User Manual - Trick
Contents
1. Do not move the brake using lift truck forks directly under any machine members CAUTION THE BENDING BRAKE CAN BE DAMAGED Page 6 SETTING THE Using the overhead crane lift the brake from the skid and place it in its desired BRAKE location Be sure the brake is properly balanced WARNING THE BRAKE TENDS TO BE TOP HEAVY AND CAN TWIST IN THE SLING Use care when moving the brake from the skid to avoid injury Figure 2 The proper lifting method for moving the brake LEVELING THE Raise the upper beam to its maximum height using the eccentric lifting levers BRAKE See Figure 2 Place an accurate spirit level on the bed at each end of the bar Shim under the legs of the brake until the bed bar shows the machine is level front to rear This will remove any twist from the bed Side to side leveling is not necessary to proper operation of the brake ANCHORING THE Anchor the leveled brake to the floor using 1 2 lag screws or bolts through the BRAKE leg mounting holes Tighten securely making sure pressure is exerted on the leveling shims Page 7 INSTALLING THE Have an assistant raise the bending apron to the horizontal position and hold it COUNTER in that position while the counterweights hare installed WEIGHTS Install a counterweight in the mounting hole in each end of the bending apron Adjust the counterweights so that they balance the bending apron in the horizontal position Tigh2. NG WARRANTIES ARE IN LI EU OF ALL OTHER WARRANTIES EXPRESSED OR I MPLI ED INCLUDING BUT NOT LI MI TED TO ANY IMPLI ED WARRANTY OF MERCHANTABI LI TY AND I MPLI ED WARRANTY OF FI TNESS FOR A PARTI CULAR PURPOSE MANUFACTURER SHALL NOT BE SUBJ ECT TO ANY OTHER OBLI GATI ONS OR LI ABILI TI ES WHATSOEVER WI TH RESPECT TO MACHI NERY PARTS ACCESSORIES OR SERVI CES MANUFACTURED OR FURNI SHED BY IT OR ANY UNDERTAKI NGS ACTS OR OMI SSI ONS RELATI NG THERETO UNDER NO CI RCUMSTANCES SHALL MANUFACTURER BE LI ABLE FOR ANY CONSEQUENTI AL OR OTHER DAMAGES EXPENSES LOSSES OR DELAYS HOW SO EVER CAUSED THERE ARE NO WARRANTI ES THAT EXTEND BEYOND THE DESCRI PTI ON ON THE FACE HEREOF Note Consumable tooling is not covered under the 3 year manufacturer s warranty RETURN OF THE PRODUCT REGI STRATI ON CARD FURNISHED WITH THE PRODUCT IS NECESSARY TO OBTAIN WARRANTY COVERAGE THEREON CARD MUST BE FULLY COMPLETED SIGNED BY THE PURCHASER AND IF APPLI CABLE SI GNED BY THE DISTRI BUTOR RETURN REGISTRATI ON CARD TO Page iv SAFETY LABELS Do not operate the U616 Brake without the proper safety labels place If your machine is missing the following labels please contact Roper Whitney Co or your authorized Roper Whitney distributor to order DO NOT USE AS OPERATING HANDLES Read and understand instruction manual before operating servicing or maintenance of this bending brake Remove bending brake from skid before use Bending brake
3. 14 HEMMING HEMMING TRADITIONAL METHOD HEMMING ANOTHER WAY Hemming is the most difficult operation to control accurately on a hand brake Hemming creates pressure loads on the machine different than those created by regular bending and optimum results will not be obtained using the same machine preloading for both hemming and bending In factory tests closing 24 Ga material all the way along was done easily with no change in the preloading settings used for bending 22 Ga material was open about 1 32 in the middle and hems in 20 Ga had an opening in the middle of just under 1 16 under like conditions If you must have tight hems in material heavier than 24 Ga do all of the bending first adjust the machine for hemming and close the hems in a second operation Hemming is traditionally done by making a maximum bend of about 135 degrees and flattening it between beam and bed by lowering the clamping levers This approach may require additional preloading in order to close the hem tightly at the center Increase the preload by tightening the upper beam tensioning adjusting nut See Figure 9 It also requires reducing clamping pressure to allow for multiple thicknesses of material Reduce clamping pressure by slackening the lower toggle pin adjusting nut and tightening the upper toggle pin adjusting nut See Figure 10 Remove the workpiece from the machine after bending Close the machine by clam
4. The Ref No column is keyed to the exploded view on the facing page The Part Number columns provide part numbers for replacement parts for each model brake covered by this manual The Part Name column provides a short descriptive name for each replacement part The Qty column identifies the quantity required for replacement Part Number Part Name Qty 257020055 Apron Assembly 1 757030144 Bending Bar 1 613012133 Screw Flat Head 5 16 18 by 1 inch 12 757180143 Bending Angle 1 601012271 Screw Hex Head 1 2 13 by 1 inch 7 679033107 Washer Lock 1 2 inch 7 457500069 Hinge Assembly right hand 1 457500070 Hinge Assembly left hand 1 657012641 Screw Hex Head 1 2 13 by 1 3 4 12 679033107 Washer Lock 1 2 inch 12 643023007 Nut Hex 1 2 13 12 621012271 Screw Set Socket 1 2 13 by 1 4 757160011 Pin Hinge 2 600134000 Fitting Grease Straight 6 657356334 Handle Grip 2 757280074 Counterweight and Rod Assembly 2 621012266 Screw Set Cup Point 1 2 13 by 1 2 4 continued Page 22 Figure 14 Exploded View of Replacement Parts Page 23 continued from page 22 Ref No 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Part Number 257020054 757080015 656164302 457080076 257090053 757130036 600083604 600073516 757160038 757260072 621012125 666023007 600134006 657164324 757080018 757160096 671023010 6570
5. end loosen the rear floor bolt at that end and shim under the leg until the light shows evenly at both ends Tighten the lower toggle pin adjusting nut against the bottom of the toggle anchor see Figure 11 UPPER BEAM TENSIONING NUTS UPPER BEAM TENSIONING SCREW LOWER BEAM TENSIONING SCREW LOWER BEAM TENSIONING NUT Figure 9 Upper Beam and Bed Tensioning Components Page 18 BRAKE CROWNING ADJUSTMENTS TOGGLE ANCHOR LOWER TOGGLE PIN ADJUSTING NUT Figure 10 Upper Beam Clamp Adjusting Components THE BEAM AND THE BED MUST BE IN CONTACT AT THE CENTER OF THE MACHINE EXAGGERATED VIEW OF GAP AT EACH END OF THE MACHINE THE GAP MUST BE EQUAL AT BOTH ENDS Figure 11 Proper Clearance Between the Upper Beam Clamp and the Bed Page 19 PRELOADING ADJUSTMENT Once the brake crown has been set the brake must be adjusted to produce straight bending and a uniform radius Follow the procedure below 1 Loosen the apron tensioning nuts on the apron see Figure 12 and the upper and lower beam tensioning nuts see Figure 9 Loosen the upper and lower beam tensioning screws see Figure 9 Raise the upper beam to its maximum open height Check the top edge of apron in relation to the top surface of the bed The top edge of apron must be 1 64 below the top surface of the bed at each end If not loosen the hinge bolts and adjust the apron up or down using the apron jack screws see Figure 13 After the
6. must be leveled and bolted to floor Adjust preload by referring to the instruction manual Adjust bending clearance by referring to the instruction manual Keep hands and fingers clear of bending jaws Do not use this bending brake beyond specified capacity Report any equipment malfunction to your supervisor DO NOT REMOVE THIS INSTRUCTION SIGN FROM THIS BENDING BRAKE Crush Hazard Keep clear of clamping beam clamp levers counter weights and sweep area Read operation and safety information prior to use GENERAL PRECAUTIONS SECTION 1 SAFETY PRECAUTIONS Before using the Roper Whitney manual brake carefully read and fully under stand the safety precautions outlined in this section GENERAL PRECAUTIONS pertain to the general workplace and to the attitudes and work habits you bring to the job SAFETY PRECAUTIONS DURING OPERATION pertain to work on the brake and are repeated in other areas of the manual where they pertain Do not consider this section to be all inclusive on the subject of safety It is intended to be a general guide to safety practices as they pertain to the machines covered by this manual No set of guidelines can substitute for a common sense informed proficient safety conscious attitude on your part Notify management or supervision whenever you feel there is any hazard involving the equipment or the performance of your job Never permit untrained individuals to operate t
7. 33154 645023010 757860140 757860141 757080009 757160142 757030003 757030004 657356334 657245118 679033112 657000390 757730005 757730006 611012410 678033110 257940052 617012266 Part Name Beam Bushing Slide Pin Ring Retaining Slide Pin Bushing Bushing Eccentric Bed Assembly Stop Rod Apron Pin Clevis Pin Cotter 3 32 by 1 inch Stud Apron Stop Collar Apron Stop Screw Apron Stop Collar 5 16 18 by 5 16 Nut Apron Stop Stud Fitting Grease 45 Degree Ring Retaining Bushing Lower Toggle Pin Pin Lower Toggle Toggle Nut lower Washer Spring Toggle Nut Upper 3 4 16 Toggle Assembly Right Hand Toggle Assembly Left Hand Bushing Toggle included with items 37 and 38 Stud 3 4 16 x 6 5 inch Clamping Lever Right Hand Clamping Lever Left Hand Handle Grip Bearing Thrust Washer Split Lock Collar Clamping Slide Plate Right Hand Slide Plate Left Hand Screw Clamping Washer Clamping Screw Adjusting Screw Assembly Screw Set Socket Head 1 2 13 by 1 2 Page 24 Qty KP PMH PHO PO HH Aa HA Aa H Figure 15 Exploded View of Replacement Parts Page 25 Figure 16 Exploded View of Finger Assemblies 1A 1B 1C 3 0 W K gt 2 2 2 4 SECTION IDENTIC
8. AL FOR ALL THREE SIZES Ref Part No Number Part Name Qty 1A 757010080 Finger Holder 5 1B 757010079 Finger Holder 4 1C 757010078 Finger Holder 3 2A 757360077 Finger Tip 5 2B 757360076 Finger Tip 4 2C 757360075 Finger Tip 3 3 617012269 Screw SSFP 1 2 13 x 3 4 4 613012133 Screw SHF 5 16 18 x 1 ND Page 26 NOTES
9. CING ANGLE Figure 5 Removal of the Bending Reinforcing Angle and the Bending Bar Remove the bending reinforcing angle and the bending bar as follows 1 Support the bending reinforcing angle and remove retaining screws Withdraw the angle from the machine see Figure 5 Support the bending bar and remove retaining screws Withdraw the bar from the machine see Figure 5 After the bending operation is complete be sure to replace the removed components attaching them with the retaining screws Tighten the screws securely Page 11 SETTING UP THE The bend angle stop can be adjusted for multiple or precision bends Adjust the BEND ANGLE angle stop as follows STOP 1 Loosen the angle stop collar set screw and move the angle stop collar out toward the end of the angle stop rod See Figure 4 2 Have an assistant move the apron to the desired position and hold it while you adjust the collar Be sure to take spring back into account when setting the angle 3 Move the angle stop collar against the angle stop stud and tighten the angle stop collar set screw to retain it in that position Page 12 GENERAL INSTRUCTIONS SECTION 6 OPERATION Operation of the brake is entirely manual and the operator has full control of the operation at all times Do not attempt to operate the brake in excess of its rated capacity Do not attempt to form wire nails rods or pipe on the machine If you are bending large sheets of mat
10. GS SLIDE PIN BUSHINGS m m TOGGLE PIN BUSHING Figure 7 Grease Lubrication Points on the Brake The upper and lower beam tensioning screws see Figure 9 are under heavy load and must not be allowed to run dry Keep them lubricated with an anti seize compound If the machine is frequently readjusted the lower apron tensioning lock nut see Figure 12 and upper beam tensioning lock nut and the lower beam tensioning lock nuts see Figure 9 they should be kept lubricated with an anti seize compound Page 16 ADJUSTING THE The retaining system used to hold the clamping levers in the open position CLAMPING require periodic adjustment Adjust the collars using the following procedure COLLARS CLAMPING COLLAR CLAMPING COLLAR SET SCREW ON O D OF LOCK CLAMPING WASHER COLLAR Figure 8 Adjusting the Clamping Lever Collars 1 Slightly loosen the set screws retaining the clamping collars each end of the machine Set screws should be loose enough to permit adjustment of the clamping collars but not so loose as to permit loss of position on the clamping collars when the clamping levers are moved 2 Tighten the clamping collars by turning them clockwise until you unable to move the clamping levers to clamp material 3 Back off the clamping collars by turning them counterclockwise until you can move the clamping levers to clamp material The collars are properly adjusted when one lever can b
11. OUNTERWEIGHT UPPER BEAM amp CLAMP FINGERS COUNTERWEIGHT CLAMPING LEVER CLAMPING LEVER BENDING APRON TENSIONING MEMBERS LOWER BEAM AND MACHINE BED Figure 1 Major Components of the Universal Finger Brake Page 3 SECTION 3 SPECIFICATIONS FEATURE MODEL U616 Bed Length 73 in Capacity on mild steel 1 flange With bending bar and angle in place 16 Ga With bending angle removed 20 Ga With bending bar and angle removed 24 Ga Minimum Reverse Bend bending bar and angle removed 1 4 in Maximum lift of beam 1 5 8 in Front to Rear Adjustment of Beam 1 1 8 in Approximate Shipping Weight 1350 Ibs Packing Heavy wood skids and blocking with a plastic cover Page 4 RECEIVING UNLOADING SECTION 4 RECEIVING AND INSTALLATION When you receive your finger brake check immediately for obvious damage which may have occurred during transit to the skidding material or to the brake itself Also check to see that all material listed on the bill of lading is present Since Roper Whitney equipment is normally sold F O B factory in Rockford IL our responsibility for transit damage ceases when the transportation company signs the bill of lading indicating it has received the items listed in good condition Report discovered damage or shortages to the carrier Make a notation on the delivery waybill and have the delivering driver sign it acknowledging the damage or shortage Submit claims for repair or rep
12. ROPER WHITNEY MODEL NO U616 UNIVERSAL FINGER BRAKE OPERATION PARTS amp MAINTENANCE MANUAL Model Purchased From It MADE IN THE USA Distributed by Trick Toals com Trick Tools 80 Truman Road Pella 50219 Phone 1 877 VAN SANT E mail sales trick tools com Here at Trick Tools we believe that our customers deserve the best value in their tool and equipment purchases We are constantly at work searching out a variety of high quality high performance tools to offer at the best prices possible Our commitment to you is that we will not offer cheap junk anywhere on our website You the customer help us to evaluate our products constantly and as soon as an ongoing quality issue is uncovered we will correct it or discontinue that product immediately We hope to earn your continued trust CONTENT AUDIENCE INFORMATION USAGE ADDITIONAL ASSISTANCE ABOUT THIS MANUAL This manual contains information on the Roper Whitney floor mounted universal finger brake for 16 gauge material Model U616 The contents include a machine description safety precautions instructions for installation adjustment operation maintenance and repair and a parts list providing a listing of repair parts The manual is written with the experienced sheet metal operator in mind The operator should be familiar with tooling machine setup materials work methods and setup and finished product inspection Experienced operat
13. age 1 SAFETY PRECAUTIONS DURING OPERATION Do not attempt to operate the brake in excess of its rated capacity Do not attempt to form wire nails rods or pipe on the machine Avoid any pinch points created by movement of the machine s components Exercise care around the bending apron counterweights Stand clear of the ends of the brake during the bend cycle or whenever the bending apron is moved Do not loosen the set screws securing the counterweight rods while the bending apron is in the vertical position WARNING SERIOUS INJURY MAY OCCUR The counterweight and rod can drop suddenly through the holder Always use the apron lift handles to apply the bending force Under no circumstances use the counterweight rods for leverage Failure to heed this warning can cause personal injury or damage to the counterweight rods Always stand clear of the apron lift handle travel arc during the bend cycle to avoid being struck by the handles WARNING SERIOUS INJURY MAY OCCUR Avoid pinch points created by the clamping and bending components Always stand clear of clamping handles If the brake has not been properly adjusted for material thickness clamping action on one end of the brake may cause the opposite clamping handle to snap forward due to the twisting stress created on the upper beam this can also indicate that the clamping collars need adjustment Refer to Section VII Periodic Main
14. al Thickness and Angle Adjustments Make the adjustment as follows 1 With the upper beam lowered to the normal operating position but not clamped tightly against the bed loosen the thickness adjustment clamping screws located on both ends of the brake see Figure 4 2 Raise the apron the 90 degree position Page 10 ADJUSTING FOR MATERIAL THICKNESS SETTING UP FOR NARROW OR OFFSET BENDS 3 Move the upper beam forward or back until proper clearance is achieved by turning the thickness adjusting screw located at rear of the leg bracket on each end of the machine see Figure 4 Final adjustment must always be toward the front of the brake to remove backlash from the adjusting screws Retighten the clamping screw on each end of the machine see Figure 4 It is sometimes necessary to remove the bending reinforcing angle to make narrow or offset bends In extreme conditions it may also be necessary to remove the bending bar The bending bar is made of tough wear resistant material to protect the edge of the apron and should be removed only when absolutely necessary to make tight reverse bends Removing the bending reinforcing angle reduces capacity by four 4 gauges The rated 16 ga capacity is reduced to 20 ga capacity Removing both the bending reinforcing angle and the bending bar reduces the 16 ga capacity to 24 gauge capacity BENDING REINFORCING ANGLE BENDING BAR LOCATED BEHIND THE BENDING REINFOR
15. amping handles and remove the blocks The bending leaf apron is wired to the center truss stud of the lower beam to prevent movement during transit Remove the wire Remove the four 4 carriage bolts nuts and washers securing the brake to the skidding DO NOT REMOVE THE BRAKE FROM THE SKID AT THIS TIME SERIOUS INJURY CAN RESULT OR THE BENDING BRAKE CAN BE DAMAGED Do not operate the brake on the skid The brake must be attached to the floor The machine is top heavy and can tip if not securely anchored The skid does WARNING AND CAUTION not provide a suitable anchoring platform SITE PREPARATION The brake must be placed on a firm floor which does not sag and which does not have any spring to it The floor must be generally level with no twisting or unevenness in the surface The floor must also be capable of accepting 1 2 lag screws or bolts for the purpose of securing the brake There must be adequate area around the brake for free movement of the operator and the handling of large sheets of metal Allow 4 to 6 feet behind the brake 6 to 8 feet in front of the brake and 3 feet on either end of the brake To move the brake off the skid and to its mounting position use an overhead crane or a fork lift with the forks above the brake If a fork lift is used secure a lifting hook on the lift forks Pass a sling under brake and secure each end on the lifting hook as shown in Figure 2
16. apron edge is adjusted to the proper position be sure to retighten the hinge bolts Adjust the upper and lower beam tensioning screws finger tight and then tighten each with a wrench approximately one full turn five flats see Figure 9 APRON TENSIONING ADJUSTING NUT Figure 12 Preloading Adjusting Components Tighten lower beam tensioning nut until the edge of the bed is 1 64 above the top edge of the apron at the center see Figure 9 The edges of the bed and apron will then be parallel from end to end with the edge of the bed 1 64 higher than the apron edge Page 20 PRELOADING 8 Tighten upper and lower beam tensioning nuts finger tight and then ADJUSTMENT using a wrench tighten each from 1 4 to 1 2 turn The bending brake is now properly adjusted for its rated gauge capacity in mild steel HINGE BOLTS APRON JACK SCREWS Figure 13 Apron Adjusting Components Page 21 Ref No ll ll NOOR WDM SECTION 9 REPAIR PARTS The table below identifies parts which may be replaced on the Roper Whitney Universal Finger brake Parts may be ordered directly from your Roper Whitney distributor If you have no distributor in your area you may order the parts directly from the company Common hardware items such as screws and nuts may be purchased locally so long as the items purchased are of equivalent quality to those originally supplied with the machine
17. e desired bend angle using the apron lift handles to apply the bending force Under no circumstances use the counterweight rods for leverage If the material being bent is long and protrudes from the machine lift it during the bending operation to avoid creases or crimps caused by material weight Always stand clear of the ends of the brake during the bend cycle Always stand clear of the apron lift handle travel arc during the bend cycle WARNING THE COUNTERWEIGHTS AND CLAMPING HANDLES CAN CAUSE INJURY Using the counterweight rods to apply bending force can damage them CAUTION THE COUNTERWEIGHT RODS CAN BE DAMAGED BENDING OF MULTIPLE THICKNESSES To avoid adjusting for every piece on a run of parts do all the single thickness bending operations first then adjust and do the multiple thickness bending Never bend against hems or seams until an adjustment has been made to compensate for the clamping of multiple thicknesses of material Never bend against hems or seams until the upper beam is set back for clearance of the multiple thicknesses of material See SETUP SECTION 5 for adjustment instructions Failure to compensate for multiple thicknesses of material may result Failure to set the upper beam back for extra clearance may result in CAUTION MACHINE COMPONENTS CAN BE DAMAGED in breakage of the clamping mechanism indentations on the upper beam jaw Page
18. e unclamped and the lever at the opposite end of the machine remains clamped It may require several adjustments at each end of the machine to achieve the proper tension During these adjustments be sure the set screws remain tight enough to prevent loss of position by the clamping collars when the clamping levers are moved 4 When the collars are properly adjusted tighten the set screws securely to retain the clamping collars in place Page 17 BRAKE CROWNING ADJUSTMENTS SECTION 8 MAINTENANCE ADJUSTMENTS When the machine does not bend properly it is sometimes necessary to readjust the crown on the beams Use the following procedure 1 Relieve all tension on the upper beam tensioning nuts and on the upper beam tensioning screw see Figure 9 Lower the upper beam onto the bed Loosen lower toggle pin adjusting nut until there is 1 4 of space between bottom of the toggle anchor and the lower toggle pin adjusting nut see Figure 10 Adjust the upper beam and lower beam tensioning screws finger tight and then tighten each with a wrench approximately one full turn five flats see Figure 9 Adjust the upper beam tensioning nuts finger tight and then tighten each with a wrench approximately one full turn five flats see Figure 9 When looking from the rear of the brake the upper beam and the bed should be in contact at the center and showing a crack of light at each end see Figure 11 If less light shows at one
19. erial which are difficult to handle you may wish to use an assistant to help in loading clamping and bending If you observe unusual noises or vibrations during machine operation check the machine condition immediately Do not attempt to operate the equipment further until the causes of unusual behavior have been found and corrected WARNING PINCH POINTS CAN CAUSE SERIOUS INJURY Avoid any pinch points created by movement of the machine s components CLAMPING THE MATERIAL Insert the material to be bent under the upper beam clamping mechanism lining up both sides so they are even with the upper beam Position short pieces of material in the center of the brake to equalize strain during bending Clamp the material by lowering the upper beam with the clamping levers If the brake has not been properly adjusted for material thickness clamping action on one end of the brake may cause the opposite clamping handle to snap forward due to the twisting stress created on the upper beam When opening the upper beam make sure the handles are moved to the horizontal position to avoid accidental forward movement of the handles caused by the weight of the upper beam THE UPPER BEAM CLAMPING MECHANISM CAN CAUSE SERIOUS Always stand clear of the clamping handles Do not place fingers near WARNING INJURY or under the upper beam Page 13 BENDING THE MATERIAL Bend the material to th
20. his equipment without close supervision Be sure you know and understand the task at hand and the hazards associated with it Observe and follow safety instructions for your work area Pay special attention to posted warnings and warning labels on the equipment Do not place speed above safety Wear appropriate clothing Loose or hanging clothing or jewelry finger rings etc can be hazardous Use the appropriate safety equipment such as eye and hearing protection and safety toe shoes If gloves are worn to protect from cuts be sure they are snug fitting and not likely to be snagged by moving equipment Keep the work area neat and orderly Be sure it is well lit that extra tools are put away trash and refuse are in the proper containers and dirt chips or debris have been removed from the working areas of the machine Be sure the floor area is clean and dry and that extension cords and similar trip hazards have been removed Use the proper tools for the job Inspect them before use to see that they are in good working condition Replace broken or defective tools and equipment Use only approved cleaning materials do not use explosive or flammable liquids to clean the machine Discard used cleaning materials in the appropriate containers Do not use compressed air to clean debris chips dirt or grit from the machine or from your clothing Remove chips and grit from the machine with a suitable brush never with your hands P
21. ing and Installation 5 PROC CIV UN 5 Unloading 5 UnpaCKINO 5 Site Preparation EO EE EE 6 Seting Brake eee ele cote OS eee ri Leveling the LUUE 7 nta Sassi densae iin Quse End eR PE ARE 7 Installing ihe CoOInterwelghls ates 8 Section 5 Setup 9 Seting Clamping ie o 9 Adjusting for Material Thickness c ccceeeceeeeeeeeeeeeeeeee 10 Setting Up Tor Narrow or Offset 11 Setting Up the Bend Angle EHI se dta a DUM 12 Section 6 Operation 13 13 Clamping the eee 13 Bending the Material tH m 14 Bending or Multiple Thicknesses iud or pei nente p erra nutu deua Ae peut tiara 14 Hemming mU o mM 15 Section 7 Periodic Maintenance 16 Lubricating Rotating Components uiia 16 L bricating Sligina Compone eise ere e entrar tee eae eee 16 Lubricating Adjusting Nuts and Screws mener enne 16 Adjusting the Clamping Collar
22. lace small sample pieces of the material to be formed between the upper beam radius bar and the bed at each end of the machine Clamp in position ei At each end of the machine tighten the lower toggle pin lock nut against the toggle anchor just enough to hold material firmly when the clamping lever is against the forward stop see Figure 3 Page 9 SETTING CLAMPING PRESSURE ADJUSTING FOR MATERIAL THICKNESS 4 At each end of the machine tighten upper toggle pin lock nut against the toggle anchor see Figure 3 5 At each end of the machine pull the clamping lever forward against the stop Each end should require equal effort Adjust one end if necessary according to the general procedure above Under normal circumstances clearance between the apron edge and the upper beam radius bar should be approximately 2 times the material thickness for 16 ga mild steel For lighter gauge material less clearance is required One and a half 1 1 2 times material thickness is usually sufficient Soft material such as aluminum may be formed with a clearance equal to the material thickness CAUTION THE BENDING BRAKE CAN BE DAMAGED Clearance must never be less than the material thickness THICKNESS ADJUSTMENT CLAMPING SCREW CLAMPING LEVER THICKNESS ADJUSTMENT air SCREW ANGLE STOP COLLAR X ANGLE STOP COLLAR ANGLE STOP i SET SCREW STUD ANGLE STOP ROD Figure 4 Materi
23. lacement to the carrier include any extra shipping charges Notify Roper Whitney Company promptly of any damage or shortages If you discover concealed damages or shortages after the carrier has departed you may still file a claim for concealed damage This should be done as quickly as possible Again notify Roper Whitney Company promptly of such damages or shortages The brake is shipped on a skid of 3 x 6 wood timbers It is secured to this skid with four 4 carriage bolts which should remain secured while the machine is unloaded and moved about The skid and brake may be moved using a suitable fork lift WHEN IN MOTION THE SKIDDED BRAKE MAY BE TOP HEAVY When lifting or moving the skidded brake with a forklift secure the brake laterally to WARNING the forklift UNPACKING The two counterweight arms rods and their counterweights are mounted separately on the wooden skid for shipment Remove these from the skit and set to one side THE COUNTERWEIGHT ARMS AND COUNTERWEIGHTS ARE WARNING HEAVY Use care when removing them from the skid to avoid injury Page 5 The clamping handles at each end of the brake are wrapped and wired in the down position to prevent damage and to prevent the handles from being used to move the brake Remove the wires and wrapping Wooden blocks are positioned between the upper and lower beam jaws to prevent damage during shipment Lift the cl
24. or parts are returned freight prepaid to Manufacturer s plant or designated service center for Manufacturer s inspection All failed parts or components must be returned to Manufacturer prepaid for inspection before credit will be issued for new parts or components Manufacturer s obligation hereunder shall be confined to such repair or replacement and does not include any charges direct or indirect for removing or replacing defective machinery or parts No warranty shall apply to machinery or parts or accessories which have been furnished repaired or altered by others so as in Manufacturer s judgment to affect the same adversely or which shall have been subject to negligence accident or improper care installation maintenance storage or other than normal use or service during or after shipment No warranty shall apply to the cost of repairs made or attempted outside of Manufacturer s plant or designated service center without Manufacturer s authorization No warranty shall apply with respect to machinery or part not manufactured by Manufacturer including but not limited to motors accessories electrical and hydraulic components if such machinery or part is subject to warranty by the manufacturer of such machinery or part No warranty claims by Customer will be honored with respect to any machinery or part from which the name and date plate has been removed or is otherwise no longer located or exhibited on such machinery or part THE
25. ors not familiar with the equipment covered will be able to set up and run the machine from the manual Novice operators can be trained from the manual but additional instruction may be needed It is strongly recommended that anyone using the equipment covered read the manual thoroughly and understand the material presented The setup and operating instructions are based on the intended application of the machine as defined by Roper Whitney Use of the machine for other applications is not precluded but use for purposes specifically excluded is not recommended and may void warranty provisions Material in this manual is confidential and Roper Whitney reserves all rights in this regard If you have questions concerning usage or operating techniques not covered by this manual or if you encounter maintenance or repair problems Roper Whitney field service and product support personnel can provide you with assistance Before calling please obtain the following information machine type machine serial number description of application you wish to attempt description of problem you have encountered Page ii TABLE OF CONTENTS About This Manual ii Warranty Provisions iv Section 1 Safety Precautions 1 General Pr cautlOrlS 1 ern Precautions During Cem 2 Section 2 Machine Description 3 Section 3 Specifications 4 Section 4 Receiv
26. ping the beam down on the bed with the clamping levers Place the workpiece on the front surface of the upper beam Swing the apron up and close the hem by squeezing the workpiece between the machined surface of the apron and the upper front surface of the radius bar This may feel awkward at first especially if you are accustomed to hemming in the traditional manner but it will get easier with practice and the end result is far superior to the traditional way It may be necessary to move the upper beam 1 8 to 3 16 to the rear to allow clearances for the hem between apron and front of beam See SETUP SECTION 5 for adjustment instructions Page 15 LUBRICATING ROTATING COMPONENTS SLIDING COMPONENTS ADJUSTING NUTS AND SCREWS SECTION 7 PERIODIC MAINTENANCE Grease fittings are provided for rotating components where wear may occur Use a medium weight bearing grease such as SAE No 30 and grease weekly when the brake is being used The rotating components are the clamping lever assembly the apron hinge assembly 2 fittings and the toggle pin bushing One set of these components is found on each end of the machine Location of these fittings is shown in Figure 7 Grease sliding components weekly as well using general purpose grease or equivalent These components include the clamping pin bushings and the slots in which they ride see Figure 7 APRON HINGE CLAMPING LEVER ASSEMBLY ASSEMBLY 2 FITTIN
27. s PP 17 Section 8 Maintenance Adjustments 18 Brake Crowning EE 18 Prelgadng PROS he Hale an eat ee 20 Section 9 Repair Parts List 22 Page iii FOREWORD This manual has been prepared for the owner and operators of Roper Whitney No U616 brake Its purpose aside from operations instructions is to promote safety through the use of accepted operating procedures Read all instructions thoroughly before operating the brake Also contained in this manual is the parts list for your brake It is recommended that only Roper Whitney or factory authorized parts be used as replacements Warranty Statement YEAR LI MI TED WARRANTY Roper Whitney Manufacturer warrants commencing with the date of shipment to first end user Customer and for a period of thirty six 36 months thereafter all machinery and parts manufactured by Manufacturer to be free of defects in workmanship and material This warranty remains in force for the above time period only if all of Manufacturer s operational procedures are followed and recommended maintenance is performed f within such warranty period any machinery or parts manufactured by Manufacturer shall be proved to Manufacturer s satisfaction to be defective such machinery or parts shall be repaired or replaced at Manufacturer s option All warranty claims are made F O B Manufacturer s plant providing such machinery
28. ten two set screws securely on each counterweight shaft WARNING THE COUNTERWEIGHTS ARE HEAVY Use care when installing the counterweights to avoid injury Be sure the set screws are tightened enough so the counterweights will not drop when the bending apron is returned to the vertical position Page 8 SETTING CLAMPING PRESSURE SECTION 5 SETUP Your new Roper Whitney Brake is pre set and should not require field adjustment The machine has been adjusted and pretensioned at the factory Excessive clamping pressure is not required or desirable It has a tendency to counteract the normal preloading adjustments and may interfere with obtaining straight and uniform bends Use only enough clamping pressure to keep the material from slipping TOGGLE ASSEMBLY UPPER TOGGLE CLAMPING LEVER PIN LOCK NUT TOGGLE ANCHOR LOWER TOGGLE PIN LOCK NUT Figure 3 Clamping Pressure Adjustments Set up adjustments are for clamping pressure material thickness setting up for narrow or offset bends setting bend angle control and setting up of the optional rear material stops Should your brake require adjustment follow instructions below Be sure the gauge thickness of the material to be formed to is within the rated capacity of the machine Then adjust clamping pressure as follows 1 At each end of the brake loosen both toggle pin lock nuts slightly before beginning adjustment see Figure 3 2 P
29. tenance When opening the upper beam make sure the handles are moved to the horizontal position to avoid accidental forward movement of the handles caused by the weight of the upper beam If you observe unusual noises or vibrations during machine operation check the machine condition immediately Do not attempt to operate the equipment further until the causes of unusual behavior have been found and corrected Page2 SECTION 2 MACHINE DESCRIPTION Roper Whitney floor mounted Universal Finger Brakes are precision machines for use in bending mild steel and other sheet metals including aluminum brass bronze copper duralumin lead monel metal silver carbon and stainless steel within rated capacity The brakes are rated to form a 1 minimum wide flange over entire length of brake on a single thickness of material of the rated gauge capacity with work angle support installed Bending capacities are reduced by four 4 gauges when the apron work support is removed Major components are shown in Figure 1 Fabricated of sturdy steel plate with appropriate gussets braces and trusses three basic longitudinal members upper beam lower beam and bending leaf apron control the clamping pressure and stress incurred in overcoming the yield strength of the material being formed Provisions for adjusting clamping force and tensioning of the longitudinal members are incorporated in the design of the bending brakes TENSIONING MEMBERS C
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