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Greenlee 555-22, Instruction Manual, Page: 29 / 44

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Greenlee 555-22 Instruction Manual Download Page 29

Greenlee / A Textron Company

29

4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

555

®

-22 Electric Bender

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.

The following flow chart shows the suggested trouble-
shooting procedures when the bender trips the switch/
circuit breaker. It by no means encompasses all possible
problems or solutions.

Troubleshooting  (cont’d)

Trips 555

®

-22 Switch/Circuit Breaker

NO

NO

YES

NO

YES

YES

Follow directions in
instruction manual.

Replace circuit
breaker.

Replace motor.

Replace bridge
rectifier (918 5997.2).

YES

NO

YES

NO

Are the proper roller supports and
shoe groove being used for the
type and size of conduit being
bent?

Is the current on the 220 VAC line
exceeding 20 amps?

Is the DC current to the motor
exceeding 17 amps?

When BEND is pressed, is the
voltage sent to the motor
220 VDC (approx.)?

Are connectors corroded?

Clean the connectors.

Clean contacts or replace
contactor.

Summary of Contents for 555-22

Page 1: ...ectric Bender INSTRUCTION MANUAL Read and understand all of the instructions and safety information in this manual before operating or servicing this tool 999 1817 0 2004 Greenlee Textron Inc IM 1227 REV 7 6 04 ...

Page 2: ...ng Instructions 15 24 Handle Removal and Replacement 25 Transportation 25 Maintenance 26 27 Troubleshooting 28 29 Exploded Views and Parts Lists 30 33 Schematic Diagrams and Parts Lists 34 38 Bending Shoes and Roller Supports 39 43 Description The Greenlee 555 22 Electric Bender is intended to bend 1 2 to 2 conduit and pipe Bending shoe groups are available to accommodate the following types Elect...

Page 3: ...ury 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 this tool Failure to wear eye protection 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 Do not use this tool ...

Page 4: ...property damage Failure to observe these precautions may result in injury or property damage 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 Unplug th...

Page 5: ...tric shock This tool s electric cord has a grounding conductor and a grounding plug as shown Do not modify the plug Connect the plug to a corresponding GFCI protected receptacle that is properly installed and grounded in accordance with all national and local codes and ordinances Do not use an adapter NEMA 6 15 Electric shock hazard Do not modify the plug provided with the tool Connect this tool t...

Page 6: ... lb Power Supply 220 VAC 15 amp GFCI protected receptacle Operating Conditions Temperature 20 C to 49 C 5 F to 120 F Relative Humidity 0 to 98 Capacity 1 2 to 2 conduit schedule 40 pipe 555 22 Electric Bender 1 Handle 2 Pendant 3 Protractor 4 Main Shaft 5 Bending Shoe 6 1 1 2 to 2 Roller Support 7 1 2 to 1 1 4 Roller Support in storage position 8 Bending Instructions Decal 9 Circuit Breaker ON OFF...

Page 7: ...ort unit for 1 2 to 1 1 4 3 17937 Bending shoe for 1 1 2 to 2 4 17984 Roller support unit for 1 1 2 to 2 PVC COATED RIGID 37279 1 1 2 to 2 40 Mil PVC Coated Rigid UPC No Key 78 3310 Description 1 00573 Bending shoe for 1 2 to 1 1 4 2 00946 Roller support unit for 1 2 to 1 1 4 3 37281 Bending shoe for 1 1 2 to 2 4 37282 Roller support unit for 1 1 2 to 2 23818 Storage box 23802 1 2 to 2 EMT UPC No ...

Page 8: ... Shoe 2 Mount the appropriate support unit onto the leg of the bender and install the hinge pin as shown Roller Support Unit Installed Setup Unplug the bender before changing accessories Accidental startup could result in serious injury Wear eye protection when operating or servicing this tool Failure to wear eye protection could result in serious eye injury from flying debris Install pin 3 Mark t...

Page 9: ...lustrated Loading the Conduit Operation 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 Do not operate the bender while wearing loose clothing Loose clothing can get caught in moving parts Failure to observe this warning could result in severe injury or death Wear eye protection when ope...

Page 10: ...ove your foot from the loading pedal c Release the switch as you approach the desired angle of bend d Press BEND momentarily until the bend is complete If bending any other size or type of conduit a Press and hold BEND b Release the switch as you approach the desired angle of bend c Press BEND momentarily until the bend is complete 6 Press UNLOAD The shoe will rotate backward Note If bending EMT o...

Page 11: ...it develops excessive side marking when bent the squeeze is set too high If the conduit becomes exces sively oval or wrinkled the squeeze is set too low 1 Use a screwdriver to loosen the set screws 2 Use a wrench to rotate both adjusting bolts 1 2 turn clockwise to INCREASE squeeze or 1 2 turn counter clockwise to DECREASE squeeze Note In order to distribute the load evenly adjust both bolts to th...

Page 12: ...ght section of conduit or pipe to the bend measured from the end to the outside edge of the conduit or pipe offset bend two opposite bends with the same degree of bend used to avoid an obstruction offset height the distance between the two legs of an offset bend measured perpendicular to the two legs also called amount of offset and depth of offset rise the distance from the end of a straight sect...

Page 13: ... 4 17 1 2 33 3 4 48 3 4 65 95 3 4 20 36 1 4 51 1 4 67 1 2 97 1 2 17 1 2 33 3 4 48 3 4 63 3 4 95 1 21 1 4 36 1 4 51 1 4 66 1 4 97 1 2 17 1 2 32 1 2 47 1 2 63 3 4 95 1 1 4 18 3 4 33 3 4 50 65 96 1 4 18 3 4 33 3 4 50 65 95 1 1 2 17 1 2 33 3 4 48 3 4 63 3 4 95 18 3 4 33 3 4 48 3 4 65 95 2 20 35 50 65 96 1 4 20 35 48 3 4 63 3 4 96 1 4 SIZE Figures are approximate 90 STUBS 1 Measure the length of the re...

Page 14: ... 3 9 2 6 2 0 1 4 Figures are approximate CONDUIT SIZE 1 2 3 4 1 1 1 4 1 1 2 2 X 3 1 16 3 1 16 3 3 16 4 4 1 4 4 1 2 Figures are approximate Offsets 1 Measure the height and length of the obstruction Select the angle to be used 2 See the Offset Table The height of the obstruction must be equal to or greater than the minimum offset 3 Refer to the X Table to find the X dimension Refer to the Offset Ta...

Page 15: ... distance When working past an obstruction it is necessary to determine the location of the first bend The center to center distance is then used to determine the location of the second bend When working toward an obstruction it is necessary to determine the location of the second bend The center to center distance is then used to determine the location of the first bend Working Past an Obstructio...

Page 16: ...e first bending mark 5 Bend the conduit 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 Determine the angle to be used 2 Find the table that corresponds to the size and type of conduit selected in Step 1 3 Under the column labeled ANGLE find the appropri ate angle F...

Page 17: ...n find the row labeled L2 Add L2 to the STRAIGHT SECTION Place the third bending mark this distance from the first bending mark 6 Make the final bending mark L1 inches from the third bending mark 7 Bend the conduit 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 3 Under the column...

Page 18: ... 14 30 16 03 17 76 21 22 28 15 MINIMUM H 6 38 Y 90 1 00 3 00 5 00 8 00 11 00 17 00 29 00 L1 90 10 01 13 01 16 01 22 01 34 01 L2 90 17 30 20 30 23 30 29 30 41 30 Z 90 11 29 11 29 11 29 11 29 11 29 MINIMUM H 11 29 3 4 EMT Y 15 2 35 10 07 17 80 25 53 33 26 40 98 52 58 64 17 87 35 133 71 L1 15 7 72 15 45 23 17 30 90 38 63 46 36 57 95 69 54 92 72 139 08 L2 15 9 17 16 90 24 62 32 35 40 08 47 81 59 40 70...

Page 19: ... L2 60 18 08 20 39 23 85 27 32 34 24 48 10 Z 60 17 02 18 17 19 91 21 64 25 10 32 03 MINIMUM H 9 74 Y 90 1 25 4 25 7 25 13 25 25 25 L1 90 15 02 21 02 33 02 L2 90 25 93 31 93 43 93 Z 90 17 12 17 12 17 12 MINIMUM H 17 12 1 1 4 EMT Y 15 0 26 7 99 15 72 23 45 31 17 38 90 50 49 62 08 85 27 131 63 L1 15 7 71 15 44 23 17 30 90 38 62 46 35 57 94 69 53 92 72 139 08 L2 15 10 07 17 80 25 52 33 25 40 98 48 71 ...

Page 20: ...16 40 19 87 26 80 40 65 L2 60 25 34 28 80 35 73 49 58 Z 60 23 22 24 95 28 42 35 34 MINIMUM H 12 61 Y 90 0 89 3 89 9 89 21 89 L1 90 20 34 32 34 L2 90 33 74 45 74 Z 90 21 77 21 77 MINIMUM H 21 77 2 EMT Y 15 5 15 12 87 20 60 28 33 36 05 47 65 59 24 82 42 128 78 L1 15 7 71 15 44 23 17 30 90 38 62 46 35 57 94 69 53 92 71 139 08 L2 15 10 19 17 92 25 64 33 37 41 10 48 83 60 42 72 01 95 19 141 56 Z 15 14 ...

Page 21: ... 12 18 13 33 14 49 16 22 17 95 21 41 28 34 MINIMUM H 6 55 Y 90 71 2 71 4 71 7 71 10 71 16 70 28 70 L1 90 10 12 13 12 16 12 22 12 34 12 L2 90 17 00 20 00 23 00 29 00 41 00 Z 90 11 26 11 26 11 26 11 26 11 26 MINIMUM H 11 26 3 4 IMC Rigid and 40 Mil PVC Coated Rigid Y 15 1 86 9 58 17 31 25 04 32 77 40 49 52 08 63 68 86 86 133 22 L1 15 7 72 15 45 23 17 30 90 38 63 46 36 57 95 69 54 92 72 139 08 L2 15 ...

Page 22: ...09 16 55 20 02 26 94 40 80 L2 60 18 27 20 58 24 04 27 50 34 43 48 29 Z 60 17 22 18 37 20 11 21 84 25 30 32 23 MINIMUM H 9 91 Y 90 1 01 4 01 7 01 13 01 25 01 L1 90 14 93 20 93 32 93 L2 90 26 16 32 16 44 16 Z 90 17 49 17 49 17 49 MINIMUM H 17 49 1 1 4 IMC Rigid and 40 Mil PVC Coated Rigid Y 15 7 15 14 87 22 60 30 33 38 06 49 65 61 24 84 42 130 78 L1 15 7 71 15 44 23 17 30 90 38 62 46 35 57 94 69 53 ...

Page 23: ...30 76 L1 60 16 41 19 87 26 80 40 66 L2 60 25 31 28 77 35 70 49 56 Z 60 23 28 25 01 28 47 35 40 MINIMUM H 12 66 Y 90 0 75 3 75 9 75 21 75 L1 90 20 35 32 35 L2 90 33 70 45 70 Z 90 21 80 21 80 MINIMUM H 21 80 2 Rigid and 40 Mil PVC Coated Rigid Y 15 4 42 12 15 19 87 27 60 35 33 46 92 58 51 81 69 128 06 L1 15 7 71 15 44 23 17 30 89 38 62 46 35 57 94 69 53 92 71 139 08 L2 15 10 27 18 00 25 73 33 46 41 ...

Page 24: ...16 40 19 87 26 80 40 65 L2 60 25 34 28 80 35 73 49 58 Z 60 22 79 24 52 27 99 34 91 MINIMUM H 12 24 Y 90 1 25 4 25 10 25 22 25 L1 90 20 34 32 34 L2 90 33 74 45 74 Z 90 21 34 21 34 MINIMUM H 21 34 2 IMC Y 15 5 04 12 77 20 50 28 22 35 95 47 54 59 13 82 31 128 68 L1 15 7 71 15 44 23 17 30 90 38 62 46 35 57 94 69 53 92 71 139 00 L2 15 10 19 17 92 25 64 33 37 41 10 48 83 60 42 72 01 95 19 141 56 Z 15 14...

Page 25: ...p 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 Transportation 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 ...

Page 26: ... Flange Mounting Screws Positioning Plate on Eccentric Housing Counter Shaft Tab on Reductor Bracket Eccentric Cam 1 2 Square Reductor Mounting Bolt Two eccentric cam mounting holes provided for varying adjustment positions 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 Chain Adju...

Page 27: ...ounting screws one on each side 3 8 Hex Mounting Screw Electrical control removed from bender 4 Remove the motor leads power cord ground wire and neutral wire before the control unit can be totally removed from the bender Ground Wire Motor Leads Disconnect power supply before servicing bender Servicing to be done only by trained service technician Failure to observe this warning could result in se...

Page 28: ...heck supply voltage circuit operation Unusual conduit characteristics Bend smaller angle to compensate Bends are overbent a few degrees Too much squeeze on 1 1 2 or 2 EMT or IMC conduit Back squeeze off per adjustment instructions Unusual conduit characteristics Bend larger angle to compensate Bends are underbent a few degrees Too little squeeze on 1 1 2 or 2 EMT or IMC conduit Increase squeeze pe...

Page 29: ...ws the suggested trouble shooting procedures when the bender trips the switch circuit breaker It by no means encompasses all possible problems or solutions Troubleshooting cont d Trips 555 22 Switch Circuit Breaker NO NO YES NO YES YES Follow directions in instruction manual Replace circuit breaker Replace motor Replace bridge rectifier 918 5997 2 YES NO YES NO Are the proper roller supports and s...

Page 30: ... Bender Note Key supplied with item 19 reductor 20 38 28 50 30 34 32 29 8 3 6 13 16 15 14 78 10 11 49 7 17 79 53 79 52 41 72 31 57 77 54 54 71 47 58 46 44 43 42 40 39 37 36 35 70 27 26 25 24 24 23 22 21 19 18 14 12 11 9 7 5 4 2 1 80 48 59 Exploded View 555 22 Electric Bender 62 62E 62D 62A 62F 62B 62C ...

Page 31: ... 60 1 17 905 4547 8 Sprocket 40 13T 1 18 500 8431 3 Key reductor sprocket 1 19 905 2388 1 Reductor worm gear 1 20 905 2787 9 Masterlink 40 1 21 905 4551 6 Chain 40 87P 1 22 905 4568 0 Bolt 3 8 16 UNC x 75 7 23 503 9758 3 Eccentric 1 24 905 4237 1 Bolt 3 8 16 UNC x 1 00 5 25 918 5828 3 Motor 220V 1 26 905 4549 4 Conduit Sealtight 1 27 918 5214 5 Elbow Sealtight 1 28 918 6683 9 Strain relief 1 29 90...

Page 32: ...37 0 Decal squeeze adjust 1 58 503 8974 2 Decal circuit breaker 1 59 905 5323 3 Pin Driv Lok 1 8 x 1 2 1 62 500 6913 6 Switch pendant 1 62A 918 6449 6 Switch center off 1 62B 503 1902 7 Handle right half 1 62C 905 3441 7 Screw 6 20 x 625 pan head self tapping 3 62D 503 1901 9 Handle left half 1 62E 503 9837 7 Cord 1 62F 503 5487 6 Decal face plate 1 65 905 4329 7 Screw 8 32 x 37 ground 1 70 905 17...

Page 33: ...an 1 918 5876 3 90 Connector 1 Leeson Motors Part No Description Qty 918 5828 3 Motor 230 volt D C 1 918 6251 5 Bell front end 1 918 6252 5 Bell rear end 1 918 6253 1 Brush plate assembly 2 918 6250 7 Bearing 203 dbl shielded 2 918 6258 2 Thrust washer wave spring 2 918 6255 8 Terminal cover 1 918 6259 0 Terminal cover 1 918 6249 3 Armature 230V 1 905 3613 4 Tie bolt 10 32 x 3 1 4 lg front 4 905 3...

Page 34: ...R BOARD TRAN 230V 115V REC TERM PENDANT SWITCH POWER CORD GROUND GROUND GREEN BREAKER PENDANT RELAY VAR GREY GREY BLACK BLUE WHITE RED PURPLE WHITE RED PURPLE BLACK BLACK BLACK WHITE WHITE GREEN BL AC K W HI TE BLACK WHITE WHITE BLACK 1 2 3 4 5 6 7 8 9 10 11 14 16 17 18 18 18 19 20 20 20 20 21 35 36 26 27 28 29 30 31 32 33 34 R E D 34 BLACK 24 BLUE 25 25 NOTE Route wires to be clear of coil armatu...

Page 35: ...2 x 50 Phillips head 7 19 905 4331 9 Screw 6 32 x 75 Phillips head 2 20 905 0632 4 Nut hex 6 32 9 21 905 4329 7 Screw ground 8 32 x 37 1 24 503 9994 2 Jumper red 3 50 1 25 503 9995 0 Jumper blue terminal to terminal 3 50 2 26 503 9996 9 Jumper blue terminal to terminal 5 50 1 27 500 0031 4 Jumper grey to CR1 coil 18 00 1 28 500 0020 9 Jumper grey to CR1 coil 12 00 1 29 500 0021 7 Jumper black brea...

Page 36: ...Bender Bender Control Schematic Diagram 3 4 1 2 1 2 3 4 PENDANT BEND UNLOAD J2 3 2 1 6 5 4 RELAYS UNLOAD BRAKE BEND J3 VI VO G NTE1936 1N4007 TIME DELAY D4 C3 1200µF K1 A A K L1 L2 TIME DELAY K1 B C3 C2 C1 1N5400 D2 A K 1N5400 D3 A K TRANSFORMER J1 F1 3A 250V 4700µF 100µF C2 C1 U1 12V 1N4007 D1 K A GND ...

Page 37: ... C1 UVX1E101MEA Nichicon 100µF 25V Capacitor 1 C2 ECE A1EU472 Panasonic 4700µF Capacitor 1 C3 EEU FC1E122S Panasonic 1200µF Capacitor 1 D1 4 1N4007 Any Diode 2 D2 3 1N5400 Any Diode 2 K1 CR50 E2 X1 12 Computer Components Inc Relay 1 J1 2 39 28 1043 Molex 4 Pin Minifit Jr Connector 2 J3 39 28 1063 Molex 6 Pin Minifit Jr Connector 1 FUSE 3 AMP 250 VOLT PENDANT 1 3 2 4 1 3 2 4 TRANSFORMER 1 4 2 2 5 3...

Page 38: ...E RELAY K3 A L1 L2 UNLOAD CONTACTOR L1 L2 TIME DELAY K1 B C3 C2 C1 VI VO G NTE1936 1N5400 D2 A K 1N5400 D3 A K F1 3A 250V 4700µF 100µF C2 C1 U1 12V 1N4007 D1 K A K3 B C3 C2 C1 K3 C C5 C6 C4 K1 C C3 C4 P1 S1 T1 220 20 P2 S3 S2 2 1 3 BEND CONTACTOR L2 L1 K1 A K4 A C2 C3 C1 S1 M1 220 VDC K4 D C5 C6 R1 2 OHM 50 WATT K1 D C5 C6 C3 K4 C C4 R3 R2 BR1 C2 C2 C1 C1 K4 B K1 B CB1B GND CB1A J1 AC PLUG PENDANT...

Page 39: ...uit includes items 2 8 1 2 501 7969 1 Pipe hook 1 3 501 7974 8 Pivot 1 4 905 2675 9 5 8 flat washer 1 5 905 1569 2 5 8 11 UNC hex nut 1 6 905 0905 6 5 8 split lock washer 1 7 905 2426 8 5 8 11 UNC x 4 Socket head cap screw 1 8 502 3422 6 Stud drive 4 Shoe not available separately Bending Shoe and Pipe Rest 1 2 to 1 1 4 EMT Conduit Key Part No Description Qty 1 501 7986 1 Pipe rest assembly for 1 2...

Page 40: ...T conduit includes items 1 4 1 1 501 8818 6 Hook 2 EMT 1 2 501 8842 9 Pin 2 EMT hook 1 3 502 3422 6 Stud drive 3 4 905 1529 3 Ring Tru Arc 5160 87 retaining 2 Bending Shoe 1 1 2 EMT Conduit Key Part No Description Qty 502 3499 4 Shoe unit 1 1 2 EMT includes items 1 4 1 1 501 8820 8 Hook 1 1 2 EMT 1 2 501 8841 0 Pin 1 1 2 EMT hook 1 3 502 3422 6 Stud drive 3 4 905 1529 3 Ring Tru Arc 5160 87 retain...

Page 41: ...le 1 10 500 0926 5 1 1 4 roller axle 1 11 500 0927 3 1 2 roller 1 12 500 0928 1 3 4 roller 1 13 500 0929 0 1 roller 1 14 500 0930 3 1 1 4 roller 1 3 2 4 14 5 10 6 6 6 9 8 7 13 12 11 1 8 4 6 5 2 3 7 1 13 15 11 10 11 14 12 9 11 Bending Shoe and Roller Support 1 1 2 to 2 40 Mil PVC Coated Rigid Conduit Key Part No Description Qty 1 503 7282 3 Roller support 1 1 2 to 2 PVC coated Rigid 1 includes item...

Page 42: ...Textron Company 42 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 555C Electric Bender Classic Bending Shoes and Roller Supports cont d EMT IMC 18 19 17 10 8 11 10 14 5 1A 13 2 1B 6 4 16 15 2 12 20 21 7 12 ...

Page 43: ...port 1 19 502 3519 2 Roller 2 EMT front 1 20 502 3792 6 Roller 2 EMT back 1 21 905 3394 1 Screw 7 16 14 UNC x 1 flat head 2 IMC Roller Support Unit Key Part No Description Qty 502 5273 9 Support unit 1 1 2 and 2 IMC roller includes items 1 and 2 1 1B 502 8334 0 Roller 1 2 502 8335 9 Spacer 2 4 502 6325 0 Frame unit 1 5 502 5274 7 Roller 1 1 2 IMC 2 6 502 3511 7 Pin roller support 1 7 502 3932 5 Pi...

Page 44: ... 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 is a subsidiary of Textron Inc www greenlee com Printed in USA ...

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