Hydraulic Pipe Bender 12 Ton 16 Ton - QSL

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hydraulic pipe bender12 ton16 ton3288835336Set up and Operating InstructionsDistributed exclusively by Harbor Freight Tools .3491 Mission Oaks Blvd., Camarillo, CA 93011Visit our website at: http://www.harborfreight.comRead this material before using this product.Failure to do so can result in serious injury.Save this manual.Copyright 2009 by Harbor Freight Tools . All rights reserved. No portion of this manual or any artworkcontained herein may be reproduced in any shape or form without the express written consent ofHarbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuingimprovements, actual product may differ slightly from the product described herein. Tools required forassembly and service may not be included.For technical questions or replacement parts, please call 1-800-444-3353.Manual Revised 09f

ContentsSafety Alert Symbol andSignal Words 3IMPORTANT SAFETYINSTRUCTIONS 3General 3Work area 3Personal safety 4Tool use and care 4Service 4Specific Safety Rules 4Specifications 6Unpacking 6Components and Controls 6Operating Instructions 7Bleeding the Bottle Jack 7Tool Set Up 7General OperatingInstructions 9User-MaintenanceInstructions 10Troubleshooting 11parts list & ASSEMBLYDIAGRAM 12bottle Jack parts list &ASSEMBLY DIAGRAM 13LIMITED 90 DAY WARRANTY 14SKU 32888/35336For technical questions, please call 1-800-444-3353.Page 2

Save This ManualNOTICE is used toaddress practicesnot related to personal injury.Keep this manual for the safetywarnings and precautions, assembly,operating, inspection, maintenance andcleaning procedures. Write the product’sserial number in the back of the manualnear the assembly diagram (or monthand year of purchase if product has nonumber). Keep this manual and thereceipt in a safe and dry place for futurereference.Safety Alert Symbol and SignalWordsIn this manual, on the labeling,and all other informationprovided with this product:This is the safety alertsymbol. It is used to alertyou to potential personalinjury hazards. Obey allsafety messages thatfollow this symbol to avoidpossible injury or death.DANGER indicatesa hazardoussituation which, if notavoided, will result in death orserious injury.WARNINGindicates ahazardous situation which, ifnot avoided, could result indeath or serious injury.CAUTION, usedwith the safetyalert symbol, indicates ahazardous situation which, ifnot avoided, could result inminor or moderate injury.SKU 32888/35336CAUTION, withoutthe safety alertsymbol, is used to addresspractices not related topersonal injury.IMPORTANT SAFETYINSTRUCTIONSInstructions Pertainingto a Risk of Fire,Electric Shock, orInjury to PersonsWARNING – When using tools, basicprecautions should always befollowed, including the following:GeneralTo reduce the risk of injury, read allthe instructions before using this tool.Work areaa.Keep the work area clean and welllighted. Cluttered benches and darkareas increase the risks of electricshock, fire, and injury to persons.b.Do not operate the tool inexplosive atmospheres, such as inthe presence of flammable liquids,gases, or dust. Air and hydraulictools create sparks which may ignitethe dust or fumes.c.Keep bystanders, children, andvisitors away while operating thetool. Distractions are able to result inthe loss of control of the tool.For technical questions, please call 1-800-444-3353.Page 3

dangerous in the hands of untrainedusers.Personal safetya.Stay alert. Watch what you aredoing and use common sensewhen operating the tool. Do notuse the tool while tired or underthe influence of drugs, alcohol, ormedication. A moment of inattentionwhile operating the tool increases therisk of injury to persons.b.Dress properly. Do not wear looseclothing or jewelry. Contain longhair. Keep hair, clothing, andgloves away from moving parts.Loose clothes, jewelry, or long hairincreases the risk of injury to personsas a result of being caught in movingparts.c.d.e.Do not overreach. Keep properfooting and balance at all times.Proper footing and balanceenables better control of the tool inunexpected situations.Use safety equipment. Wearheavy-duty work gloves during use.Non-skid safety shoes and a hardhat must be used for the applicableconditions.b.Check for misalignment or bindingof moving parts, breakage ofparts, and any other conditionthat affects the tool’s operation.If damaged, have the tool servicedbefore using. Many accidents arecaused by poorly maintained tools.There is a risk of bursting if the tool isdamaged.d.Use only accessories that areidentified by the manufacturer forthe specific tool model. Use of anaccessory not intended for use withthe specific tool model, increases therisk of injury to persons.Servicea.Tool service must be performedonly by qualified repair personnel.b.When servicing a tool, use onlyidentical replacement parts. Useonly authorized parts.c.Use only the lubricants suppliedwith the tool or specified by themanufacturer.Always wear eye protection. WearANSI-approved safety goggles.Tool use and carea.c.Do not force the tool. Use thecorrect tool for the application. Thecorrect tool will do the job better andsafer at the rate for which the tool isdesigned.Store the tool when it is idle outof reach of children and otheruntrained persons. A tool isSKU 32888/35336Specific Safety Rules1.Maintain labels and nameplateson the Hydraulic Pipe Bender.These carry important safetyinformation. If unreadable or missing,contact Harbor Freight Tools for areplacement.2.Always place the Hydraulic PipeBender on a solid, flat, levelsurface, or a workbench capable ofsupporting the weight of the PipeBender and all other additional toolsFor technical questions, please call 1-800-444-3353.Page 4

and accessories. The Pipe Bendermust always be bolted down tothe workbench when used with aworkbench.3.Make sure there is enough clearancearound the Pipe Bender for themovement of the pipe ends as thepipe is bent into position.4.Keep away from the area betweenthe die and the rollers when operatingthe Bottle Jack to avoid injury. Do notplace your hands between movingcomponents.5.Two Person Operation. For safety,when moving the Pipe Bender orbending large pieces of pipe, alwaysuse two people. When bendinglarge pipe, one person is needed tobalance the pipe in the bending dies,while a second person cranks thebottle jack’s handle.6.This product is not a toy. Keep it outof reach of children.7.The warnings, precautions,and instructions discussed inthis instruction manual cannotcover all possible conditions andsituations that may occur. It mustbe understood by the operator thatcommon sense and caution arefactors which cannot be built into thisproduct, but must be supplied by theoperator.8.Only use with accessories rated tohandle the forces exerted by this toolduring operation. Other accessoriesnot designed for the forces generatedmay break and forcefully launchpieces.SKU 32888/35336Save theseinstructions.For technical questions, please call 1-800-444-3353.Page 5

sIncludedModel # 32888Model # 3533612 Tons(24,000 pounds)16 Tons(32,000 pounds)1/2”, 3/4”, 1”,1-1/4”, 1-1/2”, 2”1/2”, 3/4”, 1”,1-1/4”, 1-1/2”, 2”,2-1/2”, 3”Degree ofBendUp to 90 Up to 90 Oil TypeHydraulic OilHydraulic OilComponents and ControlsRoller Bar (4)Bottle Jack (2)R-Pin (6)(On back ofRoller Bar)Handle (15)ValveRelease Screw(2A)Frame (1)PumpSleeve(9A)Note: For additional information regardingthe parts listed in the following pages,refer to the Assembly Diagram nearthe end of this manual.UnpackingRoller (5)Dies (7 - 12)Figure 1 - Model # 32888 - 12 TonWhen unpacking, make sure that theitem is intact and undamaged. If any partsare missing or broken, please call HarborFreight Tools at 1-800-444-3353 as soonas possible.Roller Bar (4)Roller (5)Bottle Jack (2)R-Pin (6)(On back ofRoller Bar)Handle (15)Frame (1)PumpSleeve(9A)Valve Release Screw (2A)Dies (7 - 14)Figure 2 - Model # 35336 - 16 TonSKU 32888/35336For technical questions, please call 1-800-444-3353.Page 6

Operating InstructionsRead the entire ImportantSafety Informationsection at the beginning of thismanual including all text undersubheadings therein before setup or use of this product.Inspect tool before use, lookingfor damaged, loose, andmissing parts. If any problemsare found, do not use tool untilrepaired.3.Apply pressure to the Saddle, andpump the Handle (15) quickly severaltimes.4.Check the Oil Fill Hole and, ifnecessary, top off the Oil Fill Holewith hydraulic oil.5.Replace the Oil Fill Plug and closethe Release Valve6.Test the Jack several times for properoperation before putting into use.If, after bleeding, the Jack still doesnot appear to be working properly,do not use the Jack until it hasbeen repaired by a qualified servicetechnician.Bleeding the Bottle JackSaddleTool Set UpPumpSleeve(9A)OilFillHoleHandle (15)Valve Release Screw (2A)Figure 3Oil Filler Plug (26A)IMPORTANT! Before first use, check forproper hydraulic oil level in the Jack.Then thoroughly test the Jack forproper operation prior to its actualuse. If the Jack does not workproperly, bleed excess air from itshydraulic system as follows:1.Open the Release Valve.2.Remove the Oil Filler Plug (26A) andfill the Jack with hydraulic fluid to fulllevel.SKU 32888/35336Note: The Pipe Bender is designed tobend water pipe and heavy gaugegalvanized pipe. When bendingconduit or thin walled pipe, you mayexperience problems with kinks orcreases. To help limit the problem, fillthe pipe with sand and cap both endsbefore bending.1.Always use this Pipe Bender with theJack in its upright position. Make surethat there is room on all sides of thePipe Bender for the length of pipeyou intend to bend.2.Place the unit on a solid, flat, levelsurface capable of supporting theweight of the Pipe Bender, pipes, andall other tools and accessories. ThePipe Bender must always be clampedor bolted down to the workbenchwhen used with a workbench.For technical questions, please call 1-800-444-3353.Page 7

DieFrame (1)R-Pin (6)on far end ofRoller BarRollerRollers (5)Bartouching top(4)of pipePipeFigure 4Figure 33.4.DieBottle Jack (2)To adjust the Rollers:Select the Bending Die that matchesthe size of pipe you wish to bend.Each Die is stamped with the pipesize. Place the selected bending Dieonto the Bottle Jack (2) - See Figure3.The Rollers (5) need to be adjustedso that the top of the pipe to bebent rests against the bottom of theRollers.Pipe can be bent from a shallowcurve up to a 90 angle, dependingon the position of the Rollers and thelevel of the Bottle Jack Saddle beforeoperation.a. Remove the R-Pins (6) from the twoRoller Bars (4) and slide the RollerBars out of the Rollers (5), andremove the Rollers from the Frame.b. Place the pipe to be bent on the Dieand note the holes in the Frame (1)where you need to place the Rollersso the top of the pipe will rest on thebottom of the Rollers.c. Remove the pipe.d. Hold one of the Rollers over thechosen hole and slide a Roller Barthrough the hole in the front of theFrame, the Roller, and the hole inthe back of the Frame.e. Lock in place with an R-Pin.f. Repeat d. and e. with the remainingRoller, Roller Bar and R-Pin.SKU 32888/35336For technical questions, please call 1-800-444-3353.Page 8

General Operating Instructions1.Slide the pipe you wish to bendthrough the Pipe Bender, betweenthe Die and the Rollers.Note: You may wish to first practice usingthe Pipe Bender on scrap material.2.Using the slotted end of the Handle(15), tighten (clockwise) the ReleaseValve on the Bottle Jack (2).3.Insert the Handle into the PumpSleeve (9A) and pump it up and downto raise the Bottle Jack and bend thepipe.4.When the pipe has been bent to thedesired angle, remove the Handlefrom the Bottle Jack and use it toloosen (turn counter-clockwise) theValve Release Screw up to one fullturn. This will release the pipe fromthe Pipe Bender and allow you tocarefully remove it.SKU 32888/35336For technical questions, please call 1-800-444-3353.Page 9

c. Completely fill the Housing with ahigh quality hydraulic jack oil (notincluded) until the oil just begins torun out of the Oil Fill Hole.User-MaintenanceInstructionsProcedures not specificallyexplained in this manualmust be performed only by aqualified technician.To preventserious injuryfrom TOOL FAILURE:Do not use damagedequipment. If abnormal noiseor vibration occurs, have theproblem corrected beforefurther use.1.Before each use, inspect the generalcondition of the Pipe Bender. Checkfor broken, cracked, or bent parts,loose or missing parts, and anycondition that may affect the properoperation of the product. If a problemoccurs, have the problem correctedbefore further use.Do not use damaged equipment.2.Before each use, thoroughly testthe Bottle Jack (2) for properoperation prior to its actual use. Ifthe Bottle Jack appears not to beworking properly, follow Bleedinginstructions on page 7.3.Change the hydraulic oil at leastonce every three years. To changethe hydraulic oil:d. Then, reinstall the Oil Filler Plug.4.Clean with a clean cloth using adetergent or mild solvent and wipedry. Then, store the Pipe Benderin a safe, dry location, in an uprightposition, out of reach of children andother non-authorized people.a. With the Jack fully lowered, removethe Oil Filler Plug.b. Tip the Pipe Bender to allow theold hydraulic oil to drain out of theHousing completely, and dispose ofthe old hydraulic oil in accordancewith local regulations.SKU 32888/35336For technical questions, please call 1-800-444-3353.Page 10

Pump strokefeels spongyxxTroubleshootingxUnit may have too much hydraulic oil inside,check fluid level and adjust if needed.Check that Release Valve is closed fully.Check for internal oil leaks.Valves may be blocked and may not closefully. To flush the valves:1. Lower the Saddle and securely close theRelease Valve.2. Manually lift the saddle several inches.3. Open the release valve and force thesaddle down as quickly as possible.Jack may be low on oil. Check the oil leveland refill if needed.Jack may require bleeding - see instructionson page 6.POSSIBLE SYMPTOMSPROBABLE SolutionHandle moves(Make certain that the jack is not supporting aSaddle will notOil leakingload while attempting a solution.)up when jacklift all the wayfrom filler plugis under loadDo not use a damaged or malfunctioning Jack!To prevent serious injury:Use caution when troubleshooting a malfunctioning jack.Completely resolve all problems before use. If the solutions presented in the Troubleshooting guide do notsolve the problem, have a qualified technician inspect and repair the jack before use.After the jack is repaired: Test it carefully without a load by raising it and lowering it fully, checking forproper operation, Before returning the jack to operation.xSaddlelowers underloadXXJack will notbend pipexxXPage 11For technical questions, please call 1-800-444-3353.SKU 32888/35336

parts list & ASSEMBLY DIAGRAMPart12345678DescriptionFrameBottle JackHex BoltRoller BarRollerR-Pin1/2” Bending Die3/4” Bending DieQty11222211Part9101112131415Description1” Bending Die1 1/4” Bending Die1 1/2” Bending Die2” Bending Die2 1/2” Bending Die (SKU 35336only)3” Bending Die (SKU 35336 only)HandleQty1111111SKU 35336 onlySKU 32888/35336For technical questions, please call 1-800-444-3353.Page 12

bottle Jackparts list & ASSEMBLY ptionQtyPinValve Release ScrewValve O-RingValve Ball BearingsBase AssemblyBoltPinSplit PinPump SleeveWasherPump CylinderDust arO-RingCylinderWasherDust PipePlunger ChipPlunger RodSeal KitHousingOil Filler PlugSeal 192071221221144825224347561Note: When ordering replacement parts, add an “A”suffix to part numbers shown in this Assembly Diagram.SKU 32888/35336For technical questions, please call 1-800-444-3353.Page 13

PLEASE READ THE FOLLOWING CAREFULLYThe manufacturer and/or distributor has provided the parts list and assemblydiagram in this manual as a reference tool only. Neither the manufacturer ordistributor makes any representation or warranty of any kind to the buyer thathe or she is qualified to make any repairs to the product, or that he or she isqualified to replace any parts of the product. In fact, the manufacturer and/ordistributor expressly states that all repairs and parts replacements should beundertaken by certified and licensed technicians, and not by the buyer. The buyerassumes all risk and liability arising out of his or her repairs to the originalproduct or replacement parts thereto, or arising out of his or her installationof replacement parts thereto.LIMITED 90 DAY WARRANTYHarbor Freight Tools Co. makes every effort to assure that its products meet highquality and durability standards, and warrants to the original purchaser that this productis free from defects in materials and workmanship for the period of 90 days from the dateof purchase. This warranty does not apply to damage due directly or indirectly, to misuse,abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity,improper installation, normal wear and tear, or to lack of maintenance. We shall in no eventbe liable for death, injuries to persons or property, or for incidental, contingent, specialor consequential damages arising from the use of our product. Some states do not allowthe exclusion or limitation of incidental or consequential damages, so the above limitationof exclusion may not apply to you. This warranty is expressly in lieu of allother warranties, express or implied, including the warranties ofmerchantability and fitness.To take advantage of this warranty, the product or part must be returned to us withtransportation charges prepaid. Proof of purchase date and an explanation of the complaintmust accompany the merchandise. If our inspection verifies the defect, we will eitherrepair or replace the product at our election or we may elect to refund the purchase priceif we cannot readily and quickly provide you with a replacement. We will return repairedproducts at our expense, but if we determine there is no defect, or that the defect resultedfrom causes not within the scope of our warranty, then you must bear the cost of returningthe product.This warranty gives you specific legal rights and you may also have other rights whichvary from state to state.3491 Mission Oaks Blvd. PO Box 6009 Camarillo, CA 93011 (800) 444-3353Record Product’s Serial Number Here: Note: If product has no serial number, record month and year of purchase instead.Note: Some parts are listed and shown for illustration purposes only, and are notavailable individually as replacement parts.SKU 32888/35336For technical questions, please call 1-800-444-3353.Page 14

on the Hydraulic Pipe Bender. These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 2. Always place the Hydraulic Pipe Bender on a solid, flat, level surface, or a workbench capable of su