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BendPak
INCORPORATED
OPERATION AND SERVICE MANUAL
Models
:
1000-BL
1302-BL ("Blue Bullet")
1000-BAS
1302-BAS
1000-BA
1302-BA
1502-BL
1502-BAS
1502-BA
SHIPPING DAMAGE CLAIMS
When this equipment is shipped, title passes to the pur-
chaser upon receipt from the carrier. Consequently, claims
for material damaged in shipment must be made by the
purchaser against the transportation company at the time
shipment is received.
Bend-Pak
INCORPORATED
1 Bender Operation Manual
®
®
Revision 90196
FORWARD THIS MANUAL TO ALL
OPERATORS. FAILURE TO OPERATE
THIS EQUIPMENT AS DIRECTED HEREIN
MAY CAUSE INJURY
"America's Most Popular
Tubing Bender"
BE SAFE
Bend-Pak, Inc. benders are designed and built with safety
in mind. However, your overall safety can be increased by
proper training and thoughtful operation on the part of the
operator. DO NOT operate or repair this equipment without
reading this manual and the important safety instructions
shown inside.
1645 Lemonwood Drive
Santa Paula, CA 93060 U.S.A.
Tel: 805-529-3675
Fax: 805-529-2909
Model 1502-BA
shown with typical
tooling package.
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Summary of Contents for BendPak 1000-BL
- Page 1 FORWARD THIS MANUAL TO ALL ® OPERATORS. FAILURE TO OPERATE INCORPORATED THIS EQUIPMENT AS DIRECTED HEREIN MAY CAUSE INJURY OPERATION AND SERVICE MANUAL “America’s Most Popular Models 1000-BL 1302-BL (“Blue Bullet”) Tubing Bender” 1000-BAS 1302-BAS 1000-BA 1302-BA 1502-BL 1502-BAS 1502-BA...
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Page 2: Table Of Contents
TABLE OF CONTENTS Identification Data / Warranty ............................. 3 Specifications ................................4 Important Safety Instructions............................5 Definition Of Terms / Model Identification ........................6 Installing The Electrical Plug ............................7 Turning Your New Bender On ............................8 Introduction Of Tooling Identification .......................... 8 Segment Identification Chart ............................. 11 Typical End Finishing Illustrations .......................... -
Page 3: Identification Data / Warranty
YOUR NEW BENDER This instruction manual has been prepared especially for you. Your new bender is the product of over 25 years of continuous research, testing and development and is the most technically advanced bender on the market today. READ THIS ENTIRE MANUAL BEFORE OPERATION BEGINS. The manner in which you care for and maintain your bender will have a direct effect on it's overall performance and longevity. -
Page 4: Specifications
BAS / Depth-of-Bend Plate / Automatic Bend-Depth Control ......Manual / No Automatic Stop BL / Manual Overall Length ........68” I302-BL / 65” 1502-BL Overall Length ........52” 1000-BA/1000 BAS 55” 1000-BL Overall Width ........30” I302-BL / 26” 1502-BL Overall Width ........39” Overall Height ........41”... -
Page 5: Important Safety Instructions
UPON DELIVERY 1. Carefully remove the crating and packing materials. 3. Check the voltage, phase and proper amperage requirements for the motor shown on the motor plate. 2. Inspect the bender for any signs of concealed Wiring should be performed by a certified shipment damage or shortages. -
Page 6: Definition Of Terms / Model Identification
The following definitions explain the major components There are nine different bender models available. and operating features of your machine. The RIGHT, LEFT, and REAR sides of the bender are relative to the 1000-BL 1000-BAS 1000-BA FRONT of the machine where all bending is performed. -
Page 7: Installing The Electrical Plug
1502 Series- A machine capable of bending and end fin- ishing. Equipped with both swager and internal expander. Individual hydraulic cylinders are utilized for both end fin- ishing functions. The swager and internal expander are positioned at the rear of the machine, one on each side and are positioned parallel with the main body. -
Page 8: Turning Your New Bender On
TURNING YOUR NEW few cycles due to air trapped in the lines. This is normal. The air will dissipate after use. Do not try to BENDER ON “crack” a line to help the air escape. 1. Plug the power cord into a receptacle closest to the 10. - Page 9 Half Shoe Three Quarter Shoe BACK SHOES- Back shoes, which are commonly referred to as wiper dies come in pairs and are used together with the radius dies during the bending process. These dies play an important part as their primary purpose is to form the outside radius of the bend.
- Page 10 END-FINISHING TOOLS - A variety of end finishing tools REDUCING TOOLS - Reducing tools are used for are available that perform different functions. Not every reducing or “shrinking” pipe ends to exact outside diame- tool is included with your tooling package. If you are ters.
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Page 11: Segment Identification Chart
SEGMENT EXPANDERS - Segment expanders or “seg- Keep segment sets and arbor well greased. ment sets” come in a variety of sizes and shapes, each The ARBOR which is pulled through the center of the seg- performing it's own distinct function. Segment sets are ment sets is available in two sizes. -
Page 12: Typical End Finishing Illustrations
DIGITAL CONTROL DESCRIPTION OF OPERATIONS. CONTROLS: “BA” MODELS. SELCT - Selects KEYPAD or MEMORY functions. CLEAR - Clears the SET ANGLE. ENTER - Enters the numbers displayed in SET ANGLE STOP! Before any attempt is made to operate this machine into memory. -
Page 13: Operating The Digital Control Board (Ba Models)
4. After installing a matched die set, position the tubing WARNING! 1. Either foot switch will act as an EMERGENCY so that you can begin bending. stop. 5. Check your “circle-of-swing” for allowable clearance. 2. NEVER operate the remote electric foot switches 6. -
Page 14: Description Of Three-Button Control ((Bas Models)
DESCRIPTION OF 6. Repeat these steps until all depth-of-bends have been entered. Always remember to press the CONTROLS: ENTER key prior to advancing to the next station. 7. Now press the SELCT key to illuminate the MEMORY NEVER HOLD IN COLORED CONTROL BUTTONS! - light. -
Page 15: Operating The Manual Knee Control (Bl / Bullet Models)
To use the three-button automatic controls, follow these simple instructions. 1. Position the “Auto-Stop” pointer at the desired depth of bend. 2. Position the tubing at the appropriate bend mark. 3. Check your “circle-of-swing” and prepare to begin bending. 4. Press the GREEN control button. 5. - Page 16 Sample card layout to be used in conjunction with bending instructions. Take down the number of the pipe to be bent, find and BENDING INSTRUCTIONS - Shows what radius die will remove it from the deck. Remember to place a marker of be used in addition to other tooling such as half shoes some type in its place.
- Page 17 4. Using the program card, refer to the section marked NOTE: CENTER MARKS for the list of measurements in The weld seam on the tubing should be directly in line inches where the different bends will be made. Each with the ZERO mark at this time. (See figure 2-A) CENTER MARK is measured from the left end of the tubing.
- Page 18 The ROTATION DIAL degree plate MUST NEVER be moved after bending has begun. ALWAYS be prepared to support the tubing as it is released from the dies to prevent it from hitting the ground. If the dial is accidentally moved during the bending process, re-position the dial so that the ZERO mark is located at the weld seam of the tubing, or return to the previous bend and position the pendulum point-...
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Page 19: Pattern Bending
Figure 3-C 22. Review the SYMBOLS section of the card and check for any special instructions. 23. On bend number four you will notice that a REVERSE USE HALF SHOE is again called for. Keep the ROTATION DIAL on the LEFT side for this bend. 24. -
Page 20: Blank Program Card
(This blank card may be used to make additional copies) 7. You are now ready to make your first bend. Place the Figure 1-A first bend of the master pipe or wire flat on top of the back shoes. Hold in this position. Gradually extend the radius die forward until the gates start to open and the tubing begins to bend. -
Page 21: Three Inch Tube Bending Procedure
NOTE: Figure 2-A Repeat these steps for the remaining bends. After all bends are completed, make the necessary end finishing and take a measurement for the overall cut off length. Be sure to make all notations on the blank program card for later reference. -
Page 22: Stainless Tube Bending Procedure
BENDING STAINLESS TUBING In order to get good results when bending stainless tubing, it is necessary to increase the back shoe pressure by adjusting the sequence valve similar to the procedure previously described. The recommended pressures are shown below. When using large diameter or light gauge tubing, more back shoe pressure is required. -
Page 23: Using The Standard Segment Expanders
USING THE STANDARD SEGMENT EXPANDERS - There are five standard segment sets included with your bender. Each segment set is designed to be used with a particular size tubing only. The appro- priate sizes are shown below. Standard segment sets are used for making straight expansions. -
Page 24: Using The Ball-Joint Segment Expanders
Lift the valve handle up until the arbor extends and Depress the valve handle to form the ball on the end the segment set is released. of the tubing. Be careful not to distort the end of the 10. Check the finished expansion end by placing it over tubing. -
Page 25: Using The Manifold Flange Segment Expanders
2. Place the tubing over the arbor and segment set, but 3. Position the tubing over the arbor and segment set DO NOT place the end of the tubing past the last until the tubing meets the shoulder. step on the segment set. (See figure 1-A) 4. -
Page 26: Making Male Ball Expansions
MAKING STRAIGHT EXPANSIONS - Follow these steps 7. After the tubing has been expanded, retract the die to produce straight expansions using the STEP expander by lifting up on the control handle. dies. (See chart on page 12 for typical end finishing 8. -
Page 27: Making Female Ball Expansions
4. Leave at least three inches of tubing extended Figure 3-A beyond the inside edge of the adapter collar. (See figure 2-B) Figure 2-B 11. Slowly move the tool forward until the desired ball is achieved. This procedure requires careful control. (See figure 1-B) 5. -
Page 28: Making A Manifold Flange Using The Hpf-300 Tool
4. Leave at least three inches of tubing extended Figure 2-B beyond the inside edge of the adapter collar. (See figure 1-A) Figure 1-A 12. Retract the die by lifting up on the control handle. 13. Separate the collar from the tubing. Remove tooling and return to the storage area. - Page 29 5. Snug the collar back into the clamp blocks by gently CAUTION! pushing back on the collar assembly. Pay careful attention when performing the following 6. Slowly, while depressing the valve handle down, steps. KEEP HANDS CLEAR from all pinch points. move the shaft forward until the tool enters the tubing.
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Page 30: Making A Manifold Flange Using The Cft Tool
USING THE CFT TO MAKE A MANIFOLD FLANGE. 8. Retract the die by lifting up on the control handle. 9. Separate the collar from the tubing. Remove tooling IMPORTANT NOTE: and return to the storage area. When making a manifold flange it is necessary to USING THE REDUCING TOOLS - Reducing tools are first install the pipe flange or clamp around the tube prior to finishing the ends. -
Page 31: Using The Doming Die To Finish Tailpipe Ends
8. Retract the die by lifting up on the control handle. 7. Slowly, move the tool forward until the desired finish (See figure 2-C) is achieved. (See figure 1-A) Figure 2-C Figure 1-A 9. Separate the collar from the tubing. Remove tooling 8. -
Page 32: Maintenance Introduction
5. Snug the collar back into the clamp blocks by gently pushing back on the collar assembly. 6. Slowly, while depressing the valve handle down, move the shaft forward until the tool enters the tubing. Be sure that the tool is centered with the tubing. -
Page 33: Pressure Settings
NOTE: 5. If an adjustment is required, loosen the locking nut Loose hoses and hydraulic components will not that secures the adjusting screw. always show a visual sign of leakage, however 6. To increase the pressure, turn the adjusting screw they can cause aeration of the system by clockwise;... -
Page 34: Chain Adjusting Procedure
If the return pressure needs adjusting, proceed as follows. To check and adjust the system pressure, proceed as follows. 1. Turn the machine on. 1. Turn the machine on. 2. Place a radius die and set of back shoes in 2. -
Page 35: Aligning The Guide Plate
LEVELING THE GUIDE PLATE WITH THE BACK GATES The back gates and guide plate have been precisely lev- eled at the factory and should seldom require adjust- ment. If however, the guide plate becomes unlevel with the back gates, the bending dies will become misaligned and cause the tubing to wrinkle. -
Page 36: Barrel Bushing Maintenance
6. It will not be necessary to loosen the rear most bolt ` Figure 2-C on the guide plate for this service. 7. Using a pry bar, elevate the front of the guide plate. (See figure 2-A) 2. Remove the barrel shaft nut located below the left side gate assembly. -
Page 37: Aligning The Swager Box Cylinder
7. Visually check bronze bushings for excessive wear. 5. Hold the tubing securely making sure that the Replace bushings if inside diameter is greater than HAC-300 is square within the clamp blocks. 2.005” or more. (See figure 3-A) 6. Advance the tool forward until it just makes contact with the tubing. -
Page 38: Pusher Block Maintenance
Figure 1-A Check to see if the pusher block is square to the guide 12. Shim the swager cylinder as necessary by inserting shim stock between the cylinder end block and the swager box until proper alignment is achieved. (See figure 1-B) Figure 1-B plate as illustrated below. -
Page 39: Calibrating The Depth-Of-Bend Plate Manual Models
CALIBRATING THE AUTOMATIC 3. Remove the pusher block by sliding it to the rear end DEPTH-OF-BEND SWITCH / “BAS” MODELS then off of the guide plate. 4. Carefully re-install the new pusher block (it should be tight) by reversing these steps. Before attempting the following, fIrst calibrate the depth- 5. -
Page 40: Calibrating The Digital Readout Display (Ba Models)
5. Loosen the set screw on the adjustable trip arm Figure 13-C located directly underneath the depth-of bend plate and adjust so that it just activates the micro switch. 6. Re-tighten the set screw. 7. Retract the radius die and re-check. 8. -
Page 41: Using The Jumper Board Ba Models
USING THE JUMPER BOARD 4. Read the degree of bend shown in the DIE ANGLE window on the control board and make the following adjustments. All “BA” models have a bypass device or “jumper board” included that can be used to effectively bypass the digital control board for trouble shooting or diagnostic purposes. -
Page 42: Operating The Machine Manually Using The Solenoid Valve
5. With the jumper board in place, movement of the The manual buttons control the top cylinder as follows; radius die will be controlled by the twin foot switches To advance the radius die - Press the right button only. There will be no provision for depth-of-bend inward using an insulated tool or non-conducting rod. -
Page 43: Checking The Micro Switches (Automatic Models)
The following section contains instructions and WITH THE LEVER OR BUTTON DEPRESSED - Place illustrations to aid in electrical repair. Most electrical one of the prongs from your ohmmeter on the “common” components cannot be repaired and require only removal terminal of the switch and the other on the “normally open”... -
Page 44: Checking Motor Rotation
MANUAL ELECTRIC 380 VoIt 50HZ Three Phase Incoming Power Motor Leads STARTER Line 1 1 and 7 Line 2 2 and 8 Line 3 3 and 9 The electric starter box on your bender uses movable Twist together 10, 11,12 contacts activated by a push button mechanism. -
Page 45: Trouble Shooting Procedures
TROUBLESHOOTlNG Introduction; The troubleshooting procedures shown on the following pages contain certain systems and/or conditions, possible causes and the corrective actions required. The chart gives the easiest corrective action first, then proceeds with more difficult procedures. Be certain that the person(s) working on the machine have the ability to do the service. Only certified electricians should work on electrical components. - Page 46 SYMPTOM / CONDITION POSSIBLE CAUSE CORRECTIVE ACTION BAS models - The bending ram The rear limit switch is malfunctioning. Check wire connections on the rear limit continues retracting even after the rear switch. Refer to diagram on page 50. limit switch is activated. Pressure builds Check micro switch with ohmmeter as up on the sequence valve gauge.
- Page 47 HELPFUL DIAGNOSTIC TIPS FOR DIGITAL MODELS If you feel a control problem exists with the main circuit panel, the jumper board can be used to temporarily bypass the complete control board assembly until repairs are made. (See page 41) If the top cylinder advances or retracts by itself without activating any controls and you feel the problem exists with the front display panel due to cuts or other damage, disconnect it from the main circuit panel by unplugging it from the blue wire ribbon.
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Page 48: Bending Problems
BENDING PROBLEMS Bending complications can be usually attributed to tubing thickness, tubing quality or improper radius selection. The bigger the tubing diameter, the bigger the radius and wall thickness should be. See the chart below for minimum tubing thickness and proper radius selection. Tubing Diameter Minimum Tubing Thickness Minimum Tubing Thickness... -
Page 49: Electrical Wiring Diagrams (Models Ba & Bas)
49 Bender Operation Manual Bender Operation Manual 49... - Page 50 50 Bender Operation Manual...
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Page 51: Service Parts
SERVICE PARTS PART NUMBER DESCRIPTION Oil Filter Element Filter Head Pressure Gauge Leaf Chain Section 5/16” Chain Bolt Chain Return Bolt 1040 Adjustable Chain Connector Springs For Pusher Block 1022 Pusher Block 1024 Guide Plate 1041 Chain Return Block 1034 Depth-of-Bend Plate 1034-A Rotation Dial Faceplate... -
Page 52: Deluxe 302 Die Package
DELUXE 3O2 DIE PACKAGE QTY. PART NO. SIZE TOOLING DESCRIPTION BENDING TOOLING 5R-212 2-1/2” / 63.5mm 5” / 127mm Radius Die 5R-214 2-1/4” / 57mm 5” / 127mm Radius Die 5R-200 2” / 50.8mm 5” / 127mm Radius Die 4R-214 2-1/4”... -
Page 53: Economy 202 Die Package
ECONOMY 2O2 DIE PACKAGE QTY. PART NO. SIZE TOOLING DESCRIPTION BENDING TOOLING 5R-212 2-1/2” / 63.5mm 5” / 127mm Radius Die 5R-214 2-1/4” / 57mm 5” / 127mm Radius Die 5R-200 2” / 50.8mm 5” / 127mm Radius Die 4R-214 2-1/4”... -
Page 54: Die Package For Blue Bullet
BB-1 DIE PACKAGE FOR BLUE BULLET BENDER QTY. PART NO. SIZE TOOLING DESCRIPTION BENDING TOOLING 5R-212 2-1/2” / 63.5mm 5” / 127mm Radius Die 5R-214 2-1/4” / 57mm 5” / 127mm Radius Die 5R-200 2” / 50.8mm 5” / 127mm Radius Die 4R-214 2-1/4”... -
Page 55: Die Package For Blue Bullet
BB-2 DIE PACKAGE FOR BLUE BULLET BENDER QTY. PART NO. SIZE TOOLING DESCRIPTION BENDING TOOLING 5R-212 2-1/2” / 63.5mm 5” / 127mm Radius Die 5R-214 2-1/4” / 57mm 5” / 127mm Radius Die 5R-200 2” / 50.8mm 5” / 127mm Radius Die 4R-214 2-1/4”... - Page 56 Notes: 56 Bender Operation Manual...
- Page 57 Notes: 57 Bender Operation Manual Bender Operation Manual 57...
- Page 58 To Expedite Service FAX YOUR ORDER 1-805-933-9160 Or Dial Direct 1-805-933-9970 BendPak also provides quality Above Ground Lifts to the automotive industry. Call for details and brochure 58 Bender Operation Manual...
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