EDWARDS
Safety Instructions Manual
Original Instructions - HAT1000-2
07-2018
Safety Manual Table of Contents
1 General
Operator and Supervisor Information
Signal Word De nition
Signal Word Panel
2 Signal Word Panel - Machine Front
3 Signal Word Panel - Machine Back
4 Signal Words
Warning Panel
Caution Panel
Notice Panel
Operator and Supervisor Information
This is one of four manuals supplied with your machine.
• Installation Manual
• Safety Instructions Manual
• Operations Manual
• Maintenance Manual
READ ALL MANUALS BEFORE OPERATING MACHINERY. Operating
machinery before reading and understanding the contents of all four
manuals greatly increases the risk of injury.
Each of the four machine manuals describes ‘best practices’ in handling, installing, operating and maintaining your machine. The contents
of each manual is subject to change without notice due to improvements
in the machinery or changes in National or International standards.
All rights reserved. Reproduction of this manual in any form, in whole or
in part, is not permitted without the written consent of Edwards Manufacturing Company.
Keep all manuals close to the machine to allow for easy reference when
necessary.
Provide operators with suf cient training and education in the basic
functions of the machine prior to machine operation.
Do not allow for operation of the machine by unquali ed personnel.
Edwards Manufacturing Company is not liable for accidents arising from
unskilled, untrained operation.
Do not modify or change the machine without written authorization from
Edwards Manufacturing Company. Unauthorized modi cation to a machine may result in serious operator injury, machine damage and will
void your machine warranty.
Never leave a powered machine unattended. Turn machinery OFF before walking away.
This machine is manufactured for use by able bodied and able minded
operators only. Never operate machinery when tired or under the in uence of drugs or alcohol.
Do not resell, relocate or export to a destination other than to the original
point of sale. Edwards has designed this machine to meet the standards of the original receiving country and is not liable for meeting any
governing body or performance standards beyond those of the original
receiving country.
Signal Word Definition
Indicates a hazardous situation that, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation that, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation that, if not avoided,
could result in mild or moderate injury.
Indicates information considered important, but not
hazard related.
WARNING: This product can expose you to chemicals
including Methyl Isobutyl Ketone which is known to the State of
California to cause cancer and birth defects or other reproductive harm. For more information go to http://www.p65warnings.
ca.gov.
WARNING: Some dust, fumes and gases created by pow-
er sanding, sawing, grinding, drilling, welding and other construction activities contain chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
Some examples of these chemicals are:
• lead from lead based paint
• crystalline silica from bricks, cement and other masonry
products
• arsenic and chromium from chemically treated lumber
Your risk of exposure varies, depending on how often you do this
type of work. To reduce your exposure to these chemicals, work
in a well-ventilated area and work with approved safety equipment, such as dust masks that are speci cally designed to lter out microscopic particles. For more information go to http://
www.p65warnings.ca.gov/ and http://www.p65warnings.ca.gov/
wood.
Signal Word Panel on Machine
Critical machine safety information is identi ed on signal word labels. Labels are attached adjacent to the potentially hazardous locations of the
machine. Reference the Safety Instruction Manual for additional information regarding the potentially hazardous condition identi ed on the label.
Review ALL labels on the machinery, reference the operational precautions and safe operations sections within this manual before any
operation activity is initiated.
Failure to read and understand the signal word labels af xed to the
machinery may result in operator death or injury.
1
10 Ton Tube/Pipe Bender • Signal Word Panel
2
10 Ton Tube/Pipe Bender • Signal Word Panel
Hydraulic accessory
controls powered
by
Ironworker/
Porta-Power.
Lockout power
at
Ironworker/
Porta-Power
before servicing.
Shear/Crush Hazard
Moving parts can cut
and crush.
Fluid injection Hazard
Hydraulic fluid is
under pressure.
Hydraulic fluid powers
moving parts.
Keep guards in place
Read, understand, and follow all labels shown on the
machine and described in the:
• Safety Instructions Manual
• Installation Manual
• Operations Manual
• Maintenance Manual
Keep all manuals close for easy reference.
Trained and authorized personnel are to install, operate
and service this machinery. Do not allow for operation
of the machine by unqualified personnel.
Personal protective equipment must be worn at all
times during machinery operation.
3
Warning Panel
Caution Panel
Shear/Crush Hazard
Moving parts can cut and crush. Keep
hands clear while operating. Lockout
power before servicing. Immediately
replace guards after adjustment, repair or
service.
Wear Personal Protective
Equipment
To avoid physical hazard, always wear personal protective equipment. Wear protective eyewear, clothing, gloves, footwear,
head-gear and hearing protection while
operating or servicing this machinery.
Fluid Injection Hazard
Hydraulic hoses and cylinders are under
pressure. Pressurized uid can pierce skin
and cause severe injury. To avoid physical
hazard, always wear personal protective
equipment. Keep hands clear while operating. Lockout power before servicing.
Immediately replace guards after adjustment, repair or service.
Tilting Operation
The head-frame of your Edwards 10 Ton
Tube/Pipe Bender is mounted with a yoke
and pin to a sleeve and stop mechanism in
the bender stand. This mounting con guration allows for the bender head-frame to
be operated in either a horizontal or vertical
orientation. Exercise care when changing
the operating position of the bender and
during operation of the bender.
Tilting Operation
The bender can be operated in either a
horizontal or vertical position. Exercise
care when changing the operating position
of the bender and during operation of the
bender.
Do Not Operate With Guard
Removed
Physical barriers and guards have been
designed and installed to protect the
Operator from moving parts that can pinch,
cut and crush. Keep hands clear while
operating. Lockout power before servicing.
Immediately replace guards after adjustment, repair or service to moving parts.
4
Notice Panel
Bender Operation
Edwards 10 Ton Tube / Pipe Bender machinery is capable of many functions. This
manual outlines the basic functions associated with typical bender operations and is
neither intended to create a comprehensive
list of, nor describe every operation possible
with a bender tool. Bender operations are
dangerous and require extreme care and
caution in the safe installation, operation and maintenance of the machinery. Edwards Manufacturing Company
strongly suggests reading and understanding all manuals associated with
the machinery as well as obtaining certi ed, technical, industrial machinery
operations and maintenance training to
reduce the risk of injury. Regardless of
the contents of the machinery manuals
Edwards Manufacturing Company will
not be held liable for accidents caused
by lack of training.
Refer to All Manuals
Each manual that comes with this machine
contains critical instructions regarding
proper operations, safety, installation and
maintenance procedures. Understand the
contents of each manual thoroughly. Failure
to follow proper procedures may result in
serious operator injury, machine damage
and will void your machine warranty. Keep
the manuals close to the machine for easy
reference.
Wear Personal Protective
Equipment
To avoid physical hazard, always wear personal protective equipment. Wear protective eyewear, clothing, gloves, footwear,
head-gear and hearing protection while
operating or servicing this machinery.
5
1107 Sykes St., Albert Lea, MN 56007 800-373-8206 www.edwardsironworkers.com
EDWARDS
S
EDWARDS
Installation Manual
Original Instructions - HAT1000-1
07-2018
Installation Manual Table of Contents
1 General
Operator and Supervisor Information
Signal Word De nition
Signal Word Panel
2 Installing the Bender
Environmental Requirements at Work Station
Receiving the Bender
Unpacking/Moving the Bender
3 Hydraulic Power
Powering with an Edwards Ironworker
Powering with an Edwards Porta Power
Operator and Supervisor Information
This is one of four manuals supplied with your machine.
• Installation Manual
• Safety Instructions Manual
• Operations Manual
• Maintenance Manual
READ ALL MANUALS BEFORE OPERATING MACHINERY. Operating
machinery before reading and understanding the contents of all four
manuals greatly increases the risk of injury.
Each of the four machine manuals describes ‘best practices’ in handling, installing, operating and maintaining your machine. The contents
of each manual is subject to change without notice due to improvements
in the machinery or changes in National or International standards.
All rights reserved. Reproduction of this manual in any form, in whole or
in part, is not permitted without the written consent of Edwards Manufacturing Company.
Keep all manuals close to the machine to allow for easy reference when
necessary.
Provide operators with suf cient training and education in the basic
functions of the machine prior to machine operation.
Do not allow for operation of the machine by unquali ed personnel.
Edwards Manufacturing Company is not liable for accidents arising from
unskilled, untrained operation.
Do not modify or change the machine without written authorization from
Edwards Manufacturing Company. Unauthorized modi cation to a machine may result in serious operator injury, machine damage and will
void your machine warranty.
Never leave a powered machine unattended. Turn machinery OFF before
walking away.
This machine is manufactured for use by able bodied and able minded
operators only. Never operate machinery when tired or under the in uence of drugs or alcohol.
Do not resell, relocate or export to a destination other than to the original
point of sale. Edwards has designed this machine to meet the standards of the original receiving country and is not liable for meeting any
governing body or performance standards beyond those of the original
receiving country.
Signal Word Definition
Indicates a hazardous situation that, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation that, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation that, if not avoided,
could result in mild or moderate injury.
Indicates information considered important, but not
hazard related.
WARNING: This product can expose you to chemicals
including Methyl Isobutyl Ketone which is known to the State of
California to cause cancer and birth defects or other reproductive harm. For more information go to http://www.p65warnings.
ca.gov.
WARNING: Some dust, fumes and gases created by pow-
er sanding, sawing, grinding, drilling, welding and other construction activities contain chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
Some examples of these chemicals are:
• lead from lead based paint
• crystalline silica from bricks, cement and other masonry
products
• arsenic and chromium from chemically treated lumber
Your risk of exposure varies, depending on how often you do this
type of work. To reduce your exposure to these chemicals, work
in a well-ventilated area and work with approved safety equipment, such as dust masks that are speci cally designed to lter out microscopic particles. For more information go to http://
www.p65warnings.ca.gov/ and http://www.p65warnings.ca.gov/
wood.
Signal Word Panel on Machine
Critical machine safety information is identi ed on signal word labels. Labels are attached adjacent to the potentially hazardous locations of the
machine. Reference the Safety Instruction Manual for additional information regarding the potentially hazardous condition identi ed on the label.
Review ALL labels on the machinery, reference the operational precautions and safe operations sections within this manual before any
operation activity is initiated.
Failure to read and understand the signal word labels af xed to the
machinery may result in operator death or injury.
1
Installing the Bender
This manual provides installation requirements for the Edwards
10 Ton Tube/Pipe Bender.
ALL EDWARDS HYDRAULIC ACCESSORY TOOLS ARE POWERED BY AN EDWARDS IRONWORKER OR EDWARDS PORTAPOWER, PORTABLE HYDRAULIC POWER-PLANT.
REFER TO SAFETY, INSTALLATION, OPERATIONS AND MAINTENANCE MANUALS FOR THE EDWARDS POWER-PLANT YOU
ARE USING TO OPERATE YOUR EDWARDS HYDRAULIC ACCESSORY TOOL.
Environmental Requirements at Work Station
The work station environment for your Edwards 10 Ton Tube/Pipe
Bender
must meet the following minimum requirements:
• Ambient temperature: 7.2°C - 43.3°C [45°F - 110°F]
• Relative humidity: No greater than 90% relative humidity.
• Floor area: Assure that the machinery work area provides
for a stable, adequately sized and load rated oor area for
material movement to and from the machinery work stations.
• Shelter: Protect your machinery from water, salts and cor-
rosive elements.
• Lighting: 500LUX (50 footcandles) minimum.
Receiving the Bender
Edwards Hydraulic Accessory Tools are fully assembled and are shipped
either by palletized custom wooden crate or by shrink–wrapped wooden
pallet for ease of transport and receiving.
Inspect the packaging for damage and follow shipping/receiving instructions as listed on the packaging prior to receiving the tool into your
facility.
When receiving your Hydraulic Accessory Tool, be prepared to safely
move your machinery with a fork-lift rated for the following equipment
weights:
Minimum Machinery Weights
10 Ton Tube/Pipe Bender 226.79kg/500lb
Utilize best practices for fork-lift operation. Handle material as close
to the drive surface as possible with the widest spread and deepest penetration of forks effective to service the pallet. Forks should be adjusted
and locked into the safety detent closest to the maximum available fork
spread.
Unpacking/Moving the Bender
Your Edwards 10 Ton Tube/Pipe Bender includes surface and remotely
mounted electrical cabling and hydraulic lines. Exercise caution when
removing the factory supplied packaging. Do not cut electrical wires or
hydraulic hoses.
1. Carefully remove the wooden blocking from under the three
wheeled base and carefully roll the tool off of the shipping pallet.
2. Engage the third wheel by pushing the kickstand mechanism down
with your foot. Carefully roll the tool to the workstation.
3. Locate your bender directly adjacent to the Edwards Ironworker or
Porta Power. Ensure that power controls of the Ironworker or
Porta Power are within arms-reach of the bender tool.
2
Hydraulic Power
Test the limit switch by extending the cylinder until the auto stop meets
its positive stop.
Press the red e-stop button to kill power at the Ironworker. To reset
power, twist the e-stop button and push start button at the Ironworker.
When disconnecting your Bender, simply reverse procedure. Replace
the safety cap at the push button port to restore power to your
Ironworker.
Your Edwards Tube/Pipe Bender is factory assembled and tested for
optimum performance when powered by Edwards Manufacturing Company rated hydraulic power supplies.
The Bender is powered by either an Edwards Ironworker with the factory installed Hydraulic Accessory Control Package or an Edwards PortaPower, 5hp, 3000psi, portable power unit.
ALTERNATE POWER SOURCES ARE NOT RECOMMENDED
AND MAY COMPROMISE MACHINE OPERATION, MACHINE
HYDRAULIC WARRANTY AND OPERATOR SAFETY.
Follow electrical connection installation instructions for power supply as
set forth within the Installation Manual of the Edwards Ironworker or
Porta-Power.
Powering with an Edwards Ironworker
Power selection controls are located adjacent to the starter on the feed
side of the machine. Hydraulic quick connections and accessory controls
are located on the drop-off side or end cap of the machine.
With the Ironworker power off, install Bender hoses, power and control.
Assure your M12 connections are seated properly. Align M12 male
and female fi ttings so that keyed surfaces align. Misalignment of
surfaces will prohibit correct operation.
Powering with an Edwards Porta-Power
Your Edwards Porta-Power 5hp / 3000psi / Portable Power Unit will
power all your Edwards Hydraulic Accessories.
Follow electrical connection installation instructions as set forth within
these sections of the Installation Manual:
With the Edwards Porta-Power off, install accessory hoses, power and
control. Assure your M12 connections are seated properly. Align
M12 male and female fi ttings so that keyed surfaces align. Mis-
alignment of surfaces will prohibit correct operation.
• Install the male and female Bender hydraulic hoses to the PortaPower male and female quick connect hydraulic fi ttings adjacent to
the starterbox. Both fi ttings have a detent ball setting that must be
aligned to couple and uncouple hoses.
• Remove the safety cap at the push button port. Attach the Bender
hand control, male mil. spec. control cable to the female mil. spec.
accessory push button port on the Porta-Power case. Attach the
yellow limit switch cable to the limit switch port of the Porta-Power.
With all Ironworker and Bender stations clear of hands, tools, tooling, material or debris, power up the Porta-Power by depressing
the green button on the starter box.
• Install the Bender male and female accessory hydraulic hoses to
the ironworker male and female quick-connect hydraulic fi ttings.
Both fi ttings have a detent ball setting that must be aligned to
couple and uncouple hoses.
• Remove the safety cap at the push button port. Attach the Bender
hand control male mil. spec. control cable to the female mil. spec.
accessory control port at your Ironworkers Hydraulic Accessory
package. Attach the yellow limit switch cable to the limit switch
port of the ironworker.
With all Ironworker and Bender stations clear of hands, tools, tooling, material or debris, power up the Ironworker by depressing the
green button on the starter box.
With the power on, your Ironworker machine will return to a neutral
position.
Turn the 3-position switch on the front of the machine case to the Accessory position. This operation disables the Ironworker and switches
control to the accessory hand control.
Test the Bender operation by pressing the OUT control button. Once
pressed, the cylinder will extend. Releasing pressure on the OUT control
button will stop the cylinder. Test the Bender operation by pressing the
IN control button. Once pressed, the cylinder will be retracted back into
the cylinder enclosure. Releasing pressure on the IN control button will
stop the cylinder.
With the power on, your Bender is in a neutral position.
Test the Bender operation by pressing the OUT control button. Once
pressed, the cylinder will extend. Releasing pressure on the OUT control
button will stop the cylinder. Test the Bender operation by pressing the
IN control button. Once pressed, the cylinder will be retracted back into
the cylinder enclosure. Releasing pressure on the IN control button will
stop the cylinder.
Test the limit switch by extending the cylinder until the auto stop meets
its positive stop.
If the machine fails to cycle, power down the Porta-Power by pressing
the red button on the starterbox, consult the trouble shooting section of
the Operations Manual.
Press the red e-stop button on the hand control to kill power at the Porta
Power. To reset power, twist the e-stop button and push start button at
Porta Power.
When disconnecting your Bender, simply reverse procedure. Replace
the safety cap at the push button port to restore power to your
Porta Power.
3
1107 Sykes St., Albert Lea, MN 56007 800-373-8206 www.edwardsironworkers.com
EDWARDS
S
EDWARDS
Operations Manual
Serial Number:
Original Instructions - HAT1000-3
07-2018
Operations Manual Table of Contents
1 General
Company Pro le
Machine Identi cation
Warranty
Operator and Supervisor Information
Signal Word De nition
Signal Word Panel
Operational Precautions
Machine Operations
4 Hydraulic Power Sources
Powering with an Edwards Ironworker
Powering with an Edwards Porta-Power
6 Operations Diagram
7 Component/Base Operations
Tilting Head-Frame Operation
Base Operation
8 Die Set Diagram
9 Die Set Operations
10 Head Frame Diagram
11 Protractor/Auto-Stop Control
Protractor
Auto-Stop Control
12 Bending
Loading Material
Lubrication
Bending
13 Troubleshooting
Company Profile
Edwards Manufacturing Company
manufactures a full line of high
quality, low maintenance hydraulic
ironworking machines, associated
tooling and accessories that are
EDWARDS
Tool will provide consistent, long-term service. Please take time
to study this Operator’s Manual carefully to fully understand
Ironworker and Hydraulic Accessory Tool safety procedures,
set-up, operation, care, maintenance, troubleshooting and
warranty coverage prior to putting the machine into production.
Any questions not answered within this manual can be directed
to your local Edwards Ironworker dealer or factory representative.
Contact the factory:
Edwards Manufacturing
Company
1107 Sykes Street
Albert Lea, MN 56007
507 373 8206 PHONE
507 373 9433 FAX
www.edwardsironworkers.com
used in the steel fabrication industry.
With proper operation, care, and
maintenance, your Edwards
Ironworker or Hydraulic Accessory
Warranty
Edwards Manufacturing Company will, within one (1) year
of date of original purchase (proof of purchase required),
replace F.O.B. the factory, any goods, excluding punches,
dies and shear blades, which are defective in materials or
workmanship provided that the buyer return the defective
goods, freight pre-paid, to the seller, which shall be the
buyer’s sole and exclusive remedy for the defective goods.
Hydraulic components are subject to their manufacturer’s
warranty.
Edwards Manufacturing Company will, within thirty (30) days
of date of original purchase (proof of purchase required),
replace F.O.B. the factory, any punches, dies and/or shear
blades, which are defective in materials or workmanship.
This warranty does not apply to machines and/or components
which have been altered, changed or modifi ed in any way,
or subjected to abusive and abnormal use, inadequate
maintenance and lubrication, or subjected to use beyond
seller recommended capacities and specifi cations. Edwards
Manufacturing Company shall not be liable for labor costs
expended on such goods or consequential damages.
Edwards Manufacturing Company shall not be liable to
the purchaser or any other person for loss, down-time, or
damage directly or indirectly arising from the use of the
goods or from any other cause. No offi cer, employee, or
agent of Edwards Manufacturing Company is authorized to
make any oral representations or warranty of fi tness or to
waive any of the foregoing terms and none shall be binding
on Edwards Manufacturing Company.
General Questions:
sales@edwardsmfg.us
Service Questions:
service@edwardsmfg.us
Contact your dealer:
NOTE: Edwards Manufacturing is a division of JPW Industries,
Inc. References in this document to Edwards also apply to
JPW Industries, Inc., or any of its successors in interest to
the Edwards brand.
Machine Identification
Your Edwards 10 Ton Tube/Pipe Bender has been serialized for quality
control, product traceability and warranty enforcement. Please refer to
the aluminum identifi cation tag with engraved serial number, electrical
and power specifi cations when ordering parts or fi ling a warranty claim.
1
Information
This is one of four manuals supplied with your machine.
• Safety Instructions Manual
• Installation Manual
• Operations Manual
• Maintenance Manual
READ ALL MANUALS BEFORE OPERATING MACHINERY. Operating
machinery before reading and understanding the contents of all four
manuals greatly increases the risk of injury.
Each of the four machine manuals describes ‘best practices’ in handling, installing, operating and maintaining your machine. The contents
of each manual is subject to change without notice due to improvements
in the machinery or changes in National or International standards.
All rights reserved. Reproduction of this manual in any form, in whole or
in part, is not permitted without the written consent of Edwards Manufacturing Company.
Keep all manuals close to the machine to allow for easy reference when
necessary.
Provide operators with suf cient training and education in the basic
functions of the machine prior to machine operation.
Signal Word DefinitionOperator and Supervisor
Indicates a hazardous situation that, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation that, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation that, if not avoided,
could result in mild or moderate injury.
hazard related.
Indicates information considered important, but not
Do not allow for operation of the machine by unquali ed personnel.
Edwards Manufacturing Company is not liable for accidents arising from
unskilled, untrained operation.
Do not modify or change the machine without written authorization from
Edwards Manufacturing Company. Unauthorized modi cation to a machine may result in serious operator injury, machine damage and will
void your machine warranty.
Never leave a powered machine unattended. Turn machinery OFF be-
fore walking away.
This machine is manufactured for use by able bodied and able minded
operators only. Never operate machinery when tired or under the in uence of drugs or alcohol.
Do not resell, relocate or export to a destination other than to the original
point of sale. Edwards has designed this machine to meet the standards of the original receiving country and is not liable for meeting any
governing body or performance standards beyond those of the original
receiving country.
Signal Word Panel on Machine
Critical machine safety information is identi ed on signal word labels. Labels are attached adjacent to the potentially hazardous locations of the
machine. Reference the Safety Instruction Manual for additional information regarding the potentially hazardous condition identi ed on the label.
Review ALL labels on the machinery, reference the Safety Instructions Manual, the operational precautions and the safe operations
sections within this manual before any operation activity is initiated.
Failure to read and understand the signal word labels af xed to the
machinery may result in operator death or injury.
2
Operational Precautions
Reasonable, common sense safety precautions should be observed when
operating the Ironworker or Hydraulic Accessory Tool. The following precautions are described in order of their hazard.
Electrical Hazard
Dangerous high voltages are present inside the electrical enclosure
of this product. Only quali ed, authorized, maintenance or service
personnel should gain access to the electrical panel.
Lockout Power
Danger, circuits are live. Lockout / tagout upstream power source
before any maintenance activity is performed.
Shear / Crush Hazard
Moving parts can cut and crush. Keep hands clear when servicing
and maintaining the Ironworker.
Hydraulic Fluid Hazard
WARNING: This product can expose you to chemicals
including Methyl Isobutyl Ketone which is known to the State of
California to cause cancer and birth defects or other reproductive harm. For more information go to http://www.p65warnings.
ca.gov.
WARNING: Some dust, fumes and gases created by pow-
er sanding, sawing, grinding, drilling, welding and other construction activities contain chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
Some examples of these chemicals are:
• lead from lead based paint
• crystalline silica from bricks, cement and other masonry
products
• arsenic and chromium from chemically treated lumber
Your risk of exposure varies, depending on how often you do this
type of work. To reduce your exposure to these chemicals, work
in a well-ventilated area and work with approved safety equipment, such as dust masks that are speci cally designed to lter out microscopic particles. For more information go to http://
www.p65warnings.ca.gov/ and http://www.p65warnings.ca.gov/
wood.
Hydraulic hoses and cylinders are under pressure. Pressurized uid
can pierce skin and cause severe injury. To avoid physical hazard,
always wear personal protective equipment when servicing /
maintaining the Ironworker.
Do Not Operate With Guard Removed
Physical barriers and guards have been designed and installed
(where possible) to protect personnel from moving parts that can
pinch, cut and crush. If it is necessary to remove guarding when
servicing the Bender, immediately replace guards after service and
prior to power being restored to the machinery.
Refer to Manuals
For safe installation, operation and maintenance of the machine,
read:
Installation Manual
Safety Instructions Manual
Operations Manual
Maintenance Manual
Wear Personal Protective Equipment
To avoid physical hazard wear protective eyewear, clothing, gloves,
footwear, head-gear and hearing protection.
Machine Operations
Edwards Benders are designed to bend solid round, Schedule 40
pipe, tube, square tube, and d.o.m. tube.
ALL EDWARDS HYDRAULIC ACCESSORY TOOLS ARE POWERED
BY AN EDWARDS IRONWORKER OR EDWARDS PORTA POWER,
PORTABLE HYDRAULIC POWER-PLANT.
REFER TO THE SAFETY, INSTALLATION, OPERATIONS AND
MAINTENANCE MANUALS FOR THE EDWARDS POWER-PLANT YOU
ARE USING TO OPERATE YOUR EDWARDS HYDRAULIC ACCESSORY
TOOL.
The following pages detail the proper operation procedures for
setting up and safely operating the Edwards 10 Ton Tube/Pipe
Bender.
3
Hydraulic Power Sources
Ironworker Hydraulic Accessory Package Hydraulic Accessory Tool Controls
With all Ironworker and Bender stations clear of hands, tools, tooling, material or debris, power up the Ironworker by depressing the
green button on the starter box.
Your Edwards Tube/Pipe Bender is factory assembled and tested for
optimum performance when powered by Edwards Manufacturing Company rated hydraulic power supplies.
With the power on, your Ironworker machine will return to a neutral
position.
The Bender is powered by either an Edwards Ironworker with the factory installed Hydraulic Accessory Control Package or an Edwards PortaPower, 5hp, 3000psi, portable power unit.
ALTERNATE POWER SOURCES ARE NOT RECOMMENDED
AND MAY COMPROMISE MACHINE OPERATION, MACHINE
HYDRAULIC WARRANTY AND OPERATOR SAFETY.
Follow electrical connection installation instructions for power supply as
set forth within the Installation Manual of the Edwards Ironworker or
Porta-Power.
Powering with an Edwards Ironworker
Power selection controls are located adjacent to the starter on the feed
side of the machine. Hydraulic quick connections and accessory controls
are located on the drop-off side or end cap of the machine.
With the Ironworker power off, install Bender hoses, power and control.
Assure your M12 connections are seated properly. Align M12 male
and female fi ttings so that keyed surfaces align. Misalignment of
surfaces will prohibit correct operation.
• Install the Bender male and female accessory hydraulic hoses to
the ironworker male and female quick-connect hydraulic fi ttings.
Both fi ttings have a detent ball setting that must be aligned to
couple and uncouple hoses.
Turn the 3-position switch on the front of the machine case to the Accessory position. This operation disables the Ironworker and switches
control to the accessory hand control.
Test the Bender operation by depressing the OUT control button. Once
depressed, the cylinder will extend. Releasing pressure on the OUT control button will stop the cylinder. Test the Bender operation by depressing
the IN control button. Once depressed, the cylinder will be retracted
back into the cylinder enclosure. Releasing pressure on the IN control
button will stop the cylinder. Test the limit switch by extending the cylinder until the auto stop meets its positive stop.
Depress the red e-stop button to kill power at the Ironworker. To reset
power, twist the e-stop button and push start button at the Ironworker.
When disconnecting your Bender, simply reverse procedure. Replace
the safety cap at the push button port to restore power to your
Ironworker.
• Remove the safety cap at the push button port. Attach the Bender hand control male mil. spec. control cable to the female mil.
spec. accessory control port at your Ironworkers Hydraulic Accessory package. Attach the yellow M12 limit switch cable to the limit
switch port of the ironworker.
4
Edwards Porta-Power
Powering with an Edwards Porta-Power
Your Edwards Porta-Power 5hp / 3000psi / Portable Power Unit will
power all your Edwards Hydraulic Accessories.
Follow electrical connection installation instructions as set forth within
these sections of the Installation Manual:
With the Edwards Porta-Power off, install accessory hoses, power and
control. Assure your M12 connections are seated properly. Align
M12 male and female fi ttings so that keyed surfaces align. Mis-
alignment of surfaces will prohibit correct operation.
• Install the male and female Bender hydraulic hoses to the PortaPower male and female quick connect hydraulic fi ttings adjacent to
the starterbox. Both fi ttings have a detent ball setting that must be
aligned to couple and uncouple hoses.
• Remove the safety cap at the push button port. Attach the Bender
hand control, male mil. spec. control cable to the female mil. spec.
accessory push button port on the Porta-Power case. Attach the
yellow M12 limit switch cable to the limit switch port of the PortaPower.
With all Ironworker and Bender stations clear of hands, tools, tooling, material or debris, power up the Porta-Power by depressing
the green button on the starter box.
If the machine fails to cycle, power down the Porta-Power by depressing
the red button on the starterbox, consult the trouble shooting section of
the Operations Manual.
Depress the red e-stop button on the hand control to kill power at the
Porta Power. To reset power, twist the e-stop button and push start button at Porta Power.
When disconnecting your Bender, simply reverse procedure. Replace
the safety cap at the push button port to restore power to your
Porta Power.
With the power on, your Bender is in a neutral position.
Test the Bender operation by depressing the OUT control button. Once
depressed, the cylinder will extend. Releasing pressure on the OUT control button will stop the cylinder. Test the Bender operation by depressing
the IN control button. Once depressed, the cylinder will be retracted
back into the cylinder enclosure. Releasing pressure on the IN control
button will stop the cylinder.
Test the limit switch by extending the cylinder until the auto stop meets
its positive stop.
5
Auto-Stop Control
10 Ton Tube/Pipe Bender
Operations Diagram
Protractor
0°/90° Stop
Adjustment
10 Ton Hydraulic
Cylinder
Hydraulic Hoses/
Autostop Cable
Tooling Tray
Bender Base
Die Storage
6
Component/Base Operations
Vertical Head-Frame Position
Horizontal Head-Frame Position
Tilting Head-Frame Operation
The head-frame of your Edwards 10 Ton Tube/Pipe Bender is mounted
with a yoke and pin to a sleeve and stop mechanism in the bender stand.
This mounting con guration allows for the bender head-frame to be operated in either a horizontal or vertical orientation. Positive stops at 0
and 90 degrees provide for a exible and stable operation of the bender
when working with complex bending shapes or long setups.
Rotate the tilting head frame with caution. To rotate the head-frame,
release the hand screw on the top side of the rotational sleeve, rotate the
head-frame slowly utilizing both hands as a cradle at the top (die end) of
the head frame to the desired 0 or 90 degree location. Secure the hand
screw in the bender nal working position
Left: Kickstand up (disengaged) Right: Kickstand down (engaged)
Base Operation
The heavy duty, ½” formed steel plate design is balanced like a tripod
and rolls on 3 wheels. The “kickstand” at the rear of the bender base
allows you to push the kickstand down with your foot to deploy the swiveling caster and easily roll the bender to your work station. When located
in the ideal location, ip the kickstand up to disengage the swiveling
caster and stabilize the bender on the oor.
7
Die Set Diagram
Wiper Mounting
Block
Adjustment Set
Screw
Wiper Blades(2)
Drive Holes
Forming Die
Saddle Bolt
Degree Pointer
Wiper Mounting
Bolts (2)
Saddle Pin
Saddle Strap
Fine Adjustment Bolt
Acorn Nut
8
Die Set Operations
Your Edwards 10 Ton Bender will bend solid round, schedule 40 pipe,
tube and d.o.m. tubing when equipped with the proper, matched die sets
and careful operation.
Slide a sample piece of the material being bent into the die set. If alignment of the Wiper Assembly to the Forming Die is required use the Adjustment Set-Screw to center the Wiper to the forming die. Secure the
alignment with the jamb-nut provided. Failure to properly align wiper
assembly with forming die may damage the product being bent,
die set, machine or operator.
Die sets are designed to center the bending work within the head-frame
assembly. This design feature symmetrically distributes bending forces
through the head-frame, eliminating asymmetrical stress, torque and
premature wear of your machine.
All die components are matched as a set and are speci c to the
product being bent. Never mix and match die set components.
Mixing die set components may damage the product being bent,
machine operation, and operator safety. Damage to the bender
due to mixed die components may compromise machine warranty.
Die sets contain wearing parts. Periodic cleaning and/or replacement of wearing surfaces is required to maintain the highest quality nished parts.
Die Set Installation
With the head-frame in its horizontal position, carefully load the forming
die assembly into the head-frame using the 1-1/4” diameter hardened
pin. Make sure to load with the die identi cation speci cations visible or
the die will be installed backwards.
Install the wiper assembly in the head-frame by securing the assembly
with the 1-1/4” diameter hardened pin between the top and bottom
sections of the head-frame assembly. Make sure to load with the die
identi cation speci cations visible and the wiper blades facing the forming die or the die will be installed backwards.
Check to see that the die set components are all “seated” properly in the
head-frame and that all securing pins are fully engaged in their proper
locations.
9
Head Frame Diagram
1 1/4” Hardened
Pins (2)
Yoke Assembly
7/8” Short
Hardened Pin
Hardened Pin
7/8” Long
Inner Head
Frames (2)
10
Outer Head
Frames (2)
10 Ton Cylinder
Protractor/Auto-Stop Control
Protractor
The protractor wheel will aid you in bending your product to the desired
angle. If adjustment of your protractor is required, simply loosen the
protractor mounting screws and rotate the dial to align with the 0-degree position. Re-secure the mounting screws to continue operation.
Auto-Stop Control
The Auto-Stop Control is a bending aid that, once your bend is set up to
your satisfaction, can be adjusted to reproduce that bend in successive
sections of material.
This tool is ideally suited for light manufacturing where repeatability of
bent product is desired. If ne adjustment of the Auto-Stop Control is
desired, rotate the shoulder bolt clockwise or counterclockwise as necessary.
Activation range 1/16”
When activated, the proximity switch will light up.
11
Bending
Loading Material
Rotate and secure the bender head-frame in either the vertical or horizontal working position. If working with long sections of material, be
prepared to support your material with a material rest or roller (provided
by user). Place the leading end of the material to be bent between the
forming die assembly and wiper bar assembly. Capture the material with
the saddle strap and saddle pin. Secure the material by tightening the
saddle bolt down on the material.
Lubrication
To achieve the highest quality nished bend in your material, as well
as the longest life from the bearing surfaces of your die components, a
liberal amount of lubrication should be applied to the bearing surfaces
as follows:
Schedule 40 Pipe
• Lubricate wiper blades
If the desired bend angle is beyond the reach of the initial drive hole,
push the IN button to relieve pressure between the forming die, drive pin
and head-frame. Once pressure is relieved in the assembly, you will be
able to remove the drive pin from the assembly, fully retract the cylinder
and set the drive pin in the next adjacent drive hole. Repeat the process,
progressively drawing your material through the bender until your desired bend is achieved. Make sure your material is fully supported in the
wiper assembly. Failure to support the material by drawing the material
beyond the trailing wiper blade may result in damage to the material,
machine, die set or operator. When using square dies, do no run your
material beyond the center pin.
When your bend is complete, remove your material from the bender by
pushing the IN button to extract the drive pin from the head-frame assembly, push the IN button again to return the head-frame to its starting
position, relieve the saddle bolt, pull the saddle pin and saddle. Your
material should be able to be easily removed or repositioned for further
work.
Tubing
• Lubricate wiper blades
Square Tubing
• Lubricate wiper blades
Solid Round
• Lubricate wiper blades
Lubricant can be mineral or vegetable-based, solid bodied or spray
aerosol.
Bending
Install your material into the forming die and wiper bar assembly. Secure
the material with the matched saddle strap and 7/8” (short) saddle pin.
Secure the saddle bolt against the material to be bent with a wrench and
adequate pressure to insure the material does not pull or slip from the
forming die under bending pressure.
With your material secured between the forming die assembly and
wiper bar assembly, engage the head-frame with the die set by inserting the 7/8” (long) drive pin through the top inner head-frame, through
the forming die “drive hole” and through the bottom inner head-frame.
Engage the material with the die set by activating the OUT button on the
hand held controller. Advancing the die against the material will extend
the hydraulic cylinder and “push” the inner frames of the head-frame
away from the outer frames. This initial movement will snug the die and
material together eliminating the “slack” in the assembly.
Depress the OUT button again and the material will be drawn through
the die assembly.
Depress the OUT button until your desired bend is achieved or you reach
the maximum extend of the cylinder ram for the chosen drive hole.
12
Troubleshooting
Quality parts are dependent upon conscientious bender setup, bender operation and bender maintenance. Physically review
your bender prior to any operation. Con rm all static components are tight in the assembly. Con rm all moving components
are free of obstruction. Con rm all bender tooling, forming die and wiper assemblies are seated within the assembly.
Problem Solution
Bender Inoperable Check accessory control switch
Check bender male 4-pin power cable is connected to
female limit switch port.
Check hand control Mil Spec male power cable is
connected to female Mil Spec control port
Note: Auto Cut port will NOT power the bender accessory.
Drive pins tight Check alignment of head-frame assembly bolts.
Loosen head-frame assembly bolts (4).
Reset drive pins in head-frame and die assembly.
Re-tighten head-frame assembly bolts.
Scratching of material Check alignment of material to wiper and forming
die.
Check for matched/proper die set.
Check for adequate lubrication.
Check surface quality/cleanliness of material.
Rough cylinder operation Check uid level of machine.
Check hoses for correct installation.
Check fuse at transformer box.
Auto-Stop operation Check tightness of lever.
Check for proper plunger/roller.
Material not moving through die set Check forming die saddle pin, strap and bolt; tighten as
necessary.
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1107 Sykes St., Albert Lea, MN 56007 800-373-8206 www.edwardsironworkers.com
EDWARDS
S
EDWARDS
Maintenance Manual
Original Instructions - HAT1000-4
07-2018
Maintenance Manual Table of Contents
1 General
Operator and Supervisor Information
Signal Word De nition
Signal Word Panel
Maintenance Precautions
2 Maintenance Schedule
Daily/Shift Change Visual Observation
General Maintenance - Daily
General Maintenance -Weekly
Operator and Supervisor Information
This is one of four manuals supplied with your machine.
• Installation Manual
• Safety Instructions Manual
• Operations Manual
• Maintenance Manual
Each of the four machine manuals describes ‘best practices’ in handling, installing, operating and maintaining your machine. The contents
of each manual is subject to change without notice due to improvements
in the machinery or changes in National or International standards.
All rights reserved. Reproduction of this manual in any form, in whole or
in part, is not permitted without the written consent of Edwards Manufacturing Company.
Understand the contents of each manual thoroughly. Keep all manuals
close to the machine to allow for easy reference when necessary.
Provide operators with suf cient training and education in the basic
functions of the machine prior to machine operation.
Do not allow for operation of the machine by unquali ed personnel.
Edwards Manufacturing Company is not liable for accidents arising from
unskilled, untrained operation.
Do not modify or change the machine without written authorization from
Edwards Manufacturing Company. Unauthorized modi cation to a machine may result in serious operator injury, machine damage and will
void your machine warranty.
This machine is manufactured for use by able bodied and able minded
operators only. Never operate machinery when tired or under the in uence of drugs or alcohol.
Do not resell, relocate or export to a destination other than to the original
point of sale. Edwards has designed this machine to meet the standards of the original receiving country and is not liable for meeting any
governing body or performance standards beyond those of the original
receiving country.
Signal Word Definition
Shear / Crush Hazard
Moving parts can cut and crush. Keep hands clear when servicing
and maintaining the Ironworker.
Indicates a hazardous situation that, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation that, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation that, if not avoided,
could result in mild or moderate injury.
Indicates information considered important, but not
hazard related.
Signal Word Panel on Machine
Hydraulic Fluid Hazard
Hydraulic hoses are under pressure. Pressurized uid can pierce
skin and cause severe injury. To avoid physical hazard, always wear
personal protective equipment when servicing / maintaining the
Ironworker.
Do Not Operate With Guard Removed
Physical barriers and guards have been designed and installed to
protect maintenance personnel from moving parts that can pinch,
cut and crush. If it is necessary to remove guarding when servicing
the Ironworker, immediately replace guards after service and
prior to power being restored to the machinery.
Refer to Manuals
For safe installation, operation and maintenance of the machine,
read:
Installation Manual
Safety Instructions Manual
Operations Manual
Maintenance Manual
Wear Personal Protective Equipment
To avoid physical hazard wear protective eyewear, clothing, gloves,
footwear, head-gear and hearing protection.
Critical machine safety information is identi ed on signal word labels. Labels are attached adjacent to the potentially hazardous locations of the
machine. Reference the Safety Instruction Manual for additional information regarding the potentially hazardous condition identi ed on the label.
Review ALL labels on the machinery, reference the operational precautions and safe operations sections within this manual before any
operation activity is initiated.
Failure to read and understand the signal word labels af xed to the
machinery may result in operator death or injury.
Maintenance Precautions
Electrical Hazard
Dangerous high voltages are present inside the electrical enclosure
of this product. Only quali ed, authorized, maintenance or service
personnel should gain access to the electrical panel.
WARNING: This product can expose you to chemicals
including Methyl Isobutyl Ketone which is known to the State of
California to cause cancer and birth defects or other reproductive harm. For more information go to http://www.p65warnings.
ca.gov.
WARNING: Some dust, fumes and gases created by pow-
er sanding, sawing, grinding, drilling, welding and other construction activities contain chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
Some examples of these chemicals are:
• lead from lead based paint
• crystalline silica from bricks, cement and other masonry
products
• arsenic and chromium from chemically treated lumber
Your risk of exposure varies, depending on how often you do this
type of work. To reduce your exposure to these chemicals, work
in a well-ventilated area and work with approved safety equipment, such as dust masks that are speci cally designed to lter out microscopic particles. For more information go to http://
www.p65warnings.ca.gov/ and http://www.p65warnings.ca.gov/
wood.
Lockout Power
Danger, circuits are live. Lockout / tagout upstream power source
before any maintenance activity is performed.
1
Maintenance Schedule
Your Edwards Tube/Pipe Bender will bene t from reasonable
care and periodic maintenance. Reasonable care includes daily
visual observation, as well as general maintenance procedures
at daily and weekly intervals by operator/maintenance personnel. Perform inspections and maintenance of the electrical,
hydraulic, and mechanical systems of the Edwards 10 Ton Tube/
Pipe Bender and its connection to the Ironworker or PortaPower as follows:
Daily/Shift Change Visual Observation
Electrical System
Visually inspect controls and power cording to the Ironworker or PortaPower for signs of damage. Cut, abraded or crushed electrical cords
may present an electrical hazard to the Operator and/or damage the
machinery.
Hydraulic System
Visually inspect exposed or surface mounted hydraulic hoses and ttings for signs of damage. Cut, abraded or crushed hydraulic hoses or
leaking ttings may present a hydraulic uid hazard to the Operator
and/or damage the machinery.
General Maintenance - Daily
Disconnect unit from power source.
Check bolted connections and secure as necessary.
Check bearing surface quality.
Visually inspect pipe and tube dies and their respective wiper
assemblies for chips or galling in the bearing surface.
Verify wiper blades are secure in their mounting block. The wiper
blades of your Tube/Pipe Bender are crafted from hardened
aluma-bronze. Pipe and tube dies are manufactured from billet
steel for enhanced strength and durability. These are wearing
parts that will fail over time and will require replacement. Order
additional die sets through your Edwards distributor or through
Edwards Manufacturing Company. Install replacement parts
according to the Operations Manual.
Clean your Tube/Pipe Bender daily. Disconnect the unit from its
power source rst. Do not use liquid cleaners, aerosols, abrasive
pads, scouring powders or solvents such as benzene or alcohol.
Clean your machine with a brush and soft cloth lightly moistened
with a mild, water-based detergent solution. Remove lings, dirt,
dust and grime from working surfaces. Ensure the surfaces are
fully dry before reconnecting power.
General Maintenance - Weekly
Mechanical System
Visually moving parts, guards and material hold-downs must remain
on the machine for safe operation. Clear any material obstructions
at the work station prior to visually inspecting moving parts of the
machine. Cycle the machine. Machine should operate smoothly in
hydraulic extend and retract mode.
Failure of any element of the daily/shift change visual observation will require maintenance of the affected accessory component. Please refer to the following maintenance procedures.
Disconnect unit from power source.
Check wiring harness for loose connections or damaged control
wiring. Check hydraulic ttings and hoses for wear or damage.
EDWARDS
S
1107 Sykes St., Albert Lea, MN 56007 800-373-8206 www.edwardsironworkers.com
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