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I-2

1. SAFETY RULES

Observe these safety rules to prevent injuries and accidents:

a)

Never modify the machine.    If the control circuit or other part of the machine
is modified, the ram may malfunction.

b)

Whenever the machine is not in use, remove the key from the POWER
ON/OFF keyswitch, and hand it to the chief operator for custody.

c)

Assign trained operators to the operation and maintenance of the machine.

d)

Inspect the machine before the start of the day's work.

e)

Install the machine with a rear clearance of at least 1000 mm {40 in.} where
it is not exposed to direct sunlight.    If the electrical equipment of the
machine is overheated as a result, the machine may malfunction.

f )

Before starting the operation of the machine, check that there are no
persons and obstacles around the machine.    Pay particular attention to the
rear of the machine.    Never place hand tools and parts on the installed dies
and the lower beam.

g)

Never put your hand or hands between the punches and dies.

Содержание RG35S-100

Страница 1: ...RG25 125 E02 200510 PRESS BRAKE ZII RG35S 100 OPERATOR S MANUAL...

Страница 2: ...ent injuries and accidents Do not operate the machine by guesswork Keep the manual at hand and refer to it whenever you are not sure of how to perform any of the procedures Printed in Japan Operator s...

Страница 3: ...1 Environmental conditions III 2 1 2 Input power source III 2 1 3 Things to be supplied by customer III 3 2 Installation procedures III 4 2 1 Location III 4 2 2 Lifting III 5 2 3 Foundation III 6 2 4...

Страница 4: ...e dies V 19 7 Other uses V 20 7 1 Adjusting punch holders V 20 7 2 Using one touch punch holders option V 23 7 2 1 Installing and removing punches from front V 25 7 2 2 Installing and removing punches...

Страница 5: ...I 2 2 Maintaining hydraulic system VI 4 2 1 Checking hydraulic oil level VI 4 2 2 Changing hydraulic oil VI 5 2 3 Maintaining tools VI 6 3 Lubrication VI 7 4 Hydraulic circuit diagrams VI 8 4 1 RG35S...

Страница 6: ...vi...

Страница 7: ...I 1 Part I Safety 1 Safety rules I 2 2 DANGER and WARNING plates I 10...

Страница 8: ...ce of the machine d Inspect the machine before the start of the day s work e Install the machine with a rear clearance of at least 1000 mm 40 in where it is not exposed to direct sunlight If the elect...

Страница 9: ...switch to OFF remove the key from the keyswitch and keep it by yourself Never put your hand or hands between the punch and die to support the punch Install and remove the punches as described in 4 Rem...

Страница 10: ...the punch holder levers only in the position B Affix the punch holder lever position sticker in an easy to see place to prevent procedural mistakes POSITIONS FOR OPERATING LEVER AND INSTALLING AND REM...

Страница 11: ...position where the bending speed of the ram is to be changed If this position is not correctly set the worksheet may start to bend unexpectedly l When bending a small worksheet set the stroke length...

Страница 12: ...reference to the Amada genuine punches and dies Non genuine punches and dies are different in brittleness and allowable tonnage from the genuine punches and dies Use of such non genuine tools may cau...

Страница 13: ...one side of the worksheet or otherwise be ready for its springing upward q Before bending each worksheet check that the tools are securely installed and tightened With a sharp bend or U bend the punc...

Страница 14: ...d scatter in a dangerous manner s Whenever trouble occurs during the operation of the machine press one of the EMERGENCY STOP buttons turn the POWER ON OFF keyswitch to OFF remove the key from the key...

Страница 15: ...n off the machine circuit breaker You may receive an electric shock if you touch any parts in the electrical enclosure w Be sure to perform periodic maintenance on the machine For the items of mainten...

Страница 16: ...I 10 2 DANGER AND WARNING PLATES Keep the DANGER and WARNING plates well noticeable and never remove them...

Страница 17: ...ich if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potential...

Страница 18: ...I 12...

Страница 19: ...II 1 Part II Description 1 Functions II 2 2 General view II 3 3 Specifications II 5 4 Dimensions II 6 5 Standard accessories II 9 6 Options II 10...

Страница 20: ...ce in order to keep the upper and lower beams accurately parallel A punch to die clearance setting unit allows the ram stroke length to be set to a required minimum and the working efficiency to be en...

Страница 21: ...speed or stop ram mid stroke BAR PEDAL Knobs and levers required for operation of ram are located HYDRAULIC EQUIPMENT CONTROLS Power distribution and control circuits are built in Power and hydraulic...

Страница 22: ...II 4...

Страница 23: ...at 50 60 Hz mm sec 8 9 5 7 8 5 7 8 5 8 3 10 1 Moving down speed mm sec 40 35 52 52 Number of main cylinders number of auxiliary cylinders 1 1 2 1 2 1 2 Hydraulic pump motor output kW 2 2 3 7 5 5 7 5 H...

Страница 24: ...0 28 0 33 0 28 0 33 0 33 0 40 Moving down speed ips 1 6 1 4 2 0 2 0 Number of main cylinders number of auxiliary cylinders 1 1 2 1 2 1 2 Hydraulic pump motor output HP 3 0 5 0 7 4 10 1 Hydraulic oil t...

Страница 25: ...II 7 4 DIMENSIONS F F 390 mm 15 4 in 225 mm 8 9in 400 mm 15 7 in 60 mm 2 4 in 60mm 2 4in Depth of RG35S RG50 RG80 Depth of RG100...

Страница 26: ...400 60 RG100 3000 2550 1035 370 2305 1555 2110 900 2750 3065 60 1090 250 3445 400 90 Unit in Model A B C D E F G H I J K L M N O P RG35S 47 2 40 2 36 8 14 6 77 58 9 70 9 25 6 36 2 53 3 0 98 17 5 9 8...

Страница 27: ...51 L 13 5 US gal RG50 80 2 Hydraulic oil Super Hydraulic oil 56 Nippon oil 65 L 17 2 US gal RG100 3 Stopper 2 0 ALL 4 Supporter 4 2 ALL 1 RG35S 2 RG50 3 RG80 Size L 830 mm 32 7 in long 75 mm 3 0 in hi...

Страница 28: ...gle One touch punch holders Allow punches to be installed and removed by levers without use of any other tool Dial type punch holders Allow height of punches to be adjusted with dials Double side punc...

Страница 29: ...achine is delivered to you directly from AMADA it is usually transported by the specialized carrier Instruct them where to install the machine Select such a machine installation place where the space...

Страница 30: ...wer the insulation performance of its electric parts becomes This results in the premature degradation of the electric parts Do not install the machine in such a humid place Install the machine in a p...

Страница 31: ...ulated cabtyre cable 380 400 460 V specification Model Each conductor size Current carrying capacity RG35S 9 1 A RG50 2 mm2 13 2 A RG80 3 5 mm2 23 0 A RG100 8 mm2 30 0 A 200 230 V specification Model...

Страница 32: ...dditional space to locate a tool storage case and any other necessary items Space must be available for worksheet loading part unloading machine maintenance and other tasks A space of 1000 mm 40 in or...

Страница 33: ...for layout change for example ask a qualified contractor to perform the work For the mass of the machine refer to Machine mass in the specifications on pages II 5 and II 6 This mass is that of a stand...

Страница 34: ...he like 2 4 Placing Usually fixing the machine with anchor bolts is not necessary Place base plates 150 mm 6 in square and 9 to 16 mm 0 4 to 0 6 in thick steel plates on the foundation and install the...

Страница 35: ...auge depends on the position of the mark on the lower beam as shown below When the mark is placed at the upper front of the ram insert the thickness gauge between the front leveling pin and the stretc...

Страница 36: ...td is delivered with the machine 2 7 Supplying electric power WARNING O Have a qualified electrician perform all electric work to prevent accidents and damage O Before making the electrical connection...

Страница 37: ...ON button The button illuminates and the hydraulic pump motor starts 6 Check the rotation direction of the hydraulic pump motor and immediately press the HYD OFF button The hydraulic pump motor stops...

Страница 38: ...at produces electrical noise Use a welder electric drill sander or grinder at least 10 m 33 ft away from the machine O The type of primary power cable varies with machine model Maintain the supply vol...

Страница 39: ...IV 1 Part IV Controls 1 Controls on electrical enclosure IV 2 2 Controls on upper beam IV 3 3 Hydraulic equipment controls IV 4 4 Other controls IV 6...

Страница 40: ...circuit breaker is turned to ON to supply electric power to the machine 3 HYD ON button Pressed to illuminate itself and start the hydraulic pump motor 4 HYD OFF button Pressed to extinguish the HYD O...

Страница 41: ...rgency stop condition 2 DOWN button Pressed to force down the ram 3 EMERGENCY STOP button or buttons Pressed in an emergency to stop all motions of the machine When pressed and locked the EMERGENCY la...

Страница 42: ...sually keep the knob turned fully clockwise 2 Bar pedal lock lever Not installed on RG35S Used to lock the bar pedal in the fully pressed state when the ram is closed to the multiple closing limit Loc...

Страница 43: ...when the handwheel lock knob is turned fully counterclockwise NOTICE O Do not turn the multiple closing limit setting handwheel counterclockwise with the bar pedal pressed and held Doing so may break...

Страница 44: ...le opening limit or maximum opening limit when the bar pedal is released 2 Pedal stopper Pressed to allow the ram to be operated only by a single operator The bar pedal can be pressed only when a foot...

Страница 45: ...stalling punches V 14 6 Preparing for special bending V 16 6 1 Installing and removing punch holders V 16 6 1 1 Removing punch holders V 16 6 1 2 Installing punch holders V 17 6 2 Installing punches r...

Страница 46: ...7 10 Bending operation V 38 10 1 Setting rising speed change position V 38 10 2 Setting multiple opening limit V 39 10 3 Bending worksheet V 40 10 3 1 Temporarily setting multiple closing limit V 40 1...

Страница 47: ...ction before start of day s work in Part VI 2 PREPARING FOR OPERATION Prepare the machine for operation as described below 1 Turn up the multiple opening limit setting lever to open the ram to the max...

Страница 48: ...V 4 4 Turn the cut off valve knob fully counterclockwise to enable the pressure gauge 5 Turn the pressure adjusting knob fully clockwise...

Страница 49: ...breaker 2 Turn the machine circuit breaker to ON The POWER lamp illuminates 3 Insert the key in the POWER ON OFF keyswitch and turn the keyswitch to ON 4 Push back the bar pedal lock lever except RG35...

Страница 50: ...ols with an assistant operator or operators be sure to coordinate your work with them O Be sure to remove the punches first and then the dies 4 1 Preparing for removing tools Before removing the tools...

Страница 51: ...imit of the ram to a lower position release the bar pedal to open the ram turn the multiple closing limit setting handwheel counterclockwise and press the bar pedal again 6 Release the bar pedal and t...

Страница 52: ...nch in step 1 do not support it from below with your hand as shown below Otherwise you may get your hand or fingers pinched Remove the punches from the punch holders as described below 1 Loosen the fi...

Страница 53: ...moving dies After removing the punches remove the dies from the ram as described below Removing 2V dies Loosen the die fixing bolts and remove the die DIE WASHER BOLT DIE FIXING BOLT 2V DIE DIE HOLDER...

Страница 54: ...ove the die together with the die block NOTICE O The rear clamping plates of the ram and die blocks establish the reference surface for aligning the punches and dies Never loosen them REAR FRONT FRONT...

Страница 55: ...esired position turn the POWER ON OFF keyswitch to OFF remove the key from the keyswitch and keep it by yourself Never put your hand or hands between the punch and die to support the punch When you in...

Страница 56: ...with a clearance of about 5 mm 0 2 in between them REAR REAR STEP FRONT OPERATOR SIDE FRONT OPERATOR SIDE ABOUT 5 mm 0 2 in ABOUT 5 mm 0 2 in NOTE O When using two or more dies install them so as to c...

Страница 57: ...for aligning the punches and dies Never loosen them REAR FRONT FRONT DIE BLOCK CLAMPING PLATES 1V DIE DIE BLOCK RAM CLAMPING PLATES REAR NOTE O Depending on the type of 1V die the tool height and ram...

Страница 58: ...E O When installing sectionalized punches and dies stagger them by about 5 mm 0 2 in as shown right to prevent the worksheet from being scratched PUNCH DIE ABOUT 5 mm 0 2 in 1 Slide the punch into the...

Страница 59: ...able 1 Insert the fall prevention tongue of the punch into the fall prevention groove of the clamping plate or plates as shown lower left and slide the punch into position 2 Tighten the punch holder l...

Страница 60: ...described below 6 1 1 REMOVING PUNCH HOLDERS 1 Remove the punches from the punch holders Refer to 4 Removing tools in this Part 2 Turn the POWER ON OFF keyswitch to OFF and remove the key from the ke...

Страница 61: ...BERS 1 Turn the POWER ON OFF keyswitch to OFF and remove the key from the keyswitch 2 While pushing each punch holder against the upper beam with one hand finger tighten its clamping bolts with the ot...

Страница 62: ...es rearside front WARNING O If you reach between the upper beam and ram to install the clamping plates at the rear of the punch holders you may get your hands pinched Never do so O When you install th...

Страница 63: ...plates at the rear of the punch holders and fasten them with the fixing bolts FRONT 4 Install the punches Refer to 5 Installing tools in this Part 6 3 Installing wide dies With the machine model RG100...

Страница 64: ...the scale marked on the wedge This value serves as a guide when returning the punch holder to the original state 1 Loosen the wedge fixing bolt by about a half turn with an Allen wrench 2 Loosen eith...

Страница 65: ...worksheet of mild steel to an angle of about 90 with a die V groove opening width of 10 mm 0 4 in In this example moving the wedge by one graduation of the scale changes the bend angle by 20 to 30 NO...

Страница 66: ...V 22 6 Actually bend the worksheet to check that the bend angle is uniform 7 If the bend angle is not uniform repeat the procedure from the beginning...

Страница 67: ...on Names of parts REAR CLAMPING PLATE PUNCH HOLDER LEVER FRONT FIXING BOLT FALL PREVENTION MECHANISM PUNCH HOLDER WEDGE FIXING BOLT CLAMPING BOLT CLAMP STOPPER PIN SCALE UNCLAMP STOPPER PIN WEDGE FRON...

Страница 68: ...ned to the position A the punches cannot be installed and removed from the front of the machine Position B Basic lever position Turn the lever to this position to clamp the punches and to install and...

Страница 69: ...hine You cannot safely support it with your hand or hands CAUTION O When installing a punch from the front of the machine push it straight up If the punch is pushed up inclined the clamping plate rema...

Страница 70: ...ckwise to the position A and turn up the unclamp stopper pin 4 After positioning the punch turn the punch holder lever clockwise to the position B to clamp the punch 5 Install the punch as described i...

Страница 71: ...ine You cannot safely support it with your hand or hands 1 Turn down the unclamp stopper pin and turn the punch holder lever to the position C 2 Hold the sides of the punch as shown right and remove t...

Страница 72: ...he rear clamping plate as shown right FALL PREVENTION MECHANISM 2 After positioning the punch turn the rear fixing bolts clockwise with an Allen wrench to clamp the punch 3 Install the punch as descri...

Страница 73: ...n wrench as shown right 2 Remove the punch by sliding it sideways REAR FIXING BOLTS TURN REAR FIXING BOLTS COUNTERCLOCKWISE 7 2 3 INSTALLING AND REMOVING REAR CLAMPING PLATES WARNING O Before installi...

Страница 74: ...m from the rear fixing nuts REAR FIXING BOLT BOLT COLLAR 3 Remove the bolt collars from the front clamping plate lift the punch holder and remove the rear clamping plate Assemble the rear clamping pla...

Страница 75: ...ut anti rotation keyways of the rear clamping plate 2 Insert the springs in the spring seats of the rear clamping plate and position the punch holder as shown right 3 Insert the bolt collars into the...

Страница 76: ...y break and scatter in a dangerous manner After installing the tools align them as described below When you reinstall the dies after removing them together with the die holders align them again 8 1 RG...

Страница 77: ...tools is smaller than the NC9 value set their origin with a pressure smaller than the allowable tonnage 6 Tighten the handwheel lock knob to lock the multiple closing limit setting handwheel 7 Press...

Страница 78: ...oing so will open the ram 1 Turn the POWER ON OFF keyswitch to ON 2 Check that the bar pedal lock lever is not pulled forward If pulled forward push it back UNLOCK BAR PEDAL PUSH BACK BAR PEDAL LOCK L...

Страница 79: ...f the installed tools is smaller than the NC9 value set their origin with a pressure smaller than the allowable tonnage 7 Tighten the handwheel lock knob to lock the multiple closing limit setting han...

Страница 80: ...y press the bar pedal and push back the bar pedal lock lever The bar pedal is unlocked PUSH BACK BAR PEDAL LOCK LEVER 13 Release the bar pedal to complete the tool aligning procedure The ram opens to...

Страница 81: ...tiple closing limit display to the recorded value you can repeat the same bending job 1 With the bar pedal fully pressed turn the multiple closing limit setting handwheel clockwise to apply the pressu...

Страница 82: ...ne varies in the multiple closing limit of the ram To obtain stable bending accuracy warm up the machine by applying a pressure about one third of its press capacity for about 10 min Take care not to...

Страница 83: ...ing lever The rising speed change position is set NOTE O The required press capacity cannot be obtained at any speed other than the bending speed The maximum press capacity cannot be obtained at the a...

Страница 84: ...tops 3 With the bar pedal fully pressed turn the multiple closing limit setting handwheel clockwise to close the ram to such a position that the clearance between the punch nose and die top becomes sl...

Страница 85: ...e installed dies and push it against the stoppers while aligning its center in the left right direction approximately with the center of the ram NOTE O When an uneven load is imposed on the left or ri...

Страница 86: ...e of pressing the bar pedal to stop the ram before the punches contact the worksheet and align the punch nose line with the scribed line 2 With the bar pedal fully pressed loosen the handwheel to unlo...

Страница 87: ...angle is smaller than the desired angle lower the multiple closing limit of the ram set a new worksheet and bend it as described in steps 1 to 6 above CAUTION O Do not turn the multiple closing limit...

Страница 88: ...ar pedal and open the ram to the maximum opening limit NOTICE O When stopping the machine at the end of the day s work turn off its power with the ram positioned at the multiple opening limit Turn off...

Страница 89: ...V 45 4 Turn the machine circuit breaker to OFF The POWER lamp extinguishes 5 Turn off the shop circuit breaker...

Страница 90: ...n Contact AMADA HYD ON button does not illuminate when pressed Shop circuit breaker is turned off Turn it on Pressure adjusting knob is not tightened Turn it fully clockwise Hydraulic pump motor does...

Страница 91: ...red Seal in cylinder is worn Contact AMADA Multiple opening limit is not properly set Set it again as described in 10 2 Setting multiple opening limit in this Part Multiple opening limit of ram cannot...

Страница 92: ...the emergency stop condition as described below 1 Pull the pressed EMERGENCY STOP button 2 If the multiple opening limit of the ram is set turn up the multiple opening limit setting lever to clear th...

Страница 93: ...6 3 Lubrication VI 7 4 Hydraulic circuit diagrams VI 8 4 1 RG35S VI 8 4 2 RG50 RG80 and RG100 VI 10 5 Electric circuit diagrams VI 13 WARNING O Unless you need electric and hydraulic power when maint...

Страница 94: ...or repairing it 5 Ram normally operates Refer to Checking ram for operation on next page If ram does not normally operate contact AMADA 6 EMERGENCY STOP buttons normally operate 1 Remove tools from ma...

Страница 95: ...ng limit and stops NOTICE O To close the ram with the punches and dies installed turn the multiple opening limit setting handwheel fully counterclockwise and fully press the bar pedal 3 With the bar p...

Страница 96: ...c oil tank Remove the filters and clean or change them 2 1 Checking hydraulic oil level Open the ram to the maximum opening limit turn the POWER ON OFF keyswitch to OFF and check that the hydraulic oi...

Страница 97: ...e maximum opening limit 2 Press the HYD OFF button The HYD ON button extinguishes and the hydraulic pump motor stops 3 Turn the POWER ON OFF keyswitch to OFF 4 Remove all bolts fixing the two top cove...

Страница 98: ...n a soft protective material like wood Apply rust preventive grease or machine oil to the tools and take constant care to prevent them from rusting If the same portions of the tools are repeatedly use...

Страница 99: ...ine O Post a sign to inform other workers that the machine is under maintenance Lubrication is very important to maintain bending accuracy and avoid machine troubles Be sure to appropriately lubricate...

Страница 100: ...VI 8 4 HYDRAULIC CIRCUIT DIAGRAMS 4 1 RG35S...

Страница 101: ...ulic pump 1 003 Hydraulic filter 1 004 Main cylinder 1 005 Distributor 1 006 Sequence valve 1 007 Multiple closing limit valve 1 008 Check valve 1 009 Check valve 1 010 Check valve 1 011 Cut off valve...

Страница 102: ...VI 10 4 2 RG50 RG80 and RG100...

Страница 103: ...draulic filter 3 3 3 004 Main cylinder 1 1 1 005 Auxiliary cylinder 2 2 2 006 Distributor 1 1 1 007 Solenoid valve 1 1 1 008 Multiple closing limit valve 1 1 1 009 Check valve 1 1 1 1 010 Check valve...

Страница 104: ...VI 12...

Страница 105: ...VI 13 5 ELECTRIC CIRCUIT DIAGRAM Maximum opening limit Multiple closing limit Ram up down Ram maximum opening limit Ram maximum opening limit...

Страница 106: ...VI 14...

Страница 107: ...utton switch 1 SB2 Pushbutton switch with lamp 1 9 SB3 4 5 Pushbutton switch push pull type 3 SQ1 2 Limit switch 2 SQ4 Limit switch 1 SQ9 31 Limit switch 2 10 SQ43 Limit switch 1 HL1 Indicator lamp 1...

Страница 108: ...VI 16 No Symbol Name Qty TB1 Panblock terminal 7 TB2 Panblock terminal 35 TB3 Panblock terminal 3 17 TB4 Panblock terminal 3...

Страница 109: ......

Страница 110: ...AMADA COMPANY LTD 200 Ishida Isehara Kanagawa JAPAN Printed on recycled paper...

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