Greenlee 881 & 881CT Cam Trak Hydraulic Bender Manual Manuel utilisateur

INSTRUCTION MANUAL

881 and 881CT Cam Track

®

Hydraulic Benders

and 1813 Bending Table

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

Register this product at www.greenlee.com

Español ............... 33

Français .............. 65

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

2

Description

The 881 and 881CT Cam Track

®

Hydraulic Benders

are intended to bend rigid conduit, IMC (intermediate

metallic conduit), EMT (electrical metallic conduit), and

Schedule 40 pipe. Bending shoes, follow bars, and

saddles are available for bending 2-1/2" through 4"

conduit or pipe.

The bender is to be coupled to any Greenlee hydraulic

pump capable of developing 10,000 psi with a usable oil

volume of 6 quarts or more. Suggested pumps include

the following models:

• Electric Pump (120 volt): 960 SAPS, 980

• Electric Pump (220 volt): 980-22FS, 980-22PS

Safety

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. Observe all of the safety information

provided.

Purpose of this Manual

This instruction manual is intended to familiarize opera-

tors and maintenance personnel with the safe operation

and maintenance procedures for the Greenlee 881 and

881CT Cam Track

®

Hydraulic Benders.

Keep this manual available to all personnel.

Replacement manuals are available upon request at no

charge at www.greenlee.com.

All specications are nominal and may change as design

improvements occur. Greenlee Tools, Inc. shall not be liable for

damages resulting from misapplication or misuse of its products.

Cam Track is a registered trademark of Greenlee Tools, Inc.

KEEP THIS MANUAL

Table of Contents

Description .................................................................... 2

Safety ............................................................................ 2

Purpose of this Manual ................................................. 2

Important Safety Information .....................................3–4

Identication—Major Components ............................... 5

Assembly and Operation Instructions ......................6–20

881 and 881CT Floor Operation .............................6–9

881 and 881CT with 1813 Bending Table ........... 10–20

Glossary of Bending Terms ......................................... 21

Laying Out One-Shot 90° Bends ................................. 22

Table 2—Deduct, Stub Dimensions, and

Minimum Distance from End of Conduit ..................... 22

Table 3—Ram Travel .................................................... 23

Table 4—Laying Out Two-Shot 90° Bends

for 3-1/2" and 4" Conduit (881 only) ........................... 24

Laying Out Bends ................................................... 25–27

Stubs ........................................................................ 25

Offsets ................................................................25–26

Saddles ...............................................................26–27

U-Bends ................................................................... 27

Special Bending Information Chart ........................28–31

Troubleshooting ........................................................... 32

Spanish ...................................................................33–64

French ....................................................................65–96

Illustrations and Parts Lists ..................................97–104

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

3

IMPORTANT SAFETY INFORMATION

SAFETY

ALERT

SYMBOL

This symbol is used to call your attention to hazards

or unsafe practices which could result in an injury or

property damage. The signal word, dened below,

indicates the severity of the hazard. The message

after the signal word provides information for pre-

venting or avoiding the hazard.

Immediate hazards which, if not avoided, WILL result

in severe injury or death.

Hazards which, if not avoided, COULD result in

severe injury or death.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

Read and understand all of the

instructions and safety information

in this manual before operating or

servicing this tool.

Failure to observe this warning could

result in severe injury or death.

Use only Greenlee shoes and components when

operating this bender. Other manufacturers’ shoes

and components may fail during operation, propelling

broken parts with great force.

Failure to observe this warning could result in severe

injury or death.

Pinch points:

Keep hands away from bending shoe,

follow bar, saddle, conduit, and other

moving parts when bender is in use.

Failure to keep hands away from

these areas could result in serious

injury.

Wear eye protection when operating

the bender.

Failure to wear eye protection could

result in serious eye injury from ying

debris or hydraulic oil.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

4

Do not operate while wearing loose clothing.

Loose clothing could get caught in moving parts.

Failure to observe this warning could result in severe

injury.

Do not stand in direct line with the hydraulic ram.

A component failure could propel parts with great

force, striking nearby personnel.

Failure to observe this warning could result in severe

injury or death.

Do not stand in direct line with the follow bar.

A component failure could propel the follow bar with

great force, striking nearby personnel.

Failure to observe this warning could result in severe

injury or death.

Inspect the bender, pump, and hose before each

use. Replace damaged, worn, or missing parts with

Greenlee replacement parts; a damaged or worn

component may fail and strike nearby personnel.

Some bender parts and accessories are heavy and

require more than one person to lift and assemble.

Failure to observe this precaution may result in injury

or property damage.

Make sure all hose ttings are properly seated before

starting the bend. Incomplete connections may not

allow the ram to retract after the bend is complete.

Follow the instructions and safety information

supplied with your hydraulic pump.

Note: Keep all decals clean and legible, and replace

when necessary.

IMPORTANT SAFETY INFORMATION

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

5

Identiﬁcation—Major Components

881 and 881CT Hydraulic Benders

Saddle

Follow Bar

Shoe

E

Yoke (B)

Yoke Pin (G)

Ram (A)

Spring Clip (H)

Roller Unit (D)

Hitch Pin Clips (E)

Cylinder Block Pin Unit (F)

Connecting Bar Unit (C)

Saddle Pin Unit (M)

1813 Bending Table

Ram Positioner (33) Pipe Vise Unit (38) Leg Support Unit (23)

Leg (25)

Pump Table Support (26)

Bender Mounting Unit (27)

Pipe Clamp (34)

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

6

Assembly and Operation Instructions

881 and 881CT—Floor Operation (refer to “Identiﬁcation—Major Components”)

1. Lay out the connecting bars (C), roller unit (D), and

two hitch pin clips (E).

Connecting Bar

with Bending

Instructions

Decals

2. Attach the roller unit to one of the connecting bars

with a hitch pin clip, as shown.

4. Position the ram and cylinder block so that, from the

operator’s point of view, the ram scale is up and to

the left of the ram.

3. Repeat Step 2 for the other connecting bar.

5. Attach the yoke (B) to the ram with the spring clip (H).

Decals face

outward

Ram

Travel

Scale

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

7

Assembly and Operation Instructions

881 and 881CT—Floor Operation (cont’d)

6. Select the shoe for the size of conduit to be bent.

Insert the shoe with the shoe size marking facing

up. Apply a light coat of high pressure grease to the

yoke pin then align either the EMT or Rigid/IMC hole

with the yoke and insert the yoke pin (G). Secure the

yoke pin with a hitch pin clip (E).

7. Remove one hitch pin clip from the roller shaft.

8. Lift the connecting bar and insert the follow bar.

Note: Insert the end marked START.

9. Reinsert the hitch pin clip into the roller shaft.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

8

Assembly and Operation Instructions

881 and 881CT—Floor Operation (cont’d)

Bending Mark

Saddle Insert Saddle

10. Attach the hose (L) to the pump and ram.

11. Make sure the shoe and follow bar grooves are

clean. Insert the conduit into the bender.

12. Set the conduit into the groove of the shoe. Rotate

the shoe as necessary to align the saddle with the

shoe. Position the saddle so the saddle insert is

toward the operator, as shown. Attach the saddle to

the shoe with the saddle pin unit (M); secure the pin

unit with the hitch pin clip (E).

Note: Align the bending mark on the conduit with

the outside edge of the saddle insert.

13. Rotate the pump control lever counterclockwise.

Activate the hydraulic pump until the shoe just con-

tacts the conduit. Check that the saddle and follow

bar are snug. Be sure that the follow bar contacts

the saddle. Be sure that the bending mark on the

conduit is aligned with the front edge of the saddle

insert. Calibrate the bender (refer to “Calibrate

Bender Before Bending” under “Table 3—Ram

Travel”).

Activate the hydraulic pump to begin the bend.

14. 10° of bend.

Follow the instructions and safety information

supplied with your hydraulic pump.

The instructions provided here apply to Greenlee

960 (shown in the illustrations) and 980 (not shown)

hydraulic pumps only.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

9

Assembly and Operation Instructions

881 and 881CT—Floor Operation (cont’d)

15. 45° of bend.

17. 90° of bend.

16. 60° of bend.

18. Release the hydraulic pressure. The ram will retract.

20. The 90° bend is complete.

19. Remove the saddle pin.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

10

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (refer to “Identiﬁcation—Major Components”)

1. Lay out the connecting bars (C), roller unit (D), and

two hitch pin clips (E).

Connecting Bar

with Bending

Instructions

Decals

2. Attach the roller unit to one of the connecting bars

with a hitch pin clip, as shown.

4. Insert 29" leg (25) into leg support unit (23). Tighten

the cap screw (24). Repeat for the other three legs.

5. Insert two 10-foot lengths of IMC or rigid conduit

into

the leg support unit (23). Tighten four cap screws

(24).

Note: These lengths of conduit are not furnished

with the 1813 Bending Table.

3. Repeat Step 2 for the other connecting bar.

6. Position the bender mounting unit (27) as shown,

and slide it, tabs rst, onto the two 10-foot conduits.

Decals face

outward

Tabs

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

11

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (cont’d)

15"

7. Position the bender mounting unit 15" from the

leg support unit. Tighten the two bender mounting

unit screws (28).

8. Slide the pipe vise unit (38) onto the two 10-foot

conduits, as shown.

9. Attach the second leg support unit (23) to the

10-foot conduits. Tighten the four screws (24).

10. Hang the two pipe clamps (34) over each of the

10-foot conduits. Set the pipe clamps 5" and 12"

from the bender mounting unit. Mount the pump

supports (26) onto the clamps. Do not tighten

the clamps.

Pipe Clamp

5"

Pump Support Unit

12"

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

12

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (cont’d)

Pump

Reservoir

Pump

Bracket

11 and 12. Level the table at both ends.

13. Remove the rubber feet/casters from the pump.

Attach the pump bracket (64) to the pump with the

pump bracket mounting hardware (40–43). See

illustration.

14. Slide the pump onto the pump supports. Tighten

the screws on the lower sides of the pump brackets

to secure the pump. Verify that the pump supports

are 5" and 12" from the bender mounting unit.

Tighten the pipe clamp screws.

15 and 16. Load the connecting bar and roller unit into

the bender mounting unit.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

13

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (cont’d)

START

17. Insert the follow bar into the bender with the end

marked START, as shown.

18. Support the rear of the follow bar on the pipe

vise unit.

21. Attach the hydraulic tting unit (29) to the ram, and

connect the hose to the tting unit. Set the cylinder

and yoke unit on the follow bar. Rotate the pump

control lever counterclockwise.

19 and 20. Insert the ram positioner (33).

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

14

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (cont’d)

22. Activate the hydraulic pump to extend the ram

approximately 14". DO NOT OVER EXTEND. Attach

the yoke to the ram positioner with the yoke pin (G).

Secure the yoke pin with a hitch pin clip (E).

23. Insert one cylinder block pin (F) into the hole marked

3" CONDUIT as shown.

24 and 25. Swing the ram unit into position.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

15

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (cont’d)

Saddle Pin

26. Remove the cylinder block pin from the 3" conduit

hole in the connecting bar. Rotate the pump control

lever clockwise to retract the ram. Position the

cylinder block at the proper location for the size of

conduit to be bent. Insert the two cylinder block

pins (F) through the connecting bars and through

the cylinder block. Secure the pins with two hitch

pin clips (E).

27. Remove the yoke pin from the ram positioner.

29. Load the shoe into the bender with the saddle pin

hole to the left, as shown.

28. Remove the ram positioner from the connecting

bar unit.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

16

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (cont’d)

30. Rotate the pump control lever counterclockwise.

Activate the hydraulic pump to advance the shoe

until the yoke is aligned with the proper shoe yoke

pin hole (EMT or IMC/Rigid).

31. Apply a light coat of high pressure grease to

lubricate the yoke pin, then attach the yoke to the

shoe with the yoke pin (G). Secure the yoke pin with

a hitch pin clip (E).

32. Rotate the pump control lever clockwise to retract

the ram.

33. Remove the vise unit from its position below the

follow bar. Slide the vise unit to the far end of the

bending table.

34. Insert the conduit to be bent. Rotate the pump

control

lever counterclockwise and advance the

shoe until it nearly contacts the conduit.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

17

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (cont’d)

Saddle

Saddle Insert Saddle

Align bending mark with

front edge of saddle insert.

35. Position the vise unit at a distance from the pump

support so that the vise unit will not contact the

pump support before the bend is complete. Clamp

the conduit down in the vise unit.

36. Push the follow bar back (to the right in the illustra-

tion) until the follow bar foot contacts the bender

mounting unit. Position the saddle and saddle pin

(M) where they can be reached for assembly.

37. Rock the bender frame as shown and rotate the

shoe back for the assembly of the saddle and pin.

38. Hold the shoe against the conduit and position the

saddle so the saddle insert is toward the operator.

Align the hole in the saddle with the hole in the shoe

and insert the saddle pin (M). Secure the saddle pin

with the hitch pin clip (E).

39. Allow the bender to rock forward and ensure that

the follow bar comes forward with it, so that the

follow bar contacts the saddle.

40. Rotate the pump control lever counterclockwise.

Activate the hydraulic pump until the shoe just con-

tacts the conduit. Check that the saddle and follow

bar are snug, and that the follow bar is against the

saddle, as shown. Be sure that the bending mark

on the conduit is aligned with the front edge of

the saddle insert. Attach the model 1805 Bending

Degree Indicator (35) to the conduit. Zero the indica-

tor by rotating the degree wheel.

Follow the instructions and safety information

supplied with your hydraulic pump.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

18

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (cont’d)

41. Activate the hydraulic pump to begin the bend.

43. 30° of bend.

42. 15° of bend.

44. 45° of bend.

46. 75° of bend.

45. 60° of bend.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

19

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (cont’d)

47. 90° of bend.

49. Rotate the pump control lever clockwise to retract

the shoe.

48. Remove the 1805 Bending Degree Indicator.

50. Push the follow bar back to the start position.

52. Release the vise chain.

51. Remove the saddle pin and saddle.

881 and 881CT Hydraulic Benders

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

20

Assembly and Operation Instructions

881 and 881CT with 1813 Bending Table (cont’d)

53. Remove the conduit from the bender.

54 and 55. The 90° bend is complete.

56. To change the follow bar, twist and remove.

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