855® Smart Bender® - CableOrganizer.com
Contents
1. JP1 C7 C Oo o 6 D3 z aa m D2 yi 29 TD R6 gt ooo o o 0 xt 4 o o o ei c f C2 a o ERETI Q5 o s i U3 Ud o o o t 8 E C EE a B o o 1 Ms 52 4 O ils eee d 4 3 o o e D mem om ELF n a s aa R3 sx IB BB X Cmm y on Fu D10 og e e amp NS PWM R17 5 gt 4 1 ut U o D D7 o o o BRAKE m Fe R2 in L o l oi 2 o lt gt 08 s 28109 QUADI EE pex E 09 4 H o 5 lt gt o C13 QUAD2 4 R2 a i R21 2 P i Us s HOME y o GREENLEE TEXTRON E ee Eo in 8 ci JP9 E ws HOME2 015 9 o mn o o i ex c S1 9 li o TEST R9 R0 R30 7 mo d d Pi EN 70609 LOCKOUT R31 o o o o C22 o o C24 O R26 DS Bod O BRAKE ENCODER HOME 23 Greenlee A Textron Company 28 4455 Boeing Dr Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender Standard Pendant Switch 500130502. 09 6 pajou ssa un M G 510161591 V e p oq 40 62 0 1529 je unOu 0 Z UO Spea puag e 20 V AST TL g 6 z rer OVAOOS 4nZ 007 asz snoga N3349 89 y A0sgangol Lid 2 6062 neag 3034 8902041 PAN gg 00 SZ 08 10107 AV doni cine v2 2 005 4 00 SH GM MOTTA a 2 2 2 9 NOLI d MOVIE vid ASE 4007 NL AIAS L am gau L AOL eld eed 8 yL vi iu 6 6 Z pue s 9e1U09 1109 OL veeeeNd 1 001 82 66 20 a Av 6201 82 66 X0ION 14 PE 62H z Sey d x 10100512 4 6d 01 e Z0SV OH ALAZ 5 0 01 VOS 9 5901 82 6 X9ION i pum HE m 2 er Ine A0S n10 a TES 9 20N Y xz NAW Y609Yd DA3 ALAS L 919 20 viu gey 5 2 S a gu d Wd 0123NNOO 1531 NAZZPPOIN oj 9 ER X a 901 82 6 X0ION eee 1 90 eyo S 9 Ss VIN co ar 2 2001 WIS d X001 gin o 019 031034 ASA yost 9 A Su vu Wh negan a za e e i B NOLL23MIQ MOTA DI all 1 ASE 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 23 Greenlee A Textron Company GREENLEE
3. 1 Decal shoe orientation 2 1 Decal Warfilig cocer 2 Deluxe pendant control Vinyl cover not shown 1 2 to 2 PVC shoe group Frame unit includes bearings 1 Cam repair Kiii a 1 Stripping magnetic replacement 1 Service kit includes base and LH amp RH trunnions 1 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender Electrical Control System Layout and Parts List Locate under roller support 14 COM NC NO BLACK WHITE 17 16 22 RED BLACK qp dau YELLOW MONJA MOTAN 19 20 l m Sz TO DRIVE UNIT 2 33 27 18 21 28 Key PartNo Description Key PartNo Description 1 50389416 PGU Power Wire 17 Test Pushbutton Switch 2 50382500 Motor 18 50060503 Yellow Rectifier Wires 3 50079123 Power Cord 19 50060384 Red Rectifier Wire 4 50017080 Receptacle Unit 20 50060422 Black Rectifier Wire 5 50386360 Limit Switch Wire Unit 21 50060368 Wire Unit Power AC 6 50386379 Brake Wire Unit 22 50081519 Selector Switch Unit w o knobs 7 50102354 Unload Lockout Switch Wire Unit 23 50386468 Optical Encoder 8 50060473 Relay Wire Unit 24 50054678 Power Generation Board Assembly 9 50060481 Red Relay Wire 25 50060376 Wire
4. Greenlee A Textron Company 30 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender Optional Bending Attachments for 1 2 to 2 40 Mil PVC coated Rigid 50017004 Exploded View and Parts List UPC No Key 78 3310 00572 31919 00934 1 00567 2 00570 3 51088 4 52479 5 31918 6 31916 7 53396 8 00933 9 51353 10 00923 11 00924 12 00925 13 00926 14 00927 15 00928 16 00929 17 00930 18 54910 19 23818 Part No 50005723 50319191 50009346 50005677 50005707 90510887 90524799 50319183 50319167 90533968 50009338 90513533 50009230 50009249 50009257 50009265 50009273 50009281 50009290 50009303 90549104 50238183 Description Qty Shoe unit 1 2 to 1 1 4 PVC coated Rigid includes items 1 4 1 Shoe unit 1 1 2 to 2 PVC coated Rigid includes items 4 7 1 Support unit 1 2 to 1 1 4 PVC coated Rigid includes items 8 17 1 1 2 to 1 1 4 PVC coated Rigid shoe 1 1 2 to 1 1 4 PVC coated Rigid hook 3 8 16 x 1 1 4 Socket head cap screw 1 2 13 5 8 Socket head cap screw 5 1 1 2 to 2 PVC coated Rigid shoe 1 1 1 2 to 2 PVC coated Rigid hook 1 3 4 x 1 1 2 Shoulder screw Support weldment PVC coated Rigid roller 1 Retaining ring
5. sse 5 1 2 Roller 1 3 4 Roller axlg i ns 1 correre 1 11 4 Roller axl amp uii CF 1 1 2 Roller sss 1 3 4 ROET eene 1 fe c MM TR 1 TA ROME oriens 1 Retaining ring pliers not shown 1 Metal storage box not shown 1 Greenlee A Textron Company 31 4455 Boeing Dr Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE Troubleshooting Problem Bender does not operate Probable Cause No voltage 855 Smart Bender Probable Remedy Check supply voltage circuit operation Check that switch is on Check that pendant is fully plugged in Bender operates but display is blank Insufficient voltage Pendant was plugged in while bender was on Use shorter or larger gauge extension cord Check supply voltage 80 VAC minimum Turn bender switch off and on Display comes on but bender does not bend Bender was advanced 93 degrees UNLOAD to desired position Display comes on but does not count during bend Bender turned on while conduit was fully loaded Remove conduit and initialize home position per Setting the Home Position under Operation in the instruction manual Bender operates in wrong direction Wrong conduit size and or type selected Set selector switches properly Bends are overbent a few degrees Wrong conduit size and or
6. z A iL ze pu i il AA 2 es sis er AR oy Es M E 88 id g eZ 5 off EOS 2i s E Em e s zz 12 LET E Ji uio as 5 E beak H bug BUUR uuu d Bos SEBERE P ZERE gasp amp 8 s 8 jjjlf e sjes s sje V z BE aE zp p lo 5 J e 8 ge E Ker Tam Tomas E s Id EL BE 23 B s D ms I E 2 T ze HE g EST mi ib ib lo Sae EY df docs ET ETY ETN 22 E MEE ae EE 3 8 EE zt ay ze of mn Ya ii ae 88 z 5 z _ AA Fr DIET 3 xs a 8 ES BER g 8 Mw Hi lr a 8 FRM 8 REI Jl ENS 5 I T Ei It 5 88 lr 8 1 2 dg gl 5 E 91 88 28 i kes 4 i a2 a2 83 83 10 T p Connection IET D 5 s omens 1 m SEES i 1 1 FEN i du 8 of suem st 28 Greenlee Textron Company 26 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE Input Output Board 50060309 Parts List 855 Smart Bender Reference Supplier Part Number Description Qty C1 C2 Murata RPE110COG220J050V Capacitor 22 pF
7. 855 Smart Bender Power Generation Unit 50054678 Parts List Reference Supplier Part Number Description Gty 1 9 10 12 13 Philips A104K29X7RFVVWN Capacitor 0 1 uF 50 volts 5 AVX SA115C104KAA KEMET C420C104K5R5CA C2 WIMA MKS21 06310 Capacitor film 1 uF 63 volts 1 C3 Philips A103M15Z5UFVVWA Capacitor 01 uF 50 volts 1 AVX SA105E103ZAA C4 C11 Sprague 440LS10 Capacitor 010 uF 500 volts AC C5 C8 Sprague 440LD47 Capacitor 0047 uF 500 volts AC C6 Panasonic ECE S2EU102Z Capacitor 1000 uF 250 volts 1 Cornell Dubilier 380LX102M250K052 C7 Panasonic EEU FC1E681 Capacitor 680 uF 25 volts 1 D1 Panasonic LN48YP LED T1 amber 1 Liteon LTL 4251 D2 Panasonic LN28RP LED T1 red 1 Liteon LTL 4221 D3 D10 Motorola 1N5245B Zener diode 15 volts 500 milliwatts D4 D11 Panasonic LN38GP LED T1 green Liteon LTL 4231 D5 D6 D7 Generic 1N4148 Diode 3 D8 IXYS DSEI 30 06A Diode fast recovery 30A 400 600V TO 247 see Note 1 1 Adv Pwr Tech APT30D40B Adv Pwr Tech APT30D60B D9 Vishay UF1001DI Diode ultra fast switching 1A 50V 50ns DO 41 1 D13 D14 Generic 1N4007 Diode 2 J1 J2 Molex 39 29 0063 Connector Minifit Jr 6 position gold 2 J4 Molex 39 29 0023 Connector Minifit Jr 2 position gold 1 J5 J6 J8 J9 J10 J11 Keystone 1287 Connector tab 250 x 032 6 J7 Beau 72503 C Connector terminal block 3 position no mount holes 1 Mag
8. AWARNING e Do not rotate the bending head if one or more of the bending shoes is removed Do not connect or disconnect the pendant while the power is on or permanent damage to the pendant or bender circuitry may result e The bender head pivot lock must be fully engaged in the frame hole and fully turned in the counter clockwise direction Failure to observe these warnings could cause the bending head to move rapidly in an unexpected direction resulting in severe injury or death Remove the pendant control from its storage area and plug it into the four pin receptacle on the side of the bending head The bending head can be rotated into three positions e Vertical Horizontal 1 2 to 1 1 4 shoe facing up Horizontal 1 1 2 to 2 shoe facing up To change the bending head position 1 Rotate the bender head pivot lock knob clockwise until it contacts the bending head 2 Pull out the bender head pivot lock knob 3 Pivot the bending head to the desired position 4 Release the bender head pivot lock knob so that the pin is fully engaged in the frame hole 5 Turn the pivot lock knob counterclockwise until there is resistance Do not overtighten Greenlee A Textron Company 6 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE Adjustments AWARNING Disconnect power supply before ser vicing bender Servicing to be done only by trained service technicia
9. SERVICE MANUAL GREENLEE Smart Bender and 01711 Optional Deluxe Pendant Serial Code AKN Read and understand all of the instructions and safety information in this manual before operating or servicing this tool 52033652 2007 Greenlee Textron Inc 11 07 GREENLEE Table of Contents INtHOGCUCTION pU 2 Important Safety Information 3 4 Grounding 2 4 5 5 6 JAOJUSLUTIBPIES NN NHAI 7 MaintenariCe 8 10 Bender Head 11 12 Motor 13 Tr riniori Disassenmibly 13 1 2 to 1 1 4 Side Exploded View 14 1 1 2 to 2 Side Exploded 15 1 1 2 to 2 Roller Support Unit Exploded View 16 Motor and Gearbox Exploded View and Parts List 17 Main Exploded 18 19 Main Parts List aiite rte eor Rete 20 21 Electrical Control System Layout and Parts List 22 Power Generation Unit Schematic Diagram Parts List and Layout Diagram 23 25 Input Output Board Schematic Diagram Parts List and Layout Diagram 26 28 Standard Pendant Switch Schematic Diagram Part
10. ssl Screw 7 16 14 x 1 00 hex hd 3 Shaft 11 2 Sup POM iiu citrate 1 Ring retaining 45100 87 422 Screw 1 4 20 x 37 btn 3 Screw 5 16 18 x 1 00 Skt hd 1 Screw 1 4 28 x 25 set 2 Washer 1 00 x 1 37 x 03 shim 1 Washer Belleville 1 362 x 803 2 Washer 62 x 2 00 x 06 flat el Spring extension 75 x 3 50 2 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Main Parts List cont d Key 105 106 107 108 109 111 112 113 114 115 116 117 118 119 150 151 170 176 177 178 179 201 202 203 204 205 206 207 208 209 211 212 213 221 223 224 225 226 228 229 231 240 UPC No 78 3310 54252 52108 54239 39851 38463 38544 38566 54268 50458 38592 51130 51537 38657 92644 92645 93216 86263 54911 55302 54355 07912 53390 38613 51528 54237 52646 38167 54244 38168 31710 31712 52479 51088 53396 31716 38779 10299 Part No 90542525 90521080 90542398 50398512 50384635 50385445 50385666 90542681 90504585 50385925 90511301 90515374 50386573 90526449 90526457 90532163 91862639 90549112 90553020 90543556 50079123 52031175 52031167 52031170 90533909 50386131 90515285 90542371 90526465 50381679 90542444 50381687 52031172 50317105 50317121 9052
11. Schematic Diagram o 8 gt 10 Op 5 11 cL 12 co l po 8 5 E E 13 E O 15 pi 4 16 alda 1 jg 18 Lt B z E 8 o e e of ol x a 53 e a L mela uw Ye O YO O O Y wrt m Spe g z vwe vee 2 5 zs x Jug g s a8 88 a F 8 Ih 8 5 5 2 5 gis ai 5 a Bl st 5 lI ES oo el 8 5 5 2 5 i 1 rele 2 E 1 5 5 z 2 52 ed 5 st wl of A of S 798 8252 Ra kere EER amp 16 vop vs 1 8 Eg lt lt lt x Sle asl a 5 expl 5 5 8 BZN Lld S n4nZ I MOLEX 70553 0038 Greenlee A Textron Company 29 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender Standard Pendant Switch 50013050 Parts List Reference Supplier Part Number Description Qty C1 C5 C6 C7 Vishay 1C20X7R104K050B C
12. front chain a Guard front WYRY 1 Retainer sse Rivet 3 16 pop 2 Guard weldment 1 Guard HONOM kcc 1 Sppt wldt 1 2 to 1 1 4 RLR il Drive Y Y Y en Yn 1 Spindle weldment main 1 Plate weldment drive al Sprocket 60 1 Key drive Bearing sleeve 480040 a Chain 60 92P sss Ring rtng Truarc 5100 200 4 Washer main spindle Key shoe crociera 2 Pin 1 2 to 1 1 4 sprt pvt 1 Spacer motor 1 Spacer thin motor 1 Locator weldment eccentric Nut 1 2 13 lock sss 1 Screw 10 16 x 50 hex 31 Screw cap 1 2 13 x 1 00 Ring rtng Truarc 5100 287 Screw set 1 2 20 x 75 socket 1 Link connecting 60 chain Screw 6 32 x 1 00 sltd mach Bracket limit switch sss 1 Back plate switch 4 3 Screw 5 16 18 x 1 25 skt 2 Washer flat 56 1 37 x 109 4 Switch
13. in the Maintenance section of this Rectifier manual 1 the PGU subplate by following steps 1 to 7 3 Remove the seven screws securing the front guard under Power Generation Board disassembly above and remove the guard 2 Disconnect the red black and two yellow wires 4 Remove the nine screws securing the motor cover to the rectifier 18 19 20 and remove the motor cover 3 2 screw lock washer and nut securing 5 Rotate the motor until the chain master link is the rectifier accessible at the top of the bender 4 2 in d d jin e 6 With the bender head in the horizontal position grease between the rectifier and subplate loosen the four bolts and nut securing the motor Relay n the eccentric adjusting bolt to allow chain 1 Remove the PGU subplate by following steps 1 to 7 under Power Generation Board disassembly 7 Tap the motor toward the spindle to slack the chain above taking care not to allow the encoder to contact the frame 2 Disconnect the red and black PGU relay wires 11 12 8 Remove the cotter pins master link and chain 3 Disconnect the relay wire unit 8 9 Reassemble in reverse order noting the following 4 Remove the red and black relay wires 9 10 Torque the eccentric adjusting bolt to 81 Nm y 60 ft lb while tightening the two front bolts and 5 Remove the two screws lock washers and nuts nut to maintain chain tension and then remove the relay y Us
14. Loosen the two set screws in the drive hub 6 Unplug the encoder from the I O board 7 Remove the two mounting screws and round plastic Spacers securing the encoder and pull off the encoder Note Attach a wire or string to the encoder plug at the I O board to serve as a retrieval line to pull the new wire and plug up through the unit 8 Reassemble in reverse order noting the following Torque the hub set screws to 0 16 Nm 22 in oz e Jog the motor and check Quad 1 and Quad 2 LEDs for on off pulsing 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 855 Smart Bender Motor Disassembly 1 Remove the optical encoder refer to Optical 5 Disconnect the motor leads at the relay and the Encoder disassembly in the Bender Head ground wire Disassembly section 6 Remove the five motor mounting bolts and nut 2 Remove the chain refer to Chain disassembly 7 Remove the motor 3 Remove the brake refer to Brake disassembly Note Attach a wire or string to the motor leads at 4 Loosen the motor sprocket set screws and remove the power generation board to serve as a retrieval the sprocket and key line to pull the new wire through the unit 8 Assemble in reverse order Trunnion Disassembly 1 Support the bender s entire weight which is 2 Remove the support tower on the rotary selector approximately 230 kg 500 Ib at the lifting eyes switch side but do not
15. Unit Power DC 10 50060490 Black Relay Wire 26 Test Terminal Troubleshooting 11 50060341 Red Relay PGU Wire 27 90543297 Screw 8 18 x 3 8 Ground 12 50060350 Black Relay PGU Wire 28 50060406 Wire Unit Ground 13 50386484 V 0 PGU Wire Unit 29 Test Terminal Troubleshooting 14 91858224 Limit Switch 30 Test Pushbutton Troubleshooting 15 50060309 Input Output Control Unit 31 90516559 Screw 10 16 x 5 Hex 16 Directional Test Toggle Switch 32 91863856 Circuit Breaker 20 A 33 91859972 Rectifier 600 V 35 A Greenlee A Textron Company 22 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 855 Smart Bender GREENLEE Unit 50054678 Schematic Diagram Power Generation 8 pue 5 sjejuo5 Av TH OL 6 L MS OvO Siu 89 29 MZ OENEDHXI 10 a yovld ur rA e pue 9 sype u 09 AY 01 ygo osasa NZ ow z 8d H 40pejnsui ou oq uis yeay ur aloy Jaddn o pjnous LO yeay Jamo JUNOW pjnous 801 S 0 80 pue 0 M S sdilllUd Oy vi IN 0 IOUSEM 5201 2x reuse PH Ov vi 60 811 SG9IA9 J9MOd JO NSU 1W 8 cOZNHL oj euuJau USPEH pue 0 40 ununojy
16. guard 1 1 2 and 2 Limit Switch Adj Screws Less Bend 1 2 to 1 1 4 Limit Switch Adj Screws Greenlee A Textron Company 7 855 Smart Bender Retention Cam Loosen the screws securing the retention cam With the bender oriented in the vertical position rotate the round plate until the right side edge of the cam is pointed straight down or within 1 4 left of being straight down Make sure both ends of the spring are engaged in the holes of the cam and round plate Tighten the screws while holding the round plate in position with pliers to prevent it from rotating o E 1 4 Check to make sure the roller support handle will fully engage and retract without catching on the cam holding surface This should be done in both the vertical and horizontal bending positions It should also be done with the cam positioned as far left and as far right as friction will allow it to stay 5 79 Cam Holding Surface 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE Maintenance AWARNING Electric shock hazard Disconnect the unit from power before servicing Failure to observe this warning could result in severe injury or death AWARNING Wear eye protection when operating or servicing this tool Failure to wear eye protection could result in serious eye injury from flying debris Schedule Maintenance Activity Chain Lubrication and Tension Adjustm
17. is normally closed Attach alligator clips to the common and normally closed switch terminals to check switch trip operation Do not insert meter probes into the Molex plug Brake Under normal circumstances the brake should not require adjustment However if the brake can be heard dragging while bending or if the braking performance deteriorates brake adjustment may be necessary AWARNING Do not touch the brake if the bender has been recently used It will be hot Wait an hour for it to cool off before adjusting 1 Disconnect power to the unit 2 Remove the motor cover 3 Loosen the two set screws on the brake rotor hub the part that turns 4 Slide it to a position 0 002 to 0 015 away from the mating face about 1 to 3 page thicknesses of this manual 5 Tighten the set screws to 4 Nm 35 in Ib 6 Replace the motor cover 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 855 Smart Bender GREENLEE Bender Head Disassembly AWARNING Disconnect power supply before servicing bender The bender head Input Output Board I O 1 Remove the four screws securing the top cover and remove the cover Disconnect the receptacle unit 4 Disconnect the selector switch 22 Disconnect the unload lockout switch 7 Disconnect the limit switch 5 Disconnect the optical encoder 23 Disconnect the brake wire 6 Disconnect the PGU I O cable 13 Disconnec
18. lift above the floor e Remove the two bolts and two nuts at the side of the tower Remove the outer retaining ring on each side of the bender e Slide the tower off the pivot spindle 3 Slide the remainder of the trunnion assembly off the opposite pivot spindle ACAUTION Bender head may rotate a bit when locking detent pin is disengaged Keep hands clear Remove the remaining support tower from the base Pull out the detent pin Knob and spring Remove the four bolts and swivel casters on each side Remove the stationary wheels Remove the retaining rings on the axle DU OQ gem 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 Press out the axle e Remove the wheel and washers from each side 8 Assemble in reverse order but leave out the detent pin knob and spring After all else is assembled rotate the bender head so that the top of the bender is pointed toward the kickstand and insert the detent pin assembly Hold the detent pin in while rotating the bender head back to one of its normal positions CORRECT INCORRECT Greenlee A Textron Company 13 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender 1 2 to 1 1 4 Side Exploded View Note Refer to the Main Parts List to identify the parts in this i
19. limit BZ 2RW822 A2 24 Nut hex 5 16 18 reg 2 Receptacle unit 1 Strain relief mi Shoe unit 1 2 to 1 1 4 1 Shoe unit 1 1 2 to 2 Screw mach 6 32 x 25 Guard breaker switch Breaker circuit 20 Screw cap 4 40 x 62 skt Encoder unit Screw cap 48 32 x 50 5 4 Brake motor Greenlee A Textron Company UPC No Key 78 3310 52 38807 53 54616 54 54151 55 54335 57 01648 57A 01305 57B 33476 57C 33472 57D 38649 57E 34342 57F 33580 570 01666 58 35012 06683 59 51751 60 38868 71 38221 72 00528 73 00601 74 30225 75 00543 76 00604 77 38254 78 38264 79 38255 80 38263 81 38262 82 00599 83 00493 84 38252 85 38253 86 38260 87 32027 88 31728 89 38151 90 23258 91 38256 92 38251 93 50540 94 00860 95 54819 96 54242 97 50224 98 50881 99 53018 100 54248 101 39440 104 54243 20 Part 50388070 90546164 90541510 90543351 50016482 50013050 50334760 50334727 50386492 50343424 50335804 50016660 50350129 50066838 90517512 50388681 50382217 50005286 50006010 50382250 50005430 50006045 50382543 50382640 50382551 50382632 503826
20. unload display on Is the retention cam YES engaged with the roller support NO Is the roller support NO Lower the roller support assembly Lower the roller support assembly completely disengaged YES Adjust the roller support limit switch Trips circuit breaker Are the proper support rollers and shoe groove being used for the type and size of conduit being bent YES Is the current on the 115 VAC line assembly 855 Smart Bender Won t stop Is the supply line voltage low YES NO Does bender stop when the pendant is unplugged NO Replace PGU NO Follow directions in instruction manual Bender only runs in one direction On 1 1 2 or 2 size setting is the DIR LED on the I O Board on when BEND is pressed exceeding 20 amps YES Is the DC current to the motor YES When DIR LED is on is 12 VDC measured at large relay coil NO Replace circuit where relay wire unit connects breaker NO Move 6 wire connector on PGU YES from TO I O to TEST Alter exceeding 17 amps NO When BEND is pressed is the voltage sent to the motor 20 to 50 volts over the AC line voltage YES Are connectors corroded NO YES Replace PGU Greenlee A Textron Company Replace motor NO Re
21. 19 Remove the roller support 7 3 Spray a motorcycle chain lubricant through the 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 GREENLEE 855 Smart Bender Maintenance 1 1 2 to 2 Roller Support 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 1 Disconnect the bender from the power source 2 Remove the 1 1 2 to 2 shoe refer to Changing Shoes in this section of the manual rease 3 Refer to the 1 1 2 to 2 Roller Support Unit 13 4 d h Exploded View Use a pair of needle nose pliers to d eode components in reverse order noting the disconnect the springs 104 from the holes in the following side of the bender frame beneath the roller support On both roller groups To ease the assembly of unit the split roller subassemblies begin by slipping the O rings onto the side plates Assemble the split roller subassemblies as shown and then slip the O rings into their correct positions 4 Refer to the Main Exploded View Remove the squeeze adjustment arm screw 97 and arm 74 5 Remove the three button head cap screws 96 and On the 2 ro
22. 24 50005995 50004930 50382527 50382535 50382608 50320270 50317288 50381512 50232584 50382560 50382519 90505409 50008609 90548191 90542428 90502248 90508815 90539184 90542487 50394401 90542436 855 Smart Bender Description Qty Key brake ssssseeeenenennnnnnnnees 1 Spacer round 2 Knob plastic w set screw 5 Screw flng 1 4 x 37 2 Switch 1 Board circuit seed COV cT 1 Housing lOWeT eene creans 1 Switch membrane Screw 3 20 2 2 2 22 1 3 Screw 86 32 sss Cord pendant Screw 4 x 1 2 flat head or rivet pop 3 32 OCIOW ANVE correr certet reete 1 Support weldment roller Support weldment 1 1 2 Support weldment 2 iii 1 Arm weldment adjustment iel Plate 1 1 2 outer roller 1 Spacer 2 Toller cerei ee 1 Ze RR FORE TELE FFR 1 Shaft 2 rear roller el Roller 1 1 2 I M C sse 1 Roller 1 Shaft 1 1 2 pivot roller E Sleeve 1 1 2 ccce 1 Shaft 2 pivot 1 Sleeve 2 ohaft eccentric ccn 1 Sleeve adaptor
23. 4799 90510887 90533968 50317164 50387790 50102990 52031173 Description Qty Clamp 1 Nut hex 1 4220 swiss 1 Screw 1 4 20 x 3 4 ovl pt set retention e 1 Shaft cam 1 Plate cam retention nil Spring cam 1 Screw 1 4 20 x 1 3 8 skt 1 Rollpin 1 8 x 375 Guide Spring O ring 1 50 x 1 62 x 062 2 O ring 1 75 x 1 87 x 062 2 2 Shaft 2 middle 1 Washer 1 32 1 Washer 1 16 shim i1 Ring retaining 1 Nut 1 2 conduit 10 1 Screw 1 4 28 x 3 8 socket head cap ne Screw 6 32 1 25 socket head 2 Washer 6 sn 6 Power cord ed Base assembly 1 Tower assembly trunnion L H 1 Tower assembly trunnion R H Axle Short eee 2 Ring retaining 5160 75 4 Screw flange 3 8 16 x 1 00 hex 8 Nut 3 8 16 Esna 4 Caster w side lock me 1 2 to 1 1 4 IMC Rigid hook 1 1 2 to 1 1 4
24. 50 volts 2 Murata RPE110COG220J0100V C3 C4 C5 C6 C7 C8 C9 Philips A104K29X7RFVVWN Capacitor 0 1 uF 50 volts 21 C11 C12 C13 C14 C15 AVX SA115C104KAA C16 C17 C18 C19 C20 KEMET C420C104K5R5CA C21 C22 C23 C24 C10 Nichicon UVZ1E100MDH Capacitor 10 uF 25 volts 1 C25 Philips A102K15X7RHVVWA Capacitor 001 uF 100 volts 1 D1 D2 D3 D4 D5 D7 D8 Panasonic LN28RP LED T1 red 11 D10 D12 D14 D15 Liteon LTL 4221 D9 D11 D13 D16 D17 Generic 1N4148 Diode 5 D6 VISHAY UF1001DI Diode ultra fast switching 1A 50V 50ns DO 41 1 JP1 Molex 26 60 4050 Connector locking 156 center 5 position 1 JP4 JP8 Molex 39 28 1043 Connector Minifit Jr 4 position 2 JP2 JP6 JP7 Molex 39 28 1063 Connector Minifit Jr 6 position 3 JP3 3M 2510 6002UB Connector dual row 10 position 1 JP5 Molex 39 28 1023 Connector Minifit Jr 2 position 1 JP9 Molex 39 30 2037 Connector Minifit Jr 3 position 1 RP1 RP2 RP3 Bourns 4610X 101 103 Resistor pack 10KWx8 with common 1 4 watt 596 3 R13 R14 R32 R33 Generic Resistor 10K 1 4 watt 596 4 R6 R7 R19 R21 R22 Generic Resistor 1K 1 4 watt 5 5 R3 Dale MDP1603 101G Resistor pack 100WXx8 individual 1 4 watt 5 1 R2 R4 R8 R10 R15 R16 Generic Resistor 100 1 4 watt 596 9 R28 R29 R30 R5 R12 R17 R18 R25 Generic Resistor 2 2K 1 4 watt 596 5 R11 R9 Generic Resistor 560 1 4 watt 5 2 R26 Generic Resistor 330 1 4 watt 5 1 R20 R23 R27 Generic Resistor 100 1 2 watt 596 3 R31 R24 Generic Resistor 68 1 4 watt 5 2
25. 60309 Schematic Diagram 8 8 g 28 F im kee eer tH EI SUN 3 m a ET 5 af tt u HE s Tes EI E Mur 8 3 e o Ty Min a EI 2 4 H al EE 1 i am z de a 266 gf Lg Li gB L Tus d na i
26. 9073 50390732 Rear Gear Housing 11 39074 50390740 Gasket 12 39075 50390759 Front Gear Housing 13 39076 50390767 Output Gear Shaft 14 39077 50390775 Short Spacer 15 39078 50390783 Long Spacer 16 39079 50390791 2nd Reduction Pinion Shaft w BRGs 17 53323 90533232 Wave Washer 18 39080 50390805 3rd Reduction Pinion Shaft w BRGs 19 54248 90542487 Belleville Washer 1 Torque gearbox bolts to 11 9 Nm 100 80 in Ib in 20 3981 50390813 4th Reduction Pinion Shaft sequence shown 21 39082 50390821 Small Spacer 22 54043 90540433 1 2 20 x 2 1 2 Screw 23 02298 50022989 1 4 28 x 9 1 4 Stud 2 Assemble all Belleville washers so that D s butt and O D s contact bearings 24 51705 90517059 1 4 28 Hex Nut 3 Tighten motor nuts 24 to 3 4 Nm 30 35 in Ib 25 50749 90507495 1 4 Internal Tooth Lockwasher 4 Insert commutator brushes before connecting 26 07208 50072080 OilSeal push on terminals 27 07209 50072099 Oil Seal Greenlee A Textron Company 17 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender Main Exploded View Greenlee A Textron Company 18 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender Note Torque to 54 to 61 Nm 40 to 45 ft lb L Cam Repair Kit 50079395 If the chain breaks replace it with new chain 90542509 not another master lin
27. EMT 1 Drive bolt 1 2 13 x 62 Socket head cap 5 6 1 2 to 1 1 4 Hook bolts 3 8 16 x 1 1 4 socket head cap screw 8 1 1 2 2 Hook shoulder bolts BAX 1 1 2 isses Y 6 1 1 2 2 EMT 1 1 1 2 2 IMC amp Rigid 1 Selector switch unit w o knobs 1 Flange SCrew iie 4 Greenlee A Textron Company 21 UPC No Key 78 3310 PartNo Decals not shown 38893 50078852 01445 50014455 38896 50388967 01487 50014870 38898 50388983 38899 50388991 02263 50022636 01568 50015680 38974 50389742 01453 50014536 52025721 52031174 Optional 01711 50017110 38962 50389629 01700 50017004 Service Only 05586 50055860 50079395 57H 52020832 52033403 855 Smart Bender Description Qty Decal lifting 2 Decal deluxe pendant instr 1 Decal Slet switch 517 1 Decal Slct switch type 1 Decal bender pivot lock 1 Decal roller adjustment 1 Decal roller 1 Decal operation see 3 Decal circuit
28. S1 Panasonic EVO PACO9K Momentary pushbutton switch 1 S2 Eswitch EG1218 Slide switch SPDT 1 U1 Intel N80C196KB Integrated circuit microcontroller 1 U1 AMP 821689 1 68 pin socket PLCC 1 U2 Generic 74HC373 Integrated circuit buffer 1 U3 Samsung KM62256DLP 7L IC SRAM 32K x 8 70ns 28 pin x 6 DIP 1 U4 Generic 27C256 IC EPROM 120 nsec 28 pin x 6 DIP 1 U3 U4 Robinson Nugent 286 58 28 socket dual wipe 2 U5 Microchip 93LC56 Integrated circuit EEPROM 128 x 16 bit 1 Microchip 93LC56B U5 Robinson Nugent ICO 083 S8A T 8 pin socket dual wipe U6 Generic 74HC10 Integrated circuit NAND 1 U8 Dallas DS1232 Integrated circuit timer reset control 1 Dallas DS1232LP U9 Maxim MAX4613 IC analog switch 16 pin x 3 DIP 1 U10 Generic 74HC04 Integrated circuit inverter 1 U11 Generic ULN2068B Integrated circuit buffer driver 1 x1 Fox FOX 100 20 Crystal 10MHz HC49U case mylar spacer 1 HC49U 10 000 MS Greenlee A Textron Company 27 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 855 Smart Bender Input Output Board 50060309 Layout Diagram
29. apacitor ceramic 1 uF 50 volts minimum radial 4 or Equal or Equal 2 cc X7R D1 D2 D3 D4 D5 D6 Generic 1N400x x 1 to 7 Diode 5 DS1 GT Opto MAN 6910 LED display common anode 2 digit x 56 7 seg dec 1 Agilent Tech HDSP 5521 18 lead 6 DIL or Equal or Equal J1 BERG 78541 110H Connector 100 cc x 318 mating 10 position right angle 1 or Equal or Equal single row 30 micro in gold over 50 micro in nickel P1 MOLEX 70553 0038 Connector locking SL series 100 cc 4 position 1 RN1 Generic Resistor pack 10KWx10 with common 1 4 watt 5 1 U1 Philips PCF8574P Integrated circuit 12C 8 bit I O expander 16 lead 3 DIL 1 U2 Philips SAA1064 Integrated circuit 2 LED display driver 24 lead 6 DIL 1 VR1 Micrel MIC2940A 5 0BT Voltage regulator fixed 5V low dropout 1 Mounting Hardware for VR1 Generic 344 40 Hex Nut ZN steel or stainless nylon insert 1 4 x 9 64 1 Generic 4 40 Phillips Screw ZN steel or stainless machine pan head 4 40 x 0 25 1 Standard Pendant Switch 50013050 Layout Diagram T o O 2 a 5 o o o o o o o o uo o E o 5 o o o 00006 50080 aIv y oL o o 3 S G o o Po o 2 9 o o o E Bo o o o o 2 d a E ar 22 No g o o 8 o o Mo o e o o E o GREENLEE TEXTRON 2001 Se c O
30. bender and rotate the shoe until the conduit locks up against tail roller Do not raise the support rollers as is normal for IMC e Slide the top limit switch until the contacts trip and tighten in that position e Place 1 2 rigid in the bender and rotate the shoe until the conduit locks up against the support roller e Slide the bottom switch until the contacts trip and tighten in that position e Rotate the spindle checking that the limit switch trip bolts do not snag the trip rollers Readjust the bracket mounting if necessary p mI Less Bend 1 1 2 and 2 Limit Switch Adj Screws 1 2 to 1 1 4 Limit Switch Adj Screws Greenlee A Textron Company 855 Smart Bender Brake 1 Remove the eleven screws securing the motor cover and remove the cover 2 Loosen the two set screws securing the brake rotor and remove the rotor 3 Remove the power supply leads 4 Remove the four screws securing the brake housing and remove the housing 5 Reassemble the brake housing and power leads 6 Useshims to set the brake rotor gap at 0 002 to 0 015 and tighten 7 Replace the motor cover Optical Encoder 1 Remove the four screws securing the top cover and remove the cover 2 Remove the seven screws securing the front guard and remove the guard 3 Remove the nine screws securing the motor cover and remove the cover 4 Rotate the motor until both hub set screws are accessible 5
31. by personnel A WARNING 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 Set the switches to the appropriate conduit size and type before bending Select the appropriate shoe groove and support roller for the type and size of conduit before bending Do not bend conduit over 93 degrees Overbending could result in the other shoe hook colliding with the conduit Some bender parts and accessories are heavy and may require more than one person to lift and assemble Ensure that all bystanders are away from the work area when operating the bender A WARNING Unplug the bender before changing accessories Accidental startup could result in serious injury Ensure that the work area is clean dry uncluttered and well lit Use this tool for the manufacturer s intended purpose only Use other than that which is instructed in this manual can result in injury or property damage AWARNING Adjust fork spacing to match fork tubes on bender Ensure caster brakes are locked and casters are straight before inserting forks into fork tubes Forks must extend beyond ends of fork tubes a minimum of 8 Failure to observe these precautions may result in injury or property damage Failure t thi i It i i ae Rene FRIG Soula ayer Note Keep all decals clean and legible and replace when neces
32. e a new master link and cotter pins 6 Assemble in reverse order See Electrical Control System Layout for location of key numbers Greenlee A Textron Company 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Bender Head Disassembly cont d Spindle 1 Remove the chain refer to Chain disassembly 2 Remove the 1 2 to 1 1 4 shoe refer to Changing Shoes in the Maintenance section of this manual 3 Loosen the 1 2 to 1 1 4 drive plate hub set screw 4 Remove the socket head screw in the 1 2 to 1 1 4 spindle 5 Remove the drive plate and key 6 Use a file to remove any raised edges from the spindle to prevent bearing damage 7 Remove the spindle sprocket Reassemble in reverse order Limit Switch Bracket 1 Remove the spindle refer to Spindle disassembly 2 Remove the four screws securing the two limit switches and remove the switches 3 Remove the two screws securing the bracket and remove the bracket 4 Reassemble in reverse order noting the following e The limit switch with red wires goes on top e Install the top switch so that the trip roller is as far left as possible as viewed with the switch behind the bracket e Install the bottom switch black wires with the trip roller as far right as possible as viewed with the switch behind the bracket e Temporarily install both shoes before installing the chain e Place 2 IMC in the
33. ent Maintenance Interval Every 6 months Every 6 months Cleaning and Roller Supports Lurication When drive unit Commutator Replacement performance Brushes diminishes noticeably More often if the bender is used in dusty or corrosive environments Greenlee A Textron Company 855 Smart Bender Chain Lubrication and Tension Adjustment 1 Disconnect the bender from the power source 2 Refer to the 1 1 2 to 2 Side Exploded View Remove the 1 1 2 to 2 shoe refer to Changing Shoes in this section of the manual 3 Refer to the Main Exploded View Remove the screws 23 and front chain guard assembly 4 4 Spray a motorcycle chain lubricant on the inside of the chain between the sprockets while pressing UNLOAD Lubricate the entire length of the chain 5 Check the amount of slack halfway between the Sprockets If the chain slack is More than 25 mm 1 proceed to step 6 e Less than 25 mm 1 proceed to step 10 6 Remove 11 screws 23 and the motor guard 5 7 Loosen the two motor mounting screws 25 on the front the two on the back and the nut 22 8 Torque the eccentric locator 21 to 81 Nm 60 ft lb Maintain this amount of torque while tightening the nut 22 and two front screws 25 9 Tighten the two rear screws 25 10 Assemble in reverse order 1 2 to 1 1 4 Roller Support 1 Disconnect the bender from the power source 2 Remove the support pivot pin
34. er support Message E6 or CONDUIT SUPPORT UP appears Power was turned off while bending 1 1 2 or 2 EMT IMC or rigid aluminum conduit Press UNLOAD Bending shoe will slowly unload until roller support retracts Roller support lockout switch or wire harness is bad or poorly adjusted Adjust switch Check for pinched wires and shorts to frame Roller support is locked or jammed Twist roller support handle counterclockwise Deluxe pendant displays BENDER CANNOT MAKE BENDS THAT CLOSE Due to the geometry of the bend the shoe hook would end up interfering with the first bend while making the second Follow the suggestions on the display to adjust the HEIGHT ANGLE or STRAIGHT section value Deluxe pendant displays LENGTH IS TOO SHORT or HEIGHT IS TOO SHORT The first mark must be at least one pipe diameter away from the end of the conduit to prevent damage to the conduit Follow the suggestions on the display to adjust the LENGTH or HEIGHT value Greenlee A Textron Company 33 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Troubleshooting cont d 855 Smart Bender The following flow charts show some of the most likely areas to look at for certain problems They by no means encompass all the possible problems or the only possible solutions Won t bend display blank Was pendant plugged in after the be
35. et up the bender 1 Transport the bender to the job site Lock both swivel casters Pivot the bending head to the desired position Connect the pendant to the bending head Plug the power cord into a 120 VAC 20 A GFCI protected receptacle For best performance use a dedicated circuit for this unit and do not use extension cords 6 Turn on the power switch e o mm Transporting the Bender Make sure that all components used to lift the bender are properly rated for the 231 kg 510 Ib weight Use a ramp to load and unload the bender from a truck or other vehicle that is not equipped with a lift gate To roll the bender 1 Unlock swivel casters 2 Pivot the bending head to the horizontal position with the 1 1 2 to 2 shoe facing up 3 Usethe transport handle to push and steer the bender To lift the bender 1 Pivot the bending head to the horizontal position with the 1 1 2 to 2 shoe facing up 2 Rotate the lifting eyes so that they are accessible 3 Loop the sling or attach the hooks to the lifting eyes Make sure that each side of the sling or chain is 1 m 3 long to prevent it from rubbing against the bender 4 Securely attach the sling or chain to the lifting device 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender Setup cont d Pivoting the Bending Head Connecting the Standard or Deluxe Pendant IMPORTANT
36. hen the display prompts ENTER NUMBER OF Standard Pendant DEGREES USE FOR NEGATIVE use the 1 Press and hold CLEAR and then press and hold numerical keys to enter a number from O to 9 BEND until Pr is displayed Use the e decimal key to toggle the negative sign 2 Usethe side switches to select the size and type Enter positive numbers to increase the bend to of conduit to compensate The display shows the compensate for underbending current adjust value O is factory default Enter negative numbers to decrease the bend to 3 Compensate the angle compensate for overbending e Press ANGLE SELECT A to increase the bend to e Press CLEAR to reset the compensation to the compensate for underbending factory default O e Press ANGLE SELECT v to decrease the bend to Press RESET to exit the adjust mode without compensate for overbending changing any values Press CLEAR to reset the compensation to the 5 Press ENTER to save the adjust angle and exit the factory default O adjust mode 4 Press BEND to save the adjust angle and exit the The bender retains the new adjust value even if adjust mode power is turned off The bender retains the new adjust value even if The only way to change the adjust value is to power is turned off repeat this procedure The only way to change the adjust value is to Note Once in the adjust mode the pendant can display repeat this procedure any compensation value by se
37. is symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage The signal word defined below indicates the severity of the hazard The message after the signal word provides information for pre venting or avoiding the hazard ADANGER Immediate hazards which if not avoided WILL result in severe injury or death AWARNING Hazards which if not avoided COULD result in severe injury or death ACAUTION Hazards or unsafe practices which if not avoided MAY result in injury or property damage ADANGER Read and understand all of the instructions and safety information in this manual before operating or servicing this tool Failure to observe this warning could result in severe injury or death ADANGER Do not use this tool in a hazardous environment Hazards include flam mable liquids gases or other mate rials Using this tool in a hazardous environment can result in a fire or explosion Failure to observe this warning will result in severe injury or death Greenlee A Textron Company 3 AWARNING Electric shock hazard e Connect the power cord to a 120 V 20 A receptacle on a ground fault protected circuit only Refer to Grounding Instructions Do not modify the power cord or plug Inspect the power cord before use Repair or replace the cord if damaged e Disconnect the unit from power before servicing Failure
38. k Because of the high stress on the chain the addition of a second master link will only weaken the chain further If the master link breaks replace it with a new master link 90542517 Greenlee A Textron Company 19 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 Main Parts List UPC No Key 78 3310 2 01622 3 38217 4 38983 4A 38236 4B 38244 4C 50160 5 38232 6 01607 7 38199 8 38250 9 01702 10 38193 11 54253 12 38267 13 54255 14 54250 15 54462 16 30265 17 30260 18 38457 19 55204 20 30257 20A 39488 21 38228 22 54265 23 51655 25 53903 26 52501 27 54345 28 54251 29 54240 30 38246 31 38248 32 50226 33 52597 34 85822 35 50645 36 01708 37 54124 43 38780 44 38148 45 52203 46 29708 47 86385 48 54619 49 38646 50 50572 51 86646 GREENLEE Part No 90016229 50382179 50389831 50382365 50382446 90501608 50382322 50016075 50381997 50382500 50017020 50381938 90542533 50382675 90542550 90542509 90544625 50382659 50382683 50384570 90552040 50382578 50394886 50382284 90542568 90516559 90539036 90525019 90543459 90542517 90542409 50382462 50382489 90502264 90525973 91858224 90506456 50017080 90541243 50387804 50381482 90522036 50297082 91863856 90546199 50386468 90505727 91866464 Description Qty Frame 1 Guard weldment top 1 Guard assembly
39. lecting the size or type However only the values of the last size and type viewed The pendant displays oP as it returns to are saved to memory when exiting adjust mode operating mode GREENLEE A Textron Company
40. ller group only After replacing any adapter sleeve 92 split roller components add or remove shim 6 Place one hand under the support arms 71 to washers 99 119 or 150 as needed SUPBOFE Ihe waighi of the rollar Support unk On the 1 1 2 roller group Install the two Remove Ihesccentic shaft 191 Belleville washers 100 so that the inside diam Note You may need to rotate the eccentric shaft to eters contact each other remove it Use Loctite 271 on the two hex head screws 93 A Torque to 55 Nm to 61 Nm 40 ft lb to 45 ft lb WARNING 14 Position the roller support arms 71 as shown Assemble the roller groups to the support arms 15 Reinstall the roller support unit to the bender Keep one hand under the support arms so they do not due drop completely below the set screw 107 bender is in use 16 Insert the eccentric shaft 91 Failure to observe this warning could result in severe injury or death Note You may need to rotate the eccentric shaft to get it to seat completely 17 Install the adapter sleeve 92 and three button head Pinch points Keep hands away from bending shoe rollers and conduit when 7 Lift the roller support subassembly to the left and cap screws 96 upward 18 Install the adjustment arm 74 and adjustment arm 8 On the 1 1 2 roller group screw 97 Loosen the sleeve set screw 98 and remove the 19 Attach the springs 104 to the holes in the side
41. llustration 43 Shoe Unit 1 2 to 1 1 4 consists of 221 222 223 224 and 225 Greenlee A Textron Company 14 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender 1 1 2 to 2 Side Exploded View Note Refer to the Main Parts List to identify the parts in this illustration 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 Greenlee A Textron Company 15 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender 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 Note Torque to 54 to 61 Nm 40 to 45 ft lb Two required Greenlee A Textron Company 16 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender Motor and Gearbox Exploded View and Parts List 3 N Key 78 3310 PartNo Description es i 6 1 86705 91867053 Commutator Brushes Q amp 2 86706 91867061 Brush Retention Springs 3 86707 91867070 Housing 4 86708 91867088 Brush Assembly Plate 5 86709 91867096 6 39092 50390929 Shroud 8 02863 52028638 Armature Housing Set 8A 86071 91860717 Bearing 9 54348 90543483 Belleville Washers 10 3
42. n Failure to observe this warning could result in severe injury or death Squeeze Proper squeeze adjustment for most 1 1 2 and 2 EMT and IMC conduit is when the squeeze adjustment arm is vertical at middle hole But variation in conduit can result in wrinkling or side marking of conduit If wrinkling or excessive ovalness occurs increase squeeze one position hole counterclockwise If loading conduit is difficult or if excessive side marking occurs decrease squeeze one position hole clockwise Accuracy If the accuracy of all sizes of conduit on one shoe is off in the same direction the limit switch needs to be adjusted Individual adjustments specific to one size and type of conduit should be made using the Accuracy Adjust mode Refer to the Troubleshooting section To adjust the limit switches first unplug the bender Remove the four screws that secure the top round guard and remove the guard to expose the two limit switches The top switch controls the 1 1 2 to 2 shoe Loosen the two screws and move it to the right side of the bender as shown in the diagram below to prevent overbending The bottom switch controls the 1 2 to 1 1 4 shoe Loosen the two screws and move it to the left side of the bender as shown below to prevent over bending Move either switch the opposite direction if the bender is underbending Every 1 8 of switch movement approximates 1 degree of change Tighten the screws and replace the
43. nder was turned on NO Does bender work with different good pendant NO Bent pin connector in receptacle or bad recep tacle unit NO Is fuse blown NO Is 115 VAC measured at PGU board input YES YES YES YES Turn switch off and then back on Bad pendant board bad pendant cord or plug inside pendant is unplugged Replace receptacle Will bend won t count orientation Is bending shoe on in the proper YES When jog is pressed does the bender continue to run slowly with4 out stopping after 1 2 degree NO the Start position Do Home 1 and Home 2 LEDs light when the shoe is run past Replace fuse YES Does bender cou good pendant nt with different YES Do any of the 8 LEDs on the I O board light YES Does PWM LED light when BEND is pressed NO Disconnect I O PGU cable on the I O board and reconnect to test terminal Disconnect brake wire unit Restore power and push test switch Does shoe move The toggle switch located next to the push button switch controls the direction the shoe moves NO Replace PGU NO YES YES Greenlee A Textron Company Plugged into dead circuit bad power cord or switch is bad or off NO Do both Quad 1 and Quad 2 LEDs light
44. num A202203 1 RL 1328 22 470 Choke common mode Q1 IXYS IXFK73N30 MOSFET N channel 73 76A 300V TO 264 see Note 2 1 Adv Pwr Tech APT30M40LVFR Q2 Generic PN2222A Transistor NPN 1 R1 R8 Generic Resistor 2 kO 1 4 watt 596 2 R2 R3 R12 R14 Generic Resistor 1 MQ 1 4 watt 5 4 R4 Generic Resistor 150 kO 1 4 watt 5 1 R5 Generic Resistor 12 1 kQ 1 4 watt 1 1 R6 Generic Resistor 4 75 kQ 1 4 watt 1 1 R7 R24 Generic Resistor 20 kQ 1 4 watt 1 2 R9 R11 Generic Resistor 22 O 1 4 watt 596 2 R10 R13 Generic Resistor 100 kO 1 4 watt 596 2 R15 Dale LVR 5 04W Resistor 040 O 5 watt 1 1 KRL NP 5A 04W Riedon MT 5 04W R16 R23 R25 Generic Resistor 10 kO 1 4 watt 196 3 R17 Dale CW 10 4 7K Resistor 4 7 kO 10 watt 596 see Note 3 1 KRL C 10A 4 7K Riedon UT 10 4 7K R18 Dale RS 2B 20K Resistor 20 kO 2 watt 196 1 KRL C 2A 20K Greenlee A Textron Company 24 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 855 Smart Bender Power Generation Unit 50054678 Parts List cont d Reference Supplier Part Number Description Qty Riedon UT 2B 20K R19 R21 Generic Resistor 1 kQ 1 4 watt 5 2 R20 Generic Resistor 1 5 MO 1 4 watt 5 1 R22 Generic Resistor 100 Q 1 4 watt 1 1 R26 R28 Generic Resistor 1 5 KO 1 4 watt 1 2 R27 Generic Resistor 27 4 kQ 1 4 watt 1 1 R29 Generic Resistor 68 1 kO 1 4 watt 1 1 S1 Panasonic EVO PACO9K Switch m
45. of 1 1 2 pivot roller shaft 86 with grip 90 Remove the bender frame beneath the roller support unit the sleeve 87 20 Put the bender in the horizontal bending position e Remove two hex head screws 93 Remove the Adjust the set screw 107 if necessary so that the outer roller plate 75 support arms 71 are centered between the front and back plates Engage and disengage the roller e Remove the tail roller 84 80 support unit to be sure that it moves freely e Remove all components of the split roller assembly 9 On the 2 roller group Loosen the sleeve set screw 98 and press out the 2 pivot shaft 88 Remove the sleeve 89 Remove the hex head screw 93 Remove one retaining ring 95 from the tail roller shaft 83 Remove the outer roller plate 76 Remove the tail roller 82 and center roller 85 e Remove all components of the split roller assembly Greenlee A Textron Company 9 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE Maintenance cont d Changing Shoes 1 Disconnect the bender from the power source 2 Lock the bender head in the vertical bending posi tion refer to Pivoting the Bending Head in the Setup section of this manual 3 Refer to the 1 2 to 1 1 4 Side Exploded View or the 1 1 2 to 2 Side Exploded View Use heavy duty retaining ring pliers to remove the retaining ring 26 that secures the shoe Rem
46. omentary pushbutton 1 U1 Motorola LM339AN IC Iow power guad comparitor 1 U2 Micrel MIC4422BN IC 9 A peak low side non inverting MOSFET driver 1 US HP HCPL4502 IC opto isolator 1 GT Opto HCPL4502 Siemens 6N136 Note 1 Mount D8 to bottom hole of heat sink Note 2 Mount O1 to top hole of heat sink Note 3 Bend leads and mount 0 25 off board Power Generation Unit 50054678 Layout Diagram our EN N punog O R3 od m ooooooo E oooo 5 lt gt o D6 S1 o C3 o lt gt C9 D7 R13 R14 R25 Fo R24 Fo R27 Fo E28 Fo R23 Fo o go Fo D5 n R11 Lo O O o o o e o o o o o o o x O e g E O eJ o 2 5 2 O o E a 5 55 x EL oT o o 5 E o VE Yellow Yellow e co O EO o GREENLEE TEXTRON O Red Black 2000 O s o o o o FROM RECTIFIER Greenlee A Textron Company 25 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender Input Output Board 500
47. otor brake speed is greater than 4400 rpm NO Replace optical encoder Indicates variations NO Consistently underbends by a few degrees and can t be adjusted correctly NO Clean and tighten all ground connections at frame NO Isolate motor leads from cables that plug into the I O board NO Replace optical encoder NO Replace I O board Greenlee A Textron Company YES in the conduit Use Accuracy Adjustment to compensate Limit switch arm is bent or switch is mounted backwards 37 Replace motor field 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 855 Smart Bender NO Tighten to 0 16 Nm 22 in oz torque GREENLEE 855 Smart Bender Troubleshooting cont d Accuracy Adjustment Deluxe Pendant Due to variations in conduit you may notice that the 1 Press RESET bender consistently over or underbends a particular 2 Press the 0 key three times PROGRAMMING size and type of conduit Programmed adjustments MODE appears on the display can be made to compensate for over and underbend ing conduit Each size and type of conduit can have a 3 Key in the desired size and type of conduit to unique adjustment ranging from plus 9 degrees to compensate The display shows the current adjust minus 9 degrees value O is factory default 4 W
48. ove the shoe from the spindle Drive lugs must engage in these holes 5 Mount the replacement shoe onto the spindle Align the slot in the shoe bore with the screw head on the spindle Push the shoe onto the spindle until the drive lugs are fully engaged in the drive lug holes Replace the retaining ring Motor The motor commutator brushes should last for about 1000 hours of normal use but will eventually need to be replaced 1 Disconnect power to the unit 2 Remove the motor cover 3 Remove the power cord strain relief 4 Remove the two nuts securing the shroud to the tail of the motor and remove the shroud 5 Push in the commutator brush retainer and move it toward the brush to release it 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 the maximum switch travel by pivoting the switch in its mounting holes and rotating it clockwise in its mounting slot Set the squeeze adjustment at the maximum clockwise position Move the switch in a counterclockwise direc tion with a 0 030 feeler gage between the roller arm and the body When the roller arm gage and switch body are in contact tighten the mounting screws The switch lockout circuit
49. place bridge rectifier Clean 36 nately press BEND and UNLOAD Does yellow DIRECTION LED on PGU turn on and off YES NO YES NO Use 120 VAC Replace pendant membrane switch Replace I O board Replace 91866456 relay YES Replace PGU Replace I O 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Troubleshooting cont d Makes inaccurate bends Press BEND to rotate shoe and stop it when the pendant displays between 1 6 Note the shoe position Press BEND and continue past 90 Unload to angle first stopped at between 19 65 without passing it Note shoe position Is shoe within 1 of first position stopped at YES Consistently bends all sizes of one shoe a few degrees over or bends all the sizes a few degrees under NO Consistently overbends by more than 5 and can t be properly adjusted NO Bends some sizes of one shoe 1 or 2 over and other sizes of the same shoe 1 or 2 under NO YES YES YES Isolate motor leads from all cables that go to I O board Adjust the limit switch for that shoe Bender coasts to a stop NO No load motor NO YES YES Are set screws tight in drive hub on optical encoder YES Replace optical encoder Adjust m
50. s List and Layout Diagram 29 30 Optional Bending Attachments Exploded View and Parts 31 32 38 855 Smart Bender Safety Safety is essential in the use and maintenance of Greenlee tools and equipment This service manual and any markings on the tool provide information for avoid ing hazards and unsafe practices related to the use of this tool Observe all of the safety information provided Purpose of This Manual This manual is intended to familiarize authorized Greenlee service center personnel with the safe operation and maintenance procedures for the Greenlee 855 Smart Bender Serial Code AKN Keep this manual available to all personnel Replacement manuals are available upon request at no charge at www greenlee com Other Publications Instruction Manual 52033651 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 Loctite is a registered trademark of Loctite Corporation Molex is a registered trademark of Molex Inc KEEP THIS MANUAL Greenlee A Textron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE 855 Smart Bender IMPORTANT SAFETY INFORMATION SAFETY ALERT SYMBOL Th
51. sary AWARNING 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 Greenlee A Textron Company 4 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE Grounding Instructions AWARNING Electric shock hazard e Do not modify the plug provided with the tool Connect this tool to a grounded receptacle on a 20 A GFCI pro tected circuit Failure to observe these warnings could result in severe injury or death This tool must be grounded In the event of a malfunc tion or breakdown an electrical ground provides a path of least resistance for the electric current This path of least resistance is intended to reduce the risk of electric 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 L5 20 Plug Receptacle Greenlee A Textron Company 855 Smart Bender Setup A WARNING Wear eye protection when operating or servicing this tool Failure to wear eye protection could result in serious eye injury from flying debris Follow these steps which are described in greater detail in this section to s
52. sed is selected is bad NO YES yes Refer to Won t Are polarity of rectifier relay and NO Connect wires Does BEND work when set to Unload Display motor connections correct correctly 1 1 2 or 2 size On in this section Refer to Electrical Control System Layout and Parts List N an NS YES 7 BEND N9 ee m On 1 1 2 or 2 setting does white YES Motor is wired J ISP motor lead receive positive voltage wrong internally YES NO Repl o NG eplace Can an angle be programmed Lon Disconnect I O PGU cable on the I O board and reconnect YES to test terminal Disconnect vee brake wire unit Restore power Is 100 VDC measured at the YES and push test switch Replace I O board motor leads when BEND or Replace motor shoe move The toggle switch UNLOAD is pressed located next to the push button NO switch controls the direction the shoe moves Are all pin connections making NO Replace or repair contact on 6 wire cable connecting the interconnecting NO the I O board to the PGU board cable Replace PGU YES Disconnect l O PGU cable on the I O board and reconnect to test terminal Disconnect brake wire unit Restore power and push test switch Does YES Replace I O board shoe move The toggle switch located next to the push button switch controls the direction the shoe moves NO Replace PGU 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Troubleshooting cont d Won t
53. t the Power AC Wire Unit 21 Remove the four screws securing the I O subplate and remove the assembly Assemble in reverse order noting the proper polarity of all wires as shown should be serviced disassembled while on the trunnion base Failure to observe this warning could result in severe injury or death Electronics Note Refer to the Electrical Control System Layout and Parts List for the location of key numbers o DO KRW Tn Power Generation Board PGU 1 Remove the four screws securing the top round 11 cover and remove the cover 2 Disconnect the ground jump wire 28 and the white and black leads of the Power AC Wire Unit 21 Chain 3 Disconnect the power cord neutral white wire 3 If the chain breaks replace it with new chain 4 Disconnect the power lead black from the switch 1 90542509 not another master link Because of the 5 Disconnect the PGU I O cable 13 high stress on the chain the addition of a second master link will only weaken the chain further If the 6 Disconnect the motor leads 2 master link breaks replace it with a new master link 7 Remove the four screws securing the PGU subplate 90542517 and remove the assembly 1 Remove the four screws securing the top cover and 8 Assemble in reverse order noting the proper polarity remove the top cover of all wires as shown 2 Remove the 1 1 2 to 2 shoe refer to Changing a Shoes
54. to observe these warnings could result in severe injury or death A WARNING Do not expose to rain e Do not use in wet or damp locations Do not immerse the pendant Switch in water or any other liquid Failure to observe these warnings could result in severe injury or death A WARNING Wear eye protection when operating or servicing this tool Failure to wear eye protection could result in serious eye injury from flying debris A WARNING Do not remove guards Failure to observe this warning could result in severe injury or death 4455 Boeing Dr e Rockford IL 61109 2988 USA e 815 397 7070 GREENLEE 855 Smart Bender IMPORTANT SAFETY INFORMATION AWARNING AWARNING Extension cords e Use only three wire 12 AWG Do not use tool as a step or ladder extension cords that have three prong grounding type plugs and three hole receptacles that accept the tool s plug Do not use extension cords that are longer than 30 m 100 Repair or replace damaged exten sion cords ACAUTION Conduit moves rapidly as it is bent The path of the conduit must be clear of obstructions Be sure Failure to observe these warnings clearance is adequate before starting the bend could result in Severe injury or death 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 near
55. type selected Set selector switches properly Too much squeeze on 1 1 2 or 2 EMT IMC or rigid aluminum conduit Unusual conduit characteristics Back squeeze off per adjustment instructions Refer to Accuracy in the Adjustments section or bend to a smaller angle to compensate Bends are underbent a few degrees Wrong conduit size and or type selected Set selector switches properly Too little squeeze on 1 1 2 or 2 EMT IMC or rigid aluminum conduit Increase squeeze per adjustment instructions Unusual conduit characteristics Refer to Accuracy in the Adjustments section or bend to a larger angle to compensate Greenlee A Textron Company 32 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Troubleshooting cont d Problem UNLOAD key does not work Probable Cause Roller support is not all the way down 855 Smart Bender Probable Remedy Release the roller support Unloaded to the starting position Release and press UNLOAD again Locking cam does not engage Bend key does not work for 1 2 to 1 1 4 conduit Too much squeeze on 1 1 2 or 2 EMT or rigid aluminum conduit Back squeeze off per adjustment instructions Shoe rotated too far in unload direction Roller support is not all the way down Rotate shoe with BEND key until locking cam engages Release the roll
56. when bend or unload is pressed Replace transformer unit Replace PGU Replace I O board YES Replace I O board Will bend display blank the power cord Is at least 80 volts measured at NO Install shoe per instructions in this manual YES Replace optical encoder NO Replace or adjust limit switches or wire unit YES Replace pendant board NO Replace optical encoder Find 120 VAC YES Replace pendant board 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 power source GREENLEE 855 Smart Bender Troubleshooting cont d Bender runs backwards for bend and unload Won t bend display on Greenlee A Textron Company 35 NO Does bender work with YES Jump 2 amp 4 Is proper size of conduit selected 4 Select proper size different good pendant terminals in pendant YES Does bender run NO o YES Does bender run backwards when Rotary switch cable using deluxe pendant or does bender NO is backwards or Bad pendant Bad membrane run backward when a conduit size for rotary switch unit board switch the shoe not being u
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