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Roper Whitney U616, Operation And Maintenance Manual

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ABOUT THIS MANUAL

CONTENT

This manual contains information on the Roper Whitney floor mounted universal
finger brake for 16 gauge material, Model U616.

The contents include a machine description, safety precautions, instructions for
installation, adjustment, operation, maintenance, and repair; and a parts list
providing a listing of repair parts.

AUDIENCE

The manual is written with the experienced sheet metal operator in mind.  The
operator should be familiar with tooling, machine setup, materials, work
methods, and setup and finished product inspection.  Experienced operators not
familiar with the equipment covered will be able to set up and run the machine
from the manual.  Novice operators can be trained from the manual, but
additional instruction may be needed.

It is strongly recommended that anyone using the equipment covered read the
manual thoroughly, and understand the material presented.

INFORMATION

The setup and operating instructions are based on the intended application of

USAGE

the machine as defined by Roper Whitney.  Use of the machine for other
applications is not precluded, but use for purposes specifically excluded is not
recommended, and may void warranty provisions.

Material in this manual is confidential, and Roper Whitney reserves all rights in
this regard.

ADDITIONAL

If you have questions concerning usage or operating techniques not covered by

ASSISTANCE

this manual, or if you encounter maintenance or repair problems, Roper Whitney
field service and product support personnel can provide you with assistance.
Before calling, please obtain the following information.

* machine type
* machine serial number
* description of application you wish to attempt
* description of problem you have encountered

Page ii

Summary of Contents for U616

Page 1: ...MODEL NO U616 UNIVERSAL FINGER BRAKE OPERATION PARTS MAINTENANCE MANUAL Model Purchased From Serial Date Received MADE IN THE USA ...

Page 2: ... We are constantly at work searching out a variety of high quality high performance tools to offer at the best prices possible Our commitment to you is that we will not offer cheap junk anywhere on our website You the customer help us to evaluate our products constantly and as soon as an ongoing quality issue is uncovered we will correct it or discontinue that product immediately We hope to earn y...

Page 3: ...It is strongly recommended that anyone using the equipment covered read the manual thoroughly and understand the material presented INFORMATION The setup and operating instructions are based on the intended application of USAGE the machine as defined by Roper Whitney Use of the machine for other applications is not precluded but use for purposes specifically excluded is not recommended and may voi...

Page 4: ...ting Clamping Pressure 9 Adjusting for Material Thickness 10 Setting Up for Narrow or Offset Bends 11 Setting Up the Bend Angle Stop 12 Section 6 Operation 13 General Instructions 13 Clamping the Material 13 Bending the Material 14 Bending of Multiple Thicknesses 14 Hemming 15 Section 7 Periodic Maintenance 16 Lubricating Rotating Components 16 Lubricating Sliding Components 16 Lubricating Adjusti...

Page 5: ...r accessories which have been furnished repaired or altered by others so as in Manufacturer s judgment to affect the same adversely or which shall have been subject to negligence accident or improper care installation maintenance storage or other than normal use or service during or after shipment No warranty shall apply to the cost of repairs made or attempted outside of Manufacturer s plant or d...

Page 6: ...BELS Do not operate the U616 Brake without the proper safety labels in place If your machine is missing the following labels please contact Roper Whitney Co or your authorized Roper Whitney distributor to order ...

Page 7: ...your work area Pay special attention to posted warnings and warning labels on the equipment Do not place speed above safety Wear appropriate clothing Loose or hanging clothing or jewelry finger rings etc can be hazardous Use the appropriate safety equipment such as eye and hearing protection and safety toe shoes If gloves are worn to protect from cuts be sure they are snug fitting and not likely t...

Page 8: ...nterweight rods Always stand clear of the apron lift handle travel arc during the bend cycle to avoid being struck by the handles WARNING SERIOUS INJURY MAY OCCUR Avoid pinch points created by the clamping and bending components Always stand clear of clamping handles If the brake has not been properly adjusted for material thickness clamping action on one end of the brake may cause the opposite cl...

Page 9: ...ngle thickness of material of the rated gauge capacity with work angle support installed Bending capacities are reduced by four 4 gauges when the apron work support is removed Major components are shown in Figure 1 Fabricated of sturdy steel plate with appropriate gussets braces and trusses three basic longitudinal members upper beam lower beam and bending leaf apron control the clamping pressure ...

Page 10: ...in place 16 Ga With bending angle removed 20 Ga With bending bar and angle removed 24 Ga Minimum Reverse Bend bending bar and angle removed 1 4 in Maximum lift of beam 1 5 8 in Front to Rear Adjustment of Beam 1 1 8 in Approximate Shipping Weight 1350 lbs Packing Heavy wood skids and blocking with a plastic cover Page 4 ...

Page 11: ...Whitney Company promptly of any damage or shortages If you discover concealed damages or shortages after the carrier has departed you may still file a claim for concealed damage This should be done as quickly as possible Again notify Roper Whitney Company promptly of such damages or shortages UNLOADING The brake is shipped on a skid of 3 x 6 wood timbers It is secured to this skid with four 4 carr...

Page 12: ...t securely anchored The skid does not provide a suitable anchoring platform SITE The brake must be placed on a firm floor which does not sag and which does PREPARATION not have any spring to it The floor must be generally level with no twisting or unevenness in the surface The floor must also be capable of accepting 1 2 lag screws or bolts for the purpose of securing the brake There must be adequa...

Page 13: ...e upper beam to its maximum height using the eccentric lifting levers BRAKE See Figure 2 Place an accurate spirit level on the bed at each end of the bar Shim under the legs of the brake until the bed bar shows the machine is level front to rear This will remove any twist from the bed Side to side leveling is not necessary to proper operation of the brake ANCHORING THE Anchor the leveled brake to ...

Page 14: ...h end of the bending apron Adjust the counterweights so that they balance the bending apron in the horizontal position Tighten two set screws securely on each counterweight shaft WARNING THE COUNTERWEIGHTS ARE HEAVY Use care when installing the counterweights to avoid injury Be sure the set screws are tightened enough so the counterweights will not drop when the bending apron is returned to the ve...

Page 15: ...ormed to is within the rated capacity of the machine Then adjust clamping pressure as follows 1 At each end of the brake loosen both toggle pin lock nuts slightly before beginning adjustment see Figure 3 2 Place small sample pieces of the material to be formed between the upper beam radius bar and the bed at each end of the machine Clamp in position 3 At each end of the machine tighten the lower t...

Page 16: ...s required One and a half 1 1 2 times material thickness is usually sufficient Soft material such as aluminum may be formed with a clearance equal to the material thickness CAUTION THE BENDING BRAKE CAN BE DAMAGED Clearance must never be less than the material thickness Make the adjustment as follows 1 With the upper beam lowered to the normal operating position but not clamped tightly against the...

Page 17: ... be removed only when absolutely necessary to make tight reverse bends Removing the bending reinforcing angle reduces capacity by four 4 gauges The rated 16 ga capacity is reduced to 20 ga capacity Removing both the bending reinforcing angle and the bending bar reduces the 16 ga capacity to 24 gauge capacity BENDING REINFORCING ANGLE BENDING BAR LOCATED BEHIND THE BENDING REINFORCING ANGLE Figure ...

Page 18: ...ve the angle stop collar out toward the end of the angle stop rod See Figure 4 2 Have an assistant move the apron to the desired position and hold it while you adjust the collar Be sure to take spring back into account when setting the angle 3 Move the angle stop collar against the angle stop stud and tighten the angle stop collar set screw to retain it in that position Page 12 ...

Page 19: ...ated by movement of the machine s components CLAMPING THE Insert the material to be bent under the upper beam clamping mechanism lining MATERIAL up both sides so they are even with the upper beam Position short pieces of material in the center of the brake to equalize strain during bending Clamp the material by lowering the upper beam with the clamping levers If the brake has not been properly adj...

Page 20: ...unterweight rods to apply bending force can damage them BENDING OF To avoid adjusting for every piece on a run of parts do all the single thickness MULTIPLE bending operations first then adjust and do the multiple thickness bending THICKNESSES Never bend against hems or seams until an adjustment has been made to compensate for the clamping of multiple thicknesses of material Never bend against hem...

Page 21: ...onal preloading in order to close the hem tightly at the center Increase the preload by tightening the upper beam tensioning adjusting nut See Figure 9 It also requires reducing clamping pressure to allow for multiple thicknesses of material Reduce clamping pressure by slackening the lower toggle pin adjusting nut and tightening the upper toggle pin adjusting nut See Figure 10 HEMMING Remove the w...

Page 22: ...ng general purpose grease or COMPONENTS equivalent These components include the clamping pin bushings and the slots in which they ride see Figure 7 ADJUSTING The upper and lower beam tensioning screws see Figure 9 are under heavy NUTS load and must not be allowed to run dry Keep them lubricated with an anti AND SCREWS seize compound If the machine is frequently readjusted the lower apron tensionin...

Page 23: ...he clamping levers are moved 2 Tighten the clamping collars by turning them clockwise until you are unable to move the clamping levers to clamp material 3 Back off the clamping collars by turning them counterclockwise until you can move the clamping levers to clamp material The collars are properly adjusted when one lever can be unclamped and the lever at the opposite end of the machine remains cl...

Page 24: ...en each with a wrench approximately one full turn five flats see Figure 9 4 Adjust the upper beam tensioning nuts finger tight and then tighten each with a wrench approximately one full turn five flats see Figure 9 5 When looking from the rear of the brake the upper beam and the bed should be in contact at the center and showing a crack of light at each end see Figure 11 If less light shows at one...

Page 25: ...10 Upper Beam Clamp Adjusting Components THE BEAM AND THE BED MUST BE IN CONTACT AT THE CENTER OF THE MACHINE BEAM BED EXAGGERATED VIEW OF GAP AT EACH END OF THE MACHINE THE GAP MUST BE EQUAL AT BOTH ENDS Figure 11 Proper Clearance Between the Upper Beam Clamp and the Bed Page 19 ...

Page 26: ...surface of the bed at each end If not loosen the hinge bolts and adjust the apron up or down using the apron jack screws see Figure 13 After the apron edge is adjusted to the proper position be sure to retighten the hinge bolts 5 Adjust the upper and lower beam tensioning screws finger tight and then tighten each with a wrench approximately one full turn five flats see Figure 9 Figure 12 Preloadin...

Page 27: ...ing nuts finger tight and then ADJUSTMENT using a wrench tighten each from 1 4 to 1 2 turn The bending brake is now properly adjusted for its rated gauge capacity in mild steel HINGE BOLTS APRON JACK SCREWS Figure 13 Apron Adjusting Components Page 21 ...

Page 28: ...es a short descriptive name for each replacement part The Qty column identifies the quantity required for replacement SECTION 9 REPAIR PARTS Ref Part No Number Part Name Qty 1 257020055 Apron Assembly 1 2 757030144 Bending Bar 1 3 613012133 Screw Flat Head 5 16 18 by 1 inch 12 4 757180143 Bending Angle 1 5 601012271 Cap Screw Hex Head 1 2 13 by 1 inch 7 6 679033107 Washer Lock 1 2 inch 7 7 4575000...

Page 29: ...Figure 14 Exploded View of Replacement Parts Page 23 ...

Page 30: ...096 Pin Lower Toggle 2 34 671023010 Toggle Nut lower 2 35 657033154 Washer Spring 2 36 645023010 Toggle Nut Upper 3 4 16 4 37 757860140 Toggle Assembly Right Hand 1 38 757860141 Toggle Assembly Left Hand 1 39 757080009 Bushing Toggle included with items 37 and 38 40 757160142 Stud 3 4 16 x 6 5 inch 2 41 757030003 Clamping Lever Right Hand 1 42 757030004 Clamping Lever Left Hand 1 43 657356334 Hand...

Page 31: ...18 19 20 21 52 51 30 29 28 27 26 23 24 25 47 48 50 49 37 38 39 43 41 42 14 40 36 35 34 44 45 46 31 32 33 22 Figure 15 Exploded View of Replacement Parts Page 25 ...

Page 32: ... Assemblies Ref Part No Number Part Name Qty 1A 757010080 Finger Holder 5 1 1B 757010079 Finger Holder 4 1 1C 757010078 Finger Holder 3 1 2A 757360077 Finger Tip 5 1 2B 757360076 Finger Tip 4 1 2C 757360075 Finger Tip 3 1 3 617012269 Screw SSFP 1 2 13 x 3 4 2 4 613012133 Screw SHF 5 16 18 x 1 1 Page 26 ...

Page 33: ...NOTES ...

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