Valley Bender160 User manual

Bender160™
Owner’s Manual
Supplement
0998322_C
Bender160 Owner’s Manual Supplement
© 2019 Valmont Industries, Inc., Valley, NE 68064 USA. All rights reserved.
www.valleyirrigation.com

2

3
Table of Contents
Bender160 Owner’s Manual Supplement ....................................................................................................... 1
Table of Contents ............................................................................................................................................. 3
General Information ......................................................................................................................................... 4
About This Manual ........................................................................................................................................... 4
Ancillary Equipment Warranty ........................................................................................................................ 4
Safety
Recognize Safety Information..............................................................................................................................................5
Safety Messages ..............................................................................................................................................................5
Information Messages ......................................................................................................................................................5
Use of Personal Protective Equipment................................................................................................................................6
Conductive Materials and Equipment..................................................................................................................................6
Fall Protection......................................................................................................................................................................6
Minimum Working Clearance...............................................................................................................................................7
Qualified Person ..................................................................................................................................................................7
Irrigation Equipment near Airports and Crop Dusting Aircraft .............................................................................................7
Overhead Power Lines ........................................................................................................................................................8
Minimal Lockout / Tagout Procedure....................................................................................................................................9
Sequence of Lockout ........................................................................................................................................................9
Restoring Equipment to Service .......................................................................................................................................9
Operate Safely...................................................................................................................................................................10
Safety Decals.....................................................................................................................................................................14
Overview
Bender160 Components....................................................................................................................................................19
Bender160 Swivel...........................................................................................................................................................19
Bender160 Box ...............................................................................................................................................................19
Junction Tower Box .........................................................................................................................................................19
Fixed Pipe.......................................................................................................................................................................19
Swivel Pipe .....................................................................................................................................................................19
Flexible Hose ..................................................................................................................................................................19
Bender End of Field Bender Stop ...................................................................................................................................20
Bender Stop Box.............................................................................................................................................................20
Bender Drive Unit Anchor ...............................................................................................................................................21
Optional Hold Down Components ..................................................................................................................................21
Operation
Starting the Machine.......................................................................................................................................................23
Emergency Stopping ......................................................................................................................................................23
Stopping Under Normal Conditions ................................................................................................................................23
Tilt Sensor
Restrictions
Tires................................................................................................................................................................................24
Drive Units ......................................................................................................................................................................24
Bender Anchors ..............................................................................................................................................................24
Maintenance
Safety.................................................................................................................................................................................25
Disconnect All Power ......................................................................................................................................................25
Belt Replacement ...........................................................................................................................................................26
Hose Replacement .........................................................................................................................................................26
Female Swivel Gasket Replacement ..............................................................................................................................26
Drain Seal Replacement.................................................................................................................................................27
Annual Maintenance..........................................................................................................................................................27
Troubleshooting.............................................................................................................................................. 28

4
General Information
About This Manual
Information contained in this manual applies to the Valley Bender160 option.
All information, specifications, descriptions and illustrative material contained in this manual were based on
information available at the time this publication was approved for printing.
Valmont Industries Inc. reserves the right to change specification or design at any time without notice and
without incurring any obligation. Specifications are applicable to equipment sold within the United States and
may vary outside of the United States.
Ancillary Equipment Warranty
The owner is responsible for warranty registration of all ancillary equipment such as engines, pumps and
generators with its respective manufacturer.

5
Safety
Recognize Safety Information
This irrigation equipment may be powered by high voltage which can be extremely dangerous if used improp-
erly. For maximum safety and optimum performance of the machine, all owner’s operator’s and maintenance
personnel must read and understand the owner/operator manual(s), all safety messages in this manual and
safety signs/decals on the machine before operating this equipment.
Anyone assembling, operating, servicing or maintaining this machine must read and understand all opera-
tion, maintenance, troubleshooting, testing, installation, assembly instructions and all safety messages in this
manual before operating the machine or beginning any maintenance, troubleshooting, testing, installation or
assembly of components.
These instructions alert you to certain things you should do carefully; if you don’t, you could hurt yourself or
others, hurt the next person who operates the equipment, or damage the equipment.
Safety Messages
Safety messages in this manual are preceded by the hazard symbol and one of three words, danger, warning
or caution. These messages alert you to potential hazards that could hurt you or others and or cause property
damage.
!This HAZARD SYMBOL is used to alert you to information about unsafe actions or situations, and may
be followed by the word danger, warning, or caution.
!DANGER
The HAZARD SYMBOL used with the word DANGER, will describe immediate hazards that may result in
severe personal injury or death.
!WARNING
The HAZARD SYMBOL used with the word WARNING, will describe unsafe actions or situations that may
cause severe injury, death and/or major equipment or property damage.
!CAUTION
The HAZARD SYMBOL used with the word CAUTION, will describe unsafe actions or situations that may cause
injury, and/or minor equipment or property damage.
Information Messages
Important information messages in this manual are preceded by the word NOTE.
NOTE
The word NOTE is used to alert you to information that describes procedures or tips to help you install, operate
or maintain your equipment properly.

6
Safety
Use of Personal Protective Equipment
• People working in areas where there are potential electrical hazards must use, personal protective equip-
ment that is appropriate for the specific parts of the body to be protected and for the work to be performed.
Refer to U.S. Occupational Safety & Health Administration (OSHA) Regulations (Standards - 29 CFR)
Safeguards for personnel protection. - 1910.335, or applicable national, state or local regulations, for ad-
ditional information.
• Personal protective equipment must be maintained in a safe, reliable condition and periodically inspected
or tested.
• Protective shields, protective barriers, or insulating materials must be used to protect each person from
shock, burns, or other electrically related injuries while that person is working near exposed energized
parts which might be accidentally contacted or where dangerous electric heating or arcing might occur.
When normally enclosed live parts are exposed for maintenance or repair, they must be guarded to protect
unqualified persons from contact with the live parts.
• Safety signs and tags. Safety signs, safety symbols, or accident prevention tags must be used where neces-
sary to warn people about electrical hazards which may endanger them.
Conductive Materials and Equipment
Materials and equipment that may conduct electricity must be handled in a way that will prevent them from
contacting energized power lines, exposed conductors or circuit parts.
• When handling long conductive objects (such as but not limited to truss rods, pipes, angles and ladders) in
areas with energized power lines, exposed conductors or circuit parts, work practices (such as the use of
insulation, guarding, and material handling techniques) must be used to minimize the hazard.
• Portable ladders must have non-conductive side rails.
• Do not wear conductive articles of jewelry and clothing (such as but not limited to watch bands, bracelets,
rings, key chains, necklaces, metalized aprons, cloth with conductive thread, or metal headgear) that could
come in contact with energized power lines, exposed conductors or circuit parts.
Fall Protection
Identify potential fall hazards and determine if fall protection equipment is appropriate for the task, before begin-
ning the work. Pay attention to hazards associated with routine and non-routine tasks. Inspect fall protection
equipment (harnesses, lanyards) and devices (guardrails, tie-off points) before each use. Use fall protection
equipment if required for the job. Be sure the fall protection equipment is right for the task, fits properly, and is in
good condition. Refer to U.S. Occupational Safety & Health Administration (OSHA) Regulations Standards - 29
CFR 1926.500, 1926.501 and 1926.502, or applicable national, state or local regulations for more information.
• When using scaffolds, make sure there is proper access, full planking, stable footing, and guard railing.
• When using a boom lift, keep feet firmly on the platform of a boom lift, use fall protection equipment tied-off
at all times to the guardrail or tie-off point.
• When using a ladder, make sure the ladder is non-conductive and the correct size for the task. Read the
ladder user instructions and be sure the ladder is in good condition. Make sure ladder is set on stable footing
and at the correct angle.

7
Safety
Minimum Working Clearance
To reduce the risk of injury, all persons require adequate working clearance around the electrical panel or other
electrical equipment. The table below identifies the minimum working clearance needed. Refer to U.S. Occupa-
tional Safety & Health Administration (OSHA) Regulations (Standards - 29 CFR) Safeguards for personnel pro-
tection. -1910.303(g)(1)(i), or any other applicable national, state or local regulations, for additional information.
MINIMUM WORKING CLEARANCE 0-600 VOLTS
WIDTH
OF WORKING
CLEARANCE
AREA
HEIGHT
OF WORKING
CLEARANCE
AREA
MINIMUM WORKING CLEARANCE
IN FRONT OF ELECTRICAL PANEL/EQUIPMENT
EXPOSED LIVE PARTS
ON ONE SIDE OF WORK
SPACE AND NO LIVE
GROUNDED PARTS ON
THE OTHER SIDE.
EXPOSED LIVE PARTS
ON ONE SIDE OF WORK
SPACE AND LIVE
GROUNDED PARTS ON
THE OTHER SIDE.
EXPOSED LIVE PARTS
ON ONE SIDE OF WORK
SPACE AND EXPOSED
LIVE PARTS ON THE
OTHER SIDE.
30 in (76.2 cm)
MINIMUM OR
WIDTH OF
ENCLOSURE,
WHICH EVER IS
GREATER
78 in (198.1 cm)
MINIMUM OR
HEIGHT OF
ENCLOSURE,
WHICH EVER IS
GREATER
36 in (91.4 cm) MINIMUM 42 in (107 cm) MINIMUM 48 in (122 cm) MINIMUM
Concrete, brick or tile walls shall be considered as grounded.
Qualified Person
A Qualified person is one who, by possession of a recognized degree, certificate, or professional standing, or
who by extensive knowledge, training, and experience, has successfully demonstrated his/her ability to solve or
resolve problems related to the subject matter, the work, or the project.
Only qualified persons may work on electric circuit parts or equipment that have not been de-energized.
Refer to U.S. Occupational Safety & Health Administration (OSHA) Regulations Standards - 29 CFR 1926.32(m)
and 1910.333, or applicable national, state or local regulations for additional information.
Irrigation Equipment near Airports and Crop Dusting Aircraft
• If any part of the irrigation machine comes within 3200 ft (975 m) of an airport runway, especially the ap-
proach (ends) of the runway, additional warning markers may be required. In the United States, CFR Title
14, Chapter I, Subchapter E, Part 77 – Safe, Efficient Use, and Preservation of the Navigable Airspace
describes when marking is needed.
This document is available at: www.ecfr.gov
• Marking requirements vary depending on the location of the irrigation equipment relative to the runway, the
type of airport (Civil, Military, or Heliport) and other factors. Contact the local airport authority for guidance
and specific recommendations. In the United States, guidelines for marking structures near airports are
published by the Federal Aviation Administration in Advisory Circular AC 70/7460-1L – Obstruction Marking
and Lighting.
Available here: www.faa.gov/regulations_policies/advisory_circulars
• For irrigation machines near private or unregulated airfields, including farm-based airstrips, Valley strongly
recommends complying with the same standards and requirements as Civil airports as shown in Part 77.
• Regulations vary by country, contact your local aviation authority for guidance.
Overhang cables, including overhang back cables are a particular danger. In locations where low-flying air-
craft are likely, such as within 1,500 ft (457 m) of an end of an airport runway, or where crop dusting aircraft
are common, Valley recommends adding obstruction markers to overhang cables to improve their visibility.
For large overhangs (36 ft / 10.97 m Heavy Duty and longer), five 12 in (300 mm) or 20 in (500 mm), aviation
orange marker balls are sufficient. One near the rabbit ears, two in the middle of the back cables and two in
the middle of the highest overhang cables. Refer to Section 3.5 in AC70/7460-1 for additional details. Avia-
tion marker balls are available online and from a variety of aviation and airport safety equipment providers.

8
Safety
Overhead Power Lines
Assembling, towing or transporting irrigation machine components such as but not limited to the pivot point,
linear cart, span/drive unit assemblies, overhangs and/or corner assemblies underneath or near power lines is
extremely dangerous because of the risk of electrocution.
Operating equipment that elevates irrigation machine components, such as but not limited to an aerial lift or
crane, near power lines is extremely dangerous because of the risk of electrocution. Only qualified personnel
should operate this type of equipment. Before operating the equipment, qualified personnel must read the
equipment manufacturers’ operating and safety instructions.
Refer to U.S. Occupational Safety & Health Administration (OSHA) Regulations (Standards - 29 CFR) Cranes
and derricks. - 1926.550, or any other applicable national, state or local regulations for additional information.
• Always presume that any overhead power line is an energized line unless and until the person(s) owning
the line and/or the electrical utility authorities indicate that it is not an energized line and it has been visibly
grounded.
• Before operating any equipment near any power line make sure the line has been de-energized and visibly
grounded at the point of work.
• Electrocution can occur without touching an electrical power line. Electricity, depending on the magnitude,
can jump or become induced into equipment or conductive materials that come in close proximity to, but do
not touch a power line. High wind, lightening, wet ground and other environmental conditions will increase
the possibility of electrocution and require additional consideration.
• Transmitter towers can induce the equipment or materials being handled with an electrical charge. Before
working or operating equipment near transmitter towers make sure the transmitter is de-energized.
• Select the location where the span/drive unit will be assembled to ensure that neither the irrigation machine,
or the equipment used during the assembly process, will violate the minimum clearance guidelines.
• Never operate equipment or allow the load, ropes or tag lines within 10 ft (3.05 m) of any power line rated
50 kV or lower whether it is energized or not. For lines rated over 50 kV, the minimum clearance shall be 10
ft (3.05 m) plus 0.4 in (1.1 cm) for each kV over 50 kVs.
• Never assemble, tow, transport or allow irrigation machine components underneath or within 10 ft (3.05 m)
of any power line rated 50 kV or lower whether it is energized or not. For lines rated over 50 kV, the minimum
clearance shall be 10 ft (3.05 m) plus 0.4 in (1.1 cm) for each kV over 50 kVs. Overhang support angles,
cables and spinner drive components regularly extend 10 ft to 12 ft (3.1 m to 3.7 m) above the irrigation
pipeline (span).
• Use barricades to identify areas where interference with overhead power lines could occur. Keep the as-
sembly, towing or transporting of irrigation machine components and the operation of equipment including
load, ropes or tag lines away from any power line, in the distances described above, whether the line is
energized or not.
• Always designate a person to observe clearance between the power line and all equipment being operated
or moved in order to give timely warning for all operations to STOP if the minimum clearance is violated.

9
Safety
Minimal Lockout / Tagout Procedure
The following procedure establishes the minimum requirements for the lockout of energy isolating devices
whenever maintenance or servicing is done on machines or equipment. It is used to ensure that the machine
or equipment is stopped, isolated from all potentially hazardous energy sources and locked out before person-
nel perform any servicing or maintenance where the unexpectedly energized or start-up of the machine or
equipment or release of stored energy could cause injury. All personnel, upon observing a machine or piece of
equipment which is locked out to perform servicing or maintenance shall not attempt to start, energize, or use
that machine or equipment.
When the energy isolating devices are not lockable, tagout should be used and affected personnel must wear
full personal protection.
Refer to U.S. Occupational Safety & Health Administration (OSHA) Regulations (Standards - 29 CFR) Typical
minimal lockout procedures - 1910.147 App A, or applicable national, state or local regulations, for additional
information.
Sequence of Lockout
1. Notify all affected personnel that servicing or maintenance is required on a machine or equipment and that
the machine or equipment must be shut down and locked out to perform the servicing or maintenance.
2. The authorized personnel shall identify the type and magnitude of the energy that the machine or equip-
ment utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy.
3. If the machine or equipment is operating, shut it down by the normal stopping procedure (depress the stop
button, open switch, close valve, etc.).
4. De-activate the energy isolating device(s) so that the machine or equipment is isolated from the energy
source(s).
5. Lock out the energy isolating device(s) with assigned individual lock(s).
6. Stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating fly-
wheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by
methods such as grounding, repositioning, blocking, bleeding down, etc.
7. Ensure that the equipment is disconnected from the energy source(s) by first checking that no personnel
are exposed, then verify the isolation of the equipment by operating the push button or other normal operat-
ing control(s) or by testing to make certain the equipment will not operate.
!CAUTION
•RETURN OPERATING CONTROL(S) TO NEUTRAL OR “OFF” POSITION AFTER VERIFYING THE
ISOLATION OF THE EQUIPMENT.
8. The machine or equipment is now locked out.
!DANGER
•WHEN PERSONNEL WILL BE EXPOSED TO CIRCUIT ELEMENTS AND ELECTRICAL PARTS, A
QUALIFIED PERSON MUST USE TEST EQUIPMENT TO VERIFY THAT THE CIRCUIT ELEMENTS
AND EQUIPMENT PARTS OF THE EQUIPMENT ARE DE-ENERGIZED.
Restoring Equipment to Service
When the servicing or maintenance is completed and the machine or equipment is ready to return to normal
operating condition, the following steps shall be taken:
1. Check the machine or equipment and the immediate area around the machine to ensure that non-essential
items are removed and that the machine or equipment components are operationally intact.
2. Check the work area to ensure that all personnel are safely positioned or removed from the area.
3. Verify that the controls are in neutral.
4. Remove the lockout devices and re-energize the machine or equipment.
5. Notify affected personnel that the servicing or maintenance is completed and the machine or equipment is
ready to be used.

10
Safety
Operate Safely
Valley Irrigation machines are designed with safety in mind. However, if this machine is operated incorrectly, it
may pose a safety threat to the operator. A good safety program is much like a chain, it is only as strong as its
weakest link. The manufacturer, dealer, and operator must maintain and improve all safety programs. Following
is a list of safety operating tips which you and all other persons servicing or operating the machine must read
and understand:
!CAUTION
•DO NOT OPERATE THIS MACHINE WITHOUT
FIRST READING THE OWNER’S MANUALS
FOR THE MACHINE.
•READ ALL SAFETY MESSAGES IN THIS
MANUAL AND SAFETY SIGNS ON THE MA-
CHINE.
•DO NOT LET ANYONE OPERATE THIS MA-
CHINE WITHOUT PROPER INSTRUCTIONS.
•UNAUTHORIZED MODIFICATIONS MAY IM-
PAIR THE FUNCTION AND/OR SAFETY OF
THE MACHINE.
•IF YOU DO NOT UNDERSTAND ANY PART
OF THIS MANUAL, CONTACT YOUR VALLEY
DEALER.
EMPLOYEE INSTRUCTION ON SAFETY
It is very important to instruct your employees on
the safe use of this equipment at the time of their
initial assignment to operate it. DO NOT let anyone
operate this equipment without proper instructions.
Safety training should be presented annually and
the service manager should ensure employees fully
understand the safety messages and what to do in
case of emergencies.
EMERGENCY STOPPING
The machine can be stopped at any time at any tower
by turning the disconnect switch, located underneath
the tower box, to the OFF position. Refer to Figure
10-1.
Figure 10-1 1. Disconnect Switch
1
!WARNING
PROPER GROUNDING
DO NOT attempt to start the machine until the
electrical service is properly installed and grounded
by a qualified electrician as per the electrical
standards. Refer to Figure 10-2.
If the power supplied to the machine is not grounded
properly, severe injury, or death can result should an
electrical malfunction occur.
It is your responsibility to ensure that your power
supplier and/or electrical contractor has grounded
the irrigation machine as required by the National
Electrical Code and by applicable local electrical
codes. If a machine is properly grounded and fuse
sizing is correct, there is extremely low probability of
an individual being injured by electrical shock.
1
2
3
4
5
Figure 10-2 1. Ground Rod Installation
2. Service Conductor
3. Copper Ground Rod
4. Copper Ground Wire
5. Clamp
NOTE
•All 480 VAC, 60 Hz (380 VAC, 50 Hz) power
supply services MUST be a 4 conductor
service.Three 480 VAC (380 VAC) power lines
and one ground conductor which is as large
as the power carrying conductors for that
service.
•Each time a towable machine is moved,
the ground wire MUST be reattached to the
ground rod and checked for electrical integ-
rity before restarting the machine.