EAGLE ONE TUBE BENDER

MODEL

ZX-5/6

TYPE 2

INSTALATION AND

OPERATORS MANUAL

www.eagleone.co.za

MODEL NUMBER_____________________________

SERAIL NUMBER______________________________

DATE OF MANUFACTURE_______________________

EAGLE ONE BENDERS (PTY)Ltd

7 Eagle street, Okavango Park,

Brackenfell, Cape Town,

South Africa, 7560

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WARRANTY OF EAGLE ONE PRODUCTS

This warranty is made for the exclusive benefit of the original owner and is not transferable. There is

no other warranty applicable to EAGLE ONE PRODUCTS, and no representative has the authority to

make any representation, promise or agreement except as stated in the warranty.

ONE YEAR WARRANTY*

For one year from the date of invoice, the seller will repair the bender if found to be defective in

material and workmanship without cost to the purchaser. Following the first 90 days from the date of

the original invoice, replacement parts are shipped from the manufacturer to the purchases freight

collect. Return parts are shipped prepaid to the manufacturer.

In effecting such repairs, the manufacturer may at its election, repair or replace any part which it

finds defective.

Tools and dies are warrented for a period of 90 days against defect in material and workmanship.

*During the first 90 days from date of invoice, the manufacturer will pay freight charges for

replacement of defective parts

...INTRODUCTION...

Carefully read and understand this manual before operation begins. Every EAGLE ONE

BENDER is constructed from the finest materials by highly trained and experienced

craftsmen.

They have profound interest in your bender’s successful performance and have prepared

this manual to give you the benefit of their experience.

The manner in which you operate and the care you provide this bender will have a direct

bearing on its continued successful performance. The manual has been prepared to make it

easy for you to learn the methods for proper operation and care.

READ THIS ENTIRE MANUAL. KEEP IT FOR FUTURE REFERENCE.

EAGLE ONE’s policy is to improve its products whenever possible. EAGLE ONE reserves the

right to make changes and/or improvements without incurring any obligation to do so on

previously sold products.

This manual relates to benders built after 1 January 2018. For more details on specifics of

older benders, please call EAGLE ONE BENDERS (PTY)Ltd.

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...START UP...

Upon delivery of the EAGLE ONE BENDER, check the following:

1. Carefully uncrate and discard all packaging material properly.

2. Inspect for signs of damage due to shipment and report any shipping

damage promptly to the carrier.

3. Review enclosed packing list. Be certain all components have been

shipped.

4. Check the voltage and phase of your electrical supply. All EAGLE ONE

BENDERS operate on 400 Volts and phase will be indicated on the motor

plate end the manufacturer’s identity plate.

5. NOTE: 3 Phase motors must rotate counter clockwise as seen when

facing the pump. Consult the electrician to change the rotation.

6. Make sure the bender is protected by the proper size breaker, dedicated

to the bender. Check plug and receptacle for amperage rating.

7. Check oil level and make sure the machine is not started without oil or

serious damage could occur.

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...GENREAL OPERATION OF MACHINE...

EAGLE ONE TUBE BENDERS utilize as standard a 400 volt, AC, 50 hertz three phase motor.

230 Volt, AC, 50 hertz single phase motors are available upon request.

...OPERATION OF THE ZX-6 Type 2 model...

The ZX-6 machine is started by pressing the “ON” button located on the white power box at

the right rear side of the main oil tank. The motor will immediately start and run

continuously until either the “stop” button is depressed or the “EMERGENCY STOP” button

is depressed located on the front tank of the machine.

The operator is responsible for adjusting the automatic depth of bend limit switch located

just below the right hand bending head.

Operation of the ram die and bending of pipe is accomplished by depressing the green and

yellow buttons on the face plate indicated as “FORWARD” and “RETURN”.

To extend the die and bend pipe, depress the right hand green button indicated as

“FORWARD” until either the desired depth of bend is reached by either the indicator or until

the machine stops to bend as had been pre set by the operator.

To retract, depress the left side yellow button indicated as “RETURN”.

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...BENDING DIES...

The bending dies are made of precision machined high quality steel and are heat treated for

long life and wear ability. If the tubing is prelubricated, it is unnecessary to lubricate the

radius dies. If the tubing is not prelubricated, then the dies should be lightly lubricated with

a good quality drawing oil before bending.

The dies are clearly marked with embossed numbers that indicate the pipe diameter. Take

note that the dies are marked in millimetres and that in most circumstances, the millimetres

will indicate as closest to their value in inch sizes. For example, if the die indicated that it is

50mm, the actual size will be 50.8mm or 2 inches.

The radius dies have two M12 drilled and tapped holes at the bottom wherein two M12 x

16mm Allen cap screws are to be inserted to serve as guides to hold the die true in the slider

plate. The radius die also has hole on the top to accept the die retaining bracket.

ALWAYS PLACE THE DIE WITH THE SIZE FACING UP

The toe block shoes simply slide onto the pins extending from the pivot arm. All the dies are

reversible for use on either side of the machine accepting for the 63 and 76mm toe block

dies.

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...END OF PIPE OPERATION...

The EAGLE ONE BENDER utilizes a manually operated hydraulic valve to do swaging and

reducing with a taper clamp and arbour.

When swaging or reducing, the cylinder rod will extend in order for the arbour to enter the

tube.

The cylinder rod is either extended or retracted fully. The valve bank will go on relief and a

squealing noise will be heard from the valve bank and pump. Do not hold the valve on relief

for an extended length of time as this will create heat and put unnecessary strain on the

electric motor.

Select the proper tool of combination of tools to perform the operation required.

All swaggers and reducers are designed to be screwed on the cylinder push rod and must be

completely screwed on to minimise the risk of damage or injury.

Select the correct clamps and swagger for the pipe used. Make sure that the long sides of

the tapers are facing away from the cylinder. Place the clamps around the pipe and slide

into the v-blocks. (The fit may be tight for the first few times this unit is used). Make sure

both clamps line up.

Note that clamping of the pipe will only take place once the swagger makes contact with the

pipe.

Start by pushing the lever in order for the swagger to enter the pipe and then start to

expand the pipe.

TAKE GREAT CARE OF THE DEPTH OF THE ARBOR AS NOT TO CAUSE

DAMAGE TO THE MACHINE OR INJURY TO THE OPERATOR.

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...GENERAL MAINTENACE...

Your EAGLE ONE BENDER was factory shipped with 15 litres of Castrol Hyspin AWS 46 or

equivalent hydraulic oil. Hydraulic oil that can be used or added are those that meet the

specifications of the Castrol Hyspin AWS 46 oil.

To check the reservoir oil level, the level indicator is located on the left side of the oil tank

and the level should always be visable in the window. The machine can be topped up by the

filler/ breather cap just above the level guage. If the oil level falls below the check window,

the machine should then be thoroughly inspected to determine the cause of the leak.

WEEKLY

Clean and regrease guide plate and bulk head pins.

Check all presures. Back presure should be maintained at .8 Bar.

Spray all tooling with light duty sparay lubricant to prevent rust.

Check depth of bend plate for accuracy.

MONTHLY

Inspect all hydraulic pipes for wear or cuts. Replace faulty hoses immediatly.

CHeack for and repair any hydraulic leaks.

ANNUALLY

It is recomended to change the hydraulic oil every 1500 hour of operation.

The filter should also be replace with a 10 micron unit.

Check all electrical connections

Replace any worn or defective tooling.

Check for missaligned tooling.

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...IMPORTANT SAFETY INSTRUCTIONS...

Read and understand all safety warnings before operating machine.

Keep hands clear from all moving parts and pinch areas.

Only trained operators should operate this machine.

Guard against electric shock. This machine must be grounded at all times.

Never use in or around water.

Use all tooling in a proper manner. Never use a tool for something it was not

designed for.

Never wear loose clothing or jewelry. Wear protective hair covering to contain

long hair.

Always wear gloves and appropriate safety goggles when operating this

machine.

Maintain with care. Keep machine and all work areas uncluttered.

Never stand in front of arbor when using segmented expander.

Always unplug machine when servicing. Never alter electrical components on

this machine.

This machine uses internal arcing parts which should never be exposed to

flammable vapors.

Check machine for damaged parts. Never use machine if any component is

brocken or damaged.

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...BENDING PROBLEMS...

Bending problems can usually be broken into three categories:

1. Flattening or collapsing of pipe on the outside of the bend

2. Dimpling of colapsing on the inside of the pipe.

3. Crimpling or wrinkling of the pipe on the outside of the bend.

Causes and solutions to these problems as follows:

FLATTENING OF PIPE ON THE OUSIDE:

Cause: Back presure to low.

Solution: Adjust back pressure to factory

recomended presure of .8Bar

Cause: Diameter of tubing is smaller than the

diameter of bending dies.

Solution: Select proper bending dies.

Cause: Tubing is not aluminium killed (AK) or alternativly tubing has too thin wall

thickness for diameter of tubing being bent.

Solution: Make sure tubing is AK. Wall thickness should be minimum of 2mm for

50mm and 2.5mm for 60 and 63mm

DIMPLIN OR COLAPSING ON THE INSIDE OF THE PIPE:

Cause: Back presure to low.

Solution: Adjust back pressure to factory

recomended presure of .8Bar

Cause: Diameter of tubing is smaller than the

diameter of bending dies.

Solution: Select proper bending dies.

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Cause: Tubing is not aluminium killed (AK) or alternativly tubing has too thin wall

thickness for diameter of tubing being bent.

Solution: Make sure tubing is AK. Wall thickness should be minimum of 2mm for

50mm and 2.5mm for 60 and 63mm

CRIMPLING OR WRINKLING OF THE PIPE ON THE OUTSIDE OF THE BEND:

Cause: Radius and toe block dies are misaligned.

Solution: Check and align the blocks

Cause: Incorrect matching of radius and toe block

dies.

Solution: Check and select matching dies.

Cause: Damaged radius or toe block dies.

Solution: Check condition of dies and repair or replace if nessesary.

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