and remove the tightness. If again oil comes from the thick pipes , make the
maintenance of front filling valves by disassemblying.
- Check main pressure electrical directional valve. ( electrical connection and sliding bar ) During
pressing , there has to be electrical current. )
- There can be dirt inside the main pressure security valve. ( To clean firstly , loosen seconder
security valve and place top table to bottom table without pressure and tighten this valve to it is
previous location. Than disassemly main pressure securit valve from body with speeral care and
clean it will thinner and compressed air. Check valve sliding bar and spring. )

Caution : Machine has to be absolutely off during these applications.

- Pressure switch might be adjusted to a very low valve.

- Main pressure might be adjusted to a very low valve.
- Machine may not make the leakage test. Make the position key to 2 or 3 , press on the double
hand button , top table falls down to the middle , take off your hands from double hand button and
press it again. Top table goes up.

4 – Top table does not make fast approach :

- If the top table goes down directly with pressing speed ; poppet valve is defective. Dissambly and
check spring sliding bar. )
There can be a problem on poppey valve electrical connection or contact.
- There can be a problem on connections or sliding bar of down movement direction valve.
- There can be a problem on down movement direction valve electrical connection , contact or
security socket.
- Check the machine’s top limit switch location and connection. ( It has to reach top limit swich
limiting part. )

5 – Machine is working , there are bending mistakes :

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- Check if top table is sliding to the left or right after bending. If yes , turn the eccentric bush to the
required direction in torsion bar group. Than make the stopper group adjustment. ( Look at
stopper adjustment )
- Check if the machine is balanced or not.
- Check the tools.
- Check if anti-deflection system is properly adjusted.

6 – Top table does not return back after bending :

- If we can take it up with hand button ; pressure switch may be adjusted to a very high valve. Main
pressure valve may be adjusted to a very low valve.
- Up movement direction valve sliding bar may be stuck.
- There can be a problem on up movement direction valve electrical connection contact or security
socket.
- Pneumatic pressure switch adjustment may be abolished adjustment can be made by turning the
adjustment bolt in undo section to the left or right.

7 – When the machine is in stop position , top table falls down with a very slow speed :
- Check the counter pressure valve. ( For adjustment , when top table goes down with pressing
speed , by locking M2 manometer , make the adjustment from the adjustment section of the
valve.)
- There can be dirt on seconder security , counter pressure and rapid down valves. To clean firstly ,
turn off the machine. Than loosen seconder security valve adjustment section , place top table to
bottom tool without pressure and tighten it to it is preurous location. Disassembly all montioned
valves and clean them with compressed air and thinner. Assembly the valves to their places
again.

8 – Top table speed is too low or too fast :

- Firstly check the adjustment of top table sledges.
- You can decrease the speed of the top table by tightening the adjustment section of the sequeze
valve. To increase the speed of the top table , open the adjustment of this valve.

Caution : To tighten this valve too much or tighten it to the end is dangerous.

9 – Top table speed is too low or too fast :

- Working pressure adjustment valve may be adjusted to a very little valve. İncrease the pressure
from adjustment wheel.
- Readjust the pneumatic pressure switch.

H – DEFLECTION ADJUSTMENT
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 H – 1.1 TOP DEFLECTION ADJUSTMENT ( DURMAZLAR DEFLECTION SYSTEM )

COVER WEDGE
CONNECTION PULLING WEDGE
BOLT BOLT PUSHING
SETSCREW

WEDGE

COVER

TOP TOOL

3050x300 TON HAP

4050x300-400 TON HAP 2 mm
6050x300-400 TON HAP
6050x600 TON CNC HAP
3050
3550 x160-200 TON HAP 1.3 mm COVER
3700 CONNECTION
4050 BOLT
3050x80-120 TON HAP 1.3 mm WEDGE
2050x35 PUSHING
TON HAP 1 mm SETSCREW
2550x60
WEDGE
MACHINE NAME PULLING
BOLT

Cover, wedge, wedge pulling bolt and wedge pushing setscrew has mounted inside of each other and
connected to the top beam with the help of cover connection bolt.

Mount the top tool and tighten cover connection bolts. But loosen the bolts very little not to tighten the
top tool with cover completely.

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Push the wedge with wedge pushing setscrew until touching to the top table. Tighten all the bolts
slightly.

Turn on the machine, down the top beam and pres on the top tool. While the top tool under pressure,
take back the wedge pushing setscrews. Tighten competeley all cover connection bolts, fix the
system. Tighten again all wedge pushing setscrews.

Machine deflection adjustment can be done by forward and backward movement of the wedge. To find
which wedge to adjust, make full lenght bend and according to the angles, find which wedges to
adjust.

For adjustment loosen the setscrews on the wedges. By this way wedge can move when wedge
pulling bolt tightened. After the movement of the wedge, fix it with setscrew.

Again make full length bend and check the angles. Do the wedge adjustment until reaching the
requested angles.

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 H – 2.1 BOTTOM DEFLECTION SYSTEM

The handle on the right side of the machine which has the Wila Deflection Syestem has been adjusted
at our factory.
The deflection increase if the handle is turned opposite of anti clockwise (to the left).
Deflection is decrease if turned anti clockwise (to the right).
SIKO number should be worked between 0 – 100 value. Deflection is given from the value of 0 – 100,
which the middle is 3 mm. (for 3 meter length). The suitable deflection value is done according to the
plate thickness which is going to be used.
Between the top and bottom points of the roll springs should measure 13.4 mm, which are connected
to the bolts of the deflection system. This value is adjusted between the 0 – 100 value, 13.4 mm.
Measurement should be controlled during it’s mainted period.

ATTENTION :
The turning handle has been taken out from it’s place so that damage dosen ’t occur from
transportation. When the machine is in operation place the home handle, which can be done by
placing the setscrew hole with the numered rod holes and tighening it. This way the handle is
stabilised.

Dont adjust while the machine is on pressure. This is the reason for some parts to be broken.
When the crowning is in zero position, the adjustment has to be done as below ;

Connection
A B B B B B Part
Lower beam length Part Nr.1 Part Nr.2 Part Nr.3 Part Nr.4 Part Nr.5 PIECE

2550 - - 13.6 13.5 13.4 10

3050 - - 13.6 13.5 13.4 10
3550 - - 13.6 13.5 13.4 12
3700 - - 13.6 13.5 13.4 12
4050 - 13.7 13.6 13.5 13.4 14
6050 13.8 13.7 13.6 13.5 13.4 20

5 4 3 2 1 1 2 3 4 5
B

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