Greenlee 1800 Mechanical Bender User manual

99961660 © 2012 Greenlee Textron Inc. IM 932 REV 11 5/12
1800
Mechanical Bender
1/2" through 1" Rigid and IMC Conduit
INSTRUCTION MANUAL
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

Greenlee / A Textron Company 2 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070
1800 Mechanical Bender
Allspecicationsarenominalandmaychangeasdesign
improvements occur. Greenlee Textron Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
KEEP THIS MANUAL
Table of Contents
Description ..................................................................... 2
Safety ............................................................................. 2
Purpose of this Manual .................................................. 2
ImportantSafetyInformation ......................................... 3
Setup .............................................................................. 4
Operation........................................................................ 4
Maintenance................................................................... 4
Illustrated Bending Glossary .......................................... 5
Bending Conduit .........................................................6-7
SpecialBendingInformation .....................................8-12
Illustration..................................................................... 13
PartsList ...................................................................... 14
Description
The1800MechanicalBenderisamanuallypowered
benderintendedtobend1/2",3/4"and1"rigidconduit,
IMC(intermediatemetallicconduit),andSchedule40
pipe.
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 person-
nelwiththesafeoperationandmaintenanceprocedures
fortheGreenlee1800MechanicalBender.
Keep this manual available to all personnel.
Replacement manuals are available upon request
atnochargeatwww.greenlee.com.

Greenlee / A Textron Company 3 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070
1800 Mechanical Bender
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.
Do not leave the ratchet handle in the
UPpositionwhenthebenderisnotin
use.AhandleleftintheUPposition
could fall unexpectedly.
Pinch points:
Keephandsawayfrommovingparts
andconduitwhenbending.Failureto
observethiswarningcouldresultin
severeinjury.
Weareyeprotectionwhenusingthis
bender.Failuretoweareyeprotection
couldresultinseriouseyeinjuryfrom
ying debris.
• Keeptheconduitundercontrolwhenunloadingit
fromthebender.Conduitmayfallandstrikethe
operator or nearby personnel.
• Maintainarmgriponthehandlewhenbending.
Springbackoftheconduitmaynotallowtheratchet
tofullyengage,causingthehandletospring
upwardsuddenly.
• Remove the handle and conduit before moving the
bender.Maintainarmgripwithbothhandsonthe
frameT-handletopreventthebenderfromtipping
over.
• Inspect the bender before each use. Replace any
worn,damaged,ormissingitemswithGreenlee
replacementparts.Adamagedorimproperly
assembledtoolcanbreakandstrikenearby
personnel.
• Useproperliftingpracticeswhenliftingthebender.
Thebenderweighsover75lb(34kg),andrequires
more than one person to lift.
Failure to observe these precautions may result
ininjury.
Usethisproductforthemanufacturer’sintended
purposeonly.Useotherthanthatwhichisdescribed
inthismanualmayresultininjuryorproperty
damage.

Greenlee / A Textron Company 4 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070
1800 Mechanical Bender
Setup
1. Parkthebenderonaat,rmsurface,suchas
a concrete oor. Do not set up the bender on a
inclined surface.
2. Insert a 5 ft (153 cm) length of 1" rigid conduit into
the lever unit (11) to serve as the bending handle.
Operation
1. Raise the handle completely to release the ratchet
mechanism.Manuallyrotatetheshoefullycounter-
clockwise.Lowerthehandle.
2. Slidetheconduittobebentoverthepipesupport
roller,intotheshoegroove,andpastthewheeledge
ofthepipehook.
3. Lineupthebendingmarkwiththefrontedgeofthe
pipehook.
4. Liftthehandleuntiltheratchetclicksonce.Push
thehandledown.Repeatuntilthebendiscomplete.
Note: The bender degree indicator will not compen-
sate for springback.
5. Raisethehandlebacktothestartingposition.
Lifttailofpipeandreturnshoetoloadposition.
6. Remove the conduit from the bender.
7. Lowerthehandle.
Note: Always keep the handle in the DOWN position
when not in use.
Do not leave the ratchet handle in the
UPpositionwhenthebenderisnotin
use.AhandleleftintheUPposition
could fall unexpectedly.
Remove the handle and conduit before moving the
bender.Maintainarmgripwithbothhandsonthe
frameT-handletopreventthebenderfromtipping
over.
Failuretoobservethisprecautionmayresultininjury.
Maintenance
Keepthebendercleananddry.Priortouse,addgrease
atthegreasetting(seeitem29ontheIllustration).
Lever
Unit Handle
Pipe
Supports
Pipe Hooks
Bending
Degree
Indicator
Figure 1

Greenlee / A Textron Company 5 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070
1800 Mechanical Bender
Illustrated Bending Glossary
1. back-to-back bend—anyU-shapedbendformedby
twoparallel90°bendswithastraightsectionofconduit
orpipebetweenthebends.
2. center-to-center distance—thedistancebetweenthe
successivebendsthatmakeupanoffsetorathree-bend
saddle.
3. developed length—theactuallengthofpipethatwill
be bent; refer to distance “d” in the illustration at left.
4. gain—thedifferencebetweenthestraight-linedistance
(a+a)andtheshorterradialdistance,(d)where:
q= angle of bend
r = the centerline bending radius of the bending shoe
5. kick—singlebendoflessthan90°
6. leg length — the distance from the end of a straight
section of conduit or pipe to the bend; measured from
the end to the outside edge of the conduit or pipe.
 7. offset bend—twooppositebendswiththesame
degree of bend; used to avoid an obstruction.
 8. offset height—thedistancebetweenthetwolegsof
anoffsetbend,measuredperpendiculartothetwolegs;
also called amount of offset and depth of offset.
9. rise — the distance from the end of a straight section of
conduit or pipe to the bend; measured from the end to
thecenterlineoftheconduitorpipe.Alsocalledstubor
stub-up.
10. saddle—athree-bendorfour-bendcombination;used
to avoid an obstruction.
11. shrink—theamountofconduit“lost”whenlayingout
anoffsetbendworkingtowardanobstruction.
12. springback—theamount,measuredindegrees,thata
conduit or pipe tends to straighten after being bent.
a
a
d
r
Offset Height

Greenlee / A Textron Company 6 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070
1800 Mechanical Bender
Bending Conduit
To Locate Bending Marks for Stubs
1. SeetheStubDimensionsTablefortheminimumstublength.Thedesiredstubmustbeequaltoorgreater
than the minimum stub length.
2. SeetheStubIllustrations.Measureandmarkthestublengthontheconduit.Thisismark1.Subtractthe
deductfromthestublengthandmakemark2.Mark2isthebendingmark—locatethismarkatthefront
edgeofthehook.
Stub Dimensions Table
Conduit Size Shoe Radius Minimum
Stub Length Deduct Minimum Distance
from End of Conduit
1/2"    2-5/8"* 6-1/2" 5-1/2"
1"3/4"    4-5/8" 9-1/2" 8-1/2"
1"    5-7/8" 12" 11"
Figures are approximate
*Tomeetelectricalcode,bend1/2"diameterconduitinthe3/4"positiontoproduceabendwitharadiusgreaterthan4".
STUB LENGTH
DEDUCT
MARK
NO. 2
MARK
NO. 1
STUB TO
BOTTOM
OF CONDUIT
ALIGN BENDING
MARK WITH
FRONT EDGE
OF HOOK

Greenlee / A Textron Company 7 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070
1800 Mechanical Bender
OFFSET DISTANCE[2 4 6 8 10 12 14 16 18 20 22
Max Conduit Size 3/4"
Center-to-Center 7-3/4" 15-7/16 23-3/16" 30-15/16" 38-5/8" 46-3/8" 54-1/16" 61-13/16" 69-9/16" 77-1/4" 85"
Max Conduit Size 3/4"
Center-to-Center 8" 12" 16" 20" 24" 28" 32" 36" 40" 44"
Max Conduit Size 1/2"
Center-to-Center 8-1/2" 11-5/16" 14-1/8" 16-15/16" 19-13/16" 22-5/8" 25-7/16" 28-1/4" 31-1/8"
To Locate Bending Marks for Offsets
15°
30°
45°
Offset Dimensions Table
1"
1"
1"
Tocalculatethecenter-to-centerdistanceforanyotheroffsetbend,multiply:
 (for15°bends)HeightoftheObstructionx3.86
 (for30°bends)HeightoftheObstructionx2
 (for45°bends)HeightoftheObstructionx1.4
Figure X Table
Conduit Size Approx. “X”
Distance
Minimum Distance
from End of Conduit
1/2"    2-1/2"
1"3/4"    3-1/4"
1"    4-1/4"
1. Measurethedistancefromconduitcouplingtotheedgeoftheobstructionandmarktheconduit.Thisismark1.
2. SeetheFigureXTable.SubtractXinchesfrommark1andmarktheconduit.Thisismark2.
3. Measuretheheightoftheobstruction.Thisistheoffsetdistance.RefertotheOffsetTabletondthecenter-to-
centerdistanceattheintersectionofthetoprow(offsetdistance)andtherstcolumn(offsetangle).Measure
andmarkthecenter-to-centerdistancefrommark2.Thisismark3.
4. Inserttheconduitintothebenderwithmark2alignedwiththefrontedgeofthehook.Maketherstbend.
5. Withoutremovingtheconduitfromthebender,rotatetheconduit180°.Alignmark3withthefrontedgeofthe
hookandmakethesecondbend.
Figures are approximate
Figures are approximate
←
X
→
←
THGIEH
→
ANGLE
MARK 1 MARK 3
MARK 2
→
→
←
Center-to-Center Distance
→

Greenlee / A Textron Company 8 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070
1800 Mechanical Bender
Special Bending Information
Laying Out Bends
Thefollowingillustrationsandinstructionsshowthemostcommonbends.SeetheSpecialBendingInformation
Chart for precise bending dimensions.
Stubs
Y
HEIGHT
MARK
ANGLE
1. Selectthesizeandtypeofconduit.Determinetheheightofstubandtheangleofbend.
2. FindthechartthatcorrespondstothesizeofconduitselectedinStep1.
3. UnderthecolumnlabeledANGLE,ndtheangleofbend.FindtheintersectionofrowYandtheappropriate
columnH.ThenumberatthisintersectionisthedimensionY.PlacethebendingmarkYinchesfromtheendof
the conduit.
4. SeetheOperationsectionofthismanual.
Offset
Anoffsetisusedtoroutetheconduitaroundanobstruction.Tomakeanoffset,twoequalbendsarerequired.The
distancebetweenthetwobendsisthecenter-to-centerdistance.ThisisrepresentedbyL1inthebendingtables.
Offsets: Controlling the Start of the First Bend
(usethismethodwhenworkingpastanobstruction)
L1LENGTH – X
LENGTH
HEIGHT
START OF
FIRST
BEND
BENDING
MARK 1
BENDING
MARK 2
ANGLE
1. Selectthesizeandtypeofconduit.MeasuretheheightoftheobstructionandthedistancelabeledLENGTH.
Determine the angle to be used.
2. FindthechartthatcorrespondstothesizeofconduitselectedinStep1.
3. Totherightofthesizeandtypeofconduit,ndthedimensionlabeledX.SubtractXfromLENGTH.Placethe
rstbendingmarkthisdistancefromtheendoftheconduit.
4. UnderthecolumnlabeledANGLE,ndtheangleofbend.FindtheintersectionoftheL1rowandtheappropriate
HEIGHTcolumn.ThenumberatthisintersectionisthedimensionL1.PlacethesecondbendingmarkL1inches
fromtherstbendingmark.
5. SeetheOperationsectionofthismanual.

Greenlee / A Textron Company 9 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070
1800 Mechanical Bender
Special Bending Information (cont’d)
Offsets: Controlling the Start of the Second Bend
(usethismethodwhenworkingtowardanobstruction)
L1
LENGTH TO END OF SECOND BEND
BENDING
MARK 1
BENDING
MARK 2
LENGTH – Z
ANGLE
HEIGHT
1. Selectthesizeandtypeofconduit.MeasuretheheightoftheobstructionandthedistancelabeledLENGTHTO
ENDOFSECONDBEND.Determinetheangletobeused.
2. FindthechartthatcorrespondstothesizeofconduitselectedinStep1.
3. UnderthecolumnlabeledANGLE,ndtheangleofbend.FindtheintersectionoftheZrowandtheappropriate
HEIGHTcolumn.ThenumberatthisintersectionisthedimensionZ.SubtractZfromLENGTHTOTHEENDOF
SECONDBEND.Placetherstbendingmarkhere.
4. Inthesamecolumn,ndtherowlabeledL1.PlacethesecondbendingmarkL1inchesfromtherstbending
mark.
5. SeetheOperationsectionofthismanual.
Three-Bend Saddle
L1LENGTH – Z
LENGTH TO CENTER
BENDING
MARK 1
BENDING
MARK 2
BENDING
MARK 3
L2
ANGLE
HEIGHT
1. Selectthesizeandtypeofconduit.MeasuretheheightoftheobstructionandthedistancelabeledLENGTHTO
CENTER.Determinetheangletobeused.
2. FindthechartthatcorrespondstothesizeofconduitselectedinStep1.
3. UnderthecolumnlabeledANGLE,ndtheangleofbendneeded.FindtheintersectionoftheZrowandthe
appropriateHEIGHTcolumn.ThenumberatthisintersectionisthedimensionZ.SubtractZfromtheLENGTH
TOCENTER.Placetherstbendingmarkhere.
4. Inthesamecolumn,ndtherowlabeledL1.PlacethesecondbendingmarkL1inchesfromtherstbending
mark.
5. Inthesamecolumn,ndtherowlabeledL2.PlacethethirdbendingmarkL2inchesfromthesecondbending
mark.
6. SeetheOperationsectionofthismanual.
Note: The second bend angle will be twice the number of degrees as the first and third bends.

Greenlee / A Textron Company 10 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070
1800 Mechanical Bender
Four-Bend Saddle
LENGTH – Z
BENDING
MARK 1
BENDING
MARK 2
BENDING
MARK 3
BENDING
MARK 4
L2 + STRAIGHT SECTION
HEIGHT
STRAIGHT
SECTION
LENGTH
L1 L1
ANGLE
1. Selectthesizeandtypeofconduit.Measuretheheightoftheobstruction,thedistancelabeledLENGTH,and
thedistancelabeledSTRAIGHTSECTION.Determinetheangletobeused.
2. FindthechartthatcorrespondstothesizeofconduitselectedinStep1.
3. UnderthecolumnlabeledANGLE,ndtheangleofbendneeded.FindtheintersectionoftheZrowandthe
appropriateHEIGHTcolumn.ThenumberatthisintersectionisZ.SubtractZfromtheLENGTH.Placetherst
bendingmarkthisdistancefromtheendoftheconduit.
4. Inthesamecolumn,ndtherowlabeledL1.PlacethesecondbendingmarkL1inchesfromtherstbending
mark.
5. Inthesamecolumn,ndtherowlabeledL2.AddL2totheSTRAIGHTSECTION.Placethethirdbendingmark
thisdistancefromtherstbendingmark.
6. MakethenalbendingmarkL1inchesfromthethirdbendingmark.
7. SeetheOperationsectionofthismanual.
U-Bends
Y
BENDING
MARK 1
BENDING
MARK 2
L1
LENGTH
HEIGHT
1. Selectthesizeandtypeofconduit.DeterminetheLENGTHandtheHEIGHT.
2. FindthechartthatcorrespondstothesizeofconduitselectedinStep1.
3. UnderthecolumnlabeledANGLE,nd90°.FindtheintersectionoftheYrowandtheHEIGHTcolumnthatcor-
respondstothedimensionlabeledLENGTHintheillustration.PlacetherstbendingmarkYinchesfromthe
end of the conduit.
4. FindintersectionoftheL1rowandtheHEIGHTcolumnthatcorrespondstothedimensionlabeledHEIGHTin
theillustration.PlacethesecondbendingmarkL1inchesfromtherstmark.
5. SeetheOperationsectionofthismanual.
Special Bending Information (cont’d)