GB B400 User Manual

Model B400, B400D,

B400L & B400DL

Eegor® Hydraulic Benders

Gardner

Bender

Instruction

Sheet

IMPORTANT RECEIVING INSTRUCTIONS: Visually inspect all components for shipping damage. If any

shipping damage is found, notify carrier at once. Shipping damage is NOT covered by warranty. The carrier is responsible for all repair or replacement costs resulting from damage in shipment.

GARDNER BENDER CANNOT BE HELD RESPONSIBLE FOR DAMAGE OR INJURY CAUSED BY UNSAFE USE, MAINTENANCE OR APPLICATION OF ITS PRODUCTS. Please contact Gardner Bender’s technical service department for assistance if you are in doubt as to the proper safety precautions essential to designing and setting up your particular application.

Shoe Pivot Pin

Frame Plate

Bending Shoe

4" dia. Roller

U-strap

Lock Pin

U-strap

Double Anchor Pin

Compression Roller Assembly (Roller Ass'y/Cylinder Clevis/ Roller Ass'y)

Cylinder Support Block

Cylinder

Coupler

Note: Position couplers in direction shown so as to prevent damage to hoses when making full 90˚ bend.

Follower Bar

Eegor® & Ultra EegorTM Bender Component Chart

BS4000 4"

BZ44 4"

BS2500 21⁄2"

BZ728

HC-913

B400

Eegor® Benders are shipped in metal storage cases.

BS3500 31⁄2"

BZ28 21⁄2"

BFB4000 4"

BFB3500 31⁄2"

BFB3000 3"

BZ39 31⁄2"

BS3000 3"

BZ34 3"

BZ76

CD3014

BFB2500 21⁄2"

P408S Electric Hydraulic Pump

Order Eegor® Set Model Number Size Set Pump and Hoses

Deluxe Eegor ULTRA Eegor™

Standard Eegor Bender Set

Standard Eegor ULTRA Eegor™

Standard Eegor ULTRA Eegor™ Bender Set

B400LP408S

B400DLP408S

B400DL

B400DLP408S

2-1/2",

3",

3-1/2",

4" sets

2-1/2",

3", 4"

sets

P408S Pump (2) HC913 Hoses

Pump and Hose Not Included

P408S Pump (2) HC913 Hoses

Bender

Frame

BZ70

includes

cylinder

block, top

and bottom

frame

plates and

frame pivot

assembly

with clevis

eye

Adjustable

Compression

Roller

Assembly Pins Cylinder

BZ74

BZ72

includes

all rollers,

top roller

plate

assembly,

and bottom

plate

assembly

double anchor

frame

BZ76

U-strap

BZ78 bend

shoe

CD3028

Bending

Shoes

BS4000 BS3500 BS3000 BS2500

BS4000 BS3000 BS2500

Bar U-strap

BFB4000 BFB3500 BFB3000 BFB2500

BFB4000 BFB3000 BFB2500

BZ44 (4")

BZ39 (3-1/2")

BZ34 (3")

BZ28 (2-1/2")

BZ44 (4") BZ34 (3")

BZ28 (2-1/2")

Unpacking

Remove all bender shoes, follow bars, U-straps and pins. Inspect for damage and compare these components to the complete set shown on page one for possible missing parts. Depending on which set you purchased - the basic difference in component content will be whether you purchased a set having the 31⁄2" size shoe, follow bar and U-strap included.

Maintenance of your Eegor® Bender

Aside from conventional care of the hydraulic components, very little maintenance of the Eegor® bender is required. Removing sand or dirt from grooves and moving parts will extend bender life and facilitate ease of operation.

Safety Alert Symbol

The symbol above is used in conjunction with a danger, warning or caution statement. It alerts operators, supervisors and all personnel that safety precautions are required during specific operations and specific conditions. Failure to comply with safety data could result in serious injury or death.

DANGER

Indicates a high probability of death or severe injury or major property damage could result.

WARNING

Indicates serious but less probability of death, sever bodily injury or major property damage could result.

Lubricate rollers, when needed, with molybdenum disulfide paste only (such as Dow Corning’s Molykote #G-n paste, or equivalent). For heavy use, lubricate rollers weekly. Note: Graphite formulations are not equivalent lubrication.

Bender Frame Assembly - Removal, Transporting & Storage

To remove or carry the bender frame assembly—do so by placing hand on the bottom frame plate. You should have assistance so that the lifting points are at the front end and back end of the bottom plate.

CAUTION

Avoid pinched fingers by keeping hands away from the BZ72 roller assembly, which pivots freely on a pin through the cylinder rod eye and may swing suddenly aside during handling.

The hydraulic cylinder, cylinder mounting block and compression roller assembly slide back and forth between the two frame plates.

This sliding action is a function of the bender design for locating the cylinder to meet the need of your particular conduit size; up to a full 90˚ without the need of another set-up or reposition of the conduit.

The slide action permits the bender assembly to be collapsed to a shorter length for handling and storage. When storing, be sure to remove the hydraulic hoses from the cylinder and install dust caps on the coupler ports. See the back page for details of storing the B400DL and B400L models.

CAUTION

A less serious alert, but still demands attention to detail. It indicates a hazardous condition that may cause minor injuries or property damage.

Introduction

Gardner Bender™ produces twelve versions of the Eegor® hydraulic conduit bender. Each version uses a hydraulic cylinder and electrically operated pump to produce the force necessary to bend conduit sizes 21⁄2" to 4". Differences between model numbers are based on the accessories included with each model and the length of the cylinder used to bend the conduit. Since the process of bending is the same for all models, the instructions and safety precautions apply to all application and uses of Gardner Bender™ hydraulic conduit benders.

Bending conduit encounters a wide range of situations and a variety of conduit materials. Because of the multiple job specifications, it is not possible to provide instructions covering every situation. Principal bending formulas apply to use of the model B400 series benders. Assembly instructions are specific. Follow them precisely to ensure safe, reliable and effective conduit bending.

All instructions are important, but safety alert symbols are located throughout this manual, and a separate section is included to address specific safety concepts.

Before operating Gardner Bender™ conduit benders, read and understand this entire manual. If any subjects are not understood, contact Gardner Bender at 414-352-4160; ask for technical services.

IMPORTANT—USER SAFETY AND PROTECTION: In setting up systems, take care to select the proper components and design to ensure appropriate integration with your existing operations and equipment. Observe all safety measures to avoid the risk of personal injury and damage to property and equipment through improper usage.

CAUTION

The Eegor® bender develops 30 tons of force at 9,250 psi. Greater forces will be generated between the rollers, follow bars and bending shoe. Operators must follow instructions for assembly and bending conduit to avoid pinch points and applying forces to incorrect bender components.

CAUTION

Do not use damaged parts to assemble the Eegor® bender. Items that are damaged or broken due to extensive wear must be replaced to avoid potential hazards to the operator.

Bender Assembly

A. Frame Assembly

1. Remove the frame assembly and hydraulic cylinder from the metal case. Place the assembly on a flat surface. Figure 1.

The cylinder slides within the frame

CAUTION

assembly. When lifting or moving, keep the frames as level as possible to prevent injury from moving parts.

WARNING

Keep hands and loose clothing away from all moving parts. Frames and rollers move under high pressure. Do not place hands on conduit or between conduit and follow bar during operation. Severe injuries could result.

CAUTION

Do not connect or disconnect hydraulic hose fittings with pressure in the system. A rigid hose indicates the presence of internal pressure. Prior to electrical or hydraulic repairs, retract the hydraulic cylinder and turn off the hydraulic pump.

3. Turn the pivot lock to align it with the slot in the frame. Lift the top frame off the roller assembly. Figure 3.

Figure 1: Frame Assembly

2. A pivoting lock holds the top frame in place. Figure 2.

Figure 2: Lock-on Frame

Figure 3: Removing Top Frame

4. Place your foot on the lower frame, grasp the end of the hydraulic cylinder and pull it toward you. Align the slots of the cylinder mounting block with holes in the lower frame that correspond with conduit size being bent. Figure 4.

NOTE: For model B400L and B400DL align the

cylinder block with the holes for 31⁄2" & 4" conduit size (last holes in frame). The

cylinder will remain in this position for all bending sizes and angles to 90˚.

Figure 4: Moving Cylinder Frame

5. Install the two hydraulic hoses. Apply one wrap of teflon tape to the threads on the end of the hose. Remove the pipe plugs from the pump valve, one port is marked “ADV” the other is marked “RET”. Install a hose in each port. Figure 5.

Figure 6A: Installing Couplers

Figure 6B: Installing Couplers

7. Remove the upper roller and plate assembly by pulling straight up. The upper plate and large aluminum roller are a single assembly. Figure 7.

Figure 5: Hose Installation

6. Connect the hose from the “ADV” port to the hydraulic cylinder coupler located near the base of the cylinder. Make sure there is no dirt or debris in either half prior to assembly. Push the hose coupler firmly into the cylinder coupler, then tighten coupler collar. Connect the hose from the “RET” port to the remaining cylinder coupler. Figure 6A & 6B.

IMPORTANT: The hose coupler must be firmly

seated in the cylinder coupler and held tightly while turning the coupler collar. Hand tighten the collar. Do not use tools to tighten. Failure to properly assemble couplers will inhibit oil flow.

Figure 7: Upper Roller Plate Removal

8. The lower plate and roller assembly remain in position during normal shoe and follow bar installation.

Bending Shoe and

Follow Bar Installation

A. Model B400L and Model B400DL Ultra Eegor™

1. The B400L and B400DL use a 28" hydraulic cylinder. As a result, the upper and lower plate assemblies use the 31⁄2"–4" frame holes for mounting all sizes of conduit bending shoes. See figure 8. For smaller sizes of conduit, the cylinder plunger must be advanced to position the roller assembly against the follow bar.

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