Valken TB-500 Operating Manual

Rotary draw bender

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ROTARY DRAW BENDER

MODEL:TB-500

OPERATING MANUAL

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Summary of Contents for Valken TB-500

Page 1 ROTARY DRAW BENDER MODEL:TB-500 OPERATING MANUAL...
Page 2: Table Of Contents
CONTENTS 1. INTRODUCTION 2. SAFETY PRECAUTIONS 3. UNPACKING 4. ASSEMBLY INSTRUCTIONS 5. MA INTENANCE 6. OPERATION 7. MATERIAL LAYOUT 8. BENDING SUGGESTIONS 9. PIPE BENDING AND TUBE BENDING DIAGRAMS 10. GLOSSARY OF COMMONLY USED TERMS 11. DRAWING AND PART LIST...
Page 3: Introduction
1. INTRODUCTION You have made a practical choice in TTMC an Model TB-500 Pipe and Tube Bender. It has been carefully built of high quality materials and designed to give many years of efficient service. The simplicity of design and...
Page 4: Safety Precautions
descriptions for attention. These matters for attention contain the essential information to the Operators while Operating and maintaining. Failure to follow these instructions may result in great damage on the machine or the Operator. 2. SAFETY PRECAUTIONS Safety Guide 2.1 Read this manual before Operating the machine 2.2 Keep this manual handy for answers to any questions you may have.
Page 5: Unpacking
watches, jewelry and loose fitting clothing for their own protection while operating the machine. 2.9 There must be no obstacles to obstruct the operator while in the working area. 2.10 If machine is going to be left unattended, the handle should be removed.
Page 6 floor. 4.3 After the stand welding is fastened to the floor the main machine can be assembled Begin by a gathering all of the parts and lay them out as shown below 4.5 Before the major components can be assembled, you must pre-assemble some components.
Page 7 4.6 Locate the mid-plate #2 and install the threaded lower bushing #17 as shown below and in M050-EV2. 4.7 Install the bronze pivot bushing #13 and one of the blue thrust washers #12 onto the threaded lower bushing as shown below. Coat the inside and outside of the pivot bushing and the blue thrust washers with general purpose grease.
Page 8 4.8 Locate the latch drive bars (upper #9 and lower #11) making sure the bumper pins are installed along with the snap rings. 4.9 Install upper drive bar #9...
Page 9 4.10 Install another blue thrust washer as shown below 4.11 Next install the ratchet wheel # 1 onto the lower pivot sleeve. Note the orientation of the ratchet wheel because it can be put on backwards. Orient as shown below.
Page 10 4.12 Install another blue thrust washer as shown below 4.13 Install the latch drive bar (lower) #11 orienting as shown...
Page 11 4.14 Install another blue thrust washer as shown below 4.15 Locate the bottom plate #3 and slide onto the threaded sleeve as shown below. Make sure the short bumper pin is installed in the bottom plate as shown 4.16 Locate the large locknut #14 and thread it onto the threaded sleeve as shown below...
Page 12 4.17 Using two people grab the partially assembled ratchet wheel assembly and flip it over lowering it onto the stand. Install the (4) 3/8-16 x 1” bolts and lock washers. Your assembly should look like the picture below.
Page 13 4.18 Next the top frame section can be assembled; use dwa # M050-EV4 Locate the (2) remaining thrust washers (#9). the top plate (#1) upper pivot bushing (bronze) (#10). hook drive plate (#2) and the 1 -1/2” snap ring (#15). Insert the pivot bushing into the top plate.
Page 14 4.19 Install the bronze bushing as shown below. 4.20 Install one of the blue thrust washers as shown below.
Page 15 4.21 Install the hook drive Plate. This must be oriented correctly as it can be put on backwards, see picture below 4.22 Install the remaining thrust washer and finally the 1-1/2” snap ring. 4.23 Locate the plate spacer (#4) and the rectangular spacer (#11) and fasten them to the ratchet wheel using 5/8-11 x 1-1/2 with lock washers, as shown below.
Page 16 4.24 Locate the 3 Iong spacers (#3). short spacer (2) 3/4-10 x 6.5 HHCS. and (1) 3/4-10 x9.0 HHCS with lock washers. Install the top plate assembly spacers and bolts as shown below. Do not tighten any of the main bolts yet. 4.25 Now that the majority of the machine is built, the drive lever section can now be assembled, use dwa #M050-EV3.
Page 17 4.26 Set this assembly aside and continue with the latch drive bars from the last step. Locate spacer (#6) and bolt the drive bars together with the 3/8-16 x 1 -3/4” flat head screw 4.27 Install snap ring onto shaft (#11) and slip through drive link end hole through middle and bottom plates.
Page 18 4.28 Locate lock tabs (#7). Spacer (#8). 5/8” drive pin (#5). install a 5/8” snap ring onto shaft (#5). slip shaft through holes in lock tab. upper drive lever slots and then lower drive lever slots and finally the latch plate. Install the 5/8” lower snap ring onto shaft 4.29 Install pivot pin (#12) through drive link, lock tab slots.
Page 19 Install snap rings on both sides, as shown below. 4.30 Next the anti spring back lever can be pre assembled, using dwa #M050-EV-4 locate the anti spring back lever (#7). pivot block (#8). 1/ 2 -1 3 x 1 -3/4 hex bolt. 1/2” lock. (2) 1/2” washers and (2) 5/ 1 6 x 1 hex bolts 4.31 Install on the machine as shown below...
Page 20 4.32 Install the lower latch plate as shown using (2) 1/4-20x3/4” screws...
Page 21 4.33 Install 3 springs and 6 screws as show below...
Page 22 4.34 The remaining pins can be installed in their respective locations. Each pin will get a snap ring installed onto its groove 4.34.1 Main die pin 1” dia. 4.34.2 Counter die pivot pin 1 -1/4” dia. 4.34.3 Die drive pin 7/8” dia. 4.34.4 Hook strap pin 3/4”...
Page 23: Ma Intenance
torgue the lower special hex nut to 80 ft lbs. After tightening. all pins should slide in and out easily. (DO NOT TRY TO BEND ANYTHING UNTIL ALL BOLTS ARE TIGHT) 4.36 Finally the pointer. pointer clamp and hand knob can be installed as shown below 5.
Page 24: Operation
inexpensive to replace. The machine will function with worn bushings so it is up to the owner to determine when they need replacing 6. OPERATION 6.1 Bending and dry running 6.1.1 before actually bending. Several “dry runs” should be performed to familiarize yourself with all of the machine functions. 6.1.2 Keep hands a way from the bending zone.
Page 25 6.1.8 without material in the machine. pull on the ratchet wheel clockwise, you will hear a “click” every time the lever is cycled through one stroke in speed 1. Return the lever counter clockwise and you will hear another "click". You just engaged another tooth on the ratchet wheel, continue though these cycles and you can “bend”...
Page 26 sleeve aligning the start of bend with the”0” mark on the die. 6.1.15 Select a speed and follow the above steps and begin ratcheting the machine until the you feel tension on the pull lever, as your tubing just begins to bend. position your pointer to the “0" on the degree dial, this will compensate for most of your “spring back"...
Page 27 Choose a die. either a 120 or 240 degree variety. Locate the dies center hole with the center of the machine, install the 1” diameter main die pin through the center, all the way until the snap ring bottoms out. Next install the 7/8”...
Page 28: Material Layout
with the machine will be used. Figure 1 Correct counter die position (Approximately 1/8”) a wav from the bend die CAUTION: It is critical that all of the pins are fully down all of the way to the snap ring. If you attempt to bend without making sure the pins are fully down machine damage will occur and this will not be covered under warranty.
Page 29: Bending Suggestions
formula: Alternate arc length formula clr x 2 x pi x degree of bend 7.1 Once the arc lengths are determined you can begin layout of the material using diagram #1 as a reference, 7.2 Diagram #1 shows a simple part bent on the same plane in the same direction 7.3 Diagram #2 shows bending based off of a centerline in two directions...
Page 30: Pipe Bending And Tube Bending Diagrams
hard and may need to be annealed or ordered in the “ T-0” condition. 8.2 HEAVY WALL DOM TUBING: if heavy wall materials are bent to a tight radius, they can tend to slip in the hook arm causing a poor bend result, below are some suggestions 8.2.1 Use a vise clamp on the outside of the hook arm to “...
Page 31: Glossary Of Commonly Used Terms
a= First bend arc angle b= Second bend arc angle A= First tangent B= Straight between bends C= Second tangent D= Tube outside diameter H= Height of offset L = Length of offset R1= First radius R2= Second radius t= Tube Wall Thickness 10.
Page 32: Drawing And Part List
Hard Way (HW) - Bending of a rectangular tube with its Iong side in the plane of the tube or pipe bend I.D. - Inside diameter of the tube or pipe bends Minimum Tangent- The minimum straight on the end of pipe bends required by the bending machine to form the bend Neutral Axis - That portion of the pipe or tube that is neither in compression or tension.
Page 33 11.1...
Page 34 Item. Name Ratchet Wheel Middle Support Plate Bottom Plate Support Spacer Tube Spacer Long Die Pin Bumper Pin Bumper Pin Drive Bar (upper) Bumper Pin Drive Bar (lower) Thrust Washer Pivot Sleeve Special Hex Nut Rectangular Spacer Degree Sticker Thread Bushing Snap Ring Snap Ring Spring Washer...
Page 35 11.2...
Page 36 Item. Name Top Support Plate Fixed Plate Spacer Tube Support Spacer Long Die Pin Short Die Pin Lever Fixed Block Thrust Washer Pivot Sleeve Rectangular Spacer Snap Ring Snap Ring Snap Ring Spring Washer Spring Washer Hex. Bolt Hex. Bolt Hex.
Page 37 11.3...
Page 38 Item. Name Drive Bar (upper) Drive Link Connecting Link Shaft Block Drive Pin Spacer Lock Tab Release Spacer Bumper Pin Drive Bar (lower) Pivot Pin Pivot Pin Die Pin Sleeve Bushing Thread Bushing Thrust Washer Sleeve Bushing Hex. Nut Sleeve Bushing Sleeve Bushing Sleeve Bushing Snap Ring...
Page 39 Note: This manual is only for your reference. Owing to the continuous improvement of the machine, changes may be made at any time without obligation on notice. And please note the local voltage while operating this electric machine.