Baileigh Industrial B8105 User manual

OPERATOR’S MANUAL
ROTARY DRAW BENDER
MODEL: RDB-500 (B8105)
© 2015 Baileigh Industrial, Inc.
Rev. 08/2015

Table of Contents
INTRODUCTION............................................................................................................. 1
GENERAL NOTES.......................................................................................................... 1
SAFETY INSTRUCTIONS .............................................................................................. 2
SAFETY PRECAUTIONS ............................................................................................... 5
TECHNICAL SPECIFICATIONS..................................................................................... 7
UNPACKING AND CHECKING CONTENTS.................................................................. 8
Cleaning ...................................................................................................................... 8
TRANSPORTING AND LIFTING .................................................................................... 9
INSTALLATION............................................................................................................... 9
ASSEMBLY AND SET UP ............................................................................................ 10
GETTING TO KNOW YOUR MACHINE ....................................................................... 11
GENERAL DESIGN DESCRIPTION............................................................................. 12
ELECTRICAL................................................................................................................ 13
OPERATION................................................................................................................. 15
Dry Running Machine ................................................................................................ 15
Setting Bend Angle.................................................................................................... 15
DIE SELECTION AND INSTALLATION........................................................................ 17
Material Insertion ....................................................................................................... 19
Material Insertion Limitations..................................................................................... 22
Bending More than 180 Degrees............................................................................... 23
UNDERSTANDING SPRINGBACK .............................................................................. 23
MATERIAL SELECTION............................................................................................... 23
PIPE AND TUBE BENDING DIAGRAMS ..................................................................... 25
BENDING GLOSSARY ................................................................................................. 26
BENDING SUGGESTIONS .......................................................................................... 27
Aluminum Bending .................................................................................................... 27
Heavy Wall DOM tubing ............................................................................................ 27
Bending With Square Dies ........................................................................................ 28
Square Tooling Setup................................................................................................ 28
Large Size Square..................................................................................................... 29
LUBRICATION AND MAINTENANCE .......................................................................... 30
ELECTRICAL SCHEMATIC.......................................................................................... 31
TROUBLESHOOTING .................................................................................................. 32
TABLES, CHARTS, & DIAGRAMS ............................................................................... 33
Diagram 1 ..................................................................................................................... 35
Diagram 2 ..................................................................................................................... 36
PARTS DIAGRAM ........................................................................................................ 37
Base Assembly Parts Diagram.................................................................................. 37
Main Tube Assembly Parts Diagram ......................................................................... 38
Swing Arm Assembly Parts Diagram......................................................................... 39
Lead Screw Assembly Parts Diagram ....................................................................... 40
Encoder Assembly Parts Diagram............................................................................. 41

Adaptor Plate Assembly Parts Diagram .................................................................... 42
Parts List ................................................................................................................... 43

1
1
INTRODUCTION
The quality and reliability of the components assembled on a Baileigh Industrial machine
guarantee near perfect functioning, free from problems, even under the most demanding working
conditions. However if a situation arises, refer to the manual first. If a solution cannot be found,
contact the distributor where you purchased our product. Make sure you have the serial number
and production year of the machine (stamped on the nameplate). For replacement parts refer to
the assembly numbers on the parts list drawings.
Our technical staff will do their best to help you get your machine back in working order.
In this manual you will find: (when applicable)
•Safety procedures
•Correct installation guidelines
•Description of the functional parts of the machine
•Capacity charts
•Set-up and start-up instructions
•Machine operation
•Scheduled maintenance
•Parts lists
GENERAL NOTES
After receiving your equipment remove the protective container. Do a complete visual
inspection, and if damage is noted, photograph it for insurance claims and contact your
carrier at once, requesting inspection. Also contact your distributor and inform them of the
unexpected occurrence. Temporarily suspend installation.
Take necessary precautions while loading / unloading or moving the machine to avoid any
injuries.
Your machine is designed and manufactured to work smoothly and efficiently. Following proper
maintenance instructions will help ensure this. Try and use original spare parts, whenever
possible, and most importantly; DO NOT overload the machine or make any unauthorized
modifications.

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2
Note: This symbol refers to useful information throughout the manual.
LEARN TO RECOGNIZE SAFETY INFORMATION
This is the safety alert symbol. When you see this symbol on
your machine or in this manual, BE ALERT TO THE
POTENTIAL FOR PERSONAL INJURY!
Follow recommended precautions and safe operating
practices.
UNDERSTAND SIGNAL WORDS
A signal word – DANGER, WARNING, or CAUTION
is used with the safety alert symbol. DANGER
identifies a hazard or unsafe practice that will result in
severe Injury or Death.
Safety signs with signal word DANGER or WARNING are
typically near specific hazards.
IMPORTANT
PLEASE READ THIS OPERATORS MANUAL CAREFULLY
It contains important safety information, instructions, and necessary operating
procedures. The continual observance of these procedures will help increase your
production and extend the life of the equipment.
SAFETY INSTRUCTIONS

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3
General precautions are listed on CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
SAVE THESE INSTRUCTIONS.
Refer to them often and use them to instruct others.
PROTECT EYES
Wear safety glasses or suitable eye protection
when working on or around machinery.
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause impairment or loss of
hearing. Wear suitable hearing protective devices such as ear muffs or
earplugs to protect against objectionable or uncomfortable loud noises.
BEWARE OF CRUSH HAZARD
NEVER place your hands, fingers, or any
part of your body in the die area of this
machine. Be aware of the area on either side
of the dies for crush points created by
material movement.

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4
BEWARE OF PINCH POINTS
Keep hands and fingers away from the drive
mechanisms, cylinders, ratchets, and other
moving linkage while the machine is in
operation.
KEEP CLEAR OF MOVING OBJECTS
Always be aware of the position of the material and the swing area in
which the material will travel. The material will swing with significant
force. This swing area will create pinch points and the force of the
material movement may cause serious bodily injuries.
HYDRAULIC HOSE FAILURE
Exercise CAUTION around hydraulic hoses in case of a hose or
fitting failure.
HIGH VOLTAGE
USE CAUTION IN HIGH VOLTAGE AREAS. DO NOT assume the
power to be off.
FOLLOW PROPER LOCKOUT PROCEDURES.

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5
SAFETY PRECAUTIONS
Metal working can be dangerous if safe and proper operating procedures are not followed. As
with all machinery, there are certain hazards involved with the operation of the product. Using
the machine with respect and caution will considerably lessen the possibility of personal injury.
However, if normal safety precautions are overlooked or ignored, personal injury to the operator
may result.
Safety equipment such as guards, hold-downs, safety glasses, dust masks and hearing
protection can reduce your potential for injury. But even the best guard won’t make up for poor
judgment, carelessness or inattention. Always use common sense and exercise caution in
the workshop. If a procedure feels dangerous, don’t try it.
REMEMBER: Your personal safety is your responsibility.
1. Only trained and qualified personnel can operate this machine.
2. Make sure guards are in place and in proper working order before operating
machinery.
3. Remove any adjusting tools. Before operating the machine, make sure any adjusting tools
have been removed.
4. Keep work area clean. Cluttered areas invite injuries.
5. Overloading machine. By overloading the machine you may cause injury from flying parts.
DO NOT exceed the specified machine capacities.
6. Dressing material edges. Always chamfer and deburr all sharp edges.
7. Do not force tool. Your machine will do a better and safer job if used as intended. DO NOT
use inappropriate attachments in an attempt to exceed the machines rated capacity.
8. Use the right tool for the job. DO NOT attempt to force a small tool or attachment to do the
work of a large industrial tool. DO NOT use a tool for a purpose for which it was not
intended.
9. Dress appropriate. DO NOT wear loose fitting clothing or jewelry as they can be caught in
moving machine parts. Protective clothing and steel toe shoes are recommended when
using machinery. Wear a restrictive hair covering to contain long hair.
WARNING: FAILURE TO FOLLOW THESE RULES MAY RESULT IN
SERIOUS PERSONAL INJURY

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6
10.Use eye and ear protection. Always wear ISO approved impact safety goggles. Wear a full-
face shield if you are producing metal filings.
11.Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or
across a running machine.
12.Stay alert. Watch what you are doing and use common sense. DO NOT operate any tool or
machine when you are tired.
13.Check for damaged parts. Before using any tool or machine, carefully check any part that
appears damaged. Check for alignment and binding of moving parts that may affect proper
machine operation.
14.Observe work area conditions. DO NOT use machines or power tools in damp or wet
locations. Do not expose to rain. Keep work area well lighted. DO NOT use electrically
powered tools in the presence of flammable gases or liquids.
15.Keep children away. Children must never be allowed in the work area. DO NOT let them
handle machines, tools, or extension cords.
16.Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust.
Always lock up tools and keep them out of reach of children.
17.DO NOT operate machine if under the influence of alcohol or drugs. Read warning
labels on prescriptions. If there is any doubt, DO NOT operate the machine.
18.DO NOT touch live electrical components or parts.
19.Turn off power before checking, cleaning, or replacing any parts.
20.Be sure all equipment is properly installed and grounded according to national, state, and
local codes.
21.DO NOT bypass or defeat any safety interlock systems.
22.Keep visitors a safe distance from the work area.

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7
TECHNICAL SPECIFICATIONS
Maximum Center Line Radius (CLR)*
20" (508mm)
Minimum Center Line Radius (CLR)*
.5" (12.7mm)
Minimum OD
.25" (6.35mm)
Mild Steel Pipe (Schedule 40)
3" (76.2mm)
Aluminum Pipe (Schedule 40)
3" (76.2mm)
Stainless Steel Pipe (Schedule 40)
2.5" (63.5mm)
Mild Steel Round Tube (Wall)
3" (.25) (76.2mm [6.35mm])
Aluminum Round Tube (Wall)
3.5" (.25) (88.9mm [6.35mm])
Stainless Steel Round Tube (Wall)
3.5" (.187) (88.9mm [4.75mm])
Chromolly Round Tube (Wall)
3.5" (.187) (88.9mm [4.75mm])
Mild Steel Solid Rod
2" (50.8mm)
Mild Steel Square Tube (Wall)
3" (.25) (76.2mm [6.35mm])
Power Supply
415VAC / 3ph / 50Hz
Motor
5hp (3.7kw) 415VAC / 3ph / 50Hz / 13.5A
Sound level
<70db
Shipping Weight (Lbs.)
1800lbs. (817kg)
Shipping Dimensions (L x W x H)
70” x 56” x 41” (1778 x 1423 x 1042mm)
TECHNICAL SUPPORT
Our technical support department can be reached at [e-mail] listing
support and the model number in the subject line. Tech Support handles questions on machine
setup, schematics, warranty issues, and individual parts needs: (other than die sets and blades).
List the model number, serial number and contact name and phone number as well as a brief
description of the nature of the contact in the body of the message.
For specific application needs or future machine purchases contact the Sales Department at:
[e-mail]
Note: The photos and illustrations used in this manual are representative only and
may not depict the actual color, labeling or accessories and may be intended to illustrate
technique only.
Note: The specifications and dimensions presented here are subject to change
without prior notice due to improvements of our products.

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8
UNPACKING AND CHECKING CONTENTS
Your Baileigh machine is shipped complete in one crate. Separate all parts from the packing
material and check each item carefully. Make certain all items are accounted for before
discarding any packing material.
Cleaning
Your machine may be shipped with a rustproof waxy oil coating and grease on the exposed
unpainted metal surfaces. To remove this protective coating, use a degreaser or solvent
cleaner. For a more thorough cleaning, some parts will occasionally have to be removed. DO
NOT USE acetone or brake cleaner as they may damage painted surfaces.
Follow manufacturer’s label instructions when using any type of cleaning product. After cleaning,
wipe unpainted metal surfaces with a light coating of quality oil or grease for protection.
WARNING:
SUFFOCATION HAZARD! Immediately discard any plastic
bags and packing materials to eliminate choking and suffocation hazards to children
and animals.
If any parts are missing, do not plug in the power cable, or turn the power switch on
until the missing parts are obtained and installed correctly.
WARNING:DO NOT USE gasoline or other petroleum products to clean
the machine. They have low flash points and can explode or cause fire.
CAUTION: When using cleaning solvents work in a well-ventilated area.
Many cleaning solvents are toxic if inhaled.
GAS

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9
TRANSPORTING AND LIFTING
Follow these guidelines when lifting:
•The lift truck must be able to lift at least 1.5 – 2 times the machines gross weight.
•Make sure the machine is balanced. While transporting, avoid rough or jerky motion, and
maintain a safe clearance zone around the transport area.
•Use a fork lift with sufficient lifting capacity and forks that are long enough to reach the
complete width of the machine.
•Remove the securing bolts that attach the machine to the pallet.
•Approaching the machine from the side, lift the machine on the frame taking care that there
are no cables or pipes in the area of the forks.
•Move the machine to the required position and lower gently to the floor.
•Level the machine so that all the supporting feet are taking the weight of the machine and no
rocking is taking place.
INSTALLATION
IMPORTANT:
Consider the following when looking for a suitable location to place the machine:
•Overall weight of the machine.
•Weight of material being processed.
•Sizes of material to be processed through the machine.
•Space needed for auxiliary stands, work tables, or other machinery.
•Clearance from walls and other obstacles.
•Maintain an adequate working area around the machine for safety.
•Have the work area well illuminated with proper lighting.
CAUTION:Lifting and carrying operations should be carried out by skilled
workers, such as a truck operator. Make sure the machine is well balanced. Choose a
location that will keep the machine free from vibration and dust from other machinery.
Keep in mind that having a large clearance area around the machine is important for
safe and efficient working conditions.

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•Keep the floor free of oil and make sure it is not slippery.
•Remove scrap and waste materials regularly, and make sure the work area is free from
obstructing objects.
•If long lengths of material are to be fed into the machine, make sure that they will not extend
into any aisles.
•LEVELING: The machine should be sited on a level, concrete floor. For stationary machines,
provisions for securing it should be in position prior to placing the machine. The accuracy of
any machine depends on the precise placement of it to the mounting surface.
•FLOOR: This tool distributes a large amount of weight over a small area. Make certain that
the floor is capable of supporting the weight of the machine, work stock, and the operator.
The floor should also be a level surface. If the unit wobbles or rocks once in place, be sure to
eliminate by using shims.
•WORKING CLEARANCES: Take into consideration the size of the material to be
processed. Make sure that you allow enough space for you to operate the machine freely.
•POWER SUPPLY PLACEMENT: The power supply should be located close enough to the
machine so that the power cord is not in an area where it would cause a tripping hazard. Be
sure to observe all electrical codes if installing new circuits and/or outlets.
ASSEMBLY AND SET UP
1. Remove the machine from the skid it was shipped on.
2. Check the oil level and top off if necessary.
3. Read through the remainder of the manual and become familiar with the die installation and
settings as well as normal operation.
4. Position the machine as desired following the installation guidelines.
5. Follow the electrical guidelines to connect the machine to a power supply.
WARNING: For your own safety, DO NOT connect the machine to the
power source until the machine is completely assembled and you read and
understand the entire instruction manual.

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GETTING TO KNOW YOUR MACHINE
A
B
C
D
E
G
H
J
F

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12
Item
Description
Function
A
Forward Foot Pedal
Will operate the machine in the cw direction
B
Reverse Foot Pedal
Will operate the machine in the ccw direction
C
Power Switch
For turning power on/off to the bender
D Bend Angle Controller
For programming bend angle and displaying the
bend angle position.
E
Hydraulic Cylinders
Supply the bending force to rotate the forming die.
F
Quick Release (shown with a
counter die installed)
For pivoting counter die away from bend die to
remove material quickly.
G
Main Spindle And Drive Pins
(shown with a forming die
installed)
For supporting and driving the forming die.
H
Grease Zerk
For greasing main spindle bearing
I Encoder
Recording the spindle rotation and sending that
information back to the controller to display the bend
angle and stop bending at the programmed angle.
GENERAL DESIGN DESCRIPTION
You have made a practical choice in purchasing the RDB-500 Hydraulic Bending Machine. It
has been carefully built of high quality materials and designed to give many years of efficient
service. The simplicity of design and minimum effort required to operate the machine contributes
towards meeting schedules and producing greater profits.
The RDB-500 is an electric powered hydraulically operated “Rotary Draw” bending machine. To
bend material, a bending die and counter die are required. The material is hooked by the
bending dies’ hook arm and is powerfully rotated in the clockwise direction. As the bending die
rotates, the counter die arm also rotates about the same axis, forcing the material to conform to
the radius and shape of the bending die.
The RDB-500 Bending Machine you have purchased is built of solid steel ensuring maximum
rigidity. Tongue and groove design with grade 8 bolts throughout provides very high rigidity and
stability.
Throughout this manual are listed various safety-related descriptions for attention. These
matters for attention contain the essential information to the operators while operating, and
maintaining. Failure to follow these instructions may result in great damage to the machine or
injury to the operator.

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ELECTRICAL
Motor Specifications
Your tool is wired for 415 volt, 50Hz alternating current. Before connecting the tool to the power
source, make sure the machine is cut off from power source.
Considerations
•Observe local electrical codes when connecting the machine.
•The circuit should be protected with a time delay fuse or circuit breaker with a amperage
rating slightly higher than the full load current of machine.
•A separate electrical circuit should be used for your tools. Before connecting the motor to the
power line, make sure the switch is in the “OFF” position and be sure that the electric current
is of the same characteristics as indicated on the tool.
•All line connections should make good contact. Running on low voltage will damage the
motor.
•In the event of a malfunction or breakdown, grounding provides a path of least resistance for
electric current to reduce the risk of electric shock. This tool is equipped with an electric cord
having an equipment-grounding conductor and a grounding plug. The plug must be plugged
into a matching outlet that is properly installed and grounded in accordance with all local
codes and ordinances.
WARNING: Baileigh Industrial is not responsible for any damage caused
by wiring up to an alternative 3-phase power source other than direct 3-phase. If you
are using an alternate power source, consult a certified electrician or contact Baileigh
Industrial prior to energizing the machine.
ATTENTION: HAVE ELECTRICAL UTILITIES CONNECTED TO MACHINE BY A
CERTIFIED ELECTRICIAN!
Your Baileigh Machine is Certified
Check if the available power supply is the same as required by the machine (consult
nameplate on machine)
WARNING: Make sure the grounding wire (green) is properly connected
to avoid electric shock. DO NOT switch the position of the green grounding wire if any
electrical plug wires are switched during hookup.

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14
•Improper connection of the equipment-grounding conductor can result in risk of electric
shock. The conductor with insulation having an outer surface that is green with or without
yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric
cord or plug is necessary, do not connect the equipment-grounding conductor to a live
terminal.
•Check with a qualified electrician or service personnel if the grounding instructions are not
completely understood, or if in doubt as to whether the tool is properly grounded.
•Repair or replace damaged or worn cord immediately.
Extension Cord Safety
Extension cord should be in good condition and meet the minimum wire gauge requirements listed
below:
LENGTH
AMP RATING
25ft
50ft
100ft
0-6
16
16
16
7-10
16
16
14
11-12
16
16
14
13-16
14
12
12
17-20
12
12
10
21-30
10
10
No
WIRE GAUGE
An undersized cord decreases line voltage, causing loss of power and overheating. All cords
should use a ground wire and plug pin. Replace any damaged cords immediately.
WARNING: In all cases, make certain the receptacle in question is
properly grounded. If you are not sure, have a qualified electrician check the
receptacle.

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OPERATION
Dry Running Machine
Before actually bending, several “dry runs” should be performed. This will remove any trapped
air from the cylinders and hoses. Also, this will familiarize you with the controls and functions of
the machine. To do this, set a bend angle and then activate the hydraulics to extend and retract
the cylinders to simulate a bend.
Setting Bend Angle
1. Reverse machine until both cylinders are fully retracted.
2. Set the digital controller to “0” by pressing the “F1/RST (reset)
button. The lower green number is preset position and the top
red number is the machine position.
3. In order for the machine to function the digital control needs to
have a stop point programmed for more than 5 degrees.
4. Press the “Right/Down” arrow key to activate the lower preset
degree field. Pressing the “Right/Down” arrow key will highlight
each digit field. The digit field will slowly blink when highlighted.
Machine will only bend to 200 degrees. The cylinders will
deadhead when the reach full extension.
5. When the digit is highlighted, press the “UP” arrow key to change
to the desired digit in that field.
6. When the desired bend degree is entered, press the “Circle”
button to save. The machine will now stop at this preset degree.
CAUTION: Always wear proper eye protection with side shields, safety
footwear, and leather gloves to protect from burrs and sharp edges.
CAUTION: Keep hands and fingers clear of the dies and swing arms. Stand
to the front of the machine to avoid getting hit with the material during the bending
process. When handling large heavy materials make sure they are properly supported.

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7. The digital control and preset should only be used in whole
degrees. For example 90, 91, 92 not 90.1 or 90.5. If any number
is entered after the decimal the control will add 1 to the final
degree. So it’s best to leave it at 0.
8. If you want to compensate for spring back the “0” position can
be set anywhere.
a. For example: Take a piece of material and insert it into
the die and close the counter die.
b. Activate the FWD pedal until the material just starts to
bend.
c. Set your “0” point here and that should compensate for
most of your spring back.
d. Now the preset value can be entered exactly to the
desired degree + / ‐.
9. Another way is to “Add on” spring back values to the preset.
a. To do this set your “0” position with the cylinders fully
retracted.
b. Insert material and bend a part to exactly 90° using a
framing square.
c. When still at the final position. Document the actual machine position.
d. For example: If the control reads 105° take 105‐90 = 15° (90 deg being your desired
bend angle). This will be the value you will add to your nominal degree setting when
entering preset values.
10.There is no right or wrong way to use this control. It is purely the user’s preference.
Home position with 90° Preset Stop Point. Stop position with 90° Preset Stop Point.

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DIE SELECTION AND INSTALLATION
Before any bending can take place, the
proper die set must be chosen to match the
material being bent. (EX) 1-1/2” diameter
tubing requires a die set marked 1-1/2”
tube.
A Hook Arm
B Bend Die
C Hold down Bolts
D Plastic Slide
E Counter Die Mount
F Bronze Counter Die Insert
G “0” Mark
Note: Pipe and Tube are not
the same, (see table 1) for nominal pipe
sizes. All BAILEIGH INDUSTRIAL dies are
color coded to avoid confusion between
pipe and tube (see table 2).
IMPORTANT: Damaged or worn
tooling should be replaced before
attempting to bend material. This will
ensure that bends are correct and provide a longer life to machine components.
When handling large heavy dies and/or material, make sure it is properly lifted and supported.
1. To install the die, slip the die over the centering pin until the three unequally spaced drive
pins engage the receiving holes formed in the die.
Note: The die will only fit one way.
2. When the drive pins line up the die will drop all the way down to the spindle.
3. Install and tighten the 1/2-13 socket head bolts provided with the die. Tighten these bolts
enough to hold the die firmly down to the spindle. Approximately 30-40ft-lb. (40-50N•m).
IMPORTANT: FAILURE TO PROPERLY BOLT DOWN DIE WILL RESULT IN
DAMAGE TO MACHINE AND TOOLING.
A
G
F
B
C
D
E