© 2015 Baileigh Industrial, Inc.
REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL, INC.
IS PROHIBITED. Baileigh Industrial, Inc. does not assume and hereby disclaims any liability for any damage or loss
caused by an omission or error in this Operator’s Manual, resulting from accident, negligence, or other occurrence.
Rev. 03/2015
Baileigh Industrial, Inc.
P.O. Box 531
Manitowoc, WI 54221-0531
Phone: 920.684.4990
Fax: 920.684.3944
sales@baileigh.com
OPERATOR’S MANUAL
ROTARY DRAW BENDER
MODEL: RDB-500
Table of Contents
THANK YOU & WARRANTY .......................................................................................... 1
INTRODUCTION ............................................................................................................. 3
GENERAL NOTES .......................................................................................................... 3
SAFETY INSTRUCTIONS .............................................................................................. 4
SAFETY PRECAUTIONS ............................................................................................... 7
TECHNICAL SPECIFICATIONS ..................................................................................... 9
TECHNICAL SUPPORT ................................................................................................. 9
UNPACKING AND CHECKING CONTENTS ................................................................ 10
Cleaning .................................................................................................................... 10
TRANSPORTING AND LIFTING .................................................................................. 11
INSTALLATION ............................................................................................................. 11
ASSEMBLY AND SET UP ............................................................................................ 12
GETTING TO KNOW YOUR MACHINE ....................................................................... 13
GENERAL DESIGN DESCRIPTION ............................................................................. 14
ELECTRICAL ................................................................................................................ 15
OPERATION ................................................................................................................. 17
Dry Running Machine ................................................................................................ 17
Setting Bend Angle .................................................................................................... 17
DIE SELECTION AND INSTALLATION ........................................................................ 19
Material Insertion ....................................................................................................... 21
Material Insertion Limitations ..................................................................................... 24
Bending More than 180 Degrees ............................................................................... 25
UNDERSTANDING SPRINGBACK .............................................................................. 25
MATERIAL SELECTION ............................................................................................... 25
PIPE AND TUBE BENDING DIAGRAMS ..................................................................... 27
BENDING GLOSSARY ................................................................................................. 28
BENDING SUGGESTIONS .......................................................................................... 29
Aluminum Bending .................................................................................................... 29
Heavy Wall DOM tubing ............................................................................................ 29
Bending With Square Dies ........................................................................................ 30
Square Tooling Setup ................................................................................................ 30
Large Size Square ..................................................................................................... 31
LUBRICATION AND MAINTENANCE .......................................................................... 32
ELECTRICAL SCHEMATIC .......................................................................................... 33
TROUBLESHOOTING .................................................................................................. 34
TABLES, CHARTS, & DIAGRAMS ............................................................................... 35
Diagram 1 ..................................................................................................................... 37
Diagram 2 ..................................................................................................................... 38
PARTS DIAGRAM ........................................................................................................ 39
Base Assembly Parts Diagram .................................................................................. 39
Main Tube Assembly Parts Diagram ......................................................................... 40
Swing Arm Assembly Parts Diagram ......................................................................... 41
Lead Screw Assembly Parts Diagram ....................................................................... 42
Encoder Assembly Parts Diagram ............................................................................. 43
Adaptor Plate Assembly Parts Diagram .................................................................... 44
Parts List ................................................................................................................... 45
1
1
THANK YOU & WARRANTY
Thank you for your purchase of a machine from Baileigh Industrial. We hope that you find it
productive and useful to you for a long time to come.
Inspection & Acceptance. Buyer shall inspect all Goods within ten (10) days after receipt thereof. Buyer’s
payment shall constitute final acceptance of the Goods and shall act as a waiver of the Buyer’s rights to inspect or
reject the goods unless otherwise agreed. If Buyer rejects any merchandise, Buyer must first obtain a Returned
Goods Authorization (“RGA”) number before returning any goods to Seller. Goods returned without a RGA will be
refused. Seller will not be responsible for any freight costs, damages to goods, or any other costs or liabilities
pertaining to goods returned without a RGA. Seller shall have the right to substitute a conforming tender. Buyer will
be responsible for all freight costs to and from Buyer and repackaging costs, if any, if Buyer refuses to accept
shipment. If Goods are returned in unsalable condition, Buyer shall be responsible for full value of the Goods.
Buyer may not return any special order Goods. Any Goods returned hereunder shall be subject to a restocking fee
equal to 30% of the invoice price.
Specifications. Seller may, at its option, make changes in the designs, specifications or components of the Goods
to improve the safety of such Goods, or if in Seller’s judgment, such changes will be beneficial to their operation or
use. Buyer may not make any changes in the specifications for the Goods unless Seller approves of such changes
in writing, in which event Seller may impose additional charges to implement such changes.
Limited Warranty. Seller warrants to the original end-user that the Goods manufactured or provided by Seller
under this Agreement shall be free of defects in material or workmanship for a period of twelve (12) months from
the date of purchase, provided that the Goods are installed, used, and maintained in accordance with any
instruction manual or technical guidelines provided by the Seller or supplied with the Goods, if applicable. The
original end-user must give written notice to Seller of any suspected defect in the Goods prior to the expiration of
the warranty period. The original end-user must also obtain a RGA from Seller prior to returning any Goods to
Seller for warranty service under this paragraph. Seller will not accept any responsibility for Goods returned without
a RGA. The original end-user shall be responsible for all costs and expenses associated with returning the Goods
to Seller for warranty service. In the event of a defect, Seller, at its sole option, shall repair or replace the defective
Goods or refund to the original end-user the purchase price for such defective Goods. Goods are not eligible for
replacement or return after a period of 30 days from date of receipt. The foregoing warranty is Seller’s sole
obligation, and the original end-user’s exclusive remedy, with regard to any defective Goods. This limited warranty
does not apply to: (a) die sets, tooling, and saw blades; (b) periodic or routine maintenance and setup, (c) repair or
replacement of the Goods due to normal wear and tear, (d) defects or damage to the Goods resulting from misuse,
abuse, neglect, or accidents, (f) defects or damage to the Goods resulting from improper or unauthorized
alterations, modifications, or changes; and (f) any Goods that has not been installed and/or maintained in
accordance with the instruction manual or technical guidelines provided by Seller.
EXCLUSION OF OTHER WARRANTIES. THE FOREGOING LIMITED WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED. ANY AND ALL OTHER EXPRESS, STATUTORY OR IMPLIED
WARRANTIES, INCLUDING BUT NOT LIMITED TO, ANY WARRANTY OF MERCHANTABILITY OR FITNESS
FOR ANY PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. NO WARRANTY IS MADE WHICH
EXTENDS BEYOND THAT WHICH IS EXPRESSLY CONTAINED HEREIN.
Limitation of Liability. IN NO EVENT SHALL SELLER BE LIABLE TO BUYER OR ANY OTHER PARTY FOR
ANY INCIDENTIAL, CONSEQUENTIAL OR SPECIAL DAMAGES (INCLUDING, WITHOUT LIMITATION, LOST
PROFITS OR DOWN TIME) ARISING FROM OR IN MANNER CONNECTED WITH THE GOODS, ANY BREACH
BY SELLER OR ITS AGENTS OF THIS AGREEMENT, OR ANY OTHER CAUSE WHATSOEVER, WHETHER
BASED ON CONTRACT, TORT OR ANY OTHER THEORY OF LIABILITY. BUYER’S REMEDY WITH RESPECT
TO ANY CLAIM ARISING UNDER THIS AGREEMENT IS STRICTLY LIMITED TO NO MORE THAN THE
AMOUNT PAID BY THE BUYER FOR THE GOODS.
2
2
Force Majuere. Seller shall not be responsible for any delay in the delivery of, or failure to deliver, Goods due to
causes beyond Seller’s reasonable control including, without limitation, acts of God, acts of war or terrorism, enemy
actions, hostilities, strikes, labor difficulties, embargoes, non-delivery or late delivery of materials, parts and
equipment or transportation delays not caused by the fault of Seller, delays caused by civil authorities,
governmental regulations or orders, fire, lightening, natural disasters or any other cause beyond Seller's reasonable
control. In the event of any such delay, performance will be postponed by such length of time as may be reasonably
necessary to compensate for the delay.
Installation. If Buyer purchases any Goods that require installation, Buyer shall, at its expense, make all
arrangements and connections necessary to install and operate the Goods. Buyer shall install the Goods in
accordance with any Seller instructions and shall indemnify Seller against any and all damages, demands, suits,
causes of action, claims and expenses (including actual attorneys’ fees and costs) arising directly or indirectly out
of Buyer’s failure to properly install the Goods.
Work By Others; Safety Devices. Unless agreed to in writing by Seller, Seller has no responsibility for labor or
work performed by Buyer or others, of any nature, relating to design, manufacture, fabrication, use, installation or
provision of Goods. Buyer is solely responsible for furnishing, and requiring its employees and customers to use all
safety devices, guards and safe operating procedures required by law and/or as set forth in manuals and instruction
sheets furnished by Seller. Buyer is responsible for consulting all operator’s manuals, ANSI or comparable safety
standards, OSHA regulations and other sources of safety standards and regulations applicable to the use and
operation of the Goods.
Remedies. Each of the rights and remedies of Seller under this Agreement is cumulative and in addition to any
other or further remedies provided under this Agreement or at law or equity.
Attorney’s Fees. In the event legal action is necessary to recover monies due from Buyer or to enforce any
provision of this Agreement, Buyer shall be liable to Seller for all costs and expenses associated therewith,
including Seller’s actual attorneys' fees and costs.
Governing Law/Venue. This Agreement shall be construed and governed under the laws of the State of
Wisconsin, without application of conflict of law principles. Each party agrees that all actions or proceedings arising
out of or in connection with this Agreement shall be commenced, tried, and litigated only in the state courts sitting in
Manitowoc County, Wisconsin or the U.S. Federal Court for the Eastern District of Wisconsin. Each party waives
any right it may have to assert the doctrine of “forum non conveniens” or to object to venue to the extent that any
proceeding is brought in accordance with this section. Each party consents to and waives any objection to the
exercise of personal jurisdiction over it by courts described in this section. Each party waives to the fullest extent
permitted by applicable law the right to a trial by jury.
Summary of Return Policy.
10 Day acceptance period from date of delivery. Damage claims and order discrepancies will not be accepted
after this time.
You must obtain a Baileigh issued RGA number PRIOR to returning any materials.
Returned materials must be received at Baileigh in new condition and in original packaging.
Altered items are not eligible for return.
Buyer is responsible for all shipping charges.
A 30% re-stocking fee applies to all returns.
Baileigh Industrial makes every effort to ensure that our posted specifications, images, pricing and product
availability are as correct and timely as possible. We apologize for any discrepancies that may occur. Baileigh
Industrial reserves the right to make any and all changes deemed necessary in the course of business including but
not limited to pricing, product specifications, quantities, and product availability.
For Customer Service & Technical Support:
Please contact one of our knowledgeable Sales and Service team members at:
(920) 684-4990 or e-mail us at sales@baileigh.com
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3
INTRODUCTION
The quality and reliability of the components assembled on a Baileigh Industrial machine
guarantee near perfect functioning, free from problems, even under the most demanding
working conditions. However if a situation arises, refer to the manual first. If a solution cannot be
found, contact the distributor where you purchased our product. Make sure you have the serial
number and production year of the machine (stamped on the nameplate). For replacement parts
refer to the assembly numbers on the parts list drawings.
Our technical staff will do their best to help you get your machine back in working order.
In this manual you will find: (when applicable)
Safety procedures
Correct installation guidelines
Description of the functional parts of the machine
Capacity charts
Set-up and start-up instructions
Machine operation
Scheduled maintenance
Parts lists
GENERAL NOTES
After receiving your equipment remove the protective container. Do a complete visual
inspection, and if damage is noted, photograph it for insurance claims and contact your
carrier at once, requesting inspection. Also contact Baileigh Industrial and inform them of the
unexpected occurrence. Temporarily suspend installation.
Take necessary precautions while loading / unloading or moving the machine to avoid any
injuries.
Your machine is designed and manufactured to work smoothly and efficiently. Following proper
maintenance instructions will help ensure this. Try and use original spare parts, whenever
possible, and most importantly; DO NOT overload the machine or make any unauthorized
modifications.
Note: This symbol refers to useful information throughout the manual.
4
4
IMPORTANT
PLEASE READ THIS OPERATORS MANUAL CAREFULLY
It contains important safety information, instructions, and necessary operating
procedures. The continual observance of these procedures will help increase your
production and extend the life of the equipment.
SAFETY INSTRUCTIONS
LEARN TO RECOGNIZE SAFETY INFORMATION
This is the safety alert symbol. When you see this symbol on
your machine or in this manual, BE ALERT TO THE
POTENTIAL FOR PERSONAL INJURY!
Follow recommended precautions and safe operating
practices.
UNDERSTAND SIGNAL WORDS
A signal word – DANGER, WARNING, or CAUTION
is used with the safety alert symbol. DANGER
identifies a hazard or unsafe practice that will result in
severe Injury or Death.
Safety signs with signal word DANGER or WARNING are
typically near specific hazards.
General precautions are listed on CAUTION safety signs.
CAUTION also calls attention to safety messages in this
manual.
5
5
SAVE THESE INSTRUCTIONS.
Refer to them often and use them to instruct others.
PROTECT EYES
Wear safety glasses or suitable eye protection
when working on or around machinery.
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause impairment or loss of
hearing. Wear suitable hearing protective devices such as ear muffs or
earplugs to protect against objectionable or uncomfortable loud noises.
BEWARE OF CRUSH HAZARD
NEVER place your hands, fingers, or any
part of your body in the die area of this
machine. Be aware of the area on either side
of the dies for crush points created by
material movement.
BEWARE OF PINCH POINTS
Keep hands and fingers away from the drive
mechanisms, cylinders, ratchets, and other
moving linkage while the machine is in
operation.
6
6
KEEP CLEAR OF MOVING OBJECTS
Always be aware of the position of the material and the swing area in
which the material will travel. The material will swing with significant
force. This swing area will create pinch points and the force of the
material movement may cause serious bodily injuries.
HYDRAULIC HOSE FAILURE
Exercise CAUTION around hydraulic hoses in case of a hose or
fitting failure.
HIGH VOLTAGE
USE CAUTION IN HIGH VOLTAGE AREAS. DO NOT assume the
power to be off.
FOLLOW PROPER LOCKOUT PROCEDURES.
7
7
WARNING: FAILURE TO FOLLOW THESE RULES MAY RESULT IN
SERIOUS PERSONAL INJURY
SAFETY PRECAUTIONS
Metal working can be dangerous if safe and proper operating procedures are not followed. As
with all machinery, there are certain hazards involved with the operation of the product. Using
the machine with respect and caution will considerably lessen the possibility of personal injury.
However, if normal safety precautions are overlooked or ignored, personal injury to the operator
may result.
Safety equipment such as guards, hold-downs, safety glasses, dust masks and hearing
protection can reduce your potential for injury. But even the best guard won’t make up for poor
judgment, carelessness or inattention. Always use common sense and exercise caution in
the workshop. If a procedure feels dangerous, don’t try it.
REMEMBER: Your personal safety is your responsibility.
1. Only trained and qualified personnel can operate this machine.
2. Make sure guards are in place and in proper working order before operating
machinery.
3. Remove any adjusting tools. Before operating the machine, make sure any adjusting tools
have been removed.
4. Keep work area clean. Cluttered areas invite injuries.
5. Overloading machine. By overloading the machine you may cause injury from flying parts.
DO NOT exceed the specified machine capacities.
6. Dressing material edges. Always chamfer and deburr all sharp edges.
7. Do not force tool. Your machine will do a better and safer job if used as intended. DO NOT
use inappropriate attachments in an attempt to exceed the machines rated capacity.
8. Use the right tool for the job. DO NOT attempt to force a small tool or attachment to do the
work of a large industrial tool. DO NOT use a tool for a purpose for which it was not
intended.
9. Dress appropriate. DO NOT wear loose fitting clothing or jewelry as they can be caught in
moving machine parts. Protective clothing and steel toe shoes are recommended when
using machinery. Wear a restrictive hair covering to contain long hair.
10. Use eye and ear protection. Always wear ISO approved impact safety goggles. Wear a full-
face shield if you are producing metal filings.
8
8
11. Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or
across a running machine.
12. Stay alert. Watch what you are doing and use common sense. DO NOT operate any tool or
machine when you are tired.
13. Check for damaged parts. Before using any tool or machine, carefully check any part that
appears damaged. Check for alignment and binding of moving parts that may affect proper
machine operation.
14. Observe work area conditions. DO NOT use machines or power tools in damp or wet
locations. Do not expose to rain. Keep work area well lighted. DO NOT use electrically
powered tools in the presence of flammable gases or liquids.
15. Keep children away. Children must never be allowed in the work area. DO NOT let them
handle machines, tools, or extension cords.
16. Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust.
Always lock up tools and keep them out of reach of children.
17. DO NOT operate machine if under the influence of alcohol or drugs. Read warning
labels on prescriptions. If there is any doubt, DO NOT operate the machine.
18. DO NOT touch live electrical components or parts.
19. Turn off power before checking, cleaning, or replacing any parts.
20. Be sure all equipment is properly installed and grounded according to national, state, and
local codes.
21. DO NOT bypass or defeat any safety interlock systems.
22. Keep visitors a safe distance from the work area.
9
9
Maximum Center Line Radius (CLR)*
20" (508mm)
Minimum Center Line Radius (CLR)*
.5" (12.7mm)
Minimum OD
.25" (6.35mm)
Mild Steel Pipe (Schedule 40)
3" (76.2mm)
Aluminum Pipe (Schedule 40)
3" (76.2mm)
Stainless Steel Pipe (Schedule 40)
2.5" (63.5mm)
Mild Steel Round Tube (Wall)
3" (.25) (76.2mm [6.35mm])
Aluminum Round Tube (Wall)
3.5" (.25) (88.9mm [6.35mm])
Stainless Steel Round Tube (Wall)
3.5" (.187) (88.9mm [4.75mm])
Chromolly Round Tube (Wall)
3.5" (.187) (88.9mm [4.75mm])
Mild Steel Solid Rod
2" (50.8mm)
Mild Steel Square Tube (Wall)
3" (.25) (76.2mm [6.35mm])
Power Supply
220VAC / 3ph / 60Hz
Motor
5hp (3.7kw) 220VAC / 3ph / 60Hz / 13.5A
Sound level
<70db
Shipping Weight (Lbs.)
1800lbs. (817kg)
Shipping Dimensions (L x W x H)
70” x 56” x 41” (1778 x 1423 x 1042mm)
TECHNICAL SPECIFICATIONS
TECHNICAL SUPPORT
Our technical support department can be reached at 920.684.4990, and asking for the support
desk for purchased machines. Tech Support handles questions on machine setup, schematics,
warranty issues, and individual parts needs: (other than die sets and blades).
For specific application needs or future machine purchases contact the Sales Department at:
sales@baileigh.com, Phone: 920.684.4990, or Fax: 920.684.3944.
Note: The photos illustrations used in this manual are representative only and may
not depict the actual color, labeling or accessories and may be intended to illustrate technique
only.
Note: The specifications and dimensions presented here are subject to change
without prior notice due to improvements of our products.
10
10
WARNING: SUFFOCATION HAZARD! Immediately discard any plastic
bags and packing materials to eliminate choking and suffocation hazards to children
and animals.
If any parts are missing, do not plug in the power cable, or turn the power switch on
until the missing parts are obtained and installed correctly.
WARNING: DO NOT USE gasoline or other petroleum products to clean
the machine. They have low flash points and can explode or cause fire.
CAUTION: When using cleaning solvents work in a well-ventilated area.
Many cleaning solvents are toxic if inhaled.
GAS
UNPACKING AND CHECKING CONTENTS
Your Baileigh machine is shipped complete in one crate. Separate all parts from the packing
material and check each item carefully. Make certain all items are accounted for before
discarding any packing material.
Cleaning
Your machine may be shipped with a rustproof waxy oil coating and grease on the exposed
unpainted metal surfaces. To remove this protective coating, use a degreaser or solvent
cleaner. For a more thorough cleaning, some parts will occasionally have to be removed. DO
NOT USE acetone or brake cleaner as they may damage painted surfaces.
Follow manufacturer’s label instructions when using any type of cleaning product. After cleaning,
wipe unpainted metal surfaces with a light coating of quality oil or grease for protection.
11
11
CAUTION: Lifting and carrying operations should be carried out by
skilled workers, such as a truck operator. Make sure the machine is well balanced.
Choose a location that will keep the machine free from vibration and dust from other
machinery. Keep in mind that having a large clearance area around the machine is
important for safe and efficient working conditions.
TRANSPORTING AND LIFTING
Follow these guidelines when lifting:
The lift truck must be able to lift at least 1.5 – 2 times the machines gross weight.
Make sure the machine is balanced. While transporting, avoid rough or jerky motion, and
maintain a safe clearance zone around the transport area.
Use a fork lift with sufficient lifting capacity and forks that are long enough to reach the
complete width of the machine.
Remove the securing bolts that attach the machine to the pallet.
Approaching the machine from the side, lift the machine on the frame taking care that there
are no cables or pipes in the area of the forks.
Move the machine to the required position and lower gently to the floor.
Level the machine so that all the supporting feet are taking the weight of the machine and no
rocking is taking place.
INSTALLATION
IMPORTANT:
Consider the following when looking for a suitable location to place the machine:
Overall weight of the machine.
Weight of material being processed.
Sizes of material to be processed through the machine.
Space needed for auxiliary stands, work tables, or other machinery.
Clearance from walls and other obstacles.
Maintain an adequate working area around the machine for safety.
Have the work area well illuminated with proper lighting.
12
12
WARNING: For your own safety, DO NOT connect the machine to the
power source until the machine is completely assembled and you read and
understand the entire instruction manual.
Keep the floor free of oil and make sure it is not slippery.
Remove scrap and waste materials regularly, and make sure the work area is free from
obstructing objects.
If long lengths of material are to be fed into the machine, make sure that they will not extend
into any aisles.
LEVELING: The machine should be sited on a level, concrete floor. For stationary machines,
provisions for securing it should be in position prior to placing the machine. The accuracy of
any machine depends on the precise placement of it to the mounting surface.
FLOOR: This tool distributes a large amount of weight over a small area. Make certain that
the floor is capable of supporting the weight of the machine, work stock, and the operator.
The floor should also be a level surface. If the unit wobbles or rocks once in place, be sure to
eliminate by using shims.
WORKING CLEARANCES: Take into consideration the size of the material to be
processed. Make sure that you allow enough space for you to operate the machine freely.
POWER SUPPLY PLACEMENT: The power supply should be located close enough to the
machine so that the power cord is not in an area where it would cause a tripping hazard. Be
sure to observe all electrical codes if installing new circuits and/or outlets.
ASSEMBLY AND SET UP
1. Remove the machine from the skid it was shipped on.
2. Check the oil level and top off if necessary.
3. Read through the remainder of the manual and become familiar with the die installation and
settings as well as normal operation.
4. Position the machine as desired following the installation guidelines.
5. Follow the electrical guidelines to connect the machine to a power supply.
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13
A
B
C D E
G H J
F
GETTING TO KNOW YOUR MACHINE
14
14
Item
Description
Function
A
Forward Foot Pedal
Will operate the machine in the cw direction
B
Reverse Foot Pedal
Will operate the machine in the ccw direction
C
Power Switch
For turning power on/off to the bender
D
Bend Angle Controller
For programming bend angle and displaying the
bend angle position.
E
Hydraulic Cylinders
Supply the bending force to rotate the forming die.
F
Quick Release (shown with a
counter die installed)
For pivoting counter die away from bend die to
remove material quickly.
G
Main Spindle And Drive Pins
(shown with a forming die
installed)
For supporting and driving the forming die.
H
Grease Zerk
For greasing main spindle bearing
I
Encoder
Recording the spindle rotation and sending that
information back to the controller to display the bend
angle and stop bending at the programmed angle.
GENERAL DESIGN DESCRIPTION
You have made a practical choice in purchasing the RDB-500 Hydraulic Bending Machine. 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.
The RDB-500 is an electric powered hydraulically operated “Rotary Draw” bending machine. To
bend material, a bending die and counter die are required. The material is hooked by the
bending dies’ hook arm and is powerfully rotated in the clockwise direction. As the bending die
rotates, the counter die arm also rotates about the same axis, forcing the material to conform to
the radius and shape of the bending die.
The RDB-500 Bending Machine you have purchased is built of solid steel ensuring maximum
rigidity. Tongue and groove design with grade 8 bolts throughout provides very high rigidity and
stability.
Throughout this manual are listed various safety-related 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 to the machine or
injury to the operator.
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15
CAUTION: HAVE ELECTRICAL UTILITIES CONNECTED TO MACHINE BY
A CERTIFIED ELECTRICIAN!
Check if the available power supply is the same as listed on the machine nameplate.
WARNING: Make sure the grounding wire (green) is properly connected
to avoid electric shock. DO NOT switch the position of the green grounding wire if
any electrical plug wires are switched during hookup.
WARNING: Baileigh Industrial is not responsible for any damage caused
by wiring up to an alternative 3-phase power source other than direct 3-phase. If you
are using an alternate power source, consult a certified electrician or contact
Baileigh Industrial prior to energizing the machine.
ELECTRICAL
Motor Specifications
Your tool is wired for 220 volt, 60Hz alternating current. Before connecting the tool to the power
source, make sure the machine is cut off from power source.
Considerations
Observe local electrical codes when connecting the machine.
The circuit should be protected with a time delay fuse or circuit breaker with a amperage
rating slightly higher than the full load current of machine.
A separate electrical circuit should be used for your tools. Before connecting the motor to the
power line, make sure the switch is in the “OFF” position and be sure that the electric current
is of the same characteristics as indicated on the tool.
All line connections should make good contact. Running on low voltage will damage the
motor.
In the event of a malfunction or breakdown, grounding provides a path of least resistance for
electric current to reduce the risk of electric shock. This tool is equipped with an electric cord
having an equipment-grounding conductor and a grounding plug. The plug must be plugged
into a matching outlet that is properly installed and grounded in accordance with all local
codes and ordinances.
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LENGTH
AMP RATING
25ft
50ft
100ft
0-6
16
16
16
7-10
16
16
14
11-12
16
16
14
13-16
14
12
12
17-20
12
12
10
21-30
10
10
No WIRE GAUGE
WARNING: In all cases, make certain the receptacle in question is
properly grounded. If you are not sure, have a qualified electrician check the
receptacle.
Improper connection of the equipment-grounding conductor can result in risk of electric
shock. The conductor with insulation having an outer surface that is green with or without
yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric
cord or plug is necessary, do not connect the equipment-grounding conductor to a live
terminal.
Check with a qualified electrician or service personnel if the grounding instructions are not
completely understood, or if in doubt as to whether the tool is properly grounded.
Repair or replace damaged or worn cord immediately.
Extension Cord Safety
Extension cord should be in good condition and meet the minimum wire gauge requirements
listed below:
An undersized cord decreases line voltage, causing loss of power and overheating. All cords
should use a ground wire and plug pin. Replace any damaged cords immediately.
17
17
CAUTION: Always wear proper eye protection with side shields, safety
footwear, and leather gloves to protect from burrs and sharp edges.
CAUTION: Keep hands and fingers clear of the dies and swing arms.
Stand to the front of the machine to avoid getting hit with the material during the
bending process. When handling large heavy materials make sure they are properly
supported.
OPERATION
Dry Running Machine
Before actually bending, several “dry runs” should be performed. This will remove any trapped
air from the cylinders and hoses. Also, this will familiarize you with the controls and functions of
the machine. To do this, set a bend angle and then activate the hydraulics to extend and retract
the cylinders to simulate a bend.
Setting Bend Angle
1. Reverse machine until both cylinders are fully retracted.
2. Set the digital controller to “0” by pressing the “F1/RST (reset)
button. The lower green number is preset position and the top
red number is the machine position.
3. In order for the machine to function the digital control needs to
have a stop point programmed for more than 5 degrees.
4. Press the “Right/Down” arrow key to activate the lower preset
degree field. Pressing the “Right/Down” arrow key will highlight
each digit field. The digit field will slowly blink when highlighted.
Machine will only bend to 200 degrees. The cylinders will
deadhead when the reach full extension.
5. When the digit is highlighted, press the “UP” arrow key to change
to the desired digit in that field.
6. When the desired bend degree is entered, press the “Circle”
button to save. The machine will now stop at this preset degree.
18
18
7. The digital control and preset should only be used in whole
degrees. For example 90, 91, 92 not 90.1 or 90.5. If any number
is entered after the decimal the control will add 1 to the final
degree. So it’s best to leave it at 0.
8. If you want to compensate for spring back the “0” position can
be set anywhere.
a. For example: Take a piece of material and insert it into
the die and close the counter die.
b. Activate the FWD pedal until the material just starts to
bend.
c. Set your “0” point here and that should compensate for
most of your spring back.
d. Now the preset value can be entered exactly to the
desired degree + / ‐.
9. Another way is to “Add on” spring back values to the preset.
a. To do this set your “0” position with the cylinders fully
retracted.
b. Insert material and bend a part to exactly 90° using a
framing square.
c. When still at the final position. Document the actual machine position.
d. For example: If the control reads 105° take 105‐90 = 15° (90 deg being your desired
bend angle). This will be the value you will add to your nominal degree setting when
entering preset values.
10. There is no right or wrong way to use this control. It is purely the user’s preference.
Home position with 90° Preset Stop Point. Stop position with 90° Preset Stop Point.
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19
A G F
B
C
D
E
DIE SELECTION AND INSTALLATION
Before any bending can take place, the
proper die set must be chosen to match the
material being bent. (EX) 1-1/2” diameter
tubing requires a die set marked 1-1/2”
tube.
A Hook Arm
B Bend Die
C Hold down Bolts
D Plastic Slide
E Counter Die Mount
F Bronze Counter Die Insert
G “0” Mark
Note: Pipe and Tube are not
the same, (see table 1) for nominal pipe
sizes. All BAILEIGH INDUSTRIAL dies are
color coded to avoid confusion between
pipe and tube (see table 2).
IMPORTANT: Damaged or worn
tooling should be replaced before
attempting to bend material. This will
ensure that bends are correct and provide a longer life to machine components.
When handling large heavy dies and/or material, make sure it is properly lifted and supported.
1. To install the die, slip the die over the centering pin until the three unequally spaced drive
pins engage the receiving holes formed in the die.
Note: The die will only fit one way.
2. When the drive pins line up the die will drop all the way down to the spindle.
3. Install and tighten the 1/2-13 socket head bolts provided with the die. Tighten these bolts
enough to hold the die firmly down to the spindle. Approximately 30-40ft-lb. (40-50N•m).
IMPORTANT: FAILURE TO PROPERLY BOLT DOWN DIE WILL RESULT IN
DAMAGE TO MACHINE AND TOOLING.
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20
H I J
K
L
H Spindle
I Die Drive Pins
J 1/2-13 Tapped holes for bolting
down dies
K Center Pin
L Hitch Pin
4. To install the counter die, remove
the hitch pin and insert the counter
die in the opening in the counter die
mount until the 3/4” holes line up.
5. Now insert the hitch pin through all
the holes, reinstall clip on the hitch
pin with the engraved side of the
counter die facing up.
IMPORTANT: Be sure the
long end of the counter die points away from the
hook arm, or to the right of machine.
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21
A
N
N
Bending some thicker or harder material may require the use of a special counterdie with a
1-1/4” pin mounting hole. To install the counterdie with the larger hole the two reducer collars
(N) must be removed.
To do this loosen the (2) set screw (casting type counter die mount) or the 5/16 socket head
screws (welded type counterdie mount) and slip them out of the holes. Counter dies that use
the 1-1/4” pin do not use these reducer collars.
Installing counterdie with 3/4" pin Remove reducer collars to install 1-1/4” counter die pin.
Material Insertion
1. Once the die set is properly installed, the material that matches the die can be inserted (I.E.
1-1/4”tube would go into a die mark D-1250T-R***).
2. Open the counter die assembly and insert the material past the hook arm. The start of bend
mark is engraved with an “O” on the top of the die. Once the material is placed properly, the
counter die slide block assembly can be tightened.
Inserting material to start Lubricating counter die bending
22
22
Important: Liberally apply lubricant along the counterdie and the 1/2 of the
material that contacts the counter die (A) with a WD-40 style lubricant or equivalent. Do not
lubricate the bending die. Lubricating the bending die will encourage slipping of material in the
bending die.
3. The main leadscrew has a numerical counter fastened
to the shaft; this is used to display the current position.
This number should be documented for every size die,
this will allow you to return the counter die to the exact
position every time it’s opened and closed. This will
ensure exact counter die position and repeatable
bends.
4. Tighten the counter die using light pressure on the three
legged handwheel documenting the position on the
counter.
5. After the material is installed, bending can take place.
6. Turn on the power switch.
7. Set the desired bend angle on the bend angle controller.
8. Keep hands away from the bending zone.
9. Press the right foot pedal switch to rotate the die forward. Keeping the foot pedal activated,
visually watch the digital display. The cylinders will stop when the forming die rotates to the
desired bend angle as shown on the controller. The material will need to be bent past
desired degree as all material has some degree of “springback”. This varies by material and
can even vary between the same grades of material.
10. If the bend requires more degrees. The controller will need to be set at a higher degree
number. Increase the degrees by further activating the forward foot pedal switch. This allows
the operator to gradually reach a bend angle, on the first set up piece. To determine the
amount of springback for a certain material, it is necessary to bend a sample piece. Using a
framing square or the like, bend a piece of material until a perfect 90° bend is achieved,
when checked with a square. At that point, document the machines degree position. For
example to a achieve a 90° on the piece in the picture, 105 degrees was the total bend
amount or 15 degrees of springback. Now you can add 15 degrees to any nominal bend
angle to achieve accurate results for this material.
23
23
A
Material Removal
1. After reaching the desired angle, the material needs to be removed.
2. Press the reverse (left) foot pedal. Both the die and the counter die will retract
simultaneously. Run in reverse until all bending pressure is released from the bend.
Activating the quick release lever
3. Activate the quick release counter die lever (A) and completely remove the material.
4. After the material is safely removed, press the reverse (left) foot pedal keeping hands clear
until both cylinders fully retract.
5. The machine is now at the “home” position and can be reloaded for the next bend.
6. Repeat previous steps.
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24
Material Insertion Limitations
Left Right
The left figure shows the recommended minimum / correct amount of material remaining to
be fully supported in plastic slide.
The right figure shows the maximum amount the material can be pulled through the
counterdie. Pulling the material further than shown into the counter die, it will destroy the
plastic slide.
Extreme care must be taken when bending
material with an existing bend. There must
be enough straight material to complete the
bend. If there is not enough material the bent
part of the material will crash into the counter
die and damage the machine and tooling. In
the left figure, there is not enough material to
complete a 90deg. bend. This bend will
damage the dies.
IMPORTANT: Orienting your material in this fashion will cause damage to your tooling
and machine!! DO NOT pull bent material into the counter die! Make sure you have enough
straight material on the draw side of the material to create your bend.
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25
CAUTION: It must be determined by the customer that materials being
processed through the machine are NOT potentially hazardous to operator or
personnel working nearby.
Bending More than 180 Degrees
This machine is capable of bending more than 180 degrees. Contact Baileigh Industrial
about your application.
o It will require a password to make the machine go past 200 degrees.
o Requires special tooling to allow removal of bent part. If standard tooling is used, the
material will be locked onto the die.
UNDERSTANDING SPRINGBACK
Springback can be difficult to understand. As material is bent, the materials yield strength resists
being formed. As a final degree is reached, the machine will have enough power to hold the
bend at a set degree, but as the pressure of the machine is released, the material has a
resistance built in, so it “springs back”
Springback will vary with every size, type and wall thickness, so it will never be consistent from
size to size.
The best way to determine a materials springback is to do sample bends to 90 degrees until a
perfect 90 is obtained.
At that point document the actual machine degrees.
Full manual mode is the best place to do these tests.
Use the overbend amount and enter that value into the springback field.
MATERIAL SELECTION
When selecting materials keep these instructions in mind:
Material must be clean and dry. (without oil)
Material should have a smooth surface so it processes easily.
Dimensional properties of material must be consistent and not exceed the machine capacity
values.
Chemical structure of material must be consistent.
Buy certificated steel from the same vendor when possible.
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26
Material Layout
In order to create accurate parts, you will have to layout the material in flat form. First you will
need to determine how much material is used per degree of bend. Use the multiplier table on
Table #3 to determine the arc lengths for the die in use. Or use the following formula:
Alternate arc length formula:
Example: 6.0 clr x2=12 12x3.14=37.699 37.699/360=0.1047” per degree
0.1047x 90 degrees =9.425” of material used for a 90 degree bend.
Once the arc lengths are determined you can begin layout of the material using Diagram #1 as a
reference.
Diagram #1 shows a simple part bent on the same plane in the same direction.
Diagram #2 shows bending based off of a centerline in two directions.
For symmetrical bends, centerline bending is easiest.
For non-symmetrical bends, continuous one direction bending is best.
Another way to layout material is to draw them in a 2D computer software program like Auto
Cad. There are many free programs on the internet. In a 2D program you will draw the parts
centerline only with corresponding clr’s. Then you will be able to list individual segments of
the bent part. This data can be directly entered into the control.
Another program available is BEND-TECH which is a program specifically designed for tube
bending and will give you all of the required data to make a part. This software is available
from Baileigh Industrial.
Bending with a rotary draw bender requires determining the start of bend point which will line
up with the “0” mark on the die. The portion of the tube toward the hook arm will be locked to
the die, the portion toward the counter die is the draw side and will slide along the counter
die and conform to the dies shape/radius.
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27
PIPE AND TUBE BENDING DIAGRAMS
L = Arc length (outside)
R = Rise (inside)
D = Tube outside diameter
t = Tube wall thickness
a = First bend arc angle H = Height of offset
b = Second bend arc angle L = Length of offset
A = First tangent R1 = First radius
B = Straight between bends R2 = Second radius
C = Second tangent t = Tube Wall Thickness
D = Tube outside diameter
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28
Arc Length
The length of material along the centerline of the tubing
Centerline Radius (CLR)
Distance in inches from the center of curvature to the centerline
axis of the tube bending or pipe bending bends. Abbreviated as
CLR. See Tube Bending and Pipe Bending Diagram
Degree
Angle in degrees to which the tube/pipe bends are formed (i.e. 45
degrees, 90 degrees, 180 degrees, etc.)
Easy Way (EW)
Bending of a rectangular tube with its short side in the plane of the
tube or pipe bend
Hard Way (HW)
Bending of a rectangular tube with its long side in the plane of the
tube or pipe bend
I.D.
Inside diameter of the tube or pipe bends
Minimum Tangent
The minimum straight on the end of pipe bends required by the
bending machine to form the bend
Neutral Axis
That portion of the pipe or tube that is neither in compression or
tension.
O.D.
Outside diameter in inches of the tube or pipe
Out of Plane
The deviation of the horizontal plane of a single pipe bend
between its tangent points, based on the theoretical center-line of
the pipe bend
Ovality
The distortion or flattening of pipe or tube from its normal, round
shape caused by the pipe bending process
Springback
Amount of degrees material will return after bending pressure is
released
Tangent
The straight portion of material on either side of arc of bending
bends. See Tube Bending and Pipe Bending Diagrams.
Tangent Point
The point at which the bend starts or ends. See Tube Bending
and Pipe Bending Diagrams.
Wall
The thickness in inches of tubular pipe bending material.
Wrinkles
Waving or corrugation of pipe bending bends in the inner radius.
BENDING GLOSSARY
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29
BENDING SUGGESTIONS
Aluminum Bending
If bending aluminum, lubrication is very important, if the results are less than desirable with WD40 other lubricants can be used such as:
Johnson Paste Wax (seems to work the best)
High Pressure grease
Highly rich dish soap
The bronze counter die must be polished and have no aluminum deposits or it will continue
to pick up metal.
If using BAILEIGH INDUSTRIAL’s standard counterdie is not producing desired results, roller
counter dies are also available.
BAILEIGH INDUSTRIAL has both steel rollers as well as plastic rollers. Plastic rollers are
used primarily for polished aluminum. Steel rollers would be used for non-polished materials.
Some aluminum will crack as it is being bent, 6061-T6 is very hard and may need to be
annealed or ordered in the “T-0” condition. Aluminum will age harden so if possible try to get
freshly run material.
Heavy Wall DOM tubing
If heavy wall materials are bent to a tight radius, they can tend to slip in the hook arm causing a
poor bend result, below are some suggestions
Use a vise clamp on the outside of the hook arm to “lock” the material in place.
Use a piece of two sided coarse emery cloth in between the hook arm and the material, this
works very well.
In only this application, high pressure grease applied to the DIE GROOVE also helps.
BAILEIGH INDUSTRIAL can make special clamps to hold material in place.
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30
Bending With Square Dies
Die Parts
1 Main Bending Die
2 Die Cap
3 Quick Release Handles
4 Hook-Arm
5 Hook-Arm Clamp
6 Plastic Slide
7 Slide Mount
8 Quick Release Studs
Square Tooling Setup
1. Install the bending die (1) on to the spindle. Be careful not to pinch your fingers as you lower
the die on to the spindle. The die will only fit on the spindle one way. Bolt the die to the
spindle using the holes in the die.
2. Install the plastic counter die assembly (6, 7) with the long end pointing away from the hook
arm.
3. Snug up the cap clamps (3). Do not over tighten! Or they will be overly difficult to loosen after
the bend is complete. Note: tighten clamps without material in the die. The clamps are lift
and turn, so you can position them anywhere. This allows the handles to clear the counterdie mount during bending.
4. Insert the material in to the hook arm (4) and pull in to the die. It may be a tight fit. Continue
to pull until the material is fully seated in the die’s groove.
5. Lube the counter die and the material that will slide along the counter die. Bring the plastic
counter die assembly up to the material, leaving about 1/8” to 1/4" gap. (Note: on some
thinner material it helps to keep the counter die approx. 1” away from the material)
IMPORTANT: Do not lube the bending die surfaces. This will increase the possibility for
slippage. Make sure all the die cap clamp handles (3) are inside the die diameter. They could
catch the counter die mounting assembly and break off.
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31
6. If the material slips during the bending operation, install the hook arm clamp (5). Do not use
it unless you have to.
7. Activate the bender and bend to the desired angle.
8. To remove the material, open the counter die and return bender to the “home position”.
Using a soft mallet, gently tap the cap clamps open and the material will spring out of the die
(1). Remove the material and re-snug the cap clamps.
9. Install the next piece of material to be bent and repeat these steps.
Large Size Square
When bending larger than 1.5” (38.1mm) thinner wall square tubing, the counter die position
seems to work better between 1/2" and 1” (12.7-25.4mm) farther away from the die. This seems
do reduce side wall distortion and inner wrinkling. Although this suggestion is to help on large
size, the same steps can be used for any square, if trying to achieve better results. If the square
material slips in the hook arm, use the supplied clamp and bolts to hold in place.
BAILEIGH INDUSTRIAL offer crush bend dies to form a concave crease on the inside of square
bends to reduce the possibility of wrinkling.
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32
WARNING: Make sure the electrical disconnect is OFF before working on
the machine.
Maintenance should be performed on a regular basis by qualified personnel.
Always follow proper safety precautions when working on or around any machinery.
LUBRICATION AND MAINTENANCE
Check daily for any unsafe conditions and fix immediately.
Check that all nuts and bolts are properly tightened.
On a weekly basis clean the machine and the area around it.
Lubricate threaded components and sliding devices.
Apply rust inhibitive lubricant to all non-painted surfaces.
Note: Proper maintenance can increase the life expectancy of your machine.
The fluid level in the power unit’s reservoir should be checked monthly. If the level is below
1/2 full, fill to the top with AW-46 hydraulic fluid. Hydraulic fluid and the filter should be
changed when the filter gauge reads “Change Filter”.
Check periodically for leaks. If a leak is detected, consult Baileigh Industrial.
There are four grease zerks on the machine, at the main spindle pivots. Grease these zerks
every month with only two pumps from a standard grease gun.
Check for any loose or worn parts
If hoses or fittings are replaced, they must be rated for 4000psi (275 bars, 282 kg/cm).
33
33
ELECTRICAL SCHEMATIC
34
34
Problem
Solution
Cylinders not retracting all the
way or not in sequence
Do the dry run sequence as outlined in section 8 of the
manual under operation
Machine doesn't move forward
or moves forward slowly and
does not build up pressure
Check that the solenoid valve has its wires connected. To
Check it's functionality extend the cylinder all the way, let
the machine deadhead and build up pressure
approximately 2000 (Psi). At that point rotate the autostop
dial the detent position and the pressure should drop to "0"
Psi.
Solenoid switch
Machine doesn't bend at
pressure (2000 Psi)
If trying to bend material and the machine builds up
pressure and stalls this usually means: The material is too
thick, the material has too high of a yield strength, or the
material is over the machines capacity.
Material slips in the hook arm
Too much lube on material and is transferring to the bend
die clean the bend die with degreaser.
The counter die should be lubed only
The material may need to be clamped
Wrong material for the die set
Spindle drive pins are damaged
If the bend dies are not bolted down properly the drive pins
will get damaged. Replace drive pins.
Poor Bend Results
Check proper tooling for material IE Pipe Vs Tube. Green
for pipe, Blue for tube, Red for metric and Gray for square
or rectangle tubing. See Appendix C for pipe sizing chart
Wall thickness is too thin
WARNING: Make sure the electrical disconnect is OFF before working on
the machine.
TROUBLESHOOTING
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35
PIPE
SIZES
O.D.
Pipe Schedules and Wall Thickness
5
10
40
80
160
XX STRONG
1/8
0.405
0.400
0.050
0.068
0.095
1/4
0.540
0.500
0.070
0.088
0.119
3/8
0.675
0.500
0.070
0.091
0.126
1/2
0.840
0.700
0.080
0.109
0.147
0.188
0.294
3/4
1.050
0.700
0.080
0.113
0.154
0.219
0.308
1
1.315
0.700
0.110
0.133
0.179
0.250
0.358
1-1/4
1.660
0.700
0.110
0.140
0.191
0.250
0.382
1-1/2
1.900
0.700
0.110
0.145
0.200
0.281
0.400
2
2.375
0.700
0.110
0.154
0.218
0.344
0.436
2-1/2
2.875
0.800
0.120
0.203
0.276
0.375
0.552
Material
Color
Pipe
Green
Tube
Blue
Metric
Red
Square or Rectangle
Gray
TABLES, CHARTS, & DIAGRAMS
Table 1 Standard Pipe Sizes and Schedules
Table 2 Die Color Code Chart
36
36
Degrees
Constant
Degrees
Constant
Degrees
Constant
1
0.0175
31
0.5410
61
1.0645
2
0.0349
32
0.5584
62
1.0819
3
0.0524
33
0.5759
63
1.0994
4
0.0698
34
0.5933
64
1.1168
5
0.0873
35
0.6108
65
1.1343
6
0.1047
36
0.6282
66
1.1517
7
0.1222
37
0.6457
67
1.1692
8
0.1396
38
0.6631
68
1.1866
9
0.1571
39
0.6806
69
1.2041
10
0.1745
40
0.6980
70
1.2215
11
0.1920
41
0.7155
71
1.2390
12
0.2094
42
0.7329
72
1.2564
13
0.2269
43
0.7504
73
1.2739
14
0.2443
44
0.7678
74
1.2913
15
0.2618
45
0.7853
75
1.3088
16
0.2792
46
0.8027
76
1.3262
17
0.2967
47
0.8202
77
1.3437
18
0.3141
48
0.8376
78
1.3611
19
0.3316
49
0.8551
79
1.3786
20
0.3490
50
0.8725
80
1.3960
21
0.3665
51
0.8900
81
1.4135
22
0.3839
52
0.9074
82
1.4309
23
0.4014
53
0.9249
83
1.4484
24
0.4188
54
0.9423
84
1.4658
25
0.4363
55
0.9598
85
1.4833
26
0.4537
56
0.9772
86
1.5007
27
0.4712
57
0.9947
87
1.5182
28
0.4886
58
1.0121
88
1.5356
29
0.5061
59
1.0296
89
1.5531
30
0.5235
60
1.0470
90
1.5705
Table 3 ARC LENGTH TABLE
EXAMPLE: Arc Length = Constant x Bend Radius. Example: 90deg bend with 6” clr
EXAMPLE: 1.575 (from table) x 6” (clr) = 9.45” (Arc Length)
For bends more than 90deg, Constants can be added together.
37
37
Diagram 1
38
38
Diagram 2
39
39
PARTS DIAGRAM
Base Assembly Parts Diagram
40
40
Main Tube Assembly Parts Diagram
41
41
Swing Arm Assembly Parts Diagram
42
42
Lead Screw Assembly Parts Diagram
43
43
Encoder Assembly Parts Diagram
44
44
Adaptor Plate Assembly Parts Diagram
45
45
Item
Part Number
Description
Qty.
1
M500-5A008
M500 Base Assembly
1 2 BS-0323
Foot Pad Shaft
4 3 M350-7A071
Leveling Foot
4 4 5/8-11
Hex Nut
4
5
M500-6A040
Cabinet Assembly
1 6 PP-0023
Cord Grip
3 7 PP-0290
3/4" Cord Grip
1 8 PP-0021
45 Degree Cord Grip
1 9 PP-0549
Schneider Switch Assembly
1
10
M12 X 1.75 X 30
Hex Flange
4
11
M12 X 1.75
Flange Nut
4
12
M6 X 1.0 X 10
Button Head
10
13
N/A
M500 Electrical Panel Assembly
1
14
RH19-7A024
Elect. Box Standoff
4
15
M6 X 1.0 X 30
SHCS
4
16
ME-M500-5A001
Main Tube
1
17
Imperial
.5 Lock Washer
8
18
1/2-13 X 1
HHCS
8
19
ME-M175-6A060
Tube Mount (Metric)
1
20
M10 X 1.5 X 8
Set Screw
1
21
M6 X 1.0 X 14
Hex Flange
2
22
M175-7A007
Pivot Post
1
23
ME-M175-7A008
Swivel Hub (Metric)
1
24
ME-M175-6A056
Pivot Base (Metric)
1
25
PP-0935
1.0 ID X 1.5 OD X .0625 THK
1
26
Imperial
1" Ext. Retaining Ring
1
27
M5 FLAT WASHER
Imperial
1
28
Imperial
M5 Star Washer
5
29
M5 X 0.8 X 20
SHCS
4
30
M5 X 0.8
Nut
1
31
M8 X 1.25 X 8
Set Screw
4
32
M175-6A058
Enclosure For Deep Control
1
33
PP-1293
Red Lion Controller
1
Parts List
46
46
Item
Part Number
Description
Qty.
34
M175-6A059
Box Cover
1
35
M5 X 0.8 X 10
PPMS
4
36
M500-7A023
Upper Bushing
2
37
M500-7A022
Lower Bushing
2
38
M500-7A010
Thrust Bearing (Top)
1
39
M500-7A011
Thrust Bearing (Middle)
1
40
M500-7A012
Thrust Bearing
2
41
ME-M500-6A001
Swing Arm (Top)
1
42
ME-M500-6A003
Tie Block (Long)
1
43
ME-M500-6A004
Tie Block (Short)
1
44
ME-M500-6A021
Tie Block (Front)
1
45
ME-M500-6A006
Rear Screw Block
1
46
ME-M500-6A022
Tie Block (Rear)
1
47
PP-0142
1.25 OD X 1.00 ID X 2.00 LNG
1
48
PP-0056
1.0 ID X 1.5 OD X .125 THK
1
49
ME-M500-6A002
Swing Arm (Bottom)
1
50
M20 X 2.5 X 55
SHCS
12
51
M20 X 2.5 X 70
SHCS
23
52
3/8 X 2.0
Slotted Spring Pin
7
53
ME-M500-7A017
M500 Spindle
1
54
M500-6A034
Main Spindle Key
1
55
ME-M500-5A002
Torque Arm
1
56
M24 X 3.0 X 80
SHCS
4
57
PP-0439
4" Clamp Collar
1
58
.25-28 GREASE ZERK
Straight Grease Zerk
4
59
ME-M500-6A017
Drive Key
2
60
M12 X 1.75 X 30
SHCS
4
61
ME-M500-7A007-V2
M500 Adaptor Plate
1
62
M12 X 1.75 X 45
SHCS
4
63
M20 X 2.5 X 110
SHCS
1
64
PP-1071
3/4" Dowel Pin
3
65
ME-M500-7A008
Center Pin
1
66
M24 X 3.0 X 180
SHCS
1
67
M175-7A006
Encoder Adapter
1
68
PP-1257
Encoder Coupling
1
47
47
Item
Part Number
Description
Qty.
69
PP-1256
Encoder
1
70
M500-6A038
Encoder Spacer
1
71
M500-6A037
Encoder Mount
1
72
M3 X .05 X 8
SHCS
3
73
M6 X 1.0 X 80
SHCS
2
74
ME-M500-6A007
Slide Block
1
75
ME-M350-7A046
Lead Screw Nut
1
76
PP-0209
Thrust Ball Bearing
1
77
M500-5A006
Lead Screw Assembly
1
78
ME-M350-7A047
Stop Nut
1
79
M10 X 1.5 X 12
Set Screw
1
80
PP-0036
1.0 Clamp Collar (Split)
1
81
M325-6A015-V2
Counter Bracket
1
82
PP-0137-V2
FIAMA Counter
1
83
ME-M400-7A003-3
Spider Hub
1
84
IMPERIAL.
.25 X .25 X 1.0 Key
1
85
M150-7A013
Quick Release Shaft
3
86
PP-0133
Black Ball Knob
3
87
ME-M500-5A005
Counter Die Mount (Small Dies)
1
88
M400-7A008
Reducer Bushing
2
89
M8 X 1.25 X 10
Set Screw
2
90
PP-0432
Cylinder
2
91
PP-0432-C
Clevis
1
92
M500-6A023
Trunnion
1
93
BS-0134
1-8 X 14 HHCS
1
94
1" LOCK WASHER
Imperial
1
95
1-8 HEX NUT
Imperial
1
96
PP-0853
Elbow
4
97
PP-0403-J
Pin
3
98
PP-0403-K
Hairclip
6
99
ME-M300-7A003
Center Pin
1
100
PP-0477
Hitch Pin
1
101
ME-M500-6A008
Counter Die Mounting Block
1
102
M20 X 2.5 X 80
SHCS
3
103
M500-7A024
Counter Die Pin
1
48
48
Item
Part Number
Description
Qty.
104
PP-1424
M500 Power Unit
1
105
M10 X 1.5 X 20
Hex Flange
4
106
M10 X 1.5
Flange Nut
4
NOTES
49
49
BAILEIGH INDUSTRIAL, INC. 1625 DUFEK DRIVE MANITOWOC, WI 54220
PHONE: 920. 684. 4990 FAX: 920. 684. 3944
WWW.BAILEIGH.COM
BAILEIGH INDUSTRIAL, INC. 1455 S. CAMPUS AVENUE ONTARIO, CA 91761
PHONE: 920. 684. 4990 FAX: 920. 684. 3944
BAILEIGH INDUSTRIAL LTD. UNIT D SWIFT POINT
SWIFT VALLEY INDUSTRIAL ESTATE, RUGBY
WEST MIDLANDS, CV21 1QH UNITED KINGDOM
PHONE: +44 (0)24 7661 9267 FAX: +44 (0)24 7661 9276
WWW.BAILEIGHINDUSTRIAL.CO.UK
BAILEIGH INDUSTRIAL GMBH HOFENER STRAßE 64
70736 FELLBACH
DEUTCHSLAND
WWW.BAILEIGHINDUSTRIAL.DE
BAILEIGH INDUSTRIAL PTY. LTD.
P.O BOX 1573, 126 MELROSE DRIVE TULLAMARINE,
VIC 3043 AUSTRALIA
WWW.BAILEIGHINDUSTRIAL.COM.AU
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