Roper Whitney RADIUS MASTER 911

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Summary

Introduction

Technical Support

Provides contact info for assistance, service, or parts.

Attention Boxes

Warning

Alerts to hazards causing injury or death.

Caution

Emphasizes risks of equipment damage from improper procedures.

Note

Highlights significant information or recommendations.

Personal Safety

Safe Practices

Guidelines for safe work practices and personal protection.

Unsafe Practices

Prohibits unsafe actions to prevent injury and damage.

Tool Safety

Safe Practices

Proper use, inspection, and maintenance of tools.

Unsafe Practices

Prohibits improper or unsafe tool usage.

Work Area Safety

Safe Practices

Maintaining a clean, lit, and hazard-free work environment.

Unsafe Practices

Prohibits actions that create work area hazards.

Machine Setup and Operation Safety

Safe Practices

Procedures for safe setup and operation checks.

Unsafe Practices

Prohibits unsafe practices during setup and operation.

Machine Operation and Maintenance

System Operation

Setup

Instructions for positioning and connecting the machine.

Operation

Steps for operating the machine with a workpiece.

Maintenance

Schedule

Routine maintenance tasks and their frequency.

Fill Procedure

Steps for checking and filling hydraulic fluid.

Machine Hydraulics and Pneumatics

Hydraulic and Pneumatic Schematic

Diagram of hydraulic and pneumatic components and connections.

Electrical Schematic

Diagram showing electrical components and wiring layout.

Wiring Diagram

Detailed diagram of electrical connections.

The Radius Master Model 911 is a footswitch-operated, air-over-oil corner radius machine designed for industrial use. Its primary function is to create precise corner radii on workpieces, offering a range of standard and optional die sets to meet various requirements. The machine is engineered for functionality, simplicity, safety, and ease of maintenance.

Function Description:

The Radius Master operates on an air-over-oil hydraulic system. Initially, die springs hold the die shoes open. When shop air is connected, it flows through an air valve and into the return side of the cylinder, assisting in returning the die shoe to the ready (open) position at the end of a cycle. The machine cycle begins when an operator loads a workpiece into a die opening that matches the desired corner radius and activates the footswitch. Activating the footswitch energizes a solenoid on the air valve, which shifts the air valve to direct 80-100 PSI of shop air to the power booster. The power booster, through reduction and compression, multiplies the force on the hydraulic side by a ratio of 16 to 1. This hydraulic pressure then actuates the cylinder, pulling the die shoe and blade through the workpiece to form the corner radius. The force is maintained as long as the operator holds the footswitch. Upon release of the footswitch, the solenoid de-energizes, and shop air flows back to the return side of the cylinder, raising the die shoe and blade to their ready position.

Important Technical Specifications:

Volts: 115 AC
Amps: 1.0
Air: 80-100 PSI (filtered, lubricated air required)
Capacity: 3/16"
Cutting Blades: A2 Tool Steel
Standard Radii: 1/8, 3/16, 1/4, 5/16, 3/8, 7/16, 1/2, 5/8, 3/4, 7/8, 1
Height: 49"
Width: 32"
Shipping Weight: 345 lbs

Usage Features:

Footswitch Operation: The machine is activated via a footswitch, allowing hands-free operation for loading and positioning workpieces.
Air-Over-Oil System: Utilizes a combination of shop air and hydraulic fluid to generate the necessary force for cutting.
Die Sets: Comes with standard die sets for common radii and offers optional die sets for specialized requirements.
Safety Features: Designed with numerous safety features, though operators are reminded that these do not replace an informed, proficient, and safety-conscious attitude. Safety precautions include ensuring proper tooling, maintaining a clean work area, and following all operational guidelines.
Setup: Requires placement in a well-lit area free of debris and traffic hazards. Setup involves uncrating, plugging into a standard 115 VAC outlet, and connecting to an 80-100 PSI filtered, lubricated air supply.
Operation: To operate, the machine is turned on via a switch on the front. The workpiece is placed on the table and slid into the desired die opening. The foot switch is then activated while holding the part in place.

Maintenance Features:

The Radius Master is designed for minimal maintenance to ensure dependable performance.

Routine Maintenance Schedule:
- Monthly: Drain the air filter.
- Semiannually: Check and fill the hydraulic fluid with Mobil DTE 25.
Hydraulic Fluid Fill Procedure: This procedure is necessary if a loss of power or erratic action of the upper head is observed, indicating low hydraulic fluid.
1. Remove the cylinder rod screw located at the top center of the upper die shoe.
2. Remove the table.
3. Remove the 1/2 NPT pipe plug located in the top portion of the "T" fitting.
4. Fill the fitting with Mobil DTE 25 (or equivalent) to the mid-point of the fitting threads. Securely tighten the plug.
5. Extend and retract the cylinder rod several times, noting the length of stroke. Any air in the system will rise to the top of the fitting. Re-check the oil level and again securely tighten the plug. Repeat this process until the oil level remains constant and the cylinder stroke is approximately 1/2 inch.
6. Check all connections for leaks, then replace the table. Install the screw into the cylinder rod end and adjust the die set opening to 3/16 inches.
Technical Support: Roper Whitney of Rockford, Inc. provides technical support, including Field Service Technicians and in-house Product Support staff. When seeking assistance, operators should be prepared to provide the machine type and serial number, a description of the problem, and details about the operating conditions, features, and function status.
Parts List: A comprehensive parts list is provided in the manual, detailing components for the hydraulic and pneumatic systems, electrical schematic, assembly, hydraulic fill, and die assembly, aiding in maintenance and repair.