J D Squared Model 54 Manuel utilisateur

JD Squared Inc.

2244 Eddie Williams Rd.

Johnson City, TN 37601 USA

(423) 979-0309

Model 54 Bender

Assembly and Operating Instruction Manual

Revision Date: 4/28/2015

Table of Contents

Uncrating �� 3

Assembly �� 4

Moving the bender.......................................................................................................................................... 4

Installing the handles...................................................................................................................................... 4

Floor mount or wheeled?................................................................................................................................ 4

Wheeled installation ....................................................................................................................................... 4

Floor mounted installation .............................................................................................................................. 4

Leveling the spindle........................................................................................................................................ 5

Filling the hydraulic oil tank ............................................................................................................................ 5

Electrical connection....................................................................................................................................... 5

Assembling the toggle mechanism................................................................................................................. 6

Adjusting the toggle mechanism’s over-center distance ................................................................................ 7

Tool Plate Installation �� 8

Loading the Die Set and Adjusting the Toggle �� 9

Rotate spindle to its start position................................................................................................................... 9

Installing the forming die onto the spindle ...................................................................................................... 9

Installing the U-strap....................................................................................................................................... 9

Description of the pressure die assembly..................................................................................................... 10

Installing the pressure die into the bender.................................................................................................... 10

The main operating principle of the Model 54 bender .................................................................................. 11

Adjusting the toggle mechanism for bending................................................................................................ 11

How to make a bend and remove the work piece when nished ................................................................. 12

Spindle lock operation .................................................................................................................................. 12

Computer Operation �� 13

Computer modes .......................................................................................................................................... 13

Program selection mode............................................................................................................................... 13

Operation mode............................................................................................................................................ 13

How to Calculate the Correct Bend Angle�� 13

Maintenance�� 14

Setting the spindle to zero ............................................................................................................................ 14

Exploded view of spindle components �� 15

Installing the Encoder ................................................................................................................................... 16

Encoder components �� 16

Bending Tutorial Using Template Bends �� 17

Uncrating

Parts included with bender:

1 Pressure screw pin (1” diameter)

1 U-strap pin and hitch pin clip (7/8” diameter with multiple

drilled holes)

1 Die socket set screw (3/4”-10 x 3.5” long)

1 Die washer (3/4” hole)

1 Die nut (3/4”-10 hex)

2 1/2”-13 x 2 1/2” long leveling bolts

2 1/2”-13 hex nuts

4 1/2” washers

1/2” leveling bolts

Bender’s crate with sides and top removed.

1) Remove the top and sides from the crate. Remove the 1/2” bolts attaching the bender to the crate’s oor but

do not discard them. They are used later to level the rear of the bender.

2) Removing the bender with a forklift: The bender may be lifted from the base using a forklift by inserting

the forks into the forklift access slot as shown in the above picture. The forks should be spread out as far as

they will go and still t into the slot. The bender is very top heavy and you must be careful not to let it tip and

possibly fall off the forks. We recommend you use tie downs and strap it to the forks. Also, make sure no one

is around the bender that may be hurt if the bender falls off the forks. GO SLOW AND BE VERY CAREFUL.

Removing the bender without a forklift: The bender may be rolled off the base using the procedure shown

below. In order to do this you will need to obtain 2 handles and a some 9/16” or thicker plywood. See the

section “Installing the handles” in the assembly section of these directions. Do not use the wood from the

crate’s side and top because it may not handle the bender’s weight.

1) Insert the handles and tilt the bender back. Place the plywood as shown below.

2) Carefully and slowly roll the bender down the ramp.

Forkli access slot

Page 3

Moving the bender

In order to save you money, the bender is sold without the

moving handles. Why? The 5 1/2 foot long handles will not t into

the bender’s crate and therefore must be shipped separately at

an average cost of over $40. The handle material itself however

is less than $10.

Installing the handles

Obtain 2 pieces of 1” pipe or 1 1/4” tubing at least 5 1/2 feet

long. Insert both handles into the 2 outer holes as shown to the

right and push them past the 2 inner holes until they bottom out.

Now you can easily move the bender around.

Floor mount or wheeled?

In order to achieve best results, the spindle must always be

as level as possible. To illustrate the problem, let’s assume the

bender is wheeled into position but the oor is 1ooff level from the horizon. The operator makes a 90obend.

Now the operator repositions the tube for the second bend and carefully levels the tube to the horizon and makes

the second bend. This repeats for a third bend. The result will be the rst and the last bend are now 2ooff plane

from each other. We refer to this as cork screwing. Therefore, the best way to setup up the bender is to mount it

directly to the oor as described later.

Wheeled installation

While oor mounting is denitely the best way to go sometimes the bender must be mobile. In this case, locate

the 1/2” bolts, nuts and washers you removed when uncrating the machine. Refering to the photo above, install

them back into the same holes in the base from where you previously removed them. The head of the bolt must

face down. The two bolts can now be used to level the bender.

Floor mounted installation

Remove the front wheels. Using the holes in the stand or the measurements below, mark the oor at the 4

corners of the bender’s stand. Now drill the holes and cement 1/2” threaded rods into the oor. Using 3 pairs of

nuts and washers at each corner, level the spindle’s top as described in the next section. Because the stand’s

welded dimensions may vary slightly from the drawing, verify the holes in the oor match the one’s in the bender

before cementing in the threaded rods.

Assembly

Bender shown with handles and the two rear

leveling bolts installed.

Page 4

Front corner, wheel removedBender mounted to oor

25.25

21.5

FRONT

Leveling the spindle

1) Remove 1 of the 4 socket head cap screws from the top of the

spindle as shown to the right.

2) Place a level on the spindle’s upper surface. Do not place it

anywhere else such as the top of the screws or dowel pins

because they may not be level themselves.

3) By rotating the spindle 90ofrom the front to the side and adjusting

the nuts at the 4 corners, level the spindle as accurately as

possible.

Spindle rotated in order to level front to backSpindle rotated in order to level side to side

Leveling surface

Socket head cap screw removed

Filling the hydraulic oil tank

The bender is shipped without hydraulic oil as per transportation

regulations. Remove the front oil tank access cover. Using commonly

available ISO-32 or ISO-68 hydraulic oil such as used in agricultural

equipment, ll the oil tank to approximately 1” from the top. The

tank’s oil level may be seen easily through the JD2 logo using a

ashlight. A rubber hose attached to a funnel makes this job fairly

easy.

Oil tank access cover

Electrical connection

AC SUPPLY VOLTAGE: The bender may be congured to operate on an AC supply voltage of either 110-120v

or 220-240v. The solenoid installed in the bender must match the supply voltage to the bender. The standard

motor may be wired for either voltage.

EXTENSION CORD: If you plug the bender into an extension cord, we recommend you use the shortest 10

gauge cable possible. If you use a long cable, such as 50 feet or more, or a smaller gauge cable, the power drop

through the cable may be signicant enough to trip the breaker in your building’s fuse box. The pump may also

not receive enough power to develop full pressure.

Oil tank viewed through the JD2 logo

Page 5

Empty screw hole

Assembling the toggle mechanism

1) Remove the bolts, washers and sleeves from

the handle.

2) Refering to the photo to the right, locate the 2

empty slots and holes. Place a sleeve in each

one of the 2 lower holes as shown.

3) Install the handle with the welded block to

the rear of the bender using the 2 bolts and

washers.

4) Install a sleeve in each slot. Install the remaining

2 bolts and washers into these sleeves.

5) Tighten all the bolts in the entire mechanism

very securely.

6) Verify the toggle moves freely and the safety

bar engages and disengages smoothly.

Toggle mechanism as shipped without the handle installed

Page 6

Sleeves placed in the lower 2 holes

Handle as shipped with bolts,washers and sleeves

Safety Bar Disengaged

Safety bar in the

disengaged position

Safety bar in the

engaged position

Sleeves

Safety bar engaged and all bolts have been installed

Adjusting the toggle mechanism’s over-center distance

The proper adjustment of the toggle mechanism is critical for the safe operation of the bender. The principle of

the toggle mechanism is that when engaged the middle pin will be slightly below the outer pins when the bender

is under load. This creates an over-center condition thereby preventing the toggle from disengaging when in use.

The distance that the middle pin is adjusted below the outer pins when engaged determines how difcult it will

be to disengage the toggle mechanism after the bend is complete. The dimension of 2” at the top of the adjuster

bolt is the factory setting. This will position the middle pin .050” below the outer pins when fully engaged. If the

toggle is ever disassembled, upon reassembly it must be readjusted to these values on both sides.

A small gap must be present

when the toggle is fully engaged.

Typically around .015-.030”.

is allows the safety bar to be

disengaged easily.

2”

49.5mm

Outer toggle link pins

Middle toggle link pin

Toggle mechanism’s side view

Page 7

The Model 54 has been designed to allow new tooling to be easily added in the future. This is accomplished

by using a tool plate that bolts to the pressure screw block. Various tool plate’s are available depending upon

the application. The majority of die sets use the standard 2 hole tool plate that is included with the bender. This

plate accommodates dies for up to 2.5” tube and 2” pipe. However, a die set such as 3” o.d. tube may require

a different tool plate. The correct tool plate for a particular die set can usually be determined by examining the

tooling and looking for the engraved markings such as shown below.

The dovetailed tool plate design was added

to the Model 54 in April of 2014. Therefore, if

the bender was purchased before that date it

may not have the upgrade installed. If this is

the case, please call our sales deptartment.

We feel this is a signicant improvement to

the bender and therefore offer this as a FREE

upgrade.

When the bender is under load, the dovetail

in the tool plate will suck down onto the outer

rail’s dovetail and lay at. This ensures the

tool plate’s pin holes are vertical and are not

tilted. It is CRITICAL that the tool plate and

the outer rail’s dovetailed surfaces are in full

contact under load.

To verify this, use the following procedure.

Without any tooling in the bender, push the

tool plate to the left towards the cylinder and try to raise the right side nearest the outer rail. If it does not tilt

towards the cylinder or try to lift then everything is ne. If this is not the case, there is not enough clearance

between the inner rail and the pressure screw block’s left side slot. This should only happen when a older bender

is being upgraded. To remedy this you can remove the pressure screw and using the edge of a le, remove

material from the bottom of the left slot until a clearance of .010” or slightly more is obtained. This can be seen

in the lower right photo. The amount of material to remove is usually only about .020-.030”. If you wish you may

also send the pressure screw to the factory and we will be happy to mill the slot deeper for free.

Tool plate

Outer rail Inner rail

Pressure screw block

Tool plate’s rear viewTwo hole tool plate’s front view Outer rail

Tool plate’s dovetail

must fully contact

the rail.

e engraving on the

tooling shows which

adapter to use.

Tool Plate Installation

If necessary

le here

when

upgrading

bender

Pressure screw block

Page 8

Must have .010” or

more clearance here

under load.

Rotate spindle to its start position

1) Retract the ram until it stops moving and then move it

forward slightly. If left fully retracted, the ram will pull the

spindle to the rear and lock it up. This does not harm

anything, it just won’t let you rotate the spindle by hand.

2) The drive hub has 7 teeth. One of them is much larger than

the others. This is the rst tooth. Pull the spring loaded

drive pawl’s handle out and rotate the spindle until the

drive pawl engages this tooth. This is shown to the right.

Installing the forming die onto the spindle

1) Examine the spindles upper surface and remove any debris

that may not allow the forming die to sit at. Also make

sure the four large 1” dowel pins are seated completely.

2) Install the forming die with it’s u-strap towards the cylinder.

Install the die washer and nut. Tighten securely.

Installing the round tube/pipe U-strap

1) Wipe the forming die’s groove clean. Never lubricate the groove as this would allow the tube to easily slip

during bending. Place the tube into the groove’s die.

2) Install the u-strap and insert the u-strap pin. The u-strap uses a clip pin to limit how far down the pin goes into

the u-strap. It is very IMPORTANT that you place the clip pin into a u-strap hole that allows the u-strap pin to

protrude past the u-strap’s lower surface by a 1/4” or more without the possibility of the pin hitting the spindle

button head bolts or the frame while rotating. This is shown in the picture to the lower right.

3) If bending thin wall tubing (.065” or less) you may need to tighten the

u-strap lock bolt to help prevent the tube from slipping backwards into

the die while bending. If the bolt tries to mar the tube, make a small

piece of curved metal and place it between the bolt and the tube.

Loading a Round Tube/Pipe Die Set

Drive hub’s 1st tooth Drive pawl

Forming die

Spindle top view. U-strap block

U-strap pin must extend past u-strap’s

lower surface by a 1/4” or more

U-strap pin must clear

the button head bolts as

shown here

U-strap lock bolt

1” dowel pin

Button head bolt

Page 9

Die Washer

and nut

NEVER lubricate the

forming die’s groove

U-strap pin and clip pin

Description of the pressure die assembly

The pressure die is shown in the 2 pictures below. It is sometimes referred to as a ‘followbar’. It constrains

the outside of the tube while bending. It is made up of 2 inserts and the backing block. The inserts are cast and

machined from a special, scratch and wear resistant, metal alloy. The inserts are relatively self lubricating but

are considered as consumable. They are NOT aluminum. Their typical life span is 1,000s of bends when using

clean tubing.

In the left side picture you can see the left insert is in line with the backing block and the right insert is angled.

The angled insert is the trailing insert and will always be closest to the u-strap during bending. It rides where the

tube has already been bent, thus helping to minimize the amount of attening on the outside of the bend. It is

computed to within 1/1000th of a degree at the time of manufacture to produce the best bend conditions for the

size of tubing and the bend radius. Therefore, the pressure die must be installed into the bender correctly in order

to take advantage of this design feature or you will experience poor bend quality.

In the right side picture you can see the bottom of the pressure die. The roll pin will hold the pressure die up

when the pressure screw is retracted. It must be adjusted so that the insert’s grooves are 1/16” or so below the

forming die’s groove when the tube is not loaded. This will allow the pressure die to rise slightly and level itself

when the toggle is advanced into the bending position.

The standard tool plate has 2 pin hole locations. This allows the amount of rear insert force to be tailored to

the tube being bent, thus producing a better quality of bend.

Installing the pressure die into the bender

If you examine the pressure die’s top surface you will notice the engraved word TOP and usually a circle and

tool plate outline. This engraving illustrates which tool plate is needed and what hole to place the 1” pin into.

Place the pressure die into the tool plate and align it with the engraved markings aligned with the tool plate’s

outline. The lower left picture shows a pressure die designed for the standard 2 hole tool plate. The 1” pin

obviously goes into the hole on the right side of the photo. Always be very careful to ensure the 1” pin as been

completely seated all the way down to the roll pin.

The 3” tube pressure die shown below right is designed for a 1 hole tool plate as can be seen by the engraving.

Pressure

die insert

Pressure die top view Pressure die bottom view

Roll pin

Engraved phantom

hole circle and TOP

indicator

Backing

block

A pressure die installed into a two hole

tool plate.

e engraved outlines

show how to load the

pressure die

Page 10

Angled insert

A 3” tube pressure die. It is designed for a one hole tool

plate as can be seen by the engraving.

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