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Greenlee 555 User Manual

Greenlee 555
44 pages
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555 Electric Bender
1/2" thru 2" Rigid and Thin-Wall EMT Conduit
1-1/2" and 2" IMC Conduit
Serial Numbers PL-32216-PGJ and up
INSTRUCTION MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
999 5789.2 © 2001 Greenlee Textron IM 909 REV 18 9/01

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Questions and Answers:

Greenlee 555 Specifications

General IconGeneral
BrandGreenlee
Model555
CategoryConstruction Equipment
LanguageEnglish

Summary

Introduction and Overview

Safety First

Essential safety information for avoiding hazards and unsafe practices during tool use.

Manual Purpose and Bender Description

Outlines the manual's objective and describes the 555 Electric Bender Power Unit.

Important Safety Information

Electrical, Environmental, and PPE Hazards

Covers electric shock, environmental risks, eye protection, and guards.

Additional Safety Precautions

Extension Cords and Pinch Points

Guidelines for using extension cords and avoiding pinch points during operation.

Operational and Equipment Checks

Covers inspection, avoiding loose clothing, and proper use of the tool.

Grounding Instructions

Electrical Shock Hazard Prevention

Instructions for proper grounding connection to minimize electric shock risk.

Identification

Bender Component Identification

Diagram and labels identifying key parts of the 555 Electric Bender Power Unit.

Setup

Mounting Bending Shoes

Procedure for attaching the correct size bending shoe onto the main shaft.

Mounting Support Roller and Units

Instructions for mounting the support roller or unit on the bender's leg.

Bending Instructions

Bending 1/2"-2" Rigid Conduit and EMT

Step-by-step guide for bending 1/2"-2" rigid conduit and 1/2"-1-1/4" EMT.

Bending Instructions (Continued)

Bending 1-1/2" and 2" IMC and EMT Conduits

Procedure for bending 1-1/2" and 2" IMC and EMT conduits using the bender.

Squeeze Adjustment

Adjusting Bending Pressure

How to adjust squeeze for quality bends, preventing wrinkling or side marking.

Special Application

Flat Position Bending

Using the bender in a flat position for special applications and unusual bends.

Maintenance

Gearbox Lubrication

Information on gearbox lubrication, including type of oil and flushing agents.

Illustrated Bending Glossary

Bending Terminology Definitions

Definitions and illustrations of common bending terms used in the manual.

Locating Bending Marks

90° Stub Bending Marks

How to locate marks on conduit for 90° stub bends using charts.

Finding Bending Marks for Offsets

Offset Bend Markings

Procedure for marking conduit for offset bends using charts and measurements.

Adjusting Chains

Chain Tension Adjustment

Instructions for adjusting the front chain tensioner and rear chain tensioner.

Special Bending Information

Setting Up Your Bends: Stubs and Offsets

Guide for laying out starting points for stubs and controlling offset bends.

Special Bending Information (Continued)

Offsets and 3 Bend Saddles

Instructions for controlling end of second offset bend and setting up 3-bend saddles.

Special Bending Information (Continued)

4 Bend Saddles and U-Bends

Techniques for setting up 4-bend saddles and U-bends.

Special Bending Information Chart

EMT and IMC Bending Data

Chart providing dimensions for EMT and IMC conduit bending at various angles and heights.

Special Bending Information Chart (Continued)

EMT Conduit Bending Data

Chart providing dimensions for EMT conduit bending at various angles and heights.

Special Bending Information Chart (Continued)

EMT and Rigid/IMC Conduit Bending Data

Chart provides bending data for EMT and Rigid/IMC conduits.

Special Bending Information Chart (Continued)

Rigid/IMC Conduit Bending Data

Chart providing dimensions for Rigid/IMC conduit bending at various angles and heights.

Special Bending Information Chart (Continued)

Rigid/IMC Conduit Bending Data

Chart providing dimensions for Rigid/IMC conduit bending at various angles and heights.

Special Bending Information Chart (Continued)

Rigid Conduit Bending Data

Chart providing dimensions for Rigid conduit bending at various angles and heights.

Special Bending Information Chart (Continued)

IMC Conduit Bending Data

Chart providing dimensions for IMC conduit bending at various angles and heights.

Exploded View - 555 Electric Bender

Bender Component Breakdown

Diagram showing an exploded view of the 555 Electric Bender components.

Parts List - 555 Electric Bender

Bender Component Parts

List of all part numbers and descriptions for the 555 Electric Bender.

Parts List - Control Box Unit

Control Box Component Details

List of parts specific to the solid-state electrical control box unit.

Electrical System Overview

Control and Power Module Components

Visual overview of the control module and power module with LED indicators.

Electrical System Views

Rear View and Control Box Components

Illustrates rear view of the bender and details of control box components.

Electrical Troubleshooting

Drive Motor and Power Check

Steps to troubleshoot drive motor issues and perform power checks.

Control Section Analysis

Analysis of control section for issues using LED status and pendant switches.

Electrical Troubleshooting (Continued)

Power Module Analysis

Diagnosing power module and motor malfunctions by checking resistance and components.

Electrical Component Removal and Replacement

Control and Power Module Procedures

Step-by-step guide for removing and replacing control and power modules.

Parts List - Motor

Motor Component Parts (115V/230V)

List of parts for both Pacific Scientific and Leeson brand motors.

Wiring Diagram - 115V

115V System Wiring

Diagram illustrating the wiring connections for the 115V 555 Electric Bender.

Exploded View - Control Box Unit

Control Box Assembly Breakdown

Diagram showing an exploded view of the control box unit for 115V and 230V systems.

Parts List - Control Box Unit

Control Box Unit Component Parts

List of part numbers for the control box unit, including voltage-specific items.

Wiring Diagram - 230V

230V System Wiring

Diagram illustrating the wiring connections for the 230V 555 Electric Bender.

Bending Shoe & Support Roller Parts (Rigid Conduit)

1/2 - 1-1/4" Rigid Conduit Components

List of parts for the bending shoe and support roller for 1/2 - 1-1/4" rigid conduit.

Bending Shoe & Support Roller Parts (Rigid Conduit)

1-1/2 - 2" Rigid Conduit Components

List of parts for the bending shoe and support roller for 1-1/2 - 2" rigid conduit.

Bending Shoe & Pipe Rest Parts (EMT Conduit)

1/2 - 1-1/4" EMT Conduit Components

List of parts for the bending shoe and pipe rest for 1/2 - 1-1/4" EMT conduit.

Parts - Bending Shoes

EMT Bending Shoes

Parts list for 1-1/2" and 2" EMT conduit bending shoes.

IMC Bending Shoes

Parts list for 1-1/2" and 2" IMC conduit bending shoes.

Parts List - EMT or IMC Roller Support Unit

EMT Roller Support Unit Parts

List of parts for the EMT roller support unit.

IMC Roller Support Unit Parts

List of parts for the IMC roller support unit.

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