PBB04

PBB04
INSTRUCTIONS FOR:
FLOOR & BENCH MOUNTED METAL BENDERS
MODEL NOS:
PBF04 & PBB04
Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions
and properly maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS.
USE THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE
DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
1.
SAFETY INSTRUCTIONS
2.
INTRODUCTION
3 Ensure that the metal bender is in sound condition and good
working order. Take action for immediate repair or replacement of
damaged parts. Use recommended parts only. The use of
improper parts may be dangerous and will invalidate the warranty.
3 Keep bender and associated parts clean for best and safest performance.
3 Locate the bender in a suitable, well lit work area.
3 Keep work area clean and tidy and free from unrelated materials.
3 Mount onto a strong, stable work surface or onto level and solid
ground (preferably concrete) as appropriate.
3 Ensure all non-essential persons keep a safe distance whilst the
bender is in use.
3 Check that all bending dies, pins, stops and attachments are correctly
and securely mounted before commencing a bend.
3 Wear safety goggles and gloves when bending parts.
3 Always allow enough material to extend beyond the stop block
and forming dies when making bends to ensure that the material
does not come free allowing the handle to release suddenly.
7 DO NOT bend any material other than hot rolled mild steel.
7 DO NOT operate the metal bender if damaged.
7 DO NOT allow untrained persons to operate the bender.
7 DO NOT use the metal bender for purposes other than that
for which it is intended.
7 DO NOT try to bend round stock using the sharp angle attachment.
7 DO NOT modify the bender in any way or use a handle extension
other than the one provided.
7 DO NOT try to bend material larger than the maximum sizes
stipulated below.
For light workshop use this compact metal bender comes in bench or floor mounted versions and is designed to bend flat, square or round solid
hot rolled mild steel up to the dimensions given below. The bender comes with the following accessories. A stop block, stop block support,
seven circular dies (1”,1.¼”,1.½”,1.¾”,2”,2½”), a sharp angle bend attachment, extending handle, one short hinge pin, two long hinge pins, plus
fixed and adjustable stops to aid repeat production of the same part.
BENDING CAPACITY (around a circular die) : Flat material - up to 5/16” x 2” Square or round material - up to 5/8”
BENDING CAPACITY (using the sharp angle attachment) : Use only flat mild steel 3/16” up to 2” wide or 1/4” up to 1 1/4”wide.
DO NOT bend round stock using the sharp angle attachment)
p
p
p
p
3.
3.1.
3.1.1
3.1.2
3.2
3.2.1
3.3
3.3.1
3.4
3.4.1
ASSEMBLY & PREPARATION
WARNING! Ensure that you have read and understood Section 1 Safety Instructions before operating the bender.
WARNING! To avoid serious injury do not operate the bender unless it is securely mounted to the floor or workbench.
Attach the ring/loop assembly to the floor stand or bench stand as indicated in fig.1.
Attach the loop end first by placing the long spacer (1) into the loop. Place a flat washer (3) over the bolt (2) and insert the bolt
through the loop and long spacer. Insert the protruding bolt into the mounting plate at the top of the stand ensuring that there is a
short spacer (6) sandwiched between the loop and the mounting plate. Secure with a lock washer (7) and a nut (8).
Attach the ring end to the stand in the two places indicated using the two 3/8” bolts with countersunk heads (5). Ensure that there is a
short spacer (6) inserted between the ring and the mounting plate through which each bolt passes. Place a flat washer and a lock
washer over each bolt and secure with a lock nut.
Attach the handle to the ring/loop as indicated in fig.2.
Insert the loop end of the handle inside the loop of the ring/loop assembly and secure it with one of the two longer hinge pins. The
hole selected on the handle loop will depend on the type of bend to be done. (See section 4)
Extend the handle to its full length. (See fig.2)
Remove the hair clip from the handle pin, then remove the pin from the handle. Pull the extension arm out of the handle tube and
align the hole at the end of the extension with the hole in the handle tube. Reinsert the pin and retain it by reinstalling the hairclip.
Fix the assembled unit to the floor or bench as appropriate.
Place the bender in the position where you intend to use it and rotate the handle fully in both directions to ensure that there will be no
obstructions during bending. The bender must be attached to a bench or floor using fixings which are strong enough to resist the
turning force exerted on them. Similarly the structure of the bench or floor surface must also be
sound and strong enough to resist the turning force exerted through the fixings.
fig.1
fig.2
PBF04 & PBB04 - 1 - 161003
4.
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.2
fig.5
OPERATING THE BENDER
GENERAL OPERATING INFORMATION.
The bender can produce two basic types of bend. a) Smooth radiused bends using a
combination of the circular dies provided. b) Sharp bends using the sharp angle attachment.
Making a test piece. When producing parts from dimensioned drawings it is
advisable to make a test part first from scrap material of the same thickness to be
used in the final part. A certain amount of trial and error may be necessary in setting
up the bender to achieve an accurate part. To achieve a particular bend angle you will
need to make a trial bend first and then measure it.
Using the fixed or adjustable stop. Further adjustments may be necessary but once
you know the amount of rotation necessary to achieve a particular angle this can be
repeated by using the fixed or adjustable stops provided. (See figs.3&11)
Multiple bends. When doing more than one bend, similar trial and error may be
necessary to establish the correct relationship between bends. Mark the bend
positions on the trial workpiece. Make the bends and then measure the distance
between them. Make any necessary adjustments to the measurement to achieve the
desired result.
Bend sequence. Where a number of bends are to be made in the same piece of
metal attention should be paid to the order in which the bends are made to achieve
the finished part. You may need to re-orientate the workpiece in the bender by
reversing it or inverting its position. If necessary the bender can be disassembled to
remove or reposition a complex bend configuration.
Clamping the workpiece. Generally the workpiece is automatically clamped in place
fig.4
by the action of the bender. In certain instances some slippage may occur e.g. when
forming material around a large die. This can be eliminated by clamping the end
of the material with locking pliers which then act against the stop block to prevent the material moving. (See fig.4)
fig.3
MAKING RADIUSED BENDS. ( Do not try to bend material more than 1/4” thick around the centre pin. The 1” die must be used.)
fig.7
fig.6
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
you
Use of the ‘stop block’. The ‘stop block’ prevents the material from
rotating in the bender while a forming die mounted in the handle bends
the material either round the centre pin or around another die that has
been installed on the centre pin.
Orientation of the the ‘stop block’. The ‘stop block’ can be placed in
several orientations allowing additional flexibility in the positioning of the
workpiece in relation to the forming dies. Its relationship to the
workpiece is altered by rotating it on the hinge pin or by turning it
upside down on the pin and rotating it. However, only the four
orientations shown in fig.5 should be used for bending. No matter which
face is against the workpiece, the pin through the block should always
be positioned to the right of the block centre otherwise the block may
fig.8
turn and the material will slip in the bender.
Position of the block support. The block support is used to position
the stop block vertically in the ring assembly loop as shown in fig.6.
Install the support in the appropriate loop hole where it will support the block but not interfere with the insertion of the hinge pin all the
way through the the hole in the block and into the hole in the lower part of the loop.
Installing the dies. Install in the centre of the bender the chosen die around which you are going to form the metal. Use a long
hinge pin to retain both the die and and the handle as shown in fig.7. Install the die which will do the forming into the handle loop and
retain it using the short hinge pin. The space between the two dies should be as small as possible whilst allowing the metal to pass
through.
Installing the stop block and block support. Rotate the handle anticlockwise to the approximate starting position as shown in fig.7.
Insert the metal to be formed in between the dies. Now install the stop block and block support at one of the five large holes in the ring
assembly’s loop.You will have to determine by trial and error which hole to use depending on the thickness of the material being bent,
the size of the centre pin die, and the orientation of the stop block. The block should be as close to the centre pin/die as the material
will allow. Retain the stop block with a long hinge pin.
WARNING! When making a bend or partial bend close to the end of a piece of material the bending force you are exerting on
the handle may suddenly be released as the bending die in the handle rolls off the end of the material. Watch the progress of
the die as it moves towards the end of the material and be prepared to release the pressure on the handle.
Making a bend. ( Before making a bend check that the bender is still firmly attached to the bench or floor. The floor should be clean
and dry and free from loose material. Wear non slip shoes and check that the area is clear of personnel and will remain clear whilst
are executing the bend.) If required, clamp the workpiece as shown in fig.4. Exert just enough pressure on the handle to hold the
material steady in the bender and check that the material is level. Make the bend with steady and even pressure until you reach the
desired finishing point as indicated in fig.8. ( As a rough guide to initially determine an angle when bending around a centrally
mounted die there are 16.36 degrees between the holes in the ring.) Measure the angle bent and make any necessary adjustments.
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4.3
MAKING SHARP BENDS
(Do not bend round stock using the sharp angle bend attachment.)
fig.10
fig.9
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.4
4.4.1
fig.11
Installing the sharp angle bend attachment. The sharp angle bend
attachment has only one correct orientation as shown in fig.10. and should be
installed with the block support underneath it to raise it to the correct position
vertically within the loop. Counting from the outside of the loop towards the
centre of the bender place the block support in the third lower hole.
Rest the sharp bend attachment on the block support and secure it by dropping
a long hinge pin through the fourth upper hole and all the way through the hole
in the attachment into the hole in the lower part of the loop. The longer ‘tail’ of
the attachment should now be resting to the left of the loop spacer as shown in
fig.10.
Installing the handle. Counting from the outside of the handle loop towards
the centre of the bender align the sixth hole in the handle with the centre pivot
fig.12
hole of the bender. Secure the handle by dropping a long hinge pin through
both loops.
Installing the handle die. Install the smallest die in the last hole in the handle
loop as shown in fig.11 using a short hinge pin.
fig.13
Preparation of workpiece. Mark the position of the bend or bends onto the material.
These marks will represent the inside of each bend and therefore may be on different sides
of the material depending on the shape of the item you are making. ( If you are making
two right angle bends on the same side of the material, make the marks 3mm further apart
than the desired inside dimension after the bend.)
Making a bend. ( Before making a bend check that the bender is still firmly attached to the
bench or floor. The floor should be clean and dry and free from loose material. Wear non
slip shoes and check that the area is clear of personnel and will remain clear whilst you
are executing the bend.) Slide the material into the bender so that the first marked out
bend is aligned with the tip of the sharp angle attachment. (The material face that is
touching the tip of the sharp angle attachment will become the inside of the bend. See
fig.13 which shows the action of the bender when using the sharp angle attachment.)
Exert just enough pressure on the handle to hold the material steady in the bender and
check that the material is level. Make the bend with steady and even pressure until you
reach the desired finishing point as indicated in fig.12. Measure the angle and make any necessary adjustments.
Once the required movement for a particular angle has been established it can be repeated by the use of the fixed stop as shown in
figs.11 & 12. If the finish point of a bend falls between two holes use the adjustable stop as shown in fig.3
EXAMPLE - DOUBLE TUBE CLAMP
Below is illustrated a simple example of the bend sequence required to make a simple pipe clamp using both methods of bending. The
first two bends are around a 1” die mounted on the centre pin with the stop block in place. The last two bends are made using the
sharp angle attachment. To insert the workpiece in C & D it will be necessary to temporarily remove the centre pin. Dis-assemble the
handle to remove the finished piece.
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
Sole UK Distributor
Sealey Group,
Bury St. Edmunds, Suffolk.
01284 757500
01284 703534
Web
email
www.sealey.co.uk
[email protected]
PBF04 & PBB04 - 1 - 161003
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