APK 101 Profile and Pipe Bending Machine: Comprehensive User Manual

Mac-Tech Contact Information

If you have questions about this machine or need assistance, please contact Mac-Tech:

Address: 11100 W Cleveland Ave, West Allis, WI 53227
Phone: +1 (888) 899-3237
Email: info@mac-tech.com
Website: mac-tech.com

1. Warranty

The warranty is valid for a period of 12 months.
This warranty covers the replacement or repair of parts that fail due to defective materials or workmanship.
Transport, travel, and labor costs for parts that require renewal or repair are not covered by this warranty.
Any modification to the machine without written permission or damage caused by misuse will void the warranty.
This warranty does not cover damage or costs resulting from negligence, improper usage, or modifications made without the manufacturer’s written approval.
The warranty does not cover parts subject to normal wear under regular operating conditions.
The warranty is invalid if the machine is used for operations other than those for which it was designed.

Note: For any operating or repair problems, you may contact Mac-Tech (see above).

2. Technical Specifications

Shaft Diameter: Ø100 mm
Roll Diameter: Ø315 mm
Machine Speed: 5 m/min
Machine Weight: 2080 kg
Working Voltage (3 Phase): 380/415 V
Frequency: 50 Hz
Motor: 11 kW
Max Current: 25 A
Conductor Cross Section: 5×6 mm² (minimum)

2.1 Standard Accessories

Steel (St-52) machine body construction
Rolls driven by hydraulic motor, planetary gearbox, and gears
Shafts made of special steel, hardened and ground
Manually adjustable side guide rolls
Suitable for horizontal or vertical operation
Electrical and hydraulic overload protection
Digital display for bottom rolls
Independently movable lower rolls (up/down)
Movable control panel (remote operation)
CE-compliant

2.2 Special Accessories

Customized profile rolls for pipe, profile, and angle materials
Spiral bending device
Variable rotation speed
Two-direction, hydraulically adjustable guide rolls
Mechanical guide rolls for angle bending
Digital readouts for guide rolls
NC playback control system
CNC graphic control system
Various voltage and frequency options for the electric motor

2.3 Main Dimensions of the Machine

Refer to the dimensional drawings provided with your machine or consult Mac-Tech for more information.

3. Safety Factors

3.1 Possible Dangers

The APK 101 Profile and Pipe Bending Machine is equipped with protective guards. Gears and electrical components are covered. However, the bending area around the rolls remains a potential hazard if the machine is used incorrectly or if the operator is not careful.

Important: Never bend materials outside the intended specifications (e.g., extremely hard or thick materials) without verifying machine capacity. Modifications to the machine are strictly prohibited unless authorized in writing by the manufacturer.

3.2 Machine Function

The APK 101 can bend various shapes into circular or curved forms, including:

Channels (moldings)
Sheet metals
Square and round bars
Pipe, tube, and angle materials
T profiles, NPU, NPI, brass, stainless steel, etc.

For very thick or high-strength materials, multiple bending passes may be required.

3.3 Working Area Requirements

When positioning the machine:

Choose a stable, flat floor capable of supporting the machine’s weight (2080 kg).
Maintain adequate clearance on all sides, especially at the rear and in front, to accommodate the maximum length of material being bent.
Keep bystanders and unauthorized personnel away from the immediate bending area. Use caution signs or barriers as needed.
Ensure the workspace remains free of debris, tools, or obstacles that could cause tripping or accidents.

These guidelines apply whether the machine is used vertically or horizontally.

Side supports and spiral bending devices must be properly installed and used according to the manual.
Use only approved accessories and rolls.
Ensure large or long workpieces have sufficient support to prevent tipping or shifting.

Warning: Never place unapproved items or accessories on the machine.

3.5 Noise Emissions

When operated at normal capacity, the noise level should remain below 70 dB.

3.6 Danger Zones

Pinch points around the rolls can trap fingers, clothing, or tools.
Maintenance must only be performed with the machine turned off and properly locked out from the power source.
Never remove protective guards or covers while the machine is running.

Emergency Stop: In any hazardous situation, press the Emergency Stop button immediately.

3.7 Working Positions

Main Operator Position: In front of the machine, with the control panel within easy reach.
Assistant Position (if any): At a safe distance, never in the path of moving material.

Caution: Do not insert or adjust material when the rolls are moving.

3.8 Qualified Operators

Personnel under 16 years of age are not permitted to operate this machine. Operators must:

Read and thoroughly understand this User Manual.
Be trained and authorized.
Contact Mac-Tech if they have any doubts or questions.

3.9 Operator Protective Measures

Under normal operation, no special protective devices are needed beyond the machine’s existing guards. However, operators and maintenance personnel should wear:

Safety shoes (steel-toed)
Protective gloves (especially when handling sharp or hot materials)
Eye protection if there is any risk of flying debris (e.g., from cutting or grinding nearby)

For machine repairs, keep a stocked toolbox that includes screwdrivers, wrenches, and lubrication supplies.

3.10 Machine Assembly Safety

Place the machine only on a solid, level floor.
Verify the floor can withstand the machine weight.
Keep the work area free of clutter.

3.11 Emergency Procedures

In any emergency, press the Emergency Stop button on the control panel to halt all machine functions instantly.

3.12 General Safety Warnings

Operate this machine in an indoor, dry environment away from flammable or explosive materials.
When leaving the machine, switch the main power to the OFF position.
The manufacturer assumes no liability for damage caused by unauthorized modifications or substitutions of machine parts.

4. Protection Features

The APK 101 is equipped with:

Protective covers over gears and electrical components
Circuit breakers and thermal overload relays in the electrical panel
Emergency Stop button(s)
Indicator lights for motor and oil temperature (if applicable)

Operators must never remove or disable these safety devices.

4.1 Safety Equipment Checklist

Before each shift or operation, check the following:

Protective Covers: Are they all in place and secured?
Circuit Breaker: Is it functioning correctly (switches power off when tripped)?
Indicator Lights: Are they working (power light, thermal overload light)?
Emergency Stop Button: Does it engage and cut power immediately?
Displays: If your machine has digital or NC/CNC systems, ensure they power on correctly.
Control Buttons: Forward/Reverse/Up/Down – test for proper response.
Labels and Warnings: Are they legible? Replace them if worn.
Power Cable: Inspect for damage or wear.
Control Panel Cable: Check for damage or wear.
Hydraulic Oil Level: Confirm it is within the proper range.
Lubrication Points: Ensure bearings and gears are lubricated as specified.

4.2 Shipping Damage

Upon receipt, inspect the machine for any shipping damage. If damage is found:

Note it on the transport company’s delivery receipt.
Notify the carrier and Mac-Tech immediately.

5. Machine Assembly

5.1 Transporting and Lifting the Machine

Lift the machine only with a suitable crane and lifting straps rated for at least 2080 kg.
Do not attempt to lift the machine with a forklift from underneath—this may damage its components.

Important: The manufacturer is not responsible for damages caused by improper lifting or handling.

5.2 Unpacking

Remove any plastic wrap or protective covering.
Check for physical damage sustained during shipping.
If damage is observed, do not discard the packaging; document the damage and contact the transporter and Mac-Tech.

Caution: Keep children away from packaging materials (plastics, chemical coatings, etc.).

5.3 Environmental Considerations

Place the machine away from sources of metal dust, chips, or vibrations (e.g., near forging hammers).
Avoid placing it next to equipment that induces significant vibration.
Keep the area around the machine clean and free of excess dust.

5.4 Cleaning Protective Coatings

Certain parts are coated with protective oil or grease to prevent rust. Wipe these surfaces with a clean cloth moistened with a mild solvent (e.g., diesel or approved cleaning fluid).

5.5 Leveling the Machine

For optimal performance and to reduce wear:

Use a level with at least 0.04 mm sensitivity.
Place the level on the machine table or a known flat reference surface on the machine.
Re-check levelness after 24 hours and at regular intervals (monthly or yearly, depending on usage).

6. Operating the Machine

6.1 Electrical Connections

Warning: All electrical connections must be performed by qualified electricians.

Verify the power supply matches the machine’s required specifications (voltage/frequency).
Connect the incoming power cables (L1, L2, L3, N, and PE) to the machine’s main electrical panel.
Secure all connections firmly.

6.2 Connecting the Control Panel

Position the control panel in a convenient location for the operator.
Insert the control panel cable plug into the corresponding socket on the machine.

6.3 Checking Motor Rotation Direction

After completing electrical hookups:

Turn the main circuit breaker to the ON (1) position.
Verify the Emergency Stop button is disengaged.
Press the Start button on the control panel.
Observe the rotation of the machine’s rolls. Check that it matches the directional arrows on the machine (if provided).

If rotation is incorrect, press Emergency Stop, shut off the main power, and swap any two phases (e.g., L1↔L2) at the main connections.

If the machine fails to start at all, check:
The Emergency Stop button is released.

Thermal overloads or circuit breakers have not tripped.

6.4 Control Panel (Standard) Overview

A typical standard control panel includes:

Power Switch (0/1)
Emergency Stop button
Forward/Reverse rotation buttons or foot pedal
Up/Down movement controls for the lower rolls
Digital Display for roll positions (if included)
Indicator Lights (e.g., power on, hydraulic oil temperature)

6.5 Optional Control Panel: Hydraulic Side Support

If your machine features hydraulic side guides:

Additional Toggle or Joystick Switches to raise/lower or move side supports in/out hydraulically.
Digital or LED Indicators to display side support positions.

6.6 Optional Control Panel: Digital Displays on Side Supports

Digital Readouts to precisely measure side guide positions.
May include incremental and absolute measurements to repeat bend settings accurately.

6.7 Lubrication Before Operation

Before starting daily operations:

Lubricate all points indicated in the lubrication diagram (shafts, bearings, gears, and other moving parts).
Use recommended lubricants and the correct grease/oil guns.
Wipe off any excess lubricant to prevent slipping hazards.

6.8 Filling Hydraulic Oil

Caution: The machine is shipped without hydraulic oil. Operating without filling the hydraulic system will cause severe damage.

Required Volume: 140 liters (approximately).
Recommended Hydraulic Oil Types:
- For operating temperatures -20°C to +30°C: ISO VG 32
- For operating temperatures +20°C to +50°C: ISO VG 68
(Brand examples: Shell Tellus, Total Azolla, BP Energol, Elf Hydrelf, etc.)
Change Interval: Replace hydraulic oil after 2000 working hours.
Check for Air in Lines: After filling, run the pump briefly to remove any trapped air, and recheck the oil level.
Oil Level Monitoring: A temperature/level indicator (often a yellow lamp) will warn if oil overheats or is too low.

Transmission Oil in gearboxes should also be checked and changed according to the manufacturer’s specifications (usually every 2000 hours).
Grease gear teeth lightly every 500 hours to reduce wear.

7. Usage Guidelines

Before operating the machine, ensure you have read this manual thoroughly. The manufacturer is not responsible for damage resulting from improper usage.

7.1 General Operation

The APK 101 Profile and Pipe Bending Machine can form curves and circles in:

Channels, angle irons, square/round bars
Tubes, pipes, rectangular profiles
NPU, NPI, T profiles
Other materials within the machine’s capacity

7.2 Selecting Material for Bending

Choose material within the specified capacity to avoid damaging the machine.
Ideally, material should be straight, rust-free, and clean.
Avoid bending severely bent or twisted stock to maintain consistent results.
For very thin-walled materials, consider using filler materials (e.g., sand) or specialized rolls to prevent collapse.

7.3 Using the Top Rolls

Each machine is supplied with 12 roll segments (a set) for various standard profile shapes. Correct placement of these roll segments is essential for achieving accurate bends.

7.4 Roll Positioning

Rolls must be arranged to suit the profile or shape being bent. Overloading or improper roll setup can cause accidents or damage. When bending custom or large-diameter parts, consider ordering specialty roll sets from the manufacturer or Mac-Tech.

7.5 Basic Bending Procedure

Insert Material between the rolls with minimal pressure.
Adjust Lower Rolls by moving them upward using the hydraulic controls until the material is snugly held.
Apply Pressure gradually, checking the bend radius with a template if necessary.
Rotate the rolls forward or reverse, passing the material through multiple times until the desired bend radius is achieved.
Monitor the Digital Readout (if provided) for repeatable results.

7.6 Spiral Bending

Cut a test piece matching the approximate circumference needed.
Use side guide rollers (standard or hydraulic) to maintain the spiral pitch.
Adjust the lower rolls and side guides incrementally.
For very long spiral sections, use support stands to prevent material sagging.
Horizontal operation can be advantageous for larger diameters.

7.7 Basic Bending Steps

Refer to Control Panel for rotation direction (Form 1 in original diagrams).
Position Material straight between rolls (Form 2).
Adjust Lateral Rolls (B1, B2 as indicated in the diagrams) to compress the material toward the desired diameter (Form 3).
Check the Bend with a template or by measuring. Adjust further if necessary (Form 4).
Use Lubrication for hard materials to prevent scoring or friction marks.

7.8 Vertical Bending for Channel (Molding) Material

Form 1: Shows maximum dimensions for bending large diameters.
Form 2: Shows minimum dimensions for tighter bends.

Follow recommended roll configurations to prevent channel deformation.

7.9 Bending Plate Material

Plates can be bent horizontally by using side guide rolls to support the plate.
Secure the plate firmly between the rolls before applying bending force.

7.10 Bending Square Cross-Section Material

Form 1 & 2: Illustrate roll setups for large or small diameter bends.
Form 3: Shows special rolls that may be required for certain square dimensions.

7.11 Bending Round Cross-Section Material

Form 1 & 2: Standard roll positioning for larger or smaller diameters.
Form 3: Special rolls may be necessary for continuous production or for specific diameters.

7.12 Bending Pipe Material

Use special pipe rolls when needed (thin-walled or stainless pipes often require non-marking rolls such as Delrin or Kestamid).
Overly tight bends on thin-walled tubes may cause flattening or wrinkling.

7.13 Bending Rectangular Cross-Section Material

Thicker-walled rectangular profiles can often be bent with standard rolls.
Thin-walled profiles are prone to collapse if not supported properly.
Filling tubes with sand or using specialized rolls can reduce deformation.

7.14 Bending Angle Iron (Outside)

Position the angle iron with the outer corner facing down to match the roll grooves.
Adjust side support rollers lightly, then gradually increase pressure to maintain correct alignment.
Special roll sets may improve results and prevent wrinkling.

7.15 Bending Angle Iron (Inside)

Install standard or special rolls that match the inside bend requirement.
Secure the angle so that the inner corner aligns with the roll gap.
Apply pressure and adjust side guides to prevent twisting.

7.16 Bending T-Iron (Special Rolls)

Different setups are required for inside-wing or outside-wing bending.
Ensure the T profile is centered to avoid uneven bending forces.

7.17 Bending NPU Section

Inside Wing or Outside Wing bending typically requires specialized roll grooves.
Use caution with thin flanges to avoid crimping.

7.18 Bending INP Section

Follow similar guidelines as NPU.
Check that the beam’s web and flanges are adequately supported.

8. Adjusting the Side Guides

Two side guide rollers help keep the material square:

Manual Adjustment (Standard): Use a wrench or key to move each guide roller in or out.
Hydraulic Adjustment (Optional): Operate the side guides using dedicated control panel switches or joysticks.

Warning: Do not overload side guides by forcing them into heavy work without first positioning the material properly.

9. Horizontal Position Operation

The APK 101 can be operated vertically or horizontally. To switch to a horizontal setup:

Securely tilt or rotate the machine according to the mounting instructions, ensuring the frame is braced or anchored.
Re-level the machine if necessary.
Confirm that all controls, hoses, and cables are safely routed.

Caution: Incorrect horizontal setup can cause tip-over accidents. Always consult Mac-Tech if unsure.

10. Spare Parts

Below are general references for spare parts groups. For detailed part numbers and ordering, contact Mac-Tech.