Sealey PBS90.V2 User manual

INSTRUCTIONS FOR:
INDUSTRIAL PIPE BENDERS 9 & 15 TON
MODEL No's: PBS90.V2 PBS91.V4
Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions and
properly maintained, give you years of trouble free performance.
1. SAFETY INSTRUCTIONS
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS.
USE THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE
DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
3. ASSEMBLY
4. OPERATION
2. INTRODUCTION & SPECIFICATION
üEnsure the pipe bender is in sound condition and good working order.
Take action for immediate repair or replacement of damaged parts. Use
recommended parts only. The use of improper parts may be dangerous
and will invalidate the warranty.
üKeep bender and associated parts clean for best and safest performance.
üLocate the pipe bender in a suitable, well lit work area.
üKeep work area clean and tidy and free from unrelated materials.
üUse on level and solid ground, preferably concrete.
üEnsure all non-essential persons keep a safe distance whilst the pipe
bender is in use.
üCheck that bending die is correctly seated on ram and that roller shafts are
fully engaged in the frame before operating hydraulic unit.
üUse a qualified person to lubricate and maintain the hydraulic unit.
üConfirm that the recommended hydraulic oil is used during maintenance.
üWear appropriate safety clothing including cloves and eye protection.
üKeep hands away from die and rollers when bending pipe.
▲Caution! Cut pipe edges may be sharp, take care when handling any cut
steelwork.
ûDO NOT operate the pipe bender if damaged.
ûDO NOT allow untrained persons to operate the pipe bender.
ûDO NOT exceed the rated capacity of the hydraulic unit (see below).
ûDO NOT use the pipe bender for purposes other than that for which it
is intended.
ûDO NOT top up system with brake fluid. Use hydraulic oil only.
ûDO NOT alter the pressure control valve.
üStore pipe bender in a dry, childproof area, with the hydraulic
ram retracted.
WARNING! Ensure that you have read and understood Section 1
Safety Instructions before operating the pipe bender.
WARNING! When the pipe bender is packed in its box it is
extremely heavy and will require at least 2 people to move it.
The pump unit itself is also very heavy and should be handled
with care.
3.1 Remove the pump unit from the box and place it upside down on a
smooth flat clean surface.
3.2 Identify the four 12mm socket cap mounting bolts and slide a spring
washer and then a plain washer onto each bolt. Referring to fig.1 align
the four mounting holes in the lower plate (A) with the threaded holes
in the block at the front of the pump unit. Insert the four 12mm socket
cap bolts and screw down finger tight. Take the 10mm hex key
provided and fully tighten the four bolts.
3.3 Adjacent to the mounting bolts are three tubular sockets for the tripod
legs. Insert a tripod leg into each socket. See D in fig.1. Screw an 8mm
socket cap bolt through the side of each socket to clamp the legs in
place as shown at E in fig.1. Tighten each bolt using the 6mm hex key.
3.4 Turn the assembly the right way up so that it is standing on its tripod
legs. Care should be taken when doing this, get another person to help
you as the unit is heavy.
3.5 Locate the bending rollers (see Z above) into suitable holes in the lower
plate (A) so that they are displaced equally either side of the pump unit.
3.6 Identify the pivot pin (C) for the upper plate (B) and have it ready for
insertion. (see fig.2.)
3.7 Lower the upper plate (B) onto the pipe bender so that the upward
facing shafts of the bending rollers locate into the plate and the pivot
arms are lying either side of the front of the pump block. Referring to
fig.2 align holes 'X' in the pivot arms with the hole 'Y' in the pump block
and fully insert the pivot pin (C).
Tripod mounted pipe benders suitable for bending pipes up to 180° (3 x 60°
bends). Compact hydraulics with integral 9 or 15 ton ram. Suitable for bending
DIN classified medium and heavy pipe. Two-speed hydraulic pump gives fast
positioning of pipe in dies and the power to bend up to 50mm pipe (PBS90), or
75mm pipe (PBS91). The units are supplied with six/eight interchangeable pipe
dies and are supplied in a heavy wooden crate for easy transportation.
MODEL: .............................................. PBS90........................................ PBS91
Maximum Load.........................................9ton...........................................15ton
Maximum Pipe Ø...................................50mm..........................................75mm
Height ..................................................700mm........................................700mm
Weight .....................................................53kg.......................................... 117kg
Die Sizes .................13mm(1/2"), 19mm(3/4") ............ 13mm(1/2"), 19mm(3/4")
................................ 25mm(1"), 31mm(1-1/4") ............ 25mm(1"), 31mm(1-1/4")
.................................37mm(1-1/2"), 50mm(2")............ 37mm(1-1/2"), 50mm(2")
..................................................................................... 64mm(2-1/2"), 75mm(3")
PBS90.V2, PBS91.V4 Issue No:2 07/01/16
When using hydraulic type pipe benders, the bent pipe or
tube is prone to deformation on both the inside and outside
curvature. The pipe or tube can be deformed into an oval
shape or creased depending on the wall thickness of the
material. This is not a fault and largely unavoidable.
Consider packing the pipe or tube with dried sand or similar
medium before bending as this may help to alleviate
deformation of the pipe or tube. Pack the sand tight and cap
both ends.
fig.1
fig.2

4.6 Introduce the pipe between the die and the rollers, swing down the upper
plate ensuring that it locates correctly onto the roller shafts and position the
pipe so that the centre of the required bend is in the centre of the die.
4.7 Close the release valve by turning the knob clockwise. Insert the pump
handle into the socket above the larger of the two pumping pistons
(see fig.3) and pump to close the gap between the die and pipe. Before
applying bending pressure do a final check on the positioning of the
pipe. Now insert the handle into the socket above the smaller of the
pumping pistons and pump until the required degree of bend is achieved.
4.8 Open the release valve and the piston will retract under spring tension.
Raise the upper plate and remove or reposition the pipe as required.
4.9 After use, store the pipe bender with the ram fully retracted and the
pumping pistons in the down position.
5.1 Regularly oil all moving parts.
5.2 Annually replace hydraulic oil using Sealey Hydraulic Jack Oil -
HJO/500ML or HJO/5L. Never use brake fluid.
4.1 The nut on the oil filler located on the top of the pump body doubles as
a vent and needs to be opened one turn before using the unit. The nut
should be done up tightly if the unit is moved or stored away for a long
period, to prevent hydraulic oil spillage. See fig.3.
4.2 Before using the pipe bender purge any air from the hydraulic system
by opening the relief valve situated on the side of the unit anticlockwise
and pumping the handle several times. Close release valve.
4.3 Hinge up the top plate. Select the required die (see fig.4) and place it
onto the end of the ram piston. See fig.5.
4.4 Position the rollers according to the triangular label in the centre of the
top plate. See fig.2-B.
4.5 Rotate the rollers so that the most appropriate of the three contours
available will be against the pipe.
Note! Consider packing the pipe or tube with dried sand or similar
medium before bending as this may help to alleviate deformation of the
pipe or tube. Pack the sand tight and cap the ends.
6. DECLARATION OF CONFORMITY
5. MAINTENANCE
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of this product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
fig.3
fig.5
fig.4
Parts support is available for this product. To obtain a parts listing and/or diagram,
please log on to www.sealey.co.uk, email [e-mail] or phone [phone].