Roper Whitney MBB 4181 MAGNABEND Guide

MODEL NO. MBB 4181 MAGNABEND
OPERATION, PARTS & MAINTENANCE MANUAL
Model: Purchased From:
Serial #: Date Received:

FOREWORD
ThismanualhasbeenpreparedfortheownerandoperatorsofRoperWhitneyNo.MBB4181
Magnabend. Itspurpose,asidefromoperationsinstructions,istopromotesafetythroughtheuse of
acceptedoperating procedures. Read all instructions thoroughlybeforeoperatingtheMagnabend.
Alsocontained in this manual is the parts listforyourMagnabend. Itis recommended that only Roper
Whitneyor factory authorized partsbeused as replacements.
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Warranty Statement:
3 YEAR LIMITED WARRANTY
Roper Whitney (“Manufacturer”) warrants, commencing with the date of shipment to first end-user
(“Customer”) and for a period of thirty-six (36) months thereafter, all machinery and parts manufactured by Manufacturer to
be free of defects in workmanship and material. This warranty remains in force for the above time period only if all of
Manufacturer’s operational procedures are followed and recommended maintenance is performed. If, within such
warranty period, any machinery or parts manufactured by Manufacturer shall be proved to Manufacturer’s satisfaction to
be defective, such machinery or parts shall be repaired or replaced, at Manufacturer’s option. All warranty claims are made
F.O.B Manufacturer’s plant, providing such machinery or parts are returned freight prepaid to Manufacturer’s plant or
designated service center for Manufacturer’s inspection. All failed parts or components must be returned to Manufacturer
prepaid for inspection before credit will be issued for new parts or components. Manufacturer’s obligation hereunder shall
be confined to such repair or replacement and does not include any charges, direct or indirect, for removing or replacing
defective machinery or parts. No warranty shall apply to machinery, or parts or accessories, which have been furnished,
repaired, or altered by others so as, in Manufacturer’s judgment, to affect the same adversely or which shall have been
subject to negligence, accident or improper care, installation, maintenance, storage, or other than normal use or service,
during or after shipment. No warranty shall apply to the cost of repairs made or attempted outside of Manufacturer’s plant
or designated service center without Manufacturer’s authorization. No warranty shall apply with respect to machinery or
part not manufactured by Manufacturer, including but not limited to motors, accessories, electrical and hydraulic
components, if such machinery or part is subject to warranty by the manufacturer of such machinery or part. No warranty
claims by Customer will be honored with respect to any machinery or part from which the name and date plate has been
removed or is otherwise no longer located or exhibited on such machinery or part. THE FOREGOING WARRANTIES ARE IN
LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED
WARRANTY OF MERCHANTABILITY AND IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
MANUFACTURER SHALL NOT BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES WHATSOEVER WITH
RESPECT TO MACHINERY, PARTS, ACCESSORIES, OR SERVICES MANUFACTURED OR FURNISHED BY IT OR ANY
UNDERTAKINGS, ACTS, OR OMISSIONS RELATING THERETO. UNDER NO CIRCUMSTANCES SHALL MANUFACTURER
BE LIABLE FOR ANY CONSEQUENTIAL OR OTHER DAMAGES, EXPENSES, LOSSES, OR DELAYS HOW SO EVER
CAUSED. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF.
Note: Consumable tooling is not covered under the 3 year manufacturer’s warranty.
RETURN OF THE PRODUCT REGISTRATION CARD FURNISHED WITH THE PRODUCT IS NECESSARY TO OBTAIN
WARRANTY COVERAGE THEREON. CARD MUST BE FULLY COMPLETED, SIGNED BY THE PURCHASER, AND IF
APPLICABLE, SIGNED BY THE DISTRIBUTOR. RETURN REGISTRATION CARD TO: Roper Whitney / 2833
Huffman Blvd. / Rockford, IL 61103

SAFETY INSTRUCTIONS
1. WARNING: Electricaldanger--misuseor improper installation of bending brake connected to a
sourceof electricity may result in accidental shockthatcouldcauseinjuryor death. Power cord
installationmust begrounded.
2. WARNING: Mechanical danger -- keep handsand fingers clear ofclamping keepers at all times.
Misuseor improper handling of the bending brake may result in accidentalpinchingthatcouldcause
injuryto or lossoffingers.
3. Donotoperate bending brake without reading Operator’sManual and without proper supervisory
instructions.
4. Bendingbrakeisaonepersonmachineandmustbeoperated by qualified authorized personnel.
5. Themagneticbending base is intended only for bending sheetmetalthroughthekeeperclamps.
Anyother use mayseriouslydamagethe magnetic surfaces,orcausepersonal injury.
6. Forheavyduty bending, the mountinglegsshouldbe attached to thefloorwith1/2” x 1 1/4”screws.
Ifthe bending brake is to be portable,theoptional foot platform kit #256080004 shouldbe usedfor
additionalstability.
7. Donotplaceanyforeign objects between clamping keeper and magnetic work base.
8. Whenusingshort clamping keepers,donot store full-lengthclampingkeeperon any structuralpartof
thebendingbrake. Thisalsoapplies to any foreign objects.
9. Donot clutter keeper tray with tools, bent parts,or scrapsheetmetal. Onlystore keepers in the tray.
10. Donot place or hold anyforeign steel bars or plates withinthe keeper area or attemptto reposition
anykeeper while the magnet is switched on. Failure to comply may seriously damage the magnetic
surfacesor causepersonalinjury.
11. Properhandlingproceduresarerequired for large sheet metal lengths, as they may become
awkwardto handle when themagnetisswitched off (upon loweringthebendingbeam).
12. Do not use bending brake if servicing is required.
13. Whennot inuse,turn offelectricalpower.
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SAFETY LABELS
Do not operate the Magnabend without the proper safety labels in place. If your machine is
missingthe following labels,pleasecontactRoper Whitney Co. oryourauthorized Roper Whitney
distributorto order.
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SPECIFICATIONS
Capacity: 18 ga. mild steel
BendingWidth: 49 inches
Weight: 275pounds
Electrical: 115V, 1PH, 60 HZ
SET-UP INSTRUCTIONS
(See Figure 7)
1. Attachfourlegs(Items19&20)tocolumn(Item18),usingeight 3/8-16 x 3/4 socket head cap
screws(Item 21). With approximately 5/16” clearance betweenthebrakeandthe stiffening plate,
guidethe two screws down into the slots. Levelthebrakesub-assemblyand tighten screws.
2. Setbrakesub-assembly(Item1)intoslotsintopofcolumn,usingtwo 3/8-16 x 3/4 socket head cap
screws(Item 21) andstiffeningplate(Item 22).
3. Placeangleindicator rod (Item 12) andcollar(Item27) over handle (Item 8) andattachhandleto
undersideofbendingbeam,using two 5/16-18 x 5/8 socket head cap screws (Item 10).
4. Attachanchorblock(Item13,attachedtoangleindicatorrod)tomagneticbasewithtwo#10-24x
5/8 socket head cap screws (Item 14). Be sure that brass actuator is assembled above
microswitchlever in magnetic base.
5. Attachtrays(Items 23 & 24) to rear of column with two 1/4-20 x 1/2 roundheadmachinescrews
(Item25). Narrow tray is positioned to front,overtopofcolumn.
6. Attachgaugebars(Item26)torearof magnetic base, and add collars and thumbscrews (Items 27 &
28).
7. Fastenlegssecurely to floor with appropriate screws, or use optional foot plate assembly.
8. Connectpowercord to 115voltgroundedoutlet.
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SET-UP INSTRUCTIONS
(Continued)
9. Whenrequiredtomovetheassembledbendingbrake(275 lb. weight), proper lifting shall be with an
overheador portable crane, and using a lifting sling placed securely aboutthemagnetbendingtable
andstand.
Donotattempttoslide the bending brake across the floor, because tipping may result in accidental
damageto the brake, or cause personal injury.
OPERATING INSTRUCTIONS
STRAIGHTBENDING:
1. Besuremain power is turned on, and the balldetentsontheundersideof the full length keeper are
properlylocated in the angled grooves in the magnetic base.
2. Insertthe workpiece under the keeper. Tiltthekeeperforwardand align your bend with itsfront
edge.
3. Depressandhold the safety button to apply a light clampingforce.
4. Beginbendingby lifting the handle. Fullclampingwilloccur and the safety buttoncannowbe
released. Continuebending until the desired angle is reached. The angle gauge on the handle
indicatesthe angle between the bending beam and the magnetic base. The adjustable collar
provides a stop for repeat operations.
5. Lowerthehandle to switch off themagnetandremovethe workpiece.
LIPORHEM:
1. ProceedaswithStraight Bending, but continue bend as far as bending beam will go (approximately
120°).
2. Reposition the keeper and workpieceas shownin Figure 1.
Pressthe safety button and swingthebeamoverto partially
flattenthelip.
3. Fullyflattenlip byusingmagnetic clampingonly. Position workpiece
asshown in Figure 2. Press safetybuttonandlifthandle slightly.
4. Lowerhandleand remove workpiece.
FIGURE1
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FIGURE2

FIGURE3
FIGURE4
FIGURE5
FIGURE6
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OPERATING INSTRUCTIONS
(Continued)
BOXBENDING
1. Startingwithanotchedblank, make the first two bends usingthefull
length keeper as in straight bending.
2. Select one or more of the shorter keepers and position them as
showninFigure 3. It is not necessary to makiean exactlength since
thebend will carry over up to 1”betweenkeepers, depending on the
type and thickness of material being bent.
PARTIALBENDS:
1. TheopenenddesignoftheMagnabendallowspartialbending.
2. Position the portion of the workpiece to be bent under a keeper
at the end of the magnetic base. Allow portion to be left flat to
extendbeyond the end. (Figure 4)
3. Proceedas with straight bending.
ROLLED EDGES:
1. Rollededges of various diameters may beformed,using
any mild steel round bar.
2. Position the workpiece, keeper and bar as shown in Figure 5.
Be sure that keeper does not overlap front pole piece. Position
theleading edge of theworkpiece as nearly under thecenter of
the bar as possible, to obtain a minimum flat section in the finished roll.
3. Wrapthe workpiece around the bar withthebending beam as in
straight bending. Reposition the workpiece as shown in Figure 6 and
continuetowrapuntilthedesired roll is reached. The number of
wrappingoperationswillvary with the diameter of the bar and the
material being bent.

NO. MBB 4181 PARTS CHART
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NO. MBB 4181
PARTS LIST
ITEM PART NO. PART NAME QTY.
1 256130003 BrakeSubAssembly, Magnetic 1
2 256080001 HingeAssembly 3
3 756130447 Block,Hinge 3
4 756160470 Pin,Hinge 3
5 756260471 Wire,Retainer 3
6 756020442 Beam,Bending 1
7 756020443 Beam,Extension 1
8 756460445 Handle 1
9 633356335 Grip,Plastic 1
10 611012130 Screw, SHC 5/16-18 x 5/8 2
11 656000187 Scale,Angle 1
12 756030448 Rod,AngleIndicator 1
13 756130449 Block,Anchor 1
14 611012053 Screw, SHC #10-24 x 5/8 2
15 756030450 Actuator,Microswitch 1
16 600346356 Label,Magnabend 1
17 600346332 Label,Caution 1
18 756060451 Column 1
19 756140452 Leg,R.H. 2
20 756140453 Leg,L.H. 2
21 611012173 Screw, SHC 3/8-16 x 3/4 10
22 756060454 Plate,Stiffening 1
23 756440455 Tray,Front 1
24 756440456 Tray,Rear 1
25 609012086 Screw, RHM 1/4-20 x1/2 1
26 756030444 Bar,Gauge 2
27 756260446 Collar 3
28 641012628 Screw,Thumb 3
29 256130002 CoverAssembly,Electrical 1
30 660082034 Switch,Safety 1
31* 660152661 & 660152662 IsolatorSwitch & Heater 1 ea.
*(These two parts need to be ordered together)
32 256990048 Switch,Micro 1
33 256080005 Keeper, FullLength 1
34 756360432 Keeper,Half 1
35 756360433 Keeper, 4 3/4” 1
36 756360434 Keeper, 3 3/4” 1
37 756360435 Keeper, 2 3/4” 1
38 756360436 Keeper, 1 7/8” 1
39 756360437 Keeper, 1 3/8” 1
40 756360438 Keeper, 1” 1
41 756360439 Keeper, 3/4” 1
42 756360440 Keeper, 6” 1
43 756360441 Keeper, 12” 1
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NO. MBB 4181
PARTS LIST
ITEM PART NO. PART NAME QTY.
44 600346123 Nameplate 1
45 600346350 Label,Roper Whitney 1
46 600346352 Label,Round RW 1
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MAGNETIC BRAKE SUB ASSEMBLY
(PARTA)
(PART #256130003)
MAGNETICBRAKE SUBASSEMBLY
PARTS B & C CONTINUED ON PAGES 12-13.
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MAGNETIC BRAKE SUB ASSEMBLY
PART B
(PART #256130003)
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MAGNETIC BRAKE SUB ASSEMBLY NOTES
PART C
(PART #256130003)
Beforeconnectingcoilto rectifier,hi-pot test coil between steel partsandcoillead wires.There
shallbe no current leakage with 1500 voltsA.C. for 1 second; note that only two testsare
permissibleperassembly.
Alum.cover strip must notextendabove steel poles.
Microswitch shall be turnedonwithin3° beam movement whenliftedfromthe down position.
Uponlowering the beam from the 90° position themicroswitchshallturnoff within 15° beam
movement. Adjustmentsmadewith noted part.
Notedhandle is installed only fortestingthebrake and setting the angularscale. Whenmoving
beamupto180°andreturningto 0° position there shall be no binding or beam misalignment
throughhinges.
Notedsurfacesfreeofblue paint. Remainder of brake paint blue #51-5-017.
Testingprocedure:
A. Placefull length keeper (painted) on the brake magnetic surface. With115voltsA.C. switch
poweronandcheckpilotlightindication.
B. Pressthe safety buttontoapply light clamping. Thekeepershould pull down. Ifnot,then
checkfor foreign matter under keeper, liftingdetent sticking, excessive bow in keeper, non
flatmagnetic surface, etc.
C. Turnonmain magnetic fieldbypressing safety buttonandslightly pullingbeamhandle
beyond3° movement. Measure the current draw. Should be 12 amps + 10% but will
decreaseas coil heats up. Leave the current on untilthethermaloverloadtrips. Thattakes
1to3minutes.
D. Make a full length bend with 18 gage mild steel and make sure keeper does not pop off and
bendis straight with a uniform bend angle. Bend radius shall not exceed 5/32”.
E. Filloutinspectionsheettobesignedbyforeman.
Notedpartsmustbeassembledtohingeassemblybeforeinstallingonbendingbrake.
Presspinflushwithtopsurfaceofhingeplate. Greasepinnose.
Notedsurfaces free of yellow paint. Remainder of keeper paint yellow #51-4-239.
Pressflush with top surface of keeper.
Ensurethat mating (spherical radius) surfaces of hinge block and pin are in firm contact
throughoutentiretravel. If necessaryflatten springwith punch.
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