The FITOK Hand Tube Bender is a specialized tool designed for bending tubes, providing high-quality performance in various tube bending solutions. This manual outlines its operation, technical specifications, and maintenance.
Function Description:
The primary function of the FITOK Hand Tube Bender is to create precise bends in tubing. It is suitable for forming single, offset, and other types of bends, making it versatile for different applications. The bender's design incorporates a vise clamp block, which allows it to be securely clamped in a vise. This feature is particularly useful when bending tubes made of hard materials, heavy-wall thickness, or long pieces of tubing that require additional support during the bending process. The tool is engineered to provide maximum leverage, especially for bends greater than 90 degrees, thanks to its unique right-angle leverage design.
Important Technical Specifications:
Metric Tubing Compatibility:
- Carbon Steel Hydraulic Tubing (DIN 2391 or equivalent):
- Hardness: Equal to or less than 72 HBR (130 HV).
- Tube O.D. (mm) / Bend Radius (mm) / Wall Thickness (mm) Min/Max:
- 6 / 15 / 0.8/1.5
- 8 / 24 / 1.0/1.5
- 10 / 24 / 1.0/1.5 (Carbon Steel), 1.0/2.0 (Stainless Steel)
- 12 / 38 / 1.0/2.2 (Carbon Steel), 1.0/2.0 (Stainless Steel)
- Austenitic Stainless Steel Tubing (EN ISO 1127, 304, 316, etc., or equivalent):
- Hardness: Equal to or less than 90 HRB (200 HV).
Fractional Tubing Compatibility:
- Carbon Steel Hydraulic Tubing (ASTM A179 or equivalent):
- Hardness: Equal to or less than 72 HRB (130 HV).
- Tube O.D. (in.) / Bend Radius (in.) / Wall Thickness (in.) Min/Max:
- 1/4 / 9/16 / 0.028/0.065
- 5/16 / 3/4 / 0.028/0.065
- 3/8 / 15/16 / 0.035/0.065
- 1/2 / 1 1/2 / 0.035/0.083
- Austenitic Stainless Steel Tubing (ASTM A269/A213, 304, 316, etc., or equivalent):
- Hardness: Equal to or less than 90 HRB (200 HV or less).
- Tube O.D. (in.) / Bend Radius (in.) / Wall Thickness (in.) Min/Max:
- 3/8 / 15/16 / 0.035/0.083
- 1/2 / 1 1/2 / 0.035/0.083
- HTB-4S: 1/4" O.D., 0.56" Bend Radius
- HTB-4: 1/4" O.D., 0.75" Bend Radius
- HTB-5: 5/16" O.D., 0.94" Bend Radius
- HTB-6: 3/8" O.D., 0.94" Bend Radius
- HTB-8: 1/2" O.D., 1.5" Bend Radius
- HTB-6M: 6 mm O.D., 15 mm Bend Radius
- HTB-8M: 8 mm O.D., 24 mm Bend Radius
- HTB-10M: 10 mm O.D., 24 mm Bend Radius
- HTB-12M: 12 mm O.D., 38 mm Bend Radius
Limitations:
- Cannot be used for SAF 2507 tubing over 1/4" O.D.
- Not suitable for medium-pressure tubing.
Usage Features:
Tubing Preparation:
- Ensure tubing is free of scratches and appropriate for bending.
- When installing fittings near tube bends, allow sufficient straight tubing length for proper bottoming in the FITOK tube fitting.
Measure-Bend Method:
- Estimate overall tubing length by adding all section lengths.
- Mark the starting end of the tube.
- Measure from the reference mark to the desired bend length and make a bend mark, indicating the vertex of the bend.
- Bend the tube according to the instructions.
- For additional bends, use the previous vertex mark as a new reference.
Offset Bending:
- To calculate the length of an offset bend (L) to change the fluid's center line, use the formula: L = O x A, where O is the offset dimension and A is the offset bend allowance (determined by the offset angle E).
- Offset bend allowances are provided for angles such as 22 1/2° (2.263), 30° (2.000), 45° (1.414), and 60° (1.154).
Bending Procedure (FITOK HTB Instruction):
- Swing the short handle up and release the tube fixer.
- Place the tube in the body's groove with the reference mark to the left of the tube fixer.
- Close the tube fixer loosely to hold the tube, allowing for alignment.
- Align the zero on the roller support with the zero on the dial.
- Align the bend mark on the tube with the mark on the roller support corresponding to the desired bend angle.
- Push the tube fixer firmly to secure the tube. (Avoid excessive pressure on soft tubing).
- For Bends 90° or less: Slowly swing the short handle down until the zero on the roller support reaches the desired angle on the dial. Be aware of springback.
- For Bends greater than 90°:
- Swing the short handle down until the zero on the roller support reaches 90° on the dial.
- Loosen the short handle from the U Block to allow it to swing without moving the roller support.
- Swing the short handle up until it is perpendicular to the long handle.
- Tighten the short handle to provide continuous right-angle leverage for the remaining bend.
- Continue bending until the zero on the roller support reaches the desired angle.
- After completing the bend, swing the short handle away from the tube, release the tube fixer, and remove the tube.
Reverse Bending:
- A reverse bend is made with the reference mark to the right of the hand tube fixer.
- Align the reference mark on the tube with the marks on the roller support (R mark for 90° bends, 0 to R for other angles).
- Bend the tube as described in the general bending procedure.
Bending on the Same Plane and Direction:
- For bends in opposite directions, align the tube with the raised short handle (Plane A).
- For bends in the same direction, parallel the tube to the long handle (Plane B).
Adjustment (Gain) Calculations:
- Adjustment (gain) is the difference in tubing length between a radiused bend and a sharp bend, measured from start to end.
- Tables are provided for both fractional and metric tubing to determine adjustment values for various bend angles, tube O.D.s, and bend radii. These values help in precisely marking the tubing for complex bends.
Maintenance Features:
Troubleshooting Guide:
The manual provides a comprehensive troubleshooting guide to address common issues encountered during tube bending:
- Wrinkles: Caused by an undersized bend radius or tube wall thickness being too thin. Solution: Increase bend radius or increase wall thickness.
- Flattened Tube: Caused by the bender being intended for a larger O.D. tube, tubing collapsing during bending, or the bend die flattening the tubing. Solution: Choose the correct size bender, increase wall thickness, or use a bender equipped with rollers.
- Kinks: Caused by the bender being intended for a larger O.D. tube or the link block not being parallel to the long handle prior to bending. Solution: Choose the correct size bender, ensure the link block is parallel to the long handle before bending.
- Scratches: Caused by the bender being intended for a smaller O.D. tube, a damaged tube groove, or foreign matter in the body or roller. Solution: Choose the correct size bender, repair or replace the body, or clean the bender or roller.
- Rollers Freezed: Solution: Replace damaged roller or bender.
- Excessive Deformation: Caused by improper alignment or excessive pressure on the fixing block (visible on softer tubing). Solution: Ensure proper alignment, reduce pressure.
Replacement Parts:
An exploded view and a list of components are provided for easy identification and ordering of replacement parts, ensuring the longevity and continued performance of the FITOK Hand Tube Bender. Key components include:
- Tube Fixer
- Curved Spring Washers
- Cone Screw
- Nameplate
- Dial
- Body
- Long Handle
- Sleeve
- Short Handle
- Link Block
- Curved Spring Washers
- Shoulder Screws
- Roller Support
- Pin 1
- Roller
- Pin 2
- U Block
- Roller Assembly
Springback Compensation:
- All tubing exhibits springback after bending. The amount varies based on bend angle, tubing material, wall thickness, and radius.
- Experience helps in predicting springback, with an expected compensation of 1° to 3°.
- Verify the bend angle using a protractor, template, or known angle to ensure the desired bend angle is achieved. For softer tubing (aluminum, copper), avoid bending all the way to the bend mark to account for springback.
The FITOK Hand Tube Bender is a robust and precise tool designed for efficient and accurate tube bending across a range of materials and dimensions, supported by clear operational guidelines and maintenance information.
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