Kellybuilt Pipe & Tube Benders 13/05/08

The
Kellybuilt
Fabricator
Semi-portable Pipe Bender

"Operation & Maintenance Guide"

This manual is free of charge. All personnel who operate a

Kellybuilt Bender should have a copy of this manual and read
and understand its contents. To request a copy, call or write
to the address below or download it at www.kellybuilt.com.au

Kellybuilt
455 Lugano Rd
Rugby NSW 2583
Ph: (02) 4835 7216
Fax: (02) 4835 7273
Email: sales@kellybuilt.com.au
Web: www.kellybuilt.com.au

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Kellybuilt Pipe & Tube Benders 13/05/08

The Kellybuilt Fabricator

Assembly of the Kellybuilt Fabricator:
1. Connect the fabricator to your hydraulic power source with the hydraulic hoses provided. If you have
purchased a Kellybuilt Power Pack please see the "Kellybuilt Power Pack Operation & Maintenance
Guide" for instructions on how to do this.
2. Hose connection:
One hose each from:
"Pressure" on hydraulic source to “In” on Tube Bender valve.
“Return” on hydraulic source to "Out" on Tube Bender valve.
Note: Tighten fittings with a light wrist movement only (not firmly).
3. Turn electricity on and operate hydraulic lever one way until cylinder if fully extended, and then the
other way until cylinder is fully contracted. Do this five times until all air is clear of system. Some
jerkeyness can occur, this is normal until all air is clear.
CAUTION:
OPERATORS NEED TO BE MADE
AWARE THAT THE PIPE BENDER
GENERATES SIGNIFICANT
POWER.
IT HAS CRUSH POINTS.
BE CAREFUL OF CRUSHING
FINGER OR LIMBS.
Bending Pipe with the Kellybuilt Fabricator:
1. New paint on pipe rollers and formers may cause pipe to stick in these components, resulting in
flattening of the bend. To overcome this, polish formers and rollers with emery paper to remove
paint.
2. Select pipe former required and position pins and rollers in the appropriate hole in the top cross-arm.
The numbers stamped into the the top cross-arm designate the position of the pins and rollers for the
desired size of pipe.
3. Ensure power switch is in off position before connecting power.
4. Place pipe into former and operate control valve, until pipe is bent to desired angle. If repetition work
is to be done, measure this first bend and screw up mechanical stop until it contacts moving post on
pipe bender. This will stop the stroke of the bender at the desired position.
NOTE: As soon as end post contacts stop and by-pass valve comes into operation, release the
control valve to neutral position as it is inadvisable to overload the motor for lengthy periods.
5. After bend is complete, operate control valve in reverse direction to retract former, and simply
remove bent pipe.

Bending Rod & Bar with the Kellybuilt Fabricator:

1. Place female half of die into frame, locating it with two pins through holes in die body and using the
closest pair of holes in the cross-arms.
2. Fit cast male half of die onto former shaft. Actuate as for pipe bending.
NOTE: Bar and rod can only be bent up to 90°. Maximum flat bar size 75 x 10 (3" x 3/8").

Using the Kellybuilt Fabricator as a press:

1. Raise the top cross-arm of bender out of the way.

2. Place an arbor or punch with 16mm. Shank into hole of mandrel, where pipe former usually fits.
3. Place a block of wood in front of the 75x10mm bars that support the top cross-arm.
4. Put work into position and activate ram. Ideal for pushing, removing or fitting of bearings, seals,
universal joints, pins, bushes, water pumps etc.

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Kellybuilt Pipe & Tube Benders 13/05/08

Using the Kellybuilt Fabricator to flatten pipe:

1. Put bar bender female half into bender with sharp edge towards V-Block
2. Use V-Block to press the pipe against the bar bender.

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