Summary of Contents for J D Squared 4
- Page 1 Assembly & Operating Instructions Revision 4 (7/10/2008) J D Squared Inc. 2244 Eddie Williams Rd. Johnson City, TN 37601 (423) 979-0309, FAX (423) 979-2426 Internet: www.jd2.com © Copyright 2008 by J D Squared Inc.
-
Page 2: Unpacking & Parts List
Unpacking & Parts List The basic Model 4 bender is shipped in 2 packages. Package 1 contains the lower frame only. Package 2 contains all other parts needed for assembly, excluding the hydraulic cylinder, pump and hose. If these items were also ordered with the bender, they will arrive in their own separate boxes. Upon receiving both packages verify that neither package shows any signs of damage and that all parts are present. - Page 3 To mount the bender, drill three 3/4" holes through your mounting surface. You can use the frame holes as a guide. Place two 3/4" washers on the top of each drilled hole. These washers will act as spacers to insure that the bender pins, when installed, will be completely pass through the lower frame holes.
- Page 4 Figures 6 and 7 show the complete assembly correctly installed. Note that the outside 3/4" bolt protrudes out of the bottom of the lower drive link and that the inside 3/4" bolt does NOT.
- Page 5 Being careful not to mar the engraved face of the pusher block, hammer in the 3/16" roll pin until it is flush with the pusher block's surface. Figure 11 shows this step completed. Figure 13 Pusher assembly complete - 4 -...
- Page 6 7) Screw the hydraulic cylinder completely into the hydraulic swivel block. If when tightened the cylinder's quick disconnect hose fitting is not facing in the downward direction, loosen the cylinder until it does face in the downward direction. The cylinder will have a little play in its threads. This is normal and will not cause any problems.
- Page 7 Installing Die Sets The Model 4 bender comes with 4 pins. Locate the pins listed below: 1" Diameter x 8" Frame Pin 7/8" Diameter x 8" Long Frame Pins (Long Pin) 7/8" Diameter x 6 1/4" Long Drive Pin (Short Pin)
- Page 8 STEP 2 - INSTALL THE PRESSURE DIE Pressure Die Installation Pressure dies are machined to exacting standards and must be installed in the proper orientation. Depending on whether the die set is for pipe, round or square tubing follow the appropriate directions below.
- Page 9 Looking at the top of the upper frame you will see two rows of 7/8" holes with letters or numbers beside them. The front seven row holes (1,2,3,4,E,F,G) are in a straight line and the back seven holes (A,B,C,D,5,6,7) are staggered.
-
Page 10: Operation
Operation STEP 1 - Figure 27 & 28 Using your hands, rotate the drive links clockwise until the workpiece is firmly seated in the die set with no play. With the cylinder fully retracted, extend the cylinder while guiding the pusher block into the first ratchet tooth on the frame. - Page 11 A QUICK EXAMPLE BEND As an example, let's say you want to bend a piece of 1 1/4" schedule 40 pipe 90 degrees. Place a mark on the pipe where you want the bend to start. Install the pipe and the die set into the bender. Position the mark on the pipe at the point on the forming die where the bend will start.
- Page 12 Bending Method #1 - Using Template Bends The Easy Way To Position Bends Learning the operation of a bender is fairly easy. The real challenge is accurately placing the tubing into the bender so that the bend comes out in the right position. This short tutorial ex plains the simple process of template bending.
- Page 13 Load this tube into your bender as shown in Forming Die Figure 36. Note that only the die set and tubing are visible in the figure. The actual bender and the die set’s u-strap are not shown so that you can see what we’re trying to achieve.
- Page 14 Why? Let’s say your measurement shows the two top bends are really 50 1/4” wide instead of the desired 50”. In that case, your old center mark could be off by as much as a 1/4”. The NEW center mark corrects this error. That’s the cool part about template bending.
- Page 15 31” from the rollbar’s center. Mark your tube and make the bend. Figure 41 - 3rd bend position BEND 4: 62” Position the template with the template line facing up towards the top of the rollbar as shown in figure 42.
- Page 16 D) With the tube bent correctly to 90 degrees locate the actual start of the bend. To do this, measure from the end of the tube to the far end of the 90 degree bend. In the example in figure 44 this came out at 20 1/4". Subtract 6 1/2" for the centerline radius (CLR) of the Bending Die, another 3/4"...
- Page 17 2) We cut our tube to 76 1/2". It's generally easier to work from the center out when making two bends in a tube. Divide 74 1/2" by 2 and our center point is 37 1/4" from the end of the tube. Place a mark on the tubing 37 1/4" in from one edge and mark the tubing so you will know which side is the 37 1/4 side and which side is 39 1/4".
-
Page 18: Second Method
If we now repeated the second bend, using the same 12 5/8" from the end of the tubing + 2" for the extra tubing we allowed, we would end up with a hoop 1/2" too wide. This is because the 1/4" stretch developed in the first bend will also be developed in the second bend, giving us 1/2"...
Need help?
Do you have a question about the 4 and is the answer not in the manual?
Questions and answers