Greenlee 52093598 REV 0 Manuel utilisateur

INSTRUCTION MANUAL

881GX Cam Track®

Hydraulic Bender

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

KEEP THIS MANUAL

Español ..............27-52

Français .............53-78

Cam Track® Hydraulic Bender

KEEP THIS MANUAL

Table of Contents

Safety Symbols Key ...........................................3

General Safety Warnings ....................................4

Tool Specic Safety Information .........................5

Greenlee Contact Information ............................5

Tool Description ..................................................6

Specications .....................................................6

Tool Identication ...............................................7

Decals & Locations .............................................8

Pre-Operation Inspection ...................................9

Tool Set-Up & Operation ............................ 10-13

Calculating Ram Travel for Bend Angle ............ 14

Bending Basics ......................................... 15-19

Special Bending Tables .............................. 20-23

Troubleshooting ................................................24

Storage & Transportation .................................25

Cleaning ..........................................................25

Repair Kit and Accessories .............................26

Service ..............................................................26

Disposal ............................................................26

Cam Track® Hydraulic Bender

This symbol means always wear safety

glasses with side shields or goggles

when handling or using this equipment to

reduce the risk of eye injury.

Always wear gloves when handling or

using this equipment to reduce the risk

of injury.

This symbol means read the operator’s

manual carefully before using the

equipment. The operator’s manual

contains important information on

the safe and proper operation of the

equipment.

Safety Symbols Key

In this operator’s manual and on the product, safety

symbols and signal words are used to communicate

important safety information. This section is provided

to improve understanding of these signal words and

symbols.

indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury.

indicates a hazardous situation which, if not avoided,

COULD result in death or serious injury.

indicates hazards or unsafe practices which, if not

avoided, MAY result in injury or property damage.

This is the safety alert symbol. It is

used to alert you to potential personal

injury hazards. Obey all safety

messages that follow this symbol to

avoid possible injury or death.

This symbol means always wear safety

footwear to reduce the risk of feet

striking or being struck by objects or

being in contact with thermal or chemical

materials.

This symbol indicates the risk of hands,

ngers or other body parts being crushed.

This symbol indicates the risk of striking

injuries from moving parts of the product.

This symbol indicates the risk of

components breaking free and striking

nearby personnel.

This symbol indicates the risk of

pressurized uid directed at hand or body

parts, causing skin puncture and injection

injuries.

This symbol indicates that the carry case

(or equipment) weight is more than 55 lbs.

(25 kg), use proper lifting technique to

reduce the risk of injury.

Cam Track® Hydraulic Bender

Safety is essential in the use and maintenance of

Greenlee tools and equipment. This instruction

manual and any markings on the tool provide

information for avoiding hazards and unsafe practices

related to the use of this tool.

Read all safety warnings, instructions, illustrations,

and specications provided with this tool. Failure

to follow all instructions listed below may result in

serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR

FUTURE REFERENCE.

• Use personal protective equipment (PPE).

Always wear eye protection. Protective

equipment used for appropriate conditions will

reduce personal injuries.

• Use this tool for the manufacturer’s intended

purpose only. Use other than what is instructed

in this manual could result in a hazardous

situation.

• One person must control the work process

and machine operation. Only the operator

should be in the work area when the machine is

operating. This helps reduce the risk of injury.

• Keep handles and grasping surfaces dry,

clean, and free from oil and grease. Slippery

handles and grasping surfaces do not allow

for safe handling and control of the tool in

unexpected situations.

• Some parts and accessories of this tool are

heavy. Use proper lifting techniques to reduce

the risk of injury.

• Stay alert, watch what you are doing and use

common sense when operating this tool. Do

not use this tool while you are tired or under

the inuence of drugs, alcohol, or medication.

A moment of inattention while operating power

tools may result in serious personal injury.

• Keep bystanders a safe distance from the

work area. Additional people close to the

operator increases the risk of injury to themselves

and the operator from distraction or interaction

with equipment.

General Safety Warnings • Do not let familiarity gained from frequent

use of tools allow you to become

complacent and ignore tool safety principles.

A careless action can cause severe injury within

a fraction of a second.

• Do not overreach. Always keep proper footing

and balance. This enables better control of the

tool in unexpected situations.

• Dress properly. Do not wear loose clothing or

jewelry. Keep your hair, clothing, and gloves

away from moving parts. Loose clothes, jewelry

or long hair can be caught in moving parts.

• Store idle tools out of the reach of children

and do not allow persons unfamiliar with

the tool or these instructions to operate the

tool. These tools are dangerous in the hands of

untrained users.

• • Maintain all equipment and accessories. Maintain all equipment and accessories.

Check for misalignment or binding of moving Check for misalignment or binding of moving

parts, breakage of parts and any other condition parts, breakage of parts and any other condition

that may affect the operation. If damaged, that may affect the operation. If damaged,

repair before use. Many accidents are repair before use. Many accidents are

caused by poorly maintained equipment and caused by poorly maintained equipment and

accessories. accessories.

• • Keep work area clean and well lit. Keep work area clean and well lit. Cluttered Cluttered

or dark areas invite accidents. or dark areas invite accidents.

• Daily before use, inspect the tool and correct

any problems before using to reduce the risk

of injury and prevent product damage. If any

problems are found, do not use this tool until

the problems have been xed, failure to follow

these steps increases the risk of injury.

• Proper set up is essential to minimize risk

during use. Set up the tool and work area

according to these procedures to reduce the

risk of injury.

• Follow instructions from this manual when

repairing this tool and use only identical

replacement parts. Use of unauthorized parts

or failure to follow instructions increases the risk

of injury or damage to the tool.

• Tool service must be performed only

by qualiﬁed repair personnel. Service

or maintenance performed by unqualied

personnel could result in a risk of injury.

Cam Track® Hydraulic Bender

and safer at the rate for which it was designed.

Use of the tool for operations different from those

intended can result in a hazardous situation.

• Do not modify this tool. Modifying the tool in any

manner may result in personal injury and damage

to the tool.

• Do not attempt to open the tool. It contains no

user-serviceable parts.

Greenlee Contact Information

If you have any questions, need to arrange service or

purchase parts or accessories for this Greenlee/HDE

product: Contact your local Greenlee distributor or

Greenlee’s Customer Service Center

Additional copies of this manual are available for

download at www.greenlee.com

Greenlee Customer Service

USA: 1-800-435-0786 | Canada: 800-435-0786

International: 1-815-397-7070

[email protected]

Shipping address:

Greenlee Factory Service Center

4411 Boeing Dr., Rockford, IL 61109

Tool Speciﬁc Safety Information

Before operating this tool, read and understand:

• This operator’s manual

• The instructions for any other equipment or

material used with this tool

• Markings on the tool

• Required work-site safety procedures

Failure to follow all instructions and warnings may

result in serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR

FUTURE REFERENCE.

• Keep your ﬁngers, hands, and other body

parts away from bender, attachments, conduit

and moving parts. Body parts can be struck,

crushed, fractured, or amputated if they become

caught between the attachment or between these

components and any other object.

• Do not bend Aluminum EMT. Conduit may break

causing serious injury.

• Do not stand in a direct line with the follow

bar, hydraulic ram or conduit while bending.

The bender is under high pressure during use

and has the potential to break and throw parts,

causing serious injury.

• Do not alter this product in any manner or

attach any tools that are not speciﬁed in this

manual. Use of this bender with accessories and

equipment different from those specied could

result in a hazardous situation.

• High pressure oil easily punctures skin,

causing serious injury, gangrene, or death. Do

not use your hands to check for leaks. Stay away

from pressurized components. Depressurize

hydraulic system before touching the hose/

attachments. If injured, seek medical help

immediately to remove oil.

• Use only Greenlee hoses, attachments, and

accessories in good operating condition

with proper ratings for the tool. Do not alter

products from original design, worn, damaged or

improperly rated equipment can fail and cause

serious personal injury.

• Use proper combination of accessories for the

speciﬁc conduit size. Bends will be incorrect

and injury or damage to the tool could result.

• Use the correct tool and accessories for your

application. The correct tool will do the job better

Cam Track® Hydraulic Bender

Bending Capabilities: ........................................................................ 2-1/2”, 3”, 3-1/2”, and 4” Steel Rigid, IMC, EMT

2-1/2”, 3”, 3-1/2”, and 4” Aluminum Rigid

2-1/2” and 3” Stainless Steel Rigid

2-1/2”, 3”, 3-1/2”, and 4” Schedule 40 pipe

Do not use to bend Aluminum EMT

Storage Box Dimensions (H x L x W): ....................................... 25 in. x 60 in. x 24 in. (63.5cm x 152.4cm x 60.96cm)

Bender Assembly and Accessories in Storage Box Weight: ............................................................ 882 lbs. (400 kg)

Bending Shoe Weights*: ................................................................................................................. 2 ½” – 35 lb. (16kg)

3” – 54 lb. (25kg)

3 ½” – 71 lb. (32kg)

4” – 87 lb. (39kg)

Follow Bar Weights*: ....................................................................................................................... 2 ½” – 22 lb. (10kg)

3” – 30 lb. (14kg)

3 ½” – 47 lb. (21kg)

4” – 63 lb. (29kg)

*Model Estimate

Recommended Hose & Coupler: .................................................................................................. Greenlee CAT 11289

Pump: ............................................................Greenlee hydraulic pump capable of developing 10,000 psi with a usable

oil volume of 6 quarts or more, such as the Greenlee 980 series pumps.

All speciﬁcations are nominal and may change as design improvements occur.

Speciﬁcations

Tool Description

The 881GX Cam Track® Hydraulic Bender is a bender that can be used to bend 2-1/2”-4” Rigid, IMC and EMT

conduit. This bender can be mounted and operated on the Greenlee Mobile Bending Table (MBT) or operated on the

oor. See catalog for available congurations.

Features

Dedicated 90˚ bending shoe groups containing a shoe, follow bar and saddle.

Extended yoke to reduce time changing accessories.

Lighter follow bars to optimize user ergonomics.

Spring pins to reduce the amount of hitch pins used.

Bending tables

Cam Track® Hydraulic Bender

Tool Identiﬁcation

1. Ram

2. Spring Clip

3. Yoke

4. Extended Yoke

5. Yoke Spring Pin

6. Cylinder Block

7. Cylinder Block Hitch Pins

8. Cylinder Block Hitch Pin Clips

9. Connecting Forks

10. Roller Unit

11. Roller Hitch Pin Clips

12. Piston Support

13. Ram Scale

14. Hydraulic Hose

15. Hydraulic Coupler

16. Saddle Spring Pin

17. 2-1/2 in. Shoe Group

18. 3 in. Shoe Group

19. 3-1/2 in. Shoe Group

20. 4 in. Shoe Group

a. Bending Shoe

b. Saddle

c. Follow Bar

16

17 18 19

a

b

c

1

2

3

4

6

5

7

8

9

10 11

12

13

14

15

20

Cam Track® Hydraulic Bender

Decals, Markings, & Locations

A. Ram Travel Tables Decal

B. Bending Mark Tables Decal

C. Greenlee Logo Decal

D. Crush Hazard Decal

E. Warning Decal

F. Connecting Fork Catalog Number

G. Cylinder Block Position Marks

a. Yoke Mark

b. Extended Yoke Mark

H. Shoe Conduit Type Mark

I. Follow Bar “START” Mark

J. Conduit Size Identication Marks

G

H

J

I

AB

C

D

E

D

F

J

b

a

G

Cam Track® Hydraulic Bender

Pre-Operation Inspection

1. Depressurize and disconnect the pump before

inspecting the bender. Visually inspect bender

piston seal, ttings, and hose connections for

leaking hydraulic uid. If uid is present, do not use

the bender and send it in for service.

2. Clean any oil, grease or dirt from the bender parts

and accessories. This aids inspection and helps

prevent the machine or control from slipping from

your grip. Clean and maintain per maintenance

instructions.

3. Inspect tool for wear and damage before use. Do

not use if any parts are worn, corroded, or cracked.

4. Check for proper assembly and completeness, do

not use if there are missing or misaligned parts. A

damaged, worn or improperly assembled item could

break and result in ying debris.

5. Check for the presence and condition of warnings

and decals.

6. Inspect any other equipment and accessories in

the bending system according to their instruction

manuals.

• Daily before use, inspect the tool and correct

any problems before using to reduce the risk

of injury and prevent product damage. If any

problems are found, do not use this tool until the

problems have been xed, failure to follow these

steps increases the risk of injury.

• High pressure oil easily punctures skin,

causing serious injury, gangrene, or death. Do

not use hands to check for leaks. Stay away

from pressurized components. Depressurize

hydraulic system before disconnecting the hose/

attachments or servicing. If injured, seek medical

help immediately to remove oil. Figure 1

Piston

Support

Extended

Yoke

If any problems are found,do not use until problems have

been xed. Failure to follow these instructions increases

the risk of injury.

If using the extended yoke, inspect the ram and conrm

the piston support (Fig. 1) is installed. Do not bend with

the extended yoke if the piston support is not installed.

An unsupported ram can shift during bending resulting

in poor bends and damage to the tool that increases the

risk of parts breaking and causing injury.

Cam Track® Hydraulic Bender

Tool Set-Up* & Operation When the 881 bending is to be operated of the oor,

follow these steps for set up and operation. See Mobile

Bending Table for 881 Hydraulic Bender instruction

manual for MBT mounting and operation information.

1. Check work area for:

• Adequate lighting

• A clear, level, stable and dry place for all

equipment and space for the operator to work

comfortably and according to tool operating

instructions to reduce the risk of injury.

• A clearly marked or easily recognizable work

site to prevent people from coming into the area

while the tool is being used. Barriers or cones

around work sites are ways to do this.

2. Inspect the work to be done. Determine what shoe,

follow bar, and saddle are needed for the conduit

size and type. Not using the correct shoe, follow

bar and saddle produces poor quality bends and

increases the risk of tool damage and injury.

3. Conrm all related equipment has been inspected.

4. Attach the roller unit to the single prong ends of the

connecting forks, with decals and markings facing

out, and secure with the hitch pin clips. (Fig. 2)

• Do not stand in a direct line with the follow

bar, hydraulic ram or conduit while bending.

The bender is under high pressure during use

and has the potential to break and throw parts,

causing serious injury.

• Keep your ﬁngers, hands, and other body

parts away from bender, attachments, conduit

and moving parts. Body parts can be struck,

crushed, fractured, or amputated if they become

caught between the attachment or between these

components and any other object.

• Do not bend Aluminum EMT. Conduit may

break causing serious injury.

• Some parts and accessories of this tool are

heavy. Use proper lifting techniques to reduce

the risk of injury.

• Use proper combination of accessories for the

speciﬁc conduit size. Bends will be incorrect

and injury or damage to the tool could result.

• Proper set up is essential to minimize risk

during use. Set up the tool and work area

according to these procedures to reduce the risk

of injury.

• One person must control the work process

and machine operation. Only the operator

should be in the work area when the machine is

operating. This helps reduce the risk of injury.

• Stay alert, watch what you are doing and use

common sense when operating the bender. Do

not use the bender while you are tired or under

the inuence of drugs, alcohol, or medication.

A moment of inattention while operating power

tools may result in serious personal injury.

• High pressure oil easily punctures skin,

causing serious injury, gangrene, or death. Do

not use hands to check for leaks. Stay away

from pressurized components. Depressurize

hydraulic system before touching the hose/

attachments. If injured, seek medical help

immediately to remove oil.

5. Position the cylinder block so the ram scale is

toward the oor then slide the ram in between the

connecting forks. (Fig. 3)

Figure 2

Figure 3

Scale

Floor

Cam Track® Hydraulic Bender

7. Pin the appropriate yoke to the ram piston with the

spring clip. (Fig. 5) To bend 3-1/2” and 4” conduit

after using the extended yoke, change to the yoke

and leave the cylinder block in the top position.

8. Insert the cylinder block hitch from the side where

the cylinder block extends out past the connecting

forks.(Fig. 6)

Figure 5

Figure 6

Hitch Pin

Clip Holes

Hitch

Head

Cylinder

Block

6. Line up the cylinder block holes with the appropriate

position for the conduit size and yoke. (Fig.4) Pay

attention to the marks on the connecting forks. If

the cylinder block is in the wrong position, the ram

could over extend and cause tool damage.

• The yoke is used for 2-1/2”- 4” conduit and the

cylinder block must be located at the position

marked for the conduit size.

• The extended yoke is only used for 2-1/2”and

3” conduit and the cylinder block must be

located at the top position.

Figure 4

Figure 7

9. While keeping the hitch pin head tight against the

connecting fork face, insert the clip in the hole

closest to the opposite connecting fork face. Repeat

for second pin. (Fig. 7)

CONDUIT

SIZE

CYLINDER BLOCK &

YOKE-SHOE CONNECTIONS

2-1/2”

3“

3-1/2”

4”

94848G

Forks

26309

Forks

For

Changeover

Cam Track® Hydraulic Bender

11. Arrange the shoe between the connecting forks so

the saddle connection is to the left. Align the yoke

with the EMT or IMC/Rigid connection on the shoe

depending on the type of conduit to be bent. Insert

yoke pin through the yoke and shoe until the toggles

fully expand on the other side. (Fig. 9)

12. With the ears turned toward the ram, insert the

“START” end of the follow bar from the right of the

connecting forks over the roller. (Fig. 10)

13. Once the “START” end is past the roller, turn the

follow bar so that the conduit groove is toward the

ram and the follow bar ears touch the ground. (Fig.

11)

For changeover to other shoe groups, remove cyl-

inder block hitch pin clips, as necessary, and insert

into outermost hole of hitch pin (Fig.7). Lift connect-

ing fork enough to allow the follow bar through.

Return the hitch pin clips to the appropriate holes

for bending. Do not bend without the hitch pin clips

installed, poor quality bends and tool damage could

occur.

14. Prepare the conduit by marking the bends following

the instructions in the Bending Basics section of this

manual.

15. Check the conduit, shoe and follow bar grooves

are clean. Debris on the bending surfaces increase

the risk of wrinkling or creasing of conduit and can

cause damage to the grooves in the shoe and follow

bar.

16. Insert the conduit into the bender. Push the conduit

through so the end is past the shoe at least a few

inches.

17. Arrange the saddle around the conduit at the front

of the shoe with the saddle lip facing away from the

follow bar. Insert the Saddle pin all the way through

the shoe and saddle holes until the toggles fully

expand.

18. Adjust the saddle and shoe so the back edge con-

tacts the follow bar. (Fig.12)

19. Adjust the conduit so the appropriate bending

mark is lined up with the saddle lip. See Basics of

Bending for further instructions on marking conduit.

Figure 10

Figure 11

Figure 12

Figure 9

IMC/Rigid

EMT

Saddle

Connection

Shoe Conduit

Size ID

Figure 8

Scale Hitch Pin

Clips

Cylinder

Block

Cylinder

Block

Follow Bar

Ears

Conduit

Groove

“START”

Conduit Size

Saddle Follow Bar

10. Turn the assembled bender onto the cylinder block

so the hitch pin clips and ram scale are facing up

(Fig. 8). The cylinder block is designed to level out

the bender cylinder while bending on the oor.

Cam Track® Hydraulic Bender

Figure 14

20. Place a Greenlee 900 series hydraulic pump next to

the bender on the oor so the front of the pump is

facing the operator.

21. Attach the free end of the hose from the ram to the

pump coupler, make sure the coupler is screwed

tight to ensure proper ram function. Incomplete con-

nections may not allow the ram to retract after the

bend is complete.

22. Assume a proper operating position where you are

not in the path of the conduit or ram and can clearly

see the bender scale and pump. (Fig,14)

23. Snug-up the conduit by advancing the ram accord-

ing to the pump instructions. The conduit is

snugged-up when the shoe, conduit, and follow bar

are tight. Stop the pump before the conduit starts to

bend.

24. Move the scale’s O-ring to Z-Position. See

Calculate Ram Travel section for equation and

tables.

25. Monitor the bending process. Advance the ram to

Z-position. The bend is complete when the O-ring

reaches the top of the cylinder block. Stay out of

the line of the conduit and ram while bender is in

motion.

26. When bend is complete, operate the pump, accord-

ing to its instructions to retract the ram to the start-

ing position for the next bend.

27. Remove the saddle pin, saddle and conduit from

bender. Compress the toggles and pull the Yoke and

Saddle pins out to disconnect accessories. (Fig. 15)

28. Inspect the nished bend.

Figure 15

Cam Track® Hydraulic Bender

1. Snug-up bender by advancing ram until shoe,

conduit, and follow bar are tight. The conduit should

not be able to twist between the saddle and shoe.

2. Calculate Z = X + Y

Z = Stop position on ram scale based on X and Y.

X = Scale reading at Snug-Up position.

Find X by looking where the scale and top of the

cylinder block meet.

Y = The Ram Travel from Table 1. This is how far the

ram should travel to achieve the desired bend

angle for a specic conduit size.

3. Move rubber ring to calculated Z-Position. (Fig. 16)

4. Advance ram to the Z-Position. Monitor the bend

and stop when the rubber ring touches the top of

the cylinder block. (Fig. 17)

TABLE 1 RAM TRAVEL* - "Y"

(VALUES ARE APPROXIMATE)

BEND

ANGLE

EMT (CONDUIT TRADE SIZE - in.)

2-1/2 3 3-1/2 4

10° 13/16 15/16 1 7/8

15° 1-1/16 1-5/16 1-3/8 1-3/8

30° 2 2-7/16 2-3/8 2-7/16

45° 2-15/16 3-11/16 3-3/8 3-5/8

60° 3-13/16 4-13/16 4-3/8 4-7/8

90° 5-5/16 6-13/16 6-11/16 7-1/4

BEND

ANGLE

IMC (CONDUIT TRADE SIZE - in.)

2-1/2 3 3-1/2 4

10° 1-1/8 1-3/16 1-1/16 1-3/16

15° 1-9/16 1-11/16 1-1/2 1-13/16

30° 2-7/8 3-1/4 3 3-3/16

45° 4-5/16 5 4-3/8 4-13/16

60° 5-13/16 6-3/4 5-13/16 6-7/16

90° 8-1/8 9-5/8 8-13/16 9-11/16

BEND

ANGLE

RIGID (CONDUIT TRADE SIZE - in.)

2-1/2 3 3-1/2 4

10° 1-1/16 1-3/16 1 1-1/16

15° 1-1/2 1-11/16 1-1/2 1-11/16

30° 2-7/8 3-5/16 2-7/8 3-3/16

45° 4-1/4 5 4-1/4 4-13/16

60° 5-5/8 6-11/16 5-3/4 6-7/16

90° 8-1/8 9-9/16 8-3/4 9-11/16

Figure 17

*This table shows

the distance (Y) the

ram must travel

to make a bend.

These numbers are

not the end posi-

tion located on the

scale.

Figure 16

Calculating Ram Travel for Bend Angle

After the conduit has been snugged up, the ram must travel a particular distance to achieve the desired bend angle

(Table 1). A rubber O-ring on the ram scale is used to indicate the position at which the bend angle is achieved. Use

the directions below to determine where to place the rubber O-ring on the ram scale.

XYZ

Cam Track® Hydraulic Bender

The following drawings, instructions and bending tables are intended to provide the information necessary to set up

the most common types of bends. The “Special Bending Tables” at the back of this manual, contain precise mea-

surements used for nding the marks for most common bends. Some types of bends have their own tables that

provide numbers for nding the bending marks. Below are some of the most common terms used in bending.

Basics of Bending

Glossary

Leg Length—The distance from the

end of a horizontal section of conduit

or pipe to the bend; measured from

the end to the center line, inside edge,

or outside edge of the conduit or pipe.

Stub/Stub-Up/Rise— The distance

from the end of the vertical section of

conduit or pipe to the bend; mea-

sured from the end to the center line,

inside edge, or outside edge of the

conduit or pipe.

Springback—The amount, measured

in degrees, that a conduit or pipe

tends to straighten after pressure

is released on the bender ram. For

example, a 90° bend, after pressure is

released, will spring back about two

degrees – to 88°.

Center-to-Center Distance—the distance between the

successive bends that make up an offset or a three-

bend saddle.

O.D.—The size of any piece of

conduit or pipe as measured

by its outside diameter.

Snug-up - The process of securing the conduit between

the shoe and saddle by advancing the ram enough

to keep the conduit in place but not enough to start

bending.

Ram Travel - The distance that the ram of a hydraulic

bender must move to reach a specific bend angle.

Developed/Determined Length -The actual length of

the pipe that will be bent.

Min. Stub Length - A stub must be equal to or larger

than this number to avoid crushing threads and bad

quality bends.

Deduct - A calculated number to account for gain while

bending. This number is specific to the size and type of

conduit being bent.

Bend Angle/Angle of Bend - The target bend angle .

Kick - A bend, usually less than 45o, made to change

the direction of a section of pipe.

Center Line - The imaginary line running through the

center of the conduit.

Bend Radius - The radius as measured from where the

center of the bend is located. This is a xed number

based on the bending shoe.

Dog Leg Bend/Wow - A bend, usually no more than

45o, made to change the direction of a section of pipe

not on the same plane.

Large Sweep Bends - Any bend which exceeds the

radius of one-shot 90° bending shoes supplied with

one-shot hydraulic power benders.

Comeback - When making a 90° bend having a

definite leg length (or rise) the center of the bend must

be located when using certain benders. To do this, first

measure the leg length from the end of straight section

of pipe. Then, “come back” 1/2 the gain to locate the

center of the bend.

Degree indicator - This is an instrument designed

to indicate the exact degree of bend while it is being

made.

Protractor - Made for use with Benders mounted on

Bending Table. Measures degrees – also has scale

for 18°, 20°, 21° and 22° bends when using to make a

large sweep bend.

Segment Bend - Any bend formed by a series of

bends of a few degrees each, rather than a single one-

shot bend.

Gain - The difference between the right

angle distances A & B and the shorter

distance C. Because pipe bends in

a radius and not at right angles, the

length of pipe needed for a bend will

not equal the total determined length.

A

B

C

Height/Depth of Offset - The distance that the conduit

or pipe must be re-routed to avoid an obstruction.

A

H

Cam Track® Hydraulic Bender

Figure 22

Bending Marks

TABLE 2 —MIN. STUB HEIGHT, DEDUCT (IN.)

CONDUIT SIZE 2-1/2 3 3-1/2 4

EMT

DEDUCT 21-1/2 24 27-3/4 32-1/4

MIN. STUB LENGTH (H) 24 27 31-1/4 36-1/4

MIN. DISTANCE FROM END OF CONDUIT 2-1/2 3 3-1/2 4

IMC RIGID

DEDUCT 21-1/2 24-1/4 28-1/4 32-1/2

MIN. STUB LENGTH (H) 24 26-3/4 30-3/4 35

MIN. DISTANCE FROM END OF CONDUIT 2-1/2 2-1/2 2-1/2 2-1/2

Figure 21

1. In the appropriate Special Bending Table,use the

desired stub height (H) and angle to nd Y. (Fig.20)

2. Measure Y distance from the end of the conduit and

place the bending mark here. (Fig.21)

1. Make MARK 1 by measuring to the Target Stub

Length (H). (Fig.22)

2. Make MARK 2 by measuring the DEDUCT (Table

2) from MARK 1 towards the threads. (Fig.23) The

distance between MARK 2 to the end of the conduit

cannot be less than the MIN. STUB LENGTH.

Less than 90° Bend Marks

90° Bend Marks

Figure 20

HANGLE MARK

Y

Figure 23

TARGET

STUB

LENGTH

DEDUCT

MARK

2MARK

1

90o

H

Making a Bend

1. Set up the 881 Hydraulic Bender according to its

instructions in this manual and use accessories

specic to the conduit to be bent.

2. Observe work site and select the size and type of

conduit. The conduit determines what set of table

numbers are used for nding the bend marks.

3. Determine the Stub Height (H) and the Bend Angle.

(Fig.18) These numbers determine the appropriate

numbers needed from the bending tables. Different

types of bends use different tables and variables

follow the instructions for the type of bend to know

what variables are needed.

Figure 18

Figure 19

Bending

Mark

Saddle Lip

6. Snug-up bender. Advance the ram until the conduit

cannot shift but before the conduit is actually bent.

7. Calculate Z position (see Ram Travel) for desired

bend angle and move rubber ring on the ram scale

to mark.

8. Advance ram to Z-position.

9. Reverse ram until fully retracted to release the con-

duit. Remove conduit and check bend.

ANGLE

4. Mark the conduit by following the instruction for the

type of bend and using the appropriate tables. The

Special Bending Tables are used unless otherwise

specied.

5. Insert conduit between saddle and shoe. Line up

the appropriate bending mark with the saddle lip.

and make sure the follow bar is touching the back

of the saddle. (Fig.19)

TARGET

STUB

LENGTH(H)

Cam Track® Hydraulic Bender

Bending Marks

Offsets

An offset is made to avoid an obstruction blocking the run of the conduit. To make an offset, two equal bends are

required in opposite directions to create a rise that will go around the obstruction. Depending on the end position

desired, the mark positions are based off different numbers in the tables.

TABLE 3 "X" DISTANCE (in.)

CONDUIT SIZE 2-1/2 3 3-1/2 4

EMT

X6-5/32 5-3/4 6-9/16 8-1/2

MIN. DIST.

FROM END

OF CONDUIT 2-1/2 3 3-1/2 4

IMC/

RIGID

X6-5/32 6 7 8-3/4

MIN. DIST.

FROM END

OF CONDUIT 2-1/2 2-1/2 2-1/2 2-1/2

1. Select the size and type of conduit. Measure the

height (H) of the obstruction. Use the column with

an offset that will overcome the obstruction to, nd X

and A-Measurements.

2. Make MARK 1 by measuring the distance from end

of conduit to desired start of 1st bend.

3. Make MARK 2 on conduit by subtracting X (Table 3)

from MARK 1.

The distance from MARK 2 to the end of the conduit

cannot be less than the MIN. DIST. FROM END OF

Conduit to avoid crushing threads and bad quality

bends.

4. Find the “A” distance (Table 4). Make MARK 3 on the

conduit by measuring this distance from MARK 2.

5. Aline MARK 2 with outside edge of saddle for the

1ST Bend. Advance ram to calculated Z-Position for

desired angle.

6. Rotate conduit 180˚. Aline MARK 3 with outside edge

of the saddle for the second bend.

Center-to-Center Offset (Fig.24)

TABLE 4 "A" DISTANCE* (in.)

(VALUES ARE APPROXIMATE)

For offset distances not on this table, calculate “A” by

multiplying the appropriate multiplier (Table 5) to the desired OFFSET.

O

F

S

E

T

15° 30° 45°

MAX

COND.

SIZE AMAX

COND.

SIZE AMAX

COND.

SIZE A

23/4 7-3/4

41-1/2 15-7/16 3/4 8

63-1/2 23-3/16 1-1/2 12 1/2 8-1/2

84 30-15/16 2 16 1 11-5/16

10 4 38-5/8 3-1/2 20 1-1/4 14-1/8

12 4 46-3/8 4 24 1-1/2 16-15/16

14 4 54-1/16 4 28 2 19-13/16

16 4 61-13/16 4 32 2-1/2 22-5/8

18 4 69-9/16 4 36 3 25-7/16

20 4 77-1/4 4 40 3-1/2 28-1/4

22 4 85 4 44 4 31-1/8

Figure 24

2nd

BEND

H

ANGLE

1st

BEND

TABLE 5 “OFFSET”

MULTIPLIERS

BEND ANGLE MULTIPLIER

15° 3.86

30° 2

45° 1.4

* The “A” values on this table are the same for any conduit less

than the maximum. Values in gray are for reference only. The

881 Bender cannot bend conduit less than 2-1/2”.

A

MARK

1

MARK

3

MARK

2

X

LENGTH

TO 1st

BEND

CENTER

TO

CENTER

Cam Track® Hydraulic Bender

1. Find the Special Bending Table for the size and type

of conduit. In the table nd the row with the angle

of bend and the column with the height of stub de-

sired. Use the numbers from where these intersect

to nd bending marks

2. Subtract X from the LENGTH TO 1ST BEND to nd

the position of MARK 1.

3. Measure L1 from MARK 1 and place MARK 2 here.

4. Line up MARK 2 with outside edge of saddle for the

1st Bend.

5. Rotate conduit 180˚ and line up MARK 1 with out-

side edge of the saddle for the 2nd Bend.

1. Find the Special Bending Table for the size and type

of conduit. In the table nd the row with the angle

of bend and the column with the height of stub de-

sired. Use the numbers from where these intersect

to nd bending marks

2. Subtract Z from LENGTH TO 2ND BEND to nd the

position of MARK 2.

3. Measure L1 from MARK 2 and place MARK 1 here.

4. Line up MARK 2 with outside edge of saddle for the

1st Bend.

5. Rotate conduit 180˚ and line up MARK 1 with out-

side edge of the saddle for the 2nd Bend.

When working past an obstruction, it is necessary to determine the location of the 1st Bend (MARK 1). The center-

to-center distance is then used to nd the location of the

2nd Bend (MARK 2).

Offset-Working Past an Obstruction (Fig.25)

When working toward an obstruction, it is necessary to determine the location of the 2nd Bend. The center-to-

center distance is then used to nd the location of the 1st Bend.

Offset-Working Toward an Obstruction (Fig.26)

1. Select the size and type of conduit. Find the chart

that corresponds to the size and type of conduit se-

lected in the Special Bending Tables.

2. Determine the HEIGHT and the LENGTH of the stub.

Select the angle for the bend.

3. Follow the 90° ANGLE row and the HEIGHT column

for the desired bend. Use the Y and L1 dimensions

from that box.

4. Locate MARK 1 Y distance end of conduit/threads.

5. Add L1 to MARK 1 to nd the position of MARK 2.

6. Line up MARK 1 with the outside edge of the saddle.

Bend 90°.

7. Line up MARK 2, keeping the conduit in the same

orientation. Bend 90°.

Back-to-Back or U-Bend (Fig.27)

A U-shaped bend formed by two parallel 90-degree bends with a straight section of conduit or pipe between the

bends

Figure 25

Figure 26

Figure 27

2nd

BEND

MARK

1

ANGLE

1st

BEND

MARK

2

LENGTH - X

L1

H

LENGTH - Z

MARK

1

MARK

2

L1

LENGTH

2nd

BEND

ANGLE

LENGTH

H

Length

L1

Y

MARK

1MARK

2

90o

H

LENGTH

Cam Track® Hydraulic Bender

Four-Bend Saddle (Fig.28)

1. Select the size and type of conduit. Find the chart

that corresponds to the size and type of conduit se-

lected in the Special Bending Tables.

2. Measure the HEIGHT of the obstruction and the

LENGTH TO 2ND BEND to the obstruction and the

STRAIGHT SECTION over the obstruction. Select

the angle for all bends.

3. Follow the ANGLE row to the HEIGHT column for the

desired bend. Use the Z, L1 and L2 dimensions.

4. Subtract Z from the Length to Center and measure

this distance from end of conduit/threads to nd

MARK 1. Measure L1 distance from MARK 1 to nd

MARK 2.

5. Measure L1 distance from MARK 1 to nd MARK 2.

6. Add L2 to the Straight Section length and measure

this distance from MARK 2 to nd MARK 3.

7. Line up MARK 1 with the outside edge of the saddle.

Bend to the selected angle.

8. Turn conduit 180° and line up MARK 2. Bend to the

selected angle.

9. Line up MARK 3, keeping the conduit in the same

orientation. Bend to the selected angle.

10. Turn conduit 180° and line up MARK 4. Bend to the

elected angle.

1. Select the size and type of conduit. Find the chart

that corresponds to the size and type of conduit se-

lected in the Special Bending Tables.

2. Measure the HEIGHT of the obstruction and the

LENGTH TO CENTER of the saddle. Select an angle

for the outer bends. The center bend will be twice

the selected angle. (i.e. 22-1/2° x 45° x 22-1/2°)

3. Follow the ANGLE row to the HEIGHT column for the

desired bend. Use the Z, L1 and L2 dimensions.

4. Subtract Z from the Length to Center and measure

this distance from end of conduit/threads to nd

MARK 1.

5. Measure L1 distance from MARK 1 to nd MARK 2.

6. Measure L2 distance from MARK 2 to nd MARK 3

7. Line up MARK 1 with the outside edge of the saddle

for the 1st bend. Bend to the selected angle.

8. Turn conduit 180° and line up MARK 2. Bend to twice

the selected angle.

9. Turn conduit again 180° and line up MARK 3. Bend to

the selected angle.

Three-Bend Saddle (Fig.27)

A Saddle creates a bridge to avoid an obstruction blocking the run of the conduit and returning the end of the con-

duit to the same level as the original run of conduit. They can be made using three or four bends

Saddle Bends

Figure 28

Figure 27

MARK

3

LENGTH

TO

CENTER

ANGLE

LENGTH - Z

L1 L2

2X

ANGLE

MARK

1MARK

2

H

LENGTH TO

2nd BEND

ANGLE

STRAIGHT

SECTION

MARK

3

LENGTH - Z

L1

MARK

1MARK

2MARK

4

L2 + STRIGHT SECTION

L1

H

ANGLE

Cam Track® Hydraulic Bender

Special Bending Tables (in.)

2-1/2" EMT Dia. = 2.875 Radius = 13.9 x = 6.15

ANGLE DIM.HEIGHT (H)

MINIMUM

H

10" 12" 15" 18" 24" 30" 36" 42" 48" 60"

15°

Y25.10 32.83 44.42 56.01 79.19 102.38 125.56 148.74 171.92 218.29

2.54

L1 38.62 46.34 57.93 69.53 92.71 115.89 139.07 162.25 185.44 231.80

L2 42.26 49.98 61.57 73.16 96.35 119.53 142.71 165.89 189.08 235.44

Z47.13 54.59 65.79 76.99 99.38 121.77 144.16 166.56 188.95 233.73

22.5°

Y13.46 18.69 26.53 34.37 50.04 65.72 81.40 97.08 112.76 144.12

4.47

L1 26.06 31.29 39.13 46.97 62.64 78.32 94.00 109.68 125.36 156.72

L2 31.52 36.74 44.58 52.42 68.10 83.78 99.46 115.14 130.82 162.17

Z35.82 40.65 47.89 55.14 69.62 84.11 98.59 113.08 127.56 156.53

30°

Y7.25 11.25 17.25 23.25 35.25 47.25 59.25 71.25 83.25 107.25

6.80

L1 19.83 23.83 29.83 35.83 47.83 59.83 71.83 83.83 95.83 119.83

L2 27.11 31.11 37.11 43.11 55.11 67.11 79.11 91.11 103.11 127.11

Z30.92 34.38 39.58 44.78 55.17 65.56 75.95 86.35 96.74 117.52

45°

Y3.03 7.27 11.52 20.00 28.49 36.97 45.46 53.94 70.91

12.49

L1 16.37 20.62 24.86 33.34 41.83 50.31 58.80 67.28 84.25

L2 27.29 31.53 35.77 44.26 52.75 61.23 69.72 78.20 95.17

Z29.67 32.67 35.67 41.67 47.67 53.67 56.67 65.67 77.67

60°

Y1.49 4.95 11.88 18.81 25.73 32.66 39.59 53.45

19.23

L1 26.22 33.15 40.07 47.00 53.93 67.79

L2 40.77 47.70 54.63 61.56 68.49 82.34

Z36.06 39.52 42.98 46.45 49.91 56.84

90°

Y2.51 8.51 14.51 20.51 26.51 38.51

33.95

L1 30.03 36.03 42.03 54.03

L2 51.87 57.87 63.87 75.87

Z33.95 33.95 33.95 33.95

3" EMT Dia. = 3.5 Radius = 16.48 x = 5.77

ANGLE DIM.HEIGHT (H)

MINIMUM

H

10" 12" 15" 18" 24" 30" 36" 42" 48" 60"

15°

Y23.94 31.66 43.25 54.85 78.03 101.21 124.39 147.57 170.76 217.12

2.62

L1 38.61 46.34 57.93 69.52 92.70 115.89 139.07 162.25 185.43 231.80

L2 42.93 50.65 62.25 73.84 97.02 120.20 143.38 166.57 189.75 236.11

Z47.43 54.89 66.09 77.29 99.68 122.07 144.46 166.86 189.25 234.03

22.5°

Y12.51 17.74 25.58 33.42 49.09 64.77 80.45 96.13 111.81 143.17

4.72

L1 26.05 31.27 39.11 46.95 62.63 78.31 93.99 109.67 125.35 156.70

L2 32.52 37.74 45.58 53.42 69.10 84.78 100.46 116.14 131.82 163.17

Z36.47 41.30 48.54 55.78 70.27 84.75 99.24 113.72 128.21 157.18

30°

Y6.31 10.31 16.31 22.31 34.31 46.31 58.31 70.31 82.31 106.31

7.30

L1 19.80 23.80 29.80 35.80 47.80 59.80 71.80 83.80 95.80 119.80

L2 28.43 32.43 38.43 44.43 56.43 68.43 80.43 92.43 104.43 128.43

Z31.92 35.39 40.58 45.78 56.17 66.56 76.96 87.35 97.74 118.52

45°

Y1.90 6.14 10.38 18.87 27.36 35.84 44.33 52.81 69.78

13.73

L1 20.50 24.75 33.23 41.72 50.20 58.69 67.17 84.14

L2 33.45 37.69 46.18 54.66 63.15 71.63 80.12 97.09

Z34.42 37.42 43.42 49.42 55.42 61.42 67.42 79.42

60°

Y0.02 3.48 10.41 17.34 24.26 31.19 38.12 51.98

21.48

L1 25.94 32.87 39.80 46.73 53.65 67.51

L2 43.20 50.13 57.06 63.98 70.91 84.77

Z38.66 42.12 45.58 49.05 52.51 59.44

90°

Y0.00 6.00 12.00 18.00 24.00 36.00

38.73

L1 34.93 40.93 52.93

L2 60.81 66.81 78.81

Z38.73 38.73 38.73

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