Greenlee 854 Service Manual
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Greenlee 854 Service Manual

Greenlee 854 benders: supplementary guide
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SERVICE MANUAL
854
Quad Bender
Serial Number AKM
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
52033654 REV 1
© 2008 Greenlee Textron Inc.
1/08

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Summary of Contents for Greenlee 854

  • Page 1 SERVICE MANUAL Quad Bender Serial Number AKM Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 52033654 REV 1 © 2008 Greenlee Textron Inc. 1/08...

  • Page 2: Table Of Contents

    Instruction Manual: Publication 52033653 All specifications are nominal and may change as design improvements occur. Greenlee Textron Inc. shall not be liable for damages resulting from misapplication or misuse of its products. Loctite is a registered trademark of Loctite Corporation.

  • Page 3: Important Safety Information

    Using this tool in a hazard- ous environment can result in a fire or explosion. Failure to observe this warning will result in severe injury or death. Greenlee / A Textron Company 854 Quad Bender Electric shock hazard: • Connect the power cord to a 120 volt, 20 amp receptacle on a ground fault protected circuit only.

  • Page 4: Important Safety Information

    Loose clothing can get caught in moving parts. • Inspect the bender before use. Replace worn, damaged or missing parts with Greenlee replace- ment parts. A damaged or improperly assem- bled component could break and strike nearby personnel. •...

  • Page 5: Transportation And Setup

    2. Rotate the lifting eyes so they are accessible. 3. Loop the slings through, or attach the hooks to, the lifting eyes. 4. Hoist the bender. Greenlee / A Textron Company 854 Quad Bender Pivoting the Bender Head The bender head has two bending positions — vertical and horizontal.

  • Page 6: Maintenance

    Replacement Brushes * More often if the bender is used in dusty or corrosive environments. Greenlee / A Textron Company Chain Lubrication and Tension Adjustment 1. Disconnect the bender from the power source. 2. See the 1-1/2" to 2" Side Exploded View. Remove the 1-1/2"...
  • Page 7 Remove the tail roller (82) and center roller (85). • Remove all components of the split roller assembly. Greenlee / A Textron Company 854 Quad Bender 10. Clean off all of the grease and dirt. 11. Inspect each item. Replace any worn, damaged, or missing items.
  • Page 8 Push the shoe onto the spindle until the drive lugs are fully engaged in the drive lug holes. Replace the retaining ring. Greenlee / A Textron Company 854 Quad Bender Setting Roller Support Limit Switch The switch is activated by the main outer roller support arm, in the retracted position.

  • Page 9: Maintenance

    Tighten the two mounting screws to retain the switch. Note:  The lower switch mounting slots are not used. Greenlee / A Textron Company Pointer Accuracy Note:  Pointers may be adjusted with shoes on the  spindle. 1. Loosen the two locking screws (29).

  • Page 10: Troubleshooting

    Problem Bender will not operate. Bender operates in wrong direction. Bends are overbent a few degrees. Bends are underbent a few degrees. Greenlee / A Textron Company Probable Cause No voltage. Wrong side of bender selected. Pointer is adjusted wrong.

  • Page 11: Troubleshooting

    Is the supply line voltage low? Does bender stop when the pendant is unplugged? Replace PGU. Bender only runs in one direction On 854 move pendant plug to I/O board. Does bender run both directions? Does amber or red LED light when switch is pressed?

  • Page 12: Exploded Views And Parts Lists

    1/2" to 1-1/4" Side Exploded View Greenlee / A Textron Company 43 Shoe Unit 1/2" to 1-1/4" consists of 221, 222, 223, 224 and 225 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 854 Quad Bender...
  • Page 13 1-1/2" to 2" Side Exploded View Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 854 Quad Bender The Roller Support Unit exploded view is on the following page. 44 Shoe Unit 1-1/2" to 2" consists...
  • Page 14 23258 50232584 Grip... 1 91 38256 50382560 Shaft, eccentric ..1 92 38251 50382519 Sleeve adapter ..1 Greenlee / A Textron Company 94 75 *Torque to 94 Nm (70 ft-lb) UPC No. Key 78-3310- Qty. 93 50540 94 00860 95...
  • Page 15 2. Assemble all Belleville washers so that I.D.’s butt and O.D.’s contact bearings. 3. Tighten motor nuts (24) to 3/4 Nm (30/35 in-lb). 4. Insert commutator brushes before connecting push-on terminals. Greenlee / A Textron Company UPC No. Key 78-3310- 1 86705...
  • Page 16 Main Exploded View Power Cord 209, 211, 212 (place decal in center on back) Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 854 Quad Bender 14, 28 4, 4A...
  • Page 17 4, 4A Greenlee / A Textron Company Note: These items 87 94 are available as Part No. 500 0574.0 Roller Support Unit. 854 Quad Bender 99, 119 or 150 178* *Torque to 94 Nm (70 ft-lb) 101 90 If the chain breaks, replace it with a new chain —...
  • Page 18 Breaker, circuit 20 amp ..1 50 54927 90549279 Screw, cap #8-32 x 1.37 socket ... 4 51 86841 91868416 Brake, motor ..1 52 38807 50388070 Key, brake ..1 Greenlee / A Textron Company UPC No. Qty. Key 78-3310- Part No. Description 54 54151 90541510 Knob, plastic w/ set screw ... 1 58 03129 50031295 Decal, angle .
  • Page 19 50014536 Decal, shoe orientation (not shown)... 2 178 55305 90553055 Screw, 7/16-14 x 1.75 ..1 201 52031175 Base assembly ... 1 202 52031167 Tower weldment, L.H. trunnion... 1 Greenlee / A Textron Company UPC No. Qty. Key 78-3310- Part No. Description 203 52031170 Tower weldment, R.H. trunnion ... 1 204 53390 90533909 Wheel ... 2 205...

  • Page 20: Wiring Diagram

    Wiring Diagram Greenlee / A Textron Company 854 Quad Bender YELLOW YELLOW BLACK FROM RECTIFIER GREEN BLACK WHITE 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 21: Wiring Diagram

    * Switch only (without wire harness) can be purchased as repair part 91869811 Greenlee / A Textron Company Description 854 I/O Control assembly ... 1 Wire unit, power — DC ... 1 Wire unit, power — AC ... 1 Wire unit, I/O — PGU ... 1 Wire unit, ground ...

  • Page 22: I/O Electrical Schematic

    854 Quad Bender I/O Electrical Schematic (50060180) Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 23: I/O Electrical Schematic

    R16,R17,R18,R22,R23 R5,R11,R13,R14 Generic R6,R20,R21 Generic R9,R19 Generic R10,R12 Generic Greenlee Murata Panasonic Greenlee / A Textron Company Part Number Description A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts SA115C104KAA C420C104K5R5CA ECE-A50Z4R7 Capacitor, 4.7 uF, 50 volts UF-1001-DI Diode, Ultra-Fast Switching Rectifier LN38GP...

  • Page 24: Pcb Layout

    PCB Layout (50060180) GREENLEE TEXTRON ©2000 TO PGU Greenlee / A Textron Company BRAKE 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 854 Quad Bender DIR B DIR A POWER RELAY...

  • Page 25: Power Generation Unit

    Power Generation Unit Schematic Diagram (50054678) Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 854 Quad Bender...
  • Page 26 R9,R11 Generic R10,R13 Generic Dale Riedon R16,R23,R25 Generic Dale Riedon Dale Greenlee / A Textron Company Part Number Description A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts SA115C104KAA C420C104K5R5CA MKS21.06310 Capacitor, Film, 1 uF, 63 volts A103M15Z5UFVVWA Capacitor, .01 uF, 50 volts...

  • Page 27: Power Generation Unit

    Note 1: Mount D8 to bottom hole of heat sink. Note 2: Mount Q1 to top hole of heat sink. Note 3: Bend leads and mount 0.25" off-board. Layout Diagram — Power Generation Unit (50054678) Greenlee / A Textron Company Part Number Description UT-2B 20K Resistor, 1 kΩ, 1/4 watt, 5%...
  • Page 28 Fax: Canada 800-435-0786 Fax: International +1-815-397-7070 Fax: +1-815-397-9247 4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070 • An ISO 9001 Company Greenlee Textron Inc. is a subsidiary of Textron Inc. www.greenlee.com 800-451-2632 815-397-1865 800-524-2853 Printed in USA...

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