555® Deluxe Electric Bender - Northend Rental & Construction Supply
Contents
1. O O A gos o I ME o x S S 219 SLIHM 141 fully assembled POWER CORD 143 141A TO MOTOR 25 WHITE BLACK BLACK TO PENDANT 142 LINE LOAD Greenlee A Textron Company 13 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 555 Deluxe Electric Bender GREENLEE Electrical Schematic 50060180 OL E 8901 86 68 Mp L 6 510151581 910 A06 3nL n XOL Ezy 029991214 0501 09 96 X9101N 188 999 say vau eau cad 189 NIX19 L9S0 Pr 33uVeNv cva ONv OVH AO0SAnZ 9 gt 06 ML 004 619 MOL MOL E z Bly z 20 2 yaa ZN INYONJd 031 038 XOL 20 74 Meee a 9d glu Giu E L E 8701 80 68 X9ION 3vug iNnd NOLLO3HIG 1102 Av 138 VL 1001 ezov az ee raion 19 00 412. L4 Greenlee A Textron Company 10 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender Parts List 555 Deluxe Electric Bender Key Part No Description Qty 1 50397427 Weldment 1 2 50234528 Washer 1 3 50328964 Weldment sprocket unit esee 1 4 90524098 Bearing Fiberglide 22 625 x 2 5 long 1 5 90524101 Bearing Fiberglide 22 625 x 3 75 long 1 6 90524144 Ring retaining 5100 237 sese eme 1 7 90524128 Bearing Fiberglide 01 625 x 1 00 long 2 8 50397630 Weldment countershaft seem 1 9 90540239 Ring retaining 5100 250 sss eme 1 10 50397648 Shaft lp 1 11 90524136 Bearing thrust Fiberglide 2 12 90545486 Sprocket 40 60 1 13 90542533 Sprocket 60 14T 1 14 50397656 Key countershaft nennen 2 15 90545460 Chain 60 BZP PO nt x A 1 16 90542517 Masterlink 60 1 17 90545478 Sprocket 440 19T test t a p EAE RH EAS 1 18 50084313 Key reductor sprocket 1
3. a cS 0000000 0000 coy o 8 59 4 gt 2 R10 R3 4 R2 fo R5 R12 L R16 R17 L1 L EN gt O o cc d a 55 5 E 0 uo 5 Yellow Yellow T GREENLEE TEXTRON O Red Black 2000 s EI FROM RECTIFIER Greenlee A Textron Company 19 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender Exploded View and Parts List 115 Volt Motor 115 Torque to 9 Newton meters Pacific Scientific Key Part No Description Qty 101 91864178 Motor 115 volt standard SRF 3745 4676 2 56C 1 102 91864712 FAN COVEN es 1 103 90550714 THING 1 104 91864321 1 105 91864283 End bell fiu re a 2 106 91864194 Bell rear end 1 107 91864208 M 2 108 91864224 1 109 91864275 Shell and magnet assembly 115 1 110 918
4. EMT Roller Support Unit IMC Roller Support Unit Key Part No Description Qty Key Part No Description Qty 502 35419 Support unit 50252739 Support unit 1 1 2 and 2 EMT roller 1 1 2 and 2 IMC roller includes all of the following 1 includes items 1 and 2 1 50279831 Roller unit cushioned 1 1B 50283340 1 4 50235397 8 1 2 50283359 2 5 50235109 Roller 1 1 2 EMT 2 4 50263250 1 6 50235117 Pin roller support 1 5 50252747 Roller 1 1 2 IMC 2 7 50239325 1 1 2 EMT roller 2 6 50235117 Pin roller support 1 8 50235176 Pin roller pivot 1 7 50239325 Pin 1 1 2 IMC roller 2 10 50285249 Plate 1 1 2 EMT pivot 2 8 50235176 Pin roller 1 11 50237934 Spacer 2 1 10 50235249 Plate 1 1 2 IMC pivot 2 12 90515285 Ring retaining 4 11 50237934 1 13 90524640 Ring Tru Arc X5133 98 12 90515285 Ring retaining 4 external series E retaining 1 13 90524
5. 1 2 IMG eerie 1 Stud drive 3 Ring Tru Arc retaining 2 Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender Bending Shoes and Roller Supports cont d f gt 1 2 to 1 1 4 40 PVC Coated Rigid Conduit 1 1 2 to 2 40 PVC Coated Rigid Conduit Key PartNo Description Qty Key Description Qty 1 50009460 Roller support 1 2 to 1 1 4 1 50372823 Roller support 1 1 2 to 2 PVC coated Rigid PVC coated Rigid 1 includes items 5 14 1 includes items 9 15 50005731 Bending shoe assembly 50372815 Bending shoe assembly 1 2 to 1 1 4 PVC coated Rigid 1 1 2 to 2 PVC includes items 2 4 1 includes items 2 8 1 2 50005707 1 2 50024990 1 3 90510887 3 8 16 UNC x 1 1 4 3 50179748 Pivot eminens 1 Socket head cap screw 4 90526759 5 8 Flat washer 1 4 50234226 Stud CLIN RTT 3 5 90515692 5 8 11 UNC hex 1 5 50009451 Support weldment roller 1 6 90509056 5 8 1 6 90513533 Retaining ring 5 7 90524268 5 8 11 UNC x 4 7 500
6. Bending Shoe Bending Shoe 1 1 2 EMT Conduit 1 1 2 IMC Conduit Key PartNo Description Qty Key PartNo Description Qty 50234994 Shoe unit 1 1 2 EMT 50253631 Shoe unit 1 1 2 IMC includes items 1 4 1 includes items 1 4 1 1 50188208 Hook 1 1 2 1 1 50188119 Hook 1 1 2 IMC 1 2 50188410 Pin 1 1 2 EMT hook 1 2 50188372 Pin 1 1 2 IMC 1 3 50234226 Stud drive 3 3 50234226 Stud drive 3 4 90515293 Ring Tru Arc 5160 87 4 90515285 Ring Tru Arc retaining 2 retaining T 2 Bending Shoe Bending Shoe 2 EMT Conduit 2 IMC Conduit Key PartNo Description Qty Key Part No 50235052 Shoe unit 2 EMT conduit 50252682 includes items 1 4 1 1 50188186 Hook 2 EMT 1 1 50001957 2 50188429 Pin 2 EMT 1 2 50188429 3 50234226 Stud drive 3 3 50234226 4 90515293 Ring Tru Arc 5160 87 4 90515293 retaining 2 2 2 2 42224404242 2 Greenlee A Textron Company 22 4455 Boeing Dr Description Qty Shoe unit 2 IMC includes items 1 4 1 Hook 2 IMC
7. 99A xz 991 9 MEET yevovd DAa Wh pz ee 4 viu n 100 OG IS K Whe YOLOANNOO 1531 qeay i 001 6901 82 66 9104 Jaddn junoui pjnous LO gee Z 9d ely 9 yuis yeay Y i 0 yunou pjnous 80 4 2 G 0 pue 10 6 m et NS TT d 018 031034 E ed pee Lr C I Eo Me Git 9u 9 uisyeaH pue 0 10 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 17 Greenlee A Textron Company GREENLEE 555 Deluxe Electric Bender Power Generation Unit Parts List 50083570 C1 C9 C10 C12 C13 Philips A104K29X7RFVVWN Capacitor 0 1 uF 50 volts 5 AVX SA115C104KAA KEMET C420C104K5R5CA C2 WIMA MKS21 06310 Capacitor Film 1 uF 63 volts 1 C3 Philips A103M15Z5UFVVWA Capacitor 01 uF 50 volts 1 AVX SA105E103ZAA C4 C11 Sprague 440LS10 Capacitor 010 uF 500 volts AC C5 C8 Sprague 440LD47 Capacitor 0047 uF 500 volts AC C6 Panasonic ECE S2EU102Z Capacitor 1000 uF 250 volts 1 Cornell Dubilier 380LX102M250K052 C7 Panasonic EEU FC1E681 Capacitor 680 uF 25 volt
8. SERVICE MANUAL GREENLEE 555 Deluxe Electric Bender Serial Code ADV Read and understand all of the instructions and safety information in this manual before operating or servicing this tool 99937301 2006 Greenlee Textron Inc SB 282 REV 4 1 06 GREENLEE Table of Contents Safety 2 alls 2 Other Publications 2 Important Safety Information 3 4 Handle Removal and Replacement 5 Transportation 2 tc ecrit n tuens 5 Mamenn OS iira enint 6 7 8 9 Exploded Views and Parts Lists 10 12 Electrical Control System Layout 13 Control esses nnne 14 16 Power Generation 17 19 MOOT n a a 20 Bending Shoes amp Roller Supports 21 24 555 Deluxe Electric Bender 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 This manual is intended to familiarize authorized Gree
9. 19 90523881 Reductor worm 1 20 90527879 Masterlink 40 ids ein eie ci ru b re ei cede 1 21 90545516 Chain 40 87 ennemis 1 22 90545680 Bolt 3 8 16 UNC x 775 7 23 50397583 mesi m 1 24 90542371 Bolt 3 8 16 UNC 1 00 5 25 91869730 o E 1 26 90545494 Conduit 1 27 91852145 Elbow EE ERE RR PE HER 1 28 91866839 Strain 1 29 90511700 Nut 3 4 conduit 444000 1 31 91862639 Nut 1 2 conduit lock eme 1 32 50397575 ny EE 1 34 90515285 Ring retaining 5160 75 00 2 35 90552679 Wheel m 2 36 50397680 Guard rear e FR REIR 1 37 50397699 Guard rear 1 38 50397605 1 39 90516559 Screw 10 16 50 hex 31 40 90504305 Screw 6 32 375 Phillips eee 2 41 91863856 Rc i 1 42 50297082 Guard 1 43 50259288 ERE ERE ERR 1 44 90530012 Rivet pop 1 8 X 1 8 sep HH eU 4
10. AZ Uy 10 20014 05 XOL edt Nolo3utd 2 Siva 0L vug 6 gu 2035091 4 10350 9 rd al m 99 MOL 1H WOINVHOIN 201 82 6 XeloN R 10100131 XZ Q31N33H9 ZN ia ose 25 yol NP NI 9 vu u ed 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 14 Greenlee A Textron Company GREENLEE 555 Deluxe Electric Bender Electrical Schematic 50060180 Parts List Reference Supplier Part Number Description Qty C1 C3 C4 Philips A104K29X7RFVVWN Capacitor 0 1 uF 50 volts 3 AVX SA115C104KAA KEMET C420C104K5R5CA C2 Panasonic ECE A50Z4R7 Capacitor 4 7 uF 50 volts 1 D1 D4 D5 Diodes Inc UF 1001 DI Diode Ultra Fast Switching Rectifier 3 D2 Panasonic LN38GP LED T1 Green 1 Liteon LTL 4231 D3 Generic 1N4148 Diode 1 D6 Panasonic LN28RP LED T1 Red 1 Liteon LTL 4221 D7 Panasonic LN48YP LED T1 Amber 1 Liteon LTL 4251 JP1 Molex 26 61 4050 Connector Locking 0 156 cc 5 position Gold 1 JP4 Molex 39 29 0043 Connector Minifit 4 position Gold 1 JP2 JP3 Molex 39 29 0023 Connector Minifit Jr 2 position Gold 2 JP5 Molex 39 29 0063 Connector Minifit 6 position Gold 1 Q1 Generic TIP122 Transistor NPN 1 Q1 Heat Sink Hardware AAVID 577002B04000 Heat Sink TO 220 75 x 52
11. Greenlee A Textron Company 11 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Parts List 555 Deluxe Electric Bender cont d Key 45 46 47 48 49 50 52 53 54 57 58 59 70 71 72 73 77 78 79 80 141 141A 141B 141C 142 143 144 Part No 50190539 50303929 50397591 50351915 90533895 90525019 90545524 90545451 90543351 50339370 50389742 90553233 90517407 50024973 50036386 50001124 90510518 90552687 50397486 50069195 50078690 50078712 50083570 50078674 50078879 50079123 52023691 Greenlee A Textron Company 555 Deluxe Electric Bender Description Qty Decal voltage eee 1 Decal damp 1 gt II ME d 1 E D tte Rm EE 1 nUe a E _6__ 2 Ring retaining 5100 287 sse 1 kanya d 3 1 Screw 1 4 x 50 thread forming 6 Decal squeeze adjust sse 1 Decal circuit 1 Pin Driv Eok 1 8 X scere be ur 1 Washer req d after Nov 2005 4 before Nov 2005 2 Decal instruction 1 Decal war
12. improperly assembled component could break and strike nearby personnel Some bender parts and accessories are heavy and may require more than one person to lift and assemble Use only accessories and attachments recom mended by Greenlee Do not stand on the bender the bender may tip over Do not leave the tool running unattended Do not leave the tool until it comes to a complete stop Turn the power off and unplug the tool after use Ensure that all bystanders are away from the work area when operating the bender Ensure that the work area is clean dry uncluttered and well lit Use this tool for the manufacturer s intended purpose only Use other than that which is instructed in this manual can result in injury or property damage Failure to observe these precautions may result in injury or property damage 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Handle Removal and Replacement The handle of the 555 is designed to be removable This feature is convenient when performing complex bending and makes it easy to replace a damaged handle Removal 1 Place the bender in the upright position 2 Release the spring clip on the safety snap pin 78 3 Remove the pin from the handle 79 and the sleeve of the frame 1 4 Repeat Steps 1 through 3 for the other end of the handle 5 Lift the handle to remove Replacement 1 Insert the handle 79 into the sleeves
13. of the frame 1 2 Align the holes in the handle with the holes in the sleeves 3 Insert the safety snap pin 78 Ensure that the pin goes through the handle and the sleeve on the frame 1 4 Engage the safety spring clip over the end of the pin Ensure that the loop on the clip is completely around the pin 5 Repeat Steps 2 through 4 for the other end of the handle Removing or Replacing Handle Greenlee A Textron Company 555 Deluxe Electric Bender Transportation AWARNING Make sure that the handle is properly installed and secured with the safety spring clips and snap pins before lifting or moving the bender An improperly installed handle could allow the bender to fall injuring nearby personnel Failure to observe this warning could result in severe injury or death The only proper way to lift this bender is by attaching a nylon or polyester sling around the storage spindle The sling should extend between the handle and main frame of the bender so that the handle acts as a guide for the sling as shown Make sure that all components used to lift this bender are properly rated for the 167 kg 368 Ib weight Use a ramp to load and unload from a truck or other vehicle that is not equipped with a lift gate Transporting Bender 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Maintenance There is no
14. off YES NO Replace PGU Replace I O 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Quick diagnostics for electronic problems 1 With bender unplugged switch six wire connector on PGU from To I O to Test 2 Plug unit in 3 Press BEND Contactor on will activate f not check for 12 VDC at contactor coil If 12 VDC is present replace contactor 918 6645 6 else replace I O If bender runs replace PGU On near test connector Green Power LED is ON Yellow Direction LED is OFF Red PWM LED slowly turns dimly on If not replace I O 4 Press UNLOAD Contactor on I O will activate f not check for 12 VDC at contactor coil 12 VDC is present replace contactor 918 6645 6 else replace I O On near test connector Green Power LED is ON Yellow Direction LED is ON Red PWM LED slowly turns dimly on If not replace I O 5 Press BEND With insulated object carefully press black button S1 on PGU Bender will run slowly If not replace PGU Greenlee A Textron Company 9 555 Deluxe Electric Bender 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender Exploded View 555 Deluxe Electric Bender co N Note Key supplied with item 19 reductor
15. 09230 1 2 Roller axle 1 Socket head cap Screw 1 8 50009249 3 4 Roller axle 1 8 50234226 Stud drive 4 9 50009257 1 Roller axle 1 9 50376624 1 1 2 1 10 50009265 1 1 4 Roller axle 1 10 50376616 2 1 11 50009273 1 2 1 11 90515285 Retaining ring 3 12 50009281 3 4 Roller 1 12 50372840 1 1 2 1 13 50009290 1 1 13 50372831 2 1 14 50009303 1 1 4 1 14 50376640 Support weldment 1 15 50320254 Spacer 1 Greenlee A Textron Company 23 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender Bending Shoes and Roller Supports Key 21 must be torqued to 54 to 61 Newton meters 40 to 45 ft lb Greenlee A Textron Company 24 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender Bending Shoes and Roller Supports
16. 17 Dale CW 10 4 7K Resistor 4 7 kQ 10 watt 5 see Note 3 1 KRL C 10A 4 7K Riedon UT 10 4 7K R18 Dale RS 2B 20K Resistor 20 2 watt 1 1 KRL C 2A 20K Riedon UT 2B 20K Greenlee A Textron Company 18 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender Power Generation Unit Parts List 50083570 cont d R19 R21 Generic Resistor 1 kQ 1 4 watt 5 R20 Generic Resistor 1 5 MQ 1 4 watt 5 R22 Generic Resistor 100 1 4 watt 1 R26 R28 Generic Resistor 1 5 kQ 1 4 watt 1 R27 Generic Resistor 18 7 kQ 1 4 watt 1 R29 Generic Resistor 68 1 kQ 1 4 watt 1 51 Panasonic EVQ PACO9K Switch Momentary Pushbutton U1 Motorola LM339AN IC Low Power Quad Comparitor U2 Micrel MIC4422BN IC 9 A Peak Low Side Non inverting MOSFET Driver U3 HP HCPL4502 IC Opto isolator QT Opto HCPL4502 Siemens 6N136 Note 1 Mount D8 to bottom hole of heat sink Note 2 Mount Q1 to top hole of heat sink Note 3 Bend leads and mount 25 off board Layout Diagram Power Generation Unit 50083570 0 101 4 punojt N o o o fo o o o __ Fe 6 574 o ol cc 02 01 94 CHOE a alL 5 of s D Zo 5 0000 ee o 8 lt gt o e o o 1 T S o
17. 55 Deluxe Electric Bender IMPORTANT SAFETY INFORMATION AWARNING Extension cords Use only three wire 12 AWG extension cords that have three prong grounding type plugs and three hole receptacles that accept the tool s plug Do not use extension cords that are longer than 30 m 1007 Repair or replace damaged extension cords Failure to observe these warnings could result in severe injury or death A WARNING Make sure that the handle is properly installed and secured with the safety spring clips and snap pins before lifting or moving the bender An improperly installed handle could allow the bender to fall injuring nearby personnel Failure to observe this warning could result in severe injury or death A WARNING Pinch points Keep hands away from bending shoe rollers and conduit when bender is in use Failure to observe this warning could result in severe injury or death A WARNING Unplug the bender before changing accessories Accidental startup could result in serious injury Greenlee A Textron Company 4 ACAUTION Conduit moves rapidly as it is bent The path of the conduit must be clear of obstructions Be sure clearance is adequate before starting the bend Do not operate the bender while wearing loose clothing Loose clothing can get caught in moving parts Inspect the bender before use Replace worn damaged or missing parts with Greenlee replace ment parts A damaged or
18. 555 Deluxe Electric Bender GREENLEE Unit Schematic Diagram 50083570 Power Generation 8 pue 6 06400 ur pue 9 sjoejuo 033 1W 9EZ0ZWHL A0G 3n L 02 T 69 pejou ssajun Mp L G 510151591 pseOg 0 620 15291 je JUNOW 0 H UO puag e 4 id 1594104 00 X9vi8 T TINH 8 5 WA00S 4NZb00 ASz 40089 313389 89 3908 OV 49 A0S2 40001 OVAO0S 4n0 L0 3 209734 neag 8 9929 00 XZ Juda ovioosamgi A 09 3ddi v 9 NOU V ZOOPNL AASL IMG O TO zig 8 SLY eld eeu vi 12H z pue 51021 09 1102 OL 501 85 68 2 h 208 4 8502901 89 0 0 SZ yi 10100130 SZ 2 60 0L 5 2 OL a ees 2 209140 Lo 5 7 8 t 5901 82 68 XN MLA 9 OL y90 OgIasa NZ 2 8d L 8 2 pp mus
19. 640 Ring Tru Arc 4X5133 98 14 90514912 Rollpin 59 040 187 1250 1 external series E retaining 1 15 90528484 Screw 1 2 13 UNC x 3 4 14 90514912 Rollpin 59 040 187 1250 1 cup pt Skt set 2 15 90528484 Screw 1 2 13 UNC x 3 4 16 90505425 Screw 1 2 13 UNC x 1 cup pt Skt 2 hex head cap 2 16 90505425 Screw 1 2213 UNC x 1 17 50349643 Support weldment 2 roller 1 hex head cap 2 18 50349651 Plate 2 inner roller support 1 17 50349643 Support weldment 2 roller 1 19 50235192 Roller 2 EMT front 1 18 50349651 Plate 2 inner roller support 1 20 50237926 Roller 2 EMT 1 19 50252798 Roller 2 IMC 2 21 90533941 Screw 7 16 14 UNC x 1 21 90533941 Screw 7 16 14 UNC x 1 flat head 2 flat head 2 Greenlee A Textron Company 25 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE A Textron Company USA 800 435 0786 Fax 800 451 2632 815 397 7070 Fax 815 397 1865 Canada 800 435 0786 Fax 800 524 2853 International 1 815 397 7070 Fax 1 815 397 9247 4455 Boeing Drive Rockford IL 61109 2988 USA 815 397 7070 An ISO 9001 Company Greenlee Textron Inc
20. 64259 Armature 115 1 111 91864216 rogi 2 112 91864186 Bell 1 113 91864240 Retaining TING eee 1 114 91864267 115V rper E HORE OPE 2 115 91858763 90 connector a eee 1 116 91864305 ceasuaustanners 2 117 91864313 Cover SCTEW gt 7 Note Alternate motor Check motor part number before ordering magnet shell or armature 101 91869730 Motor SRF 3648 5532 7 56C 109 91869757 Shell and magnet assembly 110 91869749 Armature Greenlee A Textron Company 20 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Bending Shoes and Roller Supports Bending Shoe and Roller Support 1 2 to 1 1 4 IMC and Rigid Conduit Key PartNo Description 1 50009362 Roller support 1 2 to 1 1 4 IMC and Rigid 50005715 Bending shoe assembly includes items 2 4 2 50005693 3 90510887 3 8 16 UNC x 1 1 4 Socket head cap screw 4 50234226 Stud drive Shoe not available separately Bending Shoe and Roller Support 1 1 2 to 2 Rigid Conduit Key PartNo Description 1 50179845 Roller support 1 1 2 to 2 Rigid 50179373 Bending shoe assembly 1 1 2 to 2 Rigid conduit includ
21. chain Set tension with the eccentric cam 60 HT Final Drive Chain Positioning Plate on Eccentric Housing Counter Shaft Four 1 4 Flange Mounting Screws Greenlee A Textron Company 555 Deluxe Electric Bender Eight Reductor Mounting Bolts four on reverse side With the eight reductor mounting bolts 22 24 loose rotate the eccentric cam with a 1 2 square drive to tension the chain Torque the eight reductor mounting bolts to 47 Newton meters 35 ft lb Two eccentric cam mounting holes provided for varying adjustment positions Reductor Mounting Bolt Eccentric Cam ES Reductor Bracket 1 2 Square Rotate eccentric cam counterclockwise Apply 20 Newton meters 15 ft lb of torque to set chain tension Then torque reductor mounting bolts to 47 Newton meters 35 ft lb 6 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender Maintenance cont d Electrical Control Unit Removal 1 Remove the cover retained by ten 5 16 hex screws 2 Disconnect the pendant switch plug from the circuit A WARNING board and remove through the cord grip 3 Remove two hex mounting screws one on each Disconnect power supply before side servicing bender Servicing to be done only by trained service technician Failure to observe this warning could result in severe injury or death 3 8 Hex Line Conn
22. damage ADANGER Read and understand all of the instructions and safety information in this manual before operating or servicing this tool Failure to observe this warning will result in severe injury or death ADANGER Do not use this tool in a hazardous environment Hazards include flammable liquids gases or other materials Using this tool in a haz ardous environment can result in a fire or explosion Failure to observe this warning will result in severe injury or death AWARNING Electric shock hazard Connect the power cord to 120 volt 20 amp receptacle on ground fault protected circuit only See Grounding Instructions Do not modify the power cord or plug Inspect the power cord before use Repair or replace the cord if damaged Disconnect from power before servicing Failure to observe this warning could result in severe injury or death AWARNING Do not expose to rain Do not use in wet or damp locations Failure to observe these warnings could result in severe injury or death AWARNING Wear eye protection when operating or servicing this tool Failure to wear eye protection could result in serious eye injury from flying debris AWARNING Do not remove guards Failure to observe this warning could result in severe injury or death 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 Greenlee A Textron Company GREENLEE 5
23. ection Mounting Screw at Circuit Breaker 4 Remove the motor leads power cord ground wire and neutral wire before the control unit can be totally removed from the bender Greenlee A Textron Company 7 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Troubleshooting The following flow charts show the suggested trouble shooting procedures for some bender problems They by no means encompass all possible problems or solutions AWARNING Electric shock hazard Contact with live circuits can result in severe injury or death Some troubleshooting steps require power to the bender This type of troubleshooting step should only be performed at authorized Greenlee service centers by personnel who are familiar with safe troubleshooting procedures Failure to observe these warnings could result in severe injury or death Won t bend Is 115 VAC measured at PGU board input YES Does the green LED on the I O board light YES 555 Deluxe Electric Bender Trips circuit breaker Are the proper support rollers Does the green LED on the PGU light YES Does amber or red LED on I O light when BEND or UNLOAD is pressed YES Does relay on I O operate when BEND or UNLOAD is pressed YES Replace PGU Greenlee A Text
24. es items 2 8 50179691 Pipe 50179748 Pivot 90526759 5 8 flat washer 90515692 5 8 11 UNC hex nut 90509056 5 8 Split lockwasher 90524268 5 8 11 UNC x 4 socket head SCIOW 8 50234226 Stud drive Shoe not available separately NOOO Bending Shoe and Pipe Rest 1 2 to 1 1 4 EMT Conduit Key PartNo Description 1 50179861 Pipe rest assembly for 1 2 to 1 1 4 EMT conduit 50179446 Bending shoe assembly for 1 2 to 2 1 4 EMT conduit includes items 2 8 2 90505972 3 8 16 UNC x socket head SCIeW 90505069 3 8 Lockwasher split 50245554 Pipe 50234226 Stud drive 90506391 3 8 16 UNC hex nut cad plated 90505328 3 8 16 UNC x 1 1 4 SAE grade 5 socket head cap screw 8 90510887 3 8 16 UNC x 1 1 4 socket head screw Shoe not available separately NOOO Greenlee A Textron Company 555 Deluxe Electric Bender 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender Bending Shoes and Roller Supports
25. is a subsidiary of Textron Inc www greenlee com Printed in USA
26. need for periodic flushing and replacing of lube in the bender gear box since it is sealed and locked tight However if the box is opened for repair and the lube is lost or contaminated by dirt then the box and parts should be flushed out and filled with 26 fluid ounces of Mobil 634 synthetic oil Flushing should be accomplished with kerosene which is a petroleum hydrocarbon that does not affect seals Note Aromatic hydrocarbons such as benzine chlorinated solvents such as carbon tetrachloride and ketones such as acetone should never be used for flushing as they are solvents for rubber They are also harmful to the environment AWARNING Disconnect this tool when not in use before servicing or adjusting and when changing shoes or conduit rollers and supports Failure to observe this warning could result in severe injury or death Chain Adjustment Both chains have to be adjusted if the final drive 60 chain is to be reset Refer to the Exploded View and Parts List 1 Remove the front cover 88 and upper rear guard 37 2 Loosen the eight mounting bolts for the reductor 19 Remove the eccentric cam and move the reductor to create chain slack 3 Remove the four retaining screws for eccentric adjustment Rotate to remove slack from the chain and align with one of the two sets of holes in the frame Remount the eccentric with the four bolts 4 Slide the reductor in slotted mounting holes to the retension
27. ning English 1 Decal warning 1 Ring retaining 5100 150 sse 2 Pin Safety snap eec Gl EE Hr denen 2 Handle P etrus 1 Sleeve axle c t eee cata gta 2 Electronic control assembly fully assembled 1 Control assembly 1 Power generation 1 Bracket electronics metal bracket only 1 Pendant control assembly sse 1 Power cord assembly 1 1 Service Kit for 52023601 no flat tire and wheel 1 consists of 32 Axle revised length 1 req d 35 tire and wheel assembly 2 req d 34 Retaining ring 2 req d 80 Sleeve axle 2 req d 70 Washer re 4 req d 12 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender Electrical Control System Layout 1416 bracket only
28. nlee service center personnel with the safe opera tion and maintenance procedures for the Greenlee 5559 Deluxe Electric Bender with Serial Code ADV Keep this manual available to all personnel Replacement manuals are available upon request at no charge Mobil is a registered trademark of Mobil Oil Corporation Other Publications Instruction Manual Publication 99937530 IM 1458 All specifications are nominal and may change as design improve ments occur Greenlee Textron Inc shall not be liable for damages resulting from misapplication or misuse of its products 555 is a registered trademark of Greenlee Textron Volex is a registered trademark of Molex Inc KEEP THIS MANUAL Greenlee A Textron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric 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 defined below indicates the severity of the hazard The message after the signal word provides information for preventing or avoiding the hazard ADANGER Immediate hazards which if not avoided WILL result in severe injury or death AWARNING Hazards which if not avoided COULD result in severe injury or death ACAUTION Hazards or unsafe practices which if not avoided MAY result in injury or property
29. ron Company NO Plugged into dead circuit bad power cord Switch is bad or off NO Check board assembly NO Replace PGU NO Unplug pendant or I O and I check switch for continuity If ok replace I O NO and shoe groove being used for NO Follow directions in the type and size of conduit instruction manual being bent YES Is the current on the 115 VAC NO Replace circuit line exceeding 20 amps breaker YES Is the DC current to the motor YES Replace motor exceeding 17 amps NO When BEND is pressed is the NO Replace voltage sent to the motor 20 to 50 K _ bridge rectifier volts over the AC line voltage 918 5997 2 YES Are connectors corroded XES Clean NO Replace PGU Won t stop Is the supply line voltage low YES Use 115 VAC NO Does bender stop when the YES Replace pendant pendant is unplugged NO Replace I O Replace PGU Bender only runs in one direction switch Does amber or red LED light NO Check and replace when switch is pressed pendant switch YES When amber or red LED is on is NO Move six wire 12 VDC measured at large relay connector PGU coil on PGU where relay wire from to to unit connects test Alternately press BEND and YES UNLOAD Does Replace 918 6645 6 relay yellow direction LED on PGU turn on and
30. s 1 D1 Panasonic LN48YP LED T1 Amber 1 Liteon LTL 4251 D2 Panasonic LN28RP LED T1 Red 1 Liteon LTL 4221 D3 D10 Motorola 1N5245B Zener Diode 15 volts 500 milliwatts D4 D11 Panasonic LN38GP LED T1 Green Liteon LTL 4231 D5 D6 D7 Generic 1N4148 Diode 3 D8 IXYS DSEI 30 06 Diode Fast Recovery 30A 400 600V TO 247 see Note 1 1 Adv Pwr Tech APT30D40B Adv Pwr Tech APT30D60B D9 Vishay UF1001DI Diode Ultra Fast Switching 1A 50V 50ns DO 41 1 D13 D14 Generic 1N4007 Diode 2 J1 J2 Molex 39 29 0063 Connector Minifit Jr 6 position Gold 2 J4 Molex 39 29 0023 Connector Minifit Jr 2 position Gold 1 5 6 8 9 10 11 Keystone 1287 Connector Tab 250 x 032 6 J7 Beau 72503 C Connector Terminal Block 3 position No Mount Holes 1 Magnum A202203 L1 Renco RL 1328 22 470 Choke Common Mode 1 Q1 IXYS IXFK73N30 MOSFET N channel 73 76A 300V TO 264 see Note 2 1 Adv Pwr Tech APT30M40LVFR Q2 Generic PN2222A Transistor NPN 1 R1 R8 Generic Resistor 2 1 4 watt 5 2 R2 R3 R12 R14 Generic Resistor 1 MQ 1 4 watt 5 4 R4 Generic Resistor 150 kQ 1 4 watt 5 1 R5 Generic Resistor 12 1 kQ 1 4 watt 1 1 R6 Generic Resistor 4 75 kQ 1 4 watt 1 1 R7 R24 Generic Resistor 20 kQ 1 4 watt 1 2 R9 R11 Generic Resistor 22 Q 1 4 watt 5 2 R10 R13 Generic Resistor 100 kQ 1 4 watt 5 2 R15 Dale LVR 5 04W Resistor 040 Q 5 watt 196 1 KRL NP 5A 04W Riedon MT 5 04W R16 R23 R25 Generic Resistor 10 kQ 1 4 watt 1 3 R
31. x 25 with Tab 1 Generic 4 40 Lock Washer Stainless Steel Split Ring or Internal Tooth 1 Generic 344 40 Hex Nut Stainless Steel 1 Generic 4 40 Phillips Screw Stainless Steel Machine Pan Head 4 40 x 0 25 1 Q2 Q3 Q4 Generic PN2222A Transistor NPN 3 R1 R2 R3 R4 R7 R8 R15 Generic Resistor 10K 1 4 watt 5 12 R16 R17 R18 R22 R23 R5 R11 R13 R14 Generic Resistor 470 Q 1 4 watt 5 4 R6 R20 R21 Generic Resistor 330 Q 1 4 watt 5 3 R9 R19 Generic Resistor 1 1 4 watt 5 2 R10 R12 Generic Resistor 150 Q 1 4 watt 5 2 U1 Greenlee 91869382 Processor Programmed 854 1 x1 Murata CST4 00MGW Resonator 4 0 Mhz 1 Panasonic EFO GC4004A4 Greenlee A Textron Company 15 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 555 Deluxe Electric Bender PCB Layout 50060180 GREENLEE TEXTRON 2000 ii o Lo R10 04 lt gt R22 lt gt c3 Lo R5 O R17 L O R14 o4 Loris R13 R23 H O R15 TE o R11 O R16 e O R8 ger olls Lora c4 07 Lo m m a pom DIRS R2 D6 Lo gt 20 RELAY PGU ad us td 05 Greenlee A Textron Company 16 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070
Download Pdf Manuals
Related Search