Mb 900 Owner's manual

REV 1 March 10 2011

Operating, Servicing, and Safety

Manual

Model # 900

90° Hydraulic Bender

CAUTION: Read and Understand

These Operating, Servicing, and

Safety Instructions, Before Using

This Machine.

1-800-467-2464

10 Cooperative Way Wright City, MO 63390

P.O. Box 110 Foristell, MO 63348

1-636-745-7757 Fax 1-636-745-2874

www.mittlerbros.com

- 2 -

Table of Contents

•Safety Pg.3

•Hydraulic Safety Precautions Pg.4

•Hydraulic System Operation Pg.5

•Machine Set up Pg.6

•Operation Pg.7

•Math Formulas Pg.8-11

•Technical Diagram Pg.12

•Optional Equipment Pg.13-15

•Maintenance Pg.16

- 3 -

SAFETY

The purpose of the safety section of this manual is to inform operators and

maintenance personnel of the precautions to be taken while operating or servicing the

machine. The following are a few basic guidelines to follow, but as with any type of

machinery good judgment and a safe attitude should be applied at all times.

1. Always disconnect power, lock-out and tag-out machine per OSHA regulations before

attempting to service this machine.

2. Always wear safety glasses or other approved eye protection while operating or

servicing the machine.

3. Keep all body parts and any foreign objects away from moving parts. Do not reach

into the machine without first disconnecting all power sources.

4. Do not attempt to override any safety device on the machine.

5. Do not operate the machine if it has been damaged or is not operating properly.

6. Do not wear jewelry (watches, rings, necklaces, etc.), or loose fitting clothing while

operating or servicing the machine.

7. The machine should only be operated or serviced by properly trained, authorized

personnel.

8. Replacement parts should have the same specification and operation as the original

parts on the machine.

9. Before starting the machine be sure it is set up properly.

10. The machine and work area should be kept neat and clean.

11. Do not operate or service any machine while under the influence of drugs or alcohol.

NOTE: THESE SAFETY RULES ARE FOR YOUR BENEFIT TO HELP PREVENT INJURY TO

YOURSELF AND/OR YOUR CO-WORKERS. REVIEW ALL SETUP AND OPERATING

PROCEDURES, WHETHER COVERED OR NOT, IN THIS MANUAL TO HELP INSURE SAFE

OPERATION OF THE MACHINE.

- 4 -

HYDRAULIC SAFETY PRECAUTIONS

WARNING

General Operation

•All WARNING statements must be carefully observed to help prevent personal injury.

•Before operating the pump, all hose connections must be tightened with the proper tools. Do not over

tighten. Connections should only be tightened securely and leak-free. Over tightening can cause

premature thread failure or high pressure fittings to split at pressures lower than their rated capacities.

•Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately shut off the

pump and release all pressure. Never attempt to grasp a leaking pressurized hose with your hands.

The force of escaping hydraulic fluid could cause serious injury.

•Do not subject the hose to potential hazard such as fire, sharp surfaces, extreme heat or cold or

heavy impact. Do not allow the hose to be altered or kink, twist, curl, crush, cut, or bend so tightly that

the fluid flow within the hose is blocked or reduced. Periodically inspect the hose for wear, because

any of these condition’s can damage the hose and possibly result in personal injury.

•Do not use the hose to move attached equipment. Stress can damage hose and possibly cause

personal injury.

•Hose material and coupler seals must be compatible with the hydraulic fluid used. Hoses also must

not come in contact with corrosive materials such as creosote-impregnated objects and some paints.

Consult the manufacturer before painting a hose. Hose deterioration due to corrosive materials can

result in personal injury. Never paint the couplers.

•Inspect machine for wear, damage, and correct function before each use. Do not use machinery that

is not in proper working order, but repair or replace it as necessary.

•Replace worn or damaged safety decals.

•Modification of a product requires written Power Team authorization.

•Use only components with the same pressure rating when assembling a system or machine.

Pump

•Do not exceed the hydraulic pressure rating noted on the pump data plate or tamper with the internal

high pressure relief valve. Creating pressure beyond the rated pressure can result in personal injury.

•Before replenishing the fluid level, retract the system to prevent overfilling the pump reservoir. An

overfill can cause personal injury due to excess reservoir pressure create when cylinders are

retracted.

Air Supply

•Shut off and disconnect the air supply when the pump is not in use or before breaking any

connections in the system.PREPARATION & SET-UP

Air Supply Hook-Up

Remove the thread protector from the air inlet of the pump. Select and install the threaded fittings

which are compatible with your air supply fittings. The air supply should be 20 CFM (.57 M3/min.) and

100 PSI (7 BAR) at the pump to obtain the rated hydraulic pressure. Air pressure should be regulated

to a maximum of 140 PSI (9 BAR). Secure your pump fitting to the air supply.

WARNING:If improperly used, pressurized equipment can be potentially hazardous. Therefore:

•Hydraulic connections must be securely fastened before building pressure in the system.

•Release all system pressure before loosening any hydraulic connection in the system.

Venting the Reservoir

To improve hydraulic fluid delivery and increase useable hydraulic fluid capacity, remove shipping

plug and install filler/vent cap before using the pump.

- 5 -

HYDRAULIC SYSTEM

1. Remove the RED Plug in the pump assembly and replace with the

supplied BLACK plug. This is the reservoir venting system

and damage or inoperability may result if not changed out.

2. Attach the hydraulic hose to the pump. Be sure to use a

quality thread sealer on both connections

3. Attach an air line fitting for your shop air to other end of the

pump.

4. Push the pump foot pedal to the release position (TOE END) to

relieve all internal pressure.

5. Push the MALE hose end, from the pump, into the FEMALE

Cylinder fitting.

6. Thread the retainer collar hand tight. NOTE: This procedure will insure that the male & female fittings

positively seat against each other, eliminating any possibility of air locking. CAUTION Failing to follow

this procedure may cause the cylinder to not retract and / or leak.

BLEED THE CYLINDER

7. Connect a compressed air supply (90PSI) to the pump.

8. Elevate the pump and hose above the cylinder.

9. Push the hydraulic pump pedal HEEL END to actuate the

cylinder. Run the cylinder out about half way. Release the pump

by pressing on the TOE END of the pedal. Repeat this process

three or four times or until the ram cylinder movement is smooth.

RED Plug should

be changed to

BLACK Plug

Pump Assembly

Hydraulic Hose

Air

Connector

TOE END

Retract

HEEL END

Pump

Push Down to

Release Pressure

Female End

Male End

Retainer Collar

- 6 -

MACHINE SETUP

1. Remove machine from packaging.

2. Place machine on table or floor.

3. Remove roller pin.

4. Rotate upper frame out of the way.

5. Remove clevis pin.

6. Remove bender shoe & follow bar from packaging.

7. Insert shoe into clevis.

Note: Shoe can be installed to rotate in either direction

to complete the bends.

8. Insert clevis pin.

9. Remove saddle pin from adjustable saddle.

10. Place saddle on to shoe as shown.

11. Insert saddle pin into saddle and shoe.

CAUTION:Be sure pin is completely through bottom saddle arm.

12. Place follow bar on to machine as shown.

13. Slide roller as close as possible to follow bar.

Note: Lubricate (oil) roller Top / Bottom and Inside Diameter

14. Close the upper frame.

15. Note: Lubricate (oil) Pin Outside Diameter Insert roller pin through the upper

frame, roller, & lower frame.

CAUTION:Be sure pin is completely through lower frame arm.

16. Machine is now ready for use.

#12 Follow Bar

#13 Roller

#10 Saddle

#5 &#8 Clevis Pin

#7 Clevis

#9 & #11 Saddle Pin

#16 Female Hydraulic

Coupler

#3 &#15 Roller Pin

#4 &#14 Upper Frame

#16

Hydraulic

Coupler

Release

Pressure

Pump

Pressure

AIR / HYDRAULIC PUMP

- 7 -

OPERATION

1. Insert tubing into channel in the shoe, follow bar, and

adjustable saddle.

CAUTION: Be sure roller pin is completely through lower

frame

2. Align the bend start point marked on tubing to the bend start

point on the bender shoe.

3. Make sure that tubing is sticking all the way through the adjustable

saddle.

4. Tighten adjustable saddle ”V” block against tubing.

CAUTION: Be sure pin is completely through bottom saddle arm.

5. Align the front edge of the follow bar with the bend start point of the bending shoe.

6. Press the foot pedal on the hydraulic pump, using short bursts until the bending shoe and follow

bar are close to the roller.

7. Check your tubing to make sure that your tubing start point is still aligned with the shoe start point.

8. Now make your bend by pressing down on the foot pedal heel on the hydraulic unit until the

desired angle is reached.

9. It usually is necessary to bend tubing past the desired angle a few degrees to account for tubing

spring back. Note: Record location of reference scale pointer to reference scale to assist in

completing future bends to same degree of bend with same tubing material, size, and wall

thickness. Then you can bend the next pieces to that same reference scale mark.

10. When desired angle is reached, press hydraulic pump foot pedal toe to release pressure.

11. Turn adjustable saddle knob counterclockwise to remove saddle pin, saddle and follow bar.

12. Repeat these steps with each additional bend.

#2 Bend Start Point

#3 Tubing Through the Saddle

#4 Roller

Male

Hydraulic

Coupler

#9 Release

Pressure

#4 &#7

Pump

Pressure

AIR / HYDRAULIC PUMP

#5 Shoe Start Point

#8 Reference Scale

#10 Follow Bar

#10 Saddle

#10 Saddle Pin

- 8 -

CORRECTED MATHEMATICAL FORMULA

FOR HYDRAULIC TUBING BENDER

WHEN USING INSTRUCTION VIDEO

The following formula should be used to determine the start point for each required bend.

The example will be for a Double Bevel Bend

L1 = 26 25 degree angle

L2 = 15 65 degree angle

L3 = 39 65 degree angle

L4 = 15 25 degree angle

L5 = 26

Bend #1 Start Point:

L1 – ½ developed length (DL25) – ½ (Gain)

26” – ½ (3.064”) – ½ (.050)

26” – 1.532” - .025” = 24.448

Bend #2 Start Point:

L1 + L2 – Gain 1 – ½ (DL65) – ½ (Gain 2)

26 + 15 - .050 –1/2 (7.941) – ½ (.973”)

26 + 15 - .050 – 3.9705 - .48895 = 36.491

Bend #3 Start Point:

L1 + L2 + L3 – Gain 1 – Gain 2 – ½ (DL65) – ½ (Gain 3)

26 + 15 + 39 - .050” - .978 – ½(7.941) – ½ (.972”)

26 + 15 + 39 - .050” -.978 – 3.9705 - 0.486 = 74.515

Bend #4 Start Point:

L1 + L2 + L3 + L4 – Gain 1 – Gain 2 – Gain 3 – ½ (DL25) – ½ (Gain 4)

26 + 15 + 39 + 15 -.050 - .978 - .978 –1/2 (3.054) – ½ (0.497)

26 + 15 + 39 + 15 - .050 - .978 - .978 – 1.527 – 0.025 = 91.442

______________________________________________________________________________________

- 9 -

GAIN FACTORS

Degree of

Bend Multiplier

Degree

of Bend

Multiplier

Degree

of Bend

Multiplier

1

.0000

31

.0136

61

.1134

2

.0000

32

.0150

62

.1196

3

.0000

33

.0165

63

.1260

4

.0000

34

.0181

64

.1327

5

.0000

35

.0197

65

.1397

6

.0001

36

.0215

66

.1469

7

.0001

37

.0234

67

.1544

8

.0003

38

.0254

68

.1622

9

.0003

39

.0276

69

.1703

10

.0005

40

.0298

70

.1787

11

.0006

41

.0322

71

.1874

12

.0008

42

.0347

72

.1964

13

.0010

43

.0373

73

.2058

14

.0013

44

.0400

74

.2156

15

.0015

45

.0430

75

.2257

16

.0018

46

.0461

76

.2361

17

.0022

47

.0493

77

.2470

18

.0026

48

.0527

78

.2582

19

.0031

49

.0562

79

.2699

20

.0036

50

.0600

80

.2891

21

.0042

51

.0637

81

.2944

22

.0048

52

.0679

82

.3074

23

.0055

53

.0721

83

.3208

24

.0062

54

.0766

84

.3347

25

.0071

55

.0812

85

.3491

26

.0079

56

.0860

86

.3640

27

.0090

57

.0911

87

.3795

28

.0100

58

.0963

88

.3955

29

.0111

59

.1018

89

.4121

30

.0126

60

.1075

90

.4292

GAIN = GAIN FACTOR FOR DEGREE OF BEND X RADIUS

EXAMPLE:

FIND THE GAIN FOR AN 85 DEGREE BEND

USING A 7 INCH RADIUS

GAIN = .3491 X 7 = 2.4437 OR 2 7/16

-- 10 --

DEVELOPED LENGTH

DEVELOPED LENGTH = .0175 X DEGREE OF BEND X RADIUS

EXAMPLE:

FIND THE DEVELOPED LENGTH OF A 70 DEGREE

BEND USING AN 8 INCH RADIUS.

DEVELOPED LENGTH = .0175 X 70 X 8 = 9.80 OR 9 13/16

________________________________________________________________________________________

-- 11 --

TABLE FOR OFFSET MULTIPLIER

Degree

of

Bend

Multiplier

Degree

of

Bend

Multiplier

1

57.30

25

2.37

2

28.65

26

2.28

3

19.11

27

2.20

4

14.33

28

2.13

5

11.47

29

2.06

6

9.57

30

2.00

7

8.21

31

1.94

8

7.18

32

1.89

9

6.39

33

1.84

10

5.76

34

1.79

11

5.24

35

1.74

12

4.81

36

1.70

13

4.45

37

1.66

14

4.13

38

1.62

15

3.86

39

1.59

16

3.63

40

1.56

17

3.42

41

1.52

18

3.24

42

1.49

19

3.07

43

1.46

20

2.92

44

1.44

21

2.79

45

1.41

22

2.67

46

1.39

23

2.56

47

1.37

24

2.46

48

1.35

DISTANCE BETWEEN BENDS = OFFSET MULTIPLIER FOR

DEGREE X OFFSET HEIGHT

EXAMPLE:

FIND THE DISTANCE BETWEEN BENDS FOR A

15 INCH OFFSET USING 25 DEGREE BENDS.

DISTANCE BETWEEN BENDS = 2.37 X 15 = 35.55 OR 35 9/16

-12-

ITEM NO.

QTY.

PART NO.

1

900-003 Cylinder Mount Block

2

1

900-002 Lower Frame

3

1

900-005 Upper Frame

4

1

900-004 Shoe Clevis

5

1

900-007 Follow Bar Roller

6

1

900-018 Scale Pointer

7

1

900-502 Hydraulic Cylinder

8

1

900-008-C Hinge Pin

9

1

900-008-

A Roller Pin

10

1

900-008-B Clevis Pin

11

1

900-006 Clevis Adapter

12

2

05/8-11x1-1/2 Hex Head

13

1

Delrin

14

1

5/16-18x1/4 Set Screw

15

2

1/4-20x1/2 Button Head

16

1

1/4-20x1/4 Set Screw

17

1

Roll Pin

1-800-467-2464 www.mittlerbros.com

5

9

3

8

14

16

13

7

1

6

12

2

15

17

11

10

4

-13-

Optional Equipment

Adjustable Saddles for 90 & 180 Hydraulic Benders

Saddle eliminates the need for individual saddles for each tubing size. Two sizes

handle 5/8” to 1-3/4” Round & Square Tubing.

Advantages

• Securely holds each tube, eliminates tube creep

• Easy Release “V” Block eliminates Stuck Saddle from tube spring back

• Easier Bend-to-Bend Alignment with light pressure on tube

2500-300 Adjustable Saddle, Small 5/8" to 1-3/8"

2500-301 Adjustable Saddle, Medium 1-1/2 to 1-3/4

2500-302 Adjustable Saddle, Large 2" OD

Pumps

900-504-6 Air Hydraulic Pump, 6' Hose & Fitting

900-508-6 Electric Hydraulic Pump, Hose & Fittings 6'

900-D Digital Read Out for 90° Hydraulic Tube Bender

900-500-DVD Tubing Bending DVD for 90 Degree Hydraulic Tube Bender

-14-

Bend Protractors

2100-4 4" Protractor Assembly

2100-5 5" Protractor Assembly

2100-6 6" Protractor Assembly

2100-7 7" Protractor Assembly

2100-8 8" Protractor Assembly

2100 4" Thru 8" Protractor Set

-15-

BEND-TECH EZ

Designed for simple 2d parts!

900-510 Bend-Tech EZ Software

BEND-TECH EZ-3D

Designed for 3d bending, with 360 degree part rotation!

900-511 Bend-Tech EZ-3D Software

BEND-TECH PRO

Full 3d Assembly & Manufacturing Instructions, plus all EZ features!

900-512 Bend-Tech Pro Software

900-513 Bend-Tech SE Software

-16-

MAINTENANCE

Inspecting The Hydraulic Fluid Level

Check the fluid level in the reservoir after every 10 hours of use. Drain and replenish the reservoir with Power Team

hydraulic fluid after every 300 hours of use approximately.

Air Hydraulic Pump

For pumps with a 105 cubic inch (1.71) reservoir capacity

Electric Hydraulic Pump

For pumps with a 2 gallon (7.61) reservoir capacity

The fluid level should be 1/2 inch (12.7 mm) from the filler /

vent cap with all cylinders retracted.

The fluid level should be 1-3/4 inch (44.5 mm) from the filler /

vent cap with all cylinders retracted.

For Machines With:

SPX Power Team

Orange & White Cylinder with Black Letters

White & Black Pump

Enerpac

Yellow Cylinder with Black Letters

Yellow & Black Pump

Use: AW 46 - Non Foaming Hydraulic Fluid

or

Flame Out # 220 Fire Resistant Hydraulic Fluid

Use: ISO 7 HF 101 Gal

or

ISO 32 HF 100 Qt.

or

Mobil DTE 24 Hydraulic Oil is Compatible with Enerpac Components

Refilling The Reservoir

If additional fluid must be added to reservoir, use only manufacturer suggested hydraulic fluid.

Clean the entire area around the filler plug before adding fluid to the reservoir.

Remove the filler plug and insert a clean funnel with filter.

The cylinder must be fully retracted and the air supply disconnected when adding the fluid to the reservoir.

MB 900 Owner's manual

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