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Baileigh Industrial MB-4X2, Operator'S Manual

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OPERATOR’S MANUAL

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

RECTANGULAR TUBE MANDREL BENDER 

MODEL: MB-4X2 

 
 
 
 
 
 
 
 
 
 
 

© 2016 Baileigh Industrial, Inc. 

REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL, INC. 
IS PROHIBITED. Baileigh Industrial, Inc. does not assume and hereby disclaims any liability for any damage or loss 
caused by an omission or error in this Operator’s Manual, resulting from accident, negligence, or other occurrence. 

Rev. 08/2016 

Baileigh Industrial, Inc. 

P.O. Box 531 

Manitowoc, WI 54221-0531 

Phone: 920.684.4990 

Fax: 920.684.3944 

[email protected] 

Summary of Contents for MB-4X2

Page 1: ...GH INDUSTRIAL INC IS PROHIBITED Baileigh Industrial Inc does not assume and hereby disclaims any liability for any damage or loss caused by an omission or error in this Operator s Manual resulting from accident negligence or other occurrence Rev 08 2016 Baileigh Industrial Inc P O Box 531 Manitowoc WI 54221 0531 Phone 920 684 4990 Fax 920 684 3944 sales baileigh com ...

Page 2: ... GUIDE 21 TOOLING REMOVAL 21 TOOLING INSTALL 21 BENDING IN SINGLE BEND MODE 25 AUTO SEQUENCE MODE 26 MULTI BEND MODE 27 BENDING ALLOWANCE 28 UNDERSTANDING SPRINGBACK 28 MATERIAL SELECTION 28 LUBRICATION AND MAINTENANCE 29 Gear Box Oil 29 Hydraulic System Maintenance 30 HYDRAULIC SCHEMATIC 31 Hydraulic Components 32 ELECTRICAL SCHEMATIC 33 Trouble Shooting 36 CART ASSEMBLY 37 MAIN FRAME ASSEMBLY 38...

Page 3: ...CONTROL BOX ASSEMBLY 46 Parts List 47 ORIGINAL PRESSURE DIE PARTS DIAGRAM 53 Original Pressure Die Parts List 54 ...

Page 4: ...e to Seller of any suspected defect in the Goods prior to the expiration of the warranty period The original end user must also obtain a RGA from Seller prior to returning any Goods to Seller for warranty service under this paragraph Seller will not accept any responsibility for Goods returned without a RGA The original end user shall be responsible for all costs and expenses associated with retur...

Page 5: ... or further remedies provided under this Agreement or at law or equity Attorney s Fees In the event legal action is necessary to recover monies due from Buyer or to enforce any provision of this Agreement Buyer shall be liable to Seller for all costs and expenses associated therewith including Seller s actual attorneys fees and costs Governing Law Venue This Agreement shall be construed and govern...

Page 6: ...Description of the functional parts of the machine Capacity charts Set up and start up instructions Machine operation Scheduled maintenance Parts lists GENERAL NOTES After receiving your equipment remove the protective container Do a complete visual inspection and if damage is noted photograph it for insurance claims and contact your carrier at once requesting inspection Also contact Baileigh Indu...

Page 7: ...es a hazard or unsafe practice that will result in severe Injury or Death Safety signs with signal word DANGER or WARNING are typically near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety messages in this manual IMPORTANT PLEASE READ THIS OPERATORS MANUAL CAREFULLY It contains important safety information instructions and necessary op...

Page 8: ...le hearing protective devices such as ear muffs or earplugs to protect against objectionable or uncomfortable loud noises BEWARE OF CRUSH HAZARD NEVER place your hands fingers or any part of your body in the die area of this machine Be aware of the area on either side of the dies for crush points created by material movement BEWARE OF PINCH POINTS Keep hands and fingers away from the drive mechani...

Page 9: ...ly injuries HYDRAULIC HOSE FAILURE Exercise CAUTION around hydraulic hoses in case of a hose or fitting failure HIGH VOLTAGE USE CAUTION IN HIGH VOLTAGE AREAS DO NOT assume the power to be off FOLLOW PROPER LOCKOUT PROCEDURES EMERGENCY STOP BUTTON In the event of incorrect operation or dangerous conditions the machine can be stopped immediately by pressing the E STOP button Twist the emergency sto...

Page 10: ... be used only for their intended use Baileigh does not recommend or endorse making any modifications or alterations to a Baileigh machine Modifications or alterations to a machine may pose a substantial risk of injury to the operator or others and may do substantial damage to the machine Any modifications or alterations to a Baileigh machine will invalidate the machine s warranty PLEASE ENJOY YOUR...

Page 11: ...k for damaged parts Before using any tool or machine carefully check any part that appears damaged Check for alignment and binding of moving parts that may affect proper machine operation 14 Observe work area conditions DO NOT use machines or power tools in damp or wet locations Do not expose to rain Keep work area well lighted DO NOT use electrically powered tools in the presence of flammable gas...

Page 12: ...ne to function properly TECHNICAL SUPPORT Our technical support department can be reached at 920 684 4990 and asking for the support desk for purchased machines Tech Support handles questions on machine setup schematics warranty issues and individual parts needs other than die sets and blades For specific application needs or future machine purchases contact the Sales Department at sales baileigh ...

Page 13: ...age painted surfaces Follow manufacturer s label instructions when using any type of cleaning product After cleaning wipe unpainted metal surfaces with a light coating of quality oil or grease for protection Important This waxy coating is NOT a lubricant and will cause the machine to stick and lose performance as the coating continues to dry WARNING SUFFOCATION HAZARD Immediately discard any plast...

Page 14: ... that all the supporting feet are taking the weight of the machine and no rocking is taking place INSTALLATION IMPORTANT Consider the following when looking for a suitable location to place the machine Overall weight of the machine Weight of material being processed Sizes of material to be processed through the machine Space needed for auxiliary stands work tables or other machinery Clearance from...

Page 15: ...e machine freely POWER SUPPLY PLACEMENT The power supply should be located close enough to the machine so that the power cord is not in an area where it would cause a tripping hazard Be sure to observe all electrical codes if installing new circuits and or outlets Anchoring the Machine Once positioned anchor the machine to the floor as shown in the diagram Use bolts and expansion plugs or sunken t...

Page 16: ...13 OVERALL DIMENSIONS ...

Page 17: ...14 ...

Page 18: ...15 ...

Page 19: ...16 ...

Page 20: ...ine with ample lighting 3 Check over parts carefully to ensure all parts are accounted for and undamaged 4 Your machine is tested by our technicians before leaving our factory 5 Inspect your machine again after it is operational Please notify us if something is missing or if damaged has occurred DIE STRUT ROD CLAMP DIE BEND DIE WIPER DIE PRESSURE DIE ASSEMBLY PRESSURE DIE TOOLING MANDREL ROD PRESS...

Page 21: ...e sure that the table is leveled using the provided foot pegs unless it is a 20 foot table in which we recommend it be fastened to the concrete 5 Attach the hydraulic hoses from the table to the corresponding parts on the machine manifold cylinder extend hose goes to port A on the manifold 6 Next connect the proximity cable to the mating plug on the machine 7 Now that the table is level and attach...

Page 22: ...ontact Running on low voltage will damage the motor In the event of a malfunction or breakdown grounding provides a path of least resistance for electric current to reduce the risk of electric shock This tool is equipped with an electric cord having an equipment grounding conductor and a grounding plug The plug must be plugged into a matching outlet that is properly installed and grounded in accor...

Page 23: ... the plug is correct and properly grounded to an earth ground The warranty is void if incorrect power is supplied to the machine 2 Have an electrician install the correct plug for the application 3 Once hooked up test the machine for proper operating direction 4 The Hydraulic pump needs to be phased Press F3 momentarily and note the direction of the hydraulic pump motor The motor should turn clock...

Page 24: ... bottom of the die Fig 4 2 Begin to lower the die onto the spindle slowly line up the center bore and rock if needed to get the die to slide down Watch the orientation so the drive key line up correctly Once completely down insert the hold down bolts and tighten to 100 ft lbs 3 Install the top clamp swing arm plate and tighten the three bolts 4 Install the strut rod and tighten just so there is te...

Page 25: ... the lower shelf of the bend die 9 Now the hydraulics can be turned on on the control press the Pump Off switch to turn the power unit on Fig 6a Fig 6a Pump off screen Fig 6b Pump on screen 10 The Home position needs to be set so press the Jog Spindle tab Fig 6b 11 With the foot pedals press the left pedal or reverse until the bend cylinder is dead headed in reverse Press and hold the set home but...

Page 26: ... causing damage Adjust the micro switch if needed 16 Double check the pressure die clearance from the face of the material to the pressure die face there should be at least 8 1 2 if not using a 2 wrench adjust the pressure die nut 17 When there is sufficient clearance select pressure die and press extend Fig 7 Single bend home screen All axis retracted 18 Now you can adjust the pressure die right ...

Page 27: ...mandrel setting is critical so the body of the mandrel needs to protrude PAST the tangent line of the die set this using a straight edge Fig 9a b After successful bends have been completed the mandrel position could be documented from the back of the mandrel body to a known spot on the machine for ease of set up Fig 9a Notice the marker line on the die that is the tangent line Fig 9b Notice how th...

Page 28: ...xtend 6 And finally pressure die Extend 7 All of the green indicator lights on the controller need to all read Extend This is to ensure all of the axis are in the proper position for bending 8 Select the amount of degrees desired for the bend and enter a spring back value 9 The machine and material are now ready to be bent press the Forward pedal and the bend die will rotate and produce the bend 1...

Page 29: ... arm 15 The tubing can now be advanced Rotated as needed and positioned for the next bend AUTO SEQUENCE MODE 1 In Auto sequence mode the hydraulic axis s will operate automatically and in the correct order but before using auto sequence the first one or two bends must be proven in manual mode to make sure all of the settings are correct Fig 11 2 Before activating auto sequence be sure the material...

Page 30: ...is created and selected you can run the program and bend the part again Never activate the auto bend sequence without material installed 5 Install material and position the start of bend to the 0 or centerline axis of the machine 6 Press the auto sequence button and agree if you already made successful bends The axis will automatically clamp just like described in the single bend mode 7 Press the ...

Page 31: ... to return to its original shape after undergoing compression and stretch After the bending leaf is removed from the metal and the load is released the piece part relaxes forcing the bent portion of the metal to return slightly to its original shape The key to obtaining the correct bend angle is to over bend the metal a little and allow it to spring back to the desired angle All metals exhibit a c...

Page 32: ... lubricated with light hydraulic oil or equivalent Check for any worn or damaged parts and replace immediately Quarterly There are two grease zerks on the machine that feed the main spindle bearing Grease these zerks every three months with 3 4 pumps from a standard grease gun Note Proper maintenance can increase the life expectancy of your machine Gear Box Oil The main Planetary Gear Box is lubed...

Page 33: ...pressure is reached There are two gauges one for system pressure and one for clamp die pressure The only hydraulic circuit that is adjustable is the clamp die adjust pressure by loosening the locknut and rotate center screw until desired pressure is reached The clamp die pressure cannot exceed the system pressure Figure 2 System pressure gauge Figure 3 Clamp Die Pressure Gauge Figure 4 Pressure ad...

Page 34: ...31 HYDRAULIC SCHEMATIC ...

Page 35: ...8905853 Sight Glass CS3615 200236 Lube Devices 1 130 R978810409 Gasket Bell Housing 182 Frame 1 140 R978812549 Gasket Reservoir 5gal 1 150 R978886009 Press Gauge 2 1 2 0000PUA30 11A 4 SAE 1 151 R978837839 Pressure Gauge GSV 2 1 2 0000PUA30 11A SAE 1 160 R978813582 Hydraulic Manifold D03 3 ST AL AGA8853 1 170 R900564564 Pressure Relief Valve Main ZDBK 6 VP2 1X 210V 1 180 R978800064 Bulkhead Union 8...

Page 36: ...33 ELECTRICAL SCHEMATIC ...

Page 37: ...34 ...

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Page 39: ...ie Humps on the outside of the bend Mandrel is too far forward Flat on the outside of the bend Mandrel is too far back Machine doesn t move Hydraulic conditions not met green red indicator lights Communication Failure Mandrel Lockup Not enough lube on mandrel Pressure die set to loose Clamp die slipped Mandrel is too large for the tube being bent Hydraulics do not work Hydraulic pump is off Overlo...

Page 40: ...37 CART ASSEMBLY ...

Page 41: ...38 MAIN FRAME ASSEMBLY ...

Page 42: ...39 SPINDLE STACK ASSEMBLY ...

Page 43: ...40 SWING ARM ASSEMBLY ...

Page 44: ...41 MODIFIED PRESSURE DIE ASSEMBLY ...

Page 45: ...42 STRUT BAR ASSEMBLY ...

Page 46: ...43 ENCODER ASSEMBLY ...

Page 47: ...44 MANDREL TABLE ASSEMBLY ...

Page 48: ...45 MANDREL EXTRACTION CYLINDER ASSEMBLY ...

Page 49: ...46 CONTROL BOX ASSEMBLY ...

Page 50: ...ssembly 1 14 M8 X 1 25 X 14 Hex Flange 8 15 M550 7A039 Mounting Boss 6 16 M550 7A071 Electrical Box Pivot Hub 1 17 M350 7A058 Electrical Box Washer 2 18 PP 0683 E Stop 1 19 M10 X 1 5 X 8 Set Screw 2 20 M6 FLATWASHER Std 1 21 M6 X 1 0 X 25 SHCS 1 22 1 50 EXT RETAINING RING Std 1 23 M550 5A012 Controller Box 1 24 PP 1199 5 Hole Ground Strip 1 25 PP 0029 3 Din Rail 1 26 PP 0924 Terminal Block 8 27 PP...

Page 51: ...550 Spindle 1 49 M550 7A027 Thrust Ring 2 50 PP 1561 Thrust Washer Thin 130 X 170 X 1 4 51 PP 1560 Thrust Bearing 130 X 170 X 5 2 52 M550 7A042 Custom Bushing 1 53 M550 6A079 Swing Plate Lower 1 54 PP 1562 Roller Bearing NA 4926 1 55 PP 1562 IR Inner Race 1 56 M550 7A040 Thrust Washer 1 57 M550 6A090 Hub Key 1 58 M550 5A004 Clamp Hub Weldment 1 59 1 8 X 2 75 SHCS 4 60 PP 1563 IR 140 X 100 X 40 Inn...

Page 52: ...0 6A081 Lower Engagement Slide 1 84 M550 6A082 Top Engagement Slide 1 85 M550 6A052 Lock Key 2 86 M16 X 2 0 X 25 SHCS 3 87 M12 X 1 75 X 25 SHCS 13 88 M8 X 1 25 X 20 FHCS 4 89 M550 7A045 Clamp Die Switch Shaft 1 90 M10 X 1 5 X 30 SHCS 4 91 M16 X 2 0 X 65 SHCS 1 92 1 2 13 HEX NUT Std 3 93 M550 7A049 Stop Ring 4 94 M550 6A061 Switch Bracket 1 95 M5 X 0 8 X 8 Button Head 2 96 PP 0643 Proximity Sensor ...

Page 53: ...1 0 L Bushing 1 118 PP 1004 1 25 ID X 1 75 OD X 125 Thrust Washer 3 119 MH19 6A030 Shaft Keeper 3 120 M10 X 1 5 X 20 SHCS 3 121 M10 X 1 5 X 14 SHCS 3 122 M6 X 1 0 X 14 SHCS 9 123 M8 X 1 25 X 30 Set Screw 10 124 M550 5A014 Pressure Die Cylinder 1 125 M8 X 1 25 Hex Nut 10 126 M12 X 1 75 X 50 SHCS 1 127 M550 5A015 Mandrel Extract Cylinder 1 128 M550 7A047 Pressure Die Switch Shaft 1 129 M550 6A063 Sh...

Page 54: ...o 6 Straight Face Seal 1 152 M550 6A100 Pressure Die Guard 1 153 M550 6A101 Clamp Guard 1 154 M550 6A105 Guard Mount 1 155 M550 6A106 Guard Pivot 2 156 M550 6A107 Hinge Mount 1 157 M550 6A108 Guard Hinge 1 158 M550 7A073 Guard Spacer 1 159 M6 X 1 0 X 12 Hex Flange 3 160 M5 X 0 8 X 6 Button Head 7 161 M6 X 1 0 X 14 Hex Flange 4 162 PP 0487 M800 Guard Rivets 7 163 M10 X 1 5 X 20 Hex Flange 1 164 M55...

Page 55: ...2 M8 X 1 25 X 25 SHCS 6 183 M350 7A022 Mandrel Extract Shaft 1 184 1 8 NPT PIPE PLUG Std 1 185 M550 6A088 Mandrel Rod Support Bracket 2 186 M550 7A070 Roller Shaft 2 187 M550 7A075 Mandrel Rod Roller 2 188 M12 X 1 75 X 20 Hex Flange 2 189 PP 0035 1 Set Screw Collar 2 190 PP 1533 Knob 6 191 PP 1688 Hydraulic Power Unit 1 192 3 8 LOCK WASHER Std 4 193 375 16 X 75 HHCS 4 194 PP 1574 44t Pulley Plasti...

Page 56: ...53 ORIGINAL PRESSURE DIE PARTS DIAGRAM ...

Page 57: ...ER STUD 2 12 M550 7A077 CAM FOLLOWER 2 13 PP 0056 1 0 ID X 1 5 OD X 125 THK 2 14 7 16 20 HEX NUT STD 2 15 M12 X 1 75 X 30 HEX FLANGE 3 16 M12 X 1 75 X 35 SHCS 3 17 M8 X 1 25 X 25 FHCS 2 18 M8 X 1 25 X 30 SET SCREW 10 19 M8 X 1 25 HEX NUT 10 20 M550 6A109 PRESSURE DIE COVER KEY 1 21 M16 X 2 0 X 45 HEX FLANGE 6 22 7 8 14 HEX NUT STD 4 23 M12 X 1 75 X 40 SHCS 2 24 M12 X 1 75 X 45 SHCS 2 25 M12 X 1 75...

Page 58: ...55 NOTES ...

Page 59: ...56 NOTES ...

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