Greenlee Pipe And Tube Bender 782 Im823rev08 1f489
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INSTRUCTION MANUAL
782 Pipe and Tubing Bender Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.
999 6453.8
© 2000 Greenlee Textron
IM 823 REV 8 4/00
782 Pipe and Tubing Bender Table of Contents
Safety
Description ..................................................................... 2
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.
Safety ............................................................................. 2 Purpose .......................................................................... 2 Important Safety Information ......................................... 3 Setup ........................................................................... 4-5 Bending Pipe and Tubing .............................................. 6 Illustrated Bending Glossary ...................................... 7 Laying Out a Single Bend ........................................... 8
Purpose
Laying Out Offset Bends ....................................... 9-11
This instruction manual is intended to familiarize personnel with the safe operation and maintenance procedures for the Greenlee 782 Pipe and Tubing Bender.
Illustration and Parts List – Bender ......................... 12-13 Illustration and Parts List – Ram ............................. 14-15 Accessories ............................................................. 16-17
Keep this manual available to all personnel. Replacement manuals are available upon request at no charge. and
are ed trademarks of
Greenlee Textron.
Description The Greenlee 782 Pipe and Tubing Bender is a hydraulic-powered tool intended for bending various types of pipe and tubing, as follows: • Aluminum, brass, copper and steel tubing, 3/4" - 2-1/8" outside diameter, with 1/16" minimum wall thickness • Bendable stainless steel tubing, 3/4" - 1-1/2" outside diameter, with wall thickness from .065" to .150" • Schedule 40 pipe, Schedule 40S stainless steel pipe and Schedule 10S bendable stainless, 1/2" - 2" outside diameter • Schedule 5S bendable stainless steel pipe, 1/2" - 1-1/4" outside diameter The 782 Pipe and Tubing Bender is to be coupled to any Greenlee hydraulic pump capable of developing 700 Bar (10,000 psi). Suggested pumps include: Manual:
755 Hand Pump
Electric:
960 Electric Pump 975 Electric Pump 976-22 Electric Pump (220-Volt) 980 Electric Pump 980-22 Electric Pump (220-Volt)
KEEP THIS MANUAL Greenlee Textron / Subsidiary of Textron Inc.
2
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender
IMPORTANT SAFETY INFORMATION SAFETY ALERT SYMBOL
Wear eye protection when operating or servicing this tool. Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil.
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, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard.
• Do not stand in direct line with the hydraulic ram. A component failure could propel parts with sufficient force to cause severe injury or death. • Do not operate the bender while wearing loose clothing. Loose clothing can get caught in moving parts.
Immediate hazards which, if not avoided, WILL result in severe injury or death.
Failure to observe these warnings can result in severe injury or death.
Hazards which, if not avoided, COULD result in severe injury or death. Do not change accessories, inspect, adjust or clean tool when it is connected to a power source. Accidental start-up can result in serious injury. Failure to observe this warning can result in severe injury or death.
Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage.
• Pipe or tubing moves rapidly as it is bent. The path of the pipe or tubing must be clear of obstructions. Be sure clearance is adequate before starting the bend.
Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.
• Inspect the bender, pump, and hose before each use. Replace, worn, damaged, or missing parts with Greenlee replacement parts. A damaged or improperly assembled component could break and strike nearby personnel.
Failure to observe this warning will result in severe injury or death.
• Some bender parts and accessories are heavy and may require more than one person to lift and assemble. Failure to observe these precautions can result in injury or property damage.
Pinch points: Keep hands away from bending shoe, follow bar, saddle, and conduit when bender is in use.
Ensure that all hose fittings are properly seated before starting the bend. Incomplete connections may not allow the ram to retract after the bend is complete.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Setup 1. Use the ram pin to attach the yoke to the ram. Ram Pin
Yoke
Ram
2. Place the cylinder block of the ram between the two connecting bars.
• Place the lower connecting bar, which has two feet, on the opposite side of the ram scale. • Place the upper connecting bar, which has the pin holes marked, on the same side of the ram as the ram scale.
Upper Connecting Bar (pin hole markings face up) Ram Scale
Lower Connecting Bar (feet face down)
3. Secure the connecting bars to the cylinder block with the cylinder pins. Secure the cylinder head pins in place with the spring clips. Cylinder Head Pins
Spring Clips
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Setup (cont’d) 7. Connect the high-pressure hydraulic hose to the ram and to the pump (not shown). Note: Clean the quick-change couplers before making the connections. Hand-tighten the coupling firmly until all of the threads are engaged. Do not use tools.
4. Install the roller between the connecting bars. Align the roller with the appropriate hole and secure it with the roller pin. Secure the roller pin by turning the locking pin over the ball.
Follow the instructions and safety information supplied with your hydraulic pump.
5. Select the shoe, saddle and follow bar that correspond to the size of pipe or tubing to be bent. 6. Attach the shoe to the yoke with the yoke pin. Slide the follow bar between the shoe and the roller. Place the pipe or tubing between the shoe and follow bar. Attach the saddle to the shoe with the appropriate saddle pin.
Follow Bar
Saddle Pin
Yoke Pin
Saddle Shoe
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Bending Pipe and Tubing 6. Advance the ram until the ram has traveled the distance found in Step 4.
1. Use the hydraulic pump to advance the ram until the shoe s the tubing. Apply slight pressure to the ram. Loosen the ram travel scale nut; set the ram travel scale, which is read at the edge of the block, to zero. Tighten the nut.
7. Release the hydraulic pressure at the pump and move the tubing to the next bending position. Note: If making an offset bend, rotate the tubing 180° before making the second bend. If making a three-bend saddle, rotate the tubing 180° before making the second and third bends. If making a four-bend saddle, rotate the tubing 180° before making the second and fourth bends.
2. Mark the pipe or tubing. See the instructions in this manual for marking the pipe or tubing for the necessary bend. 3. Insert the pipe or tubing into the bender. Align bending mark with the center of the bending shoe. 4. Consult the Ram Travel Table to find the amount of ram travel necessary to accomplish the bend.
8. Repeat Steps 6 and 7 until the last bend is made. 9. Remove the pipe or tubing from the bender.
5. Use the hydraulic pump to advance the ram until the shoe, follow bar, and saddle are snug. Check the setup to be sure that: • the follow bar is in with the saddle • the bending mark on the pipe or tubing is aligned with the front edge of the saddle
Approximate Ram Travel Table for Common Bends Pipe Size
Use Hole No.
11-1/4°
15°
22-1/2°
30°
45°
60°
75°
90°
1/2"
1
1-3/8+
1-1/2
1-5/8
1-13/16
2-3/16
2-9/16
2-7/8
3-13/16
3/4"
2
3
3-1/8
3-1/4
3-1/2
3-15/16
4-3/8
4-13/16
5-1/4
1"
2
1-5/16
1-7/16
1-11/16
2
2-9/16
3-1/16
3-5/8
4-3/4
1-1/4"
4
2-3/8
2-1/2
2-13/16
3-1/8
3-3/4
4-7/16
5
5-1/2
1-1/2"
5
2-1/4
2-7/16
2-3/4
3-3/16
4
4-3/4
5-1/2
6-1/8
2"
6
2-1/4+
2-1/2+
2-7/8
3-1/4
4-1/8
5
5-3/4
6-3/8
Centerline Bending Radii Shoe Size
Bending Radius (Inches)
Bending Radius (millimeters)
1/2"
3-7/8
98.4
3/4"
4-9/32
109
1"
4-7/8
124
1-1/4"
5-5/8
143
1-1/2"
8-3/16
208
2"
9-7/16
240
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Illustrated Bending Glossary 9. height of offset - same as amount of offset
1. amount of offset - the distance that the pipe or tubing must be re-routed to avoid an obstruction; see offset bend in this glossary and Offset Bending Instructions in this manual
10. kick - a single bend of less than 90° 11. leg length - the distance from the end of a straight section of pipe or tubing to the bend; measured from the end to outside edge of the pipe or tubing.
2. back-to-back bend - any U-shaped bend formed by two parallel 90-degree bends with a straight section between the bends
12. offset bend - two opposite bends with the same degree of bend; used to avoid an obstruction
3. center-to-center distance the distance between the successive bends that make up an offset or a three-bend saddle
13. ram travel - the distance that the ram of a hydraulic bender must move to accomplish a particular bend
4. deduct - sometimes called “comeback” 5. depth of offset - same as amount of offset
14. rise - the distance from the end of a straight section of pipe or tubing to the bend; measured from the end to the center line of the pipe or tubing; also called “stub” or “stub-up”
6. developed length - the actual length of pipe that will be bent; see distance “d” in the following illustration 7. follow bar - a component common to rotary hydraulic benders; the follow bar s and follows the pipe or tubing during the bending process
15. saddle or saddle bend a three-bend or four-bend combination; used to avoid an obstruction 16. shot - a single bend
r
8. gain - the difference between the straight-line distance (a + a) and the shorter radial distance (d) where
θ
17. shrink - the amount of pipe or tubing “lost” when laying out an offset bend working toward an obstruction; see the explanation under Offset Bending in this manual
ø = angle of bend
d a
a
r = the centerline bending radius of the bending shoe
18. springback - the amount, measured in degrees, that pipe or tubing tends to straighten after being bent
Greenlee Textron / Subsidiary of Textron Inc.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Laying Out a Single Bend 1. Measure the length of the required stub. 2. Find the minimum stub length of that diameter of pipe or tubing on the Deduct and Minimum Stub Length Table. The stub you require must be equal to or longer than the minimum stub length. Note: Refer to LC if measuring at the centerline, LB if measuring at the outside radius, and LT if measuring at the inside radius. 3. Measure and mark the stub length on the conduit. This is mark 1. Subtract the deduct from the stub and mark the conduit. This is mark 2, or the bending mark. 4. Insert the pipe or tubing into the bender so that mark 2, the bending mark, lies at the leading edge of the saddle. 5. Bend the conduit. To achieve the desired angle, refer to the Ram Travel Table for Common Bends in this manual.
Deduct and Minimum Stub Length Table Pipe Size
LC
G
LB
H
LT
K
(Minimum Stub Length)
(Deduct)
Minimum Stub Length)
(Deduct)
(Minimum Stub Length)
(Deduct)
1/2"
7-1/2
4-9/16
8
5
7-1/8
4-1/8
3/4"
8-1/2
5-1/4
9
5-3/4
8
4-11/16
1"
9-3/8
6-3/8
10
7
8-11/16
5-3/4
1-1/4"
10-1/4
6-3/4
11
7-1/2
9-3/8
5-7/8
1-1/2"
12
9
13-5/8
10
11-3/4
8-1/8
2"
14
10
15-3/8
11-1/4
13
9-7/8
Example:
1-1/2" pipe 15" stub, measured at the outside radius of the pipe
Use the LC and G columns:
that the stub is greater than LC : 15 > 12 Measure the stub length (15") from the end of the pipe. Make mark 1. Deduct G (9") from mark 1. Make mark 2.
Greenlee Textron / Subsidiary of Textron Inc.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Laying Out Offset Bends “X” Dimension Table
An offset is used to route the conduit around an obstruction. To make an offset, two bends are required. The operator must measure the height of the offset and determine the angle of the offset. The distance between the two bends is the center-to-center distance.
Pipe Size
“X” Dimension
1/2"
2-1/2"
3/4"
2-1/2"
Measure the obstruction.
1"
2-1/2"
Determine the angle of the offset bends.
1-1/4"
2-1/2"
To calculate the center-to-center distance, multiply the offset height angle by the cosecant that corresponds to the cosecant. See the Cosecant Table.
1-1/2"
2-1/2"
2"
2-1/2"
Measure the distance from the end of the pipe to the obstruction. Mark this distance on the pipe. This is mark 1.
Cosecant Table Angle 1° 2° 3° 4° 5° 6° 7° 8° 9° 10° 11° 12° 13° 14° 15° 16° 17° 18° 19° 20° 21° 22° 23° 24° 25° 26° 27° 28° 29° 30°
Find the “X” dimension on the “X” Dimension Table. Measure “X” inches from mark 1 and mark the conduit. This is mark 2. From mark 2, measure the center-to-center distance on the pipe and make mark 3. See bending instructions under “Bending Conduit” in this manual.
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Cosecant 57.299 28.654 19.107 14.335 11.474 9.5668 8.2055 7.1853 6.3924 5.7588 5.2408 4.8097 4.4454 4.1336 3.8637 3.6279 3.4203 3.2361 3.0715 2.9238 2.7904 2.6695 2.5593 2.4586 2.3662 2.2812 2.2027 2.1300 2.0627 2.0000
Angle 31° 32° 33° 34° 35° 36° 37° 38° 39° 40° 41° 42° 43° 44° 45° 46° 47° 48° 49° 50° 51° 52° 53° 54° 55° 56° 57° 58° 59° 60°
Cosecant 1.9416 1.8871 1.8361 1.7883 1.7434 1.7013 1.6616 1.6243 1.5890 1.5557 1.5242 1.4945 1.4663 1.4395 1.4142 1.3902 1.3673 1.3456 1.3250 1.3054 1.2867 1.2690 1.2521 1.2361 1.2208 1.2062 1.1924 1.1792 1.1666 1.1547
Angle 61° 62° 63° 64° 65° 66° 67° 68° 69° 70° 71° 72° 73° 74° 75° 76° 77° 78° 79° 80° 81° 82° 83° 84° 85° 86° 87° 88° 89° 90°
Cosecant 1.1433 1.1326 1.1223 1.1126 1.1034 1.0946 1.0864 1.0785 1.0711 1.0642 1.0576 1.0515 1.0457 1.0403 1.0353 1.0306 1.0263 1.0223 1.0187 1.0154 1.0125 1.0098 1.0075 1.0055 1.0038 1.0024 1.0014 1.0006 1.0001 1.0000
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Laying Out Offset Bends (cont’d)
Size
Quick-Reference Gain Table
Radius
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
4"
4-1/2"
5-3/4"
7-1/4"
8-1/4"
9-1/2"
Angle 23°
.05"
24°
.05"
.06"
25°
.05"
.06"
.07"
26°
.06"
.07"
.08"
27°
.05"
.06"
.07"
.09"
28°
.06"
.07"
.08"
.10"
29°
.05"
.06"
.08"
.09"
.11"
30°
.06"
.07"
.09"
.10"
.12"
31°
.05"
.06"
.08"
.10"
.11"
.13"
32°
.06"
.07"
.09"
.11"
.12"
.14"
33°
.06"
.07"
.09"
.12"
.14"
.16"
34°
.07"
.08"
.10"
.13"
.15"
.17"
35°
.08"
.09"
.11"
.14"
.16"
.19"
36°
.09"
.10"
.12"
.16"
.18"
.20"
37°
.09"
.11"
.14"
.17"
.19"
.22"
38°
.10"
.11"
.15"
.18"
.21"
.24"
39°
.11"
.12"
.16"
.20"
.23"
.26"
40°
.12"
.13"
.17"
.22"
.25"
.28"
41°
.13"
.14"
.19"
.23"
.27"
.31"
42°
.14"
.16"
.20"
.25"
.29"
.33"
43°
.15"
.17"
.21"
.27"
.31"
.35"
44°
.16"
.18"
.23"
.29"
.33"
.38"
45°
.17"
.19"
.25"
.31"
.36"
.41"
46°
.18"
.21"
.27"
.33"
.38"
.44"
47°
.20"
.22"
.28"
.36"
.41"
.47"
48°
.21"
.24"
.30"
.38"
.44"
.50"
To use this table: Determine the gain by finding the intersection of the appropriate row (which shows bend angles from 18 ° - 48 °) and the appropriate column (which shows the size of each shoe). The number at this intersection shows the amount of gain for the bend. Example: 40 ° bend 1-1/2" pipe Gain: .25" of gain
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Laying Out Offset Bends (cont’d) Gain Factor Table 0°
1°
2°
3°
4°
5°
6°
7°
8°
9°
0°
.0000
.0000
.0000
.0000
.0000
.0000
.0001
.0001
.0003
.0003
10°
.0005
.0006
.0008
.0010
.0013
.0015
.0018
.0022
.0026
.0031
20°
.0036
.0042
.0048
.0055
.0062
.0071
.0079
.0090
.0100
.0111
30°
.0126
.0136
.0150
.0165
.0181
.0197
.0215
.0234
.0254
.0276
40°
.0298
.0322
.0347
.0373
.0400
.0430
.0461
.0493
.0527
.0562
50°
.0600
.0637
.0679
.0721
.0766
.0812
.0860
.0911
.0963
.1018
60°
.1075
.1134
.1196
.1260
.1327
.1397
.1469
.1544
.1622
.1703
70°
.1787
.1874
.1964
.2058
.2156
.2257
.2361
.2470
.2582
.2699
80°
.2819
.1944
.3074
.3208
.3347
.3491
.3640
.3795
.3955
.4121
90°
.4292
–
–
–
–
–
–
–
–
–
To use this table: Find the gain factor by finding the intersection of the appropriate row (“tens” digit of the angle) and appropriate column (“ones” digit of the angle). Multiply the gain factor by the centerline bending radius of the shoe. See the example below. Example: 64 ° bend 9-7/16" centerline radius Correct Row: row labeled “60 °” Correct Column: column labeled “04 °” Gain Factor: .1327 Total Gain for Bend: .1327 x 9-7/16" = 1.25"
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Illustration 782 Pipe and Tubing Bender
Follow Bar 10 9 4,5,6 11,12 3
2 Saddle Shoe 8 7 1
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Parts List 782 Pipe and Tubing Bender Key
UPC No. 78-3310-
Part No.
Description
Qty
1
13251
501 3251.2
Ram, Hydraulic, 27-Ton (includes items 2 - 4) ... 1
2
13252
501 3252.0
Pin Unit, Cylinder Block, .875 x 8.06" ............... 2
3
50302
905 0302.3
Clip, Hitch Pin #8 .............................................. 2
4
10826
501 0826.3
Pin, Adapter, .250 x 3.25" ................................. 1
5
04086
500 4086.3
Pin, Yoke, .995 x 3.62" ...................................... 1
6
06980
500 6980 2
Yoke, Bender ..................................................... 1
7
11083
501 1083.7
Bar Unit, Connecting, Lower ............................. 1
8
06878
500 6878.4
Bar, Connecting, Upper ..................................... 1
9
14094
501 4094.9
Roller, 1.01 x 2.50 x 6.00" ................................. 1
10
14496
501 4496.0
Pin Unit, 1.00 x 8.50" ........................................ 1
11
29937
502 9937.9
Pin, Saddle, .620 x 5.00" ................................... 1
12
02937
500 2937.1
Pin, Saddle, .871 x 6.00" ................................... 1
11289
501 1289.9
Hose Unit, 3/8" x 6' (includes the following two items) ................ 1
50760
905 0760.6
Hose, Hydraulic, 3/8" x 6' with Fittings ......... 1
50823
905 0823.8
Coupler, Quick, Hydraulic, 3/8" Male ............. 2
13382
501 3382.9
Box, Metal, Storage ........................................... 1
(Not Shown)
30390
503 0390.2
Decal, Identification ........................................... 1
34316
503 4316.5
Decal, Read IM .................................................. 1
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Illustration — 27 Ton Ram
B
B
3.75 16 1 17
18
11.75
3
2 19
4 or 4A 8 5 or 5A
10
9
6
4 or 4A
SECTION BB 7 5 or 5A
14 16 13 12 11
15
Greenlee Textron / Subsidiary of Textron Inc.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Parts List - 27 Ton Ram
Key
UPC No. 78-3310-
Part No.
Description
Qty
1
06221
500 6221.2
Scale, Piston ..................................................... 1
2
13220
501 3220.2
Retainer, Spring ................................................ 2
3
50807
905 0807.6
Coupler, Quick, 3/8" .......................................... 1
4*
01717
500 1717.9
Screw, Spring Retainer ..................................... 2
4A
11341
501 1341.0
Screw, Spring Retainer ..................................... 2
5 **
13496
501 3496.5
Washer, Flat, .321 x .460 x .040", Nylon ........... 2
5A
03420
500 3420.0
Washer, Flat, .321 x .428 x .040", Nylon ........... 2
6
13219
501 3219.9
Spring, Extension, 1.44 x 1.94 x 9.25" .............. 1
7
13229
501 3229.6
Cylinder, Hydraulic, 27-Ton .............................. 1
8
14995
501 4495.2
Piston ................................................................ 1
9
51926
905 0192.6
O-Ring, 2.62 x 3.00 x .187", Nitrile ................... 1
10
50193
905 0193.4
Backup Ring, Spiral, 2.62 x 3.00 x .185" ........... 1
11
13228
501 3228.8
Block, Cylinder .................................................. 1
12
50850
905 0850.5
Screw, Machine, #10 - 32 x .312" Flat Head ...... 2
13
21953
502 1953.7
Scale Bracket ..................................................... 1
14
13252
501 3252.0
Pin Unit, Cylinder Block, .875 x 8.06" (includes items 15 and 17) ........................... 2
15
50302
905 0302.3
Clip, Hitch Pin #8 .............................................. 2
16
50843
905 0848.3
Nut, Hex, 3/8 - 24, Light Jam ............................ 1
17
50422
905 0422.4
Roll Pin, .219 x 1.37" ......................................... 2
18
51384
905 1384.3
O-Ring, .375 x .500 x .062" ............................... 1
19
10826
501 0826.3
Pin, Adapter, .250 x 3.25" ................................. 1
12129
501 2121.9
Decal, Greenlee Safety (not shown) .................. 1
*On units manufactured prior to August 1996, use 4A. ** Use nylon washer (item 5) if possible. If the counterbore is too small (0.4425/0.4375), use alternate washer (item 5A).
Greenlee Textron / Subsidiary of Textron Inc.
15
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Accessories Shoe Groups for Tubing Catalog No. TU-G3
TU-G4
TU-G5
TU-G6
TU-G7
TU-G8
TU-G9
TU-G10
TU-G11
TU-G12
TU-G13
TU-G14
UPC No. 78-331002550 11151 14280 16444 02551 11150 11086 16445 06842 11142 11117 16403 02553 11144 11119 16413 02554 11160 11124 16414 02555 11159 11131 16415 02556 11149 11129 16416 02557 11148 11128 11080 02558 20525 20526 16417 02559 11156 11111 11644 02560 11155 11109 11071 02561 11133 11104 11070
Part No. 500 2550.3 501 1151.5 501 4280.1 501 6444.9 500 2551.1 501 1150.7 501 1086.1 501 6445.7 500 6842.3 501 1142.6 501 1117.5 501 6403.1 500 2553.8 501 1144.2 501 1119.1 501 6413.9 500 2554.6 501 1160.4 501 1124.8 501 6414.7 500 2555.4 501 1159.0 501 1131.0 501 6415.5 500 2556.2 501 1149.3 501 1129.9 501 6416.3 500 2557.0 501 1148.5 501 1128.0 501 1080.2 500 2558.9 502 0525.0 502 0526.9 501 6417.1 500 2559.7 501 1156.6 501 1111.6 501 6443.0 500 2560.0 501 1155.8 501 1109.4 501 1071.3 500 2561.9 501 1133.7 501 1104.3 501 1070.5
Greenlee Textron / Subsidiary of Textron Inc.
Description
Qty.
Shoe Group for 3/4" Tubing (includes the following three items) ...... 1 Shoe (3-27/64" Centerline Bending Radius) ..................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 7/8" Tubing (includes the following three items) ...... 1 Shoe (3-27/64" Centerline Bending Radius) ..................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1" Tubing (includes the following three items) ........ 1 Shoe (4-5/16" Centerline Bending Radius) ....................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-1/8" Tubing (includes the following three items) ... 1 Shoe (4-5/16" Centerline Bending Radius) ....................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-1/4" Tubing (includes the following three items) ... 1 Shoe (5-5/8" Centerline Bending Radius) ......................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-3/8" Tubing (includes the following three items) ... 1 Shoe (5-5/8" Centerline Bending Radius) ......................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-1/2" Tubing (includes the following three items) ... 1 Shoe (7-13/16" Centerline Bending Radius) ..................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-5/8" Tubing (includes the following three items) ... 1 Shoe (7-13/16" Centerline Bending Radius) ..................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-3/4" Tubing (Includes the following three items) ... 1 Shoe (8-1/32" Centerline Bending Radius) ....................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-7/8" Tubing (Includes the following three items) ... 1 Shoe (8-1/32" Centerline Bending Radius) ....................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 2" Tubing (Includes the following three items) ........ 1 Shoe (8-1/32" Centerline Bending Radius) ....................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 2-1/8" Tubing (Includes the following three items) ... 1 Shoe (9-17/64" Centerline Bending Radius) ..................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1
16
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Accessories (cont’d) Shoe Groups for Pipe Catalog No.
UPC No. 78-3310-
Part No.
782R-G2
13779
501 3779.4
Shoe Group for 1/2" Pipe (includes the following three items) ......... 1
13742
501 3742.5
Shoe (3-7/8" Centerline Bending Radius) ........................................ 1
782R-G3
782R-G4
782R-G5
782R-G6
782R-G7
Description
Qty.
13743
501 3743.3
Follow Bar ........................................................................................ 1
11078
501 1078.0
Saddle .............................................................................................. 1
02531
500 2531.7
Shoe Group for 3/4" Pipe (includes the following three items) ......... 1
02917
500 2917.7
Shoe (4-9/32" Centerline Bending Radius) ...................................... 1
02919
500 2919.3
Follow Bar ........................................................................................ 1
02921
500 2921.5
Saddle .............................................................................................. 1
06840
500 6840.7
Shoe Group for 1" Pipe (includes the following three items) ........... 1
02922
500 2922.3.
Shoe (4-7/8" Centerline Bending Radius) ........................................ 1
06874
500 6874.1
Follow Bar ........................................................................................ 1
02926
500 2926.6
Saddle .............................................................................................. 1
02537
500 2537.6
Shoe Group for 1-1/4" Pipe (includes the following three items) ...... 1
03064
500 3064.7
Shoe (5-5/8" Centerline Bending Radius) ........................................ 1
02949
500 2949.5.
Follow Bar ........................................................................................ 1
29465
502 9465.2
Saddle .............................................................................................. 1
02537
500 2537.6
Shoe Group for 1-1/2" Pipe (includes the following three items) ...... 1
02947
500 2947.9
Shoe (8-13/16" Centerline Bending Radius) .................................... 1
02951
5002951.7
Follow Bar ........................................................................................ 1
06877
500 6877.6
Saddle .............................................................................................. 1
02537
500 2537.6
Shoe Group for 2" Pipe (includes the following three items) ........... 1
02935
500 2935.5
Shoe (9-7/16" Centerline Bending Radius) ...................................... 1
02953
500 2953.3
Follow Bar ........................................................................................ 1
02943
500 2943.6
Saddle .............................................................................................. 1
Greenlee Textron / Subsidiary of Textron Inc.
17
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Drive, Rockford, IL 61109-2988 USA Customer Service (International): 815/397-7070 • Fax: 815/397-9247 Customer Service (North America): 800/435-0786 • Fax: 800/451-2632, 815/397-1865 Canada Fax: 800/524-2853
Printed in the U.S.A.
782 Pipe and Tubing Bender Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.
999 6453.8
© 2000 Greenlee Textron
IM 823 REV 8 4/00
782 Pipe and Tubing Bender Table of Contents
Safety
Description ..................................................................... 2
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.
Safety ............................................................................. 2 Purpose .......................................................................... 2 Important Safety Information ......................................... 3 Setup ........................................................................... 4-5 Bending Pipe and Tubing .............................................. 6 Illustrated Bending Glossary ...................................... 7 Laying Out a Single Bend ........................................... 8
Purpose
Laying Out Offset Bends ....................................... 9-11
This instruction manual is intended to familiarize personnel with the safe operation and maintenance procedures for the Greenlee 782 Pipe and Tubing Bender.
Illustration and Parts List – Bender ......................... 12-13 Illustration and Parts List – Ram ............................. 14-15 Accessories ............................................................. 16-17
Keep this manual available to all personnel. Replacement manuals are available upon request at no charge. and
are ed trademarks of
Greenlee Textron.
Description The Greenlee 782 Pipe and Tubing Bender is a hydraulic-powered tool intended for bending various types of pipe and tubing, as follows: • Aluminum, brass, copper and steel tubing, 3/4" - 2-1/8" outside diameter, with 1/16" minimum wall thickness • Bendable stainless steel tubing, 3/4" - 1-1/2" outside diameter, with wall thickness from .065" to .150" • Schedule 40 pipe, Schedule 40S stainless steel pipe and Schedule 10S bendable stainless, 1/2" - 2" outside diameter • Schedule 5S bendable stainless steel pipe, 1/2" - 1-1/4" outside diameter The 782 Pipe and Tubing Bender is to be coupled to any Greenlee hydraulic pump capable of developing 700 Bar (10,000 psi). Suggested pumps include: Manual:
755 Hand Pump
Electric:
960 Electric Pump 975 Electric Pump 976-22 Electric Pump (220-Volt) 980 Electric Pump 980-22 Electric Pump (220-Volt)
KEEP THIS MANUAL Greenlee Textron / Subsidiary of Textron Inc.
2
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender
IMPORTANT SAFETY INFORMATION SAFETY ALERT SYMBOL
Wear eye protection when operating or servicing this tool. Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil.
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, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard.
• Do not stand in direct line with the hydraulic ram. A component failure could propel parts with sufficient force to cause severe injury or death. • Do not operate the bender while wearing loose clothing. Loose clothing can get caught in moving parts.
Immediate hazards which, if not avoided, WILL result in severe injury or death.
Failure to observe these warnings can result in severe injury or death.
Hazards which, if not avoided, COULD result in severe injury or death. Do not change accessories, inspect, adjust or clean tool when it is connected to a power source. Accidental start-up can result in serious injury. Failure to observe this warning can result in severe injury or death.
Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage.
• Pipe or tubing moves rapidly as it is bent. The path of the pipe or tubing must be clear of obstructions. Be sure clearance is adequate before starting the bend.
Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.
• Inspect the bender, pump, and hose before each use. Replace, worn, damaged, or missing parts with Greenlee replacement parts. A damaged or improperly assembled component could break and strike nearby personnel.
Failure to observe this warning will result in severe injury or death.
• Some bender parts and accessories are heavy and may require more than one person to lift and assemble. Failure to observe these precautions can result in injury or property damage.
Pinch points: Keep hands away from bending shoe, follow bar, saddle, and conduit when bender is in use.
Ensure that all hose fittings are properly seated before starting the bend. Incomplete connections may not allow the ram to retract after the bend is complete.
Greenlee Textron / Subsidiary of Textron Inc.
3
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Setup 1. Use the ram pin to attach the yoke to the ram. Ram Pin
Yoke
Ram
2. Place the cylinder block of the ram between the two connecting bars.
• Place the lower connecting bar, which has two feet, on the opposite side of the ram scale. • Place the upper connecting bar, which has the pin holes marked, on the same side of the ram as the ram scale.
Upper Connecting Bar (pin hole markings face up) Ram Scale
Lower Connecting Bar (feet face down)
3. Secure the connecting bars to the cylinder block with the cylinder pins. Secure the cylinder head pins in place with the spring clips. Cylinder Head Pins
Spring Clips
Greenlee Textron / Subsidiary of Textron Inc.
4
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Setup (cont’d) 7. Connect the high-pressure hydraulic hose to the ram and to the pump (not shown). Note: Clean the quick-change couplers before making the connections. Hand-tighten the coupling firmly until all of the threads are engaged. Do not use tools.
4. Install the roller between the connecting bars. Align the roller with the appropriate hole and secure it with the roller pin. Secure the roller pin by turning the locking pin over the ball.
Follow the instructions and safety information supplied with your hydraulic pump.
5. Select the shoe, saddle and follow bar that correspond to the size of pipe or tubing to be bent. 6. Attach the shoe to the yoke with the yoke pin. Slide the follow bar between the shoe and the roller. Place the pipe or tubing between the shoe and follow bar. Attach the saddle to the shoe with the appropriate saddle pin.
Follow Bar
Saddle Pin
Yoke Pin
Saddle Shoe
Greenlee Textron / Subsidiary of Textron Inc.
5
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Bending Pipe and Tubing 6. Advance the ram until the ram has traveled the distance found in Step 4.
1. Use the hydraulic pump to advance the ram until the shoe s the tubing. Apply slight pressure to the ram. Loosen the ram travel scale nut; set the ram travel scale, which is read at the edge of the block, to zero. Tighten the nut.
7. Release the hydraulic pressure at the pump and move the tubing to the next bending position. Note: If making an offset bend, rotate the tubing 180° before making the second bend. If making a three-bend saddle, rotate the tubing 180° before making the second and third bends. If making a four-bend saddle, rotate the tubing 180° before making the second and fourth bends.
2. Mark the pipe or tubing. See the instructions in this manual for marking the pipe or tubing for the necessary bend. 3. Insert the pipe or tubing into the bender. Align bending mark with the center of the bending shoe. 4. Consult the Ram Travel Table to find the amount of ram travel necessary to accomplish the bend.
8. Repeat Steps 6 and 7 until the last bend is made. 9. Remove the pipe or tubing from the bender.
5. Use the hydraulic pump to advance the ram until the shoe, follow bar, and saddle are snug. Check the setup to be sure that: • the follow bar is in with the saddle • the bending mark on the pipe or tubing is aligned with the front edge of the saddle
Approximate Ram Travel Table for Common Bends Pipe Size
Use Hole No.
11-1/4°
15°
22-1/2°
30°
45°
60°
75°
90°
1/2"
1
1-3/8+
1-1/2
1-5/8
1-13/16
2-3/16
2-9/16
2-7/8
3-13/16
3/4"
2
3
3-1/8
3-1/4
3-1/2
3-15/16
4-3/8
4-13/16
5-1/4
1"
2
1-5/16
1-7/16
1-11/16
2
2-9/16
3-1/16
3-5/8
4-3/4
1-1/4"
4
2-3/8
2-1/2
2-13/16
3-1/8
3-3/4
4-7/16
5
5-1/2
1-1/2"
5
2-1/4
2-7/16
2-3/4
3-3/16
4
4-3/4
5-1/2
6-1/8
2"
6
2-1/4+
2-1/2+
2-7/8
3-1/4
4-1/8
5
5-3/4
6-3/8
Centerline Bending Radii Shoe Size
Bending Radius (Inches)
Bending Radius (millimeters)
1/2"
3-7/8
98.4
3/4"
4-9/32
109
1"
4-7/8
124
1-1/4"
5-5/8
143
1-1/2"
8-3/16
208
2"
9-7/16
240
Greenlee Textron / Subsidiary of Textron Inc.
6
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Illustrated Bending Glossary 9. height of offset - same as amount of offset
1. amount of offset - the distance that the pipe or tubing must be re-routed to avoid an obstruction; see offset bend in this glossary and Offset Bending Instructions in this manual
10. kick - a single bend of less than 90° 11. leg length - the distance from the end of a straight section of pipe or tubing to the bend; measured from the end to outside edge of the pipe or tubing.
2. back-to-back bend - any U-shaped bend formed by two parallel 90-degree bends with a straight section between the bends
12. offset bend - two opposite bends with the same degree of bend; used to avoid an obstruction
3. center-to-center distance the distance between the successive bends that make up an offset or a three-bend saddle
13. ram travel - the distance that the ram of a hydraulic bender must move to accomplish a particular bend
4. deduct - sometimes called “comeback” 5. depth of offset - same as amount of offset
14. rise - the distance from the end of a straight section of pipe or tubing to the bend; measured from the end to the center line of the pipe or tubing; also called “stub” or “stub-up”
6. developed length - the actual length of pipe that will be bent; see distance “d” in the following illustration 7. follow bar - a component common to rotary hydraulic benders; the follow bar s and follows the pipe or tubing during the bending process
15. saddle or saddle bend a three-bend or four-bend combination; used to avoid an obstruction 16. shot - a single bend
r
8. gain - the difference between the straight-line distance (a + a) and the shorter radial distance (d) where
θ
17. shrink - the amount of pipe or tubing “lost” when laying out an offset bend working toward an obstruction; see the explanation under Offset Bending in this manual
ø = angle of bend
d a
a
r = the centerline bending radius of the bending shoe
18. springback - the amount, measured in degrees, that pipe or tubing tends to straighten after being bent
Greenlee Textron / Subsidiary of Textron Inc.
7
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Laying Out a Single Bend 1. Measure the length of the required stub. 2. Find the minimum stub length of that diameter of pipe or tubing on the Deduct and Minimum Stub Length Table. The stub you require must be equal to or longer than the minimum stub length. Note: Refer to LC if measuring at the centerline, LB if measuring at the outside radius, and LT if measuring at the inside radius. 3. Measure and mark the stub length on the conduit. This is mark 1. Subtract the deduct from the stub and mark the conduit. This is mark 2, or the bending mark. 4. Insert the pipe or tubing into the bender so that mark 2, the bending mark, lies at the leading edge of the saddle. 5. Bend the conduit. To achieve the desired angle, refer to the Ram Travel Table for Common Bends in this manual.
Deduct and Minimum Stub Length Table Pipe Size
LC
G
LB
H
LT
K
(Minimum Stub Length)
(Deduct)
Minimum Stub Length)
(Deduct)
(Minimum Stub Length)
(Deduct)
1/2"
7-1/2
4-9/16
8
5
7-1/8
4-1/8
3/4"
8-1/2
5-1/4
9
5-3/4
8
4-11/16
1"
9-3/8
6-3/8
10
7
8-11/16
5-3/4
1-1/4"
10-1/4
6-3/4
11
7-1/2
9-3/8
5-7/8
1-1/2"
12
9
13-5/8
10
11-3/4
8-1/8
2"
14
10
15-3/8
11-1/4
13
9-7/8
Example:
1-1/2" pipe 15" stub, measured at the outside radius of the pipe
Use the LC and G columns:
that the stub is greater than LC : 15 > 12 Measure the stub length (15") from the end of the pipe. Make mark 1. Deduct G (9") from mark 1. Make mark 2.
Greenlee Textron / Subsidiary of Textron Inc.
8
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Laying Out Offset Bends “X” Dimension Table
An offset is used to route the conduit around an obstruction. To make an offset, two bends are required. The operator must measure the height of the offset and determine the angle of the offset. The distance between the two bends is the center-to-center distance.
Pipe Size
“X” Dimension
1/2"
2-1/2"
3/4"
2-1/2"
Measure the obstruction.
1"
2-1/2"
Determine the angle of the offset bends.
1-1/4"
2-1/2"
To calculate the center-to-center distance, multiply the offset height angle by the cosecant that corresponds to the cosecant. See the Cosecant Table.
1-1/2"
2-1/2"
2"
2-1/2"
Measure the distance from the end of the pipe to the obstruction. Mark this distance on the pipe. This is mark 1.
Cosecant Table Angle 1° 2° 3° 4° 5° 6° 7° 8° 9° 10° 11° 12° 13° 14° 15° 16° 17° 18° 19° 20° 21° 22° 23° 24° 25° 26° 27° 28° 29° 30°
Find the “X” dimension on the “X” Dimension Table. Measure “X” inches from mark 1 and mark the conduit. This is mark 2. From mark 2, measure the center-to-center distance on the pipe and make mark 3. See bending instructions under “Bending Conduit” in this manual.
Greenlee Textron / Subsidiary of Textron Inc.
9
Cosecant 57.299 28.654 19.107 14.335 11.474 9.5668 8.2055 7.1853 6.3924 5.7588 5.2408 4.8097 4.4454 4.1336 3.8637 3.6279 3.4203 3.2361 3.0715 2.9238 2.7904 2.6695 2.5593 2.4586 2.3662 2.2812 2.2027 2.1300 2.0627 2.0000
Angle 31° 32° 33° 34° 35° 36° 37° 38° 39° 40° 41° 42° 43° 44° 45° 46° 47° 48° 49° 50° 51° 52° 53° 54° 55° 56° 57° 58° 59° 60°
Cosecant 1.9416 1.8871 1.8361 1.7883 1.7434 1.7013 1.6616 1.6243 1.5890 1.5557 1.5242 1.4945 1.4663 1.4395 1.4142 1.3902 1.3673 1.3456 1.3250 1.3054 1.2867 1.2690 1.2521 1.2361 1.2208 1.2062 1.1924 1.1792 1.1666 1.1547
Angle 61° 62° 63° 64° 65° 66° 67° 68° 69° 70° 71° 72° 73° 74° 75° 76° 77° 78° 79° 80° 81° 82° 83° 84° 85° 86° 87° 88° 89° 90°
Cosecant 1.1433 1.1326 1.1223 1.1126 1.1034 1.0946 1.0864 1.0785 1.0711 1.0642 1.0576 1.0515 1.0457 1.0403 1.0353 1.0306 1.0263 1.0223 1.0187 1.0154 1.0125 1.0098 1.0075 1.0055 1.0038 1.0024 1.0014 1.0006 1.0001 1.0000
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Laying Out Offset Bends (cont’d)
Size
Quick-Reference Gain Table
Radius
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
4"
4-1/2"
5-3/4"
7-1/4"
8-1/4"
9-1/2"
Angle 23°
.05"
24°
.05"
.06"
25°
.05"
.06"
.07"
26°
.06"
.07"
.08"
27°
.05"
.06"
.07"
.09"
28°
.06"
.07"
.08"
.10"
29°
.05"
.06"
.08"
.09"
.11"
30°
.06"
.07"
.09"
.10"
.12"
31°
.05"
.06"
.08"
.10"
.11"
.13"
32°
.06"
.07"
.09"
.11"
.12"
.14"
33°
.06"
.07"
.09"
.12"
.14"
.16"
34°
.07"
.08"
.10"
.13"
.15"
.17"
35°
.08"
.09"
.11"
.14"
.16"
.19"
36°
.09"
.10"
.12"
.16"
.18"
.20"
37°
.09"
.11"
.14"
.17"
.19"
.22"
38°
.10"
.11"
.15"
.18"
.21"
.24"
39°
.11"
.12"
.16"
.20"
.23"
.26"
40°
.12"
.13"
.17"
.22"
.25"
.28"
41°
.13"
.14"
.19"
.23"
.27"
.31"
42°
.14"
.16"
.20"
.25"
.29"
.33"
43°
.15"
.17"
.21"
.27"
.31"
.35"
44°
.16"
.18"
.23"
.29"
.33"
.38"
45°
.17"
.19"
.25"
.31"
.36"
.41"
46°
.18"
.21"
.27"
.33"
.38"
.44"
47°
.20"
.22"
.28"
.36"
.41"
.47"
48°
.21"
.24"
.30"
.38"
.44"
.50"
To use this table: Determine the gain by finding the intersection of the appropriate row (which shows bend angles from 18 ° - 48 °) and the appropriate column (which shows the size of each shoe). The number at this intersection shows the amount of gain for the bend. Example: 40 ° bend 1-1/2" pipe Gain: .25" of gain
Greenlee Textron / Subsidiary of Textron Inc.
10
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Laying Out Offset Bends (cont’d) Gain Factor Table 0°
1°
2°
3°
4°
5°
6°
7°
8°
9°
0°
.0000
.0000
.0000
.0000
.0000
.0000
.0001
.0001
.0003
.0003
10°
.0005
.0006
.0008
.0010
.0013
.0015
.0018
.0022
.0026
.0031
20°
.0036
.0042
.0048
.0055
.0062
.0071
.0079
.0090
.0100
.0111
30°
.0126
.0136
.0150
.0165
.0181
.0197
.0215
.0234
.0254
.0276
40°
.0298
.0322
.0347
.0373
.0400
.0430
.0461
.0493
.0527
.0562
50°
.0600
.0637
.0679
.0721
.0766
.0812
.0860
.0911
.0963
.1018
60°
.1075
.1134
.1196
.1260
.1327
.1397
.1469
.1544
.1622
.1703
70°
.1787
.1874
.1964
.2058
.2156
.2257
.2361
.2470
.2582
.2699
80°
.2819
.1944
.3074
.3208
.3347
.3491
.3640
.3795
.3955
.4121
90°
.4292
–
–
–
–
–
–
–
–
–
To use this table: Find the gain factor by finding the intersection of the appropriate row (“tens” digit of the angle) and appropriate column (“ones” digit of the angle). Multiply the gain factor by the centerline bending radius of the shoe. See the example below. Example: 64 ° bend 9-7/16" centerline radius Correct Row: row labeled “60 °” Correct Column: column labeled “04 °” Gain Factor: .1327 Total Gain for Bend: .1327 x 9-7/16" = 1.25"
Greenlee Textron / Subsidiary of Textron Inc.
11
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Illustration 782 Pipe and Tubing Bender
Follow Bar 10 9 4,5,6 11,12 3
2 Saddle Shoe 8 7 1
Greenlee Textron / Subsidiary of Textron Inc.
12
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Parts List 782 Pipe and Tubing Bender Key
UPC No. 78-3310-
Part No.
Description
Qty
1
13251
501 3251.2
Ram, Hydraulic, 27-Ton (includes items 2 - 4) ... 1
2
13252
501 3252.0
Pin Unit, Cylinder Block, .875 x 8.06" ............... 2
3
50302
905 0302.3
Clip, Hitch Pin #8 .............................................. 2
4
10826
501 0826.3
Pin, Adapter, .250 x 3.25" ................................. 1
5
04086
500 4086.3
Pin, Yoke, .995 x 3.62" ...................................... 1
6
06980
500 6980 2
Yoke, Bender ..................................................... 1
7
11083
501 1083.7
Bar Unit, Connecting, Lower ............................. 1
8
06878
500 6878.4
Bar, Connecting, Upper ..................................... 1
9
14094
501 4094.9
Roller, 1.01 x 2.50 x 6.00" ................................. 1
10
14496
501 4496.0
Pin Unit, 1.00 x 8.50" ........................................ 1
11
29937
502 9937.9
Pin, Saddle, .620 x 5.00" ................................... 1
12
02937
500 2937.1
Pin, Saddle, .871 x 6.00" ................................... 1
11289
501 1289.9
Hose Unit, 3/8" x 6' (includes the following two items) ................ 1
50760
905 0760.6
Hose, Hydraulic, 3/8" x 6' with Fittings ......... 1
50823
905 0823.8
Coupler, Quick, Hydraulic, 3/8" Male ............. 2
13382
501 3382.9
Box, Metal, Storage ........................................... 1
(Not Shown)
30390
503 0390.2
Decal, Identification ........................................... 1
34316
503 4316.5
Decal, Read IM .................................................. 1
Greenlee Textron / Subsidiary of Textron Inc.
13
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Illustration — 27 Ton Ram
B
B
3.75 16 1 17
18
11.75
3
2 19
4 or 4A 8 5 or 5A
10
9
6
4 or 4A
SECTION BB 7 5 or 5A
14 16 13 12 11
15
Greenlee Textron / Subsidiary of Textron Inc.
14
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Parts List - 27 Ton Ram
Key
UPC No. 78-3310-
Part No.
Description
Qty
1
06221
500 6221.2
Scale, Piston ..................................................... 1
2
13220
501 3220.2
Retainer, Spring ................................................ 2
3
50807
905 0807.6
Coupler, Quick, 3/8" .......................................... 1
4*
01717
500 1717.9
Screw, Spring Retainer ..................................... 2
4A
11341
501 1341.0
Screw, Spring Retainer ..................................... 2
5 **
13496
501 3496.5
Washer, Flat, .321 x .460 x .040", Nylon ........... 2
5A
03420
500 3420.0
Washer, Flat, .321 x .428 x .040", Nylon ........... 2
6
13219
501 3219.9
Spring, Extension, 1.44 x 1.94 x 9.25" .............. 1
7
13229
501 3229.6
Cylinder, Hydraulic, 27-Ton .............................. 1
8
14995
501 4495.2
Piston ................................................................ 1
9
51926
905 0192.6
O-Ring, 2.62 x 3.00 x .187", Nitrile ................... 1
10
50193
905 0193.4
Backup Ring, Spiral, 2.62 x 3.00 x .185" ........... 1
11
13228
501 3228.8
Block, Cylinder .................................................. 1
12
50850
905 0850.5
Screw, Machine, #10 - 32 x .312" Flat Head ...... 2
13
21953
502 1953.7
Scale Bracket ..................................................... 1
14
13252
501 3252.0
Pin Unit, Cylinder Block, .875 x 8.06" (includes items 15 and 17) ........................... 2
15
50302
905 0302.3
Clip, Hitch Pin #8 .............................................. 2
16
50843
905 0848.3
Nut, Hex, 3/8 - 24, Light Jam ............................ 1
17
50422
905 0422.4
Roll Pin, .219 x 1.37" ......................................... 2
18
51384
905 1384.3
O-Ring, .375 x .500 x .062" ............................... 1
19
10826
501 0826.3
Pin, Adapter, .250 x 3.25" ................................. 1
12129
501 2121.9
Decal, Greenlee Safety (not shown) .................. 1
*On units manufactured prior to August 1996, use 4A. ** Use nylon washer (item 5) if possible. If the counterbore is too small (0.4425/0.4375), use alternate washer (item 5A).
Greenlee Textron / Subsidiary of Textron Inc.
15
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Accessories Shoe Groups for Tubing Catalog No. TU-G3
TU-G4
TU-G5
TU-G6
TU-G7
TU-G8
TU-G9
TU-G10
TU-G11
TU-G12
TU-G13
TU-G14
UPC No. 78-331002550 11151 14280 16444 02551 11150 11086 16445 06842 11142 11117 16403 02553 11144 11119 16413 02554 11160 11124 16414 02555 11159 11131 16415 02556 11149 11129 16416 02557 11148 11128 11080 02558 20525 20526 16417 02559 11156 11111 11644 02560 11155 11109 11071 02561 11133 11104 11070
Part No. 500 2550.3 501 1151.5 501 4280.1 501 6444.9 500 2551.1 501 1150.7 501 1086.1 501 6445.7 500 6842.3 501 1142.6 501 1117.5 501 6403.1 500 2553.8 501 1144.2 501 1119.1 501 6413.9 500 2554.6 501 1160.4 501 1124.8 501 6414.7 500 2555.4 501 1159.0 501 1131.0 501 6415.5 500 2556.2 501 1149.3 501 1129.9 501 6416.3 500 2557.0 501 1148.5 501 1128.0 501 1080.2 500 2558.9 502 0525.0 502 0526.9 501 6417.1 500 2559.7 501 1156.6 501 1111.6 501 6443.0 500 2560.0 501 1155.8 501 1109.4 501 1071.3 500 2561.9 501 1133.7 501 1104.3 501 1070.5
Greenlee Textron / Subsidiary of Textron Inc.
Description
Qty.
Shoe Group for 3/4" Tubing (includes the following three items) ...... 1 Shoe (3-27/64" Centerline Bending Radius) ..................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 7/8" Tubing (includes the following three items) ...... 1 Shoe (3-27/64" Centerline Bending Radius) ..................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1" Tubing (includes the following three items) ........ 1 Shoe (4-5/16" Centerline Bending Radius) ....................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-1/8" Tubing (includes the following three items) ... 1 Shoe (4-5/16" Centerline Bending Radius) ....................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-1/4" Tubing (includes the following three items) ... 1 Shoe (5-5/8" Centerline Bending Radius) ......................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-3/8" Tubing (includes the following three items) ... 1 Shoe (5-5/8" Centerline Bending Radius) ......................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-1/2" Tubing (includes the following three items) ... 1 Shoe (7-13/16" Centerline Bending Radius) ..................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-5/8" Tubing (includes the following three items) ... 1 Shoe (7-13/16" Centerline Bending Radius) ..................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-3/4" Tubing (Includes the following three items) ... 1 Shoe (8-1/32" Centerline Bending Radius) ....................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 1-7/8" Tubing (Includes the following three items) ... 1 Shoe (8-1/32" Centerline Bending Radius) ....................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 2" Tubing (Includes the following three items) ........ 1 Shoe (8-1/32" Centerline Bending Radius) ....................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1 Shoe Group for 2-1/8" Tubing (Includes the following three items) ... 1 Shoe (9-17/64" Centerline Bending Radius) ..................................... 1 Follow Bar ......................................................................................... 1 Saddle ............................................................................................... 1
16
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
782 Pipe and Tubing Bender Accessories (cont’d) Shoe Groups for Pipe Catalog No.
UPC No. 78-3310-
Part No.
782R-G2
13779
501 3779.4
Shoe Group for 1/2" Pipe (includes the following three items) ......... 1
13742
501 3742.5
Shoe (3-7/8" Centerline Bending Radius) ........................................ 1
782R-G3
782R-G4
782R-G5
782R-G6
782R-G7
Description
Qty.
13743
501 3743.3
Follow Bar ........................................................................................ 1
11078
501 1078.0
Saddle .............................................................................................. 1
02531
500 2531.7
Shoe Group for 3/4" Pipe (includes the following three items) ......... 1
02917
500 2917.7
Shoe (4-9/32" Centerline Bending Radius) ...................................... 1
02919
500 2919.3
Follow Bar ........................................................................................ 1
02921
500 2921.5
Saddle .............................................................................................. 1
06840
500 6840.7
Shoe Group for 1" Pipe (includes the following three items) ........... 1
02922
500 2922.3.
Shoe (4-7/8" Centerline Bending Radius) ........................................ 1
06874
500 6874.1
Follow Bar ........................................................................................ 1
02926
500 2926.6
Saddle .............................................................................................. 1
02537
500 2537.6
Shoe Group for 1-1/4" Pipe (includes the following three items) ...... 1
03064
500 3064.7
Shoe (5-5/8" Centerline Bending Radius) ........................................ 1
02949
500 2949.5.
Follow Bar ........................................................................................ 1
29465
502 9465.2
Saddle .............................................................................................. 1
02537
500 2537.6
Shoe Group for 1-1/2" Pipe (includes the following three items) ...... 1
02947
500 2947.9
Shoe (8-13/16" Centerline Bending Radius) .................................... 1
02951
5002951.7
Follow Bar ........................................................................................ 1
06877
500 6877.6
Saddle .............................................................................................. 1
02537
500 2537.6
Shoe Group for 2" Pipe (includes the following three items) ........... 1
02935
500 2935.5
Shoe (9-7/16" Centerline Bending Radius) ...................................... 1
02953
500 2953.3
Follow Bar ........................................................................................ 1
02943
500 2943.6
Saddle .............................................................................................. 1
Greenlee Textron / Subsidiary of Textron Inc.
17
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Drive, Rockford, IL 61109-2988 USA Customer Service (International): 815/397-7070 • Fax: 815/397-9247 Customer Service (North America): 800/435-0786 • Fax: 800/451-2632, 815/397-1865 Canada Fax: 800/524-2853
Printed in the U.S.A.
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