Roper Whitney 1016, Installation, Operation And Maintenance Manual

Page 1: ...KFORD INC 2833 HUFFMAN BLVD ROCKFORD ILLINOIS 61103 815 962 3011 815 962 2227FAX INSTALLATION OPERATION ANDMAINTENANCE MANUAL Version 2 1 ROPER WHITNEY CONNECTICUT FLOOR MODEL MANUAL BENDING BRAKES MODELS 816 1018 AND 1016 ...

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Page 3: ...LATION OPERATION ANDMAINTENANCE MANUAL Version 2 1 FOR 16 18 GUAGE MATERIAL All steel construction no castings Heavy tie rods for minimum deflection Removeable bending bar and angle Adjustable apron hinges Positive rear material gauge adjustment Positive clamping pressure adjustment Apron stop rod for repeat bends Replaceable bushings and hinge pin Long handles for extra leverage Work support angl...

Page 4: ...the equipment covered read the manual thoroughly and understand the material presented The setup and operating instructions are based on the intended application of the machine as defined by Roper Whitney Use of the machine for other applications is not precluded but use for purposes specifically excluded is not recommended and may void warranty provisions Materialinthismanualisconfidential andRop...

Page 5: ...nterweights 8 Section 5 Setup 9 Setting Clamping Pressure 9 Adjusting for Material Thickness 10 Setting Up for Narrow or Offset Bends 11 Setting Up the Bend Angle Stop 12 Setting Up the Optional Rear Material Stops 12 Section 6 Operation 13 General Instructions 13 Clamping the Material 13 Bending the Material 14 Bending of Multiple Thicknesses 14 Hemming 15 Section 7 Periodic Maintenance 16 Lubric...

Page 6: ...quential damages are expressly excluded from the remedies available to purchaser and the remedies provided in this warranty shall be exclusive to the extent permitted by law Note Somestatesdonotallowlimitationsonhowlonganimpliedwarrantylasts orthe exclusion or limitation of incidental or consequential damages so the foregoing limitationsandexclusionsmaynotapplytoyou Thiswarrantygivesyouspecific le...

Page 7: ...afety instructions for your work area Pay special attention to posted warnings and warning labels on the equipment Do not place speed above safety Wearappropriateclothing Looseorhangingclothingorjewelry fingerrings etc can be hazardous Use the appropriate safety equipment such as eye and hearing protection and safety toe shoes If gloves are worn to protect from cuts be sure they are snug fitting a...

Page 8: ...n cause personal injury or damage to the counterweight rods Always stand clear of the apron lift handle travel arc during the bend cycle to avoid being struck by the handles WARNING SERIOUS INJURY MAY OCCUR Avoid pinch points created by the clamping and bending components Alwaysstandclearofclampinghandles Ifthebrakehasnotbeenproperlyadjusted for material thickness clamping action on one end of the...

Page 9: ...apron work support is removed The machines are essentially identical in construction varying only in length or capacity Major components are shown in Figure 1 Fabricated of sturdy steel plate with appropriate gussets braces and trusses three basic longitudinal members upper beam lower beam and bending leaf apron controltheclampingpressureandstressincurredinovercomingtheyieldstrength of the materia...

Page 10: ...ce 16 Ga 16 Ga 18 Ga Withbendingangleremoved 20 Ga 20 Ga 22 Ga Withbendingbarandangleremoved 24 Ga 24 Ga 26 Ga MinimumReverseBend bendingbarandangleremoved 5 16in 5 16in 5 16in Maximum lift of beam 1 5 8 in 2 1 4 in 1 5 8 in Front to Rear Adjustment of Beam 1 1 8 in 1 3 8 in 1 1 8 in ApproximateShippingWeight 1640 lbs 2660 lbs 2200 lbs ClosedHems 24 Ga 22 Ga 24 Ga Packing heavy wood skids and bloc...

Page 11: ...ney Company promptly of any damage or shortages Ifyoudiscoverconcealeddamagesorshortagesafterthecarrierhasdeparted you may still file a claim for concealed damage This should be done as quickly as possible Again notify Roper Whitney Company promptly of such damages or shortages The brake is shipped on a skid of 3 x 6 wood timbers It is secured to this skid with four 4 carriage bolts which should r...

Page 12: ...he machine is topheavy and can tip if not securely anchored The skid does not provide a suitable anchoring platform SITE PREPARATION The brake must be placed on a firm floor which does not sag and which does not have any spring to it The floor must be generally level with no twisting or unevennessinthesurface Thefloormustalsobecapableofaccepting1 2 inchlag screws or bolts for the purpose of securi...

Page 13: ...y Figure 2 The proper lifting method for moving the brake Raisetheupperbeamtoitsmaximumheightusingtheeccentricliftinglevers Placean accuratespirit levelonthebedateachendofthebedbar Shimunderthelegsofthebrakeuntilthebedbarshowsthemachineislevelfront to rear Thiswillremoveanytwistfromthebed Side to sidelevelingisnotnecessaryto properoperationofthebrake Anchortheleveledbraketothefloorusing1 2 inchlag...

Page 14: ...rweight in the mounting hole in each end of the bending apron Adjust the counterweights so that they balance the bending aparon in the horizontal position Tighten two set screws securely on each counterweight shaft WARNING THE COUNTERWEIGHTS ARE HEAVY Use care when installing the counterweights to avoid injury Be sure the set screws are tightened enough so the counterweights will not drop when the...

Page 15: ...gainst the forward stop see Figure 3 Manual Brake Installation Operation and Maintenance Manual SECTION 5 SETUP The machine has been adjusted and pretensioned at the factory Set up adjust mentsareforclampingpressure materialthickness settingupfornarroworoffset bends settingbendanglecontrol andsettingupoftheoptionalrearmaterialstops Excessive clamping pressure is not required or desirable It has a ...

Page 16: ... 2 times material thickness is usually sufficient Soft material such as aluminum may be formed with a clearance equal to the material thickness SETTING CLAMPING PRESSURE ADJUSTING FOR MATERIAL THICKNESS Figure 4 Material Thickness and Angle Adjustments Make the adjustment as follows 1 With the upper beam lowered to the normal operating position but not clampedtightlyagainstthebed loosenthethicknes...

Page 17: ...e front of the brake to remove backlash from the adjusting screws 4 Retighten the clamping screw on each end of the machine see Figure 4 Itissometimesnecessarytoremovethebendingreinforcingangletomakenarrow or offset bends In extreme conditions it may also be necessary to remove the bending bar The bending bar is made of tough wear resistant material to protect the edge of the apron and should be r...

Page 18: ...n that position SETTING UP THE OPTIONAL REAR MATERIAL STOPS For repeat operations involving deeper bends it may be useful to use the optional rear material stops Figure 6 Installing and Adjusting the Optional Rear Material Stops Installandadjusttherearmaterialstopsasfollows 1 Ateachendofthemachine insertathreadedstoprod Securethestoprod usingthestoprodlocknuts seeFigure6 2 Adjustastopnutoneachstop...

Page 19: ...nsertthematerialtobebentundertheupperbeamclampingmechanism liningup both sides so they are even with the upper beam Position short pieces of material in the center of the brake to equalize strain during bending Clamp the material by lowering the upper beam with the clamping levers Ifthebrakehasnotbeenproperlyadjustedformaterialthickness clampingaction on one end of the brake may cause the opposite...

Page 20: ...suntilanadjustmenthasbeenmadetocompensate fortheclampingofmultiplethicknessesofmaterial Neverbendagainsthemsorseams untiltheupperbeamissetbackforclearanceofthemultiplethicknessesofmaterial See SETUP SECTION5 foradjustmentinstructions CAUTION MACHINE COMPONENTS CAN BE DAMAGED Failure to compensate for multiple thicknesses of material may result in breakage of theclampingmechanism Failure to set the...

Page 21: ...y require additional preloading in order to close the hem tightly at the center Increase the preload by tightening the upper beam tensioning adjusting nut see Figure 9 It also requires reducing clamping pressure to allow for multiple thicknesses of material Reduce clamping pressure by slackening the lower toggle pin adjusting nut and tightening the upper toggle pin adjusting nut See Figure 10 Remo...

Page 22: ...ggeneralpurposegrease orequivalent Thesecomponentsincludetheclampingpinbushingsandtheslotsinwhichtheyride see Figure7 Theupperandlowerbeamtensioningscrews seeFigure8 areunderheavyloadand mustnotbeallowedtorundry Keepthemlubricatedwithananti siezecompound Ifthemachineisfrequentlyreadjusted theloweraprontensioninglocknut seeFigure U andupperbeamtensioninglocknut andthelowerbeamtensioninglocknuts see...

Page 23: ...il you are unable to move the clamping levers to clamp material 3 Backofftheclampingcollarsbyturningthemcounterclockwiseuntilyou can move the clamping levers to clamp material The collars are properly adjusted when one lever can be unclamped and the lever at the opposite end of the machine remains clamped It may require several adjustments at each end of the machine to achieve the proper tension D...

Page 24: ...finger tight andthentighteneachwithawrenchapproximatelyonefullturn fiveflats see Figure 9 4 Adjust the upper beam tensioning nuts finger tight and then tighten each with a wrench approximately one full turn five flats see Figure 9 5 When looking from the rear of the brake the upper beam and the bed should be in contact at the center and showing a crack of light at each end see Figure 11 If less li...

Page 25: ...ents LOWER TOGGLE PIN ADJUSTINGNUT Figure 11 Proper Clearance Between the Upper Beam Clamp and the Bed BEAM BED THE BEAM AND THE BED MUST BE IN CONTACT AT THE CENTER OF THE MACHINE EXAGGERATED VIEW OF GAP AT EACH END OF THE MACHINE THE GAP MUST BE EQUAL AT BOTH ENDS BRAKE CROWNING ADJUSTMENTS TOGGLEANCHOR ...

Page 26: ...pron in relation to the top surface of the bed The top edge of apron must be 1 64 in below the top surface of the bed at each end If not loosen the hinge bolts and adjust the apron up or down using the apron jack screws see Figure 13 After the apron edge is adjusted to the proper position be sure to retighten the hinge bolts 5 Tighten the apron stiffener adjusting nut until the apron edge is 1 32 ...

Page 27: ...ghten the apron stiffener strap bolt located behind the lower apron tensioning nut until the horizontal gap be tweenthebedandapronisslightlygreaterinthecenterthanattheends see Figure12 Itmaythenbenecessarytobackofftheloweraprontensioning nut slightly to maintain the bed 1 64 in higher than the edge of the apron 8 Tightenupperandlowerbeamtensioningnutsfingertight andthen using a wrench tighten each...

Page 28: ...9 13 3 6 5 7 8 17 12 11 10 15 14 1 4 2 16 A Manual Brake Installation Operation and Maintenance Manual Figure 14 Exploded View of Replacement Parts Page 22 ...

Page 29: ...1 3 613012131 Screw Flat Head 5 16 18 by 3 4 21 3 613012131 613012131 Screw Flat Head 5 16 18 by 3 4 17 4 757180028 757180028 757180012 BendingAngle 1 5 601012271 601012271 Cap Screw Hex Head 1 2 13 by 1 11 5 601012271 Cap Screw Hex Head 1 2 13 by 1 9 6 679033107 679033107 Washer Lock 1 2 inch 11 6 679033107 Washer Lock 1 2 inch 9 7 457500069 457500007 457500069 HingeAssembly righthand 1 8 4575000...

Page 30: ...Manual Brake Installation Operation and Maintenance Manual Page 24 Figure 15 Exploded View of Replacement Parts 18 21 20 19 23 22 24 ...

Page 31: ...322 657164324 Ring Retaining 2 34 757080018 757080052 757080018 Bushing LowerTogglePin 2 35 757160096 757160089 757160096 Pin LowerToggle 2 36 671023010 666023044 671023010 ToggleNut Lower Nylock 2 37 657033154 657033144 657033154 Washer Spring 4 38 651023010 645023012 645023010 ToggleNut Upper 2 39 757990015 757990028 757990015 ToggleAssembly RightHand 1 40 757990016 757990029 757990016 ToggleAss...

Page 32: ... and pivot bending for versatile efficient part production Bending and gauge positioning accuracy allow a wide range of parts to be fabricatedwithrepeatprecision Features of the Autobrake 2000 include Precisionbackgaugewithmultiplestopsforhigh speedpositioning oftheworkmaterial Integralmaterialsupporttableallowspartproductionbyasingle operator whilereducingfatigue andimprovingproductivity Flange o...