Greenlee 555 Series User manual

555®
Deluxe Electric Bender
Serial Code ADV
SERVICE MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99937301 © 2006 Greenlee Textron Inc. SB 282 REV 4 1/06

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
KEEP THIS MANUAL
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any markings on the tool provide information for
avoiding hazards and unsafe practices related to the
use of this tool. Observe all of the safety information
provided.
Purpose
This manual is intended to familiarize authorized
Greenlee service center personnel with the safe opera-
tion and maintenance procedures for the Greenlee 555®
Deluxe Electric Bender, with Serial Code ADV.
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge.
Mobil is a registered trademark of Mobil Oil Corporation.
Other Publications
Instruction Manual: Publication 99937530 (IM 1458)
Table of Contents
Safety ............................................................................. 2
Purpose .......................................................................... 2
Other Publications .......................................................... 2
Important Safety Information .......................................3-4
Handle Removal and Replacement ............................... 5
Transportation ................................................................ 5
Maintenance................................................................6-7
Troubleshooting ..........................................................8-9
Exploded Views and Parts Lists ..............................10-12
Electrical Control System Layout ................................. 13
I/O Control ............................................................... 14-16
Power Generation Board.........................................17-19
Motor ............................................................................ 20
Bending Shoes & Roller Supports...........................21-24
All specifications are nominal and may change as design improve-
ments occur. Greenlee Textron Inc. shall not be liable for damages
resulting from misapplication or misuse of its products.
555 is a registered trademark of Greenlee Textron.
Molex is a registered trademark of Molex Inc.

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
This 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
preventing or avoiding the hazard.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Hazards which, if not avoided, COULD result in
severe injury or death.
Immediate hazards which, if not avoided, WILL
result in severe injury or death.
SAFETY
ALERT
SYMBOL
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning will
result in severe injury 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 in a hazardous
environment. Hazards include
flammable liquids, gases, or other
materials. Using this tool in a haz-
ardous environment can result in a
fire or explosion.
Failure to observe this warning will
result in severe injury or death.
IMPORTANT SAFETY INFORMATION
Electric shock hazard:
• Connect the power cord to a 120
volt, 20 amp receptacle on a
ground fault protected circuit only.
See Grounding Instructions.
• Do not modify the power cord or
plug.
• Inspect the power cord before use.
Repair or replace the cord if
damaged.
• Disconnect from power before
servicing.
Failure to observe this warning could
result in severe injury or death.

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
IMPORTANT SAFETY INFORMATION
• Conduit moves rapidly as it is bent. The path of
the conduit must be clear of obstructions. Be sure
clearance is adequate before starting the bend.
• Do not operate the bender while wearing loose
clothing. Loose clothing can get caught in moving
parts.
• Inspect the bender before use. Replace worn,
damaged or missing parts with Greenlee replace-
ment parts. A damaged or improperly assembled
component could break and strike nearby
personnel.
• Some bender parts and accessories are heavy
and may require more than one person to lift and
assemble.
• Use only accessories and attachments recom-
mended by Greenlee.
• Do not stand on the bender; the bender may tip
over.
• Do not leave the tool running unattended. Do not
leave the tool until it comes to a complete stop.
Turn the power off and unplug the tool after use.
• Ensure that all bystanders are away from the
work area when operating the bender.
• 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.
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 the bender before changing accessories.
Accidental startup could result in serious injury.
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.
Extension cords:
• Use only three-wire, 12-AWG
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
extension cords.
Failure to observe these warnings
could result in severe injury or death.

Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Handle Removal and Replacement
The handle of the 555 is designed to be removable. This
feature is convenient when performing complex bending,
and makes it easy to replace a damaged handle.
Removal
1. Place the bender in the upright position.
2. Release the spring clip on the safety snap pin (78).
3. Remove the pin from the handle (79) and the sleeve
of the frame (1).
4. Repeat Steps 1 through 3 for the other end of the
handle.
5. Lift the handle to remove.
Replacement
1. Insert the handle (79) into the sleeves of the frame (1).
2. Align the holes in the handle with the holes in the
sleeves.
3. Insert the safety snap pin (78). Ensure that the pin
goes through the handle and the sleeve on the
frame (1).
4. Engage the safety spring clip 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
79
1
78
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 a guide for the
sling, as shown.
Make sure that all components used to lift this bender
are properly rated for the 167 kg (368 lb) weight. Use a
ramp to load and unload from a truck or other vehicle
that is not equipped with a lift gate.
Transporting Bender
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.

Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Maintenance
There is no need for periodic flushing and replacing of
lube in the bender gear box since it is sealed and locked
tight. However, if the box is opened for repair and the
lube is lost or contaminated by dirt, then the box and
parts should be flushed out and filled with 26 fluid
ounces of Mobil®634 synthetic oil.
Flushing should be accomplished with kerosene, which
is a petroleum hydrocarbon that does not affect seals.
Note: Aromatic hydrocarbons such as benzine,
chlorinated solvents such as carbon-tetrachloride, and
ketones such as acetone should never be used for
flushing as they are solvents for rubber. They are also
harmful to the environment.
Chain Adjustment
Both chains have to be adjusted if the final drive #60
chain is to be reset. Refer to the Exploded View and
Parts List.
1. Remove the front cover (38) and upper rear guard
(37).
2. Loosen the eight mounting bolts for the reductor
(19). Remove the eccentric cam and move the
reductor to create chain slack.
3. Remove the four retaining screws for eccentric
adjustment. Rotate to remove slack from the chain
and align with one of the two sets of holes in the
frame. Remount the eccentric with the four bolts.
4. Slide the reductor in slotted mounting holes to the
retension chain. Set tension with the eccentric cam.
Disconnect this tool when not in use,
before servicing or adjusting, and
when changing shoes or conduit
rollers and supports.
Failure to observe this warning could
result in severe injury or death.
#60 HT Final
Drive Chain
Four 1/4" Flange
Mounting Screws
Positioning Plate on
Eccentric Housing,
Counter Shaft
Eight Reductor
Mounting Bolts
(four on reverse side)
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).
With the eight reductor mounting bolts (22, 24) loose,
rotate the eccentric cam with a 1/2" square drive to
tension the chain. Torque the eight reductor mounting
bolts to 47 Newton-meters (35 ft-lb).

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Maintenance (cont’d)
Electrical Control Unit Removal
Disconnect power supply before
servicing bender. Servicing to be
done only by trained service
technician.
Failure to observe this warning could
result in severe injury or death.
1. Remove the cover retained by ten 5/16" hex screws.
2. Disconnect the pendant switch plug from the circuit
board and remove through the cord grip.
3. Remove two hex mounting screws, one on each
side.
4. Remove the motor leads, power cord ground wire,
and neutral wire before the control unit can be totally
removed from the bender.
3/8" Hex
Mounting Screw
Line Connection
at Circuit Breaker

Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Troubleshooting
The following flow charts show the suggested trouble-
shooting procedures for some bender problems. They by
no means encompass all possible problems or solutions.
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.
YES
YES
YES
YES
YES
Won’t bend
Replace PGU.
NO
NO
NO
NO
Does the green LED on
the PGU light? Replace PGU.
Does amber or red LED
on I/O light when BEND
or UNLOAD is pressed?
Unplug pendant or I/O and
check switch for continuity.
If ok, replace I/O.
Does the green LED on
the I/O board light?
Check I/O board
assembly.
Is 115 VAC measured at
PGU board input?
Plugged into dead circuit,
bad power cord, or
switch is bad or off.
NO
Does relay on I/O
operate when BEND or
UNLOAD is pressed? Replace I/O.
YES
YES
NO
YES
NO
Is the current on the 115 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 20 to 50
volts over the AC line voltage?
Are connectors corroded?
Replace PGU.
Follow directions in
instruction manual.
Replace circuit
breaker.
Replace motor.
Replace
bridge rectifier
(918 5997.2).
Clean.
NO
YES
NO
YES
Trips circuit breaker
NO
Are the proper support rollers
and shoe groove being used for
the type and size of conduit
being bent?
YES Use 115 VAC.
NO
YES
NO
Replace pendant
switch.
Does bender stop when the
pendant is unplugged?
Is the supply line voltage low?
Replace PGU.
Won’t stop
NO Check and replace
pendant switch.
YES
When amber or red LED is on, is
12 VDC measured at large relay
coil on PGU (where relay wire
unit connects)?
Does amber or red LED light
when switch is pressed?
Bender only runs in one direction
NO
YES
Replace 918 6645.6 relay.
Replace PGU. Replace I/O.
Move six-wire
connector on PGU
from “to I/O” to
“test.” Alternately
press BEND and
UNLOAD. Does
yellow “direction”
LED on PGU turn
on and off?
NOYES

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
1. With bender unplugged, switch six-wire connector on
PGU from “To I/O” to “Test.”
2. Plug unit in.
3. Press BEND. Contactor on I/O will activate.
• If not, check for 12 VDC at contactor coil
— If 12 VDC is present, replace contactor
918 6645.6—else replace I/O
• If bender runs, replace PGU.
• On PGU near “test” connector:
Green “Power” LED is ON
Yellow “Direction” LED is OFF
Red “PWM” LED slowly turns dimly on
If not, replace I/O.
4. Press UNLOAD. Contactor on I/O will activate.
• If not, check for 12 VDC at contactor coil
— If 12 VDC is present, replace contactor
918 6645.6—else replace I/O
• On PGU near “test” connector:
Green “Power” LED is ON
Yellow “Direction” LED is ON
Red “PWM” LED slowly turns dimly on
If not, replace I/O.
5. Press BEND. With insulated object, carefully press
black button “S1” on PGU. Bender will run slowly.
If not, replace PGU.
Quick diagnostics for electronic problems

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Exploded View — 555®Deluxe Electric Bender
38
20
28
50
142
34
32
29
8
3
6
13
16
15
14
78
10
11
49
7
17
78
53
78
52
41
72
31
57
73
141
54
54 71
47
58
46
45
44
43
42
40
39
37 59
36
35
80
27
26
25
24
24 23
22
21
19
18
14 12
11
9
7
5
42
1
79
Note: Key supplied with item #19 (reductor).
48
70
80
70
UNLOAD
BEND
142

Greenlee / A Textron Company 11 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Parts List — 555®Deluxe Electric Bender
1 50397427 Weldment, main frame ...................................................................... 1
2 50234528 Washer, fiber ..................................................................................... 1
3 50328964 Weldment, sprocket unit .................................................................... 1
4 90524098 Bearing, Fiberglide ø2.625 x 2.5 long ............................................... 1
5 90524101 Bearing, Fiberglide ø2.625 x 3.75 long ............................................. 1
6 90524144 Ring, retaining #5100-237 ................................................................. 1
7 90524128 Bearing, Fiberglide ø1.625 x 1.00 long ............................................. 2
8 50397630 Weldment, countershaft .................................................................... 1
9 90540239 Ring, retaining #5100-250 ................................................................. 1
10 50397648 Shaft, counter .................................................................................... 1
11 90524136 Bearing, thrust Fiberglide .................................................................. 2
12 90545486 Sprocket, #40 60T ............................................................................. 1
13 90542533 Sprocket, #60 14T ............................................................................. 1
14 50397656 Key, countershaft .............................................................................. 2
15 90545460 Chain, #60 87P.................................................................................. 1
16 90542517 Masterlink, #60 .................................................................................. 1
17 90545478 Sprocket, #40 13T ............................................................................. 1
18 50084313 Key, reductor sprocket ...................................................................... 1
19 90523881 Reductor, worm gear ......................................................................... 1
20 90527879 Masterlink, #40 .................................................................................. 1
21 90545516 Chain, #40 87P.................................................................................. 1
22 90545680 Bolt, 3/8–16 UNC x .75...................................................................... 7
23 50397583 Eccentric............................................................................................ 1
24 90542371 Bolt, 3/8–16 UNC x 1.00.................................................................... 5
25 91869730 Motor ................................................................................................. 1
26 90545494 Conduit, Sealtight .............................................................................. 1
27 91852145 Elbow, Sealtight................................................................................. 1
28 91866839 Strain relief ........................................................................................ 1
29 90511700 Nut, 3/4 conduit lock .......................................................................... 1
31 91862639 Nut, 1/2 conduit lock .......................................................................... 1
32 50397575 Axle ................................................................................................... 1
34 90515285 Ring, retaining #5160-75 ................................................................... 2
35 90552679 Wheel, urethane-filled ....................................................................... 2
36 50397680 Guard, rear lower .............................................................................. 1
37 50397699 Guard, rear upper .............................................................................. 1
38 50397605 Cover, front........................................................................................ 1
39 90516559 Screw, #10–16 x .50 hex head ........................................................ 31
40 90504305 Screw, #6–32 x .375 Phillips ............................................................. 2
41 91863856 Switch ................................................................................................ 1
42 50297082 Guard, switch .................................................................................... 1
43 50259288 Nameplate ......................................................................................... 1
44 90530012 Rivet, pop 1/8 x 1/8 ........................................................................... 4
Key Part No. Description Qty.

Greenlee / A Textron Company 12 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Parts List — 555®Deluxe Electric Bender (cont’d)
Key Part No. Description Qty.
45 50190539 Decal, voltage.................................................................................... 1
46 50303929 Decal, damp warning......................................................................... 1
47 50397591 Cover, top .......................................................................................... 1
48 50351915 Decal, safety...................................................................................... 1
49 90533895 Pin, hitch............................................................................................ 2
50 90525019 Ring, retaining #5100-287 ................................................................. 1
52 90545524 Lanyard ............................................................................................. 3
53 90545451 Pin, hitch............................................................................................ 1
54 90543351 Screw, 1/4 x .50 thread-forming ........................................................ 6
57 50339370 Decal, squeeze adjust ....................................................................... 1
58 50389742 Decal, circuit breaker......................................................................... 1
59 90553233 Pin, Driv-Lok, 1/8 x 1/2 ...................................................................... 1
70 90517407 Washer, flat ............................................. (req’d after Nov. 2005) ... 4
(before Nov. 2005) ... 2
71 50024973 Decal, instruction ............................................................................... 1
72 50036386 Decal, warning (English) ................................................................... 1
73 50001124 Decal, warning (French) .................................................................... 1
77 90510518 Ring, retaining #5100-150 ................................................................. 2
78 90552687 Pin, safety snap ................................................................................. 2
79 50397486 Handle, upper .................................................................................... 1
80 50069195 Sleeve, axle ....................................................................................... 2
141 50078690 Electronic control assembly (fully assembled) .................................. 1
141A 50078712 I/O Control assembly ......................................................................... 1
141B 50083570 Power generation unit ....................................................................... 1
141C 50078674 Bracket, electronics (metal bracket only) .......................................... 1
142 50078879 Pendant control assembly ................................................................. 1
143 50079123 Power cord assembly ........................................................................ 1
144 52023691 Service Kit for 52023601 (no-flat tire and wheel) .............................. 1
consists of:
#32 Axle (revised length) ....................................... (1) req’d
#35 No-flat tire and wheel assembly...................... (2) req’d
#34 Retaining ring.................................................. (2) req’d
#80 Sleeve, axle .................................................... (2) req’d
#70 Washer ........................................................... (4) req’d

Greenlee / A Textron Company 13 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Electrical Control System Layout
BLACK
LINE
LOAD
BLACK
WHITE
GREEN
GREEN
WHITE
WHITE
BLACK
TO PENDANT
(142)
POWER CORD
(143)
TO MOTOR (25)
141
(fully assembled)
141C
(bracket only)
141B
141A
72, 65
41

Greenlee / A Textron Company 14 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
I/O Electrical Schematic (50060180)
Note: All resistors 5% 1/4W unless noted.
+5V +12V
+12V
+5V
+12V
+5V
+12V+12V+5V
+5V
RUN/BRAKE
_RUN/BRAKE__DIRECTION_
_PWM_
DIR B DIR A PWM DIRECTION MECH BRAKE UNUSED2 UNUSED1
65 43 21
TO PGU Molex 39-28-1063 JP5
5 4 3 2 1
DC POWER IN Molex 26-60-4050
JP1
18
RA1/AN1
17
RA0/AN0
16
OSC1/CLKIN
15
OSC2/CLKOUT
13
RB7
12
RB6
11
RB5
10
RB4
9
RB3
8
RB2
7
RB1
6
RB0/INT
4
MCLR
3
RA4/TOCKI
2
RA3/AN3
1
RA2/AN2/VREF
PIC16C620
U1
10K R23
10K R22
UF1001DI
D1
UF-1001-DI
D5
UF-1001-DI
D4
1N4148
D3
PN2222A
Q4
PN2222A Q3
PN2222A Q2
POWER GREEN LED D2
DIR B
AMBER LED
D7
DIR A
RED LED
D6
10K R18
.1uF/50V
C1
330 R6
2 1
RELAY COIL
Molex 39-28-1023
JP3
2 1
MECHANICAL BRAKE Molex 39-28-1023
JP2
470 R5
TIP122 Q1
150 R10
43 21
PENDANT Molex 39-28-1043
JP4
.1uF/50V
C4
330 R21
.1uF/50V
C3
330 R20
10K R17
10K
R16
10K R15
3 1
2
4.0 MHz X1
10K R7
10K R4
10K R3
10K R2
10K R1
470 R14
1K R19
470 R13
150
R12
470
R11
4.7uF/50V
C2
1K R9
10K R8

Greenlee / A Textron Company 15 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
I/O Electrical Schematic (50060180) Parts List
Reference Supplier Part Number Description Qty.
C1,C3,C4 Philips A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts 3
AVX SA115C104KAA
KEMET C420C104K5R5CA
C2 Panasonic ECE-A50Z4R7 Capacitor, 4.7 uF, 50 volts 1
D1,D4,D5 Diodes Inc. UF-1001-DI Diode, Ultra-Fast Switching Rectifier 3
D2 Panasonic LN38GP LED, T1, Green 1
Liteon LTL-4231
D3 Generic 1N4148 Diode 1
D6 Panasonic LN28RP LED, T1, Red 1
Liteon LTL-4221
D7 Panasonic LN48YP LED, T1, Amber 1
Liteon LTL-4251
JP1 Molex 26-61-4050 Connector, Locking, 0.156" cc, 5-position, Gold 1
JP4 Molex 39-29-0043 Connector, Minifit Jr., 4-position, Gold 1
JP2,JP3 Molex 39-29-0023 Connector, Minifit Jr., 2-position, Gold 2
JP5 Molex 39-29-0063 Connector, Minifit Jr., 6-position, Gold 1
Q1 Generic TIP122 Transistor, NPN 1
Q1–Heat Sink Hardware AAVID 577002B04000 Heat Sink, TO-220, .75 x .52 x .25", with Tab 1
Generic #4-40 Lock Washer Stainless Steel, Split Ring or Internal Tooth 1
Generic #4-40 Hex Nut Stainless Steel 1
Generic #4-40 Phillips Screw Stainless Steel, Machine, Pan Head, #4-40 x 0.25" 1
Q2,Q3,Q4 Generic PN2222A Transistor, NPN 3
R1,R2,R3,R4,R7,R8,R15, Generic Resistor, 10K, 1/4 watt, 5% 12
R16,R17,R18,R22,R23
R5,R11,R13,R14 Generic Resistor, 470 Ω, 1/4 watt, 5% 4
R6,R20,R21 Generic Resistor, 330 Ω, 1/4 watt, 5% 3
R9,R19 Generic Resistor, 1 kΩ, 1/4 watt, 5% 2
R10,R12 Generic Resistor, 150 Ω, 1/4 watt, 5% 2
U1 Greenlee 91869382 Processor, Programmed, 854 1
X1 Murata CST4.00MGW Resonator, 4.0 Mhz 1
Panasonic EFO-GC4004A4

Greenlee / A Textron Company 16 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
PCB Layout (50060180)
Q1
JP1
R22
RELAY
BRAKE
TO PGU
POWER
JP4
12 34
JP5
12
3
456
R15
R1
D4
R21
C4
R18
D7
DIR A
JP3
1 2
Q3
R13
R8
R9
C2
+
D3
R5
DIR B
JP2
1
2
R6
C1
D2
X1
D1
R20
C3
D6
R17
D5
R11
R12
R19
R14
R10
Q2
Q4
R23
U1
SELECTOR
R3
R4
R7
GREENLEE TEXTRON ©2000
R2
R16

Greenlee / A Textron Company 17 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Power Generation Unit Schematic Diagram (50083570)
Do not trim insulator. in heat sink. Q1 should mount to upper hole in heat sink. D8 should mount to lower hole Tighten Q1 and D8 to 5 in-lb #4-40 Phillips Screw #4-40 Nut #4-40 Lock Washer: #4-40 Flat Washer (x2) KA-118-094 Power Devices, Inc Insulator: THM7023B-MT Thermalloy Inc. Heatsink: Mounting Hardware for Q1 and D8
7
5
4
8
1
6
2
MIC4422BN U2
100K
R10
-
123
1
6 7LM339
U1A
10K/1% R16 20K/1% R7 4.75K/1%
R6 1.5K/1% R26
+15 V
20K/1% R24 10K/1% R25
- +
123
13
10 11 LM339
U1D
+170 V
1N5245B
D3
2 1
TO RELAY (Contacts 5 and 8)
BLACK J11
2 1
TO RELAY (Contacts 6 and 7)
RED J10
DSEI30-06A
D8
IXFK73N30 Q1
C10
+15 V
.1uF/50V.1uF/50V
C9
VCC GREEN LED D4 DIRECTION YELLOW LED D1
PWM RED LED
D2
2K R8 2K R1
65 43 21
TEST CONNECTOR Molex 39-28-1063 J1
EVQ-PAC09K
S1
- +
123
2
4 5LM339
U1B
100K R13 1N4148
D6
1M R12
1N4148 D7
1M R14
.01uF/50V
C3
150K R41M
R2 1M
R3
12K/1% R5
+15 V
18.7K/1% R27 1.5K/1% R28 .1uF/50V
C12
10K/1% R23
- +
123
14 8
9
LM339
68.1K/1% R29
U1C 100/1%
R22
.040/5W/1% R15
2 35
6 7 8
2 1
TO RELAY COIL (Contacts 1 and 2) Molex 39-28-1023 J4
UF1001DI
D9
HCPL4502
U3
65 43 21
TO I/O Molex 39-28-1063 J2
PN2222A Q2
1K
R19
1K R21
+15 V
.1uF/50V
C13
.1uF/50V
C1 1uF/63V
C2 1N4148
D5
22 R9
22 R11
RECTIFIER TO BRIDGE
+170 V
+15 V
1N4007 D13 1N4007 D14
2 1
AC
YELLOW
J8
4.7K/10W R17
2 1
DC- BLACK J9
2 1
DC+ RED J6
2 1
AC
YELLOW
J5
POWER GREEN LED D11
1N5245B
D10
20K/2W/1% R18
680uF/25V
C71000uF/250V
C6
.010uF/500VAC
C4
.010uF/500VAC
C11
GROUND NEUTRAL LINE .0047uF/500VAC
C5
.0047uF/500VAC C8 470uH
L1
1.5M R20
3 2 1
AC POWER IN Beau 72503-C J7
Notes: • Bend leads on R17 to mount at least 0.25" off-board. • All resistors 5% 1/4W unless noted.

Greenlee / A Textron Company 18 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Power Generation Unit Parts List (50083570)
C1,C9,C10,C12,C13 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 2
C5,C8 Sprague 440LD47 Capacitor, .0047 uF, 500 volts AC 2
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 2
D4,D11 Panasonic LN38GP LED, T1, Green 2
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
Magnum A202203
L1 Renco RL-1328-22-470 Choke, Common Mode 1
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 kΩ, 1/4 watt, 5% 2
R2,R3,R12,R14 Generic Resistor, 1 MΩ, 1/4 watt, 5% 4
R4 Generic Resistor, 150 kΩ, 1/4 watt, 5% 1
R5 Generic Resistor, 12.1 kΩ, 1/4 watt, 1% 1
R6 Generic Resistor, 4.75 kΩ, 1/4 watt, 1% 1
R7,R24 Generic Resistor, 20 kΩ, 1/4 watt, 1% 2
R9,R11 Generic Resistor, 22 Ω, 1/4 watt, 5% 2
R10,R13 Generic Resistor, 100 kΩ, 1/4 watt, 5% 2
R15 Dale LVR-5 .04W Resistor, .040 Ω, 5 watt, 1% 1
KRL NP-5A .04W
Riedon MT-5 .04W
R16,R23,R25 Generic Resistor, 10 kΩ, 1/4 watt, 1% 3
R17 Dale CW-10 4.7K Resistor, 4.7 kΩ, 10 watt, 5% (see Note 3) 1
KRL C-10A 4.7K
Riedon UT-10 4.7K
R18 Dale RS-2B-20K Resistor, 20 kΩ, 2 watt, 1% 1
KRL C-2A 20K
Riedon UT-2B 20K

Greenlee / A Textron Company 19 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Layout Diagram — Power Generation Unit (50083570)
Power Generation Unit Parts List (50083570) (cont’d)
R19,R21 Generic Resistor, 1 kΩ, 1/4 watt, 5% 2
R20 Generic Resistor, 1.5 MΩ, 1/4 watt, 5% 1
R22 Generic Resistor, 100 Ω, 1/4 watt, 1% 1
R26,R28 Generic Resistor, 1.5 kΩ, 1/4 watt, 1% 2
R27 Generic Resistor, 18.7 kΩ, 1/4 watt, 1% 1
R29 Generic Resistor, 68.1 kΩ, 1/4 watt, 1% 1
S1 Panasonic EVQ-PAC09K Switch, Momentary Pushbutton 1
U1 Motorola LM339AN IC, Low Power Quad Comparitor 1
U2 Micrel MIC4422BN IC, 9-A Peak Low-Side Non-inverting MOSFET Driver 1
U3 HP HCPL4502 IC, Opto-isolator 1
QT-Opto HCPL4502
Siemens 6N136
Note 1: Mount D8 to bottom hole of heat sink.
Note 2: Mount Q1 to top hole of heat sink.
Note 3: Bend leads and mount .25" off-board.
R18
L1
J7
Q1
+
C6
D8
C13
C12
C10
C3
C1
C9
C2
U1
J6
YellowYellow
Red Black
TEST
DIR
PWM
VCC
GREENLEE TEXTRON
POWER
R17
654 321
D2
R8
R1
D1
J8 J5
J9
D4
R15
D11
D13
RedBlack
TO RELAY
FROM RECTIFIER
©2000
TO I/OGround Neutral Line
R28
R12 R4
R22
R2
R27
R3
654
32 1
J2
C4
2 1
J4
R7
D3
R16
R6
R23
R10 Q2
U3
R13 R14
D6
D7
U2
R26
D5
R9
R11
R5
R24
R25
R29
R19
R21
C5 C8
R20
C11
+
C7
S1
D9
D10
J10J11
D14

Greenlee / A Textron Company 20 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
555®Deluxe Electric Bender
Exploded View and Parts List — 115 Volt Motor
102
109
110
111
114
113
112
103 104 105 107 108
116
117
106
Torque to
9 Newton-meters
(80 in-lb) 117
117
117
115
101
Pacific Scientific
Key Part No. Description Qty.
101* 91864178 Motor, 115 volt (standard) (SRF-3745-4676-2-56C) ......................... 1
102 91864712 Fan cover .......................................................................................... 1
103 90550714 Retaining ring .................................................................................... 1
104 91864321 Fan .................................................................................................... 1
105 91864283 End bell nut ....................................................................................... 2
106 91864194 Bell, rear end ..................................................................................... 1
107 91864208 Brush ................................................................................................. 2
108 91864224 Thrust washer.................................................................................... 1
109* 91864275 Shell and magnet assembly, 115V .................................................... 1
110* 91864259 Armature, 115V ................................................................................. 1
111 91864216 Bearing kit ......................................................................................... 2
112 91864186 Bell, front end .................................................................................... 1
113 91864240 Retaining ring .................................................................................... 1
114 91864267 Tie bolt, 115V .................................................................................... 2
115 91858763 90°connector .................................................................................... 1
116 91864305 Brush cover ....................................................................................... 2
117 91864313 Cover screw ...................................................................................... 7
*Note: Alternate motor.
Check motor part number before ordering magnet shell or armature.
101 91869730 Motor (SRF-3648-5532-7-56C)
109 91869757 Shell and magnet assembly
110 91869749 Armature