Greenlee 555 Deluxe Electric Bender Service Manual

Safety First

Read and understand all instructions and safety information before operating or servicing this tool.

(Illustration of the Greenlee 555 Deluxe Electric Bender)

Document Number: 99937301

Revision: SB 282 REV 4 1/06

Copyright © 2006 Greenlee Textron Inc.

Table of Contents

• Safety
• Purpose
• Other Publications
• Important Safety Information
• Handle Removal and Replacement
• Transportation
• Maintenance
• Troubleshooting
• Exploded Views and Parts Lists
• Electrical Control System Layout
• I/O Control
• Power Generation Board
• Motor
• Bending Shoes & Roller Supports

Safety

Safety is essential in the use and maintenance of Greenlee tools and equipment. This manual and tool markings provide information for avoiding hazards and unsafe practices. Observe all safety information.

Purpose

This manual familiarizes authorized Greenlee service center personnel with the safe operation and maintenance procedures for the Greenlee 555® Deluxe Electric Bender, Serial Code ADV. Keep this manual available. 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)

Important Safety Information

SAFETY ALERT SYMBOL ⚠️ This symbol indicates hazards or unsafe practices that could result in injury or property damage. The signal word indicates the severity of the hazard.

DANGER: Immediate hazards that WILL result in severe injury or death.

WARNING: Hazards that COULD result in severe injury or death.

CAUTION: Hazards or unsafe practices that MAY result in injury or property damage.

General Safety Warnings:

• Read and understand all instructions and safety information before operating or servicing. Failure to do so could result in severe injury or death.
• Do not use in hazardous environments (flammable liquids, gases, etc.) as this can cause fire or explosion. Failure to observe this warning could result in severe injury or death.
• 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.
• Wear eye protection when operating or servicing. Failure to do so could result in serious eye injury from flying debris.
• Do not remove guards. Failure to observe this warning could result in severe injury or death.

Electrical Hazards:

• Electric shock hazard: Connect power cord to a 120-volt, 20-amp, ground fault protected circuit only.
• Do not modify the power cord or plug.
• Inspect the power cord before use. Repair or replace if damaged.
• Disconnect from power before servicing. Failure to observe this warning could result in severe injury or death.

Operational Safety:

• Extension cords: Use only three-wire, 12-AWG cords with three-prong grounding plugs. Do not use cords longer than 30 m (100'). Repair or replace damaged cords. Failure to observe these warnings could result in severe injury or death.
• Handle installation: Ensure the handle is properly installed and secured with safety spring clips and snap pins before lifting or moving. An improperly installed handle could cause the bender to fall, injuring personnel. Failure to observe this warning could result in severe injury or death.
• Pinch points: Keep hands away from bending shoe, rollers, and conduit when the bender is in use. Failure to observe this warning could result in severe injury or death.
• Conduit movement: Conduit moves rapidly. Ensure the path is clear of obstructions and clearance is adequate before bending.
• Clothing: Do not operate while wearing loose clothing, which can get caught in moving parts.
• Inspection: Inspect the bender before use. Replace worn, damaged, or missing parts with Greenlee parts. Damaged components could break and strike personnel.
• Lifting: Some parts are heavy; lifting may require more than one person.
• Accessories: Use only Greenlee-recommended accessories and attachments.
• Stability: Do not stand on the bender; it may tip over.
• Unattended operation: Do not leave the tool running unattended. Turn power off and unplug after use.
• Bystanders: Ensure all bystanders are away from the work area during operation.
• Work area: Ensure the work area is clean, dry, uncluttered, and well-lit.
• Intended use: Use the tool only for its intended purpose as instructed in this manual. Misuse can result in injury or property damage. Failure to observe these precautions may result in injury or property damage.
• Accessory changes: Unplug the bender before changing accessories. Accidental startup could result in serious injury.

Handle Removal and Replacement

The handle is removable for complex bending and easier replacement.

Removal:

1. Place bender upright.
2. Release spring clip on safety snap pin (78).
3. Remove pin from handle (79) and frame sleeve (1).
4. Repeat steps 1-3 for the other end of the handle.
5. Lift handle to remove.

Replacement:

1. Insert handle (79) into frame sleeves (1).
2. Align handle holes with sleeve holes.
3. Insert safety snap pin (78) through handle and frame sleeve.
4. Engage safety spring clip over the pin end.
5. Repeat steps 2-4 for the other end.

(Diagram description: Shows handle (79) being removed from frame (1) with pin (78) and spring clip.)

Transportation

Ensure the handle is properly installed and secured before lifting or moving. An improperly installed handle could cause the bender to fall, injuring nearby personnel. Failure to observe this warning could result in severe injury or death.

The proper way to lift is by attaching a nylon or polyester sling around the storage spindle, extending between the handle and main frame. Ensure lifting components are rated for the 167 kg (368 lb) weight. Use a ramp for loading/unloading from vehicles without a lift gate.

(Diagram description: Illustrates a sling attached to the bender for lifting.)

Maintenance

The bender gearbox is sealed and requires no periodic flushing or lube replacement. If opened for repair and lube is lost or contaminated, flush with kerosene and refill with 26 fluid ounces of Mobil® 634 synthetic oil. Kerosene is a petroleum hydrocarbon that does not affect seals. Avoid aromatic hydrocarbons (benzine), chlorinated solvents (carbon-tetrachloride), and ketones (acetone) as they are rubber solvents and harmful to the environment.

Chain Adjustment

Both chains require adjustment if the final drive #60 chain is reset. Refer to Exploded View and Parts List.

1. Remove front cover (38) and upper rear guard (37).
2. Loosen eight reductor mounting bolts (19). Remove eccentric cam and move reductor to create chain slack.
3. Remove four eccentric adjustment retaining screws. Rotate to remove slack, align with frame holes, and remount eccentric with bolts.
4. Slide reductor in slotted mounting holes to tension chain. Set tension with eccentric cam.

(Diagram description: Shows the reductor mounting bolts, eccentric cam, and related components for chain adjustment. Includes torque specifications: 47 Newton-meters (35 ft-lb) for reductor bolts, 20 Newton-meters (15 ft-lb) for eccentric cam.)

⚠️ Disconnect power before servicing, adjusting, or changing shoes/rollers. Failure to observe this warning could result in severe injury or death.

Electrical Control Unit Removal

⚠️ Disconnect power supply before servicing. Servicing should only be done by trained technicians. Failure to observe this warning could result in severe injury or death.

1. Remove cover using ten 5/16" hex screws.
2. Disconnect pendant switch plug from circuit board and remove through cord grip.
3. Remove two hex mounting screws (one on each side).
4. Remove motor leads, power cord ground wire, and neutral wire before removing the control unit.

(Diagram description: Shows a close-up of the electrical connections with labels for "3/8" Hex Mounting Screw" and "Line Connection at Circuit Breaker".)

Troubleshooting

The following flow charts suggest troubleshooting procedures for common bender problems. They do not cover all possible issues.

⚠️ Electric shock hazard: Contact with live circuits can cause severe injury or death. Some steps require power and should only be performed by authorized service personnel familiar with safe procedures. Failure to observe these warnings could result in severe injury or death.

Won't Bend:

• Is 115 VAC measured at PGU board input?
• If YES: Does the green LED on the I/O board light?
• If YES: Does the green LED on the PGU light?
• If YES: Does amber or red LED on I/O light when BEND or UNLOAD is pressed?
• If YES: Does relay on I/O operate when BEND or UNLOAD is pressed?
• If YES: Replace PGU.
• If NO at any step, follow indicated corrective actions (e.g., check power, replace PGU, check I/O board, unplug/check switch, replace I/O).

Trips Circuit Breaker:

• Are proper support rollers and shoe groove being used for conduit type/size?
• If YES: Use 115 VAC.
• If NO: Follow directions in instruction manual.
• Is current on 115 VAC line exceeding 20 amps? (If YES, replace circuit breaker.)
• Is DC current to motor exceeding 17 amps? (If YES, replace motor.)
• When BEND is pressed, is voltage to motor 20-50V over AC line voltage? (If YES, replace bridge rectifier.)
• Are connectors corroded? (If YES, clean.)

Won't Stop:

• Is supply line voltage low? (If NO, use 115 VAC.)
• Does bender stop when pendant is unplugged? (If NO, replace pendant switch.)
• If YES to both, replace PGU.

Bender Only Runs in One Direction:

• Does amber or red LED light when switch is pressed?
• If YES: When amber or red LED is on, is 12 VDC measured at large relay coil on PGU?
• If YES: Replace 918 6645.6 relay.
• If NO: Move six-wire connector on PGU from "To I/O" to "Test." Alternately press BEND and UNLOAD. Does yellow "direction" LED on PGU turn on and off?
• If YES: Replace PGU.
• If NO: Replace I/O.

Quick Diagnostics for Electronic Problems:

1. With bender unplugged, switch six-wire connector on PGU from "To I/O" to "Test."
2. Plug in unit.
3. Press BEND. Contactor on I/O should activate.
   • If not, check for 12 VDC at contactor coil. If present, replace contactor 918 6645.6; otherwise, replace I/O.
   • If bender runs, replace PGU.
   • Check PGU near "test" connector: Green "Power" LED ON, Yellow "Direction" LED OFF, Red "PWM" LED slowly dimly ON. If not, replace I/O.
4. Press UNLOAD. Contactor on I/O should activate.
   • If not, check for 12 VDC at contactor coil. If present, replace contactor 918 6645.6; otherwise, replace I/O.
   • Check PGU near "test" connector: Green "Power" LED ON, Yellow "Direction" LED ON, Red "PWM" LED slowly dimly ON. If not, replace I/O.
5. Press BEND. With an insulated object, carefully press black button "S1" on PGU. Bender should run slowly. If not, replace PGU.

Exploded Views and Parts Lists

(Diagram description: Exploded view of the Greenlee 555 Deluxe Electric Bender with numbered parts.)

Parts List (Pages 11-12): Detailed lists of components with Key, Part No., Description, and Quantity. Key components include frame parts, bearings, sprockets, chains, reductor, motor, conduit fittings, guards, covers, screws, nuts, and electronic assemblies.

115 Volt Motor Parts List (Page 20): Exploded view and parts list for the motor, including fan cover, retaining ring, fan, end bell nut, bell, brushes, thrust washer, shell and magnet assembly, armature, bearing kit, tie bolt, connector, and brush cover.

Bending Shoes and Roller Supports (Pages 21-25): Detailed lists and diagrams for various bending shoes and roller supports designed for different conduit types and sizes:

• 1/2" to 1-1/4" IMC and Rigid Conduit
• 1-1/2" to 2" Rigid Conduit
• 1/2" to 1-1/4" EMT Conduit
• 1-1/2" EMT Conduit
• 1-1/2" IMC Conduit
• 2" EMT Conduit
• 2" IMC Conduit
• 1/2" to 1-1/4" 40 Mil PVC-Coated Rigid Conduit
• 1-1/2" to 2" 40 Mil PVC-Coated Rigid Conduit
• EMT Roller Support Unit
• IMC Roller Support Unit

Each section includes diagrams of the components and a parts list with Key, Part No., Description, and Quantity.

Electrical Control System Layout (Page 13)

(Diagram description: Schematic showing the layout and connections of the electrical control system, including power cord, pendant control, motor, and electronic control assemblies like the I/O Control and Power Generation Unit.)

I/O Control

I/O Electrical Schematic (Page 14)

(Diagram description: Detailed schematic of the I/O electrical system, showing components like PIC microcontroller, LEDs, relays, transistors, and connectors.)

I/O Electrical Schematic Parts List (Page 15):

Lists components used in the I/O schematic, including capacitors, diodes, LEDs, connectors, transistors, resistors, processor, and resonator, with their respective part numbers and suppliers.

PCB Layout (Page 16)

(Diagram description: Printed Circuit Board (PCB) layout diagram for the I/O Control assembly, showing component placement.)

Power Generation Board

Power Generation Unit Schematic Diagram (Page 17)

(Diagram description: Schematic diagram of the Power Generation Unit, illustrating its electronic components and connections, including power input, control signals, and output to relays.)

Power Generation Unit Parts List (Pages 18-19):

Lists components for the Power Generation Unit, including capacitors, diodes, LEDs, connectors, choke, MOSFET, transistors, resistors, switches, and integrated circuits (ICs), with part numbers and suppliers.

Layout Diagram - Power Generation Unit (Page 19)

(Diagram description: Layout diagram showing the placement of components on the Power Generation Unit PCB.)

Motor

Exploded View and Parts List - 115 Volt Motor (Page 20)

(Diagram description: Exploded view of the 115 Volt Motor with numbered parts. Includes a parts list detailing motor components like fan cover, armature, bearings, and brushes.)

Bending Shoes & Roller Supports

Detailed sections with diagrams and parts lists for various bending shoes and roller supports for different conduit types and sizes, as listed in the Table of Contents.