Current Tools RotaBoom 77-22, RotaBoom 77SE-22, RotaBoom 77SR-22, RotaBoom 700SP, RotaBoom 700SI Operating, Maintenance, Safety And Parts Manual

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Current Tools™ 77 Series Electric Bender – 220 Volt

with Single Shoe Groups

for bending 1/2" thru 2" RIGID - EMT - IMC

and 40 mil PVC coated RIGID Conduit

130

140

Operating, Maintenance, Safety

This manual is free of charge. All personnel who operate this Bender should have a copy of this manual and read and understand its contents. To request a copy, call or write to the address below.

CURRENT TOOLS • P. O. BOX 17026 GREENVILLE, SC 29606

800.230.5421 or 864.721.4230 • FAX 864.721.4232

and Parts Manual

06/17

Read and understand this material before operating or servicing this Bender. Failure to understand how to safely operate and service this unit may result in serious injury or death.

www.currenttools.com

TABLE OF CONTENTS

Safety Alerts ....................................................................................3

Important Safety Information ....................................................4, 5

Specifications – 77 Series Electric Bender – 220 Volt ................. 6

Model Descriptions ........................................................................ 6

Features ........................................................................................6, 7

Shoe Groups ................................................................................... 8

Conduit Centerline Bending Radii ................................................ 8

Grounding Instructions .................................................................. 9

Mounting Bending Shoes .............................................................10

Mounting Roller Supports ............................................................ 11

General Bending Instructions ................................................12, 13

Bending Instructions for

⁄2" and 2" EMT & IMC Conduit ......................................... 14-16

Squeeze Adjustment Procedure for

⁄2" and 2" EMT & IMC Roller Supports ..................................17

Maintenance ............................................................................18, 19

Stub-Up Bending Information and Charts ............................20, 21

Offset Bending Information and Charts ................................22, 23

Troubleshooting ........................................................................... 24

Exploded Views .......................................................................25, 26

Parts List ..................................................................................27, 28

Electrical System Diagram ...........................................................29

Parts List – Bending Shoes & Roller Supports .................... 30-35

jury

SAFETY ALERTS

THIS SAFETY SYMBOL is used to call your attention to instructions that concern your personal safety. It means: ATTENTION! BE AWARE! THIS IS AN IMPORTANT SAFETY INSTRUCTION!

Read, understand, and follow these safety instructions. Failure to follow these safety instructions may result in injury or death.

Safety Alert

Symbol

DAN

Immediate hazards which, if not avoided, WILL result in serious personal

or death

ARNIN

Hazards or unsafe practices which, if not avoided, COULD result in serious personal in

or death

UTI

Hazards or unsafe practices which, if not avoided, COULD result in minor personal in

or property damage

RETAIN SAFETY INFORMATION

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

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DANGER

This manual should be read and understood by all personnel who operate or service this bender. Failure to understand how to safely operate and service this unit could result in injury or death. This unit should only be operated and serviced by qualiﬁed personnel.

IMPORTANT SAFETY INFORMATION

NEVER operate the bender in an explosive atmosphere.

NEVER operate the bender in wet or damp locations. DO NOT expose the bender to rain.

ALWAYS connect to a power supply that is properly installed and meets all applicable electrical codes. See grounding instructions on page 9.

ALWAYS inspect power cord before using bender. Replace damaged or worn cords.

DO NOT modify the plug provided with the bender.

ALWAYS disconnect power to the bender before servicing.

ALWAYS make sure the circuit breaker switch is in the OFF position before plugging in. This will reduce the risk of unintentional starting.

ALWAYS use three-wire, 12 AWG extension cords that have three-prong grounding type plugs and three hole receptacles that accept the bender's plug.

NEVER use an extension cord longer than 100 feet.

ALWAYS replace damaged extension cords.

ALWAYS disconnect power to the bender before servicing or changing shoes, attachments or roller supports, and when not in use.

ALWAYS inspect the bender before operating. Replace any damaged, missing or worn parts.

NEVER alter this equipment. Doing so will void the warranty.

NEVER remove guards, they are installed for your protection.

ALWAYS check for damaged or worn parts. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.

IMPORTANT SAFETY INFORMATION — continued

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

ALWAYS use recommended accessories. Consult this manual for recommended accessories. The use of improper accessories may cause risk of injury.

ALWAYS keep hands and feet away from pinch points such as bending shoes, roller supports and conduit when bender is in use.

Operator must ALWAYS face the front of the bender with the bending degree scale visible and maintain a minimum of 3 feet distance from the bender while the conduit is being bent. All other personnel must remain out of the area while the bender is in operation.

ALWAYS use appropriate shoe groove and roller support for the type and size conduit to be bent.

If bending shoe will not turn, STOP unit and unplug before checking for any obstructions.

DO NOT use bender or attachments to do a job for which it was not designed.

ALWAYS keep conduit under control when unloading.

ALWAYS keep the path of the bending conduit clear of obstructions. Make sure all obstacles are clear of the bending path BEFORE you bend the conduit.

WARNING

CAUTION

Be sure handle is bolted securely to the bender frame before moving or lifting the bender.

NEVER stand on bender. Serious injury could occur if the bender is tipped or if the bending shoe is unintentionally contacted.

ALWAYS wear approved safety glasses when the bender is in operation.

ALWAYS wear proper apparel. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair.

ALWAYS keep children away. All visitors should be kept a safe distance from work area.

ALWAYS make bender childproof with lockouts, master switches or by unplugging unit.

The bender and some accessories exceed 50 lbs. and will require more than one person to lift, transport and assemble.

Only use the bender for its intended purpose as specified in this manual.

ALWAYS use this bender in a dry, well lighted area.

CAUTION

ALWAYS maintain bender with care. Keep bender clean for best and safest performance.

SPECIFICATIONS – 77 SERIES ELECTRIC BENDER

SPECIFICATIONS - 77 SERIES ELECTRIC BENDER WITH SINGLE SHOE GROUPS

1/2" thru 2" RIGID conduit 1/2" thru 2" EMT conduit 1/2" thru 2" IMC conduit 1/2" thru 2" 40 mil PVC coated RIGID conduit

1/2" thru 2" schedule 40 steel pipe

No modification to the 77-22 POWER UNIT is required to accommodate these shoes or roller supports.

No tools are required to install or remove these shoes and roller supports.

The 77 Series Electric Bender is NOT to be

used for bending any conduit or pipe wall thickness above schedule 40 pipe.

width 29 1/2" length 24 3/4" height 39" weight 256 lbs. Power Unit Only - without shoes and roller supports

MODEL DESCRIPTIONS

Bender Power Unit and Bender Power Unit with Shoe Group

77-22 Electric Bender Power Unit only, without shoes and roller supports

77SR-22 Electric Bender with shoe and roller support for 1/2" thru 2" RIGID conduit

and schedule 40 pipe and 1/2" thru 1 1/4" IMC conduit

77SE-22 Electric Bender with shoe and roller support for 1/2" thru 2" EMT conduit

Shoe Group ONLY for use with 77-22 Power Unit

700SI 1/2" thru 2" IMC single shoe group for 77-22 power unit

700SP 1/2" thru 2" 40 MIL PVC Coated RIGID single shoe group for 77-22 power unit

FEATURES

1. Bending Degree Scale - easy to read for exact bends.

2. Roller Supports - for supporting the conduit during bending.

3. Hinge Pin - for securing the roller supports.

4. 12 inch Wheels - for easy mobility.

5. D.C. Motor - quiet and strong.

6. Bending Instructions Decal - easy to read for quick reference.

7. Remote Pendant - with 6 foot cord. ( Bend and unload from pendant. )

8. Removable Handle - may be removed for dog-leg bends

9. Back Rails - Protect the back of bender and enable the bender to be used horizontally

130

140

FEATURES — continued

REMOVE BOTH SCREWS AND NUTS ON EACH SIDE TO REMOVE HANDLE

Special Features

The 77 Series Electric Benders have a unique feature to remove the handles during a “Dog-Leg Bend." See Figure 7a below.

Figure 7a

ARNIN

When replacing handle, be sure to replace screws and nuts and also to tighten securel

The 77 Series Electric Benders may also be used in a horizontal position The bender can operate in this position as efficiently as it does in the upright position. See Figure 7b below.

before moving or transporting

Figure 7b

SINGLE SHOE GROUPS

RIGID

700SR - for bending 1/2" thru 2" RIGID conduit, 1/2" thru

1 1/4" IMC conduit and 1/2" thru 2" schedule 40 pipe

includes the following items.

Key Catalog# Description

1 2-3000 1/2" thru 2" bending shoe 2 2-4000 1/2" thru 2" roller support 3 8-0501 Storage box (not shown)

IMC

EMT

700SE - for bending 1/2" thru 2" EMT ( Thinwall )

includes the following items.

Key Catalog# Description

1 2-3100 1/2" thru 2" bending shoe 2 2-4200 1/2" thru 2" roller support 3 8-0501 storage box (not shown)

PVC COATED RIGID

700SP - for bending 1/2" thru 2" 40 mil PVC coated RIGID

700SI - for bending 1/2" thru 2" IMC conduit

includes the following items.

Key Catalog# Description

1 2-3000 1/2" thru 2" bending shoe 2 2-4100 1/2" thru 2" roller support 3 8-0501 storage box (not shown)

includes the following items.

Key Catalog Description

1 2-3200 1/2" thru 2" bending shoe 2 2-4300 1/2" thru 2" roller support 3 8-0501 storage box (not shown)

CONDUIT CENTERLINE BENDING RADII

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 4-1/4 5-7/16 6-15/16 8-3/4 8-1/4 9

RIGID 4-1/4 5-7/16 6-15/16 8-3/4 8-1/4 9

PVC COATED RIGID 4-1/4 5-7/16 6-15/16 8-3/4 8-1/4 9

GROUNDING INSTRUCTIONS

RECEPTACLE PLUG

NEMA 6-15

WARNING

ELECTRIC SHOCK HAZARD! Only connect the bender to a 15 AMP GFCI protected circuit. DO NOT modify the plug which is provided with the unit. Failure to follow these warnings can result in serious injury or death.

Figure 9a Figure 9b

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. The bender is equipped with an electric cord having an equipment grounding conductor and a grounding plug. Only connect the bender to a 15 AMP GFCI protected receptacle which is properly installed and grounded to meet all applicable electrical codes. Do NOT use an adapter.

Do NOT modify the plug provided. If it will not fit the receptacle, have the proper receptacle installed by a qualified electrician.

Improper connection of the equipment grounding conductor can result in risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment grounding conductor to a live terminal.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the bender is properly grounded.

Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the bender’s plug.

Repair or replace damaged or worn cord immediately.

This bender is intended for use on a circuit that has a receptacle that looks like the one illustrated in Figure 9a above. The bender has a grounding plug that looks like the plug illustrated in Figure 9b above.

MOUNTING BENDING SHOE

MAIN

DRIVE HOLES

Choose the desired shoe (RIGID, IMC, EMT, or 40 mil PVC coated RIGID) and slide shoe onto the main drive sprocket shaft. See Figure 10a below.

Note: Rigid and IMC conduit are bent on the same shoe. However, the roller

supports are specific for Rigid or IMC.

SPROCKET SHAFT

MAIN DRIVE SPROCKET

BENDING SHOE

DRIVE STUDS

Figure 10a Figure 10b

DRIVE SPROCKET

Next, align the four drive studs on the back of the shoe with the four drive holes in the main drive sprocket.

Push the shoe onto the main drive sprocket shaft. See Figure 10b.

MOUNTING ROLLER SUPPORT

Choose the correct roller support for the corresponding shoe and type conduit ( RIGID, IMC, EMT, or 40 mil PVC coated RIGID ). The appropriate size and type of roller support MUST be used with the corresponding shoe size and type.

Mount the roller support on the bender. Secure the roller support with the quick release hinge pin. See Figures 11a and 11b.

Figure 11a

Bender shown with

1/2" to 2" Rigid roller support

Figure 11b

Bender shown with

1/2" to 2" EMT roller support

MOUNTING INSTRUCTIONS FOR GREENLEE® SHOES AND ATTACHMENTS

Most bending shoes and attachments for the Greenlee® 555® and 555 Classic® will fit the Model #77-22 Bender. In addition, most bending shoes and attachments for the Model #77-22 Bender will fit the Greenlee® 555® and 555 Classic® bender.

Contact Current Tools for specific applications and compatibility.

* Greenlee® 555® and 555 Classic® are registered trademarks of Greenlee/Textron.

GENERAL BENDING INSTRUCTIONS

Bending instructions for:

1/2" thru 2" RIGID conduit 1/2" thru 1 1/4" EMT conduit 1/2" thru 1 1/4" IMC conduit 1/2" thru 2" 40 mil PVC coated RIGID conduit 1/2" thru 2" schedule 40 pipe

See pages 10 and 11 for mounting shoe and roller support. Be sure to match the appropriate shoe with its corresponding roller support.

1. Mark pipe/conduit to the desired length. Note that a 2" minimum distance from the end of the conduit to the bending mark is required to eliminate flattening the end of the pipe/conduit. See Figure 12.

NOTE: Stub-up and Offset dimensions can be found on the bending charts

on pages 20 thru 23 of this manual or on the bending instruction decal on top of each bender.

2. Rotate the bending shoe to 10 degrees below the 0 ( zero ) degree setting, as shown in Figure 12 below.

DAN

operate this bender in an explosive atmosphere. Injury or Death may occur.

0°

-10°

BENDING MARK

Figure 12

MINIMUM

HOOK

GENERAL BENDING INSTRUCTIONS — continued

3. After marking the pipe/conduit, place it into the bender. See Figure 12. The pipe/conduit should slide over the correct size roller support, through the shoe groove and into the hook. The bending mark should be at the front ( OUTSIDE ) edge of the hook. See Figure 12.

4. Using the remote pendant, place the “Bend/Unload" switch in the “bend" position. Press the “Jog" button and advance the bender shoe. Be sure to check the alignment of the bending mark as the rotating shoe locks the pipe/conduit into position. Advance the bender shoe to the desired degree of bend. When the arrow on the shoe reaches the desired degree of bend, release the “Jog" button and the bender will stop.

NOTE: Due to springback in pipe/conduit, some over bending is

necessary to achieve the desired degree of bend. See page 21 or the bending instruction decal on top of each bender for approximate springback compensation figures.

5. To release the pipe/conduit, place the “Bend/Unload" switch in the “Unload" position. Press the “Jog" button and reverse the shoe far enough to release the conduit. Then, rotate the roller support out of the way. See Figure 13a & 13b. The pipe/conduit can now be removed.

ARNIN

The pipe/conduit should be under control when unloading. Failure to do this ma

result in injury or death

Figure 13a

Bender shown with

1/2" to 2" Rigid roller support

Figure 13b

Bender shown with

1/2" to 2" EMT roller support

BENDING INSTRUCTIONS FOR 1 1/2" AND 2" EMT & IMC CONDUIT

1. See pages 10 and 11 for mounting shoe and roller support.

Be sure to match the appropriate shoe with its corresponding roller support.

NOTE: The frame color of the EMT roller support is silver (see Figure 14a). The frame color of the IMC roller support is yellow (see Figure 14b).

SILVER YELLOW

EMT ROLLER SUPPORT IMC ROLLER SUPPORT

Figure 14a Figure 14b

2. Mark pipe/conduit to the desired length. Note that a 2" minimum distance

from the end of the conduit to the bending mark is required to eliminate flattening the end of the pipe/conduit. See Figure 14c.

BENDING MARK

HOOK

MINIMUM

Figure 14c

NOTE: Stub-up and Offset dimensions can be found on the bending charts on pages 20 thru 23 of this manual or on the bending instruction decal located on the top of each bender.

BENDING INSTRUCTIONS FOR 1 1/2" AND 2" EMT & IMC CONDUIT — continued

3. Rotate the bending shoe to 10 degrees below the 0 (zero) degree setting. See Figure 12.

4. After marking the pipe/conduit, place it into the bender. The pipe/conduit should slide over the roller support and through the shoe groove and into the hook. The bending mark should be at the front ( OUTSIDE ) edge of the hook. See Figure 14c.

NOTE: The appropriate size and type of roller support MUST be used

with the corresponding shoe size and type.

5. Step on the “Engaging Pedal" which will raise the rollers to come in contact with the conduit. See Figure 15. Be sure the correct rollers for the size conduit being bent are in position to engage the conduit.

NOTE: See SQUEEZE ADJUSTMENT PROCEDURE on page 17.

STOP

ENGAGING

PEDAL

ROLLERS SHOWN IN RAISED (BENDING) POSITION

Figure 15

BENDING INSTRUCTIONS FOR

1 1/2" AND 2" EMT & IMC CONDUIT — continued

6. Keep foot pressure on the engaging pedal and push the “Bend/Unload”

switch to the “Bend” position. Then press the “Jog” button. The conduit will pull the roller support against the stop. Foot pressure can then be removed from the engaging pedal. Be sure to check the alignment of the bending mark as the rotating shoe locks the conduit into position.

NOTE: If the roller support will not pull against the stop, the squeeze

adjustment is too tight and will need to be adjusted. See squeeze adjustment procedure on page 17.

Advance the bender shoe to the desired degree of bend. When the pointer on the shoe reaches the desired degree of bend, release the “Jog” button and the bender will stop.

NOTE: Due to springback in pipe/conduit, some over bending is necessary to achieve the desired degree of bend. See page 21 or the bending instructions decal located on the top of each bender for approximate springback compensation figures.

NOTE: DO NOT allow the rollers to come in contact with the bending shoe. The shoe and rollers squeeze the conduit but they should never touch each other.

7. To release the pipe/conduit, place the “Bend/Unload” switch in the “Unload”

position. Press the “Jog” button and reverse the shoe. The roller support will then drop, allowing removal of the conduit.

ARNIN

The pipe/conduit should be under control when unloading. Failure to do this ma

8. After removal of the conduit, inspect it for wrinkling or excessive side marks.

If these conditions occur, refer to the SQUEEZE ADJUSTMENT PROCEDURE. See page 17.

result in injury or death

SQUEEZE ADJUSTMENT PROCEDURE FOR

BO MUST C

1 1/2" AND 2" EMT & IMC ROLLER SUPPORTS

The 1 1/2" and 2" rollers on the single shoe EMT Roller Support and the 1 1/2" and 2" rollers on the single shoe IMC Roller Support on the 77 bender have a Squeeze Adjustment feature if wrinkling or side marking becomes a problem during the bending process. This feature allows you to increase or decrease the amount of pressure applied to the conduit during bending, thereby eliminating these problems. Begin with the 7/8" starting location of the adjusting bolts as shown in Figure 17a.

1. If wrinkling occurs, pressure against the conduit during the bending process

must increase. To increase the squeeze ( pressure ), loosen both set screws and turn both adjusting bolts one-half turn clockwise. Bend one piece of conduit to test the adjustment, and if wrinkling still occurs, repeat the procedure. Once you have achieved a good bend, tighten both set screws.

NOTE: Both adjusting bolts MUST be in contact with the bender leg. See Figure 17a.

STARTING LOCATION OF ADJUSTING BOLT

7/8"

BENDER LEG

SET SCREW

ADJUSTING BOLT

Figure 17a

STOP

TH ADJUSTING BOLTS

ONTACT BENDER LEG

Figure 17b

2. If side marking occurs, pressure against the conduit during the bending

process must be decreased. To decrease the squeeze ( pressure ), loosen both set screws and turn both adjusting bolts one-half turn counter-clock wise. Bend one piece of conduit to test the adjustment, if side marking still occurs, repeat the procedure. Once you have achieved a good bend, tighten both set screws.

NOTE: Both adjusting bolts MUST be in contact with the bender leg. See Figure 17a.

MAINTENANCE

ALWAYS disconnect power supply before removing any guards or covers and

before servicing this bender. Failure to do so ma

result in serious injury or deat

ARNIN

1. The Gear Box is filled with oil at the factory and should not require periodic

flushing. If the Gear Box is opened for repair, flush by filling the unit with an AGMA #7 oil. Next, run the unit with no load for 3 minutes. Then, drain and refill the unit with 28 fluid ounces of an AGMA #7 oil such as the ones listed below.

Amoco – Amoco Worm Gear Oil Chevron – Cylinder Oil 460X Exxon – CYLESSTIC TK460 Mobil – 600 W Cylinder Oil Shell – Sun Gear Oil 7C

2. To inspect FRONT #60 chain tension:

• Remove front cover plate.

• To adjust, loosen hex bolt with 3/4 wrench and rotate chain tensioner

toward chain as shown until chain moves no more than a total of 1/4". See Figure 18 below.

• Grease chain periodically with a good quality MP grease.

Figure 18

X SPROCKET

MAINTENANCE — continued

3. To inspect REAR #40 chain tension:

• Check chain tension after an initial break-in period of 2 - 3 hours of

use and tighten per the instructions below. See Figure 19. Thereafter, inspect monthly.

• Remove the chain guard by taking out the 2 mounting screws.

• Loosen 8 bolts ( 4 on top and 4 on bottom ) that hold the gear box

in position.

• To tighten chain, move the gear box to the left and re-tighten bolts.

• For correct tension, chain should deflect approximately 1/8".

NOTE: Be sure to keep the gear box and motor in line with the bender.

• Grease chain periodically with a good quality MP grease.

4 BOLTS ON TOP

4 BOLTS ON BOTTOM

Figure 19

• Access to the gearbox sprocket

is possible by removing access door as shown.

CHAIN GUARD

MOUNTING SCREWS

THIS COVER ALLO

ACCESS TO THE GEARBO IF ADJUSTMENT IS NEEDED

UCT

GTH

STUB-UP BENDING INFORMATION AND CHARTS — continued

PLA IN LINE EDGE OF SHOE HOOK

To locate bending marks and springback of 15, 30, 45, 60, and 90 degree bends for a desired stub:

1. Check Chart A, B, C or C1 on Page 21 for deduct length. Note that minimum stub length is deduct length plus 2".

2. Measure and mark desired stub length on conduit ( stub length mark ). Subtract “Deduct Length" from this mark and make a second mark ( bending mark ). See Fig 20a and 20b. Place bending mark at front edge of shoe hook. See Figure 20c. Check Chart A, B, C or C1 on Page 21 for springback of desired degree of bend. Bender should be advanced to this degree to obtain desired degree of bend.

Figure 20a

LENGT

Figure 20b

Figure 20c

BENDIN

LEN

TUB

DED LENGT

LENGT

CE BENDING MARK

WITH FRONT

STUB-UP BENDING INFORMATION AND CHARTS — continued

Chart A – RIGID Conduit/Schedule 40 Pipe

Conduit

Size

1/2" 7-1/2 17 33 49 64 96 3/4" 9 17 33 48 64 95

1" 11 17 32 48 63 94 1 1/4" 13-5/8 17 32 48 63 94 1 1/2" 14-7/8 17 32 48 63 94

2" 16-1/8 17 32 48 63 94

Deduct

Length

————— Springback —————

15° 30° 45° 60° 90°

Chart B – EMT Conduit

Conduit

Size

1/2" 7-1/2 16 32 48 63 95 3/4" 9 17 33 48 64 95

1" 11 17 32 48 63 94 1 1/4" 13-5/8 17 32 48 63 94 1 1/2" 14-7/8 19 35 50 66 97

2" 16-3/8 19 34 50 65 96

Deduct

Length

————— Springback —————

15° 30° 45° 60° 90°

Chart C – IMC Conduit

Conduit

Size

1/2" 7-1/2 20 36 51 67 98 3/4" 9 19 35 50 66 97

1" 11 19 35 50 66 97 1 1/4" 13-5/8 19 35 50 66 97 1 1/2" 14-7/8 17 33 49 64 96

2" 16-1/8 19 34 50 65 96

Deduct

Length

————— Springback —————

15° 30° 45° 60° 90°

Chart C1 – PVC Coated Rigid Conduit

Conduit

Size

1/2" 7-1/2 16 31 47 62 93 3/4" 9 15 31 46 62 93

1" 11 16 32 47 63 94 1 1/4" 13-5/8 15 30 46 61 92 1 1/2" 14-7/8 18 33 49 64 95

2" 16-1/8 19 34 50 65 96

NOTE: Springback figures are approximate.

Deduct

Length

————— Springback —————

15° 30° 45° 60° 90°

Minimum Stub Length = Deduct Length plus 2"

END OF CONDUIT

TO START OF

BEND

ANGLE

OFFSET HEIGHT

DEDUCT LENGTH

MARK NO. 1

MARK NO. 3

CENTER TO CENTER

LENGTH

MARK NO. 2

OFFSET BENDING INFORMATION AND CHARTS

PLA IN LINE EDGE OF SHOE HOOK

To locate bending marks for a desired offset:

1. Measure distance from end of conduit to start of bend and mark conduit. ( Mark 1 ) See Figure 22a and 22b.

2. Refer to chart E for measurement “X" (see page 23) and deduct this distance from Mark 1 and place Mark 2 on conduit. (See Figure 22b).

3. Refer to chart D (see page 23) for center-to-center distance between marks. Measure this distance from Mark 2 and place Mark 3 on conduit.

4. Layout of bends is now complete. Next, place Mark 2 in line with front edge of shoe hook and make first bend. (See Figure 22c).

5. Rotate conduit 180 degrees. Place Mark 3 in line with front edge of shoe hook and complete second bend.

Figure 22a

Figure 22b

Figure 22c

CE BENDING MARK

WITH FRONT

OFFSET BENDING INFORMATION AND CHARTS — continued

To locate center-to-center distance of offset bending marks other than those listed in Chart D, use the following multipliers. Multiply the height of offset desired by 3.86 on 15 degree bends, 2 on 30 degree bends, and 1.4 on 45 degree bends.

Chart E

Conduit Size

Figures are approximate.

1/2 3/4 1 1 1/4 1 1/2 2

“x” 3 1/16" 3 1/16" 3 3/16" 4" 4 1/4" 4 1/2"

TROUBLESHOOTING

ALWAYS disconnect power supply before removing any guards or covers and

before servicing this bender. Failure to do so ma

result in serious injury or death

ARNIN

Problem Cause Diagnosis Cure

1. Bender will not operate Power source Check for voltage If power is on, at power source go to ( #3 )

2. No power at bender Bad power cord Ohm cord for Replace cord broken wire

3. Power to bender but Circuit breaker / Check power on Turn circuit will not operate power switch in load side of breaker breaker on. the off position to neutral with If on, go to volt meter next step.

Fuse #1 blown Ohm circuit for short Replace

Control Transformer Check voltage in and out, Replace bad if input but no output

Contactor bad Check contacts and ohm Replace coil for open circuit

Bridge rectifier bad Check with Replace ohm meter

Switch bad Check with ohm meter Replace

Motor bad Check brushes and ohm Replace for open or short armature

4. Motor runs but Chain from gear box Remove cover and Replace will not bend to jack shaft broken visually check for broken parts

Bad gear box Motor running but no Replace output through gear box

Chain from jack shaft Remove cover and Replace to shoe sprocket broken visually check for broken parts

Key between motor and Remove motor from Replace key gear box missing gear box

5. Bender operates in Bad FWD / REV switch Ohm switch for open Replace one direction only contact or shorted contacts

Bad pendant cord Ohm for broken wire Replace

Bad contactor Check contacts and Replace ohm coil for open circuit

6. Contactors chatter Low power to bender Check with amp meter Do not use long drop cords

EXPLODED VIEWS

GEARBOX

MOUNT (REF)

WITH

SUPPLIED

GEARBOX

refer to PARTS LIST on page 27

190

130

120

110

100

180

170

160

150

140

SEE SEPARATE

BREAKDOWN

WITH GEARBOX

SCREWS INCLUDED

(4) 3/8-16 HEX

,75

BREAKER SWITCH

CIRCUIT

44 (7)

ELECTRICAL PLATE

MOUNTING HOLES-BENDER FRAME

76(7),80

PENDANT

REMOTE

EXPLODED VIEWS — continued

PARTS LIST — 77-22 SERIES ELECTRIC BENDER

ITEM # PART # QTY DESCRIPTION

1 ........... 77-375..........1 ..................FRAME

2 ........... 77-346..........1 ................. HANDLE

3 ...........77-004D .........1 ..................COVER

4 ........... 77-004 ..........12 ......SCREW - #8-32 X 1/2" THD CUTTER

5 ........... 77-343 ..........1 ............. SPROCKET SHAFT

6 ...........77-006A .........2 .......KEY - SQUARE, 1/4" X 3/4" LONG

7 ........... 77-007 ..........1 ........ RETAINING RING - EXT, 2 1/2"

8 ........... 77-008 ..........2 ......WASHER - PHENOLIC (JACKSHAFT)

9 ........... 77-009..........2 ............. SLEEVE BEARING

10........... 77-010..........1 ............. #60 MASTER LINK

11........... 77-011..........1 ................ #60 CHAIN

12........... 77-394..........1 ........ SPROCKET - MAIN DRIVE #60

13...........77-013B .........1 .........SLEEVE - PHENOLIC (LONG)

14........... 77-014..........1 .........WASHER - PHENOLIC (MAIN)

15........... 77-015..........2 .................. WHEEL

16........... 77-016..........2 .........PIN - COTTER, 3/16" X 1 1/4"

17........... 77-017..........2 .............WASHER - 3/4" USS

18........... 77-429..........1 ...................AXLE

19...........77-033A .........9 .......SCREW - HEX, 10 X 1/2, #2 TEKS

20........... 77-413..........1 .............CHAIN TENSIONER

21...........77-013A .........1 ........ SLEEVE - PHENOLIC (SHORT)

22...........453-16A .........2 ............. NUT - HEX #8 - 32

23........... 8092-2..........1 ..........SCREW - HEX 1/2 - 13 X 1"

24...........2-1301-4 .........4 ......NUT - HEX, 5/16 - 18 (NYLON INS.)

25..........77-002D1 ........4 .........SCREW - HEX 5/16 - 18 X 3/4

26........... 77-026..........1 ............COVER - ELECTRICAL

27........... 77-339..........1 ............ PLATE - ELECTRICAL

28...........77-028A .........2 ......... STRAIN RELIEF - PENDANT

29........... 77-028..........1 ........STRAIN RELIEF - POWER CORD

30........... 77-288..........1 ............SPROCKET - #40 B48

31........... 77-031..........1 ................CHAIN - #40

32........... 77-032..........1 .............MASTER LINK - #40

33........... 77-468..........1 ............COVER - REAR CHAIN

34..........9518SR-12 ........4 ..........NUT - HEX, 1/4-20 (LOCK)

35........... 77-237..........1 ............SPROCKET - #40 B13

36...........77-3-1A .........1 ..............PLUG - PLASTIC

37........... 77-037..........1 ................ GEAR BOX

38............504-1 ..........2 ...................GRIP

39.........77-039-220V .......1 .............MOTOR – 220 VOLT

40........... 77-040..........8 ......BOLT - FLANGE LOCK, 3/8 - 16 X 3/4

PARTS LIST — continued

ITEM # PART # QTY DESCRIPTION

41........... 77-041..........2 ...........FITTING - 90° LIQUITITE

42...........77-042A .........1 .............. FLEX CONDUIT

43..........77-043-22 ........1 ....... DECAL - SAFETY INFORMATION

44...........77-004B .........7 ..... SCREW - #8 - 32 X 5/8" THD CUTTER

45..........77-22SNP ........1 .......... SERIAL NUMBER PLATE

46........... 77-046..........1 ......DECAL - BENDING INSTRUCTIONS

47........... 77-047..........2 ...........PIN - ROLLER SUPPORT

48........... 77-048..........1 ..............CONDULET - 1/2"

49........... 77-451..........1 ................. GASKET

50........... 77-128..........1 .........GUARD - PENDANT SWITCH

51........... 77-051..........1 ....... SWITCH - FORWARD / REVERSE

52........... 77-052..........1 ...............SWITCH - JOG

53........... 77-053..........3 ... SCREW - #8 - 32 X 3/8" PAN HEAD MACH.

54........... 77-054..........2 ...............CONTACTORS

55.........77-055-220V .......1 ......... TRANSFORMER - 24 VOLT

56.........77-056-220V .......1 ...................FUSE

57........... 77-057..........1 ............. TERMINAL BLOCK

58.........77-058-220V .......1 .................RESISTOR

59.........77-059-220V .......1 ...........VARISTOR WITH WIRES

60........... 77-060..........1 .............BRIDGE RECTIFIER

61........... 77-061..........2 ....SCREW - RD. HEAD MACH., #6 -32 X 3/8"

62.........77-062-220V .......1 .............CIRCUIT BREAKER

63........... 77-063..........1 ......... COVER - CIRCUIT BREAKER

64........... 77-064..........1 .............DECAL - PENDANT

65........... 77-065..........1 ..........FISH PAPER - INSULATING

66........... 77-066..........1 ...............FUSE HOLDER

67........... 77-067..........1 ..............RETAINING RING

68........... 450-20..........4 ..................SPACER

69.........77-068-220V .......1 .........CORD - POWER (not shown)

70...........77-048A .........1 ........CORD - PENDANT (not shown)

71........... 77-714..........1 .............. ACCESS COVER

72...........77-058A .........2 ...... BRACKET - RESISTOR (not shown)

73...........452-6A .........9 .........SCREW #8 X ½” SELF DRILL

74........... 77-387..........1 .........BRACKET – TRANSFORMER

75...........77-041A .........2 ..............NUT – 1/2" LOCK

76...........77-004A .........11 .....SCREW – #8 – 32 X 3/8" THD CUTTER

77........... 747-19..........1 .................MAGNET

78........... 451-22..........1 .....SCREW 10-32 X 3/8" RD HD SLOTTED

79........... 451-21..........1 ...... NUT HEX 10 - 32 (NYLON INSERT)

80........... 747-39..........1 .......WASHER, LOCK – #8 EXT. TOOTH

81........... 747-40..........2 ..... WASHER, LOCK – 15/32" INT. TOOTH

ELECTRICAL SYSTEM DIAGRAM

PARTS LIST — SINGLE SHOES & ROLLER SUPPORTS

2-3000 & 2-4000 Bending Shoe & Roller Support — 1/2" to 2" RIGID Conduit AND Schedule 40 pipe 1/2" to 1 1/4" IMC conduit

ITEM # PART # QTY DESCRIPTION

1 ..................2-1304 .................4 .................................................... DRIVE STUD

2 ................ 2-2301-2 ................3 .......................... SCREW, SHOULDER SOCKET – 3/4" × 1 1/2"

3 ..................2-2302 .................1 ........................................ HOOK, 1 1/2"–2" RIGID/IMC

4 .............. 2-3000-101 ..............1 ......................................... SHOE – 1/2"–2" RIGID/IMC

5 .............. 2-3000-102 .............2 ................................... POINTER — DEGREE INDICATOR

6 ..................2-3002 .................1 .......................................HOOK, 1/2"–1 1/4" RIGID/IMC

7 ....................99-8 ...................2 ............................... SCREW, SKT. HD. CAP — 1/4-20 × 1/2"

8 ...................99-59 ..................4 ............................. SCREW, SKT. HD. CAP — 3/8-16 × 1 1/4"

9 ................ 450-14G ................2 .............................................. WASHER, LOCK 1/4"

10 .................2-4000 .................1 ........... ROLLER SUPPORT – 1/2" TO 2" RIGID AND 1/2" TO 1 1/4" IMC

11 ............2-4000-107A ............1 ........................ROLLER SUPPORT ASSEMBLY – 1/2" TO 1 1/4"

12 ............. 2-4000-122 ..............1 ...................................................... HINGE PIN

13 ............. 2-4000-123 ..............1 .......................................... RETAINING RING – 7/16"

14 ............. 2-4000-125 ..............1 ......................... ROLLER SUPPORT ASSEMBLY – 1 1/2" TO 2"

15 ............. 2-4000-001 ..............4 ............................... COLLAR, 3/4" I.D. — 1 1/2"–2" ROLLER

16 ............2-4000-106A ............1 ........................... WELDMENT – 1 1/2"–2" ROLLER SUPPORT

17 ............. 2-4000-128 ..............1 ................................. PIN – 3/4" DIA. FOR 1 1/2" ROLLER

18 ............. 2-4000-126 ..............1 ........................................... ROLLER — 1 1/2" RIGID

19 ............. 2-4000-127 ..............1 .............................................. ROLLER — 2" RIGID

20 ............. 2-4000-115 ..............2 .................................... PIN — 3/4" DIA. FOR 2" ROLLER

PARTS LIST — SINGLE SHOES & ROLLER SUPPORTS

2-3200 & 2-4300 Bending Shoe & Roller Support — 1/2" to 2" PVC Coated RIGID Conduit

ITEM # PART # QTY DESCRIPTION

1.......................2-1304 ..................... 4 ................................................ DRIVE STUD

2..................... 2-2301-2 .................... 3 ...................... SCREW, SHOULDER SOCKET — 3/4 × 1 1/2"

3.......................2-3203 ..................... 1 ............................ HOOK, 1 1/2"–2" PVC COATED RIGID

4................... 2-3200-101 .................. 1 ............................ SHOE — 1/2"–2" PVC COATED RIGID

5................... 2-3000-102 .................. 2 ............................... POINTER — DEGREE INDICATOR

6.......................2-3202 ..................... 1 ........................... HOOK, 1/2"–1 1/4" PVC COATED RIGID

7.........................99-8 ....................... 2 ...........................SCREW, SKT. HD. SKT. — 1/4-20 × 1/2"

8........................99-59 ...................... 4 ......................... SCREW, SKT. HD. CAP — 3/8-16 × 1 1/4"

9..................... 450-14G .................... 2 .......................................... WASHER, LOCK 1/4"

10......................2-4300 ..................... 1 ...............ROLLER SUPPORT — 1/2" TO 2" PVC COATED RIGID

11.................2-4000-107B................. 1 ....................ROLLER SUPPORT ASSEMBLY – 1/2" TO 1 1/4"

12.................. 2-4000-122 .................. 1 .................................................. HINGE PIN

13.................. 2-4000-123 .................. 1 ..................................... RETAINING RING — 7/16"

14.................. 2-4300-103 .................. 1 ..................... ROLLER SUPPORT ASSEMBLY – 1 1/2" TO 2"

15.................. 2-4000-001 .................. 4 ........................... COLLAR, 3/4" I.D. — 1 1/2"–2" ROLLER

16.................2-4000-106B................. 1 ...................... WELDMENT — 1 1/2"–2" ROLLER SUPPORT

17.................. 2-4000-128 .................. 1 .............................. PIN – 3/4" DIA. FOR 1 1/2" ROLLER

18.................... 2-1005A ....................1 ........................... ROLLER — 1 1/2" PVC COATED RIGID

19.................... 2-1005B ....................1 .............................. ROLLER — 2" PVC COATED RIGID

20.................. 2-4000-115 .................. 2 ................................ PIN — 3/4" DIA. FOR 2" ROLLER

PARTS LIST — SINGLE SHOES & ROLLER SUPPORTS

2-3100

6 1

Bending Shoe 1/2" to 2" EMT Conduit

ITEM # PART # QTY DESCRIPTION

1 ................ 2-1304 ........................ 4 ................................... DRIVE STUD

2 ...............2-2301-2 ...................... 3 ....... SCREW, SHOULDER SOCKET — 3/4" × 1 1/2"

3 ................ 2-2303 ........................ 1 ............................ HOOK, 1 1/2"–2 EMT

4 .............2-3000-102 .................... 2 ................. POINTER — DEGREE INDICATOR

5 .............2-3100-101 .................... 1 ........................... SHOE — 1/2"–2" EMT

6 ................ 2-3102 ........................ 1 .......................... HOOK, 1/2"–1 1/4" EMT

7 .................. 99-8 .......................... 2 ............. SCREW, SKT. HD. CAP — 1/4-20 × 1/2"

8 ................. 99-59 ......................... 4 ............SCREW, SKT. HD. CAP — 3/8-16 × 1 1/4"

9 ............... 450-14G ...................... 2 ............................ WASHER, LOCK 1/4"

PARTS LIST — SINGLE SHOES & ROLLER SUPPORTS

2-4200 Roller Support 1/2" to 2" EMT Conduit

ITEM # PART # QTY. DESCRIPTION

1 ..................2-1103 ................... 2 ................................ ROLLER - 1.5" EMT

2 ..................2-1108 ................... 1 .................................... SPACER TUBE

3 ..................2-1109 ................... 4 ............................... 3/4" RETAINER RING

4 ..................2-1111 ................... 1 .......................187" DIA. X 1.25 LG ROLL PIN

5 ..................2-1112 ................... 2 ............... 1/2-13 X .75 LG SET SCREW - CONE PT

6 ..................2-1116 ................... 2 .................................. ROLLER - 2" EMT

7 ..................2-1118 ................... 8 ............................ 7/16-14 X 1.00 LG FHCS

8 ............. 2-4000-107D .............. 1 ...................1/2" - 1.25" EMT ROLLER SUPPORT

9 .............. 2-4000-122 ............... 1 ................................ HINGE PIN, UPPER

10 ............. 2-4000-123 ............... 1 .............................. 7/16" RETAINER RING

11 ............ 2-4100-107D .............. 1 ..................... EMT ROLLER SUPPORT FRAME

12 ............. 2-4100-118 ............... 1 ........................... AXLE, ROLLER BRACKET

13 ............. 2-4100-119 ............... 2 ............................. BRACKET - 2" ROLLER

14 ............. 2-4100-121 ............... 1 ......................... SPRING CLIP, 2.00" ROLLER

15 ............. 2-4100-122 ............... 1 ......................... SPRING CLIP, 1.50" ROLLER

16 ............. 2-4100-123 ............... 2 ................... 3/4" DIA. PIN, 1.50" - 2.00" ROLLER

17 ............. 2-4100-124 ............... 2 ..........................................SPRING

18 ............... 2-4200-1 ................. 1 ............................. DECAL (NOT SHOWN)

19 ............. 2-4200-101 ............... 2 ....................... BRACKET, 1.50" EMT ROLLER

20 ................747-858 .................. 2 ................................. ROLLER PIN 1.50"

21 ................747-859 .................. 2 ................................. ROLLER PIN 2.00"

22 ................747-894 .................. 2 .............................. ROLLER - URETHANE

23 .................8092-2 ................... 2 ......... SCREW-HEX HEAD CAP GR5 ZINC (1/2-13 X 1)

PARTS LIST — SINGLE SHOES & ROLLER SUPPORTS

2-3000 Bending Shoe 1/2" to 2" IMC Conduit

ITEM # PART # QTY DESCRIPTION

1 ................ 2-1304 ........................ 4 ................................... DRIVE STUD

2 ...............2-2301-2 ...................... 3 ....... SCREW, SHOULDER SOCKET — 3/4" × 1 1/2"

3 ................ 2-2302 ........................ 1 ....................... HOOK, 1 1/2"–2 RIGID/IMC

4 .............2-3000-101 .................... 1 .......................SHOE — 1/2"–2" RIGID/IMC

5 .............2-3000-102 .................... 2 ................. POINTER — DEGREE INDICATOR

6 ................ 2-3002 ........................ 1 ..................... HOOK, 1/2"–1 1/4" RIGID/IMC

7 .................. 99-8 .......................... 2 ............. SCREW, SKT. HD. CAP — 1/4-20 × 1/2"

8 ................. 99-59 ......................... 4 ........... SCREW, SKT. HD. CAP — 3/8–16 × 1 1/4"

9 ............... 450-14G ...................... 2 ............................ WASHER, LOCK 1/4"

PARTS LIST — SINGLE SHOES & ROLLER SUPPORTS

2-4100 Roller Support — 1/2" to 2" IMC Conduit

ITEM # PART # QTY. DESCRIPTION

1 .................2-1108 ........................... 1 ........................................ SPACER TUBE

2 .................2-1109 ........................... 4 ...................................3/4" RETAINER RING

3 .................2-1111 ........................... 1 .......................... .187" DIA. X 1.25 LG ROLL PIN

4 .................2-1112 ........................... 2 ...................1/2-13 X .75 LG SET SCREW - CONE PT

5 .................2-1118 ........................... 8 ................................ 7/16-14 X 1.00 LG FHCS

6 .................2-1204 ........................... 2 .....................................1.50" IMC ROLLER

7 .................2-1205 ........................... 2 .....................................2.00" IMC ROLLER

8 ............2-4000-107C ...................... 1 ....................... .50" - 1.25" IMC ROLLER SUPPORT

9 ............. 2-4000-122 ........................ 1 .................................... HINGE PIN, UPPER

10 ............ 2-4000-123 ........................ 1 .................................. 7/16" RETAINER RING

11 .............. 2-4100-1 .......................... 1 ................................. DECAL (NOT SHOWN)

12 ...........2-4100-107C ...................... 1 ..........................IMC ROLLER SUPPORT FRAME

13 ............ 2-4100-118 ........................ 1 ............................... AXLE, ROLLER BRACKET

14 ............ 2-4100-119 ........................ 2 ............................... BRACKET, 2.00" ROLLER

15 ............ 2-4100-120 ........................ 2 ............................BRACKET, 1.50" IMC ROLLER

16 ............ 2-4100-121 ........................ 1 ............................. SPRING CLIP, 2.00" ROLLER

17 ............ 2-4100-122 ........................ 1 ............................. SPRING CLIP, 1.50" ROLLER

18 ............ 2-4100-123 ........................ 2 ............................... .75" PIN, FOR 2" ROLLER

19 ............ 2-4100-124 ........................ 2 ..............................................SPRING

20 ...............747-858 .......................... 2 ..................................... ROLLER PIN 1.50"

21 ...............747-859 .......................... 2 ..................................... ROLLER PIN 2.00"

22 ...............747-894 .......................... 2 ..................................ROLLER - URETHANE

23 ................8092-2 ........................... 2 .............SCREW-HEX HEAD CAP GR5 ZINC (1/2-13 X 1)

24 ............ 2-4100-126 ........................ 1 ............................ .75" PIN FOR 1 1/2" ROLLER

25 ............ 2-4000-001 ........................ 1 ...................................... .75" I.D. COLLAR

Current Tools RotaBoom 77-22, RotaBoom 77SE-22, RotaBoom 77SR-22, RotaBoom 700SP, RotaBoom 700SI Operating, Maintenance, Safety And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual