Klutch 49652 User manual

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Thank you very much for choosing a Klutch product. For future reference, please complete the
owner’s record below:
Serial Number/Lot Date Code: _______________ Purchase Date: _______________
Save the receipt, warranty and these instructions. It is important that you read the entire manual
to become familiar with this product before you begin using it.
These12 to 16 ton pipe bendersare designed for certain applications only. Northern Tool and
Equipment cannot be responsible for issues arising from modification or use of these products
in an application for which they were not designed. We strongly recommend that these
products not be modified and/or used for any application other than that for which they were
designed.
For technical questions please call 1-800-222-5381.
Table of Contents
Intended Use ----------------------------------------------------------------------------------------------- 1
Technical Specifications ---------------------------------------------------------------------------------- 1
Important Safety Information ---------------------------------------------------------------------------- 3
Assembly --------------------------------------------------------------------------------------------------- 4
Before Each Use ------------------------------------------------------------------------------------------ 4
Operating Instructions ------------------------------------------------------------------------------------ 4
49652 & 49653 – Hydraulic Pipe Benders ------------------------------------------------------------- 4
49654 – Air/Hydraulic Pipe Bender ---------------------------------------------------------------------- 5
After Each Use -------------------------------------------------------------------------------------------- 7
Maintenance ----------------------------------------------------------------------------------------------- 7
Replacement Parts --------------------------------------------------------------------------------------- 7
Parts Diagram & Parts List - 49652 ----------------------------------------------------------------------- 8
Parts Diagram & Parts List - 49653 ----------------------------------------------------------------------- 9
Parts Diagram & Parts List - 49654 --------------------------------------------------------------------- 10
Limited Warranty ----------------------------------------------------------------------------------------- 11
Intended Use
These pipe benders are designed for bending thick-walled pipes (schedule 40 and 80, including
black or galvanized) but NOT designed for bending thin walled pipe (for example, conduit) or
exhaust pipe. The benders include various size bending dies as given in the specifications below.
Technical Specifications
49652 - 12 Ton Hydraulic Pipe Bender
12-16TON PIPE BENDERS
OWNER’S MANUAL
12-16TON PIPE BENDERS
OWNER’S MANUAL
Item #’s 49652, 49653, 49654
1 of 11
WARNING:
Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and
other basic safety precautions may result in serious personal injury.
Property
Max. Capacity
Max. Bending Capacity
Max. Travel
Hyd. Oil Reservoir Capacity
Hydraulic Oil
Cast Iron Bends
Bending Applications
Max. Pipe Wall Thickness
Bending Die Diameters
Dimensions, in.
Shipping Weight
Specification
12 Tons
2" diameter Round
9-1/2"
14 oz. (400 ml)
H32
1/2" 2" Pipes
Black Pip e, Galvanized Pipe
0.179"
1/2 in., 3/4 in., 1 in., 1-1/4 in., 1-1/2 in. and 2 in.
24 x 6-1/4 x 20-1/2
95 lbs.

12-16TON PIPE BENDERS
OWNER’S MANUAL
12-16TON PIPE BENDERS
OWNER’S MANUAL
Important Safety Information
WARNING:
• Read and understand all instructions. Failure to follow all instructions may result in serious
injury or property damage.
• The warnings, cautions, and instructions in this manual cannot cover all possible conditions
or situations that could occur. Exercise common sense and caution when using this tool.
Always be aware of the environment and ensure that the tool is used in a safe and
responsible manner.
• Do not allow persons to operate or assemble the product until they have read this manual
and have developed a thorough understanding of how it works.
• Do not modify this product in any way. Unauthorized modification may impair the function
and/or safety and could affect the life of the product. There are specific applications for
which the product was designed.
• Use the right tool for the job. DO NOT attempt to force small equipment to do the work of
larger industrial equipment. There are certain applications for which this equipment was
designed. It will do the job better and more safely at the capacity for which it was intended.
DO NOT use this equipment for a purpose for which it was not intended.
• Industrial or commercial applications must follow OSHA requirements.
WARNING:
• This product may contain chemicals known to the State of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
WORK AREA SAFETY
• Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well lit.
Cluttered, wet, or dark work areas can result in injury. Using the tool in confined work areas
may put you dangerously close to other cutting tools and rotating parts.
• Do not allow the product to come into contact with an electrical source. The tool is not
insulated and contact will cause electrical shock.
• Keep children and bystanders away from the work area while operating the tool. Do not allow
children to handle the tool.
• Be aware of all power lines, electrical circuits, water pipes, and other mechanical hazards in
your work area. Some of these hazards may be hidden from your view and may cause
personal injury and/or property damage if contacted.
PERSONAL SAFETY
• Stay alert, watch what you are doing, and use common sense when operating the tool. Do
not use the tool while you are tired or under the influence of drugs, alcohol, or medication. A
moment of inattention while operating the tool may result in serious personal injury.
• Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewelry, or long hair can be
caught in moving parts. Air vents on the tool often cover moving parts and should be
avoided.
• Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant
safety goggles (not safety glasses) with side shields, or when needed, a face shield. Use a
dust mask in dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust
collection systems, and hearing protection when appropriate. This applies to all persons in
the work area.
• Do not overreach. Keep proper footing and balance at all times.
• Do not use the tool when tired or under the influence of drugs, alcohol or medication.
• Secure the work with clamps or a vise instead of your hand when practical. This safety
precaution allows for proper tool operation using both hands.
3 of 11
Property
Max. Capacity
Max. Bending Capacity
Max. Travel
Hyd. Oil Reservoir Capacity
Hydraulic Oil
Cast Iron Bends
Bending Applications
Max. Pipe Wall Thickness
Bending Die Diameters
Dimensions, in.
Shipping Weight
Specification
16 Tons
3" Diameter Round
9-1/2"
15 oz. (450 ml)
H32
1/2" 3" Pipes
Black Pipe, Galvanized Pipe
0.196"
1/2 in., 3/4 in., 1 in., 1-1/4 in., 1-1/2 in., 2 in., 2-1/2 in. and 3 in.
24-3/4 x 8-3/4 x 22-1/2
163.0 lbs.
Property
Max. Capacity
Max. Bending Capacity
Max. Travel
Hyd. Oil Reservoir Capacity
Hydraulic Oil
Cast Iron Bends
Bending Applications
Max. Pipe Wall Thickness
Operating Air Pressure
Bending Die Diameters
Dimensions, in.
Shipping Weight
Specification
16 Tons
3" diameter Round
9 1/2"
22 oz. (650 ml)
H32
1/2" 3" Pipes
Black Pipe, Galvanized Pipe
0.196"
90 PSI
1/2 in., 3/4 in., 1 in., 1-1/4 in., 1-1/2 in., 2 in., 2-1/2 in. and 3 in.
24-3/4 x 8-3/4 x 22-1/2
163.0 lbs.
Size
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
Schedule 40
Yes
Yes
Yes
Yes
Yes
Yes
Schedule 80
Yes
Yes
Yes
No
No
No
Bends up to 90 degrees
49653 – 16 Ton Hydraulic Pipe Bender
49654 - 16 Ton Air/Hydraulic Pipe Bender
2 of 11

12-16TON PIPE BENDERS
OWNER’S MANUAL
Assembly
No Assembly required
Before Each Use
• Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well lit.
Cluttered, wet, or dark work areas can result in injury. Using the tool in confined work areas
may put you dangerously close to other cutting tools and rotating parts.
• Check for damaged parts before each use. Carefully check that the tool will operate properly
and perform its intended function. Replace damaged or worn parts immediately. Never
operate the tool with a damaged part.
Operating Instructions
49652 & 49653 – Hydraulic Pipe Benders
• The pipe bender must be placed on a smooth, level surface that is capable of supporting the
weight of the pipe bender, pipe and all accessories.
• Do not exceed the maximum limit of the pipe bender posted on the frame and on the jack.
• Two person operation. For safety, when moving the Pipe Bender or bending large pieces of
pipe, always involve two people. When bending large pipe, one person is needed to balance
the pipe in the bending dies, while a second person operates the bottle jack's handle.
Bending a Pipe
1. Place the pipe bender on a solid, level floor or workbench.
NOTE: If a workbench is selected, use shop clamps to
secure the bender in place and keep it from rocking.
2. Choose the proper size bending die and slip it on the
end of the ram as shown in Figure 1.
3. Choose an angle to bend the pipe.
• 35-45 degree bend: place the rollers (#5) between the
far outside holes on the frame (Figure 2).
• 90 degree bend: place the rollers (#5) further inside
the frame to increase the bending angle.
4. To move the rollers, remove the hitch pins (#6) and roller
shafts (#4) (Figure 2), and place the rollers between
corresponding holes on each side of the frame.
5. Reinstall the roller shafts and hitch pins.
6. Place the pipe over the bending die.
NOTE: To account for pipe shortening during the bend,
make sure the pipe extends beyond the rollers and, for
short pipe, set the rollers closer together.
7. Insert the jack handle into the socket on the tube bender.
8. Make sure the release valve is closed, then use the jack
handle to advance the die and bend the pipe.
9. When finished with the bend, release the pressure by
opening the release valve on the jack. Close the valve
after the ram has fully lowered.
OPERATION TIPS AND TECHNIQUES:
• The pipe bender is designed to bend water pipe and heavy-gauge galvanized pipe that is
used in commercial applications. The bottle jack (#2) is a heavy-duty tool that should last
through several years of use. The only parts that eventually wear out, during normal use, are
the seals. If hydraulic fluid is found to be seeping from the ram of the bottle jack, you can fix
the problem by installing a seal kit (not included).
• If the ram reaches the end of its stroke but still has not completed a desired bend, release
pressure just enough to remove the pipe. Set the rollers either one or two holes farther in
toward center to finish the bend.
4 of 11
12-16TON PIPE BENDERS
OWNER’S MANUAL
• It is recommended that you make templates of accurate 45 and 90 angles. Compare these
templates to an almost-finished pipe so you do not over- or under-bend. Using templates will
speed up your work.
• If you pass the 45 angle mistakenly, you can sometimes reverse the pipe and slightly press it
enough to reach the required 45.
• Bending any angle may thin and stress the walls of the pipe and narrow its center. If you
need to make bends more than 100 degrees, it is recommended that you heat the pipe during
bending. Generally, heat weakens the metal, but it also allows it to bend more freely.
• Pipes bent past 90 will flow into the bending die, making the pipe hard to remove after
bending. Greasing the inside of the die will make this removal easier, or switching to a larger
die for bending the last few degrees will eliminate this difficulty.
• For bends up to 90 degrees for 2 1/2" or 3" tubes, tightly fill the tube with sand and plug both
ends.
49654 – Air/Hydraulic Pipe Bender
• The pipe bender must be placed on a smooth, level surface that is capable of supporting the
weight of the pipe bender, pipe and all accessories.
• Do not exceed the maximum limit of the pipe bender posted on the frame and on the jack.
• Two person operation. For safety, when moving the Pipe Bender or bending large pieces of
pipe, always involve two people. When bending large pipe, one person is needed to balance
the pipe in the bending dies, while a second person operates the bottle jack's handle.
• Bender 49654 (air/hydraulic) should be used with compressed air only. Only use clean, dry
and regulated compressed air. Never use Oxygen, carbon dioxide or any other bottled gas as
a power source for this tool.
Bending a Pipe
1. Place the pipe bender on a solid, level floor or workbench.
NOTE: If a workbench is selected, use shop clamps to
secure the bender in place and keep it from rocking.
2. Choose the proper size bending die and slip it on the
end of the ram as shown in Figure 1.
3. Turn the bottom relief valve on the jack clockwise until
it is tight to close it.
4. For hydraulic operation, insert the jack handle into the
socket on the tube bender.
For air operation, connect the hose to the air compressor
(see 49654, Using Air Pressure, below).
5. Choose an angle to bend your pipe.
35-45 degree bend: place the rollers (#5) between the far
outside holes on the frame.
90 degree bend: place the rollers (#5) further inside the
frame to increase the bending angle.
6. To move the rollers, remove the hitch pins (#6) and roller
shafts (#5) (Figure 2), and place the rollers between
corresponding holes on each side of the frame.
7. Reinstall the roller shafts and hitch pins.
8. Place the pipe over the bending die.
NOTE: To account for pipe shortening during the bend,
make sure the pipe extends beyond the rollers and, for
short pipe, set the rollers closer together.
10. Make sure the jack release valve is closed, then use the
jack handle or air to advance the die and bend the pipe.
11. When finished with the bend, release the pressure by opening the release valve on the jack.
Close the valve after the ram has fully lowered.
5 of 11

12-16TON PIPE BENDERS
OWNER’S MANUAL
OPERATION TIPS AND TECHNIQUES:
• The pipe bender is designed to bend water pipe and heavy-gauge galvanized pipe that is
used in commercial applications. The bottle jack (#2) is a heavy-duty tool that should last
through several years of use. The only parts that eventually wear out, during normal use, are
the seals. If hydraulic fluid is found to be seeping from the ram of the bottle jack, you can fix
the problem by installing a seal kit (not included).
• If the ram reaches the end of its stroke but still has not completed a desired bend, release
pressure just enough to remove the pipe. Set the rollers either one or two holes farther in
toward center to finish the bend.
• It is recommended that you make templates of accurate 45 and 90 angles. Compare these
templates to an almost-finished pipe so you do not over- or under-bend. Using templates will
speed up your work.
• If you pass the 45 angle mistakenly, you can sometimes reverse the pipe and slightly press it
enough to reach the required 45.
• Bending any angle may thin and stress the walls of the pipe and narrow its center. If you
need to make bends more than 100 degrees, it is recommended that you heat the pipe during
bending. Generally, heat weakens the metal, but it also allows it to bend more freely.
• Pipes bent past 90 will flow into the bending die, making the pipe hard to remove after
bending. Greasing the inside of the die will make this removal easier, or switching to a larger
die for bending the last few degrees will eliminate this difficulty.
• For bends up to 90 degrees for 2 1/2" or 3" tubes, tightly fill the tube with sand and plug both ends.
49654, Using Air Pressure
Follow the steps below when using air pressure with the 49654 pipe bender.
Pressurizing the System
Depressurizing the System
Follow the steps below to release the gas inside the
oil cylinder:
1. Turn off the compressor and depressurize the air
hose, then disconnect the hose from the piep
benderjack.
2. Rotate the pressure relief valve on the jack (Figure 1)
counterclockwise to open it. When the ram has fully
lowered, close the valve.
6 of 11 7 of 11
12-16TON PIPE BENDERS
OWNER’S MANUAL
After Each Use
After use, release pressure by opening the release valve on the jack. Close the release valve
after pressure is fully released and the ram is fully lowered.
Store idle equipment properly. When not in use, the jack should be stored in "closed" position
after pressure is released and pipe bender stored in a dry location to reduce rust. Inspect the
bender for good working condition prior to storage and again before re-use. For safety, store
the pipe bender in a locked cabinet, out of reach of children.
Maintenance
Maintain your pipe bender. It is recommended that the general condition of any tool be
examined before it is used. Keep your tool in good repair by adopting a program of
conscientious repair and maintenance in accordance with the recommended procedures found
in this manual.
• Keep handles dry, clean, and free from oil and grease.
• Use only identical parts with the pipe bender. Parts that may be suitable for one tool may
create a risk of injury when used with another tool.
The pipe bender is basically maintenance free, however the oil level should be kept constant.
• Too much oil will force the surplus oil to leak from the bottle jack fill plug (Figure 3).
• Not enough oilwill cause loss of power.
The oil capacity of the pipe benders is:
• 49652: about 15 ounces (450 ml)
• 49653: about 15 ounces (450ml)
• 49654: about 22 ounces (650 ml)
Adding Oil
1. Set the tube bender upright
2. Open the release valve on the bottom, front of the jack
to retract the piston rod fully, then close the valve.
3. Remove the fill plug (Figure 3).
4. Fill the jack with oil to the level of the fill plug hole and
replace the plug.
5. Fully extend the piston rod, and then retract it to expel air from the jack.
6. Remove the fill plug and repeat steps 3 -5 until all of the air is expelled.
Replacement Parts
• For replacement parts and technical questions, please call Customer Service at
1-800-222-5381.
• Not all product components are available for replacement. The illustrations provided are a
convenient reference to the location and position of parts in the assembly sequence.
• When ordering parts, the following will be required: Model Number, Serial Number/Lot Date
Code, and Description.
• The distributor reserves the rights to make design changes and or improvements to product
lines and manuals without notice.
1. Connect the air tube of the jack to a
compressor.
2. Turn the pressure relief valve on the jack
(figure 1) clockwise to close it.
3. Start the compressor to pressurize the jack.
4. Open the pressure relief valve to release
pressure, then close it again.
3. Pump the jack handle up and down by
10-20 times.

8 of 11
12-16TON PIPE BENDERS
OWNER’S MANUAL
Parts Diagram & Part List - 49652
Part No.
1
2
3
4
5
6
7
Description
FRAME
JACK
HEX BOLT
ROLLER SHAFT
ROLLER
HITCH PIN
1/2" BENDING DIE
Q’ty
1
1
2
2
2
2
1
Part No.
8
9
10
11
12
13
Description
3/4" BENDING DIE
1" BENDING DIE
1 1/4" BENDING DIE
1 1/2" BENDING DIE
2" BENDING DIE
JACKHANDLE
Q’ty
1
1
1
1
1
1
9 of 11
12-16TON PIPE BENDERS
OWNER’S MANUAL
Parts Diagram & Part List - 49653
Part No.
1
2
3
4
5
6
7
8
Description
FRAME
JACK
HEX BOLT
ROLLER SHAFT
ROLLER
HITCH PIN
1/2" BENDING DIE
3/4" BENDING DIE
Q’ty
1
1
2
2
2
2
1
1
Part No.
9
10
11
12
13
14
15
Description
1" BENDING DIE
1 1/4" BENDING DIE
1 1/2" BENDING DIE
2" BENDING DIE
2 1/2" BENDING DIE
3" BENDING DIE
JACK HANDLE
Q’ty
1
1
1
1
1
1
1

12-16TON PIPE BENDERS
OWNER’S MANUAL
Limited Warranty
Northern Tool and Equipment Company, Inc. ("We'' or '"Us'') warrants to the original purchaser
only ("You'' or “Your”) that the Klutch product purchased will be free from material defects in
both materials and workmanship, normal wear and tear excepted, for a period of one year from
date of purchase. The foregoing warranty is valid only if the installation and use of the product
is strictly in accordance with product instructions. There are no other warranties, express or
implied, including the warranty of merchantability or fitness for a particular purpose. If the
product does not comply with this limited warranty, Your sole and exclusive remedy is that We
will, at our sole option and within a commercially reasonable time, either replace the product or
product component without charge to You or refund the purchase price (less shipping). This
limited warranty is not transferable.
Limitations on the Warranty
This limited warranty does not cover: (a) normal wear and tear; (b) damage through abuse,
neglect, misuse, or as a result of any accident or in any other manner; (c) damage from
misapplication, overloading, or improper installation; (d) improper maintenance and repair; and
(e) product alteration in any manner by anyone other than Us, with the sole exception of
alterations made pursuant to product instructions and in a workmanlike manner.
Obligations of Purchaser
You must retain Your product purchase receipt to verify date of purchase and that You are the
original purchaser. To make a warranty claim, contact Us at 1-800-222-5381, identify the
product by make and model number, and follow the claim instructions that will be provided. The
product and the purchase receipt must be provided to Us in order to process Your warranty
claim. Any returned product that is replaced or refunded by Us becomes our property. You will
be responsible for return shipping costs or costs related to Your return visit to a retail store.
Remedy Limits
Product replacement or a refund of the purchase price is Your sole remedy under this limited
warranty or any other warranty related to the product. We shall not be liable for: service or labor
charges or damage to Your property incurred in removing or replacing the product; any
damages, including, without limitation, damages to tangible personal property or personal
injury, related to Your improper use, installation, or maintenance of the product or product
component; or any indirect, incidental or consequential damages of any kind for any reason.
Assumption of Risk
You acknowledge and agree that any use of the product for any purpose other than the
specified use(s) stated in the product instructions is at Your own risk.
Governing Law
This limited warranty gives You specific legal rights, and You also may have other rights which
vary from state to state. Some states do not allow limitations or exclusions on implied
warranties or incidental or consequential damages, so the above limitations may not apply to
You. This limited warranty is governed by the laws of the State of Minnesota, without regard to
rules pertaining to conflicts of law. The state courts located in Dakota County, Minnesota shall
have exclusive jurisdiction for any disputes relating to this warranty.
Distributed by
Northern Tool and Equipment Company, Inc.
Burnsville, Minnesota 55306
NorthernTool.com
Made in China
10 of 11 11 of 11
12-16TON PIPE BENDERS
OWNER’S MANUAL
Parts Diagram & Part List - 49654
Part No.
1
2
3
4
5
6
7
8
9
Description
FRAME
BOTTLE JACK
SPRING PLATE
SPRING
ROLLER
HITCH PIN
ROLLER
1/2" BENDING DIE
3/4" BENDING DIE
Q’ty
1
1
1
2
2
2
1
1
1
Part No.
10
11
12
13
14
15
16
17
Description
1" BENDING DIE
1 1/4" BENDING DIE
1 1/2" BENDING DIE
2" BENDING DIE
2 1/2" BENDING DIE
3" BENDING DIE
JACK HANDLE
HEX BOLT M8 X18
Q’ty
1
1
1
1
1
1
1
2