Model II - Tubeshark

Portable Hydraulic Tube Bender
Model II
2” capacity
Manufactured by:
GRB Innovations, LLC
63055 Corporate Place #3
Bend, OR 97701
541-382-1573
www.tubeshark.com
Page 1
TABLE OF CONTENTS
PAGE #
3.
4.
5.
6.
7.
11.
12.
12.
15.
16.
17.
18.
22.
25.
27.
30.
31.
32.
33.
34.
34.
35.
36.
37.
SUBJECT
Component Drawing
Component listing
Uncrating
Safety
Initial set-up
Principles of Operation
Tools
Operation
General Application Chart
Drive Pin Operation
Feed Shoe Pin Operation
Changing Bending Dies and Shoes
Square Die Operation
Square Bending Data
Maintenance and Tuning
Folding for Storage
Approved Fluids and Lubricants
Minimum and Maximum Wall thickness
Common Bending Dies
Specifications
Tube Consumption Chart
Warranty
Return and Cancellation Policy
Shop Notes
Page 2
E
F
T
L
C
M
O
B
D
K
J
S
A
Q
X
V
P
G
U
H
I
N
R
Page 3
W
COMPONENT DRAWING
Component Listing
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.
Q.
R.
S.
T.
U.
V.
W.
X
Frame
Bending head
Dorsal plates
Forming die
Forming shoe
Feed shoe
Hydraulic cylinder shroud
Hydraulic hose
Hydraulic pump
Hydraulic coupler
Ram head
Bending gauge (under shroud)
Machine guards
Frame locking pins
Gas struts
Gas strut locks
Axle
Wheels
Cylinder tensioner
Cylinder cam-lock
Tip over safety bracket
Cylinder mounting block
Leg locking knob (under frame)
Hydraulic Cylinder
Page 4
Uncrating
1. When your machine arrives, check the packaging for damage to the
carton that might indicate damage to the contents. Ask the driver to note
any such damage.
2. Remove all of the screws and washers at the bottom of the carton.
3. Cut the banding and lift the carton up and off of the pallet.
4. Remove the accessory packages.
5. Remove the dorsal plates that are bolted to the top of the machine for
shipping.
6. The machine is bolted to the pallet with two brackets. Remove the bolts.
7. Grasp the machine by the cross bar and tip it back as you would a hand
truck. Carefully roll the machine down and off the pallet.
*** Save the packing materials in case the machine needs to be shipped in the
future. If the equipment is returned for repair, it is your responsibility to
properly crate it. ***
STOP!
Before continuing, read through the safety and operational
instructions in this manual and in the Enerpac manual that is
enclosed. Failure to do so could result in damage to the
equipment or personal injury.
Page 5
Safety
Throughout this manual there are clearly marked safety tips that deal with
specific areas of operation. Please read these carefully. If there are any
questions concerning safety practices or equipment, contact GRB at (541) 3821573, or at the address listed at the back of this manual.
GENERAL SAFETY:
1. Inspect the machine and hydraulic system before each use for damaged,
worn, or broken parts.
2. Never operate this equipment if any part is damaged, worn or broken.
3. Never remove the safety guards or safety decals from the machine.
4. Always wear safety glasses whenever operating this equipment.
5. Never substitute non-TubeShark parts in your TubeShark bender!
TubeShark parts are the finest money can buy. They are built to
withstand the enormous forces generated by this machine. Use of nonTubeShark parts could result in serious machine damage or personal
injury. It will also void your warranty! DON’T USE THEM!
6. Never drill, weld, or modify any TubeShark component unless
specifically instructed to do so in writing by GRB.
7. All TubeShark benders are equipped with remote control hydraulic
systems, which allow you to stand clear of the machine during the
bending process. Always keep hands clear and stand to the side or rear
of the machine anytime the hydraulic system is in the “PRESSURE” or
“HOLD” position. Remember that in the “HOLD” position, the hydraulic
system is still pressurized.
8. Never disconnect any hydraulic component unless all line pressure has
been released, and the ram is in the fully retracted position.
NOTE: The hydraulic hose connection at the cylinder is easily removed by hand.
If this fitting is hard to operated, it could indicate that residual pressure is in the
line. In this case, hit the “release” button on the pump to release the pressure.
Always disconnect the power source before disconnecting the hydraulic lines
(this may be the air line or the electrical cord depending on model).
9. Never use alcohol or any drug, which could impair your judgment or
ability to operate this equipment safely.
10. Ensure that all operators of this equipment have fully read and
understood this manual and the Enerpac manuals included. If this
machine is sold or loaned, be sure that these manuals go with the
machine. If this manual is lost or damaged, a free copy may be obtained
by calling or writing to GRB.
Page 6
Initial Set-Up
UNFOLDING:
1. Move the machine to a level, flat surface.
2. Loosen the pivot frame-locking knob.
3. Fold the legs down and insert the locking pins on both sides in the down
position.
CAUTION: The folding legs must be fully lowered and locked whenever
the bending head is raised! Failure to do so will cause the machine to fall
forward.
4. Remove the head-locking pin.
Page 7
5. Loosen the two black gas strut clamping knobs.
6. Now pull the bending head straight up and forward. As the gas struts are
pulled past center, the head will continue to rise by itself.
Page 8
CAUTION: Keep hands clear of the hinge area when raising the head.
7. Pull up on the bending head and insert the lock pin.
8. Tighten the gas strut clamps on both sides just until snug. Do not over
tighten.
Page 9
HYDRAULIC HOOK-UP:
1. Refer to the hydraulic manufacturer’s manual for set-up instructions.
2. Your pump has been shipped full of oil and ready to run. All that is
required is installation of the hose, an air fitting, and reservoir venting.
3. Remove the dust plugs from the cylinder and the hose fitting.
4. Insure that both connectors are clean.
5. Push the two connectors together while tightening the collar. DO NOT
OVER TIGHTEN THIS FITTING! This fitting requires only that the collar be
screwed completely down. It does not have to be tight to seal. NEVER
use pliers or wrenches on this fitting.
CAUTION: Always inspect the hose and fittings for damage before each
use. Never operate the bender with damaged hydraulic parts.
6. Check the reservoir level and add oil if needed. Use only approved
hydraulic fluids.
7. Connect the airline (or plug in the electric pump if so equipped). The air
pump requires 100-120 psi to develop full power.
NOTE: Air powered pumps must be supplied with clean, dry lubricated air. If
an oilier is not installed on your air system, an inline oilier must be installed
on the pump prior to use.
YOUR BENDER IS NOW READY FOR OPERATION!
Page 10
Principles of Operation
And other facts
Your TubeShark bender is a rotary draw type bender. When the bend
begins, the forming shoe moves forward and captures the tube between the
forming shoe and the forming die. The tube is then pulled through the machine
guided by the feed shoe and rolled around the forming die. To function
properly, the tube must move smoothly through the feed shoe and onto the
forming die. This is why proper lubrication is essential. The forming shoe must
actually grip the tube and must not slip along the tube as the bend progresses.
This is why we do not recommend lubricating the tube where it engages the
forming shoe. It is a good idea to make a mark on the tube at the edge of the
forming shoe to be sure that no slippage occurs. In most cases, the grip of the
forming shoe is sufficient; but in some cases an additional clamp must be used
to secure the tube. This clamp is available from GRB. Use of the optional drive
pin will also reduce the tendency to slip, and is recommended for small or thin
wall tube.
The bending head complete with dies weighs approximately 140lbs. The
gas strut system on the TubeShark has been carefully engineered to provide
easy management of this heavy component. The gas strut system has three
functions: to assist raising the bending head, to support the head in the raised
and locked position, and to secure the head in the folded position. The locking
clamps use a polyurethane pellet between the knob stud and the cylinder rod.
This is to prevent damage to the rod and provides a secure grip without over
tightening.
Page 11
A Few Words About Tools
Throughout this manual we will refer to tools that are needed to properly
operate your new bender. Use of improper tools could damage your bender and
void the warranty. GRB provides the necessary tools with the machine. If you
choose to assemble your own tools, a list of substitutes is given below.
TOOL LIST:
1. 14oz – 16oz Plastic dead blow hammer
2. Good quality 1” china bristle brush
3. 3/8” short arm hex key
4. ¼” short arm hex key (for square dies)
5. 1/8” extra long hex ball driver
6. 15/16” open end wrench
7. A 5” length of ¼” steel rod with a loop or handle at one end
(alignment pin).
Operation
BASIC OPERATION:
1. Position the pump so that it is convenient, and so that you have a
clear view of the bending gauge on the side of the cylinder. The
bender is always stored with the dorsal plates in the starting position.
If the bender is not in this position, push down on the cylinder and
rotate the cam lock to disengage it from the dorsal plates.
Page 12
DO NOT FORCE THE CYLINDER DOWN BEYOND THE POINT
WHERE THE CAM ENGAGES! DOING SO MAY DAMAGE THE
SPRING TENSIONING MECHANISM. Now pull the dorsal plates
around to the starting position and re-engage the cylinder ram head
with the dorsal plates. Check both sides of the machine to ensure that
the ram head is fully seated in both fins.
2. Choose a length of tubing of the proper size for the die/shoe set that
is installed in the machine. The dies and shoes in your TubeShark
bender are high precision components! Using crooked, rusted, dented,
or damaged tubing in you bender could damage these components!
Always inspect the tubing before insertion into the bender. Also be
sure that the ends are free of burrs or sharp edges that could gouge
the machined surfaces on the dies and shoes.
3. Lubricate the feed shoe with TubeLube or other approved
lubrication. Do not lubricate the forming shoe. Improper lubrication
could result in poor bend quality, difficult operation, or shortened
die/shoe life. We highly recommend the use of our lubricants.
However, a list of approved alternatives is provided at the back of this
manual.
4. Insert tubing into the machine from the front and position as desired.
CAUTION: Never exceed the capacity limitations listed at the back of
this manual! Failure to follow this recommendation could result in
machine failure or injury, and will void the warranty.
5. The beginning of the bend will be at the front edge of the feed shoe.
Tubing will be drawn through the bending head as the forming die
rotates.
6. If the tubing has existing bends and does not stay in position when
inserted, hold the tube in position and actuate the hydraulic pump until
the pressure applied is sufficient to hold the tube.
7. Now step to the side of the machine and actuate the pump to
continue the bend.
8. Watch the bending gauge as the bend proceeds. There are four sets
of numbers on the gauge depending on which set of fins are engaged.
Fins 1 – 4 are good for 54 degrees of bend each. If a bend of 90
Page 13
degrees is desired, drive the ram forward until it stops. Now retract
the ram fully. As it retracts, it will engage the next set of drive fins.
Insure that the ram head has remained properly aligned and is not
turned. Now actuate the ram forward again until 90 degrees is
reached. This process is repeated to achieve 135 and 180 degree
bends. Under most circumstances, only the four numbered fins are
used. The intermediate fins are used in cases where excessive springback will not allow the ram head to engage the next numbered fin.
The one fin past #4 is an over-bend fin that will be discussed later.
9. When the desired bend is achieved, retract the ram fully and engage
the cylinder cam lock.
10. Pull back sharply on the dorsal plates to pop the forming shoe free of
the tube.
11. You may have to tap the forming shoe with a plastic dead blow
hammer to free it.
12. Remove the forming shoe pin and the forming shoe if desired.
13. Return the dorsal plates to the starting position.
14. The tubing will be tightly formed into the die. This is normal. For
most bends less than 180 degrees, the tube may be freed by simply
pulling down on the free end of the tube. For 180 degree bends, the
tube may be taped with a plastic dead blow hammer at both ends to
free it from the die. If one end of the tube is inside the head, a length
of 2X4 can be slid into the head from the back and used to tap the
tubing out. NEVER, NEVER, NEVER USE A METAL HAMMER FOR
ANYTHING ON YOUR TUBESHARK BENDER!
15. Re-install the forming shoe if it was removed and re-engage the ram
head for you next bend.
A FEW HINTS:
1. Always use the correct die/shoe set for the pieces to be bent. NEVER
use pipe dies to bend tubing or tube dies to bend pipe! Tubing dies
may be used to bend solid rod up to the capacities listed at the back of
this manual.
2. All metals exhibit spring back when they are bent. The amount of
spring-back is different depending on the material, wall thickness,
cross section , and even manufacturing differences. For this reason, it
is impossible to “design in” to any bender. Your TubeShark bender
is designed to allow you to over-bend as needed to compensate for
this tendency. Use a piece of practice tube to determine the amount
of over-bend needed before starting your work piece. Over-bend
compensation is covered later in this manual.
Page 14
3. A SPECIAL NOTE ABOUT 180 degree bends: Fin number 4 will bend
up to 192 degrees. This is to allow for over-bend and spring-back.
The last fin is an additional over bend that pushes to 212 degrees to
allow bending of extremely springy materials. When setting up, go
SLOW! It is important to determine the proper amount of over-bend
slowly so that you do not go too far! Soft materials can be wrapped
around the forming die and “trapped”. If this happens, the forming
die and trapped tube must be removed from the bending head. The
tube can then be spread open with a scissor jack or port-a-power type
spreader.
4. Plan your bends ahead of time to avoid clearance problems.
5. Not all metals and alloys lend themselves to bending. When
choosing material for a bending project it is wise to look for alloys,
which form well. For instance, exhaust tubing is specially formulated
to bend easily without crimping. In the thinner wall sections it will
give consistently better results that standard hot rolled and welded
tube.
GENERAL APPLICATION CHART
MATERIAL
CAPACITY
LOW CARBON STEEL ROUND TUBE
4130 STEEL ROUND TUBE
300 SERIES STAINLESS STEEL ROUND TUBE
ALUMINUM (BENDABLE ALLOYS)
COPPER & BRASS (BENDABLE ALLOYS)
SCHEDULE 10/40/80 STEEL PIPE
1018 COLD DRAWN ROUND BAR
4130 ROUND BAR (ANNEALED)
300 SERIES STAINLESS STEEL BAR
ALUMINUM SOLID BAR (BENDABLE ALLOYS)
COPPER & BRASS SOLID ROD (BENDABLE
ALLOYS)
SQUARE MILD STEEL TUBE
SQUARE MILD STEEL BAR
½”
½”
½”
½”
½”
¼”
½”
½”
½”
½”
½”
Page 15
–
–
–
–
–
–
–
–
–
–
–
2”
2”
2”
2”
2”
1 ½”
1 ¼”
1”
1”
1 ½”
1 ¼”
½” – 1 ½”
½” – 1”
Drive Pin Operation
Under most conditions the forming die is not driven during the bending
process. It is free to rotate in the frame as needed to allow the bend to
proceed. Under some circumstances however it is advantageous to drive the
forming die. This is usually indicated when slippage occurs between the forming
shoe and the tube. Small diameter and thin wall tube is most at risk for
slippage. When slippage occurs, kinking is often the result. To drive the forming
die, a ¾” hole has been drilled into the forming die, which may be aligned with
the holes in the dorsal plates. A drive pin (included with your bender) is then
placed through the dorsal plates and forming die.
DIRECTIONS:
1. With the bender in the starting position, turn the forming die by hand until
one of the ½” holes in the die aligns with the dorsal plate holes.
2. Insert the drive pin all the way in through both dorsal plates.
3. Bending can proceed as normal.
4. When the bend is finished, counter-rotate the dorsal plates about 1”.
5. At this point you have two options; You can remove the forming shoe and
return the dorsal plates and forming die to the start position as one unit or
pull the drive pin and return the plates with the forming shoe in place.
CAUTION: Always insure that the drive pin is all the way in before applying
power to the bender.
DRIVE PIN
Page 16
Feed Shoe Pin Operation
Your bender is equipped with a modified front feed shoe pin. This
refinement improves the ease of inserting the tube and extracting the bent tube.
It also improves the smoothness of operation. Our tests have shown that on
thin wall tube, bend quality is improved. In some cases you can drop one wall
thickness size without wrinkling.
This pin should be centered in the frame just as the other pin is.
CAUTION: This pin must always be installed in the front position! The front
pin is for positioning and the rear one bears the load. If they are reversed,
malfunctioning and machine damage could result. The illustration below shows
the proper position of this pin.
FRONT FEED SHOE PIN
BENDER HEAD FRAME
PROPER PIN POSITION
Page 17
Changing Bending Dies & Shoes
DIE &
1.
2.
3.
SHOE REMOVAL:
Return the ram to the fully retracted position.
Remove any tubing that is in the bender.
Push down to disengage the ram head from the dorsal plates and engage
the cylinder-locking cam to hold it out of the way. Rotate the dorsal
plates until the indicating arrows are pointing up.
CAUTION: The indicating arrows must point up before disassembling the
bender. Tension on the clutches will be released when the axle nut is
loosened, allowing the dorsal plates to swing free.
4. Remove the forming shoe.
5. Remove the axle nut and washer using the 15/16” wrench and the 3/8
hex key.
6. Remove the dorsal plate from the left (nut) side of the bender. There is
a stub on each side of the frame to hang the plates.
Page 18
7. Rotate the forming die until the ¼” hole aligns with the notch in the top
of the bending head.
8. Insert the ¼” alignment pin through the notches in the bending head, the
hole in the forming die, and the hole in the remaining dorsal plate.
The pin must be inserted fully so that the notches on both sides of the
bending head are supporting the pin, and the end of the pin is protruding
through the remaining dorsal plate at least 1 ½”.
9. Now pull the axle out while holding the dorsal plate on the pin.
Page 19
10. Remove the remaining dorsal plate and hang it on the frame stub.
11. Now lift the forming die and alignment pin out of the bending head.
12. To remove the feed shoe, use a 1/8” ball driver to loosen the 2 set
screws in the bottom of the shoe. One turn is all that is required.
13. Push the two ½” mounting pins out and remove the shoe.
DIE & SHOE INSTALLATION:
1. Check that the die and shoes to be installed are a matched set. Each
part is stamped with identification.
2. Install the feed shoe by reversing the removal steps. Center the shoe
and pins in the frame and tighten the setscrew.
CAUTION: It is a good idea to check the tightness of these screws
occasionally to prevent the pins from coming loose and jamming the
bender.
3. Rub a little paraffin or candle wax on the black urethane clutch discs.
4. Put a light film of grease on the recess cut into both sides of the forming
die.
5. Insert the ¼” alignment pin through the forming die.
6. Insert the forming die into the bending head so that the alignment pin
engages both notches in the bending head. Take care not to tear the
Teflon wear pads loose from the inside of the bending head as you insert
the die. Push the alignment pin in fully so that it extends beyond the
bending head on the right side.
7. Install the right dorsal plate onto the alignment pin. Be sure the pin
protrudes 1 ½”.
8. Insure that the radial springs are installed properly on the axle.
Page 20
SPRINGS TOWARD FRAME
9. Lubricate the axle with a very small dab of SharkGrease. There
should be only a very light film of grease on the axle!
10. Align the components and push the axle all the way through.
CAUTION: The components in you TubeShark are machined to exacting
tolerances. When the components are properly aligned, the axle will slip
through easily. Do not strike the axle with anything.
11. Remove the alignment pin.
12. Install the remaining dorsal plate, washer and nut, and tighten securely.
13. Check to see that the feed shoe pins are centered in the bending head.
They should protrude only slightly from each side of the bending head.
Now snug down the 2 setscrews in the bottom of the feed shoe.
14. Check for proper operation of the dorsal plates. The clutches should
allow the plates to be moved by hand but should retain them firmly in any
position. A candle or paraffin block may be rubbed over the black disc to
prevent squeaking and grabbing. IF the plates are too loose, check to
insure that no oil has contaminated the clutch discs, and that the radial
springs are properly installed on the axle. If the operation is still
incorrect, check the clutch discs for excessive wear. In most cases, the
disks may be reconditioned by using the following procedure:
 Clean the discs with MEK or acetone.
 Scuff the surface of the pad with a ScotchBrite type pad.
 Wipe away any debris and rub the entire pad surface with paraffin.
If this fails to correct the problem, the clutch discs may need to be
replaced. The forming die should turn with only light resistance. The
discs on the inside of the bending head are made of Teflon to provide
smooth operation.
15. Install the forming shoe and return the dorsal plates to the starting
position.
16. Release the cylinder engagement cam and insure that the ram head is
fully engaged with both dorsal plates.
Page 21
Square Die Operation
Step by step instruction for the installation and operation of TubeShark
square die sets are given below.
Identify the different parts of the square set:
Master die: Large round part with zinc chromate finish.
Base plate: Long 1” thick aluminum bar with holes at each end.
Feed Shoe: Long aluminum bar with a channel cut down it.
Forming Shoe: 4” long block with a channel and four ½” – 13 set screws.
1.
Install the base plate into the frame using two solid feed shoe pins plus the
front feed shoe pin. Use the correct set of holes in the bending head.
Never use the stepped feed shoe pin for square bending. Secure the pins
with the setscrews. You will notice that the base plate can be installed any
of four ways. It is completely symmetrical. It is advised to rotate the plate
occasionally end to end, and over , to even out the wear. See the photo on
the next page for the proper relationship of the parts.
2.
Install the master die just as you would a round forming die.
Page 22
3.
Choose a feed shoe and apply a small amount of tube oil on the bottom and
in the channel. Slide it in on top of the base plate until the stop bolt on the
bottom contacts the base plate. As with the base plate, it is advisable to
swap ends occasionally to even out wear.
4.
Lubricate the sides of the feed shoe channel every few bends. Slide the
tube into the feed shoe to the correct point. The front of the feed shoe will
be the beginning of the bend. It is usually best to arrange the welded seam
to be on top or bottom, not to the side.
Page 23
5. Install the forming shoe into the dorsal plates just as you would any
forming shoe.
FORMING SHOE PIN
The 2 set screws must point to the front of the machine and be retracted
out of the channel. NOTE: Leave the setscrews backed out.
6.
7.
8.
It is usually advisable to use the drive pin when bending square tube.
Now power the bender ahead until the forming shoe is tight against the
tube. Tighten the 4 set screw on the forming shoe using the wrench
provided. NOTE: It is best to tighten both screws on one side then both
screws on the other side. The screws should be tight enough so that the
cup points cut into the tube and get a firm grip. Do not over-tighten
however, or the tube may begin to crush. It is important that the tube does
not slip in the forming shoe during bending.
Now you can bend just as you would with the round dies. As the bend
proceeds, the feed shoe will advance out the front of the machine and the
tube will roll up and out as it forms around the master die.
Page 24
Square Bending Data
Mild Steel Welded Tube
FOR 5”R MASTER DIE
SHOE SET
1 ½ SQ
1 ½ X 1 REC
1 ½ X ¾ REC
1 ¼ SQ
1 SQ
1 X ½ REC
¾ SQ
½ SQ
MINIMUM
WALL
THICKNESS
.065
.065
.065
.065
.049
.049
.049
.035
MAXIMUM
WALL
THICKENESS
.188
.188
.188
.188
SOLID
SOLID
SOLID
SOLID
FOR 4”R MASTER DIE
SHOE SET
1 ½ SQ
1 ½ X 1 REC
1 ½ X ¾ REC
1 ¼ SQ
1 SQ
1 X ½ REC
¾ SQ
½ SQ
MINIMUM
WALL
THICKNESS
.095
.065
.065
.083
.065
.049
.049
.049
MAXIMUM
WALL
THICKENESS
.120
.188
.188
.188
SOLID
SOLID
SOLID
SOLID
Page 25
Square Bending Data (Cont.)
FOR 3”R MASTER DIE
SHOE SET
1 ½ SQ
1 ½ X 1 REC
1 ½ X ¾ REC
1 ¼ SQ
1 SQ
1 X ½ REC
¾
½ SQ
MINIMUM
WALL
THICKNESS
NR
.083
.083
.095
.083
.065
.065
.065
MAXIMUM
WALL
THICKENESS
NR
.188
.188
.188
SOLID
SOLID
SOLID
SOLID
NR = NOT RECOMMENDED
Note: Fundamentally, square tube does NOT like to bend. Getting the best
results is a matter of choosing the right material and the right bending die. As
with any bending die set, choosing a wall thickness near the center of the range
will produce the best results. Always use the largest radius master dies that will
work for your project to achieve the best bends. When bending stainless or
other hard material, the maximum allowable wall thickness is reduced by .065
and the solid cross section by .250. The minimum wall thickness, which will give
acceptable results in hard materials, is best determined by experimentation.
When bending soft materials such as aluminum, the maximum wall allowed
is .065 above what is shown in the table. The minimum wall that will give
acceptable results is best determined by experimentation.
NEVER EXCEED THE MAXIMUM ALLOWABLE WALL THICKNESS OR DAMAGE
TO THE EQUIPMENT MAY RESULT!
Page 26
Maintenance and Tuning
A. CLEANING
1. All of the surfaces and materials used in your TubeShark bender are
top quality and resistant to oils, cleaners, and degreases. Only minimal
care is needed to keep your machine in like new condition. Simple Green
or similar cleaners work well for cleaning the painted surfaces. Do not
use Lacquer on painted surfaces. Lacquer thinner and any aluminum
polish work well for cleaning up the aluminum parts.
B. LUBRICATION
1. Use the checklist below for the points needing TubeLube or similar
approved oil.
Bending head hinge ___
Folding leg hinges ___
Leg locking threaded stud ___
Gas strut pivot points ___
Hydraulic coupler threads ___
Hydraulic cylinder pivot bolt ___
2. Use the checklist below for the points needing SharkGrease or similar
approved grease.
Axle bolt ___
Forming die recesses where the Teflon pads run ___
Cylinder spring tensioning pivot sockets ___
Gas strut locking knobs (threaded studs) ___
C. HYDRAULIC MAINTENANCE
1. Refer to the Enerpac manual for maintenance of the hydraulic system.
2. Always check the fluid level at the start of each day of use.
3. Use Enerpac hydraulic fluid whenever possible. If Enerpac fluid is not
available, a list of Enerpac approved fluids is given at the back of this
manual. To ensure that your warranty is not compromised, avoid the use
of unapproved fluids!
Page 27
D. TUNING
Cylinder spring tension:
The cylinder spring tension should be set so that the ram head tracks very
lightly along the dorsal plates as it retracts from full extension. To set
properly, follow the steps below.
1. Drive the ram to full extension.
2. Tap the “retract” on the hydraulic pump to move the ram head back about
½”.
3. If the ram head falls clear of the dorsal plates, the tension is too low. If
the ram head remains tightly against the dorsal plates, the tension is too
high.
4. Adjust the twin spring mechanism at the back of the cylinder using a hex
wrench and a 9/16” open end wrench until the ram head is lightly
touching or just below the dorsal plates. While holding the nut with the
9/16” wrench, turn the hex key clockwise to increase tension and
counterclockwise to decrease tension. Insure that both springs are
compressed equally.
E. GAUGE CALIBRATION
Calibration may vary slightly from die set to die set and should be checked
if accuracy is critical to the job at hand. Follow the procedure below to
check and calibrate the gauge:
1. Place a piece of test tubing in the bender.
2. Move the ram forward until all the slack is taken out of the moving parts
and the tube is locked in the machine.
3. At this point the gauge should read “0” if properly calibrated.
4. If calibration is not correct, use a pen to mark the cylinder where “0”
should align. Remove the tube and advance the ram fully. The bending
scale is held magnetically and can easily be repositioned so that “0”
occurs at the correct position.
Page 28
F. SPRING-BACK COMPENSATION
1. Drive the tube to the desired bend as indicated on the bending gauge.
Example: 45 degrees.
2. Tap the release on the pump to slowly retract the ram just until the ram
separates from the dorsal plate fin.
3. Drive the ram forward until it just touches the dorsal plate fin.
4. Now when you read the gauge again, you will see that it has moved back
a little. Example: 42.5 degrees.
5. The amount of spring-back in this case is 2.5 degrees. (45 – 42.5)
6. Now add 2.5 to your bend and drive the ram forward again until you
reach 47.5 degrees. You will have an exact 45-degree bend in the tube.
7. This procedure only needs to be done on the first bend. As long as you
are using the same tube, you will get exactly 45 degrees, every time, by
bending to 47.5 on the scale.
NOTE: Small diameter tube will be more difficult to compensate because it
lacks the strength to force the plates back. In this case you may have to
help it find its relaxed point.
Page 29
Folding for Storage
1. Return the dorsal plates to the starting position. (ram head fully retracted
and engaged with the number one fin)
2. Disconnect the hydraulic hose at the cylinder and cap the hose and
cylinder. Push in on the coupler until the collar is removed, then pull the
coupler apart. This will minimize the amount of fluid that escapes. Hold a
rag under the coupler to catch any fluid that drips.
3. Remove the bending head locking pin.
4. Loosen both gas strut clamps.
5. Push straight down and back on the bending head until the head is sucked
into the folded position by the gas struts.
6. Tighten both gas strut clamps.
7. Remove both legs locking pins, hold the tip over the safety bracket out of
the way and raise the legs. Secure the legs with the locking knob.
The bender can now be rolled easily for storage or transportation.
Page 30
Enerpac Approved Fluids
The following hydraulic oil products are compatible with Enerpac’s HF
hydraulic oil. However, some of the products listed below are not of the same
viscosity grade (42/45 SUS @ 210F, 150/165 SUS @ 100F) and do not contain a
blue dye for identification purposes. These oils contain an anti wear additive,
rust/corrosion protection, oxidation inhibitor, and an anti-foam agent. These
fluids should only be used when Enerpac fluid is unavailable.
Amoco Rykon 15
Citgo Pacemaker XD15
Gulf Harmony 43AW
Mobil DTE 24
Shell Tellus 46
Castrol Hyspin AW32
Chevron Duro 32
Texaco Rando 32
Phillips Magus 32
Conoco Super Hyd Oil 32
Exxon Terrestic 32
Exxon Nuto H32
GRB Approved Lubricating Oils
A list of possible alternatives to our TubeLube is listed below. However,
all of these oils are inferior to our TubeLube! TubeLube uses high quality
synthetic base and a Teflon concentration that is 10 times higher than the best
of the oils listed.
Whenever possible it is advised to purchase this oil in non-aerosol form.
LPS Magnum Teflon OIL
Triflow
TAL-5
Superlube
CRC Power Lube
Break-free
GRB Approved Grease
SharkGrease is a high performance, Teflon filled, pure white lithium
grease. We are not aware of any direct substitute. Any grease of this type
should be adequate. At last resort, standard white lithium grease may be
substituted.
Page 31
Minimum and Maximum Wall Thickness
without ITS®
FOR ASTM A-513 ELECTRO-WELDED MILD STEEL
TUBE O.D.
MIN. WALL
MAX. WALL
½
.035
SOLID
¾
.049
SOLID
7/8
.035 (5”R)
SOLID
1
.049 (5”R)
SOLID
1–¼
.065 (6”R)
SOLID
1–½
.083
.250
1 – 5/8
.083
.250
1–¾
.083
.195
2
.095
.188
FOR 4130 SEAMLESS AND 300 SERIES STAINLESS
TUBE O.D.
MIN. WALL
MAX. WALL
½
.035
SOLID
¾
.049
SOLID
7/8
.049 (5”R)
SOLID
1
.065 (5”R)
SOLID
1–¼
.083 (6”R)
.250
1–½
.095
.250
1 – 5/8
.095
.188
1–¾
.095
.188
2
.109
.120
Note: for thinner wall materials inquire about the ITS®
Designed specifically as an easy add-on to your TubeShark is the ITS system
(Internal Tube Support). The ITS allows for the bending of thinner wall tubes by
providing an internal support at the start of the bend
Page 32
COMMON TUBE DIE RADIUS AVAILABLE
TUBE DIAMETER (O.D.)
AVAILABLE BEND RADII
(MEASURED TO THE TUBE CENTERLINE)
½” & ¾”
7/8” & 1”
1-1/4”
1-3/8”
1-1/2”
1-5/8”
1-3/4”
2”
3”,4”
3”,4”,5”
3”,4”,5”,6”
4”,5”,6”
4”,5”,6”,8”
6”
5”,6”,8”
6”,8”
COMMON PIPE DIE RADIUS AVAILABLE
STD. PIPE SIZE
AVAILABLE BEND RADII
(MEASURED TO THE PIPE CENTERLINE)
¼” & 3/8”
½” & ¾”
1”
1-1/4”
1-1/2”
3”,4”
3”,4”
4”,5”
4”,6”
5”,6”
COMMOM SQUARE TUBE BEND RADIUS SPECIFICATIONS
STD. TUBE SIZE
AVAILABLE BEND RADII
(MEASURED TO THE TUBE’S OUTER WALL ON THE
INSIDE RADIUS))
½”
¾”
1”
1-1/4”
1-1/2”
3”,4”,5”,6”
3”,4”,5”,6”
3”,4”,5”,6”
3”,4”,5”,6”
3”,4”,5”,6”
COMMOM RECT. TUBE BEND RADIUS SPECIFICATIONS
STD. TUBE SIZE
AVAILABLE BEND RADII
(MEASURED TO THE TUBE’S OUTER WALL ON THE
INSIDE RADIUS))
½”x 1”
¾”x 1-1/2”
1” x 1-1/2”
3”,4”,5”,6”
3”,4”,5”,6”
3”,4”,5”,6”
Page 33
TUBESHARK SPECIFICATIONS
Weight (including air pump and die set)
Dimensions (folded)
Dimensions (unfolded)
Ram capacity
Bending accuracy (using built in gauge)
Bending precision
Bend angle range
Minimum distance between bends
(same plane)
Minimum distance between bends (out
of plane)
182lbs
28”w X 24”d X 42”h
28”w X 42”d X 42”h
10 tons
+/- ¼ degree
+/- 1/8 degree
0 to 180 degrees
0”
2”
TUBE CONSUMPTION CHART
BEND
RADIUS
10°
15°
22.5°
30°
3”
4”
5”
6”
7”
8”
0.52
0.70
0.87
1.05
1.22
1.40
0.79
1.05
1.31
1.57
1.83
2.09
1.18
1.57
1.96
2.36
2.75
3.14
1.57
2.09
2.62
3.14
3.67
4.19
BEND ANGLE
45°
60°
2.36
3.14
3.93
4.71
5.50
6.28
Page 34
3.14
4.19
5.24
6.28
7.33
8.38
90°
120°
135°
180°
4.71
6.28
7.85
9.42
11.00
12.57
6.28
8.38
10.47
12.57
14.66
16.76
7.07
9.42
11.78
14.14
16.49
18.85
9.42
12.57
15.71
18.85
21.99
25.13
Warranty
All TubeShark benders are warranted from the factory to be free of
defects in materials and workmanship for ONE YEAR from the date of purchase
except as noted below. The determination of the validity of any warranty claim
is at the sole discretion of GRB. Under this warranty, GRB’s liability is
limited solely to the repair or replacement of equipment, which they
manufacture. This warranty does not cover damage due to normal wear, abuse
or neglect, or use of this tool in any way that is contrary to the guidelines given
in the operators manual.
EXCEPTIONS:
1. All Enerpac components are warranted from Enerpac Corp. See the
Enerpac warranty information for details.
Page 35
Return and Cancellation Policy
1. All sales are considered final at the time of shipment.
2. Items returned for warranty service will be examined within 10 working days
of receipt. An estimate will be written that describes which, if any, repairs are
not covered under warranty. The purchaser must authorize any non-warranty
repairs before they will be done. GRB will pay return freight on all warranty
repairs. Return freight on non-warranty repairs will be billed to
purchaser.
3. Call before returning any item to obtain a return authorization number. No
returned item will be accepted without a return authorization number clearly
printed on the outside of the package.
4. Any returned items that are used or damaged in shipping will have the cost of
refurbishing subtracted from the refund.
5. 10% restocking fee on all returns.
5. All returns must be made within 60 days of the invoice date.
ISCO/TubeShark provides a variety of accessory items to help make your
tube-forming project easier and more productive. Give us a call (541-382-1573)
or check our web site (www.tubeshark.com) for the latest news on
TubeShark.
GRB Innovations, LLC
63055 Corporate Place #3
Bend, OR 97701
(541) 382-1573
Page 36
Shop Notes
o:\ISCO\corresp\i\isco_266.doc
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