855 Smart Bender 01711 Instruction Manual ABL

INSTRUCTION MANUAL
855
SMART BENDER™
and 01711 Optional Deluxe Pendant
Serial Code ABL
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

855 Smart Bender™
Table of Contents Description

Description ................................................................... 2 The 855 Smart Bender™ is designed to bend 1/2"
Safety ........................................................................... 2 through 2" EMT, IMC, rigid steel and rigid aluminum
conduit from 0 through 90 degrees. 1/2" through 2"
Purpose ........................................................................ 2 40 Mil PVC-coated rigid steel conduit can also be bent
Important Safety Information ................................... 3–4 with optional 01700 shoe group attachment. The Smart
Bender™ operates similar to other Greenlee electric
Grounding Instructions ................................................. 5
benders with the bending action accomplished through
Specifications ............................................................... 6 a rotating shoe with a hook and stationary roller conduit
Identification ................................................................. 7 supports.
Transportation .............................................................. 8 Note: This equipment has been tested and found to
comply with the limits for a Class A digital device,
Setup ............................................................................ 8 pursuant to Part 15 of the FCC Rules. These limits are
Operation designed to provide reasonable protection against
harmful interference when the equipment is operated in
Standard Pendant .............................................. 9–10 a commercial environment. This equipment generates,
Deluxe Pendant ................................................ 11–12 uses, and can radiate radio frequency energy and, if not
Installing and Bending Conduit ........................ 13–18 installed and used in accordance with the instruction
manual, may cause harmful interference to radio
Special Bending Information ................................ 19–27 communications. Operation of this equipment in a
Assembly for 40 Mil PVC-Coated residential area is likely to cause harmful interference in
Rigid Bending Accessories .................................... 28 which case the user will be required to correct the
interference at his own expense.
Adjustments ......................................................... 29–30
Do not make any modifications to this device.
Maintenance ........................................................ 30–31 Unauthorized changes or modifications will void the
Bender Head Disassembly .................................. 32–37 user’s authority to operate this device under United
Motor Disassembly .................................................... 37 States federal law.
Trunnion Disassembly ............................................... 38
Exploded Views, Parts Lists, Safety
Schematics and Wiring Diagrams ....................... 39–49
Safety is essential in the use and maintenance of
Troubleshooting ................................................... 50–62
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.
KEEP THIS MANUAL

Greenlee Textron / Subsidiary of Textron Inc. 2 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
855 Smart Bender™
IMPORTANT SAFETY INFORMATION
SAFETY
Electric shock hazard:
ALERT • Connect the power cord to a
120 volt, 20 amp receptacle on a
SYMBOL ground fault protected circuit only.
See Grounding Instructions.
This symbol is used to call your attention to
hazards or unsafe practices which could result in • Do not modify the power cord or
an injury or property damage. The signal word, plug.
defined below, indicates the severity of the hazard. • Inspect the power cord before
The message after the signal word provides use. Repair or replace the cord if
information for preventing or avoiding the hazard. damaged.
• Disconnect the unit from power
before servicing.
Failure to observe these warnings
Immediate hazards which, if not avoided, WILL can result in severe injury or death.
result in severe injury or death.
Hazards which, if not avoided, COULD result in • Do not expose to rain.

severe injury or death. • Do not use in wet or damp
locations.
• Do not immerse the pendant
switch in water or any other liquid.
Hazards or unsafe practices which, if not avoided, Failure to observe these warnings
MAY result in injury or property damage. can result in severe injury or death.
Read and understand all of the Wear eye protection when operating
instructions and safety information or servicing this tool.
in this manual before operating or Failure to wear eye protection can
servicing this tool. result in serious eye injury from
Failure to observe this warning can flying debris.
Do not remove guards.

Do not use this tool in a hazardous
Failure to observe this warning can
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
855 Smart Bender™
IMPORTANT SAFETY INFORMATION
Extension cords:
Do not use as a step or ladder.
• 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'). • Conduit moves rapidly as it is bent. The path of
the conduit must be clear of obstructions. Be
• Repair or replace damaged sure clearance is adequate before starting the
extension cords. bend.
Failure to observe these warnings • Inspect the bender before use. Replace worn,
can result in severe injury or death. 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
Pinch points: and type before bending.
Keep hands away from bending • Select the appropriate shoe groove and support
shoe, rollers and conduit when roller for the type and size of conduit before
bender is in use. bending.
Failure to observe this warning can • Do not bend conduit over 93 degrees. Over
result in severe injury or death. 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.
Unplug the bender before changing accessories. • Ensure that all bystanders are away from the
Accidental start-up can result in serious injury. 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
Do not operate the bender while wearing loose instructed in this manual can result in injury or
clothing. Loose clothing can get caught in moving property damage.
parts.
Failure to observe these precautions can result in
Failure to observe this warning can result in severe injury or property damage.
injury or death.
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
Electric shock hazard: least resistance is intended to reduce the risk of electric
• Do not modify the plug provided shock.
with the tool. This tool’s electric cord has a grounding conductor and
• Connect this tool to a grounded a grounding plug as shown. Do not modify the plug.
receptacle on a 20 amp GFCI- Connect the plug to a corresponding GFCI protected
protected circuit. receptacle that is properly installed and grounded in
accordance with all national and local codes and
Failure to observe these warnings ordinances.
can result in severe injury or death.
Do not use an adapter.
20 Amp/120 Volt
Plug and Receptacle
Plug Receptacle
855 Smart Bender™
Specifications
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.
Conduit Centerline Bending Radius

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
Bending head shown in the

horizontal bending table position.
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
855 Smart Bender™
Identification
4
1
11
3
14 9
5 19
7
10 15
17 6
18
8
4
16
855 Smart Bender™ 16 12 13
1. Bender power head 7. Support roller locking cam 13. Lockable storage area
2. Trunnion support frame 8. Support roller squeeze adjustment 14. Power switch/circuit breaker
3. 1-1/2" to 2" bending shoe 9. Transport handle 15. Pendant control receptacle
4. 1/2" to 1-1/4" bending shoe 10. Bender head pivot lock knob 16. Leveling jack screws
5. 1-1/2" to 2" support roller system 11. Shoe retaining lock ring 17. Lifting eyes
6. Support roller engagement handle 12. Open storage area 18. Conduit size selector switch
19. Conduit type selector switch
Features
The 855 bender is designed to make high quality bends • Programmable memory allows you to preselect a
of up to 90 degrees in 1/2" to 2" EMT, IMC, rigid steel, desired angle and automatically bend to that angle for
and rigid aluminum conduit. It incorporates a number of one or more bends.
features to make bending easier and faster.
• Programmable bend angle adjustment allows you to
• Four large wheels allow easy transportability. compensate for over-bending or under-bending conduit.
• Powerful motor and efficient gearbox can bend 2" rigid • Digital display gives accurate readout of actual bend or
in 11 seconds. programmed angle.
• Working height at waist level reduces need for the • Eccentric roller system squeeze adjustment allows
operator to bend over. easy adjustment for variations in conduit.
• All conduit bending can be done without changing • Removable pendant control prevents unauthorized use
shoes or rollers. of the bender.
• Conduit bending can be done in a vertical plane while • A lockable storage area is provided for the instruc-
keeping the conduit level or in a horizontal plane to tions, pendant control, etc.
allow making kicks and offsets.
• Lifting eyes are provided for easy hoisting.
• Simple roller system automatically adjusts to EMT or • Stubs, offsets, and saddles can be easily made. An
IMC conduit sizes.
optional deluxe hand terminal tells you where to make
• The zero position for bending is automatically set by the conduit marks for any type of common bend and
selecting the size and type of conduit to be bent prior bend to the proper angle.
to bending. • Standard bender is fully upgradable with the optional
• Bender automatically compensates for conduit spring- deluxe hand terminal.
back so you simply bend to the desired angle without
• Optional shoe group attachment for bending 1/2" to 2"
using charts.
40 Mil PVC-coated rigid steel conduit.
855 Smart Bender™
Transportation Setup
The only proper way to lift this bender is by attaching When you reach your destination, lower at least two
nylon or polyester slings or chain and hooks to the jackscrews to prevent the unit from rolling. If desired, all
lifting eyes. The bender head must be in the table-top four jackscrews can be used to level the unit. Rotate the
position as shown below with the 1-1/2" to 2" shoe up. bender head to the position you desire to bend in. To
Rotate the eyes up rotate the bender head, pull out the round pivot lock
so that the slings knob while pivoting the head in the desired direction.
or hooks can be If the knob is difficult to pull out, turn the knob clockwise
hooked to or until it pushes against the frame to break it free. When
looped through the the bender is in the desired position, make sure the
eyes. Make sure detent pin fully engages in the hole. To reduce the
that each side of amount of free play in the bender head, turn the knob
the sling or chain counterclockwise until some resistance is felt.
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
Remove the pendant control from its storage area and
clear the terrain.
plug it into the four-pin pendant receptacle on the side of
Pull out on the bender head pivot lock knob. If the pivot the bender power head. This must be plugged in
lock knob cannot be pulled out far enough for the detent before the bender is turned on or it will not operate.
pin to clear the frame, turn the knob clockwise until the Plug the power cord into a 120 VAC, 20 amp GFCI-
detent pin clears the frame. Rotate the bender head so protected receptacle and turn the power switch on. Wait
that the 1-1/2" to 2" shoe is up. Make sure that the until the display comes on before pressing any keys or
detent pin locks into position. Turn the pivot lock knob the bender will not operate.
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 CON
SIZE
DU500IT8896.7
DECAL NO.
IT TYPE
onto the stand. To take the bender off the stand, push
1-1/4
CONDU
NO. 500 1487.0
1
1-1/2
DECAL
3/4
M
RIGID ALU PVC 2
1/2
down on the lever below the crossbar and pull the IMC
EMT
bender toward you until it rolls off the stand.
r hopos isting
ting ey es fo ition
Use lif
with ben
ding hea
d in a hor
up
izontal
Lift only 2" side

1-1/2" and
with the
855 Smart Bender™
Operation — Standard Pendant
SIZE
DU500IT8896.7 D
CON
DECAL NO.
BEN
CONDU IT TYPE 1 1-1/4

NO. 500 1487.0 1-1/2
DECAL
3/4
RIGID ALU
M
PVC
2 JOG
1/2
IMC
EMT
AD
UNLO
LE
ANG T
C
SELE
LE
ANG T
C
SELE
AR
r hopos isting CLE
ting ey es fo ition
Use lif
with ben
ding hea
d in a hor
up
izontal
Lift only 2" side

1-1/2" and
with the
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
Set the type and size of conduit you will be bending memory, the display shows the stored angle at all times
with the rotary selector switches located on the side except while the BEND, JOG, or UNLOAD keys are
of the bender. depressed and for about 2 seconds after they are
released. The display will not show angles greater than
Failure to do so may result in the shoe rotating the 99 or less than 0.
opposite direction than expected.
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
Bend Key: runs the shoe in the direction to bend the for the size and type of conduit selected is at the bottom
conduit according to which conduit size has been (5 o’clock position). Press BEND until the pendant
selected by the rotary size selector switch. The BEND display changes from H. and starts counting. Then
key functions only while it is pressed. The BEND key press UNLOAD until the shoe rotates backwards and
ceases to function once it reaches the maximum shoe stops. This is the proper load position for the selected
travel or an angle stored in memory. size and type of conduit and home position is now set.
Jog Key: runs the shoe in the direction to bend the The display will show H. each time there is a change in
conduit according to which conduit size has been conduit type setting, a change in conduit size to the
selected by the rotary size selector switch in 1/2-degree other shoe, and when power to the bender has been
increments. The JOG key functions any time it is interrupted.
pressed until the maximum shoe travel is reached. Accuracy Adjust Mode: due to variations in conduit,
Unload Key: runs the shoe backwards according to you may notice the bender consistently over or under
which conduit size has been selected by the rotary size bending a particular size and type of conduit. The
selector switch. The UNLOAD key functions when it is accuracy adjustment mode allows programming correc-
pressed unless the roller support locking cam is locked tions for over and under bending conduit. Minus 9 to
in position. plus 9 degree adjustments can be made for each size
and type of conduit. Press and hold CLEAR, then press
Note: The shoes can rotate a restricted amount in the
and hold BEND until Pr is displayed. Release controls
bend direction. When the maximum has been reached, the
and adjust the degrees of bend by pressing the ANGLE
BEND and JOG keys will not function. Use the UNLOAD
SELECT up and down controls. ANGLE SELECT UP
key to rotate the shoes to the proper load position.
increases and ANGLE SELECT DOWN decreases the
Angle Select ▲ : is used to set the desired bend angle bend angle for the size and type of conduit selected by
into memory. Pressing it for a moment increases the the rotary selector switches. CLEAR resets the adjust
present angle in memory 1 degree at a time. Holding it angle to zero. Any adjust angle may be displayed by
down rapidly advances the memory angle. setting the rotary selector switches to the desired size
Angle Select ▼ : functions the same as the ANGLE and type of conduit. Press BEND to save the adjust
SELECT UP key except it decreases the angle. angle and exit the Adjust mode. Only changes to the
last displayed value will be saved. Changes saved are
Clear Key: sets the display to 00 and eliminates any to permanent memory in the bender and can only be
angle from memory. It will not reset the actual present changed by reprogramming. The pendant will display
bend angle to zero. oP for two seconds when the bender returns to the
normal operating mode.
855 Smart Bender™
Operation — Standard Pendant (cont’d)

Stub Up and Offset Bending Chart to determine CONDUIT SIZE 1/2 3/4 1 1-1/4 1-1/2 2
bending marks when using standard pendant.
DEDUCT 7-1/2 9 11 13-5/8 14-7/8 16-3/8
EMT
MINIMUM STUB 9-1/2 11 13 15-5/8 16-7/8 18-3/8
STUB IMC, RIGID DEDUCT 7-1/2 9 11 13-5/8 14-7/8 16-1/8
STUB LENGTH LENGTH
MARK & PVC 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

BENDING DEDUCT
MARK 1
BENDING
STUB LENGTH
MARK 1
Finished Angle
15° 30° 45°
STUB
LENGTH OFFSET MAX CENTER MAX CENTER MAX CENTER
MARK 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
BENDING
START OF BEND MARK 2 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
BENDING X 16 2 61-13/16 2 31-15/16 2 22-1/4
MARK 1 CENTER TO CENTER
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
START OF BEND 22 2 85 2 43-15/16 2 30-3/4
X
CEN BENDING
TE
BENDING R TO MARK 2
MARK 1 CE
NT
ER
855 Smart Bender™
Operation — Optional Deluxe Pendant

Enter all dimensions in inches, converting any fractions j. 00o to 99o (Bend angle is displayed when
to decimals using the Decimal Conversion Chart below. BEND is pressed and after the home switch has
been tripped.)
Decimal k. SET FRONT OF HOOK AT MARK 2 …
Conversion (This display is skipped for stubs.)
1=9 8
.84 1/16 .06 l. 00o to 99o
Mark 2 = 31.8 4 N
Mark 3 = 36.8R TO GO O 1/8 .12
MarkSS ENTE
PRE m. SET FRONT OF HOOK AT MARK 3 …
3/16 .18
(This display is skipped for stubs and offsets.)
1/4 .25
EMT RESET
JOG
BEND
5/16 .31 n. 00o to 99o
IMC
1/2 RIGID UNLO
AD
OFFSET
SADD
LE
3/8 .37 p. MARK 1 = … PRESS ENTER TO GO ON
3/4 STUB
9
7 8 7/16 .43 (The display will repeat the bend layout for
1 ANGL
E
5 6 duplicate bends.)
4 1/2 .50
1 1/4 HEIGH
T
2 3
TH
1 9/16 .56 3. Pressing any of the six conduit size keys at any
1 1/2 LENG ENTE
R
CLEAR• 0
ER 5/8 .62 point will set that size into memory and display the
2 NUMB
11/16 .68 SELECT CONDUIT TYPE screen.

3/4 .75 4. Pressing the conduit type key at any point will cycle
13/16 .81 through the conduit types in the order of EMT, IMC,
7/8 .87 RIG, ALM, PVC … etc. The pendant will then
15/16 .93 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
1. Upon power-up, the SELECT CONDUIT SIZE screen.
prompt will be displayed alone. 6. Pressing the ANGLE key at any point will display
2. The sequence of prompts or displays is: the SELECT ANGLE screen and allow changing of
a. SELECT CONDUIT SIZE the angle with the numerical keys, then press
ENTER. The ANGLE key does not need to be
b. SELECT CONDUIT TYPE pressed if SELECT ANGLE is already displayed.
c. SELECT TYPE OF BEND 7. Pressing the HEIGHT key at any point will display
d. SELECT ANGLE the SELECT HEIGHT screen and allow changing
of the height with the numerical keys and pressing
e. SELECT HEIGHT
ENTER. The HEIGHT key does not need to be
f. SELECT LENGTH (This prompt is skipped pressed if SELECT HEIGHT is already displayed.
when the bend type is a stub.)
8. Pressing the LENGTH key at any point will display
g. MARK 1= .... PRESS ENTER TO GO ON the SELECT LENGTH screen and allow changing of
h. SET FRONT OF HOOK AT MARK 1… the length with the numerical keys and pressing
ENTER, unless the bend type is a stub in which
i. SET HOME POSITION (This prompt is dis- case the LENGTH key will do nothing. The LENGTH
played when BEND is pressed and until the key does not need to be pressed if SELECT
home switch has been tripped for the size and LENGTH is already displayed.
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.)
855 Smart Bender™
Operation — Optional Deluxe Pendant (cont’d)

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

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
SIZE
CONDU IT TYPE
CON
1
DU500IT8896.7
DECAL NO.
1-1/4
1-1/2
choose the next type. The rotary selector switches have
NO. 500 1487.0
IMC
DECAL
RIGID ALU
M
PVC 1/2
3/4
2
no effect when the deluxe terminal is used.] If the
EMT
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
ting ey es fo r hopos isting
ition
selected is at the bottom (5 o’clock position). Press
Use lif ding hea
d in a hor
izontal
with ben
Lift only
with the
1-1/2" and
up
2" side
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
Set the type and size of conduit you will be bending in conduit size to the other shoe, [RESET key is
with the rotary selector switches located on the side pressed on the deluxe pendant], and when power to the
of the bender. bender has been interrupted. Home position can only be
set when the shoe rotates in the bend direction.
Failure to do so may result in the shoe rotating the
opposite direction than expected. 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
• Do not allow a bend or coupler to go over the shoe grooves for IMC and rigid (steel and aluminum)
roller supports. conduit use green hooks, and the optional shoes for
• Do not allow the trailing end of the conduit to go bending 40 Mil PVC-coated steel rigid conduit have
over the roller supports. black hooks. Insert the conduit into the proper shoe
Failure to observe these warnings can result in groove and hook. Align the bend location marks with the
severe injury or death. front of the hook. If you wish to side load the conduit,
rotate the shoe hook to the 5 o’clock position.
855 Smart Bender™
Operation — Installing and Bending Conduit (cont’d)

MANUAL BENDING 1-1/2" and 2" Rigid and 40 Mil PVC-Coated
Rigid Conduit
Make sure that no angle is set in memory. The memory
is clear if the pendant display shows 00 when BEND, Make sure that the rollers are in the fully retracted
UNLOAD or JOG are not depressed. If 00 is not position to the right.
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,
Press the BEND key while maintaining conduit align- release the BEND key. It might be beneficial to stop
ment until slack is taken up. When the conduit starts to slightly before the angle to account for reaction time and
bend, the digital display starts to count from zero and motor braking time and then use the JOG key to
show the angle to which the conduit has been bent. advance the bend in 1/2-degree increments to prevent
The angle displayed has already compensated for overbending.
springback. When you reach your desired angle, 1-1/2" and 2" EMT, IMC and Aluminum Rigid Conduit
release the BEND key. It might be beneficial to stop
slightly before the angle to account for reaction time and Note: For aluminum rigid conduit, set squeeze to
motor braking time and then use the JOG key to minimum position.
advance the bend in 1/2-degree increments to prevent Press or jog the BEND key while engaging the roller
overbending. system using the support roller engagement handle.
855 Smart Bender™

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

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

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

VARIATIONS OF TYPES OF BENDS Four-Bend Saddles
Offsets Located by the Second Bend To make a four-bend saddle, program it as a saddle and
bend it as two offsets. Enter the conduit size and type,
If you wish to make an offset where the location of the bend type (saddle), angle, height and length (from the
end of the second bend is desired rather than the start end of the conduit to the end of the second bend). The
of the first bend, then treat the bend as a saddle to dimensions will be displayed for three marks. Lay out
make your alignment marks and then bend it as an marks 1 and 2 in normal fashion. Place a third mark the
offset. First enter the conduit size and type, bend type distance shown for mark 3 from mark 1 (not mark 2 as
(saddle), angle, height and length (from the end of the usual). Place a fourth mark the distance of the desired
conduit to the desired end of the second bend) in the straight section from the third mark. Place a fifth mark
normal fashion. Dimensions will be displayed for three the distance shown for mark 2 from the fourth mark.
marks. Lay out the first two marks on the conduit and Press the OFFSET key and then press ENTER several
ignore the third. Press the OFFSET key and then press times until the display prompts you to set the conduit at
ENTER several times until the display prompts you to mark 1. Make your first bend here. Rotate the conduit
set the conduit at mark 1. Continue to make your offset 180 degrees and make your second bend starting at the
as previously instructed. second mark. Maintain alignment and make your first
bend of the second offset starting at your fourth mark.
U-Bends on Deluxe Pendant
Rotate the conduit 180 degrees and make the second
To make a two bend “U”, treat it as a 90˚ stub and bend of the second offset starting at your fifth mark.
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.
855 Smart Bender™
Special Bending Information

This section of the manual describes a means for laying Offsets (controlling the start of the first bend)
out the starting points for various types of bends. It will
give very accurate measurements for heights and bend START OF
FIRST BEND
angles commonly used.
Stubs
LENGTH
HEIGHT
ANGLE
HEIGHT
ANGLE
LENGTH – X L1
Y
BENDING BENDING
MARK 1 MARK 2
MARK
1. Go to the following chart which is for the size and 1. Subtract the X dimension for the size of conduit to
type of conduit you are to bend. be bent from the desired length.
2. Look down to the ANGLE column until you come to 2. Place your first mark this distance from the end of
the angle you want to bend to. the conduit.
3. Look at the numbers in the row preceded by Y and 3. Go to the following chart which is for the size and
pick the one that is directly under the height (H) you type of conduit you are to bend.
want.
4. Look down to the ANGLE column until you come to
4. Place a mark this distance from the end of the the angles you want to bend to.
conduit.
5. Look at the numbers in the row preceded by L1 and
5. Make your bend after positioning the front edge of pick the one that is directly under the height (H)
the hook on your mark. 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.
855 Smart Bender™
Special Bending Information (cont’d)

Offsets (controlling the end of the second bend) Three-Bend Saddle
LENGTH TO END OF SECOND BEND

LENGTH TO CENTER
HEIGHT
HEIGHT
ANGLE
ANGLE
LENGTH – Z LENGTH – Z L1 L2
L1
BENDING BENDING BENDING BENDING BENDING

MARK 1 MARK 2 MARK 1 MARK 2 MARK 3
1. Go to the following chart which is for the size and 1. Go to the following chart which is for the size and
type of conduit you are to bend. type of conduit you are to bend.
2. Look down the ANGLE column until you come to 2. Look down the ANGLE column until you come to
the angle you want to bend to. the angle you want to bend to.
3. Look at the numbers in the row preceded by Z and 3. Look at the numbers in the row preceded by Z and
pick the one that is directly under the height (H) you pick the one that is directly under the height (H) you
want. want.
4. Subtract this Z dimension from the desired length. 4. Subtract this Z dimension from the desired length.
5. Place your first mark this distance from the end of 5. Place your first mark this distance from the end of
the conduit. the conduit.
6. Look at the numbers in the row preceded by L1 and 6. Look at the numbers in the row preceded by L1 and
pick the one that is directly under the height (H) you pick the one that is directly under the height (H) you
want. want.
7. Place a second mark this distance from your first 7. Place a second mark this distance from your first
mark. mark.
8. Make your first bend after placing the front edge of 8. Look at the numbers in the row preceded by L2 and
the hook on the first mark and your second bend pick the one that is directly under the height (H) you
after placing the front edge of the hook on the want.
second mark.
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.
855 Smart Bender™
Special Bending Information (cont’d)

Four-Bend Saddle with Straight U-Bends
STRAIGHT LENGTH
LENGTH SECTION
HEIGHT
ANGLE
HEIGHT
L2 + STRAIGHT SECTION
LENGTH – Z L1 L1
BENDING BENDING BENDING BENDING

MARK 1 MARK 2 MARK 3 MARK 4
Y 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 BENDING BENDING
the angle you want to bend to. MARK 1 MARK 2
3. Look at the numbers in the row preceded by Z and
pick the one that is directly under the height (H) you 1. Go to the following chart which is for the size and
want. type of conduit you are to bend.
4. Subtract this Z dimension from the desired length. 2. Look down the ANGLE column until you come to 90
5. Place your first mark this distance from the end of degrees.
the conduit. 3. Look at the numbers in the row preceded by Y and
6. Look at the numbers in the row preceded by L1 and pick the one that is directly under the height (H) you
pick the one that is directly under the height (H) you want the length to be.
want. 4. Look at the numbers in the row preceded by L1 and
7. Place a second mark this distance from your first pick the one that is directly under the height (H) you
mark. want.
8. Look at the numbers in the row preceded by L2 and 5. Place a second mark this distance from your first
pick the one that is directly under the height (H) you mark.
want. 6. Make your first bend after placing the front edge of
9. Add this L2 value to the desired length of your the hook on the first mark and your second mark
straight section. and your second bend after placing the front edge
of the hook on the second mark.
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.
855 Smart Bender™
Special Bending Information Chart

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
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
855 Smart Bender™
Special Bending Information Chart (cont’d)

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
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
855 Smart Bender™

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
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
855 Smart Bender™

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
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
855 Smart Bender™

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
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
855 Smart Bender™

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
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
855 Smart Bender™
Assembly Instructions for 40 Mil PVC-Coated Rigid Bending Accessories

1. Disconnect power to the bender. 6. Remove the retaining ring securing the 1/2" to
1-1/4" shoe and remove the shoe.
2. Lock the bender power head in the vertical bending
position. 7. Mount the 1/2" to 1-1/4" PVC rigid bending shoe
onto the spindle and align the slot in the back side
3. Remove the retaining ring securing the 1-1/2" to 2"
of the shoe bore with the screw head on the spindle.
shoe with the retaining ring pliers provided.
Push the shoe onto the spindle until the two drive
4. Use both hands to secure the shoe and remove the lugs are fully engaged in the two drive holes.
1-1/2" to 2" shoe from the spindle. Replace the retaining ring.
5. Mount the 1-1/2" to 2" PVC rigid bending shoe onto 8. Remove the quick release pivot shaft securing the
the spindle. Align the slot in the back side of the 1/2" to 1-1/4" roller support unit and remove the
shoe bore with the screw head on the spindle and roller support.
push the shoe on the spindle until the three drive
9. Mount the 1/2" to 1-1/4" PVC rigid roller support and
lugs are fully engaged in the three drive holes.
replace the pivot shaft.
Replace the retaining ring.
10. Reinstall the standard bending shoes and roller
support unit in same sequence.
Align the slot in
the shoe bore with
the screw head
on the spindle.
855 Smart Bender™
SERVICE Adjustments
Squeeze
Proper squeeze adjustment for most 1-1/2" and 2" EMT
and IMC conduit is when the squeeze adjustment arm is
Disconnect power supply before
vertical (at middle hole). But variation in conduit can
servicing bender. Servicing to be
result in wrinkling or side marking of conduit. If wrinkling
done only by trained service
or excessive ovalness occurs, increase squeeze one
technician.
position (hole) counterclockwise. If loading conduit is
Failure to observe this warning can difficult or if excessive side marking occurs, decrease
result in severe injury or death. squeeze one position (hole) clockwise.
Accuracy
This section of the manual describes how to disas- If the accuracy of all sizes of conduit on one shoe is off
semble and replace parts in the Greenlee 855 Smart
in the same direction, the limit switch needs to be
Bender™. Parts must be ordered from Greenlee
adjusted. Individual adjustments specific to one size and
Textron. type of conduit should be made using the Accuracy
Service of this bender should only be done by qualified Adjust mode (see Operation — Standard Pendant).
personnel who are familiar with handling of electronic
To adjust the limit switches, first unplug the bender.
components. The 855 Smart Bender™ warranty will Remove the four screws that secure the top round
become void if unauthorized repairs are attempted or
guard and remove the guard to expose the two limit
non-specified parts are used in repairs. For information
switches. The top switch controls the 1-1/2" to 2" shoe.
on parts or repair procedures not shown in this docu- Loosen the two screws and move it to the right side of
ment, contact your nearest Authorized Greenlee
the bender as shown in the diagram below to prevent
Service Center or call 800-435-2932.
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
Less Bend
Adj. Screws
1/2" to 1-1/4"
Limit Switch
Adj. Screws
Less Bend
855 Smart Bender™
Adjustments (cont’d) Maintenance

Retention Cam Chain Lubrication
Loosen the screws securing the retention cam. With the Lubrication of the drive chain is recommended every
bender oriented in the vertical position, rotate the round six months (more often if used in dusty or corrosive
plate until the right side edge of the cam is pointed environments).
straight down or within 1/4" left of being straight down. 1. Disconnect power to unit.
Make sure both ends of the spring are engaged in the
holes of the cam and round plate. Tighten the screws 2. Remove the 1-1/2" to 2" shoe.
while holding the round plate in position with pliers to 3. Remove the lower front guard.
prevent it from rotating.
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
1/4" lubed. If the total play halfway between the sprockets is
more than 1", adjust the chain.
Check to make sure the roller support handle will fully
engage and retract without catching on the cam holding 1. Disconnect power to unit.
surface. This should be done in both the vertical and 2. Remove the 1-1/2" to 2" shoe.
horizontal bending positions. It should also be done with 3. Remove the front lower guard and the motor
the cam positioned as far left and as far right as friction cover.
will allow it to stay.
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.
Cam Holding
Surface 6. Tighten the two rear bolts.
Once everything is tightened down in the proper posi- 7. Replace the motor cover, guard and shoe.
tion, push in the limit switch trip arm. You should hear Brake
the switch click on. If not, loosen the two screws and
nuts and slide the switch to the right and retighten. Under normal circumstances the brake should not require
adjustment. However, if the brake can be heard dragging
Push the cam toward the switch to make sure any free while bending or if the braking performance deteriorates,
play will not trip the switch. brake adjustment may be necessary.
Tripping Surface
of Cam
Limit Do not touch the brake if the bender

Switch has been recently used. It will be
Arm
hot. Wait an hour for it to cool off
before adjusting.
1. Disconnect power to unit.

Rotate the cam until the switch trip arm rides up on top 2. Remove the motor cover.
of the tripping surface of the cam. You should hear the
switch click on. If not, move the switch to the left to a 3. Loosen the two set screws on the brake rotor hub
point where it does. You should hear the switch click off (the part that turns).
when the cam is released. If you cannot move the 4. Slide it to a position .002" to .015" away from the
switch enough to get it to trip properly, use needlenose mating face (about 1 to 3 page thicknesses of this
pliers to slightly bend the arm. manual).
5. Tighten the set screws to 4 Nm (35 in-lb).
6. Replace the motor cover.
855 Smart Bender™
Maintenance (cont’d)
Support Rollers Rear rollers: The rear rollers should be lubricated
Front rollers: The front rollers (1-1/2" to 2") should be every six months (more often if used in a dusty environ-
cleaned and lubricated every six months (more often if ment).
used in dusty environments). 1. Apply a motorcycle chain lubricant through the 1/8"
1. Disconnect power to unit. hole in each roller.
2. Remove the 1-1/2" to 2" shoe. 2. Rotate each roller to distribute the lubricant.
3. Detach the two springs from under the roller sup- 3. Wipe away excess lube.
ports. Motor
4. Remove the squeeze adjustment arm bolt and arm.
The motor commutator brushes should last for about
5. Remove the three bolts securing the pivot bushing 1000 hours of normal use but will eventually need to be
and remove the bushing. replaced.
2. Remove the motor cover.
3. Remove the power cord strain relief.
Use both hands to grab all four lead and tail rollers 4. Remove the two nuts securing the shroud to the tail
to prevent the assemblies from pivoting and pinch- of the motor and remove the shroud.
ing fingers.
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
6. Pull out the pivot shaft. 1/4".
7. Lift the roller assembly to the left and up to remove. 6. Reassemble in reverse order.
8. Loosen the 1-1/2" bushing set screw and pull out
the handle. Removing and Installing Shoes
9. Loosen the 2" bushing set screw and press out the 1. Disconnect power to unit.
pivot pin. 2. Remove the retaining ring securing the shoe to be
10. Remove the bolt and one retaining ring from the 2" removed with retaining ring pliers.
roller assembly and pull off the side plate. 3. Use both hands to hold onto both sides of the shoe
11. Remove the tail roller, center roller, shim (if used), and pull it off the spindle.
O-ring, pivot ball, split roller, spacer, split roller, 4. Assemble in reverse order, noting the following:
pivot ball and O-ring. Align the slot in the shoe bore with the screw head
12. Clean off all the grease and dirt. on the spindle.
13. Lubricate all working surfaces with molybdenum
Align the slot in
disulfide grease.
the shoe bore with
14. Slip one O-ring over each side plate. Replace with a the screw head
new one if cut, shaved or cracked. on the spindle.
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.
855 Smart Bender™
Bender Head Disassembly

Relay
1. Remove PGU subplate (follow instructions 1-10
above).
Disconnect power supply before
servicing bender. The bender head 2. Remove red and black relay wires (9) (10).
should be serviced/disassembled 3. Remove two screws, lockwashers and nuts, and
while on the trunnion base. remove relay.
Failure to observe this warning can 4. Assemble in reverse order.
Transformer
1. Remove four screws securing top round cover and
ELECTRONICS remove cover.
Power Generation Board (PGU) 2. Disconnect transformer from I/O board (21).
1. Remove four screws securing top round cover and 3. Remove two screws securing transformer.
remove cover. 4. Assemble in reverse order.
2. Disconnect ground jump wire, and the white, black,
and green leads of I/O-Power Wire Unit (14). Input/Output Board (I/O)
3. Disconnect power cord neutral (white) wire (3). 1. Remove four screws securing top cover and remove
cover.
4. Disconnect power lead (black) from switch (1).
2. Disconnect receptacle unit (4).
5. Disconnect PGU-I/O cable (13).
3. Disconnect selector switch (22).
6. Disconnect motor leads (2).
4. Disconnect unload lockout switch (7).
7. Disconnect red, black and two yellow wires to the
rectifier (18) (19) (20). 5. Disconnect limit switch (5).
8. Disconnect the red and black PGU-relay wires 6. Disconnect optical encoder (23).
(11) (12). 7. Disconnect brake wire (6).
9. Disconnect relay wire unit (8). 8. Disconnect PGU-I/O cable (13).
10. Remove four screws securing PGU subplate and 9. Disconnect transformer cable (21).
remove subplate.
10. Disconnect I/O-Power Wire Unit (14).
11. Remove two screws, lockwashers and nuts
11. Compress the locking tabs on the eight standoffs.
securing heat sink to subplate.
Pull the board just past the locking tabs until all
12. Compress the locking tabs on the four standoffs. eight are free, and remove the board completely.
Pull the PGU board just past the locking tabs until
12. Assemble in reverse order, noting proper polarity of
all four are free, and then remove the board com-
all wires as shown.
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.

855 Smart Bender™
Bender Head Disassembly (cont’d)

Rotary Selector Switches SHOES
Removing and Installing Shoes
2. Remove the retaining ring securing the shoe to be
removed with retaining ring pliers.
CONDU IT TYPE
CON
DECAL NO.
1
SIZE
DU500IT8896.7
1-1/4
3. Use both hands to hold onto both sides of the shoe
1-1/2
and pull it off the spindle.

NO. 500 1487.0
DECAL
3/4
M
RIGID ALU PVC
2
1/2
IMC
EMT
4. Assemble in reverse order, noting the following:

Align the slot in the shoe bore with the screw head
on the spindle.
r hopos isting
ting ey es fo ition
Use lif
with ben
ding hea
d in a hor
up
izontal
Lift only 2" side

1-1/2" and
with the
Align the slot in

the shoe bore with
the screw head
on the spindle.
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
SIZE
CONDUIT
DECAL NO.
500 8896.7
CONDU IT TYPE 1 1-1/4

NO. 500 1487.0 1-1/2
DECAL
3/4
RIG ID ALUM 2
PVC 1/2
IMC
EMT
r hopos isting
ting ey es fo ition
Use lif
with ben
ding hea
d in a hor
up
izontal
Lift only 2" side

1-1/2" and
with the

remove cover.
2. Unplug receptacle unit (4).
3. Remove two screws securing receptacle and
remove receptacle.
4. Reassemble in reverse order.
855 Smart Bender™
Bender Head Disassembly (cont’d) 95

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

16. Assemble 1-1/2" roller assembly in reverse order 7. Reassemble in reverse order noting the following:
noting the following: • With the bender oriented in the vertical position,
• Slip each O-ring over side plates until reassembly rotate the round plate (111) until the right side
is complete and then slip O-rings between rollers edge of the cam is pointed straight down or within
and pivot balls. 1/4" left of being straight down. Make sure both
• Clean and lubricate all mating surfaces with a ends of the spring are engaged in the holes of the
high quality grease. cam and round plate. Tighten the screw while
holding the round plate in position with pliers to
• Use Loctite 271 on hex head bolts (93). Torque prevent it from rotating.
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. 1/4"
1/2" to 1-1/4" Roller Support Unit (503 8199.7) • Check to make sure the roller support handle will
1. Remove pivot shaft. fully engage and retract without catching on the
cam holding surface. This should be done in both
2. Remove roller support. the vertical and horizontal bending positions. It
3. Lubricate roller axles through 1/8" holes in each should also be done with the cam positioned as
roller with a chain lubricant. far left and as far right as friction will allow it to
stay.
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.
Cam Holding
3. Remove one retaining ring on each roller axle.
Surface
4. Remove axles and rollers.
• Once everything is tightened down in the proper
5. Clean and lubricate all mating surfaces with a high position, push in the limit switch trip arm. You
quality grease. should hear the switch click on. If not, loosen the
6. Reassemble in reverse order. two screws and nuts (40 and 41) and slide the
switch to the right and retighten. Push the cam
RETENTION CAM towards the switch to make sure any free play will
not trip the switch. Rotate the cam until the switch
1. Remove bolt securing retention cam and remove
trip arm rides up on top of the tripping surface of
washer, spring, shaft, and cam (113) (111) (112)
the cam. You should hear the switch trip on. If not,
(109) (108).
move the switch to the left to a point where it
2. Remove switch cover screws and switch does. You should hear the switch click off when
cover (42) (38). the cam is released. If you cannot move the
3. Remove four screws securing top cover and remove switch enough to get it to trip properly, use
cover. needlenose pliers to slightly bend the arm.
4. Unplug unload lockout switch from I/O board.
Tripping Surface
5. Remove screws and nuts securing unload lock-out of Cam
switch.
6. Pull switch unit from bender. Limit
Note: Attach a wire or string to the lock-out switch at Switch
the I/O board to serve as a retrieval line to pull the new Arm
wire and plug up through the unit.
855 Smart Bender™

CHAIN 4. Reassemble in reverse order, noting the following:
If chain breaks, replace with new chain (905 4250.9) • Limit switch with red wires goes on top.
(not another Master Link). This is due to the high stress • Install top switch so that trip roller is as far left as
on the chain. The addition of a second Master Link will
possible, as viewed with the switch behind the
only weaken the chain further. If the Master Link breaks, bracket.
it can be replaced with a new Master Link (905 4251.7).
• Install bottom switch (black wires) with the trip
1. Remove four screws securing top cover and remove roller as far right as possible, as viewed with the
top cover. switch behind the bracket.
2. Remove 1-1/2" to 2" shoe (see shoe removal). • Temporarily install both shoes before installing
3. Remove seven screws securing front guard and chain.
remove guard. • Place 2" IMC in bender and rotate shoe until
4. Remove nine screws securing motor cover and conduit locks up against tail roller. (DO NOT raise
remove motor cover. support rollers as is normal for IMC.)
5. Rotate motor until chain master link is accessible at • Slide top limit switch until contacts trip and tighten
top of bender. in that position.
6. With the bender head in the horizontal position, • Place 1/2" rigid in bender and rotate shoe until
loosen the four bolts and nut securing the motor and conduit locks up against support roller.
turn the eccentric adjusting bolt to allow chain slack. • Slide bottom switch until contacts trip and tighten
7. Tap the motor toward the spindle to slack the chain, in that position.
taking care not to allow the encoder to contact the • Rotate spindle, checking that the limit switch trip
frame. bolts do not snag the trip rollers. Re-adjust
8. Remove cotter pins, master link and chain. bracket mounting if necessary.
9. Reassemble in reverse order, noting the following:
• Torque eccentric adjusting bolt to 81 Nm (60 ft-lb) 1-1/2" and 2"
while tightening two front bolts and nut to maintain Limit Switch
chain tension. Less Bend
Adj. Screws
• Use new master link and cotter pins. 1/2" to 1-1/4"
Limit Switch
SPINDLE Adj. Screws
1. Remove chain (see chain removal). Less Bend

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.
If the accuracy of all sizes of conduit on one shoe is
7. Remove spindle/sprocket. off in the same direction, the limit switch needs to be
8. Reassemble in reverse order. adjusted. To do so, first unplug the bender. Remove the
four screws that secure the top round guard and remove
LIMIT SWITCH BRACKET the guard to expose the two limit switches. The top
switch controls the 1-1/2" to 2" shoe. Loosen the two
1. Remove spindle (see spindle removal).
screws and move it to the right side of the bender
2. Remove four screws securing two limit switches and (as shown above) to prevent overbending. The bottom
remove switches. switch controls the 1/2" to 1-1/4" shoe. Loosen the two
3. Remove two screws securing bracket and remove screws and move it to the left side of the bender (as
bracket. 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.
855 Smart Bender™
Bender Head Disassembly (cont’d) Motor Disassembly

SQUEEZE ADJUSTMENTS 1. Remove optical encoder (see optical encoder
Proper squeeze adjustment for most 1-1/2" and 2" EMT removal).
and IMC conduit is when the squeeze adjustment arm 2. Remove chain (see chain removal).
(74) is vertical (at middle hole). But variation in conduit 3. Remove brake (see brake removal).
can result in wrinkling or side marking of conduit. If
wrinkling or excessive ovalness occurs, increase 4. Loosen motor sprocket set screws and remove
squeeze one position (hole) counterclockwise. If loading sprocket and key.
conduit is difficult or if excessive side marking occurs, 5. Disconnect motor leads at relay and the ground
decrease squeeze one position (hole) clockwise. wire.
BRAKE 6. Remove five motor mounting bolts and nut.
1. Remove eleven screws securing motor cover and 7. Remove motor.
remove cover. Note: Attach a wire or string to the motor leads at
2. Loosen two set screws securing brake rotor and the power generation board to serve as a retrieval
remove rotor. line to pull the new wire through the unit.
3. Remove power supply leads. 8. Assemble in reverse order.
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.
855 Smart Bender™
Trunnion Disassembly
1. Support entire weight of bender (approx. 500 lbs.) 2. Remove support tower on the rotary selector switch
at lifting eyes, but do not lift above floor. 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.
Bender head may rotate a bit when locking detent

pin is disengaged. Keep hands clear.
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.
Note: Lifting slings must attach to lifting mechanism b. Press out axle.
within the width boundaries of the bender to prevent c. Remove wheel and washers from each side.
the lifting eyes from sliding off once the retaining 8. Remove kickstand.
rings are removed.
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
CORRECT INCORRECT rotating the bender head back to one of its normal
positions.
855 Smart Bender™
Motor and Gearbox 22
Exploded View and Parts List

26
27
15
13 22
14
16
17 12
8A
9
23 21
18
19
2 8 20
1 11
23 10
4 7
3
25 6 UPC No.
24 Key 78-3310- Part No. Description
1 86705 918 6705.3 Commutator Brushes
5 2 86706 918 6706.1 Commutator Brush Retention Springs
1
3 86707 918 6707.0 Tail Housing
4 86708 918 6708.8 Brush Assembly Plate
2 5 86709 918 6709.6 Cord
6 39092 503 9092.9 Shroud
7 86710 918 6710.0 Magnet Housing
Bolt Tightening Sequence for Gearbox Cover
8 86711 918 6711.8 Armature
8A 86071 918 6071.7 Bearing
9 54348 905 4348.3 Belleville Washers
1 10 39073 503 9073.2 Rear Gear Housing
6 11 39074 503 9074.0 Gasket
12 39075 503 9075.9 Front Gear Housing
13 39076 503 9076.7 Output Gear Shaft
4 3
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
2 5 17 53323 905 3323.2 Wave Washer
18 39080 503 9080.5 3rd Reduction Pinion Shaft w/ BRGs
1. Torque gearbox bolts to 11/9 Nm (100/80 in-lb) 19 54248 905 4248.7 Belleville Washer
in sequence shown. 20 39081 503 9081.3 4th Reduction Pinion Shaft
2. Assemble all Belleville washers so that I.D.’s 21 39082 503 9082.1 Small Spacer
butt and O.D.’s contact bearings. 22 54043 905 4043.3 1/2-20 x 2-1/2 Screw
3. Tighten motor nuts (24) to 3/4 Nm (30/35 in-lb). 23 02298 500 2298.9 1/4-28 x 9-1/4" Stud
24 51705 905 1705.9 1/4-28 Hex Nut
4. Insert commutator brushes before connecting 25 50749 905 0749.5 1/4" Internal Tooth Lockwasher
push-on terminals.
26 07208 500 7208.0 Oil Seal
27 07209 500 7209.9 Oil Seal
855 Smart Bender™
1/2" to 1-1/4" Side Exploded View
19
232
43 Shoe Unit 1/2" to 1-1/4" consists

of 221, 222, 223, 224 and 225
223
225
222
206 224
26
23
213 5 225
221
205
206
204
See page 43 for parts list.
855 Smart Bender™
1-1/2" to 2" Side Exploded View
The Roller Support Unit

exploded view is on
the following page.
3
44 Shoe Unit 1-1/2" to 2" consists

of 224, 226, 227, 228 and 229
228
226
224 227
26
226
91
92
229
74
96
97
207
207
215
215
213
See page 43 for parts list.
855 Smart Bender™
1-1/2" to 2" Roller Support Unit (500 0574.0) Exploded View
95
118
89
73 82
105
98 85
83
104
104 95
84 71
72 80
115 117
79
81
79
117 76
80
88
93
86
99, 119
116
or 150
78
77 93
100*
77 Note: Torque
78 to 54 to 61 Nm
98 (40 to 45 ft-lb)
*Two required 116
87
94
75
93 151
101
90
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
UPC No. UPC No.
Key 78-3310- Part No. Description Qty. Key 78-3310- Part No. Description Qty.
3 38217 503 8217.9 Guard Weldment, Top Chain .............. 1 96 54242 905 4242.8 Screw, Cap 1/4-20 x .37 Btn Hd ......... 3
5 38232 503 8232.2 Guard Weldment, Motor ..................... 1 97 50224 905 0224.8 Screw, 5/16-18 x 1.00 Skt Hd ............. 1
7 38199 503 8199.7 Sppt Wldt, 1/2" to 1-1/4" RLR ............. 1 98 50881 905 0881.5 Screw, 1/4-28 x .25 Set ...................... 2
19 52397 905 2397.0 Pin, 1/2" to 1-1/4" Sprt Pvt .................. 1 99 53018 905 3918.4 Washer, 1.00 x 1.37 x .03 Shim ......... 1
23 51655 905 1655.9 Screw, #10-16 .50 Hex Hd ............... 31 100 54248 905 4248.7 Washer, Belleville 1.362 x .803 .......... 2
26 52501 905 2501.9 Ring, Rtng Truarc #5100-287 ............. 2 101 39440 503 9440.1 Washer, .62 x 2.00 x .06 Flat ............. 1
43 38780 503 8780.4 Shoe Unit, 1/2" to 1-1/4" ..................... 1 104 54243 905 4243.6 Spring, Extension .75 x 3.50 .............. 2
44 38148 503 8148.2 Shoe Unit, 1-1/2" to 2" ........................ 1 105 54252 905 4252.5 Clamp, Loop Type ............................... 1
71 38221 503 8221.7 Support Weldment, Roller .................. 1 115 38592 503 8592.5 Guide, Spring ...................................... 1
72 00528 500 0528.6 Support Weldment, 1-1/2" .................. 1 116 51130 905 1130.1 O-Ring, 1.50 x 1.62 x .062 .................. 2
73 00601 500 0601.0 Support Weldment, 2" ......................... 1 117 51537 905 1537.4 O-Ring, 1.75 x 1.87 x .062 .................. 2
74 38225 503 8225.0 Arm Weldment, Adjustment ................ 1 118 38657 503 8657.3 Shaft, 2 Middle Roller ......................... 1
75 00543 500 0543.0 Plate, 1-1/2" Outer Roller ................... 1 119 52644 905 2644.9 Washer, 1/32 Shim ............................. 1
76 00604 500 0604.5 Plate, 2" Outer Roller .......................... 1 150 52645 905 2645.7 Washer, 1/16 Shim ............................. 1
77 38254 503 8254.3 Split Rollers, 1-1/2 .............................. 2 151 53216 905 3216.3 Retaining Ring #5100-62 .................... 1
78 38264 503 8264.0 Ball, 1-1/2 ............................................ 2 204 53390 905 3390.9 Wheel .................................................. 2
79 38255 503 8255.1 Split Rollers, 2 ..................................... 2 205 38166 503 8166.0 Axle, Long ........................................... 1
80 38263 503 8263.2 Ball, 2 .................................................. 2 206 51528 905 1528.5 Ring, Retaining #5160-75 ................... 2
81 38262 503 8262.4 Spacer, 2 Roller .................................. 1 207 54237 905 4237.1 Screw, Flange 3/8-16 x 1.00 Hex ..... 16
82 00599 500 0599.5 Roller Unit, 2" ...................................... 1 213 38464 503 8464.3 Pad Weldment, Jack Bolt ................... 4
83 00493 500 0493.0 Shaft, 2" Rear Roller ........................... 1 215 54276 905 4276.2 Caster, 8 Swivel .................................. 2
84 38252 503 8252.7 Roller, 1-1/2 IMC ................................. 1 221 31710 503 1710.5 1/2" to 1-1/4" IMC, Rigid Hook ........... 1
85 38253 503 8253.5 Roller, 2 Tail ........................................ 1 223 31712 503 1712.1 1/2" to 1-1/4" EMT Hook ..................... 1
86 38260 503 8260.8 Shaft, 1-1/2 Pivot Roller ...................... 1 224 52479 905 2479.9 Drive Bolt, 1/2-13 x .62
87 32027 503 2027.0 Sleeve, 1-1/2 ....................................... 1 Socket Head Cap Screw ..................... 6
88 31728 503 1728.8 Shaft, 2 Pivot ....................................... 1 225 51088 905 1088.7 1/2" to 1-1/4" Hook Bolts,
3/8-16 x 1-1/4
89 38151 503 8151.2 Sleeve, 2 ............................................. 1 Socket Head Cap Screw ..................... 8
90 23258 502 3258.4 Grip ...................................................... 1 226 53396 905 3396.8 1-1/2, 2" Hook Shoulder Bolts,
91 38256 503 8256.0 Shaft, Eccentric ................................... 1 3/4 x 1-1/2 ........................................... 6
92 38251 503 8251.9 Sleeve, Adapter .................................. 1 228 31716 503 1716.4 1-1/2, 2" EMT Hook ............................ 1
93 50540 905 0540.9 Screw, 7/16-14 x 1.00 Hex Hd ........... 3 229 38779 503 8779.0 1-1/2, 2" IMC and Rigid Hook ............. 1
94 00860 500 0860.9 Shaft, 1-1/2" Support .......................... 1 232 54880 905 4880.9 Wrench, 5/16" Hex T-handle .............. 1
95 54819 905 4819.1 Retaining Ring #5100-87 .................... 2
855 Smart Bender™
Main Exploded View

223 225
43 23
3
26 7
224
10 34
27 16 30 31
29
58
225 19
17
221 18
36
13 233
52 51 20
60
50 55
59 15
5 20A
22
8 2 233
23
Power Cord 37 170 14, 28
209, 211, 212 15

6
15
18 21
202 49 48
47 33 25 206
45 46
207 53
220 11
201 12
208
205
218
206 213 230
57
216
217
57D 57E
Optional Kit
57B 215
57G
57F
57A 204
57H
57C
855 Smart Bender™
95
118
89
73 82
105
54 98 85
231 83
104
104 95
84 71
72 80
115 117
79
81
15 79
117 76
80 88
203 93
86
116 99, 119
78 or 150
207
77 93
100
77
78
98
116 Note: Torque
87 to 54 to 61 Nm
94 (40 to 45 ft-lb)
75
220 93 151 90
101
176
41
39
106
107 38
40 42
9
32
108 109
112
35 44 113
114
111
226
228
6
91
21
74
97 92 96
224 = Cam Repair Kit #500 7939.5
4C If the chain breaks, replace it with a new

23 4B chain — not another master link — due
to the high stress on the chain. The
26 addition of a second master link will only
4, 4A weaken the chain further. If the master
226 link breaks, replace it with a new master
link (905 4251.7).
229
855 Smart Bender™
Main Parts List
UPC No. UPC No.
2 01622 500 1622.9 Frame Weldment ................................ 1 47 86385 918 6385.6 Breaker, Circuit 20 Amp ..................... 1
3 38217 503 8217.9 Guard Weldment, Top Chain .............. 1 48 54619 905 4619.9 Screw, CAP #4-40 x .62 Skt ............... 2
4 38983 503 8983.1 Guard Assembly, Front Chain ............ 1 49 38646 503 8646.8 Encoder Unit, Optical .......................... 1
4A 38236 503 8236.5 Guard, Front ........................................ 1 50 50572 905 0572.7 Screw, Cap #8-32 x .50 Skt ................ 4
4B 38244 503 8244.6 Retainer ............................................... 1 51 86646 918 6646.4 Brake, Motor ....................................... 1
4C 50160 905 0160.8 Rivet, 3/16" Pop .................................. 2 52 38807 503 8807.0 Key, Brake ........................................... 1
5 38232 503 8232.2 Guard Weldment, Motor ..................... 1 53 54616 905 4616.4 Spacer, Round Plastic ........................ 2
6 01607 500 1607.5 Guard, Bottom ..................................... 1 54 54151 905 4151.0 Knob, Plastic w/Set Screw .................. 2
7 38199 503 8199.7 Sppt Wldt, 1/2" to 1-1/4" RLR ............. 1 55 54335 905 4335.1 Screw, Flng 1/4 x .37 Thd ................... 2
8 38250 503 8250.0 Drive Unit ............................................ 1 57 01648 500 1648.2 Switch, Pendant .................................. 1
9 01702 500 1702.0 Spindle Weldment, Main ..................... 1 57A 01305 500 1305.0 Board, Circuit ...................................... 1
10 38193 503 8193.8 Plate Weldment, Drive ........................ 1 57B 33476 503 3476.0 Cover ................................................... 1
11 54253 905 4253.3 Sprocket, #60 14T .............................. 1 57C 33472 503 3472.7 Housing, Lower ................................... 1
12 38267 503 8267.5 Key, Drive Sprocket ............................ 1 57D 38649 503 8649.2 Switch, Membrane .............................. 1
13 54255 905 4255.0 Bearing, Sleeve #48DU40 .................. 2 57E 34342 503 4342.4 Screw #4-20 ........................................ 3
14 54250 905 4250.9 Chain, #60 92P ................................... 1 57F 33580 503 3580.4 Screw #6-32 ........................................ 3
15 54462 905 4462.5 Ring, Rtng Truarc #5100-200 ............. 4 57G 01666 500 1666.0 Cord, Pendant ..................................... 1
16 38265 503 8265.9 Washer, Main Spindle ......................... 2 57H 38654 503 8654.9 Strip, Magnetic .................................... 1
17 38268 503 8268.3 Key, Shoe Drive .................................. 1 58 35012 503 5012.9 Screw, #4 x 1/2" Flat Head or
18 38457 503 8457.0 Plate, Hoist .......................................... 2 06683 500 6683.8 Rivet, Pop 3/32 ................................... 2
19 55204 905 5204.0 Pin, 1/2" to 1-1/4" Sprt Pvt .................. 1 59 51751 905 1751.2 Screw, Drive ........................................ 4
20 38257 503 8257.8 Spacer, Motor Mount .......................... 1 60 38868 503 8868.1 Nameplate ........................................... 1
20A 39488 503 9488.6 Spacer, Thin Motor Mount .................. 1 71 38221 503 8221.7 Support Weldment, Roller .................. 1
21 38228 503 8228.4 Locator Weldment, Eccentric .............. 1 72 00528 500 0528.6 Support Weldment, 1-1/2" .................. 1
22 54265 905 4256.8 Nut, 1/2-13 Lock .................................. 1 73 00601 500 0601.0 Support Weldment, 2" ......................... 1
23 51655 905 1655.9 Screw, #10-16 x .50 Hex Hd ............. 31 74 38225 503 8225.0 Arm Weldment, Adjustment ................ 1
25 53903 905 3903.6 Screw, Cap 1/2-13 x 1.00 ................... 4 75 00543 500 0543.0 Plate, 1-1/2" Outer Roller ................... 1
26 52501 905 2501.9 Ring, Rtng Truarc #5100-287 ............. 2 76 00604 500 0604.5 Plate, 2" Outer Roller .......................... 1
27 54345 905 4345.9 Screw, Set 1/2"-20 x .75 Socket ......... 1 77 38254 503 8254.3 Rol, 1-1/2 ............................................. 2
28 54251 905 4251.7 Link, Connecting #60 Chain ............... 1 78 38264 503 8264.0 Ball, 1-1/2 ............................................ 2
29 54240 905 4240.9 Screw, #6-32 x 1.00 Sltd Mch ............ 4 79 38255 503 8255.1 Rol, 2 ................................................... 2
30 38246 503 8246.2 Bracket, Limit Switch .......................... 1 80 38263 503 8263.2 Ball, 2 .................................................. 2
31 38248 503 8248.9 Back-Plate, Switch .............................. 2 81 38262 503 8262.4 Spacer, 2 Roller .................................. 1
32 50226 905 0226.4 Screw, 5/16-18 x 1.25 Sk. Cap ........... 2 82 00599 500 0599.5 Roller Unit, 2" ...................................... 1
33 52597 905 2597.3 Washer, Flat .56 x 1.37 x .109 ........... 4 83 00493 500 0493.0 Shaft, 2" Rear Roller ........................... 1
34 85822 918 5822.4 Switch, Limit #BZ-2RW822-A2 ........... 2 84 38252 503 8252.7 Roller, 1-1/2 I.M.C. .............................. 1
35 50645 905 0645.6 Nut, Hex 5/16-18 Reg Jam ................. 2 85 38253 503 8253.5 Roller, 2 Tail ........................................ 1
36 01708 500 1708.0 Receptacle Unit, Pendant ................... 1 86 38260 503 8260.8 Shaft, 1-1/2 Pivot Roller ...................... 1
37 54124 905 4124.3 Strain Relief ........................................ 1 87 32027 503 2027.0 Sleeve, 1-1/2 ....................................... 1
38 38546 503 8546.1 Cover, Switch ...................................... 1 88 31728 503 1728.8 Shaft, 2 Pivot ....................................... 1
39 38638 503 8638.7 Switch Unit, Unload Lckt ..................... 1 89 38151 503 8151.2 Sleeve, 2 ............................................. 1
40 54313 905 4313.0 Screw, Mach #2-56 x .75 .................... 2 90 23258 502 3258.4 Grip ...................................................... 1
41 54314 905 4314.9 Nut, Lock #2-56 Hex ........................... 2 91 38256 503 8256.0 Shaft, Eccentric ................................... 1
42 50763 905 0763.0 Screw, Mach #8-32 x .25 .................... 2 92 38251 503 8251.9 Sleeve, Adaptor .................................. 1
43 38780 503 8780.4 Shoe Unit, 1/2" to 1-1/4" ..................... 1 93 50540 905 0540.9 Screw, 7/16-14 x 1.00 Hex Hd ........... 3
44 38148 503 8148.2 Shoe Unit, 1-1/2" to 2" ........................ 1 94 00860 500 0860.9 Shaft, 1-1/2" Support .......................... 1
45 52203 905 2203.6 Screw, Mach #6-32 x .25 .................... 2 95 54819 905 4819.1 Retaining Ring #5100-87 .................... 2
46 29708 502 9708.2 Guard, Breaker Switch ........................ 1 96 54242 905 4242.8 Screw, Cap 1/4-20 x .37 Btn Hd ......... 3
855 Smart Bender™
Main Parts List (cont’d)
UPC No. UPC No.
97 50224 905 0224.8 Screw, 5/16-18 x 1.00 Skt Hd ............. 1 221 31710 503 1710.5 1/2" to 1-1/4" IMC, Rigid Hook ........... 1
98 50881 905 0881.5 Screw, 1/4-28 x .25 Set ...................... 2 223 31712 503 1712.1 1/2" to 1-1/4" EMT Hook ..................... 1
99 53018 905 3918.4 Washer, 1.00 x 1.37 x .03 Shim ......... 1 224 52479 905 2479.9 Drive Bolt, 1/2-13 x .62
100 54248 905 4248.7 Washer, Belleville 1.362 x .803 .......... 2 Socket Head Cap Screw ..................... 6
101 39440 503 9440.1 Washer, .62 x 2.00 x .06 Flat ............. 1 225 51088 905 1088.7 1/2" to 1-1/4" Hook Bolts,
3/8-16 x 1-1/4 Socket Head
104 54243 905 4243.6 Spring, Extension .75 x 3.50 .............. 2 Cap Screw ........................................... 8
105 54252 905 4252.5 Clamp, Loop Type ............................... 1 226 53396 905 3396.8 1-1/2, 2" Hook Shoulder Bolts,
106 52108 905 2108.0 Nut, Hex 1/4-20 ................................... 1 3/4 x 1-1/2 ........................................... 6
107 54239 905 4239.8 Screw, 1/4-20 x 3/4 Ovl Pt Set ........... 1 228 31716 503 1716.4 1-1/2, 2" EMT Hook ............................ 1
108 39851 503 9851.2 Cam, Retention ................................... 1 229 38779 503 8779.0 1-1/2, 2" IMC & Rigid Hook ................ 1
109 38463 503 8463.5 Shaft, Cam Retention ......................... 1 231 01084 500 1084.0 Selector Switch Unit w/o Knobs ......... 1
111 38544 503 8544.5 Plate, Cam Retention .......................... 1 232 54880 905 4880.9 Wrench, 5/16" Hex T-handle .............. 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 Decals (not shown)
114 50458 905 0458.5 Rollpin, 1/8 x .375 ............................... 1 38893 503 8893.2 Decal, Lifting Eye ................................ 1
115 38592 503 8592.5 Guide, Spring ...................................... 1 38894 503 8894.0 Decal, Kickstand ................................. 1
116 51130 905 1130.1 O-Ring, 1.50 x 1.62 x .062 .................. 2 01445 500 1445.5 Decal, Deluxe Pendant Instr. .............. 1
117 51537 905 1537.4 O-Ring, 1.75 x 1.87 x .062 .................. 2 38896 503 8896.7 Decal, Slct Switch Size ....................... 1
118 38657 503 8657.3 Shaft, 2 Middle Roller ......................... 1 01487 500 1487.0 Decal, Slct Switch Type ...................... 1
119 52644 905 2644.9 Washer, 1/32 Shim ............................. 1 38898 503 8898.3 Decal, Bender Pivot Lock ................... 1
150 52645 905 2645.7 Washer, 1/16 Shim ............................. 1 38899 503 8899.1 Decal, Roller Adjustment .................... 1
151 53216 905 3216.3 Retaining Ring .................................... 1 02263 500 2263.6 Decal, Roller Engagement .................. 1
170 86263 918 6263.9 Nut, 1/2" Conduit Lock ........................ 1 01568 500 1568.0 Decal, Operation ................................. 3
176 54911 905 4911.2 Screw, 1/4-28 x 3/8" Skt. Hd. Cap ...... 2 38974 503 8974.2 Decal, Circuit Breaker ......................... 1
201 38141 503 8141.5 Base Weldment, Trunnion .................. 1 01453 500 1453.6 Decal, Shoe Orientation ..................... 2
202 38157 503 8157.1 Tower Weldment, L.H. Trunnion ........ 1 07248 500 7248.6 Decal, Extension Cord ........................ 1
203 38161 503 8161.0 Tower Weldment, R.H. Trunnion ........ 1 999 3576.7 Decal, Technical Assistance ............... 1
204 53390 905 3390.9 Wheel .................................................. 2
205 38166 503 8166.0 Axle, Long ........................................... 1 Optional
206 51528 905 1528.5 Ring, Retaining #5160-75 ................... 2 216 38743 503 8743.0 Stand, Anti-Movement ........................ 1
207 54237 905 4237.1 Screw, Flange 3/8-16 x 1.00 Hx ....... 16 217 31732 503 1732.6 Pin, Pivot ............................................. 1
208 52646 905 2646.5 Nut, 3/8-16 Esna Hex ......................... 4 218 50881 905 0881.5 Screw, 1/4-28 x .250 Skt Set .............. 1
209 38167 503 8167.9 Pin, Trunnion Lock .............................. 1 230 54297 905 4297.5 Spring .................................................. 1
211 54244 905 4244.4 Spring, Trunnion Lock ......................... 1 01711 500 1711.0 Deluxe Pendant Control
212 38168 503 8168.7 Knob .................................................... 1 38962 503 8962.9 Vinyl Cover (not shown)
213 38464 503 8464.3 Pad Weldment, Jack Bolt ................... 4 01700 500 1700.4 1/2" to 2" PVC Shoe Group
215 54276 905 4276.2 Caster, Swivel ..................................... 2
220 38156 503 8156.3 Block, Reinforcement .......................... 2 Service Only
233 05586 500 5586.0 Frame Unit (includes bearings) .......... 1
500 7939.5 Cam Repair Kit .................................... 1
855 Smart Bender™
Optional Bending Attachments for 1/2" to 2" 40 Mil PVC-Coated Rigid

(500 1700.4) Exploded View and Parts List
4
4
3
5
2
6
7
14
UPC No.
15 Key 78-3310- Part No. Description Qty.
16 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-
10 Coated Rigid (includes items 4–7) ..... 1
00934 500 0934.6 Support Unit, 1/2" to 1-1/4" PVC-
11 Coated Rigid (includes items 8–17) ... 1
1 00567 500 0567.7 1/2" to 1-1/4" PVC-Coated
Rigid Shoe ........................................... 1
12
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
13
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
17 11 00924 500 0924.9 3/4" Roller Axle ................................... 1
9
8 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
855 Smart Bender™
Electrical Control System Layout and Parts List
GREEN
2 GREEN 16
18 19 27
21
3
YEL
GREEN
WHITE YEL 4
BLACK RED I/O BOARD
BLACK AC K
1 20 BL TE
WHI
27
17
RED BL ACK
22
RED
PGU BOARD
BLACK
8 11 9 10
24 12
14 26 6 23 5 7 15 28
13
Key Part No. Description Key Part No. Description

1 503 8941.6 PGU Power Wire 15 500 1707.1 Input/Output Control Unit
2 503 8250.0 Motor 16 Directional Test Toggle Switch
3 503 8603.4 Power Cord 17 Test Push Button Switch
4 500 1708.0 Receptacle Unit 18 503 8643.3 Yellow Rectifier Wires
5 503 8636.0 Limit Switch Wire Unit 19 503 8642.5 Red Rectifier Wire
6 503 8637.9 Brake Wire Unit 20 503 8641.7 Black Rectifier Wire
7 503 8638.7 Unload Lock-Out Switch Unit 21 503 8647.6 Transformer Unit
8 503 8639.5 Relay Wire Unit 22 500 1084.0 Selector Switch Unit w/o knobs
9 503 8640.9 Red Relay Wire 23 503 8646.8 Optical Encoder
10 503 8175.0 Black Relay Wire 24 503 8902.5 Power Generation Board Assembly
11 503 8961.0 Red Relay–PGU Wire 26 Test Terminal (Troubleshooting)
12 503 8960.2 Black Relay–PGU Wire 27 905 4329.7 Screw, #8-18 x 3/8 Ground
13 503 8648.4 I/O–PGU Wire Unit 28 918 6644.8 Support, I/O Board
14 500 1741.1 I/O to Power Wire Unit
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
Molex
MFJ
J3:2
2
DIRECTION
1
CONTROL VCC
J3:1 1N4007
K A
D7 C1
K1 1
6 U1:A 1u/50V
J2 5 3 2
4 direction relay
3 4049
2 U1:E MOTOR +
1 11 12 INPUT(RED) OUTPUT
+HV
J7:1 TO MOTOR +
Molex 4049 RED(+) 1 C2 J5:1
Mini-fit Jr. U1:C 1 C1 1
R1 7 6 C3
Greenlee Textron / Subsidiary of Textron Inc.

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

855 Smart Bender™
Power Generation Board Layout Diagram
R21 U3 U2 TO I/O J1 LINE NEUTRAL GND
R10
1 12
R6
R5
6 5 4
2 11
D3
R13 1 2 3
+ J2
R12 K1
TO RELAY 7
R1 U1 C1
U4 J3 R15 R20
R8 1
R3
R4
R2
D7
D4 D6
T1
R16
R7
C4
+
L1 L2
D2
C2
+
R11
R9
R14
D1
Q2
C3
ANODE R18
GREENLEE/
TEXTRON INC. R19
R17
+
C5
DS1
J4
BLK (-) RED (+) -HV +HV 120VAC 0VAC
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
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
DATA BUS
20pf
U4 9186832.7
U5
U2 1
C1 VPP
20
+5V 1 27 CE A15 20
11 OC 22 WE 22 E
U7 C OE G
X1
3
10Mhz
67 60 D0 D0 3 2 A0 10 A0 A0 10
X1 P3.0/AD0 1D 1Q A0 A0
59 D1 D1 4 5 A1 9 A1 A1 9
C2 P3.1/AD1 2D 2Q A1 A1
20pf 66 58 D2 D2 7 6 A2 8 A2 A2 8
X2 P3.2/AD2 3D 3Q A2 A2
57 D3 D3 8 9 A3 7 A3 A3 7
U1:A
P3.3/AD3 4D 4Q A3 A3
.1uf 64 56 D4 D4 13 12 A4 6 A4 A4 6
BUSWIDTH P3.4/AD4 5D 5Q A4 A4
74HC86
55 D5 D5 14 15 A5 5 A5 A5 5
P3.5/AD5 6D 6Q A5 1 2 A5
2 54 D6 D6 17 16 A6 4 A6 A6 4
C3 EA P3.6/AD6 +5V 7D 7Q A6 A6
53 D7 D7 18 19 A7 3 A7 A7 3
P3.7/AD7 8D 8Q A7 A7
U3 16 25 A8 A8 25
RE S E T A8 A8
1 8 10K 62 74HC373 24 A9 A9 24
CS VCC R1 ALE A9 A9
2 7 43 20 10 21 A10 A10 21
CLK NC READY VCC GND A10 A10
3 6 52 A8 23 A11 A11 23
DI ORG P4.0/AD8 A11 A11
4 5 P0.0 6 51 A9 2 A12 A12 2
DO VSS P0.0/AIN0 P4.1/AD9 A12 A12
P0.1 5 50 A10 .1uf 26 A13 A13 26
P0.1/AIN1 P4.2/AD10 C4 A13 A13
93LC56 P0.2 7 49 A11 1 A14 A14 27
P0.2/AIN2 P4.3/AD11 A14 A14
P0.3 4 48 A12 A15
P0.3/AIN3 P4.4/AD12
P0.4 11 47 A13 D0 11 11 D0
P0.4/AIN4 P4.5/AD13 I/O1 Q1
P0.5 10 46 A14 D1 12 12 D1
R3
R4
R5
R6
P0.5/AIN5 P4.6/AD14 I/O2 Q2
P0.6 8 45 A15 D2 13 13 D2
P0.6/AIN6 P4.7/AD15 I/O3 Q3
P0.7 9 D3 15 15 D3
P0.7/AIN7 I/O4 Q4
63 D4 16 16 D4
10K
10K
10K
10K
10K R2 INST I/O5 Q5
3 D5 17 17 D5
NMI I/O6 Q6
41 D6 18 +5V 18 D6
BHE I/O7 Q7
19 D7 19 19 D7
P1.0 I/O8 Q8
20 40
P1.1 WR
21 TC55328-25PN 27C256
P1.2
22 61 28 28 14
P1.3 RD VCC VCC GND
EE.CLK/SCL 23 14
P1.4 GND
+5V
EE.DO/SDA 30 65 ADDRESS BUS
P1.5 CLKOUT
EE.DI 31 .1uf
P1.6 C5
EE.CS 32
P1.7 C6
24 HSI.0
HSI.0
18 25 HSI.1
P2.0/TXD HSI.1
17 28 HSO.0
.1uf
P2.1/RXD HSO.0
15 29 HSO.1
P2.2/EXINT HSO.1
44 34 HSO.2 +12V
+5V P2.3/T2CLK HSO.2
42 35
P2.4/T2RST HSO.3 +5V
39 26 HSO.4 +5V
P2.5/PWM HSI.2/HSO.4
33 27 HSO.5
P2.6/T2UD HSI.3/HSO.5 R7 2.2k Deluxe
38 1 Standard Pendant
P2.7/T2CAP U6:A 4 Pendant
12 13 1 TEST1 1k 1k
AGND VREF
3 2
.1uf
R8 R9 L1
36 ULN2068BI L2
VSS L3
R10 4 R11 R12
C7
68 37
10K VSS VPP 10K 10K
14 1 4
VSS VCC
R13 6 4066

10K
5 Deluxe Terminal
N80C196KB 74HC86 12
C +12V I/O Pin Term. Pin
U1:B SDA 11 10
A B
R14
10K
1 6
WATCHDOG STROBE
PENDANT/
100
R16
R15 6 TERMINAL
10K C 2 1
RXD 8 9
A B TXD/SCL 4 2 3 4
RESET
5 4 5
C RXD/SDA 3 1
TXD 4 3
A B
13 J1
U10 C Standard Pendant
SCL 1 2
1 8 A B
+5V P B RS T VCC I/O Pin Pend. Pin
2 7 +5V
C9
TD ST U9:A
3 6 1 1
TOL RST 14 7
4 5 VCC GND
U11:A GND RST 2 2
C8
+5V
T2CLK
10K
10K
10u/25v
10 5 4 DS1232 .1uF 3 3
Q P RE
9 3 4 4
CLK R17 +5V
8 6 2
Q D
7 1 U11:B
C LR QUAD ENCODER 560
6
T2UD
R18
R19
5 74HC74 9 10 MFJ6M L4
Q P RE R20
4 U1:C 11 3 6 QUAD2
CLK
3 9 8 12
Q D 1k
2 8 13 2 5
1 10 C LR L5
R22 +15V
74HC74 1 4 QUAD1
R21 74HC86 7 14
10K
Input/Output Board Schematic Diagram
+5V GND VCC 1k

.1uF J2
R23 R24 +12V
54
+5V
10K
HSO.4
HSO.5
C10 560
HSI.0
HSI.1
HSO.1
HSO.2
U1:D R25 10K TEST SWITCH TEST OUTPUT
R49 R28
12 10K R26
855 Smart Bender™
TO PGU
D2
11 10K +12V
13 R50 10K 10K SW1 330 MFJ6M
10 C1 C2 3 6
74HC86 9
R29
BRAKE SPST-ON/OFF TOG. D3
10K
7 14 8 2 5
1N4001
GND VCC R30

7 SW2
SW.SIZE.0
.1uF 6 C1 C2 1N4001 1 4
25 5 2.2k
+5V
L7 SPST-MOM. PUSH
P0.0 SW.SIZE.1
P0.1 SW.SIZE.2
P0.2 SW.SIZE.3
P0.3 SW.SIZE.4
P0.4 SW.SIZE.5
P0.5 SW.HOME.1
P0.6 SW.HOME.2
P0.7
C35 4 J3
+5V 2
PWM
3 +12V
LOCKOUT
IBRAKE
SW.TYPE.1
SW.TYPE.0
SW.TYPE.2
BRAKE
DIRECTION
2 L8 R31 R32
R34 1
J4
1 16
MFJ2M
2.2k 68
D6
2 15 R33 U12:C Mini-Fit Jack TEST2

3 14 9 U6:B 9 1
1N4001
4 13 8 6 8
5 12 10
6 11 ULN2068BI
C11
.1uF
7 10 74HC86 5
8 9 14 7
R35 VCC GND
1K C12
1K 6 3
.1uF
C13 +15V
U12:B U12:A
C14
.1uF
74HC86 74HC86
.1uF 1 +12V
+12V
1 7
+5V 4 5 1 2 +5V
C15 G
N U6:C DIR
V 9 SIGNAL OUT
D L9 R36 R37
C 11 10
C16
.1uF
C TO PGU
U12:D
D7
.1uF
74HC86
C17
2.2k 330 MFJ6M
.1uF
1 1 ULN2068BI
1 1 DIR 3 6
C18 2 3 4 2
D8 2 5
1N4001
.1uF +12V
+5V
1k
1k
1N4001 PWM 1 4
R38
C19
C20
R39
100
100
.1uF
.1uF
C21 J5
U6:D
C22
.1uF
1
R42 R43
100
100
R44
R45
15 16 L10
100
R46
.1uF
L12
R41
R40
L11
C23 ULN2068BI 2.2k 68
PWM
1
C24
.1uF
3
.1uF
100
R47
HOME1 HOME2
+15V
1 MFJ2M
3 4
1 2 3 4 5 6 7 8 9 0 1 2
HOME D9 1N4001
P1 J6 SWITCHES
Mini-Fit Jack Mini-Fit Jack
1 2 D10 1N4001 +5V
Unload Lockout
IDC2X5M
SWITCHES
Dual Row Header L13
MFJ6M
F1 1N4001 D12
LINE 6 3 D11
+12V 1N4001
.25A/250V 5 2
+12V +5V
C25 C26 R48 4 1 D13 1N4001
120 VAC LM7812CTB
LM7805CTB
1 3
J9 J8 VI VO 1 3
C27
G VI VO
4 2 G
V150LA20
.47u/250V
VR1
.47u/250V
3 1 NEUTRAL 2 VR2
2
.1uF
.1uF
1000u/25V
.1uF
.1uF
NOTES: All resistors .25W unless noted.

1000u/25V
C28
C30
C29
10u/25V
10u/25V
C32
C33
C31
C34
All capacitors are 50V unless noted. GROUND
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

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

RN1 10K
+6V +5V
+5V
1 1 2 3 4 5 6 7 8
6
U1 J1
1 V 4 10
A0 P0
2 C 5 9
A1 C P1
3 6 8
A2 P2
7 7
P3
9 6
P4
13 10 5
INT P5
14 G 11 4
SCL P6
15 N 12 3
SDA P7
D 2
+5V PCF8574 1
+6V
8
R1
10K
R2
47/.5watt
+5V
+6V
R3
10K
U2
24 10
SCL P1
23 9
SDA P2
8 1 1 1 1 1 1 1 1 1
P3
1 7 8 7 6 5 4 3 2 1 0 DS1
ADDR P4
6
P5
13
VCC P6
5 F G A B AN AN F A B
4
P7
2 3
CEXT P8
C1
C2 .0027 15
.1 P9
16
P10
12 17
GND P11
18 E D C P E D G C P
P12
19 MAN-6910
P13
20 1 2 3 4 5 6 7 8 9
P14
11 21
MPX1 P15
14 22
MPX2 P16
SAA1064
+6V +5V
P1
1 GND VR1 VR2
2 +12V 1 3 1 3
VI VO VI VO
3 SDA G G
P4 4 SCL
2 7806 2 LM78L05
IDC1X4M C3 C4
C5 C6
.1 .1
.1 .1
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
855 Smart Bender™
Troubleshooting
PROBLEM PROBABLE CAUSE POSSIBLE REMEDY
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.
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.
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
WILL BEND – WON’T COUNT
the possible problems or the only possible solutions.
NO Install shoe per
Is bending shoe on in the proper
instructions in this
orientation?
WON’T BEND – DISPLAY BLANK manual.
YES
Was pendant plugged in YES
after the bender was Turn switch off and then
back on. When jog is pressed, does the YES Replace optical
turned on? bender continue to run slowly encoder.
NO without stopping after 1/2 degree?
YES Bad pendant board, bad NO
Does bender work with pendant cord or plug inside
different (good) pendant? pendant is unplugged. Is 5 VDC measured across the center
NO Replace I/O
and right legs of the voltage regulator
NO on the I/O board labeled VR2? board.
Bent pin connector in YES
YES Replace receptacle.
receptacle or bad recep-
tacle unit? Do Home 1 and Home 2 LEDs Replace or adjust
NO
NO light when the shoe is run past limit switches or
the Start position? wire unit.
Is fuse blown? YES Replace fuse. YES
Does bender count with different YES Replace pendant
NO
(good) pendant? board.
Is 115 VAC measured at Plugged into dead circuit,
NO NO
PGU board input? bad power cord, or
switch is bad or off. Do both Quad 1 and Quad 2 NO Replace optical
YES LEDs light when bend or unload
is pressed? encoder.
Do any of the 8 LEDs on NO Replace transformer unit.
the I/O board light? YES
YES Replace I/O board.

Are metal oxide varistors YES
(MOVs) on PGU Board Replace PGU.
damaged or discolored?
NO
Does PWM LED light YES
Replace PGU.
when BEND is pressed?
NO WILL BEND – DISPLAY BLANK
Disconnect I/O-PGU NO
cable on the I/O board Is at least 80 volts measured at Find 120 VAC
and reconnect to test the power cord? power source.
terminal. Disconnect YES
brake wire unit. Restore
power and push test YES Is 12 VDC measured across
Replace I/O board.
switch. Does shoe move? center and right legs of VR1 on NO Replace I/O
(The toggle switch, lo- I/O board or does display light up board.
cated next to the push when brake is unplugged?
button switch, controls
the direction the shoe YES
moves.)
Replace pendant board.
NO
Replace PGU.
855 Smart Bender™
WON’T BEND – DISPLAY ON BENDER RUNS BACKWARDS FOR BEND & UNLOAD
Jump #2 & #4 termi- NO

Does bender work with YES Is proper size of conduit selected? Select proper size.
nals in pendant.
different (good) pendant? Does bender run? YES
YES Does bender run backwards when Rotary switch cable

NO using deluxe pendant or does bender NO is backwards or
Bad pendant Bad membrane run backward when a conduit size for rotary switch unit
board. switch. the shoe not being used is selected? is bad.
YES
NO
Are polarity of rectifier, relay and NO Connect wires
YES See Won’t Unload
Does BEND work when set to – Display On motor connections correct (see correctly.
1-1/2" or 2" size? section electrical control system layout
diagram)?
NO
YES
Does PWM LED light when BEND NO Replace I/O
board. On 1-1/2" or 2" setting, does white YES Motor is wired
or UNLOAD is pressed? motor lead receive positive voltage? wrong internally.
YES
NO
NO Replace I/O
Can an angle be programmed? board. Disconnect I/O-PGU cable on
the I/O board and reconnect to
YES test terminal. Disconnect brake
wire unit. Restore power and YES Replace I/O board.
Is 100+ VDC measured at the push test switch. Does shoe
motor leads when BEND or YES Replace motor. move? (The toggle switch,
UNLOAD is pressed? located next to the push button
NO switch controls the direction the
shoe moves.)
Are all pin connections making con- NO Replace or repair
tact on 6-wire cable connecting the interconnecting NO
the I/O board to the PGU board? cable.
Replace PGU.
YES
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 YES
Replace I/O board.
move? (The toggle switch,
located next to the push button
switch controls the direction the
shoe moves.)
NO
Replace PGU.
855 Smart Bender™
WON’T UNLOAD – DISPLAY ON TRIPS CIRCUIT BREAKER
Is the retention cam YES Lower the roller support Are the proper support rollers NO Follow directions in
engaged with the roller assembly. and shoe groove being used for instruction manual.
support? the type and size of conduit
NO being bent?
Does the bender unload YES

NO See Won’t Bend - Display
when the “LOCKOUT” On Section.
Is the current on the 115 VAC NO Replace circuit
plug is removed from the
I/O board? line exceeding 20 amps? breaker.
YES
YES
Is the retention cam Loosen cam mounting
pointed to around the NO Is the DC current to the motor YES Replace motor.
bolt and retighten while exceeding 17 amps?
7 o’clock position so that holding the outside
the ramp of the cam is washer so that the cam
not engaging the limit NO
is oriented to 7 o'clock.
switch arm? When BEND is pressed, is the NO Replace bridge
YES voltage sent to the motor 20 to 50
volts over the AC line voltage? rectifier.
Remount the limit switch
YES
farther to the right, or
bend the switch arm so YES
that the dwell portion of Are connectors corroded? Clean.
the cam won’t actuate it.
NO
Replace PGU.
WON’T STOP
Is the supply line voltage low? YES
Use 120 VAC.
NO
Does bender stop when the pen- YES Replace pendant
dant is unplugged? membrane switch.
NO
Replace PGU.
BENDER ONLY RUNS IN ONE DIRECTION

On 1-1/2" or 2" size setting, is NO
the DIR LED on the I/O Board on Replace I/O board.
when BEND is pressed?
YES
When DIR LED is on, is 12 VDC NO
measured at large relay coil Replace PGU.
(where relay wire unit connects)?
YES
Replace 918 6645.6 relay.
855 Smart Bender™
MAKES INACCURATE BENDS
Press BEND to rotate shoe and Are set screws tight Tighten to 22 inch-
NO Isolate motor leads NO
stop it when the pendant displays NO
from all cables that in drive hub on ounces torque.
between 1°-6°. Note the shoe optical encoder?
go to I/O board.
position. Press BEND and con-
tinue past 90°. Unload to angle
first stopped at (between 1°-6°) YES
without passing it. Note shoe
position. Is shoe within 1° of first Replace optical
position stopped at? encoder.
YES
Consistently bends all sizes of YES
one shoe a few degrees over Adjust the limit
or bends all the sizes a few switch for that shoe.
degrees under.
NO
Consistently overbends by more YES Bender coasts to YES
than 5° and can’t be properly Adjust motor brake.
adjusted. a stop.
NO
No-load motor YES
Replace motor field.
speed is greater
than 4400 rpm.
NO
Replace optical
encoder.
NO
Bends some sizes of one shoe YES Indicates variations

1° or 2° over and other sizes of in the conduit. Use
the same shoe 1° or 2° under. Accuracy Adjust-
ment to compen-
sate.
NO
Consistently underbends by a YES Limit switch arm is

few degrees and can’t be ad- bent or switch is
justed correctly. mounted backwards.
NO
Clean and tighten all ground
connections at frame.
NO
Isolate motor leads from cables
that plug into the I/O board.
NO
Replace optical encoder?
NO
Replace I/O board.

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 Printed in the U.S.A.

855 Smart Bender 01711 Instruction Manual ABL

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855 Smart Bender 01711 Instruction Manual ABL

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INSTRUCTION MANUAL

Read and understand all of the instructions and

999 2168.5 © 2001 Greenlee Textron IM 1266 REV 15 6/01

Table of Contents Description

Purpose of this Manual

Loctite is a registered trademark of Loctite Corporation.

KEEP THIS MANUAL

IMPORTANT SAFETY INFORMATION

Hazards which, if not avoided, COULD result in • Do not expose to rain.

Do not remove guards.

IMPORTANT SAFETY INFORMATION

Balanced bending head pivots easily as it is changed from the vertical

Bending head shown locked in the

Conduit Centerline Bending Radius

Bending head shown in the

Height .................................................................................................... 1200 mm (47")

855 Smart Bender™ 16 12 13

bender toward you until it rolls off the stand.

Lift only 2" side

Operation — Standard Pendant

CONDU IT TYPE 1 1-1/4

Lift only 2" side

Display: shows the actual angle the conduit has been

Operation — Standard Pendant (cont’d)

OFFSET-“X” 2-1/2 3-1/16 3-1/16 4 4-3/4 4-3/4

Operation — Optional Deluxe Pendant

11/16 .68 SELECT CONDUIT TYPE screen.

Operation — Optional Deluxe Pendant (cont’d)

Operation — Installing and Bending Conduit

Operation — Installing and Bending Conduit (cont’d)

Press the BEND key while maintaining conduit align-

Operation — Installing and Bending Conduit (cont’d)

Operation — Installing and Bending Conduit (cont’d)

Operation — Installing and Bending Conduit (cont’d)

Operation — Installing and Bending Conduit (cont’d)

Special Bending Information

Special Bending Information (cont’d)

LENGTH TO END OF SECOND BEND

BENDING BENDING BENDING BENDING BENDING

Special Bending Information (cont’d)

BENDING BENDING BENDING BENDING

Special Bending Information Chart

Special Bending Information Chart (cont’d)

Y 30 1.72 5.72 9.72 13.72 17.72 23.72 29.72 41.72 65.72

Special Bending Information Chart (cont’d)

Special Bending Information Chart (cont’d)

1/2" IMC, Rigid and 40 Mil PVC-Coated Rigid

3/4" IMC, Rigid and 40 Mil PVC-Coated Rigid

Special Bending Information Chart (cont’d)

1" IMC, Rigid and 40 Mil PVC-Coated Rigid

1-1/4" IMC, Rigid and 40 Mil PVC-Coated Rigid

Special Bending Information Chart (cont’d)

1-1/2" IMC, Rigid and 40 Mil PVC-Coated Rigid

2" IMC, Rigid and 40 Mil PVC-Coated Rigid

Assembly Instructions for 40 Mil PVC-Coated Rigid Bending Accessories

1-1/2" and 2"

Adjustments (cont’d) Maintenance

Limit Do not touch the brake if the bender

1. Disconnect power to unit.

Bender Head Disassembly

See Electrical Control System Layout for location of key numbers.

Bender Head Disassembly (cont’d)

and pull it off the spindle.