Textron GREENLEE 854 Instruction Manual
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Textron GREENLEE 854 Instruction Manual

Textron GREENLEE 854 Instruction Manual

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INSTRUCTION MANUAL
854
Quad Bender
Beginning with Serial Number ABT0000
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99922223
© 2007 Greenlee Textron Inc.
IM 1301 REV 13 10/07

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  • Page 1 INSTRUCTION MANUAL Quad Bender Beginning with Serial Number ABT0000 Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 99922223 © 2007 Greenlee Textron Inc. IM 1301 REV 13 10/07...

  • Page 2: Table Of Contents

    All specifications are nominal and may change as design which case the user will be required to correct the interfer- improvements occur. Greenlee Textron Inc. shall not be liable for ence at his own expense. damages resulting from misapplication or misuse of its products. Do not make any modifications to this device. Unauthorized  Loctite is a registered trademark of Loctite Corporation.

  • Page 3: Important Safety Information

    Failure to observe this warning will result in severe injury or death. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 4 Do not operate the bender while wearing loose clothing. Loose clothing can get caught in moving parts. Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 5: Grounding Instructions

    Failure to observe these warnings ordinances. could result in severe injury or death. Do not use an adapter. 20 Amp/120 Volt Plug and Receptacle Plug Receptacle Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 6: Identification

    Temperature .............. 0 °C to 49 °C (32 °F to 120 °F) Relative Humidity ..................0 to 98% Capacity ............1/2" to 2" conduit and schedule 40 pipe Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 7: Transportation And Setup

    If desired, lower all four jack screws to level the bender. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 8: Operation

    Unplug the bender before changing accessories. c. Press and hold UNLOAD until the shoe has Accidental start-up could result in serious injury. rotated back to 0°. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 9 Changing the squeeze may affect the bending accuracy. If the pointers are inaccurate after changing the squeeze, see Pointer Accuracy under Maintenance. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 10: Illustrated Bending Glossary

    Offset Bending in this manual. springback — the amount, measured in degrees, that a conduit or pipe tends to straighten after being bent. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 11: Bending Instructions

    90-1/2 23-1/2 61-1/2 91-1/2 23-1/2 22-1/2 59-1/2 3-1/2 18-1/2 33-1/2 48-1/2 63-1/2 2" 23-1/2 45-1/2 60-1/2 90-1/2 24-1/2 61-1/2 91-1/2 24-1/2 31-1/2 46-1/2 61-1/2 91-1/2 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 12 1-1/2 15-15/16 11-1/16 38-5/8 19-15/16 1-1/4 13-13/16 46-3/8 23-15/16 1-1/2 16-5/8 54-1/16 27-15/16 19-7/16 61-13/16 31-15/16 22-1/4 69-9/16 35-15/16 25-1/16 77-1/4 39-15/16 27-15/16 43-15/16 30-3/4 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 13: Special Bending Information

    Instructions. Subtract X from the LENGTH and mark the conduit, as shown. 3. Find the corresponding section of the Special BENDING BENDING Bending Information Chart. MARK 1 MARK 2 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 14 4. Mark the conduit as shown. Bend the conduit. HEIGHT ANGLE LENGTH LENGTH – Z BENDING BENDING BENDING MARK 1 MARK 2 MARK 3 HEIGHT BENDING BENDING MARK 1 MARK 2 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 15 23.53 30.46 MINIMUM H = 8.38 5.74 8.74 14.74 26.74 12.57 15.57 21.57 33.57 21.47 24.47 30.47 42.47 14.47 14.47 14.47 14.47 MINIMUM H= 14.47 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 16 29.32 36.25 50.10 23.08 24.81 28.28 35.21 MINIMUM H = 12.49 1.23 4.23 10.23 22.23 20.10 32.10 34.37 46.37 22.10 22.10 MINIMUM H = 22.10 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 17 16.27 19.73 26.66 40.52 26.51 29.96 36.80 50.76 25.45 27.19 30.65 37.58 MINIMUM H = 14.54 1.62 7.62 19.62 31.80 47.16 25.06 MINIMUM H= 25.06 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 18 MINIMUM H = 8.31 2.76 5.76 8.76 14.76 26.76 12.60 15.60 21.60 33.60 21.39 24.39 30.39 42.39 14.33 14.33 14.33 14.33 MINIMUM H = 14.33 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 19 29.25 36.18 50.04 23.00 24.73 28.20 35.13 MINIMUM H = 12.42 1.23 4.23 10.23 22.23 20.13 32.13 34.29 46.29 21.96 21.96 MINIMUM H = 21.96 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 20 19.77 26.70 40.55 26.13 29.59 36.52 50.38 24.99 26.72 30.18 37.11 MINIMUM H = 14.14 1.94 7.94 19.94 31.98 46.70 24.25 MINIMUM H = 24.25 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 21: Maintenance

    4. Spray the pivot pin. 5. Wipe away any excess lubricant. 6. Replace the roller support and pivot pin. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 22 (95) from the tail roller shaft (83). Remove outer roller plate (76). • Remove the tail roller (82) and center roller (85). • Remove all components of the split roller assembly. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 23 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 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 24: Troubleshooting

    Too little squeeze on 1-1/2" or 2" Increase squeeze per adjustment EMT or IMC conduit. instructions. Unusual conduit characteristics. Adjust pointer or bend to a larger angle to compensate. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 25 12 VDC measured at large relay UNLOAD is pressed? Replace PGU. coil on PGU (where relay wire unit connects)? Replace PGU. Replace 918 6645.6 relay. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 26: Exploded Views, Parts Lists, Schematics And Wiring Diagrams

    854 Quad Bender 1/2" to 1-1/4" Side Exploded View 43 Shoe Unit 1/2" to 1-1/4" consists of 221, 222, 223, 224 and 225 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 27 The Roller Support Unit exploded view is on the following page. 44 Shoe Unit 1-1/2" to 2" consists of 224, 226, 227, 228 and 229 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 28 52644 90526449 Washer, 1/32 shim ..........1 150 52645 90526457 Washer, 1/16 shim ..........1 89 38151 50381512 Sleeve, 2" ............1 151 53216 90532163 Retaining ring #5100-62 ........1 90 23258 50232584 Grip ..............1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 29 3. Tighten motor nuts (24) to 3/4 Nm (30/35 in-lb). 23 02298 50022989 1/4-28 x 9-1/4" Stud 4. Insert commutator brushes before connecting 24 51705 90517059 1/4-28 Hex nut push-on terminals. 25 50749 90507495 1/4" Internal tooth lockwasher Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 30 854 Quad Bender Main Exploded View Power Cord 14, 28 209, 211, 212 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 31 If the master link breaks, replace it with a new master link (90542517). Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 32 86841 91868416 Brake, motor ............1 97 50224 90502248 Screw, 5/16-18 x 1.00 socket head ....1 52 38807 50388070 Key, brake ............1 98 50881 90508815 Screw, 1/4-28 x .25 set ........2 54 54151 90541510 Knob, plastic w/ set screw ........1 99 53018 90539184 Washer, 1.00 x 1.37 x .03 shim ......1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 33 05586 500 5860 Frame unit (includes bearings) ......1 207 54237 90542371 Screw, flange 3/8-16 x 1.00 hex .....16 208 52646 90526465 Nut, 3/8-16 Esna hex ........4 209 38167 50381679 Pin, trunion lock..........1 211 54244 90542444 Spring, trunion lock ..........1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 34 854 Quad Bender Wiring Diagram Serial Numbers ABT0000 through ABT1199 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 35 50030523 Switch unit, selector ..........1 121E 50386425 Wire unit, rectificer (rec) ........1 90542797 Tie, cable (not shown) ..........3 121F 50386433 Wire unit, rectificer (yellow) ........2 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 36 POWER 2.2M 470K 2.2M 2N3906 .1u/50V DIR A .1u/50V DIR B 2.2K 1.8K 3.3K 2N3904 1N4007 2N3906 2N3904 1N4007 .1u/50V .1u/50V .1u/50V TO RELAY COIL Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 37 1.8K Resistor 3.3K Resistor R4,R8,R15,R16,R17 Resistor Resistor 470K Resistor R7,R20,R21 Resistor 2.2K Resistor R5,R6 2.2M Resistor R22,R23,R24 Resistor 4MHZ Ceramic Resonator 18-pin .3 DIP Socket Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 38 PCB Layout (50030515) Serial Numbers ABT0000 through ABT1199 TO PGU TRANSFORMER 120 VAC WHITE C101 GREENLEE TEXTRON 500 3051.5 REV. 1 BRAKE DIR. SWITCH RELAY Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 39 854 Quad Bender Power Generation Unit Schematic Diagram Serial Numbers ABT0000 through ABT1199 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 40 39-28-1063-P — J3,J7 Connector Mini-Fit Jr. Molex 39-28-1023-P — Connector — Beau 72502 — J5,J6 Connector Mini-Fit Jr. Molex 39-01-2020-P 91866936 Transistor 2N3904 Motorola 2N3904 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 41 Power Generation Unit Layout Diagram Serial Numbers ABT0000 through ABT1199 TO I/O LINE NEUTRAL TO RELAY ANODE GREENLEE TEXTRON 500 3646.7 BLK (-) RED (+) 120VAC 0VAC Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 42 854 Quad Bender Wiring Diagram Beginning with Serial Number ABT1200 YELLOW YELLOW BLACK FROM RECTIFIER GREEN BLACK WHITE Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 43 Wire Unit, PGU to Breaker ........1 91868394 Wire Unit, I/O to PGU ..........1 50386034 Cord Unit, Power ..........1 50030523 Switch, PCB Direction .........1 90542797 Tie, Cable (not shown) .........3 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 44 854 Quad Bender I/O Electrical Schematic (50060180) Beginning with Serial Number ABT1200 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 45 Resistor, 1 kΩ, 1/4 watt, 5% R10,R12 Generic Resistor, 150 Ω, 1/4 watt, 5% Greenlee 91869382 Processor, Programmed, 854 Murata CST4.00MGW Resonator, 4.0 Mhz Panasonic EFO-GC4004A4 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 46 854 Quad Bender PCB Layout (50060180) Beginning with Serial Number ABT1200 GREENLEE TEXTRON ©2000 DIR B DIR A POWER BRAKE RELAY TO PGU Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 47 854 Quad Bender Power Generation Unit Schematic Diagram (50054678) Beginning with Serial Number ABT1200 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 48 Resistor, 4.7 kΩ, 10 watt, 5% (see Note 3) C-10A 4.7K Riedon UT-10 4.7K Dale RS-2B-20K Resistor, 20 kΩ, 2 watt, 1% C-2A 20K Riedon UT-2B 20K Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 49 Note 3: Bend leads and mount .25" off-board . Layout Diagram — Power Generation Unit (50054678) Beginning with Serial Number ABT1200 Yellow Yellow GREENLEE TEXTRON Black ©2000 FROM RECTIFIER Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

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