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The Instruction Manual

1. 89 mm Radius Die 2 50 8mm 2 50 8mm SWAGER TOOLING Solid Expander Die 2 1 4 Male Ball Expander Solid Expander Die 2 Male Ball Expander 2 50 8mm 1 1 2 38mm 1 3 4 amp 2 1 4 2 amp 2 1 2 2 1 2 63 5mm Male Ball Tool SEGMENT EXPANDER TOOLING 2 114 57mm 55 112 1 1 2 38mm ACCESSORIES Tool Tray Kit Radius Die Pusher Block Springs Service Manual Small O Ring Package Other Sizes Are Available Upon Request TTA 1000 DPS 150 Manual OR 1 55 Bender Operation Manual Bender Operation Manual 55 Notes 56 Bender Operation Manual Notes 57 Bender Operation Manual Bender Operation Manual 57 To Expedite Service FAX YOUR ORDER 1 805 933 9160 Or Dial Direct 1 805 933 9970 BendPak also provides quality Above Ground Lifts to the automotive industry Call for details and brochure Operation Manual
2. SOLENOIOSUBPLATE 42 Bender Operation Manual The manual buttons control the top cylinder as follows To advance the radius die Press the right button inward using an insulated tool or non conducting rod To retract the radius die Press the left button inward using an insulated tool or non conducting rod NOTE The manual control function of the solenoid valve should effectively advance or retract the radius die under all conditions The manual button should be pressed firmly to activate SOLENOID VALVE MAINTENANCE Certain symptoms and suggested repair procedures are explained below The valve Inadvertently sticks causing the top cylinder to uncontrollably advance or retract Operating the valve manually will often dislodge foreign particles that may have become trapped in the valve spool If this does not free the valve remove the solenoid coil covers and make sure there is no foreign matter that could interfere with the moving parts Clean and reassemble The valve spool Is free but stlll does not activate with the control board or twin foot swltches Remove the solenoid valve coils and check for an open or shorted circuit Check all electrical connections The valve spool Is free and the coils are not open or shorted but It still does not activate with the con trol board or twln foot switches Check the incoming voltage to the valve Proper incoming voltage should be between 208 230 volts A C Ther
3. THESE SAFETY INSTRUCTIONS MUST BE GIVEN TO ALL OPERATORS TO READ IF THE INDIVIDUAL CANNOT READ INSTRUCTIONS MUST BE READ TO THEM 5 Bender Operation Manual Bender Operation Manual 5 INTRODUCTION Your new bender is a press style bender that is capable of bending flaring and swaging tubing up to 3 inches in diameter The thickness of the tubing plays an important part See previous chart for recommended tubing allowances The front of the bender is where all the bend ing is performed The top cylinder activates the bending or radius die which moves forward through the back shoes The bottom cylinder keeps pressure applied to the back shoes by a chain assembly and integrated hydraulic sequence valve In addition to the contoured shape of the radius dies resistance pressure is applied to help the tub ing maintain it s shape DEFINITION OF TERMS The following definitions explain the major components and operating features of your machine The RIGHT LEFT and REAR sides of the bender are relative to the FRONT of the machine where all bending is performed BENDER The whole machine including all end finishing components BODY The main 6 x 6 tubular structure that sits horizontal to the floor and is located just below the top cylinder SWAGER OR SWAGER BOX The expanding flaring unit located to the rear of the bender which utilizes pipe collars in conjunction with bullet shaped expander forming dies to perfor
4. USING THE JUMPER BOARD All BA models have a bypass device or jumper board included that can be used to effectively bypass the digital control board for trouble shooting or diagnostic purposes ALWAYS consult the factory before attempting to use the jumper board The jumper board is stored within the front upright of the bender and attached to the back side of the main circuit panel by retaining clips See figure 1 B Figure 1 B WARNING The jumper board should be used for temporary diagnostic purposes only and was not designed to permanently bypass the main circuit panel USE OF THE JUMPER BOARD alters the foot switch controls to high voltage NEVER operate the machine in or around water or damp environments This machine contains high voltage Disconnect power at the receptacle before performing any electrical repairs Secure plug so that it cannot be accidentally plugged in during service To remove and install the jumper board follow the steps outlined below 1 With the machine unplugged remove the four allen screws that secure the front display panel 2 Reach in and carefully pull up on the main circuit panel using the white handle until it disconnects from the connector located within the front upright 3 Remove the jumper board from the back side of the main circuit panel and check the fuse 4 Install the jumper board narrow end down with THE FUSE TO THE REAR by gently sliding it down between the card g
5. Thermal overload tripping The plug has been wired wrong Power is connected to the ground wire Power wire has become disconnected Check all connections in the switch box or motor Incorrect guide plate alignment worn barrel bushings or pusher block Tubing gauge is not adequate for that particular size or radius Incorrect wiring Voltage or amperage too low Left foot switch is inoperative or wire has become disconnected Right foot switch is inoperative or wire has become disconnected The return pressure is set too high The top cylinder is trying to overcome the bottom cylinder which is not retracting simultaneously Tubing is not sliding back with the radius die after the bend is made causing the gates to remain open The swager cylinder is not aligned correctly Return pressure is set too low Adjust return pressure as shown on page 33 CORRECTIVE ACTION Check voltage supply phase and wiring Refer to wiring instructions found on pages 49 50 Check thermal heaters s See page 44 Check voltage supply phase and wiring Refer to wiring instructions found on pages 7 amp 43 Check voltage supply phase and wiring Refer to wiring instructions found on pages 7 amp 43 If prob lem persists check wiring for short circuits Check amp draw Refer to motor nameplate Check plug Make sure that the green wire on the power cord is used for grounding purposes only NO POWER should be connecte
6. Before attempting the following first calibrate the depth of bend plate as previously described To properly calibrate the automatic depth of bend switch on all BAS models follow the steps outlined below 1 Turn the machine on 2 Place a set of bending dies in position 3 Advance the radius die forward until the depth of bend pointer reads 90 degrees See figure 3 A Figure 3 A 4 Gently slide the automatic depth of bend switch handle back until the two pointers are lined up with each other See figure 3 B Figure 3 B Bender Operation Manual 39 5 Loosen the set screw on the adjustable trip arm located directly underneath the depth of bend plate and adjust so that it just activates the micro switch 6 Re tighten the set screw 7 Retract the radius die and re check 8 If further adjustment is required repeat steps CALIBRATING THE DIGITAL READOUT DISPLAY BA MODELS Automatic depth of bend and digital readout functions on all BA models are performed by an electronics package consisting of three main components The circuit board assembly digital encoder and the zero angle micro switch See figure 3 C DANGER This machine contains high voltage Disconnect power at the receptacle before performing any electrical repairs Secure plug so that it cannot be accidentally plugged in during service Circuit board assembly The printed circuit board is made up of three basic componen
7. To use the three button automatic controls follow these simple instructions 1 Position the Auto Stop pointer at the desired depth of bend 2 Position the tubing at the appropriate bend mark 3 Check your circle of swing and prepare to begin bending Press the GREEN control button At this time the radius die will advance until the desired depth of bend is reached then retract to the original starting position 6 Be prepared to support the tubing as it is released from the dies pios CAUTION Be alert at all times NEVER place hands near bending area or other pinch points when motor is running USING THE REMOTE FOOT SWITCHES The remote foot switches are used for manual bending functions When using the foot switches for manual operation it is best that you position the Auto Stop pointer out of the way or at 180 degrees so that it does not interfere If you want to use the foot pedals in conjunction with the Auto Stop pointer position the pointer at the desired bend depth and proceed by pressing the RIGHT foot switch until the radius die stops at the pre set bend angle Press the LEFT foot switch to retract the radius die Always be prepared to support the pipe as it is released from the dies OPERATING THE MANUAL KNEE CONTROL BL BULLET MODELS Read the following section completely before attempting any operation of this unit All BL models are equipped with a hydraul
8. page 33 for pressure adjusting procedure 22 Bender Operation Manual BENDING STAINLESS TUBING In order to get good results when bending stainless tubing it is necessary to increase the back shoe pressure by adjusting the sequence valve similar to the procedure previously described The recommended pressures are shown below When using large diameter or light gauge tubing more back shoe pressure is required Always remember to reset the bender to 1600 P S I when you are finished Backshoe Pressure ubing Size 304 or 409 2 OD Stainless 16 or 14 For 409 Stainless tubing comes in many grades The grades shown above are the best for bending NOTE It is very important to clean and lubricate the bending dies during all bending procedures END FINISHING OPERATIONS CAUTION Before any attempt is made to use the end finishing components on this machine it is important that you have read and fully understand all operating instruc tions KEEP HANDS CLEAR of all pinch points ONLY TRAINED PERSONNEL should be near machine when it is in operation NEVER stand in front of arbor when operating internal expander ALWAYS wear safety glasses when operating this machine USING THE INTERNAL EXPANDER The internal expander uses segmented expander dies or segment sets in conjunction with an expansion arbor When the arbor is pulled through the center of the seg ment set it spreads the fingers which in tu
9. Flug Mtem 7 Torning Your New Bender On ax 2 2222 Eau 8 Introduction Of Tooling ldenil atOF ss zen ea aa 8 Segment Identification hart Hc 11 Typical End Finishing IS Fa SAS Et ER ets SE EO ke SE GE eg vai CET 12 Description Of Digital Controls BA Models EE EE EE AE ee EE Ee REE Ee ee Ee ee nennen nnne nnne EE see EE ee ee sina n rns 12 Operating The Digital Control Board BA Models ee ee ee ee ee Re ENES ERE ee ee ee ee ee ee ee nnns ee ee ee nn 13 Description Of Three Button Control BAS Models ee ee Ee RA ERE AE Ee ee ee ee ee ee ee ee ee ee ee ee nnn ee ee 14 Operating The Manual Knee Control BL Bullet Models ee ee ee Ee ee ERE ee Re ee ee ee ee Ee ee ee ee ee ee ee 15 Introduction OF Beridirig Operations sa EES nl 15 Using The Program Cand S EE e oia lc 15 Fe AES TUN Hes FA dia alcoi 19 Blank Program Ore dd EE ES ne ent AST We ie EL D MEL E CM ee LE EE 20 Three Inch Tube Bending Procedure cccccesccssececsececsececeececeucensuceseueesegeeecuecenseceseesensueeneueesueeseneeseueesseeseneesens 21 Stainless Tube Bending ProCedure cccccceccccsscecceeeeccseececseuceccsueeecsaeeeessueeessueeecseeesseeeessueeeecsueeeesegeeeseneeessaeeesas 22 Using The Standard Segment Expanders ccccccccccseccccseececeeseecceceeceseeecegseessueeeesaueeeceueeecsueeesseseessageessegeeessegeenss 23 Using The Ball Joint Segment Expanders 22222022242000000000000nonennnnnnnnennnnnennnnnnnnnnnnn
10. LENGTH section DO NOT CUT THE TUBING at the last center mark until the final bend is made See figure 1 B Figure 1 B 5 Disengage the dies and reposition the tubing so that the greater portion is now extending out the RIGHT side of the bender and the first CENTER MARK is lined up with the center of the two back shoes 6 Engage the bending dies until the pusher block springs are compressed and the tubing is held firmly See figure 1 C 7 Rotate the tubing so that the weld seam on the tubing is facing up or at the 12 o clock position The push er block springs are designed to hold the tubing secure but still allow rotation of the pipe Install the rotation dial on the RIGHT end of the tubing Loosen the butterfly nut if necessary and insert the segmented expander inside the tubing end Tighten the butterfly nut until the rotation dial is secure 9 With the rotation dial properly installed rotate the degree plate not the tubing so that the pendulum pointer is showing ZERO Make sure the butterfly nut remains tight 17 Bender Operation Manual NOTE The weld seam on the tubing should be directly in line with the ZERO mark at this time See figure 2 A time you may program your depth of bends on the digital board as described in the DIGITAL CONTROL OPERATION section position the depth of bend pointer on BAS models or elect to use the electric foot switches or manual knee control valve For beginning operators we s
11. contact with the back shoes 2 At this time visually check the oil by observing the oil sight gauge At the proper level oil should appear midway on the gauge SIGHT GAUGE Do not allow fluid level to go lower evel to go than this point 3 If oil cannot be seen it will necessary to add oil via the flller cap located on the reservoir 32 Bender Operation Manual If the oil level continues to drop and oil needs to be added frequently the machine should be checked thoroughly for possible leaks Any of the following hydraulic oils may be used Make Brand Chevron OC Turbine 46 Mobile DTE Medium Texaco Rando HD 46 Conoco Turbine 46 Shell Shell Turbo 46 Citgo AW46 Pennzoil Zoil Medium or No 10 Union 76 UNAX AW46 If the above brands are not available use any 10 medium weight mineral based hydraulic fluid with a non foaming additive NOTE The hydraulic oil should be changed after 1 500 hours of operation or yearly whichever comes first The oil filter should also be changed at this time RECOMMENDED WEEKLY MAINTENANCE Clean and re grease guide plate arbor and swager clamp blocks Check for equal chain tension See page 34 Check all pressures See page 33 Inspect all hydraulic hoses for wear or cuts Replace faulty hoses Check for hydraulic leaks Repair leaks immediately RECOMMENDED MONTHLY MAINTENANCE Check depth of bend for accuracy See pages 39 amp 4O Grease zirk fittings
12. improper use there is no way to correct other than total replacement of the cylinder To properly check the swager cylinder for proper align ment follow the steps outlined below 1 Turn the machine on 2 Install a HPF 300 or similar tool on the ST 1adapter See figure 3 B Figure 3 B 3 Position a section of squarely cut 2 tubing approximately 12 long into the clamp block area using the necessary HAC adapter collar 4 Gently snug the collar back into the clamp blocks by gently pushing back on the collar assembly 37 Bender Operation Manual Hold the tubing securely making sure that the HAC 300 is square within the clamp blocks Advance the tool forward until it just makes contact with the tubing At this time the tool should contact the complete circumference of the tubing end simultaneously If the swager cylinder is out of alignment or the cylinder shaft is bent then the tool will only partially contact the tubing circumference See illustrations IMPROPER ALIGNMENT If the swager cylinder is out of alignment proceed as follows to make proper adjustments Turn the machine off until all necessary adjustments are made Remove the two allen bolts securing the swager tool tray using a 1 8 hex wrench See figure 3 C E I Loosen the four 4 1 2 nuts or bolts attaching the cylinder to the swager box using a 3 4 socket or open end wrench It is not necessary to completely remove the nu
13. nenne nnennennnnnnnnnnnnennenne nennen 24 Using The Flare segment EX Pa Mens s s slate cena a ap 24 Using The Manifold Flange Segment Expanders iss sees see see ee Ee ee tt ee ee ee ee nennen nenne EE Ee ee EE ER ee EE Re ee ee ee EE ee 25 Introduction Of The Swager Assembly is nsus ec EE ee IR PA ee RE ee ge GR bares 25 Usd TRS gt TED expander DIES rs RE ee m 25 Makina Malie Ball AIA SION S sai ee baba ie 26 Making Female Ball AI SIONS ie ee abe v cine olaaa tooodo 2 Making AS Degree Flares OE AR RE OO OE tee 2f Making A Manifold Flange Using The HPF 300 Tool ees esse ses ees se ee ee ee ee ee Ee ee ee nennen nennen nennen nnne nnn 28 Making A Manifold Flange Using The CFT Tool ees ee ee ee Ee ee Ee ee nene ee ee ee ee ee ee Re ee nnn nnn 30 USING The RE GUCING 1 OO EE RE EE EE 30 Using The Doming Die To Finish Tailpipe Ends esse ss ees ss ees ee ee ee ee ee ee ee ee Ee ee E REE ERE Re ee ERE ee ee ee AR ee AR ee ee ee ee ee RE ee ee 31 Making Header Collectors Using the HCT 214 212 Tool ees ee ee see ee ee ee ee ee Ee ee Ee ee ee ee ee ee SERENE ERE ee ee ee ee ee ee 3l Maintenance Introducido dll licor 32 Hydraulic OS ECE a dd dais 32 Recommended Weekly Monthly Maintenance ooocncccocncccccnnccoconconccnnonncononncononncnnnnnnrnnnnnrnnonnrnnnnnnrnnnnnrnnrnnnnnnnnnnnss 32 ASS o A ss emits EE aerated Ge ee EE SE u 33 EhainAdjustuiig Pioeedie SE ee eie ee de 34 Alighing The Guide M cars 35 Bartel BUushing Man
14. not properly tripping the zero angle micro switch The encoder is malfunctioning probably due to contamination or moisture The solenoid valve spool is stuck CORRECTIVE ACTION Remove control board and check the fuse See page 41 Manually operate the solenoid valve using the manual control buttons This should dislodge any debris that may have become stuck in the valve body Visually check the control board for any possible wear or cuts Remove the front display panel by disconnecting it from the wire ribbon or install the jumper board as described on page 41 This will confirm if the problem is related to the front display panel or not If the top cylinder operates normally with the front display panel removed or the jumper board in place then return the complete digital control board assembly to the factory for repair Visually check the control board for any possible wear or cuts Remove the front display panel by disconnecting it from the wire ribbon or install the jumper board as described on page 41 This will confirm if the problem is related to the front display panel or not If the problem persists check wire connections on the right foot switch Refer to diagram on page 49 Check micro switch with ohmmeter as described on page 43 Check for broken or disconnected wires Replace if faulty Check wire connections on the left foot switch Refer to diagram on page 49 Check micro switch with ohmmeter as descri
15. represent three quarters of a circle and allow the tubing to wrap around farther although the radii are the same 4 radius die radius die BACK SHOES Back shoes which are commonly referred to as wiper dies come in pairs and are used together with the radius dies during the bending process These dies play an important part as their primary purpose is to form the outside radius of the bend These dies are used to clamp or retain the pipe as it is wrapped around the radius die Each back shoe is machined and sized according to tubing diameter The proper tubing size is stamped on the top of each back shoe NOTE Back shoes should be kept clean and lightly oiled Never use the bender without back shoes in place Never use the bender as a vice or a press Back shoe dies HALF SHOES AND THREE QUARTER SHOES Half shoes and three quarter shoes do not come in pairs Only one is required Half shoes are exactly half the length of a standard back shoe and three quarter shoes are three quarters the length These smaller shoes are required when an upcoming bend is less than ten inches from an existing bend The half three quarter shoe will be used in conjunction with the back shoe and placed only on the side where the full back shoe may interfere with the upcoming bend Details for the proper use of these tools are explained in the BENDING section NOTE Half shoes and three quarter shoes must be used with radius dies and back sh
16. starting position 27 Review the SYMBOLS section of the card and check for any special instructions for bend number five 28 On bend number five no special instructions are shown In this case return the ROTATION DIAL to the right side and install the full BACK SHOE A HALF SHOE is not required for this bend See figure 3 B and check for any END FINISHING requirements On this particular card it calls for a FEMALE BUICK BALL on the FRONT or F side of the pipe See page 12 for TYPICAL END FINISHING illustrations PATTERN BENDING To pattern bend proceed as follows In order to retain the information for later use save the information as described below NOTE Use the blank program card found on the next page as a master to make additional copies for later use 1 Select the proper tubing size and die set to do the job Try to match the radius size with that of the existing pipe 2 Place the tubing in the bender with the greater portion of the tubing protruding out the right side of the bender 3 Place the master pattern existing pipe or bent wire on the top of the back shoes so that the first bend is centered between the back shoes 29 Advance the radius die forward until the pusher block springs are compressed and the tubing is held securely 30 Rotate the tubing so that the pendulum pointer or dial indicator points to 223 degrees 31 Advance the radius die to 18 degrees then retract the die to
17. the machine IF SMOKE APPEARS OR SHORTING OCCURS DISCONNECT IMMEDIATELY RECHECK ALL CONNECTIONS Electrical On Off switch box 3 Let the bender run for approximately five minutes without operating the controls 4 At this time it is necessary to install all control han dles by properly connecting the linkages as shown Control handle linkage assembly 5 After the bender is warmed up retract the radius die that contains the sample tube On automatic models do this by depressing the left foot switch On Blue Bullet or manual models activate the knee control valve by moving the handle to the right 6 IF THE RADIUS DIE DOES NOT MOVE CONSULT THE FACTORY 7 After the radius die has completely retracted remove the sample tubing that is in place 8 Bring the radius die forward by depressing the right foot switch or by moving the manual control valve handle to the left 9 Advance the radius die to 100 degrees then retract fully Repeat this sequence for at least five times The bending die may move erratically for the first 8 Bender Operation Manual few cycles due to air trapped in the lines This is normal The air will dissipate after use Do not try to crack a line to help the air escape 10 At this time check for any possible leaks that could have developed during shipment Tighten any hoses that may have loosened 11 Check the oil level by observing the sight gauge located near the right rear sid
18. the tendency to depress or indent the tubing somewhat due to the reduced surface area on the half shoe itself The block of wood will crush as the bend is being made and will help support the tubing and minimize distortion See figure 3 A PR mr ier Eu Figure 3 A THREE INCH TUBE BENDING PROCEDURE High initial back gate pressure is required when bending three inch tubing in order to get good uniform bends Good bends will result when 13 gauge 095 wall thick ness is used 14 gauge 083 wall thickness may be used but some tube deformation or inconsistency may result These instructions MUST be followed closely for best results During this procedure use only the manual oper ating controls DO NOT USE AUTOMATIC CONTROLS 1 Upon installation of the three inch bending dies it is essential to readjust the sequence valve pressure This adjustment will require the use of a 1 4 Allen wrench and a 3 4 open end wrench 2 Loosen the securing nut on the SEQUENCE VALVE and insert the Allen wrench in the end of the adjust ing screw The Allen wrench will remain in this position during this bending process See figure 3 B Bender Operation Manual 21 Figure 3 B 1 Tubing is not required for steps 1 3 Advance the radius die and check the sequence valve pressure Sequence valve pressure is shown on the pressure gauge attached to the valve itself The correct pressure will be shown only as the radius die travels f
19. wear protective safety goggles USING THE STED EXPANDER DIES STED s are referred to as solid expander dies Each tool is marked for the proper size tubing Some of these dies perform two different functions The STED expander dies will swage expand the tubing to exact inside diameters but some can also be used for making male ball expansions The tooling applications are explained below Part Number Application STED 112 Expands 1 1 2 tubing to 1 1 2 I D STED 134 Expands 1 3 4 tubing to 1 3 4 I D STED 178 Expands 1 7 8 tubing to 1 7 8 I D STED 200 B 134 Expands 2 tubing to 2 I D Also used to make 1 3 4 Male Ball S xpansion TED 214 B 20 Expands 2 1 4 tubing to 2 1 4 Also used to make 2 Male Ball xpansion Special sizes are available upon request Bender Operation Manual 25 MAKING STRAIGHT EXPANSIONS Follow these steps to produce straight expansions using the STEP expander dies See chart on page 12 for typical end finishing illustrations 1 Retract the swager cylinder completely by lifting the valve handle up 2 Install the required STED for the appropriate tubing size on the ST 1 adapter attached to the end of the cylinder shaft 3 Install the required HAC adapter collar around the tubing and position within the swager clamp blocks The hinge should be positioned on the top side and the smaller tapered edge of the collar should be towards the cylinder shaft
20. what radius die will be used in addition to other tooling such as half shoes and three quarter shoes Also gives instructions on reversing and certain end flnishing requirements Not all applications will be shown on the card Follow these step by step instructions to bend the pipe for the card shown above 1 Select the proper tubing size for the application as called for in the DIAMETER SECTION of the card See Recommended Tubing Chart on page 48 Wipe tubing to remove excess oil 2 Install the correct radius die as called for in the BENDING INSTRUCTION section Two back shoes are required unless otherwise specifled Place tubing in the bender between the back shoes and radius die with the greater portion of the tubing extending out the LEFT side of the bender This is necessary so that you can mark the tubing with the appropriate CENTER MARKS shown on the card 3 Engage the bending dies until the pusher block springs are compressed and the tubing is held flrmly Carefully control the advancement of the radius die so as not to dent or bend the tubing at this time See figure 1 A 4 Using the program card refer to the section marked CENTER MARKS for the list of measurements in inches where the different bends will be made Each CENTER MARK is measured from the left end of the tubing Mark and number the CENTER MARKS on the tubing using a crayon or felt tip pen The last mark you make should be the cut off point shown in the O A
21. will be equally worn There are two 2 1 2 x 2 x 1 1 2 bronze bushings press fitted on the top and bottom of each side of the barrel assembly To visually check these bushings follow the steps outlined below 1 Disassemble the left side chain assembly by removing the left side chain connector See figure 2 C 36 Bender Operation Manual PL Daa dp A n om d ea Using a rubber mallet carefully tap the shaft up and out of the barrel BE CAREFUL when removing shaft to prevent threads from being damaged Be sure to keep shaft key as it is required for re installation See figure 3 B Remove the left gate assembly Clean shaft and inside of barrel of all grease and debris Visually check shaft for excessive wear Replace shaft if diameter is less than 1 997 See figure 3 C 7 Visually check bronze bushings for excessive wear Replace bushings if inside diameter is greater than 2 005 or more See figure 3 A 8 After check is completed reverse steps and adjust chain assembly as described on page 34 IMPORTANT NOTE Be sure to grease zirk fittings on each side of the barrel after re installation of gate assemblies ALIGNING THE SWAGER BOX CYLINDER The swager cylinder should be checked periodically for proper alignment If the swager cylinder is not square or centered with the swager clamp blocks the tubing will not expand correctly NOTE If the swager cylinder is damaged or bent due to
22. 3 GPM 4200 psi max output Manual Control Valve Canister type 55 000 Pounds Maximum Manual No Automatic Stop 68 302 BL 65 1502 BL Pump Output Operation Modes Hydraulic Filter Bending Force Bend Depth Control Overall Length Overall Width Overall Height Special radius dies are available Reduction tools do not come standard GAUGE WALL THICKNESS DECIMAL EQUIVALENT 1 1 1 1 52 122 159 ju 122 1 152 queo quo 4 1 5 2 2 2 2 2 3 2 2 2 2 1 BENDER CAPACITY 1 3 4 O D Tubing Pipe O D Tubing Pipe 3 4 O D Tubing Pipe DESIGN FEATURES MODELS 1302 BA 1502 BA Bending Capacity Tubing from 1 2 OD 3 OD Maximum Capacity Tube Thickness See Chart Below Maximum Bending Radius 5 Minimum Bending Radius 3 1 2 Swaging Capability Expansion Reduction Forming Swaging Capacity 1 O D Tubing 3 O D Tubing 5 H P Single or Three Phase 220 380 440 VAC 3 GPM 4200 psi max output Full Automatic or Manual Foot Switch Canister type 55 000 Pounds Maximum Digital Readout Automatic Stop and Return 62 I302 BA 64 1502 BA Pump Output Operation Modes Hydraulic Filter Bending Force Bend Depth Control Overall Length Overall Width Overall Height Special radius dies are available Reduction tools do not come standard DESIGN FEATURES MODELS 1000BL 1000 BAS Bending Capacity Tubing from 1 2 OD 3 OD
23. 4 Leave at least three inches of tubing extended beyond the inside edge of the adapter collar See figure 1 A Figure 1 A 5 To secure the tubing firmly snug the collar back into the clamp blocks by gently pushing back on the collar assembly 6 Slowly while depressing the valve handle down move the shaft forward until the expander die enters the tubing Be sure that the tool is centered with the tubing Continue moving the cylinder forward until the expansion is formed See figure 2 A NOTE NEVER run the expander die into the tubing more than 1 4 from the end of the die NEVER completely bury the die into the tubing Figure 2 A 26 Bender Operation Manual 7 After the tubing has been expanded retract the die by lifting up on the control handle 8 Separate the collar from the tubing Remove tooling and return to the storage area CAUTION BE SAFE DO NOT rush any procedure ALWAYS operate the swager unit SLOWLY and CAUTIOUSLY KEEP HANDS CLEAR from all pinch points ALWAYS wear protective safety goggles USING THE STED EXPANDER DIES OR THE B 212 TO MAKE MALE BALL EXPANSIONS IMPORTANT NOTE When making male ball expansions it is necessary to first install the pipe flange or clamp around the tube prior to finishing the ends To make a male ball expansion using the STED expander dies or B 212 proceed as follows See chart on page 12 for typical end finishing illustrations NOTE The B symb
24. 5 To make a female ball expansion place the tubing over the arbor and segment set until the tubing is positioned midway at the grooved area Depress the valve handle to flare the end of the tubing to match with the mating male ball joint See figure 3 A Figure 3 A USING THE FLARE SEGMENT SETS These segment sets are used to make 45 degree flares on tubing ends Three different sets are available that work on tubing sizes 1 1 2 2 1 2 These are not included in standard tooling packages See chart on page 12 for typical end finishing illustrations To produce a flare proceed as follows 1 Slide the proper size flare segment set over the arbor See figure 1 B Figure 1 B pns 2 Place the tubing over the arbor and segment set but DO NOT place the end of the tubing past the last step on the segment set See figure 1 A Figure 1 A 3 Depress the valve handle and rotate the tubing clockwise until the desired flare is produced NOTE Smaller size tubing should be gradually worked up onto the flare segment set until the desired flare has been produced USING THE MANIFOLD FLANGE SEGMENT SETS These segment sets are used to make donut type mani fold flanges on tubing ends They are available in five sizes 1 1 4 1 1 12 2 2 1 4 and 2 1 12 All manifold segment sets are used in conjunction with limit rings These are not included in standard tooling packages See chart on page 12 fo
25. Be sure that the tool is centered with the tubing 7 Slowly move the tool forward until the desired flare is achieved See figure 2 A Figure 2 A 8 Retract the die by lifting up on the control handle You have now completed the 45 degree flare 9 To complete the FLAT FLARE proceed as follows 10 After retracting the cylinder install the flattening tool as shown below 11 Slowly move the tool forward until the flare forms a flat surface See figure 2 B 28 Bender Operation Manual Figure 2 B TN x 12 Retract the die by lifting up on the control handle 13 Separate the collar from the tubing Remove tooling and return to the storage area USING THE HPF 300 TO MAKE A MANIFOLD FLANGE IMPORTANT NOTE When making a manifold flange it is necessary to first install the pipe flange or clamp around the tube prior to finishing the ends On this application it is necessary to use a scrap piece of tubing approximately 1 1 2 long of the same O D size This tubing section will be inserted into the tubing end to form a gasket retainer Follow these steps to produce a manifold flange using the HPF 300 tool See chart on page 12 for typical end finishing illustrations 1 Retract the swager cylinder completely by lifting the valve handle up 2 Install the HPF 300 tool on the ST 1 adapter attached to the end of the cylinder shaft 3 Install the required HAC adapter collar around the tubing and position withi
26. BendPak INCORPORATED FORWARD THIS MANUAL TO ALL OPERATORS FAILURE TO OPERATE THIS EQUIPMENT AS DIRECTED HEREIN MAY CAUSE INJURY OPERATION AND SERVICE MANUAL Models 1000 BL 1302 BL Blue Bullet 1000 BAS 1302 BAS 1000 BA 1302 BA 1502 BL 1502 BAS 1502 BA SHIPPING DAMAGE CLAIMS When this equipment is shipped title passes to the pur chaser upon receipt from the carrier Consequently claims for material damaged in shipment must be made by the purchaser against the transportation company at the time shipment is received America s Most Popular Tubing Bender Model 1502 BA shown with typical tooling package BE SAFE Bend Pak Inc benders are designed and built with safety in mind However your overall safety can be increased by proper training and thoughtful operation on the part of the operator DO NOT operate or repair this equipment without reading this manual and the important safety instructions shown inside Bend Pak INCORPORATED 1 Bender Operation Manual 1645 Lemonwood Drive Santa Paula CA 93060 U S A Tel 805 529 3675 Fax 805 529 2909 Revision 90196 TABLE OF CONTENTS Identification Bv FATUM 3 wierele is c A ere 4 Imbortant Satety Inslti UGHOFIS ES ee aibi tein De ta aon ads 5 Definition Of Terms Model ldentifi a HOE EE EE Se dn lenis EE GE EN GR ER didlo ar AEA IP Gate 6 Jar jare ne Eleotcsl
27. DATA CONTROL board stores bend depths only All data will be cleared once power is turned off The memory feature can be used when bend ing multiple or individual pipes The following instructions illustrate how to properly enter the data which is shown on the program cards 1 Press the SELCT button to illuminate the KEYPAD light 2 Press the RESET button to return the STATION window to number one 3 Using your program card enter the first degree of bend shown in the BEND DEPTH column Press the appropriate number keys to display the recommended bend depth in the SET ANGLE window Now press the ENTER key You have just entered the first bend depth in station number one 4 Press the STEP button to change the station to display the number 2 5 Using your program card enter the second depth of bend by pressing the appropriate number keys The number should appear in the SET ANGLE window If the information is correct press the ENTER key You have now entered the second bend depth in station number two Bender Operation Manual 13 6 Repeat these steps until all depth of bends have been entered Always remember to press the ENTER key prior to advancing to the next station 7 Now press the SELCT key to illuminate the MEMORY light 8 Press the RESET button This will change the STATION window to number 1 9 To double check the data that has been entered press the STEP key to advance the stations through their appr
28. E CONFIGURATION 1000 Series A machine capable of bending only Does not come with any end finishing capabilities 1302 Series A machine capable of bending and end finishing Equipped with both swager and internal expander A double ended hydraulic cylinder is used for both end finishing functions The end finishing assembly the swager and internal expander is positioned cross wised on the rear of the machine Overhead view of Model 1302 1502 Series A machine capable of bending and end fin ishing Equipped with both swager and internal expander Individual hydraulic cylinders are utilized for both end fin ishing functions The swager and internal expander are positioned at the rear of the machine one on each side and are positioned parallel with the main body CONTROL FEATURES BL or BLUE BULLET Models A hydraulic control valve is located at the front of the machine at knee height that allows the operators to manually control the machine with their leg A degree plate is mounted up front that shows proper bend depths This model does not incorporate any automatic bending features BAS Models These models have two different control modes An electric foot switch assembly for manual bend ing operations and a three button control board for auto matic functions The degrees of bends are shown on a degree plate mounted near the front of the machine which also incorporates an adjustable slide pointer that can be set
29. Maximum Capacity Tube Thickness See Chart Below Maximum Bending Radius 5 5 H P Single or Three Phase 220 380 440 VAC 3 GPM 4200 psi max output Automatic BA or BAS Manual BL Canister type 55 000 Pounds Maximum BA Digital Readout Automatic BAS Depth of Bend Plate Automatic BL Manual Pump Output Operation Modes Hydraulic Filter Bending Force Bend Depth Control Overall Length Overall Width Overall Height Special radius dies are available RADIUS SIZE 3 1 2 MAXIMUM BEND DEPTH 718 O D Tubing Pipe 4 2 O D Tubing Pipe 5 2 1 8 O D Tubing Pipe 4 1 4 O D Tubing Pipe 1 4 O D Tubing Pipe 5 1 2 O D Tubing Pipe 1 2 O D Tubing Pipe 1 2 O D Tubing Pipe O D Tubing Pipe 1 2 O D Tubing Pipe 1 2 O D Tubing Pipe 1 2 O D Tubing Pipe 180 Style 180 Style NOTE 180 STYLE DIES ARE NOT INCLUDED IN STANDARD TOOLING PACKAGES opecial size dies not listed in this manual may be manufactured to your specifications Call factory for details Special manufactured items require a 60 day minimum lead time 4 Bender Operation Manual UPON DELIVERY 1 Carefully remove the crating and packing materials 2 Inspect the bender for any signs of concealed shipment damage or shortages Remember to report any shipping damage to the carrier and make a notation on the delivery receipt 3 Check th
30. See figure 2 A If there is more than 1 32 of movement in either direction the pusher block should be replaced Figure 2 A 38 Bender Operation Manual 3 Remove the pusher block by sliding it to the rear end then off of the guide plate 4 Carefully re install the new pusher block it should be tight by reversing these steps 5 Snug the cylinder to the pusher block and thoroughly grease the guide plate CALIBRATING THE DEPTH OF BEND PLATE BL BLUE BULLET AND BAS MODELS To properly calibrate the depth of bend plate on all BL and BAS models follow the steps outlined below 1 Turn the machine on 2 Place a set of bending dies in position 3 Using a carpenters square advance the radius die until the back gates are at a true 90 degrees contacting the inside of the square evenly across the front of the gates See figure 2 B so that it reads 90 degrees at this time See figure 2 C 5 Retract the radius die and check that the pointer returns to zero If not loosen the mounting bolts on the degree plate and adjust the plate until both 90 degree and zero degree readings are achieved Figure 2 C NOTE Some tubing may experience spring back after the bend is made To compensate for this set your depth of bend pointer 2 degrees less than the actual position of the gates 39 Bender Operation Manual CALIBRATING THE AUTOMATIC DEPTH OF BEND SWITCH BAS MODELS
31. TROL DIE ANGLE ae B STATION H STOP REVERSE 12 Bender Operation Manual Domed End Reduction DESCRIPTION OF CONTROLS SELCT Selects KEYPAD or MEMORY functions CLEAR Clears the SET ANGLE ENTER Enters the numbers displayed in SET ANGLE into memory Only when KEYPAD is lighted STEP Advances station number display RESET Resets station number back to one AUTO Starts automatic cycle JOG FWD Press and hold to advance radius die manu ally Release button and all forward motion will stop Overrides AUTO button STOP REVERSE Also EMERGENCY STOP Press to stop forward movement of radius die Press again to reverse then again to stop SET ANGLE WINDOW Displays depth of bend degrees programmed for the next bend DIE ANGLE WINDOW Continuously displays the degrees of bend as the radius die moves forward STATION WINDOW Shows the position or station num ber that a particular bend depth has been programmed into REMOTE FOOT SWITCHES Used for manual opera tion The right foot switch advances the radius die while the left foot switch retracts it Either foot switch will also serve as an emergency stop WARNING 1 Either foot switch will act as an EMERGENCY stop 2 NEVER operate the remote electric foot switches in or around water or damp areas 3 If the foot switch cords become frayed or damaged in any way discontinue use until they are properly repaired 4 ALWAYS disconnect po
32. When the GREEN control button is or disconnected wires Replace if faulty released the top cylinder will advance then retract upon reaching the depth of bend switch BAS models Stuck in reverse The left foot switch is stuck shorted Check wire connections on the left foot The top cylinder will advance with the malfunctioning Refer to diagram on page 50 right foot switch or if the GREEN control Check micro switch with ohmmeter as button is held in but immediately retract described on page 43 Check for broken if either is released or disconnected wires Replace if faulty BAS models The motor runs but the The fuse is blown on the control Remove control board and check fuse are inoperative board 3 Phase models The motor is Check motor rotation See page 44 running backwards The power supply is incorrect Check voltage supply phase and wiring Refer to wiring instructions found on page 7 amp 43 46 Bender Operation Manual HELPFUL DIAGNOSTIC TIPS FOR DIGITAL MODELS If you feel a control problem exists with the main circuit panel the jumper board can be used to temporarily bypass the complete control board assembly until repairs are made See page 41 If the top cylinder advances or retracts by itself without activating any controls and you feel the problem exists with the front display panel due to cuts or other damage disconnect it from the main circuit panel by unplugging it from the blue wire ribbon W
33. bed on page 43 Check for broken or disconnected wires Replace if faulty Adjust the trip arm as described on page 40 In most case the encoder will have to be replaced You may temporarily correct the problem by cleaning the encoder as described on page 40 Manually operate the solenoid valve using the manual control buttons This should dislodge any debris that may have become stuck in the valve body Bender Operation Manual 47 BENDING PROBLEMS Bending complications can be usually attributed to tubing thickness tubing quality or improper radius selection The bigger the tubing diameter the bigger the radius and wall thickness should be See the chart below for minimum tubing thickness and proper radius selection Tubing Diameter Minimum Tubing Thickness Minimum Tubing Thickness Minimum Tubing Thickness 5 Radius 4 Radius 3 1 2 Radius SYMPTOM CONDITION Flattening or collapsing of pipe on outside of bend POSSIBLE CAUSE CORRECTIVE ACTION Incorrect back pressure Usually a low Adjust back pressure as shown on page pressure problem 33 For 3 diameter tube see bending instructions found on page 21 Bending dies are not properly matched to Select proper bending dies for the the tubing diameter particular tubing diameter Tubing diameter is actually less or more Check the actual tubing diameter using than what it is labeled a micrometer or similar measuring device Gauge thickne
34. by placing it over the end of tubing of the corresponding size The expansion should allow the tubing to fit snugly 11 The expansion can be made to fit looser by turning the buttress canister counter clockwise or tighter by turning the buttress canister clockwise HELPFUL TIP Cut off sections of tubing in all sizes approximately 3 in length and weld them to a bracket similar to the one shown below Attach to your bender and use it to check your expansions USING THE BALLJOINT SEGMENT SETS Ball joint segment sets are used to make ball joint expansions on shorter tubing ends They are available in three sizes 2 2 1 4 and 2 1 2 These are not included in standard tooling packages See chart on page 12 for typical end finishing illustrations Ball type expansions can be made quick and easily using ball segment sets on the internal expander as explained below 1 Slide the proper size ball joint segment set over the arbor See figure 1 A IN e i 7 oe Uh 3 M f E T g AED p J Figure 1 A 2 Place the tubing over the ball segment set until the tubing end is flush with the shoulder 3 Adjust the buttress canister until the grooved line on the canister is lined up with the grooved line on the pointer 24 Bender Operation Manual 4 Depress the valve handle to form the ball on the end of the tubing Be careful not to distort the end of the tubing See figure 2 A Figure 2 A
35. collar assembly 6 Slowly while depressing the valve handle down move the shaft forward until the tool enters the tubing Be sure that the tool is centered with the tubing Continue moving the cylinder forward until the expansion is formed See figure 3 B ML Figure 3 B 7 After the tubing has been expanded retract the die by lifting up on the control handle Separate the collar from the tubing Remove tooling and return to the storage area USING THE HPF 300 TOOL TO MAKE 45 DEGREE FLARES AND FLAT FLARES IMPORTANT NOTE When making 45 degree flares and flat flares it is necessary to first install the pipe flange or clamp around the tube prior to finishing the ends Follow these steps to produce flares using the HPF 300 tool See chart on page 12 for typical end finishing illustra tions 1 Retract the swager cylinder completely by lifting the valve handle up 2 Install the HPF 300 tool on the ST 1 adapter attached to the end of the cylinder shaft 3 Install the required HAC adapter collar around the tubing and position within the swager clamp blocks Bender Operation Manual 27 4 Leave at least three inches of tubing extended beyond the inside edge of the adapter collar See figure 1 A Figure 1 A 5 Snug the collar back into the clamp blocks by gently pushing back on the collar assembly 6 Slowly while depressing the valve handle down move the shaft forward until the tool enters the tubing
36. crometer or similar measuring Crimping or wrinkling of pipe device 48 Bender Operation Manual HOLS LM CN3BH 20 Hidag 2 HOLIMS LIAN OL Electrical Wiring Diagram for Three Button BAS Models HILIMS 1003 1331 JA TUA QION310S SIYIM JIMOd Bender Operation Manual 49 49 Bender Operation Manual Electrical Wiring Diagram YOLOANNOD 3S3002NJ for Digital BA Models INIA JIONTIOS S3YIM m ri 50 Bender Operation Manual SERVICE PARTS PART NUMBER DESCRIPTION 214 Oil Filter Element Filter Head Pressure Gauge Leaf Chain Section 5 16 Chain Bolt Chain Return Bolt Adjustable Chain Connector Springs For Pusher Block Pusher Block Guide Plate Chain Return Block Depth of Bend Plate Rotation Dial Faceplate Bearing For Rotation Dial Rotation Dial Pendulum Assembly Rigid Caster Assembly Swivel Caster Assembly Valve Handle Valve Top Bracket Valve Linkage Assembly Buttress Assembly Complete Breather Cap 3 4 Suction Hose Top Tool Tray wager Tool Tray wager Box Assembly 9 H P Single Phase Motor P Three Phase Motor SH P Three Phase Motor H P Single Phase Switch Box H P Three Phase Switch Box win Electric Foot Switch Assembly op Micro Depth Of Bend Switc U Angle Micro Switc Digital Control Board Complete ree Button Control Board Complete Digital Membrane BA olored Control Buttons BA Plexiglas Faceplate Cover Wiri
37. d and upon reaching the desired bend depth immediately retracts to the original starting position An emergency STOP button pauses the machine at any time and an additional auto REVERSE button activates the return sequence The electric foot switches will override the digital controls INSTALLING THE PROGRAM DATA CONTROL DIE ANOLE gt a i I I 4 pem Digital Th control STATION board i 5 l x m STATION JOG STOP Fwo REVERSE ELECTRICAL PLUG Before installing a plug on the end of the power cord it is important to check for proper voltage phase and amp requirements The tag attached to the end of the power cord or the motor identification plate will show this necessary information Due to the high amps and voltage required to operate this machine at long durations it is recommended that you DO NOT USE AN EXTENSION CORD LONGER THAN 15 FEET This motor must be grounded The GREEN wire is for ground only All wiring should be done by a certified electrician only Damage to the motor caused by improper wiring is not covered under warranty Bender Operation Manual 7 TURNING YOUR NEW BENDER ON 1 Plug the power cord into a receptacle closest to the available circuit panel IF SMOKE APPEARS OR SHORTING OCCURS DISCONNECT IMMEDIATELY RE CHECK ALL CONNECTIONS 2 After the bender is plugged in turn the machine on by depressing the ON button located on the lower right front side of
38. d replace the RED control properly The BLUE control button works stuck shorted malfunctioning button or faulty relay only when held in The GREEN control button does not function at all BAS models Both foot switches are The GREEN control button or relay is Remove and replace the GREEN control inoperative The bending die retractspast stuck shorted malfunctioning button or faulty relay the rear limit switch and the system pressure builds up and the bender groans If the RED control button is pushed then the ram will advance auto matically until reaching the depth of bend switch At this time it will then retract past the rear limit switch again and the system pressure will build BAS models The GREEN control The depth of bend switch is stuck Check wire connections on depth of button retracts the top cylinder when shorted malfunctioning bend limit switch Refer to diagram on held in Does not advance with right page 50 Check micro switch with foot switch control ohmmeter as described on page 43 Check for broken or disconnected wires Replace if faulty BAS models Stuck in forward mode The right foot switch is stuck Check wire connections on right foot The BLUE and RED control buttons are shorted malfunctioning switch Refer to diagram on page 50 inoperative The GREEN control button Check micro switch with ohmmeter as retracts the top cylinder when held in described on page 43 Check for broken
39. d to the end of the cylinder shaft 3 Install the required HAC adapter collar around the tubing and position within the swager clamp blocks 4 Leave atleast 3 1 2 of tubing extended beyond the inside edge of the adapter collar See figure 2 B Figure 2 B 5 Snug the collar back into the clamp blocks by gently pushing back on the collar assembly 6 Slowly while depressing the valve handle down move the shaft forward until the tool contacts the tubing Be sure that the tool is centered with the tubing 7 Make the reduction by advancing the tool forward towards the collar until the tool bottoms out against the tubing end Once the tool stops release the valve handle Do not apply full pressure for this operation 8 Retract the die by lifting up on the control handle See figure 2 C Figure 2 C 9 Separate the collar from the tubing Remove tooling and return to the storage area USING THE DOMING DIE TO FINISH TAILPIPE ENDS For a more finished look on tailpipe ends you may use the DOMING DIE to slightly dome the ends To properly do this follow these simple steps See chart on page 12 for typical end finishing illustrations 1 Retract the swager cylinder completely by lifting the valve handle up 2 Install the DD 134 212 tool on the ST 1 adapter attached to the end of the cylinder shaft 3 Install the required HAC adapter collar around the tubing and position within the swager clamp blocks 4 Leave the
40. d to the green ground wire See page 48 for improving bend quality Check voltage supply phase and wiring Refer to wiring instructions found on pages 7 amp 43 Check connections on micro switch Refer to diagrams on pages 49 50 Check micro switch with ohmmeter See page 43 Check for broken or disconnected wires Check connections on micro switch Refer to diagrams on pages 49 50 Check micro switch with ohmmeter See page 43 Check for broken or disconnected wires Adjust return pressure as shown on page 33 before use Wipe tubing clean Shim the swager cylinder as required See Clean and thoroughly grease bending dies page 37 The swager cylinder is bent Remove and replace swager cylinder Bender Operation Manual 45 SYMPTOM CONDITION POSSIBLE CAUSE CORRECTIVE ACTION BAS models The bending ram The rear limit switch is malfunctioning Check wire connections on the rear limit continues retracting even after the rear switch Refer to diagram on page 50 limit switch is activated Pressure builds Check micro switch with ohmmeter as up on the sequence valve gauge described on page 43 Check for broken or disconnected wires Replace if faulty The solenoid valve spool is stuck Manually operate the solenoid valve using the manual control buttons This should dislodge any debris that may have become stuck in the valve body BAS models Both foot switches function The RED control button or relay is Remove an
41. down to For example a tool marked 200 will reduce 2 1 4 tubing down to 2 O D and a tool marked 214 will reduce 2 1 2 tubing down to 2 1 4 O D Not included in standard tooling packages HCT 214 212 This tool is for making header flanges or collectors on 2 1 4 and 2 1 2 pipe ends This eliminates the need to purchase a collector when installing header type manifolds Not included in standard tooling packages IMPORTANT NOTICE Installing headers on any motor vehicle is illegal in most states and may violate the 1990 Clean Air Act Consult the EPA at 202 260 7645 for questions regarding the installation of any aftermarket perfor mance product that may alter vehicle emissions Reducing Tool HCT 214 212 HSRO A hand held pipe reshaping tool that is used for reshaping pipe ends while the tubing remains on the vehicle By tapping the tool with a hammer or mallet the tool can be used to reshape pipe ends Can be used inter nally or externally by simply reversing the tool Not avail able in standard tooling packages CAUTION ALWAYS wear protective safety glasses or goggles when using this machine BENDING PLUGS Bending plugs are used to contain the shape of pipe ends during the bending process when the radius die comes in close proximity to the pipe end Once the bend is completed the bending plug is removed Not included in standard tooling packages HSRO Bending Plug SEGMENT EXPANDERS Segment expander
42. e Is no voltage to the solenoid valve or the voltage Is too low Check the fuse on the control board or see electrical diagrams on pages 4 ELECTRICAL REPAIR WARNING Electrical equipment should be serviced by certified electrician s only This manual should not be viewed as sufficient instructions for those who are not other wise qualified to operate service or maintain the equipment discussed Although reasonable care has been taken to provide accurate and authoritative information in this manual no responsibility is assumed by the manufacturer for any consequences arising out of the use of this material The following section contains instructions and illustrations to aid in electrical repair Most electrical components cannot be repaired and require only removal and installation of new components If replacement parts are to be installed refer to the wiring diagrams found on pages 49 amp 50 DANGER This machine contains high voltage Disconnect power at the receptacle before performing any electrical repairs Secure plug so that it cannot be accidentally plugged in during servicing CHECKING THE MICRO SWITCHES AUTOMATIC MODELS The micro switches shown below play a very important part in the control features of your machine These switches remain in the circuit at all times in order for the controls to function properly DESCRIPTION MODELS MODELS Top Micro Switch X Depth ofBendSwith X Zero A
43. e during this process NOTE When a REVERSE is called for the rotation dial wil be positioned on the LEFT side for that bend only If the SYMBOL section shows a REVERSE again for the following bend the rotation dial MUST remain on the LEFT side If no REVERSE is called for the rotation dial MUST be returned to the RIGHT side 19 For bend number three REVERSE the tubing and install the HALF SHOE now See figure 3 A Figure 3 A 20 With the HALF SHOE in place and the third CENTER MARK lined up at the center of the shoes advance the radius die forward until the pusher block springs are compressed and the tubing is held securely 21 Rotate the tubing not the dial so that the pendulum pointer or dial indicator points to the proper setting as shown in the PIPE ROTATION section of the card In this case the PIPE ROTATION will be 250 degrees USE THE INSIDE set of numbers Advance the radius die to 7 degrees 22 Review the SYMBOLS section of the card and 1 Figure 3 C check for any special instructions 23 On bend number four you will notice that a REVERSE USE HALF SHOE is again called for Keep the ROTATION DIAL on the LEFT side for this bend 24 Advance the radius die forward until the pusher block springs are compressed and the tubing is held securely 25 Rotate the tubing so that the pendulum pointer or dial indicator points to 260 degrees 26 Advance the radius die to 35 degrees then retract the die to the original
44. e of the machine If the oil level appears low add oil now See page 32 for recommended hydraulic oils Oil sight gauge 12 Activate the swaging and internal expander cylinders by depressing the control handles located at the rear of the machine Cycle the cylinders to their full extent at least flve times Again these cylinders may act erratically until the air dissipates TOOLING Find the packing list that accompanied your bender item izing each tool that was to be included in your tooling package Double check the pieces you received with those that were checked off ALL THE TOOLS THAT ARE CHECKED OFF IN THE SHIPPED COLUMN DID SHIP WITH YOUR BENDER If you cannot find a certain piece that you feel should be with the shipment check with the freight carrier or observe the packing list and check the back ordered column If a certain item is back ordered it will be automatically forwarded to you A description of tooling is listed below RADIUS DIES These dies which are commonly referred to as the bending dies come in different radii and tubing sizes Each die is machined and sized according to tubing diameters The proper tube size is stamped on the top of each die 112 represents 1 1 2 tubing 134 represents 1 3 4 tubing etc The radius dies are available in three standard radii 5 4 and 3 1 2 Each standard radius die represents half of a circle or diameter 180 degree dies are also available which
45. e voltage phase and proper amperage requirements for the motor shown on the motor plate Wiring should be performed by a certified electrician only IMPORTANT SAFETY INSTRUCTIONS Read these safety instructions entirely 1 Read and understand all safety warning proce dures before operating machine 2 Keep hands clear Remove hands prior to bending forming swaging or expanding tubing Avoid pinch points 3 Keep work area clean Cluttered work areas invite injuries 4 Consider work area environment Do not expose equipment to rain Do not use in damp or wet locations Keep area well lighted 5 Only trained operators should operate this machine All non trained personnel should be kept away from work area Never let non trained personnel come in contact with or operate machine 6 Use tooling correctly Use all tooling in the proper manner Never try to use a tool for something that it was not designed for See manual for proper use 7 Dress properly Never wear loose gloves clothing or jewelry They can be caught in moving parts Non skid steel toe footwear is recommended when operat ing machine Wear protective hair covering to contain long hair 8 Always wear safety goggles when operating this machine 9 Do not overreach Keep proper footing and balance at all times 10 Guard against electric shock This machine must be grounded while in use to protect the operator from electric shock Never connect t
46. en Since bent tubing is difficult to measure It is best to measure from the centerline of the first bend to the centerline of the second bend This measurement should then be added to the measurement taken for the first bend Record this information in the CENTER MARKS section See figure 2 B 12 Look at the rotation dial and take the reading for the pipe rotation Record this information in the second PIPE ROTATION section 13 You are now ready to make your second bend With the tubing or master laying flat on top of the back shoes gradually extend the radius die forward until the gates start to open and the tubing begins to bend Continue bending until the bend depth is equal to that of the master See figure 2 C 14 Take a reading for the bend depth and mark this in the second BEND DEPTH section on the card 21 Bender Operation Manual NOTE Repeat these steps for the remaining bends After all bends are completed make the necessary end finishing and take a measurement for the overall cut off length Be sure to make all notations on the blank program card for later reference USING A BLOCK OF WOOD Some bending cards or certain bending applications require the use of a BLOCK OF WOOD This is used to cushion the tubing when a half shoe is being used The BLOCK OF WOOD should be approximately 2 x 4 x 4 and will be used together with the half shoe When half shoes are used on larger size tubing they have
47. ew bender is the product of over 25 years of continuous research testing and development and is the most technically advanced bender on the market today READ THIS ENTIRE MANUAL BEFORE OPERATION BEGINS The manner in which you care for and maintain your bender will have a direct effect on it s overall performance and longevity RECORD HERE THE FOLLOWING INFORMATION WHICH IS LOCATED AT THE FRONT END OF YOUR MACHINE Serial No Model No Manufacturing date WARRANTY Your new bender is warranted for two years on equipment structure one year on all operating components and tooling to the original purchaser to be free of defects in material and workmanship The manufacturer shall repair or replace at their option for this period those parts returned to the factory freight prepaid which prove upon inspection to be defective The manufacturer will pay labor costs for the first I2 months only on parts returned as previously described This warranty does not extend to defects caused by ordinary wear abuse misuse shipping damage or lack of required maintenance This warranty is exclusive and in lieu of all other warranties expressed or implied In no event shall the manufacturer be liable for special consequential or incidental damages for the breach or delay in performance of the warranty The manufacturer reserves the right to make design changes or add improvements to its product line without incurring any obligation to make such changes o
48. gure 1 C 5 Using a measuring tape measure the distance from the end of the tubing to the center of the back shoes This is the measurement to the first bend and should be recorded in the CENTER MARKS section of a blank card See figure 1B ANGLE window This is the depth or degrees of the first bend Record this information in the BEND DEPTH section 9 Retract the bending dies and slide the straight tubing to the left Place the tubing or master on top of the t anm back shoes so that the centerline of the second bend 1 lines up with the centerline of the back gates Be 6 Place the ROTATION DIAL on the far right end of the sure that the master lies perfectly flat straight tubing and secure by tightening the wing nut 10 Line up the second bend of the new pipe with the Center the ROTATION DIAL degree plate so that the second bend of the master Be sure that the master indicator points to zero ALWAYS USE THE remains flat on top of the back shoes Advance the NUMBERS CLOSEST TO THE CENTER OF THE radius die until the pusher block springs are ROTATION DIAL THE OUTSIDE NUMBERS ARE compressed and the tubing is held securely Make FOR SPECIAL APPLICATIONS ONLY Record the any adjustments at this time Your second bend is rotation degree as zero for your first PIPE ROTATION now correctly located See figure 2 A 20 Bender Operation Manual Figure 2 A 4 d 11 The measurement for the second bend should now be tak
49. hain assemblies during the retract sequence This is important so that the gates close in unison with the radius die Upon initiating the return sequence hydraulic fluid is split and redirected so that an equal portion is transferred to the top cylinder and bottom cylinder simultaneously If the pressure is set too high the machine will groan and strain when revers ing as the top cylinder tries to overcome the bottom cyl inder If the pressure is too low the gates may hesitate or remain open when the radius die retracts as the top cylinder receives more fluid than the bottom cylinder It is seldom necessary to readjust this pressure setting The normal operating return pressure should be set at 350 P S I This pressure reading is taken as the radius die retracts just after it releases from the back shoes This pressure setting is controlled by the flow control valve See figure 1 A and 2 A If the return pressure needs adjusting proceed as follows 1 Turn the machine on Place a radius die and set of back shoes in position Tubing will not be required for this operation 3 Advance the radius die until it just comes in contact with the back shoes 4 Using the manual controls initiate the retract sequence and read the pressure shown on the gauge located to the front of the machine 5 If an adjustment is required loosen the locking nut that secures the adjusting screw 6 Toincrease the pressure turn the adjusting
50. he green power cord wire to a live terminal This is for ground only 11 Always unplug machine before servicing Never yank cord to disconnect it from the receptacle Make sure electrical connections are good Never use an extension cord longer than 15 feet If the power cord becomes frayed replace it Never alter electrical components on this machine Never operate machine in or around water or damp environments 12 Warning Risk of explosion This equipment has internal arcing or sparking parts which should not be exposed to flammable vapors This machine should not be located in a recessed area or below floor level 13 Maintain with care Keep machine clean for better and safe performance Follow manual for proper lubrication and maintenance instructions Keep control handles and or buttons dry clean and free from grease and oil 14 Stay alert Watch what you are doing Use common sense Be aware 15 Check for damaged parts Check for alignment of moving parts breakage of parts or any condition that may affect its operation Do not use machine if any component is broken or damaged 16 Never remove electric foot switches from their protective safety housing Always remove foot from pedal enclosure between bends 17 Always allow for the Safety Circle Of Swing around the bender There should be at least 10 feet of space on both sides of the bender so that the tubing will not come in contact with persons and or objects
51. hed then automatically retract until the die is returned to the original starting position BLUE BUTTON Automatically returns or retracts the bending die to the original starting position NEVER hold the BLUE button in when retracting the bending ram RED BUTTON Serves as an Emergency Stop button Automatically stops all movement of the bending die dur ing the automatic cycle REMOTE FOOT SWITCHES Used for manual opera tion The right foot switch advances the radius die to start the bending process The left foot switch retracts the radius die Either foot switch will also serve as an emer gency stop WARNING Either foot switch will act as an EMERGENCY stop NEVER operate the remote electric foot switches in or around water or damp areas If the foot switch cords become frayed or damaged in any way discontinue use until they are properly repaired ALWAYS disconnect power cord before making any electrical repairs If any operating controls are malfunctioning discontinue immediately NOTE Practice the following bending steps without tubing and initiate a few dry runs until you understand the operating features USING THE AUTO STOP DEPTH OF BEND FEATURE The Auto Stop slide pointer is attached to the depth of bend degree plate and stops the radius die at pre set bend depths The Auto Stop feature works with either the GREEN automatic control button or the remote foot switches
52. ic control valve mounted at knee height that allows the user to operate the machine manually with their leg A degree plate with pointer is mounted near the front of the machine that gives the user accu rate bend depths BL models are not equipped with any automatic features To operate the manual control valve move the handle to the left or the plunger down to advance the radius die The handle must be fully engaged to properly control radius die movement 15 Bender Operation Manual Y 4 To retract the radius die move the handle to the right or plunger up to return to the original starting position Always be prepared to support the pipe as it is released from the dies OPERATION NOTE BL MODELS If the operating control handle is pressed half way or par tially down during the bending operation the radius die may slow down or even retract slightly To keep the bending die at a controlled speed you must fully depress the valve handle If you wish to advance the radius die a few degrees only instead of easing the handle down try tapping the handle BENDING OPERATIONS There are basically two styles of bending that can be per formed on your new bender The first is PROGRAM CARD BENDING which requires the use of PROGRAM CARDS that contain instructional data for specific applications The second is PATTERN BENDING which is the most popular method and duplicates pipes by using an existing pipe or wire pattern as a
53. ifold Flange Tool SEGMENT EXPANDER TOOLING 2 112 I 63 5mm 1 3 4 44 5mm 1 172 738mm 1 TC 30 Tubing Cutter Other Sizes Are Available Upon Request 52 Bender Operation Manual ECONOMY 202 DIE PACKAGE IDA PART NO SIZE TOOLING DESCRIPTION BENDING TOOLING 5 127mm Radius Die 5 127mm Radius Die 3 1 2 89 mm Radius Die 1 1 2 38mm SWAGER TOOLING Solid Expander Die 2 1 4 Male Ball Expander Solid Expander Die 2 Male Ball Expander STED 112 2 50 8mm 1 3 4 amp 2 1 4 2 amp 2 1 2 1 B 212 2 1 2 63 5mm Male Ball Tool SEGMENT EXPANDER TOOLING 55 134 55 112 1 1 2 38mm OR Other Sizes Are Available Upon Request 53 Bender Operation Manual Bender Operation Manual 53 BB 1 DIE PACKAGE FOR BLUE BULLET BENDER IDA PART NO SIZE TOOLING DESCRIPTION BENDING TOOLING 5 127mm Radius Die 5 127mm Radius Die 3 1 2 89 mm Radius Die 1 1 2 38mm SWAGER TOOLING Solid Expander Die 2 1 4 Male Ball Expander Solid Expander Die 2 Male Ball Expander STED 112 2 50 8mm 1 3 4 amp 2 1 4 2 amp 2 1 2 1 B 212 2 1 2 63 5mm Male Ball Tool SEGMENT EXPANDER TOOLING 55 134 55 112 1 1 2 38mm OR Other Sizes Are Available Upon Request 54 Bender Operation Manual BB 2 DIE PACKAGE FOR BLUE BULLET BENDER QTY PART NO SIZE TOOLING DESCRIPTION BENDING TOOLING 5 127mm Radius Die 5 127mm Radius Die 4 102mm Radius Die 3 1 2
54. ith the front display panel taken out of the circuit the foot switch controls should operate normally SYMPTOM CONDITION BA models Motor runs but digita board does not light up All controls are inoperative BA models The top cylinder continues forward by itself without activating any controls The keypad or foot switch have no effect BA models The top cylinder continues forward by itself without activating any controls The top cylinder stops when the left foot switch is depressed but will con tinue when released BA models The top cylinder retracts by itself without activating any controls The top cylinder will advance when the AUTO button is depressed but immediately retract when released The STOP REVERSE button is inoperative The top cylinder will stop retracting when the JOG FWD button or right foot switch is depressed but will continue reversing when released BA models The STATION window never advances even after the top cylinder has fully retracted BA models The top cylinder doesn t stop at the degree setting that was programmed into the SET ANGLE win dow 47 Bender Operation Manual POSSIBLE CAUSE Fuse is blown on control board Solenoid valve spool is stuck The AUTO key on the control board is stuck shorted malfunctioning The right foot switch or JOG FWD button is stuck shorted malfunctioning The left foot switch is stuck shorted malfunctioning The trip arm is
55. l forward until the desired ball is achieved This procedure requires careful control See figure 1 B Figure 1 B 12 Retract the die by lifting up on the control handle 13 Separate the collar from the tubing Remove tooling and return to the storage area USING THE BFED TOOLS TO MAKE FEMALE BALL EXPANSIONS IMPORTANT NOTE When making male ball expansions it is necessary to first install the pipe flange or clamp around the tube prior to finishing the ends The BFED 134 214 amp BFED 200 212 are forming tools for flaring pipe ends to make female ball expansions Each tool is stepped and has the ability to flare two dif ferent sizes The BFED 134 212 is used for tubing sizes 1 3 4 and 2 1 2 while the BFED 134 214 is used for tubing sizes 1 3 4 and 2 1 4 Follow these steps to produce female ball expansions using the BFED dies See chart on page 12 for typical end finishing illustrations 1 Retract the swager cylinder completely by lifting the valve handle up 2 Install the required BFED for the appropriate tubing size on the ST 1 adapter attached to the end of the cylinder shaft 3 Install the required HAC adapter collar around the tubing and position within the swager clamp blocks 27 Bender Operation Manual 4 Leave at least three inches of tubing extended beyond the inside edge of the adapter collar See figure 2 B 5 Snug the collar back into the clamp blocks by gently pushing back on the
56. last four digits shown are in sequential order Some cards start with a prefix such as T3 or T5 then are followed by a four digit number ALWAYS disregard the prefix and follow the last four digits only DEFINITION OF CARD SECTIONS YEAR Gives the year of the vehicle that the card pertains to DIAMETER The original equipment factory recommend ed tubing diameter for that particular vehicle O A LENGTH Overall length of tubing required for that particular pipe Also referred to as the cut off point SIDE When more than one section of tubing is required for a particular card number this section shows if it is the front rear left or right side SYMBOLS Shows certain symbols that pertain to indi vidual bending instructions that are explained in greater detail in the BENDING INSTRUCTIONS section The symbol section also includes the descriptive F and R symbols that indicate how the pipe fits on the vehicle F means front and R means rear CENTER MARKS Refers to the actual locations or mea surements that the bends will be located PIPE ROTATION Shows in degrees what the correct pipe rotation or plane is for each bend BEND DEPTH Shows in degrees what the correct bend depth is for each bend MAKE Gives the make of the vehicle Chevrolet Pontiac Ford Chrysler etc MODEL Gives descriptive factors such as the model engine and frame size 16 Bender Operation Manual BENDING INSTRUCTIONS Shows
57. lluminate the KEYPAD light 2 Find out what degree of bend is required and enter it by depressing the appropriate number keys This number will then appear in the SET ANGLE window If you make a mistake and improperly enter the wrong number simply clear the SET ANGLE by depressing the CLEAR button then re enter the proper information 3 With the KEYPAD light illuminated disregard any numbers that may appear in the STATION window 13 Bender Operation Manual 4 After installing a matched die set position the tubing so that you can begin bending 5 Check your circle of swing for allowable clearance 6 Depress the AUTO button to initiate the semi automatic cycle 7 At this time the radius die will begin to move forward until it reaches the designated depth of bend dis played in the SET ANGLE window The retract sequence will then automatically initiate reversing the radius die until it is fully retracted 8 For the remaining bends move the pipe over until the next bend position or center mark is centered between the back shoes Repeat steps 5 7 9 After all bends are completed cut off the tubing end to match the existing pipe or master CAUTION If operating controls are malfunctioning discontinue use immediately DO NOT attempt to operate machinery until controls have been repaired PROGRAMMING THE DIGITAL BOARD Follow these step by step instructions to properly utilize the MEMORY feature The PROGRAM
58. m a variety of tube end finishing INTERNAL EXPANDER The expanding flaring unit located to the rear of the machine that utilizes seg mented expander dies These segment sets are expand ed by the means of a tapered arbor pulled through their center This style of end finishing is usually required with shorter pieces of tubing such as muffler nipples which do not allow the use of a collar TOP CYLINDER The main hydraulic bending cylinder located at the top of the bender It s primary function is to activate movement of the radius dies BOTTOM CYLINDER The hydraulic cylinder located just below the body of the bender It s primary function is to apply resistance pressure to the back shoes as the radius die pushes through RESERVOIR The rear vertical leg that contains the hydraulic oil FRONT UPRIGHT The front vertical leg 6 Bender Operation Manual TOP CYLINDER SWAGER BOX INTERNAL dE EXPANDER RESERVOIR BOTTOM CYLINDER FRONT UPRIGHT Side view of Bender showing major components BENDER MODELS There are nine different bender models available 1000 BL 1000 BAS 1000 BA 1302 BL Blue Bullet 1302 BAS 1302 BA 1502 BL 1502 BAS 1502 BA The following is a brief description of their controls and operating features The model nomenclature consists of a number 1302 followed by letters BA The numbers des ignate what style frame assembly is used while the letters signify the control features FRAM
59. master USING THE PROGRAM CARDS The Program Card System contains bending data for specific applications The following instructions define each section of the card It is important that you read the entire card carefully before attempting to bend Due to the many cards and applica tions covered there may be some inaccuracies No responsibility is assumed by the manufacturer for any consequences arising from inaccuracies found on the pro gram cards Look up the card number in the appropriate reference catalog Exhaust pipes numbers start with the letter E and tail pipes numbers start with the letter T 618 EM5727 Man Tars THINS M 373 Ueto Tree amp decia 0 4 U70 a FE y 10175 X125 TRI Typical Catalog Illustration Bender Operation Manual 15 1397 UPDATED 01 90 DIAMETER BEND NO SYMBOLS CENTER MARK mam CN eC l me 17 5 8 PIPE ROTATION BEND DEPTH BENDING INSTRUCTIONS USE 3 1 2 RAD 1 1 2 SHOE EXP WI 14 250 eso pz pr hie p ee H FEMALE 8 Ae xs 1 1 8 51 5 8 277 s REV USE UIC CAVALICR CIMMARON FIRENZA J2000 SKYHAWK 2 0L ENGINE Sample card layout to be used in conjunction with bending instructions Take down the number of the pipe to be bent find and remove it from the deck Remember to place a marker of some type in its place The cards are filed in numerical sequence by the number shown on the top left section of the card Only the
60. maximum amount of tubing extended beyond the inside edge of the adapter collar as possible This will keep any slight clamp marks that may occur away from the end of the tailpipe which is usually exposed as it is installed on the vehicle See figure 3 C Figure 3 C 5 Snug the collar back into the clamp blocks by gently pushing back on the collar assembly 6 Slowly while depressing the valve handle down move the shaft forward until the tool contacts the tubing Be sure that the tool is centered with the tubing 31 Bender Operation Manual 7 Slowly move the tool forward until the desired finish is achieved See figure 1 A Figure 1 A 8 Retract the die by lifting up on the control handle Separate the collar from the tubing Remove tooling and return to the storage area USING THE HCT 214 212 This tool is for making head er flanges or collectors on 2 1 4 and 2 1 2 pipe ends This eliminates the need to purchase a collector when installing header type manifolds Not included in stan dard tooling packages IMPORTANT NOTE When making a manifold flange it is necessary to first install the pipe flange or clamp around the tube prior to finishing the ends To properly produce a header collector using the optional HCT 214 212 tool follow these simple steps See chart on page 12 for typical end finishing illustrations 1 Retract the swager cylinder completely by lifting the valve handle up 2 Install
61. mes 220 Volt 60HZ Single Phase Incoming Power Motor Leads Line 1 o and 1 Line 2 8 and 4 To reverse rotation interchange lines 5 and 8 220 Volt 60HZ Three Phase Incoming Power Motor Leads Line 1 3 and 9 Line 2 2 and 8 Line 3 1 and 7 Twist together 4 5 6 To reverse rotation interchange any two line leads 440 Volt 60HZ Three Phase Incoming Power Motor Leads Line 1 1 Line 2 2 Line 3 3 Twist together 6 and 9 Twist together o and 8 Twist together 4 and 7 To reverse rotation interchange any two line leads 220 Volt 50HZ Three Phase Incoming Power Motor Leads Line 1 Line 2 Line 3 1 6 7 12 2 4 8 10 3 5 9 11 To reverse rotation interchange any two line leads Bender Operation Manual 43 380 Volt 50HZ Three Phase Incoming Power Motor Leads Line 1 1 and 7 Line 2 2 and 8 Line 3 3 and 9 Twist together 10 11 12 Twist together 4 5 6 To reverse rotation interchange any two line leads 440 Volt 50 HZ Three Phase Incoming Power Motor Leads Line 1 1 and 12 Line 2 2 and 10 Line 3 3 and 11 Twist together 4 and 5 Twist together o and 8 Twist together 6 and 9 To reverse rotation interchange any two line leads CAUTION All BA and BAS models wired for more than 220 volts are factory equipped with a transformer to reduce the incoming voltage to the circuit board down to 220 volts AC TO CHECK FOR PROPER ROTATION On initial start up of a three phase motor check for prop er rotation It
62. n product sold previously Warranty adjustments within the above stated policies are based on the model and serial number of the equipment This data must be furnished with all warranty claims WARRANTY IS NOT VALID UNLESS WARRANTY CARD IS RETURNED 3 Bender Operation Manual Bender Operation Manual 3 SPECIFICATIONS DESIGN FEATURES MODELS 1302 BAS 1502 BAS Bending Capacity Tubing from 1 2 OD 3 OD Maximum Capacity Tube Thickness See Chart Below Maximum Bending Radius 5 Minimum Bending Radius Swaging Capability Swaging Capacity Expansion Reduction Forming 1 O D Tubing 3 O D Tubing 5 H P Single or Three Phase 220 380 440 VAC 3 GPM 4200 psi max output Full Automatic or Manual Foot Switch Canister type 55 000 Pounds Maximum Degree Plate With Adjustable Pointer Automatic Stop and Return 62 1302 BAS 64 1502 BAS Pump Output Operation Modes Hydraulic Filter Bending Force Bend Depth Control Overall Length Overall Width Overall Height Special radius dies are available Reduction tools do not come standard DESIGN FEATURES MODELS 1302BL BLUE BULLET 1502 BL Bending Capacity Tubing from 1 2 OD 3 OD Maximum Capacity Tube Thickness See Chart Below Maximum Bending Radius sd Minimum Bending Radius Swaging Capability Swaging Capacity Expansion Reduction Forming 1 O D Tubing 3 O D Tubing 5 H P Single or Three Phase 220 380 440 VAC
63. n the swager clamp blocks 4 Leave at least three inches of tubing extended beyond the inside edge of the adapter collar See figure 2 C 5 Snug the collar back into the clamp blocks by gently pushing back on the collar assembly 6 Slowly while depressing the valve handle down move the shaft forward until the tool enters the tubing Be sure that the tool is centered with the tubing 7 Slowly move the tool forward until a 45 degree flare is achieved See figure 3 A Figure 3 A 8 Retract the die by lifting up on the control handle You have now completed the 45 degree flare 9 After retracting the cylinder shaft install the flattening tool as shown below 10 Now pull the flared tubing end up against the chamfered edge of the adapter collar as shown below THIS STEP IS VERY IMPORTANT so that the tubing end is retained within the clamped area This will prevent the flared end from swelling when the insert is pressed in 29 Bender Operation Manual CAUTION Pay careful attention when performing the following steps KEEP HANDS CLEAR from all pinch points ALWAYS remove hands from the expanding area when cylinder is in motion ALWAYS wear protective safety goggles 11 Insert the scrap pipe nipple into the flared end of the tubing The nipple should hold itself in position 12 Remove hands from the swaging area and slowly move the tool forward until the scrap nipple is forced into the tube opening St
64. ng Harness ncoder U Joint For Encoder Port Control Valve 4 Port Control Valve Port Control Valve equence Valve ectric Hydraulic solenoid Valve ow Control Valve X 14 lop Cylinder x f Double End Cylinder X ingle End Cylinder x 7 Bottom Cylinder Hydraulic Pump For Bender 1040 1022 1024 1034 1034 A 1049 1114 020 2 O O O CY CO NI O1 NI NI N OT O1 C1 C1 O77 N N O O O oo XO a OO O O O O Ol 00 N N N I O OO CO OO NI O O Oc O O BR O O O gt O AO O1 NI CO oo CO ON E AB al O 4 NI CO O1 y 51 Bender Operation Manual Bender Operation Manual 51 DELUXE 302 DIE PACKAGE QTY PART NO SIZE TOOLING DESCRIPTION BENDING TOOLIN 5R 212 2 1 27 63 5mm 5 127mm Radius Die 5R 214 2 1 4 57mm 5 127mm Radius Die 5R 200 2 50 8mm 5 127mm Radius Die 4R 214 AR 200 2 508mm 4 102mm Radius Die 4 102mm Radius Die 4R 178 35R 200 1 2 89 mm Radius Die 35R 134 1 2 89 mm Radius Die 35R 112 1 2 89 mm Radius Die BS 212 ack Shoes BS 214 Back Shoes BS 200 2 50 8mm Back Shoes BS 178 Back Shoes BS 134 Back Shoes BS 112 Back Shoes HS 212 Half Shoe HS 214 Half Shoe HS 200 Half Shoe HS 178 Half Shoe HS 134 Half Shoe HS 112 Half Shoe QS 214 2 1 4 57mm Threeuarter Shoe QS 200 2 50 8mm Three Quarter Shoe 1 7 8 48mm 2 1 2 63 5mm 2 1 4 57mm One Tool Fits All Sizes 2 amp 2 1 2 2 50 8mm Man
65. ngle Micro Switch X Each micro switch has three terminals for connecting the necessary wires These terminals will be labeled as follows C or Common NO or Normally Open NC or Normally Closed To tell if the micro switch is good remove it from the machine and use an ohmmeter to check the circuits as follows WITH THE SWITCH IN THE NEUTRAL POSITION Place one of the prongs from your ohmmeter on the com mon terminal of the switch and the other on the normally closed terminal At this time there should be continuity between the two There should be no continuity between the common and normally open at this time See Fig 2 A Figure 2 A NEUTRAL POSITION SHOWN 43 Bender Operation Manual WITH THE LEVER OR BUTTON DEPRESSED Place one of the prongs from your ohmmeter on the common terminal of the switch and the other on the normally open terminal At this time there should be continuity between the two There should be no continuity between the com mon and normally closed terminals at this time See figure 1 A Figure 1 A ACTIVATED POSITION SHOWN CAUTION Replace ALL faulty switches immediately NEVER attempt to bypass or hot wire any of the micro switches MOTOR CONNECTIONS For motor lead connections refer to the charts below In addition to the motor lead wires it is necessary to connect the green ground wire Electric motor MUST be grounded at all ti
66. oes of the same corresponding size 9 Bender Operation Manual CAUTION All tooling described in this manual is heavy HANDLE WITH CARE Always wear steel toe boots when operating bender HAC s amp STED s HAC s are Commonly referred to as adapter collars while the STED s are referred to as solid expander dies HAC s are used to hold or clamp the tub ing in place when performing end finishing Operations or when using the STED s These adapter collars are heat treated which causes the inside threads or teeth to become brittle Because of this these teeth have the tendency to chip during normal use This is normal and will have no effect on their performance The STED s or solid expander dies are used to expand the tubing to exact inside diameters and are also used to create male ball expansions Both tools are stamped and marked with their appropriate tubing sizes Details on the proper use of both tools is explained in the END FINISHING section NOTE Keep collars free of debris and build up Use a wire brush periodically to clean the inside threaded area Keep all tooling lightly oiled CAUTION KEEP HANDS CLEAR when using all the tools described in this manual Improper use of these tools may result in serious bodily harm STED Expander dies Adapter Collars Bender Operation Manual 9 END FINISHING TOOLS A variety of end finishing tools are available that perform different functions Not eve
67. of logic functions in the digital control board and optical sensors of the encoder The system automatically re calibrates itself upon full retraction of the radius die as the zero angle micro switch is tripped By adjusting the trip arm that activates the zero angle micro switch you can effectively stall or advance the counting process which will in turn change the die angle reading If the die angle appears to be more than 5 degrees out of calibration it is most likely a faulty encoder Dirt oil or moisture will contaminate the encoder and cause it to malfunction If the encoder becomes contaminated remove from the machine and clean with alcohol or T V tuner spray DO NOT use harsh or oil based solvents To properly calibrate the digital readout follow the steps outlined below 1 Turn the machine on 2 Place a set of bending dies in position 3 Using a carpenters square advance the radius die until the back gates are at a true 90 degrees con tacting the inside of the square evenly across the front See figure 1 A 4 Read the degree of bend shown in the DIE ANGLE window on the control board and make the following adjustments NOTE Before making any adjustments check to make sure that the flexible coupler or U Joint is functioning properly Excessive free play will cause irregular encoder read ings If there is excessive play between the steel roller plates and the nylon rider loosen the set screws and snug u
68. ol stamped on the STED expander dies identifies the tool required for making male ball expansions The E symbol identifies the tool required for making straight expansions Some STED expander dies do not show a E or B symbol These are used for making straight expansions only The B 212 tool is used for making male ball expansions on 2 1 2 tubing only 1 Retract the swager cylinder completely by lifting the valve handle up 2 Install the required STED for the appropriate tubing size or B 212 on the ST 1 adapter attached to the end of the cylinder shaft 3 Install the required HAC adapter collar around the tubing and position within the swager clamp blocks 4 Leave at least three inches of tubing extended beyond the inside edge of the adapter collar 5 Snug the collar back into the clamp blocks by gently pushing back on the collar assembly 6 Slowly while depressing the valve handle down move the shaft forward until the tool enters the tub ing Be sure that the tool is centered with the tubing 7 Slowly bring the tool forward until it meets the marking ring etched around the circumference of the tool Do not go beyond the grooved marking ring 8 After the tubing has been expanded retract the die by lifting up on the control handle 9 DO NOT remove tubing from the collar 10 Install the DOMING DIE on the ST 1 adapter attached to the end of the cylinder shaft See figure 3 A Figure 3 A 11 Slowly move the too
69. on barrel assembly Clean and spray all dies with rust inhibitor Tighten all hydraulic hoses as required Do not over tighten Check squareness of back gates and level guide plate Shim adjust as required See page 35 Re torque mounting bolts and nuts on all hydraulic components Lubricate caster assemblies Remove any nicks or burrs from tooling with a small file Snug arbor and ST 1 to cylinder shaft ee 929 NOTE Loose hoses and hydraulic components will not always show a visual sign of leakage however they can cause aeration of the system by sucking air It is very important to tighten all hoses and mounting bolts on hydraulic components monthly PRESSURE SETTINGS There are three critical pressure settings on your bender that affect its performance These pressures should be checked weekly The following is a brief description of the pressures and the roles they play CAUTION Improper back pressure settings will cause tubing to wrinkle and or collapse and may also damage machine and or dies BACK PRESSURE Back pressure is actually resis tance pressure applied to the back gates during the bending process The pressure is transferred to the back gates via the bottom cylinder and chain assembly The setting itself is controlled by the sequence valve This resistance pressure is required in order to form the shape of the tubing as the radius die advances This pressure is read on the gauge at
70. ondition Introduction SYMPTOM CONDITION The motor does not run The motor smokes Power supply incorrect The motor shuts off The bender gives off shocks The tubing wrinkles or kinks The bender experiences loss of power The motor stalls even though the system pressure is showing less than 2000 psi BA BAS models Bending ram will retract with the button controls but not with the left foot switch BA BAS models The top cylinder will advance with the button controls but not with the right foot switch The sequence valve pressure surges high when trying to retract the bending ram The back gates remain in the open position even after the bending ram is retracted The swager cylinder does not expand the tubing straight 45 Bender Operation Manual TROUBLESHOOTING The troubleshooting procedures shown on the following pages contain certain systems and or conditions possible causes and the corrective actions required The chart gives the easiest corrective action first then proceeds with more difficult procedures Be certain that the person s working on the machine have the ability to do the service Only certified electricians should work on electrical components ALWAYS unplug the machine before servicing POSSIBLE CAUSE Circuit breaker s is off Turn breaker s on Incorrect wiring Heater in switch box has been tripped Defective electric starter motor Test and replace as needed
71. op when the scrap nipple protrudes 1 2 from the tube end See figure 3 B Figure 3 B 13 Retract the die by lifting up on the control handle 14 This will form a seat for the round donut gasket as shown below 15 Separate the collar from the tubing Remove tooling and return to the storage area CAUTION Remember on 1302 models the swager side of the cyl inder moves simultaneously when operating the inter nal expander ALWAYS REMOVE TOOLING FROM THE SWAGER AREA when finished to avoid damage to the tooling and cylinder when the internal expander is being used Bender Operation Manual 29 USING THE CFT TO MAKE A MANIFOLD FLANGE IMPORTANT NOTE When making a manifold flange it is necessary to first install the pipe flange or clamp around the tube prior to finishing the ends CFT tools are used for making manifold flanges quick and easy Not included in standard tooling packages Follow these steps to produce a manifold flange using the optional CFT tool See chart on page 12 for typical end finishing illustrations 1 Retract the swager cylinder completely by lifting the valve handle up 2 Install the appropriate CFT tool on the ST 1 adapter attached to the end of the cylinder shaft 3 Install the required HAC adapter collar around the tubing and position within the swager clamp blocks 4 Leave ONLY 1 1 2 inches of tubing extended beyond the inside edge of the adapter collar See figure 3 C Figu
72. opriate sequence Review the data that has been entered If you reach a particular station that is incorrect press the SELCT key to illuminate the KEYPAD light the SET ANGLE will show zero at this time then press the appropriate number keys and retain the data by depressing the ENTER key After correcting the improper data press the SELCT button to illuminate the MEMORY light and the RESET key to reset the STATION window Review the information once again NOTE In order to store data into program memory the KEYPAD light must be illuminated Entered data will not be shown in the SET ANGLE window until the MEMORY light is illuminated THREE BUTTON CONTROL OPERATIONS BAS MODELS Read each of the following sections carefully before attempting any operation of this unit All BAS models are equipped with a three button control board that con trols the semi automatic bending function In addition to the three button control board all BAS models are equipped with a remote foot switch for manual operation 14 Bender Operation Manual DESCRIPTION OF CONTROLS NEVER HOLD IN COLORED CONTROL BUTTONS To properly operate the colored control buttons quickly press and release By holding the colored control buttons in damage to the machine and or components may result GREEN BUTTON Activates the automatic bending cycle After pressing the GREEN button the radius die will move forward until the desired depth of bend is reac
73. orward through the bending gates while the radius die is in motion Normal operating pressure should be 1600 P S I The correct return pressure will be set at 300 350 P S I For bending three inch tubing the initial sequence valve pressure should be raised to 2000 P S I for each bender See page 33 for pressure adjusting procedure 2 To raise the sequence valve pressure turn the Allen wrench clockwise until 2000 P S I is maintained as the radius die moves forward through the bending gates The return pressure will remain unchanged 3 After proper pressures have been set the dies should be heavily greased NOTE Bending dies MUST be cleaned and polished smooth for best results 4 Position the tubing in the bender and advance the radius die forward to begin the bending process Remember to USE MANUAL CONTROLS ONLY o Ata bend depth between 30 degrees and 40 degrees the bender may start to bog down At this time start turning the Allen wrench counter clockwise to reduce the sequence valve pressure Do not adjust below 400 P S I This will allow the radius die to advance further Continue bending until the desired bend depth is reached Return the pressure to 2000 P S I for the next bend CAUTION DO NOT turn the adjustment screw beyond the end threads of the screw 6 If further bends are required repeat this procedure for each bend ALWAYS return the sequence valve pressure back to 1600 P S I when finished See
74. p the coupler assembly Be careful not to exert excessive pressure on the encoder shaft The DIE ANGLE display shows a few degrees LESS than 90 This means the gates are moving slightly before the micro switch deactivates and starts the count ing process To make the proper adjustment loosen the trip arm set screw and adjust it slightly AWAY from the micro switch lever so that upon initial movement of the gate assembly the switch immediately deactivates ALWAYS BE SURE that when the gates return to zero the trip arm still contacts the micro switch lever enough to activate it The DIE ANGLE display shows a few degrees MORE than 90 In most cases this signifies that the encoder is malfunctioning Return the radius die back to zero then slowly advance the radius die and check the DIE ANGLE display for irregularities If the counting appears to be in proper sequence then loosen the set screw on the trip arm and adjust it slightly TOWARDS the zero angle micro switch lever DO NOT adjust the trip arm far enough to allow it to crash into the micro switch upon full gate closure NOTE The back gates on digital models should close at a slight negative angle This is to compensate for the initial 1 8 of forward travel or movement the gate needs to allow the trip arm to deactivate the zero angle micro switch and start the counting process See figure 1 B GATES SHOWN AT SLIGHT NEGATIVE ANGLE RIGHT GATE 41 Bender Operation Manual
75. proper setting as shown in the PIPE ROTATION section of the card In this case the PIPE ROTATION will be 147 degrees ALWAYS use the inside set of numbers See figure 2 C Figure 2 C NOTE The rotation dial is equipped with two scales The standard scale which is used for all regular bending operations is positioned to the INSIDE of the dial The OUTSIDE scale is used for bending mirror images or opposite side pipes 16 With the rotation dial properly set at 147 degrees and the center mark lined up advance the radius die to 11 degrees as shown on the card Retract the die to the original starting position 17 Review the SYMBOLS section of the card and check for any special instructions On bend number three you will notice that a REVERSE USE HALF SHOE is called for 18 Bender Operation Manual The ROTATION DIAL degree plate MUST NEVER be moved after bending has begun ALWAYS be prepared to support the tubing as it is released from the dies to prevent it from hitting the ground If the dial is accidentally moved during the bending process re position the dial so that the ZERO mark is located at the weld seam of the tubing or return to the previous bend and position the pendulum point er to the degrees required for that particular bend 18 If a bending instruction calls for a REVERSE remove the tubing and position the ROTATION DIAL on the LEFT SIDE of the machine Be careful not to move the ROTATION DIAL degree plat
76. r the alloy to solidify DO NOT disassemble the overload relay block because motor protection could be disabled and cause possible damage to motor and or other components Thermal units must be installed and the device reset before the starter contacts will operate Install thermal units so that the type face can be read and the pawl is positioned just above the ratchet wheel LOCK OFF MECHANISM The starter can be locked only in the OFF position by lifting the metal tab labeled LOCK on the contact actuator and placing a padlock through the center of the hole in the tab HYDRAULIC CYLINDERS As with all hydraulic cylinders age and wear will reduce the effectiveness of the cylinder seals Proper mainte nance and care will result in a prolonged service life RECOMMENDED MAINTENANCE Use a small file to remove any small nicks or scratches on the chrome cylinder rods ALWAYS keep the chrome cylinder rods clean ALWAYS remove expander tooling from the swager area on 1302 models before using the internal expander to prevent damaging the cylinder rod NEVER bang the adapter collars on the cylinder shaft to release them from the tubing Be sure to change the hydraulic fluid after every1500 hours of operation or yearly whichever comes first Keep the ST 1 and Arbor tight at all times NOTE Under normal operating conditions all of the cylinders will seep oil around the area of the wiper seal This is a normal c
77. r typical end finishing illustrations To produce a manifold flange proceed as follows 1 Place the proper size segment set over the arbor See figure 1 B Figure 1 B 2 Place the proper size limit ring over the end of the tubing CAUTION NEVER use a limit ring that is defective or cracked DO NOT maintain constant pressure on the limit ring by continuing to hold the valve handle down once the expansion has been made ALWAYS wear protective safety goggles when operating the internal expander 25 Bender Operation Manual 3 Position the tubing over the arbor and segment set until the tubing meets the shoulder 4 Push the limit ring forward until it also meets the shoulder and is flush with the end of the tubing See figure 1 C Figure 1 C 5 Depress the valve handle to form the flange The flange will be formed as the raised areas expand and the tubing end is contained by the limit ring USING THE SWAGER BOX The swager box is an expanding flaring unit located to the rear of the bender which utilizes pipe collars in con junction with bullet shaped expander forming dies to per form a variety of tube end finishing CAUTION Read the following section carefully before attempting to operate the swager unit BE CAREFUL when using the swager assembly due to the extreme pressure created by the hydraulic cylinder NEVER allow untrained personnel to operate machinery KEEP HANDS CLEAR of all pinch points ALWAYS
78. re 3 C D ME SO p ch 5 Snug the collar back into the clamp blocks by gently pushing back on the collar assembly 6 Slowly while depressing the valve handle down move the shaft forward until the tool contacts the tubing Be sure that the tool is centered with the tub ing 7 Make the manifold flange by advancing the tool forward towards the collar until the cylinder stops Apply full pressure for this operation See figure 1 A Figure 1A 8 Retract the die by lifting up on the control handle 9 Separate the collar from the tubing Remove tooling and return to the storage area USING THE REDUCING TOOLS Reducing tools are used for reducing or shrinking pipe ends to exact out side diameters Each tool is marked with the appropriate size It is important to understand that the size marked on the tool will be the size that the tubing willl be reduced down to For example a tool marked 200 will reduce 2 1 4 tubing down to 2 O D and a tool marked 214 will reduce 2 1 2 tubing down to 2 1 4 O D Not included in standard tooling packages IMPORTANT NOTE Reducing tools MUST be thoroughly greased before use To properly reduce the tube end using the optional reducing tools follow these simple steps See chart on page 12 for typical end finishing illustrations 1 Retract the swager cylinder completely by lifting the valve handle up 2 Install the appropriate REDUCING TOOL on the ST 1 adapter attache
79. rn expands the tubing to an exact inside diameter The segment sets are designed to work on one size arbor only An adjust able Buttress Canister attached to the internal expander cylinder is used to control the expansion range NOTE The arbor must be snug to cylinder shaft before operation begins to avoid damaging threads USING THE STANDARD SEGMENT EXPANDERS There are five standard segment sets included with your bender Each segment set is designed to be used with a particular size tubing only The appro priate sizes are shown below Standard segment sets are used for making straight expansions See chart on page 12 for typical end finishing illustrations Part Number Maximum Expansion SS 112 1 1 2 O D tubing to 1 5 8 I D SS 134 178 1 3 4 or 1 7 8 O D tubing to 1 7 8 LED 1 SS 200 2 O D tubing to 2 1 8 1 D SS 214 2 1 4 O D tubing to 2 3 8 1 D SS 212 2 1 2 O D tubing to 2 5 8 I D IMPORTANT ALWAYS use the correct segment sets with the corresponding tubing size Incorrect usage of segment sets will result in premature wear and breakage ALWAYS keep arbor well greased Aluminum Pointer Buttress Canister Assembly The following procedure is provided as a step by step instruction to begin proper use of the internal expander 1 Turn the machine on Lift the control handle to extend the cylinder shaft Install the arbor making sure that it is threaded all the way on
80. ry tool is included with your tooling package If you are unsure as to what was included please consult your dis tributor or review the delivery receipt and invoice Each tool is marked with the appropriate size CAUTION DO NOT attempt to use these tools unless you have read and fully understand the Swaging and End Forming section HPF 300 A tool for making 45 and 90 degree flanges on pipe ends Usually for manifold connections DD 134 212 A tool for doming pipe ends or making male ball expansions when used in conjunction with the male ball expanders HPF 300 DD 134 212 DD 134 212 amp BFED 200 214 Tools for flaring pipe ends to make female ball expansions Each tool is stepped and has the ability to flare two different sizes The BFED 134 214 is used for tubing sizes 1 3 4 and 2 1 4 while the BFED 200 212 is used for tubing sizes 2 and 2 1 2 BFED 134 214 BFED 200 212 B 212 A tool used for making male ball expansions on 2 1 2 pipe ends CFT 200 amp CFT 214 Tools for making manifold flanges on 2 and 2 1 4 pipe ends Not included in standard tooling packages B 212 10 Bender Operation Manual CFT 200 REDUCING TOOLS Reducing tools are used for reducing or shrinking pipe ends to exact outside diame ters Each tool is marked with the appropriate size It is important to understand that the size marked on the tool will be the size that the tubing will be reduced
81. s or seg ment sets come in a variety of sizes and shapes each performing it s own distinct function Segment sets are used for short pieces of tubing or when the tubing end is minimized due to an existing bend They can also be used to expand tubing that is deformed in such a manner that will not permit use of the swager expander Segment sets are used in conjunction with an arbor or mandrel All seg ment sets are identified by grooved rings located at the bottom as described on the following chart There are four different types of segment sets available STANDARD SEGMENT SETS MANIFOLD FLANGE SEGMENT SETS BALL JOINT SEGMENT SETS and FLARE SEGMENT SETS i d ai d A IS TE wr Manitoid Flange Segment Set with Limit Ring Ball Joint Segment Set STANDARD SEGMENT SETS These segment sets are used to make straight expansions on tubing ends and are found in all standard tooling packages MANIFOLD FLANGE SEGMENT SETS These segment sets are used to make donut type manifold flanges on tub ing ends They are available in five sizes 1 1 4 1 1 2 2 2 1 4 and 2 1 2 All manifold segment sets are used in conjunction with limit rings Not included in standard tooling packages BALL JOINT SEGMENT SETS These segment sets are used to make ball joint expansions on tubing ends They are available in three sizes 2 2 1 4 and 2 1 2 Not included in standard tooling packages FLARE SEGMENT SETS These
82. screw slightly clockwise to decrease counter clockwise Never exceed 350 P S I CAUTION Never exceed 350 P S I for the return pressure unless specifically instructed to do so by the factory for special circumstances SYSTEM PRESSURE Your bender has a built in relief valve in order to control maximum pressure output for the entire machine As the fluid exits the hydraulic pump it first enters the swager control valve that contains an adjustable ball check relief valve See figure 3 A The normal operating system pressure should be set at 3200 P S I This pressure is read on the gauge located near the center of the machine next to the hydraulic pump See figure 3 B Figure 3 B 34 Bender Operation Manual To check and adjust the system pressure proceed as follows 1 Turn the machine on 2 Press the swager control valve down until the swager cylinder is bottomed out 3 When the cylinder bottoms out or is extended to maximum travel the pressure will surge and the machine will groan as the relief valve opens up and fluid is redirected back to the reservoir This is when the reading should be taken 4 If an adjustment is required loosen the locking nut that secures the adjusting screw on the relief valve 5 To increase the pressure turn the adjusting screw slightly clockwise to decrease counter clockwise Never exceed 3200 P S l CAUTION Never exceed 3200 P S I for the system pre
83. segment sets are used to make 45 degree flares on tubing ends Three different sets are available that work on tubing sizes 1 1 2 2 1 2 Not included in standard tooling packages NOTE 11 Bender Operation Manual Keep segment sets and arbor well greased The ARBOR which is pulled through the center of the seg ment sets is available in two sizes The HSA 114 is an arbor used exclusively for 1 1 4 and 1 3 8 tubing while the HSA 112 is used for tubing sizes 1 1 2 through 3 HSA 112 Arbor HSA 114 Arbor WARNING 1 Always remove excess tooling from swager area before using internal expander 2 To avoid breaking tooling ALWAYS use proper segment sets with appropriate tubing size 3 NEVER stand in front of arbor when operating internal expander Bender Operation Manual 11 TYPICAL END FINISHING Female Ball Flare Male Ball Flare Manifold Flange Manifold Flange with Insert DIGITAL CONTROL OPERATIONS BA MODELS STOP Before any attempt is made to operate this machine it is important that you have read and fully under stand all operating instructions described in this manual Read each of the following sections carefully before attempting any operation of this unit All BA models are equipped with a computer microprocessor that allows minor storage and recall of certain bend data It also gives the user the ability to bend automatically or manually PROGRAM DATA CON
84. should rotate counterclockwise To check motor pump rotation proceed as follows 1 Plug in bender Turn bender on 3 Depress the swager control handle If the swager cylinder extends then the rotation is correct If the swager cylinder does not extend then the rotation is wrong 4 If the rotation is wrong unplug the bender 5 Disassemble the plug and reverse any two power wires Test again If the swager cylinder still does not activate check the motor lead wiring as shown on the previous page AO ELECTRIC FOOT SWITCH On a regular basis inspect the electric foot switch assembly for wear or damage Inspect the entire length of the connecting cord for wear or deterioration DO NOT OPERATE the foot switch if any of the above is observed 44 Bender Operation Manual MANUAL ELECTRIC STARTER The electric starter box on your bender uses movable contacts activated by a push button mechanism This style of electric starter is equipped with Heaters to prevent damage to the starter switch or motor in the event of an over current situation Single phase machines use one 1 B 36 heater while three phase machines use three 3 B 25 heaters Continued over current through the thermal unit will raise its tem perature and melt the alloy allowing the ratchet wheel to rotate This releases the pawl assembly allowing the toggle spring to retract the contacts Before reset ting the relay allow one to two minutes fo
85. ss is less than the Check tubing for proper wall thickness recommended requirement See chart See chart above above for minimum tubing thickness Dimpling of pipe on inside of Incorrect back pressure Adjust back pressure as shown on page bend 33 For 3 diameter tube see bending instructions found on page 21 Gauge thickness is less than the Check tubing for proper wall thickness recommended requirement See chart See chart above above for minimum tubing thickness Bending dies are not properly matched to Select proper bending dies for the tubing diameter the particular tubing diameter Tubing diameter is actually less or more Check the actual tubing diameter using than what it is labeled a micrometer or similar measuring devise Improper chain adjustment Adjust chains as described on page 34 Improper die alignment Check the following Bronze barrel bushings may be worn Remove and replace the bushings as described onpage 36 Guide plate may be mis aligned Check Adjust and shim guide plate as described proper alignment as described on page on page 35 35 Pusher block may be worn Check for Remove and replace pusher block as proper tolerance as described on page required 38 Bending dies are not properly matched to Select proper bending dies for the tubing diameter the particular tubing diameter Tubing diameter is actually less or more Check the actual tubing diameter using than what it is labeled a mi
86. ssure unless specifically instructed to do so by the factory for special circumstances ADJUSTING THE CHAINS When the chains are prop erly adjusted the threaded chain connector will protrude from the adjusting nut approximately one quarter of an inch Both chains should have equal tension If one chain has more slack than the other tighten the chain connec tor adjusting nut using a 1 1 16 open end wrench NEVER tighten the chain connector so that it is bottomed out against the chain return block See figure 3 C Figure 3 C 5 16 CHAIN BOLT CHAIN RETURN BLOCK CHAIN CONNECTOR NOTE The chain return bolt has the tendency to loosen during normal use If it is necessary to tighten this bolt remove one of the chain connectors and tighten using a 1 3 8 open end wrench After the bolt is secure replace the chain connector and adjust as described above CAUTION If any part of the chain or assembly bolts appear to be damaged in any way discontinue use until they are replaced LEVELING THE GUIDE PLATE WITH THE BACK GATES The back gates and guide plate have been precisely lev eled at the factory and should seldom require adjust ment If however the guide plate becomes unlevel with the back gates the bending dies will become misaligned and cause the tubing to wrinkle To properly check the guide plate and back gates for proper levelness follow these steps 1 Remove bending dies from machine Retrac
87. t pusher block completely 3 Clean the guide plate and gate surface of all dirt grease and other debris 4 Seat the barrel shaft with a lead hammer 5 Tighten the barrel shaft nuts located directly underneath each back gate Do not overtighten 6 Place a straight edge across the surface of the back gates just above the guide plate See figure 1 A Figure 1 A Gate Assembly d QE Mg T pine gt Guide Plate 7 With the straight edge in position check for proper clearance as illustrated below The straight edge should contact the gate surface evenly on both sides and lay flat on the surface of the guide plate Improper alignment Guide plate is nol square with the back gates 35 Bender Operation Manual Proper alignment Guide plate is square with the back gates o 9 90 The guide plate will require adjustment shimming if there is more than 01 gap between the plain of the back gates and the surface of the guide plate the plain of the gate assemblies is not square with the guide plate the plain of the back gates is actually lower than the surface of the guide plate If it is necessary to shim the guide plate so that it is square with the back gate assemblies follow the steps as outlined below Turn the machine on Place a set of bending dies in position Advance the radius die forward until the front allen bolt on the guide plate is exposed Loosen the front allen bolt on the guide plate
88. tached to the sequence valve located near the front left side of the machine The pressure reading is taken as the dies advance through the gates during a bend The normal operating back pressure should be set at 1600 P S I In some cases it may be necessary to adjust this pressure See Three Inch and Stainless Bending Procedures found on pages 21 amp 22 If the back pressure needs adjusting proceed as follows 1 Turn the machine on 2 Place a radius die and set of back shoes in position Tubing will not be required for this operation 3 Advance the radius die until it begins to pass through the gates 4 Atthis time read the pressure shown on the gauge attached to the sequence valve See figure 3 B zi y wq c 33 Bender Operation Manual 5 If an adjustment is required loosen the locking nut that secures the adjusting screw 6 To increase the pressure turn the adjusting screw clockwise to decrease counterclockwise Never exceed 2000 P S I CAUTION Never exceed 2000 P S I for the back pressure unless specifically instructed to do so by the factory for special circumstances If it is necessary to increase the back pressure always remember to return the pressure back to 1600 P S I before proceeding with the next bend RETURN PRESSURE This pressure reading is also taken on the gauge located near the front left side of the machine The purpose of this pressure is to maintain adequate tension on the c
89. ten ancestro caian 36 Aligning The Swader BOX Cylinders se a een een ous SG RR EE 37 Pusher Bleek Malhtel AICO adri do aaa 38 Calibrating The Depth Of Bend Plate Manual Models oooccoccoccnncccnnconocccnnononononcncnnncnnononnnnonnnnnonnrnnnnnnnnonnnonnss 39 Calibrating The Depth Of Bend Switch BAS Models ee Re AE Ee ee Ee ee AE Ee ee ee ee ee ee ee ee ee ee ee ee ee ee 39 Calibrating The Digital Readout Display BA Models ee ee Ee ee Ee ee ee ee ee ee ee ee Ee ee nnn nnn 40 USING The Jumper Board BA Models ein ee 41 Operating The Machine Manually Using The Solenoid Valve iese ss ee se ee ee Ee kt ee ee ee ee ee ee Ee ee REESE REE ee ee ee ee ee ee 42 Solenoid Valve Maintenance IE en 43 Checking The Micro Switches Automatic Models ee ee ee Ee AR Ee ee ee ee Ee REEL Ee ee nenne nennen nnne nnn 43 Motor Lead Connections su ocn one edm E osx aes id bun atau ope Ee d D alana Medes 43 Checking Motor Rota Nas ee ea A accum bees dodo oae 44 Manual Electo Starter aa poma DD aa 44 Trouble Shooting Proeedufes s nn tale na 45 47 Bending Probe Si AA AAA ended 48 Electrical Wiring Diagrams Models BA 8 BAS issiria a a a a A T 49 50 Device PANS sa a A A ds 51 Deluxe 302 Die Packard A AAA 52 ECONOMY 202 DIC e cle E o3 BB 1 Die Package FOr Blue Bullet sd ES and o4 BB 2 Die Package For Blilie BUllela c 55 2 Bender Operation Manual YOUR NEW BENDER This instruction manual has been prepared especially for you Your n
90. the HCT 214 212 on the ST 1 adapter attached to the end of the cylinder shaft 3 Install the required HAC adapter collar around the tubing and position within the swager clamp blocks 4 Leave at least 4 of tubing extended beyond the inside edge of the adapter collar See figure 2 A Figure 2 A Bender Operation Manual 31 5 Snug the collar back into the clamp blocks by gently pushing back on the collar assembly 6 Slowly while depressing the valve handle down move the shaft forward until the tool enters the tubing Be sure that the tool is centered with the tubing 7 Make the collector flange by advancing the tool forward until the cylinder stops Apply full pressure for this operation See figure 3 A Figure 3 A 9 Separate the collar from the tubing Remove tooling and return to the storage area MAINTENANCE Your new bender was designed and built for years of dependable service The following maintenance schedule has been formulated to produce satisfactory performance and longevity of your machine Reasonable care and daily observation of wear items will supplement this schedule and result in a prolonged service life HYDRAULIC OIL Your new bender was shipped with approximately seven gallons of hydraulic oil The correct oil level will be shown on the sight gauge located to the rear right of the machine To properly check the oil level proceed as fol lows 1 Advance the radius die until it just comes in
91. the original starting position 32 Review the SYMBOLS section of the card and check for any special instructions for bend number six 33 On bend number six no special instructions are shown 34 Advance the radius die forward until the pusher block springs are compressed and the tubing is held securely 35 Rotate the tubing so that the pendulum pointer or Wire pattern being used as a master dial indicator points to 277 degrees 36 Advance the radius die to 9 degrees then retract the 4 Adjust the tubing out the left side of the bender so die to the original starting position that the tubing end matches the length with that of 37 You are now finished bending the pipe Remove the the master See figure 1 A Secure the straight pipe ROTATION DIAL and cut the tubing end off at the by advancing the radius die until the pusher block last O A mark See figure 3 C springs compress 19 Bender Operation Manual Bender Operation Manual 19 This blank card may be used to make additional copies NEM MEE DUM DEE ouf Bd BEND NO SYMBOLS CENTER mu od PIPE ROTATION BEND DEPTH BENDING INSTRUCTIONS 7 You are now ready to make your first bend Place the first bend of the master pipe or wire flat on top of the back shoes Hold in this position Gradually extend the radius die forward until the gates start to open and the tubing begins to bend Continue bending until the bend depth is equal to that of the master See fi
92. to any desired bend depth The control board consists of three colored buttons GREEN BLUE and RED each with its own operating functions If you choose to use the machine in the automatic mode you would simply set the pointer to 90 degrees for example then press the GREEN button At this time the bending head would activate and the radius die would begin to move forward After the desired bend depth has been reached the machine would automatically initiate the retract sequence that returns the die to the original starting position The BLUE button is for automatically returning the die to the original starting position while the RED button is an emergency stop control The electric foot switches will override the three button controls 7 Bender Operation Manual D O B Plate Three button control BA Models These models have two different control modes an electric foot switch assembly for manual bend ing Operations and a digital control board for automatic functions The digital control board eliminates the depth of bend scale and replaces it with a digital readout labeled DIE ANGLE It also offers the user the capability to pro gram certain bend depths in a desired sequence When the power is turned off all memory is erased Once a bend depth is programmed into memory the number appears in a L E D window labeled SET ANGLE The bend sequence is initiated by pressing the AUTO button At this time the die moves forwar
93. to the shaft 3 Grease the arbor thoroughly 4 Install the appropriate segment set by simply forcing the set over the head of the arbor Grasp the segment set firmly to keep fingers together o Adjust the buttress canister until the grooved line on the canister is lined up with the grooved line on the aluminum pointer Then center the X symbol on top With the buttress canister properly lined up the arbor will automatically stop so that the tubing is expanded to the exact inside diameter for the corresponding size segment set See figure 1 A 23 Bender Operation Manual Ae as Figure 1 A 6 Place the tubing over the segment set Be sure to slide the tubing all the way down to the shoulder NOTE If there is a burr or dent on the end of the tubing place the tubing on the notched end of the segment set and tap the valve handle until the burr is removed See figure 2 A kr mm SERIES Figure 2 A With the tubing in position and the buttress canister lined up you are ready to expand Tap the control handle down until the tubing begins to expand Release and rotate the tubing clockwise Repeat until a smooth uniform expansion is produced Continue depressing the valve handle and rotating the tubing until the arbor stops expanding See figure 3 A Bender Operation Manual 23 9 Lift the valve handle up until the arbor extends and the segment set is released 10 Check the finished expansion end
94. ts The main circuit panel front display panel and wire ribbon that connects the two The main circuit panel is held in position by card guides and then plugged into a pin edge connec tor mounted internally in the front upright of the bender A bypass board for trouble shooting is also attached stored piggyback style on the back of the main circuit panel See page 41 for proper use of jumper board Digital encoder The digital encoder is located just below the right side gate assembly and enclosed in a metal box As the encoder rotates by the means of a flexible coupler attached to the barrel shaft it registers degrees and shares this information with the main circuit panel Zero angle micro switch The zero angle micro switch is located up front just below the right side gate assembly and attached to the bender frame The zero angle micro switch has three distinct functions 1 Initiates the counting cycle and serves as an adjust ment device for properly calibrating the die angle 2 Resets the die angle to zero upon retraction of the radius die 3 Advances the steps in the STATION window when using the MEMORY function 40 Bender Operation Manual Figure 13 C c ENCODER MAN ORCUIT PANEL x ENCODER Bie NOTE Only slight adjustments of 4 degrees or less can be made to the die angle reading on digital models The digital readout is accurately maintained with the help
95. ts or bolts See figure 1 A Bender Operation Manual 37 Check to see if the pusher block is square to the guide PROPER POSITIONING 12 Shim the swager cylinder as necessary by inserting shim stock between the cylinder end block and the swager box until proper alignment is achieved IMPROPER POSITIONING See figure 1 B plate as illustrated below If the pusher block is excessively worn or out of square then replace the pusher block as follows 13 Tighten the four nuts or bolts securing the swager cylinder to the swager box frame 1 Using a large crescent wrench or equivalent disconnect 14 Turn the machine on and repeat check the cylinder shaft from the pusher block by turning 15 Re install the tool tray if no further adjustments are required CHECKING THE PUSHER BLOCK FOR WEAR If the pusher block becomes badly worn or out of square the radius dies could become misaligned with the back shoes causing the tubing to wrinkle Make sure that the cylinder shaft is snug to the pusher block before proceed ing To check to see if the pusher block shows signs of excessive wear use a screwdriver to pry the pusher block the cylinder shaft counterclockwise See figure 1 C up and down as illustrated below 2 Lift the cylinder up and position a block of wood underneath the rear end of the cylinder to support it and allow adequate room to clear the pusher block It is not necessary to remove any hydraulic hoses
96. uggest that manual controls are used until you become more familiar with the operating features of your machine CAUTION Before advancing the radius die check your circle of swing for allowable bending clearances 11 12 As described in the BEND DEPTH section of the card advance the radius die to 17 DEGREES then retract the die to the original starting position The rotation dial should still show ZERO at this time Review the SYMBOLS section of the card and check for any special instructions On bend number two you will notice that a HALF SHOE is called for Install the HALF SHOE now Unless a special instruction is given to change the radius size you will continue to use the 3 1 2 radius through the remaining bends NOTE Always position the HALF SHOE or THREE QUARTER 13 SHOE on the same side as the previous bend For the second bend slide the tubing to the LEFT so that the second CENTER MARK is lined up with the center of the shoes See figure 2 B Bender Operation Manual 17 Figure 2 B 14 With the HALF SHOE in place and the secondCENTER MARK lined up at the center of the shoes advance the radius die forward until the pusher block springs are compressed and the tubing is held securely Carefully control the advancement of the radius die to prevent denting or bending of the pipe at this time 15 Now rotate the tubing not the dial so that the pendulum pointer or dial indicator points to the
97. uides until it plugs into the connector The jumper board MUST be plugged firmly into the connector to function properly WARNING If the machine continues to malfunction with the jumper board in place discontinue use immediately and consult factory Bender Operation Manual 41 5 With the jumper board in place movement of the radius die will be controlled by the twin foot switches only There will be no provision for depth of bend readings IMPORTANT NOTE The top micro switch will be inactive with the jumper board in place NEVER retract the top cylinder so that it is in a bottomed out condition SERVICE NOTE WHEN RETURNING THE DIGITAL CONTROL BOARD FOR REPAIR REMEBER TO INCLUDE ALL COMPONENTS FRONT DISPLAY PANEL MAIN CIRCUIT PANEL AND WIRE RIBBON OPERATING THE MACHINE MANUALLY USING THE ELECTRIC SOLENOID VALVE All BA and BAS models incorporate an electronic sol enoid valve that controls operation of the top cylinder for all bending functions The solenoid valve is located to the rear of the machine just below the oil filter See figure 1 C The solenoid valve is an electric spool valve that uses electric magnets coils to activate the valve spool You can use the manual buttons on the end of each coil to temporarily activate the top cylinder should a malfunction occur with the automatic controls or the solenoid valve itself See figure 2 A SOLENOID COIL Figure 2 A OPERATE BUTTON
98. using a 3 8 hex wrench until the head of the bolt is flush with the surface of the guide plate See figure 1B Figure 1 B Retract and remove the radius die so that the two middle bolts are exposed on the guide plate and loosen Make sure that the head of the bolt DOES NOT protrude from the surface of the guide plate See figure 1 C Te haan ad Bender Operation Manual 35 6 It will not be necessary to loosen the rear most bolt on the guide plate for this service 7 Using a pry bar elevate the front of the guide plate See figure 2 A 8 Using shim stock 002 005 thick shim underneath the guide plate as required until proper levelness is achieved 9 Tighten all allen bolts on the guide plate then grease well VISUALLY CHECKING THE BARREL BUSHINGS FOR WEAR The barrel bushings should be checked every six months for excessive wear If the barrel bushings become worn the barrel shafts will have too much play and the gates will become misaligned causing the tubing to wrinkle See figure 2 B This diagram shows the gate assembly misaligned with the barrel due to excessive wear on the barrel bushings To check the barrel bushings for excessive wear it is nec essary to completely remove one of the gate assemblies and visually check the bronze bushings The left gate assembly is the easiest to remove If the bushings are worn on the left side of the barrel then the right side bushings
99. wer cord before making any electrical repairs NOTE Practice the following bending steps without tubing and initiate a few dry runs until you understand the operating features USING THE REMOTE FOOT SWITCHES OR AUTO BUTTON When using a card system or bending a pipe you are not required to use the Memory function Some operators will use the memory function only when multiple pipes are to be bent The most popular method will be manual or semi automatic When KEYPAD is lighted the machine will operate manually using the remote foot switches or JOG FWD button or semi automatically performing one bend at a time using the AUTO button The actual depth of bend degrees will continuously appear in the DIE ANGLE window any time the machine is running To manually operate the bender depress the right foot switch to advance the radius die and the left one to retract it The foot switches will always override the automatic controls When using the foot switches the radius die will NOT stop at the SET ANGLE CAUTION KEEP HANDS CLEAR while dies are in motion Familiarize yourself with the EMERGENCY STOP button and its operation NEVER place hands near bending area or any pinch points when motor is running ONLY TRAINED PERSONNEL should be near machine when it is in operation To bend one bend at a time using the AUTO button follow these step by step instructions 1 Turn the bender on and depress the SELCT button to i

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