BendPak 1302BA-302 Operation And Service Manual Download Page 60

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60 Bender Operation Manual

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1645 LEMONWOOD DR. SANTA PAULA, CA 93060

5245219

BLUE BULLET BENDER

SUPERSTRUCTURE

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Summary of Contents for 1302BA-302

Page 1: ...y 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 Lemon...

Page 2: ...es 27 Making A Manifold Flange Using The HPF 300 Tool 28 Making A Manifold Flange Using The CFT Tool 30 Using the Reducing Tool 30 Using The Doming Die To Finish Tailpipe Ends 31 Making Header Collect...

Page 3: ...rer shall repair or replace at their option for this period those parts returned to the factory freight prepaid which prove upon inspection to be defective The manufacturer will pay labor costs for th...

Page 4: ...20 380 440 VAC Pump Output 3 GPM 4200 psi max output Operation Modes Automatic BA or BAS Manual BL Hydraulic Filter Canister type Bending Force 55 000 Pounds Maximum Bend Depth Control BA Digital Read...

Page 5: ...this machine Never operate machine in or around water or damp environments 12 Warning Risk of explosion This equipment has internal arcing or sparking parts which should not be exposed to flammable v...

Page 6: ...it located to the rear of the machine that utilizes segmented expander dies These segment sets are expanded by the means of a tapered arbor pulled through their center This style of end finishing is u...

Page 7: ...utton controls BA Models These models have two different control modes an electric foot switch assembly for manual bending operations and a digital control board for automatic functions The digital co...

Page 8: ...s that may have loosened 11 Check the oil level by observing the sight gauge located near the right rear side of the machine If the oil level appears low add oil now See page 32 for recommended hydrau...

Page 9: ...NOTE Half shoes and three quarter shoes must be used with radius dies and back shoes of the same corresponding size HAC s STED s HAC s are commonly referred to as adapter collars while the STED s are...

Page 10: ...nd that the size marked on the tool will be the size that the tubing will be reduced down to For example a tool marked 200 will reduce 2 1 4 tubing down to 2 O D and a tool marked 214 will reduce 2 1...

Page 11: ...s is available in two sizes The HSA 114 is an arbor used exclusively for 1 1 4 and 1 3 8 tubing while the HSA 112 is used for tubing sizes 1 1 2 through 3 Bender Operation Manual 11 WARNING 1 Always r...

Page 12: ...ally Release button and all forward motion will stop Overrides AUTO button STOP REVERSE Also EMERGENCY STOP Press to stop forward movement of radius die Press again to reverse then again to stop SET A...

Page 13: ...e until it is fully retracted 8 For the remaining bends move the pipe over until the next bend position or center mark is centered between the back shoes Repeat steps 5 7 9 After all bends are complet...

Page 14: ...ns quickly press and release By holding the colored control buttons in damage to the machine and or components may result GREEN BUTTON Activates the automatic bending cycle After pressing the GREEN bu...

Page 15: ...th any automatic features To operate the manual control valve move the handle to the left or the plunger down to advance the radius die The handle must be fully engaged to properly control radius die...

Page 16: ...BEND DEPTH Shows in degrees what the correct bend depth is for each bend MAKE Gives the make of the vehicle Chevrolet Pontiac Ford Chrysler etc MODEL Gives descriptive factors such as the model engin...

Page 17: ...is showing ZERO Make sure the butterfly nut remains tight 9 You are now ready to make your first bend At this time you may program your depth of bends on the digital board as described in the DIGITAL...

Page 18: ...port 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...

Page 19: ...end number six 33 On bend number six no special instructions are shown 34 Advance the radius die forward until the pusher block springs are compressed and the tubing is held securely 35 Rotate the tub...

Page 20: ...er 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 Continue bending until the bend...

Page 21: ...se of a BLOCK OF WOOD This is used to cushion the tubing when a half shoe is being used The BLOCK OF WOOD should be approximately 2 x 4 x 4 and will be used together with the half shoe When half shoes...

Page 22: ...INLESS 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 describe...

Page 23: ...expanded to the exact inside diameter for the corresponding size segment set See figure 1 A 6 Place the tubing over the segment set Be sure to slide the tubing all the way down to the shoulder NOTE I...

Page 24: ...djust the buttress canister until the grooved line on the canister is lined up with the grooved line on the pointer 4 Depress the valve handle to form the ball on the end of the tubing Be careful not...

Page 25: ...junction with bullet shaped expander forming dies to perform a variety of tube end finishing USING THE STED EXPANDER DIES STED s are referred to as solid expander dies Each tool is marked for the prop...

Page 26: ...shing the ends To make a male ball expansion using the STED expander dies or B 212 proceed as follows See chart on page 12 for typical end finishing illustrations NOTE The B symbol stamped on the STED...

Page 27: ...bing and position within the swager clamp blocks 4 Leave at least three inches of tubing extended beyond the inside edge of the adapter collar See figure 2 B 5 Snug the collar back into the clamp bloc...

Page 28: ...the tubing Remove tooling and return to the storage area USING THE HPF 300 TO MAKE A MANIFOLD FLANGE IMPORTANT NOTE When making a manifold flange it is necessary to first install the pipe flange or c...

Page 29: ...rap pipe nipple into the flared end of the tubing The nipple should hold itself in position 12 Remove hands from the swaging area and slowly move the tool forward until the scrap nipple is forced into...

Page 30: ...UCING TOOLS Reducing tools are used for reducing or shrinking pipe ends to exact outside diameters Each tool is marked with the appropriate size It is important to understand that the size marked on t...

Page 31: ...handle down move the shaft forward until the tool contacts the tubing Be sure that the tool is centered with the tubing 7 Slowly move the tool forward until the desired finish is achieved See figure 1...

Page 32: ...to add oil via the fIller cap located on the reservoir If the oil level continues to drop and oil needs to be added frequently the machine should be checked thoroughly for possible leaks Any of the f...

Page 33: ...gure 3 B 5 If an adjustment is required loosen the locking nut that secures the adjusting screw 6 To increase the pressure turn the adjusting screw clockwise to decrease counterclockwise Never exceed...

Page 34: ...hine will groan as the relief valve opens up and fluid is redirected back to the reservoir This is when the reading should be taken 4 If an adjustment is required loosen the locking nut that secures t...

Page 35: ...urface evenly on both sides and lay flat on the surface of the guide plate 8 The guide plate will require adjustment shimming if t there is more than 01 gap between the plain of the back gates and the...

Page 36: ...e of the barrel then the right side bushings will be equally worn There are two 2 1 2 x 2 x 1 1 2 bronze bushings press fitted on the top and bottom of each side of the barrel assembly To visually che...

Page 37: ...n a section of squarely cut 2 tubing approximately 12 long into the clamp block area using the necessary HAC adapter collar 4 Gently snug the collar back into the clamp blocks by gently pushing back o...

Page 38: ...usher block shows signs of excessive wear use a screwdriver to pry the pusher block up and down as illustrated below If there is more than 1 32 of movement in either direction the pusher block should...

Page 39: ...act the radius die and check that the pointer returns to zero If not loosen the mounting bolts on the degree plate and adjust the plate until both 90 degree and zero degree readings are achieved NOTE...

Page 40: ...s three dis tinct functions 1 Initiates the counting cycle and serves as an adjustment device for properly calibrating the die angle 2 Resets the die angle to zero upon retraction of the radius die 3...

Page 41: ...nt the gate needs to allow the trip arm to deactivate the zero angle micro switch and start the counting process See figure 1 B USING THE JUMPER BOARD All BA models have a bypass device or jumper boar...

Page 42: ...d below t The valve Inadvertently sticks causing the top cylinder to uncontrollably advance or retract Operating the valve manually will often dislodge foreign particles that may have become trapped i...

Page 43: ...should be continuity between the two There should be no continuity between the common and normally closed terminals at this time See figure 1 A CAUTION Replace ALL faulty switches immediately NEVER at...

Page 44: ...omponents Thermal units must be installed and the device reset before the starter contacts will operate Install thermal units so that the type face can be read and the pawl is positioned just above th...

Page 45: ...ative or wire has become disconnected Check connections on micro switch Refer to diagrams on pages 49 50 Check micro switch with ohmmeter See page 43 Check for broken or disconnected wires BA BAS mode...

Page 46: ...s The GREEN control button retracts the top cylinder when held in Does not advance with right foot switch control The depth of bend switch is stuck shorted malfunctioning Check wire connections on dep...

Page 47: ...cted wires Replace if faulty BA models The top cylinder retracts by itself without activating any controls The top cylinder will advance when the AUTO button is depressed but immediately retract when...

Page 48: ...rt above for minimum tubing thickness Check tubing for proper wall thickness See chart above Bending dies are not properly matched to the tubing diameter Select proper bending dies for the particular...

Page 49: ...Bender Operation Manual 49...

Page 50: ...50 Bender Operation Manual...

Page 51: ...e 2 BS 200 2 Back Shoes 1 B 212 2 1 2 Male Ball Flange 2 BS 134 1 3 4 Back Shoes 1 FP 100 Flattening Plate 2 BS 112 1 1 2 Back Shoes 1 ST 1 Slip Twist Adapter HALF SHOES SEGMENT EXPANDERS QTY PART NO...

Page 52: ...Manifold Flange 2 BS 178 1 7 8 Back Shoes 1 FP 100 Flattening Plate 2 BS 134 1 3 4 Back Shoes 1 ST 1 Slip Twist Adapter 2 BS 112 1 1 2 Back Shoes SEGMENT EXPANDERS HALF SHOES QTY PART NO TOOLING DESCR...

Page 53: ...e 2 BS 200 2 Back Shoes 1 B 212 2 1 2 Male Ball Flange 2 BS 134 1 3 4 Back Shoes 1 FP 100 Flattening Plate 2 BS 112 1 1 2 Back Shoes 1 ST 1 Slip Twist Adapter HALF SHOES SEGMENT EXPANDERS QTY PART NO...

Page 54: ...Manifold Flange 2 BS 178 1 7 8 Back Shoes 1 FP 100 Flattening Plate 2 BS 134 1 3 4 Back Shoes 1 ST 1 Slip Twist Adapter 2 BS 112 1 1 2 Back Shoes SEGMENT EXPANDERS HALF SHOES QTY PART NO TOOLING DESC...

Page 55: ...x 08 F NPT x 08 F NPT 1 17 5550131 FTG 45ELB 08 NPT x 08 JIC 1 18 5550152 FTG NPL 08 NPT x 08 JIC 1 19 5550481 FTG ELB 1 4 TUBE INS 1 8 NPT 3 20 5570797 1302 1502 BLUE BULLET SERIES PE HOSE 1 4 x 4 1...

Page 56: ...nual 4 29 33 31 5 12 23 21 1 30 16 17 18 24 27 2 7 26 6 28 9 8 11 19 14 13 22 25 20 15 32 10 3 SHEET 2 OF 3 REV DWG NO A SIZE TITLE B 1645 LEMONWOOD DR SANTA PAULA CA 93060 5245217 1302 BA BENDER SUPE...

Page 57: ...Bender Operation Manual 57 1017 766 1526 SHEET 3 OF 3 REV DWG NO A SIZE TITLE B 1645 LEMONWOOD DR SANTA PAULA CA 93060 5245217 1302 BA BENDER SUPERSTRUCTURE 1 15 SCALE...

Page 58: ...BLUE BULLET SERIES HOSE ASSEMBLY 12 7 x 430mm DS 1 A 11 5570398 1302 1502 BLUE BULLET SERIES HOSE ASSEMBLY 12 7 x 1020mm DS 1 A 12 5215133 1302 1502 SERIES TOP TOOL TRAY ASSEMBLY 1 A 13 5215156 1302 1...

Page 59: ...545120 WASHER 7 8 x 1 459 SL 1 20 5545125 WASHER 1 2 x 869 SL 4 21 5550481 FTG ELB 1 4 TUBE INS 1 8 NPT 3 22 5570796 1302 1502 BLUE BULLET SERIES PE HOSE 1 4 x 8 1 A 23 5570797 1302 1502 BLUE BULLET S...

Page 60: ...nual 5 13 3 31 26 10 12 16 1 29 27 8 28 14 17 2 6 15 4 18 9 7 11 21 24 25 20 19 23 22 30 32 SHEET 2 OF 3 REV DWG NO A SIZE TITLE B 1645 LEMONWOOD DR SANTA PAULA CA 93060 5245219 BLUE BULLET BENDER SUP...

Page 61: ...Bender Operation Manual 61 766 1532 1017 SHEET 3 OF 3 REV DWG NO A SIZE TITLE B 1645 LEMONWOOD DR SANTA PAULA CA 93060 5245219 BLUE BULLET BENDER SUPERSTRUCTURE 1 15 SCALE...

Page 62: ...ASSEMBLY 12 7 x 540mm DS 2 A 10 5570397 1302 1502 BLUE BULLET SERIES HOSE ASSEMBLY 12 7 x 430mm DS 1 A 11 5570398 1302 1502 BLUE BULLET SERIES HOSE ASSEMBLY 12 7 x 1020mm DS 1 A 12 5600470 1302 1502 B...

Page 63: ...PT 1 19 5550142 FTG NPL 06 ORB x 06 F NPT 2 20 5550043 FTG NPL 12 NPT x 12 NPT 1 21 5550096 FTG ELB 08 JIC x 06 NPT 1 22 5550116 FTG 45ELB 08 JIC x 06 NPT 1 23 5550117 FTG NPL RED 08 JIC x 12 ORB 2 24...

Page 64: ...64 Bender Operation Manual...

Page 65: ...Bender Operation Manual 65...

Page 66: ...f our tooling All BendPak benders are built with 3 bending capacity so you can order three inch dies when you need them No other manufacturer uses our exclusive step cut process for the die rails that...

Page 67: ...brittle iron is used for any of our tooling All BendPak benders are built with 3 bending capacity so you can order three inch dies when you need them No other manufacturer uses our exclusive step cut...

Page 68: ...Parts Or Service Contact BendPak Inc Ranger Products 1645 Lemonwood Dr Santa Paula CA 93060 Tel 1 805 933 9970 Toll Free 1 800 253 2363 Fax 1 805 933 9160 www bendpak com www rangerproducts com pn 590...

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