Greenlee 855 User manual

SERVICE MANUAL
855®
Smart Bender®
and 01711 Optional Deluxe Pendant
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99943603 © 2007 Greenlee Textron Inc. SB 290 REV 4 10/07
Serial Code ADY

855 Smart Bender®
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
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 ADY.
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge at www.greenlee.com.
Other Publications
Instruction Manual: 99943590 (IM 1500)
All specications 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
Table of Contents
Introduction ................................................................... 2
Important Safety Information .....................................3–4
Grounding Instructions.................................................. 5
Setup ..........................................................................5–6
Adjustments .................................................................. 7
Maintenance.............................................................8–10
Bender Head Disassembly.....................................11–12
Motor Disassembly...................................................... 13
Trunnion Disassembly ................................................. 13
1/2" to 1-1/4" Side Exploded View ............................. 14
1-1/2" to 2" Side Exploded View................................. 15
1-1/2" to 2" Roller Support Unit Exploded View ......... 16
Motor and Gearbox Exploded View and Parts List..... 17
Main Exploded View...............................................18–19
Main Parts List........................................................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,
Parts List, and Layout Diagram ..........................29–30
Optional Bending Attachments
Exploded View and Parts List.................................. 31
Troubleshooting......................................................32–38

855 Smart Bender®
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
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, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
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.
Do not use this tool in a hazardous
environment. Hazards include am-
mable liquids, gases, or other mate-
rials. Using this tool in a hazardous
environment can result in a re or
explosion.
Failure to observe this warning will
result in severe injury or death.
Electric shock hazard:
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.
Disconnect the unit from power
before servicing.
Failure to observe these warnings
could result in severe injury or death.
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Do not expose to rain.
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.
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Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris.
Do not remove guards.
Failure to observe this warning could
result in severe injury or death.

855 Smart Bender®
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
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 exten-
sion cords.
Failure to observe these warnings
could result in severe injury or death.
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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.
Unplug the bender before changing accessories.
Accidental startup could result in serious injury.
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.
IMPORTANT SAFETY INFORMATION
Do not use tool as a step or ladder.
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.
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 nearby
personnel.
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.
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.
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Note: Keep all decals clean and legible, and replace
when necessary.

855 Smart Bender®
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Grounding Instructions
Electric shock hazard:
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
ReceptaclePlug
Setup
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris.
Follow these steps, which are described in greater detail
in this section, to set up the bender.
1. Transport the bender to the job site.
2. Lower at least two jackscrews or use the optional
kickstand to prevent the unit from rolling.
3. Pivot the bending head to the desired position.
4. Connect the pendant to the bending head.
5. 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 exten-
sion cords.
6. Turn on the power switch.
Transporting the Bender
Make sure that all components used to lift the bender
are properly rated for the 231 kg (510 lb) 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. Raise the jackscrews so that they clear the job site
terrain.
2. Pivot the bending head to the horizontal position
with the 1-1/2" to 2" shoe facing up.
3. Use the 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.

855 Smart Bender®
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Setup (cont’d)
Adjusting the Jackscrews
The bender is equipped with four jackscrews that can
be raised or lowered using the 5/16" T-handle Allen
wrench provided with the bender.
Retract the jackscrews when transporting the bender.
Lower at least two jackscrews to prevent the unit from
rolling when bending. If desired, level the unit with all
four jackscrews.
Using the Optional Kickstand
Lower the kickstand to temporarily prevent the bender
from moving.
To lower the kickstand:
1. Apply foot pressure to the lever above the stand
until it contacts the ground.
2. Push the bender away from you until it rolls up onto
the kickstand.
To take the bender off the kickstand:
1. Apply foot pressure to the lever below the crossbar.
2. Pull the bender toward you until it rolls off the
kickstand.
Pivoting the Bending Head
Do not rotate the bending head if one or more of
the bending shoes is removed.
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.
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The bending head can be rotated into three positions:
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.
Connecting the Standard or Deluxe Pendant
Do not connect or disconnect the pendant while the
power is on, or permanent damage to the pendant or
bender circuitry may result.
Remove the pendant control from its storage area, and
plug it into the four-pin receptacle on the side of the
bending head.
CONDUIT TYPE
DECAL NO. 500 1487.0
RIGID ALUM
PVC
IMC
EMT
CONDUIT SIZE
DECAL NO. 500 8896.7
1/2
3/4
11-1/4
1-1/2
2
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855 Smart Bender®
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Adjustments
Disconnect power supply before ser-
vicing bender. Servicing to be done
only by trained service technician.
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
difcult 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 specic 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, rst 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 guard.
1-1/2" and 2"
Limit Switch
Adj. Screws
1/2" to 1-1/4"
Limit Switch
Adj. Screws
Less Bend
Less Bend
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.
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.
Cam Holding
Surface

855 Smart Bender®
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Maintenance
Electric shock hazard:
Disconnect the unit from power
before servicing.
Failure to observe this warning 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 ying
debris.
Schedule
Component Maintenance Activity Maintenance Interval
Chain Lubrication and Tension
Adjustment Every 6 months*
Roller Supports Cleaning and Lubrication Every 6 months*
Commutator
Brushes Replacement
When drive unit
performance diminishes
noticeably
* More often if the bender is used in dusty or corrosive environments
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.
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 (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.
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855 Smart Bender®
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Maintenance (cont’d)
1-1/2" to 2" Roller Support
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).
3. Refer to the “1-1/2" to 2" Roller Support Unit
Exploded View.” Use a pair of needle-nose pliers to
disconnect the springs (104) from the holes in the
side of the bender frame beneath the roller support
unit.
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
adapter sleeve (92).
6. Place one hand under the support arms (71) to
support the weight of the roller support unit.
Remove the eccentric shaft (91).
Note: You may need to rotate the eccentric shaft to
remove it.
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.
7. Lift the roller support subassembly to the left and
upward.
8. On the 1-1/2" roller group:
Loosen the sleeve set screw (98) and remove the
1-1/2" pivot roller shaft (86) with grip (90). Remove
the sleeve (87).
Remove two hex head screws (93). Remove the
outer roller plate (75).
Remove the tail roller (84).
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).
Remove all components of the split roller
assembly.
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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
grease.
13. Replace all components in reverse order, noting the
following:
On both roller groups: To ease the assembly of
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.
On the 2" roller group only: After replacing any
split roller components, add or remove shim
washers (99, 119, or 150) as needed.
On the 1-1/2" roller group: Install the two
Belleville washers (100) so that the inside diam-
eters contact each other.
Use Loctite®271 on the two hex head screws (93).
Torque to 55 Nm to 61 Nm (40 ft-lb to 45 ft-lb).
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
drop completely below the set screw (107).
16. Insert the eccentric shaft (91).
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
cap screws (96).
18. Install the adjustment arm (74) and adjustment arm
screw (97).
19. Attach the springs (104) to the holes in the side of
the bender frame beneath the roller support unit.
20. Put the bender in the horizontal bending position.
Adjust the set screw (107), if necessary, so that the
support arms (71) are centered between the front
and back plates. Engage and disengage the roller
support unit to be sure that it moves freely.
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855 Smart Bender®
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
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.
4. Remove 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.
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 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.
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-lb).
6. Replace the motor cover.