Greenlee 555 Instruction Manual

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 ...

2 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender Table of Contents Description ..................................................................... 2 Purpose .......................................................................... 2 Important Safety Information .......................................3-4 Grounding Instructions ................................................... 5 Identification ................................................................... 6 Setup .............................................................................. 7 Bending Instructions......... ...

3 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender 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. 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, MA ...

4 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender Note: Keep all decals clean and legible, and replace when necessary 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 nearb ...

5 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender Grounding Instructions 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 ...

6 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender Identification 555 Electric Bender Power Unit 1. Bending Instructions 7. Degreed Protractor 2. Handles 8. Control Switch Cord 3. Control Switch 9. Electrical Control Box 4. Main Shaft 10. Gear Reductor 5. Right-hand Leg 11. Drive Motor 6. Left-hand Leg 8 7 1 2 3 4 5 6 9 10 11 ...

7 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender Mounting Bending Shoes Choose desired shoe size (Rigid; IMC; EMT) and slide it onto the main shaft as in Fig.1. Setup Next, align the four drive studs on the back side of shoe (Fig. 2) with the 4 holes in the main drive sprocket. Push the shoe onto the main drive sprocket. Figure 1 Mounting Support Roller and Support Units Choose desired support roller or support unit and corresponding shoe size (Rigid; IMC, EMT). Mount the support roller or support unit on the right leg of the bender as you face the unit. Secure the support roller ...

8 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender 1/2" - 2" Rigid Conduit, Schedule 40 Pipe and 1/2" - 1-1/4" EMT Refer to Setup for mounting selected shoe and support unit. Mark pipe to desired stub-up length. Note 2" min. dimension is required as shown in Fig. 4. Other stub-up Figure 4 Bending Instructions Figure 5 To release the pipe or conduit push the control switch to the UNLOAD position. Allow shoe to rotate, drop the unit support (see Fig. 6) and remove conduit (see Figs. 7 & 8). Wear eye protection when operating or servicing this tool. Failure to wear eye protection can ...

9 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender Bending Instructions (cont’d) 1/2" - 2" Rigid Conduit, Schedule 40 Pipe and 1/2" - 1-1/4" EMT (cont’d) Figure 6 Figure 7 Figure 8 ...

10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender 1-1/2" and 2" IMC and EMT Conduits Refer to Setup for mounting selected IMC shoe and support unit (see Figs. 1,2,3 & 9). Note: The outside roller on the support unit for IMC conduit has a metal roller while the outside roller on the support unit for EMT conduit has a urethane roller. Bending Instructions (cont’d) With the shoe rotated 5° to 10° before 0°˚ slide the conduit over the support rollers, through the shoe groove and hook, after conduit has been properly marked (Fig. 10). Step on the loading peddle, raising the p ...

11 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender Squeeze Adjustment Variation in conduit can result in wrinkling or side marking of 1-1/2" and 2" EMT or IMC. This bender is equipped with a unique Squeeze Adjustment feature which enables you to increase or decrease the bending pressure in order to make a quality bend. Wrinkling of 1-1/2" - 2" EMT & IMC If wrinkling occurs, INCREASE SQUEEZE by loosening set screws and turning both adjusting bolts 1/2 turn clockwise. Tighten set screws and make a test bend. If wrinkling continues, repeat procedure. Note: Both adjusting bolts must ...

12 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender back-to-back bend — any U-shaped bend formed by two parallel 90° bends with a straight section of conduit or pipe between the bends. center-to-center distance — the distance between the successive bends that make up an offset or a three-bend saddle. developed length — the actual length of pipe that will be bent; see distance “d” in the illustration at left. gain — the difference between the straight-line distance (a + a) and the shorter radial distance, (d) where: θ = angle of bend r = the centerline bending radius o ...

13 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender To Locate Bending Marks / 90° Stub 1. Check Chart A for minimum stub length. (Mark to be equal or greater than minimum dimension shown.) 2. Measure and mark desired stub length on conduit (Mark 1). Subtract “DEDUCT” from this mark and make a new mark (Mark 2). Mark 2 is the bending mark. Locate this mark at front edge. Stub to Bottom of Pipe Front Edge of Hook Mark 2 Read Scale Opposite Pointer on Bending Shoe Mark 1 Mark 2 Deduct Stub Length PIPE SIZE 1/2 3/4 1 1-1/4 1-1/2 2 RIGID 8-1/2 8-1/2 10 12-3/4 14-1/4 16-1/8 DEDUCT E ...

14 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender To Find Bending Marks - Offset 1. Measure distance from end of conduit to start of bend and mark conduit (Mark 1). 2. Refer to Chart D for measurement “X”. Measure this distance from Mark 1 only and place Mark 2 on conduit. 3. Refer to Chart C for distance between marks. Measure this distance from Mark 2 and place Mark 3 on conduit. 4. Layout of bends is now complete. Next, place Mark 2 in line with front edge of the shoe hook and make first bend. 5. Rotate conduit 180 degrees. Place Mark 3 in line with front edge of shoe hook ...

15 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender Adjusting Chains The 555 bender has two chains in the power train; one is located in the rear and one in the front. New chains will stretch slightly; therefore, the front chain should be adjusted after 10 to 20 bends have been made in 1-1/2" or 2" Rigid. To adjust front chain: loosen chain cam bolt, rotate tightening cam clockwise until all slack is out of the chain, and retighten cam bolt. To access front chain: remove shoe, roller support and front metal panel. Make sure bender is unplugged while adjusting. Replace front guard b ...

16 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender ← Y → ← HEIGHT ANGLE MARK ← ← ← ← ← L1 → ← LENGTH – X → ← HEIGHT → ← LENGTH → START OF FIRST BEND ANGLE BENDING MARK 1 BENDING MARK 2 → → Special Bending Information 1. Subtract the X dimension for the size of conduit to be bent from the desired length. 2. Place your first mark this distance from the end of the conduit. 3. Go to the following chart for the size and type of conduit you are to bend. 4. Look down the ANGLE column until you come to the angles you want to bend. 5. ...

17 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender Offsets: (Controlling the end of the second bend) ← L1 → ← LENGTH – Z → ← → ← LENGTH TO CENTER → ANGLE BENDING MARK 1 BENDING MARK 2 → → BENDING MARK 3 ← L2 → HEIGHT ← L1 → ← LENGTH – Z → ← HEIGHT → ← LENGTH TO END OF SECOND BEND → ANGLE BENDING MARK 1 BENDING MARK 2 → → Special Bending Information (cont’d) 1. Go to the following Bending Information Chart which is for the size and type of conduit you are to bend. 2. Look down the ANGLE column until you com ...

18 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender 1. Go to the following Bending Information Chart which is for the size and type of conduit you are to bend. 2. Look down the ANGLE column until you come to the angle you want to bend. 3. Look at the numbers in the row preceded by Z and pick the one that is directly under the height (H) you want. 4. Subtract this Z dimension from the desired length. 5. Place your first mark this distance from the end of the conduit. 6. Look at the numbers in the row preceded by L1 and pick the one that is directly under the height (H) you want. 7. ...

19 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender Special Bending Information Chart 1/2 EMT Dia. = .706 Radius = 4.64 X = 2.01 Y 15 3.74 11.47 19.20 26.92 34.65 42.38 53.97 65.56 88.74 135.11 L1 15 7.72 15.45 23.18 30.90 38.63 46.36 57.95 69.54 92.72 139.09 L2 15 8.94 16.66 24.39 32.12 39.84 47.57 59.16 70.75 93.94 140.30 Z 15 10.70 18.16 25.62 33.09 40.55 48.02 59.21 70.41 92.80 137.59 MINIMUM H = 0.84 Y 22.5 1.37 6.60 11.82 17.05 22.28 27.50 35.34 43.18 58.86 90.22 L1 22.5 5.20 10.43 15.65 20.88 26.11 31.33 39.17 47.01 62.69 94.05 L2 22.5 7.02 12.25 17.48 22 ...

20 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 555 Electric Bender 1 EMT Dia. = 1.163 Radius = 6.95 X = 3.22 Y 15 1.35 9.07 16.80 24.53 32.26 39.98 51.57 63.16 86.35 132.71 L1 15 7.72 15.44 23.17 30.90 38.63 46.35 57.95 69.54 92.72 139.08 L2 15 9.54 17.26 24.99 32.72 40.45 48.17 59.76 71.36 94.54 140.90 Z 15 12.51 19.98 27.44 34.91 42.37 49.83 61.03 72.23 94.62 139.40 MINIMUM H = 1.31 Y 22.5 4.33 9.56 14.78 20.01 25.24 33.07 40.91 56.59 87.95 L1 22.5 10.42 15.64 20.87 26.10 31.32 39.16 47.00 62.68 94.04 L2 22.5 13.15 18.37 23.60 28.82 34.05 41.89 49.73 65.41 96.77 Z 22.5 15.64 ...