TABLE OF CONTENTS
Identification Data / Warranty .....................................................................................................................................3
Specifications .............................................................................................................................................................4
Important Safety Instructions......................................................................................................................................5
Definition Of Terms / Model Identification ..................................................................................................................6
Installing The Electrical Plug ......................................................................................................................................7
Turning Your New Bender On ....................................................................................................................................8
Introduction Of Tooling Identification ..........................................................................................................................8
Segment Identification Chart ..................................................................................................................................... 11
Typical End Finishing Illustrations .............................................................................................................................12
Description Of Digital Controls (BA Models) .............................................................................................................12
Operating The Digital Control Board (BA Models) .................................................................................................... 13
Description Of Three-Button Control ((BAS Models) ................................................................................................14
Operating The Manual Knee Control (BL / Bullet Models) ........................................................................................15
Introduction Of Bending Operations ..........................................................................................................................15
Using The Program Cards ........................................................................................................................................15
Pattern Bending .........................................................................................................................................................19
Blank Program Card ..................................................................................................................................................20
Three Inch Tube Bending Procedure ........................................................................................................................21
Stainless Tube Bending Procedure ...........................................................................................................................22
Using The Standard Segment Expanders .................................................................................................................23
Using The Ball-Joint Segment Expanders ................................................................................................................24
Using The Flare Segment Expanders .......................................................................................................................24
Using The Manifold Flange Segment Expanders .....................................................................................................25
Introduction Of The Swager Assembly ......................................................................................................................25
Using The STED Expander Dies ...............................................................................................................................25
Making Male Ball Expansions ...................................................................................................................................26
Making Female Ball Expansions ...............................................................................................................................27
Making 45 Degree Flares ..........................................................................................................................................27
Making A Manifold 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 HCT-2I4/2I2 Tool ............................................................................................ 3I
Maintenance Introduction ..........................................................................................................................................32
Hydraulic Oil Service .................................................................................................................................................32
Recommended Weekly / Monthly Maintenance ........................................................................................................32
Pressure Settings ......................................................................................................................................................33
Chain Adjusting Procedure ........................................................................................................................................34
Aligning The Guide Plate ..........................................................................................................................................35
Barrel Bushing Maintenance .....................................................................................................................................36
Aligning The Swager Box Cylinder ............................................................................................................................37
Pusher Block Maintenance........................................................................................................................................38
Calibrating The Depth-Of-Bend Plate Manual Models ..............................................................................................39
Calibrating The Depth-Of-Bend Switch (BAS Models) ..............................................................................................39
Calibrating The Digital Readout Display (BA Models) ...............................................................................................40
Using The Jumper Board BA Models ........................................................................................................................41
Operating The Machine Manually Using The Solenoid Valve ...................................................................................42
Solenoid Valve Maintenance .....................................................................................................................................43
Checking The Micro Switches (Automatic Models) ..................................................................................................43
Motor Lead Connections ...........................................................................................................................................43
Checking Motor Rotation ...........................................................................................................................................44
Manual Electric Starter ..............................................................................................................................................44
Trouble Shooting Procedures ................................................................................................................................. 45-47
Bending Problems .....................................................................................................................................................48
Electrical Wiring Diagrams (Models BA & BAS)..................................................................................................... 49,50
Service Parts .............................................................................................................................................................51
Deluxe 302 Die Package ...........................................................................................................................................52
Economy 202 Die Package .......................................................................................................................................53
BB-1 Die Package For Blue Bullet ............................................................................................................................54
BB-2 Die Package For Blue Bullet ............................................................................................................................55
2 Bender Operation Manual
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