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Textron GREENLEE 854, Instruction Manual

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Textron GREENLEE 854 Instruction Manual Download Page 24

854 Quad Bender

Greenlee / A Textron Company

4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

24

Troubleshooting

Problem

Probable Cause

Probable Remedy

Bender will not operate.

No voltage.

Check supply voltage circuit 

operation.

Check that switch is ON.

Bender operates in wrong direction.

Wrong side of bender selected.

Set selector switch properly.

Bends are overbent a few degrees.

Pointer is adjusted wrong.

Loosen pointer locking screws and 

rotate clockwise to compensate. 

Retighten locking screws.

Too much squeeze on 1-1/2" or 2" 

EMT or IMC conduit.

Back squeeze off per adjustment 

instructions.

Unusual conduit characteristics.

Adjust pointer or bend to a smaller 

angle to compensate.

Bends are underbent a few degrees. Pointer is adjusted wrong.

Loosen pointer locking screws and 

rotate counterclockwise to compen-

sate. Retighten locking screws.

Too little squeeze on 1-1/2" or 2" 

EMT or IMC conduit.

Increase squeeze per adjustment 

instructions.

Unusual conduit characteristics.

Adjust pointer or bend to a larger 

angle to compensate.

Summary of Contents for GREENLEE 854

Page 1: ...ad Bender 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 Beginning wi...

Page 2: ...nerates uses and can radiate radio fre quency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this eq...

Page 3: ...Do not use this tool in a hazard ous environment Hazards include flammable liquids gases or other materials Using this tool in a hazard ous environment can result in a fire or explosion Failure to obs...

Page 4: ...while wearing loose clothing Loose clothing can get caught in moving parts Failure to observe this warning could result in severe injury or death IMPORTANT SAFETY INFORMATION Inspect the bender before...

Page 5: ...grounded In the event of a malfunc tion or breakdown an electrical ground provides a path of least resistance for the electric current This path of least resistance is intended to reduce the risk of e...

Page 6: ...32 F to 120 F Relative Humidity 0 to 98 Capacity 1 2 to 2 conduit and schedule 40 pipe 854 Conduit Bender 1 Bender Power Head 2 1 2 to 1 1 4 Bending Shoe 3 On Off Switch and Circuit Breaker 4 Bender...

Page 7: ...ack Screws The bender is equipped with four jack screws To park the bender at the jobsite use the 5 16 T handle Allen wrench which is shipped in the lockable storage area to lower two of the jack scre...

Page 8: ...asic instructions for marking and bending the conduit They are based on measurements with common fractions for accurate results For a higher level of precision see the Special Bending Information sect...

Page 9: ...e manual ADJUSTING THE SQUEEZE When bending 1 1 2 to 2 EMT IMC and rigid alumi num conduit the roller support must be engaged so that the roller supports the conduit the pressure against the conduit i...

Page 10: ...ection of conduit or pipe to the bend measured from the end to the outside edge of the conduit or pipe offset bend two opposite bends with the same degree of bend used to avoid an obstruction offset h...

Page 11: ...t 0 15 22 1 2 30 45 60 90 EMT 1 16 1 2 24 31 1 2 46 1 2 61 1 2 91 1 2 IMC 2 1 2 17 1 2 25 1 2 33 48 63 1 2 93 1 2 1 2 RIG 1 16 1 2 24 31 1 2 46 1 2 61 1 2 91 1 2 AL 1 16 23 1 2 31 46 1 2 61 1 2 91 1 2...

Page 12: ...nder align Bending Mark 2 with the front edge of the hook and rotate the conduit 180 Make the second bend CENTER TO CENTER BENDING MARK 1 BENDING MARK 1 BENDING MARK 2 BENDING MARK 2 START OF BEND STA...

Page 13: ...er to center distance is then used to measure and mark the distance to the first bend Offsets Working Past an Obstruction 1 Select the size and type of conduit Measure the height of the obstruction an...

Page 14: ...the conduit until the second bending mark is aligned with the front edge of the hook rotate the conduit 180 and make the second bend Then advance the conduit to the third bending mark rotate the cond...

Page 15: ...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 1...

Page 16: ...2 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...

Page 17: ...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...

Page 18: ...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...

Page 19: ...7 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...

Page 20: ...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 Y 15 4 15 11...

Page 21: ...section of the manual 3 See the Main Exploded View Remove the screws 23 and front chain guard assembly 4 4 Spray a motorcycle chain lubricant on the inside of the chain between the sprockets while pr...

Page 22: ...ove outer roller plate 76 Remove the tail roller 82 and center roller 85 Remove all components of the split roller assembly 10 Clean off all of the grease and dirt 11 Inspect each item Replace any wor...

Page 23: ...the shoe bore with the screw head on the spindle Push the shoe onto the spindle until the drive lugs are fully engaged in the drive lug holes Replace the retaining ring Pointer Accuracy 1 Loosen the...

Page 24: ...en pointer locking screws and rotate clockwise to compensate Retighten locking screws Too much squeeze on 1 1 2 or 2 EMT or IMC conduit Back squeeze off per adjustment instructions Unusual conduit cha...

Page 25: ...aged or discolored NO Does the green LED on the PGU light Replace PGU NO Unplug pendant or I O and check switch for continuity If ok replace I O Does amber or red LED on I O light when BEND or UNLOAD...

Page 26: ...Textron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 26 1 2 to 1 1 4 Side Exploded View 24 7 19 204 205 206 206 213 5 26 23 43 Shoe Unit 1 2 to 1 1 4 consists of 221 222 223 224 and...

Page 27: ...kford IL 61109 2988 USA 815 397 7070 27 1 1 2 to 2 Side Exploded View 3 207 215 207 215 213 74 96 91 92 26 224 226 226 227 228 229 44 Shoe Unit 1 1 2 to 2 consists of 224 226 227 228 and 229 232 The R...

Page 28: ...91 38256 50382560 Shaft eccentric 1 92 38251 50382519 Sleeve adapter 1 93 50540 90505409 Screw 7 16 14 x 1 00 hex head 3 94 00860 50008609 Shaft 1 1 2 Support 1 95 54819 90548191 Retaining ring 5100...

Page 29: ...brush retension springs 3 86707 91867070 Tail housing 4 86708 91867088 Brush assembly plate 5 86709 91867096 Cord 6 39092 50390929 Shroud 8 52028638 Armature housing set 8A 86071 91860717 Bearing 9 5...

Page 30: ...0 30 Main Exploded View 3 58 58 5 7 19 205 206 206 213 204 215 13 17 12 11 16 10 27 23 29 32 8 201 6 202 47 46 45 207 18 18 15 2 15 15 25 33 21 209 211 212 51 50 225 223 222 225 221 224 22 20A 14 28 2...

Page 31: ...87 94 75 93 151 101 90 93 99 119 or 150 Torque to 94 Nm 70 ft lb 93 88 76 117 95 104 83 85 105 82 80 79 81 79 80 Note These items are available as Part No 50005740 Roller Support Unit 106 107 96 92 9...

Page 32: ...reaker switch 1 47 86385 91863856 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 54 54151 90541510 Knob plastic...

Page 33: ...03 03136 50031368 Tower weldment R H trunion 1 204 53390 90533909 Wheel 2 205 38166 50381660 Axle long 1 206 51528 90515285 Ring retaining 5160 75 2 207 54237 90542371 Screw flange 3 8 16 x 1 00 hex 1...

Page 34: ...WHITE BLACK WHITE 121T 123 HV HV AC AC 0VAC 120VAC HV HV GREEN BLACK 121F TO DRIVE UNIT BLACK GREEN WHITE Note Use heat transfer grease between rectifier and PGU sub plate 121L 121K 121D 121E 121F 121...

Page 35: ...generation 1 121D 50386417 Wire unit rectificer black 1 121E 50386425 Wire unit rectificer rec 1 121F 50386433 Wire unit rectificer yellow 2 121G 50386395 Wire unit relay 1 121H 50386409 Wire unit PG...

Page 36: ...2 1 J4 D7 Red Amber DIR B R19 1K B Q5 2N3904 R16 220 R18 22K C E B Q4 2N3904 D6 1N4007 R14 3 3K Q3 1N4007 R13 1K R17 220 C11 1u 50V 10k R20 R21 10k C10 1u 50V D5 D4 TO PGU GND GND 1u 50V C8 1u 50V C9...

Page 37: ...nd Amber LED U4 MC7805 TO 220 5 VOLT Regulator U3 MC7812 TO 220 12 VOLT Regulator J4 J103 39 28 1023 Connector 2 pin Minifit Jr Molex J3 J101 39 28 1043 Connector 4 pin Minifit Jr Molex J2 J102 39 28...

Page 38: ...X1 DIR B DIR A PWR D5 D4 D3 WHITE RED R13 R4 R8 Q2 R7 R2 R6 R3 C1 R5 Q1 R18 R11 R9 R10 D6 Q3 R12 R14 R19 Q5 Q4 C5 C6 C7 U1 U2 C3 C2 U4 U3 C4 C101 D1 D102 D103 2 1 1 2 3 4 1 2 3 4 5 6 2 1 2 3 4 5 6 2...

Page 39: ...904 R1 4 7K R2 4 7K U1 F 4049 14 15 U1 A 4049 3 2 VCC HV VCC 120vac U4 B LM393NE 7 5 6 L1 HURRICANE HL8196 R20 0vac L2 HURRICANE HL8196 R15 R16 R17 R18 C3 10uF 250VAC C5 1000u 250V D3 1N914 R10 680 R6...

Page 40: ...torola 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 91868629 C5 Capacitor 1000mf 250v Nichicon LLR2D 91866...

Page 41: ...Layout Diagram Serial Numbers ABT0000 through ABT1199 D2 R11 R9 D1 Q2 ANODE R14 C3 L2 R18 R17 C5 C2 HV HV 120VAC 0VAC R19 DS1 J4 BLK GREENLEE TEXTRON 500 3646 7 RED U3 U2 TO I O J2 TO RELAY J3 K1 R15...

Page 42: ...h Serial Number ABT1200 23 47 126 122 123 121 120A 120B 120 120C 120D BLACK GREEN JP1 CN1 CN2 YELLOW YELLOW YELLOW AC AC HV HV WHITE WHITE RED BLACK YELLOW FROM RECTIFIER RED BLACK BLACK TO RELAY TO I...

Page 43: ...trol Assembly 1 120A 50060376 Wire Unit Power DC 1 120B 50060368 Wire Unit Power AC 1 120C 50386484 Wire Unit I O PGU 1 120D 50060406 Wire Unit Ground 1 121 50054678 PGU2 Assembly 1 122 50389416 Wire...

Page 44: ...0 16 OSC1 CLKIN 15 OSC2 CLKOUT 13 RB7 12 RB6 11 RB5 10 RB4 9 RB3 8 RB2 7 RB1 6 RB0 INT 4 MCLR 3 RA4 TOCKI 2 RA3 AN3 1 RA2 AN2 VREF PIC16C620 U1 10K R23 10K R22 UF1001DI D1 UF 1001 DI D5 UF 1001 DI D4...

Page 45: ...JP4 Molex 39 29 0043 Connector Minifit Jr 4 position Gold 1 JP2 JP3 Molex 39 29 0023 Connector Minifit Jr 2 position Gold 2 JP5 Molex 39 29 0063 Connector Minifit Jr 6 position Gold 1 Q1 Generic TIP12...

Page 46: ...Layout 50060180 Beginning with Serial Number ABT1200 Q1 JP1 R22 RELAY BRAKE TO PGU POWER JP4 1 2 3 4 JP5 1 2 3 4 5 6 R15 R1 D4 R21 C4 R18 D7 DIR A JP3 1 2 Q3 R13 R8 R9 C2 D3 R5 DIR B JP2 1 2 R6 C1 D2...

Page 47: ...50V C9 VCC GREEN LED D4 DIRECTION YELLOW LED D1 PWM RED LED D2 2K R8 2K R1 6 5 4 3 2 1 TEST CONNECTOR Molex 39 28 1063 J1 EVQ PAC09K S1 12 3 2 4 5 LM339 U1B 100K R13 1N4148 D6 1M R12 1N4148 D7 1M R14...

Page 48: ...Adv Pwr Tech APT30D60B D9 Vishay UF1001DI Diode Ultra Fast Switching 1A 50V 50ns DO 41 1 D13 D14 Generic 1N4007 Diode 2 J1 J2 Molex 39 29 0063 Connector Minifit Jr 6 position Gold 2 J4 Molex 39 29 002...

Page 49: ...9K Switch Momentary Pushbutton 1 U1 Motorola LM339AN IC Low Power Quad Comparitor 1 U2 Micrel MIC4422BN IC 9 A Peak Low Side Non inverting MOSFET Driver 1 U3 HP HCPL4502 IC Opto isolator 1 QT Opto HCP...

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