Manual For The 62669 16 Ton Heavy Duty Hydraulic Pipe Bender
User Manual: Manual for the 62669 16 Ton Heavy Duty Hydraulic Pipe Bender 16 Ton Heavy Duty Hydraulic Pipe Bender
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Owner’s Manual & Safety Instructions SaveThis ThisManual ManualKeep Keep manual safety warnings and precautions, assembly, Save thisthis manual forfor thethe safety warnings and precautions, assembly, operating, operating,maintenance inspection, maintenance cleaning procedures. Write the product’s themanual inspection, and cleaning and procedures. Write the product’s serial numberserial in thenumber back ofinthe back the manual near the month ifand year of purchase if product number). near theofassembly diagram (or assembly month anddiagram year of (or purchase product has no number). Keephas thisno manual and thisinmanual and dry the place receiptforinfuture a safereference. and dry place for future reference. theKeep receipt a safe and REV 15e Visit our website at: http://www.harborfreight.com Email our technical support at: productsupport@harborfreight.com When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken, please call 1-888-866-5797 as soon as possible. Copyright© 2015 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included. Read this material before using this product. Failure to do so can result in serious injury. SAVE THIS MANUAL. Table of Contents Safety.......................................................... 2 Setup........................................................... 4 Operation..................................................... 5 Maintenance................................................ 8 Parts List and Diagram............................... 10 Warranty..................................................... 12 Safety WARNING SYMBOLS AND DEFINITIONS This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Setup Addresses practices not related to personal injury. IMPORTANT SAFETY INFORMATION Read all safety warnings and all instructions. Failure to heed these markings may result in personal injury and/or property damage. Operation 1. Attach pipe bender securely to solid, flat and level surface that can support weight of pipe bender and pipe, with enough clearance for movement of pipe. Do not lay pipe bender on its side. The hydraulic ram may leak or not function properly. 9. Wear ANSI-approved safety goggles, heavy-duty work gloves, and steel-toe work boots during set up and/or use. 2. Keep hands away from ram, pipe and rollers during use. 11. Do not leave the pipe bender unattended when loaded. 3. To prevent injury from burns, do not apply heat to pipe. 12. Do not adjust safety valve. 4. Use only on free standing pipe. Do not use on pipe that is part of an assembly or that is installed into a structure. Maintenance 5. Study, understand, and follow all instructions before operating this device. 6. Keep rollers clean. If pipe rests on obstruction, it creates an uneven surface, causing excess stress and possible breakage. 7. Do not use on painted pipe or pipe that has debris on it. 8. STOP and release compression if you suspect imminent structural failure. If safe, inspect thoroughly and reposition pipe before proceeding. Page 2 10. Keep bystanders out of work area. 13. Inspect before every use; do not use if parts are loose, damaged. 14. Ram service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. 15. When servicing a ram, use only identical replacement parts . Use of unauthorized parts or failure to follow maintenance instructions may create a risk of injury. 16. No alterations shall be made to this product. 17. Only use with accessories rated to handle the forces exerted by this tool during operation. Other accessories not designed for the forces generated may break and forcefully launch pieces. For technical questions, please call 1-888-866-5797. Item 62669 23. WARNING: The brass components of this product contain lead, a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code § 25249.5, et seq.) 19. Industrial applications must follow OSHA requirements. 20. This product is not a toy. Keep it out of reach of children. 24. WARNING: This product contains di (2-ethylhexyl) phthalate (DEHP), a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code § 25249.5, et seq.) 21. Maintain labels and nameplates. These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 22. The warnings, precautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. Safety 18. Use only with included ram. IMPORTANT! Before first use: Check hydraulic fluid level and fill to 1/4″ below the fill port as needed - see instructions on page 5. Thoroughly test the Ram for proper operation. If it does not work properly, bleed air from its hydraulic system - see instructions on page 5. Setup SAVE THESE INSTRUCTIONS. Specifications Maximum Capacity Schedule 40 or 80 malleable steel pipe Maintenance Operation Pipe Type 16 Tons (32,000 lb) Item 62669 For technical questions, please call 1-888-866-5797. Page 3 Setup - Before Use: Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Safety Note: For additional information regarding the parts listed in the following pages, refer to Parts List and Assembly Diagram on page 10. Functions R-Pin (on back) Roller Setup 2" 2-1/2" 3" 1-1/2" 1-1/4" 1" Cotter Pin 3/4" 1/2" 1/2" 3/4" 1" 1 1-1/4" -1/2" 2" 2-1/2" 3" Fill Plug (on back) Piston Operation Ram Fulcrum Ram Handle Release Valve Figure A Maintenance Mounting WARNING! Attach Pipe Bender securely to solid and level surface that can support weight of Pipe Bender and pipe, with enough clearance for movement of pipe. Do not lay pipe bender on its side. The hydraulic ram may leak and not function properly. Clamp base securely to mounting surface. Page 4 For technical questions, please call 1-888-866-5797. Item 62669 Operating Instructions Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Safety Bleeding the Ram BEFORE EACH USE OR IF RAM PERFORMANCE DECREASES, check for excessive air and proper hydraulic fluid level in Ram. If Ram appears not to be working properly, it may be necessary to purge its hydraulic system of excessive air as follows: 6. Place Ram Handle over Release Valve. 2. Place Ram Handle over Release Valve. 7. Twist the Handle clockwise to close Valve. 3. Twist Handle counterclockwise to open the Valve. 8. Replace Fill Plug. 4. Insert Handle into Fulcrum, then pump Handle quickly several times. IMPORTANT: After bleeding the Ram, test the Ram for proper operation prior to its actual use. 5. Check fluid level and, if necessary, top off according to Adding Hydraulic Fluid below. 9. If, after bleeding, the Ram does not appear to be working properly, do not use it until repaired by a qualified service technician. Setup 1. Remove Fill Plug. Adding Hydraulic Fluid 1. Remove Fill Plug. 3. Replace Fill Plug. Maintenance Operation 2. Add high grade hydraulic fluid (sold separately) slowly until the fluid reaches 1/4″ below the top of the Fill Port. Item 62669 For technical questions, please call 1-888-866-5797. Page 5 Bending Pipe NOTICE: A certain amount of deformation will occur when using this Pipe Bender. Choosing the right pipe will reduce deformation. Use only ANSI Schedule 40 or 80 malleable steel pipe. Safety Note: To further reduce deformation, internal support may be provided by: a. Using mandrels. Follow mandrel manufacturer’s directions. 2. Attach Bending Die to Piston. 3. Adjust Rollers to correspond with size of Bending Die: a. Remove R-Pins from Cotter Pins, then remove Cotter Pins. b. Packing pipe with clean sand, then capping off ends with steel caps (sold separately) before bending. WARNING! To prevent injury from burns, do not apply heat to pipe. Setup NPS Pipe OD (Nominal Pipe Size) (Outside Diameter) (inches) (inches) 1/2 0.840 3/4 1.050 1 1.315 1-1/4 1.660 1-1/2 1.900 2 2.375 2-1/2" 2.88 3" 3.50 b. Move Rollers to proper positions, then replace Cotter Pins and R-Pins. 1/2" Bending Die Rollers set to 1/2" 1/2" 2" 2" 2-1/2" 1-1/2" 3" 1-1/4" 1-1/2" 2-1/2" 1" 3/4" 1/2" 1/2" 3/4" 1" 1-1/4" 3" Piston Figure B Note: Practice on scrap workpieces until familiar with Pipe Bender’s capabilities. Operation 1. Choose Bending Die the same nominal pipe size as pipe. For example: Use 1/2" Bending Die with the size marked on it with 1/2" NPS pipe. Note: Outside pipe diameters are larger than the pipe size. See Figure B. Figure C Maintenance Page 6 For technical questions, please call 1-888-866-5797. Item 62669 Note: Use only with pipe that fits the bending die exactly. Pipe will deform significantly if it does not fit the Bending Die exactly. 4. Mark center line of bend on pipe. 5. Slide pipe into Bending Die, lining up center line marked on pipe with center of Bending Die. 2" 2" 1-1/4" 1" 3/4" 1/2" 1/2" 3/4" 1" 1-1/2" 2-1/2" 3" 1-1/4" Safety 2-1/2" 1-1/2" 3" 1/2" Setup 1/2" NPS Pipe Figure D 8. Insert Handle into Fulcrum, then pump Handle until pipe reaches Bending Die. 2" 2-1/2" 1-1/2" 3" 1-1/4" 1" 3/4" 1/2" 1/2" 3/4" 1" 2" 1-1/2" 2-1/2" 3" 1-1/4" Figure E 10. Place Ram Handle over Release Valve. 11. Twist Handle counterclockwise to open the Valve and lower the piston. Item 62669 12. Remove pipe. If necessary, remove Roller(s) to allow room to remove pipe. 13. After use, store indoors out of reach of children. For technical questions, please call 1-888-866-5797. Page 7 Maintenance 7. Twist Handle clockwise to close Valve. Operation 9. Continue pumping slowly until desired angle is reached. Keep in mind that pipe may rebound slightly, so you may need to bend very slightly beyond your desired bend to get the correct bend. Practice on scrap workpieces first. 6. Place Ram Handle over Release Valve. User-Maintenance Instructions Procedures not specifically explained in this manual must be performed only by a qualified technician. Safety TO PREVENT SERIOUS INJURY FROM TOOL FAILURE: Do not use damaged equipment. If abnormal noise or vibration occurs, have the problem corrected before further use. 1. BEFORE EACH USE, inspect the general condition of the Pipe Bender and Ram. Check for: • loose hardware, • misalignment or binding of moving parts, • cracked or broken parts, • any condition that may affect its safe operation. Setup If a problem occurs, have the problem corrected before further use. Do not use damaged equipment. 2. BEFORE EACH USE, thoroughly test the Ram for proper operation prior to its actual use. If the Ram appears not to be working properly, follow Bleeding instructions on page 5. 3. AT LEAST ONCE EVERY THREE YEARS, change the hydraulic fluid: a. Remove Ram from Pipe Bender by removing two Bolts (5). b. With the Ram fully lowered, remove the Fill Plug. c. Tip the Ram over to allow the old hydraulic fluid to drain out completely. Dispose of the old hydraulic fluid in accordance with local regulations. d. With the Ram upright, completely fill the Hydraulic Unit with high grade hydraulic fluid until the fluid is 1/4″ below the top of the Fill Port. e. Turn the Release Knob counterclockwise to open the Release Valve. f. Pump the Handle up and down quickly several times to purge air from the system. g. Recheck fluid level and re-fill as needed. h. Replace the Fill Plug. i. Replace Ram on Pipe Bender. Operation 4. AFTER EACH USE, wipe with a clean cloth. Store indoors out of children’s reach. Maintenance Page 8 For technical questions, please call 1-888-866-5797. Item 62669 TO PREVENT SERIOUS INJURY: Use caution when troubleshooting a malfunctioning ram. Completely resolve all problems before use. If the solutions presented in the Troubleshooting guide do not solve the problem, have a qualified technician inspect and repair the ram before use. After the ram is repaired: Test it carefully without a load by raising it and lowering it fully, checking for proper operation, BEFORE RETURNING THE RAM TO OPERATION. Safety Troubleshooting DO NOT USE A DAMAGED OR MALFUNCTIONING RAM! POSSIBLE SYMPTOMS Fluid leaking from filler plug X Check that Release Valve is closed fully. Valves may be blocked and may not close fully. To flush the valves: 1. Lower the piston and securely close the Release Valve. 2. Manually lift the piston several inches. 3. Open the release valve and force the piston down as quickly as possible. X X PROBABLE SOLUTION (Make certain that the Ram is not supporting a load while attempting a solution.) Setup Handle moves up when ram is under load Ram may be low on fluid. Check the fluid level and refill if needed. X Ram may require bleeding - see instructions on page 5. Unit may have too much hydraulic fluid inside, check fluid level and adjust if needed. Maintenance X Operation Pump Piston will stroke feels not lift all spongy the way Item 62669 For technical questions, please call 1-888-866-5797. Page 9 Parts List and Assembly Diagram PLEASE READ THE FOLLOWING CAREFULLY Safety THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO. Parts List Part Setup 1 2 3 4 5 6 7 8 9 10 Description Frame Ram Ram Handle Washer Bolt Spring Spring Base Circlip Cotter Pin Roller Qty 1 1 1 2 2 2 1 1 2 2 Part 11 12 13 14 15 16 17 18 19 Description R-Pin 1/2" Bending Die 3/4" Bending Die 1" Bending Die 1-1/4" Bending Die 1-1/2" Bending Die 2" Bending Die 2-1/2" Bending Die 3" Bending Die Qty 2 1 1 1 1 1 1 1 1 Operation Maintenance Record Product’s Serial Number Here: Note: If product has no serial number, record month and year of purchase instead. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 10 For technical questions, please call 1-888-866-5797. Item 62669 Safety Assembly Diagram 10 9 Setup 12 11 8 7 6 5 4 2 1 17 3 14 16 Maintenance 13 15 18 Operation 19 Item 62669 For technical questions, please call 1-888-866-5797. Page 11 Limited 90 Day Warranty Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. 3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-866-5797
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