Product Manual B

Bending
Loading Material
Rotate and secure the bender head-frame in either the vertical or hori-
zontal working position. If working with long sections of material, be
prepared to support your material with a material rest or roller (provided
by user). Place the leading end of the material to be bent between the
forming die assembly and wiper bar assembly. Capture the material with
the saddle strap and saddle pin. Secure the material by tightening the
saddle bolt down on the material.
Lubrication
To achieve the highest quality nished bend in your material, as well
as the longest life from the bearing surfaces of your die components, a
liberal amount of lubrication should be applied to the bearing surfaces
as follows:
Schedule 40 Pipe
• Lubricate wiper blades
Tubing
• Lubricate wiper blades
Square Tubing
• Lubricate wiper blades
Solid Round
• Lubricate wiper blades
Lubricant can be mineral or vegetable-based, solid bodied or spray
aerosol.
Bending
Install your material into the forming die and wiper bar assembly. Secure
the material with the matched saddle strap and 7/8” (short) saddle pin.
Secure the saddle bolt against the material to be bent with a wrench and
adequate pressure to insure the material does not pull or slip from the
forming die under bending pressure.
With your material secured between the forming die assembly and
wiper bar assembly, engage the head-frame with the die set by insert-
ing the 7/8” (long) drive pin through the top inner head-frame, through
the forming die “drive hole” and through the bottom inner head-frame.
Engage the material with the die set by activating the OUT button on the
hand held controller. Advancing the die against the material will extend
the hydraulic cylinder and “push” the inner frames of the head-frame
away from the outer frames. This initial movement will snug the die and
material together eliminating the “slack” in the assembly.
Depress the OUT button again and the material will be drawn through
the die assembly.
Depress the OUT button until your desired bend is achieved or you reach
the maximum extend of the cylinder ram for the chosen drive hole.
If the desired bend angle is beyond the reach of the initial drive hole,
push the IN button to relieve pressure between the forming die, drive pin
and head-frame. Once pressure is relieved in the assembly, you will be
able to remove the drive pin from the assembly, fully retract the cylinder
and set the drive pin in the next adjacent drive hole. Repeat the process,
progressively drawing your material through the bender until your de-
sired bend is achieved. Make sure your material is fully supported in the
wiper assembly. Failure to support the material by drawing the material
beyond the trailing wiper blade may result in damage to the material,
machine, die set or operator. When using square dies, do no run your
material beyond the center pin.
When your bend is complete, remove your material from the bender by
pushing the IN button to extract the drive pin from the head-frame as-
sembly, push the IN button again to return the head-frame to its starting
position, relieve the saddle bolt, pull the saddle pin and saddle. Your
material should be able to be easily removed or repositioned for further
work.
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Quality parts are dependent upon conscientious bender setup, bender operation and bender maintenance. Physically review
your bender prior to any operation. Conrm all static components are tight in the assembly. Conrm all moving components
are free of obstruction. Conrm all bender tooling, forming die and wiper assemblies are seated within the assembly.
Problem Solution
Bender Inoperable Check accessory control switch
Check bender male 4-pin power cable is connected to
female limit switch port.
Check hand control Mil Spec male power cable is
connected to female Mil Spec control port
Note: Auto Cut port will NOT power the bender accessory.
Drive pins tight Check alignment of head-frame assembly bolts.
Loosen head-frame assembly bolts (4).
Reset drive pins in head-frame and die assembly.
Re-tighten head-frame assembly bolts.
Scratching of material Check alignment of material to wiper and forming
die.
Check for matched/proper die set.
Check for adequate lubrication.
Check surface quality/cleanliness of material.
Rough cylinder operation Check uid level of machine.
Check hoses for correct installation.
Check fuse at transformer box.
Auto-Stop operation Check tightness of lever.
Check for proper plunger/roller.
Material not moving through die set Check forming die saddle pin, strap and bolt; tighten as
necessary.
Troubleshooting
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