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Greenlee 555BAT User Manual

Greenlee 555BAT
48 pages
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Read and understand this material before operating
or servicing this equipment. Failure to understand how
to safely operate this tool could result in an accident
causing serious injury or death.
INSTRUCTION MANUAL
999 2601.6 © 1999 Greenlee Textron IM 1321 REV 2 5/99
555BAT
BATTERY-POWERED
BENDER
SERIAL CODE ACB
1
0
5
0
5
1
0
1
5
2
0
2
5
3
0
3
5
4
0
4
5
5
0
5
5
6
0
6
5
7
0
7
5
8
0
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Greenlee 555BAT Specifications

General IconGeneral
Battery Voltage18V
Operating Pressure10, 000 psi
Power SourceBattery
Voltage Range18V
Battery CompatibilityGreenlee 18V batteries

Summary

Description and Purpose

Product Description

Overview of the Greenlee 555BAT™™ Battery-Powered Bender.

Product Purpose

Explains the intended use and application of the bender.

Important Safety Instructions

Safety Alert Symbol and Definitions

Explains the hazard alert symbol and levels (Danger, Warning, Caution).

Operator Qualifications and Warnings

Specifies requirements for operating the tool safely.

Battery Safety Hazards

Covers risks associated with explosive hydrogen gas and battery acid.

Electric Shock Safety

Details precautions to avoid electrical hazards from the charger.

Operational Safety Precautions

Covers guards, pinch points, eye protection, and clothing.

Servicing and General Safety

Includes safety before servicing and general use cautions.

Grounding Instructions for Charger

Electric Shock Hazard from Charger

Details hazards and precautions related to charger grounding.

Features of the 555BAT Bender

Technical Specifications

Bending Attachment Groups

Introduction to the Bender and Batteries

Battery Performance and Care

Offers tips for optimal battery performance and maintenance.

Battery Charger Operation

Explains how the onboard battery charger functions.

Preparation for Use

Pre-Operation Safety Warnings

Covers battery gas, electric shock, and frozen battery hazards.

Initial Bender Setup Actions

Details steps like placing the bender and checking the breaker.

Connecting Battery Cables

Step-by-step guide for connecting the battery cables.

Charging and Battery Check

Instructions for charging batteries and checking their level.

Setup Procedure

Installing Bending Shoe and Support Unit

Details the process of mounting the shoe and support.

Conduit Marking and Positioning

Explains how to mark and align conduit for bending.

Bender Orientation Selection

Choosing between vertical or horizontal bending positions.

Operation Guide

General Operation Safety

Highlights key safety points during operation.

Starting the Bender and Loading Conduit

Steps to power on and prepare the bender for bending.

Conduit Bending Steps

Detailed process for bending different types of conduit.

Unloading the Bender and Conduit

Procedure to remove the bent conduit.

Adjusting the Squeeze

How to adjust pressure for optimal conduit bending.

Illustrated Bending Glossary

Bending Instructions: 90° Stubs

Stub Length Calculation and Marking

Steps to measure and mark conduit for stub bends.

Deduct and Scale Reading Tables

Reference tables for stub bend calculations.

Bending Instructions: Offsets

Offset Measurement and Calculation

Steps to measure and calculate offset dimensions.

Offset and X Tables Reference

Reference tables for offset calculations.

Additional Bending Instructions

Stub Bending Guide Details

Further guidance on bending stubs.

Working Past Obstructions

Technique for bending around obstacles.

Working Toward Obstructions

Technique for bending around obstacles.

Three-Bend Saddle Instructions

Procedure for creating three-bend saddles.

Four-Bend Saddle Instructions

Procedure for creating four-bend saddles.

U-Bend Instructions

Procedure for creating U-shaped bends.

Maintenance Procedures

Pre-Maintenance Safety

Essential safety steps before performing maintenance.

Chain Tension Adjustment

Procedure for adjusting the chain tension.

Fuse Replacement

Steps for replacing a blown fuse.

Replacing Batteries

Guide on how to replace the bender's batteries.

Electrical Control Unit Replacement

Steps for replacing the electronic control unit.

Reductor Gearbox Information

Details and cautions regarding the reductor gearbox.

Troubleshooting Guide

Exploded View of Components

Wiring Layout - General

Wiring Layout - Terminal Block Detail

Detailed diagram of the terminal block wiring connections.

Roller Support Units

Motor - 24 Volt

Control Assembly

Control Assembly Schematics

Detailed schematic diagram of the control circuitry.

Control Assembly - Electronic Components

List of electronic components used in the control assembly.

Bending Shoes and Roller Supports

Bending Shoes and Roller Supports (cont'd) - IMC

Details on parts for IMC bending shoes and roller supports.

Bending Shoes and Roller Supports (cont'd) - Rigid & PVC

Details on parts for Rigid Steel and PVC coated conduit.

Bending Shoes and Roller Supports (cont'd) - PVC

Details on parts for PVC coated conduit.

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