Summary of Contents for JD Squared Model 54
- Page 1 Model 54 Bender Assembly and Operating Instruction Manual Revision Date: 4/28/2015 JD Squared Inc. 2244 Eddie Williams Rd. Johnson City, TN 37601 USA (423) 979-0309 Copyright 2014 by JD Squared Inc.
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Page 2: Table Of Contents
Description of the pressure die assembly ..................... 10 Installing the pressure die into the bender ....................10 The main operating principle of the Model 54 bender .................. 11 Adjusting the toggle mechanism for bending ....................11 How to make a bend and remove the work piece when finished ..............12 Spindle lock operation .......................... -
Page 3: Uncrating
Uncrating Bender’s crate with sides and top removed. Parts included with bender: Pressure screw pin (1” diameter) U-strap pin and hitch pin clip (7/8” diameter with multiple drilled holes) Die socket set screw (3/4”-10 x 3.5” long) Die washer (3/4” hole) Die nut (3/4”-10 hex) 1/2”-13 x 2 1/2”... -
Page 4: Assembly
Assembly Moving the bender In order to save you money, the bender is sold without the moving handles. Why? The 5 1/2 foot long handles will not fit into the bender’s crate and therefore must be shipped separately at an average cost of over $40. The handle material itself however is less than $10. -
Page 5: Leveling The Spindle
Leveling the spindle 1) Remove 1 of the 4 socket head cap screws from the top of the spindle as shown to the right. 2) Place a level on the spindle’s upper surface. Do not place it anywhere else such as the top of the screws or dowel pins because they may not be level themselves. -
Page 6: Assembling The Toggle Mechanism
Assembling the toggle mechanism 1) Remove the bolts, washers and sleeves from the handle. 2) Refering to the photo to the right, locate the 2 empty slots and holes. Place a sleeve in each one of the 2 lower holes as shown. 3) Install the handle with the welded block to the rear of the bender using the 2 bolts and washers. -
Page 7: Adjusting The Toggle Mechanism's Over-Center Distance
Adjusting the toggle mechanism’s over-center distance The proper adjustment of the toggle mechanism is critical for the safe operation of the bender. The principle of the toggle mechanism is that when engaged the middle pin will be slightly below the outer pins when the bender is under load. -
Page 8: Tool Plate Installation
Tool Plate Installation The Model 54 has been designed to allow new tooling to be easily added in the future. This is accomplished by using a tool plate that bolts to the pressure screw block. Various tool plate’s are available depending upon the application. -
Page 9: Rotate Spindle To Its Start Position
Loading a Round Tube/Pipe Die Set Rotate spindle to its start position 1) Retract the ram until it stops moving and then move it forward slightly. If left fully retracted, the ram will pull the spindle to the rear and lock it up. This does not harm anything, it just won’t let you rotate the spindle by hand. -
Page 10: Description Of The Pressure Die Assembly
Description of the pressure die assembly The pressure die is shown in the 2 pictures below. It is sometimes referred to as a ‘followbar’. It constrains the outside of the tube while bending. It is made up of 2 inserts and the backing block. The inserts are cast and machined from a special, scratch and wear resistant, metal alloy. - Page 11 Loading a Square/Rectangle Tube Die Set Installing the forming die onto the spindle Install the square groove forming die onto the spindle exactly as described in the previous section about installing a round groove die. Installing the square groove tube clamp...
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Page 12: Adjusting The Toggle Mechanism For Bending
It seems obvious, but how is this accomplished? A key feature of the Model 54 is that it uses an absolute position encoder on the spindle. It has been factory set to read zero when the spindle is rotated to the start position. When the spindle is rotated to any arbitrary position, even if the bender was previously turned off and back on, it will always display the same value within the encoder’s .1... -
Page 13: How To Make A Bend And Remove The Work Piece When Finished
How to make a bend and remove the work piece when finished 1) Load the tube to be bent and adjust the toggle as described earlier. 2) Lubricate ONLY the outside of the tube where the pressure die slides. Do NOT oil the groove. Cooking spray works surprisingly well here. 3) Verify the pressure die’s 1”... -
Page 14: Computer Operation
That’s a lot to add up every time we want to make a bend. So, let’s just not do it. The Model 54’s has a much simpler solution. -
Page 15: Maintenance
Maintenance Setting the spindle to zero 1) Fully retract the cylinder. This will bind the spindle and lock the spindle in place. To free up the spindle, advance the cylinder slightly until the spindle can rotate freely. Rotate the spindle to its normal starting position. -
Page 16: Exploded View Of Spindle Components
Exploded view of spindle components 3/8”-16 x 3.5“ long hex bolt Spindle cap screws (4x) Spindle cap 3/4”-16 x 3.75“ long hex bolts (2x) NOTE: Does NOT use washers Upper bearing 3/8” washer Upper drive link Pin spacer (1.02” i.d.) Drive link sleeve (1”... -
Page 17: Installing The Encoder
Encoder components Installing the Encoder 1) Install the encoder mount. 2) Install the encoder onto the encoder bracket and tighten. Do not place it into the machine. 3) Slide encoder into coupling approximately .225” and tighten. Be careful not to strip the small bolt. NOTE: The shaft must not protrude into the slotted section of the coupler or it will not be able to flex properly. -
Page 18: Bending Tutorial Using Template Bends
Bending Tutorial Using Template Bends The Easy Way To Position Bends Learning to operate the bender is fairly easy. The real challenge is accurately placing the tube into the bender so that the bend comes out in the right position. This tutorial will teach you a technique called ‘Template Bending’ to make a rollbar. - Page 19 The rollbar will be 40” tall from the floor to its UPPER 20° side. It will be 62” wide, outside to outside. The top two bends are 70 and the two lower bends are 20 50" To de ter mine the total length of tubing needed, you could sit down and calculate it.
- Page 20 BEND 3: At this step you may want to use a large 90 square to help position the template. Position the template above the rollbar tube with the template line facing up towards the top of the rollbar as shown in to the right. Slide the template up or down the rollbar tube until its outside is 31”...
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