Greenlee 555BAT Instruction Manual
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Greenlee 555BAT Instruction Manual

Battery-powered bender
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INSTRUCTION MANUAL
™
555BAT
BATTERY-POWERED
BENDER
SERIAL CODE ACB
Read and understand this material before operating
or servicing this equipment. Failure to understand how
to safely operate this tool could result in an accident
causing serious injury or death.
999 2601.6
© 1999 Greenlee Textron
IM 1321 REV 2 5/99

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Summary of Contents for Greenlee 555BAT

  • Page 1 Read and understand this material before operating or servicing this equipment. Failure to understand how to safely operate this tool could result in an accident causing serious injury or death. 999 2601.6 © 1999 Greenlee Textron IM 1321 REV 2 5/99...

  • Page 2: Table Of Contents

    Greenlee Catalog Number 26330, for bending 1-1/2" – 2" Intermediate Metallic Conduit • Greenlee Catalog Number 28007, for bending 1/2" – 2" Rigid Steel Conduit or Schedule 40 Steel Pipe • Greenlee Catalog Number 37279, for bending 1/2" – 2" 40 Mil PVC– Coated Rigid Steel...

  • Page 3: Important Safety Instructions

    Safety is a critical factor in the design of Greenlee equipment. The best program starts with a safety-conscious operator. The information highlighted in this bulletin describes operating practices for the benefit of the workers who will use our equipment in their daily jobs.
  • Page 4 Failure to observe this warning can result in severe injury or death. SAVE THESE INSTRUCTIONS Additional copies of this manual are available upon request at no charge. Greenlee Textron / Subsidiary of Textron Inc. Electric shock hazard: • Do not modify the charger power cord or plug.
  • Page 5 SAVE THESE INSTRUCTIONS Additional copies of this manual are available upon request at no charge. Greenlee Textron / Subsidiary of Textron Inc. Before servicing: turn bender OFF, disconnect the charger from the power source and disconnect battery cables.

  • Page 6: Grounding Instructions For Charger

    METALLIC SCREW ADAPTER GROUNDING PIN Greenlee Textron / Subsidiary of Textron Inc. The charger’s electric cord has a grounding conductor and a grounding plug as shown. Do not modify the plug. Connect the plug to a 15-amp GFCI protected receptacle that is properly installed and grounded in accordance with all national and local codes and ordinances.

  • Page 7: Features

    4. Spare Roller Support Storage 5. Lockable Battery Compartment 6. 12-Volt Batteries 7. Roller Support Greenlee Textron / Subsidiary of Textron Inc. Secure the battery compartment by attaching a lock at the hole behind this leg. 8. Battery Charger Power Cord 9.

  • Page 8: Specifications

    Voltage ... 12 Volts Current Rating ... 60 Amp-Hours Nominal Quantity ... 2 Operating and Charging Temperature Range ... -4 to 120 F (-20 to 48 C) Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070...

  • Page 9: Bending Attachment Groups

    23499 Bending Shoe for 1-1/2" 23505 Bending Shoe for 2" 23541 Roller Support Unit for 1-1/2" – 2" 23818 Storage Box Greenlee Textron / Subsidiary of Textron Inc. 26330: 1-1/2" – 2" IMC UPC No. 78-3310- 25263 25268 25273 23818 PVC-Coated Rigid 37279: 1-1/2"...

  • Page 10: Introduction

    555BAT™ Battery-Powered Bender Introduction 555BAT™ Battery-Powered Bender The 555BAT™ is intended to bend 1/2" – 2" conduit and Schedule 40 pipe. The bender can be used in either the vertical or horizontal bending positions. With fresh, fully-charged batteries, the bender can perform over 100 bends in 2"...

  • Page 11: Preparation

    Failure to observe this warning can result in severe injury or death. Greenlee Textron / Subsidiary of Textron Inc. Batteries contain acid. Wear rubber gloves and face shield. Use insu- lated tools when inspecting or working with the batteries.
  • Page 12 5. To protect the battery cables from damage, place the excess wire into the space between the batteries and the side of the battery compartment. Greenlee Textron / Subsidiary of Textron Inc. 6. Allow the batteries to charge for approximately one hour.

  • Page 13: Setup

    Installing a Bending Shoe Greenlee Textron / Subsidiary of Textron Inc. 2. Mount the appropriate support unit onto the leg of the bender and install the hinge pin, as shown.

  • Page 14: Operation

    Failure to observe this warning can result in severe injury or death. Greenlee Textron / Subsidiary of Textron Inc. 1. Turn the Power Switch/Circuit Breaker to ON. 2. Press BEND or UNLOAD until the shoe is 5 – 10 before the 0 starting point.
  • Page 15 Press BEND momentarily until the bend is complete. Engaging the Loading Pedal (for 1-1/2" – 2" EMT or IMC Only) Greenlee Textron / Subsidiary of Textron Inc. Finished Bend 6. Unload the Bender. a. Press UNLOAD. The shoe will rotate and drop the Roller Support Unit (EMT and IMC only).

  • Page 16: Adjusting The Squeeze

    In order to distribute the load evenly, adjust both bolts to the same setting. See the illustration. 3. Tighten the set screws. Greenlee Textron / Subsidiary of Textron Inc. Adjusting the Squeeze Standard Squeeze Setting Adjusting Bolts are at the Same Setting 5/8"...

  • Page 17: Illustrated Bending Glossary

    Greenlee Textron / Subsidiary of Textron Inc. 7. offset bend — two opposite bends with the same degree of bend; used to avoid an obstruction 8.

  • Page 18: Bending Instructions

    Compensate by overbending as shown in the Scale Reading Table. STUB LENGTH BENDING DEDUCT MARK 1 BENDING MARK 1 Greenlee Textron / Subsidiary of Textron Inc. Deduct Table SIZE DEDUCT Figures are approximate Scale Reading Table SIZE 18-3/4 17-1/2 32-1/2 47-1/2 63-3/4...

  • Page 19: Bending Instructions

    180 . Make the second bend. LENGTH “X” MARK 1 CENTER TO CENTER DISTANCE LENGTH HEIGHT OBSTRUCTION Greenlee Textron / Subsidiary of Textron Inc. Offset Table OFFSET Max Conduit Size Center-to-Center Max Conduit Size Center-to-Center Max Conduit Size Center-to-Center...

  • Page 20: Additional Bending Instructions

    5. Bend the conduit. HEIGHT ANGLE MARK Greenlee Textron / Subsidiary of Textron Inc. Offsets An offset is used to route the conduit around an obstruc- tion. To make an offset, two equal bends are required. The distance between the two bends is the center-to- center distance.
  • Page 21 LENGTH TO END OF SECOND BEND ANGLE LENGTH – Z MARK 1 Greenlee Textron / Subsidiary of Textron Inc. Three-Bend Saddle 1. Select the size and type of conduit. Measure the height of the obstruction and the distance from the end of the conduit to the center (LENGTH TO CENTER) of the bend.
  • Page 22 L2 + STRAIGHT SECTION LENGTH – Z MARK 1 MARK 2 Greenlee Textron / Subsidiary of Textron Inc. U-Bends 1. Select the size and type of conduit. Determine the LENGTH and the HEIGHT. 2. Find the table that corresponds to the size and type of conduit selected in Step 1.

  • Page 23: Additional Bending Tables

    MINIMUM H = 1.12 22.5 22.5 22.5 22.5 MINIMUM H = 1.94 MINIMUM H = 2.92 MINIMUM H = 5.27 MINIMUM H = 8.03 MINIMUM H= 13.95 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 3.74 11.47 19.20 26.92 34.65...
  • Page 24 22.5 22.5 22.5 22.5 MINIMUM H = 2.66 MINIMUM H = 4.09 MINIMUM H = 7.65 MINIMUM H = 11.92 MINIMUM H = 21.38 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 1.35 9.07 16.80 24.53 32.26...
  • Page 25 22.5 22.5 22.5 22.5 MINIMUM H = 3.28 MINIMUM H = 4.94 MINIMUM H = 8.95 MINIMUM H = 13.63 MINIMUM H = 23.74 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 6.26 13.99 21.72 29.44 7.71...
  • Page 26 22.5 22.5 22.5 22.5 MINIMUM H = 2.05 MINIMUM H = 3.06 MINIMUM H = 5.49 MINIMUM H = 8.31 MINIMUM H = 14.33 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 3.03 10.76 18.48 26.21 33.94...
  • Page 27 22.5 22.5 22.5 22.5 MINIMUM H = 2.88 MINIMUM H = 4.38 MINIMUM H = 8.06 MINIMUM H = 11.32 MINIMUM H = 21.96 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 1.08 8.81 16.52 24.25 31.97...
  • Page 28 22.5 22.5 22.5 22.5 MINIMUM H = 3.47 MINIMUM H = 5.20 MINIMUM H = 9.38 MINIMUM H = 14.25 MINIMUM H = 24.72 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 5.87 13.59 21.32 29.05 7.71...

  • Page 29: Additional Bending Tables

    22.5 22.5 22.5 22.5 MINIMUM H = 3.20 MINIMUM H = 4.84 MINIMUM H = 8.80 MINIMUM H = 13.45 MINIMUM H = 23.53 Greenlee Textron / Subsidiary of Textron Inc. 2" 4" 6" 8" 10" 6.41 14.14 21.87 29.60 7.71...

  • Page 30: Maintenance

    Replace the screws. Tip the bender over onto its back to expose the bottom of the reductor. Greenlee Textron / Subsidiary of Textron Inc. 7. Insert a 1/2" square drive into the eccentric cam (8), as shown. Note: The eccentric cam has two mounting holes for different adjustment positions.

  • Page 31: Replacing The Battery

    RBRC (Rechargeable Battery Recycling Corporation) at 1-800-8-BATTERY. Provide a copy of the battery MSDS (Material Safety Data Sheet, supplied with the 555BAT™) for the battery recycler. 5. Connect the battery cables and cover the battery terminals with the protective boots, as shown.

  • Page 32: Troubleshooting

    Batteries will not charge. Low battery life. Bender overbends conduit slightly. Bender underbends conduit slightly. Greenlee Textron / Subsidiary of Textron Inc. PROBABLE CAUSE Power switch is OFF. Battery voltage is low. Battery connections are loose. Battery voltage is low.

  • Page 33: Exploded View

    555BAT™ Battery-Powered Bender Exploded View Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070...
  • Page 34 PENDANT SWITCH CORD MOTOR WHITE MOTOR LEAD BLACK BLACK MOTOR LEAD Q102 Q101 R101 PENDANT SWITCH RECEPTACLE PENDANT SWITCH BLACK BATTERY #2 BATTERY #1 SEE THE NEXT PAGE FOR A COMPLETE TERMINAL BLOCK WIRING ILLUSTRATION...
  • Page 35 Black (–) Battery Cable Red Charger Cable with Fuse Black Charger Cable with Fuse Red (+) Battery Cable Greenlee Textron / Subsidiary of Textron Inc. BLACK BLACK Connect red wire to positive (+) terminal of gauge. Connect black wire to negative (–) terminal of gauge.

  • Page 36: Parts List

    54552 50516 39822 86901 53370 53369 53936 04889 05138 Greenlee Textron / Subsidiary of Textron Inc. Part No. Description 500 4886.4 Bracket, battery mounting ... 1 503 9742.7 Frame ... 1 905 2646.5 Nut, hex, 3/8–16 lock ... 1 905 5048.0 Screw, 3/8–16 x 12.00 carriage ...
  • Page 37 05105 54764 51602 52335 05118 55058 86894 86903 05104 Greenlee Textron / Subsidiary of Textron Inc. Part No. Description 918 6895.5 Switch, double throw ... 1 500 0182.5 Electronic control unit ... 1 905 5047.1 Boot, toggle switch ... 1 918 6896.3...
  • Page 38 05143 05155 30392 33937 38974 Literature: Battery charger manufacturer’s instructions MSDS for lead/acid batteries Greenlee Textron / Subsidiary of Textron Inc. Part No. Description 500 5114.8 Wire (black) ... 1 500 5112.1 Wire (red) ... 1 500 5094.0 Wire (black) ... 2 500 5095.8...

  • Page 39: Roller Support Units

    502 3932.5 502 3510.9 502 3511.7 502 7983.1 905 2464.0 Greenlee Textron / Subsidiary of Textron Inc. Description Roller Support Unit, 1-1/2" – 2" EMT Frame unit, roller support ... 1 Screw, cap, 1/2–13 x 1.00 hex head ... 2 Screw, set, 1/2–13 x .750 slotted ...
  • Page 40 502 5274.7 502 3511.7 502 8335.9 502 8334.0 905 2464.0 Greenlee Textron / Subsidiary of Textron Inc. Description Roller Support Unit, 1-1/2" – 2" IMC Frame unit, roller support ... 1 Screw, cap, 1/2–13 x 1.00 hex head ... 2 Screw, set 1/2–13 x .750 slotted ...

  • Page 41: Motor-24 Volt

    918 6906.4 918 6907.2 918 6421.6 918 6418.6 918 6424.0 918 6426.7 Greenlee Textron / Subsidiary of Textron Inc. Description Motor, 24 Volt ... 1 90 Connector ... 1 Fan Cover ... 1 Retaining Ring ... 1 Fan ... 1 End Bell Nut ...

  • Page 42: Control Assembly

    REV 1 PIC16C620 J101 To J2 on Printed Circuit Board AMP 350715-1 J102 To J3, J4 on Printed Circuit Board J103 Greenlee Textron / Subsidiary of Textron Inc. YELLOW BLUE WHITE R101 1 OHM, 50 W WHITE BATTERY +24 Q101 IXFN200N07...
  • Page 43 555BAT™ Battery-Powered Bender Control Assembly (cont’d) Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070...

  • Page 44: Control Assembly

    AAVID Q4,5,D6 generic Q4,5,D6 generic generic Greenlee Textron / Subsidiary of Textron Inc. Model/Part No. Description Capacitor 100 F 50V ... 2 Capacitor 47 F 50V ... 1 Capacitor 4.7 F 50V ... 1 Capacitor .1 F 50V ... 3 Capacitor 10 F 50V ...

  • Page 45: Bending Shoes And Roller Supports

    905 1529.3 Retain. ring, .875, Truarc # 5160-87 ... 2 501 8818.6 Hook ... 1 501 8842.9 Pin, hook ... 1 502 3422.6 Stud, drive ... 3 Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070...
  • Page 46 905 1529.3 Retaining ring, .875, Truarc #5160-87 ... 2 500 0195.7 Hook ... 1 501 8842.9 Pin, hook ... 1 502 3422.6 Stud, drive ... 3 Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070...
  • Page 47 1/2" Roller axle ... 1 11 500 0924.9 3/4" Roller axle ... 1 12 500 0925.7 1" Roller axle ... 1 13 500 0926.5 1-1/4" Roller axle ... 1 Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070...

  • Page 48: Bending Shoes And Roller Supports

    2" Roller axle ... 1 14 503 2025.4 Spacer ... 1 Greenlee Textron / Subsidiary of Textron Inc. Customer Service (International): 815/397-7070 • Fax: 815/397-1391 Customer Service (North America): 800/435-0786 • Fax: 800/451-2632, 815/397-1865 4455 Boeing Drive, Rockford, IL 61109-2988 USA Canada Fax: 800/524-2853 Printed in the U.S.A.

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