Baileigh Industrial RDB-175 Operator's Manual
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Baileigh Industrial RDB-175 Operator's Manual

Rotary draw bender b8080
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OPERATOR'S MANUAL
ROTARY DRAW BENDER
MODEL: RDB-175 (B8080)
Rev. 03/2015
© 2015 Baileigh Industrial, Inc.

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  • Page 1 OPERATOR’S MANUAL ROTARY DRAW BENDER MODEL: RDB-175 (B8080) Rev. 03/2015 © 2015 Baileigh Industrial, Inc.

  • Page 2: Table Of Contents

    Table of Contents INTRODUCTION ......................1 GENERAL NOTES ......................1 SAFETY INSTRUCTIONS ....................2 SAFETY PRECAUTIONS ....................5 TECHNICAL SPECIFICATIONS ..................7 UNPACKING AND CHECKING CONTENTS ..............8 Cleaning ........................8 TRANSPORTING AND LIFTING ..................9 INSTALLATION ....................... 9 ASSEMBLY AND SET UP .................... 10 GETTING TO KNOW YOUR MACHINE ...............
  • Page 3 Cylinder Assembly Parts Diagram ................41 Controller Housing Assembly Parts Diagram ............42 Swing Arm Assembly Parts Diagram ................. 43 Parts List ........................44...

  • Page 4: Introduction

    INTRODUCTION The quality and reliability of the components assembled on a Baileigh Industrial machine guarantee near perfect functioning, free from problems, even under the most demanding working conditions. However if a situation arises, refer to the manual first. If a solution cannot be found, contact the distributor where you purchased our product.

  • Page 5: Safety Instructions

    Note: This symbol refers to useful information throughout the manual. IMPORTANT PLEASE READ THIS OPERATORS MANUAL CAREFULLY It contains important safety information, instructions, and necessary operating procedures. The continual observance of these procedures will help increase your production and extend the life of the equipment. SAFETY INSTRUCTIONS LEARN TO RECOGNIZE SAFETY INFORMATION This is the safety alert symbol.
  • Page 6 General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. SAVE THESE INSTRUCTIONS. Refer to them often and use them to instruct others. PROTECT EYES Wear safety glasses or suitable eye protection when working on or around machinery.
  • Page 7 BEWARE OF PINCH POINTS Keep hands and fingers away from the drive mechanisms, cylinders, ratchets, and other moving linkage while the machine is in operation. KEEP CLEAR OF MOVING OBJECTS Always be aware of the position of the material and the swing area in which the material will travel.

  • Page 8: Safety Precautions

    SAFETY PRECAUTIONS Metal working can be dangerous if safe and proper operating procedures are not followed. As with all machinery, there are certain hazards involved with the operation of the product. Using the machine with respect and caution will considerably lessen the possibility of personal injury. However, if normal safety precautions are overlooked or ignored, personal injury to the operator may result.
  • Page 9 11. Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or across a running machine. 12. Stay alert. Watch what you are doing and use common sense. DO NOT operate any tool or machine when you are tired. 13.

  • Page 10: Technical Specifications

    TECHNICAL SPECIFICATIONS Maximum Center Line Radius (CLR)* 9" (229mm) Minimum Center Line Radius (CLR)* .5" (12.7mm) Minimum OD .25" (6.35mm) Mild Steel Pipe (Schedule 40) Based on a material tensile strength of 60000 PSI – mild 2" (50.8mm) steel Aluminum Pipe (Schedule 40) 2"...

  • Page 11: Unpacking And Checking Contents

    UNPACKING AND CHECKING CONTENTS Your Baileigh machine is shipped complete in one crate. Separate all parts from the packing material and check each item carefully. Make certain all items are accounted for before discarding any packing material. WARNING: SUFFOCATION HAZARD! Immediately discard any plastic bags and packing materials to eliminate choking and suffocation hazards to children and animals.

  • Page 12: Transporting And Lifting

    TRANSPORTING AND LIFTING CAUTION: Lifting and carrying operations should be carried out by skilled workers, such as a truck operator. Make sure the machine is well balanced. Choose a location that will keep the machine free from vibration and dust from other machinery. Keep in mind that having a large clearance area around the machine is important for safe and efficient working conditions.

  • Page 13: Assembly And Set Up

    • Keep the floor free of oil and make sure it is not slippery. • Remove scrap and waste materials regularly, and make sure the work area is free from obstructing objects. • If long lengths of material are to be fed into the machine, make sure that they will not extend into any aisles.

  • Page 14: Getting To Know Your Machine

    GETTING TO KNOW YOUR MACHINE...

  • Page 15: General Design Description

    GENERAL DESIGN DESCRIPTION You have made a practical choice in purchasing the RDB-175 Hydraulic Bending Machine. It has been carefully built of high quality materials and designed to give many years of efficient service.

  • Page 16: Electrical

    ELECTRICAL CAUTION: HAVE ELECTRICAL UTILITIES CONNECTED TO MACHINE BY A CERTIFIED ELECTRICIAN! Check if the available power supply is the same as listed on the machine nameplate. WARNING: Make sure the grounding wire (green) is properly connected to avoid electric shock. DO NOT switch the position of the green grounding wire if any electrical plug wires are switched during hookup.
  • Page 17 • Improper connection of the equipment-grounding conductor can result in risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal.

  • Page 18: Operation

    OPERATION CAUTION: Always wear proper eye protection with side shields, safety footwear, and leather gloves to protect from burrs and sharp edges. CAUTION: Keep hands and fingers clear of the dies and swing arms. Stand to the front of the machine to avoid getting hit with the material during the bending process.
  • Page 19 7. The digital control and preset should only be used in whole degrees. For example 90, 91, 92 not 90.1 or 90.5. If any number is entered after the decimal the control will add 1 to the final degree. So it’s best to leave it at 0. 8.

  • Page 20: Die Selection And Installation

    DIE SELECTION AND INSTALLATION Before any bending can take place, the proper die set must be chosen to match the material being bent. (EX) 1-1/2” diameter tubing requires a die set marked 1-1/2” tube. Hook Arm Bend Die Hold down Bolts Plastic Slide Counter Die Mount Bronze Counter Die Insert...
  • Page 21 Spindle Die Drive Pins 1/2-13 Tapped holes for bolting down dies Center Pin Hitch Pin 4. To install the counter die, remove the hitch pin and insert the counter die in the opening in the counter die mount until the 3/4” holes line up. 5.
  • Page 22 Incorrect Counterdie Position Too far away from die Touching die Correct Counter Die Position Approximately 1/8” (3mm) away IMPORTANT: Be sure the long end of the counter die points away from the hook arm, or to the right of machine.

  • Page 23: Material Insertion

    Material Insertion 1. Once the die set is properly installed, the material that matches the die can be inserted (I.E. 1-1/4”tube would go into a die mark D-1250T-R***). 2. Open the counter die quick release assembly and insert the material past the hook arm. The start of bend mark is engraved with an “O”...
  • Page 24 9. If the bend requires more degrees. The controller will need to be set at a higher degree number. Increase the degrees by further activating the forward foot pedal switch. This allows the operator to gradually reach a bend angle, on the first set up piece. To determine the amount of springback for a certain material, it is necessary to bend a sample piece.

  • Page 25: Material Insertion Limitations

    Material Insertion Limitations Left Right • The left figure shows the recommended minimum / correct amount of material remaining to be fully supported in plastic slide. • The right figure shows the maximum amount the material can be pulled through the counterdie.

  • Page 26: Bending More Than 180 Degrees

    Bending More than 180 Degrees • This machine is capable of bending more than 180 degrees. Contact Baileigh Industrial about your application. o It will require a password to make the machine go past 200 degrees. o Requires special tooling to allow removal of bent part. If standard tooling is used, the material will be locked onto the die.
  • Page 27 This software is available from Baileigh Industrial. Contact your distributor for availability. • Bending with a rotary draw bender requires determining the start of bend point which will line up with the “0”...

  • Page 28: Pipe And Tube Bending Diagrams

    PIPE AND TUBE BENDING DIAGRAMS L = Arc length (outside) R = Rise (inside) D = Tube outside diameter t = Tube wall thickness a = First bend arc angle H = Height of offset b = Second bend arc angle L = Length of offset A = First tangent R1 = First radius...

  • Page 29: Bending Glossary

    BENDING GLOSSARY Arc Length The length of material along the centerline of the tubing Distance in inches from the center of curvature to the centerline Centerline Radius (CLR) axis of the tube bending or pipe bending bends. Abbreviated as CLR. See Tube Bending and Pipe Bending Diagram Angle in degrees to which the tube/pipe bends are formed (i.e.

  • Page 30: Bending Suggestions

    BENDING SUGGESTIONS Aluminum Bending If bending aluminum, lubrication is very important, if the results are less than desirable with WD- 40 other lubricants can be used such as: • Johnson Paste Wax (seems to work the best) • High Pressure grease •...

  • Page 31: Bending With Square Dies

    Bending With Square Dies • Die Parts Main Bending Die Die Cap Quick Release Handles Hook-Arm Hook-Arm Clamp Plastic Slide Slide Mount Quick Release Studs Square Tooling Setup 1. Install the bending die (1) on to the spindle. Be careful not to pinch your fingers as you lower the die on to the spindle.

  • Page 32: Large Size Square

    6. If the material slips during the bending operation, install the hook arm clamp (5). Do not use it unless you have to. 7. Activate the bender and bend to the desired angle. 8. To remove the material, open the counter die and return bender to the “home position”. Using a soft mallet, gently tap the cap clamps open and the material will spring out of the die (1).

  • Page 33: Lubrication And Maintenance

    LUBRICATION AND MAINTENANCE WARNING: Make sure the electrical disconnect is OFF before working on the machine. Maintenance should be performed on a regular basis by qualified personnel. Always follow proper safety precautions when working on or around any machinery. • Check daily for any unsafe conditions and fix immediately. •...

  • Page 34: Electrical Schematic

    ELECTRICAL SCHEMATIC...

  • Page 35: Hydraulic Diagram

    HYDRAULIC DIAGRAM...

  • Page 36: Troubleshooting

    TROUBLESHOOTING WARNING: Make sure the electrical disconnect is OFF before working on the machine. Problem Solution Cylinders not retracting all the Do the dry run sequence as outlined in section 8 of the way or not in sequence manual under operation Check that the solenoid valve has its wires connected.

  • Page 37: Tables, Charts, & Diagrams

    TABLES, CHARTS, & DIAGRAMS Table 1 Standard Pipe Sizes and Schedules PIPE O.D. Pipe Schedules and Wall Thickness SIZES XX STRONG 0.405 0.400 0.050 0.068 0.095 0.540 0.500 0.070 0.088 0.119 0.675 0.500 0.070 0.091 0.126 0.840 0.700 0.080 0.109 0.147 0.188 0.294...
  • Page 38 Table 3 ARC LENGTH TABLE EXAMPLE: Arc Length = Constant x Bend Radius. Example: 90deg bend with 6” clr EXAMPLE: 1.575 (from table) x 6” (clr) = 9.45” (Arc Length) For bends more than 90deg, Constants can be added together. Degrees Constant Degrees...

  • Page 39: Diagram 1

    Diagram 1...

  • Page 40: Diagram2

    Diagram2...

  • Page 41: Parts Diagram

    PARTS DIAGRAM Base Assembly Parts Diagram and List Item Part Number Description Qty. M150-5A014 Upright, Base PP-0035 1" Set Screw Collar PP-0064 8" Rubber Wheel PP-0043 1.0”ID x 1.1875”OD x 0.75” Lg Bushing PP-0048 4.0” Inch Caster Imperial 3/8-16 x 1 Carriage Bolt Imperial 3/8 Flatwasher Imperial...

  • Page 42: Main Tube Assembly Parts Diagram And List

    Main Tube Assembly Parts Diagram and List Item Part Number Description Qty. M150-6A013 Main Tube Imperial 3/8-16 X .75 FHCS M150-7A015 Flanged Sleeve Bushing PP-0294 Flanged Sleeve Bearing .25-28 Grease Zerk Straight Grease Zerk...

  • Page 43: Base And Power Unit Parts Diagram

    Base and Power Unit Parts Diagram...

  • Page 44: Cylinder Assembly Parts Diagram

    Cylinder Assembly Parts Diagram...

  • Page 45: Controller Housing Assembly Parts Diagram

    Controller Housing Assembly Parts Diagram...

  • Page 46: Swing Arm Assembly Parts Diagram

    Swing Arm Assembly Parts Diagram...

  • Page 47: Parts List

    Parts List Item Part Number Description Qty. ASSYMBLY M175 POWERUNIT ASSEMBLY Imperial 5/16 FLATWASHER M150-6A035 CROSS BAR M175-6A016 RISER Imperial 3/8 FLATWASHER M150-5A006 MAIN TUBE ASSEMBLY PP-1430 17MM HEX KEY PP-1494 20 MM SET SCREW COLLAR ME-M175-6A060 TUBE MOUNT (METRIC) M175-7A007 PIVOT POST PP-0403...
  • Page 48 Item Part Number Description Qty. M150-7A014 TOP BUSHING .25-28 GREASE ZERK STRAIGHT GREASE ZERK ME-M150-5A005 TORQUE ARM (METRIC) M150-6A019 5/8 DRIVE KEY ME-M175-7A005 SPINDLE PP-1071 3/4" DOWEL PIN M12 x 1.75 x 50 SHCS ME-M175-6A004 TIE BAR (SHORT METRIC) ME-M175-6A008 TIE BAR (LONG METRIC) ME-M150-7A011 SPACER SHAFT (METRIC)
  • Page 49 Item Part Number Description Qty. PP-1294 EUROPEAN ON/OFF SWITCH M4 x 0.7 x 10 SHCS M20 x 2.5 x 70 SHCS ME-M300-7A003 CENTER PIN M20 x 2.5 x 110 SHCS PP-1186 .5 x 1.5 SPRING...
  • Page 50 NOTES...
  • Page 51 NOTES...
  • Page 53 General Machinery Safety Instructions Machinery House requires you to read this entire Manual before using this machine. 1. Read the entire Manual before starting 14. Use correct amperage extension cords. machinery. Machinery may cause serious injury if Undersized extension cords overheat and lose not correctly used.
  • Page 54 Elec/Mech Pipe/Tube Bender Safety Instructions Machinery House requires you to read this entire Manual before using this machine. 1. Maintenance. 10. Avoiding Entanglement. Make sure the Pipe/Tube Bender Pipe/Tube Bender guards is turned off and disconnect from the main power must be used at all times.

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