Table of Contents
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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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Table of Contents
Related Manuals for BendPak 1502-BAS
Summarization of Contents
Shipping Damage and Safety
SHIPPING DAMAGE CLAIMS
Procedure for reporting damage discovered upon receipt of equipment.
BE SAFE
General safety precautions and warnings for operating the bender.
Warranty Information
WARRANTY
Details the manufacturer's warranty terms and conditions for the bender.
Specifications and Delivery
SPECIFICATIONS
Technical specifications for various Bender models.
UPON DELIVERY
Initial checks and procedures upon receiving the new bender.
Safety and Initial Setup
IMPORTANT SAFETY INSTRUCTIONS
Crucial safety warnings and procedures to follow before operation.
INTRODUCTION TO BENDER
Overview of the bender's capabilities and basic function.
DEFINITION OF TERMS
Explanation of key components and features of the bender.
Machine Components and Controls
BENDER MODELS
Description of available Bender models and their features.
FRAME CONFIGURATION
Details on the frame configurations for different Bender series.
CONTROL FEATURES
Explanation of control features for different Bender models.
INSTALLING THE ELECTRICAL PLUG
Instructions for safely installing the electrical plug.
Initial Operation and Tooling
TURNING YOUR NEW BENDER ON
Step-by-step guide for powering on the bender.
TOOLING
Identification and description of various bending and swaging tools.
TYPICAL END FINISHING
Illustrations of common end finishing operations.
Segment Expander Operations
SEGMENT EXPANDER TYPES
Overview of different types of segment expanders available.
STANDARD SEGMENT SETS
Description of standard segment sets for straight expansions.
MANIFOLD FLANGE SEGMENT SETS
Description of segment sets for manifold flange creation.
BALL-JOINT SEGMENT SETS
Description of segment sets for ball-joint expansions.
FLARE SEGMENT SETS
Description of segment sets for making 45-degree flares.
Digital Control Operations
DIGITAL CONTROL OPERATIONS. "BA" MODELS.
Detailed explanation of digital control board operations.
DESCRIPTION OF CONTROLS
Key for understanding the functions of digital control board buttons.
USING THE REMOTE FOOT SWITCHES OR AUTO BUTTON
Guide to using foot switches and auto button for bending.
PROGRAMMING THE DIGITAL BOARD
Instructions for programming bend data into the digital board.
Three-Button Control Operations
THREE-BUTTON CONTROL OPERATIONS "BAS" MODELS
Explanation of operations for BAS models with three-button controls.
DESCRIPTION OF CONTROLS
Key for understanding the functions of the three-button control board.
USING THE "AUTO-STOP" DEPTH-OF-BEND FEATURE
Guide to using the auto-stop depth-of-bend feature.
Manual Control Operations
OPERATING THE MANUAL KNEE CONTROL. "BL" / BULLET MODELS
Instructions for operating the manual knee control on BL models.
BENDING OPERATIONS
Overview of the two main bending styles: program card and pattern bending.
USING THE PROGRAM CARDS
Instructions for using program cards for specific bending applications.
Program Card Bending
DEFINITION OF CARD SECTIONS
Explanation of the different sections found on a program card.
BENDING INSTRUCTIONS
Details on die selection and setup for program card bending.
Pattern Bending Method
PATTERN BENDING
Procedure for duplicating pipes using a master pattern.
Specialized Bending Procedures
THREE INCH TUBE BENDING PROCEDURE
Specific instructions for bending three-inch diameter tubing.
BENDING STAINLESS TUBING
Adjustments required for successfully bending stainless steel tubing.
END FINISHING OPERATIONS
General precautions and overview of end finishing.
USING THE INTERNAL EXPANDER
Instructions for using the internal expander with segment sets.
Swager Box and Tool Operations
USING THE SWAGER BOX
Overview of the swager box for tube end finishing.
USING THE "STED" EXPANDER DIES
Instructions for using STED expander dies for swaging.
MAKING STRAIGHT EXPANSIONS
Steps for creating straight expansions using STED dies.
USING THE STED EXPANDER DIES OR THE B-212 TO MAKE MALE BALL EXPANSIONS
Procedure for making male ball expansions with STED dies or B-212.
Specific End Finishing Tools
USING THE BFED TOOLS TO MAKE FEMALE BALL EXPANSIONS
Instructions for using BFED tools to create female ball expansions.
USING THE HPF-300 TOOL TO MAKE 45 DEGREE FLARES AND FLAT FLARES
Steps for making 45-degree and flat flares with the HPF-300 tool.
USING THE HPF-300 TO MAKE A MANIFOLD FLANGE
Procedure for creating manifold flanges using the HPF-300 tool.
USING THE CFT TO MAKE A MANIFOLD FLANGE
Instructions for making manifold flanges with the CFT tool.
Specialized Tube End Finishing
USING THE REDUCING TOOLS
Steps for reducing or shrinking pipe ends to exact diameters.
USING THE DOMING DIE TO FINISH TAILPIPE ENDS
Procedure for using the doming die to finish tailpipe ends.
USING THE HCT-214/212
Instructions for making header flanges or collectors.
Maintenance Schedule
MAINTENANCE
Overview of maintenance to ensure performance and longevity.
HYDRAULIC OIL
Checking and maintaining the hydraulic oil level.
RECOMMENDED WEEKLY MAINTENANCE
Routine weekly tasks for bender upkeep.
RECOMMENDED MONTHLY MAINTENANCE
Monthly tasks for bender upkeep and inspection.
Pressure Settings and Adjustments
PRESSURE SETTINGS
Description of critical pressure settings affecting bender performance.
BACK PRESSURE
Explanation and adjustment of back pressure settings.
RETURN PRESSURE
Explanation and adjustment of return pressure settings.
SYSTEM PRESSURE
Checking and adjusting the overall system pressure.
Component Alignment and Wear
LEVELING THE GUIDE PLATE WITH THE BACK GATES
Procedure for checking and leveling the guide plate.
VISUALLY CHECKING THE BARREL BUSHINGS FOR WEAR
Inspection guide for barrel bushings to detect excessive wear.
ALIGNING THE SWAGER BOX CYLINDER
Steps for checking and aligning the swager box cylinder.
CHECKING THE PUSHER BLOCK FOR WEAR
Procedure to check the pusher block for wear or misalignment.
Calibration Procedures
CALIBRATING THE DEPTH-OF-BEND PLATE / "BL" (BLUE-BULLET) AND "BAS" MODELS
Calibrating the depth-of-bend plate for BL and BAS models.
CALIBRATING THE AUTOMATIC DEPTH-OF-BEND SWITCH / “BAS” MODELS
Calibrating the automatic depth-of-bend switch on BAS models.
CALIBRATING THE DIGITAL READOUT DISPLAY / "BA"MODELS
Procedure for calibrating the digital readout display on BA models.
USING THE JUMPER BOARD
Instructions for using the jumper board for diagnostics.
Electrical Systems and Components
OPERATING THE MACHINE MANUALLY USING THE ELECTRIC SOLENOID VALVE
Manual operation of the top cylinder via the solenoid valve.
SOLENOID VALVE MAINTENANCE
Maintenance and troubleshooting for the solenoid valve.
CHECKING THE MICRO SWITCHES / AUTOMATIC MODELS
Testing micro switches for proper function in automatic models.
MOTOR CONNECTIONS
Wiring diagrams and instructions for motor lead connections.
Electrical and Mechanical Checks
MANUAL ELECTRIC STARTER
Information on the manual electric starter and its components.
TO CHECK FOR PROPER ROTATION
Procedure for checking and verifying motor rotation direction.
HYDRAULIC CYLINDERS
Notes on hydraulic cylinder effectiveness and service life.
RECOMMENDED MAINTENANCE
General recommended maintenance practices for the bender.
Troubleshooting and Diagnostics
TROUBLESHOOTING GUIDE
Table of common symptoms, causes, and corrective actions.
HELPFUL DIAGNOSTIC TIPS FOR DIGITAL MODELS
Specific diagnostic tips for digital control system issues.
COMMON BENDING PROBLEMS
Analysis of common bending issues and their causes.
Electrical Wiring Diagrams
Electrical Wiring Diagram for Three Button "BAS" Models
Wiring diagram for BAS model benders with three-button controls.
Electrical Wiring Diagram for Digital "BA" Models
Wiring diagram for BA model benders with digital controls.
Parts and Die Packages
SERVICE PARTS LIST
List of available part numbers and their descriptions.
DELUXE 302 DIE PACKAGE
Contents of the Deluxe 302 die package.
ECONOMY 202 DIE PACKAGE
Contents of the Economy 202 die package.
BB-1 DIE PACKAGE FOR BLUE BULLET BENDER
Contents of the BB-1 die package for Blue Bullet benders.
BB-2 DIE PACKAGE FOR BLUE BULLET BENDER
Contents of the BB-2 die package for Blue Bullet benders.
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