Valken TB-500 User manual

ROTARY DRAW BENDER
MODEL:TB-500
OPERATING MANUAL

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CONTENTS
1. INTRODUCTION
2. SAFETY PRECAUTIONS
3. UNPACKING
4. ASSEMBLY INSTRUCTIONS
5. MA INTENANCE
6. OPERATION
7. MATERIAL LAYOUT
8. BENDING SUGGESTIONS
9. PIPE BENDING AND TUBE BENDING DIAGRAMS
10. GLOSSARY OF COMMONLY USED TERMS
11. DRAWING AND PART LIST

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1. INTRODUCTION
1.1
You have made a practical choice in TTMC an Model TB-500 Pipe
and Tube Bender.
It has been carefully built of high quality materials and designed to
give many years of efficient service. The simplicity of design and
minimum effort required to operate the machine contributes towards
meeting schedules and producing greater profits
1.2
The Model TB-500 is a manually powered “Rotary Draw" bending
machine. To bend material, a bending die. counter die and hook
sleeve are required. The material is hooked by the hook sleeve and
is powerfully rotated in the clockwise direction. As the bending die
rotates, the counter die remains stationary. Forcing the material to
conform to the radius and shape of the bending die. The Model
TB-500 is capable of producing 180 degree bends in one shot by
continuing to pull the ratchet lever. (200 deg. max.) Each pull of the
lever gives approximately4 degrees of movement.
1.3
The Model TB-500 Bending Machine you have purchased is built of
solid steel and high quality components ensuring maximum rigidity.
1.4
In the next chapter of this manual, there are safety-related

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descriptions for attention. These matters for attention contain the
essential information to the Operators while Operating and
maintaining. Failure to follow these instructions may result in great
damage on the machine or the Operator.
2. SAFETY PRECAUTIONS
Safety Guide
2.1 Read this manual before Operating the machine
2.2 Keep this manual handy for answers to any questions you may
have. Store it near the machine to be usable in the future
2.3 Workers shall not depend on only the safety equipment. They
shall familiarize and understand the machine before Operating and
maintaining the machine
Safety Precautions
2.4 Before being engaged in Operating this machine. Please read
and understand the entire instruction manual, and follow all the
warning signs labeled on the machine. Do not disfigure or remove
2.5 During operation please do not expose any of your body parts
near to the moving parts of the machine.
2.6 Never touch work piece or tooling unless completely stopped and
in the unloaded condition.
2.7 Before using the machine, make sure that the tooling is properly
installed to avoid accidents and machine damage.
2.8 Operators should wear safety glasses, and remove rings.

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watches, jewelry and loose fitting clothing for their own protection
while operating the machine.
2.9 There must be no obstacles to obstruct the operator while in the
working area.
2.10 If machine is going to be left unattended, the handle should be
removed.
2.11 Please do not put any tools or measuring devices on the moving
parts of the machine
3. UNPACKING
3.1 After receiving machine, visually inspect for damage. Any
damage should be reported immediately to TTMC. Inc
3.2 The machine weight is approximately 103 kg. Extreme care
should be taken when un-packaging. There are many small pieces
so check all packing material for small parts.
3.3 Check and identify all parts as shown in the bill of materials, and
layout in a clean area, for easy identification.
4. ASSEMBLY INSTRUCTIONS
4.1 Locate a position to mount the stand base in your shop. Give
enough clearance around machine to allow for operation. Approx a 6
foot radius from the center of the machine is adequate.
4.2 Fasten the stand welding to a concrete floor and use “Red Head”
style concrete anchors.
Caution: This machine must be anchored to a concrete

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floor.
4.3 After the stand welding is fastened to the floor the main machine
can be assembled
4.4 Begin by a gathering all of the parts and lay them out as shown below
4.5 Before the major components can be assembled, you must
pre-assemble some components. Looking at dwg #M050-EV2.
Locate parts #2.3.7.8.9.10.11 & 20. Install bumper pins and snap
rings into the plates orienting them as shown below. Note: # 7 & 8 are
different lengths

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4.6 Locate the mid-plate #2 and install the threaded lower bushing
#17 as shown below and in M050-EV2.
4.7 Install the bronze pivot bushing #13 and one of the blue thrust
washers #12 onto the threaded lower bushing as shown below. Coat
the inside and outside of the pivot bushing and the blue thrust
washers with general purpose grease. This will aid in holding the
thrust washers in place and provide lubrication during bending..

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4.8 Locate the latch drive bars (upper #9 and lower #11) making sure
the bumper pins are installed along with the snap rings.
4.9 Install upper drive bar #9

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4.10 Install another blue thrust washer as shown below
4.11 Next install the ratchet wheel # 1 onto the lower pivot sleeve.
Note the orientation of the ratchet wheel because it can be put on
backwards. Orient as shown below.

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4.12 Install another blue thrust washer as shown below
4.13 Install the latch drive bar (lower) #11 orienting as shown

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4.14 Install another blue thrust washer as shown below
4.15 Locate the bottom plate #3 and slide onto the threaded sleeve
as shown below. Make sure the short bumper pin is installed in the
bottom plate as shown
4.16 Locate the large locknut #14 and thread it onto the threaded
sleeve as shown below

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4.17 Using two people grab the partially assembled ratchet wheel
assembly and flip it over lowering it onto the stand. Install the (4)
3/8-16 x 1” bolts and lock washers. Your assembly should look like
the picture below.

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4.18 Next the top frame section can be assembled; use dwa #
M050-EV4 Locate the (2) remaining thrust washers (#9). the top
plate (#1) upper pivot bushing (bronze) (#10). hook drive plate (#2)
and the 1 -1/2” snap ring (#15). Insert the pivot bushing into the top
plate. Grease as you did in the previous step. Insert thrust washer
onto the pivot bushing

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4.19 Install the bronze bushing as shown below.
4.20 Install one of the blue thrust washers as shown below.

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4.21 Install the hook drive Plate. This must be oriented correctly as it
can be put on backwards, see picture below
4.22 Install the remaining thrust washer and finally the 1-1/2” snap
ring.
4.23 Locate the plate spacer (#4) and the rectangular spacer (#11)
and fasten them to the ratchet wheel using 5/8-11 x 1-1/2 with lock
washers, as shown below. Do not tighten yet

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4.24 Locate the 3 Iong spacers (#3). short spacer (2) 3/4-10 x 6.5
HHCS. and (1) 3/4-10 x9.0 HHCS with lock washers. Install the top
plate assembly spacers and bolts as shown below. Do not tighten
any of the main bolts yet.
4.25 Now that the majority of the machine is built, the drive lever
section can now be assembled, use dwa #M050-EV3. Locate the 2
drive links (#2) the shaft block (#4). Bolt together using (8) 5/16-18 X
1” as shown below.

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4.26 Set this assembly aside and continue with the latch drive bars
from the last step. Locate spacer (#6) and bolt the drive bars together
with the 3/8-16 x 1 -3/4” flat head screw
4.27 Install snap ring onto shaft (#11) and slip through drive link end
hole through middle and bottom plates. and install lower snag ring to
shaft (#11) as shown below

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4.28 Locate lock tabs (#7). Spacer (#8). 5/8” drive pin (#5). install a
5/8” snap ring onto shaft (#5). slip shaft through holes in lock tab.
upper drive lever slots and then lower drive lever slots and finally the
latch plate. Install the 5/8” lower snap ring onto shaft
4.29 Install pivot pin (#12) through drive link, lock tab slots. upper
drive bar. the drive link again. lower drive bar. and finally the lower
lock tab.

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Install snap rings on both sides, as shown below.
4.30 Next the anti spring back lever can be pre assembled, using
dwa #M050-EV-4 locate the anti spring back lever (#7). pivot block
(#8). 1/ 2-13x1 -3/4 hex bolt. 1/2” lock. (2) 1/2” washers and (2)
5/ 1 6 x1 hex bolts
4.31 Install on the machine as shown below

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4.32 Install the lower latch plate as shown using (2) 1/4-20x3/4”
screws