118914-HDS-NT Mecha Ope Us-E04-201108

PRESS BRAKE
HDS 5020/8025/1030/1303/1703/
2203/2204/3504/5006
OPERATOR'S MANUAL
This product comes standard with:
• Circuit Diagrams
• Two Operator’s Manuals
HDS-NT MECHA OPE US-E04-201108

PREFACE Read this manual carefully to obtain a thor-
ough knowledge of machine operation and maintenance.
Be sure to follow the instructions to ensure proper proce-
dures and prevent 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 per-
form any of the procedures.
For the operation of the AMNC-PC, refer to its own
operator’s manual.
This manual classifies the hazardous situations into the

following levels:
Indicates an imminently hazardous
DANGER situation which, if not avoided, will result
in death or serious injury.
Indicates a potentially hazardous

WARNING situation which, if not avoided, could
result in death or serious injury.
Indicates a potentially hazardous

CAUTION situation which, if not avoided, may result
in minor or moderate injury.
NOTICE Indicates a potentially hazardous

situation which, if not avoided, may result
in damage to the machine and tooling.
NOTE Indicates not a warning but an item of

information which should be known to
work.
Operator's Manual:
Press Brake HDS NT Series
© 2011 by AMADA CO., LTD.
No part of this publication may be photocopied or otherwise reproduced with-
out the prior written permission of AMADA CO., LTD.
Aug. 2011
ii Printed in Japan
CONTENTS
Part I Safety.................................................................................... I-1

1. Safety rules ............................................................................ I-2
2. DANGER, WARNING and CAUTION plates ........................ I-10
3. Important notice .................................................................... I-12
Part II Description.......................................................................... II-1

1. Functions ...............................................................................II-2
2. General view of machine .......................................................II-3
3. Components in electrical enclosure.......................................II-5
4. Specifications .........................................................................II-7
4-1. Machine...........................................................................II-7
4-2. Numerical controls ..........................................................II-9
4-3. Standard NC functions ...................................................II-12
5. Composition of axes .............................................................II-13
5-1. Coordinate system of operating axes ............................II-13
5-2. Coordinate system of each axis.....................................II-14
6. Backgauge ............................................................................II-16
6-1. Changing stopper fingers...............................................II-16
6-2. Coordinate system of optional stepped
stopper fingers ...............................................................II-18
6-3. Setting up detachable stationary stoppers (option)........II-19
6-3-1. Installing detachable stationary stoppers ................II-19
6-3-2. Removing detachable stationary stoppers ..............II-22
6-4. Worksheet overhang ......................................................II-24
7. Dimensions of machine ........................................................II-25
8. Standard accessories............................................................II-29
8-1. Machine..........................................................................II-29
8-2. Numerical controls .........................................................II-32
(Continued on next page.)
iii
Part III Installation.......................................................................... III-1
1. Summary ...............................................................................III-2
1-1. Environmental conditions................................................III-2
1-2. Power supply ..................................................................III-2
1-3. Installing machine ...........................................................III-3
2. Location .................................................................................III-4
3. Carrying .................................................................................III-5
3-1. Using a crane..................................................................III-5
3-2. Using rollers ....................................................................III-6
4. Foundation.............................................................................III-7
5. Cleaning................................................................................III-17
6. Supplying hydraulic oil ..........................................................III-18
7. Removing shipping brackets.................................................III-19
8. Installing stopper fingers.......................................................III-22
9. Moving rear guard.................................................................III-23
10. Supplying electric power.....................................................III-24
10-1. Connecting power cable ..............................................III-24
10-2. Checking wiring connections .......................................III-25
11. Zero returning .....................................................................III-26
12. Leveling ..............................................................................III-26
13. Paralleling upper and lower beams ....................................III-27
14. Checking movement of each axis.......................................III-28
15. Making final checks ............................................................III-29
Part IV Controls & Operation ........................................................IV-1

1. Controls on pendant control box........................................... IV-3
2. Controls on electrical enclosure ........................................... IV-6
3. Foot pedals ........................................................................... IV-8
4. Turning on power .................................................................. IV-9
5. Setting up modular tooling system ...................................... IV-10
5-1. Setting origin of each axis............................................. IV-10
5-1-1. Zero-returning all axes ........................................... IV-11
5-1-2. Setting tool origin ................................................... IV-12
5-2. Installing tools ............................................................... IV-14
5-2-1. When tool layout is set ........................................... IV-15
5-2-2. When tool layout is not set ..................................... IV-21
iv
5-3. Removing tools ............................................................. IV-25
5-3-1. When tool origin is set for tools
installed on machine .............................................. IV-25
5-3-2. When tool origin is not set for tools
6. Setting up one-touch punch holders (option)....................... IV-29
6-1. Setting origin of each axis............................................. IV-29
6-1-1. Zero-returning all axes ........................................... IV-30
6-1-2. Setting tool origin.................................................... IV-31
6-2. Installing tools ............................................................... IV-33
6-2-1. When tool layout is set ........................................... IV-34
6-2-2. When tool layout is not set ..................................... IV-43
6-3. Removing tools ............................................................. IV-50
6-3-1. When tool origin is set for tools
6-4. Other uses..................................................................... IV-54
6-4-1. Name of each part.................................................. IV-54
6-4-2. Punch holder lever positions .................................. IV-55
6-4-3. Installing and removing punches from front ........... IV-56
6-4-4. Installing and removing punches by sliding them
along groove of rear clamping plates ..................... IV-59
6-4-5. Installing and removing rear clamping plates......... IV-60
7. Bending speed of ram.......................................................... IV-63
7-1. Bending speed of 20 mm/sec (0.787 ips)
(HDS5020 to HDS2204) ............................................... IV-63
7-1-1. Bending speed for repeat processing program
created on another press brake model .................. IV-63
7-1-2. Initial value of bending speed
(slowdown speed SF) ............................................ IV-63
7-2. Relationship between bending speed and
bend angle .................................................................... IV-64
7-3. Speed change position of ram ...................................... IV-64
8. Setting speed of each axis................................................... IV-64
9. Turning off power ................................................................. IV-66
9-1. When tool origin is set for tools installed on machine ... IV-66
9-2. When tool origin is not set for tools
installed on machine ..................................................... IV-68
10. Crowning control of machines with two C-axes
(only for HDS3504 and HDS5006) ..................................... IV-69
v
Part V Maintenance........................................................................V-1
1. Inspection before start of day’s work .....................................V-2
2. Maintaining hydraulic system.................................................V-3
2-1. Checking hydraulic oil levels...........................................V-3
2-2. Changing hydraulic oil.....................................................V-4
3. Lubrication .............................................................................V-6
3-1. Guide rollers....................................................................V-6
3-2. Backgauge ......................................................................V-7
3-3. Pins of lower beam (only for HDS5006) .........................V-9
4. Changing relays....................................................................V-10
5. Cleaning heat exchanger...................................................... V-11
6. Using ram lock ......................................................................V-12
7. Fee-based consumable parts list..........................................V-13
Appendix .............................................................................................A-1
1. Noise and vibration data ........................................................A-2
2. Emergency stop time and inertial drop distance of ram ........A-3
3. Material safety data sheets....................................................A-4
3-1. Amada Grease EP No.2..................................................A-4
3-2. Amada NCA-250 .............................................................A-8
3-3. Shell Alvania EP Grease 1, 2, R0, R00, & R000 ...........A-12
3-4. THK AFB-LF Grease......................................................A-18
3-5. THK AFC Grease ...........................................................A-20
vi
Part I
Safety
1. Safety rules ..................................................................................I-2

2. DANGER, WARNING and CAUTION plates ..............................I-10
3. Important notice ..........................................................................I-12
I-1
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 and backgauge may malfunction.
b) Whenever the machine is not in use, remove the keys of the selector
switches, and hand them 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 rear air inlet and outlet openings
are obstructed and 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.
I-2
h) When changing the tools, strictly observe the following rules:
• Before installing and removing the

dies, turn the MODE SELECT
keyswitch to OFF, remove the key
from the keyswitch, and keep it by
yourself. (Install and remove the dies
as described in “5. Setting up modular
tooling system” or “6. Setting up
one-touch punch holders (option)” in
Part IV.)
• Before installing and removing the

punches, turn the HANDWHEEL to
close the ram to the desired position,
turn the MODE SELECT 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. (Install and remove the
punches as described in “5. Setting up
modular tooling system” or “6. Setting
up one-touch punch holders (option)”
in Part IV.)
• Securely fix the punches, dies, and die

holders before applying pressure to
them.
• When you install and remove the tools

with an assistant operator or
operators, be sure to coordinate your
work with them.
I-3
• Never put your hands between the
punches and dies to support a punch,
for example.
• When you install a tool by sliding it

sideways, take care not to get your
hand pinched between it and another
tool already installed.
• When applying pressure to the

punches or bending the worksheet,
turn the punch holder levers to
“Position ◯B ”.
• Install or remove the punch holder

levers only in “Position ◯
B ”.
i) When you bend worksheets with an assistant operator or operators, you

must press the foot pedals after fully ensuring the safety of all of them.
I-4
j) Before adjusting the backgauge, turn the MODE SELECT keyswitch to
OFF, remove the key from the keyswitch, and keep it by yourself. Be sure
to adjust the backgauge from the rear of the machine.
k) Correctly set the position where the closing 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 of the ram to 6 mm (0.24
in.) or less, and hold the worksheet as shown on the next page. Take care
not to get your fingers pinched between the punches and dies or between
the punches and worksheet. For how to set the stroke of the ram, refer to
the separate operator’s manual of the AMNC-PC Bender.
6 mm
(0.24 in.)
or less
I-5
Hold the worksheet as shown below.
m) Push the worksheet against the stoppers of the backgauge after the
backgauge is properly positioned. Otherwise the worksheet may be
pushed forward when the backgauge moves forward.
n) Use Amada genuine punches and dies on the machine. The machine
performs various controls by 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 cause various troubles and detract from safety of
the machine.
o) Apply to the installed tools a pressure

that is not higher than the allowable
tonnage marked on them. Unless a
proper pressure is applied to them, the
tools may break and scatter in a
dangerous manner.
When 2V-dies are used, use the
V-groove toward the rear of the
machine for additional safety from
breakage.
I-6
p) A tool may break and fly off if you
apply a force greater than its
maximum tonnage to the tool. To
minimize this risk, it is recommended
to use Amada genuine tools stamped
as shown right.
q) When bending a large worksheet, be careful of its springing upward. Hold

one side of the worksheet or otherwise be ready for its springing upward.
r) Before bending each worksheet, check that the tools are securely installed
and tightened. With a sharp bend or U-bend, the punches and dies may
eat into the worksheet and fall together with the worksheet.
I-7
s) When rebending the same worksheet, align the nose line of the punches
with the bend line of the worksheet. If the worksheet is rebent without
aligning the lines, abnormal noise may be produced, and the tools may
break and scatter in a dangerous manner.
t) Whenever trouble occurs during the operation of the machine, press one of
the EMERGENCY STOP buttons, turn the MODE SELECT keyswitch to
OFF, remove the key from the keyswitch, keep it by yourself, and fix the
problem. When picking a worksheet that has fallen into the machine, be
sure to do so from the rear of the machine. As soon as the machine
develops trouble, report it to the chief operator.
u) Before walking away from the machine, turn the MODE SELECT keyswitch
to OFF, remove the key from the keyswitch, and keep it by yourself.
v) Before opening the electrical enclosure, be sure to turn off the machine
circuit breaker. You may receive an electric shock if you touch any parts in
the electrical enclosure.
I-8
w) Be sure to perform periodic maintenance on the machine. For the items of
maintenance to be performed, refer to Part V, Maintenance.
x) Before maintaining or cleaning the machine, turn off the shop circuit
breaker, relieve the residual hydraulic pressure in the machine, and post a
sign to inform other workers that the machine is under maintenance. Also
relieve the residual pneumatic pressure in the machine when the optional
pneumatic device is installed.
y) When relocating the machine, ask AMADA about how to move the machine.
If moved incorrectly, the machine may turn over.
z) Do not climb on the electrical enclosure or machine. If you apply your

weight in a wrong place, the electrical enclosure or machine may be
damaged. If it is necessary to climb on the electrical enclosure or machine,
ask AMADA to do so.
aa) The hydraulic oil level is monitored by the machine. Given the risk of
falling, do not climb onto the machine for maintenance or adjustment. Ask
AMADA to fill or change the hydraulic oil. Filling or changing of the
hydraulic oil is the fee-based service.
ab) When installing a light curtain on the machine, observe the specified safety
distance.
Light reflection may cause false detection. Do not place light reflecting
objects below the light source of the light curtain.
I-9
2. DANGER, WARNING AND CAUTION
PLATES
Keep the DANGER, WARNING and CAUTION plates well noticeable, and never
remove them.
I-10
Hazard seriousness level
Indicates an imminently hazardous situation
DANGER which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation

WARNING which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation

CAUTION which, if not avoided, may result in minor or
moderate injury.
I-11
3. IMPORTANT NOTICE
AMNC-PC Control for HDS-NT and FBD-NT series press brakes.
This machine is controlled by a PC-based CNC unit. Modification or

installation of hardware or software other than recommended by AMADA
may cause the machine to malfunction and present the possibility of a
serious accident that could damage the machine or cause personal injury.
Read and strictly adhere to the following instructions and precautions:
1. NEVER hook up a KEYBOARD or MOUSE unless instructed to do so by

qualified AMADA personnel.
2. NEVER install or change any hardware in the electrical enclosure unless
instructed to do so by qualified AMADA personnel. This includes but is not
limited to:
• Memory boards • SCSI cards • PC cards
• Hard disk drives • CPU board
3. NEVER install or uninstall ANY software programs unless instructed to do so
by qualified AMADA personnel.
4. NEVER modify, add, delete, or move any WINDOWS files.
5. NEVER operate the system files of WINDOWS, “Control panel or registry
files, etc”.
6. When you turn on or shut down the machine, the following window will be
briefly displayed. Do not touch the screen at this time.
7. NEVER use the USB flash drive for any purpose other than loading
processing programs. Any other use of the UBS flash drive should be
under the supervision of qualified AMADA personnel.
8. NEVER use the CD-ROM drive unless under the supervision of qualified
AMADA personnel.
9. Do not use a USB flash drive or CD-ROM, which has unknown files or
programs, to protect against viruses.
I-12
Precautions when using tools with higher allowable tonnage than that of
machine and punch holders
1. Since the allowable tonnage of the machine and punch holders is 1000 kN/m
(30 US tons/ft), the maximum pressure that can be applied to the tools is
also 1000 kN/m (30 US tons/ft).
2. Enter 1000 kN/m as allowable tonnage information for the punches and dies
in accordance with the allowable tonnage of the machine and punch holders.
For how to set the allowable tonnage information of the punches and dies,
see the AMNC-PC Bender operator’s manual.
Allowable tonnage of machine and punch holders (reference)

Machine: 1000 kN/m (30 US tons/ft)
One-touch punch holders: 1000 kN/m (30 US tons/ft)
CS clamps: 1000 kN/m (30 US tons/ft)
Modular tooling system: 1000 kN/m (30 US tons/ft)
Other punch holders: 1000 kN/m (30 US tons/ft)
I-13
I-14
Part II
Description
1. Functions .................................................................................... II-2

2. General view of machine ............................................................ II-3
3. Components in electrical enclosure ............................................ II-5
4. Specifications .............................................................................. II-7
4-1. Machine................................................................................ II-7
4-2. Numerical controls ............................................................... II-9
4-3. Standard NC functions ........................................................ II-12
5. Composition of axes .................................................................. II-13
5-1. Coordinate system of operating axes ................................. II-13
5-2. Coordinate system of each axis .......................................... II-14
6. Backgauge ................................................................................. II-16
6-1. Changing stopper fingers .................................................... II-16
6-2. Coordinate system of optional stepped stopper fingers...... II-18
6-3. Setting up detachable stationary stoppers (option)............. II-19
6-3-1. Installing detachable stationary stoppers ..................... II-19
6-3-2. Removing detachable stationary stoppers ................... II-22
6-4. Worksheet overhang ........................................................... II-24
7. Dimensions of machine.............................................................. II-25
8. Standard accessories................................................................. II-29
8-1. Machine............................................................................... II-29
8-2. Numerical controls .............................................................. II-32
II-1
1. FUNCTIONS
This machine is a hydraulic down-acting press brake controlled by a
hybrid drive system. The OPENING and CLOSING foot pedals are
pressed to open and close the ram. The punches are installed on the
upper beam, and the dies are installed on the lower beam. The
worksheet is laid over the dies, supported by hand, and bent by closing
the ram onto the punches. The auxiliary cylinders installed at the
center of the lower beam prevent the worksheet from drooping at the
middle when bent over a long length. The bend angle of the
worksheet depends on the clearance between the punches and dies.
The ram is opened and closed by the main cylinders installed at the left
and right sides. The main cylinders can be controlled independently to
tilt the ram. This tilting function allows the difference in the bend angle
between the left and right sides of the worksheet to be compensated for
and the worksheet to be offset bent. The worksheet can also be
pushed against the stoppers of the backgauge to determine its bend
line. The machine can be operated from the pendant control box.
II-2
2. GENERAL VIEW OF MACHINE
D-AXIS HYDRAULIC UNITS
GUIDE ROLLER
RAM (UPPER BEAM)
MAIN CYLINDER
PENDANT ARM
PENDANT
CONTROL BOX BACKGAUGE STOPPER
STRETCH BAR
BED (LOWER BEAM)
ELECTRICAL
ENCLOSURE EMERGENCY EMERGENCY
DETECTION PLATE FOOT PEDALS STOP BUTTON AUXILIARY CYLINDERS STOP BUTTON
HDS 8025NT IS SHOWN
II-3
II-4
3. COMPONENTS IN ELECTRICAL
ENCLOSURE
[1] D1-AXIS SERVO

[1] D2-AXIS SERVO
AMPLIFIER
AMPLIFIER
[6] CC-AXIS SERVO

AMPLIFIER
[3] REGENERATIVE
RESISTOR
(EXTERNAL)
[4] I/O UNIT [5] PC UNIT
[7] NC UNIT
6-AXIS
AMPLIFIER
[2] BACKGAUGE
SERVO AMPLIFIER
II-5
[1] D-axis servo amplifiers
Ram control servo amplifiers.
[2] Backgauge servo amplifier

L-, Y-, and Z-axis servo amplifier for backgauge position control.
[3] Regenerative resistor (external)

Regenerative resistor connected to the ram control servo amplifiers
(D-axis servo amplifiers).
[4] I/O unit

Composed of a connector board (HDSCN board) for connection of
external wiring, a relay board (HDSRYboard) comprising a relay circuit,
and a remote I/O board for I/O control.
[5] PC unit
A personal computer unit for display presentation and data processing.
[6] CC-axis servo amplifier

A servo amplifier for lower-beam center crowning control.
[7] NC unit
Composed of a BENDNC board for positioning control and I/O control
and a CS1 board for sequence control.
II-6
4. SPECIFICATIONS
4-1. Machine
HDS5020 to HDS2204
HDS HDS HDS HDS HDS HDS HDS
Model
5020 8025 1030** 1303 1703 2203 2204
Modular Not
2040 2550 3060 3220 3220 3220
tooling avail-
(80.31) (100.39) (120.47) (126.77) (126.77) (126.77)
Maximum bend system able
length, mm (in.) One-touch
2070 2600 3110 3220 3220 3220 4280
punch
(81.50) (102.36) (122.44) (126.77) (126.77) (126.77) (168.50)
holders
kN 500 800 1000 1300 1700 2200 2200

Press capacity (US tons) (55) (88) (110) (143) (187) (242) (242)
Ram open-close 200 250

mm (in.)
stroke length (7.87) (9.84)
Open height
500 520
(without punch mm (in.)
(19.69) (20.47)
holders)
Ram high closing 200*

mm/sec (ips)
speed (7.874)
Ram bending 20*

mm/sec (ips)
speed (0.787)
Ram opening 200*

mm/sec (ips)
speed (7.874)
Number of main cylinders 2 2

(auxiliary cylinders) (2) (3)
1.8 × 2 2.9 × 2 4.4 × 2 4.4 × 2 7.5 × 2 7.5 × 2 7.5 × 2

kW (2.4 × 2) (3.9 × 2) (5.9 × 2) (5.9 × 2) (10.1 × 2) (10.1 × 2) (10.1 × 2)
Motor output (HP)
1.8 2.9 2.9 2.9 5.5 5.5 5.5
(2.4) (3.9) (3.9) (3.9) (7.4) (7.4) (7.4)
Hydraulic oil tank L 37.5 37.5 57.5 67.5 126.5 126.5 126.5
capacity (US gal) (9.9) (9.9) (15.2) (17.8) (33.4) (33.4) (33.4)
kg 5300 6700 8400 12000 17500 17500 21000

Machine mass (US tons) (5.8) (7.4) (9.2) (13.2) (19.3) (19.3) (23.1)
Ram tilt
difference 5 10 15 15 15 15 25
mm (in.)
between left and (0.20) (0.39) (0.59) (0.59) (0.59) (0.59) (0.98)
right sides
Maximum one-side load 50% of press capacity
*Settable by user parameter
**Available for ASTRO series only
II-7
HDS3504 and HDS5006
Model HDS3504 HDS5006
Modular
tooling Not available
Maximum bend system
length, mm (in.) One-touch
4280 6100
punch
(168.50) (240.16)
holders
kN 3500 5000
Press capacity (US tons) (385) (550)
Ram open-close 350

mm (in.)
stroke length (13.78)
Open height
620
(without punch mm (in.)
(24.41)
holders)
Ram high closing 120* 90*

mm/sec (ips)
speed (4.724) (3.543)
Ram bending 12* 9*

mm/sec (ips)
speed (0.472) (0.354)
Ram opening 120* 90*

mm/sec (ips)
speed (4.724) (3.543)
Number of main cylinders 2 2

(auxiliary cylinders) (3) (5)
7.5 × 3 15 × 2
kW (10.1 × 3) (20.1 × 2)
Motor output (HP)
5.5 7.5 × 2
(7.4) (10.1 × 2)
Hydraulic oil tank L 175 220

capacity (US gal) (46.2) (58.1)
kg 35000 60000
Machine mass (US tons) (38.5) (66.0)
Ram tilt
difference 25 45
mm (in.)
between left and (0.98) (1.77)
right sides
Maximum one-side load 50% of press capacity
*Settable by user parameter
II-8
4-2. Numerical controls
Position command method Relative (incremental)
Entry with character buttons on displays presented on

LCD screen
Entry method
Entry by teaching of each axis value
Bar code entry (during network operation)
HDS5020 to Simultaneous 9-axis automatic operation

Number of HDS2204 (D1, D2, L1, L2, Y1, Y2, Z1, Z2, CC)
control axes HDS3504, Simultaneous 10-axis automatic operation
HDS5006 (D1, D2, L1, L2, Y1, Y2, Z1, Z2, C1, C2)
D-axis 0.001 mm (0.0001 in.)
L-axis 0.01 mm (0.001 in.)
Y-axis 0.1 mm (0.01 in.)
Least input Z-axis 0.1 mm (0.01 in.)

increment
0 to 200% (HDS5020, HDS8025, HDS5006)
0 to 180% (HDS3504)
CC ratio
0 to 175% (HDS1030, HDS1303)
0 to 165% (HDS1703, HDS2203, HDS2204)
Number of
5000 to 10000
Storage capacity programs
Tool registration AMADA standard tools pre-registered
Display method 15” color LCD
USB flash drive (Do not use other than accessory USB
External storage device
flash drive.)
Power 200VAC±10%, 3 phases, 50/60 Hz±1 Hz
0 to 40°C (32 to 104°F) when operating

Temperature
Environment Electrical enclosure not exposed to direct sunlight
Humidity 75% or less (relative humidity), non-condensing
D-axis Hybrid drive
L-axis AC servomotor
Drive method Y-axis AC servomotor
Z-axis AC servomotor
CC-axis Hybrid drive
II-9
D-axis: 0.1 to 20 mm/sec (0.004 to 0.787 ips),
0.1 to 12 mm/sec (0.004 to 0.472 ips) for HDS3504,
0.1 to 9 mm/sec (0.004 to 0.354 ips) for HDS5006
(Changeable by user parameter or processing program)
L-axis: 3 to 30 m/min (9.8 to 98.4 fpm),
Feed speed 3 to 13.5 m/min (9.8 to 44.3 fpm) for HDS5006
(changeable by user parameter)
Y-axis: 6 to 60 m/min (19.7 to 196.9 fpm)
(changeable by user parameter)
Z-axis: 1 to 10 m/min (3.3 to 32.8 fpm),
1 to 5 m/min (3.3 to 16.4 fpm) for HDS5006
HDS5020 to HDS1303 0 to 200 mm (0 to 7.874 in.)
D-axis HDS1703 to HDS2204 0 to 250 mm (0 to 9.843 in.)
HDS3504, HDS5006 0 to 350 mm (0 to 13.780 in.)
L-axis All models 0 to 700 mm (0 to 27.559 in.)
State Normal Tilted
+609 to –786 mm +609 to –786 mm

Y1
(+23.976 to –30.945 in.) (+23.976 to –30.945 in.)
HDS5020
+786 to –609 mm +691 to –609 mm
Y2
(+30.945 to –23.976 in.) (+27.205 to –23.976 in.)
+864 to –1041 mm +864 to –1041 mm

Y1
(+34.016 to –40.984 in.) (+34.016 to –40.984 in.)
HDS8025
+1041 to –864 mm +931 to –864 mm
Y2
(+40.984 to –34.016 in.) (+36.654 to –34.016 in.)
+1109 to –1286 mm +1109 to –1286 mm

Travel range Y1
Y-axis (+43.661 to –50.630 in.) (+43.661 to –50.630 in.)
HDS1030 to
HDS2203
+1286 to –1109 mm +1198 to –1109 mm
Y2
(+50.630 to –43.661 in.) (+47.165 to –43.661 in.)
+1629 to –1806 mm +1629 to –1806 mm

Y1
(+64.134 to –71.102 in.) (+64.134 to –71.102 in.)
HDS2204,
HDS3504
+1806 to –1629 mm +1720 to –1629 mm
Y2
(+71.102 to –64.134 in.) (+67.717 to –64.134 in.)
+2318 to –2495 mm +2318 to –2495 mm

Y1
(+91.260 to –98.228 in.) (+91.260 to –98.228 in.)
HDS5006
+2495 to –2318 mm +2495 to –2318 mm
Y2
(+98.228 to –91.260 in.) (+98.228 to –91.260 in.)
HDS5020 to
–10 to 240 mm (–0.394 to 9.449 in.)
HDS2204
Z-axis
HDS3504 50 to 300 mm (1.969 to 11.811 in.)
HDS5006 20 to 200 mm (0.787 to 7.874 in.)
II-10
Dimension Angle
HDS5020 5 mm (0.197 in.)
HDS8025 10 mm (0.394 in.)
HDS1030
HDS1303
15 mm (0.591 in.)
D-axis HDS1703
HDS2203
HDS2204
25 mm (0.984 in.)
HDS3504
Backgauge HDS5006 45 mm (1.772 in.)
tilt
HDS5020 320 mm (12.598 in.) 12.9°
HDS8025 500 mm (19.685 in.) 14°
HDS1030
HDS1303
L-axis 500 mm (19.685 in.) 11°
HDS1703
HDS2203
HDS2204
500 mm (19.685 in.) 8°
HDS3504
HDS5006 500 mm (19.685 in.) 6°
II-11
4-3. Standard NC functions
• Offset bending
• Automatic calculation
• Angle compensation
• Playback function
• Pullback function
• All set input
• Idle timer
• Slowdown timer
• Multiple opening limits (stepless)
• Backgauge operation selection (automatic)
• Elongation compensation value table
• Angle compensation value table
• Quantity setup
• Stroke counter
• Clock function
• Integrating timer
• Tool allowable tonnage check function
• Optional input
• Elongation compensation function
II-12
5. COMPOSITION OF AXES
5-1. Coordinate system of operating axes

The machine is basically controlled by the D1-, D2-, L1-, L2-, Y1-, Y2-,
and Z-axes and by the CC ratio.
D1-axis: Axis along which the left main cylinder of the ram moves up
and down
D2-axis: Axis along which the right main cylinder of the ram moves up
and down
L1-axis: Axis along which the backgauge moves back and forth on the
left ball screw
L2-axis: Axis along which the backgauge moves back and forth on the
right ball screw
Y1-axis: Axis along which the left stopper moves left and right
Y2-axis: Axis along which the right stopper moves left and right
Z-axis: Axis along which the stopper fingers move up and down
CC (C1) ratio: Pressure ratio of the auxiliary cylinders in the lower
beam
C2 ratio (only for HDS3504 and HDS5006): Pressure ratio of the
auxiliary cylinders in the lower beam
II-13
5-2. Coordinate system of each axis
D-axis (D1, D2)
SOFT LIMIT POSITION IN

PLUS DIRECTION
+
D = 0 (TOOL ORIGIN) TRAVEL RANGE
--
SOFT LIMIT POSITION IN
MINUS DIRECTION
L-axis (L1, L2)
II-14
Y-axis (Y1, Y2)
Y=0
(Y-AXIS ORIGIN)
Y1 Y2
Y1 ZERO-RETURN Y2 ZERO-RETURN
POSITION POSITION
TRAVEL RANGE
SOFT LIMIT POSITION SOFT LIMIT POSITION
IN MINUS DIRECTION IN PLUS DIRECTION
– +
Z-axis
SOFT LIMIT POSITION

IN PLUS DIRECTION
+
TRAVEL RANGE
-- SOFT LIMIT POSITION

IN MINUS DIRECTION
Z-AXIS ZERO-RETURN POSITION
TOP SURFACE OF LOWER BEAM
II-15
6. BACKGAUGE
6-1. Changing stopper fingers

O Do not put your hand or hands between
WARNING
the punches and dies to change the
stopper fingers. Before changing the
stopper fingers, turn the MODE SELECT
keyswitch to OFF, remove the key from the
The stopper fingers are of the detachable type. They can be changed
by one touch to suit the shape of the worksheet to be bent.
1 Move the stoppers

into such a position
where they can be
reached through
either gap in the
frame of the machine.
2 Turn the MODE SELECT keyswitch to OFF, remove the key from
the keyswitch, and keep it by yourself.
II-16
3 Pull out the finger from each stopper as shown below, and install
the new finger (option) in its place. Check that the number
marked on the finger agrees with that marked on the stopper and
the numbers are facing up.
PULL OUT
SEE NOTE BELOW DETACHABLE

STOPPER FINGER
NOTE: Install stopper finger of same number as that marked on

stopper with marked numbers facing up.
II-17
6-2. Coordinate system of optional stepped
stopper fingers
The standard stopper fingers and optional stepped stopper fingers are
related to the L-axis and Z-axis values as shown below.
STANDARD STOPPER
FINGER
L-AXIS
VALUE
STANDARD STOPPER
FINGER
TOOL CENTER (IN BEND LINE DIRECTION)
L-AXIS
Z-AXISVALUE
VALUE
Z-AXIS
VALUE
OPTIONAL STEPPED
OPTIONAL STEPPED
STOPPER FINGER
STOPPER FINGER
L-AXIS 20 mm
L-AXIS
VALUE (0.79 in.)20 mm
VALUE
VALUE 3 mm
Z-AXIS
3 mm
(0.12 in.)
Z-AXIS
VALUE
NOTICE
O When the backgauge is to be used close to the installed punches, take care
so that the fingers of the stoppers on the backgauge do not interfere with the
punches.
II-18
6-3. Setting up detachable stationary
stoppers (option)
O When installing or removing the
DANGER
detachable stationary stoppers, turn the
MODE SELECT keyswitch to OFF, remove
the key from the keyswitch and keep it by
yourself, and work from the rear of the
machine.
6-3-1. INSTALLING DETACHABLE STATIONARY STOPPERS

1 Place the detachable stationary stopper on the stretch bar as
shown in Photo 1.
Photo 1
NOTICE
O To prevent damage to the machine, install the detachable stationary
finger between the movable stoppers as shown in Photo 2 on the next
page.
NOTE
O Each stopper is marked with a number. Install the No. 3 and No. 4
stoppers at the left and right sides of the backgauge, respectively.
II-19
Install detachable stationary stopper between
accessory standard movable stoppers (Y1 and Y2)
Movable stopper (Y2)
Movable stopper (Y1)

Photo 2
2 Hold the detachable stationary stopper from above as shown in

Photo 1, turn the plate at the bottom of the opposite side of the
worksheet contact surface in the direction of the arrow from the
position shown in Photo 3, and apply it to the bottom of the rack as
shown in Photo 4.
Photo 3
Photo 4
II-20
3 Turn the hexagon head bolt at the opposite side of the worksheet
contact surface clockwise with the accessory T-wrench as shown
in Photo 5. When the hexagon head bolt is tightened, the
procedure is completed.
Photo 5
NOTE
O If the hexagon bolt is overtightened, the stopper may be lifted off the
seat. Stop tightening the bolt when it has become tight.
4 Enter “1” as the value of user parameter 82 (Fixed Stopper).

NOTICE
O If the backgauge is used without entering “1” as the value of the user
parameter 82, the movable stoppers move at high speed in the Y-axis
direction. When they collide against the detachable stationary stopper,
they may damage it or themselves.
II-21
6-3-2. REMOVING DETACHABLE STATIONARY STOPPERS
1 Turn the hexagon head bolt at the opposite side of the worksheet
contact surface counterclockwise with the accessory T-wrench as
shown in Photo 6.
Photo 6
2 Hold the stopper from above as shown in Photo 7, turn the plate at
the bottom of the opposite side of the worksheet contact surface in
the direction of the arrow as shown in Photo 8, and remove it from
the rack as shown in Photo 9.
Photo 7 Photo 8
Photo 9
II-22
3 Enter “0” as the value of user parameter 82 (Fixed Stopper).
NOTE
O If the backgauge is used with “1” entered as the value of the user
parameter 82, the movable stoppers move at low speed in the Y-axis
direction. This extends the time to the completion of positioning for
bending in the next process.
II-23
6-4. Worksheet overhang
The backgauge can place a worksheet on the stretch bar.
Load capacity: 20 kg (44.1 lb)/axis (L-axis)
Gently place the worksheet on the stretch bar so that no shock is
applied to the stretch bar.
NOTICE
O When the mass of the worksheet exceeds its load capacity, the stretch bar
may drop down. In such a case, the worksheet may spring upward or slip
downward as shown below. Be sure that the worksheet mass does not
exceed the stretch bar load capacity.

II-24
7. DIMENSIONS OF MACHINE
HDS5020 to HDS2204
Unit: mm (in.)
A B C D E F G H I J K L M N P
Model Frame Lower beam Upper beam Anchor bolt Anchor bolt Leveling bolt Frame
Beam length Overall width Overall height Depth Frame height — — Gap depth
distance height height distance position distance thickness
HDS5020 2070 (81.50) 1700 (66.93) 980 (38.58) 3380 (133.07) 2620 (103.15) 1600 (62.99) 2265 (89.17) 1000 (39.37) 1840 (72.44) 70 (2.76) 1840 (72.44) 40 (1.57) 3235 (127.36) 2275 (89.57) 415 (16.34)
HDS8025 2600 (102.36) 2210 (87.01) 980 (38.58) 3920 (154.33) 2720 (107.09) 1615 (63.58) 2365 (93.11) 1100 (43.31) 2370 (93.31) 70 (2.76) 2370 (93.31) 50 (1.97) 3765 (148.23) 2275 (89.57) 415 (16.34)
HDS1030 3110 (122.44) 2700 (106.30) 980 (38.58) 4430 (174.41) 2820 (111.02) 1650 (64.96) 2365 (93.11) 1250 (49.21) 2900 (114.17) 70 (2.76) 2900 (114.17) 60 (2.36) 4275 (168.31) 2275 (89.57) 415 (16.34)
HDS1303 3220 (126.77) 2700 (106.30) 1000 (39.37) 4545 (178.94) 3010 (118.50) 1655 (65.16) 2555 (100.59) 1450 (57.09) 2930 (115.35) 80 (3.15) 2930 (115.35) 70 (2.76) 4335 (170.67) 2275 (89.57) 450 (17.72)
HDS1703 3220 (126.77) 2700 (106.30) 1000 (39.37) 4650 (183.07) 3215 (126.57) 1830 (72.05) 2755 (108.46) 1350 (53.15) 3000 (118.11) 80 (3.15) 3000 (118.11) 100 (3.94) 4610 (181.50) 2465 (97.05) 450 (17.72)
HDS2203 3220 (126.77) 2700 (106.30) 1000 (39.37) 4650 (183.07) 3215 (126.57) 1830 (72.05) 2755 (108.46) 1350 (53.15) 3000 (118.11) 80 (3.15) 3000 (118.11) 100 (3.94) 4610 (181.50) 2465 (97.05) 450 (17.72)
HDS2204 4280 (168.50) 3760 (148.03) 1000 (39.37) 5710 (224.80) 3215 (126.57) 1830 (72.05) 2755 (108.46) 1350 (53.15) 4060 (159.84) 80 (3.15) 4060 (159.84) 100 (3.94) 5670 (223.23) 2465 (97.05) 450 (17.72)
II-25
HDS3504
Unit: mm (in.)
II-26
HDS5006
Unit: mm (in.)
II-27
II-28
8. STANDARD ACCESSORIES
8-1. Machine
1) Modular tooling system specification machine
Item Description Qty

Tool box 1
Allen wrench, 3 mm 1
1 Tool Allen wrench, 6 mm 1
Single-ended wrench, 13 mm 1
Phillips screwdriver 1
Slotted screwdriver 1
37.5 L
HDS5020, HDS8025
(9.9 US gal)
57.5 L
HDS1030
(15.2 US gal)
2 Hydraulic oil
67.5 L
HDS1303
(17.8 US gal)
126.5 L
HDS1703, HDS2203
(33.4 US gal)
3 Modular tooling system 1
4 Worksheet support 2
5 Base plate 4
II-29
2) One-touch punch holder specification machine

Tool box 1
45° offset box wrench, 10 × 13 mm 1
45° offset box wrench, 14 × 17 mm 1

1 Tool Allen wrench, long type, 8 mm 1
Phillips screwdriver 1
Slotted screwdriver 1
Brass bar 1
Hammer 1
37.5 L
HDS5020, HDS8025
(9.9 US gal)
57.5 L
HDS1030
(15.2 US gal)
67.5 L
HDS1303
(17.8 US gal)
2 Hydraulic oil
126.5 L
HDS1703, HDS2203, HDS2204
(33.4 US gal)
175 L
HDS3504
(46.2 US gal)
220 L
HDS5006
(58.1 US gal)
HDS5020 10
HDS8025 13
HDS1030 15
3 Punch holder
HDS1303, HDS1703, HDS2203 16
HDS2204, HDS3504 21
HDS5006 30
II-30
HDS5020 S-5
H = 110 mm HDS8025 S-7

(H = 4.33 in.) HDS1030 S-8
HDS1303 S-8
Die holder
4
HDS1703, HDS2203 L-4
L-5
H = 75 mm HDS2204, HDS3504
S-1
(H = 2.95 in.)
L-7
HDS5006
S-1
5 Worksheet support 2
6 Base plate 4
II-31
8-2. Numerical controls
Description Qty
1 Bar code reader 1
2 LCD screen protective film 1
3 CD-ROM drive cleaning kit 1
4 Keyboard 1
5 Touch pen 1
6 USB flash drives (for system files, and processing programs) 1 each
NOTICE
O The USB flash drive for system files is labeled with a machine serial number. It stores important
machine information and must not be used to back up processing programs and other data.
II-32
Part III
Installation
1. Summary.....................................................................................III-2
1-1. Environmental conditions .....................................................III-2
1-2. Power supply........................................................................III-2
1-3. Installing machine ................................................................III-3
2. Location ......................................................................................III-4
3. Carrying ......................................................................................III-5
3-1. Using a crane .......................................................................III-5
3-2. Using rollers .........................................................................III-6
4. Foundation ..................................................................................III-7
5. Cleaning.....................................................................................III-17
6. Supplying hydraulic oil ...............................................................III-18
7. Removing shipping brackets......................................................III-19
8. Installing stopper fingers ............................................................III-22
9. Moving rear guard......................................................................III-23
10. Supplying electric power ..........................................................III-24
10-1. Connecting power cable....................................................III-24
10-2. Checking wiring connections.............................................III-25
11. Zero returning...........................................................................III-26
12. Leveling....................................................................................III-26
13. Paralleling upper and lower beams .........................................III-27
14. Checking movement of each axis............................................III-28
15. Making final checks..................................................................III-29
III-1
1. SUMMARY
1-1. Environmental conditions

• Keep the machine at least 10 m (33 ft) away from a welder or any
other equipment that may produce electrical noise and magnetic
fields.
• Where the ambient temperature is not higher than 5°C (41°F) , keep
the machine and hydraulic pump motors energized during the day's
work.
• The higher the humidity in the place where the machine is installed,
the lower 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 place where it is not subjected to dust, dirt,
and organic or corrosive gases.
1-2. Power supply

NOTICE
O Supply the machine from a power source independent of a welder or any
other equipment that may produce line voltage variations.
Power requirement: 200 VAC±10%, 3 phases, 50/60 Hz±1 Hz

Power cable for HDS5020 to HDS2204: One cabtyre cable composed
of four conductors (including grounding conductor) and thick enough to
carry required power
Power cables and grounding cable for HDS3504 and HDS5006: Four
single-conductor cabtyre cables and thick enough to carry required
power
Model Full load current Each conductor (cable) size*

HDS5020 34 A 8 mm2
HDS8025 44 A 14 mm2
HDS1030 56 A 22 mm2
HDS1303 64 A 22 mm2
HDS1703 75 A 38 mm2
HDS2203 99 A 50 mm2
HDS2204 99 A 50 mm2
HDS3504 134 A 50 mm2
HDS5006 200 A 60 mm2
*Conductor (cable) size when cabtyre cable of type 600V 2PNCT or
3PNCT is to be used.
III-2
1-3. Installing machine

III-3
2. LOCATION
The place where the machine is to be installed must have an ample
floor space. Refer to the machine dimensions given in the table below.
Also take the following points into account:
• There must be no pillars and other obstacles in the area where the
tools are installed and removed. (At least 835-mm (32.87-in.) long
tools must be able to be horizontally installed and removed.)
• The ceiling must be at least 1000 mm (40 in.) from the top of the
machine.
• There must be an additional space to place a tool storage case.
• There must be a work space where the worksheets can be easily
moved in and out and where maintenance and part quality check can
be smoothly performed. Especially, a space of 1000 mm (40 in.) or
more must be available at the rear of the machine, an enough space
must be available for the door of the electrical enclosure to be
opened, and an enough space must be available for the side covers
of the lower beam to be removed.
NOTICE
O Do not install the machine in a place where it is exposed to dust from such
operations as sandblasting and to direct sunlight, rain or wind.
Unit: mm (in.)
Model A B C D
HDS5020 3380 (133.07) 2275 (89.57) 780 (30.71) 2455 (96.65)
HDS8025 3920 (154.33) 2275 (89.57) 780 (30.71) 2985 (117.52)
HDS1030 4430 (174.41) 2275 (89.57) 780 (30.71) 3495 (137.60)
HDS1303 4545 (178.94) 2275 (89.57) 780 (30.71) 3555 (139.96)
HDS1703 4650 (183.07) 2465 (97.05) 900 (35.43) 3710 (146.06)
HDS2203 4650 (183.07) 2465 (97.05) 900 (35.43) 3710 (146.06)
HDS2204 5710 (224.80) 2465 (97.05) 900 (35.43) 4770 (187.80)
HDS3504 6455 (254.13) 3340 (131.50) 555 (21.85) 4880 (192.13)
HDS5006 8115 (319.49) 4520 (177.95) 1100 (43.31) 6570 (258.66)
III-4
3. CARRYING
O Carrying the machine is very dangerous.
WARNING
Have a qualified contractor perform the
carrying work.
3-1. Using a crane

When lifting the machine, apply the wire rope sling to the lifting holes at
the top of the left and right frames, slowly lift and carry the machine to
the location, and slowly lower the machine at the location. The wire
rope sling must be strong enough to carry the mass of the machine.
(For the mass of the machine, see the serial number plate attached to
the machine.)
LIFTING HOLE
III-5
3-2. Using rollers
When jacking up the machine, insert the claw of a jack below the
bottom surface of the left or right frame.
JACK
ROLLERS
NOTICE
O The machine has a center of gravity at its front. If the rear bottom of the
machine is jacked up without paying attention to its balance, the machine
may tip over, resulting in a very dangerous situation.
III-6
4. FOUNDATION
To maintain bending accuracy, install the machine on a flat concrete
floor that is strong enough to carry the mass of the machine and is not
likely to subside. Before carrying the machine into the location,
execute the foundation work by referring to the foundation drawing on
the pages that follow. If the ground is soft with a bearing capacity of
50 kN/m2 (1025 lbf/ft2) or less, reinforce the foundation with steel bars
or the like.
Unit: mm (in.)
Model A B C D
HDS5020 3380 (133.07) 2275 (89.57) 780 (30.71) 2455 (96.65)
HDS8025 3920 (154.33) 2275 (89.57) 780 (30.71) 2985 (117.52)
HDS1030 4430 (174.41) 2275 (89.57) 780 (30.71) 3495 (137.60)
HDS1303 4545 (178.94) 2275 (89.57) 780 (30.71) 3555 (139.96)
HDS1703 4650 (183.07) 2465 (97.05) 900 (35.43) 3710 (146.06)
HDS2203 4650 (183.07) 2465 (97.05) 900 (35.43) 3710 (146.06)
HDS2204 5710 (224.80) 2465 (97.05) 900 (35.43) 4770 (187.80)
HDS3504 6455 (254.13) 3340 (131.50) 555 (21.85) 4880 (192.13)
HDS5006 8115 (319.49) 4520 (177.95) 1100 (43.31) 6570 (258.66)
III-7
III-8
HDS5020 foundation drawing
Unit: mm (in.)
III-9
Unit: mm (in.)
III-10
Unit: mm (in.)
III-11
Unit: mm (in.)
III-12
HDS1703, HDS2203 foundation drawing
Unit: mm (in.)
III-13
Unit: mm (in.)
III-14
Unit: mm (in.)
III-15
Unit: mm (in.)
III-16
5. CLEANING
After the machine is installed on the foundation, clean it. Particularly,
remove all rust-preventive grease from the punch holders, the die
holders, and the top surface of the lower beam, using cleaning oil.
NOTICE
O Do not use a solvent or scraper that removes the paint of the machine.
III-17
6. SUPPLYING HYDRAULIC OIL
Pour the recommended hydraulic oil into the three or four hydraulic oil
tanks to the upper red line on the oil gauges when the ram is at the
maximum opening limit.
Tank capacity, L (US gal)
Model
Total D1-axis D2-axis CC (C1)-axis C2-axis
HDS5020 37.5 (9.9) 17 (4.49) 17 (4.49) 3.5 (0.92) ―
HDS8025 37.5 (9.9) 17 (4.49) 17 (4.49) 3.5 (0.92) ―
HDS1030 57.5 (15.2) 27 (7.13) 27 (7.13) 3.5 (0.92) ―
HDS1303 67.5 (17.8) 32 (8.45) 32 (8.45) 3.5 (0.92) ―
HDS1703 126.5 (33.4) 60 (15.85) 60 (15.85) 6.5 (1.72) ―
HDS2203 126.5 (33.4) 60 (15.85) 60 (15.85) 6.5 (1.72) ―
HDS2204 126.5 (33.4) 60 (15.85) 60 (15.85) 6.5 (1.72) ―
HDS3504 175 (46.2) 80 (21.14) 80 (21.14) 7 (1.85) 8 (2.11)
HDS5006 220 (58.1) 100 (26.42) 100 (26.42) 10 (2.64) 10 (2.64)
Accessory oil: Amada NCA-250
OIL GAUGES
III-18
7. REMOVING SHIPPING BRACKETS
After the machine has been installed in place, remove the shipping
brackets securing the machine parts as described below.
NOTE
O Take care not to lose the removed shipping brackets.
Upper beam
The shipping brackets securing the upper beam are positioned near the
upper left and right guide rollers.
1 Loosen the nut “A” and bolt “B” of each shipping bracket.
2 Remove the bolts “C”, and remove the block “D”.
D
C
Main cylinder covers
There are two shipping brackets on the left and right main cylinder
covers.
1 Remove the bolts securing each shipping bracket.

2 Remove the shipping brackets from the main cylinder covers.
BOLTS SHIPPING BRACKET
III-19
Backgauge
There are two shipping brackets on the L1- and L2-axes.
1 Remove the two bolts securing each shipping bracket.

2 Remove the shipping brackets from the backgauge.
3 Replace the four bolts in their original holes.
SHIPPING BRACKET (YELLOW)
(18.11 in.)
(0.20 in.)
III-20
Backgauge stoppers
There are two shipping brackets on the Y1- and Y2-axes.
1 Remove the bolt securing each shipping bracket.

2 Remove the shipping brackets from the stoppers.
3 Replace the two bolts in their original holes together with the
collars.
SHIPPING BRACKET
(YELLOW)
BOLT
COLLAR
III-21
8. INSTALLING STOPPER FINGERS
O Do not put your hand or hands between
WARNING
the punches and dies to install the
stopper fingers. Before installing the
stopper fingers, turn the MODE SELECT
The machine is shipped with the stopper fingers removed. Install them
as described below.
1 Move the stoppers into such a position where they can be reached
through either gap in the frame of the machine.
2 Turn the MODE SELECT keyswitch to OFF, remove the key from
the keyswitch, and keep it by yourself.
3 Install a stopper finger of the same number as that marked on the
stopper as shown below.
III-22
9. MOVING REAR GUARD
Move the rear guard as described below.
1 Loosen the 6 bolts securing the inside of the frame.

2 Pull the top of the rear guard to the end of the slots.
3 Tighten the 6 bolts.
SLOTS
長穴
AFTER MOVING
III-23
10. SUPPLYING ELECTRIC POWER
O Have a qualified electrician perform all
WARNING
electric work to prevent accidents and
damage.
O Before making the electrical connections,
be sure to turn off the shop circuit
breaker.
O Be sure to connect the grounding
conductor for safety.
O Use the shop circuit breaker and
grounding conductor exclusively for the
machine, and separate from those of other
equipment such as welders, drills,
sanders, and grinders.
NOTE
O The machine needs a 200 VAC±10%, 50/60 Hz±1 Hz, and 3-phase power
source.
O Use the power cable and grounding conductor that suit the power to be
handled.
10-1. Connecting power cable

Connect the power cable to the machine as described below.
1 Turn off the shop circuit breaker.

2 Turn off the machine circuit breaker on the electrical enclosure at
the left side of the machine.
3 Open the door of the electrical enclosure.
4 Run the power cable from the shop circuit breaker through the
hole into the electrical enclosure.
5 Connect the power cable to the XT1 power input terminals L1, L2,
and L3 in the electrical enclosure.
6 Connect the grounding conductor to the XTE2 ground terminal.
NOTE
O Use a grounding conductor of at least the same size as that of the
power cable conductors.
III-24
7 After the electric wiring connections are completed, check the
voltage with a tester as described below.
(1) Turn on the shop circuit breaker.

(2) Check the input voltage between the terminals L1 and L2, L2
and L3, and L1 and L3 at the lower terminal block.
(3) Turn on the machine circuit breaker QF1.
(4) Check the input voltage between the terminals L11 and L21,
L21 and L31, and L11 and L31 at the secondary side (lower
terminal block) of the machine circuit breaker QF1.
(5) If the above voltage checks find no problems, turn off the
machine circuit breaker QF1.
8 Close the door of the electrical enclosure.
10-2. Checking wiring connections

Check the wiring connections as described below.
1 Turn on the shop circuit breaker.

2 Turn on the machine circuit breaker QF1, and check that the
POWER lamp comes on.
3 Turn the POWER ON/OFF keyswitch to ON. When the initial NC
display is shown on the LCD screen and a beep is heard, the
hydraulic pump motors can be started.
4 Turn the MOTOR ON/OFF keyswitch to ON. The hydraulic pump
motors start, and the MOTOR lamp comes on.
III-25
11. ZERO RETURNING
After the power to the machine is turned on, be sure to zero-return the
machine. Unless the zero-return is performed, each axis cannot
move.
Zero-return the machine as described below.
1 Press the SETUP button shown on the LCD screen.

2 Press and hold the CLOSING foot pedal. Each axis zero-returns.
12. LEVELING
Level the machine as described below.
Leveling in left-to-right direction

1 Place a spirit level at the center of the lower beam.
2 Turn the two leveling bolts on the left or right side of the machine
to level the machine to 0.04 mm/1 m (0.00048 in./1 ft) or less.
Leveling in front-to-back direction

1 Clean the traveling surface of the lower guide roller behind the
upper beam.
2 Attach a square spirit level with a magnet to the traveling surface.
3 Turn the two leveling bolts on the front or back side of the machine
to level the machine to 0.02 mm/1 m (0.00024 in./1 ft)or less.
4 When the leveling of the machine is completed, tighten the nuts of
all leveling bolts.
GUIDE
ROLLER PLATE
III-26
13. PARALLELING UPPER AND LOWER
BEAMS
Check that the upper and lower beams are parallel at the left edge D1
and right edge D2 as shown below. If not, parallel them as described
below.
1 Remove the punch holders at the left and right edges.

2 Close the ram to 190 mm (7.48 in.), and measure the dimensions
D1 and D2 with the CLOSING foot pedal pressed and held.
3 If the dimension D2 is greater than the dimension D1 (0), add the
difference to the grid shift of the dimension D1.
If the dimension D2 is smaller than the dimension D1, add the
difference to the grid shift of the dimension D2.
NOTE
O The grid shift is adjusted by changing the value of a system parameter.
For the method of displaying the system parameter, refer to the
adjustment specification.
4 Turn off the power and then back on, and repeat steps 1 and 2.
5 Repeat steps 1 to 4 so that the difference between the dimensions
D1 and D2 becomes 0.01 mm (0.0004 in.).
DIAL GAUGES
III-27
14. CHECKING MOVEMENT OF EACH AXIS
Be sure to check the movement of each axis. Manually move each
axis, and check that each axis moves free of trouble.
NOTE
O If the ram tilts or stops midway, open it as described below.
1 Turn the POWER

ON/OFF keyswitch to EMERGENCY
ON. OPENING BUTTON
2 Press and hold the

EMERGENCY
OPENING button until
the ram reaches the
top dead center.
III-28
15. MAKING FINAL CHECKS
• Oil leakage and air removal
Check for any oil leak. After installing the tools, close the ram to
apply pressure to the tools for a few seconds. This forces air out of
the hydraulic units. In case of existing air in the hydraulic circuit, the
ram moves unsmoothly, and the alarm message “Error amount is too
large in D-axis” is displayed.
III-29
III-30
Part IV
Controls &
Operation
1. Controls on pendant control box.................................................IV-3
2. Controls on electrical enclosure..................................................IV-6
3. Foot pedals .................................................................................IV-8
4. Turning on power ........................................................................IV-9
5. Setting up modular tooling system............................................ IV-10
5-1. Setting origin of each axis .................................................. IV-10
5-1-1. Zero-returning all axes .................................................IV-11
5-1-2. Setting tool origin......................................................... IV-12
5-2. Installing tools .................................................................... IV-14
5-2-1. When tool layout is set ................................................ IV-15
5-2-2. When tool layout is not set .......................................... IV-21
5-3. Removing tools .................................................................. IV-25
5-3-1. When tool origin is set for tools installed on machine . IV-25
installed on machine ................................................... IV-27
6. Setting up one-touch punch holders (option)............................ IV-29
6-1. Setting origin of each axis .................................................. IV-29
6-1-1. Zero-returning all axes ................................................ IV-30
6-1-2. Setting tool origin......................................................... IV-31
6-2. Installing tools .................................................................... IV-33
6-2-1. When tool layout is set ................................................ IV-34
6-2-2. When tool layout is not set .......................................... IV-43
6-3. Removing tools .................................................................. IV-50
6-3-1. When tool origin is set for tools installed on machine..... IV-50
IV-1
installed on machine ....................................................IV-52
6-4. Other uses ..........................................................................IV-54
6-4-1. Name of each part........................................................IV-54
6-4-2. Punch holder lever positions ........................................IV-55
6-4-3. Installing and removing punches from front .................IV-56
6-4-4. Installing and removing punches by sliding them
along groove of rear clamping plates ...........................IV-59
6-4-5. Installing and removing rear clamping plates...............IV-60
7. Bending speed of ram................................................................IV-63
(HDS5020 to HDS2204) .....................................................IV-63
7-1-1. Bending speed for repeat processing program
created on another press brake model ........................IV-63
7-1-2. Initial value of bending speed (slowdown speed SF)...IV-63
7-2. Relationship between bending speed and bend angle .......IV-64
7-3. Speed change position of ram ............................................IV-64
8. Setting speed of each axis.........................................................IV-64
9. Turning off power .......................................................................IV-66
9-1. When tool origin is set for tools installed on machine.........IV-66
9-2. When tool origin is not set for tools installed on machine...IV-68
10. Crowning control of machines with two C-axes
(only for HDS3504 and HDS5006) ..........................................IV-69
IV-2
1. CONTROLS ON PENDANT CONTROL BOX
NOTICE
O Do not scratch or push the LCD screen surface with any sharp object.
Otherwise the LCD screen may be damaged or fail.
O Operate the LCD screen with a fingertip or the accessory touch pen.
O The LCD screen is covered with a protective film. If the film is damaged,
change it.
[1] STOP button

Effective on the SETUP and RUN displays. Pressed to stop the
pullback operation of the backgauge, instruction for the tool position,
and automatic operation of the machine. When the button is pressed,
all axes come to a stop.
[2] START button (with lamp)

Effective on the SETUP and RUN displays. Pressed to turn on the
lamp and start the pullback operation of the backgauge, instruction for
the tool position, and automatic operation of the machine.
[3] HANDWHEEL ON button (with lamp)

Effective on the SETUP and RUN displays. Pressed to turn on the
lamp and change the target value of each axis with the HANDWHEEL.
[4] HANDWHEEL
Used to position each axis. Turned clockwise to move the axis in the
minus direction and counterclockwise to move the axis in the plus
direction.
IV-3
[5] MODE SELECT keyswitch
Used to select the operation mode of the ram.
MODE
INCHING
TOOL FOOT
CHANGE PEDAL
OFF SINGLE
PALM
BUTTON
(OFF):
All axis motions are stopped.
(TOOL CHANGE):
A tool change can be made.
(INCHING):
The ram closes when the CLOSING foot pedal is pressed and
immediately stops when the CLOSING foot pedal is released.
The ram opens when the OPENING foot pedal is pressed and
immediately stops when the OPENING foot pedal is released.
NOTE
O When the CLOSING foot pedal is released while pressure is applied, the
pressure or load is removed.
(FOOT PEDAL):
The ram closes when the CLOSING foot pedal is pressed and opens
when the CLOSING foot pedal is released. The opening ram closes
again when the CLOSING foot pedal is pressed again. While the
backgauge is moving, the ram closes again if the following conditions
are met:
Condition 1: The ram is between the maximum opening limit and D’
(during angle, shape, and 3D input).
Condition 2: The ram is between the maximum opening limit and SD
(during direct input).
IV-4
(SINGLE):
The ram closes when the CLOSING foot pedal is pressed and
immediately stops when the CLOSING foot pedal is released. When
the CLOSING foot pedal is pressed and held, the ram closes to the
D-axis target value and then opens to the multiple opening limit or
maximum opening limit after the operation of the maximum closing limit
timer. The timer cannot operate when the lamp of the HANDWHEEL
ON button is turned on.
(PALM BUTTON) (option):
The machine can be automatically operated with the optional palm
buttons.
[6] EMERGENCY STOP button

Pressed in an emergency to stop all motions of the machine.
[7] Bar code reader (for network operation)

Used to read the bar code written on the work instruction sheet, search
for the corresponding processing program in the server (ASIS100PCL
or AP100), and display the processing program on the LCD screen.
IV-5
2. CONTROLS ON ELECTRICAL ENCLOSURE
[3] MOTOR ON/OFF

KEYSWITCH
[1] POWER ON/OFF
KEYSWITCH [4] MOTOR LAMP
[5] RAM LOCK ON/OFF

KEYSWITCH
[6] CD-ROM DRIVE

[2] POWER LAMP AND USB PORT
[7] MACHINE
CIRCUIT
BREAKER
[1] POWER ON/OFF keyswitch

Used to turn on and off the power to the NC.
[2] POWER lamp

Comes on to indicate that the machine circuit breaker on the electrical
enclosure is turned on.
IV-6
[3] MOTOR ON/OFF keyswitch
Used to start and stop the servo amplifiers of the D- and CC-axes.
[4] MOTOR lamp

Comes on to indicate that the servo amplifiers of the D- and CC-axes
are running.
[5] RAM LOCK ON/OFF keyswitch

Used to turn on and off the ram lock.
[6] CD-ROM drive and USB port

A CD-ROM (for maintenance) and the accessory USB flash drive can
be used.
[7] Machine circuit breaker

Used to turn on and off the power to the electrical enclosure.
The machine has an automatic power-off function. When the AMNC
application completes the shutdown procedure at the end of the job, the
NC automatically turns off the machine circuit breaker.
NOTE
O To turn on the machine circuit breaker, turn its handle to RESET and then to
ON.
IV-7
3. FOOT PEDALS
[1] CLOSING foot pedal
This foot pedal has three positions (see below) and a function for
adjusting the ram closing speed.
position ◯
A : Ram release position
position ◯
B : Ram closing position
position ◯
C : Ram stop position
When the foot pedal is EMERGENCY STOP BUTTON

pressed to the position ◯
B
EMERGENCY OPENING
shown in the figure below, BUTTON
the ram closes.
When the foot pedal is fully
pressed to the position ◯C,
the ram stops there.
When the foot pedal is
OPENING FOOT
released to the position ◯A,
PEDAL
the ram stays there in the
INCHING and SINGLE CLOSING FOOT
modes and opens in the PEDAL
FOOT PEDAL mode.
POSITION A
POSITION B
POSITION C
NOTICE
O Do not leave the ram stopped in an intermediate position for a long period of
time. The ram may tilt under its own weight.
[2] OPENING foot pedal

Pressed to open the ram. If the ram is stopped at the multiple opening
limit at the start of automatic operation or when the lamp of the
HANDWHEEL ON button is turned on, press the pedal to open the ram
to the maximum opening limit.
[3] EMERGENCY STOP button

Pressed in an emergency to stop all motions of the machine.
[4] EMERGENCY OPENING button

Pressed in an emergency to open the ram. Pressing the button forces
two motors to start and the ram to open. The button is disabled when
one of the EMERGENCY STOP buttons is pressed, when the MODE
SELECT keyswitch is set to OFF, or when the MOTOR ON/OFF
keyswitch is set to OFF.
IV-8
4. TURNING ON POWER
1 Turn on the machine circuit breaker switch.
2 Check that the POWER lamp is turned on.
3 Check that the MOTOR ON/OFF keyswitch is set to the central
position.
NOTE
O If the power to the NC is turned off without returning the MOTOR
ON/OFF keyswitch to the central position, an alarm will be displayed
when the NC is powered on the next time.
4 Turn the POWER ON/OFF keyswitch to ON.

After startup of the OS (Windows), the AMNC automatically starts
up and opens the LIST display.
IV-9
5. SETTING UP MODULAR TOOLING
SYSTEM
5-1. Setting origin of each axis

O Never put your hand or hands between the
DANGER
punches and dies. (Refer to Part I,
Safety.)
O Apply to the installed tools a pressure that
is not higher than the allowable tonnage
marked on them. Unless a proper
pressure is applied to them, the tools may
Press the SETUP button to change the LCD screen to the SETUP
display.
IV-10
5-1-1. ZERO-RETURNING ALL AXES
Zero-return all axes as described below.
1 When the following pop-up window opens, turn the MOTOR

ON/OFF keyswitch to ON.
2 Turn the MODE SELECT keyswitch to INCHING, FOOT PEDAL,

or SINGLE.
3 When the following pop-up window opens, press and hold the
CLOSING foot pedal to zero-return all axes. A signal sound is
heard during the zero-return.
NOTE
O During the zero-return, an alarm may occur, depending on the positions
of the optional stationary stoppers. Do not place the stationary
stoppers in the following positions:
1) Do not place a stationary stopper outside of a movable stopper.
2) The movable stoppers move to the end and then inward. Take care
so that the movable stoppers do not strike against the stationary
stoppers. The target Y-coordinates for the movable stoppers to
move inward are as given in the table below.
Beam length Y-coordinates (Y1, Y2) Beam length Y-coordinates (Y1, Y2)
2m (–600, 600) 6.56 ft (–23.62, 23.62)
2.5 m (–800, 800) 8.20 ft (–31.50, 31.50)
3m (–1000, 1000) 9.84 ft (–39.37, 39.37)
4m (–1300, 1300) 13.12 ft (–51.18, 51.18)
6m (–2000, 2000) 19.69 ft (–78.74, 78.74)
IV-11
5-1-2. SETTING TOOL ORIGIN

DANGER
NOTE
O Given the characteristics of the pressure sensors used, the hydraulic
pressure indications may involve some error, depending on the change in the
ambient temperature. This may produce different pressure indications for
the left and right main cylinders or may make the pressure appear to be
larger than zero although no pressure is actually applied. These are no
abnormal conditions. For details, contact AMADA.
Set the tool origin as described below.
1 Calculate the Max P value from the tool installation length

(pressure application length) by the following equation:
Max P = L × T
where,
Max P = Maximum pressure that can be applied to installed tool
(kN)
L = Tool installation length (pressure application length) (m)
T = Allowable tonnage marked on tool (kN/m)
The allowable tonnage marked on the tools may differ between
the punches and dies. Determine the maximum pressure below
which both the punches and dies can be safely used. The
allowable tonnage is proportional to the length of the worksheet to
be bent. Calculate the maximum pressure by considering the
pressure application length.
Calculation example:
When the allowable tonnage marked on the tool is 1000 kN/m and
the pressure application length is 0.5 m, the maximum pressure
below which the tool can be safely used is 1000 kN/m × 0.5 m =
500 kN.
2 Check that the D-axis target value agrees with the D-axis current
value.
If the D-axis target value does not agree with the D-axis current
value, turn the HANDWHEEL counterclockwise to set the D-axis
target value to the D-axis current value.
O When the D-axis target value does

WARNING
not agree with the D-axis current
value, pressing the CLOSING foot
pedal moves the ram automatically to
the D-axis target value in a
dangerous manner.
IV-12
3 With the CLOSING foot pedal pressed and held, slowly turn the
HANDWHEEL clockwise to close the ram. When the punches
are apart from the dies, press the ×5 button to turn on the light and
bring the punches close to the dies at a high speed (×5). Before
the punches engage the dies, press the ×5 button again to turn off
the light and bring the punches into the dies at a low speed (×0.1).
4 Slowly increase the pressure applied to the tools while checking
the current pressure displayed in the P field.
As soon as the punches engage the dies, the pressure suddenly
rises. If the tools are extremely short, operate the HANDWHEEL
with particular care.
5 When the Max P value is smaller than “Origin Pressure” displayed,

press and hold the CLOSING foot pedal, and turn the
HANDWHEEL clockwise. Below the Max P value, press the SET
button to set the tool origin.
When the Max P value is not smaller than “Origin Pressure”
displayed, press and hold the CLOSING foot pedal, and turn the
HANDWHEEL clockwise to apply pressure to the tools to “Origin
Pressure”. Or at an appropriately lower position, press the SET
1) Automatic tool origin setting
Close the ram until the current pressure displayed in the P
field reaches “Origin Pressure” displayed.
The tool origin is automatically set, although the SET button is
not pressed.
The D1- and D2-axis current values are set to “0.000 mm
(0.0000 in.)” on the display, and the message “Tool Origin
Setting completed” is displayed.
Once the tool origin is set, it cannot be automatically reset. If
you want to change the tool origin, manually set it.
2) Manual tool origin setting
When the tools are short and low in allowable tonnage so that
pressure cannot be applied to “Origin Pressure” displayed,
press and hold the CLOSING foot pedal at a pressure below
“Origin Pressure”, and press the SET button to set the tool
origin.
The D1- and D2-axis positions when the SET button is
pressed are set as the tool origin, and the D1- and D2-axis
target values are set to “0.000 mm (0.0000 in.)” on the display.
The message “Tool Origin Setting completed” is displayed.
6 If the MODE SELECT keyswitch is set to INCHING, press the
OPENING foot pedal. If the MODE SELECT keyswitch is set to
FOOT PEDAL or SINGLE, release the CLOSING foot pedal. The
ram opens to the multiple opening limit or maximum opening limit.
7 This completes the tool origin setting procedure.
IV-13
5-2. Installing tools
DANGER
Safety.)
O When changing the tools, strictly observe
the following cautions:
1 Before installing and removing the dies,
◯
2 Before installing and removing the
◯
Never put your hand or hands between
the punch and die to support the punch.
3 When you install and remove the tools
◯
with an assistant operator or operators,
be sure to coordinate your work with
them.
IV-14
5-2-1. WHEN TOOL LAYOUT IS SET

DANGER
Install the tools as described below.
1 Call the processing program.

2 Turn the MODE SELECT keyswitch to TOOL CHANGE. The
LCD screen changes to the SETUP display. (The zero-return of
all axes is assumed to be completed as described in “5-1-1.
Zero-returning all axes”.)
3 If the backgauge interferes with the installation of the tools, press

the PULL BACK button.
4 When the following pop-up window opens, press the START
button. The backgauge moves to the backward limit.
IV-15
HANDWHEEL clockwise to close the ram to the punch and die
installation position. If the ram is apart from the punch and die
installation position, press the ×5 button to turn on the light and
bring the ram close to the punch and die installation position at a
high speed (×5). When the ram comes close to the punch and
die installation position, press the ×5 button again to turn off the
light.
O When opening the ram and closing it

WARNING
again after it has been closed once,
turn the HANDWHEEL
counterclockwise to set the D-axis
target value to the D-axis current
value, and press the CLOSING foot
pedal. Unless the D-axis target
value is set to the D-axis current
dangerous manner.
NOTE
O The punch and die installation position is the ram position where the
clearance between the punches and dies becomes 1 mm (0.039 in.).
6 Turn the CLAMP switch to OPEN.

7 Prepare the dies to be installed by referring to the tool quantity list.
8 Select the first die to be installed as shown below.
9 Turn the MODE SELECT keyswitch to TOOL CHANGE.

10 Press the TOOL NAVI button.
IV-16
button. The left-hand or right-hand stopper moves to the left end
of the die installation position.
12 Turn the MODE SELECT keyswitch to OFF.

13 Check the combination of the die number and length by referring
to the tool data list, and install the die according to the left end of
the left-hand or right-hand stopper moved.
14 Repeat steps 8 to 13 to install the other dies.

15 Prepare the punches to be installed by referring to the tool
quantity list.
16 Select the first punch to be installed as shown below.

IV-17
of the punch installation position.

21 Check the combination of the punch number and length by
referring to the tool data list, and install the punch according to the
left end of the left-hand or right-hand stopper moved.
22 Repeat steps 16 to 21 to install the other punches.

23 Turn the CLAMP switch to CLOSE.
25 While pressing the CLOSING foot pedal, turn the HANDWHEEL
clockwise.
O If the ram has opened, turn the

WARNING
HANDWHEEL counterclockwise to
set the D-axis target value to the
D-axis current value, and press the
CLOSING foot pedal. Unless the
D-axis target value is set to the D-axis
current value, pressing the CLOSING
foot pedal moves the ram
automatically to the D-axis target
value in a dangerous manner.
26 If the light of the ×5 button is turned on, press the ×5 button to turn
off the light.
IV-18
Max P = L × T
where,
(kN)
500 kN.
When the Max P value is smaller than “Origin Pressure” displayed,

not pressed.
IV-19
origin.
29 Press the OPENING foot pedal to open the ram.
30 Turn the MODE SELECT keyswitch back to INCHING, FOOT
PEDAL, or SINGLE.
IV-20
5-2-2. WHEN TOOL LAYOUT IS NOT SET

DANGER


IV-21
HANDWHEEL clockwise to close the ram to the punch and die
installation position. If the ram is apart from the punch and die
bring the ram close to the punch and die installation position at a
high speed (×5). When the ram comes close to the punch and
die installation position, press the ×5 button again to turn off the
light.

WARNING
turn the HANDWHEEL
dangerous manner.
NOTE
O The punch and die installation position is the ram position where the
clearance between the punches and dies becomes 1 mm (0.039 in.).
6 Turn the CLAMP switch to OPEN.

8 Install the dies and punches.
9 Turn the CLAMP switch to CLOSE.
clockwise.

WARNING
off the light.
IV-22
Max P = L × T
where,
(kN)
500 kN.

not pressed.
IV-23
origin.
PEDAL, or SINGLE.
IV-24
5-3. Removing tools
5-3-1. WHEN TOOL ORIGIN IS SET FOR TOOLS INSTALLED ON
MACHINE
Remove the tools as described below.

LCD screen changes to the SETUP display.
SETUP display shown above applies when tool layout is set
2 If the backgauge interferes with the removal of the tools, press the
PULL BACK button.
IV-25
4 Press the TEACH TOOL POS. button. The following pop-up
window opens.
5 Press the SET button.

6 Check that the D-axis target value is set to the tool change
position “3.000 mm (0.1181 in.)”, and press the CLOSING foot
pedal to close the ram to a tool clearance of 3 mm (0.1181 in.).
The tool origin is cleared.
O Since the D-axis target value is “3.000

WARNING
mm (0.1181 in.)”, the ram continues
to close to the tool clearance of the 3
mm (0.1181 in.) as long as the
CLOSING foot pedal is pressed and
held. Check for danger, and press
the CLOSING foot pedal.

8 Turn the CLAMP switch to OPEN, and remove the punches by
sliding them sideways.
9 Remove the dies.
PEDAL, or SINGLE.
O Before closing the ram again, pay

CAUTION
attention to the relationship between the
D-axis target value and current value, and
check that the ram can be safely closed.
IV-26
5-3-2. WHEN TOOL ORIGIN IS NOT SET FOR TOOLS INSTALLED
ON MACHINE

SETUP display shown above applies when tool layout is set
PULL BACK button.

clockwise to close the ram until the clearance between the punch
tip and the die V-groove bottom becomes 3 mm (0.1181 in.).
When the punches are apart from the dies, press the ×5 button to
turn on the light and bring the punches close to the dies at a high
speed (×5). When the punches come close to the dies, press the
×5 button again to turn off the light.
IV-27
O Before pressing the CLOSING foot
WARNING
pedal, check that the D-axis current
value and target value agree with
each other. If they do not agree with
each other, turn the HANDWHEEL
counterclockwise until they agree
with each other, and press the
CLOSING foot pedal.

6 Turn the CLAMP switch to OPEN, and remove the punches by
7 Remove the dies.
PEDAL, or SINGLE.

CAUTION
IV-28
6. SETTING UP ONE-TOUCH PUNCH
HOLDERS (OPTION)
6-1. Setting origin of each axis

DANGER
Safety.)
Press the SETUP button to change the LCD screen to the SETUP
display.
IV-29
6-1-1. ZERO-RETURNING ALL AXES
Zero-return all axes as described below.
1 When the following pop-up window opens, turn the MOTOR

ON/OFF keyswitch to ON.
2 Turn the MODE SELECT keyswitch to INCHING, FOOT PEDAL,

or SINGLE.
3 When the following pop-up window opens, press and hold the
CLOSING foot pedal to zero-return all axes. A signal sound is
heard during the zero-return.
NOTE
O During the zero-return, an alarm may occur, depending on the positions
of the optional stationary stoppers. Do not place the stationary
stoppers in the following positions:
1) Do not place a stationary stopper outside of a movable stopper.
2) The movable stoppers move to the end and then inward. Take care
so that the movable stoppers do not strike against the stationary
stoppers. The target Y-coordinates for the movable stoppers to
move inward are as given in the table below.
Beam length Y-coordinates (Y1, Y2) Beam length Y-coordinates (Y1, Y2)
2m (–600, 600) 6.56 ft (–23.62, 23.62)
2.5 m (–800, 800) 8.20 ft (–31.50, 31.50)
3m (–1000, 1000) 9.84 ft (–39.37, 39.37)
4m (–1300, 1300) 13.12 ft (–51.18, 51.18)
6m (–2000, 2000) 19.69 ft (–78.74, 78.74)
IV-30
6-1-2. SETTING TOOL ORIGIN

DANGER
NOTE
O Given the characteristics of the pressure sensors used, the hydraulic
pressure indications may involve some error, depending on the change in the
ambient temperature. This may produce different pressure indications for
the left and right main cylinders or may make the pressure appear to be
larger than zero although no pressure is actually applied. These are no
abnormal conditions. For details, contact AMADA.
Set the tool origin as described below.

Max P = L × T
where,
(kN)
500 kN.
2 Check that the D-axis target value agrees with the D-axis current
value.
If the D-axis target value does not agree with the D-axis current
value, turn the HANDWHEEL counterclockwise to set the D-axis
target value to the D-axis current value.
O When the D-axis target value does

WARNING
not agree with the D-axis current
dangerous manner.
IV-31
HANDWHEEL clockwise to close the ram. When the punches
are apart from the dies, press the ×5 button to turn on the light and
bring the punches close to the dies at a high speed (×5). Before
the punches engage the dies, press the ×5 button again to turn off
the light and bring the punches into the dies at a low speed (×0.1).
5 When the Max P value is smaller than “Origin Pressure” displayed,

not pressed.
origin.
6 If the MODE SELECT keyswitch is set to INCHING, press the
OPENING foot pedal. If the MODE SELECT keyswitch is set to
FOOT PEDAL or SINGLE, release the CLOSING foot pedal. The
ram opens to the multiple opening limit or maximum opening limit.
7 This completes the tool origin setting procedure.
IV-32
6-2. Installing tools
DANGER
Safety.)
O When changing the tools, strictly observe
the following cautions:
◯
dies, turn the MODE SELECT keyswitch
to OFF, remove the key from the
◯
Never put your hand or hands between
the punch and die to support the
punch.
3 Securely fix the punches, dies, and die
◯
holders before applying pressure to
them.
4 When you install and remove the tools
◯
with an assistant operator or operators,
be sure to coordinate your work with
them.
When 2V-dies are used, use the V-groove
toward the rear of the machine for
additional safety. (Refer to Part I, Safety.)
IV-33
6-2-1. WHEN TOOL LAYOUT IS SET

DANGER


IV-34
HANDWHEEL clockwise to close the ram to the punch installation
position shown in Fig. 1. If the ram is apart from the punch
bring the ram close to the punch installation position at a high
speed (×5). When the ram comes close to the punch installation
position, press the ×5 button again to turn off the light.
3 to 5
(0.12 to 0.20 in.)
Fig. 1
WARNING
turn the HANDWHEEL
target value to the D-axis current value,
and press the CLOSING foot pedal.
Unless the D-axis target value is set to
the D-axis current value, pressing the
CLOSING foot pedal moves the ram
automatically to the D-axis target value
in a dangerous manner.

7 Install the die holders on the lower beam, and tighten the fixing
bolts.
8 Prepare the dies to be installed by referring to the tool quantity list.
9 Select the first die to be installed as shown below.
IV-35
of the die installation position.

14 Check the combination of the die number and length by referring
to the tool data list, and install the die according to the left end of
the left-hand or right-hand stopper moved.
15 Repeat steps 9 to 14 to install the other dies.

16 Prepare the punches to be installed by referring to the tool
quantity list.
17 Select the first punch to be installed as shown below.
IV-36
of the punch installation position.

22 Check the combination of the punch number and length by
referring to the tool data list, and install the punch according to the
left end of the left-hand or right-hand stopper moved.
Insert the fall prevention tongue of each punch into the fall
prevention groove of the clamping plates as shown in Fig. 2, and
slide the punch into position.
Tighten the punch holder levers clockwise to prevent the punch or
punches from falling as shown in Fig. 3.
Stagger the punches and dies by about 5 mm (0.2 in.) to prevent
the worksheet from being scratched as shown in Fig. 4.
PUNCH
DIE
ABOUT 5 mm (0.2 in.)
Fig. 2 Fig. 3 Fig. 4
23 Repeat steps 17 to 22 to install the other punches.
IV-37
clockwise.

WARNING
off the light.
Max P = L × T
where,
(kN)
500 kN.
28 When the Max P value is smaller than 30 kN, press and hold the
CLOSING foot pedal, and turn the HANDWHEEL clockwise to
apply a pressure below the Max P value and push the punches
tightly against the punch holders. (Operate the HANDWHEEL
with due care not to apply an excessive pressure. The current
pressure is displayed in the P field.)
When the Max P value is not smaller than 30 kN, press and hold
the CLOSING foot pedal, and turn the HANDWHEEL clockwise to
apply a pressure of 20 to 30 kN and push the punches tightly
against the punch holders. (Operate the HANDWHEEL with due
care not to apply an excessive pressure. The current pressure is
displayed in the P field.)
IV-38
29 Move up and down the ram two or three times to engage and align
the punches and dies. With the CLOSING foot pedal pressed
and held (pressure applied to the punches and dies), securely
tighten the fixing bolts.
O When aligning the punches and dies,

WARNING
move up and down the ram within the
die V-groove. If the ram is stroked
up and down to such an extent that
the punch tip moves out of the die
V-groove, the punch tip may strike
against the die shoulder in a
dangerous manner.
NOTE
O Tighten the fixing bolts while pressing and holding the CLOSING foot
pedal. When the CLOSING foot pedal is released while pressure is
applied, the pressure is removed, and the ram slightly opens.


not pressed.
(0.0000 in.)” on the display, and the “Tool Origin Setting
completed” is displayed.
IV-39
origin.
PEDAL, or SINGLE.
IV-40
Installing 2V-dies
Install the 2V-dies as described below.
1 Install the die holders on the top of the lower beam, and fix them
with the clamping plates of the lower beam. Since the dies and
die holders differ in length as shown in the table below, separate
the die holders by about 5 mm (0.2 in.) as shown in Fig. 5.
L size S size
Die holder 830 mm (32.68 in.) 412 mm (16.22 in.)
Die 835 mm (32.87 in.) 415 mm (16.34 in.)
NOTICE
O Set die holders for 2V-dies so that their step and the dies’ V-groove to
be used face the rear as shown in Fig. 5. This orientation is termed
“front”. This is to prevent the dies from flying toward the operator
when they break.

Fig. 5
2 Loosen the four fixing bolts of each die as shown in Fig. 6, slide
the dies from the operator’s side (the front of the machine) onto
the die holder top with the V-groove to be used facing the rear,
and approximately center the dies as shown in Fig. 7.
DIE
2V-DIE
WASHER
DIE FIXING BOLT

BOLT DIE HOLDER
Fig. 6 Fig. 7
IV-41
Installing 1V-dies
1 Loosen the four fixing bolts of each die, slide the dies from the
operator’s side (the front of the machine) onto the die holder top,
1V-DIE
(FOR FORMING SASHES)
DIE HOLDER
DIE FIXING BOLT

Fig. 8
When 1V-dies with a V-groove opening width of 32 mm (1.260 in.)

or more are installed on the top of the lower beam, they may
produce a large clearance between the punches and dies due to
the relationship between the open height and stroke. In such a
case, use the optional die blocks to reduce the clearance. Install
the die blocks by paying attention to their orientation as shown in
Fig. 9.
REAR
FRONT
Fig. 9
NOTICE
O The rear clamping plates of the lower beam and die blocks establish
the reference surface for aligning the punches and dies. Never loosen
them.
IV-42
6-2-2. WHEN TOOL LAYOUT IS NOT SET

DANGER


IV-43
HANDWHEEL clockwise to close the ram to the punch installation
position shown in Fig. 1. If the ram is apart from the punch
bring the ram close to the punch installation position at a high
speed (×5). When the ram comes close to the punch installation
position, press the ×5 button again to turn off the light.
3 to 5
(0.12 to 0.20 in.)
Fig. 1

WARNING
turn the HANDWHEEL
dangerous manner.

7 Install the die holders on the lower beam, and tighten the fixing
bolts.
IV-44
8 Install the dies and punches.
Insert the fall prevention tongue of each punch into the fall
prevention groove of the clamping plates as shown in Fig. 2, and
slide the punch into position.
Tighten the punch holder levers clockwise to prevent the punch or
punches from falling as shown in Fig. 3.
Stagger the punches and dies by about 5 mm (0.2 in.) to prevent
the worksheet from being scratched as shown in Fig. 4.
PUNCH
DIE
Fig. 2 Fig. 3 Fig. 4

clockwise.

WARNING
off the light.
IV-45
Max P = L × T
where,
(kN)
500 kN.
13 When the Max P value is smaller than 30 kN, press and hold the
CLOSING foot pedal, and turn the HANDWHEEL clockwise to
apply a pressure below the Max P value and push the punches
tightly against the punch holders. (Operate the HANDWHEEL
with due care not to apply an excessive pressure. The current
pressure is displayed in the P field.)
When the Max P value is not smaller than 30 kN, press and hold
the CLOSING foot pedal, and turn the HANDWHEEL clockwise to
apply a pressure of 20 to 30 kN and push the punches tightly
against the punch holders. (Operate the HANDWHEEL with due
care not to apply an excessive pressure. The current pressure is
displayed in the P field.)
14 Move up and down the ram two or three times to engage and align
the punches and dies. With the CLOSING foot pedal pressed
and held (pressure applied to the punches and dies), securely
tighten the fixing bolts.
O When aligning the punches and dies,

WARNING
move up and down the ram within the
die V-groove. If the ram is stroked
up and down to such an extent that
the punch tip moves out of the die
V-groove, the punch tip may strike
against the die shoulder in a
dangerous manner.
IV-46
NOTE
O Tighten the fixing bolts while pressing and holding the CLOSING foot
pedal. When the CLOSING foot pedal is released while pressure is
applied, the pressure is removed, and the ram slightly opens.


not pressed.
pressure cannot be applied to “Origin Pressure” displayed, press
and hold the CLOSING foot pedal at a pressure below “Origin
Pressure”, and press the SET button to set the tool origin.
PEDAL, or SINGLE.
IV-47
Installing 2V-dies
1 Install the die holders on the top of the lower beam, and fix them
with the clamping plates of the lower beam. Since the dies and
die holders differ in length as shown in the table below, separate
the die holders by about 5 mm (0.2 in.) as shown in Fig. 5.
L size S size
Die holder 830 mm (32.68 in.) 412 mm (16.22 in.)
Die 835 mm (32.87 in.) 415 mm (16.34 in.)
NOTICE
O Set die holders for 2V-dies so that their step and the dies’ V-groove to
be used face the rear as shown in Fig. 5. This orientation is termed
“front”. This is to prevent the dies from flying toward the operator
when they break.

Fig. 5
2 Loosen the four fixing bolts of each die as shown in Fig. 6, slide
the dies from the operator’s side (the front of the machine) onto
the die holder top with the V-groove to be used facing the rear,
DIE
2V-DIE
WASHER
DIE FIXING BOLT

BOLT DIE HOLDER
Fig. 6 Fig. 7
IV-48
Installing 1V-dies
1 Loosen the four fixing bolts of each die, slide the dies from the
operator’s side (the front of the machine) onto the die holder top,
1V-DIE
(FOR FORMING SASHES)
DIE HOLDER
DIE FIXING BOLT

Fig. 8
When 1V-dies with a V-groove opening width of 32 mm (1.260 in.)

or more are installed on the top of the lower beam, they may
produce a large clearance between the punches and dies due to
the relationship between the open height and stroke. In such a
case, use the optional die blocks to reduce the clearance. Install
the die blocks by paying attention to their orientation as shown in
Fig. 9.
REAR
FRONT
Fig. 9
NOTICE
O The rear clamping plates of the lower beam and die blocks establish
the reference surface for aligning the punches and dies. Never loosen
them.
IV-49
6-3. Removing tools
6-3-1. WHEN TOOL ORIGIN IS SET FOR TOOLS INSTALLED ON
MACHINE

PULL BACK button.
IV-50
window opens.
5 Press the SET button.

6 Check that the D-axis target value is set to the tool change
position “3.000 mm (0.1181 in.)”, and press the CLOSING foot
pedal to close the ram to a tool clearance of 3 mm (0.1181 in.).
The tool origin is cleared.

WARNING

8 Turn the punch holder levers to the left, and remove the punches
by sliding them sideways.
9 Remove the dies.
PEDAL, or SINGLE.

CAUTION
IV-51
6-3-2. WHEN TOOL ORIGIN IS NOT SET FOR TOOLS INSTALLED
ON MACHINE

PULL BACK button.

clockwise to close the ram until the clearance between the punch
tip and the die V-groove bottom becomes 3 to 5 mm (0.12 to 0.20
in.).
When the punches are apart from the dies, press the ×5 button to
turn on the light and bring the punches close to the dies at a high
speed (×5). When the punches come close to the dies, press the
×5 button again to turn off the light.
IV-52
WARNING
CLOSING foot pedal.

6 Turn the punch holder levers to the left, and remove the punches
by sliding them sideways.
7 Remove the dies.
PEDAL, or SINGLE.

CAUTION
IV-53
6-4. Other uses
6-4-1. NAME OF EACH PART
UNCLAMP CLAMP STOPPER

STOPPER PIN PIN
WEDGE
SUPPORT
FRONT CLAMPING
PLATE
REAR FIXING BOLTS
PUNCH
HOLDER LEVER
REAR CLAMPING
PLATE
FRONT FIXING BOLT
FALL PREVENTION PUNCH HOLDER

MECHANISM
IV-54
6-4-2. PUNCH HOLDER LEVER POSITIONS

Position ◯
A
Turn the lever to this position to install and remove the punches by
NOTE
O When the lever is turned to “Position ◯
A ”, the punches cannot be installed
and removed from the front of the machine.
Position ◯
B (This is basic lever position)
Turn the lever to this position to clamp the punches and to install and
remove the lever itself.
Position ◯
C
Turn the lever to this position to install and remove 100 mm (3.94 in.) or
shorter sectionalized punches from the front of the machine.
IV-55
6-4-3. INSTALLING AND REMOVING PUNCHES FROM FRONT
O Before installing and removing the

DANGER
punches, turn the MODE SELECT
Installing punches from front
O If the punch is 100 mm (3.94 in.) or more in

WARNING
length, do not install it from the front of
the machine. You cannot safely support
it with your hand or hands.
O When installing
CAUTION
a punch from the
front of the
machine, push it
straight up.
If the punch is
pushed up
inclined, the
clamping plate remains open and allows
the punch to fall.
Check that the punch does not fall when
pulled down, and then release it.
1 Turn down the

unclamp stopper pin,
and turn the punch
holder lever
counterclockwise to
“Position ◯C ”.

2 Hold the sides of the

punch as shown right,
and push the punch
upward so that it
becomes parallel with
the punch holder.
IV-56
3 Turn the punch holder
lever clockwise to
“Position ◯A ”, and
turn up the unclamp
stopper pin.

4 After positioning the punch, turn the punch holder lever clockwise
to “Position ◯B ” to clamp the punch.
5 Install the punch as described in “6-2. Installing tools”.
IV-57
Removing punches from front
O If the punch is 100 mm (3.94 in.) or more in

WARNING
length, do not remove it from the front of
the machine. You cannot safely support
it with your hand or hands.
1 Turn down the

unclamp stopper pin,
and turn the punch
holder lever to
“Position ◯C ”.

2 Hold the sides of the

punch as shown right,
and remove the
punch from the front
of the machine.

3 Turn the punch holder

lever clockwise to
“Position ◯A ”, and
turn up the unclamp
stopper pin.

IV-58
6-4-4. INSTALLING AND REMOVING PUNCHES BY SLIDING
THEM ALONG GROOVE OF REAR CLAMPING PLATES
O Before installing and removing the

DANGER
punches, turn the MODE SELECT
Installing punches in rear clamping plates

1 Insert the fall
prevention tongue of
the punch into the fall
prevention groove of
the 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
described in “6-2.
Installing tools”.
REAR FIXING
BOLTS
NOTICE
O When turning the rear
fixing bolts with an
Allen wrench to clamp
the punch, be sure to
tighten the left and
right of the rear
clamping plate parallel
and with equal force.
If you overtighten the
clamping plate with
the leverage of a long
wrench or pipe, the
durability of the
belleville springs may
suffer.
IV-59
Removing punches from rear clamping plates
O When loosening the rear fixing bolts, do

WARNING
not turn them counterclockwise more than
one and a half turns. If the bolts are
turned more than one and a half turns, the
rear fall prevention mechanism may not
operate, allowing the punch to fall in a
dangerous manner.
1 Turn the rear fixing TURN REAR FIXING BOLTS

bolts COUNTERCLOCKWISE
counterclockwise by
one turn with an Allen
wrench as shown
right.
2 Remove the punch by
sliding it sideways.
REAR FIXING
BOLTS
6-4-5. INSTALLING AND REMOVING REAR CLAMPING PLATES
O Before installing and removing the rear

DANGER
clamping plates, turn the MODE SELECT
Before installing and removing the rear clamping plates, be sure to

remove the punch holder units from the upper beam.
Removing rear clamping plates

1 Place the punch
holder unit so that the
rear clamping plate
faces down as shown
right.
REAR CLAMPING
PLATE
IV-60
2 Turn the rear fixing REAR FIXING
bolts BOLT
counterclockwise with
an Allen wrench, and
BOLT COLLAR
remove them from the
nuts.
3 Remove the bolt REAR FIXING BOLT

collars from the front
clamping plate, lift the
punch holder, and BOLT COLLAR
remove the rear
clamping plate.
Assemble the rear
clamping plate as
shown right, and store
it.
SPRING
REAR CLAMPING
PLATE

IV-61
Installing rear clamping plates
O Do not turn the rear fixing bolts

WARNING
counterclockwise more than one turn from
the finger-tightened position. If the bolts
are turned more than one turn, the rear fall
prevention mechanism may not operate,
allowing the punch to fall in a dangerous
manner.
1 Place the punch REAR FIXING BOLT

holder unit as shown
right with the keys of
the rear fixing nuts BOLT COLLAR
aligned with the nut
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 SPRING
shown right. PUNCH REAR FIXING
HOLDER NUT
3 Insert the bolt collars
into the rear fixing-bolt
installation holes of
the front clamping
plate, and
finger-tighten the rear
REAR CLAMPING PLATE
fixing bolts clockwise
with an Allen wrench
while pushing down
the front clamping
plate.
4 Turn back the rear
fixing bolts
counterclockwise by
one turn from the
finger-tightened
position, so that the
punch can be slid
sideways.
IV-62
7. BENDING SPEED OF RAM

(HDS5020 to HDS2204)
HDS5020 to HDS2204 has a maximum bending speed of 20 mm/sec
(0.787 ips). This high bending speed may produce the following
phenomena that are not found on conventional press brakes. Before
bending a worksheet, dry run the machine to check that the bending
speed is appropriate for the worksheet.
(1) The worksheet rapidly springs up when it is large.
(2) The worksheet often buckles when it is thin or weak.
(3) The worksheet collides against the ram when it is placed barely
interfering with the ram.
7-1-1. BENDING SPEED FOR REPEAT PROCESSING PROGRAM

CREATED ON ANOTHER PRESS BRAKE MODEL
When a repeat processing program created on another press brake
model is used on HDS5020 to HDS2204, its SF value is directly read as
bending speed (slowdown speed). When a program created with an
SF value of 9 (8 mm/sec (0.315 ips)) on another press brake model is
read, the machine operates at a bending speed of 20 mm/sec (0.787
ips) because the SF value is unchanged at 9.
Even if the same program is used, the bending speed that corresponds
to each SF value varies between press brake models. Given this fact,
dry run the machine to check that the bending speed is appropriate,
and then bend the worksheet.
7-1-2. INITIAL VALUE OF BENDING SPEED (SLOWDOWN SPEED

SF)
When a new processing program is created, the initial value set by the
user parameter 45 (Slow Down Speed Default) is entered by default as
bending speed (SF).
The initial value is set to SF6 (10 mm/sec (0.394 ips)) at the time of
shipment and can be changed.
When you have changed the initial value, dry run the machine to check
that the bending speed is appropriate, and then bend the worksheet.
IV-63
7-2. Relationship between bending speed and
bend angle
As one bending phenomenon, the finish bend angle may be different for
bending with the same D-axis value if the bending speed is extremely
different.
Check the finish bend angle of the first worksheet bent during automatic
operation after trial bending. If the finish bend angle is not as specified,
finely adjust the D-axis value.
7-3. Speed change position of ram

Enter an appropriate value in the slowdown position SD field so that the
ram changes from high speed to bending speed at 2 mm (0.0787 in.)
above the top surface of the worksheet.
If the slowdown position is set lower, the ram does not change from
high speed to bending speed, the tooling may strike the worksheet, and
the worksheet may flip up.
8. SETTING SPEED OF EACH AXIS

The feed speed of the backgauge, stoppers and ram can be changed
by setting the following user parameters.
(1) Changing forward speed of backgauge

The speed at which the backgauge moves forward can be set in the
range of 10 to 100%.
User parameter to set: 94 (Forwarding Speed of L Axis)
Initial value: 100%
(2) Changing slowdown position of backgauge

The position where the backgauge slows down to the speed set by the
user parameter 94 (Forwarding Speed of L Axis) can be set.
User parameter to set: 28 (Safety Axis Action Position)
Initial value: 100 mm (3.937 in.)
IV-64
(3) Changing feed speed of stoppers
The speed at which the stoppers move left and right can be set in the
range of 10 to 100%.
User parameter to set: 95 (Forwarding Speed of Y Axis)
Initial value: 100%
(4) Changing high closing speed of ram

The speed at which the ram rapidly approaches the lower beam can be
set in the range of 50 mm/sec (1.969 ips) to the maximum value.
User parameter to set: 91 (Approaching Speed of Beam)
Initial value: 200 mm/sec (7.874 ips) for HDS5020 to HDS2204
120 mm/sec (4.724 ips) for HDS3504
(5) Changing opening speed of ram

The speed at which the ram returns after completing a bend can be set
in the range of 1 to 200 mm/sec (0.039 to 7.874 ips).
User parameter to set: 92 (Slow Up Speed)
Initial value: 200 mm/sec (7.874 ips) for HDS5020 to HDS2204
(6) Setting low-speed rising end position of ram

The position where the ram ends its low-speed rising motion can be set
between the tool origin and the multiple opening limit.
User parameter to set: 93 (Slow Up Position)
Initial value: 5 mm (0.197 in.)
NOTE
O To enable the low-speed rising function for a process, enter “009” in the OP
field for the process.
IV-65
9. TURNING OFF POWER
9-1. When tool origin is set for tools installed

on machine
End the day’s work as described below.
NOTICE
O When you end the day’s work and stop the machine, close the ram until the
punch tip enters the die V-groove. If the machine is left stopped with the
ram open, there may occur such trouble as the ram tilting under its own mass
or foreign matter caught between the punches and dies.
NOTE
O The machine has an automatic power-off function. When the AMNC
application completes the shutdown procedure at the end of the job, the NC
automatically turns off the machine circuit breaker.
To turn on the machine circuit breaker, turn its handle to RESET and then to
ON.
1 Press the STOP button during automatic operation.

window opens:
4 Press the OK button.

5 Check that the D-axis target value is “3.000 mm (0.1181 in.)”.
Press and hold the CLOSING pedal until the ram stops.

WARNING
IV-66
7 Turn the MOTOR ON/OFF keyswitch to OFF and then back to the
central position.
NOTE
8 Turn the POWER ON/OFF keyswitch to OFF.

The POWER lamp goes out.
9 Turn off the machine circuit breaker.
IV-67
9-2. When tool origin is not set for tools
installed on machine
End the day’s work as described below.
NOTICE
O When you end the day’s work and stop the machine, close the ram until the
punch tip enters the die V-groove. If the machine is left stopped with the
ram open, there may occur such trouble as the ram tilting under its own mass
or foreign matter caught between the punches and dies.
O When the tools installed on the machine are short, remove them or install
tools of necessary length, and close the ram.
O If the machine has the hydraulic clamps (modular tooling system) and is to be
left idle for a long period of time, remove the tools , open the clamps, and
close the ram.
NOTE
O The machine has an automatic power-off function. When the AMNC
application completes the shutdown procedure at the end of the job, the NC
automatically turns off the machine circuit breaker.
To turn on the machine circuit breaker, turn its handle to RESET and then to
ON.
1 Turn the MODE SELECT keyswitch to INCHING.

2 Change the LCD screen to the SETUP display.
3 While pressing and holding the CLOSING foot pedal, turn the
HANDWHEEL clockwise to close the ram until the clearance
between the punch tip and die V-groove becomes 2 to 3 mm (0.08
to 0.12 in.).

WARNING
CLOSING foot pedal.

central position.
NOTE
6 Turn the POWER ON/OFF keyswitch to OFF.

The POWER lamp goes out.
7 Turn off the machine circuit breaker.
IV-68
10. CROWNING CONTROL OF MACHINES
WITH TWO C-AXES
(ONLY FOR HDS3504 AND HDS5006)
HDS3504 and HDS5006 have auxiliary cylinders installed in the lower
beam as shown below.
The center cylinder or cylinders are controlled by the crowning value C1,
and the end cylinders are controlled by the crowning value C2. The
pressure applied to each cylinder is as follows:
C1 cylinder pressure = Main pressure × (Display value C1 (%) +
Display value C2 (%))
C2 cylinder pressure = Main pressure × (Display value C1 (%) –
Display value C2 (%))
HDS3504
C2 C1 C2
CROWNING COMPENSATION
VALUE C1
VALUE C2
HDS5006
C2 C1 C1 C1 C2
VALUE C1
VALUE C2
IV-69
Of the crowning values C1 and C2, the former is automatically set
according to the worksheet thickness and material type, bend length,
and tool data. For the latter, directly enter an appropriate value.
IV-70
Entering value C2
If the worksheet is correctly bent to the target angle at the center but
not at other portions as shown below, compensate the value C2 in the
negative direction. For example, enter “–20 (%)” in the C2 field.
Determine the actual value C2 after trial bending.
ANGLE LARGER THAN TARGET ANGLE
TARGET ANGLE
If the bend length is short and the worksheet is bent to an angle larger
than the target angle at the center as shown below, compensate the
value C2 in the positive direction. For example, enter “20 (%)” in the
C2 field. Determine the actual value C2 after trial bending.
ANGLE LARGER THAN TARGET ANGLE
TARGET ANGLE
IV-71
IV-72
Part V
Maintenance
1. Inspection before start of day’s work .......................................... V-2

2. Maintaining hydraulic system...................................................... V-3
2-1. Checking hydraulic oil levels ................................................ V-3
2-2. Changing hydraulic oil.......................................................... V-4
3. Lubrication .................................................................................. V-6
3-1. Guide rollers......................................................................... V-6
3-2. Backgauge ........................................................................... V-7
3-3. Pins of lower beam (only for HDS5006)............................... V-9
4. Changing relays ......................................................................... V-10
5. Cleaning heat exchanger ........................................................... V-11
6. Using ram lock ........................................................................... V-12
7. Fee-based consumable parts list ............................................... V-13
O Unless you need electric and hydraulic power

WARNING
when maintaining or cleaning the machine, turn off
the shop circuit breaker, and relieve the residual
hydraulic pressure in the machine.
O Post a sign to inform other workers that the
machine is under maintenance.
V-1
1. INSPECTION BEFORE START OF DAY'S
WORK
Inspection before the start of the day's work is very important for the
safe and trouble-free operation of the machine. Before starting the
operation of the machine, be sure to inspect the following items.
No. Item Method Remedy

Primary power cable is not Visually check. If cable is damaged, change
1
damaged. it.
Switches, buttons, and Visually and tactually check. If switches and buttons
lamps are not functionally or malfunction or are
2 visually damaged. damaged, and if lamps are
burnt out, contact AMADA
for changing them.
Hydraulic pump motors do Aurally check. If abnormal noise is heard,
3
not produce abnormal noise. contact AMADA.
There are no hydraulic oil Visually check. If there is hydraulic oil leak,
4 leaks. contact AMADA for repairing
it.
Ram normally operates. 1 Remove tools from If ram does not normally
machine. operate, contact AMADA.
2 Change to SETUP
display, and set tool
5
origin.
3 Press CLOSING foot
pedal, and check that ram
normally operates.
EMERGENCY STOP 1 Remove tools from If ram does not stop when
buttons normally operate. machine. EMERGENCY STOP button
is pressed, contact AMADA.
2 Change to SETUP
display, and set tool
origin.
6
3 Press CLOSING foot
pedal, and press one of
EMERGENCY STOP
buttons while ram is
closing.
Tools are fixed in place. Visually and tactually check. Correctly install tools. (For
detailed procedure, refer to
“5. Setting up modular
7 tooling system” or “6.
Setting up one-touch punch
holders (option)” in Part IV,
Controls & operation.)
Tools are not damaged. Visually check. If tools are damaged,

8
change them.
V-2
No. Item Method Remedy
Hydraulic oil levels are Visually check. If hydraulic oil level or levels
proper. (When ram is at are low, add hydraulic oil.
maximum opening limit, (Refer to “2-1. Checking
9
hydraulic oil level is near hydraulic oil levels” on next
upper red line on each oil page.)
gauge.)
LCD screen is bright. Visually check. O Adjust with bright control

at bottom of pendant
control box.
10 O If LCD screen is not still
bright enough, contact
AMADA for changing its
backlight.
There is buildup of dust on Visually check. Dust buildup causes fan to
fan in heat exchanger. malfunction. Remove it.
11
(Refer to “5. Cleaning heat
exchanger”.)
Fan is running. Visually check. If fan is not running, contact

12
AMADA for changing it.
2. MAINTAINING HYDRAULIC SYSTEM

If the hydraulic oil is badly contaminated, change it. Ask AMADA or a
contractor to change the hydraulic oil.
When the oil filters are contaminated, an alarm is displayed. In such a
case, change the oil filters. Ask AMADA to change the oil filters.
2-1. Checking hydraulic oil levels

Open the ram to the maximum opening limit, turn the POWER ON/OFF
keyswitch to OFF, and check that the hydraulic oil is filled to the upper
red line on the three or four oil gauges.
If the hydraulic oil level or levels are low, add the hydraulic oil through
the filler opening at the top of each tank.
NOTICE
O Be sure to add the same hydraulic oil as originally used.
O Check that the hydraulic pressure indications are stable when pressure is
applied.
V-3
2-2. Changing hydraulic oil
Change the hydraulic oil every year. (The hydraulic oil should be
changed entirely even if it was added in the midway.)
Tank capacity, L (US gal)
Model
Total D1-axis D2-axis CC (C1)-axis C2-axis
HDS5020 37.5 (9.9) 17 (4.49) 17 (4.49) 3.5 (0.92) ―
HDS8025 37.5 (9.9) 17 (4.49) 17 (4.49) 3.5 (0.92) ―
HDS1030 57.5 (15.2) 27 (7.13) 27 (7.13) 3.5 (0.92) ―
HDS1303 67.5 (17.8) 32 (8.45) 32 (8.45) 3.5 (0.92) ―
HDS1703 126.5 (33.4) 60 (15.85) 60 (15.85) 6.5 (1.72) ―
HDS2203 126.5 (33.4) 60 (15.85) 60 (15.85) 6.5 (1.72) ―
HDS2204 126.5 (33.4) 60 (15.85) 60 (15.85) 6.5 (1.72) ―
HDS3504 175 (46.2) 80 (21.14) 80 (21.14) 7 (1.85) 8 (2.11)
HDS5006 220 (58.1) 100 (26.42) 100 (26.42) 10 (2.64) 10 (2.64)
Recommended oil: Amada NCA-250 or equivalent (see next page)
NOTICE
O When the hydraulic oil is changed, also clean the filters in the hydraulic oil
tanks.
Change the hydraulic oil as described below.
1 Open the ram to the maximum opening limit.

central position. The hydraulic pump motors stop, and the
MOTOR lamp goes out.
3 Turn the POWER ON/OFF keyswitch to OFF. The power to the
NC is turned off.
4 Remove the filler cap at the top of each tank.
5 Prepare an empty can of such a capacity as to match the tank
capacity (refer to the table above), and place it below the drain
plug of the tank. Remove the drain plug to drain the old hydraulic
oil from the tank into the can.
6 Replace the drain plug.
7 Pour new hydraulic oil through the filler opening into the tank.
8 Tighten the filler cap.
V-4
Hydraulic oil selection (Equivalent/Recommended oils)
Guaranteed kinematic viscosity (stable operation of hydraulic system):
150 to 20 cSt at oil temperature of 0 to 50°C (32 to 122°F)
Operating temperature: 0 to 50°C (32 to 122°F) at ambient temperature
of 0 to 40°C (32 to 104°F)
Equivalent oils of Amada NCA-250

Kinematic Kinematic
150 to 20 cSt
viscosity viscosity Viscosity
Manufacturer Name oil temperature
at 40°C at 100°C index
range
(104°F), cSt (212°F), cSt
–1 to 54°C
Amada NCA-250 29.6 7.79 253
(30.2 to 129.2°F)
–1 to 54°C
Esso Univis J32 29.6 7.79 253
(30.2 to 129.2°F)
–19 to 52°C
Esso Univis HVI26 25.8 9.3 376
(–2.2 to 125.6°F)
Hyrando –2 to 50°C
Nippon Oil 26.8 6.89 238
PTF26 (28.4 to 122.0°F)
Recommended oils in areas where equivalent oils are not available

<Cold area>
Kinematic Kinematic
150 to 20 cSt
range
(104°F), cSt (212°F), cSt
0 to 42°C
Mobil DTE12M 22 4.85 149
(32.0 to 107.6°F)
Tellus Oil –1 to 43°C
Shell 22.6 5.2 155
T22 (30.2 to 109.4°F)
Hyrando 2 to 45°C
Nippon Oil 23.9 5.18 154
Wide 22 (35.6 to 113.0°F)
Daphne
0 to 41°C
Idemitsu Super Hydro 21.32 4.7 144
(32.0 to 105.8°F)
X22
<Warm area>
Kinematic Kinematic
150 to 20 cSt
range
(104°F), cSt (212°F), cSt
9 to 53°C
Mobil DTE13M 32 6.1 141
(48.2 to 127.4°F)
Tellus Oil 8 to 54°C
Shell 32.8 6.56 154
T32 (46.4 to 129.2°F)
Hyrando 9 to 54°C
Nippon Oil 32.9 6.37 149
Wide 32 (48.2 to 129.2°F)
Daphne
9 to 52°C
Idemitsu Super Hydro 31.12 5.985 141
(48.2 to 125.6°F)
X32
NOTICE
O The oil temperature range shown in the tables above is only guaranteed.
V-5
3. LUBRICATION
O Before maintaining or cleaning the
WARNING
machine, turn off the shop circuit breaker,
and relieve the residual hydraulic
pressure in the machine.
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 lubricate the specified parts periodically.
3-1. Guide rollers

Apply grease to four guide rollers, two each at the top, bottom, left and
right.
Recommended lubricant: Shell Alvania EP Grease R0 or equivalent
Lubrication interval: Six months

V-6
3-2. Backgauge
Recommended lubricant
For L-axis LM guide (integral ball screw): THK AFC Grease or
equivalent
For Z-axis ball screw: THK AFC Grease or equivalent
For Z-axis LM guide: THK AFB-LF Grease or equivalent
For Y-axis LM guide: THK AFB-LF Grease or equivalent
For Y-axis rack and pinion: Amada Grease EP No.2 or equivalent
PROTECTIVE COVER
GREASE NIPPLE
(Z-AXIS BALL SCREW) GREASE NIPPLE
(Z-AXIS LM GUIDE)
GREASE NIPPLE
(L-AXIS LM GUIDE)
GREASE NIPPLE
(L-AXIS LM GUIDE)
GREASE NIPPLE
(Z-AXIS LM GUIDE)
NOTICE
O Do not apply rust-preventive oil or the like to the spiral protective cover.
Otherwise it may malfunction.
V-7
L-axis (L1, L2)
1 Remove the L-axis rail covers.
2 Apply grease to the L-axis LM guide blocks (one each at the front
and rear) through their grease nipples until a small amount of
grease bleeds out of the guide blocks of the L-axis ball screw.
3 Wipe off the grease bleeding out of the guide blocks with a waste
cloth.
4 Move the stretch bar back and forth by hand ten times.
5 Wipe off the grease bleeding out of the guide blocks and the
grease deposited on the grooves of the ball screw shaft with a
waste cloth.
6 Again move the stretch bar back and forth by hand ten times.
7 Wipe off the grease deposited on the grooves of the ball screw
shaft with a waste cloth.
8 Replace the L-axis rail covers.
Z-axis (Z1, Z2)

1 Turn off the power to the machine in the Z = 200 mm (7.87 in.)
condition.
2 Remove the Z-axis covers.
3 Apply grease to the Z-axis ball screw nut and LM guide blocks
through their grease nipples until a small amount of grease bleeds
out of the Z-axis ball screw nut and LM guide blocks.
4 Wipe off with a waste cloth the grease bleeding out of the nut and
guide.
5 Move the stretch bar up and down by hand ten times.
6 Wipe off the grease bleeding out of the nut and guide blocks and
the grease deposited on the grooves of the ball screw shaft with a
waste cloth.
7 Again move the stretch bar up and down by hand ten times.
8 Wipe off the grease deposited on the grooves of the ball screw
shaft with a waste cloth.
9 Replace the Z-axis covers.
Y-axis (Y1, Y2)

Apply grease to each rack and pinion. Apply grease through the
grease nipples to the Y-axis LM guides in the stoppers.
V-8
3-3. Pins of lower beam (only for HDS5006)
If your machine is HDS5006, apply grease to pins through their grease
nipples at the left and right sides of the lower beam.
Recommended lubricant: Amada Grease EP No.2 or equivalent
GREASE NIPPLE
V-9
4. CHANGING RELAYS
The relays used in the electrical enclosures are consumable.
Referring to the change intervals shown in the table below, ask AMADA
to change the relays.
The life of the relays depends on how often the foot pedals are turned
on and off. Although the stroke frequency does not always agree with
the on/off frequency, take the stroke frequency as a measure of the
change interval. (The stroke frequency can be checked on the
RUNNING INFO display.)
Stroke frequency Change Relays Circuit symbols
(strokes per day) interval (model and quantity)
1000 3 years Model: KA212A, KA212B,

LY2ZN-DC24V KA212C, KA212D,
2000 1.5 years (Manufacturer: KA211A, KA211B,
Omron) KA211C, KA211D,
3000 1 year Quantity: 10 KA8, KA14
NOTE
O The values of the above table do not guarantee the life of the relays and
should be taken as a measure of the change interval.
O All relays mentioned in the above table must be changed at a time.
V-10
5. CLEANING HEAT EXCHANGER
About every six months, remove the dust deposited in the heat
exchanger and on the fan motor.
Portion A
Remove four
screws
(Door of electrical enclosure)
While holding the fan mounting plate with one hand, remove the four
screws.
If the fan area (inside of the fan mounting plate and the tips of the fan
blades) is coated with dust, wipe off the dust with a dry waste cloth.
If dust is deposited in the portion A from which the fan is removed,
vacuum off the dust.
V-11
6. USING RAM LOCK
The ram lock is a device that prevents the ram from moving down
during machine maintenance and inspection. Usually, the ram lock
need not be operated when operating the machine. At the end of a
normal day’s work, close the ram until the punch tip enters the die
V-opening, and turn off the power to the machine.
The ram lock is operated with the RAM LOCK ON/OFF keyswitch on
the door of the electrical enclosure. The ram does not close when it is
at the maximum opening limit and the RAM LOCK ON/OFF keyswitch
is set to ON.
Turn the RAM LOCK ON/OFF keyswitch to ON when the ram is at the
maximum opening limit. If the RAM LOCK ON/OFF keyswitch is
turned to ON when the ram is not at the maximum opening limit, press
the foot pedal EMERGENCY OPENING button to open the ram to the
maximum opening limit.
Pressing the EMERGENCY OPENING button does not open the ram
when one of the EMERGENCY STOP buttons is pressed, when the
MODE SELECT keyswitch is set to OFF, or when the MOTOR ON/OFF
keyswitch is set to OFF.
V-12
7. FEE-BASED CONSUMABLE PARTS LIST
HDS5020
No. Unit Part name Specification or type Qty Manufacturer
1 Wear ring GP6401050-T47 4
2 Wear ring GP6901050-C380 2
3 Piston packing PT0301050-T46 2

4 O-ring ORAR00341-N7038 2
5 Wear ring GR6400996-T47 2
Captain
6 Cylinder Wear ring GR6900996-C380 4
7 Rod packing RS1300996-T46 4
8 O-ring ORAR00346-N7038 4
9 Rod packing WE3200996-T46 2

10 O-ring ORAR00242-N7038 2
11 O-ring 1B-P100 2
12 O-ring 1B-P18 4
13 D-axis unit O-ring 1B-P11 2
14 O-ring 1B-P22 2 Not specified
15 O-ring 1B-P18 1
16 O-ring 1B-P14 2
Crowning
17 O-ring 1B-P150 2
18 Backup ring T3-P150 2 NOK
19 Detector Limit switch D4N-6A31 2 Omron
20 Ram lock Limit switch LCB1-113 2 Yamatake
21 Rear guard Limit switch D4D-2AFS+D4DS-K2 1 Omron

22 Z-axis tilt Limit switch SL1-H 1 Yamatake
V-13
HDS8025
2 Wear ring GP6901320-C380 2

4 O-ring ORAR00349-N7038 2

Captain
7 Rod packing RS1301250-T46N 4
8 O-ring ORAR00354-N7038 4
9 Rod packing WE3201250-T46N 2
10 O-ring ORAR00250-N7038 2
11 O-ring 1B-P125 2
12 O-ring 1B-P18 4
15 O-ring 1B-P18 1
16 O-ring 1B-P14 2
Crowning
17 O-ring 1B-P150 2

21 Rear guard Limit switch D4D-2AFS+D4DS-K2 1 Omron
V-14
HDS1030
2 Wear ring GP6901480-C380 2

4 O-ring ORAR00429-N7038 2

Captain
8 O-ring ORAR00359-N7038 4
10 O-ring ORAR00255-N7038 2
11 O-ring 1B-P140 2
12 O-ring 1B-P22.4 4
15 O-ring 1B-P18 1
16 O-ring 1B-P14 2
Crowning
17 O-ring 1B-P180 2

21 Rear guard Limit switch D4D-2AFS+D4DS-K2 1
Abnormal operation Omron
22 Limit switch D4N-6A31 1
detection
V-15
HDS1303
2 Wear ring GP7301690-C380 2

4 O-ring ORAR00435-N7038 2

Captain
8 O-ring ORAR00363-N7038 4
10 O-ring ORAR00259-N7038 2
11 O-ring 1B-P160 2
12 O-ring 1B-P22.4 4
15 O-ring 1B-P18 1
16 O-ring 1B-P14 2
Crowning
17 O-ring 1B-P180 2

detection
V-16
HDS1703, HDS2203, HDS2204
2 Wear ring GP7502220-C380 2

4 O-ring ORAR00444-N7038 2
5 Wear ring GP7302220-C380 2

Captain

9 O-ring ORAR00446-N7038 4
10 Wear ring GR7502100-C380 2

12 O-ring ORAR00267-N7038 2
13 O-ring 1B-P210 2
14 O-ring 1B-P22.4 4
17 O-ring 1B-P18 5
18 O-ring 1B-P14 3
Crowning
19 O-ring 1B-P200 2


detection
V-17
HDS3504
2 Wear ring GP7502800-C380 4

4 O-ring ORAR00449-N7083 2

Captain
7 Rod packing RSK802650-T46 4
8 O-ring ORAR00451-N7083 4
10 O-ring ORAR00378-N7083 2
11 O-ring 1B-P270 2
12 O-ring 1B-P22.4 4
14 O-ring 1B-P11 2
Not specified
15 O-ring 1B-P18 4
16 O-ring 1B-P14 5
17 O-ring 1B-P245 2
Crowning
18 O-ring 1B-P300 1
19 Backup ring T3-P245 2
NOK
21 Detector Limit switch D4N-6A31 2
22 Rear guard Limit switch D4NS-2BF+D4DS-K2 1
Omron
Abnormal operation
detection
V-18
HDS5006
2 Wear ring GP7503370-C380 6

4 O-ring ORAR00453-N7083 2

Captain
8 O-ring ORAR00455-N7083 4
10 O-ring ORAR00382-N7083 2
11 O-ring 1B-P335 2
12 O-ring 1B-P22.4 4
14 O-ring 1B-P11 2
Not specified
15 O-ring 1B-P18 14
16 O-ring 1B-P14 3
17 O-ring 1B-P230 3
Crowning
18 O-ring 1B-P280 2
NOK
21 Detector Limit switch D4N-6A31 2
22 Rear guard Limit switch D4AS-2AFS+D4DS-K2 1
Omron
Abnormal operation
detection
V-19
Controls for HDS5020 to HDS5006
No. Unit Part name Specification or type Qty Manufacturer Remarks
1 Backlight R0279000 2 Ricoh LCD backlight
TP protective LCD screen
2 Pendant R0271268 1 Ricoh
film protective film
control box
Operation
3 Indicator light APX510-60 1 Fuji Electric
indicator light
4 Relay LY2N-D2(DC24V) 13 Omron RY board

Panasonic
5 Relay DSP2A-DC24V 14 RY board
Electric Works
PA1A-24V Panasonic
6 Relay 5 RY board
(AGP2024) Electric Works
Panasonic
7 Relay TN2-24V(APA3312) 4 RY board
Electric Works
NC2D-DC24V Panasonic
8 Relay 9 RY board
(AW8212) Electric Works
NC4D-DC24V Panasonic
9 Relay 13 RY board
I/O unit (AW8242) Electric Works
Daito
10 Fuse MP63 1 CN board
Apparatus
Daito
Apparatus
Daito
Apparatus
Daito
13 Fuse GP100 1 CN board
Apparatus
Daito
14 Fuse GP32 1 CN board
Apparatus
V-20
Appendix
1. Noise and vibration data ............................................................. A-2

2. Emergency stop time and inertial drop distance of ram.............. A-3
3. Material safety data sheets ......................................................... A-4
3-1. Amada Grease EP No.2....................................................... A-4
3-2. Amada NCA-250 .................................................................. A-8
3-3. Shell Alvania EP Grease 1, 2, R0, R00, & R000................. A-12
3-4. THK AFB-LF Grease ........................................................... A-18
3-5. THK AFC Grease ................................................................A-20
A-1
1. NOISE AND VIBRATION DATA
Noise and vibration measurement points
Noise and vibration were measured at 1 m (3.28 ft) apart from the front,
rear, and right of the machine as shown below. The noise
measurement height was 1.2 m (3.94 ft) above ground.
1m (3.28 ft)
1m (3.28 ft)
FRONT OF MACHINE
1m (3.28 ft)
Noise range A, dB Vibration, dB

Model
○
1 ○
2 ○
3 ○
1 ○
2 ○
3
HDS5020 81 84 77 55 54 56
HDS8025 81 83 79 68 65 67
HDS1030 84 87 81 64 66 69
HDS1303 84 ― ― 68 64 63
HDS1703 81 87 81 69 66 68
HDS2203 81 86 82 70 69 70
HDS2204 85 90 86 68 67 68
HDS3504 81 89 83 60 58 59
HDS5006 85 89 87 67 58 52
A-2
2. EMERGENCY STOP TIME AND INERTIAL
DROP DISTANCE OF RAM
Emergency stop Inertial drop
Model
time, ms distance, mm (in.)
HDS5020 80 12 (0.47)
HDS8025 80 12 (0.47)
HDS1303 80 12 (0.47)
HDS1703 145 13 (0.51)
HDS2203 145 13 (0.51)
HDS2204 145 13 (0.51)
HDS3504 145 8 (0.31)
HDS5006 155 12 (0.47)
A-3
ＭＡＴＥＲＩＡＬＳＡＦＥＴＹＤＡＴＡＳＨＥＥＴ
Note： Read and understand Material Safety Data Sheet before handling or disposing of product.
SECTION 1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
NAME OF PRODUCT AMADA GREASE ＥＰ№２

PRODUCT USE Lubricating grease
NAME OF COMPANY AMADA Co. Ltd.
Address 200 Ishida, Isehara, Kanagawa, Japan
DEPARTMENT Quality Assurance Dept.
ＴEL 0463-96-3423 FAX 0463-96-3403
EMERGENCY CONTACT Oil Service Division Development Group
TEL 048-281-7767 FAX 048-281-7768
DOCUMENT PREPARED＆UPDATED Updated : JUL. 2005
SECTION 2. COMPOSITON/INFORMATION ON INGREDIENTS
COMPOSITION
COMPONENTS Amount (wt%)
Highly ｒｅｆｉｎｅｄｐｅｔｒｏｌｅｕｍｏｉｌ８０～９０
Thickener（Lithium soap）＜１０
Additives ＜１０
JAPANESE COMPOSITION INFORMATION
Labour ＳａｆｅｔｙＬａｗ： Amount (wt%)
１６９ Mineral ｏｉｌ８０～９０％
PRTR Ｌａｗ： Amount (wt%)
Not Applicable
SECTION 3. HAZARDS IDENTIFICATION
EMERGENCY OVERVIEW
Warning statement:
Caution! Prolonged or repeated contact with skin may cause irritation in some cases.
Precautionary Measures:
Avoid breathing vapor and mist. Keep container closed.
Avoid contact with eyes, skin, and clothing.
Wash thoroughly after handling. Keep away from heat.
Potential health effect:
Eyes: May cause minor irritation.
Skin: May cause minimal skin irritation.
Inhalation: Vapor or mist, in excess of permissible concentrations, or in unusually high concentrations
generated from spraying, heating the material, or as from exposure in poorly ventilated
areas or confined spaces, may cause irritation of the nose and throat, headache, nausea,
and drowsiness.
Ingestion: May cause abdominal discomfort, nausea, or diarrhea.
Sensitization properties: Unknown
Chronic Properties: If prolonged exposure occurs, nausea, headache, diarrhea, and physical
discomfort.
Other remarks: None
A-4
SECTION 4. FIRST AID MAESURES
Eyes: Flush immediately with water for at least 15 minutes. Get immediate medical attention.
Skin: Wash with soap and water. Get medical attention if irritation develops.
Launder contaminated clothing before reuse.
Inhalation: Remove exposed person to fresh air if adverse effects are observed.
Ingestion: Do not make person vomit unless directed to do so by medical personnel.
Note to physician: Treat symptomatically.
SECTION 5. FIRE FIGHTIN MEASURES
Flash point (Typical), ℃ Not Determined.

Autoignition tempt., ℃ Not Determined.
Flammability limits: Not Determined.
Extinguishing media: CO2, dry chemical, or foam.
Special fire fighting procedures: Recommend wearing self-contained breathing apparatus. Water may
cause splattering. Material will float on water.
Unusual fire & explosion hazards: Toxic fumes, gases or vapors may evolve on burning.
Explosion data: Material does not have explosive properties.
SECTION 6. ACCIDENTAL RELEASE MEASURES
Procedures in Case of Accidental Release, Breakage or Leakage:

Stop the source of the leak or release. Clean up releases as soon as possible. Contain liquid to prevent
further contamination of soil, surface water or groundwater. Clean up small spills using appropriate
techniques such as sorbent materials or pumping.
Where feasible and appropriate, remove contaminated soil. Follow prescribed procedures for reporting and
responding to larger releases.
SECTION 7. HANDLING AND STRAGE
Do not weld, heat or drill container. Replace cap or bung. Emptied container still contains hazardous material
which may ignite with explosive violence if heated sufficiently.
Minimum feasible handling temperatures should be maintained.
Periods of exposure to high temperatures should be minimized.
Water contamination should be avoided.
CAUTION: Do not use pressure to empty drum or drum may rupture with explosive force.
SECTION 8. EXPOSURE CONTROLS / PERSONAL PROTECTION
Eye Protection: Chemical type goggles or face shield optional.

Skin Protection: Avoid prolonged or frequently repeated skin contact by wearing impervious
protective clothing including gloves.
Respiratory Protection: Wear a breathing mask.
Ventilation: No special ventilation is usually necessary. However, if operating
conditions create high air borne concentrations of this material,
special ventilation may be needed.
Other clothing and Equipment: No special clothing or equipment is usually necessary,
Work practices, hygienic practices: No information is available.
Other handling and storage requirements: No information is available.
Protective measures during maintenance of contaminated equipment: No Data Available.
A-5
SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES
Odor Slight odor

Appearance brown paste
Boiling point ℃ No Data Available
Solubility Insoluble in water
Density @15℃, g/cm3 0.91
Pour point ℃ No Data Available
SECTION 10. STABILITY AND REACTIVITY
Stability: Stable
Conditions to Avoid: See the Handling and storage section for further details.
Incompatibility (materials to avoid): Acids. Oxidizing agents. Halogens and halogenated compounds.
Hazardous Polymerization: Will not occur
Thermal decomposition: Smoke, carbon monoxide, aldehydes and other products of incomplete
combustion. Hydrogen sulfide and alkyl mercaptans and sulfides may
also bereleased. Under combustion conditions, oxides of the following
elements will be formed: Calcium, Sulfur, Zinc.
SECTION 11. TOXICOLOGICAL INFORMATION
Acute Oral: No Data Available:

Dermal: No Data Available:
Carcinogen: OSHA: This material is listed as Group 3 by IARC.
(Base oil) EU: The classification as a carcinogen need not apply.
SECTION 12. ECOLOGICAL INFORMATION
Biodegradation: No Data Available

Environmental fate: This material is not expected to present any environmental problems
other than those associated with oil spills.
SECTION 13. DISPOSAL CONSIDERATIONS
Waste Disposal Method:

Place contaminated materials in disposable containers and dispose of in a manner consistent with applicable
regulations. Contact local environmental or health authorities for approved disposal of this material.
SECTION 14. TRANSPORT INFORMATION
The description shown may not apply to all shipping situations.

DOT Proper Shipping Name: Not applicable.
IMDG Proper Shipping Name: Not applicable.
ICAO Proper Shipping Name: Not applicable.
TDG Proper Shipping Name: Not applicable.
NFPA Proper name: Class 1.
UN Number: Not applicable.
A-6
SECTION 15. REGULATION INFORMATION
JAPANESE REGULATORY INFORMATION

(PRTR) Pollutant Release and Transfer Register.
Industrial Safety and Health Law (Article 57-2, 1, reported objects).
Description of PRTR, Law concerning examination & regulation
of manufacture etc. of chemicals, List of chemical name.
Law concerning Industrial Waste Management.
Law concerning marine pollution control and Mineral Oil Effluent Regulation.
Water Pollution Control Law: Oil effluent regulation.
Sewage Water Law: Mineral oil effluent regulation.
Fire Defense Law.
SECTION 16. OTHER INFORMATION
References:
1. Handbook of Toxic and Hazardous Chemicals and Carcinogens (2nd ed.)

2. Registry of Toxic Effects of Chemical Substances (NIOSH, 1983)
Material safety data sheets are provided as reference information on the safe handling of hazardous or
harmful materials to companies using such materials. When referring to this data sheet, companies should
remember that they must take responsibility for implementing the proper measures for their own particular
situations. This data sheet is not a guarantee of safety.
A-7
ＭＡＴＥＲＩＡＬＳＡＦＥＴＹＤＡＴＡＳＨＥＥＴ
Note： Read and understand Material Safety Data Sheet before handling or disposing of product.
SECTION 1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
NAME OF PRODUCT ＮＣＡ－２５０

PRODUCT USE Hydraulic ｆlｕｉｄ
NAME OF COMPANY AMADA Co. Ltd.
Address 200 Ishida, Isehara, Kanagawa, Japan
DEPARTMENT Quality Assurance Dept.
ＴEL 0463-96-3423 FAX 0463-96-3403
EMERGENCY CONTACT Oil Service Division Development Group
TEL 048-281-7767 FAX 048-281-7768
DOCUMENT PREPARED＆UPDATED Updated : May. 2005
SECTION 2. COMPOSITON/INFORMATION ON INGREDIENTS
COMPOSITION
COMPONENTS Amount (wt%)
Highly ｒｅｆｉｎｅｄｐｅｔｒｏｌｅｕｍｏｉｌ -
Additives -
JAPANESE COMPOSITION INFORMATION
Labour ＳａｆｅｔｙＬａｗ： Amount (wt%)
１６９ Mineral ｏｉｌ７０～８０％
PRTR Ｌａｗ： Amount (wt%)
Not Applicable
SECTION 3. HAZARDS IDENTIFICATION
EMERGENCY OVERVIEW
Warning statement:
Caution! Prolonged or repeated contact with skin may cause irritation in some cases.
Precautionary Measures:
Avoid breathing vapor and mist. Keep container closed.
Avoid contact with eyes, skin, and clothing.
Wash thoroughly after handling. Keep away from heat.
Potential health effect:
Eyes: May cause minor irritation.
Skin: May cause minimal skin irritation.
Inhalation: Vapor or mist, in excess of permissible concentrations, or in unusually high concentrations
generated from spraying, heating the material, or as from exposure in poorly ventilated
areas or confined spaces, may cause irritation of the nose and throat, headache, nausea,
and drowsiness.
Ingestion: May cause abdominal discomfort, nausea, or diarrhea.
Sensitization properties: Unknown
Chronic Properties: If prolonged exposure occurs, nausea, headache, diarrhea, and physical
discomfort.
Other remarks: None
A-8
SECTION 4. FIRST AID MAESURES
Eyes: Flush immediately with water for at least 15 minutes. Get immediate medical attention.
Skin: Wash with soap and water. Get medical attention if irritation develops.
Launder contaminated clothing before reuse.
Inhalation: Remove exposed person to fresh air if adverse effects are observed.
Ingestion: Do not make person vomit unless directed to do so by medical personnel.
Note to physician: Treat symptomatically.
SECTION 5. FIRE FIGHTIN MEASURES
Flash point (Typical), ℃ １３６(COC)

Autoignition tempt., ℃ Not Determined.
Flammability limits: Not Determined.
Extinguishing media: CO2, dry chemical, or foam.
Special fire fighting procedures: Recommend wearing self-contained breathing apparatus. Water may
cause splattering. Material will float on water.
Unusual fire & explosion hazards: Toxic fumes, gases or vapors may evolve on burning.
Autoignition temperature: Not determined.
Explosion data: Material does not have explosive properties.
SECTION 6. ACCIDENTAL RELEASE MEASURES
Procedures in Case of Accidental Release, Breakage or Leakage:

Stop the source of the leak or release. Clean up releases as soon as possible. Contain liquid to prevent
further contamination of soil, surface water or groundwater. Clean up small spills using appropriate
techniques such as sorbent materials or pumping.
Where feasible and appropriate, remove contaminated soil. Follow prescribed procedures for reporting and
responding to larger releases.
SECTION 7. HANDLING AND STRAGE
Do not weld, heat or drill container. Replace cap or bung. Emptied container still contains hazardous material
which may ignite with explosive violence if heated sufficiently.
Minimum feasible handling temperatures should be maintained.
Periods of exposure to high temperatures should be minimized.
Water contamination should be avoided.
CAUTION: Do not use pressure to empty drum or drum may rupture with explosive force.
SECTION 8. EXPOSURE CONTROLS / PERSONAL PROTECTION
Eye Protection: Chemical type goggles or face shield optional.

Skin Protection: Avoid prolonged or frequently repeated skin contact by wearing impervious
protective clothing including gloves.
Respiratory Protection: Wear a breathing mask.
Ventilation: No special ventilation is usually necessary. However, if operating
conditions create high air borne concentrations of this material,
special ventilation may be needed.
Other clothing and Equipment: No special clothing or equipment is usually necessary,
Work practices, hygienic practices: No information is available.
Other handling and storage requirements: No information is available.
Protective measures during maintenance of contaminated equipment: No Data Available.
A-9
SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES
Odor Slight odor

Appearance Ｌ０．５（ＡＳＴＭ）
Boiling point ℃ No Data Available
Solubility Insoluble in water
Density @15℃, g/cm3 0.870
Pour point ℃ -25.0
SECTION 10. STABILITY AND REACTIVITY
Stability: Stable
Conditions to Avoid: See the Handling and storage section for further details.
Incompatibility (materials to avoid): Acids. Oxidizing agents. Halogens and halogenated compounds.
Hazardous Polymerization: Will not occur
Thermal decomposition: Smoke, carbon monoxide, aldehydes and other products of incomplete
combustion. Hydrogen sulfide and alkyl mercaptans and sulfides may
also bereleased. Under combustion conditions, oxides of the following
elements will be formed: Calcium, Sulfur, Zinc.
SECTION 11. TOXICOLOGICAL INFORMATION
Acute Oral: No Data Available:

Dermal: No Data Available:
Carcinogen: OSHA: This material is listed as Group 3 by IARC.
(Base oil) EU: The classification as a carcinogen need not apply.
SECTION 12. ECOLOGICAL INFORMATION
Biodegradation: No Data Available

Environmental fate: This material is not expected to present any environmental problems
other than those associated with oil spills.
SECTION 13. DISPOSAL CONSIDERATIONS
Waste Disposal Method:

Place contaminated materials in disposable containers and dispose of in a manner consistent with applicable
regulations. Contact local environmental or health authorities for approved disposal of this material.
SECTION 14. TRANSPORT INFORMATION
The description shown may not apply to all shipping situations.

DOT Proper Shipping Name: Not applicable.
IMDG Proper Shipping Name: Not applicable.
ICAO Proper Shipping Name: Not applicable.
TDG Proper Shipping Name: Not applicable.
NFPA Proper name: Class 1.
UN Number: Not applicable.
A-10
SECTION 15. REGULATION INFORMATION
JAPANESE REGULATORY INFORMATION

(PRTR) Pollutant Release and Transfer Register.
Industrial Safety and Health Law (Article 57-2, 1, reported objects).
Description of PRTR, Law concerning examination & regulation
of manufacture etc. of chemicals, List of chemical name.
Law concerning Industrial Waste Management.
Law concerning marine pollution control and Mineral Oil Effluent Regulation.
Water Pollution Control Law: Oil effluent regulation.
Sewage Water Law: Mineral oil effluent regulation.
Fire Defense Law.
SECTION 16. OTHER INFORMATION
References:
1. Handbook of Toxic and Hazardous Chemicals and Carcinogens (2nd ed.)

2. Registry of Toxic Effects of Chemical Substances (NIOSH, 1983)
Material safety data sheets are provided as reference information on the safe handling of hazardous or
harmful materials to companies using such materials. When referring to this data sheet, companies should
remember that they must take responsibility for implementing the proper measures for their own particular
situations. This data sheet is not a guarantee of safety.
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22
200, Ishida, Isehara, Kanagawa, JAPAN
Printed on recycled paper.

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HDS-NT MECHA OPE US-E04-201108

This manual classifies the hazardous situations into the

Indicates a potentially hazardous

Indicates a potentially hazardous

NOTICE Indicates a potentially hazardous

NOTE Indicates not a warning but an item of

Part I Safety.................................................................................... I-1

Part II Description.......................................................................... II-1

(Continued on next page.)

Part IV Controls & Operation ........................................................IV-1

(Continued on next page.)

1. Safety rules ..................................................................................I-2

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

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

• Before installing and removing the

• Before installing and removing the

• Securely fix the punches, dies, and die

• When you install and remove the tools

• When you install a tool by sliding it

• When applying pressure to the

• Install or remove the punch holder

i) When you bend worksheets with an assistant operator or operators, you

o) Apply to the installed tools a pressure

q) When bending a large worksheet, be careful of its springing upward. Hold

z) Do not climb on the electrical enclosure or machine. If you apply your

Indicates a potentially hazardous situation

Indicates a potentially hazardous situation

This machine is controlled by a PC-based CNC unit. Modification or

Read and strictly adhere to the following instructions and precautions:

1. NEVER hook up a KEYBOARD or MOUSE unless instructed to do so by

Allowable tonnage of machine and punch holders (reference)

1. Functions .................................................................................... II-2

BED (LOWER BEAM)

HDS 8025NT IS SHOWN

[1] D1-AXIS SERVO

[6] CC-AXIS SERVO

[4] I/O UNIT [5] PC UNIT

[2] Backgauge servo amplifier

[3] Regenerative resistor (external)

[4] I/O unit

[6] CC-axis servo amplifier

kN 500 800 1000 1300 1700 2200 2200

Ram open-close 200 250

Ram high closing 200*

Ram bending 20*

Ram opening 200*

Number of main cylinders 2 2

1.8 × 2 2.9 × 2 4.4 × 2 4.4 × 2 7.5 × 2 7.5 × 2 7.5 × 2

kg 5300 6700 8400 12000 17500 17500 21000

Maximum one-side load 50% of press capacity

*Settable by user parameter

**Available for ASTRO series only

Ram open-close 350

Ram high closing 120* 90*

Ram bending 12* 9*

Ram opening 120* 90*

Number of main cylinders 2 2

Hydraulic oil tank L 175 220

Maximum one-side load 50% of press capacity

*Settable by user parameter

Entry with character buttons on displays presented on

HDS5020 to Simultaneous 9-axis automatic operation