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Greenlee 555 Service Manual

Greenlee 555 benders: supplementary guide.

 
SERVICE MANUAL
®
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

Summary of Contents

  • Page 1

    SERVICE MANUAL ® 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...

  • Page 2: Table Of Contents

    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.

  • Page 3: Important Safety Information

    Failure to observe this warning will result in severe injury or death. Greenlee / A Textron Company ® Deluxe Electric Bender Electric shock hazard: • Connect the power cord to a 120 volt, 20 amp receptacle on a ground fault protected circuit only.

  • Page 4

    • 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 improperly assembled component could break and strike nearby personnel.

  • Page 5: Handle Removal And Replacement, Transportation

    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.

  • Page 6: Maintenance

    Remount the eccentric with the four bolts. 4. Slide the reductor in slotted mounting holes to the retension chain. Set tension with the eccentric cam. Greenlee / A Textron Company 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"...

  • Page 7

    Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company ® Deluxe Electric Bender 1. Remove the cover retained by ten 5/16" hex screws. 2. Disconnect the pendant switch plug from the circuit board and remove through the cord grip.

  • Page 8: Troubleshooting, Troubleshooting

    UNLOAD is pressed? Does relay on I/O operate when BEND or Replace I/O. UNLOAD is pressed? Replace PGU. Greenlee / A Textron Company ® Deluxe Electric Bender Trips circuit breaker Are the proper support rollers and shoe groove being used for...

  • Page 9

    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 ® Deluxe Electric Bender 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 10

    ® Deluxe Electric Bender ® Exploded View — 555 Deluxe Electric Bender BEND UNLOAD Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 11

    ® Parts List — 555 Deluxe Electric Bender Part No. 50397427 50234528 50328964 90524098 90524101 90524144 90524128 50397630 90540239 50397648 90524136 90545486 90542533 50397656 90545460 90542517 90545478 50084313 90523881 90527879 90545516 90545680 50397583 90542371 91869730 90545494 91852145 91866839 90511700 91862639...

  • Page 12

    Parts List — 555 ® Deluxe Electric Bender (cont’d) Part No. 50190539 50303929 50397591 50351915 90533895 90525019 90545524 90545451 90543351 50339370 50389742 90553233 90517407 50024973 50036386 50001124 90510518 90552687 50397486 50069195 50078690 141A 50078712 141B 50083570 141C 50078674 50078879 50079123...

  • Page 13: Electrical Control System Layout

    ® Deluxe Electric Bender Electrical Control System Layout GREEN WHITE BLACK Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 14

    ® Deluxe Electric Bender I/O Electrical Schematic (50060180) Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 15

    R16,R17,R18,R22,R23 R5,R11,R13,R14 Generic R6,R20,R21 Generic R9,R19 Generic R10,R12 Generic Greenlee Murata Panasonic Greenlee / A Textron Company Part Number Description A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts SA115C104KAA C420C104K5R5CA ECE-A50Z4R7 Capacitor, 4.7 uF, 50 volts UF-1001-DI Diode, Ultra-Fast Switching Rectifier LN38GP...

  • Page 16

    PCB Layout (50060180) GREENLEE TEXTRON ©2000 TO PGU Greenlee / A Textron Company BRAKE 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ® Deluxe Electric Bender DIR B DIR A POWER RELAY...

  • Page 17

    Power Generation Unit Schematic Diagram (50083570) Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ® Deluxe Electric Bender...

  • Page 18

    Generic R10,R13 Generic Dale Riedon R16,R23,R25 Generic Dale Riedon Dale Riedon Greenlee / A Textron Company A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts SA115C104KAA C420C104K5R5CA MKS21.06310 Capacitor, Film, 1 uF, 63 volts A103M15Z5UFVVWA Capacitor, .01 uF, 50 volts SA105E103ZAA 440LS10 Capacitor, .010 uF, 500 volts AC 440LD47 Capacitor, .0047 uF, 500 volts AC...

  • Page 19

    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) Greenlee / A Textron Company Resistor, 1 kΩ, 1/4 watt, 5% Resistor, 1.5 MΩ, 1/4 watt, 5% Resistor, 100 Ω, 1/4 watt, 1%...

  • Page 20: Exploded Views And Parts Lists, Exploded Views And Parts Lists, Motor

    91864313 *Note: Alternate motor. Check motor part number before ordering magnet shell or armature. 91869730 91869757 91869749 Greenlee / A Textron Company 107 108 Description Motor, 115 volt (standard) (SRF-3745-4676-2-56C) ... 1 Fan cover ... 1 Retaining ring ... 1 Fan ...

  • Page 21: Bending Shoes & Roller Supports

    3/8–16 UNC x 1-1/4 SAE grade 5 socket head cap screw ... 1 90510887 3/8–16 UNC x 1-1/4 socket head screw ... 1 Shoe not available separately. Greenlee / A Textron Company ® Deluxe Electric Bender Qty. Qty. Qty. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 22

    Hook, 2" EMT ... 1 50188429 Pin, 2" EMT hook ... 1 50234226 Stud, drive ... 3 90515293 Ring, Tru-Arc #5160-87 retaining ... 2 Greenlee / A Textron Company Bending Shoe 1-1/2" IMC Conduit Qty. Part No. 50253631 50188119 50188372...

  • Page 23

    50009273 1/2" Roller ... 1 50009281 3/4" Roller ... 1 50009290 1" Roller ... 1 50009303 1-1/4" Roller ... 1 Greenlee / A Textron Company 1-1/2" to 2" 40 Mil PVC-Coated Rigid Conduit Qty. Part No. 50372823 50372815 50024990 50179748...

  • Page 24

    ® Deluxe Electric Bender Bending Shoes and Roller Supports (cont’d) *Key No. 21 must be torqued to 54 to 61 Newton-meters (40 to 45 ft-lb). Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 25

    Roller, 2" EMT front ... 1 50237926 Roller, 2" EMT back ... 1 90533941 Screw, 7/16–14 UNC x 1 flat head ... 2 Greenlee / A Textron Company ® Deluxe Electric Bender IMC Roller Support Unit Qty. Part No. Description...

  • Page 26

    Fax: Canada 800-435-0786 Fax: 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. is a subsidiary of Textron Inc. www.greenlee.com 800-451-2632 815-397-1865 800-524-2853 Printed in USA...

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