STEEL BAR BENDER

Model No.: GW42D-1/GW42D-4

OPERATION MANUAL
ORGINAL INSTRUCTION
 STEEL BAR BENDER GW42D – OPERATION MANUAL

Contents

I Safety Notes…………………………………………………………………… 2

II Purpose………………………………………………………………………… 4

III Technical Parameters………………….…………………………………….. 4

IV Structural Features…………………………………………………………… 5

V Installation and Operation…………………………………………………... 5

VI Power supply………………………………………………………………….. 8

VII Maintenance……………………………………………………………………12

VIII Table of Standard Accessories…………………………………………… 14

Annex 1: Usage of Residual Current Device………………………………….. 15

Annex 2: Exploded View of GW42D-4......…………………………………….…16
Annex 3: Maintenance record chart………………...…………………....…….. 17
Annex 4: Motor……………………………………………………………………… 18

X After-sale Service……………………………………………………………….. 20

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 STEEL BAR BENDER GW42D – OPERATION MANUAL

I Safety Notes
1. Always install residual current device before operating the tool.
2. 15-18 Kg of N°30 automotive gear oil (SYSB62S) shall be injected into the
gear box oil cap (on the working table) before the first usage.
3. Check Table I, Table II and Table III to chose the right pile head and pile head
casing according to tensile strength and number of steel bars you want to bend
(tools for bending small-diameter steel bars are prohibited for bending large
diameters ones).
4. Always check working disk rotation direction before inserting the steel bar.
5. Remove the wheels or place the machine on two bars of wood (or other soft
material) in order to keep the machine stable on the floor.
6. Make sure that the pile head edge is lined with the stop gauge and check the
distance between the pile heads according to the bar diameter before inserting
the steel bar:

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 STEEL BAR BENDER GW42D – OPERATION MANUAL

Please refer to the table below for explanation of marks on the tool:

Figure Legend Explanation

Manual and automatic switch knob

Emergency stop pushbutton switch

Automatic startup and manual

button switch for CLOCKWISE
rotation
Manual pushbutton switch for
COUNTER CLOCKWISE (reverse)
rotation
Inject lubricant and prevent from
entrance of foreign matters

Caution! Risk of Injury

OPERATION MANUAL - Please

read the instructions carefully
before usage

Emergency stop OIL WINDOW - Check lubricant

pushbutton (rear) level according to instruction

Electric danger at electrical cabinet and

connections thereof.

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 STEEL BAR BENDER GW42D – OPERATION MANUAL

II Purpose
1. Steel bar bending machine GW42D-1～4 is featured with a compact structure,
flexible and easy operation, reliable function, stable performance, easy repair
and maintenance, nice appearance and novelty, is a gear-pair driving angle
bending machine. It can bend up to 42mm Q235 steel or 36mm C45 Class II
steel bar into various shapes according to needs. GW42D-1～4 steel bar
bending machine has the function of automatic bending and molding under the
preconditions of hand charging.
2. After working for a certain period of time, the tool shall be stopped and reused
after the working disk is turned 180 degrees. Thus, the bull gear in the reduction
box switches 180 degrees also to achieve the goal of even abrasion and enlong
the service life of the tool.
3. It is highly recommended not to bend the maximum diameter (42 mm) for a long
period of time without an adequate period of rest of the machine.

III Technical Parameters

6-42 mm 6-36 mm
BENDING CAPACITY (ob≤450N/mm2) (ob ≤650N/mm2)
Model GW42D-4 GW42D-1

OPERATION Automatic Manual

TYPE OF MOTOR YEJ 100L2-4 (Brake motor) Y100L2-4

MOTOR POWER 3 KW-4P 3 KW-4P

HORSE POWER 4 HP 4 HP

MOTOR ROTATION SPEED 1420 R/min 1420 R/min

SPEED OF WORKING DISK 12 R/min 12 R/min

NOISE VALUE (1m away) ≤80dB(A) ≤80dB(A)

WEIGHT 360 Kg. 320 Kg.

DIMENSIONS (L*W*H) 810*760*860 mm 810*760*860 mm

CERTIFICATION 2006/42/EC - 2006/95/EC / ISO 9001:2008

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 STEEL BAR BENDER GW42D – OPERATION MANUAL

IV Structural Features
Steel bar bending machine GW42D-1 mainly consists of drive mechanism,
framework and workbench. With regard to the drive mechanism, the working
disk rotates due to the drive of motor through V-belt, belt pulley and gear pair.
GW42D-4 bending machine has angle adjusting mechanism. The angle
adjusting device is fitted on the working disk to achieve automatic operation.
See the kinematic diagram of mechanism below.

Kinematic Diagram of Mechanism

输 belt pulley of input shaft

belt pulley
V-belt
input shaft

counter gear shaft Bull-gear

working disk countershaft

bull gear of main shaft

housing

V Installation and Operation

1 Steel bar bending machine GW42D-1～4 bends 6-42 mm. steel bar into various
shapes according to the needs of building works by employing pile head casing,
guide pile head, striker plate, etc. In the following figure, GW42D-4 is given as
an example to detail the installation method of work pieces.

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 STEEL BAR BENDER GW42D – OPERATION MANUAL

Method for Installation of steel bars on GW42D-4 Bending Machine

2 Following aspects shall be noted for bending steel bars of different diameters:
bending radius shall be determined according to the rebar diameters and
ultimate tensile strength, which means that suitable pile head casing, striker
plate, etc. must be used. If example is given for Class I deformed steel bar as
per 2.5 times of the steel bar diameter, recommended pile head casing or guide
pile head is listed for rebar of different diameters. Please refer to Table I for the
relationship.

Table I Class I steel Q235 (σb≤450N/mm2) unit: mm

Note: σb refers to the ultimate tensile strength (stress) of steel bar

Diameter of
steel bar 6～8 9～10 12～14 16～22 18～22 24～28 30～35 36～42

Diameter of
pile head φ 20 φ 25 φ 35 φ 54 φ 59 φ 74 φ 84 φ 99
shaft (casing)

If example is given for Class II deformed steel bar as per 3 times of the rebar
diameter, recommended pile head casing or guide pile head is listed for rebar of
different diameters. Please refer to Table II for the relationship.

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 STEEL BAR BENDER GW42D – OPERATION MANUAL

Table II Class II steel C45 (σb≤650N/mm2) unit: mm

Note: σb refers to the ultimate tensile strength (stress) of steel bar

Diameter of
steel bar 6～8 9～12 13～18 19～20 21～25 26～30 31～36

Diameter of
pile head φ25 φ35 φ54 φ59 φ74 φ84 φ99
shaft (casing)

Note: σb refers to the ultimate tensile strength (stress) of rebar.

3 According to respective tensile strength, pile head casing or guide pile head
shall be selected based on Table III and installed at the center of the working
disk. Suitable guide pile head and pile head casing shall be mounted on the
working dick and striker pile head and striker plate shall be mounted on the
guide square steel. Then, empty run can be carried out. If no failure occurs,
bending can be carried out.

4 According to the difference of diameters and strength, the maximum quantity of

rebar to be bended at the same time is given below in Table III.

Table III Maximum Quantity of Rebar to Be Bended at One Time

WARNING
DO NOT BEND STEEL BARS OF THE MAXIMUM DIAMETER FOR
SEVERAL HOURS IN ROW, IT WILL COMPROMISE THE FUNCTIONING OF
THE MACHINE.
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 STEEL BAR BENDER GW42D – OPERATION MANUAL

5 the event of failure, bending shall be stopped immediately and continued after
the failure is fixed.

6 To reduce the time of measurement, gauge may be set on the workbench to

show the installation position of rebar before shapeup.

VI Power supply
The power supply for the tool is three-phase three-wire 380V (Or other
customized voltage) and the casing must be fitted with earthing device.
The three-phase electricity shall be connected to the fuse FU. The sequence of
phases and each mechanical part shall be checked to make sure they are
correct and normal.
Only after every aspect is checked inerrably can the tool be electrified and
commissioned.

1. GW42D-1 Steel bar bending machine (manual)

• These two machines employ contactor pushbutton inching control. Contactor

interlock electrical protection is applied for equipment.

• The tool can be started only after being electrified for commissioning and
checked for normal conditions of the mechanical parts. By pushing the startup
button with hand (SBZ), the AC contractor KMZ pulls in and motor starts
operating to drive the working dick through V-belt and shift of reduction box.
SBZ shall be released only the required angle is obtained and then the working
dick stops rotating. Then, the return button shall be pushed and contactor KMF
pulls in. Motor rotates inversely to drive the working disk back to the startup
position. At that moment, SBF shall be released and motor stops operating. The
operation is finish.

SN Symbol Description Type Qty. Remark

Three-phase
1 L1,L2,L3 50HZ,380V
power supply
2 FU Fuse RT14-20 3 380V,20A

3 SBZ,SBF Button LA126A 2 380V ,10A

4 KMZ,KMF AC contactor CJT1-20 2 380V,20A
5 M Motor Y2100L-4 1 380V,3KW

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 STEEL BAR BENDER GW42D – OPERATION MANUAL

Electrical Schematic Diagram of GW42D-1

2. GW42D- 4 Steel bar bending machine (semi-automatic)

1. Switch on the power supply.

• The knob switch SA shall be switched to MAN. By pushing the startup button
(SBZ), the AC contractor KMZ pulls in and motor starts operating to drive the
working disk through the V-belt and shift into the reduction box. SBZ shall be
released only when the required angle is obtained, after releasing the working
disk will stops rotating.
• The return button shall be pushed so that contactor KMF pulls in. Motor rotates
inversely to drive the working disk back to the starting position. At that moment,
SBF shall be released and motor stops operating. Now the machine is ready for
the next bending.

• The knob switch SA shall be switched to AUT and the bending angle shall be
fixed with angle guide pin. By pushing the start button SBZ (or pressing the foot
switch K), the AC contractor KMZ pulls in, power supply is automatically
maintained and motor starts operating to drive the working disk. When the stop
piece hits the limit switch SQ, the AC contractor KMZ is released and
disconnected. KMF pulls in and power supply is automatically maintained. The
motor rotates inversely to the starting position. Now the machine is ready for the
next bending.

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

SN Symbol Description Type Qty. Specifications

Three-phase
1 L1,L2,L3 50HZ,380V
power supply
2 FU Fuse RT14-20 3 380V,20A

3 SBZ，SBF Button LA126A 2 380V ,10A

Emergency stop
4 SBT LA126A 1 380V ,10A
button
Combination
5 QS HZS-20/4 1 380V,20A
switch
6 SA Knob switch LA126A 1 380V，5A
7 SQT Stop travel switch LXK3-20S/L 1 380V,5A
Reverse travel
8 SQ YBLX-ME/8104 1 380V,5A
switch
9 K Foot switch LT4 1 380V,5A
KMZ，
10 AC contactor CJT1-20 2 380V,30A
KMF
11 M Motor Y2100L2-4 1 380V， 3KW

Electrical Schematic Diagram of GW42D- 4

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

• In the event of operation at opposite position of the panel, the rotation direction of
the working disk can be changed only by switching the combination switch.

• According to the configuration, bending control and accessories, GW42D bender

machine is divided into the following four models:

Model
GW42D-1 GW42D-4
Configuration

Motor Common motor Brake motor

Structure Common
Square steel, disk
adjustable structure
Mode of electrical Automatic
Manual operation
control bending

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

VII Maintenance
1. Lubrication
This machine employs gear pair reduction box and allows the injection of N°30
automotive gear oil (SYSB62S). Inject 15-18 Kg of oil before the first usage up
to the level, the right level is up to the half of the oil indicator window. Oil indicator
window is placed on the internal of the machine on the reduction gear box, under
the working table.
The first time lubricant change
shall be carried after six months
of usage. After that, the
lubricant shall be replaced once
per year. To change the lubricant
oil open unscrew the oil draining
bolt located under the reduction
box in the internal of the machine,
then run the motor to discharge the dirty oil.
Wait until all the oil came out then
screw firmly the draining bolt and
inject 15-18 litres of clean N°30
automotive gear oil (SYSB62S)
into the oil hole on the working
bench.
For lubricant recommendation
refer to the table below:

Brand of lubricant Grade

ISO VG 68
ROL OIL EP 68
ESSO SPARTAN EP 68
MOBIL MONIL GEAR 626
SHELL OMALA 68

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

2. Operation / Storage
• Before bending, Table I (or Table II) shall be referred to for the strength and
diameter of steel bar.
• Pile head casing shall be properly selected. It is not allowed to use
small-diameter guide pile head to bend large-diameter steel bar.
• Rustproof grease shall be coated onto the processing surface of the machine in
case of long period idling and placed indoor in a dry place.
* Humidity could cause rusting of assembling components such as working disk
internal bolt. In order to avoid it, check and make sure periodically that each surface
internal and external of the machine is dry and that there is not rust.

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

VIII. Table of Standard Accessories

(included in the machine shipment packaging)

SN Description Quantity
1 Pile head casing 1 1
2 Pile head casing 2 1
3 Pile head casing 3 1
4 Pile head casing 4 1
5 Central pile head 1 1
6 Central pile head 2 1
7 Central pile head 3 1
8 Central pile head 4 1
9 Central pile head 5 1
10 Guide pile head 3
11 Striker pile head 1
12 Striker plate 1
13 Adjusting bolt
M20X70 1
14 Locknut M20 1
15 Pedal switch 1
16 Pedal socket 1
17 Pedal plug 1

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

Annex 1: Use of Residual Current Device

It is required to use triple pole three-wire residual current circuit breaker. If the user adopts a three-pole four-wire residual current
circuit breaker, after connecting the three phase lines, the earthing line cannot be connected on the binding post of the outgoing
line of the residual current circuit breaker with the "N" mark. Otherwise, once the switch is on, it will soon trip.

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

Annex 2: Exploded View of GW42D-4

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

Annex 3: Maintenance record chart

Name Steel bar Manufacture Chengdu Gute Machinery

bending Works Co., Ltd
machine
Model Products serial
GW42D
number
times Item
Date of Enterprise(person)
purchase of purchase
Maintenance Tel. of service
date dep./person
Fault causes:
1

Repair outcome:

Client signature:
Date of Enterprise(person)
purchase of purchase
Maintenance Tel. of service
date dep./person
Fault cause:
2

Repair outcome

Client signature:
Date of Enterprise(person)
purchase of purchase
Maintenance Tel. of service
date dep./person
Fault cause
3

Repair outcome

Client signature:

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

Annex 4: Motor

Y /Y2/YEJ Series Three-Phase Induction Motors

Operation Instruction

Ⅰ. Preliminary inspection ＆ notes

1.Check carefully that all the data on the name plate, such as rated output,
voltage, frequency, etc. Should comply with actual requirements.
2.Inspect carefully that all motor parts are assembled in good condition and no
fastening members, like screws, nuts, have become loosened and detached
during transit. Remove any dusts, dirt or small foreign substances that could be
found inside the motor, with dry compressed air at a pressure about 1-2
atmospheres or by the use of a pair of bellows.
3.Be sure that all the electric connections are in close contact and free from
rust.
4.Turn slightly the shaft extension of the motor to see that the rotor can rotate
freely and without abnormal noises.
5.Measure the insulation resistance of the motor by the use of a “Megger” the
resistance in Megohms, obtained between the windings and the motor frame,
should not be less than
R= Rated volts
1000+Rate output in KW
100
If the resistance is below this value the motor must be totally dried out before it is
put into service. The drying temperature do not exceed +120℃
6.When a belt drive is used, it is very important to ensure that the axes of the
driving shafts are parallel. When a flexible direct-coupled drive is used, it is very
essential that the alignment of the machines be exact.

Ⅱ. Motor connections

This type of motor is provided six terminals, marked with U1、V1、W1 and U2、
V2、W2 The terminals are so arranged that can be either connected in star or in
delta.
For the connection of the arrangement on the terminal board are shown in Fig. 1
＆ Fig. 2 (next page).

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

w 2○￣U2○￣V2○ w 2○ U2○ V2○

∣ ∣ ∣
U1○ V1○ w1○ U1○ V1○ w1○
∣ ∣ ∣ ∣ ∣ ∣
A B C A B C

Fig. 1 Star-Connection (400V) Fig. 2 Delta-Connection(220V)

If motor is only provided three terminals, marked with U、V、W

Ⅲ. Running test and starting of the motor

1. Running test
A no-load running test is to be carried out after the motor has been thoroughly
inspected and properly connected. During the test, attention should be paid that
the direction of rotation of the motor must comply with that of the drive machine. In
case that the motor runs in the wrong direction, shut it down immediately and a
reversal of rotation will be effected by inter changing any two of the three supply
leads. The no-load running test should be carried on for 2 to 3 hours, while
running, note if any abnormal phenomenon or noise occurs and after the test.
examine if there is any oil leakage or over heating of the bearings. Before the
motor is ready to carry and load, due corrections should be made when
necessary.
2.Starting
All motor are allowed to be started at full voltage. If the capacity of the supply
is not sufficient for such as starting, a reduced voltage may be applied out at the
expense of the starting torque which is directly proportional to the square of the
terminal voltage.

Ⅳ. Maintenance inspection ＆ storage

1. In the course of running, motors should be frequently cleaned and inspected to

keep them free from moisture, dirt, metal dust and other foreign matters.
2. Immediate shut-down and inspection are obliged whenever any abnormal
noise is found in the operation, and no attempt should be tried to start the motor
again until the cause in determined and fault remedied
3. During the service, motor bearings should be well lubricated. Usually, to renew
the grease every six month. But when the bearing is overheated the used grease
must be renewed immediately.
4. When service life of the bearing comes to an end, it must be renewed.
5. When motors are kept idle in store, they must be packed as in their original
state, and the room should be kept dry, well ventilated and at a temperature

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 STEEL BAR BENDING MACHINE – OPERATION MANUAL

above 0℃ Regular inspection of motors in storage necessary to ensure that on

penetration of moisture, rusting of parts or hardening of lubricant would happen,
and due remedy should be made when needed.

Conditions
Motors of this series can continuously run at the rated power under the following
conditions:
① Altitude: Above sea level﹑not exceeding 1000m.
② Ambient temperature: it varies with seasons but not exceeding +40℃
Voltage, Frequency and duty
Frequency: 50Hz ﹑60Hz,
Connection: Y-Connection for 3KW and below whereas delta-connection for 4KW
and above.
Duty: Continuous(S1)
Insulation class: F
Protection: IP44﹑IP54 or IP55
※ Imported bearing and locked bearing at D-end on request.

X After-sale service

Thanks for your interest to our products. We will do our best to meet your future
requirements in order to get your support and encouragement.
In case of any doubt about the product you have purchased, please contact us on
the quality consultation line in following time:
Monday ~Saturday : a.m. 8:00-12:00 p.m. 14:00-18:00
In case of any malfunctioning or doubt about the operations, please first contact
us on the quality line and follow our service staff’s instructions to check and
operate; if it is confirmed that the problem cannot be resolved on the phone, our
technician will visit you for servicing.

Please be understanding that the product and its

accessories may be changed partially or completely to
improve its performance without further notification.

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