BendPak BB 1302-BA Operation And Service Manual Download Page 55

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302 Deluxe Tooling Package

BENDING DIES

PIPE COLLARS

QTY.

PART NO.

TOOLING DESCRIPTION

QTY.

PART NO.

TOOLING DESCRIPTION

5R-212

5 " Radius Die / 2-1/2"

HAC-212

2-1/2" Pipe Collar

5R-214

5 " Radius Die / 2-1/4"

HAC-214

2-1/4" Pipe Collar

5R-200

5 " Radius Die / 2"

HAC-200

2" Pipe Collar

4R-214

4 " Radius Die / 2-1/4"

HAC-178

1-7/8" Pipe Collar

4R-200

4 " Radius Die / 2"

HAC-134

2-1/2" Pipe Collar

4R-178

4 " Radius Die / 1-7/8"

HAC-112

1-1/2" Pipe Collar

35R-200

3-1/2" Radius Die / 2"

END FINISHING TOOLS

35R-134

3-1/2" Radius Die / 1-3/4"

QTY.

PART NO.

TOOLING DESCRIPTION

35R-112

3-1/2" Radius Die / 1-1/2"

HPF-300

45 / 90-Degree Flare

BACK SHOES

DD-134/212

Doming Die

QTY.

PART NO.

TOOLING DESCRIPTION

BFED-134/214

Female Ball Flare

BS-212

2-1/2" Back Shoes

BFED-200-212

Female Ball Flare

BS-214

2-1/4" Back Shoes

B-212

2-1/2" Male Ball Flange

BS-200

2" Back Shoes

CFT-200

2" Manifold Flange

BS-178

1-7/8" Back Shoes

FP-100

Flattening Plate

BS-134

1-3/4" Back Shoes

ST-1

Slip-Twist Adapter

BS-112

1-1/2" Back Shoes

SEGMENT EXPANDERS

HALF SHOES

QTY.

PART NO.

TOOLING DESCRIPTION

QTY.

PART NO.

TOOLING DESCRIPTION

HSA-112

Arbor

HS-212

2-1/2" Half Shoe

SS-212

2-1/2" Segment Exp.

HS-214

2-1/4" Half Shoe

SS-214

2-1/4" Segment Exp.

HS-200

2" Half Shoe

SS-200

2" Segment Exp.

HS-178

1-7/8" Half Shoe

SS-134

1-3/4"- 1-7/8" Segment Exp.

HS-134

1-3/4" Half Shoe

SS-112

1-1/2" Segment Exp.

HS-112

1-1/2" Half Shoe

ACCESSORIES

THREE-QUARTER SHOES

QTY.

PART NO.

TOOLING DESCRIPTION

QTY.

PART NO.

TOOLING DESCRIPTION

TTA-1000

Tool Tray Set

QS-214

2-1/4" Three-Quarter Shoe

DPS-150

Pusher Block Springs

QS-200

2" Three-Quarter Shoe

Manual

Instruction Manual

SOLID EXPANDER DIES

Video

Instruction Video

QTY.

PART NO.

TOOLING DESCRIPTION

OR-1

Bag / Assorted O-Rings

STED-212

2-1/2" Exp. Die / 2-1/4" Male Ball

STED-214

2-1/4" Exp. Die / 2" Male Ball

STED-200

2" Exp. Die / 1-3/4" Male Ball

STED-178

1-7/8" Expander Die

STED-134

1-3/4" Expander Die

STED-112

1-1/2" Expander Die

Bender Operation Manual 55

Summary of Contents for BB 1302-BA

Page 1: ...epair this equipment without reading this manual and the important safety instructions shown inside 1645 Lemonwood Dr Santa Paula CA 93060 USA Toll Free 1 800 253 2363 Tel 1 805 933 9970 www bendpak c...

Page 2: ...anifold 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 Collectors Using the HC...

Page 3: ...pay labor costs for the first l2 months only on parts returned as previously described This warranty does not extend to defects caused by ordinary wear abuse mis use shipping damage or lack of require...

Page 4: ...RES MODELS 1302BL BLUE BULLET GAUGE WALL DECIMAL BENDER CAPACITY THICKNESS EQUIVALENT RADIUS MAXIMUM SIZE BEND DEPTH Bending Capacity Tubing from 1 2 OD 3 OD Maximum Capacity Tube Thickness See Chart...

Page 5: ...than 15 feet If the Power Cord becomes frayed replace it Never alter electrical components on this machine Never operate machine in or around water or damp environments 15 Warning Risk of explosion T...

Page 6: ...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 usually req...

Page 7: ...els 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 Control Board eliminate...

Page 8: ...oses use a second wrench on the Hex Fitting to ensure the Hose does not twist during the tightening process This will ensure an proper tightening of the Hose without any pre loading conditions 10 The...

Page 9: ...TE 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 re...

Page 10: ...d 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 2...

Page 11: ...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 re...

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: ...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 completed cut off...

Page 14: ...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 butt...

Page 15: ...with 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 D...

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 engine...

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: ...pport 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 locate...

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: ...ter 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: ...use 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 Shoe...

Page 22: ...ESS TUBING In order to get good results when bending Stainless Tubing it is necessary to increase the Back Shoe pressure by adjust ing the Sequence Valve similar to the procedure previously described...

Page 23: ...s 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...

Page 24: ...e buttress canister until the grooved line on the canister is lined up with the grooved line on the pointer 4 Press the Valve Handle to form the Ball on the end of the Tubing Be careful not to distort...

Page 25: ...nction 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 proper...

Page 26: ...nishing 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 ST...

Page 27: ...bing and position within the Swaging 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 Blo...

Page 28: ...he 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 Cla...

Page 29: ...p 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 t...

Page 30: ...REDUCING 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...

Page 31: ...ve 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 figur...

Page 32: ...the proper level oil should appear midway on the gauge 3 If oil cannot be seen it will necessary to add oil via the fIller cap located on the reservoir If the oil level continues to drop the machine s...

Page 33: ...After the remaining oil has drained replace the Drain Plug 9 Remove the Cannister Type Oil Filter 10 Micron 200 psi 3 4 NPT 10 Clean the Gasket Seat if necessary 11 Place a thin film of Hydraulic Oil...

Page 34: ...ure 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 2...

Page 35: ...chine will groan as the Relief Valve opens up and Oil 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 th...

Page 36: ...surface 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 th...

Page 37: ...side 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...

Page 38: ...ly 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 on the Collar Assembly...

Page 39: ...Pusher 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 shoul...

Page 40: ...ract 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 41: ...three distinct 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 Ad...

Page 42: ...ent 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 Boa...

Page 43: ...t The Valve occasionally sticks causing the Top Cylinder to uncontrollably advance or retract Operating the Valve manually will often dislodge foreign particles that may have become trapped in the Val...

Page 44: ...ere 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 NEVE...

Page 45: ...its 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 the ratchet wheel LOCK...

Page 46: ...r 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 models The...

Page 47: ...tracts 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 depth of bend limit switch Refer...

Page 48: ...ected 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 pressed but immediately retract when r...

Page 49: ...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 Tubing diameter Tubing diam...

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

Page 51: ...Bender Operation Manual 51...

Page 52: ...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 TOOLING DESCRIPTION QTY PAR...

Page 53: ...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 DESCRIPTION QTY PART NO TOOLING...

Page 54: ...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 TOOLING DESCRIPTION QTY PAR...

Page 55: ...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 DESCRIPTION QTY PART NO TOOLING...

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Page 66: ...enders 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 actually helps contain the...

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: ...___________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ __...

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Page 70: ...___________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ __...

Page 71: ...___________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ __...

Page 72: ...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 P N 5900103 Rev D2 2021 by Ben...

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