The purpose of the safety section of this manual is to inform operators and maintenance
personnel of the precautions to be taken while operating or servicing the machine. The following are
a few basic guidelines to follow, but as with any type of machinery good judgment and a safe
attitude should be applied at all times.
1 Always disconnect power, lock-out and tag-out machine per OSHA regulations before attempting to
service this machine.
2. Always wear safety glasses or other approved eye protection while operating or servicing the machine.
3. Keep all body parts and any foreign objects away from moving parts. Do not reach into the machine
without first disconnecting all power sources.
4. Do not attempt to override any safety device on the machine.
5. Do not operate the machine if it has been damaged or is not operating properly.
6. Do not wear jewelry (watches, rings, necklaces, etc.), or loose fitting clothing while operating or
servicing the machine.
7. The machine should only be operated or serviced by properly trained, authorized personnel.
8. Replacement parts should have the same specification and operation as the original parts on the
machine.
9. All guards and covers must be in place before operating the machine.
10. Before starting the machine be sure it is set up properly.
11. Make sure the machine is properly grounded.
12. The machine and work area should be kept neat and clean.
13. Do not operate or service any machine while under the influence of drugs or alcohol.
NOTE: THESE SAFETY RULES ARE FOR YOUR BENEFIT TO HELP PREVEN T I NJURY TO YOURSELF AND/OR
YOUR CO-WORKERS. REVIEW ALL SETUP AND OPER ATING P ROCEDURES, WHETHER COVERED OR NOT,
IN THIS MANUAL TO HELP INSURE SAFE OPERATION OF THE MACHINE.
- 4 -
HYDRAULIC SAFETY PRECAUTIO NS
WARNING
General Operation
• All WARNING statements must be carefully observed to help prevent personal injury.
• Before operating the pump, all hose connections must be tightened with the proper tools. Do not over
tighten. Connections should only be tightened securely and leak-free. Over tightening can cause
premature thread failure or high pressure fittings to split at pressures lower than their rated capacities.
• Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately shut off the
pump and release all pressure. Never attempt to grasp a leaking pressurized hose with your hands.
The force of escaping hydraulic fluid could cause serious injury.
• Do not subject the hose to potential hazard such as fire, sharp surfaces, extreme heat or cold or
heavy impact. Do not allow the hose to be altered or kink, twist, curl, crush, cut, or bend so tightly that
the fluid flow within the hose is blocked or reduced. Periodically inspect the hose for wear, because
any of these condition’s can damage the hose and possibly result in personal injury.
• Do not use the hose to move attached equipment. Stress can damage hose and possibly cause
personal injury.
• Hose material and coupler seals must be compatible with the hydraulic fluid used. Hoses also must
not come in contact with corrosive materials such as creosote-impregnated objects and some paints.
Consult the manufacturer before painting a hose. Hose deterioration due to corrosive materials can
result in personal injury. Never paint the couplers.
• Inspect machine for wear, damage, and correct functio n be fore each use. Do not use machinery that
is not in proper working order, but repair or replace it as necessary.
• Replace worn or damaged safety decals.
• Modification of a product requires written Power Team authorization.
• Use only components with the same pressure rating when assembling a system or machine.
Pump
• Do not exceed the hydraulic pressure rating noted on the pump data plate or tamper with the internal
high pressure relief valve. Creating pressure beyond the rated pressure can result in personal injury.
• Before replenishing the fluid level, retract the system to prevent overfilling the pump reservoir. An
overfill can cause personal injury due to excess reservoir pressure create when cylinders are
retracted.
Air Supply
• Shut off and disconnect the air supply when the pump is not in use or before breaking any
connections in the system.
PREPARATION & SET-UP
Air Supply Hook-Up
Remove the thread protector from the air inlet of the pump. Select and install the threaded fittings which are
compatible with your air supply fittings. The air supply should be 20 CFM (.57 M3/min.) and 100 PSI (7 BAR)
at the pump to obtain the rated hydraulic pressure. Air pressure should be regulated to a maximum of 140
PSI (9 BAR). Secure your pump fitting to the air supply.
WARNING: If improperly used, pressurized equipment can be potentially hazardous. Therefore:
• Hydraulic connectio ns must be securely fastened before building pressure in the system.
• Release all system pressure before loosening any hydraulic connection in the system.
Venting the Reservoir
To improve hydraulic fluid delivery and increase useable hydraulic fluid capacity, remove shipping plug and
install filler/vent cap before using the pump.
- 5 -
#2500 BENDER CONTENTS
• 1ea Main bender assembly mounted to stand
• 1ea Swivel work table
• 1ea Rectangle shaped shelf
• 1ea Angle shaped shelf
• 2ea Rigid casters
• 2ea Swivel Casters , Locking
• 16ea 5/16-18 x 3/4 Hex Bolt (for mounting casters)
• 16ea 5/16-18 Hex Nut (for mounting casters)
• 16ea 5/16 Lock washer ( for mounting casters )
• 16ea 5/16 Flat wash er (for mounting caster s )
• 5ea “U” spacers for pressure roller shaft, 1” thick
• 1ea #2500-300 Small adj us table Saddle
• 1ea #2500-301 Medium adjustable Saddle
• 1ea Operating, Ser vicing, and Safety Manual
- 6 -
#2 SwivelEnd
#2 Swivel
End
#3 Sling Position#3 Sling Position
#4 Upper Shelf
#4 Lower Shelf
#5 Swivel Work table
#5 Swivel Work
UNCRATE & SETUP
1. Remove shrink wrap and upper crating structure. Remove the two black shelves and work table from
the skid. Locate the box that contains the casters.
2. Attach the casters to the mounting plates using the supplied hardware. The swivel casters should be
mounted on the same end of the machine as the hydraulic cylinder and digital readout.
Casters This
Casters This
3. Once the casters are installed, use a sling positioned as shown above, to lift the machine onto the
casters. CAUTION: MACHINE IS HEAVY AND MAY CAUSE DAMAGE OR INJURY IF CARE IS
NOT USED.
4. Install the bottom shelf (with angled side) onto the bottom of the frame. It will rest on the caster
mounting plates. The bent sides point up. Install the upper shelf (rectangle shaped) next. This one
also should have the bent sides pointing up. You will have to tilt the shelves to fit in between the legs
and then lay them flat.
.
table goes in here
5. Slip the swivel work table into the open end of the square tube leg
- 7 -
RED Plug should
Pump Assembly
Hydraulic Hose
Air Hose
Push Down to
HYDRAULIC SYSTEM
1. Remove the RED Plug in the pump assembly and
replace with the supplied BLACK plug. This is
the reservoir venting system and damage or
inoperability may result if not changed out.
2. Attach the hydraulic hose to the pump. Attach an air line
fitting for your shop air to other end of the pump. Be sure
to use a quality thread sealer on both connections
3. Push the pump foot pedal to the release position (TOE END)
to relieve all internal pressure. Push the MALE hose end,
from the pump, into the FEMALE Cylinder fitting & then
thread the retainer collar hand tight. This procedure will insure
that the male & female fittings positively seat against each
other, eliminating any poss i bil i ty of air locking. Failing to
follow this procedure may cause the cylinder to not retract
and / or leak.
4. BLEED THE CYLINDER; Connect a compressed air supply
(90PSI) to the pump. Elevate the pump and hose above the
cylinder. Push the hydraulic pump pedal HEEL END to actuate
the cylinder. Run the cylinder out about half way. Release the
pump by pressing on the TOE END of the pedal. Repeat this
process three or four times or until the ram cylinder movement is
smooth.
be changed to
BLACK Plug
Release Pressure
TOE END
Retract
HEEL END
Pump
- 8 -
U Saddle & Pin Assembly or
Pressure Roller
Pressure Roller
Pressure Roller in
Pressure Roller
Pressure Roller in
Adjustable Saddle Assembly
Start Mark
Square Drive Shaft
Bender Shoe
Assembly
GETTING READY TO BEND
Assembly
Rotation Direction
“U” Shims
Bend Position
Released Position
Release Handle
Follow Bar
1. Slide the main Bender Shoe over the Square Drive Shaft. Be sure that the MB and
START are facing up and that they are positioned as shown above. The START engraving should be closest to the P r es su re R ol ler Assembly.
2. Position the Pressure Roller Assembly to the correct position by adding or subtracting “U” shims until the follow bar is almost touching the bender shoe, Be Sure the Pressure
Release Handle Is in the Bend Position as Shown.
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