Greenlee 855 Instruction Manual

Serial Code ABL INSTRUCTION MANUAL Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 999 2168.5 © 2001 Greenlee Textron IM 1266 REV 15 6/01

2 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ KEEP THIS MANUAL Table of Contents Description ................................................................... 2 Safety ........................................................................... 2 Purpose........................................................................ 2 Important Safety Information ................................... 3–4 Grounding Instructions................................................. 5 Specifications ............................................................... 6 Identification................................................................. 7 Transportation .............................................................. 8 Setup............................................................................ 8 Operation Standard Pendant .............................................. 9–10 Deluxe Pendant ................................................ 11–12 Installing and Bending Conduit ........................ 13–18 Special Bending Information................................ 19–27 Assembly for 40 Mil PVC-Coated Rigid Bending Accessories .................................... 28 Adjustments ......................................................... 29–30 Maintenance ........................................................ 30–31 Bender Head Disassembly .................................. 32–37 Motor Disassembly .................................................... 37 Trunnion Disassembly ............................................... 38 Exploded Views, Parts Lists, Schematics and Wiring Diagrams ....................... 39–49 Troubleshooting ................................................... 50–62 Description The 855 Smart Bender™ is designed to bend 1/2" through 2" EMT, IMC, rigid steel and rigid aluminum conduit from 0 through 90 degrees. 1/2" through 2" 40 Mil PVC-coated rigid steel conduit can also be bent with optional 01700 shoe group attachment. The Smart Bender™ operates similar to other Greenlee electric benders with the bending action accomplished through a rotating shoe with a hook and stationary roller conduit supports. Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. Do not make any modifications to this device. Unauthorized changes or modifications will void the user’s authority to operate this device under United States federal law. 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 of this Manual This manual is intended to familiarize personnel with the safe operation and maintenance procedures for the Greenlee 855 Smart Bender™. Keep this manual available to all personnel. Replacement manuals are available upon request at no charge. Greenlee and are registered trademarks of Greenlee Textron. Loctite is a registered trademark of Loctite Corporation.

3 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Do not use this tool in a hazardous environment. Hazards include flammable liquids, gases, or other materials. Using this tool in a hazardous 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 the unit from power before servicing. Failure to observe these warnings can result in severe injury or death. Wear eye protection when operating or servicing this tool. Failure to wear eye protection can result in serious eye injury from flying debris. Do not remove guards. Failure to observe this warning can result in severe injury or death. • 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 can 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, 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 can result in severe injury or death.

4 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ IMPORTANT SAFETY INFORMATION Unplug the bender before changing accessories. Accidental start-up can 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 can 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 can result in severe injury or death. Do not operate the bender while wearing loose clothing. Loose clothing can get caught in moving parts. Failure to observe this warning can result in severe injury or death. • 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 assembled 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. Over bending 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 can result in injury or property damage. Do not use as a step or ladder.

5 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart 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 not use an adapter. 20 Amp/120 Volt Plug and Receptacle Electric shock hazard: • Do not modify the plug provided with the tool. • Connect this tool to a grounded receptacle on a 20 amp GFCI- protected circuit. Failure to observe these warnings can result in severe injury or death. Receptacle Plug

6 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Specifications Height.................................................................................................... 1200 mm (47") Width .................................................................................................... 724 mm (28.5") Depth ................................................................................................... 902 mm (35.5") Mass/Weight (bender without shoes or roller supports) ....................... 231 kg (510 lb) Power Supply ................................................................. 120 VAC (80 VAC minimum), 18 to 20 amp GFCI-protected circuit Power Output ...................................................................................................... 2.5 hp Operating Conditions Temperature .......................................................... 0 °C to 38 °C (32 °F to 100 °F) Relative Humidity ..................................................................................... 0 to 98% Capacity .............................................................................................1/2" to 2" conduit Bending head shown in the horizontal bending table position. Balanced bending head pivots easily as it is changed from the vertical bending position to the horizontal bending table position. Bending head shown locked in the vertical bending position. Size 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" EMT 4-5/16" 5-1/2" 7" 8-13/16" 8-3/8" 9-1/4" IMC, PVC 4-1/4" 5-7/16" 6-15/16" 8-3/4" 8-1/4" 9" and Rigid Conduit Centerline Bending Radius

7 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Features The 855 bender is designed to make high quality bends of up to 90 degrees in 1/2" to 2" EMT, IMC, rigid steel, and rigid aluminum conduit. It incorporates a number of features to make bending easier and faster. • Four large wheels allow easy transportability. • Powerful motor and efficient gearbox can bend 2" rigid in 11 seconds. • Working height at waist level reduces need for the operator to bend over. • All conduit bending can be done without changing shoes or rollers. • Conduit bending can be done in a vertical plane while keeping the conduit level or in a horizontal plane to allow making kicks and offsets. • Simple roller system automatically adjusts to EMT or IMC conduit sizes. • The zero position for bending is automatically set by selecting the size and type of conduit to be bent prior to bending. • Bender automatically compensates for conduit spring- back so you simply bend to the desired angle without using charts. 1. Bender power head 2. Trunnion support frame 3. 1-1/2" to 2" bending shoe 4. 1/2" to 1-1/4" bending shoe 5. 1-1/2" to 2" support roller system 6. Support roller engagement handle • Programmable memory allows you to preselect a desired angle and automatically bend to that angle for one or more bends. • Programmable bend angle adjustment allows you to compensate for over-bending or under-bending conduit. • Digital display gives accurate readout of actual bend or programmed angle. • Eccentric roller system squeeze adjustment allows easy adjustment for variations in conduit. • Removable pendant control prevents unauthorized use of the bender. • A lockable storage area is provided for the instruc- tions, pendant control, etc. • Lifting eyes are provided for easy hoisting. • Stubs, offsets, and saddles can be easily made. An optional deluxe hand terminal tells you where to make the conduit marks for any type of common bend and bend to the proper angle. • Standard bender is fully upgradable with the optional deluxe hand terminal. • Optional shoe group attachment for bending 1/2" to 2" 40 Mil PVC-coated rigid steel conduit. 855 Smart Bender™ 13. Lockable storage area 14. Power switch/circuit breaker 15. Pendant control receptacle 16. Leveling jack screws 17. Lifting eyes 18. Conduit size selector switch 19. Conduit type selector switch 7. Support roller locking cam 8. Support roller squeeze adjustment 9. Transport handle 10. Bender head pivot lock knob 11. Shoe retaining lock ring 12. Open storage area 4 1 14 10 17 2 16 7 6 8 5 3 11 19 18 4 15 12 16 13 9 Identification

8 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Setup When you reach your destination, lower at least two jackscrews to prevent the unit from rolling. If desired, all four jackscrews can be used to level the unit. Rotate the bender head to the position you desire to bend in. To rotate the bender head, pull out the round pivot lock knob while pivoting the head in the desired direction. If the knob is difficult to pull out, turn the knob clockwise until it pushes against the frame to break it free. When the bender is in the desired position, make sure the detent pin fully engages in the hole. To reduce the amount of free play in the bender head, turn the knob counterclockwise until some resistance is felt. Remove the pendant control from its storage area and plug it into the four-pin pendant receptacle on the side of the bender power head. This must be plugged in before the bender is turned on or it will not operate. Plug the power cord into a 120 VAC, 20 amp GFCI- protected receptacle and turn the power switch on. Wait until the display comes on before pressing any keys or the bender will not operate. CONDUIT TYPE DECAL NO. 500 1487.0 RIGID ALUM PVC IMC EMT CONDUIT SIZE DECAL NO. 500 8896.7 1/2 3/4 1 1-1/4 1-1/2 2 Use lifting eyes for hoisting Lift only with bending head in a horizontal position with the 1-1/2" and 2" side up Transportation The only proper way to lift this bender is by attaching nylon or polyester slings or chain and hooks to the lifting eyes. The bender head must be in the table-top position as shown below with the 1-1/2" to 2" shoe up. Rotate the eyes up so that the slings or hooks can be hooked to or looped through the eyes. Make sure that each side of the sling or chain is at least 3' long to prevent it from rubbing against the bender. Make sure all components used to lift this bender are prop- erly rated for the 231 kg (510 lb) weight. Use a ramp to load and unload from a truck or other vehicle that is not equipped with a lift gate. To transport around the jobsite, first assure that the jackscrews are retracted enough to clear the terrain. Pull out on the bender head pivot lock knob. If the pivot lock knob cannot be pulled out far enough for the detent pin to clear the frame, turn the knob clockwise until the detent pin clears the frame. Rotate the bender head so that the 1-1/2" to 2" shoe is up. Make sure that the detent pin locks into position. Turn the pivot lock knob counterclockwise until resistance is felt to lock the pin in position. To prevent the bender from rolling on its own, lower the kickstand (optional). It is located between the two swivel wheels. To set the kickstand, apply foot pressure to the lever above the stand until it contacts the ground and then push the bender away from you until it rolls up onto the stand. To take the bender off the stand, push down on the lever below the crossbar and pull the bender toward you until it rolls off the stand.

9 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Operation — Standard Pendant Set the type and size of conduit you will be bending with the rotary selector switches located on the side of the bender. Failure to do so may result in the shoe rotating the opposite direction than expected. Bend Key: runs the shoe in the direction to bend the conduit according to which conduit size has been selected by the rotary size selector switch. The BEND key functions only while it is pressed. The BEND key ceases to function once it reaches the maximum shoe travel or an angle stored in memory. Jog Key: runs the shoe in the direction to bend the conduit according to which conduit size has been selected by the rotary size selector switch in 1/2-degree increments. The JOG key functions any time it is pressed until the maximum shoe travel is reached. Unload Key: runs the shoe backwards according to which conduit size has been selected by the rotary size selector switch. The UNLOAD key functions when it is pressed unless the roller support locking cam is locked in position. Note: The shoes can rotate a restricted amount in the bend direction. When the maximum has been reached, the BEND and JOG keys will not function. Use the UNLOAD key to rotate the shoes to the proper load position. Angle Select L : is used to set the desired bend angle into memory. Pressing it for a moment increases the present angle in memory 1 degree at a time. Holding it down rapidly advances the memory angle. Angle Select M : functions the same as the ANGLE SELECT UP key except it decreases the angle. Clear Key: sets the display to 00 and eliminates any angle from memory. It will not reset the actual present bend angle to zero. CONDUIT SIZE CONDUIT TYPE DECAL NO. 500 8896.7 1/2 3/4 1 1-1/4 1-1/2 2 DECAL NO. 500 1487.0 RIGID ALUM PVC IMC EMT Use lifting eyes for hoisting Lift only with bending head in a horizontal position with the 1-1/2" and 2" side up Display: shows the actual angle the conduit has been bent in degrees. Counting does not start until the conduit actually starts to bend. If an angle is stored in memory, the display shows the stored angle at all times except while the BEND, JOG, or UNLOAD keys are depressed and for about 2 seconds after they are released. The display will not show angles greater than 99 or less than 0. Upon power-up the display will show H., which indicates that the home position must be set on the bender before installing conduit. Press UNLOAD until the shoe hook for the size and type of conduit selected is at the bottom (5 o’clock position). Press BEND until the pendant display changes from H. and starts counting. Then press UNLOAD until the shoe rotates backwards and stops. This is the proper load position for the selected size and type of conduit and home position is now set. The display will show H. each time there is a change in conduit type setting, a change in conduit size to the other shoe, and when power to the bender has been interrupted. Accuracy Adjust Mode: due to variations in conduit, you may notice the bender consistently over or under bending a particular size and type of conduit. The accuracy adjustment mode allows programming correc- tions for over and under bending conduit. Minus 9 to plus 9 degree adjustments can be made for each size and type of conduit. Press and hold CLEAR, then press and hold BEND until Pr is displayed. Release controls and adjust the degrees of bend by pressing the ANGLE SELECT up and down controls. ANGLE SELECT UP increases and ANGLE SELECT DOWN decreases the bend angle for the size and type of conduit selected by the rotary selector switches. CLEAR resets the adjust angle to zero. Any adjust angle may be displayed by setting the rotary selector switches to the desired size and type of conduit. Press BEND to save the adjust angle and exit the Adjust mode. Only changes to the last displayed value will be saved. Changes saved are to permanent memory in the bender and can only be changed by reprogramming. The pendant will display oP for two seconds when the bender returns to the normal operating mode. BEND JOG UNLOAD ANGLE SELECT ANGLE SELECT CLEAR

10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Operation — Standard Pendant (cont’d) Stub Up and Offset Bending Chart to determine bending marks when using standard pendant. CONDUIT SIZE 1/2 3/4 1 1-1/4 1-1/2 2 DEDUCT 7-1/2 9 11 13-5/8 14-7/8 16-3/8 MINIMUM STUB 9-1/2 11 13 15-5/8 16-7/8 18-3/8 DEDUCT 7-1/2 9 11 13-5/8 14-7/8 16-1/8 MINIMUM STUB 9-1/2 11 13 15-5/8 16-7/8 18-1/8 OFFSET-“X” 2-1/2 3-1/16 3-1/16 4 4-3/4 4-3/4 EMT IMC, RIGID & PVC Finished Angle 15° 30° 45° OFFSET MAX CENTER MAX CENTER MAX CENTER CONDUIT TO CONDUIT TO CONDUIT TO SIZE CENTER SIZE CENTER SIZE CENTER 2 3/4 7-3/4 4 1-1/2 15-7/16 3/4 7-15/16 6 2 23-3/16 1 11-15/16 1/2 8-5/16 8 2 30-7/8 1-1/2 15-15/16 1 11-1/16 10 2 38-5/8 2 19-15/16 1-1/4 13-13/16 12 2 46-3/8 2 23-15/16 1-1/2 16-5/8 14 2 54-1/16 2 27-15/16 2 19-7/16 16 2 61-13/16 2 31-15/16 2 22-1/4 18 2 69-9/16 2 35-15/16 2 25-1/16 20 2 77-1/4 2 39-15/16 2 27-15/16 22 2 85 2 43-15/16 2 30-3/4 STUB LENGTH STUB LENGTH MARK BENDING MARK 1 DEDUCT STUB LENGTH MARK BENDING MARK 1 STUB LENGTH BENDING MARK 1 BENDING MARK 2 START OF BEND CENTER TO CENTER X CE N T E R TO CENT ER BENDING MARK 1 BENDING MARK 2 START OF BEND X

11 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Operation — Optional Deluxe Pendant Mark 1 = 9.84 Mark 2 = 31.88 Mark 3 = 36.84 PRESS ENTER TO GO ON RESET JOG BEND OFFSET SADDLE UNLOAD STUB ANGLE HEIGHT LENGTH CLEAR NUMBER ENTER 9 8 7 6 5 4 0 1 2 3 • 1/2 3/4 1 1 1/4 1 1/2 2 EMT IMC RIGID Enter all dimensions in inches, converting any fractions to decimals using the Decimal Conversion Chart below. Decimal Conversion 1/16 .06 1/8 .12 3/16 .18 1/4 .25 5/16 .31 3/8 .37 7/16 .43 1/2 .50 9/16 .56 5/8 .62 11/16 .68 3/4 .75 13/16 .81 7/8 .87 15/16 .93 1. Upon power-up, the SELECT CONDUIT SIZE prompt will be displayed alone. 2. The sequence of prompts or displays is: a. SELECT CONDUIT SIZE b. SELECT CONDUIT TYPE c. SELECT TYPE OF BEND d. SELECT ANGLE e. SELECT HEIGHT f. SELECT LENGTH (This prompt is skipped when the bend type is a stub.) g. MARK 1= .... PRESS ENTER TO GO ON h. SET FRONT OF HOOK AT MARK 1… i. SET HOME POSITION (This prompt is dis- played when BEND is pressed and until the home switch has been tripped for the size and type of conduit selected. The bend angle will be displayed once the home switch is tripped. The display will show SET HOME POSITION each time BEND is pressed after there is a change to conduit type, conduit size change to the other shoe, after pressing RESET, and when power to the bender has been interrupted. SET HOME POSITION prompt will be skipped if the home switch was previously tripped.) j. 00o to 99o (Bend angle is displayed when BEND is pressed and after the home switch has been tripped.) k. SET FRONT OF HOOK AT MARK 2 … (This display is skipped for stubs.) l. 00o to 99o m. SET FRONT OF HOOK AT MARK 3 … (This display is skipped for stubs and offsets.) n. 00o to 99o p. MARK 1 = … PRESS ENTER TO GO ON (The display will repeat the bend layout for duplicate bends.) 3. Pressing any of the six conduit size keys at any point will set that size into memory and display the SELECT CONDUIT TYPE screen. 4. Pressing the conduit type key at any point will cycle through the conduit types in the order of EMT, IMC, RIG, ALM, PVC … etc. The pendant will then display SELECT TYPE OF BEND. 5. Pressing any of the three bend-type keys (STUB, OFFSET or SADDLE) at any time will set that bend type in memory and display the SELECT ANGLE screen. 6. Pressing the ANGLE key at any point will display the SELECT ANGLE screen and allow changing of the angle with the numerical keys, then press ENTER. The ANGLE key does not need to be pressed if SELECT ANGLE is already displayed. 7. Pressing the HEIGHT key at any point will display the SELECT HEIGHT screen and allow changing of the height with the numerical keys and pressing ENTER. The HEIGHT key does not need to be pressed if SELECT HEIGHT is already displayed. 8. Pressing the LENGTH key at any point will display the SELECT LENGTH screen and allow changing of the length with the numerical keys and pressing ENTER, unless the bend type is a stub in which case the LENGTH key will do nothing. The LENGTH key does not need to be pressed if SELECT LENGTH is already displayed.

12 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Operation — Optional Deluxe Pendant (cont’d) 9. Pressing ENTER: a. is required to store any numerical value into memory. b. when on SELECT CONDUIT SIZE screen will proceed to the next screen without changing the size. c. when on SELECT CONDUIT TYPE screen will proceed to the next screen without changing the type. d. when on SELECT TYPE OF BEND screen will proceed to the next screen without changing the bend type. e. when on SELECT ANGLE screen will proceed to the next screen without changing the angle. f. when on SELECT HEIGHT screen will proceed to the next screen without changing the height. If the bend type is a stub, then pressing ENTER will proceed to the MARK 1= … Press ENTER TO GO ON screen. g. when on SELECT LENGTH screen will proceed to the next screen without changing the LENGTH. h. when on MARK 1= … Press ENTER TO GO ON screen will proceed to next screen. i. when on any of the three SET FRONT OF HOOK AT… screens will do nothing. j. when in Accuracy Adjust mode will save any change to the last displayed adjust angle and exit Accuracy Adjust mode. 10. Pressing any of the 11 numeric keys and ENTER when the display is prompting SELECT ANGLE will display and store the numbers as they are pressed. Angles will only be displayed in whole numbers. Pressing any of the numeric keys and ENTER when the SELECT HEIGHT and SELECT LENGTH prompts are displayed will display and store the numbers immediately after a HEIGHT =" or LENGTH =" display as soon as the numbers are pressed. At any other point, pressing the numeric keys will do nothing. All numeric displays will be limited to two decimal places, except as noted above. 11. Pressing BEND: a. if the conduit size and type have not been selected, will display the SELECT CONDUIT SIZE screen but will not start the bender. b. with the conduit size, type and no bend angle or an angle of 0 in memory will run the bender. The pendant will display the actual bend angle, or SET HOME POSITION until the home switch has been tripped. Operation will stop and the prior screen will return when the BEND key is released. c. with conduit size, type and a bend angle other than 0 in memory will run the bender. The pendant will display the actual bend angle, or SET HOME POSITION until the home switch has been tripped. Operation will stop when the bend key is released, when the actual bend angle equals or exceeds the angle set in memory, or when the maximum shoe rotation has been reached. Releasing the BEND key will not change the display. The prior screen will return when the bend angle equals the angle in memory. 12. Pressing UNLOAD will run the bender backwards so the conduit can be removed. Releasing the UNLOAD key will stop operation. The UNLOAD key will not function if the conduit size and type have not been selected, or when the roller support locking cam is activated. 13. Pressing JOG will run the bender forward 1/2 degree every time it is pressed unless the maximum shoe rotation has been reached. JOG will not operate when the maximum shoe rotation has been reached. If the conduit size and type have not been selected, then the SELECT CONDUIT SIZE screen will be displayed and the bender will not start. 14. Pressing RESET: a. returns the display to the SELECT CONDUIT SIZE screen, clears all previous settings (except Accuracy Adjust Angles) from memory and clears the screen except for the prompt. b. will exit Accuracy Adjust mode without saving any change to the accuracy adjust angle. 15. Pressing CLEAR NUMBER: a. will eliminate any numerical value you are in the process of entering. b. when in Accuracy Adjust mode will set the adjust angle to zero. c. will have no effect if you are not being prompted to enter a number value. 16. Pressing a second key while a first key is already depressed will do nothing further. The first key pressed has priority.

13 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Operation — Installing and Bending Conduit CONDUIT SIZE CONDUIT TYPE DECAL NO. 500 8896.7 1/2 3/4 1 1-1/4 1-1/2 2 DECAL NO. 500 1487.0 RIGID ALUM PVC IMC EMT Use lifting eyes for hoisting Lift only with bending head in a horizontal position with the 1-1/2" and 2" side up Set the type and size of conduit you will be bending with the rotary selector switches located on the side of the bender. Failure to do so may result in the shoe rotating the opposite direction than expected. Note: Variations for deluxe pendant operation are included within brackets […]. [On the deluxe terminal, select the size and type of conduit with the six conduit size keys and the one conduit type key. Each press of conduit type key will choose the next type. The rotary selector switches have no effect when the deluxe terminal is used.] If the pendant display shows H. [deluxe pendant screen shows SET HOME POSITION], set home position on the bender before installing conduit. Press UNLOAD until the shoe hook for the type and size of conduit selected is at the bottom (5 o’clock position). Press BEND until the pendant display changes from H. [or SET HOME POSITION on the deluxe pendant] and starts counting. Then press UNLOAD until the shoe rotates backwards and stops. This is the proper load position for the selected size and type of conduit and home position is now set. After you start bending, the bender automatically stops at this load position when UNLOAD is pressed. The standard pendant displays H. [SET HOME POSITION on the deluxe pendant] each time there is a change in conduit type setting, a change in conduit size to the other shoe, [RESET key is pressed on the deluxe pendant], and when power to the bender has been interrupted. Home position can only be set when the shoe rotates in the bend direction. Note: The shoe can rotate a restricted amount in the bend direction. When the maximum rotation has been reached, BEND and JOG keys will not function. Always use the UNLOAD key to rotate the shoes to the proper load position. The shoe grooves for EMT conduit use silver hooks, the shoe grooves for IMC and rigid (steel and aluminum) conduit use green hooks, and the optional shoes for bending 40 Mil PVC-coated steel rigid conduit have black hooks. Insert the conduit into the proper shoe groove and hook. Align the bend location marks with the front of the hook. If you wish to side load the conduit, rotate the shoe hook to the 5 o’clock position. • Do not allow a bend or coupler to go over the roller supports. • Do not allow the trailing end of the conduit to go over the roller supports. Failure to observe these warnings can result in severe injury or death.

14 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Operation — Installing and Bending Conduit (cont’d) MANUAL BENDING Make sure that no angle is set in memory. The memory is clear if the pendant display shows 00 when BEND, UNLOAD or JOG are not depressed. If 00 is not displayed, press CLEAR. [The memory is clear if no angle is shown in the top row of the terminal display and is prompting for a bend type]. If an angle of 93 degrees is reached at any time while pressing BEND or JOG, the bender will stop to prevent accidentally running a hook into the conduit. Always use the UNLOAD key to rotate the shoe to the desired position. 1/2" to 1-1/4" Conduit Press the BEND key while maintaining conduit align- ment until slack is taken up. When the conduit starts to bend, the digital display starts to count from zero and show the angle to which the conduit has been bent. The angle displayed has already compensated for springback. When you reach your desired angle, release the BEND key. It might be beneficial to stop slightly before the angle to account for reaction time and motor braking time and then use the JOG key to advance the bend in 1/2-degree increments to prevent overbending. Press the BEND key while maintaining conduit align- ment until slack is taken up. When the conduit starts to bend, the digital display starts to count from zero and show the angle to which the conduit has been bent. The angle displayed has already compensated for springback. When you reach your desired angle, release the BEND key. It might be beneficial to stop slightly before the angle to account for reaction time and motor braking time and then use the JOG key to advance the bend in 1/2-degree increments to prevent overbending. 1-1/2" and 2" EMT, IMC and Aluminum Rigid Conduit Note: For aluminum rigid conduit, set squeeze to minimum position. Press or jog the BEND key while engaging the roller system using the support roller engagement handle. 1-1/2" and 2" Rigid and 40 Mil PVC-Coated Rigid Conduit Make sure that the rollers are in the fully retracted position to the right.

15 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Operation — Installing and Bending Conduit (cont’d) Apply sufficient force on the handle so that the roller system reaches its position against the stops before the conduit starts to bend. Supporting the tail end of a long conduit may ease engagement when bending vertically. Continue to press the BEND key while maintaining conduit alignment until slack is taken up. When the conduit starts to bend, the digital display starts to count from zero and show the angle to which the conduit has been bent. The angle displayed has already compen- sated for springback. When you reach your desired angle, release the BEND key. It might be beneficial to stop slightly before the angle to account for reaction time and motor braking time and then use the JOG key to advance the bend in 1/2-degree increments to prevent overbending. A roller support lock has been provided to free up one hand. Once the roller support engagement handle is brought up into position, a locking cam holds the handle in place and bending can proceed from this point without further operator action on the handle. Lifting up on the tail of the conduit makes roller engagement easier. For 1-1/2" EMT, it may be easy to go past the cam; if this happens, raise the cam by hand and rest the handle against it. If you wish to change the position of the conduit and it is held too tightly to move, rotate the handle counterclockwise to disengage the cam. Reposi- tion the conduit and relock in place. The UNLOAD key will not function while the locking cam is engaged. Note: If you are unable to raise the handle enough to engage the locking cam even after lifting up on the tail of the conduit or pushing down on the nose, the squeeze is probably set too high. If the handle easily passes by the cam on 2", the squeeze is probably set too low. PROGRAMMED BENDING Press the ANGLE SELECT UP key to place an angle into memory. Pressing it momentarily advances the stored angle 1 degree at a time. Holding it down rapidly advances the angle. Release it when the desired angle is obtained. Use the ANGLE SELECT DOWN key to reduce the angle in memory. It operates the same as the ANGLE SELECT UP key does. The ANGLE SELECT DOWN key can also be used to initiate putting an angle in memory. For large angles, this would be faster. Press the CLEAR key to remove any angle from memory and set the display to 00. If an angle is stored in memory, it will be displayed whenever the BEND, JOG or UNLOAD keys are not depressed. [Press the ANGLE key on the deluxe terminal and enter an angle using the 10 numerical keys. The decimal is not used for angles. Press ENTER to set the angle in memory.] If an angle of 93 degrees is reached at any time while pressing BEND or JOG, the bender will stop to prevent accidentally running a hook into the conduit. Always use the UNLOAD key to rotate the shoe to the desired position. Accuracy Adjustments Due to variations in conduit, you may notice the bender consistently over or under bending a particular size and type of conduit. Programmed adjustments can be made to compensate for over and under bending conduit. Minus 9 to 9 degree adjustments can be made for each size and type of conduit. Press and hold CLEAR and then press and hold BEND until Pr is displayed. Release the keys and adjust the degrees of bend by pressing the ANGLE SELECT UP or ANGLE SELECT DOWN keys. ANGLE SELECT UP increases and ANGLE SELECT DOWN decreases the bend angle for the size and type of conduit selected by the rotary selector switches. CLEAR resets the adjust angle to zero. Any adjust angle may be displayed by setting the rotary selector switches to the desired size and type of conduit while in the Accuracy Adjust programming mode. Press BEND to save the adjust angle and exit the Adjust mode. Only changes to the last displayed value will be saved. Changes saved are to permanent memory in the bender and can only be changed by reprogramming. The pendant will display oP for two seconds when the bender returns to the normal operat- ing mode. 1/2" to 1-1/4" Conduit Press the BEND key while maintaining conduit align- ment until slack is taken up. When the conduit starts to bend, the digital display starts to count from zero and show the angle to which the conduit has been bent. The angle displayed has already compensated for springback. As the conduit approaches the programmed angle, the bender slows and then stops at the pro- grammed angle. Releasing the BEND key at any time during the bend stops the bender. The bend can then be resumed from the point it was stopped. After stop- ping at the programmed angle, the BEND key will function if released and pressed again. The JOG key can be used to bend beyond the programmed angle in 1/2-degree increments. 1-1/2" and 2" Rigid and 40 Mil PVC-Coated Rigid Conduit Make sure that the rollers are in the fully retracted position to the right. Press the BEND key while main- taining conduit alignment until slack is taken up. When the conduit starts to bend, the digital display starts to count from zero and show the angle to which the conduit has been bent. The angle displayed has already compensated for springback. As the conduit ap- proaches the programmed angle, the bender slows and then stops at the programmed angle. Releasing the BEND key at any time during the bend stops the bender. The bend can then be resumed from the point it was stopped. After stopping at the programmed angle, the BEND key will function if released and pressed again. The JOG key can be used to bend beyond the programmed angle in 1/2-degree increments.

16 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Operation — Installing and Bending Conduit (cont’d) 1-1/2" and 2" EMT, IMC, and Aluminum Rigid Conduit Note: For aluminum rigid conduit, set squeeze to minimum position. Press or jog the BEND key while engaging the roller system using the support roller engagement handle. Apply sufficient force on the handle so that the roller system reaches its position against the stops before the conduit starts to bend. Supporting the tail end of a long conduit may ease engagement when bending vertically. Continue to press the BEND key while maintaining conduit alignment until slack is taken up. When the conduit starts to bend, the digital display starts to count from zero and show the angle to which the conduit has been bent. The angle displayed has already compensated for springback. As the conduit approaches the programmed angle, the bender slows and then stops at the programmed angle. Releasing the BEND key at any time during the bend stops the bender. The bend can then be resumed from the point it was stopped. After stopping at the programmed angle, the BEND key will function if released and pressed again. The JOG key can be used to bend beyond the programmed angle in 1/2-degree increments. A roller support lock has been provided to free up one hand. Once the roller support engagement handle is brought up into position, a locking cam holds the handle in place and bending can proceed from this point without further operator action on the handle. Lifting up on the tail of the conduit makes roller engagement easier. For 1-1/2" EMT, it may be easy to go past the cam; if this happens, raise the cam by hand and rest the handle against it. If you wish to change the position of the conduit and it is held too tightly to move, lift up on the cam while supporting the handle, and allow the handle to retract slightly. Reposition the conduit and relock in place. The UNLOAD key will not function while the locking cam is engaged. Note: If you are unable to raise the handle enough to engage the locking cam even after lifting up on the tail of the conduit or pushing down on the nose, the squeeze is probably set too high. If the handle easily passes by the cam on 2", the squeeze is probably set too low. UNLOADING When the conduit is bent to the desired angle, press the UNLOAD key until the shoe has rotated back about 10 or more degrees. Twist the conduit to free it from the hook and remove it from the shoe. Continue to press UNLOAD and the bender will automatically stop at the best position for end-loading the next conduit. If you want to side-load the conduit (or use the opposite side of the shoe), you need to unload beyond this point. To do so, simply release the UNLOAD key and press it again. The bender will proceed to unload. Release the UNLOAD key when the shoe has rotated to the desired position. MAKING ANOTHER BEND To make another manual bend, proceed as you did with the first one. To make another programmed bend of the same size, type and angle, load and bend the conduit just as you did the previous one. You may change the programmed angle and make a bend to the new angle without any additional changes. You can also change the size and/or type of conduit and bend to the previous angle; however, if your change requires using the opposite side of a shoe, you need to use the UNLOAD key to index the shoe. Do not use the BEND key to index the shoe. Using the BEND key will cause the bender to stop at the programmed angle. Pressing CLEAR will eliminate this, but you will need to repro- gram the bend. MAKING A FULLY PROGRAMMED BEND ON DELUXE PENDANT Select the size and type of conduit to be bent as previ- ously instructed. Select the type of bend you wish to make, using one of the three bend type keys (STUB, OFFSET or SADDLE). Enter the angle to be bent to, using the numerical keys (0 to 9). Press ENTER. The decimal key is not used for angles. Enter the height of the stub, offset or saddle, using any of the 11 numerical keys. Press ENTER. The height is from the bottom of the conduit to the center of the end of the conduit for stubs, and from the bottom of the conduit to the bottom of the second bend for offsets and saddles. If you are to make an offset or saddle, enter the length of it using the 11 numerical keys. Press ENTER. The length is from the end of the conduit to the beginning of the first bend for offsets, and from the end of the conduit to the middle of the saddle for saddles. The display screen will show where to make your alignment marks. Place mark 1 on the conduit the distance shown from the end of the conduit. For offsets and saddles, place mark 2 the distance shown from mark 1. For saddles, place mark 3 the distance shown from mark 2. Set Home Position if required. Insert the conduit into the proper shoe groove and hook and align mark 1 with the outside edge of the hook. Accuracy Adjustments on Deluxe Pendant Due to variations in conduit, you may notice the bender consistently over or under bending a particular size and type of conduit. Programmed adjustments can be made to compensate for over and under bending conduit. Minus 9 to 9 degree adjustments can be made for each size and type of conduit. Press RESET and then press 0 three times. PROGRAMMING MODE will appear on the third line of the display. Enter the desired size and type of conduit. The screen will show the current adjust angle for the selected size and type of conduit and display ENTER NUMBER OF DEGREES TO CHANGE (USE . FOR NEGATIVE). Use the numerical keys and enter the desired change in absolute value to the current adjust angle. The . (decimal) key toggles the

17 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Operation — Installing and Bending Conduit (cont’d) negative sign on and off. Pressing the CLEAR NUM- BER key changes the adjust angle to 0. Any adjust angle may be displayed by pressing the keys for the desired size and type of conduit while in the Accuracy Adjust programming mode. Press ENTER to save the adjust angle and exit the Accuracy Adjust programming mode. Only the change to the last displayed value will be saved. Press RESET to exit the Accuracy Adjust programming mode without saving a program change. Changes saved are to permanent memory in the bender and can only be changed by reprogramming. 1/2" to 1-1/4" Conduit Press the BEND key while maintaining conduit align- ment, until slack is taken up. When the conduit starts to bend, the digital display starts to count from zero and show the angle to which the conduit has been bent. Releasing the BEND key at any time during the bend stops the bender. The bend can then be resumed from the point it was stopped. As the conduit approaches the programmed angle, the bender slows and then stops at the programmed angle. After stopping at the pro- grammed angle, the BEND key will function if released and pressed again. The JOG key can be used to bend beyond the programmed angle in 1/2-degree incre- ments. Press UNLOAD until the shoe has rotated back about 10 or more degrees, and twist the conduit to loosen it from the hook. If the bend is complete, remove the conduit from the shoe. For offsets and saddles, press UNLOAD until the shoe returns and stops at the load position, move conduit to align mark 2 with the hook, rotate conduit 180 degrees, and make the next bend(s) as before. 1-1/2" and 2" Rigid and 40 Mil PVC-Coated Rigid Conduit Make sure that the rollers are in the fully retracted position to the right. Press the BEND key while main- taining conduit alignment until slack is taken up. When the conduit starts to bend, the digital display starts to count from zero and show the angle to which the conduit has been bent. Releasing the BEND key at any time during the bend stops the bender. The bend can then be resumed from the point it was stopped. As the conduit approaches the programmed angle, the bender slows and then stops at the programmed angle. After stopping at the programmed angle, the BEND key will function if released and pressed again. The JOG key can be used to bend beyond the programmed angle in 1/2-degree increments. Press UNLOAD until the shoe has rotated back about 10 or more degrees, and twist the conduit to loosen it from the hook. If the bend is complete, remove the conduit from the shoe. For offsets and saddles, press UNLOAD until the shoe returns and stops at the load position, move conduit to align mark 2 with the hook, rotate conduit 180 degrees, and make the next bend(s) as before. 1-1/2" and 2" EMT, IMC and Aluminum Rigid Conduit Note: For aluminum rigid conduit, set squeeze to the minimum position. Press or jog the BEND key while engaging the roller system using the support roller engagement handle. Apply sufficient force on the handle so that the roller system reaches its position against the stops before the conduit starts to bend. Supporting the tail end of a long conduit may ease engagement when bending vertically. Continue to press the BEND key while maintaining conduit alignment until slack is taken up. When the conduit starts to bend, the digital display starts to count from zero and show the angle to which the conduit has been bent. Releasing the BEND key at any time during the bend stops the bender. The bend can then be resumed from the point it was stopped. As the conduit approaches the programmed angle, the bender slows and then stops at the programmed angle. After reaching the programmed angle, the BEND key will become non- functional. A roller support lock has been provided to free up one hand. Once the roller support engagement handle is brought up into position, a locking cam holds the handle in place and bending can proceed from this point without further operator action on the handle. Lifting up on the tail of the conduit makes roller engagement easier. For 1-1/2" EMT, it may be easy to go past the cam; if this happens, raise the cam by hand and rest the handle against it. If you wish to change the position of the conduit and it is held too tightly to move, lift up on the cam while supporting the handle and allow the handle to retract slightly. Reposition the conduit and relock in place. The UNLOAD key will not function while the locking cam is engaged. Note: If you are unable to raise the handle enough to engage the locking cam even after lifting up on the tail of the conduit or pushing down on the nose, the squeeze is probably set too high. If the handle easily passes by the cam on 2", the squeeze is probably set too low. Press UNLOAD until the shoe has rotated back about 10 or more degrees, and twist the conduit to loosen it from the hook. If the bend is complete, remove the conduit from the shoe. For offsets and saddles, press UNLOAD until the shoe returns and stops at the load position, move conduit to align mark 2 with the hook, rotate conduit 180 degrees, and make the next bend(s) as before.

18 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ VARIATIONS OF TYPES OF BENDS Offsets Located by the Second Bend If you wish to make an offset where the location of the end of the second bend is desired rather than the start of the first bend, then treat the bend as a saddle to make your alignment marks and then bend it as an offset. First enter the conduit size and type, bend type (saddle), angle, height and length (from the end of the conduit to the desired end of the second bend) in the normal fashion. Dimensions will be displayed for three marks. Lay out the first two marks on the conduit and ignore the third. Press the OFFSET key and then press ENTER several times until the display prompts you to set the conduit at mark 1. Continue to make your offset as previously instructed. U-Bends on Deluxe Pendant To make a two bend “U”, treat it as a 90˚ stub and offset. Enter the conduit size, conduit type, type of bend (STUB), angle (90), and length (distance from end of conduit to bottom of “U”). The screen will display MARK 1=… PRESS ENTER TO GO ON. Record mark 1. Next, press OFFSET and ENTER. Then enter the height (centerline distance between the two legs) and press ENTER. The display will prompt SELECT LENGTH. Press any numerical key and ENTER. The screen will display MARK 1=…, MARK 2=…. PRESS ENTER TO GO ON. Ignore mark 1 displayed and record mark 2. Use mark 1 from the stub bend and mark 2 from the offset bend and lay out marks onto the conduit as a normal offset. Proceed to bend the conduit as a normal offset except do not rotate the conduit between bends. Operation — Installing and Bending Conduit (cont’d) Four-Bend Saddles To make a four-bend saddle, program it as a saddle and bend it as two offsets. Enter the conduit size and type, bend type (saddle), angle, height and length (from the end of the conduit to the end of the second bend). The dimensions will be displayed for three marks. Lay out marks 1 and 2 in normal fashion. Place a third mark the distance shown for mark 3 from mark 1 (not mark 2 as usual). Place a fourth mark the distance of the desired straight section from the third mark. Place a fifth mark the distance shown for mark 2 from the fourth mark. Press the OFFSET key and then press ENTER several times until the display prompts you to set the conduit at mark 1. Make your first bend here. Rotate the conduit 180 degrees and make your second bend starting at the second mark. Maintain alignment and make your first bend of the second offset starting at your fourth mark. Rotate the conduit 180 degrees and make the second bend of the second offset starting at your fifth mark.

19 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Special Bending Information This section of the manual describes a means for laying out the starting points for various types of bends. It will give very accurate measurements for heights and bend angles commonly used. Stubs Y HEIGHT MARK ANGLE 1. Go to the following chart which is for the size and type of conduit you are to bend. 2. Look down to the ANGLE column until you come to the angle you want to bend to. 3. Look at the numbers in the row preceded by Y and pick the one that is directly under the height (H) you want. 4. Place a mark this distance from the end of the conduit. 5. Make your bend after positioning the front edge of the hook on your mark. Offsets (controlling the start of the first bend) START OF FIRST BEND LENGTH ANGLE HEIGHT BENDING MARK 1 BENDING MARK 2 LENGTH – X L1 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 which is for the size and type of conduit you are to bend. 4. Look down to the ANGLE column until you come to the angles you want to bend to. 5. Look at the numbers in the row preceded by L1 and pick the one that is directly under the height (H) you want. 6. Place a second mark this distance from your first mark. 7. Make your first bend after placing the front edge of the hook on the first mark and your second bend after placing the front edge of the hook under the second mark.

20 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Offsets (controlling the end of the second bend) BENDING MARK 1 BENDING MARK 2 HEIGHT LENGTH TO END OF SECOND BEND ANGLE LENGTH – Z L1 1. Go to the following 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 to. 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. Place a second mark this distance from your first mark. 8. Make your first bend after placing the front edge of the hook on the first mark and your second bend after placing the front edge of the hook on the second mark. Special Bending Information (cont’d) Three-Bend Saddle BENDING MARK 1 BENDING MARK 3 BENDING MARK 2 LENGTH – Z L1 L2 LENGTH TO CENTER ANGLE HEIGHT 1. Go to the following 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 to. 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. Place a second mark this distance from your first mark. 8. Look at the numbers in the row preceded by L2 and pick the one that is directly under the height (H) you want. 9. Place a third mark this distance from your second mark. 10. Make your first bend after placing the front edge of the hook on the first mark and your second bend after placing the front edge of the hook on the second mark. Remember to make the second bend double the first bend. Make your third bend after placing the front edge of the hook on the third mark.

21 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Four-Bend Saddle with Straight BENDING MARK 1 BENDING MARK 3 BENDING MARK 4 BENDING MARK 2 LENGTH – Z L1 L1 ANGLE HEIGHT LENGTH STRAIGHT SECTION L2 + STRAIGHT SECTION 1. Go to the following 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 to. 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. Place a second mark this distance from your first mark. 8. Look at the numbers in the row preceded by L2 and pick the one that is directly under the height (H) you want. 9. Add this L2 value to the desired length of your straight section. 10. Place a third mark this distance from your first mark. 11. Look up the L1 dimension used above again. 12. Place a fourth mark this distance from your third mark. 13. Make your four bends by placing the front edge of the hook on the respective marks for each bend. Special Bending Information (cont’d) U-Bends BENDING MARK 1 BENDING MARK 2 Y L1 HEIGHT LENGTH 1. Go to the following chart which is for the size and type of conduit you are to bend. 2. Look down the ANGLE column until you come to 90 degrees. 3. Look at the numbers in the row preceded by Y and pick the one that is directly under the height (H) you want the length to be. 4. Look at the numbers in the row preceded by L1 and pick the one that is directly under the height (H) you want. 5. Place a second mark this distance from your first mark. 6. Make your first bend after placing the front edge of the hook on the first mark and your second mark and your second bend after placing the front edge of the hook on the second mark.

22 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Special Bending Information Chart 1/2" EMT Y 15 3.28 11.01 18.73 26.45 34.18 41.91 53.50 65.09 88.27 134.64 L1 15 7.72 15.45 23.18 30.90 38.63 46.36 57.95 69.54 92.72 139.09 L2 15 8.88 16.61 24.34 32.07 39.79 47.52 59.11 70.70 93.88 140.25 Z 15 11.13 18.60 26.06 33.53 40.99 48.45 59.65 70.85 93.24 138.02 MINIMUM H = 0.95 Y 22.5 .92 6.14 11.37 16.59 21.82 27.05 34.89 42.73 58.40 89.76 L1 22.5 5.20 10.43 15.66 20.88 26.11 31.33 39.17 47.01 62.69 94.05 L2 22.5 6.95 12.17 17.40 22.63 27.85 33.08 40.92 48.76 64.44 95.79 Z 22.5 9.09 13.92 18.75 23.58 28.41 33.24 40.48 47.72 62.21 91.18 MINIMUM H = 1.63 Y 30 3.60 7.60 11.60 15.60 19.60 25.60 31.60 43.60 67.60 L1 30 7.95 11.95 15.95 19.95 23.95 29.95 35.95 47.95 71.95 L2 30 10.27 14.27 18.27 22.27 26.27 32.27 38.27 50.27 74.27 Z 30 11.81 15.27 18.74 22.20 25.66 30.86 36.06 46.45 67.23 MINIMUM H = 2.44 Y 45 3.65 6.47 9.30 12.13 16.37 20.61 29.10 46.07 L1 45 8.29 11.12 13.95 16.78 21.02 25.26 33.75 50.72 L2 45 11.78 14.61 17.44 20.27 24.51 28.75 37.24 54.21 Z 45 12.18 14.18 16.18 18.18 21.18 24.18 30.18 42.18 MINIMUM H = 4.37 Y 60 3.77 6.08 8.38 11.85 15.31 22.24 36.10 L1 60 8.76 11.07 13.38 16.84 20.31 27.24 41.09 L2 60 13.41 15.72 18.03 21.49 24.96 31.89 45.74 Z 60 12.25 13.40 14.56 16.29 18.02 21.48 28.41 MINIMUM H = 6.61 Y 90 4.71 7.71 10.71 16.71 28.71 L1 90 10.09 13.09 16.09 22.09 34.09 L2 90 17.07 20.07 23.07 29.07 41.07 Z 90 11.38 11.38 11.38 11.38 11.38 MINIMUM H = 11.38 3/4" EMT Y 15 2.07 9.80 17.53 25.26 32.98 40.71 52.30 63.89 87.08 133.44 L1 15 7.72 15.45 23.17 30.90 38.63 46.36 57.95 69.54 92.72 139.08 L2 15 9.20 16.93 24.66 32.39 40.11 47.84 59.43 71.02 94.20 140.57 Z 15 12.08 19.55 27.01 34.47 41.94 49.40 60.60 71.79 94.19 138.97 MINIMUM H = 1.20 Y 22.5 5.00 10.22 15.45 20.67 25.90 33.74 41.58 57.26 88.62 L1 22.5 10.42 15.65 20.88 26.10 31.33 39.17 47.01 62.69 94.04 L2 22.5 12.65 17.88 23.10 28.33 33.56 41.39 49.23 64.91 96.27 Z 22.5 15.04 19.87 24.69 29.52 34.35 41.59 48.84 63.32 92.29 MINIMUM H = 2.06 Y 30 6.43 10.43 14.43 18.43 24.43 30.43 42.43 66.43 L1 30 7.93 11.93 15.93 19.93 23.93 29.93 35.93 47.93 71.93 L2 30 10.90 14.90 18.90 22.90 26.90 32.90 38.90 50.90 74.90 Z 30 13.09 16.56 20.02 23.48 26.95 32.14 37.37 47.73 68.52 MINIMUM H = 3.08 Y 45 2.36 5.19 8.02 10.85 15.09 19.33 27.82 44.79 L1 45 8.24 11.07 13.90 16.73 20.97 25.21 33.70 50.67 L2 45 12.69 15.52 18.35 21.18 25.42 29.67 38.15 55.12 Z 45 13.82 15.82 17.82 19.82 22.82 25.82 31.82 43.82 MINIMUM H = 5.53 Y 60 4.62 6.93 10.39 13.85 20.78 34.64 L1 60 10.94 13.25 16.71 20.18 27.10 40.96 L2 60 16.88 19.18 22.65 26.11 33.04 46.90 Z 60 15.45 16.60 18.33 20.06 23.53 30.46 MINIMUM H = 8.38 Y 90 5.74 8.74 14.74 26.74 L1 90 12.57 15.57 21.57 33.57 L2 90 21.47 24.47 30.47 42.47 Z 90 14.47 14.47 14.47 14.47 MINIMUM H= 14.47 DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"

23 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Special Bending Information Chart (cont’d) 1" EMT Y 15 1.35 9.07 16.80 24.53 32.26 39.98 51.58 63.17 86.35 132.71 L1 15 7.72 15.44 23.17 30.90 38.63 46.35 57.94 69.54 92.72 139.08 L2 15 9.60 17.33 25.06 32.79 40.51 48.24 59.83 71.42 94.61 140.97 Z 15 12.55 20.02 27.48 34.94 42.41 49.87 61.07 72.27 94.66 139.44 MINIMUM H = 1.32 Y 22.5 4.31 9.54 14.77 19.99 25.22 33.06 40.90 56.58 87.93 L1 22.5 10.42 15.64 20.87 26.09 31.32 39.16 47.00 62.68 94.04 L2 22.5 13.25 18.47 23.70 28.93 34.15 41.99 49.83 65.51 96.87 Z 22.5 15.72 20.54 25.37 30.20 35.03 42.27 49.51 64.00 92.97 MINIMUM H = 2.32 Y 30 1.72 5.72 9.72 13.72 17.72 23.72 29.72 41.72 65.72 L1 30 7.91 11.91 15.91 19.91 23.91 29.91 35.91 47.91 71.91 L2 30 11.69 15.69 19.69 23.69 27.69 33.69 39.69 51.69 75.69 Z 30 13.98 17.45 20.91 24.37 27.84 33.03 38.23 48.62 69.41 MINIMUM H = 3.53 Y 45 4.32 7.15 9.97 14.22 18.46 26.94 43.91 L1 45 11.00 13.83 16.66 20.90 25.15 33.63 50.60 L2 45 16.67 19.49 22.32 26.57 30.81 39.29 56.26 Z 45 17.16 19.16 21.16 24.16 27.16 33.16 45.16 MINIMUM H = 6.48 Y 60 3.52 5.83 9.30 12.76 19.69 33.55 L1 60 10.77 13.08 16.55 20.01 26.94 40.79 L2 60 18.32 20.63 24.10 27.56 34.49 48.34 Z 60 17.29 18.44 20.18 21.91 25.37 32.30 MINIMUM H = 9.97 Y 90 7.02 13.02 25.02 L1 90 14.91 20.91 32.91 L2 90 26.23 32.23 44.23 Z 90 17.61 17.61 17.61 MINIMUM H = 17.61 1-1/4" EMT Y 15 7.41 15.13 22.86 30.59 38.31 49.91 61.50 84.68 130.04 L1 15 7.71 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.72 139.08 L2 15 10.09 17.82 25.55 33.27 41.00 48.73 60.32 71.91 95.09 141.46 Z 15 13.79 21.26 28.72 36.18 43.65 51.11 62.31 73.50 95.90 140.68 MINIMUM H = 1.65 Y 22.5 2.74 7.96 13.19 18.42 23.64 31.48 39.32 55.00 86.36 L1 22.5 10.41 15.63 20.86 26.08 31.31 39.15 46.99 62.67 94.03 L2 22.5 13.97 19.20 24.42 29.65 34.88 42.72 50.56 66.23 97.59 Z 22.5 17.21 22.03 26.86 31.69 36.52 43.76 51.01 65.49 94.46 MINIMUM H = 2.89 Y 30 4.12 8.12 12.12 16.12 22.12 28.12 40.12 64.12 L1 30 11.89 15.89 19.89 23.89 29.89 35.89 47.89 71.89 L2 30 16.64 20.64 24.64 28.64 34.64 40.64 52.64 76.64 Z 30 19.20 22.66 26.12 29.59 34.78 39.98 50.37 71.16 MINIMUM H = 4.40 Y 45 2.55 5.38 8.20 12.45 16.69 25.18 42.15 L1 45 13.75 16.58 20.82 25.07 33.55 50.52 L2 45 20.88 23.71 27.95 32.20 40.68 57.65 Z 45 21.46 23.46 26.46 29.46 35.46 47.46 MINIMUM H = 8.10 Y 60 1.50 3.81 7.27 10.73 17.66 31.52 L1 60 16.34 19.81 26.74 40.59 L2 60 25.85 29.32 36.25 50.10 Z 60 23.08 24.81 28.28 35.21 MINIMUM H = 12.49 Y 90 1.23 4.23 10.23 22.23 L1 90 20.10 32.10 L2 90 34.37 46.37 Z 90 22.10 22.10 MINIMUM H = 22.10 DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"

24 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Special Bending Information Chart (cont’d) 1-1/2" EMT Y 15 5.56 13.29 21.01 28.74 36.47 48.06 59.65 82.83 129.20 L1 15 7.71 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.72 139.08 L2 15 10.02 17.75 25.48 33.20 40.93 48.66 60.25 71.84 95.02 141.39 Z 15 15.16 22.62 30.09 37.55 45.02 52.48 63.68 74.87 97.26 142.05 MINIMUM H = 1.99 Y 22.5 1.05 6.28 11.50 16.73 21.96 29.80 37.64 53.31 84.67 L1 22.5 10.41 15.63 20.86 26.09 31.31 39.15 46.99 62.67 94.03 L2 22.5 13.87 19.09 24.32 29.55 34.77 42.61 50.95 66.13 97.49 Z 22.5 18.54 23.37 28.19 33.02 37.85 45.09 52.34 66.82 95.79 MINIMUM H = 3.40 Y 30 2.52 6.52 10.52 14.52 20.52 26.52 38.52 62.52 L1 30 11.89 15.89 19.89 23.89 29.89 35.89 47.89 71.89 L2 30 16.50 20.50 24.50 28.50 34.50 40.50 52.50 76.50 Z 30 20.49 23.95 27.42 30.88 36.08 41.27 51.67 72.45 MINIMUM H = 5.05 Y 45 1.06 3.89 6.72 10.96 15.20 23.69 40.66 L1 45 13.77 16.60 20.84 25.08 33.57 50.54 L2 45 20.68 23.51 27.75 32.00 40.48 57.45 Z 45 22.67 24.67 27.67 30.67 36.67 48.67 MINIMUM H = 8.96 Y 60 2.39 5.85 9.32 16.25 30.10 L1 60 16.39 19.86 26.79 40.64 L2 60 25.60 28.06 35.89 49.85 Z 60 24.21 25.94 29.40 36.33 MINIMUM H = 13.46 Y 90 2.95 8.95 20.95 L1 90 20.22 32.22 L2 90 34.06 46.06 Z 90 23.00 23.00 MINIMUM H = 23.00 2" EMT Y 15 4.42 12.15 19.88 27.61 35.33 46.92 58.51 81.70 128.06 L1 15 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.71 139.08 L2 15 18.00 25.73 33.46 41.18 48.91 60.50 72.09 95.27 141.64 Z 15 23.00 30.47 37.93 45.40 52.86 64.06 75.25 97.64 142.43 MINIMUM H = 2.09 Y 22.5 .14 5.36 10.59 15.82 21.04 28.88 36.72 52.40 83.76 L1 22.5 10.40 15.63 20.86 26.08 31.31 39.15 46.99 62.67 94.02 L2 22.5 14.24 19.47 24.70 29.92 35.15 42.99 50.83 66.51 97.86 Z 22.5 19.05 23.88 28.70 33.53 38.36 45.60 52.85 67.33 96.30 MINIMUM H = 3.59 Y 30 1.68 5.68 9.68 13.68 19.68 25.68 37.68 61.68 L1 30 11.88 15.88 19.88 23.88 29.88 35.88 47.88 71.88 L2 30 17.00 21.00 25.00 29.00 35.00 41.00 53.00 77.00 Z 30 21.13 24.60 28.06 31.53 36.72 41.92 52.31 73.09 MINIMUM H = 5.37 Y 45 .21 3.04 5.87 10.11 14.35 22.84 39.81 L1 45 13.73 16.56 20.80 25.05 33.53 50.50 L2 45 21.40 24.23 28.47 32.72 41.20 58.17 Z 45 23.60 25.60 28.60 31.60 37.60 49.60 MINIMUM H = 9.61 Y 60 1.44 4.91 8.37 15.30 29.15 L1 60 16.27 19.73 26.66 40.52 L2 60 26.51 29.96 36.80 50.76 Z 60 25.45 27.19 30.65 37.58 MINIMUM H = 14.54 Y 90 1.62 7.62 19.62 L1 90 31.80 L2 90 47.16 Z 90 25.06 MINIMUM H= 25.06 DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"

25 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Special Bending Information Chart (cont’d) 1/2" IMC, Rigid and 40 Mil PVC-Coated Rigid Y 15 3.03 10.76 18.48 26.21 33.94 41.67 53.26 64.85 88.03 134.39 L1 15 7.72 15.45 23.18 30.90 38.63 46.36 57.95 69.54 92.72 139.09 L2 15 8.87 16.59 24.32 32.05 39.78 47.50 59.10 70.69 93.87 140.23 Z 15 11.12 18.58 26.05 33.51 40.97 48.44 59.63 70.83 93.22 138.01 MINIMUM H = 0.95 Y 22.5 .77 5.98 11.21 16.44 21.66 26.89 34.73 42.57 58.25 89.60 L1 22.5 5.20 10.43 15.66 20.88 26.11 31.34 39.17 47.01 62.69 94.05 L2 22.5 6.92 12.15 17.38 22.60 27.83 33.06 40.89 48.73 64.41 95.77 Z 22.5 9.07 13.90 18.73 23.56 28.38 33.21 40.46 47.70 62.18 91.15 MINIMUM H = 1.62 Y 30 3.49 7.49 11.49 15.49 19.49 25.49 31.49 43.49 67.49 L1 30 7.95 11.95 15.95 19.95 23.95 29.95 35.95 47.95 71.95 L2 30 10.24 14.24 18.24 22.24 26.24 32.24 38.24 50.24 74.24 Z 30 11.78 15.24 18.70 22.17 25.63 30.83 36.02 46.42 67.20 MINIMUM H = 2.42 Y 45 3.59 6.41 9.23 12.06 16.30 20.55 29.03 46.00 L1 45 8.30 11.13 13.95 16.78 21.02 25.27 33.75 50.72 L2 45 11.74 14.57 17.39 20.22 24.46 28.71 37.19 54.16 Z 45 12.13 14.13 16.13 18.13 21.13 24.13 30.13 42.13 MINIMUM H = 4.33 Y 60 1.42 3.73 6.04 8.34 11.81 15.27 22.20 36.06 L1 60 8.77 11.08 13.39 16.85 20.31 27.24 41.10 L2 60 13.35 15.66 17.97 21.44 24.90 31.83 45.69 Z 60 12.18 13.33 14.49 16.22 17.95 21.41 28.34 MINIMUM H = 6.55 Y 90 .71 2.71 4.71 7.71 10.71 16.70 28.70 L1 90 10.12 13.12 16.12 22.12 34.12 L2 90 17.00 20.00 23.00 29.00 41.00 Z 90 11.26 11.26 11.26 11.26 11.26 MINIMUM H = 11.26 3/4" IMC, Rigid and 40 Mil PVC-Coated Rigid Y 15 1.86 9.58 17.31 25.04 32.77 40.49 52.08 63.68 86.86 133.22 L1 15 7.72 15.45 23.17 30.90 38.63 46.36 57.95 69.54 92.72 139.08 L2 15 9.19 16.91 24.64 32.37 40.09 47.82 59.41 71.00 94.19 140.55 Z 15 12.06 19.53 26.89 34.46 41.92 49.38 60.58 71.78 94.17 138.95 MINIMUM H = 1.19 Y 22.5 4.85 10.08 15.31 20.53 25.76 33.60 41.44 57.12 88.47 L1 22.5 10.42 15.65 20.88 26.10 31.33 39.17 47.01 62.69 94.04 L2 22.5 12.62 17.85 23.08 28.30 33.53 41.37 49.21 64.89 96.24 Z 22.5 15.01 19.84 24.67 29.49 34.32 41.57 48.81 63.29 92.26 MINIMUM H = 2.05 Y 30 2.33 6.33 10.33 14.33 18.33 24.33 30.33 42.33 66.33 L1 30 7.93 11.93 15.93 19.93 23.93 29.93 35.93 47.93 71.93 L2 30 10.86 14.86 18.86 22.86 26.86 32.86 38.86 50.86 74.86 Z 30 13.05 16.52 19.98 23.45 26.91 32.11 37.30 47.70 68.48 MINIMUM H = 3.06 Y 45 2.31 5.13 7.96 10.79 15.03 19.28 27.76 44.73 L1 45 8.24 11.07 13.90 16.73 20.97 25.21 33.70 50.67 L2 45 12.64 15.47 18.30 21.13 25.37 29.61 38.10 55.07 Z 45 13.76 15.76 17.76 19.76 22.76 25.76 31.76 43.76 MINIMUM H = 5.49 Y 60 2.28 4.59 6.90 10.36 13.83 20.75 34.61 L1 60 10.94 13.25 16.72 20.18 27.11 40.97 L2 60 16.81 19.12 22.58 26.05 32.98 46.83 Z 60 15.36 16.52 18.25 19.88 23.45 30.38 MINIMUM H = 8.31 Y 90 .76 2.76 5.76 8.76 14.76 26.76 L1 90 12.60 15.60 21.60 33.60 L2 90 21.39 24.39 30.39 42.39 Z 90 14.33 14.33 14.33 14.33 MINIMUM H = 14.33 DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"

26 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Special Bending Information Chart (cont’d) 1" IMC, Rigid and 40 Mil PVC-Coated Rigid Y 15 1.08 8.81 16.52 24.25 31.97 39.70 51.29 62.88 86.07 132.43 L1 15 7.72 15.44 23.17 30.90 38.63 46.35 57.94 69.54 92.72 139.08 L2 15 9.59 17.32 25.04 32.77 40.50 48.23 59.82 71.41 94.59 140.95 Z 15 12.53 20.00 27.46 34.93 42.39 49.86 61.05 72.25 94.64 139.43 MINIMUM H = 1.31 Y 22.5 4.13 9.35 14.58 19.81 25.03 32.87 40.71 56.39 87.75 L1 22.5 10.42 15.64 20.87 26.09 31.32 39.16 47.00 62.68 94.04 L2 22.5 13.22 18.45 23.68 28.90 34.13 41.97 49.81 65.49 96.84 Z 22.5 15.69 20.52 25.35 30.18 35.01 42.25 49.49 63.98 92.95 MINIMUM H = 2.31 Y 30 1.58 5.58 9.58 13.58 17.58 23.58 29.58 41.58 65.58 L1 30 7.91 11.91 15.91 19.91 23.91 29.91 35.91 47.91 71.91 L2 30 11.66 15.66 19.66 23.66 27.66 33.66 39.66 51.66 75.66 Z 30 13.95 17.41 20.88 24.34 27.81 33.00 38.20 48.59 69.38 MINIMUM H = 3.51 Y 45 1.42 4.24 7.06 9.89 14.14 18.38 26.86 43.83 L1 45 11.01 13.83 16.66 20.91 25.15 33.63 50.60 L2 45 16.62 19.45 22.28 26.52 30.76 39.25 56.22 Z 45 17.11 19.11 21.11 24.11 27.11 33.11 45.11 MINIMUM H = 6.44 Y 60 1.17 3.48 5.79 9.25 12.71 19.64 33.49 L1 60 10.78 13.09 16.55 20.02 26.94 40.80 L2 60 18.27 20.58 24.04 27.50 34.43 48.29 Z 60 17.22 18.37 20.11 21.84 25.30 32.23 MINIMUM H = 9.91 Y 90 1.01 4.01 7.01 13.01 25.01 L1 90 14.93 20.93 32.93 L2 90 26.16 32.16 44.16 Z 90 17.49 17.49 17.49 MINIMUM H = 17.49 1-1/4" IMC, Rigid and 40 Mil PVC-Coated Rigid Y 15 7.15 14.87 22.60 30.33 38.06 49.65 61.24 84.42 130.78 L1 15 7.71 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.72 139.08 L2 15 10.07 17.80 25.53 33.25 40.98 48.71 60.30 71.89 95.07 141.44 Z 15 13.77 21.24 28.70 36.17 43.63 51.09 62.29 73.49 95.88 140.66 MINIMUM H = 1.63 Y 22.5 2.57 7.80 13.02 18.25 23.47 31.31 39.15 54.83 86.19 L1 22.5 10.41 15.63 20.86 26.09 31.31 39.15 46.99 62.67 94.03 L2 22.5 13.94 19.17 24.40 29.62 34.85 42.69 50.53 66.21 97.56 Z 22.5 17.18 22.01 26.84 31.66 36.49 43.73 50.98 65.46 94.43 MINIMUM H = 2.88 Y 30 4.00 8.00 12.00 16.00 22.00 28.00 40.00 64.00 L1 30 11.89 15.89 19.89 23.89 29.89 35.89 47.89 71.89 L2 30 16.61 20.61 24.61 28.61 34.61 40.61 52.61 76.61 Z 30 19.16 22.62 26.09 29.55 34.75 39.94 50.33 71.12 MINIMUM H = 4.38 Y 45 2.48 5.31 8.14 12.38 16.62 25.11 42.08 L1 45 13.75 16.58 20.83 25.07 33.55 50.52 L2 45 20.83 23.66 27.90 32.14 40.63 57.60 Z 45 21.40 23.40 26.40 29.40 35.40 47.40 MINIMUM H = 8.06 Y 60 1.46 3.77 7.23 10.69 17.62 31.48 L1 60 16.35 19.82 26.74 40.60 L2 60 25.79 29.25 36.18 50.04 Z 60 23.00 24.73 28.20 35.13 MINIMUM H = 12.42 Y 90 1.23 4.23 10.23 22.23 L1 90 20.13 32.13 L2 90 34.29 46.29 Z 90 21.96 21.96 MINIMUM H = 21.96 DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"

27 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Special Bending Information Chart (cont’d) 1-1/2" IMC, Rigid and 40 Mil PVC-Coated Rigid Y 15 5.30 13.03 20.75 28.48 36.21 47.80 59.39 82.57 128.94 L1 15 7.71 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.72 139.08 L2 15 9.94 17.67 25.39 33.12 40.85 48.58 60.17 71.76 94.94 141.31 Z 15 15.09 22.56 30.02 37.49 44.95 52.41 63.61 74.81 97.20 141.98 MINIMUM H = 1.97 Y 22.5 .90 6.13 11.36 16.58 21.81 29.65 37.49 53.17 84.52 L1 22.5 10.41 15.64 20.86 26.09 31.31 39.15 46.99 62.67 94.03 L2 22.5 13.75 18.97 24.20 29.43 34.65 42.49 50.33 66.01 97.37 Z 22.5 18.44 23.27 28.09 32.92 37.75 44.89 52.24 66.72 95.69 MINIMUM H = 3.36 Y 30 2.44 6.44 10.44 14.44 20.44 26.44 38.44 62.44 L1 30 11.90 15.90 19.90 23.90 29.90 35.90 47.90 71.90 L2 30 16.35 20.35 24.35 28.35 34.35 40.35 52.35 76.35 Z 30 20.35 23.82 27.28 30.75 35.94 41.14 51.53 72.32 MINIMUM H = 4.98 Y 45 1.06 3.88 6.71 10.96 15.20 23.68 40.65 L1 45 13.78 16.60 20.85 25.09 33.58 50.55 L2 45 20.50 23.33 27.57 31.81 40.30 57.27 Z 45 22.47 24.47 27.47 30.47 36.47 48.47 MINIMUM H = 8.82 Y 60 2.45 5.91 9.38 16.30 30.16 L1 60 16.41 19.87 26.80 40.66 L2 60 25.36 28.83 35.76 49.61 Z 60 23.92 25.65 29.12 36.04 MINIMUM H = 13.21 Y 90 3.12 9.12 21.12 L1 90 20.33 32.33 L2 90 33.77 45.77 Z 90 22.50 22.50 MINIMUM H = 22.50 2" IMC, Rigid and 40 Mil PVC-Coated Rigid Y 15 4.15 11.87 19.60 27.33 35.06 46.65 58.24 81.42 127.78 L1 15 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.71 139.08 L2 15 17.80 25.62 33.35 41.08 48.80 60.40 71.99 95.17 141.53 Z 15 22.90 30.36 37.82 45.29 52.75 63.95 75.15 97.54 142.32 MINIMUM H = 2.06 Y 22.5 5.22 10.45 15.67 20.90 28.74 36.58 52.26 83.61 L1 22.5 10.40 15.63 20.86 26.08 31.31 39.15 46.99 62.67 94.02 L2 22.5 14.09 19.31 24.54 29.76 35.00 42.83 50.67 66.35 97.71 Z 22.5 18.89 23.71 28.54 33.37 38.20 45.44 52.69 67.17 96.14 MINIMUM H = 3.53 Y 30 1.62 5.62 9.62 13.62 19.62 25.62 37.62 61.62 L1 30 11.88 15.88 19.88 23.88 29.88 35.88 47.88 71.88 L2 30 16.79 20.79 24.79 28.79 34.79 40.79 52.79 76.79 Z 30 20.92 24.38 27.84 31.31 36.50 41.70 52.09 72.88 MINIMUM H = 5.26 Y 45 .26 3.08 5.91 10.16 14.40 22.88 39.85 L1 45 13.74 16.56 20.81 25.05 33.53 50.50 L2 45 21.10 23.93 28.17 32.42 40.80 57.87 Z 45 23.27 25.27 28.27 31.27 37.27 49.27 MINIMUM H = 9.38 Y 60 1.58 5.04 8.50 15.43 29.29 L1 60 16.30 19.77 26.70 40.55 L2 60 26.13 29.59 36.52 50.38 Z 60 24.99 26.72 30.18 37.11 MINIMUM H = 14.14 Y 90 1.94 7.94 19.94 L1 90 31.98 L2 90 46.70 Z 90 24.25 MINIMUM H = 24.25 DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"

28 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Assembly Instructions for 40 Mil PVC-Coated Rigid Bending Accessories 1. Disconnect power to the bender. 2. Lock the bender power head in the vertical bending position. 3. Remove the retaining ring securing the 1-1/2" to 2" shoe with the retaining ring pliers provided. 4. Use both hands to secure the shoe and remove the 1-1/2" to 2" shoe from the spindle. 5. Mount the 1-1/2" to 2" PVC rigid bending shoe onto the spindle. Align the slot in the back side of the shoe bore with the screw head on the spindle and push the shoe on the spindle until the three drive lugs are fully engaged in the three drive holes. Replace the retaining ring. Align the slot in the shoe bore with the screw head on the spindle. 6. Remove the retaining ring securing the 1/2" to 1-1/4" shoe and remove the shoe. 7. Mount the 1/2" to 1-1/4" PVC rigid bending shoe onto the spindle and align the slot in the back side of the shoe bore with the screw head on the spindle. Push the shoe onto the spindle until the two drive lugs are fully engaged in the two drive holes. Replace the retaining ring. 8. Remove the quick release pivot shaft securing the 1/2" to 1-1/4" roller support unit and remove the roller support. 9. Mount the 1/2" to 1-1/4" PVC rigid roller support and replace the pivot shaft. 10. Reinstall the standard bending shoes and roller support unit in same sequence.

29 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ This section of the manual describes how to disas- semble and replace parts in the Greenlee 855 Smart Bender™. Parts must be ordered from Greenlee Textron. Service of this bender should only be done by qualified personnel who are familiar with handling of electronic components. The 855 Smart Bender™ warranty will become void if unauthorized repairs are attempted or non-specified parts are used in repairs. For information on parts or repair procedures not shown in this docu- ment, contact your nearest Authorized Greenlee Service Center or call 800-435-2932. SERVICE Disconnect power supply before servicing bender. Servicing to be done only by trained service technician. Failure to observe this warning can result in severe injury or death. Adjustments 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 difficult 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 specific to one size and type of conduit should be made using the Accuracy Adjust mode (see Operation — Standard Pendant). To adjust the limit switches, first 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 overbending. 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

30 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Adjustments (cont’d) 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 Once everything is tightened down in the proper posi- tion, push in the limit switch trip arm. You should hear the switch click on. If not, loosen the two screws and nuts and slide the switch to the right and retighten. Push the cam toward the switch to make sure any free play will not trip the switch. Tripping Surface of Cam Limit Switch Arm Rotate the cam until the switch trip arm rides up on top of the tripping surface of the cam. You should hear the switch click on. If not, move the switch to the left to a point where it does. You should hear the switch click off when the cam is released. If you cannot move the switch enough to get it to trip properly, use needlenose pliers to slightly bend the arm. Chain Lubrication Lubrication of the drive chain is recommended every six months (more often if used in dusty or corrosive environments). 1. Disconnect power to unit. 2. Remove the 1-1/2" to 2" shoe. 3. Remove the lower front guard. 4. Spray a motorcycle chain lubricant on the inside of the chain between the sprockets while pressing UNLOAD until the entire length of chain has been covered (do not spray on the encoder beneath the drive sprocket). 5. Replace the guard and shoe. Chain Adjustment Check the free play in the chain every time the chain is lubed. If the total play halfway between the sprockets is more than 1", adjust the chain. 1. Disconnect power to unit. 2. Remove the 1-1/2" to 2" shoe. 3. Remove the front lower guard and the motor cover. 4. Loosen the two motor mounting bolts on the front of the bender and the two mounting bolts and one nut on the back. 5. Turn the lower bolt on the front clockwise until all chain slack is removed. While maintaining tension, tighten the nut and two front bolts. 6. Tighten the two rear bolts. 7. Replace the motor cover, guard and shoe. 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. 1. Disconnect power to 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 .002" to .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. Maintenance 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.

31 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Support Rollers Front rollers: The front rollers (1-1/2" to 2") should be cleaned and lubricated every six months (more often if used in dusty environments). 1. Disconnect power to unit. 2. Remove the 1-1/2" to 2" shoe. 3. Detach the two springs from under the roller sup- ports. 4. Remove the squeeze adjustment arm bolt and arm. 5. Remove the three bolts securing the pivot bushing and remove the bushing. 6. Pull out the pivot shaft. 7. Lift the roller assembly to the left and up to remove. 8. Loosen the 1-1/2" bushing set screw and pull out the handle. 9. Loosen the 2" bushing set screw and press out the pivot pin. 10. Remove the bolt and one retaining ring from the 2" roller assembly and pull off the side plate. 11. Remove the tail roller, center roller, shim (if used), O-ring, pivot ball, split roller, spacer, split roller, pivot ball and O-ring. 12. Clean off all the grease and dirt. 13. Lubricate all working surfaces with molybdenum disulfide grease. 14. Slip one O-ring over each side plate. Replace with a new one if cut, shaved or cracked. 15. Replace the pivot ball, split roller, spacer, split roller, pivot ball, shim (if used), center roller and tail roller. 16. Fit on the side plate. 17. Reattach the retaining ring and bolt (use a high strength retaining compound on the bolt). 18. Slip the O-rings onto the pivot balls. 19. Repeat above with the 1-1/2" roller assembly, noting the following exceptions: a. there are no retaining rings. b. there is no center roller. c. remove and replace the spring anchor and shaft support. d. two spring washers are used in place of the center spacer. Use both hands to grab all four lead and tail rollers to prevent the assemblies from pivoting and pinch- ing fingers. Maintenance (cont’d) Rear rollers: The rear rollers should be lubricated every six months (more often if used in a dusty environ- ment). 1. Apply a motorcycle chain lubricant through the 1/8" hole in each roller. 2. Rotate each roller to distribute the lubricant. 3. Wipe away excess lube. 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 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 towards the brush to release it. Unplug the brush and remove it. Replace if the length is less than 1/4". 6. Reassemble in reverse order. Removing and Installing Shoes 1. Disconnect power to unit. 2. Remove the retaining ring securing the shoe to be removed with retaining ring pliers. 3. Use both hands to hold onto both sides of the shoe and pull it off the spindle. 4. Assemble in reverse order, noting the following: Align the slot in the shoe bore with the screw head on the spindle. Align the slot in the shoe bore with the screw head on the spindle.

32 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Bender Head Disassembly Relay 1. Remove PGU subplate (follow instructions 1-10 above). 2. Remove red and black relay wires (9) (10). 3. Remove two screws, lockwashers and nuts, and remove relay. 4. Assemble in reverse order. Transformer 1. Remove four screws securing top round cover and remove cover. 2. Disconnect transformer from I/O board (21). 3. Remove two screws securing transformer. 4. Assemble in reverse order. Input/Output Board (I/O) 1. Remove four screws securing top cover and remove cover. 2. Disconnect receptacle unit (4). 3. Disconnect selector switch (22). 4. Disconnect unload lockout switch (7). 5. Disconnect limit switch (5). 6. Disconnect optical encoder (23). 7. Disconnect brake wire (6). 8. Disconnect PGU-I/O cable (13). 9. Disconnect transformer cable (21). 10. Disconnect I/O-Power Wire Unit (14). 11. Compress the locking tabs on the eight standoffs. Pull the board just past the locking tabs until all eight are free, and remove the board completely. 12. Assemble in reverse order, noting proper polarity of all wires as shown. ELECTRONICS Power Generation Board (PGU) 1. Remove four screws securing top round cover and remove cover. 2. Disconnect ground jump wire, and the white, black, and green leads of I/O-Power Wire Unit (14). 3. Disconnect power cord neutral (white) wire (3). 4. Disconnect power lead (black) from switch (1). 5. Disconnect PGU-I/O cable (13). 6. Disconnect motor leads (2). 7. Disconnect red, black and two yellow wires to the rectifier (18) (19) (20). 8. Disconnect the red and black PGU-relay wires (11) (12). 9. Disconnect relay wire unit (8). 10. Remove four screws securing PGU subplate and remove subplate. 11. Remove two screws, lockwashers and nuts securing heat sink to subplate. 12. Compress the locking tabs on the four standoffs. Pull the PGU board just past the locking tabs until all four are free, and then remove the board com- pletely. 13. Assemble in reverse order, noting the proper polarity of all wires as shown. Rectifier 1. Remove PGU subplate (follow instructions 1-10 above). 2. Remove screw, lockwasher and nut securing rectifier. 3. Assemble in reverse order, using heat transfer grease between rectifier and subplate. See Electrical Control System Layout for location of key numbers. Disconnect power supply before servicing bender. The bender head should be serviced/disassembled while on the trunnion base. Failure to observe this warning can result in severe injury or death.

33 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Rotary Selector Switches CONDUIT SIZE CONDUIT TYPE DECAL NO. 500 8896.7 1/2 3/4 1 1-1/4 1-1/2 2 DECAL NO. 500 1487.0 RIGID ALUM PVC IMC EMT Use lifting eyes for hoisting Lift only with bending head in a horizontal position with the 1-1/2" and 2" side up 1. Remove four screws securing top round cover and remove cover. 2. Unplug selector switch unit (22). 3. Loosen set screws and remove knobs. 4. Remove two hex nuts. 5. Pull out selector switch unit. 6. Reassemble in reverse order, noting that flats on shafts go to the bottom. Pendant Receptacle CONDUIT TYPE DECAL NO. 500 1487.0 RIGID ALUM PVC IMC EMT CONDUIT SIZE DECAL NO. 500 8896.7 1/2 3/4 1 1-1/4 1-1/2 2 Use lifting eyes for hoisting Lift only with bending head in a horizontal position with the 1-1/2" and 2" side up 1. Remove four screws securing top round cover and remove cover. 2. Unplug receptacle unit (4). 3. Remove two screws securing receptacle and remove receptacle. 4. Reassemble in reverse order. Bender Head Disassembly (cont’d) SHOES Removing and Installing Shoes 1. Disconnect power to unit. 2. Remove the retaining ring securing the shoe to be removed with retaining ring pliers. 3. Use both hands to hold onto both sides of the shoe and pull it off the spindle. 4. Assemble in reverse order, noting the following: Align the slot in the shoe bore with the screw head on the spindle. Align the slot in the shoe bore with the screw head on the spindle.

34 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ 1-1/2" to 2" Roller Support Unit (500 0574.0) 1. Remove 1-1/2" to 2" shoe (see shoe removal). 2. Disconnect two springs that attach to 1-1/2" and 2" roller assemblies (104). 3. Remove squeeze adjustment arm screw and remove arm (97) (74). 4. Remove three screws securing pivot shaft bushing and slide bushing off shaft (96) (92). 5. Support the roller support assembly weight and pull out pivot shaft (91). 6. Lift out roller support assembly by holding the 1-1/2" and 2" tail rollers in one hand to prevent them from pivoting; lift up on the front rollers or the forked support arms with the other hand to remove. 7. Loosen the set screw securing the collar to the engagement handle (98). 8. Remove the handle (86) (90) (101) (151), collar (87), and 1-1/2" roller assembly. 9. Remove the hex head bolts and lift off the plate (93) (75). 10. Remove the tail roller, support shaft, clip, pivot ball, O-ring, roller, two Belleville washers, roller, O-ring and pivot ball (84) (94) (115) (78) (116) (77) (100) (77) (116) (78). 11. Loosen the set screw securing the collar to the pivot pin on the 2" roller assembly (98). 12. Remove the pin (88), collar (89), and 2" roller assembly. 13. Remove the hex head bolt and retaining ring and lift off the plate (93) (95) (76). 14. Remove the tail roller and shaft, middle roller and shaft, pivot ball (and any shims that might be used), O-ring, roller, spacer, roller; O-ring and pivot ball (82) (83) (85) (118) (80) (117) (79) (81) (79) (117) (80). 15. Assemble 2" roller assembly in reverse order noting the following: • Slip each O-ring over side plates until reassembly is complete and then slip O-rings between rollers and pivot balls. • Clean and lubricate all mating surfaces with a high quality grease. • If new front roller parts are used, use shim washers to control axial free play to less than 1/32". If rollers do not pivot freely, use 905 2644.9 or 905 2645.7 shim to add clearance. Use 905 3918.4 shim if play exceeds 1/32". • Use Loctite 271 on hex head bolt (93). Torque to 54 to 61 Nm (40 to 45 ft-lb). Bender Head Disassembly (cont’d) ROLLER SUPPORTS 95 118 89 73 98 117 80 71 104 84 72 115 86 116 78 77 100 77 78 98 116 87 94 75 93 151 101 90 93 99, 119 or 150 Note: Torque to 54 to 61 Nm (40 to 45 ft-lb) 93 88 76 117 95 104 83 85 105 82 80 79 81 79

35 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ 16. Assemble 1-1/2" roller assembly in reverse order noting the following: • Slip each O-ring over side plates until reassembly is complete and then slip O-rings between rollers and pivot balls. • Clean and lubricate all mating surfaces with a high quality grease. • Use Loctite 271 on hex head bolts (93). Torque to 54 to 61 Nm (40 to 45 ft-lb). 17. Reassemble roller assemblies to support arms (71) making sure that the tail rollers are to the right if the narrow gap of the support arms are towards you. 18. Reassemble support roller assembly to bender. Adjust end clearance with set screw (107) as necessary to allow non-binding retraction of roller assembly in the horizontal position. 19. Reattach springs. 1/2" to 1-1/4" Roller Support Unit (503 8199.7) 1. Remove pivot shaft. 2. Remove roller support. 3. Lubricate roller axles through 1/8" holes in each roller with a chain lubricant. 4. Reassemble in reverse order. Optional 1/2" to 1-1/4" Roller Support Unit (500 0934.6) 1. Remove pivot shaft. 2. Remove roller support. 3. Remove one retaining ring on each roller axle. 4. Remove axles and rollers. 5. Clean and lubricate all mating surfaces with a high quality grease. 6. Reassemble in reverse order. RETENTION CAM 1. Remove bolt securing retention cam and remove washer, spring, shaft, and cam (113) (111) (112) (109) (108). 2. Remove switch cover screws and switch cover (42) (38). 3. Remove four screws securing top cover and remove cover. 4. Unplug unload lockout switch from I/O board. 5. Remove screws and nuts securing unload lock-out switch. 6. Pull switch unit from bender. Note: Attach a wire or string to the lock-out switch at the I/O board to serve as a retrieval line to pull the new wire and plug up through the unit. 7. Reassemble in reverse order noting the following: • With the bender oriented in the vertical position, rotate the round plate (111) 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 screw 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 • Once everything is tightened down in the proper position, push in the limit switch trip arm. You should hear the switch click on. If not, loosen the two screws and nuts (40 and 41) and slide the switch to the right and retighten. Push the cam towards the switch to make sure any free play will not trip the switch. Rotate the cam until the switch trip arm rides up on top of the tripping surface of the cam. You should hear the switch trip on. If not, move the switch to the left to a point where it does. You should hear the switch click off when the cam is released. If you cannot move the switch enough to get it to trip properly, use needlenose pliers to slightly bend the arm. Tripping Surface of Cam Limit Switch Arm Bender Head Disassembly (cont’d)

36 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ CHAIN If chain breaks, replace with new chain (905 4250.9) (not another Master Link). This is due to the high stress on the chain. The addition of a second Master Link will only weaken the chain further. If the Master Link breaks, it can be replaced with a new Master Link (905 4251.7). 1. Remove four screws securing top cover and remove top cover. 2. Remove 1-1/2" to 2" shoe (see shoe removal). 3. Remove seven screws securing front guard and remove guard. 4. Remove nine screws securing motor cover and remove motor cover. 5. Rotate motor until chain master link is accessible at top of bender. 6. With the bender head in the horizontal position, loosen the four bolts and nut securing the motor and turn the eccentric adjusting bolt to allow chain slack. 7. Tap the motor toward the spindle to slack the chain, taking care not to allow the encoder to contact the frame. 8. Remove cotter pins, master link and chain. 9. Reassemble in reverse order, noting the following: • Torque eccentric adjusting bolt to 81 Nm (60 ft-lb) while tightening two front bolts and nut to maintain chain tension. • Use new master link and cotter pins. SPINDLE 1. Remove chain (see chain removal). 2. Remove 1/2" to 1-1/4" shoe (see shoe removal). 3. Loosen 1/2" to 1-1/4" drive plate hub set screw. 4. Remove socket head screw in 1/2" to 1-1/4" spindle. 5. Remove drive plate and key. 6. Use a file to remove any raised edges from the spindle to prevent bearing damage. 7. Remove spindle/sprocket. 8. Reassemble in reverse order. LIMIT SWITCH BRACKET 1. Remove spindle (see spindle removal). 2. Remove four screws securing two limit switches and remove switches. 3. Remove two screws securing bracket and remove bracket. Bender Head Disassembly (cont’d) 4. Reassemble in reverse order, noting the following: • Limit switch with red wires goes on top. • Install top switch so that trip roller is as far left as possible, as viewed with the switch behind the bracket. • Install bottom switch (black wires) with the trip roller as far right as possible, as viewed with the switch behind the bracket. • Temporarily install both shoes before installing chain. • Place 2" IMC in bender and rotate shoe until conduit locks up against tail roller. (DO NOT raise support rollers as is normal for IMC.) • Slide top limit switch until contacts trip and tighten in that position. • Place 1/2" rigid in bender and rotate shoe until conduit locks up against support roller. • Slide bottom switch until contacts trip and tighten in that position. • Rotate spindle, checking that the limit switch trip bolts do not snag the trip rollers. Re-adjust bracket mounting if necessary. 1-1/2" and 2" Limit Switch Adj. Screws 1/2" to 1-1/4" Limit Switch Adj. Screws Less Bend Less Bend If the accuracy of all sizes of conduit on one shoe is off in the same direction, the limit switch needs to be adjusted. To do so, first 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 above) 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 above) to prevent overbending. Move either switch the opposite direction if the bender is under- bending. Every 1/8" of switch movement approximates 1 degree of change. Tighten the screws and replace the guard.

37 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Bender Head Disassembly (cont’d) SQUEEZE ADJUSTMENTS Proper squeeze adjustment for most 1-1/2" and 2" EMT and IMC conduit is when the squeeze adjustment arm (74) 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 difficult or if excessive side marking occurs, decrease squeeze one position (hole) clockwise. BRAKE 1. Remove eleven screws securing motor cover and remove cover. 2. Loosen two set screws securing brake rotor and remove rotor. 3. Remove power supply leads. 4. Remove four screws securing brake housing and remove housing. 5. Reassemble brake housing and power leads. 6. Use shims to set the brake rotor gap at .002" to .015" and tighten. 7. Replace motor cover. OPTICAL ENCODER 1. Remove four screws securing top cover and remove cover. 2. Remove seven screws securing front guard and remove guard. 3. Remove nine screws securing motor cover and remove cover. 4. Rotate motor until both hub set screws are accessible. 5. Loosen two set screws in the drive hub. 6. Unplug encoder from I/O board. 7. Remove two mounting screws and round plastic spacers securing encoder and pull off encoder. Note: Attach a wire or string to the encoder plug at the I/O board to serve as a retrieval line to pull the new wire and plug up through the unit. 8. Reassemble in reverse order, noting the following: • Torque hub set screws to 22 inch-ounces. • Jog motor and check Quad 1 and Quad 2 LEDs for ON/OFF pulsing. 1. Remove optical encoder (see optical encoder removal). 2. Remove chain (see chain removal). 3. Remove brake (see brake removal). 4. Loosen motor sprocket set screws and remove sprocket and key. 5. Disconnect motor leads at relay and the ground wire. 6. Remove five motor mounting bolts and nut. 7. Remove motor. Note: Attach a wire or string to the motor leads at the power generation board to serve as a retrieval line to pull the new wire through the unit. 8. Assemble in reverse order. Motor Disassembly

38 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ 1. Support entire weight of bender (approx. 500 lbs.) at lifting eyes, but do not lift above floor. Note: Lifting slings must attach to lifting mechanism within the width boundaries of the bender to prevent the lifting eyes from sliding off once the retaining rings are removed. CORRECT INCORRECT Bender head may rotate a bit when locking detent pin is disengaged. Keep hands clear. 2. Remove support tower on the rotary selector switch side. a. Remove four bolts, two nuts and crossbar at base of tower. b. Remove outer retaining ring on each side of the bender. c. Slide tower off of pivot spindle. 3. Slide the remainder of the trunnion assembly off the opposite pivot spindle. Trunnion Disassembly 4. Remove remaining support tower from base. 5. Pull out detent pin, knob and spring. 6. Remove four bolts and swivel casters on each side. 7. Remove stationary wheels. a. Remove retaining rings on axle. b. Press out axle. c. Remove wheel and washers from each side. 8. Remove kickstand. a. Loosen set screw in collar. b. Press out pin. c. Remove kickstand weldment. 9. Assemble in reverse order, except for leaving out the detent pin, knob and spring. After all else is assembled, rotate the bender head so the top of the bender is pointed toward the kickstand, and insert the detent pin assembly. Hold the detent pin in while rotating the bender head back to one of its normal positions.

39 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ 1. Torque gearbox bolts to 11/9 Nm (100/80 in-lb) in sequence shown. 2. Assemble all Belleville washers so that I.D.’s butt and O.D.’s contact bearings. 3. Tighten motor nuts (24) to 3/4 Nm (30/35 in-lb). 4. Insert commutator brushes before connecting push-on terminals. Bolt Tightening Sequence for Gearbox Cover UPC No. Key 78-3310- Part No. Description 1 86705 918 6705.3 Commutator Brushes 2 86706 918 6706.1 Commutator Brush Retention Springs 3 86707 918 6707.0 Tail Housing 4 86708 918 6708.8 Brush Assembly Plate 5 86709 918 6709.6 Cord 6 39092 503 9092.9 Shroud 7 86710 918 6710.0 Magnet Housing 8 86711 918 6711.8 Armature 8A 86071 918 6071.7 Bearing 9 54348 905 4348.3 Belleville Washers 10 39073 503 9073.2 Rear Gear Housing 11 39074 503 9074.0 Gasket 12 39075 503 9075.9 Front Gear Housing 13 39076 503 9076.7 Output Gear Shaft 14 39077 503 9077.5 Short Spacer 15 39078 503 9078.3 Long Spacer 16 39079 503 9079.1 2nd Reduction Pinion Shaft w/ BRGs 17 53323 905 3323.2 Wave Washer 18 39080 503 9080.5 3rd Reduction Pinion Shaft w/ BRGs 19 54248 905 4248.7 Belleville Washer 20 39081 503 9081.3 4th Reduction Pinion Shaft 21 39082 503 9082.1 Small Spacer 22 54043 905 4043.3 1/2-20 x 2-1/2 Screw 23 02298 500 2298.9 1/4-28 x 9-1/4" Stud 24 51705 905 1705.9 1/4-28 Hex Nut 25 50749 905 0749.5 1/4" Internal Tooth Lockwasher 26 07208 500 7208.0 Oil Seal 27 07209 500 7209.9 Oil Seal Motor and Gearbox Exploded View and Parts List 22 23 10 4 6 5 2 1 20 21 16 15 13 14 17 19 18 12 22 7 1 2 9 23 8 11 8A 3 25 24 26 27 6 4 3 1 2 5

40 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ 1/2" to 1-1/4" Side Exploded View 7 19 204 205 206 206 213 5 26 23 223 225 224 222 225 221 232 43 Shoe Unit 1/2" to 1-1/4" consists of 221, 222, 223, 224 and 225 See page 43 for parts list.

41 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ 1-1/2" to 2" Side Exploded View 3 207 207 215 215 213 74 97 96 91 92 26 224 226 226 227 228 229 44 Shoe Unit 1-1/2" to 2" consists of 224, 226, 227, 228 and 229 The Roller Support Unit exploded view is on the following page. See page 43 for parts list.

42 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ 1-1/2" to 2" Roller Support Unit (500 0574.0) Exploded View 95 118 89 73 98 117 80 71 104 84 72 115 86 116 78 77 100* 77 78 98 116 87 94 75 93 151 101 90 93 99, 119 or 150 Note: Torque to 54 to 61 Nm (40 to 45 ft-lb) 93 88 76 117 95 104 83 85 105 82 80 79 81 79 *Two required

43 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ 1/2" to 1-1/4" Side, 1-1/2" to 2" Side, and 1-1/2" to 2" Roller Support Unit Parts List 3 38217 503 8217.9 Guard Weldment, Top Chain .............. 1 5 38232 503 8232.2 Guard Weldment, Motor ..................... 1 7 38199 503 8199.7 Sppt Wldt, 1/2" to 1-1/4" RLR ............. 1 19 52397 905 2397.0 Pin, 1/2" to 1-1/4" Sprt Pvt .................. 1 23 51655 905 1655.9 Screw, #10-16 .50 Hex Hd ............... 31 26 52501 905 2501.9 Ring, Rtng Truarc #5100-287 ............. 2 43 38780 503 8780.4 Shoe Unit, 1/2" to 1-1/4" ..................... 1 44 38148 503 8148.2 Shoe Unit, 1-1/2" to 2" ........................ 1 71 38221 503 8221.7 Support Weldment, Roller .................. 1 72 00528 500 0528.6 Support Weldment, 1-1/2" .................. 1 73 00601 500 0601.0 Support Weldment, 2" ......................... 1 74 38225 503 8225.0 Arm Weldment, Adjustment ................ 1 75 00543 500 0543.0 Plate, 1-1/2" Outer Roller ................... 1 76 00604 500 0604.5 Plate, 2" Outer Roller .......................... 1 77 38254 503 8254.3 Split Rollers, 1-1/2 .............................. 2 78 38264 503 8264.0 Ball, 1-1/2 ............................................ 2 79 38255 503 8255.1 Split Rollers, 2 ..................................... 2 80 38263 503 8263.2 Ball, 2 .................................................. 2 81 38262 503 8262.4 Spacer, 2 Roller .................................. 1 82 00599 500 0599.5 Roller Unit, 2" ...................................... 1 83 00493 500 0493.0 Shaft, 2" Rear Roller ........................... 1 84 38252 503 8252.7 Roller, 1-1/2 IMC ................................. 1 85 38253 503 8253.5 Roller, 2 Tail ........................................ 1 86 38260 503 8260.8 Shaft, 1-1/2 Pivot Roller...................... 1 87 32027 503 2027.0 Sleeve, 1-1/2 ....................................... 1 88 31728 503 1728.8 Shaft, 2 Pivot....................................... 1 89 38151 503 8151.2 Sleeve, 2 ............................................. 1 90 23258 502 3258.4 Grip...................................................... 1 91 38256 503 8256.0 Shaft, Eccentric ................................... 1 92 38251 503 8251.9 Sleeve, Adapter .................................. 1 93 50540 905 0540.9 Screw, 7/16-14 x 1.00 Hex Hd ........... 3 94 00860 500 0860.9 Shaft, 1-1/2" Support .......................... 1 95 54819 905 4819.1 Retaining Ring #5100-87 .................... 2 96 54242 905 4242.8 Screw, Cap 1/4-20 x .37 Btn Hd ......... 3 97 50224 905 0224.8 Screw, 5/16-18 x 1.00 Skt Hd ............. 1 98 50881 905 0881.5 Screw, 1/4-28 x .25 Set ...................... 2 99 53018 905 3918.4 Washer, 1.00 x 1.37 x .03 Shim ......... 1 100 54248 905 4248.7 Washer, Belleville 1.362 x .803 .......... 2 101 39440 503 9440.1 Washer, .62 x 2.00 x .06 Flat ............. 1 104 54243 905 4243.6 Spring, Extension .75 x 3.50 .............. 2 105 54252 905 4252.5 Clamp, Loop Type............................... 1 115 38592 503 8592.5 Guide, Spring ...................................... 1 116 51130 905 1130.1 O-Ring, 1.50 x 1.62 x .062.................. 2 117 51537 905 1537.4 O-Ring, 1.75 x 1.87 x .062.................. 2 118 38657 503 8657.3 Shaft, 2 Middle Roller ......................... 1 119 52644 905 2644.9 Washer, 1/32 Shim ............................. 1 150 52645 905 2645.7 Washer, 1/16 Shim ............................. 1 151 53216 905 3216.3 Retaining Ring #5100-62 .................... 1 204 53390 905 3390.9 Wheel .................................................. 2 205 38166 503 8166.0 Axle, Long ........................................... 1 206 51528 905 1528.5 Ring, Retaining #5160-75 ................... 2 207 54237 905 4237.1 Screw, Flange 3/8-16 x 1.00 Hex ..... 16 213 38464 503 8464.3 Pad Weldment, Jack Bolt ................... 4 215 54276 905 4276.2 Caster, 8 Swivel .................................. 2 221 31710 503 1710.5 1/2" to 1-1/4" IMC, Rigid Hook ........... 1 223 31712 503 1712.1 1/2" to 1-1/4" EMT Hook ..................... 1 224 52479 905 2479.9 Drive Bolt, 1/2-13 x .62 Socket Head Cap Screw..................... 6 225 51088 905 1088.7 1/2" to 1-1/4" Hook Bolts, 3/8-16 x 1-1/4 Socket Head Cap Screw..................... 8 226 53396 905 3396.8 1-1/2, 2" Hook Shoulder Bolts, 3/4 x 1-1/2 ........................................... 6 228 31716 503 1716.4 1-1/2, 2" EMT Hook ............................ 1 229 38779 503 8779.0 1-1/2, 2" IMC and Rigid Hook ............. 1 232 54880 905 4880.9 Wrench, 5/16" Hex T-handle .............. 1 UPC No. Key 78-3310- Part No. Description Qty. UPC No. Key 78-3310- Part No. Description Qty.

44 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Main Exploded View 19 205 206 206 213 204 215 13 17 12 11 16 10 27 7 3 5 23 26 14, 28 8 201 6 202 207 18 30 18 15 45 46 47 2 29 34 31 36 58 15 15 25 33 48 49 21 57C 57A 57B 57D 57H 57F 57G 57E 57 208 220 209, 211, 212 221 225 223 225 224 23 55 60 53 20 59 51 52 50 22 20A 43 Power Cord 37 170 233 233 216 217 230 218 Optional Kit

45 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ If the chain breaks, replace it with a new chain — not another master link — due to the high stress on the chain. The addition of a second master link will only weaken the chain further. If the master link breaks, replace it with a new master link (905 4251.7). 26 9 176 207 203 54 231 228 226 224 229 226 44 4C 4B 4, 4A 23 35 32 220 15 95 118 89 73 98 117 80 71 104 84 72 115 86 116 78 77 100 77 78 98 116 87 94 75 93 151 101 90 93 99, 119 or 150 Note: Torque to 54 to 61 Nm (40 to 45 ft-lb) 93 88 76 117 95 104 83 85 105 82 80 79 81 79 21 6 91 74 92 96 97 111 114 106 107 109 108 112 113 42 38 39 40 41 = Cam Repair Kit #500 7939.5

46 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ UPC No. Key 78-3310- Part No. Description Qty. UPC No. Key 78-3310- Part No. Description Qty. Main Parts List 2 01622 500 1622.9 Frame Weldment ................................ 1 3 38217 503 8217.9 Guard Weldment, Top Chain .............. 1 4 38983 503 8983.1 Guard Assembly, Front Chain ............ 1 4A 38236 503 8236.5 Guard, Front ........................................ 1 4B 38244 503 8244.6 Retainer ............................................... 1 4C 50160 905 0160.8 Rivet, 3/16" Pop .................................. 2 5 38232 503 8232.2 Guard Weldment, Motor ..................... 1 6 01607 500 1607.5 Guard, Bottom ..................................... 1 7 38199 503 8199.7 Sppt Wldt, 1/2" to 1-1/4" RLR ............. 1 8 38250 503 8250.0 Drive Unit ............................................ 1 9 01702 500 1702.0 Spindle Weldment, Main ..................... 1 10 38193 503 8193.8 Plate Weldment, Drive ........................ 1 11 54253 905 4253.3 Sprocket, #60 14T .............................. 1 12 38267 503 8267.5 Key, Drive Sprocket ............................ 1 13 54255 905 4255.0 Bearing, Sleeve #48DU40 .................. 2 14 54250 905 4250.9 Chain, #60 92P ................................... 1 15 54462 905 4462.5 Ring, Rtng Truarc #5100-200 ............. 4 16 38265 503 8265.9 Washer, Main Spindle......................... 2 17 38268 503 8268.3 Key, Shoe Drive .................................. 1 18 38457 503 8457.0 Plate, Hoist .......................................... 2 19 55204 905 5204.0 Pin, 1/2" to 1-1/4" Sprt Pvt .................. 1 20 38257 503 8257.8 Spacer, Motor Mount .......................... 1 20A 39488 503 9488.6 Spacer, Thin Motor Mount .................. 1 21 38228 503 8228.4 Locator Weldment, Eccentric.............. 1 22 54265 905 4256.8 Nut, 1/2-13 Lock.................................. 1 23 51655 905 1655.9 Screw, #10-16 x .50 Hex Hd............. 31 25 53903 905 3903.6 Screw, Cap 1/2-13 x 1.00 ................... 4 26 52501 905 2501.9 Ring, Rtng Truarc #5100-287 ............. 2 27 54345 905 4345.9 Screw, Set 1/2"-20 x .75 Socket ......... 1 28 54251 905 4251.7 Link, Connecting #60 Chain ............... 1 29 54240 905 4240.9 Screw, #6-32 x 1.00 Sltd Mch ............ 4 30 38246 503 8246.2 Bracket, Limit Switch .......................... 1 31 38248 503 8248.9 Back-Plate, Switch .............................. 2 32 50226 905 0226.4 Screw, 5/16-18 x 1.25 Sk. Cap ........... 2 33 52597 905 2597.3 Washer, Flat .56 x 1.37 x .109 ........... 4 34 85822 918 5822.4 Switch, Limit #BZ-2RW822-A2 ........... 2 35 50645 905 0645.6 Nut, Hex 5/16-18 Reg Jam ................. 2 36 01708 500 1708.0 Receptacle Unit, Pendant ................... 1 37 54124 905 4124.3 Strain Relief ........................................ 1 38 38546 503 8546.1 Cover, Switch ...................................... 1 39 38638 503 8638.7 Switch Unit, Unload Lckt ..................... 1 40 54313 905 4313.0 Screw, Mach #2-56 x .75 .................... 2 41 54314 905 4314.9 Nut, Lock #2-56 Hex ........................... 2 42 50763 905 0763.0 Screw, Mach #8-32 x .25 .................... 2 43 38780 503 8780.4 Shoe Unit, 1/2" to 1-1/4" ..................... 1 44 38148 503 8148.2 Shoe Unit, 1-1/2" to 2" ........................ 1 45 52203 905 2203.6 Screw, Mach #6-32 x .25 .................... 2 46 29708 502 9708.2 Guard, Breaker Switch........................ 1 47 86385 918 6385.6 Breaker, Circuit 20 Amp ..................... 1 48 54619 905 4619.9 Screw, CAP #4-40 x .62 Skt ............... 2 49 38646 503 8646.8 Encoder Unit, Optical .......................... 1 50 50572 905 0572.7 Screw, Cap #8-32 x .50 Skt ................ 4 51 86646 918 6646.4 Brake, Motor ....................................... 1 52 38807 503 8807.0 Key, Brake........................................... 1 53 54616 905 4616.4 Spacer, Round Plastic ........................ 2 54 54151 905 4151.0 Knob, Plastic w/Set Screw.................. 2 55 54335 905 4335.1 Screw, Flng 1/4 x .37 Thd................... 2 57 01648 500 1648.2 Switch, Pendant .................................. 1 57A 01305 500 1305.0 Board, Circuit ...................................... 1 57B 33476 503 3476.0 Cover ................................................... 1 57C 33472 503 3472.7 Housing, Lower ................................... 1 57D 38649 503 8649.2 Switch, Membrane .............................. 1 57E 34342 503 4342.4 Screw #4-20 ........................................ 3 57F 33580 503 3580.4 Screw #6-32 ........................................ 3 57G 01666 500 1666.0 Cord, Pendant ..................................... 1 57H 38654 503 8654.9 Strip, Magnetic .................................... 1 58 35012 503 5012.9 Screw, #4 x 1/2" Flat Head or 06683 500 6683.8 Rivet, Pop 3/32 ................................... 2 59 51751 905 1751.2 Screw, Drive ........................................ 4 60 38868 503 8868.1 Nameplate ........................................... 1 71 38221 503 8221.7 Support Weldment, Roller .................. 1 72 00528 500 0528.6 Support Weldment, 1-1/2" .................. 1 73 00601 500 0601.0 Support Weldment, 2" ......................... 1 74 38225 503 8225.0 Arm Weldment, Adjustment ................ 1 75 00543 500 0543.0 Plate, 1-1/2" Outer Roller ................... 1 76 00604 500 0604.5 Plate, 2" Outer Roller .......................... 1 77 38254 503 8254.3 Rol, 1-1/2............................................. 2 78 38264 503 8264.0 Ball, 1-1/2 ............................................ 2 79 38255 503 8255.1 Rol, 2 ................................................... 2 80 38263 503 8263.2 Ball, 2 .................................................. 2 81 38262 503 8262.4 Spacer, 2 Roller .................................. 1 82 00599 500 0599.5 Roller Unit, 2" ...................................... 1 83 00493 500 0493.0 Shaft, 2" Rear Roller ........................... 1 84 38252 503 8252.7 Roller, 1-1/2 I.M.C............................... 1 85 38253 503 8253.5 Roller, 2 Tail ........................................ 1 86 38260 503 8260.8 Shaft, 1-1/2 Pivot Roller...................... 1 87 32027 503 2027.0 Sleeve, 1-1/2 ....................................... 1 88 31728 503 1728.8 Shaft, 2 Pivot....................................... 1 89 38151 503 8151.2 Sleeve, 2 ............................................. 1 90 23258 502 3258.4 Grip...................................................... 1 91 38256 503 8256.0 Shaft, Eccentric ................................... 1 92 38251 503 8251.9 Sleeve, Adaptor .................................. 1 93 50540 905 0540.9 Screw, 7/16-14 x 1.00 Hex Hd ........... 3 94 00860 500 0860.9 Shaft, 1-1/2" Support .......................... 1 95 54819 905 4819.1 Retaining Ring #5100-87 .................... 2 96 54242 905 4242.8 Screw, Cap 1/4-20 x .37 Btn Hd ......... 3

47 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Main Parts List (cont’d) UPC No. Key 78-3310- Part No. Description Qty. UPC No. Key 78-3310- Part No. Description Qty. 97 50224 905 0224.8 Screw, 5/16-18 x 1.00 Skt Hd ............. 1 98 50881 905 0881.5 Screw, 1/4-28 x .25 Set ...................... 2 99 53018 905 3918.4 Washer, 1.00 x 1.37 x .03 Shim ......... 1 100 54248 905 4248.7 Washer, Belleville 1.362 x .803 .......... 2 101 39440 503 9440.1 Washer, .62 x 2.00 x .06 Flat ............. 1 104 54243 905 4243.6 Spring, Extension .75 x 3.50 .............. 2 105 54252 905 4252.5 Clamp, Loop Type............................... 1 106 52108 905 2108.0 Nut, Hex 1/4-20 ................................... 1 107 54239 905 4239.8 Screw, 1/4-20 x 3/4 Ovl Pt Set ........... 1 108 39851 503 9851.2 Cam, Retention ................................... 1 109 38463 503 8463.5 Shaft, Cam Retention ......................... 1 111 38544 503 8544.5 Plate, Cam Retention.......................... 1 112 38566 503 8566.6 Spring, Cam Retention ....................... 1 113 54268 905 4268.1 Screw, 1/4-20 x 1-3/8 Skt Cap ........... 1 114 50458 905 0458.5 Rollpin, 1/8 x .375 ............................... 1 115 38592 503 8592.5 Guide, Spring ...................................... 1 116 51130 905 1130.1 O-Ring, 1.50 x 1.62 x .062.................. 2 117 51537 905 1537.4 O-Ring, 1.75 x 1.87 x .062.................. 2 118 38657 503 8657.3 Shaft, 2 Middle Roller ......................... 1 119 52644 905 2644.9 Washer, 1/32 Shim ............................. 1 150 52645 905 2645.7 Washer, 1/16 Shim ............................. 1 151 53216 905 3216.3 Retaining Ring .................................... 1 170 86263 918 6263.9 Nut, 1/2" Conduit Lock ........................ 1 176 54911 905 4911.2 Screw, 1/4-28 x 3/8" Skt. Hd. Cap...... 2 201 38141 503 8141.5 Base Weldment, Trunnion .................. 1 202 38157 503 8157.1 Tower Weldment, L.H. Trunnion ........ 1 203 38161 503 8161.0 Tower Weldment, R.H. Trunnion ........ 1 204 53390 905 3390.9 Wheel .................................................. 2 205 38166 503 8166.0 Axle, Long ........................................... 1 206 51528 905 1528.5 Ring, Retaining #5160-75 ................... 2 207 54237 905 4237.1 Screw, Flange 3/8-16 x 1.00 Hx ....... 16 208 52646 905 2646.5 Nut, 3/8-16 Esna Hex ......................... 4 209 38167 503 8167.9 Pin, Trunnion Lock .............................. 1 211 54244 905 4244.4 Spring, Trunnion Lock......................... 1 212 38168 503 8168.7 Knob .................................................... 1 213 38464 503 8464.3 Pad Weldment, Jack Bolt ................... 4 215 54276 905 4276.2 Caster, Swivel ..................................... 2 220 38156 503 8156.3 Block, Reinforcement.......................... 2 221 31710 503 1710.5 1/2" to 1-1/4" IMC, Rigid Hook ........... 1 223 31712 503 1712.1 1/2" to 1-1/4" EMT Hook ..................... 1 224 52479 905 2479.9 Drive Bolt, 1/2-13 x .62 Socket Head Cap Screw..................... 6 225 51088 905 1088.7 1/2" to 1-1/4" Hook Bolts, 3/8-16 x 1-1/4 Socket Head Cap Screw........................................... 8 226 53396 905 3396.8 1-1/2, 2" Hook Shoulder Bolts, 3/4 x 1-1/2 ........................................... 6 228 31716 503 1716.4 1-1/2, 2" EMT Hook ............................ 1 229 38779 503 8779.0 1-1/2, 2" IMC & Rigid Hook ................ 1 231 01084 500 1084.0 Selector Switch Unit w/o Knobs ......... 1 232 54880 905 4880.9 Wrench, 5/16" Hex T-handle .............. 1 Decals (not shown) 38893 503 8893.2 Decal, Lifting Eye ................................ 1 38894 503 8894.0 Decal, Kickstand ................................. 1 01445 500 1445.5 Decal, Deluxe Pendant Instr. .............. 1 38896 503 8896.7 Decal, Slct Switch Size ....................... 1 01487 500 1487.0 Decal, Slct Switch Type ...................... 1 38898 503 8898.3 Decal, Bender Pivot Lock ................... 1 38899 503 8899.1 Decal, Roller Adjustment .................... 1 02263 500 2263.6 Decal, Roller Engagement .................. 1 01568 500 1568.0 Decal, Operation ................................. 3 38974 503 8974.2 Decal, Circuit Breaker ......................... 1 01453 500 1453.6 Decal, Shoe Orientation ..................... 2 07248 500 7248.6 Decal, Extension Cord ........................ 1 999 3576.7 Decal, Technical Assistance............... 1 Optional 216 38743 503 8743.0 Stand, Anti-Movement ........................ 1 217 31732 503 1732.6 Pin, Pivot ............................................. 1 218 50881 905 0881.5 Screw, 1/4-28 x .250 Skt Set .............. 1 230 54297 905 4297.5 Spring .................................................. 1 01711 500 1711.0 Deluxe Pendant Control 38962 503 8962.9 Vinyl Cover (not shown) 01700 500 1700.4 1/2" to 2" PVC Shoe Group Service Only 05586 500 5586.0 Frame Unit (includes bearings) .......... 1 500 7939.5 Cam Repair Kit.................................... 1 233

48 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ 15 16 10 11 12 13 17 9 8 14 4 5 6 7 4 1 2 3 UPC No. Key 78-3310- Part No. Description Qty. 00572 500 0572.3 Shoe Unit, 1/2" to 1-1/4" PVC- Coated Rigid (includes items 1–4) ..... 1 31919 503 1919.1 Shoe Unit, 1-1/2" to 2" PVC- Coated Rigid (includes items 4–7) ..... 1 00934 500 0934.6 Support Unit, 1/2" to 1-1/4" PVC- Coated Rigid (includes items 8–17) ... 1 1 00567 500 0567.7 1/2" to 1-1/4" PVC-Coated Rigid Shoe........................................... 1 2 00570 500 0570.7 1/2" to 1-1/4" PVC-Coated Rigid Hook........................................... 1 3 51088 905 1088.7 3/8-16 x 1-1/4" Socket Head Cap Screw........................................... 4 4 52479 905 2479.9 1/2-13 x 5/8" Socket Head Cap Screw........................................... 5 5 31918 503 1918.3 1-1/2" to 2" PVC-Coated Rigid Shoe .. 1 6 31916 503 1916.7 1-1/2" to 2" PVC-Coated Rigid Hook .. 1 7 53396 905 3396.8 3/4" x 1-1/2" Shoulder Screw.............. 3 8 00933 500 0933.8 Support Weldment, PVC-Coated Rigid Roller .................... 1 9 51353 905 1353.3 Retaining Ring .................................... 5 10 00923 500 0923.0 1/2" Roller Axle ................................... 1 11 00924 500 0924.9 3/4" Roller Axle ................................... 1 12 00925 500 0925.7 1" Roller Axle ...................................... 1 13 00926 500 0926.5 1-1/4" Roller Axle ................................ 1 14 00927 500 0927.3 1/2" Roller ........................................... 1 15 00928 500 0928.1 3/4" Roller ........................................... 1 16 00929 500 0929.0 1" Roller .............................................. 1 17 00930 500 0930.3 1-1/4" Roller ........................................ 1 18 54910 905 4910.4 Retaining Ring Pliers (not shown) ...... 1 19 23818 502 3818.3 Metal Storage Box (not shown) .......... 1 Optional Bending Attachments for 1/2" to 2" 40 Mil PVC-Coated Rigid (500 1700.4) Exploded View and Parts List

49 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Electrical Control System Layout and Parts List GREEN GREEN GREEN WHITE BLACK PGU BOARD BLACK RED YEL YEL RED BLACK RED BLACK BLACK WHITE I/O BOARD 7 1 3 18 19 2 21 22 4 5 23 6 10 9 12 20 11 13 8 26 14 17 27 27 24 15 28 16 Key Part No. Description 1 503 8941.6 PGU Power Wire 2 503 8250.0 Motor 3 503 8603.4 Power Cord 4 500 1708.0 Receptacle Unit 5 503 8636.0 Limit Switch Wire Unit 6 503 8637.9 Brake Wire Unit 7 503 8638.7 Unload Lock-Out Switch Unit 8 503 8639.5 Relay Wire Unit 9 503 8640.9 Red Relay Wire 10 503 8175.0 Black Relay Wire 11 503 8961.0 Red Relay–PGU Wire 12 503 8960.2 Black Relay–PGU Wire 13 503 8648.4 I/O–PGU Wire Unit 14 500 1741.1 I/O to Power Wire Unit Key Part No. Description 15 500 1707.1 Input/Output Control Unit 16 Directional Test Toggle Switch 17 Test Push Button Switch 18 503 8643.3 Yellow Rectifier Wires 19 503 8642.5 Red Rectifier Wire 20 503 8641.7 Black Rectifier Wire 21 503 8647.6 Transformer Unit 22 500 1084.0 Selector Switch Unit w/o knobs 23 503 8646.8 Optical Encoder 24 503 8902.5 Power Generation Board Assembly 26 Test Terminal (Troubleshooting) 27 905 4329.7 Screw, #8-18 x 3/8 Ground 28 918 6644.8 Support, I/O Board

50 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Power Generation Unit Parts List Greenlee No. Location Description Value Manufacturer Part No. – R1-R2 Resistor 4.7 KΩ / 1/4 w / 5% – – – R3, R5, R6, R8, R11, R12 Resistor 10 KΩ / 1/4 w / 5% – – – R4 Resistor 22 Ω / 1/4 w / 5% – – – R7 Resistor 68 KΩ / 1/4 w / 5% – – – R9 Resistor .04 Ω / 5 w / 1% Dale LVR-5 .04Ω – R13 Resistor 330 Ω / 1/4 w / 5% – – – R14 Resistor 4.7 KΩ / 10 w / 5% Dale CW-10 4.7K – R10, 21 Resistor 680 Ω / 1/4 w / 5% – – – R15-R18, R20 Varistor V15 0 LA 20A GE V150 LA20A – R19 Resistor 20kΩ / 2w / 1% Dale RS-2B-20K 918 6687.1 D1 Diode – Semikron SKR2F17 – D2, D6 Zener Diode IN4744-DO-41 Motorola IN 4744 – D3, D4 Diode IN914 Motorola IN 914 – D7 Diode IN 4007 Motorola IN 4007 – C1, C2 Capacitor 1mf / 50v Philips CY-30 C105M – C3 Capacitor 10mf / 250 VAC American 10mf / 20VAC – C4 Capacitor 330mf / 25v Nichicon 1E331MPA 918 6862.9 C5 Capacitor 1000mf / 250v Nichicon LLR2D 918 6688.0 K1 Relay T81H5D312-05 P & B T81H5D312-05 918 6645.6 Off Board Relay PRD-11DYO-12 P & B PRD-11DYU-12 – L1, L2 Inductor HL-8196 Hurricane HL-8196 – DSI LED LED T1-3/4 Green HP HLMP-3507 918 6690.1 U1 IC 4049 Motorola MC14049UBCP 918 6691.0 U2 OPTO-Isolator GN136N HP HCP4502 918 6692.8 U3, U4 IC LM393 Motorola LM393AN 918 5997.2 Off Board Rectifier GBPC3504 GI GBPC3504 918 6861.0 Q2 Mosfet IXFH40N30 IXYS IXFH40N30 – D1 Heat Sink – Wakefield 695-1 503 8270.5 Off Board Heat Sink – Greenlee – – J1 Connector – Beau 72503 – J2 Connector Mini-Fit Jr. Molex 39-28-1063-P – J3, J7 Connector Mini-Fit Jr. Molex 39-28-1023-P – J4 Connector – Beau 72502 – J5, J6 Connector Mini-Fit Jr. Molex 39-01-2020-P 918 6693.6 T1 Transistor 2N3904 Motorola 2N3904

51 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Power Generation Unit Schematic Diagram J3:2 2 J3:1 1 U1:E 4049 11 12 U1:B 4049 5 4 J5:1 1 J5:2 2 J7:2 2 J7:1 1 J4:1 1 J4:2 2 HP4502 U2 2 3 7 8 6 5 J2 5 4 3 2 1 6 VCC 330u/25V C4 1N914 D4 4.7K/10W R14 20K/2W R19 GRN DS1 L1 L2 C1 C2 C3 C6 C5 C4 U1:C 4049 7 6 U1:D 4049 9 10 VCC U4:A LM393NE 1 8 4 + 3 - 2 R13 330 C1 1u/50V R12 10K R8 10K R4 22 R7 68K R3 10K T1 2N3904 R1 4.7K R2 4.7K U1:F 4049 14 15 U1:A 4049 3 2 VCC +HV VCC 120vac U4:B LM393NE 7 + 5 - 6 L1 HURRICANE HL8196 R20 0vac L2 HURRICANE HL8196 R15 R16 R17 R18 C3 10uF/250VAC C5 1000u/250V D3 1N914 R10 680 R6 10K R5 10K VCC LM393NE U3:A - 2 + 3 4 8 1 J6:1 1 J6:2 2 C2 1u/50V R11 10K D2 1N4744 +HV SKR2F17 D1 Q2 IXFH40N30 .04/5W R9 1N4744 D6 A K J1:1 1 J1:2 2 J1:3 3 D7 1N4007 K A direction relay K1 8 1 INPUT(BLK) INPUT(RED) MOTOR + OUTPUT OUTPUT TO MOTOR - BLACK(-) RED(+) MFJ Molex MOTOR - -HV CONTROL DIRECTION GROUND NEUTRAL 120 VAC K2 DIRECTION CONTROL NOTE: Relay K2 mounted off-board. Mini-fit Jr. NOTE: Bridge rectifier mounted off-board. NOTE: Varistors are V150LA20A. NOTE: All resistors 1/4W unless noted. Mini-fit Jr. Molex TO MOTOR + R21 680

52 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Power Generation Board Layout Diagram D2 + R11 R9 D1 Q2 ANODE R14 C3 L2 R18 R17 + C5 C2 -HV +HV 120VAC 0VAC R19 DS1 J4 BLK (-) GREENLEE/ TEXTRON INC. RED (+) U3 U2 TO I/O J2 TO RELAY J3 K1 R15 J1 LINE NEUTRAL GND R20 R16 L1 + C4 D7 D6 1 2 7 12 11 U1 R13 U4 R8 R7 R12 R1 R5 R2 R4 R3 T1 R10 R6 D3 C1 + D4 1 1 2 3 6 5 4 R21

53 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Input/Output Board Parts List Serial Numbers ABT0000 through ABT1199 Reference Part Number Description Manufacturer U1, 12 74HC86N IC U2 74HC373 IC U3 93LC56 EEPROM Microchip only U4 9186832.7 EPROM, Programmed - 855M2 U5 SRAM-32Kx8; 35nS MAX. U6 ULN2068B Quad Driver U7 N80C196KB Microcontroller Intel only U9 HC4066 IC U10 DS1232 Watchdog IC Dallas Semi U11 74HC74 IC SW1 7101-SYCQE SPST Toggle Switch C&K or equal SW2 8121-SHCGE SPST/No Push MOM Switch C&K or equal C1,2 RPE110COG220J050V Capacitor 22pF Murata or equal C3-8,10-24, 29, 30, 32, 34, 35 RPE121X7R104K050V Capacitor, Decouple .1uF Murata or equal C9, 31, 33 CEUSM1E100 Capacitor 10uF/25V Marcon or equal C25, 26 158X474 Capacitor .47uF/250V Mallory C27, 28 CEUSM1E102 Capacitor 1000uF/25V Marcon or equal F1 313.250 Fuse .250A/250V Littlefuse 102071 Fuse Clip Littlefuse or equal VR1 MC7812CT Voltage Reg. 12V NAT./MOT. or equal VR2 MC7805CT Voltage Reg. 5V NAT./MOT. or equal 274-2AB VR Heat Sink/Hardware Wakefield or equal X1 10 MHZ XTAL HC-18 L1-12 521-9216 LED, RED T1 Dialight or equal L13 HL8146AB Inductor Hurricane Labs J1, 7, 9 39-28-1043 Connector, Minifit JR. 4 Molex J2, 3, 5, 8 39-28-1063 Connector, Minifit JR. 6 Molex J4, 6 39-28-1023 Connector, Minifit JR. 2 Molex P1 10-89-1103 Connector, Dual Row Molex D2, 3, 6-13 IN4001 Diode R1-6,10-15, 18,19, 23, 25, 26, 29, 49, 50 Resistor 10K 1/4W 5%CF R7, 30, 31, 36, 42 Resistor 2.2K 1/4W 5%CF R8, 9, 20, 22, 35, 38, 39 Resistor 1K 1/4W 5%CF R16, 40, 41, 44-47 Resistor 100 OHM 1/4W 5%CF R32, 43 Resistor 68 OHM 1/4W 5%CF R28, 37 Resistor 330 OHM 1/4W 5%CF R17, 24 Resistor 560 OHM 1/4W 5%CF R34 MDP1603-102G Resistor Pack Dip 1K Dale or equal R21, 33 4610X-101-103 Resistor Pack Sip 10K Bourns or equal R48 V150LA20A Varistor

54 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Input/Output Board Schematic Diagram IDC2X5M 6 7 8 9 1 0 SW2 SPST-MOM. PUSH C2 C1 SW1 SPST-ON/OFF TOG. C2 C1 B 10 A 11 C 12 B 9 A 8 C 6 B 3 A 4 C 5 +5V .1uF C35 U1:D 74HC86 11 13 12 VCC 14 GND 7 U10 DS1232 ST 7 RST 6 RST 5 VCC 8 GND 4 TOL 3 TD 2 P B RST 1 U11:B 74HC74 Q 8 Q 9 C LR 13 D 12 CLK 11 P RE 10 VCC 14 GND 7 U11:A 74HC74 Q 6 Q 5 C LR 1 D 2 CLK 3 P RE 4 ULN2068BI U6:A 4 1 4 1 2 3 ULN2068BI U6:B 5 9 8 6 ULN2068BI U6:D 1 3 1 16 15 ULN2068BI U6:C 1 2 9 10 11 U1:C 74HC86 8 10 9 U1:B 74HC86 6 5 4 10K R33 1 2 3 4 5 6 7 8 9 10 10K R14 U12:C 74HC86 8 10 9 VCC 14 GND 7 U12:D 74HC86 1 1 1 3 1 2 V C C 1 4 G N D 7 U1:A 74HC86 3 2 1 10K R3 10K R4 +5V .1uf C7 10K R10 +15V R32 68 D2 1N4001 R28 330 D3 1N4001 J3 MFJ6M 4 2 5 6 1 3 +12V R31 2.2k L8 C6 .1uf 10K R1 +15V +12V VR1 +12V LM7812CTB G 2 VI 1 VO 3 .1uF C29 .1uF C30 10u/25V C31 1000u/25V C28 1N4001 D12 .1uF C34 .1uF C32 +5V 10u/25V C33 VR2 +5V LM7805CTB G 2 VI 1 VO 3 V150LA20 R48 C26 .47u/250V C25 .47u/250V MFJ6M J8 6 3 5 2 4 1 1N4001 D11 1N4001 D13 1N4001 D10 1N4001 D9 1000u/25V C27 L13 F1 .25A/250V 2.2k R36 L9 .1uF C12 +12V L7 2.2k R30 1N4001 D6 +12V MFJ2M J4 1 2 +5V +12V L3 C9 10u/25v 100 R16 .1uF C10 U4 27C256 Q8 19 Q7 18 Q6 17 Q5 16 Q4 15 Q3 13 Q2 12 Q1 11 A14 27 A13 26 A12 2 A11 23 A10 21 A9 24 A8 25 A7 3 A6 4 A5 5 A4 6 A3 7 A2 8 A1 9 A0 10 G 22 E 20 VPP 1 VCC 28 GND 14 10K R6 10K R5 U3 93LC56 VSS 5 DO 4 DI 3 CLK 2 CS 1 VCC 8 NC 7 ORG 6 .1uf C3 +5V 10K R2 10K R25 +5V 10K R26 10K R23 10K R29 +5V +5V 20pf C1 20pf C2 10Mhz X1 TC55328-25PN U5 C E 20 A14 1 A13 26 A12 2 A11 23 A10 21 A9 24 A8 25 A7 3 A6 4 A5 5 A4 6 A3 7 A2 8 A1 9 A0 10 GND 14 VCC 28 WE 27 OE 22 I/O1 11 I/O2 12 I/O3 13 I/O4 15 I/O5 16 I/O6 17 I/O7 18 I/O8 19 74HC373 U2 GND 10 VCC 20 OC 1 C 11 1D 3 2D 4 3D 7 4D 8 5D 13 6D 14 7D 17 8D 18 1Q 2 2Q 5 3Q 6 4Q 9 5Q 12 6Q 15 7Q 16 8Q 19 C4 .1uf +5V C5 .1uf +5V U7 N80C196KB P2.2/EXINT 15 VREF 13 VPP 37 VCC 1 VSS 14 VSS 68 VSS 36 AGND 12 P2.7/T2CAP 38 P2.5/PWM 39 P2.4/T2RST 42 P2.1/RXD 17 P2.0/TXD 18 P1.7 32 P1.6 31 P1.5 30 P1.4 23 P1.2 21 P1.1 20 P1.0 19 NMI 3 P0.7/AIN7 9 P0.6/AIN6 8 P0.5/AIN5 10 P0.4/AIN4 11 P0.3/AIN3 4 P0.2/AIN2 7 P0.1/AIN1 5 P0.0/AIN0 6 READY 43 EA 2 BUSWIDTH 64 X2 66 HSI.3/HSO.5 27 HSI.2/HSO.4 26 HSO.3 35 HSO.2 34 HSO.1 29 HSO.0 28 HSI.1 25 HSI.0 24 RD 61 WR 40 INST 63 P4.7/AD15 45 P4.6/AD14 46 P4.5/AD13 47 P4.4/AD12 48 P4.3/AD11 49 P4.2/AD10 50 P4.1/AD9 51 P4.0/AD8 52 ALE 62 P3.7/AD7 53 P3.6/AD6 54 P3.5/AD5 55 P3.4/AD4 56 P3.3/AD3 57 P3.2/AD2 58 P3.1/AD1 59 P3.0/AD0 60 X1 67 CLKOUT 65 B HE 41 RESET 16 P2.6/T2UD 33 P2.3/T2CLK 44 P1.3 22 +5V J6 MFJ2M 2 1 R46 100 C16 .1uF +5V R40 100 R41 100 2 1 3 4 1K R34 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 R35 1K 5 4 3 2 1 R47 100 C24 .1uF C23 .1uF C21 .1uF C18 .1uF C15 .1uF C13 .1uF 10K R21 1 2 3 4 5 6 7 8 9 10 +5V MFJ6M J2 6 3 5 2 4 1 +5V C19 .1uF C20 .1uF R39 1k L12 1k R38 L11 R45 100 +5V R44 100 +5V L10 2.2k R42 +12V +12V +12V MFJ6M J5 6 3 5 2 4 1 1N4001 D8 330 R37 1N4001 D7 68 R43 +15V L4 1k R20 L5 1k R22 560 R17 560 R24 10K R13 10K R15 L2 R8 1k 10K R11 +5V 2.2k R7 C22 .1uF C17 .1uF C14 .1uF C11 .1uF 4066 U9:A GND 7 VCC 14 C 13 A 1 B 2 R9 1k 10K R12 L1 .1uF C8 +5V J1 2 1 3 4 +12V 10K R18 10K R19 +5V 74HC86 U12:A 1 2 3 74HC86 U12:B 4 5 6 10K R50 10K R49 2 1 3 4 J9 2 1 3 4 P1 TEST1 TEST2 WATCHDOG STROBE PENDANT/ Standard Deluxe PWM DIR EE.CLK/SCL EE.DO/SDA EE.DI EE.CS TEST OUTPUT TO PGU All capacitors are 50V unless noted. All resistors .25W unless noted. NOTES: GROUND LINE NEUTRAL Mini-Fit Jack BRAKE BRAKE T2CLK T2UD QUAD ENCODER DATA BUS ADDRESS BUS SW.TYPE.0 SW.TYPE.1 SW.TYPE.2 LOCKOUT PWM DIRECTION IBRAKE SW.SIZE.0 SW.SIZE.1 SW.SIZE.2 SW.SIZE.3 SW.SIZE.4 SW.SIZE.5 SW.HOME.1 SW.HOME.2 25 Mini-Fit Jack Unload Lockout SWITCHES Mini-Fit Jack HOME SWITCHES Dual Row Header SIGNAL OUT TO PGU DIR PWM HOME1 HOME2 QUAD2 QUAD1 Pendant 4 4 3 3 2 2 1 1 Term. Pin I/O Pin Deluxe Terminal Pend. Pin I/O Pin Standard Pendant 1 6 SCL SDA TXD RXD Pendant TERMINAL RXD/SDA TXD/SCL RESET TEST SWITCH 3 4 2 1 4 5 120 VAC 9186832.7 HSO.4 HSO.5 HSO.4 HSI.1 HSI.0 A15 A15 P0.7 P0.6 P0.5 P0.4 P0.3 P0.2 P0.1 P0.0 HSO.5 HSO.2 HSO.1 HSI.1 HSI.0 A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 A0 A3 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A2 A1 A0 D7 D6 D5 D4 D3 D2 D1 D0 D7 D6 D5 D4 D3 D2 D1 D0 D0 D1 D2 D3 D4 D5 D6 D7 D0 D1 D2 D3 D4 D5 D6 D7 A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 HSO.0 HSO.1 P0.5 P0.4 P0.3 P0.2 P0.1 P0.0 P0.7 P0.6 HSO.2

55 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Input/Output Board Layout Diagram 4 3 2 1 18 9 10 5001305.0 GREENLEE/TEXTRON INC. 1 1 1 GND +12V SDA SCL J9 1 2 3 4 REV. 0 J3 J5 STD DLX TERMINAL 4 3 2 1 PENDANT/ TRANSFORMER 5 TO PGU LOCKOUT HOME ENCODER BRAKE 6 4 1 5001706.3 TEXTRON INC. GREENLEE/ C27 + C31 TEST1 DIR PWM BRAKE QUAD 1 QUAD 2 HOME 1 HOME 2 J8 J2 J4 + C28 NEU LINE GND .25A/ 250V 1 2 1 3 4 5 6 2 1 2 3 4 1 2 1 2 3 4 5 6 C25 L13 VR1 VR2 C33 TEST2 SIGNAL TEST 1 4 6 5 C26 J7 J6 2 3 3 2 + J1 1 10 AC POWER SWITCHES Pendant Board Layout Diagram

56 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ .1 C4 C3 .1 VR1 7806 VO 3 G 2 VI 1 +5V LM78L05 VR2 VI 1 G 2 VO 3 .1 C6 C5 .1 10K RN1 8 7 6 5 4 3 2 1 3 8 2 4 5 6 7 9 10 1 +5V PCF8574 U1 G N D 8 V C C 1 6 P7 12 P6 11 P5 10 P4 9 P3 7 P2 6 P1 5 P0 4 A2 3 A1 2 A0 1 INT 13 SCL 14 SDA 15 SAA1064 U2 MPX1 11 MPX2 14 ADDR 1 P1 10 P2 9 P3 8 P4 7 P5 6 P6 5 P7 4 P8 3 P9 15 P10 16 P11 17 P12 18 P13 19 P14 20 P15 21 P16 22 GND 12 VCC 13 CEXT 2 SCL 24 SDA 23 MAN-6910 DS1 1 7 9 8 7 6 5 1 0 1 1 1 2 4 3 2 1 1 5 1 6 1 8 1 4 1 3 B A F P C G D E AN AN B A G F P C D E 47/.5watt R2 10K R3 +5V R1 10K +5V IDC1X4M P1 2 1 3 P4 4 +5V .1 C1 .0027 C2 +6V +6V +6V +6V SCL SDA J1 +12V GND Pendant Board Schematic Diagram and Parts List Reference Part Number Description Manufacturer U1 PCF8574P I.C. 16 Pin Dip Various U2 SAA1064 I.C. 24 Pin Dip Various P1 705-53-0003 4 Pin Right Angle Header Molex/Waldom J1 10 Pin .100" Right Angle Header Various C1, 3, 4, 5, 6 .1uF Decoupling Capacitor Various C2 .0027uF Capacitor Various R1, 3 10K .25W 5% Carbon Film Res Various R2 47 Ohms .5W 5% Carbon Film Various RN1 10K Resistor Network Various DS1 MAN-6910 Dual 7 Segment LED Display Various VR1 7806 +6V Reg. TO-220 Various VR2 78L05 +5V Reg. TO-92 Various

57 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ PROBLEM PROBABLE CAUSE POSSIBLE REMEDY Troubleshooting Bender will not operate. No voltage. Check supply voltage circuit operation. Check that switch is ON. Pendant not fully plugged in. Bender operates, but display Insufficient voltage. Use shorter or larger gauge is blank. extension cord. Check supply voltage (80 vac min.). Pendant was plugged in while Turn bender switch off and on. bender was on. Display comes on, but bender Bend angle already exceeds angle in CLEAR memory. BEND until display won’t bend. memory. counts. UNLOAD to desired position. Bender was advanced 93 degrees. UNLOAD to desired position. Display comes on but will not Bender turned on while conduit was Remove conduit and initialize count during bend. fully loaded. Home Position per operating instructions. Bender operates in wrong Wrong conduit size and/or type Set selector switches properly. direction. selected. Bends are overbent a few Wrong conduit size and/or type Set selector switches properly. degrees. selected. Too much squeeze on 1-1/2" or 2" Back squeeze off per adjustment EMT or IMC conduit. instructions. Unusual conduit characteristics. Use Accuracy Adjustment or bend to a smaller angle to compensate. Bends are underbent a few Wrong conduit size and/or type Set selector switches properly. degrees. selected. Too little squeeze on 1-1/2" or 2" EMT Increase squeeze per adjustment or IMC conduit. instructions. Unusual conduit characteristics. Use Accuracy Adjustment or bend to a larger angle to compensate.

58 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Troubleshooting (cont’d) PROBLEM PROBABLE CAUSE POSSIBLE REMEDY UNLOAD key does not work. Roller support locking cam is engaged. Release the roller support or adjust retension cam. Unloaded to the starting position. Release and repress UNLOAD. Locking cam will not engage. Too much squeeze on 1-1/2" or 2" EMT Back squeeze off per adjustment or IMC conduit. instructions. Shoe rotated too far in unload Rotate shoe with BEND key until direction. locking cam will engage. Bend key does not work for Roller support locking cam is engaged. Release the roller support or adjust 1/2 - 1-1/4" conduit. retention cam.

59 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ The following flow charts will show some of the most likely areas to look at for certain problems. They by no means encompass all the possible problems or the only possible solutions. Troubleshooting (cont’d) WILL BEND – WON’T COUNT NO YES Is bending shoe on in the proper orientation? Is 5 VDC measured across the center and right legs of the voltage regulator on the I/O board labeled VR2? Does bender count with different (good) pendant? Do both Quad 1 and Quad 2 LEDs light when bend or unload is pressed? YES YES NO YES NO YES NO When jog is pressed, does the bender continue to run slowly without stopping after 1/2 degree? YES Install shoe per instructions in this manual. Replace optical encoder. Replace pendant board. Replace or adjust limit switches or wire unit. NO NO Do Home 1 and Home 2 LEDs light when the shoe is run past the Start position? YES YES NO Is 12 VDC measured across center and right legs of VR1 on I/O board or does display light up when brake is unplugged? WILL BEND – DISPLAY BLANK Is at least 80 volts measured at the power cord? NO Find 120 VAC power source. Replace I/O board. Replace I/O board. Replace pendant board. Replace optical encoder. Replace I/O board. YES NO YES NO YES NO YES NO YES NO YES Replace transformer unit. Does bender work with different (good) pendant? Is fuse blown? Is 115 VAC measured at PGU board input? Do any of the 8 LEDs on the I/O board light? Turn switch off and then back on. Bad pendant board, bad pendant cord or plug inside pendant is unplugged. Bent pin connector in receptacle or bad recep- tacle unit? Replace fuse. Plugged into dead circuit, bad power cord, or switch is bad or off. YES Replace PGU. Was pendant plugged in after the bender was turned on? NO Are metal oxide varistors (MOVs) on PGU Board damaged or discolored? NO YES NO Does PWM LED light when BEND is pressed? Disconnect I/O-PGU cable on the I/O board and reconnect to test terminal. Disconnect brake wire unit. Restore power and push test switch. Does shoe move? (The toggle switch, lo- cated next to the push button switch, controls the direction the shoe moves.) Replace PGU. WON’T BEND – DISPLAY BLANK Replace receptacle. Replace PGU. NO YES Replace I/O board.

60 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ YES YES Troubleshooting (cont’d) YES Does bender work with different (good) pendant? Jump #2 & #4 termi- nals in pendant. Does bender run? Bad pendant board. Bad membrane switch. YES NO YES NO NO YES NO Replace I/O board. NO YES YES NO Does BEND work when set to 1-1/2" or 2" size? Does PWM LED light when BEND or UNLOAD is pressed? Can an angle be programmed? Is 100+ VDC measured at the motor leads when BEND or UNLOAD is pressed? Are all pin connections making con- tact on 6-wire cable connecting the I/O board to the PGU board? See Won’t Unload – Display On section Replace I/O board. Replace motor. Replace or repair the interconnecting cable. YES NO WON’T BEND – DISPLAY ON NO YES NO YES NO YES YES NO BENDER RUNS BACKWARDS FOR BEND & UNLOAD Rotary switch cable is backwards or rotary switch unit is bad. Select proper size. Is proper size of conduit selected? Does bender run backwards when using deluxe pendant or does bender run backward when a conduit size for the shoe not being used is selected? Are polarity of rectifier, relay and motor connections correct (see electrical control system layout diagram)? On 1-1/2" or 2" setting, does white motor lead receive positive voltage? Replace PGU. NO Replace I/O board. Disconnect I/O-PGU cable on the I/O board and reconnect to test terminal. Disconnect brake wire unit. Restore power and push test switch. Does shoe move? (The toggle switch, located next to the push button switch controls the direction the shoe moves.) Replace PGU. NO Replace I/O board. Disconnect I/O-PGU cable on the I/O board and reconnect to test terminal. Disconnect brake wire unit. Restore power and push test switch. Does shoe move? (The toggle switch, located next to the push button switch controls the direction the shoe moves.) Connect wires correctly. Motor is wired wrong internally.

61 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Troubleshooting (cont’d) WON’T UNLOAD – DISPLAY ON YES NO NO YES NO See Won’t Bend - Display On Section. Loosen cam mounting bolt and retighten while holding the outside washer so that the cam is oriented to 7 o'clock. Is the retention cam engaged with the roller support? Does the bender unload when the “LOCKOUT” plug is removed from the I/O board? Is the retention cam pointed to around the 7 o’clock position so that the ramp of the cam is not engaging the limit switch arm? YES Lower the roller support assembly. Remount the limit switch farther to the right, or bend the switch arm so that the dwell portion of the cam won’t actuate it. YES YES NO YES NO Are the proper support rollers and shoe groove being used for the type and size of conduit being bent? 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. Clean. NO NO YES NO YES YES Use 120 VAC. NO YES NO Replace pendant membrane switch. Does bender stop when the pen- dant is unplugged? Is the supply line voltage low? Replace PGU. NO YES NO On 1-1/2" or 2" size setting, is the DIR LED on the I/O Board on when BEND is pressed? Replace I/O board. Replace PGU. YES Replace 918 6645.6 relay. When DIR LED is on, is 12 VDC measured at large relay coil (where relay wire unit connects)? TRIPS CIRCUIT BREAKER WON’T STOP BENDER ONLY RUNS IN ONE DIRECTION

62 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070 855 Smart Bender™ Printed in the U.S.A. Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Drive, Rockford, IL 61109-2988 USA Customer Service (International): 815/397-7070 • Fax: 815/397-9247 Customer Service (North America): 800/435-0786 • Fax: 800/451-2632, 815/397-1865 Canada Fax: 800/524-2853 MAKES INACCURATE BENDS Press BEND to rotate shoe and stop it when the pendant displays between 1°-6°. Note the shoe position. Press BEND and con- tinue past 90°. Unload to angle first stopped at (between 1°-6°) without passing it. Note shoe position. Is shoe within 1° of first position stopped at? YES YES Consistently bends all sizes of one shoe a few degrees over or bends all the sizes a few degrees under. YES Adjust the limit switch for that shoe. YES Bender coasts to a stop. YES NO NO Replace optical encoder. No-load motor speed is greater than 4400 rpm. YES NO NO NO NO NO YES Indicates variations in the conduit. Use Accuracy Adjust- ment to compen- sate. Limit switch arm is bent or switch is mounted backwards. Adjust motor brake. Replace motor field. Replace I/O board. Replace optical encoder? Clean and tighten all ground connections at frame. Consistently underbends by a few degrees and can’t be ad- justed correctly. Bends some sizes of one shoe 1° or 2° over and other sizes of the same shoe 1° or 2° under. Isolate motor leads from cables that plug into the I/O board. Troubleshooting (cont’d) Are set screws tight in drive hub on optical encoder? Isolate motor leads from all cables that go to I/O board. Replace optical encoder. YES Consistently overbends by more than 5° and can’t be properly adjusted. NO NO Tighten to 22 inch- ounces torque. NO NO NO