DIY hydraulic pipe bender repair

Equipment for pipe bending is in demand in a wide range of applications - where there is a need to install water and gas supply systems, heating and sewerage systems. The advantage of pipe benders is the ability to obtain the required pipe bending angle without the need for heating or other rough manipulations. Real Tool offers a wide range of bending equipment - hand, electric, hydraulic and electro-hydraulic pipe benders at affordable prices. The range includes products of popular brands, including Voll, Kern, Rekon, Rems. With their help, you can bend pipes up to 90 degrees without kinks and other deformations.

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If you need to repair the pipe bender, you can also contact Real Tool for the selection of equipment, spare parts and components for maintenance, repair and modernization. Here you will find certified spare parts and consumables for repair and service at affordable prices. We offer exclusively high-quality original products from trusted manufacturers, with whom we work directly. This gives us the opportunity to assume maximum warranty obligations and establish minimum trade margins for products in a wide range of products.

To repair a pipe bender, you can contact directly the managers of our company, who will select for you the option of a part / spare part that is optimal for you in terms of price and properties for replacement or modernization. Contact Real Tool for help and get comprehensive information and technical support for your equipment.

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Our company produces hydraulic pipe benders TPG, TG with manual and electric drive, pressure testing pumps OGS and other pipe assembly tool.

If there is a lot of air in the system, it may be necessary to repeat these steps several times.

Pipe bender diagram

For light pollution ball 1 and seat 3, the malfunction can be eliminated by “water hammer”:
- screw in the screw 9 of the hydraulic cylinder up to the stop (fig. 1);
- lift the handle 8 to the uppermost position;
- sharply lower the handle 8 downward by hitting the end of the handle.
Repeat these steps if necessary.

If heavily soiled the suction valve of the hydraulic cylinder will need to be cleaned.

ATTENTION! If you are not sure that you can make repairs on your own without damaging the parts of the hydraulic cylinder, send a request for repairs to or call the phones listed in the Contact Information section.

Valve cleaning:
- remove the axle 15 connecting the handle 8 and the plunger 16;
- disconnect the handle 8 from the plunger 16;
- remove the plunger 16 with the protective jacket 18 from the sleeve 19;
- drain the oil;
- turn the hydraulic cylinder over and remove the ball 1 (fig. 4). If the ball does not pass through the hole in the copper washer under the bushing 19 (Fig. 2), you will need to unscrew the bushing 19;
ATTENTION! When assembling the hydraulic cylinder, the annealed copper washer will need to be replaced with a new one.
- inspect and clean the saddle 3 (fig. 4)
- inspect and clean the ball 1 (fig. 4). If the ball is visibly damaged (which is unlikely), replace it with another hardened steel (ball bearing) ball of the same diameter.Place a new ball on the saddle and tap it with a mild steel or non-ferrous rod for a better fit to the saddle.

Fig. 4 Fragment of the pipe bender hydraulic cylinder - drawing

For light pollution ball 2 and seat 4, the malfunction can be eliminated by “water hammer”:
- screw in the screw 9 of the hydraulic cylinder up to the stop (fig. 1);
- lift the handle 8 to the uppermost position;
- sharply lower the handle 8 downward by hitting the end of the handle.
Repeat these steps if necessary.

If heavily soiled the suction valve of the hydraulic cylinder will require cleaning and replacement of the hydraulic oil.

ATTENTION! If you are not sure that you can make repairs on your own without damaging the parts of the hydraulic cylinder, send a request for repairs to or call the phones listed in the Contact Information section.

The procedure for eliminating the injury:
- unscrew the screw 9 (Fig. 1) of the hydraulic cylinder until it stops;
- drain the hydraulic oil through the filler hole 6 or the tank cap 7 (fig. 4);
- set the hydraulic cylinder in a vice vertically and clamp it by the body 5 (Fig. 4);
- unscrew the sleeve 8 (Fig. 4) of the hydraulic cylinder by the front plate 10 (Fig. 1). From the sleeve hydraulic cylinder a significant amount of oil will leak out;
- clean the ball 2 and its seat 4 (fig. 4) with gasoline or diesel fuel; If the ball is visibly damaged (which is unlikely), replace it with another hardened steel (ball bearing) ball of the same diameter. Place a new ball on the saddle and tap it with a mild steel or non-ferrous rod for a better fit to the saddle.
- take the sleeve 8 (Fig. 4) and lightly hit the rod 12 (Fig. 1), remove it from the sleeve. If necessary, rinse the parts in diesel fuel;
- if necessary, replace the O-rings of the hydraulic cylinder (see the parameters of the rings here);
- install the rod into the cylinder liner;
Make sure that no foreign particles remain on the parts!
- screw the sleeve into the body 6 using the nut 20 (Fig. 1);
- fill the reservoir with hydraulic oil, bleed the hydraulic cylinder and remove air from the system, as indicated here.

Hydraulic, electrical, mechanical, manual. Let's fix everything!

There are quite a few hand benders on the Russian market: Ridgid, Great, Rothenberger, Voll, Reed and other lesser-known brands. the design of this truly "miracle of technology", as a rule, does not differ sharply, and they bend, no matter what the manufacturer in the person of the official representative tells you, everything is almost the same. This is the main slave hydraulic cylinder driving one small, less often two driving cylinders and, of course, a bypass valve system. I will omit the rest of the components in the description, since they hardly break. Although if you dig in your memory, there were some representatives whose frame was bent, but I would not be in a hurry to blame the manufacturer for this. Who knows what they were trying to bend there. Maybe it was a thirty round timber (all-metal blank).

There are also pipe benders with an electric hydraulic pump. There are electro-mechanical machines. Rare instances, but very comfortable. In such machines, you don't have to pump anything yourself, just press the lever or the button. It is very convenient, but due to the complexity and high cost, clients are suspicious of this equipment.

At the dawn of my career as a service engineer, I confess I did not understand why there was something to break. Later I realized that the hydraulic pipe bender has enough sores.

1. - Oil leakage.
2. - Jamming at the hydraulic level is rare.
3. - The rod does not go back into the cylinder.
4. - Mechanical damage to the master cylinder.
5. - Damage to the master cylinder seals.
6. - Loss of tightness of the master cylinder.
7. - And how the highlight of the program is the folding of oil in the drub bender.

The cause of breakdowns may be non-observance of the instructions for use, self-made repairs, improper maintenance, debris or unclean oil added to the pipe bender.

Repair of a pipe bender is not difficult, but very capacious, sometimes it also depends on the brand. And when the case is "difficult", such as curdling the oil, it will also be expensive. Well, of course not half the cost. It happens when the customers themselves climb into the pipe bender, they never admit it. Take and lose, whatever. I always remember such cases with humor.

You can bend a profile pipe using a special device - a manual pipe bender. When performing such a procedure, you can get good quality products that are used in many areas of our lives.

Bent shaped pipes are used for the manufacture of building structures, arches, greenhouses, fences, gates. They are the decoration of elegant outdoor furniture: benches, chairs, tables. Bent shaped and round metal pipes are used for the production of school desks, chairs, furniture for medicine, offices and other institutions.

A do-it-yourself hydraulic pipe bender according to your sketches or drawings, or taken from the Internet, is a special device using which you can bend pipes or rolled products at different bending angles, ranging from 0 to 180⁰.

You can buy a good hydraulic pipe bender in stores, or you can try to do it yourself, which, in terms of the quality of its functioning, will be in no way inferior to factory products.

And since improvised means and materials are used for self-production, the cost of such a bending structure will be much cheaper than serial devices. And the financial side in the manufacture of such a device, you see, for most of us, is of great importance. Considering this, many craftsmen make universal structures with their own hands, with the help of which profile and round pipes with any bending radius are easily and efficiently bent. And the Internet helps them, where you can choose not only the hydraulic pipe bender you like for making with your own hands, but also see ready-made drawings, videos, listen to or read the advice of experienced craftsmen.

Among the factory counterparts, the stalex hydraulic manual pipe bender is very popular, with the help of which metal-plastic pipes and metal products are easily bent. It is convenient for professionals to work with such a tool, since pipes can be bent directly on the construction site, and very smoothly and accurately. The design of the serial production manual pipe bender is such that when using it, flattening or kinking is completely excluded.

Peculiarities:

• creates an effort that is equal to 12 tons;
• equipped with a hydraulic drive;
• equipped with a set of interchangeable shoes;
• can function horizontally or vertically;
• provided with automatic return of the slider;
• during operation, the entire working stroke of the cylinder is involved;
• the bending radius is adjustable with vertical or horizontal supports (depending on the model).

Among the many manual pipe benders, hydraulic machines are considered the most popular and demanded. There are good reasons for this.

Hydraulic devices are able to bend even a 3-inch round pipe with high quality. They are successfully used both by professionals - for performing large volumes of work, and by novice amateurs who want to bend one or two shaped or round pipes.

In addition to such advantages as:

• ease of manufacture;
• reliability;
• strength;
• low cost,

they are also appreciated for the force of impact, thanks to which it is possible to process not only thick-walled steel pipes, but also to work with rather large products made of other metals: aluminum, copper, brass, bronze.

In addition, a special installation (jack) greatly facilitates the work of the operator, who makes a minimum of effort to obtain a large force of pressure on steel or other materials, pipes.

Before making a manual pipe bender, you need to decide on the type of device. To do this, you need to familiarize yourself with the drawings and photos, as well as diagrams of possible designs made with your own hands, watch a video, remember what materials and improvised means you have in stock, and only then start the manufacturing process. And most importantly: for what purpose and for what work do you need a structure with which you can bend the risers. Plus, it would be nice to consult with a more experienced neighbor or friend who has already dealt with the manufacture of such or a similar device. And if you're ready, you can start making the profile bending device.

Before you start making a machine for bending a round pipe, you need to stock up on everything you need:

• a hydraulic jack from a machine or tractor (you can use more powerful ones, if possible);
• shoe (punch);
• channel (about 3 meters);
• 3 rollers with axles;
• metal plates.

When making a manual pipe bender, a simple algorithm should be followed:

1. Measure the required length of the channel for the base with a tape measure and cut off 2 equal pieces with a grinder, thanks to which the base of the future hydraulic pipe bender, and with it the frame (1), will be more stable.
2. Place the cut pieces of the channel close to each other, weld from below and from above along the joint line. This platform will be the basis of the pipe bending machine.
3. Weld the side channels on both sides of the base at an angle of 110⁰.
4. Weld longer pieces to the upper part of the side channels, in which several (from 2 to 8) holes must first be drilled, placed symmetrically on both sides of the future pipe bending machine. They are designed to install axles with pressure rollers in them, by rearranging which it will be possible to adjust the bending radius of the risers.
5. Fix the jack (3) on the base with plates with holes for bolts (2) with a diameter of 10-12 mm so that it does not move when working with steel or other pipes. To do this, you need to drill the base in certain places and fix the hydraulic device with bolt strips.
6. Securely fasten the shoe (4) to the jack rod so that, if necessary, it can be easily removed and replaced with another.

Everything, the structure is ready for work, and the required dimensions are indicated on the drawing of the pipe bender made by hand, although in the photo, holes are not drilled in the upper channels (there are 2 of them, one on each side of the side channels). Therefore, the handheld hydraulic tube bender shown is designed to bend parts with only one bend radius.

The height of the bending machine is determined by the parameters of the jack and the distance "a". This means that to bend a half-inch steel pipe, this length should be approximately 2 cm (if the jack is inoperative).

It should be noted that all the force from the punch is directed to the top of the hand tube bender. Therefore, there are cases when the outer part of the bendable part is subjected to too much tension, which will contribute to a significant thinning of the wall of the circular pipe. There are even tears in the riser. Therefore, it is not always possible to use the unit to bend thin-walled pipes.

As you can see, there is nothing complicated, and the design for bending a round pipe is reliable, durable and will last for more than a dozen years. And most importantly, only improvised materials were used for its manufacture, which greatly reduced the cost of such a device.

The device is used for shaped pipes.The principle of operation of such a structure is as follows: a turntable, driven by a jack and through which the bending angle is set, is connected to the main bed by means of a hinge. The profile is pulled as a result of the rotation of the handle, which is connected to the intermediate shaft of the bending machine.

The base for the manual pipe bender and the stands are made of channels with a wall height of 125-200 mm. Cages for bearings, the base of the rollers, can be made of steel pipe, moreover, its diameter must match the diameter of the bearings.

The bending parameters can be adjusted in two ways: using the turntable and using the rollers located at the edge.

To this end, it is necessary to drill the support plates and the channel, which will ensure the mobility of the elements of the bending machine.

Both platforms of such a device are also made of channels. To raise the extreme platform of the manual pipe bender, a conventional automobile or tractor hydraulic jack is used.

To weld the vertical post from the channel, it is necessary to retreat from the edge of one side of the base of the hydraulic pipe bender about 45-50 cm. To strengthen it, it is advisable to pair two pieces.

Using the building level, it is necessary to achieve strict horizontality of the stationary platform of the homemade bending machine, and then weld the stand to it from behind. With the help of pieces of profile, build up the limiters to a height at least equal to or greater than the thickness of the profile or round pipes, which will be flexible.

Using the door hinges, connect the main frame of the hand tube bender to the guide platform. Mount the bearings on the edges of the moving and stationary platforms, as well as on the stops of such a device, using welding for this.

To strengthen the entire structure of the hydraulic pipe bender, it is necessary to use the corners, which are welded in separate places. Attach a handle to the middle shaft of the bending machine, and install bearings on the outer ones.

Place the jack underneath the guide platform, use the bolts to securely fasten it to the base and the homemade pipe bender is ready to go.

By the way, the repair of a hand-made hydraulic pipe bender can also be done independently, and here's why: no one except you knows the features of its structure and principle of operation. Therefore, only you can do a high-quality pipe bender repair yourself at home.

The bending process looks like this: first you need to install the steel pipe in the shoe and fix it on both sides. After that, you need to use a jack, thanks to which, such a device (the rod together with the shoe) will rise up. The force generated by the hydraulic drive is instantly transferred to the rollers, after which the riser will begin to bend under the preset bending radius. After the end of the folding process, the device must be lowered and pulled out the finished product. The main thing is that such a bending machine can be stopped at any time, which eliminates the possibility of injury.

Before bending a profile or round pipe, it is advisable to heed the advice of people experienced in this matter.

Firstly, home-made hydraulic pipe benders bend pipes made from any materials with sufficient quality. It is very important that with the help of the device, thick-walled products are bent, without any kind of marriage, which is beyond the strength of pipe benders of other structures made on their own at home.

Secondly, the procedure can be carried out using hot and cold methods, which also makes such devices more popular and in demand.

The highlight of cold bending is that a steel or pipe made of other metals must be filled with something before performing the operation.Sand, salt, oil or oil processing, water are well suited for this. Thanks to such fillers, the quality of bending of steel pipes or products from other metals is significantly increased, and the appearance of all kinds of unnecessary deformations is excluded.

With the hot method, you need to preheat a certain section of the steel pipe, and then bend it in the same way as a cold workpiece, but without filler.

Thirdly, in order to obtain a quality product, thick-walled structures are bent using a homemade hydraulic pipe bender using the hot bending method.

Inexperienced operators think that the bending process with a DIY metal bending machine is a fairly simple operation. But it is not so.

If you improperly handle the manual pipe bender, then unwanted defects may appear:

• a change in the diameter of a round pipe, which is caused by the so-called crushing;
• the appearance of thinning of the original samples at the place of bending of a round pipe or a profile analogue, which can lead to a deterioration in the strength characteristics of the part.

In order to minimize possible defects, it is necessary to be able to choose the right device and become familiar with the principle of its operation.

If it is necessary to perform bending identically to the template, then in order to prevent the profile or round pipe from slipping, which means that there is no difference between the template and the bent part in terms of size and configuration, it is necessary to replace the stops with metal hooks.

Usually, a homemade pipe bender with two rollers is used when bending structures with small radii, and with three large ones.

In order to improve the design, it is necessary to make a pipe bender with your own hands so that the thrust rollers can move, which will allow you to instantly change the bending radii.

In this article, we will walk you through the process of creating a do-it-yourself hydraulic pipe bender using home tools.

Indeed, in the process of performing any repair and construction work, there may be a need to bend a round or shaped metal pipe. There are two ways to solve this problem:

1. Buy a tool in the construction market. This option is suitable when there is a frequent need for bending pipes, because the price of the machine is very impressive.
2. Make a pipe bender with your own hands. This option is suitable in case of a rare need for bending.

The hydraulic pipe bender consists of:

Typical homemade pipe bender on casters

• two stops for pipes;
• hydraulic cylinders with lower as well as upper bars;
• devices for pumping oil into the cylinder;
• handle and exhaust valve screw.

The hydraulic cylinder is the main part and performs the power function, in its action it is very similar to a car jack.

There is a special hole in the upper part of the hydraulic cylinder for filling the oil and checking its level. A strap is threaded to the housing of the rear of the cylinder, and is also pressed with a fixing nut. The upper cylinder bar is secured with a lock and two screws.

Hydraulic pipe bender drawing

With the help of a very powerful spring, the reverse mechanism of the pull-out device is carried out, which, in turn, performs the bending work.

The lower bar is made as a welded structure. And to install a threaded bolt at the bottom of the cylinder, special stops are located. Thus, the stop of any pipe bender is a kind of trunnion, and the strips on which the stops themselves are located are located in its lower part. All parts of a homemade device must be made of durable steel and made by casting.

Note: repairing a pipe bender is a very difficult task due to the complexity of its design and therefore it is highly recommended to repair them in specialized workshops.It is there that the correct adjustments will be made, as well as good-quality parts will be selected.

However, some of the nuances for the maintenance of pipe benders can be done by yourself, namely:

• promptly clean all parts of the device from dirt and dust that rub in the course of their operation;
• you need to periodically check the oil level in the cylinder and top up if necessary.

Before you start, you need to decide on the radius of the future product that will be curved. Based on numerous reviews, first you should cut off a piece of metal pipe, for example, with a grinder. Next, a squeegee weld is needed for the remaining piece of pipe.

The principle of this action is very simple: it is necessary to place a metal pipe in the short part of the device, then press it from above and using the lever, which is the long part of the device, bend the pipe. However, it should be borne in mind that the installation process can be significantly difficult if the pipe diameter exceeds 25 mm.

It is quite possible to create such a device even at home, for this you need the following:

First of all, it is necessary to carry out welding work on the lower stop, similar to an inverted letter "T". After that, you will need two rollers, and their diameters must fully correspond to the diameter of the cut pipe itself.

Further, using the horizontal part of the cylinder, the winch and the roller are fixed. Thus, they must be connected by a chain, and the remaining roller is attached to the vertical part of the cylinder, which is slightly higher. It turns out that the pipe is located so that one of its ends is clamped between two rollers, and the opposite one lies on the winch.

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In the process of bending the pipe, the winch shifts. This design has its flaw: several people must take part to work on this machine, because one of them must move the winch, and the second must pull the metal pipe itself.

Note: in the process of manufacturing the pipe bender, observe safety precautions using personal protective equipment (special glasses, gloves, etc.)

There are 2 ways to bend pipes:

Visual diagram of pipe bending

With this approach, the cylinder must be filled with sand after sifting it. Further, the cylinder is clamped in a vice and then heated to a certain temperature at the bend of the pipe.

It is very important that the holes in the product are covered with special wedges, 1.5 times the product's own diameter. At the ends of the wedges, holes are needed for the outlet of working gases, which can be drilled with a conventional drill.

This option is suitable only in the winter season and is effective only at negative air temperatures. The cylinder must be closed at one end and filled with water at the other. After that, the structure is left in the cold by the time of the final freezing of the liquid in it. After these steps, much less effort can be applied to bend the metal pipe.

If, nevertheless, making a device for bending pipes at home causes you difficulties, then try to rent it, as a last resort, purchase a manual pipe bender in a store.

You may be interested in information on how to choose pipes for a warm water floor.

Read how to connect plastic water pipes here.

We also bring to your attention an article on how to make a floor screed with your own hands.

How to make a hydraulic pipe bender with your own hands, see the video: