854 Quad Bender
Greenlee / A Textron Company
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
25
Troubleshooting
(cont’d)
The following flow charts show the suggested trouble-
shooting procedures for some bender problems. They
by no means encompass all possible problems or
solutions.
Electric shock hazard:
Contact with live circuits can result
in severe injury or death.
Some troubleshooting steps
require power to the bender.
This type of troubleshooting
step should only be performed
at authorized Greenlee service
centers by personnel who are
familiar with safe troubleshooting
procedures.
Failure to observe these warnings
could result in severe injury or death.
•
•
YES
YES
NO
YES
YES
YES
Won’t bend
YES
YES
NO
YES
NO
NO
NO
NO
YES
Trips circuit breaker
Won’t stop
Bender only runs in one direction
YES
NO
Is 115 VAC measured at
PGU board input?
Plugged into dead cir-
cuit, bad power cord, or
switch is bad or off.
NO
Replace transformer unit.
Does the green LED on
the I/O board light?
YES
Replace PGU.
Are metal oxide varistors
(MOVs) on PGU board
damaged 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 is pressed?
NO
Does relay on I/O
operate when BEND or
UNLOAD is pressed?
Replace I/O.
Replace PGU.
YES
On 854 move pendant plug to
I/O board. Does bender run both
directions?
Replace direction
switch assembly.
NO
Check and replace
pendant switch.
Does amber or red LED light when
switch is pressed?
NO
Replace PGU.
When amber or red LED is on, is
12 VDC measured at large relay
coil on PGU (where relay wire
unit connects)?
Replace 918 6645.6 relay.
YES
Use 115 VAC.
Is the supply line voltage low?
YES
Replace pendant
switch.
Does bender stop when the
pendant is unplugged?
Replace PGU.
Are the proper support rollers
and shoe groove being used for
the type and size of conduit be-
ing bent?
NO
Follow directions in
instruction manual.
Is the current on the 115 VAC line
exceeding 20 amps?
NO
Replace circuit
breaker.
Is the DC current to the motor
exceeding 17 amps?
YES
Replace motor.
When BEND is pressed, is the
voltage sent to the motor 20 to 50
volts over the AC line voltage?
NO
Replace bridge
rectifier
(918 5997.2).
Are connectors corroded?
YES
Clean.
Replace PGU.
