User Manual for Models 650E, 1000E, and 1250E .
Contents
1. mm Bend radius mm Uniformity of bend angle maximum deviation 2 deg LABELS Check for clarity adhesion to machine and proper alignment Nameplate amp Serial No C Clampbar Warning Electrical warnings C Switch labelling Safety tape on front legs C FINISH Check cleanliness freedom from rust blemishes etc az SIGNATURES 12 BASIC OPERATION WARNING The Magnabend sheetmetal folder can exert a total clamping force of several tonnes see SPECIFICATIONS It is equipped with a two handed interlock to help ensure that fingers cannot be inadvertently caught under the clampbar when electro magnetic clamping is applied However it is most important that only one operator use the machine at a time It is potentially dangerous for one person to insert the workpiece and handle the clampbars while another person operates the switches NORMAL BENDING Ensure power is ON at the power outlet and the full length clampbar is posi tioned on the machine with its lifting balls resting in the locating grooves at each end 1 Adjust for workpiece thickness by rotating the eccentric adjusters at ei ther end of the clampbar Lift the bending beam up to the 90 position and check that it is parallel to the edge of the clampbar if necessary re adjust the eccentric lifters For opt2. BRN 104 RED BLU ul e BLK C E GY VARISTOR MAGNABEND 650E amp 1000E CIRCUIT 20030204 START RIGHT PPL YN PPL og FOOTSWITCH CONNECTOR ANGLE NG MICROSWITCH PNK REAY C NO 8 12 z ES _ Wr z optional MAGNET MAINS CABLE 2x 470uF BLU N BLU PNK Th MAGNABEND 1250E CIRCUIT ris 28 WARRANTY FI III II II II OOOO OOOO The Manufacturer hereby warrants this Magnabend bending machine to be free from defects in materials and or workmanship for a period of 12 months Our obligation under this Warranty is limited to repairing or replac ing faulty parts or materials and does not extend to consequential loss or damage arising from the use of the machine This Warranty does not cover faults that are due to misuse abuse negligence accident or caused during transportation Also excluded are faults arising from unauthorised repair use not according to instructions and normal wear and tear Returns under Warranty must be freight prepaid and if the Warranty Registration has not been previously returned must be accompanied by proof of the purchase date The rights and conditions under this Warranty are additional to any rights that may be conferred under the Trade Practices Act OOOO OOOO OOOO OOOO OOOO OOOO OOOO EOE OR OE ERO bb Ob bt gt t bt ot bt tb tt bt JOO OE ER RE Rb Eb bb bE bt gt
3. 1 0mm 1 2mm 1 6 mm Comments Eg Does the machine do what you expected After completing please post this form to the address on page 1 30 31 32
4. MAGNA BEND ELECTROMAGNETIC SHEETMETAL FOLDERS MAGNABEND USER MANUAL for MODELS 650E 1000E amp 1250E Contents Page INTRODUCTION 3 ASSEMBLY SPECIFICATION S cete noc ien 6 INSPECTION 4 24 32a 10 USING THE MAGNABEND BASIC OPERATION cider een RD 12 POWER SHEAR ACCESSORY E FOLDED LIP HEM 14 ROLLED EDGE 3282539 9 9 d Bob Reden 15 MAKING A TEST PIECE SIE BOXES SHORT CLAMPBARS ista 18 TRAYS GLOTIED CLAMPBARS iios 20240 21 USING BACKRSTODS 2 ossi getesesttteu ei 22 ACCURACY jai isnt nn aii beatae b a 23 MAINTENANCE 24 TROUBLE SHOOTIN na NUMEN 25 CIRCUIT DIAGRAMS az 27 WARRANTY Sunday 28 November 2010 MAGNABEND INTRODUCTION The Magnabend sheetmetal bending machine is a highly versatile and easy to use machine for bending all types of sheetmetal such as aluminium cop per steel and stainless steel The electromagnetic clamping system provides more freedom to form the workpiece into complex shapes It is easy to form very deep narrow chan nels closed sections and deep boxes that are difficult or impossible on a conventional machine The unique hinging system used for the bending beam provides a com pletely open ended machine thus greatly extending its versatility The single column stand design also contributes to the versatility of the machine by pro viding a free arm effect at the
5. bt gt t gt t ot Please fill in for your own reference Model __ Serial No Date Purchased Dealer s Name and Address Before returning your machine for repair under Warranty please contact the Manufacturer to discuss the most efficient means of transport and packaging and whether the whole or only a part of the machine needs to be returned to the factory To establish proof of purchase date please return the Warranty Registration on the following page You are advised to contact the Manufacturer before any repairs are under taken especially when using outside contractors The Warranty does not cover the costs of these contractors unless prior arrangements have been made A 29 WARRANTY REGISTRATION Model No Serial No Date Purchased Dealer s Name amp Address Customer s Name amp Address Your answers to the following questions would be appreciated Please underline the appropriate word or words How did you learn of the Magnabend Trade Fair Advertisement At a School or College Other Which is your category of use School Technical College University Plumber Maintenance workshop Automotive repair Electronics workshop Research support workshop Production workshop Sheetmetal shop Jobbing workshop Other What type of metal will you usually bend Mild Steel Aluminium Stainless Steel Copper Zinc Brass Other What thickness 0 6 mm or less 0 8
6. pull the handle as if doing an ordinary bend the START button may be released Wrap the workpiece as far as possible about 90 Reposition the workpiece as shown under Forming a Rolled Edge and wrap again Continue until the roll is closed The test shape is now complete 18 BOXES MAKING BOXES USING SHORT CLAMPBARS There are numerous ways of laying out boxes and numerous ways of folding them up The MAGNABEND is ideally suited to forming boxes especially complex ones because of the versatility of using short clampbars to form folds relatively unhindered by previous folds Plain Boxes 1 Make the first two bends using the long clampbar as for normal bending 2 Select one or more of the shorter clampbars and position as shown It is not necessary to make up the exact length as the bend will carry over gaps of at least 20 mm between the clampbars For bends up to 70 mm long just select the largest clamp piece that will fit For longer lengths it may be necessary to use several clamp pieces Just se lect the longest clampbar that will fit in then the longest that will fit in the remaining gap and possibly a third one thus making up the required length For repetitive bending the clamp pieces may be plugged together to make a single unit with the required length Alternatively if the boxes have shallow sides and you have available a slotted clampbar then it may be quicker to make the boxes in the same mann
7. the microswitch clicking ON and OFF provided there is not too much background noise If the switch does not click ON and OFF then swing the bending beam right up so that the brass actuator can be observed Rotate the bending beam up and down The actuator should rotate in response to the bend ing beam until it clutches at its stops If it does not then it may need more clutching force On the 1250E lack of clutching force usually relates to the two M8 cap head screws at either end of the actuator 26 TROUBLE SHOOTING shaft not being tight If the actuator rotates and clutches OK but still does not click the microswitch then it may need adjusting To do this first unplug the machine from the power outlet and then remove the electrical access panel On the Model 1250E the turn on point can be adjusted by turning a screw which passes through the actuator The screw should be adjusted such that the switch clicks when the bottom edge of the bending beam has moved about 4 mm On the 650E and 1000E the same adjustment is achieved by bending the arm of the microswitch b If the microswitch does not click ON and OFF even though the actuator is working properly then the switch itself may be fused inside and will need to be replaced c If your machine is fitted with an auxiliary switch then make sure it is switched to the NORMAL position Only light clamping will be avail able if the switch is in the AUX CLAMP position 3 Cla
8. aking shallow trays and pans quickly and accurately The advantages of the slotted clampbar over the set of short clampbars for making trays are that the bending edge is automati cally aligned to the rest of the machine and the clampbar automatically lifts to facilitate the insertion or removal of the workpiece Never the less the short clampbars can be used to form trays of unlimited depth and of course are better for making complex shapes In use the slots are equivalent to gaps left between the fingers of a conven tional box amp pan folding machine The width of the slots is such that any two slots will fit trays over a size range of 10 mm and the number and locations of the slots are such that for all sizes of tray there can always be found two slots that will fit it The shortest and longest tray sizes the slotted clampbar will accommodate are listed under SPECIFICATIONS To fold up a shallow tray 1 Fold up the first two opposite sides and the corner tabs using the slotted clampbar but ignoring the presence of the slots These slots will not have any discernible effect on the finished folds 2 Now select two slots between which to fold up the remaining two sides This is actually very easy and surprisingly quick Just line up the left side of the partly made tray with the leftmost slot and see if there is a slot for the right side to push into if not slide the tray along till the left side is at the next slot and try agai
9. am Extension removable Magnetic flux path he Coil Bending beam CROSS SECTION DETAIL mm SPECIFICATIONS MODEL 1250E 1320 Bending edge length 1300 665 Dist between lifters _ Backgauge 1260 640 Narrow Clampbar 1 Standard Clampbar optional d Adjustor knob 49 Et each zoe Bending beam Extension removable Magnetic flux path Bending beam CROSS SECTION DETAIL mm 10 INSPECTION SHEET EARTHING CONNECTIONS Measure resistance from mains plug earth pin to magnet body ohm ELECTRICAL ISOLATION Megger from coil to magnet body sse MIN MAX SUPPLY VOLTAGE TESTS At 260v Pre clamp full clamp release At200y Pr clamip release crei coco reet Res C Pre clamp full clamp release INTERLOCK SEQUENCE With power on pull HANDLE then press START button Check that machine does NOT activate TURN ON OFF ANGLES Movement of Bending Beam to activate full clamping measured at bottom of bending beam 4 mm to 6 Reverse motion to switch off machine Measure back from 90 Should be within the range 15 5 4 ANGLE SCALE Reading at edge of Indicator when bending beam is set to 90 with an engineer s square mi
10. e bending beam 2 the straightness of the bending edge of the clamp bar and 3 the parallelism of these two surfaces These surfaces can be checked with a precision straight edge but another good method of checking is to reference the surfaces to each other To do this 1 Swing the bending beam up to the 90 position and hold it there The beam can be locked in this position by placing a back stop clamp collar behind the angle slide on the handle 2 Observe the gap between the bending edge of the clamp bar and the work ing surface of the bending beam Using the clampbar adjusters set this gap to 1 mm at each end use a scrap piece of sheetmetal or a feeler gauge Check that the gap is the same all the way along the clampbar Any variations should be within 0 2 mm That is the gap should not exceed 1 2 mm and should not be less than 0 8 mm If the adjustors do not read the same at each end then reset them as de scribed under MAINTENANCE Notes a The straightness of the clampbar as observed in elevation from the front is not important as this gets flattened out by magnetic clamping as soon as the machine is activated b The gap between the bending beam and the magnet body as observed in plan view with the bending beam in its home position is normally about 2 to 3 mm This gap is not a functional aspect of the machine and does not affect the bending accuracy c The Magnabend can produce sharp folds in thinner
11. eat step 2 as required 44 16 TEST PIECE INSTRUCTIONS FOR FORMING TEST PIECE In order to gain familiarity with your machine and the type of operations that can be performed with it it is recommended that a test piece be formed as described below 1 Select a piece of 0 8 mm thick mild steel or aluminium sheet and cut it to 335 x 200 mm 2 Mark lines on the sheet as shown below 200 gt v8 Bend 1 180 Bend 2 90 reverse bend mark this line on the vend reverse side of the sheet Bend 3 90 Bend 4 90 Bend 5 90 This section to be rolled around 225mm round bar 3 Align Bend 1 and form a lip on the edge of the workpiece See FOLDED LIP 4 Turn the test piece over and slide it under the clampbar leaving the folded edge towards you Tilt the clampbar forward and line up Bend 2 Make this bend to 90 The test piece should now look like this 17 TEST PIECE 5 Turn test piece over and make Bend 3 Bend 4 and Bend 5 each to 90 6 To complete the shape the remaining piece is to be rolled around a 23 mm diameter round bar of steel e Select the 280 mm clamp bar and place it the test piece and the round bar on the machine as shown under ROLLED EDGE earlier in this manual e Hold the round bar in position with the right hand and apply pre clamping by pressing and holding the START button with the left hand Now use your right hand to
12. ends of the machine Ease of use flows from the fingertip control of the clamping and unclamping the ease and accuracy of bend alignment and the automatic adjustment for sheetmetal thickness A two handed interlock provides safety for the operator Fundamentally the use of magnetic clamping means that bending loads are taken right at the point where they are generated forces do not have to be transferred to support structures at the ends of the machine This in turn means that the clamping member does not need any structural bulk and hence can be made much more compact and less hindering The thickness of the clampbar is determined only by its requirement to carry sufficient magnetic flux and not by structural considerations at all Special centerless compound hinges have been developed especially for the Magnabend and are distributed along the length of the bending beam and thus like the clampbar take bending loads close to where they are generated The combined effect of the magnetic clamping with the special centerless hinges means that the Magnabend is a very compact space saving machine with a very high strength to weight ratio To get the most out of your machine please read this manual particularly the section titled USING THE MAGNABEND Please also return the WAR RANTY REGISTRATION as this will simplify any claims under warranty and also it gives the manufacturer a record of your address which facilitates keeping custo
13. er as shallow trays See next section TRAYS Lipped boxes Lipped boxes can be made using the standard set of short clampbars provided one of the dimensions is greater than the width of the clampbar 98 mm 1 Using the full length clampbar form the length wise folds 1 2 3 amp 4 2 Select a short clampbar or possibly two or three plugged together with a length at least a lip width shorter than the width of the box so that it may later be removed Form folds 5 6 7 amp 8 While forming the folds 6 amp 7 be careful to guide the corner tabs either inside or outside the sides of the box as desired 19 BOXES Boxes with separate ends A box made with separate ends has several advantages it saves material if the box has deep sides it does not require corner notching all cutting out can be done with a guillotine all folding can be done with a plain full length clampbar and some drawbacks more folds must be formed more corners must be joined and more metal edges and fasteners show on the finished box Making this kind of box is straight forward and the full length clampbar can be used for all folds 1 Prepare the blanks as shown below 2 First form the four folds in the main workpiece 3 Next form the 4 flanges on each end piece For each of these folds insert the narrow flange of the end piece under the clampbar 4 Join the box together ojo gt Flan
14. g the indicating marks adjust the adjusters until the 1 mm pieces are just lightly nipped between the bending edge and the bending beam 4 Using a 3 mm Allen key carefully loosen the grub screw to free the knurled ring of one of the adjusters Then rotate the ring till the indicat ing slit indicates I Do this without rotating the inner body of the ad juster Then re tighten the grub screw 5 Reset the other adjuster in the same manner The spring loaded lifting balls in the underside of the adjusters may stick if dirt or rust forming moisture gets in If this happens remedy it by pressing the ball in and out with a blunt tool while spraying in a penetrating lubricant such as CRC 5 56 or RP7 25 TROUBLE SHOOTING The easiest way to fix electrical problems is to order a replacement electrical module from the manufacturer This is supplied on an exchange basis and therefore is quite reasonably priced Before sending for an exchange module you may like to check the following 1 Machine does not operate at all a Check that power is available at the machine by observing the pilot light in the ON OFF switch b If power is available but the machine is still dead but feels very hot then the thermal cut out may have tripped In this case wait until the machine cools down about an hour and then try it again c The two handed starting interlock requires that the START button is pressed before the handle is pulled If the
15. gauges and in non ferrous materials such as aluminium and copper However in thicker gauges of steel and stainless steel do not expect to achieve a sharp fold see specifications d Uniformity of the bend in thicker gauges can be enhanced by using scrap pieces of the workpiece to fill in the unused portions under the clampbar 24 MAINTENANCE WORKING SURFACES If the bare working surfaces of the machine become rusty tarnished or dam aged they may be readily reconditioned Any raised burrs should be filed off flush and the surfaces rubbed with P200 emery paper Finally apply a spray on anti rust such as CRC 5 56 or RP7 HINGE LUBRICATION If the Magnabend sheetmetal folder is in constant use then grease or oil the hinges once per month If the machine is used less then it may be lubri cated less frequently Lubrication holes are provided in the two lugs of the main hinge plate and the spherical bearing surface of the sector block should also have lubricant applied to it ADJUSTERS The adjusters at the ends of the main clampbar are to control the allowance for the thickness of the workpiece between the bending edge and the bending beam The adjusters are factory set to give a thickness allowance of 1 mm when the adjuster indicators 1 To reset this proceed as follows 1 Hold the bending beam at 90 2 Insert a small piece of 1 mm sheetmetal at each end between the bending edge and the bending beam 3 Ignorin
16. ged boxes with plain corners Plain cornered boxes with outside flanges are easy to make if the length and width are greater than the clampbar width of 98 mm Forming boxes with outside flanges is related to making TOP HAT SECTIONS described in a later section see Contents 4 Prepare the blank 5 Using the full length clampbar form folds 1 2 3 amp 4 6 Insert the flange under the clampbar to form fold 5 and then fold 6 7 Using appropriate short clampbars complete folds 7 amp 8 9 RA 20 BOXES Flanged Box with Corner Tabs When making an outside flanged box with corner tabs and without using separate end pieces it is important to form the folds in the correct sequence 1 Prepare the blank with corner tabs arranged as shown 2 At one end of the full length clampbar form all tab folds A to 90 It is best to do this by inserting the tab under the clampbar 3 At the same end of the full length clampbar form folds B to 45 only Do this by inserting the side of the box rather than the bottom of the box under the clampbar 4 At the other end of the full length clampbar form the flange folds C to 90 5 Using appropriate short clampbars complete folds B to 90 6 Join the corners Remember that for deep boxes it may be better to make the box with separate end pieces 21 SLOTTED CLAMPBAR FORMING TRAYS USING SLOTTED CLAMPBAR The Slotted Clampbar when supplied is ideal for m
17. handle is pulled first then the machine will not operate Also it may happen that the bending beam moves or is bumped sufficiently to operate the angle mi croswitch before the START button is pressed If this happens make sure the handle is pushed fully back first If this is a persistent problem then it indicates that the microswitch actuator needs adjustment see below d Another possibility is that the START button may be faulty If you have a Model 1250E or larger then see if the machine can be started with one of the alternative START buttons or the footswitch e Also check the connector which connects the electrical module with the magnet coil f If clamping does not operate but the clampbar snaps down on release of the START button then this indicates that the 15 microfarad 10 uF on the 650E capacitor is faulty and will need to be replaced g If the machine blows external fuses or trips circuit breakers when oper ated then the most likely cause is a blown bridge rectifier 2 Light clamping operates but full clamping does not a Check that the Angle Microswtich is being actuated correctly This switch is operated by a square brass piece which is attached to the angle indicating mechanism When the handle is pulled the bending beam rotates which imparts a rotation to the brass actuator The ac tuator in turn operates a microswitch inside the electrical assembly Pull the handle out and in You should be able to hear
18. imum results the gap between the clampbar edge and the surface of the bending beam should be set to slightly greater than the metal thick ness to be bent 2 Insert the workpiece then tilt the front edge of the clampbar down and align the bend line to the bending edge 3 Press and hold the START button This applies pre clamping 4 With the other hand pull on the handle Full clamping is now auto matically applied and the START button should now be released Con tinue bending until the required angle is reached 5 The bending beam may be reversed about 10 to 15 to take pressure off the workpiece for checking the bend angle Reversing by more than 15 automatically turns the machine off and releases the workpiece CAUTION e To avoid the risk of damaging the bending edge of the clampbar or of denting the top surface of the magnet body do not put small objects un der the clampbar The recommended minimum bend length using the standard clampbar is 15 mm except when the workpiece is very thin or soft e The clamping force of the magnet is less when it is hot Therefore to get the best performance apply clamping for no longer than is necessary to do the bend 13 POWER SHEAR Optional accessory INSTRUCTIONS FOR USE The power shear based on the Makita Model JS 1660 provides a means for cutting sheetmetal in such a way that very little distortion is left in the workpiece This is possible because the shear removes a was
19. mers informed of any developments which may benefit them ASSEMBLY ASSEMBLY INSTRUCTIONS 1 Unpack the column and the feet and locate the packet of fasteners and the 6 mm Allen key Attach the feet to the column The pair of feet with the black and yellow safety tape should point forwards from the column The front face of the Use M10 x 16 button head screws to attach the feet Models 650E and 1000E Attach the footplate under the tips of the front feet Use two M10 x 16 cap head screws with washers Alignment of the screw holes will be made easier if the foot mounting screws are left loose until after the footplate is fitted The M8 x 20 cap head screws in the rear feet may be adjusted to level the machine and suit any unevenness in the Model 1250E A footplate is not supplied with this machine it must be With the aid of an assistant carefully place the Magnabend machine on the stand and secure it with M8 x 16 cap head screws Models 650E amp 1000E Be sure to guide the wires and connector down into the column as the machine is being lowered onto the stand Models 650E amp 1000E Remove the rear electrical access panel and plug together the 3 pin connector This connects the electromagnet in the body of the machine to the electrical unit in the column Replace the panel Model 1250E Fasten the mains cable clip to the back of the column with Model 650E Join the two halves of the tray using M6
20. mping is OK but Clampbars do not release when the machine switches OFF This indicates a failure of the reverse pulse demagnetising circuit The most likely cause would be a blown 6 8 power resistor Also check all diodes and also the possibility of sticking contacts in the relay 4 Machine will not bend heavy gauge sheet a Check that the job is within the specifications of the machine In particular note that for 1 6 mm 16 gauge bending the extension bar must be fitted to the bending beam and that the minimum lip width is 30 mm This means that at least 30 mm of material must project out from the bending edge of the clampbar This applies to both aluminium and steel Narrower lips are possible if the bend is not the full length of the machine b Also if the workpiece does not fill up the space under the clampbar then performance may be affected For best results always fill up the space under the clampbar with a scrap piece of steel the same thickness as the workpiece For best magnetic clamping the filler piece should be steel even if the workpiece is not steel This is also the best method to use if it is required to make a very narrow lip on the workpiece Filler Piece N lt Workpiece 27 CIRCUIT DIAGRAMS 10 650E START 15yF 1000E RELAY PPL WHT PNK NO RED RED ANGLE NS MICROSWITCH PNK BRN MAGNET REpC OL MAINS TERMINAL BRIDGE RECTIFIER
21. n SPECIFICATIONS BENDING CAPABILITY When using a standard full length clamp bar to bend a full length work piece MATERIAL THICKNESS LIP WIDTH BEND RADIUS yield ultimate stress minimum typical Mild steel 1 6 mm 250 320 MPa 1 2 mm 1 0 mm Aluminium 1 6 mm Grade 5005 H34 1 2 mm 140 160 MPa 1 0 mm Stainless Steel 1 0 mm Grades 304 316 0 9 mm 210 600 MPa 0 8 mm With extension bar fitted to bending beam SHORT CLAMP BAR SET Lengths Model 650E 25 38 52 70 140 280 mm Models 1000E amp 1250E 25 38 52 70 140 280 597 mm All sizes except 597 mm may be plugged together to form a bending edge within 25 mm of any desired length up to 575 mm SLOTTED CLAMPBAR When supplied a special set of 8 mm wide slots provide for forming all tray sizes in the range shown below For deeper trays use the Short Clamp bar set MODEL TRAY LENGTHS MAX TRAY DEPTH 650E 15 to 635 mm 40 mm 1000E 15 to 1015 mm 40 mm 1250E 15 to 1265 mm 40 mm SPECIFICATIONS MODELS 650E 1000E E 690 1070 Bending edge length 430 665 Dist between lifters 390 640 630 1010 I Max Backgauge 740 y 690 940 FRONT amp SIDE ELEVATIONS mm Narrow Clampbar OO denm 1 EN Standard Clampbar optional 3 N Adjustor knob 49 gt at each end Bending be
22. n Typically it takes about 4 such tries to find two suitable slots 3 Finally with the edge of the tray under the clampbar and between the two chosen slots fold up the remaining sides The previously formed sides go into the selected slots as the final folds are completed With tray lengths that are nearly as long as the clampbar it may be necessary to use one end of the clampbar in lieu of a slot 22 BACKSTOPS USING THE BACKSTOPS The backstops are useful when a large number of bends have to be made all of which are the same distance from the edge of the workpiece Once the backstops are correctly set any number of bends can be made without the need for any measuring or marking out on the workpiece Normally the backstops would be used with a bar laid against them so as to form a long surface on which to reference the edge of the workpiece No spe cial bar is supplied but the extension piece from the bending beam may be used if another suitable bar is not available NOTE If it is required to set a backstop under the clampbar then this can be done by using a strip of sheetmetal the same thickness as the workpiece in conjunction with the backstops 23 ACCURACY CHECKING THE ACCURACY OF YOUR MACHINE All functional surfaces of the Magnabend are manufactured to be straight and flat to within 0 2 mm over the entire length of the machine The most critical aspects are 1 the straightness of the working surface of th
23. n 89 max 91 4 MAGNET BODY Straightness of top surface along front pole max deviation 0 5 mm am Flatness of top surface across the poles max deviation 0 1 MM BENDING BEAM Straightness of working surface max deviation 0 25 mm Alignment of extension bar max deviation 0 25 Note Test straightness with precision straight edge INSPECTION SHEET MAIN CLAMPBAR Straightness of bending edge max deviation 0 25 mm Height of lift with lifting balls in grooves min 3 mm mm Can lifting balls be compressed flush with surface With adjusters set at 1 and the bending beam at 90 is the bending edge parallel to and 1 mm from the beam With the bending beam at 90 can the clampbar be adjusted forward to touch and rearward by 2 L HINGES Check for lubrication on shafts L and sector blocks Check that hinges rotate through 180 freely and smoothly Check hinge pins do not rotate and are loctited Have the retaining screw nuts been locked BENDING TEST A maximum specification bend to 90 at minimum supply voltage Steel test piece thickness mm Bend length mm Width of lip
24. pan head screws and nuts Attach the tray with rubber mat to the rear of the machine us ing two M8 x 12 cap head screws Fit two backstop slides to the sides of Models 1000E and 1250E Attach the two backstop bars into the back of the machine using two M8 x 16 screws for each bar Attach the tray with rubber mat to the rear of the machine using three M8 x 16 cap head screws Fit a stop collar onto each backstop bar Attach the handle s with M8 x 16 cap head screws Models 650E and 1000E The handle should be slipped down through the angle indicating ring before attaching the handle Model 1250E The handle with the angle scale must be fitted on the left side and a stop collar slipped onto it and clamped up near the top of the 2 column is the side without a join in it 3 floor bolted to the floor at the front feet 4 5 an M6 x 10 pan head screw 6 the tray 7 handle 8 Model 1250E Swing the bending beam up through 180 Unpack the an ASSEMBLY gle indicator assembly and pass the Indicator Slide over the left handle Unscrew the two M8 cap head screws from the indicator anchor block which is fastened to the base of the machine near the left handle Attach the Indicator Arms to the anchor block and tighten both M8 cap head screws by hand and then using the 6 mm Allen key tighten both screws very firmly Note The machine may not turn ON if these screws are not tight 9 Using a chlorinated solvent o
25. r petrol clean off the clear wax like coating from the working surfaces of the machine 10 Place the short clamp bars in the tray and the full length clamp bar on top of the machine with its locating balls sitting in the grooves in the top sur face of the machine 11 Plug into a power outlet and turn ON the main switch The machine is now ready for operation please refer to BASIC OPERATION in this manual Backstop Bar Tray Stop Collar Angle Indicator Foot SPECIFICATIONS NOMINAL CAPACITY Model 650E 625 mmx 1 6mm 2ft x 16g Model 1000E 1000 mm x 1 6mm 3ft x 16g Model 1250E 1250 mm x 1 6 mm 4ft x 16g CLAMPING FORCE Total force with standard full length clamp bar Model 650E 3 Tonne Model 1000E 4 5 Tonne Model 1250E 6 Tonne ELECTRICAL 1 Phase 220 240 V AC Current Model 650E 4 Amp Model 1000E 6 Amp Model 1250E 8 Amp Duty Cycle 3096 Protection Thermal cut out 70 C Control Start button pre clamping force Bending beam microswitch full clamping Machine Weight 72 kg 110 kg 150 kg Interlock the start button and the bending beam must be oper ated in correct overlapping sequence to initiate full clamping force HINGES Special centerless design to provide a completely open ended machine Rotation angle 180 BENDING DIMENSIONS 16mm min 16mm min mE 9 98mm min Standard Clampbar 49mm min Narrow Clampbar W Unlimited 4 Refer to Chart 16mm mi
26. s spiral leaving your workpiece distortion free 14 FOLDED LIP FOLDING A LIP HEM The technique used for folding lips depends on the workpiece thickness and to some extent on its length and breadth Thin Workpieces up to 0 8 mm 1 Proceed as for normal bending but continue the bend as far as possible 135 2 Remove the clampbar and leave the workpiece on the machine but move it rearwards about 10 mm Now swing the bending beam over to compress the lip Clamping need not be applied Note Do not attempt to form narrow lips on thick workpieces 3 With thin workpieces and or where the lip is not too narrow a more com plete flattening can be achieved by following with magnetic clamping only 15 ROLLED EDGE FORMING A ROLLED EDGE Rolled edges are formed by wrapping the workpiece around a round steel bar or piece of thick walled pipe 1 Position the workpiece clampbar and rolling bar as shown a Ensure that the clampbar does not overlap the front pole of the ma chine at a as this would allow magnetic flux to bypass the rolling bar and hence clamping would be very weak b Make sure the rolling bar is resting on the steel front pole of the ma chine b and not further back on the aluminium part of the surface The purpose of the clampbar is to provide a magnetic pathway into the rolling bar 2 Wrap the workpiece as far as possible then re position as shown 3 Rep
27. te strip about 4 mm wide and most of the distortion inherent in shearing sheetmetal goes into this waste strip For use with a Magnabend the shear has been fitted with a special magnetic guide The shear works well in combination with a Magnabend Sheetmetal Folder the Magnabend provides both a means of holding the workpiece fixed while being cut and also a means for guiding the tool so that very straight cutting is possible Cuts of any length can be handled in steel up to 1 6 mm thick or aluminium up to 2 mm thick To use the tool first place the sheetmetal workpiece under the clampbar of the Magnabend and position it so that the cutting line is exactly 1 mm in front of the edge of the Bending Beam A toggle switch labelled NORMAL AUX CLAMP will be found next to the main ON OFF switch Switch this to the AUX CLAMP position to hold the workpiece firmly in position Position the shear at the right hand end of the Magnabend and ensure that the magnetic guide attachment engages on the front edge of the Bending Beam Start the power shear and then push it evenly along until the cut is completed Notes 1 For optimum performance the blade clearance should be adjusted to suit the thickness of material to be cut Please read the Makita instructions supplied with the JS1660 shear 2 If the Shear does not cut freely check that the blades are sharp MAKITA POWER SHEAR IN ACTION Note that the waste strip curls out in a continuou
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