Operating, Servicing, and Safety Manual Model # 900 90° Hydraulic Bender CAUTION: Read and Understand These Operating, Servicing, and Safety Instructions, Before Using This Machine. 1-800-467-2464 10 Cooperative Way Wright City, MO 63390 P.O. Box 110 Foristell, MO 63348 1-636-745-7757 Fax 1-636-745-2874 www.mittlerbros.
-2- Table of Contents • Safety Pg.3 • Hydraulic Safety Precautions Pg.4 • Hydraulic System Operation Pg.5 • Machine Set up Pg.6 • Operation Pg.7 • Math Formulas Pg.8-11 • Technical Diagram Pg.12 • Optional Equipment Pg.13-15 • Maintenance Pg.
-3- SAFETY The purpose of the safety section of this manual is to inform operators and maintenance personnel of the precautions to be taken while operating or servicing the machine. The following are a few basic guidelines to follow, but as with any type of machinery good judgment and a safe attitude should be applied at all times. 1 . Always disconnect power, lock-out and tag-out machine per OSHA regulations before attempting to service this machine. 2.
-4- HYDRAULIC SAFETY PRECAUTIONS WARNING General Operation • All WARNING statements must be carefully observed to help prevent personal injury. • Before operating the pump, all hose connections must be tightened with the proper tools. Do not over tighten. Connections should only be tightened securely and leak-free. Over tightening can cause premature thread failure or high pressure fittings to split at pressures lower than their rated capacities.
-5- HYDRAULIC SYSTEM Pump Assembly 1. Remove the RED Plug in the pump assembly and replace with the supplied BLACK plug. This is the reservoir venting system and damage or inoperability may result if not changed out. RED Plug should be changed to BLACK Plug Hydraulic Hose 2. Attach the hydraulic hose to the pump. Be sure to use a quality thread sealer on both connections Air Connector 3. Attach an air line fitting for your shop air to other end of the pump. Push Down to Release Pressure 4.
-6- MACHINE SETUP #3 & #15 Roller Pin #4 & #14 Upper Frame #13 Roller #12 Follow Bar #16 Female Hydraulic Coupler #5 & #8 Clevis Pin #7 Clevis 1. Remove machine from packaging. 2. Place machine on table or floor. 3. Remove roller pin. 4. Rotate upper frame out of the way. #10 Saddle #9 & #11 Saddle Pin Pump Pressure Release Pressure #16 Hydraulic Coupler 5. Remove clevis pin. 6. Remove bender shoe & follow bar from packaging. 7. Insert shoe into clevis.
-7- OPERATION #8 Reference Scale #4 #2 Bend Start Point Roller #10 Follow Bar #10 Saddle Pin #10 Saddle #3 Tubing Through the Saddle #4 & #7 Pump Pressure #5 Shoe Start Point #9 Release Pressure Male Hydraulic Coupler 1. Insert tubing into channel in the shoe, follow bar, and adjustable saddle. CAUTION: Be sure roller pin is completely through lower frame 2. Align the bend start point marked on tubing to the bend start point on the bender shoe. AIR / HYDRAULIC PUMP 3.
-8- CORRECTED MATHEMATICAL FORMULA FOR HYDRAULIC TUBING BENDER WHEN USING INSTRUCTION VIDEO The following formula should be used to determine the start point for each required bend. The example will be for a Double Bevel Bend L1 = 26 L2 = 15 L3 = 39 L4 = 15 L5 = 26 25 degree angle 65 degree angle 65 degree angle 25 degree angle Bend #1 Start Point: L1 – ½ developed length (DL25) – ½ (Gain) 26” – ½ (3.064”) – ½ (.050) 26” – 1.532” - .025” = 24.
-9- GAIN FACTORS Degree of Bend Multiplier 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 .0000 .0000 .0000 .0000 .0000 .0001 .0001 .0003 .0003 .0005 .0006 .0008 .0010 .0013 .0015 .0018 .0022 .0026 .0031 .0036 .0042 .0048 .0055 .0062 .0071 .0079 .0090 .0100 .0111 .0126 Degree of Bend 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Multiplier .0136 .0150 .0165 .0181 .0197 .0215 .0234 .0254 .0276 .0298 .0322 .0347 .0373 .0400 .
-- 10 -- DEVELOPED LENGTH DEVELOPED LENGTH = .0175 X DEGREE OF BEND X RADIUS EXAMPLE: FIND THE DEVELOPED LENGTH OF A 70 DEGREE BEND USING AN 8 INCH RADIUS. DEVELOPED LENGTH = .0175 X 70 X 8 = 9.
-- 11 -- TABLE FOR OFFSET MULTIPLIER Degree of Bend 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Multiplier 57.30 28.65 19.11 14.33 11.47 9.57 8.21 7.18 6.39 5.76 5.24 4.81 4.45 4.13 3.86 3.63 3.42 3.24 3.07 2.92 2.79 2.67 2.56 2.46 Degree of Bend 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Multiplier 2.37 2.28 2.20 2.13 2.06 2.00 1.94 1.89 1.84 1.79 1.74 1.70 1.66 1.62 1.59 1.56 1.52 1.49 1.46 1.44 1.41 1.39 1.37 1.
-12- 7 9 8 16 ITEM NO. QTY. PART NO.
-13- Optional Equipment Adjustable Saddles for 90 & 180 Hydraulic Benders Saddle eliminates the need for individual saddles for each tubing size. Two sizes handle 5/8” to 1-3/4” Round & Square Tubing. Advantages • Securely holds each tube, eliminates tube creep • Easy Release “V” Block eliminates Stuck Saddle from tube spring back • Easier Bend-to-Bend Alignment with light pressure on tube 2500-300 Adjustable Saddle, Small 5/8" to 1-3/8" $95.00 2500-301 Adjustable Saddle, Medium 1-1/2 to 1-3/4 $95.
-14- Bend Protractors 2100-4 4" Protractor Assembly $100.00 2100-5 5" Protractor Assembly $110.00 2100-6 6" Protractor Assembly $120.00 2100-7 7" Protractor Assembly $130.00 2100-8 8" Protractor Assembly $140.00 2100 4" Thru 8" Protractor Set $510.
-15- BEND-TECH EZ Designed for simple 2d parts! 900-510 Bend-Tech EZ Software $69.00 BEND-TECH EZ-3D Designed for 3d bending, with 360 degree part rotation! 900-511 Bend-Tech EZ-3D Software $149.00 BEND-TECH PRO Full 3d Assembly & Manufacturing Instructions, plus all EZ features! 900-512 Bend-Tech Pro Software $275.00 900-513 Bend-Tech SE Software $399.
-16- MAINTENANCE Inspecting The Hydraulic Fluid Level Check the fluid level in the reservoir after every 10 hours of use. Drain and replenish the reservoir with Power Team hydraulic fluid after every 300 hours of use approximately. Air Hydraulic Pump For pumps with a 105 cubic inch (1.71) reservoir capacity Electric Hydraulic Pump For pumps with a 2 gallon (7.61) reservoir capacity The fluid level should be 1/2 inch (12.7 mm) from the filler / vent cap with all cylinders retracted.
