Greenlee 855 Service Manual
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Greenlee 855 Service Manual

Greenlee 855 Service Manual

01711 optional deluxe pendant
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SERVICE  MANUAL
855
®
Smart Bender
®
and 01711 Optional Deluxe Pendant
Serial Code ADY
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99943603
© 2007 Greenlee Textron Inc.
SB 290 REV 4 10/07

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Do you have a question about the 855 and is the answer not in the manual?

Questions and answers

Billy Mccall
June 11, 2025

bender will not rotate around fully from IMC/RIDGID to EMT side. stops at 94 and says " UP ". Why is this?

0
1 comments:
Mr. Anderson
June 11, 2025

The Greenlee 855 bender stops at 94 degrees and displays "UP" when trying to rotate from IMC/RIDGID to EMT side because the bender was advanced to 93 degrees. This is a known condition where the display shows "UP" and the bender does not bend further. The solution is to press the UNLOAD button to return it to the desired position.

This answer is automatically generated

0
Diego Pineda
July 30, 2025

what is a PGU and how do I replace it

0

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Summary of Contents for Greenlee 855

  • Page 1 ® Smart Bender ® and 01711 Optional Deluxe Pendant Serial Code ADY Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 99943603 © 2007 Greenlee Textron Inc. SB 290 REV 4 10/07...

  • Page 2: Table Of Contents

    Instruction Manual: 99943590 (IM 1500) All specifications 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. Smart Bender 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 855 Smart Bender Electric shock hazard: • Connect the power cord to a 120 V, 20 A receptacle on a ground fault-protected circuit only.

  • Page 4: Important Safety Information

    Be sure clearance is adequate before starting the bend. • Inspect the bender before use. Replace worn, damaged, or missing parts with Greenlee replace- ment parts. A damaged or improperly assem- bled component could break and strike nearby personnel.

  • Page 5: Grounding Instructions

    4. Securely attach the sling or chain to the lifting device. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender Wear eye protection when operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from flying debris.

  • Page 6: Setup

    1. Apply foot pressure to the lever below the crossbar. 2. Pull the bender toward you until it rolls off the kickstand. Greenlee / A Textron Company 855 Smart Bender Pivoting the Bending Head • Do not rotate the bending head if one or more of the bending shoes is removed.

  • Page 7: Adjustments

    Less Bend 1/2" to 1-1/4" Limit Switch Adj. Screws 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender ® 1/4" Cam Holding Surface...

  • Page 8: Maintenance

    3 mm (1/8") diameter hole in each roller. Rotate each roller to distribute the lubricant. 4. Spray the pivot pin. 5. Wipe away any excess lubricant. 6. Replace the roller support and pivot pin. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender ®...
  • Page 9 Remove the tail roller (82) and center roller (85). • Remove all components of the split roller assembly. Greenlee / A Textron Company 855 Smart Bender 10. Clean off all of the grease and dirt. 11. Inspect each item. Replace any worn, damaged, or missing items. 12. Lubricate all working surfaces with a high-quality grease.

  • Page 10: Maintenance

    Unplug the brush and remove it. Replace it if the length is less than 1/4". 6. Reassemble in reverse order. Greenlee / A Textron Company 855 Smart Bender Setting Roller Support Limit Switch The switch is activated by the main outer roller support arm, in the retracted position. Retract the switch from...

  • Page 11: Bender Head Disassembly

    5. Remove the two screws, lock washers, and nuts, and then remove the relay. 6. Assemble in reverse order. See Electrical Control System Layout for location of key numbers. Greenlee / A Textron Company 855 Smart Bender Input/Output Board (I/O) 1. Remove the four screws securing the top cover and remove the cover. 2. Disconnect the receptacle unit (4).

  • Page 12: Bender Head Disassembly

    Torque the hub set screws to 0.16 Nm (22 in-oz). • Jog the motor and check Quad 1 and Quad 2 LEDs for on/off pulsing. 1/2" to 1-1/4" Limit Switch Adj. Screws 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender ®...

  • Page 13: Motor Disassembly

    Note:  Lifting slings must attach to the lifting mecha- nism within the width boundaries of the bender to  prevent the lifting eyes from sliding off once the  retaining rings are removed. CORRECT INCORRECT Greenlee / A Textron Company 855 Smart Bender 5. Disconnect the motor leads at the relay and the ground wire. 6. Remove the five motor mounting bolts and nut. 7. Remove the motor. Note:  Attach a wire or string to the motor leads at  the power generation board to serve as a retrieval  line to pull the new wire through the unit.

  • Page 14: 1/2" To 1-1/4" Side Exploded View

    1/2" to 1-1/4" Side Exploded View Note:  Refer to the “Main Parts List” to identify the parts  in this illustration. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender 43 Shoe Unit 1/2" to 1-1/4" consists of 221, 222, 223, 224 and 225...

  • Page 15: 1-1/2" To 2" Side Exploded View

    1-1/2" to 2" Side Exploded View Note:  Refer to the “Main Parts List” to identify the parts  in this illustration. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender The Roller Support Unit exploded view is on the following page. 44 Shoe Unit 1-1/2" to 2" consists of 224, 226, 227, 228 and 229 ®...

  • Page 16: 1-1/2" To 2" Roller Support Unit Exploded View

    1-1/2" to 2" Roller Support Unit (50005740) Exploded View Note:  Refer to the “Main Parts List” to identify the parts   in this illustration. 100* *Two required Greenlee / A Textron Company 93 151 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender 99, 119 or 150 ®...

  • Page 17: Motor And Gearbox Exploded View And Parts List

    2. Assemble all Belleville washers so that I.D.’s butt and O.D.’s contact bearings. 3. Tighten motor nuts (24) to 3/4 Nm (30/35 in-lb). 4. Insert commutator brushes before connecting push-on terminals. Greenlee / A Textron Company UPC No. Key 78-3310- Part No. 86705 86706...

  • Page 18: Main Exploded View

    Main Exploded View 209, 211, 212 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender Optional Kit ® 14, 28...
  • Page 19 4, 4A Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender 99, 119 or 150 93 151 = Cam Repair Kit (50079395) If the chain breaks, replace it with new chain (90542509)—not another master link.

  • Page 20: Main Parts List

    90546199 Screw, cap #4-40 x .62 skt ..2 49 38646 50386468 Encoder unit, optical ...1 50 50572 90505727 Screw, cap #8-32 x .50 skt ..4 51 86646 91866464 Brake, motor ...1 Greenlee / A Textron Company 855 Smart Bender UPC No. Key 78-3310- Part No. Description 52 38807 50388070 Key, brake ...1 53 54616 90546164 Spacer, round plastic ...2 54...

  • Page 21: Main Parts List

    90542762 Caster, swivel ...2 220 38156 50381563 Block, reinforcement ...2 221 31710 50317105 1/2" to 1-1/4" IMC, Rigid hook ...1 223 31712 50317121 1/2" to 1-1/4" EMT hook ..1 Greenlee / A Textron Company 855 Smart Bender UPC No. Key 78-3310- Part No. Description 224 52479 90524799 Drive bolt, 1/2-13 x .62 socket head cap screw ..6 225 51088 90510887 1/2" to 1-1/4" hook bolts, 3/8-16 x 1-1/4 socket head cap screw ...8...

  • Page 22: Electrical Control System Layout And Parts List

    50060341 Red Relay–PGU Wire 12 50060350 Black Relay–PGU Wire 13 50386484 I/O–PGU Wire Unit 14 91858224 Limit Switch 15 50060309 Input/Output Control Unit 16 Directional Test Toggle Switch Greenlee / A Textron Company TO RELAY BLACK BLACK RED BLACK YELLOW –HV YELLOW GREEN TO DRIVE UNIT Key Part No. 17 18 50060503 19...

  • Page 23: Power Generation Unit Schematic Diagram

    Power Generation Unit (50054678) Schematic Diagram Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender ®...
  • Page 24 Generic R9,R11 Generic R10,R13 Generic R15 Dale KRL Riedon R16,R23,R25 Generic R17 Dale KRL Riedon R18 Dale KRL Greenlee / A Textron Company Part Number Description 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 ECE-S2EU102Z Capacitor, 1000 uF, 250 volts...
  • Page 25 Generic R27 Generic R29 Generic Panasonic Motorola Micrel QT-Opto Siemens 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 0.25" off-board. Power Generation Unit (50054678) Layout Diagram Greenlee / A Textron Company Part Number Description UT-2B 20K Resistor, 1 kΩ, 1/4 watt, 5% Resistor, 1.5 MΩ, 1/4 watt, 5% Resistor, 100 Ω, 1/4 watt, 1% Resistor, 1.5 kΩ, 1/4 watt, 1% Resistor, 27.4 kΩ, 1/4 watt, 1% Resistor, 68.1 kΩ, 1/4 watt, 1% EVQ-PAC09K Switch, momentary pushbutton LM339AN IC, low power quad comparitor...

  • Page 26: Input/Output Board Schematic Diagram

    Input/Output Board (50060309) Schematic Diagram HOME HOME HOME HOME SIZE SIZE SIZE SIZE SIZE SIZE EEDO/SDA EECLK/SCL EEDI EECS Greenlee / A Textron Company HSO.0 Select Pendent HSO.2 BRAKE HSO.1 DIRECTION HSI.3/HSO.5 HSI.2/HSO.4 HSO.3 HSO.2 HSO.1 HSO.0 HSI.1 HSI.0 HSO.3...
  • Page 27 U3,U4 Robinson Nugent Microchip Microchip Robinson Nugent Generic Dallas Dallas Maxim Generic Generic Greenlee / A Textron Company Part Number Description RPE110COG220J050V Capacitor, 22 pF, 50 volts RPE110COG220J0100V A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts SA115C104KAA C420C104K5R5CA UVZ1E100MDH Capacitor, 10 uF, 25 volts A102K15X7RHVVWA Capacitor, .001 uF, 100 volts...
  • Page 28 Input/Output Board (50060309) Layout Diagram TEST1 BRAKE QUAD1 QUAD2 HOME1 HOME2 TEST2 BRAKE Greenlee / A Textron Company ENCODER HOME 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender GREENLEE TEXTRON c2001 LOCKOUT ®...

  • Page 29: Standard Pendant Switch Schematic Diagram, Parts List, And Layout Diagram

    Standard Pendant Switch (50013050) Schematic Diagram Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 855 Smart Bender ®...
  • Page 30 MOLEX RN1 Generic Philips Philips VR1 Micrel Mounting Hardware for VR1 Generic Generic Standard Pendant Switch (50013050) Layout Diagram GREENLEE TEXTRON c2001 Greenlee / A Textron Company Part Number Description 1C20X7R104K050B Capacitor, ceramic, .1 uF, 50 volts (minimum), radial, or Equal .2 cc, X7R 1N400x (x=1 to 7) Diode MAN-6910 LED display, common anode, 2 digit x .56, 7 seg + dec, HDSP-5521 18-lead .6" DIL...

  • Page 31: (50017004) Exploded View And Parts List

    Optional Bending Attachments for 1/2" to 2" 40 Mil PVC-coated Rigid (50017004) Exploded View and Parts List Greenlee / A Textron Company UPC No. Key 78-3310- Part No. 00572 31919 00934 00567 00570 51088 52479 31918 31916 53396 00933 51353 10 00923...

  • Page 32: Troubleshooting

    Display comes on, but does not count during bend. Bender operates in wrong direction. Bends are overbent a few degrees. Bends are underbent a few degrees. Greenlee / A Textron Company Probable Cause No voltage. Insufficient voltage. Pendant was plugged in while bender was on.
  • Page 33 CANNOT MAKE BENDS THAT CLOSE.” Deluxe pendant displays: “LENGTH IS TOO SHORT” or “HEIGHT IS TOO SHORT.” Greenlee / A Textron Company Probable Cause Roller support is not all the way down. Unloaded to the starting position. Too much squeeze on 1-1/2" or 2"...
  • Page 34 Replace PGU. Greenlee / A Textron Company 855 Smart Bender Will bend – won’t count Is bending shoe on in the proper orientation? When jog is pressed, does the...
  • Page 35 Replace PGU. Greenlee / A Textron Company Bender runs backwards for bend and unload Jump #2 & #4 Is proper size of conduit selected? terminals in pendant.
  • Page 36 20 to 50 volts over the AC line voltage? Are connectors corroded? Replace PGU. Greenlee / A Textron Company Won’t stop Is the supply line voltage low? Does bender stop when the pendant is unplugged? Replace PGU.
  • Page 37 Isolate motor leads from cables that plug into the I/O board. Replace optical encoder. Replace I/O board. Greenlee / A Textron Company Are set screws tight Isolate motor leads in drive hub on from all cables that optical encoder? go to I/O board.

  • Page 38: Troubleshooting

    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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