3 IN 1 ROLLER MACHINE 40 INCH

Transcription

1 3 IN 1 ROLLER MACHINE 40 INCH ASSEMBLY AND OPERATING INSTRUCTIONS 3491 Mission Oaks Blvd., Camarillo, CA Visit our Web site at Copyright 2000 by Harbor Freight Tools. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. For technical questions and replacement parts, please call Revised 01/07

2 Item Specifications Description Stock Capacity Hold Down Bar Table Size Dies Roller Size Round Stock Grooves (3 sizes) Handle Dimensions Zerk Fittings Overall Dimensions Weight Hex Wrenches Save This Manual You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future reference. Safety Warnings and Precautions WARNING: When using tool, basic safety precautions should always be followed to reduce the risk of personal injury and damage to equipment. Read all instructions before using this tool! 1. Keep work area clean. Cluttered areas invite injuries. 40 inches wide; 18 gauge sheet metal 5/8 inch steel 42-5/8 (L) x 4-7/8 (W) 1, 1-1/2, 2, 4, 7, 10, 15 inches 1-21/32 (dia.) x 39 (L) inches 1/4, 5/16, 3/8 inches 30 inches Automotive 49 x 15-1/2 x 24 inches 420 lbs. 5, 6, 8 mm 2. Observe work area conditions. Do not use machines or power tools in damp or wet locations. Don t expose to rain. Keep work area well lighted. Do not use electrically powered tools in the presence of flammable gases or liquids. 3. Keep children away. Children must never be allowed in the work area. Do not let them handle machines, tools, or extension cords. 4. Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust. Always lock up tools and keep out of reach of children. 5. Do not force tool. It will do the job better and more safely at the rate for which it was intended. Do not use inappropriate attachments in an attempt to exceed the tool capacity. 6. Use the right tool for the job. Do not attempt to force a small tool or attachment to do the work of a larger industrial tool. There are certain applications for which this tool was designed. Do not modify this tool and do not use this tool for a purpose for which it was not intended. Page 2 Rev 11/01

3 7. Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving parts. Protective, electrically non-conductive clothes and non-skid footwear are recommended when working. Wear restrictive hair covering to contain long hair. 8. Use eye and ear protection. Always wear ANSI approved impact safety goggles. Wear a full face shield if you are producing metal filings or wood chips. Wear an ANSI approved dust mask or respirator when working around metal, wood, and chemical dusts and mists. 9. Do not overreach. Keep proper footing and balance at all times. Do not reach over or across running machines. 10. Maintain tools with care. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricating and changing accessories. Inspect tool cords periodically and, if damaged, have them repaired by an authorized technician. The handles must be kept clean, dry, and free from oil and grease at all times. 11. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches are removed from the tool or machine work surface before using. 12. Stay alert. Watch what you are doing, use common sense. Do not operate any tool when you are tired. 13. Check for damaged parts. Before using any tool, any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment and binding of moving parts; any broken parts or mounting fixtures; and any other condition that may affect proper operation. Any part that is damaged should be properly repaired or replaced by a qualified technician. 14. Replacement parts and accessories. When servicing, use only identical replacement parts. Use of any other parts will void the warranty. Only use accessories intended for use with this tool. Approved accessories are available from Harbor Freight Tools. 15. Do not operate tool if under the influence of alcohol or drugs. Read warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking drugs. If there is any doubt, do not operate the tool. 16. Maintenance. For your safety, service and maintenance should be performed regularly by a qualified technician. Warning: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. Page 3

4 Roller Machine Safety Precautions 1. Avoid cuts by always wearing gloves when handling sheet metal. 2. Keeps hands and clothes out of the path of the rollers. 3. The Roller Machine should only be used by an experienced operator. Unpacking When unpacking, check to make sure the following parts are included: - Roller Machine - 7 Dies - 3 Hex Wrenches If any parts are missing or broken, please call Harbor Freight Tools at the number on the cover of this manual as soon as possible. Parts of this machine come coated with a rust inhibitor. It must be removed before using. Refer to the Maintenance section on page 8. Operation The Roller Machine is used for shearing and rolling sheet metal up to 18 gauge. The Roller Machine comes pre-adjusted from the factory. Before using it, however, check that all the necessary adjustments are made (Refer to the section on Adjustments). Pressing 1. Raise the Lower Braking Die (11) to its highest level by rotating the Handle Arm (18). 2. Slide the Press Plate Brackets (8) of the Press Plate Assembly (8,9,10,54) into the receiver holes of the Lower Braking Die (11). Note that the Press Plate (10) should be facing down. 3. Raise the Press Plate (10) as necessary by turning the Hex Bolt (54) clockwise. 4. Place the workpiece so that it is centered under the Press Plate (10). 5. Rotate the Handle Arm (18) to press the workpiece. Page 4

5 Shearing 1. Scribe the cutting mark on the sheet metal. 2. Slide the sheet metal between the upper Blade (23) and the lower Blade (23) so that the upper Blade (23) is positioned directly over the cutting mark. If additional cuts of identical size are needed, the Backstop (21) can be adjusted to the required depth. The sheet metal will stop on the Backstop (21) when inserted. Refer to the Adjustments section, Adjusting the Backstop. 3. While holding the material steady, rotate the Handle Arm (18) until the material has been cut. For large pieces of sheet metal, it may be necessary to use a front table to support the metal, or have someone hold it for you. Angle Bending 1. Mark the sheet metal where it is to be bent. 2. Place the sheet metal above the Lower Braking Die (11). 3. Align the bending mark with the front edge of the Upper Die (12). If multiple bends of identical size and angle sheet metal are needed, the Backstop (21) can be adjusted to the required depth. The sheet metal will stop on the Backstop (21) when inserted. Refer to the Adjustments section, Adjusting the Backstop. 4. Rotate the Handle Arm (18) until the desired angle been formed. Use a protractor or other measuring tool to ensure accuracy. Radius Bending Radius bending is most commonly used to make cylinders and cones. Both shapes are formed by making a series of small, closely spaced bends in the work piece. For cylinders, the bends are even spaced. For cones, move one side of the sheet metal further out each time a bend is made. Pan Bending The Angle Bending feature can be used to make various sizes of pans out of sheet metal. The maximum lip (side) height is 1 inch. 1. Pre-measure and cut your material before bending. Notch the corners to the desired lip (side) height. 2. Place the sheet metal above the Lower Braking Die (11). 3. Align the bending mark with the front edge of the Upper Die (12). 4. Rotate the Handle Arm (18) until 90 degree angle been formed. Page 5

6 Use a protractor or other measuring tool to ensure accuracy. 5. Rotate the sheet metal 90 degrees counterclockwise. Allow the completed side to extend just beyond the Dies. 6. Bend the sheet metal. Repeat step 5 for the 3rd side. 7. Rotate to the final side and insert the sheet metal lip between the Dies. The formed sides will be on the outside of the Dies. 8. Before bending the 4th side, tap one corner nearer the middle of the machine. Rolling This will allow the sides to clear the upper Die (12) when raised. 1. Lift the front Cover (33) and flip backward, out of the way. 2. Drop the Rear Roll Bar (24) by loosening the Adjustment Knob (25b). 3. Insert only the leading edge of the sheet metal between the Upper Roll Bar (32) and the Lower Roll Bar (31), tighten the Adjustment Keys (27) until the Roll Bars are just snug against the sheet metal. 4. Advance the Adjustable Bolt (25b) to the desired tightness for the roll. The more the Adjustable Bolt (25b) is advanced, the tighter the roll. 5. Turn the Handle Arm (18) until the desired roll is achieved. The sheet metal should feed itself through the rollers as the Handle Arm (18) is turned. Wire Rolling 1. Select the proper size groove in the Upper Roll Bar (32) depending upon the gauge of the wire being rolled. 2. Follow steps 2 through 5 (above), under Rolling. Adjustments While making adjustments, it may be necessary to refer to the Assembly Drawing at the end of this manual Handle Removal and Adjustment The Handle Arm (18) may be adjusted or removed by removing one of the Handle Knob Assemblies (26a, 26b, 61) and loosening the Knob (59) that holds the Handle Arm (18) in place. It may then be slid out of the handle socket. Bending Die Adjustment and Removal The Upper Die (12) is segmented and can be used for varying sizes of box and pan forming. When forming a smaller box or pan, choose the desired size Upper Die (12) finger, center it and remove the others. Page 6

7 The Roller Machine can be used to bend sheet metal up to 18 gauge. The space between the Upper Die (12) and the Lower Braking Die (11) is adjustable as described below. 1. Place a piece of flat, straight wood (or metal place) between the Upper Die (12) and Lower Braking Dies (11) and raise the Lower Braking Die (11) so that the material just touches the Upper Die (12). 2. Loosen the Hex Head Screws (51) holding the Upper Die (12) in place. Do not remove the Screws. 3. Remove any unnecessary Upper Die (12) fingers. 4. Raise the Lower Braking Die (11), using the long piece of wood or metal plate as a level guide, adjust the alignment of the Upper Die (12) fingers. 5. When aligned, retighten the Hex Head Screw (51). Removal and Installation of the Upper Cutting Blade (23) 1. Remove the six Hex Head Screws (55) holding in the upper cutting Blade (23). 2. Remove (or replace) the upper cutting Blade (23), and replace the Screws but do not tighten completely. 3. Align the upper cutting Blade (23) so that it is flush with the Lower Braking Die (11). 4. Tighten all the Hex Head Screws (55). Adjustment of the Upper Cutting Blade 1. Place a 30 inch piece of thin cardboard or paper between the upper and lower Blades (23). 2. Rotate the Handle Arm (18) and cut the material. 3. Use a straightedge to determine the straightness of the cut and if the Blade (23) is in need of adjustment. 4. If the Blade (23) is bowed out (away from the front of the machine), turn the adjustment Nut (48) counterclockwise. This will tighten the Adjustment Bar (22) and push the middle of the upper Blade (23) out, while pulling in its ends. 5. If the Blade (23) is bowed in (towards the back of the machine), turn the adjustment Nut (48) clockwise. This will loosen the Adjustment Bar (22) and pull the middle of the upper Blade (23) in, while pushing its ends out. Removal and Installation of the Lower Blade 1. Remove the Hex Head Screws (57) from the lower cutting Blade (23). 2. Remove (or replace) the lower cutting Blade (23). Page 7

8 3. Replace the Hex Head Screws (57). Adjustment of the Lower Cutting Blade (23) 1. Turn the Handle Arm (18) and lower the upper Blade (23) to its lowest position. 2. Loosen the two inset Hex Head Screws (58) located on top of the Cutter Table (2). 3. Adjust the lower cutting Blade (23) by turning its Adjusting Bolts (17). The distance between the lower and upper cutting Blade (23) should be 5 to 8 percent of the thickness of the workpiece. 4. Tighten the two inset Hex Head Screws (58) located on top of the Cutter Table (2). Installation and Adjustment of the Backstop (21) 1. Screw the two Support Rods (19) into the back of the Crossbeam (3). 2. Slide the two Support Blocks (20) onto the Support Rods. 3. Attach the Backstop (21) to the Support Blocks using the Hex Head Screws (42). - If used for bending, attach the Backstop on top of the Support Blocks. - If used for shearing, attach the Backstop on the bottom of the Support Blocks. 4. Adjust the Backstop to the desired depth and tighten the Knob (41). Maintenance 1. Before using this machine, certain parts coated with rust inhibitor must be first cleaned using varnish thinner. 2. Lubricate the eccentric mechanism daily with machine oil. 3. Periodically check all nuts, bolts, and screws for tightness. 4. Periodically lubricate the rollers surface with a clean rag and machine oil. 5. Place the Cover over the rollers when not in use. PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO. Page 8

9 Parts List NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts. Page 9

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11 WARRANTY Page 11