TAPCO TOOLS MAX-I-MUM II User manual

Manufactured under one or more of the following U.S. Patents:
3,161,223 4,321,817 4,651,553 4,489,583 4,493,200
4,445,356 4,372,142 4,766,757 3,817,075 4,557,132
4,240,279 4,671,094 3,482,427 4,494,397 3,559,444
5,343,728 5,353,620 5,505,069 Other U.S. & Foreign Pats. Pend.
Featuring
• Setup
• Basic Operations
• Capacity Chart
• Parts List
• Adjustment, Care & Maintenance
• Examples of Basic Shapes
Shown with
MAX CUT-OFF
(Heavy duty roller
shear, optional)
All MAXIMUM II models come
complete with heavy duty folding
stand, stabilizer bar and foot
pads that convert to wheels for
complete portability. Shown
with optional MAX CUTOFF.
Used for commercial,
architectural and industrial
sheet metal fabrication
Brings
Commercial
Bending Power to the
Job Site
Operations Manual
TapcoTools.com | [phone]

2
TapcoTools.com 800.521.8486
MAX-I-MUM II Port-O-Bender®
MAX CUT-OFF Features
•Heavy duty roller shears.
•Hardened and captured tool
steel cutting knives for safety
and durability.
•Eliminates the need for
unsafe utility knives and
conventional shears.
•Pays for itself by reducing
scrap and costly kning
damage to bending hinges.
MAX CUT-OFF Capacities
•Up to .050 aluminum. All vinyl.
•Up to 20 ga. galvanized steel
•Up to 32 oz. copper
•Up to 24 ga. stainless steel
MAX CUT-OFF ®
Makes factory quality cuts
in commercial metals
right on your MAX-I-MUM II
Port-O-Bender
U.S. & Foreign Pats. Pend.
A basic overview of MAX-I-MUM II part names and
locations. (Detailed parts list on page 6.)
1 Hemming Handles
2 Pivot Links
3 Castings
4Back Rail
5Throat Depth
6Anvil
7 Strut
8 Wheel
9 Faspin
10 Vertical Support
11 End Assembly
MAXIMUM II PORTOBENDER
QUICK REFERENCE GUIDE
12 Lifting/Bending Handle
13 Stabilizer Assembly
14 Cross-Brace
15 Foot Rails
16 “T” Knob
17 Moving Hinge
18 Handle Plug
19 Max Cut-O (optional)
20 Locking Handle
21 Base Hinge
3
4
7
10
2
5
8
6
9
21
11
12
13
16
14
17
15
9
19
20
18
1
®

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4
5
7
8a
Faspins
Faspin
Strut Assembly
8b
6
9
ALWAYS WEAR SAFETY GLASSES
WHEN USING POWER TOOLS.
End Bracket
2 x 4 Bracket
Cross Brace
3
2
1
Steps (indicated above)
Cross
Brace
“T”Knob
Stabilizer End
Bracket
Outside
Channel
Pin
Pin
MAX-I-MUM II
and MAX 20
PRO-III Only
FRONT OF
BENDER
DETAIL
B
DETAIL
ABRAKE BRACKET ASSEMBLY DETAIL
CBRAKE BRACKET ATTACHMENT
BRAKE
BRACKET
1. Remove all parts from box. Attach 2 x 4 Bracket toVertical Support using
1/4-20 x 1 1/2" Hex Bolts and 1/4-20 2-Way Lock Nuts.
2. Slide Vertical Support into End Assemblies, securing with Faspin (part
#10678).
3. Attach Wheel Assembly to End Assembly using 1/4-20 x 2 1/2" Hex Cap
Bolt and 1/4-20 2-Way Lock Nut.
4. Fold wheels to pad position (as indicated in diagram) and stand End
Assemblies apart. Attach Cross Braces to each Assembly (see Detail A).
Align and tighten all 4“T” Knobs snugly in place.
5. Install Stabilizer End Brackets. Insert all 4 Faspins into sides of End
Bracket. Align Stabilizer Channels with End Brackets and install all 4
bolts through End Brackets and into each corner of Channels (10688
or 10689). (See Detail A also)
6. Assemble both Brake Brackets (see Detail B for correct hole positions)
securing with hex nuts. Attach Brake Brackets to Bender with the (8)
self-tapping screws provided (see Detail C).
7. Lift and lower Bender onto Max Stand by seating Brake Brackets into
center of 2x4 Brackets. Align holes in Brackets and insert all Faspins.
8. Detach End Brackets from Strut Assembly and install to rear Outside
Channels (8a) and Back Rail (8b) using 3/8-16 x 1" Hex Bolt (8a) and
1/4-20 x 3/4" Hex Wash HD Screw (8b). Re-attach to struts with faspins.
9. Adjust Strut Assembly by sliding Upper Strut over Lower Strut and install
1 1/2" bolt through proper Strut alignment hole and into both sections
of Strut and tighten with hex nut.
MAX Stand Installation Instruction
Faspin
BACK RAIL
10084
10671
10676
(assembly)

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Setting Up the MAXIMUM II Port-O-Bender®
Hinge Clip Installation
The Hinge Clip keeps the Moving Hinge in position for ease
of aligning material. It can also prevent rippling of the mate-
rial during cut o operations.
To install Hinge Clip, locate predrilled hole on bottom center
of Moving Hinge. Align holes in Clip and Hinge as shown
and insert Phillips head screw provided.
Note: You must engage Hinge Clip for proper operation of
Max Cut-O.
Faspin
Locking Handle
Handle
Plug
Hemming
Handle
Hex Bolt
Hemming Handle Installation
The MAXIMUM II Hemming Handle
Assembly includes: (2) Hemming Handles,
(4) Handle Plugs, (4) Faspins, (4) Hex Bolts.
Attach the Hemming Handle over the
Handle Plugs and secure them with
Faspins. Now tighten the 3/8"Hex Bolts
with a 9/16"wrench. Handle can be de-
tached from now on by simply removing
the Faspins.
T-Handle
Wrench
Exploded view of Handle Assembly —
First insert one end of Handle Plug into
Lifting/Bending Handle and install Faspin
through holes.
Next, insert Handle Assembly into hole
in bottom of Moving Hinge. Align hole in
hinge with Handle Plug and insert screw
using Allen wrench as shown. Secure with
1/4-20 Lock Nut.
Lifting/Bending Handle Installation
Repeat for other handles.To remove han-
dles now, simply release Faspins. Always
use more than one handle when bending.
Insert Hex Bolt through Locking Handle
of your Port -O-Bender and into base of
Hemming Handle as indicated using the
3/8"Hex Bolts provided. HAND TIGHTEN
ONLY. Repeat for other side.
Faspin
Handle
Plug
1/4-20
Lock Nut
Lifting/
Bending
Handle
Moving
Hinge
1/4-20 x 11/2" Screw
Secure
with 1/4-20
Lock Nut

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Pivot Link Adjustment Instructions
IMPORTANT: Your Port-O-Bender
®
incorporates an advanced new Micro-Adjust system that enables you to adjust the gripping
tension on material faster and easier than ever. The Pivot Links have been pre-set at the factory for average holding capacity
and ease of operation. However, it’s important that you readjust your Port-O-Bender
®
to your stock thickness.Your Port-O-
Bender
®
may also need periodic adjustment due to extreme weather and/or working conditions. It is important that you follow
these steps when you adjust your Port-O-Bender
®
to ensure proper gripping tension and maximum performance.
First check the uniformity of the clamping pressure along the entire length of
your Port-O-Bender
®
by using the following method.
TO TEST —
Cut some narrow strips of aluminum or use strips from the stock you will be using
and lock one under each shoe casting as indicated in Figure 1. Then lightly pull
the material to determine the tightness and uniformity of each Pivot Link. Refer
again to Figure 1. If the material can be moved when the Port-O-Bender
®
handle is
locked or if it requires excessive pressure to lock the handle down on the material
then the Pivot Links may need adjustment.
NOTE: All adjustments are made with the Port-O-Bender
®
in the “open”
position. All adjustments are tested with strips of material placed in the
Port-O-Bender
®
in the “locked” position.
Figure 1
TO ADJUST (Optional method)—
As an alternate method you may use a 5/8" open-end wrench
directly on the Pivot Link Stud by turning 1/4 turn either
COUNTER-CLOCKWISE to INCREASE locking tension or
CLOCKWISE to DECREASE locking tension. (See Figure 3.)
Repeat test step above to check tension.
TO ADJUST —
Insert the 3/16" hex wrench provided into the Pivot Link Stud through
the access hole in the upper link. (See Figure 2.) Turn 1/4 turn
either COUNTER-CLOCKWISE to INCREASE locking tension
or CLOCKWISE to DECREASE locking tension.
Repeat test step above to check tension.
Figure 2
Figure 3
Pivot Link
Stud
Upper
Adjustment
Link
Lower
Adjustment
Link
MAX-I-MUM II
Port-O-Bender Pivot Link Assembly
Adjusting the MAXIMUM II Port-O-Bender®
Decrease
Increase

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10094 1/4-20 Hex Flange Nut
10166 8'6" Moving Hinge
10168 10'6" Moving Hinge
10170 12'6" Moving Hinge
10172 14'6" Moving Hinge
10177 8'6" Base Hinge
10180 10'6" Base Hinge
10183 12'6" Base Hinge
10186 14'6" Base Hinge
10201 8'6" Back Rail
10203 10'6" Back Rail
10205 12'6" Back Rail
10207 14'6" Back Rail
10347 Pivot Arm-Left
10348 Pivot Arm-Right
10351 Lifting Handle Assembly
10454 8'6" Locking Handle
10458 10'6" Locking Handle
10462 12'6" Locking Handle
10464 14'6" Locking Handle
10491 8'6" Stainless Edge
10492 10'6" Stainless Edge
10493 12'6" Stainless Edge
10494 14'6" Stainless Edge
10499 8'6" Hinge Pin
10500 10'6" Hinge Pin
Item # Description Item # Description Item # Description
10501 12'6" Hinge Pin
10502 14'6" Hinge Pin
10504 12'6" Tape Measure
10505 10'6" Tape Measure
10506 8'6" Tape Measure
10511 8'6" Vinyl Strip
10512 10'6" Vinyl Strip
10513 12'6" Vinyl Strip
10514 14'6" Vinyl Strip
10519 1/4–20 x 3/4" Hex Wash HD Sc
11625 3/8-16 X 3 1/4" Hex Cap Bolt
10534 3/8" Flat Washer
10535 3/8-16 Nylock Hex Nut
10537 1/4-20 X 3/4 FL HD Sc
10538 3/8" Lock Washer
10540 Hemming Handle Assembly
10887 T-Handle Hex Key
11531 Lifting Handle Cap
11532 Moving Hinge Cap
11533 Back Rail Cap
11534 Locking Handle Cap-Right
11535 Locking Handle Cap-Left
11536 Base Hinge Cap-Left
11537 Base Hinge Cap-Right
11396 Pivot Link Assembly Kit (6)
11397 1/4" x 1 1/4" Faspin Kit (4)
11398 Handle Plug Hemming Kit
Hemming Handle Plugs (2)
3/8–16 x2 1/4" Bolt
11400 Locking Handle Pin Kit
10 pins, 20 keepers
11408 Bolt and Nut Kit
1/4–20 x 2 1/2" Bolt (5)
1/4–20 Nulok Nut (5)
11413 Hinge Clip Kit
11416 Max Handle Plug Kit
MAX Lifting Handle Plugs (2)
1/4–20 x 1 1/2" Bolt (2)
1/4–20 Nylok Nut (2)
11420 Coupling Nut Kit
Coupling Nut Kit (2)
1/4–20 x 3/4" Screw (2)
12042 MAX-II Parts Bag 10'/12'
12055 MAX-II Parts Bag 8'
12056 MAX-II Parts Bag 14'
12061 C Casting
12075 8'6" Locking Anvil
12076 10'6" Locking Anvil
12077 12'6" Locking Anvil
12078 14'6" Locking Anvil
*For Model Specic Parts, 10' part
numbers are shown in diagram.
Parts List

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For Your Records
Complete the information below and save
with this manual for future reference.
Model and Serial Number
Date and Place Purchased
Your Tapco Port-O-Bender®is virtually maintenance free and will provide you with years
of reliable and trouble-free performance, however, there are a few basic necessities
required to keep your Port-O-Bender®like new.
1. Clean the clamping surfaces each day before using. Use only clean shop towels
that are free of dirt, oil and metal chips.
2. Do not use your bender around your saw table as the cuttings may get in between
clamping surfaces and cause excessive wear or material scratching. Brush away
any cuttings or lings that accumulate.
3. Transport your Port-O-Bender®in the unlocked position. You may transport it in
the locked position if you clamp a piece of cardboard or vinyl siding between the
clamping surfaces.
4. If your material is getting scratched, examine the Stainless Bending Edge, Base
Hinge and Moving Hinge for roughness or burrs. Remove burrs with emery cloth
or replace excessively worn parts. Optional Pro Cut-O will help eliminate excessive
wear to costly bending edge.
5. Use a lightweight spray oil along the moving pivot hinge after every
40 hours of use.
Care and Maintenance of your Port-O-Bender®

EXAMPLES OF BASIC SHAPES
1
2
7
4
5
3
6
6. Outside Corner
Down
1
2
7
4
5
3
6
Down
Up
Up
Up Up
Down
2. Coping Cover
Down
1
2
3
5
4
Up
1
2
3
5
4
7. Counter Flashing
3. One Piece Sot Mitre 8. Brick Frieze
5. Hip/Ridge Cap
9. “F” Channel/Inside Corner
3
2
4
5
1
5
4
2
3
1
5
4
2
3
1
4. Reglet Flashing
Up
Up
Down Down
Down
Up
Up
Up
Up
Down
Down
Down
10. “D” Style Gutter
Up
Up
Up
Down
Down
Down
Down
Down
Down Down
Down
Down
Down Down
Up
Up
Down
Down
Up
Up
Up
Up
Up
Up
1. Gravel Stop
3
2
4
5
1
NOTE: UP & DOWN refers to the clad, painted or FINISH SIDE of
the material as it is placed into the Bender.
Down
Down
Up
SIDING & ACCESSORIES
TRIM & MOULDINGS
ROOFING
STONE
WINDOWS
OUTDOOR LIVING
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