BendPak Blue Bullet 1302-BAS Operation And Service Manual Download

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OPERATION AND SERVICE MANUAL

“America’s Most Popular Tubing Bender”

MODELS:

BB (“Blue Bullet”)

1302-BAS

1302-BAS shown

SHIPPING DAMAGE CLAIMS

When this equipment is shipped, title passes to the

purchaser 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.

BE SAFE

BendPak, 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 Dr.

Santa Paula, CA. 93060, USA

Toll Free 1-800-253-2363

Tel: 1-805-933-9970

www.bendpak.com

PLEASE READ THE ENTIRE CONTENTS OF THIS MANUAL PRIOR TO

INSTALLATION AND OPERATION. BY PROCEEDING YOU AGREE THAT YOU

FULLY UNDERSTAND AND COMPREHEND THE FULL CONTENTS OF THIS

MANUAL. FORWARD THIS MANUAL TO ALL OPERATORS. FAILURE TO

OPERATE THIS EQUIPMENT AS DIRECTED MAY CAUSE INJURY OR DEATH.

REV. D - FEB. 2019

pn# 5900103

Keep this operation manual near the
machine at all times. Make sure that ALL
USERS read this manual .

Summary of Contents for Blue Bullet 1302-BAS

Page 1: ... 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 Dr Santa Paula CA 93060 USA Toll Free 1 800 253 2363 Tel 1 805 933 9970 www bendpak com PLEASE READ THE ENTIRE CONTENTS OF THIS MANUAL PRIOR TO INSTALLATION AND OPERATION BY PROCEEDING YOU AGREE T...

Page 2: ...45 Degree Flares 26 Making A Manifold Flange Using The HPF 300 Tool 27 Making A Manifold Flange Using The CFT Tool 29 Using the Reducing Tool 29 Using The Doming Die To Finish Tailpipe Ends 30 Making Header Collectors Using the HCT 2I4 2I2 Tool 30 Maintenance Introduction 31 Hydraulic Oil Service 31 Recommended Weekly Monthly Maintenance 31 Pressure Settings 32 Chain Adjusting Procedure 33 Alignin...

Page 3: ...urer 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 the first l2 months only on parts returned as previously described This warranty does not extend to defects caused by ordinary wear abuse misuse shipping damage or lack of required maintenance This war...

Page 4: ...uction tools do not come standard DESIGN FEATURES 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 Below Maximum Bending Radius 5 Minimum Bending Radius 3 1 2 Motor 5 H P Single or Three Phase 220 380 440 VAC Pump Output 3 GPM 4200 psi max output Operat...

Page 5: ...n 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 vapors This machine should not be located in a recessed area or below floor level 13 Maintain with care Keep machine clean for better and safe performance Follow manual for proper lubrication and main...

Page 6: ...flaring unit 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 usually required with shorter pieces of tubing such as muffler nipples which do not allow the use of a collar TOP CYLINDER The main hydraulic bending cylinder located at the top of the bender...

Page 7: ...s the GREEN button At this time the bending head would activate and the radius die would begin to move forward After the desired bend depth has been reached the machine would automatically initiate the retract sequence that returns the die to the original starting position The BLUE button is for automatically returning the die to the original starting position while the RED button is an emergency ...

Page 8: ...es 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 hydraulic oils 12 Activate the swaging and internal expander cylinders by depressing the control handles located at the rear of the machine Cycle the cylinders to their full extent at least fIve times Agai...

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 referred to as solid expander dies HAC s are used to hold or clamp the tubing in place when performing end finishing Operations or when using the STED s These adapter collars are heat treated which c...

Page 10: ...and 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 tubing down to 2 1 4 O D Not included in standard tooling packages SEGMENT EXPANDERS Segment expanders or segment sets come in a variety of sizes and shapes each performing it s own distinct functi...

Page 11: ...ts 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 remove excess tooling from swager area before using internal expander 2 To avoid breaking tooling ALWAYS use proper segment sets with appropriate tubing size 3 NEVER stand in front of arbor when opera...

Page 12: ...BUTTON Automatically returns or retracts the bending die to the original starting position NEVER hold the BLUE button in when retracting the bending ram RED BUTTON Serves as an Emergency Stop button Automatically stops all movement of the bending die during the automatic cycle REMOTE FOOT SWITCHES Used for manual operation The right foot switch advances the radius die to start the bending process ...

Page 13: ... by pressing the RIGHT foot switch until the radius die stops at the pre set bend angle Press the LEFT foot switch to retract the radius die Always be prepared to support the pipe as it is released from the dies OPERATING THE MANUAL KNEE CONTROL BULLET MODELS Read the following section completely before attempt ing any operation of this unit All Blue Bullet models are equipped with a hydraulic con...

Page 14: ...ith 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 movement To retract the radius die move the handle to the right or plunger up to return to the original starting position Always be prepared to support the pipe as it is released from the dies OPERAT...

Page 15: ...d 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 and frame size BENDING INSTRUCTIONS Shows what radius die will be used in addition to other tooling such as half shoes and three quarter shoes Also gives instructions on reversing and certain end f...

Page 16: ...r 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 CONTROL OPERATION section position the depth of bend pointer on BAS models or elect to use the electric foot switches or manual knee control valve For beginning operators we suggest that manual cont...

Page 17: ...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 located at the weld seam of the tubing or return to the previous bend and position the pendulum pointer to the degrees required for that particular bend 18 If a bending instruction calls for a REVERSE remov...

Page 18: ...bend 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 tubing so that the pendulum pointer or dial indicator points to 277 degrees 36 Advance the radius die to 9 degrees then retract the die to the original starting position 37 You are now finished bending ...

Page 19: ...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 depth is equal to that of the master See figure 1 C 8 Look at the Depth of Bend plate or observe the DIE ANGLE window This is the depth or degrees of the first bend Record this information in the BEN...

Page 20: ...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 shoes are used on larger size tubing they have the tendency to depress or indent the tubing somewhat due to the reduced surface area on the half shoe itself The block of wood will crush as the bend is bei...

Page 21: ...AINLESS 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 described The recommended pressures are shown below When using large diameter or light gauge tubing more back shoe pressure is required Always remember to reset the bender to 1600 P S I when you are finished...

Page 22: ...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 If there is a burr or dent on the end of the tubing place the tubing on the notched end of the segment set and tap the valve handle until the burr is removed See figure 2 A 7 With the tubing in positi...

Page 23: ...Adjust 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 to distort the end of the tubing See figure 2 A 5 To make a female ball expansion place the tubing over the arbor and segment set until the tubing is positioned midway at the grooved area Depress the...

Page 24: ...njunction 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 size tubing Some of these dies perform two different functions The STED expander dies will swage expand the tubing to exact inside diameters but some can also be used for making male ball expansio...

Page 25: ...ishing 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 expander dies identifies the tool required for making male ball expansions The E symbol identifies the tool required for making straight expansions Some STED expander dies do not show a E or B symbo...

Page 26: ...ubing 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 blocks by gently pushing back on the collar assembly 6 Slowly while depressing the valve handle down move the shaft forward until the tool enters the tubing Be sure that the tool is centered with the tub...

Page 27: ...m 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 clamp around the tube prior to finishing the ends On this application it is necessary to use a scrap piece of tubing approximately 1 1 2 long of the same O D size This tubing section will be inserted ...

Page 28: ...crap 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 the tube opening Stop when the scrap nipple protrudes 1 2 from the tube end See figure 3 D 13 Retract the die by lifting up on the control handle This will form a seat for the round donut gasket as ...

Page 29: ...DUCING 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 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 tubing down to 2 1 4 O D ...

Page 30: ... 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 A 8 Retract the die by lifting up on the control handle Separate the collar from the tubing Remove tooling and return to the storage area USING THE HCT 214 212 This tool is for making header flanges...

Page 31: ...y 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 following hydraulic oils may be used Make Brand Chevron OC Turbine 46 Mobile DTE Medium Texaco Rando HD 46 Conoco Turbine 46 Shell Shell Turbo 46 Citgo AW46 Pennzoil Zoil Medium or No 10 Union 76 UNAX...

Page 32: ...igure 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 2000 P S I RETURN PRESSURE This pressure reading is also taken on the gauge located near the front left side of the machine The purpose of this pressure is to maintain adequate tension on the chain a...

Page 33: ...chine 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 the adjusting screw on the relief valve 5 To increase the pressure turn the adjusting screw slightly clockwise to decrease counter clockwise Never exceed 3200 P S I ADJUSTING THE CHAINS When the chain...

Page 34: ...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 the surface of the guide plate t the plain of the gate assemblies is not square with the guide plate t the plain of the back gates is actually lower than the surface of the guide plate If it is necessar...

Page 35: ...de 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 check these bushings follow the steps outlined below 1 Disassemble the left side chain assembly by removing the left side chain connector See figure 2 C 2 Remove the barrel shaft nut located below the l...

Page 36: ...on 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 on the collar assembly 5 Hold the tubing securely making sure that the HAC 300 is square within the clamp blocks 6 Advance the tool forward until it just makes contact with the tubing 7 At this time t...

Page 37: ...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 should be replaced Check to see if the pusher block is square to the guide plate as illustrated below If the pusher block is excessively worn or out of square then replace the pusher block as follows 1 Usin...

Page 38: ...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 Some tubing may experience spring back after the bend is made To compensate for this set your depth of bend pointer 2 degrees less than the actual position of the gates CALIBRATING THE AUTOMATIC DEPT...

Page 39: ... or non conducting rod NOTE The manual control function of the solenoid valve should effectively advance or retract the radius die under all conditions The manual button should be pressed firmly to activate SOLENOID VALVE MAINTENANCE Certain symptoms and suggested repair procedures are explained below t The valve Inadvertently sticks causing the top cylinder to uncontrollably advance or retract Op...

Page 40: ...chine and use an ohmmeter to check the circuits as follows WITH THE SWITCH IN THE NEUTRAL POSITION Place one of the prongs from your ohmmeter on the common terminal of the switch and the other on the normally closed terminal At this time there should be continuity between the two There should be no continu ity between the common and normally open at this time See Fig 2 A WITH THE LEVER OR BUTTON D...

Page 41: ...ring as shown on the previous page Bender Operation Manual 41 220 Volt 60HZ Single Phase Incoming Power Motor Leads Line 1 5 and 1 Line 2 8 and 4 To reverse rotation interchange lines 5 and 8 220 Volt 60HZ Three Phase Incoming Power Motor Leads Line 1 3 and 9 Line 2 2 and 8 Line 3 1 and 7 Twist together 4 5 6 To reverse rotation interchange any two line leads 440 Volt 6OHZ Three Phase Incoming Pow...

Page 42: ...ponents 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 the ratchet wheel LOCK OFF MECHANISM The starter can be locked only in the OFF position by lifting the metal tab labeled LOCK on the contact actuator and placing a padlock through the center of the hole i...

Page 43: ...rative 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 BAS models The top cylinder will advance with the button controls but not with the right foot switch Right foot switch is inoperative or wire has become disconnected Check connections on micro switch Refer to d...

Page 44: ...ls 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 depth of bend limit switch Refer to diagram on page 50 Check micro switch with ohmmeter as described on page 43 Check for broken or disconnected wires Replace if faulty BAS models Stuck in forward mode ...

Page 45: ...art 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 tubing diameter Tubing diameter is actually less or more than what it is labeled Check the actual tubing diameter using a micrometer or similar measuring devise Improper chain adjustment Adjust chain...

Page 46: ...46 Bender Operation Manual ...

Page 47: ...re 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 TOOLING DESCRIPTION QTY PART NO TOOLING DESCRIPTION 1 HS 212 2 1 2 Half Shoe 1 HSA 112 Arbor 1 HS 214 2 1 4 Half Shoe 1 SS 212 2 1 2 Segment Exp 1 HS 200 2 Half Shoe 1 SS 214 2 1 4 Segment Exp 1 HS 1...

Page 48: ... 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 DESCRIPTION QTY PART NO TOOLING DESCRIPTION 1 HSA 112 Arbor 1 HS 212 2 1 2 Half Shoe 1 SS 212 2 1 2 Segment Exp 1 HS 214 2 1 4 Half Shoe 1 SS 214 2 1 4 Segment Exp 1 HS 200 2 Half Shoe 1 SS 200 2 Segment ...

Page 49: ...re 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 TOOLING DESCRIPTION QTY PART NO TOOLING DESCRIPTION 1 HS 212 2 1 2 Half Shoe 1 HSA 112 Arbor 1 HS 214 2 1 4 Half Shoe 1 SS 212 2 1 2 Segment Exp 1 HS 200 2 Half Shoe 1 SS 214 2 1 4 Segment Exp 1 HS 1...

Page 50: ...2 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 DESCRIPTION QTY PART NO TOOLING DESCRIPTION 1 HSA 112 Arbor 1 HS 212 2 1 2 Half Shoe 1 SS 212 2 1 2 Segment Exp 1 HS 214 2 1 4 Half Shoe 1 SS 214 2 1 4 Segment Exp 1 HS 200 2 Half Shoe 1 SS 200 2 Segment...

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Page 58: ...45120 WASHER Ø7 8 x Ø1 459 SL 1 20 5545125 WASHER Ø1 2 x Ø 869 SL 4 21 5550481 FTG ELB 1 4 TUBE INS 1 8 NPT 3 22 5570796 1302 1502 BLUE BULLET SERIES PE HOSE Ø1 4 x 8 1 A 23 5570797 1302 1502 BLUE BULLET SERIES PE HOSE Ø1 4 x 4 1 A 24 5550501 FTG ELB 1 4 INS x 1 4 NPT 1 25 5550101 FTG RED 08 NPT x 04 F NPT 1 26 5550134 FTG ELB 08 NPT x 08 JIC 4 27 5550023 1 28 5550152 FTG NPL 08 NPT x 08 JIC 1 29 ...

Page 59: ...al 59 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 SUPERSTRUCTURE 1 10 SCALE ...

Page 60: ...60 Bender Operation Manual 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 61: ...E ASSEMBLY Ø12 7 x 540mm DS 2 A 10 5570397 1302 1502 BLUE BULLET SERIES HOSE ASSEMBLY Ø12 7 x 430mm DS 1 A 11 5570398 1302 1502 BLUE BULLET SERIES HOSE ASSEMBLY Ø12 7 x 1020mm DS 1 A 12 5600470 1302 1502 BLUE BULLET SERIES BOTTOM TOOL TRAY WELDMENT 1 A 13 5701479 1302 1502 BLUE BULLET SERIES SMALL TOOL TRAY 1 A 14 5711215 1302 BAS 1502 BAS BLUE BULLET DEPTH OF BEND PLATE 1 B 15 5731225 1302 BAS 15...

Page 62: ...06 NPT 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 5550128 FTG NPL 06 NPT x 06 NPT 1 25 5550130 FTG ELB 08 JIC x 08 NPT x 04 TAP 1 26 5550135 FTG RED 10 ORB x 8 F NPT 1 27 5550136 FTG TEE 06 NPT x 06 F NPT x 06 F NPT 2 28 5550138 FTG ELB 12 ORB x...

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

Page 65: ...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 process for the die rails that actually helps contain the larger size tubing better and gives you a more uniform bend Gives BendPak benders the ability to bend 3 OD tubing Six piece set comes complete with 2 BS 300 3 back shoes 1...

Page 66: ...e 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 process for the die rails that actually helps contain the larger size tubing better and gives you a more uniform bend Gives BendPak benders the ability to bend 3 OD tubing Six piece set comes comple...

Page 67: ...____________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _______________________________________...

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 5900103 ...

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